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ISSUE NO : 09
ISSUE DATE : 01.01.2013
REVISION NO : -
REVISION DATE : -
CORPORATE OFFICE:
KEC INTERNATIONAL LIMITED
463, Ceat Mahal, Dr. Annie Besant Road,
Worli, Mumbai – 400 030
India
TEL: (022) 66670200
FAX: (022) 66670299
This Company Standard is a property of KEC International Limited. Making copies or even an
extract from this is not permitted.
Page 1 of 121
COMPANY STANDARD CCH
ISSUE NO. 9 01.01.13
Page 2 of 121
COMPANY STANDARD CS – LCS
ISSUE NO. 9 01.01.13
CS 4 Fabrication Tolerances 22
CS 5 Stamping Specifications 26
The Company Standards are issued and approved by Corporate Quality and Assurance, Butibori.
Page 3 of 121
COMPANY STANDARD CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
SECTIONS
SHEET NO. 1 OF 14
1.0 SCOPE
This standard covers the requirement of Structural Steel Angles of Mild Steel & High Tensile Steel
generally used, for manufacturing of Transmission Line Tower Parts.
(All inspection specification/parameters are taken from repsective standards for reference purpose.
Final decision for acceptance / rejection shall be based on the requirements of the respective
standards and / or Customer Manufacturing Quality Plan.)
2.0 The Structural Steel shall be suitable for Hot Dip Galvanizing after fabricating the steel angles of
MS and HT grades into tower parts.
4.0 GRADES
The Material Grade shall be as mentioned in the Purchase Order and in specifications.
Page 4 of 121
COMPANY STANDARD CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
SECTIONS
SHEET NO. 2 OF 14
6.2 If any of the above Surface Defects removed by grinding the thickness should not be reduced
locally by more than 4% of the nominal thickness value.
SWEEP CAMBER
CAMBER:
Note: ** Tolerance over any part of bar (L) on given Flange width or Leg Length.
Page 5 of 121
COMPANY STANDARD CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
SECTIONS
SHEET NO. 3 OF 14
9.0 TOLERANCES
Note: As per IS 808 Difference between the Leg Lengths of equal leg angle shall be limited to 75 %
of total tolerance on leg length.
Page 6 of 121
COMPANY STANDARD CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
SECTIONS
SHEET NO. 4 OF 14
9.1.2 Leg Thickness / Flange Thickness: The Tolerance on Flange Thickness of Angles as follows:
Thickness shall be measured in the middle 1/3 rd portion of the flange width. In case of any
ambiguity, measurement by Micrometer shall be considered as final.
Table–4: As per BSEN 10056-II Flange Thickness Tolerance - Angles
Thickness Allowable Tolerance
≤ 5 mm 0.5 mm
> 5 to ≤ 10 mm 0.75 mm
> 10 to ≤ 15 mm 1.0 mm
> 15 mm 1.2 mm
Indian standard does not specify any tolerance on flange thickness. This is to be controlled by all
sectional weight parameters.
Page 7 of 121
COMPANY STANDARD CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
SECTIONS
SHEET NO. 5 OF 14
11.0 SQUARENESS
The legs shall be perpendicular to each other within the permissible tolerance given below:
k k
Table – 8
Specification Leg Length, mm Tolerance on out–of-Squareness
0
IS 1852 All sizes 1
0
ASTM A6 All sizes 1 1/2
≤ 100 k = 1.0mm
> 100 to ≤ 150 k = 1.5mm
BSEN 10056 Part II
> 150 to ≤ 200 k = 2.0mm
> 200 k = 3.0mm
12.0 SAMPLE PIECE LOCATION, PREPARATION, SHAPE AND SIZE FOR MECHANICAL TESTS
12.1 Tensile Test Sample
12.1.1 Location Of Test Samples
a) The Tensile Strength, Yield Stress and Percentage Elongation of Steel shall be determined from
the standard sample piece cut lengthwise or crosswise from Plates and lengthwise from Angles.
b) The recommended location for taking Test Sample for Angles and Plates are indicated in Fig.1.
12.1.3 For Shape, Size and Dimensions Of Test Piece for tensile testing refer IS 1608, ASTM A6 and
BSEN 10002-1.
Page 8 of 121
COMPANY STANDARD CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
SECTIONS
SHEET NO. 6 OF 14
17.2 Microscopical methods shall be used to characterize the size, distribution, number and type of
inclusions on a polished specimen surface.
17.3 Inclusion test shall be conducted by Method A (Worst Field) in accordance with ASTM E45.
This test method requires a survey of a 160 mm² polished surface area of the specimen at 100X.
The field size (size selected for image under microscope) shall equal an area equivalent to 0.50
mm² on the specimen surface as defined by a square with 0.71 mm long sides. Each 0.50 mm²
field is compared to the square fields depicted in Plate I-r in a search for the worst field, that is the
highest severity rating, of each inclusion Type A,B,C and D (Inclusion type A-sulphide, B-Alumina,
C-Silicate, D- Oxide) for both the Thin and Heavy Series. The severity level of these worst fields
shall be reported for every specimen examined.
Individual Inclusion Rating for Steel Sections shall not be more than 2.
Page 9 of 121
COMPANY STANDARD CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL
REV. NO.
STEEL SECTIONS
SHEET NO. 7 OF 14
Page 10 of 121
COMPANY STANDARD Annexure 1 of CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
SECTIONS
SHEET NO. 8 OF 14
Chart of Sectional weight and Root Radius for IS and BSEN Specification:
Note * - Sections whose sectional weights are not specified in standard is calculated by formula given
in specification and Root Radius shall be that of same flange size of section.
Page 11 of 121
COMPANY STANDARD Annexure 1 of CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
SECTIONS
SHEET NO. 9 OF 14
Chart of Sectional weight and Root Radius for IS and BSEN Specification:
Note * - Sections whose sectional weights are not specified in standard is calculated by formula given
in specification and Root Radius shall be that of same flange size of section.
Page 12 of 121
COMPANY STANDARD Annexure 2 of CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
SECTIONS
SHEET NO. 10 OF 14
Page 13 of 121
COMPANY STANDARD Annexure 2 of CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
SECTIONS
SHEET NO. 11 OF 14
Page 14 of 121
COMPANY STANDARD Annexure 3 of CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
SECTIONS
SHEET NO. 12 OF 14
ASTM A572 For all thickness For all thickness 50GL 200GL For all thickness For all thickness
Grade 50 345 450 21 18 - - - -
Grade 60 415 520 18 16 - - - -
Grade 65 450 550 17 15 - - - -
Where as –
“-“ Not Specified and
* Optional, if value is not specified, it is to be specified by the purchaser.
☻ Impact test shall be required for thickness 6mm and above incase of BSEN and Impact test shall be required for thickness 12mm and
above incase of IS Standard.
Note – Incase customer demands to follow the grade of steel mentioned on structural drawings then same shall be inspected and
teted with reference to applicable national or international standard.
RAJESH MOTGHARE RAJESH KOOLWAL
ISSUED BY SIGNATURE APPROVED BY SIGNATURE
Page 15 of 121
COMPANY STANDARD Annexure 4 of CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
SECTIONS
SHEET NO. 13 OF 14
CHEMICAL COMPOSITION (HEAT/LADDLE ANALYSIS)-MAXIMUM OR RANGE SPECIFIED
B
Grade Deoxidation C% S% P% Si% Mn% N% CEV
MILD STEEL
IS 2062: E250A Semi Killed/Killed 0.23 0.045 0.045 0.4 1.5 0.012* 0.42
IS 2062: E250BR
0.22 0.045 0.045 0.4 1.5 0.012* 0.41
IS 2062: E250BO Killed
IS 2062: E250C 0.20 0.04 0.04 0.4 1.5 0.012 0.39
BSEN10025 S 275 JR - 0.21 0.04 0.04 NS 1.5 0.012 0.4
BSEN10025 S 275 JO - 0.18 0.035 0.035 NS 1.5 0.012 0.4
JIS G 3101 SS 400 - NS 0.05 0.05 NS NS NS NS
ASTM A36 Semi Killed/Killed 0.26 0.05 0.04 0.4 NS NS NS
HIGH TENSILE STEEL
IS 2062: E350A Semi Killed/ Killed
IS 2062: E350BR
0.20 0.045 0.045 0.45 1.5 0.009* 0.42
IS 2062: E350BO Killed
IS 2062: E350C
IS 2062: E410A Semi Killed/ Killed
IS 2062: E410BR
0.20 0.045 0.045 0.45 1.6 0.009* 0.46
IS 2062: E410BO Killed
IS 2062: E410C
BSEN10025 S 355 JR - 0.24 0.04 0.04 0.55 1.6 0.012 0.45
BSEN10025 S 355 JO - 0.20 0.035 0.035 0.55 1.6 0.012 0.45
JIS G SS 540 - 0.30 0.04 0.04 NS 1.6 NS NS
ASTM A 572 Grade 50 (Plate upto
Semi Killed/ Killed 0.23 0.05 0.04 # 1.35D NS NS
100mm thick; Angle all thickness)
ASTM A 572 Grade 60 (Plate upto
Semi Killed/ Killed 0.26 0.05 0.04 # 1.35D NS NS
32mm thick; Angle upto 50mm thick)
ASTM A 572 Grade 65 (Plate 13-
Semi Killed/ Killed 0.23 0.05 0.04 # 1.65 NS NS
32mm thick; Angle 25-50mm thick)
ASTM A 572 Grade 65 (Thickness:
Semi Killed/ Killed 0.26 0.05 0.04 # 1.35 NS NS
Plate upto13mm, Angle upto25mm)
# Silicon % For Grades as per ASTM A572 Plates upto 40mm thick and Angle upto Plates over 40mm thick and Angle over
75mm thick 75mm thick
Gr.50 Si% to be 0.40% max. Si% to be 0.15% - 0.40%
Gr.60 Si% to be 0.40% max. The Size and grade is not described in this
Gr.65 Si% to be 0.40% max. specification.
Where as – NS, Not Specified; * Optional, It should be verified only if stated in order.
D
’ For each reduction of 0.01% in Carbon (max limit), an increase of 0.06% Manganese is permitted. Maximum permitted up to 1.60% of
Manganese.
B
’ Plates: Over 10mm thick – Mn% by heat analysis 0.80% min. & 0.75% by product analysis AND Plates: Upto 10mm thick – Mn% by
heat analysis 0.50% min. & 0.45% by product analysis
All High Tensile steel shall contain the presence of micro-alloying elements as follows:
EITHER - Vanadium = 0.025% min. OR Niobium = 0.015% min., AND Total Addition Of: Vanadium + Niobium + Titanium = 0.25% max.
For specific chemistry or elements presence shall be strictly as per the relevant specification. Customer’s special requirements shall be
included as and when approved.
Note – Incase customer demands to follow the grade of steel mentioned on structural drawings then same be inspected and teted
with reference to applicable national or international standard.
Page 16 of 121
COMPANY STANDARD Annexure 5 of CS – 1
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
SECTIONS
SHEET NO. 14 OF 14
# Silicon % For Grades as per ASTM A572 Plates upto 40mm thick and Angle upto Plates over 40mm thick and Angle
75mm thick over 75mm thick
Gr.50 Si% to be 0.40% max. Si% to be 0.15% - 0.40%
Gr.60 Si% to be 0.40% max. The Size and grade is not described in
Gr.65 Si% to be 0.40% max. this specification.
Where as – NS, Not Specified; * Optional, It should be verified only if stated in order.
D
’ For each reduction of 0.01% in Carbon (max limit), an increase of 0.06% Manganese is permitted. Maximum permitted up to 1.60% of
Manganese.
B
’ Plates: Over 10mm thick – Mn% by heat analysis 0.80% min. & 0.75% by product analysis AND Plates: Upto 10mm thick – Mn% by
heat analysis 0.50% min. & 0.45% by product analysis
All High Tensile steel shall contain the presence of micro-alloying elements as follows:
EITHER - Vanadium = 0.025% min. OR Niobium = 0.015% min., AND Total Addition Of: Vanadium + Niobium + Titanium = 0.25% max.
For specific chemistry or elements presence shall be strictly as per the relevant specification. Customer’s special requirements shall be
included as and when approved.
Note – Incase customer demands to follow the grade of steel mentioned on structural drawings then same shall be inspected and
teted with reference to applicable national or international standard.
RAJESH MOTGHARE RAJESH KOOLWAL
ISSUED BY SIGNATURE APPROVED BY SIGNATURE
Page 17 of 121
COMPANY STANDARD CS – 2
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
PLATES
SHEET NO. 1 OF 2
1.0 SCOPE
This standard covers the requirement of Structural Steel Plates of Mild Steel & High Tensile Steel
generally used, for manufacturing of Transmission Line Tower Parts.
(All inspection specification/parameters are taken from repsective standards for reference purpose.
Final decision for acceptance / rejection shall be based on the requirements of the respective
standards and / or Customer Manufacturing Quality Plan.)
2.0 The Structural Steel shall be suitable for Hot Dip Galvanizing after fabricating the steel plates of
MS and HT grades into tower parts.
3.0 Refer CS - 1 for Raw Material, Grades, Sampling Plan, Visual Inspection and Dimensional
Inspection of Steel Plate.
4.2 As per ASTM A6 - The Thickness shall be measures at the following points:
1) The Thickness shall be measured at 9.53mm (3/8”) to 19.05mm (¾”) from the longitudinal edge.
2) Thickness measured at any location other than point 1 the permitted variation over specified
thickness shall be 1.75 times the amount in this table, rounded to the nearest 0.25mm (0.01”).
3) Permitted variation Under specified Thickness is 0.254mm (0.01”)
Table-12: As per ASTM A6 - Permitted Variations Over Specified Thickness for Given Widths
Width of Plate
Thickness mm (inch) Under 1219 to 1524 to 1829 to 2134 to 2438 to
1219 1524 1829 2134 2438 2743
Under 6.35 (1/4”) 0.76 0.76 0.76 0.76 0.76 0.76
6.35 (1/4”) to 7.94 (5/16”) excl 0.76 0.76 0.76 0.76 0.76 0.76
7.94 (5/16”) to 9.53 (3/8”) excl 0.76 0.76 0.76 0.76 0.76 0.76
9.53 (3/8”) to 11.11 (7/16”) excl 0.76 0.76 0.76 0.76 0.76 0.76
11.11 (7/16”) to 12.7 (1/2”) excl 0.76 0.76 0.76 0.76 0.76 0.76
12.7 (1/2”) to 15.88 (5/8”) excl 0.76 0.76 0.76 0.76 0.76 0.76
15.88 (5/8”) to 19.05 (3/4”) excl 0.76 0.76 0.76 0.76 0.76 1.02
19.05 (3/4”) to 25.4 (1”) excl 0.76 0.76 0.76 0.76 1.02 1.02
25.4 (1”) to 50.8 (2”) excl 1.52 1.52 1.52 1.52 1.52 1.78
50.8 (2”) to 76.2 (3”) excl 2.29 2.29 2.29 3.30 3.30 2.79
76.2 (3”) to 101.6 (4”) excl 2.79 2.79 2.79 2.79 2.79 3.30
Page 18 of 121
COMPANY STANDARD CS – 2
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STRUCTURAL STEEL
REV. NO.
