34 90 00 Core Area.pdf

WO 6978583 REPAIR CORE AREA ROADS

SECTION 34 90 00

TRAFFIC SIGNALS

03/20

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

NAME (ACRONYM)

NCDOT (January 2018) North Carolina Department of Transportation (NCDOT) Standard Specifications for Roads and Structures

1.2 SUMMARY OF WORK

The purpose of this project is to upgrade existing traffic signal equipment at signalized intersections within the project limits and to replace loop detection demolished by the project's pavement milling and resurfacing. This project includes replacement of existing NEMA controllers and cabinets with new Model 2070E controllers housed in Type 332 base-mounted cabinets as well as signal display upgrades at selected locations.

Perform the following tasks under this contract, as shown in the Plans (the list that follows is not meant to be all-inclusive):

1. Provide underground conduit and junction boxes (i.e., pull boxes);

2. Provide 2070E traffic signal controllers with Siemens SEPAC local controller software and 170 cabinets with ancillary equipment, extending existing field wiring as necessary;

3. Modify existing cabinet foundations and provide new cabinet foundations;

4. Modify existing traffic signal displays and replace existing signal heads;

5. Demolish existing control equipment and cabinets and existing junction boxes, where designated in the Plans;

6. Provide detector loops, loop lead-in cable, junction boxes, and lead-in cables to replace existing detector loops demolished by pavement milling and resurfacing;

7. Provide pedestrian signals with pushbuttons;

8. Provide pedestrian signal pedestals and foundations;

9. Provide signal cable;

10. Provide LED blank-out signs for railroad preemption;

11. Upgrade existing controller cabinet grounding systems;

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

SECTION 34 90 00 Page 1 June 22, 2020

Wiring Diagrams; G

Provide detailed wiring diagrams that include interconnection (wired and wireless) of equipment with pin-out configurations, pin functions, and cable parts numbers. This includes configuration at each field equipment cabinet.

Use naming convention approved by the Contracting Officer and conforming to Belcore standards. Provide two paper copies and one electronic copy of the wiring diagrams in both Microstation and AutoCAD format. See Figure 1 in Attachment A for sample.

SD-03 Product Data

Provide a Type 3 material certification in accordance with Article 106-3 of the NCDOT Standard Specifications. When requested by the Government, provide additional certifications from independent testing laboratories and sufficient data to verify item meets applicable specifications. Ensure additional certification states the testing laboratory is independent of the material manufacturer and neither the laboratory nor the manufacturer has a vested interest in the other.

Identify all proprietary parts in Contractor-provided material. The Government reserves the right to reject material that uses proprietary components not commercially available through electronic or electrical supply houses.

For Contractor-provided material listed on the NCDOT ITS & Signals QPL, provide submittals in the format defined by the QPL.

For Contractor-provided material not on the QPL, provide three copies of the equipment list including three copies of catalog cuts. Clearly identify proposed material on catalog cuts by a reproducible means (highlighter pen does not transfer to copies). Ensure material lists contain material description, brand name, manufacturer's address and telephone number, stock number, size, identifying trademark or symbol, and other appropriate ratings.

Submit for approval catalog cuts and/or shop drawings for materials proposed for use on the project. Allow 30 days for review of each submittal. Do not fabricate or order material until receipt of Government's approval. All submittals will be returned as either "Approved (as submitted)", "Approved as Noted" or "Rejected." The Contractor may proceed with fabrication or ordering for items marked "Approved." If an item is marked "Approved as Noted" without any stipulation for resubmittal, then the Contractor may proceed with fabrication or ordering. For any other notations, the Contractor must revise the submittal, address comments and resubmit for approval.

Submit three copies of each catalog cut and/or drawing and show for each component the material description, brand name, stock-number, size, rating, manufacturing specification and the intended use (identified by labeling all components with the corresponding contract line item number). Present the submittals neatly arranged in the same order as the contract bid items.

Electronic submittals of catalog cuts and drawings may be accepted in lieu of hard copies.

Controllers and Cabinets including conflict monitors and base adapters; G

Conduit; G

SECTION 34 90 00 Page 2

Junction Boxes; G Signal Heads; G Signal Pedestals; G LED Blank-out Signs; G Mounting Brackets; G Stainless Steel Hardware; G

SD-06 Test Reports

Test Reports; G

Conduct an approved, standalone equipment installation test at the field site. Test all standalone functions of the field equipment using equipment provided as detailed in the Plans.

Complete approved test plan forms and turn them over to the Contracting Officer for review as a basis for rejection or acceptance. Provide a minimum notice of 30 calendar days prior to all tests to permit the Contracting Officer or his representative to observe each test.

If any unit fails to pass its standalone test, correct the unit or substitute another unit in its place, then repeat the test.

If a unit has been modified as a result of a standalone test failure, prepare a report describing the nature of the failure and the corrective action taken and deliver it to the Contracting Officer prior to re-testing the unit. If a failure pattern develops, the Contracting Officer may direct that design and construction modifications be made to all units without additional cost to the Government or an extension of the contract period.

Utilize vendor supplied device software to perform diagnostic tests of each device. The vendor supplied diagnostic software must be provided to the Government before final acceptance. Test the following features of each competent as described below.

The following items, not otherwise required to be tested elsewhere, must be tested for each controller and cabinet provided under this project: cable continuity, grounding, power-up self-test, proper controller sequencing, detector and pedestrian pushbutton calls.

