1.

1DesignandDrawings

1.1.1Therelevantdrawingsforallthetowersandtheirextensionsshallbe
furnishedtotheContractorbytheEmployerwhichshallincludestructural
drawings/erection drawings and / or shop fabrication drawings, Bill of
Materialsforallthetowersandtheirextensions.

1.1.2Thetowermemberscanbedirectlyfabricatedfromthestructural/erection
drawingswherevertherequiredfabricationdetailsareprovidedonthesameor
shopfabricationdrawings.However,ifthecontractorisrequiredtoprepare
shopfabricationdrawings,oftheirown,inadditiontothestructural/erection
drawingswithrequiredfabricationdetails,theymaypreparethesamewithout
anyadditionalfinancialimplicationtoEmployer.

ProtoAssembly:

(i)Contractors,whohavenotdonetheprotoassemblyofthetowers/tower
extensionsorhavenotsuppliedthesametowers/towerextensionsagainst
anyearlierKSEBLproject,shallbeforetakingupmassfabrication,
theContractorshallarrangeforonenumberprotoassemblyforeachtypeof
towersandextensions.KSEBLreservestherighttogetthesame
witnessedbytheirrepresentative.Afterprotoassembly,thecontractors,
shallincorporaterevisionsinthedrawings/documentsifanyonaccountof
protocorrections,andmakenecessaryendorsementwithreferencetothe
respectivepackages/LetterofAwards.Thereviseddrawing/documents
shallbesubmittedin3(three)copiesforfinalapprovalbytheEmployer.
(ii)Thecontractorswhohavealreadydonetheprotoassemblyofthetowers/
towerextensionsorhavesuppliedthesametowers/towerextensions
againstanyearlierKSEBLsprojectneednotdotheprotoassembly.
Theyshallsubmitdocumentaryevidenceviz.protoinspectionreports,
supplyrecordsetc.initssupport.However,theymaydotheprotoassembly
fortheirverificationandsatisfaction.Further,theyshallsubmit10copiesof
thestructuraldrawingsandBOMoftower/towerextensionsafter
endorsingtheprojectsnameforfurtherdistributionbyEmployer.
Nopaymentshallbemadetothecontractorontheaccountofprotoassembly
ineitherofthecasesmentionedat(i)or(ii).Inanycase,theonusofcorrect
fabrication/fitmentoftowerpartsshallliewithcontractor.Anydefect,iffound
duringerectionatsite,thesamehastoberectifiedbythecontractorwithoutany
additionalfinancialimplicationtoKSEBL.

1.1.4Whilesubmittingthestructuraldrawings,billofmaterials,shopdrawings
and any other drawings pertaining to the subject transmission line, the
ContractorshallclearlyindicateoneachdrawingKSEBLSpecificationNo.,
NameofthespecificTransmissionlineandproject,letterreferenceno.anddate
onwhichthesubmissionaremade.Thesamepracticeisalsotobefollowed
whilesubmittingdistributioncopies.
1.1.5ThetoweraccessoriesdrawingslikeNumberplate,Dangerplate,phase
plate,CircuitPlate,StepBolt,Anticlimbingdevice,poleplateandEarthing
Arrangementhavebeenstandardized(exceptBirdguard)areenclosedin
drawingsectionofthisspecification.Thecontractorisrequiredtosubmit
distributioncopiesoftheabovedrawingsafterendorsingthenameofthe
projects.HoweverdrawingofBirdGuard,Dshackleetc.shallbepreparedby
theContractorandshallbesubmittedtotheEmployer,inthree(3)copiesfor
approval.ThisdrawingshallbepreparedinA4sizeonly

1.1.6ThedrawingssubmittedbytheContractorshallbeapproved/commented
by the Employer as the case may be within fifteen (15) days of receipt of
drawingsinhisoffice.Ifthedesigns/drawingsarecommentedbytheEmployer,
theContractorshallsubmitreviseddesign/drawingsdulyincorporatingall
commentswithinfifteen(15)daysofdateofissueofcomments.The
Contractorshallsubmit15copiesofalltoweraccessoriesforfurther
distributionbytheEmployer.

