SECTION 7: STREET LIGHTING, TELECOMMUNICATION AND ELECTRICAL WORKS - CDR 7... · SECTION 7: STREET LIGHTING, TELECOMMUNICATION AND ELECTRICAL WORKS . July 2009 (Project) Version 1.1

July 2009 (Project) Version 1.1 CDR Standard Specifications

(Consultant) 7.01 - Page i

SECTION 7: STREET LIGHTING, TELECOMMUNICATION AND ELECTRICAL WORKS


(Consultant) 7.01 - Page ii

SECTION 7: STREET LIGHTING, TELECOMMUNICATION AND ELECTRICAL WORKS

Table of Contents

SECTION 7.01 STREET LIGHTING ELECTRICAL AND TELECOMMUNICATION WORKS: GENERAL REQUIREMENTS ....................................................................................... 1

7.01.1 DESCRIPTION.............................................................................................................................. 1 7.01.2 SCOPE OF WORK ........................................................................................................................ 2 7.01.3 TECHNICAL REQUIREMENTS................................................................................................. 4

SECTION 7.02 SUBSTATIONS AND TRANSFORMERS................................................................... 12 7.02.1 SCOPE............................................................................................................................................ 12 7.02.2 MATERIALS............................................................................................................................... 15 7.02.3 CONSTRUCTION REQUIREMENTS ...................................................................................... 16 7.02.4 METHOD OF MEASUREMENT............................................................................................... 18

SECTION 7.03 STREET LIGHTING: FEEDER PILLARS................................................................. 19 7.03.1 SCOPE.......................................................................................................................................... 19 7.03.2 MATERIALS............................................................................................................................... 19 7.03.3 CONSTRUCTION REQUIREMENTS....................................................................................... 23

SECTION 7.04 STREET LIGHTING: CABLES.................................................................................... 26 7.04.1 SCOPE.......................................................................................................................................... 26 7.04.2 MATERIALS............................................................................................................................... 27 7.04.3 CONSTRUCTION REQUIREMENTS....................................................................................... 29 7.04.4 MEASUREMENT ....................................................................................................................... 32

SECTION 7.05 INTERIOR LIGHTING INSTALLATIONS ............................................................... 33 7.05.1 SCOPE.......................................................................................................................................... 33 7.05.2 MATERIALS............................................................................................................................... 34 7.05.3 CONSTRUCTION REQUIREMENTS....................................................................................... 36 7.05.4 MEASUREMENT ....................................................................................................................... 36

SECTION 7.06 ROAD LIGHTING .......................................................................................................... 37 7.06.1 SCOPE.......................................................................................................................................... 37 7.06.2 MATERIALS AND EQUIPMENT............................................................................................. 39 7.06.3 CONSTRUCTION REQUIREMENTS....................................................................................... 44 7.06.4 MEASUREMENT ....................................................................................................................... 45

SECTION 7.07 WIRING DEVICES AND MISCELLANEOUS EQUIPMENT ................................ 47 7.07.1 SCOPE.......................................................................................................................................... 47 7.07.2 MATERIALS............................................................................................................................... 47 7.07.3 CONSTRUCTION REQUIREMENTS....................................................................................... 49 7.07.4 MEASUREMENT ....................................................................................................................... 50

SECTION 7.08 CONDUITS, WIREWAYS, SUPPORTING SYSTEMS AND RELATED ACCESSORIES ............................................................................................................... 51

7.08.1 GENERAL ................................................................................................................................... 51 7.08.2 MATERIALS............................................................................................................................... 52 7.08.3 CONSTRUCTION REQUIREMENTS....................................................................................... 55 7.08.4 MEASUREMENT ....................................................................................................................... 61


(Consultant) 7.01 - Page iii

SECTION 7.09 SIGN ILLUMINATION.................................................................................................. 63 7.09.1 SCOPE.......................................................................................................................................... 63 7.09.2 MATERIALS............................................................................................................................... 63 7.09.3 CONSTRUCTION REQUIREMENTS....................................................................................... 64 7.09.4 MEASUREMENT ....................................................................................................................... 65

SECTION 7.10 EARTHING SYSTEM..................................................................................................... 66 7.10.1 SCOPE.......................................................................................................................................... 66 7.10.2 MATERIALS............................................................................................................................... 67 7.10.3 CONSTRUCTION REQUIREMENTS .................................................................................................. 72 7.10.4 MEASUREMENT ....................................................................................................................... 74

SECTION 7.11 TRAFFIC SIGNALS ....................................................................................................... 75 7.11.1 SCOPE.......................................................................................................................................... 75 7.11.2 DEFINITIONS............................................................................................................................. 75 7.11.3 MATERIALS............................................................................................................................... 77 7.11.4 TRAFFIC SIGNAL OPERATION.............................................................................................. 86 7.11.5 CONSTRUCTION REQUIREMENTS....................................................................................... 89 7.11.6 MEASUREMENT ....................................................................................................................... 91

SECTION 7.12 BUILDER'S WORK ........................................................................................................ 92 7.12.1 SCOPE.......................................................................................................................................... 92 7.12.2 MATERIALS............................................................................................................................... 92 7.12.3 CONSTRUCTION REQUIREMENTS....................................................................................... 93 7.12.4 MEASUREMENT ....................................................................................................................... 96

SECTION 7.13 TESTING AND ADDITIONAL REQUIREMENTS................................................... 97 7.13.1 DESCRIPTION............................................................................................................................ 97 7.13.2 MEASUREMENT ..................................................................................................................... 100

SECTION 7.14 ELECTRICAL INSTALLATION EQUIPMENT DATA......................................... 101 7.14.1 GENERAL ................................................................................................................................. 101 7.14.2 DETAILED EQUIPMENT DATA............................................................................................ 101 7.14.3 MEASUREMENT ..................................................................................................................... 104

SECTION 7.15 TELECOMMUNICATION WORKS ......................................................................... 105 7.15.1 SCOPE ........................................................................................................................................ 105 7.15.2 GENERAL.................................................................................................................................. 105 7.15.3 INSTALLATION STANDARDS FOR CIVIL WORKS .......................................................... 106 7.15.3 EARTHING ................................................................................................................................ 109 7.15.4 MATERIALS – MANHOLES AND HANDHOLES ................................................................ 109 7.15.5 MATERIAL - PVC DUCTS....................................................................................................... 112 7.15.6 MATERIALS - DUCT FITTINGS AND ACCESSORIES ....................................................... 113 7.15.7 MATERIALS - DUCT SPACERS ............................................................................................. 115 7.15.8 MATERIALS - CABLES ........................................................................................................... 116 7.15.9 MATERIAL APPROVALS ....................................................................................................... 121 7.15.10 MEASUREMENT ...................................................................................................................... 123


(Consultant) STREET LIGHTING: GENERAL REQUIREMENTS 7.01 - Page 1 of 127

SECTION 7.01: STREET LIGHTING, ELECTRICAL & TELECOMMUNICATION WORKS: GENERAL REQUIREMENTS

7.01.1 DESCRIPTION A. The work covered in this Section includes the general and miscellaneous requirements relating to the lighting, power installation, telecommunication and civil works to be supplied and installed as required by the Drawings and Bill of Quantities. Wherever these requirements are not listed as separate items in the Bills of Quantities, they are deemed to be allowed for in the Contractor's unit rates and prices elsewhere. B. Electrical work shall be carried out in accordance with the Drawings and General Regulations and in compliance with design performance requirements to provide safe and protected systems with all equipment readily accessible for operation, maintenance and repair.

- Installations shall be completed, ready for operation and fully integrated and coordinated with all other work.

- Installations shall only be carried out by suitably qualified personnel.

- Accessories and other elements necessary to complete the installations shall be provided in accordance with specifications and recommendations of the manufacturer of the equipment or accessories.

C. The Contractor shall check that dimensions, structure, ventilating and cooling arrangements and other provisions in equipment spaces and rooms are suitable for installation, operation and maintenance of the proposed equipment. Any discrepancies on the shop and construction drawings shall be noted and the Engineer informed of such discrepancies. D. The Contractor shall liaise with the Relevant Power Authority to confirm:-

- The characteristics of supply and system earthing

- The location of incoming supply shown on the Drawings

- Space requirements and associated builder's work required for the Authority's installations.

The Contractor shall make necessary arrangements at the earliest opportunity to ensure connection as and when required and inform the Engineer in the event of any unforeseen delay. The Contractor shall provide necessary instrumentation, enclosures and accessories required by the Relevant Power Authority to effect a complete power (kWh) metering installation. E. Where systems are used before Substantial Completion for the Contractor’s benefit, all consumable elements (including lamps) and all defective equipment shall be replaced by new within seven days prior to the date of substantial completion.



7.01.2 SCOPE OF WORK A. Unless otherwise specified, electrical work includes the supply, installation, testing and commissioning of the complete electrical and telecommunication systems (new or relocated), equipment and materials shown on the Drawings and/or described in the Specification together with all associated ancillary work, support work and builder's work. B. New Works: The scope of new works shall include coordination with the relevant Power Authority for connection of the feeder pillar to the nearest available electricity supply. The Contractor shall pay for and include in his cost all fees relating to the execution of all of the civil works related to these works and any subscription and supervision fees, L.V. breaker installation costs and charges for power connections that are to be paid to the Relevant Power Authority. C. Relocation Works: The scope of work shall comprise the relocation works for existing networks or the construction of replacement networks and shall include coordination with the relevant authorities, surveying of existing conditions, production of drawings for the new works and approvals for the following items listed below. All work and equipment required for the proper execution and operation of these items shall be deemed to be included in the Contractor's price.

C.1 Electrical Works: The work shall include the relocation or replacement of existing overhead transmission poles and pole mounted transformers, supply and installation of new cables in lieu of existing electrical cables obstructing the works and/or relocation of existing M.V. cables (where applicable) and any other cables obstructing the execution of the works. The works and prices are to include for full coordination with the Relevant Power Authority, including compliance with their regulations and payment of their supervision fees, cable terminations, excavation, backfilling, warning tape and protection tiles to the Relevant Power Authority’s standards. C.2 Telephone Works: The Contractor shall coordinate fully with the Telephone Authority for the relocation of existing underground telephone cables or telephone lines and poles and the works shall include any necessary pole relocation or replacement or addition of extra poles. All work is to be completed in full conformity to the Telephone Authority’s regulations and Requirements. The Contractor shall provide proper supports and shoring for the existing telephone network ducting during excavation. The work shall include for the supporting elements and all accessories. Ducting, manholes and handholes shall not be disturbed. The Contractor shall also include in his prices payment of coordination costs and supervision fees invoiced by the telephone authorities during the construction works and any works related to the above, if not separately itemised in the Bill of Quantities.



C.3 Street Lighting: The works shall be performed to restore the lighting installation to a good operational condition. Works include checking, relocation, painting and repair of existing lighting fixtures (including replacement of faulty lamps, ballasts, igniters, etc.), in coordination with the relevant Power Authority and the Local Municipality. These works will include the inspection of the lighting fixtures and fittings, determination of necessary repairs and carrying out these repairs as instructed by the Engineer. The Contractor shall fully coordinate with the Municipality for the dismantling of existing lighting columns. These columns shall be dispatched to the Municipality in good condition or in accordance with the Engineer’s instructions. All incurred costs including the cost of coordination with and supervision fees required by the relevant Power Authority and the Municipality are deemed to be included in the rates for the relocation of the lighting poles, if not separately itemised in the Bill of Quantities.

D. Work related to the electrical and telecommunications installations provided for in this Specification shall include any or all the following systems as specified or required in the Drawings and Bill of Quantities.

1. Low Voltage Feeder Pillars

2. Medium and Low Voltage Cables

3. General Lighting Installations

4. Outdoor and Road Lighting Installations

5. Sign Illumination

6. Earthing System

7. Builder's Work

8. Telecommunication Civil Works

9. Installation Testing

10. Equipment Data. The work shall include the provision of shop drawings and calculations required by the Specification, as well as the provision of all literature and samples in connection with the approval of proposed equipment. The equipment supplied shall include all necessary items for complete installation to give a satisfactory operation notwithstanding errors and omissions.



7.01.3 TECHNICAL REQUIREMENTS A. General

A.1 All work carried out on installation shall be in accordance with the requirements of these Specifications, so that their true meaning and intent are fulfilled. Minor deviations from the Drawings may be made to accomplish this, but no changes shall be made without the written approval of the Engineer. A.2 The Specifications and Drawings are complementary documents intended for the selection of equipment having the general and specific characteristics as detailed in the documents.

B. Regulations and Standards:

B.1 Electrical work shall be carried out in accordance with the current issue of the Lebanese Codes of Practice, Relevant Power Authority Regulations and National Electric Code NEC as published by the National Fire Protection Association (USA) where not in contradiction with the aforementioned Codes of Practice and Regulations, herein referred to collectively as 'the Regulations'. B.2 Unless otherwise specified, equipment and materials shall be manufactured and installed in compliance with the requirements and recommendations of the following organisations:

IEC : The International Electrotechnical Commission

ISO : The International Standards Organisation

ITU-T : The International Telecommunications Union - Telecommunications

ITU-R : The International Telecommunications Union - Radiocommunications

CISPR: The International Special Committee on Radio Interference Local standards, where enforced and relevant, have precedence over the Standards.

B.3 Equipment shall be the latest standard product of the manufacturer. Component parts are to be the product of a single manufacturer, unless otherwise approved by the Engineer and provided that components made by other manufacturers are of a standard design and are interchangeable. B.4 Listing of approved manufacturers in the Specification does not necessarily constitute approval of all of their standard products. The Contractor shall ascertain that listed manufacturers are able to supply equipment and material in conformity with the Specification.

B.5 Equipment shall be supplied in complete factory-assembled units ready for installation on site. Any dismantling necessary for transportation or other purposes shall be arranged to limit site work to reassembly and wiring of control and power cabling.



B.6 Equipment and materials shall be stored in approved locations, under cover, free from humidity, dust, debris and rodents. Equipment sensitive to heat and humidity shall be stored in climatically conditioned areas until installed and handed over.

B.7 The Employer reserves the right to operate defective or obsolete equipment during the Defects Liability Period until it can be removed from service for repair or replacement. B.8 Where required by the Specification, the Contractor shall provide a warranty, signed by the manufacturer (including an agreement to promptly replace defective equipment or parts thereof as instructed by the Engineer) covering materials and workmanship for the Defects Liability Period. The Contractor shall assign the benefits of such a warranty to the Employer. B.9 The Contractor shall confirm that proposed equipment and material characteristics where required are compatible with the requirements of the relevant power, telecommunications or other authority having jurisdiction and are acceptable to them and shall inform the Engineer of any modifications necessary to comply with the authority's requirements. B.10 The Contractor shall confirm availability of equipment and materials proposed for use in the work prior to submission for approval. If, after approval, equipment or materials cease to be available, alternative items of equal quality and type shall be submitted for approval.

B.11 The Contractor shall label and identify all equipment, instruments, control and electrical devices etc. to indicate duty, service or function, to the satisfaction of the Engineer. Labels are to be laminated plastic or anodized aluminium discs with black surface and white core with incised lettering in English and Arabic. Alternative methods of labelling shall be submitted to the Engineer for approval. Labels shall be fixed with non-corrodible screws to equipment or adjacent permanent surfaces or as approved by the Engineer. B.12 Equipment Nameplates shall be non-corroding, robust metal, inscribed in English and Arabic and firmly fixed to the equipment at the factory. Nameplates shall indicate the name and address of the manufacturer, model, serial number, basic characteristics and ratings of equipment, elementary diagrams in accordance with the Standards.

C. Basic Design Conditions

C.1 Nominal Characteristics of Power Supply and Distribution are as follows:

Medium voltage: 20 kV, 3 phase system

Low voltage: 380 V, 3 phase, 4 wire, solidly earthed neutral

Frequency: 50 Hz.



C.2 Distribution Systems shall be supplied or derived from the voltage system previously described either as shown on the Drawings or as otherwise specified on the Drawings or by the Engineer.

C.3 Equipment shall be designed for the system voltage and frequency previously described, unless otherwise specified. Special provisions shall be made for equipment sensitive to power supply frequency and voltage variations and for equipment operated at other voltages/frequencies or by direct current sources.

C.4 KWH-Metering shall be at low voltage as shown on the Drawings.

C.5 Climatic conditions equipment, including transformers, switchgear, cables, relays, lighting fixtures, motors etc., shall be designed and derated for continuous and trouble free service under the following climatic conditions:

Altitude: 0 - 1800 m above sea level

Maximum ambient temperature: 40° C (in the shade)

Minimum ambient temperature: -10° C

Maximum relative humidity: 85 %

Different design and operating conditions shown on the Drawings take precedence over the above.

D. Lighting Design Criteria

D.1 Highway Lighting D.1.1 Surfaces on which lighting levels are to be measured include the full width of all traffic lanes and the full face of highway signs. D.1.2 The luminance and illuminance levels shown in Table 7.1.1 are maintained values for the average highway surface to which the design is applicable. For calculation purposes, the highway surface characteristic shall be taken as Type R3 CIE. Classification with Qo = 0.07 unless otherwise indicated. D.1.3 The lighting design shall be in accordance with international standards and the recommendations of the International Commission on Illumination (CIE), for the types of roads specified.



TABLE 7.01.1: AVERAGE MAINTAINED LUMINANCE AND ILLUMINANCE LEVELS

Class of Highway Parameters Main Roads & Bridges Service Roads

Minimum Maintained Average Luminance Levels (Lavg ) cd/m2 2 1

Overall Uniformity Uo= Lmin/L avg 0.4 0.4

Longitudinal Uniformity UL = Lmin/L max

0.7 0.7

Reference Horizontal Illuminance (E

average) lux 30 20

Ratio of Illuminance Uniformities

E min/Eav 1:3 1:3

E min/Emax 1.6 1.6

Threshold Increment TI (%) <10 <10

D.2 Lighting Controls D.2.1 Unless otherwise detailed on the Drawings, highway and general outdoor lighting shall be switched on by photo-electric controls and a timer which operates in parallel with the photocell. D.2.2 The photo-electric controls shall consist of omni-directional cadmium cell thermal relays using solid state photo-variable conductance element giving a 2:1 on/off ratio with the sensitivity to switch on luminaires when the daylight illumination reduces to 70 lux. This shall allow for the striking time of discharge lamps, taking into account the daylight intensity "drop off" in the region. D.2.3 Tunnel lighting photocell control modules shall be capable of adjustment to permit control of the switching level between 30 and 80 lux. The exact setting between these limits shall be determined on Site to the approval of the Engineer. D.2.4 The photo-electric control shall operate through a suitably rated contactor controlling the lighting circuits. D.2.5 Timers shall operate the contactor between definite periods. It shall be of the solar electronic, quartz type settable once throughout the year and shall be capable of operating for at least 500 hours in the case of a power failure. D.2.6 The contactor shall be rated for uninterrupted duty with a utilisation category of AC4 in accordance with IEC 60947.



E. Approval of Equipment

E.1 The Contractor shall submit to the Engineer for approval manufacturers' technical literature, computerized sheet lighting calculations with the related calculation program on a CD, shop and construction drawings and other information required by the Specification and Drawings before ordering equipment or materials and before executing any related work on site. E.2 Technical Literature includes detailed manufacturers' specifications and original catalogues or catalogue extracts, characteristics, model number, application and operating criteria of all equipment and materials together with other information necessary to satisfy the Engineer that the proposed equipment and systems are suitable and adequate. E.3 A list of proposed manufacturers of all equipment and materials, including all items for which a choice of manufacturer is at the discretion of the Contractor shall be submitted to the Engineer for approval. E.4 The Contractor shall submit manufacturer's type and routine test certificates and reports for equipment and devices in accordance with the Contract and manufacturer’s requirements and specifications. Completed test results shall be submitted in clearly identified and organised booklets, indicating item of equipment, make, model, type, date and type of test, description and procedures. If manufacturer's test certificates are considered unsatisfactory by the Engineer, independent laboratory tests shall be carried out on the equipment in accordance with the Engineer’s requirements and instructions. E.5 The Contractor shall submit itemised schedules of spare parts to be provided as required by the Specification and Drawings and state against each item the manufacturer's unit price including packaging and delivery to site.

E.6 The Contractor shall submit itemised schedules of tools and instruments to be provided and state against each item the manufacturer's unit price including packaging and delivery to site. E.7 The Contractor shall submit to the Engineer, for approval prior to installation, a schedule of all equipment and devices to be labelled and the suggested details, lettering, position and fixing methods of each label indicating its application. E.8 The Contractor shall submit samples of all equipment and materials to the Engineer for approval. Major items of equipment for which samples cannot be submitted shall be demonstrated in existing installations or by manufacturer's information, test certificates and reports.



F. Contractor's Drawings

F.1 The Drawings indicate the approximate locations and general layout of equipment. Exact and final locations and layouts together with dimensions, weights, mounting methods and accessories, where relevant, shall be shown on the shop and construction drawings. F.2 Wiring layouts shown on the Drawings shall be used as a guide only to defining basic positions, circuiting, loading and switching arrangements. Actual layouts and details of routing of circuits shall be shown on the shop and construction drawings. F.3 Shop and construction drawings shall demonstrate to the Engineer that the design requirements are understood by indicating all equipment and material proposed to be supplied and installed and by detailing fabrication and installation methods proposed to be used. Shop and construction drawings shall clearly state the name and location of the work, the names of the Engineer and Contractor, submission date, cross-references to the Drawings and Specification and the specific reference number, location, service and function of each item.

G. Maintenance Literature Prior to the final acceptance of the installation the Contractor shall submit to the Engineer six sets of manuals for all equipment supplied under the Contract. The manuals shall be A4 size bound in loose leaf binders or booklets suitably enclosed and including the following:

- Single line diagram of the complete work.

- Control, protection and circuit diagrams for all equipment.

- Setting-up, commissioning and operating instructions.

- Troubleshooting procedures.

- Maintenance instructions including schedules for preventative maintenance.

- Complete recommended spares list including manufacturer's name and catalogue number.

- Name of manufacturers' local authorised representatives and service agents. H. Manufacturers

H.1 The detailed description of equipment appearing in the following sub-divisions shall indicate the minimum quality and standard of equipment to be accepted. Products of manufacturers having a good reputation and standard shall be considered by the Engineer on an equal basis. In this respect the Engineer's decision shall be final and not subject to any justification whatsoever. H.2 Approval of a manufacturer does not necessarily constitute approval of his product as equal to that specified.



H.3 It shall be the Contractor's responsibility to ascertain that the approved material and/or equipment is in full conformity with the Engineer's specifications.

7.01.4 SAFETY AND CLEARANCES A. Prior to the start of construction, the Contractor shall check all drawings and ensure that all obstacles have been taken into account. Hs shall submit to the Engineer a list of obstructions on site including existing overhead power lines, water and drainage pipes, underground power and telephone lines. B. The Contractor shall check clearances, both vertical and horizontal, of the existing services and utilities as required by the authorities concerned. C. Construction drawings showing all services and the new installations shall be signed by both the Contractor’s Representative and the Engineer before commencement of the construction of bases for lighting columns, traffic signals poles, overhead gantry signs, sign boards PVC ducting, trenches and any other related items. 7.01.5 MEASUREMENT A. Unless shown as Pay Item in the Bill of Quantities, the fees due to be paid to relevant authorities prescribed in this section shall not be measured for direct payment but shall be considered as subsidiary works, the cost of which shall be deemed to be included in the Contract prices for other pay items. B. The provision of power supply to the L.V. feeder pillars shall be paid for as an Item, and shall include coordination with the Power Authority to provide a power supply to L.V. feeder pillars, supply and installation of L.V. breakers, subscription fees and supervision fees to be paid, including all fees relating to the execution of all civil works related to these works. C. Dismantling and removal of existing street lighting columns and wall mounted luminaires shall be measured per item for direct payment. These shall be identified, marked and transported, in a good condition, to the Owner’s stores as shown on the Drawings or as directed by the Engineer. Work shall include all necessary repairs and rehabilitation of the columns, removal and disposal of original column foundations and infilling of any voids formed through the removal of the columns all to the satisfaction of the Engineer D. Relocation of existing street lighting columns shall be measured per item for direct payment. Work shall include all necessary repairs and rehabilitation of the columns, removal and disposal of original column foundations, infilling of any voids formed through the removal of the columns and re-erection of the columns in accordance with Section 7.06, all to the satisfaction of the Engineer.



E. Rehabilitation of existing street lighting columns shall be measured per item for direct payment. Work shall include all necessary repairs and rehabilitation of the columns, as shown on the Drawings or as instructed by the Engineer.

F. Relocation of existing L.V. and M.V. cables shall be measured and paid for by the linear metre, including the coordination fees with the Relevant Power Authority, the cost of locating and uncovering of the existing cables, subsequent removal and reinstallation in new trenches, fees to be paid to the Power Authority during the interruption of power, and all necessary accessories in accordance with the Power Authority’s requirements. Trenches shall be paid separately as unclassified Excavation under the provisions of Section 2.03 of this Specification. G. Supporting of the existing telephone network shall be paid for as an Item. The Contractor shall ensure proper support for the existing telephone ducting during excavation. The works shall include for the supporting elements and all other necessary accessories. The existing ducting, manholes and handholes should not be disturbed or tampered with. The Contractor shall include in his prices coordination with the Telephone Authorities during construction and supervision of the above works, including any fees related thereto.

PAY ITEM UNIT OF MEASUREMENT

(7.1.1) Provision of Power Supply to the L.V. Feeder Pillars Item

(7.1.2) Dismantling and Removal of Existing Street Lighting Columns Number (No)

(7.1.3) Relocation of Existing Street Lighting Columns Number (No)

(7.1.4) Relocation of Existing L.V. Cables Linear Meter (m)

(7.1.5) Relocation of Existing M.V. Cables Linear Meter (m)

(7.1.6) Dismantling and Removal of Luminaires Number (No)

(7.1.7) Rehabilitation of Existing Street Lighting Columns Number (No)

(7.1.8) Rehabilitation of Luminaires Number (No)

(7.1.9) Replacement of Luminaires Number (No)

(7.1.10) Supporting of the Existing Telephone Network Item


(Consultant) SUBSTATIONS AND TRANSFORMARS 7.02 - Page 12 of 127

SECTION 7.02 SUBSTATIONS AND TRANSFORMERS 7.02.1 Scope

A. The work described in this Section consists of supplying, installing, testing and commissioning of electrical substations including:

- Switch Disconnecters - Power transformers - sealed liquid type. - Interconnecting power and control cabling and ancillary works.

