GES 10710

Technical Specification of GECOL

Steel Tower for 66kV

(Revision history)
- Issued on: Jan. 01, 2007

General Electricity Company of Libya

 Contents

1 GENERAL................................................................................................................................................5

2 TOWER TYPES......................................................................................................................................5

3 TOWER HEIGHTS.................................................................................................................................6

4 CLEARANCE FROM TOWER STEELWORK..................................................................................6

5 DESIGN BASIS FOR LOADINGS........................................................................................................6

5.1 LOADS ON SUPPORTS.............................................................................................................................7

5.2 SPECIAL LOADINGS...............................................................................................................................8
5.3 DESIGN TEMPERATURE........................................................................................................................10
5.4 CONSIDERATION OF CONDUCTOR, EARTHWIRE AND INSULATOR.........................................................10

6 LOADING ASSUMPTIONS.................................................................................................................10

6.1 SUSPENSION (TANGENT) TOWERS – 1DD02 TYPE TOWER..................................................................10

6.2 ANGLE TOWERS – 1DD10, 1DD30 AND 1DD60 TYPE TOWER...........................................................11
6.3 DEAD END/90° TOWERS – 1DD90 TYPE TOWER.................................................................................12
6.4 GANTRY TOWER – 1GT00 TYPE TOWER..............................................................................................13

7 STEEL QUALITY.................................................................................................................................13

7.1 GENERAL.............................................................................................................................................13
7.2 BOLTS AND NUTS.................................................................................................................................15
7.3 STEP BOLTS..........................................................................................................................................15

8 TOWER DESIGN..................................................................................................................................15

8.1 GENERAL.............................................................................................................................................15
8.2 MINIMUM THICKNESS OF MEMBERS....................................................................................................16
8.3 TOWER BASES......................................................................................................................................16
8.4 UNEQUAL LEG EXTENSIONS – HILL-SIDE CONDITIONS........................................................................16
8.5 LONG TENSION MEMBERS....................................................................................................................17
8.6 CONNECTIONS......................................................................................................................................17
8.7 FILLERS................................................................................................................................................17
8.8 CROSSARMS.........................................................................................................................................17
8.9 CONDUCTOR AND OVERHEAD EARTHWIRE ATTACHMENTS..................................................................18

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 8.10 MAXIMUM LENGTH OF MEMBERS...................................................................................................18
8.11 FACTOR OF SAFETY.........................................................................................................................18
8.12 DETERMINATION OF SLENDERNESS RATIO (L/R).............................................................................18
8.13 NET SECTION...................................................................................................................................19
8.14 ALLOWABLE STRESSES....................................................................................................................19
8.15 ULTIMATE ALLOWABLE BENDING, SHEARING AND BEARING STRESS..............................................21
8.16 BEAM – COLUMNS – COMBINED AXIAL COMPRESSION AND BENDING...........................................22
8.17 MAXIMUM ALLOWABLE SLENDERNESS RATIOS, L/R.......................................................................22
8.18 ALLOWABLE BOLT STRESSES...........................................................................................................22
8.19 BOLT SPACING AND EDGE DISTANCES.............................................................................................23

9 FABRICATION......................................................................................................................................23

9.1 GENERAL.............................................................................................................................................23
9.2 PREPARATION.......................................................................................................................................23
9.3 SHEARING AND CUTTING.....................................................................................................................23
9.4 USE OF TORCH.....................................................................................................................................23
9.5 HOLES..................................................................................................................................................23
9.6 BENDING..............................................................................................................................................24
9.7 WELDING.............................................................................................................................................24
9.8 GALVANIZING.......................................................................................................................................24

10 TOWER ACCESSORIES.....................................................................................................................25

10.1 ANTI-CLIMBING DEVICES AND STEP BOLTS....................................................................................25

10.2 DANGER, NUMBER, PHASE AND CIRCUIT PLATES............................................................................27

11 DRAWINGS...........................................................................................................................................28

11.1 GENERAL........................................................................................................................................28
11.2 TYPE OF DRAWINGS REQUIRED.......................................................................................................29
11.3 OTHER REQUIREMENTS...................................................................................................................31
11.4 REVIEW...........................................................................................................................................31

12 MARKING.............................................................................................................................................31

12.1 MEMBERS AND PLATES...................................................................................................................31

12.2 BOLTS.............................................................................................................................................32

13 TESTING AND INSPECTION............................................................................................................32

13.1 TESTING..........................................................................................................................................32
13.2 FULL SCALE TOWER LOADING TEST................................................................................................32

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 13.3 ASSEMBLY TEST..............................................................................................................................34
13.4 OTHER TESTS..................................................................................................................................34

14 SUBMITALS REQUIRED WITH TENDER......................................................................................35

15 SUBMITALS REQUIRED FOLLOWING AWARD OF CONTRACT...........................................35

16 PACKING AND DELIVERY...............................................................................................................36

17 DOCUMENTATION.............................................................................................................................37

18 Warranty...................................................................................................................................................37

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 GES (Technical Specification of GECOL)
Steel Tower for 66kV

1 General
The Supplier shall design, supply and fabricate all steel structures and necessary
accessories for 66kV overhead transmission line double or single circuit tower with single
earthwire. The structural designs shall be based on this specification and the attached
drawings and shall be in accordance with the most modern techniques of design and
fabrication.
The Supplier shall be responsible for determining the precise loadings for each type of
tower designed using the methods and loading combinations outlined in this specification.
The towers shall be of galvanized lattice steel construction and be square in plan. All
towers shall have an independent foundation for each of the four legs.

2 Tower types
The tower types are classified in Table 1 of this specification according to the line angle.
Table 1- Tower types
Maximum Maximum
Specification Line Angle
Type Description Wind Span Weight
No. (Degrees)
(m) Span (m)
1071010 1D(S)D02 Tangent Suspension 0 to 2 350 385
1071020 1D(S)D10 Light Angle Strain 2 to 10 350 525
Medium Angle
1071030 1D(S)D30 10 to 30 350 525
Strain
1071040 1D(S)D60 Heavy Angle Strain 30 to 60 350 525
Dead End Strain 0 to 45 entry 230 345
1071050 1D(S)D90
Extra Heavy Angle 60 to 90 350 525
1071060 1GT00 Dead End Strain 0 230 345
 Minimum weight spans to be applied 245m for Tower and Foundation design
 Type: First digit represents the number of sub-conductors per phase, the letters in
second is single (S) circuit or Double (D) circuit and third position represent the
nominal voltage 66kV and the last two digits represent the maximum line angle
for the tower. But GT means gantry tower.

3 Tower heights
Suppliers shall determine the basic height for each type of tower. The basic height of
tower shall maintain more than 8.0m Min clearance from the bottom conductor to the
normal ground level at the lowest point in the span. The sag in the conductor shall be at

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75deg. C still air.
All towers shall be provided with body extensions which will increase the tower height
by 3.0m, 6.0m and 9.0m as required. The Supplier may propose, for the approval of
GECOL, tower body extensions of greater height if supplier considers the provision of
such body extensions to be economic.
The Supplier shall also design and provide for variation of the lengths of individual legs
of both basic height towers and of body extensions so that the legs may be either 1.0m and
2.0m longer or 1.0m and 2.0m shorter than standard. The varied leg lengths shall be used
where towers are located on sloping ground.
The detail information of clearances shall be considered with GDS 6200.

4 Clearance from tower steelwork

A spacing from the conductor to tower members are determined based on flash over
characteristics of insulators and air gaps for swing angles of the insulator string as well as
the jumper conductor.
A normal insulation clearance and a minimum insulation clearance are considered,
which shall be maintained when the insulator string on the jumper sways by the normal or
maximum swing angle.
The normal swing angle will occur and last for a finite period of time during the
operation, while the maximum swing angle will occur only momentarily.
The allowable swing angle and clearances are defined as followings;
(a) Between live metal and tower steelwork in 0 deg. swing; 760mm
(b) Jumper swinging 30 deg. to the vertical; 650mm
(c) Suspension insulator string included 60 deg. to the vertical; 650mm
(d) Shield angle of earthwire in still air; 35 deg. Max.
(e) Horizontal spacing between circuits; 5.0m Min.
(f) Vertical spacing between phases on same circuits; 2.7m Min.

