132kV Over Head Lines 1.5.2.3.2.01-Rev.

6.3.3. Tests on Concrete

Para (222) The Contractor shall carry out regular routine tests on samples of concrete from the
foundation works as required by DEWA. Tests and testing procedures shall be in accordance
with BS 1881.

Para (223) Duplicate copies of all test results shall be submitted to DEWA.

Para (224) If, for any reason, DEWA orders that retrospective testing of concrete is carried out, for
example, by the cutting and testing of concrete cylinder cores, the Contractor shall carry out
such testing. However, it is understood that large scale retrospective testing will not be
ordered without good reason such as from a proven failure by the Contractor to provide the
specified concrete quality.
6.3.4. Rock Anchor Proof Tests

Para (225) Routine proof tests shall be carried out by the Contractor on one rock anchor in every leg
unless DEWA decides otherwise. The tests shall be carried out according to DEWA's
requirements to demonstrate that the uplift design capacity of the rock anchor is satisfactory.
Routine proof test loads shall not exceed the calculated maximum working uplift in the rock
anchor.

6.4. Fencing

Para (226) The fence shall be of galvanized chain link, 50 mm x 50 mm mesh, not less than 2.65 mm
strand with a PVC coating not less than 3.75 mm diameter. The fence shall extend at least
2.4 m above and 0.3 m below ground level. The mesh shall be supported using at least
four separate tensioned 3.5 mm galvanized strands with a PVC coating at least 4.1 mm in
diameter.

Para (227) Intermediate posts shall be of fully galvanized tube at least 60 mm in diameter and 2.9 mm
wall thickness. Tension posts shall be of fully galvanized tube 76 mm in diameter and wall
thickness of 4.5 mm.

Para (228) Posts shall be set nominally at 3 m intervals and shall be equipped with cranks of 500 mm on
which heavy duty anti-personnel barbed wire is to be installed. Three runs will be required
throughout.

Para (229) A hinged gate of two leaves is required with a total span of 6 meters. Locks, drop bolts and
sockets are to be provided.

Para (230) Concrete foundations are required at least 300 x 300 x 600 mm for intermediate posts and 450
x 450 x 800 mm for tensioning and hanging posts. Concrete shall be of comparable quality to
that used in tower foundations.

7. TOWERS

7.1. Line Supports

7.1.1. Form of Construction

Para (231) All towers shall be self-supporting, double circuit, broad based, lattice steel design. Tower
designs will be appropriate to the type and number of phase and earth conductors for each
section of the line route and for the type of insulator sets offered by the Contractor.

Para (232) Each type of tower shall consist of a common portion to which legs of various lengths may be
added, with body extensions as necessary. The common portion shall not require modification
to accommodate the leg or the body extensions. Extensions for 3m, 6m, 9m and 12m designs

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are required. Individual leg extensions shall be provided for use on sloping ground for the
standard tower and body extensions within the range -3m to +3m in steps of 1m. Stub setting
templates shall be provided for the complete range of leg extensions.
7.1.2. Types of Support
Para (233) Tower Types for single conductor shall be designated with the prefix 1 and tower types for
twin conductor shall be designated with the prefix 2. In the mountainous area where towers
with single conductor and two earthwires are required the tower types will be designated with
the prefix 12.
Designation
Angle of Twin Single Conductor
Support Type Deviation Height Conductor Single E/WTwo E/Ws

Suspension 00 Standard 2DL 1DL 12DL

+3m extn 2DL + 3 1DL + 3 12DL + 3
+6m extn 2DL + 6 1DL + 6 12DL + 6
+9m extn 2DL + 9 1DL + 9 12DL + 9
+12m extn 2DL + 12 1DL + 12 12DL + 12

Section/Angle 00-100 Standard 2D1 1D1 12D1

+3m extn 2D1 + 3 1D1 + 3 12D1 + 3
+6m extn 2D1 + 6 1D1 + 6 12D1 + 6
+9m extn 2D1 + 9 1D1 + 9 12D1 + 9
+12m extn 2DL + 12 1DL + 12 12DL + 12

Medium Angle 100-300 Standard - 1D3 12D3

+3m extn - 1D3 + 3 12D3 + 3
+6m extn - 1D3 + 6 12D3 + 6
+9m extn - 1D3 + 9 12D3 + 9
+12m extn 2DL + 12 1DL + 12 12DL + 12

Heavy Angle 300-600 Standard - 1D6 12D6

+3m extn - 1D6 + 3 12D6 + 3
+6m extn - 1D6 + 6 12D6 + 6
+9m extn - 1D6 + 9 12D6 + 9
+12m extn 2DL + 12 1DL + 12 12DL + 12

Right Angle 600-900 Standard 2D9 1D9 12D9

+3m extn - 1D9 + 3 12D9 + 3
+6m extn - 1D9 + 6 12D9 + 6
+9m extn - 1D9 + 9 12D9 + 9
+12m extn 2DL + 12 1DL + 12 12DL + 12

Terminal 00-450 Standard 2DT 1DT 12DT

Special Gantry 00-100 Standard 2G1

Para (234) All angle/terminal supports shall be equipped with tension insulators.
7.1.3. Design Spans
Para (235) The design of supports shall provide for the following wind and weight spans.
Normal Working Conditions
Support type Wind Span (m) Weight Spans (m)
Maximum Minimum
Suspension 360 640 As specified
Below
Angle supports 360 800 -400
Terminal supports 360 600 0
Special gantries 75 75 -75

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Broken Wire Conditions

Para (236) The following applies only to the conductor considered broken. Loadings for the intact
conductors shall be based on the spans for normal working conditions.
Support type Wind Span (m) Weight Spans (m)
Maximum Minimum
Suspension 270 480 As specified
below
Angle supports 270 800 -300
Terminal supports 270 600 0
Special gantries 75 75 -75
Para (237) (Negative values for weight spans indicate uplift)

Para (238) The basic span shall be 300 meters for all towers other than special gantries for which the
basic span shall be 30 meters.