B. Electrical work generally shall be in accordance with the requirements of Section 7.01 of the Specification.

C. Equipment and component parts shall to comply with the following Standards: - High voltage switchgear and control gear standards

:

IEC 60694

- Alternating current metal - enclosed switchgear and control gear for rated voltages above1 kV and up to and including 72.5 kV

:

IEC 62271-200

- High voltage alternating current circuit breakers

: IEC 62271-100

- Insulation coordination

: IEC 60071

- High voltage alternating current. fuse-switch combinations and fuse-circuit-breaker combinations

:

IEC 62271-105

- A.C. disconnecters (isolators) and earthing switches : IEC 62271-102

- HV switches : IEC 60265

- Metering and protective current transformers (CTs) : IEC 60044-1

- Metering and protective voltage transformers (VTs) : IEC 60044-2

- Relays : IEC 61260

- Reading instruments : IEC 60051

- Watt-hour meters : IEC 62052-11

- Power transformers : IEC 60076

- Insulating oil

:

IEC 60296

- Sulphur hexafluoride : IEC 60376

- Fuses : IEC 60282-1



D. The Contractor shall submit full technical details of the equipment proposed for the works for approval by the Engineer. The details shall include, but not be limited to, the following: - Manufacturers' catalogues, detailed description of construction, provisions for

extension, compliance with the Standards, dimensions and weights, operating characteristics, operating curves and error curves (VT, CT) for all switchgear, control gear, protective gear, metering gear etc.

- Construction methodology, dimensions, finishings for power transformers and related

equipment. - Details of miscellaneous items including pilot lights, cabling or wiring, incoming and

outgoing feeder terminal fittings, supports, labels, interlocks and bracing. E. Test Certificates shall be submitted to the Engineer by the Contractor to verify compliance with relevant Standards for each main unit or piece of equipment. Certificates shall include lightning impulse withstand, power frequency voltage, operating temperatures, short time current withstand and enclosure protection to IEC 60529 for all main equipment. E.1 Certificates for switchgear shall include verification of the making and breaking capacity, mechanical endurance/operation, verification of the degree of protection against contact with live and moving parts and internal arc tests. E.2 Each complete main unit or piece of equipment shall undergo routine tests at the manufacturer's works in accordance with the relevant Standards. The Contractor shall submit to the Engineer routine test reports, prior to shipping equipment, indicating ambient test conditions and the guaranteed rating of equipment under site conditions. E.3 Routine and special tests for power transformers shall include measurement of noise levels, winding resistance, voltage ratio, checking of the polarity/vector group, impedance voltage, load loss, no-load loss, no-load current, induced over voltage withstand test and separate source voltage withstand test.



F. Shop and Construction Drawings shall be submitted to the Engineer for approval including, but not limited to, the following:

- Plans and elevations, with indication of equipment mounted components, dimensions and weights.

- Arrangement of equipment and general layouts.

- One-line diagram of power system showing current and power ratings of all equipment, and types and locations of protective gear (relays, metering instruments, CTs, VTs etc.)

- Schematic and elementary diagrams of control circuits. Foundation details, grouting holes, base-frames and installation details etc.

- Physical arrangement of incoming and outgoing feeders, terminal fittings, instrument transformers, busbars, connections etc.

- Dimensions and weights of control power supplies and other auxiliary equipment or components.

G. The Contractor shall submit the following to the Engineer for approval prior to confirming the order with the equipment manufacturer:

- Schedules of selected equipment, relays and control gear, with complete identification of each component and its characteristics.

- Protection coordination schemes, including pick-up settings and time-grading, together with time-current curves and range of adjustments etc. as required to coordinate with upstream and downstream protective devices of the complete system.

H. The Contractor shall provide spare parts as recommended by the manufacturer, for a one year maintenance period under local conditions and allow for emergency replacement due to accidental breakage or failure. I. The Contractor shall provide tools and instruments required for normal routine inspection, testing, operation and maintenance as recommended by the manufacturer. Power transformers shall meet the approval of the Relevant Power Authority regarding the proposed manufacturer and make of equipment. A certificate to this effect from the Relevant Power Authority shall be presented to the Engineer prior to completing the order. J. The Contractor shall provide a one year warranty for equipment specified in this Section.



7.02.2 MATERIALS A. Pole- Mounted Power Transformers:

A.1 Transformers shall be manufactured in accordance with the Power Authority’s specification and subject to their approval, outdoor type, pole mounted on a platform. Specifications for poles and platforms are strictly to conform to the Power Authority’s requirements and Standards. A.2 Transformers shall be the 3-phase, liquid immersed, two-winding, sealed type, rated for continuous operation under site ambient conditions at full rated power, naturally cooled (ONAN) with off-load, manual, externally operated tap-changers, lockable in all positions, on the primary side. Transformer shall comply with IEC 60076 and 60404-2 A.3 The transformers shall be enclosed in steel tanks, with corrugated walls forming integral cooling pockets, heavy rolled welded steel bases and base frames and hermetically sealed bolted-on covers. Tanks shall be filled with insulating liquid drawn in under vacuum. Covers shall have provision for two thermometers or temperature sensors, lugs for lifting, four lashing lugs and filler-pipes with valves. Tanks shall have drain plugs at the base, earthing bolts on the covers, earthing pads on the base-frames and rating plates.

A.4 Base frames shall have four towing lugs and provision for fringeable flat rim wheels arranged for longitudinal or cross-travel. A.5 The noise level in general shall be less than 76 dB at 0.3 m for ratings up to 1600 kVA and 69 dB for ratings up to 630 kVA and in accordance with IEC 551. A.6 Windings shall be copper unless otherwise approved by the Engineer. A.7 Bushings shall be porcelain, mounted on tank covers, with arcing horns on the MV side (if not enclosed). Side bushings-for flanged and enclosed connections or plug-in bushings shall be provided for terminal connections as required or as shown on the Drawings.

A.8 Cable terminals, fittings and sealing ends shall be arranged as described in the Specification and/or as shown on the Drawings. A.9 Surfaces shall be steel grit-blasted, caustic washed and phosphatized, primed with waterproof primer and finished with weather-resistant enamel and a final coat of air- drying enamel. Alternative finishes shall only be used if approved by the Engineer.



A.10 Characteristics: - Rated power (net without fans) As indicated on the Drawings or specified by the Engineer

- Frequency 50 Hz

- Rated voltage:

MV side (primary)

LV side (secondary)

As indicated on the Drawings or specified by the Engineer

400 V

- Winding connections Dyn 11, neutral insulated and brought out

- Impedance voltage al rated current 5%

- Rated power frequency withstand voltage

50 kV

- Lightning impulse withstand voltage 125 kV

- Short-circuit apparent power of the system 500 MVA

- Duration of short-circuit withstand Two seconds

- Terminal connections

MV side

LV side

to Power Authority requirements,

as required on drawings

- Tap changer ± 2.5% and ± 5%

A.11 Accessories shall include the following:

- Magnetic liquid gauge with NO low level alarm contact.

- Dial type thermometer with NO contact and maximum pointer.

- Pressure relief device with N.C. trip contact. A.12 MV switch-disconnectors shall be of the general purpose, 3-pole, load break, short-circuit make type, Category B to IEC 60265.

- rated normal current : to Power Authority requirements

- rated short circuit making capacity (peak)

: Equal to rated peak withstand current

7.02.3 CONSTRUCTION REQUIREMENTS A. The Contractor shall ensure that concrete bases and foundations provided for installation of equipment are constructed in accordance with approved shop and construction drawings and the equipment manufacturers' drawings and that the holes for fixings bolts and provisions for the passage of cables are provided as required.



B. The Contractor shall ensure that cable trench construction and covers provided for the installation of power and control cables are in accordance with the approved shop and construction drawings. C. The Contractor shall assemble, plumb and level, equipment on concrete bases before grouting-in holding-down bolts. D. The Contractor shall ensure that earthing installations are in accordance with the requirements of Section 7.10 of the Specification and/or as shown on the Drawings. E. The Contractor shall install cables, wires, raceways, supports, cable ends and termination fittings in accordance with the appropriate sections of the Specification and/or as shown on the Drawings. F. The Contractor shall inspect equipment upon delivery to site and report any damage to the Engineer. Switchgear shall be inspected for completeness as recommended by the manufacturer and the phasing of buses, contact alignment and clearances. G. The Contractor shall check component ratings, types, sizes and wiring connections, including current and voltage transformers, fuses, switches, instruments and relays. H. Before energising, the Contractor shall carry out the following tests:

- Insulation resistance on MV equipment including busbars, bushings, through insulators and feeder terminations, using a 5000 V megger between phases and between phase and earth, with control and protection circuit, lamps and similar components disconnected.

- Insulation resistance on every cable and insulator, power, control and relay circuit of the LV systems, using the appropriate megger range.

- HV tests, using power frequency HV test sets, to 80% of IEC withstand voltage for one minute, between phases and phase to earth for each MV switchgear and transformer, disconnected.

- HV testing of feeder cables and terminations, as appropriate. Earth pit resistance and earth loop resistance at substations.

- Contact resistance on switchgear, bus connections and the like, using appropriate micro-ohm meters.

- Polarity and ratio checks on CTs.

- Calibration checks and adjustment on ammeters and voltmeters.

- Primary and/or secondary injection to check relay operations using appropriate test sets.

- Tripping of circuit breakers, once only, via the protective relay circuits.

- Power transformer insulating oil tests at an appropriate laboratory, unless otherwise recommended by the manufacturer or not required by the Engineer.



I. After energising, the Contractor shall carry out the following inspections and tests:

- Close circuit breakers in sequence, loading gradually to peak load and observe overheating using appropriate instruments/sensors.

- Check for overheating of transformer and switchgear, taking readings bi-hourly for 72 hours.

- After a prolonged test run, isolate circuit breakers, inspect isolating contacts and main contacts or contact mechanisms whilst slowly closing the circuit breaker and take necessary measurements for comparison with the manufacturer's standards.

- Inspect for loose bolts, switch contacts and the like.

- Follow manufacturer's instructions for testing and commissioning and record all readings.

7.02.4 METHOD OF MEASUREMENT

A. Transformers for outdoor transformer substations shall be measured as complete units, furnished, installed and put into operation after testing and conforming to the specifications, including electric pole, mounting chassis and platform, MV cabling, MV switch disconnector, pole-mounted metallic enclosure and all necessary accessories for correct operation to EDL standards and approval.

B. The amount of completed and accepted work measured as provided for above,

shall be paid for at the unit prices bid for the Pay Items inserted in the Bill of Quantities including full compensation for furnishing all materials, labour, equipment, tools, supplies and all other items necessary for completion of the work as specified and for testing, installation and putting into operation.

PAY ITEM UNIT OF MEASUREMENT (7.2.1) Substation (State type, size &

rating)

Number (No)

(7.2.2) Outdoor Transformer, Mounted on Pole (specify pole type and transformer ratings)

Number (No)


(Consultant) STREET LIGHTING: FEEDER PILLARS 7.03 - Page 19 of 127

SECTION 7.03 STREET LIGHTING: FEEDER PILLARS 7.03.1 SCOPE A. The work covered in this Section consists of the supply or rehabilitation of feeder pillars to supply power to lighting and other installations as required and includes mounting, testing and commissioning. B. Electrical work generally is to be in accordance with the requirements of Section 7.01 of the Specification. C. Feeder pillars shall comply with IEC standard 60598. D. The Contractor shall submit data on the types of feeder pillars proposed for the Works for approval by the Engineer. The data shall include the following:

- Construction details, standards to which pillars comply, current carrying capacities of bus bars and derating factors employed for breakers and busbars

- Manufacturer's catalogue extracts

- Dimensional and electrical characteristics samples of breakers used. E. The Contractor shall submit the following drawings for the types of feeder pillars proposed for the Works for approval by the Engineer.

- External dimensions of feeder pillars

- Details of base foundations

- Details of breakers ratings, busbars

- Glands, joints, etc.

- Mounting details.

- Other drawings as necessary for clarification of the Contractor’s proposals 7.03.2 MATERIALS A. Feeder Pillars and Lighting Control Panels

A.1 Unless otherwise specified in the Drawings, feeder pillars shall be totally enclosed, fully self contained, dust proof, weather proof, vermin proof and suitable for mounting indoors or outdoors. A.2 Cabinets shall be reinforced free standing structures, manufactured from sheet steel of adequate thickness with bolted reinforced corners, of the dwarf type, bolt- mounted onto a pre-formed, suitably-ducted concrete base.



A.3 Cabinets shall have two hinged lockable doors to provide full frontage access to the cabinet, sized according to the equipment being installed. Door keys and locks shall be standard according to the Power Authority’s requirements. The cabinet roofs shall be slanted and shall have water drip edges.

A.4 Lighting control panels shall be factory-built assemblies designed, manufactured and tested in compliance with IEC 60439, complete with all equipment and fittings incorporating moulded case circuit breakers controlling the mains supply in and the outgoing circuits. A.5 Lighting control panels shall have the following characteristics:

Voltage 1000 Volts

Main Circuit Breakers: Four-pole equipped with overload and short circuit trip mechanisms, in compliance with (IEC 60947-2 sequence III) and rated as shown on the drawings.

Branch Circuit Breakers: Single-pole equipped with overload and short circuit trip mechanisms, in compliance with (IEC 60947-2 sequence III) and rated as shown on the drawings.

Interrupting Capacity: to be rated to the short circuit level calculated at the feeder pillar location in accordance with the substation rating.

Contactors: Triple-pole, inductive type, AC 3 type ratings as shown on the drawings and in compliance with the Specification.

A.6 Timers shall be the electronic (quartz) type. Timers shall be capable of operation without interruption in the event of a power supply loss for at least 500 hrs. A.7 Busbars are to be fully insulated, rated at 1.25 times the incoming current and capable of withstanding the short circuit current for one second. The maximum temperature exposure is 50oC. A.8 Each feeder pillar shall be equipped with three ammeters each fitted with a maximum demand indicator with the associated current transformers, one voltmeter with a selector switch and protection fuse, a KWH meter, current transformer and accessories with a glass window mounted on the feeder pillar cabinet inside a special enclosure to the Power Authority specifications and approval or to installed inside the relevant substations according to the agreement with the Power Authority. A.9 Cabling within feeder pillars shall be PVC/PVC single core 1000 Volt grade with copper conductors and suitably rated taking into account the manufacturer’s recommended temperature and "bunching" derating factors. All internal wiring shall be suitably laced or clipped. A.10 The L.V. panel circuits serving street lighting shall be supplied through triple pole contactors which shall be photo-electric controlled by two photocells (mounted in parallel) with a timer connected in parallel with the photocells. An over-ride facility shall be provided for maintenance.



A.11 Photo-electric controls shall be omni-directional cadmium cell thermal relays employing solid state photo - variable conductance elements giving a 2:1 On/Off ratio with sensitivity to switch on lights when the daylight illumination reduces to 70 lux, to allow for the high pressure sodium light striking time, taking account of the rate of daylight intensity drop off in the region. The cell shall be pole mounted at a height of three metres above ground and fitted to the top of the feeder pillar. The timer shall be of the solar type, settable once throughout the year and set at definite periods for switching on and off. A.12 Equipment, busbars and conductors within the pillar shall be fully insulated so that there are no exposed live parts. A.13 Feeder pillars shall have 50 mm x 6 mm high conductivity copper main earth bars for earthing complete with a test link. A.14 A distribution diagram showing all circuit connections, MCCB ratings, cable sizes and references, etc. shall be permanently fixed to the inside of the door of each feeder pillar. A.15 Feeder pillars shall be secured against unauthorised access by means of wedge locks protected by brass plugs and key operated.

A.16 The feeder pillar final finish and colour shall be as detailed on the Drawings and/or to the approval of the Engineer.

A.17 The feeder pillar shall be assembled by a licensed manufacturer.

B. Moulded Case Circuit Breakers (MCCBs)

B.1 MCCBs shall be the thermal-magnetic type for ratings below 600A frame size, unless otherwise shown on the Drawings. MCCBs 600A and larger shall be the electronic solid-state trip type. All circuit breakers shall be 3-pole unless otherwise shown on the Drawings. B.2 Breakers shall be totally enclosed in a moulded case constructed from high quality, high temperature resistant, tropicalized, moulded insulating materials, for normal operation at 70oC within enclosures to in accordance with IEC standards, provided with quick-make, quick-break, trip-free switching mechanisms manually operated by front toggle type handles and automatically tripped under overcurrent conditions. Multi-pole breakers shall have common integral trip bars for simultaneous operation of all poles. Contacts shall be of non-welded silver alloy with arc-quenching metallic devices in accordance with IEC standards. Cable terminals shall be solderless anti-turn box lug or clamp types with set screws suitable for copper or aluminium cables. B.3 Thermal magnetic circuit breakers shall include, on each pole, a bi-metallic inverse time-delay overcurrent trip element for small overloads and instantaneous magnetic overcurrent trip elements for operation under short-circuit conditions. Circuit breakers 250A frame size and larger shall have adjustable instantaneous trips.



B.4 Thermal overcurrent trips shall be compensated to allow for an ambient temperature higher at breaker than the protected circuits or devices. Compensation shall be applicable between 25 and 50oC. In the case of adjustable thermal settings, the range of adjustment shall not exceed the maximum trip rating shown on the Drawings. B.5 When tripped automatically by overcurrent conditions, operating mechanisms of circuit breakers shall assume an intermediate position clearly indicated by the handle between on and off positions. B.6 Circuit breakers of 250A to 600/630A frame sizes shall have interchangeable thermal and electronic trip units.

B.7 Non-interchangeable trip circuit breakers shall have sealed covers. Circuit breakers with interchangeable trips are to have trip unit covers sealed to prevent tampering.

B.8 Circuit breaker ratings shall be non-current limiting, fully rated (100%) with continuous duty at site conditions, and with frame size and interrupting capacity to IEC 60947-2, sequence III (rated ultimate short-circuit breaking capacity) and a maximum trip rating as shown on the Drawings. Interrupting capacities at specified voltages and frequencies shall meet IEC 60947-2 test sequences I, II, III and IV for circuit breakers of utilisation category B.

B.9 Circuit breaker designs shall allow for the addition of electrical operators, controls and interlocking functions, under-voltage releases, shunt-trip coils, alarms and auxiliary switches, padlocking devices, key-lock devices, and the like. Such accessories shall be provided where shown on the Drawings.

C. Metering Instruments

C.1 Instruments shall be housed in enamelled, square, metal cases for flush installation. Scales and markings shall be protected and sealed. The accuracy of instruments shall be within 2% unless otherwise specified. C.2 Voltmeters shall be of the moving iron type, with centre zero adjuster, range 1.25 times nominal system voltage, 90 degree angle, size 76 x 76 mm. C.3 Voltmeter selector switches shall be the 7-position rotary type. C.4 Ammeters in the feeder pillars shall be the moving iron type, with centre zero adjuster, range 2 times nominal circuit amperage, 90o angle and 76 x 76 mm in size. C.5 Ammeter selector switches shall be of the 4-position rotary type.



C.6 Current transformers shall be of the indoor dry type, rated secondary current 5A. The rated primary current, core size and accuracy shall be determined in accordance with the nominal current of the plant protected, the short-circuit level and burden.

C.7 Voltage transformers (VT) shall be provided where required, complete with primary and secondary fuses and disconnecting device.

D. Wiring

D.1 Wiring shall be modularly and neatly arranged on master terminal boards with suitable numbering strips and appropriate cartridge type fuses where required. D.2 Connections shall be made at front of terminal board and with no live metal exposed. D.3 Metal cases of instruments, control switches, relays etc. shall be connected by bare copper conductors of not less than 2.5 mm² section to the nearest earthing bar.

D.4 Control wiring shall be copper, PVC insulated, 85oC, 600V grade and PVC -sheathed for multi-core cables. Finely stranded copper conductors and silicon rubber insulated cables shall be used in proximity to higher temperature components and as flexible cable. D.5 Wires shall be fitted with numbered ferrules of a type approved by the Engineer at each termination.

E. Miscellaneous

E.1 Anti-condensation heaters with disconnect switches and pilot lamps shall be provided in switchboards, controlled by thermostats and/or humidistats in accordance with the Drawings or as approved by the Engineer.. E.2 Schematic and wiring diagrams shall be provided in easily accessible, protected locations within each cubicle.

7.03.3 CONSTRUCTION REQUIREMENTS A. Concrete bases and foundations provided for the installation of equipment shall be constructed in accordance with approved shop, construction and equipment manufacturers' drawings. Holes for fixing bolts and provision for passage of cables shall be provided as required. B. Equipment supports, fixings and sleeves for feeders and cables to be built into concrete foundations, bases, cable trenches or building structures shall be provided and installed as and when required.



C. Concrete bases shall be assembled completely plumb and level before grouting in of holding-down bolts can commence. D. All incoming and outgoing cable supports, cable ends and termination fittings required for power and control cables shall be provided and subjected to the approval of the Engineer. E. Relays shall be set in accordance with manufacturer's instructions and in accordance with the Engineer’s approval. F. Damaged painted surfaces shall be made good by cleaning and applying rust-inhibiting prime coat and two finishing coats of a suitable enamel paint upon delivery of equipment to site. G. The Contractor shall inspect equipment upon delivery to site and report any damage to the Engineer. H. The Contractor shall inspect and check feeder pillars for completeness, component ratings, types, sizes, and wiring connections. Phasing of busbars, contacts and clearances shall also be checked. I. After installation and before handover, the Contractor shall carry out all tests required by the governing codes and any other tests the Engineer may require to check compliance of all installations with the Specification, including insulation resistance tests and operational tests. J. On the main and control circuits using a 1000V megger (2000 Megohm range) the Contractor shall check insulation resistances between phases, between phases and earth/enclosures and between neutral and earth connections. K. The Contractor shall provide portable test equipment to test time-delay characteristics of circuit breakers by simulating an overload or fault condition. He shall measure and record all test results and ambient conditions and compare the results with the manufacturer's data. L. Routine tests on site are to be carried out on every feeder pillar in accordance with IEC 60439 for items assembled from standardised components outside the works of the manufacturer. 7.03.4 MEASUREMENT A. Feeder pillars shall be measured as complete units, furnished, installed, put into operation after testing and accepted after meeting the Specification in all respects, including concrete bases, fully equipped lighting control panels and photocell control units and all related cabling and connections.



B. Lighting control panels installed in locations other than pillar enclosures shall be measured as complete units, furnished, installed, put into operation after testing and accepted as meeting the specification in all respects, including photocell control unit with the related cabling. C. The amount of completed and accepted work shall include for supplying all materials, installation, rehabilitation, testing and putting into operation, for all labour, equipment tools, supplies and other items necessary for proper completion of the work as specified. PAY ITEM UNIT OF MEASUREMENT (7.3.1) Feeder Pillar including Photocell Control

Unit (Specify type or reference) Number (No)

(7.3.2) Lighting Control Panel (Specify type or reference) Number (No)

(7.3.3) Rehabilitation of Existing Feeder Pillar

(Specify type or reference) Number (No) (7.3.4) Rehabilitation of Existing Lighting Control

Panel (Specify type or reference) Number (No)


(Consultant) STREET LIGHTING: CABLES 7.04 - Page 26 of 127

SECTION 7.04 STREET LIGHTING: CABLES 7.04.1 SCOPE A. General

A.1 The work covered in this section include the supply and installation of feeder cables, branch circuit wiring, control cables, terminations, jointing and splicing for lighting installations. A.2 Electrical work generally shall be in accordance with the requirements of Section 7.01 of the Specification. A.3 Current carrying capacities of conductors shall have been determined in accordance with the regulations for specified type of insulation and expected conditions of installation. No change shall be accepted in specified type of insulation unless warranted by special conditions and approved by the Engineer. The Contractor shall check the load and current carrying capacities of the conductors and report any discrepancies or insufficiency of sizes indicated to the Engineer. A.4 Wires and cables shall comply with IEC standards and are to bear the mark of identification of the Standards to which they are manufactured. Wires and cables not having this identification shall be rejected. A.5 The Contractor shall submit data for approval including, but not necessarily limited to, the following:

- Construction details, standards to which cables comply, current carrying capacities, derating factors for grouping and operational temperature ranges

- Manufacturer's catalogue extracts

- Dimensional and electrical characteristics

- Samples of each cable and wire and, if requested by the Engineer, other accessories.

A.6 For each lot of cable supplied, a certificate of origin issued by manufacturer shall be provided stating origin, date of manufacture, composition, standard to which it complies and test certificates.



A.7 The Contractor shall submit drawings for approval including, but not limited to, the following:

- Exact routing layouts, sections and profiles of bus ducts, trays, feeders, sub-feeder cables and branch circuits, assembly and construction sequences and method statements demonstrating coordination between various trades

- Details of supports and fixings for buses, trays and cables

- Details of connections to transformers, switchboards, panel boards etc.

- Details of terminations, splices and tappings and, where permitted, glands and bushings at enclosures

- The number and size of conductors in conduits for all branch circuits in accordance with final conduit routings.

A.8 Wires, cables and feeders shall be obtained from manufacturers acceptable to the Power Authority. The Contractor shall provide the Engineer with certified approval from the Power Authority of the proposed manufacturer and make of equipment prior to completing the order. 7.04.2 MATERIALS A. General

A.1 Unless otherwise shown on the Drawings, cables and other feeders shall have copper conductors. Cable conductors are to be stranded for sections 4 mm2 and above, based on IEC 60228 Class 2. Signal and control cables shall have solid conductors unless otherwise shown on the Drawings or approved by the Engineer. Flexible cords shall have finely stranded conductors. Conductors of single core cables 25 mm2 and above shall be compacted. Multi-core cables 35 mm2 and above shall be sectoral in shape. A.2 Conductor sizes shall be metric unless otherwise shown on the Drawings. Conductors with cross-sectional areas smaller than specified shall not be accepted. A.3 Building wiring insulation shall be colour coded or otherwise identified as required by the Regulations and as follows:

- Neutral shall be light blue or white

- Protective earth shall be green or green/yellow striped

- Phase colours where not specified by the Regulations shall be red, yellow, dark blue for 380/220 V systems and orange, brown and black/brown striped for 220/127 V systems.

The colour coding shall be maintained throughout the installation. Phase-conductors for which outer jackets are not colour coded shall have engraved alphanumeric marks (L1, L2, L3) or colour coded heat-shrinkable sleeves.



A.4 Cables buried directly in the ground shall be armoured unless specifically indicated otherwise on the Drawings.

B. Wires and Cables

B.1 Unless otherwise specified on the Drawings, single conductor cables for wiring in conduits shall have annealed copper conductors with concentric strands and be insulated with flame retardant, moisture and heat resistant PVC/E to IEC 60227 suitable for wet locations and for a conductor temperature of 85oC. Wires and cables shall be 450/750 V grade. B.2 Multi-core PVC insulated cables (0.6/1 kV) shall have annealed, copper conductors, insulated with PVC/E to IEC 60227, flame retardant, moisture and heat resistant, suitable for wet locations and conductor temperatures of 85oC, laid up, bedded with a suitable filler and sheathed in PVC. Armoured cables shall have a single layer of galvanised steel wire armour with PVC oversheathing. Cables shall comply with IEC 60502 and IEC 60811.

