ZEDTC Standard - Vol 1 - Transmission Lines Spec

ZIMBABWE ELECTRICITY TRANSMISSION AND
DISTRIBUTION COMPANY
Standard Specifications – Transmission Lines
General Specifications
Volume 1
ZETDC STANDARD SPECIFICATIONS - TRANSMISSION LINES
TABLE OF CONTENT
Part 1
Index
1.0 T-S-01-001 Scope of Works
2.0 T-S-02-001 Administrative Requirements
3.0 T-S-03-001 General Technical Requirements
4.0 T-S-04-001 Design Criteria
5.1 T-S-05-001 Conductors SP
5.2 T-S-05-002 Earth-wire SP
5.3 T-S-05-003 Optical Earth-wire SP
6.0 T-S-06-001 Insulators SP
7.0 T-S-07-001 Hardware SP
8.1 T-S-08-001 Steel Towers SP
8.2 T-S-08-002 Steel Poles SP
9.0 T-S-09-001 Grounding SP
10.0 T-S-10-001 Construction SP
11.0 T-S-11-001 Environmental Requirements SP
General Specifications Rev.: Draft
ZETDC Standard Specifications
Transmission Lines 88-420kV Date: Nov 2010
T-S-01-001 SCOPE OF WORKS
This document is the property of Zimbabwe Electricity Transmission and Distribution Company (ZETDC). ZETDC reserves the right in this document
and information contained therein. No part of this document may be reproduced or transmitted in any form or by any means, including photocopying
and recording, without the written permission of ZETDC.
T-S-01-001 Scope of Works Rev. Draft
ZETDC Standard Specifications Page 1 of 2
Transmission Lines 88-420 kV Date: Nov 2010
T-S-01-001 SCOPE OF WORKS (TEMPLATE)
Note: This chapter will be project specific and is included as a template only.
CONTENTS
1.1.1 SCOPE OF WORKS ......................................................................................................................2
1.1.1.1 Introduction ................................................................................................................................2
1.1.1.2 General .......................................................................................................................................2
1.1.1.3 Basic Technical Description of the Transmission Line ..............................................................2
1.1.1.4 Transmission Line Route............................................................................................................2
T-S-01-001 Scope of Works Rev. Draft
1.1.1 SCOPE OF WORKS
1.1.1.1 Intr oduction

This part of the Tender or Contract Document covers the Technical Specifications for the "Project"
1.1.1.2 Gener al
Short description of the project.
The works to be carried out under this Contract will comply with the document titled “ER-Powerline
Requirements” provided in the Instruction to Tenderers documentation
1.1.1.3 Basic Technical Descr iption of the Tr ansmission Line

As per the information provided in the document titled “ER-Powerline Requirements” provided in the
Instruction to Tenderers documentation
1.1.1.4 Tr ansmission Line Route

As per the information provided in the document titled “ER-Powerline Requirements” provided in the
Instruction to Tenderers documentation
T-S-02-001 ADMINISTRATIVE REQUIREMENTS
T-S-02-001 ADMINISTRATIVE REQUIREMENTS Rev. Draft
T-S-02-001 ADMINISTRATIVE REQUIREMENTS
CONTENTS
2.1.1 GENERAL .....................................................................................................................................4

2.1.1.1 Purpose .......................................................................................................................................4
2.1.1.2 Project Language ........................................................................................................................4
2.1.1.3 Correspondence ..........................................................................................................................4
2.1.1.4 Administration Documents Review and Acceptance .................................................................4
2.1.2 QUALITY ASSURANCE REQUIREMENTS ..............................................................................4
2.1.2.1 General .......................................................................................................................................4
2.1.2.2 Quality Assurance Program........................................................................................................5
2.1.2.3 Quality Plans, Inspection and Test Schedules ............................................................................6
2.1.2.4 Submission of Documents ..........................................................................................................6
2.1.2.5 Monitoring by the Employer ......................................................................................................6
2.1.2.6 Records .......................................................................................................................................7
2.1.2.7 Sub-orders ..................................................................................................................................7
2.1.2.8 Material and Test Certification...................................................................................................7
2.1.2.9 Particular QA Requirements.......................................................................................................7
2.1.2.10 Packing and Marking..............................................................................................................8
2.1.2.11 Reporting and Corrective Action............................................................................................8
2.1.2.12 Design Revision and Substitution of Material........................................................................8
2.1.2.13 Contractor’s Responsibility ....................................................................................................8
2.1.2.14 Information Required for Tender Evaluation .........................................................................9
2.1.2.15 Subcontractors and Suppliers .................................................................................................9
2.1.3 HEALTH, SAFETY AND ENVIRONMENTAL PROTECTION REQUIREMENTS ................9
2.1.4 ORGANISATION AND PERSONNEL ........................................................................................9
2.1.4.1 Organisation ...............................................................................................................................9
2.1.4.2 Key Positions..............................................................................................................................9
2.1.5 PLANNING AND SCHEDULING .............................................................................................10
2.1.5.1 General .....................................................................................................................................10
2.1.5.2 Level 3 – Contract Schedule.....................................................................................................10
2.1.5.3 Level 4 – Contract Detail Schedule ..........................................................................................11
2.1.5.4 Level 5 – The Contractor’s Detailed Work Schedules .............................................................11
2.1.5.5 Progress Monitoring Principles and System.............................................................................11
2.1.6 VARIATIONS, COST CONTROL, CASH FLOW FORECASTS AND INVOICING .............12
2.1.6.1 Procedures ................................................................................................................................12
2.1.6.2 Variations to the Work .............................................................................................................12
2.1.6.3 Cost Control - Cash Flow Schedules ........................................................................................12
2.1.6.4 Invoicing...................................................................................................................................12
2.1.7 REPORTS ....................................................................................................................................13
2.1.7.1 Monthly Progress Reports ........................................................................................................13
2.1.8 DOCUMENTS TO BE PREPARED BY CONTRACTOR .........................................................13
2.1.8.1 General .....................................................................................................................................13
2.1.8.2 Outline Drawings .....................................................................................................................13
2.1.8.3 Detailed Drawings, Design and Specifications ........................................................................13
2.1.8.4 Design Computation and Final Design Data ............................................................................14
2.1.8.5 Parts Bills .................................................................................................................................14
2.1.8.6 Catalogue Cuts, Illustrations, Etc. ............................................................................................14
2.1.8.7 Installation/Erection Manual and Drawings .............................................................................14
2.1.8.8 Commissioning Manual ...........................................................................................................14
2.1.8.9 Operation and Maintenance Manual ........................................................................................15
2.1.8.10 Final Drawings .....................................................................................................................15
2.1.8.11 Processing of Drawings ........................................................................................................15
2.1.8.12 Procedure for Delivery of Documents ..................................................................................16
2.1.9 ENGINEERING DOCUMENTATION NUMBERING SYSTEM .............................................18
2.1.10 MEETINGS ..................................................................................................................................18
2.1.10.1 Progress Review Meetings ...................................................................................................18
2.1.10.2 Project Meetings ...................................................................................................................18
2.1.10.3 Design Review Meetings......................................................................................................18
2.1.10.4 Other Meetings .....................................................................................................................18
2.1.10.5 Calls for Meetings ................................................................................................................18
2.1.10.6 Minutes of Meetings .............................................................................................................18
2.1.11 FACILITIES AND SERVICES FOR THE EMPLOYER ...........................................................19
2.1.11.1 General .................................................................................................................................19
2.1.11.2 Facilities and Services for the Employer ..............................................................................19
2.1.12 TRANSPORT, PACKING, ETC. ................................................................................................19
2.1.12.1 General .................................................................................................................................19
2.1.12.2 Packing .................................................................................................................................20
2.1.12.3 Transport Marking ................................................................................................................20
2.1.12.4 Preparation for Shipping and Storage...................................................................................21
2.1.12.5 Shipping and Transportation to Site .....................................................................................21
2.1.12.6 Inventory List .......................................................................................................................21
2.1.12.7 Storage ..................................................................................................................................21
2.1.13 EQUIPMENT DESIGNATION (EQUIPMENT MARKING) SYSTEM (EDS) ........................22
2.1.13.1 Identification System ............................................................................................................22
2.1.13.2 Labels and Plates ..................................................................................................................22
2.1.14 CUSTOMS CLEARANCE ..........................................................................................................22
2.1.15 MISCELLANEOUS .....................................................................................................................22
2.1.15.1 Documentary Film................................................................................................................22

2.1.16 TRAINING OF THE EMPLOYER’S PERSONNEL ..................................................................23
2.1.16.1 General .................................................................................................................................23
2.1.16.2 Training Objectives ..............................................................................................................23
2.1.16.3 Course Content .....................................................................................................................24
2.1.16.4 Course Documentation .........................................................................................................24
2.1.1 GENERAL
2.1.1.1 Pur pose

This chapter contains certain administrative requirements related to the implementation of the Contract.
It is the Employer’s intention that the Contractor’s own methods and procedures shall be utilised as far as
possible in the execution and administration of the Contract provided that they accommodate the
requirements contained herein.
The content of the appurtenant Technical Schedules and those provisions elsewhere in this chapter that are
of a dynamic character (e.g. requirements regarding reporting, meetings and correspondence) may be
changed during the Contract period. Both parties can propose such changes and both parties prior to
implementation shall agree on them in writing.
2.1.1.2 Pr oject Language
Reference is made to the Conditions of Contract.
2.1.1.3 Cor r espondence

All communications pertaining to this Contract shall be addressed as stated in the Technical Schedules.
The Contractor shall maintain a register for all correspondence, which shall be accessible to the Employer for
information.
The Contractor shall forward correspondence to the Employer in one original.
All correspondence between the Employer and the Contractor shall be numbered consecutively. The
numbering system shall as a basis be as follows: aa–bb-cc-dd, where aa is the originator (the Employer/the
Contractor code), bb is E (e-mail), F (fax), L (letter), M (minutes of meeting), cc is a project specific code
(e.g. 01 - administrative, 40 - steel towers, etc.) and dd is sequence number.
When e-mail documents have attached files, such documents' number, subject block and file name shall be
referred to in the e-mail text.
For e-mail and file transfer a secure connection, encrypted tunnel or equal, shall be established between the
Contractor and the Employer.
2.1.1.4 Administr ation Documents Review and Acceptance

When requested by the Employer, the Contractor shall issue his procedures to the Employer for review and
amend them if they do not comply with the requirements of the Contract.
Documents to be prepared by the Contractor in accordance with the various sections hereof shall be subject
to acceptance by the Employer.
The Employer’s review time shall not, unless stated otherwise, exceed 15 working days from the day when
the document arrives at the Employer’s office. Any subsequent document revisions shall take place within
the same time frame.
2.1.2 QUALITY ASSURANCE REQUIREMENTS
2.1.2.1 Gener al
The Contractor shall have a well-organized Quality Assurance Program (QAP) based on ISO 9000 Series
(Quality System Model for Quality Assurance in design/development, production, installation and servicing)
to assure that items and services, including subcontracted items and services, comply with this specification.
All design, manufacturing, processing, testing and inspection operations affecting the equipment or material
shall be governed by Quality Assurance procedures in accordance with the directives of the ISO 9001
standards while the production and installation shall be governed by quality assurance procedures in
accordance with the directives of the ISO 9002 standards. These may be subject to surveillance by Employer
or Employer’s representative. A tentative QAP shall be submitted together with the tender.
Within thirty (30) days of the Effective Date of Contract, the Contractor shall submit six (6) copies of his
complete quality control and assurance procedures, manuals for review and approval by the Employer. The
manual shall include pro-forma checklists for all requirements of the Contractor’s quality control and
assurance program and those called for in this Specification.
The Quality Control and Assurance Program to be submitted shall include but not necessarily be limited to
the following:
a) Program requirements for Materials and Equipment Procurement and Manufacture with description on
design control, purchased material control, quality verification tools, manufacturing control, materials
and components selection, handling and packaging, etc.;
b) Program requirements for Equipment Production with detailed description on Quality Assurance
Organization of the Contractor, Quality Assurance Functions and Procedures and Performance
Monitoring;
c) Quality Assurance Program Tests with detailed description on the test procedures to be conducted.
d) Quality Assurance Program requirements for installation and commissioning (for Turn-Key Contracts)
with detailed description on Quality Assurance Organization of the Contractor, Quality Assurance
Functions and Procedures, etc.).
Prior to production, the Contractor shall submit to Employer a fabrication sequence describing inspection
and/or tests to be performed, for use in determining inspection points which Employer may desire to witness.
Employer will advise the Contractor prior to production of those fabrication steps and shop inspection points
that Employer desires to witness.
The Contractor shall give the Employer adequate notice, forty five (45) calendar days minimum, prior to
those fabrication steps and tests which the Employer desires to witness.
2.1.2.2 Quality Assur ance Pr ogram

The Contractor shall, for all work covered by the Contract, establish and implement a quality assurance
program which as a minimum, meets the requirements set out in ISO 9001 and ISO 9002.
In addition to the requirements of these ISO’s, the Contractor shall:
a) Establish procedures for adequate planning of all quality related activities including the preparation of
quality plans.
b) Establish measures for the identification and control of items throughout all stages of the Contract. This
shall include measures to maintain traceability as identified in agreed quality plans.
c) Arrange for the protection of the quality of the product to include delivery to the specified destination.
d) Control their measuring and test equipment in accordance with established procedures for measurements
and calibration systems and ensure that such equipment that may be used by subcontractors to verify
work is similarly controlled.
e) Ensure adequate quality systems exist for compliance with the requirements of the Tender and Contract
Documents.
Where any site installation and/or test and commissioning work is involved, the Contractor shall prepare
contract-specific quality assurance procedures in agreement with the Employer prior to commencements of
such works.
The Contractor shall be responsible for specifying the quality assurance requirements to his subcontractors,
for approving subcontractors’ quality assurance programs and for ensuring compliance with the
requirements.
The Contractor shall ensure that all appropriate technical information is extracted from the Contract
documents and specifications and passed on to the subcontractors.
The Contractor shall ensure that all computer systems and software to be utilized on the project is qualified
for the application under consideration and such qualification is documented.
2.1.2.3 Quality Plans, Inspection and Test Schedules

Quality plans shall be prepared detailing the specific activities, design reviews, operations, control
procedures, inspections, testing, approvals and certification requirements applicable. Quality plans shall be
submitted to the Employer for review and approval.
Where inspection schedules are generated in support of a quality plan these are also required by the
Employer for review and approval.
The format and content of schedules shall ensure that inspection operations are planned and performed in a
systematic manner.
Documents referred to in quality plans shall be available to the Employer for review if required.
Specific quality plans shall be prepared for site work and submitted for review and approval by the Employer
prior to commencement of such work.
The Contractor shall approve all quality plans, inspection and test schedules of their subcontractors and
vendors.
The Contractor shall identify his verification requirements on the quality plans submitted to the Employer for
review and approval and shall identify the following:
a) Stages subject to random surveillance.
b) Inspections that require to be carried out or witnessed, by the Employer or a third party following
satisfactory verification and acceptance by the Contractor.
c) Hold points beyond which work cannot proceed before completion of all operations, verifications and
related activities identified after the previous hold point on the quality plan.
The Contractor shall be responsible for identifying and arranging any verification activities for statutory
approval in the country of manufacture.
The Contractor shall adhere to the reviewed quality plan(s) and notify the Employer immediately of any
deficiencies or difficulties should they arise.
Where functional testing is required, functional test schedule(s) and/or procedures shall be prepared by the
Contractor and submitted to the Employer for review and approval prior to the commencement of such
testing.
2.1.2.4 Submission of Documents

The Contractor shall submit drawings and other documents for review and approval by the Employer as
required by the Contract Specifications and Quality Plans.
A schedule of drawings and all documentation for review shall be submitted to the Employer and shall be
maintained by the Contractor to show the up-to-date status and revision of each document.
The Contractor is not authorized to proceed with manufacturing until notified that the drawings are
satisfactory to the Employer, unless the Employer waives this requirement in writing.
The Employer’s general review of drawings and data or waiver of the same shall not in any way relieve the
Contractor of any responsibility to meet all requirements of this specification or the purchase order.
2.1.2.5 Monitor ing by the Employer

The Employer reserves the right to request, review and maintain for the duration of the contract a copy of the
Contractors Quality Manual.
During the course of the Contract, the Employer reserves the right to monitor the implementation of the
Contractor’s quality assurance program. Monitoring will be by means of surveillance of activities at the
work locations and where appropriate by formal audits. Representatives of the Employer shall be afforded
unrestricted access and facilities at all reasonable times to carry out this work to verify manufacturer’s
compliance with the established manufacturing, assembly, delivery, including installation and
commissioning schedules for Turn-key contract.
The Employer reserves the right to monitor subcontractor’s activities and the Contractor shall ensure that
subcontractors are informed of these requirements.
2.1.2.6 Recor ds
The Contractor shall generate records as required by the quality assurance system and quality plans.
Records, including audit reports shall be available for inspection by the Employer.
All records shall be concisely compiled, indexed and cross-referenced to the project contract number and
they were relevant subcontract numbers. They shall be clearly identifiable to the individual parts and
assemblies to which they refer.
Those records required by the Employer, as defined in the contract specifications and quality plans shall be
available at the time of delivery of the equipment. Such records shall include reports and certification in
respect of pressure retaining components together with general traceability records for all items through
certification and build documentation as a minimum. Six (6) copies of these records shall be supplied to
Employer with the exception of radiographic films where the original set of films shall be supplied.
All records generated during the course of the Contract, including those generated as evidence of effective
implementation of the quality assurance program of the Contractor and his subcontractors, shall be retained
by the Contractor for a minimum period of five (5) years from the date of contract completion. These records
shall be made available to Employer on request during the retention period.
2.1.2.7 Sub-o rder s

All orders for materials and equipment purchased by the Contractor specifically for this Contract are subject
to inspection, tests and expediting. The Contractor shall advise the manufacturer of any interventions
received from the Employer or his authorized representative(s).
The QA program shall contain a detailed list of all sub-orders placed with sufficient information to enable
the inspectorate to function properly, including order numbers, manufacturer’s identity, equipment
specifications, delivery and dispatch dates, etc.
2.1.2.8 Mater ial and Test Cer tification

One (1) copy of all tests results recorded during an inspection visit shall be handed to the Employer or his
authorized representative(s) on that day. In addition, six (6) copies of the test certificates will be required
fifteen (15) days thereafter.
In the event that the inspection of any item is waived, test certificates shall still be required.
2.1.2.9 Par ticular QA Requir ements

General
As a supplemental document to the QA program, the Contractor shall submit for approval of the Employer a
separate document with detailed particular requirements and specific acceptance criteria of all equipment.
At Shop
Corresponding to each major and minor component of transmission line equipment, the following data are
required for submission to and approval of the Employer:
a) Test and inspection procedure;
b) Guaranteed technical rated or design data;
c) List of holdpoints and/or routine tests;

d) Acceptance criteria and reference standards;
e) Test results/data with comparison to the guaranteed data. All allowable tolerances with respect to
dimensional control of assemblies and sub-assemblies at shop shall be clearly indicated in the
manufacturer’s drawings.
At Site
The tests at site shall be in accordance with the manufacturer’s recommendation as approved by the
Employer.
The Employer or his duly authorized representative shall control said site tests, in collaboration with the
Contractor’s representatives.
2.1.2.10 Packing and Mar king

Careful packaging of all materials supplied for this contract is of utmost importance and is subject to the
control of the Employer, so that the following aspects are checked:
a) Packaged design and markings;
b) Protection of contents against damage by mechanical shock, moisture ingress, adverse atmospheric
conditions or corrosion;
c) Material quality workmanship and manufacturing of packages.
2.1.2.11 Repor ting and Cor r ective Action

The Contractor’s quality assurance program shall provide for prompt detection and correction of all
conditions adversely affecting quality, including failures, malfunctions, incidents, trends, deficiencies,
deviations, non-conformances, and defective materials. The Contractor shall establish and maintain methods
for verifying and determining the cause of an adverse condition and for initiating necessary improvement and
corrections to preclude repetition. Quality trends shall be analyzed to furnish a basis for improvement in
work performance. The Contractor’s corrective action system shall extend to the performance of other
participating contractors, sub-contractors, and Contractors, when necessary, and shall provide for the
interchange of corrective action information. Identification of the adverse condition, its cause, and the
corrective action taken shall be recorded and reported to appropriate levels of management.
The Contractor shall establish and implement procedures for reporting, verifying, analyzing, and correcting
failures, including those that occur during development and qualification testing. The procedures shall
provide assurance that the cause and mode of each failure are determined, that potential safety and
availability implications are evaluated, and that corrective action is taken.
A failure report shall be prepared to identify the failed item and its origin or source of manufacture and shall
describe the failure, the test status at time of failure, the probable cause and mode of failure, and the
recommended corrective action.
2.1.2.12 Design Revision and Substitution of Mater ial

Any revision affecting the design and manufacturing of transmission line components, i.e. towers and poles
as well as substitution of materials that is deemed necessary shall be notified by the Contractor to the
Employer for the latter’s review and approval.
2.1.2.13 Contr actor’s Responsibility

Approval by the Employer of the Contractor’s quality assurance program, quality plans and inspection and
test plans, or of those of his subcontractors will not relieve the Contractor of his obligation to provide goods
and services which meet the requirements of the Contract.
2.1.2.14 Information Requir ed for Tender Evaluation

The following information is required in order to carry out a systematic evaluation of the Contractor’s
quality assurance program and should be compiled under the heading of Quality Assurance and structured as
below:
Statement of intent for the adoption of a documented quality system and acceptance of the requirements laid
down in this specification.
Details of any recent external assessments of the proposed quality system - through Second Party audit or
Third Party assessment. The results of such audits/assessments should be submitted together with details of
any accreditation of the quality system.
Details of the procedure for quality assessments of Contractors/Subcontractors together with recent
assessments carried out. The list should include reference to the assessment standard, including the
applicable part of such a standard.
A contract specific quality plan together with supporting inspection and test schedules, as described in this
Specification.
Details of the procedures governing:
- Internal QA system audits
- Project audits
- Contractor/Subcontractor surveillance audits
Details of QA records produced and typical examples.
Details of the facilities for inspection and test.
A schedule of drawings and documentation for review and approval by Employer.
2.1.2.15 Subcontr actor s and Supplier s

For each Subcontractor the Contractor shall identify the relevant quality standard ISO 9001, 9002 or 9003 to
be selected in accordance with the guidelines given in ISO 9000-1 and in ISO 9000-3. The Contractor shall
assess Subcontractors' quality systems and their implementation to confirm adequate qualification standard.
The Contractor shall plan and carry out QS of his Subcontractors (ref. ISO 8402, Clause 3.11) at a level of
detail sufficient to ensure fulfilment of the quality requirements of the Contract. The Employer shall have the
right to participate as observer in such QS activities.
The Contractor shall submit his QS-plan(s) to the Employer for acceptance and keep the Employer informed
of any change thereof.
2.1.3 HEALTH, SAFETY AND ENVIRONMENTAL PROTECTION REQUIREMENTS

Reference is made to the Environmental Protection Requirements (EPR) Specification.
2.1.4 ORGANISATION AND PERSONNEL
2.1.4.1 Or ganisation
The Contractor’s project organisation charts for management, control and execution of the Contract are as
included in the Tender.
The Contractor shall maintain up-to-date project organisation charts, which shall be submitted to the
Employer in the event of any changes.
The Contractor shall determine which job categories are of significance to safety, and qualification
requirements for such jobs shall be established.
2.1.4.2 Key Positions

Key positions include individuals assigned to management/supervisory positions as listed in the Tender.
The appointment, transfer and replacement of personnel to all key positions shall be subject to the
Employer’s prior approval. Key positions shall be on a full time basis, unless otherwise agreed with the
Employer.
Engineering and procurement personnel in key positions shall be committed to continue through the Contract
period in order to maintain continuity.
2.1.5 PLANNING AND SCHEDULING
2.1.5.1 Gener al
The schedule hierarchy of the Project comprises the following 5 levels:
The Employer responsibility:
o Level 1 Overall implementation schedule
o Level 2 Project work plan
The Contractor responsibility:
o Level 3 Contract schedule
o Level 4 Contract detail schedule
o Level 5 The Contractor’s detailed work schedules.
The level 2 schedules contain a list of critical milestones for the project. Those relevant to this Contract are
given in the Technical Schedules and/or Appendix to Tender. These Contract milestones, which the
Contractor has an obligation to achieve, shall be the basis for the Contractor’s planning and scheduling,
progress monitoring and reporting.
The Contractor shall be responsible for planning and scheduling, progress monitoring and reporting at level 3
to 5 as described below. All schedules shall represent the total current scope of Works covering the whole
Contract period.
2.1.5.2 Level 3 – Contr act Schedule

2.1.5.2.1 Purpose
The level 3 schedules shall:
o Present a management overview.
o Provide a link between the Employer’s and the Contractor’s planning and scheduling.
o Present an aggregation of level 4-schedule information.
2.1.5.2.2 Activity Breakdown
The level 3 schedules shall:
o Reflect and include all Contract milestones
o Within each work package clearly indicate the method of work execution and interfaces/
interdependencies for key activities.
2.1.5.2.3 Format and Presentation
The level 3 schedules shall include:
o Bar chart which shows, as a minimum for each activity:
 Planned, forecast and actual start and completion dates.
 Planned and actual progress (last period and cumulative).
2.1.5.3 Level 4 – Contr act Detail Schedule

2.1.5.3.1 Purpose
The level 4 schedules are considered the working schedules of the planning system and are a reference
database for all main elements of the Works, from which reports and registers may be produced directly or
aggregated to higher planning levels for progress monitoring, analysis and information purposes.
2.1.5.3.2 Activity Breakdown
The level 4 schedules shall be split according to the main parts of the Works:
o Engineering
o Testing
o Manufacturing
o Installation
2.1.5.3.3 Format and Presentation
The level 4 schedules shall be prepared using an approved project management software application.
Subcontractor's works shall be separately identified.
The Contractor shall prepare an activity bar chart with the activities listed in early start order and showing
the following:
a) Activity code
b) Activity description
c) Duration in days
d) Early start and finish dates
e) Late start and finish dates
The Contractor shall prepare a bar chart identifying all activities, which cannot be performed without the
Employer's approval, and the need dates for the Employer's decisions.
2.1.5.4 Level 5 – The Contr actor’s Detailed Wor k Schedules

2.1.5.4.1 Purpose
The level 5 schedules shall in a flexible manner be used for presentation of detailed elements of the
Contractor’s and Subcontractors’ work plans.
2.1.5.4.2 Engineering (Level 5 Engineering Document Register)
The level 5 - engineering document register shall show for each drawing/document:
a) Document number, revision number and title
b) A defined set of milestones.
2.1.5.4.3 Special Task Schedules
The Contractor, if deemed necessary by the Contractor or the Employer shall prepare special task schedules.
Preparation of such special schedules shall not be subject to a Variation to the Works.
2.1.5.5 Pr ogr ess Monitoring Pr inciples and System

Throughout the duration of the Contract, the Contractor shall monitor progress of the Works, and shall
immediately advise the Employer in advance of any anticipated schedule delays, and the reason therefore.
The Contractor shall provide, within 30 Days after Commencement Date, the proposed progress monitoring
system for all phases of the Works.
2.1.6 VARIATIONS, COST CONTROL, CASH FLOW FORECASTS AND INVOICING
2.1.6.1 Pr ocedur es
Within 14 Days after Commencement Date, the Contractor shall submit to the Employer for review the
proposed procedures for:
• Accounting, financial control and invoicing, showing the Contractor's internal checks and control of
all transactions under this Contract, that the invoicing is reliable and accurate.
• Processing of Variations to the Works, including identifying, processing and documenting with
internal reviews, approvals and filing. Interface to other procedures shall be identified.
2.1.6.2 Var iations to the Wor k

The Contractor shall regularly issue a Variation Order summary status report, detailing the Variations to the
Works on a current period and cumulative basis by the appropriate Variation Order Request number and the
appropriate Variation Order number and by pending variations.
2.1.6.3 Cost Contr ol - Cash Flow Schedules

The Contractor shall prepare monthly cost reports. The cost report shall include monthly cash flow schedules
showing planned and actual values of the Works performed per month for the entire duration of the project
and in addition provide information on Variations to the Works and current Contract Price.
The Contractor shall keep the Schedule of Payments updated monthly and include a brief narrative on any
major deviations.
The Schedule of Payments shall show yearly total, past and projected payments.
2.1.6.4 Invoicing
The Contractor shall on a monthly basis, in accordance with the Conditions of Contract, prepare and submit
an invoice to the Employer, with the number of copies as stated in the Technical Schedules, all with full
back-up documentation, in accordance with the standard invoice format.
The invoices shall specify the different categories of the Works and any reimbursable charges and state the
amounts due.
Value Added Tax (VAT) shall only be invoiced if applicable and shall be shown as a separate item. Invoices
not including VAT shall clearly state, "VAT not charged".
Valuation of each Variation to the Works shall be shown separately on the invoice, but in the summary
Variations shall be incorporated into the gross totals of the individual items and sub items.
Invoices shall be supported by the following documentation where relevant:
a) Subcontractor and supplier invoices certified as,
b) Originals of supporting documentation, except where the Contractor is required by law to
retain such originals, in which case certified copies shall be submitted,
c) Documentation of works and supply items invoiced in accordance with the format of the
Schedule of Quantities showing items, quantities and prices invoiced (i) this period, (ii)
previous period, (iii) accumulated and (iv) remaining
c) Written verification that the service has been performed or the Materials have been received,
and
d) Any other documentation the Employer requires to enable verification of the service or
Materials and the correctness of the invoice.
The Employer shall make payments to the Contractor on the basis of approval of the Contractor's invoice
submitted in accordance with the Conditions of Contract. Payment of invoices shall be deemed to have
occurred on the date the paid amount is debited from the Employer's bank account(s).
2.1.7 REPORTS
2.1.7.1 Monthly Pr ogr ess Repor ts

The Contractor shall from the second month after the Effective Commencement Date, submit to the
Employer a monthly report related to the Works performed during the previous month. The Contractor shall
present the report with diagrams in printed format.
Cut-off date for the report shall be the last Sunday of each month. The monthly report shall be submitted to
the Employer no later than seven (7) days after the cut-off date. The monthly report shall be submitted in
four copies until the Completion Certificate is issued, and shall include as a minimum the following items:
a) Narrative of major achievements and any deviations from time schedule, reasons for delays
and deviations, with recommended actions and potential effects,
b) The level 4 schedule showing the status at the cut-off date by means of a front line or
equivalent,
d) A systematic listing and analysis of all significant time critical activities (total float=0),
e) A summary of HSE activities and reported incidents in own and major Subcontractors'
activities,
f) Report on interface activities, and
g) Narrative report on quality management activities.
2.1.8 DOCUMENTS TO BE PREPARED BY CONTRACTOR
2.1.8.1 Gener al
The general documents, calculations, certifications, manuals, drawings, etc., relating to the manufacturing
works, which are to be prepared during the detailed design by the Contractor are listed here below. The
Contractor’s attention is drawn to various sections of this Specification, where detailed contents of
documentation are specified.
The document numbering system applicable for the total duration of the Project and the related Contract
shall be in compliance to the drawing and documentation identification system as described in this
specification.
2.1.8.2 Outline Dr awings

The Contractor shall, within sixty (60) calendar days after the date of contract signing, submit outline
drawings of the materials and equipment to be furnished under this contract.
2.1.8.3 Detailed Dr awings, Design and Specifications

Before proceeding with the manufacture of equipment, the Contractor shall submit corresponding detailed
drawings, designs, and detailed specifications (in typewritten hardbound form) which shall show all details
of materials, manufacture, assembly, testing, erection, commissioning, operation and maintenance of the
equipment in conformity with the Contract requirements.
The detailed drawings and specification shall include, but not necessarily be limited to the following:
i) General assembly drawings;
ii) Assembly drawings, showing:
- sectional views,
- details of mounting of the materials and hardwares,
- function of the assemblies,
- adjustment and operating ranges,
- concrete pedestals and foundation bolts and anchors,
- field tolerances,
- all field joints,
- methods of lubrication (if required)

iii) detail manufacturing drawings showing:
- detail dimensions
- tolerances
- materials
- nameplate diagrams
iv) engineering instructions and detailed specifications for:
- manufacturing
- fabrication
- painting, including final colour scheme
- heat treatment
- welding
- surface treatment and
- testing
2.1.8.4 Design Computation and Final Design Data

After the Contractor has completed the preliminary design of the transmission line structures, he shall submit
the final design data, design analysis and design computations (referred to as designs) along with all other
specified designs and studies, all in typewritten and book bound form, clearly laid out with all the design
criteria and standards indicated for Employer’s review and approval.
2.1.8.5 Par ts Bills

The Contractor shall submit with the first drawing issue, where applicable, corresponding parts bills.
Reference to the respective detail or assembly drawing, materials used or catalogue shall be made.
2.1.8.6 Catalogue Cuts, Illustr ations, Etc.

Applicable requirements of this paragraph with reference to drawings shall apply equally to catalogue cuts,
illustrations, printed specifications, design data, analysis and calculation, and manufacturer’s descriptive
literature and instructions for all equipment furnished to demonstrate fully that all parts will conform to the
requirements and intent of the Contract Documents.
2.1.8.7 Installation/Er ection Manual and Dr awings

The Contractor shall provide the Employer with an Installation and Erection Manual covering installation
and erection procedure and instruction to facilitate smooth erection, assembly and testing on site of the
transmission line and its component to be installed.
The instructions therein shall specify the exact procedures to be followed during installation and erection,
indicate data to be measured and recorded (adjustments, setting of limits, sags, etc.), quantities, dimensions
and tolerances to be checked, etc.
The manual shall include information for handling and slinging the major pieces of transmission line
structures and line hardware, erection tolerances, settings and adjustments and special precautions to be
taken during installation.
The Contractor shall submit six (6) copies each of the Installation and Erection Manual for each schedule to
the Employer.
2.1.8.8 Commissioning Manual

The Contractor shall provide the Employer with a Commissioning Manual, which shall be similar in size and
form to the Installation Manual and shall include procedures and instructions to be followed during the
commissioning of all equipment to be installed.
The instructions therein shall specify the exact procedures to be followed during commissioning of the
transmission line and shall indicate all data to be measured (and where appropriate recorded in the manual
itself) and all adjustments, setting of limits, sagging, tower/pole grounding resistance, etc., quantities,
dimensions and tolerances to be checked.
The Contractor shall submit six (6) copies each of the Commissioning Manual for each schedule to the
Employer.
2.1.8.9 Oper ation and Maintenance Manual

The Contractor shall provide the Employer with an Operation and Maintenance Manual similar in size and
form with the other manuals and shall include procedures and instructions to be followed by the operating
and maintenance staff necessary for reliable operation and maintenance of the transmission line.
The manual shall contain at least the following documents and data:
o General description of the tower/pole, line hardware and materials;
o Main technical characteristics;
o Interconnection of each complete assembly drawings of suspension insulators and hardware;
o Instructions for transmission line maintenance personnel including periodic tests, check-points,
actions required following each trip out of the line during lightning strikes and over voltages;
o Summary of important rules, standards, safety precautions and instructions to be followed
during line maintenance, both off-line and on (live)-line maintenance:
o Safety and warning signs to be placed on the tower and/or pole structures ;
Sections on “maintenance” shall be divided into two parts, namely:
o Current (preventive) maintenance indicating inspection periods, routine cleaning and live line
washing (if required) procedures, safety checks, adjustments, etc;
o Repairs describing the dismantling, removal and replacement of parts (with spare parts),
trouble-shooting guides, repair instructions, etc.
The Operation and Maintenance Manual, supplemented by any additional drawings and project documents to
be submitted to the Employer will be the only document to be generally used by the transmission/substation
operating staff.
The Contractor shall submit six (6) copies each of the Operation and Maintenance Manual for each schedule
to the Employer. Likewise, an additional four (4) sets of CD’s containing these documents preferably in MS
Word format shall be furnished. Other formats can be accepted provided the Contractor furnishes software
for these formats.
2.1.8.10 Final Dr awings

The Contractor shall furnish four (4) sets of recordable CDs each containing copies of all drawings as finally
approved and built. Such CDs shall be suitable for CD R/W drive of computer system. Four (4) additional
prints of same drawing with dark lines on a white background shall be furnished. For all approved drawings
with no subsequent revisions, the reproducible copies earlier furnished may be considered part of this set.
The Employer will not release the final payment and the performance security until the foregoing conditions
have been fulfilled.
2.1.8.11 Pr ocessing of Dr awings

Drawings and documents mentioned above shall be submitted to the Employer for approval. The timing of
such submission shall be in accordance with the Conditions of Contract.
All documents to be approved by the Employer shall meet the following requirements:
a) They shall be marked with a document identification number, issue date and revision status;
b) They shall be submitted in at least six (6) copies printed with dark lines/letters on a light
durable paper;
c) All drawings, calculation sheets, etc. shall be folded down to A4 standard size acceptable to
the Employer.
Award of contract does not imply approval of drawings and data submitted by the Contractor with his tender.
The Contractor shall submit six (6) copies of all drawings, specifications and designs with all supporting
information to the Employer for approval. Two (2) copies will be returned to the Contractor with one of the
following marks:
“Reviewed”; this mark authorizes the Contractor to proceed with the Contract Work therein indicated.
“Reviewed as amended”; this mark authorizes the Contractor to proceed with the Contract Work therein
indicated taking into account of the notes and/or comments by the Contractor and re-submit the drawings,
specifications or designs for approval before commencing the Contract Work therein indicated.
“Returned for Correction”; this mark requires the Contractor to make the corrections indicated and re-
submit the drawings, specifications or designs for approval before commencing the Contract Work therein
indicated.
Approval of the Contractor’s drawings shall not be held to relieve the Contractor or any part of the
Contractor’s obligations to meet all the requirements of the specifications nor of the responsibility for the
correctness of the Contractor’s drawings.
When revised drawings or drawings which have been returned to the Contractor marked “Reviewed as
amended” or “Returned for Correction” are re-submitted for review, the revision block shall be completed
with description and date of revision and the appropriate revision letter or numeral which shall be clearly
indicated adjacent to the revision or modification which requires approval.
No revision affecting the design shall be made after the drawing has been “Reviewed” without re-submitting
the drawings suitably revised for formal approval.
The Employer will complete the review of the Contractor’s drawings within twenty (20) calendar days after
receipt at Employer’s Office. If within the twenty (20) calendar days, the Contractor has not received any
reply from the Employer regarding the approval drawings, the Contractor may proceed with the design and
manufacture of the particular components of either the transmission line structures, hardware and materials
as if the drawings have been approved.
2.1.8.12 Pr ocedur e for Deliver y of Documents

2.1.8.12.1 General
The Contractor shall submit the following information to the Employer. The number of copies to be shall be
as indicated below:
2.1.8.12.2 Within thirty (30) after the Effective Date of Contract:
Six (6) sets of:
o Drawing Classification Plan

o List of Detailed Drawings
o Quality Control and Assurance Program
o A detailed Project Progress and Performance Review (PPR)
2.1.8.12.3 Within forty five (45) days after the Effective Date of Contract:
Six (6) sets of:
o Design and manufacturing schedules
o Delivery, erection and commissioning schedules
o Principal drawings, schemes, tables, charts and templates

o Type test reports and literature concerning the transmission line component if not submitted
with the Tender
o A program of performance, material and workshop tests to be carried out.
2.1.8.12.4 Within sixty (60) days after the Effective Date of Contract :
Six (6) sets of:
o Outline drawings of the towers/poles, line hardwares and materials and conductors complete
with design calculation/computations and loadings
o Loadings of foundations for all items of towers/poles to be supplied and details of templates
and stubs
o Preliminary assembly drawings of the equipment with details of materials intended to be
used
o Delivery of all drawings related to civil works
2.1.8.12.5 Before beginning of manufacturing:

Six (6) sets of:
o Detailed manufacturing drawings with all important dimensions and final assembly
drawings intended to aid understanding and provide full information about the principles of
installation and erection.
o Performance and stress calculations as the Employer may require.
2.1.8.12.6 During manufacture:
Six (6) sets of:
o Progress photographs of the shop work done. Photographs shall be approximately 20 x 25
cm in size, including a margin of 2.5 cm on one of the 25 cm sides for binding. Four (4)
views will be required for each piece of equipment. Each photograph shall contain upon its
face the date, name of the manufacturer and the title of the view taken.
o Notice of material tests and shop inspection.
2.1.8.12.7 At least fifteen (15) days prior to shipment:

o Six (6) copies of Inspection Report
o Six (6) copies of Test certificates or test reports together with certificate of inspections
(additional two (2) complete sets bound in books required)
2.1.8.12.8 At least thirty (30) days prior to shipment:
o Six (6) sets of packing lists for each consignment
o Six (6) sets of instructions for loading, unloading, handling and special precautions to be
observed for storage at site.
o Six (6) sets of Installation and Erection Manuals and Final Drawings for each tower/pole
type and component, hardware and materials to be supplied.
2.1.8.12.9 Within ten (10) days after the last shipment of equipment:
o Six (6) sets of Commissioning Manual
o Six (6) sets of Operating and Maintenance Manual
2.1.8.12.10 Before issuance of Provisional Acceptance and release of Performance Security :

One (1) reproducible (rolled) and four (4) light copies of all drawings marked “Final Drawings” and four (4)
sets of recordable CD’s each containing copies of all the drawings as finally approved and built.
2.1.9 ENGINEERING DOCUMENTATION NUMBERING SYSTEM

Each document shall be given an individual document number according to the following numbering system:
A NNNN A AN /NN -A
Project code
Sequence number
Country code
System code
Contractor code
Type of document
A = Letter (Alpha)
N = Number
A manual containing applicable codes will be submitted to the Contractor at Commencement Date.
2.1.10 MEETINGS
2.1.10.1 Pr ogr ess Review Meetings

The Employer shall schedule and hold monthly progress review meetings with the Contractor to a mutually
agreed agenda. The meetings shall normally take place at the Contractor's engineering offices.
2.1.10.2 Pr oject Meetings

The Employer may request project meetings to be arranged quarterly or often if found required. Project
meetings are normally called for to discuss contractual matters.
2.1.10.3 Design Review Meetings

The Contractor may request a design review meeting as part of the process of seeking the approval of the
Employer to all engineering documentation. The Contractor shall submit a meeting agenda well in advance
of the meeting.
2.1.10.4 Other Meetings

The Contractor shall arrange discipline meetings and other meetings as necessary with Subcontractors, etc.
The Employer shall be notified in due time of such arrangements and given opportunity to attend.
The Contractor and the Employer shall as required hold meetings on specific subjects.
2.1.10.5 Calls for Meetings

Except for regular scheduled meetings, calls for meetings and agenda shall be sent out by the party calling
the meeting to all requested attendees well in advance of the meeting.
2.1.10.6 Minutes of Meetings

Minutes shall be prepared by the Employer on an agreed form and be issued for the Employer's review the
next working day after the meeting has taken place.
Matters requiring action shall be assigned the responsible party with dates for completion of such action.
Results of actions from previous meetings shall be recorded.
Copies of minutes of meetings from interface meetings and other meetingsshall be sent to the Employer.
2.1.11 FACILITIES AND SERVICES FOR THE EMPLOYER
2.1.11.1 Gener al
The Contractor shall from the Effective Commencement Date until 30 Days after the issue of the Completion
Certificate, unless otherwise agreed, provide facilities and services for the Employer as indicated below.
All facilities and services shall comply with any statutory or mandatory rules and regulations that may apply.
Full records, plans, documentation, etc. shall be maintained to support these facilities and services.
Where the Works or any part thereof is proposed to be carried out in overseas countries, the Contractor shall
assist the Employer in obtaining any visa, work and/or residence permits for the Employer's personnel
assigned to such Sites and shall obtain suitable accommodation for such personnel at the Employer's request.
2.1.11.2 Facilities and Ser vices for the Employer

Office facilities and services, of a standard as specified below, shall be provided to the Employer at the
Site(s) for up to four representatives of the Employer for the engineering and manufacturing period. The
offices shall be lockable and be located close to or within the Contractor's own offices. The following shall
be provided at each Site as applicable:
Single private offices at the Contractor's project engineering Site.
Office furniture, positioned in the above office(s) with a file/storage facility, desks, chairs, shelving, lockable
filing cabinets, lockable drawing cabinets and stick files, partitions, desk lamps, etc.
Use of a conference room for ten persons. Conference room to be furnished with chairs, table, screen and
overhead projector.
Consumables such as general office stationery, filing trays, staples, hole punch machines, rulers, pens,
erasers, copy machine paper, etc.
Use of kitchen facilities with cooker, microwave oven, kettle, refrigerator, coffee machines, cutlery and
tableware, including supply of coffee, tea and admixtures.
All cabling within the Contractor's Site(s) including the Employer's offices for access to the Contractor's IT
systems and for use of the Employer provided information systems including e-mail.
Telephone services with one extension per person. Telefax receiving and transmitting system located within
the Employer's offices and operated independently from the Contractor's similar facilities.
Services to the offices in respect of sufficient air cooling, heating, power, lighting, water, sanitation, daily
cleaning, repair, maintenance and post services.
Parking facilities for the Employer's Site team plus adequate space for visitors in close proximity to the
offices.
Use of copying machine situated close to the Employer’s offices.
Use of welfare, canteen, medical and first aid facilities for the Employer's personnel as for the Contractor's
own personnel.
2.1.12 TRANSPORT, PACKING, ETC.
2.1.12.1 Gener al
The Contractor shall be fully responsible for all aspects of transport, packing, etc.
The responsibility shall lie on the Contractor whether the dimensions of his supplied equipment and
materials in a crate or in a box will be appropriate for loading, unloading and transportation to the Site.
The Contractor must at his own expense, conduct an ocular route survey of all roads, bridges, overpasses,
etc. from the Port of Entry to the Site and examine for himself the conditions of all roads and bridges.
The Contractor shall check the capacity and availability of loading and unloading facilities, which will be
utilised in connection with his transport operation, as well as its characteristics, taking appropriate measures
to avoid damaging the same. All costs related to the reinforcement of roads, bridges and the like, if any, shall
be borne by the Contractor.
The Contractor shall co-ordinate his own transport program and shall advise the proper authorities of the
transit of the heaviest items to be transported and shall comply with the instructions given by said authorities.
All damages caused to public roads, streets or public structures shall be compensated by the Contractor at his
own expense.
2.1.12.2 Packing
Each crate, box or package must have a packing list and in addition to the usual and customary marks, the
following identifying marks:
Zimbabwe Electricity Transmission and Distribution Company
Project :
Contract No. :
Destination :
Case No. :
Gross Weight :
Net Weight :
Dimension : LxWxH
In addition, each crate, box or package shall be colour coded to aid the Employer in sorting materials for the
various supply items according to the colour codes as stated in the technical data sheets.
2.1.12.3 Tr ansport Mar king

The outside of all containers, cases, etc. shall be clearly marked with the total weight, point of maximum
weight and correct position for the attachment of lifting hooks and cables and shall bear identification marks
relating to the appropriate dispatch documents. Where appropriate, the cases or boxes shall bear special
instructions such as “top”, “handle with care”, “keep dry”, etc.
All parts of the Contracted Equipment and the Contractor's equipment shall be well-packed and protected
against loss or damage during transport by sea and over land, and while in storage. Perishable material
provided in spares and repair sets shall be provided in sealed containers with a shelf-life of at least 10 years.
All packaging shall be performed in such a way that overturning of the packages will not damage the
equipment.
Instructions for handling shall be clearly marked on all parts, packages and crates.
All parts, packages and crates shall be adequately marked in order to enable identification. Each item
contained in a package shall be clearly identified on the packaging list by its description and part number,
package date, shelf-life and assembly drawing reference, and each item shall be marked or labelled to
correspond with the packaging list.
The costs of all equipment necessary for the temporary fixing and supporting of the various parts of the Plant
and the various packages to crane hooks, rail wagons, etc., during handling, transport and storage, and the
cost of load distribution beams, etc., where they form part of the packages or crates, shall be included in the
tender price.
The Contractor shall be entirely responsible for all packing and unpacking, and any loss or damage shall be
compensated to the satisfaction of the Employer by the Contractor and, where not otherwise provided, at the
Contractor's own expense.
2.1.12.4 Pr epar ation for Shipping and Storage

The Contractor shall prepare equipment for shipment to protect it from damage during shipment and
subsequent storage not exceeding one year.
Equipment shall be completely drained of all water and thoroughly dry prior to shipment. When such
draining requires removal of plugs, drain valves, etc., the Contractor shall make sure that these parts are
reinserted or reassembled prior to shipment.
All openings and machined surfaces shall be provided with protection to prevent damage, corrosion and
entrance of foreign matter during shipment and storage.
Flanged connections shall be protected by a 12.5 mm or thicker plywood disc, or suitable alternative, bolted
to the face of the flange.
Treaded or socket weld connections shall be protected with screwed or snap-in (snap-on) type, securely held,
plastic protectors. Cast-iron plugs are not acceptable for protection unless part of the permanent assembly.
Wooden disks that cover the entire weld end area, and are secured by metal straps and fasteners shall protect
butt weld connections.
Covers, straps or fasteners shall not be welded to equipment.
Equipment shall be adequately supported for shipment. All loose parts shall be crated or boxed for shipment
and appropriately identified. If equipment is braced internally for shipment it shall be marked conspicuously,
“Remove internal braces before testing and operating”.
All large and heavy shipping units shall have suitable skids for moving. Crating shall also be adequate for
lifting with slings. If location of slings is critical, these locations shall be marked accordingly.
2.1.12.5 Shipping and Tr ansportation to Site

The Contractor shall arrange and pay for the transport of the Plant, material, etc., and his equipment to the
Site, as well as the return of his equipment from there. He shall also arrange and pay for all transport,
handling and storage of the Plant, materials and equipment within the Site. The Contractor shall be
responsible for making sure that shipping is arranged on vessels having suitable equipment for unloading of
the Plant and equipment, or that the harbour has the corresponding facilities.
2.1.12.6 Inventor y List

An inventory list approved by the Employer shall be furnished prior to the shipment of materials and
equipment, and shall consist of lists for:
o Materials
o Spare parts, tools and equipment
o Test equipment
The materials listed shall consist of an itemisation of all materials furnished at the factory site.
2.1.12.7 Stor age

The storage shall be in an environment similar to the installed location, i.e., indoor equipment shall be stored
indoors (without heating and ventilation), and outdoor equipment shall be stored outdoors. Where required to
protect against condensation and humidity, a desiccant shall be provided and its presence, with the need of
periodic removal and dry-out, shall be so marked. When electric space heaters are provided for that purpose,
these should be wired to the outside of the equipment so that energising immediately upon receipt is possible
without disassembly of crates, etc. This also requires that no combustible materials be left in the inside of the
equipment.
Items, which maybe subjected to open storage for several months on site, shall be suitably packed and
protected from the weather.
The Contractor shall provide storage and handling instructions including descriptions for periodic inspection
and/or storage maintenance to ascertain that no deterioration will occur during storage. One set of these
instructions shall be fastened securely to the outside of the shipping unit.
The Contractor shall provide at the Employer’s request, the Contractor recommended instructions for long
term storage.
When equipment is specified for export shipment, the Contractor shall include packaging adequate for export
shipment, and this packaging shall be such as to obtain approval and acceptance by transportation
companies.
All equipment shall be shipped from the factory completely assembled as far as practicable, subject to the
limitations of length, height, depth, and weight, etc. described in the Conditions of Contract or in the
Technical Data Sheets for each of the equipment under this specification.
2.1.13 EQUIPMENT DESIGNATION (EQUIPMENT MARKING) SYSTEM (EDS)
2.1.13.1 Identification System

All equipment and all component parts including cables, control wiring and terminals shall be designated
with an alphanumeric code allowing clear identification of the equipment and components during design,
installation and operation of the plant/substation. Equipment, cables, control wiring and terminals shall be
systematically marked, both on the drawings and documents and on the equipment, cables, wires and
terminals themselves.
Equipment designation codes shall be indicated on all planning documents including bills of materials, lists
of spare parts, etc. The codes will later be used for easy identification of stored equipment parts and
materials and shall be suitable for use with a computer supported registration system.
Tender drawings are in some cases already marked with designated codes; the system shall be expanded to
include detailed diagrams, cable lists, spare parts list, etc. approved by the Employer.
Wherever applicable, labels/plates bearing the EDS code shall be attached to equipment in the Contractor’s
works.
The material and fastening methods proposed for EDS labels/plates are subject to the approval of the
Employer.
2.1.13.2 Labels and Plates

A corrosion-resistant nameplate with clearly legible writing shall be permanently attached to each assembled
piece of equipment at an easily visible place. It shall provide all necessary information pertaining to the
equipment, but as a minimum, the following must be included: manufacturer’s name, type of equipment,
serial number, year of manufacture, project identification number, weight, EDS code and other relevant
information in compliance with applicable standards. Any special maintenance instructions shall also be
shown at this or other suitable location.
For other major components i.e., pumps, motors, etc., the following shall be added: Rated hp, speed, total
head, capacity, direction of rotation, and any other pertinent information.
2.1.14 CUSTOMS CLEARANCE

Reference is made to the Conditions of Contract
2.1.15 MISCELLANEOUS
2.1.15.1 Documentar y Film

The Contractor shall record and provide documentary film of the entire Works covering:
o footage on the various substations covered under this project
o site preparation and mobilisation
processing and manufacturing of materials to be used for the project

o
factory tests: type test, special test and routine test for the line components that will be
o
supplied
o All transportation and construction works including problems encountered during these
operations
o key personnel involved in the project both on the Employer’s side and the Contractor’s side
o testing of the lines
o commissioning of the lines
o etc., which the Contractor may think would be necessary for inclusion on the documentary
film.
The documentary film should last for a minimum of 20 minutes and must be on a DVD type video disk.
2.1.16 TRAINING OF THE EMPLOYER’S PERSONNEL
2.1.16.1 Gener al
If required in the technical data sheets the Contractor shall provide overseas and local training courses for the
Employer’s personnel in English.
Training shall be geared towards the technical engineers and maintenance personnel of the Employer through
the transfer of technical knowledge.
Training overseas shall include classroom instruction courses conducted on the Contractors premises during
manufacture of the equipment and hands-on training to enable the Employer's personnel to manage, install,
test, commission, maintain, operate and service the transmission lines and its associated equipment on
completion of the Works in accordance with maintenance and operating procedures established by the
Contractor. All expenses in the overseas training shall be borne by the Contractor including airfares,
accommodation, transportation and allowances.
The training overseas shall not be more than one (1) month and shall commence at the latest, two (2) months
before the date of the main shipment of the equipment to be supplied. The training shall be organised for up
to five engineers from the Employer. They should be made able to see and study the equipment to be
supplied to the Employer.
Local training shall also be conducted for up to ten (10) of the Employer’s personnel for not more than one
(1) month. The Contractor shall provide adequate training documentation and local meals to the Employer’s
personnel. The Employer shall provide training room and any available test facilities.
Candidates for training selected from among the Employer’s organization should have basic relevant
qualifications. Their experience should be of a broad and general technical nature, including general
familiarity with electronic systems and testing facilities.
2.1.16.2 Tr aining Objectives

The training courses shall be designed to:
o Enable staff to perform maintenance and take part in repair of the transmission line components and
its associated equipment by teaching principles of operation trouble-shooting methods and procedures
leading to the identification and replacement of faulty pieces of equipment, modules, units and
components, with the objective that the Employer’s personnel will become capable of carrying out
repair and maintenance without outside assistance;
o Enable staff to perform routine maintenance of the transmission line components and its associated
equipment by way of electrical and mechanical adjustments, lubrication and/or replacement of parts
subject to wear or with a limited life; and
o Provide an understanding of the software and a working knowledge of the database for additions,
modifications, and deletions and the practical use of diagnostic programs.
2.1.16.3 Cour se Content

The training course shall consist of formal courses given on the Contractor’s premises including classroom
training, instruction and explanation during shop tests and/or Factory Acceptance Tests and practical work
sessions with the Contractor’s specialists during the implementation of requirements of the Contract.
2.1.16.4 Cour se Documentation

The Contractor shall submit a daily schedule for the entire training period and a syllabus for each course with
a listing of course documentation, no later than thirty (30) days prior to the start of training.
Documentation shall be provided covering each course to a level of detail so that the text is self-explanatory
and sufficient as future reference.
Prior to the start of a course, each trainee shall receive at least one (1) set of documentation covering that
course.
The Contractor shall submit to the Employer one (1) set of course documentation per trainee no later than
fifteen (15) days prior to the start of each course.
ZETDC Standard Specifications Rev.: Draft
Transmission Lines Page 1 of 3
T-T-03 Technical Schedules - Preamble Date: Nov 2010
T-T-03 TECHNICAL SCHEDULES – PREAMBLE
CONTENTS
1. GENERAL ................................................................................................................................................................. 2
2. DEFINITIONS AND ABBREVIATIONS ................................................................................................................ 2
1. GENERAL
Tenderers/Contractors shall complete the following Technical Schedules and in addition provide the necessary technical
brochures, layouts and detail drawings.
Technical Guarantees Schedules shall contain data which shall be the basis for the contractual guarantees.
All other schedules contain preliminary data and information for better understanding of the Tender. Such data may,
subject to the approval of the Engineer, be modified during the detailed design phase. However, modifications which in the
opinion of the Engineer represent substantial changes of the intended function, quality and/or reliability of the Works will
not be approved.
In addition to the schedules, the Tenderer/Contractor shall submit with his Tender technical brochures, design calculations,
layout and preliminary arrangement drawings for the equipment and assemblies. In particular, the Tenderer/Contractor
shall include dimensioned drawings and weights for the different types of steel towers, insulator string assemblies and
those parts which influence the dimensions of the towers and Right-of-Way requirements.
2. DEFINITIONS AND ABBREVIATIONS

The following terms may be encountered in these Technical Schedules and shall be interpreted as follows:
Symbol: Shall mean:

