Lighting Super Spec. · Web viewProvide the luminaire ring as a totally enclosed wire way, which serves as a wire raceway for all electrical connections to the lights. It must be

“2018 SAMPLE” HIGH MAST LIGHTING SPECIAL PROVISIONS (November 16, 2017)This “sample” set of Lighting System Special Provisions will require editing (add, delete, modify, update, etc.) prior to use on a specific project. Some of the paragraphs included in these special provisions are project specific and may not be required on every project. Use the language when appropriate based on the plan and as directed in RED text. All RED text must be removed from the special provisions prior to the special provisions being submitted for project letting.

DIVISION SL

The following paragraph is required for all MnDOT or State Aid project contracts. All RED text must be removed from the special provisions prior to the Special Provisions being submitted for project letting

SL-1 (2104) REMOVING MISCELLANEOUS STRUCTURES

SL-1.1 DESCRIPTION

This work consists of removing or salvaging miscellaneous structures in accordance with the provisions of MnDOT 2104 and the following:

Store and protect salvaged items from damage by the Contractor until ready for reinstallation or delivery to storage. Repair or replace any damage resulting from the Contractor's operations, like in kind, or better to that condition existing, before the salvage operation.

Paint on existing lighting service cabinets and other painted items may include lead in the paint.

If this is the case, the Contractor is responsible for the proper handling, transportation, and disposal of these materials as hazardous waste. The handling, transportation, and disposal of these items must be in accordance with Occupational Safety & Health Administration (OSHA) and the Minnesota Pollution Control Agency (MPCA) regulations.

The Contractor certifies being familiar with, and will comply with, the applicable requirements in OSHA 29 CFR 1926.62 and Minnesota Rules Chapter 5206, 7025, 7035, 7045 relating to disposal and the removal of these lead painted materials.

Submit to the Engineer a completed "Contractor Certification of Disposal" form that is included elsewhere in these Special Provisions.

SL-1.2 MATERIALS

(None)

SL-1.3 CONSTRUCTION REQUIREMENTS

A. Remove Light Foundation

Item 2104.509 (Remove Light Foundation).Remove the in place light foundation as shown on the Plan in accordance with Item 2104.509 (Remove Light Foundation).

1-SL


Backfill all holes remaining from the removal of the light foundation in accordance with MnDOT 2545.3C.

B. Remove Direct Buried Lighting Cables

Item 2104.501 (Remove Direct Buried Lighting Cable).Remove in- place out- of- service (abandoned) cables in accordance with Item 2104.501 (Remove Direct Buried Lighting Cable).

Removed cables are the property of the Contractor.

“Abandoned” means underground cable no longer in service and physically disconnected to a system once the new system under contract has been completed.

Where in- place out-of-service (abandoned) cables are not removed provide the following;

1. Perform a megohm meter test of each cable run in accordance with 2545.3 K.1,2. Repair damaged cable with a Direct Buried Underground Cable Splice in accordance with

2545.3G.4.b,3. Place a Department furnished locator ball on the direct buried underground cable splice before

backfilling,4. Collect and record GPS coordinates of the installed direct buried underground cable splice and

provide to the Engineer, 5. Install new handholes in accordance with 2545.3E at both ends of each cable run, 6. Expose and protect the conductors at both ends of each cable run to allow for future locating,7. Identify the cable run at both ends with a tag durable to withstand wet locations and labeled

“ABANDONED LIGHTING CABLE”,8. Collect and record GPS coordinates of each cable run at 10 ft intervals and provide to the

Engineer,9. Provide an As Built of the approximate location and linear footage of each cable run to the

Engineer, and10. Provide a one-time locate of each cable run using red paint and red locating flags with a capital

“A” inside a circle to represent abandoned facilities before final acceptance of the project.

Noncompliance of these provisions will result in suspending the Work in accordance with 1501.2.

The requirements listed are necessary for the Department to maintain its abandoned facilities in accordance with Minnesota State Law 216D.04 Subdivision 3-Locating Underground Facility; Operator and Minnesota Rules 7560.0125 Abandoned and Out-Of-Service Facilities.

The Engineer will distribute copies of the As Builts and GPS coordinates to the project file, District Traffic Office, and MnDOT’s locating office.

C. Remove Service Cabinet

2-SL


Item 2104.509 (Remove Service Cabinet).Remove the in place service cabinet as shown on the Plan in accordance with Item 2104.509 (Remove Service Cabinet).

Removed service cabinet becomes the property of the Contractor.

D. Remove Lighting Units

Item 2104.509 (Remove Lighting Unit).Remove the in place lighting units as shown on the Plan in accordance with Item 2104.509

(Remove Lighting Unit).

Disconnect wiring to removed lighting units from any lighting unit(s) remaining in place.

Removed lighting units become the property of the Contractor. Dispose of in accordance with 2104.3.C.

E. Remove Luminaires

Item 2104.509 (Remove Luminaire). Remove the in place luminaires, lamps, and ballasts located on the in place light poles as shown

on the Plan in accordance with Item 2104.509 (Remove Luminaire).

Removed luminaires become the property of the Contractor.

Dispose of removed luminaires in accordance with 2104.3.C.

F. Remove Light Foundations

Remove the in place light foundations as shown on the Plan in accordance with Item 2104.509 (Remove Light Foundation).

G. Remove Equipment Pad

Item 2104.509 (Remove Equipment Pad).

Remove the in place equipment pad as shown on the Plan in accordance with Item 2104.509 (Remove Equipment Pad).

