Engineering Quality Standards for Telenor

Zhongxing Telecom Pakistan(Pvt.) LTD

Dec 14th, 2011

Steps of Construction
Work Package Received Site Kick off Excavation Lean concrete Steel fixing

Telenor

Concrete Pouring
Backfilling Tower Erection Diesel Generator Inspection AC Power Inspection Power Issues Shelter Installation

Guardroom Inspection

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Work Package Received:

WP should be approved by TP Design. Thorough study of WP before CW kickoff and notify any special features e.g. retaining wall, piling etc.

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SITE

KICK

OFF:

This is the first and most important step for BTS site construction. Following steps must be keenly observed. Sites coordinates should be checked, whether they match with SAR coordinates or not. Demarcation & Layout of area in the presence of owner. Levels of the site is of extreme importance. A responsible person to check the level of site w.r.t existing road, the site must be higher than ERL. A permanent BM should be marked at site at the time of kick off. That can be either any permanent structure around the site or if it is not available a brick masonry column can serve the purpose till the site is complete. This BM will serve as reference till the completion of site and to maintain site levels as per drawing. Educate the subcon about the general TP requirements and the subcon should be professional enough to fulfill and avoid any delay in work. Site construction schedule must be handed over to TP at the time of Kickoff by subcon. These general TP requirements will be elaborated step by step.

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EXCAVATION:
Points to be kept in mind for excavation. If the tower foundation area lie on the plain ground then the depth of foundation will be as per drawing from all sides, but if the foundation area lie on sloping or uneven ground then reference will be taken from mean of four corners and centre and foundation depth will be taken from that level. Excavation base should be leveled properly and should be rigid.

Excavation in progress

Telenor

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LEAN CONCRETE:

The function of lean concrete is to provide a plane and leveled working platform. Level of lean is very important as it is base of whole structure so its level with reference to benchmark should be observed accurately. The differential level w.r.t BM can cause serious problem while leveling anchor bolts and preparing for column concrete. Check the depth of lean concrete.

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STEEL FIXING:
Following points kept in mind for steel fixing: Steel should be of specified grade. Steel should be free of rust, scales. Proper spacing should be given in mesh.

Emphasis on the positions of steel in top mesh and bottom mesh top most and bottom most steel must be in same direction

Telenor

CONCRETE

POURING:

Telenor

Concrete pouring for Foundation Pad: Inspection: Following points must be observed before starting foundation pad concrete. Steel fixing is complete (for pad and column both) and meets all the standard requirements, i.e free of rust and scales, etc. Steel test from approved laboratory is available at site which confirm to G60 steel (or otherwise specified). PCC spacers are used under the steel mesh, use of brick as spacers is not acceptable. Proper concrete cover must be available on all sides. Spacing between top and bottom mesh should be as per drawing. Lean surface should be clear of all loose material. Columns layout should be marked with color on the lean, which can confirm the c/c distance between columns and also both diagonals should be equal. Columns steel cut length to be checked. Steel should be aligned i.e top and bottom mesh if the spacing is same top and bottom. Chute must be present at site and avoid the fall of concrete from more than 6 height, max. length of chute not more than 15ft and angle with horizontal not more than 30 degrees. Auto level must be present at site to check the levels. 6 cubes must be present at site at the time of pouring. 2 viberators must be present at site. Measuring box of size 12X15X18 should be present at size. This box volume comes to be 1.5 times volume of cement bag and we can achieve the required mix ratio of 1:1.5:3. Concrete Mixing time should not be less than 2 min.

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CONCRETE

POURING:

Material requirements: Foundation pad:

OPC. Sand should be coarse and free from Organic material. 50% pure crush and 50% pure crush.

In case of isolated footing Template must be fixed before starting pad concrete to confirm c/c distance.

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Chute must be present at site for Pad pouring it can be both Drum or slide chute

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Steel fixing must be complete as shown here

Steel fixing is not complete, this is not perfect condition to allow for concrete

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CONCRETE POURING:

Concrete pouring for Foundation Columns: Formwork: Steel formwork must be used. Formwork must be sealed properly be placing foam between joints and then applying plaster of Paris after tightening. Formwork should be in good condition. Formwork should be oiled properly. Formwork should be supported on all sides and at the base. Concrete Inspection: Columns should be vertical and aligned with each other. Anchor bolts should be vertical aligned and leveled w.r.t the existing BM. Anchor bolts must be concentric with the column; Eccentricity will not be accepted in any case. This can be achieved with the help of wooden spacers whose size depends upon column size and distance b/w anchor bolts. No horizontal joint is acceptable in the top 1area of formwork which remain expose after backfilling. B/B and Diagonal distances must be checked (must be rechecked b/w column pouring). Exposed length of anchor bolts should not be less than200mm in case of tower height b/w 30m-60m and 150mm for tower heights b/w 9m-18m, must not exceed this limit.

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CONCRETE POURING:
Material requirements: Foundation Columns: OPC. Sand should be coarse and free from Organic material.. 50% pure crush and 50% pass and 3/8retain crush.

Diagonal & B/B Distances:

S.No.
1 2 3 4 5 6 7 8 9
B/B Distance Tower (C) mm Height (m)

Telenor

Diagonal Distance (E) mm

9 12 15 18 30 35+2 45 60 60 special

1090 1090 1090 1090 3090 3590 5120 6620 7120

1541 1541 1541 1541 4370 5077 7241 9362 10069

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Very important is column concentricity with anchor bolts, it must not be eccentric

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Before starting pouring check level, alignment verticality of both anchor bolts and columns

In case of eccentric column Jacketing is the solution, its very expensive so try to avoid it by professional inspection during column pouring

Telenor

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CONCRETE POURING:
Beams and slabs concrete: Steel fixing should be complete and top level of slab to be maintained properly.
Material requirements:

Beams and slabs: OPC. Sand should be coarse and free from Organic material.. 50% pure crush and 50% pass and 3/8retain crush.

