2523.01 DESCRIPTION.
The work to be performed under this specification shall consist of furnishing all work, apparatus, and materials to construct, install, and place in operation to the Engineer's satisfaction, a complete highway lighting system as shown in the contract documents.

The Contractor shall furnish and install all components of the lighting system not furnished by the utility company serving the installation, including all incidental items appurtenant to the operation of the system.

All apparatus, materials, and work shall be in accordance with the contract documents and with standards, practices, and codes of the electrical industry. Particular attention is directed to the following:

National Electric Code (NEC), latest edition, including amendments;
IEEE Standards and Practices;
ANSI Standards and Practices;
NEMA Standards;
UL Standards.

The completed lighting installation shall conform to all local and special laws, codes, or ordinances of all Federal, State, and municipal authorities with due jurisdiction.

The Contracting Authority will be responsible for the cost of electric power used during installation and testing of lighting equipment and prior to final acceptance of the work. The installation shall be put into use prior to final acceptance only with the approval of the Engineer.

2523.02 MATERIALS.
Lighting materials shall meet requirements of Division 41.

Before any items are ordered or installation is started, the following list of shop drawings must be submitted for approval in accordance with Article 1105.03:

A. Required Shop Drawings:

1. Lighting poles and mastarms
2. Transformer bases
3. Slip bases
4. Roadway luminaires with lamps
5. RM-41 luminaires with lamps
6. Control cabinet components

a. Enclosure
b. Door latch mechanism
c. Contactor
d. Circuit breaker (main)
e. Circuit breaker (branch)
f. Photoelectric control
g. Test switch(es)
h. Breather drain
I. Wiring diagram, showing wire type and size
j. Component placement drawing
k. Control fuse holder
l. Surge suppressor

7. RM-40, type Y-1 connector
8. RM-40, type Y-3 connector
9. RM-40, type L-1 connector
10. RM-40, type L-2 connector
11. Insulated wire and cable
12. Additional drawings may be required on a project specific basis in accordance with the contract documents.

B. Shop Drawings Not Required:

1. Wood pole
2. Concrete
3. Reinforcing steel
4. Anchor bolts, nuts, and washers
5. Other bolts, nuts, and washers
6. Ground rods and clamps
7. RM-42, type 1 handhole
8. RM-42, type 2 handhole
9. Rigid steel conduit and fittings
10. Rigid aluminum conduit and fittings
11. Plastic conduit and fittings
12. Plastic warning tape
13. Bare copper ground wire

These drawings shall all be submitted simultaneously for each project. They shall include catalog cuts, diagrams, drawings, brochures, or other descriptive data required by the Engineer. A schematic diagram and a component placement diagram of the control cabinet and panel shall be included. All wire and cable sizes, placement of components, and dimensions shall be shown on the diagrams. All drawings shall be completely legible and shall contain adequate information to identify that the described components comply with the contract documents. Identification markings on the described items shall correspond to like markings shown on the drawings to provide easy identification of the item. Apparatus or materials shall not be installed until descriptive data has been reviewed and concurrence received from the Engineer. Each sheet or bound pamphlet shall be imprinted with the county and project number. Each set shall be assembled and shall contain one copy of the required data for each item listed on the schedule. Incorrect or incomplete submittals will be returned to the Contractor for correction. The Engineer may require certified test results and samples of materials for consideration of all items including those described by reviewed drawings.

Cast-in-place concrete used shall meet requirements of Section 2403.

2523.03 FOOTINGS.
The Contractor shall provide cast-in-place concrete footings for all lighting units not located on structures or barriers. The top portion of all footings shall be formed and poured in form work to at least 6 inches (150 mm) below the finished ground level. The footings shall conform in all respects to the details, including reinforcement and alignment to provide the correct overhang, as indicated in the contract documents.

The finished surfaces shall be smooth and free from stains and foreign material.

When shale, sandstone, broken and shattered rock, solid rock, or other similar materials are encountered, an alternate footing, shall be constructed as directed by the Engineer.