C. Connectors (LV Power)

C.1 Connectors type A-1 shall be the pressure indent types for terminations or T-taps and splices on conductors 10 mm2 and smaller. Connectors shall be a non-ferrous copper alloy applied to the conductor by mechanical crimping pressure and with vinyl insulating sleeves or phenolic insulating covers. C.2 Connectors type A-2 shall be the bolted pressure split types for terminations or T-taps and splices on conductors 16 mm2 and larger. Connectors shall be a cast non-ferrous copper alloy applied to conductor by clamping with minimum of two screws and provided with a phenolic insulating cover. C.3 Connectors type B-1 shall be the pre-insulated, spring types for branch circuit and fixture wiring. Connectors shall be steel-encased springs with shells, insulated with vinyl caps and skirts of a manufacture approved by the Engineer.



D. 20 KV MV Cables Three Core MV Cables (24kV maximum between phase), XLPE insulated, shall comply with IEC 60502 and shall have the minimum following characteristics in compliance with Relevant Power Authority standards and to comply with their specifications:

- Conductor: Copper, circular, stranded and compacted, 70mm2.

- Conductor Screen: Extruded semi-conducting layer

- Insulation: Extruded cross-linked polyethylene (XLPE), minimum 4.5mm thick

- Insulation Screen: Non-Metallic Part - Directly applied extruded semi-conducting material, readily strippable

Metallic Part - A layer of copper tape applied with 30% overlap

- Filling and Bedding: Polypropylene extruded over laid up cores to form compact circular bedding

- Outer Sheath: Extruded PVC (colour red) type ST2 to IEC 60502

- Embossing: Electric cable 20000 V

- Short-Circuit Rating: 10 KA for one second 7.04.3 CONSTRUCTION REQUIREMENTS A. Wiring and Cabling Installations

A.1 Building wires and cables shall be installed in conduits, trunking or ducts indoors and outdoors in conduits unless otherwise shown on the Drawings. A.2 Bunching of wires in raceways shall be in accordance with raceway filling factors permitted by the Regulations. A.3 Before pulling wires in conduits the Contractor shall check that the inside of conduits and raceways are free of burrs and are dry and clean.

A.4 Lubricants shall be used for pulling wires or cables if the character of pull would otherwise damage conductors, insulation or jackets. The types of lubricants to be used shall be approved by the Engineer. A.5 Cables and wires pulled inside very high conduit risers shall be supported at the upper end of risers and at intermediate points by split rubber grommets to relieve any stresses on conductors. A.6 At every branch circuit outlet and pull-box, cables shall be left slack to allow for inspection and for connections to be made. Cables terminating in outlet boxes shall be left with at least 250 mm extra length for terminations.

A.7 Joint or taps in wires and cables, if permitted by the Engineer, shall be permanently accessible or made only in boxes or cabinet gutters.



A.8 Connectors for terminating or making T-taps and splices shall be Type A-1 on conductors 10 mm2 or smaller, Type A- 2 for conductors 16 mm2 and larger and Type B-1 for branch circuit and fixture wiring.

A.9 Insulating covers shall be applied to prevent exposure of bare cable connections. A.10 Conductors of wires and cables up to 16 mm2 shall be tightly twisted and where possible, doubled back before being clamped with set screws. Where two or more wires are looped into same terminal these conductors shall be tightly twisted together before inserting into terminals. Bare conductors shall not project beyond any insulated shrouding or mounting of a line terminal. Cables sizes 16 mm2 and larger shall terminate in tunnel lugs with set-screws or bolted or sweated compression connectors.

A.11 Mains and feeder cables in pull-boxes, wireways and wiring gutters of panel boards or distribution cabinets shall be tagged with cable or circuit numbers and the conductor size identification in accordance with the Schedules. A.12 Where two or more circuits are run to or through a control device, outlet box or ceiling junction box, each circuit shall be tagged as a guide to making connections.

B. Feeder and Sub-Feeder Installation (0.6/1 kV)

B.1 Cables shall be directly buried, armoured type, rated 600/1000V. B.2 Where cables are fixed to steel trays or supporting structures, galvanised cast steel clamps (or moulded plastic clamps for single core cables) as approved by the Engineer and/or as shown on Drawings shall be used at distances not exceeding 20 diameters. B.3 Joints or splices shall not be accepted on main and sub-feeders. Cables shall be supplied in lengths sufficient for a straight unjointed termination-to-termination pull through. B.4 Directly buried cables crossing under roads, pipe banks or other services shall be laid in heavy duty PVC duct banks. B.5 Buried cables liable to mechanical damage shall be drawn through PVC conduits or concrete pipes. If steel conduits are to be used, all three phase conductors, neutral and protective earth circuits shall be in the same conduit. B.6 Wires and cables shall be routed to prevent exposure to excessive heat or corrosive agents. If either condition is unavoidable, cables shall be of the type designed for the particular condition.



B.7 Insulating covers shall be applied to prevent exposure of bare cable connections. Insulating covers shall be purpose made and provide a minimum insulation level equal to that of the corresponding conductor insulation. B.8 Glands for various single-core and multicore cables shall be purpose made and suitable for rigid mounting to the equipment enclosures.

C. Feeder Cable Jointing and Termination

C.1 Through joints shall not be allowed in feeder cables where adequate manufacturer's lengths are available. Where a joint is accepted by the Engineer as necessary, it shall be made inside boxes, handholes or manholes. C.2 Through joints and terminations shall be carried out strictly in accordance with the cable manufacturer's recommendations and made with the correct specified materials, boxes, tapes, compounds or mixtures, stress cones, glands and bonds as applicable. Skilled operatives shall be employed for jointing of these cables. The qualifications of operatives carrying out these tasks shall be submitted to the Engineer for approval prior to work commencing on site. Joints shall be filled with epoxy resin after taping unless contrary to the cable manufacturer's recommendations. Sample site constructed cable terminations and through-joints shall be submitted to the Engineer prior to commencing work on site. Samples shall be constructed in the presence of the Engineer and shall be available to the Engineer for testing and inspection in accordance with the manufacturer's recommendations. C.3 Cutting tools for jointing and terminating of cables shall be purpose made, to prevent damage to insulation in general and for shielding of MV cables. C.4 Cleaning of lacquer on conductors shall be by use of a sponge and white spirit unless otherwise instructed or approved by the Engineer.

D. Testing

D.1 Cable tests shall be carried out in accordance with the requirements of the Regulations and Standards. D.2 The Contractor shall provide megger testers of various ranges as applicable and HV test equipment as necessary for testing MV installations. 500V megger testers shall be used on installations with nominal voltage up to 500V, 1000V megger on installations with nominal voltage of over 500V and up to 1000V. D.3 Insulation resistance for LV power and lighting installations shall be carried out in accordance with IEE Regulations 60613-5 through 60613-8 D.4 Insulation resistance for control and signal cables shall be a minimum 10,000 Megohm-km for PE insulated cables and 100 Megohm-km for PVC insulated cables, all measured core-core and core-earth, in accordance with the Regulations.



7.04.4 MEASUREMENT A. High Voltage Cables and Pilot Cables shall be measured by the linear metre installed, directly buried in trenches, to the Power Authority’s requirements, excluding trench excavation and backfill. Pilot Cables shall match existing cables with regard to number of cores and thickness. B. Oil Filled Junction Boxes for the 66kv High Voltage Cables shall be measured by the number of completed and accepted unit for the specified H.V. Cable, complete including refilling of oil in cables and necessary protection in accordance with the Power Authority’s requirements. C. M.V. Cables shall be measured by the linear metre installed, directly buried in trenches, to the Power Authority’s requirements, including trenching. D. LV. Cables shall be measured by the linear metre installed in ducts or clipped on cable tray or supports as specified, or directly buried in trench, including trenching, ducting and cable trays. E. The amount of completed and accepted work shall include for furnishing all materials including cable trays where required, installation, testing and putting into operation, for all labour, equipment, tools and supplies and all other items necessary for the proper completion of the work.

PAY ITEM UNIT OF MEASUREMENT

(7.04.1) High voltage cables (specify type and size)

Linear meter (m)

(7.04.2) Pilot cables Linear meter (m)

(7.04.3) Oil filled junction box for high voltage cables

Number (No)

(7.04.4) Medium voltage cables (specify type and size)

Linear meter (m)

(7.04.5) Low Voltage cables (specify type and size)

Linear meter (m)


(Consultant) INTERIOR LIGHTING INSTALLATIONS 7.05 - Page 33 of 127

SECTION 7.05 INTERIOR LIGHTING INSTALLATIONS 7.05.1 SCOPE A. the work covered in this section includes complete indoor lighting installations including fixtures, control gear, mounting provisions, accessories and connections to circuit wiring and to corresponding lighting control equipment. B. Electrical work generally shall be in accordance with the requirements of Section 7.01 of the Specification. C. Unless otherwise specified, fixtures shall be manufacturer's standard series, designed and manufactured for the purpose and application required, generally in accordance with the Schedule of Lighting Fixtures (if indicated), complying with IEC 60598 and CISPR 1 and to other sections of the Specification. D. The lighting fixture layouts have been determined from photometric data of specified fixtures to achieve desired levels and uniformity of illumination. The Contractor shall check the layouts shown on the Drawings to ensure the exact positions of fixtures with respect to structural members, ducts, pipes, other installations and ceiling panels and tiles. Certain fixtures are shown in provisional positions, pending preparation of the final equipment layout drawings. Such fixtures shall be located in coordination with the final equipment layout so that illumination is as intended by the design. E. The Contractor shall submit data to the Engineer for approval including, but not limited to, the following:

- Detailed literature on each fixture, lamp and control gear including manufacturer's name, catalogue number, rating, material specification, overall dimensions, operating characteristics and principles

- Details of changes to standard fixtures for adaptation to conditions of installation and to the Specification

- Photometric data for lighting calculations including polar light distribution curves, coefficient of utilisation, glare classification, efficiency and depreciation factors.



F. The Contractor shall submit drawings to the Engineer for approval including, but not limited to, the following:

- The exact position of each fixture on reflected ceiling plans, with an indication of ceiling features, structural members, ducts, pipes and other fittings, as applicable and pertinent to the installation

- Installation details including suspension and mounting provisions

- Purpose made fixtures or lighting assemblies with full details

- Wiring details, circuit and panelboard references and special lighting control arrangements.

G. The Contractor shall submit to the Engineer fully equipped samples of each fixture type, modified if required, together with colour and texture samples of each fixture. 7.05.2 MATERIALS A. High Intensity Discharge Lamp Fixtures

A.1 Fixtures shall be complete units including integral ballasts (and igniters for HPS lamps where indicated) and lamps of required number and type and shall have lighting distribution characteristics as indicated on the Drawings, in accordance with the Specification and to the Engineer’s approval. A.2 Fixtures shall have mounting accessories, such as suspension rods or chains, rails or brackets, and protective glass covers with gaskets for protection against dust and humidity or the type of corrosive atmosphere predominant in the location. A.3 Ballast and igniter devices shall be power factor compensated to at least 0.9 lagging, and a type specially selected for the lamp type and size used. Lamps shall be able to start with at least +/-10% variation from nominal line voltage and continue in normal operation with dips attaining 20% for four seconds. Compensation shall be provided to ensure there is no significant increase in the operating current during starting and that gear losses do not exceed 10% of normal wattage. RF suppression circuits shall be provided.

B. Lamps Lamps shall be the tubular, high pressure sodium (SON-T) plus and shall have the following characteristics: Lamp type Initial Luminous Output Lifetime (Hours)

400 W (SON-T) 55,000 12,000

250 W (SON-T) 31,500 12,000

150 W (SON-T) 16,500 12,000



C. Fluorescent Fixtures

C.1 Lamp holders shall be manufactured from heavy duty, moulded white plastic with non-corroding spring contacts and shall conform to IEC 60400, C.2 Lamp holders for industrial fittings shall be the spring-loaded turret types, heavy duty and dust protected. C.3 Ballasts shall conform to IEC 60921. Only single or two-lamp ballasts shall to be used in any one fixture. Two-lamp ballasts shall be the lead-lag, series type. Equipment shall be enclosed in a sheet steel casing with a corrosion resistant finish. Ballasts shall be suitable for operation from a 220 V ± 10%, 50 Hz power supply. C.4 The ballast thermosetting compound shall not soften, liquefy or support combustion under any operating condition or upon ballast failure and shall fill the ballast enclosure and dampen vibrations. Temperature rises, under normal operating conditions, shall not exceed 55oC above a maximum ambient temperature of 40oC. C.5 Each ballast shall have a one-time external fuse and fuse holder rated in accordance with the manufacturer's instructions. C.6 Ballasts shall be the switch start, rapid start or dimming type, as stated in the fixture description and as shown on the Drawings. The power factor shall be corrected to above 0.9, having the manufacturer's lowest case temperature. The sound rating shall not exceed the level given in the Standards. C.7 Ballasts shall be manufactured and certified for each specific lamp and for operation from a nominal power supply, with voltages and frequencies equal to the nominal voltage and frequency of the distribution network. C.8 Capacitors shall conform to IEC 61049, having snap-type connectors and fastening, bolt type M8, for fixing to fixtures.

C.9 Starters shall comply with IEC 60155 and shall be selected in conjunction with the respective ballast and lamp. C.10 Electronic ballasts for use on 26 mm and 38 mm diameter krypton or argon filled tubes shall be used in conjunction with electronic dimming controls. Dimming shall be possible down to 5% of normal output. Ballasts shall be supplied by a manufacture approved by the Engineer, with a service life in excess of 10000 hours.

D. Metal Halide Lamps:

D.1 Metal halide lamps shall be manufactured in accordance with IEC 61167 with E40 bases. The guaranteed average life shall not be less than 10000 hours and luminous outputs, after 100 hours burning, shall be above 32500 lumens for 35 W lamps.



D.2 The permissible base temperature shall not be greater than 250oC, and the maximum bulb temperature not greater than 550oC. Lamp burning for a 2000 W, 220 V lamp shall be possible up to 75oC.

7.05.3 CONSTRUCTION REQUIREMENTS A. Metal earthing frames for fixtures shall be installed as described in Section 7.10 of the Specification. B. The Contractor shall ensure that all enclosed fixtures are insect/dust tight when installed and suitably weatherproof for installations subject to weather conditions. C. New lamps shall be installed in fixtures immediately prior to hand-over and when instructed at other times by the Engineer. Lamps used for temporary service shall not be used for final lamping of fixtures. D. The Contractor shall carry out illumination measurements taken at selected locations, to determine levels and uniformity, if so instructed by the Engineer. E. The Contractor shall measure power factors, currents and voltages for all installations with discharge lamps and present this information to the Engineer. The Engineer shall instruct verification of the measurements, if he considers it necessary, which shall be carried out at the Contractor’s expense. 7.05.4 MEASUREMENT The work prescribed in this section shall be measured under the provisions of Section 7. 06 - Road Lighting.


(Consultant) ROAD LIGHTING 7.06 - Page 37 of 127

SECTION 7.06 ROAD LIGHTING 7.06.1 SCOPE A. General

A.1 The work covered in this section comprises outdoor area and road lighting including luminaires, bracket/arms, columns, power distribution and control, protective earthing and builder's work including column foundations, cable earth pits, cable trenches and ductwork. A.2 Electrical work generally shall be in accordance with the requirements of Section 7.01 of the Specification. A.3 Luminaires generally shall comply with IEC 60598 and the applicable C.I.S.P.R. recommendations. The Contractor shall verify manufacturers’ compliances with these standards and the applicable local regulations and design standards. A.4 Minor deviations from the Drawings shall be considered by the Engineer for improvement in construction details, but no changes shall be made without the written approval of the Engineer. A.5 Unless otherwise specified, equipment shall be designed and derated for continuous and trouble-free service at a 30oC ambient temperature and 85% relative humidity, with temperature reaching 40oC in direct sunlight and with a high UV content. Equipment shall be designed to withstand exposure to direct sunlight under full operating conditions. A.6 The Contractor shall submit to the Engineer a complete set of data for approval including, but not limited to, the following:

- Detailed literature, in English, for each type of luminaire or fixture, lamp and control gear including manufacturer's name, catalogue number, rating, material specification, overall dimensions, operating characteristics and principles, and any modification to a standard product if applicable

- Detailed specifications and drawings for each column type including shape, base/mounting flanges, bolts and nuts, cross-sections, design criteria and calculations, brackets, finishes, provisions for cabling, service cut-out or circuit-breaker etc.

- Photometric data for lighting calculations including polar curves, coefficients of utilisation, efficiency and depreciation factors.



A.7 The Contractor shall submit drawings for approval including, but not limited to, the following:

- Layout of equipment in the exact positions with mounting and construction details, concrete foundation dimensions and reinforcement, routing and sections of duct- banks and trenches, backfill and packing material and earthing rods.

- Cabling and wiring diagrams, single line drawings, loads, phase distribution, protection and control, earthing and the like

- Calculations of illumination and luminance levels and glare, based on CIE methods.

A.8 The Contractor shall submit fully equipped samples of luminaires or other materials or components, if required by the Engineer. A.9 The Contractor shall provide items necessary for maintenance, and up to 5% (or nearest whole unit) of the installed quantities of each type of lamp, control gear, fuses, luminaire covers, breaker, special bolts or nuts, lamp-holders and the like which are subject to burning, breakage or failure. A.10 The Contractor shall submit references from projects using the same type of luminaires for the Engineer’s evaluation and approval.

B. Design Criteria

B.1 The lighting design criteria applicable to all roads are detailed on the Drawings. The road surface on which the lighting levels are to be measured is defined as the width of all the traffic lanes of all road ways, ramps, interchanges, etc. B.2 Luminance and illuminance levels specified below are the maintained average level which shall be calculated and substantiated by the Contractor. Initial values after 100 hours of operation shall be submitted and substantiated by computer printouts (established by an approved computer programme) for the results. The Contractor shall confirm the lumen and luminaire dirt depreciation factors after two years of operation as detailed or recommended by the manufacturers, to assist the Engineer in assessing the maintained lighting levels of the installation. B.3 Luminance and illuminance levels and uniformities shall be calculated by the Contractor for the travel lanes. The Contractor shall take account of the different elevations of roadways and ramps in his lighting calculations. The Contractor shall arrange for the luminaire manufacturers to carry out the final setting of all lights after site erection to ensure maximum utilisation of light output.

B.4 Maintained lighting levels for all traffic roads shall be as specified under Section 7.01 of the Specification. B.5 The Contractor shall check the locations of all columns to ensure that their installation does not cause any conflict with services or features.



B.6 Clearances required by international and national regulations shall be applied. In the case of a conflict, the issue shall be reported to the Engineer accompanied with the proposed solution for approval before proceeding with any works. It is the Contractor's responsibility to ensure that above regulations and clearances required are satisfied.

7.06.2 MATERIALS AND EQUIPMENT A. Lighting Columns

A.1 Columns shall be of octagonal section, tapered, formed sheet steel, electrically welded and of the height specified and as shown on the Drawings. Columns up to 12 metres height shall be one-piece sections. Columns above 12 metres and up to 20 metres height shall only be supplied in two-piece sections if they are of the slip joint type with sufficient overlap to ensure correct a vertical alignment of the column after assembly. Columns shall have a minimum wall thickness of 3 mm at the base. Sheet steel used in column manufacture shall have a minimum rupturing resistance of 37 kg/mm² and minimum yield strength of 24 kg/mm². A.2 Tops of columns shall be designed to receive single or multiple arm brackets or other arrangement as required to support the number of luminaires shown on the Drawings. Bracket arrangements are to be designed to ensure that failure due to wind-induced oscillations does not occur and rotation from the desired alignment is not possible. A.3 Column cross-sections, thickness of steel, joints, welds, bolts etc. shall be designed to withstand gust wind velocities of 160 km/hr in the most unfavourable direction at a height of 10 metres above ground level when the columns are fully equipped. Steel fatigue shall not exceed half the elastic limit, taking into account dynamic stresses due to vibrations. Steel flange plates of adequate thickness shall be solidly welded onto the lower edges of columns as shown on the Drawings and shall have the specified number of holes for holding down bolts together with central cable access holes of not less than 150 mm diameter. A.4 Access doors of a weatherproof construction shall be positioned at column bases and shall be suitably sized to insert and service the supply cable terminations and protective devices. Doors shall be flush fitting with a retaining mechanism and a positive locking arrangement with a removable hexagonal key. Columns shall be reinforced at the door opening.

A.5 Opposite each door, a non-hygroscopic baseboard of suitable size to accept appropriate equipment shall be fixed to the inside of the column by purpose-made brackets. Stainless steel earthing studs with washers and nuts shall be welded inside the column near the access door.



A.6 Welds shall be smooth with all spatter removed. The inside and outside surfaces of columns shall be cleaned by pickling or blasting and shall be free of grease. Steel components of columns shall be hot-dip galvanised after fabrication. The minimum thickness of zinc coating shall be 500 g/m2 on both the inside and outside surfaces of columns. Galvanising shall be to BS EN 12502-3:2004. Any damage to the galvanising shall be rectified during erection by wire brushing the affected area and treating with an approved rust converter to the satisfaction of the Engineer. Flange plates and the inside and outside of column bases up to 2.5 metres above ground level shall be coated with heavy bitumen paint prior to erection. Washers and nuts used for fixing columns onto foundations shall be protected by approved covers, to the Engineer’s satisfaction.

A.7 Columns with one or two luminaires shall be connected over one phase and neutral. Columns with three or more luminaires shall be connected over 3 phases and neutral, unless otherwise shown on the Drawings. Bolted terminals and cable lugs shall be provided with 3 phases and neutral terminals, for incoming and outgoing 3 phase 4 wire cables and of the sizes shown on Drawings. One SP circuit breaker, rated according to lamp wattage and to the short circuit level calculated at the column location shall be provided for each luminaire. Circuit breakers shall be compensated and rated for a 50oC ambient temperature with interrupting capacity as specified under other sections of the Specifications or Drawings and shall be mounted in weatherproof enclosure on the baseboard. Wiring shall be PVC insulated 3 or 4 core with an 85oC conductor temperature. Cables shall be a minimum of 4 mm² copper conductor.

A.8 For columns installed close to the sea, the zinc coating shall be a minimum of 170 microns to the relevant EN Standards. The columns shall be finished with an epoxy painting of two layers over the galvanization.

B. Road Lighting Luminaires

B.1 Luminaires shall be totally enclosed, dust protected and splash proof, with lamp compartment protection conforming to IP 66 of IEC 60529 and control gear protection to at least IP 65. Luminaires shall be shock resistant and specially designed to house the required lamps, electrical gear and accessories. Casings shall be corrosion resistant, extruded or pressure die-cast aluminium alloy. B.2 Exposed metal parts of luminaires shall be factory finished, stove enamelled, with suitable corrosion resisting paint capable of resisting heat emitted by lamps during continuous operation and under full sunlight conditions. The colour shall be as shown on the Drawings or as agreed with the Engineer. B.3 Mirror reflectors shall be single piece, 99.5% purity, glazed and anodized aluminium or die-cast, super-purity aluminium vapour-deposited, coated with a transparent layer of silicon protection against wiping. B.4 Luminaire protectors shall be manufactured from heat and shock resistant glass, mounted with sealed covers to the approval of the Engineer. Ozone and UV resistant ethylene propylene, or an equivalent rubber compound approved by the Engineer, shall be used to ensure watertight sealing of the front glass.



B.5 Lamp sockets shall be manufactured from high grade porcelain, mounted in support brackets with a provision to adjust lamps vertically and axially. Lamp support and locking systems shall grip and prevent lamp movements in operation. B.6 Ballasts and control gear shall be mounted in luminaires in separate compartments isolated from lamps and with enclosed terminal blocks fitted with quick-disconnect electrical leads. Where required, control gear shall be contained in a prewired box, having an enclosure of IP 65 of IEC 60269 and mounted on luminaire rings separated from luminaires. Control gear shall be plug-in types for operation at 220 V ac single phase, 50 Hz; ballasts shall be specially selected for each particular type of lamps used and lamps are to be able to start with at least +/-10% variation of nominal voltage and continue in normal operation with dips attaining 20% for four seconds. Control gear losses shall not exceed 10% of normal lamp wattage. RFI suppression devices shall be provided. Power factors shall be compensated to at least 0.9 lagging. B.7 Terminal blocks shall be of the suitable screw-tunnel type, clearly marked with arrangements to facilitate maintenance, quick replacement and easy disconnection of individual components. B.8 Types of lamps shall be as shown on the Drawings and as described in the relevant Section of the Specification.

C. Underbridge and Underpass Lighting Luminaires

C.1 Underbridge and underpass lighting luminaires shall be totally enclosed and dustproof, conforming to IP65 of IEC 60529, shock resistant and specially designed to house the required lamps, electrical gear and accessories. Bodies shall one-piece extruded aluminium (magnesium - silicon alloy) having a wall thickness of not less than 2.5 mm. C.2 Exposed metal parts of luminaires shall be factory finished, stove enamelled, with corrosion resisting paint capable of resisting heat emitted by lamps during continuous operation, or anodized to a minimum thickness of 15 microns. The whole assembly shall be treated against corrosion by anodising the aluminium. C.3 Mirror reflectors shall be 99.5% purity, polished aluminium reflectors and coated with transparent layers of silicon to protect against wiping. C.4 Control gear shall be mounted on a "plug-in" type control gear tray and shall be housed within the luminaires to an IP65 tightness level. C.5 HRC fuse cartridges, suitably rated and conforming to IEC 60269 shall be provided, complete with bases for the protection of luminaires. Fuses shall be rated to withstand starting currents and located in the control gear enclosures.



C.6 Ground wire shall be connected through the plug and socket connectors to ensure that the ground potential is maintained on the gear tray when it is being removed from the luminaire for maintenance purposes. C.7 Luminaires shall have a hinged front glass with a continuous assembly which shall comprise of a clear toughened glass plate, not less than 5.0 mm thick, capable of swinging to the vertical position. The front glass assembly shall seat on to a silicone non- rotting type gasket and once seated shall provide the required degree of protection with a continuous closing system. Glass shall be shatterproof in order to prevent shards falling on the carriageway below. Each luminaire shall have an HRC fuse for protection. C.8 Luminaires shall be complete with their mounting accessories and supported from unistrut galvanised steel channels fixed to the soffit of the ribbed slab. Fixing details shall be submitted for approval by the Engineer. Luminaires shall be provided with a three phase terminals for incoming and outgoing cables and an outgoing connection for the power supply to the luminaires. C.9 Underbridge luminaires shall be fixed flush with the underside of the soffit between the ribbed beams with a cover matching the deck surface to the satisfaction of the Engineer. C.10 Underpass luminaires shall be installed in a neat continuous line to the satisfaction of the Engineer. Any necessary realignment shall be made by the Contractor at no additional cost. C.11 Fixings shall be approved by the Engineer. All bolts used shall be stainless steel, painted after installation with a two pack anti-corrosion paint to the approval of the Engineer.

C.12 Fixings shall be such that their installation, including luminaries and trays, is capable of being carried out with a minimum of safety factor 3 to 1 per fixing. C.13 Luminaires shall be wired with one-metre lengths of cable, terminating in a junction box in accordance with the Drawings. Earthing wires shall be solidly connected to the earthing studs inside the luminaire. C.14 Lamp sockets shall be high grade porcelain, mounted in support brackets with provisions to adjust lamps vertically and axially. Lamp supports and locking systems shall grip and prevent lamp movement in operation.



