Section 6 Part 012 TABLE OF CONTENTS 12 12.1 12.1.1 12.1.2 12.1.3 12.1.4 12.1.5 12.

General Specification

ROAD LIGHTING ...................................................................................... 2 GENERAL ................................................................................................ 2 Scope References Submittals Quality Assurance Delivery, Storage and Handling 2 2 3 5 5

SUPPLY OF EQUIPMENT......................................................................... 6 6 7 8 9 10 11 14 15 16 17 17 18

12.2.1 Design Criteria for Columns and Masts 12.2.2 Column and mast fabrication requirements 12.2.3 Specific requirements for columns 12.2.4 Specific requirements for high masts 12.2.5 Doors and base compartments for columns & masts 12.2.6 Luminaires and Lamps 12.2.7 Cable 12.2.8 Control Gear 12.2.9 Distribution Equipment, Cut-outs 12.2.10 Distribution Equipment Isolators 12.2.11 Photoelectric Control Units (PECU'S) 12.2.12 Feeder Pillars 12.3

INSTALLATION ....................................................................................... 21 21 21 21 22 22 23 24 25 30 31

12.3.1 General Requirements 12.3.2 Temporary Lighting 12.3.3 Electricity Supply 12.3.4 Removal of Existing Installations 12.3.5 Reuse of Existing Columns 12.3.6 Wiring in Luminaires and Columns 12.3.7 Feeder Pillars 12.3.8 Cable Installation 12.3.9 Duct Installation 12.3.10 Performance Testing

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Section 6 Part 012 12. 12.1 ROAD LIGHTING GENERAL

General Specification

12.1.1 Scope 1 2 This Part includes road, street and under bridge lighting and lighting for road signs. Related Sections and Parts: This Section Part 1, General Part 2, Site Clearance Part 3, Earthworks Part 10 Road signs Part 11, Works in Relation to Services Part 13, Traffic Signals Section 5, Concrete. 3 The National Electricity Cooperation (NEC), Electric Networks Department, NEC (EN) and its Street Lighting Section, may require work to be executed on their installations during the period of the Contract. The Contractor shall afford all facilities to NEC (EN)s contractors or workmen until their work is complete. The Contractor shall co-ordinate the work of NEC (EN) and his own activities and when necessary shall amend his programme of working to suit all requirements of NEC (EN) and shall keep the Engineer informed in writing of all arrangements made.

12.1.2 References 1 The following standards and other documents are referred to in this Part: BS 65, Vitrified clay pipes, fittings and ducts, also flexible mechanical joints for use solely with surface water pipes and fittings BS 88, Supplementary requirements for fuses of standardized dimensions and performance for industrial purposes BS 729, Hot dip galvanized coatings on iron and steel articles BS 791, Solid-stem calorimeter thermometers BS 2484, Straight concrete clayware cable covers BS 3871 Miniature and moulded case circuit breakers IEC898 Miniature circuit Breakers IEC 947-2 LV Switchgear and Control Gear BS 4343, Plugs, socket-outlets and couplers for industrial purposes BS 4360, Weldable structural steels BS 4533, Luminaires BS 4848, Hot-finished hollow sections BS 5135, Process of arc welding of carbon and carbon manganese steels

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IEC 947-3 Air-break switches, air-break disconnectors, air-break switch disconnectors and fuse combination units for voltages up to and including 1000 V a.c. and 1200 V d.c. BS 5467, Cables with thermosetting insulation for electricity supply for rated voltages of up to and including 600/1000 V and up to and including 1900/3300 V BS 5486, Requirements for type-tested and partially type-tested assemblies BS 5489, Road lighting BS 5649, Lighting columns BS 5972, Photoelectric Control Units for Road Lighting. BS 6121, Mechanical Cable Glands for Elastomer and Plastic Insulated Cables BS 6141 PVC insulated pvc sheathed circular flexible cables BS 6346, PVC-insulated Cables for electricity Supply BS 6360 High conductivity stranded copper shaped conductor with XLPE insulation BS 6622, Cables with extruded cross-linked polyethylene or ethylene propylene rubber insulation for rated voltages from 3800 6600 V up to 19 000/33 000 V BS 6746 Extruded black pvc over sheath BS 7671 Requirements for electrical installations BS 7430, Code of practice for earthing BS EN 60529, Degrees of protection provided by enclosures BS EN 60598, Luminaries for roadway lighting Institution of Lighting Engineers (ILE), Code of Practice for Electrical Safety ISO 9002, Quality assurance in production and installation Institution of Electrical Engineers (IEE), Wiring Regulations Ingress Protection IP22, Electrical cut-out protection Ingress Protection lP54, Electrical enclosure dust and water proof ratings Ingress Protection lP66, Classification of compression glands 12.1.3 1 Submittals Before beginning the installation, the Contractor shall confirm in writing to the Engineer that he has obtained approval from concerned authorities of the clearances provided to overhead and underground lines. The Contractor shall not order any equipment before approval has been given in writing by the Engineer. The approval procedure shall be as follows: (a) contractor submits his proposal to the Engineer (4 copies). All submissions shall give clear, detailed characteristics of the equipment proposed, together with calculations, where necessary, including catalogue identification references. Documents shall be in the English and Arabic languages the submission shall be comprehensive and clearly state any manufacturer's deviations from the specification

(b)

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Section 6 Part 012 (c) (d) (e) (f)

General Specification

manufacturer's literature with the submission shall be originals and not photocopies. the submission will be reviewed by the Engineer the submission will be submitted to concerned authorities Street Lighting Section with the Engineers comments to obtain their approval approval will be transmitted to Contractor in writing after receipt of NEC Street Lighting Section approval.

concerned authorities reserves the right to direct the Contractor to provide equipment of a make and type which is essential to achieve the design criteria. 3 The Contractor shall at his own expense, present samples to the concerned authorities Street Lighting Section of each type of equipment to be used which shall exactly conform to the designated requirements. The samples shall only be submitted after approval of their technical characteristics. Approval of samples by concerned authorities Street Lighting Section shall not in any way relieve the Contractor of his contractual obligations in respect of the suitability of the equipment or its final performance once installed and for the coordination of the elements into a fully operational installation. The design and manufacture of columns shall comply with BS 5649 and all test certificates for the columns shall be provided to the Engineer at least five days before the columns are delivered to site. The Contractor shall provide the required shop drawings and calculations as well as the provision of all literature and samples in connection with the approval of proposed equipment. The Contractor shall submit calculations on each cable to confirm that the installation meets the requirements of the current IEE Wiring Regulations as follows: (a) (b) current (c) (d) (e) 8 disconnection time is satisfactory cable is of sufficient current carrying capacity for the load under running and starting conditions protective devices shall discriminate fully as intended. maximum volt drop is not exceeded equipment to be installed is of sufficient rating for the prospective fault

The Contractor shall keep duplicate daily records on drawings of all work carried out as work proceeds, one copy of which shall be kept available for the use of the Engineer. On completion of the work, one copy of the daily records shall be handed to the Engineer. Electrical schematics shall show the method of cabling to all items of electrical equipment as installed. The Contractor shall provide full manufacturers data sheets for all equipment installed. The Contractor shall prepare and hand to the Engineer within thirty days of the date of the completion of the Works the designated number of sets of record drawings which shall be prepared on copies of the contract drawings or

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Section 6 Part 012

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transparencies. The record drawings shall include the following: (a) (b) (c) technical details of every type of equipment installed, including operating and maintenance instructions the drum number for underground cables lighting circuit arrangement and schedules. The drawing shall fully indicate (with accurate dimension) the size, type and position of equipment cables, ducts, joints and feeder pillars with particular regard for the need to accurately locate buried cables after completion spares list test certificates, including lantern carriage winch test certificates test result.