SD-10 Operation and Maintenance Data

Provide at least two hard copies along with one electronic copy (on CD or DVD) of the following manuals:

Operator's Manuals; G

Maintenance Procedure Manuals; G

Training Manuals; G

Provide installation, operations, and training manuals for all Contractor-provided software.

The manuals provided above must be in addition to manuals provided with and stored inside each control equipment cabinet.

SD-11 Closeout Submittals

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As-built Drawings; G

Provide all manuals and plan of record (i.e., "as-built") documentation.

All as-built plans and documentation must be reviewed and accepted by the Contracting Officer prior to final acceptance of the project. All documentation, except as otherwise specifically approved by the Contracting Officer, must meet the following requirements:

1. Provide final as-built plans on 11" x 17" paper along with a PDF of each as-built plan sheet. Provide draft as-built plans for Government review on 22" x 34" paper. No documentation for as-built plans smaller than 11" x 17" will be accepted.

2. Provide any documentation that exceeds the size of 11" x 17" paper in a reproducible format 22" x 34" in size.

3. For electrical schematics and cabinet wiring diagrams not bound into printed manuals, provide paper copies at least 22" x 34" in size.

4. No non-plan documentation smaller than 8.5" x 11" will be accepted.

5. Do not fold or crease reproducibles.

As a minimum, provide the documentation described in the paragraphs below.

Plan of Record Documentation:

Provide as-built drawings that depict any changes of components, measurement or layout of the Plans. Show all construction changes, with the final location and depth of conduits, wiring external to the cabinet, detector locations, etc., in detail in a reproducible format. Submit as-built construction changes within 10 consecutive calendar days after the Observation Period begins. Note and date each change on the drawings.

Failure to revise as-built documentation to reflect current work may result in withholding of payments until the as-built documentation is brought current. The submitted as-built documentation may be field-checked by the Contractor Officer at the Contracting Officer's discretion. If the as-built documentation is found to have an unacceptable number of inaccuracies, the Contracting Officer may withhold payment until the as-built plans are corrected.

Store documentation for signals in a manila envelope placed in a weatherproof holder inside the cabinet drawer. Store all documentation provided with the controllers and cabinets, including manuals, electrical schematic diagram, and cabinet wiring diagram inside the envelope in the weatherproof holder. Provide two marked-up "redline" copies of the signal plan and the electrical and programming detail, placing one copy in the weatherproof holder inside the cabinet drawer immediately upon installation of the cabinet and giving the second copy to the Contracting Officer.

The Government will provide the Contractor one electronic copy of the Plans for the Contractor's use in developing the as-built drawings. Modify the original electronic file such that all changes are marked with callout boxes or other method approved by the Contracting Officer. Any other base maps that may be necessary for the Contractor to prepare the as-built drawings in accordance with this Specification will be the Contractor's responsibility.

Use CAD conventions that are consistent with those used on the original plans.

Within 10 consecutive calendar days after the Observation Period begins, SECTION 34 90 00 Page 4 provide one reproducible copy of the draft as-built plans in hard copy format for review. Provide draft hard copy as-built drawings on 22"x 34" bond plan sheets.

Upon receipt of review comments from the Contracting Officer, correct any errors and make all necessary revisions to the draft as-built plans prior to final acceptance of the project. Submit final as-built plans in electronic and hard copy format. Provide final hard copy as-built drawings on 11"x 17" bond plan sheets. Provide electronic plans in MicroStation (latest release in use by the North Carolina Department of Transportation (NCDOT)) format along with copies of the same files saved/exported in AutoCAD (latest release in use by the Government) format.

GPS Coordinates; G

Provide real world GPS coordinates for all junction boxes and controller cabinets provided or utilized under this project as well as for any existing controller cabinets that are retained and reused. Provide the coordinates in feet units using the North Carolina State Plane coordinate system (1983 North American Datum also known as NAD '83). provide coordinates that do not deviate more than 1.7 feet in the horizontal plane and 3.3 feet in the vertical plane. Global positioning system (GPS) equipment able to obtain the coordinate data within these tolerances may be used. Submit cut sheets on the GPS unit proposed to collect the data for approval by the Contracting Officer.

Provide both digital copies and hard copies of all information regarding the location (including to but not limited to manufacturer, model number) in the Microsoft Excel spreadsheet using the format shown in example table below.

In addition to Excel format, provide a digital copy of the location information as an ESRI Shapefile (.SHP file format).

Name Location Latitude Longitude Manufacturer Model #

Equipment Cabinet

Junction Box 1 (Phase 2 Side)

Junction Box 2 (Phase 2 Side)

Junction Box 3 (Near Cabinet)

Junction Box 4 (Phase 6 Side)

Junction Box 5 (Phase 6 Side)

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Name Location Latitude Longitude Manufacturer Model #

Junction Box 6 (Phase 4 Side)

1.4 OBSERVATION PERIOD

1.4.1 General

A 30-day Observation Period will begin upon the successful completion of the installed site tests, as well as the correction of all known deficiencies, including minor construction items and punch-list items developed by the Contracting Officer. During this period the Government will observe equipment and software operation to determine that all components operate properly according to the requirements of the Plans and these Specifications over an extended period of time.

During the Observation Period, respond to failures of the Contractor's equipment within two hours and make repairs within eight hours. For items that pose a traffic safety hazard such as a controller failure, make repairs within four hours. If any failures affect major system components for more than 48 hours, the Government will suspend the Observation Period beginning when the failure occurred. Resume the Observation Period after successful repair or replacement.

