Erection Manual Rev_01
Content
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
Eski Güvercinlik Yolu No : 113 P.K. 9 06560 Gazi/ANKARA Tel : +90-312 296 2000 Fax : +90-312 296 2999 www.mitaspole.com
Prepared/Revised by
Approved by
1
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
INSTRUCTIONS for INSTALLATION AND LIFTING OF POWER TRANSMISSION POLES 1- INTRODUCTION :
• Installing high polygonal poles (with conical slip joints) requires particular attention when assembling and erecting the pole. It is necessary to subcontract these operations to specialist companies having experience of this activity and being equipped with the appropriate tools. Our instructions will make the installation easier and safer and will assure its quality. For any extra technical information, feel free to contact to our Engineering Department.
• •
The whole responsibility of the installation and the erection lies with the installer and includes material, non-material or others risks consecutive or non-consecutive.
2- REQUIRED TOOLS AND DOCUMENTATION
• • Technical Documentation: Design calculations, jacking force table and torque force table are indicating slip joint lengths, high mast weight and position of the gravity centre. Safety Systems : 2 Tireforts and cable for fitting the pole sections together (the cable length must be longer than the total length of all pole sections) OR 2 pieces safety turnbuckles for each slip joint (prevents slip off the pole sections and keep them together)( Photo 1 ).
•
•
PHOTO 1 Jacking Systems: if there are M24 bosses, 2 hydraulic jacks capable to develop a force limited to 18.5 tons each (Photo 2).
2
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
PHOTO 2 • • • Wood supporting pieces to be put for heightening and aligning the sections. Lifting crane to be used for positioning and aligning the sections on the wood supporting pieces (capacity superior to the heaviest section). Crane and slings/steel chain strong enough for erecting the pole on the foundation block according to the procedure defined by the crane driver during the site survey.
3- PREPARATION OF ELEMENTS & FITTING THEM TOGETHER :
• Align the pole sections according to drawing FIG-1. Poles sections to be assembled should be close to the foundation and bottom of sections should be supported by wood supporting pieces. The pole sections shall be placed in such a position that crane could place them on the foundation without moving too much. Pole sections shall be aligned in accordance with longitudinal welding and ladder fixing parts in line. Clean up carefully the surfaces to be fitted together (male and female parts) Clean threads of anchor bolts in the foundation of pole from concrete residue, which may have spilled on anchor bolts during laying foundation, by a wire brush and chisel. Turn nuts on to see that they fit properly or not. Threads of anchor bolts must be
3
• •
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
covered with a tape during concrete pouring operation to avoid damages of anchor bolt threads. • Install one nut to each anchor bolt and tighten them according to the thickness of the base plate, considering the height of the nut to be attached above to connect base plate with leaving enough space above. (PHOTO 3 )
PHOTO 3 • • Balance level on the all the nuts with a spirit level and thus, establish the first reference for the perpendicularity of the pole to be installed. Mark minimum and maximum splice lengths by a marker or sticky tape on the body. Splice lengths are specified in drawings or calculation notes. (PHOTO 4).
PHOTO 4
•
Start assembling with base section. It is important to position the appropriate side facing up considering installation of the accessories to be connected. Install male section into female section as much as possible by use of crane. It may be required to use a
4
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
sledgehammer to help fit the sections together. Do not hit the pole itself, put a piece of wood. • After fitting the sections, check visually the straightness of the sections, and arrange level of wooden wedges as well. (Photo 5).
PHOTO 5
•
Use jacking lugs welded on pole sections to install hydraulic jack in order to fit male and female sections together properly. Flat sides of sections shall be connected properly. Force from hydraulic jack shall be applied on both sides. Do not stop when you have only reached the theoretical lengths (Photo 6 and assembly information below)
PHOTO 6
5
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
Assembly
Principle of « slip joint window » Values are examples
kN Maxi 816 Mini 408
Slip joint force
Slip joint is OK if values are within this window
Slip length
Mini 1670
Nominal 1820
Maxi 1970
mm
•
Do the mentioned steps to fit other sections also.