(d) (e) (f) 11

Within the time stated above, the Contractor shall submit two copies of the record drawings for the approval of the Engineer. After receipt of such approval the Contractor shall provide one set of reproducible transparent negative drawings and two sets of prints on paper to the Engineer for his retention. In addition to the foregoing, the Contractor shall provide in each distribution unit a good quality print on paper showing the street lighting distribution line diagram of that particular section. These prints shall be mounted on the inside of the door of each distribution unit, be of an adequate size to be legible and shall be covered in clear plastic to prevent undue deterioration. In order to achieve accurate record drawings, all relevant information relating to the Works shall be entered on to drawings kept for the purpose immediately the Work has been carried out. The marked prints shall be available for inspection at the Contractors site office at any reasonable time during the progress of work. The Contractor shall prepare and hand to the Engineer within thirty days of the date of Completion of the Works the designated number of sets of operation and maintenance manuals. The Engineer will decide on the scope and detail required for the operation and maintenance manuals. Operating instructions for the lantern carriage winches shall be placed in a prominent position on the high mast. Operating instructions shall be provided on a durable media and not vulnerable to vandalism. Quality Assurance Road lighting works shall be carried out by specialist contractors or subcontractors having experience in the provision and installation of lighting columns, provision and laying of cables and ducts, and provision and installation of supply connections to all electrical equipment. Specialist contractors or subcontractors shall be prequalified by concerned authorities Street Lighting Section for new street lighting installation. All cables shall be certified by the manufacturer as suitable for installation in UAE

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Section 6 Part 012 3

General Specification

All materials shall be approved by concerned authorities before ordering. Only products with a proven record of performance, efficiency and long life will be considered for approval by concerned authorities. All works, equipment and materials shall comply with statutory and other regulations, Codes of Practice and Standards current at the date of Tender including the UAE Wiring Regulations All columns and brackets shall be produced by lighting column manufacturers registered and certified for the manufacture, supply and certification of lighting columns under their quality assessment schedule to ISO 9002. Column manufacturers not registered and certified accordingly will only be permitted if a satisfactory submission is made for quality assurance. Facilities shall be provided for the Engineer to inspect the lighting columns during the course of manufacture and application of protective treatment. Any equipment or items damaged in transit will not be acceptable for incorporation in the works and the Engineer shall have the right to reject such items. In the case of minor damage to galvanising or painting the Engineer may permit repairs to be carried out. Any such repairs shall be carried out in accordance with the recommendations of the supplier. Delivery, Storage and Handling Each drum of cable shall be accompanied by duplicate copies of test certificates, bearing the cable description and name of manufacturer. Such certificates shall be handed to the Engineer. Cable drums must have an indication of the length, size of cable and the number of cores it contains. Cables stored in the open in unshaded locations which are liable to strong direct sunlight must be protected unless the cable supplier confirms that the cable is capable of withstanding the conditions without deterioration or reduction in the predicted life. All cables shall be delivered to site with the manufacturers' seals, labels, or other proof of origin intact such labels and seals shall not be removed until the cable is required for use, and shall be retained for inspection. All column delivered to the site shall be stored clear of the ground by placing on blocks. Care shall be taken to avoid damaging column and mast sections by placing them on top on one another. The Contractor shall submit a detailed method statement giving details of the proposed method of lifting the columns into position. Lifting methods shall adequately address safety and avoid damage to columns and masts. SUPPLY OF EQUIPMENT 6/ 33

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Section 6 Part 012 12.2.1 1 Design Criteria for Columns

General Specification

For all columns the stress and deflection calculations shall be based on the maximum bracket and luminaire projection, on the bracket arm, with projected area, length and weight as designated. In still air conditions, loaded with the designated luminaires, positioned in any of the variable locations, there shall be no appreciable deflection of the column or mast. The maximum permissible deflection in the column or shall be 1 deg. in any 1 m length with a maximum total of 7.5 degs. over the whole shaft under the maximum design wind loading. Columns shall be steel & designed in accordance with BS 5649. Columns must be designed to withstand a wind force gusting up to 120 km/h. The "K" factor for columns over 8 m in height shall be 2.2. Columns shall be designed to support lanterns with the data given by the Engineer. All columns of the same mounting height and with the same arrangement shall be identical in construction. Column bracket arms and spigots shall be so designed that when assembled with the column shaft the design attitude of the arm and projection shall be as designated. The luminaire fitting spigot shall be 42 mm diameter by 125 mm length unless otherwise designated, or of a length and diameter to suit the luminaire. The securing arrangement of the bracket arm to the column shall be positive to ensure that the arm does not rotate and shall be such that the bracket can be fixed in any one of four 90 positions in relation to the column door opening. Bracket fixing screws shall be of stainless steel. Bracket arms shall be so designed that when assembled with the column shaft the design attitude of the arm and spigot shall be 5 above the horizontal. The mounting height and bracket projection of each column shall be as designated. Mounting height shall be measured from the surface of the carriageway to the photometry centre of the luminaire and the bracket projection shall be measured from the centreline of the column shaft to the centre of the luminaire. Each column shaft shall be suitable for use with any bracket outreach specified for a given mounting height. Each type of high mast column shall be supplied with foundation drawings, foundation bolts and four nuts. Bolts and templates and two spanners for each

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Section 6 Part 012 type of nuts must be supplied. 17 18

General Specification

For columns, four slots as designated are to be provided on a flange plate of suitable size for foundation bolts to fix the column on the foundation. The manufacturer of the street lighting column shall prepare and supply the detailed specification, dimensions and design for reinforced concrete column foundations. Column fabrication requirements All columns shall be hot dipped galvanised to BS 729 Part I or BS 791/71. Street lighting columns shall be steel, tubular stepped in shape with a base flange with foundation bolts, nuts, washers, wooden base board and earthing terminals. Strengthening shall be provided at door and compartment openings. Care shall be taken to ensure that rounded edges are provided at the corners of door and compartment openings to avoid any stress concentrations. The column shall be made from hollow section to BS 4848 Part 2 in steel to BS 4360 grade 43C or any other approved equivalent norms. The hollow section shall have minimum tensile strength of 430 MPa and minimum field stress of at 255 MPa. Columns shall be in one piece tubular (round) stepped shape and flanged (bolted) type. Welding shall comply with the requirements of BS 5135 as appropriate. Detailed welding procedures and procedure trials, if required, shall be in accordance with BS 5135. Columns with a joint above the base section are not acceptable. Columns manufactured from tubular steel of circular cross-section shall have a single swaged or sleeved joint only at the point where the base section meets the reduced shaft diameter. The completed column shall be truly vertical and the angle of the luminaire shall be checked so that it is square to the column, horizontal in end elevation and similar to all other luminaires in the installation. The base flange plate is to be manufactured from steel plate which is free from lamination. The main shaft of the pole penetrates the full depth of base plate and is to be welded above and below using a semi-automatic MIG shielded arc process. Any additional strength is to be provided by gussets located between hole positions.

