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C O N T E N T S

SL.NO. CHAPTER PAGE NO.

1. STRUCTURAL DESIGN 1

2. SPECIFICATIONS 10

3. SALIENT FEATURES OF IS CODES 18

4. COST ESTIMATION 42

5. GUIDELINES FOR CONTRACTS 49

A P P E N D I C E S

1. DESIGN AND DRAWINGS 60

2. BILL OF MATERIALS 115

3. MARKET RATE ANALYSIS 151

4. CHECK LIST FOR TOWER WORKS 155

5. LIST OF IS CODES AND REFERENCES 158

CHAPTER – I

STRUCTURAL DESIGN

1. STRUCTURAL DESIGN 1.1 SCOPE:

This Manual covers the design of 4 legged 40M Ground Based self supportingtower and the design of 30M self supporting Roof Top Tower.

1.1.1 ROOF TOP TOWER

i) The design of 30m high self supporting roof top tower has provision oftruncation at 25,20 and 15m levels. Top level of the tower has been consideredat a level of 36 m for all heights of the tower. It is assumed that the height ofbuilding is 6m for 30 m tower.

ii) The tower is designed as angular construction in segments of 2.5 m heightwith square base. The bottom width of the tower is 3500 mm and the topwidth of the tower is 1300 mm for 30 meter height. The tower consists of14 panels having top 4 straight panels of length 1250 mm each and remaining10 panels of length 2500mm The bottom 10 panels shall have a slope of 1 in22.72 (0.0439 rad.). The bottom 2 panels are truncated each time to get therequired height.

iii) The tower shall be capable of supporting the following .

a. 6 nos. of panel antennas for WLL systems at 1.5 m from top of tower. (1.50 X0.16 m, 35 kg )

b. 4 nos. of 0.6 m dia microwave solid dish antennas at a platform 6.5 m fromtop of tower. ( 0.6 m dia, 20 kg )

c. 6 nos. of panel antennas for GSM systems at 11.5 m from top of tower. (1.50X 0.16 m, 35 kg )

iv) Other accessories includes lightening protection system, aviation obstructionlamp, ladder, vertical wave guide, antenna mounting fixtures and working platform.

1.1.2 GROUND BASED TOWER

i) The tower is designed with bottom square base of width of 2000mm.

ii) The tower is capable of supporting the following :

a. 3 Nos. of Panel antennae for GSM systems at 2.5m from top of tower(1.50 x 0.16m, 35 kg)

b. 3 Nos. of panel antennae for WLL system at 5.0m from top of tower(1.50 x 0.16m, 35 Kg).

c. 2 Nos. of 0.6 M dia microwave solid dish antennae.

iii) Other accessories includes lightening protection system, aviation lighting,ladder,vertical wave guide, antenna mounting fixtures and working platforms.

1.2 LOADS:

The tower is designed to withstand following loads.

i) Dead Loadii) Self Weight of Tower.iii) Self Weight of Antenna.iv) Self Weight of Platform.v) Self weight of ladder assembly (45x45x4) @ 16 kg/mvi) Self weight of wave guide @ 7 kg/m.

1.2.1 WIND LOAD

i) Wind Load on Tower.ii) Load due to Wind on Antenna And Other Accessories.

1.2.2. The following wind speed as per IS: 875 (part -3) is considered.

For Roof top tower following wind speeds are considered.

a. 200 kmph (55 m/sec) : Leh Region of Jammu & Kashmir, North Eastern States of India.

b. 180 kmph (50 m/sec) : Assam, Coastal region of eastern parts, Kuttch &Kambath region of Gujrat, Punjab, Haryana,Rajasthan, Delhi, U.P, Bihar, Northern M.P,

West Bengal, Tamilnadu and part of Andra Pradesh.c. 160 kmph (45m/sec) : Part of Andhra Pradesh, Western Coast of India,

Orissa.d. 140 kmph (40 m/sec) :Kerala , Karnataka, Maharasta, M.P, Chattisgarh,

Jharkand.

For Ground based tower following wind speeds are covered.

a. 180km/hr Assam, Coastal region of eastern parts, Kuttch & Kambath region of Gujrat, Punjab, Haryana, Rajasthan, Delhi, U.P, Bihar,Northern M.P, West Bengal, Tamilnadu and part of Andra Pradesh

b. 140km/hr Kerala , Karnataka, Maharasta, M.P, Chattisgarh, Jharkand.

However for specific place, reference may be made to IS 875 (Part-3)-1987 given atAppendix – I..

1.2.3 No seismic analysis has been carried out for tower design incorporated in this manual,as the same is not expected to be critical for towers of height upto 40m and located in zonesII & III of IS 1893-2002.

1.3. ANALYSIS:

1.3.1 Wind load on the tower are computed separately by MS Excel Program andincorporated in analysis, which is done by STAAD Pro software. A sample STAADinput file is given in APPENDIX I.

1.3.2 WIND LOAD

Wind load has been calculated as per IS: 875 – 1987 (Part 3)

Design wind speed is calculated as follows :

Vz = Vb k1 k2 k3 , where

Vz = Design wind speed at any height of ‘z’ in m/Sec.Vb = Basic wind speed in m/Sec. as per IS875(Part-3)-1987

k1 = 1.08, Probability factor (risk co-efficient) as per table 1 of IS 875-1987) given at Appendix - I

k2 = Terrain, height & structure size factor category 2 and class B as per Table-2 of

IS 875-1987 (Part 3) given at Appendix - I

k3 = Topography factor = 1 as per table 3 of IS 875-1987 (Part B) given at Appendix - I

k1, k2, & k3 shall be adopted as applicable case to case.

Design wind pressure, pz = 0.60 Vz2

The tower is analyzed for face wind as well as diagonal wind.

1.3.3 Wind load on face of tower is calculated as follows:-

F = Cf pz Ae (as per clause 6.3 of IS 875-1987 (Part 3)), where

F = Wind load

Cf = Force co-efficient as per table 30 of IS 875-1987 (Part 3). For calculated solidity Ratio given at Appendix - I

Ae = Effective frontal area.

1.3.4 . Wind load on diagonal direction of tower is calculated as follows:-

F = 1.20 Cf pz Ae (as per Clause 6.3.3.5 (b) of IS 875-1987 (Part3) )

Since this load will be acting at 45 degree to the tower face, the resolved load

will be acting in the ‘x’ direction and the same amount will be acting in the ’z’

direction.

1.3.5 Wind load on antenna is calculated based on the area of antenna. Force coefficient depending on Aspect ratio as per EIA/TIA standard (Table A) is considered forGSM/WLL antenna.

T A B L E ‘A’Appurtenance Force Co-efficient

Aspect Ratio ≤ 7 Aspect Ratio ≥ 25Member Type CA CA

Flat 1.4 2.0Cylindrical 0.8 1.2

Aspect Ratio – Overall length/width ratio in plane normal to wind direction (Aspect ratio isnot a function of the spacing between support points of a linear appurtenance nor the sectionlength considered to have a uniformly distributed force).Note : Linear interpolation may be used for aspect rations other than shown.

For Dish antenna load due to wind is considered as per Andrew Hand book without Radome . Wind load on different microwave antennas are given in Appendix - I

T A B L E ‘B’

Antenna Type AntennaDia. Ft (m)

FA Max.Lb (N)

FS MaxLb (N)

MT Max.Ft. lb (N.m)

Standard AntennaWithout Radome(except LD2, PF4And LD4 Series)

2 (0.6) 4(1.2)

6(1.8)8 (2.4)

10 (3.0)12 (3.7)15 (4.6)

215 (960)870 (3870)1950(8670)

3460 (15390)5410 (24060)7800 (34690)

12170 (54130)

60 (270)240 (1070)530 (2360)950 (4230)

1480 (6580)2130 (9470)3330 (14680)

100 (140)615 (830)

1730 (2350)3940 (5340)7080 (9600)

11680 (15840)24400 (33090)

Wind load due to ladder is taken as same in both cases. Direction of antenna isconsidered along the direction of wind.

1.3.6 : Tower is idealized as a space structure with pin jointed 3D truss elements as perClause 3.4.2 of IS:800 – 1984. The geometry of tower is shown in fig.1 & 2. Thetower has been analyzed for the following load combinations.

i. Dead load + Wind load with wind blowing normal to the face oftower.

ii. Dead load + Wind load with wind blowing diagonal to the face oftower.

1.3.7 The sizes of leg and bracing members have been checked for the maximum forcescomputed from the analysis. The sizes of the various members of the tower are designed asper the Indian standard code of practice for general construction in steel IS 800-1984.

1.3.8 Limiting Slenderness Ratio for the Members are considered as per IS 802 given in Appendix - I.

i) Leg members 120ii) Other Members 200iii) Redundant Members 250

1.3.9 The result of tower weight for various wind speeds and heights are given in Table C.The details of analysis and design for different wind speed are given in Appendix I.

1.3.10 Maximum drift is within limits of + 0.5 degree.

1.3.11 Foundation loads given in table D are working loads i.e. excluding factor of safety. Foundation is to be designed with factor of safety as per relevant I.S codes.

1.3.12 Frequency of the tower may be checked as per Clause 7.1 of IS 85 (Part 3)-1987

for dynamic effects on the tower.

1.3.13 Design of base plate :

The base plate of tower leg shall be designed taking into account permissible bearingstress of concrete mix and axial force derived from tower analysis.

The centre of gravity of tower leg, base plate and supporting concrete column/beamshall coincide to avoid moments to eccentricity. Care shall also be taken while

welding stiffeners to base plate that centre of gravity is not shifted.

1.3.14 The design of anchor bolt involves determination of numbers, diameter and length ofbolt required to safely withstand the tensile force and shear force induced on the towerleg.

The anchor bolt shall be designed with root size of bolt and not with nominal diameteras per IS 1367 Part 3.

1.4 FOUNDATION

1.4.1 ROOF TOP TOWER :

The foundation for Roof Top Tower shall be designed as per the positions of availablecolumns. Grids are to be formed by interconnecting the columns to match the base ofthe tower.

1.4.2 GROUND BASED TOWER :

Foundation design shall be done as per IS 456-2000.Detailed soil investigation maybe carried out wherever considered necessary. The foundation details for various SBC’s

and wind speed of 180 km/hr and 140 km/hr are at Appendix 1.

T A B L E ‘C’

WEIGHT OF ROOF TOP TOWERS FOR DIFFERENT WIND SPEEDS

WIND SPEED PARAMETERS 15 m 20m 25m 30m

Base width (cm) 218 262 306 350

Weight of Tower componentonly (Kg)

1225 1832 2603 3523140

Total weight (incl. Bolts &other components in Kg.)

3046 4287 53221 6535

Base width (cm) 218 262 306 350


1311 1978 2810 3793160


3132 4433 5528 5805

Base width (cm) 218 262 306 350


1380 2096 2965 4023180


3201 4551 5683 7035

Base width (cm) 218 262 306 350


1445 2220 3166 4356200


3266 4675 5884 7368

WEIGHT OF GROUND BASED TOWERS FOR DIFFERENT WIND SPEEDS

WIND SPEED PARAMETERS 40m

Base width (cm) 200

Weight of Tower component only (Kg) 6457140

Total weight (incl. Bolts & other components in Kg.)8192

Base width (cm) 200

Weight of Tower component only (Kg) 7791

180

Total weight (incl. Bolts & other components in Kg.)9313

T A B L E ‘D’

1. FOUNDATION FORCES FOR ROOF TOP TOWER

WIND SPEED FORCES IN KG. 15 m 20m 25m 30m

Compressive forces 17926 26776 35814 45288

Tensile force shear 17832 26109 34890 44030Shear (xx-direction) 2831 3011 3598 4182

200 Kmph

Shear (zz-direction) 2563 2520 3001 3631


Tensile force shear 15328 22437 29844 37564Shear (xx-direction) 2513 2638 3097 3575180 KmphShear (zz-direction) 2352 2256 2604 3133


Tensile force shear 12615 18338 24242 30356Shear (xx-direction) 2046 2087 2489 2861160 Kmph

Shear (zz-direction) 1953 1796 2132 2540


Compressive forces 9965 14726 19652 24787Tensile force shear 9486 13923 18597 23470Shear (xx-direction) 1660 1656 1945 2255

140 Kmph Shear (zz-direction) 1667 1449 1678 2015

2. FOUNDATION FORCES FOR GROUND BASED TOWER.

WIND SPEED FORCES IN KG. 40m

Compressive forces 88956

Tensile force shear 86425180 Kmph Shear (xx-direction) 2790

Compressive forces 71935

Tensile force shear 66666

Shear (xx-direction) 2735

CHAPTER – II

SPECIFICATIONS

2. SPECIFICATION

2.1.0 GENERAL

2.1.1 Civil work shall be in general carried out in accordance with CPWD specifications1996 Volume I to VI with up to date correction slips 1 to 14 and revised CPWSpecifications 2002 for Mortar, Cement concrete and RCC.

2.1.2 Steel tower works shall be carried out as per the following specifications.

2.2.0 MATERIALS

2.2.1 The tower materials consists of legs/bracings shall be of M.S. angles of grade ‘A’ asper IS: 2062-1999 & IS: 808-1989 and satisfy the relevant tests as per IS codes.

2.2.2 The material for gusset/splice plates shall be of M.S. angles of grade ‘A’ as per IS:2062 & IS 3502-1994.

2.2.3 The materials for nuts, bolts shall be of grade 4.6 and as per 6639-1972, IS 1364(PartI to V) –2002, IS 1367(Part VIII) –1992, plain washers as per IS 6610-1972 andspring washers of Type-B as per IS 3063-1994, IS 1148-1982, IS 2015-1977.

2.2.4 A test certificate bearing IS certification marks for materials are acceptable. If testcertificates are not available, the materials shall be tested in the approved lab or whereauthorized by the Engineer-in-Charge.

