Iraq Goverment Regulation-1

Ministry of Electricity Technical Specification for 400 and 132 kV Overhead Transmission Lines
PART 4 DESIGN AND ENGINEERING

TABLE OF CONTENTS
Page
4.1. TOWERS AND STRUCTURES 4
4.1.1 Type and Duties 4
4.1.2 Loadings and Parameters 4
4.1.2.1 Loadings 4
4.1.2.2 Parameters 5
4.1.2.3 Outline and Loading Drawings 7
4.1.2.4 Loads and Load Combinations 7
4.1.2.5 Stringing Loads 9
4.1.2.6 Tower Extensions Table 9
4.1.2.7 Double Circuit Lines 9
4.1.3 Tower Design Criteria 10

4.1.3.1 General 10
4.1.3.2 Materials 10
4.1.3.3 Towers and Structures 10
4.1.3.4 Towers Steelwork Design 11
4.1.3.5 Welding 14
4.1.3.6 Steel Detailing 14
4.1.4 Tower Fabrication 14

4.1.4.1 General 14
4.1.4.2 Submittals 14
4.1.4.4 Fabrication 15
4.1.4.5 Marking 15
4.1.4.6 Bending 15
4.1.4.7 Punching 15
4.1.4.8 Other 16
4.1.5 Tower Testing 16

4.1.5.1 General 16
4.1.5.2 Requirements 16
4.1.5.3 Procedures 16
4.1.5.4 Reports 18
4.1.6 Tower Attachments 18

4.1.6.1 Step Bolts 18
4.1.6.2 Grounding 18
4.1.6.3 Auti-Climbing Devices 19
4.1.6.4 Bird Guards 19
4.1.6.5 Warning and Identification Plates 19
4.1.7 Foundation Design Parameters 19

4.1.7.1 General 19
4.1.7.2 Foundation Types 20
4.1.7.3 Design Parameters 20
4.1.7.4 Foundation Classification and Parameters for Design 21
4.1.7.5 Dimensions 21
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4.1.7.7 Foundation Stability 22

4.1.7.8 Reinforcement of Stems and Chimneys 22
4.1.8 Grounding 23
4.1.8.1 General 23
4.1.8.2 Soil Receptivity Tests 23
4.1.8.3 Grounding Types 23
4.1.8.4 Installation 23
4.1.8.5 Resistance Check 24
4.1.8.7 Connections 24
4.1.8.8 Counterpoise Installation 24
4.1.9 Design Briefs for Approval by Engineer 25

4.1.9.1 With Tender 25
4.1.9.2 After Award of Contract 25
4.2 CONDUCTOR 26
4.2.1 Conductor Type and Details 26
4.2.2 Conductor Loading Parameters 26
4.2.3 Conductor Sag and Tension Data 27
4.3 SHIELDWIRE 27
4.3.1 Shieldwire Types and Details 27
4.3.2 Shieldwire Loading Parameters 27
4.3.3 Shieldwire Sag and Tension Data 28
4.4 INSULATOR AND ASSOCIATED HARWARE 28

4.4.1 Suspension and Tension Assemblies 28
4.4.2 Insulators 29
4.4.2.1 Tangent Tower Suspension Insulator Strings 29
4.4.2.2 Type B Tower Suspension Insulator Strings 29
4.4.2.3 Type C and D Tower Tension Insulator Strings 29
4.4.2.4 Insulator Supply Requirements 29
4.4.3 Conductor Grading Rings 30
4.4.4 Conductor Suspension Clamps 30
4.4.5 Conductor Deadend Assembly 31
4.4.6 Deadend Assembly Associated Hardware & Fittings 31
4.4.7 Conductor Vibration Dampers 31
4.5 SHIELDWIRE FITTINGS 32

4.5.1 Shieldwire Suspension Assembly 32
4.5.2 Shieldwire Strain Assembly 32
4.5.3 Shieldwire Hardware 32
4.5.4 Shieldwire Vibration Dampers 32
4.6 SPACER DAMPER SYSTEM 33

4.6.1 General 33
4.6.2 Design Requirements 33
4.6.3 Conductor Clamp Design 33
4.6.4 Mechanical Strength 34
4.6.5 Corona Extinction Voltage 34
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4.6.6 Ozone Resistance 35

4.6.7 Electrical Resistance 35
4.6.8 Quality of Elastomer 35
4.6.9 Aeolian Vibration & Sub-Conductor Oscillation 36
4.6.10 Movement 36
4.6.11 Jumper Loops 37
4.7 TRANSPOSITIONS 37
4.7.1 General 37
4.7.2 Transpossition Tower Design 37
4.7.3 Clearances 37
4.8 PACKAGING, SHIPPING & TRANSPORT 38

4.8.1 Packaging 38
4.8.1.1 Scope 38
4.8.1.2 General 38
4.81.3 Steelwork 38
4.8.1.4 Conductors and Cables 39
4.8.1.5 Insulators 39
4.8.1.6 Hardware, Accessories and small members 39
4.8.2 Shipping 39
4.8.3 Customs & Documentation 40
4.8.4 Marking & Color Coding 40
4.8.5 Storage Areas in Iraq 40
4.9 TOWER SPOTTING 41

4.9.1 Plans & Profiles 41
4.9.2 Tower Plotting 41
4.9.3 Structure Lists 42
4.9.4 Clearances 42
4.9.5 Plotting Template 43
APPENDIX 4.0: Summary of Relevant Factors of Safety 43
Figure 1 & 2 44
Figure 3 & 4 45
APPENDIX 4.1: Extracts from Design Standards No. 10, Transmission 46
Structures, US Dept. of Interior, Bureau of Reclamation
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4 DESIGN AND ENGINEERING
4.1 TOWERS & STRUCTURES
4.1.1 TYPE & DUTUES
Towers for the 400-KV transmission lines shall be rigid self supported type. The
towers have been given code letters.
These designate:
a) Circuit number (ie) X and Y.
b) Supplier code number (ie) 1,2,3 etc.
c) Tower types (ie) A, B, C, D and E.
Show code letters under (a) first circuit number followed by supplier code number,
followed by tower type code letter.
Tower type letters are as follows:
X Denotes towers destined for use on single circuit lines,
Y Denotes towers destined for use on double circuit lines,
A Denotes rigid tangent suspension tower,
B Denotes rigid 0-10 deg. angle and long span suspension tower,
C Denotes rigid 0-45 deg. angle and semi-deadend tower,
D Denotes rigid 0-90 deg. angle and terminal tower,
E Denotes rigid transposition tower.
If the contracts are awarded in such manner that different contractors each supply the
same tower type, then the towers are to be identified by a number (1 or 2) located
between the letters.
For example: XA- Denotes a rigid tangent tower for the single circuit lines.
YA- Denotes a rigid tangent tower for the double circuit lines.
X1C- Denotes a rigid 0-45 deg. Angle and semi-deadend tower for
single circuit lines as supplied by a specific contractor.
X2C- Denotes a rigid 0-45 deg. Angle and semi-deadend tower for
single circuit lines as supplied by a second contracto
4.1.2 LOADING AND PARAMETERS
4.1.2.1 Loadings
1. Wind
The maximum design gust velocity is 40m/s acting at an elevation of 10 m above the
surface of the ground. The gust velocity shall vary with height in accordance with the
following expression:
V= 40(H/10)1/7 , where V= gust velocity, m/s, at an elevation of H meters.
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Gust pressures on the shield wires, conductors, guys and towers are calculated in
accordance with the following expression:
Ps = 0.000613 x Vs2 x a
Pc = 0.000613 Vc2 x a
Pt = 0.001Vt2
Where: Ps = gust pressure, kPa, at mean shieldwire elevation.

Pc = gust pressure, kPa, at mean conductor elevation.
Pt = gust pressure, kPa, at tower elevation of 15m, 30m, 45m, etc.
Vc = gust velocity, m/s at mean conductor elevation.
Vt = gust velocity, m/s at elevation of 15m, 30m, 45m, etc.
a = gust factor = 0.6
apply the design average wind velocity of 15 m/s directly to the shieldwires,
conductors and towers, using the above expres-sions, but without any variation of
wind velocity with height and without the application of the gust factor.
Make no reduction in wind pressures on the downwid conductor of the bundle. Allow
the wind pressure on rigid towers to act on 2 times (twice) the projected area of the
windward face (s).
2. V-string Tilt
Ensure one leg of V-String insulator assembly does not go into compression under
application of 25 m/s wind at 10 deg. C.
3. Terminology
The WORKING LOAD or DESIGN LOAD is that load resulting from application of
all vertical and/ or horizontal forces which are either real weights of the
particular elements or are calculated according to the rules and formulas
quoted in this Specification.
The DESIGN LOAD or WORKING LOAD, multiplied by appropriate FACTOR OF

SAFETY, gives rise to the ULTIMATE LOAD.
ULTIMATE STRESS is that stress which is induced by the ULTIMATE LOAD.
The term ULTIMATE STRESS or ULTIMATE LOAD is the theoretical value of

