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CHAPTER â 5 ERECTION OF TOWERS AND FIXING OF ACCESSORIES 1.0 TOWER ERECTION:
1.1 The towers shall be erected on the foundations not less than 14 days (if OPC
has been used)/ 21 days (if PPC has been used) after concreting or till such
time that the concrete has acquired sufficient strength. The towers are erected
as per the erection drawings furnished by the manufacturers to facilitate
erection. For the convenience of assembling the tower parts during erection
operations, each member is marked in the factory to correspond with a number
shown in the erection drawing. Any damage to the steel and injuring of
galvanizing shall be avoided. No member shall be subjected to any undue over
stress during erection. 1.2 There are three main methods of erection of steel
transmission towers which are described as below: a) Built up method or
Piecemeal method. b) Section method. c) Ground assembly method. 1.3 Built Up
Method: 1.3.1 This method is most commonly used for the erection of 132 kV, 220
kV and 400 kV transmission line towers due to the following advantages: a) Tower
materials can be supplied to site in knocked down condition, i.e., in pieces
which facilitates easier and cheaper transportation. b) It does not require any
heavy machinery such as cranes, etc. c) Tower erection activity can be done in
any kind of terrain and throughout most of the year. d) Availability of workmen
at cheaper rates. 1.3.2 This method consists of erecting the towers member by
member. The tower members are first set out and kept on the ground serially
according to erection sequence to avoid time loss due to searching for them as
and when required. 1.3.3 In order to maintain speed and efficiency, a small
assembly party can be sent ahead of the main erection gang for sorting out the
tower members, keeping the members in correct position on the ground and
assembling those panels on the ground which can be erected as a complete unit.
The main corner leg members are prepared by fitting all cleats / plates for
joints & bracings and step bolts. 1.3.4 The erection progresses from the bottom
upwards. The four main corner leg members of the first section of the tower are
first erected and kept in position by fixing temporary rope guys. More than one
leg section of each corner leg may be bolted together at the ground and erected
in case they are short in length and light in weight. 1.3.5 The cross bracings
of the first section, which may be assembled on the ground, are raised one by
one as a unit and bolted to the already erected corner leg angles. The first
section of the tower thus built and horizontal struts (belt members), if any,
are bolted in position. 1.3.6 For smaller base towers / vertical configuration
towers, one derrick / gin pole is used. For wide based towers and if one
assembled section / panel of the tower is to be erected, then two derricks / gin
poles are placed, one each on the top of diagonally opposite corner legs. These
are guyed using ropes and temporary ground anchors. 88 Construction Manual for
Transmission Lines 1.3.7 For assembling the second section of the tower, the
derrick / gin pole is placed on the top of one corner leg. First, the leg
members of the second section are hoisted and assembled. The temporary rope guys
are shifted to the legs of the second section when they are being raised for
erection. The legs of the second section / storey are kept in position by fixing
the temporary rope guys. The bracings of the second section are then hoisted and
assembled. 1.3.8 The derrick is then shifted to the corner leg member on the top
of the second section to raise the parts of third section of the tower in
position for assembly. Derrick(s) / Gin pole(s) and the temporary rope guys for
the leg members are thus moved up as the tower is built up. This process is
continued till the complete tower is erected. 1.3.9 The stages in this method of
erection are shown in Appendix â A and Appendix â B. 1.3.10 Cross â arms are
assembled on the ground. 1.3.11 The bird guards and hangers for suspension
towers are fitted on the cross â arms. 1.3.12 A rope is passed through a pulley
fixed on the tower peak. The cross â arms are raised up with this rope and fixed
to the main body of the tower. 1.3.13 The method of erection is shown in
Appendix â C. 1.3.14 For heavier towers, a small boom is rigged on one of the
tower legs for hoisting purposes. 1.3.15 The members / sections can be hoisted
either manually or by pulling with a tractor or by winch machines operated from
the ground. 1.4 Section Method: 1.4.1 The major sections of the tower are
assembled on the ground and the same are erected as units. Either a mobile crane