2.2.5 Two or more pieces shall not be welded or joined to makeup for the required length ofmember if required properly designed joint should be provided.

2.3.0 FABRICATION

2.3.1 The fabrication of tower shall be done in accordance with IS 800-1984.

2.3.2 The fabrication of various components of the tower shall be done in accordance withthe approved drawings and suitable markings for manufacturer’s identity or itemmarking for each section for enabling in easy assembling and traceability at site. All

dimensions shall be checked on the template floor with reference to drawings before manufacture and if, any deviation is required after check, and the same shall

be done only with the approval of the Engineer-in-charge.

2.3.3 The contractor shall maintain a master steel tape of an approved make besides othermeasuring instruments.

2.3.4 STRAIGHTENING

All materials shall be straightened and or flattened by pressure unless required for ashape of curvilinear form before fabrication and shall be free from twists.Straightening shall not damage the material. The parts when assembled adjacentsurfaces shall be in close contact. Hammering shall not be permitted for straightening.Sharp kinks or bends shall be rejected.

2.3.5 CUTTING

Cutting may be affected by shearing, flame cutting or sawing. The surface so cut shallbe clean, smooth square and free from any distortion.

2.3.6 BENDING AND WELDING

(i) Mild steel angle sections up to 75x75mm (up to 6mm thick) may be bent cold up toand including bend angle of 10 degree, angles above 75x75mm (thickness up to 6mm)and up to and including 100x100mm (thickness up to 8mm) may also be bent cold upto the bend angle of 5 degree. All other angle sections not covered above shall bebent hot.

(ii) Butt-welding, if used, in members shall be carried out either by submerged arc orshielded arc welding.

(iii) Welding shall be free from cracks, discontinuity in welding, under- size, over-size orunder cutting. It should be cleaned off slag and other deposit.

(iv) Welds shall be adequately tested using radiography or other well-known methods ofnon-destructive testing.

2.3.7 HOLES

(i) Holes for bolts shall be drilled using jigs provided with hardened steel bushes andshall not be punched or formed by flame cuttings process. All drill burns shall becompletely removed. Drilling of holes shall be done before galvanizing.

(ii) Holes on both sides of the bend line in a bent member shall be drilled after bending.The relative position of these holes shall be checked using proper templates.

(iii) Holes shall be circular and of a diameter 1.5 mm more than the dia of the bolt.

(iv) Holes shall be drilled at right angles to the surface of the plates or angles, unlessotherwise specified.

(v) The accuracy of location of hole shall be such that for any group when assembledthey shall admit the bolt at right angles to the plane of the connection.

(vi) Spacing of bolts and edge distances shall be in accordance with IS 800-1984.

(vii) Butting ends of main leg members shall be cut with saw. Flame cutting or shearingshall not be permitted.

2.3.8 MARKING

Identification marks allotted to each member shall be distinctly stamped with markingdyes of 16mm size before galvanizing.

2.3.9 TOLERANCES

Fabrication tolerance shall not exceed those specified in IS 7215-1974 as applicable togroup “B” structure.

2.4.0 GALVANIZING

2.4.1. Hot dip galvanizing protects steel from corrosion by providing a thick, tough metalliczinc coating, which completely covers the steel surface and seals it from the corrosiveaction of its environment. The galvanized coating provides outstanding abrasionresistance. Where there is damage or minor discontinuity in the coating of zinc,

protection of the steel is maintained by the cathodic action of the surrounding galvanizedcoating. Metallic zinc is strongly resistant to the corrosive action of normal environments andhot dip galvanized coatings therefore provide long-term protection for steel.

2.4.2 Zinc for galvanizing should conform to IS 13229-1991.

2.4.3 All members and fasteners of Tower structures are to be hot dip galvanized. Galvanizing of members of the tower shall conform to IS 4759 and 2629. Bolts and otherfasteners shall be galvanized in accordance with IS 1367 (part 13). The total mass ofgalvanizing coating shall not be less than 610gm/sqm (i.e.85 micron) thickness.

2.5.0 PAINTING

Painting of galvanized steel towers is required to give additional protection and togive ‘Day warning’ as per additional protection and civil aviation specifications.

2.5.1 COASTAL AREA

All steel galvanized sections like L angles, flats, tubular sections, bolts and nuts etc.shall be given a coat of ETCH primer. Zinc Chromate primer shall be applied overETCH primer. Synthetic enamel paint of two or more coat thickness shall be appliedover the above.

2.5.2 NON COASTAL AREA:

In the non-coastal area Zinc Chromate may be applied instead of zinc phosphatepainting shall be done in accordance with IS 1477 Part I & II. Priming coat of zincChromate/phosphate shall conform to IS 104.

2.5.3 CLEANING

Dust, grease and rust on galvanized tower members namely angles, tees, platesrailing, ladders, racks etc. shall be removed by wire brushing and cleaned with a piece ofcloth.

2.5.4 APPLICATION OF ETCH PRIMER

After cleaning the tower members a first coat of an etch primer has to be applied tothe tower structure members. The etch primer consists of polyvinyl butyralphosphoric acid catalyst and zinc chromate base and are supplied separately. Theyshould be mixed before use in the specified ratio of four parts base to one partcatalyst or as specified by the manufacturer. The primer is to be applied uniformly toget a very thin and almost invisible coat and every part of the tower structure shouldbe treated with this primer. Subsequent painting of the zinc chromate primer shouldbe commenced within two hours of application of the primer. The etch primer oncemixed should be used up immediately.

2.5.5 APPLICATION OF PAINT

After 48 hours of application of primer, the first coat of the paint should be appliedcarefully, well brushed into the surface, corners, crevices etc. should be uniform andeven. The second coat of paint should be applied 48 hours after the application of thefirst coat. Care should be taken to see that the painting is not carried out at the hottesttime of the day and air pockets should be avoided.

2.5.6 SPECIAL REMARKS

(i) The painting shall be done carefully so that all corners and crevices of the mast receivethe paint and no base surface is left exposed anywhere. Special care is to be taken inapplying paint at the place where galvanized coating has got removed.

(ii) No driers such as Litharge or Turpentine are to be used. The practice of mixingkerosene oil with paint is strictly forbidden.

2.5.7 PAINTS

Paints shall be synthetic enamel of the best quality and anticorrosive and withstandexposures to outside conditions. They should be of standard quality equivalent tosynthetic enamel paint of Shalimar or Berger paints or Asian paints.

2.5.8 ORANGE AND WHITE BANDS (DAY MARKINGS)

To conform to Civil Aviation regulations the towers shall be painted in alternate bands ofinternational orange and international white, terminating with orange at to and the bottom,Height of each band should be not exceed 6 metres and should not be less than 0.5 metres.The correct shade for the international orange corresponds to ISI shade 592 as given in theIndian Standard Institution Publication-colours for ready mixed paint.

2.6.0 RECTIFICATION / REPAIRS TO DAMAGED PARTS

2.6.1. Damaged components of the steel work should be rectified as per directions of theEngineer-in-charge minor damages to the galvanizing shall be made good bycleaning the damaged portion free of all rust and applying a zinc rich paste to thesame thickness as the original coat of galvanizing.

2.6.2 Members of components, which are dented, bent or twisted in transit or by handlingduring erection shall not be used on work but shall be replaced as directed by theEngineer-in-Charge.

2.6.3 ERECTION

(i) It shall be ensured that structural components with correct markings as indicated indrawings are used in correct position.

(ii) At the base connections the foundation bolts shall be located correctly using templatesand grouted ensuring that all templates are in one horizontal plane. After erection ofthe first panel, its verticality shall be checked and corrected if necessary.

(iii) Further erection work shall proceed panel by panel, bolts and nuts shall be finallytightened up to the torque specified using torque wrenches. Verticality of the tower shall bechecked after complete erection of each panel. Each panel shall be completed in all respectsand shall have the approval of the Engineer-in-charge before proceeding to the next panel.

(iv) If a panel is to be left incomplete, it shall be ensured if necessary by erection oftemporary bracings that all the members erected form a stale configuration, sufficient towithstand dead and wind loads.

(v) The joint shall be made by drawing the light members into position with barrel drifts.Drifts may be used on the heavier members only to secure them in correct position.No member shall be force fitted. Any error in steel work, which prevents the

assembly and fitting up to the parts by the proper use of drifts, shall be investigatedimmediately. If any defect or deficiency in the member comes to notice, the same shall berectified as per directions of the Engineer-in-Charge.

(vi) Packing plates shall be provided at the joints as shown on approved drawings in orderto make up the change in the thickness of the parts jointed. No other packing platesshall be used.

(vii) Hot dip galvanized bolts and nuts and washers of class 5.6 shall be provided in allconnections involving leg members main diagonals as well as horizontal throughinter section of the main diagonals in k brace, panels and plain bracings

(viii) Hot dip galvanized contact surfaces of joints providing with hot dip galvanized boltsnuts and washers shall be free of oil, paint and lacquer or other coatings and shall be scored by wire brushing or light blasting after galvanization and prior to assembly.

(ix) Bolts used for connections shall not be not less than 12mm dia. And the length shallbe such that not more than half of the pitch of the thread lies inside the grip length.The threaded portion of the bolt shall protrude by not less than 3mm beyond the locknut after it has been fully tightened.

(x) Bolts and nuts shall be tightened by using the part turn method. The net shall bebrought to the snug, tight position after which it will be given a further half to oneturn depending upon the length of the bolt. In joints with several fasteners all the nutsbolts shall be brought to the snug tight position, before tightening furthersystematically. The nut rotation from snug tight condition is given in the table below:

NUT ROTATION FROM SNUG TIGHT CONDITION

Bolt length(as measured fromunderside of head toextreme end of point)

BoltsfacesNormalto boltaxis.

One face normalTo bolt axis & other facesloped not more than1:20 (bevel washer notused)

Bolt faces slope notmore than 1:20 fromnormal to bolt axis(bevel washers notused).

Upto including 4 dia. 1/3turn 1/2 turn 2/3 turnOver 4 dia. But notexceeding 8 dia.

1/2 turn 2/3 turn 5/6 turn

Over 8 dia. But notexceeding 12 dia.

2/3 turn 5/6 turn 1 turn.

(xi) Alternatively nuts may be tightened using a calibrated wrench so that the proof loadof the bolt specified in IS 1367 is achieved “snug tight is defined as the tightness attained bya few impacts of an impact wrench or the full effort of a man using an ordinary spudwrench. Following this initial operation, bolts shall be placed in remaining holes in theconnection and brought to snug tight position”.

2.6.4 VERTICALITY TOLERANCES

The verticality for towers of different heights shall be within the provisions of Table 1(III) (b) of IS 12843:1989 viz., + H/1000 or +/- 20mm (whichever is less) and H/1500or +/- 25mm (whichever is less) for towers up to and including 30mtrs height andover30mtrs height respectively. (H refers to the height of tower).

2.6.5 MOUNTING OF FIXTURES, LIGHTNING CONDUCTOR, AND AVIATIONLIGHTS ETC.

Approval of the Engineer-in-Charge shall be obtained before mounting fixtures andother accessories such as lightning conductors, aviation lights etc. any deviation oralteration in approved plan shall have the approval of the Engineer-in-charge.

2.6.6 EARTHING

(i) PLATE EARTH

Pit size of 900 x 900 x 3000 mm is excavated and copper plate of size 600 x 600 x 3mm is placed vertically in the excavated pit. The plate shall be connected to the GIpipe of 19mm dia by copper wire. The bolt, nuts, check nuts and washers shall be ofcopper. The pit is filled with charcoal and salt up to a depth of 900 mm andremaining portion filled with loose soil without stones. The masonry chamber atground level of size 700 x 700 x 150 mm with a hole in the middle to pass the GI pipeof 19mm dia with a provision for funnel and provided with CI frame and cover withlocking arrangements. The funnel shall be fixed with wire mesh. The manhole covershall be painted and marked with resistance of the earth. Plate earth placed in twodiagonally opposite tower legs shall be interconnected by means of insulated 70sqmmcopper wire.

(ii) RING EARTH

The trench alround at one metre away from the lower base shall be excavated to adepth of one metre. 50 x 6 mm GI flat (with Zinc coating 610 gm/sqm) placed at thebottom of the trench. Both ends of GI plate are brought above to the ground .The GIplates are inter connected by GI strips and bolted. The ends shall be terminated in anenclosed masonry chamber of internal size 300 x 300 x 300 mm. The chamber shallbe provided with CI frame and cover and painted. All the tower legs are connectedwith ring earth with 50x6 mm GI flat with two bolts. The ring earth shall beconnected to one of the plate earth.

2.6.7 LIGHTENING CONDUCTOR

(i) The lightening conductor is fixed at top of tower. The copper-lightening conductor is1500 mm long and 25mm dia hollow tube of minimum wall thickness of 1.6mm. Thelightning spike shall be fixed to the tower with Teflon sleeve to avoid direct contact

with tower. The spike is connected to plate earth by 70 sqmm. insulated multistrandcopper wire. The copper wire shall be fixed to the tower with necessary lugs.

2.6.8 WORKING PLATFORM AND LADDER

A working platform with railings is provided at a height from where erection andmaintenance of Antenna, Aviation lamps, Lightening arrester etc. can be done easily.A ladder from rooftop up to top of platform at tower is provided with safety rings.Width of ladder shall be minimum 300 mm and safety ring of 750 mm shall beprovided. Entry from ladder up to top of platform shall be such that no extra effortswill require to reach at the platform. Width of platform should be minimum 600mm.

2.6.9 WAVE GUIDE

Waveguide is provided in towers to carry the feeder cables from Antenna fixed at topof tower up to Transmission room. It is a tray of galvanized M.S. angles and Flats of600mm width. This should not bend sharp at right angles at turning points to avoiddamage to running feeder cables.

