AM-0001 Repair Kastner Specifications.pdf

FY21 OMA REPAIR KASTNER HELIPORT LIGHTING

KASTNER AIRFIELD, CAMP ZAMA, KANAGAWA, JAPAN

SECTION 26 56 20

AIRFIELD AND HELIPORT LIGHTING AND VISUAL NAVIGATION AIDS

02/19

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.

ASTM INTERNATIONAL (ASTM)

ASTM A123/A123M (2017) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A153/A153M (2016a) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C2 (2017; Errata 1-2 2017; INT 1 2017) National Electrical Safety Code

IEEE C62.11 (2012) Standard for Metal-Oxide Surge Arresters for Alternating Current Power Circuits (>1kV)

IEEE C62.41.1 (2002; R 2008) Guide on the Surges Environment in Low-Voltage (1000 V and Less) AC Power Circuits

IEEE C62.41.2 (2002) Recommended Practice on Characterization of Surges in Low-Voltage (1000 V and Less) AC Power Circuits

JAPANESE INDUSTRIAL STANDARDS (JIS)

JIS C 3612 (2002) 600V Flame Retardant Polyethylene Insulated Wires

JIS C 3605 (R2002) 600 V Polyethylene Insulated Cables, Type CV

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

ANSI/NEMA WC 71/ICEA S-96-659 (2014) Standard for Nonshielded Cables Rated 2001-5000 Volts for use in the Distribution of Electric Energy

NEMA C119.1 (2016) Electric Connectors - Sealed Insulated Underground Connector Systems Rated 600 Volts

SECTION 26 56 20 Page 1 AM0001

NEMA WC 70 (2009) Power Cable Rated 2000 V or Less for the Distribution of Electrical Energy--S95-658

NEMA WC 74/ICEA S-93-639 (2012) 5-46 kV Shielded Power Cable for Use in the Transmission and Distribution of Electric Energy

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020; ERTA 20-1 2020; ERTA 20-2 2020; TIA

20-1; TIA 20-2; TIA 20-3; TIA 20-4)

National Electrical Code

NFPA 70B (2019) Recommended Practice for Electrical Equipment Maintenance

U.S. DEPARTMENT OF AGRICULTURE (USDA)

REA Bull 1753F-205 (1993) Filled Telephone Cables (PE-39)

U.S. FEDERAL AVIATION ADMINISTRATION (FAA)

FAA AC 150/5345-3 (2007; Rev F) Specification for L-821 Panels for Control to Airport Lighting

FAA AC 150/5345-5 (2006; Rev B) Specification for Airport Lighting Circuit Selector Switch

FAA AC 150/5345-7 (2013; Rev F) Specification for L-824 Underground Electrical Cable for Airport Lighting Circuits

FAA AC 150/5345-10 (2014; Rev H) Specification for Constant Current Regulators Regulator Monitors

FAA AC 150/5345-26 (2008; Rev D) FAA Specification for L-823 Plug and Receptacle, Cable Connectors

FAA AC 150/5345-42 (2019; Rev J) Specification for Airport Light Bases, Transformer Housings, Junction Boxes and Accessories

FAA AC 150/5345-46 (2016; Rev E) Specification for Runway and Taxiway Light Fixtures

FAA AC 150/5345-47 (2005; Rev B) Specification for Series to Series Isolation Transformers for Airport Lighting Systems

FAA AC 150/5345-53 (2012; Rev D) Airport Lighting Equipment Certification Program

FAA AC 150/5370-10 (2018; Rev H; Errata 1 2019) Standard Specifications for Construction of Airports

FAA E-2519 (1972; Rev A) Types I and II

SECTION 26 56 20 Page 2 AM0001

FAA FO 6850.19 (1978) Frangible Coupling

UNDERWRITERS LABORATORIES (UL)

UL 6 (2007; Reprint Sep 2019) UL Standard for Safety Electrical Rigid Metal Conduit-Steel

UL 44 (2018) UL Standard for Safety Thermoset-Insulated Wires and Cables

UL 83 (2017; Reprint Mar 2020) UL Standard for Safety Thermoplastic-Insulated Wires and Cables

UL 360 (2013; Reprint Nov 2018) UL Standard for Safety Liquid-Tight Flexible Metal Conduit

UL 486A-486B (2018) UL Standard for Safety Wire Connectors

UL 797 (2007; Reprint Mar 2017) UL Standard for Safety Electrical Metallic Tubing -- Steel

UL Electrical Construction (2012) Electrical Construction Equipment Directory

1.2 SYSTEM DESCRIPTION

Provide airfield and heliport lighting and visual navigation aids as indicated.

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Protection plan; G

Training; G

SD-02 Shop Drawings

Lighting; G

Composite drawings showing coordination of work of one trade with that of other trades and with structural and architectural elements of the work. Provide sufficient detail to show overall dimensions of related items, clearances, and relative locations of work in allotted spaces. Indicate where conflicts or clearance problems exist between the various trades.

SD-03 Product Data

When equipment or materials are specified to conform to the

SECTION 26 56 20 Page 3 AM0001 standards or publications and requirements of AASHTO, ANSI, ASTM, AEIC, ETL, IEEE, IES, NEMA, NFPA, or UL, or to an FAA, FS, or MS, include proof that the items furnished under this section conform to the specified requirements. The label or listing in UL Electrical Construction or ETL or the manufacturer's certification or published catalog specification data statement that the items comply with applicable specifications, standards, or publications and with the manufacturer's standards will be acceptable evidence of such compliance. Provide manufacturer prepared certificates when the manufacturer's published data or drawings do not indicate conformance with other requirements of these specifications.

Control panel; G

Type L-823 Connectors; G

Runway edge lights; G

Runway threshold and end lights; G

Taxiway edge lights; G

Light bases, each type; G

Helipad Perimeter Lights; G

List of airfield lighting materials and equipment with the FAA AC 150/5345-53 Appendix C review date.

