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NL Cypress- CS150303CONSTRUCTION SPECIFICATIONS FOR TRAFFIC SIGNAL INSTALLATION AT Belt Line Road @ Wrangle Drive/Olympus Boulevard Prepared by: Kevin Hoppers, P.E., PTOE Kimley-Horn & Associates, Inc. Firm No. F-928 1-2 Standard Specifications Supplementary Conditions TABLE OF CONTENTS Page # Section 1 - City of Coppell's Supplementary Conditions 1-1 to the NCTCOG General Provisions For this project, the Standard Specifications for Public Works Construction – North Central Texas Council of Governments Fourth Edition; the City of Coppell Standard Construction Details (Ord.#2006-1129); TxDot Standard Specifications for Construction and Maintenance of Highways, Streets, and Bridges; and Appendix ‘C’ Design Criteria and Standards in the City of Coppell Subdivision Ordinance (Ord.#94-643) shall govern all work to be done, together with any additional Supplementary Conditions, Specific Project Requirements, General Notes, Description of Pay Items and/or Technical Specifications included herein. Section 2 - Specific Project Requirements 2-1 Section 3 - Description of Pay Items 3-1 Section 4 - Technical Specifications 4-1 1-3 Standard Specifications Supplementary Conditions SECTION 1 STANDARD SPECIFICATIONS SUPPLEMENTARY CONDITIONS 1-4 Standard Specifications Supplementary Conditions CITY OF COPPELL SUPPLEMENTARY CONDITIONS TO THE NORTH CENTRAL TEXAS COUNCIL OF GOVERNMENTS GENERAL PROVISIONS THESE SUPPLEMENTARY CONDITIONS AMEND THE STANDARD SPECIFICATIONS FOR THE PUBLIC WORKS CONSTRUCTION – NORTH CENTRAL TEXAS COUNCIL OF GOVERNMENTS, FOURTH EDITION AS INDICATED BELOW. ALL PROVISIONS WHICH ARE NOT AMENDED OR SUPPLEMENTED REMAIN IN FULL FORCE AND EFFECT. ALL PROVISIONS AMENDED REMAIN IN FULL FORCE AND EFFECT AS AMENDED. DIVISION 100: GENERAL PROVISIONS ITEM 101. – DEFINITIONS & ABBREVIATIONS SC-101.1 Engineer: The word "Engineer" in these contract documents and specifications shall be understood as referring to CITY ENGINEER, City of Coppell, P.O. Box 9478, Coppell, TX 75019, Engineer of the Owner, or such other representatives as may be authorized by said owner to act in any particular position. Owner: The word "Owner" in these contract documents and specifications refers to the CITY OF COPPELL acting through its authorized representatives. Calendar Day: Add the following sentence to the end of the working days definitions: “Hours worked before 8:00 a.m. or after 5:00 p.m., all weekends and holidays are subject to overtime. Overtime request or scheduled testing must be made in writing and approved by the City of Coppell. Seventy- two hours notice required. All overtime incurred by the City for inspection services and any overtime incurred by the testing laboratory shall be paid by the Contractor. If not paid, such cost may be deducted from partial payments.” The pay rate scale for Inspector overtime charges will be $54/hr. All other terms used in these Supplementary Conditions which are defined in the General Provisions shall have the same meanings used in the General Provisions. ITEM 103.3 – SURETY BONDS SC-103.3.1 Add following sentence to Item 103.3.1: 1-5 Standard Specifications Supplementary Conditions "Maintenance Bond shall be required in the amount of 50% of the cost of the public improvements for a 2 year period." ITEM 103.4 - INSURANCE SC-103.4.6 Add the following new item: “103.4.6 If OWNER requests in writing that other special insurance be included in the property insurance policy, CONTRACTOR shall, if possible, include such insurance, and the cost thereof will be charged to OWNER by appropriate Change Order or Written Amendment. Prior to commencement of the Work at the site, CONTRACTOR shall in writing advise OWNER whether or not such other insurance has been procured by CONTRACTOR.” SC-103.4.7 Add the following new item: “103.4.7 CONTRACTOR intends that any policies provided in response to Item 1.26 shall protect all of the parties' insured and provide coverage for all losses and damages caused by the perils covered thereby. Accordingly, all such policies shall contain provisions to the effect that in the event of payment of any loss or damage the insurer will have no rights of recovery against any of the parties named as insured or additional insured, and if such waiver forms are required of any Subcontractor, CONTRACTOR will obtain the same.” ITEM 103.6 - NOTICE TO PROCEED AND COMMENCEMENT OF WORK SC-103.6 Add following sentence to end of Item 103.6. “Before Contractor starts the Work at the site, a conference attended by Contractor, Engineer and others as appropriate will be held to discuss the schedules referred to in Items 105.3, 108.1 and 109.5.1, to discuss procedures for handling Shop Drawings and other submittals and for processing Applications for Payment, and to establish a working understanding among the parties as to the Work.” ITEM 104.2 - CHANGE OR MODIFICATION OF CONTRACT SC-104.2.1 104.2.1 Amend the last sentence in Paragraph two of Item 104.2.1 to delete the following "except as provided below." 1-6 Standard Specifications Supplementary Conditions Add the following sentence to the end of paragraph two in Item 104.2.1. " T h e u n i t p r i c e o f a n i t e m o f U n i t P r i c e W o r k s h a l l b e s u b j e c t t o r e - e v a l u a t i o n a n d adjustment under the following conditions: ITEM 105.1 – CONTRACT DOCUMENTS SC-105.1.1 Add the following language at the end of the Item 105.1.1: "If there is any conflict between the provisions of the Contract Documents and any such referenced standard specifications, manuals or codes, the provisions of the Contract Documents shall take precedence over that of any standard specifications, manuals or codes." SC-105.1.3 Amend the first sentence of Item 105.1.3 by changing "such copies" to be "five copies". ITEM 105.2 - WORKMANSHIP, WARRANTIES AND GUARANTEES SC-105.2.2 Amend the first sentence of Item 105.2.2 to change the words "one year" to "two years". ITEM 105.4 – CONSTRUCTION STAKES SC-105.4 Delete Item 105.4 in its entirety and insert the following in lieu thereof: "Construction stakes/surveying shall be provided by the CONTRACTOR. Monumentation has been provided for establishing vertical and horizontal control. The Contractor shall be responsible for establishing all lines and grades, and the precise location of all proposed facilities. The ENGINEER may make checks as the Work progresses to verify lines and grades established by the Contractor to determine the conformance of the completed Work as it progresses with the requirements of the construction documents. Such checking by the Engineer shall not relieve the Contractor of his responsibility to perform all Work in connection with Contract Drawings and Specifications and to the lines and grades given therein." ITEM 107.3 - OWNER'S OFFICERS, EMPLOYEES OR AGENTS SC-107.3.2 Replace Item 107.3.2 with the following new paragraph: 1-7 Standard Specifications Supplementary Conditions “107.3.2 Conflict of Interest City Charter states that no officer of the City shall have a financial interest, direct or indirect, in any contract with the City, nor shall be financially interested, directly or i n d i r e c t l y , i n t h e s a l e t o t h e C i t y o f a n y l a n d , o r r i g h t s o r i n t e r e s t i n a n y l a n d , materials, supplies or services. This prohibition does not apply when the interest is represented by ownership of stock in a corporation involved, provided such stock ownership amounts to less than one percent (1%) of the corporation stock. Any violation of this prohibition will constitute malfeasance in office. Any officer or employee of the City found guilty thereof should thereby forfeit his office or position. Any violation of this prohibition with the knowledge, expressed or implied, of the persons or corporations contracting with the City shall render the contract voidable by the City Manager or the City Council. The Contractor represents that no employee or officer of the City has an interest in the Contractor.” ITEM 107.14 - STATE AND LOCAL SALES AND USE TAXES SC-107.14 Delete Item 107.14 and substitute the following in lieu thereof: “107.14 Recent legislation has removed the sales tax exemption previously provided by Section 151.311 of the Tax Code covering tangible personal property purchased by a contractor for use in the performance of a contract for the improvement of City-owned realty. It is still possible, however, for a contractor to make tax-free purchase of tangible personal property, which will be incorporated into and become part of a City construction project through the use of a "separated contract" with the City. A "separated contract" is one, which separates charges for materials from charges for labor. Under such a contract, the contractor becomes a "seller" of those materials, which are incorporated into the project, such as bricks, lumber, concrete, paint, etc. The contractor issues a resale certificate in lieu of paying the sales tax at the time such items are purchased. The contractor then receives an exemption certificate from the city for those materials. (This procedure may not be used, however, for materials, which do not become a part of the finished product. For example, equipment rentals, form materials, etc. are not considered as becoming "incorporated" into the project). Utilization of this "separated contract" approach eliminates the need for bidders to figure in sales tax for materials, which are to be incorporated into the project. The successful bidder's bid form will be used to develop the "separated contract" and will determine the extent of the tax exemption. Upon execution of the construction contract, the contractor shall furnish a breakdown (per item) of 1) materials incorporated into the project; and 2) labor, equipment, supervision and materials not incorporated into the project.” 1-8 Standard Specifications Supplementary Conditions ITEM 107.19 - PROTECTION OF WORK AND OF PERSONS AND PROPERTY SC-107.19.2.1 Add the following new Item 107.19.2.1 immediately after Item 107.19.2: “107.19.2.1 Should CONTRACTOR cause damage to the work or property of any separate Contractor at the site, or should any claim arising out of CONTRACTOR'S, OWNER, ENGINEER, Consulting Engineer or any other person, CONTRACTOR shall promptly attempt to settle with such other Contractor by agreement, or to otherwise resolve the dispute by arbitration or at law. CONTRACTOR shall, to the fullest extent permitted by Laws and Regulations, indemnify and hold OWNER, ENGINEER and Consulting Engineer harmless from and against all claims, damages, losses and expenses (including, but not limited to, fees of engineers, architects, attorneys and other professionals and court and arbitration costs) arising directly, indirectly or consequentially out of any action, legal or equitable, brought by any separate Contractor against OWNER, ENGINEER or Consulting Engineer to the extent based on a claim arising out of CONTRACTOR'S performance of the Work. Should a separate Contractor cause damage to the work or property of CONTRACTOR or should the performance of work by any separate Contractor at the site give rise to any other claim, CONTRACTOR shall not institute any action, legal or equitable, against OWNER, ENGINEER or Consulting Engineer or permit any action against any of them to be maintained and continued in its name or for its benefit in any court or before any arbiter which seeks to impose liability on or to recover damages from OWNER, ENGINEER or Consulting Engineer on account of any such damage or claim. If CONTRACTOR is delayed at any time in performing or furnishing Work by any act or neglect of a separate Contractor and OWNER and CONTRACTOR are unable to agree as to the extent of any adjustment in Contract Time attributable thereto, CONTRACTOR may make a claim for an extension of time in accordance with Item 1.36. An extension of the Contract Time shall be CONTRACTOR's exclusive remedy with respect to OWNER, ENGINEER and Consulting Engineer for any delay, disruption, interference or hindrance caused by any separate Contractor.” ITEM 107.23 – EXISTING STRUCTURES, FACILITIES AND APPURTENANCES SC-107.23.2a Add the following new Item 107.23.2a immediately after Item 107.23.2: “107.23.2a Existing Utilities and Sewer Lines: The Contractor shall be responsible for the protection of all existing utilities or service lines crossed or exposed by the construction operations. Where existing utilities or service lines are cut, broken or damaged, the CONTRACTOR shall replace the utilities or service lines with the same type of original construction, or better, at his own cost and expense. This 1-9 Standard Specifications Supplementary Conditions includes any and all irrigation systems, whether or not they are identified on the plans. If it is necessary to change or move the property of any owner or of a public utility, such property shall not be moved or interfered with until authorized by the ENGINEER. The right is reserved to the owner of any public utility to enter upon the limits of the project for the purpose of making such changes or repairs of their property that may be made necessary by the performance of this contract.” ITEM 108.1 – PROGRESS SCHEDULE SC-108.1 Amend the first sentence of Item 108.1 by adding the following at the beginning of the sentence: "If requested by Owner, Engineer or Contractor". ITEM 108.3 - OTHER CONTRACTORS; OBLIGATION TO COOPERATE SC-108.3 Delete the last sentence of the second paragraph and substitute the following in lieu thereof: "In such event, Contractor shall be entitled to an extension of working time only for unavoidable delays verified by the Engineers, as provided in Item 108.8; however, no increase in the contract price shall be due the Contractor." Insert the following sentence at the end of the second paragraph of Item 108.3: "The ENGINEER shall coordinate such other work with the CONTRACTOR and schedule events to minimize delay caused to the CONTRACTOR. No additional time shall be given to the CONTRACTOR of such related work except as provided in Item 108.8." ITEM 108.8 - DELAYS; EXTENSION OF TIME; LIQUIDATED DAMAGES SC-108.8 Add the following at the end of the last paragraph in Item 108.8: "No extension of the contract time shall be allowed unless the CONTRACTOR can demonstrate the delay caused an adverse impact to the critical path and that loss of time can not be made up by revising the sequence of the work of the project." 1-10 Standard Specifications Supplementary Conditions DIVISION 200:SITE PROTECTION AND PREPARATION ITEM 203 – SITE PREPARATION: 203.3.2 Add the following sentence after the second sentence: “The method of protection shall be 2 inch by 4 inch wood railing unless otherwise shown on the Plans or directed by the Engineer.” ITEM 203.7 - EMBANKMENT: 203.7.3.Strike the first sentence and replace with the following: "Earth embedment and select material shall be compacted to between 95 percent and 100 percent of Standard Proctor Density as determined by ASTM D-698 at, or up to five (5) percentage points above, optimum moisture content, using mechanical compaction methods, unless otherwise specified in the Plans or Specifications." DIVISION 300:ROADWAY CONSTRUCTION ITEM 303. – PORTLAND CEMENT CONCRETE PAVEMENT: 303.2.4 Mineral Admixtures. Delete paragraph 303.2.4 in its entirety. The use of Fly Ash as an admixture in any Class of concrete is specifically prohibited without written approval of the Engineer. ITEM 303.5 - CONSTRUCTION METHODS: 303.5.4 Joints 303.5.4.2 Expansion Joints:Replace with the following: "Expansion joints shall be installed perpendicularly to the surface and centerline of the pavement. Expansion Joint material shall be redwood boards, 3/4-inch in width, and extended through curbs. Expansion joints are to be installed at each end of radius at street intersections. Expansion joints shall be equally spaced between intersections with not less than one every 200 linear feet of pavement, unless otherwise specified on the Plans or directed by the Engineer. 303.5.4.2.3 Proximity to Existing Structures: Add to end of sentence, "or as directed by the Engineer". 303.5.4.3 Contraction Joints. Delete the first sentence of the first paragraph and insert the following: "Contraction or dummy joints shall be sawed to T/4 inches in 1-11 Standard Specifications Supplementary Conditions depth, and 1/4 inch in width, and installed every 20 linear feet of pavement, and extend through curb, unless otherwise directed by the Engineer." 303.5.6 Finishing. 303.5.6.1 Machine. Add the following paragraph at the end of this subsection: "Fog sprays powered by pressure pumps, and capable of covering the entire area of freshly placed concrete with a fine mist, shall be used if water is needed for finishing operations." 303.5.6.2 Hand. Add a new paragraph after first paragraph which reads as follows: "Fog sprays powered by pressure pumps, and capable of covering the entire area of freshly placed concrete with a fine mist, shall be used if water is needed for finishing operations." DIVISION 500:UNDERGROUND CONSTRUCTION AND APPURTENANCES ITEM 504. – OPEN CUT - BACKFILL: 504.2.3.3.3 Additional Requirements (2) Additional Requirements for Type "B" backfill when used in streets: Insert the following paragraph at the beginning of this subsection: "All trench backfill shall be compacted to between 95 percent and 100 percent of Standard Proctor Density as determined by ASTM D-698 at, or up to five (5) percentage points above, optimum moisture content, using mechanical compaction methods unless otherwise specified in the Plans. Water jetting may be used only with specific written permission of the Engineer." ITEM 504.5 - EMBEDMENT: 504.5.3.2 Compaction. 504.5.3.2.1 Densities - Areas Not Subjected to or Influenced by Vehicular Traffic. Amend the second sentence by striking the words "to a density comparable with adjacent undisturbed material" and replacing with "to a density between 95 percent and 100 percent Standard Proctor Density as determined by ASTM D-698 at, or up to five (5) percentage points above, optimum moisture content, unless otherwise specified in the Plans or directed by the Engineer." 