Backfill all holes remaining from the removal of the equipment pad in accordance with MnDOT

2545.3C.

H. Salvage Service Cabinet

3-SL


Item 2104.523 (Salvage Service Cabinet).Salvage the in place service cabinet as shown on the Plan and in accordance with Item 2104.523

(Salvage Service Cabinet).

Deliver salvaged service cabinet to storage location as specified in the Contract, or as directed by the Engineer.

Repair or replace any damage to the salvaged materials resulting from the hauling operation at no expense to the Department.

I. Blank

J. Salvage Lighting Units

Item 2104.523 (Salvage Lighting Unit).Salvage the lighting units as shown on the Plan or as directed by the Engineer in accordance with

Item 2104.523 (Salvage Lighting Unit).

The lighting unit is defined in 2545.1C Definitions.

Disconnect wiring to the salvaged lighting units from any lighting units remaining in place.

Deliver salvaged lighting units to the storage location as specified herein, or as directed by the Engineer. Repair or replace any damage to the salvaged materials resulting from the hauling operation at no expense to the Department.

K. Salvage Luminaires

Item 2104.523 (Salvage Luminaire).Salvage the luminaires and lamps (if required) as shown on the Plan.

Deliver salvaged luminaires to the storage location as specified in the Contract, or as directed by

the Engineer. Repair or replace salvaged luminaires damaged from the hauling operation at no additional cost to

the Department.

L. Salvage Light Foundations

Item 2104.523 (Salvage Light Foundation).Salvage light foundations as shown on the Plan or as directed by the Engineer in accordance with

Item 2104.523 (Salvage Light Foundation).

Clean the foundations of dirt and debris before delivery to storage.

4-SL


Backfill holes remaining from the removal of the foundations in accordance with MnDOT 2545.3C.

Deliver the salvaged foundations to the storage location as specified in the Contract, or as directed

by the Engineer.

Repair or replace salvaged foundations damaged from the hauling operation at no additional cost to the Department.

M. Salvage Steel Light Foundations

Item 2104.523 (Salvage Steel Light Foundation).Salvage the steel light foundations as shown on the Plan or as directed by the Engineer.

Clean the foundations of all dirt and debris before delivery to storage.

Backfill all holes remaining from the removal of the foundations in accordance with MnDOT 2545.3C.

Deliver salvaged foundations to the storage location as specified in the Contract, or as directed by the Engineer. Repair or replace salvaged foundations damaged from the hauling operation at no additional cost to the Department.

(The following language is used for Non-Federally Funded Projects Only)All Red text must be removed from the special provisions prior to the special provisions being submitted for project letting.

N. Delivery of Salvaged Materials

Disassemble salvaged materials as specified in the Contract and as directed by the Engineer. Deliver the salvaged materials to MnDOT’s Electrical Services Section (ESS), 6000 Minnehaha Avenue, St. Paul, MN, 55111, or as directed by the ESS Stockroom, unless otherwise specified elsewhere in the Contract. Contact the ESS Stockroom (651-366-5720) at least 3 business days before delivery of the salvaged materials. Notify the Engineer before contacting the ESS Stockroom.

Obtain a salvaged material receipt from the ESS Stockroom that shows MnDOT has received the salvaged material.

Submit to the Engineer a copy of this receipt for the permanent project records.

(The following Section to be used for Federally Funded Lighting Projects Only)All Red text must be removed from the special provisions prior to the special provisions being submitted for project

5-SL


letting.

SL-1.4 (2104) HAUL SALVAGED MATERIAL

This work consists of loading and hauling materials designated for salvage and storage in accordance with the provisions of MnDOT 2104 and the following:

Disassemble salvaged materials as specified in the Contract and as directed by the Engineer. Deliver the salvaged materials to MnDOT’s Electrical Services Section (ESS), 6000 Minnehaha Avenue, St. Paul, MN, 55111, or as directed by the ESS Stockroom, unless otherwise specified elsewhere in the Contract. Contact the ESS Stockroom (651-366-5720) at least 3 business days before delivery of the salvaged materials. Notify the Engineer before contacting the ESS Stockroom.

Repair or replace salvaged materials damaged from the hauling operation at no additional cost to the Department.

Obtain a salvaged material receipt from the ESS Stockroom that shows MnDOT has received the salvaged material. Submit to the Engineer a copy of this receipt for the permanent project records.

Hauling of salvaged materials to the Department at the location specified in the Contract is paid for under Item No. 2104.601 (HAUL SALVAGED MATERIAL) at the contract LUMP SUM price which is payment in full for all costs relative to hauling the materials to, and depositing the materials, at the location specified in the Contract.

SL-2 (2545) LIGHTING SYSTEMS

This work consists of providing labor, equipment, and materials for construction of a lighting system in accordance with the applicable provisions of MnDOT 2471, MnDOT 2545, and current edition of the National Electric Code, the Plans, and the following: SL - 2.1 GENERAL

A. 2545 Definitions

Definitions are in accordance with Standard Specifications for Construction Section1103 and as follows:

1. Approved/Qualified Products List (APL).

2545 ABBREVIATIONS

D GLOSSARY OF ACRONYMS AND ABBREVIATIONSAcronyms and abbreviation used in the Contract to represent full text in accordance with 1102 “Abbreviations and Measurement Units” and as shown in Table 2545-1:

6-SL


Ensure Division S Special Provisions “As-Builts” are included in the Division S Special Provisions.This would include the pay item 2011.601.Be sure to include Pay Item 2011.601 AS BUILT to your pay item list as this will trigger the Division S Special provisions to be added.After the July 2015 Project letting date the As-Builts verbiage should automatically be included in Division S Special Provisions by MnDOT’s Project Management & Technical Support Office. Note required verbiage below in the measurement and payment section of these special provisions.All Red text must be removed from the special provisions prior to the special provisions being submitted for project letting.