Isolation transformers; G

Encapsulated isolation transformers; G

Constant current regulators, each size; G

Circuit selector switch; G

Control cable; G

Frangible couplings; G

Type P-605 Sealant; G

Type P-606 Sealant; G

Materials and equipment; G

SD-06 Test Reports

Visual inspection; G

Progress testing for series lighting circuits; G

Counterpoise system test and inspection; G

Operating test; G

Distribution conductors, 600-volt class; G

SECTION 26 56 20 Page 4 AM0001

Electrical acceptance tests; G

Low-voltage continuity tests; G

High-voltage insulation resistance tests; G

Constant current regulators, each size; G

SD-07 Certificates

Qualifications of contractor; G

Certified documentation of qualifications, as specified.

Special tools; G

List of special tools and test equipment required for installation, maintenance and testing of the products supplied by the Contractor. Items to be listed include, but are not limited to, the following:

4-Jack positioning jig, for in-pavement light bases.; G

Elevated light level; G

Crimping tool; G

Cable penciler

List of parts; G

A list of parts and components for the system by manufacturer's name, part number, nomenclature, and stock level required for maintenance and repair necessary to ensure continued operation with minimal delays.

SD-08 Manufacturer's Instructions

Posted instructions; G

Submit proposed disgrams, instructions, and other sheets prior to posting.

SD-10 Operation and Maintenance Data

Constant current regulators, Data Package 5; G

Maintenance and repair instructions; G

Instructions necessary to check out, troubleshoot, repair, and replace components of the systems, as specified.

Posted operations and maintenance instructions

Submit in accordance with Section 01 78 23 OPERATION AND

MAINTENANCE DATA.

SD-11 Closeout Submittals

SECTION 26 56 20 Page 5 AM0001

As-built drawings

1.4 MAINTENANCE MATERIAL SUBMITTALS

1.4.1 Spare Parts

Provide spare parts as indicated in this specification as part of this contract. The spare parts must be provided at the end of construction.

They must be in addition to any items consumed during construction or in testing.

1.5 QUALITY CONTROL

1.5.1 Regulatory Requirements

In each standard referred to herein, consider the advisory provisions to be mandatory, as though the word "must" has been substituted for "shall" or "should" wherever it appears. Interpret references in these standards to "authority having jurisdiction," or words of similar meaning, to mean Contracting Officer.

1.5.1.1 Code Compliance

Comply with the requirements and recommendations of NFPA 70 and IEEE C2 and local codes where required.

1.5.2 Standard Products

a. Use only approved equipment listed in FAA AC 150/5345-53 with addendum for the date of delivery the exception of Air Force threshold lights and Army heliport fixture colors and intensities. Inspect wire and cable for date of manufacture. Materials must be certified and listed as "Approved Airport Lighting Equipment" downloadable from:

http://www.faa.gov/arp/pdf/534553ad.pdf . Do not use wire and cable manufactured more than one year before delivery to job site.

b. Provide materials and equipment listed by FAA, UL, or ETL, when such equipment is listed or approved. Do not use askarel, tetrachlorethylene and insulating liquids containing polychlorinated biphenyls (PCBs) in equipment.

c. Material and equipment must be a standard product of a manufacturer regularly engaged in the manufacture of the product and essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening.

d. Where two or more items of the same class of equipment are required, provide products of a single manufacturer; however, the component parts of the item need not be products of the same manufacturer unless stated in this section.

1.5.3 Qualifications of Contractor

a. Provide documentation that the aviation lighting equipment contractor and installation electricians are experienced in installing, testing and maintaining aviation lighting systems of a similar complexity.

Similar complexity, in increasing complexity, are the following:

elevated edge lights and signs, in-pavement lights, and approach light

SECTION 26 56 20 Page 6 AM0001 systems. Include a list of government projects and 3 years of experience in constructing similar projects. Include written certification that systems have performed satisfactorily for not less than 18 months. Provide a list of airfield lighting schools or seminars attended in the last 5 years.

b. Submit certification containing the names and the qualifications of persons recommended to perform the splicing and termination of medium-voltage cables approved for installation under this contract.

Indicate that any person recommended to perform actual splicing and termination has been adequately trained in the proper techniques and has had at least 3 recent years of experience in splicing and terminating the same or similar types of cables approved for installation. Any person recommended by the Contractor may be required to perform a dummy or practice splice and termination, in the presence of the Contracting Officer, before being approved as a qualified installer of medium-voltage power or series lighting cables. If that additional requirement is imposed, provide short sections of the approved types of cables with the approved type of splice and termination kits, and detailed manufacturer's instruction for the proper splicing and termination of the approved cable types.

1.5.4 Protection Plan

Submit detailed procedures to prevent damage to existing facilities or infrastructures. If damage does occur, the procedures must address repair and replacement of damaged property at the Contractor's expense.

1.5.5 Prevention of Corrosion

1.5.5.1 Metallic Materials

Protect metallic materials against corrosion as specified. Do not use aluminum in contact with earth or concrete. Do not use aluminum conductors.

1.5.5.2 Ferrous Metal Hardware

Ferrous metal hardware must be hot-dip galvanized in accordance with ASTM A123/A123M and ASTM A153/A153M .

1.6 DELIVERY, STORAGE, AND HANDLING

The Contractor must deliver, store and secure all airfield lighting materials an equipment in accordance with the manufacturers' requirements.

1.7 PROJECT/SITE CONDITIONS

Items furnished under this section must be specifically suitable for the following unusual service conditions:

1.7.1 Altitude

Any equipment must be suitable for operation up to an altitude of 3,000 m.

1.7.2 Other

Material or equipment to be installed underground; in handholes, manholes, or underground vaults; or in light bases must be suitable for submerged

SECTION 26 56 20 Page 7 AM0001 operation.

