STANDARD SPECIFICATION OF TRANSMISSON LINE

(SECTION-TOWER: MATERIALS, FABRICATION, ERECTION

& STRINGING)

SECTION-IVC

TOWER: MATERIALS, FABRICATION,

ERECTION & STRINGING
STANDARD SPECIFICATION OF TRANSMISSON LINE
(SECTION-TOWER: MATERIALS, FABRICATION, ERECTION
& STRINGING)

TECHNICAL SPECIFICATIONS

SECTION-IV C

TOWER: MATERIALS, FABRICATION, ERECTION & STRINGING

Revision History
Revision Date Clause Ref Description
No.
Rev-0 June’2021 First Release

Rev-1 Sept’2021 First Revision

Rev-2 Jan’2022 Second Revision

Rev-3 Feb’2022 Third Revision

Rev-4 July’2022 Fourth Revision

Rev-5 Aug’2022 Fifth Revision

Rev-6 April’2023 Sixth Revision

Rev-7 Dec’2023 Seventh Revision
Rev-8 Jan’2025 Eight Revision
Rev-9 Jan’2025 Ninth Revision
STANDARD SPECIFICATION OF TRANSMISSON LINE
(SECTION-TOWER: MATERIALS, FABRICATION, ERECTION
& STRINGING)

TECHNICAL SPECIFICATIONS

SECTION-IV C

TOWER: MATERIALS, FABRICATION, ERECTION & STRINGING

CONTENTS

Clause No. Description Page No.

1.0 Transmission Tower Materials 1

2.0 Inspection & Tests 26

3.0 Tower Erection, Stringing and Installation of Line Materials 26

4.0 Field Quality Plan 40

5.0 Manufacturing Quality Plan 40

Annexure-I Test Procedures for Bird Flight Diverters 43

Annexure-II Site Acceptance Testing (SAT) for FO Cabling 46

Appendix I List of Major T&P used in Tower Erection & Stringing

Appendix II Pre–Commissioning procedures for Transmission lines

Appendix III Manufacturing Quality Plan for Transmission lines

 STANDARD SPECIFICATION OF TRANSMISSON LINE
(SECTION-TOWER: MATERIALS, FABRICATION, ERECTION
& STRINGING)

TECHNICAL SPECIFICATIONS
SECTION- IV C
TOWER: MATERIALS, FABRICATION, ERECTION & STRINGING

1.1 Transmission Tower Materials

1.1.1 Tower Steel Sections
For Non-Snow Regions, IS Steel Sections including plates of any tested quality A,
B0 or BR in conformity with IS 2062:2011 corresponding to grade E250
(Designated Yield Strength 250 MPa) and/ or grade E350 (Designated Yield
Strength 350 MPa) may be used in towers, extensions, stubs and stub setting
templates. For Snow Regions, IS Steel Sections including plates of tested quality C
in conformity with IS 2062:2011 corresponding to grade E250 and/or E350 shall
be used. The Contractor can use other equivalent grade of structural steel angle
sections and plates conforming to latest International Standards viz BSEN 10025.
However, use of steel grade having designated yield strength more than that of
EN 10025 grade S355 JR/JO (designated yield strength 355 MPa) is not permitted,
unless otherwise indicated in this specification.
Steel plates below 6mm size exclusively used for packing plates/ packing washers
produced as per IS 1079 (Grade-0) are also acceptable. However, if below 6mm
size plate are used as load bearing plates viz gusset plates, joint splices etc. the
same shall conform to IS 2062 or equivalent standard meeting mechanical
strength/ metallurgical properties corresponding to grade E250 or above grade
(designated yield strength not more than 355MPa), depending upon the type of
grade incorporated into design. Flats of equivalent grade meeting mechanical
strength/ metallurgical properties may also be used in place of plates for packing
plates/ packing washers. The chequered plates shall conform to IS 3502. SAILMA
350HI grade plate can also be accepted in place of HT plates (EN 10025 grade S355
JR/ JO/ IS 2062:2011– grade E350, as applicable) provided SAILMA 350HI grade
plate meet all the mechanical properties of plate as per EN 10025 grade S355
JR/JO (designated yield strength 355 MPa)/ IS 2062:2011–grade E350. While
selecting equivalent grade, requirement of IS 2062 for particular grade has to be
fully complied. Further, material shall be imported from the manufacturers having
valid BIS license.
During execution of the project, if any particular section is not available, the same
shall be substituted by higher section/ Grade. Any cost on account of the same
shall be borne by the Contractor. However, design approval for such substitution
shall be obtained from the Employer before any substitution and records of such
substitutions shall be maintained by the Contractor.

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(SECTION-TOWER: MATERIALS, FABRICATION, ERECTION
& STRINGING)

1.1.2 Fasteners: Bolts, Nuts and Washers

1.1.2.1 All tower members shall be joined together with Hexagonal Bolts and nuts. All
hexagonal bolts and nuts shall conform to IS 12427. They shall have hexagonal
head and nuts, the heads being forged out of the solid, truly concentric, and
square with the shank, which must be perfectly straight.
All bolts and nuts shall be galvanized as per IS 1367 (Part-13)/IS 2629.
1.1.2.2 The bolt shall be of 16/ 24 mm diameter and of property class 5.6 as specified in
IS 1367 (Part-III) and matching nut of property class 5.0 as specified in IS 1367
(Part-VI). Alternatively, contractor may use 12mm diameter of property class 6.8
in place of 16 mm diameter bolts. However use of both 12 mm and 16 mm
diameter bolts simultaneously in the same package is not permitted. Matching
Nut for 12 mm diameter bolts shall be property class 6 as specified in IS 1367
(Part-VI).
1.1.2.3 Bolts up to M16 and having length up to 10 times the diameter of the bolt should
be manufactured by cold forging and thread rolling process to obtain good and
reliable mechanical properties and effective dimensional control. The shear
strength of bolts for 5.6 grade should be 310 MPa minimum as per IS 12427. The
shear strength of bolts for 6.8 grade should be minimum 372 MPa. Bolts should
be provided with washer face in accordance with IS 1363 (Part-I) to ensure proper
bearing.
1.1.2.4 Nuts for hexagonal bolts should be double chamfered as per the requirement of
IS 1363 Part-III. It should be ensured by the manufacturer that nuts should not be
over tapped beyond 0.4mm oversize on effective diameter for size up to M16.
1.1.2.5 Fully threaded bolts shall not be used. The length of bolts shall be such that the
threaded portion will not extend into the place of contact of the members.
1.1.2.6 All bolts shall be threaded to take the full depth of the nuts and threaded for
enough to permit firm gripping of the members, but not further. It shall be
ensured that the threaded portion of each bolt protrudes not less than 3mm and
not more than 8mm when fully tightened. All nuts shall fit tight to the point where
the shank of the bolt connects to the head.
1.1.2.7 Flat and tapered washers shall be provided wherever necessary. Spring washers
shall be provided for insertion under all nuts. These washers shall be steel
electrogalvanised, positive lock type and 2.5 mm in thickness for 12mm dia bolt
,3.5mm in thickness for 16mm dia bolt and 4.5mm for 24 mm bolt.
1.1.2.8 To avoid bending stress in bolts or to reduce it to minimum, no bolt shall connect
aggregate thickness of members more than three (3) times its diameter.
1.1.2.9 The bolt positions in assembled towers shall be as per structural drawing.
1.1.2.10 Bolts at the joints shall be so staggered that nuts shall be tightened with spanners
without fouling.
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1.1.2.11 To ensure effective in-process Quality control it is desirable that the manufacturer should have in house
testing facility for all tests like weight of zinc coating, shear strength and other tests etc. The manufacturer
should also have proper Quality Assurance System which should be in line with the requirement of this
specification and IS 9001 series Quality System Standard.
1.2 Design and Drawings

1.2.1 In case design of tower is covered in the scope of Contractor: -

1.2.1.1 The following design calculation and drawings are required to be furnished to the
Employer
A) Alongwith the bid:
i) Detailed design calculations and drawings for A/DA/QA (as applicable)
type tower of any one wind zone applicable for each of the package
quoted by the Bidder
ii) Line diagram of all the tower types indicating live metal clearances,
ground clearance, mid span clearance, shielding angle etc. as applicable
in the package.
iii) Typical foundation sketches adopted for various types of soil. Bidder has
to furnish along with the bid one sample calculation for one type of
foundation for Towers at A i) above.
The above is for assessing the present design capability of the Bidder and
should not be construed as review/ approval of correctness of drawings/
designs by the Employer. Subsequent to the award, successful Bidder shall
have to comply with the technical specifications irrespective of the
designs/drawings submitted at the bidding stage without any financial
implication to the Employer.
B) After award of contract:
The Contractor shall submit detailed design of tower & extension
alongwith stress diagram/ computer output together with sample
calculations for few critical members etc., stub templates and loading/
rigging arrangement of tower testing to enable the Employer to make a
preliminary check regarding structural stability of tower (before) tests.
In case, contractor proposes to use tested design of tower/ towers
meeting all technical specification stipulations, the approved copy of
design/ drawing of tower from utility along with proto type test report
shall be submitted to purchaser for approval.
1.2.1.2 After successful testing of the tower and subsequent approval of design, drawings
and bill of materials, the Contractor shall submit the documents to the Employer
for necessary distribution with in fifteen (15) days after approval of drawings:

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& STRINGING)

a) Detailed design calculation and drawing for towers and foundations.

b) Detailed structural drawings indicating section size, length of members, sizes
of plates along with hole to hole distance & joint details etc.
c) Bill of materials,
d) Shop drawings showing all details relevant to fabrication including cutting
and bending details against each member.
e) All the drawings for the tower accessories.
1.2.2 In case of Employer design tower: -
1.2.2.1 The relevant drawings for all the towers and their extensions shall be furnished to
the Contractor by the Employer which shall include structural drawings/ erection
drawings and/ or shop fabrication drawings, Bill of Materials for all the towers and
their extensions as well as construction drawings for foundations.
1.2.2.2 The tower members can be directly fabricated from the structural/ erection
drawings wherever the required fabrication details are provided on the same or
shop fabrication drawings. However, if the contractor is required to prepare shop
fabrication drawings, of their own, in addition to the structural/ erection drawings
with required fabrication details, they may prepare the same without any additional
financial implication to Employer.
1.2.3 Proto Assembly:
i) Contractors, who have not done the proto-assembly of the towers/ tower
extensions or have not supplied the same towers/ tower extensions
against any earlier POWERGRID’s project, shall before taking up mass
fabrication, the Contractor shall arrange for one number proto assembly
for each type of towers and extensions. POWERGRID reserves the right to
get the same witnessed by their representative. After proto-assembly, the
contractors, shall incorporate revisions in the drawings/ documents if any
on account of proto corrections, and make necessary endorsement with
reference to the respective packages/ Letter of Awards. The revised
drawing/ documents shall be submitted for final approval by the
Employer.

