Standard Operating (Work) Procedure Document No.

KEC-Q-TL-SOP-0016

Revision No. 00
TOWER ERECTION
Sheet No 1 of 24

PROCEDURE FOR TOWER ERECTION WITH GUIDELINES

 Standard Operating (Work) Procedure Document No. KEC-Q-TL-SOP-0016

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TOWER ERECTION
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CONTENTS
S. N. DESCRIPTION PAGE NO.
I COVER SHEET 1
II CONTENTS 2
III ABBREVIATIONS 3
1 PURPOSE 4
2 SCOPE 4
3 EXCLUSION 4
4 APPLICABILITY 4
5 REFERENCE DOCUMENTS 4
6 RESPONSIBILITY 4
7 PRE-REQUISITES 4
8 EQUIPMENT’S & ACCESSORIES 4-5
9 CONSTRUCTION SEQUENCE
a) INSPECTION & SORTINGOUT
b) TREATMENT OF JOINTS
c) ASSEMBLY
d) METHODS FOR ERECTION
e) STEPS IN TOWER ERECTION 5, 6, 7, 8, 9, 10, 11,
f) TIGHTENING & PUNCHING OF BOLTS & NUTS 12, 13, 14, 15 & 16
g) FINAL INSPECTION
h) TACK WELDING OF BOLTS & NUTS & PAINTING
i) REPLACEMENT
j) FIXING ACCESSORIES
k) VERTICALITY CHECKING OF ERECTED TOWER
10 ACCEPTANCE CRITERIA 16
11 SAFETY MEASURES/PRECAUTIONS 16 & 17
12 RECORDS 17
13 ANNEXURE I 18 & 19
14 ANNEXURE II 20 & 22
15 ANNEXURE III 23 & 24
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ABBREVIATIONS

DS - Designated Staff
FQP - Field Quality Plan
PM - Project Manager
QCE - Quality Control Engineer
SI - Store In Charge
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1. PURPOSE:
This document describes the step wise work procedure to carry out the Erection work of 11-132 / 220 / 400 /
765 kV D/C , 800 kV HVDC or other kind of Transmission Line work in planned and controlled manner with
reference to the drawings, technical specification and standards.

2. SCOPE :
This includes Tower Erection for all Types of Towers substructure works as indicated on Technical Specification
/ Drawing. The work shall be carried out in accordance with the specification and corresponding approved
drawings.

3. EXCLUSION :
In case of very specific & mandatory customer’s need their processes & formats can be followed as a part or in
full. However in case of any conflict most stringent norms must be followed.

4. APPLICABILITY:

This procedure is primarily developed for Transmission works but same can be used in similar kind of Test
Station, Railway & Distribution works, at sites across all locations as per specification.

5. REFERENCE DOCUMENTS :
Following Documents / Drawings / Codes have been referred for the preparation of this procedure:
 IS : 5613 (Part 2 / Section 2) - 1985, IS : 5613 (Part 3 / Section 2) – 1989 (Installation of lines)
 IS: 4082-1986 (Storage of construction material at site)
 IS: 7293-1974 (Safety code for working with construction machineries)
 Welding Standards as per requirement (viz. ASME & IS)
 IS: 13416 Part1- 1992 (Falling material hazards prevention), IS: 13416 Part2- 1992 (Fall Prevention)
 A few international standards and recommendation from (Saudi, Africa etc) were also referred.

6. RESPONSIBILITY:
Responsibility of implementation of this procedure rest with below mentioned officials
a) PRIMARY: Section-In-Charge, Site Supervisor, Site Engineer
b) SECONDARY: Project Manager (PM), Quality Control Engineer (QCE), Store in-charge (SI), Surveyor

7. PREREQUISITE:
 Generic Contract Documents (as applicable)
 Field Quality Plan (FQP)
 Foundation Check Report
 Approved Tower Schedule
 Approved Erection Drawings
 Completion of Civil Work
 Availability of tested handling/lifting equipments, tools, tackles.
 Availability of skilled manpower.

