2014 - State Library of Oregon: State Employeeslibrary.state.or.us/repository/2014/201403281308355/index.pdfii ODOT Inspector’s Manual for Signal Construction January 2014 ... January

2014

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ii ODOTInspector’sManualforSignalConstruction January 2014

Oregon Department of Transportation

HIGHWAY DIVISION Traffic - Roadway Section

Salem, Oregon

REVISED January 2014

Oregon Department of TransportationHIGHWAY DIVISION

Traffic - Roadway SectionSalem, Oregon

REVISEDJanuary 2014

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ODOTInspector’sManualforSignalConstruction iiiJanuary 2014

Table of Contents

General .......................................................................................................1

ConTaCTs .....................................................................................................2

CoordinaTion wiTh oThers ....................................................................4

CoordinationwithRegionTraffic&OtherAgencies ........................................4CoordinationwithAgencyElectricalCrew&Permits ......................................4Workthatrequiresanelectricallicense ..........................................................5SupplementalInspection .................................................................................7

MaTerials ....................................................................................................8

Blue,GreenandRedSheets ............................................................................8Pre-qualifiedmaterials ....................................................................................8PoleSubmittals ................................................................................................8Verifying Stainless Steel ...................................................................................8RedSheetMaterials .........................................................................................9BlueSheetMaterials ......................................................................................11

Catalogue Cut Sheets ................................................................................11Blue Sheet Example ...................................................................................13Bond Wire .................................................................................................16Bonded Bushings .......................................................................................17Cable Ties ..................................................................................................18Conduit (Metallic) .....................................................................................19Conduit (Non-Metallic)..............................................................................20Conduit Bushings ......................................................................................21Conduit Hub and Conduit Body .................................................................22Conduit Plug ..............................................................................................23Expansion Fitting .......................................................................................24Ground Rod & Clamp ................................................................................25Junction Boxes (Cast Iron) .........................................................................26Junction Boxes (Concrete) .........................................................................27Junction Boxes (Hybrid) .............................................................................28Junction Boxes (Hand Hole) .......................................................................29Terminal Blocks .........................................................................................30THWN & XHHW Wire ................................................................................31Underground Warning Tape .....................................................................32Aluminum Sign Mounting Framework ......................................................33Backplates .................................................................................................34Control Cable ............................................................................................35

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iv ODOTInspector’sManualforSignalConstruction January 2014

Eyebolt, Turnbuckle, Strandvise ................................................................36Interconnect Cable ....................................................................................37LED Modules (Vehicle & Ped) ....................................................................38Loop Feeder Cable .....................................................................................39Loop Splice ................................................................................................40Loop Wire (XHHW/DUCT) .........................................................................41Messenger Cable .......................................................................................42Meter Base ................................................................................................43Pedestal (Pedestrian Signal) ......................................................................44Pedestal (Vehicle Signal) ...........................................................................45Pedestrian Signal ......................................................................................46Pedestrian Signal Mount ...........................................................................47Preformed Loops .......................................................................................48PTR Signs ...................................................................................................49Push Button ...............................................................................................50Riser Frames ..............................................................................................51Service Cabinet ..........................................................................................52Signal Head Covers ...................................................................................53Spanwire Hanger ......................................................................................54Terminal Cabinet .......................................................................................55Tether & Stabilizer Cable ...........................................................................56Tether Clamp .............................................................................................57Tri-Stud Adaptors ......................................................................................58Vehicle Signal Bracket (Adj.) ......................................................................59Vehicle Signal Visor ...................................................................................60Vehicle Signals...........................................................................................61In-line Fuse Holder ....................................................................................62Photoelectric Cell ......................................................................................63TC Cable ....................................................................................................64

GreenSheetMaterials ...................................................................................65Catalogue Cut Sheets ................................................................................65Green Sheet Example ................................................................................66Controller Cabinet .....................................................................................68Controller ..................................................................................................69Conflict Monitor ........................................................................................70Load Switch ...............................................................................................71Flasher ......................................................................................................72Detector Amplifier .....................................................................................73Isolator (DC and AC) ..................................................................................74Modem ......................................................................................................75Relay (FTR) ................................................................................................76

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ODOTInspector’sManualforSignalConstruction vJanuary 2014

Communications Bracket ..........................................................................77Preemption Interface (Cabinet) .................................................................78Preemption Detector (Field) ......................................................................79GPS Time Sync Module ..............................................................................80Video & Radar Detection ..........................................................................81Audible Pedestrian Signal .........................................................................82Battery Back-up System ............................................................................83Beacon ......................................................................................................84Fiber Optic Connection Patch Panel ..........................................................85

ConsTruCTion ..........................................................................................87

General ..........................................................................................................87ChangestothePlansandSpecifications........................................................87ElectricalService(PowerSource) ..................................................................88TelephoneHook-Up .......................................................................................89SignalHeadAlignmentandPoleLocation .....................................................90PoleLocation .................................................................................................92JunctionBox(JB)Locations ............................................................................94PoleandPedestalFoundations ......................................................................96TrenchingforConduit ....................................................................................98ConduitInstallation .....................................................................................100ConcreteorPolymerConcreteJBsInstallation ............................................102CastIronJunctionBoxInstallation ...............................................................104ConduitTrenchBackfill ................................................................................106Bonding and Grounding ...............................................................................108PullingWiresandCables .............................................................................110WoodPoleInstallation .................................................................................112StrainPoleInstallation .................................................................................114MastArmPoleInstallation ..........................................................................116TerminalCabinetInstallation .......................................................................118MessengerCableInstallation.......................................................................120TetherandStabilizerCableInstallation .......................................................122WiringPoles .................................................................................................124SpanwireHangerInstallation .......................................................................126AdjustableBracketInstallation ....................................................................128PedestrianSignalMountInstallation ...........................................................130PedestrianSignals&Push-ButtonInstallation .............................................132VehicleSignalInstallation ............................................................................134ProgrammedSignalHead&LouverInstallation ..........................................136SawcuttingDetectorLoops ..........................................................................138DetectorLoopWireInstallation ...................................................................140

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vi ODOTInspector’sManualforSignalConstruction January 2014

LoopWireEntranceInstallation ..................................................................142SealingDetectorLoops ................................................................................144PreformedDetectorLoopInstallation .........................................................146LoopWireSpliceInstallation .......................................................................148FirePreemptionSystemInstallation ............................................................150LuminaireInstallation ..................................................................................152ServiceCabinetInstallation .........................................................................154Model332ControllerCabinetInstallation ..................................................156Model336sControllerCabinetInstallation .................................................158FieldInspection&SignalTurn-On ...............................................................160FinalClean-Up&FinalInspection ................................................................161AsConstructedDrawings .............................................................................161RequestingChangestoStandardDrawingsandSpecifications ...................162

readinG Plan sheeTs ............................................................................ 163

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ODOTInspector’sManualforSignalConstruction 1January 2014

GeneralTheobjectiveofthismanualistoprovideProjectManagersandInspectorswithgeneralinformationtoassistinthesuccessfulinstallationandcompletionoftrafficsignalsandotherhighwayelectricalprojectsonthestatehighwaysystemincompliancewiththecontractdocuments.ThismanualassumesthatPreliminaryEngineeringandDesignEngineeringhavebeendonecorrectly.

ThematerialcontainedhereinisforinformationalpurposesonlyanddoesNOTreplace,modifyorsupersedeanycontractdocument.Assuch,thismaterialmayormaynotapplytoanyparticularsignaldesignorinstallationdependingupontheindividualfactorspresentateachlocation.

Incaseofconflictbetweenthismanualandanyofthecontractdocuments,theprioritystatedinsubsection00150.10oftheSpecificationsisused:

00150.10(a)OrderofPrecedence-TheEngineerwillresolveanydiscrepanciesbetweenthesedocumentsinthefollowingorderofprecedence:

o ContractChangeOrders;o SpecialProvisions;o Agency-prepareddrawingsspecificallyapplicabletotheProjectandbearing

theProjecttitle;o Reviewedandaccepted,stampedWorkingDrawings;o StandardDrawings;o ApprovedUnstampedWorkingDrawings;o SupplementalSpecifications;o StandardSpecifications;ando Allothercontractdocumentsnotlistedabove

Foradditionaltrafficsignalinformationandtofindthemostcurrentversionofthismanual(updatedeachyearinJanuary)visittheTrafficSignalStandardswebsite:

http://www.oregon.gov/ODOT/HWY/TS/pages/signals.aspx

SignalOperationalApprovals MicrostationCabinetPrintsFlashingYellowArrows Std.Dwgs.andDetailsDesignReviewandApproval OARRuleMakingProcessDesign Manuals Product Approval & EvaluationTechnicalAdvisors&Bulletins (Blue, Green, & red sheets)DraftingTools Drawings&Database

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2 ODOTInspector’sManualforSignalConstruction January 2014

Contacts

ODOT Traffic Standards Unit (Statewide)discipline name Phone

All doug Bish, P.e.TrafficStandardsManager 503-986-3594

TrafficSignals

Scott Cramer, P.E.TrafficSignalEngineer 503-986-3596Joe searcy, electricianTrafficSignalStandardsSpecialist 503-986-3577VacantIllum.&TrafficSignalControlSystemSpecialist 503-986-3251Katie Johnson, P.E.TrafficSignalQCEngineer 503-986-3595Martin Klug, P.E.TrafficDesignEngineer 503-986-3586

TrafficStructures

Scott Jollo, P.E.TrafficStructuresEngineer 503-986-3069will woods, P.e.TrafficStructuresSpecialist 503-986-3238

Illumination ernest Kim, P.e.IlluminationEngineer 503-986-3587

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ODOT Traffic Signal Timing & Electrical Contacts

region discipline name Phone

StatewideElectrical(TSSU) LauraWilson–LeadSignalTech 503-378-2956

Timing CraigBlack,P.E. 503-986-3576

1

ElectricalJohnSapp-Manager 503-969-1035

TimDamm 971-673-6201

Timing

DougAnderson–Signals,West 503-731-8213

TiffanySlauter,P.E.–Signals,East 503-731-3014

PhuongNguyen–RampMeters 503-731-3004

2Electrical

RichHinkle-Manager 503-986-2705

FredTrummel 503-986-2706

TimingJulieInfante,P.E. 503-986-2826

JamieSchmidt 503-986-5819

3Electrical

TerriMoxley–Manager 541-474-3149

TerryBrock–North 541-957-3667

BretLeslie–Coastal 541-269-5217

CurtDuncan–South 541-621-2329

TimingRayLapke,P.E.-North 541-957-3536

DanDorrell,P.E.-South 541-774-6354

4Electrical BradStevens 541-388-6221

Timing DavidHirsch,P.E. 541-388-6472

5Electrical

JohnTaylor-North 541-276-4675

JoeGastanaga–South 541-889-4243

Timing DonFine 541-963-1594

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Coordination with Others

Coordination with Region Traffic & Other AgenciesODOTRegionTrafficisresponsiblefortheoperationofthetrafficsignalunlessthereisanintergovernmentalagreement(IGA)withalocalagencytoprovidethemaintenanceandsignaltiming.Verifywhois(orwillbe)responsibleformaintenanceandsignaltimingwiththeappropriateRegionTrafficSignalTimingcontact.

Theresponsiblepartyshouldbecontactedinadvanceofanyworkthatwillimpacttheproperfunctioningofthetrafficsignal.Temporarysignaltimingisoftennecessarytomaintainacceptabletrafficconditionsforthefollowingtypeofwork:

• Removalofexistingloopdetection

• Temporarylaneusechangesatsignal

• Temporarylanereductionsnearsignal

ODOTRegionTraffic(orthelocalagencyprovidingmaintenance/signaltiming)shouldbeinvolvedin:

• thepre-constructionmeeting

• issuesthatariseduringconstruction

• thesignalturn-on

• finalinspection

Theagencyshouldalsobetold(inwriting)atwhattimetheirresponsibilitywillbegin.ThisresponsibilityisdetailedinSection00990.70(h)oftheSpecifications.

Coordination with Agency Electrical Crew & PermitsItiscriticalthattheProjectManager/Inspectorcoordinatessupplementalinspectionwithagencyelectriciansandelectricalpermittingagencies(see00170.02).AccordingtoOregonLawitisrequiredthatspecificpartsandpiecesoftheinstallationbeONLYinstalledbyalicensedelectrician.Agencyelectriciansandelectricalpermittingagenciesmustalsoverifytheseinstallationsbeforetheprojectproceedsoriscompleted.Paycloseattentiontotheelectricalpermittingagenciesrequirementsandtimelinesdescribedintherequiredpermits.Failuretocomplywithpermitswilladdsignificanttimeandcosttotheproject.

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Work that requires an electrical license Theselistsweredevelopedin1999bytheOregonBuildingCodesDivisionasperOregonAdministrativeRule(OAR)918-282-0120(1)duetoarequestforclarificationoftrafficsignalworkthatrequiresanelectricallicense.FailuretofollowtheselistsisaviolationofOregonLawandshouldbereported.

a license is required to:1. Installgroundrodsandgrounding/bonding2. Installconduitinafooting3. Installluminairesonthepole4. Installpedestrianpushbuttons5. Installpedestriansignalheads6. Installvehiclesignalheads7. Installinteriorilluminatedsignsonpole8. AssembleandlayALLconduitinafoundationorditch9. Assembleandhandleconduitforboringoperations10. Install pull line in conduits11. PullwireandcableinALLraceways(conduits,poles,arms)12. InstallALLwireandmakingconnections13. Spliceandsolderloopwirestoloopfeedercables14. InstallALLcabinets(terminal,meterbase,etc.)

a license is noT required to:1. Digaholeforafootingintheground2. Tierebarcagesforthefootings3. Installanchorrodsinafooting4. Formthepolebase5. Unloadthepolesfromatrailer6. Unloadthearmsfromthetrailer7. Unloadlightfixturesfromtrailer8. Installarmsonthepoles9. Installpolesontotheirbases10. Uncratepedestriansignalheads11. Uncratevehiclesignalheads12. Assemblepedheadsintoanassembly,ontheground13. Assemblevehicleheadsintoanassembly,ontheground14. Digaditchforconduit15. Layconduitalongsidetheditch16. Installpolywarningtapeinditchaboveconduit17. Backfilladitchafterconduitisassembled18. Installgravelunderjunctionboxes19. Installconcretejunctionboxes20. Installvehicledetectorloops(saw,clean,placewire,seal)

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Aspersection00960.30,everypersonengagedintheinstallationofelectricalequipmentandwiringsystemsshallpossessavalidOregonelectricallicenseorregistration:

o GeneralSupervisingLicense

o GeneralJourneyman’sLicense

o ElectricalApprenticeRegistration(mustbeworkingunderthedirectsupervisionofanindividualwithanelectricallicense)

AcopyoftheelectricallicenseorapprenticeregistrationtotheEngineerisrequiredbeforeperforminganywork(obtainatthepre-constructionconference).Inaddition,OAR918-030-0920requiresanindividual’slicensetobevisiblewhenonthejobsite,unlessitwouldcreateasafetyissue.Ifalicenseorregistrationisnotvisible,itshouldalwaysbeimmediatelyavailableuponrequest.

