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CC - Item 3F - Claims and Demand 2007-03
E M f O ~ q e _ NDOftft0ftATED ~9g9 • ROSEMEAD CITY COUNCIL STAFF REPORT TO: THE HONORABLE MAYOR AND CITY COUNCIL FROM: ANDREW C. LAZZARETTO, CITY MANAGE DATE: FEBRUARY 13, 2007 SUBJECT: RESOLUTION NO. 2007-03 -ADOPTING THE 2007 SUPPLEMENT TO THE STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION "GREENBOOK" SUMMARY Members of the Greenbook Committee, appointed by the Board of Directors of Public Works Standards, Inc., have prepared the 2007 Supplement to the 2006 Edition of the Standard Specifications for Public Works Construction "Greenbook." Adoption of the supplement is required in order that provisions contained therein can be enforced on public works projects. Staff Recommendation Staff recommends that the City Council adopt Resolution No. 2007-03 ANALYSIS The Standard Specifications for Public Works Construction, popularly known as the "Greenbook," is updated and republished every three years. The Greenbook was last published in 2006. In each of the subsequent two years, a supplement is adopted by the Greenbook Committee to further modify and update the previously published book. City Council adopted the 2006 edition of the Greenbook for use in public works construction on February 14, 2006. PUBLIC NOTICE PROCESS This item has been noticed through the regular agenda notification process. Submitted by: / (A~ 9V4_ Ken Rukavina, P.E. City Engineer Attachment A: Resolution 2007-03 Attachment B: 2007 Supplement to the Greenbook APPROVED FOR CITY COUNCIL AGENDA: v 0 0 RESOLUTION NO. 2007-03 A RESOLUTION OF THE CITY COUNCIL OF THE CITY OF ROSEMEAD ADOPTING THE 2007 SUPPLEMENT TO THE STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION "GREENBOOK" WHEREAS, members of the Greenbook committee, appointed by the Board of Directors of Public Works Standards, Inc., have prepared the 2007 Supplement to the Standard Specifications for Public Works Construction "Greenbook," and WHEREAS, uniformity of standards serve to minimize conflict and confusion in public works construction and tend to lower. construction costs for future public works projects through competitive bidding by private contractors. NOW, THEREFORE, THE CITY COUNCIL OF THE CITY OF ROSEMEAD DOES HEREBY RESOLVE AS FOLLOWS: SECTION 1. The 2007 Supplement to the Standard Specifications for Public Works Construction "Greenbook" prepared by the Greenbook Committee, appointed by the Board of Directors of Public Works Standards, Inc., be adopted. PASSED, APPROVED, AND ADOPTED THIS 13TH DAY OF FEBRUARY 2007. YOR ATTEST: CITY CLERK 0 • v 411J 2007 SUPPLEMENT TO "GREENBOOK" STANDARD SPECIFICATIONS- FOR PUBLIC WORKS CONSTRUCTION 2006 EDITION Adopted By The GREENBOOK COMMITTEE of Public Works Standards, Inc. 0 Published By M.Building News Division of BNi Publications, Inc. 990 Park Center Drive, Suite E, Vista, CA 92081 (760) 734-1113 Copyright © 2006 by Public Works Standards, Inc. 2 2007 Supplement to "Greenbook" -PAGE 4 - REVISE OR ADD THE FOLLOWING COMMON USAGE TERMS IN 1-3.2 TO READ BMPs Best Management Practices CCFRPM ............................................Centrifugally Cast Fiberglass Reinforced Plastic Mortar CIPCP ...............................................................:.........................Cast-in-place concrete pipe CIPP Cured-in-place pipe HDPE High Density Polyethylene LED ....................................................................................................Light emitting diode MUTCD ..............................................................Manual on Uniform Traffic Control Devices PAV Pressure Aging Vessel PG Performance Graded RTFO ..............................................................................................Rolling Thin Film Oven SWPPP Stormwater Pollution Prevention Plan VTCSH Vehicle Traffic Controls Signal Heads - PAGE 6 - ADD THE FOLLOWING INSTITUTIONAL ABBREVIATIONS TO 1-3.3 EIA ETL FCC IEEE . IMSA. ITE..... REA... Electronic Industries Association .......................................Electrical Testing Laboratories ...........................Federal Communications Commission ............Institute of Electrical and Electronics Engineers International Municipal Signal Association ..........................................Institute of Traffic Engineers Rural Electrification Administration - PAGE 27 - REVISE 7-1 TO READ: 7-1 THE CONTRACTOR'S EQUIPMENT AND FACILITIES. 7-1.1 General. The Contractor shall furnish and maintain in good condition all equipment and facilities as required for the proper execution and inspection of the Work The Contractor shall provide and maintain enclosed toilets for the use of employees engaged in the Work. These accommodations shall be maintained in a neat and sanitary condition, and regularly pumped out. 7-1.2 Temporary Utility Services. The Contractor shall, at its own expense, make all arrangements necessary for the provision of temporary utility services necessary for its own use during performance of the Work. The Contractor shall not draw water from any fire hydrant (except to extinguish a fire), without obtaining permission from the water utility owner. 2007 Supplement to "Greenbook" 3 7-1.3 Crushing and Screening Operations. Unless otherwise specified in the Special Provisions, the establishment and operation of portable screens and crushers will not be allowed on or adjacent to the Work site. - PAGE 30 - REVISE 7-8 TO READ: 7-8 WORK SITE MAINTENANCE. 7-8.1 General. Throughout all phases of construction, including suspension of the Work, and until acceptance per 6-8, the Contractor shall keep the Work site clean and free from rubbish and debris. Rubbish and debris collected on the Work site shall only be stored in roll-off, enclosed containers prior to disposal. Stockpiles of such will not be allowed. When required by the Special Provisions, the Contractor shall provide a self-loading motorized street sweeper equipped with a functional water spray system . The sweeper shall clean all paved areas within the Work site and all paved haul routes at least once each working day The Contractor shall ensure there is no spillage along haul routes. Any such spillage shall be removed immediately and the area cleaned. Should the Contractor fail to keep the Work site free from rubbish and debris, the Engineer may suspend the Work per 6-3 until the condition is corrected. 7-8.2 Air Pollution Control. The Contractor shall not discharge smoke, dust, equipment exhaust, or any other air contaminants into the atmosphere in such quantity as will violate any Federal, State, or local regulations. The Contractor shall also abate dust nuisance by'cleaning, sweeping and spraying with water, or other means as necessary. The use of water shall conform to 7-8.6. 7-8.3 Noise Control. Noise generated from the Contractor's operations shall be controlled as specified in the Special Provisions. 7-8.4 Storage of Equipment and Materials. 7-8.4.1 General. Materials and equipment shall be removed from the Work site as soon as they are no longer necessary. Before inspection by the Engineer for acceptance, the Work site shall be cleared of equipment, unused materials, and rubbish so as to present a satisfactory clean and neat appearance. Excess excavated material shall be removed from the Work site immediately unless otherwise specified in the Special Provisions. Forms and form lumber shall be removed from the Work site as soon as practicable after stripping. 7-8.4.2 Storage in Public Streets. Construction materials and equipment shall not be stored in streets, roads, or highways for more than 5 days after unloading unless otherwise specified in the Special Provisions or approved by the Engineer. All materials or equipment not installed or used in construction within 5 days after unloading shall be stored at a location approved by the Engineer. Excavated material, except that which is to be used as backfill in the adjacent trench, shall not be stored in public streets unless otherwise specified in the Special Provisions or approved by the Engineer. Immediately after placing backfill, all excess material shall be removed from the Work site. 4 2007 Supplement to "Greenbook" 7-8.5 Sanitary Sewers. 7-8.5.1 General. The flow of sewage shall not be interrupted. Should the Contractor disrupt the operation of existing sanitary sewer facilities, or should disruption be necessary for performance of the Work, the Contractor shall bypass the sewage flow around the Work. Sewage shall be conveyed in closed conduits and disposed of in a sanitary sewer system. Sewage shall not be permitted to flow in trenches nor be covered by backfill. Whenever sewage bypass and pumping is required by the Plans or Specifications, or the Contractor so elects to perform, the Contractor shall submit per 2-5.3 a working drawing conforming to 7-8.5.2 detailing its proposed plan of sewage bypass and pumping. 7-8.5.2 Sewage Bypass and Pumping Plan. The plan shall indicate the locations and capacities of all pumps, sumps, suction and discharge lines. Equipment and piping shall be sized to handle the peak flow of the section of sewer line to be bypassed and pumped. Equipment and piping shall conform to 7-10, the Plans, and the Special Provisions. Bypass piping, when crossing areas subject to traffic loads, shall be constructed in trenches with adequate cover and otherwise protected from damage due to traffic. Lay-flat hose or aluminum piping with an adequate casing and/or traffic plates may be allowed if so approved by the Engineer. Bypass pump suction and discharge lines that extend into manholes shall be rigid hose or hard pipe. Lay flat hose will not be allowed to extend into manholes. The Contractor shall provide a backup bypass pumping system in case of malfunction. The backup bypass system shall provide 100 percent standby capability, and be in place and ready for immediate use. Each standby pump shall be a complete unit with its own suction and discharge piping. In addition to the backup system, the Contractor shall furnish and operate vacuum trucks when required by the Plans or Special Provisions. 7-8.5.3 Spill Prevention and Emergency Response Plan. The Contractor shall prepare and submit per 2-5.3 a spill prevention and emergency response plan. The plan shall address implementation of measures to prevent sewage spills, procedures for spill control and containment, notifications, emergency response, cleanup, and spill and damage reporting. The plan shall account for all storm drain systems and water courses within the vicinity of the Work which could be affected by a sewage spill. Catch basins that could receive spilled sewage shall be identified. Unless otherwise specified in the Special Provisions, these catch basins shall be sealed prior to operating the bypass and pumping system. The Contractor shall remove all material used to seal the catch basins when the bypass and pumping system operations are complete. The Contractor shall be fully responsible for containing any sewage spillage, preventing any sewage from reaching a watercourse, recovery and legal disposal of any spilled sewage, any fines or penalties associated with the sewage spill imposed upon by the Agency and/or the Contractor by jurisdictional regulatory agencies, and any other expenses or liabilities related to the sewage spill. 2007 Supplement to "Greenbook" 5 7-8.6 Water Pollution Control. 7-8.6.1 General. The Contractor shall conform to all applicable local, state and Federal regulations and laws pertaining to water pollution control. The Contractor shall conduct and schedule its operations, and follow and implement best management practices in such a manner as to prevent water pollution. The Contractor shall also conform to the following requirements: 1) Sediments shall not be discharged to a storm drain system or receiving waters. 2) Sediments generated on the Work site shall be contained on the Work site using appropriate BMPs. 3) No construction-related materials, waste, spill, or residue shall be discharged from the Work site to streets, drainage facilities, receiving waters, or adjacent property by wind or runoff. 4) Non-storm water runoff from equipment, vehicle washing, or any other activity shall be contained within the Work site using appropriate BMPs. 5) Erosion shall be prevented. Erosion susceptible slopes shall be covered, planted or otherwise protected in a way that prevents discharge from the Work site. 7-8.6.2 Best Management Practices(BMPs). The Contractor shall implement and maintain such BMPs as are relevant to the Work, and as are specifically required by the Plans or Special Provisions. The Contractor shall be responsible throughout the duration of the Contract for installing, constructing, inspecting, maintaining, removing and disposing of 13MPs for wind erosion control, tracking control, erosion and sediment control, non-storm water control, and waste management and materials pollution control. Unless otherwise directed by the Engineer, the Contractor shall be responsible for BMP implementation and maintenance throughout any temporary suspension of the Work. 7-8.6.3 Storm Water Pollution Prevention Plan(SWPPP). When so specified in the Special Provisions, or if so required by a jurisdictional regulatory agency, the Contractor shall prepare and submit per 2-5.3 a storm water pollution prevention plan. The SWPPP shall conform to the requirements specified in the Special Provisions and those of the jurisdictional regulatory agency. The Notice of Intent will be filed by the Agency. 7-8.6.4 Dewatering. Dewatering shall be performed by the Contractor when specifically required by the Plans or Specifications, and as necessary for construction of the Work. Dewatering shall be performed in conformance with all applicable local, state and Federal laws and permits issued by jurisdictional regulatory agencies. Permits necessary for treatment and disposal of accumulated water shall be obtained by the Contractor or the Agency as specified in the Special Provisions. Accumulated water shall be treated prior to disposal if so specified in the Special Provisions or required by a permit. The Contractor shall submit a working drawing and related supporting information per 2-5.3 detailing its proposed plan and methodology of dewatering and treatment and disposal of accumulated water. The plan shall identify the location, type and size of dewatering devices and related equipment, the size and type of materials composing the collection system, the size and type of equipment to be used to retain and, if required, treat accumulated water, and the proposed disposal locations. If the proposed disposal location is a sanitary sewer, the Contractor shall submit to the Engineer written evidence of permission from the owner. If the proposed disposal location is a storm drain system or receiving body of water, the Contractor shall submit written evidence of permission from the owner of the storm drain 2007 Supplement to "Greenbook" system and, if not obtained by the Agency, original signed permits from jurisdictional regulatory agencies or written evidence that such permits are not required. 7-8.6.5 Payment. Unless otherwise specified in the Special Provisions, payment for implementation and maintenance of BMPs shall be considered as included in the Contract Unit Price for each item in the Bid. Payment for dewatering shall be as specified in the Special Provisions. -PAGE 32 - DELETE 7-10.2 AND REPLACE WITH: 7-10.2 (Not Used) -PAGE 43 - ADD 200-2.2.3 TO READ: 200-2.2.3 Quality Requirements. The material shall conform to the following: TABLE 200-2.2.3 (A) Tests I Test Method No. I Requirements R-value' Sand Equivalent Percentage Wear 100 revolutions 500 revolutions Calif. 301 Calif. 217 ASTM C 131 surface drvl I ASTM C 127 1. the K-value requirement will be waived, provided the material has an SE of 55 or more. 2. Not more than 15 percent by weight shall be particles with a bulk specific gravity below 2.50. 80 Minimum 50 Minimum 15 Maximum 52 Maximum 2.58 Minimums The Engineer may waive percentage wear and specific gravity requirements, provided that the material has a minimum durability of 40 in accordance with Calif. Test 229. PAGE 53 - REVISE 201-1.2.5 TO READ: 201-1.2.5 Fly Ash. Fly ash is specified in alternate class and special exposure mixes. Fly ash may be used in any other mix when approved by the Engineer. The amount of fly ash and portland cement used shall be based upon trial batches in accordance with 201-1.1.4. Fly ash shall not be used with Type IP (MS) or Type M portland cement. Class C fly ash shall not be used where sulfate resistant concrete is required. Except for special exposure mixes, whenever Type V portland cement is specified Type ll portland cement and Class F fly ash may be used or Class F fly ash maybe used as an addition to Type V portland cement. The Contractor shall furnish a Certificate of Compliance conforming to 4-1.5 as specified in 2-5.3. The Certificate of Compliance shall be signed by the supplier identifying the type of fly ash and stating that the fly 2007 Supplement to "Greenbook" ash complies with ASTM C 618 and these Specifications. Supporting test data shall be fii nished when requested by the Engineer. All testing and sampling procedures shall conform to ASTM C 31 L Separate silo storage facilities shall be provided Suitable facilities shall be provided to discharge the fly ash into the cement hopper in accordance with 201-1.3.1. Fly ash shall be stored in such a manner as to permit ready access for the purpose of inspection and sampling and be suitably protected against contamination or moisture. Should any fly ash show evidence of contamination or be otherwise unsuitable, the Engineer may reject it and require that it be removed from the site. All fly ash used in concrete for any individual structure shall be from the same source and of the same class in combination with the same source and type of portland cement, unless otherwise approved by the Engineer. (a) Class F Fly Ash. Class F fly ash shall conform to ASTM C 618 and the following: Loss on ignition SO3 content Moisture content 4% maximum 3% maximum 1% maximum When sulfate resistant or special exposure concrete is specified, test results shall be submitted to the Engineer as specified in 2-5.3. The test result shall show that the fly ash to be used is effective in contributing to sulfate resistance in conformance with ASTM C 618, Table 3 (optional physical requirements) as tested in accordance with ASTM C 1012. The data submitted shall be less than 6 months old. Class F fly ash, as a percent by weight of total cementitious material, may exceed 20 percent when approved by the Engineer. (b) Class C Fly Ash. Class C fly ash shall conform to ASTM C 618 and the following: Loss on ignition SO3 content Moisture content 2% maximum 4% maximum 1% maximum Class C fly ash, as a percent by weight of total cementitious material, shall not exceed 30 percent, unless otherwise approved by the Engineer. Class C fly ash shall not be used where sulfate resistant concrete is required. -PAGE 62 - REVISE THE FIRST PARAGRAPH OF 201-3.6 TO READ: 201-3.6 Type "C" Sealant (Asphalt-Latex Emulsion Joint Sealant). Asphalt-latex emulsion joint sealant shall be designated for mixing and'application by hand methods and shall be suitable for use at temperatures above 10°C (50°F). The sealing compound shall be an emulsion consisting of paving asphalt, emulsified with rubber latex in a suitable emulsifying agent. Rubber latex shall be natural rubber or synthetic latex containing approximately 40 percent solids. The resulting emulsion shall consist of a minimum of 55 percent paving asphalt and a minimum of 36 percent rubber latex. \.I 2007 Supplement to "Greenbook" - PAGE 69 - REVISE 203-1.1 TO READ: 203-1.1 General. Paving asphalt shall be steam-refined asphalt produced from crude asphaltic petroleum or a mixture of refined liquid asphalt and refined solid asphalt. It shall be homogeneous and free from water and residues from distillation of coal, coal tar, or paraffin oil. - PAGE 70 - REVISE 203-1.2 TO READ: 203-1.2 Testing Requirements. Paving asphalt shall be specified by performance grade and shall conform to the requirements in Table 203-1.2 (A). TABLE 203-1.2 (A) Grade AASHTO Test PG 64-10 PG 64-16 PG 64-28 PG 70-10 Original Binder Flash Point, °C, minimum T48 230 230 230 230 Solubility, minimum T44 99.0 99.0 99.0 99.0 Viscosity, 135°C, Pa s, maximuma T316 3.0 3.0 3.0 3.0 Dynamic Shear Test Temperature, °C T315 64 64 64 70 Dynamic Shear, 10 rad/s, G'/Sins, kPa, minimum T315 1.00 1.00 1.00 1.00 RTFO Aged Binder T240 Mass Loss, maximum T240 1.00 1.00 1.00 1.00 Dynamic Shear Test Temperature, °C T315 64 64 64 70 Dynamic Shear, 10 rad/s, G'/Sind, kPa, minimum T315 2.20 2.20 2.20 2.20 Ductility, 25°C, 5 cm/min, cm, minimum T51 75 75 75 75 RTFO and PAV Aged Binder R28 PAV Aging Temperature, 'C R28 100 100 100 110 Dynamic Shear Test Temperature, °C T315 31 28 22 34 Dynamic Shear, 10 rad/s, G'•Sind, kPa, maximum T315 5000 5000 5000 5000 Bendin Beam Test Temperature, °C T313 0 -6 -18 0 Creep Stiffness, MPa, maximum T313 300 300 300 300 m-value, minimum T313 0.300 0.300 0.300 0.300 This requirement may be waived by the Enaineer if the suoDlier warrants t hat the navina a sphalt ran he a Aemiateiv mim ned nnrl mlxwA at temperatures that meet all applicable safety standards. "If the PAV aged binder exceeds 5000 kPa at the designated test temperature, it will be deemed acceptable if it is less than 5000 kPa when tested at a WC higher test temperature. 