EXTERNAL PLANT

ISSUE II: FEBRUARY’94

COLLAPSIBLE STEEL DRUMS

FOR TELECOM CABLES

SPECIFICATION
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TEC
NO.TE/121/AOF-94(OLD No)
New No. G/CBD-02/01.FEB94

© TEC

TELECOMMUNICATION ENGINERING CENTRE

KHURSHID LAL BHAWAN, JANPATH
NEW DELHI-110001
INDIA

All Rights Reserved and no part of this publication may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording, scanning or otherwise without written permission from the Telecommunication
Engineering Centre, New Delhi.
 GOVERNMENT OF INDIA
DEPARTMENT OF TELECOMMUNICATIONS
TELECOM ENGINEERING CENTRE

SPECIFICATION FOR COLLAPSIBLE STEEL DRUMS

FOR TELECOM CABLES

TEC SPEC. NO. TE121AOF94 FEBRUARY 1994

(New No G/CBD-02/01.FEB94)

1.0 Scope:

1.1 This specification details the general requirements to be met by collapsible steel drums
used for supply, transport and storage of telecom cables.
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2.0 General:

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2.1 The specification requires reference to the following specifications. The latest issue of
the specification will be referred to unless reference is made to a particular issue.

i) I.S.168 - Specification for ready mixed paint, air drying, semi-glossy/matt

for-general purposes.

ii) I.S. 808 - Dimensions for hot rolled steel beam, column, channel and angle
sections.

iii) 1.S.822 - Code of procedure for inspection of welds.

iv) I.S.1363 - Specification for hexagon head bolts screws and nuts of product
grade C.

v) I.S.1730 - Spec. for steel plates, sheets, strips and flats for structural and
general engineering purposes - dimensions.

vi) I.S.2062 - Specification for steel for general structural purpose.

vii) I.S.2074 - Specification for ready mixed paint, air drying, red oxide-zinc
chrome, priming.

viii) I.S.9595 - Recommendations for metal arc welding of

carbon and carbon manganese steels.

ix) ITD S/WT-I08 - specification for cable drum.

2.2 This specification covers only the technical requirements and does not include all the
provisions of a contract.

3.0 Steel and Fastener:

 3.1 Steel: The steel used in the construction of the drum shall conform to Grade A of 1S-
2062 and shall meet the parameters detailed below:

i) Chemical composition:

Carbon Max. 0.23%

Manganese Max. 1. 50%
Sulphur Max. 0.05%
Phosphorous Max. 0.05%

ii) Mechanical properties: The samples of steel when tested for tensile strength and
elongation shall meet the following requirements:

(a) Tensile strength - Min. 410 MPa

(b) Elongation - Min. 23%
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3.1.1 The drum manufacturer shall furnish a certificate either from the steel manufacturer or
from a recognised laboratory regarding the conformance to 1S-2062 for the quality of
the material.

3.2 Fasteners: The fasteners shall conform to 1S-1363 and shall be Nickel/chromium plated.

3.2.1 The drum manufacturer shall furnish a certificate from the manufacturer of fasteners or
from a recognised laboratory regarding the conformance of the fasteners to 1S-1363.
The fasteners will be visually examined by the inspector for the coating.

4.0 Construction of the drum:

4.1 Detailed constructional features and dimensions shall generally be in accordance with
the Table-1 & the Drawings CD/01, CD/02 and CD/03.

4.2 The drum shall be designed in such a way that assembly and dismantling should not
require any special arrangements, since these are required to be dismantled in the field.

4.3 The drums shall be designed for lifting in the following modes:

(a) Spindle lifting - the drum with cable can be lifted by an overhead crane and spreader
beam with the. help of chains or slings from both ends of a suitable spindle passed
through the bore of the centre tube/bosses, or by two suitable jacks operating on each
end of the spindle.