ODOT Inspector’s Manual for Signal Construction January 2014

6

As per section 00960.30, every person engaged in the installation of electrical equipment and wiring systems shall possess a valid Oregon electrical license or registration:

o General Supervising License

o General Journeyman’s License

o Electrical Apprentice Registration (must be working under the direct supervision of an individual with an electrical license)

A copy of the electrical license or apprentice registration to the Engineer is required before performing any work (obtain at the pre‐construction conference). In addition, OAR 918‐030‐0920 requires an individual’s license to be visible when on the jobsite, unless it would create a safety issue. If a license or registration is not visible, it should always be immediately available upon request.

License Example:

Apprentice Registration Example (must be accompanied by photo ID):

The following Building Codes Division website has a license holder search tool: http://www.cbs.state.or.us/bcd/licensing.html

Check the Expire Date!

Home Address of license holder located here

Home Address of Registration holder located here

ThefollowingBuildingCodesDivisionwebsitehasalicenseholdersearchtool: http://www.cbs.state.or.us/bcd/licensing.html

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Supplemental Inspection

Thisschedulebelowsummarizestheminimumamountofassistedinspectionsrecommendedforeachcontract.

Type of Inspection

when to request inspection Contact

required advance Notice

1

Pole&controller

layout inspection

Aftercurb(orEP)radiiare laid out and pole and controllerlocationsare

staked

RegionTraffic 3 days

2

Conduit &backfillinspection00960.42(e)

During conduit installation,butbefore

backfill

RegionElectricians 3 days

3In-groundelectrical inspection

Afterformsandconduitsareinplace,butbeforefoundationsarepoured

RegionElectricians 3 to 5 days

4Looplayoutinspection

00990.43(b)(3)

Aftercrosswalksandloopsarelaidout,butbeforecuttingbegins

RegionTraffic 3 days

5

Loopinstallationinspection

00990.43(b)(3)

Atthebeginningofloopinstallations

RegionElectricians 3 to 5 days

6Field

inspection00990.70(g)

Atanticipatedsignalcompletiondate

RegionElectricians

1 to 2 weeks

7Pre-signalturn-on

inspection

Atanticipatedsignalcompletiondate RegionTraffic 1 to 2

weeks

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Materials

Blue, Green and Red SheetsThe“Blue”Sheetsaredescribedindetail,startingonpage11.

The“Green”sheetsaredescribedindetail,startingonpage65.

The“Red”sheetsaredescribedindetail,startingonpage9.

Pre-qualified materialsCurrently,onlytwoitemsusedfortrafficsignalinstallationsarespecifiedfromthestandardQualifiedProductsList(QPL):backerrodmaterialandhot-meltloopsealant.See 00990.10.

Pole SubmittalsPoleshopdrawingsmustbestampedbyanOregonRegisteredProfessionalEngineer.Pre-qualifiedpoleshopdrawingsmustbeara“reviewed”stampfromtheODOTTrafficStructuresEngineerpriortouseontheproject.

Verifying Stainless Steel

Themajorityoffastenersandhardwareusedfortrafficsignalinstallationarerequiredtobestainlesssteel(Type304or316).Aquickandeasywaytoverifyamaterialisstainlesssteelistouseamagnet.StainlesssteelisNOTmagnetic.

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Red Sheet MaterialsPursuanttoors 479.540 and oar 918-261-0037thefollowing“qualifiedproductslist”nowknownasthe“REDSHEETS”wascreated.Thislistis noT used for constructionqualificationorapprovalofproductsduringconstruction,butasastatewidelistofcertificationexempttrafficmanagementsystemscomponentsusedbyODOTandotherapplicablepublicagencies.TheexemptionfromcertificationremovestheULorNRTLcertificationrequirementsofREDSHEETlisteditemsusedintrafficmanagementsystems.ThecurrentversionoftheREDSHEETScanbefoundhttp://egov.oregon.gov/ODOT/HWY/TRAFFIC/Signals.shtml

TheredsheetsshouldbegiventotheStateBuildingCode,CityorCountyElectricalInspectorontheprojectifthereareissuesaboutalackofULorNRTLcertificationfortrafficsignalequipment.

red sheet list – revised 2/27/13Any item that is listed in the ODOT maintained prequalified products list known as the BLUE SHEETS.

Any item that is listed in the ODOT maintained prequalified products list known as the GREEN SHEETS.

ConTroller CaBineTBrand / ManuFaCTurer Model ParT# Code*Safetran 337 COPMcCain 337 M30730 COPPreeMPTion inTerFaCe (Cabinet)Brand / ManuFaCTurer Model Code*3MOpticom 754 COPConduiT rePairBrand / ManuFaCTurer Model Code*Carlon Split Duct ODOTBridGe suBMarine CaBleBrand / ManuFaCTurer Model Code*Draka StandardBridgeSubmarineCable ODOTMoVaBle BridGe VerTiCal warninG GaTesBrand / ManuFaCTurer Model Code*B&BRoadway VW-4 ODOT

* agency Code: ODOT=OregonDepartmentofTransportationCOP=CityofPortland

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Blue Sheet MaterialsThe“SubmittalsforFieldQualificationEquipmentandMaterials–ElectricalEquipmentandMaterials”(commonlyreferredtoasthe“BlueSheets”)containalistofmaterialsandequipmentthatarenormallyqualifiedbytheInspector.Brandnamesandmodelnumbersarelistedformosttypesofequipment.Thecontractormustsubmittwocopies,appropriatelymarked,tosatisfytherequirementsofStandardSpecificationsSection00960.02.

ThislistisupdatedfrequentlybytheTrafficSignalStandardsUnitandisavailableat:http://www.oregon.gov/ODOT/HWY/TS/pages/signals.aspx.ContacttheTrafficSignalEngineerforthecurrentlistifyoucan’tdownloadthemfromthatsite.

Materialsarrivingattheprojectsiteshouldbeaccompaniedbypropercertifications.NomaterialsshallbeincorporatedintotheprojectbeforecertificationsarereceivedandcheckedforcompliancebytheInspector.FieldverifythatmaterialscheckedontheBluesheetsarethesamepartstobeincorporatedintotheproject.IfthepartsdonotmatchonesmarkedontheBlueSheets,NEWsubmittalswillneedtobesubmitted.

Theinspectorisresponsiblefortheinitialqualification(exceptasnotedbelowformaterialsrequiringcataloguecutsheets),inspectingandacceptingallbluesheetmaterialsthatareinstalledontheproject.

Catalogue Cut SheetsTheContractorshallsubmitcataloguecutsheetsforanyequipmentandmaterialsthatarenotlistedinthe“bluesheets”.Thecutsheetshallidentifythespecificproductintendedtobeused;manufacturer’sname,identifyingnumber,andsize(whenitisnecessaryorcustomaryinthetradetoidentifysuchmaterials).Suchsheetsshallbesupplementedwithdataasappropriate,includingbutnotlimitedtodetailedscaledrawingsandwiringdiagrams.Mail/Fax/e-mailcutsheetstotheTrafficSignalEngineerforinitialqualificationofmaterial(s).Submittalsofpoorcopiesthatarenotclearlymarkedwillbereturnedforcorrection.

Read the instructions included in the blue sheets carefully. New updated instructions are printed with the sheets. Please follow these instructions.

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Blue Sheet Example Table of Contents

The contractor will check boxes if the material is NOT on the project. For all boxes checked, the material page(s) for these items should be deleted from the submittal. Table of Contents page

Always check the revision date! Use the most current version

The “Initial Submittal” box is for inspector use only.

Complete this after contract is awarded and BEFORE work starts.

Inspector will review the contents page. If it looks correct check “agree” box. If it doesn’t

Blue Sheet Example Table of Contents

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Blue Sheet Example Material Page for Bonded Bushings

The material name, description, and use are described for each material.

Contractor will check box(es). Except for conduit and wire, DO NOT CHECK MORE THAN 2 BOXES.

Contractor will circle catalogue/part no. if more than one option is listed.

Contractor may also write‐in materials proposed for installation based on the project plans and specs. A catalogue cut sheet MUST be submitted for write‐in

Always check the revision date! Use the most current version.


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Inspector will review the material page. If it looks correct check “Qualified” box. If it doesn’t look correct check “returned” box and send back to contractor for correction.

Submit write‐in materials and cut sheet to the Traffic Signal Engineer for approval. The “Qualified as Noted” box typically only used by the Traffic Signal Engineer for write‐ins.

If CMO is required for a material, this check box will be on the page. Inspector will check box and date when CMO is received.

Complete this after work is installed.

Inspector will check one of the two boxes.

Write‐in the “quantity accepted” and/or “quantity rejected”. Writing in “ALL” is acceptable.


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Bond Wire Blue Sheets Common Electrical

DESCRIPTION: Typically 6 AWG, 7 Strand copper wire. THWN insulated required when installed in conduit.

USE: Bond/grounding wire for 120V AC circuits.

Typical Sources of Info: Specs: 00960.50(a) & 02920.23 Std. Dwg: TM450, TM452, & TM472 Plan Sheets: NO

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Bonded Bushings Blue Sheets Common Electrical

DESCRIPTION: Metallic conduit bushings with a lug to clamp bond wires and an insulated throat. Aluminum not allowed.

USE: On the ends of conduit allowing bonding of the conduit system.

Typical Sources of Info: Specs: 00960.42(4) & 02920.12 Std. Dwg: TM472 Plan Sheets: NO

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DESCRIPTION: Black nylon or plastic strips UV resistant, with a positive, non‐release binding. No metal grippers allowed.

USE: Strapping control cable/wire to messenger cable on spans. Installed at 6” spacing.

Typical Sources of Info: Specs: 00990.40(b) & 02920.22 Std. Dwg: TM452 Plan Sheets: NO

Cable Ties Blue Sheets Common Electrical

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DESCRIPTION: Galvanized rigid conduit and fittings and liquid‐tight flexible metal conduit. IMC (Intermediate Metallic Conduit) not allowed.

USE: Houses electrical conductors.

Typical Sources of Info: Specs: 00960.41, 00960.42 & 02920.10 Std. Dwg: NO Plan Sheets: Typically NO (only the size of conduit is shown on plans)

Conduit (Metallic) Blue Sheets Common Electrical

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DESCRIPTION: o PVC (marked for electrical use, typically Grey), schedule 40 standardo High Density Polyethylene, schedule 40 standardo Fiberglass rigid non‐metallic conduit and fittings, schedule 40. Typically

used for elbows

USE: Houses electrical conductors.

Typical Sources of Info: Specs: 00960.42 & 02920.11 Std. Dwg: NO Plan Sheets: Typically NO (only the size of conduit is shown on plans)

Conduit (Non-Metallic) Blue Sheets Common Electrical

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DESCRIPTION: Conduit bushings with insulated throat but no bonding lug. Metallic style has an insulated throat.

USE: Used on the ends of conduit when bonding lugs are not required to protect the electrical wiring.

Typical Sources of Info: Specs: 00960.42(g)(4) & 02920.12 Std. Dwg: NO Plan Sheets: NO

Conduit Bushings Blue Sheets Common Electrical

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DESCRIPTION: o Hub: Nylon insulated steel or malleable iron connector, with neoprene

“O” ring o Conduit Body: Malleable iron conduit body hot dip galvanized with cover

and moisture‐proof gasket

USE: o Hub: To provide a watertight connection to meter bases, service

cabinets, terminal cabinets and cast iron junction boxeso Conduit Body: Conduit transition/pull point

Typical Sources of Info: Specs: 02920.12 Std. Dwg: TM465 & TM488 Plan Sheets: NO

Conduit Hub

Conduit Body

Conduit Hub and Conduit Body Blue Sheets Common Electrical

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DESCRIPTION: Closed cell polyethylene foam style is pre‐formed for a specific conduit size. Spray foam not allowed. Cut to a supplier suggested length for conduit sizes. Mechanical device (clay/putty material called Duct Seal) style fits into conduit opening to form a seal to conduit and wires/cables.

USE: Inserted into exposed end of conduit in foundations and junction boxes, to keep debris out of the conduit. Not watertight.

Typical Sources of Info: Specs: 00960.42(g) & 02920.28 Std. Dwg: NO Plan Sheets: NO

Conduit Plug Blue Sheets Common Electrical

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DESCRIPTION: Weatherproof, malleable iron with a hot‐dip galvanized finish.

USE: To provide for limited conduit expansion movement when crossing expansion joints in/on structures and between fitted enclosures.

Typical Sources of Info: Specs: 00960.42(k) & 02920.12 Std. Dwg: NO Plan Sheets: Typically NO

Expansion Fitting Blue Sheets Common Electrical

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DESCRIPTION: Copper coated 5/8 inch metal rod, 8 feet to 10 feet long with clamp.

USE: To ground electrical installation. All poles, conduit runs with 120V+ AC, and controller cabinet must be bonded to ground rod using full‐contact clamps.

Typical Sources of Info: Specs: 00960.50(b) & 02920.27 Std. Dwg: TM450, TM452, TM455, TM457, TM482, TM485 & TM492 Plan Sheets: NO

Ground Rod & Clamp Blue Sheets Common Electrical

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DESCRIPTION: Watertight boxes of cast iron, gasketed lid held down with stainless steel screws. For traffic areas the lids shall be recessed type and for surface mounted the lids shall be overlapping.

USE: As a pull point or wire access point in traffic areas (pavement).

Typical Sources of Info: Specs: 00960.44 & 02920.14(b) Std. Dwg: NO Plan Sheets: YES

Junction Boxes (Cast Iron) Blue Sheets Common Electrical

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DESCRIPTION: Open‐bottom boxes of pre‐cast reinforced concrete with brass or stainless steel fasteners. Polymer concrete also allowed.

USE: As a pull point or wire access point.

Typical Sources of Info: Specs: 00960.44 & 02920.14(c), (d) Std. Dwg: TM472 Plan Sheets: YES (location & size)

Junction Boxes (Concrete) Blue Sheets Common Electrical

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DESCRIPTION: Open‐bottom boxes made of polymer, fiberglass, and/or polymer concrete.

USE: As a pull point or wire access point.

Typical Sources of Info: Specs: 00960.44 & 02920.14(e) Std. Dwg: TM472 Plan Sheets: YES (location & size)

Junction Boxes (Hybrid) Blue Sheets Common Electrical

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DESCRIPTION: Open bottom boxes made of polymer, fiberglass, and/or polymer concrete.

USE: As a pull point/wire access point for communication cables like fiber optic, etc.

Typical Sources of Info: Specs: 00960.44 & 02920.14(e) Std. Dwg: TM472 Plan Sheets: YES (location & size)

Junction Boxes (Hand Hole) Blue Sheets Common Electrical

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DESCRIPTION: Sectional wire termination points, 600 Volt rated, solder‐less connections, tubular clamp, sized for wire being terminated, channel mount assembly.

USE: For terminating wires/cables in terminal cabinet on a signal pole.

Typical Sources of Info: Specs: 00990.41(a) & 02925.41(c) Std. Dwg: TM488 Plan Sheets: NO

Terminal Blocks Blue Sheets Common Electrical

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DESCRIPTION: Stranded copper conductor, color coded wire. o THWN wire has PVC insulation and nylon jacket. Visually, this insulation

is “shinier” than XHHW o XHHW wire has cross‐linked polyethylene insulation. This insulation is

more durable than THWN

USE: To provide electricity to equipment for all single conductor applications.