1-12 Standard Specifications Supplementary Conditions DIVISION 800:MISCELLANEOUS CONSTRUCTION & MATERIALS ITEM 803 – SLOPE AND CHANNEL PROTECTION: 803.3.3 Riprap Construction Methods 803.3.3.6 Mortar Riprap. Add the sentence: “Mortar or concrete type shall be approved by the Engineer and shall conform to A.S.T.M. C 387-83.” SECTION 2 SPECIFIC PROJECT REQUIREMENTS 2-2 Specific Project Requirements SPECIFIC PROJECT REQUIREMENTS The construction specifications, which apply to this project are the Standard Specifications for Public Works Construction - North Central Texas Council of Governments Fourth Edition. The following Specific Project Requirements contain general and specific project requirements applicable to this project in the City of Coppell. These individual specifications control for this project. Additional amendments to the NCTCOG Standard Specifications are contained in Section 3 - Supplementary Conditions to the Standard Specifications for Construction. In the event that an item is not covered in the Project Drawings (Construction Plans) and these Specifications, then the Standard Specifications for the City of Coppell, Texas shall apply. In addition, reference to the following shall be considered as referring to the specifications or Method of Test as set forth by these organizations and shall be considered as part of the Specifications when referenced. A.S.A.American Standards Association A.S.T.M.American Society of Testing Materials A.A.S.H.T.O.American Association of State Highway & Transportation Officials A.C.I.American Concrete Institute A.W.S.American Welding Society A.W.W.A.American Water Works Association S.S.P.C.Steel Structures Painting Council, Federal Specifications Treasury Department U.L.Underwriters Laboratories N.E.M.A.National Electrical Manufacturers Association W.P.C.F.Water Pollution Control Federation TX.DOT Texas Department of Transportation C.D.G.S.City of Dallas General Specifications S.S.P.W.C.N.C.T.Standard Specifications for Public Works Construction North Central Texas T.M.U.T.C.D.Texas Manual on Uniform Traffic Control Devices 2-3 Specific Project Requirements 1.1 OWNER: The "OWNER" or “City” as referred to in these Specifications is the City of Coppell, 255 Parkway Boulevard, P.O. Box 9478, Coppell, Texas 75019. 1.2 ENGINEER: The "Engineer" as referred to in these Specifications is the City Engineer, City of Coppell, Engineer of the Owner, or such other representatives as may be authorized by said owner to act in any particular position. 1.3 STANDARD CONSTRUCTION SPECIFICATIONS FOR THE CITY OF COPPELL: All improvements described in this Proposal and Construction Drawings shall be performed in accordance with the Project Drawings and Specifications. In the event that an item is not covered in the Project Drawings and Specifications, then the City of Coppell Standard Construction Details (Ord.#2006-1129), and Appendix ‘C’ Design Criteria and Standards in the City of Coppell Subdivision Ordinance (Ord.#94-643) shall apply. 1.4 SITE: The Contractor shall limit his work to the area shown on the Project Drawings as within the street right-of-way. Entrance onto private property shall be at the expressed approval of the ENGINEER, only. 1.5 PROJECT DESCRIPTION: This work shall consist of the installation of a new traffic signal at the intersection of Belt Line Road and Wrangler Drive/Olympus Boulevard. The work at this installation shall include all components necessary for the “turn key” construction of the traffic signals as shown in the plans, including but not limited to: signals/signal heads; controllers and cabinets, opticom, wiring, pole/mast arms with foundations, electrical hookup, video detection, etc. This work shall generally consist of all necessary work to produce operational traffic signals at all locations. Traffic pull boxes and conduit were installed at the time the road was constructed, and will be utilized for this installation. 1.6 CALENDAR DAY COUNT: Calendar days shall be counted by the Engineer on the basis of the definition set out in the General Conditions of Agreement. The calendar day count shall be suspended upon receipt by the Engineer of a written request for final inspection. The calendar day count shall resume upon receipt by the Contractor of a written list of items necessary to satisfactorily complete the project. This process shall continue until such time as the project is accepted by the Engineer, and the Owner. The calendar day count will not be suspended or otherwise affected by use of completed portions or "substantial completion" of any of the project. 1.7 SAFETY PRECAUTIONS: The Contractor shall comply with all applicable laws including the Occupational Safety and Health Act of 1970, ordinances, rules, regulations and order of any public authority have jurisdiction for the safety of persons or property to protect them from damage, injury or loss. He shall erect and maintain, as required by existing conditions and progress of the work, all reasonable safeguards for safety and protection, including posting danger signs and other warnings against hazards, promulgating safety regulations and notifying owners and users of adjacent utilities. 2-4 Specific Project Requirements 1.8 SOIL INVESTIGATION: A geotechnical investigation report has not been prepared. The Contractor shall visit the site and acquaint himself with the site conditions. 1.9 SURVEY AND FINISHED GRADES: Horizontal and vertical control is provided by the owner as shown on the plans. The Contractor shall be responsible for layout and staking of all grades and lines for construction utilizing qualified survey personnel. The Contractor shall preserve all stakes or markings until authorized by the Engineer to remove same. The Contractor shall bear the cost of the re-establishing any control or construction stakes destroyed by either him or a third party and shall assume the entire expense of rectifying work improperly constructed due to failure to maintain established points and marks. No separate payment shall be made to the Contractor for construction staking which shall be considered incidental to the project and payments made under specific Pay Items shall be considered as full compensation for these requirements. 1.10 CONFORMITY WITH DRAWINGS: All work shall conform to the lines, grades, cross- sections, and dimensions shown on the Drawings. Any deviation from the Drawings which may be required by the exigencies of construction will be determined by the Engineer and authorized by him in writing. 1.11 TESTING LABORATORY SERVICE: The Owner shall make arrangements with an independent laboratory acceptable for testing as required by the construction plans and standard specifications. The Contractor shall bear all related costs of retests, or reinspections. The Contractor shall notify the ENGINEER in a timely manner of when and where tests or inspections are to be made so that they may be present. One copy shall be provided to the contractor of all reports and laboratory test results. Testing by the Owner does not alleviate the contractors' responsibility for his own quality assurance/quality control testing. Contractor shall replace any deficient construction items. 1.12 SUSPENSION OF WORK: If the work should be stopped or suspended under any order of the court, or other public authority, the Owner may at any time during suspension upon seven days written notice to the Contractor, terminate the Contract. In such an event, the Owner shall be liable only for payment for all work completed plus a reasonable cost for any expenses resulting from the termination of the Contract, but such expenses shall not exceed $5,000. 1.13 PRESERVATION OF TREES: Permission of the Engineer must be obtained for removal of trees that obstruct the installation of the improvements as outlined for this project in these Contract Documents. The penalty for the removal or destruction of a tree without obtaining written permission from the Engineer shall be $500.00 per caliper inch payable to the Owner. If damage is occurring or is likely to continue, tree guards shall be erected when so directed by the Engineer at the Contractor's expense. 2-5 Specific Project Requirements 1.14 COOPERATION OF CONTRACTOR: The Contractor shall have on the project at all times, as his agent, a competent Superintendent capable of reading the plans and specifications and thoroughly experienced in the type of work being performed. The Superintendent shall have full authority to execute orders or directions and to promptly supply such materials, equipment, tools, labor and incidentals as may be required. Such superintendence shall be furnished irrespective of the amount of work contracted. The Superintendent and the Contractor shall be responsible for supervision of all work performed by the subcontractor at all times during construction. 1.15 WARNING DEVICES: The Contractor shall have the responsibility to provide and maintain all warning devices in accordance with the TMUTCD and take all precautionary measures required by law to protect persons and property while said persons or property are approaching, leaving or within the work site or any area adjacent to said work site. Additionally, two-way traffic and 20 mph advisory signs for each direction of traffic shall be placed on both sides of all intersections. No separate compensation will be paid to the Contractor for the installation or maintenance of any warning devices, barricades, lights, signs or any other precautionary measures required by law for the protection of persons or property. The Contractor shall assume all duties owned by the City of Coppell to the general public in connection with the general public's immediate approach to and travel through the work site and area adjacent to said work site. Where the work is carried on, in, or adjacent to, any street, alley, sidewalk, public right-of- way or public place, the Contractor shall at his own cost and expense provide such flagmen and watchmen and furnish, erect and maintain such warning devices, barricades, lights, signs and other precautionary measures for the protection of persons or property as are required by law. The Contractor shall submit a traffic control plan to be reviewed by the City prior to the beginning of work. No lane shall be barricaded before 9:00 a.m. or after 4:00 p.m. No less than one lane of traffic in each direction shall be provided at all times. The Contractor is responsible for providing and maintaining flagmen, watchmen, warning devices, barricades, signs, and lights, and other precautionary measures shall not cease until the project shall have been accepted. If the Engineer discovers that the Contractor has failed to comply with the applicable federal and state law (by failing to furnish the necessary flagmen, warning devices, barricades, lights, signs or other precautionary measures for the protection of persons or property), the Engineer may order such additional precautionary measures as required by law to be taken to protect persons and property, and to be reimbursed by the Contractor for any expense incurred in ordering such additional precautionary measures. In addition, the Contractor will be held responsible for all damages to the work and other public or private property due to the failure of warning devices, barricades, signs, lights, or other precautionary measures in protecting said property, and whenever evidence is found of 2-6 Specific Project Requirements such damage, the Engineer may order the damaged portion immediately removed and replaced by and at the cost and expense of the Contractor. If the damages are not corrected in a timely fashion, then the City shall have the right to repair the damage and charge the cost back to the Contractor. All of this work is considered incidental and shall not be separate pay item. 1.16 EXISTING UTILITIES, STRUCTURES AND OTHER PROPERTY: In regards to existing utilities, structures and other property within, crossing or adjacent to the site, the Contractor understands and accepts the following conditions: a.Prior to any excavation, the Contractor shall determine the locations of all existing water, gas sewer, electric, telephone, telegraph, television, and other underground utilities and structures. This includes the water and sanitary sewer services. b.After commencing the work, the Contractor will use every precaution to avoid interferences with existing underground and surface utilities and structures, and protect them from damage. c.Where the locations of existing underground and surface utilities and structures are indicated, these locations are generally approximate, and all items that may be encountered during the work are not necessarily indicated. The Contractor shall determine the exact locations of all items indicated, and the existence and locations of all items not indicated. d.The Contractor shall repair or pay for all damage caused by his operations to all existing utilities, public property, and private property, whether it is below ground or above ground, and he shall bear sole responsibility to settle the total cost of all damage suits which may arise as a result of this operations. e.To avoid unnecessary interferences or delays, the Contractor shall coordinate all utility removals, replacements and construction directly with the appropriate utility company. 1.17 DRAINAGE: The Contractor shall maintain adequate drainage at all times. 1.18 PROJECT MAINTENANCE: The Contractor shall maintain, and keep in good repair, the improvements covered by these plans and specifications during the life of the contract. 1.19 CLEANUP: During Construction. The contractor shall at all times keep the job site as free from all material, debris and rubbish as is practicable and shall remove same from any portion of the job site when it becomes objectionable or interferes with the progress of the project, and/or when requested to do so by the Owner. 2-7 Specific Project Requirements Final. Upon completion of the work, the Contractor shall remove from the site all plant, materials, tools and equipment belonging to him and leave the site with an appearance acceptable to the Engineer and the Owner. The Contractor shall thoroughly clean all equipment and materials installed by him and shall deliver over such materials and equipment in a bright, clean, polished and new-appearing condition. 1.20 INSPECTION: The word "Inspection" or other forms of the word, as used in the contract documents for this project shall be understood as meaning an Owner's agent will observe the construction on behalf of the Owner. The agent will observe and check the construction in sufficient detail to satisfy himself that the work is proceeding in general accordance with the contract documents, but he will not be a guarantor of the Contractor's performance. 1.21 DISPOSAL OF WASTE AND SURPLUS EXCAVATION: All trees, stumps, slashings, brush or other debris removed from the site as a preliminary to the construction of the various improvements shall be removed from the property by the Contractor. Any required burning and/or disposal permits shall be the sole responsibility of the Contractor. All excavated materials in excess of that required for backfilling shall be removed from the job site and disposed of in a satisfactory manner by the Contractor. 1.22 WATER FOR CONSTRUCTION: The Contractor shall make the necessary arrangement for securing and transporting all water required in the construction of this project, including water required for mixing of concrete, sprinkling, testing, flushing, flooding, or jetting. The Contractor shall provide water as required at his own expense. 1.23 GUARANTEE: All work shall be guaranteed against defects resulting from the use of inferior materials, equipment or workmanship for a period of two (2) years from the date of final completion and acceptance of the project. 2-8 Specific Project Requirements SHOP DRAWINGS, PRODUCT DATA AND SAMPLES 1.1 GENERAL: A.Contractor to submit Shop Drawings, Product Data and Samples as required by the Contract Documents and as specified in other sections of the specifications. 1.2 SHOP DRAWINGS: A.As soon as practicable after contract award, submit to the Engineer, for review, the required number of bound copies of shop drawings of all items as specified in the various sections of these specifications, accompanied by letters of transmittal. B.Shop drawings shall include: Manufacturer's catalog sheets and/or descriptive data for materials and equipment; showing dimensions, performance characteristics, and capacities and other pertinent information as required to obtain approval of the items involved. C.No work requiring shop drawings will be executed until review and acceptance of such drawings has been obtained. 1.3 PRODUCT DATA: A.Preparation: 1.Clearly mark each copy to identify pertinent products or models. 2.Show performance characteristics and capacities. 3.Show dimensions and clearances required. B.Manufacturers standard schematic drawings and diagrams: 1.Modify drawings and diagrams to delete information that is not applicable to the work. 2.Supplement standard information to provide information specifically applicable to the work. 1.4 SAMPLES: Provide samples as indicated in other parts of these specifications. 1.5 CONTRACTOR RESPONSIBILITIES: A.Review Shop Drawings and Product Data prior to submission. B.Determine and verify: 1.Field measurements. 2.Field construction criteria. 3.Catalog numbers and similar data. 4.Conformance with specifications. 2-9 Specific Project Requirements C.Coordinate each submittal with requirements of the work and of the Contract Documents. D.Begin no work that requires submittals until return of submittals with Engineer's review. E.Keep one (1) approved copy of shop drawings or product data at job site at all times. 1.6 SUBMISSION REQUIREMENTS: A.Make submittals promptly and in such sequence as to cause no delay in the work or in the work of any other contractor. B.Number of submittals required: 1.For shop drawings and product data: Submit the number of copies that the contractor requires, plus two that will be retained by the Engineer. C.Submittals shall contain: 1.The date of submission and the dates of any previous submissions. 2.The project title. 3.The names of: a.Contractor b.Supplier c.Manufacturer 4.Identification of the product. 5.Field dimensions, clearly identified as such. 6.Relation to adjacent or critical features of the work or materials. 7.Applicable standards, such as ASTM or Federal Specification numbers. 8.Identification of deviations from Contract Documents. 9.Identification of revisions on re-submittals. 10. Contractor's stamp, initialed or signed, certifying to review of submittal, verification of products, field measurements and field construction criteria, and a\coordination of the information within the submittal with requirements of the work and of Contract Documents. 11. Fabrication and erection drawings lists and schedules. 12. Basis of design and design calculations signed and sealed by a registered professional engineer. 13. Seal and signature of a register engineer on all structural submittals. D.REVIEW: 1.Shop drawing and product data information review will be general. Such review will not relieve the contractor of any responsibility and work required by the Contract. 