stress or load at which failure would be ultimately approached.
For this Specification, for steel design the ultimate stresses are based on
the minimum yield strength of the steel.
4.1.2.2 Parameters
Use weight and wind spans, design angles and maximum and minimum heights to the
bottom of the crossarm as follows:
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Height to
Weight Span Wind Span
Crossarm
Design
Tower Type Conductor Shieldwire Angle Tangent Min. Max.
Angle
Single Circuit Lines m m m m m m
Tangent 0 deg. 520 570 425 425 25 37
Small angle
0-10
& long span 760 835 475 650 25 67
deg.
tangent
Medium
angle & 0-45
760 760 360 675 21.14 33.14
semi- deg.
deadend
Large angle
0-90
& full 830 830 300 720 21.14 33.14
deg.
deadend
Transposition 0 deg. 400 450 350 350 31 37
Double Circuit Lines
Tangent 0 deg. 465 510 724 425 25 37
Small angle
0-10
& long span 675 750 425 425 25 67
deg.
tangent
Medium
angle & 0-45
675 675 330 330 21.14 33.14
semi- deg.
deadend
Large angle
0-90
& full 740 740 275 275 21.14 33.14
deg.
deadend
Use the following design requirements:
Tower types A, B, C, D and E are to be of a rigid self supporting design.
Adjacent faces on rigid towers types A and B may be dissimilar, but opposite
faces are to be identical.
The extension increment is to be 1.5 meters measured vertically.
Rigid tower individual leg extensions are to have a minimum vertical height of
1.5 meters and a maximum vertical height of 7.5 meters. Tower body
extensions shall have a height of 6.0 meters measured vertically, and multiples
of 6.0 meters, if required.
All net transverse conductor, shield wire and tower loads are to be applied in
the same direction and all net longitudinal conductor, shield wire and tower
loads are to be applied in the same direction, for any given load combination.
Tower types A, B and E are suspension-type towers and tower types C and D
are strain-type towers.
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The shield wire is to be located so that the angle of coverage from the shield
wire to the outside conductor of the outside phase is 20 degrees at the tower.
The minimum height of the shield wire above the bottom of the crossarm is the
to be 3.5 meters for the type A and B Towers, 7 meters for the type C and D
towers and 5.0 meters for the type E towers. For double circuit lines, the
minimum height shall be indicated by tenderer.
4.1.2.3 Outline and Loading Drawings
Ensure the phase spacing shall not be less than 9 meters. The tangent tower phase
spacing shown on the specification drawings is 9 meters. If the actual phase spacing
on the tangent tower as designed is to be greater than 9 meters, increase the phase
spacing on all other tower types accordingly for spans greater than 700 meters,
ensure the phase spacing is not less than 10 meters. For double circuit line, the
vertical and horizontal phase spacing shall be provided by tenderer.
Use the loads (provided by tenderer) which include the applicable factors of safety.
Design the towers to ultimate stresses. The factors of safety to be used are as follows:
a) All design loads: 1.5.
b) All stringing, maintenance and climbing loads: 2.0.
c) Dead weight of tower for all load cases shall be the actual tower weight
without any factor of safety.
Provide crossarms for type C and D towers which are adequate for their duty. If
necessary provide different crossarms for the inside and outside of heavy angles. For
straight line section positions and for terminal positions provide identical crossarms on
both sides of the tower.
Suspension insulator strings for jumper loops may not be required on the phase isside
the angle on type C and D towers located at angles. The maximum allowable angle of
swing of jumper loops is 30 degree from the vertical and counterweights may be
utilized in the jumper loop suspension assembly to ensure this angle of swing is not
exceeded under all conditions of maximum gust and/ or tower angle.
4.1.2.4 Loads and Load Combinations
The following paragraphs briefly describe in general terms the basis of the loads and
load combinations.
a) Tangent Tower
1. Maximum Gust: The maximum gust loads are acting in turn in three different
directions. Parallel to, at 45 degrees to, and perpendicular to, the line direction.
The factor of safety is 1.5.
2. Broken Wire: One conductor of one bundle is broken during the application of the
average wind velocity. The factor of safety is 1.5.
3. Stringing:
The conductors are strung after the shield wires are strung. The average
wind velocity is blowing during stringing and the longitudinal loads derived from
normal stringing operations are applied at any or all shield wire load points or any
conductor load point. The factor of safety is 2.0.
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4. Maintenance: Any one shield wire or any one bundle requires maintenance during
the application of the average wind. The vertical load includes allowances for men
and maintenance equipment at any one shield wire or any one bundle support
location. The factor of safety is 2.0.
5. Climbing: Horizontal members carry the weight of one man in addition to the
stringing and maintenance loads. The factor of safety is 2.0.
6. Ladder: In addition to the stringing and maintenance loads, the crossarm carries a
ladder supporting men and equipment. The factor of safety is 2.0.
b) Long Span and 0-10 degree Angle Tower
The loads and load combinations are the same as for the tangent tower except that
the transverse components of the conductor and shield wire tensions are included
and the broken wire load allows one shield wire plus one bundle, both in the same
span, to be broken.
c) 0-45 deg. Angle and Semi-Deadend Tower
1. Maximum Gust Semi-deadend: The maximum gust load acts parallel to the long
axis of the crossarm. Also in combination with one shield wire and one bundle
missing from the same span. The transverse loads include the transverse
components of cable tensions and the longitudinal loads presume the tower to be
in a tangent position. The factor of safety is 1.5.
2. Stringing: The average wind is blowing during the stringing operation and the tower
is to act as a full deadend during stringing. For the transverse load the tower is in
the angle condition, and for the longitudinal load the tower is in the tangent
condition. The factor of safety is 2.0.
3. Maintenance: any one shield wire plus any one bundle requires maintenance
during the application of the average wind. The vertical load includes allowances
for men and equipment at any one shield wire support point and any one conductor
support point and at all jumper loop locations. The factor of safety is 2.0.
4. Uplift: In combination with the maximum gust and agnle, the tower acts in an uplift
capacity with no shileld wires or conductors missing. The factor of safety is 1.5.
5. Climbing and Ladder: same as for the tangent tower.
d) 0-90 deg. Angle and Terminal Tower
1. Tangent Deadend: The larger of the maximum gust act with the tower as a full
terminal tower in the tangent position. The factor of safety is 1.5.
2. Maximum Angle Deadend: The larger of the maximum gust acts with the tower as
a full terminal tower at the maximum angle position. The factor of safety is 1.5.
3. Maximum Angle: The larger of the maximum gust acts with the tower in the
maximum angle condition without any shield wires or conductors mission. The
factor of safety is 1.5.
4. Stringing, Maintenance, Climbing, Ladder and Uplift: Same as for 0-45 deg. Angle
and Semi-Deadend tower.
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e) Transposition Tower
1. Maximum Gust: The maximum gust act at 90 deg. to the line direction. No wires
are broken and the transverse component of the transposed conductor tension is
included. The factor of safety is 1.5.
2. Broken Wire, Stringing Maintenance, Climbing and Ladder: Same as for the
tangent tower and including allowances for the transverse component of the
transposed conductors.
4.1.2.5 Stringing Loads
1. Specified Stringing loads on suspension type structures include for temporary

fouling of running board while passing ove3r stringing block.
2. Ensure specified stringing loads are compatible with Contractor's method of

stringing.
3. Ensure specified stringing loads are not exceeded.
4.1.2.6 TOWER EXTENSIONS TABLE
EXTENSIONS (metres)
TOWER TYPES
Rigid Body Rigid Leg
Tangent Tower Type A 6, 1.5, 3.0, 4.5, 6.0
0 to 10 deg Angle & Long Span Tangent Tower 6, 12, 18 24,

1.5, 3.0, 4.5, 6.0
Type B 30, 36
0 to 45 deg Angle & Semi Deadend Tower Type C 6, 1.5, 3.0, 4.5, 6.0
0 to 90 deg Angle & Long Span Tower Type D 6, 1.5, 3.0, 4.5, 6.0
Tangent Transposition Tower Type E - 1.5, 3.0, 4.5, 6.0
4.1.2.7 Double Circuit Lines
The load and load combinations of the 400 KV double circuit lines covered by this
paragraph shall be in strict accordance with those stipulated in 4.1.2.4 with exception
fo the requirements described hereunder:
1. Tangent Tower
Broken wire: Shieldwire broken or both conductors of one bundle broken during the
application of the average wind velocity. The factor of safety is 1.5.
2. Long Span and 0-10 deg. Angle Tower
Broken wire: One bundle broken plus one shieldwire or one conductor of one bundle,
both in the same span, to be broken. The factor of safety is 1.5.
3. 0-45 deg. Angle and Semi deadend Tower

Longitudinal unbalance: A longitudinal unbalanced load has been provided at the
shieldwire and any one bundle conductor location or at any two bundle conductor
locations, all in the same span. The factor of safety is 1.5.
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4. 0-90 deg. Angle and terminal Tower
Longitudinal unbalance: Same as for 0-45 deg. Angle and semi-deadend tower.
4.1.3 TOWER DESIGN CRITERIA
4.1.3.1 General
Design galvanized steel towers, structures, footings and accessories for 400 KV
transmission lines.
Design leg and body extensions to increase tower heights as shown on the
drawings.
4.1.3.2 Materials
Ensure all component parts of towers comply with the latest international or British
standards applicable, or as specified, or with an equivalent approved standard of
the country of manufacture.
Fabricate galvanized structural steel from open hearth steel to B.S. 4360 or
approved equivalent.
Ensure that galvanized holts, nuts and washers are equivalent to ASTM
Specification a 325 and/ or A 394, or to appropriate ISO standards.
4.1.3.3 Towers and Structures
Ensure specified stringing loads are adequate for contractor's stringing methods
and procedures, and if necessary, increase these loads to suit the contractor's
procedures.
Design transmission line towers and structures to conform to dimensions, loadings

and duties as specified and also design for:
a) Simplicity and ease of erection.
b) Sub-assembly of panels on ground.
c) Erection of panels by gin pole or derrick.
Keep the number of members to a minimum and the number of like members to a
maximum, consistent with reasonable economy.
Minimum thickness of structural steel is to be as follows:
Main leg angles 8 mm

Crossarms 6 mm
Gusset plate 6 mm
Secondary angles 5 mm
Channels 5 mm
Ensure that sections used in the design of all structure types are readily available
from standard sources of supply.
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4.1.3.4 Tower Steelwork Design
1. General
Design all structures and their components to withstand without failure the stresses
resulting from the design loading combinations shown on the loading drawings which
include the overload factors specified.
Members shall be of such size, shape and length as to preclude damage or failure
from vibration or stress reversal.
In addition to the stringing and maintenance loads, design all horizontal members and
others sloped up to 30 deg. (including crossarm and bridge chords, stressed bracings
and redundant) to carry a vertical concentrated load of 1800 N ultimate, applied at
their centers.
In addition to the stringing and maintenance loads, ensure that all crossarm and
bridge chord members are capable of supporting an ultimate vertical ladder load at
any position within one (1) meter of each phase centre line of 4450 N. Apply the
ladder load as two 2225 N point loads 0.3 m apart.
2. Redundant (bracings without calculated stress)
Design redundant to carry 2.5 percent of the axial load of the members they restrain,
in accordance with the procedure shown in Figure.1, in addition to the 1800 N vertical
load described above.
3. Design Stresses
Ensure that the ultimate stress of any tower member is not greater than the ultimate
allowable stress values, as determined from the following:
a) The ultimate allowable compressive stress on the gross section of axially loaded
compression members is derived as follows:
Formula 1: Fa = Fy [1-1/2(KL/r/cc)2] kPa
Formula 2: Cc = (2E/Fy) Where E = 200 x 10 6 kPa
And provided that the width-thickness ratio, b/t, is not more than the limiting value
given by:
Formula 3: (b/t) Limit = 6564/(Fy) kPa (Fy in Kpa)
In which b shall be the distance from the edge of the fillet to the extreme fibre, and t
shall be the thickness of the material. If the width-thickness ratio exceeds the (b/t) limit
(Formula 3), then Formula 1 and 2 shall be modified by substituting the value Fcr for
Fy given by:
Formula 4: Fcr = Fy{1.8- [0.8(b/t)/b/t limit]} kPa

When L/r exceeds Cc, then
Formula 5: Fa = (1974 x 106)/ (KL/r)2 kPa

b) The value of the K in the expression KL/r takes into account the continuity or
discontinuity of the member and its method of connection. Use the K factors for this
purpose recommended in section C of the American Society of Civil Engineers Manual
No. 52, issued in 1971, "Guide for Design of Steel Transmission Towers"
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Take the ultimate allowable bending stress (Fb) on extreme fibers as the applicable
yield point (Fy).
Take the ultimate allowable shearing stress (Fs) as 5/8 of the applicable yield point
(Fy)
Ensure that the ultimate allowable bearing stress for connected materials specified
herein is the lesser of twice (2 times) the yield strength or 1.24 times the ultimate
tensile strength.
Beam-columns, combined axial compression and bending design members

simultaneously subjected to both axial compression and bending stresses to meet the
following requirements:
Formula 6: fc/ Fc + fb/ Fb(1-fc/ Fc)1
where:
Fc = actual axial compressive stress 9resultant axial force divided by the effective
cross sectional area of the member).
Fb = actual bending stress at extreme fibers (bending moment divided by the section
modulus)
4. Tower Bolts
The minimum size bolt shall be 16mm in diameter. Minimum nominal increase in bolt
diameters shall be 3mm. Detailing practice should not allow bolts in tension except
where specifically called for the design the threaded portion of the bolt shall not
encroach on bearing surface. The shank shall protrude beyond the nut a minimum of 4
mm.
Use only one bolt diameter per tower unless otherwise agreed by the engineer.
For all towers, use only one grade of steel to fabricate bolts of any one particular
size.
Supply and use only hexagon shaped bolt heads, and nuts.
5. Slenderness Ratios
Ensure that the slenderness ratio, KL/r, does not exceed the following values:
Max. KL/r
Column or tower legs and beam chords 150
Compression bracings having calculated stress 200
Redundant, (bracings without calculated stress) 240
Tension members of tower cross-arm hangers 325
Other tension members 400
Where: L= The unsupported length of the member.
r = The radius of gyration of the member about the axis under