A successful 30-day Observation Period must consist of continuous operation with no more than a total of five calendar days of non-operation due to mechanical, electrical, or other malfunctions.

The Observation Period must be completed by the project completion date and prior to final acceptance of the project. The Observation Period will not begin without the approval of the Contracting Officer.

1.4.2 Final Acceptance

Final acceptance is defined as the time when all work and materials described in the Plans and this Specification have been provide by the Contractor; all parts of the work have been approved and accepted by the Contracting Officer; and the traffic signals have been operated continuously and successfully for the 30-day Observation Period.

Final acceptance will not occur until operational tests have been satisfactorily completed, all punch-list discrepancies have been rectified, all documentation has been delivered and accepted.

1.5 WARRANTY

Unless otherwise required herein, provide manufacturer's warranties on Contractor-provided equipment for material and workmanship that are customarily issued by the equipment manufacturer or that are at least one year in length, whichever is greater, from the date of final acceptance of the project by the Contracting Officer. Include unconditional coverage

SECTION 34 90 00 Page 6 for all parts and labor necessary or incidental to repair of defective equipment or workmanship and malfunctions that arise during warranty period.

For light emitting diode (LED) traffic signal modules, provide a written warranty against defects in materials and workmanship for a period of 60 months after installation of the modules. During the warranty period, the manufacturer must provide replacement modules within 45 days of receipt of modules that have failed at no cost to the Government.

Ensure all Contractor-provided equipment, including pieces and components of equipment, hardware, firmware, software, middleware, internal components, and subroutines which perform any date or time data recognition function, calculation, or sequencing will support a four digit year format for a period of at least 50 years and will support user-definable parameters for setting the start and end dates for daylight savings time.

Upon receipt of the Contracting Officer's written final acceptance of project, transfer manufacturer's warranties with proper validation by the manufacturer to the Government. Provide warranties in the name of the Government.

PART 2 PRODUCTS

2.1 GENERAL

Provide new equipment, materials, and hardware unless otherwise required.

Inscribe manufacturer's name, model number, serial number, and any additional information needed for proper identification on each piece of equipment housed in a case or housing.

Except for the signal controller and cabinet , signal equipment, material, and hardware must be pre-approved on the NCDOT ITS and Signals Qualified Products List (QPL) by the date of installation. Equipment, material, and hardware not pre-approved when required will not be allowed for use on the project. Consult the QPL website to obtain pre-approval procedures.

The 2018 NCDOT ITS and Signals QPL is available on the NCDOT's website at the following address:

https://connect.ncdot.gov/resources/safety/Pages/ITS-and-Signals- Qualified-Products.aspx

2.1.1 Operation and Maintenance Data

Provide the following for all products:

Operator's Manuals

Maintenance Procedure Manuals

Training Manuals

2.2 OBSERVATION PERIOD

Prior to final acceptance, all Contractor-provided equipment and software

SECTION 34 90 00 Page 7 must successfully complete a 30-day Observation Period.

The 30-day Observation Period is considered to be part of the work included in the total contract time and must be completed prior to final acceptance of the project.

Final acceptance will occur following the successful completion of the 30-day Observation Period and after all documentation requirements have been fully satisfied.

Refer to the "Installed Site Tests" and "Observation Period" subsections of this Specification for additional requirements.

2.3 FIRMWARE AND LICENSING UPGRADES

Provide the Government with a license to duplicate all programmable devices in equipment for maintenance and software upgrades. Provide binary or hexadecimal format files for each device that may be programmed by the Government. Ensure files are provided on PC compatible compact disks or other approved media.

Ensure software/firmware performance upgrades that occur during the contract period up through final acceptance of the project are provided to the Government at no additional cost.

Make software/firmware upgrades that are developed to correct operating characteristics available to the Government at no additional cost until the warranty period expires.

Provide licensed copies of all software/firmware to the Government for any programmable devices provided by the Contractor under this project. The Government will have the right to install any and all software/firmware for maintenance and support on all hardware provided under this contract.

This includes traffic signal controllers. Provide software/firmware for maintenance and support on workstations, laptop computers, system support software, utility software, traffic signal controllers and all other programmable devices.

2.4 WIRE AND CABLE

Provide wire and cable on reels. When requested by the Contracting Officer, provide samples of wire and cable to the Government at no additional cost.

Provide either 0.05" x 0.30" aluminum wrapping tape or 0.06" stainless steel lashing wire for lashing cables to messenger cable.

2.5 PAINTING

Where painting of signal heads is required, apply paint at the factory.

No field painting will be allowed except when paint has been scratched or marred. In such cases, apply two field coats of the same color and grade enamel as the original paint to the scratched or marred portions. For the aforementioned unfinished components that require field painting, prepare the surface to receive the paint in accordance with the coating manufacturer's instructions, including application of primer.

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2.6 PERFORMANCE OF WARRANTY REPAIR AND MAINTENANCE

Ensure the manufacturer agrees to provide prompt technical support to the Government electronics technicians for a period of one year after the end of the warranty period at no cost to the Government. Defective parts replaced under warranty by the Government will be returned to the vendor at the vendor's request. After project acceptance and at the request of the Government, the manufacturer must perform warranty repairs to equipment which fails during the warranty period at no cost to the Government including freight costs to ship repaired equipment back to the MCAS Cherry Point. Ensure all equipment is repaired and returned to the MCAS Cherry Point within 21 calendar days of receipt by the manufacturer.

