Design and Construction Details

Design & Construction (D&C) Works activities occur during the first two years of the 15 year Term, and address the design and implementation of the Improved Freeway lighting Systems. This will include the D&C of new lighting elements and also non‐lighting elements and will be coordinate with future work that Michigan Department of Transportation (MDOT) will perform. The D&C Contractor Aldridge Electric (Aldridge) is dually responsible for both the D&C Works and also the Operations & Maintenance (O&M) Works to the existing infrastructure, as well as the new infrastructure.

Construction Approach

Freeway Lighting Partners (FLP) approach to the Design and Construction is to build upon the extensive survey and design work that was conducted during the proposal phase. Construction will begin in segments that are devoid of lighting by replacing missing fixtures and repairing/replacing circuits and panels. Construction will next focus on replacing existing median and ramp fixtures with new LED type fixtures. Year two construction will continue with median and ramp fixture replacement and proceed to high mast fixtures and finally tunnel fixtures in that order. O&M services will commence November 24, 2015 of the project term. At the conclusion of the construction period October 2017, the system will be operational and will then continue to be fully maintained thru the remaining 13 year O&M Term by Engie Services Group (Engie).

Survey Phase

FLP will begin the Project by augmenting and completing the detailed survey of the existing freeway lighting system that we conducted during the proposal stage. We plan to begin this survey immediately after August 24, 2015 (Commercial and Financial Close). FLP intends to initially survey only those areas that do not require a lane closure such as ramps, high mast lighting, and panels. Upon approval of final submittals we will finish those survey areas that require a lane closure such as median lighting and tunnel/underpass lighting.

The purpose of the survey is to document the condition of the existing lighting system, particularly:

• Identify non-working panel and circuits
    • Locate panel and provide each one with a GPS reading
    • Note any visible corrosion on panels
    • Evaluate condition of circuit wiring
    • Evaluate the condition of the panel feeders
    • Identify missing wiring (due to theft)
    • Document condition of raceways and handholes
    • Identify foundations with missing poles and evaluate foundation condition
    • Evaluate condition of poles and note any corrosion
    • List all foundations requiring repair
    • Document the age/condition of fixtures
    • Describe what level of temporary traffic control is required at each work area

    Design Phase

    Parallel with the survey phase, FLP’s design and construction planning teams will continue their efforts begun during the proposal phase to finalize what capital improvements will be required to bring the lighting system to its ultimate goal of conformance. The design phase is expected to last six months.

    The FLP approach to design and planning is to create task forces composed of the best people from each group to brainstorm ideas on the most effective solution to each task.

    Capital Improvements 1

    Initial capital improvements will begin midway through year one after the early submittals and detailed survey is completed enough to generate the early design submittals and obtain approval of same.

    The focus for the first year of capital improvements is to make sure all electrical control panels are in good operating condition. Three person crews will be assigned to this task, each working one panel location at a time. All panels and cabinets will be locked. Panel locations with repeated theft occurrences will have additional anti-theft precautions added. Along with this effort, any substandard circuits will be replaced with new aluminum underground cabling. Circuits that have experienced theft will have cable theft-prevention devices installed at pole foundations and handholes.

    Next we plan to replace the missing poles with new poles and LED fixtures. There are approximately (260) poles that will be installed according to our pre-proposal site surveys. This is an easy way to improve the percentage of operational lighting assuming there is not too much needed infrastructure repairs to support the new fixtures.

    Concurrently with missing pole replacement, FLP will replace existing High Intensity Discharge (HID) fixtures with new Light Emitting Diode (LED) luminaires. While FLP will not perform cable resistivity testing, missing cable will also be replaced at this time. Replacement cable will be 90°C rated 600V wire with RHH/RHW/USE-2 type insulation, and cable larger than #8 AWG will use AA-8000 grade aluminum. FLP believes that the use of aluminum conductor cable for larger wire will discourage future theft. We also intend to replace any cabling circuits that experience intermittent outages.

    In the first construction season, two three person crews will be assigned to upgrading ramp lighting after a given ramp’s service panel has been restored. These crews will be responsible to restore circuits, restore foundations, repair cable splices, and install anti-theft devices. Our surveys indicate that approximately 10 new ramp foundations are required. In addition we believe an additional approximately 20 ramp foundations require the anchor bolts to be repaired.

    Simultaneously, a crew of approximately 20 people will be formed to commence median lighting repairs. The work will occur on one or both sides of the median barrier wall with a lane and its inside shoulder being closed for up to 1 ½ miles in length. Crews will repair foundations, restore circuits, replace missing poles and fixtures, and change out High Pressure Sodium (HPS) fixtures for new LED fixtures.

    Existing single shepherd’s crook HPS fixtures will be replaced with two LED fixtures with a double arm. The existing pole wire will be re-used to power both new fixtures at each pole.