Themassfabricationshallbetakenupfromthestandardshopdrawings.The
overallresponsibilityoffabricatingtowermemberscorrectlylieswiththe
ContractoronlyandtheContractorshallensurethatallthetowermembers
canbeassembled/fittedwhileerectingwithoutanyunduestrainonthem.

1.1.7Otherthantheitemsindicatedabovesomeotherdrawingsanddocuments,
suchasBOM,Shopdrawings,structuraldrawingsfortowers/extensionsbased
onsinglelinediagramgivenbytheEmployer,whicharerequiredforthe
project,shallalsobedevelopedbytheContractor.However,noextracoston
thisaccountshallbepayabletotheContractor.

1.2Materials

1.2.1TowerSteelSections
ISSteelSectionsoftestedqualityofconformitywithIS:2062:2011gradeE250
(DesignatedYieldStrength.250MPa)and/orgradeE350(DesignatedYield
Strength350MPa)aretobeusedintowers,extensions,stubsandstubsetting
templates.ForSnowZonetowersMS&HTSteelSectionsshallconformto
E250GradeC&E350GradeCrespectively.TheContractorcanuseother
equivalentgradeofstructuralsteelanglesectionsandplatesconformingto
latestInternationalStandardsvizBSEN10025.However,useofsteelgrade
havingdesignatedyieldstrengthmorethanthatofEN10025gradeS355JR/JO
(designatedyieldstrength355MPa)isnotpermitted,unlessotherwise
indicatedinthisspecification.
Steelplatesbelow6mmsizeexclusivelyusedforpackingplates/packing
washersproducedasperIS:1079(Grade0)arealsoacceptable.However,if
below6mmsizeplateareusedasloadbearingplatesvizgussetplates,joint
splicesetc.thesameshallconformtoIS:2062orequivalentstandardmeeting
mechanicalstrength/metallurgicalpropertiescorrespondingtogradeE250or
abovegrade(designatedyieldstrengthnotmorethan355MPa),depending
uponthetypeofgradeincorporatedintodesign.Flatsofequivalentgrade
meetingmechanicalstrength/metallurgicalpropertiesmayalsobeusedin
placeofplatesforpackingplates/packingwashers.Thechequeredplatesshall
conformtoIS:3502.SAILMA350HIgradeplatecanalsobeacceptedinplace
ofHTplates(EN10025gradeS355JR/JO/IS2062:2011gradeE350,as
applicable)providedSAILMA350HIgradeplatemeetallthemechanical
propertiesofplateasperEN10025gradeS355JR/JO(designatedyield
strength355MPa)/IS2062:2011gradeE350.
Fordesigningoftowers,preferablyrationalisedsteelsectionshavebeenused.
Duringexecutionoftheproject,ifanyparticularsectionisnotavailable,the
sameshallbesubstitutedbyhighersection/Grade.Anycostonaccountofthe
sameshallbebornebytheContractor.However,designapprovalforsuch
substitutionshallbeobtainedfromtheEmployerbeforeanysubstitutionand
recordsofsuchsubstitutionsshallbemaintainedbytheContractor
1.2.2Fasteners:Bolts,NutsandWashers.
1.2.2.1AlltowermembersshallbejoinedtogetherwithHexagonalBoltsand
nuts.All
hexagonalboltsandnutsshallconformtoIS12427.Theyshallhavehexagonal
headandnuts,theheadsbeingforgedoutofthesolid,trulyconcentric,and
squarewiththeshank,whichmustbeperfectlystraight.
AllboltsandnutsshallbegalvanizedasperIS:1367(Part13)/IS:2629.
1.2.2.2Theboltshallbeof16/24mmdiameterandofpropertyclass5.6as
specified in IS:1367 (PartIII) and matching nut of property class 5.0 as
specifiedinIS:1367(PartVI).
1.2.2.3BoltsuptoM16andhavinglengthupto10timesthediameterofthe
bolt should be manufactured by cold forging and thread rolling process to
obtain good and reliable mechanical properties and effective dimensional
control.Theshearstrengthofboltsfor5.6gradeshouldbe310MPaminimum
asperIS:12427.Boltsshouldbeprovidedwithwasherfaceinaccordancewith
IS:1363 (PartI) to ensure proper bearing. 1.2.2.4 Nuts for hexagonal bolts
should be double chamfered as per the requirement of IS:1363 PartIII. It
shouldbe ensuredbythe manufacturer that nuts should not be over tapped
beyond0.4mmoversizeoneffectivediameterforsizeuptoM16.1.2.2.5Fully
threaded bolts shall not be used. The length of bolts shall be such thatthe
threaded portion will not extend into the place of contact of the members.
1.2.2.6Allboltsshallbethreadedtotakethefulldepthofthenutsandthreaded
forenoughtopermitfirmgrippingofthemembers,butnotfurther.Itshallbe
ensuredthatthethreadedportionofeachboltprotrudesnotlessthan3mmand
notmorethan8mmwhenfullytightened.Allnutsshallfittighttothepoint
wheretheshankoftheboltconnectstothehead.
1.2.2.7Flatandtaperedwashersshallbeprovidedwherevernecessary.Spring
washersshallbeprovidedforinsertionunderallnuts.Thesewashersshallbe
steelelectrogalvanised,positivelocktypeand3.5mminthicknessfor16mmdia
boltand4.5mmfor24mmbolt.
1.6.2.8Toavoidbendingstressinboltsortoreduceittominimum,nobolt
shallconnectaggregatethicknessofmembersmorethanthree(3)timesits
diameter.
1.2.2.9 The bolt positions in assembled towers shall be as per structural
drawing.
1.2.2.10Boltsatthejointsshallbesostaggeredthatnutsshallbetightenedwith
spannerswithoutfouling.
ToensureeffectiveinprocessQualitycontrolitisdesirablethatthe
manufacturershouldhaveinhousetestingfacilityforalltestslikeweightof
zinccoating,shearstrengthandothertestsetc.Themanufacturershouldalso
haveproperQualityAssuranceSystemwhichshouldbeinlinewiththe
requirementofthisspecificationandIS:9001seriesQualitySystemStandard.
1.3TowerAccessories
Arrangementshallbeprovidedforfixingofalltoweraccessoriestothetower
ataheightbetween2.5metersand3.5metersabovethegroundlevel.