Typical Sources of Info: Specs: 00960.45, 02920.20, 02920.21 & 02920.23 Std. Dwg: TM470 Plan Sheets: YES

THWN & XHHW Wire Blue Sheets Common Electrical

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DESCRIPTION: Red polyethylene film, 6” wide, 4 mils thick. Printed with “CAUTION BURIED ELECTRICAL LINE” legend (or similar legend).

USE: To warn of buried electrical line for any conduit located outside of the paved roadway. Placed the full length of the conduit, 6” below the ground surface.

Typical Sources of Info: Specs: 00960.42(e) & 02920.13 Std. Dwg: NO Plan Sheets: NO

Underground Warning Tape Blue Sheets Common Electrical

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DESCRIPTION: An aluminum assembly for mounting signs on a mast arm, pole and spanwire installations. The Type A mount is used on spanwire installations and the Type B mount is used on mast arm and pole installations (an adjustable bracket without tenon).

USE: To attach signs to a mast arm or span wire.

Typical Sources of Info: Specs: 02925.62(a),(c),(d) & 02925.67(c) Std. Dwg: TM465 Plan Sheets: YES (mast arm and pole installations only)

Type A (Spanwire Mount)

Type B (W/O Tenon Mount)

Aluminum Sign Mounting Framework Blue Sheets Traffic Signal Specific

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DESCRIPTION: Aluminum sheet powder‐coated flat black louvered or black polycarbonate attached with stainless steel screws and washers. Plans may specify reflective sheeting along the edge.

USE: Shield around vehicle signal to provide a contrast to the background.

Typical Sources of Info: Specs: 00990.42(a) & 02925.64(e) Std. Dwg: TM460 Plan Sheets: Typically NO (Plan sheets will state if reflective sheeting is required)

Backplates Blue Sheets Traffic Signal Specific

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DESCRIPTION: Multi‐conductor bundled cable with assorted stranded copper wires (typically 14 AWG, but may be other sizes). Must meet color code on standard drawings.

USE: Used to provide electrical energy. Strapped to messenger cable on spans, used in mast arms. May also be used in conduit runs.

Typical Sources of Info: Specs: 02920.20, 02920.21, 02920.22, & 00990.40(a) Std. Dwg: TM470 Plan Sheets: YES

Control Cable Blue Sheets Traffic Signal Specific

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DESCRIPTION: Hardware for attaching spanwire installations to strain poles. Hot‐dip galvanized.

USE: An eyebolt and strandvise is used to hang the messenger cable (cable above signal heads).

An eyebolt, “S” hook (state supplied, designed to yield if the tether cable is struck by a high load), turnbuckle and strandvise is used to hang the tether cable (cable below signal heads).

Typical Sources of Info: Specs: 00990.40(c), 00990.40 (d), & 02920.24 Std. Dwg: TM452 Plan Sheets: NO

Eyebolt “S” Hook Turnbuckle Strandvise

Tether Cable

Strandvise

Messenger Cable

Eyebolt

Eyebolt, Turnbuckle, Strandvise Blue Sheets Traffic Signal Specific

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DESCRIPTION: Shielded cable containing 6+ twisted pairs of No. 19 AWG wires. REA spec. PE‐22 (air‐core, for overhead) or PE‐39 (gel‐fill, for underground), polyethylene jacket.

USE: For communication between traffic signal controllers. Installed with no splices between separate signal controllers.

Typical Sources of Info: Specs: 00990.40(e) & 02920.22 Std. Dwg: TM498 Plan Sheets: YES

Interconnect Cable Blue Sheets Traffic Signal Specific

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DESCRIPTION: Light Emitting Diode (LED) Unit which replaces incandescent bulbs in signal heads and pedestrian heads. Flange mount type, clear.

USE: To illuminate vehicle and pedestrian signals.

Typical Sources of Info: Specs: 00990.42(a), 00990.42 (b), & 02925.51(b) Std. Dwg: TM460 Plan Sheets: NO

LED Modules (Vehicle & Ped) Blue Sheets Traffic Signal Specific

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DESCRIPTION: Polyethylene jacketed, shielded cable with two twisted No. 14 AWG wires and bare tinned copper drain wire or No. 14 AWG wires wrapped with mylar tape. IMSA Spec. No. 50‐2. May also be No. 18 AWG wires if shown in the plans.

USE: Connects pairs of loop wires to controller, splice only at the junction box nearest the loop wires.

Typical Sources of Info: Specs: 02920.22 Std. Dwg: TM475 Plan Sheets: YES

Loop Feeder Cable Blue Sheets Traffic Signal Specific

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DESCRIPTION: Two‐piece plastic enclosure flooded with silicon grease. Includes screw on silicon grease filled wire connectors.

USE: Used to connect loop feeder and loop wire (splice point).

Typical Sources of Info: Specs: 00990.43(b)(4) Std. Dwg: TM475 Plan Sheets: NO

Loop Splice Blue Sheets Traffic Signal Specific

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DESCRIPTION: Stranded copper conductor, with cross‐linked polyethylene insulation, No. 14 AWG wire. Encased in a polyethylene tube (sleeve). Wire and tube must be stamped with proper IMSA 51.7.

USE: Used to detect vehicles. Loop wire is installed in the pavement in a circle or diamond pattern. The pair of loop wires, from the pavement to the junction box, is manually twisted 4 to 6 turns per foot.

Typical Sources of Info: Specs: 00990.43(2) & 02920.23 Std. Dwg: TM475 & TM480 Plan Sheets: YES

Loop Wire (XHHW / DUCT) Blue Sheets Traffic Signal Specific

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DESCRIPTION: Bare steel cable comprised of 7 strands of galvanized wire. Utilities grade 3/8 inch diameter with 11,500 lbs. break.

USE: Supports control cables, signal heads and signs on a spanwire installation.

Typical Sources of Info: Specs: 00990.40(c) & 02920.22 Std. Dwg: TM452 Plan Sheets: YES

Messenger Cable Blue Sheets Traffic Signal Specific

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DESCRIPTION: Socket into which the power company’s meter will be installed. Stainless steel or powder coated base.

USE: For power companies to meter power. Used between power source and service cabinet for temporary signals only (located on a temporary signal pole). Note: for permanent installations, the meter base is inclusive to the “Service Cabinet”.

Typical Sources of Info: Specs: 00960.49(a) Std. Dwg: TM455 & TM485 Plan Sheets: YES

Meter Base Blue Sheets Traffic Signal Specific

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DESCRIPTION: Four inch diameter galvanized steel pipe mounted on a cast aluminum or galvanized cast iron base.

USE: Freestanding pole for mounting of pedestrian signals.

Typical Sources of Info: Specs: 02925.33 (a) & 02925.33(c) Std. Dwg: TM457 Plan Sheets: YES

Pedestal (Pedestrian Signal) Blue Sheets Traffic Signal Specific

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DESCRIPTION: Four inch diameter galvanized steel pipe with welded base plate bolted to a cast aluminum or galvanized cast iron transformer base.

USE: Freestanding pole for mounting vehicle signals. Other equipment may be mounted with vehicle signal.

Typical Sources of Info: Specs: 02925.33(a) & 02925.33(b) Std. Dwg: TM457 Plan Sheets: YES

Pedestal (Vehicle Signal) Blue Sheets Traffic Signal Specific

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DESCRIPTION: Pole mounted signals. Aluminum powder coated black or black polycarbonate with stainless steel hardware.

USE: To indicate walk/don’t walk pedestrian phases at marked crosswalks.

Typical Sources of Info: Specs: 00990.42(d) & 02925.65(a) thru (c) Std. Dwg: TM467 Plan Sheets: YES

Pedestrian Signal Blue Sheets Traffic Signal Specific

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DESCRIPTION: Swing open clam shell compartment.

USE: To connect pedestrian signal to pole, with wire terminals.

Typical Sources of Info: Specs: 02925.65(d) Std. Dwg: TM467 Plan Sheets: YES

Pedestrian Signal Mount Blue Sheets Traffic Signal Specific

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DESCRIPTION: Four turns of No. 14 AWG XHHW or No. 16 AWG TFFN wire encased in either schedule 40 PVC or rubber hydraulic hose totally filled with sealant.

USE: Used to detect vehicles in thin, poor pavement or concrete bridge decks.

Typical Sources of Info: Specs: check special provisions Std. Dwg: NO Plan Sheets: YES

Preformed Loops Blue Sheets Traffic Signal Specific

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DESCRIPTION: Flat black, painted, aluminum alloy case with part‐time legend when lit. LED illuminated legend.

USE: To indicate part time restrictions when turned on. Typically used at ramp meters, and for restricted turn moves when signals have railroad preemption.

Typical Sources of Info: Specs: NO Std. Dwg: TM497 Plan Sheets: YES

PTR Signs Blue Sheets Traffic Signal Specific

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DESCRIPTION: Push button boxes with “H” style mounts.

USE: For pedestrians to request the walk phase.

Typical Sources of Info: Specs: 00990.43(a) & 02925.66 Std. Dwg: TM467 Plan Sheets: YES

Push Button Blue Sheets Traffic Signal Specific

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DESCRIPTION: Aluminum framework of ¼ inch channel or 1/8 inch sheet stock. One piece welded construction for newer installations, two‐piece bolt together for retro‐fit. Both styles anodized after fabrication.

USE: To raise the controller cabinet from the foundation 8 inches, providing additional work space under the cabinet. Use building paper gasket and non‐hardening water tight seal between riser and cabinet and between foundation and riser.

Typical Sources of Info: Specs: NO Std. Dwg: TM482 Plan Sheets: Typically NO

Riser Frames Blue Sheets Traffic Signal Specific

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DESCRIPTION: Stand‐alone (temporary installations) or Base mounted service cabinet with integral meter base. Includes circuit breakers, contactors, test switches, neutral and ground bars. Stainless, powder coated aluminum, or galvanized steel cabinet.

USE: Used to provide fused electrical service for permanent installations.

Typical Sources of Info: Specs: 00990.41(c) & 02925.40 Std. Dwg: TM485 Plan Sheets: YES

Base Mounted Service Cabinet Types:

BMC BMCL BMCF BMCFL

Stand Alone Service Cabinet Types:

SC SCL

Service Cabinet Blue Sheets Traffic Signal Specific

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DESCRIPTION: Yellow prefabricated nylon “bag”. Includes a fine mesh insert for signal testing with integral elastic bands and clips to secure the covers to the signal head visors (may cover the complete head and backboard).

USE: To cover vehicle and pedestrian signal heads until the signal is turned on.

Typical Sources of Info: Specs: 00990.42(g) & 02925.68 specials only Std. Dwg: NO Plan Sheets: NO

Signal Head Covers Blue Sheets Traffic Signal Specific

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DESCRIPTION: A fitting of cast bronze that attaches to the messenger cable with two “U” bolts. A wire outlet body hangs from this with a clevis pin through adjustable slot. All fasteners shall be type 304/316 stainless steel.

USE: To mount vehicle signal and signs on span wires. Allows equipment to hang plumb from spanwire, provides cable entrance when wire is installed with correct drip loop.

Typical Sources of Info: Specs: 02925.62(c) Std. Dwg: TM463 Plan Sheets: NO

Spanwire Hanger Blue Sheets Traffic Signal Specific

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DESCRIPTION: Constructed of 1/8 inch stainless, galvanized steel, or powder coated aluminum. Contains terminal blocks. Weatherproof fittings at the bottom for span wire installations.

USE: To house terminal blocks on poles for all signal circuits.

Typical Sources of Info: Specs: 00990.41(a) & 02925.40 Std. Dwg: TM488 Plan Sheets: YES

Terminal Cabinet Blue Sheets Traffic Signal Specific

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DESCRIPTION: ¼ inch galvanized steel cable comprised of 7 strands of galvanized wire. Class A coating conforming to ASTM A 475.

USE: Attached at the bottom of equipment to stabilize and prevent wind movement.

Typical Sources of Info: Specs: 00990.40(d) & 02920.22 Std. Dwg: TM452 Plan Sheets: YES

Tether Cable

Stabilizer Cable

Tether & Stabilizer Cable Blue Sheets Traffic Signal Specific

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DESCRIPTION: Fitting on bottom of span mounted signal or sign constructed of 1 ½ inch galvanized steel pipe or galvanized metal conduit with plate welded on bottom, tether wire keeper bolted to plate. Galvanized after fabrication. All fasteners type 304/316 stainless steel.

USE: To attach tether cable to vehicle signals and signs.

Typical Sources of Info: Specs: NO Std. Dwg: TM463 Plan Sheets: NO

Tether Clamp Blue Sheets Traffic Signal Specific

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DESCRIPTION: Fitting of cast aluminum with steel insert, powder coated as per spec. Three bolts, split washers, nylon insert lock‐nuts if stainless steel, with 2 stainless steel backing washers.

USE: To mount signals and signs to span wire hanger.

Typical Sources of Info: Specs: 02925.62(e) Std. Dwg: TM463 Plan Sheets: NO

Tri-Stud Adapters Blue Sheets Traffic Signal Specific

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DESCRIPTION: An extruded aluminum assembly that is adjustable. Its full length supports a vehicle signal on a mast arm and attaches to the arm by means of stainless steel cables.

USE: To mount vehicle signals and signs on a mast arm. Allows for adjustment of signal for height and full support of signal sections.

Typical Sources of Info: Specs: 00990.42(f) & 02925.62(d) Std. Dwg: TM462 Plan Sheets: YES

Vehicle Signal Bracket (Adj.) Blue Sheets Traffic Signal Specific

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DESCRIPTION: Aluminum powder coated black or black polycarbonate open at bottom standard (tunnel). Visor must attach to signal heads with stainless steel screws.

USE: On all signal heads to direct the illumination to the motorist.

Typical Sources of Info: Specs: 00990.42(a) & 02925.64(d) Std. Dwg: NO Plan Sheets: NO

Vehicle Signal Visor Blue Sheets Traffic Signal Specific

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DESCRIPTION: Aluminum powder coated black or black polycarbonate. May have 1,2,3,4, or 5 signal faces. May be programmable. All fasteners shall be type 304/316 stainless steel except for brass terminal screws.

USE: To direct vehicles at intersections.

Typical Sources of Info: Specs: 00990.42(a), (c), 02925.64, & 02925.67(a) Std. Dwg: TM460 Plan Sheets: YES

Programmed head

Vehicle Signals Blue Sheets Traffic Signal Specific

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DESCRIPTION: 30A 600V single pole or double pole in‐line fuse holder with KTK fuse, insulating boots, and set‐screw terminations.

USE: To splice illumination wires and provide a fused disconnect in the luminaire/signal pole base.

Typical Sources of Info: Specs: 00970.42 & 02920.26 Std. Dwg: NO Plan Sheets: NO

Inside pole base

In-Line Fuse Holder Blue Sheets Illumination Specific

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DESCRIPTION: A photoelectronic device used for turning on illuminated signs or luminaires meeting specifications under 00970.

USE: To activate illumination systems, luminaires at traffic signals and interior illuminated signs.