8. EQUIPMENT :
 Derrick Pole
 Poly Propylene Ropes - 12 to 32 mm dia. (Depending on the requirement)
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 Winch
 Tirfor
 Chain blocks
 Single way Pulley.
 Hammer
 Ring Spanner
 D Spanner (as per requirement)
 Box Spanner (as per requirement).
 Drift Pins
 Safety Belts
 Centre Punch
 Helmets
 Crow Bar
 Portable Welding Machine
 Mobile Crane
 Helicopter / Drone

9. CONSTRUCTION SEQUENCE :
The later stated construction sequence is followed for the complete erection of tower, for which certain
checks are necessary which are as under stated.
 Material is to be sent to the sites of erection (as per tower schedule) from store with proper indent.
 Indent shall contain the following information –
 Type of tower
 No. of towers.
 Extension, if any
 Type of tower to be erected shall be identified from the Foundation check report / Tower schedule &
the same to be sent to the required location.
 Site to be visited for checking the condition (accessibility of vehicles, water level, ROW issue, etc)
 Forecast for weather conditions to be checked.
 Checking of foundation oldness with respect to the foundation report.
 Towers shall be erected after the concrete is at least 14 days old, but a gap of 28 days shall be
preferred. (IS5613-3-2 14.1). Unless special procedures or technique are followed for early erection.
 INSPECTION & SORTING OUT :

 Complete tower which has been sorted out at stores shall be transported to the above predetermined
work site / location and are unloaded, checked (as per structural drawing / bill of materials) and stacked
at site.
 All the members shall be sorted out properly at the erection site to check that all items are available &
shall be placed in a manner such that they are easily located during erection.
 Any shortage shall be immediately reported to the Section in-charge & PM, which is then reported to
the concerned supply unit thru mail mentioning the reason of shortage.
 The sorting at site involves identifying the members in the sequence of erection as well as to place them
in the respective corners to avoid imbalances during lift and installation.
 The members shall be visually examined for defects in protective surface finish.
 If any defects are found in case of hot dip galvanized members, the damage shall be repaired by applying
two coats of zinc rich paint having at least 90% zinc content after cleaning the surface ensuring the
surface is dry before the application of paint. (IS5613-3-2 14.2)
 Members bent in transit shall be straightened such that the protective surface finish is not damaged.
 Any damaged or wrongfully fabricated members considered unsuitable for sound construction shall be
scrapped & replaced with correct ones.
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 Reaming of holes (if found of less size) shall be done with knowledge to customer & approval of the PM.

 TREATMENT OF JOINTS :
Before starting assembly, specially for the lines in coastal or highly polluted areas, the surfaces at connection
points shall be applied a coat of aluminum or zinc-rich paint in case of galvanized members, and red oxide
or zinc chromate paint in case of painted members. (IS5613-3-2 14.3)

 ASSEMBLY :
Irrespective of the method followed for the erection of towers, the points mentioned below shall be
observed:
 Straining of the members shall not be permitted for bringing them into position. It may, however, be
necessary to match the hole positions at joints and to facilitate this, drift pins not more than 450 mm
long may be used. (IS5613-3-2 14.4 a))
 All plan diagonals relevant to a section of tower shall be placed in position before assembly of upper
section is taken up.
 All bolts shall have their nuts facing outside the tower for horizontal or nearly horizontal bolt
connections and downwards for vertical bolt connections.
 The cross-arms may be assembled on ground facilitating the lifting sequence as; the top cross arm shall
be lifted first, followed by the middle and bottom cross-arms.
 The tips shall be fully tightened before lifting into position.
 Such bolts which are not accessible for tightening by ordinary drift spanners, may be tightened with the
help of box or ratchet ring spanners.
 Preassembly techniques shall consider placement of the assembled sections to provide for the most
efficient, safe lifting for erection.
 Structural assemblies, which are not sufficiently rigid to be raised in one piece, shall be stiffened by
means of adequate temporary bracings or ropes tied to secure movement.
 Towers assembled on the ground shall be placed on suitable blocking so as to be kept free of dirt, mud
or other foreign material that might adhere to the structure or damage the coating.
 Blocking shall be placed in such a manner as to provide a flat surface in order to prevent overstressing
or distortion of members and to maintain the true geometric shape of the assembled members.
 Mud, dirt, white rust and other foreign material shall be removed from the contact surfaces of joints
prior to assembly.
 The diameter, type, and length of bolts as shown on these drawings shall be used for each connection.
 Nuts may be tightened during ground assembly, or they may be partly tightened followed by final
tightening before stringing.
 In extreme cold weather the assembly or erection workers shall exercise care to avoid subjecting
members to sudden stresses, which could cause brittle fractures.
 Care shall be taken to avoid distorting the hole with a drift pin.
 Bolts shall not be driven in any manner that will distort them or damage the threads.
 Tower assembly shall be fitted with number, danger, phase and circuit plates as well as anti-climbing
device(except barbed wire) and bird guards (on suspension towers), as described in the approved
drawing.