2.6.10 AVIATION OBSTRUCTION LAMP

230V AC LED aviation obstruction lamp (Saraj, Binoy, Aviads, Litten or equivalent)with Light Dependent Resistance Sensor (day night automatic timer) with necessaryMCB switches shall be provided at top of the tower.

CHAPTER – III

SALIENT FEATURES OF IS CODES

SALIENT FEATURES OF INDIAN STANDARDS

SLNo

INDIANSTANDARD

NUMBERIMPORTANT PROVISION OF THE CODE REMARKS

1. IS 2062 : 1999Steel forgeneralstructuralpurposesspecification.(Fifth revision)

10.0: Tensile test: In accordance with IS: 1608

10.1.1: Plates, strips, sections (Angles, tees, beams, channels, etc.) and flats. Number of samples to be tested from a cast/heat and a class of steel product shall be as follows. * a) For cast/heat size upto 100 tonnes- 2 samples. b) For cast size between 100 to 200 tonnes- 3 samples. c) For cast size over 200 tonnes – 4 samples.

11.0: Bend test : In accordance with IS: 1599

11.1: Number of bend tests: Bend test shall be made from finished steel from each cast. The number of tests for every 50 tonnes of material or part thereof shall be as given below

Class of steel product No. of bend tests. Plates, strips One crosswise Sections One lengthwise for each type Flats & Bars (round, One lengthwise. Hexagonal.etc.)

12.1: Impact test: shall be carried out for materials having thickness /diameter greater than or equal to 12mm.

12.2: Test shall be carried out as per IS: 1757.

12.3.1: Test samples shall be taken from each 50 tonnes or part thereof.

13.0: Y Groove Crackability test: * Test shall be in accordance with IS: 10842 for products of only Grade-C material having thickness 12mm and above.

17.0: Calculation of mass: The mass of steel shall be calculated on the basis that steel weighs 7.85g/cubic cm

*AmendmentNo.1 June2001

*AmendmentNo.3 June2003

19.3: Marking: The ends of the rolled products shall be painted with a colour code as given below: Grade A Green Grade B Grey

Grade C Orange.

2. IS 808:1989(Reaffirmed1999)Dimensions forhot rolled steelbeam , column,channel andangle section(Thirdrevision )(incorporatingAmendmentNo.1)

7.0. Dimensions, mass & tolerances.7.1: Nominal dimensions and mass of equal & unequal angles shall conform to the values given in sections 5 &6 [Page 8 to 13A].

7.2: Dimensional and mass tolerances of the various sections shall conform to the appropriate values stipulated in IS 1852: 1985.

8.0. Sectional properties are given in table 5.1 & 6.1. [Page 8 to 13A]

3. IS 1730: 1989SupersedesIS:1741(Reaffirmed1995) Steel plates,sheets, strips &flats forstructural &general Engg.purposes-Dimensions (Secondrevision)

4.1 & 4.2: Table 1: Standard nominal thickness of plates in mm 5,6,7,8,10,12,14,16,18,20,22,25,28,32,36,40,45,50,56 & 63.

4.3:Table 3: Mass per metre of Plates [Page 3]

7.1 & 7.2 :Table 8: Standard nominal thickness of flats in mm 3,4,5,6,8,10,12,15,20,25,30,40 & 50.

7.2 :Table 9: Dimensions & mass of hot rolled steel flats [Page 7]

4. IS 3502:1994(Reaffirmed1998)Steel Chequeredplates-specification(Secondrevision)

Fig. 1. Typical illustrations of the patterns of chequered plates [Page 2]7.0. Selection and preparation of test samples.

7.1: The recommended location for taking test samples is indicated in Fig. (2)[Page-2]. The test piece shall be cut lengthwise or cross wise.

8.1: Tensile test shall be conducted in accordance with IS 1608: 1972

8.1.1: The tensile properties of chequered plates shall conform to Grade A of IS 2062 : 1992or 1977: 1975.

8.1.2: No. of samples for tensile test shall be in accordance

with IS 2062 :1992 or IS 1977:1975.

9.1: Bend test shall be conducted in accordance with IS 1599:1985

9.3: No. of samples for bend test shall be in accordance with IS 2062:1992 (or) IS 1977:1975.

10.0. Dimensions & rolling Tolerances.10.1. Chequered plates shall normally be supplied in sheared edges and the dimensions and rolling tolerances shall be as specified in 10.2 & 10.310.4. Chequered height :Unless specified otherwise, the minimum bead height of chequered plates shall be 0.8mm.

12.0.Retests: Should any one of the test pieces firstselected fail to pass any of the tests specified in this

standard, two further samples shall be selected for testing in respect of each failure.

13.2:The material may also be marked with standard mark.

5. IS 1852: 1985(Reaffirmed1998)Specificationfor rolling andcuttingtolerances forhot- rolled steelproducts(Fourthrevision)

IS 1852: 1985

4.3: Equal & unequal leg angles.4.3.1: Leg length: The tolerance on leg length shall be as Follows.

Leg lengthOver upto & i/cmm mm

Tolerance

- 45 + or - 1.5mm45 100 + or - 2.00100 - + or - 2 percent

4.3.2: Out of square: The legs of angles shall be perpendicular to each other within a tolerance of + or - 1.0 degree.

4.3.3: The difference between the leg lengths of equal leg angles shall be limited to 75% of the total tolerance (Plus & minus) specified on the leg length.

4.3.4: Camber: The permissible limits for the camber shall be as follows.

Leg length mm Camber max. mm Less than 100 To be agreed between the manufacturer and the purchaser

IS 1852: 1985

I/c & over 100 0.2% of length

4.3.5: Weight: The tolerance of weight per metre shall be + or - 5% for 3mm thick angles and +5%, - 3% for over 3mm thick angles as specified in IS: 808(Part 5) 1976 & IS 808 (Part 6) 1976.

6.0. Rolling tolerance for flats

6.1 width: Tolerances on width

Overmm

Upto & i/cmm

Tolerancemm- 50 + or -1.0

50 75 + or -1.575 100 + or -2.0100 - + or -2% subject

to a maximum of6mm6.2 : Thickness

Thickness mm Tolerance mm

Up to & i/c 12 + or - 0.5mm

Over 12 + or - 4% subject to amax.1.5mm.

6.4 Weight: Tolerance on weight per metre shall be + or - 5% for 3mm thickness and +5% & - 3% - over 3mm thickness of weight Specified in Table – 1 of IS 1731: 1971

7.0 .Rolling & cutting tolerance for Plates:

7.1 Width: The tolerance on width of plates.

Lengthmm

Widthmm

Thicknessmm

Toleranceon Widthmm

Upto& i/c8000

Upto& i/c2000

Upto & i/c20over 20

-0.0+ 10.0- 0.0+15.0

7.2 Length:

7.2.1: The tolerance on length of plate produced in noncontinuous mills shall be

Length Thickness mm Toleranceon length

on lengthOver up to & i/cmm mm

up to & i/c 20 -0.0 + 10mm

- 2200 Over 20 -0.0 + 15mm

2200 3000 Up to & i/c 20

Over 20

- 0.0+ 0.5%- 0.0

+ 15mm3000 6300 Up to & i/c 20

Over 20

- 0.0 + 0.5%

-0.0- 0.5%

7.2.2: The tolerances for length of plates from 5 to 10mm thickness produced in continuous mill

Length mm Tolerance mm Up to 2500 + 25mm

- 0.0

Over 2500 + 1% of the length subject to a max. of 70mm

-0.0

7.3: Tolerance on thickness:

Thickness Tolerance in % of normal thickness

Less than 8mm + 12.5- 5.0

From 8 to 12mm + 7.5- 5.0

over 12mm + or - 5.0

7.3.1: The measurement shall be taken at a distance of at least 15mm inside from the edge. * *Amendment

No.2 April2001

6. IS 7215:1974(Reaffirmed1995)Tolerances forfabrication ofSteel structures.

0.3*GroupB: Steel structures having special characteristics and structures subjected to dynamic loading excluding wind/ seismic, like crane ,gantry girders,its supporting

structure, chimneys , microwave and transmission line towers, sub-station and power station structures, Industrial buildings and bunkers, etc.

*AmendmentNo.1 May1992

Group C: Steel structure not subjected to dynamic loading, like platform galleries, stairs, etc. which do not require closer tolerances as required for group B structures.

2.0 .Built- up section2.1: The tolerances on the dimensions of individual rolled steel components shall be as specified in IS:1852- 1973.

2.2: In the case of joints designed as friction grip joints using high tensile friction grip fasteners, the difference in thickness if any shall be adjusted by chamfering or by providing packing pieces.2.3: The max. permissible gap S between the components in the straight and curved portion of structures assembled by riveting or bolting shall be as given in Table1 [Page 4]2.4: Deviation in depth & Width at joints: For rolled beams & built-up-members (welded or riveted), the difference in width or depth or both at the joint between two adjacent members shall not exceed the values given in Table 2 [Page 6].2.9.1: Maximum permissible out- of- square of flanges in built up girders.Table-3 [Page 8]

10.0: Deviations on dimensions of holes for riveting & bolting.

10.1: Pitch distance: The permissible deviations + or – 1mm for group B & + or - 2mm for group C

structures.

10.2: Dimensions of drilled holes: The nominal diameter of drilled holes & permissible deviations on diameter, perpendicularity ,over lapping of holes etc. shall be as specified in Table-7.[Page-19]

10.2.1, 10.2.2, 10.2.3, 10.2.4, 10.2.5 relating to deviations.

10.3: Scratches or grooves on the cylindrical surfaces of the drilled holes shall be limited as given in Table-8. [Page-21]

7 IS: 13229-1991(Reaffirmed1995)Zinc forGalvanizing-Specification

6.1:The material shall conform to the chemical composition as specified in Table –1 [Page1]

8.1: Unless specified otherwise, the mass of each ingot shall not be more than 30kg.

9.2: The method of preparing samples for chemical & spectrographic analysis from ingots selected under 9.1 shall be in accordance with IS 1817: 1961 & IS 8816 : 1978 respectively.

12.2.1: The material may also be marked with the standard mark.

13.0: Test certificate: The supplier shall provide test certificate for each consignment giving information like cast/lot, number corresponding chemical composition, etc.

8. IS 209: 1992(Reaffirmed1997)Zinc Ingot-Specification(Fourthrevision)

3.0 Grades: This Standard covers 2 grades of zinc namely Zn 99.99 & Zn 99.95

9.0: Sampling: 5% of the ingot shall be selected from each consignment.

9.2: Method of preparing samples for chemical analysis as per IS 1817: 1961 & IS 8816:1978.

13.0. Test certificate:- If required the supplier shall be provide test certificate for each consignment.

9 IS 2629-1985(Reaffirmed1998)Recommendedpractice for hot-dip galvanizingof iron and steel(First revision)

IS 2629-1985

3.0 Base metal for galvanizing

3.1 Steel: Mild steel is the most common material

4.0 Preparation of the metal surface for galvanizing

4.1 Cleaning: If an article is contained by oil, grease or paint, pretreatment in special solvents will be necessary for their removal. Generally a sodium hydroxide solution obtained by dissolving 10 to 15 kg of sodium hydroxide in 100 liters of water is used.

4.2: Cleaning of castings: If not properly cleaned before annealing, develop burnt- on and patches at the surface which are not removed by normal pickling.

4.3: Pickling: Both hydrochloric acid and sulphuric acid solutions may be used for pickling.4.4: Rinsing: After pickling, the article should be rinsed in

running water.

5.0: Galvanising:5.1: Quality of Zinc: Zinc used for galvanizing shall conform to any of the grades specified in IS 209-1992 zinc ingot ( fourth revision )or IS 13229: 1991 Zinc for galvanizing. *

5.2: Aluminium additions: Aluminium may be added to the galvanizing bath in the dry process to the extent of about 0.005% (0.007% max) [0.05 - 0.07 g/kg of zinc] to reduce the oxidation of molten metal and brighten the appearance of the article.

5.3 Bath Temperature:The control of bath temperature is essential if the quality of the product is to be consistent and zinc is to be used economically. The bath temperature may vary from 440’C to 460’C and a working temperature of 450’C is commonly used.

5.5: Rate of immersion: The work should be immersed as rapidly as possible but with due regard to operator’s safety.

6.0.Testing & Inspection:6.2. Uniformity in thickness: Galvanized articles shall be tested for uniformity in thickness of coating in accordance with preece test given in IS: 2633-1986. For quick approximate measurements of thickness, magnetic gauges may be used, but such instruments shall be suitably calibrated before use.

6.3: Mass of coating: The mass of zinc coating may be determined in accordance with IS: 6745-1972.6.4: Adhesion tests:

6.4.1: Pivoted hammer test for zinc coated fabricated products. (Fabricated from plates,bars, strips etc.)

7.1: Sufficient care should be exercised while storing packing and handling of galvanized products.

Appendix-A: (Clause 0.2 & 0.4) Defects, their causes & remedial measures * [Page 15 to 18]Appendix-B (Clause 0.5) Working conditions & safety measuresAppendix-C (Clauses 4.3 & 4.6.4.1) Test methods.

*AmendmentNo.3 January2001

*AmendmentNo. 1 Dec.1988 page15to17, lastcol. Substitute“may berejected” for“yes” and“may beaccepted” for“No”whereverappearing.

10 IS: 4759:1996(Reaffirmed2001)

4.3: Galvanizing: The steel products may as far as practicable, be galvanized in accordance with IS:2629-

2001)Hot-Dip Zinccoatings onstructural steel& other alliedproducts –Specification.(Third revision)

1985

Annexure-A (clause 1.2) Properties of the articles to be coated that affect the result of hot dip galvanizing ( for information only) [Page 4 & 5]

6.1: Mass of Zinc coating:

Requirements for the mass of the coating for different classes of materials are given in Table-1 [Page 2]

8.1.2: Each lot shall be tested separately for the various requirements of the specification. The number of units to be selected from each lot for this purpose shall be as given in Table-2 [Page 2].