1.7.3 Environmental Requirements

The airfield for this project has the following requirements:

Location - Camp Zama, Kanagawa, Japan Altitude - 110 m above mean sea level.

Maximum Exterior Temperature - 30 degrees C.

Minimum Exterior Temperature - 2 degrees C.

1.7.4 Existing Airfield Lighting Systems

Existing airfield lighting systems must remain in operating condition and interruptions must be held to a minimum. Where interruptions are ncessary, they must be scheduled as approved in writing by the Contracting Officer.

Prior to the scheduled time for each interruptions, all necessary materials and a sufficient labor force must be assembled to permit completing the work within the scheduled time interval. Under no circumstances must any of the existing airfield lighting circuits be left inoperative without making provisions for suitable temporary connections in the affected area or areas. All airfield lighting circuits covered under this Contract must be replaced in such a manner that they will be operational at dusk each day. The Contractor must submit to the Contracting Officer a plan for outages and maintaining lighting and lighting control.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

Provide airfield lighting as indicated on contract drawings.

2.2 AIRFIELD LIGHTING CONTROL AND MONITORING SYSTEM (AFLCMS)

2.2.1 Control Panel

FAA AC 150/5345-3 , Type L-821, Type 2, Style 3 Quantity and color of lenses must conform to FAA AC 150/5345-3 and must correspond to the actual circuits indicated. Provide Class W Control Panel for Building 1022 and provide Class F (mounted in a console panel) for Building 1038.

2.3 RUNWAY LIGHTING SYSTEM

Include runway edge lights, runway threshold lights, mounting structures, controls, and the associated equipment and interconnecting wiring to provide complete runway lighting systems as indicated. Use in-pavement light fixtures that withstand a minimum static single wheel load of 22,680 kg.

2.3.1 Runway Edge Lights

FAA AC 150/5345-46 , Type L-861(L) LED, elevated medium-intensity, airfield and heliport Type L-852E(L) LED, in-pavement medium-intensity, white lights.

2.3.2 Runway Threshold and End Lights

FAA AC 150/5345-46 , Type L-852(L) LED, in-pavement, medium-intensity, SECTION 26 56 20 Page 8 AM0001 omnidirectionalType L-850D(L) LED, in-pavement, high-intensity, bidirectional airfield and heliport lights as indicated. For threshold lights use aviation green filter and for end lights use aviation red filters. Combine these lights in a single bidirectional fixture with the appropriate color filters as indicated.

2.4 TAXIWAY LIGHTING SYSTEMS

Include edge lights, and all associated equipment, power supplies and controls, mounting devices, and interconnecting wiring to provide complete systems. If LED fixtures are used, provide fixtures that are compatible with the associated constant current regulators.

2.4.1 Taxiway Edge Lights

FAA AC 150/5345-46 , Type L-861T(L) LED for elevated taxiway edge lights with 45-watt, 6.6A lamp and blue lens or yellow lens or LED as indicated and FAA AC 150/5345-46 , Type L-852E(L) LED, Class 1 for semiflush taxiway edge lights with a 23W-watt, 6.6A lamp and blue filter.

2.5 HELIPAD LIGHTING SYSTEMS

2.5.1 Helipad Perimeter Lights

2.5.1.1 In-Pavement Lights

FAA AC 150/5345-46 , Type L-852E(L) LED with aviation yellow filters.

Mount fixtures on FAA Type L-868 bases.

2.6 LIGHT BASES

FAA AC 150/5345-42 Type L-867 or L-868. Use steel bases, Class 1, Size as indicated or as required to accommodate the fixture or device installed.

Use Size C where more than one distributed control module is installed in the light base. Where used as pull boxes in (single or multiple) can plazas use L-867D bases. Provide base plates, cover plates, and adapter plates to accommodate various sizes of fixtures.

Furnish each base with internal and external one-hole ground lugs for attaching ground or counterpoise cables.

Furnish each base with a 1.2 m braided, 25 square mm equivalent ground strap with one-hole lug compression fittings. Utilize straps made for the purpose of grounding the light fixture to the base can interior grounding lug.

2.7 SNOW PLOW RINGS

Provide cast ductile iron unidirectional snow plow rings for in-pavement light fixtures, as indicated. The rings must be suitable for the light fixture and L-868 light base cans indicated. Rings must have four stainless steel spring pins and black powder coat finish. Ring must be provided with a silicone rubber O-ring and six ceramic fluoropolymer coated bolts and 2-piece locking washers.

2.8 LAMPS AND FILTERS

Provide lamps of the size and type indicated, or as required by fixture manufacturer for each lighting fixture required. Include filters of

SECTION 26 56 20 Page 9 AM0001 colors as indicated and conforming to the specification for the light concerned or to the standard referenced.

2.9 ISOLATION TRANSFORMERS

2.9.1 Encapsulated Isolation Transformers

FAA AC 150/5345-47 , Type (G) L- 831 . Provide each transformer with rating as indicated. Insulation Level Primary voltage rating 5000 volts RMS, Secondary 600 V RMS. Operating Temperature range minus 55 degrees C to plus 65 degrees C. Resistant to UV exposure and ozone. Suitable for areas contaminated with oils, aircraft fuels, soil acids, alkalis, and deicing fluids. Compatible with FAA Style 2 and Style 9 connectors.

2.10 SURGE ARRESTERS

Provide surge arresters in accordance with IEEE C62.11 , IEEE C62.41.1 and IEEE C62.41.2 as applicable with ratings as indicated. Provide surge arresters on the line side of the constant current regulator (CCR).

Provide series circuit surge arresters for locations with a lightning flash density of 8 or more flashes per square kilometer per year.

2.11 SURGE PROTECTIVE DEVICES

As required in Section 26 20 00, INTERIOR DISTRIBUTION SYSTEM.