Hz hertz
kW (MW) kilowatt (mega-)
kWh (GWh) kilowatt hours (giga-)
VA(kVA, MVA) volt-ampere (kilo-, mega-)
A (kA) ampere (kilo-)
V (kV) mean volt (kilo-)
kV/mm kilovolts per millimeter
a.c. alternating current
d.c. direct current
IN rated (nominal) current
UN rated (nominal) voltage
Ah ampere-hours
lm lumen
lm/W lumen per watt
min minute
min.(max.) minimum (maximum)
μ (prefix) micro (= 10-6)
rms root mean square
p.u. per unit
p/p peak to peak
N Newton
Nm Newton meter
2
Pa, N/m Pascal, Newton per square meter
bar bar (1 bar = 105 N/m2 = 0.1 M Pa)
Symbol: Shall mean:

kg kilogram
ton (t) metric tonne (= 1000 kg)
mWC meters water column (10.2 mWC = 1 bar)
l litre
h hour
s or sec second
l/h litres per hour
l/s (l/min) litres per second (per minute)
rpm revolutions per minute
No. number
dB decibel
T (tesla) flux density
F Farad
o
C degrees centigrade
K kelvin
t temperature, thickness, time
2
m square meter (mm2 for square millimeter, etc.)
m3 cubic meter (mm3 for cubic millimeter, etc.)
m3/s cubic meters per second
3
Nm /h Normal (atmospheric) cubic meters per hour
m meter
cm centimeter
mm millimeter
J joules or Nm
% per cent
el. elevation
degr. degrees
ppm parts per million
cst centi-stoke
m/s meter per second
T-S-03-001 GENERAL TECHNICAL REQUIREMENTS
T-S-03-001 GENERAL TECHNICAL REQUIREMENTS Rev. Draft
T-S-03-001 GENERAL TECHNICAL REQUIREMENTS

CONTENTS
3.1.1 SCOPE ............................................................................................................................................3
3.1.1.1 General .......................................................................................................................................3
3.1.1.2 Services to be provided by the Contractor .................................................................................3
3.1.1.3 Services to be provided by Employer .........................................................................................3
3.1.2 CONTRACTOR’S CAMPS AND TEMPORARY FACILITIES ..................................................3
3.1.2.1 Camps .........................................................................................................................................3
3.1.2.2 Solid Wastes ...............................................................................................................................3
3.1.2.3 Power Supply .............................................................................................................................3
3.1.2.4 Explosives ..................................................................................................................................4
3.1.3 TESTS AND INSPECTION ...........................................................................................................4
3.1.3.1 General .......................................................................................................................................4
3.1.3.2 Care of the Site ...........................................................................................................................4
3.1.3.3 Inspection on Contractor’s Premises ..........................................................................................5
3.1.3.4 Tests on Contractor’s Premises ..................................................................................................5
3.1.3.4.1 Routine Tests ......................................................................................................................5
3.1.3.4.2 Type Tests ..........................................................................................................................5
3.1.3.4.3 Factory Acceptance Tests ...................................................................................................5
3.1.3.4.4 Field Tests ..........................................................................................................................6
3.1.3.4.5 Waiver of Factory Acceptance Tests Witnessing / Inspection by Employer .....................6
3.1.4 MATERIALS .................................................................................................................................7
3.1.5 TEST OF MATERIALS .................................................................................................................7
3.1.6 WORKMANSHIP ..........................................................................................................................7
3.1.7 GUARANTEES AND PARTICULARS ........................................................................................7
3.1.8 ELECTRIC WELDING (WHEN APPLICABLE) .........................................................................8
3.1.8.1 Preparation of Base Material ......................................................................................................8
3.1.8.2 Welding Procedure .....................................................................................................................8
3.1.8.3 Qualification of Welders and Welding Operators ......................................................................8
3.1.8.4 Welded Construction and Stress Relief ......................................................................................8
3.1.8.5 Acceptance of Welded Structures ..............................................................................................8
3.1.8.6 Cleaning......................................................................................................................................8
3.1.8.7 Provisions for Erection and Installation .....................................................................................8
3.1.9 STANDARDS ................................................................................................................................8
3.1.9.1 Prescribed Standards ..................................................................................................................8
3.1.9.2 Designation of Trade Name or Catalogue Name and Number ...................................................9
3.1.10 TROPICAL SERVICEABILITY ...................................................................................................9
3.1.10.1 General ...................................................................................................................................9
3.1.11 ENVIRONMENTAL REQUIREMENTS AND OPERATING ENVIRONMENTAL
CONDITIONS ................................................................................................................................9
3.1.11.1 General ...................................................................................................................................9
3.1.11.2 Operating Environmental Conditions ...................................................................................10
3.1.12 CLEANLINESS ...........................................................................................................................10
3.1.13 CORROSION PROTECTION .....................................................................................................10
3.1.13.1 General .................................................................................................................................10
3.1.13.2 Surface Protection ................................................................................................................10
3.1.13.3 Painting.................................................................................................................................10
3.1.13.4 Galvanizing ..........................................................................................................................11
3.1.13.5 Bituminous Paint ..................................................................................................................11
3.1.14 STRUCTURAL STEEL AND CAST IRON ................................................................................11
3.1.15 COPPER, ALUMINIUM ALLOYS AND CLAD STEEL ..........................................................12
3.1.16 CEMENT ......................................................................................................................................12
3.1.17 ERECTION...................................................................................................................................12
3.1.18 DAYWORK AND MATERIAL RATES.....................................................................................12
3.1.19 INTERCHANGE ABILITY AND STANDARDIZATION OF SMALL EQUIPMENT AND

MATERIALS ...............................................................................................................................12
3.1.20 SPARE PARTS AND SPECIAL TOOLS ....................................................................................13
3.1.21 GENERAL ELECTRICAL REQUIREMENTS...........................................................................13
3.1.1 SCOPE
3.1.1.1 Gener al
This specification covers the general technical requirements applicable to tests, materials, workmanship and
standards involved in the design and manufacture of materials and equipment for overhead transmission lines
rated 88 kV and above. Supplementary requirements for the various line components are contained in the
appurtenant sections of the Specifications.
It is not the Employer's intent to specify all technical requirements nor to set forth those requirements
adequately covered by applicable codes and standards. The Contractor shall furnish high quality design
assuming that all supplied and installed equipment and materials meet the requirements of this specification
and industry standards.
The Contractor shall bear full responsibility that the designs used are in accordance with all standards and
applicable regulations and perform under the conditions and to the standards specified herein.
No deviations shall be made from this specification and standards unless waived or modified in writing by
the Employer. The Contractor shall obtain from its sub-contractor(s)/supplier(s) a statement as to compliance
with this specification without exception and/or if there are any exceptions, these shall be described in detail
and included in the Contractor’s Tender. The Contractor shall add a statement that no other exceptions are
taken to this specification.
3.1.1.2 Ser vices to be pr ovided by the Contr actor

The Contractor shall provide the services specified in the Technical Schedules.
3.1.1.3 Ser vices to be pr ovided by Employer

The Employer shall provide the services listed in the Technical Schedules.
3.1.2 CONTRACTOR’S CAMPS AND TEMPORARY FACILITIES
3.1.2.1 Camps
The Contractor shall at all times provide adequate accommodation and facilities for his workforce, in
accordance with the Environmental Protection Requirements.
The Contractor shall obtain the necessary approval from the relevant authorities in connection with the
establishing of his camps.
Unless otherwise instructed or agreed, upon completion of the Contract, the Contractor shall dismantle and
remove all structures forming part of his camp, and shall arrange for the disconnection of utilities, remove
drains and culverts, backfill trenches, fill in all latrine pits, soak ways and other sewage disposal excavations,
with the exception of items and services which are required to revert to the ownership of the Employer or
which may be transferred to other contractors, and shall restore the site, as far as practicable, to its original
condition and leave it neat, tidy and stable to the approval of the Employer.
3.1.2.2 Solid Wastes

The Contractor shall make all provisions, for collection and disposal of solid wastes from all camps and
places of working. Wastes shall be collected at least twice a week.
3.1.2.3 Power Supply

The Contractor shall arrange for the supply of electric power and lighting as required for the construction of
the Works. Any generator plant shall be adequately silenced and located so as to keep the noise level at the
nearest housing or office area below 65 dB (A). The power supply shall comply with the Zimbabwean or
other widely accepted standards.
3.1.2.4 Explosives
The Contractor shall provide suitable, safe and secure storage for explosives to be used, take all
responsibility during blasting operations, and observe all relevant laws and regulations.
3.1.3 TESTS AND INSPECTION
3.1.3.1 Gener al
The Contractor shall provide a test specification covering all tests on Contractor’s premises. Successful
completion, as deemed by the Employer, of Inspection and Tests on Contractor’s premises shall be a
prerequisite to shipment of all materials, structures, conductors and hardware. Following successful
completion of inspection and tests on his premises, the Contractor shall obtain the approval to proceed with
the delivery of the structures, materials, conductors and hardware from the Employer in accordance with the
Technical Specification of the said items.
The objective of the test specification shall be to set forth the means, manner and circumstances in which to
verify compliance with the Contract requirements including all functional and operational performance
claims for the material, components, equipment, software or system made by the Contractor and/or the
original equipment manufacturer.
The test specification shall include a program for Factory Acceptance Test (FAT) and detail the following:
a. Requirements to be tested;
b. Step-by-step method of testing;
c. Expected results of tests.
Approval of the test specification/procedure will not prejudice the Employer’s right to order additional tests,
should the Employer deem, following approval but before his acceptance of the material, equipment,
software or system(s) for shipment, that certain conditions or combination of conditions were not foreseen in
the test specification, in order to demonstrate that performance requirements of this Specification have been
met.
Tests shall only be conducted with the aid and in accordance with test specification(s) and standards clearly
identified as approved for use by the Employer, and, where applicable, employ test instruments of suitable
quality calibrated to manufacturer’s recommendations by a reputable agency within the previous six (6)
months.
The Contractor shall provide for the expenses of unrestricted return airfare, hotel accommodation including
inland transportation at the Contractor’s country of origin for the Employer’s staff on factory acceptance
tests. The trip(s) for the factory acceptance tests will be carried out by at least two (2) of the Employer’s staff
unless otherwise indicated in the Technical Schedules of the equipment for a minimum duration of ten (10)
days test period or the duration of the tests as indicated in the Schedule of Timings submitted by the
Contractor. Costs for these expenses shall be included in the price for the particular equipment to be
witnessed by the Employer or his authorized representative(s).
3.1.3.2 Car e of the Site

The Contractor shall be responsible for the operation and maintenance of all Works relating to the Contract
during the execution of the Works and for as long thereafter as he remains on the Site. The Contractor shall
be entirely responsible for providing all temporary site installations of every kind that may be required for
carrying out the Works including the facilities in respect of office, living accommodation, sanitation and
sewage disposal, fenced storage areas, lockable sheds, sheds, installation for supply of industrial water,
power and compressed air as are specified in the Conditions of Contract. The Contractor shall plan all
temporary site installations required for the Works to the approval of the Employer
All costs for the construction and/or supervision and the removal or handing over to the Employer of all
temporary site installations shall be deemed to have been included and allowed for in his prices stated in the
Schedules of Quantities.
The Contractor shall be entirely responsible for the running and maintenance throughout the period when he
is carrying out work at the site, of all installations required.
The costs for running and maintenance of the temporary site installations together with any other running
costs necessary for the satisfactory execution of the Works, shall be deemed to have been included and
allowed for in his prices in the Schedules of Quantities.
3.1.3.3 Inspection on Contr actor’s Pr emises

The Employer reserves the right to inspect all shop and assembly work associated with the Works, verify
quantities consigned to stores and inspect quality control and assurance records as well as Shop and Purchase
Order records. When scheduled, and as often as the Employer deems appropriate, progress will be monitored
with respect to Key Dates in the Contract Schedule and the sequence of events and activities on the
Contractor’s Project Progress Review.
The Contractor shall demonstrate and furnish evidence that general progress is being maintained so that no
activities are in danger of becoming the critical path and that specific progress of those activities on the
critical path meet all target dates set by the Contractor as well as Key Dates in the Contract Schedule.
The Contractor shall furnish the Employer, a list of Suppliers and the components, materials, conductors,
structures and other equipment to be furnished by them for use in the Works, in sufficient time to permit
inspection and testing of all components, materials, and the equipment. Purchase Orders shall clearly indicate
the level of inspection to which purchased items will be subject.
All shop orders or instructions to production and manufacturing departments shall quote the pertinent
requirements of the Specification and shall bear a suitable notation advising quality control inspection
requirements. A system for advising the quality control department of the same shall exist. If so requested by
the Employer, the Contractor shall furnish triplicate copies of the designated internal orders and instructions.
3.1.3.4 Tests on Contr actor ’s Pr emises

3.1.3.4.1 Routine Tests
The Contractor shall perform routine tests in accordance with requirements of the Specification and the
Contractor’s test specification approved by the Employer. The Contractor shall give the Employer access to
Works to determine or assess compliance with the provisions of this Specification or to witness the
Contractor’s routine shop tests. The Contractor shall submit results of routine tests within fifteen (15) days
after performance of the tests.
3.1.3.4.2 Type Tests
The Contractor shall carry out all type tests called for in this specification and such tests in the Standard in
accordance with the criteria and to the extent specified in the Specification and on custom manufactured
items as called for by the Employer to obtain required performance data.
Upon submission of relevant test certificates from an independent testing agency approved by the Employer,
and proof that the structures, hardware, conductors and materials to be tested are identical to that covered by
the test certificates, the Employer will waive the requirements for corresponding type tests called for in this
Specification and/or specified in the Standards.
3.1.3.4.3 Factory Acceptance Tests
Prior to shipping and final inspection, tests hereinafter referred to as Factory Acceptance Tests (FAT) shall
be conducted by the Contractor at his plant and will be witnessed by the Employer.
The Contractor shall carry out tests, as may be required by the specified Standards and the Quality Control
and Assurance Program, as well as the entire test program, approved by the Employer, prior to the witnessed
FAT, remove all faults found and correct all failures so that to the best of his knowledge, no functional or
procedural errors will occur during the witness FAT.
At the commencement of the witness FAT, all equipment shall be brought together in one place, integrated
and the configuration/setup at the factory site shall be identical to that to be installed at the site and have
reached its final form, not to be changed during the FAT and until commencement of commissioning at site.
The Contractor shall immediately advise the Employer should failures occur, take remedial action subject to
the Employer’s approval and proceed with the FAT as and when directed by the Employer. It shall be the
Employer’s prerogative to order a repeat of all such tests that he deems may have been affected by the
failure.
The Contractor shall ensure that during the test, all hard copies from output devices are retained and that no
outside parties interfere in any way with testing, equipment or test instruments, fixtures and jigs for the entire
duration of the FAT. Only the Contractor’s personnel who are needed on the testing of the structures and its
components shall be allowed in the test area. The Contractor shall appoint a chief-tester who shall be
responsible for conducting the test, ensuring at all times that the test instruments, fixtures, jigs and all other
equipment needed for testing and those of the Contractor’s personnel who in any way may contribute to the
test, including testers, specialists and maintenance personnel are available prior to the scheduled
commencement of each test or as and when instructed by the Employer.
The chief-tester shall also be responsible in ensuring that an accurate record of tests is kept and each
individual test is duly initialled and dated by the tester and marked either passed or failed with annotations of
antecedents and observations concerning the test. For each day of testing, the chief-tester shall submit to the
Employer the proposed disposition of each criterion that failed during the previous day of testing, prior to
commencement of the tests scheduled for that day. Tests witnessed by the Employer will be initialled
accordingly by him on the test record. The test record and dispositions, and any other pertinent supporting
data and documents shall form part of a test report to be submitted in accordance with the specification.
3.1.3.4.4 Field Tests
The Contractor shall perform field tests and acceptance tests on the various transmission line components in
order to determine whether the requirements of the specifications have been fulfilled. The Contractor shall
submit field tests and acceptance tests criteria to be performed to the Employer for review and approval. The
Contractor shall perform no tests unless approved and witnessed by the Employer or his authorized
representatives.
3.1.3.4.5 Waiver of Factory Acceptance Tests Witnessing / Inspection by Employer
Where Factory Acceptance Tests (FAT) to be witnessed by Employer’s representative(s) have been
required in the Technical Schedules of a particular transmission line component, the costs of witnessing
these tests shall be deemed included in the price for the transmission line component.
If however, the Employer opted not to witness the Factory Acceptance Tests, the Employer will issue a
Certificate of Waiver of Tests Witnessing/Inspection for the transmission line component and materials. In
such case, the Contractor shall proceed with the Factory Tests in accordance with the requirement of the
specification and the manufacturer’s test specification as approved by the Employer.
Issuance of the Certificate of Waiver of Tests Witnessing/Inspection for the transmission line component
required to be witnessed by Employer’s representative(s) however, shall not be construed by the Contractor
that the Employer is waiving its right for a claim on the costs of the Factory Acceptance Tests which are
supposed to be witnessed by the Employer’s representative(s). Such costs of Tests Witnessing shall be
deducted from the contract amount and shall include the following:
a. The cost of unrestricted return airfare amount (economy class) to be given by the Contractor and
approved by the Employer;
b. Daily Hotel Room/Lodging Rate in the amount of US$200.00/day per participant for a duration of ten
(10) days test period, and
c. Daily Travel Allowance of US$100.00/day per participant for a duration of ten (10) days test period.
Where Factory Tests are not required to be witnessed by the Employer’s representative(s) as indicated in
the Technical Schedules of the transmission line component, a Certificate of Waiver of Tests Witnessing/
Inspection will be issued also by the Employer. In this case, no claim whatsoever can be made by the
Employer on the Contractor as a result of waiving the Factory Acceptance Tests.
3.1.4 MATERIALS
All materials to be used under this Contract shall be new, the best of their respective kinds and free from
defects and imperfections. All materials shall comply with the latest revisions or editions of the specified
standards unless otherwise specified or permitted by the Employer. In particular, materials shall not be of a
quality inferior to the various standards specified for a particular component of the transmission line.
Materials shall conform to the most recently published standards listed in the specification for each Section
regarding the class or type of the materials. When other standards are used, the Contractor shall indicate the
equivalence between the materials used and the corresponding standard listed in the specification, and shall
obtain the approval of the Employer before starting the manufacture of the transmission line equipment and
materials.
Materials and finishes shall be suitable for the purpose intended and for the tropical conditions under which
the transmission line components are to operate.
The names of manufacturers of transmission line components contemplated for incorporation in the work
together with performance capacities and other significant information pertaining to the equipment shall be
furnished for approval. Equipment and articles installed or used without such approval shall be at the risk of
subsequent rejections.
3.1.5 TEST OF MATERIALS

Materials, parts and assemblies thereof entering into the work shall be tested, unless otherwise directed,
according to the best commercial method for a particular type and class of work. When the Contractor
desires to stock materials not manufactured specifically for the equipment furnished, satisfactory evidence
that such material conforms to the requirements herein stated should be furnished, in which case tests on
these materials may be waived. Certified mill test reports of materials will be acceptable.
Certified copies of test reports shall be furnished in triplicate as soon as possible after the tests are made and
shall be in the manufacturer’s possession prior to incorporating the material in the work. The reports shall be
in such a form as to enable determining compliance with the applicable specifications for the material in the
work. The reports shall be in such form as to enable determining compliance with applicable specifications
for the material tested. When requested, tests shall be made in the presence of a duly authorized inspector.
3.1.6 WORKMANSHIP
Workmanship shall be of first-class quality and in accordance with the best modern practice for the
manufacture of high-grade line structures, conductors and hardware, notwithstanding any omissions from
this specification and drawings.
All materials supplied under this specification shall be unused, of recent manufacture, free of defects or
irregularities and the best available considering durability, strength and intended service suitability and the
best engineering practice.
All parts shall conform to the dimensions shown on, and shall be built in accordance with approved
drawings. The surface finish of all parts and components shall be in conformity with the respective strength,
fit and service requirements.
Like parts and spare parts shall be interchangeable whenever possible.
Machining of renewable parts shall be accurate and to specified dimensions so that replacement of those
parts fabricated or made according to dimensions so indicated in the drawings could be readily installed.
3.1.7 GUARANTEES AND PARTICULARS

The Works shall comply with the technical guarantee data stated in the Technical Schedules. The
Contractor shall be responsible for any discrepancies, errors and omissions in the particulars and guarantees,
whether the Employer has approved such particulars and guarantees or not.
3.1.8 ELECTRIC WELDING (WHEN APPLICABLE)
3.1.8.1 Pr epar ation of Base Mater ial

Members to be joined by welding shall be cut accurately to size with edges sheared, flame-cut, or machined
to suit the required type of welding and to allow thorough penetration and good fusion of the weld with the
base metal. The cut surfaces shall be free of defects such as laminations, surface defects caused by shearing
or flame-cut operations, or any other injurious defects. The edges to be welded shall be free from rust, oil,
grease, and other foreign matter.
3.1.8.2 Welding Pr ocedur e

All welding shall be performed in accordance with a procedure which shall be in accordance with standards
equal to those required by the “Standard Qualification Procedure” of the American Welding Society.
3.1.8.3 Qualification of Welder s and Welding Oper ator s

All welders and welding operators assigned to the work shall have passed a performance qualification test at
least equal to that specified in the operator qualification rules of the AWS “Standard Qualification
Procedure”. Welder Certificate(s) shall be submitted for the Employer’s reference.
3.1.8.4 Welded Constr uction and Str ess Relief

All weld fabricated parts except minor parts, those where stress is not important, or those which are
specifically exempted from stress relieving, shall be designed, fabricated, and inspected in accordance with
the ASME Boiler and Pressure Vessel Code, Section VIII, Part UW, Requirements for Unfired Pressure
Vessels Fabricated by Welding, or an approved equivalent standard. All such parts shall be stress-relieved as
a unit prior to machining. Radiographic or other non-destructive weld tests will not be required except when
it is desired to make such examination as a means of judging acceptability of any weld when, in the opinion
of the Employer, doubt exists as to their quality in which case such tests shall be made at the Contractor’s
expense.
3.1.8.5 Acceptance of Welded Str uctur es

The acceptance of the welded work shall depend upon correct dimensions and alignment and absence of
distortion in the structure, upon satisfactory results from the examination and testing of the joints in
accordance with the instructions given on the drawings and the soundness of the welds and upon general
good workmanship.
3.1.8.6 Cleaning
All excess weld materials, slag, splatter and flux residues shall be removed from the steel work.
3.1.8.7 Pr ovisions for Er ection and Installation

All parts of the equipment to be assembled on site must be connected by means of screws and bolts/nuts.
Welding is not acceptable except for accessories and where expressly stated.
3.1.9 STANDARDS
3.1.9.1 Pr escr ibed Standar ds

Unless specified otherwise in the various sections of this technical specification for the transmission line
component, the design, manufacture and testing of all works under this Contract shall comply with the latest
revision or edition of an approved standard.
The latest edition of each standard shall mean the latest edition available at the date of Contract signing.
Towers/poles, conductors, hardware and materials meeting other internationally accepted standards, which
ensure an equal or higher quality than the standards mentioned, would also be accepted.
In the event of any apparent conflict among standards, codes or this specification, the Contractor shall refer
the conflict to Employer for written resolution before start of fabrication. Final decision regarding the
acceptance of proposed standards is the prerogative of the Employer.
No deviation from the accepted standards shall be made subsequent to the Contract without the written
approval of the Employer.
Standards listed in individual technical specification pertain mostly to IEC, ISO and ASTM standards as the
Employer’s references. Other internationally known standards however, shall also apply, provided such
standards are equivalent in all respect to the standard prescribed and to the specific requirements described in
the individual transmission line component specification. The Contractor shall submit copies of such
standards for the Employer’s review and approval. For any such standards, which are not written in the
English language, the Contractor shall make available copies of an English translation thereof.
The Contractor will be required to hand over to the Employer two copies of all approved Standards or an
English translation thereof.
Where the Contractor is not bound by the Contract to a particular standard or code, he shall, on request and
free of charge, furnish the Employer with two English language copies of the Standard or Code of Practice to
which he intends to supply materials or carry out work. Such copies shall be provided within 21 days of the
request being made.
Where no standards exist, as in the case of patented or special materials, all such materials and workmanship
shall be of the best quality, and full details of the material and any quality control tests to which they may be
subject shall be submitted to the Employer for approval.
The Contractor shall at all times keep copies of the specified standards and codes and all amendments thereto
available for reference and inspection at the site.
3.1.9.2 Designation of Tr ade Name or Catalogue Name and Number

For convenience in designation in the Specification, certain components of the transmission line or processes
are designated by trade name or catalogue name and number. Such designations shall be deemed to be
followed by the words “or equivalent” whether such words are shown or not, and the Contractor may offer
any material or process which shall be equal in every respect to that so indicated or specified. The burden of
proof acceptable to the Employer, as to the comparative quality and suitability of alternative shall be upon
the Contractor. If the Contractor’s request is not approved, the Contractor shall not ask or be permitted to use
the same alternative materials or equipment in modified form.
3.1.10 TROPICAL SERVICEABILITY
3.1.10.1 Gener al
In choosing materials and their finishes due regard is given to the tropical conditions under which the
transmission line components are to work. Only tropical grade materials should be used and shall be treated
and processed for delivery, storage and service under conditions of high temperature, high humidity, heavy
rainfall and mildew and fungus conducive environment.
Tropical grade materials and processes shall be in accordance with the best commercial and industrial
practices and shall be subject to the approval of Employer.
3.1.11 ENVIRONMENTAL REQUIREMENTS AND OPERATING ENVIRONMENTAL

CONDITIONS
3.1.11.1 Gener al
All materials, hardware, equipment and other transmission line components to be furnished shall be capable
of withstanding the operating environmental conditions specified.
Special measures shall be taken such as the use of chemically inert parts and proper surface preparation and
paint application (where applicable) in accordance with this specification for transmission line components
installed at Site(s) with a corrosive atmosphere, to protect exposed metal parts and other materials
susceptible to chemical reaction.
Transmission line components susceptible to deterioration from climatic conditions or subject to the
formation of fungus or any other form of parasitic life shall preferably not be used, but if used and cannot be
avoided, these must be permanently protected.
3.1.11.2 Oper ating Envir onmental Conditions

All transmission line components furnished under the scope of this specification shall meet the performance
and rating requirements of this specification and all Contractors’ guarantees shall be based on operation
within the environment specified hereunder.
3.1.12 CLEANLINESS
At time of shipment, the structures (e.g. towers, poles) and their components such as hardware, conductors,
insulators, etc., shall be thoroughly clean and ready for export shipment.
All waste such as metal chips or filings, welding stubs, dirt, rags, debris and any other foreign material shall
be removed from the interior of each component. All mill scale, rust, oil, grease, chalk, crayon or paint
marks and other deleterious materials shall be removed from all interior and exterior surfaces.
Solvent and heavy cleaning, if required, shall be performed in accordance with recognized standards.
Cleaning of stainless steel surfaces shall be performed with solvents, cloths and abrasive that does not
contain halide. Only stainless steel, clean, iron-free, hand or power tools and aluminium oxide abrasive shall
be used on stainless steel components. Materials used to clean carbon steel or cast iron shall not be used to
clean stainless steel surfaces.
3.1.13 CORROSION PROTECTION
3.1.13.1 Gener al
All parts of the work shall be protected against corrosion under service conditions. The protection shall also
prevent corrosion during transport, storage and erection.
Damage to the protection during transport, erection etc. and jointing shall be repaired to the same quality as
specified for the object.
3.1.13.2 Sur face Pr otection

All steel and iron surfaces to be painted shall be prepared by means of sand or shot blasting or other
approved method.
The surface shall be of clean metal and shall be dry and free from any foreign matter at the time of painting.
3.1.13.3 Painting
The Employer shall approve the quality and colours as well as the application of the paints. The Contractor
shall submit detailed information, samples and the manufacturer’s recommendations for the paints for
approval. The painting shall be carried out in an efficient and workmanlike manner to the satisfaction of the
Employer.
All ungalvanised external surfaces except nuts, bolts and washers which may be removed for maintenance
purposes shall be painted as follows:
1. A primary coat of rust-inhibiting paint with minimum thickness 10µm (0.07 – 0.09 kg/m²)
2. Two coats of non-glossy oil and weather resisting paint, the second of which shall be applied
on completion of work tests with thickness 30µm (0.13 – 0.16 kg/m²).
The coats of paint shall have different colours.
After equipment has been erected, the priming paint shall be cleaned and repaired where necessary and two
coats of final paint shall be applied.
3.1.13.4 Galvanizing
Except where otherwise specified all ferrous parts shall be galvanized.
Galvanizing shall be applied by the hot-dip process and shall consist of a continuous coating to minimum
thickness as follows:
Average of Any Individual
Specimens tested Specimen tested
mm (g/m2) mm (g/m2)
a) Rolled steel exposed to
the atmosphere only t<5 mm 87 ( 610) 79 ( 550)
t>5 mm 95 ( 685) 87 ( 610)
b) Rolled steel under ground surface 215 (1550) 190 (1370)
c) Cast iron and malleable iron 87 ( 610) 70 ( 500)
d) Bolts, nuts and washers 45 ( 305) 45 ( 305)
The zinc coating shall meet the requirements according to ASTM A123, A153, A239 and A385, or relevant
BS.
All steel shall be fully fabricated before galvanizing, no machine or shop works, boring, punching etc. will
be allowed after galvanizing. Minor damage to the galvanizing resulting from transportation and the like
shall be repaired at site in an approved manner, e.g. by painting with an approved zinc-rich paint, containing
at least 92 weight per cent zinc powder.
After galvanizing all members shall be dipped in a dichromate solution bath to avoid formation of white rust
during storage and transportation.
Prior to bundling of towers, after galvanizing, all members shall be completely dry.
3.1.13.5 Bituminous Paint

All underground steelwork except anchor bolts, reinforcement and other steel encased in concrete, shall be
painted with two coats of bitumen or bituminous paint of a type to the approval of the Employer. The paint
or bitumen shall be applied to 500 mm above ground on steel and to 150 mm above the upper surface of
concrete where concrete foundations are used.
3.1.14 STRUCTURAL STEEL AND CAST IRON

Structural steel shall be made by the open-hearth basic oxygen or electrical furnace process, and shall
comply in quality with the requirements for ST37-2 in DIN17100 or Grade 43 A in BS 4360. Steel of higher
tensile grade if offered, shall comply with relevant DIN or BS Standards.
Only two strength classes may be used, low tensile steel (yield point 220-250 N/mm2) and a high tensile steel
(yield point 300-350 N/mm2).
Steel shall comply with the requirements of ASTM A143 and embrittlement tests shall be made in
accordance with that specification.
If the Contractor intends to use more than one quality of steel, he will be required to take every precaution to
the satisfaction of the Employer against any possible intermixing of different qualities during transport,
storage, handling, manufacture and installation.
Cast iron shall have a tensile strength of at least 140 N/mm2. It shall be made from the best grey pig and
scrap iron and shall be close-grained, tough and uniform in character.
Malleable iron shall be of the black hearth type with a tensile strength of not less than 330 N/mm2.
3.1.15 COPPER, ALUMINIUM ALLOYS AND CLAD STEEL

Copper and aluminium-stranded conductor shall meet the requirements of IEC standards.
The specification of the proposed aluminium alloys shall be submitted for approval.
If aluminium-clad steel is to be supplied it shall be Alumoweld or equal.
If copper-clad steel is to be supplied, it shall be Copperweld or equal.
3.1.16 CEMENT
Cement for concrete shall be of ordinary Portland cement conforming to the BS standard or other equivalent
standard. Weathered or congealed cement, or cement more than six months old after production shall not be
permitted to be used unless otherwise approved by the Employer after quality test.
3.1.17 ERECTION
All erection work shall be planned and carried out in collaboration with the Employer taking into
consideration the stipulations of the relevant Safety Rules, and shall be to the approval of the Employer.
The Contractor's obligations with regards to the provision of Contractors’ equipment are set out in the
relevant Clauses of the conditions of contract. With regards to the supplies of electricity, water and
compressed air for use in the execution of the Works, reference is made to the relevant Clauses of the
conditions of contract.
The Contractor shall provide at the site during all erection work, such labour together with qualified
experienced supervision as shall be necessary for the erection work to the satisfaction of the Employer. All
the costs of the provision at the site of such labour and supervisory staff, together with all costs for the
provision of staff during loading and unloading of the Contractor's plant and equipment, shall be deemed to
have been included by the Contractor in his price stated in the schedules, and no extra payment of the above-
mentioned costs shall be required by the Contractor nor allowed by the Employer. For labourers/works
provided by the Employer, reference is made to the conditions of contract.
All plant shall be inspected during erection and shall pass such tests as are required by the Employer to prove
compliance with the requirements of the contract, notwithstanding earlier testing at the Contractor's
workshop.
3.1.18 DAYWORK AND MATERIAL RATES

If required, the contractor shall carry out additional works at the rates as specified under Daywork in the
Schedules of Quantities. Materials shall be delivered at the specified rates.
Necessary particulars to enable the Contractor to prepare drawings and schedules for such work will be
provided by the Employer.
Individual leg extensions will be paid for at the ton prices quoted in the Daywork schedules in the Schedules
of Quantities.
Work at Daywork rates shall not be carried out without the written consent of the Employer.
When this work is in progress the Contractor shall submit timesheets in duplicate to the Engineer showing
the number of men, the number of hours worked and the detailed quantities of material used for such work.
Timesheets shall be approved and certified by the Engineer at the time such work is carried out. Payments
will be made only on the basis of certified timesheets.
All applications for payment for work at Daywork rates shall be accompanied by duly signed statements
from the Engineer authorizing the carrying out of such work, and shall be submitted within three months of
the completion of the work.
3.1.19 INTERCHANGE ABILITY AND STANDARDIZATION OF SMALL EQUIPMENT AND

MATERIALS
All like parts shall be fully interchangeable with no requirement for alteration or adjustment.
The Contractor shall be responsible for the standardization of small equipment, materials and devices he
would supply. He shall arrange and perform the necessary coordination work with his manufacturers for the
purposes of such standardization.
All transmission line components or elements of mass production shall be standardized if possible. Such
components, parts and elements shall include, but shall not be limited, to the following:
o Bolts and Nuts
o Spacers
o Dampers
o Clamps (Dead End Compression Type or Bolted Type Strain Clamp)
o Cotter pins, keys
o All other hardware and materials necessary for a complete insulator string assembly
In order to achieve standardization with the transmission line components or elements to be supplied under
other contracts, the Employer reserves the right to impose upon the Contractor the type and brand of
preferred component or element.
3.1.20 SPARE PARTS AND SPECIAL TOOLS

A list of spare parts and special tools to be supplied is included in the Technical Schedules for each of the
line component and materials under this specification.
In addition to the above, the Contractor shall include with his Tender, a list of additional spare parts and tools
he considers necessary for safe and reliable operation and maintenance.
All spare parts shall be readily interchangeable with the ones, which they are to replace. They shall be of the
same material, of identical size and manufacture and shall have the same properties as the corresponding
parts of the installed equipment. Specified conditions relating to tests, treatment of surfaces and painting, etc.
of the installed equipment shall also apply to spare parts.
All spare parts shall be properly packed (and where necessary treated) in such a manner as to allow
prolonged storage at the Site, considering the ambient conditions prevailing there. In due time, the
Contractor shall inform the Employer of the eventual precautions to be taken for the proper storage of the
spare parts.
The Contractor shall provide a spare parts list containing at least the following information:
o Name and address of manufacturer and order identification number
o Item description including drawing no., material designation, units to be ordered
o List of items for which the respective spare parts can be used
o Item price.
3.1.21 GENERAL ELECTRICAL REQUIREMENTS

The supply of the transmission line equipment and hardware for high and low voltage installation shall be
complete to the extent required to put the transmission line in satisfactory operating conditions, with all the
requirements completely connected and interconnected.
The Contractor must supply all minor items (fittings, terminal connectors and other accessories, etc.) which
are necessary although not expressly described in the Technical Specifications, in order to guarantee the
trouble free operation and ease in the maintenance of the supplied transmission line equipment and its
components (or parts of transmission line system) with particular reference to the provisions to be taken in
order to avoid dangerous or wrong operations.
The transmission line components shall be designed in such a way as to bear without damage and permanent
deformation the consequences of over-voltage of internal or atmospheric origin and of the short circuit
currents within the limits stated in the Technical Specification.
All towers, steel poles and other transmission line structures shall be securely connected to the general
earthing system in compliance with accepted Standards.
T-S-04-001 DESIGN CRITERIA
T-S-04-001 GENERAL DESIGN CRITERIA Draft
T-S-04-001 GENERAL DESIGN CRITERIA
CONTENTS
4.1.1 SCOPE............................................................................................................................................2
4.1.1.1 General .......................................................................................................................................2
4.1.1.2 Services to be provided by the Contractor .................................................................................2
4.1.1.3 Services to be provided by Employer .........................................................................................2
4.1.2 CODES AND STANDARDS ........................................................................................................2
4.1.2.1 General .......................................................................................................................................2
4.1.3 Electrical Characteristics ................................................................................................................2
4.1.3.1 Conductor Clearances to Ground and/or neighbouring objects..................................................3
4.1.3.2 Phase Spacing .............................................................................................................................3
4.1.3.3 Phase to Earth Clearance ............................................................................................................4
4.1.3.4 Shield Angle of Overhead Earth Wire........................................................................................4
4.1.3.5 Current Rating and Short Circuit ................................................................................................4
4.1.3.6 Corona ........................................................................................................................................4
4.1.4 Mechanical Design .........................................................................................................................4
4.1.4.1 General .......................................................................................................................................4
4.1.4.2 Conductors and Earthwire ..........................................................................................................4
4.1.4.2.1 Wind Loads ........................................................................................................................4
4.1.4.2.2 Load Cases (LC or LE).......................................................................................................5
4.1.4.3 Steel Towers and Poles...............................................................................................................5
4.1.4.3.1 Wind Loads ........................................................................................................................5
4.1.4.3.2 Load Combinations ............................................................................................................6
4.1.4.3.3 Load Factors .......................................................................................................................6
4.1.4.4 Insulators and Fittings ................................................................................................................6
4.1.4.4.1 Wind Loads ........................................................................................................................6
4.1.4.4.2 Load Combinations ............................................................................................................6
4.1.4.4.3 Load Factors .......................................................................................................................7
4.1.4.5 Foundations ................................................................................................................................7
4.1.4.5.1 Foundation Loadings ..........................................................................................................7
4.1.4.6 Quality Assurance Requirements ...............................................................................................7
4.1.5 DATA AND DOCUMENTATION REQUIREMENTS ...............................................................7
4.1.5.1 General .......................................................................................................................................7
4.1.5.2 Data and Information to be Furnished with Tender ...................................................................7
4.1.5.3 Data and Information to be Furnished After Award of Contract ...............................................7
4.1.5.4 Data Submission Schedule .........................................................................................................8
4.1.1 SCOPE
4.1.1.1 Gener al
This specification covers the general design criteria for overhead transmission lines rated 88 kV and above.
adequately covered by applicable codes and standards. The Contractor shall furnish high quality design
assuming that all supplied and installed equipment and materials meet the requirements of this specification
and industry standards.
The Contractor shall bear full responsibility that the designs used are in accordance with all standards and
applicable regulations and perform under the condition and to the standards specified herein.


4.1.2 CODES AND STANDARDS

4.1.2.1 Gener al
The design shall be in accordance with, but not limited to, the latest issues of the following applicable
standards, including all addenda, in effect at time of purchase order unless otherwise stated in this
specification.
IEC - International Electrotechnical Commission Publications
60826 - Design Criteria of overhead transmission lines
ISO - International Standards Organization
9001 - Quality System Model for Quality Assurance in Design/ Development, Manufacture and Testing
9002 - Quality System Model for Quality Assurance in Production, Installation and Servicing
These codes and standards set forth minimum requirements which may be exceeded by the Contractor if, in
the Contractor's judgment and Employer's acceptance, superior or more economic designs or materials are
available for successful and continuous operation of the Contractor's materials as required by this
specification.
In addition to the applicable standards, the Contractor shall comply with applicable national and local laws,
codes, regulations, statutes and ordinances.
If the Contractor customarily uses standards other than mentioned, the Contractor shall describe the
equivalences and/or differences of such standards with his Tender. In any event, the Contractor shall list all
those standards he proposes to use in the supply of the specified materials and equipment.
In the event of any apparent conflict among standards or theses specifications, the Contractor shall refer the
conflict to the Employer for written resolution.
4.1.3 ELECTRICAL CHARACTERISTICS

The electrical characteristics are stated in the Technical Schedules and are selected to conform as far as
possible with the existing installations.
4.1.3.1 Conductor Clear ances to Gr ound and/or neighbour ing objects

The minimum clearance requirements from line conductors and overhead earth wires to ground or to objects
under or beside the line shall be as specified in the Technical Schedules and the table below.
Voltage level (KV) In Substations (m) Across Roads (m) Across Railways (m)
11 2,75 5,8 10,5
22 2,75 5,8 10,5
33 2,75 5,8 10,5
66 3,00 6,0 10,9
88 3,20 6,1 11,1
132 3,50 6,7 11,5
220 4,50 7,0 12,4
330 5,50 7,3 13,4
420 5,50 7,3 13,4
Description 88kV 132kV 220kV 330kV 420kV

(mm) (mm) (mm) (mm) (mm)
Crossings:
Land accessible to pedestrians only 5,000 5,000 6,000 6,100 7,000
(or buildings, poles, structures and
walls, etc., upon which a man may
stand)
Normal Ground 7,000 7,000 7,300 7,600 8,000
Road Crossing 7,600 7,600 7,900 8,250 9,000
Railway Crossing, Non-electrified 7,600 7,600 7,900 8,250 9,000
(above rail level)
Railway Crossing, Electrified (above 13,400 13,400 13,400 13,400 13,400
rail level)
In Substations 3,200 3,500 4,500 5,500 5,500
Cross with overhead lines < 1 kV 3,500 3,500 4,000 5,000 5,000
Cross with overhead lines > 1 kV 4,500 4,500 5,000 5,000 5,500
Cross with Telecommunication Lines 3,500 3,500 4,500 5,000 5,000
88kV: It is ZETDC practice that new 88kV lines shall be built for 132kV in case of future upgrading,
hence the clearances should be the same as for 132kV.
4.1.3.2 Phase Spacing

The minimum horizontal spacing between fixing points of phases on the towers shall be derived from the
following formula:
D = 0.8 √(f+1) + 0.007 U
where: D = horizontal spacing in m.
f = final conductor sag at the maximum operating conductor temperature in m
l = vertical length of insulator string in m
U = highest voltage in kV
Alternatively the conductor to earth clearances in towers will determine the phase spacing.
4.1.3.3 Phase to Ear th Clear ance

The minimum air clearance between any phase conductor or any live part and grounded part shall for the
different wind loads, causing different swing-out angles of the strings, be as specified in the Technical
Schedules and the table below.
Description 88kV 132kV 220kV 330kV 420kV
(mm) (mm) (mm) (mm) (mm)
Phase to Earth Clearance in
Towers, minimum air clearance:
Still air 1,250 1,300 2,400 2,800 3,200
Reduced wind, 20 m/s 850 1,100 2,000 2,200 2,800
Full wind 510 800 1,200 1,400 2,200
88kV: It is ZETDC practice that new 88kV lines shall be built for 132kV in case of future upgrading,
hence the clearances should be the same as for 132kV.
The specified clearance between line conductors and support steelwork shall be obtained on the assumption
that the conductor may leave the suspension clamp at any angle between 0° and 20° to the horizontal
measured from the plane of the clamp.
Under the specified wind loadings, it shall be assumed that the jumper loops will swing transversely through
an angle not greater than that stated in the Technical Schedules. To ensure this, each complete jumper may
be provided with jumper weights if necessary. Where jumper insulator sets are to be provided these may be
equipped with weights and be to the approval of the Engineer.
4.1.3.4 Shield Angle of Over head Ear th Wir e

The maximum shield angle of the overhead earth wire(s) over the outer line conductor shall from the vertical
be as stated in the Technical Schedules.
4.1.3.5 Cur r ent Rating and Short Cir cuit

Conductors, connections, joints and accessories shall be capable of carrying the specified rated currents
without exceeding the temperature rise specified in the relevant Standard or as agreed by the Engineer.
These parts shall also withstand specified short circuit currents without mechanical deformation or thermal
damage.
The rated currents applicable for the project are stated in the Technical Schedules.
4.1.3.6 Cor ona

Conductor fittings, insulator strings and accessories shall be designed so that, when installed, no visible
corona discharges appear at the specified system voltage.
4.1.4 MECHANICAL DESIGN
4.1.4.1 Gener al
For the overall design basis the IEC 60826 "Design Criteria of overhead transmission lines" for the security
class as specified in the Technical Schedules has been selected.
4.1.4.2 Conductors and Ear thwir e

4.1.4.2.1 Wind Loads
The wind load(s) acting on conductors and earth wires shall be derived from the following formula:
Qc = 0.625 (W c )2 C c Ac R c sin2φ
where: Qc = Wind load in N/m
Wc = Wind speed in m/s at height of the centroids of the span
Cc = drag factor
Ac = effective frontal area in m2/m

Rc = Span length reduction factor
φ = Angle of wind incidence to the direction of the line
The wind speeds (W c ), drag factor (C c ) and span length reduction factors (R c ) are stated in the Technical
Schedules.
4.1.4.2.2 Load Cases (LC or LE)
The following load cases and design limitations shall apply on conductors and earth wires. Applied
temperatures and percentages (%) of the utilization of the conductors and earth wires (UTS) are stated in the
Technical Schedules.
a) Phase conductors:
LC-1: Minimum temperature (T1), full wind (W1), maximum tension not to exceed P1 % of UTS
LC-2: Minimum temperature (T1), still air (W0), initial tension not to exceed P2 % of UTS.
LC-3: Everyday temperature (T2), still air (W0), final tension not to exceed P3 % of UTS.
LC-4: Final sags under maximum operating conductor temperature (T3).
b) Earth wire(s):
LE-1: Minimum temperature (T4), full wind (W1), maximum tension not to exceed P4 % of UTS
LE-2: Minimum temperature (T4), still air (W0), initial tension not to exceed P5 % of UTS.
LE-3: Everyday temperature (T5), still air (W0), final tension not to exceed P6 % of UTS.
LE-4: Everyday temperature (T5), still air (W0), final sag not to exceed P7 % of Conductor sag
LE-5: Final sags under maximum operating conductor temperature (T6).
4.1.4.3 Steel Tower s and Poles

The wind load(s) acting on steel towers and poles shall be derived from the following formula:
Qt = 0.625 (W t )2 C t A t H t
where: Qt = Wind load in N/m
Wt = Wind speed in m/s at height 10 m (meter) above ground level
Ct = drag factor
At = effective frontal area in m2/m
Ht = Height factor
φ = Angle of wind incidence to the direction of the line
C t shall be derived from the following formulas:
a) Tower body, square tower:
C tb = 4.30(1-1.16Ø)
where Ø = effective frontal area divided by the area enclosed by the boundary of the frame;
0.05 < Ø < 0.45.
b) Crossarms:
No shielding effect shall be considered, i.e. assume
C tc = 3.5 for 0.1 < Ø < 0.7.
For a square lattice tower the maximum load occurs when the wind blows on to a corner. It is assumed to be
1.2 times the load for the face-on wind.
c) Poles:
For tubular steel poles the factor C p is constant
The wind speeds (W t ), drag factors (C t ) and height factors (H t ) are stated in the Technical Schedules.
4.1.4.3.2 Load Combinations

Poles and towers are to be designed to withstand the following load combinations:
1. High wind at 90º to the line: Maximum wind speed at a conductor temperature of T1 and at an
earth wire temperature of T4, initial tension.
2. High wind at 45º to the line: Maximum wind speed at a conductor temperature of T1 and at an
earth wire temperature of T4, initial tension.
3. Exceptional conditions: Broken wire condition and longitudinal overload condition at a
conductor temperature of T2 and at an earth wire temperature of T5,
final tension in accordance with IEC 60826.
4. Construction and maintenance Loading conditions in accordance with IEC 60826.
Tower loadings should be calculated according to IEC 60826 with wind and temperature loading for:
(i) Normal transverse (conductor on whole of wind span, insulator strings on projected area and tower
steel on projected area).
(ii) Vertical loads (weight of conductors and earth wires over the weight span, weight of conductors and
earth wires over the uplift span and tower weight taken at 100%).
Special loading will apply without wind load at minimum temperatures (broken wire, either one
conductor phase or the earth wire and erection loads as per IEC).
4.1.4.3.3 Load Factors

The load factors/factors of safety (F t ) as stated in the Technical Schedules shall tentatively apply in the
pole/tower design for the applicable load combinations whereas;
F t 1: Worst normal working condition : Load combination 1 and 2
F t 2: Exceptional condition : Load combination 3
F t 3: Construction and maintenance conditions : Load combination 4
4.1.4.4 Insulators and Fittings

The wind load(s) acting on insulators and insulator strings shall be derived from the following formula:
Qi = 0.625 (W i )2 C i A i
where: Qi = Wind load in N/m
Wi = Wind speed in m/s at average attachment height of the insulators
Ci = drag factor
Ai = effective frontal area in m2/m
The wind speeds (W i ) and drag factor (C i ) are stated in the Technical Schedules.
4.1.4.4.2 Load Combinations

The insulators except suspension clamps, compression type dead end clamps or strain clamps, shall be
designed for the same load combinations as for towers
4.1.4.4.3 Load Factors

The load factors/factors of safety (F i ) as stated in the Technical Schedules shall tentatively apply in the
design of insulators and insulator strings including steel fittings incorporated in the insulator strings for the
applicable load combinations whereas for;
F i 1: Worst normal working condition : Load combination 1 and 2
F i 2: Exceptional condition : Load combination 3
F i 3: Construction and maintenance conditions : Load combination 3
(All fittings shall at least have the same ultimate strength as that of the insulators)
4.1.4.5 Foundations
4.1.4.5.1 Foundation Loadings
Foundations shall be designed for all loads transferred from poles/towers with the same load combinations as
for towers, weight of poles/towers and the relevant soil parameters and with an additional safety factor F f as
stated in the Technical Schedules.
The lattice steel towers shall have a safety factor F o against overturning / uprooting as stated in the
Calculations shall be made according to recognized methods for design of eccentric loaded foundations.
4.1.4.6 Quality Assur ance Requir ements

The Contractor shall have methods to assure that the performed design and services, including subcontracted
design and services, comply with this specification. The provisions of the Specifications and Technical
Schedules for the relevant transmission line components shall apply.
4.1.5 DATA AND DOCUMENTATION REQUIREMENTS
4.1.5.1 Gener al
The Contractor’s furnished data and information shall be the guaranteed performance data. The accuracy of
such information and its compatibility with overall performance requirements specified by the Employer are
the sole responsibility of the Contractor.
All information submitted as part of Tender Data will become part of the Contract data for the successful
Tenderer. Any deviation from such data requires the Employer's approval.
4.1.5.2 Data and Information to be Fur nished with Tender

The Contractor shall furnish the following information with his Tender:
a. Filled-in Technical Schedules;
d. A detailed overall schedule, sufficient to demonstrate the Contractor's ability to perform the
design according to the time requirements.
e. QA program and ISO 9001 Certification;
f. Reference lists;
g. Detailed list of all exceptions and/or deviations taken by the Contractor to the requirements
of this specification or, if none are taken, a statement indicating that no exceptions or
deviations are taken by the Contractor.
4.1.5.3 Data and Information to be Fur nished After Awar d of Contr act
The following shall be submitted after award of Contract:
a. Design and Quality Conformance Reports;
b. Drawings, instructions and other reference material for the specified design tasks.
f. Detailed QA Program based on ISO 9001;
g. Detailed Project Progress and Performance Review (PPR).

The Contractor shall furnish in the manner, number of copies and within the time set forth in the Contract,
design reports and drawings in accordance with the requirements of the Contract.
4.1.5.4 Data Submission Schedule
Item/ Contractor’s submittal date To be reviewed by the

Description Employer before fabri-
cation or shipment
a Technical Data requested by this
specification With Tender Yes
b Proposed schedule to meet delivery date With Tender Yes
c QA Program and ISO 9001Certification With Tender Yes
60 days after effective
d Design Report commencement date of Yes
Contract
e List of standards used With Tender Yes
T-S-05-001 CONDUCTORS SP
T-S-05-001 CONDUCTORS Draft
T-S-05-001 CONDUCTORS
CONTENTS
5.1.1 Scope ..............................................................................................................................................2
5.1.1.1 General .......................................................................................................................................2
5.1.1.2 Works to be provided by the Contractor ....................................................................................2
5.1.1.3 Works to be provided by the Employer ......................................................................................2
5.1.2.1 General .......................................................................................................................................2
5.1.3 TECHNICAL REQUIREMENTS..................................................................................................3
5.1.3.1 Design Requirements .................................................................................................................3
5.1.3.1.1 General ...............................................................................................................................3
5.1.3.2 Greases .......................................................................................................................................4
5.1.3.3 Manufacturing Requirements .....................................................................................................4
5.1.3.3.1 Stranding ............................................................................................................................4
5.1.3.3.2 Joints...................................................................................................................................4
5.1.3.3.3 Surface Condition ...............................................................................................................4
5.1.3.4 Materials and Workmanship.......................................................................................................4
5.1.3.5 Stress-Strain and Creep Data ......................................................................................................4
5.1.3.6 Compression Dead End and Splices ...........................................................................................5
5.1.3.6.1 General ...............................................................................................................................5
5.1.3.6.2 Sleeves for Conductor ........................................................................................................5
a) Mid-Span Joint Sleeves ..............................................................................................................5
b) Jumper Sleeve.............................................................................................................................5
b) Repair Sleeve ..............................................................................................................................5
5.1.3.7 Additional Requirements ............................................................................................................5
5.1.3.8 Tools ...........................................................................................................................................5
5.1.3.9 Conductor Reels .........................................................................................................................6
5.1.3.10 Preparation for Shipping and Storage.....................................................................................6
5.1.3.11 Quality Assurance Requirements ...........................................................................................7
5.1.4 INSTALLATION ...........................................................................................................................7
5.1.5 TESTS ............................................................................................................................................7
5.1.5.1 General .......................................................................................................................................7
5.1.5.2 Shop Tests ..................................................................................................................................8
5.1.5.3 Design Tests ...............................................................................................................................8
5.1.5.4 Quality Conformance Tests ........................................................................................................8
5.1.5.5 Test Reports................................................................................................................................8
5.1.6.1 General .......................................................................................................................................8
5.1.6.2 Data and Information to be Furnished with the Tender..............................................................8
5.1.1 SCOPE
5.1.1.1 Gener al
This specification covers the technical and associated requirements for AAC (All Aluminium Conductors),
AAAC (All Aluminium Alloy Conductors), ACAR (Aluminium Conductors - Alloy Reinforced), ACS
(Aluminium Clad Steel), ACSR (Aluminium Conductors Steel Reinforced), AACSR (Aluminium Alloy
Conductors Steel Reinforced, ACSR/ACS (Aluminium Conductors Aluminium Clad Steel Reinforced)
AACSR/ACS (Aluminium Alloy Conductors Aluminium Clad Steel Reinforced) Conductors and their
respective splice materials and splice installation tools, for the use in switchyards, substations and overhead
transmission lines rated 88 kV and above.
adequately covered by applicable codes and standards. The Contractor shall furnish high quality materials
meeting the requirements of this specification and applicable industry standards.
The Contractor shall bear the full responsibility that the conductors have been designed and manufactured in
accordance with all standards and applicable regulations and perform under the conditions and to the
standards specified herein.
5.1.1.2 Wor ks to be pr ovided by the Contr actor

The Contractor shall provide the equipment, accessories and services specified in the Technical Schedules.
5.1.1.3 Works to be pr ovided by the Employer

The Employer shall provide the materials and services listed in the Technical Schedules.