 METHODS FOR ERECTION

Towers shall be erected by any suitable method in the sequence best adapted to the equipment, workers’
experience and site conditions which will not overstress structure members.
Generally there are three main methods of erection of steel transmission towers which are described as
below:
1) Air Erection (Erection by Helicopter / Drone)
2) Erection thru Mobile Crane
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3) Manual Erection with Gin pole / Derrick .

 Air Erection (Erection by Helicopter)

This method is generally used in hilly areas where no other means of erection are possible.
 The assembled tower on ground is lifted by the helicopter with sufficient lifting ropes attached to
the lifting holes provided at different level in the structure.
 At times partial sections are erected, as first section which connects to the stub is firstly erected &
then the remaining portion erected in one or two goes.
 The helicopter with lifted assembly hovers over the field, guys are already attached to the required
portion of tower.
 This is then secured to firm ground support by the ground crew, then the required bolted connection
is joined.
 After completely joining the helicopter releases the tower support & flies back to picking location.
 On completion of the erection the guys are released.

Tower Erection thru Helicopter

 Erection Thru Mobile Crane
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This method is generally used in when speeding up of work is required, as it saves a lot of time. Generally
telescopic boom type cranes are suitable since it doesn’t require much time for assembly as in the fixed
boom crane.
 The base for the crane is to be made at appropriate ground, to avoid unbalancing of crane while
lifting.
 Proper way thru is to be made for crane to reach at the erection site.
 The tower assembly (whole or part) is then lifted by the crane with guy wires tied at appropriate
points on tower.
 The assembly is then to be placed at the stubs. While placing it is required to pull the guy ropes for
bringing the joints to the exactly position, which is done manually.
 One or four group of workers will then join the assembly with the stub thru nut & bolts & tighten it.
 After this guy ropes need to be tied to the different anchorage point and properly tensioned as to
provide a support for the erected assembly.
 If the assembly is done in 2-3 portions then the next portion is to be lifted in same manner as stated
above and fitted over the bottom assembly.
 After completion of whole tower erection the guy points can be released up on confirming the
stability of tower.

Tower Erection with Mobile Crane

 Manual Erection by Gin Pole

This method contains erection of tower by using a gin pole & then lifting the parts or panels accordingly.
A gin pole is a boom of steel or aluminum pipe, wood pole or latticed truss secured at its base and usually
inclined at a slight angle to the vertical. Generally the lifting is done in any or combination of the two
ways.
1) Built Up or Piece Meal Method
2) Section Method
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 BUILT UP OR PIECEMEAL METHOD

 This method is most commonly used for the erection of 132 kV, 220 kV and 400 kV transmission line
towers due to the following advantages:
Tower materials can be supplied to site in knocked down condition, i.e. in pieces which facilitates
easier and cheaper transportation.
It does not require any heavy machinery such as cranes, etc.
Tower erection activity can be done in any kind of terrain and throughout most of the year.
Availability of workmen at cheaper rates.
 This method consists of erecting the tower member by member.
 The tower members are first set out and kept on the ground serially according to erection sequence
to avoid time loss due to searching for them as and when required.
 In order to maintain speed and efficiency, a small assembly party can be sent ahead of the main
erection gang for sorting out the tower members, keeping the members in correct position on the
ground and assembling those panels on the ground which can be erected as a complete unit. The
main corner leg members are prepared by fitting all cleats / plates for joints & bracings and step
bolts.
 The erection progresses from the bottom upwards. More than one leg section of each corner leg
may be bolted together at the ground and erected in case they are short in length and light in weight.
 The main legs of the tower to be attached to the stub would be lifted by individual pieces and fixed
with the stubs using the cleats, plates and bolts as per the drawing.
 Since the legs are not self supported at this stage, they would be anchored individually using guyed
ropes diagonally.
 After erections of each leg ensure that the guy must be supported by 32mm crowbar & the angle of
guy must be 30°-45° degree from horizontal.