5 Design basis for loadings

The tower design loadings shall be calculated by the Supplier in accordance with ASCE
(American Society of Civil Engineers) Manual 10 - Design of Latticed Steel Transmission
Structure – and as outlined hereafter. Shielding factor of the leeward face shall be applied
to 1.5 for tower and solidity factor of insulator shall be applied to 0.5 for insulator.

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 5.1 Loads on Supports

5.1.1 Transverse loads

(a) Due to Wind on conductors


Case1: In case of area that wind velocity is 35m/s

Maximum projected area of conductors; 90 daN/m2


Case2: In case of area that wind velocity is 45m/s

Maximum projected area of conductors; 145 daN/m2

(b) Due to Wind on earth wire


Case1: In case of area that wind velocity is 35m/s

Maximum projected area of earth-wire; 100 daN/m2


Case2: In case of area that wind velocity is 45m/s

Maximum projected area of earth-wire; 160 daN/m2

(c) Due to Wind on Insulators


Case1: In case of area that wind velocity is 35m/s

Maximum cylindrical area of insulator; 0.5 × 180 daN/m2


Case2: In case of area that wind velocity is 45m/s

Maximum cylindrical area of insulator; 0.5 × 285 daN/m2

(d) Due to Wind on Tower Itself


Case1: In case of area that wind velocity is 35m/s

Maximum projected area of tower steel members; 1.50 × 235 daN/m2


Case2: In case of area that wind velocity is 45m/s

Maximum projected area of tower steel members; 1.50 × 380 daN/m2

(e) Combined load due to line deviation

(f) Diagonal wind load; See clause 5.2.3

35 m/s of wind velocity will be applied to the general regions. 45m/s of wind velocity
will be applied to the regions of Jalo, Tripoli city and Ghat

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5.1.2 Vertical loads
(a) The weight of conductors and earthwire
(b) The weight of insulators and hardware for conductors and earthwire
(c) Special vertical load due to different level of tower with adjacent towers
(d) Tower dead weight.

5.1.3 Longitudinal loads

(a) Unbalanced tension load due to different span of strain towers;
20% of maximum working tension shall be considered at normal condition for
1DD30, 1DD60 and 1DD90 (angle tower condition only) type tower
(b) Maximum working tension due to broken condition of conductors and earthwire
(c) Maximum working tension on terminal position (dead end) tower
(d) Diagonal wind load; see clause 5.2.3

5.2 Special Loadings

5.2.1 General
Special care is required during construction and maintenance operations as they are the
occasions when failure of a line component is most likely to cause injury or loss of life.
Construction and maintenance practices should be regulated to eliminate unnecessary
and temporary loads which would otherwise demand expensive reinforcing of the supports.

5.2.2 Construction and Maintenance Loads

(a) Tower erection procedures frequently impose dynamic and unbalanced loads. The
strength of all lifting points and of all components should be verified for the static
loads produced by the proposed erection method.
(b) In the calculation of loads on the structures, wire tensions shall be used as everyday
temperature still air condition.
(c) Vertical loads resulting from the tensions as determined above shall be calculated for
the vertical angles applicable in any combination of loads
(d) Angle tower should withstand the transverse loads produced by the tensions as
determined above.
(e) Supports used as dead-ends during stringing and sagging shall withstand longitudinal
loads resulting from the sagging tensions given above in any combination of loads.

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5.2.3 Diagonal Wind load
Transverse wind loadings shall be calculated as per Wind span in clause 2, but with ø =
45º. These shall be combined with the vertical loads due to the weight spans given in
clause 2.
This load case applied to 1DD02 and 1DD10 type tower only.
The diagonal wind loading shall not be considered as the broken wire conditions.

In case of area that wind velocity is 35m/s, the diagonal wind loads may be considered
as follows:

For tower body; (Pa × 1.42 × 1.5 × 235 daN/m2) × 0.71 in the transverse and
longitudinal direction simultaneously.

For crossarm; (Pa × 0.75 × 1.5 × 235 daN/m2) × 0.71 in the transverse and
longitudinal direction simultaneously.

For conductor; (Pa x 0.75 x 90 daN/m2) × 0.71 in the transverse and longitudinal
direction simultaneously.

For earth wire; (Pa x 0.75 x 100 daN/m 2) × 0.71 in the transverse and longitudinal
direction simultaneously

In case of area that wind velocity is 45m/s, the diagonal wind loads may be considered
as follows:

For tower body; (Pa × 1.42 × 1.5 × 380 daN/m2) × 0.71 in the transverse and
longitudinal direction simultaneously.

For crossarm; (Pa × 0.75 × 1.5 × 380 daN/m2) × 0.71 in the transverse and
longitudinal direction simultaneously.

For conductor; (Pa x 0.75 x 145 daN/m 2) × 0.71 in the transverse and longitudinal
direction simultaneously.

For earth wire; (Pa x 0.75 x 160 daN/m 2) × 0.71 in the transverse and longitudinal
direction simultaneously.

Where, Pa = Projected area of one face

5.2.4 Single circuit load

All double circuit towers shall be designed for both single circuit and double circuit
loading. The single circuit loading includes one earthwire and only one three phase circuit.
The single circuit loading shall not be considered as the broken wire conditions.

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5.2.5 Line man
All structural members that may be required to support a linesman should demonstrate,
by calculation, the capacity to support a 1500N load, applied vertically at their mid-point.

5.3 Design temperature

The following design temperatures shall be considered for tower design
(a) EDS (Every Day Stress); +25 degree C still air condition.
(b) MSC (Maximum Sag Condition); +75 degree C still air condition.
(c) MLC (Maximum Load Condition); +10 degree C with wind condition.
(d) Minimum temperature for reference; -5 degree C still air condition.

5.4 Consideration of conductor, earthwire and insulator

The kinds of conductor and earthwire to be used and insulator set shall be considered in
design according to related GDS which will be supplied by GECOL.

6 Loading assumptions

6.1 Suspension (Tangent) Towers – 1DD02 type tower

6.1.1 General
Suspension (Tangent) towers shall be designed to withstand the different combinations
of loads as specified hereafter. All members sloped at less than 30º to the horizontal shall
be capable of carrying a central vertical load of 1500N without permanent distortion.

6.1.2 Design Spans

Design spans shall be as given in Clause 2 .

6.1.3 High Wind Loading – Maximum Weight span

The towers shall be designed to withstand the transverse wind loadings acting on the
different components of the line calculated as per Clause 5.1 . These shall be combined
with the vertical loads (including those due to insulators and line accessories), due to the
weight spans given in Clause 2 .

6.1.4 High Wind Loading – Minimum Weight span

Transverse wind loadings shall be as in 6.1.3 above combined with minimum vertical
loads.

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6.1.5 Broken wire loading
The towers shall be designed to withstand the breakage of any one conductor or one
earthwire. The working tensions of conductor shall be taken 70% of maximum working
tension.
50% of the vertical loads shall be applied to the attachment points on the broken side of
the conductor and/or earthwire.

6.1.6 Construction and Maintenance Loads

The tower shall be designed accordance with clause 5.2.2 .
The towers shall be designed to withstand the maximum stringing or sagging tensions
combined with the resultant vertical loads.
These loading conditions shall be verified with every possible combination of stringing
sequence on conductors and earthwire.