C.15 Ballasts and control gear shall be mounted in luminaires in separate compartments isolated from lamps and with enclosed terminal blocks fitted with quick-disconnect electrical leads. Control gear shall be contained in a prewired box, having an enclosure of IP 65 and mounted on luminaire rings separated from the luminaires. Control gear shall be of the plug in type for operation at 220 V, ac, single phase, 50 Hz; ballast shall be specially selected for each particular type of lamp used and lamps shall be able to start with at least a +/-10% variation of nominal voltage and continue in normal operation with dips attaining 20% for four seconds. Control gear losses shall not exceed 10% of normal lamp wattage. RFI suppression devices shall be provided. Power factors shall be compensated to at least 0.9 lagging.

D. Floodlights

D.1 Floodlights shall be totally enclosed, weather, dust and shock resistant in accordance with IP 66 of IEC 60529. D.2 Floodlight housing shall be made of high pressure die-cast aluminium alloy, closed at the front by hinged framed protectors highly resistant to thermal and mechanical shocks and set in position by a continuous closing system to the approval of the Engineer. The enclosures shall be in accordance with IEC 60598 and shall be suitable for operation in an ambient temperature of 70oC. D.3 Reflectors shall be of high purity (over 99% reflectance) anodised aluminium, secured in precision-aligned internal tracks to provide the beam distribution required. D.4 Connection boxes shall be located at rear of the floodlight bodies with gland connections to accept 4 mm2 PVC/PVC three-core cables. D.5 Control gear shall be of the plug-in type, 220 V, 50 Hz, power factor compensated to at least 0.9 lagging. Ballasts and ignitors shall be of the type specially adapted for the makes of lamps selected. Ignitors shall be of the electronic thyristor type. Lamps shall be able to start with at least +/- 10% line voltage and with normal operation dips up to 20% for four seconds. Compensation shall be included to ensure that there is no large increase in operating current during starting. Control gear losses shall not exceed 10%. Cables for internal wiring in control gear compartments shall be single core 2.5 mm2 copper conductors with high temperature insulation and sheathing. D.6 Exposed metal parts of floodlights shall be painted with corrosion and heat resistant paint, resisting operating temperatures attained in direct sunlight and while the lamps are operational. D.7 Floodlights shall be located as shown on the Drawings and mounted on specially designed brackets to allow swivelling in any desired direction and locking firmly in final position. Protector scales shall be provided for accurate setting.

D.8 Bolted earthing terminals shall be provided for each fitting.



7.06.3 CONSTRUCTION REQUIREMENTS A. Equipment shall be constructed to be readily accessible for operation, maintenance and repair. Minor deviations from the Drawings may be made to accomplish this but no changes shall be made without the approval of the Engineer. B. Before commencement of construction of columns and masts the Contractor shall ensure that bases are suitable for column installation. Holding-down and plumb adjusting nuts, washers, locknuts or nyloc nuts shall be stainless steel or cadmium plated. C. Columns shall be erected to ensure that luminaires are located on a line parallel to the theoretical profile of the road. The alignment of columns, both horizontally and vertically, shall be secured to the satisfaction of the Engineer. Brackets shall be set at 90 degrees to the longitudinal axis of road. D. After demonstrating to the Engineer that specified lighting requirements have been met, the Contractor shall carry out the final setting and locking in position of the floodlights. E. Cable ducts shall be directly buried except at crossings with other service work or roads where they shall be ducted. F. Each column shall be separately earthed in accordance with the Drawings and to the satisfaction of the Engineer G. The Contractor shall carry out a visual inspection of each piece of equipment, to check its condition, quality of workmanship, alignment, perpendicularity, labelling and the like, are all in conformance with the Specification and Drawings. H. Insulation resistance and continuity tests shall be carried out on each circuit and piece of equipment before energisation, with circuit breakers in the open position and lamps not installed. I. Operational tests shall be carried out on all circuit breakers and control gear, with lamps installed, including recording voltage at terminals of ballasts on final columns of each circuit and at distribution panels. J. Performance tests shall be carried out after 100 hours normal operation and shall include measurement of lighting levels and uniformity on the required illuminated surfaces. K. Other tests shall be carried out as required by the Engineer to verify conformity with the Specification. L. Earthing resistance tests shall include measurement of earth electrode resistance at the final points of circuits and continuity of protective conductors. M. Results of tests shall be recorded on site and signed by witnessing parties. A copy of all test results shall be presented to the Engineer for record and approval.



N. The Contractor shall provide equipment and labour including instruments and provisions for carrying out testing. 7.06.4 MEASUREMENT A. Lighting columns, complete with bracket arms, openings and doors with retaining chain, luminaires, lamps, control gear, internal cabling, fuse box with incoming and outgoing cable terminations and protective devices and all necessary accessories mounted on foundation in accordance with the Specification, shall be measured by the number furnished, installed and put into operation after testing and accepted as meeting the specification in all respects, to the Engineer’s approval. B. Wall-mounted or pole-mounted brackets, complete with luminaire, lamp, control gear, internal cabling, weatherproof fuse box with cable terminations and protective devices and all necessary accessories in accordance with the Specification shall be measured by the number furnished, installed and put into operation after testing and accepted as meeting the specification in all respects, to the Engineer’s approval. C. Street lighting luminaires shall be measured by the number of completely installed units complete with lamps, control gear, fuse box, cabling and all necessary accessories, and put into operation as per the requirements of the Specification D. Underbridge and underpass luminaires shall be measured by the number of completely installed units complete with lamps, control gear, connection boxes, pull boxes and internal cabling and put into operation in accordance with the requirements of Specification. E. Interior lighting units and floodlights shall be measured by the number of completely installed units complete with lamps, connections and internal cabling and put into operation in accordance with the requirements of the Specification. F. The amount of completed and accepted work measured as provided for above shall be paid for at the unit prices for the Pay Items inserted in the Bill of Quantities, which prices shall be full compensation for furnishing all materials, labour, equipment, tools, supplies and all other items necessary for the proper completion of the works as specified and for testing, installation and commissioning.



PAY ITEMS UNIT OF MEASUREMENT

(7.6.1) Lighting Columns (specify type, height, number of brackets and type/ intensity of luminaires) Number (No)

(7.6.2) Wall-mounted Luminaires on Brackets (specify bracket type/ length and intensity of luminaires) Number (No)

(7.6.3) Street Lighting Luminaires (specify type/ intensity) Number (No)

(7.6.4) Underbridge Luminaires (specify type and intensity of luminaires) Number (No)

(7.6.5) Underpass Luminaires (specify type and intensity of luminaires) Number (No)

(7.6.6) Floodlight (specify fitting, type and intensity of luminaires) Number (No)

(7.6.7) Interior Lighting Units (specify fitting, type and intensity of lamps) Number (No)


(Consultant) WIRING DEVICES AND MISCELLANEOUS EQUIPMENT 7.07 - Page 47 of 127

SECTION 7.07 WIRING DEVICES AND MISCELLANEOUS EQUIPMENT 7.07.1 SCOPE A. The work covered in this Section includes wiring devices, lighting switches, socket outlets, outlet boxes and plates. B. Electrical work generally shall be in accordance with the requirements of Section 7.01 of the Specification. C. Components shall be standard manufactured items, uniform and modular, complying with the Standards stated herein and approved by the Engineer. D. The Contractor shall submit data for approval by the Engineer, including catalogues, detailed literature, manufacturers’ names, catalogue numbers, rating, specification, overall dimensions and special features, as applicable for each item. E. The Contractor shall submit drawings for approval including, but not limited to, the following:

- Position of each item including outlet boxes and fittings on layout drawings, with box and equipment types and sizes

- Wiring diagrams of special items. F. The Contractor shall submit samples of each type of device for approval by the Engineer. 7.07.2 MATERIALS A. Outlet Boxes and Plates - Generally

A.1 Surface or recessed boxes shall be suitable for the types of related conduits or cable system. Shapes and sizes of boxes shall be of compatible standards as switches, socket outlets and lighting fixtures selected and of various types and mounting methods required. A.2 Unused openings in outlet boxes shall be closed with knock-out closers manufactured for the purpose. A.3 Blank plates shall be installed on outlet boxes on which no apparatus is installed or where the apparatus installed does not have a suitable cover for the box. Blank plates for wall outlets shall be attached by bridges with slots for horizontal and vertical adjustment. A.4 Floor outlets and plates shall be water-tight and impact resistant.



B. Metallic Outlet Boxes

B.1 Recessed and concealed boxes shall be manufactured of galvanised pressed steel, with knock-outs for easy field installation. Boxes shall be punched as required on Site. B.2 Outdoor surface or recessed boxes shall be galvanised cast iron with threaded hubs and PVC gaskets to ensure watertightness and with stainless steel or non-ferrous, corrosion resistant screws. B.4 Metallic outlet boxes shall be obtained from the same manufacturer as conduits or other related equipment approved by the Engineer.

C. Moulded Plastic Outlet Boxes

C.1 Boxes and covers used with PVC conduit systems shall be heavy gauge pressure moulded plastic, minimum 2 mm thick, self extinguishing, with a softening point of not less than 85

oC. Boxes shall have provisions for securely terminating

conduits and shall be of a suitable manufactured standard for the required application. C.2 Boxes shall have brass inset threads to receive cover screws and for mounting devices or accessories, push-fit brass earth terminals and steel insert clips to provide additional support for pendants or for heat conduction. Neoprene gaskets shall be provided for weatherproof installations.

C.3 Approval of the source of moulded plastic outlet boxes shall be obtained from the Engineer prior to completing the equipment order.

D. Switches

D.1 Switches shall be quick-make, quick-break types with silver alloy contacts in arc resisting moulded bases and toggle, rocker or push-button as specified on the Drawings or by the Engineer, for inductive or resistive loads up to full rated capacity and arranged for side and/or back connection.

D.2 Weather proof switches (type S5) shall be 20A, 240V, for installation outdoors, enclosed in weatherproof outlet boxes, type IP 54.

D.3 Approval of the source of switches shall be obtained from the Engineer prior to completing the equipment order.

E. Socket Outlets

E.1 Sockets shall have injection moulded plastic bases with self-adjusting, non-expanding contacts to prevent permanent distortion, arranged for side and/or back connection and with screw terminals accepting at least three parallel branch-circuit wires.



E.2 Weatherproof socket outlets shall be of the types indicated below, enclosed in surface mounted cast metal boxes and with covers comprising spring-retained gasketed hinged flaps. The enclosures shall be pre-designed boxes and covers for the type of socket outlet specified. Approval of the source of socket outlets shall be obtained from the Engineer prior to completing the equipment order. E.3 Weatherproof socket outlets type R05, shall be 13 A, 250 V, 2 pole plus earth, to EN 1363, with safety shutters.

E.4 Weatherproof three phase socket outlets shall be type R44 with three poles, earth and neutral 32 Amps, 400 V, IP X4.

7.07.3 CONSTRUCTION REQUIREMENTS A. The Drawings indicate the approximate locations of outlets and equipment. Exact locations shall be determined on site. Any conflict that would place an outlet in an unsuitable location shall be referred to the Engineer. B. Mounting heights for outlet boxes and similar equipment shall be uniform within the same or similar areas. Mountings shall be as shown on the Drawings or as approved by the Engineer. Unless otherwise shown or instructed, lighting switches and socket outlets shall be mounted at 1200 mm and 300 mm respectively from the finished floor level. Switches of the toggle type shall be mounted with their long dimension vertical and operating handles up when in the “on” position. C. Single pole switches shall switch the phase wire. The Contractor shall not run neutral wires through switches having a neutral shunt or bridge. D. Additional outlets to those shown on the Drawings shall be provided as required by equipment manufacturers for control or other wiring. E. Exposed outlet boxes shall be securely fastened to walls using machine screws to permanent inserts or lead anchors. F. Recessed outlet boxes shall have neat openings to allow for the thicknesses of finishings and extension rings shall be used if required. Damaged finishings shall be repaired to their original condition prior to the installation of fittings or plates. G. Exposed boxes and plates shall be installed plumb, square and parallel to the finished wall surface. Exposed plates covering recessed boxes shall rest neatly on the wall surface without gaps and fully covering the box. H. Grouped outlets shall be arranged neatly so that fittings are accessible and clear. I. Damaged fittings or plates with a damaged finish shall be rejected by the Engineer. Fittings and plates shall be protected against damage after installation.



J. Fittings and equipment shall be inspected and approved by the Engineer for fixing and workmanship. K. Megger tests shall include switch and socket outlet tests together with the insulation resistance of wiring installations. L. Devices shall be tested for operation and performance as intended at full load without any signs of heating. M. Equipment shall be insulation- tested and observed under full-loading for not less than 3 days. 7.07.4 MEASUREMENT The items for switches and sockets shall include plates, boxes and all wiring, fittings and fixtures and shall be measured by the number furnished, installed and put into operation after testing and accepted as meeting the specification in all respects. PAY ITEMS UNIT OF MEASUREMENT (7.7.1) Switch (type) Number (No) (7.7.2) Socket Outlet (type) Number (No)


(Consultant) CONDUITS, WIREWAYS, SUPPORTING SYSTEMS AND RELATED ACCESSORIES 7.08 - Page 51 of 127

SECTION 7.08 CONDUITS, WIREWAYS, SUPPORTING SYSTEMS AND RELATED ACCESSORIES 7.08.1 GENERAL A. The work covered in this section include raceways and associated conduits, wireways, cable trays and other installations and accessories necessary to support and protect cables, feeders, sub-feeders, branch circuits and wiring of low current systems, communications and signal cables. B. Electrical work generally shall be in accordance with the requirements of Sections 7.01 of the Specification. C. Conduits, wireways, cable trays and fittings shall be designed, constructed and installed in accordance with safe working practices and with reliable mechanical protection for wires and cables in accordance with the Regulations. D. The Contractor shall submit data for approval by the Engineer including, but not limited to, the following:

- Manufacturers' catalogues with specifications for raceways including conduits, trunking and related accessories

- Samples of each type of raceway and accessory. E. The Contractor shall submit drawings for approval including, but not limited to, the following:

- Routing of conduits, trunking and other associated equipment with details of boxes, accessories and expansion joints.

- Typical assembly details for installation of trunking, trays and other associated equipment.

- Construction details of pull boxes

- Typical installation details including connection of conduits to metal enclosures, connections of flexible conduits, vapour-tight installations in cold rooms, weatherproof installations and earthing connections.

F. The manufacturers of conduits, wireways and related accessories shall be approved by the Engineer prior to completing the equipment order.



7.08.2 MATERIALS A. Rigid Heavy Gauge Steel Conduit

A.1 Rigid heavy gauge steel conduits shall be fabricated using heavy gauge drawn and welded steel, threaded at both ends, to BS 4568-1:1970 and BS 31:1940 Class B (threaded), with class 4 protection for rigid steel conduit, zinc coated inside and outside by the hot-dip process or by sherardization. A.2 Fittings shall be the threaded type, galvanised or cadmium plated malleable cast iron. Fittings used in corrosive atmospheres are to be specially treated. Fittings and components shall comply with BS EN 50086-1:1994 and BS 31:1940. A.3 Locknuts for securing conduits to metal enclosures shall have a heavy hexagonal or castellated pattern for fastening. A.4 Bushings for terminating conduits shall be smooth rounded brass rings. A.5 Miscellaneous fittings including reducers, chase nipples, three piece unions, split couplings and plugs shall be standard fittings designed and manufactured for the particular application.

B. Light Gauge Steel Conduit

B.1 Light gauge steel conduits shall be fabricated from welded steel, non-threaded, galvanised externally and protected internally with corrosion-resistant enamel in accordance with and to the relevant BSI Standards. B.2 Conduits in corrosive atmospheres shall be manufactured from a copper silicon alloy in accordance with the relevant BSI Standards. B.3 Fittings for light gauge steel conduits shall be of the threadless pressure type, galvanised or cadmium plated malleable cast iron. Fittings used in corrosive atmospheres shall be specially treated in accordance with the relevant BSI Standards.

C. Flexible Steel Conduit

C.1 Flexible steel conduits shall be fabricated from steel, cold rolled and annealed, non-threaded, formed from a continuous length of helically wound and interlocked strip steel, with fused zinc coating on the inside and outside, and to BS 731:1958. C.2 Flexible conduits impervious to liquids shall have PVC jackets extruded over cores. C.3 Flexible conduit fittings generally shall be the threadless, hinged clamp types, manufactured from galvanised or cadmium-plated malleable cast iron. Fittings used in corrosive atmospheres are to be specially treated in accordance with relevant BS Standards.



C.4 Straight connectors shall be in one piece. The female ends shall have hinged clamps and deep slotted machine screws for securing to conduits and male ends shall have threads and locknuts.

C.5 Angle Connectors of 45 or 90 degrees and terminal connectors shall be as specified for straight connectors, except that they shall be two-piece sets with removable upper sections.

D. Rigid Heavy Gauge PVC conduit

D.1 Flexible steel conduits shall be fabricated from rigid unplasticised polyvinyl chloride with high impact and high temperature resistance, flame retardant, non-hygroscopic and non-porous, to BS EN 61386-1:2004. D.2 Flexible steel conduits shall be unbreakable, non-inflammable, self extinguishing, heavy moulded plastic. Expansion couplings shall be the telescoping double tube types, with at least two inner water-tight neoprene rings. D.3 Conduits, boxes and accessories shall be assembled by cementing, using manufacturer's recommended products and appropriate connectors or spouts. Where no spouts are available, smooth bore male PVC bushes and sockets shall be used.

E. Steel Conduit Accessories

E.1 Conduit sleeves through outside walls shall be cast iron with end and intermediate integral flanges and with internal diameter larger than the diameter of the through-conduit. The sleeve length shall correspond to the wall thickness. The space between a sleeve and the corresponding conduit shall be packed with oakum to within 50 mm of both faces. The remainder shall be packed with a plastic compound or lead, held in place by heavy shield plates bolted at both ends to the flanged ends of the sleeve. Alternative sleeves shall only be used if approved by the Engineer. E.2 Supports and hangers shall be galvanised malleable cast iron straps or structural steel sections with hot dip galvanised bolts and nuts. E.3 Expansion joints for embedded steel conduits (type A) shall be watertight, flexible conduits with end fittings to receive fixed conduits. The length shall allow movement within the range of the joints and shall not to be less than 20 times the diameter of the conduit. Conduits shall be covered with thick rubber tubing with 5 mm minimum gap around the tubes. Bonding jumpers with earth clamps shall be electrically connected to both sides of joints. E.4 Expansion joints for exposed steel conduits (type B) shall be sleeves with fittings to permit telescoping of one conduit into the sleeve. Movable conduits shall be fitted with watertight bushings. Joints shall be weatherproof and made from galvanised malleable iron or steel. Bonding jumpers with earth clamps shall electrically connect both sides of joints.



E.5 Expansion joints for exposed steel conduits shall be (type C) PVC-sheathed flexible steel conduits terminating in pull boxes and securely fixed on each side of structural expansion joints. Bonding jumpers shall form electrical connections to both sides of the joints.

E.6 Tags shall be 50 mm diameter and made of steel with indented lettering, treated with rust inhibitors and with a baked-enamel finish.

F. Cable Trays and Ladders

F.1 Cable tray and ladder components include cable trays or ladders as shown on the Drawings, bends, elbows, tees, couplings and plates, rubber grommets, hangers, bracket supports and other system accessories required for safety and protection of the cable installations. F.2 Trays shall be heavy gauge perforated sheet steel, hot-dip galvanised after manufacture, minimum 1.5 mm thick, with sides not less than 45 mm deep and as shown on the Drawings. Fittings shall be of the same material as the tray. Covers, where shown on the Drawings, shall be a minimum 1.0 mm thick galvanised sheet steel, snap-on type, forming a rigid assembly with the tray. F.3 Ladders shall be fabricated from 2 mm mild carbon steel, hot-dip galvanised after manufacture. Ladder side channels shall be a minimum of 127 x 32 mm, strengthened by reinforcing inserts for torsional rigidity. Rungs shall be slotted to take cable cleats or ties and conduit clamps and to have 50 x 25 mm channels spaced at 300 mm centres. F.4 Galvanising shall be in accordance with BS EN ISO 1461:1999 (335 gr/m2), applied after fabrication. F.5 Coatings applied to cable trays or cable ladders shall be black applied after the prime coat. F.6 Trays and ladders shall be standard metric sizes, 150, 300, 600 and 900 mm wide, and at least 2.5 m in length. The size of a tray or ladder shall be determined by the number and sizes of cables in accordance with the Regulations and/or as shown on the Drawings. Trays or ladders shall have strength and rigidity to provide support for cables contained within them. Deflection between supports shall not exceed 1/350 under full loading capacity. F.7 Earthing connectors for plastic coated trays or ladders shall be provided on each coupling between adjacent sections.

G. Wiring and Cable Trunking

G.1 Wiring and cable trunking components include wireway bases, clip-on covers, couplings, end plates, wall flanges, panels, rubber grommets, elbows, tees, adapter plates and necessary hangers, supports and accessories.



G.2 Steel trunking shall conform to BS EN 50085 and shall be fabricated using galvanised sheet steel, minimum 1.5 mm thick, protected internally and externally with a corrosion- resistant finish such as zinc or cadmium with a top coat of enamel. G.3 PVC trunking shall be high impact, heavy duty, self- extinguishing, rigid PVC with grooved double locking clip-on covers. The product shall be approved by the Engineer before ordering. Trunking shall be capable of receiving functional slot-in hangers and demountable separators to segregate wiring systems as required. G.4 Trunking sizes shall be selected by the Contractor as required to accommodate the number of conductors permitted by the Regulations and/or as shown on the Drawings and approved by the Engineer.

H. Weatherproof Wiring and Cable Trunking

H.1 Weatherproof trunking shall be hot-dip galvanised sheet steel trunking and cover. The type of weatherproof trunking and the manufacturer shall be approved by the Engineer prior to placing the order. H.2 Weatherproof trunking shall have outwardly turned flanges to receive covers and internal sleeve couplings between sections. H.3 Gaskets between sections of trunking shall be made of neoprene bonded cork. H.4 Removable flanged covers shall be secured with galvanised steel holding screws.

I. Supporting Systems Supporting systems shall be constructed using hot-dip galvanised sheet steel, complying with BS EN 10143:2006. The thickness of channels shall be at least 2mm. 7.08.3 CONSTRUCTION REQUIREMENTS A. Conduits and Wireways Generally

A.1 Unless otherwise indicated on the Drawings, all light and power circuits, communications, signal and low current systems wiring shall be drawn inside conduits or wireways towards the equipment. Separate conduit and wireway installations shall be used for HV cables, normal light and power circuits, emergency light and power circuits and communication, signal and other low current system wiring. A.2 Junction, pull and splice boxes of ample capacity shall be provided as indicated or required. All boxes shall remain permanently accessible. A.3 Tools and accessories for forming and installing conduit and wireway systems shall be purpose made for the particular application and used in accordance with manufacturers' instructions.



A.4 Conduits and wireway installations shall be concealed from public view as far as possible. A.5 Sizes of conduits and wireways not shown on the Drawings shall be selected in accordance with the Regulations and in relation to the number and size of conductors to be held. The minimum size of conduit for all applications shall be 20 mm diameter, unless otherwise shown on the Drawings. A.6 Conduits and wireways shall be joined together and connected to electrical boxes, fittings and cabinets to provide continuity and support. Earthing jumpers shall be installed on all steel conduits to ensure effective electrical continuity irrespective of whether a separate protective earth conductor is required or not.

B. Raceway Application and Installation

B.1 Rigid heavy gauge PVC shall be used for conduits in underground installations, in screed below pavements and in duct banks. B.2 Rigid heavy gauge steel shall be used for conduits for surface mounted main and sub-feeder installations, except where otherwise shown on the Drawings. B.3 Rigid heavy gauge PVC shall be used for conduits in embedded, underfloor installations for lighting and power circuits. B.4 Steel shall be used for conduits for low current, communication and signal system wiring, except where otherwise shown on the Drawings or described in the particular section of the Specification. B.5 Steel shall be used for conduits over suspended ceilings for lighting and power installations. B.6 Flexible conduits shall be used for connections to motors, vibrating and non-rigidly fixed equipment and to fixtures installed in false ceilings. B.7 Conduits considered to be subject to undue risk of damage by shock or corrosion shall be brought to the attention of the Engineer. Copper silicone alloy tubes shall be used in corrosive atmospheres. B.8 Conduits shall not cross pipe shafts, vents or openings. B.9 Conduits shall be installed at least 100 mm clear of and preferably above pipes of other non-electrical services. B.10 The Contractor shall obtain approval from the Engineer for the position of sleeves where conduits pass through reinforced concrete. Additional openings shall only be allowed in finished slabs with the permission of the Engineer, but shall always be drilled and not broken. Sleeves shall be inserted to maintain the correct position and alignment during construction work.



B.11 The Contractor shall provide a movement joint, of a type detailed in the Drawings or as approved by the Engineer, in each conduit run over 30 metres in length and at crossings of expansion joint in structures. B.12 Conduits shall not cross waterproof structures unless permitted by the Engineer. In such cases, specially designed and approved fittings shall be used. B.13 The Contractor shall make good all holes for conduits passing through walls, floors and ceilings with cement or similar fire-resisting material to the full thickness. B.14 Conduit runs between outlets, fittings or fittings and outlets shall not contain more than the equivalent of two quarter bends (180 degrees total). B.15 Bending of conduits shall be made without damaging the conduit or tubing and without reducing the internal diameter. In-situ bending of conduits is permissible only with the approval of the Engineer. B.16 Cut ends of conduits shall be reamed to remove burrs and sharp edges. B.17 Conduits shall be aligned in order that that condensation can drain to a plug at the lowest point. B.18 Before wiring, conduits shall be swabbed through. Cables shall not be drawn into any section of the system until the relevant conduits and draw boxes are fixed in position. B.19 Conduits shall be properly capped until the wiring conductors are drawn in. B.20 Conduit and fittings installed outdoors shall be watertight and highly resistant to corrosion. Appropriate fittings, threaded and hubbed boxes, gaskets with screw on covers shall be used.

B.21 Rigid conduits shall not be terminated or fastened to motor frames or bases. B.22 The length and radius of flexible conduits used for motors and vibrating equipment shall permit bending of feeder cables without damage to either conductor or insulation. B.23 Draw strings of 3mm galvanised stranded steel wire or equivalent strength cord with wooden blocks fastened at ends shall be installed in empty service conduits. B.24 Standard elbows shall be used for conduit sizes over 40 mm. For smaller sizes, field bends shall only be used provided no damage occurs to the conduit and if the method of bending is approved by the Engineer.



B.25 Tags shall be fitted to conduits entering or leaving floors, walls or ceilings for the identification of conduits and circuits. Tags shall also to be placed at suitable intervals throughout the system, as determined by the Engineer.