8.2.1: The sample selected according to col. 1 & 2 of Table 2 shall be tested for visual requirements as per 6.2.

8.2.2: Three test specimens shall be cut from each sample for the determination of mass of zinc coating as described in 9.2.

8.3: Criteria for conformity: In case a test specimen representing a sample unit fails to conform to the requirements specified in 9.2 with respect to the mass of zinc coating the second and third specimen shall be tested. If the number of defective units in a lot exceeds the acceptance number as specified in col.3 of Table-2, the lot shall be rejected, else accepted.

9.0.Test procedure

10.1.2The articles may also be marked with standard mark.

11 IS:6639:1972(Reaffirmed1995)Specificationfor HexagonBolts for Steelstructures

6.0. General requirements

6.1: Sampling, inspection & acceptance criteria shall be as per IS 1367(Part 17) :1992 *

6.3: Hexagon nuts used with hexagon bolts shall be as per IS 1363 (Part 3)-1992

6.5: The approx. weight of hexagon bolts & nuts has been given in appendix A [Page 4].

*AmendmentNo.5November1999

12 IS 1364(Part 1) : 2002

3.0.Dimensions: See fig. 1 & Tables 1 & 2 [Page 3 to 9]

ISO 4014: 1999Hexagon headbolts, screwsand nuts ofproduct gradesA&B.Part 1:Hexagon headbolts ( sizerange M1.6 toM 64)(Fourthrevision)

4.0. Specifications and reference standards: See Table 3 [Page 10].

13. IS: 1364(Part 2) : 2002ISO 4017: 1999Hexagon headbolts, screwsand nuts ofproduct gradesA&B.Part 2:Hexagon headscrews ( sizerange M 1.6 toM64) (Fourthrevision)

3.0 .Dimensions: See fig. 1 & Tables 1 & 2 [Page 3 to 8]

4.0. Specifications and reference standards : See Table 3 [Page 9]

14 IS: 1364(Part 3) : 2002ISO 4032:1999Hexagon headbolts, screwsand nuts ofproduct gradesA&B.Part 3:Hexagon Nuts,style 1 ( sizerange M1.6 toM 64) (Fourthrevision)

3.0. Dimensions: See fig. 1 & Tables 1 & 2 [Page 2 & 3]

4.0. Specifications and reference standards: See Table 3 [Page 4]

15 IS: 1364 (Part 4) : 1992ISO 4035: 1986

3.0.Dimensions :See fig. 1 & Tables 1 & 2 [Page 2 & 3]

(Reaffirmed1998) Hexagonhead bolts,screws and nutsof productgrades A&B.Part 4:Hexagonthin nuts ( chamfered)(size rangeM1.6 to M 64)(Third revision)

4.0. Specifications and reference standards :See Table 3 [Page 3]

16 IS 1364 (Part 5) : 2002ISO 4036: 1999Hexagon headbolts, screwsand nuts ofproduct gradesA&B.Part 5:Hexagonthin nuts-product grade B(unchamfered)(size range M1.6 to M 10)(Fourthrevision)

3.0. Dimensions: See fig. 1 & Table 1 [ Page 2]

4.0. Specifications and reference standards : See Table 2 [Page 3]

17 IS 1367(Part 8) : 2002,ISO 2320 :1997 Technicalsupplyconditions forthreaded steelfastenersPart 8:Prevailingtorque typesteel hexagonnuts- mech. &performanceproperties.(Third revision)

Table1: Designation system for nuts with nominal heights >/ = 0,8d

Table 2: Designation system and stresses under proof load for nuts with nominal heights > / = 0, 5d & < / = 0, 8d.

18 IS 1148-1982(Reaffirmed2001)Specificationfor Hot-rolledsteel rivet bars(up to 40mmdiameter) forstructuralpurposes.

2.0. Supply of materials

2.1: General requirements relating to supply of rivet bars for structural purposes shall conform to IS: 8910-1978.

for Hot-rolledsteel rivet bars(up to 40mmdiameter) forstructuralpurposes.(ThirdRevision)(IncorporatingAmendmentNos.1&2)

6.0. Lengths:

6.1: Unless otherwise agreed to between the purchaser and the manufacturer, rivet bars shall be supplied only in multiples of 250mm length.

7.0. Dimensional tolerance7.1:

Diameter of bar Total tolerancemm mmBelow 20 0.4020 0.4522 to 24 0.50Over 24 2% of diameter

7.1.1: All the tolerance specified shall be minus tolerances. When special plus & minus tolerances required by the purchaser the sum of such tolerances shall not be specified as less than the above total tolerances.

8.0. Selection of test samples

9.0. Tensile Test :

9.1. One tensile test shall be made from the finished steel for every 10 tonnes of a cast or part thereof :9.2: The tensile properties of steel when determined in accordance with IS:1608-1972 shall be given in Page 6.9.3: No tensile test shall be carried out on bars below 6mm.

10.0. Dump test :10.1: One dump test for every 10 tonnes of a cast or part thereof. One additional test shall be made for each variation in diameter.10.3: Dump test shall not be applicable to bars below 6mm.

11.0 Bend test:11.1: One dump test for every 10 tonnes of a cast or part thereof. One additional test shall be made for each variation in diameter11.2 Bend test shall be carried out in accordance with IS:1599-1974

12.0 Shear test :12.1: One shear test for every 10 tonnes of a cast or part thereof. One additional test shall be made for each variation in diameter12.2 Shear test shall be carried out in accordance with

IS:5242:1979

13.0. Packing and marking13.1: Rivet bars shall be securely bundled.13.2.1: The material may also be marked with the standard mark.

19. IS 7145: 1973(Reaffirmed1995)Technicalsupplyconditions fortorquewrenches.

6.0. General requirements

6.1.2: Spacing of graduations: Unless otherwise specified, in the individual standard, the torque scale from zero to maximum value shall be divided into nor less than 20 approximately equal division.

6.1.3: Marking: Graduation marks, numericals and letters shall be permanent, legible and of adequate size for easy reading in both daylight and artificial light.

6.1.7: Requirements not covered in this standard shall conform to IS: 2092-1962 specification for dial gauges.

7.0. Accuracy:

7.1. The wrenches shall indicate the applied torque at room temperature within + or - 0.05W, where W is the applied torque required within the range of the wrench.7.2: Fig. 1 shows various angles of power application to click type torque wrenches [Page-2]

8.0. Test:8.1: Calibration accuracy test Each wrench shall be subjected to a calibration accuracy test at one half, three quarters and full load, for accuracy as specified in 7.1.

8.2: Over load Wrenches shall be subjected to an over load of 50% over maximum capacity and then shall be rechecked for accuracy and for permanent set.

10.0. Sampling: The sampling plan for various characteristics shall be as given in 10.1 and 10.2.11.0. Marking: The wrenches shall be stamped with the manufacturers name or initials or trade-mark, type of wrench, capacity and year of manufacture, if asked by the purchaser.The range of the torque wrench shall be marked on the body or on the dial.

20 IS 2015-1977(Reaffirmed2000)Specificationfor T-Nuts(First revision)[ IncorporatingAmendmentNo.1]

2.0. Dimensions & Tolerances shall be given in Table-1. [ Page 1]

3.0. Mechanical properties: The mechanical properties for T- Nuts made of steel shall conform to those given under property class 8 of IS: 1367-19804.0. Designation: A T-Nut of width a = 22mm shall be designated as: T-Nut 22 IS :2015

5.0. General requirements: The T-Nuts shall comply with the requirements of IS: 1367 - 1980 in so far as manufacture, workman ship, marking and packing are concerned.

6.0. ISI certification marking: Details available with the ISI

21 IS: 2016-1967(Reaffirmed1996)Specificationfor plainwashers ( First revision)

4.1: The dimensions for machined washers, punched washers, types A&B shall be as given in Tables 1, 2 & 3 (page 6 to 11). These tables also give the size of bolt or screw for which the washers are suitable.

*4.3: In respect of concentricity tolerance, permissible deviations for parallelism and flatness, the machined and punched washers shall conform to precision and ordinary washers respectively as specified in IS: 5369-1975 [Pages 6 to 9 -Table 1].

a) First column heading – Delete ‘H12*’b) Columns under ‘D’ & ‘S’- Deletec) Foot-note with ‘*’ mark – Delete.

7.2. The product may also be marked with standard mark.

*AmendmentNo.4 October1982

22 IS 5369-1975(Reaffirmed2001)Generalrequirementsfor plainwashers & lockwashes(First revision)

3.0 Dimensional Accuracy3.1: Permissible deviations: Precision grade washers shall be specified in Tables 1 & 2 [Page 1 & 2]3.2: Permissible deviation: Ordinary grade washes shall be specified in Table 3 & 4. [Page 2& 3]

6.0. Other requirements6.1. The washers shall be free from cracks, burrs, pits and other defects.

6.2: Metallic washers shall conform to IS: 1387- 19677.0. Sampling & acceptance: Shall be in accordance with IS: 6821-1973.

8.0. Testing of materials & coating: The material constituting the washers & lock washers has to be tested only if special requirements are

specified for the materials, similarly it applies to testing of coating.

10.0. Marking: The label on the carton or bag shall carry the size number of pieces of manufacturers mark or

trade mark

23 IS 6610:1972(Reaffirmed1996)Specificationfor heavywashers forSteel structures

1.0. Washer diameter range 14 to 42mm

2.0 Dimensions shall be as per Table 1 [Page 1]

3.0 Materials shall be made from steel.

4.0 Other requirements for the heavy washers not covered in this standard shall conform to the requirements applicable for black washers specified in IS:5369-1969 ‘General requirements for plain washers and lock washers’

24 IS 3063: 1994(Reaffirmed1999)Fasteners –single coilrectangularsection springlock washers-Specification(Secondrevision)

4.0. The dimensions of the spring lock washers shall be as given in Table 1A & 1B [Page3 & 4].

9.0.General requirements

10.0. Sampling and acceptance: The sampling and acceptance criteria shall be in accordance with IS 6821:1993.

11.0. Tests:

11.1: Hardness test shall be in accordance with IS 1501 (Part 1): 1984.

11.2: Permanent Set test: as specified in Table 2A & 2B. [Page 5]

11.3: Permanent load test: as specified in Table 2A & 2B. [Page 5]

11.4: Twist test

25 IS:1929-1982(Reaffirmed1996)Specificationfor hot forgedsteel rivets forhot closing (12to 36 mmdiameter)

3.0. Dimensions: The dimensions of rivets shall be as shown in Table 1 to 3. [Page 2 to 4]

5.0. Acceptance tests: shall be in accordance with IS: 10102-1982

5.3: Shear test: When tested by the method prescribed in IS: 10102-1982, the Mild steel rivets shall satisfy a

diameter)(First revision) (Incorporatingamendment 1,2& 3)

minimum shear strength of 260 Mpa & high tensile rivets a minimum shear strength of 370 MPa .

5.4: Head soundness test: When tested by methodprescribed in IS 10102-1982 rivets at room

temperature shall withstand the test without exhibiting any sign of cracking.

6.0. Designation:

6.1: A mild steel snap head rivet of 16mm diameter having a length of 70mm shall be designated as: Snap head rivet 16x70 IS: 1929 For high tensile steel shall be designated as: Snap head rivet 16x70 HT IS: 1929.

7.0. Marking: All rivets shall be marked with the manufacturer’s trade-mark on the head in raised fig.

8.1: General requirements shall be in accordance with IS 10102-1982

26 IS 800: 1984(Reaffirmed1998)Code ofpractice forgeneralconstruction inSteel(Secondrevision)(Incorporatingamendment No.1&2)

5.7.3: Width of lacing bars: In riveted construction, the minimum width of lacing shall be as follows:Nominal rivet Dia. Width of lacing bar mm mm

22 6520 6018 5516 50

5.7.4: Thickness of lacing bars: The thickness of flat lacing bars shall be not less than one- fortieth of the length between the inner end rivets or welds for single lacing & one-sixtieth of this length for double lacing riveted or welded at intersections.

8.10.1: Pitch of rivets. a) Minimum pitch: The distance between centres of rivets should be not less than 2.5 times the nominal diameter of the rivet.

b) Maximum pitch: (i) The distance between centres of any two adjacent rivets shall not exceed 32 t or 300mm whichever is less, where ‘t’ is the thickness of the thinner outside plate.

8.10.2: Edge distance:

(a) The minimum distance from the centre of any hole to the edge of a plate shall not be less than that given in Table 8.2 [Page 97].

8.11.1: Pitches, edge distance for tacking bolts: The requirements for bolts shall be the same as for rivets in 8.10 and its sub-clauses.

11.9.1: Painting shall be done in accordance with IS: 1477 (Part I) 1971& IS: 1477(Part-II):1971

27 IS:875(Part-3) 1987(Reaffirmed1997) Code ofpractice fordesign loads(other thanEarth Quake)for buildingsand structures .Part 3 -windloads.(Secondrevision)

5.2: Basic wind speed: Fig. 1 gives basic wind speed map of India (Page 9). Basic Wind speed for some important cities/towns is also given in appendix A [Page 53].

5.3: Design wind speed:5.3.1: Risk coefficient (K1) factor: Table 1- Risk coefficients for different classes of structure in different wind speed zones [Page 11].

5.3.2.1: Terrain, height and structure, size factor (K2): Table 2- K2 factor to obtain design wind speed variation with height in different terrains for different classes of buildings/structures. [Page 12].

5.3.2.4: Changes in terrain categories: See Table 3 -Fetch and developed height relationship. [Page 12].