Para (239) The term basic span length shall mean the horizontal distance between centers of adjacent
supports on level ground from which the height of standard supports is derived with the
specified conductor clearances to ground in still air at maximum temperature.

Para (240) The term wind span shall mean half the sum of adjacent horizontal span lengths supported on
any one structure.

Para (241) The term weight span shall mean the equivalent length of the weight of conductor supported
at any one structure at minimum temperature in still air. At suspension positions, the
minimum weight of conductor supported shall not be less than 25 per cent of the total weight
of conductor in the two adjacent spans at minimum temperature in still air.

Para (242) The term equivalent span is as defined in Sags and Tensions.

Para (243) In steeply sloping country where the gradient between adjacent support points exceeds 10
degrees to the horizontal special consideration shall be given to the vertical loading on
supports.
7.1.4. Conductor Tensions for Support Design

Para (244) Conductor tensions for support design shall be derived from an equivalent span equal to the
design wind span for angle tension supports.
7.1.5. Support Loadings - General

Para (245) The assumed maximum simultaneous working loadings on supports shall be derived from the
angles of line deviation, conductor tensions and design spans as specified in Clauses 7.1.3 and
7.1.4.

Para (246) Calculation of stresses in support members under normal and assumed "broken wire" loadings
shall be made for the worst conditions of loadings of that particular member for the range of
loadings for which the support may be employed.

Para (247) All members inclined at less than 45 degrees to the horizontal shall be designed to withstand
the weight of a man plus tools (100 kg) applied perpendicularly at its midpoint
7.1.6. Assumed Normal Working Loadings

7.1.6.1. Suspension Supports

Para (248) Vertical loadings - the self-weight of the support, insulators and all other fittings and the
maximum and minimum dead weights of line and earth conductors.

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Para (249) Transverse loadings - a wind pressure of 1050 N/m2 at right angles to the line on the whole
projected areas of the conductors (x2 for duplex conductors) and earthwires including aircraft
warning spheres.

Para (250) In addition a wind pressure of 2592 N/m2 on 1.5 times the projected area of the members of
one longitudinal face of the support and a wind pressure of 1050 N/m2 on the full projected
area of the insulator strings.

Para (251) Longitudinal loading - Nil

7.1.6.2. Angle Tension Supports

Para (252) Vertical loadings - the self-weight of the support, insulators and all other fittings and the
maximum and minimum dead weights of line and earth conductors. Where cross arms are not
pointed in plan at the outer ends, the design shall allow for the entire vertical loading to be
applied to a single outer corner of each cross arm.

Para (253) Transverse loadings - a wind pressure of 1050 N/m2 at right angles to the line on the whole
projected areas of the conductors (x2 for duplex conductors) and earthwires including aircraft
warning spheres plus the transverse horizontal components of the relevant maximum
conductor and earthwire tensions, resolved for the maximum or minimum angle of deviation
concerned.

Para (254) In addition a wind pressure of 2592 N/m2 on 1.5 times the projected area of the members of
one longitudinal face of the support, and a wind pressure of 1050 N/m2 on the full projected
area of insulator strings.

Para (255) Longitudinal loadings - 15% of maximum working tension applied to each phase conductor
attachment point and to each earthwire attachment point, applied at right angles to the axis of
the cross arm and not in the line of the conductors except at zero deviation.

7.1.6.3. Terminal Supports

Para (256) The loading for terminal supports shall include the following conditions.
(a) One circuit of phase conductors, together with its over-running earthwire erected only.
(b) Both circuits and earthwires erected.
(c) With and without downleads erected.

Para (257) The loading for terminal supports shall also make allowance for the auxiliary crossarms.

Para (258) Vertical loadings - the self-weight of the support, insulators and all other fittings and the
maximum and minimum dead weights of line and earth conductors. Where crossarms are not
pointed in plan at the outer ends, the design shall allow for the entire vertical loading to be
applied to a single outer corner of each cross arm.

Para (259) Transverse loadings - a wind pressure of 1050 N/m2 at right angles to the line on the whole
projected areas of the conductors (x2 for duplex conductors) and earthwires including aircraft
warning spheres plus the transverse horizontal components of the relevant maximum
conductor and earthwire tensions, resolved for the maximum or minimum angle of entry
concerned.

Para (260) In addition a wind pressure 2592 N/m2 on 1.5 times the projected area of the members of one
longitudinal face of the support, and a wind pressure of 1050 N/m2 on the full projected area
of insulator strings.

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Para (261) Longitudinal loadings - The longitudinal horizontal components of the relevant maximum
conductor and earthwire tensions, resolved for the maximum or minimum angle of entry
concerned.

Para (262) Terminal supports shall be designed for downleads having a maximum tension of 7kN per sub
conductor and earthwire slack spans to the substation. The number of slack span earthwire
connections to be assumed shall be 2 per line earthwire.

Para (263) Terminal supports shall be designed for the following angles of exit of downleads and slack
span earthwires.

Para (264) In plan – 00-450 to the centre line of the main crossarm or auxiliary crossarm.

Para (265) In elevation - 00-450 to the horizontal.

7.1.7. Assumed Broken Wire Loadings

Para (266) For suspension towers, the unbalanced load due to the breakage of any one earth wire at
maximum working tension plus one complete phase bundle, or two complete phase bundles.
Para (267) The numbers of complete phase conductors and/or earth wires assumed broken for any
support shall be as follows.