2.12 CONSTANT CURRENT REGULATORS

2.12.1 Regulators

FAA AC 150/5345-10 , Type L-828, without monitoring dry-type system and with current rating or 6.6A. Use regulators of ferroresconant design to reduce EMI, increase efficiency, and provide a power factor not less than

0.95. Provide regulators that operate on 50 Hz, have internal primary switch included, have input voltage of 208 and be controlled by 120 VAC external control voltage. Provide 5 brightness steps, as indicated.

Insure that constant current regulators are compatible with signs, and other connected loads.

2.12.2 Basic Impulse Level (BIL)

Provide 60-kV series circuit BIL except that 4-kW, 7.5-kW and 10-kW regulator series circuits may have a BIL of 25 kV.

2.13 CIRCUIT SELECTOR SWITCH

FAA AC 150/5345-5 , Type L-847, for two circuit control, Class A, indoor, Rating 1, for 6.6 amperes.

2.14 MATERIALS AND HARDWARE

2.14.1 Wire and Cable

Use copper conductors installed in conduit. Do not provide or install wire and cable manufactured more than one year before delivery to the job site.

SECTION 26 56 20 Page 10 AM0001 j2ee9kbm Line

2.14.1.1 Conductor Sizes

Conductor size conforming to American Wire Gage (AWG) or metric trade size. Use stranded conductors for sizes larger 10 square mm. Unless otherwise indicated 10 square mm and smaller may be solid or stranded.

2.14.1.2 Low Voltage Wire and Cable

a. UL 83 , Type THWN-2 UL 44 Type XHHW-2 or JIS C 3612 or JIS C 3605 equivalent.

2.14.1.3 Wire and Cable for Series Lighting Circuits

a. FAA AC 150/5345-7 , Type L-824 for crosslinked polyethylene Type C 5000-volt cable. Use unshielded cable for series airfield and heliport lighting.

2.14.1.4 Safety (Equipment) Grounding System

Safety (Equipment) Grounding System for constant voltage (parallel) circuits: minimum 16 square mm bare stranded copper, annealed or soft drawn.

2.14.1.5 Sequence Flashing Trigger Circuits

REA Bull 1753F-205 compliant cables.

2.14.1.6 Control Cable

Multiconductor type for 120 V ac control, rated 600 volts, 4 square mm, and conforming to the following unless indicated or specified otherwise.

Insulate each conductor with a thickness of not less than 0.762 mm and rate for continuous operation at 90 degrees C. Conductors must be color coded. An overall jacket of heavy-duty neoprene rated for direct burial must be included. Cable must conform to NEMA WC 70for rubber insulation, ANSI/NEMA WC 71/ICEA S-96-659 for cross-linked polyethylene insulation, or NEMA WC 74/ICEA S-93-639 for ethylene-propylene rubber insulation.

2.14.1.7 Cable Tags

Install cable tags for each cable or wire at duct entrances entering or leaving manholes, handholes, and at each terminal within the lighting vault, and in all base cans. Use stainless steel, bronze or copper strip cable tags, approximately 1.59 mm thick or hard plastic 3.18 mm thick suitable for immersion in salt water and impervious to petroleum products. Use sufficient material length for imprinting the legend on one line using raised letters. Permanently mark or stamped with letters not less than 6.4 mm in height as indicated. Two-color laminated plastic is acceptable. When providing plastic tags utilize white colored with markings of black color to provide contrast so that identification can be easily read. Use nylon or stainless steel ties must be of a type that will not deteriorate when exposed to water with a high saline content and to petroleum products.

2.14.1.8 Cable Connectors and Splices

FAA AC 150/5345-26 , Item L-823 for connections and splices appropriate for FAA Type L-824 cable.

SECTION 26 56 20 Page 11 AM0001

2.14.2 Conduit, Conduit Fittings, and Boxes

2.14.2.1 Rigid Metal Conduit (RMC) or Electrical Metallic Tubing (EMT) and Fittings

UL 6 and UL 797 .

2.14.2.2 Liquid-tight Flexible Metal Conduit (LFMC)

UL 360 liquid-tight flexible metal conduit. See Sections 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION and 26 20 00 INTERIOR DISTRIBUTION

SYSTEM.

2.14.2.3 Outlet Boxes for use with RMC, EMT, of LFMC

See 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION.

2.14.2.4 Plastic Duct for Concrete Encasement

Provide as specified in Section 33 71 02 UNDERGROUND ELECTRICAL

DISTRIBUTION.

2.14.2.5 Plastic Conduit for Direct Burial

Provide as specified in Section 33 71 02 UNDERGROUND ELECTRICAL

DISTRIBUTION.

2.14.2.6 High Density Polyethylene (HDPE) Electrical Conduit for Directional Bore

Provide as specified in Section 33 71 02 UNDERGROUND ELECTRICAL

DISTRIBUTION.

2.14.2.7 Frangible Couplings and Adapters

FAA FO 6850.19 and FAA E-2519 . Provide upper section of frangible coupling with one of the following:

a. Unthreaded for slip-fitter connections.

b. 61.1 mm 16N-1A modified thread for nut and compression ring to secure 53 mm EMT.

c. 53 mm 11-1/2-N.P.T. (tapered) with 5.6 mm nominal wall thickness to accept rigid conduit coupling.

d. Frangible Couplings for specialized applications as approved.

e. Electrical Metallic Tubing UL 797 , where indicated for use with frangible couplings and adapters.

2.14.3 Electrical Tape

Provide as specified in Section 33 71 02 UNDERGROUND ELECTRICAL

DISTRIBUTION.

2.14.4 Ground Rods

As specified in Section 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION.

SECTION 26 56 20 Page 12 AM0001

2.14.5 Bolts and Hardware

2.14.5.1 Locking Type Washers

Use locking washers of the two-piece wedge-lock design to prevent damage to the fixture. Do not use split-ring, serrated or star type lock washers.