Typical Sources of Info: Specs: 00970.43 & 02926.41(e) Std. Dwg: TM465 Plan Sheets: YES

Photoelectric Cell Blue Sheets Illumination Specific

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DESCRIPTION: Typically a three conductor No. 10 AWG cable with XHHW conductors and overall PVC jacket.

USE: Illumination cable between the luminaire and the in‐line fuse holder in the pole base.

Typical Sources of Info: Specs: 00970.42 Std. Dwg: NO Plan Sheets: NO

Inside luminaire arm and pole

TC Cable Blue Sheets Illumination Specific

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Green Sheet MaterialsThe“SubmittalsforConditionalQualification–ControllerEquipment”(commonlyreferredtoastheGreenSheets)containalistofmaterialsandequipmentthatarenormallytestedforenvironmentalandfunctionalrequirements(chambertesting)bytheTrafficSignalServicesUnit(TSSU).Thecontractorsubmitsthreecopies,appropriatelymarked,forconditionalqualificationbytheInspector.

ThislistisupdatedfrequentlybytheTrafficSignalStandardsUnitandisavailableat:http://www.oregon.gov/ODOT/HWY/TS/pages/signals.aspx.ContacttheTrafficSignalEngineerforthecurrentlistifyoucan’tdownloadthemfromthatsite.

Theinspectorisresponsiblefortheconditionalqualificationoftheinitialsubmittalonly(exceptasnotedbelowformaterialsrequiringcataloguecutsheets).TSSUorAgencyElectriciansareresponsibleforinitialchambertestingacceptance,inspecting,andacceptingthesematerialsinstalledontheproject.

Catalogue Cut SheetsTheContractorshallsubmitcataloguecutsheetsforanyequipmentandmaterialsthatarenotlistedinthe“greensheets”.Thecutsheetsshallidentifythespecificproductintendedtobeused;manufacturer’sname,identifyingnumber,andsize(whenitisnecessaryorcustomaryinthetradetoidentifysuchmaterials).Suchsheetsshallbesupplementedwithdataasappropriate,includingbutnotlimitedtodetailedscaledrawingsandwiringdiagrams.Mail/Fax/e-mailcutsheetstotheTrafficSignalEngineerforinitialqualificationofmaterial(s).Submittalsofpoorcopiesthatarenotclearlymarkedwillbereturnedforcorrection.

Read the instructions included in the Green Sheets carefully. New updated instructions are printed with the sheets. Please follow these instructions.

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Green Sheet Example Material Page For Controller Cabinet

Always check the revision date! Use the most current version (when the contract is awarded)

Contractor will check this box if material is NOT on project

Contractor may also write‐in materials proposed for installation based on the project plans and specs. A catalogue cut sheet MUST be submitted for write‐in materials.

The material name

Contractor will check one box per sub‐category

Example of Sub‐category (332 cabinets)

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Green Sheet Example Material Page For Controller Cabinet


Inspector will review the material page. If it looks correct check “Conditionally Qualified” box. If it doesn’t look correct check “returned” box and send back to contractor for correction.

Submit write‐in materials and cut sheet to the Traffic Signal Engineer for approval.

The “Inspected & Accepted” is completed by TSSU or the Agency Electrician after the materials are

The “Chamber Testing Acceptance” is completed by TSSU after the materials are tested and before they are installed

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DESCRIPTION: 332 and 334 are ground mounted. 336s are pole mounted.

USE: Houses the equipment to run the traffic signal.

Typical Sources of Info: Specs: 02925.40 & 02925.67(b) Std. Dwg: TM482 Plan Sheets: YES

Controller Cabinet Green Sheets

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DESCRIPTION: Model 2070 standard. Model 170E may be used if shown in plans.

USE: The brains of the traffic signal.

Typical Sources of Info: Specs: 02925.42 Std. Dwg: NO Plan Sheets: YES

Controller Green Sheets

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70 ODOTInspector’sManualforSignalConstructionJanuary 2014

DESCRIPTION: Model 210

USE: Monitors the green indications (vehicle) and walk indications (pedestrian) to ensure conflicting movements are not serviced at the same time. Also monitors voltages.


Conflict Monitor Green Sheets

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USE: Powers the signal and pedestrian indications in the field.

Typical Sources of Info: Specs: 02925.42 Std. Dwg: NO Plan Sheets: Typically NO

Load Switch Green Sheets

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USE: Powers the signal indications when in flash mode.


Flasher Green Sheets

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Detector Amplifier Green Sheets


USE: A device that is capable of detecting the changes in the electrical energy produced by a sensor. Detects the change in inductance when vehicles move over a loop detector and places a “call” into the controller.


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Isolator (DC and AC) Green Sheets

DESCRIPTION: Model 242 (24 VDC pedestrian push button) and Model 252 (120 VAC railroad preemption).

USE: Detects when a pedestrian pushes a button or when a train is approaching and puts a “call” into the controller.


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DESCRIPTION: Model 400 and stand‐alone.

USE: Provides communications between traffic signals and/or to the central traffic signal operations office.


Modem Green Sheets

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USE: Switches the power from the load switches (normal operation) to the flashers (flash operation).


Relay FTR Green Sheets

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DESCRIPTION: Mounting assembly with a din rail.

USE: Used to mount communication equipment inside the controller cabinet.


Communication Bracket Green Sheets

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DESCRIPTION: Several models acceptable for use.

USE: Detects an emergency vehicle (that is using a preemption emitter in their vehicle) and puts a “call” into the controller.


Preemption Interface (Cabinet) Green Sheets

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DESCRIPTION: Several models acceptable for use.

USE: Detects an emergency vehicle (that is using a preemption emitter in their vehicle) which is recognized by the preemption interface in the cabinet.

Typical Sources of Info: Specs: 00990.46 Std. Dwg: TM465 Plan Sheets: YES

Preemption Detector (Field) Green Sheets

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USE: To keep accurate time in the traffic signal controller. Accurate time is critical when the traffic signal is interconnected with other signals and/or operates in time‐of‐day, day‐of‐week plans.


GPS Time Sync Module Green Sheets

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DESCRIPTION: Camera mounted to mast arm or luminaire arm.

USE: Alternative detection mode for vehicles.

Typical Sources of Info: Specs: NO Std. Dwg: NO Plan Sheets: YES (green sheet listed systems only)

Video & Radar Detection Green Sheets

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DESCRIPTION: Audio unit mounted near signal head and/or pushbutton.

USE: Provides sight impaired pedestrians’ audible information regarding the pedestrian phases.

Typical Sources of Info: Specs: 00990.42(h) specials only Std. Dwg: NO Plan Sheets: YES

Audible Pedestrian Signal Green Sheets

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DESCRIPTION: Model FXM1000/CE

USE: Provides power to the traffic signal when commercial power is out.


Battery Back-up System Green Sheets

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DESCRIPTION: o Solar Powered 24/7 Flashing Beacon Systemo School Zone & Actuated Solar Flashing Beacon Systemso RRFB (Rapid Rectangular Flashing Beacon) Systems

USE: To provide emphasis of a sign or indicate when the sign restrictions are active (e.g. school zone).

Typical Sources of Info: Specs: NO Std. Dwg: NO Plan Sheets: YES (Green sheet listed systems only)

RRFB

School Zone

24 / 7

Beacon Assemblies (Various) Green Sheets

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DESCRIPTION: A factory terminated patch panel that eliminates the need for field terminations in controller cabinet.

USE: to connect the fiber optic wiring from the junction box to the controller cabinet.

Typical Sources of Info: Specs: See ITS special provisions Std. Dwg: NO Plan Sheets: NO

Fiber Optic Connection Patch Panel Green Sheets

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Construction

General Each of the following pages in this section acquaints the inspector with an area/phase of construction or type of equipment used when installing a traffic signal. The pages are loosely arranged in the order in which an inspector should encounter the subject.

Each page suggests action to be taken prior to construction, installation sequence or tips, and cautions against common pitfalls and oversights. A “typical sources of info” has also been included for easy referencing to the relevant contract documents. The information given is meant to be used in conjunction with the appropriate section(s) of the Standard Specifications, Special Provisions, project specific plan sheets and/or standard drawings.

Illustrations have been provided to demonstrate construction practices and clarify equipment installation procedures.

Changes to the Plans and Specifications Any changes made in the field are subject to the approval of the ENGINEER OF RECORD. The Inspector should note the changes as they occur, so that it will be easier to record these changes on the As‐Constructed drawings (see page 171).

Engineer of Record

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Electrical Service (Power Source) PRIOR TO INSTALLATION

o The Project Manager coordinates with the Contractor for the electric servicehook‐up. 00960.70.

o Electrical service should be installed as shown on the project plans unlessfield conditions indicate otherwise.

o If relocation is required, the Inspector should consider the locations of theutility company power source, the location of underground utilities, and thelocation of the signal controller, and then call the Engineer of Record forassistance.

INSTALLATION

o Utility companies should be notified at least two weeks in advance of thetime power is needed at the site to allow them time to make adjustments orinstall equipment and wiring as necessary.

CAUTION-POTENTIAL PROBLEMS

o Considerable time and expense can be saved if the power source is agreedupon prior to construction. Changes made at this stage are the leastexpensive to incorporate into the construction plans.

o Conduit and wiring between the power source and signal service cabinet arespecified by the electrical permit. See plan sheet.

Typical Sources of Info: Specs: 00960.49 & 00960.70 Std. Dwg: NO Plan Sheets: YES Blue Sheet/Green Sheet Info: NO

Existing Power Source

Conduit and wiring from the power source to the BMCL, as required by power company

Traffic Signal Service

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Telephone Hook-Up PRIOR TO INSTALLATION

o Determine a site address for the signal controller cabinet. Could be the sameas the power meter if it has a site address on the billing statement.

o Determine a billing address to send the phone bills to. Typically to the LeadRegion Electrician’s address.

INSTALLATION

o Contact Information Systems 503‐986‐ 3225. They will send out the ODOTrep through DAS and contact the local phone company engineer or rep tomeet on site to discuss the details.

o Meet on site. Invite Region Traffic and Agency Electrician to the site visit.

o Electrical contractor to install the conduit, phone box and pull string basedon site meeting. Typically, the phone companies require a 2 inch conduit.


o There could be a cost to getting the site address (but not normally the case).Typically getting an address has been through a Public Works Department,City Hall, or the local 911 Administrator.

Typical Sources of Info: Specs: NO Std. Dwg: NO Plan Sheets: YES Blue Sheet/Green Sheet Info: NO

Coordinate conduit and wire with telephone company. Contractor is responsible to see that phone connection is operational at system turn‐on.

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Signal Head Alignment and Pole Location Head location must be established before pole layout can be finalized. The lane dimension head (in conjunction with the pole entrance chart) determines exactly where each piece of equipment on the mast arm or span wire must be located in relation to the lane lines. This in turn, determines where the pole should be located.

PRIOR TO INSTALLATION

o Lay out preliminary lane lines from typical sections.

o Lay out curbs and back of walk or edge of pavement.

o “Roughly" locate poles from plans.

o "Roughly" locate path of span or arm.

o Verify signal head alignments.

INSTALLATION

o Locate lane‐dimensioned head (from plans), then measure back to the poleusing the dimensions shown in the plan sheet.

Calculation for Rough locate of pole:

1. Determine Mast Arm Length (“MA” value)

2. Find the Lane Dimension Head (only head that is dimensioned to a laneline) and the corresponding Lane Dimension Head distance (“LDH”value)

3. Determine distance from tip of mast arm to the Lane Dimension Headfrom the pole entrance chart (“D” value)

4. Determine if the location of the lane dimension head is between thepole and lane line (example 1 calc: add “LDH” value) or not (example 2calc: subtract “LDH” value).

5. “MA” – “D” (+ or ‐) “LDH” = rough distance from lane line to mast armpole location


o If lane lines on road plan or striping plan do not match lanes on signal plans,contact Engineer of Record.

o If the rough locate of pole will be in conflict with other features (sidewalk,utilities, etc.), contact the Engineer of Record. A different design and/orpole size may be needed.

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Pole Location Poles location must be field verified. Final pole location may need adjustment due to utility conflicts, radius changes, striping changes, ADA walk designs, etc. Verify signal head alignment first (see page 91).


o Lay out curb or edge of pavement radius.

o Lay out back of sidewalk, including ADA ramp/bypass (if such).

o Lay out raised island (if such).

o Poles should be 5’ min. from face of curb.

o Poles should be 6’ min. from edge of pavement.

o Pole islands must be raised and have a minimum area of 75 square feet.

o Poles with pedestrian signals should be within crosswalk alignmentprojection.

INSTALLATION

o N/A


o Changing pole location may require a different type of strain or mast armpole.

o Changing pole location may require auxiliary equipment (i.e. push‐buttonposts, pedestrian pedestals, etc.).

o Mast arms come in 5’ increments, thus relocations requiring different polesand arms will be in 5’ increments.

o A longer or shorter mast arm may require a different type pole andfoundation.

o Changing pole location may require illumination re‐design.

o Fit poles to ADA ramps, back of walk, out of the landing area. TM458.

Typical Sources of Info: Specs: NO Std. Dwg: TM458 Plan Sheets: YES Blue Sheet/Green Sheet Info: NO

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Junction Box (JB) Locations


o Layout curb radius, concrete walk, crosswalks and wheelchair ramps.

o Layout edge of pavement and pedestrian landings in non‐curbed sections.

o Layout approximate location of detector loops.

INSTALLATION

o Stake JBs relative to locations on plans. Junction box locations areapproximate; changes can be made to better fit site. 00960.44(a).

o JBs are to be no more than 300’ apart; intermediate JBs may not be shownon plans, but 300’ is the maximum, unless specified differently. 00960.44(a).

o Apron type junction boxes must be installed in gravel shoulders wereincidental traffic may occur. 00960.44(a) & Plan Sheets.

o Only cast iron JBs are allowed in traffic areas (i.e. Concrete or AC roadwaysurface). Plan Sheets.

o Do not install cast iron junction boxes in non‐paved areas or without p.c.c.envelope in paved areas. Plan Sheets.


o Compare signal plans to Roadway plans (or existing facilities) for conflicts.

o Verify JB type and material. Plan Sheets.

o Concrete JBs in pedestrian landings should be located by pole, away fromedge of pavement, or installed with a concrete apron behind walk withinR/W.

o Do not install JBs in the slope of ramps or driveways.

o Concrete JB's in concrete walks may be subject to incidental traffic.

Typical Sources of Info: Specs: 00960.44 Std. Dwg: TM472 Plan Sheets: YES Blue Sheet/Green Sheet Info: pgs. 26, 27, 28 & 29

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Pole and Pedestal Foundations


o Verify location and finish grade before excavating.

o Determine anchor rod alignment. Plan Sheets for mast arm orientation &TM652.

o Inspect poles for damage or defects. Measure anchor rod diameter & anchorplate diameter of pole. TM652.