2007 Supplement to "Greenbook" - PAGE 70 - REVISE 203-1.3 TO READ: 203-13 Test Reports and Certification. Paving asphalt shall be supplied by Caltrans or other State Department of Transportation approved vendors or as specified in the Special Provisions. At delivery time, the supplying vendor shall deliver to the purchaser a certified copy of the test report. This report shall indicate the vendor's name, grade of paving asphalt delivered, date and point of delivery, quantity delivered, ticket number, purchase order number, and results of specified tests. The certified test report and the testing required in connection with the report shall be submitted to the Agency in accordance with 2-5.3.4. Until the certified test report and samples of the material have been reviewed by the Engineer to determine their conformity with the specified requirements, the material to which such report relates and any work in which it may have been incorporated as an integral component, will be only tentatively accepted by the Agency. Final acceptance will be dependent upon the determination by the Engineer that the material involved conforms to the Specifications. REVISE 203-1.4 TO READ: 203-1.4 Temperatures. Paving asphalt shall not be heated during its manufacture, storage, or during construction so as to cause formation of carbonized particles. At no time shall the temperature be higher than 5°C (10°F) below the actual flash point of the paving asphalt, nor shall it be raised above 190°C (375°F) after loading into a tank car or truck for transport. Unless otherwise specified in the Special Provisions, the various grades of paving asphalt shall be applied within the temperature range indicated in Table 203-1.4 (A). TABLE 203-1.4 (A) ASPHALT GRADE PLANT MIXING TEMPERATURE °C (°F) DISTRIBUTION APPLICATION TEMPERATURE °C (°F) Minimum Maximum Minimum Maximum PG 70-10 150 (300) 175 (350) 140 (285) 175 (350) PG 64-28 135 (275) 160 (325) 140 (285) 175 (350) PG 64-16 135 (275) 160(325) 140 (285) 175 (350) PG 64-10 135 (275) 160(325) 140 (285) 175 (350) Paving asphalt shall be heated in such a manner that no steam or hot oils will be introduced into the paving asphalt during heating. The Contractor shall furnish and keep on-site an accurate thermometer suitable for determining the temperature of the paving asphalt. - PAGE 71 - REVISE 203-1.5 TO READ: 203-1.5 Distributing Equipment. Distributing equipment shall conform to 203-2.5. 10 2007 Supplement to "Greenbook" - PAGE 71 - REVISE 203-1.6 TO READ: 203-1.6 Measurement and Payment. For all volumetric quantities to be paid for at a Contract Unit Price, the unit of measurement shall be the liter (U.S. gallon) at a temperature of 15°C (60°F). In converting weight to volume, computations shall be based on Table 203-1.6 (A). TABLE 203-1.6 (A) Grade of Material I Liters Per Tonne At 15°C Grams Per Liter At 15°C (Gallons Per Ton At 60°F) (Lbs. Per Gallon At 60°FJ PG 70-10 981 (235) 1020 (8.51) PG 64-28 981 (235) 1020 (8.51) PG 64-16 981 (235) 1020 (8.51) -PAGE 80 - REVISE 203-6.1 TO READ: 203-6.1 General. Asphalt concrete shall be the product of mixing mineral aggregate and up to 15 percent reclaimed asphalt pavement (RAP) with paving asphalt conforming to 203-1 at a central mixing plant. RAP shall conform to 203-7.2.2, except the viscosity of RAP asphalt recovered in accordance with ASTM D 1856 (Abson Recovery Method) will not be required. RAP asphalt content may be detemlined in accordance with Calif. Test 382, except the aggregate correction factor shall not be applied. Asphalt concrete will be designated by class and grade i.e., "C2-PG 6410". Asphalt concrete containing up to 15 percent RAP shall be identified by adding the suffix "RAP" to the class and grade, i.e., "C2-PG 6410 RAP". -PAGE 85 - REVISE THE FIRST LINE OF 203-6.7.1 TO READ: 203-6.7.1 General. All aggregates, binder, and RAP, where applicable, shall be mixed in a REVISE THE SECOND PARAGRAPH OF 203-6.7.1 TO READ: Uniformity of distribution of binder shall be determined by an extraction test made in accordance with any of the following test methods or other published test methods approved by the Engineer: ASTM D 2172 California Test Method 382 ASTM D 4125 • 2007 Supplement to "Greenbook" 11 - PAGE 87 - REVISE 203-7.1 TO READ: 203-7.1 General. Recycled Asphalt Concrete (RAC) shall be the product of mixing reclaimed asphalt pavement, virgin aggregates and paving asphalt and/or recycling agent. RAC will be designated by class and grade, i.e., "C2-PG 64-10-RAC." The end product shall meet both the gradation and asphalt grade specified. REVISE THE SECOND PARAGRAPH OF 203-7.2.2 TO READ: The RAC supplier shall perform sand-equivalent tests on the unextracted RAP, and tests for RAP asphalt content, RAP asphalt viscosity or performance grade, and gradation of RAP aggregates on solvent extracted samples of RAP taken from stockpiles. Solvent extractions shall be performed in accordance with ASTM D 2172 and the RAP asphalt shall be recovered in accordance with ASTM D 1856 (Abson Recovery Method). The minimum sand-equivalent value of the unextracted RAP shall be 80, when determined in accordance with California Test 217. REVISE THE LAST PARAGRAPH OF 203-7.2.3 TO READ: The test results of the RAC binder shall meet the RTFO and PAV test requirements in Table 203- 1.2(A) for the PG grade specified. -PAGE 89 - REVISE THE THIRD PARAGRAPH OF 203-7.3.2 TO READ: When the amount of RAP to be added is over 15 percent of the total mix, a job mix formula, supporting test data, and blending charts shall be submitted to the Engineer for. approval in accordance with 2-5.3. Blending charts shall be used to determine the grade of new paving asphalt. The supporting test data for RAC shall include the result for stability, swell and moisture vapor susceptibility. These tests are in addition to the tests for the RAP stockpile specified in 203-7.2.2. - PAGE 94 - REVISE 203-10.2.1 TO READ: 203-10.2.1 Paving Asphalt. Paving asphalt shall be PG 64-10 conforming to 203-1, or as specified in the Special Provisions. s • 12 2007 Supplement to "Greenbook" -PAGE 95 - REVISE THE FIRST PARAGRAPH OF 203-10.2.4 TO READ: 203-10.2.4 Composition and Grading. The class shall be C2 unless otherwise specified on the Plans or in the Special Provisions. Where Alternate Rock Products-Type S, Section 400, are specified, the class and grade shall be Type 111-C3-PG 64-10 or as specified in the Special Provisions. REVISE 203-11.2.1 TO READ: 203-11.2.1 Paving Asphalt. Paving asphalt used for asphalt-rubber shall be PG 64-16 and shall be modified with an asphalt modifier. Performance Graded paving asphalts other than PG 64-16 may be used if so specified in the Special Provisions. -PAGE 103 - REVISE THE LAST PARAGRAPH OF 203-12.2.2 TO READ: Screenings shall be medium 9.5mm (3/8 inch) unless otherwise specified. Screenings shall be preheated to between 127°C (260°F) to 163°C (3257) and adequately coated with 0.70 percent to 1 percent PG 64-10 paving asphalt at a central mixing plant to prevent free dust. The exact amount of paving asphalt shall be recommended by the Contractor and approved by the Engineer. Screenings shall conform to the requirements of Table 200-1.2 (B). s s 2007 Supplement to "Greenbook" 13 -PAGE 175 - REVISE 209 TO READ: SECTION 209 - STREET LIGHTING AND TRAFFIC SIGNAL 209-1- GENERAL. The following material specifications set forth the requirements for components installed in conjunction with the construction of street lighting and traffic signal systems. 209-2 REFERANCE SPECIFICATIONS. In addition to the requirements of the Plans, Specifications, and Special Provisions, all of the components shall conform, where applicable, to the current following regulations and codes: a. NEMA b. UL c. EIA d. REA e. Aluminum Association Publication 30 f ANSI g. AASHTO "Standard Specification for Structural Support for Highway Signs, Luminaires and Traffic Signals" h. ETL i. IEEE j. MEL SPEC k. AWS Dl.l "Structural Welding Code" 1. FCC. 209-3 COMPONENTS FOR STREET LIGHTING AND TRAFFIC SIGNAL SYSTEMS. 209-3.1 General. The following material Specifications set forth the requirements for components that are common to street lighting and traffic signal systems. All materials furnished and installed shall be new, except materials specified on the Plans or in the Special Provisions to be reused. 209-3.2 Anchor Bolts, Nuts, and Washers. Anchor bolts shall conform to ASTM A307 and shall be tested in accordance with 206-1.1.3. Each anchor bolt shall be round, have a minimum of 200mm (8 inches) of thread, and be provided with 2 nuts and 2 flat 6mm (1/4 inch) thick washers. Nuts shall be symmetrically formed with the hole centered and at right angles to the face. Nuts shall be tapped to fit a corresponding thread on the anchor bolt such that the nut can be run the entire length of the thread by the fingers without undue forcing, and without play or rocking. Anchor bolts, nuts, and washers shall be galvanized by the hot-dip process conforming to 210-3, or cadmium plated with Type NS coating conforming to ASTM A165. 209-3.3. Standards. 209-3.3.1 General. Standards shall have an aluminum identification plate attached with stainless steel rivets or screws, as specified on the Plans. Each Standard shall have a handhole in the base and a handhole cover. The handholes shall conform to the details shown on the Plans or Standard Plans. 6 a 14 2007 Supplement to "Greenbook" The handhole cover shall be securely attached to the Standard with tamper-resistant hardware or as detailed on the Plans or specified in the Special Provisions. 209-3.3.2 Straightness. For street lighting and pedestrian Standards the maximum deviation shall not exceed the tolerance specified in Table 209-3.3.2(A) when measured with the Standard in the vertical position. For traffic signal standards the maximum deviation shall not exceed the tolerance specified in Table 209-3.3.2(A) when measured with the Standard in the horizontal position. TABLE 209-3.3.2(A) Length of Standard - Excluding Base Maximum Allowable Deviation From String Line' Over Equal to or Less - 6.4 m (21 feet) 12.7 mm (112 inch) 6.4 m (21 feet) 7.92 m (26 feet) 19.04 mm (3/4 inch) 7.92 m (25 feet) 10.67 m (35 feet) 25.40 mm (1 inch) 10.67 m (35 feet) 12.19 m (40 feet) 31.75 mm (1 inch) 12.19 m (40 feet) - As specified in the Special Provisions. 1. The maximum deviation shall be measured from a string line on the face of the standard, in a plane passing through the longitudinal axis. Short crooks in the Standard shall not exceed 0.35mm (1/4 inch) deviation from the centerline of the Standard for each 1.52m (5 feet) of length. Offsets or jogs due to mold extensions or joints shall not exceed 1.59mm (1/16 inch) in thickness along the surface of the Standard. 209-3.3.3 Metal Standards. 209-3.3.3.1 General. The top of each Standard shall be equipped with an ornamental cap which shall be securely held in place by a 19mm (3/4 inch) diameter hex head machine bolt. Provisions shall be made for substituting 19mm (3/4 inch) diameter steel insulator pin. The cap and cap support surface shall have sufficient strength to transfer to the Standard, from a point 127mm (5 inches) above the top of the cap, a 4,226 N (950 Ibs) horizontal loading. Metal standards shall withstand, without permanent deformation, a maximum horizontal load of 4,226 N (950 lbs) applied to the center of the cap that is attached to the Standard. In addition, metal standards shall withstand, without exceeding a deflection of 59mm (2-5/16 inches) a normal horizontal load of 1,646 N (370 lbs) applied to the cap that is attached to the top of the Standard. Exposed edges of plates that comprise the base assembly shall be finished smooth. Exposed corners shall be rounded unless otherwise shown on the Plans. Slots or drilled holes shall have a tolerance of 0 to + 3.18mm (1/8 inch). Metal standards shall be equipped with anchor bolt covers made of metal of the same type as that used for the shafts or as specified on the Plans or Standard Plans. Anchor bolt covers shall be equipped with all necessary fittings and hardware for securing the bolt covers to the Standard. 209-3.3.3.2 Steel Standards. Unless otherwise specified in the Special Provisions, steel standards shall be fabricated from sheet steel of weldable grade having minimum yield strength, after fabrication, of 276 MPa (40,200 psi). When a single-ply 8 mm (5/16 inch) thick steel standard is specified, a 2-ply steel standard with an equivalent section modulus may be substituted unless otherwise specified in the 2007 Supplement to "Greenbook" 15 Special Provisions. Certified test reports that verify conformance to this minimum yield strength shall be submitted to the Engineer in accordance with 2-5.3.4. Steel standards may be fabricated from full length sheets or shorter sections. Each section shall be fabricated from not more than 2 pieces of sheet steel. Where 2 pieces are used, the longitudinal welded seams shall be directly opposite each other. When the sections are butt welded together, the longitudinal welded seams on adjacent sections shall be placed to form continuous straight seams from the base to the top. In addition, butt welded sections shall be strengthened by inserting a welded sleeve at each joint. The sleeve shall be fabricated from steel 3.43 mm (1/8 inch) nominal thickness or thicker of the same composition as the steel used in the Standard. The sleeve shall have a minimum length of 2.54 cm (1 inch). The sleeve shall be centered at the joint and have the same taper as the Standard such that the outside of the sleeve is in full contact throughout its length and circumference. The weld metal at the transverse joint shall extend to the sleeve. No transverse joint shall occur within 7.62 cm (3 inches) of mast arm fittings. All welds shall be continuous and conform to the requirements of 209-2. Welds joining the shafts of Standards to their base plates shall be as shown on the Plans or Standard Plans. However, alternative weld joint details may be approved by the Engineer. Approval of alternative weld joint details will be contingent upon the proposed weld joint passing both weld procedure and nondestructive testing as deemed necessary by the Engineer. All costs of the weld procedure and nondestructive testing shall be home by the Contractor. Longitudinal welds in steel tubular sections will be tested by the Agency in conformance with the requirements in California Test 664. The sampling frequency shall be as directed by the Engineer. Welds may be made by the electric resistance welding process. Exposed welds shall be ground flush with the base metal. Steel standards shall be galvanized by the hot-dip process conforming to 210-3, or cadmium plated with Type NS coating conforming to ASTM A165. If specified in the Special Provisions or shown on the Plans, steel standards shall be painted in accordance with 210-1. 209-3.3.3.3 Aluminum Standards. Aluminum standards shall be fabricated from seamless tubing conforming to "6063-T6 wrought aluminum alloy of the Specifications of the Aluminum Association" or the specifications in Table 209-3.3.3.3(A). TABLE 209-3.3.3.3(A) ITEM ASTM SPECIFICATION NO. Castings B26/B26M Luminaire Arm B490-90a Spun Shaft 8241/B241M Square Extruded Shaft 8429 The wall thickness of the shaft shall be a minimum of 6mm (1/4 inch). Aluminum standards shall be supplied with a mill finish, and be uniform and commercially sound in conformance with ASTM 13209M. 209-33.4 Fiberglass Standards. Fiberglass standards shall consist of fiberglass-reinforced thermosetting plastic poles. Fiberglass standards shall be hollow, tapered or with tapered sections, be non-conductive and chemically inert. Fiberglass standards shall be in conformance with AASHTO and ANSI specifications in 209- 2. The Contractor shall submit to the Engineer a Certificate of Compliance from the manufacturer in accordance with 2-5.3. The certificate shall include a copy of all applicable test reports. The test reports shall • • 16 2007 Supplement to "Greenbook" be signed and stamped by the licensed engineer that supervised the tests. The certificate shall also comply with 4-1.5 and certify that the Standards were manufactured in accordance with an Agency-approved testing and quality control program. Fiberglass standards shall be constructed of continuous fiberglass filaments combined with thermosetting polyester and ultraviolet-resistant resin. The fiberglass and resin ratio shall contain at least 65 percent glass and 35 percent resin by weight. The resin shall be pigmented as required by the Standard Plans or Special Provisions and be of uniform color throughout the entire body of the Standard. The glass filament shall be helically wound under tension at angles to provide axial strength. The finish of shall be smooth. Fiberglass standards shall be flame resistant in accordance with ASTM D635. In addition fiberglass standards shall be reinforced in areas of handholes, conduit entrance openings, and mast arm connections. Fiberglass standards shall be direct burial or have an anchor base as shown on the Plans or the Standard Plans. The base shall be bonded to the pole with an adhesive recommended by the manufacturer, and coated with an aliphatic-type acrylic-modified polyurethane finish. Each Fiberglass standard shall be equipped with a removable aluminum or galvanized steel pole top cap. An aliphatic-type acrylic-modified polyurethane coating shall be applied to the exterior of each fiberglass standard. The coating shall be semi-gloss, weather resistant and match the color of the resin specified in the Special Provisions. The coating shall have a minimum of 0.075mm (3 mils) dry film thickness. A one liter (1 quart) can of the coating that matches the specified color shall be furnished as specified in the Special Provisions. The polyurethane coating shall be tested by for adhesion in accordance with the requirements of ASTM D 3359, Method A and shall have a scale rating of 5A. The adhesion testing shall be conducted before and after the accelerated weathering evaluation by the manufacturer. The Contractor shall provide the Engineer with a copy of the test results from the manufacturer in accordance with 2-5.3. The test reports shall be signed and stamped by the licensed engineer that supervised the tests. Finished surfaces shall be capable of withstanding a minimum of 2,500 hours of accelerated weathering when tested by the Agency, in accordance with the requirements of ASTM G 53. Testing lamps shall be UV-13 (313nm wavelength). The testing cycle shall consist of 4 hours of ultraviolet (UV) exposure at 600C (1400F), followed by 4 hours of condensate exposure at 400C (1000F). After testing, the finished surface of fiberglass standards shall exhibit the following: a) Fiber Exposure -None b) Crazing-None c) Checking - None d) Chalking - Very slight e) Change in color - May dull slightly. Each fiberglass standard shall be spiral-wrapped in its entirety with a weatherproof wrap for protection during shipping and storage- 209-3.4 Mast Arms. Mast amts shall be fabricated from the same material specified for the adjoining Standards, except for fiberglass standards. Mast arms for fiberglass standards shall be fabricated from aluminum. Mast arms shall be fabricated in conformance with 209-2, 209-3.3.3.2 or 209-3.3.3.3 depending on the material the mast arm is fabricated from. Mast arms shall be smoothly curved to the approximate configuration shown on the Plans or Standard Plans. A smooth curving arm is required. Mast arms shall have an aluminum identification plate attached with stainless steel rivets or screws, as specified on the Plans. 2007 Supplement to "Greenbook" 17 Exposed welds, except fillet and fatigue resistant welds on top of the mast amrs shall be ground flush with the base metal. Mast arms shall be fiunished complete with all necessary fittings and hardware for attachment of the arm to the adjoining Standard. 209-3.5 Conduit. 209-3.5.1 General. Conduit shall be as shown on the Plans or specified in the Special Provisions. 209-3.5.2 Rigid Metallic Conduit. Conduit and conduit fittings shall be galvanized by the hot-dip, electrodepositing, or metallizing process in accordance with 210-3. Conduit shall conform to Underwriters' Laboratories, hrc, publication UL 6 for Rigid Metallic Conduit, and shall bear the UL label on each length. The zinc coating shall be tested in conformance with the requirements in ASTM Designation: A 239. 209-3.53 Galvanized Pipe. Galvanized pipe used as conduit shall conform to the following: a) ASTM A53 Grade A. b) Only standard lengths shall be supplied to the Work site. c) Need not be UL listed 209-3.5.4 Rigid Non-Metallic Conduit. Rigid non-metallic conduit shall conform to the requirements of the UL Standard for Rigid Non-Metallic Conduit, Publication UL 651 (PVC Schedule-80) and UL 651B (HDPE). Rigid non-metallic conduit connections shall be of the solvent weld type. 209-3.6 Pull Tape or Rope. Pull tape or rope shall be as specified in the Special Provisions and used to install wires or cables. Pull tape shall consist of a flat, woven, lubricated, soft-fiber polyester tape with a minimum tensile strength of 8,000 N (1,800 lbs.) and shall have a painted sequential measurement marling at least every meter (3 ft.). Pull rope shall be a 6.25 mm (Ya in.) diameter polyethylene rope with a minimum tensile strength of 8,000 N (1,8001bs). 