2.14.5.2 Anti-Seize Compound

Use anti-seize compounds for elevated light fixtures with stainless steel bolts but not for ceramic-metallic/fluorocarbon polymer coated bolts for in-pavement light fixtures. Use as recommended by the fixture manufacturer to provide the required clamping force except as indicated in Part 3 of this specification.

2.14.5.3 Ceramic-Metallic/Fluorocarbon Polymer Coated Bolts

Ceramic-metallic/fluorocarbon polymer coated bolts must be used for in-pavement light fixtures or may be used where recommended by the fixture manufacturer in lieu of using an anti-seize compound.

2.14.5.4 Stainless Steel Bolts for Elevated Fixtures

Use anti-seize lubricating compound.

2.14.6 Sealants for Fixtures and Wires in Drilled Holes or Saw Kerfs

FAA AC 150/5370-10 , Type P-605 and FS SS-S200E/D, self leveling joint sealant, for use in asphaltic concrete (AC) or Portland cement concrete (PCC) pavement compatible with AC pavement and having a minimum elongation of 50 percent. Do not use formulations of Type P-606 which are compatible with PCC pavement only.

2.14.7 Manufacturer's Nameplates

Provide on each item of equipment a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable.

2.14.8 Field Fabricated Nameplates

Provide field fabricated nameplates as specified in Section 26 20 00

INTERIOR DISTRIBUTION SYSTEM.

2.14.9 Spare Airfield Lighting Equipment Materials

Contractor must provide the following equipment and materials:

a. Lamps - Type and Quantity

b. Isolation Transformers - Type and Quantity

c. Constant Current Regulators - Type and Quantity

d. FAA L-823 Connectors - Type and Quantity

e. Control Cable - Type and Quantity

SECTION 26 56 20 Page 13 AM0001

f. FAA L-824 Cable - Type and Quantity

g. Lamps for Airfield Lighting Fixtures and Signs

h. Refractors and Filters for Airfield Lighting Fixtures - Type and Quantity

i. Light Bases - Type and Quantity

j. Frangible Couplings - Type and Quantity

k. Sequenced Flashing Light System - Provide a spare part trunk with parts.

2.15 ACCESSORIES

2.15.1 Special Tools

List of special tools and test equipment required for installation, maintenance of testing of the products supplied by the Contractor. Items to be listed include, but are not limited to, the following:

4-Jack Positioning Jig, used to install the light base to ensure correct orientation and leveling of in-pavement fixtures.

Crimping Tool

Cable Penciler

Elevated Light Level

PART 3 EXECUTION

3.1 LIGHT FIXTURE INSTALLATION REQUIREMENTS

3.1.1 Existing Airfield Lighting Systems

Existing airfield lighting systems must remain in operating condition and interruptions must be held to a minimum. Where interruptions are necessary, they must be scheduled as approved in writing by the Contracting Officer. Prior to the scheduled time for each interruption, all necessary materials and a sufficient labor force must be assembled to permit completing the work within the scheduled time interval. Under no circumstances must any of the existing airfield lighting circuits be left inoperative without making provisions for suitable temporary connections in the affected area or areas. All airfield lighting circuits covered under this Contract must be replaced in such a manner that they will be operational at dusk each day. The Contractor must submit to the Contracting Officer a plan for outages and maintaining lighting and lighting control.

3.1.2 General Installation Requirements

Conform to IEEE C2 , NFPA 70 , NFPA 70B, and requirements specified herein.

Circuits installed underground must conform to the requirements of Section 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION, except as required herein.

Steel conduits installed underground must be installed and protected from corrosion in conformance with the requirements of Section 26 20 00

SECTION 26 56 20 Page 14 AM0001

INTERIOR DISTRIBUTION SYSTEM. Electrical metallic tubing (EMT) must not be installed underground or encased in concrete. Except as covered herein, perform excavation, trenching, and backfilling in accordance with the requirements of Section 31 23 00.00 20 EXCAVATION AND FILL.

3.1.3 Airfield Light Fixture Installation

Use 2-part locking type washers for the installation of all airfield light fixtures. Tighten bolts to washer manufacturers recommended torque based on bolt type used. Use only adjustable torque limiting tools.

Where stainless steel bolts are used for elevated fixture installation use an anti-seize lubricating compound.

Where ceramic-metallic/fluorocarbon polymer coated bolts are used for in-pavement fixture installation do not use anti-seize lubricating compounds.

3.1.4 Light Base Installation

3.1.4.1 Installation in Cored Pavement

Wipe down the sides and bottom of each light base immediately prior to installation. For bored hole installations cover the inside faces of bored hole and bottom and sides of light base with a coating of compatible P-606 sealant that will completely fill the void between concrete and base. Use a jig or holding device when installing each light fixture to ensure positioning to the proper elevation, alignment, level control, and azimuth control. Orient the light fixture with the light beams parallel to the runway or taxiway centerline and facing in the required direction.

Outermost edge of fixture must be level with the surrounding pavement.

Remove surplus sealant or flexible embedding material. The holding device must remain in place until sealant has reached its initial set. Properly arrange fixture lead wires with respect to their connecting position.

Block the wireway entrance into the light recess to retain the sealant material during curing.

3.1.4.2 Installation in Concrete Bed

Where light base can is partially embedded in concrete with jig or holding devices, leave device in place for minimum 24 hours. Let base can set for an additional 48 hours before remaining concrete is placed to the top of the light base.

3.1.5 Frangible Requirements

Install frangible supports, couplings, and adapters as indicated or specified. At the 300 m cross bar and beyond, mount approach lights up to

1.83 m above concrete foundation on threaded frangible couplings and 53 mm electrical metallic tubing (EMT). For mounting heights greater than 1.8 m, mount approach lights on low-impact resistant frangible towers as indicated. The elevation of approach lights must be as indicated on drawings.