SL - 2.2 MATERIALS

A. Arc-Flash Hazard Warning Labels

1. Provide 4 in H x 6 in W vinyl or polyester labels meeting the following:

1.1. White background,1.2. Orange background behind the WARNING text,1.3. Black text,1.4. Self-adhesive,1.5. Machine printed letters and numbers, and1.6. Water-resistant.

2. Figure 1 is for information and reference only.

7-SL

Table 2545-1Acronyms and Abbreviations Used

Acronym or Short Form Full Name or Meaning

APL Approved/Qualified Products List


Figure 1: Arc-Flash Warning Label – Category 1

The following paragraph should be included when the District wants Rigid Steel Conduit run from the source of power to the service cabinet when a ground mount transformer is used.All red text must be removed from the Special Provisions prior to the Special Provisions being submitted for project letting.

B. SOP Rigid Steel ConduitConduit installed from the Source of Power (SOP) to the lighting service cabinet must be RSC

NOTE:The DESIGNER MUST DETERMINE if long cable runs will require line loss calculations. In some cases the line loss may require the use of 2 AWG conductors in place of 4 AWG conductors for the long cable runs. If larger cable is required include the text below.Allow extra time as this size cable is not inventoried by any distributors.

All Red text must be removed from the special provisions prior to the special provisions being submitted for project letting.

C. Direct Buried Lighting Cable

The direct buried lighting cable must be in compliance with MnDOT 3815.2C.1 except as shown

8-SL


below:

The four individual conductors must be 2 AWG.The following paragraph should be included when the District wants to use Handholes when designing a lighting system. Delete the pulling vault paragraph below when using handholes. Do not keep both paragraphs in the special provisions.All red text must be removed from the Special Provisions prior to the Special Provisions being submitted for project letting.

D. Equipment Pad B

Provide and install a complete concrete equipment pad in accordance with MnDOT Standard Plate No. 8106, at the locations indicated in the Plan. Construct the equipment pad in accordance with MnDOT 2545.3F using concrete Mix No. 3F52.

Use the equipment pad mentioned for mounting of a lighting service cabinet. Use reinforcement bars in the foundation that conform to the requirements of MnDOT 3301.The following text is provided as the designer needs to determine the type of cabinet that needs to be used. Some electric utilities require cold sequence disconnects and others do not when 240/ 480 VAC systems are installed. The designers need to determine ahead of time the cold sequence disconnect requirements:All Red text must be removed from the special provisions prior to the special provisions being submitted for project letting.

E. Service Cabinet, Type L1 (240/480 VAC) With Cold Sequence Disconnect

Provide and install a MnDOT approved Service Cabinet Type L1 in accordance with 3850.2B with a Cold Sequence Disconnect before the meter socket on an equipment pad concrete foundation at the location shown on the Plans for supplying power to the lighting system.

The cold sequence disconnect and utility termination lugs are not required in the Xcel Energy service area unless the authority having jurisdiction requires it.

F. Service Cabinet, Type L2 (240/480 VAC)With Cold Sequence Disconnect

Provide and install a Service Cabinet Type L2 in accordance with 3850.2C with a Cold Sequence Disconnect before the meter socket on an equipment pad concrete foundation at the locations shown on the Plans for supplying power to a lighting system.

The cold sequence disconnect and utility termination lugs are not required in the Xcel Energy service area unless the authority having jurisdiction requires it. G. High Mast Lighting Unit, Type 3-100

9-SL


Provide and install Lighting Units, Type 3-100 in accordance with the details in the Plan and at the locations indicated in the Plan. Each lighting unit consists of the following:

1. A steel standard,2. luminaires (with 180 degree external light shields), 3. ballasts4. lamps5. mast head assembly6. lowering system 7. support cables8. luminaire ring assembly9. winch assembly10. portable or integral power unit

Provide all electrical components required for a complete lighting unit installation, including lightning transient suppression.

Install the lighting units, as much as possible, out of areas where water ponds.Shape the area surrounding the lighting units to provide drainage.

Provide Lighting Units, Type 3-100 with a 100 foot nominal luminaire mounting height.

Provide luminaires equipped with a 180 degree external light shield.

NOTE:The DESIGNER MUST DETERMINE if the lighting system needs external light shields. If none are required remove the purple bolded text above. If external light shields are required change the above text to normal font and black text.


1. Design

Design the lighting units in accordance with the current edition of the AASHTO "Standard Specification for Structural Supports for Highway Signs, Luminaires and Traffic Signals", and meet the following requirements:

(1.1) Compute the wind pressure (P) using the formula found in 3.8.1- Wind Pressure Equation of the Specifications. Use a wind speed of V-80 mph.

(1.2) Add the following to Table 3.8.6-1, WIND DRAG COEFFICIENTS, Cda of the Specifications:

Hexdecagonal (16 sided) Cda= 1.10 for wind speed.10-SL


2. Materials

Conform to MnDOT 2471 for Material, fabrication and erection requirements.

3. Pole Shafts

Provide 16-sided light standard pole shafts in single welded units or in telescoping sections and cold formed. If provided in telescoping sections, the number must not exceed 4 sections per pole. Uniformly taper each section from top to bottom and fabricate so that it is telescoped over the next one down without the use of field welds. The sections must overlap a minimum of one and one-half (1 ½) times the O.D. of the shaft at the location of the lap joint with full contact between facing surfaces.

