Specs - Steel Poles & Accessories

Electrification and Grid Upgrade along the CLSG Transmission Line in Monrovia (Liberia)
funded by KfW
Part II, Section-VII E Requirements
Doc No : Volume 1, Section III
CHAPTER 1
STEEL POLES, CROSS ARM ASSEMBLIES, GUY SETS AND OTHER ACCESSORIES FOR
22kV AND 0.4kV DISTRIBUTION LINES
CONTENTS
S.No DESCRIPTION PAGE NO.

1.0 SCOPE 1
2.0 STANDARDS 1
3.0 MATERIALS, CONSTRUCTIONAL DETAILS AND WORKMANSHIP 2
4.0 THE SPECIFIC TECHNICAL REQUIREMENTS OF VARIOUS 3
EQUIPMENTS
4.1 Steel Poles 3
4.2 Cross-arm assemblies for single pole structure 8
4.3 Suspension & tension fittings for 22kV AAAC Conductors 9
4.4 LT Suspension & Anchoring Assemblies 11
4.5 Stay sets 16
4.6 G.I. Spike earthing set 20
4.7 Danger plates 21
4.8 G.O. Air break switch (sectionalizing switch) 22
5.0 GALVANIZATION 26
6.0 INSPECTION 27
7.0 QUALITY ASSURANCE 27
8.0 GUARANTEED TECHNICAL SPECIFICATION 29
9.0 DEVIATION SCHEDULE 29
10.0 TECHNICAL PARTICULAR 29
Contents Chapter - 1
Steel Poles & crossarms
funded by KfW
CHAPTER 1
STEEL POLES, CROSS ARM ASSEMBLIES, GUY SETS AND OTHER ACCESSORIES FOR 22kV AND 0.4kV
DISTRIBUTION LINES
1.0 SCOPE
1.1 These specifications cover the design, engineering, manufacture, assembly, testing at
manufacturer's works before dispatch of octagonal tubular steel poles, cross arm
assemblies, guy sets, danger plates, GI spike earthing sets for 22kV Single pole and 0.4kV
Distribution line, Suspension and Tension Fittings suitable for 120 sq.mm. AAAC Conductor
for use on 3 phase, 50 Hz, solidly earthed 22kV Overhead lines and Suspension & Anchoring
assemblies for LT ABC at various construction sites for 22/0.4kV distribution network, for
Power Distribution in Double Bridge: Pipeline Police Academy GAP and Du port road-
Rehab GAP in Monrovia, Liberia.
1.2 The design and workmanship shall be in accordance with the best engineering practices to
ensure satisfactory performance throughout the service life.
1.3 Any material and equipment not specifically stated in this specification but which are
necessary for satisfactory operation of the equipment shall be deemed to be included unless
specifically excluded and shall be supplied without any extra cost. Components having
identical rating shall be interchangeable. The bidder has to furnish the testing facilities
2.0 STANDARDS
The steel poles, cross arm assemblies, cross brace assemblies and pole guard arms, guy sets,
earthing sets etc. shall conform to therelevant IEC standards and any other equivalent
neutrally acceptable International Standards (as amended upto date) mentioned below shall
be applicable to the materials and processes used in the manufacturing of these equipment:
Table 1
ISO 20805:2005 : Hot-rolled steel sheet in coils of higher yield strength with improved
formability and heavy thickness for cold forming
BS 3288 : Part 1: 2014 : Insulator and conductor fittings for overhead power lines.
Performance and general requirements
ISO 10684:2004 : Fasteners Hot dip galvanized
ISO 10721 : Steel structures
Page 1 of 30 Chapter 1
funded by KfW
ISO 752:2004 : Zinc Ingot

ASTM E350 - 18 : Standard Test Methods for Chemical Analysis
ISO 657/V : Specifications For Rolling And Cutting Tolerances For Hot-Rolled
ISO 1035/IV Steel Products
ISO 657/13
ISO 4995-1978
ISO 12944-4:2017 : Paints & Varnishes
ASTM A123 : Recommended Practice for Hot Dip Galvanizing of Iron and Steel
Articles
ASTM A123 : Method of Testing Uniformity of Coating of Zinc;
ISO 1461:2009(en) : Hot-Dipped Galvanized Coatings on Round Steel Wires
IEC 60335-2-71 : Specification For Poultry Incubators
ASTM A90 : Determination Of Mass Of Zinc Coating On Zinc Coated Iron And
Steel Articles
ASCE Manual 72 : :
SEI 48-05
IEC 60120 : Dimensions of ball and socket couplings of string insulator units
IEC 60372 : Locking devices for ball and socket couplings of string insulator units
- Dimensions and tests
IEC 61109 : Insulators for overhead lines- Composite suspension & tension
Insulators for A.C. systems with a nominal voltage greater than

1000V- definitions, test methods and acceptance criteria.
NFC 33-040 : Suspension Equipment
NFC 33-041 : Anchoring Devices
Whenever there is a difference in the Standards the most stringent criteria shall apply.
3.0 MATERIALS, CONSTRUCTIONAL DETAILS AND WORKMANSHIP

3.1 Materials used in the manufacture of all the equipment shall be new and best quality and
class most suitable for performance under the specified conditions.
3.2 Steel used for manufacture of various equipment shall be in conformity with the general
requirements relating to the supply of materials laid done in relevant international
standards.
3.3 The material analyzed in accordance with ISO 13520:2015 or other relevant international
standard shall not show sulphur and phosphorous contents of more than 0.060% each.
3.4 Equipment shall be well-finished, clean and free from harmful surface defects. Ends of steel
poles, angle sections etc. shall be cut square and shall be straight.
funded by KfW
3.5 The bolts, nuts & pack washers and guy wire strand & cross arm guard wire shall be hot dip
galvanized as per ISO 1461:2009(en) or other relevant international standards. The quality
of zinc shall be at least Zn 98 grade specified in ISO 752:2004. The zinc coating shall be
adherent, smooth, reasonably bright, continuous and free from such imperfections and flux,
ash and dross, inclusions, flake and black spot, pimples, lumpiness and runs.
3.6 The steel poles shall be hot dip galvanized with minimum 125 micron thickness of zinc
coating and steel base plates with minimum 125 micron thickness of zinc coating generally
as per ASTM A123 and tested as per relevant international standards..
3.7 The articles shall withstand minimum 4 dips of one minute duration. The uniformity of
galvanized coating shall be determined by the preece test as prescribed in ASTM A123.
3.8 Suspension and Tension Fittings shall be made of Aluminum Alloy and all nuts and bolts shall
be made of hot dip galvanized steel with minimum thickness of zinc coating of 85 micron as
per ISO 10684:2004(en) Part XIII or other relevant international standards..
4.0 THE SPECIFIC TECHNICAL REQUIREMENTS OF VARIOUS EQUIPMENTS