 After this the lattices & bracings are lifted and joint with each other. This completes erection of base
structure (leg extension or body extension).
 Then the gin pole is to be attached to a suitable corner. With the help of hook provided on gin pole’s
base the leg & pole are fixed together on a support strut.
 Proper care shall be taken to provide soft/cushioning material between the pole & leg member to
avoid abrading of galvanising due to friction & pressure.
 The top of a single gin pole is kept in the center of the structure by suspending it from the leg
members at any elevation using guys & temporary ground anchors.
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 Two wire-guys about 60° to 90° apart in the plan view are attached to the top of the gin pole to
resist or support the load to be lifted.
 For safety, a third, and preferably a fourth guy, is installed in front to prevent the pole from falling
over backward in the event of an unexpected impact or the sudden release of load.
 It is recommended to use 10t capacity turn buckle at the guying support.

 For smaller base towers / vertical configuration towers, one derrick / gin pole is used. For wide based
towers and if one assembled section / panel of the tower is to be erected, then two derricks / gin
poles are placed, one each on the top of diagonally opposite corner legs.
 A rope is passed thru the pulley block attached to the top end of the gin pole & other end from the
pulley block affixed to the bottom of stub. The free end at bottom of stub is tied to the winch for
pulling & the other end is left free for clamping to the members to be lifted.
 First, the leg members of the second section are hoisted and assembled. The temporary rope guys
are shifted to the legs of the second section when they are being raised for erection. The legs of the
second section / storey are kept in position by fixing the temporary rope guys. The bracings of the
second section are then hoisted and assembled.
 The derrick is then shifted to the corner leg member on the top of the second section to raise the
parts of third section of the tower in position for assembly. Derrick(s) / Gin pole(s) and the temporary
rope guys for the leg members are thus moved up as the tower is built up. This process is continued
till the complete tower is erected.
 Ensure that activities are carried out as instructed in the pre-inspection checklist (KEC/Corp EHS/FT-
004/Rev-00)
 The stages in this method of erection are shown overleaf.
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TOWER ERECTION BUILT UP METHOD

ERECTION OF TOWER BODY (FIRST STOREY)

 Cross - arms are assembled on the ground.

 The bird guards and hangers for suspension towers are fitted on the cross - arms.
 A rope is passed through a pulley fixed on the tower peak. The cross - arms are raised up with this
rope and fixed to the main body of the tower.
 The method of erection is shown below.
 For heavier towers, a small boom is rigged on one of the tower legs for hoisting purposes.
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 The members / sections can be hoisted either manually or by pulling with a winch machines
operated from the ground.

 SECTION METHOD
 The major sections of the tower are assembled on the ground and the same are erected as units.
The derrick / gin pole used is approximately 10m long and is held in place by means of guys on the
side of the tower to be erected.
 The two opposite sides of the tower section of the tower are assembled on the ground. Each
assembled side is then lifted clear of the ground with the derrick / gin pole and is lowered into
position on bolts to stubs or anchor bolts. One side is held in place with props or rope guys while
the other side is being erected. The two opposite sides are then laced together with cross members
and bracings / diagonals, and the assembled section is lined up and made square to the line.
 After completing the first section, the derrick / gin pole is set on the top of the first section. The
derrick / gin pole is made to rest on a strut of the tower immediately below the leg joint. The derrick
/ gin pole has then to be properly guyed into position.
 The first face of the second section is raised. To raise the second face of this section, it is necessary
to shift the foot of the derrick / gin pole on the strut of the opposite side of the tower. After the two
opposite faces are raised, the bracings on the other two sides are fitted and bolted up.
 The last lift raises the top of the towers. After the tower top is placed and all side bracings have been
bolted up, all the guy are removed except the one which is to be used to lower the derrick / gin pole.
 Sometimes, one whole face of the tower is assembled on the ground, hoisted and supported in
position. The opposite face is similarly assembled and hoisted and then the bracing angles
connecting these two faces are fitted.
 The cross - arms are assembled and erected in the manner given above.
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Pole Support

Tower Erection Manually

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 STEPS OF ERECTION METHODOLOGY :

 Erection of tower will start from first panel from Ground level i.e. erection progresses from the bottom
/ Stub upwards. Erection of tower shall be done member by member of the first panel. Four main corner
leg members of the first panel of the tower are firstly erected followed by erection of bracings &
redundant of transverse face & longitudinal face. Erection of 2nd panel be continued in the above
manner and immediately after that the Oblique view & Plan view of the First Panel with all plates be
installed & nuts / bolts properly fitted / tightened.