2-10 Specific Project Requirements 2.Satisfactory shop drawings will be so designated and all sets, except four (4), returned to the Contractor. Rejected shop drawings will be so designated and all sets except two (2) will be returned to the Contractor, with indications of the required corrections and changes. 3.Rejected shop drawings will be corrected and resubmitted to the Engineer for Acceptance. 1.7 RESUBMISSION REQUIREMENTS: A.Make any corrections or changes in the submittals required by the Engineer and resubmit until accepted. B.Shop Drawings and Product Data: 1.Revise initial drawings or data, and resubmit as specified for the initial submittal. 2.Indicate any changes that have been made other than those requested by the Engineer. 1.8 ENGINEER'S RESPONSIBILITIES: A.Review submittals with reasonable promptness. B.Affix stamp and initials or signature, and indicate requirements for re-submittal, or acceptance of submittal. C.Return submittals to Contractor for distribution, or for resubmission. SECTION 3 DESCRIPTION OF PAY ITEMS 3-2 Description of Pay Items SECTION 3 - DESCRIPTION OF PAY ITEMS This section includes comments concerning various Pay Items so that the contractor can fully understand the scope of work involved in the Pay Items. 1. Construction No Pay Items: All work necessary for the orderly completion of the project, but not specifically included as a pay item in the Proposal, shall be considered subsidiary to the Contract and no separate or additional payment will be made therefore. For example, there shall be no separate payment for the following: (a) removal and replacement of any signs with the exception of the new signs paid under various Bid Items, (b) removal of spoils, (c) water for construction, (d) surveying to re-establish grade, (e) maintenance of existing traffic control during construction, (f) permitting from other entities, (g) any other incidentals necessary to complete the work. The above items are not meant to be a total and complete list of subsidiary items but only representative of the types of items that should be included in the various pay items associated with this project. 2. Construction Pay Items: Pay items as listed in the proposal shall be measured and paid for in accordance with the applicable measurement and payment paragraphs in the Standard Specifications for Public Works Construction - North Central Texas Council of Governments Fourth Edition, unless modified by these special provisions. All work for this project shall be governed by the Standard Specifications for Public Works construction - North Central Texas Fourth Edition, as prepared by the North Central Texas Council of Governments, the City of Coppell Standard Construction Details (Ord. #92-554), and Appendix 'C' Design Criteria and Standards in the City of Coppell Subdivision Ordinance (Ord. #94-643), together with any additional Supplementary Conditions, Specific Project Requirements, General Notes or Description of Pay Items included herein. 2.1 Pay Item #I-1 - Mobilization & Demobilization: This pay item shall consist of the mobilization for the construction of the project. It is anticipated that the project will be constructed in multiple phases. This pay item shall be inclusive of any and all mobilizations and demobilizations associated with the project. Measurement and Payment shall be as follows: one-half the mobilization and demobilization shall be paid with the first pay estimate after the initial mobilization has taken place. On all subsequent pay estimates, measurement and payment shall be prorated on the basis of the percent of the job complete plus the initial 50% (i.e., when the pay request reflects 50% payment of the total contract amount, then the contractor will be paid for 75% of the mobilization pay item, etc.) Payment shall be total compensation for furnishing all labor, materials, tools, and equipment necessary to complete the work. 3-3 Description of Pay Items 2.2. Pay Item #I-2 - Installation of Highway Traffic Signals: This work includes the furnishing and installation of new highway traffic signals including traffic signal controllers and cabinets in accordance with the appropriate details and specifications, including City of Coppell "TS-2 Type 2 Cabinet Specifications" and "Specification for Fully-Actuated Solid State Controller unit (TS-2) with Time-Based Coordination, Preemption, and Closed Loop Operation" as well as Item 680 in TxDOT's 2004 Standard Specifications for Construction and Maintenance of Highways, Streets and Bridges. This item will also include supplying an upload-download device for each signal installation. Measurement and Payment for installation of highway traffic signals work performed and materials furnished, completed and in place as provided herein shall be made on the basis of the price bid per lump sum (LS) and shall be total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.5. Pay Item #I-3 Thru #I-6 - Traffic Signal Pole with 32, 36, 44, and 48 Foot Mast Arm: This work shall include the furnishing and installation of traffic signal poles with various length mast arms as indicated on the plans. Said traffic signal poles shall be installed in accordance with City of Coppell standards and "Specification for Mast Arm Pole Assembly", and NCTCOG standards. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.5. Pay Item #I-7 Pedestrian Signal Pole: This work shall include the furnishing and installation of pedestrian signal poles as indicated on the plans. Said pedestrian signal poles shall be coated and installed in accordance with City of Coppell standards and "Specification for Mast Arm Pole Assembly", and TxDOT Item 687. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.6 Pay Items #I-8 Thru #I-10 Traffic Signal Foundations & Pedestrian Pole Foundations: This work shall include the furnishing and installation of traffic signal foundations type 36-A and 36-B as indicated in the plans. This item will also cover the installation of pedestrian signal pole foundations type 24-A as indicated in the plans. All work shall be in accordance with the appropriate details and specifications, including Item 656 in TxDOT's 2004 Standard Specifications for Construction and Maintenance of Highways, Streets and Bridges. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 3-4 Description of Pay Items 2.7 Pay Item #I-11 Traffic Signal Controller Foundation: This work shall include the furnishing and installation of the traffic signal controller foundation in accordance with City of Coppell standards and specification "Underground Traffic Signal Requirements; Conduit, Ground Boxes, Concrete Cabinet Foundations, and Installation Procedures", and NCTCOG standards. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.9.Pay Item #I-12 & I-13 – 3-Section & 5-Section Signal Head w/Backplate: This work shall include the furnishing and installation of 3-section signal heads with backplates. Said signal heads shall be installed in accordance with City of Coppell standards and specification "Polycarbonate Resin Traffic Signal Heads - 12 Inch, Expandable, Adjustable Type", and NCTCOG standards. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.10 Pay Item #I-14 Pedestrian Signal Sections: This work shall include the furnishing and installation of polycarbonate, symbolic pedestrian signal sections in accordance with the appropriate details and specifications, including Item 682 in TxDOT's 2004 Standard Specifications for Construction and Maintenance of Highways, Streets and Bridges. Pedestrian signal head shall be of the “count down” variety. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.11 Pay Item #I-15 Pedestrian Push Button and Sign Assemblies: This work shall include the furnishing and installation of pedestrian push button and sign assemblies in accordance with City of Coppell standards and specification "Vehicle and Pedestrian Detectors; Detector Amplifiers; Lead in Cable; Pedestrian Push Buttons; Installation Procedures", and NCTCOG standards. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.12 Pay Item #I-16 Uni-Directional Opticom Detector: This work shall include the furnishing and installation of uni-directional opticom detectors in accordance with the appropriate details and specifications, including the Emergency Management Response System special specification. 3-5 Description of Pay Items Measurement and Payment shall be made on the basis of the bid price per linear foot (LF) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.13 Pay Item #I-17 Traffic Signal Confirmation Lights: This work shall include the furnishing and installation of traffic signal confirmation light assemblies with clear globe on the mast arms and in the locations as designated by the Owner. Contractor shall furnish and install Pelco Part Number SM-0286 traffic signal confirmation lights, or equal. Confirmation light shall be mounted high enough to be visible above the street name sign. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. Any necessary extensions shall be considered subsidiary to this pay item. 2.15 Pay Item #I-18 Video Imaging Vehicle Detection System: This work shall include the furnishing and installation of video imaging vehicle detection systems in accordance with the appropriate details and specifications. System provided shall be AutoScope Encore, or approved equal. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.16 Pay Item #I-19 Cabinet Mounted Communication Equipment: This work shall include the furnishing and installation of all necessary cabinet mounted equipment for communication between the traffic signal controller and remote city locations via the 12 strand fiber provided under item I-33. This pay item shall cover the installation of necessary equipment in the new cabinet being installed at Belt Line Road and Wrangler Drive/Olympus Boulevard. This equipment will include a Corning AnyLAN integrated single-panel housing, 24-fiber LC Duplex with Corning fiber jumpers. Jumpers shall be 2-F singlemode LC-LC duplex. The equipment will also include an Ethernet switch. The switch shall be EtherWan, model EX72089-0VB hardened managed switch with 8 ports, or approved equal. Switch shall be equipped with an EtherWan 41-136046 power supply and EtherWan fiber modules. Measurement and Payment shall be made on the basis of the bid price per lump sum and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. Completion of the work shall include those items listed herein as well as any additional items required to interface between the fiber and the traffic signal controller and the video detection system. 2.17 Pay Item #I-20 thru #I-22 PVC Conduit & RMC Conduit: This work shall include the furnishing and installation of 2” and 3" PVC conduit, and 2” RMC Conduit in accordance with City of Coppell standards and specification "Underground 3-6 Description of Pay Items Traffic Signal Requirements; Conduit, Ground Boxes, Concrete Cabinet Foundations, and Installation Procedures", and NCTCOG standards. Measurement and Payment shall be made on the basis of the bid price per linear foot (LF) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.18 Pay Item #I-23 Furnish & Install Type ‘A’ Ground Box: This work shall include the furnishing and installation of ground boxes ion accordance with City of Coppell standards and specification "Underground Traffic Signal Requirements; Conduit, Ground Boxes, Concrete Cabinet Foundations, and Installation Procedures", and appropriate TxDot standard details. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.19 Pay Item #I-24 3 Conductor #6 Gauge Wire: This work shall include the furnishing and installation of 3C #6 gauge wire in the locations shown in accordance with City of Coppell standards and specification "Multiple Conductor and Single Conductor Traffic Signal Cable and Wire", and NCTCOG standards. Measurement and Payment shall be made on the basis of the bid price per linear foot (LF) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.20 Pay Item #I-25 1 Conductor #6 Gauge Bare Wire: This work shall include the furnishing and installation of 1C #6 gauge bare wire in the locations shown in accordance with City of Coppell standards and specification "Multiple Conductor and Single Conductor Traffic Signal Cable and Wire", and NCTCOG standards. Measurement and Payment shall be made on the basis of the bid price per linear foot (LF) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.21 Pay Item #I-26 1 Conductor #8 Gauge Wire: This work shall include the furnishing and installation of 1C #8 gauge wire in multiple locations of the project in accordance with City of Coppell standards and specification "Multiple Conductor and Single Conductor Traffic Signal Cable and Wire", and NCTCOG standards. Measurement and Payment shall be made on the basis of the bid price per linear foot (LF) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 3-7 Description of Pay Items 2.22 Pay Item #I-27 16 Conductor #14 Gauge Wire: This work shall include the furnishing and installation of 16C #14 Gauge wire in multiple locations of the project in accordance with City of Coppell standards and specification "Multiple Conductor and Single Conductor Traffic Signal Cable and Wire", and NCTCOG standards. Measurement and Payment shall be made on the basis of the bid price per linear foot (LF) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.23 Pay Item #I-28 Opticom Cable This work shall include the furnishing and installation of opticom cable as recommended by the manufacturer in multiple locations of the project in accordance with City of Coppell standards and specifications. Measurement and Payment shall be made on the basis of the bid price per linear foot (LF) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.24 Pay Item #I-29 Video Cable: This work shall include the furnishing and installation of VIVDS Video cable in multiple locations of the project in accordance with the recommendation of the manufacturer. Cable furnished shall be of the type recommended for use with the AutoScope Encore video system. Measurement and Payment shall be made on the basis of the bid price per linear foot (LF) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.25 Pay Item #I-30 3 Conductor #14 Gauge Wire: This work shall include the furnishing and installation of 3C #14 gauge wire in multiple locations of the project in accordance with City of Coppell standards and specification "Multiple Conductor and Single Conductor Traffic Signal Cable and Wire", and NCTCOG standards. Measurement and Payment shall be made on the basis of the bid price per linear foot (LF) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.26 Pay Item #I-31 5 Conductor #14 Gauge Wire: This work shall include the furnishing and installation of 5C #14 Gauge wire in multiple locations of the project in accordance with City of Coppell standards and specification "Multiple Conductor and Single Conductor Traffic Signal Cable and Wire", and NCTCOG standards. 3-8 Description of Pay Items Measurement and Payment shall be made on the basis of the bid price per linear foot (LF) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.27 Pay Item #I-32 7 Conductor #14 Gauge Wire: This work shall include the furnishing and installation of 7C #14 Gauge wire in multiple locations of the project in accordance with City of Coppell standards and specification "Multiple Conductor and Single Conductor Traffic Signal Cable and Wire", and NCTCOG standards. Measurement and Payment shall be made on the basis of the bid price per linear foot (LF) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.28 Pay Item #I-33 12 Strand Corning AnyLan Pre-terminated Fiber: This work shall include the furnishing and installation of fiber optic cable in the locations as shown on the plans. The cable shall be Corning AnyLan pre-terminated 12 fiber singlemode trunk with opti-tip connectors. The lengths as shown in the plans are approximate, and are based on the best information available to us at this time. Upon completion of the conduit installation, it shall be the contractors responsibility to verify the actual length necessary to make the connections indicated in the plans. As this type of cable is pre-terminated with “plug & play” ends at the factory it is imperative that the correct length be ordered. Any shortage will be the sole responsibility of the contractor. Measurement and Payment shall be made on the basis of the bid price per linear foot (LF) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. Payment will be made on the basis of the actual length of cable provided and installed. 2.29 Pay Item #I-34 Power Service and Pedestal Equipment: This work shall include the furnishing and installation of power service and pedestal equipment in accordance with City of Coppell standards and specification "Power Service and Service Equipment and General System Wiring Procedures", and NCTCOG standards. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.30 Pay Item #I-35 Opticom Detector Phase Selector: This work shall include the furnishing and installation of opticom detector phase selectors in accordance with the appropriate details and specifications, including the Emergency Management Response System special specification. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 3-9 Description of Pay Items 2.31 Pay Item #I-36 UPS System: This work shall include the furnishing and installation of an uninterrupted power supply system, Clary Corporation, Model SP-1000, or equal with a six battery cabinet in accordance with the appropriate details and specifications, including TxDOT Specification. This item shall include the installation of the externally mounted cabinet to house the system. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.32 Pay Item #I-37 Furnish and Install Illuminated Street Name Signs: This work shall include the furnishing and installation of illuminated street name signs in accordance with this specification, and as indicated in the drawing. Signs shall be edge lit LED illuminated with an 18” tall viewing area. Signs shall be “Classic Thinline” model from Southern Manufacturing, or approved equal. Signs shall be mounted to the mast arm using an Astro-Brac® SP0140 or approved equal. A photocell shall be provided to control when the sign is illuminated. The photocell shall be set up such that all lights are on or off at the same time. Lights shall not come on or turn off at different times. Measurement and Payment shall be made on the basis of the bid price per each (EA) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.33 Pay Item #I-38 Furnish and Install Miscellaneous Signs: This pay item shall consist of the furnishing and installation of standard street signs at the locations specified by the Owner. All signs shall be manufactured and mounted in accordance with City of Coppell standards and Texas MUTCD guidelines. Measurement and Payment shall be made on the basis of the bid price per Lump Sum (LS) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. 