2.7 SIGNAL HEAD - GENERAL

Fabricate vehicle signal head housings and end caps from die-cast aluminum. Fabricate 12 inch and 16-inch pedestrian signal head housings and end caps from die-cast aluminum. Fabricate 9-inch pedestrian signal head housings, end caps, and visors from virgin polycarbonate material.

Provide visor mounting screws, door latches, and hinge pins fabricated from stainless steel. Provide interior screws, fasteners, and metal parts fabricated from stainless steel.

Fabricate tunnel and traditional visors from sheet aluminum.

Fabricate tunnel and traditional visors for vehicle signal heads from ultraviolet and heat-stabilized virgin polycarbonate material. Fabricate tunnel and traditional visors for pedestrian signal heads from sheet aluminum.

Paint all surfaces inside and outside of signal housings and doors. Paint outside surfaces of tunnel and traditional visors, wire outlet bodies, wire entrance fitting brackets and end when supplied as components of messenger cable mounting assemblies, pole and pedestal mounting assemblies, and pedestrian pushbutton housings. Have electrostatically-applied, fused-polyester paint in highway yellow (Federal Standard 595C, Color Chip Number 13538) a minimum of 2.5 to 3.5 mils thick. Do not apply paint to the latching hardware or rigid vehicle signal head mounting brackets for mast arm attachments, messenger cable hanger components or balance adjuster components.

Paint the signal housings and visors black (Federal Standard 595C, Color Chip Number 17038) when:

a. The existing pedestrian and vehicle signals at the intersection where the new signals will be installed are painted black;

b. The vehicle signal will be mounted on metal poles or mast arms that currently have a black finish; and

For signals at all other locations, paint the signal housings highway yellow (Federal Standard 595C, Color Chip Number 13538).

Have the interior surfaces of tunnel and traditional visors painted an alkyd urea black synthetic baking enamel with a minimum gloss reflectance and meeting the requirements of MIL-E-10169, "Enamel Heat Resisting, Instrument Black."

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For pole mounting, provide side of pole mounting assemblies with framework and all other hardware necessary to make complete, watertight connections of the signal heads to the poles and pedestals. Fabricate the mounting assemblies and frames from aluminum with all necessary hardware, screws, washers, etc. to be stainless steel. Provide mounting fittings that match the positive locking device on the signal head with the serrations integrally cast into the brackets. Provide upper and lower pole plates that have a 1¼-inch vertical conduit entrance hubs with the hubs capped on the lower plate and 1½-inch horizontal hubs. Ensure that the assemblies provide rigid attachments to poles and pedestals so as to allow no twisting or swaying of the signal heads. Ensure that all raceways are free of sharp edges and protrusions, and can accommodate a minimum of ten Number 14 AWG conductors.

For pedestal mounting, provide a post-top slipfitter mounting assembly that matches the positive locking device on the signal head with serrations integrally cast into the slipfitter. Provide stainless steel hardware, screws, washers, etc. Provide a minimum of six 3/8 X 3/4-inch long square head bolts for attachment to pedestal. Provide a center post for multi-way slipfitters. Provide post-top slipfitter mounting assemblies that are either the same color as the housing of the pedestrian or vehicle signal head that will be attached to them (e.g., provide black assemblies for black signal heads and yellow assemblies for yellow signal heads) or which have a natural aluminum finish. Comply with the painting requirements for signal heads listed above.

For light emitting diode (LED) traffic signal modules, provide the following requirements for inclusion on the North Carolina Department of Transportation ( NCDOT)'s Qualified Products List (QPL) for traffic signal equipment.

1. Sample submittal,

2. Third-party independent laboratory testing results for each submitted module with evidence of testing and conformance with all of the Design Qualification Testing specified in Section 6.4 of each of the following Institute of Transportation Engineers (ITE) specifications:

a. Vehicle Traffic Control Signal Heads - Light Emitting Diode (LED) Circular Signal Supplement

b. Vehicle Traffic Control Signal Heads - Light Emitting Diode (LED) Vehicle Arrow Traffic Signal Supplement

c. Pedestrian Traffic Control Signal Indications - Light Emitting Diode (LED) Pedestrian Traffic Signal Modules.

(Note: The North Carolina Department of Transportation currently recognizes two approved independent testing laboratories. They are Intertek ETL Semko and Light Metrics, Incorporated with Garwood Laboratories. Independent laboratory tests from other laboratories may be considered as part of the QPL submittal at the discretion of the Government.)

3. Evidence of conformance with the requirements of these specifications,

4. A manufacturer's warranty statement in accordance with the required warranty, and

SECTION 34 90 00 Page 10

5. Submittal of manufacturer's design and production documentation for the model, including but not limited to, electrical schematics, electronic component values, proprietary part numbers, bill of materials, and production electrical and photometric test parameters,

6. Evidence of approval of the product to bear the Intertek ETL Verified product label for LED traffic signal modules.

In addition to meeting the performance requirements for the minimum period of 60 months, provide a written warranty against defects in materials and workmanship for the modules for a period of 60 months after providing the modules. During the warranty period, the manufacturer must provide replacement modules within 45 days of receipt of modules that have failed at no cost to the Government. Repaired or refurbished modules may not be used to fulfill the manufacturer's warranty obligations. Provide manufacturer's warranty documentation to the Government during evaluation of product for inclusion on the ITS and Signals QPL.

2.8 Vehicle Signal Heads

Comply with the ITE standard "Vehicle Traffic Control Signal Heads."