PLATES
SHEET NO. 2 OF 2
4.3 The Thickness shall be measured at any point situated more than 25mm from the transverse or
longitudinal edges of the plate, other than locally ground areas.
Table – 13: As per BSEN 10029 – Plates, Class A
Nominal Thickness Allowable Lower Allowable Upper
3 mm < 5 mm Tolerance
- 0.4 mm Tolerance
+ 0.8 mm
5 mm < 8 mm - 0.4 mm + 1.1 mm
8 mm < 15 mm - 0.5 mm + 1.2 mm
15 mm < 25 mm - 0.6 mm + 1.3 mm
25 mm < 40 mm - 0.8 mm + 1.4 mm
40 mm < 80 mm - 1.0 mm + 1.8 mm
80 mm < 150 mm - 1.0 mm + 2.2 mm
5.2 As per ASTM A6 permitted sectional weight variation is given below in the Table-1
Table-15: Permitted % of Variations in Average Weight/Square foot of Lots for Widths Given Below
Over 48 to 60
48 and under 60 to 72 excl 72 to 84 excl 84 to 96 excl 96 to 108 excl
2 excl
Specified Weights, lb/ft
Upto 1232 1232 to <1524 1524 to <1829 1829 to <2134 2134 to <2438 2438 to <2743
Over Under Over Under Over Under Over Under Over Under Over Under
To 10, excl 4.00 3.00 4.50 3.00 5.00 3.00 5.50 3.00 6.00 3.00 7.50 3.00
10 to 12.5, excl 4.00 3.00 4.50 3.00 4.50 3.00 5.00 3.00 5.50 3.00 6.50 3.00
12.5 to 15.0, excl 4.00 3.00 4.00 3.00 4.50 3.00 4.50 3.00 5.00 3.00 5.50 3.00
15 to 17.5, excl 3.50 3.00 3.50 3.00 4.00 3.00 4.50 3.00 4.50 3.00 5.00 3.00
17.5 to 20, excl 3.50 2.50 3.50 2.50 3.50 3.00 4.00 3.00 4.50 3.00 4.50 3.00
20 to 25, excl 3.50 2.50 3.50 2.50 3.50 3.00 3.50 3.00 4.00 3.00 4.00 3.00
25 to 30, excl 3.00 2.50 3.50 2.50 3.50 2.50 3.50 3.00 3.50 3.00 3.50 3.00
30 to 40, excl 3.00 2.00 3.00 2.00 3.00 2.00 3.00 2.00 3.50 2.00 3.50 2.50
40 to 81.7, excl 2.50 2.00 3.00 2.00 3.00 2.00 3.00 2.00 3.50 2.00 3.50 2.00
81.7 to 122.6, excl 2.50 2.00 3.00 2.00 3.00 2.00 3.00 2.00 3.50 2.00 3.50 2.00
122.6 to 163.4, excl 2.50 1.50 2.50 1.50 2.50 1.50 2.50 1.50 2.50 2.00 2.50 2.00
163.4 to 245.1, excl 2.50 1.00 2.50 1.00 2.50 1.00 2.50 1.00 2.50 1.00 2.50 1.00
6.0 Refer clause 12.0 on page 5 of CS - 1 for sample piece location, preparation, shape and size.
7.0 Conduct Tensile test, Bend test, Charpy test & chemical test as given on Page 6 of CS - 1.
8.0 For Yield Stress, Ultimate Tensile Strength, % of Elongation, Bend, Charpy and Chemical values
refer Annexure 3 & 4 on page 11, 12 and 13 of CS - 1.
Page 19 of 121
COMPANY STANDARD CS – 3
ISSUE NO. 9 01.01.13
COLOUR CODIFICATION FOR STEEL
REV. NO.
GRADE IDENTIFICATION
SHEET NO. 1 OF 2
1.0 SCOPE
This standard is applicable to all specifications and grades of steel presently being used for tower
structures.
2.0 PROCEDURE
Color-coding shall be done on all material at Re-Roller or Vendor premises. Incase material received
without color then color shall be applied at KEC Raw Yard before unloading. Color-coding scheme
shall be used to identify the steel specification and grade for angle, plate, flats and channel sections.
Page 20 of 121
COMPANY STANDARD CS – 3
ISSUE NO. 9 01.01.13
COLOUR CODIFICATION FOR STEEL
REV. NO.
GRADE IDENTIFICATION
SHEET NO. 2 OF 2
Page 21 of 121
COMPANY STANDARD CS – 4
ISSUE NO. 9 01.01.13
1.0 SCOPE
This standard covers the Tolerances on Dimensions for fabrication of tower parts.
Note: Company Standards shall be applicable when the Standards like National and International are
not available or the customer does not state the reference standard or specific requirements.
2.0 REFERENCES:
IS: 802 Part 2, IS: 7215, & IS: 1852
Page 22 of 121
COMPANY STANDARD CS – 4
ISSUE NO. 9 01.01.13
4.4.6 For all critical parts the hole diameter of connecting cleat and plates shall be increased by 1mm
than normal hole diameter. These items will be identified on the fabrication sketch.
4.4.7 Angle members / leg members holes shall be maintain as per specified tolerance only.
4.4.8 The diametrical clearance between hole diameter and bolt-nominal diameter shall be diametrical
1.5mm or as specified by the customer.
4.4.9 Hole ovality (difference between minimum & maximum diameter of a hole) shall be permitted
upto + 0.4 mm and - 0 mm.
4.4.10 Hole taperness (difference between diameter of hole at both the face of thickness) shall be
permissible max 0.8mm.
4.5 End Security Of Holes
To Suit Bolt Size Cut Edge Security Subject to Minimum Rolled Edge Minimum
M: 12 2 or min 20 min 16 mm
M: 16 2 or min 23 min 20 mm
M: 20 2 or min 28 min 25 mm
M: 24 2 or min 38 min 33 mm
Page 23 of 121
COMPANY STANDARD CS – 4
ISSUE NO. 9 01.01.13
NOTE: ** Tolerance for Critical Joint Hole Distances – Where joints have 3 or more than 3 items
joined together. These joints shall be specified on shop sketches.
Tolerances for **Critical Joint Hole Distances
Joint Consecutive Hole Distance + 0.75mm
Joint Cumulative Hole Distance + 1.50mm
Joint Hole Back Mark (Gauge line) + 0.75mm
4.7 For making hole sizes following size of punch and drill shall be used
Bolt size Size of Punch / Drill
16mm 17.75mm
20mm 21.75mm
5/8” or 15.88mm 17.75
¾” or 19.05mm 20.75
5.0 STAMPING
5.1 Stamping of item mark number shall be done on each piece of the tower item before hot dip
galvanizing. Stamping shall be done as per Company Standard CS - 5.
5.2 The stamping has Nine alphanumeric characters. The stamping generally has project number,
tower type and mark number. All high tensile members shall have „H‟ as prefix in stamping. The logic /
sequence of stamping characters can be kept as per customer requirement.
Page 24 of 121
COMPANY STANDARD CS – 4
ISSUE NO. 9 01.01.13
7.0 BENDING
The Bending of tower parts shall be done as per the Company Standard CS - 6.
8.0 BURRS
8.1 The Burrs due to Cropping, Punching, Drilling, Cutting, Gas Cutting etc., shall be ground
completely. All Fabricated items shall be free from burrs.
8.2 Grinding of burrs shall be done on the item so that grinding marks should not appear on the
surface of item. Only area of burrs shall be ground.
Note: All measuring and testing equipments used for dimensional verification shall be calibrated as
per calibration plan
Page 25 of 121
COMPANY STANDARD CS – 5
ISSUE NO. 9 01.01.13
1.0 SCOPE
This specification covers the shapes and sizes of Letters and Digits stamped on Tower Parts before
Galvanizing.
2.0 SHAPES
The shape of letters and digits shall be as shown in Annexure 1.
3.2 The Marking of Item Number shall be stamped on tower parts before Hot Dip Galvanizing. The
marking shall be clearly visible after hot dip galvanizing.
4.0 STAMPING
4.1 Stamping of Item Number shall be done on each piece of the item before hot dip galvanizing. The
letters and digits of the stamping should be completed and care should be taken that stamping is not
done on any hole or notching.
4.2 Stamping shall be done in one row for complete item number along the length of angle or along
the longer edge of Gusset Item.
4.3 In case sufficient space is not available the stamping of item number may be broken and done in
two rows.
x xxx x xxxx
X X> 100 mm
Y Y< 400 mm
Page 26 of 121
COMPANY STANDARD CS – 5
ISSUE NO. 9 01.01.13
In case of any hole occurring in between 100 mm and 400 mm from the last hole of end joint the
stamping shall be adjusted on the flange width such that its letters and digits are not cut by the hole or
it may even go beyond 400 mm from the last hole of the end joint.
Page 27 of 121
COMPANY STANDARD Annexure 1 of CS – 5
ISSUE NO. 9 01.01.13
Page 28 of 121
COMPANY STANDARD CS – 6
ISSUE NO. 9 01.01.13
SPECIFICATION FOR BENDING
REV. NO.
OPERATION
SHEET NO. 1 OF 2
1.0 SCOPE
This Standard covers the requirement of Bending Operation for all tower parts for Mild Steel and High
Tensile Steel grades.
2.0 PURPOSE
To define the process parameters for Bending Operation and Tolerance for acceptance.
Page 29 of 121
COMPANY STANDARD CS – 6
ISSUE NO. 9 01.01.13
SPECIFICATION FOR BENDING
REV. NO.
OPERATION
SHEET NO. 2 OF 2
6.0 GENERAL
6.1 All Hot Bend material shall be air-cooled.
6.2 The Bend shall be of even profile and free from any Surface Damages.
6.3 Scaling, Hammer Marks, Excessive Burning and Die Marks on hot bend material shall not be
permitted.
6.4 Only skilled operator to be deployed for bending operation.
Page 30 of 121
COMPANY STANDARD CS – 7
ISSUE NO. 9 01.01.13
SPECIFICATION FOR PLUGGING OF
REV. NO.
HOLES BY WELDING
SHEET NO. 1 OF 1
1.0 SCOPE
This is applicable for all types/sizes of Holes, which require Hole Plugging.
(Hole plugging by welding shall be done only after prior approval from QA)
6.0 GRINDING
The welded surface after plugging shall be thoroughly ground using a grinder to obtain a smooth
surface and make it flush with parent metal.
Page 31 of 121
COMPANY STANDARD CS – 8
ISSUE NO. 9 01.01.13
1.0 SCOPE
The standard covers all types of galvanizing tests for galvanized tower parts / structures.
2.0 Visual defects in galvanizing coating, acceptance criteria and methods of rework
TABLE-1
Code Reference Is: 2629 Acceptance Criteria For Visible Defects In Galvanizing Coating And Method Of
Plant Practice Rectification
Re-Galvanizing (By
No Defects Manual Rectification Tolerance stripping complete piece /
item)
No
Bare Spots/ Max Permitted 4mm
1 Except Tiny Yes*
Black Spots Across
Spots upto 4mm
Yes
Yes
2 Flux Marks Marks Can Be Removed --
Only When In Big Patches
By Wire Brushing
Yes Yes
Rough Surface (Only
3 Roughness Can Be -- Only When Roughness Is
During Galvanizing)
Smoothened By Filing Too Widespread
Yes Yes
4 Pimples If In Small Quantity By -- Only When Dross
Filing Contamination Is Heavy
Yes Yes
5 Lumpiness If Affected Area Is Less, -- Only When Observed In
By Filing Widespread Areas
Hard Zinc
6 No -- Yes
Contamination
Yes
Ash / Oxide Yes
8 Generally Removed By --
Contamination Only When In Gross Lumps
Filing & Brushing
Yes
9 Blisters No Few Small Blisters
Only When Widespread
Page 32 of 121
COMPANY STANDARD CS – 8
ISSUE NO. 9 01.01.13
As per ISO 1461 Zinc coating thickness shall be as given below in Table 1 for Steel and Table 1A for
Fasteners
Table – 1: Zinc coating thickness as per ISO 1461 (Samples that are not centrifuged)
Article and its Local coating thickness (min) Mean coating thickness µm (min)
2 2
thickness µm „g/m µm „g/m
≥ 6 mm 70 505 85 610
≥ 3 mm to < 6 mm 55 395 70 505
≥ 1.5 mm to < 3 mm 45 325 55 395
< 1.5 mm 35 250 45 325
Castings ≥ 70 505 80 575
Castings < 6 mm 60 430 70 505
Table – 1A: Zinc coating thickness as per ISO 1461 (Samples that are centrifuged)
Local coating thickness (min) Mean coating thickness µm (min)
Article and its thickness 2 2
µm „g/m µm „g/m
Articles with threads
≥ 20 mm 45 325 55 395
≥ 6 mm to < 20 mm diameter 35 250 45 325
< 6 mm diameter 20 145 25 180
Other articles (including castings):
≥ 3 mm 45 325 55 395
< 3 mm 35 250 45 325
Page 33 of 121
COMPANY STANDARD CS – 8
ISSUE NO. 9 01.01.13
As per ASTM 123 & ASTM 153 Zinc coating thickness for Steel – Table 2 and Fasteners – Table 2A
Table – 2: Zinc coating thickness as per ASTM 123
Steel Thickness inch, mm
<1/16 1/16 to <1/8 1/8 to 3/16 >3/16 to <1/4 ≥¼
Material category
(<1.6) (1.6 to <3.2) (3.2 to 4.8) > 4.8 to <6.4) (≥ 6.4)
2 2 2 2 2
µm „g/m µm „g/m µm „g/m µm „g/m µm „g/m
Structural Shape & Plate 45 320 65 460 75 530 85 600 100 705
Strip and Bar 45 320 65 460 75 530 85 600 100 705
Pipe and Tubing 45 320 45 320 75 530 75 530 75 530
Wire 35 245 50 355 60 425 65 460 80 565
As per IS 4759 Zinc coating thickness for steel and fasteners shall be as given below in the Table 3:
Table 3: Zn coating Thickness as per IS 4759 Minimum Value or Average Mass of
Coating
Product 2
„g/m Microns
i) Castings grey iron, malleable iron 610 86
ii) Fabricated steel articles
5mm thick and over 610 86
Under 5mm but not less than 2mm 460 65
Under 2mm but not less than 1.2mm 340 48
iii) Threaded work other than tubes and tube fittings
10mm diameter and over 300 43
Under 10mm diameter 270 38
Page 34 of 121
COMPANY STANDARD CS – 8
ISSUE NO. 9 01.01.13
As per BS 729 Zinc coating thickness for steel and fasteners shall be as given below in the Table 4:
Table 4: Zn coating Thickness as per BS 729 Minimum average coating weight
for any individual test area
Category
„g/m2 Microns
Steel articles 5mm thick and over 610 85
which are not Under 5mm but not less than 2mm 460 64
centrifuged Under 2mm but not less than 1mm 335 47
Grey and Malleable iron castings 610 85
Threaded work and other articles which are centrifuged 305 43
Note: –
1) 1 g/m2 = 0.14 microns
2) For structural steel sections the minimum coating weight referred to in Table 4 shall be the average
of determinations over a test area of 600 to 1200 mm2
3) The nuts are tapped up to 0.4 mm oversize after galvanizing and the threads are oiled.