PLAN VIEW OBLIQUE VIEW

 Checks before proceeding for erection of next panel :
 Each & every member of transverse & longitudinal face of first two panels to be erected.
 Each & every member of oblique & plan view of the first panel to be erected.
 Every plate to be fitted in the first & second panel. Every leg joint shall have one inside cleat & two
cover plate fitted with all nuts/bolts tightened as per approved drawings.
 All Nuts/bolts of proper size & length to be fully fitted & completely tightened. No hole should be
vacant without nuts / bolts.
 Before tightening it shall be ensured that spring washers & pack plates are placed in relevant gaps
between the members as shown in the drawing.
 Erection of third panel should not be started before completion of all the above in the bottom panels in
all aspects and visual verification / confirmation.
 Similarly all panels up to waist levels to be erected as per the above steps / process.
 After erection of tower up to waist level, all nuts/ bolts to be fully tightened completely. Erection of cage
to be done as mentioned below :
 Four main corner leg members of the cage of the tower are firstly erected followed by erection of
bracings & redundant of transverse face & longitudinal face of the cage, Oblique view & Plan view (
if any) with all plates to be installed & nut/bolts Properly fitted.
 Checks before proceeding for erection of X-arms & Peak are similar to as stated above.
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 Erection of X-arms should not be started before completion of Cage in all aspects and visual
verification and certify for next panel erection.
 All X-arms & peak to be completely assembled at Ground with all nuts & Bolts tightened completely.
 Assembled X-arms & Peak shall be uplifted to the respective cage level (Starting from Top to bottom)
and fitted with all plates & nuts / bolts tightened completely.
 After complete erection of the tower, all blank holes, if any, are to be filled by bolts and nuts of
correct size.
 TIGHTENING AND PUNCHING OF BOLTS AND NUTS :
 Once the entire tower is installed, the next would be to set out a team for the tightening of all the bolts
and also to ensure that all the members are in place.
 All empty holes are to be filled in with nut and bolt of appropriate size and a spring washer.
 All nuts shall be tightened properly using correct size spanners.
 Before tightening it should be seen that filler washers and plates are placed in relevant gaps between
members, bolts of proper size and length are inserted, and one spring washer has been inserted under
each nut. In case of step bolts, spring washer shall be placed under the outer nut.
 The tightening shall progressively be carried on from the top downwards, care being taken that all bolts
at every level are tightened simultaneously.
 It may be better to employ four persons, each covering one leg and the face to his left.
 The threads of bolts projecting outside nuts shall be punched at three positions on the diameter to
ensure that the nuts are not loosened in course of time & on the treads of the bolts deep enough not to
give room of loosening under any circumstances.
 Suitable punches to create three impressions must be used. This will be implemented till the ACD level
(may vary according to client specs).
 If during tightening a nut is found to be slipping or running over the bolt threads, the bolt together with
the nuts shall be changed outright.
 FINAL INSPECTION

Even after the full completion of the erection of tower, implement a process of checking the same, section
wise before the tacking welding works to ensure that the tower is in perfect condition for taking the loads
during the stringing operations.

 TACK WELDING OF BOLTS AND NUTS & PAINTING:

 Welder must be qualified for welder test before performing Tack welding as per client’s requirement.
 Welding electrode must be equivalent to specifications of customer or standards (e.g. code AWS-E6013
of 2.5 to 3.5mm diameter maximum) & also of a reputed make. Local make of welding electrodes are
not acceptable (may vary from client to client).
 The threads of all the bolts, projected outside the nuts shall be welded at two / three diametrically
opposite places. The circular length of each welding shall be at least 10mm / 6mm (may vary from client
to client).
 The welding shall be provided from ground level to bottom cross arm for double circuit towers. However,
for river crossing towers, the welding shall be provided from ground level to 30m height from stub level.
(May vary from client to client).
 After welding zinc-rich paint with at least 90% zinc content shall be applied to the welded portion. At
least two coats of the paint shall be applied. (IS5613-14.5.2)
 REPLACEMENT
 If any replacements are to be effected after stringing and tensioning or during maintenance, leg
members and material bracings shall not be taken out without reducing the tension of the tower with
proper guying or releasing the conductor. If the replacement of cross-arms becomes necessary after
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stringing, the conductor shall be suitably tied to the tower at tension points or transferred to suitable
roller pulleys at suspension points.
 FIXING OF ACCESSORIES
 The U-Bolts for earth wire suspension hardware are fitted on the top plate of the suspension towers.
 The supports for the anti - climbing device are fitted on the main corner legs of all the towers. The anti
- climbing devices (Flats with edges cut to a sharp point) are installed after the stringing work has been
completed.
 The number plates are fitted at the place provided for them on the face of the tower.
 Wherever there are roads near the tower, these should be fitted on the face from which they can be
seen from the road.
 The phase plates are fitted on the holes provided for them on the top leg of the cross – arms if the phase
sequence is known at the time of erection of towers. Otherwise, these are fitted after the phase
sequence is finalized.
 VERTICALITY CHECKING OF ERECTED TOWERS:
 The finally erected tower shall be truly vertical after erection and no straining is permitted to bring it in
alignment.
 The verticality of the tower is checked using a theodolite/total station placed away from the tower but
in the longitudinal and transverse center lines of the tower.
 The tolerance limit for verticality shall be maximum one in 360. (IS5613 C4.2)