28. IS 613: 2000Copper rods & bars forelectricalpurposes-Specification(Third revision)

3.0. Supply of materials shall be conform to IS 1387

9.0. Mechanical properties.9.1: Tensile test : Hardness shall be in accordance with IS 1608 to IS 1501 (Parts 1&2)9.2: Bend test shall be as per IS 1599

12.1.1: The number of bars/rods to be selected for test at random over the whole lot as per Table-6.[Page-4]

29 IS 2309: 1989Protection ofBldgs. andallied structuresagainstlightning –code of practice (Secondrevision)

8.1.4 & 8.1.5 Table: 1: Over all assessment of risk [Page7]8.2.: Zone of protection

9.0. General consideration of design

10.1 Table 3: List of recommended materials for component parts [Page-15]11.1 Table: 4:- Minimum dimensions component parts [Page-16]

30. IS 12843: 1989(Reaffirmed1995)Tolerances forerection of steelstructures

3.0. Tolerances: The tolerances on deviations in the erected steel structures shall not exceed the values specified in Table 1 [ Sl. No. (iii) b [1]& [2]] [Page 1]

31. IS 816:1969(Reaffirmed1998)Code ofPractice for useof metal arcwelding forgeneralconstructions inMild steel (First revision)

6.2. Fillet welds6.2.1: Size: The size of a normal fillet shall be taken as the minimum leg length ( see fig.4) For deep penetration welds, the size of the filled should be taken as the minimum leg length + 2.4mm.6.2.2: The size of fillet weld shall not be less than 3mm nor more than the thickness of the thinner part joined. The minimum size of the first run or of a single run fillet weld shall be as given in Table-1.[Page-11]6.2.3: Effective throat thickness: Shall not be less than 3mm and not exceed 0.7 t & 1.0 t under special circumstances. t = thickness of thinner part.6.2.5: Fillet weld applied to the edge of a plate or section.

See fig.5A,5 B ,6A, 6B ,6C,7[Page 13]8.0. Welding in compression members.8.3: Joints in compression members.9.0. Welding in tension members.9.1: The spacing of weld should not exceed 105cm.10.0: Lacing & Battening:10.1: General design consideration refer IS: 800-198410.2: Lacing: The amounts of lap measured along either edge of the lacing bar should be not less than 4 times the thickness of the bar or members whichever is less.10.3: Battening: Where tie or batten plates over lap the main members the amount of lap should not be less than four times the thickness of the plate.10.3.2: The size of fillet welds connecting tie or batten plates to the main members should not be less than

half of the thickness of the plate and in no case less than 5.0mm.15.3: Welding procedure: For procedure of welding and pre-& post-heat treatment, reference should be made to IS 823:1964.

32. IS 822:1970(Reaffirmed1997)Code ofprocedure forinspection ofwelds.

6.5: Welding procedure6.6: Inspection during welding6.7: Deviations

7.0: Inspection after welding7.1: Visual inspection7.2: Inspection of weld dimensions7.3: Mechanical testing7.4: Non-destructive tests.7.4.1: Table-1- Guide lines for use of different methods of

non-destructive examinations of welds [ Page 17]

9.0. Acceptance.

33. IS 104-1979(Reaffirmed1999)Specificationfor ready mixedpaint, brushing,zinc chrome,priming.(Secondrevision)

3.4 :Table1: Requirements for ready mixed paint, brushing, zinc chrome, priming [ Page 5]

4.2: Marking: The container may also be marked with ISI certification mark.

5.0. Sampling: As prescribed under 3 of IS 101:1964

6.0. Test methods: Test shall be conducted as prescribed in Appendices A&B & IS: 101:1964.

34 IS:123-1962(Reaffirmed-1996)Specificationfor ready mixedpaint, brushing,finishing, semi-gloss, forgeneralpurposes, toIndian standardcolours.(Revised)

3.0. Sampling: as prescribed in 3 of IS 101-1964

4.2: Requirements: Table-1 Requirements for ready mixed paint, brushing, finishing, gloss for general purposes with the distinctive colours as specified in the title. [Page-6]

4.3: The minimum weight in kg/10 litres of this material when tested in accordance with 25 of IS: 101-1964 is 15.5.It shall be with in + /- 3% of the sample approved against this specification if any.

4.4: Water content: It shall not exceed 0.5% when tested as prescribed in 14 of IS 101-1964.

5.0. Tests : Tests shall be conducted as prescribed in IS 101-1964.

6.2: Marking:

6.2.1: The product may also be marked with standard mark.

AmendmentNo.2 July1988Table 1 –add newrequirementafter s.no(viii)(ix)// wetcapacity//between -10%& +20% ofthe approvedsample// 10

35 IS 2339:1963(SupersedingIS: 165 & 166 -1950)(Reaffirmed1999)Specificationfor Aluminiumpaint forgeneralpurposes.

3.1. There shall be two type of material. (a) Brushing & (b) Spraying.

3.1.1:The type of material required, whether brushing or spraying, shall be stated in the contract.

5.2: The material shall also comply with the requirements given in Table-1*. Requirements for aluminium paint for general purposes [Page-6]

5.3: The minimum weight in kg/10 liters of the materials when tested in accordance with 25 of IS: 101-1961

*AmendmentNo.3Sep.1988Table 1 –add newrequirementafter s.no(vii):

is 9. It shall be, however, within +/-3% of the sample approved against the specification if any.

6.1: Tests shall be conducted as prescribed in IS 101-1961.

6.1.1: Unless specified otherwise, the materials shall be tested after keeping in an air -tight container for 48 hours after mixing .

7.1: * Packing: The paint shall be packed in dual containers. However ,when varnish medium is more than 4 liters, aluminium paste may be packed separately.7.2.1: The containers may also be marked with standard mark.

after s.no(vii):(viii)// wetcapacity//between -10%& +20% ofthe approvedsample// 10

*AmendmentNo.2 August1982

36 IS 2074: 1992(Reaffirmed1998)Ready mixedpaint, airdrying, redoxide zincchrome,primingspecification( Secondrevision)

5.8: The material shall also conform to the requirements given in Table 1 when tested according to the methods given in Col.4 of the Table-1 [Page-2]*

5.9: Water content: If water is suspected to be present in the material, it shall not exceed 0.5% when tested as prescribed in IS 101 ( part 2/sec 1) 1988.

7.0: Tests:7.1: Tests shall be conducted as per the method referred to in col.4 & 5 of Table 1 & in 5.1 to 5.9

7.2: Unless otherwise specified pure chemicals and distilled water (See 1070:1992) shall be employed in tests.

8.1: Packing: The paint shall be packed in metal containers conforming to IS 1407: 1980 or IS 2552: 1989.

8.2: Marking: The container shall be marked with the following

a) Name of the materialb) Col. of the materialc) Indication of the source of manufactured) Batch No. or lot No.e) Month & year of manufacture.

Annexure B (Clause 5.1.1): Determination of chromic anhydride & zinc oxide.

Annexure-C (Clause 5.7): Test for resistance to sea water

*AmendmentNo.1 June-1997- Table1page-2#sl.no.(iii)(c)col 2-substitute thefollwing forexistingmatter: ‘Glossvalues,specular60degrees’

#sl.no.(iii)(c ),col 3-substitute thefollwing forexistingmatter: ‘Notmore than 40units’

#sl.no.(vi), col4- substitute‘(Part 5 / Sec2 )’ for‘ (Part5 / Sec 1)’

Annexure D (Table 1, Sl.no.(vii) : Determination of volume solids.

Annexure E (Table 1, Sl.No.xi) : Method for accelerated storage stability test.

2 )’ for‘ (Part5 / Sec 1)’

37. IS 5905:1989(Reaffirmed1998)SprayedAluminium andzinc coatings oniron and steelspecification(First revision)

3.2. Recommended scheme: a) Grade A- minimum protection-20 years b) Grade B- minimum protection-10 years

Table-1: Recommended nominal coating thickness for Grade A & Grade B schemes for various requirements (Clause 3.2 & 6.4) [Page-2]

6.4: Thickness of the coating: The minimum local thickness at any point shall not be less than 75 %of the specified nominal thickness.

6.4.1: The measurement of thickness shall be made by magnetic method described in IS 3203:1982

7.0. Retreatment of defective areas.

7.1: Any defective area shall be cleared of all sprayed metal by blasting or other suitable mean and reprepared to conform to the requirement of 4, prior to respraying.

8.0. Additional Protective measures:8.1: Sealing & finishing coats wherever applied on zinc & aluminium to provide additional protection should be applied without delay. Contamination of the sprayed surface with oil, grease, dirt, finger marks, etc. shall be avoided.

38. IS 5666 : 1970(Reaffirmed1999)Specificationfor Etch primer

3.2: The material, suitable for spraying brushing, shall be prepared by mixing the base of the accelerator components in equal proportions by volume.

3.4: Viscosity: The viscosity of the mixed material shall be with in + /- 10 seconds of the approved sample when tested as prescribed in 7.4 of IS 101-1964.

3.5: Drying time3.5.1 : Air Drying3.5.2: Force Drying4.2: Marking4.2.1: The containers may be also marked with the ISI certification mark.5.0. Sampling5.1: Samples of the material shall be drawn as prescribed under 3 of IS-101-19646.1: Tests shall be conducted as prescribed in 3.3 to 3.9.

AmendmentNo.1September1989

39 IS: 1477 (Part I) 1971Code ofpractice forpainting offerrous metalsin buildings.(Part I-Pretreatment) ( First revision)

5.1: Pretreatment and priming of ferrous metals under controlled conditions of the factory gives the best results and it is therefore advisable to adopt this method whenever possible.

5.1.1: Application of a suitable priming coat should follow pretreatment without delay.

7.0. On-site pretreatment7.1. Surfaces untreated or protected with a temporary protective-These should be dealt with at site, as given in 7.1.1 to 7.1.47.2: Surfaces containing temporary protective ; Scale, rust etc. such surfaces should be dealt with at site, as given in 7.2.1

7.3: Surfaces already factory pretreated and/or primed.

7.4: Solvent cleaning: This shall be done in accordance with 6.1.1

7.6 Mechanical Cleaning: This shall be carried out in accordance with 6.2.1

7.7: Etching or wash primers: This shall be done in accordance with 6.6

9.1: After completion of the pre-cleaning the ferrous surfaces shall be immediately painted unless a rust- proofing or other interim process is employed.Appendix-A (Clauses 6.2.1 & 6.2.4) Sand blasting:

A-1.1: Sand blasting produces an excellent surface for painting and though, it may be initially more expensive than other methods, it is very economical over a period of years. As with any other method, it can be performed to varying degrees of completion as described in A-1.2, A-1.3, A-1.4.

A-2: Working principle of sand blasting equipment.

40 IS:1477 (Part II) 1971(Reaffirmed1995)Code ofpractice forpainting offerrous metalsin buildings.(Part IIpainting) (First revision)

6.0.Painting Schedules:

6.1: Preparation of surfaces: The surface preparation shall be done in accordance with 6, 7, & 8 of IS: 1477 (Part I)-1971.

6.2. Painting: The painting operations given in 6.2.1 to 6.2.4 shall be in conformity with the provisions of 3, 4 & 5 of this standard. The selection of paints for the paint systems shall be in accordance with Table-1.[Page 10 & 11]

7.1:The principles of maintenance painting are summarized in Table-2 [Page 13]

8.2: Inspection of surfaces prior to painting: Inspection methods will depend on whether an article is to be painted for the first time or is to be repainted.

8.5: General inspection before & after painting: The field tests mentioned in 8.5 .1 & 8.5.2 may be carried out for facility of inspection during and after

painting.

Appendix-A: (Clause 6.3) Brushing of paint.

Appendix-B: (Clause 6.4) Spraying of paint.

Appendix-C: (Clause B-2.2) Spray painting defects: Causes & remedies

Appendix-D: (Note 4 under Table 1) [Indian standards on paints & enamels]

41 IS 7205:1974(Reaffirmed1995)

2.1: The management of the organization erecting the steel work should analyze the proposed erection scheme

1995)Safety code forerection ofstructural Steelwork

for safety.

3.1: The supervisory staff should be well trained in enforcing safety regulations and be able to distinguish safe and unsafe workmanship.

4.0: Statutory requirements: Where statutory provisions exist, the same shall be complied within addition to the provisions contained in this code.

5.0. Safety of Men

5.20: Safety against fire

5.24: Lifting appliances

5.25: Slinging

5.26: Riveting operations

5.27: Welding & gas cutting

6.0 : Safety of structure.

CHAPTER – IV

COST ESTIMATION

4. C O S T E S T I M A T I O N

4.1 The preliminary cum detailed estimate for all works are required to

be prepared for obtaining Administrative Approval and expenditure

sanction as well as technical sanction.

4.2 The preliminary cum detailed estimate shall be prepared on the basis

of approved schedule of rates e.g., CPWD DSR 2002. For items not

covered in the approved Schedule of Rates approval of the Zonal Chief

Engineer(Civil) shall be obtained for the description, specification and

analysis of such items.

4.3 A sample estimate based on DSR 2002 and market rate items based

on the experience of tower works as adopted by Superintending

Engineer (Civil) Pune/Chennai is enclosed. The basic rates of

material and labour are as on April 2004.

Name of the work: Sample Cost Estimate for Providing 40M Narrow base tower including foundation.

ABSTRACT OF COST

SNO DESCRIPTION OF ITEM AMOUNT

1 EARTH WORK 28422

2 CONCRETE WORK 6197

3 REIFORCED CEMENT CONCRETE 131420

4 BRICK WORK 15639

5 STEEL WORK 596819

6 FINISHING 34827

7 ALLIED WORKS 57390__________

TOTAL 870714

Add 15.66% on DSR items for increase in 192638 30167 Total 900881 Add 5% contingencies * 45044 Total 945925 Say 9,46,000

Technically sanctioned for Rs 9,46,000/-(Rupees Nine lakhs Forty Six Thousands only)

*Note: Works contingencies have been considered based on CPWD Works Manual 2002

Name of the work:Sample estimate for Providing 40M Narrow base tower including Foundation.