2.34 Pay Item #I-39 Furnish & Install Pavement Markings: This pay item shall consist of the furnishing and installation of pavement markings as indicated in the plans. Markings shall be placed in the location shown in the plans and in accordance with the City of Coppell standard details. Pavement marking material (buttons, stripes, arrow, etc.) shall be in accordance with city standards as outlined in the appropriate details. Measurement and Payment shall be made on the basis of the bid price per Lump Sum (LS) and shall be the total compensation for furnishing all labor, materials, and equipment necessary to complete the work. SECTION 4 TECHNICAL SPECIFICATIONS AND DESCRIPTION OF PAY ITEMS SECTION 4 CONTENTS: TS 2 CABINET ASSEMBLY Page 4-2 FULLY-ACTUATED SOLID STATE CONTROLLER UNIT Page 4-11 UPLOAD-DOWNLOAD DEVICE Page 4-12 SPECIFICATION FOR MAST ARM POLE ASSEMBLY Page 4-13 POLYCARBONATE RESIN TRAFFIC SIGNAL HEADS Page 4-17 UNDERGROUND TRAFFIC SIGNAL REQUIREMENTS Page 4-22 MULTIPLE CONDUCTOR AND SINGLE CONDUCTOR Page 4-27 TRAFFIC SIGNAL CABLE AND WIRE POWER SERVICE & SERVICE EQUIPMENT /Page 4-40 GENERL SYSTEM WIRING PROCEDURES RETROREFLECTIVE PREFABRICATED PAVEMENT MARKINGS Page 4-43 4-2 Technical Specifications & Description of Pay Items TS2-TYPE 2 CABINET SPECIFICATIONS 1.0 TS 2 CABINET ASSEMBLY 1.1 This specification describes the minimum acceptable requirements for a TS 2 cabinet assembly to house a NEMA TS 1 Type 2 solid state full-actuated controller unit. The cabinet assembly shall be configured by NAZTEC to City of Coppell specification, or approved equal. 1.2 Cabinet Design Requirements 1.2.1 Vertical shelf support channels shall be provided to permit adjustment of shelf location in the field. The channels shall have a single continuous slot to allow shelves to be placed at any height within the cabinet. Channels with fixed notches or holes are not acceptable. 1.2.2 Each cabinet shall be equipped with an extra set of unistrut channels or a keyhole panel on either side of the front section of the cabinet to permit the purchaser to mount additional equipment as necessary. 1.2.3 Shelves shall be at least 330 mm deep and be located in the cabinet to provide a 12.5 mm clearance between the back of the shelf and the back of the cabinet. A 38-mm drawer shall be provided in the cabinet, mounted directly beneath the controller support shelf. The drawer shall have a hinged top cover and shall be capable of storing documents and miscellaneous equipment. This drawer shall support to 22.5 kg in weight when fully extended. The drawer shall open and close smoothly. Drawer dimensions shall make maximum use of available depth offered by the controller shelf and be a minimum of 600 mm. 1.2.4 Two shelves shall be provided in the cabinet and shall be at minimum 305 mm apart in height. There shall be sufficient shelf space to accommodate a controller unit 330-mm high, an MMU, one 8 position card rack and external power supply. An additional space at least 305-mm high, 325 mm wide, and 305 mm deep shall be provided. The controller unit, MMU, card racks, and power supply shall be placed on the shelves in such a manner that sufficient ventilation is provided to all components. Labels showing the proper placement of each component shall be provided along the shelves to ensure proper placement. 1.2.5 The cabinet shall be vented and cooled by 2 thermostatically controlled fans. The fans shall be a commercially available model with a capacity of at least 2.7 m 3/min. The thermostats shall be adjustable range of 20 °C to 43°C. A press-to-test switch shall be provided to test the operation of the fans. 4-3 Technical Specifications & Description of Pay Items 1.2.6 The cabinet shall be provided with a unique five digit serial number which shall be stamped directly on the cabinet or engraved on a metal or metalized mylar plate, epoxied or riveted with aluminum rivets to the cabinet. The digits shall be at least 5 mm in height and located on the upper right sidewall of the cabinet near the front. 1.3 Cabinet Door 1.3.1 The cabinet shall be provided with one door in front that will provide access to the cabinet. The door shall be provided with three hinges with non-removable stainless steel pins, or a full-length piano hinge with stainless steel pins spot welded at the top of the hinge. The hinges shall be mounted so that it is not possible to remove them from the door or cabinet without first opening the door. The bottom of the door opening shall extend at least to the bottom level of the back panel. The door and hinges shall be braced to withstand a 74-kg per vertical meter of door height load applied to the outer edge of the door standing open. There shall be no permanent deformation or impairment of any of the door or the cabinet body when the load is removed. 1.3.2 The cabinet door shall be fitted with a Number 2 Corbin lock and a stainless steel handle with a 16 mm (minimum) diameter shaft (or equivalent cross-sectional area for a square shaft) and a three point latch. The lock and latch design shall be such that the handle cannot be released until the lock is released. One key shall be provided for each cabinet. A gasket shall be provided to act as a permanent dust and weather resistant seal at the controller cabinet door facing. The gasket material shall be of a nonabsorbent material and shall maintain its resiliency after long term exposure to the outdoor environment. The gasket shall have a minimum thickness of 6.25 mm. The gasket shall be located in a channel provided on the cabinet or on the door(s). An “L” bracket is acceptable in lieu of this channel if the gasket is fitted snugly against the bracket to insure a uniform dust and weather resistant seal around the entire door facing. Any other method is subject to purchaser approval during inspection of an order. 1.3.3 A locking auxiliary police door shall be provided in the door of the cabinet to provide access to a panel that shall contain a signal shutdown switch, a signal flash switch, a manual-automatic switch, and a manual advance push-button switch on a six foot retractable cord. Manual control of the controller unit from the police door shall override any external control (external logic, etc.) in effect when the Manual-Automatic switch is in the manual position. Each actuation of the manual advance push-button switch shall advance the controller to the next interval. Manual control shall not override any calls for preemption. The police door shall be gasketed to prevent entry of moisture or dust and the lock shall be provided with one brass key. 1.3.4 The intake for the vent system shall be filtered with a permanent air filter. The minimum filter dimensions shall be 406.4 mm wide by 304.8 mm high by 25 mm thick. The filter shall be securely mounted so that any air entering the cabinet must pass through the filter. The cabinet opening for intake of air shall be large enough to use the entire filter. The air intake and exhaust vent shall be screened to prevent entry of insects. 4-4 Technical Specifications & Description of Pay Items The screen shall have opening no larger than 8.1 mm2. The total free air opening of the exhaust vent shall be large enough to prevent excessive back-pressure on the fan. 1.4 Wiring 1.4.1 All wiring within the cabinet shall be neat and routed such that opening and closing the door or raising or lowering the back panel will not twist or crimp the wiring. All wiring harnesses shall be either braided, sheathed in nylon mesh sleeving, or made of PVC or polyethylene insulated jacketed cable. Wiring leading to the cabinet door shall be sheathed in nylon mesh sleeving or be PVC jacketed cable only. 1.4.2 Size A. All conductors between the main power circuit breakers and the signal power bus shall be a minimum size 10 AWG stranded copper. All conductors carrying individual signal lamp current shall be a minimum size 14 AWG stranded copper. All AC service lines shall be of sufficient size to carry the maximum current of the circuit or circuits they are provided for. Minimum cabinet conductor wire size shall be 22 AWG stranded copper. All wiring and insulation shall be rated for 600 V or greater. B.Conductors for AC common shall be white. Conductors for equipment grounding shall be green. All other conductors shall be a color different than the foregoing. C.No P.C. boards will be allowed on the back panel of the cabinet. All wiring must be done from the ABC Harnesses to the Back Panel using standard 19-gauge wiring. 1.4.3 A barrier terminal block with a minimum of three compression fitting terminals designed to accept up to a #4 AWG stranded wire shall be provided for connection of the AC power lines. The block shall be rated at 50 Amperes. 1.4.4 All terminals shall be permanently identified in accordance with the cabinet wiring diagram using an anodized silk screening process on the aluminum panel. Where through-panel solder lugs or other suitable connectors are used, both sides of the panel shall have the terminals properly identified. Identification shall be placed as close to the terminal strip as possible. A. Each controller input and output function shall be distinctly identified with no obstructions, at each terminal point in the cabinet, with both a number and the function designation. The same identification must be used consistently on the cabinet wiring diagrams. The back panel shall be wired and labeled according to the TS2-1992 specification MODE 6 – User defined I/O which converts existing unused TS1 inputs to extra vehicle detectors and preempts. B. Each load switch socket shall be identified by phase number, overlap number, and pedestrian phase number as applicable. No cabinet equipment, including the load switches themselves, may obstruct these identifications. 4-5 Technical Specifications & Description of Pay Items C. Each flash transfer base and power relay base shall be properly identified with no possible obstructions. D. Each harness within the cabinet shall be distinctly identified by function on the connector end. E. The flasher socket shall be distinctly identified with no possible obstruction. F. All other sockets needed within the cabinet to fulfill the minimum requirements of the Invitation to Bid, or attachments thereof, shall be distinctly identified. 1.4.5 The controller unit harnesses (ABC plugs) shall be long enough to reach any point 400 mm above the timer shelf. The conflict monitor harness and any required auxiliary harness shall reach 600 mm from the conflict monitor shelf. 1.4.6 An unused, spare terminal block providing ten terminals shall be provided. This block shall be double 8-32 X 5/16" binder head screw design with shorting bars. These terminal strips shall be located on the lower third of either side of the cabinet. 1.4.7 Copper ground buses shall be provided for both the power supply neutral (common) and chassis ground. Each bus bar must provide a minimum of ten unused terminals with 8-32 X 5/16" or larger screws. The AC neutral and chassis ground buses shall be jumpered together with a minimum #10 AWG wire. 1.4.8 A 20 Ampere and a 50 Ampere thermal type circuit breaker shall be mounted and wired in the cabinet. The 20 ampere breaker shall protect the base light, trouble light, GFCI receptacle, modem duplex receptacle, and fans. The 50 ampere breaker shall protect the signal load circuits, controller circuits, conflict monitor, flasher, and card rack detector power supply. The breakers shall be Square "D" QUO 150 Series, no other brand will be allowed. 1.4.9 The circuit breakers shall be equipped with solderless connectors and installed on the right side wall (facing the cabinet) or lower right hand side of the back panel inside the cabinet. The breakers shall be easily accessible. The breakers shall be positioned so that the rating markings are visible. 1.4.10 A Ground Fault Circuit Interruption (GFCI) type duplex receptacle shall be mounted and wired in the lower right side wall of the cabinet. An additional duplex receptacle (for use with communications modems) shall be mounted and wired in the upper left side of the cabinet behind the preempt/interconnect panel. These receptacles shall be wired on the load side of the 20 Amp circuit breaker. 1.4.11 The above breakers are in addition to any auxiliary fuses which may be furnished with the controller to protect component parts, such as transformers, etc. 1.4.12 The load side of the main circuit breaker shall be protected by a two stage lightning surge suppresser, equivalent to the EDCO ACP340 (with LED indication along with a set dry contacts for alarm capabilities to indicate proper operation). 4-6 Technical Specifications & Description of Pay Items 1.4.13 The suppresser ground connection shall be connected to the cabinet by means of a short, heavy copper ground strap. The strap shall be bonded to the cabinet. 1.4.14 The suppresser shall be connected to the line filter as recommended by the manufacturer. Number 10 AWG or larger wire shall be used for connections to the suppresser, line filter and load switch bus. 1.4.15 A fluorescent light, with switch and a rapid start ballast, shall be installed in the cabinet. This light shall be turned on when the cabinet door is opened, and turn off when the cabinet door is closed. An MOV or other such transient suppression device shall be placed across the AC power input to the light. 1.4.16 A radio frequency interference (RFI) suppresser shall be provided and installed on the load side of the signal circuit breaker and shall be protected by the surge protector. This filter shall be rated at 50 amperes and shall provide a minimum attenuation of 50 decibels over the frequency range of 200 Kilohertz to 75 Megahertz. 1.4.17 Transient suppression devices shall be placed on the coil side of all relays in the cabinet. DC relay coils shall have, as a minimum, a reversed biased diode across the coil. AC relays shall have MOV's or equivalent suppression across their coils. RC networks are acceptable. One suppression device shall be supplied for each relay. 1.4.18 Except where soldered, all wires shall be provided with lugs or other approved terminal fittings for attachment to binding posts. Insulation parts and wire insulation shall be insulated for a minimum of 600 volts. 1.4.19 The outgoing traffic control signal circuits shall be of the same polarity as the line side of the power source. 1.4.20 A switch shall be provided on the inside face of the cabinet door that shall be labeled Test-Normal. When the switch is in the Normal position, call for flashing operation shall remove the power from the controller unit. When the switch is in the Test position, the call for flashing operation shall permit the controller unit to continue to run so that its operation can be observed. 1.4.21 A switch shall be provided near the Test-Normal switch to cause the controller unit, and any auxiliary equipment, to stop timing. It shall be labeled "STOP TIMING". 1.4.22 The cabinet shall be wired so that activation of the MMU will cause the controller unit, and any auxiliary equipment, to stop timing. 1.4.23 Conflict and manual flash shall be wired for all red. 1.4.24 The cabinet shall be designed and equipped with enough transfer relays for the purchaser to change any main street indications (movements 2, 6, and/or 1, 5) to amber 4-7 Technical Specifications & Description of Pay Items for the conflict and/or manual flash operation on the face of the back panel or a side panel, using only simple tools. 1.4.25 Transfer relays shall be the plug-in type manufactured by Magnecraft or equivalent. The relays shall have contacts a minimum of 3/8" diameter in size and shall be rated at a minimum of 30 Amps 102/240 VAC, 20 Amps 28 VDC. 1.4.26 The red enable and remote reset from the conflict monitor shall be terminated on the face of the back panel. 1.4.27 A 75 Amp, solid state relay shall be wired between the RFI filter output and the load switch power bus. The relay shall be controlled by the signal shutdown switch and the flash switch. The relay shall be mounted to a heat sink designed to allow maximum current flow at 74 C without damaging the relay. 1.4.28 All exposed AC wiring points, including the RFI filter, surge suppresser, and solid state relay shall be covered with a clear non-conductive plastic cover to prevent accidental contact. Unless otherwise noted in this specification, wiring at terminal strips is exempt from this requirement. 1.4.29 An input point shall be provided on the back panel to allow external reset of the Malfunction Monitoring Unit. 1.4.30 The load switch outputs shall be brought out through posted 10-32 X 5/16" binder head screw terminals. Field wiring for the signal heads shall be connected at this terminal strip. 1.4.31 The cabinet shall be equipped with an auxiliary power connector to plug in a generator f o r e l e c t r i c a l s e r v i c e . T h e c i r c u i t s h a l l b e a c t i v a t e d b y t h e p r e s e n c e o f 1 2 0 V A C generator line voltage that will supply a relay to transfer the supply source to generator power. The connector shall be located inside an accessible panel on the rear of the cabinet and shall allow a plug to be present with the access door closed and locked. 2.0 DETECTOR PANEL AND CARD RACK 2.1 The cabinet shall have a 20 loop detector panel mounted on the left side of the cabinet. This panel shall provide for all connections between loops at the street and the detector amplifiers as described in the following sections. 2.2 Detector Card Rack 2.2.1 The card rack shall have 12 positions (10 slots for vehicle, 2 slots for Opticom preemption). The detector card rack shall have a rigid frame and shall be fabricated from aluminum and shall have slots set in a modular fashion such that the PCB edge connectors shall plug into the rear while sliding between top and bottom card guides for each module. Mounting flanges shall be provided and be turned outward for ease of 4-8 Technical Specifications & Description of Pay Items access. The detector card rack shall be bolted to a cabinet shelf. It shall be possible to unbolt the rack using simple tools. 2.2.3 All wiring to the rack shall be labeled and neatly run to other parts of the cabinet and detector termination panel. 2.2.4 The slots shall be numbered 1 to 10 for loop amplifiers and 1 to 2 for preemption left to right when viewed from the front of the rack. A flange shall be provided on the top and the bottom of the rack to label each individual channel. 2.2.5 The Detector DC Supply shall be bussed to a common point and wired to the Intersection Detector Panel. 2.2.6 The Chassis Ground shall be bussed to a common point and wired to the Detector Panel. 