4- FITTING ACCESSORIES ON THE POLE :
• After fitting all sections together, install accessories according to work shop drawings. Accessories for a power transmission pole are mainly as follows : (Photo 5) ‐ ‐ ‐ ‐ ‐ ‐ ‐ Cross arms Ladders Safety rail on the ladder Anti access equipment Lifting arms Safety turnbuckles between shafts Rope
6
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
PHOTO 7
•
Do not forget to install safety turnbuckles between shafts (Photo 8) to prevent shafts from slip off when lifting the pole OR attach a safety sling from the level where the pole will be lifted by the main crane to the base plate of the pole. ( PHOTO 9 )
PHOTO 8 7
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
PHOTO 9
5- LIFTING THE POLE :
The whole responsibility of the operation lies with the crane driver and crane company and includes material, non-material or others risks consecutive or non-consecutive. • • • Main crane shall be determined with a suitable tonnage and boom length according to the height and weight of the pole. Choose slings / steel chains according to pole total weight. Crane driver shall determine the position of the main crane so as to close to the foundation and so as to operate the crane boom in a vertical position as much as possible, while lifting and assembling the pole. Sling the pole from lifting brackets. Keep a second crane with a smaller tonnage ready in the field, so as to support the pole from the bottom, if required, depending on the weight of pole. The mission of that second crane is to prevent the pole from being dragged along the ground, while the main crane positions the pole from horizontal to vertical and to allow the main crane to maneuver more easily. (PHOTO 10)
• •
8
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
PHOTO 10
•
Before lifting the pole, connect ropes suitable for the length of the pole from opposite crossarms tips, in order to position the holes of base plate to coincide with anchor bolts and to control and guide the pole. Now lifting of pole can start. As the main crane lifts the pole, the second crane will make the lower part approach the pole to the foundation. ( PHOTO 11 )
•
9
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
PHOTO 11
• •
When the pole becomes in vertical position, lower part of pole will be approached to the foundation without lifting from the ground too much. As direction of the lower section will determine the direction of line, turn it to the appropriate direction and lower it slowly and carefully onto the anchor bolts. Site supervisor should direct the crane operator to position the holes of base plate coinciding with the anchor bolts. Use also the ropes connected to the cross arms in carrying out this operation. Lower the body on the pre-leveled nuts. Check the perpendicularity of the pole visually as well and tighten all the first nuts on base plate and then tighten second nuts (contra nuts) in order to prevent first nuts from becoming loose. ( PHOTO 12 )
•
10
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
PHOTO 12 • Remove all the slings/steel chain connecting the pole to the crane and connected to the cross arms to direct the pole. These operations can be carried out either using the ladder on the pole or basket of the crane After final leveling the pole with leveling nuts, fill up the empty space between the base plate and the foundation block with special concrete for finishing; keep a hole for air and water flow.
•
11
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
12
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
6-WARNINGS:
‐ ‐ ‐ The Staff who works at high altitude should work with safety belts. There should not be unauthorized and irrelevant people in the field of assembly. The Staff should wear helmet against substances which may fall down during assembly.
13
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
Eski Güvercinlik Yolu No : 113 P.K. 9 06560 Gazi/ANKARA Tel : +90-312 296 2000 Fax : +90-312 296 2999 www.mitaspole.com
Prepared/Revised by
Approved by
1
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
INSTRUCTIONS for INSTALLATION AND LIFTING OF POWER TRANSMISSION POLES 1- INTRODUCTION :
• Installing high polygonal poles (with conical slip joints) requires particular attention when assembling and erecting the pole. It is necessary to subcontract these operations to specialist companies having experience of this activity and being equipped with the appropriate tools. Our instructions will make the installation easier and safer and will assure its quality. For any extra technical information, feel free to contact to our Engineering Department.
• •
The whole responsibility of the installation and the erection lies with the installer and includes material, non-material or others risks consecutive or non-consecutive.
2- REQUIRED TOOLS AND DOCUMENTATION
• • Technical Documentation: Design calculations, jacking force table and torque force table are indicating slip joint lengths, high mast weight and position of the gravity centre. Safety Systems : 2 Tireforts and cable for fitting the pole sections together (the cable length must be longer than the total length of all pole sections) OR 2 pieces safety turnbuckles for each slip joint (prevents slip off the pole sections and keep them together)( Photo 1 ).
•
•
PHOTO 1 Jacking Systems: if there are M24 bosses, 2 hydraulic jacks capable to develop a force limited to 18.5 tons each (Photo 2).
2
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
PHOTO 2 • • • Wood supporting pieces to be put for heightening and aligning the sections. Lifting crane to be used for positioning and aligning the sections on the wood supporting pieces (capacity superior to the heaviest section). Crane and slings/steel chain strong enough for erecting the pole on the foundation block according to the procedure defined by the crane driver during the site survey.
3- PREPARATION OF ELEMENTS & FITTING THEM TOGETHER :
• Align the pole sections according to drawing FIG-1. Poles sections to be assembled should be close to the foundation and bottom of sections should be supported by wood supporting pieces. The pole sections shall be placed in such a position that crane could place them on the foundation without moving too much. Pole sections shall be aligned in accordance with longitudinal welding and ladder fixing parts in line. Clean up carefully the surfaces to be fitted together (male and female parts) Clean threads of anchor bolts in the foundation of pole from concrete residue, which may have spilled on anchor bolts during laying foundation, by a wire brush and chisel. Turn nuts on to see that they fit properly or not. Threads of anchor bolts must be
3
• •
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
covered with a tape during concrete pouring operation to avoid damages of anchor bolt threads. • Install one nut to each anchor bolt and tighten them according to the thickness of the base plate, considering the height of the nut to be attached above to connect base plate with leaving enough space above. (PHOTO 3 )
PHOTO 3 • • Balance level on the all the nuts with a spirit level and thus, establish the first reference for the perpendicularity of the pole to be installed. Mark minimum and maximum splice lengths by a marker or sticky tape on the body. Splice lengths are specified in drawings or calculation notes. (PHOTO 4).