5.1.2.1 Gener al
The conductors furnished shall be in accordance with, but not limited to, the latest issues of the following
applicable standards, including all addenda, in effect at time of purchase order unless otherwise stated in this
specification.
60104 - Aluminium-Magnesium-Silicon Alloy Wire for Overhead Line Conductors
60888 - Zinc-Coated Steel Wires for Stranded Conductors
60889 - Hard-Drawn Aluminium Wire for Overhead Lines
61089 - Round Wire Concentric Lay Overhead electrical Stranded Conductors
61232 - Aluminium-clad steel wires for electrical purposes
61394 - Overhead lines - Characteristics of greases for aluminium, aluminium alloy and steel bare
conductors
61395 - Overhead electrical conductors - Creep test procedures for stranded conductors
62219 - Overhead electrical conductors - Formed wire, concentric lay, stranded conductors
61284 - Overhead lines - Requirements and tests for fittings
These codes and standards set forth the minimum requirements which may be exceeded by the Contractor if,
in the Contractor's judgment and Employer's acceptance, superior or more economic designs or materials are
specification.
The materials and services furnished shall comply with and not prevent the Employer's compliance with all
applicable standards of the local codes.
It is the intent of this specification to allow supply of conductors according to IEC Standards. If the
Contractor customarily produces the specified conductor(s) of national standards other than mentioned, the
Contractor shall describe the equivalences and/or differences of such standards with his Tender. For any such
standards, which are not written in the English language, the Contractor shall make available copies of an
English translation thereof. In any event, the Contractor shall list all those standards he proposes to use in the
supply of the specified conductor(s).
5.1.3 TECHNICAL REQUIREMENTS
5.1.3.1 Design Requir ements

5.1.3.1.1 General
The type(s) of conductor(s) to be furnished and its/their detailed characteristics is/are specified in the
Technical Schedules. The standard design requirements for the basic conductor types are:
a) ACSR Conductors following IEC Standards
A1/S1A ACSR conductor with outer layer(s) of hard-drawn aluminium wire type A1 per IEC
60889 and core layer(s) of regular strength, Class A zinc-coated steel wires per IEC
60888, fabricated to meet IEC 61089 requirements.
A1/S1B ACSR conductor with outer layer(s) of hard-drawn aluminium wire type A1 per IEC
60889 and core layer(s) of regular strength, class B zinc-coated steel wires per IEC
60889 and core layer(s) of high strength, class A zinc-coated steel wires per IEC 60888,
fabricated to meet IEC 61089 requirements.
60889 and core layer(s) of high strength, class B zinc-coated steel wires per IEC 60888,
fabricated to meet IEC 61089 requirements.
60889 and core layer(s) of extra high strength, class A zinc-coated steel wires per IEC
60889 and core layer(s) of extra high strength, class B zinc-coated steel wires per IEC
b) Special Conductor Types

Special conductor requirements will be indicated in the Technical Schedules. These may
include, but are not limited to the following types:
SD - Self-damping conductors, i.e., some or all aluminium layers consist of trapezoidal-

shaped wires.
HT - High temperature conductors
PC - Painted conductors, i.e., outer layer(s) consist of painted wires.
5.1.3.2 Gr eases
When so specified in the Technical Schedules, the conductor(s) shall be protected by high melting point
grease in accordance with IEC 61394. This inhibitor shall be applied as specified in the Technical
Schedules.
(1) Steel core only. The grease shall be applied to fully fill the inner and outer interstices of
the conductor steel wire core only.
(2) Full conductor. The grease shall be applied to fully fill all interstices of the complete
conductor (steel core and aluminium layer(s)).
5.1.3.3 Manufactur ing Requir ements

5.1.3.3.1 Stranding
All wires of the conductor(s) shall be concentrically stranded. The wires in each layer shall be evenly and
closely stranded around the underlying wire(s). The tension in individual wires in a layer shall be sufficient
to hold each wire firmly in place with only enough strand separation to prevent crowding or "bird caging" at
the time of stranding and during installation. All steel and aluminium wires shall lie naturally in their
position in the stranded conductor(s) and, when the core and/or the aluminium wires are cut, the wire ends
shall remain in position or be readily replaced by hand and then remain approximately in position.
5.1.3.3.2 Joints
For permissible joints during manufacture, the provisions of IEC 61089 to conductors manufactured to IEC
Standards shall apply.
5.1.3.3.3 Surface Condition
The completed conductor shall be smooth, free from nick, burrs, aluminium or steel particles, dirt and
excessive die grease. The conductor shall be absolutely free of copper dust and copper particles. If so
specified, the outer conductor surface shall receive an additional treatment to make it non-specular (non-
reflective).
5.1.3.4 Mater ials and Wor kmanship

The materials shall conform to the applicable Standards and be of recent manufacture and unused.
Workmanship shall conform to industry standards and good practices.
5.1.3.5 Str ess-Str ain and Cr eep Data

The Contractor shall supply Stress-Strain and Creep data for the specified conductor(s) in the Technical
Schedules. The data shall be in the form of coefficients and, additionally, in the form of stress-strain curves.
The Contractor's Stress-Strain and Creep data shall be obtained from stress-strain tests on the conductor(s)
produced under this contract, if so required in the Technical Schedules.
Stress-Strain and Creep tests shall be performed according to IEC 61089 and 61395 or Employer-approved
equivalent.
If no stress-strain test is required by the Employer in the Technical Schedules, the Contractor shall provide
the stress-strain data based on his own new tests, or based on previous tests on a conductor identical to the
specified or based on a conductor constituted of the same outer/core materials and number of strands as
specified, approximately the same lay (in function of conductor outer diameter) and, for other than
monometallic conductors, the same cross-sectional area ratio of outer layers to total conductor.
The required stress-strain coefficients apply to a polynomial of 4th order (which describes the applicable
initial and creep stress-strain curves) of the form
Y = A0 + A1*X + A2*X2 + A3*X3 + A4*X4,
where Y is the stress in N/mm2 times HA or HS, as applicable, and X is the percent elongation. (HA and HS
are the cross-sectional area ratios of outer layers and core layers, respectively, to the total conductor). For the
final stress-strain curve Y is a straight line in function of X and a slope of the corresponding A1.
Y = A1*X
5.1.3.6 Compr ession Dead End and Splices

5.1.3.6.1 General
If splice materials (including compression dead-ends) are specified in the Technical Schedules, the
Contractor shall supply such materials suitable for the specified conductors, and pertinent instructions.
The complete conductor splice and compression dead-end, when installed according to the Contractor's
instructions, shall have a minimum mechanical strength equal to 95% (percent) of the rated tensile strength
(RTS) of the conductor.
The electrical resistance of the installed splices and dead-ends shall be no less than that of an equal length of
bare conductor.
The filler compound shall be as per the Contractor's recommendation, except that a compound based on zinc
chromate is not acceptable.
The Contractor shall provide drawings for the splices and compression dead-ends, including the length(s)
before and after compression.
The Contractor shall provide his recommended procedures for making splices, one instruction and
procedures in each splice material box.
5.1.3.6.2 Sleeves for Conductor
All of the joint sleeves and repair sleeves shall be of compression type and suitable for the specified
conductor.
a) Mid-Span Joint Sleeves
The joint sleeve for mid-span shall consist of steel compression sleeve for the core, and aluminium
compressed sleeve for the overall conductor for ACSR and single aluminium sleeve for all aluminium
conductor. The aluminium sleeve shall be made of aluminium alloy and the steel sleeve shall be made of
carbon steel.
b) Jumper Sleeve
The jumper sleeve shall be made of aluminium alloy. The tensile strength of the finished joint must be no
more than 30% (percent) of the ultimate breaking strength of the conductor.
b) Repair Sleeve
The repair sleeve shall be made of aluminium alloy.
5.1.3.7 Additional Requir ements

The Contractor shall supply initial and final Sag -Tension Charts for the specified conductor(s) based on the
Stress-Strain and Creep test conducted under this specification. The cost of preparing the sag and tension
charts shall be included in the tender unit price for the conductor(s).
Information relative to the preparation of the charts are given in the Technical Schedules for reference.
5.1.3.8 Tools
If splicing tools are specified in the Technical Schedules, the Contractor shall supply such tools and
pertinent information.
If, in the opinion of the Contractor, the quantities of the specified tools are not adequate to make the
necessary splices or compression dead-ends in the specified conductor(s), the Contractor shall offer the
appropriate quantities of tools and provide an explanation in the Technical Schedules.
The Contractor shall provide, apart from instructions requested in paragraph 5.1.3.6, instructions for the
proper operation, maintenance and calibration of the compressor(s) and the use and storage of die(s).
If comealongs are specified in the Technical Schedules, the Contractor shall supply such tools and
pertinent information. The specified comealongs should be properly sized and must be adequate enough to
properly hold the specified conductor(s). The Contractor shall provide, apart from instructions requested in
paragraph 5.1.3.6, instructions for the proper use, maintenance and storage of the comealong(s).
5.1.3.9 Conductor Reels

The conductors shall be supplied on reels as specified in the Technical Schedules. If returnable metal reels
are specified, they will be returned to the Contractor on or before a time period elapsed as indicated in the
Technical Schedules, after the conductors are received at the contract-designated destination.
The conductors shall be packed for export and the reels shall be sturdy enough to withstand rough, but
normal and customary, handling during loading, transport, unloading, field deployment and installation. The
inside surfaces of the drum and flanges shall be smooth and without protrusions so that the conductor is not
damaged during winding and unwinding. The conductor shall be protected by plastic or other suitable
material against dust and sprays (particularly salt spray). Steel-banded lagging is required on the outside of
wooden flanges and between the flange I-beams of metal reels.
Reels shall be marked with arrows showing the direction in which the reel should be rolled and in which the
outer end of the conductor points.

a) General
The Contractor shall prepare the conductors, splicing material and special installation tools for shipment to
protect them from damage during shipment and subsequent storage not exceeding one year, unless otherwise
specified in the Technical Schedules.
The storage of the conductors will be in an environment similar to the installed location. The splicing
materials and tools shall be stored in a warehouse or similar location.
The Contractor shall provide, at the Employer's request, the Contractor's recommended instructions for long-
term storage.
b) Packing and marking of splicing materials and tools
Splicing materials and tools shall be packed in individual boxes. Individual boxes may be shipped in larger
shipping units such as containers or pallets. For shipping limitations, length, width, weight, etc., reference is
made to the Technical Schedules.
Such shipping units shall be plainly marked by stencil or with a firmly fastened metal tag with the following
information as a minimum:
a - Name of the Employer
b - Name of the Contractor
c - Name of the Project
d - Project/order number
e - Destination
f - Name of Supplier
g - Case Number
h - Shipping Unit (e.g., 1 of 3, etc.)
i - Dimensions
j - Handling instructions
k - Gross weight (kg)

l - Net weight (kg)
m - Tare weight (kg)
c) Marking of conductor reels

Individual conductor reels shall be plainly marked, on the outside of both flanges, with a firmly fastened
metal tag with the following information as a minimum:
e - Destination
g - Case Number
i - Reel No. (*)
j - Dimensions
k - Handling instructions
l - Conductor length on reel (m)
m - Gross weight (kg)
n - Net weight (kg)
o - Tare weight (kg)
(*)
Reels shall be marked consecutively from a production run to permit the Employer to
match conductors for parallel stringing of conductor bundles, as applicable.

The Contractor shall have methods to assure that items and services, including subcontracted items and
services, comply with this specification. The provisions of the Contract shall apply.
5.1.4 INSTALLATION
Installation will be by the Employer or the Contractor as specified in the Technical Schedules and
monitored by the Employer’s representative(s).
When the installation is by the Contractor such as for turnkey contracts, complete details of installation and
stringing methods, proper handling and storage, stringing methods and performance records, etc., shall be
furnished for the Employer’s review and approval.
5.1.5 TESTS
5.1.5.1 Gener al
All materials shall comply with the test criteria, and the Employer's acceptance of the conductors and
accessories shall not relieve the Contractor of his responsibility for meeting all the requirements of this
specification.
The Contractor shall carry out at his own expense all tests necessary to ensure the satisfactory design and
manufacture of conductors in accordance with IEC Standards.
Conductors shall be given the manufacturer's routine shop tests and quality conformance tests and shall be
witnessed by the Employer or his authorized representative(s) unless waived in writing. No conductors shall
be shipped until released for shipment by the Employer.
The Contractor shall make all preparations for tests and provide the test apparatus and personnel and shall
notify the Employer the date of the tests to be witnessed in accordance with the requirements of this
specification.
5.1.5.2 Shop Tests

The conductors shall be subjected to the design (or Type) tests, if specified, and quality conformance (or
Sample) tests in accordance with IEC 61089. Even though the Employer or his representative performs or
witnesses the required tests and the conductors meet the acceptance criteria, the Contractor shall not be
relieved of the responsibility of providing conductors conforming to all requirements of the specification.
5.1.5.3 Design Tests

The Contractor shall perform a stress-strain test and provide a certified test report for the specified
conductors, if so required by the Employer in the Technical Schedules.
The Contractor shall perform breaking strength tests, and provide a certified test report, for the specified
conductors, if so required by the Employer in the Technical Schedules.
If applicable to the specified conductor, the Contractor shall perform tests, or provide recent (approximately
1 year) prior test results, to demonstrate that the jointing of individual aluminium wires meets the
requirements of IEC 61089, Paragraph 5.5.5.
5.1.5.4 Quality Confor mance Tests

Quality conformance tests are required in accordance with IEC 61089 paragraph 6.2.2 'Sample Tests' and
paragraph 6.3 'Sample Size'. Test reports are required.
5.1.5.5 Test Repor ts

Six (6) copies of test reports of all standard tests performed subsequent to the date of award and all routine
tests witnessed by the Employer’s representative shall be certified by the inspector and submitted to the
Employer.
The Contractor shall bear the cost of furnishing these records and reports.
5.1.6.1 Gener al
The Contractor’s furnished data and information shall be the guaranteed performance data, predicted
performance interface requirements and installation/stringing features of all Contractors' furnished materials.
The accuracy of such information and its compatibility with overall performance requirements specified by
the Employer are the sole responsibility of the Contractor.
All information submitted as part of the Tender data will become part of the Contract data for the successful
Contractor. Any deviation from such data will require the approval of the Employer.
5.1.6.2 Data and Information to be Fur nished with the Tender

b. Brochures and catalogues to support the filled-in Technical Schedules and to allow the
Employer to evaluate the conductors being offered;
c. Descriptive material brochures, drawings, instructions and other reference material for the
specified splicing materials and installation tools and materials;
d. A detailed overall schedule, sufficient to demonstrate the Contractor's ability to perform the
work to meet the delivery, installation and stringing dates for the conductors;
f. Reference lists;
g. Detailed list of all exceptions and/or deviations taken by the Contractor to the requirements
of this specification or, if none are taken, a statement indicating that no exceptions or
deviations are taken by the Contractor.
a. Design Test and Quality Conformance Test reports;
b. Drawings, instructions and other reference material for the specified splicing materials and
installation tools and materials;
c. Drawings, instructions and other reference material for the stringing/installation methods of
conductors;
d. Sag tension charts and templates for the conductor specified;
e. Details of Conductor reels;
g. Detailed Project Progress and Performance Review (PPR) for the conductor;
h. As-built drawings as finally approved.
instruction manuals in accordance with the requirements of the Contract. The Contractor shall furnish
information indicating recommended maintenance practice, approximate time required for routine
maintenance, and tools required for maintenance.
The Contractor shall provide the required installation instructions and technical data for proper installation.

cation or shipment
With Tender (if no test is
d Stress-strain and Creep Data Yes
specified)
15 days after test (if test is
e Stress and Creep Data Yes
specified)
f List of standards used With Tender Yes
g Fabrication Sequence 45 days before fabrication No
h Notification of Factory Test 30 days before test No
i Packing and Storage 30 days before fabrication No
j Installation Instruction 30 days before shipment No
k Documents for Records With shipment No
l Tests Reports 15 days after test Yes
T-S-05-002 EARTHWIRE SP
T-S-05-002 OVERHEAD EARTH WIRES Draft
T-S-05-002 OVERHEAD EARTH WIRES
CONTENTS
5.2.1 SCOPE............................................................................................................................................2
5.2.1.1 General .......................................................................................................................................2
5.2.1.3 Works to be provided by Employer............................................................................................2
5.2.2 CODES. AND STANDARDS .......................................................................................................2
5.2.2.1 General .......................................................................................................................................2
5.2.3.1.1 General ...............................................................................................................................3
5.2.3.2 Greases .......................................................................................................................................3
5.2.3.3 Manufacturing Requirements .....................................................................................................3
5.2.3.3.1 Stranding ............................................................................................................................3
5.2.3.3.2 Joints...................................................................................................................................3
5.2.3.3.3 Surface Condition ...............................................................................................................3
5.2.3.6 Compression Dead End and Splices ...........................................................................................4
5.2.3.6.1 General ...............................................................................................................................4
5.2.3.6.2 Sleeves for Earth wire ........................................................................................................4
a) Mid-Span Joint Sleeves ..............................................................................................................4
b) Jumper Sleeve.............................................................................................................................5
b) Repair Sleeve ..............................................................................................................................5
5.2.3.7 Additional Requirements ............................................................................................................5
5.2.3.8 Tools ...........................................................................................................................................5
5.2.3.9 Earth wire Reels .........................................................................................................................5
5.2.3.10 Preparation for Shipping and Storage.....................................................................................5
5.2.3.11 Quality Assurance Requirements ...........................................................................................6
5.2.4 INSTALLATION ...........................................................................................................................7
5.2.5 TESTS ............................................................................................................................................7
5.2.5.1 General .......................................................................................................................................7
5.2.5.2 Shop Tests ..................................................................................................................................7
5.2.5.3 Design Tests ...............................................................................................................................7
5.2.5.4 Quality Conformance Tests ........................................................................................................7
5.2.5.5 Tests Reports ..............................................................................................................................7
5.2.6.1 General .......................................................................................................................................8
5.2.6.2 Data and Information to be Furnished With Proposal ................................................................8
5.2.1 SCOPE
5.2.1.1 Gener al
This specification covers the technical and associated requirements for galvanized steel wires (GSW) and
aluminium-clad steel (ACS) wires and their respective splice materials and splice installation tools, for use
as Overhead Earth Wires in switchyards, substations and overhead transmission lines rated 88 kV and above.
Where the earth wires include all aluminium or aluminium alloy wires the Conductor Specification T-S-05-
001 shall apply.
For earth wires with optical fibres embedded the Optical Earth Wire Specification T-S-05-003 shall apply.
The Contractor shall bear full responsibility that the earth wires have been designed and manufactured in
the Employer. The Contractor shall obtain from its sub-contractor(s)/suppliers a statement as to compliance
5.2.1.2 Works to be pr ovided by the Contr actor

5.2.1.3 Works to be pr ovided by Employer

5.2.2 CODES. AND STANDARDS

5.2.2.1 Gener al
The earth wires furnished shall be in accordance with, but not limited to, the latest issues of the following
applicable standards, including all addenda, in effect at the time of the purchase order unless otherwise stated
in this specification.
60888 - Zinc-Coated Steel Wires for Stranded Earth wires
61089 - Round Wire Concentric Lay Overhead Electrical Stranded Earth wires
61394 - Overhead lines - Characteristics of greases for aluminium, aluminium alloy and steel bare
conductors
ASTM - American Society for Testing Materials

A363 - Zinc-Coated (galvanized) Steel Overhead Ground Wire Strand
A474 - Aluminum-coated Steel Wire Strand
B341 - Aluminum-Coated (Aluminized) Steel Core Wire for Aluminum Earth wires, Steel Reinforced
B415 - Hard-Drawn Aluminum-clad Steel Wire
B416 - Concentric-Lay-Stranded Aluminum-Clad Steel Earth wires
E-139 - Conducting Creep, Creep-Rupture, and Stress-Rupture Tests of Metallic Materials
B500 - Zinc-coated (Galvanized) and Aluminum-Coated (Aluminized) Stranded Steel Core Wire for
Aluminum Earth wires, Steel Reinforced (ACSR/AW)

specification.
It is the intent of this specification to allow supply of earth wires according to (IEC or ASTM, etc.)
Standards. If the Contractor customarily produces the specified earth wire of national standards other than
mentioned, the Contractor shall describe the equivalences and/or differences of such standards with his
Tender. For any such standards, which are not written in the English language, the Contractor shall make
available copies of an English translation thereof. In any event, the Contractor shall list all those standards he
proposes to use in the supply of the specified earth wire.

5.2.3.1.1 General
The type(s) of earth wire(s) to be furnished and its/their detailed characteristics is/are specified in the
5.2.3.2 Gr eases
When so specified in the Technical Schedules, the earth wires shall be protected by high melting point
grease in accordance with IEC 61394. This inhibitor shall be applied as specified in the Technical
Schedules.
5.2.3.3 Manufactur ing Requir ements

5.2.3.3.1 Stranding
All wires of the earth wire shall be concentrically stranded. The wires in each layer shall be evenly and
closely stranded around the underlying wire(s). The tension in individual wires in a layer shall be sufficient
to hold each wire firmly in place with only enough strand separation to prevent crowding or "bird caging" at
the time of stranding and during installation.
5.2.3.3.2 Joints
For permissible joints during manufacture, the provision of ASTM B341, B416 and B498 apply.
5.2.3.3.3 Surface Condition
The completed earth wire(s) shall be smooth, free from nick, burrs, aluminium or steel particles, dirt and
excessive die grease. The earth wire(s) shall be absolutely free of copper dust and copper particles.

The materials shall conform to the applicable Standards and be of recent manufacture and unused.
Workmanship shall conform to industry standards and good practices.

The Contractor shall supply Stress-Strain and Creep data for the specified earth wire(s) in the Technical
Schedules. The data shall be in the form of coefficients and, additionally, in the form of stress-strain curves.
The Contractor's Stress-Strain and Creep data shall be obtained from stress-strain tests on the earth wire(s)
Stress-Strain and Creep tests shall be performed according to IEC 61089 or Employer-approved equivalent.
the stress-strain data based on his own new tests, or based on previous tests on a earth wire identical to the
specified or based on a earth wire constituted of the same outer/core materials and number of strands as
specified, approximately the same lay (in function of earth wire outer diameter) and, for other than
monometallic earth wires, the same cross-sectional area ratio of outer layers to total earth wire.
The required stress-strain coefficients apply to a polynomial of 4th order (which describes the applicable
initial and creep stress-strain curves) of the form
Y = A0 + A1*X + A2*X2 + A3*X3 + A4*X4,
where Y is the stress in N/mm2 times HA or HS, as applicable, and X is the percent elongation. (HA and HS
are the cross-sectional area ratios of outer layers and core layers, respectively, to the total earth wire). For the
final stress-strain curve Y is a straight line in function of X and a slope of the corresponding A1.
Y = A1*X
5.2.3.6 Compr ession Dead End and Splices

5.2.3.6.1 General
If splice materials (including compression dead-ends) are specified in the Technical Schedules, the
Contractor shall supply such materials suitable for the specified earth wires, and pertinent instructions.
The complete earth wire splice and compression dead-end, when installed according to the Contractor's
instructions, shall have a minimum mechanical strength equal to 95 percent of the rated tensile strength
(RTS) of the earth wire.
The electrical resistance of the installed splices and dead-ends shall be no less than that of an equal length of
bare earth wire.
The filler compound shall be as per the Contractor's recommendation, except that a compound based on zinc
chromate is not acceptable.
The Contractor shall provide drawings for the splices and compression dead-ends, including the length(s)
before and after compression.
The Contractor shall provide his recommended procedures for making splices, one instruction and
procedures in each splice material box.
5.2.3.6.2 Sleeves for Earth wire

All of the joint sleeves and repair sleeves shall be of the compression type and suitable for the specified earth
wire(s).
a) Mid-Span Joint Sleeves
For zinc coated (galvanized) overhead ground wire, the joint sleeve for mid-span joints shall consist of a
galvanized steel compression sleeve, while for aluminized and aluminium clad overhead ground wire the
joint sleeve shall be made of aluminium compression sleeve. The aluminium sleeve shall be made of
aluminium alloy and the steel sleeve shall be made of carbon steel.
b) Jumper Sleeve
The jumper sleeve shall be made of aluminum alloy. The tensile strength of the finished joint must be no
more than 30 percent of the ultimate breaking strength of the earth wire.
b) Repair Sleeve
The repair sleeve shall be made of aluminum alloy.
5.2.3.7 Additional Requir ements

The Contractor shall supply initial and final Sag-Tension Charts for the specified earth wire based on the
Stress-Strain and Creep test conducted under this specification. The cost of preparing the sag and tension
charts shall be included in the tender unit price for the earth wire.
Information relative to the preparation of the charts are given in the Technical Schedules for reference.
5.2.3.8 Tools
If splicing tools are specified in the Technical Schedules, the Contractor shall supply such tools and
pertinent information.
If, in the opinion of the Contractor, the quantities of the specified tools are not adequate to make the
necessary splices or compression dead-ends in the specified earth wire(s), the Contractor shall offer the
appropriate quantities of tools and provide an explanation in the Technical Schedules.
The Contractor shall provide, apart from instructions requested in paragraph 5.1.3.6, instructions for the
proper operation, maintenance and calibration of the compressor(s) and the use and storage of die(s).
If comealongs are specified in the Technical Schedules, the Contractor shall supply such tools and pertinent
information. The specified comealongs should be properly sized and must be adequate enough to properly
hold the specified earth wire(s). The Contractor shall provide, apart from instructions requested in paragraph
5.1.3.6, instructions for the proper use, maintenance and storage of the comealong(s).
5.2.3.9 Ear th wir e Reels

The earth wires shall be supplied on reels as specified in the Technical Schedules. If returnable metal reels
are specified, they will be returned to the Contractor on or before a time period elapsed as indicated in the
Technical Schedules, after the earth wires are received at the contract-designated destination.
The earth wires shall be packed for export and the reels shall be sturdy enough to withstand rough, but
normal and customary, handling during loading, transport, unloading, field deployment and installation. The
inside surfaces of the drum and flanges shall be smooth and without protrusions so that the earth wire is not
damaged during winding and unwinding. The earth wire shall be protected by plastic or other suitable
material against dust and sprays (particularly salt spray). Steel-banded lagging is required on the outside of
wooden flanges and between the flange I-beams of metal reels.
outer end of the earth wire points.

a) General
The Contractor shall prepare the earth wires, splicing material and special installation tools for shipment to
protect them from damage during shipment and subsequent storage not exceeding one year, unless otherwise
The storage of the earth wires will be in an environment similar to the installed location. The splicing
materials and tools shall be stored in a warehouse or similar location.
term storage.

shipping units such as containers or pallets. For shipping limitations, length, width, weight, etc. reference is
e - Destination
g - Case Number
i - Dimensions
l - Net weight (kg)
c) Marking of earth wire reels

Individual earth wire reels shall be plainly marked, on the outside of both flanges, with a firmly fastened
metal tag with the following information as a minimum:
e - Destination
g - Case Number
i - Reel No. (*)
j - Dimensions
l - Earth wire length on reel (m)
n - Net weight (kg)
(*)
Reels shall be marked consecutively from a production run to permit the Employer to
match earth wires for parallel stringing of earth wire bundles, as applicable.

5.2.4 INSTALLATION
Installation will be by the Contractor as specified in the Technical Schedules and monitored by the
Employer’s representative(s).
When the installation is by the Contractor such as for turn-key contracts, complete details of installation and
stringing methods, proper handling and storage, stringing methods and performance records, etc. shall be
5.2.5 TESTS
5.2.5.1 Gener al
All materials shall comply with test criteria, and Employer acceptance of the earth wires and accessories
shall not relieve the Contractor of his responsibility for meeting all the requirements of this specification.
manufacture of earth wires in accordance with ASTM or equivalent IEC Standards.
Earth wires shall be given the manufacturer's routine shop tests and quality conformance tests and shall be
witnessed by the Employer or his authorized representative unless waived in writing. No earth wires shall be
shipped until released for shipment by the Employer.
notify the Employer the date of the tests to be witnessed forty five (45) days in advance.
5.2.5.2 Shop Tests

The earth wires shall be subjected to the design (or Type) tests, if specified, and quality conformance (or
Sample) tests in accordance with IEC 61089 or equivalent ASTM Standards. Even though the Employer or
his representative performs or witnesses the required tests and the earth wires meet the acceptance criteria,
the Contractor shall not be relieved of the responsibility of providing earth wires conforming to all
requirements of the specification.

The Contractor shall perform a stress-strain test and provide a certified test report for the specified earth
wires, if so required by the Employer in the Technical Schedules.
The Contractor shall perform breaking strength tests, and provide a certified test report, for the specified
earth wires, if so required by the Employer in the Technical Schedules.
If applicable to the specified earth wire, the Contractor shall perform tests, or provide recent (approximately
1 year) prior test results, to demonstrate that the jointing of individual aluminium wires meets the
requirements of IEC 61089, Paragraph 5.5.5.
5.2.5.4 Quality Confor mance Tests

Quality conformance tests are required in accordance with IEC 61089 paragraph 6.2.2 'Sample Tests' and
paragraph 6.3 'Sample Size'. Test reports are required.
5.2.5.5 Tests Repor ts

tests witnessed by the Employer’s representative shall be certified by the inspector and submitted to the
Employer within fifteen (15) days after test.
5.2.6.1 Gener al
All information submitted as part of Proposal Data will become part of contract data for the successful
Contractor. Any deviation from such data requires the Employer's approval.
5.2.6.2 Data and Information to be Fur nished With Pr oposal

a. Filled-in Schedules of Section E.2.5 of the Technical Schedules;
b. Brochures and catalogues to support the filled-in Technical Schedules and to allow
the Employer to evaluate the earth wires being offered;
c. Descriptive material brochures, drawings, instructions and other reference material
for the specified splicing materials and installation tools and materials;
d. A detailed overall schedule, sufficient to demonstrate the Contractor's ability to
perform the work to meet the delivery, installation and stringing dates for the earth
wires;
f. Reference lists;
g. Detailed list of all exceptions and/or deviations taken by the Contractor to the
requirements of this specification or, if none are taken, a statement indicating that no
exceptions or deviations are taken by the Contractor.
a. Design Test and Quality Conformance Test reports;
b. Drawings, instructions and other reference material for the specified splicing
materials and installation tools and materials;
c. Drawings, instructions and other reference material for the stringing/installation
methods of earth wires;
d. Sag-tension charts and templates for the earth wire specified;
e. Details of Earth wire reels;
g. Detailed Project Progress and Performance Review (PPR) for the earth wire;
instruction manuals in accordance with the requirements of the Contract.
The Contractor shall furnish information indicating recommended maintenance practice, approximate time
required for routine maintenance, and tools required for maintenance.

Description Employer before
fabrication or shipment
Technical Data requested by this
a
specified)
specified)
f Fabrication Sequence 45 days before fabrication No
g Notification of Factory Test 30 days before test No
h Packing and Storage 30 days before fabrication No
i Installation Instruction 30 days before shipment No
j Documents for Records With shipment No
k Tests Reports 15 days after test Yes
T-S-05-003 OPTICAL EARTHWIRE SP
T-S-05-003 OPTICAL EARTH WIRE Rev. Draft
T-S-05-003 OPTICAL EARTH (GROUND) WIRE (OPGW)
CONTENTS
5.3.1 SCOPE............................................................................................................................................2
5.3.1.1 General .......................................................................................................................................2
5.3.2.1 General .......................................................................................................................................2
5.3.3.1 Description of Services...............................................................................................................3
5.3.3.5 Sag/Tension Data .......................................................................................................................8
5.3.3.6 Tools ...........................................................................................................................................8
5.3.3.7 OPGW Reels ..............................................................................................................................8
5.3.3.8 Preparation for Shipping and Storage.........................................................................................8
5.3.3.9 Quality Assurance Requirements .............................................................................................10
5.3.3.10 Other Technical Requirements for OPGW...........................................................................10
5.3.4 INSTALLATION .........................................................................................................................10
5.3.5 TESTS ..........................................................................................................................................10
5.3.5.1 General .....................................................................................................................................10
5.3.5.2 Cable Tests ...............................................................................................................................10
5.3.5.3 Fibre Tests ................................................................................................................................12
5.3.5.4 Field Tests ................................................................................................................................15
5.3.5.5 Test Reports..............................................................................................................................15
5.3.6 DATA AND DOCUMENTATION REQUIREMENTS .............................................................15
5.3.6.1 General .....................................................................................................................................15
5.3.6.2 Data and Information to be Submitted with the Tender ...........................................................15
5.3.6.3 Data and Information to be Submitted After Award of Contract .............................................15
5.3.6.4 Data Submission Schedule .......................................................................................................16
5.3.1 SCOPE
5.3.1.1 Gener al
This specification covers the technical and associated requirements for Composite Overhead Earth (Ground)
Wires with Optical Fibres (OPGW) and their accessories, attachments, splice materials and splice installation
tools, for use on overhead transmission lines rated 88 kV and above.
The Contractor shall bear the full responsibility that the OPGW have been designed and manufactured in



5.3.2.1 Gener al
The OPGW furnished shall be in accordance with, but not limited to, the latest issues of the following
applicable standards and recommendations, including all addenda, in effect at the time of the purchase order
unless otherwise stated in this specification.
60104 - Aluminium-Magnesium-Silicon Alloy Wire for Overhead Line Conductors
60888 - Zinc-Coated Steel Wires for Stranded Conductors
60889 - Hard-Drawn Aluminium Wire for Overhead Lines
61089 - Round Wire Concentric Laid Overhead Electrical Stranded Conductors
61395 - Overhead electrical conductors - Creep test procedures for stranded conductors
62219 - Overhead electrical conductors - Formed wire, concentric lay, stranded conductors
60304 - Standard Colours for Identification and Coding
60793 - Optical Fibres. Measurement methods and test procedures
60794 - Optical Fibre Cables. Specifications
ITU - International Telecommunication Union

G.650 - Definitions and test methods
G.652 - Characteristics of single-mode optical fibre and cable
the Contractor's judgment and the Employer's acceptance, superior or more economic designs or materials
are available for successful and continuous operation of the Contractor's materials as required by this
specification.
It is the intent of this specification to allow supply of optical earth wires according to International Standards
(IEC, ISO, etc.). If the Contractor customarily produces the specified optical earth wires of national
standards other than mentioned, the Contractor shall describe the equivalences and/or differences of such
standards with his Tender. For any such standards, which are not written in the English language, the
Contractor shall make available copies of an English translation thereof. In any event, the Contractor shall list
all those standards he proposes to use in the supply of the specified optical earth wire.
5.3.3.1 Description of Services

The composite fibre optic overhead ground wire covered by this specification shall be made up of buffered
flexible glass optical telecommunications fibres contained in a protective central fibre optic unit surrounded
by concentric-lay stranded metallic wires either in single or multiple layers as required in the Technical
Schedules. It has a dual purpose of providing the electrical and physical characteristics of conventional
overhead ground wire and the optical transmission properties of optical fibre. The supply of OPGW shall
include all the required cable accessories, hardware and components necessary for proper installation and
operation of the OPGW.

5.3.3.2.1 General
The OPGW cable construction shall comply with the requirements set forth in the relevant IEC publications.
The OPGW shall meet both the construction and performance requirements such that the ground wire
function, the optical fibre integrity and optical transmissions characteristics are suitable for the intended
purpose.
The cable shall consist of multiple optical fibre units as stated in the Technical Schedules. There shall be
no factory splices within the cable structure of a continuous cable length.
The OPGW shall withstand lightning, short circuit currents, induced currents and voltages from the power
conductors, and expected abnormal external conditions, as well as normal service conditions, without
impairment to the optical signal transmission or degradation of the optical fibre specification for the lifetime
of the project.
The complete OPGW shall have a design lifetime of at least 40 years of service.
The OPGW shall be grounded at each tower through jumper assemblies and approved clamps to be used for
connections.
The Contractor shall provide a written guarantee that the proposed OPGW to be supplied shall be able to
carry the specified fault current and its specified duration without causing annealing, deformation
degradation or damage to the stress carrying steel strands, the aluminium protective coating, the aluminium-
alloy wires if any, the central fibre optic unit encasing the optical fibre and the supporting and guiding
assembly (and any inserts and filling compounds used) and the optical fibres.
The number, diameter and cross-sectional areas of the aluminium-clad steel wires and the number of optical
fibres shall comply with the requirements listed in the Technical Schedules.
5.3.3.2.2 Basic Construction
General
The cable construction shall conform to the applicable requirements of this specification as well as
applicable clauses of IEC 1089 related to stranded conductors.
The basic construction shall have bare concentric-lay stranded metallic wires with the outer layer having left-
hand lay unless otherwise specified in the Technical Schedules. The stranded wires may be of multiple
layers with a combination of various metallic wires within each layer. The direction of lay shall be reversed
in successive layers with the direction of the external layer being left hand. The type of metallic wire that
will be used shall be as stated in the Technical Schedules.
The overhead ground wire shall be so stranded that when the complete OPGW is cut, the individual wires
can be readily regrouped and then held in place by one hand. For multilayer wires, the wires in each layer
shall be evenly and closely stranded around the underlying wire(s). The tension in individual wires in a layer
shall be sufficient to hold each wire firmly in place with only enough strand separation to prevent crowding
at the time of stranding and during installation.
The completed cable shall be uniformly cylindrical and shall withstand all handling during manufacture,
shipping and installation without being deformed from its cylindrical form in such a way as to cause
detrimental forces and stresses and/or damage to the encased optical fibres.
The make-up and lay of wires shall be such as to produce a cable essentially free from a tendency to untwist
or spring apart when cut.
The completed composite overhead ground wires with optical fibre (OPGW) shall be smooth, free from nick,
burrs, aluminium, zinc or steel particles, dirt and excessive die grease. The wire shall be absolutely free of
copper dust and copper particles.
The finished wires shall contain no joints or splices unless otherwise approved by the Employer.
Breaking Strength
The rated breaking strength of the completed OPGW shall be taken as no more than 90% of the sum of the
rated breaking strengths of the individual wires, calculated from their nominal diameter and the specified
minimum tensile strength.
The rated breaking strength shall not include the strength of the optical unit. The fibre optic unit shall not be
considered a load bearing tension member when determining the total rated breaking strength of the OPGW.
5.3.3.2.3 Central Fibre Optic Unit
General
The central fibre optic unit shall be designed to house and protect multiple buffered optical fibre units from
damage due to forces such as crushing, bending, twisting, tensile stress, moisture and water/moisture ingress.
The central fibre optic unit and the outer stranded metallic conductors shall serve together as an integral unit
to protect the optical fibres from degradation due to vibration and galloping, wind loading, wide temperature
variations, lightning and fault current, as well as environmental effects, which may produce hydrogen.
Depending on the requirements stated in the Technical Schedules, the central fibre optic unit encasing the
optical fibres should be an aluminium tube, channelled aluminium rod or a stainless steel tube.
For an aluminium and/or stainless steel tube, it may be fabricated as a seamless extruded tube, seam welded
or a tube without a welded seam.
For an aluminium rod, it may be fabricated with one or more channels or grooves and formed into a helix to
house the optical fibres. An outer protective shield may be applied around the rod such as an aluminium tube
or a helically applied overlapping aluminium tape to provide an additional mechanical and environmental
barrier.
Filling Compound
The interstices of the fibre optic unit and cable shall be filled with a suitable compound to prohibit any
moisture ingress from outside or any water longitudinal migration along the fibre optic unit or along the fibre
optic cable. The water tightness of the cable shall meet or exceed the test performance criteria as per IEC
60794. The filling compound to be used shall be compatible with all the components it may come in contact
with and shall absorb and/or inhibit generation of hydrogen within the cable.
The filling compound shall not affect the colour of the primary or secondary coating, or encapsulates
commonly used in splice enclosures, shall be easily removed from the secondary coating with a non-toxic
cleaning solvent. The filling compound used shall be a non-toxic homogenous waterproofing gel that is free
of dirt and foreign matter, non-hygroscopic, electrically non-conductive, non-nutritive to fungus, free from
all smell and shall not affect human skin.
The filling compound shall remain stable for ambient temperatures between –20oC and +80oC and shall not
drip, flow or leak with age or at high temperature during short duration lightning strikes and short circuit
currents.
Central Structural Member(s)
Structural member(s), if necessary may be used to limit the stress on the fibres inside the central fibre optical
unit.
5.3.3.2.4 Optical Fibre
Fibre Core and Cladding
The fibres shall comply with the geometrical data given in the Technical Schedules. Generally, single-
mode fibres, dispersion-unshifted and multi-mode fibres with 50/125 μm and 62.5/125 μm core/clad
diameters are considered in this specification.
The core and the cladding shall consist of all glass, which is predominantly silica (SiO 2 ). Factory splicing of
fibre is not allowed.
The Contractor shall present a graph showing the typical reflective index profile of the fibre. The Contractor
shall also present a tension test and give the stress corrosion factor value and typical plot of variables over
tension and probability for break.
Primary Coating
The bare fibre shall be primarily coated with UV-cured acrylic material for protection from abrasion during
subsequent handling or manufacturing.
The primary coated fibres shall be proof tested for a time longer than 1.0 s with a strain of minimum 1.0 %.
The Contractor shall state the applied strain force.
5.3.3.2.5 Buffer Construction

A buffer for protection from physical damage shall surround the individually coated fibres during
fabrication, installation and performance of the OPGW. Depending on the requirements specified in the
Technical Schedules, the buffer construction that may be used to isolate the fibres, can either be a loose
buffer or a tight buffer construction.
For a loose buffer construction, it shall consist of a tube that surrounds each fibre or fibre group, such that
the inner diameter of the tube is greater than the outside diameter of the fibre or fibre group. The interstices
inside and outside the tube may be filled with a filling compound.
The tight buffer construction shall consist of suitable materials that come in contact with the coated fibre.
5.3.3.2.6 Marking of Fibres
The Contractor shall give information about:
- Number of tubes
- Number of fibres in each tube
- Colour codes
The colour shall have good-fast property and shall comply with the colours specified in IEC 60304. The
colour coding method shall be submitted to the Employer for approval.
The original colour coding system shall be visible or discernible throughout the design life of the OPGW.
Colouring utilized for colour coding optical fibres shall be integrated into the fibre coating and shall be
homogenous. The colour shall not bleed from one fibre to another and shall not fade during fibre preparation
for termination or splicing. The optical fibre colour code to be used shall be as stated in the Technical
Schedules.
5.3.3.2.7 Maximum Working Tension and Ultimate Tensile Strength
Maximum working tension (MWT) shall be calculated for maximum allowable sag of 2% on nominal span
lengths and under the wind conditions specified in the Technical Schedules.
Ultimate Tensile Strength (UTS) of the optical fibre cable shall be designed to exceed 2.5 times the
maximum working tension.
Associated Hardware and Fittings
5.3.3.2.8 Splice Box
The fibre optic cable (OPGW) shall be joined in splice boxes located on the tower legs or pole body at the
locations where the OPGW is dead ended. The fibre optic leads shall be brought down and up the
towers/poles on the inside of the tower legs supporting the splice box.
The splice box shall be of the corrosion resistant metallic material and watertight. The box shall be able to
contain trays for the required number of fibres specified in the Technical Schedules. The splice box shall be
equipped with a locker and shall be designed for direct mounting to the tower.
The splice box shall include the mounting hardware, optical fibre splice kits, OPGW and/or cable entry seals
and all accessories for a permanent optical joint.
Splice boxes for transmission line towers/poles shall be designed for connection of two optical fibre ground
wires. Splicing boxes for the gantry towers of the substation shall be designed for connection of one optical
fibre ground wire and one optical fibre feeder cable.
The OPGW leads shall be attached to the tower/pole at 1.0 m interval by double groove aluminium alloy
clamps specifically designed to accommodate the diameter of the composite fibre optical ground wire.
The splice box shall be installed on the towers/poles at a height of approximately 5 meters (min.) from the
ground. The OPGW leads shall be laid in a loop at the tower/pole side. The length of the OPGW leads shall
be such that the splicing can be made on the ground 10 meters from the tower/pole.
The splicing shall be made by fusion welding. The attenuation in any single splice shall be less than 0.20 dB
at 1550 nm with an average value of maximum 0.15 dB and at 1310 nm less than 0.25 dB and 0.20 dB,
respectively.
The Contractor shall submit with the bid complete information regarding the splice boxes and the method
and equipment to be used for mounting, splicing and testing.
5.3.3.2.9 Dead End Clamp Assembly

The Contractor shall furnish a complete assembly to dead end the OPGW to the transmission dead end and
terminal structures consisting of an approved dead end clamp, the necessary hardware components to link the
dead end clamp to the supporting structure and the jumper assembly to bond and ground the OPGW to the
structure.
Dead end clamps shall be of the type specified in the Technical Schedules and shall be of such design and
material capable of developing after installation a minimum of 95% of the rated breaking strength of the
OPGW and shall not permit slippage of the shield wire in the gripping section.
The dead end clamps shall be capable of carrying the maximum current for which the OPGW is designed
without causing overheating or loss of mechanical strength.
Dead end clamps shall allow the OPGW to be continuous through the clamp without cutting and splicing.
The hardware linkage to connect the dead end clamp to the supporting structure shall be galvanized steel
with stainless steel centre bolt with nut, stainless steel cotter key and galvanized steel connecting plate.
The grounding jumper assembly shall be provided with a tight-fit aluminium alloy parallel groove bolted
clamp for the OPGW end and one-bolt galvanized steel clamp for the structure end.
5.3.3.2.10 Suspension Clamp Assembly
The Contractor shall furnish a complete assembly to support the OPGW at the transmission suspension
structures consisting of an approved suspension clamp, armour rod set, the necessary hardware components
to link the suspension clamp to the supporting structure and the jumper assembly to bond and ground the
OPGW to the structure.
The suspension clamp shall be of the free-centre bolted type and shall be provided with aluminium alloy
armour rod for mechanical protection of the OPGW. The body and keeper of the suspension clamp shall be
made of aluminium alloy, the centre bolted pin and cotter key shall be of stainless steel and the U-bolts shall
be either galvanized steel or stainless steel.
The hardware linkage to connect the suspension clamp to the supporting structure shall be galvanized steel
with stainless steel bolted pins and nuts provide with stainless steel cotter keys.
The grounding jumper assembly shall be provided with a tight-fit aluminium alloy parallel groove bolted
clamp for the OPGW end and one-bolt galvanized steel clamp for the structure end.
5.3.3.2.11 Damping System
The Contractor shall recommend the type, number and location of dampers for vibration control of the
OPGW, based on the prevailing wind velocity, wire tension and low average temperature data. The
recommendation together with supporting calculations shall be submitted by the Contractor for the
Employer’s review and approval.
Aeolian vibration dampers shall be of the Stockbridge or Spiral type of high efficiency damping
characteristics extending to the range of frequencies that may produce wire strand and central core tubing
fatigue damage.
Dampers shall be of such design and construction that when installed and working within the OPGW design
loads and operating environment, they will not become loose, twisted or cause abrasion and/or fatigue to the
strands at the clamping area. Damper clamps shall be provided with torque-control bolts of the breakaway
type.

The materials shall conform to the applicable Standards, of recent manufacture and unused. Workmanship
shall conform to industry standards and good practices.

The Contractor shall supply Stress-Strain data for the specified cable(s) as stated in the Technical
Schedules. The data shall be in the form of coefficients and, additionally, in the form of stress -strain curves.
The Contractor's stress-strain and creep data shall be obtained from stress-strain tests on the cable(s)
Stress-strain tests shall be performed according to IEC 61089 or Employer-approved equivalent.
the stress-strain data based on his own new tests, or based on previous tests on a cable identical to the
specified or based on a cable constituted of the same materials and number of strands as specified,
approximately the same lay (in function of cable outer diameter).
5.3.3.5 Sag/Tension Data

The Contractor shall furnish the initial and final Sag-Tension Charts and data for the specified OPGW based
on the Stress-Strain and Creep test conducted under this specification. Calculations shall be submitted to the
Employer for approval.
The OPGW sag shall not exceed 80 percent (theoretically calculated sag) of the final sag of the conductor at
the no wind loading condition. In addition, if a companion standard overhead earth wire is installed in the
same tower, the sags of both the optical ground wire and standard overhead earth wire shall match the same
no wind final condition, within one (1) wire diameter tolerance.
5.3.3.6 Tools
The Contractor shall furnish a list of special tools aside from those mentioned in the Technical Schedules,
identifying the function of each tools and the specific items for which it is used.
The Contractor shall also provide instructions for the proper operation, maintenance and calibration of all
tools furnished, including instructions for proper storage.
If comealongs are required in the installation, the Contractor shall supply such tools and its pertinent
information. If, in the opinion of the Contractor, the specified comealongs are not adequate to properly hold
the specified cable(s), the Contractor shall offer the appropriate comealongs and provide an explanation in
the Technical Schedules. The Contractor shall provide instructions for the proper use, maintenance and
storage of the comealong(s).
5.3.3.7 OPGW Reels

The OPGW cables shall be supplied on reels as specified in the Technical Schedules. If returnable metal
reels are specified, they will be returned to the Contractor on or before a time period elapsed as indicated in
the Technical Schedules, after the cables are received at the contract-designated destination.
The OPGW shall be packed for export and the reels shall be sturdy enough to withstand rough, but normal
and customary, handling during loading, transport, unloading, field deployment and installation. The inside
surfaces of the drum and flanges shall be smooth and without protrusions so that the conductor is not
damaged during winding and unwinding. The OPGW shall be protected by plastic or other suitable material
against dust and sprays (particularly salt spray). Steel-banded lagging is required on the outside of wooden
flanges and between the flange I-beams of metal reels.
outer end of the wire points.

a) General
The Contractor shall prepare the OPGW, splicing material and special installation tools for shipment to
protect them from damage during shipment, inland transport and subsequent storage not exceeding one year,
unless otherwise specified in the Technical Schedules.
The storage of the OPGW will be in an environment similar to the installed location. The splicing materials
and tools shall be stored in a warehouse or similar location.
term storage.

shipping units such as containers or pallets. For shipping limitations, length, width, weight, etc. reference is
e - Destination
g - Case Number
i - Dimensions
l - Net weight (kg)
c) Marking of OPGW reels

Reel numbers shall be painted in clear and legible manner in two locations on the outside of each flange and
on two opposite locations on the lagging.
Each reel shall be tagged with two shipping tags. One tag shall be attached to the outside of one of the reel
flanges and the second tag shall be attached to the inside of the reel flange. Tags shall be weather resistant
metal tags containing the following information as a minimum:
e - Destination
g - Case Number
i - Reel No.
j - Dimensions
l - OPGW length on reel (m)
n - Net weight (kg)
The tags should clearly indicate OPGW in the description.

The outer end of the OPGW shall be fastened to the inner surface of the reel flange a minimum of 25 mm
below the wood lagging. The cable end shall be securely fastened to prevent the cable from becoming loose
during shipment. A minimum of 4 m of the inner end of the OPGW shall be accessible for connection to the
optical measuring equipment without removing wood lagging or the outer layer of protection. This length of
cable shall be securely fastened and protected during shipment.
A seal shall be applied to each end of the OPGW to prevent the entrance of moisture into the optical fibres or
the escape of filling compound during shipment and storage. Two extra seals shall be shipped with each reel
and should be accessible without removing the lagging.
Each reel shall be marked on the outside flange to indicate the direction the reel should be rolled during
shipment in order to prevent loosening of the cable on the reel.
The Contractor shall furnish at the time of shipment, a certified record of final quality control measured
values for each fibre on each reel. This certification shall be attached to the outside flange of the reel in a
weatherproof package.

5.3.3.10 Other Technical Requir ements for OPGW

Other requirements and features for the optical ground wire, if required by the Employer are stated in the
5.3.4 INSTALLATION
5.3.5 TESTS
5.3.5.1 Gener al
The OPGW and its accessories shall comply with test criteria, and Employer acceptance of the OPGW and
its accessories shall not relieve the Contractor of his responsibility for meeting all the requirements of this
specification. All routine tests required herein should be witnessed by the Employer or his authorized
representative unless waived in writing or specified in the Technical Schedules and no OPGW shall be
shipped until released for shipment by the Employer or his authorized representative.
The test equipment, test methods, measurements and computation shall be in accordance with the latest
applicable requirements of the IEC Publications in cases where otherwise set forth and shall be subject to the
5.3.5.2 Cable Tests

5.3.5.2.1 Design Tests
The OPGW shall be subjected to the design (or Type) tests in accordance with the Test Methods mentioned
in the IEC publications. However, design tests may be waived at the option of the Employer if the OPGW of
identical design has been previously tested to demonstrate the capability of the manufacturer to furnish
cables with the desired performance characteristics. As a minimum, the following tests shall be performed on
the cables:
a. Water ingress test
No water shall leak through the open end of the 1 m sample. If the first sample fails, one additional 1 m
sample, taken from a section of cable adjacent to the first sample shall be tested for acceptance.
b. Seepage of flooding compound
The seepage of flooding compound tests shall be done in accordance with the IEC test specification.
The filling and flooding compound shall not flow (drip or leak) at 65oC.
c. Short circuit test
An increase in measured optical attenuation greater than 1.0 dB/test fibre km at 1550 nm for single-mode
fibres and at 1300 nm for multimode fibres shall constitute failure. Birdcaging or breaking of the wire
strands shall also constitute failure.
Dissection of the cable following the test should show no distortion of any component of the cable, including
the optical fibres, buffer tubes, and any aluminium or other components. Distortion of any kind that can be
attributed to the test other than test set up procedures or hardware shall constitute failure.
d. Aeolian vibration test
Any significant damage to any component of the cable, or permanent or temporary increase in optical
attenuation greater than 1.0 dB/test fibre km at 1550 nm for single-mode fibres and at 1300 nm for
multimode fibres shall constitute failure.
e. Galloping test
Any significant damage to any component of the cable, or permanent or temporary increase in optical
attenuation greater than 1.0 dB/test fibre km at 1550 nm for single-mode fibres and at 1300 nm for
f. Sheave test
Any significant damage to the OPGW cable or central fibre optic unit at any points above deformation limits
of 0.50 mm shall constitute failure. A permanent increase in optical attenuation greater than 1.0 dB/test fibre
km at 1550 nm for single-mode fibres and at 1330 nm for multimode fibres shall constitute failure.
g. Crush and impact test
This test shall be carried out in accordance with the IEC test specification.
A permanent or temporary increase in optical attenuation value greater than 0.1 dB change in sample at 1550
nm for single-mode fibres and at 1300 nm for multimode fibres shall constitute failure. The Contractor shall
state the maximum crush strength.
h. Creep test
This test shall be done in accordance with IEC test specifications.
i. Fibre strain test
This test shall be carried out in accordance with IEC test specifications.
Fibre breakage during the test shall constitute a failure.
j. Strain margin test
Strain margin is defined as the amount of stress a cable can sustain without strain on the fibre. A permanent
or temporary increase in optical attenuation greater than 1.0 dB/test fibre km at 1550 nm for single-mode
fibres and at 1300 nm for multimode fibres up to the strain margin shall constitute failure.
k. Stress-strain test
Any visual damage to the OPGW strands or permanent or temporary increase in optical attenuation greater
than 0.2 dB/test fibre km at 1550 nm for single-mode fibres and 0.5 dB/test fibre km at 1300 nm for
l. Cable cut-off wavelength (single-mode fibre)
The cut-off wavelength, l cc of the cabled fibre shall be less than 1250 nm.
m. Temperature cycling
The Contractor shall prove that the cable operates according to the specification and shall maintain its
mechanical and optical integrity when exposed to the following temperature extremes: -40oC to +85 oC.
The change in attenuation between extreme operational temperatures for single-mode fibres shall not be
greater than 0.2 dB/km. For unshifted single-mode fibres, the attenuation change measurements shall be
made at 1310 nm and 1550 nm. For dispersion-shifted single-mode fibres, the measurements shall be at 1550
nm. For multimode fibres, the change shall not be greater than 0.5 dB/km. The multimode fibre measurement
shall be made at 850 nm and 1300 nm.
The result shall be presented in a diagram showing attenuation versus temperature for all fibres in the cable,
individually for both 1300 and 1550 nm. The Contractor shall state the number of cycles, different
temperatures and time before measurement at a stated temperature.
Routine tests shall be performed on a sampling basis such that each reel will meet the criteria stated below.
The following routine tests, but not limited to these shall be performed on the cable:
a. Mechanical and electrical test (wire before stranding)
Tests for the mechanical and electrical properties of the wires shall be made before the stranding. This shall
include determination of:
1. Tensile strength
2. Elongation
3. Diameter
4. Resistance
5. Thickness of aluminium (applicable to aluminium clad steel wire)
6. Twist test (applicable to aluminium clad steel wire)
7. Bending test (applicable to aluminium alloy 6201-T81 wire)
b. Mechanical and electrical tests on central fibre optic unit and spacers
This shall include determination of :
1. Tensile strength
2. Resistance
3. Elongation
c. Tests on complete OPGW
Tensile/elongation tests to determine the stress on cable (daN), strain on the cable (mm), attenuation on
looped fibres (dB) at 1550 nm , elongation on fibre (5) by phase shift method, and eventual slippage at dead
end clamp shall be performed in the completed OPGW. For the breaking strength of the complete OPGW, it
shall not be less than the specified rated breaking strength of the OPGW.
5.3.5.3 Fibr e Tests

5.3.5.3.1 Design Tests
The following design tests but not limited to these shall be performed on the optical fibre:
a. Attenuation variation with wavelength
The measurement shall be made in accordance with ITU recommendations
For unshifted single-mode fibres, the attenuation coefficient for wavelengths between 1285 nm and 1330 nm
measured in a cable delivery length shall not exceed the attenuation coefficient at 1310 nm by more than 0.1
dB/km.
The attenuation coefficient, in wavelength interval 1530-1570 nm measured in a cable delivery length, shall
be max. 0.22 dB/km as a mean value of all fibres and shall not exceed the maximum limit of 0.25 dB/km for
one individual fibre.
The Contractor shall provide graphs showing the typical spectral variation of the attenuation.
b. Attenuation at the water peak

The measurement shall be made using the same procedures as item a. above.
For unshifted single-mode fibres, the attenuation coefficient at the water peak found within 1383 nm + 3 nm
shall not exceed 3 dB/km.
For multimode fibres, the attenuation coefficient at 1380 nm shall not exceed the attenuation coefficient at
the 1300 nm wavelength by more than 3 dB/km.
c. Attenuation with bending
The Contractor shall give the specification of how the test will be performed i.e. the weight of the load,
cylinder diameter (bending radius), and the number of bends.
d. Temperature cycling
The Contractor shall prove that the optical fibres operate according to the specification and shall maintain
its mechanical and optical integrity when exposed to the following temperature extremes: -55oC to +85 oC.
The result shall be presented in a diagram showing attenuation versus temperature for all fibres in the cable,
individually for both 1300 and 1550 nm. The Contractor shall state the number of cycles, different
temperatures and time before measurement at a stated temperature.
a. Optical Requirements
i) Attenuation Requirements:
The following measurements, if required in the Technical Schedules shall be performed on all fibres:
a. multimode fibre attenuation coefficient at:

1. 850 nm
2. 1310 nm
b. unshifted single-mode fibre attenuation coefficient at:

1. 1310 nm
2. 1550 nm
c. dispersion-shifted attenuation coefficient at 1550 nm
The attenuation coefficient for multimode fibre and unshifted single-mode fibre shall be specified on the
basis of the maximum individual fibre attenuation coefficient in the cable.
ii) Attenuation Uniformity
The attenuation of the fibre shall be distributed uniformly throughout its length such that there are no point
discontinuities in excess of 0.1 dB for single mode fibre and 0.2 dB for multimode fibre at any design
wavelength.
iii) Chromatic Dispersion (Single-mode fibre)
Dispersion measurements shall be made in accordance with IEC publications.
iv) Multimode fibre bandwidth
Multimode fibre measurements shall be made in accordance with IEC test specifications.
v) Mode field diameter (single-mode fibre )
Mode field diameter measurements shall be done in accordance with IEC test specification.
b. Geometrical Requirements
i) Multimode optical fibres
a. Core Diameter: The permissible deviation from the nominal value for all designs (50 mm or
62.5 mm) shall be < 3 mm.
b. Core noncircularity: Core noncircularity measurements shall be carried out.
c. Concentricity error: Core-to-clad concentricity error measurements shall be made in

accordance with IEC test specifications.
d. Numerical aperture measurements: The numerical aperture measurements shall be made in

accordance with IEC test specifications. The nominal value of NA shall be as follows:
1. 50/125 : The nominal value shall be between 0.20 and 0.23.