5.0 STENCILING
5.1 Item Number shall be stenciled on every piece on the top of the bundle or if loose, on every piece
of item number.
5.2 Stenciling shall be done on outer surface of the tower parts after galvanizing. Stenciling shall be
done as per Company Standard CS-9.
5.3 In case of customer specification stenciling on tower parts shall be done as per their requirements.
7.0 REJECTION
Material shall be rejected if item during galvanizing gets over pickled causing reduction in material
thickness or flange width or visible surface defect.
Page 35 of 121
COMPANY STANDARD CS – 9
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STENCILING OF
REV. NO.
ITEM NUMBERS
SHEET NO. 1 OF 2
1.0 SCOPE
This specification covers stenciling of Item Number on tower parts and the Shapes and Sizes of
letters and digits used for the same.
2.0 STENCILING
2.1 Stenciling shall be done in such a way that letters and digits of stenciling are complete and care
shall be taken to avoid elimination of any part of stenciled letters and digits due to Hole/Notch on the
surface.
2.2 Stenciling shall be done in one row for complete item number, along the length of angle or longer
edge of the Gusset Item.
2.3 In case sufficient space is not available the stenciling of Item Number may be broken and shall be
done in two rows at one location only.
3.2 ON CLEATS
3.2.1 Stenciling shall be done on Outer Flange surface of the angle such that bottom of letters and
digits is towards the toe of the angle.
3.2.2 Stenciling shall be done on any space available on the outer flange surface.
Page 36 of 121
COMPANY STANDARD CS – 9
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STENCILING OF
REV. NO.
ITEM NUMBERS
SHEET NO. 2 OF 2
3.3 ON GUSSETS
Stenciling shall be done on any available space preferably near the longer edge or in between the
holes along the longer edge of the gusset.
6.0 SHAPES
The shapes of the letters and digits shall be as shown in Figure-1 and Figure-2 of this specification.
7.2 The tolerances on other dimensions forming the shape of the letters and digits stenciled on the
material shall be ± 5.0 percent.
9.0 Letters, Digits or Signs other than those given in Figure-1 & Figure-2 of Annexure 5 shall
not be used unless and otherwise required by the customer.
Page 37 of 121
COMPANY STANDARD Annexure 5 to CS – 9
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STENCILING OF ITEM
REV. NO.
NUMBERS
SHEET NO. 1 OF 2
Page 38 of 121
COMPANY STANDARD Annexure 5 to CS – 9
ISSUE NO. 9 01.01.13
SPECIFICATION FOR STENCILING OF
REV. NO.
ITEM NUMBERS
SHEET NO. 2 OF 2
Page 39 of 121
COMPANY STANDARD CS - 10
ISSUE NO. 9 01.01.13
1.0 SCOPE
This Standard covers the Zinc to be used for Hot Dip Galvanizing.
2.0 REFERENCE
IS: 209, IS: 13229; ASTM B6; ISO R752; DIN 1706
3.0 GRADE
3.1 The grade of Zinc used for Hot Dip Galvanizing shall be as per IS 209, IS 13229, ISO R752, DIN
1706 and ASTM B6.
3.2 In case this grade is not available, grade Zn 98.5 as per IS: 13229 or Prime Western Z19001 as
per ASTM B6 may be used with prior approval of Works.
99.900
ASTM B6 0.03 0.02 0.02 0.01 0.100
HG
98.000
ASTM B6 0.5-1.4 0.20 0.05 0.20 Al - 0.01 0.14-1.04
PW
Page 40 of 121
COMPANY STANDARD CS – 10
ISSUE NO. 9 01.01.13
Page 41 of 121
COMPANY STANDARD CS – 11
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
DOMESTIC PROJECTS – ITEM WISE REV. NO.
AND SINGLE TOWER WISE SHEET NO. 1 OF 5
1.0 SCOPE
This specification covers the bundling and packaging for Domestic projects.
Page 42 of 121
COMPANY STANDARD CS – 11
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
DOMESTIC PROJECTS – ITEM WISE AND REV. NO.
SINGLE TOWER WISE SHEET NO. 2 OF 5
3.18 Wires shall be tightened in such a manner that bundles shall have in-built lifting hooks made
from same bundle wires. Enclosed photo for reference on page 5 of 5 in annexure I to CS-11
3.19 Maintain the bundle height less than the width of bundle for bundles stability.
3.20 In case of special requirements specified by customer, the same shall be followed
Page 43 of 121
COMPANY STANDARD CS – 11
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
DOMESTIC PROJECTS – ITEM WISE AND REV. NO.
SINGLE TOWER WISE SHEET NO. 3 OF 5
3.22 A transparent polythene sheet of 180 gauge is used to cover all six faces of the boxes to arrest
water seepage inside the box – in rainy and winter season.
3.23 The gross weight of wooden box shall not exceed 1000 Kgs or weight per box shall be as
specified by the customer.
3.24 Size of the wooden box shall be as per approved drawings or applicability.
3.25 Box shall be strapped at minimum two places along the periphery of the box. Wood for wooden
box shall be jungle wood, mango wood or processed wood.
3.26 Stencil details like project number, box number, color code if any and any other information if
demanded by the customer.
3.27 A list containing the items and pieces packed in the box shall be put inside the box. The list shall
be put in sealed polythene bag.
Figure-1
Page 44 of 121
COMPANY STANDARD Annexure I to CS - 11
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
DOMESTIC PROJECTS – ITEM WISE AND REV. NO.
SINGLE TOWER WISE SHEET NO. 4 OF 5
6.0 PROCEDURE FOR SINGLE TOWER WISE BUNDLING OR PACKAGING OF ITEMS ABOVE
600 mm:
6.1 Incase customer specifies or Works Head decides bundling for domestic projects to be done
single tower wise i.e panel wise (stubs, body below waist, body above waist, cross arms, beam,
peak, body or leg extensions etc) to be complied.
6.2 The bundling shall be done Tower Type wise and the members of two different types of towers
shall not be put in same bundle.
6.3 Pieces in a bundle shall be arranged lengthwise in descending order. Shorter length pieces shall
be kept at the top of the bundle.
6.4 The pieces shall be packed with heel at top (Reverse V) or Interlocking for bundle intactness.
6.5 To provide stability to a bundle, height of a bundle shall not be more than the width of a bundle.
6.6 Maximum weight of bundle shall not exceed 1250 Kgs however in case of left over items in the
lot, the bundle weight may exceed upto 1450 Kgs.
6.7 The wire used for reeving bundles to be of minimum 3.25mm (10SWG) hot dip galvanized. Use
HDG 4.06mm (8SWG) wire for section sizes having flange measuring 150mm and above.
6.8 The reeving wire passing through the end security holes of all pieces in a bundle shall be twisted
and bent back to prevent opening during handling. Both ends of bundle
6.9 Based on bundle weight, volume and size strapping to be decided. Usage of number of straps
shall be decided to make the pieces inside the bundle intact. Strapping should ensure that pieces
inside bundles are not loose and will not fall. Strap tightening should not bend the pieces.
6.10 Bundles which are not required to be strapped shall be tied with hot dip galvanized wire refer
point 6.7
6.11 At least one end of pieces inside bundle to be secured by reeving with one end of bundle. Not a
single piece to be bundled without reeving or in loose condition inside bundle.
6.12 Tighten the strap by tensioner and seal the ends by clamp seals using a sealer. (Refer CS 13
for specification of strap and clamp seal)
6.13 If required or suitable, In a bundle all pieces shall be aligned at one end of the bundle for ease
in tightening and counting at customer stores / warehouse.
6.14 Open ends of pieces on top of bundle (normally in midlength
of bundles) will be tightened by strap and the strap will be
maximum 100mm away from the end of top piece (practice was
to put strap at 200-500mm away from the end as shown in the
photograph).
Wrong practice -
6.15 For supply and construction projects pieces shall be distributed from both the ends of bundle to
maintain the bundle stability and minimise the bundle height. All pieces in a bundle shall be reeved
together even though they are put at both the ends of a bundle.
Page 45 of 121
COMPANY STANDARD Annexure I to CS - 11
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
DOMESTIC PROJECTS – ITEM WISE AND REV. NO.
SINGLE TOWER WISE SHEET NO. 5 OF 5
Below pictures shows the arrangement of small plate and cleat items for
bundling. This is a tower wise bundling.
Page 46 of 121
COMPANY STANDARD CS - 12
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
REV. NO.
EXPORT PROJECTS
SHEET NO. 1 OF 10
1.0 SCOPE
This specification covers bundling, packaging of tower parts, bolts, nuts, washers and tower
accessories for export projects.
2.0 MATERIAL
Refer CS – 13 for material specifications used for packaging.
Page 47 of 121
COMPANY STANDARD CS – 12
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
REV. NO.
EXPORT PROJECTS
SHEET NO. 2 OF 10
4.13 The number of straps and nylon ropes on a length of bundle shall be as follows:
Table – 1: For Number of Nylon ropes and Straps on a Bundle
Length of Bundle No. of Straps No. of Nylon ropes
Upto 2000 mm 2 2
Above 2000 – 4000 mm 3 3
Above 4000 – 6000 mm 4 4
Above 6000 – 8000 mm 5 4
Above 8000 – 10000 mm 6 5
Above 10000 – 12000 mm 7 6
Above 12000 – 14000 mm 8 7
Figure - 1.
Project Tower Type
Color Color
Project Tower
Color Type
Color
4.15 Labeling – Labels shall be made of resin or metal as specified by the customer. Contents on the
label shall consist of manufacturer, PO reference number, bundle / box number, shipping mark,
destination, net weight, gross weight, number of pieces and any other information specified by the
customer.
Page 48 of 121
COMPANY STANDARD CS – 12
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
REV. NO.
EXPORT PROJECTS
SHEET NO. 3 OF 10
5.6 For supply and construction projects pieces shall be distributed from both the ends of bundle to
maintain the bundle stability and minimise the bundle height. All pieces in a bundle shall be reeved
together even though they are put at both the ends of a bundle.
5.7 Open ends of pieces on top of bundle (normally in midlength
of bundles) will be tightened by strap and the strap will be
maximum 100mm away from the end of top piece (practice was
to put strap at 200-500mm away from the end as shown in the
photograph).
Wrong practice -
7.0 PACKAGING OF WOODEN BOXES (Cleats/ Gussets and Bolt, Nuts & Accessories)
7.1 All Gussets, cleats and small bracings upto 600 mm length shall be reeved itemwise and packed
in wooden boxes.
7.2 All bolt, nuts, step bolts, pack washers, spring washers and tower accessories packed in gunny
bags shall be packed in wooden box.
7.3 A transparent polythene sheet of 180 gauge is used to cover all six faces of the boxes to arrest
water seepage inside the box.
7.4 The gross weight of wooden box shall not exceed 1000 Kgs or weight per box shall be as
specified by the customer.
7.5 Size of the wooden box shall be as per approved drawings.
7.6 Box shall be strapped at minimum two places along the periphery of the box.
7.7 Box labels shall be made of resin or metal as specified by the customer. Contents on the label
shall consist of manufacturer, PO reference number, bundle / box number, shipping mark,
destination, net weigth, gross weight, number of pieces and any other information specified by the
customer.
7.8 A list containing the items and pieces packed in the box shall be put inside the box. The list shall
be put in sealed polythene bag.
RAJESH MOTGHARE RAJESH KOOLWAL
ISSUED BY SIGNATURE APPROVED BY SIGNATURE
Page 49 of 121
COMPANY STANDARD CS - 12
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
REV. NO.
EXPORT PROJECTS
SHEET NO. 4 OF 10
7.9 Single tower packing - To facilitate easy counting (at site – tower location) Tie the small items like
plates/cleats per tower quantity together using “Plastic cable ties” and then arrange in the box.
7.10 On decision of FG department Plastic cable tie can be used up to 12mm thick material.
7.11 Plastic Cable Ties to be used as shown below in Fig-A. Do not fill box as shown below in Fig-
B.
Fig-A Fig-B
8.0 BUNDLING OF PLATES, CLEATS / GUSSETS AND SMALL BRACINGS INCASE OF TOWER
WISE PACKAGING
8.1 Bundling shall consist of all plates, cleats and small bracings up to 600mm length
8.2 For bundling, items shall belong to a single tower. No mixing of other tower items in one bundle
8.3 The items shall be reeve together to form a bundle. Steel wire shall pass from minimum one hole
each of every item to form a bundle. Enclosed photo for reference. For photo refer Page 8 of 9 of
Annexure I to CS – 12
8.4 Depending upon the size variations of items, weight of bundle / bundle type shall be decided -
600Kg, 400kg, 200kg and 60kg
8.5 Following table shall be followed for bundling (for clarity see enclosed photo on page 8 of 9 in
annexure I to CS-12) –
8.6 Wires shall be tightened in such a manner that bundles shall have in-built lifting hooks made from
same bundle wires. Enclosed photo for reference on page 8 of 8 in annexure I to CS-12
8.7 Maintain the bundle height less than the width of bundle for bundles stability.
8.8 In case of special requirements specified by customer, the same shall be followed.
RAJESH MOTGHARE RAJESH KOOLWAL
ISSUED BY SIGNATURE APPROVED BY SIGNATURE
Page 50 of 121
COMPANY STANDARD CS – 12
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
REV. NO.
EXPORT PROJECTS
SHEET NO. 5 OF 10
Page 51 of 121
COMPANY STANDARD CS – 12
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
REV. NO.
EXPORT PROJECTS
SHEET NO. 6 OF 10
13.0 The above Standard Packaging Specification shall be followed unless otherwise specified by
the Purchaser / Customer. In case of special requirements specified by the customer, the same shall
be followed.
RAJESH MOTGHARE RAJESH KOOLWAL
ISSUED BY SIGNATURE APPROVED BY SIGNATURE
Page 52 of 121
COMPANY STANDARD Annexure I to CS - 12
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
REV. NO.
EXPORT PROJECTS
SHEET NO. 7 OF 10
Page 53 of 121
COMPANY STANDARD Annexure I to CS - 12
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
REV. NO.
EXPORT PROJECTS
SHEET NO. 8 OF 10
Unsupported end of top pieces in bundles are deflected downward as shorter pieces are put
between two longer pieces and strapped on unsupported length.
Page 54 of 121
COMPANY STANDARD Annexure I to CS - 12
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
REV. NO.