209-3.7 Pull Boxes. Pull boxes, covers, and extensions shall be approved by the Agency or as shown on the Plans or Standard Plans and/or specified in the Special Provisions. When a ballast, transformer or other device is to be placed in a non-metallic pull box, the pull box shall be provided with recesses for a hanger. 209-3.8 Splice Insulation. 209-3.8.1 General. Splice insulation shall be as specified herein or as specified in the Special Provisions. 209-3.8.2 Splice Insulation Tape and Pads. Splice insulation shall consist of layers of vinyl chloride electrical insulating tape, confomilng to ASTM D 2301, Type I. Low-voltage tape shall be UL or ETL listed and shall be the following types: a) Self-fusing, oil and flame-resistant, synthetic rubber. b) Pressure-sensitive, adhesive, polyvinyl chloride, 0.15 mm minimum thickness. Tape for insulating splices in high-voltage (over 600 V) circuits shall be designed for use on 5kV circuits and shall be resistant to ozone, corona and water. Insulating pads shall be composed of a laminated 2 mm (1/16 inch) thickness of electrical grade polyvinyl chloride and a 3mm (1/8 inch) thickness of butyl splicing compound with removable liner. t • 20 2007 Supplement to "Greenbook" TABLE 209-4.1.2(A) MATERIAL ASTM NO. Prestressed Steel A 416 Deformed Bar A615 Grade 40 or Grade 60/A706 Base Plate A 36 Base Anchor Lugs A 36 2094.1.3 Casting of Concrete Standards. Reinforced concrete standards shall be cast in rigid steel molds such that the relief in the design of the concrete standard is sharp and distinct. Longitudinal steel reinforcement shall be securely anchored to the top and bottom of the mold plates and shall be placed to provide 19.1mm (3/4 inch) minimum concrete cover except within 610mm (2 feet) of the top where the minimum cover shall be 15.9 mm (5/8 inch). Reinforced concrete standards shall be cured in accordance with the following phases: a) Mold Cure: Reinforced concrete standards shall be cured in their molds until the concrete has attained a set sufficiently hard to prevent deformation or slipping of cable strands. b) After the mold cure is complete, the remaining cure shall conform to 207-2.7. After sufficient curing, the entire outside surface shall be blasted to remove cement laitance and develop the surface texture. 2094.1.4 Finish of Concrete Standards. The finish shall be without cracks or crazing, rock pockets or any discoloration or ridges and shall have a uniform surface (without objectionable mold marks) and texture throughout the entire length. Surface defects extending less than 15.9mm (5/8 inch) in the shell may be repaired without the prior approval of the Engineer. The repair shall be made by a method that will produce a permanent bond and a surface that blends into the color and surface appearance of the remainder. Surface defects extending greater than 15.9 mm (5/8 inch) into the shell shall not be repaired prior to inspection by the Engineer. Reinforced concrete standards containing voids or insufficient cover over prestressing cables, reinforcing steel or a blocked central opening or duct will not be accepted. 2094.1.5 Acceptance and Rejection of Concrete Standards. Reinforced concrete standards shall be labeled or marked in a permanent fashion to indicate the manufacturer, and month and year of fabrication. Markings shall be located within 610mm (2 ft.) of the bottom but not on the hand-hole cover. Markings shall be visible through the handhole opening. A lot shall be defined as 100 reinforced concrete standards or less of the same design, produced in sequence on consecutive working days, and bearing the specified markings. The standards composing each lot shall be uniform in color and surface appearance: A new lot number shall be assigned if there is any change in the size, type, or spacing of reinforcing or prestressing steel, concrete mix, or curing method. The frequency of sampling and testing shall be as specified in the Special Provisions. The Contractor shall notify the Engineer, in writing, at least five days prior to any contemplated change in supplier or source of raw materials, and shall obtain approval of any changes before the standards are delivered to the Agency. i 2007 Supplement to "Greenbook" 21 209-4.2 Wire/Conductors. 209-4.2.1 General. Wire shall be a single strand of drawn metal that may or may not be insulated. Conductor shall be a single (solid) or multiple (stranded) strands metal that are insulated. Cable shall be multiple wires or conductors that are insulated and enclosed in an insulating cable jacket. Copper wire shall conform to ASTM B 3 and B 8. Wire sizes shall be based on the American Wire Gage (AWG). The wire diameter shall not be less than 98 percent of the specified AWG diameter. All conductors shall have clear, distinctive and permanent markings on the outer surface throughout the entire length showing the manufacturer's name or trademark, insulation type letter designation, wire size, and voltage rating. Conductor insulation shall be a solid color or basic colors with a permanent colored stripe unless otherwise specified in the Special Provisions. Solid or basic colors shall be homogenous throughout the full depth of insulation except for the clear nylon layer, if present. 209-4.2.2 Series Circuits Conductors. Wire for series street lighting systems shall be No. 8 solid copper wire. The wire shall be insulated with a 2.80mm (0.110 inch) thickness of black polyethylene insulation per Standard S-61-402 of the Insulated Power Cable Engineers Association, and designated for operation at 5,000 volts. The Contractor shall submit a Certificate of Compliance in accordance with 2-5.3.3 and 4-1.5, for all 5,000-volt (6.6 Amp.) series lighting conductors. Where isolating transformers or external (remote) ballasts are used, the secondary wires, in the Standard, from the transformer or external (remote) ballast to the luminaire shall be insulated No. 10 AWG solid copper wire. The insulation for these wires shall be black, rated, and UL approved for 600V operation. The insulation shall be standard THW or THWN/THHN grade polyvinyl chloride, conforming to the applicable provisions of ASTM D 2219 and D 2220. 209-4.2.3 Multiple Circuits Conductors. Conductors for multiple circuits shall be of the type, size and insulation colors specified in Table 209-4.2.3(A) or on the Plans. The insulation shall be THW or THHN/THWN, or as specified on the Plans, grade polyvinyl chloride, conforming to the applicable provisions of ASTM D 2219 and D 2220. At any point the minimum thickness of any THW or THHN/THWN insulation shall be 1.4mm (0.055 inches) for conductor sizes No. 14 AWG to No. 10 AWG, inclusive and 1.5 mm (0.059 inches) for No. 8 AWG to No. 2 AWG inclusive. 6 22 2007 Supplement to "Greenbook" TABLE 2094.2.3 (A) M lti l Ci it Identification p u e rcu s Function Insulation Colors Band Size Base Stripe' Symbols` Multiple Service Ungrounded Line 1 Blk. None NBR 8 (Stranded) Ungrounded Line 2 Red None NBR 8 Grounded/Neutral Wht. None NBR 8 Street Lighting Ungrounded Line 1 odd Blk. None NBR 8 Pull Box to Pull Box° (Stranded) Ungrounded Line 2 (even) Red None NBR 8 Grounded/Neutral Wht. None NBR 8 Street Lighting Ungrounded Line 1 odd - Blk None NBR 10 Pull Box to Luminaire° Ungrounded Line 2 even Red None NBR 10 (Solid) Grounded/Neutral Wht. None NBR 10 Lighting Control Ungrounded to PEU Blk. None C1 10 From Luminaire's with PEU's to Luminaire's Switching leg of PEU to terminal strip. Red None C2 10 without PEU's (Solid) Switching leg of PEU to unswitched Luminaire'. Put. None NBR 8/10' NBR = No Band Required PEU = Photoelectric Unit a. Band conductors in each pull box and near ends of termination point. b. Both wires between external high intensity discharge (HD) ballast lamp shall be black No. 10 Solid wire. c. "S" if circuit is switched on line side of service equipment by utility. d. Color code: Blk-Black, Pur: Purple and Wht.-White e. No. 8 Stranded conductor from pull box to pull box and No. 8 solid wire in the Standards. 209-4.3 Splicing Units and Terminal Blocks. 2094.3.1 Disconnecting Splice Connector (High Voltage). 2094.3.1.1 Connector Case. The case or shell shall be formed of a neoprene or plastic composition having a volume resistivity not less the 1013 ohms per cm (3.94 x 1012 ohms per inch). The diameter of the case shall not exceed 6.35cm (2 1/2 inches) and the length shall not exceed 25.4 cm (10 in). The case shall withstand a load of 888.9 N (2001bs) applied normal to the axis of the case without rupture, cracking, or permanent deformation. The two halves of the case shall lock together with screw threads forming a watertight joint and be separated by a neoprene "O" ring under compression when the connector is assembled. The wires that are to be spliced shall attach to the connector by a self threading lug made from a No.'8 AWG solid copper wire. The connecting lug shall be slotted at 90 degrees to provide a pressure fit between the male and female parts. All metal parts shall be cadmium plated. Each half of the case shall be completely filled with a sealing compound complying with 209- 4.3.1.2 and held in place with a wire/cable entrance plug designed to accommodate any cable having an overall diameter of between 8.79 mm (11/32 inch) and 15.24mm (5/8 inch). 2094.3.1.2 Sealing Compound. The sealing compound for the cable connector case shall be a viscous paste composed of oil and an inert mineral filler. The compound shall be waterproof and resistant to oxidation, weathering and biological attack. The volume resistivity shall not be less than 1012 ohms per cm (3.94 x 1011 ohms per inch). N' 2007 Supplement to "Greenbook" 23 When the sealing compound is exposed to air for 18 hours in a film 3.18 mm (1/8 inch) thick at a temperature of 21°C ± 1.1°C (70°F ± 2°F) absorption of water shall not exceed 3mg per sq cm. (0.02 oz per sq in) of surface area in contact with the water. When allowed to dry in contact with air, the lineal shrinkage of the exposed surface of the compound shall not exceed 0.2%. 209-4.3.1.3 Electrical Characteristics. When two wire/cable ends are connected and sealed in the connector case with sealing compound, the unit shall sustain an electrical stress of 11,000 volts at of 21 °C± 1.1 °C (70°F± 2°F), without breakdown, after immersion in water for 18 hours. 209-4.3.2 Fused Splice Connectors. Fused disconnect connectors shall have no exposed metal parts except for the head of a stainless steel assembly screw. The head of the stainless steel assembly screw shall be recessed a minimum of 0.8 mm (1/32 inch) below the top of a plastic boss which surrounds the head. Fused splice connectors shall completely enclose the fuse and shall protect the fuse against damage from water and weather. The contact between the fuse and the fuseholder shall be spring pressure. Fuses shall be standard midget, ferrule type, with "Slow Blow" feature and shall be 10mm x 38 mm (3/8 inch x 1-1/2 inch). 209-4.3.3 Terminal Blocks. Terminal blocks shall have a minimum of 12 positions with terminals rated at size No. 8 AWG or larger, to accept the field wires indicated on the Plans. 209-4.4 High Pressure Sodium Luminaires. 2094.4.1 General. High-pressure sodium luminaires shall be the enclosed cutoff type with a horizontal burning lamp unless otherwise specified in the Special Provisions or on the Plans. Each luminaire shall consist of a housing, a reflector, a refractor or lens, a lamp socket, an internal (integral) ballast, starter, a terminal strip and a lamp. Each mast arm mounted luminaire shall be fiunished without a photoelectric unit receptacle unless otherwise specified in the Special Provisions or on the Plans. If a photoelectric unit receptacle is included, a rain tight shorting cap shall be installed If a luminaire housing is provided with a hole for the receptacle, the hole shall be closed, covered and sealed with weatherproof material. The housing shall be fabricated from aluminum Housings that are painted shall withstand a 1000-hour salt spray test as specified in ASTM B 117. Other metal parts of the housing shall be fabricated from metal that equals or exceeds the corrosion resistance and finish of the metal used for the housing. The housing shall be equipped with a slip-fitter capable of mounting on a 50 mm (2 inches) pipe tenon and of being adjusted 5 degrees from the axis of the tenon. The clamping brackets of the slip-fitter shall not bottom out on the housing bosses when adjusted within the ± 5 degree range. . No part of the slip-fitter mounting brackets shall develop a permanent set in excess of 0.5 mm (1/64 inches) when the four 10 mm (3/8 inches) diameter cap screws used for mounting are tightened to 13 Nm (9.62 ft•lbs). Luminaries to be mounted on horizontal mast arms, shall be tested in conformance with California Test 611, and be capable of withstanding cyclic loading in (G = Acceleration of Gravity): a) A vertical plane at a minimum peak acceleration level of 3.0 G peak-to-peak sinusoidal loading (same as 1.5 G peak) with the internal ballast removed, for a minimum of 2 million cycles without failure of any luminaire parts, and "Oo \ie 24 2007 Supplement to "Greenbook" b) A horizontal plane perpendicular to the direction of the mast arm at a minimum peak acceleration of 1.5 G peak-to-peak sinusoidal loading (same as 0.75 G peak) with the internal ballast installed, for a minimum of 2 million cycles without failure of any luminaire parts, and c) A vertical plane at a minimum peak acceleration level of 1.0 G peak-to-peak sinusoidal loading (same as 0.5 G peak) with the internal ballast installed, for a minimum of 2 million cycles without failure of any lummaire parts. The surface of each reflector shall be specular and shall be protected by either an anodized finish or a silicate film. Each refractor or lens shall be mounted in a frame that is hinged to the housing and secured with a spring- loaded latch. Each refractor shall be made of glass or polycarbonate plastic as specified in the Special Provisions. Each lens shall be made of heat and impact resistant glass. The optical system, consisting of the reflector, refractor or lens, lamp socket and lamp, shall be contained in a sealed chamber. The seal shall consist of a gasket between the reflector and refractor or lens and a gasket between the reflector and lamp socket. The chamber shall have provision for a filtered flow of air in and out due to lamp heat. Filtering shall be accomplished by either a separate filter or a filtering gasket. Each lamp socket shall be a porcelain enclosed mogul-multiple type. The shell shall contain integral lamp grips to assure electrical contact under conditions of normal vibration. The socket shall be mounted in the h,minaire in a manner to permit pre-setting a variety of specified light distribution pattems. The socket shall be rated for 150OW and 600V, and shall be rated for a 4KV pulse. When the ballast, starter and terminal strip are mounted on a down-opening door, the door shall be hinged and secured to the lummaire separately from the refractor or flat lens flame. The door shall be removable and replaceable. The door shall be secured to the housing in a manner to prevent its accidental opening when the refractor or flat lens frame is opened. Field conductors connected to the luminaire shall terminate on a barrier type terminal block secured to the housing. Terminal screws shall be captive and equipped with wire grips for conductors up to No. 6 AWG. Each temunal position shall be clearly identified. The minimum fight distribution for each luminaire shall be as shown on the isolux diagrams on the Plans. The maximum brightness of each cutoff luminaire, with the lamp indicated shall be as specified in Table 2094.4.1(A). TABLE 209-4.4.1(A) Lamp ANSI Code No. Lamp Wattage Maximum Brightness (cdlm 2) S55 150 140 S66 200 140 S50 250 175 S67 310 210 S51 400 260 Brightness readings specified are based on the use of a brightness meter with an acceptance angle of 1.5 degrees. When measured on the 90-degree and 270-degree lateral angle line, the maximum brightness shall not exceed the above specified brightness when the meter is located at a horizontal distance of 37m (121 ft 6.% in) and a vertical distance of 2.3m (7 ft 6 in) between the luminaire and the meter, or at an angle of 3 degrees 35 minutes from the horizontal to the line between the luminaire and the meter. Measurements shall be made from both the 90 degree line and the 270 degree line and w OW 2007 Supplement to "Greenbook" 25 averaged. The lamp for each test shall be operated at the wattage necessary to produce a light output as specified in Table 209-4.4.1(B). TABLE 209-4.4.1(B) Lam Wattage Lumens 150 16,000 200 22,000 250 27,000 310 37,000 400 50,000 2094.5 Lamp Ballasts. 2094.5.1 General. The input voltage for ballasts and ballast types shall be as shown on the Plans or as specified in the Special Provisions. The ballast shall be plainly marked as to its operating voltage and wattage characteristics. Noise generated by the ballast or in combination with the starting aid shall be minimized. The ballast, including starting aid, shall incorporate protection against normal lamp failure modes. Ballasts for luminaires to be mounted on mast amts, brackets or lowering assemblies shall be located within the lunvnaire housing. Each ballast shall be designed for the type, characteristics and wattage of the lamp it is to operate and it shall provide lamp starting and waveforms, voltage and current specified in the Special Provisions. Ballasts shall also be designed to operate under outdoor conditions, either mounted internally (integral) within the lummaire or lighting fixture or mounted externally (remote) to the luminaire. Ballasts shall provide reliable starting and operation at ambient temperatures down to -30°C (-22°F) for the rated life of the lamp. The ballast shall be designed for continuous operation at ambient air temperatures from -20°C (-4°F) to 65°C (149°F) without reduction in ballast life. Ballasts shall have a design life of not less than 100,000 hours. Ballast shall be designed to operate for a minimum of 180 cycles of 12 hours on and 12 hours off, with the lamp circuit in an open or short-circuited condition and without measurable reduction in the operating requirements in 2094.4.1. Heat-generating components shall be mounted so as to use the portion of the luminaire they are mounted on as a heat sink. Capacitors shall be located as far as practicable from heat-generating components or shall be thermally shielded to limit the case temperature to 75°C (167°F). Transformers and inductors shall be resin-impregnated for protection against moisture. Capacitors, except those in starting aids, shall be encased in metal and hermetically sealed. Ballasts shall be tested in conformance with ANSI C82.6-1980. 2094.5.2 Internal Ballasts. Each internal ballast shall consist of separate components, each of which shall be capable of being easily replaced. A starting aid which is encapsulated will be considered as a single component. Each component shall be provided with screw terminals, NEMA tab connectors or a single multi- circuit connector. All conductor terminals shall be identified as to the component terminal to which they are connected Internal ballasts shall be tested within the luminaire and shall be rated at a minimum temperature of 105° C ( 221 ° F) or as specified in the Special Provisions. 2094.53 Remote Ballasts. Ballasts to be located remote (external) from the luminaire shall be the submersible type and shall conform to 2094.8.3. All components, including starting aids, shall be enclosed in a single housing. Ballast leads shall extend a minimum of 300 nun (11-13/16 inches) from the housing. Steel N 26 2007 Supplement to "Greenbook" housings shall be galvanized or painted. Ballast housings shall be clearly labeled to indicate lamp type, lamp wattage and input voltage. 2094.5.4 Starting Aids. Starting aids, if required, shall be interchangeable between ballasts of the same wattage and manufacturer without adjustment. 2094.5.5 High Pressure Sodium Lamp - Constant Wattage (CW) or Constant Wattage Auto- Regulator (CWA) - Ballasts. CW and CWA ballasts shall have a ballast characteristic curve which will intersect both of the lamp-voltage limit lines between the wattage limit lines and remain between the wattage limit lines throughout the full range of lamp voltage. This requirement shall be met not only at the rated input voltage of the ballast, but also at the lowest and highest input voltage that the ballast is rated Throughout the rated lifetime of the lamp, the ballast curve shall fall within the limits of lamp voltage and wattage specified in the Special Provisions. 209-4.5.6 Regulator Type Ballasts. 2094.5.6.1 General. Regulator type ballasts shall be lag-type or lead-type conforming to the following: a) For nominal input voltage and lamp voltage, the ballast design center shall not vary more than 7.5 percent from rated lamp wattage. b) The ballast shall be designed such that a capacitance variance of ±6 percent will not cause more than a ±8 percent variation in lamp wattage regulation throughout the rated lamp life for nominal input voltage. c) The lamp current crest factor shall not exceed 1.8 for input voltage variation of ±10 percent at any lamp voltage from initial through life. 2094.5.6.2 Lag-Type. Lag-type regulator ballasts shall have the primary and secondary windings electrically isolated and, when operated with the appropriate lamp, shall have the following characteristics and maintain the following lamp operation: a) The power factor shall be not less than 90 percent throughout the life of the lamp at nominal line voltage with a nominally rated reference lamp. b) Lamp wattage regulation spread at any lamp voltage from nominal through life shall not vary by more than 18 percent for a±10 percent input voltage variation. 