2. 62.5/125: The nominal value shall be between 0.27 and 0.29.
ii) Single-mode optical fibres
a. Concentricity error: Core-to-clad concentricity error measurements shall be made in

accordance with IEC test specification. Offset between the centre of the core and the centre
of the cladding shall be < 1.0 mm.
iii) Parameters common to both Multimode and Single-mode fibres
a. Cladding diameter: The cladding diameter measurements shall be made in accordance with
ITU Recommendations. The cladding outside diameter shall be 125.0 mm + 2.0mm.
b. Cladding noncircularity: Cladding noncircularity measurements shall be made in

accordance with ITU Recommendations. The cladding noncircularity shall be < 2%.
c. Coating diameter: Coating diameter measurements shall be made in accordance with ITU
Recommendations. For tight buffer fibres, the Contractor shall specify a method as long as
the measurement accuracy and repeatability is equivalent to the procedures described in the
ITU Recommendations..
The nominal coating diameter should be 250 mm for standard protective coating. For tight-
buffered cable designs, an additional buffering with a nominal diameter of 400, 500, 700 or
900 mm may be used.
c. Mechanical Requirements
i. Fibre Tensile Proof Test:
Individual fibres shall be proof tested in accordance with ITU recommendations. A fibre at each end of the
test sample that has not been subjected to full proof test loading shall be discarded. All fibres shall be
subjected to a minimum proof stress of 0.35 GN/m2 for 1 s equivalent.
5.3.5.4 Field Tests

Field tests and acceptance tests for the OPGW and accessories shall be performed by the Contractor and
witnessed by the Employer’s representative(s). The Contractor shall provide instructions and acceptance
criteria for field testing for the Employer’s review and approval prior to conduct of such tests and
commissioning the OPGW. The Contractor shall conduct no tests unless approved by the Employer.

Six (6) certified copies of tests reports of all standard tests performed subsequent to the date of award and all
routine and quality conformance tests shall be certified by the inspector and submitted to the Employer
within fifteen (15) days after tests.
5.3.6.1 Gener al
Contractor furnished data and information shall be the guaranteed performance data, predicted performance,
interface requirements and installation/stringing features of all Contractors' furnished materials. The
accuracy of such information and its compatibility with overall performance requirements specified by the
Employer are the sole responsibility of the Contractor.
All information submitted as part of Tender Data will become part of contract data for the successful
5.3.6.2 Data and Information to be Submitted with the Tender

The Contractor shall furnish the following information with his bid:

b. Brochures and catalogues to support the filled-in Technical Schedules and to allow the Employer to
evaluate the OPGW being offered;
c. Descriptive material brochures, drawings, instructions and other reference material for the specified
splicing materials and installation tools and materials;
d. A detailed overall schedule, sufficient to demonstrate the Contractor's ability to perform the work to
meet the delivery, installation, stringing, testing and commissioning dates for the OPGW;
e. Design/Type Test Report;
f. QA program and ISO 9001 Certification;
g. Reference lists;
h. Detailed list of all exceptions and/or deviations taken by the Contractor to the requirements of this
specification or, if none are taken, a statement indicating that no exceptions or deviations are taken
by the Contractor.
5.3.6.3 Data and Information to be Submitted After Awar d of Contr act

The Contractor shall furnish drawings and information in quality and quantity as specified in the Contract,
for the Employer’s review and comments as follows:
a. Design Test and Quality Conformance Test reports, if not submitted with the bid;
b. Drawings, instructions and other reference material for the specified splicing materials and
installation tools and materials;
c. Drawings, instructions and other reference material for the stringing/installation methods of OPGW;
d. Sag-tension charts and templates for the OPGW specified;
e. Details of OPGW reels;
f. Graphs showing the typical spectral variation of the attenuation
g. Diagrams showing the effect of tensile load of the composite cable on the attenuation characteristic
and elongation of the fibres
h. List of drawings and schedule of submittal;
i. Detailed QA Program based on ISO 9001;
j. Detailed Project Progress and Performance Review (PPR) for the OPGW;
k. As-built drawings as finally approved.
The Contractor shall provide in the manner, number of copies and within the time set forth in the
specification, instruction manuals in accordance with the requirements of the Contract
required for routine maintenance and a list of spare parts and tools required for this maintenance.

cation or shipment
specified)
specified)
i Installation Instruction 30 days before shipment No
T-S-06-001 INSULATORS SP
T-S-06-001 INSULATORS Rev. Draft
T-S-06-001 INSULATORS
CONTENTS
6.1.1 SCOPE............................................................................................................................................2
6.1.1.1 General .......................................................................................................................................2
6.1.2.1 General .......................................................................................................................................2
6.1.3 TECHNICAL REQUIREMENTS......................................................................................................3
6.1.3.1 Description of Services...............................................................................................................3
6.1.3.2 Suspension Type Insulators of Ceramic or Glass Materials .......................................................3
6.1.3.3 Horizontal Line Post and Long Rod Insulator Units of Ceramic Materials ...............................4
6.1.3.4 Polymeric Insulators ...................................................................................................................5
6.1.3.5 Operating Environment ..............................................................................................................5
6.1.3.6 Spares and Special Tools ............................................................................................................5
6.1.3.7 Insulator Marking .......................................................................................................................5
6.1.4 INSTALLATION ...........................................................................................................................7
6.1.5 TESTS ............................................................................................................................................7
6.1.5.1 General .......................................................................................................................................7
6.1.5.2 Shop Tests ..................................................................................................................................7
6.1.5.3 Design Tests ...............................................................................................................................7
6.1.5.4 Test Reports..............................................................................................................................11
6.1.6.1 General .....................................................................................................................................11
6.1.6.2 Data and Information to be Furnished with Tender .................................................................11
6.1.6.3 Data and Information to be Furnished After Award of Contract .............................................11
6.1.1 SCOPE
6.1.1.1 Gener al
This specification covers the technical and associated requirements for Toughened glass, Ceramic and
Polymeric Insulators of type suspension, post or long rod for use in A.C. and D.C. overhead transmission
lines rated 88 kV and above.
The Contractor shall bear full responsibility that the insulators have been designed and manufactured in



6.1.2.1 Gener al
The insulators furnished shall be in accordance with, but not limited to, the latest issues of the following
applicable standards, including all addenda, in effect at the time of the purchase order unless otherwise stated
in this specification.
60060-1 General Definitions & Test Procedures
60120 Dimensions of Ball and Socket Couplings of String Insulator Units
60305 Characteristics of String Insulator Units of the Cap and Pin Type
60372 Locking Devices for Ball and Socket Couplings of String Insulators
60383-1, 2 Tests on Insulators of Ceramic Material or Glass for Overhead Lines with a Nominal Voltage
greater than 1000 V
60433 Ceramic insulators for A.C. systems. Characteristics of String Insulators Units of the Long
Rod Type
60437 Radio Interference Test on High Voltage Insulators
60471 Dimensions of Clevis and Tongue Coupling of String Insulator Units
60507 Artificial Pollution Tests on High Voltage Insulators to be used on A.C. Systems
60575 Thermal-mechanical Performance Test and Mechanical Performance Test on String Insulator
Units
60672-1 Specification for ceramic and glass insulating materials. Part 1: Definitions and classification
60672-2 Specification for ceramic and glass insulating materials. Part 2: Methods of tests
60672-3 Specification for ceramic and glass insulating materials. Part 3: Individual materials
60797 Residual strength of string insulator units of glass or ceramic material for overhead lines after
mechanical damage of the dielectric.
60720 Characteristics of Line Post Insulators

60815 Guide for Selection of Insulators in Respect of Polluted Conditions
61109 Composite Insulators for A.C. Overhead Lines with a Nominal Voltage greater than 1 kV -
Definitions, Test methods and Acceptance Criteria
61211 Insulators of ceramic or glass for overhead lines. Impulse puncture test in air
61245 Artificial Pollution Tests on High Voltage Insulators to be used on D.C. Systems
61325 Insulators for Overhead Lines with a nominal voltage above 1000 V – Ceramic or Glass
Insulator Units for D.C. Systems
61466-1 Composite string insulator units for overhead lines. Standard strength classes and end fittings
61466-2 Composite string insulator units for overhead lines. Dimensions and electrical characteristics
61467 Insulators for overhead lines. A.C. power arc tests on insulator tests
61952 Insulators for overhead lines - Composite line post insulators for A.C. with a nominal voltage
above 100V.
ISO International Standards Organization
9001 Quality System Model for Quality Assurance in Design/ Development, Manufacture and
Testing
9002 Quality System Model for Quality Assurance in Production, Installation and Servicing
in the Contractor's judgment and Employer's acceptance, superior or more economic designs or materials are
specification.
It is the intent of this specification to allow supply of insulators according to IEC Standards. If the Contractor
customarily produces the specified insulator of national standards other than mentioned, the Contractor shall
describe the equivalences and/or differences of such standards with his Tender. For any such standards,
which are not written in the English language, the Contractor shall make available copies of an English
translation thereof. In any event, the Contractor shall list all those standards he proposes to use in the supply
of the specified insulator.
6.1.3.1 Descr iption of Ser vices

The insulators covered by this specification are for use in transmission lines rated 88 kV and above.
Depending on the requirements stated in the Technical Schedules, the insulator unit should be of wet-
processed porcelain, toughened glass or composite materials.
The insulator unit shall be supplied complete with the required attachments and hardware to receive the
conductor required for the transmission line as specified in the Technical Schedules. The characteristics of
the various attachments or hardware shall be as required in the Technical Specification for Hardware and its
corresponding Technical Schedules.
6.1.3.2 Suspension Type Insulator s of Cer amic or Glass Mater ials

6.1.3.2.1 Design Requirements
The insulator design, fabrication and resultant characteristics shall be in accordance with the codes and other
particular requirements specified herein.
Insulator shells shall be made of commercial quality wet process porcelain or toughened glass in accordance
with IEC 61325. The colour of the glaze of porcelain or glass shells shall be as specified in the Technical
Schedules. When units are coupled together there shall be no contact between the shell of one unit and the
metal parts of the next adjacent unit when strings are in their service position. Design of the head shall be
cylindrical and shall be made such that it will produce uniform mechanical and electrical stress distribution.
6.1.3.2.2 Metal Parts
Pins and caps shall be designed to transmit the mechanical stresses to the shell by compression and to
develop uniform mechanical strength of the insulator. The metal parts shall retain their rated mechanical
strength even when the porcelain skirts are partially or completely broken off.
Pins shall be made of drop-forged, upset-forged, or machined-steel. The insulator pins, if specified in
Technical Schedules, shall be protected against electrolytic corrosion by the use of a sleeve of pure zinc,
zinc alloy or a corrosion-intercepting sleeve. The sleeve shall be fused to the pin so that no gap exists
between pin and sleeve and shall be so positioned on the pin as to intercept the cement line.
Caps shall be of copper-bearing drop-forged steel or heat-treated malleable cast iron or ductile cast iron. The
hole for the cotter key in a socket type cap shall be on the side of the cap opposite the socket opening. The
hole shall be counter-sunk in such a manner that the eye of the cotter key when in the locked position maybe
engaged by a hot-line key puller, to provide for disengagement of insulator units under energized conditions.
All ferrous parts, except stainless steel, shall be galvanized.
Insulator units shall be furnished with the size and type of connection specified in the Technical Schedules.
The dimensions and tolerances of ball and socket connections and tongue-clevis connections shall be in
accordance with IEC 60120.
Insulator units with ball-socket connection shall be furnished with a locking device of the split cotter key
type installed in the socket hole of the insulator cap. The cotter key shall be of such design and size to meet
the tests specified herein. The cotter key shall provide positive locking against unintentional disengagement
of insulator units during use and handling to provide easy connection to other units or hardware. Cotter keys
shall be made from cold-drawn bronze, brass or stainless steel wire of approximately half-round section
having the following properties:
Pins for tongue-clevis type connection shall be of drop-forged, upset-forged or machined steel. Locking
device of split cotter key type shall be used to prevent disengagement of insulator units. Cotter keys shall
allow easy connection to other units or hardware.
Material shall be free of defects, of recent manufacture, and unused. Workmanship shall conform to industry
standards and best practices.
Metal caps shall be free from cracks, seams, shrinks, air holes, burrs, and rough edges. Metal pins shall be
free from laps, folds, seams, burrs, and rough edges. Surfaces of metal parts shall be smooth with no
projecting points or irregularities, which may cause corona.
Insulator units after assembly shall be concentric and coaxial.
6.1.3.3 Horizontal Line Post and Long Rod Insulator Units of Cer amic Mater ials
6.1.3.3.1 Design Requirements
The horizontal mounted line post and/or long rod insulators shall be made of high-grade, wet-process high
strength porcelain, suitable for the type of pole or structure specified in the Technical Schedules.
Depending on the requirements stated in the Technical Schedules, the porcelain body shall be made of
either two or single unit solid core insulator.
Clamp brackets shall be made of ductile iron.
All ferrous parts, except stainless steel andaluminium shall be galvanized.
The top clamp for the conductor to be used for the transmission line as specified in the Technical
Schedules, shall be made of aluminium.
Mounting bolts shall be made of steel complete with accessories suitable for the type of structure specified
in the Technical Schedules.
6.1.3.4 Polymer ic Insulators

6.1.3.4.1 Materials
All materials shall content with the general requirements as for ceramic and glass insulators.
Weather sheds and sheath material shall be 100 % silicone based polymer material.
End fitting material shall be forged steel, hot-dip galvanised and shall be permanently sealed to prevent
moisture and foreign materials from entering the end fitting-rod interface.
Rod material shall be vinylester or epoxy with an electrical grade glass fibre matrix and manufactured by
pultrusion processing.
If so stated in the Technical Schedules the insulators shall be equipped with aluminium grading/corona
rings and/or arching horns, which can be installed by hot stick method or removed without disassembling the
insulator and hardware assembly.
6.1.3.4.2 Dimensions and tolerances
Dimensions and tolerances for end fittings shall be in accordance with the requirements as for ceramic and
glass insulators and for the complete insulators according to the insulator assembly drawings.
6.1.3.4.3 Electrical and Mechanical Requirements
Type test shall be performed on a number of insulators in accordance with IEC 61109.
The electrical characteristics of insulators shall be as stated in the Technical Schedules.
If so stated in the Technical Schedules insulators and accessories shall be designed with corona rings
and/or arching horns so that, when installed, no visible corona discharges appear at the system voltage
specified.
The corona extinction voltage shall be at least 1.15 times the highest system voltage level when lowering
from a level with visible corona.
Radio interference tests of the complete insulator sets shall be performed in accordance with IEC Publication
60437. The noise level shall not exceed 60 dB over 1 mV at 145 kV test voltage and 500 kHz measuring
frequency.
Electromechanical or mechanical failing load test shall be performed in accordance with IEC 61109.
6.1.3.5 Oper ating Envir onment

The insulator units shall meet the performance requirements of this specification while operating within the
environment specified in the Technical Schedules.
6.1.3.6 Spar es and Special Tools

If required, the Contractor shall furnish spares and special tools described in the Technical Schedules,
which are necessary for normal installation and maintenance of the insulators furnished by Contractor.
6.1.3.7 Insulator Mar king

6.1.3.7.1 Ceramic and Glass Insulator units
Each insulator unit shall be marked with the name or trademark of the manufacturer and the year of
manufacture in accordance with IEC-60383. In addition, each insulator unit shall be marked with the
specified electromechanical or mechanical failing load in conformity with IEC 60383, or the first part of the
designation in accordance with IEC-60305.
6.1.3.7.2 Polymeric Insulators

Each insulator unit shall on the top weathershed be marked with the name or trademark of the manufacturer,
manufacture code date, production lot number and mechanical strength rating.

The Contractor shall prepare the insulator units for shipment to protect them from damage during shipment
and transport and subsequent storage not exceeding one year, unless specified otherwise in the Technical
Schedules.
The storage will be in an environment similar to the installed location. The Contractor shall provide storage
and handling instructions including descriptions for periodic inspection and/or storage maintenance to
ascertain that no deterioration will occur during storage. One set of these instructions shall be fastened
securely to the outside of the shipping unit. The Contractor shall provide, at the Employer’s request, the
Contractor’s recommended instructions for long term storage.
For shipping limitations, length, width, weight, etc., reference is made to the Technical Schedules.
For suspension type insulator units, packing shall comply with the Technical Schedules and the following:
a. Insulators, unless otherwise specified, shall be packed for shipment in crates with closed ends of
sufficient strength to prevent injury to the contents, withstand palletizing and resist failure during transit,
storage, and subsequent handling in the field.
b. Unless otherwise specified, each crate of insulators with a unit spacing of from 127 mm to 165 mm
shall consist of a string of six assembled and connected units or each crate shall consist of two parallel
strings of six units each, with each string of six units assembled and connected.
c. Each crate of insulators with a unit spacing of up to 200 mm shall consist of a string of five
assembled and connected units.
d. In addition each crate shall be marked on the sides and on each end with a distinguishing code for
insulators of different type. The Contractor shall submit a description of marking he proposes for each type,
for the Employer’s review. Prominent weather-resistant coloured marking will be acceptable.
e. Individual crates may be shipped in larger shipping units such as containers or pallets. Such
shipping units shall be plainly marked by stencil or with a firmly fastened tag with the following information
as a minimum:
e - Destination
g - Case Number
i - Dimensions
k - Quantity
l - Gross weight (kg)
m - Net weight (kg)
n - Tare weight (kg)
For long rod or post type insulator units including polymeric insulators, adequate support shall be provided
to prevent breakage of the units during shipment and transport.
Each box or container of insulator units shall be marked with the number of pieces contained therein, the
catalogue number or class number or description of the contents and the manufacturer’s name.

6.1.4 INSTALLATION
Installation will be by the Employer or Contractor as specified in the Technical Schedules and monitored
by the Employer’s representative(s).
6.1.5 TESTS
6.1.5.1 Gener al
All materials shall comply with the test criteria, and the Employer's acceptance of the insulators shall not
relieve the Contractor of his responsibility for meeting all the requirements of this specification.
The Contractor shall carry out, at his own expense, all tests necessary to ensure the satisfactory design and
manufacture of the insulator units in accordance with IEC Standards.
If so required in the Technical Schedules the Employer or his authorized representative shall witness all
tests unless waived in writing, and no insulator units shall be shipped until released for shipment by the
Employer or his authorized representative.
The Contractor shall make all preparation for the tests and provide the test apparatus and personnel and shall
notify the Employer the date of the tests to be witnessed in accordance with the requirements of this
specification.
Actual test procedures to be used shall be subject to Employer’s acceptance and approval.
6.1.5.2 Shop Tests

Insulator units shall be subjected to the design, quality conformance, and routine tests in accordance with
IEC test requirements and all other applicable tests mentioned in this Specification. Even though the
Contractor performs the required tests and the insulators meet the acceptance criteria, the Contractor shall
not be relieved of the responsibility of providing insulators conforming to all requirements of the
specification.

6.1.5.3.1 General
Design tests in accordance with applicable IEC standards and corresponding certified test reports are always
required when the insulator type is the Contractor’s new design or the Contractor’s previous design with
significant design changes (i.e. prototype). For this, the Contractor shall submit the test procedures he intends
to use for the Employer’s review and acceptance.
If the insulator units to be supplied are not a prototype, a certified design test report of duplicated production
type following the prescribed tests as for shop tests shall be submitted as specified in the Technical
Schedules.
Certificates of all design or type tests required for suspension insulator units under IEC Standard shall be of
the latest supply conducted by an internationally known, reputable and independent testing laboratory.
Certificates of design tests or type tests conducted at the manufacturers own testing laboratory will not be
accepted.
6.1.5.3.2 Suspension Type Insulator Unit (for A.C. Insulators)
The insulator units to be supplied shall comply with the Design Test specified in IEC and the following
additional tests:
a. Steep front-of-wave test

Steep front-of-wave test shall be performed on ten (10) insulator units selected at random from the first
production lot offered for inspection:
1. The insulator units shall be subjected to five successive positive and negative impulse flashovers
with a wave having an effective rate of rise of 2,500 kV per microsecond. The insulator units shall
be tested singly.
2. Each unit shall then be verified to be electrically intact by applying low-frequency voltage. The
rated wet-low frequency withstand voltage shall be applied to each unit and no electrical puncture
shall occur.
Failure of any one unit either in the front-of-wave or subsequent low frequency withstand voltage test
shall be cause for testing another twenty (20) units.
Failure of more than one unit from the total so tested shall constitute failure to meet the requirements
of this specification.
b. Thermal-Mechanical Performance Test
A Thermal-Mechanical Performance Test shall also be performed in accordance with IEC Publication
60383 with the acceptance criteria as follows:
1. The result of this performance test shall match the result of the ordinary M & E failing load test.
i. Mean value and standard deviation of the performance test shall not change.
ii. Fracture pattern shall not change.
2. Acceptance constant, K, should be equal to or greater than 3, when the sample size is ten.
R − Rs
That is, 3≤ K =
S
where R : Mean value
Rs : M & E rated value
S : Standard deviation
3. Each value measured should not be lower than the specified M & E strength.
4. Electrical puncture should not occur before the ultimate fracture.
6.1.5.3.3 Suspension Type Insulator Unit (for D.C. Insulators)

The Contractor shall carry out all the type, sample and routine tests as enumerated in IEC 61325.
The Contractor shall submit test reports regarding D.C. pollution and power arc performance.
a. Type Tests
The Contractor shall submit with his tender the type test reports specified below. Type test reports to
be submitted by the Contractor shall be from a reputable internationally known independent testing
laboratory.
If the Contractor fails to submit such reports, the Tender is liable to be rejected.
1. Verification of the dimensions, in accordance with IEC 61325 Clause 22
2. Electromechanical failing load test, in accordance with IEC 61325 Clause 23. The acceptance
criteria shall be as follows:
i) X > Rating + 3S where:
X – mean value of test results
S – standard deviation of the test results
ii) Each value measured shall not be lower than the specified electromechanical failing load
iii) Electrical puncture shall not occur before reaching ultimate failure.
3. Thermal runaway test, in accordance with IEC 61325 Clause 20
4. Dry lightning impulse withstand test, in accordance with IEC 61325 Clause 14
5. Dry D.C. withstand voltage test, in accordance with IEC 61325 Clause 15
6. Ion migration test, in accordance with IEC 61325 Clause 18
7. Impulse over voltage test, in accordance with IEC 61325 Clause 17 with steepness of impulse:
2500 kV/microsecond
8. Thermal mechanical performance test, in accordance with IEC 61325 Clause 25. The acceptance
i) X > Rating + 3S where: X – mean value of test results
ii) Each value measured shall not be lower than the specified electromechanical failing load.
iii) The results of this performance test shall match the results of the ordinary
electromechanical failing load test. Mean value and standard deviation of the performance
test shall not change significantly. Fracture pattern shall not change.
iv) Electrical puncture shall not occur before reaching ultimate failure.
9. SF6 puncture test, in accordance with IEC 61325 Clause 16.

10. Zinc sleeve test, in accordance with IEC 61325 Clause 35.
11. Residual mechanical performance test, in accordance with IEC 61325 Clause 26.
b. Sample Tests
The Contractor shall keep the Employer informed on the progress on the manufacturing of materials
and works, so that the inspection and testing can be performed in the presence of Employer’s
representative.
Before every inspection and test supervised by the Employer, the Contractor shall assure himself that
the work is in all respects ready for inspection and testing, in accordance with these specifications.
Full and complete testing of all components shall be carried out to the satisfaction of the Employer.
The test listed below shall be carried out on each production lot of insulators at the expense of the
manufacturer, and these insulators and split pins shall be added by the Contractor, free of charge, to the
number specified in the tender documents. The insulators as have been subjected to sample tests shall
not be included in the delivery lot.
The sample tests are to be performed on the sample E1, E2 or E3. The size of these samples shall be
determined in IEC 61325 Clause 10.
Lot Size (N) Sample Size
E1 E2 E3
N < 300 Subject to Agreement
300 < N < 2000 4 3 4
2000 < N < 5000 8 4 8
5000 < N < 10000 12 6 12
1. Verification of the dimensions, in accordance with IEC 61325 Clause 22.

2. Body resistance test, in accordance with IEC 61325 Clause 19.
3. Verification of the displacement, in accordance with IEC 61325 Clause 27.
4. Verification of the locking system, in accordance with IEC 61325 Clause 28.
5. Temperature cycle test, in accordance with IEC 61325 Clause 29.

6. Electromechanical failing load test, in accordance with IEC 61325 Clause 23. The acceptance
i) X > Rating + 3S where:
X – mean value of test results
ii) Each value measured shall not be lower than the specified electromechanical failing load.
iii) Electrical puncture shall not occur before reaching ultimate failure.
7. Impulse over voltage test, in accordance with IEC 61325 Clause 17 with steepness of impulse:
2500 kV/microsecond
8. Residual mechanical performance test, in accordance with IEC 61325 Clause 26.
9. Porosity test, in accordance with IEC 61325 Clause 31.
10. Zinc sleeve test, in accordance with IEC 61325 Clause35.
11. Galvanizing test, in accordance with IEC 61325 Clause 32.
c. Routine Tests
The manufacturer shall carry out, at his own expense, the routine tests specified in IEC 61325. The
routine tensile load shall be 50% of the electromechanical failing load.
1. Routine visual inspection in accordance with IEC 61325 Clause 33.
Number of insulator units to be tested: All
2. Routine mechanical test in accordance with IEC 61325 Clause 34.
3. Routine electrical inspection in accordance with IEC 61325 Clause 21.
6.1.5.3.4 Horizontal Line Post /Long Rod Insulator

The insulator units to be supplied shall comply with all the design tests specified in the applicable IEC
standards.
6.1.5.3.5 Routine Tests (for A.C. Suspension, Line Post and Long rod Insulators)
If so specified in the Technical Schedules the Employer shall witness all routine tests. All tests shall be in
accordance with the applicable IEC standards.
6.1.5.3.6 Quality Conformance Tests (for A.C. Suspension, Line Post and Long rod Insulators)
If so specified in the Technical Schedules the Employer shall witness all quality performance tests. All tests
shall be in accordance with the applicable IEC standards, except for the acceptance criteria for the combined
Mechanical and Electrical Strength tests for ceramic and glass A.C. suspension insulator units where the
acceptance criteria shall be as follows;
X =≥ rating + 3S
where: X = average value obtained on the sample of the ten insulator units tested
S = standard deviation for the ten insulator units tested
Each value measured shall not be lower than the specified mechanical and electrical strength.
Electrical puncture shall not occur before reaching ultimate failure.

and quality conformance tests shall be certified by the inspector and submitted to the Employer within fifteen
(15) days after test.
6.1.6.1 Gener al
Contractor-furnished data and information shall be the performance data, predicted performance and
installation features of all Contractors' finished materials. The accuracy of such information and its
compatibility with overall performance requirements specified by Employer are the sole responsibility of the
Contractor.
All information submitted as part of the Tender Data will become part of contract data for the successful
Contractor. Any deviation from such data requires the Employer’s approval.

Together with the tender, the Contractor shall submit the following information:
a. Filled-in Technical Schedules
b. An outline drawing of each insulator unit including a cross-sectional view of the insulator
shell, and the following information:
1. Type designation in accordance with Standards used, if applicable;
2. Shell diameter and unit spacing with manufacturing tolerances;
3. Leakage distance, total and shielded portions;
4. Mechanical and electrical characteristics;
5. Size of ball and socket or tongue-clevis parts, if suspension type of insulator unit is to be
supplied;
6. Materials
7. Unit weight
8. Identification marking
9. Manufacturer’s catalogue number
10. Each drawing shall be identified by a drawing number
c. Additional descriptive material brochures, additional drawings and other reference material to
support the filled-in Technical Schedules and to allow the Employer to properly evaluate the
insulators being offered;
d. A detailed overall schedule, sufficient to demonstrate the Contractor’s ability to perform the
work to meet the delivery and installation;
e. Certified type test reports performed by an independent testing laboratory;
f. Tentative QA Program and ISO 9001 Certification;
g. Detailed list of all exceptions and/or deviations taken by the Contractor to the requirements of
this specification or, if none are taken, a statement indicating that no exceptions or deviations
are taken by the Contractor.
The following shall be submitted after award of contract:
a. Certified Quality Conformance and Routine Test Reports;
b. Bill of materials and parts list or identifying sketch showing components;
c. Detailed insulator outline drawings;
d. Installation procedures;
e. Detailed QA Program based on ISO 9001;

f. Detailed Project Progress and Performance Review (PPR) for the insulators;
g. As-built drawings as finally approved.
instruction manuals in accordance with the requirements of the Contract.
required for routine maintenance, and test of spare parts (if any) and tools required for this maintenance.

cation or shipment
d Design or Type Test Reports With Tender Yes
e List of standards used With Tender Yes
j Installation Instruction 30 days before shipment No
T-S-07-001 HARDWARE SP
T-S-07-001 HARDWARE Rev. Draft
T-S-07-001 HARDWARE
CONTENTS
7.1.1 SCOPE............................................................................................................................................2
7.1.1.1 General .......................................................................................................................................2
7.1.2.1 General .......................................................................................................................................2
7.1.3.1 General .......................................................................................................................................3
7.1.3.1.1 Workmanship .....................................................................................................................3
7.1.3.1.2 Zinc Coating .......................................................................................................................3
7.1.3.2 Specific Requirements ................................................................................................................3
7.1.3.2.1 Accessories for Conductor .................................................................................................3
7.1.3.2.2 Accessories for Shield/Earth Wire .....................................................................................5
7.1.3.2.3 Parallel Groove Clamp and/or Wedge Clamp for Earth Wire ............................................5
7.1.3.2.4 Damper for Earth Wire .......................................................................................................5
7.1.3.2.5 Bird Diverter for Earth Wire or OPGW .............................................................................6
7.1.3.3 Marking ......................................................................................................................................6
7.1.3.5 Spares and Special Tools ............................................................................................................6
7.1.4 INSTALLATION ...........................................................................................................................7
7.1.5 TEST ..............................................................................................................................................7
7.1.5.1 General .......................................................................................................................................7
7.1.5.2 Type Tests ..................................................................................................................................7
7.1.5.3 Quality Conformance Tests (Sample Test) and Routine Tests...................................................7
7.1.5.3.1 For the Suspension and Tension Clamp for the conductor. ................................................7
7.1.5.3.2 For the Preformed Armour Rods. .......................................................................................8
7.1.5.3.3 For the Conductor Spacer/Damper .....................................................................................8
7.1.5.3.4 For the Jumper Device: ......................................................................................................9
7.1.5.3.5 For the Vibration Damper: .................................................................................................9
7.1.5.3.6 For the Suspension and Tension Earth Wire Assembly: ....................................................9
7.1.5.3.7 For Miscellaneous Hardwares: ...........................................................................................9
7.1.5.4 Test Reports................................................................................................................................9
7.1.6.1 General .....................................................................................................................................10
7.1.6.2 Data and Drawings to be Furnished with Tender .....................................................................10
7.1.6.3 Data and Drawings to be Furnished After Award ....................................................................10
7.1.1 SCOPE
7.1.1.1 Gener al
This specification covers the technical and associated requirements for transmission line hardware and
accessories for conductors, earth wires and insulator strings for use in A.C. and D.C. overhead transmission
lines rated 88 kV and above.
The Contractor shall bear full responsibility that the hardware and accessories have been designed and
manufactures in accordance with all standards and applicable regulations and perform under the condition
and to the standards specified herein.
the Employer. The Contractor shall obtain from its sub-contractor a statement as to compliance with this
specification without exception and/or if there are any exceptions, these shall be described in detail and
included in the Contractor’s Tender. The Contractor shall add a statement that no other exceptions are taken
to this specification.

7.1.1.3 Wor ks to be pr ovided by Employer


7.1.2.1 Gener al
The hardware furnished shall be in accordance with, but not limited to, the latest issues of the following
applicable standards, including all addenda, in effect at time of purchase order unless otherwise stated in this
specification.
61854 - Overhead lines - Requirements and tests for spacers
61897 - Overhead lines - Requirements and tests for Stockbridge type aeolian vibration dampers
specification.
It is the intent of this specification to allow supply of hardware according to IEC Standards. If the Contractor
customarily produces the specified hardware of national standards other than mentioned, the Contractor shall
describe the equivalences and/or differences of such standards with his Tender. For any such standards,
which are not written in the English language, the Contractor shall make available copies of an English
translation thereof. In any event, the Contractor shall list all those standards he proposes to use in the supply
of the specified hardware.
7.1.3.1 Gener al
7.1.3.1.1 Workmanship
All parts shall be new and of the highest class and shall be furnished uniformly in quality and smoothly on
the surface in conformity to the best commercial practice without any harmful defects such as flaws, ruts, air
holes, cracks, burrs and rough edges, etc.
Filling or plugging of any defective parts shall not be permitted. The design shall avoid sharp corners or
projections, which will produce high electrical stress in normal operation.
The design of adjacent metal parts and contacting surfaces shall be so made as to prevent corrosions of the
contact surfaces and to maintain good electrical contact under service conditions.
7.1.3.1.2 Zinc Coating
All the iron and steel parts and members shall be zinc coated upon completion of the fabrication. The zinc
coating is to be uniform, clean, smooth and free from burrs, sharp edges, lumps and dross so that
interconnecting parts will fit properly and parts may be assembled and disassembled readily. The zinc
coating shall be carried out by the hot dip process for all parts.
Threaded parts shall be coated after being threaded and excessive zinc shall be removed from the threads.
Nuts and locknuts shall be retapped after being coated and shall be capable of being threaded the entire
length of threads without use of tools.
7.1.3.2 Specific Requir ements

7.1.3.2.1 Accessories for Conductor
a. Suspension Clamp for Conductor
Depending on the requirements stated in the Technical Data Sheets, the body of the suspension clamp shall
be made either of aluminium alloy, malleable iron or ductile iron and shall be so made as not to deform the
conductor and loosen the individual strands of the conductor. The materials of the clamp and its fittings shall
conform to the following:
Clamp body, keeper High strength and heat treated cast aluminium alloy pieces
Cotter bolts, U-bolts and other Ferrous metals Galvanized mild steel
Cotter pins Stainless steel
b. Tension Clamp for Conductor

The tension clamp for conductor shall be of the wedge, bolted or compression type as specified in the
Technical Schedules. The wedge and bolted type tension clamps shall consist of a clamp body, a wedge or
keeper, a doubling plate and other necessary metallic fittings. The materials of the wedge and bolted type
tension clamp shall conform to the following or equivalent and all ferrous materials shall be hot-dip zinc
coated.
Clamp body, keeper pieces wedge, jumper fitting High strength and heat treated cast Aluminium alloy
Eye-bolt, nut, bolt, locknut U-bolt, cotter bolt, Galvanized mild steel
spring washer connecting bar
Cotter pins Stainless steel
After clamping, the electrical resistance of the tension clamp must be less than that of the conductor joined
thereby with the same length as the tension clamp.
c. Preformed Armour rods

The preformed armour rods are used at all suspension points of the conductor. The shape of the preformed
armour rods shall be terminated with rounded ends and shall be of corona-free design at voltage levels 230
kV and above. Each rod shall be made of heat-treated aluminium alloy wires. The characteristics of the
preformed armour rods shall be as specified in the Technical Schedules.
d. Conductor Spacer/Damper (If Required)

The spacer for the specified conductor and bundled arrangement of conductors with the specified spacing
shall consist of an interlinking body and clamps for gripping the sub conductors as shown on the specified
drawings and/or Technical Schedules. The spacer body frame shall be made of zinc coated hot rolled steel,
carbon steel pipe for pressure tube, or aluminium-alloy and the clamps of the line spacer shall be hinge type
made of aluminium alloy. The clamp fastener shall be aluminium alloy breakaway bolt. When necessary,
welding of steel shall be carried out before galvanizing in accordance with applicable standards. The spacer
shall have the following performance and durability:
(i) The conductor spacer shall allow movement in all directions and shall fatigueless withstand
repeated compressive loads and tensile loads in vertical, horizontal transverse and horizontal
longitudinal directions.
(ii) The spacers shall be installed at a spacing not exceeding 75 m with unequal spacing in the
same span within 10% variation. Shorter spacing for the first spacer away from the suspension
points shall be applied. The Contractor shall recommend the spacer spacing application.
(iii) The conductor damper shall not be deformed by impulsive loads due to electro-magnetic
attraction of short circuit current of 50 kA through the bundled conductors.
(iv) The clamps of the conductor spacer shall not slip relative to the conductor when being turned
by 180 degrees.
(v) The corona noise from the conductor spacers shall not exceed that of the bundled conductors.
e. Jumper Device (If Required)

The jumper device shall have the following performances:
(i) The clamps of the reinforcement and jumper spacers shall not slip relative to the jumper
conductors and the reinforcing galvanized steel wire strands when the jumper conductors and
the jumper device are swung together to the side way.
(ii) The reinforcement and jumper spacers shall not deform by impulsive load due to electro-
magnetic attraction of short-circuit current of 50 kA throughout the conductor.
(iii) The clamps of the reinforcement and jumper spacers shall not slip and the jumper device shall
not deform when subjected to the assumed load during the construction work.
(iv) After the assembly of the jumper device, each reinforcing galvanized steel wire strand shall
withstand the tensile load of 15,000 N or more.
(v) The corona noise from the jumper device shall not exceed that of the bundled conductors.
f. Damper for Power Conductor

The conductor vibration damper shall be suitable for the specified conductor and shall be of the stockbridge
or loop type. The damper shall be modern, highly efficient and multi-resonant type and designed to control
aeolian vibration and to prevent fatigue damage to the conductor. The vibration damper for the conductor
shall consist of the damper weights, which are resiliently supported from a galvanized strand wire by a
suitable clamp.
The Contractor shall specify the nominal weight of the damper.
g. Conductor Comealong
Conductor comealongs shall have an ultimate tensile strength of not less than 22,250 N.
7.1.3.2.2 Accessories for Shield/Earth Wire

Suspension Earth Wire Assembly
The earth wire suspension assembly for the specified wire size and type shall consist of a free-centre type
suspension clamp, a link, a U-clevis and a preformed armour rod as shown in the attached drawings and/or
Technical Data Sheets, so as to be supplied as a complete set. The suspension clamp shall be made of
aluminium alloy. The characteristics of the clamp for the earth wire suspension assembly shall be as
Tension Earth Wire Assembly

The tension earth wire assembly for the specified wire size and type shall consist of two tension devices and
a jumper clamp as shown in the attached drawings and/or Technical Schedules, so as to be supplied as a
set. The tension device shall consist of a wedge, bolted or compression type tension clamp, a link and two U-
clevises as shown in the attached drawings or specified in the Technical Data Sheets. The tension clamp shall
be made of aluminium alloy or galvanized steel. The characteristics of the clamp for the tension assembly
shall be as specified in the Technical Schedules.
The jumper clamp for the tension earth wire assembly shall be used for fastening the jumper of earth wire at
the tower top and shall have an aluminium alloy body as shown in the drawings. The characteristics of the
jumper clamp shall be as specified in the Technical Schedules.
7.1.3.2.3 Parallel Groove Clamp and/or Wedge Clamp for Earth Wire
Depending on the requirements stated in the Technical Schedules the clamp to be used for connecting the
jumper wire to the earth wire, can either be a parallel groove clamp or a wedge type pressure clamp.
The clamp shall be made of aluminium alloy and must be suitable for the specified overhead earth wire and
type.
The parallel groove clamp shall be of the bolted type while the wedge pressure clamp shall be of
compression type. The slip strength of the clamp must not be less than 15 percent of the ultimate breaking
strength of the shield wire being connected. The shape of the parallel groove clamp shall be as shown in the
drawings.
7.1.3.2.4 Damper for Earth Wire
The Contractor shall supply the vibration damper for the earth wire of the Stockbridge, loop or spiral types.
The vibration damper for the earth wire shall consist of damper weights, which are resiliently supported from
a galvanized strand wire by a suitable clamp.
The Contractor shall recommend the number and spacing of dampers for the specified earth wire including
physical and mechanical characteristics.
7.1.3.2.5 Bird Diverter for Earth Wire or OPGW

The Contractor shall supply, if required, the bird diverter to be installed on the earthwire or OPGW of an
approved type.
The Contractor shall also recommend the number and spacings of bird diverters to be installed on the
earthwire on bird migratory spans based on the Environmental Impact Assessment (EIA) findings.
7.1.3.3 Mar king

Individual items of the hardware and accessories shall carry identification marks so as to facilitate
assembling and sorting in the warehouse or on site. Marking, such as production record code, as customarily
provided by Contractor are acceptable.

Line hardware shall meet the performance requirements of this specification while operating within the
environment specified in the Technical Schedules.
7.1.3.5 Spar es and Special Tools

If required, the Contractor shall furnish spares and special tools described in the Technical Schedules,
which are necessary for normal installation and maintenance of the insulators furnished by Contractor.

The Contractor shall prepare the hardware for shipment to protect them from damage during shipment and
subsequent storage not exceeding one year, unless specified otherwise in the Technical Schedules. The
hardware shall be boxed, crated and protected to prevent damage from handling during loading,
transportation and delivery.
securely to the outside of the shipping unit.
For shipping limitations, length, width, weight, etc., reference is made to the Technical Schedules.
Packing shall comply with the requirements of the Technical Schedules and the following:
Each crate shall be marked on the sides and on each end with a distinguishing code for materials of different
type. The Contractor shall submit a description of marking he proposes for the Employer’s review.
Prominent weather-resistant colour marking will be acceptable.
Individual crates may be shipped in larger shipping units such as containers or pallets. Such shipping units
shall be plainly marked by stencil or with a firmly fastened tag with the following information as a
minimum.
e - Destination
g - Case Number
i - Dimensions
k - Quantity
m - Net weight (kg)

7.1.4 INSTALLATION
When the installation is by the Contractor, such as for turnkey contracts, complete details of installation,
proper handling, transport and storage at site, testing, performance guarantees, etc., shall be furnished for the
7.1.5 TEST
7.1.5.1 Gener al
Line hardware and accessories shall comply with test criteria, and Employer’s acceptance of hardware and
accessories shall not relieve the Contractor of his responsibility for meeting all the requirements of this
specification.
The Contractor shall carry out, at his own expense all tests necessary to ensure the satisfactory design and
manufacture of the line hardware and accessories in accordance with the applicable IEC standards.
The Employer or his authorized representative shall witness all routine tests required in the applicable
standards unless otherwise waived in the Technical Schedules and no hardware and accessories shall be
shipped until released for shipment by the Employer.
notify the Employer the date of the test forty five (45) days in advance.
Actual test procedures to be used shall be subject to the Employer’s acceptance and approval.
7.1.5.2 Type Tests

These tests are intended to establish design characteristics of line hardware and accessories. They are
normally made once and repeated only when the design or the material of the fittings is changed. Design
tests or type tests can be omitted, if a design record of the same materials can be submitted.
7.1.5.3 Quality Confor mance Tests (Sample Test) and Routine Tests
Quality Conformance Tests are intended to verify the quality of materials and workmanship. They are to be
made on fittings taken on random from the various lots offered for acceptance. Routine tests on the other
hand, are intended to eliminate defective materials. They are also to be made on every fitting of the type to
which they are applicable.
In general, the following quality conformance and routine tests shall be performed as a minimum:
7.1.5.3.1 For the Suspension and Tension Clamp for the conductor.
The following inspections and tests shall be carried out:
- Visual and Dimensions
- Slip Strength
- Breaking Strength
- Zinc Coating: coating weight and uniformity
7.1.5.3.2 For the Preformed Armour Rods.

- Assembling
- Slip Strength
7.1.5.3.3 For the Conductor Spacer/Damper
a. In order to confirm the performance and durability of the conductor spacers/dampers mentioned the
following inspections and tests should be carried out:
- Wear Resistance
- Twist Withstand
- Slip Strength of clamp
- Compression Withstand
- Zinc Coating: Coating weight and uniformity
b. The above mentioned tests of wear resistance, twist withstand, slip strength of clamp and compression
withstand for the conductor spacer shall be carried out and the spacer shall prove to exceed the
following requirements:
(1) Wear Resistance
The spacer shall withstand the following conductor motions without loss of function due to wear
and production of harmful strain on the conductor.
(i) Vertical Vibration (Aeolian Vibration):

Amplitude + 1 mm
Repetition 1 X 108
Frequency 40 Hz
Tension of Conductor 35,000 N
Vertical Load 2 X 10 kg
(ii) Horizontal Transverse (Sub-span Oscillation):

Loading + 50 kg
Repetition 1 X 105
Frequency 2 - 5 Hz
Tension of Conductor 35,000 N
(iii) Horizontal Longitudinal:

Amplitude + 50 mm
(Coupling with two horizontal and two vertical conductors)
Repetition 7 X 106
Frequency 2 - 5 Hz
Tension of Conductor 35000 N
(2) Twist Withstand .

Under this condition, the spacer shall be twisted by 180 degrees and then returned to the initial
position. The twist of 180 degrees shall be repeated ten times. During and after ten times of twists,
no slips shall occur between clamps of the spacer and conductors clamped thereby, and no
conductor damage shall be found.
(3) Slip Strength of Clamp.

Under this condition, the spacer shall be twisted until the clamp of the spacer begins to slip relative
to the conductor clamped thereby. The twisting torque when the clamp begins to slip relative to the
conductor clamped thereby shall not be less than 50 N-m for the spacer.
(4) Compression Withstand.

The spacer shall withstand ten applications of the impulsive compression of 12,500 N. During and
after ten times of impulsive compression, no slip shall occur between clamps of the spacer and
conductors clamped thereby, no distortion of the spacer shall be found.
7.1.5.3.4 For the Jumper Device:

a. Visual and Dimensions
b. Wear resistance, twist withstand, slip strength of clamps and compression withstand for reinforcement
and jumper spacers
c. Tensile withstand of reinforcing galvanized steel wire strand
d. Zinc coating: Coating weight and uniformity
7.1.5.3.5 For the Vibration Damper:

a. Visual and Dimensions
b. Wear Resistance
c. Twist Withstand
d. Slip Strength of Clamps
e. Compression Withstand
f. Zinc Coating: Coating Weight and Uniformity
7.1.5.3.6 For the Suspension and Tension Earth Wire Assembly:

The following inspections and tests shall be carried out to the earth wire suspension assembly:
a. Visual
b. Construction and Dimensions
c. Slip and Breaking Strength
d. Zinc Coating: coating weight and uniformity
7.1.5.3.7 For Miscellaneous Hardwares:

a. General Inspection
b. Slip and Breaking strength
c. Zinc Coating: coating weight and uniformity

Six (6) certified copies of the reports of all standard tests performed subsequent to the date of award and all
7.1.6.1 Gener al
Contractor furnished data and information shall be the guaranteed performance data, predicted performance
interface requirements and installation features of all Contractors' furnished materials. The accuracy of such
information and its compatibility with overall performance requirements specified by Employer are the sole
responsibility of the Contractor.
Contractor. Any deviation from such data requires the Employer’s approval.
7.1.6.2 Data and Dr awings to be Fur nished with Tender

The Contractor shall furnish the following information with his bid:
b. Outline drawings of each hardware and the following information:
1. Type designation in accordance with Standard used, if applicable;
2. Unit dimension with manufacturing tolerances;
4. Materials
5. Unit weight
7. Manufacturer’s catalogue number
c. Additional descriptive material brochures, additional drawings and other reference material to support
the filled-in Technical Data Sheets and to allow the Employer to properly evaluate the various types of
hardware being offered;
d. A detailed overall schedule, sufficient to demonstrate the Contractor’s ability to perform the work to
meet the delivery and installation;
e. Certified type test reports;
f. Tentative QA Program and ISO 9001 or 9002 Certification;
g. Detailed list of all exceptions and/or deviations taken by the Contractor to the requirements of this
specification or, if none are taken, a statement indicating that no exceptions or deviations are taken by
the Contractor.
7.1.6.3 Data and Dr awings to be Fur nished After Awar d

b. Bill of materials and parts list or identifying drawings showing components;
c. Detailed hardware outline drawings;
e. Detailed QA Program based on ISO 9001 or 9002;
f. Detailed Project Progress and Performance Review (PPR) for the hardware;
g. As-built drawings as finally approved.

cation or shipment

cation or shipment
d Assembly/Component Drawings and
performance data With Tender Yes
e Special Tools and Equipment List With Tender Yes
f Design or Type Test Reports With Tender Yes
g List of standards used With Tender Yes
h Fabrication Sequence 45 days before fabrication No
j Notification of Factory Test 30 days before test No
j Packing and Storage 30 days before fabrication No
k Installation Instruction 30 days before shipment No
l. Documents for Records With shipment No
m Tests Reports 15 days after test Yes
T-S-08-001 STEEL TOWERS SP
T-S-08-001 STEEL TOWERS Rev. Draft
T-S-08-001 STEEL TOWERS
CONTENTS
8.1.1 SCOPE............................................................................................................................................3
8.1.1.1 General .......................................................................................................................................3
8.1.2.1 General .......................................................................................................................................3
8.1.3.1 Design.........................................................................................................................................4
8.1.3.1.1 General .................................................................................................................................................................. 4
8.1.3.1.2 Tower Types and Duties ........................................................................................................................................ 5
8.1.3.1.3 Clearance ............................................................................................................................................................... 5
8.1.3.1.4 Design, Wind and Weight Spans ........................................................................................................................... 5
8.1.3.1.5 Design Loads ......................................................................................................................................................... 5
8.1.3.1.6 Application Charts, Sag and Tension Charts ......................................................................................................... 6
8.1.3.1.7 Design of Steel Members ...................................................................................................................................... 6
8.1.3.1.8 Design of Connections .......................................................................................................................................... 6
8.1.3.1.9 Anti Vandal Bolts and Nuts ................................................................................................................................... 7
8.1.3.1.10 Design of Stub Angles in Concrete ................................................................................................................... 7
8.1.3.1.11 Body and Leg Extensions ................................................................................................................................. 7
8.1.3.1.12 Miscellaneous ................................................................................................................................................... 8
8.1.3.2 Material Requirements ...............................................................................................................8
8.1.3.2.1 Structural Steel ...................................................................................................................................................... 8
8.1.3.2.2 Bolts, Nuts and Washers........................................................................................................................................ 8
8.1.3.2.3 Guy Wires ............................................................................................................................................................. 9
8.1.3.2.4 Minimum Guy Breaking Strength ......................................................................................................................... 9
8.1.3.2.5 Guy Tests............................................................................................................................................................... 9
8.1.3.2.6 Marking of Guy Wires........................................................................................................................................... 9
8.1.3.3 Detailing and Fabrication .........................................................................................................10
8.1.3.3.1 General ................................................................................................................................................................ 10
8.1.3.3.2 Framing ............................................................................................................................................................... 10
8.1.3.3.3 Splices and Bolted Connections .......................................................................................................................... 10
8.1.3.3.4 Drilling and Punching.......................................................................................................................................... 11
8.1.3.3.5 Bending ............................................................................................................................................................... 11
8.1.3.3.6 Stub Angle Setting Templates ............................................................................................................................. 11
8.1.3.3.7 Welding ............................................................................................................................................................... 11
8.1.3.3.8 Field Connections ................................................................................................................................................ 12
8.1.3.3.9 Galvanizing ......................................................................................................................................................... 12
8.1.3.4 Tower Attachments ..................................................................................................................13
8.1.3.4.1 Conductor and Shield Wire Attachments ............................................................................................................ 13
8.1.3.4.2 Step Bolts ............................................................................................................................................................ 13
8.1.3.4.3 Notice Plates ........................................................................................................................................................ 13
8.1.3.4.4 Anti-Climbing Devices ........................................................................................................................................ 13
8.1.3.5 Shop Assembly and Inspection ................................................................................................13
8.1.3.6 Design Calculations ..................................................................................................................14
8.1.3.7 Drawings ..................................................................................................................................14
8.1.3.8 Marking ....................................................................................................................................14
8.1.3.9 Preparation for Shipping and Storage.......................................................................................15
8.1.3.10 Quality Assurance Requirement ...........................................................................................16
8.1.4 INSTALLATION .........................................................................................................................17
8.1.5 TESTS ..........................................................................................................................................17
8.1.5.1 General .....................................................................................................................................17
8.1.5.2 Material Tests ...........................................................................................................................17
8.1.5.3 Shop Tests ................................................................................................................................17
8.1.5.4 Load Testing (Full Scale Tower Test) ......................................................................................17
8.1.5.5 Mechanical Tests ......................................................................................................................18
8.1.5.6 Galvanizing Tests .....................................................................................................................18
8.1.5.7 Trial Assembly of Prototype Structures ...................................................................................18

8.1.6.1 General .....................................................................................................................................18
8.1.6.2 Data and Information to be Furnished with the Tender............................................................19
8.1.1 SCOPE
8.1.1.1 Gener al
This specification covers the technical and associated requirements for self-supporting and guyed lattice steel
towers for use in overhead transmission lines rated 88 kV and above. The towers shall be supplied complete
with structural steel works, guy wires, bolts, nuts, washers and miscellaneous fittings.
The Contractor shall bear full responsibility that the towers have been designed and manufactured in



8.1.2.1 Gener al
The specified material and services shall be furnished in accordance with, but not limited to, the following
codes and standards or to applicable equivalent standards of the country of the manufacturer, including all
addenda, in effect at the time of the purchase order, unless otherwise stated in this specification:
ASTM - American Society for Testing and Materials

A36-92 Standard Specification for Structural Steel
A123-89 Standard Specification for Zinc (Hot-Galvanized) Coatings on Products Fabricated from
Rolled, Pressed, and Forge Steel, Plates, Bars and Strips
A143-89 Recommended Practice for Safeguarding Against Embrittlement of Hot-Dip Galvanized
Structural Steel Product and Procedure for Detecting Embrittlement
A153-82 Standard Specification for Zinc Coating
A239-89 Standard Test Method for Locating the Thinnest Spot in a Zinc (galvanized) Coating of Iron
or Steel Articles by the Preece Test (Copper Sulphate Dip)
A325-93 Standard Specification for High-Strength Bolts for Structural Steel Joints, Including Suitable
Nuts and Plain Washers
A384-80 Recommended Practice for Safeguarding against Warpage and Distortion during Hot-dip
Galvanizing of Steel Assemblies
A394-93 Standard Specification for Galvanized Steel Transmission Tower Bolts and Nuts
A563-93 Standard Specification for Carbon and Alloy Steel Nuts
F436-82 Standard Specification for Hardened Steel Washers
AWS American Welding Society

D1.1-92 Structural Welding Code - Steel
A5.1-91 Specification for Carbon Steel Covered Arc-Welding Electrodes

A5.17-89 Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc-Welding
AZI American Zinc Institute

Inspection Manual for Hot - Dip Galvanized Products (Latest Edition)
ASCE American Society of Civil Engineers

ASCE Manual No.52, “Design of Steel Transmission Structures”

9001 Quality System Model for Quality Assurance in Design/Development, Manufacture and
Testing
SSPC Steel Structures Painting Council

“Good Painting Practice”, Steel Structures Painting Manual, Vol.1, Steel Structures Painting
Council
“Systems and Specifications”, Steel Structures Painting Manual, Vol.2, Steel Structures
Painting Council
specification.
It is the intent of this specification to allow supply of towers according to the standards specified in this
specification. If the Contractor customarily produces the specified towers of national standards other than
proposes to use in the supply of the specified towers.
8.1.3.1 Design
8.1.3.1.1 General
All designs are to be made in accordance with the information provided in this Specification, Technical
Schedules and on the accompanying Conceptual Drawings. All outline dimensions are fixed but where
no dimensions are given, the framing may be modified to suit the Contractor's design, subject to compliance
with all the requirements of the Specification.
The Contractor should aim at keeping the number of members to a minimum and the number of like
members to a maximum consistent with reasonable economy. Opposite faces of the towers shall be identical
but adjacent faces may be dissimilar.
The Contractor, at the Employer's request, shall explain and provide all the necessary information pertaining
to the design of any or all elements of the structure. In the event that the Contractor fails to provide
satisfactory explanations of any assumptions made in the designs, all modifications, which in the opinion of
the Employer are deemed necessary, shall be made at no extra cost to the Employer.
The tower structure components shall resist the design loadings and stresses not exceeding the yielding,
buckling, fracture, or any other limiting conditions specified in this specification and the applicable
standards.
8.1.3.1.2 Tower Types and Duties

The towers shall be of the types as stated in the Technical Schedules and on the Conceptual Design
Drawings.
The standard types of towers shall if required be designed so that the towers may be extended or reduced by
body and leg extensions of the height.
If, during the finalising of the line route, it is learned that special towers are required for some reason (e.g. to
cross over or under an existing transmission line) a modified tower from the range being supplied under the
Contract shall be used wherever possible. Such special towers may also be towers with reduced height, for
location on high spots. In such cases shortened towers may be necessary to minimise insulator swing out
problems in neighbouring towers.
A specially designed tower may only be used where circumstances are such that a modified standard tower
would be impracticable. The Contractor shall inform the Engineer immediately when the need for such a
tower becomes apparent.
Special towers, special foundations, special extensions and special parts for standard towers, shall be
provided where required and shall be of approved design. The type of tower to be used at each position shall
be approved by the Engineer.
8.1.3.1.3 Clearance
The structural framing shall be such as to maintain the clearances between conductor and steel as shown on
the drawings. The path of the conductors and jumpers should be accounted for when checking these
clearances.
8.1.3.1.4 Design, Wind and Weight Spans

The expression "span length" shall be taken to mean the horizontal distance between the centre lines of
adjacent towers.
The design, wind and weight span lengths shall be as stated in the Technical Schedules on which all-
standard tower heights, assuming level ground, shall be based.
8.1.3.1.5 Design Loads