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Section 6 Part 012 12.2.3 1 2 3 Specific requirements for columns

General Specification

The top of the column shall be designed and provided as suitable to fix the bracket arm collar with the top of the column. Threaded holes for Allen socket screws on top of the column on the required sides are to be provided. All dimensions for tubular round columns shall be according to Table 12.1 or Table 12.2. All dimensions are in mm. Table 12.1 Schedule of Dimensions for Tubular (Round) Columns Dimension/ Detail Height 6m 4250 8m 6020 10m 8000 12m 9500

Length of column (without bracket arm) (between flange plate and column only) Thickness of the column Bottom of the column - inside diameter Bottom of the column - outside diameter Distance between columns base flange plane to door opening Size of door opening Distance between door openings Length of base compartment Door opening top to top of the column Outside diameter of the top of the column Inside diameter of the top of the column Details and size of base flange plate Four foundation bolts with two nuts and washers per bolt

4 192 200 400 600x140 NA 1170 3080 70 62 450 x 450 x 10 thick. 800 x 25

4 192 200 500 600x140 NA 1270 4750 70 62 450 x 450 x 20 thick. 800 x 25

4 192 200 500 600x140 NA 1270 6730 102 94 size varies 20 thick. 800 x 25

4 192 200 500 600x140 100 2000 7500 102 94 size varies 30 thick. 900 x 33

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Table 12.2 Schedule of Dimensions for Octagonal Columns Dimension/Detail Length of column (without bracket arm) (between flange plate and column only) Thickness of the column Bottom of the column - inside diameter (across flat) Bottom of the column - outside diameter (across flat) Distance between columns base flange plane to door opening Size of door opening Door opening top to top of the column Outside diameter of the top of the column Inside diameter of the top of the column Details and size of base flange plate four foundation bolts with two nuts and washers per bolt 12.2.5 1 2 6m 4800 Height 8m 6500 10m 8000 12m 9985

4 148 156 400

4 183 191 500

4 242 250 500

4 242 250 500

600x100 3800 60

600x130 5400 60

600x135 6900 78

600x135 8885 78

52 450 x 450 x 10 thick. 800 x 25

52 450 x 450 x 10 thick. 800 x 25

70 size varies 20 thick. 800 x 25

70

size varies 30 thick. 900 x 33

Doors and base compartments for columns Each column shaft shall have a base compartment large enough to offer easy access to the equipment therein. A weatherproof door shall be provided for each opening which shall be interchangeable between columns of the same mounting height. To avoid accidental spillage of water from irrigation of flooding the bottom of the door shall be at least 0.5m above the top of the foundation. A stainless steel durable non-corroding tamper-proof lock device shall be provided of the triangular headed screw type, unless designated otherwise. Where applicable, door lock recess shall incorporate adequate drainage such that they are unlikely to become blocked and so form a water trap.

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Section 6 Part 012 4 5

General Specification

Door openings are to be kept to the minimum size consistent with the cable termination units and any control gear. Doors shall be located at 180 to the kerb line so that they doors can be opened at all times without encroaching onto the highway. The door openings and cable slots shall be free from any irregularities and burrs. Keys are to be provided with the first consignment of columns at the rate of 10 % of the total number of columns. Cable entry slots shall be 50 mm wide x 150 mm long, and shall be positioned directly below the door opening. The lower edge of the slot shall be 500 mm below ground level. A baseboard of non-hygroscopic hardwood, minimum thickness 15 mm, shall be securely fixed in each compartment and shall be of sufficient size to accommodate the cable termination unit. Single purpose earth terminals shall be provided in a readily accessible position, preferably on the left hand side of the opening and on the column door. A brass or stainless steel nut and bolt arrangement shall be used as the method of fixing. A spring clip device is not acceptable as a fixing method. All door lock hinges and catches shall be regreased before handover. Columns shall be numbered in accordance with NEC Street Lighting Regulations. Luminaires and Lamps The luminaires for roadway lighting shall be to BS EN 60598 Luminaires for roadway lighting or equivalent at designated mounting heights. The luminaires shall be capable of achieving the performance specification requirements set out in the contract according to BS 5489. The number, type and power rating of the luminaires shall be as shown in the schedule of luminaires. Luminaires shall be complete with integral control gear for use with elliptical/tubular lamps. The sections of the luminaires shall fit together tightly to prevent the entry of dust and water to protect the control gear and shall comply with IP 66. Asbestos gaskets shall not be used. The control gear shall be in a compartment with an IP 43 rating and shall be prewired and mounted on a gear tray which is firmly secured. Electrical components shall be protected from the direct heat from the lamp.

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Section 6 Part 012 7 8 9

General Specification

Provisions shall be made to allow easy access to the lamp and control gear for maintenance or replacement. The optical system shall comprise of a reflector made from pressed high purity aluminium that is anodised and polished. The incoming cable terminal block and earth fixing screw shall be securely fixed to the gear tray or the Metallic body of the luminaire and a cable restraining device shall be mounted close to the terminal block. The spigot entry of the luminaire shall be compatible with the brackets to be supplied. The colour of the luminaire body shall be grey unless specified elsewhere in the contract. The technical data for the luminaire shall clearly state the wind area to be used for structural calculations for the columns or masts. A cable holder shall be mounted near the terminals in a metallic compartment. The side entry mounting socket accepts a 125 mm long spigot and 50 mm diameter or adjustable from 45 mm to 60 mm. The exterior side of both compartment shall be with grey colour finishing. All luminaires shall be supplied complete, tested and ready for working and shall be fitted with all necessary starters, igniters, ballasts, and power factor correction capacitors to give a minimum power factor of 0.85 lagging. Luminaires shall be designed so that any moisture collecting in the bracket cannot enter the luminaire. Drain holes in the luminaire protector are not acceptable. All electrical equipment shall be mounted on a detachable gear tray which must be securely fixed to the main body in such a way as to ensure good earthing continuity. Where the optical system includes metal reflectors, they shall be faceted, one-piece reflectors of high purity on oxidised aluminium. On removal from the fitting, the reflectors shall be capable of being refixed in the correct optical relationship to the light source, without adjustment. Lamp supports shall be arranged to ensure constant register of the lamp in relation to the optical control system in all conditions. Reflectors and other components which require cleaning shall be free from sharp edges and projections which might cause injury. The luminaire protector shall be made of glass or acrylic which has a smooth exterior. The protector or one piece sealed optic shall be securely attached to the luminaire, but capable of easy removal and replacement. Luminaires shall be supplied with earth terminal and with lamp holders wired to
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a terminal block in heat resisting non-hygroscopic insulated 0.75 mm stranded

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copper conductors, cleated to prevent movement and to ensure that no cables hang below the luminaire canopy. 21 An earth connection is to be provided in the control gear compartment. When access to this compartment has been attained, the earth connection shall be visible and readily accessible without removing any components, and all Metallic components shall be earthed to this point. If the control gear compartment is provided with its own cover, the latter shall be adequately hinged with the cover in the open position. The terminal block shall be shielded with suitable insulating material to prevent contact during lamp replacement and routine maintenance. The shield is to be captive in that it shall not be necessary to completely detach it from the luminaire to inspect the connection at the terminal block. Luminaires are to be designed for easy wiring and repair. The lamp support devices or optical reflector mirror shall be such that all optional choice positions are clearly and permanently marked. Luminaires shall be fitted with a standard plug and socket arrangement mounted on the body and suitable for use with a three lugged bayonet fitting photoelectric control unit. The socket shall be permanently wired to the luminaire terminal block. A weatherproof gasket shall be provided between the socket and canopy and the socket shall be securely fixed by not less than three screws. The socket mounting shall be such that the canopy can be removed to give access for maintenance to the luminaire without removal or disconnection of the socket. The socket shall be constructed of glass filled nylon to BS 5972 and offering Class II protection from electric shock as defined in BS EN60598. Lighting units for all types of high mast columns shall be cut-off flood lights each with tropicalised control gear of 240 V, up to 1000 W SON-T high pressure sodium lamps. The lighting distribution shall be adjustable with both symmetrical and directional distribution capability. High pressure sodium vapour gas discharge elliptical lamps of 400 W, 220/240 V and 50 Hz will be SON-T type with an elliptical bulb with a diffusing coating with E-40 base. Lamps shall be suitable for use on 220-240 V 50 Hz a.c. power supply. Lamps shall have a built-in igniter with self-igniter. Initial luminous flux output shall be 47 000 lm. High pressure mercury vapour fluorescent elliptical lamps of 125 W, 220/240 V and 50 Hz and E-27 base will be MBF/U type with an elliptical outer envelope with inner surface coated with a fluorescent power which convert ultraviolet radiation into visible radiation, or light. These will be suitable for use in universal operating position. Initial luminous flux output shall be 6200 lm. Low pressure sodium tubular (SOX) lamps of 180 W, 220/240 V 50 Hz shall be SOX type with a discharge tube enclosed in a clear tubular outer envelope and BY 22 base. Lamps shall have a built-in, igniter with self-igniter. Initial luminous flux output shall be 33 000 lm.