Para (268) For suspension towers, the unbalanced load due to the breakage of any one earth wire at
maximum working tension and one complete phase bundle of two conductors, or two
complete phase bundles.

Para (269) For all other towers the unbalanced load due to the breakage of any one earth wire at
maximum working tension and two complete phase bundles.

Para (270) In the case of suspension insulator sets only, the tension applied to the support cross arm may
be assumed to be reduced to 70 per cent of the normal conductor design tension.

Para (271) The design shall take into account that longitudinal broken wire loads may act either in the
same, or in an opposite direction, to other specified longitudinal loads.

7.1.8. Earthquake Loadings

Para (272) The Contractor shall fully consider the effect of possible earthquake loading on supports.

Para (273) In so doing calculations shall show that at any point the structure shall be capable of
withstanding the following combination of loads.
(a) Maximum vertical loads due to conductors, fittings, insulators and steelwork.
(b) Transverse or longitudinal earthquake load equal to 10 percent of the vertical load obtained from
(a) above.
(c) Transverse and longitudinal loads derived from 5 percent of the maximum design wind pressures
at the coincident temperature.

7.1.9. Erection and Maintenance Loadings

Para (274) The Contractor shall derive the loading on supports due to the support erection methods he
proposes to use. The proposed erection methods shall be defined in the Tender.

Para (275) All support crossarms and earthwire attachments shall be designed to withstand vertical loads
due to conductor weight spans of twice those specified.

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Para (276) Angle/section supports may be required to withstand a temporary "dead-end" condition with
backstays at every conductor and earthwire level. The design shall consider that backstays are
attached to the support body and angled at 30° to the horizontal. All angle/section support
crossarms and earthwire attachments shall be designed to terminate conductors, on one side
only, at the maximum sagging tensions. Maximum sagging tensions shall take into account
the over tensioning to be carried out for conductor creep compensation. Angle/section support
bodies need not be designed permanently for the temporary "dead-end" condition. Temporary
reinforcement of support bodies may be used.
7.1.10. Factors of Safety for Supports
(a) Normal Working Loadings

Para (277) Each type of suspension support shall be designed so that no failure or permanent distortion
shall occur when tested with applied forces equivalent to twice the maximum simultaneous
working loadings specified.

Para (278) Each type of angle or terminal support shall be designed so that no failure or permanent
distortion shall occur when tested with applied forces equivalent to 2.5 times the maximum
simultaneous working loadings specified.
(b)Broken Wire Loadings

Para (279) All support shall also be designed so that no failure or permanent distortion occurs when
tested with applied forces equivalent to 1.25 times the maximum simultaneous working
loadings resulting from the assumed breakage of earthwires or phase conductors as specified.
(c) Earthquake Loadings

Para (280) All supports shall also be designed so that no failure or permanent distortion occurs when
loaded with applied forces equivalent to 1.5 times the maximum simultaneous working
loadings specified.
(d)Erection and Maintenance Loadings

Para (281) All supports shall also be designed so that no failure or permanent distortion occurs when
loaded with applied forces equivalent to twice the maximum simultaneous working loadings
specified.

7.2. Construction Design and Detailing of Supports

7.2.1. General

Para (282) The members of lattice steel towers shall be designed and detailed in accordance with either
one of the following together with the requirements of this Specification.
(a) DD133 issued by the British Standards Institution.
(b) Manual 52 issued by the American Society of Civil Engineers.

Para (283) If the Contractor wishes to depart, in any respect, from either publication listed above he shall
detail such amendment in his Tender.

Para (284) All designs shall be such that no trouble shall arise in service from vibration or excessive
deflection due to the use of too light a section.

Para (285) The design of supports shall be such as to keep the number of different parts as small as
possible, and shall facilitate transport, erection and inspection.

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Para (286) All support crossarms shall be arranged so that they can be removed without disturbing main
support members and their bolts.

Para (287) Modifications may be made to standard support designs where DEWA directs that such are
required to suit special loading conditions.

7.2.2. Minimum Allowable Steel Thickness

Para (288) In considering the risk of damage during transport and assembly and of damage after erection,
the steel thickness for supporting structures shall not be less than those given in the table
below:
Open Section Box Section or Tube
Main legs and main crossarm 6mm 4.76mm
Members
Bracing members 5mm 3mm
Redundant members 5mm 3mm
Steel below ground 6mm 6mm

Para (289) Box sections and tubes shall have adequate means of drainage.

Para (290) The minimum angle size used in structures shall be 45x45x5 mm. The thickness of
foundations stubs shall exceed the thickness of the leg member to which it is attached by
2 mm minimum.

7.2.3. Maximum Slenderness Ratios of Steel Members

Para (291) The ratio between unsupported length of a member and the relevant radius of gyration, L/r
shall not exceed:
L/r
Leg members and crossarms 120
(Excluding crossarm ties)
Bracings 200
Redundant members 250
Members loaded in tension only 350
7.2.4. Bolted Connections

Para (292) All structural bolts of a given diameter and step bolts shall be of one steel quality only.

Para (293) Bolts shall be dimensioned so that the thread of any bolt (except step bolts) shall not form part
of the shearing plane between steel members. Where step bolts are incorporated in a structural
joint they shall be ignored in the calculation of the strength of the joint except that step bolt
holes shall be considered in determination of the net member area. Bolt lengths shall be such
that the nut, after tightening, can be secured by punching of the exposed thread if required.
The thread projection through the nut shall be a minimum of 3 threads and a maximum of
15mm. Each bolt shall incorporate a spring washer fitted underneath the nut.

Para (294) Bolt thread profiles shall be of ISO form.