consideration.
K= As defined herein.
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Where single angle members of double web system are bolted together at their
intersection, assume that the tension member provides effective intermediate support.
Take the radius of gyration r of a member reduced in section by bolt holes as that for
the gross section.
6. Net Section
Use the net area of towel members when computing the tensile strength. In deducting
the area of bolt holes from the gross area of a member, take the diameter of the hole
as 2 mm larger than the nominal diameter of the bolt.
Calculate the net area of a single angle tie member connected through one leg only,
or double angle connected on one side of a gusset plate, as follows:
Formula 7 : Net Area = (3a12+ 4a1a2)/ (3a1+a2)
Where: a1= net area of connected leg (s).
a2 = net area of outstanding leg (s)
Ensure that in multi-bolt connections with more than one (1) gauge line, the net
section of the connected leg is the least area which can be obtained by deducting from
the cross sectional area of the holes to be deducted from the gross section, count the
full area of the first hole cut by the line of holes under consideration. Determine the
value of X as follows:
Formula 8: X = 1 (S2/4GH)
Where: S = Longitudinal spacing (stagger) in millimeters between two successive

holes in the line of holes under consideration.
G = Transverse spacing (gauge) in millimeters between the same two

holes as for S.
H = Diameter of hole (bolt diameter plus 2 mm).
Calculate the net area of single angle tension members with both legs connected as
described above except that for holes in opposite legs of angles, the value of G should
be the sum of the gauges from the back of the angle less the thickness of the angle.
Do permit the net area used to determine tensile strength to exceed 85 percent of the
gross area.
7. Member Connections
The minimum thickness of gusset plates shall be 6 mm. the minimum thickness of
any steel member prior to galvanizing shall be 5 mm.
The minimum thickness of tower legs and cross-arm chords shall be 1/16 of the leg
dimension.
The minimum width of a punched leg of an angle or channel shall be twice the bolt
diameter plus 13 mm.
The minimum size of a channel shall be 102 mm at 8 kg/m.
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Do not consider the material adjacent to a burned edge, for a distance equal to the
thickness of the material a part of the net section for tension members in stress
calculations.
4.1.3.5 Welding
Welding is not permitted except by specific approval of the engineer.
4.1.3.6 Steel Detailing
Place horizontal members wherever possible so that the horizontal leg is on top.
Install members so as to avoid any depression that can hold water.
Make allowance in gauge dimensions on steel members for the thickness of

subsequent galvanizing and the possible formation of spelter fillets inside the
angles for adequate erection clearance after galvanizing.
Ensure that composite compression members have stitch bolts so spaced as to

give a slenderness ratio of the individual angles less than that of the composite
member.
Ensure that composite tension members have stictch bolts spaced as necessary.
Ensure that all ties are shortened 1 mm for each meter of length..
Restrict the maximum length of members to 6.5 meters for medium sections and 8
meters for legs and heavy bracings.
Ensure that maximum unsupported length of a crossarm hanger does not exceed
2.45 meters.
Locate leg splices as near as possible and immediately above structure panel
points.
4.1.4 TOWER FABRICATION
4.1.4.1 General
Supply materials, fabricate trial assemble, test and deliver galvanized steelwork for
400 KV transmission lines as shown in the drawings and Specifications.
4.1.4.2 Submittals
Submit detail drawings in advance of fabrication and as specified.
Submit erection drawings showing location of all members and the number and
length of bolts required for each connection.
4.1.4.3 Materials
Structural steel: BS 4360:1970. Grades 43A and 50B

Bolts, nuts and washers: ASTM A325 or A394
Welding (where approved): BS 1856 for Grade 43 , BS 2642 for Grade 50 B
Equivalent materials are acceptable.
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4.1.4.4 Fabrication
Minimum spacing of bolts and edge distances are shown below:
Minimum Bolt Minimum Edge Distance

Diameter
Spacing Rolled Edge Sheared Edge Flame Cut Edge
mm
mm mm mm mm
16 40 19 22 25
19 48 25 29 32
22 57 32 35 38
4.1.4.5 Marking
Identify each structural steel member with a letter/ number combination to correspond
to the erection drawing.
Ensure that the two or three digit mark defining the tower type is followed by numbers
indicating the member number for each member of each tower type. For example:
YA-3, YA-26, XA-328, XA-472L

X1C-4, X1C-36, Y1C-418,Y1C-727R
XA-8, YA-15, YB-38L, YB-139
Ensure that like members have the same number. Carry out marking before
galvanizing with letters at least 16 mm high and which are clearly legible after
galvanizing. Ensure that the marking in no way impairs the mechanical strength of the
member.
4.1.4.6 Bending
Use cold bending whenever possible. Submit bending procedure for approval and
ensure that it is in accordance with recognized standards. Any material showing signs
of cracking will be rejected. Do not carry out hot bending without prior approval.
Cold bend tower members in a hydraulic press with a suitable die to prevent bucking
of the legs. Do not perform this process under quick impact but in a slow moving
press. Use this technique of bending to bend members through angles up to
approximately 45 degree.
Whenever hot bending is required, do not heat with a torch but in an oven so that the
member is uniformly heated to a distance of approximately 150 mm on either side of
the bend point. Depending on the material to be bent, use proper heat treatment
procedures to preserve the original characteristics of the metal. Do not permit notching
or welding.
4.1.4.7 Punching
Ensure that the centre of any hole does not vary more than 1.5 mm from its position
as shown on the drawing. Ensure that the centre-to-centre distance of end holes in a
group of holes does not vary more than 1.5 mm from the dimension shown or the
drawing.
Do not plug or weld incorrectly punched holes. Ensure that punches and dies are
sharp and true and all punched holes round, true the size and free from ragged edges
and burrs. Ensure that diameters of the finished holes are equal to the nominds
diameters of the bolts plus 1.5 mm.
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Do not punch material above 12.5 mm thick.
4.1.4.8 Other
1. Defects and Cuts: Ensure that materials used for fabrication are free from mill and
shop defects. Make cuts cleanly and without drawn or ragged edges. Submit all
flame cut procedures for prior approval.
2. Bolts, Nuts and Washers: Secure all connections by bolts, nuts and one 3 mm
minimum thick flat washer.
3. Galvanizing: Galvanize tower steel and fasteners to BS 729.
4. Assembly of Prototypes: Completely assemble each prototype tower with matching

units including extension footings after galvanizing.
5. Testing: Test towers in accordance with the Specification. If tests indicate

modifications are required, incorporate such approved modifications into the
towers and final drawings.
6. Mill Order and Test Reports: Furnish copies of all mill orders and all certified mill
test reports covering the physical and chemical properties of the steel to be used.
4.1.5 TOWER TESTING
4.1.5.1 General: Carry out full scale tests on each tower type except for the
transposition tower. These tests shall be with maximum leg extension arrangements.
4.1.5.2 Requirements
Perform the tests in accordance with, but not limited to, the following requirements:
Erect the tower on a rigid foundation and ensure that the vertical axis through the
centre of the tower is not out of plumb by more than two-tenths of one percent (0.2%)
of the height at any level. Ensure that the members comprising the test tower are of
the same grade material and standard of fabrication as those which will be used in the
construction of the line.
Galvanize the test structure completely in all respects, including hardware, fittings,
etc., all as shown and specified on the detail drawings.
4.1.5.3 Procedures
Prepare a test program in accordance with the following test requirements:
The tower shall be assembled and erected in accordance with the detailed
drawings supplied by the contractor and approved by the Engineer.
The erected tower shall be complete with ladder-bolts and hardware fittings, such
as U-bolts, strain links etc.
The arrangement and position of pulling cables and dynamometers shall be in

accordance with the test loading drawings.
Test load combinations shall be the ultimate loads, including overload factors.
Loads within a combination above 80% of the ultimate loads of that combination,
shall be applied in 5% increments, each increment being held for 5 minutes.
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Each tower tested shall withstand each ultimate loading combination specified
without failure.
Failure
a) Failure shall be considered as any permanent distortion or excessive deflection of

a member, or elongation of bolt holes of more than 0.8 mm.
b) In case of any such failure, the design shall be modified before retesting for the
loading condition which caused failure and for all untested combinations until the
structure has been found satisfactory.
c) After completion of all test loads the structure shall be visually examined for signs
of distress or local failure.
Destruction Test
The towers shall be tested to destruction.
The destruction test shall be carried out as required by the Engineer with
applicable loads being simultaneously increased in increments of 5% above the
100% test loads until failure occurs.
Submit the testing program to the Engineer for approval 30 days prior to the
performance of the tests. Include but do not be limited to diagrams showing the points
of location the magnitude of the loads to be applied, the designated points for
deflection measurements and the methods and facilities of applying and measuring
the loads on the tower. Calibrate the load measuring devices prior to and following the
test in accordance with the manufacturer's recommendations.
Carry out each test in accordance with the test procedure.
Ensure that the test structure withstands, without any sign of failure as defined
hereafter, the load cases specified within the design requirements and which, in the
opinion of the Engineer, are necessary to prove the design assumption of stress
distribution.
Measure tower deflections under load by suitable procedures at the points designated.
Record deflection readings for the "before-load", "load-on" and "load-off" conditions.
Consider any conspicuous yielding, bowing of compression members, elongation of

bolt holes or any defect under any of the load cases as a failure. Correct the origin of
such a failure and retest the tower.
Carry out the tower test in the presence of the Engineer's representative who shall
conduct a visual check of all members of the tower for signs of failure following the
completion of each test.
Upon completion of testing, dismantle the tower for inspection of all members for any
evidence of excessive permanent set, shear failure of bolts or member failure in
bearing. Should the tests indicate that changes or modifications are required, have
these changes first approved before incorporation them into the final drawings.
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The Engineer's representative shall, upon satisfactory completion of the tests, select
certain test tower members, take test coupons from these members and perform
tensile tests to determine the actual yield strength of those members, of the test tower
The intention of these test is to ensure that the satisfactory tower loading test were a
result of adequate design, rather than due to the actual yield strength of the material
being in excess of the values used in the design calculations.
If these physical test show test show that the yield strengths were in excess of the
design values, then show by interpretation of the test results that, if the members had
possessed yield strengths used in the design, the tower would have withstood the
required loading test, otherwise modify the sizes of the members accordingly.
If it is shown by the test coupons that steel members on the test coupons that steel
members on the tested tower were of substantially higher strength than the specified
tensile strengths, and if instructed by the Engineer fabricate and test a second tower
at no cost to the Employer using steel of the correct strengths as specified for
fabrication.
4.1.5.4 Reports
Furnish (2) copies of a complete report of all tower tests in the report, include but do
not be limited to the following:
Detailed diagrams showing the manner in which all loads were applied and the
deflection records.
Photographs showing tower prior to testing, tower after final completion of 100
percent testing, tower after destruction test. Also tower and failed members after
any failure in the test series.
Certified mill test reports of members used in the test tower.
The test results of the test coupons takes following the completion of the test.
Any calculation necessary for acceptance of the test as proof of the adequacy of the
tower design.
4.1.6 TOWER ATTACHMENTS
4.1.6.1 Step Bolts
Provide each tower with step-bolts of an approved type on one of the legs, spaced not
more than 0.40 meters apart, on alternate faces of the leg starting immediately above
the anti-climbing device and continuing to within one (1) meter of the shieldwire peak
attachment point(s). Provide step-bolt holes between the ground line and the anti-
climbing device. Ensure that each step-bolt withstands a vertical load of at least 1330
N.
4.1.6.2 Grounding
Provide the holes necessary for accommodating the specified counterpoise and
grounding connection on each leg of every tower and extension. Also provide holes on
each shieldwire.
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4.1.6.3 Anti-climbing devices
Fit each tower with an anti-climbing device of the barbed wire type as shown on the
drawings, fixed at a height of approximately 3 to 5 meters above ground, or in the
case of long individual leg extensions, immediately above the extension on the tower
body. Select a position for the anti-climbing device on the tower such that standard
device is used regardless of the tower body extensions which may be employed.
Where necessary ensure access is restricted on hip framing.
4.1.6.4 Bird Guards
Equip the towers with approved devices immediately above each conductor
suspension assembly attachment point to prevent the perching and nesting of birds at
these points, as shown on the Drawings, or as agreed by the Engineer
4.1.6.5 Warning and Identification Plates
Provide conspicuous danger plates, circuit plates, phase plates, and line and tower
number plates of approved types which are resistant to fading under the climatic
conditions at site, and fix them in the positions as shown in the drawings. (Above the
anti-climbing device).
Manufacture danger plates from sheet iron to show white characters on a vitreous
enameled red background. Ensure the plate is not less than 1.5 mm thick and not less
than 300 mm by 300 in area.
Ensure that characters are the maximum possible size to accommodate the following
text in Arabic and English, together with a centrally disposed lighting type flash
extending the full width of the Plate:
DANGER
Do not touch these wires even those fallen on the ground
Submit Arabic text, which must appear above the English text, for approval by the
Engineer before manufacture commences.
Ensure that the line and tower number plate is approximately 300 mm long by 300 mm
wide and is attached centrally, immediately below the danger plate.
Provide phase identification plates marked R, S and T respectively, to indicate the