Provide housings with provisions for attaching backplates.

Provide visors that are 8 inches in length for 8-inch vehicle signal head sections. Provide visors that are 10 inches in length for 12-inch vehicle signal heads.

Provide a termination block with one empty terminal for field wiring for each indication plus one empty terminal for the neutral conductor. Have all signal sections wired to the termination block. Provide barriers between the terminals that have terminal screws with a minimum Number 8 thread size and that will accommodate and secure spade lugs sized for a Number 10 terminal screw.

Mount termination blocks in the yellow signal head sections on all in-line vehicle signal heads. Mount the termination block in the red section on five-section vehicle signal heads.

Provide vehicle signal head interconnecting brackets. Provide one-piece aluminum brackets less than 4.5 inches in height and with no threaded pipe connections. Provide hand holes on the bottom of the brackets to aid in providing wires to the signal heads. Lower brackets that carry no wires and are used only for connecting the bottom signal sections together may be flat in construction.

For mast arm mounting, provide rigid vehicle signal head mounting brackets and all other hardware necessary to make complete, watertight connections of the vehicle signal heads to the mast arms and to provide a means for vertically adjusting the vehicle signal heads to proper alignment.

Fabricate the mounting assemblies from malleable iron or aluminum, and provide serrated rings made of aluminum. Provide stainless steel cable attachment assemblies to secure the brackets to the mast arms. Ensure all fastening hardware and fasteners are fabricated from stainless steel.

Provide LED vehicular traffic signal modules (hereafter referred to as modules) that consist of an assembly that uses LEDs as the light source in lieu of an incandescent lamp for use in traffic signal sections. Use LEDs

SECTION 34 90 00 Page 11 that are aluminum indium gallium phosphorus (AlInGaP) technology for red and yellow indications and indium gallium nitride (InGaN) for green indications. Provide the ultra bright type LEDs that are rated for 100,000 hours of continuous operation from -40°F to +165°F. Design modules to have a minimum useful life of 60 months and to meet all parameters of this specification during this period of useful life.

For the modules, provide spade terminals crimped to the lead wires and sized for a #10 screw connection to the existing terminal block in a standard signal head. Do not provide other types of crimped terminals with a spade adapter.

Ensure the power supply is integral to the module assembly. On the back of the module, permanently mark the date of manufacture (month & year) or some other method of identifying date of manufacture.

Tint the red, yellow and green lenses to correspond with the wavelength (chromaticity) of the LED. Transparent tinting films are unacceptable.

Provide a lens that is integral to the unit with a smooth outer surface.

2.8.1 LED Circular Signal Modules

Provide modules in the following configurations: 12-inch circular sections, and 8-inch circular sections. All makes and models of LED modules purchased for use on this project must appear on the current NCDOT ITS & Signals QPL.

Provide the manufacturer's model number and the product number (assigned by the North Carolina Department of Transportation) for each module that appears on the 2012 or most recent ITS & Signals QPL. In addition, provide manufacturer's certification in accordance with Article 106-3 of the Standard Specifications, that each module meets or exceeds the ITE "Vehicle Traffic Control Signal Heads - Light Emitting Diode (LED) Circular Signal Supplement" dated June 27, 2005 (hereafter referred to as VTCSH Circular Supplement) and other requirements stated in this specification.

Provide modules that meet the following requirements when tested under the procedures outlined in the VTCSH Circular Supplement:

Module Type Max Wattage at 165F Nominal Wattage at 77F

12-inch red circular 17 11

8-inch red circular 13 8

12-inch green circular 15 15

8-inch green circular 12 12

For yellow circular signal modules, provide modules tested under the procedures outlined in the VTCSH Circular Supplement to insure power required at 77° F is 22 Watts or less for the 12 inch circular module and 13 Watts or less for the 8-inch circular module.

SECTION 34 90 00 Page 12

Note: Use a wattmeter having an accuracy of ±1% to measure the nominal wattage and maximum wattage of a circular traffic signal module. Power may also be derived from voltage, current and power factor measurements.

2.8.2 LED Arrow Signal Modules

Provide 12-inch omnidirectional arrow signal modules. All makes and models of LED modules purchased for use on this project must appear on the current NCDOT ITS & Signals QPL.

Provide the manufacturer's model number and the product number (assigned by the NCDOT) for each module that appears on the 2018 or most recent ITS & Signals QPL. In addition, provide manufacturer's certification in accordance with Article 106-3 of the Standard Specifications, that each module meets or exceeds the requirements for 12-inch omnidirectional modules specified in the ITE "Vehicle Traffic Control Signal Heads - Light Emitting Diode (LED) Vehicle Arrow Traffic Signal Supplement" dated July 1, 2007 (hereafter referred to as VTCSH Arrow Supplement) and other requirements stated in this specification.

Provide modules that meet the following requirements when tested under the procedures outlined in the VTCSH Arrow Supplement:

Module Type Max Wattage at 165F Nominal Wattage at 77F

12-inch red circular 12 9

12-inch green circular 11 11

For yellow arrow signal modules, provide modules tested under the procedures outlined in the VTCSH Arrow Supplement to insure power required at 77° F is 12 Watts or less.

Note: Use a wattmeter having an accuracy of ±1% to measure the nominal wattage and maximum wattage of an arrow traffic signal module. Power may also be derived from voltage, current and power factor measurements.