Para (295) Bolt tightening torque shall be such that any zinc accumulations or burrs are leveled and the
joint fully closed. Bolt tightening torques shall be shown on the support erection drawings.

Para (296) The minimum bolt diameter for structural members shall be 16mm.

Para (297) The nuts of all bolts loaded in tension (e.g. U-bolts and those used for insulator and earthwire
attachment plates) shall be fitted with an additional locknut.

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Para (298) All bolt holes shall be drilled/formed to diameters as close as practicable to the nominal bolt
diameter, typically 1.5mm greater than bolt diameter.

7.2.5. Crossarm Ends

Para (299) The crossarm tips of tension supports shall be so arranged that two holes for the attachment of
conductor erection and maintenance tackle are provided adjacent to each hole for tension set
shackles. It shall be possible to apply full conductor tension safely to either additional
attachment point.

7.2.6. Supports in Sloping Ground

Para (300) The Contractor shall measure ground levels at every support site over an area, and in a
pattern, which meets with DEWA's approval. The Contractor shall submit to DEWA for his
approval sketches for each support site showing the following:-
(a) Ground level cross-sections
(b) Support setting level
(c) Any necessary extensions/reductions to support legs
(d) Any necessary modifications to the approved foundations.

Para (301) The support setting level chosen shall be marked on the line profile drawing and ground and
other clearances shall be rechecked.

Para (302) Extensions/reductions to support legs may be provided by the following:

(a) For lattice steel towers - single hillside leg extensions/reductions.
(b) For any structure with reinforced concrete foundations - approved reinforced concrete leg
extensions provided that no such extension exceeds 1 meter.

7.3. Support Accessories

7.3.1. Anti-Climbing Guards

Para (303) Each support shall be fitted with an approved anti-climbing device generally as shown on the
drawings attached to this Specification. The device shall be fitted at a level on the support 3m
to 4.5m above the highest ground level at the support base.

Para (304) In order to provide climbing access for authorized personnel the anti- climbing device shall
incorporate gates on each step bolt leg. Gates shall be designed to open upwards and shall be
secured with bolts/brass padlocks.

Para (305) All padlocks shall be operated with one key. 25 copies of the key shall be handed over prior to
taking over of the line.

7.3.2. Step Bolts

Para (306) Each support shall be provided with step-bolts of an approved type on diagonally opposite
legs at not more than 380mm centers starting immediately above the anti-climbing device and
continuing to the support top.

Para (307) Holes for removable step-bolts below the anti-climbing guards shall be provided at not more
than 380mm centers on step bolt legs.

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7.3.3. Access Ladders and Platforms

Para (308) Towers in excess of 60 meters in height shall be equipped with access ladders and working
platforms. Ladders shall commence at the anti-climbing device level and continue to the top
crossarm level. They shall be hoop-caged and inclined from the vertical. Passing platforms (2
square meters approx) shall be provided at approximately 25m intervals. Working platforms
(4 square meters approx) shall be provided at each conductor crossarm level. All platforms
shall be railed. Step bolts shall be provided from the top platform to the earthwire level.
7.3.4. Bird Guards

Para (309) Guards of an approved type shall be fitted on crossarms above all suspension strings in such a
position as to deter large birds from perching on the steelwork directly above the insulators.
Guards should be fitted in such a way as to allow removal without interference to structural
steelwork.
7.4. MATERIALS AND FABRICATION
7.4.1. General
7.4.1.1. Packing

Para (310) The whole of the plant shall be packed where necessary in non-returnable cases or on non-
returnable drums or otherwise prepared for overseas shipment to Dubai without sustaining
damage. All packing shall become the property of the Employer. The Contractor shall, at
suitable intervals during the execution of the Contract, deliver such packing to stores selected
by the Employer at no extra cost.

Para (311) Bundles of steel angle sections shall be properly tied together by an approved method and
care taken to ensure that they are robust and not of excessive length for handling during
shipment. Bundles shall be as large as possible to provide stiffness and resistance to careless
handling.

Para (312) Unless the Contractor can offer an equally acceptable method, bundles of angles shall be
arranged in rectangular formation with notched outer stout wooden battens to locate the
angles, the battens being compressed on the bundles by outside tie bolts - the above binders
being located at sufficiently close intervals to form a strong and homogeneous element.

Para (313) It will not be necessary for tower steelwork to be bundled into individual tower units, but
unless otherwise approved by DEWA, each consignment must consist of complete towers,
extensions or sets of foundation steelwork.

Para (314) Packing cases where used shall be strongly constructed; timber less than 25mm in thickness
shall not be used. The contents of packing cases shall be securely bolted or fastened in
position with struts or cross battens. Cross battens supporting weight in any direction shall not
rely for their support on nails or screws driven lengthwise into the grain of the wood, but shall
be supported by cleats secured from the inside.

Para (315) Bolts and nuts shall be double bagged and crated for shipment.

Para (316) Crating together of components of dissimilar metals shall be avoided.

Para (317) Particular attention shall be given to strutting before packing cases are fastened down. Cases
shall be up-ended after packing to prove that there is no movement of the contents.

Para (318) Timber wedges or chocks shall be firmly fastened in place to prevent their displacement when
the timber shrinks.

Para (319) If light parts are fastened to the sides of a case, hoop-iron straps, secured by screws, shall be
used for the purpose. Nails driven in and bent over shall not be permitted.

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Para (320) Where bolts are used, large washers shall be fitted under the head and nut to distribute the
pressure and the timber is to be strengthened by means of a pad.

Para (321) The Contractor's attention is drawn to the later provisions of this Specification wherein the
Contractor shall be required to suitably protect all steelwork before shipment to prevent
damage to galvanized surfaces by white rust.