line conductor phases. Fit in approved positions on terminal and other strain type
towers. Provide phase identification on both sides of transposition towers thereto.
Provide enameled aerial number plates approximately 950 mm by 650 mm by 1.6 mm

thickness and fix them in an approved position on both transverse faces of every tenth
tower. Provide fixing holes at the bridge of all towers in both transverse faces. Fix the
plates with fiber washers front and back on the securing bolts.
For double circuit lines, provide circuit number plates marked in Roman numeral one
(I) on one circuit and Roman numeral two (II) on the other circuit.
4.1.7 FOUNDATION DESIGN PARAMETERS
4.1.7.1 General
For tendering only, design a range footings for the support of the towers and provide
with the tender one (1) detailed set of calculations and dimensional drawings showing
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the assumptions, methods designs of foundations for the tangent tower type in two (2)
soil classifications, one of which must be for D type soil.
Provide calculations and dimensional drawings after award of the contract as above
for all towers and all soil classifications for approval by the Engineer.
The final design parameters must be substantiated by sufficient field test carried out
by the Contractor to establish the capacities of his designs in representative soils.
Separate tests must be conducted in cohesive and non cohesive soils as well as in
rock. The costs of establishing the parameter will be considered to be included in the
foundation unit rates
4.1.7.2 Foundation Types
Design Foundations for rigid towers with concrete encased stubs or concrete piers
with anchor bolts.
For the tender, designs will be considered for the following tower footings:
a) Concrete-encased stub towers leg with base pyramid and chimney sections.
b) Concrete pile or caisson footings.
c) Concrete spread footings.
d) Any other acceptable and proven designs.
Design for one or more of the above types of foundation.
4.1.7.3 Design Parameters
Table 4.1.7.4 gives various foundation classifications as well as allowable concrete

densities, angles of uplift and ultimate bearing pressures. Increase the loads derived
from the tower design calculations by thirty percent (30%) for application to foundation
designs.
Provide designs for dry and wet soils the latter being fully saturated. Consider four
(4) types of soil and their characteristics as given in the table.
Provide fabricated foundation steel (stub angles, etc.) that are galvanized for their full
length.
Consider the possible deterioration of the consistency of cohesive soils and the
resulting decrease there from of their carrying capacity. If ground water exists,
consider the corresponding decrease of weight of the soil and buoyancy of the
foundation material due to uplift conditions.
Extend the tops of foundations above ground level so that the lowest exposed
galvanized steel is not less than 300 mm above the ground level or the high water
level of irrigated areas, marshes, flood plains, rivers, lakes and ponds, consider the
impact load due to running water.
Do not rely entirely upon adhesion between galvanized stubs and the concrete
foundation blocks for transmitting load to the foundations. Provide as necessary bolted
cleats or clip the angles secured to the stubs to transfer at least 50 percent of the stub
load to the foundation block.
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Design foundations to undercut as much as possible the foundation hole and gain
direct resistance from undisturbed soil.
For cast in situ or driven piles be sure that the value of the friction used in design is
established by actual tests carried out in various representative soils.
Such test should be conducted to recognized pile testing standards with care and
precision and should evaluate the bearing, uplift and lateral capacity of the pile.
Include the cost of the test in the foundation unit rates.
The Contractor may decide to have more than one design applicable to ground
conditions of the four particular foundation type classifications in table 4.1.7.4 which
will remain the guide for the purposes of payment. However the limits of soil conditions
for any particular design will be established by the field tests carried out by the
Contractor.
4.1.7.4 FOUNDATION CLASSIFICATIONS AND PARAMETERS FOR DESIGN
Foundation Type A B C D
Very dense
Dense sand, Soft and
Hardpan, sand
stiff to medium very soft
rock, hard clay,
Soil Type clay, loose clay, loose
cemented compact
gravel, medium silt, loose
gravel soils, compact
silt sand
gravel
Maximum ultimate
vertical downward 600 kPa 360 kPa 120 kPa 60 kPa
pressure
Maximum ultimate
vertical downward 400 kPa 240 kPa 80 kPa 40 kPa
bearing pressure
Maximum assumed
1600
density of soil 1440 kg/cu m 1040 kg/cu m 900 kg/cu m
kg/cu m
resisting uplift
Density of concrete 2240 1280
2240 kg/ cu m 1280 kg/ cu m
resisting uplift kg/cu m kg/cu m
Allowable angle of
conical frustum 20 degrees 10 degrees 5 degrees 0 degrees
resisting uplift
Maximum ultimate
100 kPa 7 kPa per
lateral soil (passive 60 kPa per 20 kPa per
per meter meter of
pressure) to resist meter of depth meter of depth
of depth depth
horizontal shear
Note: 1 kPa = 0.01097 kgf/ cm sq; 1 kPa = 20.89 P.S.F
4.1.7.5 Dimensions
Determine dimensions of all footings from tower reactions for the most critical
combination of down thrust, uplift and/or horizontal shear. Ensure that the design
keeps to a minimum the load eccentricities on the base of footings. For footing with
base pyramids, assume that resistance to uplift to engage the inverted frustum of a
pyramidal cone of earth whose sides form an angle with the vertical as given in table
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4.1.7.4. when computing the volume of the frustum, ensure that the effective depth
from the ground line shall not exceed:
For square footing - 1.5 times the side dimension
For circular footings - 1.5 times the diameter
For rectangular footing - either 1.5 times the length or 3 times the breadth,
whichever is the lesser
4.1.7.6 Materials
Design footings of concrete or materials resistant to the corrosive ground conditions

present in the area traversed by the transmission lines. Do not consider as suitable
normal quality galvanized steel coated with paint or emulsion if it is buried directly in
the ground.
Ensure that the concrete quality is in accordance with CP 114: part 2 1950 (BSI-
Standard Code of Practice). Pay particular attention to achieving a high density
concrete that will resist the ingress of harmful salts in solution in the subsurface water.
4.1.7.7 Foundation Stability
Use, unless otherwise agreed by the Engineer acceptable techniques for establishing
foundation stability as follows:
Foundations each having a concrete encased galvanized steel stub with a base
pyramid:
An acceptable technique employing passive pressure is shown in Figure 2. Take the

depth D to the top of the base pyramid, otherwise treat it as in b below.
Reinforced concrete spread footings:
An acceptable technique for calculating maximum toe pressure, and overturning

stability, is contained in Design Standard No. 10 Transmission Structures, of the
United States Department of the Interior, Bureau of Reclamation. (See Appendix 4.1)
In Chapter 2 of this Standard, Figure 8, Drawing DS-10-7, 3/8/65 deals with thrust
foundations and Figure 7, Drawing DS-10-7, 3/8/65 deals with uplift foundations. Be
aware that Clauses 2.6 and 2.10 of this Chapter state that the stability formulae shown
in the Figures, use Working Loads and, if satisfied, give a factor of safety of 1.3
minimum. Make appropriate adjustments to suit the factors of safety specified in this
document.
a) Pile Footings:
An acceptable technique for calculating overturning stability is contained in Design

standard No. 10, Transmission Structures, of the United States Department of the
Interior, Bureau of Reclamation. Figure 3, Drawing DS-10-7, 3/8/65, in Chapter 2,
deals with such footings. (See Appendix 4.1)
4.1.7.8 Reinforcement of Stems and Chimneys
Use vertical and hoop steel reinforcement for foundations and/ or chimneys.
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Allow adequate cover over reinforcing steel. Allow space for normal measures of
vibration compaction during pouring.
4.1.8 GROUNDING
4.1.8.1 General
Ensure that tower grounding conforms with the materials and dimensions shown on
the Drawings. Choose and install the type of grounding for each individual tower in
accordance with the requirements of the soil resistivity measurements. Carry out such
measurements and unless specifically approved by the Engineer, ensure that the
resistance of each tower to earth does not exceed 25 ohms.
4.1.8.2 Soil Resistivity Test
Take tests at each tower location . ensure that the method of testing is approved by
the Engineer. Submit all test results and the type of grounding chosen for each tower
on a suitable form for approval of the Engineer.
4.1.8.3 Grounding Types
Use Seven (7) basic grounding systems as shown on the drawings.
a) Type G1: Standard tower foundation with the grounding, but with provision for the
addition of grounding, for application where the tower resistance is sufficiently low
as not to require additional grounding.
b) Type G2: Standard tower foundation with one(1) ground rod, or one (1) copper
wire grid per foundation.
c) Type G3: Type G2 as described above plus the addition of long ground roads
or ground rod extensions driven to a depth agreed to by the Engineer.
d) Type G4: Type G2 or G3 as described above plus the addition of at least 150
meters of counterpoise laid in diagonally opposite directions and with the
counterpoise wire installed under the outside phase conductors and in opposite
directions, that is, at least 75 meters in each direction.
e) Type G5: Type G4 as described above plus the addition of at least 150 meters
of counterpoise, installed as above and located under the opposite outside phase
conductors.
f) Type G6: Type G5 described above plus the addition of one (1) continuous
counterpoise to one adjacent tower installed under a pair of outside phase
conductor.
g) Type G7: Type G6 described above plus the addition of one (1) continuous
counterpoise installed under the opposite outside phase conductors.
4.1.8.4 Installation
Install all tower foundations with two (2) copper leads connected to the main structural
steel component of the tower or mast foundation and brought outside the foundation,
by at least 50 cms, installing one lead approximately 0.5 meters below ground and the
other lead near the bottom of the foundation. (Allow sufficient length of each lead to
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protrude from the foundation to ensure adequate connection to the counterpoise wires
and/ or the ground rods or grid).
Interconnecting the individual foundations at each tower is not required.
4.1.8.5 Resistance Check
After installation for the various grounding systems as required, verify the resistance of
the tower and report it to the Engineer on the appropriate form. At the time of such
checks, ensure that the tower is completely erected and the overhead shield wire is
not connected to the tower steelwork. Ensure that any resistance surpassing 25 ohms
is subject to the written approval of the Engineer.
4.1.8.6 Materials
Design grounding systems to use the following materials or their equivalents:
a) Ground rods: Minimum 16 mm diameter by 3 m long, copper or copper clad steel

with provision for coupling rods together and provided with a suitable clamp for
connection of copper ground wires or leads.
b) Grid: Stranded copper, minimum size 3 strand each 3.7 mm hard drawn copper, or
single strand 6.4 mm hard drawn copper.
c) Foundation internal leads: Stranded or solid copper minimum size as in (b) above.
Connections by sweated lugs and bimetals.
d) Counterpoise: Annealed, Single-strand of copper clad steel wire minimum diameter