4.1 Steel Poles
The purchaser may at its discretion furnish the design and fabrication data of one or more
types of poles necessary for fabrication and testing of poles by the supplier or
alternatively may ask the bidder to work out the optimum designs of poles and in that
Employer.
Design of Poles shall be worked out and checked preferably as per ASCE Manual- 72 / SEI -
48- 05 or other relevant international standards. Poles shall be pre-drilled and supplied
complete with pole top cap and base plate.
4.1.2 Specific Constructional Requirement
4.1.2.1 Poles shall be designed to withstand the worst possible combination of simultaneous
loading of
• Lateral loads consisting of wind forces on conductors corresponding to wind spans, wind
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force on insulators, wind force on pole and maximum conductor tension.

• Vertical loads consisting of pole self-weight, weights of conductors, insulators, cross-arm,
additional equipment, lineman and compressive force due to reaction of stays wherever
applicable.
4.1.2.2 Steel poles for HV (22 kV), HV / LV mixed shall be worked out for the following types and
applications:
HV and HV / LV Mixed Lines:

Table 2
S.N. Type of pole Nominal Application Working
Height Load
i. Alignment pole(AL) 11 m Angle up to 10° 430 daN
ii. Light Angle (LA) Angle up to 40°, section & derivation 990 daN
iii. Heavy Angle (HA) Angle above 40° and Terminal Pole 1220 daN
iv. Pole Mounted Sub- Double 11 m pole H - configuration 1250 daN
Station (PMSS) only for mounting 22/0.4 kV, 50kVA,
100 KVA and 200 KVA transformers
The following span lengths may be considered for adoption (as per relevant IEC)
Table 3
Nominal System Voltage kV Number of circuits Span Range (m)
(rms)
22 1 80-110
LV Lines:
Table 4
S.N. Type of pole Nominal Application Working load
Height
i. Alignment Pole (AL) 9m Angle up to 2° 190 daN
ii. Section Pole 9m All other locations and angle up to 90° 550 daN
S.N. Line Locality Conductor Formation Maximum wind span in

i. LV Line Inhabited Suspension / Tension 45 m
4.1.2.3 Contractor shall submit the detailed design & drawing of pole for each above said 22kV
Transmission line for approval of Client and sample drawing showing dimension &
funded by KfW
configuration are enclosed.

4.1.2.4 Poles shall satisfy the dimensional length and pole top loading requirements as per the
design parameters listed in this specification. The dimensions across flats for top and
bottom for all poles are listed in this specification/drawings as a preferred design to utilize
one dimension for each type of pole length in so far as design & working load criteria is
met.
4.1.2.5 Working Load
Working Load of a pole specified herein and defined as the load which when applied at
250 mm below top will induce the maximum permissible stress in the pole, shall be
marked on each pole.
4.1.2.6 The standard poles shall be suitable for the specified applications based on the design
parameters given in Table 2, 3 & 4.
4.1.2.7 A through hole of 14 mm diameter shall be provided in each pole at a height of 300 mm
above the planting depth for earthing. The location of hole at a height of 300 mm shall be
got approved from the Employer before manufacturing of the poles.
4.1.2.8 Base Plates

Poles shall be supplied with separate square steel base plate fabricated from steel as per
relevant Standards. Min. thickness of base plates shall not be less than 6 mm. Design
calculations of thickness of steel base plates shall be submitted for check and review by
Employer.
4.1.2.9 Guying
Poles for small angle locations (0 - 30°) shall be self-supporting. However; the poles for
larger angle and terminal locations in un-inhabited areas can be provided with Anchor
Guys placed the direction of the bi-sector of the angle at angle locations or length wise at
the terminal locations. In the inhabited areas guys are not allowed; but Struts or two
poles mechanically secured together can be deployed.
4.1.2.10 Fabrications and Finish
funded by KfW
i. Poles shall be fabricated by cold bending of steel sheets of appropriate size and length in
to octagonal shape and single continuously welded joint. The welding shall be done in an
inert atmosphere preferably under a nitrogen jacket.
ii. All welding, cutting, machining, and fabrication shall be done prior to galvanization.
iii. The Poles shall be straight, smooth, octagonal and conical and shall be well finished,
clean, and free from burs, indentations and other surface defects.
iv. Holes and earthing arrangements shall be provided as per structure drawings. All holes
and pole top shall be blocked with plastic plugs / tightly fitting plastic cap to avoid entry of
water into the hollow of the pole.
v. Two M-12 earthing studs placed diametrically opposite and flush welded with internal
surface of the pole; complete with M-12 GI Nut, Bolt, Plain and Spring washer set, shall be
provided each at 2700 mm below pole top and 500 mm below ground level in HV line
poles and at 400 mm below pole top and 500 mm below ground level for LV line poles.
vi. Ground level shall be marked with a 12 mm wide paint strip all around in black color.
vii. A prototype pole as per approved design shall be fabricated and tested at an authorized
approved test bed as per IEC: 60652 or may be mutually agreed up to breaking load in the
presence of the inspectors of the Client before proceeding with mass fabrication of the
poles.
4.1.2.11 Design Parameters and Factor of Safety
Description 11m
Basic 100
Span (m) Wind 110
Weight 150
Wind pressure On pole 1200
(N/m2) On conductors at 10°C 600
Vertical loads 1.18
Transverse loads 1.8
Longitudinal loads 1.8
Factor of Safety
Ultimate load 1.8
Conductor minimum
3.0
breaking strength
Planting Depth (m) 1.6*
funded by KfW
Allowable Deflection at Pole Top 5% of expose length