2094.5.63 Lead-Type. Lead-type regulator ballast (CWA) shall when operated with the appropriate lamp, have the following characteristics and shall maintain the following lamp operation: a) The power factor shall be not less than 90 percent when the ballast is operated at nominal line voltage with a nominally rated reference lamp. b) Lamp wattage regulation spread at any lamp voltage from nominal through life shall not vary by more than 30 percent for ±10 percent input voltage variation. 2094.5.7 Autotransformer or Reactor Type Ballast. Each nonregulating reactor, autotransformer, or high reactance ballast shall, when operated with the appropriate lamp, have the following characteristics and maintain the following lamp operations: a) The power factor shall be not less than 90 percent when the ballast is operated at nominal line voltage with a nominally rated reference lamp. b) Lamp wattage regulation spread at any lamp voltage from nominal through life shall not vary by more than 25 percent for S percent input voltage variation. v 04~ 2007 Supplement to "Greenbook" 27 c) For nominal input voltage and lamp voltage, the ballast design center shall not vary more than 7.5 percent from rated lamp watts. d) The lamp current crest factor shall not exceed 1.8 for an input voltage variation of ±5 percent at any lamp voltage from initial through life. 2094.5.8 Physical Requirements. External leads for multiple to multiple and series to multiple secondary connections shall be Type USE No. 10, rated 600VAC. Primary conductors for series to multiple ballasts shall be rated for use on 5000VAC circuits. Ballast leads shall extend a minimum of 300 mm (11-13/16 inches) from the case. The ballast insulation shall be NEMA 185°C (3657) or as specified in the Special Provisions. Series to multiple ballasts shall withstand the application of 12,000VAC from core to primary coil and from coil to coil for a one minute period. Series to multiple ballasts secondaries and multiple-to-multiple ballast shall withstand the application of 2,200VAC from core to coils and, for multiple units only, from coil to coil for a one minute period These tests shall be made immediately after operation of the ballast at full load for 24 hours. Non-submersible ballast shall be provided with metal half-shell coil protection, moisture resistant, synthetic varnish impregnated windings and shall be suitable for outdoor operation in a rain tight enclosure. Each ballast to be installed in a pull box shall be the submersible type and be provided with handle and a hanger. 2094.6 High Pressure Sodium Lamps. High pressure sodium lamps shall conform to ANSI Standard C 78 "Tamp Specifications, Physical and Electrical Characteristics of High-hrtensity Discharge Lamps," when tested in conformance with the requirements in ANSI Standard C78.388, "Methods of Measurement of High Pressure Sodium Lamp Characteristics." High-pressure sodium lamps shall have a minimum average rated life of 24,000 hours. 2094.7 Photoelectric Controls. 2094.7.1 General. Photoelectric controls shall consist of a photoelectric unit which plugs into an EEI- NEMA twist lock receptacle integral with the luminaire. Photoelectric controls, if required in the Special Provisions or on the Plans, shall be capable of switching multiple lighting systems directly. 2094.7.1.1 Photoelectric Unit. Photoelectric units shall provide an output in response to changing light levels. The response level shall remain stable throughout the life of the control unit. Components shall not require periodic replacement. Photoelectric units shall have a "tumon" between 10 and 50 lux and a "turn off' at between 1.5 and 5 times "turn-on." Measurements shall be by the procedures specified in "EEI-NEMA Standards for Physical and Electrical Interchangeability of Light-Sensitive Control Devices Used in the Control of Roadway Lighting". Photoelectric units shall also conform to the following: a) The supply voltage rating shall be 60 Hz, 105-130 V, 210-240 V, or 1-5-240 V, as specified. b) The load rating shall be 1000 W minimum, incandescent, mercury or fluorescent. c) The operating temperature range shall be from -29°C (-20°F) to 65°C (149°F). d) The power consumption shall be less than 10 W. e) The unit shall be housed in a weatherproof enclosure. 0 The base of the unit shall be provided with a three prong, EEI-NEMA standard, twist-lock plug mounting. g) Be equipped with a "fail-on" feature. V-6 'Fri 28 2007 Supplement to "Greenbook" 2094.7.1.2 Contactor. The contactor shall have contacts rated to switch the specified lighting load and shall be normally open, unless otherwise specified in the Special Provisions. The contactor shall be either the mechanical armature type or the mercury displacement type. The contacts of the mechanical armature type contactor shall be either fine silver, silver alloy, or superior alterative material. The contactor shall have a minimum rating of 30A, per contact, inductive load. 2094.7.13 Terminal Blocks. Terminal blocks shall be rated at a minimum of 30A, 600V or as specified in the Special Provisions. Terminal blocks shall be molded from phenolic or nylon material and shall be the barrier type with plated brass screw terminals and integral type marking strips. 2094.8 Transformers. 2094.8.1 General. Multiple to multiple and series to multiple transformers shall be of the single-phase, dry type designed for operation on a 60 Hz supply. 2084.8.2 Electrical Requirements. Transformer ratings shall be 120/480V, 240/480V, 480/120V or 480/240V for multiple to multiple units or as shown on the Plans. Transformer ratings for series to multiple units shall be 6.OA/120V or 6.6A/4.8kv or as shown on the Plans. Secondary 480V windings shall be center tapped Volt-ampere ratings shall be as shown on the Plans. Transformer efficiency shall exceed 95 percent for multiple to multiple units and 80 percent for series to multiple units. Secondary voltage regulation and tolerance shall be ±3 percent from half load to full load for multiple to multiple units and +10 percent (maximum) at no load to t3 percent at full load for series to multiple units. Transformers shall have a decal showing a connection diagram. The diagram shall show either color coding or tagging of wires with primary (H1, 1-12) or secondary (XI, X2) markers, and shall also show the primary and secondary voltage and volt-ampere rating. 2094.83 Submersible Type Transformers. Submersible type transformers shall be securely encased in a rugged corrosion resistant, watertight case and shall withstand a 5-day test submerged in 600 mm (23-5/8 inches) of salt water (2 percent salt by mass) with 12-hour on and off periods. The operating periods shall be at full load. Leads of submersible transformers shall be brought out through one or more sealed hubs and shall be secured in a manner that will withstand a 450-N (101 lbs force) static pull without loosening or leaking. 209-5 MATERIALS FOR TRAFFIC SIGNAL SYSTEMS. 209-5.1 Steel Pedestrian Standards and Pedestals for Controller Cabinets. All steel pedestrian standards and pedestals for controller cabinets shall be constructed of 3mm (1/8 inch) or thicker galvanized steel, 100mm (4 inch) schedule 40 galvanized steel pipe, or size 103 conduit. Steel pedestrian standards and pedestals shall be constructed in conformance with 209-3.3, with the top designed for post top slip-fitting. Galvanized steel pipe shall conform to ASTM A53. Push button posts shall also be manufactured of 63.5 nun (2-'/z inch) schedule 40 galvanized steel pipe conforming to ASTM A 53. 209-5.2 Pedestals. Pedestals shall have an aluminum identification plate attached with stainless steel rivets or screws, as specified on the Plans. All welds shall be continuous and conform to the requirements of 209-2, 209-3.3.3.2 or 209-3.3.3.3 depending on the material the pedestal is fabricated from. Exposed welds shall be ground flush with the base metal. Pedestals shall be galvanized by the hot-dip process conforming to 210-3, or cadmium plated with Type NS coating conforming to ASTM A 165. If specified in the Special Provisions or shown on the Plans, pedestals shall also be painted in accordance with 210-1. U, Nw 2007 Supplement to "G.reenbook" 29 Pedestals shall be fiunished complete with all necessary fittings and hardware for attachment of the controller cabinet to the adjoining pedestal. 209-53 Conductors and Cable. 209-53.1 General. Copper wire shall conform to ASTM B 3 (solid) and 209-4.2. Wire sizes, other than wires used in loop detector lead-in cable, shall be based on the American Wire Gage (AWG). The wire diameter shall not be less than 98 percent of the specified AWG diameter. Conductors used in loop detector lead-in cable shall conform to the requirements in ASTM B 286. A Certificate of Compliance shall be submitted by the Contractor in conformance with 2-5.3 and 4-1.5 for each type of cable used in the Work. Unless otherwise specified on the Plans or in the Special Provisions, Table 209-5.3.1(A) shall be used to identify the conductors to be used in the Work. TABLE 209-5.3.1(A) Identification Circuit Signal Phase Insulation Colors Band ° Size Function Base Stripe° Symbols Vehicle Signals` 2,6 Red, Yet., Brn. Blk. 2.6 14 4,8 Red, Yel., Brn. Ora. 4.8 14 1,5 Red, Yet., Brn. None 1.5 14 3,7 Red, Yel., Brn. Pur. 3.7 14 2p, 6p, . Red, Bm. Blk. 2p, 6 14 Pedestrian 4p, 8 Red, Brn. Ora. 4p, 8 14 Signals` 1P, 5 Red, Brn. None 1p, 5 14 3p, 7 Red, Brn. Pur. 3p, 7 14 2p, 6 Blue BIk. P-2, P-6 14 Pedestrian 4p, 8 Blue Ora. P-4, P-8 14 Push Buttons` 1p, 5 Blue None P-1, P-5 14 3 .7 Blue Pur. P-3, P-7 14 Traffic Signal Underground between Service Blk. None CON-1 6 Controller Cabinet Switch & Cabinet Red None CON-2 6 Sign Lighting Ungrounded Line 1 BIk. None SL-1 10 Ungrounded Line 2 Red None SL-2 10 Pedestrian Push Buttons Wht. Bilk. NBR 14 Grounded and Signals Wht. None NBR 10 Common Sign Lighting Wht. None NBR 12 Railroad Pre-Em tion Blk. Blk. R 14 Spares BIk. None NBR 14 NBR = No Band Required a. On overlaps, insulation is striped for first phase in designation, e.g. Phase (2 & 3) insulation is striped as for phase 2. b. Band for overiap and special phases as required. c. These requirements do not apply to signal cable. d. Band conductors in each pullbox and near each termination point. On signal light circuits, a single band may be placed around 2 or 3 ungrounded conductors comprising a phase. e. Conductors between ballasts and sign lighting lamps shall be No. 16 and color shall correspond to the ballast leads. f. The No. 14 AWG conductor shall be solid copper in a 0.41 mm (0.016 in) minimum polyvinyl chloride insulation incased in a 0.13 mm (0.005 in) minimum clear nylon jacket. The No. 10 conductor shall be solid copper in a 0.56 mm (0.022 in) minimum polyvinyl chloride insulation incased in a 0.20 mm (0.008 in) minimum clear nylon jacket. g. Color Code: Yel-Yellow, Bm-Brown, Blu-Blue, BIk-Black, Wht-White, Ora-Orange and Pur-Purple. All single conductors, multi-conductor cables, and lead-in cables, shall have clear, distinctive and permanent markings on the outer surface throughout the entire length showing the manufacturer's name or trademark, insulation type letter designation, conductor size, voltage rating and the number of conductors. The multi 30 2007 Supplement to "Greenbook" .conductor cable jacket shall be black polyethylene binder sheath, rated for 600V and 75°C (1670F), or black polyvinyl chloride conforming to IMSA 9-1. Filler material, if used to make the multi-conductor round, shall be polyethylene. Conductor insulation shall be of a solid color or of basic colors with a permanent colored spiral stripe under the nylon jacket, as detailed in Table 2094.2.3(A) unless otherwise specified in the Special Provisions. Solid or basic colors shall be homogeneous through the firll depth of insulation. Identification stripes shall be a continuous spiral over the entire length of the conductor. For conductor size No. 2 and larger, the insulation may be black and the ends of the conductors shall be taped with electrical insulating tape of the required color for a minimum of 508 mm (20 inches). 209-53.2 Materials. 209-53.2.1 General. Individual wires in the cable shall be solid copper with Type THWN or polyvinyl chloride insulation as specified in the Special Provisions, and shall conform to the requirements in 209-4.2.1 and ASTM 13286. The minimum thickness of Type THWN insulation, at any point, shall be 0.3mm (0.012 inches) for No. 14 conductor and 0.4mm (0.016 inches) for No. 10 conductor. The minimum thickness of the polyvinyl chloride insulation, at any point shall be 0.41mm (0.016 inches) for No. 14 AWG conductor and 0.56mm (0.022 inches) for No. 10 AWG conductor. No. 14 AWG conductors shall have a 0.127mm (0.005 inches) minimum thickness clear nylon jacket and the No. 10 AWG conductors shall have a 0.203mm (0.008 inches) clear nylon jacket. 209-53.2.2 Three-Conductor Cable. Three conductor cable shall be used for pedestrian push buttons and a spare. Three conductor cable shall consist of 3 No. 14 AWG wires. The cable jacket shall have a minimum average thickness of 1.1 mm (0.043 inches) and a minimum thickness of 0.9mm (0.035 inches). The nominal outside diameter of the cable shall not exceed 10 mm (3/8 inches). The color code of the wires shall be blue/black stripe, blue/orange stripe and whitelblack stripe. 209-53.23 Five-Conductor Cable. Five conductor cable shall consist of 5-No. 14 AWG wires. The cable jacket shall have a minimum average thickness of 1.lmm (0.043 inch) and a minimum thickness of 0.9mm (0.035 inch). The nominal outside diameter of the cable shall not exceed 13mm (1/2 inch). The color code of the wires shall be red, yellow, brown, black, and white. 209-53.2.4 Nine-Conductor Cable. The nine conductor signal cable shall consist of 8-No. 14 AWG wires and 1-No. 12 AWG wire. The cable jacket shall have a minimum average thickness of 1.5mm (0.059 inch) and shall have a minimum thickness of 1.2mm (0.047 inch). The nominal outside diameter of the cable shall not exceed 17mm (11/16 inch). The color for the No. 12 AWG wire shall be white. The color code for the No. 14 AWG wires shall be as specified in Table 209-5.3.2.4(A). TABLE 209-53.2.4(A) PRIMARY COLOR COLOR CODE Red Yellow/Black stn Yellow BrownBlack str Brown Black Red/Black str Whiteffilack strip 209-53.2.5 Twelve-Conductor Cable. Twelve conductor cable shall be used for vehicle signals, pedestrian signals, spares, and the signal common or as specified in the Special Provisions. Twelve conductor cable shall consist of 11-No. 14 AWG wires and 1-No. 12 AWG wire. The cable jacket shall have a minimum average thickness of 1.5mm (0.059 inch) and shall have a minimum thickness of 1.2mm (0.047 inch). The nominal 2007 Supplement to "Greenbook" 31 outside diameter of the cable shall not exceed 20mm (3/4 inch). The color code of the No. 12 AWG wire shall be white.. The color code and functional connections for the No. 14 AWG wires shall be as specified in Table 209- 5.3.2.5(A), unless otherwise specified in the Special Provisions or approved by the Engineer. TABLE 209-53.2.5(A) Color Code Termination Phase Red Vehide Signal Red 2A6, 6, or 8 Yellow Vehicle Signal Yellow 2, 4, 6, or 8 Brown Vehicle Signal Green 2, 4, 6, or 8 Red/Black stripe Vehicle Signal Red 1, 3, 5, or 7 Yellow/Black stripe Vehicle Signal Yellow 1, 3, 5, or 7 Brown/Black stripe Vehicle Signal Green 1, 3, 5, or 7 Black/Red stripe Spare, or Ped. Signal use as required for Vehicle Signal red or"Don't Walk" - BladvWhite sbi Spare, or use as required for Yellow - Black Spare; or Ped. Signal use as required for Vehicle Green or'WaV - - RedNVhite stripe Ped. Signal "Don't Walk" - Brown/While stripe Ped. Signal Valk" - 209-531.6 Twenty Eight -Conductor Cable: Twenty Eight conductor signal cable shall consist of 27-No. 14 AWG wires and I-No. 10 AWG wire cabled with polyethylene fillers, if necessary to make the cable round Clear binder tape shall be used to wrap the cable core. The black polyvinyl chloride cable jacket shall have a minimum average thickness of 2mm (0.08 inch) and shall have a minimum thickness at any point of 1.6mm (0.06 inch). The cable jacket shall have printed on the outside the manufacturers name, the type of insulation for each wire, the number of wires of each size, the size of the wires in the cable and the voltage rating. Sequential footage marking shall also be shown on the surface of the jacket, printed at 0.61m (2 foot.) intervals. The nominal outside diameter of the cable shall not exceed 23mm (7/8 inch). The voltage rating shall be 600V and the temperature rating shall be 75°C (167°F). Signal commons in each cable shall be kept separate except at the signal controller. Each cable shall be labeled in each pull box, "Cl" or "C2". The cable identified as "Cl" shall be used for signal Phases 1,2,3, and 4. The cable identified "C2" shall be used for signal Phases 5,6,7, and 8. The "CI" and "C2" cable may also be used as shown on the Plans or as specified in the Special Provisions. The reel size shall allow for up to 610m (2000 ft) of cable maximum with a 69.8mm (2-3/4 inch) arbor hole. The color code for the No. 10 AWG wire shall be white. The color code and functional connections for the No. 14 AWG wires shall be as shown in Table 209-5.3.2.6(A), unless otherwise specified in the Special Provisions. ArA- r7_S- up r 34 2007 Supplement to "Greenbook" Crimp-style connectors shall be applied with a tool that is designed to prevent opening of the handles until the crimp is complete. An equipment grounding conductor bus shall be provided in each controller cabinet. The bus shall be grounded to the cabinet and shall be connected to the metal conduit system or other approved ground with a No. 8 or larger, grounding conductor. With all of the cabinet equipment in place and connected, the resistance between the grounded conductor terminal bus and the equipment grounding conductor bus shall be 50 M92 minimum, when measured with an applied voltage of 150VDC. If a direct current (DC) circuit is to be grounded, the circuit shall be connected to the equipment ground only. Two or more terminal blocks shall be provided for field connections. Terminals blocks for field connections shall be installed within 560mm (22-1/16 inches) of the face on the cabinet and shall be oriented for screwdriver operation from the door opening. All terminals shall be a minimum of 125mm (4-7/8 inches) above the foundation. No more than 3 conductors shall be brought to any one terminal. Two flat metal jumpers, straight or U shaped, may also be placed under a terminal screw. At least 2 full threads of all terminal screws shall be fully engaged when the screw is tightened. No live parts shall extend beyond the barrier. Wiring diagrams shall conform to 307-4.3. 209-5.4.3 Cabinets. 209-5.4.3.1 General. Controller cabinets shall be rainproof and conform to the dimensions shown on the Plans or the Standard Plans. The cabinet top shall be crowned 13mm (1/2 inch.) or slanted to the rear to prevent standing water. Cabinets and doors shall be fabricated of either 1.8mm (1/16 inch) minimum thickness cold rolled steel,(l.8mm (1/16 inch) minimum thickness stainless steel or 3mm (1/8 inch) minimum thickness aluminum. All exterior seams shall be continuously welded. 'Exterior welds shall be ground smooth. Edges shall be filed to a radius of 0.8 mm minimum. Metal shelves or brackets shall be provided to support the controller unit and auxiliary equipment. Machine screws and bolts shall not protrude beyond the outside wall of the cabinet. Conduit shall enter the bottom and towards the front of the cabinet unless otherwise shown on the Plans. A pliable seal, composed of caulking compound or mastic, shall be placed between each controller cabinet and the concrete foundation to prevent water, dust and dirt from entering the cabinet. 209-5.4.3.2 Steel Cabinets. Cabinets fabricated from steel shall be finished with a polymer or enamel coating system conforming to Color No. 14672 of Federal Standard 595B. Coatings shall be commercially smooth, substantially free of flow lines, paint washout, streaks, blisters and other defects that would impair serviceability or distract from the general appearance. Coatings shall conform to the following requirements: a) Coating Hardness: The finish shall have a pencil lead hardness of HB minimum using an Eagle Turquoise pencil. I in M. 2007 Supplement to "Greenbook" 35 b) Salt Spray Resistance: Undercutting of the film of the coating system shall not exceed 3mm (1/8 inch) average, from lines scored diagonally and deep enough to expose the base metal, after 336 hours exposure in a salt spray cabinet in conformance ASTM B117. c) The cabinet shall suffer no coating loss when subjected to the following: 1. Two test specimens 100mm x 200mm (3-7/8 inches x 7-7/8 inches), of the same material and coating as the cabinet supplied, shall be furnished by the Contractor for the tests. The samples shall be furnished by the Contractor at no additional cost to the Agency. 