2.2.7 The Logic Ground shall be bussed to a common point and wired to the Detector Panel. 2.3 Detector Panel 2.3.1 The Detector Panel shall provide all connections between the detector loops and the detector amplifiers as well as all necessary preemption inputs and hardwire communications terminals. 2.3.2 The panel shall be constructed of 3.2 mm aluminum. 2.3.3 The panel shall contain a 76 mm horizontal slot in each corner to accommodate 6.3 mm mounting bolts. 2.3.4 All inputs from the loops shall be brought through posted 10-32 X 5/16 inch binder screw terminals or 8-32 X 5/16 inch binder screw terminals. 2.3.5 Each loop pair shall be protected by lightning surge suppresser. The suppressers must be mounted behind the panel using feed through screw terminals to attach the suppressers. 2.3.6 Each detector will have a test switch such that when the switch is closed, a call is placed upon that detector input. The test switch will have three positions; no effect, permanently on, and momentarily on. 2.3.8 A chassis ground bus bar shall be provided on the panel and connected to the cabinet by an insulated braided copper ground strap. The strap shall be bonded to the cabinet. 3.0 PREEMPT / COMMUNICATION PANEL 3.1 A preempt / communication panel shall be part of the detector panel and provide all interface circuits and wiring for preemption and communication functions. The panel shall be located on the left side of the cabinet interior. 4-9 Technical Specifications & Description of Pay Items 3.2 Three input relay circuits, with 120 VAC coil and contacts rated for the application, shall be provided on the preempt panel. These circuits shall be used to isolate the incoming preempt commands from the controller unit logic circuitry. The circuits shall b e p r o g r a m m a b l e t o o p e r a t e w i t h e i t h e r a n o r m a l l y o p e n o r n o r m a l l y c l o s e d r e l a y contact by jumpers on a terminal strip. A barrier strip protected from accidental contact by service personnel shall be supplied to connect the external input. It shall be possible to use either a neutral or hot 120 VAC input. Relays used shall be plug-in Potter Brumfield K10P series/Magnecraft W-78 series or interchangeable equivalent. The relays shall be mounted in relay sockets. 3.3 Adequate protection of the input relay circuits as well as the preemptor circuitry shall be provided to eliminate damage or false preemption commands caused by line transients or lightning surges. The devices shall have a minimum rating of 20 Joules. 3.4 Three momentary test switches, one for each preempt circuit, shall be provided on the preempt panel. The operator shall not be exposed to hazardous voltages during operation of the test switches. 3.5 All necessary interconnection cables and mounting hardware shall be provided. 3.6 There shall be a switch on the preempt/communication panel, which shall release the local controller to operate in an isolated, full-actuated manner, when necessary for maintenance purposes. The switch positions shall be labeled “SYSTEM” and “FREE”. 3.7 Terminal connections for 3 twisted pair communication lines and one telephone line shall also be provided. The protection will consist of series 25 ohm resistors, 15 volt transorbs, and other devices, which allow protection including primary overvoltage protection, resettable overcurrent protection, secondary clamping voltage protection, and fast transient filtering. The secondary overvoltage stage shall allow peak voltages of no more than 250 volts. The fast transient filtering stage shall provide no less than 40 dB/decade of attenuation to transients above the required pass band. The protection shall be provided in an integrated closure with eight (8) input/output terminations and ground connection. 4.0 POWER SUPPLY 4.1 The power supply shall be a shelf mounted, enclosed, 24 VDC power supply in accordance to Clause 5.3.5 of the NEMA Standards Publication TS 2-1992. 4.2 One power supply cable per power supply shall be furnished and installed in each cabinet. The wires shall be terminated to bus bars, terminals on the front of the back panel, detector panels, or connector as appropriate. The connections shall be with forked spade lugs or otherwise as needed. Each individual wire shall be cut to the length required to reach the point at which it is to be connected. 4-10 Technical Specifications & Description of Pay Items 4.3 Power supply should be adequate, and compatible with Autoscope Encore video detection system. 4-11 Technical Specifications & Description of Pay Items SPECIFICATIONS FOR FULLY-ACTUATED SOLID STATE CONTROLLER UNIT (TS-2) WITH TIME BASED COORDINATION, PREEMPTION, AND CLOSED LOOP OPERATION 1.0 SCOPE 1.1 This specification sets forth the minimum requirements for a shelf-mounted (16) sixteen-phase full-actuated solid state controller unit with internal Time-Based Coordination (TBC), railroad/fire (emergency vehicle) preemption and closed loop secondary operation. 2.0 CONTROLLER UNIT 2.1 The controller shall be a Naztec TS-1, Type 2 controller or equal. The controller shall come equipped with an Ethernet communication port. 4-12 Technical Specifications & Description of Pay Items SPECIFICATIONS FOR UPLOAD-DOWNLOAD DEVICE 1.0 SCOPE 1.1 This specification sets forth the minimum requirements for an upload-download device to be supplied with each traffic signal installation. The purpose of this device is to allow programming to take place in a shop environment and the unit can then be transported to the cabinet and upload of the new program can be accomplished quickly with minimal interruption to the operation of the signal. 2.0 UNIT 2.1 The unit shall be a Panasonic Toughbook CF30 Intel Dual Core Processor L7500 (1.60 GHz) 13.3” XGA LCD Touch screen, or approved Equal. 3.0 HARDWARE REQUIREMENTS 3.1 This unit shall be equipped with a minimum of 4.0GB SDRAM (DDR2-667MHz). 3.2 160GB HDD shock-mounted and quick-release 3.3 The unit should include an A/C adapter, and D/C vehicle adapter. 3.4 A DVD Super Multi Drive 3.5 Intel® Wireless WiFi Link 5100 802.11a/b/g/draft-n 3.6 A 6 cell primary battery. 3.7 Backlit Keyboard 3.8 Bluetooth® v.2.0 + EDR (Class 1) 4.0 SOFTWARE REQUIREMENTS 4.1 Operating system of the unit shall be Windows XP Professional, SP3. 4.2 System shall be pre-loaded with Nastec software. 4-13 Technical Specifications & Description of Pay Items SPECIFICATION FOR MAST ARM POLE ASSEMBLY 1.0 GENERAL 1.1 This specification covers steel (as specified in Plans) mast arm and pole assemblies, which, shall include transformer base. All mast arm pole assemblies, as supplied and installed, must conform to the detailed drawings and/or to the requirements in the Plans as to height, general design and finish. 1.2 Drilled shaft foundations for each mast arm pole installation shall be considered an integral part of the respective mast arm pole assembly, when loading and wind design factors are applied. 1.3 Each assembly shall be designed to withstand wind and ice loads per respective signal head(s), sign(s) and on all surfaces of the support assembly, in accordance with the American Association of State Highway and Transportation Officials "Specifications for Structural Supports for Highway Signs, Luminaries and Traffic Signals" and other pertinent specifications of this body. Unless otherwise shown in the Plans, wind speeds used for design shall be based on a 50-year mean recurrence interval. Wind drag coefficient shall be 1.2. Allowable unit stresses in each component of each assembly shall be as provided in the AASHTO Specifications above mentioned. 1.4 All castings shall be true to pattern in form and dimensions, free from pouring faults, sponginess, cracks, blowholes and other defects in any position affecting their strength and value to service intended. Surfaces shall have a workmanlike finish, and no sharp unfilleted angles or corners will be allowed. 1.5 All parts of assemblies of the same manufacturer shall be interchangeable. 1.6 Each pole assembly shall be designed to support respective required dead loads of signal heads, signs and the stresses applied to the exposed areas of all appurtenances based on wind and ice loads per Section 1.3 above. 2.0 POLE SHAFT 2.1 Pole shafts shall be fabricated to satisfy strength requirements of Section 1.0. Welded joints in shafts or arms shall develop the full required strength of the welded member. 2.2 Fabrication. Round continuously tapered shafts shall be formed and welded, and shall have no more than one (1) longitudinal welded joint and no horizontal welded (transverse) joints. After forming and welding, the tapered shaft may be longitudinally rolled under sufficient pressure to flatten welds and to assure 4-14 Technical Specifications & Description of Pay Items continuous uniform taper (on .10-in/ft. or .14-in/ft.). All welds shall be smooth so as to attain the external appearance characteristics of the pole itself. 2.3 All shafts shall meet strength requirements of Section 1.0, and shall be provided with reinforced handholes if shown on the Plans. 3.0 SHAFT BASE 3.1 Steel shaft bases shall be fabricated and constructed with an opening of a size and shape to receive the shaft and shall be welded to the shaft by continuous welds which develop strength of the base and of the adjacent shaft section. Four mounting holes shall be provided in the shaft base with a bolt circle pattern compatible with transformer base. Transformer base mounting bolts and four nuts shall be provided for securing shaft base to transformer base. Ornamental casting covers are required to cover exposed base mounting bolts. 4.0 TRANSFORMER BASE A transformer base of the size and design shown in the plans shall be provided for each pole assembly. The base shall be of fabricated steel and shall develop the strength of the respective adjacent base and shaft. A handhole with cover of the minimum dimensions shown on the plans shall be provided. The cover shall be securely held in place with a noncorrosive holding device such as one or more galvanized bolts. One or more corrosion resistant steel plates, conforming to ASTM Designation A 123, shall be furnished as necessary where the base is subject to abrasive action due to the rotating capabilities of the assembly. The location is generally considered to be the supporting ring on the bottom of the transformer base. The interior side of the hand hole cover shall have a multi terminal (12 min.) compression CV6 Terminal block mounted to it for all signal conductor connections. This is the only point that the splices are to be made. 5.0 ANCHOR BOLTS AND SHIMS Four steel anchor bolts, and template for proper alignment of bolts in foundation, shall be furnished for each pole assembly. Allowable unit stress for each anchor bolt shall be as provided in AASHTO Specifications mentioned in Section 1.4. Transformer base installations require each anchor bolt to be top threaded and fitted with one nut and one flat washer. A set of six (6) "U" shaped galvanized steel shims (3 each, 1/8 inch thick and 3 each, 1/16 inch thick) shall also be furnished with each transformer base. Shoe base poles require that each anchor bolt be top threaded and provided with two (2) nuts and two (2) flat washers. The embedded end of anchor bolts shall have a 900 bend as shown on the Plans, and have a minimum elongation in 2 inches of 16 percent, or in 8 inches of 14 percent. 4-15 Technical Specifications & Description of Pay Items 6.0 SIGNAL HEAD AND LUMINAIRE MAST ARMS Mast arms shall be of the design shown in the Plans and arm and attaching hardware shall meet strength requirements of Section 1.0. Fastening the mast arm assemblings to the shaft by use of set screws (which would cut into or groove the shaft) guys, rods or sway braces will not be acceptable. 7.0 FINISH Painted Finish - All surfaces at the time of paint application shall be in accordance with the requirements of Brush-Off-Blast-Cleaning as specified in Steel Structures Painting Council Specification SSPC-SP7. When shipped, the outside of each assembly shall be coated in a manner that will assure all surfaces, at the time of erection, will be coated with a dry, smooth, continuous, uniform, tightly adhering, nonchalking film that is a minimum of two (2) mils thick measured over the peaks of the anchor pattern. The dried film shall contain, on a weight basis, a minimum of 20% binder solids and a minimum of 25% pigment capable of chemically inhibiting corrosion. A minimum of 12% of the film shall be a chromate type corrosion inhibiting pigment. The inside of each assembly may either be coated in the same manner as the outside or may coated by an acceptable red lead primer. After erection of the assembly, the shop coat shall be touched up with shop primer. After the touch up coat is thoroughly dry, each pole assembly shall be provided with a one (1) mil (dry) thick film of paint specified and approved by the Engineer: Color Product name and #: Super OGF Black; S-400 Cure: 400F- 10-12 MIN PMT Control #: S-400 Resin Type: Super polyester resin Gloss Level: 70-80% “or equivalent”. 8.0 CERTIFICATION REQUIREMENTS The Contractor shall submit for approval by the Engineer, five (5) prints of drawings which show all pertinent information and data required for verifying structural adequacy, and all fabrication and erection details. a.The drawings shall be prepared on sheets 24 x 36 inches in size, with 1 1/2 inch left margin and other margins of 1/2 inch. b.Each sheet shall have a title in the lower right hand corner which includes the names of the Contractor, Fabricator and sheet numbering. 4-16 Technical Specifications & Description of Pay Items c.All material of each component shall be referenced to ASTM Specifications, or to other specifications provided minimum yield points or yield strength and elongations are shown. d.Drawings for only one assembly need be submitted for two or more which are of identical design and dimensions. e.Approval of the drawings shall not relieve the Contractor of the responsibility for correctness and completeness of the drawings, shop fit field connections and proper galvanizing designs when galvanizing is required. f.The drawings shall bear a fully descriptive, detailed certification thereon that the assemblies were structurally designed in accordance with criteria specified in Section 1.0 and specified in the Plans. g.The drawings shall be submitted to and approved by, the Engineer prior to fabrication. 4-17 Technical Specifications & Description of Pay Items POLYCARBONATE RESIN TRAFFIC SIGNAL HEADS 12 INCH, EXPANDABLE, ADJUSTABLE TYPE 1.0 GENERAL 1.1 The Traffic control signal heads shall be in accordance with TxDOT section 682 Vehicle and Pedestrian Signal Heads. 1.2 Each traffic signal face shall consist of a number of identical signal sections rigidly fastened together in such a manner as to present a continuous pleasing appearance. 1.3 All signal heads shall be of the LED variety. 1.4 All signal head housings and back plates shall be black in color. 2.0 SIGNAL FACES AND SIGNAL HEADS 2.1 Signal faces and signal heads shall be as shown in the Plans, and installed per requirements in these specifications. 2.2 All housing cases of signal heads shall be rigidly attached, at top and bottom to 1 1/2" (inside diameter) standard pipe supporting arms or similar hardware, radiating from hubs at the vertical central axis of the head and rigidly attached there to in a manner that will assure permanent alignment of the separate housings. The hub shall be designed to conform to the type of mounting attachment specified and provision shall be made for carrying the leads from each housing enclosed in the supporting arms to a single outlet in the mounting attachments. All units of the assembled head shall be of adequate strength for the purpose intended and shall be constructed of materials not affected by continuous exposure to sunlight or corrosive atmospheres. 2.3 All traffic signal heads are to be equipped with rigidly-mounted, standard 5-inch backplates, of sectioned aluminum or of polycarbonate. Backplates are to be mounted so that signal section door hinging movement is not inhibited, and are to be black in color. Polycarbonate backplates are to have the black color impregnated during the manufacturing process, and painting will not be acceptable. 3.0 HOUSINGS, DOORS, VISORS AND LENSES 3.1 The housing of each section shall be a one piece polycarbonate resin material with sides, top and bottom integrally molded. The housing shall be at least .090" (2.3 mm) thick and shall be ribbed so as to produce the strongest possible assembly consistent with light weight. Two or more sets of internal bosses shall be provided in each section for mounting of a terminal block. Terminal blocks shall be securely mounted (see Section 10). 4-18 Technical Specifications & Description of Pay Items 3.2 The top and bottom exterior of the housing shall be of such shape to assure perfect alignment of assembled sections. The top and bottom of the housing shall have an opening two inches (50.8 mm) in diameter to permit entrance of 1 1/2" (38.1 mm) pipe brackets. 3.3 Individual signal sections shall be fastened together either with at least 4 machine screws between each section or by the bolt and washer method. Complete signal faces shall provide positive locked positioning when used with serrated brackets, mast-arm or span-wire fittings. 3.4 Provision shall be made for accommodation of the particular type of mounting specified and attachment of doors, optical units and such other accessories as may be specified for the particular installation. Cases shall be designed for adequate strength. Fittings and accessories shall be of rust resistant materials capable of withstanding constant exposure to sunlight and corrosive atmospheres, including salt air. All traffic signal housing cases when assembled, together with doors, lenses and mounting attachments, shall comprise a dust-and-moistureproof housing for the optical units, and shall be of such construction as to assure permanent alignment of all lenses in the signal faces. Portions of cases providing for attachment to supporting arms shall be molded with large bosses for the supporting arms. Each housing case shall be so attached to its supporting hardware that it will be adjustable by rotation about its horizontal axis, and may be rigidly clamped in position required. Provision shall be made for carrying the signal leads enclosed in the mounting attachment. 