Para (322) Phase Conductors and earthwire shall be wound on steel or wooden drums in lengths as long
as practicable. All drums will be non-returnable and tenderers should therefore allow for any
additional costs.

Para (323) Drums shall be stoutly constructed to withstand the rigor of transportation, handling and
stringing procedures.

Para (324) Where wooden drums are used the construction must be such that any nail driven into any
surface shall have the head not less than 5mm below the surface.

Para (325) Each tail of the conductor shall be securely fastened to the drum in an approved manner. The
drum faces in contact with the conductor shall be lined with an approved material such as
impregnated paper or felt and the same material shall preferably separate the individual layers
of conductor on the drum. Any exposed tail of the conductor shall be sealed in an approved
manner to prevent the ingress of moisture or dirt during transit or storage.

Para (326) The whole of the drum's circumference shall be enclosed by stout wooden battens which shall
be retained by nails and at least 2 tensioned steel bands in the case of wooden drums or by an
approved system of tensioned steel bands in the case of steel drums. The diameter of the
barrel of a drum shall be not less than 30 times the diameter of the conductor and a space of
50 mm shall be retained between the outer conductor layer and the rim of the drum.

Para (327) All wooden drums and battens shall be protected from deterioration on site by termite or
fungus attack by an approved impregnation treatment at the works before dispatch. Such
impregnation shall not be harmful to the conductor.

Para (328) If wooden Conductor drums deteriorate on site due to their lack of robustness, insufficient
care in handling or insect attack, the Contractor shall carry out repairs or treatment to
DEWA's approval. If, in DEWA's opinion, the extent of drum deterioration is such that
conductor cannot be strung without damage, such drum and conductor shall be rejected.

Para (329) The following particulars shall be indelibly stenciled on both flanges of every drum.
- Contract title and reference number
- Manufacturer's name
- Direction of un-winding
- Lifting instructions and limitations

Para (330) An aluminum name plate shall be fixed to each drum clearly showing the following:-
- Conductor material and stranding
- Length of Conductor on drum
- Net weight
- Gross weight
- Manufacturer's batch number
- Manufacturer's drum number
- Winding date
- Approximate Measurements

Para (331) All Conductors ordered specifically as spare material for the Employer shall be supplied on
steel drums.

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Para (332) All stencil marks on the outside of casings shall be either of a waterproof material or protected
by shellac or varnish to prevent obliteration in transit.

Para (333) Wood wool shall be avoided as far as possible.

Para (334) Waterproof paper and felt linings shall overlap at seams at least 12mm and the seams secured
together in an approved manner, but the enclosure shall be provided with screened openings
to obtain ventilation.

Para (335) Each crate or package shall contain a packing list in a waterproof envelope and copies in
triplicate shall be forwarded to DEWA prior to dispatch.

Para (336) All items of material shall be clearly marked for easy identification against the packing list.

Para (337) All cases, packages, etc. shall be clearly marked on the outside with a shipping mark to
indicate the total weight, to show where the weight is bearing and the correct position of the
slings and shall bear an identification mark relating them to the appropriate shipping
documents. Details of the shipping mark will be provided to the Contractor at an early stage.

Para (338) DEWA may require inspecting and approving the packing before the items are dispatched but
the Contractor shall be entirely responsible for ensuring that the packing is suitable for transit
and such inspection will not exonerate the Contractor from any loss or damage due to faulty
packing.
7.4.1.2. Galvanizing

Para (339) Except where specified to the contrary all iron and steel used in the construction of the
Contract Works shall be galvanized after all sawing, shearing, drilling, punching, filing,
bending, machining and removal of burrs is completed. The zinc coating is to be uniform,
clean, smooth and as free from spangle as possible. Galvanizing shall be applied by the hot
dip process, in accordance with BS 729 or BS 433 as applicable, and shall normally consist of
a coating of at least 610 grams of zinc per square meter of surface. No alternative process
shall be used. For the section of line from the Diamond Crossing Point to Awir Substation
including the gantry structures at the Diamond Crossing Point additional galvanizing
protection is required and the coating shall be at least 900 grams of zinc per square meter of
surface. From Awir to Hatta the normal galvanizing coating of 610 gm/m2 is required.
Galvanizing shall withstand the tests set out in ISO 1459, 1460 and 1461 as appropriate or
such other standards as may be approved.

Para (340) Steel tower materials shall be treated with Sodium Dichromate solution, PretonW20 or other
approved solution after galvanizing to prevent formation of white storage stain. The
contractor shall be responsible for remedial measures should the formation of white storage
stain occur.

Para (341) In the event that it is found that galvanized parts are subject to the formation of white storage
stain during shipment or storage on Site, DEWA shall either:-
(a) Approve a system of scrubbing and protective painting to be applied on Site, if in his opinion this
is expedient, or
(b) Forthwith order that the affected parts shall be condemned and that all future shipments shall
receive, before dispatch from the works, extra or special dip or spray treatment to individual
members to his approval without extra charge to the Employer.

Para (342) Either of the above measures shall not be held as a cause for failure to meet the Line
Completion Dates.

Para (343) All components to be galvanized shall be of the full dimensions specified. The preparation
for galvanizing and the galvanizing itself shall not distort or adversely affect the mechanical
properties of the material. After galvanizing holes shall be free from nodules of spelter.

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Para (344) The means of control in the various stages of the galvanizing process shall be such as to
prevent zinc/iron alloys reaching the surface of a member.

Para (345) Hot-dip galvanized members shall have a continuous and adhesive coating, as even as the
shape and properties allow. Contact surfaces shall be free from flux impurities and
accumulations of hard zinc. After galvanizing the member shall be cleaned, so as to allow safe
handling.