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General Specification

High pressure sodium vapour gas discharge tubular lamps of 1000 W, 380/440 V and 50 Hz shall be SON-T type with clear tubular hard glass envelope with E40 base. Lamps shall be suitable for 380/440 V, 50 Hz a.c. power supply. Lamps shall have a external igniter, without self-igniter. Initial luminous flux output shall be 135 000 lm. High pressure sodium vapour gas discharge tubular lamps of 400W to 50W, 220/240 V and 50 Hz shall be SON-T type with clear tubular hard glass envelope with E4-40 base. Lamps shall be suitable for 220-240 V, 50 Hz a.c. power supply. Lamps shall have either a built-in or external igniter. Initial luminous flux output shall be: Table 12.3 Initial Luminous Flux Output of Lamps Wattage 400 250 150 100 70 50 Luminous Output 55000 32000 16500 10500 6600 4400

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12.2.7 Cable 1 2 All cable shall be in accordance with part 6 of section 21 of the General Specification and the following requirements All cabling to and between columns shall be multicore XLPE insulated steel wire armoured and PVC sheathed to BS 5467 rated 600/1000 volt. Damaged cables shall be replaced. Cables shall not be pulled out to straighten them after laying and cable stockings shall be used for all cable hauling. Underground through joints and tee joints are not allowed. Unless otherwise designated, all cable oversheaths shall be black for LV cables. All cable lengths shall be measured checked and confirmed before ordering or installing cables. Cable drums shall be supported by suitable purpose made jack stands and axles while the cables are being drawn off. In no circumstances shall drums be rolled in a direction other than indicated on the side of the drum. Where cables are pulled into ducts, sufficient rollers shall be used to guide the cables so as to prevent contact with the duct ends. All designated cable lengths are net lengths and approximate only.

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General Specification

All cables shall run directly from point to point without joints unless the length required is in excess of the length obtainable in one piece from the cable manufacturer. Three - phase groups of single-core cables shall be laid, wherever possible, in trefoil formation and touching each other. Multi-core SWA cables in trenches or ducts shall be single wire armoured. Steel tape armouring will not be permitted. The maximum permitted voltage drop at the furthermost column cut-out, under normal conditions, shall be 8 V below feeder pillar incoming voltage. The means of identification of the cable shall be one or other of the following: (a) (b) an engraved plastic or brass label securely fixed to the cable sealing box a stamped brass or aluminium label securely tied to the cable close to the sealing box with galvanised iron or tinned copper binding wire.

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Self-adhesive embossed plastic labels will not be accepted as permanent means of identification. The means of identification shall give the cable size, number of cores, and function together with the cable reference number if one has been allocated. All cables above ground in feeder pillars or sub-stations shall be identified by means of engraved or stamped plastic or brass labels. The labels shall bear details of the code size, number of cores, function, and reference number (if any) and shall be securely attached to the cables with galvanised iron or tinned copper binding wires. All cables running underground shall be identified at joint positions, in draw pits, and elsewhere at intervals not exceeding 30 m, by means of heavy gauge stamped brass labels securely fixed with at least two ties of heavy gauge galvanised iron binding wire. The cores of all control cables shall be individually identified, at terminations, by means of approved plastic ferrules bearing indelible characters, in accordance with the numbering on the relevant wiring diagram. Control Gear All items of control gear shall be fitted with shrouds over all terminals to prevent accidental contact by persons. The control gear shall have a clearly marked circuit diagram or other marking to show the terminal connections in relation to all other components. A separate earth terminal shall be provided on all components. The capacitor shall have an aluminium body. Control gear (choke, capacitor, igniter and related items) shall be suitable to withstand temperatures up to 86 C. Internal connections shall be with heat resistant wire and with porcelain or

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Section 6 Part 012 nylon connectors. 4 5

General Specification

Ballasts shall also be suitable for use at single phase voltage designated by the Engineer and shall be reasonably silent in operation. All tappings shall be brought to suitably marked standard terminals to which lamp and supply connections shall be made. Ballasts shall be mounted within the body of the luminaire. Igniters shall be mounted within the body of the luminaire. Each igniter shall be fitted with a device which will detect the presence of a faulty lamp and automatically limit the generation of HV pulses. Igniters shall be suitable for use with lamp, ballast and PFC capacitor included in the control gear set. Non-metallic capacitors shall be supplied with a fixing band which shall not damage the capacitor when fitted and, if metallic shall be provided with a separate earth terminal. Capacitors shall have a tolerance of 10 % of marked value.

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All electrical sockets shall be BS 4343 type, IP54 minimum, or manufacturers standard. All electrical sockets shall be BS 4343 type, IP54 minimum, or manufacturers standard. Street Lighting Cut-outs Cut-outs in columns shall be phenolic moulded, three phase, and suitable for
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looping two 25 mm cables. 2 Cut-outs shall: (a) (b) (c) (d) (e) (f) (g) tracking. 3 be to BS 88 Part 2 be of the combined single phase and neutral type incorporate an earth terminal
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be suitable for concentric or PVC armoured cables of up to 25 mm crosssectional area with capacity for looping in and out have all metal parts tinned be provided with a minimum of 2 fixing screws be manufactured from material which is non-hygroscopic and non-

Terminals and contacts shall have a rating of not less than 40 Amp and be suitable for BS 88 fuses of 6 A, 12 A, 16 A or 20 A ratings, selected from the table below: Wattage For 1Lamp For 2 Lamps For 3 Lamps 50W 6 6 6 70 W 6 6 6 100 W 6 6 10 150 W 6 6 10 250 W 10 16 16 400 W 10 10 20 16/ 33

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The cut-outs shall comply with the 16th Edition of the IEE Wiring Regulations. A cut-out used as a means of isolation shall have the facility for padlocking. The service cut-out shall have a moulded enclosure, offering a minimum protection of IP22, capable of withstanding severe impact. Separate terminals shall be provided for live, neutral and earth conductors complete with terminal shields to prevent accidental contact with all live conductors. Cut-outs shall be sized to accommodate the designated cables, but with a
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minimum of 25 mm cables. 9 10 Cable armouring shall be bonded as an integral part of the cut-out, and complete with cable armour clamp shrouds. The cut-out shall be suitable for mounting on a wooden back board or DIN rails.

12.2.10 Distribution Equipment - Isolators 1 The isolators shall be switch disconnectors, with fuses where appropriate, complying with IEC 947-3 (previously BS 5419), AC22 class of duty, with a nominal rating of 32 A and be 2-pole or 4-pole as appropriate. Isolators shall be capable of clearing the designated short-circuit fault current for 3s duration. Where switches operate by manual operation, the speed of operation shall be independent of the effort of the operator. The isolator shall be DIN-rail mounted in a non-metallic, weatherproof, impact resistant moulded enclosure with a lockable hinged cover. The unit shall be suitable for mounting in the base compartment of a lighting column. Isolators shall provide in-built switch fuse loop terminals for downward loop feeds to traffic signs, bollards and related equipment. Isolators shall incorporate a locking facility to the off' switch position only. All isolating devices shall be 2-pole for single phase systems or 4-pole for three phase systems. The isolators shall be rated to suit the local environmental conditions of UAE.

