RAW MATERIAL INSPECTION & TESTIN G

Job Raw Material Testing

Customer General
Document [DOC/RMT/01, Rev. 00]
no.
Date [2011/07/01]
To All Partners & Internal use
Made by KNSB
Approved by TRMB

General:
Date 2012/05/25

This standard aims at helping test personnel perform the test in an

appropriate method by describing the measuring method of all
testing of material with acceptance criteria’s. Ramboll
4th Floor, Plot No 7,
Opp. Orchid International
Scope: School,
Kavuri Hills, Guttala Begumpet,
Hyderabad - 500 033
The material testing is responsibilities of partners and this standard
India
covers overview of testing requirement for Tubes, Plates, Angles,
Rods, Fasteners, and U-Bolts etc. T +91 40 4456 7200
www.ramboll.in

All the partners are responsible to purchase material from reputed

supplies and Ramboll will not encourage any partner in purchasing
material from any suppliers which are not reputed or traders.

Page 1 of 7 DOC/RMT/01, Rev. 00

 1. TESTING OF TUBES

All the tubes used for Ramboll Towers must be made accordance to IS-1161 / IS
1239 and the hot rolled steel strips for welded tubes & pipes must be accordance to
IS 10748.

1.1. Hot Rolled Steel strips Material specification (Ref. IS 10748)

1.1.1. Tensile Properties:

Grade Tensile Yield Stress, Percentage Internal

Strength, Min Min MPa elongation, Min Diameter of
MPa at Gauge Length Bend

3 410 240 25 2t

5 490 310 15 3t

1.1.2. Chemical Composition:

Grade Yield Stress, Carbon, % Manganese, Sulphur, Phosphorus,

Min. Mpa Max. % Max. % Max. % Max.
3 240 0.16 1.20 0.040 0.040

5 310 0.25 1.30 0.040 0.040

1.2. Tensile Properties of Steel Tubes (Ref. IS 1161):

Material Grade Tensile Strength, Yield Stress, Min Percentage

Min MPa MPa elongation, Min
at Gauge Length

YST 240 410 240 17

YST 310 450 310 14

1.3 Sampling and permissible defectives for physical Test (Ref. IS 4711):

1.3.1 Sampling for material procured in coil condition:

Number of samples to be tested from each heat of one thickness shall be as follows
and if any one sample failing in meeting the specification, the complete lot stands
rejected. There is no double sampling allowed for raw material testing.

Lot Size / Heat number Sample Size Rejection Number

Up to 100 Tonnes 2 Samples 0

100 ~ 200 Tonnes 3 Samples 0

Above 200 Tonnes 4 Samples 0

Page 2 of 15 DOC/RMT/01, Rev. 00

 1.3.2 Sampling for material procured in Tube condition:

Lot Size in Sample Size Acceptance Rejection

Sampling Method
Nos. in Nos. Number (a) Number (r)
Up to 300 Single (First) 3 0 0
Single (First) 5 0 2
301 to 800
Double (Second) 5 1 2
Single (First) 8 0 2
801 to 3000
Double (Second) 8 2 3
3001 and Single (First) 13 1 3
Above Double (Second) 13 3 4

• If the single sampling, the number of defective items are less than or equal
to the corresponding acceptance number (a), then the lot shall be declared
as confirming to the requirement of that test,

• If the number of defectives are greater than or equal to the corresponding

rejection number (r), the lot shall be deemed as not meeting the
requirement for that particular physical test,

• If the number of defectives are more than acceptance number but less than
the rejection number, a second sample of the same size as the first shall be
taken to determine the conformity or otherwise of the lot.

• The number of defectives found in the first and second sampling shall be
combined and if the combined number of defectives are less than or equal
to corresponding acceptance number of the second sample, the lot shall be
declared as confirming to the requirements of the particular physical test,
otherwise not.

1.3.3 Random Sampling by Ramboll for material in process:

Ramboll team shall pick any samples at any stage as an audit process which will be
sent to 3rd party NABL accredited lab by Partners (Manufacturer). The reports will
be compared with original Material test certificate from supplier, in-house testing
reports and if found any discrepancies the complete material will be kept on hold
further process.

1.4 Procedure for Tensile Test:

1.4.1 Sample selection:

• All material suppliers are supposed to send extra length for the tubes
required to be tested as per sampling plan or it is partners responsibility to
make supplier mandatory to supply extra length for the samples quantities
as per sampling plan.

• Tensile test samples shall be taken transverse to the direction of rolling,

but strips below 600mm width, longitudinal test pieces may be taken for
testing. The sample for tensile test shall be from end of the coil after
coiling. This sample selection is only applicable for partners who are
purchasing coils for making tubes in-house.