Fabricate all pole shafts and base plates from high strength, low alloy, weathering steel conforming to MnDOT 3309 (min. yield strength 50,000 psi). Blast clean after fabrication meeting Steel Structures Painting Council Surface Preparation Specification number 10 near white blast. Remove oil, grease and weld splatter prior to blast cleaning. The steel will not be painted.

No field welds are permitted. Welds must be smooth and thoroughly cleaned of flux and spatter. Weld longitudinal pole seams at a uniform rate of travel and ensuring 60% to full penetration type welds. Back-up bars are permitted, and when used, use back-up bars that are continuous, contoured for full contact, and conform to the same material specification as the parent structure. It is the Contractor's responsibility to allow for possible welding distortion in the base plate and to ensure flush seating of leveling and hold-down nuts against a fully developed base plate.

When testing fillet welds, use 30% tested by magnetic particle testing methods.

Circumferential welds are subject to complete ultrasonic inspection.

Inspect one-hundred percent of the longitudinal seam welds in the slip joint area by the Ultrasonic Test Method for thicknesses 5/16" and greater and Magnetic Particle Tested using the Yoke Method for thinner materials. Inspect twenty-five percent of the remaining longitudinal seam welds by the Magnetic Particle Testing Method.

Test all welds in accordance with MnDOT 2471.3. Submit to the Engineer a report covering such testing.

Assemble the axis of the pole shafts in straight lines. Fabricate the bottom surfaces of the base plates 90 degrees to their axis. The outer surface must not be marred by careless handling and ensure it’s in a condition to uniform weathering.

Provide the pole with a high base fabricated from steel conforming to the same specifications as the shaft sections and taper through the arc of formed panels assembled by means of longitudinal

11-SL


welds. The base must attach to the shaft with 100% penetration circumferential welds and must allow ample room to house the winch, circuit breakers, etc. It must totally conceal the anchor bolts. Attach the internal base plate to the skirt by means of two circumferential fillet welds.Provide a reinforced access opening, of ample size, to allow for servicing and maintenance in the skirt. Supply a hinged door with stainless steel hinges and tamper proof fasteners to secure the opening.

The high base must also include a 10" x 15" handhole on the backside of the skirt 180 degrees from the access door.

4. Luminaires, Ballast and Lamps

Provide luminaires, ballasts, lamps, and 180 degree external light shields as individual items from the same manufacturer. As a unit, their projected area must not exceed 3.4 square feet.

Provide MnDOT approved High Mast Luminaires as indicated on the Plan.

Provide luminaires equipped with a 180 degree external light shield.

NOTE:The DESIGNER MUST DETERMINE if the lighting system needs external light shields. If none are required remove the purple bolded text above. If external light shields are required change the above text to normal font and black text.


Provide Lighting Units, Type 3-100 with 3 luminaires.

The Plan must indicate the following:1. Lamp type2. Operating Voltage3. Wattage4. Local Photo Cell control5. Lens typeAll Red text must be removed from the special provisions prior to the special provisions being submitted for project letting.

MnDOT approved High Mast Luminaires are listed on MnDOT Approved/Qualified Products Lists WEB site for Lighting:

http://www.dot.state.mn.us/products/index.html

12-SL

http://www.dot.state.mn.us/products/index.html


5. Lowering System

It is the intent of the contract to provide a lowering system that raises and lowers the luminaire ring by an internally-supported cable system and, when in the "raised" position, the luminaire ring is held by the cable system.

The lowering system consists of a two cable hoisting system consisting of a stainless steel head assembly, stainless steel luminaire ring and junction box, stainless steel winch drums and corrosive resistant winching system, with a portable or internal (one HP) 60 Hertz, single phase, 115/240 volt, reversible, AC, Totally Enclosed Fan Cooled (TEFC), continuous duty motor with built-in magnetic brake and 15 amp circuit breaker.

6. Mast Head Assembly

Provide mast head assemblies manufactured of stainless steel and that consist of a formed channel bolted to the top of the pole shaft with four stainless steel bolts, nuts and lock washers. Provide mast head assemblies covered by a hinged hood with a closed position locking mechanism.

The channel must support four galvanized cable sheaves 6" in diameter (2 for each hoisting cable) with cable keepers to ensure proper cable guidance, two cone guides and bumpers to secure the horizontal position of the luminaire ring, and a power cord sheave. Provide the sheaves with permanently lubricated bronze bearings and stainless steel axle pins.

Provide the power cord sheave made of cast aluminum with a minimum of 16" in diameter. Provide a sufficient groove in the sheave to totally embed a 1" in diameter power cord. Provide sheave groove walls straight up and down and the groove bottom rounded and smooth. Provide a cord keeper to prevent the power cord from working out of the sheave.

Provide no latches at the top of the pole, nor in the masthead assembly, to latch the hoisting cables.

7. Support Cables

Pre-form the lowering and raising stainless steel aircraft cables. Provide a winch cable with a 1/4 inch diameter minimum. Provide a 7 x 19 strand cable made in accordance with MIL-W-5424B, Amendment 1 (USAF). Provide each cable with a hoisting strength of at least 6,000 pounds. Provide the two hoisting cables continuous from the luminaire ring to the winch drum and of sufficient length to be two (2) times the length of the pole shaft plus twenty (20) feet.

“Work” the stainless steel cables by hand to remove all "reel lay" prior to being strung in a pole.