    All missing arms will be replaced. The new arms may not exactly match the existing arms, but lighting will meet illuminance requirements.

    We estimate that 25-30% of median barrier wall foundations require repairs. These repairs range from replacing the anchor bolts, to crack repairs, all the way up to small or large structural repairs on a givenside of a median foundation. Foundations will only be replaced if they show major structural damage. Missing handhole and transformer base covers will be replaced. Missing pole caps and nut covers will not be replaced. Dented and leaning poles will only be replaced if they are a safety concern. Lastly, existing negative foundation anchor bolt protrusion will remain in place.

    All work will be performed under proper temporary traffic control plans. Median lighting work will commence in year one but will not finish until close to the end of year two.

    By the end of Month 15, 90% of the improved lighting system will be operational, based on the assumption that the existing system at Commercial and Financial Close is approximately 70% operational.

    Capital Improvements 2

    The second construction season will also see a program of the systematic replacement of existing HPS and metal halide fixtures with new energy efficient LED fixtures. Careful planning will allow FLP to replace the oldest and least efficient fixtures first.

    Any raceways that are blocked or non-usable will be replaced. Handholes, both new and existing, will be equipped with anti-theft devices, as required.

    We plan to save replacing the newest fixtures until late in the second construction season. However, some median and ramp fixtures will not be replaced during the Capital Improvement Phase. This includes approximately 1,437 LED fixtures along I-94 and I-96 that were recently replaced. 424 ramp and median lights on I-96, 27 ramp lights on I-275 and 629 mainline and ramp lights on I-94 and will remain in place. Lastly, 357 existing lights along M-39 will not be replaced during the D&C phase. In addition, any median and ramp fixtures scheduled to be replaced on MDOT major projects in the next two years will not be replaced by FLP.

    Existing high-mast fixtures will be replaced with new LED fixtures because a significant energy savings (59%) can be realized. Four person crews will perform this work during winter months since most work does not interfere with traffic. All 2,892 high-mast fixtures will also have their lowering devices checked/repaired for proper operation.

    Our pre-proposal site surveys conducted on September 9-11, December 10-12, January 5-6, and January 15, identified the tunnel fixtures as being mostly operational. Assuming our detailed survey confirms our belief, FLP’s intention is to defer replacing the tunnel fixtures until late in the Capital Improvement Phase. Our belief is that the industry is making progress in developing more efficient LED solutions for tunnel light fixtures. Also, by performing this work late in the Capital Improvement Phase, service life can be extended.

    A 12 person crew will change out the existing tunnel fixtures with new LED fixtures. Since the new fixtures are more efficient, it will take about 973 less LED fixtures to replace the existing HPS fixtures.

    Within tunnels, non-functioning conduit supports, cables, and junction boxes will also be repaired or replaced. Visual corrosion will be logged into the MMIS. Because the tunnels within the Project are shorter in distance than 1,000 feet, we assume NFPA 502 standard is not applicable.

    FLP has determined that it will not replace all the underpass lighting during the D&C period because there is no cost effective energy efficient replacement fixture. Our Proposal does include the replacement of 271 underpass fixtures during the D&C phase. FLP does intend to replace all the rest of the underpass fixtures on an as-needed basis during the O&M phase, therefore, by the completion of the O&M term all these fixtures will have been replaced.

    All repairs, upgrades, and replacements will be logged into the MMIS. By the end of year two the D&C work will be in conformance.

    Performance & Innovations

    During the design and capital Improvement work, FLP has devised a number of creative innovations that will provide MDOT with an enhanced final lighting system.

    At time of installation, FLP will adjust lumen output of many of the new LED luminaires by dimming between 5-30%. After approximately seven years use, performance of each LED engine begins to degrade thus FLP will manually compensate by adjusting the lumen output level higher to compensate for natural decay of lumen output. This manual setting results in a lower initial power level for higher energy savings in the first seven years of service. This increased savings is reflected in our energy modeling. In addition, the initial lower power level was incorporated into our design when we made our fixture selections.

    FLP has designed its lighting system utilizing an astronomical clock for light control of outdoor fixtures, in lieu of photocells. The astronomical clock allows for more precise and reliable lighting control which results in improved energy savings.

    FLP has selected an LED tunnel luminaire that delivers about a quarter more lumen output than the existing High Intensity Discharge (HID) equivalent (HPS and metal halide) tunnel fixture; this permits new tunnel lighting with 20 percent fewer luminaires. Energy savings related to reduced fixture count adds to the high energy efficiency of LED equipment.

    Theft prevention is a big concern on this project. FLP has designed several innovations to prevent theft such as tamperproof covers on handholes, heavy concrete lids on pullboxes, and continuous steel collars around frangible bases. All three innovations prevent access to the cable by unauthorized personnel.

    Lastly, the use of aluminum cabling for replacement of larger gauge wire will deter theft since aluminum cable has little salvage value.


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