6.2 Angle Towers – 1DD10, 1DD30 and 1DD60 type tower

6.2.1 General
The towers shall be designed for both single circuit and double circuit loading as
described in 6.1.1 .
The additional loads due to wind on jumper strings, and the weight of jumper strings,
shall be taken into account when determining the design loadings of heavy angle (1DD60
type) tower only.
Angle towers shall be designed to withstand the different combinations of loads as
described hereafter. All members sloped at less than 30° to the vertical shall be capable of
carrying a central vertical load of 1500N without permanent distortion.

6.2.2 Design Spans

These shall be as given in Clause 2 .

6.2.3 High Wind Loading – Maximum Weight span

The towers shall be designed to withstand the transverse wind loadings acting on the
different components of the line calculated as per Clause 5.1 . These shall be combined
with the vertical loads (including those due to insulators and line accessories), due to the
weight spans given in Clause 2 .

6.2.4 High Wind Loading – Minimum Weight span

The loads as calculated in Clause 6.2.3 shall be applied with minimum vertical loads.

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6.2.5 Broken Wire Loading – Maximum Weight span
Any two broken conductors or one conductor and one earthwire with minimum angle
and maximum angle of line deviation and tensions in unbroken conductors and vertical
loads calculated as above. 50% of the vertical loads shall be applied to the attachment
points on the broken side of the conductor and/or earthwire.
For the single circuit tower, broken condition shall be considered any one conductor or
earthwire broken with above loads.

6.2.6 Broken Wire Loading – Minimum weight span

The loads as calculated in Clause 6.2.5 shall be applied with minimum vertical loads.

6.2.7 Construction and Maintenance Loads

The tower shall be designed in accordance with clause 5.2.2 .
The towers shall be designed to withstand twice the maximum stringing or sagging
tensions combined with the resultant vertical loads.
These loading conditions shall be verified with every possible combination of stringing
sequence on conductors and earthwire.

6.3 Dead End/90° Towers – 1DD90 type tower

6.3.1 General
Dead End/90° towers shall be designed for both single and double circuit loading as
described in Clause 6.1.1 .
The additional loads due to wind on jumper strings and the weight of jumper strings
shall be taken into account when determining the design loadings of these towers.
Dead end towers shall be designed to withstand the different combinations of loads as
described hereafter.
All members sloped at less than 30º to the vertical shall be capable of carrying a central
vertical load of 1500N without permanent distortion.

6.3.2 Design Spans

These shall be as given in Clause 2 .

6.3.3 High Wind Loading – Maximum Weight span

The towers shall be designed to withstand this loading condition as calculated in clause
6.2.3 for an angle of line deviation of 90º.

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 The tower shall be designed to withstand, when erected at actual angles to the incoming
line, the loads imposed by the conductors and earthwires strung on the line side only with a
longitudinal wind on the tower.
The entry line angle of Dead end tower shall be considered from 0 to 45 degrees with
maximum working tension and the other side, 0 degree with slack span.

6.3.4 High Wind Loading – Minimum Weight span

The loads as calculated in clause 6.3.3 shall be applied with minimum vertical loads.

6.3.5 Broken Wire Loading – Maximum Weight span

The tower shall be designed to withstand this loading condition as for clause 6.2.5 for
both 0º and 90º angle.

6.3.6 Broken Wire Loading – Minimum Weight span

The loads calculated as clause 6.3.5 above shall be applied with minimum vertical loads.

6.3.7 Construction and Maintenance Loads

The loads calculated and applied in clause 6.2.7 above shall be applied for angles of 0°
and 90°.

6.4 Gantry tower – 1GT00 type tower

6.4.1 General
Gantry tower shall be designed for entry position of substation or power plant. This type
of tower has to one beam and two columns for one circuit with two earth wires.

6.4.2 Design spans

These shall be as given in Clause 2 .

6.4.3 High wind loading

The towers shall be designed to withstand the transverse wind loadings acting on the
different components of the line calculated as per Clause 5.1 and maximum working
tensions in longitudinal direction. These shall be combined with the vertical loads
(including those due to insulators and line accessories), due to the weight spans given in
Clause 2 .
Broken wire, diagonal wind, construction and maintenance conditions are not required
for this tower.

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7 Steel quality

7.1 General
The steel to be supplied shall comply with the requirements of the following standards
or other equivalent standards and codes. At the discretion of the designer some or all of the
tower members may be used high tensile steel, but all bolts shall be high tensile steel.

7.1.1 International Standards Organization

(a) ISO Standard ISO 630: Structural Steels
(b) ISO Recommendation ISO/R657: Hot-Rolled Steel Sections

7.1.2 American Society for Testing and Materials

(a) ASTM A36: Specification for Structural Steel Standard
(b) ASTM A121: Specification for Zinc-Coated (galvanized) Steel Barbed Wire
(c) ASTM A123: Specification for Zinc (hot-galvanized) Coatings on Products fabricated
from rolled, pressed, and forged steel shapes, plates, bars and strips
(d) ASTM A143: Safeguarding against embrittlement of hot galvanized structural steel
products and procedure for detecting embrittlement
(e) ASTM A153: Standard Specification for Zinc Coating (hot dip) on Iron and Steel
Hardware
(f) ASTM A239: Standard Test Method for Locating the Thinnest Spot in a Zinc
(Galvanized) Coating on Iron or Steel Articles by the Preece Test
(g) ASTM A242: Standard Specification for High-Strength Low-Alloy Structural Steel
(h) ASTM A307: Standard Specification for Carbon Steel Externally Threaded Standard
Fasteners
(i) ASTM A325: Standard Specification for High-Strength Bolts for Structural Steel
Joints
(j) ASTM A370: Method and Definitions for Mechanical Testing of Steel Products
(k) ASTM A384: Safeguarding against Warp age and Distortion during Hot-Dip
Galvanizing of Steel Assemblies
(l) ASTM A385: Recommended Practice for providing High Quality Zinc Coatings (Hot-
Dip)
(m) ASTM A394: Standard Specification for Galvanized Steel Transmission Tower Bolts
(n) ASTM A441: Standard Specification for High-Strength Low-Alloy Structural
Manganese-Vanadium Steel

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 (o) ASTM A572: Standard Specification for High-Strength Low-Alloy Columbium-
Vanadium Steel of Structural Quality
(p) ASTM A588: Standard Specification for High-Strength Low-Alloy Structural Steel
with 50ksi (345Mpa) Minimum Yield point to a 4-inch (100mm) Thickness
(q) ASTM A751: Methods, Practice and Definitions for Chemical Analysis of Steel
Products

7.1.3 American Institute of Steel Construction (AISC)

(a) Specifications for the Design, Fabrication and Erection of Structural Steel for
Buildings (AISC Steel Specification)
(b) Code of Standard Practice for Steel Buildings and Bridges (AISC Standard Practice)
(c) Specification for Structural Joints using ASTM A325 and A490 Bolts
(d) Structural Steel Detailing
(e) Manual of Steel Construction

7.1.4 American Welding Society (AWS)

(a) AWS D1.1: Structural Welding Code

7.2 Bolts and nuts

All bolts and nuts shall comply with the latest revisions of ASTM A325 and ASTM
A394 or ISO1461 Grade 5.8/6.8/8.8 or other equivalent specification and be galvanized in
accordance with ASTM A153.
Bolt threads shall be such that the nut can be easily screwed over the entire threaded
length without excessive play. The threaded length shall be such that the nut can be fully
tightened up but also that none of the thread lies within the section being jointed. There
shall be a minimum projection of three (3) full threads beyond the nut when it is tightened
on the bolt.
All bolts shall be supplied with flat washers, spring washer and nuts. Preferably bolts of
only one size diameter shall be supplied if possible. All bolts shall be of the same grade. If
more than one bolt diameter is used the variation diameter between different sizes shall be
at least 4mm.
An additional 3% of the total number of bolts, nuts, washers and spring washer shall be
supplied

7.3 Step bolts

These shall be a minimum of 16mm in diameter and 180mm length. They shall conform
to steel quality above. Each bolt shall be supplied with two nuts and spring washer.