1.3.1StepBolts&Ladders

Eachtowershallbeprovidedwithstepboltsasperdrawingenclosedinthe
sectionofdrawing.ThestepboltsconformingtoIS:10238ofnotlessthan
16mmdiameterand175mmlong,spacednotmorethan450mmapartand
extendingfrom2.5metersabovethegroundleveltothetopofthetower.
However,theheaddiametershallbe35mmasindicatedintheenclosed
drawing.Thestepboltshallbefixedontwodiagonallyoppositelegsuptotop
ofthetowersforsingle,doubleandmulticircuittowers.Eachstepboltshallbe
providedwithtwonutsononeendtofastentheboltsecurelytothetowerand
buttonheadattheotherendtopreventthefeetfromslippingaway.Thestep
boltsshallbecapableofwithstandingaverticalloadnotlessthan1.5KN.For
specialrivercrossingtowers,laddersalongwithprotectionringsasperthe
Employerapproveddesignshallbeprovidedincontinuationofthestepbolts
ononefaceofthetowerfrom30metersabovegroundleveltothetopofthe
specialstructure.From2.5mto30mheightofsuperstructurestepboltsshall
befixedontwodiagonallyoppositelegs.Suitableplatformusing6mmthick
perforatedchequeredplatesalongwithsuitablerailingforaccessfromstep
boltstotheladderandfromtheladdertoeachcrossarmtipandtheground
wiresupportshallalsotobeprovided.Theplatformshallbefixedontowerby
usingcountersunkbolts.