(b) Flange lifting - the drum wi.tll the cable may be lifted by an elevating platform or
forks of a forklift. The forks of the forklift would span both flanges and lie parallel with
the drum spindle axis.

4.4 A plate 150 mm x 150 mm shall be permanently fitted to the outside surface of each
flange to which cable identification labels, test reports etc., can be attached or mounted.
 5.0 Materials for components:

5.1 Assembly of flanges:

5.1.1 Flat Rim: Flat rim shall be made from steel flats of 75 mm width and 8 mm thickness
conforming to 15-1730 (Hot rolled). To make up the required length, flats of standard
length shall be welded. The nominal mass for 75 mm x 8 mm flat shall be 4.71 kg/m.

5.1.2 Inner ring: The inner ring will serve as the landing for the barrel plate in the assembly of
the drum. This shall be formed from MS angles conforming to IS-808, or alternatively
from MS flats conforming to IS-1730, and as per the following requirements:

Flange dia Details of MS angles Details of flats

(mm) Size (mm) Nom. Mass Size (mm) Nom. Mass
kg/m kg/m
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upto 2100 75x75x6 6.8 100x6 4.71

Above 2100 100x100x6 9.2 100x8 6.28

5.1.3 A corrugated M.S. sheet with the pitch as shown in Drawing CD/01, shall be continuously
welded to both inner ring and rim on both sides of the sheet to complete the assembly
of the flange. The inner surfaces of the flanges shall be perpendicular to the axis of the
spindle bore.

5.1.4 Necessary reinforcement in the form of cross arms is to be provided inside the inner ring
as shown in Drawing CD/01. A spindle bore of 80 mm dia at the centre and drive hole of
50 to 52 mm dia as shown in Table-1 at a distance of 300 mm or less from the centre
shall be provided to facilitate loading and transmission of motion on take-up assembly.

5.2 Cable end guide:

5.2.1 This shall be provided on one of the flanges of the drum as shown in Drawing CD/02. The
thickness of the guide shall be such that the cable can rest on the guide without slipping.

5.3 securing of Cable Ends:

5.3.1 The inner end of the cable will be secured to the flange by tieing to the distance pieces
provided at 8 places, equally spaced to the extent possible on the inner side of the flange

as shown in Drawing CD/01 and it should rest over the cable end guide. The top end of'
the cable shall be secured to one of the flanges by tieing the same to the distance pieces
provided as above.

5.4 Drum Barrel:

 5.4.1 This will be formed from the MS sheet conforming to grade A of IS-2062 and having a
minimum thickness of 2 mm upto the drum size 2100 mm and between 2 mm & 3 mm to
drum sizes above 2100 mm. Both ends of barrel shall be welded to form a cylinder of
diameter shown in Table-I. The minimum barrel diameter shall not be less than 14 D +
150 mm, where 0 is the final diameter of the cable in mm.

5.5 Tie rods:

5.5.1 The flanges shall be securely clamped together by the number of tie rods specified in the
Table-I. The tie rods shall be equally spaced and arranged on the pitch circle dia D, where
D= D2-100 mm (ref Drawing CD/01).

5.6 Width between the flanges (Traverse):

5.6.1 The width between the flanges shall conform to the dimensions shown in Table-I.
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5.7 Internal distance bolts:

5.7.1 Internal distance bolts of M20 size shall be provided to prevent deformation of flanges
curing loading/unloading operations. These blots shall be equally spaced and arranged
100 mm below the rim.

Note: These will not be insisted for a period of one year, during which period the
performance of the drums will be watched, and a decision on the requirement will be
reviewed at the end of one year.

5.8 Covering of the drum:

5.8.1 The drum shall be covered with a steel sheet of 1 mm thickness or with wooden battens.
The covering sheet will be fixed to the rim of the flanges at equal intervals of 500 mm by
means of screws and nuts confirming to IS-1363.

5.8.2 Wooden battens: The requirements of wooden battens shall be as in ITD spec. No. S/WT
108.

Note: The use of wooden battens for covering shall be reviewed after a period of trial for
one year.

