The types of pipe are specified in accordance with their application and intended usage. For a brief description of typical applications see section 603.02. For a more detailed description, see Ohio Department of Transportation’s (ODOT) Drainage Design Manual and the plans.

Materials (603.02)

Type A Conduits

Type A conduits are sealed culvert cross drains under pavements, paved shoulders, and embankments. These culvert cross drains are used to convey water from one side of the roadway to the other. These culverts can be either smooth lined or corrugated. Type A conduits are under pavement and open at both ends.

Type B Conduits

Type B conduits are storm sewers under pavements, paved shoulders, and commercial or industrial drives. Storm sewers are used to convey water from one manhole or a catch basin to the other. Storm sewers are always smooth lined. Type B conduits have one or both ends closed with a drainage structure.

Type C Conduits

Type C conduits are storm sewers not under pavements or paved shoulders and commercial or industrial drives. Like the Type B conduits these conduits are connected to a manhole or catch basin and are always smooth lined. Type C conduits have one or both ends closed with a drainage structure.

Type D Conduits

Type D conduits are culverts placed under residential driveways or bikeways. These conduits can be either smooth lined or corrugated.

Type E Conduits

Type E conduits are farm drain headers in or outside the right-of -way or used for ditch elimination beyond the paved shoulder. These conduits can be either smooth lined or corrugated.

Type F Conduits

Type F conduits are other miscellaneous pipe where a butt joint or a short length jointed pipe would be undesirable. Outlets for underdrain or farm drains, house drain connections, pull box drains, or for steep portions of a median outlet under an embankment are examples of Type F applications. These conduits can be either smooth lined or corrugated.

Soil and Granular Embankment

The soil and granular embankment requirements are listed in C&MS 203.02R. Recycled asphalt is not allowed for use as bedding and backfill material. If there is any doubt about the suitability of the proposed soil or granular embankment, send a sample to the district laboratory for classification.

Structural Backfill Type 1, 2 and 3

The Structural Backfill material requirements are listed in C&MS 703.11. Type 1 is an Item 304 material without the fracture count requirement. Type 2 is a sand material. The Type 1 and 2 materials are allowed for all bedding and backfill operations. The Type 3 is an open-graded No.57 or No.67 material and is allowed to control severe ground water problems only.

Low Strength Mortar Backfill (LSM)

In some cases, the plans designate the use of LSM as bedding and/or backfill material. The requirements for LSM can be found in C&MS 613. There are three Types of mixes. Type 1 mix is a mixture of cement, fly ash, sand, and water. The Type 2 mixture substitutes an entrained air additive for the fly ash. The Type 3 mixture is a mixture of fly ash and water. All three mixes may be used, or an alternative mix submitted for approval by the Contractor may be used if the plans do not call out a mix. The alternate mixes shall meet the criteria in C&MS 613. Changes in the material type or amount or sand gradation are allowed, as long as the final mix has the required strength, fills the voids, and sets up.

Material Provisions (603.04)

General

All pipes, including plant inspected and certified materials are inspected for dimensions and condition after being delivered to the project. Where the dimensions fail to comply with the specified tolerances, or where the pipe includes defects described herein or in the specifications, the pipe is not approved for placement on the project.

Acceptance

Concrete pipe and thermoplastic pipe are accepted under the TE-24 system. Under the TE-24 system, the pipes are randomly inspected by an ODOT Inspector at the plant. But not all the pipe pieces are inspected at the plant.

Metal pipe are accepted under the TE-215 certification program. Under this certification program, the pipe is not inspected at the plant. The material is delivered with a certification card.

For further detail on the Certification Program contact the District Testing Engineer or refer to Materials Managements Sampling and Testing Program Manual.

Rejection and Checking of Pipe

All pipe should be inspected prior to the incorporation into the work. All pipe should be randomly checked for minimum diameters, spans, heights, or dimensions shown in the plans.

Any pipe may be rejected at any time whether approved under the TE-24 system, the certification program, or any other program. This would include material damaged during shipment or placement.

Examples for Rejections

The following is a list of reasons to reject the pipe in the field. Reference is made to the current edition of the Materials Managements Sampling and Testing Program Manual.

Non-Reinforced Concrete Pipe

1. Fractures or cracks passing through the wall or joints.

2. Minor flaws such as a single crack not exceeding 2 inches (51 mm) length at either end of a pipe, or a single fracture or spall in the joints not exceeding 3 inches (76 mm) around the circumference of the pipe or 2 inches (51 mm) in length into the joint, are not to be considered cause for rejection unless these defects exist in more than 5% of the entire shipment.

3. Defects that indicate imperfect mixing and/or molding. (Honeycombed or open texture).

4. Cracks sufficient to impair the strength, durability, or serviceability of the pipe. Any crack passing through the wall would be sufficient to impair the strength of the pipe because it lacks the reinforcing to resist loading.

5. Damaged ends or manufacturer’s defects that would prevent making a satisfactory joint.

Reinforced Concrete Pipe

1. Fracture or cracks passing through the wall, except for a single end crack that does not exceed the depth of the joint.

2. Defects that indicate imperfect mixing and/or molding. (Honeycombed or open texture).

3. Exposed reinforcing steel or reinforcing steel without minimum cover, except for spacers and vertical longitudinal wires in the bell and spigot of the pipe joint.

4. Damaged ends or a manufacture defect that would prevent making a satisfactory joint.

Precast Reinforced Concrete Box, 3-sided Flat Top or Arch Sections

1. Accuracy of the span or rise dimensions with internal dimensions varying by more than 1 % or 1½ inches (38mm), which ever is less.

2. Haunch dimensions cannot vary by more than 3/4 inches (19mm) from plan.

3. Wall thickness cannot be less than 1/4 inches (6mm) of the plan dimension.

4. Fractures or cracks greater than 0.01 inches (0.25mm) passing through the slab or walls.

5. Defects that indicate imperfections in proportioning, mixing, or forming.

6. Unsound concrete or spalls can be determined by sounding or by visual inspection. Areas extending completely through the wall or surface area with more than 1 square foot (0.1 square meters) of unsound concrete or spalls are cause for rejection. Smaller areas can be repaired (after inspection) with material meeting the requirements of 705.21 and on an approved list.

7. Honeycomb areas more than 2 square feet (0.2 square meters) or any honeycombing which extends more than one half through the wall thickness. Honeycombing less than 2 square feet (0.2 square meters) can be repaired by grout rubbing.

8. Patching or repairs not authorized by the Department.

9. Exposed reinforcing steel or reinforcing steel lacking minimum cover.

10. Damaged ends or manufactures defects that would prevent making a satisfactory joint.

Vitrified Clay Pipe

1. Fractures or cracks passing through the barrel or socket. A single crack at the spigot end of the pipe not exceeding 75 % of the depth of the socket, or a single fracture in the socket not exceeding 3 inches (76 mm) around the circumference or 2 inches (51 mm) lengthwise may be permitted.

2. Chips or fractures on the interior of the pipe exceeding 2 inches (51 mm) in length, 1 inch (25 mm) in width, and a depth of more than 1/4 of the thickness of the shell.

3. Cracks sufficient to impair the strength, durability, or serviceability of the pipe.

4. Any crack passing through the wall of the pipe would be sufficient to impair the strength of the pipe because it lacks the reinforcing to resist loading.

Thermo Plastic Pipe (Includes All Polyethylene and Polyvinyl Chloride Pipe)

1. Any cuts, punctures, cracks, or separations in the interior or exterior of the pipe.

2. Deviation from true shape (usually out of round by more than 2% of the diameter) or deviation from straight centerline.

3. Any damaged ends or manufacturing defects that would prevent the sealing of the joints.

4. Non-uniform color or texture.

Metal Pipe (Includes All Steel and Aluminum Pipe)

1. Any cuts, punctures, cracks, or separations in the interior or exterior of the pipe.

2. Uneven laps.

3. Deviation from straight centerline.

4. Deviation from true shape (Usually out of round by more than 2% of the diameter of the pipe). Minor repairs such as minor bending of the metal, refinishing the galvanizing, or re-rounding may be allowed.

5. Ragged or diagonal sheared edges.

6. Loose, unevenly lined, or spaced spot welds.

7. Unfinished ends.

8. Bruised, scaled, or broken coating.

9. Excessive dents or bends in the metal.

10. Any damage or manufacturing defects that would impair the jointing of the pipe.

Excavation (Minimum Trench Widths) (603.05)

603.05A Method A

See Standard Drawing DM-1.4

A cut situation (Method A) is defined as a field situation where the top of the trench is above the top of the pipe. This is where the existing ground is above the top of the pipe.

603.05B Method B

See Standard Drawing DM-1.4

A fill situation (Method B) is defined as a field situation where the top of the pipe is above the top of the trench. In this situation the fill or new embankment is constructed to the spring line of the pipe, and then the trench is constructed.

Ground Water

The specifications require the Contractor to remove the ground water from the trench. This can usually be done by using pumps, deep wells, diversion ditches, or pipes. In some cases, pumping operations will not remove sufficient ground water to construct the project. As a last resort, the Projects Engineer may allow the Contractor to place Structural Backfill Type 3 below the pipe to help relieve the water flow. When permitted, the Structural Backfill Type 3 is only placed below the bottom of the pipe. This material is very porous and should relieve the water problems in most cases. This work is performed at no additional cost to the Department.

When using Structural Backfill Type 3 backfill material, the material on top of the Type 3 Material should be Structural Backfill Type 1 to prevent the fine portion of the surrounding soils or backfill from migrating into the void space in the Type 3 backfill material following construction.

Another alternative to relieving the water to construct the pipe as stated above is to use Item 613 Low Strength Mortar Backfill (LSM) to cut the water off. Sheet piling can also be used to cut the water off. The expense of both of these methods should be carefully evaluated. Unless designated in the plans, the cost of the LSM or sheet piling is the responsibility of the Department.

Foundations

The foundation of a conduit must uniformly support the conduit during construction and for the life of the conduit. Soft conditions and rock conditions are two situations that are important to evaluate in the field. Soft conditions are the most common situations that come up in the field. In general, if the workers can stand and work in the trench, the foundation is adequate for construction. If the material is too soft, then the Project Engineer should investigate the cause of the problem. Review all available soil borings in the area or dig test pits to find the extent of the soft material. Make certain that the proposed remedy is appropriate for both the construction technique and materials used in the work.

Sand or well-graded aggregate may be used to replace the soft material. Make sure that groundwater issues are addressed (as discussed above). It is rare that there is a need to undercut more than 2 feet (.6m) of material to restore support for the pipe. Corrections of soft conditions within 1 foot (.3m) below the bottom of the trench are at the Contractor’s expense except for undercuts shown in the plans. The correction made below this 1-foot (.3m) depth is the Department’s responsibility. When rock boulders are encountered, they should be removed to at least 6 inches (150 mm) below the pipe. When rock is found under the full length of the pipe, the rock should be removed to a 6 inches (150 mm) average depth below the pipe.

General

Minimum trench widths are specified to assure that adequate room is provided for the proper placement and compaction of bedding and backfill material below the springline of the pipe and to allow for the proper joining of the pipe sections. Maximum trench widths are not specified for pipes. The Contractor will build to the minimum trench width to save on backfill material. Spot checks of the trench width are required to ensure proper widths, adequate working room and that the specifications are being observed. These checks need to be recorded on CA-P-1 Daily Pipe Inspection Form.

All trench walls shall be as vertical as practical to a height above the pipe.

The first step to determine the minimum required trench width is to determine the span (outside to outside at the widest point) of the pipe. This is easily measured in the field and should be recorded on the CA-P-1 Daily Pipe Inspection Form. Once the span is known, the minimum trench width (W) can be calculated. The following example illustrates a calculation for the minimum trench width.

Given: Plastic Pipe

Span= 38 inches (960 mm)

W = Minimum Trench Width = 1.25 Span+ 1 foot (.3m)

W = 1.25(38”/12”/’(960mm/1000 mm/m)) + 1 foot (.3m)

= 4.958 FT. (1.5m)

Bedding (603.06)

See Standard Drawing DM-1.4. The following tables are furnished to reflect the Standard Drawing. There are four different Types of Bedding. The Types of Bedding depends on the type of specified conduit. Table 603.A shows the different Types of Bedding.

Bedding Type	Structural Backfill Thickness	Middle one-third
Type 1	6 inches (150mm)	Do nothing
Type 2	6 or 3 inches (150 or 75mm)	Loosen
Type 3	0 inches (0mm)	Loosen
Type 4	0 inches (0mm)	Do Nothing

Table 603.A – Bedding Types

Type 1 bedding is required for all reinforced concrete box sections and 3-sided structures that are placed on a slab.

Type 2 bedding consists of the placement of a minimum depth of 3 or 6 inches (75 or 150mm) of structural backfill. See Table 603.B below for material type, pipe type, and the thickness of bedding required.

Furnish a loosened middle one-third for each case.

Material	Pipe Type	Bedding	Thickness of Structural Backfill Bedding
706.01,706.02,706.03	Type A	Type 2	3 inches (75mm)
706.01,706.02,706.03	Type B	Type 2	3 inches (75mm)
706.01,706.02,706.03	Type C	Type 3	0 inches (0mm)
706.01,706.02,706.03	Type D	Type 3	0 inches (0mm)
All Plastic and Metal	Type A	Type 2	6 inches (150mm)
All Plastic and Metal	Type B	Type 2	6 inches (150mm)
All Plastic and Metal	Type C	Type 2	6 inches (150mm)
All Plastic and Metal	Type D	Type 2	6 inches (150mm)

Table 603.B – Pipe Type

Type 3 bedding is only for Type C and D concrete conduit.

Type 4 Bedding consists of shaping the existing or natural ground to place the pipe. Type 4 bedding is required for only all Type E and F conduits.

The bedding that is extended 30 % up around the conduit is compacted by shoveling, spudding, or flooding. It is absolutely critical that the material in this haunch zone (between the flow line of the pipe and the 30% diameter elevation) be compacted to a maximum density and all the voids are filled. The structural performance of a pipe relies significantly on the compaction of the haunch material.

Laying Conduit (603.07)

General

The construction of the pipe should always start at the outlet end of the pipe run. This procedure should only be changed under special conditions. This means that the work will progress up grade, which makes the jointing of the pipe easier. The Contractor is responsible for the accuracy of the pipe alignment and the grading. The Engineer should ensure the work is progressing in accordance with the plan.

Inlet End

All pipe inlets will be a normal fabricated end piece. For concrete pipe the inlet would be the bell section. The design is based on this type of inlet. If the bell is cut off the design is incorrect and flooding will occur. Box culverts are also designed for the bell at the inlet. Metal pipe has a square edge and can be cut to fit. The cut end is then coated to match the pipe coating. Plastic pipe can have either a square edge, or a bell end. Any inlet that does not have a normal fabricated end piece must be replaced.

Laying Conduit

The Contractor’s surveyor or foreman usually lays out the location and the grade of the pipe. The starting elevation is usually established at the outlet end of the pipe run and carried forward to the inlet end of the pipe run. The pipe grade is established by using a string line, batter boards, or lasers.

Using Batter Boards and String Line

When a string line or batter boards are used the following procedure is followed. The plan pipe grade is roughly established by using grade stakes at the surface of the pipe trench or at the bottom of the trench. The grade stakes are placed at 25 feet (7.5m) or 50 feet (15 m) intervals.

The grade stakes by themselves do not offer sufficient control for the Contractor to place the pipe. The stakes are generally offset too far from the pipe installation to be used directly. Longer grade stakes are used to establish the string line or batter board height to establish the actual construction grade line. The Contractor will place batter boards across the pipe trench and then pull a string line over the batter boards. The string line is set in place directly over the pipe centerline at the same slope as the trench bottom and pipe flow line. A level rod or a marked rod is used to measure the correct distance between the string line and the pipe flow line or trench bottom. This rod is used to keep the pipe or trench bottom on grade throughout the pipe run.

Using a Laser

On most construction projects a laser is used to maintain the pipe grade. A laser light beam is used in the trench or above the pipe trench. The laser light beam is established at grade directly over the pipe as the string line was used when using batter boards in the example above. Once this grade is established measurements are made to the pipe invert or the trench bottom to hold the grade throughout the construction. This method is the most convenient and is preferred by most Contractors.

Final Grade of Large Pipe Structures

Pay particular attention when placing large pipe structures such as concrete boxes. The final grade should be accomplished by raking the granular material with a screed board. The screed board should be as long as the width of the box (Span + 2 times the wall thickness). Then attach a 4 feet (1.2 m) long level to the top of the screed board. Starting at the outlet end, the workers should screed the granular material, filling in low spots and leveling off the high spots. This special attention will expedite the setting of the box sections.

Alignment of Large Pipe Structures

Once the centerline of the box sections is established, a string line or laser should establish the outside of the box sections. The string line or laser is established about 2 inches (50 mm) from the outside of one of the edges of the box sections. Alignment can be easily monitored by measuring over from this line. If a string line is used, then it is usually attached to the footer re-steel.

Placement of Concrete Box and Pipe and Clay Pipe

The setting of the pipe or box starts at the outlet end of the trench, and construction continues to the inlet end (up-grade). It is easier to work upgrade with the help of gravity to hold the pipe or box sections together than to work downgrade. The tongue or spigot (male) end of the pipe or box is always downgrade. The bell or grooved (female) end of the pipe is always up-grade. The construction proceeds this way to minimize the bedding material trapped in the pipe joint and to maximize the hydraulic flow into the pipe or box.

The pipe or box construction may use chains, cables, spud bars, wooden blocks, or pipe pullers to place the sections of pipe together. The type of equipment used depends on the size of the pipe. The Contractor is responsible for placing the pipe or box at the required grade. The final position of the sections of pipe must form a smooth grade. If the Contractor cannot place the box sections together to within 1 inch (25 mm) then the Project Engineer should require the use of winches.

When it is necessary to field cut a pipe, the section cut must have a concrete cradle or collar. The cut section of pipe must not be an end piece. The final joint must be stable. The inlet end must have the groove or bell intact to maximize the hydraulic flow into the pipe or box.

Common Problems Associated with Box Culvert Placement

1. Standing water in the trench makes it difficult to determine the evenness of the bedding.

2. Most joint annular spaces are 1/4 inches (6 mm) to ½ inches (12 mm). If the bedding is irregular, lining up the tongue into the receiving bell will be difficult. Because boxes are wide and flat, any irregularities in the bedding can cause the tongue of the box not to be properly started into the bell. If this is apparent before attaching the winches and anchors, pull the box out of the way and check the bedding again.

3. If the trench conditions are unstable, the line and grade cannot be held and the area must be stabilized by the use of drainage (pumps) or the removal of unstable sub-soils.

4. Boxes that do not hang plumb may be caused by improper anchorage location. If using a four-part sling, longer or shorter clevises may help alleviate the problem. Be consistent in hooking the rigging to the box culvert.

5. Take care to ensure that both vertical portions of the tongue get started evenly into the bell of the previously set box to keep from pulling the box into its home position unevenly.

6. If footers or head walls are specified consult the supplier to determine if the actual lay length of the individual boxes plus joint creep will be greater than the culvert length shown in the design plans.

7. The Contractor is responsible for the accuracy of the pipe alignment and the grading. The Engineer should ensure the work is progressing in accordance with the plan.

Placement of Three Sided Flat Top and Arch Top Structures

The flat top and arch top structures require an approved shop drawing prior to installation. These details should be thoroughly examined prior to the installation of the sections.

The placement and jointing of these structures are approximately the same as concrete boxes, with the differences noted below.

The arch and flat top sections are placed on a footing designated in the plans. Newer designs will have the footing at zero grades. If needed, the sections can be placed on Masonite or steel shims to properly align the sections.

Place the sections by crane from the outlet end to the inlet end (Up-grade). The crane holds the sections in place while winches and/or spud bars are used to make the final placement.

When the sections do not completely come together, a gap tolerance of 1 inch (30 mm) per joint is desirable. The most important dimension is the top gap of the joint. The top elevation of the sections of the arch or flat top sections should be at approximately the same elevation. This maximizes the strength of the joint. If the jointing cannot be done successfully, then the use of winches should be considered.

Joining Conduit (603.08)

Type A, B, C, D, and F conduits are required to have sealed, banded, bell and spigot, tongue and groove, or bolted joints. Type E conduits are permitted to have open joints.

Metal Pipe 707.01 – 707.24

Corrugated metal pipe joints shall be sealed with coupling bands with bolts. The bands are placed around the first placed pipe and then the second pipe is brought into position. The two pipe sections should be within 1 inch (25 mm). Check the joint to ensure the ribs or dimples line up, then join the sections. The bolts are tightened sufficiently to securely close the band. For large diameter corrugated metal pipe, the band should be hammered in place by the use of a mallet to ensure the seating of the band. The permissible differences between adjacent sections is ½ inch (15mm) for conduits greater than 54 inches (1350 mm) and 0.109 inch (2.77 mm) in wall thickness. The permissible differences between adjacent sections is ¼ inch (7mm) for conduits less than or equal to 54 inches (1350 mm). Strutting is required for conduits greater than 54 inches (1350 mm).

Plastic Pipe 707.31

Thermoplastic joints may be sealed with a coupling band or by a gasket bell and spigot joint. The joint will not allow any infiltration by the backfill. Tightened sufficiently, use the cable ties with thermoplastic split couplers, to securely close the band. When bells with locking lugs are furnished place them so that all the detents or lugs lock into the corrugation valleys.

Joint Sealing of Concrete Pipe and Clay Pipe 706.01, 706.02, 706.04, 706.08

Concrete pipe and clay pipe are required to have sealed joints with one of the following:

1. Sealed bituminous pipe joint filler (C&MS 706.10) (commonly known as “bear grease”) is placed to completely fill the joints. After the joint filler is placed, trowel the material for a smoothed finish inside and out in place. It is common for this material to drip off top surfaces, but this should be kept to a minimum.

2. Preformed butyl rubber material (C&MS 706.14) may be used. The joint must be primed on both sides prior to the installation of the butyl material. This material is placed completely around the joint. The material will overlap 6 inches (150mm) at the ends. The joint is sealed but the material may not completely fill the joint from the inside to the outside. The joint must be sealed from water and fine infiltration.

3. Resilient and flexible gasket joints (C&MS 706.11 for concrete pipe, or C&MS 706.12 for clay pipe) may be used.

4. Other materials may be used if approved by the Project Engineer.

Joint Sealing of Epoxy Coated Reinforced Concrete Pipe 706.03

1. Epoxy coated reinforced concrete pipe (C&MS 706.03) must be sealed with fibrated coal tar joint compound placed in accordance with the manufacturers recommendation. After the joint filler is placed, trowel the material for a smooth finish inside and out in place. The outside of the pipe is completely sealed.

2. If the plans call out resilient and flexible gasket joints conforming to 706.11 or 706.12 then furnish these joints and test them as required.

Joint Sealing of Concrete Boxes 706.05

A. Concrete Boxes are required to have sealed joints with one of the following:

3. Resilient and flexible gasket joints (C&MS 706.11 for concrete pipe, or C&MS 706.12 for clay pipe) may be used.

4. Other materials may be used if approved by the Project Engineer.

B. Concrete Boxes are required to have the Outside and Inside Surfaces sealed

There are no critical joints; each section is independent. The exterior joint gap on the top, the interior sides, and bottom gaps of the Precast Reinforced Concrete Box are filled with C&MS 706.02 mortar before placing the membrane waterproofing or joint wrap.

Joint Filling the Outside Surfaces of Three-Sided Flat Top Sections 706.051

The critical joint is the top exterior. The top exterior joint of the Three-Sided Flat Top sections are designed with a keyway detailed in the shop drawings. This keyway is filled with a non-shrink mortar (C&MS 705.22). All other joints see the specification.

Joint Filling the Outside Surfaces of the Three-sided Arch Sections 706.052

There are no critical joints; each section is independent. The joints of the arch sections have a 45-degree chamfer. The external side of the joint shall be cleaned prior to the installation of any sealing material. One continuous section of flexible plastic gasket (C&MS 706.14) is placed from the bottom of the leg on one side to the bottom of the leg of the other. The chamfer section is primed at the project site prior to the installation of the flexible plastic gasket (C&MS 706.14). The primer is a type that has been recommended by the flexible plastic gasket (C&MS 706.14) manufacturer. Each joint, sealed with flexible plastic gasket (C&MS 706.14), is covered with a 9-inch (225 mm) wide strip of Type 3 Membrane Waterproofing (C&MS 711.29). A primer is placed on the external side of the joint under the area of the Type 3 Membrane Waterproofing. The primer used is as recommended by the Type 3 Membrane Waterproofing manufacturers. The plan or the shop drawing may allow other joint sealers.

Exterior Coatings and Waterproofing (603.09)

Areas In Contact With the Backfill Material

Membrane waterproofing is placed in accordance with the plans. Areas of the box, 3-sided flat top, or arch shall be clean prior to the placement of the (C&MS 512) Sheet Type 2 Membrane Waterproofing. Place the Sheet Type 2 Membrane Waterproofing in all areas that are in contact with the backfill material. When asphalt is in direct contact with the top of the box sections, or Three-Sided Flat Top sections then use Sheet Type 3 Membrane Waterproofing. No joint wrap is required under the membrane.

Areas Not In Contact With the Backfill Material

Areas of the box, 3-sided flat top, or arch outside the limits of the granular backfill. The epoxy sealer is applied to the top surface and 1 foot (0.3 m) down the legs of the structure. This area includes the joint. The joint wrap is at least 9 inches (230 mm) wide and is one continuous roll per joint. The joint shall be clean prior to the installation of the joint wrap.

Backfilling (603.10)

General

Backfill materials are defined as all materials above the bedding material and below the subgrade of the pavement structure or the ground elevation. The backfill materials may be Structural Backfill Type 1 or 2, soil, or granular embankment. These backfill materials are required or an option depending on which type pipe is specified and whether the field situations are a cut or fill.

See Standard Drawing DM-1.4 for details.

Structural Backfill Type 1 and 2 are allowed for all backfill applications. There is an option to switch to a soil or granular embankment at certain heights above the pipe depending whether the pipe is located in a cut or fill. Structural Backfill Type 1 or 2 is required for specific width as measured from the outside diameter of the pipe or structure to the trench wall. The minimum height above the pipe for the Structural Backfill represents the location where the material may change to soil or granular embankment. The height of the Structural Backfill may be less than shown if the subgrade is closer to the top of the pipe than the minimum required. Example: The minimum Structural Backfill height required is 4 feet (1.2 m). If the subgrade elevation were 3 feet (0.9 m) above the pipe, then the height of the Structural Backfill would be 3 feet (0.9 m).

Compaction Equipment	Total Weight of Equipment	Height above Pipe	Required Width
No Hoe Rams but Small Equipment	Less Than or Equal to 1 ton (0.9 metric ton)	0 to 2 feet (0 to 0.6m)	3 times span or 12 Feet (3.6m)+ span Whichever is less
Hoe Rams Small Equipment Medium Equipment	Greater Than or Equal to 1 ton (0.9 metric ton) but Less Than or Equal to 8 tons (7 metric tons)	Greater Than 2 feet (.6m) but Less Than or Equal to 4 feet (1.2m)	3 times span or 12 Feet (3.6m)+ span Which Ever is Less
Hoe Rams Small Equipment Medium Equipment Large Equipment	Greater Than 8 tons (7 metric tons)	Greater Than 4 feet (1.2m)	No Restrictions

Type A, B Conduits

Cut Situations

In a cut, Structural Backfill Type 1 or 2 is required for Type A and B conduits for a height of 4 feet (1.2 m). See Standard Drawing DM-1.4

Fill Situations

In a fill, Structural Backfill Type 1 or 2 is required for a height of 2 feet (0.6 m) above the pipe and for a distance equal to 4 feet (1.2 m), or one span of the pipe, whichever is less (span is measured as the outside diameter of the pipe at the widest point). See Standard Drawing DM-1.4

Optional Backfill

In the cut and fill situations described above, Soil and Granular Embankment may be substituted above these heights to the subgrade or ground elevation.

Type C Conduits Except for Plastic Pipe, Type D Conduits Except for Plastic Pipe, and Type F Conduits Except for Underdrain Outlets in a Cut or Fill Situation

Place and compact the backfill in the trench with either Structural Backfill Type 1 or 2, Soil, or Granular Embankment. For these pipe types there are no changes in the width requirements for the trench between cut and fill situations. See Standard Drawing DM-1.4

Type C and D Conduits for Plastic Pipe in a Cut or Fill Situation

For Type C and D thermoplastic pipe, Structural Backfill Type 1 or 2 is required for 1 foot (.3m) above the pipe for cuts or fill situations. Structural Backfill may be substituted with soils and/or granular embankment above the 1-foot (.3m) height to the subgrade or ground elevation.

See Standard Drawing DM-1.4

Type E Conduit

Place and compact the backfill in the trench above the bedding with either Structural Backfill Type 1 or 2, Soil, or Granular Embankment to a height equal to two thirds of the conduit rise then place and lightly place and compact backfill to a height of 1 foot (.3m) above the conduit.

Type F Conduits for Underdrain Outlets in a Cut or Fill Situation

Place the backfill in the trench above the bedding with Granular Material as defined in C&MS 605.02. See Standard Drawing DM-1.2.

Long Span Structures Type A, B, C, D

Long span Structures are defined as Precast Reinforced Concrete Boxes (C&MS 706.05), Precast Reinforced Concrete, Flat Top Three-sided Culverts (C&MS 706.051), or Precast Reinforced Concrete Arches (C&MS 706.052) structures.

The following are trench specifications for new construction. Reconstruction plans may indicate other trench configurations.

Cut Situations

In cuts, Structural Backfill Type 1 or 2 is required for 4 feet (1.2 m) above the top of the structure or to a height equal to the subgrade (which ever is less), and to a width equal to 2 feet (0.6 m) measured from the outside of the structure to the trench wall.

Fill Situations

In a fill, Structural Backfill Type 1 or 2 is required for 2 feet (0.6m) above the top of the structure and for a width equal to 4 feet (1.2 m) measured from the outside of the structure to the trench wall.

Optional Backfill

In a cut or fill above the minimum heights specified soils and/or granular embankment may be used.

Placement and Compaction Requirements (603.11)

General

Trench conditions can change from location to location. The bottom and trench walls may change from rock to soft clay or silt. The compaction equipment used by the Contractor may change from the bedding to the backfill material. All backfill material lifts except Structural Backfill Type 3 are 8 inches (200mm) thick. Structural Backfill Type 3 is 12 inches (300mm) thick.

Soils Compaction Requirements

For soil embankment the density requirement is 96% of AASHTO T 99.

For soils that meet the requirements of C&MS 603 the One-Point Proctor Method along with the Ohio Typical Density Curves can be used to establish the compaction requirements. The one point proctor and the moisture content of the proctor soil are used to find the curve that represents the tested soil. Once the curve is found, only 96% of the maximum dry density is required. The detailed procedures for compaction testing are explained in section for Supplement 1015.

Granular Embankment and Structural Backfill Type 1 & 2 Compaction Requirements

Controlling the compaction of granular embankment by using the Test Section Method is superior over any other method. The Test Section Method allows for the adjustment of the density requirements to meet the material, compaction equipment, and the trench condition changes. When the trench bottom or the trench walls are too soft, the fixed density requirement may not be physically achievable. This may not be a result of Contractor negligence but a result of field conditions. It is difficult to obtain fixed density in soft foundation conditions. A test section is used to establish the compaction controls.

Compaction acceptance and procedures are detailed in Supplement 1015

According to 603.06, when Type 2 Bedding is used, the middle 1/3 of the pipe bedding is left uncompacted (or lightly compacted to hold the grade of the pipe). If you divide the span or the diameter of the pipe into 3 parts; the bedding below the middle 1/3 of pipe is left uncompacted or lightly compacted.

Structural Backfill Type 3

Due to physical differences between Type 1, 2, and 3, the compaction controls are different. The Type 3 material (#57's or #67's) is not conducive to compaction testing; using a procedural method controls the compaction requirements.

Compaction Requirements for Structural Backfill Type 3 (# 57 or #67)

There is no compaction testing requirements for the placement of the Type 3 material. The material is placed at a maximum lift thickness of 12 inches (300 mm). The material is then compacted to approximately 85% of the original lift thickness. The compaction should consist of vibratory plates, jumping jacks, or hand tamps. Although it may not seem like the compaction effort is accomplishing very much, it seats the material in place. To demonstrate the effectiveness of this compaction effort, fill a concrete mold with type 3 material and then weigh the filled mold. Then fill a second concrete mold using three equal lifts of type 3 material. Compact with a flat device after each lift is placed. Then weigh the second mold. The difference in weight will be about 20%. The same conditions exist in a pipe trench.