C. Steel Conduits

C.1 Conduits into sheet metal enclosures or outlet boxes shall be terminated in a threaded hub or securely held in place by two lock-nuts either side of the sheet metal and terminated with an insulating bushing. C.2 3-piece unions or split couplings shall be used at conduit joints and terminations. Running threads shall not be used. C.3 Additional threaded cuts on galvanised steel conduits shall be painted with zinc based coating resistant to corrosion. C.4 Any damage to the protective coatings of conduits shall be repaired to give at least the original degree of protection. C.5 For outdoor mounted steel conduits an anti-corrosion coating of zinc-chromate based paint and two weather resistant finish coats of enamel, of a colour approved by the Engineer, shall be applied. C.6 Galvanised conduits through screed shall be painted with a heavy coat of emulsified bitumen. C.7 Galvanised steel conduits buried in the ground or placed in wet or damp locations shall be coated with two heavy coats of hot bitumen. Conduits shall be covered by at least 600 mm of fill if buried in planting soil and at by least 300 mm if under walkways. C.8 Hardwood or threaded iron plugs shall be used for capping ends of unused steel conduits.

D. PVC Conduits

D.1 PVC Conduit couplings and terminations into spouted fittings shall be made watertight and permanent using a method approved by the Engineer. D.2 Conduits terminating in switchgear, fuse boards, trunking, adaptable boxes or other non-spouted enclosures shall be connected using smooth bore male PVC bushes and sockets. D.3 Conduit ends and fittings shall be cleaned and jointed using PVC cement recommended by the manufacturer and approved by the Engineer. D.4 Semi-permanent adhesive shall be used in joints requiring expansion couplers.



D.5 Conduits over 25 mm diameter shall be hot bent by a method approved by the Engineer. Conduits not exceeding 25 mm diameter may alternatively be cold bent using bending springs.

E. Embedded Conduits

E.1 Conduits in concrete slabs shall be placed parallel to the main reinforcing steel. E.2 Conduits in partitions or side walls shall be horizontal. E.3 Pull-boxes for embedded conduits shall not to be used unless specific approval is given by the Engineer E.4 Conduits in gardens and landscaping areas shall be encased in concrete, minimum thickness 50 mm, or to the thickness detailed on the Drawings. E.5 PVC conduits in reinforced concrete structures shall be installed after placing reinforcement and before concreting.

F. Exposed Conduits

F.1 Conduits on walls shall be neatly aligned, both horizontally and vertically. F.2 Clamps, hangers, clips, expansion sleeves in inserts and lead anchors for exposed conduits shall be approved by the Engineer before use. F.3 The spacing of clamps or clips for supporting steel conduits shall not to be greater than the following:

Conduit Size (mm) Maximum Spacing of Supports (Metres)

20 3.00

25 3.60

32-38 4.25

50-63 5.00

75 and larger 6.00



F.4 Spacing of clamps or clips for supporting PVC conduits shall not to be greater than:

Conduit Size (mm) Maximum Spacing of Supports (Metres)

Conductors Rated Conductors Rated 60OC and Below Above 60OC

20 1.25 0.60

25-50 1.50 0.75

63-75 1.80 0.90

90-125 2.00 1.00

150 2.50 1.25

F.5 Bends and fittings shall be firmly fastened to conduits at each side of the bend and within 900 mm of each outlet box, junction box, cabinet or fitting.

G. Cable Trays

G.1 Cable tray runs shall be completed before the installation of cables. G.2 Supports shall be provided to prevent stress on cables at the tray edges. Cable trays extending through partitions and walls shall be protected by fire-proof non-combustible barriers. G.3 Sharp edges, burrs and projections shall be removed from cable trays. Trays shall be fixed using suspension rods or steel angle brackets approved by the Engineer at spacings not exceeding 1 metre or as shown on the Drawings. G.4 Connection fittings on trays, such as tees, bends and crossings shall be purpose made with radii to permit cable bending. G.5 A minimum clearance of 250mm shall be maintained between tops of trays and ceilings, beams and other services and between trays in multi-tier formation. G.6 Cables shall be secured to trays with purpose made straps or saddles and arrange in one layer only, evenly spaced or as shown on the Drawings, with a minimum spacing of one diameter of the larger of the two adjacent cables or of a trefoil formation of single core cable circuit. G.7 Metal trays shall not be used as earth continuity conductors. Flexible tinned copper straps shall be connected to the nearest bare earthing conductor at a maximum spacing of 30 metres.

H. Underground Ducts Ducts shall be installed in accordance with Section 7.15 of the Specification.



I. Support Systems

I.1 Each run of supporting systems shall be completed before the installation of cables or luminaires. I.2 Supports shall be provided to prevent stress on cables at channel edges. Sharp edges, burrs and projections shall be removed from channels. I.3 Channels for tunnel luminaires shall be fixed using approved stainless steel suspension rods at spacings not exceeding 1 metre or as shown on the Drawings and/or as recommended by the manufacturer. I.4 Connection fittings shall be purpose made with radii to permit cable bending standards. I.5 Channels shall not be used as earth continuity conductors. Channels shall be connected by flexible tinned copper straps to the nearest bare earthing conductor at maximum 30 metre spacings.

7.08.4 MEASUREMENT A. Conduits and trunking shall be measured by the linear metre, furnished, installed, put into operation after testing and accepted by the Engineer as meeting the Specification in all respects. B. The amount of completed and accepted work shall include for supplying all materials, installation of conduits, boxes, testing and putting into operation, labour, equipment tools, supplies and other items necessary for proper completion of the work as specified. C. Supply and installation of conduit boxes shall be deemed to be included in the rates and prices of other items in the related sections. D. Cable trays, supporting systems for tunnel luminaires shall be measured by the linear metre. The rate shall include any labour, tools, supplies and other items necessary for the completion of the work as specified. E. Support systems for tunnel luminaires shall be measured by the linear metre for the total length of the luminaries it is supporting, including any labour, tools, stainless steel screws and stainless steel rods.



PAY ITEMS METHOD OF MEASUREMENT (7.8.1) Conduits (size and type) Linear Metre (m) (7.8.2) Cable Trunking (purpose and type) Linear Metre (m)

(7.8.3) Cable Trays (size and type) Linear Metre (m) (7.8.4) Support System (purpose and type) Linear Metre (m)


(Consultant) SIGN ILLUMINATION Section 7.09 - Page 63 of 127

SECTION 7.09 SIGN ILLUMINATION 7.09.1 SCOPE A. The work covered in this Section consists of supplying, installing and putting into satisfactory operation the equipment for lighting road signs.

B. The supply and installation of road signs are covered in Section 6.08.

7.09.2 MATERIALS A. Floodlights

A.1 Wide angled floodlights for overhead signs shall be of the totally enclosed type, weather, dust and shock resistant and designed to house 250 watt MBIF lamps, conforming to IP 64 of IEC 60529. A.2 The bodies of floodlights shall be made of extruded, pressure die-cast or fabricated aluminium alloy boxes with very high resistant glass on the front faces capable of withstanding thermal and mechanical shocks and set into grooves in the box by special gaskets. The reflector shall be of high purity (99.9%) anodized aluminium secured in precision aligned internal tracks to provide wide beam distribution. The side covers shall allow easy access to the optical block. The whole enclosure shall be in accordance with IEC 60598-2-5 and suitable for operation in ambient temperatures of up to 70oC. A.3 Connection boxes shall be located at the rear of the floodlight bodies with gland connections to accept 4 mm2./SWA/PVC two core cables. Lamps and control gear shall be mounted in two different and isolated compartments or the control gear shall be housed remotely. Floodlights shall be provided with an earthing terminal.

B. Lamps Halide Metal Lamps shall have the following characteristics:

- Nominal lamp watts 250 watts

- Minimum lumen output after 100 hours burning 19,000 lumens

- Average life 10,000 hours C. Control Gear:

C.1 Control Gear shall be of the plug-in type, for operation at 220 volts, 50 Hertz, power factor compensated to at least 0.9 lagging. The ballast shall be of a type specially adapted for the particular make of lamps selected.



C.2 The lamp shall be able to start with at least a +/-10% line voltage and normal operation with dips attaining 20% for four seconds. Compensation shall ensure that there is no large increase in the operating current during starting. The control gear losses shall not exceed 10% of the nominal lamp wattage. A device shall be provided for the suppression of radio and television interference. C.3 The cables for the internal wiring in the control gear compartments shall have single core 2.5 mm2 copper conductors with neoprene or cross-linked polyethylene or an equivalent insulation and sheath approved by the Engineer. C.4 The exposed metallic parts of luminaires shall be painted with a corrosion and heat resistant paint to the satisfaction of the Engineer.

7.09.3 CONSTRUCTION REQUIREMENTS A. The Contractor shall check that the signs are adjusted and set correctly relative to the vertical plane and the road axis and shall then proceed with electrical installation and fitting of the floodlights. B. Overhead Signs

B.1 Floodlights shall be located as shown on the Drawings and mounted on the front edge of the platform. A specially designed mounting bracket shall be provided for each light allowing for swivelling in any direction and enabling it to be locked firmly into its final position. The feeder cable shall be routed via the duct in the supporting frame up to platform height where it shall be glanded into a suitable metal-clad waterproof box and terminated into a non-automatic TP and N40 ampere miniature circuit breaker isolator. A SP phase, five ampere, miniature circuit breaker board within the enclosure shall distribute power to the individual floodlights using 4 mm2 two-core PVC/SWA/PVC cable. B.2 The earth of the cables shall be bonded to the earth terminal of each enclosure.

C. The floodlights or associated brackets and fixings shall not obstruct the view of the sign face. Additional screening where required shall be added to the top or bottom edges of the sign in the event of excess glare to oncoming traffic. D. The Contractor shall be responsible for the final setting and locking in position of the floodlights after demonstrating to the Engineer that the specified sign lighting requirements has been met.



7.09.4 MEASUREMENT Sign illumination shall be measured as the number of floodlight installations complete with lamps, supporting steelwork, switchgear, control gear, interconnecting cabling and earthing as necessary, supplied, erected and put into operation in accordance with the Specifications. PAY ITEM UNIT OF MEASUREMENT (7.9.1) Floodlight Installation for Sign Illumination (Specify type) Number (No) (7.9.2) Floodlight Installation for Illuminated Gantry Sign (Specify type) Number (No)


(Consultant) EARTHING SYSTEM 7.10 - Page 66 of 127

SECTION 7.10 EARTHING SYSTEM 7.10.1 SCOPE A. The work covered under this section includes the provision of earthing installations for every electrical source and protective earthing and equipotential bonding based upon the TN-S system, including:

- Mains earthing terminals or bars

- Exposed conductive parts of electrical equipment

- Extraneous conductive parts

B. Electrical work generally shall be completed in accordance with the requirements of Section 7.01 of the Specification.

C. The Contractor shall carry out work in accordance with the following:

- IEC publications 60364-3 and 60364-4-41: Electrical Installations in Buildings

- The latest edition of the IEE Regulations for Electrical Installations in Buildings - London.

D. Terms used on the Drawings and in the Specification are defined as follows:

Earth: Conductive mass of the Earth whose electric potential at any point is conventionally taken as zero

Earth Electrode: Conductor or group of conductors in initial contact with, and providing electrical connection to, Earth

Exposed Conductive Part: Any part which can be readily touched and which is not a live part, but which may become live under fault conditions

Extraneous Conductive Part: Any conductive part not forming part of the electrical installation such as structural metalwork of a building, metallic gas 1 pipes, water pipes, heating tubes etc. and non-electrical apparatus electrically connected to them i.e. radiators, cooking ranges, metal sinks etc. and non-insulating floors and walls

Protective Conductor: A conductor used for protection against electric shock and connecting together any of the following parts:

- Exposed conductive parts

- Extraneous conductive parts

- Earth electrode(s)

- Main earthing terminal or bar(s)

- Earthed point of the source(s)

Electrically Independent Earth Electrodes: Earth electrodes located sufficiently far apart so that the maximum current likely to flow through one of them does not significantly affect the potential of the other(s)



Main Earthing Terminal Or Bar: A terminal or bar provided for the connection of protective conductors including equipotential bonding and functional earthing conductors to the means of earthing

Equipotential Bonding: Electrical connections for exposed and extraneous conductive parts giving a substantially equal potential

Earthing Conductor: Protective conductor connecting a main earthing terminal or bar of an installation to an earth electrode or to other means of earthing.

E. Prior to ordering materials, the Contractor shall submit details to the Engineer for approval which shall include, but not be limited to: Manufacturer's catalogues for earth rods, connecting clamps, earthing conductors, protective conductors, bonding conductors, connectors and other accessories, exothermic welding kits and tools and samples of conductors as requested. F. The Contractor shall submit drawings for approval including, but not limited to, the following:

- Precise locations of earth pits, rods and details of installations and connections

- Precise routing of buried earthing conductors with indications of cross-section, depth and cover

- Cross sectional area of all earthing, protective and bonding conductors

- Layout and details of earthing provisions at substations, generator rooms, switchgear, distribution panelboards etc., indicating fittings used, insulation, plates and marking, passage and routing of earthing conductors, conduits, sleeves, grooves, niches etc., giving sizes and dimensions of component parts.

G. The source and manufacturer of all earthing materials shall be submitted to the Engineer for approval prior to completing the order. 7.10.2 MATERIALS A. General

A.1 Component parts of earthing system (TN-S) include the following:

- Earth electrode (rods, tapes etc.)

- Main earthing terminals or bars

- Earthing conductors

- Protective conductors

- Equipotential bonding conductors

- Electrically independent earth electrodes for special systems

- Accessories and termination fittings, bonding, welding kits and other materials.



A.2 Earth electrodes consist of one or more earth rods, interconnected by buried earthing tape or cables, having a total combined resistance value, during any season of the year and before interconnection to other earthed systems or earthing means, of not exceeding 5 ohms. The distance between two rods shall not be less than the length of one rod or 3 metres, whichever is the smaller.

A.3 Ring type earth electrodes consist of earthing conductors, in closed loops, buried in exterior wall foundations underneath the waterproofing or around the perimeter of the building foundations as shown on the Drawings, to which all earthing conductors shall be connected. Insulated connection flags into the building, of the same material as the earthing conductors, shall be located at service entrance and main switchboard rooms, terminating in bolt-type earth points (studs) or test-links for connection to main earth bars. Additional earth rods connecting with the earth ring shall be provided if necessary to bring down earth electrode resistance to an acceptable value. A.4 Functional earth electrodes shall be provided separately from, but interconnected to, other earth electrodes through suitably rated (470 V) spark gaps. Functional earth electrodes shall be used for earthing electronic equipment (communication equipment, digital processors, computers etc.) as required by the Specification or on the recommendation of the manufacturer. A.5 Other types of earth electrode may be used, if approved by the Engineer, including:

- Cast iron pipes with special surround material

- Copper plate(s)

- Tape mats (strips).

A.6 Main earthing bars shall be provided at points of service entrances or main distribution rooms or as described in the Specification or shown on the Drawings, to which all earthing conductors, protective conductors and bonding conductors shall be connected. Two insulated main earthing conductors shall be provided, one at each end of the bar, connected by testing joints to earth electrodes at two separate earth pits. Conductors shall be sized to carry the maximum earth fault current of the system at the point of application with a final conductor temperature not exceeding 160oC for at least 5 seconds. Main earthing conductors shall be a minimum of 120 mm2 in cross section or as otherwise shown on the Drawings. A.7 Testing joints (test links) shall be provided in an accessible position on each main earthing conductor, between earthing terminals or bars and the earth electrode.

A.8 Protective conductors shall be separate for each circuit unless otherwise detailed on the Drawings. Where a protective conductor is common to several circuits, the cross-sectional area of the protective conductor shall be the largest of the conductor sizes. Selection of sizes shall be in accordance with NEC Regulations.



A.9 Protective conductors shall not to be formed by conduits, trunking or ducting. Where armoured cables are specified and the armour is steel, it may be used as a protective conductor, if approved by the Engineer and if not otherwise shown on the Drawings.

A.10 Series connections of protective conductors from one piece of equipment to another shall not be permitted. Extraneous and exposed conductive parts of equipment shall not be used as protective conductors, but shall be connected by bolted clamp type connectors and/or brazing to continuous protective conductors which shall be insulated by moulded materials. A.11 The earth fault loop impedance for final circuits supplying socket outlets shall be such that disconnection of protective devices on overcurrent occurs within 0.4 seconds and for final circuits supplying only fixed equipment the earth fault loop impedance at every point of utilization is to be such that disconnection occurs within 5 seconds. A.12 All extraneous conductive parts of buildings such as metallic water pipes, drain pipes, other service pipes and ducting, metallic conduit and raceways, cable trays and cable armour shall be connected to nearest earthing terminals by equipotential bonding conductors. The cross-sections of protective bonding conductors shall not be less than half that of the protective conductor connected to respective earthing terminal and a minimum of 4 mm2.

A.13 Main incoming and outgoing water pipes and any other metallic service pipes shall be connected by main equipotential bonding conductors to main earth terminals or bar. Bonding connections shall be as short as practicable between point of entry/exit of services and the main earthing bar. Where meters are installed, bonding shall be made on the premises side of the meter. Cross-sections of conductors shall not be less than half that of the earthing conductor connected thereto, and minimum of 6 mm2. A.14 Connections of every earthing conductor to earthing electrode and every bonding conductor to extraneous conducting parts shall be labelled in accordance with the Regulations as follows:

SAFETY ELECTRICAL CONNECTION - DO NOT REMOVE

A.15 Protective and earthing conductors shall be identified by standard green-and-yellow markings either on the insulation wrapping or painted directly onto the bar conductors. A.16 Source earthing conductors (or neutral earthing conductors) shall be identified by continuous black insulation and labelled 'neutral earthing'.



B. Transformer Substation Earthing

B.1 Outdoor ring main units which are individually mounted shall be connected to earth electrodes by single insulated earthing conductors, bolted at earthing terminals. B.2 Transformer earthing terminals shall be connected to LV main earthing bars by bare copper earthing conductors with not less than 20 mm2 per 100 kVA of transformer rating with an overall minimum area of 35 mm2 and shall be subject to Power Authority approval. B.3 Transformer neutral (star points) shall be connected by insulated earthing conductors (colour black) to LV side main earthing bars. Neutral earthing conductors shall be sized for a maximum earth fault current of 5 seconds with a final conductor temperature not exceeding 160oC or sized not less than 30 mm2 per 100 kVA of transformer rating, with an overall minimum of 50 mm2. Where a neutral is directly connected to an earth electrode, an insulated disconnecting device shall be provided at the transformer. B.4 Lightning arrestors shall be directly connected to earth electrodes, following the shortest path. Each lightning arrester shall be connected at a dedicated earth rod.

C. Road Lighting

C.1 Separate protective earthing cables for lighting column circuits shall be installed with power circuits, terminating at LV supply position in lighting control panels and looped into column earthing terminals. The last column in each lighting circuit, unless otherwise shown on the Drawings, shall be bonded via an earthing bolt to a single 16 mm diameter copper covered steel rod, 2.5 metres long, driven into the ground adjacent to the column. Bonding shall be completed with 6 mm2 stranded bare copper conductors. C.2 Connections between rods and earthing conductors shall be made by the Cadweld process producing a fused joint. Bolted connections shall be used for connections to removable items of equipment only.

D. Mechanical Plant Rooms and Fixed Machinery

D.1 Mains earthing of loops shall be conveniently located in mechanical plant rooms and connected by earthing conductors to exposed conductive parts of the motor control centre at its earthing bar and to motors, switches and other electrical equipment at their earthing terminals using 20 x 2 mm bare copper strips or 35 mm2 bare copper conductors or as required to carry a maximum earth fault current for 1 second with a final conductor temperature not exceeding 200oC. Conductors shall be securely fixed, either recessed in floor grooves or niches or fixed to walls by appropriate staples. Earth bars or loops shall be securely fixed to building walls with copper or brass saddles. D.2 Mains earthing bar loops shall be connected at two extreme and separate points to earth electrodes either directly through two test joints by insulated earthing conductors or connected to the mains earth bar by protective conductors.



D.3 Earth terminals for motors and other equipment shall be connected by protective earth conductors for each branch circuit to the earth terminal/bar at the motor control centre, panel or distribution unit.

E. Earthing of Main Distribution Boards, Panelboards, Lighting Installations and

Wiring Accessories

E.1 Mains earthing bars shall be provided in mains distribution rooms and connected to earth electrodes by two insulated conductors (minimum 120 mm2) via testing joints. E.2 Earthing bars of main distribution boards shall be connected by bare earthing conductors directly to mains earthing bars at the mains distribution room and by protective conductors run with incoming feeders from respective supply points. E.3 Distribution, lighting and power panelboards shall be connected by protective conductors run together with incoming feeder cables connecting earth terminals in panelboards with respective mains distribution board earthing bars. E.4 Socket outlets shall be earthed by protective conductors looped with branch circuits and connected to earth terminals within socket outlet boxes. E.5 Protective conductors of all final ring sub-circuits shall be in the form of a ring having both ends connected to earth terminals at the origin of circuits in the panelboards. E.6 Lighting fixtures and other exposed conductive parts of electrical installations, such as switches, heaters and air conditioning units shall be connected by protective earth conductors to earthing terminals of respective panelboards.

F. Materials and Products

F.1 Earth rods shall be copper clad steel, 14 mm diameter, 2.5 m length, extendible as necessary to obtain the required earth resistance. Earth rods shall be complete with couplings, heads and bolted connectors of sufficient size and number to connect all cables terminated thereto. F.2 Buried earth conductors shall be bare annealed copper strip conductors 25 x 2.5 mm, or annealed stranded copper conductors with a 70 mm2 minimum cross-section. F.3 Where earth rods are to be used, earth electrodes shall consist of parallel and perpendicular copper strips, 2.4 m apart, welded together by exothermic welds to form a grid. Tape shall be 25 x 2.5 mm strip conductors.



F.4 Earth pits shall be precast square or circular section concrete handholes (minimum 450 mm internal diameter) with concrete covers and extending to about 150 mm below the tops of the earth rods. Earth pits shall be provided for each earth rod where connected to an earthing conductor. Covers shall have inset brass plates with the inscription: 'Earth Pit - Do Not Remove'.

F.5 Earthing conductors shall be insulated or bare copper conductors as described in the Specification for the particular application. F.6 Testing joints (test links) shall be copper or copper alloy, with bolted end connections, disconnectable using specialist tools and suitably sized for earthing conductors or earth bar connections. Links shall be fixed to porcelain or other insulating supports approved by the Engineer. F.7 Protective conductors shall be single core stranded annealed copper, PVC insulated cables, having rated insulation grade compatible with the circuit protected or a conductor forming part of a multi-core cable and colour coded. F.8 Mains earthing bars shall be hard drawn copper, 40 x 4 mm where formed into a closed loop, and 50 x 6 mm where open ended. Earth bars shall be labelled 'Main Earth Bar' and shall be drilled for conductor connections at a spacing not less than 75 mm and shall be supplied with copper alloy bolts, nuts and washers and wall mounted insulators. F.9 Protective bonding conductors shall be bare copper strip conductors, annealed stranded copper cable or flexible straps with cross-sectional areas as described in Sub- Section 7.08. F.10 Earthing accessories shall be copper or copper alloy, purpose made, of an approved design, compatible with points of connection and of adequate cross-section and current carrying capacity. Connectors and clamps shall be of the bolted type. Bolts, nuts and washers shall be high quality phosphorus bronze or copper silicon alloy.

7.10.3 Construction Requirements A. The complete earthing system shall be electrically continuous and mechanically secure. B. Earth rods shall be sited in order that resistance areas associated with individual rods do not overlap. Earth rods shall be located at a distance greater than 600 mm from foundations of buildings. Where rock is encountered, holes of sufficient size shall be drilled before inserting the rod. Conductive filler such as Marconite or Bentonite or other non- corrosive filler shall be provided around the rod. C. Buried earthing conductors shall be laid at a depth not less than 0.8 metres from the ground surface.



D. Earthing conductors shall follow the shortest paths between the earth rods and mains earthing terminals or bars and shall run in PVC conduits (ducts) fastened to building structures by supports approved by the Engineer, extending 0.2 metres above ground level. Earthing conductors shall be protected against mechanical damage and corrosion. E. Separate protective conductors which are not part of a cable shall be fixed on the same support or drawn into same conduit as the circuit conductors. F. Non-conductive paint, enamel or similar coating shall be removed at threads, contact points and surfaces. Bonding shall be completed using suitable, specifically designed fittings. G. Bolted connections shall be protected against corrosion either by filling with Vaseline or coating with a special anti-corrosion compound and providing effective capping. H. Earth connections shall be easily accessible. If an accessible earth connection is not possible, connecting methods approved by the Engineer, using exothermic welding or brazing techniques, shall be employed. I. Where earth connections between dissimilar metals are to be made, bimetallic fittings shall be used, protected by moisture resisting bituminous paint or by protective adhesive tape to exclude moisture. J. The combined resistance of earth electrodes shall be measured during the dry season. K. The electrical continuity of all earthing and protective conductors including the main and supplementary equipotential bonding conductors shall be checked. L. The earth fault loop impedance of all circuits shall be measured and checked against calculated impedance figures. M. The operation of residual current protective devices shall be checked. N. The Contractor shall submit the following:

- Scaled drawings, as-installed, showing actual layout and specification of all components of the earthing system

- The nature of soil and any special earthing arrangements etc.

- Date and particulars of soil conditioning method and agents if used

- Test conditions and results obtained.



7.10.4 MEASUREMENT A. Earthing shall be measured by the number of completed sets of earthing items, to be

supplied, installed, tested and put into operation in accordance with the Specifications.

B. The amount of completed and accepted work measured as provided for above, shall

be paid for at the unit prices bid for the Pay Items inserted in the Bill of Quantities, which shall be full compensation for furnishing all materials, labour, equipment tools, supplies and all other items necessary for the proper completion of the Works as specified and for testing, installation and putting into operation.