Anchor bolts shall be placed to provide for placement of nuts and washers on the top and bottom of the transformer base or pole flange with ample room for adjustment and plumbing the pole. When slip bases are used, Contractor shall position anchor bolts so that they do not interfere with the operation of the slip base. Anchor bolts shall be placed in accordance with Article 2405.09, B.

2523.04 GROUNDING.

A. General Requirements.
A component of the lighting system will be defined to be grounded when it is electrically bonded to a driven ground rod or a multiple system of ground rods producing a resistance to ground of 25 ohms or less when installed and tested in accordance with the contract documents.

Major components of the lighting system, such as control stations, lighting units, and sign structures, and all metal duct work in exposed locations or installed on roadway bridges, shall be grounded with ground rods and connections described in Article 4185.04. Details of these and other locations to be grounded will be shown in the contract documents.

B. Grounding Installations.
Whenever the ground rod installation does not have a resistance to ground of 25 ohms or less, the Contractor shall couple additional rods to the first, and drive to the full depth until the required resistance is obtained. If a maximum depth of 50 feet (15 m) is reached, or if obstacles to further driving are encountered, ground rods in multiple shall be added until the required resistance to ground is obtained.

Permissible grounding installations are as follows:

1. In no case shall any portion of the ground rod be closer than 18 inches (0.5 m) to the finished earth surface. All rods shall be driven as nearly vertical as possible. A full length ground rod shall be driven when possible.

2. When rock or other obstructions prevent driving the rod to full depth, two half-length sections may be driven, with the approval of the Engineer. The two half-length sections shall be considered as a minimum length rod when additional rods are required to obtain the specified resistance to ground.

3. Where two half-length rods can not be driven to the required depth, full length rods shall be placed horizontally at a depth of not less than the adjacent trench depth.

4. Minimum horizontal clearance between all rods in a multiple ground installation shall be 6 feet (2 m).

2523.05 BREAKAWAY AND SLIP BASES.
The Contractor shall furnish and install breakaway bases or slip bases of the size and type specified in the contract documents for each light pole not mounted on a roadway bridge. All bases for a project shall be of one type and manufacturer and shall be a commercially available product. Details of bases shall be shown in the contract documents.

Each breakaway base shall have a nonmetallic spacer impervious to galvanic action placed between the breakaway base and pole base mounting flange.

2523.06 POLES AND MASTARMS.
The Contractor shall furnish and install poles at all locations indicated in the contract documents.

Pole length shall be as shown in the contract documents.

All poles and mastarms shall be carefully erected and shall be checked for vertical alignment, mounting height, and overhang, after installation, with mastarm and luminaire installed. Single mastarm poles shall be raked so the side of the shaft opposite the mastarm is plumb. Poles without mastarms, or with more than one mastarm, shall be erected so the center line of the pole shaft is plumb. The plumbing tolerance shall be within 1/32 inch per foot (3 mm/m).

The pole posture shall be checked at not less than three radial locations on the shaft. For poles required to have plumb shaft center lines, the checking positions shall be approximately 120 degrees apart, as viewed from above. For raked poles required to have one side plumb, the check points shall be at the side to be plumbed, and at 90 degrees in either direction, as viewed from above.

Plumbing of the poles shall be accomplished by use of double nuts on each anchor bolt. The nuts shall be located above and below the bottom mounting flange of the breakaway base, or above and below the pole base or slip base mounting flange where breakaway bases are not required. Washers shall be installed in accordance with details in the contract documents. Base leveling shims or alternate pole mounting methods will be permitted only when indicated.

After the erection has been inspected and approved, the space between the mounting flange and the concrete footing shall be neatly filled with an approved non-shrink grout and finished as detailed.

Mastarms shall be of the type and length specified. Unless otherwise shown in the contract documents, mastarms greater than 8 feet (2.4 m) in length shall be Type B, and all others shall be Type A. All lighting poles and mastarms on a project shall be of the same type and material.

Insect barriers shall be provided in the ends of all mastarms at the point of luminaire attachment.

Wood poles shall be of the length and class specified and shall be set plumb in drilled holes as directed by the Engineer. Embedment shall be not less than 8 feet (2.5 m). Additional embedment may be required by the Engineer if warranted by soil conditions.