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 Holes for step bolts shall be provided about 350mm apart in two diagonally opposite
corners, commencing from the anticlimbing device up to 1,000mm below the tower top.
Step bolts shall not be used as part of any bolted connection.

8 Tower design

8.1 General
The detailed tower design shall generally be in accordance with the principles set out in
the “Design of Latticed Steel Transmission Structure” of the American Society of Civil
Engineers 10-97.
At the crossarms of heavy angle, extra heavy angle and terminal towers provision shall
be made to fit a jumper string.
Strain plates on strain and terminal towers shall have auxiliary maintenance strain holes
on each side of the strain hole, suspension tower crossarms shall have a maintenance lifting
plate close to the normal suspension points.
Two holes of 17.5mm in diameter shall be provided in all leg members of each tower for
an earthing connector. Holes shall also be provided on the earthwire peak of all towers for
the connection of earthwire bonding leads.
The towers shall be designed to withstand the loads as calculated in clause 5 and 6
without failure or distortion of any component. These calculated loads are the loads which
will be applied to the tower when full scale tests in accordance with this specification
(clause 13.2 ) are carried out.

8.2 Minimum thickness of members

The members shall not be less than the following thickness:
General requirements, tower legs and main crossarms 5mm
Other stress, carrying members 4mm
Redundant members 4mm
Connection plates, including gussets 4.5mm
Minimum diameter of connecting bolts 12mm

8.3 Tower bases

The towers shall be designed that the lower portions can be assembled separately from
the upper portions, and used for setting foundations. A light horizontal bracing shall be
provided for the lower portion of each tower, to ensure that it remains square in plan while
the foundation is being set.
The height above ground level of the main horizontal member at the top of the base shall

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not exceed 7.5m. An increase in height to 8.5m may be permitted in exceptional cases, but
only if it can be shown that this is a considerable economic or easy erection advantage.
The dimensions on the drawings of the bases shall be sufficient to enable the lengths of
temporary tie members, to be used to maintain the correct leg spacing when foundation
setting, to be calculated.

8.4 Unequal leg extensions – Hill-side conditions

In rough terrain use of different height leg extensions is not unusual. Under these
conditions, applied horizontal loads do not split equally between applicable tower faces.
This shall be accounted for in the determination of member stresses.

8.5 Long tension members

All tension members shall be detailed shorter than the theoretically required length by an
amount equal to one millimeter for each meter of length. The amount that the member is
shortened shall be shown on the supplier’s detail drawing.

8.6 Connections

8.6.1 General
Joints and connections shall be detailed so as to facilitate assembly, inspection and
painting, and to avoid spaces in which water can lodge.
Unless specified or denoted otherwise, all connections shall be bolted. Braces and
redundant members may be connected by one bolt which shall be placed on the inner
gauge line.

8.6.2 Main leg member

Butt splices shall be used in all cases for connection of equal sized angles. Where lap
splices are used, the heel on the inside angle shall be chamfered to clear the fillet of the
outside angle. If lap splicing is used the Supplier shall submit additional calculations to
prove the adequate strength of the joint. Leg splices shall be located near and above the
horizontal members or above diagonal brace connections, but clear of the connected all
members.

8.6.3 All other members

All other members shall be in one piece where practical and all double diagonal web
system members shall be connected at their point of intersection by at least one bolt.
Where gusset plates are used, brace members designed for compression should, as far as
practical, be connected to the main members with at least one bolt

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 Cross bracing angles are not to be coped where they cross each other. If connection
cannot be made without cutting, both angles shall be cut and a gusset plate used.

8.7 Fillers
Fillers are required at the gap more than 3mm on connection between members. Two or
more adjacent holes, filler plate should be used instead of ring fillers.

8.8 Crossarms
Eccentric loading on crossarms shall be reduced to a minimum and avoided, if possible.
Where brackets cause bending near ends of arms, the arms shall be reinforced with
additional angles.
Redundant bracing shall be required between the upper and lower chords of crossarms
when diagonal braces are used between the two lower chords of an arm.

8.9 Conductor and overhead earthwire attachments

Design and detail requirements for conductor and overhead ground wire attachment
points shall be provided. These shall be sufficient to provide for conductor or insulator set
type proposed in accordance with GDS standard supplied by GECOL.

8.10 Maximum length of members

Individual tower members shall not exceed 8.0m in length except by special agreement
in each specific case.

8.11 Factor of safety

All towers and tower foundations shall be capable of resisting any combination of the
basic design loads multiplied by a factor of safety as follows;

8.11.1 Tower members included stub and cleats

(a) 2.5 for Normal condition – All wire intact of double or single circuit.
(b) 1.5 for Broken wire condition.
(c) 2.0 for Construction and maintenance condition.

8.11.2 Foundation
(a) 2.5 for Normal condition – All wire intact of double or single circuit.
(b) 2.0 for Broken wire, construction and maintenance condition.

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 8.12 Determination of slenderness ratio (L/r)

8.12.1 General
Leg member is defined as a member which is bolted in both faces and where
connections are at both ends of the member or of the unsupported panel, resulting in
concentric loading. Double angle members connected back-to-back with loadings through
back-to-back legs may be considered a leg member. Brace member is defined as a member
with normal framing eccentricities at both ends of the members connected by one leg.

8.12.2 Single Angle Members

The maximum L/r of angles with symmetrical bracing on each leg of the angle shall be
computed as follows:
(a) L is the unsupported length between bracing points (redundant members considered
fully effective) and, r is the minimum radius of gyration of the member.
The maximum L/r of angles with staggered bracing on each leg of the angle shall be as
follows:
(a) L is the distance between bracing points (redundant members considered fully
effective) on one leg of the angle and, r is the radius of gyration of the member for its
axis which is parallel to the supporting member; or,
(b) L is the distance between the bracing point on one leg and the adjacent bracing point
on the other leg and, r is the minimum radius of gyration of the member.
The maximum L/r of single angle brace members connected by one leg in a double-
brace system (the crossed diagonals are bolted at their intersection) shall be computed as
follows;
(a) L shall be the greatest length from centre of end connection to point of intersection
and, r is the minimum radius of gyration of the member.
The maximum L/r of single angle brace members connected by one leg with
intermediate support (or supports) in one plane shall be computed as follows:
(a) L shall be the distance between centers of end connections; and, r is the radius of
gyration of the member for its axis which is parallel to the supporting member(s) or,
(b) L shall be the greatest length from centre of end connection to point of support or
greatest distance between adjacent supports, whichever is greater; and, r is the
minimum radius of gyration of the member.

8.13 Net section

The determination of net section shall be as specified in the AISC Manual of steel
Construction and as noted below:

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 The net section of single angle tension members connected by one leg shall be the net
section of the connected leg plus the net area of the unconnected leg. The area of open
holes in the unconnected leg should be deducted.

8.14 Allowable stresses

8.14.1 Tension Members

Ultimate allowable unit tensile stress through the minimum net section shall not
exceed the following, where is the specified minimum yield stress:
(a) Members concentrically loaded such as leg members bolted at connection in both
faces and double angle members (connected though the back-to-back legs).
=
(b) Single angle members connected by one leg for lap joint.
= 0.90
(c) For tension members with large eccentric loading, a combined bending and tension
load analysis may be required (see AISC Manual of Steel Construction).