EXPORT PROJECTS
SHEET NO. 9 OF 10
One or two longer pieces projecting out of the bundle by more than 500 mm. These projecting
pieces are susceptible for transit damage / bend
Too many smaller pieces bundled together making bundle height more than width and make the
bundle and unstable. Pieces on top of the bundle are likely to get collapsed during transit
making straps loose.
Page 55 of 121
COMPANY STANDARD Annexure I to CS - 12
ISSUE NO. 9 01.01.13
PACKAGING OF TOWER PARTS FOR
REV. NO.
EXPORT PROJECTS
SHEET NO. 10 OF 10
Below pictures shows the arrangement of small plate and cleat items for
bundling. This is a tower wise bundling.
Page 56 of 121
COMPANY STANDARD CS – 13
ISSUE NO. 9 01.01.13
BUNDLES AND BOXES PACKAGING
REV. NO.
MATERIAL SPECIFICATIONS
SHEET NO. 1 OF 4
1.0 SCOPE
This standard covers specifications for Steel Strapping, Steel Clamps/Seal, Steel Wires, Nylon Rope,
Wooden Rafters, Niwar/Hessian Cloth, Labels and Wooden Box used for packaging Tower Parts.
2.0 REFERENCE
For Straps IS 5872, Strap Clamp / Seals IS: 2062, For Steel Wires IS 280 & IS 4826
Page 57 of 121
COMPANY STANDARD CS – 13
ISSUE NO. 9 01.01.13
BUNDLES AND BOXES PACKAGING
REV. NO.
MATERIALSPECIFICATIONS
SHEET NO. 2 OF 4
Page 58 of 121
COMPANY STANDARD CS – 13
ISSUE NO. 9 01.01.13
BUNDLES AND BOXES PACKAGING
REV. NO.
MATERIALSPECIFICATIONS
SHEET NO. 3 OF 4
9.0 LABELS:
9.1 Labels shall be made of Resins or Metal
9.2 Dimensions and Tolerance of Labels as given below in the tables:
Metal Label -
Table – 1: Dimension and Tolerance for Metal Label
Parameters Dimensions (mm) Tolerances (mm)
Width 100 +/- 2
Length 150 +/- 2
Thickness 0.4 +/- 0.04
Slot (LXW) 45 X 3 +/- 1 on L & +/- 0.4 on W
Distance of slot from ends (Length) 11.5 +/- 0.5
Distance of slot from ends (Width) 27.5 +/- 0.5
Distance between the slots 127 +/- 1
Resin Label –
Table – 2: Dimension and Tolerance for Resin Label
Parameters Dimensions (mm) Tolerances (mm)
Width 80 +/- 2
Length 145 +/- 2
Thickness 0.6 +/- 0.04
Slot (LXW) 40 X 0.1 +/- 1 on L & +/- 0.02 on W
Distance of slot from ends (Length) 20 +/- 1
Distance of slot from ends (Width) 20 +/- 1
Distance between the slots 105 +/- 1
Page 59 of 121
COMPANY STANDARD CS – 13
ISSUE NO. 9 01.01.13
BUNDLES AND BOXES PACKAGING
REV. NO.
MATERIALSPECIFICATIONS
SHEET NO. 4 OF 4
10.0 NAILING –
10.1 All nails shall be of 8 to 10 Gauges.
10.2 Rust free nails shall be used for nailing.
10.3 Length and gauge of nails shall be selected on the thickness of joint.
10.4 Each nail shall have proper head at top. Half or broken head nails shall not be used for nailing.
10.5 Nailing shall follow zigzag pattern at maximum of 75mm in length.
10.6 Nailing shall be straight and should not be nailed in bend condition. Only head of nail shall be
visible on the surface.
10.7 Nailing shall be done properly so its head or end should not protrude out from either side.
10.8 All corners of box shall be nailed with plated or painted metallic strip. The length and width of
strip shall not protrude out at joints.
10.9 Proper care shall be taken during nailing Planks or Ribs so that crack due to hammering or
nailing pressure can be prevented.
Page 60 of 121
COMPANY STANDARD CS – 14
ISSUE NO. 9 01.01.13
PACKAGING OF BOLTS, NUTS AND
REV. NO.
ACCESSORIES
SHEET NO. 1 OF 2
1.0 SCOPE
This standard covers the packaging of Bolts, Nuts, Washers and Accessories at supplier‟s premises.
Page 61 of 121
COMPANY STANDARD CS – 14
ISSUE NO. 9 01.01.13
PACKAGING OF BOLTS, NUTS AND
REV. NO.
ACCESSORIES
SHEET NO. 2 OF 2
SAMPLE TAG
Supplier:
Items: Bolts and Nuts
Size: M ----- x ------
Grade: 5.6 / 5
Quantity: Nos. Weight: Kgs.
Batch no: Month/year:
4.0 PACKAGING
4.1 All bolts, nuts and accessories shall be packed in woven HDPE bags coated with LDPE lining
from inside.
4.2 Woven HDPE bags shall be 100 to 120 GSM and thickness shall be in the range of 600 to 700
Microns
4.3 HDPE bags shall be waterproof and shall be checked for 20 minutes under water showers for
verification of water seepage in the bags.
4.4 HDPE bags shall be put inside gunny bags.
4.5 Gunny bags shall be free from oil stains and dirty spots.
4.6 Gunny bags shall be 0.8 to 1.0 mm thick.
4.7 Gunny bags and HDPE bags shall be stitched together with polyester thread. Stitching shall be at
a distance of minimum 20 mm from the edge of the bag.
4.8 Identification tags polythene bags shall be stitched along with gunny bags at right hand corner of
the bag.
4.9 Gunny bags shall be printed with supplier‟s identification and product identification.
4.10 The packed items gunny bags shall not get wet in rainwater or any other source of water.
Page 62 of 121
COMPANY STANDARD CS – 15
ISSUE NO. 9 01.01.13
SPECIFICATION FOR PACK
REV. NO.
WASHERS
SHEET NO. 1 OF 6
1.0 SCOPE
This standard covers the specifications for Pack Washers and Hardened Washers used as a packing
while fastening the joints in Galvanized Transmission Towers.
(All inspection specification/parameters are taken from repsective standards for reference purpose.
Final decision for acceptance / rejection shall be based on the requirements of the respective
standards and / or Customer Manufacturing Quality Plan.)
2.0 REFERENCE:
Indian Standard – IS 2016, IS 5639, IS 2629
Deutsche Institut Fur Normung – DIN 126, DIN 267 Part 10
American Standard – ANSI B18.22.1, ASTM F 436, ASTM A153
3.0 MATERIAL
3.1 The Washers shall be made of steel, brass, aluminium or any other suitable metal specified in the
standard or purchaser specification. For chemistry of raw material review the manufacturers mill test
certificate.
3.2 As per ASTM F 436 Washers upto and including 1 ½ inch in bolt size shall be hardened and
washers over 1 ½ inch may be either hardened or carburized at the option of the manufacturer.
5.0 WORKMANSHIP
The washers shall be free from cracks, burrs, pits and other defects. The holes shall be reasonably
concentric with the outer periphery. All sharp edges shall be removed. There should be no Cup
Formation or Steel Marks on any surface of Washers
0.04 0.05
Type 1 -- -- -- --
Heat 0.05 0.06
Product 0.040 0.050 0.15-0.35 0.45-0.65 0.25-0.45 0.25-0.45
Type 3
0.045 0.055 0.13-0.37 0.52-0.68 0.22-0.48 0.22-0.48
Page 63 of 121
COMPANY STANDARD CS – 15
ISSUE NO. 9 01.01.13
SPECIFICATION FOR PACK
REV. NO.
WASHERS
SHEET NO. 2 OF 6
6.2 If customer does not specifies the Chemical composition of pack washers then the results shall
conform to IS 2062 E 250 A / Fe 410WA as mentioned below in Table 2:
6.3 Chemical composition of finish material shall conform to grade of specification mentioned in the
purchase order.
Page 64 of 121
COMPANY STANDARD CS – 15
ISSUE NO. 9 01.01.13
SPECIFICATION FOR PACK
REV. NO.
WASHERS
SHEET NO. 3 OF 6
10.0 GALVANISING
10.1 In case customer does not specify the requirements then the washers shall be Galvanized, as
per IS 1367 Part XIII with 54 microns in average for domestic projects and ASTM A 153 Class C with
53 microns in average for export projects.
10.2 In case Washers are required to be supplied Hot Dip Galvanized, the galvanizing requirements
shall conform to IS 2629, IS 2633, IS 4759, IS 6745 or ASTM A-153 Class C, ASTM A-239.
10.3 As per LOA and Technical Specification of PGCIL, washers shall be supplied to PGCIL projects
conforming to IS 2629, IS 2633, IS 4759 and IS 6745 with Zinc coating thickness of 86 microns.
11.0 FINISH
11.1 Washers shall be supplied in natural finish unless otherwise specified in Purchase Order.
11.2 Washers surface should not bear any thick Oil or Paint Marks.
11.3 Washers shall be free of excess mill scale, excess coatings and foreign material on bearing
surfaces.
11.4 Arc and Flame cut washers shall be free of metal spatter.
12.0 PACKAGING
For Packaging details refer CS 14 OR As per customer requirements.
Page 65 of 121
COMPANY STANDARD Annexure 1 to CS – 15
ISSUE NO. 9 01.01.13
SPECIFICATION FOR PACK
REV. NO.
WASHERS
SHEET NO. 4 OF 6
Page 66 of 121
COMPANY STANDARD Annexure 2 to CS – 15
ISSUE NO. 9 01.01.13
SPECIFICATION FOR PACK
REV. NO.
WASHERS
SHEET NO. 5 OF 6
As per ASTM F436 - Dimensions of Hardened Square Beveled and Square Clipped Washers:
ID A A
A T T
A
SQUARE BEVELED SQUARE CLIPPED
Square Beveled and Clipped Square BeveledA Clipped
Slope or Nominal Edge
Bolt size Dimension 'A' Dimension 'ID' Dimension 'T'
Taper in Distance (E)B,
inch (mm) inch (mm) Inch (mm) Inch (mm)
Thickness inch (mm)
1/2" (12.7) 1 3/4" (44.45) 17/32" (13.49) 5/16" (7.94) 1:6 7/16" (11.11)
5/8" (15.88) 1 3/4" (44.45) 11/16" (17.46) 5/16" (7.94) 1:6 9/16" (14.29)
3/4" (19.05) 1 3/4" (44.45) 13/16" (20.64) 5/16" (7.94) 1:6 21/32" (16.67)
7/8" (22.23) 1 3/4" (44.45) 15/16" (23.81) 5/16" (7.94) 1:6 25/32" (19.94)
1" (25.40) 1 3/4" (44.45) 1 1/8" (28.58) 5/16" (7.94) 1:6 7/8" (22.23)
1 1/8" (28.58) 2 1/4" (57.15) 1 1/4" (31.75) 5/16" (7.94) 1:6 1" (25.40)
1 1/4" (31.75) 2 1/4" (57.15) 1 3/8" (34.93) 5/16" (7.94) 1:6 1 3/32" (27.78)
1 3/8" (34.925) 2 1/4" (57.15) 1 1/2" (38.10) 5/16" (7.94) 1:6 1 7/32" (30.96)
1 1/2" (38.10) 2 1/4" (57.15) 1 5/8" (41.28) 5/16" (7.94) 1:6 1 5/16" (33.34)
A
- Rectangular beveled washers shall conform to the dimensions shown above, except that one side
may be longer than that shown for the A dimension.
B
- Clipped edge E shall not be closer than 7/8" of the bolt diameter from the center of the washer.
Page 67 of 121
COMPANY STANDARD Annexure 3 to CS – 15
ISSUE NO. 9 01.01.13
SPECIFICATION FOR PACK
REV. NO.
WASHERS
SHEET NO. 6 OF 6
As per ASTM F436 Dimensions of Hardened Circular, Clipped Circular & Extra-Thick Washers
CIRCULAR AND EXTRA THICK CLIPPED CIRCULAR
I OD
O IDI OO
I D
D
. . . .
D D D D
E
TT Table 4 E
- TT
Circular, Clipped & Extra Thick Circular and Clipped Extra Thick Clipped
Nominal size, Nominal O.D, Nominal I.D, Thickness (T), inch (mm) Min Edge
in (mm) in (mm) in (mm) distance (E)A ,
Minimum Maximum Minimum) Maximum
inch (mm)
1/4" (6.35) 0.625 (15.88) 0.281 (7.14) 0.051 (1.3) 0.08 (2.03) … … 0.219 (5.56)
5/16" (7.94) 0.688 (17.48) 0.344 (8.74) 0.051 (1.3) 0.08 (2.03) … … 0.281 (7.14)
3/8" (8.53) 0.813 (20.65) 0.406 (10.31) 0.051 (1.3) 0.08 (2.03) … … 0.344 (8.74)
7/16" (11.11) 0.922 (23.42) 0.469 (11.91) 0.051 (1.3) 0.08 (2.03) … … 0.406 (10.31)
1/2" (12.7) 1.063 (27) 0.531 (13.49) 0.097 (2.46) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 0.438 (11.13)
9/16" (14.29) 1.188 (30.18) 0.625 (15.88) 0.11 (2.79) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 0.5 (12.7)
5/8" (15.88) 1.313 (33.35) 0.688 (17.48) 0.122 (3.1) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 0.563 (14.3)
3/4" (19.05) 1.468 (37.29) 0.813 (20.65) 0.122 (3.1) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 0.656 (16.66)
7/8" (22.23) 1.75 (44.45) 0.938 (23.83) 0.136 (3.45) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 0.781 (19.84)
1" (25.4) 2 (50.8) 1.063 (27) 0.136 (3.45) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 0.875 (22.23)
1 1/8" (28.58) 2.25 (57.15) 1.188 (30.18) 0.136 (3.45) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 1 (25.4)
1 1/4" (31.75) 2.5 (63.5) 1.375 (34.93) 0.136 (3.45) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 1.094 (27.79)
1 3/8" (34.93) 2.75 (69.85) 1.5 (38.1) 0.136 (3.45) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 1.219 (30.93)
1 1/2" (38.1) 3 (76.2) 1.625 (41.28) 0.136 (3.45) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 1.313 (33.35)
B B
1 3/4" (44.45) 3.375 (85.73) 1.875 (47.63) 0.178 (4.52) 0.28 (7.11) 0.305 (7.75) 0.375 (9.53) 1.531 (38.89)
2" (50.8) 3.75 (95.25) 2.125 (53.98) 0.178B (4.52) 0.28B (7.11) 0.305 (7.75) 0.375 (9.53) 1.75 (44.45)
C C
2 1/4" (57.15) 4 (101.6) 2.375 (60.33) 0.24 (6.1) 0.34 (8.64) 0.305 (7.75) 0.375 (9.53) 2 (50.8)
2 1/2" (63.5) 4.5 (114.3) 2.625 (66.68) 0.24C (6.1) 0.34C (8.64) 0.313 (7.95) 0.375 (9.53) 2.188 (55.58)
2 3/4" (69.85) 5 (127) 2.875 (73.03) 0.24C (6.1) 0.34C (8.64) 0.313 (7.95) 0.375 (9.53) 2.406 (61.11)
C C
3" (76.2) 5.5 (139.7) 3.125 (79.38) 0.24 (6.1) 0.34 (8.64) 0.313 (7.95) 0.375 (9.53) 2.625 (66.68)
3 1/4" (82.55) 6 (152.4) 3.375 (85.73) 0.24C (6.1) 0.34C (8.64) 0.313 (7.95) 0.375 (9.53) 2.875 (73.03)
C C
3 1/2" (88.9) 6.5 (165.1) 3.625 (92.08) 0.24 (6.1) 0.34 (8.64) 0.313 (7.95) 0.375 (9.53) 3.036 (77.11)
3 3/4" (95.25) 7 (177.8) 3.875 (98.43) 0.24C (6.1) 0.34C (8.64) 0.313 (7.95) 0.375 (9.53) 3.313 (84.15)
C C
4" (101.6) 7.5 (190.5) 4.125 (104.78) 0.24 (6.1) 0.34 (8.64) 0.313 (7.95) 0.375 (9.53) 3.5 (88.9)
A
- Clipped edge E shall be not closer than 7/8" of the bolt diameter from the center of the washer.