ii) The contractors who have already done the proto-assembly of the towers/
tower extensions or have supplied the same towers/ tower extensions
against any earlier POWERGRID’s project need not do the proto assembly.
They shall submit documentary evidence viz. proto-inspection reports,
supply records etc. in its support. However, they may do the proto-
assembly for their verification and satisfaction. Further, they shall submit
the structural drawings and BOM of tower/ tower extensions after
endorsing the projects name for further distribution by Employer.
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& STRINGING)

Alternatively, in place of physical proto assembly (as specified in (i) and (ii) above),
contractor may also carry out proto assembly using any suitable software/3D
modelling software.
No payment shall be made to the Contractor on the account of proto-assembly
in either of the cases mentioned at (i) or (ii).
In any case, the onus of correct fabrication / fitment of tower parts shall lie with
contractor. Any defect, if found during erection at site, the same has to be
rectified by the contractor without any additional financial implication to
POWERGRID.

1.2.4 All the drawings shall have a proper name plate clearly displaying the name of
Employer on right hand bottom corner. The approval for exact format of the
nameplate shall be provided to the successful bidder for incorporation of the same
on all the drawings.
1.2.5 The Contractor is required to submit the drawings as mentioned in clause 1.5.1 for
Employer’s approval. While submitting the designs, structural drawings, bill of
materials and any other drawing pertaining to the subject transmission line, the
Contractor shall clearly indicate on each drawing POWERGRID Specification No.,
Name of the transmission line and project, letter reference No. and date on which
the submission are made. The same practice is also to be followed while submitting
distribution copies.
1.2.6 The tower accessories drawings like Number plate, Danger plate, phase plate,
Circuit Plate, Anti-climbing device, Pole plate, Step Bolt and Earthing Arrangement
have been standardized (except Bird Guard) and are enclosed in drawing section of
this specification. The contractor is required to submit distribution copies of the
above drawings after endorsing the name of the projects. However, drawing of Bird
Guard, D-shackle etc. shall be prepared by the Contractor and shall be submitted to
the Employer for approval.
1.2.7 The drawings submitted by the Contractor shall be approved/ commented by the
Employer as the case may be within fifteen (15) days of receipt of drawings in
Employer office. If the designs/ drawings are commented by the Employer, the
Contractor shall submit revised design/ drawings duly incorporating all comments
within fifteen (15) days of date of issue of comments.
The mass fabrication shall be taken up from the shop drawings. The overall
responsibility of fabricating tower members correctly lies with the Contractor only
and the Contractor shall ensure that all the tower members can be assembled/
fitted while erecting without any undue strain on them.

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& STRINGING)

1.2.8 The Contractor is required to furnish the progress of submissions and approvals of
designs and drawings on twenty fifth day of every month till the completion of all
the design activities.
The details shall include description of design/ drawing, schedule date of
submission, actual date of submission, schedule date of approval, actual date of
approval, schedule date of submission of distribution copies, actual date of
submission of distribution copies, schedule date of tower test, actual date of tower
test and ‘Remarks’ column. Provision of six additional columns shall also be made
in the above progress report to indicate date of comments issued by the Employer
and details of submission of revised designs/ drawings.
1.2.9 Other than the items indicated above, some other drawings and documents such as
BOM, Shop drawings, structural drawings for towers/ extensions which are required
for the project, shall also be developed by the Contractor based on single line
diagram provided by the Employer. However, no extra cost on this account shall be
payable to the Contractor.
1.3 Tower Accessories
Arrangement shall be provided for fixing of all tower accessories to the tower at
a height between 3.5 meters and 4.5 meters above the ground level.
1.3.1 Step Bolts & Ladders
Each tower shall be provided with step bolts as per drawing enclosed in the
section of drawing. The step bolts conforming to IS 10238 of not less than 16mm
diameter and 175 mm long, spaced not more than 450 mm apart and extending
from 3.5 meters above the ground level to the top of the tower. However, the
head diameter shall be 35mm as indicated in the enclosed drawing. The step bolt
shall be fixed on two diagonally opposite legs up to top of the towers for single,
double and multi circuit towers. Each step bolt shall be provided with two nuts on
one end to fasten the bolt securely to the tower and button head at the other end
to prevent the feet from slipping away. The step bolts shall be capable of
withstanding a vertical load not less than 1.5 KN. For special river crossing towers,
ladders alongwith protection rings as per the Employer approved design shall be
provided in continuation of the step bolts on one face of the tower from 30 meters
above ground level to the top of the special structure. From 3.5m to 30m height
of super structure step bolts shall be fixed on two diagonally opposite legs.
Suitable platform using 6mm thick perforated chequered plates alongwith
suitable railing for access from step bolts to the ladder and from the ladder to
each cross-arm tip and the ground wire support shall also to be provided. The
platform shall be fixed on tower by using counter-sunk bolts.
1.3.2 Insulator Strings and Earth wire Clamps Attachments

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& STRINGING)

a) For the attachment of suspension Insulator string, if required a suitable

dimensioned swinging hanger on the tower shall be provided so as to obtain
specified clearances under respective swinging condition of the strings. The
hanger, extensions links, D-shackles etc. as required shall be of same rating/
strength as that of corresponding rating/ Ultimate tensile Strength of Insulator
string. The design and supply of hanger, D-shackles, strain plate, extension link
etc. are also in the scope of Contractor.
b) At tension towers, strain plates of suitable dimensions under each cross-arm
tip, shall be provided for taking the hooks or D-shackles of the tension
insulator strings. Full details of the attachments shall be provided to the
contractor. To achieve requisite clearances, if the design calls for providing
extra D-shackles, link plate etc. before connecting the insulator string the
same shall be supplied by the Contractor. These items shall be same
rating/strength as that of as that of corresponding rating/ Ultimate tensile
Strength of Insulator string.
c) D shackles, if required for attachment of Insulator strings, shall be supplied by
the contractor from the identified and approved sub-vendor/ supplier of
Hardware fittings.
1.3.3 Earth wire Clamps Attachments
For Suspension and tension clamp for attachment of earthwire, wherever
required, the Contractor shall supply U–Bolts, D–Shackles etc. for attachment of
clamp to the tower. Full details of the attachments shall be provided to the
contractor. These items shall be same rating/ strength as that of corresponding
rating/ Ultimate tensile Strength of earthwire suspension/tension clamp.
1.3.4 Anti climbing Device
Barbed wire type anti climbing device, as per enclosed drawing shall be provided
and installed by the Contractor for all towers. The barbed wire shall conform to IS
278 (size designation A1). The barbed wires shall be given chromating dip as per
procedure laid down in IS 1340
1.3.5 Danger, Number, Circuit and Phase plate
Danger Plates, Circuit plates, Phase Plates and Number plates shall be provided
and installed by the Contractor. These Danger/ Number/Phase/ Circuit Plate shall
be as per the drawings enclosed in the section of drawing. The contractor shall
submit distribution copies of the same endorsing the package details (i.e. line
name, LOA No. etc.) and installed by the Contractor.
a) Each tower shall be fitted with a danger plate, number plate, circuit plate
and a set of phase plates for single circuit tower and two sets of phase plates
for double circuit tower. The transposition towers should have provision of
fixing phase plates on both the transverse faces.
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b) The letters, figures and the conventional skull and bones of danger plates
shall conform to IS 2551 and shall be in a signal red on the front of the plate.
c) The corners of the danger, number and circuit plates shall be rounded off to
remove sharp edges.
d) The letters of number and circuit plates shall be red enameled with white
enameled background.
1.3.5.1 Bird Guard
To prevent birds perching immediately above the suspension insulator strings (I
type/ V type) and fouling the same with dropping, suitable bird guards shall be
provided on all suspension towers. In case of I string Bird Guard as per IS 5613
shall be provided at cross arm tips. In case of V string, saw type Bird Guard shall
be provided on all the members/ redundant members provided on Top and
Bottom plan of cross arm/ Girder/ BOOM/ Beam of Suspension. The typical
drawing of Bird guard is attached at the drawing section of this specification.
Suitable provision of cleat/ plate to be provided on all Suspension towers
facilitating installation of bird guard after stringing.
1.3.6 Aviation Requirements
1.3.6.1 Aviation requirements viz Span marker, night marker (obstruction light) and
painting of towers conforming to IS 5613 shall be in the scope of Contractor,
wherever indicated in BPS.