2523.07 LUMINAIRES.
The Contractor shall furnish and install luminaires of the type and rating specified. All roadway luminaires must be leveled after installation unless a tilt is specified. When light distribution is specified, the Contractor shall insure that the luminaire has the necessary components and is adjusted properly. Printed instructions regarding luminaire components and adjustment shall be provided to the Engineer by the Contractor.

2523.08 CIRCUITS.
Unless otherwise specified, the roadway lighting circuit shall be an underground, multiple system, totally encased in conduit. Circuits and control stations shall be constructed in accordance with the contract documents.

Circuits shall be complete with all necessary accessories for proper operation. Disconnecting devices, protective devices, and all other equipment shall be thoroughly coordinated to secure a safe operating lighting system. If any changes in arrangement of the circuit system are considered necessary by the Contractor, details of changes and reasons shall be submitted to the Engineer for approval. Changes shall not be made without prior approval of the Engineer.

2523.09 EXCAVATION.
Holes for pole footings and direct embedded poles shall be drilled.

Details of trenching for underground circuits will be shown in the contract documents. Excavated material shall be piled sufficiently away from the trench to prevent cave-ins. The trench bottom shall be accurately graded to provide for placement of cable or duct work at a uniform depth. Provisions shall be made to prevent surface water from entering the trench. Water present shall be removed before duct work is installed, unless otherwise directed by the Engineer.

2523.10 ELECTRICAL DUCTS.

A. General Requirements.
Details of duct installations will be shown in the contract documents. The completed duct systems shall be watertight. Expansion fittings shall be used where duct runs cross structural expansion joints and elsewhere as directed by the Engineer.

Metal conduit joints shall be threaded. The mating threads shall be treated with pipe joint compound. All other threads shall be treated with an approved rustproofing compound. Plastic conduit joints shall be of the solvent welded socket type.

After the duct runs are installed, the Contractor shall demonstrate that the runs are clear by pulling an approved brush or conduit swab through the entire length of each run. Deleterious material shall not be permitted to remain in the duct. Terminal ends shall be securely capped until cable is installed. Before the wire and cable is installed, terminal ends of metal conduit shall be fitted with threaded insulating bushings, and terminal ends of plastic conduit shall be fitted with socket type, bell end fittings.

In no case shall aluminum conduit be embedded in concrete.

B. Underground Ducts.

1. Lighting Circuit Ducts.
Lighting circuit ducts shall be Schedule 40 plastic conduit. As field conditions permit, the runs shall be installed to avoid adding bends or total bend angle to the design layout. The total bend angle between pulling points shall not be more than 360 degrees.

2. Crossing Ducts.
Unless otherwise shown in the contract documents, crossing ducts shall be Schedule 80 PVC conduit. Crossings to be placed without disturbing the existing surface shall be installed by jacking or boring methods approved by the Engineer. Jetting will not be permitted.

3. Primary Service Ducts.
Installation requirements for lighting circuit and crossing circuit ducts shall apply.

C. Exposed Exterior Ducts.
All ducts for exposed installations shall be rigid steel conduit, unless otherwise shown in the contract documents. When not shown in the contract documents exposed ducts shall be supported at intervals of 6 feet (1.8 m) or less. Hangers or clamps to be attached to concrete structures shall be anchored by means of expanding anchors in drilled holes. The use of driven or explosive set anchors will not be permitted.

2523.11 HANDHOLES.
The Contractor shall construct handholes of the size and type and at locations shown in the contract documents, unless otherwise specified by the Engineer. Handholes shall not be constructed in ditch bottoms, low areas where ponding of water may occur, or where they will be subject to normal vehicular traffic.

Access ducts shall be provided for each general direction of the circuit branch run, and shall be positioned for ease of cable installation.

Handholes shall be positioned so that the top is at the same inclination as the adjacent grade.

2523.12 JUNCTION BOXES.
Junction boxes of the type specified shall be furnished and installed as indicated in the contract documents.