2.9 PEDESTRIAN SIGNAL HEADS

Provide pedestrian signal heads with international symbols that meet the MUTCD. Do not provide letter indications.

Comply with the ITE standard for "Pedestrian Traffic Control Signal Indications" and the following sections of the ITE standard for "Vehicle Traffic Control Signal Heads" in effect on the date of advertisement:

a. Section 3.00 - "Physical and Mechanical Requirements"

b. Section 4.01 - "Housing, Door, and Visor: General"

c. Section 4.04 - "Housing, Door, and Visor: Materials and Fabrication"

d. Section 7.00 - "Exterior Finish"

Provide a double-row termination block with three empty terminals and

SECTION 34 90 00 Page 13 number 10 screws for field wiring. Provide barriers between the terminals that accommodate a spade lug sized for number 10 terminal screws. Mount the termination block in the hand section. Wire all signal sections to the terminal block.

Where required by the plans, provide 16-inch pedestrian signal heads with traditional three-sided, rectangular visors, 6 inches long. Where required by the plans, provide 12-inch pedestrian signal heads with traditional three-sided, rectangular visors, 8 inches long.

Provide 2-inch diameter pedestrian pushbuttons with weather-tight housings fabricated from die-cast aluminum and threading in compliance with the NEC for rigid metal conduit. Provide a weep hole in the housing bottom and ensure that the unit is vandal resistant.

Provide pushbutton housings that are suitable for mounting on flat or curved surfaces and that will accept 1/2-inch conduit provided in the top.

Provide units that have a heavy duty push-button assembly with a sturdy, momentary, normally-open switch. Have contacts that are electrically insulated from the housing and push-button. Ensure that the push-buttons are rated for a minimum of 5 mA at 24 volts DC and 250 mA at 12 volts AC.

Provide standard R10-3 signs with mounting hardware that comply with the MUTCD in effect on the date of advertisement. Provide R10-3E signs for countdown pedestrian heads and R10-3B for non-countdown pedestrian heads.

Design the LED pedestrian traffic signal modules (hereafter referred to as modules) for installation into standard pedestrian traffic signal sections that do not contain the incandescent signal section reflector, lens, egg crate visor, gasket, or socket. Provide modules that consist of an assembly that uses LEDs as the light source in lieu of an incandescent lamp. Use LEDs that are of the latest aluminum indium gallium phosphorus (AlInGaP) technology for the Portland Orange hand and countdown displays.

Use LEDs that are of the latest indium gallium nitride (InGaN) technology for the Lunar White walking man displays. Provide the ultra-bright type LEDs that are rated for 100,000 hours of continuous operation from -40°F to +165°F. Design modules to have a minimum useful life of 60 months and to meet all parameters of this specification during this period of useful life.

Design all modules to operate using a standard 3 - wire field installation. Provide spade terminals crimped to the lead wires and sized for a #10 screw connection to the existing terminal block in a standard pedestrian signal housing. Do not provide other types of crimped terminals with a spade adapter.

Ensure the power supply is integral to the module assembly. On the back of the module, permanently mark the date of manufacture (month & year) or some other method of identifying date of manufacture.

Provide modules in the following configuration: 16-inch displays which have the solid hand/walking man overlay on the left and the countdown on the right, and 12-inch displays which have the solid hand/walking man module as an overlay. All makes and models of LED modules must appear on the current NCDOT Traffic Signal QPL.

Provide the manufacturer's model number and the product number (assigned by the NCDOT) for each module that appears on the 2018 or most recent

SECTION 34 90 00 Page 14

Qualified Products List. In addition, provide manufacturer's certification in accordance with Article 106-3 of the Standard Specifications, that each module meets or exceeds the ITE "Pedestrian Traffic Control Signal Indicators - Light Emitting Diode (LED) Signal Modules" dated August 04, 2010 (hereafter referred to as PTCSI Pedestrian Standard) and other requirements stated in this specification.

Provide modules that meet the following requirements when tested under the procedures outlined in the PTCSI Pedestrian Standard:

Module Type Max Wattage at 165F Nominal Wattage at 77F

Hand indication 16 13

Walking Man indication 12 9

12-inch green circular 16 13

Note: Use a wattmeter having an accuracy of ±1% to measure the nominal wattage and maximum wattage of a circular traffic signal module. Power may also be derived from voltage, current and power factor measurements.

Provide module lens that is hard coated or otherwise made to comply with the material exposure and weathering effects requirements of the Society of Automotive Engineers (SAE) J576. Ensure all exposed components of the module are suitable for prolonged exposure to the environment, without appreciable degradation that would interfere with function or appearance.

Ensure the countdown display continuously monitors the traffic controller to automatically learn the pedestrian phase time and update for subsequent changes to the pedestrian phase time.

Ensure the countdown display begins normal operation upon the completion of the preemption sequence and no more than one pedestrian clearance cycle.

2.10 SIGNAL CABLE

Provide 16-4 and 16-7 signal cable that complies with IMSA specification 20-1 except provide the following conductor insulation colors:

a. For 16-4 cable: white, yellow, red, and green;

b. For 16-7 cable: white, yellow, red, green, yellow with black stripe tracer, red with black stripe tracer, and green with black stripe tracer.

Apply continuous stripe tracer on conductor insulation with a longitudinal or spiral pattern.

Provide a ripcord to allow the cable jacket to be opened without using a cutter. IMSA specification 19-1 will not be acceptable. Provide a cable jacket labeled with the IMSA specification number and provide conductors constructed of stranded copper.