• For Partners procuring tubes directly from the supplier, the sample of
longitudinal strip cut from the tube, not including welding.

Page 3 of 15 DOC/RMT/01, Rev. 00

 1.4.2 Sample Preparation:

To receive exact results, you must have specimen which is meeting the
specification and if the specimen has bad quality, the results of your test are wrong
and not reliable.

The specimen can be made by machining process or made from blanking operation
by press tool. However, we recommend all partners to make a press tool for
making specimen and refer picture.

Blanking Tool Belt grinding to finish edges

1.4.3 Specimen Dimensions:

Specimen Shape:

Specimen Dimensions:

Gauge Parallel Radius of Width of

Thickness Width (W)
Length (L) Length (P) Fillet (R) Grip (B)

<3mm 25mm 50mm Approx. 60 20mm Min. 30mm Min

>3mm 25mm 50mm Approx. 60 15mm Min. 30mm Min.

Page 4 of 15 DOC/RMT/01, Rev. 00

 1.4.4 Testing Machine:

• The testing machine used for tensile test shall be composed with load
moving device, load measuring device, test piece grip holders and
elongation measuring device. All testing machine must be universal and
have integrated with computer, having software installed to have Stress &
Strain Curve.

• The UTM shall be installed on a right foundation and not be shaken,

• In the case of where the UTM has been overhauled and reassembled or
subjected to modification of its main part or reinstallation, it shall be used
only after being verified with condition for use.

• The UTM shall be re-verified for accuracy at certain intervals.

1.4.5 Testing Methodology:

The following procedure is adopted in ensuring that the data recorded from tensile
test specimens was taken in an organised and consistent manner.

• Care is to be taken to ensure that the specimens did not have any notching
or cracks while Specimen preparation or any surface defects that would
adversely affect the tensile tests,

• Before loading the specimens in the machine, the computer system

connected to the machine was set up by inputting the necessary
information of gauge length and width of the specimen. The computer
system is then prepared to record data and output necessary load-
deflection graphs.

• The specimens loaded into the machine, and a tensile test is performed.
The data is recorded electronically and the load-deflection curve will be
shown on the computer screen as a visual representation.

Page 5 of 15 DOC/RMT/01, Rev. 00

 1.4.6 Results of Tensile Test:

The below graphs shows results of Tensile test carried out as per procedure.

1.4.6.1 Calculation of Tensile Strength:

Tensile strength is calculated by dividing the load at break by the original minimum
cross sectional area. The result is expressed in Mega Pascal’s (MPa) and reported to
three significant figures.

Load at Break
Tensile Strength =
(Original Width) x (Original Thickness)

1.4.6.2 Calculation of Percentage elongation:

Percent elongation is calculated by dividing the elongation at the moment of

rupture by the initial gauge length and multiplying by 100. When gauge marks or
extensometers are used to define a specific test section, only this length is used in
the calculation, otherwise the distance between the grips is used as the initial
gauge length. The result is expressed in percent and reported to two significant
figures.

Elongation at Rupture x 100

Percentage Elongation =
(Initial Gauge Length)

Page 6 of 15 DOC/RMT/01, Rev. 00

 1.4.6.3 Causes of uncertainty in Tensile Testing:

The prevision of the results of tensile tests is limited by factor related to material,
test piece, testing equipment, test procedure and method of calculation of the
mechanical properties.

More specially, the following causes of uncertainty can be mentioned:

• Some degree of in homogeneity, which exists even when a processing

batch obtained from a single heat of material,

• Test piece geometry, preparation method and tolerance,

• Testing machine and associated measuring systems (stiffness, drive,

control, method of operation),

• Measurements of test piece dimensions, gauge length marking,

extensometer initial gauge length, measurement of force and extension,

• Test temperature and loading rates in the successive stage of the test,

• Human or software errors associated with determination of the tensile

properties.

1.5 Tolerances:

1.5.1 Straightness tolerance:

The tube shall not deviate from straightness by more than 1mm in any 600mm
length and the straightness deviation cannot be interpreted as 10mm per 6000mm.

1.5.2 Thickness Tolerances:

Description Tolerance
+Not limited
Welded (ERW) Tubes
- 10 Percent
+Not limited
Seamless Tubes
-12.5 Percent

1.5.3 Diameter Tolerance:

Description Tolerance
Up to and including 48.3mm +0.4mm
dia. Tubes - 0.8mm
Over 48.3mm dia. Tubes ± 1.0 Percent

1.5.4 Visual Defects :

All Tubes must be free from Cracks, surface flaws, laminations, rolling marks, tool
marks, pitting, heavy rust, dents, varnish, painting and no deviations allowed on
visual defects.