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Section 6 Part 012 12.2.11 Photoelectric Control Units (PECU'S) 1 2

General Specification

All PECU'S shall be guaranteed for a period of six years. Any unit failing within six years shall be replaced with a new unit. The PECU'S shall be installed on a luminaire mounting at the nearest lighting
2

column from the feeder pillar. Three core, 6 mm cu PVC SWA PVC cable shall be provided to connect the PECU'S to the feeder pillar. 3 The photoelectric cell shall be controlled by a 4 A HBC control fuse within the feeder pillar and shall be completely weatherproof and not affected by moisture, vibration or changes in temperature and capable of continuous satisfactory operation over extended periods in an ambient temperature of up to 60 C. A suitable manual override switch shall be installed to permit usage at times outside the periods during which the lights normally operate. The cell shall operate at an illuminance pre-set to ON 80/100 lx and the ratio of ON to OFF shall be approximately 1 to 2. A minimum 15 s delay shall be provided to ensure that transient switching does not occur. The control system in the feeder pillar shall be such that a time switch shall act as an override in the event of a failure of the photocell control unit The time switch shall be a weatherproof, 24-hour dial time switch motor driven with a clock accuracy of 5 min/year and shall have a 48-hour synchronous spring release (manually rewindable) to maintain clock operation and output switching during power supply failure. Power supply shall be 240 V, 50 Hz and output contact rating shall be 30 A at 240 V (resistive). PECU'S and their associated relays (or other switching devices) shall have prematched responses and shall be housed in the same envelope. Where the load to be switched is greater than the PECU can switch directly, a contactor shall be used. The cell shall be hermetically sealed against the ingress of moisture and shall be contained in a strong impact resistant low profile translucent housing, the surface of which shall be non-oxidising and impervious to discoloration. No provisions shall be made for adjustment to the calibration. There must be no need to orientate the switch to give a specified operation. Provided that the month and year marks on the units are current when supplied, this date will constitute the start of the guarantee period for the PECU. In all cases, the switching level of 70 lux shall not vary more than plus or minus 10 % during the guaranteed life of the unit.

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Section 6 Part 012 12.2.12 Feeder Pillars 1

General Specification

All parts of equal size and rating shall be interchangeable. The number of joints shall be kept to a minimum. Bolted electrical joints shall be secured by corrosion proof bolts with locking washers. Where designated or directed by the Engineer, the enclosure shall have provision for expansion by the addition of extra outgoing ways. Shells shall be constructed of galvanised sheet steel, cast-iron or glass reinforced plastic as directed by the Engineer. Roofs shall be constructed of galvanised steel, cast iron or concrete as designated or directed by the Engineer. Where concrete bases are designated, suitable bolting flanges for mounting onto concrete plinths shall be provided. Removable aprons shall be provided to permit installation of cables from below. Outdoor weatherproof free-standing feeder pillars shall be provided as designated or as directed by the Engineer. The cabinets shall be reinforced fibreglass polyester enclosures constructed to minimum IP54 mounted on a suitable concrete foundation. The cabinets shall be lockable and shall be provided with a means of ventilation by a free passage of air through the unit, but this shall not reduce its overall degree of weather protection. All equipment contained within shall be suitable for the climatic conditions of UAE Feeder pillars shall comply with the relevant parts of BS 5486 except as otherwise designated in this Part. Enclosures shall be lockable and fully weatherproof to the designated IP rating. IP ratings shall be in accordance with BS EN 60529. Materials, construction and finishes shall be suitable for the conditions of temperature and humidity designated by the Engineer, taking into account any temperature rise due to direct sunlight. All metal parts shall be plated, galvanised or painted with corrosion resistant finishes. The finish shall provide protection against corrosion caused by tannic and other acids in falling leaves. The fault rating of feeder pillars shall be such that they are able to carry the full prospective short-circuit current designated by the Engineer for a minimum duration of 1 s without damage. All conductors shall be copper. Where designated or directed by the Engineer, a means of isolation shall be provided on the incoming supply. Provision shall be made for padlocking in the open position. Busbars of full rating, making allowance for holes, shall be constructed of harddrawn, high conductivity copper and mounted on insulators at the rear of the distribution pillar. Busbars shall be insulated with non-hygroscopic, non-tracking insulation and all live parts shall be insulated, screened or shielded. Neutral conductors shall be insulated from earth to allow use on TN-S systems. 19/ 33

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Neutral connectors shall have separate connections for each outgoing cable. 13 14 Where feeder pillars have out paths of greater than 100 A capacity, busbars shall be provided for neutral and earth connections. The neutral busbar shall be mounted in parallel with the phase busbars and arranged so that each neutral connection is physically identified with the appropriate circuit. A separate earth bar shall be provided at the bottom of the feeder pillar and shall be of sufficient length to accommodate a discrete connection for each circuit including 25 % spare capacity. The minimum crosssectional area after drilling of holes shall be as specified in BS 7430. Neutral busbars and connections shall have the same rating as the associated phase conductors. Neutral connections shall be clearly labelled with the circuit reference of the associated fuse or circuit-breaker. The neutral bar shall be colour marked black and the earth bar green and yellow. The colouring of bars shall not be continuous unless it is also the insulating medium otherwise the colour marking shall be such that it cannot be mistaken for an insulating covering. Insulated dividing barriers shall be provided between phase contact assemblies and between phase and neutral. The barriers shall be constructed so that it will not be possible to insert a fuse link or circuit-breaker between phases or between phase and neutral. Where link disconnectors are designated, they shall incorporate contact tightening devices on both fixed and hinged contacts. Suitably insulated operating tools for tightening the contacts shall be provided in each feeder pillar. Feeder pillars shall contain a 3-pole moulded case circuit breaker of a suitable size (minimum 100 A), a 4-pole contactor suitably rated (contacts shall be fitted with a snap action to prevent chatter) with 240 V a.c. coil within IP54 enclosure and a 3-phase MCB distribution board complete with single pole M9 Type 3 miniature circuit breaker (minimum 20 A rated). Where distribution boards are required, they shall be totally enclosed in galvanised steel or plastics cases. Distribution boards shall be MCB type, with main RCD device protecting all outgoing from the board. Supply to feeder pillars will be at 415 V, 50 Hz, 3-phase, 4-wire plus protective
2

15

16

17

18

19

20

conductor and will generally be provided by up to two 75 mm 4-core PVC cables. Two suitable type CW cable glands with shrouds shall be provided for termination of these cables. 21 An appropriate number of single phase and neutral MCBS for each circuit with
2

cable glands to take up to 25 mm cable shall be provided in each cabinet. 22 23 All MCBS and protective device shall be rated to withstand a short-circuit current of 9 kA or the scheduled value if higher. The pillars shall be generally wired as designated. Each column along a circuit

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Section 6 Part 012

General Specification

route shall be connected to a different phase within each line of three (Red, Yellow, Blue) to give a balanced overall circuit load. Each feeder pillar may only supply right, 3-phase circuits, and the circuit cable runs shall have a length not exceeding 1000 m. 24 25 26 27 Twenty five percent spare capacity shall be allowed within all distribution boards. Fuse protection shall be in the form of BS 88 fuses in shrouded fuse carriers. All fixing and connection access shall be from the front. Outgoing circuits shall be labelled with the circuit reference and the fuse or circuit-breaker rating. Where designated, a metal clad anti-condensation heater shall be provided at the bottom of each feeder pillar in such a position that it is accessible but does not impede cable access. It shall be shielded to prevent contact The rating of the heater and the means of control shall be as directed by the Engineer. All internal wiring shall be enclosed in trunking or conduit. Access to cable terminations shall be by means of a removable cover plate. All cable access shall be from the front with entry from below. Cable entry and termination provisions shall be suitable for the designated size and type of cable or as directed by the Engineer Cable terminators arrangements shall be suitable for compression lugs or bolted clamps. Cable support cleats shall be adequate to support the cables in normal service and to restrain them under fault conditions. The arrangement shall be such that all cable terminations can be readily made from the front. An earth electrode shall be installed at each feeder pillar and shall have a resistance to true earth of not more than 10 ohms. The size of the electrode
2

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32

shall be 16mm by 2.5m length and shall be driven to a depth that penetrates the summer water table by at least 2m. The earth bar shall be connected to the earth electrode by means of a stranded copper conductor of minimum cross2

sectional area of 70 mm .