2. Two 230mm (9-1/16 inches) diagonal scratches exposing bare metal will be made on one specimen. The specimen will be soaked in de-mineralized water for 192 hours. A 25 mm (1 inch) wide strip of masking tape will be tightly affixed to the scratched surface and removed with one quick motion; evidence of blistering, softening, or peeling of the paint or coating from the base metal shall be cause for rejection. Testing will be in conformance with California Test 645, except that conformance to the 180 degree bend test will not be required. d) Metal preparation shall'conform to the 3-step iron phosphate conversion coating bonderizing technique. e) The inside walls, doors, and ceiling of the housing shall be finished the same as the out side. 209-5.4.3.3 Stainless Steel Cabinets. Cabinets fabricated from stainless steel shall conform to the following: a) Annealed or quarter hard stainless steel sheet shall be used and shall conform to ASTM A666 for Type 304 Grades A or B. b) Welding shall be by the gas tungsten arc welding (GTAW) process using bare stainless steel welding electrodes. Electrodes shall conform to American Welding Society (AWS) A5.9 for ER308 chromium-nickel bare arc welding electrodes. c) Procedures, welders and welding operators for welding on stainless steel shall conform to AWS C5.5. d) Exposed, exterior surfaces shall be ground or brushed to a 0.6 µm to 1.3 Rm finish using iron- free abrasives or stainless steel brushes. e) All overlapping exterior seams shall meet the requirements of NEMA Type 4 enclosures. f) After grinding or brushing, no rust discoloration shall show when subjected to the following: 1. Forty-eight hours of exposure in a salt spray cabinet in conformance with ASTM B 117; and 2. Twenty-four hours of exposure in a tap water spray cabinet with the water temperature between 38°C (100°F) and 45°C (113°F). Any cabinet which shows any rust discoloration anywhere on its surface after the test will be rejected. g) Cabinets that have been rejected because of surface discoloration may be cleaned, passivated and resubmitted for testing. 209-5.4.3.4 Aluminum Cabinets. Cabinets fabricated from aluminum sheet shall conform to the requirements in ASTM B209 or B209M for 5052-H32 aluminum sheet and conform to the following: a) Welding shall be done by the gas metal arc welding (GMAW) process using bare aluminum welding electrodes. Electrodes shall conform to AWS A5.10 for ER5356 aluminum alloy bare welding electrodes. 36 2007 Supplement to "Greenbook" b) Procedures, welders and welding operators for welding on aluminum shall be qualified in conformance with AWS B3.0 and C5.6. c) Surfaces shall be finished in conformance with Military Specification MIL-A-8625C "Anodic Coatings for Aluminum and Aluminum Alloys" for a Type H, Class 1 coating, except that anodic coating shall have a minimum thickness of 0.02mm and a minimum coating weight of 0.04 mg/mm2. Anodic coating shall be sealed in a 5 percent aqueous solution of nickel acetate (pH 5.0 to 6.5) for 15 minutes at 97°C (207°F). Prior to applying anodic coating the cabinets shall be cleaned and etched as follows: 1. Immerse in inhibited alkaline cleaner such as Oaklite 61 A or Diversey 909, or equivalent, 45-60 g/L (6-8 oz./gal), 71°C (160°F) for 5 minutes. 2. Rinse in cold water. 3. Etch in a solution of 11 g (0.39 oz.) of sodium fluoride, plus 30-45 g (4-6 oz) of sodium hydroxide per liter (gal) of distilled water at 60°C to 65°C (140°F to 149°F) for 5 minutes. 4. Rinse in cold water. 5. Desmut in a 50 percent, by volume, nitric acid solution at room temperature for 2 minutes. 6. Rinse in cold water. 209-5.4.3.5 Doors. The cabinet shall have a single front door equipped with a lock. The door width shall be as shown on the Standard Plans. When the door is closed and latched, the door shall be locked! The handle shall have provision for locking in the closed position. The handle shall have a minimum length and steel shank as shown on the Standard Plans. The handle shall be fabricated of cast aluminum or of zinc-plated or cadmium-plated steel. The cabinet frame shall be designed so that the latching mechanism will hold tension on and form a firm seal between the door gasketing and frame. Locks shall be the solid brass, 6-pin tumbler rim type, with rectangular, spring-loaded bolts. Locks shall be left hand, and rigidly mounted with stainless steel machine screws approximately 50mm (2 inches) apart. Keys shall be removable in the locked and unlocked positions, and 2 keys shall be furnished with each cabinet. The front position of the lock shall extend 3-9mm (1/8-1/4 inches) beyond the outside surface of the door. The latching mechanism shall be a 3-point cabinet latch with nylon rollers. The center catch and pushrods shall be zinc-plated or cadmium-plated steel. Pushrods shall be turned edgewise at the outer supports and shall be 6mm (1/4 inch) x 20mm (3/4 inch) minimum. Nylon rollers shall have a minimum diameter of 20mm ( 3/4 inch) and shall be equipped with ball bearings. Cadmium plating shall conform to the requirements in Military Specification MIL-QQ-416b. Zinc plating shall conform to 210-3. Doors shall be equipped with 3 bolt butt hinges. Each hinge shall have a fixed pin. Doors larger than 560mm (22-1/16 inches) or 0.56m2 (6.03 feet2) in area shall be equipped with catches to hold the door open at both 90-degrees and 180-degrees, plus or minus 10 degrees. Catches shall be 9 mm (3/8 inch) diameter, minimum plated steel rods. Catches shall be capable of holding the door open at 90- degrees in a 90km/h (56 mph) wind at an angle perpendicular to the plane of the door. A police panel shall be mounted on the door as shown on the Standard Plans and shall be equipped with a lock keyed to a master police key. Two keys shall be furnished with each cabinet for the police lock. Each police key shall have a shaft at least 45mm (1 % inches) in length. Police panels shall not be famished for controller assemblies that do not control traffic signals. Ip 00. 2007 Supplement to "Greenbook". 37 Door hinges, pins and bolts shall be made of stainless steel. Hinges on aluminum cabinets may be aluminum with a stainless steel hinge pin. Hinges shall be bolted to the cabinet. Hinge pins and bolts shall not be accessible when the door is closed. Gasketing shall be provided on all door openings and shall be dust-tight. Gaskets shall be permanently bonded to the metal. The mating surface of the gasketing shall be covered with a silicone lubricant to prevent sticking of the mating surfaces. Details of alternative designs shall be submitted in conformance with 2-5.3.3. Metal shelves or brackets shall be provided to support the controller unit and auxiliary equipment. Machine screws and bolts shall not protrude beyond the outside wall of the cabinet. Conduit shall enter the bottom and toward the front of the cabinet unless shown otherwise on the Plans. A pliable seal, composed of caulking compound or mastic, shall be placed between each controller cabinet and the concrete foundation to prevent water, dust and dirt from entering the cabinet. 209-5.4.3.6 Cabinet Ventilation. Each controller cabinet shall be provided with one of the following as specified in the Special Provisions: a) Eight screened, raintight vent holes 12 mm (1/2 inch) in diameter or larger, in the lower side or bottom of the cabinet. b) Louvered vents with a permanent metal mesh. c) Four-ply woven polypropylene air filter held firmly in place that will pass 2.83 m3/min. (100 cfm) of air. Each controller cabinet shall be equipped with an electric fan with ball or roller bearings and a capacity of at least 2.83 m3/min. (100 cfm). The vents shall be able to pass this volume of air. The fan shall be thermostatically controlled and shall be manually adjusted to turn on between 32°C (90°F) and 65°C (149°F) with a differential of not more than 6°C (42°F) between automatic turn on and turn off. The cabinet fan circuit shall be fused at 125 percent of the ampacity of the fan motor installed. . The fan and cabinet vent holes shall be located with respect to each other so as to direct the bulk of the air flow over the controller or through the ventilating holes of the controller where those holes exist. 209-5.4.3.7 Cabinet Accessories. The following accessories shall be famished with each cabinet assembly as required by the Plans, Standard Plans, or Special Provisions. a) Labels. A permanent printed, engraved or silk screened label shall be provided for the following equipment and for all other removable items of equipment: 1. Receptacles for relays and switching devices. 2. Switches, fuses and circuit breakers. Labels shall conform to the designations on the cabinet wiring diagram. Labels for all shelf- mounted equipment shall be on the face of the shelf below the item. Labels for wall-mounted equipment shall be below the item. b) Convenience Receptacle. A convenience receptacle shall be mounted in a readily accessible location inside the cabinet. The convenience receptacle shall be a duplex, 3-prong, NEMA, Type 5-15R grounding outlet and shall conform to UL Standard 943. 38 2007 Supplement to "Greenbook" c) Lighting Fixture. The lighting fixture shall be a florescent lighting fixture, mounted on the inside top of the cabinet near the front edge. The fixture shall be provided with an F15T8, cool white lamp operated from a normal power factor UL or ETL listed ballast. The "On-Off' switch for the lighting fixture shall be either of the following: 1. A toggle switch mounted on the inside door panel. 2. A door-actuated switch that turns the light on when the door is open, and off when the door is closed. d) Surge Arrestor. The surge arrestor shall reduce the effects of power line voltage transients and shall have ratings as follows: Recurrent eak voltage 184V Ener ratio maximum 20 J Power dissipation averse 0.85 W Peak current for pulses less than 7 s 1250 A Standby current shall be one milliampere or less for 60 Hz sinusoidal input. e) Terminal Blocks. Terminal blocks shall be rated 600VAC, minimum, and shall be provided; with nickel, silver or cadmium plated brass binder head screw terminals. Heavy duty terminal blocks shall be rated at 20A and shall be provided with 12 poles with No. 10 x 8mm (5/16 inch) nickel plated brass binder head screws and nickel plated brass inserts. Each pole position shall be provided with 2 terminal positions. The terminal blocks shall be the barrier type, with shorting bars in each of the 12 positions, and shall be provided with integral type marking strips. Light duty terminal blocks shall be rated at 5A and shall be provided with 12 poles with No.6 x 3- mm (1/8 inch) binder head screws. Each pole position shall be provided with one terminal position. 209-5.4.4 Components. 209-5.4.4.1 Toggle Switches. Toggle switches shall have poles as required and shall be rated at 200 percent of circuit current for circuits of 10A or less and 125 percent of circuit current for circuits over 10A. 209-5.4.4.2 Cartridge Fuses. Cartridge fuses shall be installed in panel mounted fuseholders. Fuse type and rating shall be as recommended by the fuse manufacturer for the type of load being protected. 209-5.4.4.3 Circuit Breakers. Circuit breakers shall conform to 209-3.11 except that the circuit breakers shall have a minimum interrupting capacity of 5000A, rms. 209-5.4.4.4 Connectors. Connectors used for interconnecting various portions of circuits together shall be designed and constructed for the application involved. Connectors shall be designed to provide positive connection of all circuits, and easy insertion and removal of mating contacts. Connectors shall be permanently keyed to prevent improper connection of circuits. Connectors, or devices plugging into connectors, shall be provided with positive means to prevent any individual circuit from being broken due to vibration, pull on connecting cable or similar disruptive force. N N 2007 Supplement to "Greenbook" 39 209-5.4.5 Dual 5-Way Active Data Bridge. 209-5.4.5.1 General. . Dual 5-way. active data bridges shall be provided in the controller assemblies when shown on the Plans or specified in the Special Provisions. The bridge shall provide a 4-wire transmission interconnection between a dedicated common port and four multiple ports. The bridge shall incorporate a splitter channel and a combiner channel. Multiple inputs shall be connected to a common output in the combiner channel and in the splitter channel a common input shall be connected to multiple outputs. Splitter and combiner shall be separate and independent allowing operation in full-duple data transmission applications. The bridge shall be equipped with a front-panel-accessible potentiometer with continuous adjustment of cross-bridge gain or loss within two switch-selectable loss/gain ranges suitable for most data applications; -30dB to -1 OdB and -1 OdB to +l OdB. Either range shall be independently selectable for each channel. The level to which each channel is adjusted shall be common to all cross-bridge port combinations in that channel (that is, if the splitter-channel potentionmeter is set for +3dB gain, all common-to-multiple-port paths in the splitter shall receive a +3dB level increase). All ports of the bridge, both common and multiple, shall be characterized by a balanced 60052 terminating impedance. The module's active circuit shall allow unused multiple ports to be left unterminated without affecting the transmission response of the ports in use. Input, output and line monitor jacks on the front panel of the bridge shall allow isolated-module isolated-facility, and cross-bridge measurement of transmission parameters in both the splitter and combiner channels. The bridge shall be powered from input voltage of-22 to -56VDC at a maximum current of 60mA. Each dual 5-way active bridge unit shall be individually packaged in a housing. All circuitry shall be solid state, constructed on removable industry standard circuit boards with plug-in edge connectors. All test jacks, edge connectors and external plug connectors shall be of a type and material suitable for use in the above stated environment without deterioration of electrical connection for the useful life of the equipment. The physical size of the case shall not exceed 3700cm3 (104.77 ft) (approximately 17.5cm x 20cm x 10cm (6-7/8 inches x 7-7/8 inches x 3-15/16 inches) and shall be suitable for mounting to the frame of a field cabinet. Mounting holes shall be provided for attaching the unit to one side of the frame of a relay rack. Input and output ports shall be provided for five full duplex telephone circuits with input and output ports labeled as to function. Level control or switches and level adjustment potentiometers along with the input and output level test jacks shall provide external adjustments without removal of the housing. 209-5.4.5.2 Application. The bridge shall be used to interconnect several 4-wire data modems to a common data channel or data link. The common data link shall be terminated at the distant end into a central processor unit (CPU) or computer. A bridge shall be used to provide the central transmission arrangement or "hubbing" network, that extends data transmission to outlying terminals. Tandem bridge arrangements to expand the number of multiple ports of a 4-wire data hubbing network shall be effected by direct connection of one multiple port iti each channel of the first bridge to the common port of the same channel of a second bridge to provide a 4-wire data bridge with one common and 7 multiple ports. 209-5.4.5.3 Circuit Description. The combiner channel of the bridge shall consist of a variable- gain integrated-circuit operational amplifier with an input summing circuit. The summing circuit shall N so 40 2007 Supplement to "Greenbook" add the transmission energy from all multiple input ports at a low-impedance summing point to provide input port isolation. The output of the amplifier shall be connected to a transformer for balanced connection to the facility. The splitter channel shall consist of a transformer-input-variable-gain, integrated-circuit operational amplifier and a power amplifier. The output of the power transformer shall be a low impedance and shall drive eight 3000 resistors to drive impedance at the multiple output circuits and provide isolation, between output circuits. The multiple ports in the splitter and combiner channels of the bridge shall be isolated and balanced via an output transformer and matched precision resistors in each channel. 209-5.45.4 Electrical Requirements. Electrical requirements shall be as specified in Table 209-5.4.5.4(A). TABLE 209-5.4.5.4(A) S litter channel loss/ gain -30 to +10dB usable range Combiner channel loss/ gain -30 to +10dB usable range Maximum output level (overload point) Splitter: +5Dbm Combiner: +12dBm Level change with loading 1dl3 maximum, one port to all ports loaded. Noise 20dBm maximum Input port impedance Splitter (multiple ports): 6008 balanced. Combiner common port): 60052 balanced. .Output port impedance Splitter (multiple ports): 6000 balanced. Combiner common port): 6000 balanced. Harmonic distortion Splitter: less than one percent at + 3dBm Combiner: less than one percent at + 6 dBm Frequency response ± 1 dBm re 100011z level, 300 to 5000Hz Delay distortion Less than 75p, 400 to 3000Hz Cross-port coupling loss crosstalk Greater than 55dB Mounting One position Operating environment - 70C to 540C (-190F to 1290F), humidity to 95% (no condensation) 209-5.4.5.5 Testing and Trouble shooting. Complete testing and troubleshooting instructions, circuit diagrams and pictorial component location and identification guides shall be provided with each bridge. 209-5.5 Traffic Signal Faces and Fittings. 209-5.5.1 Signal Faces. Each vehicle signal face shall be of the adjustable type conforming to ITE Publication ST-00813. Metal signal sections shall conform to the requirements of California Test 666. Any fracture within the housing assembly or a deflection of more than one-half the lens diameter of the signal section during the wind load test will be considered a structural failure. Plastic signal sections shall conform to the requirements of California Test 605. Any fracture within the housing assembly, or deflection of more than 10 degrees in either the vertical or horizontal plane after the wind load has been removed form the front of the signal face, or a deflection of more than 6 degrees in either the vertical or horizontal plane after the wind load has been removed from the back of the signal face will be considered structural failure. Vehicle signal faces, except arrow and "X" faces, shall conform to the requirements of California Test 604. M so 2007 Supplement to "Greenbook" 41 Adjustment shall permit rotation of 360 degrees about a vertical axis. The number and type of sections shall be as specified in the Special Provisions or shown on the Plans. Each vehicle signal face shall be installed at the location and mounted in the manner shown on the plans. Unless otherwise shown on the Plans, all vehicle signal faces shall contain 3 sections arranged vertically; red-top, yellow-center, and green-bottom. All new vehicle signal faces, except programmed visibility type, installed at any one intersection shall be of the same manufacturer and of the same material. Top openings of signal faces shall be sealed with neoprene gaskets. 209-5.5.2 Optical Units. Each optical unit shall consist of a lens, a reflector or reflector assembly, a lamp receptacle and a clear traffic signal lamp conforming to the following: a) Lenses, reflectors, reflector assemblies, lamp receptacles, lamps, wiring and light distribution shall conform to ITE Publication ST-00813. b) Each lens shall be of the best quality glass, true to color and free of imperfections. c) Reflectors shall conform to ITE Publication ST-008B except that the reflectors shall be made of silvered glass or of specular aluminum with an anodic coating. Reflector ring holders shall be made of cast aluminum. A single piece formed metal reflector ring holder may be used. 209-5.5.3 Signal Sections. Each signal section housing shall be either die-cast or permanent mold-cast aluminum conforming to ITE Publication ST-088B or, when so specified in the Special Provisions shall be structural plastic. Signal sections shall conform to the following: a) Maximum height shall be 260 mm (10-1/4 inches) for 200 mm (7-7/8 inches) sections and 375 mm (14-3/4 inches) for 300 mm (11-13/16 inches) sections. b) Housings shall be provided with a one-piece, hinged, square-shaped door designed to permit access to the section for relamping without the use of tools. The door shall be secured by a method that will hold the door closed during the loading tests specified in these Specifications. The lens shall be mounted in the door in a watertight manner. c) Exposed hardware, such as hinge pins and door latching devices, shall be manufactured of Type 304 or 305 stainless steel. Interior screws and fittings shall be manufactured of stainless steel or steel with a corrosion resistant plating or coating. d) An opening shall be provided in the top and bottom of each section to receive a 40 mm (1-9/16 inch) pipe. Two hundred millimeter (7-7/8 inches) and 300 mm (11-13/16 inches) sections produced by an individual manufacturer shall be capable of joining to form a signal face in any combination. This interchangeability is not required between metal and plastic signal sections. e) Gaskets, including those for the door, lens, reflector and lampholder, shall be made of a material that is not affected when installed in a signal section with a metal or plastic housing that is operated continuously for 336 hours. 