B
- 3/16 inch nominal
C
- 1/4 inch nominal
Page 68 of 121
COMPANY STANDARD CS – 16
ISSUE NO. 9 01.01.13
SPECIFICATION FOR SPRING
REV. NO.
WASHERS
SHEET NO. 1 OF 8
1.0 SCOPE
This specification covers the dimensions, physical properties and method of testing for helical spring
washers as per national and international standards for various bolt sizes.
(All inspection specification/parameters are taken from repsective standards for reference purpose.
Final decision for acceptance / rejection shall be based on the requirements of the respective
standards and / or Customer Manufacturing Quality Plan.)
4.0 WORKMANSHIP
4.1 The flat faces of washers and the inner and outer peripheries shall be smooth and free from
knurling, serrations, die marks, deep scratches, etc, although slight feed roll marks shall be
permissible.
4.2 Washers shall also be free from burrs, rust, pit marks, loose scale and defects that might affect
their serviceability.
4.3 The clearances and angles of the cut ends shall be in such degree so that the washers do not
cause lapping when they are completely compressed and shall not be liable to tangle or link together
when in the free condition.
Page 69 of 121
COMPANY STANDARD CS – 16
ISSUE NO. 9 01.01.13
SPECIFICATION FOR SPRING
REV. NO.
WASHERS
SHEET NO. 2 OF 8
6.0 COILING
As per ASME B18.21.1 Washers shall be coiled so that the free height is equivalent to twice the
thickness of the washer section. The gap and relationship of the severed ends shall be such as to
prevent washers from tangling and to ensure that washers compress flatly.
8.2 Spring washers shall be made of spring steel complying with the specifications of DIN 17221 or
DIN 17222, or for spring steel with equivalent properties, the grade being at the manufacturers
discretion.
Table – 2: As per DIN 17222 chemical composition of Spring steel shall be as follows:
Width range C55 0.50 – 0.60 0.60 – 0.90 0.035 0.025 0.35
6-325mm, and
C62 0.60 – 0.67 0.60 – 0.90 0.035 0.025 0.35
Thickness
0.40-3.0mm. C80 0.75 – 0.85 0.60 – 0.90 0.035 0.025 0.35
Page 70 of 121
COMPANY STANDARD CS – 16
ISSUE NO. 9 01.01.13
SPECIFICATION FOR SPRING
REV. NO.
WASHERS
SHEET NO. 3 OF 8
8.3 As per IS 4072 chemical composition for steel of spring washers shall be as given below in the
table:
Grade Designation C% Si % Mn % S% P% Cr % V%
(max) (max)
1 55C6 0.50-0.60 0.10-0.35 0.50-0.65 0.050 0.050 - -
2 65C6 0.60-0.70 0.10-0.35 0.50-0.80 0.050 0.050 - -
3 70C6 0.65-0.75 0.10-0.35 0.50-0.80 0.050 0.050 - -
4 80C6 0.75-0.85 0.10-0.35 0.50-0.80 0.050 0.050 - -
5 38Si7 0.35-0.42 1.50-1.90 0.60-0.80 0.040 0.040 - -
6 50Si7 0.45-0.55 1.50-2.00 0.50-0.80 0.050 0.050 - -
7 55Si7 0.50-0.60 1.50-2.00 0.70-1.00 0.050 0.050 - -
8 60Si7 0.55-0.65 1.50-2.00 0.70-1.00 0.050 0.050 - -
9 50CrV4 0.47-0.55 0.15-0.35 0.80-1.10 0.035 0.035 0.90-1.20 0.07-0.12
8.4 Chemical composition of Finished Product after check analysis shall not exceed the limits
specified above in the table by more than the following permissible variation:
Constituent Permissible variation over the maximum or under
minimum specified limits, in percent
C, Carbon 0.02
Mn, Manganese:
Upto 0.9% 0.03
Over 0.9% 0.04
Si, Silicon:
Upto 0.35% 0.02
Over 0.35% 0.05
S, Sulphur 0.005
P, Phosphorus 0.005
Page 71 of 121
COMPANY STANDARD CS – 16
ISSUE NO. 9 01.01.13
SPECIFICATION FOR SPRING
REV. NO.
WASHERS
SHEET NO. 4 OF 8
10.0 GALVANISING:
10.1 The Spring Washer shall have Electro galvanized or Hot Dip galvanized coating (unless
otherwise specified in Purchase Order).
10.2 Electro galvanizing shall be in accordance with Grade 4 (Fe/Zn 25) as per IS: 1573, BS 3382
Hot Dip Galvanizing shall be in accordance with IS: 1367(Part XIII), BS 729, DIN 267 Part 10, ASTM
A 153.
Page 72 of 121
COMPANY STANDARD CS – 16
ISSUE NO. 9 01.01.13
SPECIFICATION FOR SPRING
REV. NO.
WASHERS
SHEET NO. 5 OF 8
10.2.1 The Electro Galvanized Spring washers shall have a minimum of coating thickness of 25
microns. Test shall be done in accordance with testing method as per IS: 3203.
10.2.2 Average coating thickness shall be minimum 38 microns. Each individual piece of spring
washer shall meet this requirement.
10.3 Hot Dip Galvanizing shall be done meeting the requirements specified in IS 1367 Part XIII,
ASTM 153 and DIN 267 Part 10.
10.4 Hot Dip Galvanizing shall not entail the loss of hardness property of Spring Washers due to hot
dip galvanizing process (if specified in Purchase Order).
10.5 In case the Spring Washers are hot dip galvanized the minimum Inner diameter shall be 0.2 mm
more than specified above in order to accommodate the Zinc Coating.
10.6 In case spring washers are Hot Dip Galvanized then the galvanizing requirement shall be as
mentioned below for relevant specifications –
10.6.1 As per IS 1367 Part XIII
2
1) Each individual sample shall meet the requirement of 300 g/m (43 µ) when tested by Stripping
Method or by Coating Thickness Gauge.
2
2) The average of individual samples tested shall meet the requirement of minimum 375 g/m (54 µ)
when tested by Stripping Method or by Coating Thickness Gauge.
3) Uniformity of coating thickness shall be carried out as per IS: 2633. Samples shall withstand
minimum four dips of one minute each.
4) The Adhesion of Zinc Coating shall be carried out as per IS 2629. Zinc on sample should not be
flake off after prying the surface with a Stout Knife.
11.2 The zinc coating shall be smooth and reasonably uniform in thickness.
Page 73 of 121
COMPANY STANDARD CS – 16
ISSUE NO. 9 01.01.13
SPECIFICATION FOR SPRING
REV. NO.
WASHERS
SHEET NO. 6 OF 8
12.0 RETEST
If any one of the samples selected fail to meet the requirements, then twice the number of samples
first taken shall be so tested, and if any one of these fails the batch represented by the samples shall
be rejected or the batch may be re-galvanized and re-submitted for testing.
13.0 PACKAGING
For Packing details refer CS – 14 or As per customer requirements.
14.0 INSPECTION
14.1 The entire quantity ordered shall be packed and kept ready in all respects prior to inspection by
Inspecting Engineer.
14.2 The material shall be cleared for dispatch on satisfactory conformance to all requirements.
14.3 For acceptance or rejection or dispatch clearance MICC shall be issued with remarks and sign
on the documents.
Page 74 of 121
COMPANY STANDARD Annexure 1 to CS – 16
ISSUE NO. 9 01.01.13
SPECIFICATION FOR SPRING
REV. NO.
WASHERS
SHEET NO. 7 OF 8
16.0 DIMENSIONS
16.1 As per IS 3063 & DIN 127 Dimensions of Type A and Type B Washers of nominal sizes 12 mm,
16 mm and 20 mm to suit M12, M16 and M 20 Bolts shall be as follows:
s s
600 r
d1
d2 d2
b
k
h„
h
TYPE A TYPE B
d1 d2 b s r' k* h' - Type A h - Type B
Bolt size
Basic Tol + max Basic Tol + Basic Tol + Nom Min Max Min Max
10 10.2 0.5 18.1 3.5 0.2 2.2 0.15 0.5 0.3 5 5.9 4.4 5.2
12 12.2 0.5 21.1 4 0.2 2.5 0.15 1 0.4 5.8 6.8 5 5.9
16 16.2 0.8 27.4 5 0.2 3.5 0.2 1 0.4 7.8 9.2 7 8.3
20 20.2 1 33.6 6 0.2 4 0.2 1 0.4 8.8 10.4 8 9.4
24 24.5 1 40 7 0.25 5 0.2 1.6 0.5 11 13 10 11.8
30 30.5 1.2 48.2 8 0.25 6 0.2 1.6 0.8 13.6 16.1 12 14.2
36 36.5 1.2 58.2 10 0.25 6 0.2 1.6 0.8 13.6 16.1 12 14.2
1) 2)
42 42.5 1.2 68.2 12 0.25 7 0.25 2 0.8 15.6 18.4 14 16.5
1) 2)
48 49 1.5 75 12 0.25 7 0.25 2 0.8 15.6 18.4 14 16.5
1) 2)
52 53 1.5 83 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
56 57 1.5 87 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
60 61 1.5 91 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
64 65 1.5 95 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
68 69 1.5 99 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
72 73 1.5 103 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
80 81 1.5 111 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
90 91 1.5 121 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
100 101 1.5 131 14 0.25 8 0.25 2 1 18 21.2 16 18.9
Note:
1) Test values for spring force test as described in specification is not been specified for this sizes.
2) Test values for the test for permanent set as described in speification is not been specified for this
size.
Page 75 of 121
COMPANY STANDARD Annexure 2 to CS – 16
ISSUE NO. 9 01.01.13
SPECIFICATION FOR SPRING
REV. NO.
WASHERS
SHEET NO. 8 OF 8
As per ASME B18.21.1Dimensions of Spring Washers of nominal sizes ½”, 5/8”, ¾” 7/8” and 1” to
suit ½”, 5/8”, ¾” 7/8” and 1” Bolts shall be as follows:
T to ti
A B
B
W
W
Page 76 of 121
COMPANY STANDARD CS – 17
ISSUE NO. 9 01.01.13
1.0 SCOPE
This standard covers the chemical, visual, dimensional, mechanical and galvanizing requirements for
hot dip galvanized Hexagon and Square Head Transmission Bolts in the size range M12, M16, M20
& M24 (as per IS, ISO, DIN) and inch series sizes ½”, 5/8”, ¾”, 7/8”, 1” (as per ASTM).
(All inspection specification/parameters are taken from repsective standards for reference purpose.
Final decision for acceptance / rejecton shall be based on the requirements of the respective
standards and / or Customer Manufacturing Quality Plan.)
X2
Page 77 of 121
COMPANY STANDARD CS – 17
ISSUE NO. 9 01.01.13
Figure 2
Y1
Y222
Y11
Y2
6.0 DIMENSIONS
6.1 Dimensions of the Bolts shall be as per IS: 12427 / ISO: 4016 / DIN: 7990 / BS: 4190 / ASME
B18.2.1 or as Specified in Purchase Orders. For Dimensions see Annexure -2 and Symbols for
Dimensions as per Figure 3
o o
15 to 30
x
x
d e
Ø a w
Ød
d Øds
gl sl b
c k S
l
Figure 3
6.2 The effective Thread Length shall be measured as given below and shown in Figure 4:
6.2.1 The Bolt Length (l) shall first be measured.
6.2.2 A Screw Ring Gauge shall then be fitted on to the Bolt by hand, to the fullest extent.
6.2.3 Distance between Bearing Faces of Bolt Head and Ring Gauge shall then be measured (ls).
6.2.4 Difference of lengths (l-ls) shall be the effective Thread Length and shall be controlled in the
limits as indicated (Refer Figure-4).
Page 78 of 121
COMPANY STANDARD CS – 17
ISSUE NO. 9 01.01.13
Figure 4
l
ls
Screw Ring
Gauge
6.3 Dimensions of the Nut shall be as per IS: 1363 Part-3 / ISO: 4034 / DIN EN 24034 / ASME
B18.2.2 as Specified in Purchase Order. For Dimensions & Tolerances of the nuts comply with the
values given in Annexure - 2 & Symbols of Dimensions are as per Figure 5.
0 0
15 to 30
d e
dw
m‟ s
m Figure 5
Page 79 of 121
COMPANY STANDARD CS – 17
ISSUE NO. 9 01.01.13
8.3 The diameter of the circle so formed on the head due to the chamfering shall not be less than
90% of the minimum width across the flats distance.
0 0
8.4 Nuts shall be chamfered on both faces at an angle of 15 to 30 so that the diameter of the circle
so formed is not less than 90% of the minimum width across the flats.
9. PROPERTY CLASS
9.1 Property Class of Bolt shall be 4.6/5.6/5.8/6.8 or 8.8 as per ISO: 898 Part I/Specified in Purchase
Order.
9.2 Property Class of Nut shall be 4/5/6 or 8 as per ISO: 898 Part II/Specified in Purchase Order.
10 CHEMICAL COMPOSITION
10.1 Bolt-Nut shall be manufactured from Carbon Steel with Chemical Composition as per Anexure-
1.
10.2 The Manufacturer shall carry out Chemical Analysis for each size of Raw Material (wire rods)
used for manufacture of Bolts & Nuts.
10.3 The result shall meet the requirement of the relevant specification and shall be suitable for the
process of manufacture adopted.
10.4 One sample shall be drawn for Chemical Analysis for each Grade & Size of raw material for
each 20 MT and part thereof by the manufacturer.
10.5 KEC Representative shall do the verification of Chemical Properties on the basis of one sample
for each Grade & Size of Bolts & Nuts.