INSTALLATION

o Inspect cage for vertical bar size, ties, and clearance. TM653.

o Verify correct number and sizes of FIBERGLASS conduit bends are installedand bundled at top. Plan Sheets.

o Conduits are not to be spliced/coupled at foundation edge. 00960.42(d).

o Inspect anchor rods for diameter, length, and proper alignment in template.TM652.

o Foundations are constructed with one continuous concrete pour, except for4” pad at top. 00962.43 & TM653.

o Ground rods must be outside of foundation for mast arm and strain poles inthe nearest junction box. TM450 & TM452.

o Pole and pedestal foundations are poured against undisturbed material.Some minor back‐fill is allowed with well compacted materials. 00962.41(a).


o Steel cage and template can be displaced by pour or vibratory equipment.

o Improper anchor rod alignment or adjustment of anchor rods after concretehas set may be cause rejection of foundation. 00962.43.

o Temporary casings used during construction must be removed. 00963.43(c).

o All conduits in foundations must be FIBERGLASS. 00960.42(d).

o Put spacers between conduits when bundling to allow for bushings to beinstalled later.

Rebar Size Number: Each number equals 1/8”. For example, a #5 bar is 5/8”

Typical Sources of Info: Specs: 00962.43 & 00963 Std. Dwg: TM450, TM452, TM457, TM458, TM650 thru TM653, TM660 &TM661 Plan Sheets: TYPICALLY NO

Blue Sheet/Green Sheet Info: pgs. 44 & 45

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Trenching for Conduit


o Utilities shown on plans are approximate. Always request a 'locate' beforetrenching. 00150.50(c).

o Lay out all poles, JB's and controller before trenching.

INSTALLATION

o Trenching for conduit shall be accomplished in the general pattern shown onthe plans. Actual location of conduit runs may vary as necessary to avoidobstructions. Runs should be straight as possible. 00960.42(a).

o Trench adequate depth to provide minimum cover for conduit, as required inSection 00960.41(c).

o Saw‐cut pavement before trenching. An approved pavement saw must beused. An “earth saw”, “conduit wheel”, etc. are not approved. 00960.41(a).

o Hold trench width to a practical minimum. 00960.41(d)(2)(a).


o Un‐located utilities are expensive and dangerous.

o Check permit to ensure that greater trench depths aren't required.00960.41(c).

o 'Hand‐trenching' may be necessary in landscape, irrigated areas, under curblines or for utility conflicts. 00960.40(a).

o Plans sheets may specify horizontal directional drilling (HDD) only so as notto disturb the existing roadway and traffic.

o Most trenching will be done with a backhoe. It also may be done with atrencher, but care must be taken to provide proper backfill of a narrowtrench.

Typical Sources of Info: Specs: 00960.41 Std. Dwg: NO Plan Sheets: YES (for HDD requirements only) Blue Sheet/Green Sheet Info: NO

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Conduit Installation PRIOR TO INSTALLATION

o Conduits approved for use on signal projects are non‐metallic (PVC, HDPE,and Fiberglass) and galvanized rigid metal conduit.

o Place 2” sand bedding in bottom of trench before laying PVC conduit unlessCLSM is to be used. 00960.41(g)(1).

INSTALLATION

o Rigid metal conduit must be reamed, threaded, free of burrs and joined witha coupling. Coat threads with rust preventative compound. 00960.42(g)(1).

o PVC conduit ends must be clean, dry, primed, and free of burrs beforecementing. 00960.42(g).

o The contractor has the option to increase the conduit size for theirconvenience at no extra cost to the Agency. 00960.42(a).

o Conduit elbows must be FIBERGLASS. 00960.42(f).

o Risers in junction boxes are PVC. 00960.42(g)(3).

o Conduit in Foundations must be FIBERGLASS. 00960.42(d).


o In corrosive soils, metallic conduit must be coated or wrapped. (Also typicallyspecified around high voltage electrical devices). 00960.42(a).

o Conduit for future use shall be installed with polyethylene pull line, andcapped. 00960.42(g) & 00960.42(i).

o Conduit installed under railroads requires a sleeve. 00960.41(e).

o Conduit installed on structures requires expansion fittings at all structureexpansion joints. 00962.42(k).

o Must be installed by licensed Electrician.

o MUST be inspected by Region Electrician before backfill. 00960.42(e).

o Conduit must be same size outlet‐to‐outlet (no reducers). 00960.42(a).

Typical Sources of Info: Specs: 00960.41, 00960.42, & 02920.10 thru 02920.12 Std. Dwg: NO Plan Sheets: YES

Blue Sheet/Green Sheet Info: pgs.17, 19, 20, 21, 22, 23 &, 24

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Concrete or Polymer Concrete JBs Installation PRIOR TO INSTALLATION

o Determine finish grade for top of JB.

o Excavation for JB must be adequate for 12” (min.) depth of ¾” – 0” gravelbedding. TM472.

o All FIBERGLASS conduit bends and risers must enter box from underneathand be concentrated at either end of box. 00960.42(h)(1) & (h)(3).

INSTALLATION

o Place box on bedding, backfill sides with well compacted material.

o Verify finish grade.

o Locate box 12” from back of curb. TM472.

o Do not install in traffic areas. TM472.

o Do not install in gravel shoulders without apron. 00960.44(a).

o Bond metallic lid if 25v (or greater) power is present. 00960.50(g).

o Lids are held down with two stainless steel or brass hex head bolts. TM472.


o Top of box shall be flush with the surrounding grade or top of curb.00960.44(a).

o Be sure junction box is not resting on conduits.

o Marked with post and paddle where appropriate. See 00960.44(b) &TM570.

o Lid should be marked with appropriate label (Traffic Signals,Communications, Street Lighting or power). TM472.

o Must be fitted with galvanized cast iron, galvanized steel, or cast aluminum,or concrete polymer recessed lid, loading rated for incidental traffic. BlueSheets.

o Only install in flat areas of sidewalk (do not install in slopes of ramps ordriveways). TM472.

Typical Sources of Info: Specs: 00960.44 & 002920.14 Std. Dwg: TM472 Plan Sheets: YES

Blue Sheet/Green Sheet Info: pgs. 27 & 29

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Cast Iron Junction Box Installation


o Determine finish grade for top of JB. In pavement areas leave box down ½”from finish grade. 00960.44(a).

o JB must be a minimum of 12” from E.P. or curb. Plan Sheets.

o Provide 6” of bedding and 4” of Portland Cement Concrete under JB. PlanSheets.

o Provide 4” of PCC Concrete on all sides of JB. Asphalt will not provideadequate support. Plan Sheets.

INSTALLATION

o Drill bottom of box for conduit entrances.

o Install metal conduit bends/risers into JB using malleable iron conduit hubs.

o Verify finish grade and secure JB in place during concrete pour around box.

o Finish concrete, sloping up ¼” to finish grade.

o Cover held down with stainless steel cap screw or Hex bolts.


o JBs installed without PCC concrete envelope will break conduit ends andsever conductors. Must be Portland Cement Concrete not Asphalt Concrete.

o 5/8” drain conduit must be imbedded into gravel bedding in order tofunction.

o To prevent sloughing of roadway, do not install JB's within 12” of top ofslope.

Typical Sources of Info: Specs: 00960.44 & 02920.14 Std. Dwg: NO Plan Sheets: YES Blue Sheet/Green Sheet Info: pg. 26

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Conduit Trench Backfill PRIOR TO INSTALLATION

o PVC conduit to be backfilled with granular material or native materialtypically has 2” sand bedding and 2” sand cover. 00960.41(g)(1).

o PVC conduit to be backfilled with CLSM needs no bedding.00960.41(g)(1)(c)(2).

o CLSM backfill is required in all existing traffic areas (roadway & shoulder)trenches. 00960.41(g)(1)(c)(2).

INSTALLATION

o Backfill and compact in 6” layers up to 6” below finish grade.00960.41(g)(1)(c)(1).

o Conduit trench backfill under pavement can be accomplished with eithercompacted selected granular material (paved non‐traffic) or CLSM(controlled low strength material) backfill (traffic areas). 00960.41(g).

o Trenches outside of paved areas can be backfilled with compacted selectedgeneral (native) material free of clods and rocks. 00960.41(g)(1)(c)(3).

o Place underground marking tape in ALL TRENCHES NOT using CLSM forbackfill.

o Finish final 6” to match surrounding surface. 00960.41(g)(1)(d) &00960.41(g)(2).


o Contractor should be cautioned "Do not cover conduit runs until inspected"as required by 00960.42(e).

o Make sure that at least one trench/backfill is inspected by an AgencyElectrician. 00960.42(e).

o Make sure conduit doesn't 'float up' when using CLSM backfill.

o Plug all conduit ends during backfill operation, to keep debris from enteringconduit. Keep plugged until wire is pulled. 00960.42(g).

Typical Sources of Info: Specs: 00960.41 & 00960.42 Std. Dwg: NO Plan Sheets: NO Blue Sheet/Green Sheet Info: pg. 32

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Bonding and Grounding PRIOR TO INSTALLATION

o Bonding and grounding is typically necessary for all conduits with ACconductors and for all signal poles, pedestals, controller cabinet and servicecabinet.

o Identify which conduits will have AC circuits and which will have only DCcircuits. DC circuits are used for pedestrian push buttons, loop detectionsystems, and fire preemption systems.

o Choose appropriate location for ground rods at all poles, pedestals, andcabinets. The ground rod may be located in an adjacent junction box.TM450, TM452, TM455, TM457, TM482, & TM485.

INSTALLATION

o Generally a bond wire is necessary in most conduits. 00960.50(f).

o Install bonding lugs on conduits where needed. 00960.42(g)(4).

o Drive ground rods, attach appropriate size grounding electrode conductorand grounding lug. Bond conduit to ground rod if needed. 00960.50.

o Bond metallic JB lids to conduit bonding lug (if AC power present) with 4’minimum length bond wire (to enable the removal of the cover).00960.50(g) & TM472.


o Bonding & Grounding can get rather complicated so this is one area whererequesting assistance from Agency Electricians is STRONGLY suggested.

o Remember to connect bond wires to conduit bonding lugs when conductorsare pulled.

o Ground rods must be installed in a minimum of a JB/1. On wood poles, allequipment less than 8’ above ground shall be bonded at each pole as perstd. Dwg. TM455.

o All ground and bond wires must be stranded conductors. 00960.50(a).

o Bonding to the JB is not required in a non‐metallic junction box with non‐metallic lid. (note: a grounding conductor may still be routed through the JB)

o Bonding is required in a metallic junction box or with metallic lids if there areany AC circuits in the box. 00960.50(g).

Typical Sources of Info: Specs: 00960.50 Std. Dwg: TM450, TM452, TM455, TM457, TM472, & TM485 Plan Sheets: NO Blue Sheet/Green Sheet Info: pgs. 16 & 17

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Pulling Wires and Cables


o Verify that all conduit bushings (with or without) bonding lugs are installedbefore pulling wires. 00960.42(g)(4).

o Verify that bond wire is included with wire and cables (if required).00960.50.

o Verify that all wiring used meets the color code requirements. TM470.

INSTALLATION

o Always pull wires and cables by hand in a straight line with the conduitopening, using a pulley device if necessary to achieve a straight line.00960.45.

o Use approved lubricant to reduce pulling strain and prevent insulationdamage. 00960.45.

o Typically requires one person pulling the wire and one person feeding thewire in the conduit.


o Be sure conduit is clean before pulling wires. Use a mandrel and compressedair (existing conduit and new conduit). 00960.45.

o Inspect pulled ends of conductors for insulation damage, replace if damage isdiscovered.

o No splicing is allowed outside of terminal cabinets (Splicing loop wire tofeeder cable splices in junction boxes is the only exception). 00990.40(a).

o Do not use any mechanical means to apply or multiply pulling force.

o Do not tie or tape conductors or cables together inside conduit. 00960.45.

o Leave slack in each wire and cable as per 00990.40(a):

o junction box nearest the controller (6 feet)

o junction box (2 feet)

o pole (2 feet)

o controller cabinet (6 feet)

Typical Sources of Info: Specs: 00960.45 Std. Dwg: NO Plan Sheets: NO Blue Sheet/Green Sheet Info: pgs. 16, 31, 39 & 41

Pulling Wires and Cables


o Verify that all conduit bushings (with or without) bonding lugs are installedbefore pulling wires. 00960.42(g)(4).

o Verify that bond wire is included with wire and cables (if required).00960.50.

o Verify that all wiring used meets the color code requirements. TM470.

INSTALLATION

o Always pull wires and cables by hand in a straight line with the conduitopening, using a pulley device if necessary to achieve a straight line.00960.45.

o Use approved lubricant to reduce pulling strain and prevent insulationdamage. 00960.45.

o Typically requires one person pulling the wire and one person feeding thewire in the conduit.


o Be sure conduit is clean before pulling wires. Use a mandrel and compressedair (existing conduit and new conduit). 00960.45.

o Inspect pulled ends of conductors for insulation damage, replace if damage isdiscovered.

o No splicing is allowed outside of terminal cabinets (Splicing loop wire tofeeder cable splices in junction boxes is the only exception). 00990.40(a).

o Do not use any mechanical means to apply or multiply pulling force.

o Do not tie or tape conductors or cables together inside conduit. 00960.45.

o Leave slack in each wire and cable as per 00990.40(a):

o junction box nearest the controller (6 feet)

o junction box (2 feet)

o pole (2 feet)

o controller cabinet (6 feet)

Typical Sources of Info: Specs: 00960.45 Std. Dwg: NO Plan Sheets: NO Blue Sheet/Green Sheet Info: pgs. 16, 31, 39 & 41

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Wood Pole Installation Wood poles are normally used for temporary signal installations.


o Inspect poles for splits or in‐transit damage.

INSTALLATION

o Locate utilities before drilling holes.

o Verify setting depths.

o Rake pole away from the applied load.

o Install anchors opposite the applied load.

o Backfill around pole with granular material.

o ALL wiring on pole shall be in a conduit. TM455.


o Bond all equipment within 8’ of finish grade at each pole. TM455.

o Ensure that recommended embankment values will be present during allapplicable stages of construction

Typical Sources of Info: Specs: 00225.15, & 02120.10 Std. Dwg: TM455 Plan Sheets: YES Blue Sheet/Green Sheet Info: pgs. 36, 42, 54, 56 & 57

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Strain Pole Installation Strain poles are galvanized steel poles to which spans are attached. These spans are used to support signal equipment located over the roadway.


o Check pole tag for proper information. 00962.46(i).

o Inspect factory welding (conduit hub). TM652 & 00962.46(g).

o Check for wire hanger hook and grounding lug. TM452, TM661, &00962.50(a).

o Repair galvanizing damage from handling. 00962.46(j)(1).

o Install eyebolts and pole cap.

INSTALLATION

o Concrete foundations require 7 days minimum of cure before pole shafts canbe erected. Don’t load pole until foundation reaches design strength. See00962.43 then Table 00540‐1. Break concrete test cylinders to verify. 00440.

o Install leveling nut & washer on anchor rods. TM652 & 00962.46(j)(2)(a).

o Install top washer & nut, rake pole to counteract load using leveling nuts.00962.46(j)(2)(a).

o Pour Grout (concrete) pad with ¾” pole drain (weep hole). TM653.


o Tighten anchor rods according to 00962.46(j).

o Poles and arms can be round or octagonal but two types shall not be mixedon project. TM651, general note #5.

o Reinstall handhole cover until wiring can be completed.