Documentation Requirements - 601 Slope and Channel Protection

1. Concrete riprap

a. Size, spacing, depth, and clearance maintained on reinforcing steel

b. Concrete items of 499 apply

c. Joint width and depth and how filled if used

d. Amount of curing compound used

e. Dimensions of cutoff wall (length x width x depth)

f. Measure length and width for pay

2. Crushed aggregate slope protection

a. Measure depth of crushed aggregate placed

b. Measure length and width for pay

3. Concrete slope

a. Depth of concrete

b. Depth increased from 6 to 18 inches (15 to 46 cm) on last 3 feet (1 m) of bottom edge

c. Depth and spacing in both directions of joints

d. Amount of curing compound used

e. Measure length and width for pay

4. Dump Rock Fill

a. Stone placed conforms to Type________ (A, B, C or D, 703.19)

b. Measure length and width for pay

5. Rock Channel Protection

a. Stone placed conforms to type ______ (A, B, C or D, 703.19)

b. Large stone placed on a 6 inches (15 cm) bed of _______ (#3, #4 aggregate)

c. Measure length x width x depth for pay

d. Note type of filter used (if fabric), width of lap, and pin placement and length. If stone, note depth and material used.

6. Paved gutter

a. Make drawing showing section of gutter

b. Widths and depth of joint

c. Spacing on joints

d. Joint filler used

e. Amount of curing compound required and used

f. Base wet prior to placing concrete

g. Measure length for pay as per 601.12

Documentation Requirements - 602 Masonry

1. Take adequate measures to keep concrete from freezing. State method used.

2. Blocks and brick wet before placing

3. Mortar composed of one part cement to two parts sand

4. Full mortar joints used

5. Method of cure

6. Measure length x width x depth for pay

7. Headwalls

a. Form dimensions - height to invert, total height, width, and thickness

b. Size and number, spacing and clearance maintained on reinforcing steel if required

c. Quantity for pay from standard

d. Method of cure

e. Backfill placed in loose lifts of 4 inches (10 cm) or less and tamped

8. Precast Headwalls & Wing walls

a. Must be pre-approved before use and produced by a certified precast concrete producer and shipped with a TE-24.

b. Measure length x width x depth for pay

c. Use non-shrink grout to fill void between conduit and wall

Documentation Requirements - 603 Pipe Culverts, Sewers, and Drains

1. Document on form CA-P-1 or CA-P-3 as appropriate.

2. Must be produced by a certified precast concrete producer and shipped with a TE-24.

3. Measure length for pay (Note: Pay through or to the center of all junctions such as manholes, catch basins, etc. as per 603.14 of the C&MS)

4. Document the following on the CA-P-1 Daily Pipe Inspection Form for each run of conduit.

a. List the equipment, number of passes, and lift thickness required for the bedding used

b. List the equipment, number of passes, and lift thickness required for the backfill used

c. List the type of the backfill material moisture density curve used if required

d. List all the compaction checks of the bedding

e. List all the compaction checks of the backfill

f. List how the haunch material is compacted

Clearing Site and Restoring Damaged Sites (603.10) Documentation

1. Use CA-P-1 Daily Pipe Inspection Form for each run of conduit.

a. Note how the site was restored (type of pavement replacement)

b. Note how the excavated material was taken care of (removed and disposed or used)

Field Paving of New or Existing Pipes (603.11) Documentation

1. Use the CA-P-1 Daily Pipe Inspection Form for each run of conduit.

a. Note either existing or proposed pipe being field paved

b. Note height of cover placed before field paving

c. Note any repairs that were done before the field paving

d. Note type of reinforcement used

e. Note how reinforcement was attached to the pipe

f. Note the quantity of concrete furnished

604 Manholes, Catch Basins, Inlets, Inspection Wells, Junction Chambers, Precast Reinforced Concrete Outlets, Or Monuments

Description (604.01)

The types of structures are specified in accordance with their application and intended usage. For a brief description of typical applications see section 604.02. If you need a more detailed description, see Ohio Department of Transportation’s (ODOT) Drainage Design Manual and the plans.

Materials (604.02)

1. Structure concrete, Class C is the precast material.

2. Brick and masonry units are the cast in place material.

3. Precast reinforced concrete manhole, catch basin, and inlet sections are per the material specification information with the Standard Drawings showing the dimensions.

4. Precast reinforced concrete outlet is per the material specification information with the Standard Drawings showing the dimensions.

5. Preformed expansion joint fillers is the material that can be used between the precast structures and a poured in place structure.

6. Epoxy-coated reinforcing steel is required only in the top of precast structures.

7. Gray iron cast frames, grates, and covers are per the material specification information and dimensions as shown on the Standard Drawing.

8. Angle steel welded frames and grates are per the material specification information and dimensions as shown on the Standard Drawing.

9. Steps are per the Standard Drawings showing the dimensions and locations.

10. A resilient and flexible gasket joint is the material that is used for the precast structures that are only on sanitary sewer runs.

11. Curing is the material that is used per the standard Drawing requirements.

12. Mortar is the material that is used per the standard Drawing requirements.

Construction Methods, General (604.03)

The drainage structures are placed before placing the storm sewers. Check that the drainage structures are at the locations and elevations shown on the plans and according to the proper standard drawing. Record these on the CA-P-3 Structure Inspection Form. The locations and elevations shown on the plans may need to be adjusted in the field. Record these on the CA-P-3 Structure Inspection Form. The manhole castings are placed at the elevation and station with offset to the center of the casting. Record these on the CA-P-3 Structure Inspection Form. If this location or elevation is not attainable then adjust the structure as needed. Record these on the CA-P-3 Structure Inspection Form.

The manhole base is placed at the elevation with station and offset to agree with the pipe elevation with station and offset. Record these on the CA-P-3 Structure Inspection Form. If this location or elevation is not attainable then adjust the structure as needed. Record these on the CA-P-3 Structure Inspection Form.

Only a flat slab top for manholes as shown on the standard construction drawing is to be used. Record this on the CA-P-3 Structure Inspection Form. All covers with lifting devices must remain in place after construction. Record this on the CA-P-3 Structure Inspection Form.

If the structure elevation changes by more than 1 foot (0.3 m), the Department will pay for this change. Record this on the CA-P-3 Structure Inspection Form.

Ensure that the underdrain outlet pipe is thoroughly mortared to the precast reinforced concrete outlet.

All lateral sewer connections including drops and leads except pipe included in 603 is part of the structure for payment. Record these on the CA-P-3 Structure Inspection Form.

Ensure that the conduit is as shown on the standard construction drawings (that is, they do not protrude inside the structure walls). Record this on the CA-P-3 Structure Inspection Form.

Ensure that structure concrete or mortar cement is not freezing. Record these temperatures on the CA-P-3 Structure Inspection Form.

If the ambient temperature is 40° F (4° C) or less ensure that the precast concrete structure throughout the entire mass is a temperature of between 50 and 80° F (10 and 27° C) before the contractor places the mortar. Record these temperatures on the CA-P-3 Structure Inspection Form.

Ensure that all iron frames, tops, and covers of the type shown on the plans are placed on a mortar bed. Record this on the CA-P-3 Structure Inspection Form.

Ensure that all earth or debris resulting from construction operations that enter the manholes, catch basins, junction chamber, inlets, and precast reinforced concrete outlets is removed. Record these removals on the CA-P-3 Structure Inspection Form.

If reconstruction is specified, ensure the following are performed:

1. The existing castings are carefully removed and clean.

2. For manholes, remove the existing walls down to the spring line or below as necessary. Record the depth of removal on the CA-P-3 Structure Inspection Form.

3. For catch basins and inlets, remove existing walls below the window openings, grates, or any points of wall failure. Record the depth of removal on the CA-P-3 Structure Inspection Form.

4. Using the salvaged casting, reconstruct the structure to the new grade, conforming as nearly as practicable to the existing dimension and type of construction. Record this elevation on the CA-P-3 Structure Inspection Form.

If adjustment to grade is specified, ensure the following are performed:

1. Carefully remove the existing frame, adjust the height of supporting walls, and then reset the existing frame in a bed of mortar or structure concrete to the new grade. Record this work and elevation on the CA-P-3 Structure Inspection Form.

2. Ensure the existing cover or grate is removed and cleaned and then one of the following is done: Record this work and elevation on the CA-P-3 Structure Inspection Form.

a. A new casting is installed to provide the proper elevation or

b. An approved adjusting device that is on file at the Laboratory is installed to provide the proper elevation or

c. An adjusting device approved by the Engineer is installed per the manufacturer’s recommendations to provide the proper elevation.

Excavation and Backfill (604.04)

Ensure that the excavation is to dimensions that provide ample room for construction. Require the removal of unsuitable material below the structure bedding. The contractor must replace unsuitable material with Item 603 Structural Backfill. Record the material type and depth on the CA-P-3 Structure Inspection Form. The Department will provide compensation for this removal and replacement of unsuitable material below the bedding for precast structures, and below the structure for cast-in-place structures, according to the Contract or by Supplemental Agreement.

Backfilling follows the completion of the work as closely as the type of construction will permit. Ensure that the structure while backfilling is not disturbed. Backfill structures located within the pavement area with structural backfill to the subgrade according to Item 603, Type A or B conduit. Backfill structures located outside of the pavement area according to Item 603, Type C conduit. Record the material type and elevation depth on the CA-P-3 Structure Inspection Form for each structure.

Brick and Block Masonry (604.05)

Ensure that all brick and concrete block masonry units are thoroughly wet before laying them in the mortar, and that they are laid with full mortar joints.

Ensure that the concrete and mortar do not freeze. Do not set brick and masonry units having a temperature of 40° F (4° C) or less with mortar until heated. When required, heat to ensure that a temperature of 50 to 80° F (10 to 27° C) is obtained throughout the entire mass of the material. Record the temperature on the CA-P-3 Structure Inspection Form. Ensure that the exposed surfaces of all brick and block masonry are cured by covering them with wet burlap for 48 hours or by applying curing membrane according to Item 511. Record the curing type on the CA-P-3 Structure Inspection Form.

Precast Concrete Modular Construction (604.06)

Ensure that furnished precast bases are on a compacted structural backfill bed having a minimum thickness of 3 inches (75 mm). Ensure that the structural backfill bed is level and uniformly supports the entire area of the base. Record the material used and how that material was compacted on the CA-P-3 Structure Inspection Form.

Ensure that all openings in the structures are thoroughly filled with mortar. Ensure that all joints are sealed between modules with materials specified in Item 603 for Type A, B, C, D, or F conduit.

Ensure that median inlets are cured with the same materials and methods specified in 622.07. Ensure that the manufacturer of precast modular items is certified according to Supplement 1073.

Concrete (Cast-In-Place) (604.07)

Ensure that the structure concrete is placed and furnish as shown on the plans. Record all information on the CA-P-3 Structure Inspection Form as required by Item 511.

Method of Measurement (604.08)

The Department will measure Manholes, Inlets, Catch Basins, Monument Assemblies, Reference Monuments, Inspection Wells, Junction Chambers, and Precast Reinforced Concrete Outlets, whether new, reconstructed, or adjusted to grade, by the number of each type of structure complete and accepted. Record each type on the CA-P-3 Structure Inspection Form that is paid for that day.

Basis of Payment (604.09)

The Department will pay for accepted quantities at the contract prices. . Record the reference Item number on the CA-P-3 Structure Inspection Form.

Documentation Requirements - 604 Manholes, Catch Basins, Inlets, etc.

1. Catch Basin

a. Pad dimensions (length x width x depth)

b. Blocks wet prior to placing

c. Mortar composition, one part cement to two parts sand by volume

d. Full mortar joint used

e. How cured

f. Take adequate measures to keep concrete from freezing. State method used

g. Backfill placed as per 603.10, 603.11

h. Measure inside dimensions

2. Pre-cast catch basin or manhole

a. Precast basin set on a bed of compacted granular material (type of granular material used)

b. Must be produced by a certified precast concrete producer and shipped with a TE-24.

c. All openings in structure sealed with (mortar or bituminous material)

d. Backfill placed in 4 inch (10 cm) loose lifts and tamped

3. Manholes

a. Pad dimensions - length x width x depth or diameter and depth

b. Joints between riser section sealed by rubber gasket or mastic material

c. Backfill placed in 4 inch (10 cm) loose lifts and tamped

d. Steps are required

e. All openings made in manhole sealed with concrete or grout

f. Measure inside dimensions

4. Inlets

a. Pad dimensions (length x width x depth)

b. Blocks wet prior to placing

c. Mortar composition, one part cement to two parts sand by volume

d. Full mortar joints used

e. how cured

f. Take adequate measures to keep concrete from freezing. State method used.

g. Backfill placed in 4 inch (10 cm) loose lifts and tamped

h. Measure inside dimension.

5. Monument assemblies (as per standard drawing)

a. Dimensions of concrete poured

b. Diameter and depth of pipe placed

c. Pipe filled with concrete sand compacted by flooding

d. 1 inch (2.5 cm) diameter x 36 inch (91 cm) steel rod placed 3 inches (8 cm) minimum from bottom of pipe and 6 inches (15 cm) below pavement surface and on correct alignment

6. Reference Monuments

a. Diameter and depth of hole drilled

b. Top 6 inches (15 cm) formed

c. Hole filled with Class C concrete

d. ½ inch (1 cm) steel rod embedded in plastic concrete to a depth of 6 inches (15 cm) on correct alignment

e. Top cured

f. Document on CA-P-3.

605 Underdrains

Description (605.01)

The types of underdrains are specified in accordance with their application and intended usage. For a brief description of typical applications see section 605.02. If you need a more detailed description, see the ODOT Drainage Design Manual and the plans.

Materials (605.02)

Use approved granular material consisting of No. 8, 9, or 89 size air-cooled blast furnace slag, limestone, or gravel for underdrain backfill only but not for underdrain outlet pipes.

Pipe for 605 Rock-Cut Underdrains.

When the pay item description says Rock Cut Underdrains and the kind of pipe is not specifically itemized in the Proposal, then use one of the following:

1. Corrugated Polyethylene Drainage Tubing (Perforated) 707.31

2. Polyvinyl Chloride plastic Pipe 707.41

3. Polyvinyl Chloride Corrugated Smooth Interior Pipe (Perforated Per 707.31) 707.42

4. Polyvinyl Chloride Solid Wall Pipe (Perforated Per 707.31) 707.45

Provide the pipe type on the 605 CA-P-2 Structure Underdrain Form.

Pipe for 605 Pipe Underdrains

When the pay item description says Shallow Pipe Underdrains or Deep Pipe Underdrains and the kind of pipe is not specifically itemized in the Proposal, then use one of the following:

1. Perforated Concrete Pipe 706.06

2. Concrete Drain Pipe Extra Quality 706.07

3. Perforated Vitrified Clay Pipe 706.08

4. Clay Drain Tile Extra Quality 706.09

5. Corrugated Steel Underdrains, Type III 707.01

6. Corrugated Polyethylene Drainage Tubing (Perforated) 707.31

7. Polyvinyl Chloride plastic Pipe 707.41

8. Corrugated Aluminum Alloy Pipe and Underdrains, Type III 707.21

If the size and type of the underdrains required is a 6-inch (150 mm) shallow pipe underdrain, and the kind of pipe material is not specifically itemized, then use 4-inch (100 mm) 707.31 perforated corrugated polyethylene drainage tubing. An example would be “6-inch shallow pipe underdrains” listed in the description, then the contractor can furnish 4-inch 707.31 underdrains placed at the same location as the “6-inch shallow pipe underdrains”. Provide the pipe type on the 605 CA-P-2 Structure Underdrain Form.

Pipe for 603 Type F Conduit Underdrain Outlets.

The backfill requirements are as per 603. When the pay item description says “603 Type F Conduit Underdrain Outlets” and the kind of pipe is not specifically itemized in the Proposal, then use one of the following:

1. Corrugated Polyethylene smooth lined pipe 707.33

2. Polyvinyl Chloride plastic Pipe (non-perforated) 707.41

3. Polyvinyl Chloride corrugated smooth interior pipe 707.41

4. Polyvinyl Chloride solid wall pipe 707.45

Provide the pipe type on the 605 CA-P-2 Structure Underdrain Form.

Pipe for 605 Construction Underdrains

Corrugated Polyethylene Drainage Tubing (Perforated) 707.31 is the only pipe type permitted.

Provide the pipe type on the 605 CA-P-2 Structure Underdrain Form.

Pipe for 605 Prefabricated Edge Underdrains

Prefabricated Edge Underdrains 712.10 is the only pipe type permitted.

Provide the pipe type on the 605 CA-P-2 Structure Underdrain Form.

Pipe Underdrains Construction (605.03)

Construct underdrains as follows:

Excavation

Underdrain ID	6inches (150mm)	4 inches (100mm)
Trench Width	14 inches (350mm)	10 inches (250mm)

Provide the trench width on the 605 CA-P-2 Structure Underdrain Form.

If filter fabric is specified, note this on the 605 CA-P-2 Structure Underdrain Form along with a sketch of how the fabric was placed and overlapped at the top of the trench.

Laying Underdrain

Lay the underdrain true to line and grade with close fitting joints. Use locking bands or smooth sleeve type couplers matching the underdrain material type to join 707.01, 707.31, 707.41, and 707.21. When bell and spigot underdrain is used, lay it with the bell end facing up grade. Set the underdrain on a solid bed shaped to fit the underdrain throughout its entire length. Make all necessary connections with branches, wyes, tees, transitions, and bends that match the underdrain material type. Close the upper ends of underdrains with suitable plugs.

Lay perforated underdrain so that the perforations are in the bottom half of the underdrain.

Provide the pipe joint type on the 605 CA-P-2 Structure Underdrain Form.

Backfilling

Inspect the underdrains before placing any granular material. Place the granular material for the full width of the trench around the underdrain, and extend it to the bottom of the pavement or base as shown on the plans. If underdrains are placed outside of the pavement or base area, extend the granular material to within 4 inches (100 mm) of the finished grade. Fill the remaining depth of the trench with 203 Embankment material. Provide the pipe backfill material type on the 605 CA-P-2 Structure Underdrain Form.

Protection

Place the pavement over the underdrain trench within 90 days after placing the trench backfill. If the trench remains open for longer than 90 days, remove and replace backfill contaminated by soil. Provide the dates when the underdrains were placed and the date the pavement was placed over the underdrain trench on the 605 CA-P-2 Structure Underdrain Form.

Construction Underdrains (605.04)

Excavation

Construction Underdrain	4 inches (100mm)
Trench Width	10 inches (250mm)

Provide the trench width on the 605 CA-P-2 Structure Underdrain Form.

Trench depth and backfill

Construct the trench depth to that shown on the plans or 30 inches (750 mm). Backfill the full width and height of the trench with granular material. Provide the pipe backfill material type and trench depth on the 605 CA-P-2 Structure Underdrain Form.

Outlet

Outlet the construction underdrains as possible into the ditch or drainage structures. There is no change in pipe types for the outlet. Provide the trench outlet location on the 605 CA-P-2 Structure Underdrain Form.

Removal

Do not removed Construction underdrains at any time. If a construction practice requires the construction underdrains to be removed, then install replacements as soon as possible. Example would be if trenching for a culvert would cut the construction underdrains.

Provide the dates when the construction underdrains were placed on the 605 CA-P-2 Structure Underdrain Form.

Prefabricated Edge Underdrains (605.05)

Install the prefabricated edge underdrains against the outside wall of a 4-inch (100 mm) trench, and backfill the trench adjacent to the pavement with granular material. Place the granular material in one or more lifts with a vibratory compactor run over the final lift to compact the granular material before placing the asphalt plug. Place the first layer of the granular material simultaneously with the trenching operation to hold the edge underdrains flush against the trench wall.

Splice the prefabricated edge underdrains as required before placing in the trench, using material furnished by the manufacturer and according to the manufacturer’s directions. Require the manufacturer to furnish all material required for the splices, and furnish any equipment required for splicing. Construct splices to prevent separation of adjoining sections of the prefabricated edge underdrain panels. Provide the dates when the prefabricated edge underdrains were placed on the 605 CA-P-2 Structure Underdrain Form.

Underdrain Outlets (605.06)

Construct outlets per 603 and document this work as required in 603. The manufacturer must supply outlet fittings that transition between the underdrains and the outlet pipe. These are included in the 605 pay items. Place underdrains and outlets on fractured slab projects, such as crack and seat, rubblized, or break and seat projects before fracturing the existing pavement.

Mark all underdrain outlets with a wooden lath prior to final seeding. Clean all debris from the outlets after final seeding. These are included in the 605 pay items.

Aggregate Drains (605.07)

Construct the aggregate drains after the completion of pavement.

Excavation

Excavate trenches for aggregate drains to a minimum width of 12 inches (0.3 m) and to the depth shown on the plans. Slope the bottom of the trench to drain and keep it free from loose particles of soil. Excavate the trench to provide a clean exposure of the granular pavement courses to be drained. Provide the dates when the aggregate drains were placed on the 605CA-P-2 Structure Underdrain Form along with a sketch.

Placing and Backfilling

Use granular material for the drains. Place the aggregate to a minimum depth of 8 inches (200 mm) above the bottom of the trench. Backfill the remaining depth of the trench with suitable embankment material according to Item 203. Provide how the aggregate drains were backfilled on the 605CA-P-2 Structure Underdrain Form.

Method of Measurement (605.08)

How were the underdrains measured? Example: station to station or by wheel or other. Provide this on the 605CA-P-2 Structure Underdrain Form.

Basis of Payment (605.09)

Note the length paid per day. Provide this on the 605CA-P-2 Structure Underdrain Form.

Documentation Requirements - 605 Underdrains

1. Edge drains

a. Document on form CA-P-2

b. Trench backfilled with granular material, document type of aggregate

c. Measure as per 605.08

d. Provide precast reinforced concrete outlet per 605.06 as required

2. Aggregate drains

a. Width and depth of trench

b. Trench backfilled filled with granular material, document type of aggregate

c. Measure as per 605.08

d. Ends re-opened after final seeding

606 Guardrail

Description (606.01)

This work consists of constructing or reconstructing guardrail, guardrail posts, bridge terminal assemblies, end terminals, and impact attenuators, including the furnishing, assembling, and erecting of all component parts and materials.

Guardrail shall be deep beam rail Type 5, 5A, or 8. Appurtenances shall include bridge terminal assemblies, end terminals, and impact attenuators. Construction of the various types of guardrail include the furnishing, assembling, and erecting of all component parts and materials, complete in place, at the location shown on the plans or as directed, and according to the manufacturer’s recommendations where applicable.

Setting Posts (606.03)

The posts shall be set or driven plumb in a manner that prevents battering or distorting of the posts. The posts shall be trimmed that are set or driven more than 1-inch above grade. The trimmed posts shall be treated with a preservative material specified in 712.06.

Type 5 guardrail posts shall be spaced 6 feet, 3 inches on center measured along the centerline of the rail and constructed with either wood or plastic blockouts. Each end of Type 5 guardrail barricades shall be constructed without blockouts and with a flared end section.

Type 5A guardrail posts shall be spaced 3 feet, 1 1/2 inches on center measured along the centerline of the rail and constructed with blockouts. Each end of Type 5A guardrail barricades shall be constructed without blockouts and with a flared end section.

Type 8 guardrail posts shall be spaced 6 feet, 3 inches (1.905 m) on center measured along the centerline of the rail and constructed with blockouts.

Erecting Rail Elements (606.04)

The plans shall show to erect either standard design (single-faced) guardrail or barrier design (double-faced) guardrail.

Erect rail elements in a manner resulting in a smooth, continuous installation. Shop-curved rail shall be used on curves with radii from 5 to 70 feet (1.5 to 22.4 m). Do not allow straight elements to be bent or curved to fit a radius.

The bolts shall be tightened through expansion joints as tight as possible to prevent the rail elements from sliding past one another longitudinally. Ensure that the bolts long enough to extend at least 1/4 inch (6 mm) beyond the nuts.

Splice bolts that extend more than 1/2 inch (13 mm) beyond the nuts shall not be used. For double-faced guardrail, the bolts shall extend from 1/4 to 1 inch (6 to 25 mm) beyond the nuts.

Do not allow burning or welding in the field. The Engineer may approve making holes in the field, but only for special details in exceptional cases. The Engineer may approve field punching, cutting, and drilling if the Contractor demonstrates that its methods do not damage the surrounding metal.

The galvanized surfaces shall be repaired that have been abraded such that the base metal is exposed, including threaded portions of all fittings and fasteners, and cut ends of bolts as specified by ASTM A 780.

The guardrail shall be erected so that the bolts at expansion joints are located at the centers of the slotted holes. The rail elements shall be lapped in the direction of traffic. The plates at each splice shall make contact throughout the area of the splice.

Guardrail Rebuilt (606.05)

Unless otherwise shown on the plans, the rebuilt guardrail shall be of the same type and spacing of members as the existing guardrail.

The following materials shall be new: posts, blockouts, bolts, washers, and incidental hardware as necessary to complete the guardrail, except: (1) existing steel posts and blockouts that are not damaged and have a good galvanized coating may be reused, and (2) guardrail splice bolts that are undamaged and were not removed during salvage may be reused.

Impact Attenuators (606.06)

Before installation of the attenuator, all corresponding shop drawings, installation drawings and instructions from the manufacturer shall be made available for the Engineer’s inspection.

The top of each foundation shall be graded at the same elevation as the adjacent travel lane and/or paved shoulder. The anchors for the attenuator shall be adjusted to avoid pavement joints.

Method of Measurement (606.07)

The Department will measure Guardrail, new or rebuilt, of the type specified by the number of feet from center-to-center of end posts, excluding anchor assemblies. If, however, end connections are made to masonry or steel structures, the Department will measure to the center of the normal post bolt slot. If rail element is used across a bridge, the Department will measure to the first post off the bridge.

The Department will measure Anchor Assembly of the type specified by the number each assembly furnished and erected complete.

The Department will measure Bridge Terminal Assembly of the type specified by the number of each assembly furnished and erected complete.

The Department will measure Impact Attenuator of the type specified by the number of each furnished and erected complete.

The Department will measure Guardrail Post of the kind specified by the number of each furnished and erected.

Basis of Payment (606.08)

The additional costs associated with furnishing and installing extra-length posts instead of standard-length guardrail posts are incidental to Guardrail Post, 8-foot (2.44 m) or Guardrail Post, 9-foot (2.75 m).

For the extra costs associated with furnishing and installing extra-length posts in lieu of standard-length guardrail posts, payment for 9-foot (2.75 m) guardrail posts is considered full compensation.

Documentation Requirements

Use Form CA-D-3A to document the following items:

1. Depth post driven, post spacing

2. All cuts and abrasions on wood post treated with application of approved preservative

3. Rail erected accurately to line and grade all hardware drawn tight

4. Anchor assemblies and bridge terminal assemblies

a) Number, diameter, and depth of holes drilled

b) Top 4 inches (10 cm) of concrete anchor formed

c) Diameter, length, number of anchor bolts placed

d) Number, spacing, size, and clearance maintained on reinforcing steel

e) Top cured

f) Measure and pay as per 606.07

607 Fence

Documentation Requirements - 607 Fence

1. Distance between line post

2. Depth line post driven

3. Diameter and depth of concrete used to encase post placed in dip section, fence not attached to post for minimum 5 day cure, 3 days for high early

4. Post for end, corner, gate, pull, and intermediate anchor assemblies driven to a depth of __________ (If not driven to grade, diameter and depth drilled for encasement)

5. Fabric clipped to post at top wire, bottom wire and alternate wires between

6. Document location and measure as per 607.09

608 Walks, Curb Ramps, and Steps

Documentation Requirements - 608 Walks, Curb Ramps, and Steps

1. Sidewalk

a. Depth and width of base if any

b. Depth of concrete

c. Wet subgrade if necessary and compact

d. Spacing on joints – 5 foot (1.5 m) intervals

e. Surface texture

f. Amount of curing compound (used and required)

g. Measure length and width for pay quantity

h. All forms were oiled

i. Expansion material was placed at full depth at ______________(location)

j. Slope = ________(inches/ft [cm/m] cross slope)

2. Steps

a. Form dimensions (riser and tread)

b. Amount of curing

c. Number and size of reinforcing bars - clearance maintained

d. Measured length

3. Curb ramps

a. When added to existing walk, measure and pay by the square foot (square meter)

b. When placed with new walk, pay each

609 Curbing, Concrete Medians, and Traffic Islands

Documentation Requirements - 609 Curbing, Concrete Medians, and Traffic Islands

1. Curb & Curb and Gutter

a. Form dimensions or slip form (if slip formed, measure finished curb dimensions)

b. Joint spacing

c. Joint dimensions and how filled

d. Amount of curing compound used and required

e. Oil forms

f. Subgrade compacted and wetted

g. Joints sawed or formed by metal plates

h. Measure length for pay and document location. (Station and plan location)

610 Cellular Retaining Walls

This specification covers to general types of retaining walls. The first are walls made up of layered and tiered precast reinforced blocks. The second are constructed with metal columns and front and rear metal filler panels. Both of these wall types are specialized and require Director’s approval. Acceptable Manufacturers are some times indicated in the plan notes.

Documentation Requirements - 610 Cellular Retaining Walls

1. Director’s approval is required

2. Manufacturer’s wall type must be in successful commercial use for a period of at least 3 years

3. For galvanized metal walls the Contractor must furnish 3 copies of the Manufacturer’s “Analysis and Coating Test Certificate”.

4. State type size, and quantity of units

5. Precast concrete units, must be produced by a certified precast concrete producer and shipped with a TE-24.

6. Type of backfill used and how compacted.

7. Measure and pay as per 610.08 and 610.09 of the C&MS

613 Low Strength Mortar Backfill

Documentation Requirements – 613 Low Strength Mortar Backfill

This section recommends minimum documentation and critical inspection requirements for Item 613. The following documentation requirements must be recorded in the appropriate sections of the CA-P-1 Pipe Construction Form and in the project daily reports. Specifications or other requirements waived by the Project Engineer shall be noted in the daily diaries.

1. Record on the CA-P-1 form how the pipe was anchored to prevent it from floating in the trench

2. Record how the LSM was brought up in the trench. Indicate if the LSM was brought up on both sides of the pipe evenly.

3. Indicate if forms or embankment was placed at ends of pipe to prevent the LSM from flowing into the ditch

4. Record if the LSM was brought up to grade line as specified in plans

5. A comparison needs to be made between the quantity installed and the quantity computed from the plans (take-off quantity). Record both the installed and take-off quantity on the CA-P-1 form. Measure and pay the computed amount of cubic yards (cubic meters) unless it is determined by the engineer that the amount used is reasonable for pay. Documentation of the take-off and installed quantities is an important part of the record particularly when paying less than the quantity delivered.

614 Maintaining Traffic

Description (614.01)

This work consists of maintaining and protecting vehicular and pedestrian traffic according to these provisions. For through traffic, the Special Provisions or the plans will designate whether the highway will be closed with detours, roads and run-arounds provided or whether traffic will be maintained through all or portions of the project.

Traffic Facilities (614.02)

Vehicular and pedestrian ingress and egress for all property adjacent to any improvement shall be provided at all times.

Contractor maintenance responsibilities, including pothole patching begins for a section of highway when the Contractor begins the Work in that section and ends with the acceptance of the Work under 109.11 or 109.12. The two directions of a divided highway are considered separate highway sections and the start of Work on one direction does not begin maintenance responsibilities on the other direction.

Traffic Control General (614.03)

The traffic control shall conform to the requirements of the plan, standard construction drawings shown on the plans, and the OMUTCD for Streets and Highways, hereinafter called the Ohio Manual, for the installation, maintenance, and operation of all traffic controls and traffic control devices. When the plans or standard construction drawings do not cover a specific traffic control situation, the necessary traffic control devices shall be placed according to the Ohio Manual and use the procedures required by the Ohio Manual.

The OMUTCD (Ohio Manual on Uniform Traffic Control Devices) has three levels of compliance to indicate the type of standard and whether it is mandatory, recommended, or optional:

o All mandatory conditions are listed under the section heading “Standard”

o All recommended conditions are listed under the section heading “Guideline”

o All allowed conditions are listed under the section heading “Option”

o A fourth grouping was added, “Support,” to include statements that were not mandatory, recommended or optional, but rather general information

Supplement 1061 prequalifies the portable changeable message boards. Only two panel of information shall be allowed.

Drums, signs, sign supports, barricades, impact attenuators, and other traffic control devices that are certified to meet NCHRP 350 safe-crash standards or as modified by Contract Documents shall be used. Do not allow heavy non-yielding devices or supports that do not conform to the current standards of NCHRP 350 unless allowed by Contract Documents.

Ensure the drums are furnished with Type G reboundable reflective sheeting complying with the requirements of 730.191. Ensure that owner identification markings on construction drums are no more than 1 inch (25 mm) in character height and are located at least 2 inches (50 mm) below the reflectorized bands or on the top or bottom horizontal surfaces of the drum. Ensure the drums are ballasted according to the manufacturer’s recommendations.