3.5 Traffic control signal housing cases shall be of the sectional adjustable expandable type. The assembled housings for each signal face shall consist of three or more individual sections each designed for housing a single complete optical unit, rigidly connected by means of bolts extending through each section or by individual connectors between sections and forming a single "Signal Face". Both the top and bottom of each section shall be provided with an opening to accommodate 1 1/2" pipe brackets. A locking ring shall be integrally molded around the bottom opening Around the top opening shall be either an integrally molded locking ring or a separate splined locking ring designed to fit into notches. The locking rings shall have a minimum of 46 evenly spaced teeth and shall be so designed that top and bottom rings will mate to provide a perfectly aligned signal head with flush connection between the outer circumference of the sections. Individual units shall be so manufactured that all units are interchangeable. 3.6 "Top" and "Bottom" as used in this section refer to the head assembly in vertical orientation. All heads are to be mounted horizontally. 4.0 HOUSING DOOR 4-19 Technical Specifications & Description of Pay Items 4.1 The housing door of each signal section shall be a one piece polycarbonate resin material. The door shall be attached to the housing by means of two stainless steel hinge pins, or by polycarbonate hinge pins which are an integrally molded part of the housing door. 4.2 Two stainless steel wing screws are to be installed on the side of the door to provide for opening and closing the door without the use of any special tools. Wingscrews shall have a flat-bearing surface or stainless steel flat washer to prevent gouging of the housing door by the wingscrews. Wingscrews shall remain captive in the housing door when the door is open. 4.3 As an alternate to 4.2, a positive latching mechanism, integrally molded into the housing and housing door, is acceptable. 4.4 Design of door, housing, and visor shall be such that no light is visible in the profile view of the signal face. 5.0 OPTICAL SYSTEM 5.1 Each optical system shall be provided with an optical unit consisting of a reflector assembly with leads to the terminal block (which is to be furnished in each complete housing) together with all bolts, nuts, screws, clips, hinges, lugs and incidentals necessary for mounting the various parts of the optical assembly. 5.2 Optical system shall consist of a yellow or yellow arrow, green or green arrow lens with a nominal size of 8 3/8 " (200 mm) or 12" (300 mm) as specified.All indicators (red, yellow & green, including PED) shall be LED assemblies . Lenses shall be glass and shall be permanently marked, in an inconspicuous manner, indicating the top of the lens and the name or trademark of the manufacturer. When installed, each lens shall be properly "top" oriented in the horizontally mounted head. 6.0 REFLECTORS (Not applicable) 7.0 LAMP RECEPTABLE (Not applicable) 8.0 WIRING 8.1 Each LED assembly shall be provided with two flexible insulated color coded leads not smaller than No. 18 American Wire Gauge. These leads are to be securely fastened to the lamp socket and connected to a terminal block in the same section by means of solderless wire connectors or binding screws and spade lugs. Color coding for the identification of the different leads shall be individual so that each lead can be identified separately by coding alone. In general, the coding for the identification of the leads shall be as follows: Lens Hot Wire Neutral Wire Red Red White w/R Tracer 4-20 Technical Specifications & Description of Pay Items Yellow Arrow Red w/Y Tracer White w/R & Y Tracer Yellow Yellow White w/Y Tracer Green Green White w/G Tracer St. Arrow Blue White w/B Tracer Lt. Arrow Blue w/R Tracer White w/B & R Tracer Rt. Arrow Blue w/Y Tracer White w/B & Y Tracer 9.0 VISORS 9.1 Each signal door shall be equipped with a detachable standard tunnel (unless otherwise shown in the Plans), polycarbonate resin visor fastened at four or more points to the door. 9.2 The visor shall have a downward tilt of 3 1/2 to 5 degrees and shall encompass approximately 300 degrees of the lens. Heads may be shipped with visors detached. If heads are shipped with visors attached, visors shall be easily removed and replaced without damage to visor or signal head. 10.0 TERMINAL BLOCKS 10.1 Each optical unit (or section) of each signal head shall be wired to a terminal block mounted near the bottom inside of the unit. The terminal block shall be securely mounted in an accessible position, be of molded weatherproof construction, and be equipped with identified terminals for signal (interior) and field wires. Binding screws shall be provided for field wires. Solderless connectors or binding screws shall be provided for interior wiring to the optical unit. 10.2 In addition to individual terminal blocks described above, each multiple section signal (head) will be provided with a common terminal block mount in the top section of each signal head. Each assembled signal head shall be wired by the supplier to the common terminal block. 10.3 If specified, an additional terminal block located within a compartment shall be provided for common wiring of multiple signal heads located on a single pole or pedestal. The terminal compartment shall be weatherproof with cover and molded- construction terminal block with separate, identified terminals for signal and field wires. A sufficient number of terminals shall be provided to handle all optical unit wires. A minimum of twelve connector sets shall be provided. Color coding of leads shall be maintained, individually, from each optical unit lampholder to respective terminal in the compartment. Commons from each housing shall be grouped and carried to one terminal in the compartment. 4-21 Technical Specifications & Description of Pay Items 10.4 Use of terminal compartment described in 10.3 does not eliminate the requirements for those specified in 10.1 and 10.2. 11.0 MOUNTING AND ATTACHMENTS 11.1 All mounting attachments shall be of adequate strength for the purpose intended and shall be constructed of materials not affected by continued exposure to sunlight or corrosive atmospheres, particularly salt air. Provisions shall be made for carrying the signal leads enclosed in the mounting attachment. The mounting attachment, together with supporting arms and assembled housings, shall comprise a dust-and- moisture-proof enclosure for optical units and lead wiring. Mounting attachments shall be as specified for the particular head on the Plans. 11.2 The signal heads, vertically mounted on the signal mast arms shall be installed so that door hinges are on the bottom edge, and all doors open downward. 12.0 MATERIAL All material used in construction of major signal components shall be of polycarbonate resin. This material shall be such that it will withstand 70 foot-pounds of impact without fracture or permanent deformation. 13.0 COLORS The color of signal heads and hardware shall be black. The underside of visors shall be painted a flat black. Color as specified shall be integrally impregnated in the polycarbonates resin in the molding process. 14.0 MEASUREMENT AND PAYMENT 14.1 Measurement: Traffic signal heads and backplates of the types specified on the Plans will be measured per each unit. Materials required and used in installation, such as LED’s, attachment pipe and brackets, hardware, internal head wiring, paint, etc., will not be measured directly, but will be considered subsidiary to the Item "Traffic Signal Sections". 14.2 Payment: Traffic signal head and backplate units, provided, installed and in place, will be paid for at the unit price bid for respective types specified in the bid item list. Said prices shall be full compensation for providing and installing heads and backplates, and for furnishing and installing all described attachment hardware, signal lamps, internal wiring, and paint and for all labor, tools, materials, equipment and incidentals necessary to complete the work. 4-22 Technical Specifications & Description of Pay Items UNDERGROUND TRAFFIC SIGNAL REQUIREMENTS: CONDUIT, GROUND BOXES, CONCRETE CABINET FOUNDATIONS AND INSTALLATION PROCEDURES 1.0 CONDUIT 1.1 Description 1.1.1 This item shall govern for the furnishing and placing of conduit of the types and sizes indicated on the plans, including ground boxes, fittings, expansion joints, attachments and incidentals. 1.1.2 Unless otherwise shown on the Plans, all conductors shall be in conduit except when in metal poles. All conduit and fittings shall be of the sizes and types shown on the plans. 1.1.3 The Contractor may, at his own expense, use conduit of larger size than specified on the Plans providing that the larger size is used for the entire length of conduit run. 1.2 Materials 1.2.1 All conduit and fittings shall meet the requirements of the National Electrical Code and shall be listed by Underwriters Laboratories, and shall be marked in accordance with the applicable requirements of the NEC. 1.2.2 Ground boxes, expansion joints and conduit fittings shall be fabricated from a material similar to the connecting conduit unless indicated otherwise on the plans and shall be listed by Underwriters Laboratories. 1.2.3 Rigid metal conduit shall be steel, hot-dipped galvanized inside and outside. When tested in accordance with ASTM designation: A 90 zinc coating shall be a minimum of 1.5 ounces per square foot. Electrical metallic tubing and intermediate metal conduit shall be steel, hot-dipped galvanized on the outside and protected on the inside with a suitable corrosion resistant material. Fittings shall be rain-tight. Set screw and pressure cast fittings will not be permitted. 1.2.4 Polyvinylchloride and high-density polyethylene conduit shall meet the requirements of NEMA Standard TC-2 and UL 651, and the requirements of NEC for Rigid Nonmetallic Conduit. Unless otherwise noted on the plans, PVC conduit shall be heavy-wall (Schedule 40). 1.2.5 Flexible conduit shall be liquid-tight metal meeting requirements of NEC and shall be UL-listed. Where conduit system is metallic, all lengths of flexible metal conduit shall be fitted with bonding jumpers. 4-23 Technical Specifications & Description of Pay Items 1.3 Construction Methods 1.3.1 The conduit, ground boxes, fittings and incidentals shall be placed in accordance with the lines, grades, details and dimensions shown on the plans, or as directed by the Engineer. Installation of conduit shall be in accordance with the requirements of NEC. Conduit placed for concrete encasement shall be secured and supported in such a manner that the alignment will not be disturbed during the placement of the concrete. No concrete shall be placed until all of the conduit ends have been capped and all box openings closed. 1.3.2 Where conduit is threaded in the field, a standard conduit cutting die with a 3/4 inch tape per foot shall be used. Conduit placed on structures shall be firmly fastened within 3 feet of each outlet box, ground box or fitting and at other locations as required by the NEC. 1.3.3 When required by the Engineer, immediately prior to installation of conductors or final acceptance, a spherical template having a diameter of not less than 75 percent of the inside diameter of the conduit shall be drawn through the conduit to insure that the conduit is free from obstruction; then all conduit ends shall be closed using permanent type caps. 1.3.4 Conduit terminating in controller cabinet shall extend vertically, approximately two inches above the concrete foundation. Field bends in rigid metal conduit shall have a minimum radius of 12 diameters of the nominal size of the conduit. 1.3.5 Each length of galvanized rigid metal conduit where used, shall be reamed and threaded on each end and couplings shall be made up tight. White-lead paint or equal shall be used on threads of all joints. PVC conduit shall be joined by solvent-weld method in accordance with the conduit manufacturer's recommendations. No reducer couplings shall be used unless specifically indicated on the Plans. 1.3.6 All conduit and fittings shall have the burrs and rough places smoothed and shall be clean and free of obstructions before the cable is installed. Ends of conduits shall be capped or plugged until starting of wiring. A nylon or non-metal pull tape shall be used in pulling cables and conductors through PVC conduit. Metal tapes will not be permitted in PVC conduit. The conduits shall be placed as shown on the Plans or as directed by the Engineer. 1.3.7 PVC conduit which is to be placed under existing pavement, sidewalks, and driveways shall be placed by first providing a void through which the PVC conduit shall be inserted. The void may be accomplished by either boring or jacking a mandrel. If it is determined by the Engineer that it is impractical to place the conduit as outlined above due to unforeseen obstructions, written permission may be granted by the Engineer for the Contractor to cut the existing pavement. Pits for jacking or boring shall not be closer than two feet to the back of the curb or outside edge of the shoulder unless otherwise directed by the Engineer. The jacking or boring method 4-24 Technical Specifications & Description of Pay Items used shall not interfere with the operation of street, highway, or other facility, and shall not weaken or damage any embankment, structure, or pavement. Heavy jacks are to be used for jacking. Boring is to be done by mechanical means providing a maximum one-inch cover cut for the conduit to be placed, and use of water or other fluids in connection with the boring operation will be permitted only to the extent to lubricate cuttings. Water jetting will not be permitted. Where conduit is to be placed under existing asphaltic pavement, the jacking method is to be used unless written approval is given by the Engineer for placement of conduit by boring. 2.0 GROUND PULL BOX 2.1 General 2.1.1 The purpose of this specification is to describe a precast concrete, ground (pull) box with cover and extension (if required) for use in underground traffic signal systems. The box shall be used for terminating and beginning conduit runs of various sizes and also for accessibility when pulling signal or interconnect cable. 2.2 Description 2.2.1 This item shall govern the construction, furnishing and installation of precast ground boxes in accordance with locations and details shown on the plans. Unless otherwise noted on plans, ground boxes shall be precast concrete. 2.2.2 The assembly shall consist of box, cover, and extension (if required). The box and extension shall be precast concrete. The cover shall be galvanized steel. The cover shall be fabricated so as to fit properly in a recessed lip for full and stable contact on the box and be secured thereon with at least two stainless steel bolts. The legend "Traffic Signals" shall be integrally cast into the top surface of the cover, and the cover shall be provided with a sturdy, stainless steel drop handle to facilitate removal. 2.2.3 The ground boxes shall have the minimum outside dimensions (LWH) of 19" x 13" x 12". The bottom portion of each will be open, with sturdy flange around the perimeter so that the box seats firmly on the top of extension. A minimum of four knockouts, to accept three inch duct, one on each end and side, shall be provided in each box and extension section. 2.3 Materials 2.3.1 Concrete used for constructing the precast concrete ground boxes shall be Class A conforming to the requirements of the Standard Specifications for Public Works Construction North Central Texas, "Concrete For Structures". Reinforcing steel used in the construction of the ground boxes shall conform to the requirements of the "Steel Reinforcement". 2.4 Construction Methods 4-25 Technical Specifications & Description of Pay Items 2.4.1 The construction and installation of the ground boxes shall be carried out in compliance with the requirements herein stated and in conformity with the details shown on the plans. Upon completion of the work, each installation shall present a neat and workmanlike finished appearance. 3.0 CABINET FOUNDATIONS 3.1.1 All concrete materials and their preparations shall be in accordance with the requirements contained in Standard Specifications for Public Works Construction North Central Texas, "Drilled Shaft Foundation," and the additional requirements herein. 3.1.2 All concrete used in the project shall have the following mix proportions and characteristics: a.Minimum Sacks of Cement (Type 11 Portland) per cubic yard - 5.0 b.Maximum Water - Cement Ratio - 6.5 c.Maximum Size of Aggregate - 1 inch d.Minimum Compressive Strength (28 day cure at 70 F.) 3000 psi e.Slump Range in inches - 3 to 5 Use of a cement dispersing agent is permissible, but not required when the temperature of ambient air or of the concrete mix is above 85 F. 3.2 Excavation for all required foundations shall be done in accordance with lines and depth indicated on the Plans. All loose material shall be removed from the excavation before the concrete is placed. Any water shall be removed by pumping or bailing. The use of explosives will not be permitted. 3.2.1 Foundations shall be constructed to the dimensions shown on the Plans or directed by the Engineer. Care shall be used to insure that the top of the finished foundation is exactly level. Anchor bolts and conduits shall be held rigidly in place by a template until the concrete is set. A mechanical vibrator shall be used for compacting and working the concrete. After the concrete has been placed and the top struck off, it shall be covered with wet cotton or burlap mats, for not less than ninety-six (96) hours. 3.2.2 Backfill shall be tamped with mechanical tamps in 6-inch layers to the density of the surrounding ground. Where excavation is made in the surfaced shoulder, the shoulder shall be replaced with material equal to the original construction. 3.2.3 All excavated material not required for backfill shall be promptly removed and disposed of by the Contractor outside the limits of the project. 4-26 Technical Specifications & Description of Pay Items 3.2.4 No concrete shall be placed when the atmosphere temperature is at or below 40 F. (taken in shade away from artificial heat) unless permission to do so is given by the Engineer. 