3.1.6 Elevated Light Fixtures

Elevated lights must be frangibly mounted, not to exceed 350 mm in height except where higher mounting is permitted in snow accumulation areas. For equipment exceeding 350 mm in height, frangibly mount as indicated. Use a

SECTION 26 56 20 Page 15 AM0001

4-jack positioning jig to install the light base to ensure correct orientation and leveling. The individual setting the jig must fully understand reference marks that are provided by the surveyor. Check azimuth by survey before the concrete anchor is placed and again before paving. A factory representative of the light base manufacture must be on-site.

3.1.6.1 Elevated Light Level

Level elevated light fixture using manufacturers system required for fixture type.

3.1.7 In-Pavement Airfield and Heliport Lights

Remove water, debris, and other foreign substances prior to installing in-pavement light base and light. Use a 4-jack positioning jig, obtained from the L-868 base manufacturer, to install the light base to ensure correct orientation and leveling. The individual setting the jig must fully understand reference marks that are provided by the surveyor. Check azimuth by survey before the concrete anchor is placed and again before paving. Do not place the near light base edge closer than two feet from a planned pavement joint. If conflict occurs, immediately notify the Contracting Officer Representative of the conflict.

3.1.7.1 In-Pavement Light Installation

For in-pavement installations, pavement around the light base must be level with the surrounding pavement; dished or mounded pavement near the light base is not acceptable.

3.1.7.2 Snow Plow Ring Installation

For in-pavement fixtures that require snow plow rings, coordinate the light base can, light fixture and snow plow ring to meet the installation tolerances shown in the paragraph Light Fixture Installation Tolerances.

The Contractor may need to provide spacer rings to meet these tolerances.

The top edge of the snow plow ring must be slightly higher than the top of the light fixture. Install the silicone rubber O-ring to seal the light base can. Install the ceramic fluoropolymer coated bolts to attach the light fixture and snow plow ring to the light base can.

3.1.8 Light Fixture Installation Tolerances

IN-PAVEMENT ELEVATED

ELEVATION

(relative to finished pavement surface)

+0 mm, -1.59 mm (fixture edge on low side in snow areas or on high side in non-snow areas)

+6.35 mm, -0 mm

AZMUTH (*)

(w/respect to line parallel to RW/TW centerline)

+/- 1/2 degree +/- 1/2 degree

SECTION 26 56 20 Page 16 AM0001

IN-PAVEMENT ELEVATED

LEVEL +/- 1/2 degree +/- 1/2 degree

STATIONING

(in line parallel to RW/TW centerline)

50.8 mm +/- 50.8 mm

OFFSET

(perpendicular to RW/TW centerline)

6.35 mm +/- 6.35 mm

(*)For omni-directional fixtures the Azimuth does not apply.

3.1.9 Isolation Transformers

Conform to FAA AC 150/5345-26 for transformer lead connections. Plug transformer secondary connectors directly into a mating connector on the transformer secondary leads. During installation, cover mating surfaces of connectors until connected and clean when plugged together. At joint where connectors come together, install heat shrinkable tubing with waterproof sealant or with two half-lapped layers of tape over the entire joint. Joint must prevent entrapment of air which might subsequently loosen the joint.

3.2 CABLES

3.2.1 Cable Installation

In addition to the requirements of Section 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION, use kit type connectors to splice 5 kV single-conductor series lighting cables. During installation, keep mating surfaces of connectors covered until connected and clean when plugged together. At joint where connectors come together, install heat shrinkable tubing with waterproof sealant. Joint must prevent entrapment of air which might subsequently loosen the joint.

3.2.2 Low Voltage Cables

For splices in wires 10 square mm single conductor cable, use FAA AC 150/5345-26 Type L-823 connectors. Splices below grade or in wet locations must be sealed type conforming to NEMA C119.1 or must be waterproofed by a sealant-filled, thick wall, heat shrinkable, thermosetting tubing or by pouring a thermosetting resin into a mold that surrounds the joined conductors.

Cable must be rated 600 volts, except that secondaries of isolation transformer to in-pavement lights installed in pavement saw kerf and 48 volt DC control cables may be 300 volts. Other parts of cable systems such as splices and terminations must be rated at not less than 600 volts. Splices in wires 16 square mm and smaller must be made with an insulated, solderless, pressure type connector, conforming to the applicable requirements of UL 486A-486B . Splices in wires 10 square mm single conductor cable must be made with FAA AC 150/5345-26 Type L-823 connectors. Splices below grade or in wet locations must be sealed type conforming to NEMA C119.1 or must be waterproofed by a sealant-filled, thick wall, heat shrinkable, thermosetting tubing or by pouring a

SECTION 26 56 20 Page 17 AM0001 thermosetting resin into a mold that surrounds the joined conductors.

3.2.3 Airfield 5kV Series Lighting Cables

3.2.3.1 Connectors

Use kit type connectors to splice 5 kV single-conductor series lighting cables. During installation and prior to covering with earth, cover mating surfaces of connectors until connected and clean when plugged together. At joint where connectors come together, install heat shrinkable tubing with waterproof sealant with two half-lapped layers of tape over the entire joint. Joint must prevent entrapment of air which might subsequently loosen the joint.

3.2.3.2 Crimping Tool

Use only splice kit manufacturer's crimping tool on splice connectors for all primary and secondary airfield cable splices. Crimping tool must have an embossed die with gauge marks for gauge of cable being used.

3.2.3.3 Cable Penciler

Airfield cable insulation must only be removed using cabling penciler made specifically for airfield cable.

3.2.4 Cable Markers

Provide cable markers or tags for each cable at duct entrances entering or leaving manholes or handholes and at each termination within the lighting vault. Provide not less than two tags per cable in in each manhole or handhole, one near each duct entrance hole. Immediately after cable installation, permanently attached tags to cables and wires so that they cannot be accidentally detached.