If equipment, vehicles, and material are stored or parked on highway rights-of-way, they shall be located not less than 6 feet (2 m) behind existing guardrail or not less than 30 feet (9 m) beyond the traveled way unless otherwise permitted by the Engineer. At night if any such material or equipment is stored between the side ditches, or between lines 6 feet (2 m) behind any raised curbs, they shall be clearly outlined with dependable lighted devices that are approved by the Engineer.

Flaggers (614.08)

Whenever one-way traffic is established, at least two flaggers shall be used unless the Engineer authorizes otherwise, and signs, cones, barricades, and other traffic control devices shall be erected according to the Ohio Manual. Flaggers shall maintain positive and quick means of communication at the opposite ends of the restricted area.

Asphalt Concrete for Maintaining Traffic (614.13)

The Contractor may use either a Type 1 or Type 2 mix of Item 448 asphalt concrete PG 64-22, or an asphalt concrete surface course the Engineer approves. Surface course materials shall be placed where the Engineer directs for maintenance of the existing pavement, shoulders, or structures.

Where materials are placed in small quantities or under adverse conditions, the Engineer may waive specification requirements for placing and finishing if, in the judgment of the Engineer, it is determined that the Contractor can obtain satisfactory results in providing a smooth and durable pavement surface.

Performance (614.14)

If, in the opinion of the Engineer, the Contractor is not furnishing proper maintenance of traffic facilities and proper provisions for traffic control, the Department may take the necessary steps to place them in proper condition, and the Department will deduct the cost of such services from any money that may be due or become due the Contractor.

Method of Measurement (614.15)

The Department will measure Work Zone Marking Signs as the number of sign installations, including the sign, necessary supports, and all attachment hardware. The Department will include all other work zone signs under Maintaining Traffic unless separately itemized.

The Department will measure Work Zone Pavement Markings complete in place, by class and material, in the units designated.

The Department will measure line quantities as the length of the completed stripe, including gaps, intersections, and other sections of pavement not normally marked.

Basis of Payment (614.16)

Unless separately itemized, the lump sum price bid for Maintaining Traffic shall include the cost of removal or covering of conflicting pavement markings and layout, application and removal of pavement markings when required, maintaining the existing highway in a safe condition for public use, removing abrasive and salt residue remaining from snow and ice control performed by the Department or local governments, providing flaggers; and their equipment; and furnishing, maintaining in an acceptable condition, and subsequently removing the following work zone traffic control items as required by the Contract Documents:

A. Signs, supports, and warning lights.

B. Drums, cones, gates, barricades, and vertical panels.

C. Flashing arrow panels.

D. Work zone traffic signals.

E. Lighting for work zone signals and flaggers.

If traffic permanently damages beyond use, any of the following items, the Department will compensate the Contractor for the fair market value of the damaged item according to 109.05 provided the Contractor has pursued but failed to obtain compensation from the motorist. Follow the procedures given in 107.15 for compensation for traffic damage to completed permanent items of Work, to obtain compensation from the motorist before requesting compensation from the Department.

A. Flashing arrow panel.

B. Work zone signal, pole, or controller.

C. Lighting unit or pole.

D. Changeable message sign.

The lump sum price bid for Detour Signing includes the cost of the Contractor furnishing, installing, maintaining, and removing the detour signing shown on the plans and their necessary supports.

The Department will pay for the following items under their associated item numbers: 502 Bridges, 615 Roads and Pavement, 622 Portable Concrete Barrier. The Department will pay for aggregate and calcium chloride authorized by the Engineer and used for Maintaining Traffic under Items 410 and 616.

Documentation

Use the ODOT Long Term Inspection Form (CA-D-8) for long-term projects that are under temporary traffic control 24/7. Below are the guidelines of how and when to fill out the form.

Purpose of form: To document the condition of the work zone traffic control.

When to review:

— At the beginning of each project;

— Immediately following a change to the work zone traffic control (construction phase change); and

— Weekly through the duration of the project. It is suggested that the review be performed on the morning of the day prior to the last work day for the week. (Example: If the project normally works Monday through Friday, then perform the review on Thursday morning; if the project normally works Monday through Thursday, then perform the review on Wednesday morning.)

— All inspections are to include a nighttime review (preferably twice a month).

— Following receipt of information regarding a reported crash.

Who is to use this form:

— ODOT Project personnel – in accordance with the inspection schedule

— Contractor personnel – if a Worksite Traffic Control Supervisor is specified in the contract documents, the review is to be performed and documented on a daily basis.

— ODOT District Work Zone Traffic Manager – in conjunction with routine program responsibilities.

— ODOT County Managers – to document permit or ODOT maintenance work zones.

GENERAL:

“Urgent box (upper right corner)”

1. This box is used to show the seriousness of the condition at the work site. If this will require immediate attention (when life-threatening conditions are present) check the “Urgent: Correct Immediately” box. This box is to be checked if one (1) or more life-threatening conditions are present. The contractor will have 24 hours to correct the deficiency. If conditions are not life threatening, then the contractor will have up to five (5) working days to correct the noted deficiencies. The ODOT reviewer will have the discretion of reducing the timeframe for deficiency correction based on the deficiency circumstances (Example: Improper flagging techniques or misaligned drums/cones should be corrected almost immediately vs. repairing an impact attenuator which requires parts. Time frames may be negotiated.)

2. When the “urgent” box is checked, write the word “urgent” in the appropriate section’s comments to indicate a life threatening situation.

“County / Route / Section / Project No.”

Self-explanatory; record all information accordingly. This information is repeated at the top of page 2.

“Day/Date”

1. Fill in the day of the week as well as the date. This information is repeated at the top of page 2.

“Time” & “AM / PM”

1. Fill in the time of the review.

2. Circle “AM” or “PM.”

This information is repeated at the top of page 2.

“Weather Condition” & “Day / Night”

This information in important since weather and ambient lighting conditions affect the visibility of pavement markings and signs.

1. Fill in the weather conditions.

2. Circle “Day” or “Night.”

“Type of Operation/Traffic Control”

1. Circle the type of operation/traffic control that is being performed at the time of the review. Use “other” to document situations not described.

“Work by”

1. Document who is working on the roadway. In the case of a contractor or utility, include the company name.

“Work ( In / Not In ) Progress

1. Circle “in” if operations are being performed during the review or “not in” if no operations are in progress.

“Posted Speed”

1. Fill in the posted speed which is in effect at the time of the review.

Section A: “Drive Through:”

Drive through the work zone at the posted speed and take note of the traffic’s movements and reactions to the traffic control devices. Inadequacies or deficiencies are noted by checking the box to the right of each element. Further information, including location references is recorded in the comments box. Space for additional comments and/or recommendations if provided at the bottom of page 2.

“1. Are maneuvers difficult or unexpected?”

Based on the drive through and observation of the traffic, make a determination of the adequacy of the overall work zone traffic control. If problems are observed, check the box & record the observed problem in the comments section.

“2. Adequate warning of conditions?”

Do the signs provide adequate reaction time? If no, check the box & record the observed problem in the comments section.

“3. Is signing clear / uncluttered and properly spaced?”

Are the warning signs visible and easy to read and understand? If no, check the box & record the observed problem in the comments section.

“4. Are traffic control devices sufficiently visible?”

Are all the traffic control devices (signs, cones, plastic drums, tubular markers, arrow panels, etc.) visible? If not, check the box & record the observed problem in the comments section.

“5. Any incidents, congestion points or delays?”

Did you observe any incidents (crashes, breakdowns, etc.), congestion or delay (as defined by the policy)? If so, check the box and record the observed problem in the comments section.

“Comments: (include location reference)”

Use this space for additional information on any item listed above. Write the word “urgent” here if a situation is considered life threatening. In order to ensure that corrections are made, include location reference information and details about the deficiency here

Section B: “Signs:” See Chapter 7, Sections B through E of the OMUTCD.

“1. Need to be: removed / repositioned / covered”

Are all of the signs visible and appropriate? If no, check the box and circle one of the statements that best describes the condition: “Removed” when the sign is not necessary or inappropriate for the traffic control; “Repositioned” when a sign is found in an incorrect location; or “Covered” when the sign covers a conflicting message. Also note the sign location(s) and message(s) in the comments section.

“2. Need: cleaning / replacement”

Are the signs legible? Can they be read at night? If no, check the box and circle one of the statements that best describes the condition: “Cleaning” if a sign is dirty; and/or “Replacement” when the sign is not longer legible under either day or night conditions.

“3. Additional signs needed (define in comments)”

Based on your observations made during the drive through (Section A) and knowledge of the requirements of OMUTCD Chapter 7, are any additional signs required? If yes, check the box and note your recommendation in the comments section, including legend and location.

“4. Conflicting signs: permanent / temporary”

Based on your observations made during the drive through (Section A), did you perceive any of the sign messages to be conflicting? If so, check the box and note your recommendation in the comments section, including legend and location.

“5. Non- NCHRP 350 approved sign support”

Refer to the Office of Materials Management Web page and check the ‘Approved List’ category section titled Approved Traffic Control Devices in Work Zones. Check the box when not in compliance with the ODOT standards. Note the location & sign legend in the comments section.

“6. View blocked by vegetation or other signs”

Based on your observations in answering question 4 during the drive through (Section A), did you observe any signs that were obscured? If yes, check the box and note the sign and location in the comments. Also note what is blocking the view.

“Comments: (include location reference)”

Section C: “Portable Changeable Message Signs” See Chapter 6, Section 6F.52 and Chapter 1, Section 1A.14 of the OMUTCD.

“Check Here If Not Applicable”

Self explanatory.

“1. Operation Does Not Meet Guidelines?”

Check the box if the message on the PCMS is giving conflicting information or guidance. Note the message in the comments section. If there is more than one PCMS on the project, also note the location.

“2. Inappropriate Message?”

Check the box if the message on the PCMS is unclear or does not pertain to the work zone. Note the message in the comments section. If there are more than one PCMS on the project, also note the location.

“3. Too Much Information?”

Check the box if the message on the PCMS exceeds the OMUTCD guidance. Note the message in the comments section. If there is more than one PCMS on the project, also note the location.

“4. Not Dimmed At Night / Not Delineated (No Cones / Barrels)”

Check the box if the PCMS is not dimmed at night or if the required delineation is missing. Note the location in the comments section.

“Comments: (include location reference)”

Section D: “Arrow Panel” See Chapter 6, Section 6F.53 of the OMUTCD

“Check Here If Not Applicable”

Self explanatory.

“1. Incorrect Placement?”

Based on your observations made during the drive through (Section A), was the arrow panel located correctly or necessary. If not, check the box and note the location in the comments section. Include your recommendation for the correct location or need.

“2. Malfunction (Bulb Out, Improper Alignment, Etc.)”

Circle one of the statements that best describes the condition: “Malfunction” if the entire panel is out; “Bulb Out” if one or more bulbs are out; or “Improper Alignment” if one or more of the bulbs appear dimmer than the other due to being out of alignment. Note the location(s) of problems on the board as well as the location of the board itself in the comments section.

“3. Not Dimmed At Night”

Check the box if the arrow panel is not dimmed at night . Note the location in the comments section.

“Comments: (include location reference)”

Section E: “Drums / Cones / Tubular Markers” See Chapter 6, of the OMUTCD.

Circle the type of devices that are being used at the time of the review. Inadequacies or deficiencies are recorded based on the category of channelizing device: D for drums, C for cones or TM for tubular markers.

“1. Taper Length Too Short”

Refer to Chapter 6, Section 6C.08 of the OMUTCD. Check the box if the taper length is too short for the conditions (speed & lane width). If too short, check the box applicable to that device (column D, C or TM) and note the location, deficiency & recommendation in the comments section.

“2. Device Spacing Too Long”

Refer to Chapter 6, Section 6F.55 of the OMUTCD. When using 42” reflectorized cones at night, the spacing between devices shall be 40’ in the tangent section (the cones should not be used in the taper). Based on your observations made during the drive through (Section A), check the box applicable to that device (column D, C or TM) if the space between devices exceeds the maximum length based on the conditions (speed). Note the location and recommendation in the comments section.

“3. Additional Devices Needed”

Based on your observations made during the drive through (Section A), if hazards are not adequately protected or delineated, check the box under the letter heading for that device. Note the location and recommendations in the comments section.

“4. Misaligned”

Based on your observations made during the drive through (Section A), check the box under the letter heading for that device if the drums, cones or tubular markers are out of alignment in either the transition or tangent areas. Note the location and recommendations in the comments section.

“5. Condition (Repair / Clean / Replace)”

Based on your observations made during the drive through (Section A), circle the statement that describes the condition and check the box under the letter heading applicable to the device(s). Note the condition and location in the comments section.

“6. Reflective Bands (Missing / Damaged)”

“Comments: (include location reference)”

Section F: “Traffic Barrier” Refer to Chapter 6, Section 6F.75 of the OMUTCD or applicable Standard Construction Drawing (SCD)

“1. Improper Barrier Wall Flare”

Based on your observations made during the drive through (Section A), check the box if the concrete barrier flare does not meet the requirements of the barrier transition shown in the standard construction drawings. Note the deficiency and location in the comments section.

“2. Terminal Treatment In Clear Zone”

Based on your observations made during the drive through (Section A),check the box if the end of the concrete barrier is located within the clear zone and is not protected by an approved end treatment.

“3. Barrier Needs To Be Realigned / Removed / Connected”

Based on your observations made during the drive through (Section A), circle the statements that best describes the condition; “realigned” when gaps greater than one inch are found between barrier joints or needs straightening; “removed” when the barrier is no longer needed to protect the work area; or “connected” if the barrier sections are not connected according to applicable SCD. Check the box if any of the situations are observed and note the deficiency and location in the comments section.

“4. Attenuator (Repair / Replace)”

Based on your observations made during the drive through (Section A), circle the statement that describes the condition: “repair” when damage has occurred; or “replace” when the device cannot be repaired. Check the box if any of the situations are observed and note the deficiency and location in the comments section.

“5. Delineators (Clean / Additional Needed)”

Based on your observations made during the drive through (Section A), circle the statements that describe the condition: “clean” when the delineators on the side of the barrier are dirty; “additional” when they are missing from the barrier. Check the box if any of the situations are observed and note the deficiency and location in the comments section.

“6. Object Markers (Clean / Additional Needed / Replace) Glare Screen (Clean / Repair)” Based on your observations made during the drive through (Section A), circle the statements that describes the condition: “clean” when the retro-reflectivity of the vertical panels is reduced due to dirt; “additional” when object markers are missing; “replace” when the color does not meet the standards; or “repair” when broken or missing vertical panes are observed. Check the box if any of the situations are observed, and note the deficiency and location in the comments section.

“Comments: (include location reference)”

“Maintenance of Traffic Deficiencies and Action Taken”

“Notification: Verbal / Written / Correct By”

Circle the method by which the information contained in this report was transmitted to the contractor. Include the date by which the corrections need to be made.

“Corrected In A Timely Manner: Yes / No / Date Corrected”

Circle yes if the corrections were made by the date which was established at the time of inspection. Circle no if the corrections were not made by that date.

“Section(s) Requiring Correction”

Circle the letter which represents the section(s) which require remedial action.

“Estimate Withheld?

Circle yes if the estimate was withheld because corrections were not made.

“Field Review By:”

Note your name and the date of the review.

“Work Stoppage Ordered”

Circle yes if a work stoppage was ordered because corrections were not made.

“Copy: Contractor, Inspector, Engineer, County Manager, or Other”

Circle the entity and note who the copy of the report form was given to.

Section G: “Flagging Operations” Refer to Chapter 6, Section 6E of the OMUTCD

“Check Here If Not Applicable”

Self explanatory.

“1. Additional Signing Needed?”

Based on your observations made during the drive through (Section A), check the box if the required signs are missing. Note which signs are missing in the comments section.

“2. Are Flaggers Positioned Correctly?”

Based on your observations made during the drive through (Section A), check the box if the flagger is not positioned correctly based on OMUTCD Chapter 7, Section XXX or SCD XXXX. Note the location in the comments section.

“3. Highly Visible?”

Based on your observations made during the drive through (Section A), check the box if the flagger is not highly visible as you approach the work zone activity. Note the location of the flagger and your recommendation in the comments section.

“4. Properly Attired?”

Based on your observations made during the drive through (Section A), check the box if the flagger is not wearing attired as described in the OMUTCD Chapter 7, Section XXX. Note the deficiency in the comments section.

“5. Flagging Correctly?”

Based on your observations made during the drive through (Section A), check the box if the flagger is not flagging in accordance with OMUTCD Chapter 7, Section XXXX. Note the deficiency in the comments section

“Comments: (include location reference)”

Section H: “Pavement Markings” Refer to Chapter 6, Section 6F.65 of the OMUTCD

“Permanent / Temporary & Paint / Tape”

Circle the appropriate type and materials for the pavement markings.

“1. Remove”

Based on your observations made during the drive through (Section A), check the box if inappropriate pavement markings are found. Note the locations in the comments section.

“2. Repair”

Based on your observations made during the drive through (Section A), check the box if the pavement markings have shifted or are not visible at night. Note the deficiency and location(s) in the comments section.

“3. Need Additional”

Based on your observations made during the drive through (Section A), check the box if any pavement markings are missing. Note the deficiency and location(s) in the comments section.

“4. Confusing (Markings Not Eradicated)”

Based on your observations made during the drive through (Section A), check the box if any conflicts are observed between the permanent and temporary pavement markings which could cause driver confusion. Note the location(s) in the comments section.

“Comments: (include location reference)”

Section I: “Raised Pavement Markers” Refer to chapter 6, Section 6F.57 of the OMUTCD

“Check Here If Not Applicable”

Self explanatory.

“Permanent / Construction”

Circle the appropriate type of raised pavement markers in use.

“1. Missing”

Based on your observations made during the drive through (Section A), check the box if raised pavement markers are missing based on ODOT SCD XXXX. Note the location(s) in the comments section.

“2. Need Additional”

Based on your observations made during the drive through (Section A), check the box if additional raised pavement markers are needed to provide positive guidance to the motorists. Note the location(s) in the comments section.

“3. Remove”

Based on your observations made during the drive through (Section A), check the box if either existing or temporary raised pavement markers are observed. Note the location(s) in the comments section.

“4. Do Not Correspond To Pavement Markings”

Based on your observations made during the drive through (Section A), check the box if either existing or temporary raised pavement markers that do not correspond to the current pavement markings are observed. Note the location(s) in the comments section.

“Comments: (include location reference)”

Section J: “Miscellaneous”

“1. Adequate Buffer Space?”

Refer to Chapter 6, Section 6C.06 Activity Area, of the OMUTCD. Check the box if the buffer space does not meet the minimum. Note the observed length in the comments section.

“2. Is The Work Area Protected?”

Based on your observations made during the drive through (Section A), check the box if the work area is not protected by drums, cones, tubular markers or barrier as required by the appropriate ODOT MT- SCD.

“3. Equipment Proper Stored / Protected?”

Based on your observations made during the drive through (Section A), check the box if equipment is stored within the clear zone without being protected. Note the location in the comments section.

“4. Are Lane Closures In Accordance With Allowed Hours

Refer to ODOT Permitted Lane Closure Map, Plans or Contract. Check the box if observed the observed lane closure(s) is occurring outside of allowed hours. Note the time and duration in the comments section.

“5. Evidence Of A Crash?”

Crashes can be caused by the work zone traffic control plan. The answers to the below 3 questions should be used to determine if a change is needed to improve the situation. Based on your observations made during the drive through (Section A), Circle yes if evidence of a crash is either observed or has been reported to the ODOT project staff.

a. Damaged TCD’s?

Circle yes if Traffic Control Devices (TCD) are being continually damaged at the same location. Note the damage and location(s) in the comments section.

b. Debris?

Circle yes if debris as the result of a crash is observed. Note the type of debris and location(s) in the comments section.

c. Skid Marks?

Circle yes if skid marks are present. Note the length and location(s) in the comments section.

“6. Other Devices / Situations”

Based on your observations made during the drive through (Section A), include an assessment of other devices, such as a truck mounted attenuator, that might be in use during the review. If the application is inappropriate, check the box and document in the comments section.

“Comments: (include location reference)”

Write the word “urgent” here is a situation is considered life threatening. In order to ensure that corrections are made, include location reference information and details about the deficiency here.

“Additional Comments / Recommendations”

Use this space to record additional information / recommendations for any item listed above.

b. The ODOT Short-Term Form (CA-D-7) is for those projects that are typically set up and torn down daily. Below is the guidelines of how and when to fill out the form.

For projects where the MOT is set up new each day, such as mill and fill operation, form CA-D-7 (Short Term Work Zone Review) should be completed each day with each new setup. (for maintenance, utility, permit and daily contract operations)

“County / Route / Section / Project No.”

Self-explanatory; record all information accordingly.

“Date”

Fill in the date

“Time & AM/PM.”

Fill in the time of the review.

Circle "AM or PM"

“Weather Conditions”

Fill in the weather conditions.

“TYPE OF OPERATION / TRAFFIC CONTROL”

Circle the type of Operation / Traffic Control that is being performed at the time of the review.

Use "Other" to document situations not described.

“WORK BY”

Document who is working on the roadway, in the case of a contractor or utility, include the company name.

“TRAFFIC CONTROL / SAFETY DEVICES”

(Signs, Flagger, Cones, Drums, Arrow Board, Signals, PCMS, Other....)

Used to describe the effectiveness of the traffic control devices. Drive through the work zone at the posted speed and take note of the traffic's movements and reactions to the traffic control devices.

“CONDITION”

Used to describe any inadequacies or deficiencies with the Condition of the Traffic Control and Safety Devices. If no inadequacies or deficiencies are noted check "NONE" and continue to Placement. If Conditions are not adequate record deficiencies and corrective action to be taken. When deficiencies have been corrected record date. Examples of items to review.

1. Are the traffic control devices legible?

2. Are they clean and reflective?

3. Do any of them need to be replaced?

4. Are any non-standard?

5. Are they the correct size?

“PLACEMENT”

Used to describe any inadequacies or deficiencies with the Placement of the Traffic Control and Safety Devices. If no inadequacies or deficiencies are noted check "NONE" and continue to Visibility. If Placement is not adequate record deficiencies and corrective action to be taken. When deficiencies have been corrected record date. Examples of items to review.

1. Are the traffic control devices appropriate?

2. Do they provide adequate reaction time?

3. Are any of the messages conflicting?

4. Are the maneuvers difficult or unexpected?

“VISIBILITY”

Used to describe any inadequacies or deficiencies with the Visibility of the Traffic Control and Safety Devices. If no inadequacies or deficiencies are noted check "NONE" and continue to Flagger. If Visibility is not adequate record deficiencies and corrective action to be taken. When deficiencies have been corrected record date. Examples of items to review.

1. Are all traffic control devices visible?

2. Are they easy to read?

3. Are they blocked by vegetation or other signs?

4. Do any need to be repositioned?

“FLAGGER”

Used to describe any inadequacies or deficiencies with the Flagger or the Flagger Operations. If no inadequacies or deficiencies are noted check "NONE" and continue to Traffic Flow Problems. If the Flagger or the Flagger Operations are not adequate, record deficiencies and corrective action to be taken. When deficiencies have been corrected record date. Examples of items to review.

1. Are the flaggers positioned correctly and highly visible?

2. Are they attentive to oncoming traffic?

3. Are they flagging properly?

4. Are they properly attired?

5. Are the paddles / flags visible and clean?

6. If temporary traffic signal, are signal heads visible?

“TRAFFIC FLOW PROBLEMS”

Review for evidence of crashes, incidents, congestion points, delays, violations of PLCM, etc. If no evidence is noted check "NONE" and continue to the CONFORMANCE / ADEQUANCY WITH TRAFFIC CONTROL STANDARDS section. Record any evidence of crashes, incidents, congestion points, If Traffic Flow Problems exist record corrective action to be taken. Examples of items to review:

1. Are lane closures in accordance with allowed hours (PLCM, )

Permit, Plans, Contract)?

2. Is there evidence of skid marks and / or accident debris?

3. Is there damage or reoccurring damage to traffic control devices?

“CONFORMANCE / ADEQUANCY WITH TRAFFIC CONTROL STANDARDS”

Review for non-compliances with OMUTCD, SCD, plans or permit. If no non-compliances are noted check "NONE" and continue to INTERACTION OF WORK VEHICLES AND TRAFFIC section. If the Standards are not adequate record corrective action to be taken. Examples of items to review.

1. Proper spacing between signs?

2. Is the taper rate and drum spacing correct?

3. Is there adequate buffer space?

4. Is the work area protected?

“INTERACTION OF WORK VEHICLES AND TRAFFIC”

Review the interaction of work vehicles entering and exiting the work zone. If no inadequacies or deficiencies are noted check "NONE". If interactions are not adequate or safe record deficiencies and record corrective action to be taken. Examples of items to review.

1. Is there excessive braking for vehicles entering or exiting the work zone?

2. Is there sufficient area in the work zone for work vehicles?

3. Is there excessive dirt or mud on the road?

“PROPER STORAGE OF EQUIPMENT AND MATERIALS”

Review the storage area of the equipment and materials in the work zone. If no inadequacies or deficiencies are noted check "NONE". If storage area is not adequate or safe record deficiencies and record corrective action to be taken. Examples of items to review.

1. Is the equipment and material properly protected or outside the clear zone?

2. Is the equipment and material to close to open travel lanes?

“MAINTENANCE OF TRAFFIC DEFICIENCES AND ACTION TAKEN”

Notification: Verbal / Written - To whom

1. Circle how corrective action information was provided.

2. Record to whom the notification was provided to.

“Correct by date”

Provide the date by which the corrections need to be made.

“Corrected in a timely manner”

1. Circle Yes if the corrections were made by the date established at the time of the inspection.

2. Circle No if the corrections were not made by that date.

“Date corrected”

Record date corrected.

“Section(s) requiring correction(s)”

Circle the letter which represents the section(s) which require remedial action.

“Field review by”

Note your name and the date of the review.

“Copy to: DWZTM / County Manager /Contractor / Construction or Other”

Circle the entity and note who the copy(s) of the report form was given to.

Daily Documentation Requirements - 614 Maintaining Traffic

1. Carry on inspector's diary (Form CA-D-3) items of work performed by contractor. Erecting barricade fences, traffic zones established, flagger, or off-duty patrolmen used to control traffic

2. What kind of sheeting do the signs have? G or H

3. All barricades and barrels are in good shape and have adequate reflectivity

4. When road is closed document all items used (barrels, barricades, signs, etc.). If a camera is available, taking a couple of snap shots is a good idea.

5. A statement should be recorded daily on the Inspector’s diary that traffic control was adequate for work performed. Any accidents should be accurately documented

6. Locations required when placing temporary striping, reflectors, and barrier wall

7. Pay as per 614.16 of the C&MS

615 Roads and Pavements for Maintaining Traffic

Documentation Requirements - 615 Roads and Pavements for Maintaining Traffic

Document any work as if it were being performed as its own item (203, 442, 452, 616, etc.).

616 Dust Control

Documentation Requirements - 616 Dust Control

The minimum documentation and critical inspection requirements for Item 613 includes recording the following inspection points in the project daily reports. Specifications or other requirements waived by the Project Engineer should also be noted in the daily reports.

1. Measure or weigh water truck capacity to determine the water volume per load

The units of measurement can be converted using the following conversions: 1 ft³ = 7.48 gal.; 1 lb. water = 0.12 gal.

2. Record the bag count or weigh bills for calcium chloride when used.

617 Reconditioning Shoulders

Specification Changes

No specification changes to the 2005 C&MS.

Because of the simplicity of this item of work, no detailed explanation of the item is required in this manual.

Documentation Requirements - 617 Reconditioning Shoulders

1. Materials.

2. Place location or stationing where material was used.

3. Shoulder preparation.

4. Average depth and width.

5. Spreading.

6. How was material compacted?

7. Attach initialed dated tape to tickets and covert as per 617.06-1 of the C&MS.

8. Measure and pay according to 617.06 and 617.07.

9. Document on the CA-EW-12 and CA-D

a. Do not duplicate the information on these forms unless necessary.

618 Rumble Strips on Shoulders

Documentation Requirements - 618 Rumble Strips on Shoulders

1. Document Type 2 or Type 3

2. Measure and document width and depth of cut

3. Dust properly controlled

4. How were grindings disposed?

5. Measure length for pay

620 Delineators

Delineators - General

This information is intended to serve as a guide for construction personnel where the contractor furnishes and installs delineators. However, it may also be useful for maintenance personnel performing the same functions. Inspection procedures are outlined. This information points out the various important features and references the applicable specification or standard drawing.

Materials (620.02)

Make sure that all delineator materials used on a project are approved and are listed on the Qualified Product List at the following web site:

http://www.dot.state.oh.us/testlab/applists/QPLWEB/qpl.htm

Delineator Lateral Placement (620-3)

Delineator Lateral Placement, SCD TC 61.10

The top of the delineator post shall be 48 inches above the edge of the pavement.

The delineator post shall be placed 12 feet and 6 inches outside the outer edge of the pavement or the delineator post shall be placed 2 feet and 6 inches outside the outer edge of the shoulder.

Placement of Delineator on Curves and Tangent Sections

Delineators shall be spaced 400 feet apart on the tangent sections.

Delineators on the horizontal curves shall be spaced according to the table in the SCD TC-61.10.

Delineators should be provided on the outside of horizontal curves on interchange ramps.

The color of the delineator reflector shall conform to the color of the pavement markings nearest the delineator.

Spacing for Delineators, SCD TC 61.10

Delineator Placement on Ramps, SCD TC 61.10

Delineator Installation (620.05)

Delineators shall be installed facing traffic except for red reflectors facing wrong-way traffic, if used.

Protective paper covering the face of flexible post-mounted reflectors shall not be removed until after installation.

Ensure that delineator posts are not more than 1:50 out of plumb. If soil conditions may cause the post to be out of plumb, the Contractor may drive a pilot shaft before installation.

Install the flexible posts using methods and equipment that conforms to the post manufacturer’s recommendations.

Documentation Requirements - 620 Delineators

Document depth that post was placed on CA-D-3A

Document type of post and reflector on CA-D-3A

Total of each color and location where they were placed on CA-D-3A

Turn in total of all colors for pay on CA-D-3A

621 Raised Pavement Markers (RPM)

Raised Pavement Markers – General

This information is intended to serve as a guide for construction personnel where the contractor furnishes and installs raised pavement markers. However, it may also be useful for maintenance personnel performing the same functions. Inspection procedures are outlined. This information points out the various important features and references the applicable specification or standard drawing.

Conduct 25 – 75% inspection during the installation activities which include daily start-up, intermittent, and end of day inspection. Additionally, conduct 80 – 100% inspection of all installed RPM’s prior to final acceptance.

Materials (621.02)

Make sure that all RPM materials used on projects are approved and are listed on the Qualified Product List at the following web site:

http://www.dot.state.oh.us/testlab/applists/QPLWEB/qpl.htm

Installation RPM Casting (621.04)

1. References

i. Brochure for RPM Installation Procedure

See Traffic Engineering Manual, Section 350-3 at the following web site:

http://www.dot.state.oh.us/traffic/Publication%20Manuals/TEM/Part_03/TEM_300_complete_041505.pdf

2. RPMs shall be placed when the pavement surface temperature and the ambient air temperature are at least 40 °F (5 °C) and the pavement is dry.

3. RPMs shall not placed under the following conditions:

· On pavement surfaces with cracking, spalling, or failure of underlying base material.

· Within 1 foot (0.3 m) of active signal detector loop wires.

· Over pavement markings except with the Engineer’s approval.

· Closer than 2 inches (50mm) to a pavement construction (transverse or longitudinal) joint or within an intersection.

· Within 3 feet (1 m) of a bridge expansion joint.

Brochure for RPM Installation Procedure

1. Casting Installation

Typical Saw Cut

i. Pavement must be saw-cut to the dimensions for the casting being used.

2. Casting in Saw Cut Without Epoxy

i. Each pavement cut must be inspected prior to adding epoxy.

ii. When a casting is inserted in the cut without epoxy all 4 leveling lugs/tabs must contact the pavement surface.

All four keel-ends of castings must be below the surrounding pavement surface.

3. Casting Centered in Saw Cut Lengthwise

i. Each casting must be centered lengthwise and should have 1/8" clearance between pavement cut and casting for epoxy to bond properly.

ii. Only the leveling lugs/tabs should be in contact with pavement surface after insertion of casting in pavement so that minimum of 1/8 inches of epoxy is the bonding adhesive between casting and pavement.

iii. The pavement cut must be completely dry and free of dust, dirt or any other material that will interfere with the adhesive bond.

iv. Epoxy on the active reflector face must be removed immediately.

v. Saw cut – casting fit must be periodically checked as saw blades wear to insure correct dimensions are maintained

4. Properly Installed RPM with Epoxy Around Casting

i. Two component epoxy adhesive approved, must be on QPL is to be used to fill the pavement cut to within 3/8" of top of pavement cut, prior to placing casting.

ii. After placing casting:

The 4 leveling lugs/tabs must be in contact with pavement surface.