8.14.2 Compression Members

Compression on the gross section of axially loaded compression members where (KL/r)
is less than :

------------------- (a)

Compression on the gross section of axially loaded compression members where (KL/r)
is greater than or equal to :
= 1970000 / (KL/r) -------------------- (b)

in equations (a) and (b) shall be equal to:

= √ (2E/ ) ------------------- (c)

where:

= min. guaranteed yield strength of the steel in MPa

E = modulus of elasticity of the steel (199810 MPa)

Fa = allowable compressive stress in MPa

Cc = Column slenderness ratio dividing elastic and inelastic

buckling

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 (KL/r) in equations (a) and (b) shall be equal to the largest effective slenderness ratio of
any un-braced segment of the member. L shall be as determined from working point to
working point on the design drawings.
The equations (a) and (b) are applicable provided the largest width-thickness ratio (b/t)
is not more than the limiting value given by:
(b/t) = 210 /√
in which b = distance from edge of fillet to extreme fiber, and t = thickness of material.
If the width – thickness ratio exceeds (b/t) Lim, but is not greater than 20 the equations
(a) and (b) shall be modified by substituting for the value of given by:

for (b/t) ..........(e)

and,

for (b/t) .........................(f)

8.14.3 Effective Slenderness Ratios

For leg sections or post members bolted at connections in both faces, K shall be used as
1.0.
For all other compression members carrying calculated stress the following adjusted
slenderness ratios, KL/r, shall be used:

For members with concentric

(1) Loading at both ends of the

Unsupported panel and L/r ≤120

For members with concentric

Loading one end and normal framing

(2) =30+0.75 L/r
Eccentricities the other end of the

Unsupported panel and L/r ≤120

For members with normal framing

(3) =60+0.5 L/r eccentricities at both ends of the

unsupported panel and L/r ≤120

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 For members unrestrained against

(4) rotation at both ends of the unsupported

panel and L/r from 120 to 200

For members partially restrained

Against rotation at one end of the

(5) =28.6+0.762 L/r
Unsupported panel and L/r from 120 to
225

For members partially restrained

(6) =46.2+0.615 L/r against rotation at both ends of the

unsupported panel and L/r from 120 to 250

8.15 Ultimate allowable bending, shearing and bearing stress

Ultimate allowable bending stress, Fb, on extreme fibers shall be taken as the applicable
yield point, .
Ultimate allowable shearing stress, Fv, shall be taken as 5/8 of the applicable yield point,
.
Ultimate allowable bearing stress, Fp, shall be taken as 1.5 times the applicable yield
point, but, not exceed Fu. (Min tensile strength).

8.16 Beam – Columns – Combined axial compression and bending

Members simultaneously subjected to both axial compression and bending stresses shall
be designed in accordance with Section 1.6, Combined Stresses, AISC Manual of Steel
Construction, latest edition. Latticed beam columns shall be designed considering effects
of shear deformation.

8.17 Maximum allowable slenderness ratios, L/r

8.17.1 Tension Members

Tension members of tower crossarms (hangers) - 370

8.17.2 Compression Members

Main leg and crossarm chord member - 150
For other members having calculated stress - 200

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 For redundant members without calculated stress - 250
All redundant members, without computed stress, may be designed to carry a stress of
not less than 2.5% of the stress in the member they brace.

8.18 Allowable bolt stresses

8.18.1 Allowable Shear Stress on Bolts for reference only

Supplier shall propose their standard and specification of the bolts and nuts
For ASTM A394 bolts:
On gross area of shank - 207 MPa (30,000 psi)
On net area at root of threads - 310 MPa (45,000 psi)
For ASTM A325 bolts:
On gross area of shank - 276 MPa (40,000 psi)
On net area at root of threads - 393 MPa (57,000 psi)

8.18.2 Allowable Bearing Stress on Bolts

See clause 8.15 about allowable bearing stress on bolts

Connecting members shall bear only on the shank of bolts and not on the threaded
portion.

8.19 Bolt spacing and edge distances

8.19.1 The minimum spacing of bolts and edge distances shall be maintained as follows:
Bolt diameter Minimum bolt Minimum edge distance (mm)
(mm) spacing (mm) Rolled edge Sheared edge Flame Cut edge
12 30 13 16 19
16 40 19 23 26
20 50 28 31 34
24 64 35 38 42

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8.19.2 Bolt hole diameters shall be no more than 1.5mm greater than bolt diameters. Holes
in mild steel material more than 20mm thick or in high tensile steel material more
than 14mm thick shall be drilled or sub-punched and reamed. Holes may be
punched in thinner material.

9 Fabrication

9.1 General
The Specification for “The Design, Fabrication and Erection of Structural Steel for
Buildings” from the Manual of Steel Construction, American Institute of Steel
Construction shall apply where appropriate.

9.2 Preparation
Before being laid out or worked on in any manner, the structural shapes shall be straight
and undamaged. Straightening will not be permitted. Sharp kinks or bends will be cause for
rejection of the material. Templates shall be laid flat without distortion while work is being
laid out.

9.3 Shearing and cutting

Shearing and cutting shall be performed with care and all portions of work shall be
finished neatly. Any burrs detrimental to the tower or a safety hazard shall be removed by
grinding or other means. Ends shall be square within 1.5 degrees.

9.4 Use of torch

Curved edges and sections impractical to shear and edges being prepared for welding
may be cut with a burning torch. Wherever practicable, the torch shall be mechanically
guided. Edges prepared for welding or subject to high stresses shall be free from sharp
notches.

9.5 Holes
All holes shall be cylindrical and perpendicular to the surface of the member. Where
necessary to avoid distortion of the holes, holes close to the points of bend shall be made
after bending. The bolt holes shall be not more than 1.5mm larger in diameter than the
nominal diameter of the bolt.
The welding of mispunched holes shall not be permitted. When holes are mispunched so
that the net section of a member is decreased, the member shall be discarded.
No holes shall be punched in members within 100mm of a point of bending until after
such member has been bent.

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 The supplier shall provide holes in the tower steel members for mounting of all signs
and anticlimbing devices as specified in clause 10.2 .

9.6 Bending
Material shall be heated to bend, except plates which may be bent cold. However, no
heating or cold working shall be permitted which would cause embrittlement of the steel
and high tensile members may not be bent cold through more than 5°.
All bending shall be done in such a manner that the full section and member length will
be maintained within 5% reduction and that the physical properties of the material will not
be impaired.
Members bent hot shall be heated in a non-oxidising flame over a sufficient area to
prevent excessive deformation.
Hot bends shall be nested for slow cooling in air. All bends shall be finished free from
waves and folds.
When material is bend, all holes near the bend shall be punched after the bending.

9.7 Welding
Where severe bending of crossarm or other members is unavoidable, flanges of angle
sections may be cut and welded with the prior approval of the GECOL’s Engineer.
Otherwise welding of members or gusset plates shall not be permitted unless by special
arrangement with the GECOL.
Cutting the outstanding leg of angles or flanges of channels and then welding at the bend
point shall not be permitted.
All welding involving steels shall be done in accordance with ASTM A384 and the
welding procedure requirements of AWS D1.1, “Structural Welding Code”.

9.8 Galvanizing
Galvanizing shall be as follows:
(a) After the shop work on members is completed and accepted the members shall be
cleaned of rust, loose scale, dirt, oil grease and other foreign substances preferably by
a combination of sand blasting and acid bath.
(b) After being cleaned, all materials, except tower bolts and nuts, shall be coated in
accordance with ASTM A123. Where members are of such lengths that they cannot be
dipped in one operation, great care shall be exercised to prevent warping. Sharp kinks
or bends will be cause for rejection of the material.
(c) Tower bolts, nuts, washers and spring washer for the tower member connections shall
be galvanized in accordance with ASTM A153.