The towers including all combinations of extensions shall be designed to withstand the loading conditions
stated in the Specifications and Technical Schedules.
The specified wind loads on towers shall be applied on twice the projected steel area of the front face. The
wind load shall be applied at suitable panel joints. The Contractor shall indicate on the design drawings the
magnitude and location of the wind forces assumed in the design.
Weight of and wind loads on insulators and hardware shall be included in the tower loadings.
Additional loads to which the towers may be subjected during the erection of towers themselves and of the
conductors and insulators shall be included.
All members placed horizontally or inclined not greater than 30 degrees shall be designed for a maintenance
load of 1.5 kN at the point which will produce the greatest stress in the member. This includes also members
in the cross-arms.
Secondary members shall be designed for a force resulting from 2.5 % of the load in the bar being restrained
assessed in accordance with the drawings.
The cross arm chord shall be designed for a ladder load of 4.5 kN at the adverse position combined with
either the stress produced by shield wire or conductor loads in erection and maintenance conditions.
8.1.3.1.6 Application Charts, Sag and Tension Charts

Charts showing how the various tower types can be applied during tower plotting, taking the provisions of
this specification, and such issues as wind/weight span combinations and angles, into account, shall be
supplied by the Contractor for approval by the Employer. This shall be submitted with the Tender.
Sag and tension charts for conductors and earth wires shall be submitted by the Contractor in good time for
examination and approval prior to commencement of stringing.
8.1.3.1.7 Design of Steel Members

Unless specified herein, design of tower members and connections shall comply with the requirements of
ASCE Manual 52 “Design of Latticed Steel Transmission Structures”.
Stresses in tension members shall be calculated from the net area after reduction for holes. In case of a single
angle member connected by one flange only, the net area shall be reduced by 10%. Allowable ultimate tensile
stress is equal to the yield point F y of the steel.
Redundant members supporting leg members or supporting other members shall be designed for a transverse
load at each node point of minimum 1.7% of the maximum load in the leg member or the other member
respectively.
Allowable stress in tension and compression on extreme fibres is equal to the yield point F y of the steel.
The ratio between unsupported length of a member and the relevant radius of gyration, L/r, shall not exceed:
1. Compression members L/r
- Leg members 120
- Other members 200
- Redundant members 250
2. Tension members 350
Minimum thickness of members shall be:
Open Section Closed Section
- Leg and main compression members in cross arms 6 mm 4 mm
and shield wire peak
- Members embedded in concrete foundations 8 mm 6 mm
- Other members 4 mm 3 mm
- Redundant members 3 mm 2.5 mm
- Gusset plates 6mm or minimum thickness of
connecting member
Maximum lengths of members shall not exceed twelve (12) meters.
8.1.3.1.8 Design of Connections

Bolts shall conform to the requirements as specified in this Specification.
Only three (3) diameters of connection bolts and two (2) thicknesses of washers shall be used on any one
type of tower and such sizes shall be maintained in all towers of the same type. All bolts of the same
diameter shall be of the same quality.
Connections shall be designed for bearing and shear in the plane of the threads, not friction.
Bolted connections may have one (1) bolt only.
Minimum bolt spacing is equal to three (3.0) times the bolt diameter.
Minimum distance from the centre of the bolt to an edge is equal to two (2.0) times the bolt diameter.
The distance from the centre of a bolt to the face of the outstanding flange of an angle or other members shall
be such as to permit the use of a socket wrench, in tightening the nut.
The bolt diameter shall be equal to the bolt diameter plus 1.5mm.
Minimum bolt diameter shall be twelve (12.0) mm.
Allowable ultimate bearing stress for bolts as well as members is equal to one (1.0) times the ultimate stress
F u of the steel.
Allowable ultimate shearing stress for bolts and members is equal to point six (0.6) times the yield point F y
of the steel.
Minimum thickness of washers shall be four (4.0) mm.
8.1.3.1.9 Anti Vandal Bolts and Nuts

If so decided by the Employer, the bolts/nuts up to and including the anti-climbing devices or to a specific
height stated in the Technical Schedules shall be of the anti-theft type. Prices of this option shall be quoted
under the appropriate items in the Schedules of Quantities.
8.1.3.1.10 Design of Stub Angles in Concrete

The stub angles shall have the same length for any height of tower of the same type and shall be placed with
the same slope as the tower legs. Stubs shall be provided with anchorage, which shall be designed in
accordance with the requirements of ASCE Manual 52, “Design of Latticed Steel Transmission Structures”.
8.1.3.1.11 Body and Leg Extensions

All standard types of towers shall if specified in the Technical Schedules be designed with body and leg
extensions so that the tower heights may be extended or reduced. These extensions shall be compatible with
and connect directly to the bottom of the basic body.
An extended tower shall be designated by the addition to its standard designation of the letter 'E' followed by
the height of the extension in metres and a reduced height of tower by the letter 'R' followed by the reduction
in metres.
Standard and extended towers shall be designed for and provided with independent single leg extensions for
use on steeply sloping ground.
Extensions and reductions shall be designed so that the towers with their foundations shall comply with all
the specified requirements for the standard height towers and foundations.
In the event of a tower design that removes basic leg extensions to install longer leg extensions, the
Contractor, in pricing the longer leg extensions in the Schedule of Quantities shall consider only the
incremental cost for the application of such longer leg extensions. The Employer reserves the right to procure
spare leg extensions (longer than the basic leg) computed as follows:
Ci × WLa
C=
WLa − WLo
where: C = Cost of applicable leg extension, CIF delivery point
Ci = Incremental cost of leg extension in "Supply Only" of Schedule of Quantities

WLa = Weight of applicable leg extension
WLo = Weight of basic leg extension
8.1.3.1.12 Miscellaneous
The design shall be such as to keep the number of different parts as small as possible and to facilitate
transport, erection and inspection.
All self-supporting towers shall have a square tower body with identical bracings in all four sides.
Horizontal members shall be placed wherever possible so that the horizontal flange is on the top. Pockets
and depressions likely to hold water shall be avoided and, if not avoidable, shall be properly drained.
Horizontal frames shall be provided at the top of the leg sections and the point of splices in the tower leg. If
required for rigidity, stability or other reasons, additional frames shall be provided at sections where
necessary.
Tension members shall not be made of flats or rods.
All double diagonal web-system members shall be connected at their point of intersection by at least one
bolt.
The holes necessary for accommodating the grounding counterpoise connections as specified shall be
provided on each leg of every tower and extension. Holes for all required number signs, danger signs, step
bolts, etc., shall be provided on each tower.
Approved means shall be provided on all towers and extensions to avoid risk of livestock being caught and
injured in the angles between tower members. Suspension towers shall be equipped with approved devices
immediately above each suspension insulator attachment point, to prevent the perching of birds at these
points.
8.1.3.2 Mater ial Requir ements
8.1.3.2.1 Structural Steel

Unless otherwise specified in the Technical Schedules and/or the Conceptual Design Drawings structural
steel members shall be fabricated from hot-rolled steel shapes with structural grade ASTM A36 or ASTM
A572 latest edition, and shall be detailed and fabricated in accordance with the AISC "Code of Standard
Practice for Steel Buildings and Bridges," and the AISC "Specification for Structural Steel for Buildings".
Flat bars and rods shall not be used as tower members.
Where high-strength steel is specified or proposed by the Contractor, precautions shall be taken by the
Contractor to ensure that the identity of high-strength steel is maintained throughout fabrication to avoid the
possible substitution of mild steel for the designated high-strength members.
The Contractor shall furnish properties for structural steel shapes. All structural members shall conform to a
standard dimensioning practice.
The total weight of structural steel shall be calculated in accordance with Section 9 of the AISC Code.
8.1.3.2.2 Bolts, Nuts and Washers

The quality of standard steel tower bolts and nuts shall be equivalent to ASTM Specifications A394 or A325.
All bolts shall have full length shanks, shall be furnished with regular hexagon heads and nuts with Class 2A
threads and dimensions before galvanizing shall conform to ANSI Specifications B18.2.1 for bolts and
B1.2.2 for nuts and shall be complete with one standard spring lock washer to ASA Specifications B27.1
1965. Nuts for A325 bolts shall be in accordance with ASTM-A563.
All U-bolts shall be complete with at least six (6) nuts.
8.1.3.2.3 Guy Wires

The guy wire shall be of extra high strength galvanised steel wires in accordance with ASTM A475. The zinc
coating shall be of Class A.
Guyed towers shall be complete with guys, guy wire make-offs and erection lugs. The guy wire make-offs
shall be of an approved type. If preformed guy grips are employed then the completed make-off assembly shall
include a compression fitting to prevent the unauthorised dismantling of the preformed guy grip. The
compression fitting shall be so located that the efficiency of the guy grip is unaffected and be made of suitable
material to prevent corrosion when it is coupled with the guy wire. The guy wire tail when it protrudes within
the loop of the preformed guy grip shall be securely clamped to the thimble of the make-off assembly.
Preformed guy grips shall be applied once only and if a grip is removed for any reason a new grip shall be
substituted.
The steel guy wires shall be preformed so that they remain inert and do not move relative to each other when
the guy wire is cut. Turnbuckles or other approved devices shall be provided in each guy wire for adjusting the
tension in the guy wires after erection and during maintenance. The Contractor shall provide a calibrated
measuring device so that the tension in the guy wires can be checked after erection.
8.1.3.2.4 Minimum Guy Breaking Strength

The minimum guy breaking strength shall be the greater of:
1) Maximum guy tension produced by governing transverse load divided by 0.7; or

2) Maximum guy tension produced by governing longitudinal load divided by 0.7
The modulus of elasticity shall be taken as 159GPa for steel stranded guy strands.
8.1.3.2.5 Guy Tests

Complete guy assemblies comprising support shackle, guy termination, guy wire (minimum length 5 m), guy
termination, guy adjustment device and guy anchor rod shall be subject to its specified minimum tensile
failing load for one minute. After maintaining the load for one minute, and if practical the complete guy
assembly shall be taken to failure and the mode of failure recorded. The Contractor shall give the Engineer
the requisite period of notice prior to undertaking the tests and shall submit to the Engineer a test programme
and procedure.
When required the Contractor shall determine the pre-tension required in the guys by undertaking a tensile
test on the guy and guy terminations. The minimum length of guywire shall not be less than 5 m. Both the
elastic-plastic extension of the guy and guy termination shall be measured separately. The results of the test
together with the Contractor’s pre-tensioning proposals shall be submitted to the Engineer.
Sample tests shall be carried out in accordance with the requirements of BS183.
8.1.3.2.6 Marking of Guy Wires

Guy markers are to be used for marking the guys of all guyed towers. The guy markers shall be made from
PVC or polyethylene material with ultra-violet inhibitors to enhance their life span.
The guy markers will need to be permanently attached to the guy wires under all weather conditions, including
veld fires.
8.1.3.3 Detailing and Fabr ication
8.1.3.3.1 General
Fabrication shall conform to the AISC Code of Standard Practice for Steel Building and Bridges and the
following additional requirements:
Deformed or bent material will not be accepted. Material that is deformed or bent to a minor degree shall not
be used unless straightened by methods acceptable to the Employer.
All copes, blocks, and other reentrant cuts shall have 13 mm minimum radius fillets.
Shearing shall be to gauge, with clean-cut edges and no variation in length beyond that noted on the shop
detail drawings. All bevel cutting shall be accurate, and a variation of more than 1.60 mm shall be cause for
rejection.
Punching shall be to gauge to ensure the accuracy demanded for this type of work. Only sharp dies and
punches shall be used, and burrs caused by work dies or punches will be cause for rejection. The centre-to-
centre distance between the end-holes of a piece shall not vary by more than 1.60 mm.
Where bending of members is required it shall be moderately sharp and true to the shop detail drawings.
When applicable, galvanizing assemblies shall conform to the recommended practices of ASTM A384.
8.1.3.3.2 Framing
Ease of assembling in the field is of utmost importance. All details shall be based on this consideration
wherever practicable.
Eccentric connections shall be avoided. Where it is economically impossible to eliminate eccentricities the
additional stresses introduced shall be accounted for in the stress calculations.
Redundant and mutual support systems utilized to provide joint restraints or reduce the unsupported lengths
of the members shall be framed in such a manner so that no reliance on the flexural rigidity of any member
shall be required.
8.1.3.3.3 Splices and Bolted Connections

Minimum bolt spacing, end and edge distances shall be as specified in this specification and otherwise
comply with the ASCE Design of Latticed Steel Transmission Structures.
All field connections shall be bolted and the shank of all bolts shall extend full size completely through the
connected members. Use of gusset plates should be kept to a minimum. The length of the bolts and threads
shall be such that bearing is upon the shank and not upon the thread. When installed, the bolt shall project
through the nut not less than 3mm and not more that 10mm. However, design shall be for shear in the plane of
threads. All bolts shall be fully tensioned.
Splices in all members shall be of the butt-splice or lap-splice type
Leg members of templates, if applicable, and towers shall lap on the outside of stub angles to facilitate
template removal and setting of pre-assembled towers where single stub-type legs are employed.
A leg splice shall be provided at the top of the first panel of the basic tower body and body extensions in
order that the leg extensions plus one panel may be assembled and erected to enable accurate setting of
grillage type foundations, if applicable.
Where angles are lap spliced, the heel of the inside angle shall be chamfered to clear the fillet of the outside
angle.
End connection of angle members shall be detailed in such a manner that blocking or flattening the
outstanding leg is not required.
Splices shall be as close as possible to a node point. In sloping or vertical members splices shall be above the
closest node point.
All bolts, nuts, ring fills and lock washers shall be furnished in excess of the actual number required in
quantity sufficient to compensate for normal field losses. The excess quantities shall be at least five per cent
(5%) greater than the actual requirements.
8.1.3.3.4 Drilling and Punching

Drilled or punched holes are acceptable for materials up to 12 mm in thickness. Materials over 12 mm in
thickness shall be drilled or sub-punched and reamed. All burrs left by the drill or punch shall be removed
completely.
Allowance shall be made in gauge dimensions on steel members for the thickness of subsequent galvanizing
and the possible formation of spelter fillets inside the angles so as to allow adequate erection clearance after
galvanizing.
Holes shall be accurately placed so that, except for tension members, no drifting will be necessary at site to
enable assembly.
8.1.3.3.5 Bending
All bending of pieces shall be done cold prior to galvanizing. However, hot bending where advisable, shall
be specified on the drawings. Any hot bending shall be done in such a manner that the full section shall be
maintained and so that the physical properties of the steel will not be impaired.
Bending of cross arm hanger bars is not permitted.
8.1.3.3.6 Stub Angle Setting Templates

Stub angle setting templates shall be furnished under these Specifications. They shall be made of galvanized
structural steel of the same quality as the towers. The setting templates for each type will be required for
setting the stub angles of each tower type together with any combination of body and leg extensions.
8.1.3.3.7 Welding
Unless otherwise specified herein, or note on the Employer's design drawings, welding shall conform to the
AISC Specification and welder and weld procedure qualifications shall be in accordance with AWS D1.1,
Section 5 "Qualifications". A written welding procedure specification as shown in Appendix E of AWS
D1.1 (Forms E-1, E-2 or E-3 as applicable) shall be prepared for each procedure and submitted for review
and acceptance by the Employer prior to use. Weld details on the Contractor's shop detail drawings shall
include identification of weld and method to be used for making the weld in accordance with AWS D1.1,
Section 2, "Design of Welded Connections", and Section 4, "Technique."
Welding electrodes shall be AWS A5.1, low hydrogen classification E70XX-EXXX, for submerged arc
welding, unless noted otherwise on Employer's design drawings. Where steel other than ASTM A36 is
specified electrode selection will be subject to acceptance by the Employer.
Fillet welds shall be full size and of proper profile for the full length specified on the Employer's design
drawings. Butt welds shall be full penetration welds, unless otherwise noted on the Employer's design
drawings. Preheat and interpass temperature requirements of AWS D1.1 Table 4.2 shall be followed. Welds
shall be visually examined to ensure that there are no slag inclusions, craters, cracks or undercuts in excess
of those permitted by AWS D1.1. Defects shall be removed in accordance with AWS D1.1, Section 3.7, and
then rewelded.
Care shall be taken in assembling and fitting, and welding shall be controlled to minimize shrinkage stresses
and distortion. All finished work shall be of good quality and have a neat appearance without warpage.
Caution shall be exercised to obtain full penetration welds where specified on Employer's design drawings.
Where specified on Employer's design drawings welds shall be made continuous by means of seal welds
between strength welds.
When inspection of a weld zone is called for on Employer's design drawings, procedures shall be in
accordance with the non-destructive testing procedures of AWS D1.1.
The final weld of a component designated for stress relief on Employer's design drawings shall be subjected
to ultrasonic inspection prior to and after stress relieving.
8.1.3.3.8 Field Connections

Field connections shall be assembled with galvanized bolts of a size and material specified on Employer's
technical requirements and design drawings.
Bolt lengths shall be selected so that members bear upon the shank and not upon the threads.
Plain or bevelled galvanized washers shall be provided at all connections and shall be in accordance with
ASTM F436.
Bolts, nuts, washers and palnuts shall be furnished with an excess over net requirements for each size,
varying with the quantities involved; 100 percent for 5 or less, 50 percent for 6 to 10, 25 percent for 11 to 30,
and 10 percent for 31 and greater.
8.1.3.3.9 Galvanizing
Unless otherwise specified in the Purchase Order, all structural steel shall be hot-dip galvanized after
fabrication in accordance with ASTM A123.
Fabrication and preparation of material for galvanizing shall conform to the requirements of ASTM A143.
When specified in Technical Requirements data sheets, embrittlement tests of designated galvanized material
shall be performed in accordance with ASTM A143.
Bolts, nuts and washers shall be galvanized in accordance with ASTM A153. Bolts and nuts shall be
assembled after galvanizing and shall fit with finger pressure only and nuts shall be interchangeable on any
bolt without shake. Wrench tightness or spinning fit shall be cause for rejection.
Only virgin zinc shall be used in galvanizing, and the use of remelted zinc is prohibited. Inspection of
galvanizing shall follow the procedures of the AZI Inspection Manual.
Heavy runs or lumps of excess zinc will not be acceptable in any area where they will interfere with bolt hole
alignment (such as the "drip end" of punched angle braces, etc.), with matching flat surfaces which are to be
bolted together, or are of such size and location that normal handling or erection may cause them to be
dislodged. Sharp, pointed, "stickers" of zinc, which could cause injuries in handling, shall be removed.
Straightening of steel after galvanizing shall be accomplished without the use of heat. Steel so straightened
shall be inspected to assure no delamination or cracking of galvanizing layer.
The zinc coating shall withstand the minimum number of dips of the Preece Test, according to ASTM
Specification A239.
Bolts shall be spun-galvanized and rechasing of bolt threads after galvanizing shall not be permitted. Nut
threads shall be tapped after galvanizing but not to cause appreciable rocking of the nuts to the bolts.
All steel works shall be dipped into a solution of dichromate after galvanizing for white rust protection.
Pipe, tubing or box sections shall not be double-dipped.
All materials shall be cleaned and washed after galvanizing to remove traces of flux, flux inclusions, preflux
salts, acid ash, dross or other extraneous materials. The presence of wet storage stain (White Rust) shall be
cause for rejection.
Small areas of damage to the galvanizing may be repaired with the acceptance of Employer. The repair shall
be made by thoroughly cleaning the damaged area and then applying a stick of powder type zinc repair
compound such as Galv-Weld or alternate acceptable to the Employer in accordance with the manufacturer's
instructions.
8.1.3.4 Tower Attachments
8.1.3.4.1 Conductor and Shield Wire Attachments

For the attachment of each suspension insulator string a U-bolt in line with the conductor suitable shackle or
hanger, permitted to swing longitudinally through 180 degrees shall be supplied.
For the attachment of each earth wire suspension clamp a U-bolt in line with the earth wire, or suitable
shackle, permitted to swing longitudinally through 180 degrees, shall be supplied.
For the attachment of each tension insulator string and shield wire tension clamp, a suitable uneven leg
shackle permitted to swing vertically, shall be supplied.
The conductor and shield wire tension attachments shall have a minimum strength horizontally and along the
direction of the line equivalent to the ultimate tensile strength of the conductor and the overhead earth wire,
respectively.
Besides the attachment points for the insulator strings and overhead earth-wires all towers shall have service
attachment points/holes for stringing and maintenance purposes.
8.1.3.4.2 Step Bolts

Each tower shall be provided with step bolts on one of the legs for single circuit tower and on two diagonally
opposite legs for double circuit tower from approximately 2.5 meters above ground level to the cross arm
and from thereon to each ground/earth wire peak. Step bolts shall be furnished for each leg extension in an
amount of 25% of the step bolt holes. These bolts shall not be less than 16 mm diameter, double nut type,
180 mm long with 35 mm diameter, symmetrical head, two hexagon nuts and spring washers, spaced not
more than 450 mm apart.
Each bolt shall withstand without permanent deformation a vertical load of at least 1.35 kN applied at the
bolt head.
8.1.3.4.3 Notice Plates

Conspicuous danger and property plates and also route and tower number plates of approved types vitreous
enamelled and resistant to fading under the climatic conditions at site, shall be provided and fixed in
approved positions on all towers. The route and tower number plates shall be attached centrally immediately
below the danger plate.
Phase plates of approved types (colour coded) to indicate the line conductor phases shall be provided for
each circuit and fixed in approved positions on all towers.
On longer transmission lines aerial number plates shall be provided and fixed in an approved position on the
earth wire peak(s) (opposite sides) of every tenth tower(or on the cross arm on lines without earth-wire
peaks).
Enamelled plates shall be provided with fibre washers, front and back, at the securing screws or bolts.
8.1.3.4.4 Anti-Climbing Devices

Each tower shall be fitted with anti-climbing devices of approved type, the component parts of which shall
be securely fixed to prevent pilferage shall be fixed at a height of approximately 3.5 metres above ground.
The position of the anti-climbing device on the tower shall be such that a standard device is used regardless
of the arrangement of tower body and leg extensions, which may be employed.
8.1.3.5 Shop Assembly and Inspection

All built-up assemblies shall be shop bolted complete with washers, after galvanizing, and shipped as a unit.
When specified in the Purchase Order, the Contractor shall completely assemble in the presence of the
Employer one (1) structure of each type before the first shipment of such structures. Any errors in the shop
detail drawings or shop work shown by this assembly shall be immediately corrected. The Contractor's
Tender shall include the work required for these shop assemblies.
Any material rejected by the Employer for failure to conform with this specification or the Purchase Order
shall be corrected or replaced by the Contractor. The fact that material has been inspected, or the Employer
has waived the right to inspect any material, shall not prevent rejection of the material if it is found not to be
in proper condition or to have fabrication inaccuracies preventing proper assembly.
8.1.3.6 Design Calculations

The Contractor shall perform complete design calculations of each tower and shall submit checked
calculations and drawings for the Employer's review and distribution in the quantity, manner and time set
forth in the this specification.
8.1.3.7 Dr awings
Three (3) sets of drawings shall be submitted to the Employer for approval.
The size and layout shall be in accordance with the General Technical Requirements.
These drawings shall show the following data and information for the towers listed in the technical
Schedules including body and leg extensions:
a) An outline drawing of the tower showing all basic design dimensions.
b) Electrical clearances. Note: Deflections of insulator sets shall be considered.
c) Specified loading conditions.
d) A tabulation of the calculations showing the design of each member, i.e. steel quality, angle size,
unsupported length, slenderness ratio, number and size of connection bolts required, ultimate strength of
each member in compression, tension, shear and bearing and maximum design load from the loading
conditions.
e) A tabulation form showing the design of the redundant members.
f) Wind loads on the tower at each point of application.
g) A tabulation showing the total stress in each member due to each specified ultimate loading case.
h) Stress diagrams or computer data so that the client can readily check the strength of the tower from the
loading conditions specified.
i) A detail of the conductor, earth wire and foundation attachments, including design calculations
j) The compression and reactions and corresponding horizontal shears for each governing load case.
k) All erection shop drawings shall show the members assembled in place, clearly indicating all dimensions,
the size, number and lengths of bolts required in each connection and the piece mark of each member.
l) A bill of materials shall be prepared in tabulation form, listing all material required for fabrication and
assembly of the tower including bolts, nuts, step bolts, packings and washers. The list shall show the
number of members required, the piece mark and the total weight of the body and each extension. For
purpose of computing member weights, a specific density of 7.85 grams per cubic centimetre of steel
shall be used. Deductions shall not be made for clippings and bolt holes. All weights shall be black
weights (ungalvanized).
m) Assembly drawings.
8.1.3.8 Mar king

All pieces shall be distinctively marked with erection marks clearly visible after galvanizing, corresponding
to those on the erection drawings. Additionally, all tower members shall be marked with "ZETDC" to
identify the same as the property of Zimbabwe Electricity Transmission and Distribution Company. Steel
stamping dies, minimum 16 mm high, shall be used and special care shall be taken to see that all erection
marks are made in such a manner as not to be obliterated in transit, or in any way damage the galvanizing or
impair the strength of the member.
In marking the members, each marking shall be prefixed by letters, which indicate the type of the tower. For
members that are used in more than one type of tower, all tower-type designations shall appear on the
marking.
In addition, the members shall be marked with water-proof ink stencil minimum 25 mm high after
galvanizing to ease logistics and erection of the towers.
The diameter and the length of bolts shall be marked on each bolt end so as to be visible after galvanizing.
An additional Contractor identification mark shall be stamped immediately in front of the piece identification
marks. This Contractor identification mark shall be submitted to the Employer for acceptance and
registration prior to first use.
When towers are fabricated from steel of different qualities, an applicable suffix shall be added to the piece
mark identifying the steel class.
Identification marks shall be located conspicuously to permit easy reading. Marking of like pieces shall be
identical in location, and pieces over four (4) metres in length shall be marked at both ends.
Identification marks shall be applied as follows:
Before galvanizing - stamp with 1.6 mm deep, 12 mm minimum height steel die letters and numerals. After
galvanizing neatly stencil a 6 mm wide straight line, to underline the identification marks, made with durable
paint or ink that will adhere to the galvanized surface and remain legible.
Either attaching die stamped steel tags or plastic tags with permanent markings shall identify all small items
that are not adaptable to die marking and are not boxed. The tags shall be attached with non-corrosive wire.

To facilitate segregation of tower parts at the stockyard and to maximize the efficiency of erection,
packaging of steel towers shall be as follows:
All tower parts, including stub angles, plates and tower part members shall be colour coded. The colour code
shall be painted on both ends of the tower parts for all angular members and around the edges for plates. The
colour codes shall be as specified in the Technical Schedules.
All stub angles shall be packaged per unit tower per type i.e., four (4) pieces per bundle.
All cleats including bolts and nuts with spring washers for stub angles shall be packaged per unit tower per
type in wooden boxes with corresponding colour code painted on all corners of the box.
All basic body towers shall be packaged per unit tower per type. Each package shall not exceed three (3)
metric tons. The contents of each package per unit tower per type shall be identical for any succeeding unit
type. The numbering of each package shall indicate tower type (basic), tower number and number of pieces
included in the package.
Example:
S1 -Basic/Tower No./Package No./Qty. in this package
S1 -Basic/ 1 of 200/ 2/ 8
All bolts and nuts with spring washers shall be packaged in tin cans or wooden boxes per unit tower per type
and numbered as follows:
Example:
S1 Bolts (Basic)/Tower No./Package No./Quantity
All plates and gussets for the basic tower shall be packaged in wooden boxes per unit tower per type and
numbered as follows:
Example:
S1 Plates (Basic)/Tower No./Package No./Quantity
All body extension tower parts shall be packaged per unit tower per type. The weight of each package shall
not be more than three (3) metric tons. The contents of each package per unit per tower shall be identical for
any succeeding unit tower. The numbering of each package shall indicate the tower type and extension
tower number, and number of pieces included in the package.
Example:
S1 3.0 Body Ext./Tower No./Package No./Quantity
S1 6.0 Body Ext./Tower No./Package No./Quantity
All bolts and nuts with washers and plates for the body extensions shall be packaged in wooden boxes per
unit tower per type and numbered as follows:
Example:
S1 3.0 Plates & Bolts/Tower No./Package No./Quantity
All tower parts/members shall be marked as indicated in the tower parts list. The markings shall be
embossed, the size of which will be approved by the Employer.
All package numbers for the steel tower shall be in label form. The size of the label shall be 5 cm x 10 cm.
The label shall be waterproof and all letterings on the label shall be printed. This label shall be attached on
every bundle of package. Each bundle or package shall have at least two (2) labels; each label to be visible
on each side of the bundle.
All bundles or packages for steel towers shall be properly strapped to avoid disintegration of the bundle
when subjected to unnecessary impact. The strap shall be properly placed so that the breakage of one (l) or
two (2) straps will not allow disintegration of the bundle or package.
Smaller pieces shall be bundled, with all the pieces in any bundle having the same mark.
All small pieces such as bolts and connections for ground/earth wire and insulators shall be packed in boxes
of not more than 70 kg gross weight each. Bolts of different size or length shall be wrapped in separate
sacks before boxing. Description, quantity, bolt size, and length shall be clearly marked on the outside of the
sacks and boxes.
When specified in the Purchase Order, bundling and packaging shall be in lots for each individual structure.
Boxes or other containers shall be clearly marked to indicate the type of tower for which the enclosed
material is intended, and the quantity and marks or description of contents shall be shown on the outside.
Shipping shall be as specified by the Purchase Order and shall be in complete tower lots. All identifications
shown on bundles, boxes or other containers shall be included on the Contractor's shipping and packaging
lists.
8.1.3.10 Quality Assur ance Requir ement

The Contractor shall have methods in place prior to starting work to assure that items and services, including
subcontracted items and services, comply with this specification.
Fabrication, processing, testing and inspection operations affecting the material will be subject to quality
assurance surveillance by the Employer.
Prior to production the Contractor shall submit to the Employer a fabrication sequence describing inspection
and/or tests to be performed, for use in determining inspection points which the Employer may desire to
witness. The Employer will advise the Contractor prior to production of those fabrication steps and shop
inspection points that the Employer desires to witness.
The Contractor shall give the Employer adequate notice, forty five (45) working days, minimum, prior to
those fabrication steps and tests, which the Employer desires to witness.
All deviations from this specification must be documented and referred to the Employer for resolution.
The Contractor shall furnish the following documents for the Employer's records:
a- A Certificate of Compliance stating the following: "All work provided under this
specification complies with all requirements of this specification and accepted deviations."
b- Documents identifying deviations and their acceptance.
c- Certified mill test reports
d- Welder and weld procedure qualifications
e- NDT procedures and test reports
f- Shop test reports
The provisions of the General Technical requirements shall apply.
8.1.4 INSTALLATION
8.1.5 TESTS
8.1.5.1 Gener al
Tests shall be carried out by the Contractor to the satisfaction of the Employer before shipment of the tower
materials. All materials shall comply with test criteria, and the Employer’s acceptance of the steel towers and
its components shall not relieve the Contractor of his responsibility for meeting all requirements of this
specification.
manufacture of steel towers and its components in accordance with the applicable standards mentioned
herein in the specification.
The steel towers and its components shall be given the manufacturer’s routine shop tests and quality
conformance tests and shall be witnessed by the Employer, if required in the Technical Schedules, unless
waived in writing. No towers or any of its components shall be shipped until released for shipment by the
Employer.
The Contractor shall make all preparations for tests and provide test apparatus and personnel and shall notify
the Employer, the date of the tests to be witnessed forty five (45) days in advance.
8.1.5.2 Mater ial Tests

The Contractor shall furnish three (3) copies of certified mill test reports covering chemical and mechanical
properties of the structural steel. Stock material may be used with the Employer’s concurrence where the
Contractor’s stock can be satisfactorily identified with the specified ASTM specification.
8.1.5.3 Shop Tests

The Contractor shall furnish a shop test report for the Employer’s review and records showing the results of
all tests made during fabrication.
8.1.5.4 Load Testing (Full Scale Tower Test)

If required by the Employer, one or more of each standard tower type complete with all extensions, step bolts
and anti-climbing devices shall undergo full scale testing in accordance with IEC Publication 60652
"Loading tests on overhead line towers", at the place of manufacture or at a testing station to be agreed upon.
The tower shall be erected on a rigid foundation and the vertical axis through the centre of gravity shall not
be out of centre by more than two tenths percent (0.2%) of the height at any level.
The members comprising the test tower shall be of the same grade material and class of fabrication as will be
used in the construction of the towers for the line.
The tower shall sustain the load including overloads specified in this specification. These loads shall be
applied in increments and shall be held constant for a period of five (5) minutes before increasing or
removing the loads.
In addition, the Employer shall request that a destruction test of the tower be carried out. The Employer shall
specify the loading case, which will be used for this test.
The Contractor shall submit for the Employer’s approval his proposed method and facilities of applying and
measuring the loads on the structure. The load measuring devices with appropriate numbering shall be
suitably calibrated prior to and following the test in accordance with the manufacturer’s recommendation in
the presence of the Employer’s representative(s).
Structure deflections under load shall be measured by suitable procedure at points designated. Deflection
readings shall be recorded for the “before- load” and “load-off” conditions.
The Contractor shall submit, forty five (45) days prior to the performance of the tests, his testing programs to
the Employer for review and approval. These shall include test procedures, diagrams or test arrangements
showing the points of location and magnitude of the loads to be applied, the designated points for deflection
measurements, etc.
The tests shall be carried out in the presence of the Employer or the Employer’s representative(s), who shall
conduct a visual check and evaluate all parts of the structure(s) for sign of failure following the completion
of each test.
After completion of the test(s), the test structure can be considered "failed" if the structure experienced any
of the following:
a) After the loads have been removed, the tower structure does not return to its original position within
reasonable tolerance;
b) Failure (i.e. bending, yielding, breaking, etc.) of the material or weld is detected; and
c) Test structure does not pass all physical and dimensional checks as required in the Quality
Conformance and Acceptance Test specified in this specification.
Such a failure shall be corrected and tested at the Contractor’s expense.
The test reports shall include all the required documents according to the IEC publication 60652.
8.1.5.5 Mechanical Tests

Mechanical tests on the material used in the fabrication of the structures shall include ultimate tensile
strength, yield strength and elongation. Mill certificates, if available, may be supplied in lieu of these tests.
8.1.5.6 Galvanizing Tests

Galvanizing tests shall be carried out according to the latest ASTM Specifications A123, A143, A153 and
A239 on the structural shapes, bolts, nuts and other small miscellaneous hard wares.
8.1.5.7 Tr ial Assembly of Pr ototype Str uctur es

A trial assembly of each type of tower and extensions shall be made in a horizontal position on the ground.
8.1.6.1 Gener al
8.1.6.2 Data and Information to be Fur nished with the Tender

a. Filled-in technical data of the Technical Data Sheets;
b. Certified mill test reports;
c. Description and outline drawings of proposed structures including configuration, member shapes,
sizes and material thickness, materials and dimensions of all major components, anticipated
deflections and representative connection details;
d. Description of design calculations to be performed and buckling criteria to be used;
e. Reference lists;
f. Pamphlets and literature of the proposed steel towers and components to be furnished;
g. Proposed time bar schedule to meet delivery date of the steel towers and its components;
h. ISO 9001 Certification;
i. Tentative Quality Control procedures and qualifications, and non-destructive testing to be
performed;
j. Estimated weight of each type of tower including body extensions.
a. List of Drawings and schedules of submittals;
b. List of Codes used;
c. The final design calculations showing design assumptions, analysis, joint fixity, foundation fixity,
eccentricities induced to structure deflections and assumptions and computations used to determine
radius of gyration and other critical sections;
d. Foundation drawings for each type of tower;
e. Maximum moments, shears, axial loads and member section modules required and furnished for at
least every 6.0 m length, and at base, joints, splices and other critical sections;
f. Chart and sag templates;
g. Detailed assembly and fabrication drawings;
h. Bill of materials and parts list for each type of tower;
i. Weights of each section and components of each type of tower including summary of total weights
for each type of tower;
j. Test Reports;
k. Calculations of stresses in base plates, attachment connections, anchor bolts and moment
connections;
l. Stress analysis for all connections showing stress distribution against wall buckling or puncture;
m. Maximum horizontal and vertical deflection at top of structure, at shield wire and conductor
attachments, and at cross arm joints.
n. Detailed QA Program based on ISO 9001.
Erection drawings shall each show only one (1) structure with its component parts, and each piece shall have
an identification mark. The number and length of bolts, with type of washer, nuts and locknut required for
the assembly shall be shown at each connection. A complete list of material listing quantities of all material
required for the structure or part structure shown, including bolts, nuts, locknuts, washers shall be shown on
the Contractors’/Supplier’s shop detail drawings. The bill of material shall include the quantity of pieces
required, mark number, description, size, length, weight and total weight of material shown on the drawing,
and the reference drawing on which the member is detailed.
Shop detail drawings shall show each individual member’s dimensions and tolerances, welding
requirements, connections, identification mark, quantities, material designation, surface treatment, and a bill
of material.
The Contractor/Supplier shall furnish in the manner, number of copies and within the time set forth in the
Contract, instruction manuals in accordance with the requirements of the General Technical Requirements.
The Contractor/Supplier shall furnish information indicating recommended maintenance practice,
approximate time required for routine maintenance, and tools required for maintenance.
The Contractor/Supplier shall provide the required installation instructions and technical data for proper
installation.

cation or shipment
d List of drawings and its schedule of of 60 days after Effective date of
Yes
submittals Contract
e Detailed outline drawings including detail 60 days after Effective date of
Yes
design report and calculations Contract
f Drawings certified for Erection and 120 days after Effective date
Yes
Construction of Contract
i Notification of Factory Test 30 days before test No
j Procedures, Packing and Storage 30 days before fabrication No
k Installation Instruction Manual 30 days before shipment No
l Documents for Records With shipment No
T-S-08-002 STEEL POLES SP
T-S-08-002 STEEL POLES Rev. Draft
T-S-08-002 STEEL POLES
CONTENTS
8.2.1 SCOPE............................................................................................................................................2
8.2.1.1 General .......................................................................................................................................2
8.2.2.1 General .......................................................................................................................................2
8.2.3.1 Design.........................................................................................................................................4
8.2.3.2 Materials .....................................................................................................................................6
8.2.3.3 Detailing .....................................................................................................................................7
8.2.3.4 Fabrication ..................................................................................................................................7
8.2.3.5 Material Preparation ...................................................................................................................9
8.2.3.6 Welding ......................................................................................................................................9
8.2.3.7 Surface Preparation and Painting .............................................................................................10
8.2.3.8 Preparation for Shipping and Storage.......................................................................................11
8.2.3.9 Marking ....................................................................................................................................11
8.2.3.10 Quality Assurance Requirement ...........................................................................................12
8.2.4 INSTALLATION .........................................................................................................................12
8.2.5 TESTS ..........................................................................................................................................12
8.2.5.1 General .....................................................................................................................................12
8.2.5.2 Material Tests ...........................................................................................................................13
8.2.5.3 Shop Tests ................................................................................................................................13
8.2.5.4 Quality Conformance Inspection ..............................................................................................13
8.2.5.5 Load Testing (Full Scale Pole Test ) ........................................................................................14
8.2.6.1 General .....................................................................................................................................14
8.2.6.2 Data and Information to be Furnished with Tender .................................................................14
8.2.1 SCOPE
8.2.1.1 Gener al
This specification covers the technical and associated requirements for tubular steel pole type of transmission
structures for use in overhead transmission lines rated 88 kV and above. The structures shall be supplied
complete with structural steel works, bolts, nuts, washers and miscellaneous fittings.
The Contractor shall bear full responsibility that the pole structures have been designed and manufactured in
accordance with all standards and applicable regulations and perform under the condition and to the



8.2.2.1 Gener al
The specified material and services shall be furnished in accordance with, but not limited to, the following
codes and standards or to applicable equivalent standards of the country of the manufacturer, including all
addenda, in effect at the time of the purchase order, unless otherwise stated in this specification:
ASTM - American Society for Testing and Materials

A36/A36M Standard Specification for Structural Steel, Book 01.04
A123 Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products, Book
01.06, 15.08.
A143-89 Recommended Practice for Safeguarding Against Embrittlement of Hot Dip Galvanized
Structural Steel Products and Procedure for Detecting Embrittlement
A153 Specification for Zinc Coating (Hot Dip) on Iron and Steel Hardware, Book 01.06.15.08.
A239-89 Standard Test Method for Locating the Thinnest Spot in a Zinc (Galvanized) Coating of Iron
or Steel Articles by the Preece Test (Copper Sulphate Dip)
A307 Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile, Book 01.01,
15.08
A325 Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile
Strength, Book 15.08
A354 Specification for Quenched and Tempered Alloy Steel Bolts, Studs and Other Externally
Threaded Fasteners
A370 Test Methods and Definitions for Mechanical Testing of Steel Products
A384 Recommended Practice for Safeguarding against Warpage and Distortion during Hot-dip
Galvanizing of Steel Assemblies
A394 Standard Specification for Galvanized Steel Transmission Tower Bolts and Nuts
A435 Standard Specification for Straight Beam Ultrasonic Examination of Steel Plates for
Pressure Vessels
A449 Specification for Quench and Tempered Steel Bolts and Studs
A490 Specification for Heat Treated, Steel Structural Bolts, 150 ksi (1035 Mpa) Tensile Strength
A563 Specification for Carbon and Alloy Steel Nuts
A572/A573M Specification for High-Strength Low Alloy Columbium-Vanadium Steels of Structural
Quality
A588/A588M Specification for High Strength Low-Alloy Structural Steel with 50 ksi (345 Mpa) Minimum
Yield Point to 4 in. (100mm) Thick
A615 Standard Specification for Deformed and Plain Billet Steel Bars for Concrete Reinforcement
A633/A633M Specification for Normalized High Strength Low Alloy Structural Steel
A673/A673M Specification for Sampling Procedure for Impact Testing of Structural Steel
A687 Specification for High Strength Non-Headed Steel Bolts and Studs
A780 Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings
A871/A871M Specification for High Strength Low Alloy Structural Steel Plate with Atmospheric
Corrosion Resistance
F436-82 Standard Specification for Hardened Steel Washers
AWS American Welding Society

D1.1-92 Structural Welding Code - Steel
A5.1-91 Specification for Carbon Steel Covered Arc-Welding Electrodes
A5.17-89 Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc-Welding
AZI American Zinc Institute

Inspection Manual for Hot - Dip Galvanized Products (Latest Edition)
ASCE American Society of Civil Engineers

ASCE Manual No.72, “Design of Steel Transmission Pole Structures”, Second Edition, 1990

9001 Quality System Model for Quality Assurance in Design/Development, Manufacture and
Testing
NEMA National Electrical Manufacturers Association

No. TT-1 Tapered Tubular Steel Structures
SG-6 Part 36 Outdoor Substations (Structures, Pole Top Frame, etc.)
SSPC Steel Structures Painting Council

“Good Painting Practice”, Steel Structures Painting Manual, Vol.1, Steel Structures Painting
Council
“Systems and Specifications”, Steel Structures Painting Manual, Vol.2, Steel Structures
Painting Council
specification.
It is the intent of this specification to allow supply of poles according to the standards specified in this
specification. If the Contractor customarily produces the specified poles of national standards other than
proposes to use in the supply of the specified poles.
8.2.3.1 Design
8.2.3.1.1 General
All designs are to be made in accordance with the information provided in this Specification, Technical
Schedules and on the accompanying Conceptual Drawings. All outline dimensions are fixed but where no
dimensions are given, modifications can be made to suit the Contractor’s design, subject to compliance with
all the requirements of the specification.
The structure design calculations shall be the responsibility of the Contractor. It shall be designed for the
configuration, loadings and limitations provided elsewhere in the tender documents.
The Contractor, at the Employer’s request, shall explain and provide all the necessary information pertaining
to the design of any or all elements of the structure. In the event that the Contractor fails to provide
satisfactory explanations of any assumptions made in the designs, all modifications, which in the opinion of
the Employer are deemed necessary, shall be made at no extra cost to the Employer.
Wind pressures specified and clearances are based on members of circular cross section. Values shall be
adjusted by the Contractor as necessary to reflect the shape factor of the tubular sections actually furnished.
Structures shall be designed so that member unit stress does not exceed the yield point stress of the material.
The ratio of major axis of tubular diameter to wall thickness shall be such that local buckling does not govern
member design. Structure deflections shall conform to NEMA Standard Publication No. SG-6-Part 36 and
deflections shall be based on net loads.
Columns shall have a welded base drilled to fit the foundation anchor bolt pattern.
Columns shall be either circular in cross section or polygonal with a minimum of eight sides, and shall be
tapered from top to the base.
The crossarm member shall be of the same cross section as columns, with taper and upsweep conforming to
the Employer’s general arrangement drawings. The strength of the attachment of crossarms to the columns
shall be sufficient to develop the full capability of the crossarm.
The tensile stress perpendicular to the grain of steel specified for rolled plates shall not exceed 235 N/mm2
regardless of the published or actual yield strength of the material.
Members requiring more than one length of tubular section shall be constructed by telescoping the sections
together with sufficient overlap to develop the full strength of the member. Minimum overlap shall be 1.5
times the tubular diameter for each section. Alternative methods may be recommended by Contractor and
submitted to the Employer for consideration and possible acceptance.
Where a splice can develop tension, as in rigid frames, it shall be provided with a positive bolted connection
so that the elevations between adjacent rigid frame columns can be maintained.
Members that are to be painted shall be constructed of plates appropriately shaped to form a hermetically
sealed tubular section having a constant taper. Hermetically sealed units are not required for galvanized
tubular sections.
Rigging accessories, insulator attachment plates, ladder and lighting brackets, and hand line attachments
shall be welded to the structure.
The allowable bond stress on anchor bolts shall be compared in accordance with ACI 318. The allowable
concrete compressive stress shall be as specified in the Foundation Specifications. Anchor bolts shall be
designed to transfer the load to the foundation without the use of grout under the base plate.
8.2.3.1.2 Pole Types and Duties

The poles shall be of the types as stated in the Technical Schedules and on the Conceptual Design
Drawings.
The standard types of poles shall if required be designed so that the poles may be extended or reduced by
extensions of the height.
If, during the finalising of the line route, it is learned that special poles are required for some reason (e.g. to
cross over or under an existing transmission line) a modified pole from the range being supplied under the
Contract shall be used wherever possible. Such special poles may also be poles with reduced height, for
location on high spots. In such cases shortened poles may be necessary to minimise insulator swing out
problems in neighbouring poles.
A specially designed pole may only be used where circumstances are such that a modified standard pole
would be impracticable. The Contractor shall inform the Employer/Engineer immediately when the need for
such a pole becomes apparent.
Special poles, special foundations, special extensions and special parts for standard poles, shall be provided
where required and shall be of approved design. The type of pole to be used at each position shall be
approved by the Employer/Engineer.
8.2.3.1.3 Design, Wind and Weight Spans

The expression "span length" shall be taken to mean the horizontal distance between the centre lines of
adjacent poles.
The design, wind and weight span lengths shall be as stated in the Technical Schedules on which all
standard pole heights, assuming level ground, shall be based.
8.2.3.1.4 Clearance
The structural framing shall be such as to maintain the clearances between conductor and steel as shown on
the drawings. The path of the conductors and jumpers should be accounted for when checking these
clearances.
8.2.3.1.5 Design Loads

The steel pole shall be designed to withstand the loading conditions shown in these Specifications
The specified wind load on the steel pole shall be applied on twice the projected steel area of the front face.
The wind load shall be applied throughout the exposed length of steel pole. The Contractor shall indicate on
the design drawings the magnitude and the location of the wind forces assumed in the design.
Weight of and wind loads on insulators and hardware shall be included in the tower loadings.
Additional loads to which the towers may be subjected during the erection of towers themselves and of the
conductors and insulators shall be included.
8.2.3.1.6 Application Charts, Sag and Tension Charts

Charts showing how the various tower types can be applied during tower plotting, taking the provisions of
this specification, and such issues as wind/weight span combinations and angles, into account, shall be
supplied by the Contractor for approval by the Employer. This shall be submitted with the Tender.
Sag and tension charts for conductors and earth wires shall be submitted by the Contractor in good time for
examination and approval prior to commencement of stringing.
8.2.3.1.7 Analysis
Elastic methods of analysis shall be used. Stability shall be provided for the structure as a whole and for each
structural element. The load effects resulting from the deflected shape of the structure and individual
elements shall be considered.
The analysis shall include all structural members (including interpole ties, bracings and guys, if required) in
their actual, manufactured geometry and sizes. When values for the following are specified in the tender
documents, the analysis shall include: differences in support elevation, support movement and erection
tolerances.
8.2.3.1.8 Allowable Stresses

The allowable stresses for tubular members, guys and connection bolts shall comply with the requirements of
ASCE Manual 72, Design of Steel Transmission Pole Structures.
8.2.3.2 Mater ials
8.2.3.2.1 General
All materials shall comply with the requirements of an ASTM specification unless otherwise specified.
Material to be welded shall comply with the requirements of ANSI/AWS D1.1.
8.2.3.2.2 Structural Plate

Plate and “product of a coil” that is used to produce load carrying components shall be considered a
structural plate. Material used for grounding plates, identification plates, pole caps, disposable cage plates
and similar components does not need to be classified as structural plates.
Structural plates less than or equal to 32 mm in thickness shall conform to ASTM A36, ASTM A572 or
ASTM A871.
Structural plates greater than 32 mm in thickness shall conform to ASTM A36, ASTM A633 or ASTM
A871.
Structural plate materials shall meet the Charpy impact requirements of this Specification.
The silicon content of plate to be galvanized shall be limited to the following:
Shaft material: Si < 0.06%
Other: Si < 0.06% or 0.15% < Si < 0.40%
8.2.3.2.3 Bolts, Nuts and Washers

Material for anchor bolts shall conform to ASTM A615 Gr 75 and shall meet the Charpy impact
requirements of this Specification and shall be galvanized in accordance with ASTM A153.
Material for headed bolts shall conform to: ASTM A307, ASTM A325, ASTM A490 or ASTM A449 when
bolt diameter exceeds 38 mm and shall be galvanized in accordance with ASTM A153.
Threaded rod shall conform to ASTM A36, ASTM A354, ASTM A449, ASTM A588 or ASTM A687.
Nuts shall conform to ASTM A563.
Washers shall conform to ASTM F436.
8.2.3.2.4 Charpy Impact Requirements

Charpy impact properties shall be determined in accordance with ASTM A370 and A673.
8.2.3.2.5 Weld Material

The material used for making welds shall be compatible with the parent material, as defined by ANSI/AWS
D1.1-92 and shall meet the impact requirements specified in this Specification for the lowest toughness
requirements of the plates being joined.
8.2.3.3 Detailing
8.2.3.3.1 Typical Details

Telescoping splices joining sections (slip joints) shall be designed to assure a minimum lap of 1.5 times the
largest inside diameter of the outer section.
Circumferential Welds
Shaft-to-shaft, pole shaft-to-base plate, and pole shaft-to-flange shall be full penetration welds.
Arm shaft-to-arm bracket shall be partial penetration groove weld with fillet overlay, sized to develop the
full strength of the shaft.
Others (lugs and plates for grounding, jacking, climbing and identification) shall be fillet and/or groove
welds sized to develop the loading requirements of the attachment.
Longitudinal Welds
Longitudinal welds in the outer section of slip joints and within 76 mm of a full penetration weld shall be full
penetration.
Longitudinal welds shall be a minimum of 80% penetration in other locations.
Conductor plate attachment weld shall be full penetration weld.
Bolt holes
Bolt holes shall have a maximum diameter of:
- anchor bolt diameter + 9.7 mm
- other bolt diameter + 3.3 mm
Anchor bolts shall be caged.
Plate Bends
The minimum inside radius of plate bends shall be such that cracking does not occur. Care must be taken to
prevent the steel from cracking especially at the free ends of the bend either during the bending operation or
subsequently due to residual stresses.
8.2.3.4 Fabr ication
8.2.3.4.1 General
Fabrication shall be performed in strict compliance with the Employer’s approved shop detail drawings.
Material substitution or deviations from the final approved drawings shall not be made without written
approval from the Employer.
The manufacturer shall accurately identify all material to assure proper usage.
8.2.3.4.2 Pole Shaft

The pole shaft shall present the most pleasing appearance possible consistent with the strength requirements
in the specification and drawings. Poles shall be continuously tapered from top to bottom with a uniform
slope. No multi-ply steel plates will be allowed for the pole structure fabrication. Shafts shall be made with
the number of sections specified in the Technical Schedules.
The cross section of the pole shall be as stated in the Technical Schedules with all sides equal. Shaft
diameter of a fabricated section should not be less than the design diameter.
8.2.3.4.3 Pole Slip Joint

Pole sections shall be made with telescopic slip joints for easy assembly either in air or on the ground at the
construction site. Overlapping shall not be less than one and a half (1.5) times the largest inside diameter of
the female section.
The taper of each section at a slip joint should match the taper of the adjacent section to provide proper
splice tolerances. No circumferential weld within a shaft section shall be permitted. Other types of
connection will not be permitted.
8.2.3.4.4 Insulator Attachment

Attachment for insulator assembly to the pole shaft shall also be provided and shall be made compatible with
the type of insulator support to be installed.
8.2.3.4.5 Anchorage
Poles shall be furnished for concrete anchor base construction. Minimum compressive strength of concrete
shall be as stated in the Foundation Specifications.
8.2.3.4.6 Base Plate

The base plate shall be made of steel and welded to the pole at the factory. The thickness of the base plate
shall be suitable for the required length and strength of the pole.
8.2.3.4.7 Anchor Bolts and Cluster

Anchor bolts shall be straight without a hook or bent at the bottom. In order to set the anchor bolts properly,
for each set of anchor bolts two (2) templates (one at the top and at the bottom) shall be furnished that will
hold the anchor bolts in a rigid position cluster while concrete is being poured.
The templates shall be fabricated to allow an unobstructed opening through the centre. This is to permit the
use of a tremie for the placing of the concrete. This opening shall be a minimum of 300 mm, in order to
receive the set of double templates.
8.2.3.4.8 Crossarms
Crossarms shall be furnished with hoisting lugs to facilitate line construction and maintenance.
8.2.3.4.9 Other Pole Attachments

Step Bolts or Climbing Device
Each pole shall be provided with permanent lugs for removable step bolts from approximately 2.5 meters
above ground level to the pole cross arm and from thereon to the ground/earth wire peak. These shall be
secured in place to prevent undesired lifting by hand lines, etc.
The step bolts shall be not less than 16 mm diameter, 180 mm long with 35 mm diameter, symmetrical head,
spaced not more than 450 mm apart. The bolts shall withstand without permanent deformation a vertical load
of at least 137 kg applied at the bolt head.
Notice Plates and Open Holes
Conspicuous danger and property plates and also route and pole number plates of approved types vitreous
enamelled and resistant to fading under the climatic conditions at site, shall be provided and fixed in
approved positions on all poles. The route and pole number plates shall be attached centrally immediately
below the danger plate.
Phase plates of approved types (colour coded) to indicate the line conductor phases shall be provided for
each circuit and fixed in approved positions on all poles.
On longer transmission lines aerial number plates (one on each side) shall be provided and fixed in an
approved position on the top of every tenth pole.
Enamelled plates shall be provided with fibre washers, front and back, at the securing screws or bolts.
Grounding/Earthwire Provision
Grounding clamps or nuts suitable for the size of ground/earth wire specified in the Technical Specifications
for grounding/earthing shall be provided near the top and base of each pole. The wire lug shall be welded to
the exterior of all tubular column sections near the top and the base for grounding/earthing, in addition to any
other ground/earth wire requirements shown on the Employer’s general arrangement drawing.
8.2.3.4.10 Anti-Climbing Devices

If stated in the Technical Schedules each pole shall be fitted with anti-climbing devices of approved type,
the component parts of which shall be securely fixed to prevent pilferage shall be fixed at a height of
approximately 3.5 metres above ground. The position of the anti-climbing device on the pole shall be such
that a standard device is used regardless of the pole extensions, which may be employed.
8.2.3.5 Mater ial Pr epar ation

Edges shall be in accordance with ANSI/AWS D1.1. Burrs or sharp notches that may be detrimental to the
structure or that pose a safety hazard shall be removed. Re-entry cuts shall be rounded.
Care shall be taken to prevent separation of the outer surface and reduction of the cross sectional properties
below those required by design. If separation occurs during bending, it shall be repaired in accordance with
ANSI/AWS D1.1. Mill scale shall not be considered as the surface.
When hot bending is required, heating shall be done evenly over the entire bend area and shall be of
sufficient temperature to minimize separation and necking down of the cross section. The temperature used
in hot bending shall be such that the physical properties of the steel are not diminished.
All components shall be clearly marked by stamping. Stamped marks shall be a minimum of 12.7 mm high
letters, made prior to finish coating, and readable after coating.
8.2.3.6 Welding
Unless otherwise specified herein, or noted on the Employer’s design drawings, welding shall conform to the
AISC Specification and welder and weld procedure qualifications shall be in accordance with AWS D1.1,
Section 5 “ Qualifications”. A written welding procedure specification shall be prepared for each procedure
and submitted for review and acceptance by the Employer prior to use. Weld details on the Contractor’s shop
detail drawings shall include identification of weld and method to be used for making the weld in accordance
with AWS D1.1, Section 2, “Design of Welded Connections”, and Section 4, Technique.
Preheat and interpass temperature of AWS D1.1 shall be followed. Welding shall be done by the shield
metal-arc, gas shielded flux core, gas shield metal-arc or submerged-arc processes. Welding electrodes shall
be AWS A5.1, low hydrogen classification E70XX-EXXX, for submerged arc welding, unless noted
otherwise on the Employer’s design drawings. Where steel other than ASTM A36 is specified electrode
selection will be subject to acceptance by the Employer.
The storage of welding consumables (welding wire, electrodes, fluxes and gases) shall be in accordance with
AWS D1.1 and the welding consumables manufacturer’s recommendations.
Care shall be taken in assembling and fitting, and welding shall be controlled to minimize shrinkage stresses
and distortion. All finished work shall be of good quality and have a neat appearance without warpage.
Caution shall be exercised to obtain full penetration welds where specified on the Employer’s design
drawings.
When inspection of a weld zone is called for on the Employer’s design drawings, procedures shall be in
accordance with non-destructive testing procedures of AWS D1.1 and the following additional requirements:
Circumferential and longitudinal welds within the slip joint area of tubular sections shall be shear wave
ultrasonically inspected in accordance with NEMA No. TT-1.
Longitudinal welds in tubular sections, which do not meet the acceptance criteria of visual inspection, shall
be magnetic particle or dye penetrant tested.
Base plate fillet welds shall be ultrasonically inspected prior to and after galvanizing or painting in
accordance with NEMA No. TT-1.
Attachment welds shall be examined by magnetic particle or dye penetrant testing in accordance with AWS
D1.1.
The Contractor shall furnish a shop test report indicating complete test results of all non-destructive testing
and inspection conducted.
The final weld of a component designated for stress relief on the Employer’s design drawings shall be
subjected to ultrasonic inspection prior to and after stress relieving.
8.2.3.7 Sur face Pr epar ation and Painting
8.2.3.7.1 Galvanizing
Unless otherwise specified, all structural steel shall be hot-dip galvanized after fabrication in accordance
with ASTM A123. SSPC SP8 surface preparation will proceed galvanizing. Exposed welds shall be
mechanically cleaned.
Fabrication and preparation of material for galvanizing shall conform to the requirements of ASTM A143.
When specified in the Technical Schedules, embrittlement test of designated galvanized material shall be
performed in accordance with ASTM A143.
Bolts, nuts and washers shall be galvanized in accordance with ASTM A153. Bolts and nuts shall be
assembled after galvanizing and shall fit with finger pressure only and nuts shall be interchangeable on any
bolts without shake. Wrench tightness or spinning fit shall be cause for rejection.
All anchor bolts shall be galvanized for the threaded length plus 152.4 mm.
Repair of damaged hot dip galvanized surfaces shall be in accordance with ASTM A780.
Only virgin zinc shall be used in galvanizing, and the use of re-melted zinc is prohibited. Inspection of
galvanizing shall follow the procedures of the AZI Inspection Manual.
Heavy runs or lumps of excess zinc will not be acceptable in any area where they will interfere with bolt hole
alignment (such as the “drip end” of punched angle braces, etc.), with matching flat surfaces which are to be
bolted together, or are of such size and location that normal handling or erection may cause them to be
dislodged. Sharp, pointed, “stickers” of zinc, which could cause injuries in handling, shall be removed.
Straightening of steel after galvanizing shall be accomplished without the use of heat. Steel so straightened
shall be inspected to assure no deformation or cracking of galvanizing layer.
The zinc coating shall withstand the minimum number of dips of the Preece Test, according to ASTM A329.
Bolts shall be spun-galvanized and rechasing of bolt threads after galvanizing shall not be permitted. Nut
threads shall be tapped after galvanizing but not to cause appreciable rocking of the nuts to the bolts.
All materials shall be cleaned and washed after galvanizing to remove traces of flux, flux inclusions, preflux
slats, acid ash, dross or other extraneous materials. The presence of wet storage stain (White Rust) shall be
cause for rejection.
Pipe, tubing or box sections shall not be double-dipped.
8.2.3.7.2 Painting
When a painted finish is specified, the paint shall be environmentally friendly, with high solids content, low
Volatile Organic Compounds, and within toxic acceptable levels.
Only the following materials will be acceptable in the formulation of the paint system:
- Triglycidyl Isocyanurate (TGIC) or Urethane polyester powder
- Two-component Organic Zinc-Rich Urethane liquid
- Zinc Rich Epoxy powder
- Two-component Polyamidoamine Epoxy liquid
- Two-component Acrylic Aliphatic Poly -Urethane liquid
- Two-component Tar-Extended Polyurethane Liquid with Pre-catalyzed one component Polyurethane
resin (touch-up)
The paint system formulation shall be agreed upon between the Employer and the Contractor before
acceptance of the purchase order and will be clearly stated on the purchase order.
The Contractor shall furnish as part of the scope of supply for the poles touch-up material with each type of
pole structure.