6.0 Welding:

6.1 The welding procedure should be as specified in IS-9595, such that the welded portions
comply with the requirements specified in the subsequent clauses, in regard to their
local properties and also to their influence on the construction of the drum.

6.2 All the welded parts shall be of the highest standard, and shall conform to the following:

6.2.1 Visual Inspection:- The welded parts shall be free from the following types of defects,
when examined visually, preferably with the assistance of a magnifying lens or the
 magnifying torch:

Weld defects occurring at the surface such as blow holes, pipes, exposed porosity,
exposed inclusions, unfilled crate and unfused welds.

6.2.2 Non-destructive test:- The completed welds shall be subjected to the non-destructive
testing by Liquid Penetrant Detection Flaw method as per 15-822 and the requirements
shall conform to the following:

There shall not be any cracks and blow holes on the welded surface. The detection of
isolated pin holes up to a diameter of 1.5 mm will not be a cause for rejection.

6.3 In the case of dispute, or as alternatives to the above method, any of the following NDT
methods as per-IS-822 may be adopted with concurrence of the inspecting authority.

a) Radiographic examination
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b) Ultrasonic testing, and

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c) Magnetic particle flaw detection.

7.0 Painting of the drum:

7.1 The steel drums shall be painted with one coat of metal primer as per IS-2074 and two
coats of anti-corrosive paint NO.356 Golden Yellow colour as per 15-168.

7.2 Both metal primer and anti-corrosive paint coatings shall meet the following
requirements:

i) Material conformance to : Drum manufacturer shall furnish a

1S-2074 for primer and either from the manufacturer of the
paints IS-168 for anti-corrosive paint. Paints or from a recognised
. laboratory.

ii) Drying time, hard dry : Not more than 18 Hrs for the primer
and not more than 6 Hrs for the anti-
corrosive paint.

iii) Finish : Smooth finish - Visual examination.

iv) Colour : Visual examination.

v) Scratch hardness : No such scratch as to show the bare

metal.

vi) Resistance to salt spray : Shall not show any signs of corrosion
after continuous exposure to salt
spray for four days.

vii) Flash point : Minimum 30 deg. C.

 7.3 All name plates shall be painted in yellow colour and all letters shall be black in colour.
8.0 Workmanship and finish:

8.1 The workmanship of the drum shall conform to the best trade practices. The principle of
standardisation shall he adopted to the maximum extent, consistent with the
specification requirements and good engineering practice.

9.0 Tests on assembled drums:

9.1 Visual inspection:

9.1.1 The drum shall be visually examined for absence of broken flanges and loosely fitted tie
rods. There shall be no sharp edges, protrusions, cavities, grooves, roughness, weld
spatter, weld flux etc. on any surface, especially that which may Come into contact with
the cable.
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9.2 Deflection of the flanges:

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9.2.1 with the drum fully loaded after being wound with cable at tensions up to 500 kg, the
deflection of the flanges shall not exceed 3% of width between the flanges.

9.3 Drop test on loaded drum:

9.3.1 Drums shall be loaded to their normal capacity and the test performed on both covered
and uncovered samples. The drum shall be rolled without any initial speed, off a step of
the height tabulated below, on to a substantially flat concrete base covered with soft
wooden planks:

Gross drum Wt. (Drum &. Cable) Step height

Up to 3000 kg 1000 mm

Over 3000 kg 600 mm

9.3.2 The drum shall fall freely to land on both rims simultaneously and perpendicularly.

9.3.3 The drum is considered to have passed the test, if there is no resultant damage to the
cable and the cable drum remains in a satisfactory condition without break-up of any
components. It shall also be possible to continue normal use of the drum and no
destruction or hazard shall occur which would hamper cable laying operation.