1.3.6.2 Night Markers (Obstruction lights)

1.3.6.2.1 The scope of night markers covers the design, manufacture, testing at
manufacturers works, if any, supply, delivery, erection, testing and
commissioning of medium intensity, low intensity, lights along with storage
battery & solar panel, control panel, cables, clamps other accessories etc. as per
the provision of IS 5613 (Part-II/Section-I) regarding night & day visual aids for
denoting transmission line structures as per the requirement of directorate of
flight safety.
1.3.6.2.2 The detail of each component of medium intensity, low intensity lights &
associated accessories to be provided on the towers shall be as per the technical
specifications given in the preceding clauses and IS/ICAO, International Standards
recommended practices.
1.3.6.2.3 One set of Aviation Lights shall consist of one medium intensity light & two/four
(as applicable) low intensity lights along with all accessories such as solar panel,
control panel, batteries, cables etc.
1.3.6.2.4 Medium Intensity Light

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& STRINGING)

Medium Intensity light shall be provided on the top of each tower. The medium
light should have night time intensity as per ICAO requirements in international
Standards Recommended Practices. The light on top of the structure should flash
at the rate of 20 sequences per minute. The effective intensity during night time
for the medium flashing light shall be 1600 CD. The light shall conform to ICAO
requirements/ BS 3224a and shall have weather protection conforming to IP 55.
The above lights conforming to ICAO specifications flashing red lights shall be DC
operated through a suitably sized battery bank at the operating voltage 12V/24V
DC. The burning life of the lamps shall be maximum possible in view of the
maintenance hazard of H.T. live but in no case, it should be less than 15,000
burning hours. In case of failure of the lamp before 15,000 burning hours, the
same shall have to be replaced by the Contractor free of cost even if the pendency
of contract expires. The light shall be equipped with radio suppression facility
conforming to BS800 in order to avoid any interference with signals of PLCC etc.
1.3.6.2.5 Low Intensity Lights
Two/ four (as applicable) nos. of low intensity lights are required to be put on
each of the towers. Placement drawing for the same shall be submitted by the
bidder Contractor.
The light shall be stationary lamp with minimum effective intensity of 32 CD. of
red light. The lamps shall conform to the ICAO requirement/relevant BS and shall
have weather protection of minimum IP 55 class.
Two/four nos. of L.I. lamp required for each tower shall be operated through a
suitable size common battery bank solar panel as per the requirement of
operating voltage and load current of the type of lamps being offered.
The burning life of the lamps shall be maximum possible in view of the
maintenance hazard of H.T live line, but in no case, it should be less than 15,000
burning hours. In case of failure of the lamp before 15,000 hours, the same shall
have to be replaced by the Contractor free of cost even if the pendency of
contract expires.
The low intensity lamp shall not generate any R.F. which can interfere with the
PLCC signals.
1.3.6.2.6 Storage Battery
Storage Battery required for the above purpose shall be sealed maintenance free,
valve regulate lead acid and suitable for mounting on the top of the transmission
line towers. Contractors shall offer the most optimum capacity of the Battery
Bank at 120hour discharge rate (considering 80 % percentage usage) matching
with the load requirement of the type of lamps being offered including any power
loss in the associated cables. The battery sizing shall conform to JISC 8707/
relevant Indian Standard or any other internationally recognized standard. The
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battery shall be hermetically sealed explosion proof and self-resealing type and
free from orientation constraints. The working temperature ranges shall be
minimum 00 C and maximum 500 C. Performance certificate of the offered
batteries shall be submitted by the Contractor.

1.3.6.2.7 Battery Box

The battery box suitable for mounting on power transmission tower shall be
robust construction suitable to accommodate desired number of storage
batteries with proper clearance between the batteries. The sides and the top of
the battery box shall be made from MS sheets not less than 14 SWG thickness
duly mounted on MS angle frame. The bottom of the battery box shall have
suitably designed MS structure to freely hold the total weight of the
batteries. The batteries should be placed on insulated base with proper drainage
holes. Lifting lugs shall be provided. Dust and vermin proof lockable doors shall
be provided for safety and easy access to the batteries for the maintenance. The
battery box should incorporate the design for proper ventilation system in order
to prevent a gas concentration inside the box. The ventilation opening shall be
protected against rain/ splash water and dust. The inside of the battery box shall
be lined with insulating polyurethane plating and the exterior painted with
weather proof polyurethane paint. The cable entry into the battery box shall be
through suitable cable glands.
1.3.6.2.8 Solar Modules
Solar module required for the system shall be suitable for mounting on the
transmission line towers and shall be designed for high performance, maximum
reliability and minimum maintenance and shall be installed below bottom cross
arms levels. The solar modules shall be IP 55 grade protection class. These should
be highly resistant to water, abrasion, nail, impact and other environmental
factors.
These should be placed on the tower at a most optimum angle so as to harness
the maximum solar energy and facilitate self-cleaning and shall conform to
relevant Indian/ International Standards.
Module mounting frames shall be weather proof suitable for mounting on tall
towers. Details of mounting frames shall be furnished by the Contractor.
Junction box shall be provided with weather proof hinged lid with provision for
cable glands entry and protections grade of class IP-55.
The Contractor shall submit the basis of selecting the numbers of solar modules.

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The provision for design, supply & erection of mounting arrangements for
photovoltaic modules on the transmission towers in a suitable manner to harness
maximum solar energy shall be in the scope of the Contractor.
Provision for design, supply & erection of resting platform for the erection of
battery bank in a closed enclosure with safety arrangement on the transmission
towers shall also be in the scope of the Contractor. The design and load
consideration for safety of towers due to additional plate form shall be kept in
view while designing, selecting the above.
1.3.6.2.9 Control Panels
Control panels shall consist of solar charge controller, flasher unit, sensor,
isolator, MCB, Voltmeter, Ammeter and other control gears. Panel enclosure shall
be fabricated out of 14 SWG CRCA sheet and thoroughly treated and painted.
Suitable neoprene rubber gasket and pad locking device shall be provided and the
protection class shall be of IP 55 class.
The Solar charge controller shall be most efficient and preferably fully solid
state. It shall be provided with protection to load against increase in temperature,
Surge, automatic low voltage and automatic disconnection and reconnection
during high inrush current and normalcy respectively.
The flash regulator shall be provided for regulating light flashing. The same shall
be completely solid state and provided with flash rate set points. The protection
against overload current shall also be provided.
Necessary sensor/ timer shall be provided in the system to “switch on” the light
automatically in the evening and poor visibility period and switch off the same
during day time and normal visibility period.
1.3.6.2.10 Cables, Cable Glands, Conduits and Accessories
The cable to be supplied and erected shall be of multi strands copper conductor,
weather proof, PVC insulated PVC sheathed, armoured 1.1 KV grade. The same
shall conform to IS 1554.
All the cable accessories such as thimble, glands etc. shall be in the scope of
supply and erection of the Contractor.
Supply and erection of all the PVC conduits and accessories shall be in the scope
of the contract. All the conduit and accessories shall be as per the relevant ISS or
ISI brand.
The inter-connection cable/ conduit will be clamped in a secured manner with the
tower members and any interconnection should be made only inside the
environmentally protected junction box.
1.3.6.2.11 Earthing
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& STRINGING)

All the installations on the tower shall be securely and properly earthed with the
tower body by using flexible copper braided wire. Cost of earthing material shall
deem to be included in the total cost.

1.3.7 Bird Flight Diverter

Bird diverters shall be placed in identified stretches as per the conditions

stipulated by forest authority or other appropriate authority to avoid the chances
of collision of birds with transmissions lines. These Bird Diverters shall be placed
on earth wire/OPGW only (in case of transmission line(s) having two or more
bundle conductors in each phase) and on all phase conductors also( only in case
of transmission lines having single conductor in each phase) in staggered manner
at a distance of 10 m, unless otherwise specified by forest/ wildlife authority, in
the central 80% of identified spans. An indicative sketch of the placement of the
bird diverter is attached in the drawing section of this specification.

The dynamic solar powered LED type Bird Flight Diverter, consist of warning disc
(2-D or 3-D in design) and associated clamps & connectors, shall be preferred in
areas where foggy/dusty weather persists or intensity of light is low or the
sections of the lines lying in the route of migratory birds. BFD may be mixture of
LED and Non-LED BFD, where on a line LED type BFD should be at least 20%. For
solar powered LED type diverter, following additional requirement shall be
fulfilled:

(a) LED shall be of Orange colour with adequate light intensity so that it is
clearly visible from a distance (>300 m) even during foggy/dusty weather/
under low intensity of light.

(b) Battery shall be guaranteed for service life of 5 years and shall be suitable
for at least 100 hours of flashing operation by single charge.

(c) An automatic power cut-off electronics circuit shall be provided to

improve battery life so that during day time (due to high intensity of light
from sun), the circuit gets cut off & stops flashing and the circuit switches
on automatically under low intensity light condition.

(d) Position of solar cell shall be such that it gets sunlight irrespective of
direction of the diverter face and the dust & snow does not decrease its
efficiency.

Bird Flight Diverter (BFD) shall be designed for expected service life of at least 15
years. The Bird Flight Diverter shall be lightweight (total weight for each Non-
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LED & LED type BFD shall not more than 500 gm and 800 gm respectively), and
should be easily installed by hand or by hot stick (under live line condition) or by
any other suitable method. Length of bird diverter, from connection point to
end, should not be more than 430 mm. The bird diverters should retain good
physical characteristics under all weather conditions, within a range of extreme
temperatures i.e. from -150 C to 850 C for conventional conductor and maximum
operating temperature under emergency loading conditions may be considered
to withstand temperature in case of HTLS conductor. Contractor/ subcontractor
shall submit valid test report/test certificate for mechanical test, ageing test i.e.
solar radiation test & sand and dust test as per MIL- STD 810 F etc. from
accredited third-party laboratory for the design which they intend to supply. The
grip on the earthwire/OPGW should ensure that the Bird-Flight Diverter remains
in the applied position and does not move along the span under Aeolian
vibration or other conditions.

Generally Suspended devices i.e. Dynamic Bird Flight Diverters shall be used in
the transmission line as bird diverters.
1.3.7.1 Suspended devices: Dynamic Bird Flight Diverters

Bird flight Diverters shall have one warning disc(2-D or 3-D in design) which shall
be attached to the wire through spring loaded clamp & connectors. Warning disc
shall be made through injection moulding of UV stabilized plastic while the
attachment clamp shall be made of UV stabilized engineered composite plastic.
All fasteners and spring shall be of stainless steel.
1.3.7.1.1 Warning Disc

Warning disk of Bird Flight Diverter must swing, sway, must not flip on the
powerline in high wind velocity, rotate and should have contrasting coloured
(combination of any two colours from Red,black, Yellow, Orange, White) retro-
reflective surface with Sun and Moon light reflectors on both faces. The colour
change, while revolving, shall provide significant forewarning. Warning disk must
glow in dark & glow in the dark shall remain activated for at least 12 hours after
exposure to sunlight and the warning disk in the BFD should have strong
luminescence properties that emit immense light to provide enhanced visibility
to the birds at night. If Glow in dark stickers are used, the same shall be
laminated and suitable for all weather conditions. The Warning disc should be
aerodynamically stable so that diverter faces minimum amount of drag force
which provide swing and rotation effect under medium/strong wind speed.