PHOTO 4
•
Start assembling with base section. It is important to position the appropriate side facing up considering installation of the accessories to be connected. Install male section into female section as much as possible by use of crane. It may be required to use a
4
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
sledgehammer to help fit the sections together. Do not hit the pole itself, put a piece of wood. • After fitting the sections, check visually the straightness of the sections, and arrange level of wooden wedges as well. (Photo 5).
PHOTO 5
•
Use jacking lugs welded on pole sections to install hydraulic jack in order to fit male and female sections together properly. Flat sides of sections shall be connected properly. Force from hydraulic jack shall be applied on both sides. Do not stop when you have only reached the theoretical lengths (Photo 6 and assembly information below)
PHOTO 6
5
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
Assembly
Principle of « slip joint window » Values are examples
kN Maxi 816 Mini 408
Slip joint force
Slip joint is OK if values are within this window
Slip length
Mini 1670
Nominal 1820
Maxi 1970
mm
•
Do the mentioned steps to fit other sections also.
4- FITTING ACCESSORIES ON THE POLE :
• After fitting all sections together, install accessories according to work shop drawings. Accessories for a power transmission pole are mainly as follows : (Photo 5) ‐ ‐ ‐ ‐ ‐ ‐ ‐ Cross arms Ladders Safety rail on the ladder Anti access equipment Lifting arms Safety turnbuckles between shafts Rope
6
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
PHOTO 7
•
Do not forget to install safety turnbuckles between shafts (Photo 8) to prevent shafts from slip off when lifting the pole OR attach a safety sling from the level where the pole will be lifted by the main crane to the base plate of the pole. ( PHOTO 9 )
PHOTO 8 7
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
PHOTO 9
5- LIFTING THE POLE :
The whole responsibility of the operation lies with the crane driver and crane company and includes material, non-material or others risks consecutive or non-consecutive. • • • Main crane shall be determined with a suitable tonnage and boom length according to the height and weight of the pole. Choose slings / steel chains according to pole total weight. Crane driver shall determine the position of the main crane so as to close to the foundation and so as to operate the crane boom in a vertical position as much as possible, while lifting and assembling the pole. Sling the pole from lifting brackets. Keep a second crane with a smaller tonnage ready in the field, so as to support the pole from the bottom, if required, depending on the weight of pole. The mission of that second crane is to prevent the pole from being dragged along the ground, while the main crane positions the pole from horizontal to vertical and to allow the main crane to maneuver more easily. (PHOTO 10)
• •
8
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
PHOTO 10
•
Before lifting the pole, connect ropes suitable for the length of the pole from opposite crossarms tips, in order to position the holes of base plate to coincide with anchor bolts and to control and guide the pole. Now lifting of pole can start. As the main crane lifts the pole, the second crane will make the lower part approach the pole to the foundation. ( PHOTO 11 )
•
9
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
PHOTO 11
• •
When the pole becomes in vertical position, lower part of pole will be approached to the foundation without lifting from the ground too much. As direction of the lower section will determine the direction of line, turn it to the appropriate direction and lower it slowly and carefully onto the anchor bolts. Site supervisor should direct the crane operator to position the holes of base plate coinciding with the anchor bolts. Use also the ropes connected to the cross arms in carrying out this operation. Lower the body on the pre-leveled nuts. Check the perpendicularity of the pole visually as well and tighten all the first nuts on base plate and then tighten second nuts (contra nuts) in order to prevent first nuts from becoming loose. ( PHOTO 12 )
•
10
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
PHOTO 12 • Remove all the slings/steel chain connecting the pole to the crane and connected to the cross arms to direct the pole. These operations can be carried out either using the ladder on the pole or basket of the crane After final leveling the pole with leveling nuts, fill up the empty space between the base plate and the foundation block with special concrete for finishing; keep a hole for air and water flow.
•
11
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
12
VALMONT MITAS POLES INDUSTRIES
POLE ASSEMBLY and ERECTION MANUAL FOR NONTUBULAR STEEL POLES
6-WARNINGS:
‐ ‐ ‐ The Staff who works at high altitude should work with safety belts. There should not be unauthorized and irrelevant people in the field of assembly. The Staff should wear helmet against substances which may fall down during assembly.
13