10.0 Test certificate:

10.1 The manufacturer or supplier shall, when so required by the purchaser or the testing
authority, supply a test certificate granted by a recognised laboratory giving the results
of the chemical, physical and other tests batchwise, indicating that the materials used in
the manufacture of the drums comply with the requirements of this specification.

11.0 Test plan:

 11.1 The test plan for various tests is in Appendix-I.

12.0 Markings on the drum:

12.1 Each flange shall be stencilled in a contrasting colour on exterior surfaces of the drum
with the words "Roll this way" and these words shall be underlined by a direction arrow.
The arrow shall point in the direction opposite to the direction in which outer end of the
cable emerges. The markings shall be clear, distinct and visible from a distance of about)
3 metres.

12.2 Other markings shall be clearly stencilled "or otherwise marked in accordance with the
marking instructions "given in the cable specifications and also as shown in Drawing CD/
03).

12.3 Each drum shall bear a distinguishing number neatly painted on both the flanges for
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individual identification.

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13.0 Procedure for loading and unloading:

13.1 The procedure for loading and unloading of the drum is outlined in Section-A of
Appendix-II.

14.0 Procedure for assembly and dismantling:

14.1 The procedure for assembly and dismantling of the drum is outlined in Section-8 of
Appendix-II.

**********END OF THE SPECIFICATION***********

 TABLE - 1
DRUM DIMENSIONS (in mm)

Flange
700 950 1200 1500 1650 1650 1850 2150 2300 2600 280
dia (D1 )

Barrel 400 400 600 700 800 960 960 1270 1400 1500 180
dia (D2)

300 575 700 825 825 825 825 825 900 900 100
Traverse
(L1)

Spindle <--------------------------------------------------------------------80--------------------------------------------
bore (d1)
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Drive hole <---------------------------------------------50 to 52--------------------------------------------------------
dia (d2)

Tie rod <-----------------------------------------------------20/25----------------------------> 25 25 2

Dia

No. of <----------------------------- 4 -------------------------------------------------------------------------------------

tie rods
per drum

Notes:
1. Tolerances on the above dimensions shall be as per the Drawing CD/01.

2. In the case of drums with flange dia. up to 2150 mm, the tie rods 20 mm dia. or
alternatively 25 mm dia. (left· to the discretion of manufacturer) can be used.

3. The above table is only for guidance. If any cable manufacture desires to have sizes other
than those covered in the Table-l, he do so subject to the following conditions, and also
that the differ dimensions, with the relevant drawings be furnished to DOT at the t of
offer for inspection.

Conditions:

i) The minimum barrel diameter shall not be less than 14D+150 m where D is the final
diameter of the cable in mm. The barrel diameter shall not be less than 40% of the
flange diameter.

ii) The width between the flanges (traverse) shall not be less the 33% and not more than
66% of the flange diameter.
 APPENDIX - I
TEST PLAN - TEC SPEC NO. TE121AODR2(New No G/CBD-02/01.FEB94)

Sl. Clause Name of Test Sampling plan

No No.
1 3.1 i) Material conformance to Test certificate from manufacturer of steel or
5.1.3 Grade A of 15-2062 from a recognised laboratory for the first batch of
5.4 & supply and then once a year.
5.8.1

ii) Chemical -do-

composition
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iii) Tensile Strength 5 samples for the first batch of supply and then
once a year.

iv) Elongation -do-

2 3.2 Fasteners Test certificate from the manufacturer of the

Materials fasteners or from a recognised laboratory for the
Conformance first batch of supply and then once in a year.
To IS-1363

3 5.1.2 Inner ring: Test certificate from the manufacturer of angles

Materials or from a recognised laboratory for the first batch
Conformance of supply and then once in a year.
To IS-808/
IS-1730

4 6.3 NDT of welds Test certificate from a recognised laboratory –

a) In case of dispute, one drum from the disputed

batch
b) If an alternative, one drum from the first batch
of supply and then once a year
 5 7.1 Paints: Test certificate from the manufacturer of paint or
7.2.1 i) & i) Material conformance and IS- from a recognised laboratory for the first batch of
ii) 168 supply and then once a year.

ii) Drying time, hard dry Test certificate from the manufacturer of paint or
from a recognised laboratory for the first batch of
supply and then once a year.
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SAMPLE TESTS:

2
3.2.1

4.1 to 4.4,
5.1.3,
5.1.4 &
5.2 to 5.7
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Ni/Cr plating –
Visual inspection

Visual examination &

dimensions of the drum as per
Table-1
10 nos. for each batch of supply.