1.3.2InsulatorStringsandEarthwireClampsAttachments

a)FortheattachmentofsuspensionInsulatorstring,ifrequiredasuitable
dimensionedswinginghangeronthetowershallbeprovidedsoasto
obtainspecifiedclearancesunderrespectiveswingingconditionofthe
strings.Thehanger,extensionslinks,Dshacklesetc.asrequiredshallbeof
samerating/strengthasthatofcorrespondingrating/Ultimatetensile
StrengthofInsulatorstring.Thedesignandsupplyofhanger,Dshackles,
strainplate,extensionlinketc.arealsointhescopeofContractor.
b)Attensiontowers,strainplatesofsuitabledimensionsundereachcross
armtip,shallbeprovidedfortakingthehooksorDshacklesofthetension
insulatorstrings.Fulldetailsoftheattachmentsshallbeprovidedtothe
contractor.Toachieverequisiteclearances,ifthedesigncallsforproviding
extraDshackles,linkplateetc.beforeconnectingtheinsulatorstringthe
sameshallbesuppliedbytheContractor.Theseitemshallbesame
rating/strengthasthatofasthatofcorrespondingrating/Ultimatetensile
StrengthofInsulatorstring.
c)Dshackles,ifrequiredforattachmentofInsulatorstrings,shallbesupplied
bythecontractorfromtheidentifiedandapprovedsubvendor/supplierof
Hardwarefittings.

1.3.3EarthwireClampsAttachments
ForSuspensionandtensionclampforattachmentofearthwireWherever
required,theContractorshallsupplyUbolts,DShacklesetc.forattachment
ofclamptothetower.Fulldetailsoftheattachmentsshallbeprovidedtothe
contractor.Theseitemsshallbesamerating/strengthasthatofcorresponding
rating/UltimatetensileStrengthofearthwiresuspension/tensionclamp.

1.3.4AnticlimbingDevice
Barbedwiretypeanticlimbingdevice,asperencloseddrawingshallbe
providedandinstalledbytheContractorforalltowers.Thebarbedwireshall
conformtoIS278(sizedesignationA1).Thebarbedwiresshallbegiven
chromatingdipasperprocedurelaiddowninIS:1340

1.3.5Danger,Number,CircuitandPhaseplate
DangerPlates,Circuitplates,PhasePlatesandNumberplatesshallbeprovided
andinstalledbytheContractor.TheseDanger/Number/Phase/CircuitPlate
shallbeasperthedrawingsenclosedinthesectionofdrawing.Thecontractor
shallsubmitdistributioncopiesofthesameendorsingthepackagedetails(i.e.
linename,LOANo.etc)andinstalledbytheContractor.
a)Eachtowershallbefittedwithadangerplate,numberplate,circuitplate
andasetofphaseplatesforsinglecircuittowerandtwosetsofphase
platesfordoublecircuittower.Thetranspositiontowersshouldhave
provisionoffixingphaseplatesonboththetransversefaces.
b)Theletters,figuresandtheconventionalskullandbonesofdangerplates
shallconformtoIS2551andshallbeinasignalredonthefrontofthe
plate.
c)Thecornersofthedanger,numberandcircuitplatesshallberoundedoff
toremovesharpedges.
d)Thelettersofnumberandcircuitplatesshallberedenameledwithwhite
enameledbackground.

BirdGuard

Topreventbirdsperchingimmediatelyabovethesuspensioninsulatorstrings(
Itype/Vtype)andfoulingthesamewithdropping,suitablebirdguardsshall
beprovidedonallsuspensiontowers.IncaseofIstringBirdGuardasperIS
5613shallbeprovidedatcrossarmtips.IncaseofVstring,sawtypeBird
Guardshallbeprovidedonallthemembers/redundantmembersprovidedon
TopandBottomplanofcrossarm/Girder/BOOM/BeamofSuspension.The
typicaldrawingofBirdguardisattachedatthedrawingsectionofthis
specification.Suitableprovisionofcleat/platetobeprovidedonall
Suspensiontowersfacilitatinginstallationofbirdguardafterstringing.

