DEPARTMENTAL MATERIALS SPECIFICATION DMS-11040

Traffic Safety Division 1 – 4 Effective Date: October 2025

Review Date: October 2025

DMS-11040

Electrical Conductors Effective Date: October 2025

1. DESCRIPTION

This Specification governs the materials, composition, quality, sampling, and testing of electrical conductors.

2. UNITS OF MEASUREMENTS

The values given in parentheses (if provided) are not standard and may not be exact mathematical conversions. Use each system of units separately. Combining values from the two systems may result in nonconformance with the standard.

3. MATERIAL PRODUCER LIST

The MPLs associated with this DMS include notations that identify products or materials that are pre-certified to comply with Buy America, Gold Star certification. Submit the Department’s “Buy America Certification” Form 2812 found on TxDOT.gov for Gold Star certification. Provide additional form or documentation upon Department request. Submit a new form if material or product Build America, Buy America (BABA) compliance status changes. BABA compliance status change means anytime the product’s Buy America status, as represented on the MPL, changes. The Department maintains authority for establishing BABA material classifications (iron or steel, manufactured product, construction material, or excluded material).

The Traffic Engineering Section of the Traffic Safety Division (TRF-TE) maintains the Material Producer List (MPL) of all materials in accordance with the requirements of this Specification. Materials appearing on the MPL entitled “Roadway Illumination and Electrical Supplies” require no further sampling and testing before use, unless deemed necessary by the project Engineer or TRF-TE.

4. BIDDERS’ AND SUPPLIERS’ REQUIREMENTS

The Department will only purchase or allow on projects those products listed by producer and product code or designation shown on the MPL.

Use of pre-qualified product does not relieve the Contractor of the responsibility to provide product that meets this Specification. The Department may inspect or test material at any time and reject any material that does not meet the Specifications.

5. PRE-QUALIFICATION PROCEDURE

5.1. Pre-Qualification Request. Submit a request for evaluation under DMS-11040 to trf-electrical-illumination-submittals@txdot.gov.

Include the following information in the request.

Company name

Physical and mailing addresses

Contact person, phone number, and email address

Traffic Safety Division 2 – 4 Effective Date: October 2025

5.2. Pre-Qualification Sample. Include the following with the pre-qualification request.

Submit two legible copies of catalog cut sheets for all components required for each type of electrical conductor, marked to indicate the specific product and size submitted for pre-qualification

For each color of insulated conductor and bare grounding conductor, submit a 3-ft. sample

For each breakaway fuse holder, submit a sample

For all products, submit quality assurance (QA)/quality control (QC) documentation from Article 6., “Quality Assurance/Quality Control Requirements.”

Provide additional samples when directed, following Department submittal guidelines.

Submit all materials for pre-qualification at no cost to the Department.

5.3. Evaluation. TRF will notify prospective Bidders and suppliers after completion of material evaluation.

5.3.1. Qualification. If approved for Department use, TRF-TE will add the material to the MPL.

Report changes in the composition or in the manufacturing process of any material to TRF-TE. Significant changes reported by the producer, as determined by the Director of TRF, may require a re-evaluation of performance. The Department reserves the right to conduct whatever tests it deems necessary to identify a pre-qualified material and determine if there is a change in the composition, manufacturing process, or quality that may affect its durability or performance. In case of variance, the Department’s tests will govern.

5.3.2. Failure. Producers not qualified under this Specification may not furnish materials for use on Department projects.

Producers failing to qualify may submit a request for re-evaluation after 12 mo. have elapsed from the date of the original request. TRF-TE may modify this time limit at its discretion. In the request for re-evaluation, document the cause of the issue and corrective action taken.

The Department normally bears the costs of sampling and testing; however, the producer will bear the costs associated with materials failing to conform to the requirements of this Specification. The Director of TRF will assess this cost at the time of testing, and amounts due will be billed to the producer.

5.4. Periodic Evaluation. The Department reserves the right to conduct random sampling and testing of pre-qualified materials to verify performance and Specification compliance and to perform random audits of documentation.

Failure of materials to comply with the requirements of this Specification as a result of periodic evaluation may be cause for removal of those materials from the MPL. In case of variance, the Department’s tests will govern.