209-5.5.4 Metal Signal Sections. Each metal signal section shall be provided with a metal visor and/or backplates as specified in the Special Provisions. Visors shall conform to 209-5.5.8. Backplates shall conform to 209-5.5.10. so so 42 2007 Supplement to "Greenbook" 209-5.5.5 Plastic Signal Sections. Housing shall be either molded in one piece or shall be fabricated from two or more pieces joined into a single piece. The plastic shall have ultraviolet stability, be unaffected by the heat of the lamp used and be self-extinguishing. Housing and doors shall be colored throughout and shall be black matching Color No. 17038, 27038 or 37038 of Federal Standard 595B. Each plastic signal face shall be provided with plastic or metal visor as specified in the Special Provision. Visors shall conform to 209-5.5.8. Plastic signal sections shall also be provided with plastic backplates as specified in the Special Provisions. Plastic backplates shall conform to 209-5.5.10.2. A serrated nylon washer shall be inserted between each plastic signal section and the metal mounting assembly. Each washer shall be not less than 4mm (5/32 inch) nor more than 6 mm (1/4 inch) thick. Serrations shall match those on the signal section and the mounting assembly. 209-5.5.6 Fittings. Each section in a face shall be joined to the adjacent section by one of the following methods: 1. A minimum of 3 machine screws for 200 mm (7-7/8 inch) sections and four machine screws for 300 mm (11-13/16 inch) sections installed through holes near the front and rear of the housings. Machine screws shall be No. 10 and each shall be provided with a nut, flat washer and lock washer. 2. Two machine screws (each with a nut, flat washer and lock washer) through the 40 mm (1- 9/16 inch) pipe opening. The fastening system shall consist of two large flat washers to distribute the load around the pipe opening and three cartage bolts, each with a nut and lock washer. Minimum size of the machine screws shall be No. 10. Minimum size cartage bolts shall be 6 mm (1/4 inch). The supporting section of each signal face supported solely at the top or bottom shall be provided with reinforcement. Reinforcing plates shall be either sheet aluminum, galvanized steel or cast aluminum. Each plate shall be not less than 2.7mm (7/64 inches) thick and shall have a hole concentric with the 40mm (1- 9/16 inch) pipe mounting hole in the housing. Sheet aluminum reinforcing plates shall be placed both inside and outside the housing. Galvanized steel reinforcing plates shall only be placed inside, and aluminum reinforcing plates shall be placed only on the outside of the housing. Reinforcing plates placed on the outside of the housing shall be finished to match the color of the signal face and mounting hardware. A minimum of 3 No. 10 machine screws shall be installed through holes in the plates and matching holes in the housing. Each screw shall have a round or binder head and shall be provided with a nut and lock washer. Where a signal face is to be supported by a Type MAS side attachment slip-fitter inserted between 2 sections, a spacer or spacers shall be placed between the 2 sections. The vertical dimensions of the spacers shall permit proper seating of the serrations between the slip-fitter and the 2 sections. Holes in spacers shall align with the front holes in the section housings. In addition to the fastening through the large opening in the housings, the 2 sections shall be joined with at least 2 machine screws through holes near the front of the housings and the spacers, and through matching holes in a reinforcing plate installed in each housing. Machine screws shall be No. 10 size. Spacers shall be made of the same material as the signal housings. Reinforcing plates and machine screws shall be as specified herein. Reinforcing plates will not be required where the housing is provided with reinforcing webs connecting the rear of the housing with the top, bottom and sides. N N 2007 Supplement to "Greenbook" 43 Holes for machine screws shall be either cast or drilled during fabrication of the signal section. Each hole shall be surrounded by a 3mm (1/8 inch) minimum width boss to permit contact between signal sections about the axis of the hole. 209-5.5.7 Electrical Components. Lamp receptacles and wiring shall conform to TTE Publication ST 008B. The metal portion of the medium base lamp socket shall be brass, copper or phosphor bronze. Each lamp receptacle shall be wired with a conductor, connected to the shell of the receptacle, with white insulation, and a conductor, to the bottom or end terminal of the receptacle, with a black insulation or insulation color-coded. Conductors shall, in turn, be connected to a terminal block mounted inside at the back of the housing. The terminal block shall have sufficient screw type terminals or NEMA type tab connectors to terminate all field conductors and lamp conductors independently. The terminals to which field conductors are attached shall be permanently identified or conductors shall be color-coded to facilitate field wiring. Lamp receptacle conductors shall be No. 18, or larger, 600V, appliance wiring material (AWM), with 0.75mm (1/32 inch) thickness insulation rated for 105°C (221°F) or with insulation conforming to Military Specification MIL-W 16878 D, Type B, with vinyl nylon jacket rated for 115°C (239°F). The manufacturer's name or trademark, conductor size, insulation type letter designation and temperature rating shall be marked on the insulation or a Certification of Compliance in conformance with 4-1.5 shall be submitted by the Contractor with each shipment of traffic signal faces in accordance with 2-5.3. 209-5.5.8 Visors. Each signal section shall be provided with a removable visor conforming to TTE Publication ST-00813. Visors shall be classified, on the basis of lens enclosure, as full circle, tunnel (bottom open), or cap (bottom and lower sides open). Unless otherwise specified in the Special Provisions, visors shall be the tunnel type. Visors shall be a minimum of 240 mm (9-7/16 inches) in length for nominal 300 mm (11-13/16 inches) round lenses and 180 mm (7-1/16 inches) in length for nominal 200 mm (7-7/8 inches) round lenses, with a downward.tilt between 3 degrees and 7 degrees. Metal visors shall be made from 1.2 nun (3/64 inch) minimum thickness, aluminum alloy sheets. Plastic visors shall conform to the following: a) Visors shall be either formed from sheet plastic or assembled from one or more injection, rotational or blow molded plastic sections. b) Sections shall be joined using thermal, chemical or ultrasonic bonding or with aluminum rivets and washers permanently colored to match the visor. c) Visors shall be of black homogeneous colored material with lusterless finish. Each visor shall be secured to its door in a manner that will prevent its removal or permanent deformation when the wind load specified in California Test 605 for plastic visors or California Test 666 for metal visors is applied to the side of the visor for 24 hours. 209-5.5.9 Directional Louvers. Where shown on the Plans, directional louvers shall be furnished and installed in the signal visors. Directional louvers shall be so constructed as to have a tight fit in the signal visors. Dimensions of louvers and arrangements of vanes shall also be as shown on the Plans. The outside cylinder may be constructed of 0.75 mm (1/32 inch) nominal thickness, or thicker, sheet steel. The vanes may be constructed of 0.4 mm (1/64 inch) nominal thickness, or thicker, sheet so so 44 2007 Supplement to "Greenbook" steel. Alternatively, the cylinder and vanes may be constructed of 5052-H32 aluminum alloy of equivalent thickness. 209-5.5.10 Backplates. 209-5.5.10.1 General. Where shown on the Plans, backplates shall be furnished and installed on signal faces. Dimensions, materials and installation details shall be as shown on the Plans. No background light shall show between the backplate and the signal face or between sections. 209-5.5.10.2 Plastic Backplates. Plastic backplates shall be either formed from sheet plastic or assembled from extruded molded or cast sections. Backplates shall be of black homogeneous colored material with a lusterless finish. Each plastic backplate shall be secured to the plastic signal face in a manner that will prevent its removal or permanent deformation when the wind-load test specified in 209-5.5:8 is applied to either the front or the rear of the signal face. The permanent deformation of any portion of the backplate shall not exceed 5 degrees forward or backward after the wind loading have been applied for 24 hours. a) Sections shall be factoryjoined using: 1) Solvent cement recommended by the manufacturer, 2) Aluminum rivets and washers painted or permanently colored to match the backplate , or 3) No. 10 machine screws with washer, lock washer and nut, painted to match the backplate. b) When a plastic backplate requires field assembly, it shall be joined with a minimum of 4 No. 10 machine screws at each field assembled joint. Each machine screw shall be provided with an integral or captive flat washer, a hexagonal head slotted for a standard screwdriver, and either: 1) A locking nut with an integral or captive flat washer, or 2) A nut, flat washer, and lock washer. Machine screws, nuts, and washers shall be stainless steel or steel with a zinc or black oxide finish. In lieu of the screws shown on the Plans, plastic backplates may be fastened to the plastic signal face using self-threading No. 10 steel screws. The screws shall have an integral or captive flat washer and a hexagon head slotted for a standard screwdriver, and shall be stainless steel or steel with a zinc or black oxide finish. 209-5.5.10.3 Metal Backplates. Where a metal backplate consists of 2 or more sections, the sections shall be fastened with rivets or with aluminum bolts peened after assembly to prevent loosening. In lieu of the screws shown on the Plans, plastic backplates may be fastened to the plastic signal face using self-threading No. 10 steel screws. The screws shall have an integral or captive flat washer and a hexagon head slotted for a standard screwdriver, and shall be stainless steel or steel with a zinc or black oxide finish. 209-5.5.11 Circular Light Emitting Diode Signal Modules. 209-5.5.11.1 General. LED signal modules shall consist of an assembly that utilizes light emitting diodes as the light source. Modules shall be from the same manufacturer and each size shall be the same model. Modules shall be single, self-contained devices, not requiring on-site assembly for installation into the existing traffic signal housings. Modules shall fit into traffic signal section housings built in conformance with the fI E. publication ST-008B without modification to the housing. Special tools shall not be required for their N 2007 Supplement to "Greenbook" 45 installation. Installation of LED signal modules shall only require removal of the optical unit components (lens, gaskets, lamp, lamp socket and reflector) from the traffic signal section. Each LED signal module shall be designed to be installed in the door frame of the signal housings specified in the Contract Documents. The module shall be sealed securely in the door flame with a one-piece ethylene propylene rubber (EPDM) gasket and shall be weather tight. LED signal modules shall be sealed units with 2 conductors for connecting to power, a printed circuit board, a power supply, a lens and gasket and shall be weatherproof after installation and connection. The circuit board and power supply shall be contained inside the module. Circuit boards shall conform to Chapter 1, Section 6, of the "Transportation Electrical Equipment Specifications" published by the State of California, Department of Transportation or as specified in the Special Provisions. Conductors for LED signal modules shall be 1 in (3 feet 3-3/8 inches) in length, with terminals attached, and shall conform to 209-5.3. Connections shall be to the terminal block in the signal face or shall utilize an adapter that screws into the medium base lamp socket. Contacts shall be brass. Splices will not be allowed. The lens shall be integral to the module, shall be convex with a smooth outer surface and shall be made of ultraviolet stabilized plastic or glass. The lens shall be capable of withstanding exposure to ultraviolet light for a minimum period of 48 months without exhibiting evidence of deterioration. LED's shall utilize aluminum indium gallium phosphate (AllnGaap) technology and shall be the ultra bright type or equivalent rated for 100,000 hours of continuous operation from -10°C (420F) to +740C (165°F). Each individual LED shall be wired such that physical damage or the failure of 1 LED will result in the loss of not more than 5 percent of the LED signal module light output. Maximum power consumption requirements for LED signal modules shall be specified in Table 209- 5.5.11.1(A). TABLE 209-5.5.11.1(Al LED Signal Module Power Consum tion at 25°C 770F 740C 165°F 300 mm 11 13/16 in Circular 25.0 Watts 30.0 Watts 200 mm 7 7/8 in Circular 15.0 Watts 18.0 Watts 300 mm 11 13/16 in Arrow 15.0 Watts 18.0 Watts LED signal modules shall be rated for a minimum useful life of 48 months. 209-5.5.11.2 Physical and Mechanical Requirements. LED signal modules shall: a) Have a maximum mass of 2.0 kg (4.4 lb avoirdupois). b) Be rated for use in the operating temperature range of -40°C (-420F) to +74°C (+165°F). c) Be protected against dust and moisture intrusion in conformance with NEMA Standard 250- 1991 for Type 4 enclosures. d) Be manufactured to withstand mechanical shock and vibration from winds and other sources as specified in the Special Provisions. e) Have the manufacturer's name, trademark, model number, serial number, lot number and the month and year of manufacture permanently marked on the back of each module. f) Have prominent and permanent vertical markings for correct indexing and orientation within a signal housing. The markings shall consist of an "UP" arrow, or the word "UP" or "TOP". 00 L `J 46 2007 Supplement to "Greenbook" 209-5.5.11.3 Operating Characteristics. The following operating characteristics shall be identified and submitted to the Engineer in conformance with 2-5.3: a) Rated voltage, b) Power consumption and c) Volt-ampere (VA). Enclosures, excluding the lens, containing either the power supply or electronic components of LED signal modules shall be made of UL94VO flame retardant materials. Lens may be tinted or use transparent film or material with similar characteristics to enhance "ON/OFF" contrasts. The use of tinting or other materials to enhance "ON/OFF" contrasts shall not affect chromaticity and shall be uniform across the face of the lens. If a polymeric lens is used, a surface coating or chemical surface treatment shall be used to provide front surface abrasion resistance. 209-5.5.11.4 Photometric Requirements. The minimum initial luminous intensity values for LED signal modules shall conform to Section 11.94 of ITE publication ST-008B at 25°C (77°F). Luminous intensity values shall meet or exceed 85 percent of the standard light output values specified in the ITE VTCSH, after 48 months of continuous use over the temperature range of -40°C (-42°F) to +74°C (165°F) in a traffic signal operation. Measured chromaticity coordinates shall conform to Section 8.04 and Figure 1 of the ITE VTCSH over the temperature range of -40°C (-42°F) to +74°C (165°F). 209-5.5.11.5 Electrical Requirements. a) LED signal modules shall operate over a voltage range from 95VAC to 135VAC at a frequency of 60 Hz ± 3 HZ. b) Fluctuations of line voltage shall have no visible effect on the luminous intensity of the indications. Rated voltage for the measurements shall be 120V. c) LED signal modules and associated on-board circuitry shall conform to FCC Title 47, SubPart B, Section 15 regulations concerning the emission of electronic noise. d) Circuitry shall include voltage surge protection to withstand high-repetition noise transients as specified in Section 2.1.6 of NEMA Standard TS2-1992. e) Circuitry shall prevent perceptible flicker over the specified voltage range. f) LED signal modules shall provide a power factor of 0.90 or greater while operating throughout the temperature range of -40°C (-42°F) to +74°C (165°F). g) Total harmonic distortion (current and voltage) induced into an AC power line shall not exceed 20 percent while operating throughout this temperature range. h) Wiring and terminal blocks shall conform to Section 13.02 of the ITE VTCSH. Two secured color coded 600V, 20 AWG minimum, jacketed wires shall be provided for electrical connection for each LED signal module. The wires shall conform to the NEC, rated for service at or greater than 105°C (221 °F). LED signal modules shall be operationally compatible with the controller assemblies (solid state load switches, flashers and conflict monitors) shown on the Plans or specified in the Special Provisions. M 00 2007 Supplement to "Greenbook" 47 209-5.5.11.6 Arrow LED Signal Modules. Arrow LED signal modules shall conform to Section 9.01 of the ITE VTCSH for arrow lenses. In addition LED's shall be spread evenly across the illuminated portion of the arrow area. Each arrow LED signal section indication shall provide an average luminous intensity of 5500cd/mz (511 cd/ft2). Measurements shall be performed at the rated operating voltage of 120VAC. 209-5.5.11.7 Testing Requirements. LED signal modules tested or submitted for testing shall be representative of typical average production units. Circular LED signal modules shall be tested in conformance with the requirements in California Test 604. Optical testing shall be performed with the LED signal module mounted in a standard traffic signal section but without a visor or hood attached to the signal section. The number of units tested (sample size) shall be determined by the quantity of each models in the shipment. The sample size shall conform to the American National Standard Institute/Acceptance Sampling in Quality Control, ANSI/ASQC ZIA. Sampling parameters to be used for the random sample testing, if any, shall be as specified in the Special Provisions. Specified parameters may be tested on the sample. Acceptance or rejection of the shipment shall conform to ANSI/ASQC ZIA for shipments which are sampled randomly. Upon rejection of a shipment the Contractor shall arrange for pick-up of the rejected shipment at no cost to the Agency. 209-5.5.11.7 Certificate of Compliance. The Contractor shall submit a Certificate of Compliance from the manufacturer conforming to 4-1.5 in accordance with 2-5.3. The certificate shall certify that the LED signal modules comply with the requirements in these Specifications. The certificate shall also include a copy of the applicable test reports on the LED signal modules. 209-5.5.12 Programmed Visibility Vehicle Signal Sections. 209-5.5.12.1 General. Programmed visibility vehicle signal sections shall provide a nominal 300 mm (11-3/4 inch) diameter circular or arrow indication. Color and arrow configuration shall conform to ITE Publication ST-0088. Each signal section shall be provided with: a) A cap visor. b) An adjustable connection that permits incremental tilting from 0 to 10 degrees above or below the horizontal while maintaining a common vertical axis through couplets and mounting. Temminal connections shall permit external adjustments about the mounting axis in 5 degree increments. Signal sections shall be mountable with ordinary tools and capable of being serviced without tools. Adjustments shall be preset at 4 degrees below the horizontal, unless otherwise specified in the Special Provisions. 209-5.5.12.2 Programmed Visibility. The Contractor shall program the signal section as recommended by the manufacturer, shown on the Plans or specified in the Special Provisions. The visibility of each indication shall be capable of adjustment or programming within the section. When programmed, the indication shall be visible only in those areas or lanes to be controlled, except that during dusk and darkness a faint glow to each side will be permissible. Prior to programming, each signal section with a yellow indication shall provide: a) A minimum luminous intensity of 2500 cd on the optical axis. b) A maximum intensity of 100 cd at 15 degrees at from 0.5 to 2 degrees horizontal from the axis. c) A maximum of 10 cd at from 2 to 15 degrees horizontal from the axis. 00 L `J 48 2007 Supplement to "Greenbook" Under the same conditions, the intensity of the red indication and the green indication shall be a minimum of 19 to 38 percent, respectively, of the yellow indication. Each signal face or each signal section shall include integral means for regulating its luminous intensity between limits in proportion to the individual background luminance. Lamp intensity shall not be less than 97 percent of uncontrolled intensity at 10,000 lux and shall reduce to 15 ±2 percent of maximum intensity at less than 10 lux. The dimming device shall operate over an applied voltage range of 95 to 135 V, 60 Hz and a temperature range of-40°C (-42°F) to 74°C (165°F). 