6.54 mm.
e) Clamps to tower steel to be bronze or copper as recommended by the

manufacturers, such that galvanic corrosion is eliminated.
4.1.8.7 Connections
Clean all connections thoroughly and cover with a liberal coating of an approved
Electrical Joint Compound. Tin connection of copper to materials other than copper or
bronze in accordance with standard practice. Join copper wires by Cadwelding or by
other approved methods. Where mechanical jointing is employed, seat all wires in the
correct sized connection. Protect all joints by Denso compound and/or Denso tape or
by other approved means.
4.1.8.8 Counterpoise Installation
Bury counterpoise wire at the following depths:
a) Rocky terrain min. 0.1 m.

b) Normal soil min. 0.5 m.
c) Cultivated land min. 0.8 m.
d) Under roads, railways, etc. 0.7 m.
Wave the counterpoise slightly from side to side to avoid it lifting out of the ground due
to temperature changes or other causes.
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4.1.9 DESIGN BRIEFS FOR APPROVAL BY ENGINEER
4.1.9.1 With Tender
Submit outline drawings to scale for each tower type which shall show dimensions,
clearances, sizes of members, and weights of all units as listed in the schedule of
required towers, body extensions and leg extension.
Submit also one (1) set of detailed calculations for the foundations for one (1) tower
type and two (2) soil classifications, all as called for and described in table 4.1.7.4, and
in clause 4.1.7.1
4.1.9.2 After award of Contract
a) Submit the outline drawings, called for in Clause 4.1.9.1 revised as necessary.
b) Submit loading drawings, which show the cases of design loads for which the
tower is designed.
In load cases where wind on tower is included show the magnitude, direction and
location of the point loads used in the design to represent wind. Where applicable,
show the Span-Angle diagram.
c) If design facilities permit, submit three (3) copies of the computed output for each
tower, giving the loads in all members for all load cases analyzed and an envelop
of the maximum loads (positive and negative) for each member. Where unequal
leg extension combination and body extensions are specified analyze sufficient
combinations of these units to draw out the maximum loads in all members.
d) Submit detailed calculations for all footing (foundation) for all specified soil
conditions and if site conditions require it, for other soil conditions.
Base all calculations on ultimate loads, i.e., apply the overload factors specified to
all forces before analysis. Do not apply the overload factor to the dead weight of
the tower steel.
e) Submit detail drawings which show, in full detail with identification marks, all
members fillers bolts and fittings.
Ensure that each such drawing has a schedule of the material on that drawing,
with or without weights. See (h) below. Supply also a table of bolt nut, and washer
dimensions, including diameters, and threaded and grip lengths.
f) Submit erection drawings which show the location of all members, fillers and fitting
and also the length and diameter of bolts at each location. Indicate which detail
drawing applies to each section of the tower on these drawings.
g) Submit foundation setting drawings which in addition, where applicable, give the
dimensions out-to-out at the top of the foundation stubs in both the tower face and
in the diagonal.
h) Submit bills of material drawings. Ensure that each unit, as listed in the schedule of
required units for each tower, has an individual Bill of Material, listing all items
necessary for one complete such unit. List members by mark number, size,
specification, length, unit weight, number of such pieces and the total weight of
these pieces. Include all bolts, washers, fillers, step bolts, U-bolts, etc, and list
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similarly. Show the applicable detail drawing number against each item. Give the
total weight of all items in the unit.
More than one Bill, pertaining to one tower, may be on one drawing.
4.2 CONDUCTOR
4.2.1 CONDUCTOR TYPE AND DETAILS
1. Provide line conductors of ACSR 490/65 according to DIN standard.
2. Fabricate the conductors of heat-treated aluminum and steel wires having the
mechanical properties specified in DIN standard.
3. Ensure that the Aluminum and steel wires in each layer of the conductor shall be
evenly and closely stranded over the wires beneath them.
And ensure that all wires in the finished conductor lie naturally in their correct
positions including those of the inner layers, with or without the presence of the
other layers. See that when the conductor is cut, wire ends remain in position or
are readily replaced by hand, and being replaced, they remain in position
thereafter.
4. Have conductors greased internally between aluminum and steel with a suitable
and approved grease which does not react with aluminum of the conductors, such
as B.P. energrease P.R.3 having a drop point of 100 oC.
5. Ensure that the conductor characteristics are similar to the following:

Number & size of stranding Al 54/3.4 mm; Steel 7/3.4 mm
Conductor diameter 30.6 mm
Sectional area 553.83 sq.mm
Rated ultimate tensile strength (RTS) 15,586 kgf
Weight 1.852 kg/m
Temperature coefficient of linear expansion Final, 19 x 10-6 per deg. C.
D.C Resistance at 20o C 0.05896 ohms/km
Moduli of Elasticity 7000 kgf/mm2
These values were used in the calculations leading to the preparation of this
specification.
4.2.2 CONDUCTOR LODADING PARAMETERS
Ensure that the maximum allowable conductor tensions are governed by the following:
a) Temperature 0 deg C, bare conductor, maximum gust including gust factor: final
tension not to exceed 40% RTS.
b) Temperature minus 15 deg C, no load: final tension not to exceed 25% RTS.
c) Temperature +25 deg C, no load: final tension not to exceed 20% RTS.
d) Temperature minus 10 deg C, no load: final tension not to exceed 30% RTS.
Ensue that for ground clearance purposes, the conductor sag is the final unloaded sag
at 90 deg C, with the appropriate creep allowances included.
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4.2.3 CONDUCTOR SAG AND TENSION DATA
When the source of supply for the conductor is decided obtain from the manufacturer
precise conductor details, which include but are not limited, to the following:
Type, code name (if any), details of aluminum, overall diameter, cross-section area,
rated tensile strength, mass per kilometer, number and diameter of strands,
coefficients of expansion, electrical resistance to alternating and direct currents,
temperature at which these resistances are applicable, current rating, annealing
temperature, initial and final moduli of elasticity and stress at which the initial modulus
of elasticity changes slope.
Forward these and other relevant data which include test results, if any, and creep
data to the Engineer for approval.
After the approval of the above, prepare and submit to the Engineer for approval
complete sag and tension calculations pertaining to the work. Include but do not be
limited to initial and final sags for horizontal deadend spans for the full range of
spans anticipated and ensure that the span increment is not greater than 25 meters.
Calculate sags and tensions for the specified loading parameters as well as all loading
conditions required for plotting and other purposes deemed necessary. Include but do
not be limited to the following:
a) For ground clearance purposes: final, unloaded at 90 deg C.
b) For uplift conditions: initial and final unloaded at minus 15 deg C.
c) For insulator swing: final at +25 deg C with average wind velocity acting on bare
conductor.
Ensure that all final sags and tensions include the appropriate allowances for creep
and specify the creep allowances as such.
4.3 SHEILDWIRE
4.3.1 SHEILDWIRE TYPES AND DETAILS
1. Ensure that the type is identical to that manufactured under the trade name
DORKING.
2. Provide sheildwire with characteristics similar to the following:
Type & Code name A C S R Dorking
Stranding Aluminum 12/3.20, Steel 7/3.20
Normal Diameter 16 mm
Weight 0.7069 kg/m
Sectional area 152.8 sq mm
Modulus of elasticity Final 107 x 10-6 KPa
Rated Tensile Strength (RTS) 8042 kgf
Final Coefficient of Linear Expansion 15.3 x 10-6 per oC
A.C Resistance 50oC,50 Hz. 0.335ohms/ km
D.C Resistance 0.2989 ohms/ km
4.3.2 SHIELDWIRE LOADING PARAMETERS
Ensure that the maximum allowable shieldwire tensions are governed by the
parameters quoted for the conductor in clause 4.2.2 Sub-Clauses 'a; to 'd'
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Also that the shieldwire final sag for a span of 475 meters, unloaded and at mean
ambient temperature of 25 deg C, is not greater than 75% of the conductor sag under
the same conditions.
4.3.3 SHIELDWIRE SAG AND TENSION DATA
When the source of supply for the shieldwires is decided, obtain from the manufacturer,
precise shield-wire details which include, but are not limited to, the following:
1. Type, details of steel and aluminum, overall diameter cross section area, rated
tensile strength, mass per kilometer, number and diameter of strands, electrical
resistances, current rating, initial and final moduli of elasticity, temperature
coefficients of expansion etc.
Forward these and other relevant data which include test results and creep data, if any,
to the Engineer for approval.
2. With the approval of the above, prepare and submit to the Engineer for approval
complete sag and tension calculations for both shieldwires. Include but do not be
limited to initial and final sags for horizontal deadend spans for the full range of
spans anticipated and ensure that the span increment is the same as for the
conductor.
3. Calculate sags and tensions for the specified loading and sag parameters.
4. make the appropriate allowances for creep and in all final sags and tensions and
specify the creep allowances as such.
4.4 INSULATORS AND ASSOCIATED HARDWARE
4.4.1 Suspension and Tension Assemblies
1. Provide in accordance with approved drawings the following:
a) V-Suspension assemblies for suspension towers type A and E. Complete with

insulators suspension clamps and all hardware. Nominal strength rating of 7000 kg.
b) V-Suspension assemblies for suspension towers type B. Complete with insulators,
suspension clamps and all hardware. Nominal strength rating of 11000 kg.
c) Dead-end assemblies for strain towers, types C and D. Complete with insulators,
compression fittings, grading ring and all hardware. Nominal strength rating of 2 x
15000 kg.
d) Jumper loop suspension assemblies for strain tower types C and D. Complete with
insulators, suspension clamps counterweights (if required) and all hardware.
Nominal strength rating of 7000 kg.
2. Provide adequate bearing area between fittings and avoid 'point' or 'line' contacts
wherever this is possible without adversely affecting the flexibility of the fitting.
3. Galvanize components of conductor suspension assembly made of steel or

malleable iron.
4. Do not use hook fittings for attaching insulator sets to tower crossarms.
5. Lock all bolts with locknuts and cotter pins or by other approved means.
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6. Under the worst combination of mechanical loads, ensure that the load on any
insulator shall not exceed fifty percent of the rated M&E strength of that insulator.
7. Provide insulator hardware with an ultimate breaking strength which is equal to or

greater than the rated M&E strength of the insulator.
4.4.2 Insulators
4.4.2.1 Tangent Tower Suspension Insulator Strings
Provide fog type insulator discs (glass or porcelain) each with a unit spacing of 146 mm
and pin diameter of 20 mm.
Ensure that the total creepage (leakage) length or each insulator string is not less than
11600 mm, and the mechanical (M&E) strength is not less than 7000 kg. ensure total
length of strings including fittings, extension links and clamps conform with dimensions
shown in tower outline drawing.
Submit the insulators which shall be provided, for pollution test under the direction of the
Engineer and at an independent and approved testing laboratory.
These test shall be carried out on separate units, as well as on complete insulator
strings.
Such tests would be to the cost of the Contractor or Manufacturer proposing the use of
such insulators and the test will decide the number of discs needed in each strings.
The Engineer shall approve the type and number of insulator used on the type A and E
tower.
4.4.2.2 Type B Tower Suspension Insulator Strings
Ensure insulators have mechanical (M&E) strength of not less than 11000 kg. ensure
insulator discs have creepage length profile, and all essential characteristics similar to
or better than those used for the tangent towers but with different color, and ensure
number of insulators per string corresponds with the number of insulators on the
tangent towers.
The Engineer shall approve the type and number of insulators used on the type B tower.
4.4.2.3 Type C&D Tower Tension Insulator Strings
Ensure tension sets comprise of twin strain insulator strings, each string
with a nominal M&E strength of not less than 15000 kg, and ensure number of
insulators per string is not less than the number per string on the tangent towers.
Ensure overall creepage length over each strain string is not less than 12500 mm and
overall length of each string is not less that 4200 mm.
The Engineer shall approve the type and number of insulators used on the type C and D
Tower tension sets.
4.4.2.4 Insulator, Supply Requirements
1. Correct all flashover and withstand voltage levels to Normal Temperature and
Pressure in accordance with BS 137. Verify the flashover and withstand
performances together with the arc gap dimensions by test.
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2. Test for Corona and Radio Interference in accordance with section 3Part 7-7.7.2
and 7.7.3, Volume II of this Specification. Ensure that the RIV of the entire insulator
assembly when tested in accordance with NEMA 107, does not exceed 750
microvolt.
3. Provide insulator units of the suspension insulator string of toughened glass or