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 (d) After being galvanized, all materials shall be straightened by being rerolled or pressed,
where required, to remove warps caused by the galvanizing process. The material
shall not be hammered or otherwise straightened in a manner that will injure the
protective coating. If the GECOL considers the material has been harmfully bent or
warped in the process of fabrication or galvanizing, such defects shall be cause for
rejection. Material on which the galvanizing has been damaged by straightening shall
be redipped. Any member on which the galvanized coating becomes damaged after
having been dipped twice shall be rejected.
(e) All galvanized members shall be safeguarded against embrittlement in accordance
with ASTM A143 “Safeguarding Against Embrittlement of Hot Galvanized Structural
Steel Products and procedure for Detecting Embrittlement” and all galvanizing shall
be done in accordance with ASTM A384 and A385.
(f) Preventive treatment against “White Rust”: All parts shall be treated with “Sodium
Bichromate” to protect the galvanizing from white rust formation.

10 Tower accessories

10.1 Anti-Climbing devices and step bolts

10.1.1 Location and General Requirements

Each tower shall be fitted with an approved anti-climbing device at height of not less
than 3 m, but not more than 4.5 m, from the ground on sloping ground the height is
measured from the ground which is highest.

The anti-climbing device shall be provided with a hinged gate at the corner of the tower
where steps are approved in order to allow easy access of linesmen and other authorized
persons.

The hinged gate shall open away from the direction of ascent. These hinged sections
shall be provided with a closing fitting suitable for accommodating a padlock but shall be
left by the Supplier with a nut and bolt until such time as padlocks are fitted by the
GECOL.

In general areas galvanized spikes shall be used in the horizontal member of lower
panel. In special areas, if necessary, barbed wire may be utilized.

In the spike type, the spike grade shall be grade 6.8 and the minimum distance between
spikes shall not be less than 150 mm. where spikes are bolted to the tower member the
spike threads must be clenched after installation. The drawing of spike is as the following
figure.
In case of barbed wire type, Barbed wire shall be 12.5 gauge with 14 gauge 4 point

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round barbs 100 mm on centre, with galvanized coating conforming to ASTM A121.
Galvanizing of other parts of the anti-climbing device shall be to ASTM A123

77

62

M12 x 6a
before hot dip gaivanizing

10.1.2 Standardization
The position of the anti-climbing device should preferably be such that a standard device
is used regardless of the arrangement of the tower body and leg extensions which may be
employed.
Spikes or anti-climbing devices equipped with tensioned good quality barbed wire to the
approval of GECOL are preferred.
Where the design of tower is such that they can be climbed on the inner face, the anti-
climbing device shall extend inside the tower to prevent this. In this respect particular
attention should be given to application on leg extensions.

10.1.3 Step Bolts

Step bolts shall be provided on all towers to the requirements of clause 7.1 .
The steps shall be spaced on the inner gauge line of alternate legs of angle about 350mm
on centers. The step bolt holes shall be spaced so that any combination of assembled tower
body, body extension and leg extension shall result in the 350mm spacing of the entire step
bolt ladder. Permanent step bolts shall be installed immediately above the anti-climbing
device and continuing to the overhead earthwire.

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 The first step bolt below each crossarms shall be conveniently located on the transverse
face of the tower and the remaining step bolts shall be alternatively placed on the
remainder of the tower leg and any extension.
Holes for removable step bolts below the anti-climbing device shall be provided at a
maximum of 350mm spacing to a point one meter above ground level.

10.2 Danger, number, phase and circuit plates

10.2.1 General Requirements

Conspicuous danger plates, route and number plates, resistant to fading under climatic
conditions on site shall be provided for all towers and phase color plates as specified
hereafter and GECOL specifications.
All danger and number plates shall generally be attached to towers on the transverse
faces of all towers so that they may be read when looking along the line with one’s back to
the source. At road crossings and possibly at a few other locations it may be necessary to
fit plates to one of the longitudinal faces, and this should be allowed for in the design of
fixing brackets.
All plates shall be of adequate thickness (min. 2mm) of material to ensure no bending of
plates can take place and no cracking of surface coloring can occur. Damaged, chipped or
cracked plates and surface coloring will not be accepted.
All plates shall be textile-glass reinforced plastics and shall be provided with bolt (M12
× 40mm), nut and washer.
All numbers and notices on the plates covered in the section will be duplicated in both
English and Arabic.
Prior to commencing mass production of plates the supplier shall submit a sample for
approval by the GECOL.

10.2.2 Danger Plates (GECOL specification GES 12450)

Danger plates shall be 300mm long by 200mm wide and 2mm thick and fitted to every
tower, being fitted centrally just above the anti-climbing guard level (2 plates for every
tower). Danger plates shall be approved by the GECOL. Lettering shall be red color on
white background.

10.2.3 Number Plates (GECOL specification GES 12452)

Tower number plates, carrying also the circuit identification numbering shall be fitted to
every tower and adjacent to and below the danger plates. Numbering shall be black color
on yellow background.

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10.2.4 Phase Plate (GECOL specification GES 12451)
Phase plate shall be provided separately for each circuit on each tower suitably located
under the respective circuit on each tower.

10.2.5 Circuit Plate (GECOL specification GES 12453)

Circuit plate shall be provided each circuit on each tower suitably located top conductor
crossarm end.

11 Drawings

11.1 General
All dimensions, calculations and recording or stresses and loadings on drawings and
members sizes (structural shapes) to be furnished, shall be in the metric system of weights
and measures (SI). All written information shall be in the English language. The metric
system of weights and measures shall be used.
All design drawings shall be to ISO A sizes listed below.
A0 – 841mm x 1189mm
A1 – 594mm x 841mm
A2 – 420mm x 594mm
A3 – 297mm x 420mm
A4 – 210mm x 297mm
Shop detail and erection drawings shall be on size 594mm x 841mm sheets.
Recommended scales to be used are: 1:1, 1:2, 1:5, 1:10, 1:15, 1:20, 1:25, 1:30, 1:40,
1:50 1:100, 1:250
Shop detail drawings should be to 1:20 with greater detail shown in 1:10 or 1:5.
Design drawing may be 1:100.
When members of a tower are made of a high strength low alloy steel, the drawings
shall clearly identify these members. All members shall be clearly marked as to type and
grade of steel.

11.2 Type of drawings required

11.2.1 Loading Diagrams

These shall show the loads to be applied to the towers and their application points for all
the loading assumptions detailed in clause 6 calculated according to clause 5 .

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11.2.2 Design Drawings
Preliminary Design Drawings shall show:
(a) Tower outline dimensions
(b) Size of main members
(c) Size of redundant members
(d) The electrical clearance for all critical conditions
(e) The position of the ground line
(f) The height of each bay and such other dimensions as may be to determine the buckling
length of compression members
(g) A clear indication of how every member and plate is to be fitted with respect to the
adjacent members and the length of every bolt, the thickness of every pack washer,
and any other information required for the rapid and accurate assembly of the towers
on site
(h) Sufficient dimensions in bottom bay to enable all bolt hole centres in this section of
the tower to be easily and accurately determined
(i) Calculated footing reactions
(j) L/r ratio for compression members.
(k) Final Design Drawings shall show:
The information included in the preliminary drawings plus the calculated stress and
safety factor of all essential members for the specified loading conditions. This shall
include the stress diagrams and/or computations used for obtaining the stresses.

11.2.3 Shop Detail Drawings

Shop Detail Drawings shall show:
(a) Each panel
(b) All parts or pieces with identification marks
(c) All information required for fabrication including, but not limited to, dimensions for
cutting and punching
(d) All holes, hole sizes, batters and distances between each
(e) All dimensions required for setting components in the field
(f) Enlarged details where necessary to provide clarity
(g) The Weight of all tower components shall be accurately and completely shown
(h) A bill of material for all material shown on the drawing including:
A. The mark designating the part or piece

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 B. A description of each part (length and section)
C. Number of pieces required

11.2.4 Erection Drawings

Basic Tower Erection Drawings shall show:
(a) The position, assembly number and part marks of each member, including crossarms,
shall be shown on a single sheet if possible
(b) Size and number of bolts required for each connection
(c) Total weight of tower sections
(d) A bill of material showing:
A. Number of parts required
B. Description of parts including size and weight
C. Mark used for each part
D. Complete bolt list showing size and length
E. Cross reference to appropriate shop detail drawings
Tower Body and Leg Extension Erection Drawings shall show the same information
required for the basic tower.