PAY ITEMS UNIT OF MEASUREMENT (7.10.1) Feeder Pillar Earthing (Each type) Number (No) (7.10.2) Column Earthing Pit (Each type) Number (No) (7.10.3) Earthing of Electrical Installations

(Each type) Item (7.10.4) Mechanical Room Earthing Item


(Consultant) TRAFFIC SIGNALS 7.11 - Page 75 of 127

SECTION 7.11 TRAFFIC SIGNALS 7.11.1 SCOPE A. The work covered in this section consist of the supply and installation of the traffic signal system complete with controllers, loop detectors, traffic signal masts, signal heads, lamps, pedestrian facilities, cabling, connections and all necessary services for the complete installation. B. The controller and signal masts shall be installed on fixed foundations or bases and the supply and construction of these, together with all necessary ducts, drawpits, trenches, excavations and similar civil works shall be provided by the Contractor in conformity with the requirements outlined in Subsection 7.11.5 "Construction Requirements" and as further detailed in Section 7.12 "Builder's Work". 7.11.2 DEFINITIONS For this Section of the Specification the undermentioned definitions shall apply. Where applicable, the meanings of the terms are detailed in BS 6100 Section 2.4.1: 1992 Highway Engineering. A. Vehicle-Actuated Traffic Signals: Traffic signalling equipment in which the duration of the red and green signals and the time of the cycle vary in relation to the traffic flow into and through the controlled area. B. Fixed-Time Traffic Signals: Traffic signalling equipment in which the duration of the red and green signals are fixed in relation to each other and together form a fixed cycle. C. Semi Vehicle-Actuated Traffic Signals: Traffic signalling equipment providing Vehicle Actuated control of the minor roads including Vehicle Extension Periods up to the Maximum Green Period. D. Pedestrian Demand Traffic Signals: Traffic signalling equipment actuated by push buttons and providing right of way for pedestrians, who when the request is made, do not have right of way. E. Traffic Signal Sequence: Traffic signal head aspects to provide the following facilities:

Option 1 (Vehicle/Vehicle) VEHICLE A G A R R R RA G

VEHICLE B R R RA G A R R



Option 2 (Vehicle/Pedestrian) VEHICLE G A R R R RA G

PEDESTRIAN R R R G FG R R

If specified the flashing green (FG) pedestrian right-of-way shall be accompanied by an audible signal. F. Right-Of-Way: The condition which applies when a green signal is displayed to traffic at the approach to a primary signal face and which permits traffic to proceed if the way is clear, but with special care to turning traffic, giving way to pedestrians who are crossing. G. Traffic Stream: Vehicles in one or more lanes on the same approach to the controlled area which, when they have the right-of-way, will move in the same direction. H. Stage: A condition of signal lights during a period of the cycle which gives right-of-way to one or more particular traffic movements. A stage may be considered as starting at the point at which all phases that have right-of-way during the stage have been set to green, and all phases terminating have been set to red and ending at the point at which the phase loses right-of-way. Stages may be considered as being separated by interstage timing periods during which phases lose and gain right-of-way to establish a new stage. I. Interstage Period: The period between the end of one stage and the start of the next. J. Phase: The sequence of conditions applied to one or more streams of traffic and where required combinations of vehicular traffic and pedestrians, which always receive identical signal light indications throughout the complete cycle. K. Minimum Green Run Period: The duration of the phase green signal before it is terminated. L. Vehicular Extension Period: The additional duration of green signal time secured by the operation of a detector by vehicles having right-of-way. M. Maximum Green Run Period: The maximum time for which a phase can continue to be extended by its associated detection equipment after a demand has been made by traffic on another phase. N. Early Cut-Off: A condition in which one or more traffic streams are permitted to move after the stoppage of one more of the traffic streams which, during the preceding stage, have been permitted to run with them.



O. Late Release: A condition in which one or more traffic streams are permitted to move before the release of other traffic streams which, during the subsequent stage, are permitted to run with them. P. Cycle: A control scheme in which the stages are given in a fixed order. Q. Staggered Ambers: A condition where on a change of right-of-way the warning to traffic streams about to start commences during the warning to traffic streams called upon to stop. R. All Red: A condition where, on a change of right-of-way, the commencement of a warning to traffic streams about to start commences after the termination of the warning to traffic streams called upon to stop. S. Normal Clearance Period: A fixed inter-stage period giving staggered ambers. T. Fixed Extra Clearance: A fixed inter-stage period longer than the normal clearance period. U. Turning Traffic: Vehicles turning left or right after passing the stop line or primary signal face. V. Demand: A request for right-of-way for traffic on a phase which has no right-of-way when the request is made. W. Forced Change: A condition which causes change to a selected stage, unless the controller is in an inter-stage or a minimum green period, in which case the change to the selected stage shall be deferred until the expiry of the minimum green period providing the condition is still present at that time. 7.11.3 MATERIALS A. General

A.1 Materials used in the manufacture of traffic signal equipment shall be fit for purpose and the workmanship shall conform to the best modern practice. Materials shall be selected or treated so that no corrosion shall occur during the lifetime of the installation. A.2 The equipment shall be designed to operate on A.C. 220 volts single phase 50 Hz. The equipment shall function satisfactorily should the voltage vary within plus 15 percent or minus 20 percent and should the frequency vary within plus or minus four percent. If the equipment is sensitive to voltage fluctuations within the above stated limits an automatic voltage stabiliser shall be incorporated in the system. A.3 Electronic equipment shall use components of assessed quality in accordance with the system outlined in BS 9000 General Requirements for a System for Electronic Components of Assessed Quality.



A.4 All equipment shall be designed and derated for continuous operation at a 50

oC ambient temperature and 100 percent relative humidity with temperatures

reaching 70oC in direct sunlight with a high ultra violet content. The equipment shall

be suitable for uninterrupted full load operation exposed to sun, dust storms, corrosive elements, frost, snow and similar adverse climatic conditions. Particular attention shall be given to the fact that the controllers shall be installed upon open sidewalks and exposed to direct sunlight for extended periods each day. A.5 All wiring shall be neatly and securely fixed in position using a method approved by the Engineer. The wiring shall be in high temperature PVC insulated cables and colour-coded for ease of identification. All terminals shall be of an adequate size. A.6 All equipment shall be standard and have type approval from a National Department as specified on the Drawings or acceptable to the Engineer. It shall have a proven 'in service' record and documentary evidence of this shall be submitted to the Engineer. Additionally a full environmental test should be carried out on a production sample by an Independent Test House and a certificate supplied to show the suitability of the equipment for use in the specified environment. A.7 All equipment and associated service requirements shall comply with BS EN 12368: 2000 Traffic Control Equipment Signal Heads and with local requirements covering timing, sequence, phasing detectors, modes, facilities and other options as may be detailed.

B. Controllers

B.1 Enclosure: Each controller shall be housed in a dust tight and weatherproof enclosure conforming to IP 65 of IEC 60529. The housing shall be made from aluminium alloy, galvanised sheet steel or glass-reinforced polyester as specified. The surface shall be treated light grey with paint having high ultra-violet reflective and corrosion inhibiting qualities and so designed as to minimise the effect of solar radiation on the equipment. B.2 The housing shall be constructed of material not less than 2 mm thick and internally ribbed where necessary to provide a rigid structure and support framework for the necessary internally mounted equipment. All external corners and edges, except for the lower edges, shall be rounded. B.3 The front and rear of the enclosure shall be fully accessible through one side or two centre opening doors fitted with gaskets and compression type recessed hinges and centre-mounted cylinder locks with three locking points. B.4 Where specified the enclosure shall be fitted with access doors on one side only and the internal equipment shall be hinge mounted on a frame for access to the front and rear. The housing shall be adequately braced and supported to carry the weight of the equipment when moved to the open position.



B.5 Provision shall be made for manual control of the traffic signal control system by means of either a "built-in" flap type access door or a separate "bolt-on" unit as specified. The "bolt-on" manual control unit shall have an enclosure to a similar specification to that of the controller. Access to the controller and manual controls shall be protected with locks with keys of different patterns; 2 keys for each lock. Corresponding locks and keys for each controller or manual control shall be identical for enclosures of the same make and pattern. B.6 The controller and manual control enclosure for each intersection shall provide sufficient space to house all standard equipment including vehicle detector modules, local interface and master equipment for use in a cabled or wireless system and shall be capable of operating as an isolated intersection or as a linked system. B.7 Controller Electronic Equipment: Controllers shall be solid state microprocessors, using integrated circuits of modular construction installed on "plug-in" printed circuit board assemblies. The controller shall consist of logic modules, memory module, signal switching module and input control and detector module, main power distribution unit together with a timing unit, manual control panel and chassis with fixed wiring to accommodate the various "plug-in" modules as necessary. B.8 The controller shall be equipped suitable for operation up to 4 stages and 8 phases in the fixed time, semi or full vehicle actuated operation, manual and amber flashing mode and be equipped to meet the method of control specified for the particular intersection. B.9 The controller shall be capable of expansion by the addition of logic modules up to 16 stages and phases at a future date. The logic shall be programmable so that stages may be called in any order and, for safety reasons, it shall be possible to prohibit the appearance of certain stages. B.10 The controller shall be equipped with circuit facilities to monitor and prohibit the display of conflicting failure that may result in the display of conflicting signals; these shall be automatically switched off within 0.5 seconds and shall not be capable of re-connection until the fault has been corrected.

B.11 A diagnostic and interrogation control unit shall be supplied with each controller which shall provide a means of changing the intersection parameters and give visual displays of circuit functions to enable a rapid maintenance service and indicate the stage in operation, termination or running of minimum green time, signal state for each phase and stored demands. B.12 The time clock shall be of the real time quartz type having the same accuracy and monitoring as that of the mains frequency with which it shall be synchronised. The time clock module shall be programmed to provide the time plan dependent control and to be used in the dedicated intersection or in the area or group co-ordinated system as required; it shall accept, operate and pass on the green signal hurry calls and provide any other time based requirement as specified on the Drawings.



B.13 The module shall be provided with a battery operated "stand by" unit for use in the event of a mains failure which shall function for a minimum of 200 days and be arranged so that when the supply is returned, the signals will reset without loss of function. B.14 Controllers shall be capable of being fitted with modules to provide priority facilities for emergency or other public vehicles fitted with the necessary equipment. The introduction or cancellation of a priority signal shall never override a normal minimum green period on any stage sequence specified for safety reasons but the priority signal may convert a running signal to a minimum green run period. B.15 Controllers shall be fitted with adjustable auto transformer signal dimming facilities to reduce the intensity of the aspect signals to between 5-50 % of full intensity during the night hours. All signals shall be reduced by the same amount which shall be adjustable and capable of being set between the limits specified. B.16 The reduced intensity shall not affect the colour of the light signal which shall comply with the limits set out in BS 1376:1974 B.17 Switching of the reduced signal aspect intensity of each intersection shall be provided by photo electric control relay supplying the traffic signals through a tapped auto transformer controlled by a change-over Contactor to IEC 60947:1 or a solid state contactor to IEC 60158:2. B.18 The photo-electric controls shall consist of 2 omni-directional cadmium cell thermal relays connected in series using solid state photo-variable conductance elements giving a 2:1 on/off ratio with sensitivity to switch on lights when the daylight illumination reduces to 70 lux. The photo-electric cells shall be mounted at the top of the nearest traffic signal mast or other purpose designed high mounting and connected to the controller via the duct system. B.19 The photo-cell control module shall be capable of adjustment to permit switching levels between 30 and 80 lux. The exact settings between these limits shall be determined on Site and approved by the Engineer. B.20 The two photocells shall be connected in series so that failure of one cell (in the closed position) shall allow the other to control the circuit. B.21 An on-off switch shall be installed in the controller and arranged so that in the "on" position the traffic signal dimming system is functional and the "off" position shall ensure that the contactor and dimming remain de-energised whilst the control system remains functional.

C. Controller Electrical Equipment

C.1 All circuit wiring shall have a current carrying capacity in accordance with design requirements. C.2 Traffic signal head wiring and switching equipment shall be suitable for a



normal maximum lamp load of 2.0 kilowatts to allow for uprated signal lamps where used on high speed road intersections. All components and accessories shall be adequately derated and sufficiently sized so as to ensure reliability in operation and require only routine maintenance for a minimum of five years of operation. C.3 A separately switched 13A BS 1363 power socket outlet shall be provided for maintenance purposes. C.4 A heavy duty (HD) master switch and fuse shall be provided to isolate all equipment in the controller from the mains supply. The master switch shall be DP and rated at not less than 20 amps. C.5 A HD switch and fuse shall be provided to isolate the power from the controller logic. The controller fuse shall be rated at 10 amps.

C.6 A separate HD switch rated at not less than 10 amps shall be provided to control traffic signal lamps. The operation of this switch shall not affect the controller logic. C.7 A fault on any signal feeder or a short circuited lamp shall not cause any major damage to the controller. Damage shall be limited to replacement of fuses or plug-in lamp switching modules. C.8 To enable the controller to be used in a future wider area control system, a separate switch fuse outlet shall be provided to supply electrical power to the associated equipment. The main to this switch shall not be disconnected by the controller switch. C.9 Where deemed preferable or if otherwise specified the HD switches and fuses may be substituted with Moulded Case Circuit Breakers (MCCB's) conforming to IEC 60947-2. The MCCB's shall be of equivalent rating and provide overcurrent and fault protection. C.10 All HD switches, fuses and MCCB's shall be derated for use in the climatic conditions detailed. All control and protection equipment shall be properly labelled showing the purpose and function of the equipment controlled. C.11 The controller shall be fitted with a voltage monitor and in the event of a supply loss of less than 50 milliseconds the controller shall continue to function normally. Should the supply failure exceed 50 milliseconds the controller shall shut down without malfunction and the control logic shall be retained without loss. C.12 Where specified, the controller shall be fitted with a mains failure standby unit which shall comprise a fixed 32 amp 3 pin plug suitable for the connection of a portable 32 ampere socket and flexible cable connected to a mobile generating set.

C.13 The fixed plug and portable socket shall be in accordance with IEC 60309 and located in an IP 65 enclosure within the base of the enclosure.



C.14 The enclosure shall be accessible from a key operated external flap cover which, when opened, shall be interlocked with the mains supply through a contactor which shall inhibit the reconnection of the mains supply whilst the portable socket is inserted and the access flap is open. C.15 The return of the mains supply shall be indicated by LED's connected on the mains supply input terminals so that the indication provided can be used to manually disconnect and remove the portable socket and generating plant, re-lock the flap and hence restore the supply to the controller for mains operation in the normal manner. C.16 Upon restoration of supply the controller shall re-commence operation at the all red state for a period of 5 seconds after which signals shall change to a pre-determined stage and continue to function in the selected mode. C.17 The equipment shall not exceed the radio interference limits laid down in BS 800:1983 (CISPR 14 is equivalent).

D. Signal Head Assemblies

D.1 Signal heads shall be of lightweight modular construction with lenses and housing manufactured from self-coloured moulded polycarbonate plastic or cast aluminium. Signal heads when assembled shall be capable of individual adjustment and the assembly shall be dust protected and splash proof with an enclosure conforming to IP 54 of IEC 60529. D.2 Signal heads shall be selected from 200mm or 300mm diameter modular aspects as specified on the Drawings or instructed by the Engineer. D.3 Signal head assemblies shall be available in the various configurations allowing filter left or right aspects and alternative traffic symbols as required for specific intersections. Masks for inclusion in specific aspects with the specified symbol shall be provided if required by the intersection design. Each configuration shall be a complete unit and fitted with the appropriate polypropylene backing sheet to complete the assembly. Signal aspect optical units shall be fitted with a pre-focus tungsten halogen signal lamps mounted within aluminium reflectors and fitted with a wide angled self coloured acrylic lens. Each aspect shall be fitted with a visor and an anti-phantom light inserted to prevent false signals from incident sunlight. D.4 Signal lamps shall be low voltage supplied from a built-in encapsulated transformer for each aspect. The lamps shall be 50 watt for use on normal intersections but where high speed roads (speeds above 80 kph) form part of the intersection, 100 watt lamps shall be used. D.5 Light signals for vehicles shall be directed towards the vehicles at a point approximately 50-100 metres (200-400 metres for high speed roads) from the signal face and at a point 1.5 metres above and along the centre line of the carriageway; where light signals are used for individual traffic lanes the signal shall be directed along the centre line of that lane. The light intensity along this axis shall be 400 Candelas (800 Candelas for high speed roads) for the red and green aspects and at least



twice these values for the amber (yellow) signal. D.6 Each aspect shall be uniform in appearance within the core of the viewing angle, without secondary maxima and the colours of the light transmitted shall comply with the limits specified in BS 1376:1974. D.7 Where specified, traffic light signals shall be duplicated and displayed in miniaturised format mounted at driver eye level in a position adjacent to primary signal face or the traffic stop line. D.8 Signal Heads intended for pedestrians shall generally be of the two aspect type and shall be rectangular with 300mm sides. The red aspect "standing" symbol shall be at the top and the green "walking" symbol at the bottom. The luminance of the signal head along the directed axis shall be 3500 Candelas per square meter. D.9 The signal axis shall be directed along the centreline of the section of the road given over to pedestrian access.

E. Pedestrian Push Button Unit

E.1 The pedestrian push button unit shall be a cast aluminium or galvanised sheet metal-fabricated box fitted with a glass or acrylic display mounted adjacent to the pedestrian access. Provision shall be made to illuminate internally the part of the display marked with the legend "WAIT" (English and Arabic) in white on a blue background. The lamp shall be a 60 watt E27 cap in accordance with IEC 60064. E.2 Push buttons shall be plastic, with plungers and mountings designed to minimise the effect of jamming. Enclosures shall be dust protected and weatherproof conforming to IP 54 of IEC 60529. The push-button circuits shall operate at voltages less than AC 60 volts.

F. Signal Head Mountings

F.1 Signal head assemblies shall be mounted on straight or cantilever masts by brackets supporting both the top and bottom of the signal head assembly. A combination of the mounting methods shall be used as indicated on the Drawings. F.2 Signal head assemblies shall be attached by stainless steel clamps and mounting brackets incorporating wiring ducts for the signal head wiring. The attachment shall allow vertical and angular adjustment of the signal head assembly and shall be suitable for the signal head presentation.



F.3 Signal masts of the straight and cantilever type shall be dimensioned in accordance with the Drawings. The cantilever section shall be not less than 168mm diameter dependent upon the length of the outreach and as indicated on the Drawings. Masts shall be designed and constructed to provide adequate support and stability for the signal head and shall be suitable to support more than one assembly. The masts shall be of tapered construction for aesthetic reasons for both the vertical and cantilever sections. The masts shall be complete with weather-proof caps and bolt down baseplates. F.4 Masts shall be constructed from seamless steel, conical in shape with a wall thickness not less than 4.5mm and a tensile strength of 510 MN/m2 Masts and mast components shall be hot dipped galvanised finish conforming to BS EN ISO 1461:1999 and the minimum thickness of zinc coating shall be 450gm per m2 on the inside and outside surfaces. No machining operation shall be allowed after completion of the galvanising process. Masts shall be painted with two coats of epoxy resin paint to an approved colour finish after completion of the galvanising process. F.5 Poles shall be complete with base compartments and accessible top compartments and terminal chambers for connecting signal heads and incoming cable terminations. F.6 Mounting heights of signal centres, the type of signal head assembly and the signal presentation shall be as detailed on the Drawings.

G. Detector Loops

G.1 Detector loops shall be of the inductive type consisting of multiple turns of single core 1.5 mm2 flexible elastomeric insulated and Hypalon sheathed cable installed in slots in the roadway and filled and sealed with an epoxy resin compound. The cable shall be installed at a depth of not less than 50mm below the road surface. G.2 Each loop shall be complete with its own feeder cable connected back to the controller. The feeder cable shall be a twin twisted flexible cable of 1.5 mm2 conductor size and of similar specification to the loop cable. The feeder cable shall be screened to prevent false signals or the effects of stray inductance. Connections between feeders and loops shall be crimped, permanently insulated and protected with shrink sleeving and enclosed within the epoxy filler. G.3 Where special non-standard detector loops are required these shall be supplied and installed to the approval of the Engineer. G.4 Loop dimensions and spacing from the stop line shall be as detailed on the Drawings.

G.5 Loop detectors shall cover the total width of the carriageway with individual loops for each traffic lane. Loops shall be installed to provide signals for right filter vehicles and for left turning vehicles as detailed on the Drawings. G.6 Detectors and control modules shall be arranged to detect the presence and



estimated speed of vehicles within the active loop area. Two or three detection loops shall be installed and spaced apart in appropriate traffic lanes if required, for speed detection and for signal extension times as required. Detector loops shall be of a suitable design and appropriately installed to ensure that parked vehicles within or adjacent to the detector loop shall not affect the detector operation.

H. Cables

H.1 Single core cables for use in controllers or signal masts, aspects or pedestrian or manual controllers shall be 450/750 volt flexible PVC insulated copper in accordance with BS 6004:2000 with HT PVC insulation where operating in high ambient temperature conditions. The conductor size shall be in accordance with the circuit requirement. Cables shall be bunched, clipped and properly secured to form a complete wiring loop. H.2 Multi-core cables to signal masts and equipment shall be stranded copper PVC insulated and sheathed 600/1000 volt to BS 6346:1997. Where multi-core cables are installed directly in the ground, they shall be single wire armoured and sheathed.

J. Earthing

J.1 All non current carrying parts of the equipment and installation shall be earthed and connected back to an earth bar installed within the controller. J.2 The armouring and screens of all multi-core cables installed directly in the ground shall be bonded and connected to the earth bar together with the earth core of the electricity supply cable. A separate single-core copper PVC insulated (green/yellow) wire shall be installed back to the electricity supply point if the incoming cable does not include an earth.

J.3 Where traffic signals are provided with 3 pin sockets and plugs for connection of portable mains supply units, the earth pin shall be permanently connected to the traffic signal earthing system. J.4 The earthing installation shall conform to the Earthing Procedures as detailed in Part 7-10 of this Specification.



7.11.4 TRAFFIC SIGNAL OPERATION A. The adjustment controls for the minimum green, inter-green and vehicle extension times shall be adequately protected from inadvertent or unauthorised adjustment. The setting adjustment ranges shall be as follows: -

- Minimum Green Stage: 1-15 seconds in one second intervals.

- Vehicle Extension Times: 1, 1.5, 2, 4, 5 or 6 seconds.

- Maximum Green: 8-68 seconds in 4 second intervals.

- Amber: Preset to 2, 3, 4, 5 or 6 seconds.

- Inter-Green Periods: 4-12 seconds in 1 second intervals (this includes 'All Red').

- Fixed Extra Clearance: 6-12 seconds in 1 second intervals to be selected individually for any cyclic change of right-of-way.

- It shall be possible to provide variable inter-green times between stages. B. The operation of all signals shall be positive without dark intervals, flickering of lights or conflicting signal indications. C. The following modes of operation shall be available by manual selection at the controller:

- Fully Vehicle actuated Mode

- Semi Vehicle-actuated Mode

- Fixed time Mode

- Flashing amber Mode

- Manual Mode D. Full Vehicle Actuated Mode When in full vehicle actuated mode, operation shall automatically revert to either of the following conditions as detailed on the Drawings or instructed by the Engineer:

- The 'All Red' condition in preparation for the next demanded stage when no traffic has been detected for a predetermined period.

- A specified stage or cycle through two or more stages on minimum greens in the absence of any demands or outstanding extensions from the detectors.



E. Semi-Vehicle Actuated Mode Inductive loop detectors on side roads shall operate the controller as follows:-

- If there is no demand from minor road or pedestrian stages the controller shall revert to the main road (or nominated stage) green condition.

- Minor road stages shall be activated upon detection of a demand, subject to minimum green and inter-green periods of the main stage cycle.

- Minor road stages shall remain on green up to a pre-set maximum period if vehicle detector signals continue to be received.

- The controller shall be free to change from a demand dependent stage provided both the minimum green timer and the extension timer have been expended.

- Minor stages shall not automatically appear in the signal cycle unless a demand has been registered by the controller.

F. Fixed Time Mode The controller shall cycle automatically through all (or certain selected) stages in a cyclic order giving the preset inter-green and maximum green times for each stage. G. Flashing Amber Mode Each controller shall be equipped with a reliable electronic flasher which shall flash all amber signal indications during emergency conditions. The flashing sequence shall be introduced by the operation of a manual switch and a time-switch shall be included in the equipment supplied. The flashing rate shall be between 55 and 85 flashes per minute with approximately equal on and off intervals. The introduction sequence to the flashing mode shall be as follows:

- The running stage shall be terminated by an amber signal.

- All amber signals shall flash and all other vehicle and pedestrian signals (without amber) shall be extinguished.

- To resume normal operation and end the flashing mode sequence, all signals shall indicate red for a short preset period, followed by the normal signal sequence starting with the green light cycle for the major road.

H. Manual Mode:

H.1 Manual control shall be effected from a manual control panel housed either separately or forming part of the controller but accessible through a flap door with a separate key.



H.2 It shall be possible to manually switch the controller to operate in any one of the following modes:

- Vehicle actuation

- Fixed time

- Manual control with one button operation per stage change.

H.3 Operation of individual stage buttons shall cause the controller to move to, and remain on, the selected stage, subject to the expiry of the minimum green phase of the current stage. H.5 A warning light shall be provided to show the expiry of the minimum green (i.e. awaiting a new command). Operation of the stage button when the light is unlit shall have no effect. H.6 Pedestrian facilities shall be available for integration with the intersection signals or separately if the facility is sufficiently removed from the intersection control area. H.7 An exclusive fixed time pedestrian stage or a shared fixed time pedestrian and vehicle stage shall be provided. H.8 The pedestrian facility shall be operated either automatically within the signal cycle or by pedestrian operated push-buttons. H.9 Additional facilities shall be provided between the green and red pedestrian facility such as the green pedestrian signal flashing, an audible signal or a flashing amber vehicle sign if specified on the Drawings. H.10 The controller shall be suitable for use in an Area Group Traffic (AGT) control system and, when this is required, each controller shall be provided with the extra control modules for this purpose. H.11 AGT control systems shall be established either by central control computer or by clock controller signal plan as indicated on the Drawings or Schedules. This Specification excludes supply and installation of this central equipment but includes suitable equipment installed within the intersection controllers where required. H.12 The intersection controllers shall be programmed to operate in accordance with a fixed signal plan actuated by time control, the programme shall be pre-determined with reference to the required traffic pattern for the time, day, week and month concerned. H.13 The AGT control shall be connected to intersection controllers either by a wireless or cabled system, as indicated on the Drawings or Schedules.



7.11.5 CONSTRUCTION REQUIREMENTS A. Civil Works Civil works shall be completed in accordance with Section 7.12 Builder’s Work and generally as outlined below.

A.1 Concrete Foundations This Section covers the requirements for concrete foundations and bases required for signal masts, controller and other equipment. A.1.1 The foundations shall either be specifically constructed for the item of equipment or incorporated with other structures such as cable drawpits, all as shown on the Drawings. A.1.2 Foundations shall either be pre-cast or cast in-situ as detailed on the Drawings and/or as instructed by the Engineer. A.1.3 Excavation for construction of the foundations shall be in soil of any nature and may involve excavation in rock or demolition of old structures. Where the foundations are located in a backfill, the backfill shall be fully completed before foundation excavation is carried out. The Engineer shall inspect the excavations and give his approval before construction of the foundations may commence. A.1.4 Foundation excavations shall be clean and neatly formed. Following approval from the Engineer, the base and sides of each excavation shall be lined with a heavy duty sheet bitumen or polythene waterproof membrane before work on foundation construction commences. A.1.5 Where pre-cast foundations are to be installed they shall be inserted in the excavation supported at the correct level and grouted-in. In-situ foundations shall be constructed as shown on the Drawings with the concrete placed and compacted in each foundation in one operation. A.1.6 Concrete and reinforcement shall conform to the requirements of Specifications Section 5: Concrete and Structures.