Minimum Breaking Load 101kN
Stay wires Max. Tension 90% of min. breaking load
Min. angle to the pole 37°
Minimum 0°C
Temperature
Maximum +40°C
*Subject to approval of foundation design.
4.1.2.12 Tolerances
i. Length
The tolerance on the length shall be as follows:
- Length of any section + 40 mm
- Overall length of pole + 25 mm
ii. Straightness
The finished pole shall not be out of straightness by more than 1/600 of its length.
The rolling and cutting tolerance for hot rolled steel products shall be in accordance with
relevant international standards.
4.1.3 Tests
The following tests shall be conducted in accordance with IEC: 60652:
i. Visual Check and Verification of Dimensions: Visual Check and Dimensional Verification
of poles shall be carried out as per approved drawing.
ii. Tensile and Chemical Composition Tests: Tensile and Chemical Composition tests shall
be made on the steel used for manufacture of poles in accordance with relevant IEC.
iii. Deflection Test: Poles shall conform to the test requirements when tested in accordance
with relevant international standards. Temporary deflection due to applied load at the
point of application of load shall not exceed 157.5 mm.
iv. Permanent Set Test: Permanent set test will be carried out immediately after the
deflection test and the permanent set measured from the zero position after the release
of the appropriate load at the point of application shall not exceed 13 mm.
v. Breaking Load Test: In addition to the above, the poles shall be tested for withstanding
funded by KfW
maximum permissible loads, i.e. 1.8 times working load without breaking or deforming
and the pole shall remain serviceable after removal of the load.
B M Q P MQP nd submit all
relevant records to the inspector of the Client / Purchaser along with call for inspection.
Testing shall be done on the required number of poles of each type / size as per standard
sampling plan prescribed here in. Tests shall be done by supplier / manufacturer at an
authorized / approved test bed in the presence of the inspector of the Client and / or
representative of the Purchaser.
4.1.4 Sampling Plan For Testing

The sampling plan for testing of poles shall be as specified in the relevant standard; but
number of samples shall not be less than specified below:
i. For chemical analysis: 1 in a lot of 500, 2 in a lot of 501 1000, 3 in a lot of 1001 2000,
4 in a lot of 2001 3000 and 5 in a lot of 3001 and above.
ii. For deflection and permanent set: 5 in a lot size up to 500, 8 in a lot of 501 1000, 13 in
a lot of 1001 2000, 18 in a lot of 2001 3000 and 20 in a lot of 3001 and above.
4.1.5 Marking
The poles shall be marked with designation, manufacturer's identification and year of
manufacture. The poles shall also be marked with BIS certification mark if applicable.
4.2 Cross Arm Assemblies for single pole structure
4.2.1 The cross-arm assemblies for single pole structure including pole clamps and Top
Hamper for Pin Insulator shall be supplied as assembled cross arms for 22 kV octagonal
pole lines.
4.2.2 Specific Constructional Requirements
4.2.2.1 Cross-arms shall be made out of 100 x 50 x 6.4 mm M.S. Channel
4.2.2.2 The cross arm shall be hot dipped galvanized as per relevant international standards.
4.2.2.3 The cross-arm should not be welded/ jointed at any place except as specified.
4.2.2.4 The clamps for the cross-arm shall be of G.I. & shall be hot dipped galvanized as per
funded by KfW

4.2.2.5 The clamps shall be designed to fit for the specified octagonal steel poles.
4.2.2.6 The proto of each type of cross arm assembles shall be fabricated and assembled
before mass fabrication and the same shall be got approved from the Client/Consultant
before taking up mass fabrication.
4.3 Suspension & Tension Fittings for 22 kV AAAC Conductors:

i) Suspension Fittings shall constitute of a cross arm strap (for fixing it on a GI channel
of 100 x 50 mm), a ball clevis, a socket clevis and a Suspension Clamp.
ii) Tension fittings shall constitute of a cross arm strap (for fixing it on a GI channel of
100 x 50 mm), a ball clevis, a socket clevis and a Strain Clamp (Type-B as per IEC
60502-1).
4.3.1. When installed, the tension clamp shall withstand a holding force of at least 95 % of the
UTS (of the conductor) without allowing the conductor to slip or get damaged.
4.3.2. The current carrying capacity of the tension and suspension clamp shall be equal to or
better than that of the conductor it is holding.
4.3.3. Suspension and Tension fittings shall be suitable for use with the Ball and Socket type (B
and S type) composite tension insulators, conforming to the latest edition of IEC-61109.
The fittings shall match the end fittings of the Insulators.
4.3.4. Tests as per IEC 60502-1or other relevant international standards.
4.3.2.1. Type Test
i) The following shall constitute Type Tests for Tension and Suspension Clamps:
a. Visual Examination;
b. Verification of Dimensions;
c. Slip Strength Test;
d. Ultimate Strength Test;
e. Electrical Resistance Test; and
ii) The following shall constitute Type Tests for Fittings except Clamps:
a. Visual Examination;
b. Verification of Dimensions;
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c. Galvanization Test (for nuts, bolts and washers).

d. Mechanical Test; and
e. Chemical Composition test (except for nuts, bolts and washers).
Bidder shall submit along with his bid, copies of reports of all type tests conducted within
last 7 years on Suspension and Tension Fittings of identical design and specification at NABL
(National Accreditation Board for Testing and Calibration Laboratories) accredited
laboratories.
4.3.2.2. Routine Tests

Manufacturer shall, during manufacture himself conduct and shall furnish, at time of
inspection, record of the tests for review by Inspecting Officer.
i) Visual Examination Test;
ii) Mechanical Routine Test except in case of Suspension Clamp.
4.3.2.3. Acceptance Tests

i) The following shall constitute Acceptance Tests for Suspension and Tension Clamps:
a. Visual Examination Test;
b. Chemical Composition Test;
c. Verification of Dimension;
d. Mechanical Tests;
e. Ultimate Strength Test; and
f. Electrical Resistance Test.
ii) The following shall constitute Acceptance Tests for Tension Fittings except Clamps:
a. Visual Examination Test;
b. Chemical Composition Test;
c. Galvanization Test (for nuts, bolts and washers).
d. Verification of Dimension; and
e. Ultimate Strength Test;
4.3.5. Inspection
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All acceptance tests, routine tests and inspection shall be made at the place of manufacture
unless otherwise especially agreed between the Client/Consultant and the manufacturer.
The manufacturer shall wi
facilities to satisfy him that material is being furnished in accordance with this specification.
4.3.6. Marking
Each Suspension and Tension Clamp shall carry the following information embossed/
indelibly inscribed thereupon:
i) Name or trade mark of the manufacturer;
ii) Month and year of manufacturer;
iii) Country of manufacturer; and
iv) Any other information as agreed between the client and the Contractor.
4.3.7. Packing
For packing, wooden cases / Boxes / Double Gunny bags shall be used. The packing shall be
fit to withstand rough handling during transit and storage at destination. The heads and
threaded portion of fasteners fitting should be properly protected against damage. The
gross weight of the packing shall not normally exceed 50 kg per box or case. All different
fitting components shall be packed in different cases and shall be completed with minor
accessories fitted in places. All Nuts shall be hand- tightened over the bolts and screwed
upto the farther point. The packing list should be got approved by the tenderer before
dispatching the material.
4.4 LT Suspension & Anchoring Assemblies:

4.4.1. Anchoring Clamps
The clamps should be designed to Anchor LT-AB cable with insulated messenger. The clamp
should consists of an Aluminum alloy corrosion resistant castled body, bail of stainless steel
and self-adjusting plastic wedges which shall anchor/hold the neutral messenger without
damaging the insulation.
• No losable part in the process of clamping arrangement
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• The clamp should conform to the standard NFC 33-041 and 33-042.The clamp body should
be made of corrosion resistant Aluminum alloy, bail should be of stainless steel and
wedges should be weather and UV resistant polymer.
• Ultimate tensile strength of the clamp should not be less than 15 KN for 50/70sq.mm
insulated messenger wire & 10 KN for 25/35 sq.mm insulated messenger wire.
• Slip load of the clamp should not be less than 3 KN for 50/70 sq.mm. Messenger wire & 2
KN for 25/35 sq.mm messenger wire.
4.4.2. LT Anchoring Assembly

Anchoring assemblies are used to firmly attach the messenger of ABC to a support and
transmit the mechanical tension:
• at the end of a run or to the supporting structures
• at a major change in direction.
4.4.2.1. Anchoring assemblies shall be supplied in sets to ensure compatibility of the materials
against corrosion or wear of moving parts.
4.4.2.2. Each Anchoring Assembly shall include:
• One number tension bracket.
• One number wedge type tension clamp
• Flexible Rope for fixing tension clamp to bracket
4.4.2.2.1. Tension Bracket of Anchoring Assembly
The tension bracket shall be made out of a single piece of Aluminium alloy suitable for
attachment to a pole either by
a) 16mm galvanized steel bolt (s) or
b) Two stainless Steel straps of 20mm x 0.7 mm.
The tension bracket should be designed to ensure the Flexible rope cannot slip out at any
angle.
The tension bracket should be rated and tested for the loads specified in Table-5. The load
shall be applied at an angle of 45º from the normal to the surface of mounting of the
bracket.
Table 5
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Conductor Rating Load for deformation Load for

Size <10mm (Newtons) deformation
(Sq.mm.) <30mm & no-break
(Newtons)
25-35 1500 Kg. 12,000 15,000
50-95 2000Kg 15,600 19,500
4.4.2.2.2. Flexible Rope of Anchoring Assembly

• The Anchoring assembly shall be supplied with a stainless steel flexible Rope to connect the
Tension Clamp to the Tension Bracket.
• The rope should have sufficient flexibility to ease the torsional movement of the ABC
System.
• The Rope should be pre-fitted with compression type end fittings to secure the tension
clamp.
• A wear resistant moveable saddle should be un-loosably fitted on the Rope to prevent
abrasion at the point of fitting into the tension bracket.
• The Rope should have sufficient mechanical strength to withstand the mechanical test for
the complete assembly tests in this specification.
4.4.2.2.3. Wedge Type Tension Clamp of AA

• Wedge type clamps shall be used for clamping the messenger without damaging the
insulation.
• The clamp shall be capable of clamping an uncut messenger so that it can continue without
break to the connecting point or next span.
• The clamp shall be fully insulating type of mechanical and weather resisting thermoplastic.
• No bolts or loose parts are allowed as part of the Clamping system.
• No tools shall be needed for fitting the messenger into the clamp.
• The clamp shall be self-tightening and capable of holding without slippage the load specified
in the Table-6.
Table 6
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Conductor Size Rating (Kg.) T start T final

Sq. mm. Dia. (mm) (1 minute) (1 minute)
(Newtons) (Newtons)
25-35 8-11 1000 Kg. 8,000 10,000
50-54 8-11 1500 Kg. 12,000 15,000
70-95 13.5-16 2000 Kg. 12,000 15,000
After fitting the insulated messenger in the clamp, load T start will be held for 1 minute &
then load increased to T final at rate between 5000 7,500 N/mtr. In each case there shall
be no breakdown of any part of clamp and slippage of messenger in relation to the clamp.
4.4.3. Suspension Clamp:

4.4.3.1. The clamp should be designed to hang LT AB cable with insulated neutral messengers. The
neutral messengers should be fixed by an adjustable grip device. A movable link should
allow longitudinal and transversal movement of the clamp body.
• No losable part in the process of clamping arrangement.
• The clamp should conform to the standard NFC 33040 or equivalent IEC, if any.
• The clamp and the link made of Polymer should provide an additional insulation
between the cable and the pole.
• The clamps and movable links should be made of weather and UV resistant glass
fiber reinforced polymer.
• Clamps should be fixed with pole by eye hook / bracket. Bracket should be made of
corrosion resistant aluminum alloy.
• Ultimate tensile strength of the clamp should not be less than 15 KN for 50/70
sq.mm. Insulated messenger wire &4.3 KN for 25/35 sq.mm. Insulated messenger
wire.
• Maximum allowable load of the clamp should not be less than 20 KN for 50/70
sq.mm. insulated messenger wire&15 KN for 25/30 sq.mm insulated messenger
wire.
4.4.4. Suspension Assembly
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4.4.4.1. Suspension Assembly is used for supporting an ABC by installation on the messenger at an
intermediate point of support such as a pole. It can accommodate small angles of deviation
upto 30°.
4.4.4.2. Suspension Assemblies shall be supplied in sets to ensure compatibility of the materials
against corrosion or wear of rotating/moving parts.
4.4.4.3. Each Suspension Assembly shall consist of:
• One number Suspension Bracket.
• One number moveable (articulated) connecting link.
• One number Suspension Clamp.
4.4.4.3.1. Suspension Bracket of SA:
▪ The Suspension Bracket shall be made from single piece aluminum alloy suitable for
attachment to a pole by either:
• 16 mm galvanized steel bolt or
• Two stainless steel straps.
• The Suspension Bracket shall be provided with an upper bulge to prevent the clamp from
turning over on the Bracket for more than 45 mm from the horizontal or to within less than
60 mm from the pole / fixing structure.
• The Suspension Bracket should be so designed to ensure that the articulated link cannot slip
out of it.
• Suspension Brackets shall be designed to withstand a load applied at the anchoring point of
the movable link as per Table 7 below without deformation of more than 10mm or
breakdown (there should be no longitudinal component of load parallel to the plane of
fixing).
Table 7
Conductor Size Normal Load
Sq. mm. Dia. (mm) rating (N)
(kg)
25-35 8-11 1500Kg. 12500
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70-95 13-17 2000Kg. 14000
4.4.4.3.2. Movable (Articulated) Link of SA