209-5.6 Pedestrian Signal Sections. 209-5.6.1 General. Pedestrian signal sections shall be as shown on the Plans or as specified in the Special Provisions. Message symbols shall be white "WALKING PERSON" and Portland orange "UPRAISED HAND" conforming to the requirements in the ITE "Pedestrian Traffic Control Signal Indications" and the "Manual of Uniform Traffic Control Devices. The height of each symbol shall be not less than 250mm (9-3/4 inches) and the width of each symbol shall not be less than 165mm (6-1/2 inches). Each housing including the front screen, shall have maximum overall dimensions of 470mm (18-1/2 inches) wide, 483mm (19-1/64 inches) high and 292mm (11-'/z inches) deep. All new pedestrian signal sections installed at any one intersection shall be the same manufacturer and type. The luminance of the "UPRAISED HAND" symbol shall be 3750 cd/m2 (348.56 cd/sf) minimum and the luminance of the "WALKING PERSON" symbol shall be 5300 cd/m2 (492.64 cd/sf), minimum, when tested in conformance with California Test 606. The uniformity ratio of an illuminated symbol shall not exceed 4 to 1 between the highest and the lowest luminance area. The luminance difference between a nonilluminated symbol and the background around the symbol shall be less than 30 percent when viewed with the visor and front screen in place and at a low sun angle. Brightness measurements for pedestrian signal sections designed for an incandescent lamp shall be made when the signal is equipped with an A-21 traffic signal lamp operated at a voltage to produce 665 lm. Each housing including the front screen, shall have maximum overall dimensions of 470mm (18- 1/2 inches) wide, 483mm (19-1/64 inches) height and 292mm (11-1/2 inches) deep. All new pedestrian signal sections installed at any one intersection shall be the same manufacturer and model. 209-5.6.2 Components. 209-5.6.2.1 General. Each pedestrian signal section shall consist of a housing, two-color message plate, a reflector assembly, one incandescent lamp or one LED module conforming to 209-5.5.11, with sockets and a front screen. 209-5.6.2.2 Message Plate. Each message plate shall be one piece and shall be made of 3mm (1/8 inch) minimum thickness, ultraviolet stabilized polycarbonate plastic or 4.7mm (3/16 inch) tempered glass. The symbols shall be applied to the inside smooth surface of the message plate. 209-5.6.2.3 Reflector Assembly. Each reflector assembly shall consist of a double reflector or 2 single reflectors. Reflectors shall conform to ITE Publication ST-008B. Reflectors shall be made of either aluminum or plastic. Each completed reflector shall, when operated with the appropriate lamp and lens, provide the message brightness specified. Plastic reflectors shall consist of molded or vacuum-formed plastic, with a vacuum-deposited aluminum reflecting surface. The plastic used shall not distort when the reflector is used with the lamp M 00 2007 Supplement to "Greenbook" 49 of the wattage recommended by the manufacturer of the section. In addition, the UL nonmechanical loading temperature of the material shall not be exceeded by more than 10°C (50°F) in conformance with UL 746B. 209-5.6.2.4 Front Screens. Front screens shall be provided on each signal face as shown on the Plans or specified in the Special Provisions. The front screen. shall not fracture, separate at the welds or compress more than 3mm (1/8 inch) when a 75 mm (2-15/16 inch) diameter, 1.8kg (4 lb) ball is dropped onto the screen from a height of 1.2m (3 feet 11-1/4 inches). The screen will be lying in a horizontal position and supported on its edges for this test. The message plate will be removed from the pedestrian signal housing, when the pedestrian housing is used to support the front screen during the test, so there will be no back support for the screen. The screen and frame shall be fabricated from aluminum anodized flat black, or finished with lusterless black exterior grade latex paint formulated for application to properly prepared metal surfaces, or shall be fabricated from flat black plastic. One of the following types of screens shall be provided as specified in the Special Provisions: a) Honeycomb Screens. Honeycomb screen shall consist of 1. Aluminum 5mm (3/16 inch) hexagon cells, 10mm (3/8 inch) thick or, 2. Plasticl0mm (3/8 inch) squares, 13mm (1/2 inch) thick with a wall thickness of 1.5mm (1/16 inch). 3. A clear front cover of 3mm (1/8 inch) minimum thickness acrylic plastic sheet or 1.5mm (1/16 inch) minimum thickness polycarbonate plastic. Honeycomb screens shall be installed tilting downward, at an angle of 15 ± 2 degrees, out from the top. Honeycomb screens shall completely cover the message plate. The honeycomb screen and cover shall be held firmly in place by stainless steel or aluminum clips or stainless steel metal screws. b) Eggcrate or Z-crate Screens. Eggcrate or Z-crate screens shall consist of 1. 38mm (1-1/2 inch) deep eggcrate or Z-crate screen of 0.8mm (1/32 inch) nominal thickness polycarbonate. The eggcrate or Z-crate screen shall be mounted in a frame constructed of lmm (1/32 inch) minimum thickness aluminum alloy or polycarbonate. Eggcrate or Z-crate screens shall be installed parallel to the face of the message plate and shall be held in place by stainless steel screws. The visor described in 209-5.6.2.6 is not required with this type screen. 209-5.6.2.5 Housing. Pedestrian signal housings shall conform to 209-5.5.3. 209-5.6.2.6 Visors. Visors shall be constructed of a material similar to the housing. The top of the visor shall extend a minimum length of 150mm (5-7/8 inches) at the top and 125mm (4-7/9 inches) at the bottom when measured from the front surface of the housing. The front shall be normal to the top. 209-5.6.3 Finish. The exterior of each housing and visor and the interior of the visors shall be painted in conformance with 210 or as specified in the Special Provisions. 209-5.6.4 Controls. Pedestrian signals sections shall be capable of being controlled by solid-state switching devices specified for traffic signal controller assemblies. L _ J Li. 50 2007 Supplement to "Greenbook" 209-5.6.5 Terminal Blocks. Each pedestrian signal section shall be provided with a terminal block conforming to 209-4.3.3 or as specified in the Special Provisions. All field wiring shall connect to this terminal block. 209-5.6.6 LED Pedestrian Signal Section "Upraised Hand" Module. 209-5.6.6.1 General. In addition to the requirements in 209-5.5.11 these LED modules shall conform to the following specifications. The installation of the LED modules shall not require modification of a standard lamp socket or reflector. LED modules shall be designed as retrofit replacements for existing optical units and shall not require special tools for installation. Maximum power consumption requirements for these LED modules shall be 15.OW at 25°C (77°F) and 18.OW at WC (165°F). The luminance of the "Upraised Hand" symbol shall be a minimum of 3,750 cd/m2 (348 cd/ft2). The color of the "Upraised Hand" shall be Portland orange conforming to the requirements of ITE "Pedestrian Traffic Control Signal Indications" and the MUTCD. The height of each symbol shall be not less than 250mm (9-27/32 inches) and the width of each symbol shall not be less than 165mm (6- 1/2 inches). The uniformity ratio of an illuminated symbol shall not exceed 4 to 1 between the highest luminance area and the lowest luminance area. LED modules shall be rated for a minimum useful life of 48 months. 209-5.6.6.2 Physical and Mechanical Requirements. In addition to the requirements in 209- 5.5.11 the physical and mechanical requirements for these LED modules shall conform to the following specifications. LED modules shall not require a specific mounting orientation or have a variance in light output, pattern or visibility for any mounting orientation. Installation of LED pedestrian signal modules shall only require removal of the lamp. LED modules shall be rated for use in the operating temperature range of -40°C to +74°C (-12°F to 1657). 209-5.6.6.3 Photometric Requirements. The minimum initial luminous intensity values shall be 3750 cd/m2 (347.22 cd/ft). Luminous intensity values shall meet or exceed 85 percent of 3750 cd/m2 (347.22 cd/ft2) after 48 months of continuous use over the temperature range of -40°C to +74°C 427 to 1657) in a traffic signal operation. The measured chromaticity coordinates shall conform to 5.3.2.1 and Figure C of the ITE VTCSH while operating throughout the temperature range of -10°C to +74°C (-420F to 1657). 209-5.6.6.4 Electrical Requirements. Electrical requirements for LED modules shall conform to 209-5.5.11.4 or as specified in the Special Provisions. 209-5.6.6.5 Testing. The LED pedestrian signal modules tested or submitted for testing shall be representative of the typical average production units. Modules shall be tested in accordance with California Test 606. Optical testing shall be performed with the module mounted in a housing as specified in the Special Provisions or on the Plans but without a visor or hood attached to the housing. 209-5.6.6.6 Quality Assurance Testing. Quality assurance testing may be performed by the Agency on each new light emitting diode pedestrian signal module. The number of units tested (sample size) shall be determined by the quantity of each model in the shipment. The sample size shall N 00 2007 Supplement to "Greenbook" 51 conform to the requirements in the American National Standard Institute/Acceptance Sampling in Quality Control. ANSUASQC ZI A. The Engineer will determine the sampling parameters to be used for the random sample testing. The parameters specified in the Special Provisions may be tested on each sample. The basis of acceptance or rejection of the shipment shall be the criteria specified in ANSUASQC ZIA for shipments that are sampled randomly. Upon rejection of the shipment the Contractor shall arrange for pick-up of the shipment at no cost to the Agency. 209-5.6.6.7 Certificate of Compliance. A Certificate of Compliance shall be submitted in conformance with 209-5.5.11.7. 209-5.7 Signal Mounting Assemblies. Signal mounting assemblies shall consist of Size 41 standard steel pipe or galvanized conduit, necessary fittings, slip-fitters and terminal compartments. Pipe fittings shall be ductile iron, galvanized steel, aluminum alloy Type AC-84B No. 380, or bronze. Mast arm slip-fitters, post top slip-fitters and terminal compartments shall be cast bronze or hot-dip galvanized ductile iron. After installation, any exposed threads of galvanized conduit brackets and areas of the brackets damaged shall be cleaned with a wire brush and painted with 2 applications of an approved unthinned zinc-rich primer (organic vehicle type) conforming to 210. Aerosol cans shall not be used. Each terminal compartment shall be fitted with a terminal block containing a minimum of 12 poles, each with 2 screw type terminals. Each screw type terminal shall be designed to accommodate at least five No. 14 conductors. A cover shall be provided on the compartment to give ready access to the terminal block. Where used to bracket mount signals, the terminal compartment shall be designed to bolt securely to a pole or standard. The horizontal dimension of the mounting assembly members between the vertical centerline of the terminal compartment or slip-fitter and the vertical centerline of each signal face shall not exceed 280 mm (11-1/32 inches), except where required to provide proper signal face- alignment or permit programming of programmed visibility signal faces unless otherwise directed by the Engineer. Mounting assemblies shall be watertight and free of sharp edges or protrusions which might damage conductor insulation. Mounting assembly members shall be either plumb or level, symmetrically arranged and securely assembled. Each mounting assembly shall be provided with positive locking, serrated fittings that, when mated with similar fittings on the signal faces shall prevent the faces from rotating. Fitting shall permit fastening at increments of not more than 7 degrees. Construction shall be such as to permit all conductors to be concealed. For post-top mounting of signals, a slip-fitter shall be used: The slip-fitter shall fit over a 115mm (4-1/2 inches) outside diameter pipe or tapered standard end. Each slip-fitter shall be provided with cadmium-plated steel set screws, arranged as shown on the plans. Each slip-fitter used to post-top mount signals with brackets shall be provided with an integral terminal compartment. Each mounting assembly shall be oriented to provide maximum horizontal clearance to the adjacent roadway. 209-5.8 Detectors. 209-5.8.1 General. Vehicle detectors shall be the type or types shown on the Plans. All sensor units, control units and amplifiers shall conform to the specifications in the Special Provisions. The units shall not be affected by transient voltages when tested in conformance with the requirements in 00 C_J 52 2007 Supplement to "Greenbook" California Test 667. After a power interruption the units shall return to normal operation within one minute. Each unit shall be provided with a light or meter, for each output circuit, to indicate when the detector is detecting a vehicle. Each detector shall operate over the range of voltages from 100V to 135V at 60 Hz. Circuitry shall be solid-state, except relays with normally closed contacts may be used for the output circuit. Units shall use printed circuit boards designed to facilitate identification of components. This shall be done by either part identification markings or by providing a pictorial diagram showing the physical location and identification of each component. Each printed circuit board shall conform to the following minimum quality requirements: a) NEMA FR-4 glass cloth base epoxy resin board, 1.5mm (1/4 inch) minimum thickness, b) Organic masking, c) Gold plated contacts. Units shall be designed to provide vehicle detection without readjustment from -18°C to 71°C (0°F to 160°F). 209-5.8.2 Inductive Loop Detectors. 209-5.8.2.1 General. The term "inductive loop detector" shall be defined as a complete installation consisting of a loop or group of loops installed in the roadway, as shown on the Plans, lead- in cable and sensor unit with a power supply installed in a controller cabinet. 209-5.8.2.2 Sensor Unit Construction. "Card" type sensor units shall conform to the requirements in "Traffic Signal Control Equipment Specifications" issued by the State of California Department of Transportation, and all addenda thereto current at the time of advertising the Contract., Shelf mounted sensor units shall conform to the requirements in Section 11 of the NEMA Standards Publication No. TS. 1. Capacitors or inductors necessary for loop tuning shall not be mounted external to the sensor unit. 209-5.8.2.3 Construction Materials. Conductor for inductive loop detectors shall be continuous and unspliced and shall conform to the Special Provisions or the following: a) Type 1 loop wire shall be Type RHW-USE neoprene-jacketed or Type USE cross-linked polyethylene insulated No. 12 stranded copper wire. The minimum insulation thickness at any point shall be 1.0mm (1/32 inch) or. b) Type 2 loop wire shall consist of a conductor inside of plastic tubing. The conductor shall be Type THWN or Type XHHW, No. 14 stranded copper wire. The tubing shall be polyethylene or vinyl, rated for use at 105°C (2217) and shall be resistant to oil and gasoline. The tubing shall have a maximum outside diameter of 7mm (1/4 inch) and a minimum wall thickness of 0.71mm (1/32 inch). The conductors shall not be spliced inside the tubing. Conductor for loop detector lead-in cable shall be 2 No. 16 (19 x 29) stranded tinned copper. Loop detector lead-in cable shall conform to the calculated cross sectional area of ASTM Designation B 286, Table 1. The lead-in cable shall conform to the Special Provisions or the following: a) Type B lead-in cable shall be insulated with 0.5 mm (1/64 inch) of high-density polyethylene. The conductors shall be twisted together with at least 6 turns per meter (3 feet 3-3/8 inches) and the twisted pair shall be protected with a copper or aluminum polyester shield. A No. 20, 4P 00 2007 Supplement to "Greenbook" 53 minimum, copper drain wire shall be provided and connected to the equipment ground within the cabinet. The cable shall be provided with a high-density polyethylene or high-density polypropylene outer jacket with a nominal thickness of 0.8mm (1/32 inch). An amorphous interior moisture penetration barrier of nonhydroscopic polyethylene or polypropylene fillers shall be provided or. b) Type C lead-in cable shall conform to the International Municipal Signal Association's (IMSA) Specifications No. 50-2. A No. 20 minimum copper drain wire shall be provided and connected to the equipment ground within the cabinet. All detector lead-in cable connections and/or terminations shall be soldered. 209-5.8.2.4 Sealants. The sealant for filling slots shall conform to one of the following: a) Elastomeric Sealant. Elastomeric sealant shall be a polyurethane material of a composition that will within its stated shelf life, cure only in the presence of moisture. Sealant shall be suitable for use in both asphalt concrete and portland cement concrete. The cured sealant shall have the performance characteristics shown in Table 209-5.8.2.4(A). TARLR 2(14-; RI AIAI Specifications ASTM Requirement Designation Hardness (indentation) at 250C (770F) and 50% relative humidity (Type A Model 1700 only) D2240 Rex. 65-85 Tensile Strength, pulled at 508 mm 20 in per minute D412 Die C 3.45 MPa 0.50 psi) mina Elongation: pulled at 508 mm per minute D412 Die C 400%, min. Flex at -40°C (-400F): 0.6 mm Free Bend (180°) over a 13 mm 1/2 inch Mandrel. - No cracks Weather Resistance: Weatherometer 350 h cured 7 days at 250C 77°F 50% relative humidity. D822 Slight chalking Salt Spray Resistance: 28 days at 380C (1000F) with 5% NaCI, 3.45 MPa (518 psi) min. Die and pulled at 508 mm 20 inch per minute. B117 tensile, 400% min. elongation Dielectric Constant over a temperature range of-30°C (-220F) D 150 Less than 25% change t b) Asphaltic Emulsion Sealant. Asphaltic emulsion sealant shall conform to the State of California's Specification 8040-41A- 15 and shall only be used for filling slots in asphalt concrete pavement. This material shall not be used in slots which exceed 16 mm (5/8 inch) in width or where the slope causes the material to run from the slot. The material shall not be thinned in excess of the manufacturer's recommendations and shall not be placed when the air temperature is less than 7°C (45°F). c) Hot-Melt Rubberized Asphalt Sealant. Hot-melt rubberized asphalt sealant shall be in solid form at room temperature and fluid at an application temperature of 190°C (374°F) to 205°C (401°F). Fumes from the material shall be non-toxic. Sealant shall be suitable for use in both asphalt concrete and portland cement concrete. Performance characteristics of the cured hot-melt rubberized asphalt sealant shall be as shown in Table 209-5.2.4(B). 00 54 2007 Supplement to "Greenbook" T A Ri ,F. 209-5-RIA(H) Specification ASTM Designation Requirement Cone Penetration, 250C 770F 150-q'(5.3 oz), for 5 sec. D3407, Sec. 5 3.5 mm (1/8 inch) max. Flow, 600C (140°F) D3407, Sec. 6 5 mm (3/16 inch) max. Resilience, 25°C (770F) D 3407, Sec. 8 25% min. Softening Point D 36 82°C 1800F min. Ductility, 250C 770F 50 mm/min. 2 inch min. D113 300 mm (11 13/16 inches) min. Flash Point, Cleveland Open Cup, °C °F D92 288°C 5500F Viscosity, Brookfield Thermosel, No. 27 Spindle, 20 m, 1900C 3740F D4402 2.5-3.5 D- -s 209-5.8.3 Magnetic Detectors. 209-5.8.3.1 General. Each magnetic detector amplifier shall be a low noise, high gain amplifier designed for use with all types of magnetic detector sensing units as specified by the Agency in the Special Provisions. Sensitivity of units shall be readily adjustable by a knob on the front panel. An indicator light shall be provided to indicate detector operation. The sensing elements shall be no larger the 58mm (2-14 inches) in diameter and shall contain no moving parts or transistors. The element casing shall be constructed of non-ferrous materials suitable for use in the environment that it will operate in and shall be sealed to prevent the entrance of moisture. The element shall be shaped to facilitate pushing into conduit and shall not have any sharp edges along its length. The overall length of the sensing elements shall not exceed 530mm (20-7/8 inches). 209-5.8.3.2 Performance Characteristics. Each magnetic detector shall be capable of being activated by a voltage induced in the coil of the sensing element by the passage of a vehicle at any speed from 5 to 130km/hr (3 to 81 mph). Any vehicle passing within 450mm (17-3/4 inches) of either end of the sensing elements shall provide an output closure. 209-5.8.3.3 Amplifier Unit Construction. Each amplifier shall be provided with an integral power supply. Each amplifier shall be designed to provide ease of maintenance with all electronic components readily accessible. All input and output circuits for each amplifier shall enter via a single MS connector. Connector circuitry for the amplifiers shall be as shown in the Table 209-5.8.3.3(A). Tahla 9119-G RA WAl MS Connector Circuit 18 - 8 Pin Magnetic Detector - A Magnetic Detector + B 120 V, ac+ C Chassis Ground D Detector Common F Output N.O. F Output N.C. G Grounded Conductor, AC- H All controls, indicator lights, fuse holders and connectors shall be mounted on the front of the amplifier. 