Page 80 of 121
COMPANY STANDARD CS – 17
ISSUE NO. 9 01.01.13
10.2.6 The Angle of Wedge used for the Wedge Loading Test for M12, M16, M20 and M24 Bolts
shall be as follows:
Property Class for
Nominal dia. of
Bolt with plain shank length ls 2d Bolt with plain shank length ls 2d
Bolt „d‟ mm
4.6, 5.6, 5.8 & 8.8 6.8 4.6, 5.6, 5.8 & 8.8 6.8
d 20 10 6 6 4
20 d 39 6 4 4 10
The Hardness of the Wedge shall be minimum 45 HRC.
10.2.7 Head Soundness Test
1) Test shall be conducted on Bolts having diameter less than or equal to 16 mm and lengths less
than 2.5 times the diameter.
2) The Test Plate shall have a thickness above 32 mm and the value of „‟ (Refer Figure-6) shall be
0 0
60 for testing bolts of Grade 4.6 & 5.6 and 80 for testing bolts of Grade 5.8, 6.8 & 8.8.
3) There shall be no crack on the Shank Head fillet after the head is hammered.
Figure - 6
10.2.8 Hardness Test shall be conducted on Bolt Head for bolts grade 5.6 and on Shank End for
bolts of grade 5.8 after stripping the bolt of galvanized coating and polishing thoroughly the Test
Surface to smoothness.
Page 81 of 121
COMPANY STANDARD CS – 17
ISSUE NO. 9 01.01.13
10.3.1 Mechanical Test method for Nuts shall be as per IS: 1367(Part 6) or ISO: 898 Part 2 and
Mechanical Properties as per Annexure - 3.
Page 82 of 121
COMPANY STANDARD CS – 17
ISSUE NO. 9 01.01.13
12.0 GALVANIZING
Bolt nuts shall be galvanized as per requirement mentioned in Purchase order or with respect to
relevant standards.
12.1 The Fasteners shall be Hot Dip Galvanized as per IS: 1367 Part XIII or ASTM A: 153
12.2 The galvanized coating requirements on the Bolts & Nuts shall be as per IS: 1367(Part XIII) or
ASTM A: 153.
12.3 Nut Thread shall be tapped oversize according to the following diametric allowances in order to
accommodate the galvanizing on Bolt Threads
As per IS 1367 Part XIII As per ASTM A 563
NUT SIZE OVER TAPPING NUT SIZE OVER TAPPING
M 12 +0.3 mm M ½ inch ± 0.018 inch / 0.46 mm
M 16 +0.4 mm M 5/8 inch ± 0.020 inch / 0.51 mm
M 20 +0.5 mm M ¾ inch ± 0.020 inch / 0.51 mm
12.4 The Bolt Threads shall not be Re-died, Re-cut or Re-rolled after galvanizing.
12.5 Bolt-Nuts shall be oiled at the time of Buttoning i.e., assembling.
12.6 Zinc Coating Requirements:
12.6.1 Weight Of Zinc Coating:
Test to determine the weight of Zinc Coating per unit area of the Bolts, Nuts shall be as per
Appendix-B of IS: 1367(Part XIII) and shall meet the following requirements as per IS: 1367(Part
XIII) or ASTM A: 153 as required.
Specification Min. Wt. (gm/m2) Thickness (micron)
IS: 1367 (Part XII) Individual 300 43
Average 375 54
ASTM A: 153 Individual 305 43
Average 381 54
Page 83 of 121
COMPANY STANDARD CS – 17
ISSUE NO. 9 01.01.13
Note: In addition to Inspection & Testing of Raw Material and Process Material, the Manufacturer
shall conduct inspection & testing on Finished Material after drawing samples for, Mechanical Test as
per Table-1 as per IS: 2614 and Table-2 for Galvanizing Tests as per IS: 1367(Part XIII).
14.0 RETEST
Should any one the specimen fails a galvanizing test then a sample of double the number of the; first
sample shall be drawn and the test re-conducted. If any single specimen from the second sample
fails the test, then the entire lot represented by the samples shall be deemed Rejected due to
improper galvanizing and may be re-galvanized for Inspection & Testing again.
15.0 MARKING
The Bolt Heads shall bear embossed markings to indicate the grade of the Bolt and name of the
manufacturer. If customer specifies the marking then it shall be done as per customer specification.
16.0 PACKAGING
Refer CS – 14 for Packing of Bolt and Nuts or As per customer requirements / specification.
16.0 INSPECTION
16.1 The full consignment of Bolts/Nuts shall be kept ready in all respects and packed prior to
inspection by KEC Representative.
16.2 Once the material is found acceptable on satisfactory inspection results, all the bags shall be
sealed for dispatch to the destination specified.
16.3 KEC inspector shall issue MICC after inspection stating the status of inspection. MICC shall be
issued for accepted and rejected lot.
Page 84 of 121
COMPANY STANDARD Annexure 1 to CS – 17
ISSUE NO. 9 01.01.13
MECHANICAL PROPERTIES OF STEEL BOLTS AS PER IS 1367 PART 3, IS 12427 / ISO 898
PART 1 / DIN: 20898 Part I:
M 12 42200 23600
M 16 78500 44000
5.6 310 79-99.5 HRB
M 20 122000 68600
M 24 176000 98800
M 12 43800 32000
M 16 81600 59700
5.8 322 82-99.5 HRB
M 20 127000 93100
M 24 184000 134000
M 12 50600 37100
M 16 94000 69100
6.8 375 89-99.5 HRB
M 20 147000 108000
M 24 212000 155000
M 12 70000* 50700*
M 16 130000* 91500*
8.8 515 22-32 HRC
M 20 203000 147000
M 24 293000 212000
* For Structural Bolting
Note: ** All grade, size and specification of bolts shall be mandatory shear tested and it shall meet
the minimum shear load value mentioned above in the table.
MECHANICAL PROPERTIES OF STEEL NUTS AS PER IS 1367 PART 6, ISO 898 PART 2 and
DIN: 20898 Part 2:
Property Class 5 Property Class 6 Property Class 8
Nominal
Size of Nut Proof Load Hardness Proof Load Hardness Proof Load Hardness
in N in HV in N in HV in N in HV
M12 51400 59000 74200
130 - 302 150 - 302 200 - 302
M16 95800 109900 138200
M20 154400 176400 225400
146 - 302 170 - 302 233 - 302
M24 222400 254200 324800
Page 85 of 121
COMPANY STANDARD Annexure 2 to CS – 17
ISSUE NO. 9 01.01.13
Hardness -
Grade Scale of Hardness Minimum Maximum
Type 0 Rockwell B 80 100
Type 1,2, 3 Rockwell C 25 34
Hex Nuts, Proof Load (lbf) Heavy Hex Nuts, Proof Load (lbf)
Grade O A D DH A D DH
Dia, 52 69 68 90 135 150 75 100 150 150 175
½” 7379 9791 9649 12771 19157 21285 10643 14190 21285 21285 24833
5/8” 11752 15594 15368 20340 30510 33900 16950 22600 33900 33900 39550
¾” 17368 23046 22712 30060 45090 50100 25050 33400 50100 50100 58450
7/8” 24024 31878 31416 41580 62370 69300 34650 46200 69300 69300 80850
1” 31512 41814 41208 54540 81810 90900 45450 60600 90900 90900 106050
1 3/8” 60060 79695 78540 103950 155925 173250 86625 115500 173250 173250 202125
Hardness Of Nuts -
HRB 55 min 68 min 84 - 68 min 84 -
HRC 32 max 32 max 38 24 - 38 32 max 38 24 - 38
Page 86 of 121
COMPANY STANDARD Annexure 3 to CS – 17
ISSUE NO. 9 01.01.13
CHEMICAL COMPOSITION OF STEEL BOLTS ISO: 898 Part I, DIN: 20898 Part I & IS: 1367 Part III
Chemical Composition Limits (Check Analysis) % Tempering
Property Class C% P% S% Temp. C
Min. Max. Max. Max. Min.
4.6 -- 0.55 0.05 0.06 --
5.6 0.13 0.55 0.05 0.06 --
5.8 -- 0.55 0.05 0.06 --
6.8 -- 0.55 0.05 0.06 --
Carbon steel with B. Mn / Cr.
Quenched and tempered
0.15 0.40 0.035 0.035 425
8.8
Carbon steel quenched and
tempered
0.25 0.55 0.035 0.035 425
1. Free cutting steel is allowed for Property class 4.6, 5.8 & 6.8 with the following composition:
S - 0.34% Max, P - 0.11% Max & Pb - 0.35% Max
2. For the nominal diameter above 20mm the steel specified for property class 10.9 may be necessary
in order to achieve sufficient hardenability.
CHEMICAL COMPOSITION OF STEEL NUTS ISO: 898 Part II, DIN: 20898 Part II & IS: 1367 Part VI
Chemical Composition Limits (Check Analysis) %
Property C% Mn % P% S%
Class Max. Max. Max. Max.
4, 5 & 6 0.50 -- 0.06 0.15
8 0.58 0.25 0.06 0.15
Nuts of Property Class 4, 5 & 6 may be manufactured from free cutting steel unless otherwise agreed
between the manufacturer and purchaser. In such case following are permissible. S - 0.34% Max, P -
0.11% Max & Pb - 0.35% Max
Page 87 of 121
COMPANY STANDARD Annexure 4 to CS – 17
ISSUE NO. 9 01.01.13
OVERTAPPING ALLOWANCE FOR NUTS AFTER HDG ZINC COATED AS PER ASTM A 563
Page 88 of 121
COMPANY STANDARD Annexure 5 to CS – 17
ISSUE NO. 9 01.01.13
DIMENSIONS OF BOLTS AS PER IS: 12427 / ISO: 4016 / DIN EN: 24016:
o o
15 to 30
x
x
d e
Ø a w
Ød
d Øds
gl sl b
c k S
l
Figure 3
DIMENSIONS OF BOLTS AS PER IS: 12427 / ISO: 4016 / DIN EN: 24016
Shank diameter ds 11.3 12.7 15.3 16.7 19.16 20.84 21.16 22.84 23.16 24.84
Washer face dw 16.47 18.0* 22.0 24.0* 27.7 30.0* 31.35 34.0* 33.25 36.0*
Head thickness k 7.05 7.95 9.25 10.75 11.6 13.4 13.1 14.9 14.1 15.9
Width across flat s 17.57 18.00 23.16 24.0 29.16 30.0 33.0 34.0 35.0 36.0
Page 89 of 121
COMPANY STANDARD Annexure 6 to CS – 17
ISSUE NO. 9 01.01.13
o o
15 to 30
x
x
d e
Ø a w
Ød
d Øds
gl sl b
c k S
l
Figure 3
Page 90 of 121
COMPANY STANDARD Annexure 7 to CS – 17
ISSUE NO. 9 01.01.13
E d G
LT
LG F
H L
Figure 3
Dimensions in Millimeters -
LT - Thread Length
Length Length
Nominal E' - Shank F' - Width Across G' - Width Across H' - Head Height, R' - Radius of
Less than Above
Dia Diameter, mm Flats, mm Corners, mm mm Fillet, mm
152.4mm 152.4mm
mm max min max min max min Max min max min max min
12.70 13.081 12.243 19.050 18.415 21.996 20.980 9.246 7.671 0.762 0.254 31.75 38.10
15.88 16.307 15.367 23.825 23.012 27.508 26.238 11.278 9.601 1.524 0.508 38.10 44.45
19.05 19.507 18.517 28.575 27.635 32.995 31.496 13.310 11.557 1.524 0.508 44.45 50.80
22.23 22.733 21.641 33.325 32.233 38.506 36.754 15.342 13.487 1.524 0.508 50.80 57.15
25.40 25.959 24.790 38.100 36.830 43.993 41.986 17.780 15.011 2.286 0.762 57.15 63.50
Dimensions in Inches -
LT - Thread Length
E' - Shank G' - Width Length
F' - Width Across R' - Radius of Length
Nominal Diameter, Across Corners, H' - Head Height, inch Less
Flats, inch Fillet, inch Above 6"
Dia, inch inch inch than 6"
max min Basic max min max min Basic max min max min max min
1/2 0.500 0.515 0.482 3/4 0.75 0.73 0.87 0.83 11/32 0.36 0.30 0.03 0.01 1.25 1.50
5/8 0.625 0.642 0.605 15/16 0.94 0.91 1.08 1.03 27/64 0.44 0.38 0.06 0.02 1.50 1.75
3/4 0.750 0.768 0.729 1-1/8 1.13 1.09 1.30 1.24 1/2 0.52 0.46 0.06 0.02 1.75 2.00
7/8 0.875 0.895 0.852 1-5/16 1.31 1.27 1.52 1.45 37/64 0.60 0.53 0.06 0.02 2.00 2.25
1 1 1.022 0.976 1-1/2 1.50 1.45 1.73 1.65 43/64 0.70 0.59 0.09 0.03 2.25 2.50
Page 91 of 121
COMPANY STANDARD Annexure 8 to CS – 17
ISSUE NO. 9 01.01.13
Page 92 of 121
COMPANY STANDARD Annexure 9 to CS – 17
ISSUE NO. 9 01.01.13
H H
F
Dimensions in Inches
Runout of Runout of
Bearing Bearing
G' - Width Face FIM - Face FIM -
F' - Width Across
Nominal Dia, Across H' - Head Height, inch for specific for specific
Flats, inch
Inch Corners, inch proof load proof load
Upto 150000 psi
150000 psi & above
Basic max min max min Basic max min inch inch
1/2 0.500 3/4 0.750 0.736 0.866 0.840 7/16 0.448 0.427 0.019 0.014
9/16 0.563 7/8 0.875 0.861 1.010 0.982 31/64 0.496 0.473 0.020 0.015
5/8 0.625 15/16 0.938 0.922 1.083 1.051 35/64 0.559 0.535 0.021 0.016
3/4 0.750 1-1/8 1.125 1.088 1.299 1.240 41/64 0.665 0.617 0.023 0.018
7/8 0.875 1-5/16 1.312 1.269 1.516 1.447 3/4 0.776 0.724 0.025 0.020
1 1.000 1-1/2 1.500 1.450 1.732 1.653 55/64 0.887 0.831 0.027 0.022
Dimensions in Millimeters
Runout of Runout of
Bearing Face Bearing Face
Nominal F' - Width Across G' - Width Across H' - Head Height,
FIM for specific FIM for specific
Dia, mm Flats, mm Corners, mm mm
proof load Upto proof load 1034
2 2
1034 N/mm N/mm & above
mm max min max min max min mm Mm
12.700 19.050 18.694 21.996 21.336 11.379 10.846 0.4826 0.3556
14.288 22.225 21.869 25.654 24.943 12.598 12.014 0.5080 0.3810
15.875 23.825 23.419 27.508 26.695 14.199 13.589 0.5334 0.4064
19.050 28.575 27.635 32.995 31.496 16.891 15.672 0.5842 0.4572
22.225 33.325 32.233 38.506 36.754 19.710 18.390 0.6350 0.5080
25.400 38.100 36.830 43.993 41.986 22.530 21.107 0.6858 0.5588
Page 93 of 121
COMPANY STANDARD CS – 18
ISSUE NO. 9 01.01.13
SPECIFICATION FOR ANTI THEFT BOLT
REV. NO.