Two (2) stainless steel chains and latches must secure the hoisting cables to the base of the

13-SL


pole while in the static load position.

8. Luminaire Ring Assembly

Fabricate the luminaire ring assembly with stainless steel and the assembly must consist of the following:

a. Luminaire ring constructed of stainless steelb. Two bumper rings constructed of stainless steelc. Hoisting cable terminator cone tubes constructed of stainless steeld. Compensating springs constructed of steele. Weatherproof terminal connector enclosure constructed of stainless steelf. Weatherproof electric inlet connector for luminaire testingg. Luminaire slipfitter of the proper diameter and length, permanently installed on the

luminaire ring at the required spacing to accommodate the type and number of luminaires specified.

Provide all luminaire rings with three, four or six (as required by the by the project) 2 inch slipfitters. Provide one of the stainless steel slipfitters with welded in place 1 inch half couplings for the possible installation of FAA approved obstruction lights.

Hold the luminaire assembly firm to the masthead assembly by two (2) compression springs at the end of the hoisting cables and within the stainless steel support cable terminal tubes. The springs must compress to hold the weight of the luminaire ring assembly and the luminaires plus three hundred (300) pounds. Equip the inner portion of the ring with a PVC shock absorbing tube protecting the pole and luminaires during the raising-lowering operation.

Provide the luminaire ring as a totally enclosed wire way, which serves as a wire raceway for all electrical connections to the lights. It must be of adequate size and shape to accommodate the number of luminaires and wiring scheme as shown in the Plans. Provide stainless steel hardware (bolts, nuts and washers).

NOTE:The DESIGNER MUST DETERMINE if the lighting system needs external or internal motor. In order for the warranty to be honored by Millerbernd these motors must be exercised twice yearly. Include the following Paragraph if you want the system to have an internal motor.


9. Integral Winch Assembly (with internal motor)

The integral winch assembly consists of a worm gear speed reducer with a ratio of 72:1. Fabricate the worm gear housing of aluminum or other non-corrosive material. The assembly must also consist of a double output shaft and two stainless steel drums with calibrated adjustable clutches which compensate for the cable winding of both drums. Support the double output shaft by two outboard bearing assemblies.

14-SL


Equip the input or drive pulley with a brake pad to serve as a safety brake if the motor drive belt should break.

Winch assembly will provide the luminaire ring with a minimum raising speed of 12 feet per minute. Mount the entire winch assembly to the winch mounting channel in the pole base. Electrical insulating pads must be installed to separate the aluminum winch casing from the steel mounting channel to eliminate galvanic corrosion.

The ultimate support of the luminaire ring must not be dependent upon the winch assembly.

The internal power unit motor shall meet the following requirements:

a. Totally Enclosed Fan Cooled (TEFC)b. One (1) Horse Powerc. Continuous dutyd. 240 VACe. 60 Hertzf. Reversible g. Magnetic NEMA 4 brake h. 15 amp circuit breakeri. 1725 RPMj. 56C Frame

Mount the Unit to the winch on an internal bracket and utilize a V-drive belt to power the winch input or drive pulley.

Equip the motor with a power cord equipped with a NRTL listed, weatherproof 30 amp 480 volt pin and sleeve plug connector to mate with the power supply cord connector. Operate the motor by a spring return to neutral push button control in non-metallic enclosure on a 20' long extension cord.

NOTE:The DESIGNER MUST DETERMINE if the lighting system needs external or internal motor. Include the following Paragraph if you want the system to have an external motor. If you choose this option maintenance will have to bring the motor and removable bracket to each high mast for servicing the luminaires.


10. Integral Winch Assembly (with external portable motor)

The integral winch assembly consists of a worm gear speed reducer with a ratio of 72:1. Fabricate the worm gear housing of aluminum or other non-corrosive material. The assembly must

15-SL


also consist of a double output shaft and two stainless steel drums with calibrated adjustable clutches which compensate for the cable winding of both drums. Support the double output shaft by two outboard bearing assemblies.

Equip the input or drive pulley with a brake pad to serve as a safety brake if the motor drive belt should break.

Winch assembly will provide the luminaire ring with a minimum raising speed of 12 feet per minute. Mount the entire winch assembly to the winch mounting channel in the pole base. Electrical insulating pads must be installed to separate the aluminum winch casing from the steel mounting channel to eliminate galvanic corrosion.

The ultimate support of the luminaire ring is not dependent upon the winch assembly.

The external power unit motor shall meet the following requirements:

a. Totally Enclosed Fan Cooled (TEFC)b. One (1) Horse Powerc. Continuous dutyd. 240 VACe. 60 Hertzf. Reversible g. Magnetic NEMA3 brake h. 15 amp circuit breakeri. 1725 RPMj. 56C Frame

Mount the Unit to the winch on an external removable bracket and utilize a V-drive belt to power the winch input or drive pulley.

Equip the motor with a power cord equipped with a NRTL listed, weatherproof 30 amp 480 volt pin and sleeve plug connector to mate with the power supply cord connector. Operate the motor by a spring return to neutral push button control in non-metallic enclosure on a 20' long extension cord.

11. Electrical Requirements

(11.1) Provide bonding and grounding that meets the provisions of MnDOT 2545.3R, as detailed in the Plans and as follows:

a.Use 5/8th inch by 15 foot NRTL listed ground rod electrodes.

b. Drill the copper shielding for each cable assembly, in each pole base, with an 11/32 drill and place on the grounding stud provided in the pole base.

c.Place a Re-usable screw type active clamping ground lug with a tang on top of the shielding.