• Movable Links are used between the Suspension Bracket and Suspension Clamp to allow a
degree of movement and flexibility between the two.
• Moveable Links should be made fully of insulating type of mechanical and weather resistant
thermoplastic. A metallic wear resistant ring should however be fitted at point of contact
between the Suspension Bracket and the movable link.
• The Movable link should be unlosable fitted to the Bracket and the Clamp.
4.4.4.3.3. Suspension Clamp of SA

• Suspensions Clamps are used for locking the messenger of the ABC bundle without
damaging the insulation or allowing the messenger to become dismounted from the fitting.
• The Suspension Clamp shall accommodate messenger wires from 25 to 95 sq.m.
• The Suspension Clamp shall be made fully of insulating type of mechanically strong and
weather resistant plastic.
• Bolts should not be used for clamping / locking the messenger in the Clamp.
• There shall be no losable parts in the Suspension clamp.
• The Suspension Clamp should be unloosably fitted to the rest of the Suspension Assembly.
4.5 Stay Sets

4.5.1. The stay sets, as shown in drawing required for anchoring 22 kV double (H) pole line, shall
comprise of the following:
• Galvanized stranded steel wire strand 12 m long, 7/4.00 mm, 70kgf/mm2 quality.
• Single bow turn buckle assembly suitable for attachment on one side to pole with pole
stay clamp and other side through 20 mm dia eye bolt with a nut and lock nut to the
stranded steel wire strand.
• Mild steel galvanized anchor rod with M.S. galvanized anchor plate
• Guy strain insulator
• Pole stay clamp
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4.5.2. Design and Constructional Requirement

The stay sets shall confirm to ISO 10684:2004(en) or any other equivalent standards
which ensure better performance.
4.5.3. Galvanized stranded steel wire strand

4.5.3.1. The steel wire shall be drawn from steel made by the open hearth basic oxygen or electric
furnace process and of such quality that when drawn to the specified wire size and hot
dip galvanized, the finished steel wire strand and individual wire shall be of uniform
quality and have the properties and characteristics as specified in the specification. Joints
are permitted in the individual wires during stranding but such joints shall not be less
than 15 m apart in completed strand. The wires shall be circular & free from scale,
irregularities, imperfection, flaws, splits & other defects. The wires shall not contain
sulphur and phosphorous exceeding 0.06% each.
4.5.3.2. The wires (7/4.0 mm) shall be of tensile grade 4 having minimum tensile strength of 700
N/mm2 as per relevant international standards.
4.5.3.3. The lay length of layers of steel wires shall be 12 to 18 times the overall dia and shall have
right hand lay. When distributed pull is applied at the ends of completed strand, each
wire shall take equal share of the pull.
4.5.3.4. The steel wire shall be hot dip galvanized in accordance with ASTM A123 or other
4.5.3.5. The no. of dip and weight of zinc on individual wire shall be as per ASTM A123 or other
relevant international standards..
4.5.3.6. The galvanized stranded steel wire strand shall be provided with thimble (4 nos.) made
out of mild steel galvanized flat 2.64 mm thick.
4.5.4. Turn Buckle Assembly

4.5.4.1. Single bow turn buckle assembly, as per enclosed drawing shall comprise 20 mm dia mild
steel rod bent in A shape 460 mm deep, 20 mm radius at bend point and 35 mm round
rod at each end fixed to ISMC 100 mmx50 mm (wt. 9. 2kg/m), length 300 mm. The I SMC
100x50 mm shall have a hole in the center through which 20 mm dia, 46.0 mm long eye
bolt with 305 mm threaded bolt and provided with 2 nuts one out of which to act as lock
funded by KfW
nut. The eye of eye bolt nut shall be of 30 mm dia.
4.5.4.2. The turn buckle assembly is connected with pole with full clamp as per enclosed drawing.
4.5.5. Stay Rod

4.5.5.1. The galvanized stay rod with galvanized anchor plate shall comprise anchor bolt of 20 mm
diameter , 2590 mm long, quality 420 N/mm2 with 50 mm diameter eye at one end and
75 mm threaded portion at the other end. The threaded end of the stay rod is provided
with mild steel galvanized plate 300x300x6 mm held in position by nut on either side of
the plate.
4.5.6. Guy Strain Insulators for Stay Wire Assembly
The guy strain insulators shall conform to relevant international standards.
4.5.6.1. General Requirements

i) The porcelain insulator shall be sound, free from defects, thoroughly vitrified and
smoothly glazed.
ii) The design of the insulator shall be such that the stresses due to expansion and
contraction in any part of the insulator shall not lead to its deterioration.
iii) The glaze shall be brown in colour. The glaze shall cover the entire porcelain surface
parts except those areas that serve as supports during firing.
4.5.6.2. Type of Insulators

i) The standard guy strain insulators shall be of designation 'c' as per relevant
international standards.
ii) The recommended type of guy strain insulators for use in guyed sets for anchoring
poles of different voltage rating shall be as follows:
System Voltage (kV) Designation of Insulators

24 C (2 Insulators to be used in series)
4.5.6.3. Dimensions
The dimensions of guy strain insulators shall be in accordance with enclosed drawing.
funded by KfW
4.5.6.4. Basic Insulation Levels