S.N Description of Item Unit Qty. Rate AmountDSRCODE

SUB HEAD : EARTH WORK:

1 Earth work excavation over areas (exceeding 30cm depth, 1.5m in width as well as 10sqm on plan) including disposal of excavated earth lead upto 50m and lift upto 1.50mt. disposed earth to be levelled and neatly dressed. I. All kinds of soil. a. Lift upto 1.5m One 90cum 91.50 8235

2.6.1Cum

b. Lift from 1.50m upto 3.00m One 30cum 103.95 31192.6.1+2.27.1

Cum

2 Earth work excavation over areas (exceeding 30cm depth, 1.5m in width as well as 10sqm on plan) including disposal of excavated earth lead upto 50m and lift upto 1.50mt. disposed earth to be levelled and neatly dressed.a. Ordinary rock.

I. Lift upto 1.5m One 20cum 139.30 27862.7.1

Cum

II. Lift from 1.5m upto 3.00m One 10cum 161.65 16172.27.2

Cum

b. Hard rock (blasting prohibited)

I. Lift upto 1.5m One 20cum 293.75 58752.7.3

Cum

II. Lift from 1.5m upto 3.00m One 10cum 316.10 31612.7.3+2.27.2 Cum

3 Filling available excavated earth (excluding rock) in trenches, plinth sides of foundation, etc in layers not exceeding 20cms in depth: consolidating, each deposited layer by ramming and watering lead upto 50m and lift upto 1.5m. One 120cum 30.25 3630 2.26 Cum

Total28422


SUB HEAD :CONCRETE WORK4 Providing and laying in position cement concrete of specified grade excluding the cost of centring and shuttering. All work upto plinth level. a. 1:3:6 (1 cement: 3 coarse sand : 6 graded stone aggregate 40mm nominal size) One 4cum 1549.15 6197

4.5.6Cum

Total6197 SUBHEAD : REINFORCED CEMENT CONCRETE

5 Providing and laying in position specified grade of reinforced cement concrete excluding the cost of centring, shuttering finishing and reinforcement. All work upto plinth level. a. 1:1.5: 3 (1 cement : 1.5 coarse sand : 3 graded stone aggregate 20mm nominal size One 28cum 2116.20 59254

5.1.2Cum

6 Centring and shuttering including strutting propping etc., removal of form for all works upto plinth level.a. Foundations, footings, bases of columns etc, for mass concrete. One 12sqm 61.10 733

5.14.1Sqm

b. Lintels, beams, plinth beams, girders, bressumers and cantilevers. One 40sqm 87.95 3518

5.14.5Sqm

c. Columns, pillars, piers, Abutments, posts and struts. One 13sqm 135.80 1765

5.14.6Sqm

7 Reinforcement for R.C.C. work including straightening, cutting, bending, placing in position and binding all complete. a. Thermo mechanically treated (TMT) bar One 3000kgs 21.85 65550

5.29.7Kg

8 R.C.C. work smooth finishing of the exposed

surfaces with cement mortar 1:3 (1cement : 3 fine sand) One 15sqm 40.00 600

5.31m

SqmTotal

131420 SUB HEAD : BRICK WORK

9 Brick work with F.P.S. bricks of class designation 50 in Cement mortar 1:6 ( 1 cement : 6 coarse sand) a. In foundation and plinth One 12cum 1303.25 15639

6.2.4mCum

Total15639


SUB HEAD :STEEL WORK

10 Making and supplying at site anchor MS bolts of 32mm dia and of required length conforming to IS: 2062, threaded at top upto 150mm length and welded with lugs of 100mmx100mmx10mm thick plate at 50mm above from bottom including suitable hexagonal nuts 2 Nos and MS washers on each bolt etc complete all as directed by the Engineer-in-charge. One 260kg 47.80 12428

(MR)Kg

11 Labour charges for arranging and fixing the anchor bolts in position during conc Each 32nos 101.00 3232

(MR)(Base plate and anchor bolts will be supplied

by the department at site of work at free of cost.)

12 Structural steel work welded in built up sections, trusses and framed work including cutting, hoisting, fixing in position and applying a priming coat of approved steel primer all complete. One 430kg 24.30 10449 10.4

Kg13 Supplying at site galvanised steel tower materials with average mass of zinc coating of 610 gms/Sqm (ie approximately 85 microns) consisting of angles, flats, bars, plates,gusset plates, ladders connecting plate, base plates, bolts and nuts washers all fabricated as per approved drawings and specifications for erection of tower One 9800kgs 48.70 477260

(MR)Kg

14 Labour charges for erection of tower upto a height of 40m including lifting upto required levels with necessary tools and plants required all as directed by the Engineer - in - charge. One 9800kgs 6.15 60270

(MR)kgs

15 Horizontal cable tray with Galvanised iron sections connected by bolts & nuts or by welding to required line and level including connecting legs as required. one 600kgs 55.30 33180

(MR)kgs

Total596819 SUB HEAD:FINISHING

16 12mm cement plaster of mix 1:6 (1 cement: 6 fine sand). One 10sqm 44.00 440

13.8.4Sqm

17 White washing with lime to give an even shade: a. New work (three or more coats) One 15sqm 4.65 70

13.70.1Sqm


18 Painting with LUXOL. High Gloss synthetic enamel paint or equivalent in two or more coats over and including base coats of etching primer (BISON wash primer or equivalent) and BISON HB Zinc phosphate primer or equivalent to required shade and colour. One 10.40MT 3299.70 34317

(MR)M.T

Total34827 ALLIED WORKS:

19 Supplying and fixing LED aviation obstruction lamp of Saraj,Binoy,Aviads,Litten or equivalent with Light Dependent Resistance sensor (day and night automatic timer )with necessary MCB switches armoured cables,clamps, etc. Each 1nos 14165 14165

(MR)

20 Earthing with copper earth plate 600mm x 600mm x3mm thick as per enclosed drawing no---including accessories and providing masonary enclosure with cover plate having locking arrangements and watering pipe etc including filling charcoal or coke and salt complete as required and as directed by engineer in charge Each 2nos 6050.00 12100

(MR)

21 Providing and fixing 70sq.mm insulated copper cables of approved quality from the tower top to earth pit with necessary clamps, fixtures . etc.,required One 70mtr 327.00 22890

(MR)Metre

22 Providing and fixing spike type lightening arrester with necessary fixtures at top of the tower.The spike shall be insulated from tower byTeflon material. The spike shall be connected to copper plate earthing by insulated 70sqmm multistrand copper wire with proper lugging arrangement as directed by the Engineer in charge ( The cost of 70sq mm copper wire shall

be paid for seperately) Each 1nos 3200.00 3200(MR)

23 Providing Ring earthing by running GI flat of size 50x6mm alround at 1m away from tower base in ground at a depth of one Metre from ground level. All tower legs shall be connected connected to ring earth by 50x6mm GI flat with necessary accessories, etc., Both ends of the GI flats shall be brought to ground level and terminated in an enclosed brick masonary chamber of inside size 300x300x300 mm with 50 class designation bricks in cement mortar 1:6(1Cement : 6 Coarse sand) including necessary excavation, foundation concrete 1:5:10 (1Cement:5Coarse Sand:10 graded stoneS.N Description of Item Unit Qty. Rate Amount

DSRCODE

agggregate 40 mm nominal size)plastering 12mm thick in cement mortar 1:3(1 Cement :3fine sand) with hinged CI cover and frame of size 300x300mm (weight of cover not less than 4.5 kgs) with proper locking arrangement complete all as directed by the Engineer-in-charge. One 15mtr 206.40 3096

(MR)Metre

24 Supplying and mixing Roff superplasticiser 410 admixture at the dosage of 300ml per bag of cement used for RCC 1 : 1 1/2 :3 as recommended by the manufacturer specification only in columns /stems all completeas directed by the Engineer-in-charge. One 17Lit 114.04 1939

(MR)Litres

Total57390

Note:

The estimate is based on DSR 2002 except for item nos10,11,13,14,18,19,20,21,22 ,23,24 and 25, which are market rate items. The rates for these items as per actual observation during April, 2004 made on similar works for labour and material at PUNE/CHENNAI

CHAPTER – V

GUIDELINES FOR CONTRACTS

6. GUIDELINES FOR CONTRACT6.1. GENERAL:

i. All works shall be carried out on the basis of contracts drawn on Forms BSNL7/8/11

ii. A set of sample “Additional condition” given below shall be added to the standardcondition to take into account the special requirement of the work.

iii. The work shall be entrusted only to approved and eligible contractors as per existingprocedure. However, works can be entrusted to “Specialised contractors” for whichthe Zonal Chief Engineers may enlist specialised agencies for such works. Guidelinesfor Enlistment of Specialised Agencies are enclosed.

6.2 ADDITIONAL CONDITIONS :

i. The intending tenderers shall note that the work is of urgent nature and is to bepositively completed within the stipulated period. Therefore, only those contractors who areconfident and capable of carrying out the work within the stipulated period should apply forthe work.

To ensure good progress, the contractor shall, within 7 days of the award of work,submit a programme to the Engineer-in-charge for completing the work within thestipulated period. Due to the urgency of the work, failure to commence the workwithin 10 days of the award of the work, would result in forfeiture of the amount ofEarnest Money without any notice to the contractor. The Engineer-in-charge shall at

his discretion have the authority to cancel the work and get the work executed by anyother alternate means for which no claim shall be entertained from the contractor.

However, if the commencement of the work is held up on account of reasons beyondhis control, it shall be the sole responsibility of the contractor to bring the matter tothe notice of the Engineer-in-charge and obtain permission in writing for delay incommencement of the work. .

ii.. The work is of specialised nature . Therefore, the agency entrusted with the workshall get the steel towers manufactured (fabrication and galvanising) only from firmsapproved by the Engineer – in-Charge. This condition shall, however, not beapplicable to approved specialised agencies by the CE.

iii. The tenderers shall take into consideration the Drawings and Specifications andquote the rates accordingly. The quoted rates shall be comprehensive complete

including all charges such as Insurance, transportation , taxes fixed by the Central/StateGovernment etc. Nothing extra shall be payable over the quoted rates.

iv. It is likely that the work shall be executed in restricted areas and therefore a fewrestrictions may be in force for security purposes. The contractor shall be bound tofollow all such restrictionsand nothing extra shall be payable.The tenderers shall makenecessary enquiries relating to such instructions before quoting their rates and nothingextra will be payable on this account.

v. Wherever the work site is in non-BSNL building, the contractor shall takeextra precautions for avoiding damages to the building/premises. The Engineer-in-charge shall be indemnified against any claims on account of damages to thebuilding/premises of the landlord and shall be legally responsible for compensatingthe landlord as may be assessed by the Engineer-in-charge.

vi. Normally, no departmental materials shall be issued to the contractor for the work.The Contractor shall arrange himself all materials conforming to prescribedspecifications. However, whenever the Engineer-in-charge may, at his discretion,issue materials to the contractor for the work., the materials so issued shall begot insured against loss/damage etc.. The contractor shall also ensure that only therequired quantities of the departmental materials are used for the work.. In the eventof excess consumption beyond the required quantities, the Engineer-in-charge shallhave the right to recover at the market rates for which the certificate of the Engineer-in-charge shall be final and binding.

vii. The Electrical items of work shall be carried out through Licensed Electrician.

viii. The completed work shall be inspected for approval by the “Acceptance Testing Unitof the Telecom. Circle”. It shall be the responsibility of the contractor to offer thecompleted work for inspection and approval of the A/T in co-ordination with and asper the directions of the Engineer-in-charge and nothing extra shall be payable on thisaccount. If the completed work is not found satisfactory as per the prescribedspecifications, corrective measures ordered by the Engineer-in-charge shall be carriedout immediately by the contractor without any additional expenditure liability to theBSNL.

ix. Wherever roof top towers are erected, the contractor shall take adequate precautions forensuring that no damage is caused to the existing water proofing of the terrace. Inthe event of any damage caused by the contractor to the water proofing of the terrace,he shall be responsible for rectifications. The contractor shall also be responsible forsuch all those defects to the water proofing which may come to the notice of the Engineer-in-charge during the next monsoon for which an amount of 10% of the SecurityDeposit for the work shall be retained until the next monsoon and shall be refundedthereafter.

x. All materials which are tested for use in the work shall be procured well in advance sothat enough time is available for testing and approval of these materials by the Engineer-in-charge. While the civil work shall be in general be carried out in accordancewith CPWD Specifications 1996 Volume I to VI with up to date correction slipNo.1 to 14 and Revised Specification 2002 for mortar, concrete and RCC andthe work

of steel towers shall be carried out as per the Specifications contained in this contractat Page . . . . to . . . . . . .

6.3. GUIDELINES FOR ENLISTMENT OF SPECIALISED AGENCY :

i. The applicants desiring enlistment should have satisfactorily completed atleast threeSteel Towers of height not less than 15 mtrs. in Govt./Public Sector during the lastthree years. The works carried out for Reputed Private Company may also be

considered at the discretion of Zonal Chief Engineer. The work of erection of mast/pole shallnot be considered as Tower work for this purpose.

ii. The capacity of the plant for manufacturing the tower shall not be less than………metric tonnes per month.

Iii The applicant shall be required to submit the Income Tax Returns for the last 3 financialyears.

iv. The applicant should furnish a solvency certificate for not less than Rs. 30 lakhs inthe prescribed proforma in a sealed cover from his bankers.

v. Intending applicant shall be required to own a Plant containing Machinery andEquipment as per Table.

vi. Validity of enlistment shall initially be for two years and for re-enlistment, thecontractor shall apply three months before the expiry of the period of enlistment.

vii. In case the enlisted contractor fails to participate atleast 10% of tenders invited byBSNL Zone. during two consecutive years, his enlistment shall stand removed. Thedecision of the enlistment authority shall be final.