3.2.5 Maximum Allowable Non-Armored Cable Pulling Tension, Using Dynamometer

Cable Tension Kg

2 - 1/C #8 solid 125

3 - 1/C #8 solid 167

4 - 1/C #8 solid 250

2 - 1/C #6 stranded 191

3 - 1/C #6 stranded 286

4 - 1/C #6 stranded 382

1 - 2/C #8 stranded 139

1 - 3/C #8 stranded 180

1 - 4/C #8 stranded 266

1 - 2/C #6 stranded 207

1 - 3/C #6 stranded 311

1 - 4/C #6 stranded 400

SECTION 26 56 20 Page 18 AM0001

Cable Tension Kg

1 - 6/C #12 stranded 143

1 - 12/C #12 stranded 286

1 - 12 pair #19 solid 105

1 - 25 pair #19 solid 246

1 - 50 pair #19 solid 482

1 - 100 pair #19 solid

3.3 COUNTERPOISE

Install counterpoise above multiple conduits/duct banks for airfield lighting cables, with the intent being to provide a complete cone of protection over the airfield lighting cables. When multiple conduits and/or duct banks for airfield cable are installed in the same trench, the number and location of counterpoise conductors above the conduits must be adequate to provide a cone of protection measured 22 1/2 degrees each side of vertical. Install one continuous length of conductor, except where distance exceeds the length usually supplied. Install the counterpoise approximately 150 mm above single duct lines that are not adjacent to pavement. Where trenches or duct lines intersect, electrically interconnect the counterpoise wires. Connect the counterpoise conductor to a ground rod at every 600 m of cable run, at lighting vault(s) (but not to vault equipment), and at feeder connection to light circuit(s).

Install the counterpoise conductor in a separate duct under roads, railroads and paved areas, above the highest duct containing electrical or communications circuits.

For in-pavement light fixtures, connect the counterpoise to the exterior one-hole ground lug on fixture bases installed in pavement subject to routine aircraft traffic (runway touchdown zone lights, runway centerline lights, runway guard lights and taxiway centerline lights). Where fixture bases are installed in pavement not subject to routine aircraft traffic (runway and taxiway edge lights) do not connect the counterpoise to fixture bases. In such cases, install the counterpoise at a location half way between the fixture line and the defined runway or taxiway edge. Use exothermic welding for all counterpoise connections. Provide counterpoise ground rods at maximum 600 m spacing.

3.4 SAFETY (EQUIPMENT) GROUNDING SYSTEM

The purpose of the safety ground is to protect personnel from possible contact with an energized light base that may result from a shorted power cable or isolation transformer. Install and connect a 16 square mm conductor by one of the following methods from base to a ground rod

a. Connect each fixture base to a dedicated ground rod located outside the base on the side opposite the counterpoise.

b. Bond a group of adjacent fixture bases to a common safety ground conductor.

Connect the safety ground conductor to ground rods by exothermic welding and bolted connections. A safety ground is not required for in-pavement fixture bases where a counterpoise is connected to the exterior ground lug. In all cases connect the light fixture, whether in-pavement or elevated, to the base interior ground lug by means of a braided ground

SECTION 26 56 20 Page 19 AM0001 strap specified in paragraph "Light Bases".

3.5 DUCT LINES

Duct lines as required in Section 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION and as indicated. Ducts must be installed in trench for 24 hours before trench is backfilled to allow ducts to reach final ground temperature.

3.6 HANDHOLES

The handholes as required in Section 33 71 02 UNDERGROUND ELECTRICAL

DISTRIBUTION.

3.6.1 Handholes Within Paved Areas

Handholes within paved areas must have their top surface flush with grade, -0 to +6.35 mm.

3.6.2 Handholes Within Unpaved Areas

Handholes within unpaved areas must have their top surface +/-25.4 to +50.8 mm above grade.

3.7 CONSTANT CURRENT REGULATORS

Install as indicated in strict accordance with manufacturer's instructions.

3.8 CIRCUIT SELECTOR SWITCHES

Install as indicated and in strict accordance with manufacturer's instructions.

3.9 APPLICATION

3.9.1 Exothermic Welding

Utilize only personnel who are experienced in and regularly engaged in this type of work to make these connections. Prior to any installations in the field, provide documentation that the welding kits, materials and procedures to be used for welded connections are satisfactory. Comply with the manufacturer's recommendations and the following:

a. Remove all slag from welds.

b. The light fixture base cans should be provided with internal and external one-hole ground lugs that are coated with hot dipped galvanizing, the same as the rest of the base cans. The external ground lug should be bolted to a separate ground lug that is exothermically welded to a 21 square mm stranded bare copper grounding cable. That is connected to a ground rod for Air Force or Army projects or the counterpoise for Navy projects.

c. All direct buried welds must be thoroughly coated 6 mil of 3M "Scotchkote", or approved equivalent, or coated with coal tar bitumastic material to prevent surface exposure to corrosive soil or moisture.

SECTION 26 56 20 Page 20 AM0001

3.9.2 Field Fabricated Nameplate Mounting

Provide number, location, and letter designation of nameplates as indicated. Fasten nameplates to the device with a minimum of two sheet-metal screws or two rivets.

3.9.3 Equipment for Silicone Sealant

Equipment for silicone sealant must be air-powered pump, components, and hoses as recommended by the sealant manufacturer. Hoses and seals must be lined to prevent moisture penetration and withstand pumping pressures.

Equipment must be free of contamination from previously used other type sealant.

3.9.4 Concrete

Concrete used in underground structures, such as manholes, handholes, pull boxes and foundations must have minimum 28-day strength of 27.56 MPa.

Similar structures in areas where freeze/thaw conditions are common, must have minimum 28-day strength of 31.00 MPa. Concrete used for non-structural items, such as equipment pads, must have minimum 28-day strength of 13.78 MPa.

3.9.5 Grounding

Ground non-current carrying metallic parts associated with electrical equipment as specified in Section 33 71 02 UNDERGROUND ELECTRICAL

DISTRIBUTION.

3.10 FIELD QUALITY CONTROL

Notify the Contracting Officer five working days prior to each test.