Page 7 of 15 DOC/RMT/01, Rev. 00

 1.6 Ductility Test:

1.6.1 Cold Bend test:

The finished tubes must be capable of withstanding the bend without showing any
sign of fracture or failure. The tube must be bent at 900 to the plane of bend.

Un-galvanised tubes must be capable of being bent cold without cracking of steel
through 1800 around a former having radius of the bottom of groove in the plan of
bending equal to six times the outside diameter of the tube.

Galvanised tubes must be capable of being bent in cold without cracking in the
steel, through 900 around a forming a radius at the bottom of groove equal to eight
times the outside diameters of the tube.

1.6.2 Flattening test:

This test is applicable for tubes above 50mm diameter and testing must be carried
out accordance to IS 2328. Ring, not less than 40mm in length cut from the ends
of selected tubes with edges rounded shall be flattened between parallel plates with
the weld.

Weld Test:

Test Specification Criteria

No opening shall
occur by fracture in
the weld until the
Weld Seam
85%
distance of 85%
D position reached

Parent Material Test:

Test Specification Criteria

No cracks or breaks
in the metal,
elsewhere than in
Weld Seam weld shall occur
75%
D position until the distance of
75% is reached.

Page 8 of 15 DOC/RMT/01, Rev. 00

 Close Flattening test:

Test Specification

Re-test & Sampling method:

If any one of the test piece first selected failed in the test, two further samples
shall be selected for testing in respect of each failure from the same lot. If these
additional test pieces pass the test, then the lot shall be deemed to comply with
the test. In case, additional test pieces failed in testing, the complete lot shall be
deemed as not complying with the specification.

2. TESTING OF PLATES:

All the Plates used for Ramboll Towers must be accordance to IS-2062

2.1. Hot Rolled Steel Plate Material specification (Ref. IS 2062):

2.1.1. Tensile Properties:

Grade Tensile Yield Stress, Min. MPa Percentage Internal Bend
Strength, Elongation, Diameter
Min. MPa Min. at Gauge
<20 20-40 >40
Length ≤ ≥
E250 410 250 240 230 23 3t 2t

2.1.2. Chemical Composition:

Grade Carbon, Manganese Sulphur, Phosphorus, Silicon, Carbon

% Max. , % Max. % Max. % Max. % Max. Equivalent
(CE), %Max.
E250 0.23 1.50 0.045 0.045 0.040 0.042

2.3 Sampling and permissible defectives for physical Test (Ref. IS 2062):

Number of samples to be tested for each thickness shall be 2 per heat/Lot.

And if any of the samples fail to meet the specifications, two further samples shall
be taken for each failure. If both the samples taken meet the specification then the
lot shall be declared as confirming to the requirement of the test but if any of the
samples fails to meet the specification then the lot shall be declared as not
confirming to the requirement of test.

2.3 Procedure For tensile Test:

As per chapter 1.4

Page 9 of 15 DOC/RMT/01, Rev. 00

 3. TESTING OF FASTNERS:

All Fasteners being used for Ramboll Towers must be accordance to IS 1367 or ISO
4014-8.8U-tZn and must be procured only from Suppliers who have been approved
/ recommended by Ramboll. It is not allowed to use different brands in one bolt
connection.

All fasteners must accompany with supplier test certificate along with 3rd party test
results without which all fasteners shall not be considered for use.

All fasteners including studs used for Antenna mounts shall be made with
centrifuged galvanising process and coating thickness shall be as per below:

Diameter of fastness Local coating thickness Mean coating thickness

(minimum in µm (minimum in µm
≥ 20mm 45 55
≥ 6mm < 20mm 35 45

3.1 Bolts Material specifications

All bolts for Ramboll towers must be full threaded and length shall be as per
drawings.

All structural bolts M10 and larger shall be grade 8.8 and stamped with brand name
with clearly showing 8.8 on head of the Bolts.

3.1.1 Proof Loads:

Property Class
Thread Size
4.6 5.6 8.8

M8 8240 10200 21200

M10 13000 16200 33700
M12 19000 23600 48900
M14 25900 32200 66700
M16 35300 44000 91000
M18 43200 53800 115000
M20 55100 68600 147000
M22 68200 84800 182000
M24 79400 98800 212000
M27 103000 128000 275000
M30 126000 157000 337000
M33 156000 194000 416000
M36 184000 229000 490000
M39 220000 273000 586000