6.4 DISCIPLINARY CONDITIONS:

1. The Contractor may be removed from the approved list of contractors if he;

i. Has failed to execute a contract; or execute it unsatisfactorily; or is proved to

be responsible for constructional defects; or more than once.

ii. Is no longer in possession of adequate Plants and machinery as mentioned in

item No 6.3 (v).

iii. Is litigious by nature or

iv. Has repeatedly violated any important conditions of contracts; or

v. Has failed to execute a contract, or executes or unsatisfactorily, or is proved to

be responsible for constructional defects or more than on occasion ; or

vi. Has failed to abide by the conditions of Enlistment; or

vii. Is found to have given false information at the time of Enlistment; or

viii. Is declared or is in process of being declared bankrupt/insolvent, winding up,

dissolved or partitioned ; or

ix. Repeatedly violate the labour regulations and rules (more than two occasions)

6.5. APPLICATION FORM

i) Name of applicant, his present nationality, fullAddress and telephone number(s) :

ii) Whether the firm is Private or Public Limitedconcern or a registered Partnership Firm?(attested copies of deeds or Articles of Associationto be enclosed). :

iii) Name of the person holding the Power of Attorneyand present Nationality with liabilities.(Attested copy of Deeds to be enclosed) :

iv) Names of partner, their present Nationality andliabilities (Attested copy of Partnership Deed tobe enclosed) :

v) Name of Bankers and full address(The banker’s report in original, in sealed cover,giving his/their financial capacity to handle worksof the required magnitude should be enclosed) :

vi) Place of business :

vii) List of works executed

a. Name of work :

b. Type of Tower : (Roof

Top/GroundBased)

c Height of Tower :

d. Year of execution :(to be shown separately) :

e. Date of completion :

f. Amount :

g. Authority under which executed :

NOTES :

a. For works done in the Departments other than the Department of Telecommunications/BSNL, attested copies of certificates from the officers under whom works werecarried out should be enclosed.

b Works executed under Central Government, State Government and/or Public SectorUndertaking will be considered for enlistment. The enlistment committee shall havethe discretion to consider works executed for reputed private bodies also.

viii. Whether the applicant has Engineering Organisationcapable of dealing with Structural Steel works andhas sufficient machinery and plants etc. at disposal ?(full details of organization machinery, plantequipments tools along with ownershipdocuments to be given) :

xi. Whether the applicant is enlisted with any otherDepartment? If so, the details thereof :

x. Whether the applicant is a share holder of anyfirm enlisted in the Department/BSNL? :

xi. Whether the applicant or any of his partners orshare holder of the company is a member(s) ofthe Indian Parliament or of any State Legislature ? :

xii. Whether the applicant or any of his partners orshareholder is a/are dismissed Govt. Servant(s)? :

xiii.. Has the applicant or any of his partners or shareholders of the company been black listed orremoved from the approved list of contractors ordemoted to lower class or orders passed banning/suspending business with the applicant etc. by anyDepartment in the past? :

xiv. Whether the applicant has under his employment a dismissed Govt. Servant? :

xv. A list of those persons who are working with the applicant in any capacity and whoare near relative to any Gazetted Officer in the Department of Telecom./BSNL/ or in

the Ministry of Communications should be submitted. The applicant should alsointimate the names of such persons who are employed by him subsequently.

NOTE :

a. The specialized agencies are not entitled to tender for works in the Civil Wing of the Department of Telecom./BSNL in which their near relative(s) is/are workingas Junior Accounts Officer, Assistant Accounts Officer, Accounts Officer or within the

ranks of Chief Engineer and Junior Engineer (both inclusive) and any breach of thiscondition by any contractors would be sufficient to debar him from Enlistment.

b. The term “near relative” shall mean wife, husband, parents and grand parent,children and grand children, brothers and sisters, uncles, aunts, cousins, nephews andnieces and their corresponding in-laws.

C E R T I F I C A T E S

i) I/We certify that I/We have read the rules for enlistment of contractors and am/areprepared to abide by them as amended from time to time.

ii) I/We certify that I/We will not get myself/ourselves registered as contractor(s) in theBSNL under more than one name.

ii) I/We certify that I/We did not retire as an Engineer of Gazetted rank or as anyGazetted Officer employed in Engineering or Administrative duties in theEngineering Department of the Government of India during last two years. I/We alsocertify that I/We have neither such a person under my/our employment nor shall I/Weemploy any such a person within two years of his retirement, unless permitted by thecompetent authority.

iv) We certify that none of the partners/directors retired as an Engineer of Gazettedrank or as any Gazetted Officer employed in Engineering or Administrative duties inthe Engineering Department of the Govt. of India during the last two years. We alsocertify that we have neither under our employment any such person nor shall weemploy any person within two years of his retirement except with the prior permissionof the Government (for limited companies and partnership firms).

Date : Signature of the applicant

Place : Address :

6.6 SPECIMEN FORM OF SOLVENCY CERTIFICATE FROMTHE SCHEDULED BANK

This is to certify that to the best of our knowledge and information that

1. _______________________________________________________________(Name of the individual or the firm)

2. ________________________________________________________________

_______________________________________________________________(Name of the proprietor in case of a sole proprietorship concern or names of partners in case of partnership concern as per bank’s record, be indicated).

3. _______________________________________________________________

________________________________________________________________(Address of the customer as per bank record)

is/are customer(s) of our bank, is/are respectable and can be treated as good for

any engagement upto a limit of Rs. _______________ (Rupees ____________

________________________________________________________ only).

This certificate is issued without any guarantee or responsibility on the bank or any of the Officers).

Manager

Bank :

NOTE :

This certificate should be issued on the letterhead of the Bank and addressed to theDesignated Officer in a sealed cover. (The Solvency/Banker’s Certificate is required to besent to the Enlisting Authority)

6.7. CERTIFICATE OF BANK BALANCE

(Name of the Bank)Branch’s Name & address

________________________________

________________________________

Dated : __________________________

This is to certify that M/s. _____________________________________________

is having Current / SB A/c No. _____________________________________________

in our Branch and t he minimum balance maintained during the last 6 months is

Rs. _________ (Rupees ________________________________________________

only).

Signature of the Manager

Designation_________________________ with StampSeal of the Bank

NOTE : This certificate should be issued on the original letterhead of the Bank andaddressed to the Designated Officer in a sealed cover. (TheSolvency/Banker’s Certificate is required to be sent to the Enlisting Authority.

6.8. EVALUATION OF SPECIALISED AGENCIES :

ITEMSMARKS(OBTAINED)

MARKS(MAX)

A PERFORMANCE OF WORKS (45 MARKS) Experience of similar works

40 M or above .. .. .. 25 to 40 M .. .. .. 15 to 25 M .. .. ..

15 10 8

B. TURNOVER (20 MARKS) Marks shall only be given for those years during which the Firm has an annual turn over of Rs.75 lakhs (Information must Be supported by Audited Balance Sheet for the last 3 years Upto 2002-2003. For the current year, certificate from the Statutory auditors certifying turnover for 2003-2004 must be Furnished).

One year .. .. ..

2 years .. .. ..

3 years .. .. ..

10

15

20

C. TECHNICAL PERSONNEL (10 MARKS) a) Graduate Mechanical/Civil Engineers with more than 3

years experience One number Above one number

7

b) Diploma Mechanical/Civil with more than 5 years experience Two numbers Above two numbers

3

D. SOLVENCY (10 MARKS) Solvency of the bidder from bank 30 lakhs .. .. .. 50 lakhs .. .. .. 100 lakhs .. .. ..

5 8 10

E. PLANT AND EQUIPMENT (15 MARKS)TOTAL - 100 MARKS

TABLE “E”

MACHINARIES AND EQUIPMENTS

Sl. No. Description Minimum Number 1. Heavy duty steel for Punching, Shearing,

Cropping, notching and bar shearing stations upto 12mm thick plates 25 mm dia holes with HP 1 Nodrives B.H. after modifications

2. Universal machine for Punching, Shearing, Cropping, notchingstations upto 8 mm thick plates 10mm dia holeswith 2 HP drives . 1 No

3. Universal Radial Drilling Machine 50mmCapacity with variable speed control 3 HP Drive 1 No.

4. Jigs and fixtures for punching, shearing machineAnd slotted jig stations 2 Nos

5. Pillar drilling machine with variable speeddrive 40mm capacity heavy duty with 3 HPdrives 2 Nos

6. Double headed bench grinder with 0.5 HP drive 1 No. 7. 400 amps Air cooled welding set with draft motor 1 No.

8. 300 amps Air cooled welding set with draft motor 9. Open hearth blower fan with 1 HP drive 1 No. 10. Gas cutting apparatus with ‘IOL’ cut-ovgen sets

with regulator 2 Nos. 11. Torque wrenches of sizes 3 Nos. 12. Pug cutting machine 1 No. 13. Magnetic drilling machine 1 No. 14. Grinders portable 2 Nos. 15. Hydraulic pipe bending machine 1 No. 16. Hack saw pipe cutting machine 1 No. 17. Pipe bending Jig 1 No.

APPENDIX – III

MARKET RATE ANALYSIS

Market rate items analysis (Refer CPWD DAR for Electrical works & Civil works) 1 Providing earthing with copper plate 600x600x3mm

Rate unit quantity Amount Materials

600x600x3mm copper plate 176.80 one kg 10.80 kgs 1909.44 Funnel,tinned brass bolt,nut checknut,washer 120.00 1set 1.00 set 120.00 locking arrangement with hinged cover 450.00 1set 1.00 set 450.00 20mm GI pipe medium class 90.00 one metr 2.70 mtr 243.00 Total 2722.44 Add Wastage 5% 136.12 Total 2858.56 Coke 600.00 100kg 240.00 kgs 1440.00 Salt 500.00 100kg 5.00 kgs 25.00 Labour Wireman Grade I 200.00 per day 0.50 nos 100.00 Khallasi 110.00 per day 0.50 nos 55.00 Total 4478.56 Add T&P 2% 89.57 Total 4568.13 Earth work(for 3.04cum as per DAR 1997 for civil works Mate 110.00 per day 0.24 nos 26.40 Beldar/coolee 110.00 per day 2.40 nos 264.00 Extra for additional lift of 1.5m Mate 110.00 per day 0.03 nos 3.30 beldar 110.00 per day 0.33 nos 36.30

Refilling earth( for 3.04 cum as per DAR 1997) Mate 110.00 per day 0.06 nos 6.60 coolie 110.00 per day 0.76 nos 83.60 bhisthi 110.00 per day 0.06 nos 6.60

Masonary chamber (300x 300 x300mm) 450.00 Lumpsum 1.00 nos 450.005444.93

Add 1% Water Charges 54.45 Total 5499.38 Add 10%CP & OH 549.94 Total 6049.32

Say 6050.00

2 Ring earthing alround tower Analysis for 2.086mx2.086m tower base ie for 26.3m GI flat) Excavation for trenches (5.50cum) length= 4x4.086=16.344 upto leg 4*0.5=2.00 Total=18.344x0.3x1.00=5.50 cum Mate 110.00 per day 0.44 nos 48.40 Beldar/coolies 110.00 per day 4.51 nos 496.10 Filling earth mate 110.00 per day 0.11 nos 12.10

coolies 110.00 per day 1.38 nos 151.80 bhisthi 110.00 per day 0.11 nos 12.10

50x6mm MS flat 35.00 kilogram 65.04 kgs 2276.30 L=(4x4.086)+(2x2)+(4x1.5)=26.3 Weight=26.3x2.355=61.94kgs Zinc coating at 610g/sqm 12.00 kilogram 64.09 kgs 769.10 bolts,nuts and miscellaneous items 20.00 ls 1.00 nos 20.00 CI cover with locking arrangements 450.00 1set 1.00 set 450.00 Masonary chamber 300x300x300mm 450.00 LS 1.00 nos 450.00 Labour for laying and jointing GI flat Grade I Wire men 180.00 per day 0.50 nos 90.00 coolie 110.00 per day 1.00 nos 110.00 Total 4885.90

Add 1% Water charges 48.86 Total 4934.76 Add 10% CP& OH 493.48 Total (for 26.3m) 5428.23 Rate for one metre 206.40

3 Orienting anchor bolts by using template Analysis for 32 bolts Beldar 110.00 per day 4.00 nos 440.00 Mason 150.00 per day 2.00 nos 300.00 cost of white grease 120.00 one kilo 3.50 kgs 420.00 Labour for greasing both thread, checknut etc coolie 110.00 per day 3.00 nos 330.00 Fixing bolts in position including 110.00 per day 10.00 nos 1100.00 Scaffoldings, miscellaneous 300.00 ls 1.00 nos 320.00

2910.00 Add 1% water charges 29.10 total 2939.10 Add 10% CP & OH 293.91 Total(Rate for 32 nos) 3233.01

Rate for each 101.03 Say 101/-

4. Description of item Supplying at site galvanised steel tower material with average mass of zinc coating of 610 gms/sq m (ie approximately 85 microns) consisting of angles, flats, bars, plates, gusset plates, ladders, connecting plates, base plates, bolts, nuts and washers all fabricated as per approved drawings and specifications for errection of tower structure a)Angles, flats, girders,Plates,Nuts and bolts,with plain/spring washers of various sizes.