2523.13 BACKFILLING.
After inspection of the completed trench, duct work, and cables, the Contractor shall backfill the trench with the material that was removed, unless stated otherwise in the contract documents or directed by the Engineer. Backfill material shall be placed in layers with the first layer not exceeding 2 feet (0.6 m) of loose thickness and each succeeding layer not exceeding 1 foot (0.3 m) of loose thickness. Each layer shall be compacted by hand or mechanical tampers. Material containing glass, metal, concrete, brick, cinders, or any other abrasive material shall not be used for backfill within 6 inches (150 mm) of the cable or conduit. Approved plastic warning tape shall be installed in all trenches.

Backfill around direct embedded poles and handholes shall be the material that was removed, and it shall be placed in layers not exceeding 6 inches (150 mm) of loose thickness and shall be compacted by hand or mechanical tampers.

Excess material at pole footings and handholes constructed on slopes shall be shaped as indicated. All other disturbed areas shall be shaped to the original contours as directed by the Engineer.

2523.14 WIRE OR CABLE.
The Contractor shall furnish and install wire or cable of the size and type specified. When installing wire or cable in a conduit system, the Contractor shall provide equipment to demonstrate to the Engineer that at no time a pulling tension of 0.008 pound per circular mil (70 N/mm²) of conductor is exceeded.

Unreeled wire or cable shall not be left on the surface of the ground or exposed to mechanical abrasion. All wire or cable that is stressed or damaged in any way shall be replaced at the Contractor's expense. Wire or cable shall not be installed with dirt or any other abrasive material adhering to it.

A lubricant shall be used when wire or cable is pulled. The lubricant shall be UL listed and shall be designed for use with the specified cable and conduit. The use of graphite or petroleum lubricants will not be permitted. The pulling device must be attached to each conductor, and all wire or cable within a single duct must be pulled simultaneously.

2523.15 CONNECTORS.
Connectors of the type specified shall be furnished and installed at the locations shown in the contract documents. Connector assemblies shall be supplied with a disposable mounting pin, when required, and sufficient silicone compound to lubricate the metal parts and rubber housings. Complete instructions shall be furnished with each connector.

2523.16 SPLICES.
Splices shall be made with approved connector assemblies. Splices in the system will only be allowed in pole shafts, handholes, pull boxes, breakaway bases, and other specified locations.

2523.17 CONTROL STATION.
The Contractor shall furnish the components specified and construct the control station as indicated in the contract documents.

2523.18 SEEDING AND FERTILIZING.
In locations where erosion control work has been completed or turf has been established, the Contractor shall restore the areas disturbed by application of seed and fertilizer as indicated in the contract documents.

2523.19 PAINTING.
The bottom flange of aluminum transformer bases shall be painted on the inside and outside surfaces with two coats of zinc-rich paint

2523.20 COOPERATION WITH UTILITY COMPANIES.
The utility company shall provide secondary service to the project in the vicinity indicated. The Contractor will consult and cooperate with the utility company in locating the distribution lines and service poles so lines will be as short and direct as possible. If the utility company is unable to perform the required work the Contractor shall furnish and install the service poles and will be paid in accordance with Article 1109.03. The cost for extension of power lines and for furnishing and installing meter sockets and meter loops as required in the contract documents will be the responsibility of the Contracting Authority.

The entire transformer pole installation, when required, including all accessories and appurtenances, shall be installed by the utility company that is to supply service in accordance with their agreement for service. The Contractor shall cooperate with the utility company so that connections may be made in the proper manner and at the proper time.

All apparatus and material for the pole mounted control station, as shown in the contract documents, shall be furnished and installed by the Contractor; upon acceptance of the project, it will become the property of the Contracting Authority.

If pad mounted transformers and control stations are specified, they shall be furnished and installed as specified in the contract documents and approved by the designated utility company.

2523.21 FINAL ACCEPTANCE.
Electrical tests of all systems shall be performed after the circuit installation work is complete, and at any other stage of construction when directed by the Engineer. These tests shall include an insulation resistance measurement for all underground circuit cable, voltage measurements, and a ground resistance test for each individual grounding installation.