Typical Sources of Info: Specs: 00440, & 00962 Std. Dwg: TM660 & TM661 Plan Sheets: YES Blue Sheet/Green Sheet Info: pgs. 36, 42, 54, 56 & 57

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Mast Arm Pole Installation Mast arm poles are galvanized steel poles with attached cantilevered arms that are used to support signal equipment located over the roadway.


o Check pole tag for proper information. 00962.46(i).

o Inspect factory welding (conduit hub). TM652 & 00962.46(g).

o Check pipe sleeve at mast arm mount for proper rounding. TM652.

o Check for wire hanger hook (“J” hook) and grounding lug. TM450, TM661, &00962.50(a).

o Repair galvanizing damage from handling. 00962.46(j)(1).

INSTALLATION

o Concrete foundation requires 7 days of cure before pole shaft can beerected. Don’t load pole until foundation has reached design strength. See00962.43 then Table 00540‐1. Break concrete test cylinders to verify. 00440.

o Install leveling nut and washer on anchor rods. TM652 & 00962.46(j)(2)(a).

o Install top washer and nut, rake pole to counteract load using leveling nuts.00962.46(j)(2)(a).

o Pour Grout (concrete) pad with ¾” pole drain (weep hole). TM653.


o Tighten anchor rods according to 00962.46(j).

o Poles and arms can be round or octagonal, but two types shall not be mixedon a project. TM651, general note #5.

o Reinstall hand‐hole cover until wiring can be complete.

o Check for mast arm mounting plate fit/bolting (plate warp or bolts notseating).

o Use DTI (direct tension indicator) washers when installing 8 bolt armconnections. TM652 to TM651 note #22 to 00930.40(d).

Typical Sources of Info: Specs: 00440, & 00962 Std. Dwg: TM650, TM651, TM652, & TM653 Plan Sheets: YES Blue Sheet/Green Sheet Info: NO

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Terminal Cabinet Installation Terminal cabinets are mounted on poles. They are used as a splice point for the wiring from the signal controller cabinet and the wiring to the signal indications.


o Check galvanizing and/or powder coating. 02925.40.

o Check for 3 lines of mounting brackets for single sectional terminal blocks(quantity & size as needed). 0990.41(a).

o Check pole for conduit hub and that lower mounting hole has been drilledand tapped. TM488.

INSTALLATION

o Mount to pole with close pipe nipple into factory installed conduit hub.Lower TC mount is 3/8” stainless steel bolt with ½” metal pipe spacer.TM488.

o Terminal cabinets for strain poles should have watertight compressionfittings in bottom for control cable entrance.TM488 & 00990.41(a).

o Label all terminals with mechanically printed labels. 00940.41(a).


o Required number of terminal blocks varies, but should be distributed equallyamongst the three lines. 00990.41(a).

o 3 spare terminal blocks required in all terminal cabinets. 00990.41(a).

o Do not bring bond wire into TC. Bond messenger cable to pole. TM450 &TM452.

o Do not terminate Fire Pre‐Emption or Illumination wiring in terminal cabinet.00990.46.

o Plans may specify recessed terminal cabinets. Recessed terminal cabinetsare contained within the pole.

Typical Sources of Info: Specs: 00990.41(a) & 02925.40 Std. Dwg: TM488 Plan Sheets: YES Material Info: pg. 55

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Messenger Cable Installation Messenger cable is used to suspend equipment over the roadway in a span wire installation.


o Install ¾” galvanized eyebolt as specified. TM452.

o Install strandvise bail onto eyebolt.

INSTALLATION

o Insert messenger cable into strandvise.

o Take up slack to minimum sag. (5% sag = 1.5’ drop in 30’ span). TM452.

o Trim off excess cable.

o Only one messenger cable may be attached to an eye bolt. Multiplemessenger cables attached to a single eyebolt is not allowed. TM452.


o Messenger cable does not use 'S' Hooks or turnbuckles. TM452.

o Bond messenger cable to pole. TM452.

Typical Sources of Info: Specs: 02920.22 Std. Dwg: TM452 Plan Sheets: YES Blue Sheet/Green Sheet Info: pgs. 36 & 42

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Tether and Stabilizer Cable Installation Tether and stabilizer cable are used to prevent movement of equipment suspended from messenger cable.


o Install 1/2” ‐ 3/4” galvanized eyebolt as specified. TM452.

o Install 'S' hook onto eyebolt, turnbuckle onto 'S' hook, strandvise bail ontoturnbuckle. TM452.

o 'S' hooks are State furnished by TSSU call 503‐378‐2956. TM452 &00990.40(d).

INSTALLATION

o Insert tether cable into strandvise and take up tension with turnbuckle.

o Trim excess cable.

o For stabilizer system see the signal plan sheets.

o Close “S” hook on eyebolt side (pole side only). TM452.

o Only one tether cable attached to an eye bolt. Multiple tether cablesattached to a single eye bolt is not allowed. However, the stabilizer cable(ifused) is typically attached to the same eyebolt as the tether cable.


o Tether and stabilizer cable requires the use of 'S' hooks and turnbuckles onboth ends. TM452.

o See TM463 for tether clamp details (cable is installed below lock bolts and iswrapped in sheet lead).

o Do not use high strength or larger cable. May not break when snagged.

Typical Sources of Info: Specs: 02920.22 Std. Dwg: TM452 Plan Sheets: YES Blue Sheet/Green Sheet Info: pgs. 36 & 56

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Wiring Poles Wiring poles consists of single conductors or control cable brought into terminal cabinets via underground conduit then distributed to various pieces of equipment.


o Verify 'J' hooks above terminal cabinet entrance to strain pole and abovemast arm connection on mast poles. TM450.

o Become familiar with the color code and wiring shown on plans. TM470.

o Signal heads normally use No. 14 AWG. Plan Sheets.

o Illumination on signal poles normally use No. 10 AWG. Plan Sheets.

o Signal conductors are stranded copper, THWN wire. Plan Sheets.

o Illumination and power conductors are stranded copper, XHHW wire. PlanSheets.

INSTALLATION

o Use cable Strain reliefs to support wires or cables at "J" hooks above terminalcabinets (strain pole) and above mast arm connections. TM450.

o Wire mast arms with control cables (One 7 conductor wire cable per vehiclehead). 00990.40(a).

o Span‐wire control cables exit bottom of TC (using watertight compressionfittings) and are attached to messenger cable with tie wraps every 6”.TM452.


o Observe the color code requirements. TM470.

o Install 3 spare conductors as shown in plan sheets.

o Cables on a span wire may bypass terminal the cabinet, for example firepreemption cable.

o Tape off ends of extra conductors. 00990.40(a).

o No splices are allowed outside of the terminal cabinets (except for loop wireto loop feeder cable in the junction box). 00990.40(a).

o Follow wire slack requirements. 00990.40(a).

Typical Sources of Info: Specs: 00960.45, 00990.40, 02920.22, & 02920.23 Std. Dwg: TM470 Plan Sheets: YES Blue Sheet/Green Sheet Info: pgs. 31, 35, & 64

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Spanwire Hanger Installation Spanwire hangers are used to suspend equipment from messenger cables. They also provide a cable entrance into the equipment.


o Check dimensions for specified head‐to‐travel lane relationship. See pg. 91

o Verify head/sign clearance for appropriate conduit length for spanwirehangers. TM452 & TM463.

INSTALLATION

o Install hardware with anti‐seize compound. TM463.

o Extension shall be 1 ½” galvanized rigid conduit drilled and tapped to acceptset‐screw on hanger. TM463.

o Mount signal head to tri‐stud using lock‐nuts (or lock washers and Hex nuts),form control cable into drip loop, thread through hanger into signal head.Terminate wire and install tether. TM463.

o All set‐screws go through wall of conduit. With conduit extending 5/8”beyond set screw.

o Adjust length of conduit nipple to achieve proper mounting height.

o Verify correct vertical clearance between the pavement and the bottom ofthe equipment on the span wire is met, 18’ minimum to 19’ maximum.TM452.


o Bind control cable into a drip loop that is lower than the throat of thehanger.

o Control cable must be arched over the span wire hangers to avoid damage.TM463.

o Span wire hangers use ‘U’ bolts for attachment, not ‘J’ or ‘L’ bolts. TM463.

o Always seal tri‐stud adapters with silicon seal. TM463.

Typical Sources of Info: Specs: 02925.62 Std. Dwg: TM463 & TM465 Plan Sheets: NO Blue Sheet/Green Sheet Info: pg. 54

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Adjustable Bracket Installation Adjustable brackets are typically used to suspend equipment from mast arms. They also provide a cable entrance into the equipment.


o Check dimensions for specified head‐to‐travel lane relationship. See pg. 91.

INSTALLATION

o Install hardware with anti‐seize compound.

o Verify correct vertical clearance between the pavement and the bottom ofthe equipment on the mast arm is met, 18’ minimum to 19’ maximum.TM450.


o Adjustable brackets require a safety cable. TM462 & 02925.62(d).

o Do not over tighten.

o Trim excess portion of gusseted tube above the top of the U‐bolt (6”maximum allowed above top U‐bolt). TM462.

Typical Sources of Info: Specs: 02925.62 Std. Dwg: TM462 & TM465 Plan Sheets: YES Blue Sheet/Green Sheet Info: pgs. 33 & 59

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Pedestrian Signal Mount Installation Hinged mounting brackets (clamshell mounts) are a two‐piece, ready‐to‐use assembly into which the pedestrian signal is installed. TM467.


o Drill pole for flange mount & ½” NF stainless steel, allen head, mountingbolts. TM467.

INSTALLATION

o Mount terminal compartment and assemble.


o Check visibility from far end of crosswalk, adjust as necessary.

o PLUMBING PIPE AND FITTINGS are not permitted.

o Clamshells must be mounted with the hinge at the rear of the pedestriansignal housing but may need to be reversed to allow for the opening of thepedestrian signal. Make sure that the pedestrian signal can be opened formaintenance. TM467.

o Make sure crosswalk lines up with poles that have pedestrian indications.

Typical Sources of Info: Specs: 02925.65 Std. Dwg: TM467 Plan Sheets: YES Blue Sheet/Green Sheet Info: pg. 47

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Pedestrian Signals & Push-Button Installation


o Verify that pole has been drilled at proper location. See Pole Entrance Chartfor mounting orientation.

o Verify direction of directional arrows on H frame. TM467 & 00990.43(a).

o Housing, doors and visors shall be powder coated aluminum orpolycarbonate. Blue Sheets & 02925.65(b) & (c).

o Pedestrian signal heads consist of a one‐section housing and use LEDhand/man or LED countdown hand/man modules. 02925.65(a) & (b).

o Push‐buttons are installed in a one‐piece aluminum ‘H’ extrusion whichincludes the legend. 02925.66(c).

INSTALLATION

o Bolt clamshell to pole, draw wiring from pole & connect to contact terminals.

o Bolt 'H' Frame to pole, draw wiring from pole & connect to contact terminals.


o Use LED only for pedestrian signals. 02925.65(a).

o Push buttons shall be tamper‐proof. 02925.66(d).

o Verify angle of crosswalk before mounting head & button.

o Verify that signal head covers are installed over the pedestrian signals untilthe signal is turned‐on. 00990.42(g).

o Verify the mounting height of push button is 3’6” above the paved surfacenear the pole (measured from the center of the push button). TM450,TM452, & TM458.

o Verify that the A.D.A. Reach distance for the pushbutton (from the face ofcurb to face of pedestrian push button) is 24” or less. TM458.

o Verify the mounting height of the pedestrian signal is 7’ to 7’6” above thepaved surface near the pole (measured from the bottom of the pedestriansignal). TM450 & TM452.

Typical Sources of Info: Specs: 00990.42(d), 00990.43(a), & 002925.65 Std. Dwg: TM467 Plan Sheets: YES Blue Sheet/Green Sheet Info: pgs. 46 & 50

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Vehicle Signal Installation Vehicle signals are comprised of individual signal face sections configured to serve any particular intersection. 02925.64.


o Determine type of signal head to be installed. Plan Sheets & TM460.

o Install hardware onto span wire, or install hardware onto signal head formast arm/pole mounts.

o Install tether clamp hardware to bottom of signal for span wire mount.

o Vehicle signal shall be aluminum powder coated ‘flat black’ or polycarbonate(head, visor, and backplate). 02925.64(d) & (e).

o Indications shall be LED with clear lenses. 02925.64(a).

o All hardware and fasteners shall be stainless steel. 02925.62(a).

INSTALLATION

o Suspended from span wires with hangers, conduit nipples, and tri‐studadapters. See pg. 133.

o Mounted to mast arms and poles with adjustable brackets. See pg. 136.

o Verify correct vertical clearance between the bottom of the equipment andthe pavement is 18’ minimum to 19’ maximum. TM450 & TM452.


o Install back plates on all signal heads. 00990.42(a).

o Cover signal heads until signal is activated. 00990.42(g).

o Install bottom hole plug and drill a ¼” drain hole in bottom plug. 02925.64.

o Verify that signal head covers are installed over the signal heads until thesignal is turned‐on. 00990.42(g).

Typical Sources of Info: Specs: 00990.42, 02920.51, 02925.51, & 02925.64 Std. Dwg: TM460 & TM462 Plan Sheets: YES Blue Sheet/Green Sheet Info: pgs. 34, 60 & 61

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Programmed Signal Head & Louver Installation Programmed signal heads and geometrically programmed louvers are designed to selectively limit the visibility zone. A common use is for intersections that are too close together (to restrict visibility to the other signal location).


o Shim spanwire hanger so as to better restrict movement which could varythe visibility zone. TM463.

INSTALLATION

o Installation is essentially the same as for standard signal heads. See pg. 142.

o Program (aka mask of portions of the lens) the head before placing the signalinstallation into operation. This is typically done during the signal turn‐onwith assistance from the Region Signal Operations Engineer.

o Geometrically programmed louvers are used inside the visor of a standardsignal head.


o Programmed signal heads are the same as standard signal heads, except thatprogrammed signal heads use cutaway visors. 00990.42(c).

Typical Sources of Info: Specs: 00990.42(c) Std. Dwg: NO Plan Sheets: YES Blue Sheet/Green Sheet Info: NO

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Sawcutting Detector Loops Sawcutting detector loops provides a slot into which the DUCTED XHHW loop wires are installed.


o Mark out loop locations and loop wire returns. 00990.43(b)(3).

o Loop wire returns cannot be routed through adjacent loops.

INSTALLATION

o Sawcuts shall be at least ½” wide. 00990.43(b)(1) .

o Sawcuts shall be deep enough to allow min. 2” cover over all wires placed inslot (Deeper for existing Open Graded Mix). TM475.

o Flush sawcut with high pressure water stream before cuttings dry, blow outwater and debris with high pressure/volume air, check the entire slot for anyforeign debris, dry slot thoroughly with air or use vacuum/extractor system.00990.43(b)(1).


o Detector loop installations are the most failure‐prone portion of a signal.Careful construction according to specifications greatly reduces this failurerate.

o Round corners to prevent insulation damage.

o Check thoroughly for rock shards in bottom of sawcut.

o Install PVC sleeve pavement joint and crack crossings as per TM475.

o Pavement too thin to obtain cover, consult engineer of record for options.

o Do not sawcut and seal NEW open graded mix, install in base lift AC.00990.43(b)(1) & TM475.

o For EXISTING open graded mix, see TM475.

o Avoid sharp corners for loop wire returns. Round off all corners, NO MORETHAN 90 AT ANY ANGLE POINT. TM475 & 00990.43(b)(1).