5.5. Disqualification. Causes for disqualification and removal from the MPL may include, but are not limited to, the following.

Falsification of documentation

Producer fails to report any change in material composition or manufacturing process to TRF-TE

Material fails to meet the requirements of this Specification as a result of periodic evaluation

Producer has unpaid charges for failing samples

TRF-TE will remove disqualified producers from the MPL and will not allow submission of material for re-qualification for 12 mo., at the discretion of the Department.

5.6. Re-Qualification. Once the disqualification period established by TRF-TE has elapsed, producers disqualified and removed from the MPL may begin the re-qualification process by submitting a request in

Traffic Safety Division 3 – 4 Effective Date: October 2025 accordance with Section 5.1., “Prequalification Request,” including additional documentation identifying the cause of the problem and corrective action taken. The re-qualification process will then follow all subsequent Sections of Article 5., “Prequalification Procedure.”

6. QUALITY ASSURANCE/QUALITY CONTOL REQUIREMENTS

The manufacturer must demonstrate a commitment to quality by submitting QA/QC program documentation with the following minimum requirements.

Written statement of the company’s QA/QC policy

Name of employee with special QA/QC training and with QA/QC as a primary job responsibility

Written procedure for handling orders for conductors manufactured to Department specifications

Written procedure for keeping track of conductors manufactured, certified, and tested for Department orders

Checklist of features for Department conductors with QA/QC employee’s signature

7. MATERIAL REQUIREMENTS

7.1. General Requirements. Provide new materials that are listed for the intended use. Comply with the applicable provisions of the NEC and NEMA standards. Provide UL-listed components. When UL is referenced, consider materials certified by any current Nationally Recognized Testing Laboratory (NRTL) as shown on the OSHA website. Provide evidence of NRTL certification to produce electrical conductors.

Faulty fabrication or poor workmanship in materials, equipment, or installation will be justification for rejection. Provide manufacturer’s warranties or guarantees when offered as a customary trade practice.

7.2. Conductor Material. Provide new annealed copper electrical conductors that are UL listed and meet the requirements of ASTM B3 and B8. Provide insulated electrical conductors with NEC, Type XHHW, or other XLP insulation rated for a minimum of 600 V, unless other insulation type or rating is specifically shown on the plans. Provide stranded electrical conductors, except for the required Size 6 AWG solid bare grounding electrode conductor at the electrical service.

7.3. Splicing Material. For splice insulating material, provide one of the following.

Heavy-wall heat-shrink tubing with factory-applied internal sealant, UL listed for 600 V or greater. When required, provide hot-melt adhesive strips or tape with a minimum dielectric strength of 300 V per mil, to fill the gap and seal the ends of the heat-shrink tubing when two or more conductors at one end of a splice are present. Hot-melt adhesive is supplied in strips or rolls and has a backing (release paper) to prevent the tape from sticking to itself. Rubber tape will not be allowed as a substitute for hot-melt adhesive.

UL-listed non-shielded cold-applied polymeric gel cable splice (gel cap) rated for 600 V.

7.4. Splicing Connectors. For connectors, provide the following.

UL-listed compression or screw-type pressure connectors, terminal blocks, crimp connectors, split bolt connectors, or grounding electrode connectors rated for the amperage and equal to or greater than the overcurrent protection device

UL-listed, 600-V rated wire nuts with factory-applied internal waterproofing sealant

7.5. Breakaway Fuse Holders. Provide one-pole or two-pole, watertight, breakaway, inline fused connectors designed for use with breakaway pole bases and that:

are UL listed, 600-V rated, prevent energized parts from being exposed after breaking away, have breakaway connector boots that fit multiple wire sizes (may be dual-wire “feed-in-feed-out” type), have neutral connectors marked white, and

Traffic Safety Division 4 – 4 Effective Date: October 2025 are listed on the MPL.

7.6. Ground Rod. For ground electrodes, provide UL-listed copper clad steel ground rods of the sizes shown on the plans. Ensure all ground rods are a minimum diameter of 5/8 in. and are a minimum length of 8 ft.

Provide ground rod clamps that are listed for direct burial and when installed in concrete are listed for concrete encasement.

8. ARCHIVED VERSIONS.

Archived versions are available.