16-SL


d. Provide bonding of the 6 AWG solid bare grounding conductor to the pole base

11/32” grounding stud by using a UL listed Re-usable screw type active clamping ground lug with a tang that connects to the 11/32 ̋ pole base grounding stud and to the grounding terminal in the pole circuit breaker enclosure.

e.A No. 6 bare copper wire must connect the pole grounding lug to the equipment ground terminal in the pole circuit breaker box and to the pole grounding electrode system (steel piling or alternate grounding system).

f. Tighten the entire assembly (copper shielding and the grounding lug) to form an electrically bonded and grounded connection.

g. Apply an oxide inhibiting agent to the connection after both final connection and assembly.

(11.2) Pole Base Electrical Provisions

Provide a circuit breaker box of weather tight drip proof construction in the pole base. The design must keep electrical components inside the base of the pole dry.

The circuit breaker enclosure must meet the following requirements:

a.Maximum of 19 1/2 inches high, 9 1/4 inches wide, and 5 1/8 inches deep;b. Have a NEMA 3R rating;c.Contain two single pole or one double pole (as required by the by the project)

240/480 volt, 20 ampere circuit breakers.d. Carry a minimum AIR/AIC rating of 22,000.

The enclosure must also provide four (4) 8 AWG cord with a 30A, 480 Volt AC pin and sleeve female connector used as the source of power for the luminaires.

(11.3) Pole Electrical Cable

Provide a Type W flexible power cord, with four (4) 8 AWG conductors (2 phase wires, 1 neutral wire, and 1 equipment ground wire). The cord must maintain its flexibility in ambient temperatures as low as -20 degrees Fahrenheit. The use of SO rated electrical cable is not acceptable as power cord in this application.

Provide to the Engineer the manufacturer's specification for the power cord they intend to employ, together with a written statement from the manufacturer that the electrical and physical properties of the cord will serve the intended purpose, and that the pole height free hanging static condition will not affect its satisfactory performance. Do not order the cord prior to written approval by the Engineer.

17-SL


Provide the power cord with a 30 amp, 480 volt pin and sleeve weatherproof male plug connector on the pole base end, and terminate at the luminaire ring junction box by a deluxe Kellems grip. Provide end fittings approved by the Engineer.

Tether the power cord between the hoisting cables with a stainless steel chain harness attached to the lifting cables for returning it to the base for reconnection.Provided stainless steel hardware (bolts, nuts and washers).

(11.4) Test Cord

Provide a 10-foot "test" cord with a 30 amp, 480 volt pin and sleeve connector for connecting between the circuit breaker enclosure power supply cord connector and the "lowered" luminaire ring inlet connector.

(11.5) Luminaire Ring Electrical Provisions

Provide a weather tight, 4-prong grounding type pin and sleeve inlet connector on the ring or distribution box to allow illumination of luminaires while in the "lowered" position through use of the test cord specified above.

The luminaire ring wiring must consist of one common neutral, two current carrying conductors and a ground conductor as shown in the Plans. Provide No. 10 AWG, Type XHHW FR-1 rated for 90°C conductors in the lowering assembly.

Label or identify the circuits to each light fixture in the junction and distribution box on the luminaire ring in accordance with the fixture identification shown in the Plans.

No electrical disconnects permitted at the top of the pole.

(11.6) Luminaire Ring Junction Box to Luminaire Conductor Requirements

A minimum 10 AWG to a maximum of 6 AWG stranded conductor is required.

12. Lightning Protection

Provide each Lighting Unit with a lightning rod that provides a 45 degree cone of protection for all parts of the luminaires and mast head assembly.

13. Operations and Maintenance Manual

Provide and deliver, to the Engineer upon completion of the project, three (3) copies of an operating and maintenance instructions manual for the high mast system. These instructions must include, (but not be limited to) the following:

18-SL


1) Spare parts lists2) Lubrication charts3) Lubricating procedures4) Recommended maintenance schedules.5) Use a suitable hard cover, loose leaf type binder for all material included in the operation and

maintenance manual.

Index and cross reference all material using a table of contents at the beginning of the manual.

The manual must contain copies of the following:6) All final approved shop drawings7) Working drawings8) As-Built Contract Plans9) Include brochures or copies of catalog pages which show the manufacturer's name and

catalog numbers of electrical components and equipment part numbers.

Provide, at no cost to the Department, an operation and maintenance manual as described above.

14. Drawings, Materials and Suppliers Lists

Provide detailed shop drawings in accordance with the applicable provisions of MnDOT 2471.3B within 38 calendar days after approval date of the Contract. Provide with the detailed shop drawings a list of proposed suppliers of all component parts of the lowering device. Include with the poles shipped to the job site in sections, shop drawings must show the method of joining the sections.

Prior to ordering and fabrication of the materials, all materials and structural features must be approved by the Engineer.

15. Design Computations

Submit with the shop drawings for approval, complete computations covering design and stress analysis of the poles and their sections.

H. Cast-In-Place Concrete Piling Delivered 12"

Deliver piling in accordance with MnDOT 2452.

Provide the steel shells for concrete piling in accordance with MnDOT 3371.

I. Blank

J. Cast-In-Place Concrete Piling Driven 12"

19-SL


Drive cast-in-place concrete piles in accordance with 2452 except as modified below.

1. Driving Cast-In-Place Concrete Piles

Fully weld all required pile splices in conformance with Bridge detail B201. Do not use commercial drive-fit pile splices.