The epoxy should ooze out from under the casting from all sides filling all voids around the casting and be level with pavement surface.

RPM Lens Replacement

1. References

i. Brochure for RPM Installation Procedure

See Traffic Engineering Manual Section 350-3 at the following web site:

http://www.dot.state.oh.us/traffic/Publication%20Manuals/TEM/Part_03/TEM_300_complete_041505.pdf

2. Remove Reflector

i. Pry old reflector out of casting.

ii. Use eye protection when replacing reflector.

3. Clean the casting:

i. Scrape old pad material and adhesive out of reflector pocket, using an air hammer or wire brush.

ii. Sandblast the casting pocket to remove all residual adhesive, rust, and other contaminants.

iii. It is important that the casting is clean to ensure long-lasting performance.

4. Apply Adhesive

i. Peel the release liner from the back of the reflector.

ii. Apply a wide bead (approximately 3/8 inch) of an adhesive (as approved ODOT QPL) in the center of the adhesive pad on the back of the reflector.

5. Install Reflector into Casting

i. Place the reflector into the casting pocket.

ii. Apply foot pressure on the reflector for 1-3 seconds.

iii. Adhesive must flow out around all edges of the reflector to indicate that the adhesive completely covers the entire bottom of the reflector and provides a uniform adhesive layer between the reflector and the casting.

Remedial Actions for Poorly Installed RPM Castings

This information is intended to serve as a guide for construction and/or maintenance personnel where the RPM castings are poorly installed. Also, it provides a guide to the necessary remedial action to fix the problem.

The RPM casting shall be installed properly according to the following references:

Item 621.03 “Layout”.

Item 621.04 “Installation of RPM Casting”.

Standard Construction Drawings TC-65.10 and TC-65.11.

The following information provides examples of defectively installed RPM castings and also describes remedial action to fix the problem:

Defective Installation: The RPM is installed with all four lugs/tabs not resting on the pavement such as shown in Figure 1 below:

Figure 1

Remedial Action:

Remove and reinstall the RPM casting at a new location.

New RPM location shall not exceed 25% of the specified RPM spacing.

If necessary to relocate the RPM to a distance greater than 25% of the RPM spacing, do not install the affected RPM.

Fill the old cavity on the roadway surface with epoxy or asphalt concrete from where the RPM casting is removed.

Defective installation: The RPM is installed but does not fill the voids with epoxy all around the casting or the RPM is installed but the epoxy is not all around the casting to the surface of the pavement such as shown in Figure 2.

Figure 2

Remedial Action:

Blow out dirt from around casting with compressed air.

Fill the voids and seal the RPM casting all around with epoxy as shown in Figure 3.

Figure 3

Defective installation: The RPM casting is installed near or on a longitudinal joint or crack on the roadway surface such as shown in Figure 4.

Figure 4

Remedial Action:

Seal all the cracks with epoxy up to nine inches from the RPM casting as shown in Figures 5, 6 and 7.

Figure 5

Figure 6

Figure 7

Defective installation: The RPM is installed but the epoxy adhesive is not hardened or the epoxy adhesive is not uniform gray in color such as shown in Figure 8.

Figure 8

Remedial Action:

Remove and reinstall the RPM casting at a new location.

New RPM location shall not exceed 25% of the specified RPM spacing.

If necessary to relocate the RPM to a distance greater than 25% of the RPM spacing, do not install the affected RPM.

Fill the old cavity on the roadway surface with epoxy or asphalt concrete from where the RPM casting is removed.

Defective installation: The RPM is installed on construction joints which have extensive failure such as shown in Figure 9.

Figure 9

Remedial Action:

Remove and reinstall the RPM casting at a new location.

New RPM location shall not exceed 25% of the specified RPM spacing.

If necessary to relocate the RPM to a distance greater than 25% of the RPM spacing, do not install the affected RPM.

Fill the old cavity on the roadway surface with epoxy or asphalt concrete from where the RPM casting is removed.

Documentation Requirements - 621 Raised Pavement Markers

1. Verify castings to be used are on the Qualified Products List (QPL) before permitting installation.

2. Verify the epoxy to be used to install the casting is on the ODOT approved list.

3. Check depth and width of saw cut per Standard Const, Drawing TC 65.10. Make sure that the keels of the casting are placed into the slots that the tips of the RPM snowplow deflecting surfaces on the keels are below the pavement surface and all four lugs (Tabs) on the keels of the casting are in contact with the pavement.

4. Check before placement of the epoxy, the saw cut is clean of all loose material and dry. Saw cut should have 1/8 inch all sides clearance of the casting.

5. Verify ambient air temperatures are at least 40 degrees Fahrenheit (5 degrees Centigrade) and the pavement is dry.

6. Check epoxy is an A+B mixture, thoroughly mixed (grey color) and in accordance with manufacture’s recommendations.

7. Check that sufficient epoxy is in and between the slots to ensure that all voids beneath and around the casting are filled.

8. Placement of RPM castings shall be 6" from any construction joint (Lateral or Longitudinal).

9. Location and / stations are per Standard Const. Drawing TC 65.11 and TC 65.12.

10. Check quantity totals for payment.

11. Document on CA-D-3B.

12. Verify RPM reflectors to be used are on the Qualified Products List (QPL) before permitting installation.

13. Verify the adhesive to be used to attach the reflector is on the ODOT approved list.

14. Verify that all dirt, dust, oil, grease, rust, moisture, parts of damaged reflectors, or any foreign matter is removed that impairs adhesion of the reflector to the casting.

15. Verify reflector area of the castings shall be sandblasted to 80% bare metal.

16. Verify the application of adhesive is in a single bead, sufficient to squeeze out on all sides of the reflector when pressure is applied, to seat the reflector and seal out moisture.

17. Document on CA-D-3B.

622 Concrete Barrier

Description

This work consists of furnishing and placing portland cement concrete barrier on the accepted and prepared subgrade, subbase course, or existing pavement. This item also consists of furnishing, placing, maintaining, and removing portable concrete barrier.

Placing Concrete (622.03)

The concrete barrier will be constructed by either cast-in-place, precast, or slip-form methods. For slip-form construction, conform to 609.04.C. For cast in place construction, conform to the proper SCD.

1. RM- 4.3 Single Slope Barriers

2. RM- 4.4 Single Slope Barrier Transitions

3. RM- 4.5 Single Slope Barrier, Type D

4. RM- 4.6 Concrete Barrier End Sections

Portable Concrete Barrier (622.04)

The individual sections of PCB shall not less than 10 feet (3 m) long. See SCD RM- 4.2, 32” Portable Concrete Barriers for details. If intending to use the barrier at one location on the project, the Contractor may slip-form barriers in place without joints, or with grooved or sawed joints to facilitate removal. Any barrier sections damaged during handling or by traffic shall be either repaired or replaced, for the life of the project.

Joints (622.04)

The joints for cast-in-place or slip-formed barrier shall be constructed of the type and dimensions and at the locations specified in the plans.

Contraction Joints.

The Contractor may construct unsealed contraction joints by either sawing, using metal inserts inside the forms, using a grooving tool, or using full-width 3/4-inch (19 mm) thick preformed joint filler conforming to 705.03. Joints shall either be sawed, tooled, or formed by inserts, a minimum of 1/8 inch (3 mm) wide and 3 inches (75 mm) deep. The joints should be sawed as soon as curing allows sawing to the required depth with minimal spalling of the concrete surface.

Expansion Joints.

The 3/4-inch (19 mm) preformed joint filler shall conform to 705.03 to construct expansion joints at the centerline of and around each bridge pier column and on either side of each sign support foundation.

Horizontal Construction Joints.

If and as shown on the plans, the Contractor may place horizontal construction joints.

Finish (622.06)

Check the surface of the barrier with a straightedge for irregularities of more than 1/4 inch in 10 feet (6 mm in 3 m) after the contractor has checked and made corrections. Document any findings on CA-D-3.

Curing (622.07)

Concrete Curing shall be according to 511.17, Method B and the following additional requirements. Ensure that the curing compound is approved. For small areas, allow the use of other acceptable methods.

Do not allow any load or any work that will damage newly placed concrete. A minimum of 36 hours of cure time is required on any concrete placed first at a horizontal construction joint. The Contractor may cure precast sections according to 515.15. The Contractor may also use radiant heated forms for curing.

The Contractor may use 511.17, Method A for curing of short sections of barrier (leave-outs); however, before the curing is completed for any leave-outs, material conforming to 705.07, Type 2 at the normal rate specified in 511.17, Method B shall be applied.

The Contractor may cure horizontal construction joints between the foundation and the upper portion of the barrier, and between portions of the upper barrier placed separately according to 511.17, Method A or B. The membrane should not be removed before placing the next portion of the concrete barrier.

Method of Measurement (622.08)

Measure Concrete Barrier by the number of feet (meters) along the centerline of the top of the barrier, including all transitions, end terminals, and bridge pier sections as specified, complete in place.

Measure Portable Concrete Barrier and Portable Concrete Barrier, Bridge Mounted by the number of feet (meters) for each application of the barrier placed according to the plans. Measure each re-use of barrier sections at a different location required by the plans separately.

Do not measure repaired or replacement barrier sections damaged during handling or by traffic.

Basis of Payment (622.09)

The cost of all inserts, sleeves, fittings, connectors, reinforcement, dowels, preformed filler, excavation, and backfill is incidental to these items.

Documentation Requirements

1. Form dimensions

2. Conform to section 609.04C if slip formed

3. Number and clearance maintained on reinforcing steel if any used

4. Joint spacing and thickness of expansion material used

5. Joints saw cut, formed with metal plates, or expansion material

6. Amount of curing compound required and used

7. Measure length for pay

8. Use form CA-D-3 for documentation

624 Mobilization

Documentation Requirements

Pay in accordance with 624.02.

625 Highway Lighting

General (625.01)

The following information does not alter or supersede the Contract Documents. It is provided as a guide for the ODOT personnel assigned to a project to help them with their work.

Electrical construction work must adhere to the Contract Documents which commonly include proposal notes, project plans, Standard Drawings, and Construction and Material Specifications. In addition there may be building or electrical codes or change orders that must be followed.

Contractor Prequalification

Only Contractors prequalified by the ODOT Office of Contracts for Work Type 43 ‑ Highway Lighting shall be allowed to do the highway lighting items of work on the project.

Respect for Contractor

Contractors are prequalified for specialized work types. They bring expertise to the project and an independent perspective from the project management team. As the Contractor reviews plans and specifications, he wants to ensure that he can install material that will ultimately operate as the designer intended. The Contractor relies the Engineer to guide the project, to approve materials and work, and to ensure that he will be paid for work completed. It is important to remember that even when the roles of the project team and the Contractor conflict successful completion of the project relies on all those involved and the maintenance of good working relationships.

Protection of Utility Lines

The Contractor is to notify all utilities before construction work begins. Names and addresses of these utilities are given in the project plans. It is also the Contractor=s responsibility to contact the Ohio Utility Protection Services (1‑800‑362‑2764) to have utility locations marked in all areas where digging is involved.

Plan Discrepancy, Design Ambiguity, Consultation with Designer

When there is a question regarding the intent of the plan, the Engineer should:

1. Define the discrepancy or ambiguity.

2. Determine if more than the highway lighting is affected.

3. Identify the standard drawings and specification pertinent to the situation.

4. Determine potential solutions.

5. If the issue involves the location of the luminaires or light poles, the mounting height of the luminaries above the pavement, the luminaire to be used or the lamp to be used; the Engineer should consult ODOT=s design office and the designer to ensure that the performance goals for the lighting system will still be met by the solution under consideration.

6. Consider the maintenance of the installation if the solution is implemented. Will parts not normally stocked by the maintaining agency be required or will tools and equipment not normally at the disposal of the maintenance crews be required or will special training of the workers be required?

7. Evaluate potential solutions for safety. Consider measures needed to keep errant vehicles from striking the item, the danger to those who must maintain the installation, the danger to traffic from the maintenance activities

8. Determine if applicable codes and regulations will be met. Commonly involved will be the National Electric Code, The National Electric Safety Code and Utility Company requirements. There may also be state and local building codes.

Materials (625.05)

Highway lighting items are found in 625 with detailed descriptions of materials in 725.

In general, all material furnished shall be new and of first quality (unless otherwise noted in the plans) and shall be identified either by a permanently attached name plate or by an indelible marking.

Before installation, all material shall be checked to determine that it is indeed the material that has been specified, that the appropriate material process has been completed and that all paperwork in hand.

Four procedures are commonly used to ensure that the correct materials are installed.

1. Qualified Products List (QPL)

2. ODOT Plant Sampling and Testing Plan (TE‑24 Certification)

3. Certified Drawings or Certified Catalog Cuts

4. Project Inspection of Material

Qualified Products List

Lighting material which may be on a Qualified Products List:

1. Pull Box

2. Junction Box

3. Conduit

4. Wire and Cable

5. Ground Rod

6. Photocell

The Office of Materials Management maintains the Qualified Products Lists. The Engineer can verify that the material is on a Qualified Products List (QPL) through ODOT=s Construction Management System (CMS). After verifying that the material being supplied is that specified by the contract and on such a list, the project may accept the material.

TE‑24 Material Certification

Lighting material for which TE‑24 Certification may be obtained:

1. Pull Box

2. Junction Box

3. Anchor Bolt

The ODOT Plant Sampling and Testing Plan (TE‑24 system) is administered by the Office of Materials Management. This system was designed to allow certain material to be sampled, tested, approved and stocked for future use on ODOT projects. The material is inspected at the manufacturing or distribution site. Each approved lot of material is assigned a certification number and documented on Form TE-24. Material from the approved lot may then be transferred directly to an ODOT project or it can be transferred to other warehouses, such as a Contractor=s storage facility, then transferred to a project at a later date.

Certified Drawings or Certified Catalog Cuts (625.06)

Lighting material requiring Certified Drawings or Catalog Cuts:

1. Luminaires

2. Luminaire Supports (Towers, Lowering Devices, Poles, Bracket Arms)

3. Power Service Equipment

4. Portable Power Units

5. Temporary Lighting Systems

The Contractor shall submit two copies of shop drawings or catalog cuts prior to the installation of the material. The submittal ensures that the State has a good record of the material installed should there be any question about the material meeting criteria or should additional or replacement units be required.

Each submittal shall identify the project and the bid reference number under which the item is being provided. Drawings or catalog cuts shall be clearly marked by circling or underlining to indicate the exact item and options being supplied. If a given item is to be supplied under multiple bid item reference numbers, separate and complete documentation packages shall be submitted for each bid item reference number. If multiple items are to be supplied under a single bid reference number, all the items to be supplied under said reference number shall be submitted as a package. The Contractor=s cover letter for each package is to certify in writing that each manufactured item in the package conforms to all contract requirements for that item.

The submittal of certified drawings or catalog cuts does not relieve the Contractor from furnishing, additional information concerning the material as deemed necessary by the State.

Project Inspection of Material

The following materials are normally manufactured to standards that meet ODOT criteria and therefore do not have a QPL, do not normally have a TE-24 and shop drawings or catalog cuts are not normally required:

1. Exothermic Welds

2. Insulating Varnish

3. Split Bolt Connector

4. Expansion Fittings

5. Connector Kits

6. Splice Kits

7. Copper Crimps and Compression Connectors

8. Light Pole Decals

9. Circuit Identification Tags

10. Cable Grips

11. Wood Service Poles

12. Fuses for Control Center and Connector Kits

13. Photoelectric Cell and Bracket

14. Secondary Lightning Arrestor

15. Guy Anchors and Anchor Rods

16. Weather Heads

17. Watertight Hubs

18. Remote Ballast Enclosures and Mounting Brackets

Project inspection of material is used to verify that the material at hand is that listed on a QPL or described on a TE-24 or for which certified shop drawings or catalog cuts have been received and that the material complies with the requirements of the contract documents. For material not on a QPL which does not have a TE-24, and for which shop drawings or catalog cuts are not required, the project inspection of material is limited to comparing the material at hand with the requirements of the contract documents.

Luminaires (625.08)

A luminaire consists of a housing containing the reflector, refractor, lamp socket and lamp. Unless specified otherwise, the housing will also contain the ballast components (core and coil, capacitor, starter) required for the lamp being used. The housing may also have optional components such as fuses or a photocell when such has been specified. The housing is fitted with the necessary clamps or other provisions for attaching the luminaire to its support and terminal block for the incoming power.

Verify that the luminaire installed at each location is one of the luminaires listed in the plan for that location. Verify that the distribution, lamp type and lamp wattage are as specified in the plans. Instructions packed with the luminaire will explain the distributions that the luminaire is capable of producing and how to set any adjustments in the luminaire to provide each distribution. Verify that ballast is compatible with the circuit voltage and lamp.

Conventional Luminaire

The conventional luminaire used by ODOT is also known in the trade as an AOvate@ or ACobra Head@ fixture. It may be equipped with a flat or a dropped style refractor as specified.

Verify that the luminaire is properly leveled according to the instructions packed with the luminaire.

Side‑Mount Roadway Luminaire

This luminaire reminds one of a floodlight.

Verify that the Atilt@ has been set as specified in the plan according to instructions packed with the luminaire. Verify that the luminaire is oriented Anormal@ to the line of survey for the roadway being lighted unless the plans stipulate otherwise.

High Mast Luminaire

These luminaires are mounted on tall structures equipped with devices to bring the luminaires to ground level for servicing.

Verify that the luminaire is not Atwisted@ with regard to its bracket arm. There are three distributions commonly used. If the luminaire has a rotatable refractor, verify that it has been aligned properly.

Low Mast Luminaire

Low mast luminaires are the same luminaire as a high mast luminaire but installed as a fixed unit on a pole of more traditional height.

Underpass Luminaire

Underpass luminaires are used to light roadways beneath bridge decks. Commonly they are wall mounted on a pier cap or abutment. Sometimes they may be ceiling mounted on the underside of the deck or to a panel attached to the deck supporting beams or pendant mounted on suspension pipes attached to the structure. Occasionally they will be post top mounted on short poles.

Verify that the luminaire has been attached to the structure at the location and in the manner specified.

Lamps

Verify that the lamp is one of the brands listed in the plan. Verify that the lamp type and wattage is compatible with the luminaire and its ballast. Unless specified otherwise for a particular installation, the lamps are to have clear envelopes. Do not substitute lamps with Afrosted@ envelopes. Verify that the installation date has been properly marked on the base of the lamp. Instructions packaged with the lamp explain how to use the dating provision built into the base.

Supports (625.09)

The inspection of the supports (poles, arms, towers, lowering devices, brackets, etc.) consists of two phases: inspection of the components and inspection of the completed assembly. While these may be done together, it is better if the components are inspected upon arrival at the project since there is then more time to obtain replacements or correct faults.

Inspection of Support Components

Three areas are examined in this phase: welding, galvanizing and compliance with shop drawings.

Inspection of Welds

Examine each weld for the following:

1. Each of the welds called for by the certified shop drawings is present and there is no weld present that is not shown on said drawings.

2. There is no misalignment of the parent material being joined by the weld.

3. There has been no warping of the parent material by the weld.

2. Each weld is of the type, size and continuity shown on the shop drawings.

3. Each weld is of full cross section without excessive concavity or convexity.

4. There is no over filling or cratering at either the beginning or the end of the weld.

5. There is no undercutting (a shallow groove melted into the base metal adjacent to a weld and left unfilled by weld metal) along any weld.

6. There is no porosity(pitting or pinholes) in any weld.

7. There is no crack or discontinuity in either the base metal or weld material along any weld.

Inspection of Galvanizing

Examine the galvanizing for the following:

1. There are to be no spots where the galvanizing is missing or loose and can be flaked off with a penknife.

2. There should be no ash that has been picked up from the top of the bath which usually appears as coarse lumps.

3. There should be no pimples from entrapped bath scum particles.

4. There should be no blisters from hydrogen gas absorbed during pickling being released and rupturing the surface of the galvanizing.

5. There should be no flux inclusions from flux picked up from the top of the bath during dipping and burned on during immersion.

6. There should be no lumps or runs of excess zinc from delayed run‑off of molten metal trapped near surface discontinuities such as joints, seams or holes as the part was lifted from the bath.

7. There should be no rust stains from impurities from the pickling process weeping at seams and folds.

8. There should be no general overall roughness from over pickling or of excess zinc bath temperature and/or immersion time.

9. There should be no patches of dull gray coating from slow cooling of the heavier cross sections of the part after immersion.

10 The galvanizing should have a uniform appearance.

Excessive galvanizing faults and gross imperfections or overall poor workmanship may be cause for rejection of the support. Minor scratches in galvanized surfaces can be accepted.

Compliance with Shop Drawings

Supports are frequently shipped to the job site and stored prior to assembly and erection as components which gives opportunity for the components to get mixed up leading to improper assemblies since the basic design often does not prevent errors. Therefore, prior to beginning the assembly of a given support, it is necessary to check the major dimensions of the various components against the shop drawing for the support to verify that this has not occurred.

On poles, verify the length, base diameter, top diameter and wall thickness of each pole or section of the pole for poles shipped in multiple sections that are field assembled. Verify the length, width and thickness of the base plate along with the bolt circle diameter, bolt hole size and number of anchor bolt holes provided.

On bracket arms for conventional supports, verify the arm length and arm rise.

On lowering devices, verify the diameter of the luminaire mounting ring and number of luminaire arms on the ring. Also, verify the length of the power cord along with the wire size and number of conductors in the cord. Verify the diameter and length of each piece of hoisting cable.

Assembly of Supports

Support components stored in the field should be kept off the ground to prevent finish blemishes where the component lay in contact with a damp surface earth or water. Support components and assembled supports should be loaded, transported, unloaded, stored and erected in a manner avoiding damage to the factory applied surface finishes.

On multi-piece poles, verify that the sections to be assembled are the correct pieces for the pole at hand. Before tightening each telescopic joint between the sections, verify that the sections are properly oriented and that the male section has been marked to indicate when full insertion has been achieved. Verify that the process used for tightening the joint between sections is approved by the pole manufacturer and that the pole is not bent during the tightening process.

On each steel light pole used with an aluminum transformer base, verify that both the bottom of the pole base plate and the top of the transformer base were given a coat of zinc rich paint prior to assembly.

On each light pole, verify that the cable grip in the light pole is properly installed as shown in SCD HL‑10.12 to prevent damage to the pole and bracket cable.

On each light tower, verify that the luminaire ring has the correct number of mounting arms and that each arm is attached such that when the tower is erected the arms will be in the positions relative to the roadway as shown on SCD HL-10.31. If the lowering device is equipped with top laches, verify that when the luminaire mounting ring is fully raised and latched, the latch indicator on each latch will be in the Aextended@ or Avisible@ position. Verify that all moving parts on the head frame assembly and hoist mechanism have been lubricated in accordance with the manufacturer=s instructions.

Verify that all parts are in place and that all fasteners have been properly installed according to the manufacturer=s instructions.

Verify that each hand hole door or cover closes with no excessive gaps.

Verify that a light amount of anti‑seize or grease lubricant has been worked into the threads of each fastener holding each removable cover in place.

Erection of Supports

Prior to erection, verify that nuts can be easily turned by hand onto the threads of each anchor bolt.

When leveling nuts are to be used, verify that the leveling nuts are level before beginning the lift to set the support.

Each support should be lifted and set by crane with the hoist line attached at a point as far above the center of gravity of the support as possible, with a tethering cable from the lifting point to the base of the pole. The lifting point on poles made up of sections slip fitted together should be above the uppermost joint. Hoisting should be smooth and continuous without abrupt jerks. Light tension should be maintained in the hoist lines until an anchor nut has been threaded onto each anchor bolt far enough that the bolt is projecting though the nut by a full thread.

Verify that each support with a transformer base has been plumbed using leveling shims approved by the base manufacturer, installed between the base and the foundation according to the base manufacturer=s instructions and limitations and that the anchor nut on each anchor bolt has been properly tightened.

Verify that each support with an anchor base installed directly on a foundation without leveling nuts has been plumbed using leveling shims approved by the pole manufacturer installed between the base and the foundation according to the pole manufacturer=s instructions and limitations and that the anchor nut on each anchor bolt has been properly tightened.

Verify that each support with leveling nuts is plumbed by adjusting the leveling nuts and that both the anchor nut and the leveling nut on each anchor bolt has been properly tightened.

Verify that a light tower has been plumbed early in the morning when there is minimum heat effect from the sun.

Verify that each support has been plumbed when there is no appreciable wind.

Verify that the space between the top of the foundation and the base of the support has NOT been grouted.

When a high mast support (light tower) is equipped with a lowering device that has top latches, verify that the ring engages all latches simultaneously. This is often referred to as Aleveling@ the ring. It should be done following the manufacturer=s directions. Generally the procedure is to place a block on each hoisting cable that is attached to the ring a few inches above the ring in such a manner that the block will slide along the cable when the block contacts the portion of the mechanism at the top of the tower. The ring is then raised until all blocks have made contact, but not fully raised. The ring is then lowered and the distance between each block and the ring measured. Hoisting cables are then adjusted to make the measurements equal. The process is repeated until no further adjustments are required. The blocks are removed and the lowering device operated several times through its full cycle watching all latches for proper operation.

Verify that support identification decals have the proper legend and that the decals are located approximately 7 feet (2.1 m) above the base of the pole facing oncoming traffic.

Foundations (625.10)

Foundation inspection normally consists of three parts: location, excavation and concrete placement.

Foundation Location

After the location of each foundation has been staked, verify that the location is that specified in the plan and that Ohio Utility Protection Service and all utilities in the area have been allowed at least 48 hours to mark their utility locations relative to the proposed foundation. Then verify that the location appears logical. Be alert for the following:

1. Installing the lighting item at the staked location will require removal of vegetation that shields adjacent property owners from the highway.

2. Installing the lighting item at the staked location will locate the item at the top of the back slope, in a cut cross section or at the bottom of the fill in a filled cross section where guardrail is to be used to keep errant vehicles from going down the slope.

3. Installing the lighting item at the staked location will place the item under an overhead utility line or over an underground utility line.

4. Installing the lighting item at the staked location will require a graded access drive for the construction that has not been addressed in the plan.

The designer should be consulted prior to relocating any support more than 10 feet (3.0 m) or if two or more adjacent supports need to be relocated.

Excavation

Foundations are to be placed only in undisturbed soil or compacted embankment.

If a minor cave‑in should occur, the Contractor may, with the approval of the Engineer, continue excavating using sleeving or casing. When bedrock is encountered, the Engineer may reduce the specified foundation depth.

If construction crews must leave the job site with a hole unfilled, it shall be covered and marked with cones, barrels or warning tape.

Placement of Concrete

Verify that the top of the foundation will be at the proper elevation.

Tops of foundations shall be finished smooth and level to enable proper plumbing of the light pole.

Verify that the anchor bolts are of the correct size and number and that each bolt is securely held in the correct position. The use of an anchor bolt setting template is encouraged. Verify that each anchor bolt will project the proper distance from the foundation.

Verify that conduit ells are present and that each ell is of the correct size and material and that each is properly oriented.

Verify that all reinforcing bars are present and that each is of the correct size and shape.

Verify that all items to be cast into the foundation, along with any forming aids, are secured in such a manner that they will not move out of position during the placement of concrete.

Verify that water encountered in the foundation excavation is pumped out before concrete placement. If this is not feasible, verify that the concrete is placed by the tremi‑tube method.

Verify that the concrete is of the proper design, has been properly mixed, has the correct slump and is properly handled during placement. Verify that the concrete is vibrated to eliminate voids.

Verify that the top of the foundation is properly finished and that the concrete is properly cured.

Pull Boxes / Manholes (625.11)

Verify that each pull box is of the size and material specified.

Verify that each pull box is at the planned location unless the planned location puts the box in a low spot with respect to the surrounding surface. In such cases, notify the Engineer so that the Engineer, in consultation with the designer if necessary, may attempt to move the box to a location where it will be less likely to hold water.

Verify that a light amount of anti‑seize or grease lubricant has been work into the threads of each fastener holding the cover in place.

Junction Boxes (Handholes)

Verify that each junction box is of the correct size and material and securely fastened in the correct location. Verify that a light amount of anti‑seize or grease lubricant has been work into the threads of each fastener holding the cover in place.

Conduit (625.12)

Verify that each conduit run is of the correct size and material.

Verify that each cut end on each piece of conduit is reamed to remove rough edges.

Verify that all field cut threads on galvanized conduit have been coated with zinc rich paint.

Verify that each expansion or deflection fitting has a bonding strap for ground continuity when used with metal conduit.

Verify that each conduit run has been properly fastened in place.

Verify that the Contractor shall check each run of conduit by rodding (pushing a mandrel through the empty conduit) or pulling a cleaning puck through the conduit.

Verify that each run of conduit being left empty for future use contains a No. 10 AWG pull wire or equivalent.

Verify that each end of each conduit run is terminated either in a box connector that contains an integral bushing or with a separate bushing to protect cable pulled into the conduit.

Trench (625.13)

Verify that the trench did not deviate more than 6 inches (150 mm) from the line designated unless such deviation has been approved by the Engineer. Verify that the sidewalls and bottom of the trench do not have any protruding sharp rocks.

When duct cable is installed in the trench, verify that the backfill material within 2 inches (50 mm) of the duct cable does not contain pieces larger than 1/2 inch (13 mm).

Verify that the backfill is placed in compacted layers not to exceeding 4 inches (100 mm) in thickness.

When caution tape is specified, verify that the tape is installed 6" to 8" (150 to 200 mm) below grade.

Power Service (625.15)

Power service includes all equipment from the connection point to the utility company to the beginning point of the individual lighting circuits.

Verify that the power service location will be readily accessible both to maintenance personnel and to utility company personnel. There should be a safe parking area for service vehicles since the site will be visited regularly. The location should not be prone to standing or flowing water during rain events or to drifting snow. If the location appears unreasonable, involve the designer and the utility company as soon as possible, since moving a power service often means redesigning the lighting circuits.

Verify that the Contractor has been in touch with the utility company and become aware of any utility company requirements which may differ from the requirements of the Contract Documents.

Verify that the photocell is facing the north sky, unless otherwise stipulated by the plan, and that no artificial lighting source is disrupting its proper operation.

Verify that the conduits are neatly routed and fasten securely in place.

Verify that enclosures are securely mounted.

Verify that enclosure covers are in place and that fasteners for the covers have had anti-seize or grease worked into the threads.

Verify that moving parts of the switch gear have been lubricated and operate smoothly.

Verify that no debris has been left in enclosures and that the wiring in each enclosure is neat, orderly and tied into place where appropriate.

Grounding (625.16)

The conducting portions of those items containing electrical conductors are to be connected to each other and to earth electrodes to lessen the chance of injury and damage from unwanted electrical currents. Connecting the various conducting portions together to form the continuous path for the flow of stray electrical currents, often referred to as bonding, in ODOT=s projects is generally an incidental to the construction. Installation of the earth electrodes and the connection of the conducting portions to those electrodes is often referred to as grounding and in ODOT=s projects payment is somewhat related to the electrodes installed.

Ground Rods

Verify the ground rods specified have been installed. When additional rods have been added to lower the resistance, verify that the installation of each rod was approved prior to its installation.

Verify that the connection between the ground rod and the grounding cable is an exothermic weld. When additional rods have been added to reduce the resistance, verify that the additional connections are exothermic welds.

The normal ground rod item is for one rod driven into earth and the lead between the rod and the first connection and the associated connections. The earth resistance is then checked. When said resistance exceeds the specified limit, an additional rod is to be driven and connected to the first. The earth resistance of the pair is then checked. The process is repeated until the resistance of the group is lower than the specified limit. Payment is then made at the per rod price for each rod installed.

ODOT has reserved the right to approve the use of each additional rod before it is installed and may decline to install additional rods; thereby stopping the process at any point. When ODOT stops the installation of additional rods, it may decide to take another course of action to lower the earth resistance. If no additional action is taken, then by default the earth resistance becomes acceptable as it stands.

Exothermic Welds

An exothermic weld often has a rougher surface texture on the weld metal than one may be used to seeing, but the weld is not to have other signs of a poor quality weld such as porosity, cratering, cracking or undercutting.

Structure Grounding

Verify that each grounding electrode is acceptable before structure construction makes modification of the electrode or the installation of additional electrodes along side impractical. Remember that if some of the electrodes are driven rods that such rods are incidental to the structure grounding system, not separate items. However, if due to high resistance, additional rods are driven, those rods are not incidental to the structure grounding system.

Verify that the necessary bonding jumpers are in place and functioning correctly before structure construction makes the installation of additional jumpers impractical.

Structures present special needs. Not only is it not practical to have a separate ground rod for each light pole or similar item mounted upon the structure, but also there are elements of the structure itself that need grounding. Thus the normal practice is to use bonding jumpers to connect all exposed metal items together and thence to the several electrodes frequently utilizing the main conducting portions of the structure as the main grounding buss. This means that electrodes are often under footers and bonding jumpers are frequently embedded in the structure. If something is left out or does not function as intended and it is not discovered until the final stages of construction, the grounding can become expensive, unsightly and less than desired. Unfortunately structure designers all to often include little in the way of specific details for the structure grounding. Therefore, it is imperative to be constantly thinking ahead to fully understand where each electrode and jumper is to be located and to verify that it is in place and functioning correctly at each stage.