The test voltage of the insulators shall be as under:
Designation of Dry one-minute Power Wet one-minute Power
Insulator frequency withstand frequency withstand voltage KV
voltage KV (rms) (rms)
C 27 13
4.5.6.5. Mechanical Strength
The guy insulator shall be suitable for the minimum failing loads of 88 KN.
4.5.6.6. Tests
The insulators shall comply with the following routine, type and acceptance tests as per IEC
60335-2-71
i) Routine Test
Visual examination
ii) Type Tests

a) Visual examination
b) Verification of dimensions
c) Temperature cycle test
d) Dry one minute power-frequency voltage withstand test
e) Wet one minute power-frequency voltage withstand test
f) Mechanical strength test
g) Porosity test
iii) Acceptance Tests: (to be conducted in the following order)
a) Verification of dimensions
b) Temperature cycle test
c) Mechanical strength test
d) Porosity test
The copies of the type tests shall be supplied with the tenders. The supplier shall keep the
funded by KfW
record of routine tests performed by him and furnish the same as and when required by
the client/consultant.
4.5.6.7. Marking
Each insulator shall be legibly and indelibly marked to show the following:
a) Name and trade mark of the manufacturer
b) Year of manufacture
c) BIS certification mark, if any
Marking on porcelain shall be printed and not embossed.
4.6 GI Spike Earthing set

4.6.1. GI Spike earthing shall be provided on every pole of MV and LV lines.
4.6.2. The GI spike earthing set shall comprise of galvanized earthing rod with accessories and
galvanized steel wire earthing lead for connecting earthing rod to octagonal pole complete
with accessories.
4.6.3. The earthing rod shall have 1853 mm (i.e. 25 + 1752 + 76) long fabricated from 20 mm dia
M.S. Rod, the bottom of which to be made cut of the same rod in the shape of a cone 76
mm long and the forged head made out of the same rod with 30 mm (dia) = 25 mm
(height). The earthing arrangements should consist of G.I. Bolt/nut and washers. The raw
materials, as required for manufacture, shall comply with the relevant latest international
Standard with all amendments, additions and alternation, for obtaining the required
strength.
4.6.4. No crack shall develop and deformation to take place in the top head and/or bending of
rod when driven into the ground by a 7.5 kg hammer in a manner usually adopted in
driving rods to the ground.
4.6.5. The screw thread design of the stay rod and nut should be as follows :
M 16 x 2 -7H/8g for 16 mm dia stay rods and Y 20 x 2.5-7H/8g for 20 mm rod and the sizes
of the threads should be as per relevant international standards. The screw threads of rods
and nuts shall be properly lubricates at the time of supply.
4.6.6. The earthing lead shall be galvanized stranded steel wire strand 7/4.00 mm, 70 kgf/mm 2
quality, 3 m long with terminal lugs at both ends and provided with bolts and nuts 12 mm
funded by KfW
dia suitable for connecting on one end with the pole and other end to the earthing rod.
The galvanized steel wire strand shall conform to relevant international standards.
4.6.7. The mild steel earthing rod and galvanized stranded steel wire lead (strand) and all bolts &
nuts shall be hot dip galvanized/ electro plated as per relevant international Standard
specification and shall be tested for weight and uniformity of Zinc coating as per relevant
standards.
4.6.8. The tolerances shall be as given below:
• Length = 1/2 %
• Other dimensions = 5%
• Small forged portion (15, 25 and 40 mm) = 10 %
4.6.9. The following additional tests shall be carried.
• Galvanization test
• Dimensional sheet
• Stress test by hammering: (7/8 times) the rods into the normal soil by a hammer.
4.6.10. The forged head of the earthing rod shall carry manufacturer's identification mark.
4.7 Danger Plates

i. The danger plate, as shown in enclosed drawing shall be in accordance with relevant
ii. The size of the danger plate shall be 250mm x 200 mm.
iii. All letterings shall be centrally spaced. The dimensions of the letters, figures and their
respective position shall be as shown in the drawing. The size of letters in words in each
language and spacing between them shall be so chosen that these are uniformly written in
the space earmarked for them.
iv. The danger plate would the written in English and French. The type and size of lettering
and language shall be got approved from the client/consultant before taking up mass
fabrication.
v. The plate shall be made from mild steel sheets of at least 1.6 mm thick and the corners of
the plate shall be rounded off. The plate shall be vitreous enamelled white with letters,
figures and the conventional skull and cross bones in signal red colouron the front side.
funded by KfW
The rear side of the plate shall also be enamelled.

vi. The name of the supplier, trade mark and client/consultant's name shall be marked in such
a manner without interfering with the purpose for which the plate is intended.
vii. The following tests shall be performed on the danger plates as per relevant international
standards.
• Visual examination
• Dimensional check
• Test for weather proofness
viii. The plates shall be packed in wooden crates suitable for rough handling during transport
and storage and acceptability by road transports.
4.8 G.O. AIR BREAK SWITCH (SECTIONALIZING SWITCH):
4.8.1 This section covers the design, engineering, manufacture, testing, supply, delivery, off-
loading and performance requirements of 22kV, 200 amps, triple pole Gang Operated Air
Break (G.O.A.B.) Switches for outdoor installation on the 22kV line on tapping &
sectionalizing points.
4.8.2 Material & general Construction Details:
The air break switches shall have triple pole construction and shall be suitable for horizontal
having a three porcelain insulator manually operated rocking type arrangement.
i. Operating Mechanism
The operating mechanism shall be suitable for manual operation from ground level by one
person with ease and shall be so designed that all the three phases open or close
simultaneously. The switches shall be robust in construction and shall be protected against
over travel or straining that may adversely affect any of its parts. The load break switch shall
be fitted with self-contained arc extinguishing devices e.g. interrupter heads with
independent manual operation.
An operating rod consisting of galvanized iron pipe of 30mm diameter and of about 6000
mm length shall be provided for closing and opening operations.
The AB Switches shall be capable to resist any chance of opening out when in closed
position. The vertical down rod should be provided with adequate joint in the mid-section
to avoid bending or buckling. Additional leverage should be provided to maintain
funded by KfW
mechanical force with minimum efforts.