Insulation resistance measurements shall be made with all lamps or ballasts disconnected from the circuit and all neutral lines properly grounded. Insulation resistance shall not be less than 100 megaohms, and shall be measured with a properly calibrated 500 volt megaohmmeter.

Voltages in the cabinet from phase to phase and phase to neutral at no load and at full load shall be measured and recorded. Voltage readings at the last termination of each circuit shall be measured and recorded.

Ground resistance measurements shall be made with the ground rod, or system of ground rods as described in Article 2523.04, disconnected from the circuit neutral wire. The resistance to earth of each individual grounding installation shall not be greater than 25 ohms, and shall be measured with a Wheatstone bridge type ground resistance tester in accordance with the manufacturer's instructions.

The Contractor shall perform electrical tests, and shall demonstrate to the Engineer that the lighting system complies with requirements of the contract documents.

The Contractor shall furnish to the Engineer a written report of all test results for a permanent record.

The insulation resistance report shall contain measurements from each insulated line to ground, and between all combinations of lines in a given circuit or contained in a single duct.

The voltage measurement report shall contain measurements for each cabinet and each circuit.

The ground resistance report shall contain measurements for each grounding installation identified by a lighting unit number and at other grounding locations by a means approved by the Engineer.

All components of the lighting system must be in satisfactory operation in accordance with the ratings and requirements specified.

After satisfactory completion of required testing, the complete lighting system shall be placed in operation for a 30 calendar day trial period, and final approval of the installation will not be made until the trial period ends. During the trial period, the Contractor shall service and maintain the installation and shall make such adjustments or replacements as are required at the Contractor's expense. The Contractor will not be required to pay for energy consumed by the system, and working days will not be charged, during this trial period.

All areas where the existing ground has been disturbed by the Contractor shall be reshaped to original contours or as otherwise directed by the Engineer.

Final acceptance of all lighting installations will be based on satisfactory results of electrical tests performed by the Contractor and satisfactory completion of the 30 calendar day trial period.

2523.22 METHOD OF MEASUREMENT.
The quantities of the various items involved in the construction of highway lighting will be measured in accordance with the following:

A. Lighting Poles.
The Engineer will determine by count the quantity of Lighting Poles furnished and installed.

B. Electrical Circuits.
The quantity of Electrical Circuits will be the quantity shown in the contract documents in linear feet (meters).

C. Handholes and Junction Boxes.
The Engineer will determine by count the quantity of Handholes and Junction Boxes furnished and installed.

D. Control Cabinet.
The Engineer will determine by count the quantity of Control Cabinets furnished and installed.

E. Under Deck Lighting.
The Engineer will determine, by count, the quantity of Under Deck Lighting luminaires furnished and installed.

2523.23 BASIS OF PAYMENT.
The quantities of the various items involved in the construction of highway lighting will be paid in accordance with the following:

A. Lighting Poles.
For the quantity by count of Lighting Poles furnished and installed, the Contractor will be paid the contract unit price per unit. This payment shall be full compensation for materials, equipment, excavation, and installation of the pole, luminaire, mastarm, footing, base, ground rod, wiring within the pole, and connectors within the pole, in accordance with the contract documents.

B. Electrical Circuits.
For the number of linear feet (meters) of Electrical Circuits constructed the Contractor will be paid the contract unit price per linear foot (meter). This payment shall be full compensation for materials, equipment, excavation, and installation of the conduit and the wiring/cables between the connectors in the poles, including switches.

C. Handholes and Junction Boxes.
For the quantity by count of Handholes furnished and installed in accordance with the contract documents, the Contractor will be paid the contract unit price per unit. This payment shall be full compensation for materials, equipment, excavation, and installation of the handholes and junction boxes.

D. Control Cabinet.
For the quantity by count of Control Cabinet furnished and installed in accordance with the contract documents, the Contractor will be paid the contract unit price per unit. This payment shall be full compensation for materials, equipment, excavation, meter socket, meter loop, control cabinet pole, and installation of control cabinet and all internal circuitry.

E. Under Deck Lighting.
Under Deck Lighting luminaires shall be complete including lamps, ballast, and mounting device.