11.2.5 Anchor Drawings

Anchor drawings shall show:
(a) Anchor setting dimensions, angles, and batter (in mm per cm of rise)
(b) Part marks and position of each
(c) Bend point or bend line
(d) A bill of material showing:
A. Number of parts required
B. Description of parts including size and weight
C. Mark used for each part
D. Complete bolt list showing size and length
E. Cross reference to appropriate shop detail drawings

11.3 Other requirements

The complete files of all final approved drawings, showing details of each tower type as
supplied shall be furnished as soon s possible on completion of fabrication.

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 11.4 Review

11.4.1 All drawings shall be subjected to review by the GECOL for conformity with
control documents.
Review of detail drawings shall in no way relieve the Supplier from entire responsibility
for errors or discrepancies thereon. No alterations shall be made by the Supplier in the
finally reviewed drawings without notifying the GECOL in writing.

11.4.2 The GECOL will review and return to the Supplier one set of prints marked with
the GECOL’s degree of acceptance. The Supplier shall make necessary revisions or
prepare new drawings or calculations as required by GECOL for resubmittal.
Resubmitted prints and calculations will be subject to the same routine as before.
Revision number and date shall be shown on all drawings or calculations revised. Time
required for such revisions and resubmittal of drawings or calculations will not entitle the
Supplier to any extension in delivery time.
Any drawing changed by the Supplier during the development of his design, shall be
resubmitted to the GECOL for review.

11.4.3 GECOL review of the Supplier’s drawings and calculations shall be for general
arrangement, design concept and conformance to the requirements and intent of the
contract documents. Neither the review nor lack of review by GECOL of any
drawing or calculation shall waive any of the requirements of the Contract
Documents, or relieve the Supplier from responsibility for correctness of the
drawings or calculations: defective work, materials, or equipment resulting from
any errors therein will be subject to rejection.

12 Marking

12.1 Members and plates

All members of the structures shall be stamped prior to galvanizing with numbers and/or
letters to conform to the piece marks on the erection drawings.
Each piece of structural steel shall be marked by stamping with a heavy steel stamp
which produces a mark at least 16mm high and of sufficient depth to be legible after
galvanizing.
The mark shall be placed, preferably near one end in the same relative position on each
member, so as to be easily seen after assembly of the tower. They shall be positioned so as
not to reduce the effective net section of the member.

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 The marking shall also include the brand of the manufacturer and identification symbols
for the grade and quality of the steel.

12.2 Bolts
All bolts heads shall be marked by raised or depressed mark, to identify the
manufacturer. In addition they shall be marked to indicate the grade of steel used.

13 Testing and inspection

13.1 Testing
All towers shall be tested in accordance with the IEC 652 – Loading Tests on overhead
Line Towers and the standards as specified herein. Following completion of the tests, three
certified copies of the test report at least shall be submitted to GECOL. No towers shall be
shipped until the test reports have been approved by GECOL.
Routine and sample tests shall be carried out at the Supplier’s factory, as required.
Type tests shall be carried out at an approved independent test station or at the Supplier’s
station and be witnessed by a representative of an approved independent test authority or
other representative acceptable to GECOL. However, the tower load calculations and the
complete tower stress analysis, including the computer input and output, must have been
previously approved by GECOL.
Inspection may be made during all stages of manufacture, testing and shipment.
Inspection may be at the point of shipment or delivery or construction site, etc. at
GECOL’s option. However, inspection and acceptance shall not relieve the Supplier of his
responsibility for conformance with these specifications.

13.2 Full scale tower loading test

(a) For a full scale tower loading test, one of each type of tower (body, body extension
and leg extensions) shall be fabricated in accordance with approved detailed
drawings, assembled in accordance with approved erection drawings and tested on a
fixed foundation at an approved tower test site according to IEC 60652. The cost of
full scale tower tests shall be listed as a separate item in the supplier.
Each type of tower shall be tested for each of the specified loading conditions, except
for a condition where the calculations show that every member is more highly
stressed under other conditions for which tests are carried out. The tests shall be
performed on a galvanized tower with the longest body and leg extensions. The
sequence of test loading cases shall be approved by GECOL.
Each loading corresponding to each load step and the corresponding longitudinal and
transversal deflections shall be measured before and after removing of the load.
(b) Test deflections shall be recorded to provide at least the following information:

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 Longitudinal and transverse deflections at ground wire peak, ends of conductor
crossarms, centre of tower and at tower waist.
GECOL reserves the right to modify the above after review of the tower design and
the tower test facility.
(c) The Supplier shall submit the testing program for approval by GECOL. The tower
testing program shall list the loadings and load combination cases that will be used for
testing of the tower.
The testing program shall also include a description of the testing installation, of the
load application procedure and of the equipment intended to measure the loads and
the deflections. All measuring equipment used such as dynamometers, load cells, etc.
shall be calibrated in the presence of GECOL’s representative or be certified by a
qualified independent testing agency immediately before and after testing.
(d) The adjustment of loads in steps shall be as detailed in Clause 4 of IEC 60652. For the
final 100% step the loads shall be maintained for 5 minutes. Should a failure occur
during this period, the tower shall be considered to have failed the test
(e) Failure shall be defined as:
A. Any noticeable permanent distortion of a member or elongation of bolt holes of more
than 1mm.
B. Any shear failure in bolts.
C. Any member failure in bearing.
In case of any such failure, the Supplier shall consult with GECOL in modifying the
design and details. These modifications must be approved by GECOL before retesting
for the loading condition which caused failure and for all untested combinations until
the structure has been found satisfactory. Retesting of previously, successfully
completed tests are not required.
Upon completion of testing, disassembly of the tower shall include inspection of all
members for any evidence of excessive permanent set, shear failure of bolts, or
member failure in bearing not determined during the full scale testing program.
(f) All design and detailing defects determined during the tests or during the
disassembly shall be corrected on all towers of that type and also on other types not
tested having similar configuration, details or design concept.
Any modification to members or joints, and extra tests that GECOL may consider
necessary, shall be deemed to have been included in the bid prices.
The Supplier upon receipt of written approval from GECOL of acceptance of
satisfactory performance of the tower loading test, may start fabrication of the
structures except those members requiring modifications. Fabrication of these
members may not commence until revised detail and erection drawings have been
approved by GECOL.

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 After disassembly inspection (see below) of the tower and confirmation that all
components are completely undamaged the tower may be supplied against delivery
requirements.
(g) Within 7 days after completion of the tower loading test, the Supplier shall furnish a
full and comprehensive report (three copies) as specified in IEC 60652 of each tower
test and shall include detailed diagrams and tabulation showing amounts and methods
of load application and deflection records of each load test, photographs of test setup
and description (with photographs) of all failures.
Included in the report shall be mill test reports of the material used and the results of
any tensile tests of specimens cut from any members which failed during the testing
program. Particular emphasis shall be placed on the determination of the yield point
of the material.

13.3 Assembly test

To confirm the correct fitting and perfect interchangeability of all corresponding parts
one of each type of tower to be supplied shall be assembled completely on the ground at
the manufacturing works with parts taken at random from lots of finally treated
components. The tower bodies shall be assembled in sections and shall demonstrate that
each section fits the adjacent section, that the leg extensions fit all body extensions and that
foundation stub angles.
During testing all members, plates, bolts and nuts shall fit together snugly without any
distortion of any part. If it is demonstrated that all components fit together correctly when
the complete tower has been assembled and tightened the tower will be deemed to have
complied with this test.
If there is any distortion, fouling of members, or bolts or any misalignment or distortion
of components the Supplier shall consult with GECOL in modifying the details or design if
necessary. These modifications must be approved by GECOL and correct with the
modified components verified.
This test shall be attended by GECOL’s representative but this will not relieve the
Supplier of his responsibility for absolute correct assembly of all towers. The Supplier
shall also provide to GECOL a certificate of the Proof of Fit Test for each tower type, all
associated body and leg extensions, and foundation stub angles that have been assembled
satisfactorily.