1.4TowerFabrication

Thefabricationoftowersshallbeinconformitywiththefollowing:
1.4.1Exceptwherehereinaftermodified,detailsoffabricationshallconformto
IS:802(PartII)ortherelevantinternationalstandards.
1.4.2Thetowerstructuresshallbeaccuratelyfabricatedtoconnecttogether
easilyatsitewithoutanyunduestrainonthebolts.
1.4.3 No angle member shall have the two leg flanges brought together by
closingtheangle.
1.4.4 The diameter of the hole shall be equal to the diameter of bolt plus
1.5mm.
1.4.5Thestructureshallbesuchthatallpartsareaccessibleforinspectionand
cleaning.Drainholesshallbeprovidedatallpointswherepocketsof
depressionarelikelytoholdwater.
1.4.6Allsteelsectionsbeforeanyworkisdoneonthem,shallbecarefully
leveled,straightenedandmadetruetodetaileddrawingsbymethodswhichwill
notinjurethematerialssothatwhenassembled,theadjacentmatchingsurfaces
areinclosecontactthroughout.Noroughedgesshallbepermittedintheentire
structure.
1.4.7DrillingandPunching

1.4.7.1Beforeanycuttingworkisstarted,allsteelsectionsshallbecarefully
straightenedandtruedbypressureandnotbyhammering.Theyshallagainbe
truedafterbeingpunchedanddrilled.
1.4.7.2Holesforboltsshallbedrilledorpunchedwithajigbutdrilledholes
shallbepreferred.Thepunchingmaybeadoptedforthicknessupto12mm.
Tolerancesregardingpunchholesareasfollows:
a)Holesmustbeperfectlycircularandnotolerancesinthisrespectare
permissible.
b)Themaximumallowabledifferenceindiameteroftheholesonthetwo
sidesofplatesorangleis0.8mm.i.e.theallowabletaperinapunched
holes should not exceed 0.8mm on diameter.Holes must be square withthe
platesoranglesandhavetheirwallsparallel.
1.4.7.3Allburnsleftbydrillsorpunchshallberemovedcompletely.Whenthe
towermembersareinpositiontheholesshallbetrulyconcentric/matchingto
eachother.Drillingorreamingtoenlargeholesshallnotbepermitted.
1.4.8Erectionmark
1.4.8.1Eachindividualmembershallhaveerectionmarkconformingtothe
componentnumbergiventoitinthefabricationdrawings.Themarknumbers
shallbemarkedwithmarkingdiesof16mmsizebeforegalvanisingandshall
belegibleaftergalvanising,

1.4.8.2ErectionMarkshallbeABBCCDDD
A=EmployerscodeassignedtotheContractorsAlphabet
BB=ContractorsMarkNumerical
CC=TowerTypeAlphabet.
DDD=NumbermarktobeassignedbyContractorNumerical.
ErectionmarkforhightensilesteelmembersshallbeprefixedbytheletterH