Para (346) Box sections shall be provided with air holes so as to minimize the risk of bursting during
heating in the zinc tank.

Para (347) For bolts and nuts the galvanized coating shall be at least 375 grams of zinc per square meter
of surface. Bolts shall be completely galvanized including threads, but the threads shall be
left uncoated in the case of nuts.

Para (348) If during inspection prior to shipping any galvanized part is found to be imperfect it is to be
replaced. The whole of the expense involved in the replacement of the imperfect part is to be
borne by the Contractor.

Para (349) The Contractor shall provide for the use of DEWA, an instrument for checking galvanizing
thickness, e.g. Elcometer, or otherwise agree with DEWA an approved method of testing
galvanizing on Site.

Para (350) If in the opinion of DEWA, the extent of damage found on Site to a galvanized part appears
capable of repair, the Contractor may, after receiving such agreement, attempt to effect repair
by approved methods. The agreement to attempt repair shall not bind DEWA to accept the
repaired part when this is re-offered for inspection. Galvanizing repair shall be carried out
with a zinc rich paint of not less than 92 per cent zinc content.

Para (351) Adequate surface preparation and correct application are essential to such repair process. The
Contractor shall submit his proposals to DEWA in detail for approval.

Para (352) Steel wires shall be galvanized in accordance with B.S. 443 or approved similar standard.

7.4.1.3. Castings

Para (353) All castings shall be as free from blow holes, flaws and cracks as is practicable. No welding,
filling or plugging of defective parts shall be done without the sanction of DEWA and then
only with his approval in writing. All cast-iron is to be of close-grained quality approved by
DEWA. Cast-iron is not to be used for any part of the equipment which is in tension or which
is subject to impact stresses.
7.4.1.4. Welding

Para (354) Welding may only be carried out where specified on drawings and shall then only be
undertaken by welders of proven competence. The welding method used, unless otherwise
specified, shall be manual arc welding with coated electrodes, and in accordance with
BS.5315 or an approved equal.

Para (355) Pockets and cracks which are common points of attack for corrosion and can constitute "acid
pockets" in connection with hot-dip galvanizing, must be sealed with a weld bead.

Para (356) In all cases where fabrication welds are liable to be highly stressed, such as maybe the case in
parts subjected to reversals of stresses in operation, the Contractor shall supply DEWA with a

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general arrangement drawing of the fabrication and, at a later date but before fabrication
commences, a detailed drawing of all proposed weld preparations on the fabrication.

Para (357) Before such welding commences the Contractor shall satisfy DEWA that the welders or
welding operators are qualified in accordance with the requirements of the appropriate section
of BS.2654 or such other standard as may be approved.

Para (358) After scrutinizing the general arrangement and welding detail drawings the Engineer will
inform the Contractor of the stages at which inspection will be required. It will be the
Contractor's responsibility to notify DEWA when one or more of the inspection stages will be
reached and no further work is to be carried out until the specified stage has passed DEWA's
inspection.

Para (359) In addition to the above, DEWA or his representative reserves the right to visit the
Contractor's Works at any reasonable time during fabrication of the items of plant and to
familiarize himself with the progress made and the quality of the work to date.

Para (360) In the event of the Contractor wishing to make an alteration to any part of the weld
preparation, he is first to submit to DEWA a copy of the revised drawing showing the
amended preparation in detail and to await confirmation of its acceptance or non-acceptance.
7.5. Support Steelwork
7.5.1. Steel

Para (361) Steel shall comply with approved national or international standards such as ASTM, BS, DIN,
ISO, and shall only be manufactured and rolled in approved mills.

Para (362) In order to reduce the risk of material confusion, only two grades of steel shall be permitted.
Suitable grades are a mild steel or low yield steel (yield point in the range 220-280N/mm2)
and a high yield steel (yield point 300-360N/mm2). High yield steel shall have a resistance to
brittle fracture at least equal to BS.4360 Grade 50B.

Para (363) Certified mill test reports shall be acceptable evidence as to the yield point and ultimate
strength of the steel used and shall be furnished on request of DEWA.

Para (364) High yield stock shall, be marked distinctively prior to fabrication, by a blue water paint stripe
along the entire length or some other approved method of marking.

Para (365) Before welding of members is carried out the Contractor shall submit a chemical analysis of
the material to DEWA for his approval.
Para (366) All support members shall be stamped with distinguishing numbers and/or letters
corresponding to those on the approved drawings or material lists. These erection marks shall
be impressed before galvanizing and are to be clearly readable afterwards.
7.5.2. Fabrication

Para (367) Individual members shall be true to shape and fully interchangeable with members bearing the
same erection mark. During check assembly, members must not be forced into position in
such a manner that deformation or unacceptable stresses occur.

Para (368) All bending of high tensile steel shall be performed between temperatures of 850-1000°C.
Bends of a difficult nature on mild steel shall be performed at 800°C but otherwise cold
bending may be employed, i.e. at a temperature above 18°C.

Para (369) Any holes adjacent to a bend line, or near the weld with the "cut and weld" or "cut open and
weld-insert plate" technique must be drilled and must be positioned so that at least 12mm of
the parent metal exists between the edge of the hole and the weld line.

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Para (370) Mild steel members up to 16mm thickness and high yield steel up to 14mm thickness may be
sheared to length. Members in excess of these dimensions must be sawn or flame cut. Ends of
member must be true to angle and free from burrs and notches.
7.5.3. Bolt Holes

Para (371) Hole diameters shall be not greater than the bolt diameter plus 1.5mm, in the un-galvanized
state.

Para (372) Holes may be punched up to a thickness of 19mm for mild steel and 14mm for high tensile
steel provided that the hole diameter is equal to or greater than the material thickness.