porcelain and together with their metal fittings ensure that they comply with BS 137.
4. Provide all insulators of the ball and socket or other approved standard type. Ensure
that the locking device is either a socket key (cotter pin) or security clip ("W" clip) to
applicable ASA, IEC, BA or AS specifications, excepting that cotter pins are of
stainless steel. Ensure that all locking devices are suitable for hot-line maintenance.
5. Ensure that the design is such that stresses due to expansion and contraction in any
part of the insulator do not lead to the development of defects.
6. Ensure that insulating material does not engage directly with hard metal. Ensure that
all fixing material is of approved quality, is applied in an approved manner and does
not enter into chemical action with metal parts or cause fracture by expansion in
service. Where cement is used as a fixing medium, ensure that cement thicknesses
are as small and even as possible and centre and locate correctly the individual
parts during cementing.
7. Mark each insulator unit legibly and indelibly with the manufacturer's name or trade-
mark, the month and year of manufacture, a mark indicating the minimum failing
load and other marks such as the insulator catalogue number to assist in identifying
the representative selection of batches for the purposes of the type tests.
4.4.3 Conductor Grading Rings
1. Provide grading rings of an approved type for attachment to the yoke at the live end,
as shown in the drawings.
2. Ensure that the mechanical strength of grading rings safely withstands a load of
1000 newtons applied at the extremity.
3. Ensure that the grading ring and its attachment to the yoke safely withstands aeolian
and sub conductor vibration.
4.4.4 Conductor Suspension Clamps
1. Ensure that the clamp bodies of conductor suspension clamps are of aluminum
material and of sufficient size to accommodate the conductor & preformed armour
rod. Ensure that the clamp is of the socket type and allows its live-line
disengagement from the insulator string.
2. Ensure that conductor suspension clamp is free to pivot in the vertical plane about a
horizontal axis, transverse to the centerline of the conductor.
3. Ensure that suspension clamp bolts are torqued in such a manner as to permit the
complete conductor to slip before failure of the latter occurs. Clamp the conductor
mechanically in an approved manner.
4. Ensure that the outermost point of clamping pressure is not less than two (2)
conductor diameters inside the outermost point of contact between the conductor
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and its supporting groove (the conductor being assumed to be horizontal). Ensure
that the supporting groove beyond the latter point is curved in the vertical plane to a
minimum radius of 150 mm and for a sufficient distance to allow for the conductor
leaving the clamp tangentially at the maximum inclination shown in the drawings.
Ensure that the mouth of the supporting groove is also slightly flared in plan and that
the grooves in the clamping piece or pieces are bell-mounted at each end to a
minimum radius of 25 mm for a distance of 12.5 mm, unless otherwise approved.
Ensure that the supporting length of the clamp is sufficient to keep the bearing
pressure in the conductor negligible.
5. Where suspension clamps are used at angle positions or in other special

circumstances, provide clamps for which the values given in 4 above are suitably
modified and are approved by the Engineer.
6. Ensure that conductor grooves and bell-mouths are smooth and free from waves,
ridges or other irregularities.
4.4.5 Conductor Deadend Assembly
Ensure that the deadend assembly consisting of a compression type aluminum body, a
steel-clevis deadend and a bolted jumper terminal, is of a size to fit the conductor in
accordance with the conductor manufacturer's recommendations and the drawings.
4.4.6 Deadend Assembly Associated Hardware and Fittings
1. Provide hardware and fittings made of forged steel or malleable iron and having
mechanical strength as specified.
2. Use yoke plates as shown in the drawings for the attachment of the twin bundle and
of the grading rings to the insulator string.
3. Fit conductor strain assemblies at each end of their insulator strings with shouldered
extension links suitable for standard strain carrier yokes of live-line maintenance
equipment.
4.4.7 Conductor Vibration Dampers
Provide the conductors with vibration dampers of the stockbridge or other approved
type.
Design the dampers so as to limit conductors vibrations to an acceptable level with

spacer dampers as to prevent damage to the conductor and to individual strands of the
conductor. Prior to fabrication, submit to the Engineer test and other relevant data
proving the efficiency of the proposed damper.
Galvanize damper components made of steel or malleable iron in accordance with

Specification BS729.
Determine the number of vibration dampers per span and the locations of attachment
and have such data approved by the Engineer.
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4.5 SHIELDWIRE FITTINGS
4.5.1 Shieldwire Suspension Assembly
Provide the shieldwire suspension assembly in accordance with the drawings and
consisting but not limited to, the following components to complete the design
requirements:
a) Preformed aluminum alloy Armour Rods for shieldwire.
b) Shieldwire suspension clamp.
c) Associated hardware and fittings for shieldwire suspension assembly (including

fittings required for grounding loop connections).
Galvanize components of the shieldwire suspension assembly made of steel or

malleable iron. Secure bolts, nuts and washers with cotter pins, locknuts or by other
approved means.
Ensure each shieldwire assembly includes preformed armour rods for the protection of
the shieldwire at the clamping area. Provide a shieldwire suspension clamp of the
socket type of malleable iron and of sufficient size to accommodate the shieldwire plus
a set of preformed armour rods. In addition to the hardware and fittings required for the
assemblies, provide two-bolt connectors as shown in the Drawings for the grounding
loop connections of the shieldwire to the tower steelwork.
4.5.2 Shieldwire Strain Assembly
Provide the shieldwire strain assembly in accordance with the drawings and consisting
of the following components:
a) Shieldwire compression dead-end.
b) Associated hardware and fittings for shieldwire assemblies (including connection of

ground loop to tower).
Provide the shieldwire compression deadend of an approved type which shall not permit
slipping of, damage to, or failure of the complete shieldwire or any part thereof, at a load
less than ninety-five percent of the ultimate strength of the shieldwire.
Supply shieldwire strain assemblies in sets covering both sides of the tower and
including the necessary connectors for connecting the grounding loop to the shieldwires
on both sides of the tower as well as to the tower itself, as shown in the drawings.
4.5.3 Shieldwire Hardware
Ensure that the shieldwire hardware has an ultimate breaking strength at least one point
six (1.6) times the maximum loads.
4.5.4 Shieldwire Vibration Dampers
Provide the shieldwire with vibration dampers of the Stockbridge or other approved
type.
Design the dampers so as to limit shieldwire vibrations to an acceptable level and attach
them in such a manner as to prevent damage to the shieldwire and to individual strands
of the shieldwires. Prior to fabrication, submit to the Engineer test and other relevant
data proving the efficiency of the proposed damper.
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Galvanize damper components made of steel or malleable iron in accordance with

Specification BS729.
Determine the number of vibration dampers per span and the locations of attachment
and have such data approved by the Engineer.
4.6 SPACER-DAMPER SYSTEM
4.6.1 General
This section covers the specific requirements for spacer-dampers designed to

accommodate a bundle of two 30.51 mm diameter aluminum alloy stranded conductors
at 457 mm centers.
4.6.2 Design Requirements
No other bundled lines employing spacer-dampers have been installed in this area and
therefore no data is available on the expected levels of aeolian vibration or sub-
conductor oscillation. In the design of the spacer-damper, take into account any
topographical, meteorological and conductor data provided in this Specification as well
as topographical and meteorological conditions known to exist in Iraq and also the
experience of other utilities in similar climates with respect to the best design to combat
aeolian and sub-conductor oscillations.
Submit full details of all data used in establishing the suitability of an existing spacer
damper design or the requirements of a new design for performance under the
conditions to be experienced on this transmission line, to the Engineer for his approval
prior to start of production.
Design the spacer-dampers so that no loose parts need to be removed to permit

installation on the transmission line.
Ensure the materials used are resistant to the corrosive atmosphere known to exist in
Iraq.
4.6.3 Conductor Clamp Design
If a metal clamp is used, ensure that the clamp body and clamp cap each have an
effective length in bearing on the conductor of not less than 75 mm. Exclude exit radii in
meeting this requirement. Provide a six (6) mm exit radius where the conductor leaves
the clamp body and clamp cap and a three (3) mm relieving radius on the edges of the
clamp body and clamp cap parallel to the conductor.
Provide the clamp body and clamp cap preferably of aluminum alloy. Ferrous material
may be used for the clamp body and clamp cap provided that a non-ferrous liner is used
where the clamp is in contact with the conductors.
If metallic clamps are used, ensure that the groove of the clamp body and clamp cap is
smooth and free of projections, grit or other material which would cause damage to the
conductor when the clamp is installed on the conductor.
Conductor clamps must be unaffected by the application or presence of grease in the

conductor.
Ensure that all clamping hardware is captive to prevent its removal from the spacer-
damper and that there are no loose or readily detachable parts. Provide shear head
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bolts to tighten the clamp onto the conductor with the correct bolt tension of fit with
preset torque wrench.
Orient all clamping bolts with heads down. Provide an approved locking device on all
threaded connections to ensure that threaded connections will not become loose due to
vibration.
Give consideration in the design to prevent the clamp cap from slipping on the lip
surfaces when being tightened, since this slippage could cause the conductor to deform
into the gap between the clamp body and clamp cap.
Design bolted connectors to meet the applicable industry standards. If the connector
which tightens the clamp onto the conductor is a galvanized steel bolt, provide it with
rolled threads which have been chemically de-greased.
Incorporate in the design of bolted connectors if used the use of Belleville washers to
Specification S.A.E J773a Latest Edition or an equivalent energy storing device. Design
these to regulate the tension in the connector which in turn will regulate the clamping
force on the conductor. Accomplish this by using these washers either singly or in
combination so that with the washer (s) installed with connector, the required clamping
force on the conductor is achieved by compressing the washer (s) one half turn to their
limit.
Ensure that any connector retains the specified clamping force on the conductor after
cold flow has occurred on the conductor such that its nominal diameter is reduced by
one (1) percent.
Other alternative methods of providing a clamping force on the conductor without the
use of bolts may be permitted subject to the approval of the Engineer.
Be aware the conductor is an ACSR and ensure clamping requirements are suitable.
4.6.4 Mechanical Strength
Ensure that the spacer-damper shows no evidence of mechanical damage or

permanent deformation of any of its component parts when subjected to the static
loading test indicated in Figure 3. Apply the test loads to mandrels of the proper
diameter clamped in the spacer-damper clamps as would be normal with the conductor.
Do not allow the mandrels to slip in the testing machine. Raise each load from zero to a
test value of 1600 newtons in 5 seconds and hold it at this value for 2 minutes. Then
release the load and examine the spacer-damper for signs of permanent deformation or
mechanical damage.
Also test a second unit in a similar manner except that when the load has been held at
1600 newtons for 2 minutes, increase it at a rate not to exceed 4450 newtons per
minute until failure occurs. Describe the nature of the failure.
Carry out the above tests for each production lot. Choose the samples to be tested at
random. Define the number of samples per production lot tested by recognized industry
standards, have them approved by the Engineer prior to the start of manufacture and
describe them in the test report (s).
4.6.4 Corona Extinction Voltage