Diameter of circular warning disk shall not be less than 150 mm. If warning disk
is quadrilateral or trapezoid, then shortest arm length should not be less than 90
mm and total surface area of warning disc should not be less that 15,000 mm2
(including air vents). Thickness of the warning disc shall not be less than 3 mm.
Minimum reflective area on each face of warning disk shall not be less than 3500
mm2 . Glow in Dark area also should not be less than 3500 mm2 for LED type

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BFD and not less than 7500 mm2 for the non LED type BFD. All suspension
hardware which are directly exposed (moving or static) must be corrosion free.
Bearing swivel shall be made of stainless steel and should allow free spinning in
minimum wind speed of 1 km/hour & be made of sealed bearing to avoid
deposition of sand and/or soil particles and helps in smooth rotation.
1.3.7.1.2 Clamp

The clamp of the Bird flight diverter shall be made of UV stabilized engineered
composite plastic (polymer) or metal or carbon fibre. Spring type clamp, suitable
for holding earth wire/ OPGW/conductor shall be used.

It shall be capable of supporting the Bird flight diverter during installation and
prevent damage or chaffing of the earth wire/ OPGW/conductor during erection
or continued operation. The clamp shall have smooth and permanent grip to
keep the Bird flight diverter in position on the earth wire/ OPGW/conductor
without damaging the strands or causing premature fatigue failure of the earth
wire/OPGW/conductor under the clamp. More than 50% of clamp gripping area
shall be in contact with earth wire/OPGW/conductor. The groove of the clamp
body and clamp cap shall be smooth, free from projections, sharp end/edges,
abrasions, grit or materials which could cause damage to the earth
wire/OPGW/conductor when the clamp is installed. In case of metallic bird
diverters, the parts of clamp, touching earth wire/OPGW/conductor must be
made of material, which is bad conductor of electricity.

The Clamp shall have strong grip on earth wire/ OPGW/conductor. The clamp
should not slip when pulled by a force of 250 N in the direction parallel to
earthwire/ OPGW/conductor. The details/ properties of Earthwire
/OPGW/conductor are mentioned in relevant section of Earth wire/OPGW of
Technical specification. All exposed metal parts of clamp shall be corrosion free.
The Clamp must be able to bear pulling load of minimum 500 N.

1.3.7.2 The supplier shall guarantee that there shall not be any failure/ breaking of bird
flight diverters under normal operating condition. In the event of any failure/
breaking of bird flight diverters during the first five (05) years of service, supplier
shall supply to the purchaser free of cost spare bird flight diverters equal to the
failed bird flight diverters quantity.

1.3.7.3 Tests & Certifications

1.3.7.3.1 Type Tests

Report/ Certificate for following type tests conducted in any NABL or equivalent
accredited laboratory shall be submitted to the Purchaser. All of the following
tests shall be conducted on the same sample. However, No. of Samples for type
tests shall be as per relevant standard or procedure specified in Annexure-I to

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this Section. Type test report shall be valid for 10 years from the date of
successful completion of test.

1 Mechanical Strength test As per Annexure-I

a) Direct Pull Test
b) Clamp Slip Test/Grip Retaining Strength Test
2 Vibration test As per Annexure-I
3 Temperature cycle test As per Annexure-I
4 Corrosion Resistance Test As per Annexure-I
5 Ageing test As per Annexure-I

6 Heating cycle test As per Annexure-I

7 Radio Interference test Voltage , (applicable for As per Annexure-I

bird diverters for use on transmission line at 220
kV and above)

8 Visual Corona Test (applicable for bird As per Annexure-I

diverters for use on transmission line at 220 kV
and above)

1.7.7.3.2 Acceptance tests

Following acceptance tests shall be carried out on at least 20 (twenty) samples in

presence of the representative of the purchaser:

1 Visual Examination Test As per Annexure-I

2 Verification of Dimensions As per Annexure-I
3 Mechanical Strength test As per Annexure-I
(Only one of the 20 samples shall be subjected
to ultimate failing load)
a) Direct Pull Test
b) Clamp Slip Test/Grip Retaining Strength Test

1.4 Tower Fabrication

The fabrication of towers shall be in conformity with the following:
1.4.1 Except where hereinafter modified, details of fabrication shall conform to IS 802
(Part-II) or the relevant international standards.
1.4.2 The tower structures shall be accurately fabricated to connect together easily at
site without any undue strain on the bolts.
1.4.3 No angle member shall have the two leg flanges brought together by closing the
angle.
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1.4.4 The diameter of the hole shall be equal to the diameter of bolt plus 1.5 mm.
1.4.5 The structure shall be such that all parts are accessible for inspection and cleaning.
Drain holes shall be provided at all points where pockets of depression are likely
to hold water.
1.4.6 All steel sections before any work is done on them, shall be carefully leveled,
straightened and made true to detailed drawings by methods which will not injure
the materials so that when assembled, the adjacent matching surfaces are in close
contact throughout. No rough edges shall be permitted in the entire structure.
1.4.7 Drilling and Punching
1.4.7.1 Before any cutting work is started, all steel sections shall be carefully straightened
and trued by pressure and not by hammering. They shall again be trued after
being punched and drilled.
1.4.7.2 Holes for bolts shall be drilled or punched with a jig but drilled holes shall be
preferred. The punching may be adopted for thickness up to 12 mm. Tolerances
regarding punch holes are as follows: -
a) Holes must be perfectly circular and no tolerances in this respect are
permissible.
b) The maximum allowable difference in diameter of the holes on the two
sides of plates or angle is 0.8mm. i.e. the allowable taper in a punched holes
should not exceed 0.8mm on diameter.
c) Holes must be square with the plates or angles and have their walls parallel.
1.4.7.3 All burns left by drills or punch shall be removed completely. When the tower
members are in position the holes shall be truly concentric/ matching to each
other. Drilling or reaming to enlarge holes shall not be permitted.
1.4.8 Erection mark
1.4.8.1 Each individual member shall have erection mark conforming to the component
number given to it in the fabrication drawings. The mark numbers shall be marked
with marking dies of 16mm size before galvanising and shall be legible after
galvanizing.
1.4.8.2 Erection Mark shall be A-BB-CC-DDD
A = Employer’s code assigned to the Contractors- Alphabet
BB = Contractor’s Mark-Numerical
CC = Tower Type Alphabet.
DDD = Number mark to be assigned by Contractor - Numerical.

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Erection mark for high tensile steel members shall be prefixed by the letter “H”
1.5 Quantities and weights
1.5.1 The quantities of the following items have been envisaged in Metric Tonne (MT)
in case of Employer design towers and in ‘Nos.’ in case of Contractor design
towers, in the relevant price Schedules for various types of towers: -
i) Basic Body
ii) Body Extensions, wherever required
iii) Leg Extension
iv) Stubs & Cleats
v) Bolts & Nuts including spring washers and step bolts etc. for above items
During detailed engineering, proto corrected shop drawings shall be released by
POWERGRID for fabrication and manufacturing as per the Technical Specification
to the Contractor. The contractor shall carry out proto-assembly after fabrication
from the Employer’s shop drawing for his verification/ satisfaction prior to mass
production of the tower.
The manufacturing of the above items shall be taken up in such a manner that the
Equipment/ Material offered for inspection to POWERGRID are on completed
tower basis for each type of tower, completed Stubs & Cleats set basis so as to
facilitate availability of erectable tower of each type and erectable stubs & cleats
set for casting of foundation. After inspection of the offered Equipment/ Material
by POWERGRID representative(s), CIP shall be issued by POWERGRID for the
material meeting the Technical Specification. However, MICC shall be issued only
on Completed Tower Basis for each type of tower (comprising the required Basic
Body, body extensions wherever required, four (4) equal or defined unequal Leg
Extension, Bolts & Nuts along with D-shackles, Hangers, Packing and Spring
Washers) and on completed Stubs & Cleats set basis for each type of tower
foundations (comprising a set of stubs & Cleats, required Bolts and Nuts along
with Spring Washers).
Towers to be supplied by the Contractors/ Tower Manufacturers shall be
dispatched Panel wise as per mutually agreed procedure with Employer Quality
Assurance & Inspection Department.
Accordingly, the payment shall be released on completed Tower Basis for each
type of tower (comprising the Basic Body, body extensions, wherever applicable,
bolts & nuts along with spring washer and step bolts, four (4) equal or defined
unequal leg extensions wherever applicable for a completed tower) and on
completed Stubs and Cleats set basis for each type of foundation (comprising a
set of stubs & cleats, required Bolts and nuts along with Spring Washers) based

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on the weight of the tower parts as calculated as per Clause 1.5.3 and fasteners
based on the unit rates incorporated in the contract.
1.5.2 The provisional quantities required (including provisional spare tower quantity)
are mentioned in the respective Schedules of BPS. Final quantities shall be
determined after completion and approval of the detailed route survey. The final
quantities of tower including spare towers shall be confirmed by the Employer/
Site -in-charge based on the requirement of quantities of various towers furnished
by the Contractor after completion of detailed survey. Hence it will be
responsibility of the Contractor to intimate the exact requirement of all towers
and various line materials required for line immediately after the survey.
The Employer reserves the right to order the final quantities including required
quantities of spares for which the rates quoted in the Bid shall be valid. Regarding
quantity variation the provisions of relevant clauses of SCC shall apply.
1.5.3 The estimated total weight of tower/ tower parts as well as bolts & nuts along
with spring washers and step bolts to be supplied by the Contractor under various
packages have been envisaged in the relevant Price Schedule. Though fully
galvanised tower parts are to be supplied, the weight of tower shall mean the
weight of tower calculated by using the black sectional (i.e. ungalvanised) weight
of steel members of the size indicated in the approved fabrication drawings and
bill of materials, without taking into consideration the reduction in weights due
to holes, notches and bevel cuts etc. but taking into consideration the weight of
the D shackles, hangers, strain plates, pack plates, gusset plates, extension
link/plates and pack washers etc. The weight of stub and cleats also shall be
calculated in similar manner. The weight of strain plates, pack plates, extension
link and gusset plates shall mean the weight of its circumscribing rectangle,
without taking into considerations the reductions in weight due to holes, notches
etc. The weight of D-shackles, hangers and pack washers shall be net actual
weight taking into consideration reduction due to holes. For bolts and nuts along
with spring washers and step bolts, the weight per tower shall be calculated from
the bolt schedule applicable to each type of towers and body extensions as
approved by the Employer. The rate quoted by the bidder for tower/tower parts
supply, is deemed to be inclusive of galvanising charges including the cost of zinc.
1.5.4 The contractor is permitted to get inspected and supply upto 2.5% extra fasteners
to take care of losses during erection. No payment shall be admissible for these
extra supplies.
1.6 Galvanising
1.6.1 Fabricated Tower Parts & Stubs

The tower parts, stubs and pack washers shall be hot dip galvanized. The
galvanization shall be done as per requirements of IS 4759 after all fabrication

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work is completed. The contractor shall also take guidelines from the
recommended practices for hot dip galvanizing laid down in IS 2629 while
deciding and implementing galvanizing procedure. The mandatory requirements
however, are specified herein.