13.4 Other tests

13.4.1 Mechanical and Chemical Properties of Tower Material

Tests shall be performed on samples as per ISO 630 Section 6. These shall include
tensile tests, bend tests, impact tests and product analysis for chemical composition.

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13.4.2 Bolts and Nuts
Tests shall be performed on samples according to ASTM A325 and A394. These shall
include tests for chemical composition, hardness and tensile strength.

13.4.3 Galvanizing
The weight, thickness, uniformity and adherence of the zinc coating shall be tested
according to ASTM A123, ASTM A153 and ASTM A239 to comply with the requirements
of the Technical Schedules.

14 Submitals required with tender

Submittals required with Tender are three copies each of:
(a) The Tender Data Schedules attached to this Specification for each type of tower
offered.
(b) Detailed calculations performed according to this specification for the tower design
loads and diagrams showing all tower design loading conditions.
(c) Outline drawings of proposed towers showing dimensions, ground line and foundation
loads.
(d) Drawings of tower footings and stubs to be buried into the concrete.
(e) Drawings showing electrical clearances for all critical conditions.
(f) Drawings of attachments of insulator strings and earthwire for all types of towers and
drawings showing vertical and horizontal distances between points of attachment of
insulator strings and the position of these points relative to the points of attachment of
the earthwire.
(g) Drawings of configuration and fixation of all accessories including danger, number,
phase and circuit plates.
(h) The supplier’s quality assurance program and/or manual together with a list of
international/national standard specifications covering raw material, manufacturing
processes, tolerances, test procedures, etc. and a list of tests normally carried out on
raw materials and a description of test equipment used shall be supplied.
(i) List of major projects for which the tower designer and manufacturer have supplied
towers and the dates of commissioning of these lines.

15 Submitals required following award of contract

Submittals required following award of contract are three copies each of:
(a) Details of manufacturing and test schedules and transportation/delivery proposals.
(b) Final design drawings, erection drawings and anchor drawings.

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 (c) The successful Supplier shall also supply details of any dimensions (not shown on the
drawings) which may be requested by GECOL.
(d) Outline drawings showing the electrical clearances and leading dimensions.
(e) A table of fabrication tolerances, including the tolerance for straightness of members.
(f) A table showing the quantity, length, section of each piece, including bolts, pack
washers, gusset plates, etc. for each tower type and size.
(g) The successful Supplier shall also supply with the first calculation submitted, the
following information:
A. The minimum permissible distance of the centre of bolt holes of each diameter from:
The end of the member, cut edges, uncut edges, an adjacent bolt hole and the inside of
an adjacent flange
B. The clearance in bolt holes, that is, the difference between the diameter of the hole
and that of the bolt.
C. The tolerance to be permitted in the position of bolt holes as regards: Their distance
apart and their distance from the datum line or working point.
D. The maximum and minimum permissible length of bolt projection beyond the nut.
E. A table of recommended tightening torques for the various bolt sizes.
F. Schedule of permissible stresses in tension, shearing and bearing, and the formula or
graph for determining the permissible stress in compression.
G. Calculations showing the maximum load, maximum stress and permissible stress in
each member, and the maximum and permissible load in each joint. Also calculations
showing the uplift and compressive loads applied to the foundations.
H. Test certificates for steel quality and galvanizing
I. Test certificates for bolt and nut quality and galvanizing.
J. Schedule of tower test loads.
K. Detailed tower testing program, including a schedule of all the loads to be applied in
each of the test cases set out in the schedule of test loads
L. Full reports on the tower type tests.

16 Packing and delivery

The supplier shall provide packing of the tower as is required to prevent their damage or
deterioration during transit to their final destination and long period of storage. The
packing shall be sufficient to withstand, without limitation, rough handling during
transportation and the exposure to extreme temperatures, salt and precipitation.
(a) All towers shall be delivered from the factory to the specified site or GECOL

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 warehouse.
(b) Small parts such as “U” bolts, tower bolts and nuts, pack washers, spring washer, filler
plates, etc. shall be shipped in bulk with like items packaged separately.
(c) Maximum permissible length of a single member specified from the point of view of
convenience in handling transport and erection shall not be more than 6.0 meters or
the limits fixed by the shipping or other transport agencies whichever is less.
(d) The angle sections up to 1 m length and all the gussets plates shall be despatched in
strong wooden boxes whereas separate bundles shall be made for sections from 1- 2 m
2 -4 m 4- 6 m, 6- 7 m length for every tower towards better inventory control
handling and easy erection.
(e) The bundles shall be prepared with strong and galvanized binding steel wire up to
length of 2m and galvanized steel strip beyond 2 m with intermediate strips at an
interval of 1.5 m with ends well tagged and packing underneath.
(f) Cleat angles gusset plates brackets filler plates and other loose pieces shall be nested
and bolted together in multiples or securely wired together through holes. Each
bundle or package shall be appropriately marked. Each tower has to be packed
separately with all its elements in one package and if the tower is heavy it can be
separated in two boxes.
(g) These bundles shall also be dispatched in wooden boxes if necessary as per the
requirements of shipping or other transport agencies.
On the package, a name plate shall be attached being not detachable and indelibly shall
include the appropriate items as the designation and dimension or quantity of product,
gross weight, the name and trade mark of supplier, etc. The characters shall be English
capital roman letters and Arabic numeral characters. The size of characters shall not be less
than 4mm.

17 Documentation
All documents supplied under this specification shall be documented to the extent that
the end user can easily understand its theory of operation, performance, installation and
maintenance for the product. All documents shall be submitted being filed in order to
approve of GECOL and reorder later.
Language in all documents and drawings shall be written in English and dimensions
shall be used in metric SI-units.

18 Warranty
The supplier shall provide a full one-year limited warranty on all articles supplied. The
warranty shall cover all parts and all costs, which are directly attributable to the supplier.
Warranty coverage shall begin on the date that the articles are received.

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 Check list for assembly test at manufacturer’s factory
Tower
Test item Point Requirements
Type
• Visual inspection and check design dimension
1) 1)
1) Vertical distance between upper arm and under arm
• 2) 2)
2) Width of the lowest crossarm
3) 3)
3) Distance between legs at the ground level
• Measurement of Slenderness ratio (L/r)
1) Tension Members: Max. 370
2) Compression Members
- Main leg and crossarm chord member: 1) 1)
Max. 150 •
- For other members having calculated stress: 2) 2)
Max. 200
- For redundant members without calculated stress:
Max. 250

1) 1)
• Check dimension of individual member
1) Check doubtable member to surface condition and
2) 2)
dimension
•
2) Confirm safety factor
3) 3)
3) Check the bracing having the much stress
4) Measurement of plate dimension by sampling 4) 4)

• Check the size of bolt hole and quantity 1) 1)

reasonableness
1) Main post, Arm post, Arm tie • 2) 2)
2) Important bracing
3) Point applied by butt joint 3) 3)

• Check reasonableness of using Filler plate and Ring

• 1) 1)
filler
• Check reasonableness of processing of insulator
• 1) 1)
string connection plate
• Check the consistency of bolt hole at place which
• 1) 1)
both members are overlapped
• Check the cutting processing of member edge at
• 1) 1)
place which both members are touched
• Check the milling processing of inside member edge
• 1) 1)
when used Lap joint and Butt joint
• Check whether the number of member is punched or
• 1) 1)
not

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