Ensure by test that spacer-dampers are free from visible corona when operated at all
voltages up to 243 kV phase to ground.
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4.6.5 Ozone resistance
Provide non-metallic spacer-damper parts resistant to ozone attack and comply with the
required test.
Submit previous data showing that the test has been carried out on the non-metallic
parts of the unit. If this data is not available, perform the ozone test. If this test shows
the design does not meet the requirements of this Specification, modify the design until
the Specification requirements are met.
Conduct the test for ozone resistance, which is a modified version of ASTM standard
D1149 latest edition as follows:
a) Place two (2) finished full size specimens, mounted in their normal housing, in an
ozone chamber for 500 hours. Ensure that the concentration of ozone is 50 parts per
hundred million.
b) Ensure that one specimen is unstressed and subject the second specimen to the
maximum stress the design of the spacer-damper allows.
c) Deem any sign of deterioration as failure.
4.6.6 Electrical Resistance
a) Examine a spacer-damper sample to find the central part that has a potential of 50
volts relative to either sub-conductor when 300 volts is applied across the two sub
conductors.
b) Make a solid electrical connection to this central part and apply a 60 Hz potential
between this connection and one of the sub-conductor clamps. Gradually raise this
potential until the non-metal part of the spacer-damper can be seen to have suffered
damage. Note the current and voltage at this time.
c) Should no damage have occurred to the non-metal part up to an applied potential of

500 volts, then leave the potential at 500 volts and apply another potential of 250
volts between the second sub-conductor and the central connection. Leave these
potentials applied for 30 days without damaging the non-metal parts
d) Should damage have occurred, apply potentials of eight percent, sixty percent and
forty percent of the potential which damaged the first part across the central
connector and each of the remaining sub-conductors except that the lowest applied
potential shall not be less than 55 volts.
e) Measure the currents flowing in each circuit. Record the length of time until the
occurrence of damage provided this happens within 30days (720 hours cumulative).
f) If no signs of damage can be seen or smelled, then define damage to have occurred
when the current drawn by each circuit reaches twice the original value.
Submit a plot of initial watts loss versus time-to-damage with the test results.
4.6.7 Quality of Elastomer
If the design of the spacer-damper employs electrometric materials, use laboratory test
during production to set control standards for quality assurance in accordance with the
following ASTM standards, latest editions, or other standards if approved by the
Engineer.
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Specimen Conditioning D832

Tensile strength, according to D412
Tear Strength D624
Compression Set D395/D575
Low Temperature stiffness D1053
Rebound Resilience (Yerzley) D945
State of Cure D599
Change in Properties of Electrometric Vulcanizates Resulting from Immersion in Liquids
D471
Specific Gravity and Density of Plastics by Displacement D792
Low Temperature Compression Set of Vulcanized Elastomers D1229
Indentation Hardness of Rubber and Plastics by Means of a Durometer D2240
Prepare and condition, as described in the ASTM specifications, elastomer specimens

from the same mix batch as the elastomer that is used for the manufacture of the
sample spacer-dampers.
In addition to the tests listed above, specify the Tc temperatures (max. rate of
crystallization) for all ingredients of the mixes. If unwilling to disclose this information,
produce certified results of laboratory tests made on specimens of the mix that show the
variation of rate of crystallization with temperature.
4.6.8 Aeolian Vibration and Sub-Conductor Oscillation
Ensure that the spacer-dampers limit the aeolian vibration amplitude to a maximum of 5
mils (0.127mm) determined by the method described in IEEE Committee report entitled
"Standardization of Conductor Vibration Measurements" (Paper 31TP65-156). Do not
use rigid or semi-articulated spacer dampers.
Submit theoretical, laboratory and field data to show that the design of the spacer-
damper, when installed at the spacing recommended, will to the best of knowledge
based upon the available meteorological and conductor data, perform efficiently to
combat aeolian and sub-conductor oscillations.
Regulate the location of the spacer-dampers within each span to provide maximum
damping performance by charts or tables. Ensure that the charts or tables show the
recommended number and separation between spacer dampers for the various span
lengths expected to be employed.
4.6.9 Movement
Ensure and prove by test the spacer damper will accommodate the following
movements (Figure 4) without slipping distortion of the conductor, or damage to the
conductor or spacer damper.
a) Longitudinal Movement: Horizontal longitudinal parallel movement of one sub-

conductor relative to the other of ten (10) degrees as measured by the deflection of
the vertical long axis of the spacer damper from its position normal to the conductor.
b) Vertical Movement: Vertical movement of one sub-conductor relative to the other of

fifteen (15) degrees as measured by the vertical deflection of the horizontal axis of
the spacer damper from its position normal to the conductor.
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c) Conical Movement: Conical or angular movement of the spacer damper clamp on

one sub-conductor of ten (10) degrees as measured conically about the normal
conductor axis relative to the other conductor.
4.6.10 Jumper Loops
Ensure spacer requirements for jumper loop are identical to those of the spacer-
dampers except that the control of aeolian vibration and sub-conductor oscillation is not
required.
Provide sufficient spacers or spacer dampers on jumper loops to efficiently control the
spacing of the twin conductors in the loops.
4.7 TRANSPOSITIONS
4.7.4 General
Transpose the phases of the 400 kV transmission lines when the distances between
sub-stations are exceeding 100 Km.
In each case, accomplish the complete transposition or roll in three (3) stages (1/3 roll
each) located as follows, in order that the length of each phase in each position is equal
over the line length:
a) Stage 1 1/3 roll located at 1/6 the total line length.
b) Stage 2 1/3 roll located at 1/2 the total line length.
c) Stage 3 1/3 roll located at 5/6 the total line length.
4.7.5 Transposition Tower Design
Carry out each stage of roll by means of incorporating two (2) transposition towers into
the line in place of standard line towers but with a reduction to the normal line span of
approximately 33 percent.
Provide self-supporting towers of galvanized steel with the upper part being a shaft. Set
the crossarms in triangular formation with two (2) phases carried (one each side) at the
lower level and one (1) phase on the upper level. Also provide two (2) shieldwire peaks
but do not transpose shieldwires.
A different solution for transposition with strain type transposition towers may also be
used.
4.7.6 Clearances
Ensure that clearances to ground, to steel work and phase to phase are not less than
those specified for normal tangent towers.
Maintain the specified phase to phase clearance throughout the transposition spans
under all conditions.
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4.8 PACKAGING, SHIPPING AND TRANSPORT
4.8.4 Packaging
4.8.1.1 Scope
Included in this section are minimum requirements to ensure that all materials pertaining
to the Works are packed and transported to their destination without sustaining any
damage or deterioration. Also included are details of documents to be provided and
requirements for labeling and marking of containers.
Write and submit to the engineer a comprehensive specification covering packaging,

marking, color coding, documentation etc, to be used by all manufacturers, suppliers
and shippers etc. include, but not be limited to, any methods or procedures described
herein.
4.8.1.2 General
Ensure that all materials, plant and items forming part of the Works are adequately
packed to provide protection against corrosion, physical damage, contamination or
damage from water, dust or from any other source during handling, all necessary
transport and storage.
Handle all crates, drums, boxes, bundles, reels etc carefully at all times and do not
drop, dump, throw or push items from, onto or into any form of transport, during storage
or at any other time.
4.8.1.3 Steelwork
Strap bundles of steel work with extra heavy duty galvanized steel straps. Include only
like members in any one bundle and place in an interlocking fashion and strap
sufficiently to prevent slippage of internal members when the bundle is tilted.
Secure members of each bundle with wire passing through member holes at each end
of the bundle. Limit the weight of each bundle to approximately 500 kg.
Prior to shipping dip all steel materials in a suitable solution such as sodium bichromate
to protect the galvanizing from "white rust" corrosion during transport. Submit full details
of the proposed treatment to the Engineer.
For short members (1 m long or less), limit the size of each bundle to approximately 0.3
m x 0.3 m in height and width. Use extra straps to prevent slippage within each bundle
and, if possible, secure bundles to pallets and double strap the pallets in both directions.
Limit the weight of each pallet to a approximately 500 kg.
Wire small members, such as gusset plates, clip angles etc, together in small bundles
and pack in heavy gauge drums or strong boxes with totally closed-in sides bottom and
top. Pack drums no more than two-thirds full and fix a strongly braced solid cover
directly above the items. Provide lifting holes or lugs on all drums. Limit the net weight
of drums to 50% of the drum capacity. For details of boxes see Clause 4.8.1.6.
Place bolts, nuts, washers and similar accessories in boxes or in small steel pails. If
pails are used, securely wire each lid and place the pails on a pallet. Place a second
pallet on top of the pails so that its members directly touch and secure all pail lids.
Double strap the pallets in both directions.
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Handle and store bundles of steelwork horizontally and never on end. Do not use
metallic lifting lugs or chains, except that manilla rope is used for lifting bundles of
steelwork. Protect the lifting surfaces of fork lift trucks with strips of wood or rubber.
Keep all steelwork off the ground, truck beds warehouse floors, wharfs etc by means of
suitable blocking. Also used blocking between layers and bundles when these are
stored or piled. Ensure that all blocking is sufficient to keep members from bending and
to allow easy use of slings and fork lifts.
4.8.1.4 Conductors and Cables
Pack all conductors and cables on the supplier's recommended reels, which should be
non-returnable wooden type with wooden lagging, all dipped in anti-termite solution prior
to painting. Provide all reels with steel hubs with a through hole of minimum diameter 75
mm. provide waterproof paper between the conductor and the drum and the lagging.
Securely nail all lagging to the reel flanges and ensure nails are correctly driven and do
not enter conductor and double strap with straps inset into the lagging. Indicate on each
reel, in addition to other labeling requirements, an arrow showing the direction of roll.
Attach a metallic label showing, serial number, conductor length, type, gross weight,
tare weight and cubic measure.
Lift reels by means of a bar through the hubs for attaching to slings or chains which
must have spreader bar above the drum if a single lift point is used. When using fork lift
trucks, carry reels with the hub axis parallel to the direction of travel and ensure that
lagging is not damaged by the lifting forks. Do not lift reels by threading the chain
through the nubs or by slinging around the lagging. Keep reels upright on the flanges
during handling and storage. Do not store or roll reels on rough surfaces. Roll reels as
little as possible and only on smooth surfaces and only in the direction of the arrow.
Never pile or store conductor reels more than two reels deep. Use suitable blocks to
keep reels off the ground during site storage. Store drums in rows or double rows with
sufficient loading space between each row or double row. Rotate drums by a quarter
revolution each six month while in storage.
4.8.1.5 Insulators
Pack insulators in strong wooden crates with side members a minimum of 12 mm thick
and end members a minimum of 25 mm thick. Ensure that side members are a
minimum of 100 mm wide with a smooth outside surface. Pack crates on pallets and
secure with double straps in both directions.
4.8.1.6 Hardware, Accessories and Small Members
Pack in wooden boxes made of lumber a minimum of 25 mm thick, with reinforced

edges, corners and ends. Use nails that are ringed or spiraled. Line boxes with
waterproof paper and double strap in both directions. Limit the weight of boxes to
approximately 100 kg. Leave suppliers standard cardboard boxes intact and over-pack
with wooden boxes size designed to suit.
4.8.2 Shipping
Make all arrangements for all forms of transport used to ensure that all items are
transported safely and on time to their destination. Use only reputable carriers which
have regular schedules to the required destination.
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Investigate the facilities, reliability and record of carriers, ports and other depots. Make
arrangement to supplement any deficiencies that may be expected.
Investigate the possibility of through transport by road or rail to Iraq, and check for
problems such as delays, shortage of rolling stock or suitable road vehicles and the
acquisition of permits.
Keep the number of carriers to a minimum, and avoid transshipments or double