A.1.7 The position of anchor bolts and the level of the top surface of each foundation shall be exactly determined and adjusted. PVC ducts of the sizes shown on the Drawings shall be installed in the foundation. A.1.8 The top surface of foundation blocks shall be horizontal and to the level as detailed on the drawings. Any surface which is found to be out of tolerance by plus 25mm or minus 10 mm shall be corrected in a method proposed by the Contractor and approved by the Engineer.



A.1.9 Any design of the Civil Works carried out by the Contractor or his consultants and advisors shall take into consideration foundation soil conditions and shall be approved by the Engineer prior to commencement of construction.

A.2 Underground Duct System A.2.1 The Contractor shall supply and install underground ducts and cable drawpits indicated on the Drawings or as required on site for installation of the cables. A.2.2 The Contractor shall be responsible for all excavation, draining trenches, forming of duct assembly, backfilling, removal of excess soil and restoring the finished grade to its original condition. A.2.3 Ducts shall not be installed by cutting across the finished road surface. Where this operation is required ducts shall be installed by approved trenchless techniques such as thrust boring or pipe jacking. A.2.4 Ducts shall be made of high impact, acid and alkali resistant polyvinyl chloride (PVC) and shall be of the specified class, diameter and wall thickness as detailed in the Standards and/or on the Drawings. They shall be of the non-sparking type and suitable for direct burial in the ground. The minimum tensile strength of the ducts shall be 400 MN/m2 and impact strength shall be 40 MN/m2. Each section of the duct shall have one end tapered. The joined part shall be equal or longer than 80mm in length. The junction shall be water and sand proof. A.2.5 A 3mm nylon rope shall be left inside empty ducts to allow for the future pulling of cables. The nylon rope shall be cut at a length of one metre outside the duct head into the drawpit and securely fixed to a wooden block so that the rope shall not be lost inside the duct. A.2.6 Multiple ducts shall be laid within a trench in a close cluster formation.

B. Electrical Works

B.1 Traffic signal operational stages including pedestrian phases as shown in the drawings are indicative only and may be amended upon the instruction of the Engineer. The cycle shown in the Drawings may be accepted, revised or may demand extra facilities which are deemed to be inclusive in the B.O.Q. unit price. B.2 MP terminals shall be supplied for each controller. B.3 On completion of erection of traffic signals, the Contractor shall submit programmes for vehicle actuated and fixed time modes with full details for operation of each to the Engineer. B.4 A detailed list of controller components to be supplied and a recommended spare parts schedule to cover the first five years of operation shall be submitted by the Contractor to the Engineer.



7.11.6 MEASUREMENT Traffic signals shall be measured as the number of completed sets of signals comprising: controller, electronics, loop sensor units, loops, signal masts and heads with interconnecting cables and earthing as necessary, supplied, erected and put into operation in accordance with the Specification, including all foundations, ducts, drawpits and associated Civil Works. PAY ITEM UNIT OF MEASUREMENT (7.11.1) Traffic Signal Installation (type) Set


(Consultant) BUILDER'S WORK 7.12 - Page 92 of 127

SECTION 7.12 BUILDER'S WORK 7.12.1 SCOPE A. The work covered in this section includes the construction of cable and duct trenches, equipment foundations, bases and supports, ducts and duct banks, manholes, handholes and earth pits, chases, holes and the like, sleeves, bolts, brackets and fixings including grouting. B. Materials and workmanship for Builder’s Work, unless specified within this section, shall be in accordance with the relevant requirements of Section 5: Concrete and Structures. C. The Contractor shall confirm locations and dimensions of all builder's work required for electrical work. Shop and construction drawings and other data shall be submitted to the Engineer for checking and approval before proceeding with the work. D. For routes of services below ground, the Contractor shall agree the precise locations with the Engineer and shall set out the locations clearly and accurately, identifying the positions with temporary marker posts. 7.12.2 MATERIALS A. Components

A.1 Polyvinyl chloride (PVC) ducts for outdoor power and lighting cable installations shall be non-sparking, suitable for direct burial in the ground and have a minimum tensile strength of 500 kg/cm2 and an impact strength of 5 kg/cm2, supplied in standard 6 m lengths, with one end of each length tapered. Ducts shall be of the nominal size shown on the Drawings, with minimum wall thicknesses of 3.2 mm for 100 mm ducts and 4.7 mm for 150 mm ducts. A.2 Duct supports shall be pre-formed and non-metallic. Supports containing metal shall have the metal non-continuous and not capable of forming a magnetic loop. A.3 Covers for trenches in electrical rooms and other floors, unless otherwise specified or shown on the Drawings, shall be flanged chequered steel plates with angle or channel-section frames, suitably reinforced to support anticipated loads and finished with zinc chromate primer and two coats of grey enamel. A.4 Covers for manholes and handholes shall be in accordance with BS EN 124:1994, cast iron with concrete on top, recessed, and of a suitable duty for the particular application. Covers shall match the surrounding side walk finish. The Contractor shall submit samples for the Engineer's approval before proceeding with the works.



A.5 Brackets, supports, rails and tracks for supporting electrical installations shall be galvanised steel, fixed with expansion bolts of a suitable size and material. Plastic inserts and lead anchors are not acceptable unless approved by the Engineer for specific light duty installations.

A.6 Duct spacers shall be easily assembled and of the heavy duty type design. Spacers shall be designed to limit slip both between themselves and with the ducts whilst concreting and backfilling operations. A.7 Duct spacers shall be suitable for multiple placements. They shall be interconnectable, or at least have matching surfaces to adjacent surfaces. A.8 Duct spacers shall be delivered to site in basic sizes that can be joined together to support any number of ducts. They shall be made of unplasticised, polyvinyl chloride (PVC) or an alternative approved by the Engineer. Duct spacers shall provide a uniform separation of the ducts both vertically and horizontally within the trench excavation.

B. Composite Construction

B.1 Foundations and bases shall be reinforced concrete, approved by the Engineer after submission of design calculations. Dimensions, levels and surface finishes shall be suitable for the type of equipment to be installed, either as shown on the Drawings or in accordance with shop and construction drawings approved by the Engineer. B.2 Concrete surround for duct banks for power distribution systems and outdoor lighting cable installations crossing water, sewage mains, roadways and where shown on the Drawings, shall be reinforced concrete Class 270/20 using sulphate-resisting Portland cement. Reinforcement shall consist of 12 mm diameter longitudinal bars at approximately 300 mm centres along the bottom and sides of duct banks with 10 mm diameter U-shaped transverse bars at 400 mm centres. The concrete shall extend at least 300 mm beyond each side of the crossing. B.3 Cable manholes and handholes shall be reinforced concrete Class 270/20 using sulphate-resisting Portland cement with approved waterproof membranes on external surfaces, cable supports, pull-eyes, drain pits and drain pipes as required. The dimensions and reinforcement shall be as shown on the Drawings or in accordance with approved standard details shown on shop and construction drawings and approved by the Engineer.

7.12.3 CONSTRUCTION REQUIREMENTS A. The width of cable trenches shall be as small as practicable with vertical sides. Mud, rock projections, boulders and hard spots shall be removed from the base of excavations to leave surfaces trim and level. The Engineer shall inspect and approve the trench excavations before work proceeds further.



B. Directly buried PVC cable ducts shall be laid as follows:

- Ducts shall be laid and jointed to the required line and level on a sand bed, covered with sand and the trench backfilled to ground level with excavated soil free from stones and other debris and compacted by mechanical means approved by the Engineer in layers not exceeding 300 mm thick

- Concrete tiles shall be laid to fully cover the cable duct, extending to a minimum of 50 mm beyond the sides of the duct and placed 300 mm below ground level

- Warning tape or galvanised steel mesh shall be provided along duct runs at a depth of 200 mm below ground level.

C. Underground cable duct assemblies shall be constructed as follows:

- Duct assemblies shall be laid to the required line and level, using duct supports adequately spaced to prevent sagging and breaking of the duct couplings and watertight seals. Secure with cords (not tie wires) where necessary

- Duct banks shall be laid with a minimum longitudinal slope of 1% draining to an exterior manhole, handhole or other location as indicated on the drawings or instructed by the Engineer.

- Ducts shall be joined using waterproof cement to the manufacturer's recommendations, so that the joint is both water and sandproof with at least an 80 mm overlap between duct units.

- 3 mm galvanised steel wire shall be provided inside empty ducts for future pulling of cables. The wire shall extend 1 metre beyond the duct banks at both ends and be securely fixed to the wooden bungs sealing the duct.

D. Ducts ending in cable manholes or handholes shall be neatly cut and reamed and set behind chamfered precast concrete duct end blocks or terminated with appropriate bell-mouth bushings set into the concrete wall. Other duct ends shall be capped in accordance with the Drawings or to the approval of the Engineer. E. Conduits and ducts at entries into buildings or manholes shall to be sealed with plastic moulds or wooden bungs to prevent entry of rodents, gas and vapour. F. Sleeves or ducts in equipment foundations shall be provided in accordance with approved shop and construction drawings or as directed by the Engineer, whose approval of the sleeve or duct installation is necessary prior to concreting. G. Support frames for switchgear located over cable trenches, where shown on the Drawings or required by equipment design, shall be installed prior to concreting. H. Anchor bolts for support frames in foundations and other concrete structures shall only be permitted when the Engineer has approved the Contractor’s proposals for carrying out this work. I. Holes and chases in in-situ concrete shall be cast in. Cutting or drilling of concrete shall not be permitted without prior approval from the Engineer.



J. No holes and chases shall be cut or drilled in precast concrete without prior approval from the Engineer. K. No holes shall be cut or drilled in structural steelwork without prior approval from the Engineer. L. Holes and chases in masonry shall not exceed the following dimensions:

Size of holes: 300 mm square

Depth of vertical chases: 1/3 wall thickness or, in cavity walls, 1/3 leaf thickness Depth of horizontal chases: 1/6 wall or leaf thickness. M. When cutting masonry the Contractor shall:

- Ensure that the mortar is fully set before commencing

- Cut carefully and neatly, avoiding spalling, cracking or other damage to surrounding structure

- Keep holes to the smallest practicable size and ensure they do not exceed specified dimensions

- Cut chases in straight lines and horizontally and vertically only; chases shall not be set back to back on opposite sides of a wall, but offset by a distance equivalent to not less than the wall thickness.

N. The Contractor shall submit proposals to the Engineer for his approval for bridging over preformed holes for ducts which exceed 460 mm width. O. Directly buried ducts and underground duct assemblies shall be inspected by the Engineer before backfilling or concreting. A steel mandrel or other device whose diameter equal to 90% of the inside diameter of the duct and is 500 mm long shall be pulled through the entire run of the duct and shall pass through without getting stuck. Ducts which do not allow mandrels to be pulled through are to be repaired or replaced to the satisfaction of the Engineer. P. Ducts shall be cleaned with stiff bristle brushes pulled through the entire length prior to pulling through cables.



7.12.4 MEASUREMENT A. Duct installation shall be measured by the linear metre of multiple duct run installed in trench, in bridge deck or in concrete encasement, completed and accepted with reference to the number and size of duct. Measurement shall be along the axis of the duct from end to end and shall include all bends, couplings and bushings. Concrete encasement, as specified, shall not be measured for direct payment but shall be considered as a subsidiary item, the cost of which shall be deemed to be included in the Pay Item for the duct. B. Foundations and bases shall be measured separately each by number according to the type and size employed. C. Cable draw-pits shall be measured as the number of completed and accepted units. D. Trenches shall be measured by linear metre completed, including concrete tiles, warning tape and excavation and backfilling to levels and dimensions as specified on the Drawings. E. Hot Dip Galvanized Pull Box shall be measured as the number of completed and accepted units. PAY ITEM UNIT OF MEASUREMENT (7.12.1) PVC Duct (Specify location and size) Linear Metre (m) (7.12.2) Foundations and Bases (Specify type & size) Number (No) (7.12.3) Cable Drawpits (Specify type) Number (No) (7.12.4) Trench (Specify type and depth) Linear Metre (m)

(7.12.5) Hot Dip Galvanized Pull Box (Specify type & size) Number (No)


(Consultant) TESTING AND ADDITIONAL REQUIREMENTS 7.13 - Page 97 of 127

SECTION 7.13 TESTING AND ADDITIONAL REQUIREMENTS 7.13.1 DESCRIPTION The work included in this section includes labelling, marking and testing of equipment necessary prior to commissioning. This section shall be read in conjunction with other relevant sections of the Specification. A. Labelling All items of equipment shall be adequately and clearly labelled in English and Arabic. Labelling shall be in accordance with the schematic diagram, a copy of which shall be incorporated in the Operation and Instruction Manual.

A.1 General: Each item of switchgear and all other items of plant, whether individual or forming part of a switch or control panel, shall be clearly labelled on the exterior of casings.

A.2 Lighting columns shall be numbered in Arabic and English with black lettering of sufficient size to be visible from a passing vehicle. Columns shall be identified strictly in accordance with the coding and locations shown on the Electrical Installation Drawings.

A.3 Switchgear: All control switchgear labels shall be engraved on traffolite to give black lettering on a white background and shall indicate the voltage, current rating and phase colour together with the manufacturer's distinguishing mark. A separate label shall include the service controlled.

A.4 Overall Scheme: All switchgear, distribution boards and apparatus shall be included in an overall identification scheme and labelled accordingly.

A.5 Warning Labels: "Danger High Voltage" labels in English and Arabic with red lettering and electrical flashes shall be located on the doors of each sub-station enclosure to be immediately visible whilst opening the fence access gates before entry. Warning labels for individual items of equipment where different voltages occur within the same equipment shall comprise white letters of 5mm height on a crimson or fire red background.

A.6 Phase Markers: The interior of each item of electrical equipment shall be clearly marked to show the phases by means of coloured plastic sleeving or discs.

A.7 Circuit Lists: Circuit lists shall be mounted on the inside of distribution board lids or doors, placed so that they are easily readable. Each list shall comprise of a printed sheet sealed into a semi-rigid clear plastic cover provided by a specialist supplier.



A.8 Cable Core Identification: If the core insulation is not suitably coloured, AC power cable cores shall be identified at their terminations by coloured sheaths of the heat or chemically shrinkable type, to indicate the respective phases and neutral.

A.9 Accessory Identification: All accessories such as local switches, switch-fuses and isolators used for the control of equipment and lighting fittings shall carry engraved identification plates to indicate the circuit number and phase to which the accessory is connected; as shown on the Drawings.

A.10 Prior to final testing the Contractor shall confirm that all labelling is intact over the whole site and that all cables have been fitted with circuit markers wherever the cable emerges from the duct system or enters into a building.

B. Testing and Commissioning

B.1 Testing and inspection of the installation shall be carried out in accordance with the regulations and standards listed in the documents after completion of the work to prove compliance with the Specification. The tests shall be carried out in the presence of and to the satisfaction of the Engineer.

B.2 Manufacturers’ test certificates for appropriate equipment shall be handed to the Engineer prior to the site testing being carried out.

B.3 All test results shall be recorded on site and signed by all witnessing parties. Subsequently three copies of all such documents shall be submitted to the Engineer.

B.4 At least 24 hours notice shall be given to the Engineer of proposed testing together with a list of the equipment to be used. In particular proposals shall be submitted for measuring the luminance and illumination levels and for calculating the average levels as specified elsewhere in the Specification.

B.5 All tests including where applicable, insulation tests, continuity tests, effectiveness of earthing, measuring of earth electrode resistance, shall be carried out.

B.6 No repeat test shall be carried out until the cause has been established and rectification of the failure has been carried out.

B.7 The following tests shall be carried out on site:

B.7.1 MV Cables

All MV cables shall be tested to the requirements of I.E.C. 60502 and shall include:

- MV D.C. test between conductors to earth.

- Dielectric leakage current at the test voltage.

- Insulation resistance test after above tests taken with a 1000 volts megger.



Upon completion of all tests the cables shall be left in a fully discharged condition.

B.7.2 LV Cables

All LV cables shall be tested. The tests shall include:

- Insulation resistance test taken between conductors and between conductors and separate earthing cables taken with a 500 volt megger.

- Continuity tests

Approval shall be obtained from the Engineer before starting any tests and for authorisation of connection of the power supply to the installation.

B.7.3 Visual Inspections

The following inspections shall be carried out on completion of the work:

- Condition of the equipment and quality of the workmanship.

- Level, perpendicularity and alignment of the poles and luminaires.

- Actual characteristics of the equipment.

B.7.4 Measurement of Insulation Resistance

Insulation resistance tests shall be carried out on the various LV circuits. The tests shall be performed after installation, in accordance with approved standards to determine the adequacy of insulation between phases and also between neutral and earth (lamps shall be removed during the test where applicable). The resistance of the earthing of all metallic frames shall also be tested.

B.7.5 Operational Tests

Normal functioning of all lamps: Operational tests shall be carried out on all power equipment. The voltage at the terminals on the final column in each circuit shall be recorded.

B.7.6 Performance Tests

Performance tests shall be carried out after 100 hours of normal functioning and shall include measurement of the lighting levels and uniformities on the road surfaces. The results shall be submitted to the Engineer in tabulated form.

B.8 The Engineer shall reserve the right to take any action he may consider necessary, in the event of the measured values not conforming with the lighting design criteria specified above. Any other tests found necessary by the Engineer to verify conformity of the installation with the Specifications shall also be carried out.



C. Earthing Tests

After installation of the individual earthing systems and after the whole installation has been connected, an earth resistance test shall be carried out on the earth bar and the readings obtained officially recorded. Three readings shall be obtained for each sub-station relating to the two earth paths connected individually and in parallel. An Evershed and Vignoles or similar earth tester approved by the Engineer shall be used and all results tabulated and handed to the Engineer. D. Handling of Equipment. Slings, lifting tackles and cranes required shall be provided for the safe handling, off-loading and installation of all items supplied. The necessary test certificates for such equipment shall also be provided. Protection of surfaces and floors during installation shall be the responsibility of the Contractor together with any making good required. Programming of deliveries shall be co-ordinated to ensure accessibility of equipment at the appropriate stage of construction. E. Maintenance and Protection Maintenance and protection of all equipment shall be provided during storage, delivery installation and until hand over upon completion. 7.13.2 MEASUREMENT The provisions of this section of the Specification are not measured for direct payment, but shall be considered as subsidiary works; the costs of which shall be deemed to be included in the Contract prices for the relevant Pay Items.


(Consultant) ELECTRICAL INSTALLATION EQUIPMENT DATA 7.14 - Page 101 of 127

SECTION 7.14 ELECTRICAL INSTALLATION EQUIPMENT DATA 7.14.1 GENERAL A. The work covered in this section covers the details required from manufacturers and other sources for the supply of electrical equipment. B. Information and data on the principal items of equipment shall be listed in Schedule No 4: Manufacturers in accordance with Clause 5.1 of the Bid Conditions and Procedures. C. On award of the Contract, the Contractor shall supply information and data confirming compliance of the equipment with the Specifications and listed in the Summary of Equipment Manufacturers as required by the Detailed Equipment Data. The Engineer reserves the right to request any further information necessary to check compliance of the proposed equipment with the Specifications. 7.14.2 DETAILED EQUIPMENT DATA A. The following information shall be included in the Summary of Equipment Manufacturers:

A.1 Luminaires

(a) Name of manufacturer.

(b) Type of luminaire with manufacturer's catalogue and descriptive leaflet.

(c) Details of construction with detailed specifications of materials used.

(d) Total electrical load of luminaire.

(e) Lighting characteristics of the luminaire:

- Total luminous output in percent of lamps output.

- Isocandela diagrams in all azimuths.

- Isolux curves on a horizontal surface.

- Coefficient of utilisation.

(f) Weight of complete fitting

(g) Luminaire dirt depreciation curves.



A.2 Lighting Columns

(a) Name of manufacturer

(b) Column type(s) with manufacturer's catalogue and descriptive leaflet.

(c) Details of construction with detailed specification of material used for column and holding down bolts.

(d) Calculations showing details of stresses under maximum wind loading and gusting.

(e) Calculations and sizes necessary concrete support bases.

A.3 Lamp Control Gear

(a) Ballast

(i) Name of manufacturer.

(ii) Type(s) with manufacturer's catalogue and descriptive leaflet

(iii) Operating design characteristics of lamp (starting and normal).

(iv) Losses in normal operation.

(v) Minimum starting voltage.

(vi) Variation of lamp lumen output with voltage.

(vii) Starting current (with cold and hot lamps).

(viii) Minimum voltage for lamp extinction.

(ix) Power factor before and after correction.

(x) Conductor temperature when the ballast is operating inside the luminaire, placed in an ambient temperature of 50

oC.

(xi) Wiring diagram and characteristics of each component.

(b) Condenser for Power Factor Correction

(i) Name of manufacturer.

(ii) Type(s) with manufacturer's catalogue.

(iii) Characteristics: capacity, voltage and temperature rating.

(iv) Maximum operating temperature in an ambient temperature of 50oC.



A.4 Lamps

(a) Name of manufacturer.

(b) Type(s) with manufacturer's catalogue.

(c) Lamp operating characteristics (starting and normal).

(d) Starting time and starting current in cold and hot conditions.

(e) Minimum voltage for lamp extinction.

(f) Spectral distribution of the light emitted.

(g) Lumen output after 100 hours and 200 hours operation.

(h) Variation of lumen output with voltage variation.

(i) Variation of lumen output with lamp life.

(j) Average lamp life, under defined conditions.

(k) Lamp temperature, while operating in the proposed fixture in an ambient temperature of 50oC. The critical spot location of lamp temperature shall be identified.

A.5 Cables (MV and LV)

For each type of cable:

(a) Manufacturer.

(b) Specification.

(c) Standard to which it complies.

(d) Rated voltage.

(e) Manufacturer's catalogue, with indications of cable proposed.

A.6 LV Switchgear

(a) Manufacturer.

(b) Specification, with manufacturer's catalogue.

(c) Construction drawings.

(d) Characteristics of each component.

(e) Foundations block detail.

(f) General Arrangement.



A.7 Other Equipment

(a) Manufacturer.

(b) Type.

(c) Catalogue, with indication of equipment proposed.

(d) Detailed Specification.

(e) Construction drawing and wiring diagram.

7.14.3 MEASUREMENT The provisions of this section of the Specification are not measured for direct payment, but shall be considered as subsidiary works the cost of which will be deemed to be included in the Contract prices for the relevant Pay Items.


(Consultant) TELECOMMUNICATION WORKS 7.15 - Page 105 of 127

SECTION 7.15 TELECOMMUNICATION WORKS 7.15.1 SCOPE The work covered in this section includes the following:

- Supply and installation of the complete ductwork system, including manholes and handholes, for the subsequent installation of the telephone network cabling.

- Supply and installation of telephone poles for the subsequent installation of the telephone network cabling.

- Removal or relocation of existing telephone poles and ducts

- Supply and installation of telephone cabling 7.15.2 GENERAL A. The Contractor shall include within his rates for the supply and installation of any temporary telephone cabling required to maintain the existing telephone system during the contract. Temporary telephone cabling is defined as that required to maintain any working part of the existing system due to:-

- Road works affecting the existing system ductwork or cabling but not requiring re-routing.

- Damage to existing ductwork or cabling due to reconstruction work.

- Re-routing of existing ductwork or cabling to facilitate construction. B. Temporary telephone cabling shall be replaced by cables routed within the ductwork system as soon as possible. C. All work undertaken and materials provided in association with the existing telephone ductwork/cabling system shall be coordinated with and be to the written approval of the Ministry of Post and Telecommunications (MPT), prior to any work commencing. The responsibility of this work shall remain with the Contractor. D. The drawings of the new ductwork system for the telephone network shall be considered as provisional until the contractor has submitted the drawings to the MPT and obtained written approval. This approval shall include routing, duct bank quantities, location and sizes of manholes. A copy of the approval shall be issued to the Engineer prior to the commencement of work. The Contractor shall include for any revisions to the drawings to meet MPT requirements. E. Upon award of the Contract, the Contractor shall arrange for a co-ordination meeting with both the MPT and the Engineer. The Contractor shall prepare an agenda for the meeting, including a programme of work addressing all aspects relevant to the telephone system, to be issued prior to the meeting.



F. Environmental Requirements The installation shall be suitable for operation under the following conditions:

- Ambient temperature: 0°C to 35°C

- Relative humidity: 90% max at 35°C G. Co-ordination with Other Utilities The following table lists the various separation limits for the telecommunications ductwork from other sources:-

Utility Parallel Distance

>10 m

Parallel Distance

<10 m

Cross- over

Water mains, sewer pipes, manholes, joint boxes 300 mm 150 mm 150 mm

Lamp standard bases. Traffic signal bases 150 mm 100 mm --

Power cables:

< 600 V

300 mm

100 mm

300 mm

< 13.8 kV 1000 mm 200 mm 1000 mm

< 33 kV 2000 mm 500 mm 1000 mm

< 69 kV 5000 mm 1000mm 1000 mm

7.15.3 INSTALLATION STANDARDS FOR CIVIL WORKS A. Ductwork System: General

A.1 The ductwork system for the telephone cabling shall be located in the road verge and ducts shall be encased in concrete unless otherwise agreed with the Engineer. A.2 The telephone system shall have PVC ducts of 97 mm I.D bore.

B. Ductwork System: General Installation Details

B.1 The line and level of the duct formation shall be kept as straight as possible. Manholes shall be provided at direction changes, both laterally and in gradient. B.2 The configuration of the duct formation shall be as indicated on the Drawings or as specified by the Engineer. B.3 Ducts shall not be laid in the absence of the Engineer unless prior permission has been received. B.4 Ducts shall be watertight between manholes/handholes. Installation methods shall prevent sand and soil from entering the ducts.



B.5 At manholes, handholes and vault walls the bond between the outside surface of the duct and the wall shall be watertight. B.6 Ducts shall be terminated flush to handholes, manholes and cable vaults inside walls. Edges shall be bevelled off. B.7 Ducts entering manholes, handholes and cable vaults shall be plugged and watertight. The plugging mechanism or material shall be readily removable to allow for future cable installation. B.8 Ducts shall enter manholes, handholes and cable vaults at 90° ± 10° to the structure walls. B.9 The duct entry and exit points at manholes and handholes shall be centrally or symmetrically located. B.10 At locations between manholes/handholes where the duct formation must be modified due to obstructions the formation shall be altered to provide the smoothest possible alignment of the duct. B.11 The duct may be curved by up to 90°. The cold bending radius for PVC ducts shall not be less than 12 metres on preformed bends. 5° couplings shall be used where smaller radii are required; the alignment shall be to the approval of the Engineer. B.12 All ducts shall be mandrel tested after installation. B.13 Upon completion, all ducts shall be provided with a nylon draw cord. This cord shall be of sufficient strength to enable the pulling through of a drawing rope.

B.14 Where the required depth of cover as originally specified cannot be achieved in-situ concrete slabs shall be provided above or integral with the duct structure in accordance with the Engineer’s instructions. The slabs shall be reinforced with a minimum of 6 kg steel/m²).