The fabricated tower parts and stubs shall have a minimum overall Zinc coating
of 610 gm per sq. m of surface area except for plates & sections below 5mm which
shall have Zinc coating of 460 gm per sq. m of surface area. The average zinc
coating for all sections and plates 5mm & above shall be maintained as 87 microns
and that for plates & sections below 5mm shall be maintained as 65 microns.

However, for coastal areas or creek regions or aggressive soil areas or under
marine environment, as specifically mentioned in BPS the fabricated tower parts
and stubs shall have a minimum overall zinc coating of 900 gm/ sqm of surface
area except for plates and sections below 5mm which shall have a minimum
overall zinc coating of 610 gm/sqm of surface area. The average zinc coating for
all sections and plates 5mm and above shall be maintained as 127 microns and
that for plates and sections below 5mm shall be maintained as 87 microns.

The zinc coating shall be adherent, reasonably uniform, smooth, continuous and
free from imperfections such as black/ bare spots, ash rust strains, bulky white
deposits/ wet storage strains and blisters.

The surface preparation for fabricated tower parts and stubs for hot dip
galvanizing shall be carried out as indicated herein below:

(i) Degreasing & Cleaning of Surface: Degreasing and cleaning of surface,

wherever required, shall be carried out in accordance with clause 4.1 of IS
2629. After degreasing the article shall be thoroughly rinsed. However, if
acidic degreasers are used rinsing is not required.

(ii) Pickling: Pickling shall be done using either hydrochloric or sulphuric acid
as recommended at clause 4.3 of IS 2629. The actual concentration of the
acids and the time duration of immersion shall be determined by the
Contractor depending on the nature of material to be pickled. Suitable
inhibitors also shall be used with the acids to avoid over pickling. The acid
concentration, inhibitors used, and maximum allowable iron content shall
form part of plant standard to be formulated and submitted to employer
along with Quality Assurance Program.

(iii) Rinsing: After pickling, the material shall be rinsed, preferably in running
water to remove acid traces, iron particles or any other impurities from the
surface. Two rinse tanks are preferable, with water cascading from the
second tank to the first to ensure thorough cleaning. Wherever single tank
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is employed, the water shall be periodically changed to avoid acid

contamination, and removal of other residue from the tank.

(iv) Fluxing: The rinsed article shall be dipped in a solution of Zinc ammonium
chloride. The concentration and temperature of the flux solution shall be
standardized by the contractor depending on the article to be galvanized
and individual circumstances. These shall form part of plant standard to be
formulated and submitted to Employer along with Quality Assurance
Program. The specific gravity of the flux solution shall be periodically
monitored and controlled by adding required quantity of flux crystals to
compensate for drag-out losses. Free acid content of the flux solution also
shall be periodically checked and when it is more than two (2) grams of free
acid per litre of the solution, it shall be neutralized. Alternatively, Ph value
should be monitored periodically and maintained between 5.0 to 5.5.

(v) Drying: When dry galvanizing is adopted the article shall be thoroughly
dried after fluxing. For the purpose of drying, the contractor may use hot
plate, air oven or any other proven method ensuring complete drying of
the article after fluxing and prior to dipping in the molten zinc bath. The
drying process shall be such that the article shall not attain a temperature
at which the flux shall get decomposed. The article thus dried shall be
galvanized before the flux coating picks up moisture from the atmosphere
or the flux layer gets damaged or removed from the surface. The drying
procedure, time duration, temperature limits, time lag between fluxing,
drying, galvanizing etc. shall form part of plant standard to be formulated
and submitted to employer along with Quality Assurance Program.

(vi) Quality of Zinc: Any one or combination of the grades of zinc specified in IS
209 or IS 13229/ Prime Western (PW grade) (Zn 98.65%) or other
comparable international standard shall be used for galvanizing. The
contractor shall declare the grade(s) of zinc proposed to be used by them
for galvanizing. The molten metal in the zinc bath shall contain minimum
98.5 % zinc by mass. It shall be periodically measured and recorded. Zinc
aluminum alloy shall be added as per IS 2629.

(vii) Dipping Process: The temperature of the galvanizing bath shall be

continuously monitored and controlled. The working temperature of the
galvanizing bath shall be maintained at 450+/-100 C. The article should be
immersed in the bath as rapidly as possible without compromising on
safety aspects. The galvanizing bath temperature, immersion angle & time,
time duration of immersion, rate of withdrawal etc. shall be monitored and
controlled depending upon the size, shape, thickness and chemical
composition of the article such that the mass of zinc coating and its

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uniformity meets the specified requirements and the galvanized surface is

free from imperfections and galvanizing defects.

(viii) Post Treatment: The article shall be quenched in water. The quench water
is to be changed/ drained periodically to prevent corrosive salts from
accumulating in it. If water quenching is not done then necessary cooling
arrangements should be made. The galvanized articles shall be dipped in
chromating solution containing sodium dichromate and sulphuric acid or
chromic acid base additive at a predetermined concentration and kept at
room temperature to retard white rust attack. The temperature of the
chromate solution shall not exceed 650 C. The articles shall not be stacked
immediately after quenching and dichromating. It shall be ensured that the
articles are dry before any further handling operation.

(ix) Storing, Packing and Handling: In order to prevent white rust formation
sufficient care should be exercised while storing handling and transporting
galvanized products. The articles shall be stored in an adequately
ventilated area. The articles shall be stored with spacers in between them
and kept at an inclination to facilitate easy drainage of any water collected
on the articles. Similar care is to be taken while transporting and storing
the articles at site.

The Contractor shall prepare a detailed galvanizing procedure including Flow Chart
with control parameters and all plant standards as required above and submit to
POWERGRID for approval as part of Quality Assurance Plan.

1.6.2 Fasteners

For fasteners, the galvanizing shall conform to IS 1367 (Part-13). The galvanizing
shall be done with centrifuging arrangement after all mechanical operations are
completed. The nuts, may however be tapped (threaded) or rerun after
galvanizing and the threads oiled. The threads of bolts & nuts shall have a neat fit
and shall be such that they can be turned with finger throughout the length of the
threads of bolts and they shall be capable of developing full strength of bolts.
Spring washers shall be electro galvanized as per Grade-IV of IS 1573.

1.7 Earthing
Each tower shall be earthed. The tower footing resistance shall not exceed 10
ohms. The Contractor shall measure the tower footing resistance (TFR) of each
tower during dry weather after it has been erected and before the stringing of the

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earth wire. Pipe type earthing and counter poise type earthing shall be done as
required in accordance with the following standards:
IS 3043 Code of practice for Earthing
IS 5613 Code of practice for Design, Installation and maintenance
(Part-II/Section-2) of overhead power lines
1.7.1 The drawings for pipe & counterpoise type earthing are enclosed with these
specifications.
1.7.2 For pipe type earthing, length of flat indicated in the Section Drawing is indicative
only and actual length shall vary depending on site requirement (to avoid fouling
of pipe type earthing with foundation base slab). The payment for the pipe type
earthing shall be as per the unit rates in the BPS irrespective of the length of flat
1.7.3 For counterpoise type earthing, the earthing will vary depending on soil resistivity.
For soil resistivity less than 1500 ohms-meter, earthing shall be established by
providing 4 lengths of 30m counterpoise wire. Otherwise, for soil resistivity
greater than 1500 ohms meter earthing shall be established by providing 4 length
of 70m counterpoise wire. The contractor shall also measure tower footing
impedance using high frequency Tower footing impedance measurement kit, in
addition to Tower footing resistance (TFR). The value of Tower footing resistance
as well as tower footing impedance shall not exceed 10 Ohms.
1.7.4 The provisional quantities for pipe type earthing and counterpoise earthing are
indicated in the BPS. The bidders are required to quote unit rates for the same in
appropriate schedule of BPS. The quoted price shall include fabrication, supply
and installation of earthing material including supply of coke, salt etc. In case of
counterpoise type earthing, the unit rates shall correspond to 120/280 meters of
counterpoise wire per tower.
1.7.5 Chemical pipe/ counter poise type earthing shall be provided in some locations
as decided by Site In charge, where due to high resistivity tower footing
resistance/ impedance below 10 ohms is not achieved with normal pipe/ counter
poise type earthing. The provisional quantities for chemical pipe type earthing
and counterpoise earthing are indicated in the BPS. For chemical pipe/ counter
poise type earthing, ground enhancement material/ back fill/ grounding
compound shall be used. The material should generally conform to IEC 62561
(Part-7). The material should be permanent and maintenance free. It should not
dissolve or decompose or otherwise pollute the soil or local water table &
environment and should not depend on the continuous presence of water or
moisture in the surrounding to maintain its conductivity. The material of the
earthing enhancing compound in its set form should have a resistivity of less than
0.12 ohm-m (as per IEEE 80-2000, Clause No. 14.5(d)). It should have hygroscopic
properties and should not cause burns, irritation to eyes, skin etc. Test report for
the following test on earthing enhancement compound (conducted at accredited
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laboratory as per IEC 62561 (Part-7) shall be submitted by the contractor to the
site in charge.
• Resistivity test using soil box
• Leaching test
• Sulfur determination
• Corrosion test
1.7.6 Earthing for River Crossing Towers /Pile foundation
Galvanised earthing strip of flat 50x6 mm is to be provided in two legs of tower
for each location with proper arrangement of connecting these strips by 16 mm
bolts shall be provided in the stubs. The Earthing strip from the tower leg may be
connected to the MS liner through the pile cap (an indicative drawing is enclosed
at drawing section). In case the length of the liner embedded in the ground/ river
bed is less than 3m or pile without liner the earthing strip shall be extended along
the pile & embedded in the soil upto min. 3m depth from the present minimum
RL. After execution of the earthing tower footing resistance/impedance is to be
measured and should be maintained below 10 Ohms by suitable measures. In case
due to specific soil conditions required tower footing resistance/ impedance
below 10 Ohms is not achieved, then additional separate earthing (pipe/
counterpoise type) may be provided. Only bolted connections are allowed for
connecting this strip to achieve desired length. Contractor shall submit the
detailed drawing for approval of Employer before installations.
Note: During O&M stage, in case it is observed that MS liner/ strip embedded in
the ground/ river bed is exposed due to scouring etc. and length of embedment
of liner/strip is less than 3m. Earthing strip may be extended in the ground/ river
bed upto 3m from the other end of the liner/ strip by POWERGRID.