Para (373) All other holes must be drilled and the quality of the drilling must be such that there are no
burrs, score marks or sharp edges left in or around the holes.

Para (374) Wrongly drilled holes may not, wholly or partially, be refilled by welding or plugging.
7.5.4. Bolts, Nuts and Washers

Para (375) Joints in structural steelwork shall be secured by means of approved bolts, nuts and spring
washers. Nuts and heads of bolts shall be of the hexagonal type. Nuts (except lock nuts) shall
be full bearing on the underside. Spring washers shall be of rectangular section and of the
following minimum thicknesses.
Bolt diameter (mm) Min. thickness of spring washer (mm)
16 and above 5

Para (376) All bolts and screwed rods shall be galvanized including the threaded portions. All nuts shall
be galvanized with the exception of the thread which shall be oiled.

Para (377) All washers shall be included in this Contract. Taper and spacing washers shall be fitted
where required.

Para (378) Nuts shall be finger tight on the bolt and will be rejected if, in the opinion of DEWA, they are
considered to have an excessively loose or tight fit.
Para (379) Bolts with re-died threads after galvanizing will be rejected.

Para (380) The Contractor shall request his Supplier to select two samples of each type of bolt and nut to
be used in the Contract and send these two samples to the Engineer for approval within one
month of the date of issuing the sub-order.
Para (381) DEWA will reject bolt consignments which fall in any respect below the standard of samples
submitted and approved. The importance of supplying good quality well finished nuts and
bolts cannot be over emphasized.

7.5.5. Tolerances

Para (382) Members and bolts, including washers, shall be manufactured to as per national or
international standards. The following tolerances are to be considered as minimum
requirements.
(a) Members
i) On the overall length of any member (where not otherwise specified) ±1mm
ii) On the specified hole diameter in the black (on the punched side, when punched) +0.15, -
0mm.
iii) Maximum increase in punched hole diameter on the die side 0.7mm or thickness ±15
whichever is the greater.
iv) On the centers of holes in a group ±0.75mm.

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v) On the centers of group of holes +1.5mm.

vi) On back marks ±0.5mm.

Para (383) The permitted tolerance for straightness for finished material, i.e. after galvanizing, shall be
calculated on the basis of an offset in the centre of a length of bar equal to 0.1 per cent (1mm
in 1 metre) of the length considered. Additionally, where the bar length exceeds 3 meters the
offset shall be measured in any 3 meter length and shall not exceed the same proportional
tolerance (3mm in 3 meters). Members fabricated outside these tolerances will be rejected.

(b) Bolts
i) Plus tolerance on black diameter 0.1mm. Plus tolerance on diameter after galvanizing
0.3mm.
ii) Tolerances on nominal length of bolt +1mm.
7.6. Erection of Supports
7.6.1. General

Para (384) The erection method for supports shall be such that the required safety factors for the support
members are maintained throughout the operation. In addition the erection equipment shall be
such that the statutory safety factors for such equipment are maintained under all conditions of
its operation. Erection procedures and practices shall be implemented to provide the highest
levels of safety for all personnel on the site.

Para (385) The Contractor shall detail his proposed erection methods and submit these to DEWA for
approval.

Para (386) Unless DEWA specifies to the contrary, supports shall be assembled and erected with bolts
finger tight only. Final tightening of bolts to approved torques shall only take place when all
members are in place.

Para (387) Spanners used during erection shall be well shaped and fit closely on the nut to avoid
damaging nuts and bolts. Before assembly of members, joints shall be free of earth, or any
other substance which might prevent the correct alignment of members.
Para (388) All supports shall be vertical under the stresses set up by the completed overhead line.

Para (389) After erection all supports shall be cleaned of all foreign matter or surplus paint.

7.6.2. Erection of Lattice Steel Towers

Para (390) Where steel members arrive on Site with slight distortions due to handling in transit, they
shall be straightened by the Contractor using an approved means and offered to DEWA for
inspection and acceptance or rejection before erection commences.

Para (391) Where derricks are used for lifting panels they shall preferably be floated. If floating is not
possible the derrick shall be supported only at approved locations on the legs.

Para (392) Whenever wire slings or ropes are liable to abrade a support member, the member shall be
suitably protected by heavy Hessian bags or strips, or by some other approved method.

Para (393) The Contractor shall make use of temporary struts on panels prior to lifting, if in the opinion
of DEWA, there is a likelihood of damage occurring to that panel during lifting.

Para (394) Suitable ladders shall be used whenever necessary during erection, but such ladders and
removable step bolts shall be removed when erection work is not in progress.

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Para (395) Drifting and hammering of steelwork during assembly and erection is not permissible.
7.6.3. Painting of Supports
a. General

Para (396) Support painting at or above conductor level shall be carried out before the erection of
insulators. All surfaces to be painted shall be cleaned such that all oil, grease and dirt is
removed before paint is applied. Painting shall not be carried out when the atmosphere is
damp or dust laden. Each paint coat shall be allowed to dry and harden before the next coat is
applied. All painting shall be carried out after the supports are erected and completed in all
other respects. Particular care shall be taken to coat thoroughly all recesses, edges, joints,
intersections of members and bolt heads and nuts.
b. For all Steel Supports

Para (397) The concrete foundation and support steelwork shall be painted with two coats of an approved
bitumen based paint. The application of the paint shall extend from 300mm below ground
level to 300mm above the top of the concrete foundation.
c. In areas Liable to Flooding
The painting regime given in b) above shall be extended to a height of 300mm above highest expected
flood level.
d. In Corrosive Atmospheres

Para (398) Where required by DEWA, all galvanized support steelwork shall be painted with one coat of
calcium phosphate primer and one coat of light grey, high-build, chlorinated rubber paint or
other approved system of paint. The chlorinated rubber paint shall be such as to give a dry
film thickness of 75 microns.