AND NUTS
SHEET NO. 1 OF 2
1.0 SCOPE:
This standard covers the requirements of inspection & testing of galvanized Anti-Theft Bolt Nuts.
2. 0 REFERENCE SPECIFICATIONS:
As per drawing mentioned in Purchase order and following standards as applicable
IS: 1363 (Part-I to III) IS: 10238 ISO / DIN EN 2 4034
IS: 1367 (Part-I to III) BS: 4190 ISO / DIN EN 2 4016
IS: 1367 (Part-VI) DIN 267 (Part 10) ISO 898(Part I & II)
IS: 1367 (Part-XIII) DIN EN 20898 (Part 1 & 2) ASTM A 153
IS: 12427 DIN EN 20898 (Part 6 & 7) ASTM F 812 & 788
ASTM A 394 ASTM 563 ASME B18.2.1
Page 94 of 121
COMPANY STANDARD CS – 18
ISSUE NO. 9 01.01.13
SPECIFICATION FOR ANTI THEFT BOLT
REV. NO.
AND NUTS
SHEET NO. 2 OF 2
8.0 MARKING:
Bolt Heads shall have marking of manufacturer and grade of bolt.
9.0 PACKING:
For Packaging of Anti Theft Bolt Nuts shall be as per bolts and nuts packing CS-14
Page 95 of 121
COMPANY STANDARD CS – 19
ISSUE NO. 9 01.01.13
SPECIFICATION OF SAMPLING PLAN
REV. NO.
FOR INSPECTION AND TESTING
SHEET NO. 1 OF 8
1.0 SCOPE
This Standard covers sampling plan for inspecting and testing the Raw Material, In-Process Material,
Fabricated Material, Galvanized Material and Finished Material under various National and
International standards.
2.0 REFERENCE
2.1 For Raw Material, Fabricated Material & Galvanized Material - IS 2062, IS 2500, IS 2629, IS
4759, BSEN 10025, ASTM A6, A36, A572, A123 and applicable standards
2.2 For Bolt, Nuts, Washers and Accessories - IS 2614, IS 1367 Part XIII, A153, A307, A394, A563
Page 96 of 121
COMPANY STANDARD CS – 19
ISSUE NO. 9 01.01.13
SPECIFICATION OF SAMPLING PLAN
REV. NO.
FOR INSPECTION AND TESTING
SHEET NO. 2 OF 8
3.1.3 For Galvanizing Tests (Mass test, Uniformity test, Adhesion test) of Tower Members
number of samples as per IS 2629 & IS 4759:1
All the material of the same type in a coating bath having uniform coating characteristics shall be
grouped together to constitute a lot. Sampling shall be done as given below in the table:
No. of units in No. of units to be Acceptance
thetoLot
Up 25 selected in
3 a sample No.
0
26 to 100 5 0
101 to 150 8 1
151 to 500 13 1
501 to 1000 20 2
1001 to 10000 32 3
Over 10000 50 5
3.2.2 For Mechanical Tests (Hardness, Proof, Shear, Wedge, Head soundness) of Fasteners
number samples as per IS 2614:
Lot size Sample Size Acceptance No.
Upto 1000 5 0
1001 to 3000 8 0
3001 to 10000 13 0
10001 to 35000 20 0
Over 35000 32 1
3.2.3 For Galvanizing Tests (Mass test, Uniformity test, Adhesion test) of Fasteners number of
samples as per IS 1367 Part XIII:
Total Number of Fasteners in Number of Test Samples
Upto andBatch
including 500 3
501 Up to and including 35000 5
Over 35000 8
If any one of the samples selected fail to meet the requirements then twice the number of samples
first taken shall be so tested, and if any one of these fails the batch represented by the samples shall
be rejected. Refer CS-19 clause 6.0 Procedure for Re-test.
Page 97 of 121
COMPANY STANDARD CS – 19
ISSUE NO. 9 01.01.13
SPECIFICATION OF SAMPLING PLAN
REV. NO.
FOR INSPECTION AND TESTING
SHEET NO. 3 OF 8
4.1.1 For Visual and Dimensional Tests refer CS-19 clause no. 3.1.1 for number of samples.
4.1.2 For Mechanical and Chemical Tests number of samples as per ASTM A6:
Test Parameters Sampling
Mechanical test: Yield Stress
Ultimate Tensile
% of Elongation Two sample per heat / cast
Bend test
Charpy / Impact
Chemical tests Two sample per heat / cast
4.1.3 For Galvanizing Tests (Mass test, Uniformity test, Adhesion test) of Tower Members
number of samples as per ASTM A 123:
Number of pieces in lot Number of specimens
3 or less 100%
4 to 500 3
501 to 1200 5
1201 to 3200 8
3201 to 10000 13
10001 and over 20
Page 98 of 121
COMPANY STANDARD CS – 19
ISSUE NO. 9 01.01.13
SPECIFICATION OF SAMPLING PLAN
REV. NO.
FOR INSPECTION AND TESTING
SHEET NO. 4 OF 8
4.2.2 For Mechanical Tests number of samples for items as per ASTM A 394 (Bolts), A 563 (Nuts),
F 436 (Washers), A 307 (Step Bolts):
4.2.3 For Chemical Test number of samples for items as per specifications ASTM A 394 (Bolts), A
563 (Nuts), F 436 (Washers), A 307 (Step Bolts) shall be:
One sample for each grade, size, lot / batch and raw material used.
4.2.4 For Galvanizing Tests (Mass test, Uniformity test, Adhesion test) number of samples as
per ASTM A 153:
Number of pieces in lot Number of specimens
3 or less 100%
4 to 500 3
501 to 1200 5
1201 to 3200 8
3201 to 10000 13
10001 and over 20
Page 99 of 121
COMPANY STANDARD CS – 19
ISSUE NO. 9 01.01.13
SPECIFICATION OF SAMPLING PLAN
REV. NO.
FOR INSPECTION AND TESTING
SHEET NO. 5 OF 8
5.1.3 For Galvanizing Tests (Mass test, Uniformity test, Adhesion test) of Tower Members and
Bolt Nuts and Washers number of samples as per ISO 1461 (BS729 is replaced by ISO1461):
Lot size Sample size
1–3 All
4 – 500 3
501 – 1200 5
1201 – 3200 8
3201 – 10000 13
>10000 20
6.0 SAMPLING FOR IN-PROCESS INSPECTION OF STEEL SHAPES & PLATES IN ABSENCE
OF HEAT/CAST IDENTIFICATION:
6.1 FOR STEEL SHAPES AND PLATES
6.1.1 For Visual and Dimensional Tests refer CS-19 clause no. 3.1.1 for number of samples.
6.1.2 For Sectional weight, Mechanical and Chemical Tests number of samples shall be
mentioned below:
Test Parameters Sampling
a) Sectional weight test If material is not as per cast / heat wise then it shall be
b) Mechanical test: Yield Stress treated as lot. Sampling of lot shall be done as mentioned
Ultimate Tensile below.
% of Elongation
Bend test If lot is: 0MT to 10MT – 1 sample
Charpy / Impact Above 10MT and below 40MT – 2 samples
40MT & Above – 3 samples, and
c) Chemical test For every additional 20MT – 1 sample
6.2 Inclusion rating, grain size, microstructure shall be per grade, per size, per heat and per
lot.
7.0 SAMPLING PLAN FOR ZINC INGOTS & MOLTEN ZINC FROM GALVANIZING BATH -
7.1 Incoming zinc to be tested/verified for each receipt of consignment and inline with CS-10.
7.2 Weekly molten zinc in bath to be tested and recorded. Compliance as per applicable standard.
Flange 1
Flange2
Total No of Readings on one Angle is 30 Points from both the Flanges. (Inside & Outside
both)
9.3 Sampling Plan for Visual and Dimensional Audit Inspection of Fabricated and Galvanized
Tower Members
Acceptance Rejection
Lot Size Sample Size
Number Number
Up to 500 nos. 03 00 01
1.0 SCOPE:
This standard covers the procedures that can be followed to safeguard against the possible
embrittlement of steel hot-dip galvanized after fabrication and outlines test procedures for detecting
embrittlement.
2. 0 PURPOSE:
The purpose of this standard is to detect the embrittlement of hot-dip galvanized steel after
fabrication in line with the applicable standard & customer requirement.
3.0 TERMINILOGY:
The loss or partial loss of ductility in steel where an embrittlement product characteristically fails by
fracture without appreciable deformation: types of embrittlement usually encountered in galvanized
steel are related in aging phenomena, cold working, and absorption of hydrogen.
5.1.5 The galvanized article should withstand a degree of bending substantially the same as the
ungalvanized article.
5.1.6 Flaking or spalling of the galvanized coating is not to be construed as an embrittlement failure.
5.1.7 For thread articles, the test shall be made on the unthreaded portion.
5.2 Test of small steel castings and steel hardware of such shape or size that do not permit bending:
5.2.1 The article having shape or size that do not permit bending may be struck a sharp blow with a
2-lb or 1 kg hammer.
5.2.2 Compare the results of sample of galvanized article with the sample of ungalvanized article
after stroking a blow of 2 lb or 1 kg.
5.2.3 If the article withstands such a blow in the ungalvanized condition, but after galvanizing cracks
under the blow, it shall be considered as embrittle.
Bending Load
l d
2”
L1
t
L2
7.0 PROCEDURE
Following is a procedure to conduct test:
1) Test shall be conducted on Universal Testing Machine or by any other means in which a press
with the load applied slowly, until fracture of the galvanized test specimen occurs.
2) The length of the test specimen and the distance between the supports are shown in the table
mentioned above.
3) After the test distance along the gauge length from each punch mark to the corresponding edge of
the fracture shall be measured to 0.01 inch or 0.25 mm with a flexible scale and the percentage of
elongation calculated from the sum of these distances.
4) For determining the percentage reduction in thickness after fracture the reduction shall be
measured with a ball – point micrometer at the three locations indicated in Fig 2 namely – „a‟ - outer
side of hole, „b‟ - inner side of hole and „c‟ - middle of leg.
5) The percentage reduction of thickness shall be calculated on the basis of the original thickness of
the angle and the average of the three values at „a‟, „b‟ and „c‟.
6) The test shall be made upon galvanized specimens having a temperature not below 600 F or 160 C
and not over 900 F or 320 C when used.
Fracture
c
b
a
9.0 For hot dip galvanized externally threaded fasteners, an alternate test for embrittlement is
detailed in Test method F 606.
This test method determines the embrittlement in a metallic coated externally threaded fasteners
covered by the product specifications of ASTM Committee F-16.
B. The torque method described shall be one method for determining the embrittlement in the
material.
1) The test fixture shall comprise of a hardened wedge, plates and a hardened washer.
2) The wedge shall have an angle as specified in the table mentioned below.
3) Other dimensions and properties shall be in accordance with Wedge Tension Testing of Bolts.
4) The plates shall be steel and have a thickness such that, after installation and tightening, a
minimum of three full threads of the test fastener will be in the grip.
5) The hole in the plates shall be as close to the major diameter of the fasteners being tested as
practical but not greater than the hole in the hardened washer.
6) The hardened washer shall be in conformance with specification F 436.
7) If the torque method of tightening is used then the tightening torque shall be determined using a
load-measuring device capable of measuring the actual tension induced in a fastener as the fastener
is tightened.
8) Three fasteners from the test lot shall be selected at random.
RAJESH MOTGHARE RAJESH KOOLWAL
ISSUED BY SIGNATURE APPROVED BY SIGNATURE
9) Each shall be assembled into the load-measuring device, mated with a nut and the nut tightened
until a load equal to 75% of the specified minimum ultimate tensile strength of the fasteners is
induced.
10) The torque required to induce this load shall be measured and the arithmetic average of the
three-measured torques shall be the tightening torque.
11) The surface against which the nut is torqued should be similar in hardness and finish to that of
test fixture Fig A and use of a hardened washer is recommended.
12) To meet the requirements of this test the fastener shall show no evidence of embrittlement failure
when visually examined and the retightening shall not be less than 90% of the initial tightening
torque.
Test Fastener
Wedge
Plat
es
Hardened F 436
washer with surface
finish of 16 micro ches
or less
NOTE:
1 – For expedience sake the test fixture shown above reflects a single bolt under load. It should be
noted, however, that test fixtures with multiple test locations are acceptable.
2 – Work is continuing on this test method and revisions are anticipated. Additionally caution should
be taken when applying this test procedure. The heads of embrittled fasteners may suddenly break
off and become flying projectiles capable of causing serious injury or binding.
RETEST:
If one test specimen found embrittled by the above mentioned tests then two additional specimens
should be tested. Failure of either the second or the third specimen shall be cause for rejection of the
lot that the samples represent.
1. SCOPE:
This standard covers the requirements of Billets / Blooms / Slabs of Mild Steel and High
Tensile Steel for re-rolling into structural steel angles and plates confirming to IS 2062 and
BSEN 10025 respectively for galvanized transmission towers.
2. PURPOSE:
The purpose of this standard is to ensure the quality and proper identification of Billets /
Blooms / Slabs.
And obtain the required mechanical and chemical properties suitable to respective
applicable standards.
3. TERMINOLOGY:
To fulfill the purpose following definitions shall apply:
b. Bloom: A semi-finished forged rolled or continuously cast product. The cross section is
square or nearly rectangular (excluding slab) and the cross section is generally more than
125mmX125mm (or equivalent cross sectional area).
c. Slab: A semi-finished rolled, forged or continuously cast product intended for re-rolling or
forging. The cross section is rectangular. The thickness does not exceed one third of the
width.
4. MANUFACTURE:
Steel shall be manufactured by any process of steel making except the Bessemer process. It
may be followed by secondary refining.
Steel shall be supplied semi-killed or killed. Rimming steel may also be supplied subject to a
special agreement between the purchaser and the supplier.
5. GRADES:
The grade of material shall be as mentioned in the Purchase orders.
6. SAMPLING PLAN:
The samples shall be selected from Billets / Blooms / Slabs of Mild Steel and High Tensile
Steel as follows:
For Chemical Analysis: Selection of test sample for analysis shall be taken from the
location as shown below in the figure:
8. TESTS:
8.1 Material offered shall be examined through following tests: 1. Nitrogen Test If required
2. Microstructure if required
3. Grain size if required
8.2 BEND: In supply of billets, blooms and continuously cast billets and blooms the bend
shall not exceed 5mm per meter of length.
In supply of slabs and continuously cast slabs the bend shall not exceed 8mm per meter of
slab length.
8.3 CAMBER: In supply of billets, blooms and continuously cast billets and blooms the
camber shall not exceed 3mm per meter of length.
In supply of slabs and continuously cast slabs the camber shall not exceed 8mm per meter
of slab length.
9. DIMENSIONS:
The billets, blooms and slabs including continuously cast shall be reasonably square.