Each shipment shall include a detailed packing list identifying all items by part number, including hardware.
Special care shall be exercised in the handling, packaging and shipping of the materials to prevent denting,
bending, or any other damage of the sections, crossarms and anchor bolt cages. Suitable cushioning,
protective padding, dunnage or nonmettalic spacers shall be used to prevent fangs and flanges welded to the
tubular sections from damaging other tubular parts and to prevent damage and shifting during transit.
Pieces such as corner legs and crossarms shall be shipped loose.
Small parts and fasteners shall be carefully boxed, crated, bagged or otherwise containerized and protected
for shipment. Small pieces shall be bundled, with all the pieces in any bundle having the same mark. All
small pieces such as bolts, ground wire and insulator connections shall be packed in boxes of not more 70 kg
gross weight each. Bolts of different size or length shall be wrapped in separate sacks before boxing.
Description, quantity and marks or description of contents shall be shown on the outside.
Shipping shall be as specified in the Purchase Order and shall be in complete structure lots. All
identifications shown on bundles, boxes or other containers shall be included on the Contractor’s shipping
and packaging lists.
All materials shall be arranged to allow safe unloading at site.
Shop painted or galvanized steel will be stored in the field pending erection. The Contractor shall provide
storage and handling instructions to minimize damage to painted or galvanized surfaces.
8.2.3.9 Mar king

All parts of poles shall be appropriately marked or numbered or to identify the same as belonging to specific
type of poles. The pole and its parts shall also bear the marking to identify the same as the property of the
Employer. All markings shall be indelible and clearly visible after galvanizing. Pieces, which are part of a
structure, shall be marked with structure type number, followed by the proper assembly item and other
identification marks.
Example: TP2-20-A1 (Steel pole type TP2, 20 m, member A1)
In marking the parts, each marking shall be prefixed by letters, which indicate the type of poles then
followed by parts number. Letterings shall have a minimum height of fifteen (15) mm. Special care shall be
taken to see that all markings are made in such manner as not to be obliterated in transit, or in any way
damage the galvanizing or affect the strength of the structure.
Identification marks shall be located conspicuously for easy reading. Marking of like pieces shall be identical
in location, and pieces over 4 m in length shall be marked at both ends.
Identification marks shall be applied by stamping into the steel a 1.6 mm deep identification mark before
galvanizing using 15 mm minimum height, steel die letters and numerical. After galvanizing, a straight line
with a minimum width of 6 mm shall be stencilled to underline the identification marks. The stencilled line
shall be made with durable paint or ink that will adhere to the galvanized surface, and be legible. All small
items that are not adaptable to die marking and are not boxed shall be identified by either attaching die
stamped steel tags or standard white cloth shipping tags. The tags shall be attached with non-corrosive wire.
8.2.3.10 Quality Assur ance Requir ement

The Contractor shall have methods in place prior to starting work to assure that items and services, including
subcontracted items and services, comply with this specification.
Fabrication, processing, testing and inspection operations affecting the material will be subject to quality
assurance surveillance by the Employer.
Prior to production the Contractor shall submit to the Employer a fabrication sequence describing inspection
and/or tests to be performed, for use in determining inspection points which the Employer may desire to
witness. The Employer will advise the Contractor prior to production of those fabrication steps and shop
inspection points that the Employer desires to witness.
The Contractor shall give the Employer adequate notice, forty five (45) working days, minimum, prior to
those fabrication steps and tests, which the Employer desires to witness.
All deviations from this specification must be documented and referred to the Employer for resolution.
The Contractor shall furnish the following documents for the Employer's records:
a- A Certificate of Compliance stating the following: “All work provided under this
specification complies with all requirements of this specification and accepted deviations”.
b- Documents identifying deviations and their acceptance.
c- Certified mill test reports
d- Welder and weld procedure qualifications
e- NDT procedures and test reports
f- Shop test reports
The provisions of the General Technical requirements shall apply.
8.2.4 INSTALLATION
8.2.5 TESTS
8.2.5.1 Gener al
All materials shall comply with the test criteria, and the Employer’s acceptance of the steel poles and its
components shall not relieve the Contractor of his responsibility for meeting all the requirements of this
specification.
manufacture of steel poles and its components in accordance with the applicable standards mentioned herein
in the specification.
The steel poles and its components shall be given the manufacturer’s routine shop tests and quality
conformance tests and shall be witnessed by the Employer, if required, unless waived in writing. No steel
poles shall be shipped until released for shipment by the Employer.
notify the Employer the date of the tests to be witnessed forty five (45) days in advance.
8.2.5.2 Mater ial Tests

The Contractor shall furnish three (3) copies of certified mill test reports covering chemical and mechanical
properties of the structural steel. Stock material may be used with the Employer’s concurrence where the
Contractor’s stock can be satisfactorily identified with the specified ASTM specification.
Plate materials shall be subjected to the Charpy V-notch impact testing in the longitudinal direction in
accordance with ASTM A370 Type A Figure II, and ASTM A 673. The guaranteed Charpy V-notch
properties shall be no less than 20 Nm at the test temperature specified in the Technical Scedules.
All welded electrode material shall also meet the Charpy V notch impact test requirements and shall have the
physical properties equal to the steel to be welded.
Anchor bolt material shall be subjected to the Charpy V-notch impact testing in the longitudinal direction in
accordance with ASTM A370 Type A Figure II, and ASTM A673. The guaranteed Charpy V-notch
properties shall be no less than 20 Nm at the test temperature specified in the Technical Schedules. One (1)
Charpy V-notch impact test shall be made from each heat and diameter of as rolled bar (frequency “P” piece
testing).
Ultrasonic inspection of base plate material shall be performed in accordance with ASTM A435 including
acceptance standards, except that within 380 mm of the weld area a 100 percent coverage longitudinal beam
test shall be performed.
8.2.5.3 Shop Tests

All hermetically sealed tubular sections shall be shop tested to 103kN/m2.
The Contractor shall furnish a shop test report for the Employer’s review and records showing the results of
all tests made during fabrication.
8.2.5.4 Quality Confor mance Inspection

This is intended to eliminate defective materials and components of the steel poles. Each component shall be
inspected for conformance to the fabrication drawings. This inspection shall include, but not limited to:
a. ultrasonic inspection of all base plate material prior to welding for laminations;
b. visual inspection of dimensions to assure that tolerances are met;
c. visual inspection of cut edges to ANSI/AWS D1.1 criteria;
d. visual inspection of bent surfaces for surface separations (supplemented by mag particle in
questionable areas);
e. visual inspection of bolt holes to assure that they are cylindrical, perpendicular, free of burrs and
without torn or ragged edges;
f. visual inspection of all welds to ANSI/AWS D1.1 Section 8 criteria;
g. ultrasonic inspection of all full penetration welds after galvanizing (maybe waived if routine audits
show no history of defects);
h. magnetic particle inspection of all structural partial penetration or fillet welds to ANSI/AWS D1.1
Section 8 criteria;
i. visual inspection of finish;
j. magnetic thickness measurement of finish coatings.
8.2.5.5 Load Testing (Full Scale Pole Test )

If required by the Engineer, one pole of each standard type complete with all extensions, step bolts and
anti-climbing devices shall undergo full scale testing in accordance with IEC Publication 60652 "Loading
tests on overhead line poles", at the place of manufacture or at a testing station to be agreed upon.
The pole shall be erected on a rigid foundation and the vertical axis through the centre of gravity shall not be
out of centre by more than two tenths percent (0.2%) of the height at any level.
The pole structure shall sustain the load including overloads specified in this specification. These loads shall
be applied in increments and shall be held constant for a period of five (5) minutes before increasing or
removing the loads.
The Contractor shall submit for the Employer’s approval his proposed method and facilities of applying and
measuring the loads on the structure. The load measuring devices with appropriate numbering shall be
suitably calibrated prior to and following the test in accordance with the manufacturer’s recommendation at
the presence of the Employer’s representative(s).
Structure deflections under load shall be measured by a suitable procedure at points designated. Deflection
readings shall be recorded for the “before-load” and “load-off” conditions.
The Contractor shall submit, forty five (45) days prior to the performance of the tests, his testing programs to
the Employer for review and approval. These shall include test procedures, diagrams or test arrangements
showing the points of location and magnitude of the loads to be applied, the designated points for deflection
measurements, etc.
The pole to be tested shall be inspected in the presence of the Employer’s representative(s), who shall
conduct a visual check and evaluate all parts of the structure for sign of failure following the completion of
each test.
After completion of the test, the test structure can be considered a failure if the structure experienced any of
the following:
a) After the loads have been removed, the pole structure does not return to its original position within
reasonable tolerance;
b) Failure (i.e. bending, yielding, breaking, etc.) of the material or weld is detected; and
c) Test structure does not pass all physical and dimensional checks as required in the Quality
Conformance and Acceptance Test specified in this specification.
Such a failure shall be corrected and tested at the Contractor’s own expense.
The test reports shall include all the required documents according to IEC publication 60652.
8.2.6.1 Gener al

a. Filled-in technical data of the Technical Schedules;
b. Certified mill test reports;
c. Description and outline drawings of proposed structures including configuration,

member shapes, sizes and material thickness, materials and dimensions of all major
components, anticipated deflections and representative connection details;
d. Description of design calculations to be performed and buckling criteria to be used;
e. Reference lists;
f. Pamphlets and literature of the proposed steel poles and components to be furnished;
g. Proposed time bar schedule to meet the delivery date of the steel poles and its
components;
h. ISO 9001 Certification;
i. Tentative Quality Control procedures and qualifications, and nondestructive testing
to be performed;
j. Estimated weight of each type of pole including body extensions.
a. List of Drawings and schedules of submittals;
b. List of Codes used;
c. The final design calculations showing design assumptions, analysis, joint fixity,
foundation fixity, eccentricities induced to structure deflections and assumptions and
computations used to determine radius of gyration and other critical sections;
d. Foundation drawings for each type of poles;
e. Maximum moments, shears, axial loads and member section modules required and
furnished for at least every 20 foot (6.09 m) length, and at base, joints, splices and
other critical sections;
f. Chart and sag templates;
g. Detailed assembly and fabrication drawings;
h. Bill of materials and parts list for each type of pole;
i. Weights of each section and components of each type of pole including summary of
total weights for each type of pole;
j. Test Reports;
k. Calculations of stresses in base plates, attachment connections, anchor bolts and
moment connections;
l. Stress analysis for all connections showing stress distribution against wall buckling
or puncture;
m. Maximum horizontal and vertical deflection at the top of the structure, at shield wire
and conductor attachments, and at cross arm joints.
n. Detailed QA Program based on ISO 9001.
Erection drawings shall each show only one (1) structure with its component parts, and each piece shall have
an identification mark. The number and length of bolts, with type of washer, nuts and locknut required for
the assembly shall be shown at each connection. A complete list of material listing quantities of all material
required for the structure or part structure shown, including bolts, nuts, locknuts, washers shall be shown on
Contractor’s/Supplier’s shop detail drawings. The bill of material shall include the quantity of pieces
required, mark number, description, size, length, weight and total weight of material shown on the drawing,
and the reference drawing on which the member is detailed.
Shop detail drawings shall show each individual member’s dimensions and tolerances, welding
requirements, connections, identification mark, quantities, material designation, surface treatment, and a bill
of material.
The Contractor/Supplier shall furnish in the manner, number of copies and within the time set forth in the
Contract, instruction manuals in accordance with the requirements of the General Technical Requirements.
The Contractor/Supplier shall furnish information indicating recommended maintenance practice,
approximate time required for routine maintenance, and tools required for maintenance.
The Contractor/Supplier shall provide the required installation instructions and technical data for proper
installation.

cation or shipment
d List of drawings and its schedule of 60 days after Effective date of
Yes
submittals Contract
e Detailed outline drawings including detail 60 days after Effective date of
Yes
design report and calculations Contract
f Drawings certified for Erection and 120 days after Effective date
Yes
Construction of Contract
i Notification of Factory Test 45 days before test No
j Procedures, Packing and Storage 30 days before fabrication No
k Installation Instruction Manual 30 days before shipment No
l Documents for Records With shipment No
T-S-09-001 GROUNDING SP
T-S-09-001 GROUNDING MATERIALS Rev. Draft
T-S-09-001 GROUNDING MATERIALS
CONTENTS
9.1.1 SCOPE............................................................................................................................................2
9.1.1.1 General .......................................................................................................................................2
9.1.2.1 General .......................................................................................................................................2
9.1.3.1 General .......................................................................................................................................3
9.1.3.2 Workmanship .............................................................................................................................3
9.1.3.3 Zinc Coating ...............................................................................................................................3
9.1.3.4 Specific Requirements ................................................................................................................3
9.1.3.5 Marking ......................................................................................................................................4
9.1.3.9 Other Technical Requirements for the Grounding Materials .....................................................5
9.1.4 INSTALLATION ...........................................................................................................................5
9.1.5 TEST ..............................................................................................................................................5
9.1.5.1 General .......................................................................................................................................5
9.1.5.2 Type Tests ..................................................................................................................................5
9.1.5.3 Quality Conformance Tests (Sample Test) and Routine Tests...................................................5
9.1.5.4 Field Tests ..................................................................................................................................6
9.1.5.5 Test Reports................................................................................................................................6
9.1.6.1 General .......................................................................................................................................6
9.1.6.2 Data and Information to be Submitted With Tender ..................................................................7
9.1.6.3 Data and Information to be Submitted After Award of Contract ...............................................7
9.1.1 SCOPE
9.1.1.1 Gener al
This specification covers the technical and associated requirements for grounding materials for use in
switchyards, substations and overhead transmission lines rated 88 kV and above.
The Contractor shall bear full responsibility that the grounding materials have been designed and
manufactured in accordance with all standards and applicable regulations and perform under the conditions
and to the standards specified herein.



9.1.2.1 Gener al
The materials furnished shall be in accordance with, but not limited to, the latest issues of applicable
standards, including all addenda, in effect at time of the purchase order unless otherwise stated in this
specification.
in the Contractor's judgment and the Employer's acceptance, superior or more economic designs or materials
are available for successful and continuous operation of the Contractor's materials as required by this
specification.
It is the intent of this specification to allow supply of grounding materials according to IEC Standards. If the
Contractor customarily produces the specified grounding materials of national standards other than
proposes to use in the supply of the specified grounding materials.
9.1.3.1 Gener al
Grounding materials shall be constituted of counterpoise wires and earth rods made of materials specified in
the Technical Schedules and accessories such as compression and/or bolted terminals and connectors,
corrosion protective vinyl tapes, bolts and nuts as shown in the Employer's drawings.
The proposed assembly items in the Tender shall consist of a combination of the counterpoise wire and earth
rod with the associated connectors and accessories as follows:
a) Earth Rod: Type G-1 consisting of a ground rod and adequate length of ground conductor of
the type specified in the Technical Schedules and one terminal connector.
b) Counterpoise Wire: Type G-2 consisting of a ground rod and 40m length of ground
conductor of the type specified in the Technical Schedules, one terminal connector and
vinyl tape.
9.1.3.2 Workmanship
All parts shall be new and of the highest class, and shall be furnished uniformly in quality and smoothly on
the surface in conformity to the best commercial practice without any harmful defects such as flaws, ruts,
cracks, etc.
All wires of the counterpoise wire shall be concentrically stranded. The wires in each layer shall be evenly
and closely stranded around the underlying wire(s). The tension in individual wires in a layer shall be
sufficient to hold each wire firmly in place with only enough strand separation to prevent crowding or “bird-
caging” at the time of stranding and during handling and installation.
The design of adjacent metal parts and contacting surfaces shall be so made as to prevent corrosions of the
contact surfaces and to maintain good electrical contact under service conditions.
9.1.3.3 Zinc Coating

All the iron and steel parts and members shall be zinc coated upon completion of the fabrication. The zinc
coating is to be uniform, clean, smooth and free from burrs, sharp edges, lumps and dross so that
interconnecting parts will fit properly and parts may be assembled and disassembled readily. The zinc
coating shall be carried out by the hot dip process for all parts.
Threaded parts shall be coated after being threaded and excessive zinc shall be removed from the threads.
Nuts and locknuts shall be retapped after being coated and shall be capable of being threaded the entire
length of threads without use of tools.
9.1.3.4 Specific Requir ements

9.1.3.4.1 Galvanized Steel Wire
The galvanized steel wire for the counterpoise shall conform to the requirements of IEC standards or
equivalent. The characteristics of the galvanized steel wire are indicated in the Technical Schedules.
9.1.3.4.2 Copper Ground Conductor
Ground conductor made of copper either soft drawn or hard drawn concentric stranding copper conductor
shall be used, if required in the Technical Schedules. The copper conductor shall be in accordance with
applicable international standards. The copper conductor shall have the characteristics specified in the
9.1.3.4.3 Ground Rod
The length, diameter and technical features of the ground rods are specified in the Technical Schedules.
For galvanized ground rods, it shall be provided with a galvanized rod clamp to attach and electrically
connect the counterpoise wire to the earth rod.
For copper ground rods, the ground rod shall have a conical swaged point at one end and shall have a
continuous smooth copper covering of at least 0.254 mm thickness molten or copper bonded (electro-
deposit) to a steel core. The copper clad or pressed type will not be accepted.
9.1.3.4.4 Terminal Connector
Each terminal for connecting the counterpoise wire or wire from the ground rod to the tower leg shall be as
stated in the Technical Schedules and shall be of the make suited for the type of ground conductor that will
be applied and to the galvanized tower leg. If copper grounding will be used, the terminal connector for the
tower leg should be provide with bimetal insert, which will be suitable to both the tower leg and the ground
conductor. The shape of the terminal and the sectional shape shall be as shown in the Employer's drawings.
9.1.3.4.5 Vinyl Tape
The vinyl tape for protection against corrosion of the counterpoise wire shall be supplied in an adequate
quantity by the Contractor, and the amount shall be submitted by the Contractor together with the Tender.
9.1.3.5 Mar king

Individual items of the grounding materials shall carry identification marks so as to facilitate assembling and
sorting in a warehouse or at the site. Markings, such as production record code, as customarily provided by
the Contractor are acceptable.

Grounding materials and accessories shall meet the performance requirements of this specification while
operating within the environment specified in the Technical Schedules.

The Contractor shall prepare the grounding materials for shipment and transport to protect them from
damage during shipment and transport and subsequent storage not exceeding one year, unless otherwise
securely to the outside of the shipping unit.
The Contractor shall provide, at the Employer's request, the Contractor's recommended instructions for long
term storage. (See requirements in the Technical Schedules).
For shipping limitations, length, width, weight, etc. reference is made to the Technical Schedules.
Packing shall comply with the requirements of the Technical Schedules and the following:
Each crate shall be marked on the sides and on each end with a distinguishing code for materials of different
type. The Contractor shall submit a description of marking he proposes for the Employer's review.
Prominent weather-resistant coloured marking will be acceptable.
Individual crates may by shipped in larger shipping units such as containers or pallets. Such shipping units
shall be plainly marked by stencil or with a firmly fastened tag with the following information as a
minimum.
e - Destination
g - Case Number
i - Dimensions
k - Quantity
m - Net weight (kg)

services, comply with this specification. The provisions of the General Technical Requirements shall apply.
9.1.3.9 Other Technical Requir ements for the Gr ounding Mater ials
Other features for the grounding materials, if required by the Employer are stated in the Technical
Schedules.
9.1.4 INSTALLATION
Installation of grounding materials and accessories will be by the Employer or the Contractor as specified in
the Technical Schedules and monitored by the Employer’s representative(s).
In order to prevent pilfering, the ground electrode shall be embedded inside the concrete pad- and chimney
foundations, up to the appropriate depth, and on towers with grillage foundations, the ground electrodes shall
be attached underground.
When the installation is by the Contractor, such as for turnkey contracts, complete details of installation,
proper handling, transport and storage at site, testing, performance guarantees, etc., shall be furnished for the
9.1.5 TEST
9.1.5.1 Gener al
Grounding materials and accessories shall comply with the test criteria, and the Employer’s acceptance of
grounding materials and accessories shall not relieve the Contractor of his responsibility for meeting all the
requirements of this specification.
The Contractor shall carry out, at his own expense all tests necessary to ensure the satisfactory design and
manufacture of the grounding materials and accessories are in accordance with the applicable IEC Standards.
All routine tests required in the applicable standards shall be witnessed by Employer or his authorized
representative unless otherwise waived in the Technical Schedules and no grounding materials and
accessories shall be shipped until released for shipment by the Employer.
notify the Employer the date of the test forty five (45) days in advance.
Actual test procedures to be used shall be subject to the Employer’s acceptance and approval.
9.1.5.2 Type Tests

These tests are intended to establish design characteristics of grounding materials and accessories. They are
normally made once and repeated only when the design or the material of the grounding system is changed.
Design tests or type tests can be omitted, if a design record of the same materials can be submitted.
9.1.5.3 Quality Confor mance Tests (Sample Test) and Routine Tests
Quality Conformance Tests are intended to verify the quality of materials and workmanship. They are to be
made on materials taken on random from the various lots offered for acceptance. Routine tests on the other
hand, are intended to eliminate defective materials. They are also to be made on every material of the type to
which they are applicable.
In general, the following quality conformance and routine tests shall be performed as a minimum:
For the ground wire:
The following inspections and tests shall be carried out on the stranded wire and individual wires:
a) Individual wire
- Tensile strength, elongation and twisting
- Zinc coating: Coating weight, uniformity and wrapping (if galvanized earth conductor is
required
b) Stranded wire
- Visual and Construction
- Weight
- Breaking strength
For the ground rod:

The following inspections and tests shall be carried out on the ground rod and component clamp:
- Visual and Dimension
- Zinc Coating: Coating weight and uniformity (if galvanized ground rod is used)
For the terminal connector:

a) Before Compression
- Zinc Coating: Coating weight and uniformity (if galvanized ground wire and rod are
used)
b) After Compression
- Breaking Strength
9.1.5.4 Field Tests

Field tests and acceptance tests for the materials shall be performed by the Contractor and witnessed by the
Employer’s representative(s). The Contractor shall provide instructions and acceptance criteria for field-
testing for the Employer’s review and approval prior to the conduct of such tests. The Contractor shall
conduct no tests unless approved by the Employer.

Six (6) certified copies of tests reports of all standard tests performed subsequent to the date of award and all
9.1.6.1 Gener al
Contractor furnished data and information shall be the guaranteed performance data, predicted performance
interface requirements and installation features of all Contractors' furnished materials. The accuracy of such
information and its compatibility with overall performance requirements specified by the Employer are the
sole responsibility of the Contractor.
9.1.6.2 Data and Information to be Submitted With Tender

b. An outline drawing of each grounding material and the following information:
1. Type designation in accordance with Standard (e.g., ANSI or IEC) used, if applicable;
2. Unit dimension with manufacturing tolerances;
4. Materials
5. Unit weight
7. Manufacturer’s catalog number
c. Additional descriptive material brochures, additional drawings and other reference material to support
the filled-in Technical Schedules and to allow the Employer to properly evaluate the various
grounding materials being offered.
d. A detailed overall schedule, sufficient to demonstrate the Contractor’s ability to perform the work to
meet the delivery and installation;
e. Certified type test reports;
f. Tentative QA Program and ISO 9001 or 9002 Certification;
g. Detailed list of all exceptions and/or deviations taken by the Contractor to the requirements of this
specification or, if none are taken, a statement indicating that no exceptions or deviations are taken by
the Contractor.
9.1.6.3 Data and Information to be Submitted After Awar d of Contr act

The following shall be submitted by the Contractor after award of Contract:
b. Bill of materials and parts list or identifying sketch showing components;
c. Detailed Grounding outline drawing;
e. Detailed QA Program based on ISO 9001 or 9002;
f. List of drawings and its submittal;
g. Detailed Project Progress and Performance Review (PPR) for the grounding materials;
The Contractor shall furnish in the manner, number of copies and within the time set forth in the contract,
instruction manuals in accordance the General Technical Requirements.
required for maintenance (if required) and the list of spare parts and tools required for this maintenance.

cation or shipment
d Assembly/Component Drawings and
performance data With Tender Yes
e Special Tools and Equipment List With Tender Yes
f Design or Type Test Reports With Tender Yes
j Notification of Factory Test 30 days before test No
j Packing and Storage 30 days before fabrication No
k Installation Instruction 30 days before shipment No
l. Documents for Records With shipment No
T-S-10-001 CONSTRUCTION SP
T-S-10-001 CONSTRUCTION Rev. Draft
T-S-10-001 CONSTRUCTION
CONTENTS
10.1.1 SCOPE .............................................................................................................................................3
10.1.1.1 General ...................................................................................................................................3
10.1.1.2 Works to be provided by the Contractor ................................................................................3
10.1.1.3 Works to be provided by the Employer...................................................................................3
10.1.2 CODES AND STANDARDS .........................................................................................................3
10.1.3 RIGHT OF WAY (ROW) ...................................................................................................................4
10.1.4 ACCESS FOR CONSTRUCTION .........................................................................................................4
10.1.5 BUSH CLEARING .............................................................................................................................5
10.1.6 CROSSINGS .....................................................................................................................................5
10.1.7 MATERIAL TRANSPORT AND HANDLING ........................................................................................6
10.1.8 LINE SURVEYS AND DESIGN ............................................................................................................6
10.1.8.1 Profile Survey .........................................................................................................................6
10.1.8.2 Plan and Profile Drawings.....................................................................................................6
10.1.8.3 Clearances ..............................................................................................................................7
10.1.8.4 Tower/pole Application Charts ..............................................................................................7
10.1.8.5 Sag Template ..........................................................................................................................7
10.1.8.6 Tower/pole Plotting ................................................................................................................8
10.1.8.7 Site Inspection, Tower/pole Locations ...................................................................................8
10.1.9 SOIL INVESTIGATIONS ....................................................................................................................8
10.1.9.1 General ...................................................................................................................................8
10.1.9.2 Light Ram Sounding (Kunzelstab) Test and Test Pitting ........................................................9
10.1.9.3 Standard Penetration Test (SPT)............................................................................................9
10.1.9.4 Dutch Cone Test (CPT) ........................................................................................................10
10.1.9.5 Vane Shear Test ....................................................................................................................10
10.1.9.6 Soil Resistivity Tests .............................................................................................................10
10.1.9.7 Soil Laboratory Analysis ......................................................................................................10
10.1.9.8 Chemical Analysis ................................................................................................................10
10.1.9.9 Data obtained .......................................................................................................................10
10.1.10 FOUNDATIONS ..........................................................................................................................11
10.1.10.1 Foundation Types .................................................................................................................11
10.1.10.2 Design Criteria .....................................................................................................................12
10.1.10.3 Pole and Tower leg connection and anchorage ...................................................................15
10.1.10.4 Setting Out of Foundations...................................................................................................16
10.1.10.5 Foundations Located in Slopes ............................................................................................16
10.1.10.6 Foundation Tolerances.........................................................................................................16
10.1.10.7 Soil Excavation .....................................................................................................................16
10.1.10.8 Rock Excavation ...................................................................................................................17
10.1.10.9 Backfill..................................................................................................................................17
10.1.10.10 Stub Setting ...........................................................................................................................17
10.1.10.11 Concrete Work ......................................................................................................................18
10.1.10.12 Rock Anchors........................................................................................................................21
10.1.10.13 Foundation Uplift Test .........................................................................................................22
10.1.11 PILES FOR TOWER/POLE FOUNDATIONS ..................................................................................22
10.1.11.1 Type of Piles .........................................................................................................................22
10.1.11.2 Size and Length of Piles .......................................................................................................22
10.1.11.3 Materials for Piles ................................................................................................................23
10.1.11.4 Concrete for Piles Against Sulphates in Soils ......................................................................23
10.1.11.5 Structural Design of Piles ....................................................................................................23
10.1.11.6 Detail of Piles .......................................................................................................................24
10.1.11.7 Manufacture of Reinforced and Prestressed Concrete Piles................................................25
10.1.11.8 Installation of Pile ................................................................................................................26
10.1.11.9 Pile Extension .......................................................................................................................28

10.1.11.10 Pile Tests ..............................................................................................................................28
10.1.12 TOWER/POLE EARTHING ...............................................................................................................28
10.1.12.1 General .................................................................................................................................28
10.1.12.2 Driving of Ground Rods .......................................................................................................28
10.1.12.3 Installation of Counterpoise .................................................................................................29
10.1.12.4 Ring-Shaped Grounding Electrode ......................................................................................29
10.1.12.5 Measurement of Ground Resistance .....................................................................................29
10.1.13 TOWER/POLE ERECTION ...............................................................................................................29
10.1.13.1 Erection ................................................................................................................................29
10.1.13.2 Repair of Damage ................................................................................................................30
10.1.13.3 Anti-climbing Guard.............................................................................................................30
10.1.13.4 Guard Against Birds .............................................................................................................30
10.1.13.5 Erection Tolerances .............................................................................................................30
10.1.14 INSTALLATION OF INSULATORS, CONDUCTORS AND EARTH-WIRES ............................................31
10.1.14.1 Insulators and Fittings .........................................................................................................31
10.1.14.2 Conductor Joints and Tension Assemblies ...........................................................................31
10.1.14.3 Earth-wire Joints and Tension Assemblies...........................................................................31
10.1.14.4 Repair Sleeves ......................................................................................................................31
10.1.14.5 Tools and Equipment ............................................................................................................32
10.1.14.6 Stringing ...............................................................................................................................32
10.1.14.7 Sagging .................................................................................................................................33
10.1.14.8 Clamping In ..........................................................................................................................34
10.1.14.9 Sagging Tolerances ..............................................................................................................35
10.1.14.10 Transposition Insulator Sets .................................................................................................35
10.1.14.11 Vibration Dampers ...............................................................................................................35
10.1.14.12 Bird-Diverters ......................................................................................................................35
10.1.15 SPARE MATERIALS ...................................................................................................................35
10.1.16 ENVIRONMENTAL PROTECTION REQUIREMENTS (EPR) ..........................................................35
10.1.17 TOOLS .......................................................................................................................................35
10.1.18 DATA SUBMISSION SCHEDULE .................................................................................................36
10.1.1 SCOPE
10.1.1.1 Gener al
This specification covers the technical and associated requirements for the construction of overhead
transmission lines rated 88 kV and above.
The Contractor shall bear the full responsibility that the design and construction have been undertaken in
accordance with all standards and applicable regulations and that all materials, equipment and accessories
supplied perform under the conditions and to the standards specified herein.
the Employer. The Contractor shall obtain from its sub-contractor(s)/suppliers(s) a statement as to
compliance with this specification without exception and/or if there are any exceptions, these shall be
described in detail and included in the Contractor’s Tender. The Contractor shall add a statement that no
other exceptions are taken to this specification.

10.1.1.3 Works to be pr ovided by the Employer


The construction works and design requirements stated in this specification shall be in accordance with, but
not limited to, the latest issues of the following applicable standards, including all addenda, in effect at time
of purchase order unless otherwise stated in this specification.
60826 - Design Criteria of overhead transmission lines
ASCE - American Society of Civil Engineers
ASCE Manual No.52, “Design of Steel Transmission Structures".
specification.
It is the intent of this specification to allow for the supply of materials and construction works according to
the specified Standards. If the Contractor customarily produces materials or perform the construction works
of national standards other than mentioned, the Contractor shall describe the equivalences and/or differences
of such standards with his Tender. For any such standards, which are not written in the English language, the
Contractor shall make available copies of an English translation thereof. In any event, the Contractor shall list
all those standards he proposes to use in the supply of the specified materials and construction of the Works.
10.1.3 RIGHT OF WAY (ROW)

The Employer is responsible for the Right of Way (ROW) for the line route, including issues such as impact
mitigation and compensation, within the conditions specified in the Contract. Reference is also made to the
Environmental Protection Requirements specification.
The obtaining of permissions and access along the ROW, but not transport routes and access tracks leading
into the ROW will be provided by the Employer to enable the Contractor to carry out the erection of the
lines. The Contractor is entitled to use existing access routes and tracks where and if such facilities exist.
Obtaining of permissions for access tracks into the line ROW shall be the responsibility of the the Contractor
without any extra charge to the Employer.
All necessary authorizations, permits and approvals as may be required to ensure access for construction,
storage and transportation of materials/equipment and all other authorizations as may be required for the
construction of the line will be the responsibility of the Contractor.
The width of the ROW shall be as stated in the Technical Schedules.
10.1.4 ACCESS FOR CONSTRUCTION

The Contractor shall construct all access roads necessary for the construction of the line. The Employer will
not make any additional payments for the construction of access roads. At the end of the line construction the
access roads to towers/poles shall be left in a fairly acceptable condition for future use by the Employer's
operation and maintenance personnel, unless otherwise as decided by the Employer for environmental
reasons.
In general an access track shall be built along the line route (ROW). This will be the main access for
construction and maintenance, and it will be located within the ROW.
The Contractor shall make all necessary arrangements for access roads (in addition to the one along the
ROW) with the property owners, but if any difficulties arise the Contractor shall inform the Employer about
such difficulties.
If the Employer is unable to provide the above-mentioned wayleave (ROW) in time, the construction
programme shall be modified by agreement with the Employer.
All manhandling of materials to the site, which is rendered necessary by restricted access rights, must be
agreed with the Employer and paid for at the daywork rates stated in the Schedules of Quantities. Restricted
access rights may arise as a result of specific wayleave restrictions, but not as a result of difficult ground
conditions.
The arrangements for the removal, where necessary, of obstructions such as cultivated trees, pipes, field
drains, village houses or huts, telephone, telegraph and power lines, preventing the erection of the permanent
works will be made by the Employer or, if the Employer so requires, by the Contractor at the expense of the
Employer at the given daywork rates, except where such works shall be covered by specified unit prices.
The Contractor shall be responsible for the maintenance of fences and farm gates to the satisfaction of the
property owners or occupants. On completion of the Contract Works all fences and gates shall be left in the
same condition as they were found. Where additional permanent gates become necessary in existing fences
to provide access to the Site, they shall be supplied and installed by the Contractor to approval at the rates
specified in the Schedules of Quantities. Where any locks are required to the permanent gates, these shall be
to the approval of the Employer.
The Employer will pay for unavoidable damage to crops, but the Contractor shall, at his own expense, make
good to the reasonable satisfaction of the Employer, authorities, owners and tenants concerned, all land,
property, roads, tracks, bridges, drains, fences, walls, hedges, gates and the like which are damaged or
disturbed during the execution of the Works and shall remove all surplus construction material after erection.
Temporary provisions shall be made by the Contractor to prevent straying of, or damage to, livestock during
the execution of the Works and until the permanent reinstatement of fences, walls, hedges, gates and the like
is completed. The Contractor shall be held responsible for any damage to livestock due to failure to comply
with the above requirements.
In the event of any dispute or complaint arising between the owner or occupant of property and the
Contractor over reinstatement of fences or gates, damage to crops, or over other works on his property, the
Contractor shall attend to the matter properly and immediately inform the Employer of the circumstances.
10.1.5 BUSH CLEARING

The Contractor shall provide for clearing of trees and bush throughout the line route at the unit prices
specified in the Schedules of Quantities.
The width of the cleared strip (Right of Way) and possible additional requirements with respect to clearing
around tower/pole sites shall be as stated in the Technical Schedules.
However, the width of the strip may vary according to the mean height of the bush or forest and shall be
determined by ensuring that any tree after falling will not be less than 7 m clear of the tower/pole centre line, or
standing trees would not cause flashover from a conductor deflected up to 45o from the vertical. In determining
the flashover clearance and in estimating the mean height of the bush or forest due allowance shall be made for
seasonal growth. The strip of land shall be completely cleared of all trees, scrub and undergrowth by felling
not more than 150 mm above ground. Tree stumps are to be burned to prevent re-growth but the Contractor
shall ensure no bush fires ensue as a result of the burning of tree stumps along the ROW.
The Contractor shall not clear the line route by bull-dozing or other mechanical equipment unless approval to
do so has been obtained from the Employer, property owners or occupants, and care shall be taken to avoid
unnecessary removal of top soil, damage or interference to farm roads, ploughed lands, water courses, contours
and land ridges to avoid soil erosion. Should such damage be incurred, the Contractor shall make repairs where
necessary to the satisfaction of the owners or occupants of property.
All timber and bush shall be removed to the outer limits of the cleared strip, except when used as erosion
protection in seasonal stream courses.
Anthills shall be smoothly levelled off to a slope not exceeding 15o, wherever they may cause ground clearance
problems.
If so stated in the Technical Schedules an adequate vehicle access track along the length of the cleared line
route, to each tower/pole site, shall be established where possible for purposes of construction. Any alternative
route for the track shall be agreed with the Employer.
The extent of land clearance during the construction period shall be determined by the requirements for safe
construction and the strip of land to be cleared for operational purposes shall be in a completely cleared
condition at the agreed handing over date for the whole transmission line.
If required, disposal of timber, brush, etc. other than as stated above, or any land drainage or bridging or
prevention of soil erosion or similar special work arising as a result of the construction of the transmission line
shall be executed to approval at rates to be agreed.
10.1.6 CROSSINGS
The Contractor shall make all necessary temporary provisions and take all necessary precautions, including
the erection of guard structures as required where the line crosses roads, railways, telecommunication lines,
power lines, buildings, rivers or other obstacles, in order to maintain the safety of the public and to avoid
damage. The Contractor shall notify the Employer and the owner of any such obstacle in reasonable time
before he intends to make the crossing.
Prior to making the crossing the Contractor shall obtain the Employer's approval of the precautionary
arrangements and installation methods intended for use, and the time required for the work.
The relevant National regulations shall be complied with for all crossings.
No additional payment shall be made for any temporary guarding or scaffolding required for erection of the
conductors at such crossings.
If not stated otherwise in the Technical Schedules existing power lines will have to be shut down before
stringing of conductors and earth-wires at crossing points. Where possible, this work shall be carried out on
weekdays, but where necessary it may have to be undertaken on Sundays or public holidays. In any event,
the work shall be carried out only under the supervision of the Employer or their representative, and the
Contractor shall give a minimum of ten (10) days clear notice of the dates on which each crossing is to be
effected, or such other time as may be required by the Employer. No extra charge, in addition to the prices
quoted for stringing in the Schedules of Quantities, for work required to be carried out on Sundays or public
holidays will be accepted.
10.1.7 MATERIAL TRANSPORT AND HANDLING

The Contractor shall carry out all transport and handling of all materials. Prices for this shall be incorporated
in the relevant Schedules of Quantities for construction works.
For materials supplied by the Contractor the place of delivery is storages or depots at Site. It is up to the
Contractor to decide where such storages and depots shall be located.
All transport and handling of all materials, from storages or depots at Site to individual tower/pole sites shall
be included in the unit prices for construction works.
The Contractor shall be responsible for timely delivery to Site of materials.
The Contractor shall provide all vehicles, machinery, tools and equipment necessary to carry out the Contract
Works. He shall also be responsible for the adequate supply of fuel, lubrication and spare parts.
All materials shall be handled carefully to avoid breakage and damage. The Contractor shall be responsible
for such damage and for the delivery of the correct types and quantities of material to each tower/pole site.
The Contractor shall replace any breakage or damage or loss, at his own cost.
10.1.8 LINE SURVEYS AND DESIGN
10.1.8.1 Pr ofile Sur vey

The Contractor shall be responsible for all line survey and profiling using modern methods that are suitable
for digitalised profiles that can be used in combination with line design/optimisation/tower/pole plotting
computer software.
The Contractor shall also be responsible for the location of tower/pole positions (tower/pole plotting) on the
profiles in accordance with this specification and all setting out (tower/pole pegging) for construction, all to
the approval of the Employer.
Where the line route is running parallel to another similar line of the same voltage, the towers/poles shall be
located in step with those of the existing towers/poles where possible.
The Contractor shall be responsible for checking the correctness of longitudinal profiles when surveying for
tower/pole site pegging, and carry out correction of plans, profiles and design accordingly.
Where survey pegs have been removed or lost, the Contractor shall be responsible for their accurate
replacement.
The line shall basically run along the line route shown on the line route maps. The Employer shall approve
any deviations from the planned line route.
Before construction commences the contractor shall provide the Employer (at not less than seven days
notice) with lists of the towers/poles that have been pegged and are available for inspection.
10.1.8.2 Plan and Pr ofile Dr awings

Profiles shall be drawn to the following scales:
o Horizontal scale : 1:5000
o Vertical scale : 1:500
Ground details, buildings, etc., shall be shown to within the distance on either side of the centre line as
A north arrow shall be shown for each plan and profile sheet.
Location and description of benchmarks and other ground control survey monuments shall be shown.
Route or section length on plan centre line, every whole kilometre with a heavy line, and a tick mark at 100
metre intervals shall be shown.
Survey sketches of power and telephone lines crossing the new line shall be made and show the following
details:
o Voltage,
o Tower/pole numbers,
o Rough sketch of tower/pole configurations,
o Centre of the two nearest towers/poles on the left and right side of the centre line, even when
these are further away from the centre line than 30 m,
o Angle between crossing line and profile centreline,
o Elevation of suspension points of conductors and earth wires.
o Sag of conductors between two structures,
o Temperature at time of survey.
o Centre line profile of the crossing line shall be shown.
Where the side slope is 5% or greater side profiles shall be shown for the left and right side of the centre line
at the distances as specified in the Technical Schedules.
Profile lines shall be indicated as follows, looking in the direction of the higher station number:
o Centreline profile : solid line ( )
o Up-slope profile 1 : dotted line, from C/L (.............)
o Up-slope profile 2 : dashed line, from C/L (--------)
The Contractor shall also provide a master plan, preferably to a scale of 1:50,000 to correlate all survey
sheets, indicate main communications, property boundaries, trigonometrical stations relative to the line route,
and tabulate all data required for pegging of tower/pole positions, including angle points with the appropriate
measurements and directions and angles of deviation.
10.1.8.3 Clear ances

The structures shall be located so as to provide the minimum electrical clearances under the maximum sag
conditions.
10.1.8.4 Tower /pole Application Char ts

Application charts shall be prepared by the Contractor for each tower/pole type, and submitted to the
Employer for approval.
Each application chart shall show the minimum and maximum weight span and wind span capability for a
specific line angle at the design span.
10.1.8.5 Sag Template

Before submitting profiles for approval the Contractor shall provide the Employer with three sets of sag
templates based on the range of equivalent spans required. Each template is to be clearly endorsed with the
design loading conditions, particulars of conductors, equivalent span and scales, which shall be appropriate
to the scales of the relevant profile drawings.
The sag templates shall be used in the design of the transmission line to determine graphically on plan and
profile drawings the location and height of structures and show the lowest conductor at the maximum
temperature specified, and for checking and planning in the field.
Sag data for preparation of the above curves shall be shown on drawings submitted with the templates.
The sag templates shall be made of heavy-duty transparent celluloid or plastic material.
10.1.8.6 Tower /pole Plotting

Tower/pole plotting shall be carried out by the Contractor to the approval of the Employer. Electronic
submission of profiles may be considered, depending on the compatibility of systems and other practical
issues.
Structures shall be plotted on the profile in the most optimum location considering both engineering and
economics. Considerable study and several layouts may be required in rough terrain to determine optimum
structure location.
In order to maintain clearances, uplift, insulator swing and structural loadings within required limits, the
location of each structure shall conform to the requirements set out in the tower/pole application charts.
Structures shall be located on the plan view with correct stationing by scaling along the centre line from a
reference point of known stationing.
The Contractor shall submit to the Employer for approval, copies of profiles and structure lists, upon which
shall be indicated: number of towers/poles, type of tower/pole, deviation angle, actual span lengths, weight
and wind span, intersection lengths, type of foundation, leg extensions, conductor and earth-wire
attachments, number of joints, number of dampers, grounding and a free space for notes of crossings and
remarks.
10.1.8.7 Site Inspection, Tower /pole Locations

Each tower/pole site as plotted on the plan and profile drawings and pegged on site shall be inspected to
assure optimum location for safety of operation and line reliability as well as optimization for construction
and maintenance.
Areas subject to water or wind erosion shall be avoided where possible, in particular for the selection of
tension towers/poles. Areas where the risk for damage to tower/pole foundations by torrential floods is
obvious shall be avoided.
The Contractor shall locate and peg the centre point of all towers/poles to the satisfaction of the Employer
and shall provide and install a suitable temporary marker carrying the tower/pole number. Each tower/pole
location shall be defined by its longitudinal co-ordinate as established by measuring the distance to an
adjacent survey peg with known co-ordinate. The Contractor shall keep a record of all tower/pole locations
"as installed".
The Contractor shall locate the tower/pole foundations from the tower/pole centre point and shall perform all
additional measurements necessary to facilitate construction. In particular, the Contractor shall measure the
slope of the ground at each tower/pole location and he shall, on the basis thereof, select and propose
tower/pole leg extensions as required.
The Contractor shall provide all site inspection data to the Employer, with the completed plan and profile
and structure list, for approval.
Unless otherwise specified in the Technical Schedules straight line towers/poles shall be installed so as to
have the cross-arm at right angles to the line direction, and angle structures to have the cross-arm bisecting
the line deviation angle.
Tolerances of centres of tower/pole location shall be as follows:
o In span length: 1.0 m
o Deviation from straight line between two adjacent tower/pole centres: 0.05 m
10.1.9 SOIL INVESTIGATIONS
10.1.9.1 Gener al
The Contractor shall be responsible, at costs included in the Schedule of Quantities, for ascertaining that the
foundations to be employed are suitable for the sub-soils encountered at each tower/pole site. For this
purpose the Contractor will be responsible for the classifying of the sub-soils at each tower/pole site at an
early stage of the Contract.
Consequently, the Contractor shall perform sub-soil investigations at a sufficient number of tower/pole
locations to the depth and methods approved by the Employer. The details of performing the tests, tools and
equipment to be used shall be submitted to the Employer for approval.
The minimum extent of soil investigations shall be as follows:
o General soil survey along the alignment to record terrain types, surface soils, and any risk of
flooding.
o Light ram sounding (Kunzelstab test) and shallow test pit (minimum 2.5 m depth) with soil
classification for at least every 2 km of the alignment.
o Standard Penetration Tests (SPT) or CPT for at least every 10 km of the alignment.
o Additional Kunzelstab, SPT or CPT in-between in case of variations in the soil conditions.
o Vane shear tests in case soft clay soil is encountered.
The Contractor shall issue a detailed programme for the soil investigations, which shall be submitted, to the
Employer for approval. The Employer may order additional borings during the course of the work.
The sub-soil investigations shall be carried out under the supervision of a qualified soils engineer, who shall be
subject to approval of the Employer. An approved soil test laboratory shall carry out analyses of soil samples.
All results together with geotechnical assessments and foundation recommendations shall be submitted to the
Employer as a soils report issued by a qualified geotechnical consultant.
Depending on the foundation type used, the Contractor shall be responsible for ascertaining that the sub-soil is
not of a nature such as to cause corrosion of buried steelwork or deterioration of concrete.
The Contractor shall be responsible for any tower/pole settlement or failure due, in the opinion of the
Employer, to insufficient care having been taken in his investigation of ground conditions or in design or
installation of the foundations.
Soil investigations will be paid for the items and at rates as shown in the Bill of Quantities, i.e. by number of
soundings / borings of the different types and the number of laboratory tests. Soil resistivity tests will be paid
by a Lump Sum for all testing. All mobilisation, demobilisation, general soil survey, transport and moving
between tower/pole sites, transport of samples, supervision, geotechnical assessments and reporting, etc., shall
be included in the rates.
10.1.9.2 Light Ram Sounding (Kunzelstab) Test and Test Pitting

Sub-surface investigations for soil classification and selection of foundation type by the use of Light Ram
Sounding / Kunzelstab test should generally be performed to a depth between 5 meters and 10 meters below
ground level, depending on the soil resistance. The test shall be performed such that the number of blows per
10 cm of penetration is obtained continuously along the penetrated depth.
Where the results indicate soft soil, the sounding shall be carried on until firm soil strata are reached.
The light ram sounding shall normally be supplemented by a test pit to a minimum 2,5 m depth to classify
the soil types and properties, and to select samples for laboratory analysis.
The data obtained from each test location shall include the date of test, structure number, location, ground
surface condition, sample depth, visual soil classification, limits of soil strata, ground water level, expected
maximum water level, etc. The data thus obtained shall be prepared in final approved form to show the
penetration record and nature and extent of the soil strata and submitted to the Employer.
The penetration values should be used to determine soil classification and soil properties based on
recognized relationships between the Kunzelstab penetration and N-value determined by SPT or point
resistance by CPT. The suggested relationship shall be confirmed by calibrations in the field and approved
by the Employer.
10.1.9.3 Standar d Penetr ation Test (SPT)

This method may be used for sub-soil test to any depth. The SPT test shall be performed in such a manner
that the number of blows per foot/metre of penetration can be obtained at intervals of 1 m. The testing is
done below a casing according to standard procedure. Samples taken with the split spoon sampler shall be
subjected to soil classification and routine laboratory testing. The data obtained shall be prepared in final
approved form to show the penetration records and soil types.
10.1.9.4 Dutch Cone Test (CPT)

This method may be used for sub-soil test to any depth. The test shall be performed in such a manner that the
cone resistance and the local friction of the friction jacket can be obtained separately, continuously or at
every change in stratum but at intervals not greater than 50 cm. The data obtained shall be prepared in final
approved form to show the values of cone resistance, local friction, and the ratio of local friction to cone
resistance.
10.1.9.5 Vane Shear Test

This method may be used only for very soft to medium clay at any depth depending on the capability of the
equipment. The test shall be performed in such a manner that the maximum and minimum torque required to
rotate the blade of the vane embedded in soil can be obtained at intervals not greater than 1 m. The data
obtained shall be prepared in final approved form to show the undisturbed and remould shear strength of soil
along the boring depth.
10.1.9.6 Soil Resistivity Tests

The measurement of earth resistivity expressed in ohm-meter shall be performed in accordance with Article
8.02, Four-Point Method of IEEE Standard No. 81.
The Contractor shall recommend the type and extent of grounding electrodes in accordance with the results
of ground resistances and earth resistivity obtained. Selection of grounding electrode type shall be suitable
for each tower/pole and its particular site conditions. The data obtained shall be prepared in an approved
form and submitted to the Employer for approval.
Four copies of the list of ground electrode in an approved form shall be submitted for approval of the
Employer.
Preliminary measurement of ground resistance and earth resistivity under this Clause shall be made as soon
as possible after award of the Contract, and the submission of the measurement and four copies of the list of
grounding electrodes shall be made within six (6) months after award of the Contract.
10.1.9.7 Soil Labor ator y Analysis

Laboratory analysis of selected samples from test pits and SPT borings shall be analysed for the following:
o visual soil classification
o Atterberg limits (plastic and liquid limits)
o soil grading (sieve / hydrometer analysis)
Representative large samples from the different soil types encountered (taken in test pits and sources of
imported backfill) shall be subject to moisture - density testing according to AASHTOT99 (Standard
Proctor) to determine compaction characteristics (maximum dry density and optimum moisture content).
10.1.9.8 Chemical Analysis

At selected locations, the Contractor shall determine the concentration of sulphates, the degree of alkalinity
in soil and ground water and chlorides as C1- at the depth approved by the Employer. The values of sulphate
concentration shall be expressed in per cent of S0 4 for sulphates in soils and in parts of S0 4 per million for
sulphates in ground water. Alkalinity shall be expressed as a pH and parts CaC0 3 per million and the C1-
content of water in soil as parts per million (ppm).
10.1.9.9 Data obtained

The data obtained from each sub-soil test by the methods of test aforementioned shall include date of test,
structure number, location, ground surface condition, test method, sample elevation, limits of strata, ground
water level, expected maximum water level, soil classification and up to the depth of sub-soil test, and
laboratory test data. The data thus obtained shall be prepared in final approved form to show the nature and
extent of the soil strata over the area under consideration and recommended bearing capacities.
Selection of foundation type shall be made for each tower/pole foundation to suit its particular site
conditions. The Employer reserves the right to make the final selection of foundation type for each
tower/pole site based upon its judgement of the nature of sub-soil conditions or other factors affecting
construction or operation of the transmission line.
Four copies of the final soils report and foundation list in an approved form shall be submitted for approval
of the Employer.
All sub-soil investigations and tests shall be made as soon as possible after award of the Contract. Field and
laboratory test logs shall be submitted to the Employer as agreed during the investigation period. Final soils
report and final foundation list shall be submitted within six months after award of the Contract.
10.1.10 FOUNDATIONS
10.1.10.1 Foundation Types
10.1.10.1.1 General
Suitable types of foundations shall be designed for each soil class and tower/pole type:
o Steel grillage foundations for all tower types.
o Type concrete pad and chimney, all tower/pole types.
o Rock foundations for all tower/pole types.
o Special foundations, i.e. raft type or piled type in very poor soil conditions, for all
tower/pole types when and if necessary.
As far as practical, for any one standard tower/pole type, the foundation stubs and the foundations
themselves shall be identical for standard towers/poles and extended towers/poles.
For the standard lattice tower types, the design of the foundations for the compression and the tension leg
shall be the same.
Foundation design shall be modified when this is necessary due to ground water, or other complications, in
order to provide the required factors of safety.
The upper surface of all types of concrete foundations shall be sloped in an approved manner to prevent
accumulation of water and the whole exposed surface shall be rendered with concrete composed of one part
of cement and two parts of sand.
10.1.10.1.2 Pad and Chimney Foundations

Concrete spread footings of pad and chimney type can normally be used where the bearing capacity of the
ground at foundation level is at least 100kN/m2.
The foundations shall be designed for eccentric loading according to a recognized geotechnical design
method.
The density of the soil shall be assumed as stated in the Technical Schedules. The density of concrete shall
be assumed to be 2300 kg/m3 and 1300 kg/m3 above and below highest ground water level, respectively.
Lattice steel towers shall also be checked for uplift resistance.
The main concrete block may be pyramidal in shape. To provide necessary uplift resistance, the base of the
pyramid should be extended by means of a reinforced concrete pad. For lattice steel towers, the pad and
chimney foundations may be constructed with undercut excavation if possible.
The chimney shall be reinforced for the full uplift and shear loads. The adhesion between the galvanized
stubs and concrete foundation blocks shall be calculated to transmit 50% of the entire load to the foundation.
Cleats, bolted on the stubs, shall transmit the remaining 50%.
The tower stubs, which shall have the same inclination as the tower leg member, shall extend into the main
concrete block.
All steelwork below ground level (except concrete reinforcement rods) shall be completely galvanised and
firmly keyed and grounded into concrete designed to withstand the load due to the specified conditions.
Concrete shall be reinforced in order to ensure that the concrete stresses do not exceed the allowable stresses.
10.1.10.1.3 Rock Foundations