2.11 UNDERGROUND CONDUIT - GENERAL

Provide material, equipment, and hardware under this section that is pre-approved on the ITS and Signals QPL.

SECTION 34 90 00 Page 15

Refer to the following articles of the Standard Specifications:

Backfill 1018-2

Graded Stone 545-2 and 545-3

2.11.1 Conduit Bodies, Boxes and Fittings

Use conduit bodies, boxes, and fittings that meet UL Standard 514A or 514B for electrical and communications installations.

2.11.2 Conduit Types

2.11.2.1 Rigid Metallic Conduit

Provide rigid hot dipped galvanized steel conduit that meets UL Standard 6 with rigid full weight sherardized or galvanized threaded fittings.

2.11.2.2 PVC Conduit

Provide non-metallic conduit and duct including associated couplings, approved for below ground use with or without concrete encasement in accordance with UL Standard 651A. Provide Schedule 40 conduit unless otherwise specified.

2.11.2.3 Solid-Wall HDPE Conduit

Use HDPE conduit that conforms to UL Standard 651B. Provide conduit meeting the requirements of the table below with minimum wall thickness ratios corresponding to EPEC-40 (Schedule 40), EPEC-80 (Schedule 80) or EPEC-B (SDR 13.5) as listed in UL Standard 651B, Table 5.1, 5.2 and 5.3.

Conduit Trade Size Provide

1" EPEC-40

1-1/4" EPEC-40

1-1/2" EPEC-B (SDR 13.5)

2" EPEC-B (SDR 13.5)

2-1/2" EPEC-B (SDR 13.5)

3" EPEC-B (SDR 13.5)

4" EPEC-B (SDR 13.5)

5" EPEC-80

6" EPEC-80

Ensure the PE resin compounds used in manufacturing the conduit meet or exceed the cell classification PE 334420C (black with 2% minimum carbon

SECTION 34 90 00 Page 16 black) or PE 334420E (colored conduit with UV inhibitors) in ASTM D3350 and the table below.

Property Requirement Test Method

Density 0.940 - 0.947g/cm3 ASTM D1505

ASTM D792

ASTM D4883

Melt Index (condition 190/2.16 is acceptable)

< 0.4 grams/10 minutes ASTM D1238

Flexural Modulus 80,000 psi, min. ASTM D790

Tensile Strength 3,000 psi, min. ASTM D638

Elongation 400%, min. ASTM D638

Slow Crack Growth Resistance An ESCR as per condition B, 10% IGEPAL requirement of F50>24 hrs is allowable

ASTM D1693

Hydrostatic Design Basis "0" for Non-Pressure Rated Pipe

ASTM D2837

UV Resistance (Outdoor Conduit Only)

Stabilize with at least 2% by weight carbon black or colored with UV Inhibitor

ASTM D4218

Provide conduits in the colors for the applications shown in the table below. For conduits manufactured with stripes, ensure the stripes are uniformly located around the conduit with 120 degrees of separation. Do not use "Solid Yellow" or "Black with Yellow Stripes" conduit.

Conduit Contents Preferred Solid Color Alternate

Signal Cable Black None

Loop Lead-In Cable White Black w/ White Stripes

Electrical Power Cable Red Black w/ Red Stripes

Ensure the HDPE conduit is resistant to benzene, calcium 1 chloride, ethyl alcohol, fuel oil, gasoline, lubricating oil, potassium chloride, sodium chloride, sodium nitrate and transformer oil and is protected against degradation due to oxidation and general corrosion.

Provide factory lubricated, low friction, conduit with a coefficient of friction of 0.10 or less in accordance with Telcordia GR-356. Ensure the supplied conduit is identified and certified as meeting, UL Standard 651B.

Ensure the conduit is marked at least with the following information on 10 ft or less intervals:

1) Material: HDPE

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2) Trade Size: i.e., 2"

3) Conduit Type: SDR 13.5 or EPEC-B

4) Manufacturer's name or trademark

5) Manufacturer's identity code to identify manufacturing date, facility, etc.

6) UL symbol or UL listing number

Provide coilable conduit that is supplied on reels in continuous lengths for transportation and storage outside. Ensure that the process of providing the coilable conduit on the reel does not alter the properties or performance of the conduit for its intended purpose.

2.11.3 Conduit Plugs, Pull Line, and Tracer Wire

Provide conduit plugs that provide a watertight barrier when provided in conduit. Provide conduit plugs sized in accordance with conduit. Ensure conduit plug provides a means to secure a pull line to the end of the plug. Provide removable and re-usable duct plugs. Conduit plugs are not required to be listed electrical devices.

For all spared conduits, provide 3/4", pre-lubricated, woven polyester tape, pull line with minimum rated tensile strength of 2,500 lb. Pull lines are not required to be listed electrical devices.

2.11.4 Mechanical Couplings for HDPE Conduit

Provide mechanical couplings that are both watertight and airtight for joining two segments of HDPE conduit of like diameter. Provide couplings designed to accommodate pneumatic methods of cable installation. Provide couplings suitable for burial underground and which meet the following requirements:

a. The coupling must not fail by leakage when subjected to sustained internal pressure testing as noted in ASTM F 2176.

b. The coupling must not fail by leakage when subjected to sustained external pressure testing as noted in ASTM F 2176.

c. The coupling assemblies tested must be able to comply with the tensile loading requirements as specified in ASTM F 2176.

d. As specified in ASTM F 2176, the coupling must not fail when conditioned at low temperature conditions of 10° F and tested by an impact with a force of 20 ft-lb using Type "B" as described in Test Method ASTM D 2444.