4.0 MEASUREMENT AND PAYMENT 4.1 Cabinet Foundation a.Measurement. Foundations will be measured per each unit. Materials required and used in installation, such as reinforcing steel, ground rods and forms will not be measured directly but will be considered subsidiary to the Items "Drilled Shaft Foundation" and "Cabinet Foundation". b.Payment. Foundations installed in place, will be paid for at the unit price bid for respective types specified in the bid item list. Said prices shall be full compensation for furnishing and installing all required materials, such as reinforcing steel, concrete, ground rods, anchor bolts, and for all labor, materials, tools, equipment, all backfilling, and incidentals necessary to complete the work. 4.2 Ground Boxes a.Measurement. Ground boxes will be measured per each unit. Materials required and used in installation, such as bedding gravel, will not be measured directly, but will be considered subsidiary to the Item "Ground Boxes". b.Payment. Ground boxes, provided and installed in place as shown on the Plans will be paid for at the unit price bid specified in the bid item list. Said prices shall be full compensation for furnishing and installing and for all labor, tools, materials, equipment and incidentals necessary to complete the work. 4.3 Conduit a.Measurement. Conduit of the respective sizes and material type specified on the Plans, will be measured per lineal foot. Materials required and used in installation, such as couplings and connecting hardware, will not be measured directly, but will be considered subsidiary to the Item "Conduit". b.Payment. Conduit, provided and installed in place will be paid for at the unit price bid for respective size and type specified in the bid item list. Said prices shall be full compensation for furnishing and installing all described connecting hardware, for cleaning existing conduit sections (those to be reused) and for all labor, tools, materials, equipment and incidentals necessary to complete the work. 4-27 Technical Specifications & Description of Pay Items MULTIPLE CONDUCTOR AND SINGLE CONDUCTOR TRAFFIC SIGNAL CABLE AND WIRE 1.0 GENERAL This specification covers polyvinylchloride compound-jacketed polyethylene- insulated multi-conductor cable, and polyvinylchloride compound-insulated single conductor wire, rated 600 volts, for use in signal systems in underground conduit, as aerial cable supported by a messenger or for induction loop detector wire. 2.0 GENERAL CONSTRUCTION Cable under this specification shall be composed of uncoated copper conductors individually insulated with heat stabilized polyethylene (multi-conductor) or with polyvinylchloride compound (single conductor) as specified herein. Multiple insulated conductors shall be laid up in a compact form, bound with suitable tape, and jacketed with polyvinylchloride compound. 3.0 CONDUCTORS 3.1 The copper conductors shall, before insulating, conform to the requirements of ASTM Designation B-3, latest revision for soft annealed copper wire, and ASTM B-8 for concentric lay, stranded copper wire. 3.2 The conductors shall be stranded unless otherwise specified in the plans and specifications. 3.3 The number and size of the conductors shall be as specified in the plans and specifications. 4.0 INSULATION 4.1 Multi-Conductor Cable The insulating compound before application to the conductors shall be heat-stabilized polyethylene conforming to the requirements of ASTM Designation Dl 248, 63T, Type 1, Class B, Grade 4. The insulation shall be applied concentrically about the conductor. Insulation after the application to the conductors shall meet the following requirements when tested in accordance with the procedures given in ASTM Designation Dl 351, latest revision, and ASTM Designation D470, latest revision. Physical Properties of Polyethylene Insulation 4-28 Technical Specifications & Description of Pay Items a.Initial Properties: Tensile strength, lbs. per sq. in., minimum 1400 Elongation at rupture, percent, minimum 350 b.After 48 hours in air oven at 100 °C: Tensile strength, percent of original, minimum 75 Elongation at rupture, percent of original, minimum 75 c.Cold Bend Test, 1 hour at -55°C; plus or minus 1 degree no cracks (Mandrel diameter 2.5 times insulation diameter). 4.2 The nominal thickness of the insulation shall be not less than that specified in Table 1. The minimum thickness of the insulation shall be not less than 90 percent of the nominal value. 4.3 Moisture Absorption a.After a twenty-four hour immersion in tap water at 50°C plus or minus 1°C, the specific indicative capacity of the insulation shall be not more than 2.5. After a continued fourteen day immersion, the specific inductive capacity shall be not more than 1.5 percent higher than the value determined at the end of the first day, nor more than 1.0 percent higher than at the end of the seventh day. b.The moisture absorption tests shall be conducted in accordance with methods specified in IPCEA S-61-402, NEMA WC5, latest revision. 4.4 Electrical Properties a.Dielectric Strength Each processed length of insulated conductor before cabling shall withstand the test voltage specified in Table 1 for a period of 5 minutes after immersion in water for not less than 6 hours and while still immersed. b.Insulation Resistance Each processed length of insulated conductor, after withstanding the Dielectric Strength Test, and while still immersed, shall comply with the insulation resistance requirements of Table I. c.The Dielectric Strength and Insulation resistance Tests shall be conducted in accordance with the requirements of ASTM Designation D470, latest revision. 4-29 Technical Specifications & Description of Pay Items TABLE I INSULATION THICKNESS, TEST VOLTAGE AND INSULATION RESISTANCE Conductor Size AWG Insulation Thickness Inches Test Voltage Insulation Resistance at 60°F. Megohms - 1000 Feet 20 .025 2500 15,000 19 .025 2500 15,000 18 .025 2500 15,000 17 .025 2500 15,000 16 .025 2500 14,800 15 .025 2500 13,700 14 .025 2500 12,600 13 .030 3000 13,200 12 .030 3000 12,100 11 .030 3000 11,000 10 .030 3000 10,100 9 .030 3000 9,200 8 .030 3000 8,300 4.5 Single Conductor Cable The insulation shall be tough, durable, stabilized polyvinylchloride compound meeting the requirements of Underwriter's Laboratories Type THW. 4.6 The physical characteristics of the insulation shall be as given in Table II. Tests of these characteristics shall be made in accordance with ASTM designation D- 470, latest revision. 4-30 Technical Specifications & Description of Pay Items TABLE II a. Initial Properties: Tensile strength, lbs. per sq. inch, min. Elongation, percent, min. 2300 250 b.After 120 hours in Air Oven at 100 °C: Tensile strength, percent of original, min. Elongation at rupture, percent of original, min. 85 60 c.Cold Bend Test. 1 Hour at -55°C, no cracks (Mandrel Diameter 2.5 times covering diameter) d. Flame Test, self-extinguishing in minutes, max.1 4.7 Thickness, Diameters and Weights a.The completed conductor shall conform to the requirements of Table III. b.The thickness of the insulation shall be not less than 90% of the nominal value in Table III. c.The minimum spot thickness shall be not less than 70% of the nominal thickness. TABLE III Conductor Size AWG Nominal Thickness of Covering Approx. O.D. Inches Approx. Weight Lbs/M Ft. 4 .045".300 131 6 .045".260 85 8 .045".220 56 10 .030".174 34 12 .030".140 23 5.0 CONDUCTOR COLOR CODING 5.1 Multi-Conductor Cable Standard color coding for cables shall be in accordance with Table IV. When permitted by the purchaser, the conductor coding may be numerals and words printed on the conductor insulation. Base colors shall be obtained by the use of colored insulation. Tracers shall be colored stripes or bands which are part of, or firmly adhered to, the surface of the insulation in such a manner as to afford distinctive circuit coding throughout the length of each wire. Tracers may be in 4-31 Technical Specifications & Description of Pay Items continuous or broken lines, such as a series of dots or dashes, and shall be applied longitudinally, angularly, spirally or in other distinctive patterns. TABLE IV CONDUCTOR COLORS AND SEQUENCE Conductor No.Base Color First Tracer 1 Black 2 White 3 Red 4 Green 5 Orange 6 Blue 7 White Black 8 Red Black 9 Green Black 10 Orange Black 11 Blue Black 12 Black White 13 Red White 14 Green White 15 Blue White 16 Black Red 17 White Red 18 Orange Red 19 blue Red 20 red Green 21 orange Green 5.2 The color sequence may be repeated as necessary. Color code sequence applies when cable is composed of mixed sizes. 5.3 Special color coding, when specified in unpaired conductor cables, shall consist of black for all conductors except that one conductor shall be identifiable conductor in each layer. 4-32 Technical Specifications & Description of Pay Items 5.4 For combination cables consisting of pairs with single conductors, color code sequence given in Table IV, shall be used for pairs, repeated as necessary. 5.5 Single Conductor Cable Black covering shall be used for signal and power circuit positive. White covering shall be used for signal and power circuit common. Red covering shall be used for detector positive. Blue covering shall be used for detector circuit common. Covering colors shall be obtained by use of colored polyvinylchloride. 6.0 CONDUCTOR ASSEMBLY (MULTI-CONDUCTOR CABLE) 6.1 Two-Conductor Cable a.Two-conductor cables shall have a maximum length of lay not more than 30 times the installed conductor diameters. b.Two-conductor cables shall be of the round, twisted type. c.Fillers shall be used where necessary to form a two-conductor round twisted cable. 6.2 Multi-Conductor Cables Having More Than Two Conductors a.In multi-conductor cables having more than two conductors, the single conductors shall be laid up symmetrically in layers with lay not exceeding the following: Number of Maximum Conductors Length of Lay 3 35 times insulated conductor diameter 4 40 times insulated conductor diameter 5 or more 15 times assembled core diameter b.Each layer of conductors in the cable shall be laid in a direction opposite to that of adjacent layers. When permitted by the purchaser, unidirectional lay may be used. The outer layer shall be left-hand lay. 6.3 Fillers shall be used, where necessary, to secure a uniform assembly of conductors of a firm, compact cylindrical core. Fillers shall be of a nonmetallic moisture-resistant material which has no injurious effect on adjacent components. 6.4 The conductor assembly shall be covered with a spiral wrapping of a moisture- resistant tape applied so as to lap at least 10 percent of its width. 4-33 Technical Specifications & Description of Pay Items 7.0 JACKET (MULTI-CONDUCTOR CABLE) 7.1 Over the taped conductor assembly there shall be applied a tightly fitting polyvinylchloride compound jacket which shall meet the following requirements when tested in accordance with ASTM Designation D1047, latest revision. PHYSICAL PROPERTIES OF POLYVINYL CHLORIDE JACKET a. Initial Properties: Tensile Strength, lbs., per sq. in., min. Elongation at rupture percent, min. 1800 250 b.After 5 days in air oven at 100°C: Tensile Strength percent of original, min. Elongation at rupture percent of original, min. 85 60 c.Head Shock Test, Air Oven, 1 hour at 121 °C: no cracks d.Heat Distortion Test, Air Oven, 1 hour at 121 °C: Decrease in thickness, percent, max.50 e.Cold Bend Test, 1 hour at -40°C: no cracks f. Flame Test, minutes burning, max.1 g.After 4 hours in ASTM No. 2 oil at 70 °C: Tensile Strength, percent of original, min. Elongation at rupture, percent of original, min. 80 60 7.2 The nominal thickness of the jacket shall be as specified in Table V. The average thickness shall be not less than 90% of the specified thickness. The minimum thickness shall be not less than 70% of the nominal thickness. TABLE V Calculated Diameter of Cable Under Jacket, Inches Jacket Thickness 0.425 and less 45 0.426 - 0.700 60 0.701 - 1.500 80 1.501 - 2.500 110 4-34 Technical Specifications & Description of Pay Items 2.501 and larger 140 8.0 IDENTIFICATION 8.1 Each shipping length of multi-conductor cable shall have a tape showing the name of the manufacturer and the year in which the cable is manufactured, placed over or under the tape covering the conductor assembly before the application of outer coverings. As an alternate method of identification, the above information may be applied to the outer surface of the jacket. 8.2 Each shipping length of single conductor shall have indented printing on a tape or other permanent identification showing the name of the manufacturer and the year in which the conductor is manufactured. 9.0 SAMPLING, INSPECTING AND ACCEPTANCE 9.1 Inspection and tests shall be made prior to shipment and at the place of manufacture. 9.2 The Contractor shall furnish the Engineer in suitable form, a certified report of the tests made on the cable to show compliance with this specification. 9.3 Tests on Entire Cable - The individual conductors of each length of completed cable shall meet the voltage and insulation resistance requirements of Section 4, except that the final electrical test on multiple conductor cables may be made without immersion in water. Each conductor of a multiple conductor cable shall be tested against all other conductors and shield if present. 9.4 Sample Tests - One sample for establishing conformity to this specification shall be taken from each 10,000 feet or fraction thereof, of each type and size of cable except that for the physical dimensions and the visual inspection a sample shall be taken from each reel. I n case that these samples fail to meet the requirements of this specification, two additional samples shall be selected from new cable lengths and the lot shall be accepted if retests are both satisfactory. However, in case of any failure on the retest, the lot shall be rejected. 10.0 PACKING AND MARKING FOR SHIPMENT Reels for multi-conductor cable shall be substantially constructed and in good condition. The cables shall be suitably protected. Each end of the cable shall be available for testing, properly sealed, and protected against injury. Each reel shall be plainly and permanently marked with manufacturer's full description of the cable, giving the length of the cable on the reel, the number of conductors in the cable and the date of shipment from the factory. 11.0 INSTALLATION OF CABLE 4-35 Technical Specifications & Description of Pay Items 11.1 General 11.1.1 The cables shall be installed in the conduit. The conduit must be continuous, reasonably dry, completely free of debris, and without any sharp projections, edges, or short bends. The conductors shall be installed in such manner and by such methods as to insure against harmful stretching of the conductor or damage to the insulation and shall conform to the recommendations of the cable manufacturer. The Contractor shall furnish, at the request of the Engineer, at least two copies of the manufacturer's recommendations, including methods of attaching pulling tension per conductor size and per radius of conduit bend, and the type of lubricant to be used. 11.1.2 All cables in a given conduit run shall be pulled at the same time and the conductors shall be assembled to form one loop in such a manner that the pulling tension is distributed to all the cables. Long, hard pulls will necessitate the use of pulling eyes. For short runs, the cables may be gripped directly by the conductors by forming them into a loop to which the pull wire or rope can be attached. The insulation on each conductor shall be removed before the loop is formed. The method used will depend on the anticipated maximum pulling tension in each case. 11.1.3 In many instances, existing conduits which contain signal cable are to be used for the installation of new cables. In such locations, the existing cable(s) may be used to pull in the new cables. Should the Contractor desire to install new cables without removing the existing cables, the new installation shall be done in such a way as to prevent damage to the existing and/or new cables. In the event of damage, the Contractor shall bear the responsibility of replacement of defective cables. 11.1.4 The manufacturer's recommended maximum pulling tensions shall not be exceeded under any circumstances. If so required by the Engineer, the Contractor shall insert a dynamometer in the pull wire as the cables are being pulled into the conduit to demonstrate that the maximum tensions are not being exceeded. The cable shall be fed freely off the reel into the conduit without making a reverse curve. At the pulling end, the pull wire and or other suitable devices shall be used as required to reduce any hazards to the cable during installation. The cables shall be adequately lubricated to reduce friction and further minimize possible damage. Such lubricants shall not be the grease or oil type used on lead sheathed cables but shall be one of several commercially available wire pulling compounds that are suitable for these kinds of cables. They shall consist of soap, talc, mica, or similar materials and shall be designed to have no deleterious effect on the cables being used. 11.1.5 The cables shall be neatly trained to their destinations in manholes, cabinets, pole bases, pullboxes, and all other terminations. The cable manufacturer's recommended values for the minimum bending radii to which cables may be bent for permanent training during installation shall be adhered to. These limits do not apply to conduit bends, sheaves or other curved surfaces around which these cables may be pulled 4-36 Technical Specifications & Description of Pay Items under tension while being installed. Larger radius bends are required for such conditions. 11.2 Wire and Cable 11.2.1 All wire and cable shall conform to the requirements shown on the plans, except wire and cable specifically covered by other items of this contract. The minimum size of conductors shall be as indicated on the plans. 11.3 Controller Cabinet Wiring 11.3.1 Wiring for the controller shall consist of connecting to its terminals (1) wires to signals (2) wires to detectors (3) wires to pedestrian push buttons (4) the power wires, (5) the ground wires, and (6) the interconnect wires. At the controller all conductors from the field shall be stripped back and an eye hook formed in the wire. These "hooks" shall be inserted under the binder head screw and tightened securely. Other wiring for the controller shall be as required by the wiring diagrams and instructions furnished with the controller by the manufacturer. 