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Cover of concrete not proper and top bar not in correct position

Anchor bolts to be properly covered while concreting

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General Civil Works Checks

Entrance gate must be installed properly, gate hinges, main bolt and drop bolt must be properly secured. Brickwork must be up to standard, i.e proper english bond must be followed. Plaster finishing must be up to standard. All concrete edges must be chamfered. Site drainage should be proper, drain conduits must be below crush layer. Angle irons and barbered wire executed properly. All grounding bars size should be (300x30x5)mm. Front access must be properly constructed.

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BACKFILLING:

Backfilling is very important; if it is not done properly it can result in settlement. Backfilling shall be done with approved material and properly in layers, mechanical compactor may be used at site with ingression of moisture simultaneously for proper compaction

TOWER

INSPECTION:

Telenor

Torque check to be done for all bolts both for maximum and minimum torques. All braces and joint plates should be properly seated there should not be any gap b/w two overlaying members. Galvanization should be up to standards. Fall arrestor should be properly installed. There should be no rust on tower components. At least two threads of each anchor bolt should be exposed. No extra holes be present in tower main legs or braces. Lightning arrestor should be installed on the opposite side of BTS. ACWL should be installed and commissioned. Climbing ladder and rest platform installed and secured properly. No member/bolts should be missing. All four legs of the tower should be connected to the earthing ring buried underneath. ZRC spray is not allowed on tower components.

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Joint plates not seated in both the cases

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TORQUE VALUES:
Bolt Diameter Min. Torque (N-m) Max. Torque (N-m)

M10

15

22

M12
M16 M20 M22 M24

40
78 120 145 172

55
110 170 206 245

AC

POWER

INSTALLATION:

Telenor

Power cable should be properly routed to the intake box. The buried portion should be at least 9 below ground in PVC conduit. AC distribution cabinets as per design and grounded to bus bar and properly water proof. All electrical and earthing cables are to be labeled end to end. All electrical components are both internally and externally grounded. All cable entry glands properly fixed and watertight. All power sockets are properly installed. Connection for power to Guard room should be proper and light, fan and sockets in guard room properly executed. Power intake box must be present at site and properly routed at the time of PAT (irrespective of availability of PP).

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Cable Labeling

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AC POWER INSTALLATION

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POWER ISSUES

TP Transformer Diesel Generator and external fuel tank Panels and breakers Rectifier

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TP Transformer

Separate transformer of required rating for the site must be available Transformer installation must be secure. Physical inspection of transformer. (mounting and oil leakage, etc) Transformer neutral and body grounding must be done with yellow green cable of approved specification. Proper D links must be installed. Energy meter must be available and cable connectivity and mounting of meter must be secure. Voltage measurement for phase to neutral and phase to earth must be checked.

DG SET & FUEL TANK INSPECTION:

Telenor

DG set must be of required rating. Vibration dampers rubber pads should be provided under genset body. The exhaust of generator should not be interfering and pointing outward not toward the equipment. DG set should be checked on load and unload conditions. Check for any fuel, water or oil leakage inside. DG set must be grounded both internally and externally. Emergency shutdown switch must be operational. DG set counters (hour meter, frequency meter, voltmeter and oil pressure gauge ) Fuel alarm cable should be connected. Genset batteries terminal should be greased. Both WAPDA charger and Dynamo should be working and out put must be checked. Cables arrangement should be proper inside the canopy. There should be no Alarm on the control panel of DG set. Fuel tank is properly mounted and grounded. No evidence of leakage and corrosion in any part of fuel tank. Fuel tank gauge should be serviceable. Check the cycle of transfer from main power source to emergency.

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Check the rating of generator, sr. no. and brand name

PANELS AND BREAKERS

Telenor

Intake box must be properly mounted and surge arrester must be present and functional. Cables terminals must be secured with thimbles (thimbles must be attached by thimble compressor not by hammering). Load connectors should be tightened. Selector switch must be checked on all three positions i.e 0,1,2. All the breakers should be labeled.

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Rectifier

Rectifier type according the design. Three input phases must be connected to cabinet. Rectifier body grounding must be done. Surge arrestor must be present and functional. Physical inspection of rectifier cabinet all nuts and bolts tightened properly, door hinges and locks properly installed. No alarm should be present in rectifier. Check the no. of strings and racks of batteries. Batteries must be labeled properly.

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Shelter Installation

Flooring should be free of any defects and curls. Walls should be in perfect condition and free from any damage No leakage should be observed on the roof water leakage test must be performed. All the power sockets should be properly installed and working. All equipment layout must be as per approved drawing Temperature sensor and door sensor should be properly installed and cables should be properly patched. AC should be properly installed i.e leveled, cables and drain pipes properly routed, AC must not be above any equipment. Gas pressure must be checked in ACs. Fire extinguisher should be installed at proper location and should have the requisite pressure inside. Door Lock should be correctly installed.

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Shelter Installation

GUARDROOM INSPECTION:

Telenor

Guard room is installed and commissioned properly. Guard room is grounded. Door latch is in serviceable condition. Fire extinguisher is present in room and in serviceable condition i.e check the pressure gauge.

Guard room Inspection

Telenor

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THANKS