10. ACCEPTANCE CRITERIA

 Conformity to assembly as per approved drawing.
 Conformity to no Mismatch of holes.
 Conformity to Verticality & Water Level.
 Conformity to Tightening of Nuts Bolts should be as per torque requirement.
 Conformity to Tack Welding & Painting as per requirement.

11. SAFETY MEASURES/PRECAUTIONS:

 Ensure that checks are carried according to the pre-inspection checklist (KEC/Corp EHS/FT-004/Rev-00)
 Weather forecasting is to be seen before starting the erection work.
 Ensure that erection is started after clearance of foundation for tower erection.
 The material to be loaded at store according to the latest bill of material of the tower, with no mismatch.
 The material to be tied properly so that it does not fall during transportation.
 Material unloading at site to be carried out with safety.
 Adequate warning signals, notice boards, etc should be depicted at or near the working place, highlighting
the danger involved in non-observance of safety rules.
 Before start of the job the condition of the stub to be checked by means it is not in loose condition.
 All persons must wear Safety shoe, helmet. Those are going up shall wear double lanyard safety harness
along with rope grab fall arrestor. No deviation to be done for working at height.
 In each stub one by one leg to be installed and the leg to be supported with three guy rope so that it should
not topple.
 From each leg the bracing members to be erected. To stabilize the leg in the first leg member all the bracing
members to be connected.
 Before bringing the derrick pole at site it shall be ensured by the store that the third party certification for
the derrick pole is completed. Once the derrick pole dispatched for the site a copy of third party certificate
to be dispatched.
 In each leg the double / triple sheaving pulley to be installed to pull the derrick pole.
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 The ropes to be installed in the pulley prior to the tying of pulley in the leg member.
 Simultaneously the fall arrestor rope is also to be installed in the leg and every person those who are climbing
shall hook there rope grab fall arrestor.
 At the time of leg member erection a retractable fall arrestor is to be fixed, so that while climbing for fixing
the life line rope the person can use the retractable fall arrestor initially. Once one tier gets over the
retractable fall arrestor can be shifted to next level.
 While moving from point to point 100% safety harnesses hooking to be ensured and double lanyard harness
is to be ensured always.
 Use of tractor for pulling is to be prohibited at site.
 While using a winch it should be ensured that the rotating parts are properly fenced.
 Winch to be operated by competent person only.
 The gang leader shall give the signal for pulling or loosening of the ropes in different points.
 Only in case of any unwanted situation the stop signal can be given by any person.
 Once the member is lifted to the required position unless it is fixed with the load bearing member, in no
situation the load shall be release.
 At the time of lifting the bracing assembly persons shall be away from the lifting area. Once the assembly
reaches to a particular place near to the fixing point, then only persons shall go near the fixing point.
 While lifting the cross arm, in no case the load should go to tower top. A diversion pulley is to be fixed and
only from bottom the pulling needs to be performed.
 The bolts are to be carried in the tool bag at height. While climbing it should not be carried. It should be
pulled up with rope from ground so that chances of fall material can be reduced.
 Ensure that unless all the members tightened up to the required torque the stringing activity shall not be
started even hanging of insulators shall not be done.