1.7.7 In case of location where foundation is classified as hard rock and laying of
counter poise earthing at required depth of 1 m below the ground level is not
feasible, the earthing shall be provided at reduced depth as per enclosed drawing
of “counter poise earthing in hard rock strata. For the payment of hard rock
earthing, the unit rate under the contract for chemical counter poise earthing
shall be applicable.

1.7.8 Additional earthing shall be provided on every 7 to 8 km distance at tension tower

(exact quantity & location to be decided by Site In-charge) for direct earthing of
both shield wires (earhwire/ OPGW). Indicative drawing of shield wire earthing
arrangement is enclosed at relevant section (Drawing) of technical specification.
The scope of work shall inter-alia include supply & installation of PG clamp & down
lead clamps and supply & installation of additional earthing (pipe type or counter
poise type) depending upon soil resistivity. Additional earthwire bits required for
down leads connecting shield wires with the earthing shall be either supplied by
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Owner separately (as Owner supplied material) or shall be supplied by contractor

(payable as per unit rate of GS Earthwire under the contract), as may be decided
by Site-In-Charge.

1.7.9 Additional Rod type earthing shall be provided in one of the foundation pit
(diagonally opposite to pipe type earthing) of all the transmission line towers in
normal soil (i.e. Dry, Wet cultivated, Wet, PS, FS & Black Cotton soil) in addition
to pipe type earthing. This additional earthing MS Rod of 40 mm dia & 3.0 M
length shall be driven after excavation of foundation pit and connected to stub
cleat. The indicative drawing of Rod type earthing is enclosed in the section of
drawing.

1.8 Standards
1.8.1 The design, manufacturing, fabrication, galvanising, testing, erection procedure
and materials used for manufacture and erection of towers, design and
construction of foundations shall conform to the following Indian Standards (IS)/
International Standards which shall mean latest revisions, with amendments/
changes adopted and published, unless specifically stated otherwise in the
Specification. In the event of supply of material conforming to Standards other
than specified, the Bidder shall confirm in his bid that these Standards are
equivalent to those specified. In case of award, salient features of comparison
between the Standards proposed by the Bidder and those specified in this
document will be provided by the Contractor to establish their equivalence.
1.8.2 The material and services covered under the:se specifications shall be performed
as per requirements of the relevant latest standard code referred hereinafter
against each set of equipment and services

Sl. Indian Standard Title

No.
1 IS 209 Zinc INGOT - Specification

2 IS 278 Galvanized steel barbed wire for fencing-

Specification
3 IS 800 General construction in steel - Code of practice

4(a) IS 802(Part 1) Use of structural steel in overhead transmission

Sec 1-2015 line towers - code of practice part 1 materials,
Sec 2-2016 loads and design strengths
Section-1: Materials and loads
Section-2: Design Strengths.

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Sl. Indian Standard Title

No.
4(b) IS 802(Part 2) Code of Practice for use of structural steel in
Overhead Transmission Line Towers: Part-2
Fabrication, Galvanising, inspection & Packing

4(c) IS:802(Part 3) Code of Practice for use of structural steel in

Overload Transmission Line: Part-3
Tower testing
5 IS 808 Dimensions for Hot Rolled Steel Beam, Column,
Channel and Angle Sections.
6(a) IS 875 Code of Practice for Design Loads (other than
Part-1, 2, 4, 5 Earthquakes) for Buildings and Structures.

6(b) IS 875 Design Loads (other than Earthquakes) for

Part-3 Buildings and Structures- Code of Practice
7 IS 1363 Hexagon head bolts, Screws and Nuts of product
Part-1, 2, 3 Grade `C’
8 IS 1367, Technical Supply Conditions for Threaded Steel
Part 1 to 20 Fasteners
9 IS 1477 Code of practice for Painting of Ferrous Metals in
Buildings:
Part-I: Pre-treatment
Part-II: Painting.
10 IS 1573 Electro-Plated Coatings of Zinc on iron and Steel
11 IS 1852 Rolling and Cutting Tolerances of Hot Rolled Steel
Products
12 IS1893 Criteria for Earthquake Resistant Design of
Part 1 Structures
Part 2
Part 3
Part 4
13 IS 2016 Specification for Plain Washers
14 IS 2062 Hot Rolled medium and High tensile Structural
steel
15 IS 2074 & IS 2074 Ready Mixed Paint. Air Drying, Red Oxide Zinc
(Part-1) Chrome, Priming Specification.
16 IS 2551 Danger Notice Plates

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Sl. Indian Standard Title

No.
17 IS 2629 Recommended Practice for Hot Dip Galvanizing of
iron and steel.
18 IS 2633 Method of Testing Uniformity of Coating of Zinc
Coated Articles
19 IS 3043 Code of Practice for Earthing
20 IS:3063 Fasteners-Single coil Rectangular Section Spring
Lock Washers
21 IS 3757 Specification for High Strength Structural Bolts
22 IS 4759 Specification for Hot-dip zinc coatings on structural
steel and other Allied products
23 IS 5369 General Requirements for Plain Washers and Lock
Washers
24 a) IS 5613 (Part 1) Code of Practice for Design installation and
Maintenance of Overhead Power Lines: Lines up to
and including 11 KV
Section-1: Design,
Section-2: Installation and Maintenance
24 b) IS 5613 (Part 2) Code of Practice for Design installation and
Maintenance of Overhead Power Lines: Lines
above 11 KV and upto and including 220 KV
Section-1: Design,
Section-2: Installation and Maintenance
24 c) IS 5613 (Part 2) Code of Practice for Design installation and
Maintenance of Overhead Power Lines: 400kV
Lines
Section-1: Design,
Section-2: Installation and Maintenance
25 IS 6610 Specification for Heavy Washers for Steel
structures
26 IS 6623 High Strength Structural Nuts
27 IS 6639 Hexagon Bolts for Steel Structure.
28 IS 6745 Method for Determination of Mass of Zinc coating
on zinc coated iron and Steel Articles.
29 IS 10238 Fasteners - Threaded Steel Fasteners - Step Bolts
for Steel Structures
30 IS 12427 Fasteners - Threaded Steel Fasteners - Hexagon
Head Transmission Tower Bolts
31 Publication No. Regulation for Electrical Crossing of Railway Tracks
19(N)/700

The standards mentioned above are available from

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Reference Abbreviation Name and Address

BIS/IS Bureau Of Indian Standards.

Manak Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi - 110001
INDIA
ISO International Organisation for
Standardization.
ISO Central Secretariat
BIBC II
Chemin de Blandonnet 8
CP 401
1214 Vernier, Geneva
Switzerland

2.0 Inspection and Tests

2.1 General
All standard tests, including quality control tests, in accordance with appropriate
Indian/ International Standard, shall be carried out unless otherwise specified
herein.
2.1.1 Inspection
In addition to the provision of GCC and Cl. 1.7.3 of Section II of this Specification,
the following shall also apply:
a) The Contractor shall keep the Employer informed in advance about the time
of starting and of the progress of manufacture and fabrication of various
tower parts at various stages, so that arrangements could be made for
inspection.

b) The acceptance of any part of items shall in no way relieve the Contractor
of any part of his responsibility for meeting all the requirements of the
Specification.

2.1.2 The Employer or his representative shall have free access at all reasonable times
to those parts of the Contractor’s works which are concerned with the
fabrication of the Employer’s material for satisfying himself that the fabrication
is being done in accordance with the provisions of the Specification.

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2.1.3 Unless specified otherwise, inspection shall be made at the place of manufacture
prior to dispatch and shall be concluded so as not to interfere unnecessarily with
the operation of the work.
2.1.4 Should any member of the structure be found not to comply with the supplied
design, it shall be liable to rejection. No member once rejected shall be
resubmitted for inspection, except in cases where the Purchaser or his
authorized representative considers that the defects can be rectified.
2.1.5 Defect which may appear during fabrication shall be made good with the
consent of the Employer according to the procedure proposed by the Contractor
and its approval.
2.1.6 All gauges and templates necessary to satisfy the Employer shall be supplied by
the Contractor.
2.1.7 The specified grade and quality of steel shall be used by the Contractor. To
ascertain the quality of steel used, the inspector may at his discretion get the
material tested at an approved laboratory.
3.0 Tower Erection, Stringing and Installation of Line Materials
3.1 General
3.1.1 The scope of erection work shall include the cost of all labour, tools and plant such
as sagging bridges/ working platform, power operated winch machines, cranes of
suitable capacity and height (wherever feasible), tension stringing equipment,
mechanized rope way wherever required for hilly areas for transportation of
materials and all other incidental expenses in connection with erection and
stringing work. The stringing equipment shall be of sufficient capacity to string the
bundle conductors of specified size. Use of Tractor for tower erection & final
sagging shall not be permitted.
Use of helicopter for faster erection of transmission line, particularly in difficult
and inaccessible terrain, may be considered subject to the required clearance
from Director General of Civil Aviation (DGCA) / any other competent authority.
3.1.2 The Contractor shall be responsible for transportation to site of all the materials
to be supplied by the Contractor as well as proper storage and preservation of the
same at his own cost, till such time the erected line is taken over by the Employer.
Similarly, the Contractor shall be responsible for transportation, proper storage,
safe custody, and loss or damage of all Employer’s supplied items for
incorporation in the lines and shall maintain and render proper account of all such
materials at all times. The Contractor shall reimburse the cost of any of the
materials lost or damaged during storage and erection over and above specified
and permitted in Clause 3.13.2 of this section.