1.5Quantitiesandweights
1.5.1 The quantities of the following items have been envisaged in Metric
Tonne(MT)intherelevantpriceSchedulesforvarioustypesoftowers:
i)BasicBody.
ii)BodyExtensions.
iii)LegExtension.
iv)Stubs&Cleats
v)Bolts&Nutsincludingspringwashersandstepboltsetc.
Duringdetailedengineering,protocorrectedshopdrawingsshallbereleased
byKSEBLforfabricationandmanufacturingaspertheTechnical
SpecificationtotheContractor.Thecontractorshallcarryoutprotoassembly
afterfabricationfromtheEmployersshopdrawingforhisverification/
satisfactionpriortomassproductionofthetower.
Themanufacturingoftheaboveitemsshallbetakenupinsuchamannerthat
the Equipment/Material offered for inspection to KSEBL are oncompleted
towerbasisforeachtypeoftower,completedStubs&Cleatsset
basissoastofacilitateavailabilityoferectabletowerofeachtypeand
erectablestubs&cleatssetforcastingoffoundation.Afterinspectionofthe
offeredEquipment/MaterialbyKSEBLrepresentative(s),CIPshallbe
issuedbyKSEBLforthematerialmeetingtheTechnicalSpecification.
However,MICCshallbeissuedonlyonCompletedTowerBasisforeachtype
oftower(comprisingtherequiredBasicBody,bodyextensionswherever
required,four(4)equalordefinedunequalLegExtension,Bolts&Nutsalong
with Dshackles,Hangers, Packing and Spring Washers) and on completed
Stubs&Cleatssetbasisforeachtypeoftowerfoundations(comprisingasetof
stubs
&Cleats,requiredBoltsandNutsalongwithSpringWashers).
Towerstobesuppliedbythecontractors/TowerManufacturersshallbe
dispatchedPanelwiseaspermutuallyagreedprocedurewithEmployerQuality
Assurance&InspectionDepartment.
Accordingly,thepaymentshallbereleasedoncompletedTowerBasisforeach
typeoftower(comprisingtheBasicBody,bodyextensions,wherever
applicable,bolts&nutsalongwithspringwasherandstepbolts,unequalleg
extensionswhereverapplicableforacompletedtower)andoncompleted
StubsandCleatssetbasisforeachtypeoffoundation(comprisingasetofstubs
&cleats,requiredBoltsandnutsalongwithSpringWashers)basedonthe
weightofthetowerpartsascalculatedasperClause1.5.3andfastenersbased
ontheunitratesincorporatedinthecontract.
1.5.2 The provisional quantities required (including provisional spare tower
quantity)are mentioned in the respective Schedules of BPS. Final quantities
shallbedeterminedaftercompletionandapprovalofthedetailedroutesurvey.
Thefinalquantitiesoftowerincludingsparetowersshallbeconfirmedbythe
Employer/Siteinchargebasedontherequirementofquantitiesofvarious
towersfurnishedbytheContractoraftercompletionofdetailedsurvey.Hence
itwillberesponsibilityoftheContractortointimatetheexactrequirementof
alltowersandvariouslinematerialsrequiredforlineimmediatelyafterthe
survey.TheEmployerreservestherighttoorderthefinalquantitiesincluding
requiredquantitiesofsparesforwhichtheratesquotedintheBidshallbevalid.
RegardingquantityvariationtheprovisionsofrelevantclausesofSCCshall
apply.
1.5.3Theestimatedtotalweightoftower/towerpartsaswellasbolts&nuts
alongwithspringwashersandstepboltstobesuppliedbytheContractorunder
variouspackageshavebeenenvisagedintherelevantPriceSchedule.Though
fullygalvanisedtowerpartsaretobesupplied,theweightoftowershallmean
theweightoftowercalculatedbyusingtheblacksectional(i.e.ungalvanised)
weightofsteelmembersofthesizeindicatedintheapprovedfabrication
drawingsandbillofmaterials,withouttakingintoconsiderationthereduction
inweightsduetoholes,notchesandbevelcutsetc.buttakingintoconsideration
theweightoftheDshackles,hangers,strainplates,packplates,gussetplates,
extensionlink/platesandpackwashersetc.Theweightofstubandcleatsalso
shallbecalculatedinsimilarmanner.Theweightofstrainplates,packplates,
extension link and gusset plates shall mean the weight ofits circumscribing
rectangle,withouttakingintoconsiderationsthereductionsinweightdueto
holes,notchesetc.TheweightofDshackles,hangersandpackwashersshallbe
netactualweighttakingintoconsiderationreductionduetoholes.Forboltsand
nutsalongwithspringwashersandstepbolts,theweightpertowershallbe
calculatedfromtheboltscheduleapplicabletoeachtypeoftowersandbody
extensionsasapprovedbytheEmployer.Theratequotedbythebidderfor
tower/tower parts supply, is deemed to be inclusive of galvanising charges
includingthecostofzinc.
1.5.4Thecontractorispermittedtogetinspectedandsupplyupto2.5%extra
fastenerstotakecareoflossesduringerection.Nopaymentshallbeadmissible
fortheseextrasupplies.