12. RECORDS :
 Erection Check List (KEC-Q-TL-SA-CL-0017) (Annexure I)
 Standard Operating (Work) Procedure Document No. KEC-Q-TL-SOP-0016

Revision No. 00
TOWER ERECTION
Sheet No 18 of 24

ANNEXURE I
Checklist:

Document No. KEC-Q-TL-SA-CL-0017

CHECKLIST Rev. No 00
KEC / Client Name / Project
TOWER ERECTION Report No.
/ Location No. / 001
PROJECT :
CLIENT NAME :
1. LOCATION NO. Date:
2. TYPE OF TOWER
3. TYPE OF FOUNDATION
4. APPROVED DRAWING NO.
S.N. Item Checked Results Observations
Before Erection
Setting period of foundation is allowed for at least 14 days as per
1 Yes / No.
specification.
2 Weather conditions are favorable to commence work. Yes / No.
All tested tools and plants, safety equipment’s in working conditions
3 Yes / No.
are available at site.
All equipments to be used for erection are tested, certified & in god
4 Yes / No.
working condition.
All tower members, Nuts / bolts are available at site without any
5 damage, bent or rusting and kept serially according to erection Yes / No.
sequence.
Benching / revetment, if any, completed. If not, then program of
6 Yes / No.
completion.
7 Shut down of power line, if required, is arranged. Yes / No.
Required no. of safety helmets, safety belts & safety shoes are being
8 Yes / No.
used.
Guying of tower provided as per approved drawings and norms.
9 Yes / No.
Guying to be terminated on firm ground.
Mid & Post Erection
Subsequent section are erected only after complete erection and
10 Yes / No.
bracing of previous section.
Any undue stress, bending or damage of member during erection
11 Yes / No.
noticed.
12 Any substitute of tower member erected, if yes, member nos. Yes / No.
All nuts/bolts, flat/spring washers are provided as per approved
13 Yes / No.
drawings.
All bolts to have the nuts facing outside for horizontal or near
14 horizontal bolt connections and downwards for vertical bolt Yes / No.
connections.

Page 1 of 2
 Standard Operating (Work) Procedure Document No. KEC-Q-TL-SOP-0016

Revision No. 00
TOWER ERECTION
Sheet No 19 of 24

15 Filing of holes or cutting of members during erection observed. Yes / No.

16 Any heavy hammering of bolt causing damage of threads noticed. Yes / No.

17 Tightening is done progressively from top to bottom. Yes / No.

All bolts at same level on all the four faces tightened simultaneously
18
starting from leg to face on right side by four individuals.

19 Slipping / running over nuts / bolts are replaced by new ones. Yes / No.
Threaded portion of bolts projected outside of nut is not less than 3
20 Yes / No.
mm and not more than 8 mm.
Punching of threads projected outside is done at three positions on
21 Yes / No.
dia.
Tack welding of nuts at two diametrically opposite places up to the
22 bottom cross arm and each weld length at least 10 mm or as per Yes / No.
requirement.
23 Zinc rich (atleast90% zinc content) on the tack welds on the nuts Yes / No.
24 Details of missing member, nut, bolts etc. Yes / No.
25 Remarks (If Any)

(Site Supervisor / Engineer) (QA / Q C Engineer) (Site Supervisor / Engineer) (QA / QC Engineer)
for KECIL for KECIL For CLIENT FOR CLIENT

Page 2 of 2
 Standard Operating (Work) Procedure Document No. KEC-Q-TL-SOP-0016

Revision No. 00
TOWER ERECTION
Sheet No 20 of 24

ANNEXURE II
Dos & Don’ts:
Right Wrong

All Members Properly Assembled Member Missing

No Bend Members Member Bend

Proper Welding Improper Welding

 Standard Operating (Work) Procedure Document No. KEC-Q-TL-SOP-0016

Revision No. 00
TOWER ERECTION
Sheet No 21 of 24

Dos & Don’ts:

Right Wrong

Proper Identification No Identification

Use of Winch for Erection Use of Tractor for Erection

 Standard Operating (Work) Procedure Document No. KEC-Q-TL-SOP-0016

Revision No. 00
TOWER ERECTION
Sheet No 22 of 24

Dos & Don’ts:

DOs DON’Ts
Keeping material at right place and above ground. Keep material unevenly & in mud.

No force fitting done while assembling. Members are force fitted during assembly.

No bolts are hammered for fitting. Hammering for penetration of bolts done.

Exact size of bolt & nuts used as per drawing Any size of bolts & nuts are used for fitting.

Winch used for lifting the material Tractor used for lifting the material

All members as per drawing are fitted. Certain members are left to be assembled.

Proper packing between the gin pole & tower leg is No packing between gin pole & tower leg is
provided. provided.