2.11.5 Duct and Conduit Sealer

Use duct and conduit sealer or mastic which is a putty-like compound and:

a. Is permanently non-hardening, non-oxidizing, and non-corrosive to metals, rubber, plastic, lacquer and paints;

b. Is readily workable for thumbing into openings and forming into seals

SECTION 34 90 00 Page 18 around wires inside conduits and openings around conduits;

c. Has a service temperature range of minus 30°F to 200°F;

d. Is clean, non-poisonous and non-injurious to human skin;

e. Seals against water, dust and air and must adhere to wood, glass, plastics, metal, rubber and painted surfaces; and

f. Is non-conductive.

2.12 JUNCTION BOXES - GENERAL

Provide electrical junction boxes with covers of the type and size indicated by the contract or the Plans for the termination of conduits, for splicing loop wires to loop lead-in cables and for storing spare cable.

Except for special-sized junction boxes, material, equipment, and hardware provided under this section must be pre-approved on the ITS and Signals

QPL.

Provide #57 or #67 washed stone aggregates in conformance with Sections 545 and 1005 of the Standard Specifications.

2.12.1 Polymer Concrete (PC) Junction Boxes

Provide polymer concrete (PC) boxes which are stackable, have bolted covers and have open bottoms. Ensure vertical extensions of 6 inches to 12 inches are available from the junction box manufacturer.

Use polymer concrete material made of an aggregate consisting of sand and gravel bound together with a polymer and reinforced with glass strands to fabricate box and cover components which are exposed to sunlight. Other thermosetting glass-reinforced materials may be used for components which are not normally exposed to sunlight.

Provide certification that the polymer concrete boxes and covers meet Tier 15 requirements of ANSI/SCTE 77. Provide certification that testing methods are compliant with ANSI/SCTE 77.

Provide junction box covers with the required logos on the cover as follows (see NCDOT Roadway Standard Drawing No. 1716.01 for additional details):

a. For standard size and oversized junction boxes that contain traffic signal cable and loop lead-in cable, provide covers with the standard TRAFFIC SIGNAL logo;

b. For standard size junction boxes that house electrical service conductors, provide covers with the standard ELECTRIC logo; and Provide at least two size 3/8" diameter hex head stainless steel cover bolts to match inserts in the box. Provide pull slot(s) with stainless steel pin(s). Polymer concrete junction boxes are not required to be listed electrical devices.

SECTION 34 90 00 Page 19

2.12.2 Junction Box sizes

Provide junction boxes and covers of the following sizes as called for in the Plans:

Junction Box Size Minimum Inside Dimensions

Standard Size 16"(L) x 10"(W) x 10"(D)

Oversized 30"(L) x 15"(W) x 24"(D)

2.12.3 Loop Sealant

Provide the Contracting Officer with a Type 3 material certifications and material safety data sheets (MSDS) for the sealant in accordance with Article 106-3 of the Standard Specifications.

Provide loop slot sealant that completely encapsulates loop wire when provided according to manufacturer's instructions. Provide loop sealant that does not generate temperatures greater than 220° F. Ensure sealant bonds with asphalt and concrete pavement saw slots so sealant and encapsulated loop wire do not come out of slot. Ensure sealant is self-leveling, but with sufficient viscosity to prevent exit from saw slot when provided along a 10% grade.

Provide sealant that protects loop wire by preventing the entrance of dirt, water, rocks, sticks, and other debris into saw slot, and is resistant to traffic, water, gasoline, chemical and chemical fumes, mild alkalis, oils, and mild acids. Ensure sealant will not be affected by water and sealant does not chemically interact with pavement and loop wire insulation.

Ensure loop sealant has sufficient flexibility to permit expected pavement expansion and contraction due to weather and to permit pavement movement due to traffic without cracking for a temperature range of -40 to 160° F.

Provide sealant with a usable life of at least ten minutes once mixed, when the ambient temperature is 75° F. Ensure sealant dries to tack-free state in less than 2 hours, and does not flow within or out of saw slot after exposed surface has become tack free. Tack free time will be determined by testing with a cotton ball until no sealant adheres to cotton ball and no cotton adheres to sealant.

Ensure two-part sealant cures within 48 hours to attain 95% of published properties for the cured material.

Ensure one part sealant cures within 30 days to attain 95% of published properties for the cured material.

2.12.4 Loop Wire

Provide loop wire composed of 19-strand conductor insulated by a cross-linked polyethylene compound. Ensure insulated conductors are completely encased in tubes of low density polyethylene compound. Print manufacturer's name, manufacture year, and any applicable part number on encasing tube at intervals of 2 feet or less.

SECTION 34 90 00 Page 20

Provide #14 AWG copper conductors fabricated from 19 strands that comply with ASTM B3 before insulating. Ensure stranded conductors use either concentric or bunch stranding, and comply with circular mil area and physical requirements of ASTM B8 or ASTM B174 for bunch stranding.

Provide insulating compound that is cross-linked thermosetting black polyethylene in accordance with ASTM D 2655. Ensure insulation is applied concentrically about conductor. Provide insulation thickness not less than

0.026 inch at any point and minimum average thickness of 0.030 inch as measured by UL Standard 62.

Ensure insulation of finished conductor will withstand application of a 60 Hertz or 3,000 Hertz, 7,500 volt (RMS)…