1.6Galvanising
1.6.1FabricatedTowerParts&Stubs
Thetowerparts,stubsandpackwashersshallbehotdipgalvanized.The
galvanizationshallbedoneasperrequirementsofIS4759afterallfabrication
workiscompleted.Thecontractorshallalsotakeguidelinesfromthe
recommendedpracticesforhotdipgalvanizinglaiddowninIS2629while
decidingandimplementinggalvanizingprocedure.Themandatory
requirementshowever,arespecifiedherein.
Unlessotherwisespecifiedthefabricatedtowerpartsandstubsshallhavea
minimumoverallZinccoatingof610gmspersq.mofsurfaceareaexceptfor
plates&sectionsbelow5mmwhichshallhaveZinccoatingof460gmspersq.
mofsurfacearea.Theaveragezinccoatingforallsectionsandplates5mm&
aboveshallbemaintainedas87micronsandthatforplates&sectionsbelow
5mmshallbemaintainedas65microns.
Undermarineenvironment,asspecificallymentionedinBPSthefabricated
towerpartsandstubsshallhaveaminimumoverallzinccoatingof900gms/
sqmofsurfaceareaexceptforplatesandsectionsbelow5mmwhichshall
haveaminimumoverallzinccoatingof610gms/sqmofsurfacearea.The
averagezinccoatingforallsectionsandplates5mmandaboveshallbe
maintainedas127micronsandthatforplatesandsectionsbelow5mmshall
bemaintainedas87microns.
Thezinccoatingshallbeadherent,reasonablyuniform,smooth,continuous
andfreefromimperfectionssuchasblack/barespots,ashruststrains,bulky
whitedeposits/wetstoragestrainsandblisters.
Thesurfacepreparationforfabricatedtowerpartsandstubsforhotdip
galvanizingshallbecarriedoutasindicatedhereinbelow:
(i)Degreasing&CleaningofSurface:Degreasingandcleaningofsurface,
whereverrequired,shallbecarriedoutinaccordancewithclause4.1of
IS26291985.Afterdegreasingthearticleshallbethoroughlyrinsed.
However,ifacidicdegreasersareusedrinsingisnotrequired.
(ii)Pickling:Picklingshallbedoneusingeitherhydrochloricorsulphuricacid
asrecommendedatclause4.3ofIS26291985.Theactual
concentrationoftheacidsandthetimedurationofimmersionshallbe
determinedbytheContractordependingonthenatureofmaterialtobe
pickled.Suitableinhibitorsalsoshallbeusedwiththeacidstoavoidover
pickling.Theacidconcentration,inhibitorsused,andmaximum
allowableironcontentshallformpartofplantstandardtobe
formulatedandsubmittedtoemployeralongwithQualityAssurance
Program.
(iii)Rinsing:Afterpickling,thematerialshallberinsed,preferablyinrunning
watertoremoveacidtraces,ironparticlesoranyotherimpuritiesfrom
thesurface.Tworinsetanksarepreferable,withwatercascadingfrom
thesecondtanktothefirsttoensurethoroughcleaning.Wherever
singletankisemployed,thewatershallbeperiodicallychangedtoavoid
acidcontamination,andremovalofotherresiduefromthetank.
(iv)Fluxing:TherinsedarticleshallbedippedinasolutionofZinc
ammoniumchloride.Theconcentrationandtemperatureoftheflux
solutionshallbestandardizedbythecontractordependingonthearticle
tobegalvanizedandindividualcircumstances.Theseshallformpartof
plantstandardtobeformulatedandsubmittedtoemployeralongwith
QualityAssuranceProgram.Thespecificgravityofthefluxsolutionshall
beperiodicallymonitoredandcontrolledbyaddingrequiredquantityof
fluxcrystalstocompensatefordragoutlosses.Freeacidcontentofthe
fluxsolutionalsoshallbeperiodicallycheckedandwhenitismorethan
two(2)gramsoffreeacidperlitreofthesolution,itshallbeneutralized.
Alternatively,Phvalueshouldbemonitoredperiodicallyandmaintained
between5.0to5.5.
(v)Drying:Whendrygalvanizingisadoptedthearticleshallbethoroughly
driedafterfluxing.Forthepurposeofdrying,thecontractormayusehot
plate,airovenoranyotherprovenmethodensuringcompletedryingof
thearticleafterfluxingandpriortodippinginthemoltenzincbath.The
dryingprocessshallbesuchthatthearticleshallnotattaina
temperatureatwhichthefluxshallgetdecomposed.Thearticlethus
driedshallbegalvanizedbeforethefluxcoatingpicksupmoisturefrom
theatmosphereorthefluxlayergetsdamagedorremovedfromthe
surface.Thedryingprocedure,timeduration,temperaturelimits,time
lagbetweenfluxing,drying,galvanizingetcshallformpartofplant
standardtobeformulatedandsubmittedtoemployeralongwith