Bonding Along Circuits

Verify that all of the conducting items containing the conductors of each circuit are bonded to form a continuous path back to the source of the circuit.

At light poles, verify that metal conduits entering the base of the pole are bonded to the pole.

At pull boxes, verify that the metal conduits entering the pull box are bonded together and that the metal lid and lid frame are bonded to the metal conduits.

At junction boxes, verify that the metal conduits entering the junction box are bonded to the box.

At the expansion and deflection joints in conduits of conducting materials, verify that a bonding strap has been install across the joint.

When non conducting conduit or duct is used, verify that a grounding conductor has been installed to provide for the continuous grounding path when necessary.

Wiring and Cabling (625.17)

Field wiring of highway lighting circuits is broken into three types.

Pole and Bracket Cable

Pole and bracket cable is the insulated single conductor used in a light pole (but not in a light tower) to connect from the distribution cable, up the pole and out the bracket arm to the light fixture (in a tower the electrical wiring from the base of the tower to the luminaires is a component of the lowering device).

Verify that each run of cable is of the sized and type specified. The wire size and insulation are to be indelibly marked on the insulating jacket at frequent intervals along the length of the cable.

Verify that each run of cable is installed in a continuous piece without inline splices between the terminations shown on the plan.

Verify that the insulating jacket was not nicked nor portions shaved away as the cable was pulled into place.

Verify that the cable was not stretched as it was pulled into place. If the cable can be pulled back and forth by hand enough to move both ends, stretching probably did not occur.

Verify that a cable support was installed at the upper end of the vertical run of cable up the pole.

Verify that there is enough length on each end of the run for the cable to be routed properly to its termination and still remain slack.

Distribution Cable

Distribution cable is the insulated single conductor used to construct lighting circuits from the control equipment of the power service to the disconnect kits of a light pole, the terminal block of a light tower or the disconnect switch for underpass or sign lighting.

Verify that each run of distribution cable is of the size and type specified. The wire size and insulation are to be indelibly marked on the insulating jacket at frequent intervals along the length of the cable.

Verify that each run of cable is installed in a continuous piece without inline splices between the terminations shown on the plan.

Verify that the insulating jacket was not nicked nor portions shaved away as the cable was pulled into place.

Verify that the cable was not stretched as it was pulled into place. If the cable can be pulled back and forth by hand enough to move both ends, stretching probably did not occur. Unfortunately for the larger wire sizes and the longer runs commonly encountered in highway lighting circuits, the cable cannot be pulled by hand. Thus, the most common indication of stretching is when the length of pulling lead exiting the raceway is greater than the length of cable entering the raceway or the pulling forces are greater than normally encountered; both of which are not easily detected by other than experienced installers.

Verify that there is enough length on each end of the run for the cable to be routed properly to its termination and still remain slack.

All cables shall be labeled in accessible enclosures (pull boxes, hand holes, transformer base, device housing, etc.). A minimum of 5 feet (1.5 m) of extra cable shall be provided for each conductor at all terminal points.

Duct‑Cable

Duct cable consists of insulated conductors, of the type used for distribution cable, installed into a duct and shipped as an assembly to the project. It is used in place of conduit and distribution cable to speed the installation of underground circuits.

Verify that the temperature of the duct‑cable was above 32° F (0° C) throughout the installation process.

It is permissible to install duct cable when the outdoor air temperature is actually below those temperatures, but the Contractor must obtain authorization from the Engineer. The Contractor shall submit in writing his method of heating the duct cable and maintaining the duct cable at a uniform temperature throughout the installation process. To assure that the duct cable is heated uniformly, the heating process shall keep the temperature of the duct cable above 32° F (0° C) a minimum of 24 hours prior to installation. Under conditions such as the preceding where the temperature of the duct cable can be expected to vary widely during the installation process, the expansion and contraction of the duct cable must be taken into consideration. Typically, the duct cable length will decrease (or increase) one foot per thousand feet (0.3 m per 300 m) for each ten degree Fahrenheit (5.6 degree Celsius) decrease (or increase) in temperature.

Verify that the duct of the installed duct cable extends out of any conduit sleeve through which it passes enough to allow for the expansion and contraction in the duct due to seasonal changes in temperature. Typically a projection of two to three inches (50 to 75 mm) is appropriate at the usual installation temperatures for the lengths of run typical in ODOT’s installations.

As received on the reel from the manufacturer, it will appear that the cables inside the duct and the duct are equal in length but in reality the cables are shorter than the duct. In order to reel the assembly onto the shipping spool both the cables and the duct were anchored to the spool. As the duct cable assembly is unrolled from the shipping spool, the cables will be drawn into the duct resulting in empty duct at the start of the run. For the assemblies typically used in ODOT=s projects, leaving 25 feet (7.6 m) of duct for each 1,000 feet (300 m)of run to be installed at the start of the run, in addition to that required as slack for connections at the start of the run, will compensate for this. At the end of the run, only the slack amount for connections is required.

Verify that the insulating jacket of each cable within the duct has not been damaged when the duct was stripped to allow the connections to be made. Often the length of duct to be stripped is such that no protection can be slid over the cables and into the end of the duct which means that the cables within are saved from damage only by the skill of the person stripping the duct.

When a duct cable assembly has been passed through a conduit sleeve, verify that the duct has been sealed to each end of the sleeve by means of a molded boot or wrapped sealing pad.

Verify that the seal installed between the cables and the duct is installed in the same location and in the same manner as outlined under the installation of distribution cable into conduits.

Verify that there is enough length on each end of the run for each cable to be routed properly to its termination and still remain slack.

Conductor Identification

At each access point (pole base, pull box, junction box, switch gear enclosure, etc.) each conductor of each run of the field wiring (pole and bracket cable, distribution cable, duct cable) of each circuit is to be identified by applying a tag to the conductor indelibly marked to indicate the circuit and the use of that conductor within the circuit.

Connections (625.18)

This covers the connection of the field installed wire and cable to other such wire and cable and to the various items of equipment.

Sizing Conductor to Device Terminal

When the circuit conductor is of a larger size than the device terminals can accommodate, verify that the connection has been made by splicing a short piece of smaller wire onto the end of the large wire and then connecting the smaller wire to the device terminal. The smaller wire is normally identical to the larger wire in all aspects except for size. The smaller wire must be large enough to carry the current that the circuit protection will allow. It is not acceptable to cut back some of the strands of a conductor, so that the remaining stranded will fit into the terminal.

Crimped Compression Connections

Verify that the die in the compression tool was for the connector applied and that the connector is sized to match the wire to which it was applied and that the tool used was of a type that did not release the connector from the die once compression started until full compression was achieved.

Pull-Apart and Bolted Connections

Verify that the internal connector is properly applied to the conductors.

Verify that the insulating cover was cut to proper step for a snug fit over the insulation on each entry to the housing.

Verify that the internal parts are all present in good condition and are fully seated into the housing.

Verify that the male half of the housing is a snug fit and fully inserted into the female half of the housing.

Verify that a thin coating of the kit manufacturer=s approved non conducting grease has been used at the joint between the two halves of the housing, between the housing and each cable entering the housing and on other internal parts as show in the manufacturer=s instruction to allow the parts to slide smoothly into place and help seal out water.

Verify that there are no sharp bends in each cable where the cable enters the housing sufficient to cause the housing to pull away from the insulating jacket on the cable.

When the kit is to contain a fuse, verify that the fuse is of the proper ampacity.

Where the kit contains bolted connections, verify that the connections have been properly tightened before the housing was closed.

Verify that there is sufficient slack in the cables being connected to permit bringing connector kits outside of the pole, transformer base or junction box in which it is housed for servicing.

Unfused Permanent Connections

Verify that the internal connection is via a proper crimp compression connector.

Verify that the mold surrounding the connection is completely filled with resin.

Verify that the connection is positioned within the mold such that the resin properly surrounds the connection.

Verify that there are no voids in the resin.

Verify that no fillers have been used.

Verify that the resin has properly set.

Test Procedures (625.19)

There are a number of tests normally utilized to ascertain that the lighting installation has been well constructed and is in good operational order. For a particular test to have meaning, it must be properly conducted and the results properly interpreted.

Verify that the equipment used to conduct the test is in working order and calibration.

Grounding Electrodes

Verify that each specific grounding electrode meets the requirements of the earth resistance test.

The first key to conducting a successful test of a grounding electrode is to understand what constitutes the electrode. A single driven rod is an electrode. When that rod fails the earth resistance test and another rod is added, the electrode then becomes both rods together. However, in the case of a light tower where two rods are typically specified, the initial electrode is the two rods together rather than each rod separately. In structure grounding, the cluster of driven piles at the end of a pier footer should be considered as a single electrode with the cluster at the other end of that same footer considered as a separate electrode. A continuous grid of mesh, bars or cables laid beneath a footer is one electrode but separate grids under different portions of the same footer are separate electrodes. Wires buried in a radial pattern from a single pole constitute an electrode.

The second key to successful ground resistance is to understand the limitations of the various test instruments and procedures. The chosen procedure must be appropriate for both the electrode under test and the conditions in which the electrode is installed and the instrument must be capable of producing valid results for the situation at hand.

Circuit continuity

The key to the proper checking of circuit continuity is to remember the objective and to test one conductor at a time. The objective is to see that the conductor is connected to the desired device point and that the conductor has not been connected to any other devices. The difficulty is that the devices are scattered over a large area thus requiring the other conductors of the same circuit to be used as returns for the test signal. For the test to be of use often means that testing must start at one node in the circuit and test all connections along an isolated link from that node. Additional nodes and links are then added one at a time and the continuity of the conductors rechecked until the entire circuit has been verified.

Cable Insulation

This test is designed to verify that the insulation of each conductor in the circuit and permanent and bolted connections in that conductor are in good conditions be impressing a much higher than normal voltage on the conductor using the change in leakage current over time. Care must be used not to impress the test voltage on devices normally connected by the circuit since the devices would probably be damaged. Since the other conductors in the circuit must often be used as the return path, it is necessary to use care to ensure that the other conductors are not damaged while serving as signal returns and careful interpretation of the results to determine whether the leakage is from a conductor failing the test or from a failure in the return path.

Lowering Device Operation

This test is simply repeated operation of the lowering deice on a light tower to verify that is operates smoothly and correctly throughout its full range cycle of motions.

System Performance

The test uses the concept Ainfant mortality@ to determine if the equipment is likely to operate satisfactorily throughout the projected life of the installation. The concept is the equipment is most likely to fail from manufacturing defects and installation in the first few hours of use and that once these hours are past it is likely to run the rest of its life with only normal maintenance. In conducting the test, it is important to recognize the significance of each component malfunction encountered and to properly interpret whether the malfunction indicates a need to extend the test period.

Provide information to maintaining agency

Ensure that each maintaining agency receives the documents pertinent to the maintenance and operation of the lighting units for which it is responsible. Typically included are:

1. A copy of the plan marked to show any changes made during the construction.

2. A copy of each certified shop drawing or catalog cut.

3. A copy of each instruction or parts manual supplied by each manufacturer.

Documentation Requirements

1. Luminaires

a. luminaire has the distribution, lamp and aiming stipulated in the Contract Documents

b. luminaire has been Aleveled@

2. Supports

a. support is the one stipulated for that location by the Contract Documents

b. support is comprised of the correct components according to the certified shop drawings

3. Pull boxes

a. pull box is the size and type stipulated for that location by the Contract Documents

b. if supplied under plant sampling and testing program, that it has a TE‑24

c. drain is documented on form CA‑P‑1

4. Conduit

a. conduit is the size stipulated for that location by the Contract Documents

b. conduit is of the material stipulated for that location by the Contract Documents

c. measure length installed

5. Trench

a. location and depth is as stipulated by the Contract Documents

b. there are no sharp rocks in backfill adjacent to duct

c. backfill is placed in 4 inch (100 mm) lifts and mechanically tamped

d. measure length installed

6. Grounding electrodes

a. electrode is installed as stipulated for that location by the Contract Documents

b. grounding conductor connected to ground rod with exothermic weld

c. document ground resistance

7. Wire and Cable

a. wire size and insulation is as stipulated for that location by the Contract Documents

b. Measure length installed

626 Barrier Reflectors

Barrier Reflectors – General (626.01)

This information is intended to serve as a guide for construction personnel where the contractor furnishes and installs barrier reflectors. However, it may also be useful for maintenance personnel performing the same functions. Inspection procedures are outlined. This information points out the various important features and references the applicable specification or standard drawing.

Materials, Qualified Product List (QPL) (626.02)

Make sure that all barrier reflectors used on a project are approved and listed on the Qualified Product List at the following web site:

http://www.dot.state.oh.us/testlab/applists/QPLWEB/qpl.htm

Barrier Reflector Installation (626.04)

i. Ensure that the color of the reflector matches the color of the nearest edge line.

ii. Ensure type A & A2 reflectors are installed within the concave surface of the guardrail.

iii. Ensure that the guardrail reflector unit fits within the channel exposed to traffic and not protrude beyond the depth of the channel.

Barrier Reflector Type A and A2

iv. Ensure that the type B & B2 are installed with the top of the barrier reflector so its height is 26 inches(650 mm) above the near edge of pavement, except that the top of the barrier reflector is at least 3 inches (75 mm) below the top of the concrete barrier.

Barrier Reflector Type B and B2

Ensure that the barrier reflector does not extend further than 5 inches (125 mm) in a horizontal direction towards the traffic lanes.

Ensure that loose concrete, rust, dirt and other loose materials must be removed from the surface of the concrete barrier or guard rail using a wire brush. Apply adhesive to clean and moisture-free surface according to manufacturer’s recommendations.

Make sure that all barrier reflectors used on a project are approved and listed on the ODOT Qualified Product List at the following web site:

http://www.dot.state.oh.us/testlab/applists/QPLWEB/qpl.htm

Documentation Requirements - 626 Barrier Reflectors

1. Document on CA-D-3A that installation performed as per 626.04

2. Document on CA-D-3A that material and products based on certified test data and all drawings

3. Document on CA-D-3A the types of barrier reflector for pay

630 Traffic Signs and Sign Supports

Description (630.01)

This information is intended to serve as a guide for construction personnel where the contractor furnishes and installs traffic control devices and appurtenances. However, it may also be useful for maintenance personnel performing the same functions. Inspection procedures for various types of traffic control devices are outlined, mainly in the form of check lists to assist project personnel in performing their duties. This information points out the various important features of each device and references the applicable specification or standard drawing. Illustrations are used for easy recognition of the device or feature being discussed.

Sign Service

Sign service shall comply with SCD’s TC-32.10 and TC-32.11 and the plans. Additional information is provided in TEM Section 240-7.2 and C&MS Item 631.04. Basically, it consists of cable and equipment to provide a complete electrical service from either an underground source or an overhead direct drop to separately furnished disconnect switch with enclosure. The equipment could include a weatherhead, a conduit riser with necessary fittings, attachment clamps and cable. A thorough review of the plans should be made to determine the specific requirements of the maintaining agency for sign service.

When required, an electric meter base will be furnished by the applicable utility and installed by the contractor as part of the sign service work.

The sign service shall terminate at the meter base, if used; otherwise termination shall be at the switch enclosure. Sign service may be by:

1. Direct drop by means of a weatherhead and conduit riser routed to the switch enclosure;

2. Underground conduit and the pole interior to the enclosure; or

3. Underground and structure-attached conduit to the enclosure (for overpass mounted signs).

The conduit riser shall comply with Item 725 and the plans, and the weatherhead shall be threaded aluminum or galvanized ferrous metal 732.16.

The disconnect switch shall be a single-throw safety switch meeting the voltage and capacity requirements of the plans. The enclosure shall be a NEMA Type 4 ICS 1-110.15 with sufficient volume to accommodate an internal transformer when specified. The enclosure shall contain a solid neutral bar.

A ground wire shall be used as shown on SCDs TC-32.10 and TC-32.11 leading to a ground rod installed in accordance with TEM Section 240-7.3.

Foundations (630.05)

Staking

Sign support foundations shall be located so that the sign face is at a right angle to the roadway lanes served, unless the plans specify otherwise. An example of an exception is the W1-6 Large Arrow sign (black arrow on yellow background) which is located as shown in TEM Figure 298-24.

Foundations should be staked by the contractor in accordance with the locations shown on the plans.

The stakeout locations should be checked for:

1. The presence of obstructions which could restrict motorists' proper visibility of the sign from the point where they are expected to read the sign. Curved roadway locations should especially be checked.

2. Obvious conflicts with overhead power lines or other utilities. There should be available a proper safe clearance from overhead lines for construction operations, in compliance with the National Electric Safety Code and any local codes.

3. Possible conflict with underground facilities.

Foundation locations may be adjusted when necessary to overcome difficulties such as those shown in TEM Figure 298-24 and discussed herein, with the concurrence of the project engineer. Adjustment should not violate minimum clearance dimensions as shown on SCDs TC-42.10 and TC-42.20 and the OMUTCD.

Excavation

Foundations shall be placed only in undisturbed soil or compacted embankment and excavation shall be by an earth auger of the specified diameter to the specified depth. See TEM Figure 298-25 for a diagram of a foundation excavation.

If a minor cave-in should occur, the contractor may continue excavation using an increased diameter; or use sleeving, casing or other method approved by the project engineer. However, the foundation concrete will be measured as determined from plan dimensions. The contractor shall remove all extraneous material from the excavation before concrete placement. When subsurface obstructions are encountered, permission may be granted by the project engineer to replace the excavated material and relocate the foundation. When bedrock is encountered, that portion of the specified foundation depth within the bedrock may be reduced as much as 50 percent.

Placement

Anchor bolts and conduit ells shall be of the correct size and furnished with the support. At least one 2 inch (51 millimeters) minimum conduit ell shall be furnished and capped if unused. Anchor bolts, conduit ell(s) and EMT (Electric Metallic Tubing) shall be oriented in the foundation according to the plans, conduit runs and ground rod location. All anchor bolts shall be provided with standard steel hex nuts, leveling nuts and plain washers. The nuts shall be capable of developing the full strength of the anchor bolts. Reinforcing bars, tie loops and tie bars shall be of the correct size and arranged with the anchor bolts into cages according to the applicable SCD TC-21.10 or SCD TC-21.20. A special foundation design will be required when soil with a load bearing capacity of less than 2,000 pounds per square foot (9700 kg/m²) is encountered.

Anchor bolts shall be vertical with their ends projecting the correct distance above the foundation surface in compliance with the plans. When the distance the anchor bolts project above the foundation surface is not specified, a rule of thumb is four times the bolt diameter. The anchor bolts shall be tied to the cage tie bars according to standard details.

The rebar cage shall be supported 3 to 4 inches (75 to 100 millimeters) above the bottom of the excavation by a piece of concrete block or similar material. The cage shall be positioned with a clearance of 3 inches (75 millimeters) from the excavation wall by similar blocking so that after concrete placement a full thickness cover is assured. A template and/or frame shall be used to rigidly hold the anchor bolts and conduit ell(s) in the specified pattern during concrete placement. A form shall be oriented according to the plans to shape the foundation into a square from the surface or grade shown to a nominal 6 inches (150 millimeters) below ground line. The template and form may be combined. Gaps of 6 inches (150 millimeters) or less between the foundation and adjacent paved surfaces shall be eliminated by increasing the formed foundation.

Water encountered in the foundation excavation shall be pumped out before concrete placement.

If this is not feasible, concrete should be placed by the tremi-tube method.

Concrete conforming to Item 499 and Item 511 shall be placed and vibrated to eliminate voids. Care should be exercised during vibrating to avoid disturbing the anchor bolts, conduit ell(s) and reinforcing cage.

Forms may be removed as soon as the concrete has hardened sufficiently so as not to be susceptible to damage, 511.16.

Minor earth caving external to the hole which may have occurred during excavation using sleeving or casing should be corrected after concrete placement by backfilling and tamping in accordance with 203.

Joint filler complying with 705.03 shall be placed between the formed foundation and adjacent paved surfaces.

Supports and poles may be erected, signs installed and span wire load applied only after the concrete has aged sufficiently to be in compliance with 630.

Curing and Loading

Curing and loading of concrete for traffic control devices shall comply with 511.17.

Concrete for foundations of sign supports shall be cured, have bracing removed and be loaded only when the concrete has achieved the age shown below:

	Age of Concrete in Days
	Without Beam Test	With Beam Test **
Curing	7	5
Removing Bracing	7	3
Loading*	14	7

* No load shall be applied or other work done that will damage new concrete or interfere with its curing.

** Beam test specimens shall be poured from the same batch, immediately before, during or after foundation pour. Specimen configuration shall be to ODOT requirements. Specimens when tested shall have at least an average modulus of rupture for two tests of not less than 650 pounds per square inch (4.5 MPa).

Overhead Supports in General (630.06)

General

Various general aspects of overhead sign supports are addressed in this section. TEM Table 297-7 provides an overall summary of the structure types, allowable sign area on each and the span or arm length.

Pole and Support Inspection

This inspection checklist covers the general features of strain poles, mast arm type signal supports and overhead sign supports. Features pertaining only to specific pole or support types will be found in the sections of this manual covering exclusively those poles or supports.

1. When poles and supports of the combination type are specified, they are to provide extra length as necessary for a highway lighting function and welded-on bracket arm plate(s) complying with SCD HL- 10.12 or SCD HL-10.11, for attachment of a separately furnished luminaire arm. An upper handhole and an additional internal J-hook are to be furnished.

2. Supports may be of an alternate design utilizing all non-tapered tubing structural members.

3. Poles and supports should be inspected when received if possible, but certainly prior to erection.

4. General dimensions should be checked first, including pole length, base diameter, top diameter, and wall thickness. Similar mast arm dimensions should also be checked. Wall thickness is most easily measured with calipers at the end. Caps on poles may have to be removed.

5. Orientations of the various appurtenances should be checked against the plan’s orientation diagram if such is available; otherwise orientations may be determined from certified shop drawings and the intersection drawing.

6. Base plate dimensions should be checked including thickness, bolt circle diameter and bolt hole size. Base plates may be plate or cast steel according to 730.04.

7. A handhole with ground lug is to be furnished, with a cover plate complying with 730.05 and a stainless steel chain complying with 730.10.

8. Blind half-couplings shall be provided where required. Sharp edges shall be rounded to prevent damage to cable or wires. Blind half-couplings shall be plugged when not in use. Couplings may be for signal or interconnect cable entrance or for attaching supports for traffic control equipment and for hubs for controller cabinets. Entrance couplings shall be threaded for use with threaded weatherheads.

9. An internal J-hook shall be furnished and located as indicated on the plans.

10. A pole cap conforming with 730.06 shall be furnished, and in place before final inspection.

11. An arm cap conforming with 730.07 shall be furnished for chords or mast arms.

12. All strain poles and overhead sign and signal supports shall be grounded (even if no power is available).

13. Welding and galvanizing shall be inspected in accordance with 630.

14. Supports are to include sign brackets, U-bolts and clamps.When required by the plans, supports are to include luminaire support arms, bracing rods, other necessary structural members and signal hanger clamps with clevis.

15. The correct number and size of anchor bolts and conduit ells shall be furnished for placement in the foundation.

16. Anchor bolt diameter and length shall be according to the plans and SCD TC-21.10 or TC- 21.20. Anchor bolt ends may have an L-bend or be fitted with a tapped steel plate. Threaded ends shall not to be damaged and shall be galvanized at least 2 inches (50 millimeters) beyond the threads. The galvanizing should be in good condition, and absent or damaged galvanizing should be repaired by the application of two coats of zinc-rich paint. Galvanizing thickness should permit the turning of nuts by a wrench without difficulty. Loose rust on anchor bolts should be removed.

17. All anchor bolts shall be provided with standard steel hex nuts, leveling nuts and plain washers. The nuts are to be able to develop the full strength of the anchor bolts.

Inspection of Welds

All welds of supports shall be inspected visually as soon as possible following support delivery. Welds should be inspected for flaws and imperfections under good lighting conditions using a magnifying glass as necessary. Evidence of any of the following faults or other imperfections such as warping and misalignment may be cause for rejection of the support. The following features of welds should be checked:

1. A check should be made for the actual presence of all welds called for by the certified shop drawings and standard drawings.

2. Welds on tapered tubes, pipe or structural shapes shall be continuous around the joint. Welds requiring terminations shall be of the correct length.

3. Welds shall not exhibit cracks or discontinuities in base metal or weld material and shall not show evidence of porosity, showing up as pitting or pinholes. The galvanizing layer may cover such flaws, but their existence should be checked.

4. Welds shall be full cross section without excessive concavity or convexity. Required weld terminations shall be filled to full section without depressions or craters.

5. There should be no evidence of undercut, a condition where a shallow groove is melted into the base metal adjacent to a weld and left unfilled by weld metal.

6. Base plates shall be welded to two ply poles with AWS prequalified welds in conformance with 730.04.

7. Arm attachment plates shall be welded inside and outside with fillet welds. Each fillet weld shall be equal to the wall thickness of the respective tubing.

Inspection of Galvanizing

The galvanizing cover of supports shall be inspected visually as soon as possible following delivery. The galvanizing should be inspected externally and internally for flaws and imperfections in daylight or strong artificial light. In accordance with 513.26, supports shall be loaded, transported, unloaded, stored and erected in a manner avoiding damage to any feature including the galvanizing. Supports stored in the field should be kept off the ground to prevent the galvanizing from contacting water which may result in a premature oxidation condition. The galvanizing should have the appearance of a uniform application. Supports should be checked for assurance that the following flaws or imperfections do not exist:

1. Loose or bare spots in the galvanizing where improper preparation has prevented metal adherence in the molten zinc bath. Poles should be rejected if the point of a penknife can flake off the galvanizing layer.

2. General overall roughness, a symptom of over-pickling or of excess zinc bath temperature and/or immersion time.

3. Pimples, due to entrapped bath scum particles.

4. Blisters, due to hydrogen gas absorbed during pickling and coming out at the time of galvanizing.

5. Flux inclusions, picked up from the top of the bath when dipping and burnt-on during immersion.

6. Ash, usually in course lumps picked up from the top of the bath.

7. Patches of dull gray coating, due to the slow cooling of heavier cross sections of supports after immersion.

8. Excess zinc lumps or runs, due to delayed molten metal run-off from surface discontinuities such as joints, seams or holes.

9. Rust stains, due to the weeping of impurities from the pickling process at seams and folds.

Excessive galvanizing faults and imperfections combined with general poor workmanship may be cause for rejection of the support. Gross imperfections may lead to the suspicion of inadequate protective cover which may require inspection with a magnetic instrument. Items 1 through 6 may be cause for rejection. Items 7 through 9, if extreme, may also be cause for rejection, because of poor appearance even if the protection of the support is not affected.

After erection, supports should be given a final inspection for any damage to the galvanizing due to improper handling in the erection process. Damage due to slings, etc., which is more serious than superficial brightening is to be repaired by the contractor with the application of two coats of zinc-rich paint.

Weight of Supports

TEM Tables 297-8a through 297-8f provide information on the weight of various overhead sign supports. For all structures, the weight of the pipe support has been given where pipe has been frequently used in place of tapered tubes. In general, the tapered tube support will be lighter than the pipe support. The support numbers listed may be preceded by I-129, 815, 844 or other designation instead of TC.

For estimating purposes, a 10 x 10 foot (3.0 x 3.0 meter) sign (excluding the sign lighting) weighs approximately 250 pounds (113 kilograms).

Assembly and Erection Procedure

Erection procedures pertaining to specific pole or support types will be found in the sections of this manual devoted exclusively to those poles or supports. In general the following assembly and erection procedure applies:

1. To minimize erection time and the hazard to workers and road users where traffic is maintained, supports should be erected with mast arms attached, and horizontal sign support members (over the roadway) should be prewired for lighted signs or other traffic control devices. See the notes in plans for traffic maintenance requirements when span-type sign support members are erected.

2. Support components shall be assembled with their threaded fasteners tightened in accordance with 630.06. Fasteners ½ inch (13 millimeters) or greater shall have anaerobic adhesive applied to the threads according to the manufacturer’s recommendations. Nuts shall be tightened by the “turn of the nut” method.

3. The “turn of the nut” method shall be in accordance with 513.20. Nuts shall be made snug tight by the effort of a person using an ordinary spud wrench followed by an additional 1/12 to 1/6 turn.

4. Leveling nuts shall be placed on the anchor bolts, initially clearing the foundation surface by at least 1/4 inch (6 millimeters) and forming a horizontal plane.

5. Poles or supports shall be raised into position with equipment of adequate lifting capacity and used in a manner preventing damage to attached appurtenances (signs, brackets, luminaries, etc.) and to the galvanizing. The weight of poles or supports is given in TEM Tables 297-8a through 297-8f for the use of the contractor in the erection procedure.

6. With the pole or support’s base plate resting on the leveling nuts, the plain washers and anchor nuts shall be placed on the anchor bolts, the support plumbed in a vertical position or raked as required, and anchor nuts given a preliminary tightening.

7. After any necessary leveling nut adjustments are made to assure that supports are essentially vertical after attachment of signs, sign lighting equipment or signals the anchor nuts shall have anaerobic adhesive applied and be final tightened in accordance with the instructions for assembling fasteners given in the foregoing paragraphs 2 and 3.

8. Anchor nuts are not to be covered with bolt covers or a cover base regardless of support location (Item 630.06B).

9. Poles or supports which are prewired before erection should be checked to determine if the erection procedure has disturbed the wiring. Wire for lighted signs should be supported by looping wire over the J-hook in the vertical support member (Item 631.05). Cable supported by cable support assemblies should be checked to determine if the sling is over the J-hook and if the adjustment is proper to eliminate strain on the cable jacket.

Overhead Sign Supports By Type

General

The previous section addressed general assembly and erection guidelines for strain poles and supports. The following sections provide additional information specific to various types of supports. For the most part the information is provided in a checklist format.

Span Wire Support

Span Wire sign supports shall comply with SCD TC-17.10 and the plans. These sign supports consist of strain poles, messenger wire with accessories and sign hangers. Strain pole size and type, anchor base or embedded, shall be as specified.

1. Strain poles shall be inspected in accordance with 632 and general features of the poles shall be inspected in accordance with 630. Welds shall be inspected according to 630 and the galvanizing shall be inspected according to 630.

2. Erection shall be in accordance with the general procedure given in 630 except as hereafter noted.

a. For the initial rake of strain poles of the anchor base type or embedded type poles, see 632.

b. The upper messenger wire shall be assembled with its accessories according to the standard drawing. Preformed guy grips are not permitted because wind loads on the signs can cause failure of the grips. Alternate methods of attaching messenger wire to strain poles may be used:

i. Span wire clamp with clevis, anchor shackle and thimbles on the messenger wire, or

ii. Messenger wire wrapped twice around the strain pole and secured with a 3-bolt clamp of the proper size.

c. The upper messenger wire shall be fitted with its signs, furnished under other items of work, and the vertical clearance to sign bottoms adjusted within clearance limits over the roadway. The sag of the upper messenger wire shall be between 4 and 5 percent.

d. It is essential that the lower messenger wire have more slack than the upper wire. The sag should be approximately 3 inches (75 millimeters) greater than the upper wire. This sag adjustment shall be made before the sign hangers are attached to the lower wire.

e. Sign hangers shall be clamped snugly to the lower wire by U or J bolts. In the case of back-to-back signs, the lower messenger wire running in between the sign hangers, is clamped between bolted spacers that are slightly thinner than the messenger wire (see SCD TC-17.10).

Single Arm Support

1. Single arm supports shall comply with certified shop drawings, SCD TC-16.20 and the plans.

2. Welds, galvanizing, and general features of the support shall be inspected in accordance with 630.

3. For arms of two telescoping pieces, a 15-inch (400 millimeters) overlap is required. The overlapped arms shall be secured with a stainless or galvanized steel hex head through-bolt with nut.

4. Arm caps shall cover at least fifty percent of the end area (Item 730.07).

5. A minimum of two brackets shall be provided for each sign, each attached to the arm by steel clamps with carriage bolts. The clamps should be able to be tightened in a manner to firmly grasp the arm so as to prevent sign rotation.

6. If signs are lighted, disconnect switch enclosure mounting brackets may be required on the support.

7. Erection shall be in accordance with the general procedure given in 630, except as hereafter noted.

a. The contractor may choose to attach the signs and any sign lighting items before erection.

b. Signs are installed at the same elevation. For this purpose, adjustment is provided by two pairs of slotted holes in the sign bracket for attachment of the arm clamp.

c. Contact between galvanized clamp flanges and aluminum sign brackets shall be prevented by the use of chloroprene gaskets.

d. Initial rake shall be adjusted so that under the load of signs, the pole will assume an essentially vertical position and the arm rise will be within the limits specified on the standard drawing, 3 inches (75 millimeters) minimum, 12 inches (300 millimeters) maximum.