12.3 12.3.1 1

INSTALLATION General Requirements The Contractor is responsible for all liaisons with concerned authorities Street Lighting Section in respect of programming the installation and commissioning of the complete street lighting system. He shall ensure that concerned authorities Street Lighting Section are at all times kept informed of the current progress of the work and that his approved subcontractor programmes the work in the designated sequence in accordance with the approved programme.

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Section 6 Part 012 2 3 4 5 6 7 8

General Specification

The Contractor shall excavate and backfill all trenches required for the installation of cables and ducts in accordance with part 3 of this specification. The Contractor shall reinstate surfaces disturbed by his operations and provide temporary reinstatement as directed by the Engineer. The execution of all electrical work shall be supervised by a qualified person with a thorough experience in road lighting and associated equipment. Only workmen who have had experience in the erection of road lighting shall be employed on the work of erection. Before carrying out any electrical works to existing services, authorisation must be obtained in writing from all relevant authorities. The Contractor shall carry out all electrical tests and ensure satisfactory results as set out in the ILE Code of Practice for Electrical Safety. Where an existing installation has been extended the relevant parts of the existing system and equipment earthing shall be inspected and tested for compliance with the IEE Wiring Regulations. A completion certificate as detailed in the IEE Wiring Regulations shall be issued following the inspection and testing of the installation and any corrective action found necessary. Temporary Lighting Where the existing installation is to be disconnected during the Contract Period, temporary lighting shall be provided. At no time shall design road lighting standards be lower than those existing prior to the start of the Contract. Any form of temporary lighting & lighting levels must be approved by the Engineer. Temporary lighting shall not be removed or disconnected until the permanent installation has been inspected and approved by the Engineer and has been energised. Electricity Supply Lunminaires and equipment shall be suitable for use on a three phase and neutral 415v 50hz supply. Removal of Existing Installations The Contractor shall obtain record drawings of the existing installation from the NEC before any work is carried out to the existing street lighting and provide the Engineer with one copy of the record drawings obtained. Existing columns shall be removed under the supervision of NEC Street

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Section 6 Part 012 Lighting Section. 3

General Specification

The Contractor shall carefully excavate existing material from around the column (including concrete) and dismantle any existing equipment to be removed and temporarily reinstate the excavation. All lamps, luminaires and fittings shall be removed before excavating around the columns. The equipment shall then be either re-erected as designated, or, if not to be reused, shall be removed to a designated location. No existing highway or footway lighting shall be switched off, dismantled or removed without the prior approval of the Engineer. Adequate temporary highway or footway lighting to the satisfaction of the Engineer must be provided when it is necessary to remove existing lighting from any area still open to vehicle or pedestrian traffic. Where any existing illuminated or non-illuminated traffic signs are fixed to columns to be removed, they shall be refixed to the nearest replacement column. If the nearest replacement column is more than 5 m away from the column to be removed, poles and looped services shall be provided as necessary. All existing loops shall be reconnected to the nearest replacement column. Existing cables shall be disconnected, insulated and covered to the satisfaction of NEC and the Engineer before removal of the column. The column shall be supported by ropes at all times and excavated down to the base taking care not to damage the electricity supply cables or any other adjacent services. Under no circumstances shall the equipment be pushed or pulled straight before it has been fully excavated. The column shall be lifted from the foundation by means of a crane and tackle approved by both NEC and the Engineer. All columns, codes, lamps and luminaires to be removed under the contract shall remain the property of NEC Street Lighting Section. Such items are to be delivered to the NEC store. Proof of delivery shall be obtained by a signed receipt from NEC witnessed by the Engineer. Reuse of Existing Columns Where existing columns are to be repositioned, the column bracket and paintwork shall first be inspected for any damage. Shall damage be noted it shall immediately be reported to the Engineer. The columns to be repositioned shall be carefully removed and stored for reuse. Existing columns to be reinstalled shall be re-erected as described for new

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Section 6 Part 012 columns. 4 5 6

General Specification

Existing columns, whether repositioned or not, shall be fitted with double pole fuse isolators. All removals shall be authorised in advance in writing by the concerned authorities and the Engineer. Before excavating around the column, any items of equipment identified by the Engineer shall be carefully removed and placed into storage as follows: (a) after disconnection of the supply, carefully excavate around the column, first exposing all public utilities, underground services and other installations, until it can safely be removed without damage to the column or its protection system remove the foundation concrete and bracket arm before transporting to remove all associated cabling where lighting columns are to be removed.

(b) the store (c) 12.3.6 1

Wiring in Luminaires and Columns Wiring between the terminal block in the luminaire and the components in the base of the column or each unit shall be 2-core with integral earth wire to BS 6004. Wiring to photoelectric control units shall be 3-core with integral earth wire. The yellow core shall be used for the switch wire. The 3-cores shall be used as follows: Red - Phase Blue - Neutral Yellow or White - Switch

All installation requirements described in the ILE Code of Practice Clause 11 shall apply.
2

Internal wiring in the luminaires shall be 24/0.2 mm tinned copper conductor, suitably insulated with non-hygroscopic heat-resisting material, and luminaire design shall be such as to facilitate wiring on site.
2

5 6

A 6.0 mm earth wire with camped tag bonded to earth lug on column and the column door earth terminal shall be provided. All cable routes shall be clear of control gear and limited to horizontal and vertical runs. Cables entering terminals shall show no bare wire nor shall the insulation be taken into the electrical conducting part of the terminal. All cable shall be neatly bunched together and securely taped. . Terminal blocks shall be clearly marked and the wiring shall be so arranged that the luminaire can be dismantled, for purposes of routine cleaning and lamp replacement, without any electrical wiring disconnections.

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Section 6 Part 012 8 12.3.7 1

General Specification

A suitable means of clamping the cables and a substantial earthing terminal shall be provided in the luminaire. Feeder Pillars Clearances within the enclosure shall be sufficient to permit closing and locking of the doors with switches inside in any position and also locked. Electrical clearances and creep distances between conductors and to earth shall not be less than 25 mm. Testing of the completed distribution pillar shall be carried out as required by BS 5486 Part 1 and the appropriate test certificates provided. Access shall be by means of hinged doors or lift-off covers as designated or as directed by the Engineer. Doors shall be fitted with locking bars to secure both top and bottom of each door. The means of locking shall be as designated. Natural ventilation shall be provided to limit the temperature rise to the manufacturers recommendations. Ventilation apertures shall not reduce the IP rating below designated rating and shall be screened to prevent entry of vermin. Where specified, air inlets and outlets shall be provided with dust filters. Pillars shall be finished in the designated colour or as directed by the Engineer. All pillars shall be fitted with removable lifting devices mounted one at each end and as near as possible to the balance line. Any equipment which is not stable on its own supports shall be fitted for transit and storage with returnable extension feet to provide stability. Any special tools for assembling or locking shall be supplied. A data plate shall be fixed to the pillar detailing the following information: (a) clients reference/serial number (b) year of manufacture (c) normal current rating of busbars (d) normal current rating of incoming unit (e) gross weight (kg), when fully equipped (f) manufacturer's name and reference number.