All nuts are properly punched & tack welded. Improper punching & tack welding done.

Bent or wrongly fabricated member used for quick

No bent or wrongly fabricated member used.
completion of work.

Final checking is done after tower erection Final checking isn’t carried out after tower erection.

All lifting equipments are properly checked for any No checking or partial checking of lifting equipment
defect before start of work. is done before start of work.
 Standard Operating (Work) Procedure Document No. KEC-Q-TL-SOP-0016

Revision No. 00
TOWER ERECTION
Sheet No 23 of 24

ANNEXURE III
Pre-Inspection Checklist:

Pre-Inspection Checklist for Tower Erection

KEC/Corp EHS/FT-004/Rev-00
Date of Inspection :
Name of Line and Location Number:
PM/Construction Manager/Engineer:
EHS Manager /Engineer/Officer :
S. NO. Check point Status Remark, IF Any
Backfilling of foundation soil completed before taking up
1
tower erection.
Proper shutdown to be taken during erection work (as &
when required )accordingly massage to be
2
communicated to all worker apart from this Discharge rod
to be use for shutdown line.
Access to be clear and safe to reach the destination, and
3
excavated pit or undulation of the land should be cleared.

Derricks and other Tools & Plants like wire rope, rope, D-
4 shackle, pulleys etc. to be used for erection work , it must
be of good quality, of sufficient capacity for the job.

Only tested lifting equipment, tools & tackles to be used

5
for erection work and record available.
6 All lifting T&Ps must be color code.
Visual inspection of Polypropylene / Fiber rope before
7
use like strength of rope, free from damage, no joint etc.
Visual Inspection of wire rope slings before use like sling
8
not corrosion, bend without cracking, no wire cut etc.
Visual Inspection of pulley before use like side flat size
not more than 08 mm, gap between roller and side not
9
more than 33mm, proper locking and safety pin in open
type pulley.
Visual Inspection of D-shackle before use like pin in
10
seated, identification of load, check the wear etc.
11 Whether all members of tower reach at site.
12 Precaution during slinging on sharp edges
13 Proper tag line is used for guiding lifting loads
All tie members/ diagonal members are fitted as the
14 tower is erected progressively upward to avoid uneven
transmission of loads.
All Nuts & Bolt of stub are fitted in tower and are
15
reasonably tightened.
Adequate guying arrangement provided at different levels
16 to ensure proper stability of the tower being erected
progressively.
 Standard Operating (Work) Procedure Document No. KEC-Q-TL-SOP-0016

Revision No. 00
TOWER ERECTION
Sheet No 24 of 24

Proper size and length of crowbars for guying. If there

17 are loose soil angles or channels to be provided. Driving
of crowbar to sufficient safe depth
18 Cross arm lifted with minimum 2 sheave pulleys
The derricks are provided minimum 3 number guys ropes
19
and to prevent form slipping.
In case erection of tower is done with central derrick / gin
20 pole, adequate precautions are taken for guying /
anchoring arrangement.
21 The bolts to be carried in the tool bags at height.
All step bolts have been available at site and properly
22
tightened.
Whether adequate precautions are taken when working
23
near Road/Rail/River/Adjoining Power Line.
Appropriate safety messages / posters / warnings are
24
displayed at site to caution the workers
Cordoning on all sides displaying Red Flags / Tape/ Light
25 and warning signs for restricted to public / children
moving nearby.
Ensure no harm on environment/ nature like animals
26
during the tower erection.
Ensure area must be neat & clean after completion of
27
work
Remove all unwanted material from site like bolts,
28
washers, carry bags, etc.
Ensure no chemical contamination of soil or water leave
29
at site.
Good housekeeping to be maintained & avoid to keep the
30
material on the walkway
Adequate no. of fitter / ground helper are deployed for the
31
tower erection work.
Whether adequate working in the ground are sufficiently
32
away from the tower when erection in progress?
Whether adequate precaution Job safety analysis and its
33 proper action are taken when working near shut down
work / Road / Rail / River / Adjoining power line
34 Any other::
35 Any other:
36 Any other:
Comments / Remarks:

Note : No work carried out with short contingency deviation, It must cascaded to senior management, so if it is minor
deviation than need to be approval from Regional EHS Manager / RM, or if it is major deviation than need to be
approved corporate South Asia / T&D-EHS.

(PM/CM/Engineer) (EHS Manager/Engineer/officer)