Typical Sources of Info: Specs: 00990.43(b) Std. Dwg: TM475 Plan Sheets: NO Blue Sheet/Green Sheet Info: pg. 41

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Detector Loop Wire Installation PRIOR TO INSTALLATION

o Recheck sawcut for adequate width & depth.

o Recheck sawcut for foreign debris.

INSTALLATION

o Press loop wire into sawcut using a blunt, non‐metallic tool. Do not forcewire; The No. 14 AWG wire with duct should slip effortlessly into a ½” wideslot. If it doesn't, find out why, before duct or wire insulation is damaged.00990.43(b)(3).

o If two (or more) loops are to be installed in series, each pair of loop wiresmust return to the junction box before connecting loops in the series.TM475

o Wedge 1” lengths of backer rod into all sawcuts as loop wire hold‐downs.Hold‐downs should be placed no more than 12” apart and 6” from anycorners. 00990.43(b)(3).

o Test (megger) each loop 1.) Before splicing and sealing 2.) Before splicingafter sealing and 3.) After splicing and sealing. Contractor shall provide areport with data for each phase of testing. 00990.43(b)(5).


o Installing detector loop wires requires good practices and great care to avoiddamage which is not readily apparent.

o Detector loops are failure‐prone. Loops may function initially, then failmonths later when moisture intrudes through minor damage to the wireinsulation.

o All loops are to be wound clockwise. Five turns of wire is standard (or asshown on plan sheets). TM475.

o Loops located more than 500 feet from the controller cabinet may requiremore than 5 turns of wire. Plan Sheets.

o Twisted pairs in a too‐narrow slot can hang up requiring excess force toproperly seat in bottom of sawcut.

o Avoid kinking or deforming ducted wire.

o Loop wire returns are twisted 4‐6 turns per foot from loop to the splice in thejunction box. 00990.43(b)(3) & TM475.

Typical Sources of Info: Specs: 00990.43(b) Std. Dwg: TM475 Plan Sheets: YES Blue Sheet/Green Sheet Info: pgs. 41 & 48

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Loop Wire Entrance Installation The Loop wire entrance provides loop wire access to junction box conduit stubs. In the event of a loop failure, the loop can be re‐cut into these entrance points. There are two types of wire entrances:

1. PVC CONDUIT OPTION‐6” PVC conduit sleeve with AC cold mix cap/seal.

2. SAND POCKET OPTION‐6” max. opening cut into pavement, filled with sandand capped with AC cold mix.


o Verify which option to install. Plan Sheets.

o Sand pocket option: sawcut 6”x6” maximum opening or 4” minimumdiameter core drill opening. TM480.

o Take care not to damage conduit stub.

INSTALLATION

o PVC Option: center conduit sleeve in hole and fill around box or sleeve withhard, non‐flexible epoxy (not loop sealant). TM480.

o PVC Option: After epoxy cures, sawcut loop wire slots through epoxy andPVC sleeve/box.

o After installing wires, seal conduit with approved sealer, fill with sand andcap with cold mix AC. TM480.


o Improperly sealed sawcut into sleeve or pocket may allow loop sealantmigration into the conduit.

o Cap loop wire entrances with cold mix AC, not loop sealant. TM480.

Typical Sources of Info: Specs: NO Std. Dwg: TM480 Plan Sheets: YES Blue Sheet/Green Sheet Info: pgs. 39, 40, 41, & 48

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Sealing Detector Loops PRIOR TO INSTALLATION

o Be sure backer rods are in place. 00990.43(b)(3) & TM475.

INSTALLATION

o Place sealant directly into sawcut, using manufacturer’s recommendations.00990.43(b)(3).

o High temperature sealants must be placed in lifts to avoid heat damage toinsulation. 00990.43(b)(3).

o Surface of sealant should be within 1/8” of pavement surface withoutprotruding. 00990.43(b)(3).

o Surface of sealant is installed ½” below existing Open Graded Mix AC.00990.43(b)(3).



o Use only QPL listed sealants. Loop sealants shall be proportioned, mixed, andinstalled in accordance with manufacturer recommendations. 00990.10.

o On sloped sections, duct tape can be used to contain sealant in sawcut.Remove tape after sealant is fully cured. 00990.43(b)(3).

o If sealant runs or puddles on pavement surface, discontinue operation untilcontractor corrects his placement method.

o DO NOT QUICK COOL SEALANT WITH WATER. 00990.43(b)(3).

o Maintain clean and DRY sawcut before sealing.

o DO NOT seal loops at temperatures below 40F (as per manufacturerinstructions).

o If sealant is NOT installed ½” below existing open graded pavement surfacewater dams may form causing puddles or ice patches.

Typical Sources of Info: Specs: 00990.43(b) Std. Dwg: TM475 Plan Sheets: NO Blue Sheet/Green Sheet Info: pg. 8 (Backer Rod and Sealant from QPL)

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Preformed Detector Loop Installation Preformed detector loops are typically used in thin pavement areas and concrete surfaces. They are sealed systems from loop to junction box.


o Mark out loop locations and loop wire return to first junction box.

INSTALLATION

o Sawcut pavement for loop trench, clean trench bottom and sides as forstandard loop slots. Place preformed loop and return in sawcut and bed withsand to bottom of adjacent surfacing.

o Repave sawcut with material matching adjacent surfacing.

o They may be installed during the paving operation in the base lift of AC.


o Preformed loops to be poured into bridge decks (or P.C.C. pavement) shouldbe supported throughout at 2”‐4” below finish grade (See Bridge plans forfurther details).

o Test loops before backfilling.

o ALL preformed loops should be marked for direction wire is wound and INand OUT wires.

o We are now accepting a number of new systems; hydraulic hose, PVCconduit etc. consult designer when new systems are called for by plans.

Typical Sources of Info: Specs: NO Std. Dwg: NO Plan Sheets: YES Blue Sheet/Green Sheet Info: pg. 48

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Loop Wire Splice Installation Loop wire splices are made between pairs of loop wires (loops wired in series). They are also made between loop wires and loop feeder cable.


o Remove outer jacket of loop feeder cable, cut & remove drain wire andwoven shield to 4” to 6” back of intended splice. 00990.43(b)(4).

INSTALLATION

o Remove insulation from conductors, install screw on silicon grease filled wireconnector, install black plastic self‐locking straps, turn back wire connectors,insert into two piece plastic enclosure filled with silicon grease. TM475.

o Label both ends of loop feeder cable and loop wires with loop number.TM475.



o Do not ground the shield or drain wire in J.B.

o All splices for permanent installations must be made inside junction boxesnot loop access. TM475.

Typical Sources of Info: Specs: 00990.43 Std. Dwg: TM475 Plan Sheets: NO Blue Sheet/Green Sheet Info: pgs. 39, 40 & 41

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Fire Preemption System Installation


o Examine physical layout of intersection to ensure proper placement ofdetectors.

INSTALLATION

o Mount detector unit using appropriate method dependent upon placement(span wire or mast arm). Plan Sheets & TM465.

o Connect fire preemption cable to controller cabinet with a single, unsplicedlength of fire preemption cable. 00990.46.


o Remember to knock out appropriate weep hole. TM465.

o Pole mounted detector units must be mounted at least 19’ above roadwaysurface.

o One‐channel detectors may have two input tubes. Aim both at 1000’approach point (See manufacturer’s recommendations).

o Cable is never spliced and bypasses terminal cabinets. 00990.46.

Typical Sources of Info: Specs: 00990.46 Std. Dwg: TM465 Plan Sheets:YES Blue Sheet/Green Sheet Info: pgs. 78 & 79

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Luminaire Installation


o Plans specify luminaire arm length and luminaire type, and wattage.

o Locate and verify pole position.

o Wiring for illumination is not routed through the controller cabinet. PlanSheets.

o Service cabinets for signals with illumination normally include a test switch.TM485.

o Mount photo electric cell as per 00970.43. (20’‐36’ up pole).

INSTALLATION

o Luminaires must be installed level. If roadway profile grade is greater than 4percent, rotate luminaire on arm so side‐to‐side so position of leveling pad isparallel with roadway grade. 00970.44.

o Mark lamp base with month & year installed. 00970.44(b).

o Support conductors with strain relief at top of pole.

o Some local agencies use a photocell on each luminaire rather a systemphotocell.


o If a pole location is changed more than 6’ laterally or 3’ perpendicular,consult ENGINEER OF RECORD. Luminaire or arm length may need to bechanged.

o Luminaires attached to signal poles are shown on the signal plans. Stand‐alone luminaires are shown on the Illumination Plan Sheets.

Typical Sources of Info: Specs: 00970 Std. Dwg: TM650, TM660, & TM465 Plan Sheets:YES Blue Sheet/Green Sheet Info: pgs. 62, 63, & 64

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Service Cabinet Installation


o Verify the service is in a safe and protected area.

o Verify the BMC is located 10 feet or more from the controller cabinet.TM485.

INSTALLATION

o Wire from the service cabinet to the controller cabinet is installed in aseparate conduit. Wire typically consists of two No. 6 AWG XHHW wiresand a bond wire. Plan Sheets.

o Do not route illumination circuit wiring through controller cabinet. PlanSheets.

o Install 2 ground rods 6’ minimum apart in JB/1’s, as per the NEC. Install PVCconduit between the JB and BMC. TM485.


o Contractor obtains the required permits and arranges for utility to inspectpower service. 00960.70.

o Refer to section “Electrical Service (Power Source)” on page 89.

o NEVER mount service equipment on controller cabinets.

o Check the service cabinet for damage to galvanizing and/or powder coating,repair as needed.

o Check the meter base for damage to powder coating, repair or replacecabinet if damaged coating cannot be repaired.

Typical Sources of Info: Specs: 00960.49, 00990.41, & 02925.40 Std. Dwg: TM485 Plan Sheets:YES Blue Sheet/Green Sheet Info: pg. 52

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Model 332 Controller Cabinet Installation Model 332 controller cabinets are specified for most signal installations.


o Install the riser frame to new foundation. TM482.

o Verify that the ground rod is in place. TM482.

o Verify the controller cabinet is located 10 feet or more from the servicecabinet. TM482.

o All traffic signal control equipment must be submitted for physical,functional, and environmental testing. 00990.70(a).

o After testing, the control cabinet will be released to the contractor forinstallation. 00990.70(e) & (f).

o The TSSU will deliver and install all internal control equipment at day of turn‐on. 00990.70(f).

INSTALLATION

o Install building paper gasket between riser frame and foundation. Installnon‐hardening water‐tight seal between riser frame and controllercabinet.TM482.


o Ground rod is installed inside controller cabinet in conduit area. TM482.

o Slack wire coiled neatly in riser frame at bottom of cabinet. 00990.40(a).

o Verify controller cabinet is in a protected area, behind pole and away fromtraffic.

o Metal pole bollards near the controller cabinet may be shown on plans (toprotect the cabinet from low‐speed vehicle strikes; i.e. Cabinet located neara parking lot).

Typical Sources of Info: Specs: 00990.70, & 02925.40 Std. Dwg: TM482 Plan Sheets:YES Blue Sheet/Green Sheet Info: pg. 68

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Model 336s Controller Cabinet Installation Model 336s controller cabinets are pole mounted cabinets typically used for temporary signal installations.


o Check to see that cabinet bottom is attached.

o All traffic signal control equipment must be submitted for physical, functionaland environmental testing. 00990.70(a).

o After testing, the control cabinet will be released to the contractor forinstallation. 00990.70(e) & (f).

o The TSSU will deliver and install all internal control equipment at day of turn‐on. 00990.70(f).

INSTALLATION

o Mount cabinet onto pole with Nom. 1 ½” wide galvanized steel or stainlesssteel bands. TM455.


o Intake vent must be screened and cooling fan operational for controller tofunction properly.

o Maintain access to cabinet when used at a temporary signal installation

o DO NOT locate controller cabinet in path of pedestrians. Locate on side ofpole away from traffic. Pole Entrance Chart.

Typical Sources of Info: Specs: 00990.70, & 02925.40 Std. Dwg: TM455 Plan Sheets:YES Blue Sheet/Green Sheet Info: pg. 68

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Field Inspection & Signal Turn-On PRIOR TO TURN-ON

o Coordinate with Region Traffic, Agency Electricians, TSSU Signal techs, andthe Contractor to establish the Field Inspection and Turn‐on schedule.

o The Agency Electricians will perform a Field Inspection.

o Ensure the Contractor completes the “punch list” items provided by theAgency Electrician’s Field Inspection.

DAY OF TURN-ON

o Contractor is required to be present during the signal turn‐on to un‐bagsignal heads and correct any errors. 00990.70(h).

o Flaggers and associated TP&DT should be on‐site and ready. Turning‐on anew signal without flaggers may be possible, but turning‐on a re‐built signalalways requires flaggers.

o Region Traffic (or the maintaining agency) provides the signal timing.

o Traffic Signal Services Unit will bring and install all of the components (thathave been tested and approved) inside the controller cabinet. 00990.70(f).

o Note the date and time of signal turn‐on. After traffic signals are turned onand operating as designed (or in some cases upon project completion), theagency responsible for maintenance will assume operation and maintenanceof the signal (see 00990.70(h)). The Contractor then starts the warrantyperiod for their workmanship on the project (see 00990.75).


o Signal turn‐on’s on a Friday or the day before a holiday are stronglydiscouraged.

o TURN‐ON DOES NOT CONSTITUTE FINAL APPROVAL. 00990.70(h).

o Note the required advance notice timeframes. 00990.70(g) & (h).

o Ensure that all striping and signing (either temporary or permanent) is inplace, such as stop bars, crosswalks, lane lines, lane use arrows, “SignalAhead” and “New Traffic Pattern Ahead” signs, lane use signs, etc. . Stripingmay be installed up to two weeks prior to scheduled signal turn‐on date.

o Ensure that any inappropriate/conflicting signing (STOP signs, “stop ahead”signs) or striping is promptly removed or covered up.

Typical Sources of Info: Specs: 00990.70, & 00990.75 Std. Dwg: NO Plan Sheets:NO Blue Sheet/Green Sheet Info: NO

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Final Clean-Up & Final Inspection When the signals on the project have been successfully turned‐on and all work (including punch list items) and clean‐up has been satisfactorily completed, the project is ready for final inspection (see 00150.90). Region Traffic and Agency Electricians (or the agency responsible for maintenance) should be included in the final inspection.

Upon completion of the work installing the traffic signal, and before acceptance of the project, the Contractor must clean and remove all rubbish and equipment on the highway right‐of‐way which is a result of the contract work. See 00140.90. For traffic signal installations, this typically includes excess excavated material resulting from the construction of boring pits, pole foundations, and conduit trenches. All excavations should be finished to the existing contours of the ground‐line surrounding the work area.

All waste materials must be disposed of at an approved location. See 00290.20(c). Disposing of these materials on property adjacent to the highway will not be acceptable unless approved by the Project Manager.