Para (399) The support shall be painted orange and white in equal alternate vertical sections of one
seventh of the total support height, the top and bottom sections being orange. Section lines
between colors shall be sharply defined and level.

7.7. Inspection and Testing During Manufacture

7.7.1. General

Para (400) All plant shall be inspected during manufacture and tested by DEWA.

Para (401) Every facility shall be provided by the Contractor to enable DEWA to carry out the necessary
inspection of the plant and the costs of all tests during manufacture and preparation of test
records shall be borne by the Contractor.

Para (402) The passing of such inspection or test will not, however, prejudice the right of DEWA to
reject the Plant if it does not comply with the Specification when erected, or give complete
satisfaction in service.

Para (403) Instruments shall be approved and shall, if required by DEWA, be calibrated by a recognized
National Physical Laboratory or such other body as may be approved, at the expense of the
Contractor.

Para (404) Breakdown test voltages shall be measured by means of a crest or electro-static voltmeter
connected to the high voltage side of the transformer, or by an instrument connected to the
low voltage side of the transformer supplying the test voltage and calibrated in an approved
manner by means of a sphere spark gap. Electrical tests, other than impulse test, shall be
carried out at a frequency of 50Hz.

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Para (405) In the event that any item of equipment has to be retested owing to failure or rejection of the
initial tests, then the cost of such retesting, including travelling and accommodation costs of
DEWA, shall be borne by the Contractor.
7.7.2. Test Certificates

Para (406) Two sets of all principal test records, test certificates and performance details for all tests
carried out in accordance with the provisions of this Contract shall be supplied to the
Employer and two sets to DEWA. These test records, certificates and performance details
will be supplied for all tests, whether or not they have been witnessed by DEWA. The
information given on such test certificates and performance details shall be sufficient to
identify the material or equipment to which the certificate refers. Certificates shall also bear
the Contract reference and heading.
7.7.3. Rejection of Plant

Para (407) Any item of plant or component which fails to comply with the requirements of this
Specification in any respect whatsoever at any stage of manufacture, test, erection or on
completion at Site maybe rejected by DEWA either in whole or in part as he considers
necessary.

Para (408) After adjustment or modification if so directed by DEWA, the Contractor shall submit the
item for further inspection and/or tests. Plant or components with defects of such a nature that
the requirements of this Specification cannot be fulfilled by adjustment or modification are to
be replaced by the Contractor at his own expense and to the satisfaction of DEWA.
7.7.4. Lattice Steel Towers

Para (409) (a) Design Tests - DEWA will select straight line and angle supports which shall be
assembled at an approved independent testing station, or other approved place experienced in
such tests, for test on a rigid foundation. If the Contractor, in carrying out erection of supports
on site, proposes to assemble the supports on the ground and subsequently raise them to the
vertical position, the sample support submitted for tests shall be so assembled and raised to
the vertical position on the test foundation in the presence of DEWA, if he so requires.

Para (410) Each structure, complete with crossarms, shall then be submitted to such test loads, in such
order as DEWA may specify, to prove compliance with the factors of safety stated in the
Schedules. The tests shall be applied in accordance with IEC 652 - Loading tests on overhead
line towers.

Para (411) Generally, suspension supports will be tested to destruction and tension supports will be tested
to ultimate design loads. However, in the event of premature failure during full scale tests,
such as would call into question the tower design philosophy, DEWA may instruct the
Contractor to full scale test other tower types.

Para (412) If required by DEWA, these tests may be repeated from time to time on structures assembled
from members selected by DEWA.

Para (413) No part of a structure tested to destruction shall be used in the permanent works and the
Contractor shall confirm disposal to DEWA.

Para (414) Where support tests are satisfactorily completed and not taken to destruction, the support shall
be carefully inspected after dismantling to ensure that no parts have been damaged, bundled
separately from routine support material, and marked for use in the permanent works at a
position of relatively light loading. A complete set of new bolts shall be supplied in such
cases.

Para (415) (b) Sample and Routine Tests - Samples of the material for supports and fittings shall be
tested in accordance with BS4360 or such other standard as may be approved. Tenderers

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should note that DEWA will inspect as soon as available at the Contractor's works the first
consignment of complete foundation steelwork and stub setting templates.

Para (416) Thereafter routine inspection of galvanized steelwork will be limited to complete structures,
with or without foundation steelwork, the weight of steel to be inspected being not less than
500 tons for each inspection visit by DEWA.

Para (417) Where the Contractor requires additional inspection visits to be made the cost of travel,
subsistence, accommodation and salary of DEWA's inspector will be deducted from the value
of the appropriate Payment Certificate.

Para (418) To maintain fabrication standards, DEWA may call for repeat check erections of any tower
type during the manufacturing period at no extra cost.

7.7.5. Galvanizing
7.7.5.1. General

Para (419) Galvanized wire shall be tested in accordance with BS 443. Other galvanized articles shall be
tested in accordance with ISO 1459, 1460 and 1461 as appropriate or such other standard as
may be approved. If evidence of white storage stain is apparent upon receipt at site of
bundled steel section, DEWA shall order the Contractor to make such tests as he deems
necessary to determine the extent of damage, if any, and the remedial measures necessary.
7.7.5.2. Measurement of Galvanizing Thickness

Para (420) The Contractor shall have available on site for DEWA's use an instrument suitable for the
accurate checking of galvanizing thickness. The gauge shall be available from the time of
arrival of the first consignment of steelwork until the issue of the Taking Over Certificate.
The gauge will be handed over to DEWA on completion of the Works

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