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The gross weight shall also be stencilled externally. Detailed distribution board schedules within feeder pillars shall be provided. Feeder pillars shall be fitted with a backboard together with distribution fuse board (with integral 100 A isolator) and cable chamber. Engraved black on white labels shall be provided and fixed to the pillar with self-tapping screws. A separated dedicated earth terminal block shall be fitted to the backboard within the base compartment of columns or posts. This shall be fitted irrespective of any other terminals available. Crimped connections shall be used wherever possible. The dedicated earth terminal block shall be connected to the NEC (EN) earth terminal. For circuit conductors in the range of 16 mm2 to 35 mm2, the circuit protective conductor shall have a cross-sectional area not less

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Section 6 Part 012

General Specification

than 16 mm2 copper equivalent. The metal door of the base compartment of metallic columns or of the door and frame to feeder pillars shall be earth bonded. Nowhere shall metallic columns, posts, feeder pillars, or conduits be relied upon as the sole earth path. An earth spike shall be connected to each high mast and to the further most column in each run of 12 m columns. 12.3.8 1 2 3 4 Cable Installation The installation of all cables shall be carried out in accordance with part 6 of section 21 of Construction Specification The type, manufacture and method of joint shall be approved by the Engineer before the work begins. Cables shall only be handled when the ambient temperature in the area of the cables is above the minimum recommended by the manufacturer. Cables shall be offered for inspection immediately after installation and before any coverings are applied. Cables shall be handled, terminated and installed in accordance with the cable manufacturers recommendations. The technical advice of the manufacturers specialists shall be followed if any special conditions or unusual circumstances apply. Cables shall only be handled when the ambient temperature in the area of the cables is above the minimum recommended by the manufacturer. Cables shall be offered for inspection immediately after installation and before any coverings are applied. Cables shall be handled, terminated and installed in accordance with the cable manufacturers recommendations. The technical advice of the manufacturers specialists shall be followed if any special conditions or unusual circumstances apply. Once a cable has been drawn off the drum, it shall immediately be laid in position. No cable shall be left lying on the surface after removal from the drum for more than the minimum practicable time. Once a cable has been drawn off the drum, it shall immediately be laid in position. No cable shall be left lying on the surface after removal from the drum for more than the minimum practicable time. Cable joining and sealing compounds shall be of a type approved by the cable manufacturer. A tropical grade compound shall be used in locations where the normal ambient temperature is likely to exceed 30 C. Solderless cable sockets and ferrules for use with aluminium conductors, if required, shall be made from electrical quality aluminium. All solderless cable sockets and ferrules shall be installed using clamping tools

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Section 6 Part 012

General Specification

of the same manufacture, strictly in accordance with the manufacturers recommendations. The completed connections shall, in every case, meet the performance requirements of BS 4579. 14 Cable joint boxes shall be of polycarbonate or similar transparent material with high impact resistance. The type and manufacture shall be to the approval of the Engineer. The joint filling compound shall be of the cold-pour resin type and shall be polyurethane or epoxy resin and shall not contain filler material other than that required to improve the characteristics of the compound. The resin fitting shall not be inserted into the joint box until the joint has been inspected and approved by the Engineer. For straight through joints (or combined straight and tee joints) connection of cores shall be by the compression method only. For tee joints (or branch joints) connection of service cable to continuous main cable cores shall be by means of clamps with screws except that the screws shall not bear on the cable cores. A copper earth bond shall be provided through the joint of fault carrying capacity equal to the circuit protective conductor. The total resistance of the earth path through the joint shall be not more than that of an equal length of the earth conductor of the un-jointed cable. Where tee joints are indicated, the cable shall be laid so that joint positions between drum lengths coincide with tee joint positions. All tee and other branching joints shall be made with the main cable unbroken, except in the case where a separate straight through joint would otherwise be required immediately adjacent to a branching joints. Cables in straight through joints and, where the procedure is allowable under the preceding clause, main cables in tee and other branching joints shall be jointed core-to-core without crossing. Approved safety precautions shall be taken when any work is to be done on an existing cable. Cabling will be looped into each column by means of an approved street lighting cut-out. Intermediate joints will only be permitted where designated or where the length of cable recorded is in excess of the length obtainable in one piece from the cable manufacturer. All joints shall be shown on the installation drawings. Intermediate joints in polymeric insulated cables shall be made using materials and methods approved by the cable manufacturer for the situation.

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Section 6 Part 012 28

General Specification

Unless otherwise designated, cable glands shall be of brass and comply with BS 6121 where applicable, and shall be of a design appropriate to the type of cable being terminated. Cable glands for use with aluminium strip or aluminium wire armoured cables shall be of tin nickel plated brass. Alternatively, they may be of aluminium provided that this will not be incompatible with other materials with which it may be in contact. Glands for cables with metallic inner sheaths shall incorporate a bonding connection. Except where it is impracticable to do so, the cable cores shall be taken through the terminating box directly to the terminals of the equipment, without crosses, and shall be made off with sweated cast brass cable sockets, or an approved type of hydraulically crimped socket. All cable sealing boxes shall be marked on the outside with 15 mm diameter painted discs, in the appropriate colours, to indicate the disposition of the phase and neutral conductors within them. Compression glands installed externally shall be classified IP66 and be provided with closefitting PVC shrouds. In addition to the requirements of the Conditions of Contract, all testing and commissioning shall be carried out according to the requirements of the relevant BS, CP and IEE Standards or other standards and regulations as may be stated or implied in this Part. Each completed system with the installation shall be tested as a whole under operating conditions to ensure that each component functions correctly in conjunction with the rest of the installation. The Contractor shall afford access at all times to the NEC to enable them to inspect work during and after erection and to be present at all tests. Upon completion of laying and terminating underground cable runs, the Contractor, in the presence of the Engineer or his duly authorised representative, shall carry out pressure tests in accordance with the relevant British Standards. The Contractor shall provide all apparatus and labour required for such tests and within a reasonable time thereafter shall present the Engineer with certificates witnessed by the Engineer. Terminations for armoured cable shall incorporate a method of rating off the armour which ensures a permanent earth bond between the cables terminated to the satisfaction of the Engineer. The cable armour shall be bonded to the earth terminal block in each column. As soon as is practicable after the completion of installation and jointing of the designated cables, or of any useable group of such cables, the tests described below, together with such other tests and measurements to prove compliance with this Part shall be made.

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Section 6 Part 012 40

General Specification

An insulation tester shall be used to measure the insulation resistance between each conductor and the remaining conductors and between each conductor and the metallic sheath (if any) and armouring. The test voltage to be applied shall be at least 1000 V. The above tests shall be carried out both before and after any pressure tests and the insulation resistance shall not be less than the figures in the appropriate BS. A voltage test of 15 minutes duration shall be applied in accordance with BS 5467 Appendix 88, BS 6622 Appendix C8 or BS 6346 Table 5, as applicable. Proposals for the appropriate test in respect of other types of cable shall be submitted for approval. An earth continuity test shall be carried out to verify that the cable armouring and metal sheath, if any, have been properly bonded to earth. Phase rotation and phase correspondence shall be tested to prove that the cables have been correctly connected. Where a new cable has been jointed to an existing cable, the voltage test designated above may be carried out at a reduced voltage if the existing cable has been in service for more than five years. In such a case the test voltage shall be determined by applying a factor K to the value given in the appropriate British Standard as referred to above, and the value of K shall be as given in the following table: Table 12.5 Age of Cable and K Value Age of existing cable in years 0-5 5 - 10 10 - 15 15 - 20 20 - 25 25 - 30 K 1.0 0.9 0.8 0.7 0.6 0.5