handling at ports or airports and depots as far as possible. Ensure that all warehouses
used en route are suitable and that all items can be stored without any deterioration or
damage from water, sunlight, dust or any other cause.
When possible avoid sending partial consignments. If such are required, ship items
such as steel towers in complete units.
4.8.3 Customs and Documentation
Make all the necessary arrangements for Customs clearances in Iraq, and the country
of origin. Obtain all necessary export and import permits and any other documents
required for the transport and clearance of the goods. Forward copies of all forms and
documents relating to Customs, Permits, Packing Lists, Bills of Lading and Insurances
etc to the Engineer.
Law of Iraq No. 157 has been passed to facilitate the entry into and transit within Iraq of
good, materials and equipment necessary for the construction of major projects,
including this project.
4.8.4 Marking and Color Coding
Ensure that all labels, markings and color codes etc. on all bundles, crates, boxes
drums and reels etc. are clear, legible, waterproof, not affected by sunlight and are
securely fixed or painted thereon. Use the standard project shipping mark in all cases.
Apply this and any mark authorized by the Employer to several surfaces of the
packages and ensure that the marks are visible at a distance. Apply any special decals
required by the exporting country onto all packages.
Establish a standard form of address for use on all packages. Include in the information
on the outside of each package details of contents, size, weight, order numbers,
shipper, shipping contract numbers, etc.
Apply standard markings such as Lift here, No hooks, Fragile etc.
Ensure that oil, paint and other hazardous or inflammable materials are marked
accordingly, including Flash point and recommended storage temperature.
Mark all bundles, boxes, bags etc. and package inside larger containers with full details
of contents.
4.8.5 Storage Areas in Iraq (Shown as "site Store")
Prepare adequate storage areas in suitable locations in Iraq. Grade the areas to provide
an even, firm surface, sloped to facilitate drainage and to permit the easy and safe used
of mobile cranes and fork lift trucks and to allow delivery and collection trucks to enter
and leave safely.
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Provide a security fence 2 m high topped with barbed wire all around the areas, with
suitable gates wide enough to allow large vehicles to pass. Floodlight the areas at night
and provide a security guard of adequate numbers at all times of the day and night.
Provide adequate supplies of wood blocks and ensure that all items are blocked off
clear of the ground at all times. Build and provide covered areas within the security
compound and store there in all items that have to be protected against rain, dust, sand
and strong sunlight.
Arrange for stores compound to be efficiently laid out and all items deposited in a neat
and simple manner, so that the contents of the store can be readily checked by the
Engineer. Keep bin cards or similar stores records up-to-date to show incoming and
outgoing material and present stocks.
4.9 TOWER SPOTTING
4.9.1 Plans & Profiles
Strip plans and profiles for the complete line lengths scaled 1:2000 horizontally and
1:200 to vertically, will be provided by the Contractor.
Plot thereon the proposed tower locations and submit the plotted profiles in duplicate to
the Engineer for approval. If there are no major corrections involved, the Engineer will
return one (1) copy of the plan and profile sheets within one (1) month.
Present information on the profiles such that a continuity from one profile to another for
each transmission line is maintained and tower types, heights and locations, ground
clearance curves, conductor sags, etc. are shown clearly and accurately to such an
extent that the profiles can act as complete drawings for subsequent material quantity
requirements and construction purposes.
4.9.2 Tower Plotting
Plot the structures and ensure that the most efficient use of towers and extensions is
obtained in accordance with good engineering practice.
Ensure weight to wind span ratios do not allow conductors to swing more than angles
shown below under various wind conditions.
Maximum Conductor Swing

Tower Type
Wind Condition A B E
Steady wind of 15.0 m/s at 25 deg C 20 deg 50 deg 35 deg
Steady wind of 25.0 m/s at 10 deg C 45 deg 60 deg 50 deg
Gust wind of 44.0 m/s at 10 deg C 60 deg 70 deg 65 deg
Ensure, under still air conditions at -15 degrees, the weight to wind span ratio at
suspension tower types, A, B and E is not less than 0.5.
Strengthen long tangent lengths between angle locations and/or deadend type towers
by the inclusion of type B towers at regular intervals which do not exceed every twelve
towers. For plotting purposes use same span limitations for these type B towers as for
the normal tangent towers.
During plotting and any subsequent span revisions during the period of the Contract, do
not exceed the following span length limitations:
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a) Any span length on one side of a suspension type structure shall not be less than
33.3 percent of the span length on the other side of the tower.
b) In any ruling span section (i.e., deadend structure to deadend structure), no span
shall exceed the average span by more than 50 percent nor shall any span exceed
the ruling span by more than 25 percent.
c) At angles, do not exceed limitations of span-angle diagrams.
In locations where high towers are required (crossing river, power lines, etc.) utilize the
type B tower as the crossing tower. If the particular situation warrants a higher tower
than that shown in the drawings, then increase the height of the B tower to suit. The
proposed height increase and subsequent designs shall be subject to the approval of
the Engineer.
Ensure that at a major river crossing, the towers immediately adjacent to the crossing
towers are full deadend type D towers.
4.9.3 Structure Lists
Prepare the structure lists on reproducible sheets from approved plan and profile
drawings and submit them to the Engineer for approval. Ensure that these lists are
complete for each transmission line and include but be not limited to, the following
information:
a) Temporary construction structure number.
b) Final structure numbers.
c) Tower types.
d) Tower heights to the crossarm.
e) Body and individual leg extensions.
f) Tower crossing details (rivers, canals, roads, power lines etc.).
g) Danger signs.
h) Phase plates.
i) Chainage equations.
j) Provisions for remarks and revisions.
k) References to the relevant plans and profiles.
4.9.4 Clearances
Maintain the following minimum clearances under the maximum sag condition (final sag,
still air, 90 deg C), in meters:
Normal ground 8.25
Main road crossings 10.0
Minor road crossings 9.0
Railway crossings 13.75
Buildings on which a man can stand 6.75
Power line crossing 5.0
Navigable rivers to high water 14.75
Oil pipe lines 10.0
Communications lines 6.0
Main Canal 16.0
Maintain the following minimum horizontal distances from tower locations, in meters:
To centerline of railway tracks 50.0
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To centerline of roads, bridges and pipelines 100.0

To centerline of power and communication circuits 50.0
To account for minor variation in ground topography and foundation installation, plot the
transmission lines with an additional clearance of 0.5 meters over those specified
above.
4.9.5 Plotting Template
Refer submitting plans and profiles for approval, provide the Engineer with two complete
sets of transparent sag templates made of stout perspex or plexiglass material. Ensure
that these templates include but are not limited to, the final conductor sag in still air at
the maximum conductor temperature of 90 deg C, the ground clearance line (excluding
0.5 meters excess allowance) and the final conductor sag in still air at the minimum
conductor temperature of -15 deg C. inscribe on each template the conductor name and
description, the design loading conditions, the ruling span upon which the template is
based, the range of ruling spans for which the template is applicable and references to
the line sections to which the template is to be applied. Scale the template to the same
scale as the plan and profiles.
The formula for calculating the ruling span (RS) shall be:
RS = [(L13 + L23 +.+.Ln3)/(L1 + L2 +..+ Ln)]1/2

Where L1, L2, .. Ln individual span lengths in m within a ruling span section.
Table: Appendix 4.0
Summary of Relevant Factors of Safety
1.5 on maximum design working loads.

Tower:
2.0 on maximum stringing and maintenance working loads.
1.3 on ultimate tower loads (1.95) on maximum design
Foundations: working loads and (3.0) on maximum design stringing and
maintenance working loads
Suspension 2.0 on maximum design or stringing and maintenance
Insulators: working loads.
Hardware for Braking loads of hardware equal to or greater than the rated
Conductor: M&E strength of the supported insulator string.
1.6 on maximum ultimate loads (2.08 on maximum design
Hardware for
working loads and 3.2 on maximum design stringing and
Shieldwire:
maintenance working loads).
Conductor: 2.5 on Maximum design working loads
Shieldwire: 2.5 on Maximum design working loads.
Compression
2.38 on Maximum design working loads.
Fittings:
Tension Sets and
2.5 on Maximum design working loads.
Fittings:
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APPENDIX 4.1
EXTRACTS FROM DESIGN STANDARDS NO. 10

"TRANSMISSION STRUCTURES"
Published by United States Department of

The Interior Bureau of Reclamation
Office of the Chief Engineer, Denver Colorado
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Iraq Goverment Regulation-1

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Iraq Goverment Regulation-1

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Ministry of Electricity Technical Specification for 400 and 132 kV Overhead Transmission Lines

PART 4 DESIGN AND ENGINEERING

4.1.3 Tower Design Criteria 10

4.1.4 Tower Fabrication 14

4.1.5 Tower Testing 16

4.1.6 Tower Attachments 18

4.1.7 Foundation Design Parameters 19

4.1.7.7 Foundation Stability 22

4.1.9 Design Briefs for Approval by Engineer 25

4.4 INSULATOR AND ASSOCIATED HARWARE 28

4.5 SHIELDWIRE FITTINGS 32

4.6 SPACER DAMPER SYSTEM 33

4.6.6 Ozone Resistance 35

4.8 PACKAGING, SHIPPING & TRANSPORT 38

4.9 TOWER SPOTTING 41

4 DESIGN AND ENGINEERING

4.1 TOWERS & STRUCTURES

4.1.1 TYPE & DUTUES

Tower type letters are as follows:

X Denotes towers destined for use on single circuit lines,

Y Denotes towers destined for use on double circuit lines,

A Denotes rigid tangent suspension tower,

C Denotes rigid 0-45 deg. angle and semi-deadend tower,

D Denotes rigid 0-90 deg. angle and terminal tower,

E Denotes rigid transposition tower.

4.1.2 LOADING AND PARAMETERS

V= 40(H/10)1/7 , where V= gust velocity, m/s, at an elevation of H meters.

Where: Ps = gust pressure, kPa, at mean shieldwire elevation.

The DESIGN LOAD or WORKING LOAD, multiplied by appropriate FACTOR OF

ULTIMATE STRESS is that stress which is induced by the ULTIMATE LOAD.

The term ULTIMATE STRESS or ULTIMATE LOAD is the theoretical value of

Use the following design requirements:

Tower types A, B, C, D and E are to be of a rigid self supporting design.

4.1.2.3 Outline and Loading Drawings

a) All design loads: 1.5.

b) All stringing, maintenance and climbing loads: 2.0.

4.1.2.4 Loads and Load Combinations

b) Long Span and 0-10 degree Angle Tower

c) 0-45 deg. Angle and Semi-Deadend Tower

5. Climbing and Ladder: same as for the tangent tower.

d) 0-90 deg. Angle and Terminal Tower

4.1.2.5 Stringing Loads

1. Specified Stringing loads on suspension type structures include for temporary

2. Ensure specified stringing loads are compatible with Contractor's method of

3. Ensure specified stringing loads are not exceeded.

4.1.2.6 TOWER EXTENSIONS TABLE

0 to 10 deg Angle & Long Span Tangent Tower 6, 12, 18 24,

Tangent Transposition Tower Type E - 1.5, 3.0, 4.5, 6.0

4.1.2.7 Double Circuit Lines

2. Long Span and 0-10 deg. Angle Tower

3. 0-45 deg. Angle and Semi deadend Tower

4. 0-90 deg. Angle and terminal Tower

4.1.3 TOWER DESIGN CRITERIA

4.1.3.3 Towers and Structures

Design transmission line towers and structures to conform to dimensions, loadings

a) Simplicity and ease of erection.

b) Sub-assembly of panels on ground.

c) Erection of panels by gin pole or derrick.

Minimum thickness of structural steel is to be as follows:

Main leg angles 8 mm

4.1.3.4 Tower Steelwork Design

2. Redundant (bracings without calculated stress)

Formula 1: Fa = Fy [1-1/2(KL/r/cc)2] kPa

Formula 2: Cc = (2E/Fy) Where E = 200 x 10 6 kPa