Rock anchors may be used where good quality rock is encountered at or near the ground surface.
Rock anchors shall consist of deformed bars, not less than 25 mm in diameter, securely grouted in holes pre-
drilled in the rock. Required number, depth and spacing of the bars will depend on the quality of the rock.
The Employer shall in each case approve the contractor's proposed solution.
If required by the Employer the capacity of selected rock anchors shall be tested at site. Payment of testing as
ordered by the Employer will be made according to relevant unit prices in the Schedules of Quantities.
Rock foundations in concrete may be constructed in holes blasted in the rock. The holes shall be made in
such a manner as to eliminate the possibility of serious cracking of the rock. The dimensions of the holes
shall be approved.
The stubs shall be completely galvanised, except that it shall be permissible to cut off, on site, lengths at the
bottom ends of the stubs where the upper surface of the rock is at or near ground level. The stubs shall be
firmly keyed and grouted into the rock, and shall be encased as for other types of foundations. The encasing
concrete shall extend down to the upper surface of the rock or into the rock. The depth of the stub grounded
into rock shall not be less than 1000 mm.
10.1.10.1.4 Steel Grillage Foundations

The steel grillage foundation shall consist of galvanised steel angle members. If the grillage consists of an
open grill, the spaces between the bars shall not exceed the width of a bar. The steel grillage shall be
designed according to ASCE Manual No.52, “Design of Steel Transmission Structures”.
Steelwork for grillage foundation shall, after galvanising, be treated with a bituminous or other approved
paint or compound.
10.1.10.1.5 Special Foundations

Where ground conditions are unsuitable for the installation of the types of foundations described above, the
Contractor will be required to make arrangements to provide piled or raft or other special foundations as may
be approved.
The total uplift, compression and horizontal forces assumed for the design of special foundations should be
those developed on the tower/pole under consideration at the particular site.
10.1.10.2 Design Cr iter ia
10.1.10.2.1 General
Foundations shall be designed for all the specified tower/pole types for a variety of soil conditions, both in
dry and fully submerged conditions, and for rock. The tendering shall be based on the soil types described in
this Chapter and the Technical Schedules.
The responsibility for proving the adequacy of the foundation type at each tower/pole site shall rest with the
Contractor. The necessary soil surveys and tests shall therefore be undertaken by the Contractor in
accordance with these specifications, including also assessment of the highest occurring ground water levels
and any risk of flooding. In waterlogged locations, the Contractor shall make water analysis to assess the
suitable cement type and corrosion risk of buried steel.
In exceptionally poor soil special foundation designs such as rafts or piling may be required, or removal of
poor soil and backfill with better materials.
Suggested foundation types and conceptual foundation designs are shown on the conceptual design drawings
of foundations.
The Contractor shall with his Tender submit calculations and drawings of his proposed designs. The
drawings shall show structural arrangement and details as well as geometry and volume of excavation,
concrete and reinforcement.
The Contractor may propose alternative types of foundations to those indicated in the technical
specifications, providing these comply with all requirements specified. The alternatives shown in the Tender
documents shall in any case be priced, while alternatives shall be priced separately.
10.1.10.2.2 Concrete
Concrete shall have a minimum 28 day's strength as specified in the Technical Schedules in accordance
with BS 1881/BS EN12390.
10.1.10.2.3 Steel Reinforcement

Steel reinforcement shall consist of hot rolled deformed bars conforming to the requirements of BS 4449
grade of steel "High Yield" with minimum yield strength as specified in the Technical Schedules.
10.1.10.2.4 Soil Classification

For design and tender purposes the soil has tentatively been classified into a number of types as specified in
the Technical Schedules. The soil parameters specified are preliminary and may be amended once soil tests
are available.
Relevant soil class and ground water conditions shall be determined for each tower/pole site based on field
survey and results from soil tests carried out by the Contractor. If it should prove economic, the properties
stated for each soil class may be adjusted on the basis of soil test results, but these specifications shall be
used for tendering purposes. Any adjustment after soil investigation results are available shall be to the
10.1.10.2.5 Design Parameters

Allowance shall be made in foundation design for the effects of seasonal rains and drying out of surface
soils.
Concrete foundations shall be designed with a minimum height above ground as stated in the Technical
Schedules. In flooded areas the height of concrete foundations shall be carried above flood level to ensure
protection of the steel against corrosive water. Such foundations are, if required, marked “high foundations”
and shall for tender purposes be designed for the height above ground level as specified in the Technical
Schedules.
The upper surface of concrete foundations shall be slightly sloped to prevent accumulation of water.
The minimum depth of the foundations shall be as stated in the Technical Schedules.
Single footings of tower/pole foundations shall be tested for uplift / overturning if required by the Employer.
The minimum concrete cover for reinforcing bars shall be as stated in the Technical Schedules.
Under all reinforced foundations a blinding layer of concrete of 100 mm shall be laid.
All concrete structures shall be designed in accordance with BS 8110, Structural Use of Concrete or
European Standard EN 1992 (Eurocode 2), and BS 4461/BS 4449:1998, Cold Twisted Steel Bars for
Concrete Reinforcement or other equivalent internationally recognized standard. The Contractor shall in his
Tender specify the standards he proposes to use.
The maximum stresses in concrete foundation structures under the specified loading conditions, taking the
relevant safety factors into account, shall be in accordance with the relevant standards.
10.1.10.2.6 Foundation Loadings and Load Combinations

Foundation design loads shall be computed on the basis of the maximum axial and horizontal tower base
reactions (including all specified tower design overload factors) and further multiplied by the load factors
specified in the Technical Schedules. Maximum foundation shear force from any load combination for the
download leg will be assumed to act simultaneously with the maximum foundation compression force.
Maximum foundation shear force from any load combination for the uplift leg will be assumed to act
simultaneously with the maximum foundation uplift force.
All combinations of tower and leg extension heights, as stated in the tower design specification, shall be
considered in determining the maximum tower base reactions.
Foundations shall be proportioned to resist the foundation design loads in accordance with the formulas
shown below. Reinforced concrete foundation components shall be designed in accordance with the
requirements of ACI Standard 318, latest revision. No additional load factors need be applied (in excess of
those mentioned above); however, appropriate ACI "Capacity reduction factors" shall be considered in the
design.
For pedestal design, the concrete and steel reinforcement shall be capable of resisting the bending moment
about two axes caused by the maximum horizontal web shears both in traverse and longitudinal directions.
However, in such case, the bending moment can be reduced by the effective lateral earth pressure. The
passive earth pressure shall be equal to γs tan2 (45o+Ø/2) from 0.5 meter below ground line, where γs is the
unit weight of soil and Ø is the angle of repose of the particular soil type. If circular shape pedestal is
employed, the steel reinforcement may be calculated on the assumption that they are distributed as circular
tube embedded in concrete.
In the determination of pile length of pile type foundation, Pu and Pc shall not be greater than 75 % (percent)
of the corresponding ultimate strength of soil obtained from the sub-soil test.
The foundations shall be proportioned to meet the following requirements (See below for clarification of
abbreviations applied);
a) Uplift Requirements;
1. Pad Foundation : Wc + Ws ≥ Tu
2. Rock Foundation : Wc + Fr ≥ Tu
b) Overturning + Uplift Requirements;
1. Pad Foundation : Mrs + Mrc + Mrp ≥ Mou
2. Rock Foundation : Mrc + Mrp + Mrf ≥ Mou
Tu − Wc − Wsv Mup × do
3. Pile Foundation : Pu = + ≤ 1.5 Pua
n ∑d 2
c) Overturning + Compression Requirements;
B Moc
1. Pad Foundation : E ≤ where E ≤
6 Qz + Wsv + Wc
Qz + Wc Mcp × do
2. Pile Foundation : Pc = + ≤ 1.5 Pca
n ∑d 2
d) Pad Foundations Limiting Soil Bearing Pressure Requirements;
B  Qc + Wc  6e 
1. E ≤ , 1 +  ≤ 0.75σ
6  B 2  B
B 2(Qz + Wc )
2. E > , ≤ 0.75σ
6 B 
3B − e 
2 
Moc
Note: e =
Qz + Wc
Where;
Wc = Effective weight of concrete foundation
Ws = Effective weight of soil in inverted truncated pyramid (excluding volume of concrete embedded
therein) extending upward from the top edge of foundation pad toward the ground surface.
Pyramid volume is defined by applicable "angle of repose". The critical surface at ground level of
the pyramid volume is defined as square with a quarter of circle at the corner.
Wsv = Effective weight of rectangular block of soil (excluding volume of concrete embedded therein)
lying directly above foundation pad.
Fr = Ultimate frictional resistance which can be mobilized around the periphery of a rock foundation.
Tu = Ultimate axial foundation design load in uplift.
Qz = Ultimate axial foundation design load in compression.
Pua = Allowable capacity of driven pile in tension.
Pca = Allowable capacity of driven pile in compression.
Mrs = Resisting moment (about toe of pad) caused by effective weight of soil above foundation pad.
Mrc = Resisting moment (about toe of pad) caused by effective weight of foundation concrete.
Mrp = Resisting moment (about toe of pad) caused by passive earth pressure acting on vertical surfaces of
foundation concrete from 0.5 meter below ground line to base of foundation.
Mrf = Resisting moment (about toe of pad) caused by vertical friction forces which can be mobilized
around the periphery of a footing pad or rock foundation.
Mou = Ultimate overturning moment (about toe of pad) caused by foundation design loads (axial uplift
and horizontal web shears) applied at the top of the foundation.
Moc = Ultimate overturning moment (about centre line of bottom face of the pad) caused by foundation
design loads (vertical compression and horizontal web shears) applied at the top of the foundation.
Mup = Ultimate overturning moment (about C.G. (centre of gravity) of pile group) which is caused by
foundation design loads (vertical uplifts and horizontal shears) applied at the top of the foundation.
Mcp = Ultimate overturning moment (about C.G. of pile group) which is caused by foundation design
loads (axial compression and horizontal web shears) applied at the top of the foundation.
n = number of driven piles in a given pile group.
do = Distance from C.G. of pile group to outermost pile.
d = Distance from C.G. of pile group to any given pile in the group.
B = Width of footing pad.
σ = Applicable net ultimate bearing capacity of the soil.
E = Eccentricity of the gross bearing pressure distribution on the base of a pad with respect to the C.G.
of the pad.
e = Eccentricity of the net bearing pressure distribution on the base of a pad with respect to the C.G. of
the pad.
Pu = Ultimate load on individual pile in tension.
Pc = Ultimate load on individual pile in compression.
10.1.10.3 Pole and Tower leg connection and anchorage
10.1.10.3.1 Self Supporting Towers

For self supporting lattice steel towers the connection of the tower to concrete foundations shall be by means
of a steel stub angle. The stub angle shall have the same size as the leg member to which it connects, and
shall be hot-dip galvanized for the full length.
Typical layout is shown on the conceptual drawings. The stub angle shall be provided with holes for
earthing and connections to tower body in accordance with tower detail drawings.
Cleats bolted to the stub to provide adequate bond with the concrete shall provide the anchorage of the steel
stub angle in concrete foundations.
All stub angles shall have at least two cleats at the lower end. Minimum embedded length at the stub angle
shall be as required to resist pullout.
The spacing between cleats shall be three times the flange width of the cleat. Minimum distance from upper
cleat to the top of concrete shall be eight times the flange width of the cleat angle.
10.1.10.3.2 Guyed V-towers

For guyed V-towers the connection of the tower to the concrete foundation shall be by means of a centre bolt
extending through the tower/leg steel pad and base plate.
Foundations for guys shall be stayed concrete anchors in soil and or rock anchors
Typical layouts of foundations and guy anchors are shown on the conceptual drawings
10.1.10.3.3 Steel Poles

Steel poles shall be connected to the concrete foundation by anchor bolts embedded in the concrete
foundation. Typical layouts of foundations are shown on the conceptual drawings
10.1.10.4 Setting Out of Foundations

Setting out of foundation positions shall be related to tower/pole centre. The Contractor shall provide
necessary setting out data and ensure correct correlation between towers/poles and foundations.
Towers/poles on straight lines shall be positioned with the crossarm perpendicular to the line direction.
Angle towers/poles shall have the crossarm bisecting the line deviation angle.
The permitted tolerances for tower/pole centre positioning are:
o Longitudinal, relative to position plotted : 1.0 m
o Transversal, relative to centre line : 0.05 m
10.1.10.5 Foundations Located in Slopes

If the cross profile, taken for hillside extensions, shows insufficient earth weight against uplift, tower
footings must be extended. Tower hillside extensions should be in steps of one meter. Care shall be taken to
avoid unnecessary removal of topsoil and platforms shall be avoided.
Where towers/poles are located in hillsides where erosion may be expected, special precautions shall be
taken by pitching after backfilling of foundations or other method approved by the Employer.
10.1.10.6 Foundation Toler ances

All foundations shall be accurately placed in their specific positions and within the following tolerances:
o Tolerance of horizontal level of the four stub joints : ±3 mm
o Tolerance for adjustment of tower base between two stubs ;
 in diagonal : ±10 mm
 in tower face : ±5 mm
The Contractor shall supply approved setting templates for footings and stubs.
10.1.10.7 Soil Excavation

During excavation, the Contractor shall take adequate precautions to prevent soil disturbances, which might
affect the bearing capacity of the foundations or the safety of personnel and Site Works.
Before excavations are commenced the Contractor shall submit his proposals with regard thereto for the
Employer's approval. When necessary, excavations shall be secured by plank and struts and kept free of
water by pumping or other means during the course of the work. The sides of excavations shall normally be
vertical, unless the soil stability requires inclined slopes, as agreed with the Employer.
If excavations are left open for more than a few days, they shall be fenced or otherwise protected to prevent
people and animals from falling in. Thorn bush, etc. may be used for fencing of the excavations.
Foundations intended for soil shall not be placed directly on bare rock. Minimum 10 cm well compacted
sub-grade of sand or gravel shall be placed between the rock and the foundation base.
If excavations are deeper than required, blinding concrete or well-compacted gravel shall be placed at the
bottom of the pit to bring the excavation to the required elevation.
10.1.10.8 Rock Excavation

Written approval shall be obtained from the Employer before explosives are used for excavating foundations
with rock. The Contractor shall be responsible for complying with local regulations concerning the use of
explosives and for the safe-keeping and handling of explosives. During operations involving the handling or
use of explosives, the Contractor shall be responsible for the safety of personnel, Site Works and people or
properties in the vicinity of the Site. The Contractor shall make good at his own expense any damage caused
by the use or mishandling of explosives.
10.1.10.9 Backfill
Backfilling shall not be carried out until after the Employer has inspected and approved the foundation.
Suitable excavated soil may be used as backfill material. Rock and soil not suitable for compaction shall be
removed and replaced with a suitable backfill to the approval of the Employer. Organic matters or soft clay
or silt shall not be used as backfill material. All temporary timbering, shuttering, etc. and all decomposable
or perishable material shall be removed from the excavations prior to backfilling.
Backfill shall be placed in layers of approximately 15 cm thickness. Each layer shall be carefully compacted
by means of suitable plant, to the approval of the Employer. The materials to be compacted shall not contain
stones greater than 10 cm in diameter.
In backfilling for concrete footings, the pad of the footing shall be covered first with a 30 cm layer of fine
material before any material with stones is deposited.
Prior to and during compacting operations, the backfill shall have the optimum practicable moisture content
required for the purpose of compaction.
The materials shall be compacted to minimum 95 % (percent) of the maximum density obtainable in the
Standard Proctor Density as specified in AASHTO T99 / ASTM D698 (Method A).
The Employer may periodically perform backfill soil density tests to ensure the desired degree of backfill
compaction is achieved.
Backfill shall be carried out to a minimum height of 20 cm above the original ground surface to compensate
for future settlement of the filling.
All backfill of tower/pole foundation shall be protected in an approved manner from being washed away by
running water. At all tower/pole positions, the surface of the ground shall be sloping from the tower/pole
legs to provide drainage as required. No additional payment will be made for such work.
Stabilised backfill shall be used if and where so directed by the Employer. Stabilised backfill shall consist of
minimum 5% cement by dry weight of the soil. Payment will be made at Daywork rates.
At certain places, additional protection against erosion may be required. Any such work, when decided in
agreement with and authorized by the Employer, will be paid for on the basis of the Daywork rates.
10.1.10.10 Stub Setting

If stubs are used for tower foundations, they shall be set by the use of suitable templates or complete tower
bases and leg extensions. The templates must be sufficiently accurate and rigid to hold the stubs in the
correct position while the concrete for the foundation structure is placed. The templates shall not be struck
until at least 24 hours after the concrete has been cast. The spacing and levels of the stubs after the templates
have been struck shall be such as to ensure correct alignment of the towers without forcing of members
during erection.
10.1.10.11 Concr ete Wor k
10.1.10.11.1 General
The Contractor shall supply all labour, materials and equipment required for the concrete work and all tests
required and shall:
a. Mix, transport, place, compact, finish and cure all concrete
b. Erect and dismantle all forms and formwork
c. Fix all reinforcement, and
d. Embed as required all items, whether supplied and erected by himself or by other Contractors,
all in accordance with these specifications and approved drawings.
Concrete foundations for self-supporting towers and steel poles shall be cast in situ.
10.1.10.11.2 Cement
The cement to be used shall be ordinary Portland cement meeting the requirements of BS 12/BS EN 197 or
equivalent and shall be approved by the Employer. It shall be delivered to the site in bulk cement containers
or in sealed bags clearly marked with the maker's name and shall be carefully stored in a water proof shed
with a raised floor or in a silo of approved design. Each consignment of cement shall be stored apart from
earlier consignment and the cement shall be used in the order in which it is delivered. Any consignment,
which has become caked or otherwise adversely affected, shall not be used and shall be removed from site
immediately.
Where Portland cement concrete may be liable to chemical attack, sulphate resistant cement to BS 4027 may
be used where approved.
If required by the Employer, samples from the cement to be used on Site are to be taken to a laboratory or
testing station approved by the Employer to demonstrate compliance with BS 12/BS EN 197 or BS 915/BS
4550-6:1978 or BS 4027 as applicable.
10.1.10.11.3 Aggregates
All aggregates shall be obtained from sources approved by the Employer, and shall be clean and free of clay,
earth, organic matter, salt or other impurities. The aggregates shall comply generally with the requirements
of BS 882/BS EN 12620.
For both fine and coarse aggregates, the Contractor shall furnish samples to the Employer together with such
full details and test results as the Employer may require. No aggregates may be used in the works until
approved by the Employer.
During the work the Employer shall order such tests as he may consider necessary on the aggregates and any
aggregates found to have unsuitable characteristics at any time shall not be used in the work and shall be
removed from the site, at no extra costs for the Employer.
The various fractions of fine and coarse aggregates shall be stored separately and in such a manner as to
avoid the admixture of dirt in the concrete. Aggregates shall be handled in such a way that separation is
avoided.
The grading of the fine and coarse aggregates shall be such that when they are mixed in the proportions
decided for the required class of concrete, the grading of the combined aggregate shall be suitable for making
a dense concrete of appropriate workability, containing the proportions of cement and water prescribed.
The proportions of fine and coarse aggregates and the maximum size of coarse aggregates to be used shall be
The concrete mix design shall be to the approval of the Employer before concrete works can commence.
The Contractor shall submit samples of the concrete material to the Employer well in advance of
commencing any concrete work, and also have test cubes made and tested for the aggregates and the cement
he intends to use. Concrete works must not commence until such samples and tests are to the Employer's
approval.
10.1.10.11.4 Water
The water to be used for mixing and curing of concrete shall at all times be kept clean and free from
deleterious matters such as oil, acid, alkali, silt, salts, organic materials, etc., and shall be obtained only from
sources approved by the Employer.
10.1.10.11.5 Admixtures
The Contractor shall use admixtures, if required, listed below in order to improve the quality of concrete or
mortar such as workability and finish and water tightness as per Manufacturer's instructions only with the
approval of the Employer
a. Water-reducing and set-retarding agent to ASTM C494.
b. Plasticizer.
10.1.10.11.6 Steel Reinforcement

The steel reinforcement shall consist of hot rolled deformed bars conforming to the requirement of BS
4461/BS 4449:1998 or other equivalent standard approved by the Employer.
The number, placing and fixing of bars shall be in accordance with approved drawings and approved bar
bending schedules.
All steel rod reinforcement shall be clean and free from loose mill scale, loose rust, oil and grease or other
harmful matter and except at bends shall be truly straight before being surrounded with concrete. Evidence
of steel quality shall be provided. The numbers, lengths, diameters, forms and positions of all reinforcing
bars shall be in accordance with approved drawings.
Steel reinforcement bars shall be carefully bonded to the tower/pole steelwork before concreting.
The steel reinforcement shall be so connected as to form a rigid cage or mat. To prevent displacement before
or during concreting, the bars shall be secured one to the other with 18-gauge soft iron wire. Sufficient
precast rings or distance/spacer blocks shall be used between the reinforcement and the bottom and sides of
the excavations to ensure the correct cover of concrete round the bars. (The distance/spacer blocks shall be
made of concrete of not less strength than of the concrete in which they occur).
Steel reinforcement shall be bent cold in a manner, which will not damage the material.
Bends, cranks or other operation on reinforcing bars shall be in accordance with approved drawings. Where
splices or overlapping in reinforcement are required the rods should, unless otherwise approved, have an
overlap of not less than the following:
Mild Steel Reinforcement High Tensile Steel Reinforcement

Bars with Bars without Bars with Bars without
U-hooks U-hooks U-hooks U-hooks
29 x d 45 x d 34 x d 50 x d
where d = diameter of rod.
10.1.10.11.7 Concrete Mixing

Cement shall be measured by weight, either by use of one or more complete bags or by weighing on Site.
Other ingredients shall be measured by weight or by volume, and concrete shall be mixed in batches using
one or more complete bags of cement. When mixing by volume is adopted, suitable batch boxes of approved
dimensions shall be made and used for the measurement of coarse and fine aggregates. A suitable container
for the measurement of water shall also be used.
All concrete shall be thoroughly mixed by machine with only sufficient water to ensure a workable mix.
Consistency tests shall be made when required by the Employer. The slump in a truncated cone 300 mm
high and of standard dimensions shall be between 25 and 50 mm, corresponding to a stiff plastic consistency.
10.1.10.11.8 Formers
All formers shall be accurately constructed to prevent loss of concrete and to produce the correct foundation
shape. Formers shall be sufficiently strong to withstand the pressure arising from the concrete during
compaction and shall be capable of removal without undue disturbance to the concrete. Wooden formers
shall be kept wet if necessary to prevent shrinkage. Formers shall not be removed before the concrete has
sufficiently hardened and in no case less than 36 hours after pouring. Where undercutting of the excavations
is permitted the Contractor shall ensure the soil is excavated correctly to template and the surfaces lined with
waterproof paper to prevent leeching of cement or fine aggregate from the concrete block.
10.1.10.11.9 Placing and Compacting

Concrete shall be transported from the mixer to the place of casting in such a manner that separation of the
aggregates does not occur.
The concrete shall be placed in its final position as soon as possible and in no case more than half an hour
after mixing. The method of placing shall be such as to ensure that the concrete in its final position may be
dense and homogenous.
Compacting shall be carried out in a manner approved by the Employer, and vibrators and other compacting
equipment shall be to the approval of the Employer.
Joints in the concrete foundations are to be avoided as much as possible. Where the construction of the
foundation is such that joints are unavoidable adequate chipping of the old concrete to a rough, clean surface
free from loose particles shall ensure bond between the old and new concrete. Immediately before placing
the new concrete, this cleaned surface shall be primed with a layer approximately 15 mm thick of a wet mix
of cement and fine sand in equal proportions.
The Employer can stop any concrete work whenever weather conditions are unfavourable and the Contractor
has not taken necessary precautions.
10.1.10.11.10 Time for Foundations to Set

Unless otherwise approved, towers/poles with concrete foundations shall not be erected until the foundations
have cured for a minimum fourteen days, or such longer or shorter time as may be approved, depending on
the type of cement used and on local conditions.
10.1.10.11.11 Surface Finish

Unless otherwise shown on the drawings, all permanently visible concrete surfaces shall have a regular finish
of uniform texture, free from holes, pins and formwork.
Concrete that is damaged or honeycombed must be removed by chipping to sound concrete and replaced
with mortar or concrete. If major defects occur, the Employer has the right to refuse the defective parts, if
necessary a whole foundation, which should then be removed.
The upper surface of the concrete for all types of foundations shall be sloped in an approved manner to
prevent accumulation of water and the whole exposed surface shall be rendered with concrete composed of
one part of cement to two parts of sand.
10.1.10.11.12 Curing
All concrete shall be cured by being kept continuously moist for a period of at least 10 days after casting,
though in certain cases the Employer may vary this period. The curing shall be effected by covering all
concrete surfaces with Hessian or a layer of sand, to be kept wet by continuous watering.
Curing compounds of approved type may be used with the permission of the Employer.
10.1.10.11.13 Testing of Concrete

All testing of concrete shall be carried out in accordance with the requirements of BS CP 114, clause 601 and
BS 1881/BS EN 12390. During mixing of concrete for each section of the work and at such other times as
directed by the Employer, 3 sets of test cubes, size 15x15x15 cm shall be taken, each set consisting of 6
cubes. From each set 3 cubes shall be tested after 7 days and the remaining 3 cubes after 28 days. The
compressive strength of the cubes after 28 days shall not be less than that specified in the Technical
Schedules.
Consistency and bleeding tests and such other preliminary tests as the Employer may direct, shall be taken as
often as directed by the Employer. No concrete of any type or class shall be used in the works before the
preliminary tests have shown specified compressive strength and workability.
All test cubes shall be well marked and cured as specified.
Testing of reinforcement steel and concrete materials shall be carried out in accordance with the relevant
British Standard as directed by the Employer. The Contractor shall be responsible for providing such
samples as may be required by the Employer for such testing.
10.1.10.12 Rock Anchors
10.1.10.12.1 Drilling in Rock

All drilling operations shall be carried out by qualified personnel, using only approved methods and
equipment. Drilling mud and lubricants on drill rods shall be used only where permitted by the Employer.
The drilling of holes in rock for anchors, drainage and grouting may be carried out by means of percussion
rock drilling machines. The diameter of holes for anchors shall be sufficient for grouting and installation of
the steel bar.
When holes are completed, they shall be temporarily plugged, until they are used for their purpose.
10.1.10.12.2 Anchors
Anchor bolts may be used for anchoring concrete structures to rock. Strengthening of the rock may be
effected by means of grouted-in bolts.
Anchors in rock shall be of a quality approved by the Employer. They shall consist of deformed steel bars
meeting the requirements of type "High Yield" according to BS 4449. The bars shall be thoroughly cleaned
before they are placed in position.
Anchors in rock shall be grouted-in either by the Perfo method or the SN method. The Perfo method implies
that the two halves of a perforated steel tube of the same length as the hole are first to be filled with a still
sand-cement mortar. They shall then be put together and inserted right to the bottom of the drill hole.
Immediately afterward the bar shall be driven into the tube by means of a pneumatic hammer so that the
mortar, pressed through the perforations of the tube, completely fills the space between the bar and the rock.
According to the SN method the holes shall first be filled with mortar through a hose inserted to the bottom
of the hole and successively pulled out as the mortar fills the hole. The bar is then driven into the hole by
means of a pneumatic hammer.
The holes shall be thoroughly cleaned with water and air immediately before they are filled with mortar.
The grout may be a suitable sand-cement mortar. The consistency and composition thereof shall be
Where required by the design or directed by the Employer the protruding ends of the bars shall be bent.
Where directed by the Employer testing of the anchors shall be carried out. The protruding ends of the bars
shall then be given a sufficient length from the surface of the rock to allow the fixing of a hydraulic jack
provided by the Contractor. The matrix of the jack shall be designed so as to ensure a satisfactory grip up to
stresses of 300 N/mm2 in the bar. It is envisaged that in case the number of failures is found to be five per
cent or less, normally not more than five per cent of the total number of anchorages will be tested as above
prescribed.
10.1.10.13 Foundation Uplift Test

If ordered by the Employer, one or several complete foundations shall undergo uplift test at testing locations
along the line route to be agreed upon.
The Contractor shall provide a comprehensive testing program, which shall be subject to approval by the
Employer prior to testing.
Payment for foundation uplift test as ordered by the Employer will be made as per the item prices in the
Schedules of Quantities.
10.1.11 PILES FOR TOWER/POLE FOUNDATIONS
10.1.11.1 Type of Piles

Except as specifically required and shown on the drawings, piles for tower/pole foundations shall be
classified in accordance with the following types:
10.1.11.1.1 Reinforced Concrete Piles

These types of piles shall be constructed of conventionally reinforced concrete in which there is no
application of internal stresses during the casting process. They may be cast and cured in a casting yard and
delivered to the site for driving or cast at the site if space is available.
10.1.11.1.2 Prestressed Concrete Piles

These types of piles shall be reinforced concrete piles in which there is an application of internal stresses
during the casting process. They are general cast at factory and delivered to the site for driving.
10.1.11.1.3 Cast-in-place Concrete Piles

These types of piles may be installed by placing concrete in a preformed hole, with or without a steel shell or
casing, in the ground. The shell or casing, if employed, may be left in place or gradually withdrawn as the
concrete is placed.
10.1.11.2 Size and Length of Piles

Unless specified, the size and length of piles shall conform to the following requirements:
Type of Piles Minimum Effective Perimeter Length

cm m
Reinforced and Prestressed

Concrete Piles
Short piles 72 Up to 7
Long piles 120 8 to 20
Cast-in-place Concrete Piles Minimum diameter = 35 Up to 25
If not specified, effective perimeter and length of cast-in-place concrete piles, intended to be used as
alternatives, shall not be less than that of reinforced or prestressed concrete piles. Piles with hollow cross
sections are acceptable.
After the approval of the design and detail of piles, pile foundations, pile load tests and results of sub-soil
tests, the Contractor shall submit to the Employer the number and length of piles to be used for each
foundation for approval before proceeding with the piling work.
10.1.11.3 Mater ials for Piles
10.1.11.3.1 Concrete
The concrete for piles shall be manufactured using ingredients and quality control specified under the
requirements in ACI Recommendation for Design, Manufacture and Installation of Concrete Piles except as
otherwise specified herein. The concrete for each type of pile shall be in accordance with the following
requirements:
Type of Pile Specified Standard Cylindrical Minimum Cement Content

Strength in 28 days kg/m3
2
kg/cm
Reinforced Concrete Pile 280 350
Prestressed Concrete Pile 350 400
Cast-in-place Concrete Pile 210 300
10.1.11.3.2 Reinforcing Steel for Piles

The prestressing wires, deformed bars and plain round bars shall conform to an approved Standard.
10.1.11.4 Concr ete for Piles Against Sulphates in Soils

The Contractor shall follow the following requirements for concrete piles against sulphate attack caused by
sulphates in soil:
Classification of Soil Reinforced Concrete Prestressed Concrete Cast-in-Place

Condition Pile Piles Concrete Piles
Case Sulphate Sulphate Type of Minimum Type of Minimum Type of Minimum
as SO 4 as SO 4 Portland cement Portland cement Portland cement
in soil in cement content cement content cement content
% ground (kg/m3) (kg/m3) (kg/m3)
water
(ppm)
1 0.1-0.5 150-200 I 350 I 400 I 385
II 310 II 340
2 0.5-1.0 1200- II 350 II 350 II 385
2500 V 310 V 310 V 340
3 Above Above II 385 V 340 V 350
1.0 2500
The cement contents recommended in the table are suitable for concrete mixes having slump of 0, 2.5 and 10
cm for prestressed, reinforced and cast-in-place concrete piles respectively. For tremie placing, the slump of
15 cm may be employed. In addition, the concrete must be capable of being compacted to produce a dense
impermeable mass.
10.1.11.5 Str uctur al Design of Piles
10.1.11.5.1 Capacity of Piles

The Contractor shall design the minimum pile capacity in accordance with the following sizes of piles:
Size of Piles Allowable Tension Allowable Compression

kg kg
72 cm effective perimeter 5,000 10,000
The design of the piles shall also provide adequate structural strength to resist the expected driving stresses
without damaging the piles.
The allowable stresses in concrete and reinforcing steel shall be as specified in ACI Standard 318.
10.1.11.5.2 Longitudinal Reinforcement

Longitudinal reinforcing steel for reinforced and cast-in-place concrete piles shall have an area of not less
than 1.5 per cent nor more than 8 per cent of the gross cross-sectional area of the pile.
10.1.11.5.3 Lateral Reinforcement

Lateral reinforcement for reinforced and cast-in-place concrete piles shall be only spiral or equivalent hoops
with minimum diameter of 6 mm and shall be spaced not more than 15 cm on centre except at each end of
the pile for a distance of three-pile diameters, the spacing shall be one third of the aforementioned value.
Lateral reinforcement for prestressed concrete piles shall be only spiral or equivalent hoops with a minimum
diameter of 4 mm. The spacing shall be 5 turns of 2.5 cm pitch at each end, 7.5 cm pitch for the next meter
and a maximum pitch of 15 cm for the intermediate section.
10.1.11.5.4 Lifting Points

Lifting points of piles shall be designed in such a manner that these points shall be those theoretically
producing the least bending moment throughout the length of the piles.
In the design of lifting points, the minimum of 33 per cent impact during handling and transportation shall be
taken into account.
10.1.11.5.5 Splicing
In general, a pile shall be of continuous single length. If the Employer permits splicing, the Contractor shall
submit the design and detail of splices for the approval of the Employer. Pile splices shall develop the
requisite strength in compression, bending, tension, shear and torsion at the points of splices during driving
and in service.
10.1.11.6 Detail of Piles

In addition to the dimension of pile and steel reinforcement arrangement, the detailed drawings submitted for
the approval of the Employer shall conform to the following requirements:
a) Pile Tip : The pile tip for reinforced and prestressed concrete piles shall be flat.
b) Covering : Minimum clear covering of concrete over main steel reinforcement shall conform to
the following requirements:
Type and Exposure Minimum Clear

Covering in cm
Reinforced concrete piles
- normal exposure 3.8
- marine or corrosive substance exposure 7.5
Prestressed concrete piles
Type and Exposure Minimum Clear

Covering in cm
- normal exposure 2.5
- marine or corrosive substance exposure 4.0
Uncased cast-in-place concrete piles 7.5
Cased cast-in-place concrete piles 3.8
c) Edges and Corners
The top edges and corners of the reinforced and prestressed concrete piles shall be chamfered.
d) Lifting Points
Lifting points of piles shall be clearly marked by a band of paint or by providing holes with steel
pipe sleeve to indicate the points of attachment of the handling slings.
e) Dowel Bars
Dowel bars shall be used to anchor each pile into the pile cap and shall be designed to develop
full allowable tension load in each pile. The length of the dowel bars pre-embedded in the top
part of pile during manufacturing shall conform to the following requirements:
Size of Piles Minimum Pre-embedded

Length in m
72 cm effective perimeter 2.00
120 cm effective perimeter 3.30
140 cm and 160 cm effective perimeter 3.30
10.1.11.7 Manufactur e of Reinfor ced and Pr estr essed Concr ete Piles
10.1.11.7.1 General
Manufacture of reinforced and prestressed concrete piles shall conform to the requirements specified in ACI
Recommendation for Design, Manufacture and Installation of Concrete Piles and shall conform to the
following requirements:
10.1.11.7.2 End Forms

End forms shall be securely fastened to the pile form so that the pile head will remain in a true plane
perpendicular to the pile axis.
10.1.11.7.3 Hollow Cores

Hollow cores in a pile must be concentric with the pile centre line throughout the entire length of the hollow
section.
Forms shall be of an approved water resistant material and shall resist breakage or deformation during the
placing of the concrete.
10.1.11.7.4 Embedded Dowel Bars

Dowel bars shall be accurately set in the forms parallel to the axis of the pile and secured to prevent
movement during concrete placing.
Particular care shall be used to ensure proper cover of embedded dowel bars.
10.1.11.7.5 Curing
Concrete piles shall be maintained in a moist condition for at least 5 days after placing or until design
strength is obtained. Curing shall be done by means of water curing, membrane curing or steam curing.
10.1.11.7.6 Manufacturing Tolerances

Piles shall be manufactured to the following dimension tolerances:
(1) Length ± 10 mm per 3 meters of length
(2) Cross section:
- Wall thickness of hollow section -3 mm to + 10 mm
- Solid section -3 mm to + 12 mm
(3) Deviation from straight line of not more than 4 mm per 3 meters of length.
(4) Deviation of internal core from true position ± 10 mm.
(5) Pile head ± 2 degrees to the true plane
10.1.11.7.7 Prestressed Wire Cutting

Prestressed wires shall not be cut off until the concrete strength reaches 250 kg per square centimetre. The
cutting shall be such that all prestressing steel are flush with the end of the pile otherwise they shall be
ground out.
10.1.11.7.8 Handling, Transportation and Storage

Piles shall not be handled, transported or stored in any way, which will result in damage to the piles. Piles
shall be lifted and blocked for storage at predesignated points in such a manner that bending stresses will be
within acceptable limits specified in the design of piles.
The Employer reserves the right to reject any pile at any time throughout the delivery and storage if the
Employer determines that the pile may be unsuitable due to improper fabrication, handling or storage.
10.1.11.8 Installation of Pile
10.1.11.8.1 Reinforced and Prestressed Concrete Piles

Piles shall be installed accurately to the required position, alignment and depth with gravity, steam, internal
combustion hammers or by other means approved by the Employer. The drop length of the hammer shall not
exceed 90 cm. The weight of the hammer and the striking part shall be at least equal to the weight of the pile
being driven and shall develop an energy per blow of not less than 3 kg-m per 10 kg of weight driven, except
short piles where a hand-driven hammer may be used, the weight of the hammer shall not be less than 100
kg.
The pile driving procedure shall not subject piles to excessive and undue abuse producing crushing and
spalling of the concrete, injurious splitting, deformation of the steel or misalignment. The pile to be driven
shall have the top face perpendicular to the longitudinal axis of the pile and it shall be ensured that no steel
reinforcement or dowel bars protrude from the head.
Piles being driven shall have an adequate driving head to distribute the blow of the hammer to the head of
the pile. The driving head shall be axially aligned with the hammer and the pile.
Between the driving head and the hammer, there shall be a capblock to protect the pile and the hammer from
damage. Capblocks may be made of hard wood or other materials capable to transmit the energy to the pile
effectively without excessive elastic energy losses.
The top of the piles shall be covered by a suitable cushion while they are being driven. Cushions shall be at
least 10 cm thick of soft wood block or 16 layers of gunnysacks. A new cushion shall be provided for each
pile, or replaced during driving when the cushion becomes highly compressed, charred or burned.
Piles shall be secured against lateral movement during driving by leads or other suitable means. Excessive
manipulation of piles during or after driving to force them into proper positions will not be permitted. All
piles pushed up by the driving of adjacent piles or by other causes shall be driven down. The top of the piles
at cut-off elevation shall not be out of position shown on the drawings more than 1 per cent of pile length nor
more than 15 cm after driving.
Any pile damaged by reason of internal defects, or by improper driving, or driven out of its proper location
shall be corrected at the Contractor's expenses by one of the following methods approved by the Employer
for the pile in question:
(1) The pile shall be withdrawn and replaced by a new pile and, if necessary, a longer one.
(2) A second pile shall be driven adjacent to the defective pile.
All materials forced up between the piles shall be removed to the base elevation approved by the Employer
before a gravel sub-base or concrete is placed.
All piles, except the reinforcement therein, shall be cut-off at the specified elevation; vertical piles shall be
cut-off to true horizontal planes, and batter piles shall be cut-off to planes normal to the axis of the piles.
Reinforcement steel shall be left extending from all piles above the specified cut-off planes for anchorage
into the base pad of the footings as shown on the drawings.
During driving, an accurate record of the penetration and blow count of each pile driven shall be kept by the
Contractor. These records shall be available to the Employer at all times.
For estimating and evaluation purpose, the ultimate resistance of vertical piles shall be determined by the
Danish formula:
∞WH
Q=
S
S+ 0
2
2∞WHL
S0 =
AE
Where
Q = Ultimate resistance to driving in kg
W = Weight of striking parts of hammer in kg
H = Height of drop for the hammer in cm
S = Average penetration, in cm per blow for the last 5 blows
So = Elastic compression of pile in cm if all available hammer energy is used for compression of
pile
L = Length of pile as driven in cm
A = Cross-sectional area of pile, cm2
E = Modulus of elasticity for pile material, kg/cm2 (recommended value of 2.2 x 105 kg/cm2)
∞ = Efficiency of hammer. Values given below may be substituted by manufacturer's efficiencies
or net delivered energies if based on actual tests:
Diesel hammer: 100 %
Single-acting air or steam hammer: 80 %
Gravity hammers: 100 % for hammers released by triggers and 75 % for hammers actuated
by rope and friction winch.
When driving batter piles with a gravity hammer, the effective height or drop is reduced and
friction also occurs in the guides. Taking the coefficient of friction as 0.1, the effective value
of drop H' to be used in the formulaes in place of H shall be taken as follows:
H' = H (cos φ - 0.1 sin φ ); where φ = angle between the batter and the vertical
The Contractor shall furnish to the Employer the data required for use in the aforementioned
formula. The minimum penetration or ultimate resistance to which the piles shall be driven
shall be as instructed by the Employer.
10.1.11.8.2 Cast-in-place Concrete Piles

The Contractor shall submit details of installation of the cast-in-place concrete piles for approval of the
Employer. Placing of concrete where water is present shall be performed by the tremie method specified or
by other approved means.
10.1.11.9 Pile Extension

When the pile has been driven a short distance below grade, the extension of pile or lowering of the pile cap
may be employed.
If the extension of pile is exercised, the use of epoxy grout and a doweled splice is recommended.
Splices should develop the requisite strength in compression, bending, tension, shear and torsion at the point
of splices during driving and in service.
10.1.11.10 Pile Tests

The Contractor shall perform pile load tests on piles driven for foundations for pile type tower/pole footings
to determine the load-settlement relationship for an individual pile. The Employer will determine the piles to
be tested and the number of pile load tests required. The Contractor shall provide all labour, materials,
equipment, and apparatus for performing the pile load tests. Loading tests shall not be started until at least 7
days have elapsed after driving and not less than 14 days after pouring of cast-in-place piles.
Test piles shall be of the same diameter and materials as the permanent piles and shall be driven with the
same equipment and in the same manner as specified for such piles. Test piles should be driven in advance of
final driving of permanent piles for determination of final lengths. These piles shall be of greater length than
the length assumed in the design in order to provide possible variation of soil conditions. During driving, an
accurate record of the penetration and blow count of each pile driven shall be kept by the Contractor. Cast-
in-place test piles shall be of the minimum specified length and installed of the same materials as the
permanent piles. If approved by the Employer, test piles may become an integral part of the pile groups in a
footing.
The tests of piles shall be in accordance with ASTM D1143, Standard Method of Testing Piles under Static
Axial Compressive Load or ASTM D3689, Standard Method of Testing Individual Piles under Static Tensile
Load. Lateral load test shall be done by a method approved by the Employer.
10.1.12 TOWER/POLE EARTHING
10.1.12.1 Gener al
All towers/poles shall be permanently and effectively earthed.
The individual tower/pole footing resistance shall be as specified in the Technical Schedules.
Individual tower/pole earthing shall be made with ground rods, coils or radiating counterpoise. In areas
having high earth resistivity, such as in sand, gravel or rock formation, a supplementary radiating
counterpoise with or without longitudinal counterpoise or ring shaped grounding electrode may be
employed.
In order to prevent pilfering, the ground electrode shall be embedded inside the concrete pad- and chimney
foundations, up to the appropriate depth, and on towers with grillage foundations, the ground electrodes shall
be attached underground.
If so specified in the Technical Schedules, sections of towers/poles, normally over the first few kilometres
in and out of substations shall be connected together by continuous counterpoise cable, which also shall be
connected to the substation-earthing grid.
10.1.12.2 Dr iving of Gr ound Rods

The ground rods shall be driven to the required depth by hand-operated weight pipe. If the soil is too hard or
dense to use hand operated weight pipe or where it is required to drive extendable ground rods, the
Contractor is required to use mechanically operated hammers. The hammer shall be mounted on a rig, which
provides guides for the rod and a winch for control of the hammer. The ground rod driving tools shall be
submitted to the approval of the Employer. Driving of rods by hand hammering is not permitted.
Where soil conditions prevent driving of ground rods to the required depth, the Contractor shall follow the
instructions of the Employer.
10.1.12.3 Installation of Counter poise

The counterpoise cable shall be buried to a minimum depth of 50 cm, or 75 cm in cultivated land. If solid
rock is encountered at a lesser depth than required, the counterpoise shall be laid on top of the solid rock and
covered with soil. Where solid rock is encountered on the surface the wire shall be laid on the surface away
from the rock. In the case where laying aside is not possible, the wire shall be laid in cracks with loose rocks
placed on the wire and anchored with a rock anchor to prevent displacement. The wire shall be laid as
straight as possible without sharp bends.
a. Radial Counterpoise.
The radial counterpoise installation for a tower/pole shall be made up of two (2) or four (4)
radial arms of counterpoise. Each arm shall have at least 15 meters in length or as directed by
the Employer.
b. Longitudinal Counterpoise.
The longitudinal counterpoise shall be installed in addition to the radial counterpoise and buried
at the depth of 50 cm, or 75 cm in cultivated land. The connection between radial counterpoise
and longitudinal counterpoise shall be of heavy-duty exothermic type connector or compression
type connector.
10.1.12.4 Ring-Shaped Gr ounding Electr ode

The installation of a ring-shaped grounding electrode shall consist of one wire buried at a minimum depth of
50 cm around the tower. The diameter of the ring-shaped grounding electrode shall be approximately 20
meters. From each tower leg or pole, there shall be a wire diagonally connected to the ring-shaped
grounding electrode. The connection to be used shall also be a compression type connector.
10.1.12.5 Measur ement of Gr ound Resistance

The Contractor shall measure the ground resistance of the individual tower/pole foundation in the dry season
with the measuring instruments and method approved by the Employer. The results of measurement shall be
recorded in an approved form and submitted to the Employer for consideration.
a) Initial Ground Resistance.
The initial ground resistance is obtained by measuring ground resistance of the grounding
electrode when they are installed in position.
b) Final Ground Resistance.
After the tower/pole foundation has been completed, the Contractor shall measure ground
resistance at the tower stub/pole base. In case the ground resistance value is less than the
required value, it is considered to be the final ground resistance.
In the event that more than the required value is encountered, the Contractor shall improve the
tower/pole ground resistance until a satisfactory result, in the opinion of the Employer, is
obtained. That value would then be considered final.
Each tower/pole ground resistance within 3 km from a substation/switchyard shall be strictly
kept below the required value.
10.1.13 TOWER/POLE ERECTION
10.1.13.1 Er ection
Towers/poles may be erected by any suitable method, provided that no overstressing of any component parts,
footings, stubs, etc., occurs. Horizontal loads on foundations during tower/pole erections shall be avoided or
reduced to a minimum.
Prior to commencing any erection the Contractor shall submit for the approval of the Employer a written
account of the method(s) of erection and the erection plant proposed for use. The Contractor shall provide
all necessary tools and equipment. Erection of towers/poles shall be performed with first-class workmanship
and under the supervision of well qualified Site Employees and Foremen.
Joints shall be thoroughly cleaned before assembly.
Bolts shall not be fully tightened until all members of a tower/pole or all members of an independent sub-
assembly have been fitted. After initial assembly, but before stringing of conductors and earth-wires,
thorough checking shall be made that all bolts are tightened to the correct torque and that all nuts are locked
in an approved manner. Only suitable wrenches, which have been approved by the Employer, shall be used.
Washers shall be used on all bolts. Bolts shall project through the tightened nuts with a minimum of 3.0 mm
and a maximum of 10 mm. The threads shall not be exposed to shear forces. All bolts and nuts shall be
securely tightened. No steel members shall be forced into position.
The Contractor shall establish his own checking routine to be performed prior to the Employer's final
checking. During the Contractor's checking all nuts shall be secured by punching. The threads shall be
punched with at least 90-degree angles between punches.
If required by the Employer, all bolts and nuts at less than 3 meters above the ground shall be secured by
tack welding the bolt threads at their emergence from the nuts in order to prevent pilfering. Each weld shall
be brushed to remove traces of slag and coated with two layers of zinc rich paint. Alternatively, anti-theft
bolts/nuts shall be used for parts or all of the towers, as instructed by the Employer prior to the Contractor
placing orders for the supply of bolts/nuts.
After erection of all towers, the steelwork within 50 mm of the upper surface of the concrete, and the upper
surface of the concrete itself shall be painted with two coats of bituminous or other approved paint.
Suitable ladders shall be used whenever necessary during erection of the towers/poles. All ladders and
removable step bolts shall be removed when erection work is not in progress.
At each tower/pole the Contractor shall install the relevant tower/pole signs as specified.
Handling and storage of all material shall be such as to prevent injury to members or damage to the zinc-
coating. Steel in storage shall be lifted off the ground.
Distinct, legible and durable marking of all parts shall be the responsibility of the Contractor.
After erection all towers/poles shall be cleaned of all foreign matter.
10.1.13.2 Repair of Damage

Deformed members shall be straightened in a manner approved by the Employer, or replaced. Members,
which may have suffered a strength reduction by deformation, shall be replaced. If fabrication errors are
discovered, the Contractor shall notify the Employer who will decide whether the errors may be corrected in
the field or if the member shall be replaced. No field welding will be accepted.
Repair and means of repair of damaged zinc coating, including white rust, shall be subject to the approval of
the Employer.
10.1.13.3 Anti-climbing Guar d

All towers/poles shall be equipped and erected with anti-climbing guards according to approved drawing.
10.1.13.4 Guar d Against Bir ds

If so specified in the Technical Schedules all towers/poles shall be equipped with an approved device
immediately above each suspension insulator string attachment, to prevent perching of birds.
10.1.13.5 Er ection Toler ances

All towers/poles shall be vertical within a tolerance at the tower/pole top of 0.3 per cent of the tower/pole
height after conductors and earth-wires have been clamped in.
10.1.14 INSTALLATION OF INSULATORS, CONDUCTORS AND EARTH-WIRES
10.1.14.1 Insulators and Fittings

Insulators shall be handled with the utmost care in order to avoid chipping or cracking of the discs, and
bending of the pins. Insulators shall remain in their shipping crates until required for assembly at the
tower/pole site.
Before assembly all units shall be closely inspected. Bent pins will not be allowed. In order to minimize the
risk of pin bending no rope slings shall be used for lifting assembled units, but a suitable hook shall be
applied to the insulator.
Invisible disc cracks may be detected by sounding each unit with a light wood or hard-rubber club. Cracked
units shall be replaced, the cracked ones shall immediately be destroyed in order to avoid unintentional re-
use.
Prior to installation and immediately before hanging, the insulators shall be thoroughly cleaned and all cotter
pins shall be checked for correct positioning and freedom from defects.
Insulator strings may be climbed only without shoes or with shoes with rubber soles.
All bolts, nuts and cotter pins shall be installed so as to facilitate easy inspection and live line maintenance
work.
It is the Contractor's responsibility to ensure that all insulator strings are assembled in accordance with
approved drawings.
10.1.14.2 Conductor J oints and Tension Assemblies

Compression joints and tension clamps shall be installed in accordance with good engineering practice. The
Contractor shall submit detailed written instructions for the complete installation procedure for the approval
of the Employer.
The man appointed by the Contractor to be responsible for the installation of the joints and tension
assemblies shall punch his identification sign on each assembly.
All installation of joints and clamps shall be made in the presence of the Employer and shall be punched with
his identification sign.
Wherever possible full use shall be made of maximum drum lengths of conductors and earth-wires in order
to reduce the number of joints.
The Employer shall approve the number of joints and their location in the spans.
No joints shall be made in spans, which cross main roads, power lines, or in the major river crossings, nor,
whenever conductor drum lengths permit, in spans immediately adjacent thereto.
The distance between joints of the same conductor shall in no case be less than 100 m. Joints shall in no case
be installed closer than 15 m to the centre of suspension clamps or closer than 100 m to tension clamps.
The Contractor shall keep a record of all joints and tension clamps giving the location, type and date of each
assembly.
10.1.14.3 Ear th-wir e J oints and Tension Assemblies

Earth-wire joints and tension clamps shall also be made in accordance with the requirements of the previous
clause where applicable. The procedure to be followed shall be as recommended by the manufacturer.
10.1.14.4 Repair Sleeves

In the case of damage to the conductor aluminium strand an approved repair sleeve shall be installed
provided the damage consists of not more than 2 strands broken or knocked deeper than one half of their
diameter. When more than 2 strands are so damaged, the damaged section of the conductor shall be cut out.
Repair sleeves shall be installed in the presence of the Employer.
10.1.14.5 Tools and Equipment

Tools and equipment shall conform to IEEE Standard 524, Guide to the Installation of Overhead Trans-
mission Line Conductors.
Stringing pulleys shall have adequate strength and be of approved design. They shall be equipped with ball
or roller bearings. The sheave diameter measure at the bottom of the groove shall not be less than 18 times
the outside diameter of the conductor or earth-wire. The groove shall be wide enough for the passage of
compression joints. Stringing pulleys for the conductors and earth-wires shall have the sheave grooves lined
with electrically conductive neoprene or equivalent.
Pulleys shall be inspected daily for proper operation. The use of defective pulleys will not be permitted.
Running out blocks shall have grooves of a shape and size in accordance with the requirements of IEEE
Standard 524. The sheaves shall be lined with boned neoprene or equivalent. Unlined sheaves made of
aluminium or magnesium alloy may be used for installation of galvanized steel stranded overhead ground
wire.
Come-along clamps shall be of the type to grip the conductor more firmly when the holding power grows
automatically as the tension of the conductor increases.
Suitable hydraulic compressors equipped with pressure gauge and dies or other approved types shall be used
for tension joints and compression dead-end connector assemblies.
Length meter for measuring the conductor during paying out shall be provided.
10.1.14.6 Str inging

Conductors and earth-wires shall be run out from drums mounted on trailers or drum stands.
Conductors and earth-wires shall be pulled out and strung by the use of the Controlled-Tension Method.
Conductors shall as a principle never be allowed to touch ground.
The Contractor shall submit in writing, for the approval of the Employer, a complete and detailed stringing
plan, description of the stringing equipment and the stringing and sagging procedure intended for use.
Unless otherwise approved by the Employer the tension stringing procedure shall be in strict conformity with
the recommendations of the manufacturer of the stringing equipment. Only specially trained linesmen must
be employed who are well acquainted with the handling and running of the particular equipment to be used.
Reliable means of instantaneous two-way communication must be available between the pulling and the
braking crews and between these crews and any observation posts that may be placed along the stringing
section.
The stringing equipment shall be set up so as not to cause excessive vertical loads on the towers/poles. The
distance to the nearest tower/pole through which the cables are being strung shall be selected with due regard
to the relative levels of the pulleys on the tower/pole and the stringing equipment. A reasonable allowance
should also be made for possible accidental over-tensioning of the cables.
Tools for stringing of conductors, earth-wires, clamps and joints shall be to the approval of the Employer.
Stringing shall be executed in such a manner that destruction, over tensioning of individual wires or layers,
or other deformation or damage to the conductors shall not occur. The use of 'service' compression joints for
the purpose of pulling out conductors during erection, the use of insulators and line materials in general for
erection purposes will not be allowed. Auxiliary erection clamps, or hauling devices shall be of approved
design, and shall under erection conditions allow no relative movement of strands or layers of the
conductors. Cutting of layers of conductors shall be carried out with tools designed not to damage underlying
strands. Cropping or shearing of complete conductors shall not be permitted. The cut ends of the conductors
and the joints, clamps and fittings attached to the conductor themselves shall be treated in an approved
manner to prevent ingress of moisture.
Stringing pulleys shall preferably be located at approximately the same levels as the conductors and earth-
wires will occupy when installed.
At all times during stringing the conductors and earth-wires shall be handled and protected so as not to be
scratched, nicked, abraded, kinked or damaged in any way. If during stringing it should prove inevitable to
lower the conductors to the ground, suitable non-metallic lagging shall be placed underneath.
Conductors, which have been subject to bird-caging during stringing, will not be accepted, and care shall be
taken to position equipment in such a manner that the chances for bird-caging to occur are minimized.
Stringing tensions shall at no times exceed corresponding sagging tensions by more than 20%.
If, for any reason, stringing operations in progress must be interrupted, the conductors and earth-wires may
be left in the stringing pulleys, but their tension shall be reduced as far as possible. In all cases, however, the
cables must be kept completely clear of the ground, say by approximately 2 m, and sufficiently far away
from any obstacles, which might cause abrasion of the cables if touched by them.
If the conductors and earthwires have to be left in the pulleys during night-time, the ground clearance must
be increased or the cables must be guarded to prevent safe passage of possible off-road vehicles, which may
operate in the area during night-time.
If the interruption lasts for more than 40 hours or if stormy weather has prevailed, the cables shall be closely
inspected for damage. Such inspection applies particularly to the suspension points where the cables have
been resting in the pulley sheaves.
At all times during stringing, sagging and clamping operations, the conductors, earth-wires, reels and hauling
equipment shall be effectively grounded.
In order to prevent overstressing of towers/poles, the Contractor shall make suitable arrangements for
temporary staying of towers/poles, where necessary. Suitable plates (detachable or otherwise) shall be
provided on the towers/poles for attachment of any temporary guys.
Damages to the conductors or earth-wires shall immediately be reported to the Employer who will instruct
the Contractor how to proceed.
The Contractor shall make any necessary special arrangements for running out and sagging the conductors
where the route crosses buildings, orchards, plantations, gardens, or other ground over which erection cannot
be carried out in the normal manner. No extra charge for manhandling of materials or for any special
precautions or methods necessary at such positions shall be allowed.
The Contractor shall also make such special arrangements as the Employer may approve where power lines
are to be crossed.
No additional payment will be made for the erection of the conductors and earth-wires over roads, rivers,
navigable waterways, railways, and communication circuits, or over or under existing power lines which
have been made dead for the time being. Where the conductors and earth-wires have to be erected whilst the
power to be crossed is alive, payment additional to the prices stated in the Schedules of Quantities shall be at
rates to be agreed and shall include any special scaffolding or equipment required.
10.1.14.7 Sagging
The Contractor shall submit for approval longitudinal profiles with curves showing the correct initial and
final sags and tensions of the conductors and earth-wires at various temperatures and spans. Allowance shall
be made for permanent elongation of conductors and earth-wires as may take place in service.
The Contractor shall provide three complete sets of sag templates in celluloid or similar material based on
approved equivalent spans or other approved methods. The templates shall show the conductor sags at 80oC
after permanent elongation and in still air, and the ground clearance line. An additional curve is to be
marked on the templates to enable the minimum weight condition at 20oC to be checked in accordance with
the Specification. Each template shall be clearly endorsed with the design loading conditions, type of
conductor, and basis of calculation, equivalent span or curve parameters and the scale appropriate to the
scale of the relevant profile.
The Contractor shall submit for approval of the Employer, sag and tension charts for use during erection
which shall be established with due regard to the specific stringing methods to be employed so that
remaining creep after clamping may be assessed and taken into account with reasonable accuracy.
Erection sagging charts or tables shall show sag in still air against span length for temperatures between 15o
and 65oC in increments of 5oC.
Sagging temperature shall be read from a certified thermometer, the bulb of which has been inserted in an
approximately 50 cm long piece of conductor with the inner layers removed. The thermometer so equipped
shall be freely suspended in the air without any shielding and not less than 3 m above ground. Temperature
readings will be taken only after 20 minutes' exposure.
The Contractor shall provide suitable dynamometers, thermometers, sighting rods and other approved
apparatus necessary for the proper checking of the work. Dynamometers, if used, shall preferably read in
kilograms or Newton, and, when required by the Employer, shall be tested and, if necessary, re-calibrated.
After completion of stringing operations the conductors and earth-wires shall be sagged in accordance with
agreed sagging procedure and relevant erection sagging chart or table. It is essential that prescribed hold
periods before definite sagging are rigorously observed.
The Contractor shall check the sag of each conductor and earth-wire of a sagging section in at least one span
of approximate average length. The sags shall also be checked in all spans exceeding 450 m and in spans on
each side of angle structures and sharp breaks in profile. Intermediate spans shall be inspected for uniform
sag.
The total number of spans to be measured shall be as follows:
Sagging Section Span Number of Measurements