ii. Galvanizing
All ferrous parts except springs shall be hot dip galvanized and zinc coating shall not be less
than 610 gm/sq. meter. All brass parts should be silver plated and all nuts and bolts should
be hot dip galvanized.
iii. Contacts
AB Switches shall have heavy duty self-aligning type contacts made of tin plated hard drawn
electrolytic copper/brass. The various parts should be accordingly finished to ensure
interchangeability of similar components. The surface of the contact shall be rounded
smooth and silver-plated to thickness of not less than 30 microns. The fixed (female)
contacts shall be spring loaded pressure type so as to ensure firm contact and proper
alignment. The springs shall, however, not carry any current. Arcing contacts with spring
assisted operation shall be provided. The arcing contacts shall open after the main contacts
and close before the main contacts.
In nut shell the male and female contact assemblies shall ensure:
1. Electro-dynamic withstands ability during short circuits without any risk of repulsion of
contacts.
2. Thermal withstands ability during short circuits.
3. Constant contact pressure even when the lower parts of the insulator stacks are subjected
to tensile stresses due to linear expansion of connected bus bar of flexible conductors either
because of temperature variations or strong winds.
4. Wiping action during closing and opening.
5. Fault alignment assuring closing of the switch without minute adjustments.
iv. Base and Mounting
A rigid base of galvanized steel channel of size approximately 75 x 40 x 6mm. shall be
provided with suitable holes, clamps and bolts for mounting firmly on steel structure. It shall
be suitable for both horizontal and vertical mounting.
v. ARCING HORNS
Arcing horns shall be simple and replaceable type. They should be capable of interrupting
line-charging current. They shall be of first make and after break type.
funded by KfW
vi. Padlocking
Suitable padlocking or other approved locking arrangement shall be provided for locking the
operating handle both in the ON and in the OFF position.
vii. Earthing Terminal
Two earthing terminals having clamping bolts with a minimum diameter of 12mm, with
nuts, washers and spring washers shall be provided on the frame of each pole. The earthing
terminals shall be of electroplated brass and of adequate size to carry full short circuit
current.
viii. Other Features.
• Live parts shall be designed to avoid sharp point edges and other corona producing
surfaces as far as possible.
• The switch blades shall be so assembled that all three phases operate in synchronism.
Fixed guides shall be provided for proper seating of the contacts even when a blade is
out of alignment to a minor extent.
• There should not be any play or backlash to produce non-uniform travel of the blades of
the three phases and all the three phases shall make simultaneous closing with good
electrical contact.
• A suitable arrangement for accelerating the opening of contacts shall be provided to
avoid excessive sparking.
4.8.3 Specific Technical Requirements:

i. POST INSULATORS
High strength porcelain insulators shall be used for supporting and insulating the fixed
contacts and the moving blades. Creepage distance should be adequate for highly polluted
outdoor atmosphere in open atmosphere. They shall be made of homogeneous material,
with uniform glazing, free from cavities and other flaws and have a high quality smooth
finish. They shall withstand the maximum expected static and dynamic loads to which the
switch may be subjected during its service life. They shall conform to IEC 60273 and shall be
subjected to all the tests provided in these standards and in IEC 60383.
The porcelain and metal parts shall be assembled in such a manner that any thermal
funded by KfW
expansion differential between the metal and porcelain parts through the range of
temperature variation shall not loosen the parts or create undue internal stresses which
may affect the electrical or mechanical strength. Cap and base of the insulators shall be
interchangeable with each other. The cap and base shall be properly cemented with
insulators to give perfect grip. Excess cementing must be avoided.
ii. TEMPERATURE RISE
The maximum temperature attained by any part of the equipment when in service at site
under continuous full load conditions and exposed to the direct rays of Sun shall not exceed
45 degree above ambient.
4.8.4 Tests:
The firm should have all type test certificate including the following:-
1. Temperature-rise tests;
2. Measurement of the resistance of the main circuit;
3. Short-time withstand current and peak withstand current tests;
4. Tests to prove the ability of the switch to make and break the specified currents;
5. Tests to prove satisfactory mechanical operation and endurance;
6. Verification of the protection;
7. Tightness tests; electromagnetic compatibility (EMC) tests.
8. Lightning impulse voltage test with positive & negative polarity.
9. Power Frequency voltage dry test and wet test
10. Milli volt drop tests
4.8.5 Technical Particulars

The air break switches shall conform to the following specifications
S.No Description Load Break Switch
1) Rated Voltage 24 kV
2) Normal continuous rating 200A
3) Short time rating: current rms (3 sec) 25kA
peak
4) Power frequency withstand voltage, one minute, dry and wet, rms
funded by KfW
Across isolating distance 60kV

Between phases and to earth 50kV
5) Impulse voltage withstand level, peak (1.2, 50 µs wave)
Across isolating distance 145 kV
Between phases and to earth 125 kV
6) Power frequency puncture withstand 1.3 times the actual flash over
voltage voltage
7) Mainly active load breaking capacity 200A
8) Transformer off-load current breaking 6.3 A
capacity
9) Line charging current breaking 6.3 A
capacity
10) Cable charging current braking 10A
capacity
5 GALVANIZATION
5.1 The galvanized bolts & nuts, spring washers etc. shall be tested for uniformity of coating
and weight of zinc as per ISO 1461:2009(en)or other relevant international standards..
The galvanized steel wires of completed steel strand and completed steel strand shall be
tested for routine and acceptance tests as per ISO 1461:2009(en)or other relevant
5.2 Uniformity in Thickness
The uniformity in thickness of coating shall be tested in accordance with preece test given
in ASTM A123 M T U Z C A or other relevant
international standards. For quick approximate measurements of thickness, magnetic
gauge duly calibrated may be used. Method of testing uniformity on zinc coated articles
shall be in accordance with relevant international standards.
There shall be a Pole Top Cap to protect the pole from Ingress of water and humidity and
rusting.
funded by KfW
5.3 Mass of Zinc Coating