Page 10 of 15 DOC/RMT/01, Rev. 00

 3.1.2 Minimum ultimate Tensile loads:

Proof load in N according to Property Class

Thread Size
4.6 5.6 8.8
M8 14600 18300 29200

M10 23200 29000 46400

M12 33700 42200 67400

M14 46000 57500 92000

M16 62800 78500 125000

M18 76800 96000 159000

M20 98000 122000 203000

M22 121000 158000 252000

M24 141000 176000 293000

M27 184000 230000 381000

M30 224000 280000 466000

M33 278000 347000 576000

M36 327000 408000 678000

M39 390000 488000 810000

3.1.3 Mechanical and Physical Properties as per ISO898-1 & IS1367:

Property Class
Mechanical and Physical
8.8
property Units 4.6 5.6
d ≤ 16mm d ≥ 16mm
2
Nominal Tensile strength N/mm 400 500 800 800

Minimum Tensile strength N/mm2 400 500 800 830

Min. HV 120 155 250 255
Vickers Hardness
Max. HV 220 220 320 335

3.2 Dimensional specification – Nuts:

All structural bolts M8 and smaller shall be minimum of 5.6 grades and Nuts of M8
shall be grade 5.

All plain washers for bolts larger than M10 shall be HV 200 (UTS 640 MPa or
N/mm2).

U-Bolts shall be stainless (A2) material with yield strength according to SS2333 or
AISI304 in annealed condition. All nuts shall be stamped with grade and supplier
name.

Page 11 of 15 DOC/RMT/01, Rev. 00

 3.2.1 Proof Loads:

Proof load in N according to Property Class

Thread Size
4 5 8
M8 13900 21600 31800
M10 22000 34200 50500
M12 32000 51400 74200
M14 43700 70200 101200
M16 59700 95800 138200
M18 97900 121000 176600
M20 125000 154400 225400
M22 154500 190900 278800
M24 180000 222400 324800
M27 234100 289200 422300
M30 286100 353400 516100
M33 353900 437200 638500
M36 416700 514700 751600
M39 497800 614900 897900

3.2.2 Mechanical Properties:

Thread Size Mechanical Properties

Stress Under Vickers Hardness
Property Class Greater Less Than
Proof Load HV
than or Equal to
N/mm2 Min. Max.
M7 M10
4 M10 M16 380 188 302
M16 M39
M7 M10 590
130
5 M10 M16 610 302
M16 M39 630 146
M7 M10 940
8 M10 M16 950 188 302
M16 M39 920

Page 12 of 15 DOC/RMT/01, Rev. 00

 3.3 Test Methods:

3.3.1 Tensile Test for machined Test Pieces:

So

r r

do

d
Lo b
Lc
Lt

d = Nominal diameter S0 = Cross section area before tensile test,

d0 = Cross section area before tensile test, Su = Cross section area after fracture
Lc = Length of straight potion (Lo+ do) r = Fillet radius (r ≥ 4mm)
Lt = Total Length of test piece (Lc+2r+b) b = Threaded length (b ≥ d)
Lu = Final gauge length

3.3.2 Proof Load Test For Full Size Bolt and Screw:

Load

dh
1d

X
d

Load

d = Nominal diameter
dh = Hole diameter

Page 13 of 15 DOC/RMT/01, Rev. 00

 3.3.3 Test For Tensile Strength Under Wedge Loading of Full-Size Bolts and
Screws:

(d/2)min.
b

1d

dh
d
r1

r1 = rmax + 0,2 rmax = da max - ds min

2

r = radius of curvature under head d = Nominal diameter

da = Transition diameter ds = Transition diameter
b = Hardness: 45 HRC min. c = Radius or Chamfer of 450
dh = Hole diameter

3.3.4 Proof Load Test For Nuts:

Load

H ardened
h>d

d
dh

A xial C om pressive Test

d = Nominal diameter dh = Hole diameter

h = Nominal Height of Nut

Page 14 of 15 DOC/RMT/01, Rev. 00

 4.1.1 TESTING OF GALVANISING:

4.1 Specification of Zinc Ingot:

Zinc Ingot must be procured from best suppliers and all the specification must be
met as per below chemical composition. Zinc Ingot has generally two grades and
one with 99.99% Zinc & another with 99.95% Zinc.

Specification in Percentage (%)

Constituent
Grade with 99.99% Zinc Grade with 99.95% Zinc
Zinc, Minimum 99.99 99.95

Lead, Maximum 0.003 0.025

Cadmium, Maximum 0.003 0.020

Iron, Maximum 0.003 0.005

Tin, Maximum 0.001 0.001

Copper, Maximum 0.002 0.002

Thallium, Maximum 0.001 -

Indium, Maximum 0.0005 -

Total Impurities 0.01 0.05

3.2 Specification of Zinc Bath:

Constituent Specification in Percentage (%)

Zinc, Minimum 98.5
Lead, Maximum 1.30
Aluminium, Maximum 0.007

Page 15 of 15 DOC/RMT/01, Rev. 00