209-5.8.3.4 Construction Materials. The cable from the pull box adjacent to the magnetic detector sensing element to the field terminals in the controller cabinet shall be the type specified for inductive loop detectors. so 2007 Supplement to "Greenbook" 55 209-5.9 Pedestrian Push Button Assemblies. Pedestrian push button assembly housings shall be either die-cast or permanent mold cast aluminum or, when specified in the Special Provisions, shall be ultraviolet stabilized, self-extinguishing, structural plastic. Plastic housings shall be black matching Color No. 17038, 27038 or 37038 of Federal Standard No. 595B or as specified by the Agency in the Special Provisions and shall be colored throughout. Assemblies shall be rainproof and shockproof in any weather conditions. , Switches shall be the phenolic enclosed precision snap-acting type, single-pole, double-throw, switching unit, with screw type terminals, rated 15A at 125VAC, and shall conform to the following: a) Have a stainless steel plunger actuator and be provided with a U-frame to permit recessed mounting in the push button housing. b) Have an operating force of 2.5N (9oz) to 3.6N (13oz) and a minimum release force of IN (4oz). c) Pre-travel shall be 0.4mm (1/64 inch) maximum. d) Overtravel shall be 0.6mm (1/32 inch) minimum. e) Differential, travel shall be O.Olmm to 0.05mm. 0 The actuator shall have a minimum diameter of 50mm (1-31/32 inches). Pedestrian push button signs shall be porcelain enameled metal or structural plastic. PAGE 193- REVISE THE SIXTH LINE OF 213-1.5.5 TO READ: 2°C (4°F). Asphalt cement shall be PG 64-10. Specimen hanging rack shall consist of a - PAGE 229 - REVISE 302-1 TO READ: 302-1 COLD MILLING OF EXISTING PAVEMENT. 302-1.1 General. The Contractor shall cold mill existing pavement as shown on the Plans and specified in the Special Provisions. The type of pavement and depth to be cold milled shall be as shown on the Plans or specified•in the Special Provisions. The presence of pavement fabric, rubberized material (i.e. ARHM, REAS, ARAM's, etc.), or steel reinforcement within the depth to be cold milled shall be noted on the Plans or in the Special Provisions. The surface after cold milling shall be uniformly grooved or ridged unless otherwise specified in the Special Provisions. The outside lines of the milled pavement shall be neat and uniform. The milled pavement shall be true to grade and cross section. When the straightedge specified in 302-5.6.2 is laid on the finished surface parallel to the centerline of the roadway, the surface shall not vary from the edge of the straightedge more than l Omm (3/8 inch) at any point, except at intersections or at changes of grade. Any areas that are not within tolerance shall be brought to grade within 1 working day following initial cold milling. Cold milling operations shall be performed without damage to the remaining pavement. Whenever cold milling is adjacent to existing Portland cement concrete curbs, gutters or pavement, the Contractor shall protect these improvements from damage. Any Portland cement concrete curbs, gutters or pavement damaged during cold milling operations shall be repaired as directed by the Engineer at the Contractor's 00 r"" LA-i 56 2007 Supplement to "Greenbook" expense. Any Portland cement concrete curbs, gutters or pavement that is cracked or displaced shall be removed and replaced at the Contractor's expense. Replaced sections of Portland cement concrete curb, gutter or pavement shall be a minimum of 1.52m (5 feet) in length or to the next joint. 302-1.2 Milling Machine. Milling machines shall be specially designed for cold milling of asphalt concrete, Portland cement concrete, or a combination of asphalt and Portland cement concrete pavement. Milling machines shall conform to the following: a) The cutting drum shall be a minimum of 1500 mm (60 inches) wide and shall be equipped with carbide-tipped cutting teeth placed in a variable pattern to produce the desired finish. b) Be self-propelled and capable of removing the pavement to the depth shown on the Plans. c) Be equipped with a conveyor system that will immediately convey the milled material into a transport vehicle for disposal as specified in the Special Provisions. d) Have the capability of spraying water at the cutting drum to minimize dust. e) Be designed so that the operator can observe the milling operation, at all times, without leaving the controls. f) Be adjustable for slope and depth. g) Be able to deep cut, in one pass, to the maximum depth recommended by the manufacturer without producing fumes or smoke. The Contractor shall provide smaller machines if required to cold mill areas that are inaccessible to the larger machine and to provide the surface specified in the Special Provisions. 302-1.3 Cold Milling to Specified Elevations. 302-1.3.1 General. Milling to specified elevations is the controlled removal of a portion of the existing pavement and underlying base or substrate. The finished elevations and depth of cut shall be as shown on the Plans or specified in the Special Provisions. 302-1.3.2 Milling Machine. Milling machines used for milling to specified elevations shall conform to 302-1.2. The machines shall also be equipped with automatic grade controls that reference the existing pavement elevations or independent grade references. The references shall be those required to achieve the specified elevations shown on the Plans. 302-1.4 Profile Milling. 302-1.4.1 General. Profile milling is the controlled removal of a portion of the existing pavement to a nominal depth using longitudinal grade controls to remove surface irregularities in the pavement and improve ride ability. The grade shall be as shown on the Plans. 302-1.4.2 Equipment. Milling machines used for profile milling operations shall conform to 302-1.2. The Contractor shall also use a minimum 6m (20 foot) paving ski with spring loaded feet attached to the bottom at not more than 0.5m (18 inch) increments. The upper portion of the ski shall be one-piece and manufactured such that the ski does not flex or bend by more than 5mm (3/16 inch) when supported off of the surface of the pavement by an attachment located at the ski's longitudinal center of gravity. The grade control system of the milling machine shall be referenced to the center of the ski. During profile milling operations, the center of the ski shall be on a line coincident with the transverse centerline of the milling machine's cutting drum. A ski shall be attached to each side of the milling machine cutting drum during the first pass, and on one side of the milling machine on subsequent, adjacent passes with a joint matching grade control on the other side. N 2007 Supplement to "Greenbook" 57 The resultant milled surface shall not deviate from the grade shown on the Plans, using the straight edge specified in 302-5.6.2, by more than 6mm (1/4 inch) at any point. 302-1.5 Full Depth Milling. 302-1.5.1 General. Full depth milling,is the removal of the full depth of the existing pavement as shown on the Plans or specified in the Special Provisions. When full depth milling is specified, the Contractor shall continuously control the depth of milling to stay no more than 13mm (1/2 inch) below the fidl depth of the existing pavement. hi areas of resurfaced trenches, individual excavations or bore holes, the required depth of milling shall be the same as that of the adjacent pavement. The Contractor shall remove existing asphalt concrete overlay from gutters adjacent to any area specified to be cold milled, as directed by the Engineer. 302-1.5.2 Equipment. Milling machines used for full depth milling of pavement shall conform to 302-1.2 and be capable of milling a minimum depth of 250mm (10 inches) in a single pass. 302-1.6 Cold Milling of Composite Pavements. Composite pavements are pavements that consist of more than one material overlaid with another (e.g. Portland cement concrete overlaid with asphalt concrete). The thickness of each existing pavement material shall be shown on the Plans. The area and depth of a composite pavement to be cold-milled shall be as shown of the Plans. 302-1.7 Work Site Maintenance. Work site maintenance shall conform to 7-8. A motorized street sweeper shall follow within 15 m (50 feet) of the cold milling machine unless otherwise approved by the Engineer. 302-1.8 Disposal of Millings. Unless otherwise specified in the Special Provisions.all material removed shall be considered the property of the Contractor and shall be disposed of by the Contractor. 302-1.9 Traffic Signal Loop Detectors. The Contractor shall not mill within 300mm (12 inches) of any existing loop detectors that are shown to be protected in place on the Plans or in the Special Provisions. Traffic signal loop detectors that were shown to be protected in place but are damaged or removed shall be replaced in conformance with 7-9. 302-1.10 Pavement Transitions. Structures and vertical joints within the cold-milled areas that are transverse to through traffic shall be ramped in conformance with 7-10 and 306-1.5.1. Ramps shall be constructed the same day as the existing pavement is cold milled and removed prior to placement of the permanent paving. 302-1.11 Measurement. Cold milling will be measured by the linear meter (foot) along the edge of the transverse joint lines, adjacent curb, gutter, or cross gutter, or by the square meter (square foot) as shown in the Bid. The amount of each type of pavement cold milled (asphalt, concrete, or composite pavement) shall be measured separately. 302-1.12 Payment. The Contract Unit Price for cold milling each type of pavement shall include cold milling, construction and removal of pavement transitions, disposal of millings, and all other necessary work. -PAGE 236 - DELETE 302-5.2 AND REPLACE WITH THE FOLLOWING: 302-5.2 (Not Used.), 00 1 58 2007 Supplement to "Greenbook" - PAGE 237 - REVISE 302-5.4 TO READ: 302-5.4 Tack Coat. If the asphalt concrete pavement is being constructed directly upon an existing hard- surfaced pavement, a tack coat of PG 6410 paving asphalt at an approximate rate of 0.25 Ilmz (0.05 gallon per square yard) or SS-lh emulsified asphalt at an approximate rate of 0.25 Umz to 0.45 Umz (0.05 to 0.10 gallon per square yard) shall be uniformly applied upon the existing pavement preceding the placement of the asphalt concrete. The surface shall be free of water, foreign material, or dust when the tack coat is applied. To minimize public inconvenience, no greater area shall be treated in any one day than is planned to be covered by asphalt concrete during the same day, unless otherwise approved by the Engineer. A similar tack coat shall be applied to the surface of any course, if the surface is such that a satisfactory bond cannot be obtained between it and a succeeding course. The contact surfaces of all cold pavement joints, curbs, gutters, manholes, and the like shall be painted with either SS-lh emulsified asphalt or PG 64-10 paving asphalt immediately before the adjoining asphalt concrete is placed. - PAGE 246 - REVISE THE FIRST LINE OF 302-7.2.2 TO READ: 302-7.2.2 Tack Coat. The tack coat shall be PG 64-10 paving asphalt. -PAGE 397 - REVISE 400-1.1.2 TO READ 400-1.1.2 Source. Before beginning portland cement concrete and asphalt concrete work, the Contractor shall submit the name of the supplier to the Engineer as specified in 2-5.3. The supplier shall have on file with the Agency mix designs for portland cement concrete conforming to 201-1.1.1, and asphalt concrete conforming to 203-6.2, when required by the Specifications. The Contractor or supplier shall resubmit required information when any change is made. M M 2007 Supplement to "Greenbook" 59 - PAGE 399 - REVISE 400-4.1 TO READ: 400-4.1 General. Asphalt concrete shall be a mixture of mineral aggregate and up to 15 percent reclaimed asphalt pavement (RAP) with paving asphalt conforming to 203-6.1 at a central mixing plant. RAP shall conform to 203-7.2.2, except the viscosity of RAP asphalt recovered in accordance with ASTM D 1856 (Abson Recovery Method) will not be required. RAP asphalt content may be determined in accordance with Calif. Test 382 except the aggregate correction factor shall not be applied. This material will be designated by the type of asphalt concrete, class and grade, i.e., "III-B2-PG 64-10". Unless otherwise specified on the Plans or in the Special Provisions, III-B3-PG 64-10 shall be used. Asphalt concrete containing up to 15 percent RAP shall be identified by adding the suffix "RAP" to the class and grade, i.e., "III-132-PG 64-10 RAP". Acceptance of asphalt concrete shall conform to 203-6.4.1. - PAGE 406 - ADD THE FOLLOWING TO 500-1.1.7: e) End Seals. The beginning and end of the new pipe liner shall be sealed to the host pipe with an epoxy or other material. The epoxy or other material shall conform to 211-2 and be submitted for approval to the Engineer in conformance with 2-5.3. The approved epoxy or other material shall be compatible with the lining material and host pipe and shall provide a watertight seal. The finished liner shall protrude a minimum of 25mm (I inch) and a maximum of 50mm (2 inches) into the manhole, unless otherwise shown on the Plans or specified in the Special Provisions. Liner material shall be cut smooth and parallel with the manhole wall. The interface between the host pipe and the pipe liner shall be sealed 360 degrees. When the pipe liner extends through the manhole it shall be sealed as shown on the Plans and as specified in the Special Provisions. - PAGE 408 - REVISE THE HEADING FOR 500-1.3 TO READ: 500-1.3 HDPE Solid-Wall Pipe Liner. - PAGE 409 - REVISE THE HEADING FOR 500-1.3.8 TO READ: 500-1.3.8 Service Connections and End Seals. REVISE THE HEADING FOR 500-1.4 TO READ: N M so 2007 Supplement to "Greenbook" 500-1.4 Cured-In-Place Pipe Liner. -PAGE 410- REVISE THE HEADING FOR 500-1.4.7 TO READ: 500-1.4.7 Service Connections and End Seals. REVISE THE HEADING FOR 500-1.5 TO READ: 500-1.5 PVC Pipe Lining System. - PAGE 412 - REVISE THE HEADING FOR 500-1.5.8 TO READ: 500-1.5.8 Service Connections and End Seals. - PAGE 414 - REVISE 500-1.7.7 TO READ: 500-1.7.7 Service Connections and End Seals. Existing service connections shall be reinstated through the use of a remote control unit or excavation. Service connections and end seals shall conform to 500-1.1.7. The beginning and end of the new HDPE pipe liner shall be sealed to the rehabilitated host pipeline. If sealing material is required, it shall be compatible with the HDPE pipe and shall provide a watertight seal. DELETE 500-1.7.8 REVISE THE HEADING FOR 500-1.7.9 TO READ: 500-1.7.8 Repair and Rejection. REVISE THE HEADING FOR 500-1.8 TO READ: 500-1.8 CCFRPM Liner Pipe. - PAGE 415 - REVISE 500-1.8.8 TO READ: 500-1.8.8 Service Connections and End Seals. Service Connections and end seals shall conform to 500-1.1.7. 00 2007 Supplement to "Greenbook" 61 - PAGE 421 - REPLACE "FLEXIBLE" WITH "FLEXURAL" IN THE EIGHTH LINE OF 500-1.10.3 (f), 6). REVISE 500-1.10.4 TO READ: 500-1.10.4 Service Connections and End Seals. Service connections and end seals shall conform to 500-1.1.7. DELETE 500-1.10.5. REVISE THE HEADING FOR 500-1.10.6 TO READ: 500-1.10.5 Repair and Rejection. - PAGE 423 - REVISE 500-1.11.9 TO READ: 500-1.11.9 Service Connections and End Seals. Service connections shall be exposed and connected to the liner pipe by use of a saddle approved by the Engineer as specified in 2-5.3. Service connections and end seals shall conform to 500-1.1.7. REVISE THE HEADING FOR 500-1.12 TO READ: 500-1.12 PVC Closed Profile Liner Pipe. - PAGE 425 - REVISE 500-1.12.8 TO READ: 500-1.12.8 Service Connections and End Seals. Service connections and end seals shall conform to 500-1.1.7. REVISE THE HEADING FOR 500-1.13 TO READ: 500-1.13 Machine Spiral Wound PVC Pipe Liner. - PAGE 426 - REVISE 500-1.13.7 TO READ: 500-1.13.7 Service Connections and End Seals. Service connections and end seals shall conform to 500-1.1.7. 00 171 62 2007 Supplement to "Greenbook" - PAGE 429 - ADD 500-2.5 TO READ: 500-2.5 Epoxy Mastic and Flexible PVC Liner System. 500-2.5.1 General. This subsection describes the installation of the mastic primer and epoxy mastic that bonds to the cleaned, repaired and prepared interior concrete substrate, then follows with the mechanical locking of the flexible PVC liner into the epoxy mastic. The integral locking extensions in the flexible PVC liner are embedded to their full depth into the epoxy mastic. 500-2.5.2 Materials. 500-2.5.2.1 Plastic Liner. The liner shall be manufactured from a PVC compound in accordance with 210-2. The plastic liner shall be a flexible PVC Liner with a minimum thickness of 1.65 mm (1/16 inch) and conform to 210-2.4. 500-2.5.2.2 Mastic Primer. The epoxy mastic primer shall be a two-part coating that is applied to the prepared concrete substrate. 500-2.5.2.3 Epoxy Mastic. The epoxy mastic shall be a two-part 100% epoxy coating for bonding and filling voids in properly prepared concrete substrate. 500-2.5.3 Locking Extensions. All liner to be embedded in the epoxy mastic shall have integral locking extensions and meet the requirements of 210-2.2.4 except for the dimensions requirement. The locking extensions shall have a shape, height, web thickness, and spacing that will allow the liner to be held permanently in place and be able to meet the pull-out requirements of 500-2.5.9. 500-2.5.4 Chemical Resistance and Physical Property Testing. The plastic liner sheet and accessories shall conform to 211-2 and 210-2.4. 500-2.5.5 Preparation and Repair of Substrate. Prior to applying the mastic primer, the structure shall be cleaned and prepared in accordance with 311-1.6 and repaired in accordance with 311-1.9. 500-2.5.6 Installer Qualifications. Applicators and welders of the plastic liner shall be qualified in accordance with 311-1.2. 500-2.5.7 Installation. 500-2.5.7.1 Priming. The mastic primer shall be applied to 76 µm (3 mils) minimum to 127 µm (5 mils) maximum thickness. The primer shall be allowed to dry before applying the epoxy mastic. 500-2.5.7.2 Epoxy Mastic Application. A finishing trowel or other suitable tool shall be used to apply the epoxy mastic to a uniform minimum thickness of 6.4 mm (1/4 inch). 500-2.5.7.3 Plastic Liner Application. The plastic liner shall be placed while the wetting ability of the epoxy mastic is at its optimum, be pressed into the mastic, and rolled to remove any trapped air. The lining system shall be allowed to cure for the amount of time recommended by the lining manufacturer. The average dry film thickness of the cured lining system, including the liner sheets and the applied epoxy mastic, when completed shall not be less than 8 mm (315 mils). I 2007 Supplement to "Greenbook" 63 500-2.5.8 Field Jointing of Liner. 500-2.5.8.1 General. The Contractor shall utilize the maximum size plastic liner sheet that is practical and will provide the minimum number of seams. Vertical and horizontal seams shall overlap a minimum of 13 mm (1/2 inch) and shall be welded with 25 mm (1 inch) weld strips. Comer strips may • be used at inside and outside corners, or liner may be wrapped around comers. The Contractor shall be allowed to heat the liner to facilitate turning corners. Excessive heating of the liner material to facilitate turning comers shall be avoided. 500-2.5.8.2 Field Joints in Manhole and Structure Rehabilitation. Field joints in the liner shall be Type AL-2 unless AL-1 or AL-3 is approved by the Engineer. a) Type AL-1 joint shall consist of a 100 mm (4 inch) wide joint strip centered over a 25 mm (1 } inch) maximum gap between sheets and securely welded along each edge of adjacent liner with a 25 mm (1 inch) welding strip. b) Type AL-2 joints shall be made with integral joint flaps with locking extensions removed 25 mm (1 inch) from one side per 210-2.2.6. The flap shall be overlapped a minimum of 13 mm + (1/2 inch) and the overlap secured to the adjacent liner by means of a 25 mm (1 inch) welding ! strip. c) Type AL-3 joints shall consist of a 25 mm (1 inch) wide weld strip centered over a 6 mm (1/4 inch) maximum gap between sheets and securely welded along each edge of adjacent liner. 500-2.5.83 Installation of Welding Strips. Installation of welding strips shall conform to 311-1.5.4. 500-2.5.9 Pull Test for Locking Extensions. Liner locking extensions embedded in epoxy mastic shall withstand a test pull of at least 3.5N per linear mm (20 pounds per linear inch), applied perpendicularly to the concrete surface for a period of 1 minute without rupture of the locking extensions or withdrawal from the epoxy mastic or delaminating of the mastic from the concrete substrate. This test shall be made at a temperature between 21 °C to 27°C (70°F to 80°F). 500-2.5.10 Inspection. After installation of the protective lining system, the surface of the liner shall be cleaned and prepared by the Contractor and then inspected by the Engineer. Field testing shall be in accordance with 311-1.10. 500-2.5.11 Repair of Defects and Holidays. The Contractor shall repair all defects and damage in the plastic liner in accordance with 311-1.9. -PAGE 436 - REVISE THE FIRST LINE OF 600-4.2.1 TO READ: 6004.2.1 Asphalt Rubber. Paving asphalt used for asphalt rubber shall be PG 64-10 conforming to 203- sa 2007 Supplement to "Greenbook" t• Y: F A I I4 S { c~ 41~