The mass of zinc coating shall be determined in accordance with relevant international
standards..
5.4 Adhesion Test
The adhesion test shall be carried out as per relevant international standards.
6 INSPECTION
6.1 The bidder shall intimate the manufacturing schedule to the Client/Consultant and give a
I waive of inspection by
the client/consultant, the supplier shall be responsible for successful performance of the
equipment" as per the stipulations of the specification.
7 QUALITY ASSURANCE
7.1 Quality Assurance Program
To ensure that the equipment and services under the scope of this contract, whether
-
sub-
the specification, the Contractor shall submit suitable quality assurance programme for
approval of Consultant/Client to control such activities at all points. Such programmes shall
be outlined by the contractor and shall be finally accepted by Client/Consultant after
discussions on award of Contract. A quality assurance programme furnished by the bidder
shall generally cover the following.
a) Contractor organization structure for the management and implementation of the
proposed quality assurance Programme.
b) Documentation control system
c) Qualification data of contractor key personnel.
d) Procedure for purchase of materials, parts, components and selection of sub-
contractor services including manufacturer, source inspection incoming raw
material inspection, verification of material purchases etc.
funded by KfW
e) System for shop manufacturing and site erection controls including process
control and fabrication and assembly control.
f) Control of non-conforming items and system/steps for correcting such items.
g) Control of calibration and testing of measuring and testing equipments.
h) Inspection and test procedure both for manufacture and field activities.
i) System for indication and appraisal of inspection status
j) System for quality audits
k) System for authorizing release of manufactured product to the client/consultant
l) System for maintenance of records
m) System for handling, storage and delivery; and
n) A quality plan detailing out the specific quality control procedure adopted for
controlling the quality characteristics relevant to each item of equipment
furnished.
7.2 Quality Assurance Documents
The contractor shall be required to submit the following quality Assurance Documents
before dispatch of the equipment
i) All Non-destructive Examination procedures, stress relief and weld repair
procedure actually used during fabrication.
ii) Welder and welding operator qualification certificates.
iii) Welder's identification list, listing welder's and welding operator's qualification
procedure and welding identification symbols.
iv) Material mill test reports on components as specified by the specification.
v) Specification plan with verification, inspection plan check points, verification
sketches, if used and methods used to verify that the inspection and testing
points in the inspection plan were performed satisfactory.
vi) Sketches and drawings used for indicating the method of traceability of the
radiographs to the location on the equipment
vii) All Non-Destructive Examination results reports including radiography
interpretation reports.
viii) Stress relief time temperature charts
funded by KfW
ix) Factory test results for testing required as per applicable codes/standards
referred in the specifications.
The authorized representative reserves the right to carry out Quality Audit and
Quality Surveillances of the Systems and, procedures of the contractor/his
manufacturer's quality management and control activities.
8 GUARANTEED TECHNICAL SPECIFICATION

8.1 The tenderers shall give the guaranteed technical particulars of this specification and
submit the same with the tenders.
9 DEVIATION SCHEDULE
9.1 The tenderer shall furnish the details of deviation sought by him from the technical
specification and furnish the same along with the tender. In case of Nil deviation the
same may also be indicated in the schedule and furnished with the tender document.
10 TECHNICAL PARTICULARS
Description Specified
Shape Octagonal / Tubular
Steel grade for pole Fe-510 as per ISO 20805: 2005 or ISO 630 or equivalent as
per BSEN- 10025or other relevant international standards.
Steel grade for Base plate RCC M20
Mild Steel plate S275 as per relevant international
standards.
Height of pole m 9m for LV lines, 11m for 22kV lines
Pole Type Octagonal galvanized steel pole
Min. thickness of Zn. coating on Pole Pole = 125 micron
Min. thickness of Zn. coating on Base Plate = 125 micron
Base -plate
Min. Thickness of Zn coating for 85 micron
Nuts and Bolts and Earth Stud.
funded by KfW
Applicable Standards ISO 1461:2009(en), ISO 20805: 2005 and ASCE (American
Society of Civil Engineers) Manual- 72. /SEI 48-05or other

Specs - Steel Poles & Accessories

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Electrification and Grid Upgrade along the CLSG Transmission Line in Monrovia (Liberia)

S.No DESCRIPTION PAGE NO.

ISO 752:2004 : Zinc Ingot

Insulators for A.C. systems with a nominal voltage greater than

3.0 MATERIALS, CONSTRUCTIONAL DETAILS AND WORKMANSHIP

4.0 THE SPECIFIC TECHNICAL REQUIREMENTS OF VARIOUS EQUIPMENTS

4.1.2 Specific Constructional Requirement

force on insulators, wind force on pole and maximum conductor tension.

HV and HV / LV Mixed Lines:

S.N. Line Locality Conductor Formation Maximum wind span in

configuration are enclosed.

4.1.2.8 Base Plates

4.1.2.10 Fabrications and Finish

4.1.2.11 Design Parameters and Factor of Safety

Allowable Deflection at Pole Top 5% of expose length

4.1.4 Sampling Plan For Testing

4.2 Cross Arm Assemblies for single pole structure

relevant international standards.

4.3 Suspension & Tension Fittings for 22 kV AAAC Conductors:

c. Galvanization Test (for nuts, bolts and washers).

4.3.2.2. Routine Tests

4.3.2.3. Acceptance Tests

4.4 LT Suspension & Anchoring Assemblies:

4.4.2. LT Anchoring Assembly

Conductor Rating Load for deformation Load for

4.4.2.2.2. Flexible Rope of Anchoring Assembly

4.4.2.2.3. Wedge Type Tension Clamp of AA

Conductor Size Rating (Kg.) T start T final

4.4.3. Suspension Clamp:

70-95 13-17 2000Kg. 14000

4.4.4.3.2. Movable (Articulated) Link of SA

4.4.4.3.3. Suspension Clamp of SA

4.5 Stay Sets

4.5.2. Design and Constructional Requirement

4.5.3. Galvanized stranded steel wire strand

4.5.4. Turn Buckle Assembly

nut. The eye of eye bolt nut shall be of 30 mm dia.

4.5.5. Stay Rod

4.5.6.1. General Requirements

4.5.6.2. Type of Insulators

System Voltage (kV) Designation of Insulators

4.5.6.4. Basic Insulation Levels

ii) Type Tests

4.6 GI Spike Earthing set

4.7 Danger Plates

The rear side of the plate shall also be enamelled.

mechanical force with minimum efforts.

4.8.3 Specific Technical Requirements:

4.8.5 Technical Particulars

Across isolating distance 60kV

5.3 Mass of Zinc Coating

8 GUARANTEED TECHNICAL SPECIFICATION

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