Correct all deficiencies and repeat tests. Field test reports must be written, signed and provided as each circuit or installation item is completed. Include resistance-to-ground and resistance between conductors field tests, and continuity measurements for each circuit. For each series circuit measure the input voltage and output current of the constant current regulator at each intensity. For multiple circuits measure the input and output voltage of the transformer for each intensity setting. Provide report documenting the visual inspection of the lights operation, installed fixtures or units.

3.10.1 Visual Inspection

Inspection reports must be prepared and provided as each stage of installation is completed. Identify the activity by contract number, location, quantity of material placed, and compliance with requirements.

3.10.2 Operating Test

Upon completion of tests, show by demonstration in service that circuits, control equipment, and lights covered by the contract are in good operating condition. Operate each switch in the control tower lighting panels so that each switch position is engaged at least twice. During this process, observe lights and associated equipment to determine that each switch controls properly corresponding circuit. Provide telephone or radio communication between the operator and the observers. Repeat tests from the alternate control station, from the remote control points, and again from the local control switches on the regulators. Test each

SECTION 26 56 20 Page 21 AM0001 lighting circuit by operating the lamps at maximum brightness for not less than 30 minutes. Visually examine at the beginning and at the end of this test to ensure that the correct number of lights are burning at full brightness. Conduct one day and one night operating test for the Contracting Officer.

Provide performance test reports, upon completion and testing of the installed system, in booklet form showing all field tests performed to adjust each component and all field tests performed to provide compliance with the specified performance criteria. For each test, indicate the final position of controls.

3.10.3 Distribution Conductors, 600-Volt Class

Using an instrument which applies a voltage of approximately 500 volts providing a direct reading in resistance, performing testing to verify that no short circuits or accidental grounds exist.

3.10.4 Counterpoise System Test and Inspection

At accessible locations, visually inspect counterpoise system to ensure continuity of counterpoise system. Test continuity of counterpoise system to the vault grounding system in manhole closest to the vault.

3.10.5 Progress Testing for Series Lighting Circuits

Conduct a megger test on each section of circuit or progressive combinations of sections as they are installed. Test each section or progressive combination of sections with a megohmmeter providing a voltage of approximately 1000 volts, a direct reading in resistance. Document all results. Eliminate faults found by these tests, and re-test before proceeding with the circuit installation.

3.10.6 Electrical Acceptance Tests

Perform acceptance tests for series and multiple airfield and heliport lighting circuits only on complete lighting circuits. Each series and multiple lighting circuit must receive a high voltage insulation test.

Check that cable insulation resistance to ground is not less than 50 megohms per FAA-C-1391, Installation and Splicing of Underground Cable.

3.10.7 Low-Voltage Continuity Tests

Test each series circuit for electrical continuity. Eliminate faults indicated by this test and perform retest before proceeding with the high-voltage insulation resistance test.

3.10.8 High-Voltage Insulation Resistance Tests

Subject each series lighting circuit to a high-voltage insulation resistance test by measurement of the insulation leakage current with a suitable high-voltage test instrument which has a steady, filtered direct current output voltage and limited current. High-voltage tester must include an accurate voltmeter and microammeter for reading voltage applied to the circuit and resultant insulation leakage current. Do not exceed voltage test values specified below.

a. Test Procedure: Disconnect both leads from regulator output terminals and support so that air gaps of at least 75 mm or as defined by

SECTION 26 56 20 Page 22 AM0001

FAA AC 150/5345-7 Table 1 exists between bare conductors and ground.

Clean and dry cable sheaths for a distance of 25 m from ends of cables and exposed insulation at ends of cables. Connect ends of both conductors of the circuit together and to high-voltage terminals of test equipment, and test voltage applied as specified in the following tabulation between conductors and ground for a period of 5 minutes.

Test Voltage, DC

First Test on New Circuits

Test on Existing Circuits

High Intensity Series Lighting Circuits (5,000 volt leads, 500 and 200 watt transformers)

9000 5000

Medium Intensity Series Lighting Circuits (5,000 volt leads, 30/45 watt transformers)

6000 3000

600-Volt Circuits 900 600

When additions are made to existing circuits, test only new sections in accordance with "First Test on New Circuits" in table above. To ensure reliable operation, test complete circuit at reduced voltages indicated above.

b. Leakage Current: Measure and record insulation leakage current for each circuit after a 1 minute application of the test voltage. If leakage current exceeds values specified below, sectionalize the circuit and retest, and repair or replace defective parts. Leakage current limits include allowances for the normal number of connectors and splices for each circuit as follows:

1. Three microamperes for each 300 m of cable.

2. Two microamperes for each isolation transformer.

3. If measured value of insulation leakage current exceeds calculated value, sectionalize the circuit and test as specified for each section. Repair or replace defective components until repeated tests indicate an acceptable value of leakage current for the entire circuit.

c. Resistance Values versus Cable Length

An alternate test procedure for circuit validation is to use a megohmeter. Use 5000V test for new circuits and 3000V test for existing circuits. If the minimum resistance values are not achieved then use the leakage current test indicated above.

SECTION 26 56 20 Page 23 AM0001

Circuit Length in Feet Meters Minimum Resistance to Ground (Megohms)

<3,000 50

3,000-6,000 40

6,000 30

3.11 FINISHING

Painting required for surfaces not otherwise specified and finish painting of items only primed at the factory must be as required in Section 09 90 00

PAINTS AND COATINGS.

3.12 CLOSEOUT ACTIVITIES

3.12.1 Demonstration

After completion of installations and the above tests, circuits, control equipment, and lights covered by the contract must be demonstrated to be in acceptable operating condition. Each switch in the control tower lighting panels must be operated so that each switch position is engaged at least twice. During this process, lights and associated equipment must be observed to determine that each switch properly controls the corresponding circuit. Telephone or radio communication must be provided between the operator and the observer.