As Constructed Drawings Once the signal installation has been accepted, as constructed (red line, not modified CADD) drawings will need to be made by the inspector and sent in with the semi‐final records. ANY part of the installation of the traffic signal that differs from the original design needs to be noted so that others will have accurate information as to how it was built. Especially important to note are changes in:

o location of junction boxes

o vehicle signal heads

o conduit runs

o wiring

o pole locations

o Utilities

The changes noted on the drawings need to be detailed/complete enough to accurately amend the original plans. The as constructed drawings you submit will be reviewed by the Traffic‐Roadway Section and the final mylars will be altered to reflect construction changes.

Traffic Roadway Section will send copies of the final mylars to the appropriate region and district offices and electrical crew for their records. They rely on the drawings to be accurate and to aid them in the maintenance of the traffic signals and illumination.

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Requesting Changes to Standard Drawings and Specifications

If an error, omission, or need for clarification is discovered in the standard drawings or specifications, please let us know so we can address the issue in a future update. If you have a great idea, we want to hear it. Feedback from the field is EXTREMELY important for producing and maintaining quality drawings and specifications.

We want to hear from you!

To request changes to the Standard Drawings, use the following form:

http://www.odot.state.or.us/ffp/hwy/roadway/request‐for‐std‐dwg‐change.htm

To request changes to the Specifications, use the form on the following web site:

http://www.oregon.gov/ODOT/HWY/SPECS/pages/spec_change_request.aspx

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Reading Plan Sheets Standard drafting symbology is used in signal design to represent common appurtenances, providing valuable information to the user without using any text. As such, the user should become familiar with the standard symbols and line styles that are used for signal design.

Bubble notes are used in conjunction with the standard drafting symbology to provide the specific information about the installation. The bubble notes have been designed to be “intelligent”, such that an experienced user will be able to read the signal plan sheets without much assistance from the bubble note legend text. For example:

Bubble notes use abbreviations for equipment that can be definedentirely by the bubble note legend text :

Bubble notes use abbreviations AND variables (shown in pink) forequipment that must be further defined by where/how it is used:

Regardless of experience level, it is always advised to read the bubble note legend text at least once because changes in text may occur. For example:

VS.

If there is conflict between symbology and the bubble note, contact the Engineer of Record for clarification.

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Poles are labeled consecutively for entire project

Signal head type (2) & mount type (B) info on leader‐line

Sign mount type (AB) info on leader‐line

Lane Dimension Head ‐ See pg. 91

On this Type 4 signal pole: A 40’ mast arm, two pedestrian indications, two push buttons, one terminal cabinet, and one sign.

Install phase 4 vehicle signal

Replace variables in text when reading: “Install channel (D), (1) barrel fire preemption detector unit”

Detailed on other plan sheet: not paid under traffic signal bid item

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In this 1½” conduit: 1 No. 8 AWG THWN wire (common) 13 No. 14 AWG THWN wires (3 spare wires

for phase 4 are inclusive to this wirecount)

4 conduits enter this junction box: Two conduits defined on

detector plan, and Two 1 ½” conduit

2 conduits in this trench (one 1½” and one defined on the detector plan)

3 spare wires for phase 4 are inclusive to the number of wires listed below (13 No. 14 AWG)

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In this 1½” conduit: 2 No. 6 AWG XHHW wires. Typical wiring between the BMCL & controller cabinet. (Bonding wire also required by specifications – not shown on plans)

In this 1½” conduit: 4 No. 10 AWG XHHW wires(for illumination fixtures)

3 No. 12 AWG THHN wires(for photo electric cell)

Illumination wiring ALWAYS bypasses the controller cabinet

Photo electric cell located on pole No. 3

There are 4 conduits in this trench. three conduits carry all the wiring going directly into the controller cabinet. One conduit is for future use (CS).

Power Source

Conduit and wiring from the power source to the BMCL is always according to the requirements of the power company (permit)

Wiring for photo electric cell

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Door orientation is shown on the plan sheet by the controller cabinet symbology

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Any changes to temporary lane use may require modification to the signal indications or phasing. ALWAYS contact EOR for

The signal head type (2) is located on the leader‐line.

This portion of span wire (between the pole and the signal indication) has: 6 control cables

with 7 No. 14AWG conductors

Two firepreemptionfeeder cables

This portion of span wire (between the pole and the signal indication) has: 3 control cables with 7 No. 14

AWG conductors one fire preemption feeder cable

Permanent signal symbology may be shown to provide reference

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Wood poles are non‐standard. They are designed by the contractor and submitted to ODOT for review and approval.

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Loop No. 12 for phase 1

2 pairs of loop wires (one from loop no. 13 & one from loop No. 14) are entering the 2” sand pocket block out.

In the 3” conduit there is a total of 15 loop feeder cables (2+1+4+2+1+5)

1 pair of loop wires (from loop no. 12) is entering the 2” sand pocket block‐out

1 loop feeder cable for phase 1 (for loop no. 12)

Replace variables in text when reading: “Install (2) phase (1) loop feeder cables”

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Lines represent loop feeder cable

Loops are wired in series. (Splice inside the junction box)

Total of 15 Loop feeder cables entering the controller cabinet (Count the number of lines crossing into the controller cabinet). Two loop feeder cables for phase 1.

Loops are wired in series. (Splice inside the controller cabinet)

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A

ADA Reach Distance ∙ 132 Adjustable Vehicle Signal Bracket ∙ 59,

128 Aluminum Sign Mounting Framework ∙

33 Anchor Plate ∙ 96 Anchor Rod ∙ 96 As‐Constructed Drawings ∙ 161 Audible Pedestrian Signal ∙ 82

B

Backer Rod ∙ 8, 140, 144 Backplates ∙ 34, 134 Battery Back‐up System ∙ 83 Beacon Assemblies ∙ 84 Blue Sheet Material Info ∙ 11–15 BMC ∙ See Service Cabinet Bonding & Grounding

Bond Wire ∙ 16 Bonded Bushings ∙ 17 Ground Rod & Clamp ∙ 25 Installation ∙ 108

Bushings ∙ 17, 21

C

Cabinets Controller Cabinet ∙ 68, 156, 158 Reading Plan Sheets ∙ 168, 169 Riser Frames ∙ 51, 156 Service Cabinet ∙ 52, 154 Terminal Cabinet ∙ 55, 118

Cable Ties ∙ 18 Casings ∙ 96 Catalogue Cut Sheets ∙ See Blue or

Green Sheet Material Info Clamshell ∙ See Pedestrian Signal

Mount Color Code ∙ 110, 124 Communications Bracket ∙ 77 Conduit

Bushings ∙ 17, 21 Conduit Body ∙ 22 Conduit Hub ∙ 22, 118 Conduit Plug ∙ 23 Cover Requirements ∙ 98 Elbows ∙ 100 Expansion Fitting ∙ 24, 100 Future Use ∙ 100 In Foundations ∙ 96, 100 In Junction Boxes (Risers) ∙ 100 Installation ∙ 100 Metallic ∙ 19 Non‐Metallic ∙ 20 Reading Plan Sheets ∙ 167 Trench Backfill ∙ 106 Trenching ∙ 98 Underground Warning Tape ∙ 32,

106 Conflict Monitor ∙ 70 Contacts ∙ 2 Control Cable ∙ 35, 110, 124 Controller ∙ 69 Controller Cabinet ∙ 68, 156, 158, 168,

169 Wire Slack Requirement ∙ 110

Controller Cabinet Components Communications Bracket ∙ 77 Conflict Monitor ∙ 70 Controller ∙ 69 Detector Amplifier ∙ 73 Fiber Optic Connection Patch Panel

∙ 85Flasher ∙ 72 GPS Time Sync Module ∙ 80 Isolator (DC and AC) ∙ 74 Load Switch ∙ 71 Modem ∙ 75 Relay (FTR) ∙ 76

Coordination with Others Agency Electrians ∙ 3, 4, 7, 160, 161 Field Inspection ∙ 7, 160 Final Inspection ∙ 161 Permits ∙ 4 Region Traffic ∙ 3, 4, 7, 160, 161 Signal Turn‐On ∙ 160 Supplemental Inspection ∙ 7 TSSU ∙ 3, 65, 160

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D

Detector Amplifer ∙ 73 Drafting Symbology ∙ 164–65

E

Electrical License ∙ 5–6 Electrical Permits ∙ 4, 88 Electrical Service ∙ 88 Engineer of Record ∙ 87 Expansion Fittings ∙ 24, 100 Eyebolt ∙ 36, 120, 122

F

Fiber Optic Connection Patch Panel ∙ 85

Field Inspection ∙ 7, 160 Final Inspection ∙ 161 Fire Preemption Systems

Installation ∙ 150 Preemption Detector (Field) ∙ 79 Preemption Interface (Cabinet) ∙ 78

Flasher ∙ 72 Foundations ∙ 96

Loading Foundation ∙ 114, 116

G

GPS Time Sync Module ∙ 80 Green Sheet Material Info ∙ 65–67 Ground Rod & Clamp ∙ 25 Grounding ∙ See Bonding & Grounding

H

H‐Frame ∙ See Push Button

I

Illumination In‐Line Fuse Holder ∙ 62 Installation ∙ 152 Photoelectric Cell ∙ 63, 152 TC Cable ∙ 64

In‐Line Fuse Holder ∙ 62 Inspection ∙ See Coordination with

Others Interconnect Cable ∙ 37 Isolator (DC and AC) ∙ 74

J

Junction Boxes Cast Iron ∙ 26, 104 Concrete ∙ 27, 102 Hand Hole ∙ 29 Hybrid ∙ 28, 102 Location ∙ 94 Wire Slack Requirement ∙ 110

L

Lane Dimension Head ∙ 90, 166 LED Modules ∙ 38 Load Switch ∙ 71 Loop Detection

Backer Rod ∙ 8, 140, 144 Detector Amplifier ∙ 73 Loop Feeder Cable ∙ 39, 148 Loop Sealant ∙ 8, 144 Loop Splice ∙ 40, 148 Loop Wire ∙ 41, 140 Loop Wire Entrance ∙ 142 Preformed Loops ∙ 48, 146 Reading Plan Sheets ∙ 172, 173 Sawcutting Detector Loops ∙ 138 Sealing Detector Loops ∙ 144 Testing & Reports ∙ 140, 144, 148

Louvers ∙ 136

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M

Materials General Info ∙ 8 Messenger Cable ∙ 42, 120 Meter Base ∙ 43 Modem ∙ 75

P

Pedestals Pedestrian ∙ 44 Vehicle ∙ 45

Pedestrian Signals & Mounts ADA Reach Distance ∙ 132 Audible Pedestrian Signals ∙ 82 LED Modules ∙ 38 Mounting Height Requirements ∙

132 Pedestrian Pedestals ∙ 44 Pedestrian Signal ∙ 46, 132 Pedestrian Signal Mount ∙ 47, 130 Push Button ∙ 50, 132 Signal Head Covers ∙ 53, 132

Permits ∙ 4, 88 Photoelectric Cell ∙ 63, 152 Poles

Anchor Plate ∙ 96 Anchor Rod ∙ 96 Foundations ∙ 96 Loading Foundation ∙ 114, 116 Mast Arm Pole Installation ∙ 116 Pole Location ∙ 90, 92 Reading Plan Sheets ∙ 166 Strain Pole Installation ∙ 114 Submittals ∙ 8 Wire Slack Requirement ∙ 110 Wiring Poles ∙ 124 Wood Pole Installation ∙ 112

Power Source ∙ See Electrical Service Preformed Loops ∙ 48, 146 Pre‐Qualified Materials ∙ See Materials

General Info Programmed Signal Head ∙ 136 PTR Signs ∙ 49 Push Button ∙ 50, 132 PVC Conduit Option ∙ See Loop Wire

Entrance

Q

QPL ∙ See Materials General Info

R

Reading Plan Sheets ∙ 163–73 Rebar Size Number ∙ 96 Relay (FTR) ∙ 76 Riser Frames ∙ 51, 156 Risers ∙ See Conduit In Junction Boxes

S

Sand Pocket Option ∙ See Loop Wire Entrance

Service Cabinet ∙ 52, 154 S‐Hook ∙ 36, 122 Signal Head Covers ∙ 53, 132, 134 Signs

Aluminum Sign Mounting Framework ∙ 33

PTR ∙ 49 Span Wire Installations

Cable Ties ∙ 18 Eyebolt ∙ 36, 120, 122 Messenger Cable ∙ 42, 120 Reading Plan Sheets ∙ 170, 171 S‐Hook ∙ 36, 122 Span Wire Hanger ∙ 54, 126 Stabilizer Cable ∙ 56, 122 Strandvise ∙ 36, 120, 122 Tether Cable ∙ 56, 122 Tether Clamp ∙ 57, 122 Tri‐Stud Adaptors ∙ 58, 126 Turnbuckle ∙ 36, 122

Splicing ∙ 110, 124, 148, 150 Stabilizer Cable ∙ 56, 122 Strandvise ∙ 36, 120, 122 Supplemental Inspection ∙ 7

T

TC Cable ∙ 64

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Telephone Hook‐Up ∙ 89 Terminal Blocks ∙ 30, 118 Terminal Cabinet ∙ 55, 118 Testing & Reports for Loop Wire ∙ 140,

144, 148 Tether Cable ∙ 56, 122 Tether Clamp ∙ 57, 122 Tri‐Stud Adaptors ∙ 58, 126 Turnbuckle ∙ 36, 122 Turn‐on ∙ 160

U

Underground Warning Tape ∙ 32, 106

V

Vehicle Signals & Mounts Adjustable Vehicle Signal Bracket ∙

59, 128 Backplates ∙ 34, 134 Head Types ∙ 134 Lane Dimension Head ∙ 90, 166 LED Modules ∙ 38 Louvers ∙ 136 Programmed Signal Head ∙ 136 Reading Plan Sheets ∙ 166 Signal Head Alignment ∙ 90 Signal Head Covers ∙ 53, 134 Span Wire Hanger ∙ 54, 126 Tri‐Stud Adaptors ∙ 58, 126 Vehicle Pedestal ∙ 45 Vehicle Signals ∙ 61, 134 Vertical Clearance ∙ 126, 128, 134 Visors ∙ 60

Vertical Clearance of Overhead Equipment ∙ 126, 128, 134

Video & Radar Detection ∙ 81 Visors ∙ 60

W

Wire & Cable Bond Wire ∙ 16, 108

Color Code ∙ 110, 124 Control Cable ∙ 35, 110, 124 Interconnect Cable ∙ 37 Loop Feeder Cable ∙ 39, 148 Loop Wire ∙ 41, 140 Messenger Cable ∙ 42, 120 Pulling Wires and Cable ∙ 110 Reading Plan Sheets ∙ 167 Slack Requirement ∙ 110 Splicing ∙ 110, 124, 148, 150 Stabilizer Cable ∙ 56, 122 TC Cable ∙ 64 Tether Cable ∙ 56, 122 THWN ∙ 31 Wiring Poles ∙ 124 XHHW ∙ 31

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Documents

2014 - State Library of Oregon: State Employeeslibrary.state.or.us/repository/2014/201403281308355/index.pdfii ODOT Inspector’s Manual for Signal Construction January 2014 ... January