11.3.2 All field wiring in cabinets shall be neatly done. Incoming cables shall be trained to their destination and neatly laced together. Communication and detector lead-in cables shall be clearly identified by use of metal or plastic tags. For example: Eastbound Right Lane. 11.4 Signal Head Wiring 11.4.1 Wiring for the signal head shall consist of connecting the terminal block in each signal section to the common terminal block in each signal face and where applicable, connecting the common terminal block in each signal face to the terminal block in the signal-head terminal compartment. All such connecting wires shall be number twelve (12) American Wire Gauge. All conductors running from any terminal points located in the pole or transformer base to the signal head terminals shall likewise be number twelve (12) A.W.G. The Contractor shall furnish the NO. 12 A.W.G. for this work. 11.5 Terminals and Splices 11.5.1 Except for controllers, the ends of all wires which are to be attached to terminal posts shall be provided with soldered terminals that meet the requirements of the National Electrical Code. 11.5.2 Unless otherwise called for in the plans, splices will be permitted in the wires of signal conductors only in the base of each signal pole at terminal points called for in the plans. If lead-in conductors from detectors to controller are of different type than the detector leads, a water-tight splice, acceptable to the Engineer, may be made in ground box adjacent to the detector location. Splices at points other than as stated above may be made only with the written permission of the Engineer. All splices shall be water 4-37 Technical Specifications & Description of Pay Items tight. Splicing methods shall be in accordance with good electrical practice and the cable manufacturer's recommendations. All materials used shall be high quality and specifically intended for these purposes. The cables shall be trained to their final position and cut to proper lengths. The jacket and insulation shall be removed as required. In doing this, use proper care to insure against nicking the conductors. The connector shall be soldered. Heat shall be applied by the use of hot solder. Heating the connection with a direct flame will not be permitted. Care shall be used to protect the insulation when soldering. The entire surface shall be cleaned taking special care in cleaning outside jacket in order to remove the wax finish. Before the first layer of tape is wrapped, the entire area shall be coated with an electric grade rubber cement. After this solvent has dried, the connection shall be insulated with electrical grade rubber splicing compound tape to proper thickness. This tape requires a pressure and thus must be stretched to 2/3 width when applied. The completed splice shall be covered with a half-lap layer of vinyl plastic electrical tape. This wrapping shall be smooth but the tape shall not be stretched more than necessary. 11.5.3 Splices in communication cables shall include the shield. Splices between cable pairs shall be made with Scotchlock solderless connectors designed for this specific application. The completed splice shall be insulated with a re-enterable plastic splice case. Splices at points other than those shown on the plans may be made only with the written permission of the Engineer. 11.5.4 The Engineer shall select at random at least 5 splices to be thoroughly inspected. The Contractor shall, in the presence of the Engineer, sectionalize the splice to expose the various layers of materials and the connector. The splice shall be thoroughly checked for compliance to these special provisions. The splice shall then be remade by the Contractor. This work shall not require extra payment, but is considered subsidiary to other items in the contract. All of the splices selected for this inspection shall conform to the requirement of these special provisions. If any splices fail to meet these requirements, ten (10) more splices shall be selected to random by the Engineer for inspection. 11.6 Enclosed Wiring 11.6.1 Except for span wire suspended cables and electrical wiring within steel signal poles, all cables and single conductor wire above the ground surface shall be enclosed in approved metal conduit up to but no closer than one foot of the lowest power conductor. The power entrance to the controller may be made through underground polyvinyl-chloride conduit. 11.7 Identification of Signal Wires 11.7.1 IMSA color coded signal cable shall be used to wire bases, pullboxes and controllers. Colors shall be continuous from the point of origin to the point of termination. Splices will be permitted if same colors are spliced. 4-38 Technical Specifications & Description of Pay Items 12.0 GROUNDING AND BONDING 12.1 There shall be a properly installed and connected ground rod for each controller cabinet and power drop to reduce any extraneous voltage to a safe level. The location of the ground rod shall be such as to minimize the length of the grounding-conductor run. All grounding circuits shall be substantial and permanent and shall be electrically continuous with an ohms-to-ground resistance not to exceed 10 ohms when tested by a volt-ohm-meter. 1 2.2 Signal and Controller 1 2.2.1 The signal pole housing, controller housing, signal common and service common shall be grounded. All groundings shall be as shown on the plans and/or may be indicated in the manufacturer's specifications and wiring diagrams. All grounding devices used shall conform to the requirements of the National Electrical Code. The service common at the pole from which the power is taken shall be grounded. 1 2.3 Conduit and Signal Posts 1 2.3.1 Metal conduit and metal signal posts or pedestals shall be bonded to form a continuous system and shall be effectively grounded. Bonding jumpers shall be No. 8 copper- wire or equal. 12.4 Grounding Connectors and Electrodes 1 2.4.1 The grounding conductor shall be a No. 8 A.W.G. stranded copper wire. The conductor shall be bonded to ground rods. Ground rod electrodes shall be copper- bonded steel being at least 5/8 inch in diameter and shall be driven into the ground to a depth sufficient to provide the required resistance between electrodes and ground (10 ohms). All ground rods shall be a minimum of six feet long. When the location precludes driving a single ground rod to a depth of six feet or when a multiple ground rod matrix is used to obtain the required resistance to ground, ground rods shall be spaced at least six feet apart and bonded by a minimum No. 8 A.W.G. copper wire. Connections to underground metallic conduit shall not be considered sufficient for grounding requirements. Connection of grounding circuits to grounding electrodes shall be by devices which will ensure a positive, fail-safe grip between the conductor and the electrode (such as lugs or pressure connectors). No splice joint will be permitted in the grounding conductor. 4-39 Technical Specifications & Description of Pay Items 13.0 MEASUREMENT AND PAYMENT Single and multi-conductor cable, installed and in place, and of the size and number of conductors specified on the Plans, will be paid for at the unit prices bid as specified in the bid item list. Said payment shall be full compensation for furnishing and installing cable with proper grounding, and for all labor, tools, materials, equipment and incidentals necessary to complete the work. 14.0 GUARANTY If it is the normal trade practice for the manufacturer to furnish a guaranty for the work provided herein, the Contractor shall turn this guaranty over to the Engineer for potential dealing with the guarantor. The extent of such guaranty will not be a factor in selecting the successful bidder. 4-40 Technical Specifications & Description of Pay Items POWER SERVICE AND SERVICE EQUIPMENT AND GENERAL SYSTEM WIRING PROCEDURES 1.0 POWER SERVICE AND SERVICE EQUIPMENT 1.1 Power Service Connection 1.1.1 The Contractor shall make all arrangements for connection to the power service, shall obtain meter and meter socket from the Power Company when they are required and install them in accordance with the Plans, and shall furnish and install all other materials necessary to make the power connection which are not furnished by the Power Company. Coordination with the correct service provider and/or TXU for all service related issues will be the requirement of the Contractor. 1.1.2 Unless otherwise called for in the Plans, the power connection shall be made to a 115- 125 volt, single-phase, 60 cycle A.C. supply. The wire used for the power connection shall be a minimum size as indicated on the Plans and shall be insulated for six hundred (600) volts. The common wire shall be white-coded and the power positive shall be black-coded. 1.1.3 The Contractor shall coordinate with the City of Coppell's Building Inspection Department for permitting issues related to electrical connections.A 'No Cost' permit will be required for this service.Please call 972/304-3500 to make the necessary arrangements. 1.2 Power Service Equipment Requirements Power service equipment shall meet the following requirements: (a) Lightning arrestor will be required. It shall be of the valve type, 0-650 volt with bracket for cabinet mounting and shall be connected between hot leg and ground, per drawing in Plans. (b) Circuit breakers will be required. They shall be 125 Ampere Frame, single pole, 120 volt, 5000 IAS meeting Federal Specification W-C-375A, installed as shown on the appropriate TxDOT detail sheets. (c) All miscellaneous hardware, i.e., conduit, conductors, pedestal cabinet and weatherhead, shall be installed as shown on the appropriate TxDOT detail sheets. Conductors shall be of the size indicated and be type THW meeting applicable ASTM specifications. 1.21 Power service shall be provided by underground service with pedestal service type PS, as indicated on TxDOT standard detail ED (8)-03 or approved equal. 2.0 SYSTEM WIRING METHODS 2.1 Controller 4-41 Technical Specifications & Description of Pay Items Wiring for the controller shall consist of connecting to its terminals (1) wires to signals, (2) wires to detectors, (3) the power wires and (4) the ground wires. Other wiring for the controller shall be as required by the wiring diagrams and instructions furnished with the controller by the manufacturer. 2.2 Signal Heads Wiring for the signal head shall consist of connecting the terminal block in each signal section to the common terminal block in each signal face to the terminal block in the signal head terminal compartment. All such connecting wires shall be of the size and type indicated in the plans, or appropriate details. 2.3 Splices Unless otherwise called for in the Plans, splices will be permitted in the wires of signal conductors only in the transformer base or handhold of each signal pole at terminal points called for on the Plans. Splices at points other than as stated above may be made only with the written permission of the Engineer. All splices shall be watertight. 2.4 Terminals Except for controllers, the ends of all wires which are to be attached to terminal posts shall be provided with solderless terminals that meet the requirements of the National Electrical Code. 2.5 Wire and Cable All wire and cable shall conform to the requirements shown on the Plans, except wire and cable specifically covered by other items of this contract. The minimum size of conductors shall be as indicated on the Plans. 2.6 Enclosed Wiring Except for span wire suspended cables and electrical wiring within steel signal poles, all cables and single conductor wire within twenty-one (21) feet above the ground surface shall be enclosed in approved metal conduit. Power-tap lines carried down poles shall be placed in metal conduit. The power entrance to the controller shall be made through underground polyvinylchloride conduit only. 2.7 Identification of Signal Wires Numbered identification tags of metal, plastic or tape shall be placed around each wire adjacent to wire ends in the controller cabinet, signal head and signal-pole-base terminal boxes. 2.8 Signal and Controller 4-42 Technical Specifications & Description of Pay Items The signal poles, controller housing, signal common and service common shall be grounded. All grounding shall be as shown on the Plans and/or as may be indicated in the manufacturer's specifications and wiring diagrams. All grounding devices used shall conform to the requirements of the National Electric Code. The service common at the pole or service pedestal from which the power is taken shall be grounded. 2.9 Conduit and Signal Poles Metal conduit and metal signal poles or pedestals shall be bonded to form a continuous system and shall be effectively grounded. Bonding jumpers shall be No. 8 copper wire or equal. 2.10 After the signal cable connecting the signal and the controller is in place, the unfilled portion of the conduit openings shall be sealed with a sealing compound in accordance with the National Electrical Code. 2.11 The sealing compound used shall have a melting point of not less than two hundred (200) degrees Fahrenheit, and shall not be adversely affected by the surrounding atmosphere or moisture. 3.0 MEASUREMENT AND PAYMENT 3.1 Wire and cable referred to in Section 1.0 is covered by other parts of this specification. Payment for wire and cable is per respective items in the bid item list. 3.2 Power Service a.Measurement. The power service will be measured per each unit. Materials required in installation, such as lightning arrestor, circuit breaker, enclosure, foundation, and incidentals will not be paid for directly, but will be considered subsidiary to the Item "Power Service Pedestal and Equipment". b.Payment. Power service, installed in place, will be paid for at the unit price bid as specified in the bid item list. Said payment shall be full compensation for furnishing and installing, circuit breakers, weatherheads, lightning arrestor and required incidentals and for all labor, tools, equipment, materials and incidentals necessary to complete the work. 4-43 Technical Specifications & Description of Pay Items RETROREFLECTIVE PREFABRICATED PAVEMENT MARKINGS SECTION 1.0 SCOPE OF WORK AND GENERAL CHARACTERISTICS 1.1 This specification shall govern the materials, composition, application, measurement, and payment of pavement markings of the color, length thickness, and width as specified in the Plans and in accordance with the lines and positions shown on the Plans or as established by the Engineer. It is the object of this specification to insure the installation of tightly adherent, defect- free pavement markings of quality, visibility, and durability, to either asphaltic or portland cement road surfaces. Markings to be installed on roadways under traffic operation conditions shall be placed with a minimum of interference to the operation of the facility. 1.2 Pavement marking material shall be 3-M Stamark High Performance Tape, or approved equal. 2.0 MATERIAL APPLICATION AND EQUIPMENT 2.1 The general application method, material, and equipment used shall conform with the manufacturer's recommendations. All lane and word/symbol marking configurations shall be in accordance with the "Texas Manual on Uniform Traffic Control Devices", as currently amended. The general application procedure is as follows: 2.1.1 Clean the road surface by high pressure air. Blast cleaning may be required by the Engineer on existing road surfaces. 2.1.2 Pre-mark the road surface with chalk or crayon where the markings are to be applied. 2.1.3 Prime the road surface using recommended primer and applicator, extending beyond outlined area a minimum of 1". 2.1.4 Apply marking material in accordance with manufacturers specific recommendations making sure all edges are firmly adhered and no material is overlapping. 2.1.5 Tamp or roll the applied markings with a minimum 200 lb. load. 2.2 It is the intent of the equipment requirements specified above to insure the placement of pavement markings meeting the requirements of this specification. All markings placed that do not meet the requirements of this 4-44 Technical Specifications & Description of Pay Items specification and fail to adhere to the road surface properly shall be completely removed and replaced at the expense of the Contractor. 3.0 CONSTRUCTION METHODS 3.1 a.The Contractor shall use a crew experienced in the work of installing pavement markings and shall supply all the equipment and materials necessary for the placement of the pavement markings. b.The pavement marking material shall be applied within the material temperature limits recommended by the supplier. c.The pavement upon which the pavement markings are to be placed shall be cleaned and prepared, to the satisfaction of the Engineer, prior to placement of the markings. d.Cleaning shall be by any effective method approved by the Engineer, that completely and effectively removes contaminants, loose materials, and conditions deleterious to proper adhesion. When blast cleaning is required by the Plans or by the Engineer, the blast cleaning shall be done in accordance with State of Texas Special Specification Item "Blast Cleaning." Portland cement concrete surfaces shall not be cleaned by grinding. e.Portland cement concrete surfaces shall be further prepared after cleaning by complete sealing with a methylmethacrylate sealer or primer with an adhesive or adhesion promoter, approved by the Engineer, prior to placement of the markings. Methylmethacrylate sealers, adhesives, or adhesion promoters shall match infrared spectra and/or other data of approved materials of file at the Materials and Tests Laboratory in Austin, Texas. f.When deemed necessary by the Engineer, asphaltic surfaces exhibiting polished aggregate shall be primed with a sealer, adhesive, or adhesion promoter meeting the requirements specified for sealers, adhesives, and adhesion promoters to be used on portland cement concrete surfaces. g.All other pavement surfaces may be prepared by any effective method, approved by the Engineer, that will insure complete removal of all materials or conditions deleterious to proper adhesion of the markings to the roadway surface. 4.0 PERFORMANCE Installed pavement markings shall meet all requirements of this specification for a minimum of 30 calendar days after final installation of pavement markings is complete. Pavement markings that fail to meet all requirements of this specification 4-45 Technical Specifications & Description of Pay Items shall be removed and be replaced with pavement markings meeting the requirements of this specification at the expense of the Contractor. The Contractor shall replace all pavement markings failing the requirements of the specification within 30 working days following notification by the Engineer of such failing pavement markings. All pavement markings, including replacement markings, shall meet all requirements of this specification for a minimum of 30 calendar days after final installation of original and necessary replacement pavement markings. 5.0 MEASUREMENT AND PAYMENT Shown on the Plans are the specified colors, widths, and configurations of required markings along with a quantity computation for each type. Quantity estimates are given for Contractor's information only. a.Measurement of applied material will be considered as described in the Proposal and Plans. b.Payment. All lane and word/symbol markings, installed in place, will be paid for at the unit price bid as specified in the bid item list. Said payment shall be full compensation for all cleaning and removal, furnishing and installing all markings and for all labor, equipment, tools, materials, and incidentals necessary to complete the work.