or a derrick / gin pole is used. The derrick / gin pole used is approximately
10m long and is held in place by means of guys on the side of the tower to be
erected. 1.4.2 The two opposite sides of the tower section of the tower are
assembled on the ground. Each assembled side is then lifted clear of the ground
with the derrick / gin pole and is lowered into position on bolts to stubs or
anchor bolts. One side is held in place with props or rope guys while the other
side is being erected. The two opposite sides are then laced together with cross
members and bracings / diagonals, and the assembled section is lined up and made
square to the line. 1.4.3 After completing the first section, the derrick / gin
pole is set on the top of the first section. The derrick / gin pole is made to
rest on a strut of the tower immediately below the leg joint. The derrick / gin
pole has then to be properly guyed into position. 1.4.4 The first face of the
second section is raised. To raise the second face of this section, it is
necessary to shift the foot of the derrick / gin pole on the strut of the
opposite side of the tower. After the two opposite faces are raised, the
bracings on the other two sides are fitted and bolted up. 1.4.5 The last lift
raises the top of the towers. After the tower top is placed and all side
bracings have been bolted up, all the guy are removed except the one which is to
be used to lower the derrick / gin pole. Erection of Towers and Fixing of
Accessories 89 1.4.6 Sometimes, one whole face of the tower is assembled on the
ground, hoisted and supported in position. The opposite face is similarly
assembled and hoisted and then the bracing angles connecting these two faces are
fitted. 1.4.7 The cross â arms are assembled and erected in the manner given at
paras 1.3.9 to 1.3.11. 1.5 Ground Assembly Method: 1.5.1 This method consists of
assembling the tower on the ground, and erecting it as a complete unit. This
method is not useful when the towers are large and heavy and the foundations are
located in arable land where assembling and erecting complete towers would cause
damage to large areas or in hilly terrain where the assembly of complete tower
on slopping ground may not be possible and it may be difficult to get the crane
into position to raise the complete tower. This method is not generally adopted
because of non-availability of good approach roads to tower location. 1.5.2 For
this method of erection, a level piece of ground close to the footing is chosen
for the tower assembly. On slopping ground, however, elaborate packing of the
low side is essential before assembly commences. 1.5.3 The complete tower is
assembled in a horizontal position on even ground. The tower is assembled along
the direction of the line to allow the cross arms to be fitted. 1.5.4 After the
assembly is complete, the tower is picked up from the ground with the help of a
crane and carried to its location and set on its foundation. 1.6 Tightening of
Bolts & Nuts and Punching of Threads: 1.6.1 All empty holes are to be filled in
with nut and bolt of appropriate size and a spring washer. 1.6.2 All nuts shall
be tightened properly using correct size spanners. Before tightening it should
be ensured that filler washers and plates are placed in relevant gaps between
members, bolts of proper size and length are inserted and one spring washer is
inserted under each nut. In case of step bolts, spring washer shall be placed
under the outer nut. 1.6.3 The tightening shall be carried on progressively from
the top downwards, care being taken that all bolts at every level are tightened
simultaneously. It is advisable to employ four persons, each covering one leg
and the face to his right. 1.6.4 The threads of bolts shall project outside the
nuts by one to two threads and shall be punched at three positions on the top
inner periphery of the nut and bolt to ensure that the nuts are not loosened in
the course of time. 1.6.5 If during tightening, a nut is found to be slipping or
running over the bolt threads, the bolt together with the nut shall be changed
outright. 1.7 Tack Welding of Bolts & Nuts: 1.7.1 Tack welding is got done of
all the nuts & bolts from the ground level upto bottom cross arm level, or as
specified in the contract. 1.7.2 The threads of all the bolts projecting outside
the nuts shall be welded with the nuts at two diametrically opposite places. The
length of each welding shall be at least 10 mm, or as specified in the contract.
1.7.3 After welding, cold galvanizing paint (Zinc rich paint having at least 90%

percent zinc content) shall be applied to the welded portion. At least two coats
of the paint shall be applied. 15-II.5. Tower Erection
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