QualityAssuranceProgram.

(vi)QualityofZinc:Anyoneorcombinationofthegradesofzincspecifiedin
IS209orIS13229orothercomparableinternationalstandardshallbe
usedforgalvanizing.Thecontractorshalldeclarethegrade(s)ofzinc
proposedtobeusedbythemforgalvanizing.Themoltenmetalinthe
zincbathshallcontainminimum98.5%zincbymass.Itshallbe
periodicallymeasuredandrecorded.Zincaluminumalloyshallbeadded
asperIS2629.
(vii)DippingProcess:Thetemperatureofthegalvanizingbathshallbe
continuouslymonitoredandcontrolled.Theworkingtemperatureofthe
galvanizingbathshallbemaintainedat450+/10degreeC.Thearticle
shouldbeimmersedinthebathasrapidlyaspossiblewithout
compromisingonsafetyaspects.Thegalvanizingbathtemperature,
immersionangle&time,timedurationofimmersion,rateof
withdrawaletcshallbemonitoredandcontrolleddependinguponthe
size,shape,thicknessandchemicalcompositionofthearticlesuchthat
themassofzinccoatinganditsuniformitymeetsthespecified
requirementsandthegalvanizedsurfaceisfreefromimperfectionsand
galvanizingdefects.
(viii)PostTreatment:Thearticleshallbequenchedinwater.Thequench
wateristobechanged/drainedperiodicallytopreventcorrosivesalts
fromaccumulatinginit.Ifwaterquenchingisnotdonethennecessary
coolingarrangementsshouldbemade.Thegalvanizedarticlesshallbe
dippedinchromatingsolutioncontainingsodiumdichromateand
sulphuricacidorchromicacidbaseadditiveatapredetermined
concentrationandkeptatroomtemperaturetoretardwhiterustattack.
Thetemperatureofthechromatesolutionshallnotexceed65degreeC.
Thearticlesshallnotbestackedimmediatelyafterquenchingand
dichromating.Itshallbeensuredthatthearticlesaredrybeforeany
furtherhandlingoperation.
(ix)Storing,PackingandHandling:Inordertopreventwhiterustformation
sufficientcareshouldbeexercisedwhilestoringhandlingand
transportinggalvanizedproducts.Thearticlesshallbestoredinan
adequatelyventilatedarea.Thearticlesshallbestoredwithspacersin
betweenthemandkeptataninclinationtofacilitateeasydrainageof
anywatercollectedonthearticles.Similarcareistobetakenwhile
transporting and storing the articles at site. The Contractor shall prepare a
detailedgalvanizingprocedureincludingFlow
Chartwithcontrolparametersandallplantstandardsasrequiredaboveand
submittoKSEBLforapprovalaspartofQualityAssurancePlan.
1.6.2Fasteners.
For fasteners, the galvanizing shall conform to IS1367(Part13). The
galvanizingshall be done with centrifuging arrangement after all mechanical
operationsarecompleted.Thenuts,mayhoweverbetapped(threaded)orrerun
aftergalvanizingandthethreadsoiled.Thethreadsofbolts&nutsshallhavea
neatfitandshallbesuchthattheycanbeturnedwithfingerthroughoutthe
lengthof the threads of bolts and they shall be capable of developing full
strengthofbolts.SpringwashersshallbeelectrogalvanizedasperGradeIVof
IS1573.