Cantilever Support

1. Cantilever supports shall comply with certified shop drawings, SCD TC-12.30 and the plans.

2. Welds, galvanizing, and general features of the support shall be inspected in accordance with 630.

3. Supports with arm lengths18 feet (5.5 meters) and over shall have truss members. Truss members may be angles or pipe.

4. One blind half coupling shall be welded to the top chord approximately 12 inches (300 millimeters) beyond or outside of the first sign bracket for a sign less than 20 feet (6.1 meters) long. A second blind half coupling shall be welded near the second sign bracket for signs 20 feet (6.1 meters) or longer.

5. Erection shall be in accordance with the general procedure given in 630, except as hereafter noted.

a. The contractor may choose to attach the sign(s) and any sign lighting items before erection.

b. Signs are centered vertically on the chords.

Center-Mount Support

1. Center-mount supports shall comply with certified shop drawings, SCD TC-9.30 and the plans.

2. Welds, galvanizing, and general features of the support shall be inspected in accordance with 630.

3. Sign clearance above the roadway shall be a minimum of 17 feet (5.2 meters).

4. Arms may be either square or round tube. The arm attachment design shall be in accordance with standard details for either square arms or round arms with separate cradle.

5. A blind half coupling shall be located on the pole.

6. Erection shall be in accordance with the general procedure given in 630, except as hereafter noted.

a. Signs are centered vertically on the arms.

b. Signs may be mounted laterally on the support in an eccentric position. However, a minimum of 2 feet (0.6 meter) of sign length shall remain to one side of the pole centerline.

c. The contractor may choose to attach the sign and any sign lighting items before erection.

Semi-Overhead Support

1. Semi-overhead supports shall comply with certified shop drawings, SCD TC-9.10 and the plans.

2. Welds, galvanizing, and general features of the support shall be inspected in accordance with 630.

3. Sign clearance above the ground shall be at least 10 feet (3.0 meters) unless a lower height is approved by the project engineer to provide sign visibility through preceding overpass structure(s).

4. Arms may be either square or round tube. The arm attachment design shall be in accordance with standard details for either square arms or round arms with separate cradle.

5. A blind half coupling shall be located on the pole.

6. Erection shall be in accordance with the general procedure given in 630, except as hereafter noted.

a. Signs are centered vertically on the arms.

b. Signs may be mounted laterally on the support in an eccentric position. However, a minimum of 2 feet (0.6 meter) of sign length shall remain to one side of the pole centerline.

c. The edge of the sign shall be back at least 2 feet (0.6 meter) from the edge of the curb.

d. The contractor may chose to attach the sign and any sign lighting items before erection.

Span Truss Support

1. End frames for span truss supports shall comply with certified shop drawings, the plans and SCD TC-7.65 for aluminum trusses and SCD TC-15.115 for steel trusses.

2. Welds, galvanizing, and general features of the support shall be inspected in accordance with 630.

3. Handholes shall be oriented on the end frame downstream vertical member on the side away from the direction of traffic.

4. The size of truss members shall be in accordance with standard details. Truss member joints may be of two different designs.

5. Switch enclosure mounting brackets shall be in place and a chase nipple installed on both end frame vertical members which are away from the direction of traffic.

6. An angle shall be furnished and welded onto the end frame, near the top, to support the lower chords of the span box. Stainless steel U-bolts shall be used with aluminum trusses and galvanized steel U-bolts with steel trusses.

7. End frame vertical members shall be furnished with steel clamps and a separate tee or angle (alternate) for supporting the upper chords of the span box. Stainless steel U-bolts shall be used with aluminum trusses and galvanized steel U-bolts with steel trusses.

8. An internal J-hook shall be in each end frame in the downstream vertical member.

9. When using an aluminum truss, the following shall apply:

a. Aluminum trusses shall comply with certified shop drawings, SCD TC-7.65 and the plans.

b. Welds shall be inspected according to 630.

c. End caps shall be on each end of chords. The top front end caps shall be tapped for wiring.

d. A blind half coupling shall be welded to the front top chord of the truss approximately 12 inches (300 millimeters) beyond or outside of the first sign bracket for each sign. Sharp edges shall be rounded to prevent damage to wires.

e. Span length shall be in accordance with shop drawings and the plans.

f. Span box camber shall be in accordance with standard details.

g. Flanges between span box sections may be cast or fabricated with forged flanges as an alternate.

h. Flange attachment hardware shall be stainless steel bolts and nuts.

i. Supports shall be furnished with necessary sign brackets, U-bolts, luminaire support arms, bracing rods and other necessary structural members

10. When using a steel truss, the following shall apply:

a. Steel trusses shall comply with certified shop drawings, SCD TC-15.115 and the plans.

b. Steel truss checking instructions are the same as those for aluminum trusses, except as hereafter listed.

i. The galvanizing shall be inspected according to 630.

ii. Flanges between span box sections shall be forged.

iii. Flange attachment hardware shall be galvanized steel bolts and nuts.

11. See the notes in the plan for traffic maintenance requirements when span type sign support members are erected.

12. The base plates of end frames shall be placed on anchor bolt leveling nuts, plain washers and anchor nuts placed, the frames plumbed into a vertical position in both longitudinal and lateral directions, and nuts made tight in accordance with 630.

13. Truss camber shall be correct. The various truss sections shall be assembled in the arrangement and sequence shown on the shop drawing.

14. Trusses may be assembled into a total span while lying on blocks with wedges. Flanges on truss section ends may be aligned by driving in the wedges as necessary. All flange bolts are then assembled and made tight.

15. Two cranes may be necessary when lifting very long trusses or the heavier steel trusses. For reference, truss weights are given in 630.

16. Care should be taken in the attachment of slings. Trusses should be lifted at positions of a quarter to a third of the total span. Slings should be attached to the top chords and the horizontal diagonals.

17. Trusses may be easily overstressed by poor handling, and care should be taken when moving assembled trusses for temporary storage, during transportation to the erection location and in the erection procedure.

18. Trusses shall not be erected unless at least one sign is in place within eight hours, or the trusses are fitted within the same period with damping devices approved by the project engineer (630.06 B).

19. Attachment of the box truss to the end frames shall be by four U-bolts. Aluminum trusses shall be attached by 5/8 inch (16 millimeters) stainless steel bolts according to SCD TC-7.65 and steel trusses shall be attached by 3/4 inch (19 millimeters) galvanized steel bolts according to SCD TC-15.115.

20. The contractor may choose to attach the sign(s) and any sign lighting items before erection.

21. Signs are centered vertically on the chords (not considering the height of Exit Panels).

Overpass Structure-Mounted Support

1. Overpass structure-mounted supports shall comply with the plans and SCD TC-18.24 for flush type supports and SCD TC-18.26 for skewed type supports.

2. Overpass structure-mounted supports include sign brackets and two different kinds of steel Z-bars which are fastened to bridge concrete. For steel beam bridge mounting, aluminum angles at the bottom are to extend between sign brackets and short galvanized steel angles bolted to the bridge steel. For overpass structures essentially perpendicular to the roadway underneath, sign brackets are flush mounted to Z-bars for direct sign viewing. For overpass structures skewed to the roadway underneath, a wedge-shaped box structure is inserted between the sign brackets and Z-bars to provide for direct sign viewing.

3. The number of sign brackets will vary according to the bracket spacing as required by SCD TC-22.20. Bracket details are also shown on the standard drawing.

4. The number of aluminum frames in skewed supports shall equal the number of sign brackets. Frame details shall be in accordance with standard details and are to include two angles placed diagonally.

5. Front upper and lower members of skewed supports shall be aluminum angles with a length equal to the sign length.

6. The skewed support structure shall be internally braced by two aluminum angles extending diagonally and horizontally through the interior.

7. For bridge clearance above a roadway of less than 17 feet (5.2 millimeters), the sign clearance above the bottom of the bridge shall be 3 inches (75 millimeters) minimum without, or 15 inches (400 millimeters) minimum with, sign lighting fixtures on the lower edge of the sign.

8. Supports shall be mounted on the overpass structure so the sign is horizontal regardless of bridge slope (630.06 D).

9. Expansion double wedge steel anchor bolts shall be used to fasten the support’s Z-bars to the overpass structure concrete parapet. Intended locations of anchor bolts are to be approved by the project engineer before any field drilling. Z-bars “A” are used at the top and Z-bars “B” at the bottom of parapet concrete.

10. For a steel beam bridge mounting, aluminum angles at the bottom shall be fastened to short galvanized steel angles bolted to the bridge steel.

11. Chloroprene gaskets shall be used to prevent contact between aluminum sign brackets or support frames and steel Z-bars or bolted-on angles.

12. If the sign extends more than 4 feet (1.2 meters) above or below the attaching Z-bars, intermediate sign brackets shall be provided.

13. For precast beam bridges, aluminum angles at the bottom shall be fastened to short steel angles and two expansion double wedge steel anchor bolts shall be used.

14. After sign erection, the sturdiness of the support to bridge attachment should be checked.

Ground-Mounted Sign Supports

General

This section provides additional information, generally in the form of checklists, about various ground-mounted supports. TEM Section 221 addresses general guidelines about sign supports and TEM Section 240-5 provides additional design information about ground-mounted supports.

Posts

1. Ground-mounted sign supports of the post type shall be U-channels or square posts of the number specified and be as shown on SCD TC-41.20.

2. Post lengths appearing on the plans are approximate and the contractor is responsible for determining the exact length of required posts before cutting to length (630.06A).

3. No. 4 U-channel posts consist of two No. 2 posts bolted back to back. No. 6 U-channel posts consist of two No. 3 posts bolted back-to-back. Back-to-back posts are assembled by 5/16 inch (8 millimeters) steel bolts, lock-washers and nuts on 4 inch (100 millimeters) centers below the ground line and 16 inch (400 millimeters) centers above the ground line. No. 4 and No. 6 U-channel posts cannot be installed in exposed locations.

4. Posts should have a line of paint 48 inches (1.20 meters) from the end, which will be in the earth. The mark when driven to a distance of 6 inches (150 millimeters) above the ground indicates a post driven to the proper depth.

5. If it is necessary to cut posts to correct length in the field, the cut end should be covered with two coats of zinc-rich paint and the cut end driven in the earth or embedded when required (except for back-to-back posts).

6. Posts shall yield when hit and shall be driven to a depth of 42 inches (1.05 meters). Posts are typically not to be embedded in concrete unless specified in the plans or ordered by the project engineer to overcome problems such as adverse soil conditions or generally prevalent bedrock close to the surface. The driven depth has been established to assure best yielding characteristics. Deeper depths are not beneficial in this regard.

7. Caution shall be used when driving posts in areas of buried cable.

8. Posts shall not to be driven in drainage ditches.

9. Posts shall be installed vertically and at right angles to the edge of pavement, unless otherwise required. Exceptions may be NO PARKING signs and STOP signs located at intersections with curved approaches. In this situation STOP signs should be placed perpendicular to a line from the viewing point where they are normally recognized and stopping action would begin.

10. Posts shall be driven without bending, distortion or end mutilation. Mutilation may be prevented by the use of a driving cap. Posts should be checked to see if the paint mark is 6 inches (150 millimeters) out of the ground after driving.

11. Posts located in paved areas shall be driven through a hole provided by sleeving or core drilling. After driving, the hole shall be patched with asphalt concrete or approved bituminous material.

12. At locations where posts cannot be driven, the post may be moved at no additional cost to ODOT, when approved by the project engineer.

13. Typical vertical and horizontal clearances of signs are shown on SCDs TC-42.10 and TC- 42.20.

“One Way” Sign Supports

Square posts which are capable of supporting signs at right angles to other signs on the post are designated as “one-way” sign supports for the most common application. This is shown on SCD TC-41.50.

Standard Beams

1. Ground-mounted sign supports of the non-breakaway beam type shall be rolled steel, wide flange sections of the size and weight specified (from the list on SCD TC-41.10). Non-breakaway beams shall be protected by guardrail or concrete barrier installed for another purpose. Inspection of beams of the breakaway type is covered in 630.

2. Beam lengths appearing on the plans are approximate and the contractor is responsible for determining the exact length of required beams before fabrication (630.06 A).

3. Galvanizing shall be inspected in accordance with 630.

4. Beams shall be embedded in a concrete foundation in accordance with SCD TC-41.10.

5. Beams shall be raised into position with equipment of adequate lifting capacity and in such a manner as to prevent damage to the galvanizing. The beams shall be braced in a plumb and square position until the concrete has cured. The age of the concrete before it is considered cured and before signs are permitted to be erected is to be in accordance with 630.

Breakaway Beams and Connections

1. Ground-mounted sign supports of the breakaway beam type shall be rolled steel, wide flange sections of the size and weight specified (from the list on SCD TC-41.10).

2. Beam lengths appearing on the plans are approximate and the contractor is responsible for determining the exact length of required beams before fabrication (630.06 A).

3. Beams shall use a slip base design. Alternate designs of breakaway connections are permitted.

4. Base plates shall be fabricated to standard details and welded-on with a bead equal to the beam flange and web thickness respectively, but not less than 1/4 inch (6.4 millimeters).

5. Welding and Galvanizing shall be inspected in accordance with 630.

6. All portions of beams should be shop assembled, in accordance with SCD TC-41.10.

7. The beam upper portions shall be joined by the bolts attaching the fuse and hinge plates. The plates shall be fabricated to standard details with the fuse plate having notched holes at the bottom and the hinge plate having unnotched holes. The steel hex head bolts, with washers under both head and nut, shall be tensioned in the shop to the final specified value. For S4x7.7 (S100x11.5) beams only, malleable iron beveled washers are used under bolt head and nuts.

8. Torque limiting nuts may be used instead of conventional nuts on the fuse and hinge plates (SCD TC-41.10, Note 5).

9. The beam lower portions should be joined by steel hex head bolts inserted with their nuts uppermost. A galvanized bolt retainer plate shall be sandwiched between the base plates. Flat washers shall be used under both bolt head and nut as well as under the bolt retainer plate. Bolts shall be snug tightened for delivery to the site with final torquing to be done after erection.

10. Torque limiting nuts may be used instead of conventional nuts on the base plates (SCD TC-41.10, Note 5). The nuts shall be snug tightened, but not to the point where the upper area shears away.

11. Base plate skewed notches should point toward the roadway along the path of typical vehicle collision. The skewed notches of both base plates should match.

12. For beams located in medians, the base plates should be welded-on upside down as compared with those of beams located on the right side of the roadway, so the base plate skewed notches will point toward each roadway along the path of vehicle collision from either direction of traffic.

13. For beams located in medians, fuse plates shall be used on both sides of the beam.

14. For beams located on the right side of the roadway, fuse plates shall be on the side of the beam facing traffic.

15. For the alternate design, special foot brackets shall be bolted to the upper beam portion, and four couplings incorporating a breakable reduced section are connected between the foot brackets and threaded anchor inserts embedded in the foundation. The couplings permit use of the design in medians where collision can occur in either direction of traffic.

16. The alternate design uses four hinge/fuse plates incorporating a thinned section and bolted where the beam is cut through just under the sign. The pair of plates on the impact side of the beam sever upon impact and a pair on the opposite side bend to allow the beam to swing upward out of the path of the impacting vehicle.

17. Beams should be erected in a single unit because they are easier to plum, square and brace when the entire assembly is raised and set in concrete.

18. Beams shall be erected in accordance with the procedure given for non-breakaway beams in 630.

19. A sloping concrete foundation top surface is required on the high ground side to prevent a water pooling pocket and permit drainage as per SCD TC-41.10. For the alternate design, the foundation top shall be level in the area of the breakable couplings.

20. When a supplemental panel is required below an extrusheet sign, the panel is fastened by sign backing assemblies to the parent sign. The panel shall be separated from the sign by the width of the fuse plate plus 1 inch (25 millimeters). This is to permit unhindered hinge plate bending in the event of a vehicle collision.

21. After the foundation concrete is cured, base plate nuts shall be loosened in turn and retightened with a torque wrench in a systematic manner to the specified maximum torque shown in the table on SCD TC-41.10, also shown in TEM Table 297-9. Torque wrenches used should be calibrated daily.

22. When torque limiting nuts are used on base plates, the nuts shall be loosened in turn and tightened in a systematic manner until the upper area shears away, assuring that the correct torque has been applied.

23. At least four weeks following the erection of signs on breakaway beams, the breakaway feature shall be inspected by the contractor for evidence of shifting or loose fasteners.

24. All loose fasteners shall be re-torqued to specified values. Base plate fasteners shall be loosened and re-torqued even if no shifting or looseness is detected. However, if the base plate connection was made with torque limiting nuts, re-torquing will only be required if looseness can be detected. Re-torqued conventional nuts at this time shall have anaerobic adhesive applied, or as an alternate, new torque limiting nuts of the proper range may be used.

Signs

General

Signs should be inspected when received on the job site if possible, but certainly prior to erection.

The signs should be inspected for conformance with the plans, certified shop drawings, catalog cuts and material specifications.

Flatsheet signs are typically of aluminum sheet cut into geometric shapes of the size specified.

Dimensions and thickness are to be as shown on SCDs TC-52.10 and TC-52.20. Bolt holes are to be drilled or punched (630.04).

Extrusheet signs are fabricated of aluminum sheet and extrusions, joined by spot welding and assembled by bolts (SCD TC-51.11). As an alternative, panels extruded in a single operation may be used (SCD TC-51.12). Extruded panels and spot welded panels shall not be used in the same sign. There shall be no appreciable deviation from flatness on the face of an assembled sign.

Overlay signs are of aluminum sheet of the thickness specified and used to cover the legend of extrusheet signs. Signs with overlays should be checked for any loose rivets holding the overlay sign.

All signs shall be reflectorized by being covered with the appropriate grade of sheeting. The sheeting shall be of the correct color, firmly attached and free of tears, wrinkles, blisters or blemishes.

Sign legend shall be in accordance with the plans, certified shop drawings and the OMUTCD.

The type of copy on extrusheet signs shall be as shown on the certified shop drawings. Available types of copy are listed in TEM Table 297-6.

All signs shall be identified on the reverse side by decals as described in 630.

Extrusheet signs shall also to be identified by information in a detachable form on the back (see Item 630.04).

Sign Storage

Signs shall be suitably protected and identified for shipment and storage. Extrusheet signs shall be kept rigid by backbracing or crating and the sign face covered with protective material. The backbracing shall extend sufficiently below the sign lower edge to keep the sign off the ground.

Extrusheet and flatsheet signs shall be stored in a vertical position.

Signs must be stored in such a manner that the packaging paper or cardboard material does not get wet. If the packaging material or slip sheeting should become wet, the paper should be removed immediately from contact with sign faces to prevent damage to reflective sheeting on the faces.

In the case of signs furnished by ODOT for erection by the contractor, the contractor shall be responsible for the storage and care of the signs after their transfer (630.08).

Sign Copy

TEM Table 297-6 provides information about the sign copy used, type, material used, design features, etc.

Sign Identification Decals

All signs shall be identified on the reverse side by decals of Type F white reflective sheeting (730.18) with silk screened numerals. Information shall be coded by screened-on or punched-out numerals before decal application and shall include: sheeting manufacturer and year of sign fabrication. At the time of erection, month and year of erection shall be scratched out by the contractor. This procedure is described in 630.04, which also contains an illustration of the decal. Decals for overlay signs may be on the front surface.

The following codes shall be used on the decals to identify the manufacturer of the sheeting.

0 - Avery Dennison

1 - Minnesota Mining and Manufacturing Company (3-M)

2 - Sakai Trading-New York, Inc.

3 - Nippon Carbide Industries (USA)

4 - Morgan Adhesives Company

5 - American Decal and Manufacturing Company

6 - Stimsonite Corporation

7 - Reflexite North America

Sign Erection (630.07)

General

This section provides information on erection of the signs. Assembly and erection of various types of overhead sign supports are addressed in 630.04 and 630.05 and ground-mounted supports are addressed in Section 630.06.

Ground-Mounted Flatsheet Signs

When erecting ground-mounted flatsheet signs the following provisions apply:

1. Typical vertical and lateral clearances of ground-mounted flatsheet signs are shown on SCD TC-42.20.

2. Flatsheet signs shall be fastened to posts by 5/16 inch (8 millimeters) hex head steel bolts with a 3/8 inch (10 millimeters) ID x 1 1/4 inch (32 millimeters) OD wide washer under the bolt head and using a lock washer and hex nut. For U-channel posts, at each bolt a bearing plate shall be used behind the sign is used to reinforce the sign, as indicated on SCD TC-41.20. The hardware and bearing plates are furnished with the signs.

3. Posts supporting groupings of flatsheet signs in multiple arrangements will require the use of sign backing assemblies made up of bolted together short sections of posts. Sign backing assemblies are furnished with the signs unless separately itemized.

4. Flatsheet signs mounted so as to be read by motorists using bridges shall be erected on special steel posts in accordance with SCD TC-41.40.

5. Street Name signs shall be erected on square supports in accordance with SCD TC- 41.40.

Ground-Mounted Extrusheet Signs

When erecting ground-mounted extrusheet signs the following provisions apply:

1. Typical vertical and lateral clearances of ground-mounted extrusheet signs are shown on SCD TC-42.10.

2. Mounting clips and other attachment hardware shall conform with SCD TC-51.11.

3. Supplemental panels erected under ground-mounted extrusheet signs mounted on nonbreakaway beams shall be fastened directly to the beams. The panel shall be separated from the parent sign by 1 inch (25 millimeters) to conform with SCD TC-42.10. When the panel is too short to reach between the beams, the panel may be fastened to the parent sign by sign backing assemblies.

4. Supplemental panels erected under ground-mounted extrusheet signs mounted on breakaway beams shall be fastened to the parent sign by sign backing assemblies. The panel shall be separated from the parent sign by the width of the fuse plate plus 1 inch (25 millimeters).

5. Exit Panels erected above extrusheet signs shall be attached by sign backing assemblies furnished with the Exit Panel.

6. The signs should be checked after erection to verify that the beams extend to the top of the signs and that the signs are horizontal and the clearances satisfactory.

Overhead Signs

When erecting overhead signs the following provisions apply:

1. The clearance above the roadway for the bottom of overhead signs shall be a minimum of 17 feet (5.2 meters), or as shown on the plans.

2. Overhead signs shall be vertical or horizontal regardless of the sag of supporting messenger wire, mast arm rise, chord camber or overpass slope.

3. Signs erected on span wire supports shall be attached in accordance with SCD TC- 17.10.

4. Signs erected on single arm supports (SCD TC-16.20) shall be installed so their bottom edge is at the same elevation. Sufficient adjustment for this purpose is provided by the two pair of slotted holes in the sign brackets for the attachment of the arm clamps. The clamps shall be tightened sufficiently to prevent sign rotation about the arm.

5. Signs mounted on semi-overhead supports (SCD TC-9.10) shall be erected so that their edge clearance from the curb line is at least 2 feet (0.6 meter).

6. Extrusheet signs over 8 feet (2.4 meters) in height may be delivered in two pieces for assembly in the field (630.08).

7. Extrusheet signs erected on supports with two arms shall be centered vertically.

8. Mounting clips and other attachment hardware for extrusheet signs shall conform with SCD TC-51.11.

9. Signs mounted on center-mount supports (SCD TC-9.30) may be mounted laterally on the support in an eccentric position when required by the plans. However, a minimum of 2 feet (0.6 meter) of sign length shall remain to one side or the other of the vertical member centerline.

10. Overlay signs erected in the field over existing extrusheet signs shall be attached by blind rivets at spacings as required in 630.04.

11. Flatsheet signs used in connection with signals supported by span wire shall be fastened to the messenger wire by special attachments in accordance with SCD TC-41.41.

12. Flatsheet signs used in connection with signals supported in a swinging condition on mast arm supports shall be fastened to the arm by a special attachment in accordance with SCD TC-41.41.

13. Exit Panels erected above extrusheet signs shall be attached by sign backing assemblies furnished with the Exit Panel.

14. Extrusheet signs shall be attached to rigid overhead supports using sign brackets in accordance with SCD TC-22.20. Signs extending more than 4 feet (1.2 meters) above or below an attachment point require the use of intermediate sign brackets.

Sign Inspection

After sign erection, the contractor shall inspect all signs under both day and night conditions. Any necessary adjustments in lateral position or orientation to correct visibility deficiencies shall be made to the satisfaction of the project engineer (630.13).

Overhead Guide Signs should typically be centered over the lane(s) to which they apply. Down arrows on the signs should normally be centered over the proper lane as viewed by the road user.

The maximum displacement of a down arrow from the center of a lane should not be more than 2 feet (0.6 meter).

Overhead Guide Signs situated on curved roadways and incorporating down arrows may have the arrow(s) adjusted within the sign and/or the entire sign moved laterally so the arrows when seen from a typical viewing distance on the curve will appear to be over the proper lane(s).

Night conditions inspection is to assure that each sign has visible and uniform reflectivity. Any signs not having proper reflectivity should be noted and cleaned or replaced by the contractor.

631 Sign Lighting

General

Sign lighting is not necessary for overhead guide signs when Type H or J reflective sheeting is used for the reflective legends. Therefore, for new installations, sign lighting will normally not be used.

Guidelines and design information on sign lighting are addressed in TEM Sections 212 and 240-7.

This section provides additional information about what to look for when installing sign lighting.

1. Check certified shop drawings, catalog cuts, etc. for luminaires, ballasts, switches and enclosures.

2. Luminaires for mercury vapor sign lighting shall comply with 731.01 and shall consist of a housing containing a reflector, lamp socket, wiring and a door containing a glass lens or refractor, meeting the following requirements:

a. The housing shall be adequately reinforced cast aluminum with a natural finish or painted gray.

b. The reflector shall be highly reflective aluminum.

c. The lamp socket shall be a porcelain shrouded mogul screw with lamp grips and a large center spring providing firm contact with a lamp base.

d. The door shall be an aluminum frame either cast with a natural finish or a formed extrusion with an anodized finish. The door shall be hinged securely to the housing and provided with a spring loaded latch. Hinges shall be stainless steel and designed so that unintentional door separation is impossible. Latches shall be stainless steel and are not to require tools for opening.

e. A flexible readily removable gasket shall be attached to the housing or door so a waterproof seal is formed when the door is closed and the gasket compressed. The glass lens shall be mounted within the door and sealed with elastic cement or a gasket.

f. The glass lens shall be borosilicate or equivalent, able to withstand hail or the thermal shock of freezing rain.

g. Drainage weepholes shall be provided in the housing or door depending upon the luminaire’s bottom or top position on a sign.

3. Mercury vapor lamp sizes shall be as specified. Ballast type shall match the specified lamp wattage. Lamp watts and ANSI code are shown in TEM Table 297-11 and SCD TC-31.21.

4. Sign lighting shall be controlled by a disconnect switch within an enclosure. The switch shall be a two-pole minimum, single throw, fused safety disconnect type rated at 600 volts and 30 amperes (C&MS Item 631.06). The fuse size shall be as specified. A solid neutral bar shall be provided.

5. The enclosure shall be weatherproof and lockable, complying with NEMA standard Type 4 ICS 1-110.15. Enclosure size shall be as specified (See SCD TC-32.10).

6. Each enclosure shall be furnished with at least one padlock. Padlocks shall have a corrosion resistant body and a corrosion proof steel shackle. All padlocks for a project are to be keyed alike from an appropriate master key number obtained by the contractor from the maintaining agency.

7. Sign service to the enclosure shall be in accordance with the plans. Service wiring cable size shall be as specified, single conductor rated at 600 volts and not less than Number 4 AWG (631.04). Sign service underground from a pull box to a foundation mounted support, or to a support mounted on a concrete median barrier, is shown on SCD TC-32.10. Sign service from a direct drop is shown on SCD TC-32.11.

8. Sign wiring from the disconnect to the luminaires shall be the size specified, single conductor rated at 600 volts and not less than Number 10 AWG (631.05). The wiring shall be fully protected within enclosures, support interiors, junction boxes, rigid or flexible conduit and luminaire housings. Wiring shall be continuous from the disconnect switch to a junction box mounted on the sign support or overpass structure. The junction box shall permit disconnection of wiring when a sign and its lighting equipment is removed as a unit. A junction box shall be installed for each sign. Wiring shall be continuous from the junction box to the first luminaire on a sign and continuous between additional luminaires on the sign.

9. Luminaire ballast shall be located within the luminaire (integral) or in a weatherproof housing attached to or beside the luminaire (contiguous). Wiring to the ballast shall be continuous with permitted disconnection at the sign support junction box (see paragraph 8).

10. The wiring routing for wired signs shall be as shown on SCD TC-31.21.

11. Luminaire supports complying with SCD TC-31.21 are specified for new installations. Support arms are of welded tubular design incorporating an attachment flange and a luminaire support plate. The arms are bolted to a continuous rectangular galvanized steel tube forming the lower portion of the sign’s glare shield. The face of the rectangular tube shall be covered with non-reflective sheeting complying with 730.20 so as to match the color of the glare shield sheeting. Support arms shall not be mounted upside down or in any other manner than that permitted by the SCD.

12. Luminaires shall be adjusted to a proper aiming angle according to the manufacturer’s instructions and inspected at night to determine if they are providing uniform illumination to the sign face.

Sign Lighting Inspection and Testing

1. In accordance with 631.11, sign lighting and electrical signs shall meet the requirements of the following tests as required by 625.19 and performed by the contractor:

a. Ground rod resistance to ground (see 632).

b. Cable insulation (megger) test (see 632).

c. Ten-day performance test (see 632).

2. During the ten-day performance test, failure of lamps, ballasts and transformers may be corrected by replacement of the faulty component but will not require restart of the entire test period.

3. The contractor should perform a circuit test on all sign lighting cable and wire conductors to determine if there are any short circuits, cross circuits or other improper connections. Circuit testing may be done in accordance with 632 .

4. The test results shall be reported to the project engineer in the test information required by 625.19. The test results should be documented.

5. During the ten-day performance test, a night inspection shall be performed by the contractor and final adjustments made to sign lateral positions and the aiming angle of luminaires to the satisfaction of the project engineer (631.11). The adjustments are to eliminate excessive brightness and glare and to obtain optimum sign face reflected brightness, uniformity of illumination, visibility and legibility.

6. Following successful completion of a ten-day performance test and after there has been a partial or final acceptance of the project, the contractor should turn over to the project engineer all manuals, diagrams, instructions, guarantees and related material. The project engineer should transfer the material to the maintaining agency. For ODOT-maintained signs, the material should be given to the appropriate ODOT District Office.

7. After the project has been accepted by ODOT, the project engineer should immediately notify the maintaining agency that as of a certain exact time and date, the agency is responsible for the maintenance.

Documentation Requirements – 630 / 631 Traffic Signs and Sign Supports

1. Ensure signs and supports are in compliance with plans and approved catalog sheets

2. Document depth, diameter, or foundations

3. Document steel and clearance maintained (if used)

4. Document support stubs (if placed)

5. Document anchors - diameter and depth (if used)

6. Document size and depth driven of drive post used

7. Document curing used on concrete

8. Measure appropriate units for foundations and/or supports used and turn in for pay

9. Document type, size, background sheeting and legend sheeting for signs

10. Measure signs and turn in for pay as per 630.14

632 Traffic Signals and 633 Signal Controllers

General (632.01)

This information is intended to serve as a guide for construction personnel where the Contractor furnishes and installs traffic control devices and appurtenances. However, it may also be useful for maintenance personnel performing the same functions. Inspection procedures for the various type traffic control devices are outlined, mainly in the form of check lists to assist project personnel in performing their duties. This information points out the various important features of each device and references the applicable specification or standard drawing. Illustrations are used for easy recognition of the device or feature being discussed.

Qualified Products List (QPL)

All 632 and 633 devices should be checked against the Qualified Products List before they are incorporated into a project.

Foundations (632.14)

See Item 630 for additional information relative to concerns in the installation of foundations for poles and controller cabinets.

Electrical Appurtenances

General

This section will be used to provide additional information about various electrical appurtenances involved in the traffic signal installations, such as pull boxes, conduit and ground rods.

Pull Boxes

Pull boxes shall be of the specified sizes (see SCD HL-30.11 and the plans), typically 18 inches (460 millimeters) or 24 inches (610 millimeters), and the specified material.

The word on the cover should be “TRAFFIC” when the pull box is part of a traffic signal system unless the plans require the word “ELECTRIC” or other marking. The word shall be formed on the surface or displayed on an attached metal plate in accordance with 725.06, 725.07 or 725.08.

The location of pull boxes shall be as shown on the plans. However, pull boxes in low drainage areas may be adjusted to eliminate drainage problems, or feasible methods of positive drainage may be used in accordance with 603 and details on SCD HL-30.11, with the approval of the Engineer.