SL - 2.3 CONSTRUCTION REQUIREMENTS

A. Light Pole White “Neutral” Terminations

Terminate the white neutral grounded conductor in light pole in accordance with 2545.3G.3 and as follows:

Provide and install split bolt connectors for splicing the white neutral grounded conductor. Do not use insulated wire splice connector blocks.

A. Arc-Flash Hazard Warning Labeling

1. Calculate available fault current in accordance with 2545.3X and 2565.3 CC.2. Establish available fault current and apply the appropriate label as follows.3. Use the current edition of NFPA 70E “Standard for Electrical Safety in the Workplace” to

determine the required PPE category and personal protective equipment.4. If the available fault current is ≤ 25,000 amps then provide a label with the

following information shown in Example 1.

Example 1Warning Arc Flash HazardAppropriate PPE RequiredArc Flash Boundary 19 Inches Arc Flash PPE Category ____1___Working Distance 18 Inches Arc Flash Personal Protection Equipment (PPE)List required clothing, Min Arc Rating of 4 cal/cm², and protective equipment in accordance with the PPE Table from the current edition of NFPA 70E Standard for Electrical Safety in the WorkplaceEquipment ID

5. If the available fault current is ˃ 25,000 amps:

5.1. Determine PPE requirements in accordance with the current edition of NFPA 70E Standard for Electrical Safety in the Workplace, and

20-SL


5.2. Provide a label with the following information shown in Example 2. Fill in the ___ (blank) with the required arc-flash PPE category and arc-flash boundary distance.

Example 2Warning Arc Flash HazardAppropriate PPE RequiredArc Flash Boundary Feet_Arc Flash PPE Category ________Working Distance 18 Inches Arc Flash Personal Protection Equipment (PPE)List required clothing, Min Arc Rating of ___ cal/cm², and protective equipment in accordance with the PPE Table from the current edition of NFPA 70E Standard for Electrical Safety in the WorkplaceEquipment ID

6. Install labels on the front of the dead front door of the electric service cabinet at eye level.

The following Section should only be included in projects when the contractor is going to be required to do excavation work. It should not be included when you are doing a luminaire replacement project.


B. Maintain Existing Roadway Lighting

Maintain and keep in operation lighting systems in accordance with 2545.3 B and as follows:

Except during any periods of authorized work suspension, the Contractor is responsible for all maintenance of any existing lighting system within the limits of the construction project in accordance with the applicable provisions of MnDOT 1514and until final written acceptance of the project by the Engineer (MnDOT 1716). This maintenance includes:

1. lighting units, 2. luminaires, 3. lamps (after 30% or more of the lamps are burned out),4. lighting service cabinet(s), 5. photoelectric controls, 6. foundations (concrete or steel), 7. cable, 8. damage and knockdowns (due to Contractor operations) 9. Locate all underground lighting facilities in accordance with Minnesota State Statute 216D.

21-SL


The responsibility for locating underground lighting facilities shall be transferred to the Contractor on the project start date as shown on the proposal. Locating of underground lighting facilities shall be in accordance with Minnesota State Statute 216D.

MnDOT’s locating group will provide an initial locate of the underground lighting facilities within the project limits at the request of the Contractor at the start of the project. The request for the initial locate must be submitted to MnDOT’s Locating Office a minimum of four (4) working days prior to the project start date.

Locate requests that are within the construction project limits will continue to be received by MnDOT’s locating office. These locate tickets will be forwarded to the Contractor’s representative responsible for coordinating locate requests within the projects limits. The locate tickets will be forwarded via e mail or fax. Confirmation of receipt of the locate ticket must be sent by the Contractors representative back to MnDOT’s Locating Office within two (2) hours of MnDOT’s sending the Contractor’s representative the locate request.

The Contractor responsible for locating all underground lighting facilities will repair any damage as the result of improperly located or unmarked underground lighting facilities within the project limits.

The repair of the damaged underground lighting facilities must be in accordance with 2545.3A, 2565.3B and in accordance with RTMC design and construction requirements all to the satisfaction of the Engineer. This work is considered incidental.

It is the Contractor’s responsibility to notify MnDOT’s Locating Office to provide contact information and establish the contractor has assumed responsibility for locating MnDOT’s underground lighting facilities within the project limits. The form below shall be filled out by the Contractor’s representative and provided to the Engineer at the pre-construction meeting, a copy of the completed form should be sent to the following:

Electrical Services Dispatch Phone: (651)366-5750Fax: (651)366-5742E mail: [email protected] Minnehaha Ave. St. Paul, MN 55111-4014

and

Locating Supervisor Phone: (651)755-9061Fax: (651)366-5742E mail: [email protected] Minnehaha Ave. St. Paul, MN 55111-4014

22-SL

mailto:[email protected]

mailto:[email protected]


(The following Section should be left on its own page so the contractor can remove it and use the blank page)


Locating Responsibility FormJob S.P. Number ______________________

Job Type ______________________

Start Date ______________________

End Date ______________________

T.H. ______________________

Location ______________________

Lighting/ Signal Inspector ______________________

Contractor ______________________

Contractor (24 Hour Contact) ______________________

Project Manager ______________________

Phone Number ______________________

Fax Number ______________________

Email ______________________

Electrician ______________________

Phone Number ______________________

Locator Area ______________________

Project Engineer ______________________

Phone Number ______________________

Chief Inspector ______________________

23-SL


Phone Number ______________________

Weekly Meeting ______________________

Until final written acceptance of the project by the Engineer (MnDOT 1716) this work is considered incidental.