C. PVC Ducts in Concrete

C.1 The minimum thickness of concrete surround to the ducts shall be 75 mm. The concrete shall key into the sides of excavation. C.2 Ducts shall be supported by spacers positioned at intervals of not more than 500mm. The spacers shall be at least 75mm long. C.3 Warning tape shall be installed within the backfilling layers Warning tape shall be 70mm wide, yellow PVC, durably marked with the text 'WARNING - TELEPHONE CABLE' at not more than 50cm intervals. C.4 Concrete immersion vibrators (pokers) with a maximum OD of 30 mm shall be used to place concrete between the ductwork and the sides of the excavation.



C.5 Where reinforced concrete is required, the Contractor shall submit a method of installation to the Engineer for approval prior to concreting.

C.6 In locations where concrete encased PVC ducts are installed with less than a 400 mm depth of cover, the concrete formation shall be increased on the top section by an additional 100 mm thickness of reinforced concrete.

D. Excavation and Backfilling for Manholes

D.1 Excavation and backfilling for manholes and handholes shall be carried out in accordance with the applicable sections of Part 3: Earthworks. D.2 For the installation of precast structures, the bottom of the excavation shall be levelled with a layer of compacted gravel, hardcore or similar material, as accepted by the Engineer. The base of the excavation shall be sufficiently smooth and level to allow the structure to be installed with the minimum adjustment to the frame and cover height. D.3 In-situ concrete manholes and handholes shall have the base of the excavation levelled with a minimum of 5 cm of concrete blinding. Blinding shall not be considered as part of the specified cover to reinforcement.

E. Concrete Manhole Structures

E.1 Concrete structures shall comply with Part 5: Concrete Works. E.2 Earthing facilities shall be provided as required by the design and according to MPT Standards. E.3 The completed installation shall comprise a watertight structure, furnished with cable supports, cable pulling facilities, ladders, bonding and earthing materials etc. as specified, and free from construction materials, debris and water. Manholes shall have marking plates installed in accordance with MPT requirements. E.4 The reinforcing steel used in manhole construction shall be provided with earthing bonds to permit the inter-connection of all metallic conducting materials in the manhole. E.5 Provision shall be made for the maximum designed numbers of ducts to exit the manhole. Pre-formed plastic duct terminators (socket banks) shall be cast into the manhole structure during its construction. E.6 Should ductwork be cast directly into the manhole wall, the additional duct capacity shall be stopped approximately 100 cm from the manhole outer wall and plugged at both ends. E.7 Bottom ducts shall always be used as the working duct runs to facilitate access to the unused ducts.



F. Testing on Completed Ducts

F.1 All ducts shall be rodded and cleaned before testing. A test mandrel with a main body of 200 mm length and 95 mm diameter shall be pulled through each new 100 mm duct run. If any obstruction is encountered, the duct shall be cleaned again and, if necessary, repaired before it is tested again. F.2 Bends of radius 2 metres and less, which will not pass the reference mandrel, shall be proven with a ball mandrel of 95 mm diameter. F.3 At the discretion of the Engineer, a pressure test may be requested to verify the watertightness of the completed duct work. F.4 Pressure testing shall consist of pressurising a duct to 25 Kpa (0.25 kg/cm²) for 30 minutes. F.5 Pressure testing shall be carried out on 10% of the installed length of duct. Should any length of duct fail to hold the required pressure for the indicated time, all the ducts within the affected section shall be tested. F.6 Structural Concrete shall be tested in accordance with Part 5: Concrete Works.

7.15.3 EARTHING A. General Principles

A.1 All manhole furnishings shall be earth bonded by the provision of an earth ribbon around the inside of the manhole perimeter, with an earth ribbon installed into each jointing bay for connection to cable earths during jointing. The bond ribbon shall be secured to the manhole walls at 30 cm intervals. A.2 Reinforcing steel in every manhole and handhole shall have at least two earth wires bonded to the steel, accessible on the inside, for connection to the bonding ribbon.

7.15.4 MATERIALS – MANHOLES AND HANDHOLES A. Manholes and handholes shall be constructed in accordance with Section 8.05: Manholes, Chambers and Gullies B. Design Requirements

B.1 The types of manholes to be used shall be selected depending on the number of ducts installed at each end as shown in Table B.2.



TABLE B.2: DUCT ENTRANCE FORMATION

Type of Manhole Maximum Number of Ducts Entering One Face

of the Manhole

Number of Ducts in Each

Layer

Number of Layers I Type T Type

4 4 1 7 -

8 4 2 7 -

12 4 3 7 -

16 4 4 7 -

20 4 5 7 -

24 4 6 7 -

28 4 7 7 -

28 4 7 10 12

32 4 8 10 12

B.2 Manholes and handholes shall be precast under the controlled conditions of a fabrication yard unless otherwise agreed and approved by the Engineer.

B.3 Manholes shall be fully equipped with the full complement of accessories such as pulling eyes, ladders, ladder supports and cable brackets; all to the approval of the Engineer. B.4 The strength of the manholes and handholes shall be sufficient for the intended use. Structural calculations and detailed design drawings to verify the strength of each size and type of manhole and handhole shall be submitted for approval by the Engineer.

C. Long Term Performance Requirements

C.1 The manholes and handholes shall be capable of withstanding typical service conditions for a period of twenty years without detriment to the operation and maintenance characteristics. C.2 Manholes and handholes shall be designed and manufactured so that exposure to environmental conditions during storage, transport, installation and operation shall not degrade their physical, operational or maintenance characteristics. C.3 The environmental conditions include ambient air temperature variations from -15° to +35°C and direct solar radiation up to +52°C, unless specified elsewhere in the Contract Documents and Drawings or by the Engineer.



D. Manhole Accessories

D.1 Unless shown otherwise on the Drawings, manholes shall be provided with a sump approximately 200 mm deep by 300 mm by 300 mm long wide placed directly below the manhole opening. The floor shall slope slightly towards the sump.

D.2 Two pulling eyes shall be installed opposite each duct face at 300 mm above and below the top and bottom ducts and on the vertical centre line of the duct face. The installed pulling eyes shall be able to withstand a hauling tension of 30 kN. D.3 The manhole earthing system shall be installed around the top inside walls of the manhole. The ribbons shall be joined by soldering. The ribbons shall be attached to the manhole reinforcement in at least 2 places. The ribbons shall be fastened to the walls at every 300 mm. D.4 A ladder support shall be installed in the manhole collar suitable for the attachment of a manhole ladder. The access collar shall also include steps for entry and exit. D.5 The manhole marker plate shall be marked with the manhole number and installed on the same side and at the same level as the ladder support.

E. Manhole Cover Assembly

E.1 The manhole cover and frame shall be manufactured from cast iron compliant with an appropriate grade of iron to BS EN 1561: 1997. The cover and frame shall comply with the dimensions specified. E.2 The manhole covers shall have a diameter of 730 mm. The frames and covers shall be designed so they are interchangeable and fit together in such a way that the cover does not rock on the frame. E.3 The cover and frame shall include a locking bolt system which fastens the cover onto the frame. The bolt shall be approximately 10 mm diameter and have a unique head design to minimise unauthorised access to the manhole. The Contractor shall submit details of the locking bolt system to the Engineer for approval. E.4 The frames shall have four evenly spaced holes with a diameter of approximately 20 mm, sufficient to accommodate a shackle for lifting purposes. E.5 Manholes covers and frames shall be designed to withstand the maximum anticipated traffic loads. E.6 Manhole covers shall be designed to withstand an evenly distributed dead load of fill and road surfacing of 12 Kpa. E.7 Two slots shall be provided in each cover for lifting or prising.



E.8 Covers and frames shall be completely coated with a bituminous material to reduce corrosion.

F. Handhole Cover Assembly The handhole cover and frame shall be manufactured from cast iron of the medium heavy duty type to BS EN 124 (1994). The cover and frame shall comply with the dimensions as specified. 7.15.5 MATERIAL - PVC DUCTS A. Standards

A.1 The PVC ducts shall be manufactured in accordance with:

BS 3506:1969: Clause 2 grade 1

BS EN ISO 9002: Quality Systems - model for quality assurance in production and installation

B. Long Term Performance Requirements

B.1 PVC ducts supplied in compliance with this specification shall be capable of withstanding the typical service conditions for a period of thirty years without detriment to their operation and maintenance characteristics. B.2 PVC ducts shall be designed, manufactured and packaged so that exposure to the environmental conditions during storage, transport, installation and operation shall not degrade their physical or operation and maintenance characteristics.

C. Manufacturing Standard

C.1 PVC duct sections for telephone systems shall be manufactured in accordance with the following criteria:

Outside diameter 100 mm

Effective length 6000 mm ± 25 mm

Wall thickness 1.5 ± 0.2 mm

C.2 The ducts shall be compliant with all applicable requirements of BS 3506:1969 C.3 Each section of duct shall be provided with bell and spigot ends. The spigot end shall be chamfered to produce a 15° bevelled edge along the outer circumference, the bell end shall be preformed into a plain bell socket suitable for coupling with the chamfered spigot end of the adjacent duct. C.4 Joints between the ducts shall be watertight.



7.15.6 MATERIALS - DUCT FITTINGS AND ACCESSORIES

A. General

A.1 This section covers the minimum standards and requirements for the construction, properties, testing and packing of PVC duct fittings and accessories. A.2 The fittings included in this specification are:

- Bend (90° - 2000 mm radius)




- Double Bell Coupling (0°)

- Double Bell Coupling (5°)

- Sleeve

A.3 The accessories included in this specification are:

- Duct plug

- Duct sealant

- PVC Cement

A.4 PVC duct fittings and accessories shall be capable of withstanding typical service conditions for a period of thirty years without detriment to their operation and maintenance characteristics. A.5 PVC duct fittings and accessories shall be designed, manufactured and packaged so that exposure to environmental conditions during storage, transport, installation and operation shall not degrade their physical or operation and maintenance characteristics.

B. Duct Fittings

B.1 Bends (90° - 2000 mm radius) and (90° - 1000 mm radius) shall be used to provide a 90° directional change to the duct run. B.2 Bends (45° - 2000 mm radius) and (45° - 1000 mm radius) shall be used to provide a 45° directional change to the duct run. B.3 The bends shall be provided with bell and spigot ends; and they shall have a 150 mm straight extension on the ends, the spigot end shall be chamfered to produce a 15° bevelled edge along the outer circumference. The length of the straight part of the bell shall be at least 80 mm. B.4 90° bends shall bear a mark where they can be cut into two equivalent 45° bends.



B.5 Double Bell Couplings (0°) shall be used to connect two straight spigot ended ducts. B.6 Double Bell Couplings (5°) shall be used to connect two spigot ended ducts and also to provide a 5° directional change to the duct run. B.7 Double Bell Couplings shall be at least 200mm in length with an inner ridge in the middle to act as a stopper for the duct. B.8 Joints between two ducts with double bell couplings shall be watertight. B.9 Sleeves shall be used to provide a repair over a PVC duct. They shall also be used to provide a strong straight coupling between two straight (spigot) ends of ducts. B.10 Sleeves shall be straight PVC tubes at least 3000 mm in length with an inner diameter to fit over the outer diameter of the PVC duct.

C. Duct Plug

C.1 Duct plugs are mechanical devices used to seal the duct from the entry of water. They shall be so manufactured to be installed and removed by simple hand tools. C.2 The plugs shall be designed to accommodate the tolerances of manufacture of the PVC duct types into which they are to be installed. C.3 The method of installation shall not be hazardous to either personnel or adjacent cables. C.4 It shall be possible to remove any plug without damage to either duct or cable. C.5 An eye shall be provided on the inner side of the plug, to which a draw cord can be attached.

D. Duct Sealant

D.1 The duct sealant is used to seal ducts which are to have cables installed. The duct sealant shall be capable of sealing more than one cable per duct. D.2 The sealant shall require a minimum of preparation time on site prior to application. D.3 The sealant shall be a putty which can be easily removed to allow the installation of additional cables. D.4 The installed sealant shall effectively seal the duct from the entry of water.



E. PVC Cement Ducts shall be jointed using a suitable type of PVC cement approved by the Engineer. The joints shall be watertight. 7.15.7 MATERIALS - DUCT SPACERS A. General This section describes the design of duct spacers for Telecommunications Ducts.

A.1 The design of the duct spacer shall allow for simple system installation. Spacers shall be interchangeable. A.2 Duct spacers shall be delivered as single and double cradle models. A.3 Duct spacers shall be delivered in basic sizes that can be joined together to support any number of ducts. A.4 Duct spacers shall be capable of withstanding typical service conditions for a period of thirty years without detriment to their operation and maintenance characteristics. A.5 Duct spacers shall be designed, manufactured and packaged so that the physical, transmission and operation and maintenance characteristics shall not degrade when exposed to the environmental conditions during storage, transport, installation and operation. A.6 The cradles of the duct spacers shall be at least 30 mm wide and have a diameter of 110 mm to accommodate PVC-ducts as specified. A.7 Duct spacers shall be suitable for multiple row and column placement. They shall be interconnectable having mating surfaces which can be matched to adjacent spacers. A.8 The duct spacers shall provide a uniform separation of the ducts within the formation in the trench (both vertically and horizontally). A.9 The duct spacers shall be of a heavy duty design. A.10 The duct spacers shall be designed to limit slip with the ducts in the formation during construction and backfilling. A.11 The duct spacers shall be made of virgin unplasticised, polyvinylchloride (PVC), or a suitable alternative if approved by the Engineer. A.12 The PVC shall have a minimum tensile strength of 50 MPa, tested in accordance with ASTM D 638.



A.13 All materials shall be new and shall not contain fillers, plasticizers or additives which may react harmfully with PVC ducts. A.14 No constituent material shall be used which will adversely affect the long term mechanical strength of the PVC.

7.15.8 MATERIALS - CABLES A. Multipair Cables This section describes multipair telephone cables, complete with polyolefin insulation and sheathing, moisture barriers, jelly filling and copper conductors. The cables shall satisfy the requirements of IEC 60708 for audio frequency cables, with polyolefin insulation and sheathing and with moisture barriers. B. Delivery of Cables

B.1 Multipair cables shall be delivered to site on wooden drums and protected against damage in transit either by providing sufficient free space of at least 20cm between the cable and the outside circumference of the drum or by wrapping the cable with a flexible blanket 5cm thick made from a wood fibre filling between two layers of strong paper. B.2 Each cable drums shall be endorsed with the manufacturer's identification marks. B.3 Identification details shall be stencilled with paint and stamped on a metal plate nailed on the cheek of the drum. These details shall include: type, size and gauge of cable, length of cable on the drum, drum number, weight and the manufacturer's name.

C. Tests

C.1 The manufacturer shall submit certification confirming that the following tests have been carried out, together with the results of the tests.

C.1.1 Water Penetration Test

(i) A three metre test piece shall be cut at or near one end of the cable. For the initial

prototype evaluation, two samples, one from each end, shall be cut from each cable. In case the test fails for one sample, the test shall be repeated with eight additional samples. Only one failure shall be accepted for the 10 samples.

(ii) The sample under test is kept straight in a horizontal plane. One end of the sample

shall be connected suitably through a watertight gland to a water pipe containing a 1 metre head of water. The connection shall be such that the cable sheath shall not



be squeezed tight nor shall it allow leakage of water at this point. The other end of the cable shall be free.

(iii) The 1 metre head of water shall be applied for 14 days at an ambient temperature

of 20°C. No air bubbles shall remain trapped in this pipe. Any bubbles that may be present initially should be removed by agitating the water column using a thin wire for this purpose.

(iv) The test shall be deemed to have started after ensuring that the head of water is 1

metre and all air bubbles have been eliminated. The sample shall not be disturbed during the period under test. During this period, no water shall have seeped from the cable sample.

C.1.2 Compound Flow Test:

Prepare three 30cm long test samples as follows: Remove 13cm of jacketing material from one end of each of the samples then remove 80mm of shielding material and core wrap to expose the cable core. Flare the end of the cable core slightly so that the pairs are separated. Suspend the test sample in an air oven with the flared end of the cable pointing downward. Condition the test samples for a period of 24 hours at a temperature of 65 ± 1°C. At the end of this test period, there shall be no evidence of flowing or dripping of compound from either the core or sheath interfaces.

D. Jointing Materials and Joint Closures for Multipair Cables

D.1 Multipair cables shall be jointed by I.D.C. (Insulation Displacement Contact) connectors, grease filled, operated by machine or hand tools. D.2 If a machine is used for jointing, it shall be possible for the corresponding connector to be operated by means of a hand tool. D.3 The connectors shall be of the "one connector per wire" type or of the "connection module type" which can accommodate several pairs or quads each. D.4 Soldered twist joints shall not be accepted.

Single Line Connectors

D.5 The connectors shall be suitable for two (2) wires of 0.4 to 0.9mm in diameter with solid PE conductor insulation or foam-skin conductor insulation not exceeding the outside diameter of 1.62mm. D.6 The overall dimensions of the connectors shall not exceed the following when in use:

- length: 13mm

- width: 9mm

- thickness: 6mm



D.7 The individual wires shall be inserted into the connector without any stripping or special preparation. The connector body shall be of transparent plastic in order to allow the observation of the correct lead-in of the wires. The connection shall be provided with jelly inside which shall insulate and protect the connection against corrosion and shall provide a seal against moisture. D.8 Reliable connections shall be ensured by the provision of at least two contact points forming a durable contact. The conductor shall be pressed onto a blade and retained in that position. D.9 A special splicing tool shall be used for pressing the connectors with the appropriate force in order to ensure perfect contact and good clamping and to avoid wire breakage. D.10 The splicing pliers shall be of the universal type capable of crimping different single wire connector types as well as manual crimping of connection modules. It shall be of robust design but as light as possible and easy to handle. It shall have a parallel closing action.

D.11 The electrical and mechanical requirements are as follows:

- Durable contact; during normal service the resistance shall not increase above 5 milliohm,

- Minimum insulation resistance: 100 GOhm; the measurement being taken after 5 days following either water immersion for waterproof connectors or at a constant temperature of 40°C and 65% relative humidity for non-waterproof connectors,

- Dielectric strength: 3000 V rms 50 Hz for one minute, after a period of 24 hours at 20°C and 65% relative humidity,

- Resistance to surge current: A surge current of 5 kA, 8/20 microseconds is applied 5 times with a one minute time-lag between two consecutive shocks, the difference between the contact resistances before and after the test must not be greater than 5 milliohm,

- Wire pull-out: minimum 85% of wire breaking strength.

Connection Modules

D.12 Each connection modules shall consist of a dry cover and base and an encapsulated body. All three elements shall be made from polycarbonate or an equivalent material approved by the Engineer. The module shall utilise self-stripping U-contacts, wire channels and cut-off blades.

D.13 The module shall provide standard two wire splicing. D.14 The module shall enable utilisation of the U-contact principle for pairs or quads of solid-PE or foam-skin insulated conductors, not exceeding the outside diameter of 1.65mm.



D.15 The U-contact shall grip a conductor between two cantilever legs and shall provide a tight connection. D.16 The base, body and cover shall be crimped by means of a hand hydraulic crimping machine and by a simple hand presser. D.17 Covers shall be removable for further pair rearrangements. D.18 Test entry ports at the front side of the module body shall provide access for testing individual pairs. D.19 The electrical and mechanical requirements shall be fulfilled as follows:

- Durable contact: During normal service the resistance shall not increase above 10 milliohm,

- Minimum insulation resistance : 25 GOhm, the measurement being performed after having remained at a temperature of 40°C and a relative humidity of 93% for 10 days,

- Dielectric strength: 3000 V rms 50 Hz for one minute, after a period of 24 hours at 20°C and 65% relative humidity,

- Resistance to surge current : a surge current of 5 k, 8/20 microseconds is applied 5 times with a one minute time-lag between two consecutive shocks, the difference between the contact resistances before and after the test must not be greater than 5 milliohm,

- Wire pull-out: minimum 85% of wire breaking strength.

Joint Closures

D.20 Joint closures shall satisfy the following requirements:

- The joints and cables shall be moisture proof,

- The joints shall be able to withstand mechanical handling,

- The joints are compatible with the different components and materials of the cables and the joint.

- Jointing shall be carried out on site by a specialist operator who shall be able to adapt the cables to different jointing configurations (straight or branching into 2, 3 or 4 cables) and in different surroundings (overhead, underground in manholes or directly buried),

- The closure shall not require complicated or delicate apparatus and shall be based on an unambiguous prescribed sequence that can be inspected and tested both while being made and when completed. The joint closure must be operational as soon as the closure is completed.

- The closure shall be completely accessible to allow further work on the joint,

- The closure shall be robust and transportable without affecting the effectiveness of the product.



Field of Application

D.21 Joint configurations (straight or branched) shall be assembled in accordance with the following:

- The cables shall be joined in opposition, i.e. the cable on the exchange side and those on the distribution side are on one side and the other of the joint closure.

- The total number of pairs of the cable or cables on the distribution side shall be equal to that of the exchange side cable,

- The gauge of the conductors of the cable or cables on the distribution side shall be equal to or larger by 0.1mm to 0.25mm than that of the cable on the exchange side.

Nature and Description

D.22 The joint closures shall be made using one of the following construction techniques:

- Heat-shrinkable sleeves coated with temperature sensitive paint (the paint disappearing when the optimum shrinking temperature is reached),

- Mechanical sleeves consisting of shells assembled by captive screws and/or clamps ensuring total waterproofness of the joint.

D.23 The proposed closures shall be of a type approved by the Telecommunications Provider and currently in use. D.24 The Contractor shall state the origin of the proposed sleeves and submit references from other users for the approval of the Engineer. D.25 When stored, the sleeves shall indefinitely withstand normal temperature ranges without any deterioration or distortion.

D26 Heat-shrinkable sleeves shall be made of polyethylene reticulated either by irradiation or by a chemical process. They shall be black in colour and protected against ultra violet radiation. The outer surface shall not have any crevices or grooves. The end sections shall be clean with no break marks.

D.27 Heat-shrinkable sleeves shall shrink under the effect of heat at a temperature above 100°C. They shall be capable of shrinking without damage when a butane or propane blowpipe flame is passed over the surface of the sleeves.

D.28 Two types of heat-shrinkable sleeves shall be used for the joint closure of local network cables: cylindrical and split sleeves.

(a) Cylindrical sleeves

The inside surface shall be coated uniformly with an adhesive compound to a

thickness of 0.3 to 1.0mm, which melts during the shrinking of the sleeve and ensures the watertightness of the closures without altering the characteristics of the cable sheaths.



Sleeves of a diameter larger than 50mm shall be supplied with paraffin impregnated paper lining on the inside surfaces, in order to avoid any contact with the interior adhesive surface during storage.

(b) Split sleeves

Split sleeves are in the form of rectangular sheets, heat shrinkable in the direction

of its width. The inner face of the sheet shall be coated with a heat meltable adhesive

compound, of thickness 0.3 to 1mm, protected by a sheet of paraffin impregnated paper.

The adhesive sheet shall include a device to allow the closing of the sleeve around

the joint to be protected. The cylindrical sleeve when formed shall have an overlapping band covered in a

fusible adhesive compound which shall ensure the transverse watertightness of the sleeves.

D.29 The sleeves to be supplied in the package of maintenance materials and for directly buried cables shall be of the split type.

D.30 The sleeve set shall include all the necessary accessories and materials, including desiccant and materials to ensure cable shield continuity for all branching cables.

7.15.9 MATERIAL APPROVALS A. Type Approval Testing

A.1 Type Approval Test results, samples and reports are required for acceptance of designs and materials. These results are intended to assure that products have been designed to provide fault-free service for the required life of the system. A.2 Type Approval shall not be granted until a Type Approval sample has been evaluated. A.3 The Contractor shall not proceed with ordering and delivery from manufacturers until written approval by the Engineer has been received. A.4 Manholes and handholes shall comply fully with the Type Approval requirements.



B. Quality System Accreditation

B.1 Manufacturers of materials conforming to this specification shall show evidence that the product has been manufactured according to a Quality System conforming to ISO 9002. B.2 The Engineer may request a copy of the Manufacturers’ Quality Manual to verify the Quality Control Procedures used in manufacture and delivery of the product.

C. Summary of Reports and Testing Frequency

C.1 Two categories of test reports are required: Type Approval and Quality Control. C.2 All reports submitted shall include the following details:

- Manufacturer’s name

- Project number

C.3 Quality Control reports shall also include:

- Date of delivery

- Identification of materials included in the Report.

C.4 The report shall detail all results in the same order and shall refer to the relevant clause of the specification.

D. Compliance Statement The Contractor shall supply a clause by clause compliance statement, with the complete specification, including the following.

- Structural calculations and detailed design drawings where applicable.

- Full details of concrete i.e. grade, reference standard etc. and full details of reinforcement, where applicable.

- Details of the grade of cast iron material to be used.

- Structural calculations or other evidence to verify that the strength of the material is suitable.

- Details of all Quality Control tests to be applied during manufacture shall be submitted for Type Approval.

E. Quality Control Test Reports Results of Quality Control tests on the material, as required by the specification used for manufacture, shall be submitted for each production batch.



F. Packing The package shall be of adequate construction to protect the items during storage and transportation. 7.15.10 MEASUREMENT A. PVC ducts shall be measured and paid for by the linear meter of multiple duct run installed in concrete encasement completed and accepted with reference to the number and size of duct, including trench excavation and backfill. Measurement shall be net as fixed in position. B. Manholes and Handholes shall be measured and paid for as the number of each type constructed and accepted. C. All labour and materials in connection with temporary cabling necessary to maintain existing telephone system is deemed to be included in the prices and no additional costs shall be payable. D. The rate for work in association with installation of PVC ducts, manholes and handholes shall be inclusive of surveys to ascertain the location and depth of any other services, using electronic plant location equipment and excavation of test pits, marking and setting out of works; excavation in any soil type to depth of cover as specified, shoring support dewatering etc. as required; additional excavation to any depth or width required to facilitate entry into any existing cable vault, tunnel or building. E. The rate for work in association with installation of cables shall be inclusive of all jointing and fixing including materials and specialist equipment necessary. Where a connection is to be made into an existing manhole the rate shall include for refurbishment washing, cleaning of rubble and drying out of the manhole. F. The amount of completed and accepted work measured as provided above, shall be paid for at the unit prices bid for installing PVC conduit and the construction of telephone manholes/handholes as specified in the Bill of Quantities. Prices shall be full compensation for furnishing all materials, for all labour, equipment, tools, supplies and all other items necessary for the proper completion of the Work as specified. G. New telephone poles, as erected complete with foundations and fittings necessary for fixing of telephone cables, shall be measured and paid for by the number of poles installed in accordance with the Telecommunications Provider’s requirements, approved and accepted. H. Multipair telephone cables shall be measured by the linear metre installed in ducts or installed on poles as specified.



PAY ITEMS UNIT OF MEASUREMENT (7.15.1) PVC Duct (Specify type and location) Linear Meter (m) (7.15.2) Telephone Handhole (Specify type) Number (No) (7.15.3) Telephone Manhole (Specify type) Number (No) (7.15.4) Supply and install new Telephone Pole

(Specify type) Number (No) (7.15.5) Supply and Install New Multipair Telephone

Cables (in ducts/ on poles) (Specify type) Linear Metre (m)