Details of cost for 2000.00 Kg Steel Sections 1600.00 Kg Add 5& wastage 80.00 Kg 1680.00 Kg 1680.00 Kg 26.00 43680 Plates 360.00 Kg Add 5& wastage 18.00 Kg 378.00 Kg 378.00 30.00 11340 Nut nolts 114.00 Kg Add 5& wastage 6.00 Kg 120.00 Kg 120.00 35.00 4200 Galvanising (Finished) 2000.00 10.00 20000 Labour (Actual Observation) Black Smith 3.85 Each 180.00 693 Assistant black smith 3.58 Each 150.00 537 Driller 6.25 Each 150.00 937.5 Fitter 3.85 Each 180.00 693 Grinder 5.12 Each 180.00 921.6 Beldar 19.45 Each 150.00 2917.5 Mistry 1.85 Each 150.00 277.5 Sundries LS 500.00 500 Trasportation (byTata 407 Tempo) 1.00 Job 1000.00 1000

87697 Add % Water Charges 876.97

88574 Add % CP & OH 8857.4

97431 Cost of 2000.00 Kg 97431.48 Cost of 1.00 Kg 48.72

Say Rs 48.7

5 Description of item Labour charges for errection of tower upto a height of 40m including lifting upto required levels withnecessary tool

Details of Cost for 2000.00 Kg

Sorting & Numbering Fitter 3.00 Each 180.00 540 Assistant Fitter 5.00 Each 150.00 750 Beldar 10.00 Each 110.00 1100 Mistry 0.50 Each 150.00 75 Numbermarker 1.00 Each 150.00 150

Lifting Assistant Fitter 2.00 Each 150.00 300 Beldar 6.00 Each 110.00 660

Erection Erecter 6.00 Each 180.00 1080 Assistant Fitter 4.00 Each 150.00 600 Beldar 10.00 Each 110.00 1100 Scaffolding LS 1500 Lifting Equipements LS 1500

Correction & Checking Erecter 2.00 Each 180.00 360 Assistant Fitter 2.00 Each 150.00 300 Beldar 5.00 Each 110.00 550

Sundries & Misc like caution noticing Welding grinding etcLS 500

11065

Add (1%water charges) 110.65

11176

Add (10%CP&OH) 1117.6

12293

Cost of 2000.00 Kg 12293.22

Cost of 1.00 Kg 6.15

6 Supplying of required length 32mm dia MS anchor bolts including threading

and 2 nos of bolts and welding 50x50mm plate at bottom Analysis for one bolt 1m 32mm dia Anchor bolts one kg 61.65 32.00 1972.80 Threading ls 350.00 2nos bolts kg 0.6 40.00 24.00 Base plate(.05x0.05x8mmthick) kg 0.16 33.00 5.28 Transport from dealer to Fabricatils ls 30.00 Transport from Fabrication unit tls ls 30.00 Labour(Fabricating cutting etc) Blacksmith per day 0.5 180.00 90.00 Assistant black smith per day 1 150.00 150.00

2652.08 Add 1% Water Charges 26.52

Total 2678.60 Add 10% CP and OH 267.86 total rate for 61.65kg 2946.46 Rate per one kg 47.79

Say 50.00

7 Providing and fixing spike type lightening arrester with necessary fixtures at top of the tower.The spike shall be insulated from tower byTeflon material. The spike shall be connected to copper plate earthing by insulated 70sqmm multistrand copper wire with proper lugging arrangement as directed by the Engineer in charge ( The cost of 70sq mm copper wire shall be paid for seperately) Material Spike each 1.00 2600.00 2600.00 Teflon sleev 35.00 Screws,etc 10.00 Labour Fitter per day 0.70 180.00 126.00 coolie per day 1.00 110.00 110.00 Total 2881.00 Add 1% Water Charges 28.81 Total 2909.81 Add 10% CP and OH 290.98

Total 3200.79

8 Supplying and fixing super plasticiser 4101ts admixture at 300ml per bag of cement used for RCC 1:1.5:3as recommend Rate for 10 litres 929.00 Transport from 100.00 Total 1029.00 Add 10% CP & OH 102.90 Total 1131.90 Rate per litre 113.18

9 Providing & fixing 70 sq.mm copper insulated cable

Rate for 50m

Material 70 sq.mm. Copper cable metre 52.5 300.00 15750.00 Labour Wire ment Grade I per day 1 180.00 180.00 Helper/coolie per day 1 110.00 110.00 Lugs and miscellaneous ls 1 150.00 150.00

16190.00 water charges 1% 161.90

16351.90 Add CP & OH at 10% 1635.19 Total rate for 50 metres 16351.90 Rate for 1 metre 327.04

Rate 327.00 per metre

10 LED lamp (Rate for one set)

Materials

aviation lamp each 1 10000 10000 MCB switch each 2 500 1000 Armoured cable metre 25 45 1125 Holder clamp metre 25 25 625

with labour 12750

Add 1% W.C 127.5

12877.5 Add 10% C.P 1287.75

14165.25Say 14165/each

APPENDIX – IV

CHECK LIST FOR TOWER WORKS

CHECK LIST FOR EXECUTION

SL.NO DESCRIPTION YES/NO REMARKS

MATERIAL1. On receipt of tower material at site

check availability of all sections as perdrawing .

2 All steel members shall generallyconform toIS: 226-1975/IS 2062-1999.

3 Test certificate from the manufacturerSAIL/TISCO/VSPL available

4 Independent test report from approved labavailable on the quality of steel .

5 Steel members shall be free from cracks,lamination , excessive rust and scaling.

6 Edges of members shall not be sharp.7 Position of holes must conform to

drawing. Holes shall have their axisperpendicular toThe surface bored.

8 Test certificate for mass of zinc coating available.9 Galvanisation thickness is checked in

the fieldBy instruments (ELCOMETER etc)

10 The adhesion of zinc coating should becheckedBy giving pivoted hammer blows. The zinccoating shall not flat off when applied pivothammer blows.

ERECTION11 Whether base width of the tower is as per the

drawing12 Whether top width of the tower is as per the

drawing13 Whether height width of the tower is as per the

drawing14 Whether condition of welding at various locations

is satisfactory.15 Bulky white deposits and blisters and is

satisfactory16 Whether quality of primer (if applied) is

satisfactory17 Whether any mispunch/excess holes are made in

any member18 Whether the tightening of bolts is checked with

torque wrench and found satisfactory19 Whether length of any bolts are short20 Whether any gap is observed between the

chequered plate at working platform level

21 Whether any lack of fit in any member due todefective fabrication

22 Whether the member dimensions, member length,slope, section sizes etc. are as per drawing.

23 Whether bolt holes, bolt size, bolt no. and itsposition on member is as per drawing.

24 Whether gusset plates, spacers, washers, nuts etc.are placed as per drawing.

25 Whether all the members are reasonably straight26 Aviation obstruction lamps are LDK sensor fixed

and properly connected27 Earthing checked for required resistance28 Lightening conductor properly connected to the

earth pit29 Necessary safety belt and safety shoes are

provided to the workers30 Insurance as per contract is available31 Verticality of the erected tower checked with the

help of plumb bob and/or theodalite.(The theodalite if used should be checked forvertical error before use).

FOUNDATION32 Structural feasibility ascertained from landlord/

Engineer 33 Structural design done for fixing of foundation

bolts on existing columns based on designreactions and support conditions.

34 Dismantling of existing columns or beams doneCarefully avoiding damage to existing structureAnd waterproofing.

35 Welding if required to extend the columns doneproperly to achieve bond lengths.

36 Sufficient curing or setting time given to RCCWork before commencing the erection work.

37 Anchor bolts placed in the concrete foundationShould be held in position with steel template.Position of template and foundation bolts checkedAccording to the drawing.

38 Centre to centre and Diagonal distances checkedcorrect to millimeter.

39 The distances rechecked after setting of concrete.40 Levels of template of foundation checked.41 Levels of finished tower stem top checked42 Base plate in full contact with the concrete stem43 Threading of bolts and nuts should be thoroughly

Cleaned and soaked with linseed oil and coveredWith plastic bags till erection.

44 Soil Exploration /investigation carried out.45 Before laying of lean concrete the soil strata

shall be approved by the Engineer-in-charge.

4. INSTRUMENTS REQUIRED AT SITE :

i. Theodolite with stand : 1 Noii. Leveling staff : 2 Nos.iii. Steel tape : 30M : 1 No.

15M : 1 No.iv. Engineers spirit level : 2 Nos.v. Safety helmets : 2 Nos.vi. Safety belt with rope : 2 Setsvii. Binoculars : 2 setsviii. Torque wrench : 1 No.ix. Elcometer : 1 No.x. Earth Megger : 1 No.

APPENDIX – V

LIST OF IS CODES AND REFERENCES

LIST OF INDIAN STANDARDS REFERED

SLNo

INDIAN STANDARD NUMBER

1. IS 2062 : 1999Steel for general structural purposes specification. (Fifth revision)

2. IS 808:1989(Reaffirmed 1999) Dimensions for hot rolled steel beam , column,channeland angle sections (Third revision ) (Incorporating amendment No.1)

3. IS 1730: 1989Supersedes IS:1741 (Reaffirmed 1995) Steel plates, sheets, strips & flatsfor structural & general Engg. purposes- Dimensions (Second revision)

4. IS 3502:1994(Reaffirmed 1998)Steel Chequered plates-specification (Second revision)

5. IS 1852:1985(Reaffirmed 1998) Specification for rolling and cutting tolerances for hotrolled steel products (Fourth revision)

6. IS 7215:1974(Reaffirmed 1995) Tolerances for fabrication of Steel structures.

7 IS: 13229-1991(Reaffirmed 1995) Zinc for Galvanizing-Specification

8. IS 209: 1992(Reaffirmed 1997)Zinc Ingot-Specification (Fourth revision)

9 IS 2629-1985(Reaffirmed 1998)Recommended practice for hot-dip galvanizing of ironand steel(First revision)

10 IS: 4759:1996(Reaffirmed 2001) Hot-Dip Zinc coatings on structural steel & other alliedproducts – Specification. (Third revision)

11 IS:6639:1972(Reaffirmed 1995) Specification for Hexagon Bolts for Steel structures

12 IS 1364 (Part 1) : 2002 ISO 4014: 1999 Hexagon head bolts, screws and nuts of product gradesA&B.Part 1: Hexagon head bolts ( size range M1.6 to M 64) (Fourthrevision)

13. IS: 1364 (Part 2) : 2002ISO 4017: 1999 Hexagon head bolts, screws and nuts of product gradesA&B.

A&B.Part 2 :Hexagon head screws ( size range M 1.6 to M64) (Fourthrevision)

14 IS: 1364 (Part 3) : 2002ISO 4032:1999 Hexagon head bolts, screws and nuts of product gradesA&B.Part 3 :Hexagon Nuts, style 1 ( size range M1.6 to M 64) (Fourthrevision)

15 IS: 1364 (Part 4) : 1992ISO 4035: 1986 (Reaffirmed 1998) Hexagon head bolts, screws and nutsof product grades A&B. Part 4 :Hexagon thin nuts ( chamfered) (sizerange M1.6 to M 64)(Third revision)

16 IS 1364 (Part 5) : 2002ISO 4036: 1999 Hexagon head bolts, screws and nuts of product gradesA&B.Part 5: Hexagon thin nuts-product grade B (unchamfered) (size range M1.6 to M 10) (Fourth revision)

17 IS 1367 (Part 8) : 2002ISO 2320 : 1997 Technical supply conditions for threaded steel fastenersPart 8: Prevailing torque type steel hexagon nuts- mechanical &performance properties. (Third revision)

18 IS 1148-1982(Reaffirmed 2001)Specification for Hot-rolled steel rivet bars (up to 40mmdiameter) for structural purposes.(Third Revision) (IncorporatingAmendment Nos.1&2)

19. IS 7145: 1973(Reaffirmed 1995)Technical supply conditions for torque wrenches.

20 IS 2015-1977(Reaffirmed 2000) Specification for T-Nuts (First revision)[ IncorporatingAmendment no.1]

21 IS: 2016-1967(Reaffirmed 1996) Specification for plain washers ( First revision)

22 IS 5369-1975(Reaffirmed 2001) General requirements for plain washers & lock washes(First revision)

23 IS 6610:1972(Reaffirmed 1996) Specification for heavy washers for Steel structures

24 IS 3063: 1994

(Reaffirmed 1999) Fasteners – single coil rectangular section spring lockwashers-Specification (Second revision)

25 IS:1929-1982(Reaffirmed 1996) Specification for hot forged steel rivets for hot closing(12 to 36 mm diameter) (First revision) (Incorporating amendment 1,2 &3)

26 IS 800: 1984(Reaffirmed 1998)Code of practice for general construction in Steel(Second revision) (Incorporating amendment No. 1&2

27 IS:875 (Part-3) 1987(Reaffirmed 1997) Code of practice for design loads (other than EarthQuake) for buildings and structures . Part 3 -wind loads.(Second revision)

28. IS 613: 2000Copper rods & bars for electrical purposes- Specification (Third revision)

29 IS 2309: 1989Protection of Bldgs. and allied structures against lightning – code ofpractice (Second revision)

30. IS 12843: 1989(Reaffirmed 1995) Tolerances for erection of steel structure

31. IS 816:1969(Reaffirmed 1998) Code of Practice for use of metal arc welding forgeneral constructions in Mild steel ( First revision)

32. IS 822:1970(Reaffirmed 1997) Code of procedure for inspection of welds.

33. IS 104-1979(Reaffirmed 1999) Specification for ready mixed paint, brushing, zincchrome, priming. (Second revision)

34 IS:123-1962(Reaffirmed-1996) Specification for ready mixed paint, brushing, finishing,semi-gloss, for general purposes, to Indian standard colours. (Revised)

35 IS 2339:1963(Superseding IS: 165 & 166 -1950) (Reaffirmed 1999) Specification forAluminium paint for general purposes.

36 IS 2074: 1992(Reaffirmed 1998) Ready mixed paint, air drying, red oxide zinc chrome,priming specification ( Second revision)

37. IS 5905:1989(Reaffirmed 1998) Sprayed Aluminium and zinc coatings on iron and steelspecification (First revision)

38. IS 5666 : 1970(Reaffirmed 1999) Specification for Etch primer

39 IS:1477 (Part I)1971 Code of practice for painting of ferrous metals in buildings. (Part IPretreatment) ( First revision)

40 IS:1477 (Part II) 1971(Reaffirmed 1995) Code of practice for painting of ferrous metals inbuildings. (Part II painting) (First revision)

41 IS 7205:1974(Reaffirmed 1995) Safety code for erection of structural Steel work

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