Maintain and repair any damage that in the opinion of the Engineer has occurred by someone other than the Contractors operation. The Department will pay for this work in accordance with MnDOT 1403 (EXTRA WORK).

During any periods of authorized work suspension, the contractor is responsible for maintenance of the existing, temporary, and newly constructed lighting systems.

PROVIDE TO THE DEPARTMENT CONTACT INFORMATION WITH NAMES AND TELEPHONE NUMBERS FOR 24 HOURS A DAY, 7 DAYS A WEEK MAINTENANCE AS DEFINED ABOVE.

C. Light Foundation, Design T-100, and Concrete Service Slab

Provide and install a Light Foundation, Design T-100, and Concrete Service Slab in accordance with the details in the Plan, and at the locations indicated in the Plan.

Anchor rods for the high mast poles must conform to the details shown in the Plans. Provide inspection and testing in accordance with the provisions of MnDOT 2471.3M.

Provide templates over the anchor rod protrusions and leave in place until the concrete has cured.

Each base must contain one spare 2 inch non-metallic conduit 90 degree elbow, capped at each end, for a future alternate grounding system. This conduit elbow is in addition to extra conduit elbows called for in the Plans.

Place a concrete service slab 6' x 6' x 4 inches thick in front of the door at the base of each tower unit. Use concrete mix MnDOT 3A32 and reinforce with 66-66 Steel Fabric (MnDOT 3303).

The purpose of the service slab is to provide a standing area for the maintenance personnel while servicing the lowered light ring. The Engineer will stake the slab elevations.

D. Tower Unit Installation

24-SL


Install tower units in accordance with MnDOT 2545.3H and FHWA “Guidelines for the installation, inspection, Maintenance and Repair of Structural Supports for Highway Signs, Luminaries, and Traffic Signals”

http://www.fhwa.dot.gov/bridge/signinspection.cfm

and as follows:

The leveling and top nuts must both be securely tightened against the light standard base plate. Tighten the leveling nuts and top nuts as follows:

1. Lubricate, with a brush on anti-seize lubricant, the threads of the nuts and protruding anchorages.

2. Set leveling nuts to allow a 3 inch clearance from the top of the foundation to the bottom of the tower unit base plate to allow the use of the manufacturer specific nut tightening tool.

3. After the tower unit is set on the anchorages, tighten the top and bottom nuts to a snug-tight condition.

4. Mark a reference position on the top nut and bottom leveling nut while in a snug-tight condition with a suitable marking on one flat side of the nut with a corresponding reference mark on the base plate at each bolt. This marking is done to provide reference points for tightening.

5. Turn the nut 1/12 of a revolution.

6. Incrementally turn the top or bottom nuts “in a star pattern” at least two full tightening cycles.

7. After the tightening procedure is completed, verify the proper nut rotation.

8. After 48 hours, with the entire tower unit installed, check the nuts to assure they have maintained tightness. If additional tightening is required, follow Steps 3 thru 6.

E. Electrical Service

Coordinate the installation of Electrical Service, provide power to the service cabinets, and verify the actual work to be done and all associated costs.

Proposed source of power addresses are identified in the Plan.

Fees for the “Application for Electrical Service” and payment to the electric utility for providing the electrical service connections is the responsibility of the Contractor.

25-SL

http://www.fhwa.dot.gov/bridge/signinspection.cfm


Secure approval from the Engineer for any changes to the Electrical Service as reflected in the Plan.

No measurement is made of the various items that constitute Electrical Service, however this work is included as part of the project (the electrical service costs will not be paid for as part of the pay item).

Provide the Engineer a copy of the invoice from the electric utility. Payment is the electric utility invoice cost plus 10%.

The payment is compensation in full for all costs incidental thereto, including, but not limited to, providing power to service cabinets, electric utility fees, Power Utility Company Coordination, notifying MnDOT of ownership details, and all materials and labor necessary to construct the Electrical Service.

F. Compliance with NEC Article 110. 24

Provide fault current calculations in accordance with 2565.3 CC and as follows:

1. Electric Service Information Form

Fill out the following electric service information form for lighting systems.

Provide to the Engineer, prior to final acceptance of the project, four (4) copies of the electric service information form for lighting systems and the Engineer will distribute copies as follows:

1. MnDOT Electrical Services Section.2. MnDOT Traffic Electrical Systems Engineer.3. MnDOT District Traffic Engineer.4. City of _________ or County of________.

The Contractor furnished "electrical service information form for lighting systems" is considered incidental work.

26-SL


(The following form should be left on its own page so it can be removed from the special provisions and used by the contractor) See the next page of this document


27-SL


SL-4.4

28-SL


MEASUREMENTS AND PAYMENTS

Ensure Division S Special Provisions “As-Builts” are included in the Division S Special Provisions.This would include the pay item 2011.601.

2011.601/01000 AS BUILT AS BUILT LS LUMP SUM 2016After the July 2015 Project letting date the As-Builts verbiage should automatically be included in Division S Special Provisions by MnDOT’s Project Management & Technical Support Office.The District needs to include the verbiage below to trigger installation of Divisions S Special Provisions. All Red text must be removed from the special provisions prior to the special provisions being submitted for project letting.

A. As Built Drawings and GPS Coordinates

As Built drawings and GPS coordinates in accordance with Division S Special Provisions “AS-Builts” including Pay Item No. 2011.601 (AS BUILT).

29-SL

Documents

Lighting Super Spec. · Web viewProvide the luminaire ring as a totally enclosed wire way, which serves as a wire raceway for all electrical connections to the lights. It must be