Pull boxes located in sidewalks, traffic islands and curbed areas close to the roadway, where wide turning vehicles could drive over them, may be adjusted to eliminate the problem, or a concrete pull box with a heavy duty lid may be used with the approval of the Engineer.

Trench

Trenching shall be in accordance with 625.13 and as shown in TEM Figure 498-7. Any change in dimensions will require approval by the Engineer.

Trenching may be in earth or in paved areas, according to plan details. Trenching and subsequent restoration of surfaces in paved areas shall be in accordance with SCD HL-30.22.

Trenching work in paved areas shall be divided into two pavement depths for payment; less than 6 inches (150 millimeters) and 6 inches (150 millimeters) or greater, as described in 625.20.

The trench in paved areas may be 4 inches (100 millimeters) wide when cut by a Vermeer type trencher. In this case, the trench shall be backfilled with concrete full depth, except that the bottom 4 inches (100 millimeters) above the conduit may be 625.13 tamped backfill.

Conduit

Metal conduit shall comply with 725.04, with sizes according to the plans. It shall be made from domestically produced steel, and the domestic steel content of the conduit shall be certified by the manufacturer or supplier before it is approved for installation.

The routing of loop detector wire in conduit through curb or under shoulder shall be as shown on SCD TC-82.10.

Conduit containing cable and/or wire shall have the terminal at the high end completely sealed in an approved manner, with removable sealing compound or a molded plastic or rubber device compatible with the conduit, cable jacket and wire insulation, according to 625.12.

After placement, a conduit which will not have cable or wire pulled into it during construction shall have a pull wire installed in it, and the terminal at the high end shall be sealed with removable sealing compound, a molded plastic or a rubber device, according to 625.12.

Difficult pulling and possible jacket skinning may occur when an attempt is made to install too many cables or wires within a given conduit. The reason could be design error in new systems or attempts to insert an excess number or size of cable or wire in existing conduit.

Good electrical practice requires that the combined cross section of all cables and wire within a conduit should be less than (or equal to) 40 percent of the conduit inside area:

a1 + a2 + a3 + etc. < 0.40Ci

a = cable or wire across section area, sq. in. (mm²)

Ci = conduit inside area, sq. in. (mm²)

A calculation can be made using the above formula. The cross section area of conduit, cable and wire is shown in TEM Table 497-1.

Ground Rod

A ground rod shall be driven below groundline near the foundation of every strain pole and overhead sign or signal support whether there is power in the vicinity or not, as shown on SCDs TC-21.20, TC-32.10 and TC-32.11.

Ground rods shall comply with 725.16 and be installed in accordance with 625.16. A ground wire of insulated 600-volt No. 4 AWG 7-strand soft drawn copper shall be attached by an exothermic weld. The typical exothermic weld procedure is described in 632.

Insulating varnish shall be applied to the weld and any exposed conductor.

Exothermic Weld

The following procedure is typical and may be used unless the manufacturer’s instructions differ.

1. The end of the ground wire shall be in an un-flattened, unbent, clean and dry condition to assure a good weld.

a. Bent and out-of-round conductor wire will hold the mold open causing weld material leakage. A cable cutter should be used to make un-deformed ends. If a hacksaw is used, the insulation should first be peeled, as the saw tends to coat the cable with plastic material, which must be cleaned off.

b. Corroded cable shall be cleaned. Oily or greasy cable should be cleaned with a solvent that dries rapidly and leaves no residue. Very greasy cable can be “cooked out” by dipping into molten solder.

c. Wet cable can cause the blowing of molten metal out of the mold, and the cable should be dried by a hand torch or a quick drying solvent such as alcohol.

2. Ground rod ends which have been mutilated in driving can hold the mold open and should be cut off. Rod ends shall be clean and dry.

3. The weld mold shall be clean before use. Damp or wet molds can cause porous welds and should be dried by heating.

4. The cable shall be inserted into the side of the mold so the cable is 1/8 inch (3 millimeters) back from the center of the tap hole. The mold shall be placed on the ground rod so the cable sits on top of the rod (see TEM Figure 498-8). A clamp or locking pliers should be used on the rod to keep the mold from sliding down during the welding process, and the conductor should be marked at the mold surface so it can be verified that the conductor has not shifted before the weld is made.

5. The steel disk shall be inserted into the crucible and the cartridge contents poured on top, being careful that the disk is not upset. The cartridge should be tapped when pouring, to make sure the starting powder comes out and spreads evenly over the welding powder. A small amount of starting powder should be placed on the top edge of the mold under the cover opening for easy ignition.

a. The proper cartridge size is marked on the mold tag and is the approximate weight of the powder in grams.

b. If the proper cartridge size is not available, two or more small cartridges or part of a larger cartridge can be used.

6. The mold cover will be closed and the starting powder ignited with a flint gun. If it is necessary to hold down the cover during the flash of igniting powder, a long tool should be used and the hand should be kept away.

Power Service for Traffic Signals (632.24)

General

Power service for traffic signals shall comply with SCD TC-83.10 and the plans. It shall consist of the equipment needed to provide a pole-attached wiring raceway and disconnect switch, for use with separately furnished power cable routed from the service point to the controller cabinet. As shown in TEM Figure 498-9, unless otherwise specified, the equipment includes a weatherhead, a conduit riser with necessary fittings and attachment clamps when required, and a disconnect switch with enclosure (632.24).

A thorough review of the plans should be made to determine that the specific requirements of the maintaining agency for power service have been satisfied.

A ground wire shall be used as shown on SCD TC-83.10, leading to a ground rod installed in accordance with 632.

The LB type fitting under the controller cabinet (SCD TC-83.10) may have to be installed before erecting the pole because of interference with the foundation.

Electric Meter Base

When required, an electric meter base shall be furnished by the applicable utility and installed by the Contractor as part of the power service work.

Conduit Riser and Weatherhead

Power cable is the only type cable or wire permitted through the power service conduit riser.

The conduit riser shall terminate at the meter base, if used; otherwise, termination shall be at the switch enclosure. From there conduit connection to the controller cabinet is as shown on the plans. Conduit connection could be:

1. immediately to the controller cabinet on the same pole;

2. downward by underground conduit and possibly a pull box to a nearby foundation-based controller cabinet;

3. upward by another riser on the pole to span wire and a remote cabinet location.

The conduit riser shall comply with 725.04 and the plans, and the weatherhead shall be threaded aluminum or galvanized ferrous metal (732.16). Risers on painted poles shall be painted to match the poles.

Disconnect Switch

The disconnect switch shall be a UL listed single-throw safety switch or circuit breaker, meeting the voltage and capacity requirements of the specifications. The amperage rating of the fuse or circuit breaker shall be 5 to 10 amperes greater than the peak load rating of the equipment service. The enclosure shall be a UL listed water tight lockable stainless steel NEMA Type 4, supplied with UL listed conduit hubs, and the enclosure shall contain a solid neutral bar normally grounded to the enclosure (732.21).

Pole and Support Inspection - General

See 630 for information about pole and support inspection.

Traffic Signal Supports (632.16)

General

This section will be used to provide additional information about traffic signal supports. Various types of overhead signal supports are also depicted in TEM Table 497-4.

Strain Pole Type Support

Strain poles shall comply with the certified drawings, SCD TC-81.10 and the plans.

They shall be galvanized unless paint is specified in the plans, and the general features should be inspected in accordance with 630.

When strain poles of the embedded type are specified, they shall include an extension for embedment below groundline and a welded-on ground sleeve. The pole extension shall be sufficient to reach within 3 inches (76 millimeters) of the foundation depth as specified in the table in SCD TC-21.20, or the extension may be a minimum of 6 feet (1.8 meters) if a reinforcement cage is provided as also shown on the SCD. The cage shall overlap at least 24 inches (610 millimeters) of the pole extension and reach to within 3 to 4 inches (76 to 102 millimeters) of the foundation’s specified depth. A special foundation design is required when soil with a load bearing capacity of less than 2,000 pounds per square foot (9700 kilograms per square meter) is encountered. Embedded poles normally do not include a handhole or blind half couplings for internal wiring.

When shown on the certified drawings, and as permitted by 732.11, strain poles may be tapered tubes with a cross section which is circular or a regular polygon of six or more sides, or may be a type consisting of straight sections with a tapered effect accomplished by the use of reducers.

Strain poles used to support traffic signals or signs (SCD TC-17.10) shall be furnished with one or more span wire clamps with shackles for attachment of messenger wire (see SCD TC-84.20).

The messenger wire may be attached by wrapping twice around the pole and securing with a three-bolt clamp, as shown in SCD TC-84.20, when used on round, tapered steel strain poles.

Erection of these poles shall be in accordance with the general procedure given in Section 630, except as noted in this section.

For the initial rake of strain poles of the anchor base type, leveling nuts shall be adjusted to provide a rake of one-eighth to one-half inch per foot (11 to 42 millimeters per meter) of pole in the direction opposite to the contemplated span wires and are to be made snug tight. Further adjustment may be necessary to assure that the strain poles are essentially vertical after the application of span wire load.

For the initial rake of strain poles of the embedded type, poles shall be embedded in concrete to provide a rake of one-eighth to one-half inch per foot (11 to 42 millimeters per meter) of pole in the direction opposite to the contemplated span wire and braced. The age of the concrete before it is considered cured, before the bracing may be removed, and before the permitted application of span wire load, shall be in accordance with 630.

Single Arm Support

Single arm supports shall comply with the certified drawings, SCD TC-81.20 and the plans. General features of the support shall be inspected in accordance with 630, and except as noted in this section, erection of the support shall be in accordance with the general procedure given in 630.

Welds shall be inspected according to 630 and the galvanizing inspected according to 630.

For arms of two telescoping pieces, a 15 inch (380 millimeters) overlap is required. The overlapped arms shall be secured with a stainless or galvanized steel through-bolt with hex head or nut(s). Arm caps shall cover at least 50 percent of the end area (732.11).

An arm clamp with clevis shall be furnished at each signal position, as well as a hole with a rubber grommet for the outlet of signal cable.

The installation of small signs and their attachment to the arms should be checked. Any possible interference between swinging signals and signs should also be checked.

Blind half couplings shall be located on the pole of the support for mounting pedestrian signal heads or controller cabinets when required by the plans.

Signal heads shall be installed so that their bottom surface is 16 to 18 feet (4.9 to 5.5 meters) above the roadway. The signals shall be installed at essentially the same elevation. Drop pipes should be used only when necessary to maintain the clearance between 16 to 18 feet (4.9 to 5.5 meters). If the clearance without a drop pipe will be slightly over 18 feet (5.5 meters), it is permissible to omit the drop pipe, with the maintaining agency’s approval.

Initial rake shall be adjusted so that under the load of signals, the pole will assume an essentially vertical position and the arm rise be within the limits specified on SCD TC-81.20, i.e., 3 inches (76 millimeters) minimum and 12 inches (300 millimeters) maximum.

Sag and Vertical Clearance

TEM Figure 498-13 illustrates sag guidelines and vertical clearance standards for traffic signals.

Signal Span Messenger Wire and Appurtenances

General

This section will be used to provide additional information about signal span messenger wire and appurtenances.

Signal Messenger Wire and Cable

Messenger wire and accessories shall comply with SCD TC-84.20 and 732.18. Messenger wire diameter shall be in accordance with the plans.

The height at which the messenger wire is to be attached to the pole will, in some instances, be shown on the plans. In cases where this is not shown, the Contractor is responsible for determining the proper attachment height. This determination shall consider the relative elevation of pavement to pole foundation top, the desired clearance between pavement and the bottom of each signal, i.e., 16 to 18 feet (4.9 to 5.5 meters), the sag in the messenger wire (3 to 5 percent), and the height of each signal.

Alternate methods of attaching messenger wire to strain poles may be used, as follows:

1. Span wire clamp with clevis, anchor shackle and thimbles on the messenger wire, or

2. Messenger wire wrapped twice around the strain pole and secured with a three-bolt clamp of the proper size, when used on round, tapered strain poles.

If the messenger wire attachment to strain poles makes use of the alternative with pole clamps and anchor shackles, the wire is to be hooked through the shackle using a thimble and secured with a three-bolt clamp. A preformed guy grip shall not be used for messenger wire attachment at the pole. Guy grips of the proper size may be used at bull rings (aerial corners)

Thimbles with a correct groove size for the messenger wire (or the wire and eye of guy grips) are to be used at anchor shackles and bull rings. When three-bolt clamps are used, the wire tail is to be served as shown in the Section on Messenger Wire. See the Section on Messenger Wire for the installation procedure for preformed guy grips.

Thimbles with a correct groove size for the messenger wire or the preformed guy grip shall be used to connect to anchor-type shackles or to bull rings at span wire aerial corners.

Messenger wire sag shall comply with 632.22 and the Section on Sag and Vertical Clearance.

The signal cable shall be attached to the messenger wire by lengths of preformed lashing rod.

The lashing rod shall be the proper internal diameter to snugly hold the cable, but not cut into its jacket. See the Section on Wire Lashing for further information.

A drip loop shall be formed in the signal cable at each weatherhead, and should extend at least 6 inches (150 millimeters) below the weatherhead (see TEM Figure 498-14).

Cables or groups of cables up to a maximum of four, hanging within pole interiors, shall have their strain relieved by cable support assemblies as described in 632, TEM Figure 498-14 and SCD TC-84.20.

Messenger Wire Served Ends

Messenger wire may be attached to various accessories by looping the wire to make an eye.

The wire end shall be secured by a three-bolt clamp, and the cut wire end or tail shall be “served” with construction wire or clamped with a sleeve device as shown on SCD TC-84.20. The following illustrations show both serving methods for the wire tail:

Preformed Guy Grips

Preformed guy grips are made of helically shaped high-strength steel wire. They are available in sizes fitting the outside diameters of messenger wire and form an eye permitting attachment to various accessories.

As shown in SCD TC-84.20, they should be used at bull rings of span wire aerial corners (see the following illustration). Thimbles are used in the eye of grips in accordance with standard details in the SCD.

Grips are installed on an end of the messenger wire by wrapping a first leg of the grip to the messenger wire. In most cases, the accessory to which the grip is to be attached must be inserted in the eye of the grip with a thimble before the second leg of the grip is wrapped. The second leg is then applied to the combined first leg and messenger wire. The following illustrations show the wrapping sequence.

Guy grips shall not be used on messenger wire used for span wire sign supports. In this application, wind load on the signs can cause failure of the grips (see SCD TC-17.10). Guy grips shall not be used for attachment to signal strain poles (SCD TC-84.20(5)).

Cable and Wire

In certain instances, the plans will assign a color code usage for each cable, or a typical usage by color code. All connections should be made observing these assignments, and any deviations, if determined necessary, should be recorded. When a color code usage is not provided, good electrical wiring practice would still dictate that color code wiring on the project be consistent.

Typically, white is reserved for the neutral or common leg of a circuit. The following provides additional information about various types of cable and wire contained in Table 732.19-1:

1. Signal cable is used as the electrical connection between signal heads and the controller cabinet at an intersection. The cable may be either IMSA 19-1, which has a jacket of polyvinyl chloride, IMSA 20-1, which has a polyethylene jacket, or IPCEA S-61-402. The number of conductors and wire gage shall be as specified on the plans. Conductors shall be of copper and stranded, and conductor insulation shall be color coded. Splices are not permitted in signal cable (632.23), and the cable should be scanned to be sure that there are none.

a. As temperatures decrease, signal cable gets stiffer and harder, becoming brittle when below freezing. In very cold weather, the cable should be handled with care so as not to damage the jacket or insulation when unreeling, flexing and installing. The method of measurement of signal cable is shown in TEM Figure 498-16.

2. Interconnect cable is used as the connection between intersections for systems of signals (although there is no significant difference between signal and standard interconnect cable).

a. The cable may be either IMSA 19-1, IMSA 20-1 or IPCEA S-61-402 as in signal cable, or twisted pair/shielded interconnect cable conforming to RUS PE-39 may be required by the plans.

b. Twisted pair/shielded cables are less prone to pick up induced current as a result of nearby electrical devices or magnetic fields, and are necessary for certain types of communication systems which may be used to interconnect signals. The number of conductors and wire gage shall be as specified. It should be noted that in the case of twisted pair/shielded cable, the number of conductors is typically referred to as the number of pairs (pair count), i.e., six conductor cable would be referred to as a three-pair cable. Conductors shall be of copper and are usually solid.

3. Interconnect cable of the integral messenger type is aerial self-supporting cable with a "figure 8" cross section. The cable may be either IMSA 19-3, which has a jacket of polyvinyl chloride, or IMSA 20-3, which has a polyethylene jacket. Shielded versions, IMSA 19-4 and IMSA 20-4, may be required by the plans. The number of conductors and wire gage shall be as specified. Conductors shall be of copper and stranded, and conductor insulation shall be color coded.

a. Twisted pair/shielded interconnect cable of the integral messenger type conforming to RUS PE-38 may also be required by the plans.

4. Loop detector wire is laid in turns in saw slots cut into the pavement and routed by the groove to the edge of pavement and to a pull box. The wire is single-conductor No. 14 AWG.

a. The conductor shall be of copper and stranded. Loop detector wire consists of detector wire inserted into a flexible plastic tubing (732.19) meeting specifications IMSA 51-5. The tubing shall encase the wire completely from the splice at the lead-in cable through the entire loop turns and back to the splice.

5. Lead-in cable for detector loops is spliced to loop wire and routed to detector units in the controller cabinet. The cable shall be two-conductor No. 14AWG with jacket of 0.04 inch (1 millimeter) minimum black polyethylene and insulation of polyethylene. Each conductor shall be stranded copper. The conductor pair shall be twisted and shielded.

6. Lead-in cable for magnetometers is spliced to the lead which is a part of magnetometer probes and routed to detector units in the controller cabinet. The cable is four-conductor No. 18 AWG with a jacket of 0.026 inch (0.66 millimeter) minimum high density polyethylene and a low capacitance insulation. Each conductor shall be stranded copper, and insulation shall be color coded. The four conductors shall be twisted.

7. Power cable is used as the connection between the service pole or service drop and the controller cabinet. The cable normally is two-conductor and UL:RHH/RHW/USE type. The wire gage shall be as specified. Conductors shall be color coded, of aluminum and stranded.

a. Stranded copper may be substituted with an AWG one gage higher (wire one size smaller).

b. When specified, power cable may be three conductor. Single conductor cables may be substituted for a two (or three) conductor cable, but color coding should still be provided.

8. Service cable is used to bring power to the vicinity of an isolated intersection. The cable is normally two-conductor (duplex) and XHHW type or cross-linked polyethylene with a 0.045 inch (1.14 millimeter) minimum jacket. The wire gage shall be as specified. The cable is aerial self-supporting with one conductor being an uninsulated ACSR (aluminum conductor, steel reinforced) messenger wire. An insulated conductor of stranded aluminum is twisted around the messenger. Stranded copper with an AWG one gage higher (wire one size smaller) may be substituted for the aluminum conductor. Three-conductor (triplex) may be specified where two insulated conductors are twisted around the messenger wire. The uninsulated messenger serves as the grounded neutral of the power supply.

9. Ground wire is used to connect signal or sign supports to ground rods. The wire shall be single-conductor No. 4 AWG made of seven-strand soft drawn copper with white insulation and rated at 600 volts. The wire is used as part of the 625.16 Ground Rod item.

Lashing of Overhead Cable

A preformed helical lashing rod shall be of the proper internal diameter to tightly secure overhead cable(s) to the messenger wire. A lashing rod should not be loose or so tight as to be impressed deeply or cut into the cable jacket. If either deficiency is observed, the proper internal diameter may be determined by the following formula: C approx. = (0.85) (D+m), where C is the lashing rod internal diameter, D is the cable jacket diameter and m is the messenger wire gage (all dimensions in inches (millimeters)).

For groups of several cables of varying diameter, the internal diameter of the lashing rod may be best determined by a graphic layout to scale.

Signal cable routed on messenger wire should neatly pass the bull rings in its path. Also, signal cable routed around an aerial corner formed in the span wire at a bull ring should have a radius in its routing small enough to form a tangency with the bull ring.

Cable Support Assemblies

As shown in TEM Figure 498-14, a cable support assembly makes use of a flexible tubular wire mesh device called a cable grip which has a gentle holding action over its length and which is used to eliminate strain or damage to the jacket of cable(s) hanging in the interior of poles.

The support assembly consists of the grip attached to a single “U” eye support bale and a sling when necessary. The grip may be used on an individual cable or a group of cables up to a maximum of four (see 632.21). The grip shall be the proper size and strength for the cable(s), of stainless steel or tin coated bronze, and may be either a “closed” or “split with rod” type. The split type is used when a cable end is not available. In this application, the grip mesh is not a continuous tubular weave, but is split for wrapping around the cable(s) and is secured by a rod which is inserted through alternate weaves at each side to form a tube.

The support’s bale shall be hung over the pole J-hook if sufficient length is available; otherwise, a sling shall be made of messenger wire, clamps and thimbles. The sling wire is to be passed through the bale eye, adjusted to the proper length and hung on the J-hook.

Pole interiors should be checked by removing pole caps to verify that cable support assemblies are in place, hung on the J-hook and properly adjusted to eliminate cable jacket strain.

Aerial Interconnect Cable

For aerial interconnect cable, the following standards and guidelines apply:

1. Aerial interconnect cable and accessories shall comply with SCD TC-84.20 (illustrated in part in TEM Figure 498-15). Interconnect cable may be supported on separate messenger wire or be the integral messenger self-supporting type with a "figure 8” cross section, if specified on the plans.

2. Metal poles with messenger wire supported interconnect cable are to be furnished with pole clamps. The pole clamp may provide clevis(es) to which the messenger is attached and terminated, or may provide a stud to which a clamp assembly can be bolted.

3. Messenger wire ends are to be looped and secured with three-bolt clamps or a messenger vise, or a preformed guy grip dead end may be used (see 632). If clamps or vises are used, the wire tail shall be served (see 632). Thimbles with a correct groove size for the messenger wire shall be used to connect to the clevis of the pole clamp.

4. When messenger wire is to be grounded to a metal pole, a ground clamp, an insulated ground wire and a bolt tapped into the pole shall be used (also see item 10 in this section).

5. Wood poles with interconnect cable shall be fitted with through-bolts holding a clamp assembly or with a thimble eye-bolt to which the messenger may be attached and terminated.

6. The clamp assembly shall be suitable to the type of cable support, either messenger wire or self-supported cable with "figure 8" cross section. Clamp assemblies for "figure 8" interconnect cable differ slightly from those intended for use with separate messenger, inasmuch as the clamp used with "figure 8" must allow a small gap for the web of the "figure 8" cable which joins the messenger to the cable.

7. When messenger wire or "figure 8" cable is to be grounded on a wood pole, a ground clamp and an insulated ground wire stapled to the pole and covered by a molding shall be used (also see Item 10 in this section). The ground clamp used with "figure 8" cable shall be a type with teeth to penetrate the jacket over the messenger. The ground wire shall be bonded to an existing ground wire or to a ground rod.

8. Standard interconnect cable shall conform to C&MS Table 732.19-1 and have the number of conductors and wire gage specified. There is no difference between standard interconnect cable and signal cable, only in the application. Interconnect cable of the shielded type may be specified in the plans. The interconnect cable should be marked with the correct nomenclature. Solid conductors are not permitted (732.19) unless specified in the plans. Splices may be used on long lengths of interconnect cable (632.23) and shall be accomplished only in weathertight splice enclosures. Splice enclosures may be either aerially located on the messenger wire or be a pole-mounted box type (see SCD TC-84.20). Where the aerial enclosure is clamped to the span, it should be within 2 feet (0.6 meter) of a pole to improve accessibility. No measurement allowance is given for splices.

9. Aerial interconnect cable is to have a sag between three to five percent of pole spans or is to match existing utility lines.

10. Messenger wire supporting interconnect cable, and the integral messenger of self-supporting type cable, is to be grounded in cable runs at the first and last poles and on intermediate poles at intervals not to exceed 1200 feet (366 meters) (also see item 4 of this section for grounding on metal poles, and item 7 for grounding on wood poles).

11. As temperatures decrease, interconnect cable gets stiffer and harder, becoming brittle when below freezing. In very cold weather, the cable should be handled with care so as not to damage the jacket or insulation when unreeling, flexing and installing.

12. Standard interconnect cable may be attached to supporting messenger wire by lengths of preformed lashing rod or by spinning wire. Lashing rods shall be of the proper internal diameter to snugly hold the cable but not cut into its jacket (see 632).

13. Aerial interconnect cable of the integral messenger self-supporting type (with a "figure 8” cross section) shall have its wind stability increased by being twisted or spiraled once every15 feet (4.6 meters) of span. This is done by clamping the tensioned cable to every other pole and then going to intermediate poles and twisting the cable before tightening their attachment clamps.

14. When the interconnect cable is attached to a pole and continues in a relatively straight line past the pole, this is an intermediate support; whereas, if the interconnect cable turns at the pole, it is a corner or turning point. Certain types of clamps may be well suited for intermediate support applications, while other designs are required for corner clamps. The clamps shown on the left side in SCD TC-84.20 are usually not suitable for corner clamps if the change of direction is more than about 10 degrees. See SCD TC-84.21 when the change of direction is more than about 10 degrees.

Method of Measurement for Cable and Wire

TEM Figures 498-16 through 498-20 illustrate the method of measurement for signal cable, interconnect cable, detector lead-in cable, power cable and service cable, respectively. 632.29 also specifies the method of measurement for cable and wire.

Signal Equipment and Wiring

General

This section will be used to provide additional information about other signal equipment and wiring.

Controller Cabinet

While the layout of controller cabinets may vary, the following requirements and guidelines apply:

1. The prewired cabinet should be checked against certified drawings, the wiring diagram for the cabinet and the plans.

2. The cabinet should be fitted with a small door-in-door (police door) unless otherwise specified. The cabinet should be in good condition, revealing no evidence of damage, with its material free of cracks and pinholes. The doors and seals should fit properly. The cabinet exterior should appear as metallic aluminum unless a color is specified. The cabinet interior may be similar to the exterior or may be flat white. The method of cabinet mounting should be as shown on the plans and the cabinet should be securely mounted.

3. Cabinets equipped with solid state controllers shall be provided with a suitable number of sturdy adjustable metal shelves to mount the specified equipment and to provide the required space for designated future equipment (733.03).

4. The equipment shall be arranged for easy withdrawal and replacement, without the necessity of disturbing adjacent equipment. The permanent location of equipment within the cabinet, as well as the shelves themselves, should allow free circulation of air and not restrict air flow from fan ducts or vents. Components on shelves and devices on the door shall be arranged so that a 1 inch (25 millimeter) minimum space separates them when the door is closed. This minimum space shall not be compromised by plugs, wires, controls or similar items. Terminals and panel-mounted devices with exposed contact points located next to shelf mounted equipment shall be provided with spacers, shelf lips or other means to assure that component units cannot be accidentally moved into contact with any exposed electrical terminal points. A minimum 4 inches (100 millimeters) clear area from the bottom of the cabinet should be reserved for the routing of cables. No shelf, component or panel-mounted item shall be located in the bottom 6 inches (150 millimeters) of cabinets, with the exception that terminal blocks only in pedestal or pole mounted cabinets may be installed as close as 4 inches (100 millimeters) to the bottom.

5. Ready accessibility should be provided for items such as load switches, flasher, relays, terminal blocks and fuses which are mounted on or plugged into panels on the cabinet back or sides. Switches, controls and indicator lights should be easily operable and visible without having to move equipment from their positions.

6. Major equipment items should bear a name plate, brand or indelible marking for identification as to type, model, catalog number and manufacturer’s name or trademark.

7. The furnished controller unit should be checked for the correct type, number of phases, and available control functions required by the plans. Controller units should be furnished with all auxiliary equipment necessary to obtain the operation shown in the plans.

8. When specified, other equipment may be a part of the prewired cabinet, such as: a coordinator, an on-street master, interconnection equipment, preemption equipment, time clock or weekly programmer, and special relays.

9. Furnished detector units should be checked to see if the correct quantity is installed, and the proper type used with each loop and each detector phase. When multi-channel detector units are furnished, the plans may require the provision of special cabinet wiring and an adapter harness to allow single channel detector units to be readily substituted.

10. The prewired cabinet should also be checked for the following auxiliary equipment:

a. A forced air ventilating fan automatically controlled by a thermostat shall be furnished.

b. A conflict monitor shall be furnished. When the plans so specify, according to 733.03, an increased capability monitor shall be furnished. The minimum number of monitor channels, related to the number of phases for the intersection, should conform to 733.03.

c. Load switches should be provided in sufficient quantity for the interval sequence shown in the plans. The switches shall be solid state NEMA triple signal type with input indicator lamps. The minimum number of load switch sockets furnished, related to the number of phases for the intersection, shall conform to 733.03.

d. A flasher (or flashers) shall be solid state NEMA type.

e. Relays required for the proper operation of the specified equipment shall be furnished.

f. Lightning protection devices shall be furnished for the protection of solid state controllers. They should be located on the incoming power line and on loop detector leads where these connect to the terminal block. When solid state coordinators are furnished, they should be protected by devices across each conductor and ground on the interconnect cable (see 733.03(A.2.f.)).

g. A convenience outlet and lamp shall be furnished. The outlet should contain at least one standard three-wire plug receptacle of the ground-fault circuit-interrupting type. The lamp should be an incandescent type, located in the upper part of the cabinet, and controlled by a switch.

h. A main power breaker shall be furnished. The fan, convenience outlet and lamp should be wired on a branch of the AC+ power line preceding the main breaker, so that these may be operated independently of the main breaker control. This preceding branch should itself contain an auxiliary breaker rated at 15 amp.

i. A radio interference filter should be installed in the incoming AC+ power line between the main breaker and solid state equipment. If the equipment furnished does not provide signal and flasher circuit switching at the zero voltage point of the power line sinusoid wave form, filters should also be provided for the load switches and flasher.

j. A manual control cord with push button should be furnished only when the plans so require (733.03). The cord should be at least 5 feet (1.5 meters) long.

k. Switches required for the proper operation of specified equipment should be furnished and labeled as to function and setting position. The following switches should be grouped behind the small door-in-door (police door): signal shutdown switch, flash control switch and an automatic/manual transfer switch (when manual control is specified).

l. Terminal blocks should not be obstructed by other equipment. Terminal points should accept spade type wiring terminals except for incoming power terminal points which may be either the type to accept bare wire or spade terminals. Contact between adjacent terminal points may be either by bus bar or by wire jumpers with spade terminals.

11. The incoming power bus should be fed from the line side of the incoming 120 VAC power line after the circuit has passed through the main power breaker. A signal bus relay should control power to the bus supplying power for the signal load switches. The requirement for radio interference filters (733.03) should be adhered to, with the buses supplying load switches and flashers being filtered if load switches do not switch at the zero voltage point of the power line sinusoid wave form. A common terminal bus insulated from the cabinet should be furnished for the connection of the neutral wire of the incoming 120 VAC power line. This common bus should have sufficient terminal points to accommodate all potential cabinet wiring as well as field wiring. A separate common terminal, insulated from the panel, should be used for the interconnect common (if interconnection is a part of the system).

12. The cabinet should include a ground bus bar with an adequate number (at least three) of ground terminal points (733.03). This bus bar should be grounded to the cabinet. The ground bus bar will normally be bonded to the common terminal bus using at least a No. 8 AWG copper wire.

13. Wiring bundles should be neatly arranged and grouped as to voltage and function, and they should be lashed or restrained so that they do not interfere with the access to equipment, including terminal blocks or buses. The harnesses should be of sufficient length and should be easily traced through the cabinet. All conductors should be stranded, with labeled spade type terminals or plug connectors. The wiring should be color coded, with solid white for the AC common, black for the AC line side power (AC+), and solid green or white with green stripes for the safety ground.

14. Incoming cable and wire should be identified by tags or bands (632.05). The size, material and method of tag or band identification should be in accordance with 725.02, except that marking may be by indelible pen on plastic tags instead of embossed letters. The identification on the tags or bands should conform to the wiring diagram for the cabinet and its intersection, with typical abbreviations in accordance with the Table in 632.05 (reproduced in Table 497-2).

15. Two copies of the schematic and wiring diagram for each cabinet and its intersection should be furnished by the Contractor. The diagrams are to be updated to reflect any changes made during construction. The diagrams should be neat and legible, on durable paper, and folded in a moisture-proof envelope fastened to the cabinet interior.

Cable and Wire Identification

As noted in 632.05, cables and wires shall be identified as shown in TEM Table 497-2.

Vehicular Signal Heads and Wiring

Illustrations of the signal head visors, hangers and wiring discussed herein are presented in TEM Figure 498-21.

1. Signal heads shall conform to the plans, 732.01 and SCD TC-85.20. Signal heads shall have the correct number of faces (one-way, two-way, three-way or four-way) and each face shall be made up of the correct number of optical sections (one, three, four or five). Sections shall be of the correct lens size, i.e., 8 or 12 inches (200 or 300 millimeters), color and ball or arrow configuration. Arrow lenses are only to be the 12 inch (300 millimeter) size. It should be noted that arrow lenses are made in Rights, Lefts and Throughs (up). The use of the proper arrow lens should be checked.