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3.1.3 Contractor shall set up required number of stores along the line and the exact
location of such stores shall be discussed and agreed upon with the Employer.
Employer during the kick off meeting at site supplied items shall be dispatched to
the stores set up by the Contractor.
3.1.4 Payment for stringing shall be done on the basis of per kilometer and irrespective
of number of tension/ suspension towers. However, stringing for river crossing
spans with special towers (Anchor to Anchor) have been given separately in the
BPS. The units of measurement for tower erection and other line materials, like,
earth wire, Hardware fittings and Accessories for conductor & earth wire are
indicated in the BPS.
3.1.5 While handing over the Employer supplied OPGW drums, the testing (fibre loss
and length measurement using OTDR) of OPGW in each drum shall be carried out
by Contractor in presence of OPGW supplier and/or Employer representatives.
3.1.6 After installation of OPGW, the testing of each section shall be carried out by
Contractor in presence of Employer representatives. In case of any damage / high
loss in the fiber, the total length of that particular section/ portion of OPGW shall
be replaced by the contractor and in such case, the de-stringing & re-stringing
shall be carried out by the contractor without any extra cost to Employer and cost
of additional OPGW cable, hardware fittings and joint box, if any, for replacement
of damaged OPGW etc. shall be recovered from the contractor. However,
introduction of additional joints in the links due to replacement of OPGW in
damaged portion shall be allowed subject to meeting the optical link budget.
3.1.7 In case FO Cabling (OPGW, Approach cable etc.) installation is covered under the
scope of package, Site Acceptance Testing (SAT) for FO Cabling shall be carried
out by contractor as per Annexure-II.
3.1.8 For crossing of 33kV/11kV/LT lines during stringing, shut down shall be obtained
by Employer. However, contractor shall be required to arrange bypass
arrangement for such lines with suitable LT/HT power cables whenever shutdown
cannot be arranged during stringing.
The bypassing work shall be executed with suitable 33kV/11kV/LT cables,
following all electrical guidelines and proper safety measures in co-ordination
with concern DISCOM/agency/authority. However, the healthiness of cables shall
be ensured by the contractor before installation at each crossing. The
33kV/11kV/LT line shall be restored after the completion of stringing work, with
confirmation from Employer. The work shall be carried out as per the direction of
the Engineer-in-Charge.
The payment of bypass arrangement shall be inclusive of suitable cables and all
necessary items/arrangements/works required for successful bypassing of
existing 33kV/11kV/LT lines that includes de-stringing of existing 33kV/11kV/LT
conductors and their restoration after completion of stringing. The provisional
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quantities for bypass arrangements are indicated in the BPS. The bidders are
required to quote unit rates for the same in appropriate schedule of BPS.
The Contractor shall be entirely responsible for repair/rectification/replacement
of any damage to the existing 33kV/11kV/LT line of DISCOM/agency/authority
during the execution of the work.

3.2 Treatment of Minor Galvanization Damage

Minor defects in hot-dip galvanized members shall be repaired by applying zinc
rich paint to the satisfaction of the Employer before erection.
3.3 Assembly
The Contractor shall give complete details of the erection procedures he proposes
to follow. For erection of towers using crane (wherever feasible) Cranes of
suitable capacity along with other necessary T&P, power operated hydraulic/
motorized winches, Gin pole/ Derrick etc. shall be deployed by the Contractor
accordingly.
In case erection of tower is carried out by conventional method, Gin Pole/ center
mast shall be used for erection of 400 kV towers with +18 m & higher extensions
and 765 kV towers with +9 m & higher extensions. For these extension towers, in
cases of difficult site conditions/constraints, derricks for tower erection, if
proposed by the contractor, to be permitted only with approval of CGM/ ED
(Region).
3.3.1 The method for the erection of towers shall ensure the following:
a) Straining of the members shall not be permitted for positioning. It may,
however, be necessary to match hole positions at joints using tommy bars
not more than 450 mm in length;
b) Prior to erection of an upper section, the lower sections shall be completely
braced, and all bolts provided tightened adequately in accordance with
approved drawings to prevent any mishap during tower erection;
c) All plan diagonals, oblique bracings etc. for relevant section of tower shall
be in place prior to assembly of an upper Section;
d) The bolt positions in assembled towers shall be as per IS 5613 (Part
II/Section 2);
e) Tower shall be fitted with number, danger, Bird guard, circuit plate, pole
plate and phase plates as well as anti-climbing device, as described;
f) After complete erection of the tower, all blank holes, except for additional
holes, if any in universal plates and/or in redundant members at different
levels for fixing tower accessories (viz. Tower Number plate, Danger plate,
Phase plate etc.) are to be filled by bolts and nuts of correct size.

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g) The towers shall not be out of vertical by more than 1 in 360 before stringing
is carried out.

3.3.2 Tools & plants and PPEs

In addition to the provisions stipulated in the sections of bidding document under

conditions of contract, Safety Plan etc., the following shall also apply:
Broad list & basic parameters of major T&P to be used for tower erection &
stringing is enclosed at Appendix I to this specification.
The above-mentioned list is not exhaustive and all T&Ps/ PPEs required for
execution of works covered under the contractor scope of work within the
schedule in a safe manner, to be deployed by the Contractor.
The contractor shall provide details of all Tools & Plants including lifting machines,
lifting tools/ lifting tackles/ lifting gears and all types of ropes and slings and PPEs
to be deployed at site for approval of site-in-charge/ project manager as part of
safety plan.
All the tools and plants required for safe and efficient tower erection should be
available at site. Detailed list of T&P being deployed by the contractor and used
by different erection gangs shall be maintained.
Tools and plants should be tested as per applicable standards and safety norms.
Relevant test certificates should be available at respective sites.
Derricks/ Gin pole and other load bearing tools i.e. Wire rope, PP rope, D–
Shackles, pulleys etc. must be inspected for their healthiness before putting them
in use. Only tested tools with valid test certificates should be used. Periodic
testing should be carried out to check safe working capacity as per safety plan.
Homemade tools shall not be allowed to use at site.
All necessary PPEs like hand gloves, Safety Belts (Full body harness), safety
helmet, safety shoes, etc. as per relevant IS should be used and their healthiness
should be ensured.
All the persons working on tower should wear safety helmet, gloves, safety
harnesses, fall arrester, high visible vest and safety shoes as the per job
requirements. Similarly, all the persons working on ground should wear safety
helmet, high visible vest and safety shoes. Detailed list of safety equipment & PPEs
being used by the gangs shall be maintained at site.
Condition of safety equipment should be visually checked before every use. These
should be tested as per applicable standards; safety norms and necessary test
certificate should be available. Also, periodic check should be carried out to
ensure their requisite strength.

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3.3.3 Use of safety nets

Suitable safety nets shall be used during tower erection activity to provide
protection to workers in case of fall from heights.

3.4 Tightening of Bolts and Nuts

3.4.1 All nuts shall be tightened properly using torque wrench, applying the torque
recommended by manufacturer of bolts & nuts and proper tightening of bolts &
nuts shall be checked by Site-Engineer randomly. Before tightening, it will be
verified that filler washers and plates are placed in relevant gap between
members, bolts of proper size and length are inserted, and one spring washer is
inserted under each nut. In case of step bolts, spring washers shall be placed
under the outer nuts. The tightening shall progressively be carried out from the
top downwards, care being taken that all bolts at every level are tightened
simultaneously. The threads of bolts projecting outside the nuts shall be punched
at their position on the diameter to ensure that the nuts are not loosened in
course of time. If, during tightening, a nut is found to be slipping or running over
the bolt threads, the bolt together with the nut shall be replaced.
3.4.2 The threads of all the bolts projected outside the nuts shall be welded at two
diametrically opposite places; the circular length of each welding shall be at least
10mm. The welding shall be provided from ground level up to waist level for single
circuit towers and up to bottom cross arm level for double circuit towers and
single circuit vertical configuration towers subject to maximum 30 m height from
ground level. After welding the surface of welding shall be cleaned, dried and
made free of oil, grease and corrosion product and on this surface Zinc–Rich Paint
shall be applied by means of a brush according to the paint manufacturer’s
recommendations. Zinc Rich Paint, Pre-mixed type paint, based on organic/
inorganic binders specially formulated for steel surfaces may be used. The dried
film of Zinc Rich Paint should contain a minimum of 90 percent Zinc Dust by mass.
The cost of welding and paint including application of paint shall be deemed to be
included in the erection price.
3.5 Insulator Hoisting
Suspension insulator strings shall be used on Suspension towers and tension
insulator strings on angle and dead-end towers. These shall be fixed on all the
towers just prior to the stringing. Damaged insulators and strings, if any, shall not
be employed in the assemblies. Prior to hoisting, all insulators shall be cleaned in
a manner that will not spoil, injure or scratch the surface of the insulator, but in
no case shall any oil be used for that purpose. Also, for checking the soundness of

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Porcelain Disc insulators, IR measurement using 10 kV (DC) Megger shall be

carried out on 100% insulators (Not applicable for porcelain longrod insulators/
Composite longrod insulators/Glass disc insulators). Corona control rings/ arcing
horn shall be fitted in an approved manner. Torque wrench shall be used for fixing
various line materials and components, such as suspension clamp for conductor
and earth wire, etc., whenever recommended by the manufacturer of the same.