The preferred sizes for width across flat of billets, blooms slabs including continuously cast
shall be 50, 63, 75, 80, 85, 90, 100, 110, 125, 150, 165, 200, 250 and 320mm.
Length of billets, blooms, slabs (including continuously cast) shall be supplied in lengths
between 3 and 13 meters as specified by the purchaser.
10. TOLERANCES:
In case of billets, blooms, slabs (including continuously cast) below tolerances shall apply:
PRODUCT WIDTH ACROSS FLAT (MM) THICKNESS (MM) TOLERANCES (MM)
BILLETS Up to 75 --- 1.5
Over 75 --- 3.0
BLOOMS Up to and including 150 --- + 4.0
- 3.0
Over 150 --- + 6.0
- 3.0
SLABS Up to and including 150 + 3.0
- 4.0
Over 150 + 3.0
- 6.0
Up to and including 300 --- + 3.0
- 6.0
Over 300 --- + 5.0
- 10.0
A tolerance of 150 mm shall be permitted on the specified length of billets, blooms, slabs
(including continuously cast) and cast billet ingots.
SAIL C 15 Grey
One band and two Two bands and two
C 18 Green Two dots at end
dots at one end dots at one end
C 20 Orange
C15 MMn Grey
One band and one Two bands and one
C18 MMn Green One dots at end
dots at one end dots at one end
C20 MMn Orange
C15 HMn Grey
One band and three Two bands and three
C18 HMn Green Three dots at end
dots at one end dots at one end
C20 HMn Orange
Green at
NECO Mild Steel NA NA NA
one end
Blue at
JINDAL Mild Steel NA NA NA
one end
Brown at
ADHUNIK Mild Steel NA NA NA
one end
Black at
JAI BALAJI Mild Steel NA NA NA
one end
Orange at
LLOYDS Mild Steel NA NA NA
one end
Green at
IMPORTS Mild Steel NA NA NA
one end
12. CHEMICAL COMPOSITION: The ladle analysis of steel shall be as given in Table-D.
Incase of steel is manufactured with defined chemistry then TDC – Technical Delivery
Condition to be followed.
Table-D: Ladle Analysis for Mild Steel
Designation Carbon Manganese Grade A, max Grade B, max Grade C, max
C15 0.12-0.18 0.30 to 0.60 Sulfur-0.040 Sulfur-0.040 Sulfur-0.040
C18 0.15-0.21 0.30 to 0.60 Phosforus-0.040 Phosforus-0.040 Phosforus-0.040
C20 0.17-0.23 0.30 to 0.60 Carbon Eq.-0.42 Carbon Eq.-0.41 Carbon Eq.-0.39
C15 MMn 0.12-0.18 0.60 to 1.00
C18 MMn 0.15-0.21 0.60 to 1.00
C20 MMn 0.17-0.23 0.60 to 1.00
C15 HMn 0.12-0.18 1.00 to 1.50
C18 HMn 0.15-0.21 1.00 to 1.50
C20 HMn 0.17-0.23 1.00 to 1.50
Permissible Variation on Ladle Analysis Over Maximum or Under Minimum Limits, %Max
Carbon Manganese Sulfur Phosphorus Copper
Elements
0.02 0.03 0.005 0.005 0.03
Notes:
1. Variations shall not be applicable both over & under the specified limit in several determinations
in a heat.
2. Rimming steels not permitted.
3. The minimum Si content in silicon killed steel shall not be less than 0.10 percent when the steel
is Al/Al-Si killed, the requirement regarding minimum silicon content need not apply. The silicon
content shall not exceed 0.40 percent.
4. When micro-alloying elements like Nb, V and Ti are used individually or in combination the total
content shall not exceed 0.2 percent.
5. Nitrogen content of the steel should not exceed 0.012 percent and shall be ensured by the
manufacturer by occasional check analysis.
6. Details of elements other than those specified may be supplied, if agreed at the time of enquiry.
7. In order to get the desired properties, the chemical composition can be mutually agreed to
between the manufacturer and the purchaser within the stipulation of IS 2062: 1992.
8. If other elements are added, they shall be mentioned on the inspection report. Elements not
quoted in Table-D shall not be intentionally added to the steel without the agreement of the
purchaser, other than for the purpose of finishing the heat. All reasonable precautions shall be
taken to prevent the addition from scrap or other materials used in manufacture of such elements
which effect the harden ability, mechanical properties and applicability.
9. Maximum value for nitrogen does not apply if the chemical composition shows a minimum total
Al content of 0.020% or alternatively min. 0.015% acid soluble Al or If sufficient other N binding
elements are present. In this case the N binding elements shall be mentioned in the inspection
document.
10. Project specific Technical delivery condition to be referred for final ladle/product analysis.
13. RETEST:
If a test does not give the specified results, two additional tests shall be carried out at
random on the same lot. Both retests shall confirm to the requirement of this standard
otherwise the lot shall be rejected.
1.0 SCOPE
This standard covers the requirement for hot finished welded, hot finished seamless and electric
resistance welded or high frequency induction welded plain carbon steel tubes for structural
purposes.
(All inspection specification/parameters are taken from repsective standards for reference purpose.
Final decision for acceptance / rejection shall be based on the requirements of the respective
standards and / or Customer Manufacturing Quality Plan.)
2.0 The Structural Steel shall be suitable for Hot Dip Galvanizing after fabricating pipes into telecom
or transmission line tower parts.
Table – 3: As per IS 4711 Sampling for Physical Tests (Tensile, Bend, Flattening and Drift)
Lot Stage of sample Sample size Acceptance no. Rejection no.
Up to 150 First 2 0 Note 1
151 to 300 First 3 0 2
Second 3 0 1
301 to 800 First 5 0 2
Second 5 1 2
801 to 3000 First 8 0 2
Second 8 2 3
3001 and above First 13 1 3
Second 13 3 4
Note 1: If one sample fails to meet the requirement, the purchaser may select 2nos. of sample randomly from the same lot and both the
samples should comply with the requirements except the original failed length.
Note 2: The test pieces for physical tests may be cut from the same item wherever possible.
5.0 TOLERANCES:
Table – 4: Tolerances on dimensions of pipes / tubes as per following standards
Parameter As per IS 1161 As per IS 1239
Outside Upto & including 48.3mm + 0.4% & - 0.8%
Diameter Over 48.3mm ± 10%
Thickness Welded tubes + Not limited & -10% Welded Tubes:
(for all i. Light + Not limited & - 8%
sizes) ii. Medium & Heavy + Not limited & -10%
Seamless tubes +Not limited & -12.5% Seamless tubes + Not limited & -12.5%
Weight Single tube: Single tube:
i. Light +10% & -8% i. Light +10% & -8%
ii. Medium & Heavy ± 10% ii. Medium & Heavy ± 10%
For 10 tonne lots: For 10 tonne lots:
i. Light ± 5% i. Light + 7.5% & - 5 %
ii. Medium & Heavy ± 7.5% ii. Medium & Heavy ± 7.5%
6.0 WORKMANSHIP:
The tubes shall be cleanly finished and free from scale. They shall be free from cracks, surface flaws,
laminations and other defects. The ends shall be cut cleanly and square with the axis of tube.
Welded tubing shall be free of protruding metal on the outside surface of the weld seam.
9.0 STRAIGHTNESS:
The tubes shall not deviate from straightness by more than 1mm in any 600 mm length.
10.0 MARKING:
i Each tube shall be suitably marked with the manufacturers name or trade mark & class of the tube
ii The tubes shall also be marked with the standard mark.
Ii Different classes shall be identified by the below mentioned color codes –
S No Class of Tube Color code
1 Light tubes Yellow
2 Medium tubes Blue
3 Heavy tubes Red
11.1 Sampling and Preparation of test specimen for galvanizing tests. The sampling shall be as
below in the table –
Nominal Bore Sample Size
Up to 25 mm 1 tube / 1000 tubes or part thereof
Above 25 mm 1 tube / 500 tubes or part thereof
The test specimen shall be cut approximately 100mm in length from opposite ends of the lengths of
tube selected for testing. Before cutting the test specimen, 50mm from both ends of the sample shall
be discarded.
Annexure 1: As per IS 1161 - Sizes and Properties of Steel Tubes for Structural Purposes
NB, OD, Thickne ID, Unit wt. Outer surface Inside surface Two ends Total Surface
mm mm ss,mm mm Kg/m area, m2 area, m2 surface area, m2 area of pipe, m2
15 21.3 2 17.3 0.947 0.0669 0.0543 0.0002 0.1214
15 21.3 2.6 16.1 1.21 0.0669 0.0506 0.0003 0.1177
15 21.3 3.2 14.9 1.44 0.0669 0.0468 0.0004 0.1140
20 26.9 2.3 22.3 1.38 0.0845 0.0700 0.0004 0.1548
20 26.9 2.6 21.7 1.56 0.0845 0.0681 0.0004 0.1530
20 26.9 3.2 20.5 1.87 0.0845 0.0644 0.0005 0.1493
25 33.7 2.6 28.5 1.98 0.1058 0.0895 0.0005 0.1958
25 33.7 3.2 27.3 2.41 0.1058 0.0857 0.0006 0.1922
25 33.7 4 25.7 2.93 0.1058 0.0807 0.0007 0.1873
32 42.4 2.6 37.2 2.54 0.1331 0.1168 0.0006 0.2506
32 42.4 3.2 36 3.1 0.1331 0.1130 0.0008 0.2470
32 42.4 4 34.4 3.79 0.1331 0.1080 0.0010 0.2421
40 48.3 2.9 42.5 3.23 0.1517 0.1335 0.0008 0.2859
40 48.3 3.2 41.9 3.56 0.1517 0.1316 0.0009 0.2841
40 48.3 4 40.3 4.37 0.1517 0.1265 0.0011 0.2793
50 60.3 2.9 54.5 4.08 0.1893 0.1711 0.0010 0.3615
50 60.3 3.6 53.1 5.03 0.1893 0.1667 0.0013 0.3574
50 60.3 4.5 51.3 6.19 0.1893 0.1611 0.0016 0.3520
65 76.1 3.2 69.7 5.71 0.2390 0.2189 0.0015 0.4593
65 76.1 3.6 68.9 6.42 0.2390 0.2163 0.0016 0.4569
65 76.1 4.5 67.1 7.93 0.2390 0.2107 0.0020 0.4517
80 88.9 3.2 82.5 6.72 0.2791 0.2591 0.0017 0.5399
80 88.9 4 80.9 8.36 0.2791 0.2540 0.0021 0.5353
80 88.9 4.8 79.3 9.9 0.2791 0.2490 0.0025 0.5307
100 114.3 3.6 107.1 9.75 0.3589 0.3363 0.0025 0.6977
100 114.3 4.5 105.3 12.2 0.3589 0.3306 0.0031 0.6926
100 114.3 5.4 103.5 14.5 0.3589 0.3250 0.0037 0.6876
110 127 4.5 118 13.6 0.3988 0.3705 0.0035 0.7728
110 127 4.8 117.4 14.5 0.3988 0.3686 0.0037 0.7711
110 127 5.4 116.2 16.2 0.3988 0.3649 0.0041 0.7678
125 139.7 4.5 130.7 15 0.4387 0.4104 0.0038 0.8529
125 139.7 4.8 130.1 15.9 0.4387 0.4085 0.0041 0.8512
125 139.7 5.4 128.9 17.9 0.4387 0.4047 0.0046 0.8480
135 152.4 4.5 143.4 16.4 0.4785 0.4503 0.0042 0.9330
135 152.4 4.8 142.8 17.5 0.4785 0.4484 0.0044 0.9314
135 152.4 5.4 141.6 19.6 0.4785 0.4446 0.0050 0.9281
150 165.1 4.5 156.1 17.8 0.5184 0.4902 0.0045 1.0131
150 165.1 4.8 155.5 18.9 0.5184 0.4883 0.0048 1.0115
150 165.1 5.4 154.3 21.3 0.5184 0.4845 0.0054 1.0083
150 168.3 4.5 159.3 18.2 0.5285 0.5002 0.0046 1.0333
150 168.3 4.8 158.7 19.4 0.5285 0.4983 0.0049 1.0317
150 168.3 5.4 157.5 21.7 0.5285 0.4946 0.0055 1.0285
150 168.3 6.3 155.7 25.2 0.5285 0.4889 0.0064 1.0238
200 219.1 4.8 209.5 25.4 0.6880 0.6578 0.0065 1.3523
200 219.1 5.6 207.9 29.5 0.6880 0.6528 0.0075 1.3483
200 219.1 5.9 207.3 31 0.6880 0.6509 0.0079 1.3468
Annexure 2: IS 1239: Dimensions & Nominal Mass of Steel Tubes – Light, Medium & Heavy
Nominal Bore, Ooutside Diameter Thickness, Unit wt. Kg/m
mm Maximum Minimum mm Plain End Screwed & Socketed
Light:
6 10.1 9.7 1.8 0.360 0.363
8 13.6 13.2 1.8 0.515 0.519
10 17.1 16.7 1.8 0.670 0.676
15 21.4 21.0 2.0 0.947 0.956
20 26.9 26.4 2.3 1.38 1.39
25 33.8 33.2 2.6 1.98 2.00
32 42.5 41.9 2.6 2.54 2.57
40 48.4 47.8 2.9 3.23 3.27
50 60.2 59.6 2.9 4.08 4.15
65 76.0 75.2 3.2 5.71 5.83
80 88.7 87.9 3.2 6.72 6.89
100 113.9 113.0 3.6 9.75 10.00
Medium:
6 10.6 9.8 2.0 0.404 0.407
8 14.0 13.2 2.3 0.641 0.645
10 17.5 16.7 2.3 0.839 0.845
15 21.8 21.0 2.6 1.21 1.22
20 27.3 26.5 2.6 1.56 1.57
25 34.2 33.3 3.2 2.41 2.43
32 42.9 42.0 3.2 3.10 3.13
40 48.8 47.9 3.2 .56 3.60
50 60.8 59.7 3.6 5.03 5.10
65 76.6 75.3 3.6 6.42 6.54
80 89.5 88.0 4.0 8.36 8.53
100 115.0 113.1 4.5 12.2 12.5
125 140.8 138.5 4.8 15.9 16.4
150 166.5 163.9 4.8 18.9 19.5
Heavy:
6 10.5 9.8 2.6 0.487 0.490
8 14.0 13.2 2.9 0.765 0.769
10 17.5 16.7 2.9 1.02 1.03
15 21.8 21.0 3.2 1.44 1.45
20 27.3 26.5 3.2 1.87 1.88
25 34.2 33.3 4.0 2.93 2.95
32 42.9 42.0 4.0 3.79 3.82
40 48.8 47.9 4.0 4.37 4.41
50 60.8 59.7 4.5 6.19 6.26
65 76.6 75.3 4.5 7.93 8.05
80 89.5 88.0 4.8 9.90 10.1
100 115.0 113.1 5.4 14.5 14.8
125 140.8 138.5 5.4 17.9 18.4
150 166.5 163.9 5.4 21.3 21.9