2. Lenses shall be aligned properly in their frames so their optical configuration directs most of the light to the forward sector.

3. As noted in TEM Section 420-4.2, signal heads shall have a yellow finish, unless otherwise specified in the plan.

4. Cutaway type visors (732.01) shall be fastened to each optical section, unless open bottom tunnel visors or other types are specified, and the interior finish of the visors shall be flat black.

5. Signals should be clean and the assembly tight. Gaskets should be in good condition and lens door hinges and latches should be in good working order. All openings not used for mounting purposes shall be closed by waterproof caps.

6. Five-section faces, arranged in accordance with SCD TC-85.20 and the plans, are to use galvanized pipe, elbows and tubular hardware, painted to match the signal head.

7. Swinging signals shall be installed in a plumb condition. A balance adjustor should be used only when necessary to achieve plumb (632.06).

8. Swinging signals suspended from a mast arm shall be fitted with a universal hanger permitting swinging in both longitudinal and transverse directions (632.06).

9. When specified by the plans, disconnect hangers shall be used with signal heads.

10. Drop pipes, 1 1/2 inch (38 millimeter) diameter galvanized pipe, are a source of trouble and are aesthetically unattractive; therefore, they are intended to be used only when they are necessary to permit signals to be suspended above the roadway within a clearance of 16 to 18 feet (4.9 to 5.5 meters). Signals supported by span wire, with sag required between 3 and 5 percent (SCD TC-84.20), shall be brought to proper clearance by adjusting the attachment height of the span wire to the poles. Because of the 2 foot (0.6 meter) clearance tolerance, drop pipes should not be necessary in most cases.

11. When the plans so specify, backplates shall be fitted to signal heads.

12. Signal cable shall be routed into the interior of heads through the entrance fitting using a grommet. The cable shall be routed to each face’s terminal block, which is typically in the yellow indication section but may be in the green section. Conductors shall be fitted with spade type terminals and shall be fastened securely to the correct terminal points. Conductors shall be identified according to the wiring diagram. Signal cable shall not be spliced, either between signals or in signal face interiors.

13. External signal cable shall to be fashioned into a drip loop extending at least 6 inches (150 millimeters) below the entrance fitting but shall not chafe on the signal.

14. Lamps may be either incandescent (732.04.B)or light emitting diode (LED) (732.04.C) as specified in the plans Incandescent lamps shall have a clear glass envelope and a rated life of 8000 hours. Lamp sockets shall be rotated so as to position the open portion of each incandescent lamp filament in an upward position. All vehicular signal lamps shall be prequalified in accordance with 732.04(B) & (C).

15. Each face of a signal head shall be oriented to its approach of traffic and its locking device securely tightened. Orientation or aiming of standard signals should be done so that the maximum light intensity from a standard signal is directed slightly below the horizontal center; thus, on a level approach, the face of the signal should be essentially vertical. When an approach to a signal is on a grade, the signal may be tilted slightly to point the signal axis parallel to the grade of the approach. Horizontal aiming should orient the axis of signal display parallel to the centerline of the approach for straight approaches when the signal is over the roadway. When the approach roadway is curved, or when a signal is not over the roadway, the axis should be directed at a point on the approach which is 175 to 625 feet (54 to 191 meters) in advance of the intersection, the distance being dependent on the speed of approaching traffic. For convenience, OMUTCD Table TS-1 has been reproduced in part as TEM Table 497-3.

16. When a vehicular traffic signal head has been erected and faces approaching traffic, it shall either be in operation as a stop-and-go signal or a flasher, or it shall be covered or bagged. This is an OMUTCD requirement (OMUTCD Section 6B-19) and cannot be ignored. Typically, the plans will contain an item for “Covering of Vehicular Signal Heads” which will require the contractor to cover, maintain the covering, and subsequently remove the covering when the signal is ready to commence operation.

17. Normally, the plans will provide the “covering” item for each new signal head, but will not provide them for any existing heads which are to be removed. The intent is that “covering” will be necessary for the new heads until they and their associated controller and wiring have been checked by circuit testing (see 632), while any existing signals at the intersection will continue to control traffic. When the new signals are uncovered and placed in operation, the existing signals can be quickly removed. Specific maintenance of traffic requirements in any plan may require a different means to assure the unused signals are not exposed to traffic.

Optically Programmed Signal Heads

Programmed heads (see TEM Section 420-4.6) shall conform to certified drawings, 732.02 and 732.03, and the plans. They are to have the correct number of optical sections making up each face. Programmed heads have many points of similarity to regular heads. Items 2, 3, 5, 11, 12, 13, 16 and 17 of 632 also apply to these signal heads. For more detailed information, see publications by the manufacturer.

Each optical section shall be fitted with a visor (732.02 and 732.03) and the interior surface of visors shall have a flat black finish.

Programmed heads shall be mounted in a manner permitting little or no motion. If mounted on a mast arm, a rigid adapter shall be used. Heads of more than three vertical sections mounted on a mast arm shall be fitted with pipe backbracing, as shown on SCD TC-85.20. The pipe shall be a minimum of 17 inches (430 millimeters) behind the signal center axis so that adequate clearance is provided for the programming procedure. If heads are supported by span wire, a tether messenger wire shall be attached to a fitting in the bottom of the signal’s lower section.

Customarily the manufacturer’s representative will program the signals, but in accordance with the plans, the contractor is responsible for the correct aiming and masking of the signal so as to be visible to drivers or pedestrians only in the area indicated on the plans.

Signals are pre-tilted to cover most situations. The yellow indication section should be aimed first and the other sections aimed similarly. The housing shall be opened and the lamp collar and diffuser removed. The roadway inverted image should be observed on the surface of the glass with the eye held a distance of 2 feet (0.6 meter) behind. The image observed is where the optics are pointed. The tilt of the integral adapter shall be adjusted so the horizon appears at the lower third of the glass. The adapter screws are then to be tightened. All sections shall be at the same tilt angle.

The signal shall be rotated horizontally so the image on the glass covers the proper roadway lane(s). The bolts of the mounting adapter shall be loosened and the signal rotated around its serrated surface. The movement of traffic should be examined on the glass. When the roadway image appears correct, that is, pointed in the direction where it should be seen, all screws may be tightened. All sections of the signal should now be adjusted and rigid in their mountings, properly aimed and ready for masking.

The yellow indication section of the signal should be masked first since it transmits a brighter image. The other colors can then be masked identically.

Masking requires the use of opaque tape furnished by the manufacturer. The tape shall be applied to the glass, up to the edge, and squeegeed flat to remove air bubbles. The tape initially should be applied horizontally to the glass to cover the image of the sky and that portion of the roadway which is distant. After this is done, tape should be applied to the images on the sides of the lane(s) where the signal is not to be visible. In many cases, signal visibility is desired for a left turn lane only, and visibility to the adjacent through lane should be masked. Excess tape extending beyond the edge of the glass should be trimmed away, taking care not to cut on the surface of the glass.

The reduced area on the glass should be checked to verify that its image is the only area in the roadway which should see the signal. The lamp collar and diffuser may now be replaced and the housing latched.

The boundaries of the area in the roadway where the signal is to be visible should be explored on foot to verify that the head is properly programmed.

Pedestrian Signal Heads

Pedestrian signal heads shall conform to 732.05, certified drawings, the plans and SCD TC-85.10. Signals shall have the correct type of light source and lettering height in accordance with the plans (632.08).

Housings shall have a black finish, unless otherwise specified (732.05). Visors shall be fitted over each message, except one type may have the entire face protected by a flat black sunshade fastened close to the lens. The interior surface of visors shall be flat black finish. Signals should be clean and the assembly tight. Gaskets should be in good condition and lens door hinges and latches in good working order.

Housings shall be positioned with a minimum set back of 2 feet (0.6 meter) from the curb and a height of 8 to 9 feet (2.4 to 2.7 meters) above the sidewalk for adequate clearance. The heads shall be oriented toward their crosswalk and locked securely in position.

Lamps for pedestrian signal heads may be either incandescent (732.04.A) or light emitting diode (LED) (732.04.C) as specified in the plans .

Pedestrian push buttons shall conform to Section 404-2, certified drawings, and 732.06. Push button housings shall have a yellow finish, unless otherwise specified. The push button shall be positioned 3.5 to 4 feet (1.1 to 1.2 meters) above the sidewalk.

Push buttons on metal poles shall be installed over a 3/4 inch (19 millimeters) maximum field drilled hole with edge protected by two coats of zinc-rich paint and a rubber grommet inserted.

The push button housing curved back shall be positioned over the hole, wiring routed through to the electrical mechanism and the housing secured by stainless steel screws. Unused holes in the housing shall be plugged. Push buttons on wooden poles shall have their wiring in conduit connected to a fitting of the signal support.

Signal head supports (conduit and fittings) on wooden poles shall be grounded, using a ground clamp and an insulated ground wire stapled to the pole and covered by a molding.

If specified in the plans, pedestrian signal heads may be covered in accordance with 632.25.

OMUTCD Section 2L-3 addresses standards for the signs used where push buttons are provided to actuate pedestrian signals. The sign legend shall conform to the plans.

Loop Detector Slot and Wire

TEM Figures 498-23 and 498-24 illustrate details related to the following discussion of loop detector slots and wiring.

1. Slots cut into the pavement forming rectangular detection loops shall be in accordance with the plans and SCD TC-82.10.

2. The slots shall be a minimum of 3/8 inch (9.5 millimeters) in width and shall have a minimum depth of 2 inches (50 millimeters) in concrete and 4 inches (100 millimeters) in asphalt concrete. SCD TC-82.10 requires that loop corners be made at a drilled or bored hole, about 1 1/4 inches (32 millimeters) in diameter, and with the same depth as the saw slot. Any sharp edges at the saw slots and the holes shall be chiseled out.

3. The slot depth shall accommodate the specified number of turns of wire laid so that the uppermost wire has a covering of at least 3/4 inch (19 millimeters). The number of wire turns shall comply with the plans and the table in SCD TC-82.10 (also shown in Figure 498-23). A separate slot leading from the loop to the pavement edge is typically cut for each loop.

4. When permitted by the Engineer, loops installed in new asphalt concrete may be sawed and the loop wire(s) embedded with sealant in a subsurface course with subsequent covering by the surface course.

5. Some plans may specify the use of preformed loops placed on the pavement for covering by a surface course of asphalt concrete.

6. If the problem of loop installations in brick streets is encountered, the Engineer should consult with the local traffic engineer for recommendations.

7. Loop locations may be adjusted to avoid manholes. Loops should not be placed across pavement joints. Instead, lateral and longitudinal adjustments should be considered, with the approval of the project engineer. If joint crossing is unavoidable or major pavement cracks are encountered, the following techniques may be used (see Figure 498-24).

a. In Technique A, the loop wires are laid over the joint or crack within a 3 inch (75 millimeter) square or circular hole cut to slot depth. The wires are laid in an “S” shape and the hole filled with elastic joint material or asphalt concrete.

b. In Technique B, the slot at the joint or crack is saw cut to twice-normal width and depth. The wires are laid so as to conform to the deepened slot which is injected with soft setting butyl rubber up to the depth of the original slot. The original slot depth and the remaining perimeter of the slots are embedded with standard sealant cured to a flexible state.

c. In Technique C, the slot at the joint or crack is enlarged. The wires are encased in a length of plastic tubing which should be large enough to loosely hold all wires and may be slit lengthwise to facilitate construction. Before placing it in the slot, the ends and the longitudinal slit are to be taped shut to prevent the entry of loop sealant. The enlarged slot is then filled with loop sealant.

8. Before loop wire is placed, all slots shall be brushed, blown clean of loose material and completely dry.

9. Loop detector wire shall be single-conductor No. 14 AWG insulated wire, type IMSA 51-5 with stranded copper conductors, unless otherwise specified. The wire should be marked at intervals with the wire gage, UL label and type. The detector wire is contained inside a flexible plastic tube, as required by IMSA 51-5.

10. The correct turns of loop wire (TEM Figure 498-23), up to a maximum of four, shall be placed in the slots, to comply with 632.23 and the plans. The wire shall be pushed to the bottom of the slots with a blunt wooden tool (or equivalent) to avoid damaging the insulation.

11. The wires with tubing at the pavement edge or curb shall be led into a conduit of the size shown in SCD TC 82.10. Care should be taken to prevent excessive slack at the point where the wires enter the conduit. The high end of the conduit shall be sealed in accordance with SCD TC 82.10.

12. The detector wire shall be twisted in the conduit leading from the pavement edge to the pull box. The flexible plastic tubing shall cover the wire completely from the splice at the lead-in cable, through the entire loop turns and back to the splice. The tubing provides extra protection from abrasion and allows the wire to slide inside the tubing in case of pavement shift or cracks, thus minimizing the possibility of breakage. Since wire/tubing includes an air pocket, it will tend to float to the surface when sealant is applied to the slot. For this reason it is usually necessary to wedge short lengths of the tubing, or similar devices, into the slot to wedge down the tubing/wire. These are usually needed at 1 to 2 foot (0.3 to 0.6 meter) intervals.

13. The slots shall be completely filled with approved sealant and left undisturbed until cured to a flexible state. Sealants on the ODOT prequalified list shall be used, in accordance with the manufacturer’s recommendations. Materials which set up to a hard or brittle state are not acceptable.

14. Detector loops are measured as “each” loop installed and the item includes wire, pavement cutting and sealant.

Loop Detector Lead-In Cable

Unless otherwise specified, loop detector lead-in cable (Table 732.19-1) shall be two conductor No. 14 AWG twisted pair shielded, with a jacket of black polyethylene 0.04 inch (1 millimeters) thick minimum, and polyethylene insulation with conductors of stranded copper.

Within the pull box, loop wire ends shall be joined to the conductors of the lead-in cable by soldering and covered with insulating material (see TEM Figure 498-25). An approved, poured epoxy waterproof splice kit shall be used. It is understood that epoxy splice kits are easily damaged by freezing temperatures encountered prior to mixing. Damaged epoxy components may sometimes be recognized if either of the components has turned or is streaked milky white.

Lead-in cable shall be routed to the controller cabinet, fitted with soldered spade type terminals and fastened to the correct points of the terminal block. The lead-in cable’s shielding shall be grounded to the ground bus within the cabinet.

If a pull box is not specified on the plans, the splice between the loop wire and lead-in cable shall be made in the first entered pole or pedestal, except where the controller cabinet is mounted on the pole or pedestal. If the controller cabinet is mounted on the pole or pedestal, the loop wires may be routed directly into the cabinet and no lead-in cable is necessary.

Loop detector lead-in cable is measured in accordance with Section 632-9 and TEM Figure 498-18.

The poured epoxy splice in the pull box is included.

Magnetometer Probes and Lead-In

Magnetometer sensor probes (TEM Figure 498-26) may be set in the pavement, or under and in bridge decks in accordance with SCD TC-82.10 at the locations shown on the plans.

Although core drilling may be performed after concrete placement, it is preferred that probe holes in new concrete be formed by pouring concrete around a vertical piece of capped vinyl-chloride or other non-metallic tubing. Probe holes in existing concrete must be core drilled. Probe installations under bridge decks may be as shown in Figure 498-26. The lead from probes should be in non-metallic conduit. Probes in bridge slabs should be centered in the reinforcing steel grid square which is nearest to the probe’s plan location. The center of a grid square may be located by the use of a Pachometer metal locator. The procedure for use of such an instrument is given in Section 632-10.10.

Probe holes in pavement and bridge decks shall be approximately 3/4 inch (19 millimeters) greater than the probe diameter. The probe shall be set so as to have a covering of at least 1 ½ inches (38 millimeters). However, deeper placement may be used if recommended in the manufacturer’s instructions.

The probe lead, which is a part of the probe(s), is to be led from the probe(s) to the edge of pavement, to the bridge parapet wall or under the bridge deck, depending on the design used.

When in pavement and bridge decks, the slot for the lead shall be a minimum of 3/8 inch (9.5 millimeters) in width and have a depth of 2 inches (50 millimeters) in concrete and 4 inches (100 millimeters) in asphalt concrete.

Probe holes and slots are to be brushed, blown clean of loose material and completely dry. The probes are to be set and leads pushed to the bottom of slots with a blunt wooden tool (or equivalent) to avoid damaging the insulation. Probe holes and slots are to be completely filled with approved sealant and left undisturbed until cured to a flexible state. The sealant should be the same as for loop detector slots, as given in 632.

Probe leads in slots at the pavement edge or curb shall be led into a 3/4 inch (19 millimeters) conduit connecting to a roadside pull box. Care should be taken to prevent excessive slack at the point where the lead enters the conduit. The high end of the conduit is to be sealed in accordance with SCD TC-82.10.

Unless otherwise specified, lead-in cable (Table 732.19-1) shall be four-conductor No. 18 AWG color coded, twisted, with a jacket of 0.026 inch (0.66 millimeters) minimum high density polyethylene and a low capacitance insulation with conductors of stranded copper.

Within the pull box, the probe lead ends shall be joined to the conductors of the lead-in cable by soldering and covered with insulating material. An approved poured epoxy waterproof splice kit shall be used. The kit should be the same as for loop detector lead-in cable as given in 632.

Lead-in cable shall be routed to the controller cabinet and fitted with soldered spade type terminals and fastened to the correct points of the terminal block. The shielding of lead-in cable shall be grounded to the ground bus within the cabinet.

The installation of magnetometer probes includes: the probe(s) and lead, the provision of probe holes and pavement slots when used, sealant for the probe holes and slots, and plastic conduit where required. Probes are measured as individual units with the attached lead. Several probes may be on a single lead.

Magnetometer lead-in cable is measured in accordance with 632 and TEM Figure 498-19. The poured epoxy splice in the pull box is included.

Use of Pachometer Instrument

A Pachometer is an instrument used to detect the location of metal such as reinforcement bars under a concrete cover. The instrument is a magnetic detector which operates on the principle of the change in magnetic flux due to the presence of ferrous metal.

A probe is connected to the instrument and is passed over the concrete surface being examined. The instrument will indicate when the pole of the probe is parallel to and directly over the axis of a reinforcing bar. Use of the instrument will, therefore, outline the sides of a grid square for accurate magnetometer probe location in the center.

Signal Performance Tests and System Checks

General

Traffic control signal components and the entire system shall be tested as required by various specifications to assure proper operation before acceptance. Ground rods shall be tested for satisfactory low resistance to ground. A circuit test should be performed on all conductors to make sure there are no shorts, crosses and high resistance or other improper connections. A cable insulation or megger test shall be performed on all conductors to verify the integrity of the insulation covering. All traffic control equipment in the controller cabinet should be checked for correct settings and all controls manipulated for assurance of an operable system.

Finally, the traffic control system shall successfully pass a ten-day performance test, which will give an opportunity for any hidden flaws to reveal their presence. As a final “housekeeping” check, equipment should be observed for any evidence of unattached ground wire, unlatched or unbolted doors, etc.

The results of the various tests are to be entered by the contractor on test report forms (TEM Form 496-6) as required by 632.28.

Ground Rod Test

All ground rods shall be tested by the Contractor for earth resistance to ground, as required by 632.28(B).

Short-Circuit Test

Before the performance of any cable insulation (megger) test or the ten-day performance test, a short-circuit test shall be performed by the Contractor using a volt-ohmmeter or other approved instrument (TEM Form 496-6 and 632.28(C)). Short-circuit tests shall be conducted with all electrical loads, power sources, equipment grounds, and earth grounds disconnected (see TEM Figure 498–28).

Signal cable routed to signal heads may be tested with connection made to the lamp sockets, but without the lamps being installed.

Each conductor shall be measured against every other conductor and ground to assure that no short-circuits, cross-circuits, or other improper connections exist. Continuity should not exist between any conductor and any other conductor including ground.

Circuit Continuity Test

Each circuit branch shall be disconnected and tested by the Contractor for continuity by temporarily jumpering each branch at its termination and measuring the temporarily looped circuit for assurance that no open circuits exist (TEM Form 496-6 and C&MS 632.28(D)). This testing is illustrated in TEM Figures 498-29 through 498-32. Each circuit branch should be according to plan, with no high resistance connections and with the proper identification.

Lead-in cable for loop detector wire shall be tested before and after the cable is spliced to the loop wire.

Circuit continuity of signal cable may be done by applying 120 volts to each outgoing circuit and observing that only the specific lamps are lighted.

Cable Insulation Test (Megger Test)

This testing is illustrated in TEM Figures 498-33 and 498-34.

1. Each conductor of cable or wire terminating at the controller cabinet shall be tested by the Contractor for insulation resistance measured to ground (TEM Form 496-6 and C&MS 632.28(E)). A listing of the resistance reading for each conductor is to be included in the test results furnished to the Engineer.

2. Cable and wire insulation can be faulty but the imperfections can be easily overlooked, leading to eventual electrical failure of the wiring. Weakening of insulation properties may be caused by poor storage conditions and stress due to rough handling during installation. Dirt is especially troublesome, since it is an electricity conductor and can penetrate small cracks in the insulation.

3. Insulation testing shall be performed with all conductors disconnected from their points on the terminal block in the cabinet so there is no chance of any voltage being present, and to prevent damage to any connected equipment. One megger instrument terminal shall be attached to a termination of jumpered together ends of conductors or to the end of a single conductor cable or wire undergoing testing. The other megger instrument terminal shall be attached to the cabinet ground bus bar.

4. Insulation resistance shall be measured for the wire of roadway loops after the embedding of the wire with sealant in slots.

5. The meter pointer of the megger instrument (or equivalent indication) should be adjusted to zero and the test switch activated. Test duration should be as recommended by the instrument manufacturer.

6. The insulation resistance measured to ground for each conductor shall not to be less than 10 megohms. Cable or wire not meeting this reading shall be replaced.

7. After completion of the cable insulation test, all cabinet wiring shall be connected in accordance with the wiring diagram. The Contractor shall demonstrate to the satisfaction of the Engineer that all circuits are continuous and operating correctly, free from shorts, crosses and unintentional grounds.

Functional Test

Before energizing the traffic signals the following functional checks should be made:

1. The incoming AC voltage should be checked.

2. Operation of the following equipment should be checked: cabinet ventilating fan, fan thermostat, and convenience outlet with lamp (when furnished). The filter(s) used with the fan should be unobstructed.

3. Timing settings on solid state controllers should be varied over their ranges and all functions activated to verify that the controls are operable without fault.

4. Timing settings in accordance with the plans should now be entered on the controller, time clock, etc. and checked for corrections. On some projects, timing settings will be provided by the maintaining agency and are not listed in the plans.

5. An agreement should be reached with the contractor and the maintaining agency on the procedure to be followed in the event of a signal failure prior to acceptance.

6. Before signals are energized to control traffic, the maintaining agency should be notified and given an opportunity to check the installation and timing settings.

After energizing the traffic signals the following functional checks should be made. In the event the signals are controlling traffic at the time, these checks should be made with caution to protect the safety of workers, pedestrians and drivers.

1. The function of all cabinet switches should be checked, including the power on/off switch and manual control (when furnished).

2. The traffic signals (and controller indicator lights) should be observed to verify that the controller is timing consistently the intervals and phases set into the controls. A stopwatch is suggested, especially to check critical short intervals. All controllers functions should be activated to verify that operation is proper.

3. The detector units should be investigated to determine which pavement loop(s) or other type sensor is associated with which unit. The visual indication of units (light, meter, etc.) should be observed to determine that each vehicle (truck, car, motorcycle, etc.) entering sensor areas is properly detected on the associated unit and that no extraneous calls occur when the sensor area is vacant. When a detector unit is set for "presence," a detection call should continue as long as a vehicle is positioned over the associated sensor. Concurrent with detection, the appropriate controller indicator light should also exhibit the detection.

4. The flasher switch should be activated to cause the signal heads to flash. Their indications should be checked to verify if they are correct. The flasher switch is then to be returned to the normal or signal mode and a check made of the resumption of normal stop-and-go operation.

5. The conflict monitor should not be activated by normal signal operation or by the manipulation of cabinet switches. If at any time the monitor is activated, the contractor is required to determine the cause of the problem and make appropriate changes and adjustments before beginning the ten-day performance test. The Contractor should test the conflict monitor by artificially causing a number of different conflicting indications and checking that at each test the monitor causes the signals to begin flashing and places the controller in a "stop timing" mode. Artificial conflict may be caused by touching a jumper wire between two load switch outputs that would signal a traffic conflict. Other methods of artificially caused conflicts may be used at the discretion of the contractor.

6. Signals which are interconnected should be observed to determine if offset relationships are maintained in accordance with settings during all periods of the day.

7. When preemption equipment is furnished as part of the cabinet installation, the proper functioning of the equipment should be checked. The equipment should be activated and observations made to determine if the required sequence of intervals and phases is called for in a correct and safe manner.

8. On projects having equipment furnished for future use only, the equipment should be checked to verify that it is properly installed and operable in a correct manner.

Some signal control equipment, such as time clocks (or switches) and weekly programmers, are intended to vary the timing patterns at different periods of the day or days of the week. To determine if these required changes are occurring at the proper times, it is necessary that observations be made to check the operation at transition times over a period of several days.

The change in timing shall not be extremely drawn out or abrupt. The accuracy of time clocks and weekly programmers should be checked. Programmed changes should occur within five minutes of scheduled times for clocks of the electromechanical type and within one minute for clocks of the solid state type. No significant cumulative clock error should be noted during the ten-day performance test.

After successful completion of the ten-day performance test, and after a partial or final acceptance of a project, the Contractor is to turn over to the Engineer all manuals, diagrams, instructions, guarantees and related material, as required by 632.05. It is recommended that the Engineer list this material in the project diary as a permanent record of the transfer. The Engineer should transfer the material to the maintaining agency. For ODOT-maintained signals the material should be given to the District Roadway Services Manager.

After a traffic control system project has been accepted by ODOT, the Engineer should immediately notify the maintaining agency that as of a certain exact time and date, the agency is responsible for the operation and maintenance of the system.

Ten-Day Performance Test

Before acceptance of the traffic control system, the Contractor shall furnish all personnel and equipment required to successfully operate the system continuously for ten consecutive days without major malfunction or failure (632.28(G)).

At least seven days prior to the beginning of the performance test, the Contractor shall notify the Engineer of the starting date. The Engineer will notify the maintaining agency (632.28(G)).

The Contractor shall arrange with the utility supplying the power for purchase of the energy required to conduct the test. All costs of personnel, equipment, electrical energy and incidentals required to perform the test are to have been included in the contract unit prices for the respective items tested.

Minor failures such as lamps, a single detector or an individual signal head, etc. shall be immediately replaced or repaired and will not cause restart of the test.

A major malfunction or failure, such as a master or local controller, interconnect equipment, etc. will cause termination of the test, and after replacement or repair of the malfunctioning or failed equipment, the beginning of a new ten-day test.

Items which have been repaired or which are replacements are to be monitored by the Contractor for a period of ten days to provide assurance of their reliability.

The complete test results are to be furnished to the Engineer on test reporting forms in accordance with 625.19. The Contractor is to record in the test results the beginning and end of the test, and the method and date of the correction of each fault.

The Engineer should record the following events in the project diary: the date of the beginning of the ten-day performance test, a day-by-day record of faults as they occur during the test, and the date of the successful completion of the performance test.

Final Signal Installation Check

After all wiring is completed and all testing completed and accepted, a final inspection of the traffic control system should be performed to assure a neat and workmanlike appearance.

1. All spare conductors should be connected to the ground bus bar in the controller cabinet.

2. All ground wires should be properly connected.

3. The spade type ends of conductors should be sound. After all testing is completed, they should be reinstalled on their correct points of terminal blocks and tightened.

4. A visual check should be made for any signs of arcing, melted insulation, etc.

5. All debris from wiring work or packaging materials should be cleaned from the bottom of cabinets.

6. Cabinet vents should be checked to assure that they are unobstructed and all filters should be clean and in place.

7. Duct sealing material shall be used to seal the conduit entering the cabinet from the base.

8. All doors on the optical sections of vehicular and pedestrian signal heads shall be closed and latched.

9. No wires or cable should be visible under the base plates of poles and pedestals.

10. The handhole covers on poles and end-frames shall be securely fastened.

11. Pedestals with transformer type bases shall have the access door securely fastened.

12. The covers on pull boxes shall be securely bolted.

Documentation Requirements - 632 Traffic Signal Equipment

1. Review certified drawings prior to work commencement

a. Document depth and width of cut for detector loop wire in pavement

i. Cuts blown clean

ii. What kind of material used to fill cuts after loop placement

b. Foundations

i. Excavate as per 503.04

ii. Perform concrete work as per 511

iii. No load applied for 14 days, 7 days with beam break of 650 pounds or more

c. Document each type of equipment installed as per certified drawings provided by supplier and as per individual specifications included in 632.

2. Test as per 632.28

3. Measure and pay per 632.29 and 632.30

Documentation Requirements - 633 Traffic Signal Controllers

1. Review certified drawings prior to starting work

a. All electrical parts of sufficient capacity and marked per 633.03

b. Diagrams and manuals furnished to engineer before installation. Documents modified upon completion of work

i. Controllers tested and pre-qualified as per 633.06

ii. Individual items provided and documented as per items 633.07 thru 633.17

iii. Test in accordance with Item 632.28

iv. Measure and pay as per 633.18 and 633.19

632/633 Supplemental Information

Please refer to the Traffic Engineering Manual (TEM) for a complete list of forms, supplementary information, and updates. The following figures are examples of typical installations, and forms.

Form 496-3 Traffic Signal Timing Chart

Form 496-4 Traffic Signal Detector Chart

Form 496-5 Coordination Time Chart

Form 496-6 Report of Electrical Tests

Figure 498-6. Concrete Pull Box

Figure 498-7. Trench Details

Figure 498-8. Exothermic Weld

Figure 498-9. Power Service

Figure 498-10. Strain Pole Supports

Figure 498-11. Strain Pole Attachment Details

Figure 498-12. Single Arm Support

Figure 498-13. Sag and Vertical Clearance Diagram

Figure 498-14. Cable Support Assembly

Figure 498-15. Aerial Interconnect Cable

Figure 498-16. Method of Measurement for Signal Cable

Figure 498-17. Method of Measurement for Interconnect Cable

Figure 498-18. Method of Measurement for Detector Lead-In Cable

Figure 498-19. Method of Measurement for Power Cable

Figure 498-20. Method of Measurement for Service Cable

Figure 498-21. Vehicular Signal Heads

Visors for Signal Heads

Hangers for Signal Heads

Figure 498-21. Vehicular Signal Heads

Wiring a Signal Head

Figure 498-22. Pedestrian Signal Heads

Figure 498-23. Loop Detector Placement and Installation

Loop Perimeter feet (meters)		Number of Turns
40	(less than 12)	4
40-160	(12 to 49)	3
over 160	(over 49)	2

Loop Construction

Figure 498-24. Loop Detector Slots and Wiring

Figure 498-25. Loop Detector Wiring

Figure 498-26. Magnetometer Probes and Lead-In

Figure 498-27. Ground Rod Testing

Figure 498-28. Short-Circuit Test

Figure 498-29. Circuit Continuity Test of Loop Wire

(Before Splice to Lead-In Cable)

Figure 498-30. Circuit Continuity Test of Loop Wire and Lead-In Cable

Figure 498-31. Circuit Continuity Test of Signal Cable Disconnected from Heads or Other Cables Such as Interconnect and Loop or Magnetometer Lead-In

Figure 498-32. Circuit Continuity Test of Signal Cable With Cable Connected to the Signal Heads and Lamps Installed

Figure 498-33. Cable Insulation Test (Loop Detector Wire)

Figure 498-34. Cable Insulation Test (Signal Cable)

Figure 498-35. SCD TC-81.20 Signal Support Design Chart

Figure 498-36. Plan Details for Strain Poles

Figure 498-37. Plan Details for Signal Supports - Arm Lengths

(table is continued in Figure 498-38)

Figure 498-38. Plan Details for Signal Supports - Mast Arm Orientation

(table continued from Figure 498-37)

638 Water Mains and Service Branches

Documentation Requirements - 638 Water Mains and Service Branches

1. State that materials conform to 638.02

2. Document clearance between pipe and walls of trench - 6 inches (15 cm) minimum, 12 inches (30 cm) maximum. Ensure proper clearance between water line and any utility crossing or underground structure

3. Grade shaped to receive bell

4. Type of sheeting and bracing used to support and protect adjacent utilities

5. Type and thickness of bedding

6. State that trench was kept free from water

7. State that pipe was carefully handled

8. Tracer tape installed 1 foot (.3 m) above top of pipe extending full length

9. Joints installed according to manufacturer’s recommendation

10. Perform and document backfill as per 603 type B and C conduits

11. Document hydrostatic testing and disinfection as per 638.09 and 638.10

12. Measure as per 638.19 and 638.20