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42 43 44 45 46

47

Trench making, duct laying, backfilling and similar operations shall be in accordance with the requirements of BS 7671 and the local authorities or Section 19 Part 3 which ever is more stringent. The following paragraphs are for those aspects which apply additionally to cable, installations markers, covers and related items. Marker posts and slabs shall be reinforced concrete or steel or heavy-duty plastic of an approved type suitable for the duty. Precast reinforced concrete or equal approved marker posts shall be installed at intervals of not more than 50 m along all underground cable routes, at all joints positions, at all changes of direction and at both ends of road crossings, except

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General Specification

where such posts are likely to cause an obstruction to vehicles or pedestrians or to be liable to damage. In such cases, marker slabs shall be used. 50 Marker posts and slabs shall bear the following inscriptions in clearly legible lettering in both English and Arabic: (a) for HV cable routes, 'High Voltage Cables' (b) for LV cable routes, 'Electric Cables' (c) for joint positions, 'Electric Cable Joint. 51 All cables not in ducts and where designated shall be protected by a continuous layer of proprietary interlocking concrete or earthenware or plastic cable covers of such a width as will extend for at least 50 mm on each side of the cable. All cable covers shall comply with the impact requirements of BS 2484. Concrete cable covers, if more than 300 mm in length, shall be suitably reinforced. All cable covers shall bear on their upper surface a permanent warning legend. All cable covers shall be placed so that the underside is not less than 100 mm nor more than 150 mm above the top of the cable. Cables buffed direct in the ground shall be indicated by a continuous strip of brightly coloured plastic tape. The plastic marker tape shall have black letters on yellow in English and Arabic stating "Caution Buried Electric Cable". Where HV and LV cables run in the same cable trench, the HV cables shall be protected by an independent run of cable covers. Unless otherwise designated, and except where cables enter buildings or traverse railways or roads or other paved areas likely to be subject to vehicular traffic, underground cables shall be buried direct in the ground. Cables between columns shall be buried at a minimum depth of 450 mm within trenches as designated. The bottom of the trench shall be free from stones or similar hard substances and shall be firm and of smooth contour. The Contractor shall provide and spread fine dune sand to a depth of 100 mm in the bottom of the trench to provide a uniform bed for the cables. Unless otherwise designated, low-voltage cables placed in the same trench shall be laid with a lateral spacing between the cables of 50 mm. Unless otherwise designated, low-voltage cables placed in the same trench as telephone or other communications cables shall be separated from them by at least 300 mm. Unless otherwise designated, high-voltage cables shall be separated from low voltage or telephone cables placed in the same trench by at least 300 mm. All cables shall be placed at least 300 mm clear of all other services in any direction.

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Section 6 Part 012 64

General Specification

Cables shall be snaked from side to side of the trench for a distance of 3 m on each side of buried joints to avoid any risk of mechanical tension in the joint, and for a distance of 3 m in advance of entries to draw pits, buildings, or other fixed structures. Before cable laying is begun, all cable trenches shall be drained, the bottoms graded and tamped, and all loose stones and similar debris removed. Where designated, cables shall be installed in two tiers in the same trench. The first tier of cables shall be covered with sufficient salt-free sand or selected soil, well compacted in 75 mm layers to give a firm level bed for the second tier which shall placed not less than 300 mm above the tops of the cables in the first tier. The second tier of cables shall be covered as described above. Where two tiers of cables are laid in the same trench, the lower tier shall be installed at such a depth as will permit the upper tier to be installed at the designated depths. Cables laid in trenches shall be covered with backfill and the appropriate cable covers with the minimum of delay. While the trench is being backfilled, all large or sharp stones or other debris shall be removed from the fill material. In paved areas, the backfill shall be well compacted up to the underside of the existing paved construction (including sub-base). Above this level, temporary reinstatement shall be of similar construction to the original. Duct Installation Where cables (a) (b) (c) (d) cross roads or other paved areas with vehicular access cross unpaved areas regularly used by vehicles enter buildings pass through corrosive soils.

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12.3.9 1

or elsewhere as designated, they shall be drawn into underground pipe ducts. 2 A steel draw wire or nylon or polypropylene cord shall be inserted in each duct run immediately after its installation. A 2 m surplus shall be left at each end of each run, neatly coiled and attached to a crossbar preventing the wire or cord from being drawn into the duct. Underground pipe ducts shall be one of the following: (a) (b) (c) best quality salt-glazed stoneware pipes with proprietary self-aligning spigot and socket joints. heavy gauge unplasticised PVC conduits with tapered sleeve or spigot and socket joints best quality vitrified clay pipes to BS 65, with glazed internal surface and a proprietary self-aligning and self-sealing joint.

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Section 6 Part 012 4 5 6 7 8 9 10

General Specification

All ducts shall have a nominal internal diameter of 100 mm unless designated otherwise. The internal diameter of ducts used to provide cable entries into buildings shall have a space factor less than 25 %, unless otherwise designated. All dual systems shall be installed so that no undue strain is placed on cables when pulled in. Cable manufacturers recommendations shall be followed. All underground cable ducts shall, so far as possible, be run in straight lines. Duct runs crossing roads shall be straight and, wherever possible, perpendicular to the axis of the road. Except in the case of short isolated duct runs such as road crossings, underground cable duct runs shall terminate in draw pits. Cable ducts passing under roads carrying heavy vehicles shall be completely surrounded with lean mix concrete Ducts shall be laid so as to drain naturally towards one or both ends, where adequate provision for drainage shall be made. Adequate precautions shall be taken to prevent the cable duct system acting as a stormwater or groundwater drainage system. A minimum fall of 1 in 200 shall be provided for drainage purposes. Any work carried out requiring the use of split ducts shall be carried out in such a manner as to preserve the withdrawability of the cables concerned. Notwithstanding the type of duct to be used generally, cable ducts laid in ground which is liable to subsidence shall be of heavy gauge PVC with spigot and socket joints, and shall be installed on a concrete bed as designated above, but without concrete surround. If two or more cables are to be installed in the same duct, the aggregate of their cross-sectional areas shall not exceed 30 % of the cross-sectional area of the duct. All trenches excavated for the laying of cable ducts shall be completely backfilled and rammed before cable installation work begins. Immediately following the installation of any duct run, the interior of the duct shall be thoroughly cleaned by twice drawing through the ducts a suitable brush once in each direction. Following this, the ends of each run shall be sealed with a suitable hardwood or plastic sealing plug which shall be left in position until cable laying is about to begin. Before any cables are installed in the ducts, each duct shall be proved by drawing through it a polished hardwood mandrel 300 mm long having spherical ends and a diameter 6 mm less than the nominal duct diameter.

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Section 6 Part 012 12.3.10 Performance Testing 1

General Specification

A certificate of Initial Performance of Installation shall be issued when tests have been passed as follows: (a) (b) the initial photometric tests shall be made after the installation has been in operation for between l00 and 150 h of lighting the location of test positions shall be distributed along the length of the installation and shall be as directed by the Engineer. All service tests throughout the testing period shall be made at these positions.

Readings shall be taken with a portable calibrated luminance meter. The measurements shall be taken by a qualified lighting engineer and the accuracy of the meter shall conform with the requirements of BS 5489. Measurement of the supply voltage at the column or post shall be taken at the time of each test and the illumination measurement shall be adjusted for any variation from the declared value. Allowance shall be made for control gear taps immediately before the initial tests are made. The lamps and all components of the luminaire which may affect the optical performance shall be cleaned and correctly adjusted. All photometric testing shall be witnessed by the Engineer, unless otherwise notified in writing. A minimum of 7-days notice shall be given to the Engineer before testing begins. After testing the certificates shall be submitted to the Engineer for approval. END OF PART

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