1 1
2-6 2
7-15 3
16 or more 4
Where and if the Employer wants to check sags himself, the Contractor shall furnish such assistance in
equipment and personnel as may be required.
Sagging sections shall be limited to such length as can be sagged satisfactorily.
Final sagging of conductors shall not be made earlier than 8 hours, and not later than 48 hours after they have
been taken up to approximate specific sag. All conductors of a sagging section shall be sagged at the same
time.
Conductor tension shall be equalized between sagging sections so that the insulator strings will be vertical
when successive sagging sections have been clamped in.
The Contractor shall keep a record on approved schedules of the particulars of the sagging of conductors and
earth-wires on each sagging section.
At 20oC in still air, in any span, the earth-wire sag shall be approximately 20 per cent less than the line
conductor sag.
10.1.14.8 Clamping In
After finishing sagging operations, the conductors and earth-wires shall be clamped-in according to agreed
procedure. Tension clamps shall be installed and properly anchored in advance of clamping-in at suspension
strings. In order to make future adjustments possible, approximately one half of the available length
adjustment of turnbuckles shall remain after anchoring.
Clamping-in shall be affected within 48 hours after completion of sagging unless otherwise agreed.
In transferring the conductors from the stringing pulley to the suspension clamps, the conductors shall be
carried by neoprene lined hooks with a long enough saddle-shaped bearing surface not to damage the
conductors or any part thereof, or by means as agreed by the Employer. The neoprene lining shall be
electrically conductive.
Armour rods shall be installed in strict accordance with the manufacturer’s instruction. They shall be centred
within plus or minus 5 cm when installed; the difference between the ends of the rods shall not exceed 5 mm.
All marking of conductors, e.g. for the centring of clamps or armour rods shall be done with tape or other
inoffensive means. Scratch marks or similar will not be permitted.
Tightening torque of clamp bolts shall be as recommended by the manufacturer.
At suspension towers/poles the earth conductor suspension clamp shall be securely bonded to the tower/pole
steelwork with a conductor having a cross-sectional area of not less than the earth conductor. The bond shall
be terminated with compression lugs and be flexible so as not to interfere with the suspension clamp
movement. At tension towers/poles the earth conductor shall be securely bonded to the tower steelwork/pole
in an approved manner.
10.1.14.9 Sagging Toler ances

Immediately after clamping-in, sag tolerances of plus or minus 2% of specified sag will be permitted,
provided that all conductors in the span assume the same sag and specified clearance to ground will be
obtained.
Suspension insulators shall be vertical within plus or minus 30 mm longitudinally.
The maximum permissible difference in sag between any two phases, or conductors in different phases, shall
not exceed 200 mm.
10.1.14.10 Tr ansposition Insulator Sets

If so specified in the Technical Schedules, transposition of phase conductors shall be carried out in
accordance with relevant approved drawings. Transposition arrangements shall be installed in or next to
tension towers/poles. Counterweights may be used to limit swing of the loops.
10.1.14.11 Vibr ation Damper s

Vibration Dampers shall be installed as specified within 48 hours after clamping in. Dampers shall be
located, installed and clamped in accordance to the manufacturer's recommendations.
Before installation all dampers shall be thoroughly cleaned and inspected for bent spring wires, distorted
clamps or other damage.
10.1.14.12 Bir d-Diver ter s

If so specified in the Technical Schedules bird flight diverters that indicate the position of earthwires in a
span will be required in migration routes for birds along the transmission line route. Bird flight diverters will
need to be approved by the Employer.
10.1.15 SPARE MATERIALS

All excess or spare materials supplied under this Contract or provided to the Contractor under separate
supply contracts, shall be delivered by the Contractor to the Client’s depot of their choice. The materials
shall have proper packaging, and the Contractor shall provide complete material lists.
10.1.16 ENVIRONMENTAL PROTECTION REQUIREMENTS (EPR)

The Contractor shall comply with the EPR Specification.
If so stated in the Technical Schedules an Environmental Supervisor will be appointed by the Employer to
carry out the liaison with affected parties, to monitor the Contractor’s compliance with the EPR, as well as
general co-ordination of environmental issues. This person will report to the Employer or the Employer's
representative.
10.1.17 TOOLS
If so specified in the Technical Schedules the following tools and appliances may be purchased under this
Contract:
(i) One set of special tools and equipment for the normal maintenance of the transmission lines and
associated equipment.
(ii) One set of special lifting and handling equipment for the normal maintenance of the transmission
lines.
(iii) One set of special tools and equipment required for the dismantling, reassembly, checking or
adjustment (but not normal maintenance) of the transmission lines and associated equipment.
Each tool or appliance shall be clearly marked with its size and/or purpose and may be used for the purpose
of construction. They shall be handed over to the Employer upon taking over of the lines.
Each set of tools and appliances under category (i), together with the smaller items under (ii) and (iii) shall
be suitably arranged in fitted steel boxes. The number of boxes shall be determined taking into account the
type and size of tools and appliances and what can practically be grouped together. If the weight of any box
and its content should be such that it cannot be conveniently carried, it shall be equipped with steerable
rubber tyre wheels.
Each box shall be fitted with a lock and shall be painted black and clearly marked in white letters with the
name of the project and equipment for which the tools and appliances are intended.
The tools and appliances packed in suitable boxes shall be handed over to the Employer at the time of issue
of the Taking Over Certificate.
10.1.18 DATA SUBMISSION SCHEDULE

cation or shipment
a Technical data requested by this
d Transmission line design data With Tender Yes
e Foundation design data With Tender Yes
f List of standards used With Tender Yes
g Fabrication Sequence 45 days before fabrication No
h Notification of Tests 30 days before test No
i Packing and Storage 30 days before fabrication No
j Installation/erection Instruction 30 days before installation Yes
k Documents for Records With shipment No
l Tests Reports 15 days after test Yes
T-S-11-001 ENVIRONMENTAL REQUIREMENTS SP
T-S-11-001 ENVIRONMENTAL PROTECTION REQUIREMENTS Rev. Draft
T-S-11-001 ENVIRONMENTAL PROTECTION REQUIREMENTS
CONTENTS
11.1.1 SCOPE............................................................................................................................................3
11.1.1.1 General ...................................................................................................................................3
11.1.1.2 Services to be provided by the Contractor .............................................................................3
11.1.1.3 Services to be provided by Employer .....................................................................................3
11.1.2 Monitoring ......................................................................................................................................3
11.1.3 The Purpose of the EPRS ...............................................................................................................3
11.1.4 Administrative Institutions .............................................................................................................4
11.1.5 Contractor’s Code Of Conduct .......................................................................................................5
11.1.6 Employment And Sub-Contracting ................................................................................................5
11.1.6.1 Employment ...........................................................................................................................5
11.1.6.2 Sub-Contracting......................................................................................................................5
11.1.7 Environmental Aspects Of Design .................................................................................................6
11.1.8 General Guidelines For Construction .............................................................................................6
11.1.9 Temporary Works...........................................................................................................................7
11.1.10 Protection Of Vegetation ............................................................................................................7
11.1.10.1 Bush Clearing in the Line Route ............................................................................................7
11.1.10.2 General Woodland Vegetation ...............................................................................................8
11.1.10.3 Rare and Endangered Species ................................................................................................8
11.1.10.4 Wetland Areas ........................................................................................................................8
11.1.10.5 Sites of Special Interest ..........................................................................................................8
11.1.11 Protection Of Fauna....................................................................................................................8
11.1.12 Protection Of Archaeological And Paleontological Sites And Materials...................................9
11.1.13 Protection Of Infrastructure And Private Property .....................................................................9
11.1.13.1 Roads and Road Transport .....................................................................................................9
11.1.13.2 Water Supplies .....................................................................................................................10
11.1.13.3 Private Property, Schools and Institutions............................................................................11
11.1.14 Erosion Protection ....................................................................................................................11
11.1.15 Refuse and Waste Control ........................................................................................................11
11.1.16 Water Pollution Control ...........................................................................................................12
11.1.16.1 General Guidelines ...............................................................................................................12
11.1.16.2 Water Discharge From The Works.......................................................................................12
11.1.16.3 Fuel Storage and Workshop Areas .......................................................................................12
11.1.16.4 Ablution and Toilet Facilities ...............................................................................................12
11.1.16.5 Silt Traps ..............................................................................................................................13
11.1.16.6 Sedimentation Ponds ............................................................................................................13
11.1.16.7 Groundwater .........................................................................................................................13
11.1.17 Air Pollution Control ................................................................................................................14
11.1.18 Noise Pollution Control ............................................................................................................14
11.1.18.1 Restriction on Working Hours..............................................................................................14
11.1.18.2 Plant and Equipment ............................................................................................................14
11.1.19 Explosives ................................................................................................................................14
11.1.20 Stockpiles And Spoil Dumps ...................................................................................................15
11.1.21 Borrow Areas And Quarry Sites...............................................................................................15
11.1.22 Labour Camps ..........................................................................................................................15
11.1.23 Health .......................................................................................................................................16
11.1.24 Training Of Employees ............................................................................................................16
11.1.25 Respect For Cultural Values, Beliefs And Property Rights .....................................................17
11.1.26 Compensation ...........................................................................................................................17
11.1.27 Rehabilitation Of Works Areas ................................................................................................17
11.1.27.1 General .................................................................................................................................17

11.1.27.2 Shaping of Areas ..................................................................................................................17
11.1.27.3 Grassing ................................................................................................................................18
11.1.27.4 Trees And Shrubs .................................................................................................................18
11.1.1 SCOPE
11.1.1.1 Gener al
This chapter outlines the Contractor’s duties and responsibilities with respect to environmental protection
during construction of overhead transmission lines rated 88 kV and above.
The Contractor shall carry out the specified environmental protection requirements to the approval of the
Employer.
If so instructed by the Employer, the Contractor shall implement additional mitigation measures payable
under the applicable rates in the Daywork Schedule.
It is not the Employer's intent to specify all environmental requirements or to set forth those requirements
adequately covered by applicable standards. The Contractor shall bear the full responsibility with all the
requirements herein and the costs of compliance are deemed to be included in the unit rates in the Schedule
of Quantities.
No deviations shall be made from this specification unless waived or modified in writing by the Employer.
The Contractor(s) shall obtain from its sub-contractor(s) / supplier(s) a statement as to compliance with this
specification without exception and/or if there are any exceptions, these shall be described in detail and
included in the Contractor’s Tender. The Contractor shall add a statement that no other exceptions are taken
to this specification.


11.1.2 MONITORING
If so specified in the Technical Schedules an Environmental Supervisor (ES) will be on site on part time or
full time basis to monitor the works. The ES will report to the Employer's Site Manager and participate in all
site meetings and the day-to-day running of the project.
The environmental monitoring will mainly concentrate on the following aspects of preventative or potential
impacts minimisation measures during construction:
o line route bush clearance
o site establishment
o soil erosion
o noise and dust nuisance
o water pollution
o disturbance of archaeological and cultural sites
o disruption of the socio-economic fabric
o local employment and other specified benefits to indigenous communities.
In addition, the ES will handle Right of Way issues falling under the responsibility of the Employer.
11.1.3 THE PURPOSE OF THE EPRS

The construction of high voltage transmission lines gives rise to potential environmental impacts associated
with earth-moving, loss of vegetative cover, foreclosure of other land uses, soil erosion; degradation of
vistas, destruction of cultural sites and interference with movements of wildlife, livestock, and local
residents. The impacts of maintenance and repair, although similar, are less significant than those from
construction because the latter breaks previously undisturbed ground, with potential ecological and social
implications. Transmission lines exert few indirect impacts. Virtually all-environmental impacts of
transmission lines are direct and occur along or very near the line.
Any standard contract for the construction of transmission lines contains general clauses that promote
environmental protection during construction. The Environmental Impact Assessment (EIA) provides a
project with specific information on the potential impacts identified.
In general efforts shall be made to avert adverse impacts by alignment (line routing), as long as this is
technically and economically feasible. Other impacts shall be mitigated within the context of the construction
contract, hence the requirements in this Chapter.
11.1.4 ADMINISTRATIVE INSTITUTIONS

In addition to these requirements, the Contractor shall comply with the statutory requirements of Zimbabwe.
For the Contractor’s guidance, the main statutory requirements related to environmental protection are given
in the Acts listed hereunder:
o Environmental Management Act [Chapter 20:27]
o Water Act (Cap. 20:24]
o Forest Act [Chapter 19:05]
o Agricultural Land Settlement Act [Chapter 20:01]
o Parks and Wildlife Act [Chapter 20:14]
o National Museums and Monuments Act [Chapter 25:11]
o Communal Land Act [Chapter 20:04]
o Land Acquisition Act [Chapter 20:10]
o Mining and Minerals Act [Chapter 21:05]
o Explosives Act [Chapter 10:08]
o Parks and Wildlife Act [Chapter 20:14]
o The Roads Act [Chapter 20:14]
o Factories and Works Act [Chapter 14:08]
o Rural Land Act [Chapter 20:18]
Relevant ministries and offices that may be contacted as needed are listed in the Technical Schedules.
These institutions are located in the provinces where the following ministries or authorities are located;
o Environmental Management Authority
o Parks and Wildlife Management Authority
o Agricultural Rural Development Authority
o City Councils (various)
o Rural District Councils (various)
o Department of Natural Resources
o Ministry of Agriculture, Mechanisation & Irrigation Development
o Ministry of Energy and Power Development
o Ministry of Environment & Natural Resources Management
o Ministry of Health and Child Welfare
o Ministry of Labour and Social Welfare
o Ministry of Lands and Rural Resettlement
o Ministry of Local Government, Urban and Rural Development
o Ministry of Mines and Mining Development
o Ministry of Public Works
o Ministry of Transport Infrastructural Development
o National Museums and Monuments of Zimbabwe
o Rural Electrification Agency
o Village Development Committees
o Ward Development Committees
o Zimbabwe Electricity Supply Authority Holdings
o Zimbabwe Farmers Union
o Zimbabwe National Water Authority
In addition, various regulations and statutory instruments have been promulgated under the Above Acts. Of
particular note are:-
i. Water (Effluent and Wastewater Standards) Regulations, 1977 (Amended 1982);

ii. Public Health (Effluent) Regulations, 1977;
iii. Explosives Regulations, 1989 (1990) Statutory Instrument 72 of 1989;
iv. Natural Resources (Protection) Regulations, 1976;
v. Factories and Works (General) Regulations RGN No. 263 of 1976
It should be noted that the Environmental Management Act above is an Act to provide for the sustainable
management of natural resources and protection of the environment; the prevention of pollution and
environmental degradation. This Act repealed the Natural Reources Act [Chapter 20:13]; the Atmospheric
Pollution Prevention Act [Chapter 20:03]; the Hazardous Substances and Articles Act [Chapter 15:05] and
the Noxious Weeds Act [Chapter 19:07].
It is the Contractor’s responsibility to familiarise himself and ensure compliance with the above Acts,
regulations and statutory instruments, and any other Acts not listed above which might be relevant to his
operations. Additional guidelines and/or protection measures issued by the respective Government
Ministries or Departments shall also be considered by the Contractor.
11.1.5 CONTRACTOR’S CODE OF CONDUCT

In general, human beings are normally averse to invasion of privacy, regardless of status of society (modern
or traditional). They expect an element of respect from outsiders.
Therefore, the contractor shall prepare a draft code of conduct for the workforce for submission to the
Employer before commencement of work. The code of conduct shall be discussed during the planning phase
of the project and thereafter finalised.
11.1.6 EMPLOYMENT AND SUB-CONTRACTING
11.1.6.1 Employment
The Contractor is encouraged to employ labour intensive techniques as much as possible. It is preferred that
the Contractor and his Sub-contractors employ local residents of the area through which each section of the
transmission line passes. The Contractor shall tighten controls on employment to ensure that people from
outside the area are not employed at the expense of locals, except in the case of skilled or specialised areas.
11.1.6.2 Sub-Contr acting

The Contractor shall endeavour to engage local sub-contractors, particularly in areas not requiring specialist
line construction skills, such as:
o Bush clearing;
o Access road construction and maintenance;
o Excavation and/or concrete works for tower foundation footings;
o Haulage of materials;
o Watering of roads for dust abatement;
o Rehabilitation and maintenance of disturbed areas;
o Road Maintenance;
o Construction and maintenance of any buildings required for site establishment;
o Catering;
o Refuse disposal;
o Security.
11.1.7 ENVIRONMENTAL ASPECTS OF DESIGN

The following safety features shall be applied:
1. Anti-climbing device to prevent climbing of towers.
2. Tower-foot earthing for lightning and over voltage protection.
3. Design of lower part of tower legs to prevent animals from getting trapped.
4. Adherence to statutory electrical clearances.
5. Bird guards to prevent insulator contamination by bird droppings.
6. Bird diverters to prevent birds from being maimed or killed in the event of a collision with transmission
lines
7. Use of anti-theft bolts and nuts to reduce the risk of tower collapse resulting from pilfering of steel
members.
8. At substations, the transformer foundation plinth shall be designed with a sump to trap oil in the event of
accidental spillage; the sump shall be sized to accommodate all the oil in the transformer, including
allowances for expansion of the oil due to high temperature. The sump shall be covered with a steel grid
overlaid by a layer of stones, to reduce oxygen supply and thereby minimise the risk of oil fires.
9. To improve visibility, spans crossing flight paths within 2000m of an aerodrome or airport, the
conductors or overhead earth wires shall have spherical markers of diameter not less than 60 cm and
spaced not more than 30 m located on the highest line; red or white with orange coloured markers shall
be displayed alternately. Where additional aircraft warning lights are required, these shall be to the
approval of the Employer and all associated costs for installation of the lights shall be to the approval of
the Employer.
11.1.8 GENERAL GUIDELINES FOR CONSTRUCTION

In general the Contractor shall conduct his activities so as to cause the least possible disturbance to existing
amenities, whether natural or man-made, so as to comply with all relevant statutory requirements.
Requirements with respect to access roads and wayleaves are specified in T-S-10-001 Construction SP of
these technical specifications.
The Contractor shall abide by the following general environmental guidelines during the course of
undertaking the works.
1. The Contractor shall not establish or undertake any activities that, in the opinion of the Employer, are
likely to permanently affect the scenic quality of the works area. Where required, the Employer may
direct the Contractor to refrain from such activities or to take ameliorative actions to reduce the adverse
effect of such activities on the scenic quality of the environment.
2. Painting or marking of natural features shall not be permitted. Marking for surveying and other
purposes shall be carried out only with pegs and beacons.
3. No work shall be carried outside the defined area of the Works without the prior written approval from
the Employer.
4. The Contractor shall take all necessary actions to ensure that water quality in nearby rivers and streams
is not adversely affected. Other than that which must be there for operational reasons, no construction
activity will take place within 30 metres of a riverbank, whether the riverbed is dry or wet.
5. The effects of runoff and erosion within construction areas shall be minimised.
6. To minimise air and noise pollution, contractors shall use only equipment in good condition, which shall
be properly maintained.
7. Blasting shall only be carried out when unavoidable. Where blasting has to be carried out it shall be
strictly controlled.
8. On- or off-site, workers shall not wantonly kill or injure any creatures except those (such as rats, flies
and mosquitoes) known to be vectors of disease.
9. The Contractor's Health & Safety Officer and the Employer shall document accidents at a construction
site. Safety rules and procedures shall be tightened in the light of that information to reduce the chances
of recurrence.
10. The Contractor and his subcontractor(s) shall at all times exercise due care and diligence not to damage
fences, walls, drains, roads, tracks, buildings, fields, pasture, hedges and trees. All damage shall be made
good at the first opportunity, at the Contractor’s cost.
11. Disturbance or disruption of the daily lives of local communities and their livelihood, including noise
and dust pollution shall be minimised in as far as is practicable.
12. The Contractor shall ensure that the construction Site is maintained in a neat and tidy condition at all
times.
13. The Contractor shall employ as many locals as is practically possible for the execution of the Works.
The following specific environmental guidelines shall be observed and implemented by the Contractor in
mitigation of potential environmental impacts in areas of activity, access roads, borrow areas, spoil disposal
areas, labour camps and storage areas.
11.1.9 TEMPORARY WORKS

1. Use of existing facilities such as access roads and site establishment sites and/or their improvement shall
be preferred to the construction of new ones.
2. Public access roads used by the Project shall be maintained in a trafficable, safe and minimum dust
condition, at all times. Driving speeds shall be limited to 40km/hr. Courtesy shall be extended to other
road users with all construction traffic expected to give way to members of the public.
3. A minimum of two toilets for temporary camps, and full ablution facilities for permanent camps shall be
provided. The use of the bush for relieving oneself shall be strictly prohibited. Latrines at camps will be
closed and sealed after completion of works.
4. Camps and storage areas shall be located away from drainage courses and wetlands. Wherever possible,
they will be sited within urban industrial areas.
5. Camps and work-sites shall be kept clean and tidy.
6. Fuel, lubricants and other chemicals shall be stored in above ground storage facilities such that the entire
surface area can be visually inspected. Tanks shall be inspected twice daily and any leakage stopped
immediately.
7. Sumps surrounded by low bunds and floored with impermeable material shall be constructed beneath all
oil storage tanks. Other than trivial amounts, oil spilled to sumps will be removed for recycling or safe
disposal.
8. Oil changes in machinery and equipment including vehicles shall take place only in depots (never in the
field). Drip pans will be placed under the equipment throughout oil changes and lubrication.
9. Construction workers are discouraged from woodcutting and fishing, and shall be dismissed for
unauthorised hunting. Contractors and their workforce may use local supplies of wood, within
moderation, if there is no local shortage; but they should purchase wood from the local population rather
than just taking it freely.
10. Demobilisation from a site will include removal and safe disposal of all temporary structures and wastes.
Stored topsoil shall be restored to site which will be planted with indigenous grasses, where instructed
by the Employer. No un-drained water will remain on site.
11.1.10 PROTECTION OF VEGETATION
11.1.10.1 Bush Clear ing in the Line Route

Bush clearing is specified in the Construction Specification T-S-10-011.
11.1.10.2 Gener al Woodland Vegetation

The Contractor shall ensure that all work is undertaken in a manner that minimises the impact on vegetation,
outside the immediate area of the Works. The following shall apply with respect to the protection of areas of
vegetation adjacent to the area of the Works.
1. Vegetation clearance shall only take place within the wayleave.
2. To facilitate line of sight for the line survey, branches may be pruned from mature tees but without
chopping down the entire tree; younger and flexible trees shall be pulled as necessary from the line of
sight taking due care to avoid permanent damage.
3. No tree or shrub outside the area of the Works shall be felled, topped, cut, pruned, or otherwise
interfered with, without the prior written approval of the Employer.
4. No tree or shrub outside the area of the Works shall be felled, topped, cut or pruned until it has been
clearly designated for this purpose by the Employer. Where pruning is required it shall be by carried out
with manual methods.
5. Spoil shall not be heaped directly against trees if in so doing it can damage the stem.
6. No tree or other combustibles outside the area of the works shall be burned for any purpose.
7. Where the Works involve clearing and ground excavation, top-soil and sub-soil shall be selectively
removed and stockpiled separately for replacement in the reverse order in which they were removed, to
facilitate reinstatement of sites and their subsequent natural rehabilitation.
8. Trees which have been selected for preservation within or adjacent to any area of the Works shall be
fenced around their drip line, and no open fires shall be permitted under these trees.
9. Earth-moving equipment shall be thoroughly washed before bringing to site and the washings caught in
a sump, and incinerated. So doing is intended to destroy adhering seeds and soil. Equipment brought
from outside Zimbabwe will be repainted before importation, and sprayed with insecticide on arrival, to
reduce the risk of introducing exotic pests to the country.
11.1.10.3 Rar e and Endanger ed Species

Any protected plant species found should be reported to the Employer, prior to clearing or stripping any area,
who will provide specific guidelines for their removal and transplanting.
11.1.10.4 Wetland Ar eas

Wetlands are frequently nesting areas for reed nesting bird species, and are natural habitats for a variety of
sensitive ecological communities. Where disturbance of these sensitive areas cannot be avoided, the
following construction guidelines shall apply:
1. Construction work shall, where possible, be restricted to the late dry season.
2. Wetlands shall be excavated by approved methods, that avoid the development of quagmire conditions
and subsurface compaction that would result from the use of heavy machinery.
3. After construction, the natural ground level and drainage pattern shall be restored.
11.1.10.5 Sites of Special Inter est

These are sites that normally are very limited in extent and number. If they contain rare or endangered
species of flora and fauna, then it will be highly desirable that such sites are minimally disturbed, or
preferably, that the line route avoids them altogether.
Sites of special interest shall be identified during the survey, and the conservation practice shall be specified
on a case-to-case basis.
11.1.11 PROTECTION OF FAUNA

The mitigation guidelines on vegetation, if adhered to, will generally help to protect those species whose
habitat is in the project area.
The Contractor shall ensure that all work is undertaken in a manner that minimises the impact on the local
fauna. The following guidelines shall apply with respect to fauna management and protection.
1. Under no circumstances shall any animals be handled, removed, killed or interfered with by the
Contractor, his employees, his subcontractors or his subcontractors’ employees.
2. The Contractor, his subcontractors or their employees shall not bring any domestic animals onto the
Site.
3. The Contractor shall ensure that the Site is kept clean and tidy and free from rubbish which would attract
animal pest species.
4. There shall be no feeding of native animals.
5. Where animal tracks are found, these paths shall be kept open and freely passable at all times.
11.1.12 PROTECTION OF ARCHAEOLOGICAL AND PALEONTOLOGICAL SITES AND

MATERIALS
The following guidelines shall apply during construction:
1. In carrying out construction of the Works, the Contractor, subcontractors and their suppliers of materials
shall comply with the provisions of Zimbabwean law.
2. The Contractor shall ensure that key members of his staff are familiar with archaeological and
paleontological materials likely to be found in the project area.
3. Should the Contractor expose any archaeological artefacts during excavation, work shall cease
immediately and the Employer shall be notified as soon as possible.
4. Upon receipt of such notification, the Employer shall arrange for the excavation to be examined as soon
as is practicable, and shall advise the Contractor of necessary actions to be taken.
5. Under no circumstances shall archaeological artefacts be removed, destroyed or interfered with by the
Contractor, his employees, his subcontractors or his subcontractors’ employees.
11.1.13 PROTECTION OF INFRASTRUCTURE AND PRIVATE PROPERTY

The following guidelines shall apply in order to mitigate the impacts of construction activities on public
infrastructure and private property in the project area.
11.1.13.1 Roads and Road Tr anspor t

11.1.13.1.1 General
In carrying out construction of the Works, the Contractor, subcontractors and their suppliers of materials
shall comply with the provisions of the relevant laws of Zimbabwe.
Where designated access routes are indicated in the Contract, the Contractor shall use no other routes without
the approval of the Employer.
Where possible, medium-sized vehicles shall be used in transporting labour and materials in order to
minimise noise and general wear of the roads.
Where black cotton soils are prevalent, heavy construction vehicles and plant should not be used on access
roads during the rainy season, unless the access roads are upgraded by laying suitable gravel and installing
drainage to prevent the occurrence of quagmire conditions.
11.1.13.1.2 Maintenance of Roads

i. All public and private roads used by the Contractor, subcontractors or suppliers for the
construction of the Works shall be kept trafficable and free of excessive dirt and mud arising
from the Works.
ii. Where existing gravel roads are used frequently by the project in any part of the works as access
roads for transporting labour, plant and materials, the Contractor shall contribute towards the
maintenance or upgrading of the roads in any one of the following ways:
a) Routine maintenance, consisting of gravelling and dust control by watering. The level of
contribution, specific programme and equipment to be used shall be agreed with the
Employer.
or
b) Negotiate a road maintenance/users “fee”, payable to the relevant authorities in lieu of road
maintenance described above.
iii. The Contractor shall select his preferred option, formulate and implement the necessary
administrative details with relevant parties, without any undue delay. Where there is delay for
any reason, contingency plans shall be put in place, upon approval of the Employer.
iv. Any area of public road, which is closed because of the Works, shall not be reopened until
appropriate safety and traffic management measures have been completed, and until the
Employer confirms that it is in a suitable condition for use by the public.
v. The Contractor shall periodically water all gravel roads in the proximity of dwellings, where
these are heavily used by construction traffic, to minimise dust emission.
11.1.13.1.3 Third Party Access
i. The Contractor shall, at all times, maintain access for the authorised representatives of utility
providers and allow emergency operations to be carried out on any utility or service facilities
within the site.
ii. The Contractor shall not use public or private rights of way for depositing or storing plant or
materials, and shall maintain those parts of the public or private right of way not temporarily
occupied by the Works in a clean, passable and safe condition at all times.
iii. The Contractor shall execute the Works in such a manner that safe access, (including disabled
persons access, where they existed prior to site possession), to all properties is maintained at all
times. Methods of construction and programming of the Works shall be such that vehicular
access to properties affected by the Works is not restricted. Normal access shall be reinstated
immediately after completion of the Works.
iv. The Contractor, his employees, subcontractors and their employees, in all instances shall exercise
utmost driving control and driver care.
11.1.13.1.4 Traffic Safety and Management
i. Where work is carried out on or adjacent to a trafficked highway, the Contractor shall ensure that
personnel, at all times, wear high visibility fluorescent garments.
ii. All proposals, details, execution, maintenance, removal and necessary reinstatement associated
with traffic safety and management, temporary decking, road crossings for transmission lines,
and other structures on public roads, shall be subject to the approval of the Roads Authority. The
Contractor shall supply all information required for consultation with appropriate authorities,
including the Local Authority and Police.
iii. All traffic safety and management measures necessitated by the Works shall be fully operational
before the Contractor commences work which affects a highway.
iv. The Contractor shall provide suitable entry and exit signs, at points of access to and from the site,
for vehicles and plant engaged on the Works.
v. The Contractor shall make all necessary arrangements including notices to relevant authorities for
the provision, erection, maintenance, repositioning, covering and uncovering and final removal of
all traffic signs as the progress of the works requires.
11.1.13.2 Water Supplies

1. Where possible, the transmission line shall be routed in such a manner that dams, boreholes, wells and
pipelines are avoided.
2. In the event of unavoidable disruption to water supplies, the Contractor shall provide alternative water
supplies to those communities whose supply is affected.
3. The provisions in these technical specifications on water pollution control shall apply.
11.1.13.3 Pr ivate Pr oper ty, Schools and Institutions

Along a transmission line route, there may be several private properties, schools and other institutions that
may be disrupted during construction.
The following guidelines shall apply to mitigate the impacts on private property and institutions:
1. Where possible, the transmission line route shall be selected to avoid houses and built up areas,
plantations, cattle kraals, orchards, and other valuable private property.
2. The siting of spoil dumps, borrow areas, access roads and labour camps shall avoid areas where valuable
private property will be disturbed or destroyed.
3. Where blasting is required, pre-blasting inspections of buildings falling inside the blast pressure zone
shall be carried out by the Contractor to establish and record the status of the buildings.
4. Blasting shall be carried out in accordance with the provisions of Zimbabwe regulations.
5. The provisions in these technical specifications on pollution abatement shall apply.
6. Where possible, the Contractor shall confine construction work through schools and institutions to
periods during school holidays. Where this is not possible maximum care shall be taken when working
in and around schools to avoid injuring children and damage to property.
7. Work through crop fields shall, if possible, be carried out during the agricultural off-season.
8. Where fences are breached or sports fields dug up, the Contractor shall reinstate them immediately after
completion of construction. Where required, alternative facilities shall be provided.
9. The Contractor shall ensure that access to services, fields and water supply by private property owners is
not disrupted.
10. Any reasonable conditions demanded by the land owner shall be respected and complied with, in as far
as it is practicable.
11. Where any of the above cannot be avoided or is infringed upon, fair compensation shall be negotiated
and paid by the Employer.
11.1.14 EROSION PROTECTION

1. Where tower construction is undertaken on steep embankments of loose soil, measures shall be taken, as
approved by the Employer, to prevent disturbed soil being washed into the rivers during storms.
2. Slopes may be stabilised with lines of brushwood anchored in place by driven stakes. The stakes shall be
of durable timber so as not to rot or be eaten too quickly by termites. The steeper the bank, and the
looser the soil, the more deeply shall the stakes be driven in.
3. Where the transmission line crosses streams and drainage paths, the Contractor shall submit erosion
protection plans for approval by the Employer.
4. For sites prone to land slip erosion, grouted stone pitching with weep holes for drainage shall be used.
The Employer and the Contractor shall agree beforehand areas where erosion protection is required.
11.1.15 REFUSE AND WASTE CONTROL

1. Littering shall be avoided. All refuse shall initially be placed in bins provided by the Contractor for such
purposes, and subsequently disposed of in approved refuse dumps. No burning of waste shall be
permitted.
2. All hazardous wastes, materials soiled with hazardous wastes and non-biodegradable matter, shall not be
disposed of on the Site. All such waste shall be stored in an approved manner, on Site, and removed at
regular intervals to off Site waste disposal facilities designed to handle such hazardous waste.
3. Wooden conductor drums, nails and other waste material deemed to be useful might be donated to the
local communities on approval by the Employer.
11.1.16 WATER POLLUTION CONTROL
11.1.16.1 Gener al Guidelines

1. The Contractor shall design, construct, maintain and operate suitable temporary pollution control
facilities necessary to prevent the discharge of polluting matter or visible suspended materials into
private property, rivers, streams or existing drainage systems.
2. All diverted and pumped water shall be discharged at locations on the surface from which it cannot re-
enter the Works, and in a manner which does not cause erosion, pollution or nuisance to landholders,
other contractors employed by the Employer, or other persons within or adjacent to the Site.
3. Disposal of waste oil from workshops and other areas shall not cause pollution. Oil separators shall be
employed, where necessary.
4. The burning of plastic material shall not be permitted and all such material shall be disposed of in a
manner acceptable to the Employer.
5. Soil contaminated by cement or other chemicals shall be removed and placed in approved disposal areas,
identified by the Contractor.
6. Before any work is carried out in any area of the site, all specified or directed or approved pollution
control measures shall be in place and operational.
11.1.16.2 Water Dischar ge Fr om The Works

Wastewater quality standards of effluent from construction sites that shall be maintained for the general
protection of public health and the ecosystem are outlined below.
1. Quality of Discharge Water
i. All water effluent discharge from the Works areas, whether from runoff or construction
operations, shall be free from chemical and oil pollution.
ii. The wastewater or effluent shall contain no other constituents in concentrations which are
poisonous or injurious to humans, animals, fish or other forms of aquatic life, or which are
deleterious to agricultural use.
2. Testing
i. Where there is a risk of pollution of water courses from the Contractor’s operations, the
Contractor shall arrange to take water samples at each discharge point as and when necessary, or
as directed by the Employer, and shall have the samples analysed for pollutants by an approved
laboratory. Copies of the reports shall be submitted to the Employer within fourteen days of the
tests having been carried out.
ii. In addition to samples from the discharge points, the Contractor shall take and have tested water
samples from 500 m upstream and 500 m downstream of the Works. The suspended sediment
concentration in the watercourse, 500 m downstream from the discharge point shall be limited to
10% above baseline conditions.
11.1.16.3 Fuel Storage and Wor kshop Ar eas

1. Fuel dispensing areas and workshop areas for machinery maintenance shall be provided with concrete
hard standing surfaces draining to oil separators.
2. Drainage into watercourses from fuel storage and machinery maintenance areas shall be treated to
remove oil and/or fuel.
3. Soil contaminated by fuel and oil leakage shall be removed and disposed of off Site in an approved
manner.
11.1.16.4 Ablution and Toilet Facilities

1. The Contractor’s labour force shall be provided with approved adequate ablution and toilet facilities
within labour camps. All construction sites served by migratory site establishments shall have Blair type
or other approved toilet facilities, which shall be properly rehabilitated upon demobilisation of the
transit camp. Alternatively, transit camps may be provided with chemical toilets.
2. Pit latrines and septic tank soak-aways shall be sighted a minimum distance of 30 m down-slope from
wells, boreholes and springs. Distances should be greater in sandy soils, or fissured material through
which water can easily percolate.
3. Relieving oneself in the bush or bathing and washing utensils, vehicles and equipment in rivers and
streams shall be strictly forbidden.
11.1.16.5 Silt Tr aps

Where necessary, the Contractor shall construct and maintain silt traps to comply with pollution control
requirements. Scoured and transported material shall be cleaned regularly from behind the silt traps, and
traps damaged by accumulation of material reinstated. Silt traps may be constructed as follows:
1. Supports
o Steel posts 1.5 m long.
o 100 x 100 x 4 mm diameter galvanised steel mesh.
o Bidim A14 or equivalent geotextile fabric.
2. Installation
Steel posts shall be installed at three metre centres maximum and driven into the ground to a depth of one
metre. The mesh shall be securely wired to the steel posts and the geotextile secured to the mesh. The
geotextile shall be buried in a trench to a minimum depth of 200 mm. The trap shall be so located as to
impound all drainage water that could find its way into the protected water.
The Contractor is at liberty to propose, for approval, alternative silt trap design whose performance shall be
equal to or better than those specified above.
11.1.16.6 Sedimentation Ponds

1. The Contractor shall construct, operate and maintain adequately sized sedimentation ponds with suitable
oil traps at each point where water is discharged from the works, or as otherwise directed by the
Employer. Construction of the ponds shall take place prior to topsoil stripping or any other construction
activity in the areas to be drained.
2. Unless otherwise approved by the Employer, all water emanating from surface and underground
excavations shall be discharged into these sedimentation ponds, to remove sand, silt, cementitious
material and other suspended matter. The Contractor shall apply pH correction andcarry out other
treatment as necessary to achieve the specified standard for water discharge from the Works. Should
any oil escape from the oil separator to enter the pond, the outflow from each sedimentation pond shall
be arranged so as to prevent any floating oil from leaving the pond irrespective of the volume of water
entering the pond.
3. Drainage conduits or channels shall be sized to adequately handle the expected flows.
4. Ponds shall be constructed using suitable materials natural to the site. They shall be sub-divided to
enable alternative sections to be cleaned while other sections are in operation.
5. To ensure the satisfactory operation of the system, accumulations of silt and oil shall be removed and
disposed of by the Contractor at intervals, and in areas, approved by the Employer.
6. The sedimentation ponds shall be emptied only by discharge from outlet pipes following treatment of
the stored water.
7. Natural ground water and storm water from areas outside the immediate area of the Contractor’s
activities shall be prevented from flowing into the ponds.
11.1.16.7 Gr oundwater
1. The Contractor’s working methods and systems shall be designed so as not to significantly affect
groundwater around the Works. Removal of ground water shall not cause damage to the Works, or to the
property of third parties, and shall not cause nuisance.
2. Significant lowering of the natural groundwater table shall be avoided.
3. Disposal of water taken from the works shall be in a safe and proper manner, and shall fulfil the
pollution control requirements specified in these specifications.
4. Temporary works for the control of groundwater shall be removed and the ground reinstated when they
are no longer required.
11.1.17 AIR POLLUTION CONTROL

1. The Contractor shall take measures, as necessary, to reduce the emission of particulate matter from
blasting operations, excavations, road transport, rock crushing, material sieving, borrow areas, and other
related construction activities.
2. Equipment and vehicles that exhibit excessive emissions of exhaust gas due to poor engine adjustment
or other inefficient operating conditions shall not be used.
3. Burning of cleared trees and brush, combustible materials, construction materials and rubbish shall only
be permitted when the Employer considers atmospheric conditions favourable. It is preferable that such
material be used in slope stabilisation, erosion control works, site rehabilitation, or made available to
local landowners or users.
11.1.18 NOISE POLLUTION CONTROL

Construction activities such as blasting, operation of plant and equipment, and heavy vehicles will result in
noise nuisance to residents and animals in the project area. The following guidelines shall be followed to
restrict noise levels to acceptable limits.
11.1.18.1 Restr iction on Wor king Hour s

The Contractor shall restrict any of his operations, which result in undue noise disturbance to nearby
communities and dwellings to between the hours of 06:00 and 18:00, unless otherwise approved by the
Employer.
11.1.18.2 Plant and Equipment

1. As far as is practicable, the Contractor shall bring to Site, and employ on the works, only
environmentally acceptable and quietly operating plant and equipment, compatible with the safe and
efficient construction of the Works.
2. All plant shall be properly maintained and relevant service records completed. All plant shall be
provided with effective silencers and anti-vibration devices, and shall be operated according to the
manufacturer’s recommendations, in such a manner as to avoid causing excessive noise emissions or
vibrations.
11.1.19 EXPLOSIVES
1. The Contractor shall use explosives only in circumstances where it is safe to do so, having due regard to
the safety of persons, third party property and the safety of the works.
2. The Contractor shall obtain all necessary licences and shall provide and, where appropriate, maintain a
secure explosives store in accordance with the relevant Explosives Regulations and to the approval of
the Employer.
3. Blasting shall be carried out carefully so as to avoid loosening or shattering rock beyond the required
line of excavation, and all loose or shattered rock shall be removed by scaling down or other means
before personnel will be permitted to restart operations after blasting.
4. Notices of blasting operations shall be posted on site. Before each firing, the Contractor shall give
audible warning, clear the area, and shall take positive measures to prevent personnel from entering the
danger area.
5. The Contractor shall strictly comply with the provisions of Zimbabwe law.
6. Explosives shall be stored in structures appropriately designed for them.
7. Where there is blasting in and close to rivers, no pollution of watercourses resulting from the chemicals
shall be permitted.
8. Where explosives may damage existing foundations or structures, alternative methods, such as silent
demolition, shall be employed using approved chemicals.
11.1.20 STOCKPILES AND SPOIL DUMPS

1. Where no longer required, stockpiles and spoil dumps shall be shaped and re-vegetated to blend with the
local topography as far as is practicable.
2. Drainage shall be provided to control base water flow such that migration of fines is kept within the
stockpile or dump.
3. Where possible, old borrow pits shall be used for disposal sites in preference to undisturbed sites.
11.1.21 BORROW AREAS AND QUARRY SITES

4. Borrow pits and quarry sites shall be excavated in such a manner that water, except for direct
precipitation, will not collect and stand therein.
5. In operating borrow pits and quarry sites, the requirements in these specifications on water, air and noise
pollution shall apply.
6. When locating borrow pits, all wetlands, archaeological sites, and burial sites shall be avoided.
7. Special care shall be exercised for borrow areas located in stream courses. The following guidelines
shall apply:
i. Before removing or preparing to remove riversand from any stream, approval shall be obtained from
the relevant authorities.
ii. The Contractor shall comply with provisions of Zimbabwe regulations regarding conditions for
abstraction of sand.
iii. Sand abstraction and rehabilitation works shall, where possible, be undertaken in the dry season.
iv. Before undertaking any sand abstraction, the Contractor shall submit plans, including safety
provisions, for sand abstraction for approval by the Employer.
v. In accessing the riverbed to remove sand, care shall be taken not to damage the stream banks, and
where possible existing access routes shall be utilised. In all cases a single route shall be used to
access the river. The extraction of sand shall be limited to riverbed deposits. Priority shall be given
to desilting operations where possible.
vi. The use of plant and machinery in the riverbed to abstract the sand shall be minimised as much as
possible. A back-acting excavator, with limited usage of a bulldozer or a shovel dozer, shall
undertake excavation and loading.
vii. The Contractor shall take all measures necessary to minimise water pollution for the protection of
downstream users. The measures shall include temporary diversion of the stream, if necessary.
viii. The Contractor shall avoid stockpiling sand in the vicinity of the sand abstraction site, and shall, as
far as possible, load sand directly onto trucks for haulage. If stockpiling cannot be avoided, the sand
piles shall be located a minimum distance of 30 m away from the riverbanks.
ix. The contractor shall rehabilitate the sand abstraction site soon after extracting the required amount
of sand, in accordance with the provisions of these specifications.
x. Boulders shall reinforce unconsolidated bank material disturbed by sand abstraction works or
gabions fitted flush with the bank.
xi. Slopes on bank approaches shall be adequately protected as appropriate to prevent erosion.
11.1.22 LABOUR CAMPS

In establishing labour camps, the following general guidelines shall apply:
1. Camps shall be sited on naturally level ground and on deep soils suited to the construction of ablution
and toilet facilities.
2. Sites shall not impinge on scenic undisturbed areas or other areas used by the public, and shall be
screened from major roads. No labour camp shall be established in National Parks.
3. The provisions in these specifications for the protection of vegetation, wetlands, animals and pollution
control shall apply.
4. Drainage facilities shall be installed in and around the site to prevent storm water from flooding the site.
5. Cutting of indigenous trees for firewood for cooking and warming shall be strictly prohibited. The
Contractor shall supply the labour force with adequate firewood.
6. Grass and forest fires shall be prevented by sound control of cooking and warming fires.
7. Proper security measures shall be employed to ensure that public property in the vicinity of the site is
not pilfered or damaged by the labour force.
8. The Contractor shall provide his own facilities so as to avoid over-stressing of existing local medical
facilities.
9. A First Aid post and portable chemical toilets shall be provided at each temporary labour camp.
10. Adequate accommodation and ablution facilities shall be provided to avoid overcrowding.
11. All non-migratory labour camps shall be fenced and gated. Access into and out of the camps shall ensure
human and traffic safety, at all times.
12. On demobilisation, the area shall be made good and re-vegetated in accordance with the provisions in
these specifications.
13. Permanent structures shall be handed over to local communities at the end of the Contract.
11.1.23 HEALTH
The transient nature of transmission line construction could serve as a vehicle for spreading disease such as
cholera and some resistant strains of STD and malaria, particularly in densely populated areas. To minimise
the spread of communicable diseases the following guidelines shall apply during construction:
1. Where practicable, and without prejudice to the Contractor’s other contractual obligations, preferential
employment shall be given to members of the local community through which the work front or fronts
will be located during the course of construction of the transmission line. This policy will minimise
migrant labour and the spread of communicable diseases with which it is associated.
2. The Contractor shall provide health facilities and First Aid posts for the labour force to avoid over-
stressing existing facilities. Such facilities shall be properly staffed.
3. In areas where malaria is prevalent, preventive medicines shall be distributed to the workforce free of
charge, on a regular basis. The use of mosquito nets is also encouraged.
4. The Contractor shall take measures to educate and sensitise the labour force on the risks of
communicable diseases such as malaria, STD’s, including HIV/AIDS. Male and female condoms shall
be distributed to contract workers.
5. In the case of serious injuries on site, traffic accidents etc., the Contractor shall formulate a plan to deal
with such emergencies, prior to possession of site, for approval by the Employer.
6. Protective clothing shall be issued to categories of the workforce who require such clothing, free of
charge.
7. The provisions in these specifications on pollution control and sanitation shall apply.
11.1.24 TRAINING OF EMPLOYEES

The Contractor shall arrange that all his employees and those of his sub-contractors be trained to ensure the
following:
1. A basic understanding of the key environmental features of the Site and its environs.
2. Thorough familiarity with the environmental protection requirements as they apply to the Works.
3. The ability to identify archaeological artefacts, burial sites, special flora and fauna.
4. Awareness of any other environmental matters, which are deemed to be necessary by the Employer.
5. Basic first aid.
11.1.25 RESPECT FOR CULTURAL VALUES, BELIEFS AND PROPERTY RIGHTS

Sacred sites may exist in the project area. Even if these sites do not fall within the transmission line impacts
zone, there is always a risk that members of the Contractor’s workforce might stray into them and desecrate
the shrines therein. This could create unnecessary friction between the project and the local communities.
With respect to contractor/community relations the following guidelines and rules shall apply.
1. The Contractor and his sub-contractors shall conduct their operations in a manner that will not upset the
socio-religious order of communities in the project area. Local traditional beliefs shall be respected.
2. In the interest of harmony and good public relations, the Contractor is strongly encouraged to develop
rapport with local chiefs and traditional leaders through regular consultations and communications.
The Contractor or his sub-contractors are prohibited from entering places considered to be sacred.
11.1.26 COMPENSATION
Compensation related to the obtaining of Right of Way is the responsibility of the Employer.
Damage occurring as a result of non-compliance with these specifications shall be made good by the
Contractor at his own expense.
All claims for private property accidentally damaged by the Contractor shall be paid by the Contractor within
a reasonable period of time.
11.1.27 REHABILITATION OF WORKS AREAS
11.1.27.1 Gener al
The Contractor shall rehabilitate disturbed areas of both Permanent and Temporary Works, including but not
limited to quarries, borrow and spoil areas, the Contractor’s works and accommodation areas (including the
areas designated for the Employer’s use) and the areas required for the construction of temporary access
roads, as well as such other areas as may be specified or instructed by the Employer. Such rehabilitation
shall comprise, where necessary, grassing and planting of trees and shrubs, and erosion protection, and shall
be carried out at the earliest opportunity during the course of the Works. The following general guidelines
for the rehabilitation of work areas shall apply:
1. On slopes where the risk of erosion is likely, low ridges or beams parallel to the contours, or other
approved erosion control features shall be made across the working width.
2. Heavily compacted soils shall be lightly ripped to encourage re-vegetation in areas not prone to erosion.
3. Where coarse substrate exists (e.g. rockwaste, gravel etc.), a layer of subsoil from the stockpiles shall be
placed to a minimum depth of 75 mm and lightly compacted. Topsoil shall then be placed preferentially
on sites of greatest disturbance to a depth of 75 mm on top of the sub-soil layer. The natural seed store
contained in the topsoil should be sufficient for natural re-vegetation over one to two years.
4. On loose or erosion-prone slopes, grass planting or seeding is required, preferably using local
indigenous creeping grasses.
5. The planting of grass, trees and shrubs shall be carried out during periods most likely to produce
beneficial results.
6. Rehabilitation measures shall be at the latest carried out immediately following completion of
construction of the permanent Works.
11.1.27.2 Shaping of Ar eas

1. Cut and fill slopes shall be shaped in a manner such that the final ground appears as a natural extension
of the adjacent undisturbed ground profiles.
2. Shaped surfaces shall be left slightly rough to facilitate binding with topsoil or the natural establishment
of vegetation.
11.1.27.3 Gr assing
The method of establishing grass may be sodding, hydro seeding or hand seeding as approved by the
Employer.
1. Sodding
Areas to be grassed by sodding shall be given a layer of topsoil at least 75 mm thick unless, due to the
presence of suitable subsoil, the Employer determines that the topsoil may be omitted. The areas to be
sodded shall be thoroughly watered before hand, so that they are wet to a depth of at least 150 mm when
sods are placed. The surface shall be made slightly rough to ensure a good penetration of roots into the soil.
Sods shall be protected against drying out and shall be kept moist from the time of harvesting until finally
placed.
The first row of sods shall, where it is possible, be laid in a straight line and, if on a slope, starting at the
bottom of the slope. The sods shall be butted tightly against each other, care being taken not to stretch or
overlap sods. Where a good fit cannot be obtained, the intervening space shall be filled with topsoil.
Adjacent rows shall be placed with the joints staggered. Each sod shall be held in position by a wooden stake
approximately 300 mm long by 20 mm in diameter hammered into the soil.
2. Grass Types
Grass types planted shall be those normally endemic to the area, and shall not be of the exotic type.
3. Maintenance of Grass
i. All planted grass shall receive a good dressing of suitable fertiliser at about one handful per square
metre (about 400 kg per hectare).
ii. The Contractor shall maintain the grassed areas for a minimum period of 3 months.
11.1.27.4 Tr ees And Shr ubs

Trees and shrubs shall be planted as directed by the Employer.
Directly after planting, each plant shall be well watered to establish the plant firmly in the soil. After the soil
is set, additional soil shall be added where necessary to bring the whole backfill to within 150 mm of the
ground surface, in order to re-ensure that sufficient water can be retained. All trees shall be tied to a suitable
treated timber stake planted firmly in the ground. After planting, the ground surface around the plant shall
be covered with mulch in order to minimise evaporation.
The Contractor shall maintain the trees and shrubs for a minimum period of 3 months. Maintenance shall
include watering and keeping the plants free from weeds and pests.

ZEDTC Standard - Vol 1 - Transmission Lines Spec

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ZIMBABWE ELECTRICITY TRANSMISSION AND

Standard Specifications – Transmission Lines

T-S-01-001 SCOPE OF WORKS

T-S-01-001 SCOPE OF WORKS (TEMPLATE)

1.1.1 SCOPE OF WORKS

1.1.1.1 Intr oduction

1.1.1.3 Basic Technical Descr iption of the Tr ansmission Line

1.1.1.4 Tr ansmission Line Route

T-S-02-001 ADMINISTRATIVE REQUIREMENTS

T-S-02-001 ADMINISTRATIVE REQUIREMENTS

2.1.1 GENERAL .....................................................................................................................................4

2.1.15.1 Documentary Film................................................................................................................22

2.1.1.1 Pur pose

2.1.1.2 Pr oject Language

Reference is made to the Conditions of Contract.

2.1.1.3 Cor r espondence

2.1.1.4 Administr ation Documents Review and Acceptance

2.1.2 QUALITY ASSURANCE REQUIREMENTS

2.1.2.2 Quality Assur ance Pr ogram

2.1.2.3 Quality Plans, Inspection and Test Schedules

2.1.2.4 Submission of Documents

2.1.2.5 Monitor ing by the Employer

2.1.2.7 Sub-o rder s

2.1.2.8 Mater ial and Test Cer tification

2.1.2.9 Par ticular QA Requir ements

c) List of holdpoints and/or routine tests;

2.1.2.10 Packing and Mar king

2.1.2.11 Repor ting and Cor r ective Action

2.1.2.12 Design Revision and Substitution of Mater ial

2.1.2.13 Contr actor’s Responsibility

2.1.2.14 Information Requir ed for Tender Evaluation

2.1.2.15 Subcontr actor s and Supplier s

2.1.3 HEALTH, SAFETY AND ENVIRONMENTAL PROTECTION REQUIREMENTS

2.1.4 ORGANISATION AND PERSONNEL

2.1.4.2 Key Positions

2.1.5 PLANNING AND SCHEDULING

2.1.5.2 Level 3 – Contr act Schedule

2.1.5.3 Level 4 – Contr act Detail Schedule

2.1.5.4 Level 5 – The Contr actor’s Detailed Wor k Schedules

2.1.5.5 Pr ogr ess Monitoring Pr inciples and System

2.1.6 VARIATIONS, COST CONTROL, CASH FLOW FORECASTS AND INVOICING

2.1.6.2 Var iations to the Wor k

2.1.6.3 Cost Contr ol - Cash Flow Schedules

2.1.7.1 Monthly Pr ogr ess Repor ts

2.1.8 DOCUMENTS TO BE PREPARED BY CONTRACTOR

2.1.8.2 Outline Dr awings

2.1.8.3 Detailed Dr awings, Design and Specifications

- methods of lubrication (if required)

2.1.8.4 Design Computation and Final Design Data

2.1.8.5 Par ts Bills

2.1.8.6 Catalogue Cuts, Illustr ations, Etc.

2.1.8.7 Installation/Er ection Manual and Dr awings

2.1.8.8 Commissioning Manual

2.1.8.9 Oper ation and Maintenance Manual

2.1.8.10 Final Dr awings

2.1.8.11 Pr ocessing of Dr awings

2.1.8.12 Pr ocedur e for Deliver y of Documents

o Drawing Classification Plan

o Principal drawings, schemes, tables, charts and templates

2.1.8.12.5 Before beginning of manufacturing:

2.1.8.12.7 At least fifteen (15) days prior to shipment:

2.1.8.12.10 Before issuance of Provisional Acceptance and release of Performance Security :

2.1.9 ENGINEERING DOCUMENTATION NUMBERING SYSTEM

2.1.10.1 Pr ogr ess Review Meetings