1 sample/size/batch of supply

3 5.1.1 Flat for rim:

i) Dimensions 3 nos./each batch of supply.
ii) Nominal mass - Do-

4 5.1.2 Inner ring:

i) Dimensions 3 nos./size/batch of supply.
ii) Nominal mass -do-

5 5.8.2 Wooden battens- As in ITD Spec. No. S/WT-108

material conformance &
thickness

6 7.2 vi) & i) Resistance to salt spray One sample from the first batch of supply and
vii) then once a year.
ii) Flash point -Do-
 7 6.2.1 & Test on welds One for every batch of 20 drums or less
6.2.2

8 9.2.1 Deflection of flanges on loaded The first drum from the particular drum
drum manufacturer and subsequently either one
drum for every 200 or one drum in a quarter
each size, each drum manufacturer.

9 9.3.1 Drop test on loaded drum -Do-

ROUTINE TESTS TO BE CONDUCTED ON EACH DRUM:

Sl. Clause No. Name of test

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No
1 5.8 Covering of the drum with steel sheet/wooden battens - visual
inspection for absence of gaps to avoid pilferage of cable.

2 7.2 iii) i) Finish

iv) & v) ii) Colour
iii) Scratch hardness
colour of name plates

3 7.3 Colour of name plates

4 9.1.1 Visual inspection
5 12.0 Marking on the drum

*************** End of test plan***************

 APPENDIX - II

Section-A: PROCEDURE FOR LOADING AND UNLOADING

1. The loading/unloading of drums should be done with the help of a crane. During loading
the following points may be carefully looked into:
a) The drum should be lifted by chains or slings from both ends of a suitable spindle passed
through spindle bore.

b) Alternatively, the drum can also be handled during loading by forklift. When lifted by
forklift the drum may be raised by the forks of the forklift. The forks of forklift should span
both flanges and lie parallel to the spindle axis of the drum.

2. Movement of the Drum: The drums should always be transported/moved for laying
operations on cable laying trailers only. In exceptional circumstances when such facility
cannot be immediately provided, the drums can be rolled taking sufficient precaution to
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ensure proper movement/braking arrangements.

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3. Storing: The drums both in assembled condition and dismantled condition shall be stored in
such a way that they should not get corroded.

Section-B: PROCEDURE FOR ASSEMBLY AND DISMANTLING:

I. Procedure for Assembly:

1. Place the flange wheel on wooden plates facing the outside of it to the floor.

2. Put the cylindrical barrel on the flange wheel in such a way that it encircles the inner ring.

3. Fix up the upper flange wheel in such a way that the inner ring is fixed inside the barrel.

4. Insert the tie rods in such a way that these pass through the appropriate holes.

5. When the cylinder is fixed in both flange wheels completely, put the nuts on the tie rods
and tighten them by means of a torque wrench applying the torque of one ton.

6. After completion of tightening of the nuts on both flange wheels raise the drum to ordinary
position and brake the rolling of the drum by means of two wooden blocks.
 II. Procedure for Dismantling:

1. Remove the nuts of the tie rods on one of the flange wheels and lower the drum gently such
that this side comes downwards.

2. Remove the nuts of tie rods from the top flange also.

3. Remove the top flange wheel from tie rods.

4. Remove the screws from the bottom flange to release the barrel.

5. Stack the flanges and barrel for subsequent transportation.

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