3.6 Handling of Conductor and Earth wire

3.6.1 Running Out of the Conductors
3.6.1.1 The conductors shall be run out of the drums from the top in order to avoid
damage. The Contractor shall be entirely responsible for any damage to tower or
conductors during stringing.
3.6.1.2 A suitable braking device shall be provided to avoid damaging, loose running out
and kinking of the conductors. Care shall be taken that the conductors do not
touch and rub against the ground or objects which could scratch or damage the
strands.
3.6.1.3 The sequence of running out shall be from the top down i.e. the earth wire shall
be run out first followed in succession by the conductors. Unbalanced loads on
towers shall be avoided as far as possible. Inner phase of line conductors shall be
strung before the stringing of the outer phases is taken up.
3.6.1.4 The Contractor shall take adequate steps to prevent clashing of sub conductors
until installation of the spacers/ spacer dampers. Care shall be taken that sub
conductors of a bundle are from the same Contractor and preferably from the
same batch so that creep behavior of sub conductors remains identical. During
sagging, care shall be taken to eliminate differential sag in sub-conductors as far
as possible. However, in no case shall sag mismatch be more than 25mm.
3.6.1.5 Towers not designed for one sided stringing shall be well guyed and steps taken
by the Contractor to avoid damage. Guying proposal along with necessary
calculations shall be submitted by the Contractor to Employer for approval. All
expenditure related to this work is deemed to be included in the bid price and no
extra payment shall be made for the same.
3.6.1.6 When the transmission line runs parallel to existing energised power lines, the
Contractor shall take adequate safety precautions to protect personnel; from the
potentially dangerous voltage built up due to electromagnetic and electrostatic
coupling in the pulling wire, conductors and earth wires during stringing
operations.
3.6.1.7 The Contractor shall also take adequate safety precautions to protect personnel
from potentially dangerous voltage build up due to distant electrical storms.
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3.6.2 Running Blocks

3.6.2.1 The groove of the running blocks shall be of such a design that the seat is
semicircular and larger than the diameter of the conductor/ earth wire and it does
not slip over or rub against the slides. The grooves shall be lined with hard rubber
or neoprene to avoid damage to conductor and shall be mounted on properly
lubricated bearings.
3.6.2.2 The running blocks shall be suspended in a manner to suit the design of the cross-
arm. All running blocks, especially at the tensioning end will be fitted on the cross-
arms with jute cloth wrapped over the steel work and under the slings to avoid
damage to the slings as well as to the protective surface finish of the steel work.
3.6.3 Repairs to Conductors
3.6.3.1 The conductor shall be continuously observed for loose or broken strands or any
other damage during the running out operations.
3.6.3.2 Repairs to conductor if accidentally damaged, shall be carried out with repair
sleeve.
3.6.3.3 Repairing of the conductor surface shall be carried out only in case of minor
damage, scuff marks, etc. The final conductor surface shall be clean, smooth and
free from projections, sharp points, cuts, abrasions, etc.
3.6.3.4 The Contractor shall be entirely responsible for any damage to the towers during
stringing.
3.6.4 Crossings
Derricks or other equivalent methods ensuring that normal services need not be
interrupted nor damage caused to property shall be used during stringing
operations where roads, channels, telecommunication lines, power lines and
railway lines have to be crossed. However, shut down shall be obtained when
working at crossings of overhead power lines. The Contractor shall be entirely
responsible for the proper handling of the conductor, earth wire and accessories
in the field.
Joint measurement of electrical clearances shall be done by the Engineers of
Employer and contractor after completion of final sagging in major crossing spans
i.e. Railway crossing, River crossing, National/ State Highway crossing, expressway
crossing, transmission line crossing (132kV and above voltage level) by using hand
held clearance measurement device/ total station. Deviation, if any, is to be
attended immediately. Value of measured electrical clearances is to be recorded
for future reference.
3.7 Stringing of Conductor and Earth wire

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3.7.1 The stringing of the conductor shall be done by the control tension method. The
equipment shall be capable of maintaining a continuous tension per bundle such
that the sag for each conductor is about twenty percent greater than the sags
specified in the stringing sag table.
3.7.2 The contractor shall give complete details of the stringing methods he proposes
to follow. Prior to stringing the Contractor shall submit the stringing charts for
the conductor and earth wire showing the initial and final sags and tension for
various temperatures and spans alongwith equivalent spans in the lines for the
approval of the Employer.
3.7.3 A controlled stringing method suitable for simultaneous stringing of the sub
conductors shall be used. The conductors making up one phase bundle shall be
pulled in and paid out simultaneously. The synchronous stringing of one phase
with six bundle conductors may be carried out by using one TSE of adequate
capacity. However, two pullers of adequate capacity, towing (4+2) or (3+3)
conductors combined with two sets of tensioners may also be used. These
conductors shall be of matched length. Conductors or earth wires shall not be
allowed to hang in the stringing blocks for more than 96 hours before being pulled
to the specified sag.
Conductor creep are to be compensated by over tensioning the conductor at a
temperature of 300C for ACSR or AACSR BERSIMIS, SNOWBIRD & LAPWING /260C
for AAAC/ AL59 conductors and ACSR or AACSR MOOSE, ZEBRA, PANTHER lower
than the ambient temperature or by using the initial sag and tensions indicated in
the sag and tension chart.
3.8 Jointing
3.8.1 When approaching the end of a drum length at least three coils shall be left in
place when the stringing operations are stopped. These coils are to be removed
carefully, and if another length is required to be run out, a joint shall be made as
per the specifications.
3.8.2 Conductor splices shall not crack or otherwise be susceptible to damage in the
stringing operation. The Contractor shall use only such equipment/ methods
during conductor stringing which ensures complete compliance in this regard.
3.8.3 All the joints on the conductor and earth wire shall be of the compression type, in
accordance with the recommendations of the manufacturer, for which all
necessary tools and equipment like compressors, dies etc., shall be obtained by
the Contractor. Each part of the joint shall be cleaned by wire brush till it is free
of dust or dirt etc., and be properly greased with anti-corrosive compound. If
required and as recommended by the manufacturer, before the final compression
is carried out with the compressors.

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Dimensions of compression type joints (Dead end clamps, MS compression joints,

jumper cones, repair sleeves etc.) shall be measured before and after
compression to check compliance as per approved drawings. Record of dimension
measurement shall be maintained by the Contractor. POWERGRID site engineer
shall check the records and verify the dimensions on sample basis.
3.8.4 All the joints of splices shall be made at least 30 meters away from the tower
structures. No joints or splices shall be made in spans crossing over state/
National highway, railways, power lines and major river crossing. Not more than
one joint per sub conductor per span shall be allowed. The compression type
fittings shall be of the self-centering type or care shall be taken to mark the
conductors to indicate when the fitting is centered properly. During compression
or splicing operation; the conductor shall be handled in such a manner as to
prevent lateral or vertical bearing against the dies. After compressing the joint
the aluminium sleeve shall have all corners rounded, burrs and sharp edges
removed and smoothened.
3.8.5 During stringing of conductor to avoid any damage to the joint, the Contractor
shall use a suitable protector for mid span compression joints in case they are to
be passed over pulley blocks/ aerial rollers. The pulley groove size shall be such
that the joint alongwith protection can be passed over it smoothly.
3.9 Tensioning and Sagging Operations
3.9.1 The tensioning and sagging shall be done in accordance with the approved
stringing charts or sag tables. The “initial” stringing chart shall be used for the
conductor and final stringing chart for the earth wire. The conductors shall be
pulled up to the desired sag and left in running blocks for at least one hour after
which the sag shall be rechecked and adjusted, if necessary, before transferring
the conductors from the running blocks to the suspension clamps. The conductor
shall be clamped within 96 hours of sagging in.
3.9.2 The sag will be checked in the first and the last section span for sections up to
eight spans, and in one additional intermediate span for sections with more than
eight spans. The sag shall also be checked when the conductors have been drawn
up and transferred from running blocks to the insulator clamps.
3.9.3 The running blocks, when suspended from the transmission structure for sagging,
shall be so adjusted that the conductors on running blocks will be at the same
height as the suspension clamp to which it is to be secured.
3.9.4 At sharp vertical angles, conductor and earth wire sags and tensions shall be
checked for equality on both sides of the angle and running block. The suspension
insulator assemblies will normally assume verticality when the conductor is
clamped.

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3.9.5 Tensioning and sagging operations shall be carried out in calm whether when
rapid changes in temperature are not likely to occur.
3.10 Clipping In
3.10.1 Clipping of the conductors into position shall be done in accordance with the
manufacturer’s recommendations.
3.10.2 Jumpers at section and angle towers shall be formed to parabolic shape to ensure
maximum clearance requirements. Pilot suspension insulator strings shall be
used, as per design requirement, to restrict jumper swing to design values.
Balancing weights shall be provided with pilot insulator strings in case of triple/
quad/ hexa bundle line and for all lines with composite insulators.
3.10.3 The Jumper drop shall be maintained as per design requirement. Jumper length
calculations for different line deviation angles shall be submitted by the
Contractor to Employer/ Site-In-Charge. The jumpers shall be prepared to the
required length & compressed with jumper pads at site stores. These shall be
assembled with due care taking into consideration conductor bundle
configuration and installed correctly.
3.10.4 Fasteners in all fittings and accessories shall be secured in position. The security
clip shall be properly opened and sprung into position.
3.11 Fixing of Conductors and Earth wire/OPGW Accessories and Bird Guard
Conductor and earth wire/ OPGW accessories including spacers, spacer dampers
(for bundle conductor) and vibration dampers shall be installed by the Contractor
as per the design requirements and manufacturer’s instruction within 24 hours of
the conductor/earth wire clamping. While installing the conductor and earth wire
accessories, proper care shall be taken to ensure that the surfaces are clean and
smooth and that no damage occurs to any part of the accessories or of the
conductors. Torque wrench shall be used for fixing the Dampers/ Spacer Dampers,
Suspension Clamps etc. and torque recommended by the manufacturer of the
same shall be applied. Bird guard shall be installed on all suspension towers.
Stringing shall not be considered completed without installation of Bird guard and
all Conductors and Earth wire/ OPGW Accessories.
3.11.1 Insulated Conductor sleeve

Insulating sleeve shall be used on bare conductor of Jumper of transposition

tower as per site requirement with approval of Employer site in-charge. However,
Insula􀀍on sleeves shall not be used for HTLS conductors. Insulating sleeve shall
provide minimum 66kV class insulation. The protective conductor cover shall be
made of silicone rubber. The conductor cover shall be secured with the
application of self-adhesive silicone rubber tape.

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Insulating tape and insulating sleeve shall be suitable for conductor operating
temperature of 0 to 180 degree centigrade. The insulating sleeve and insulation
tape shall be Flame, Arc, UV & Ozone Resistant.

Supply & installation charges for insulated conductor sleeve shall be payable pro-
rata basis as per unit rate of respective BPS items under the contract.

Type tests on Insulated Conductor sleeve

The required type tests on insulation sleeve are stipulated hereunder. The
specified type tests under the following clause shall not be required to be carried
out if a valid test certificate is available for a similar design. The tests certificate
shall be considered valid if:
i) Tests conducted earlier is either conducted in accredited laboratory
(accredited based on ISO/IEC vide 25/17025 or EN 45001 by the National
accreditation body of the country where laboratory is located) or witnessed
by the representative(s) of POWERGRID or utility and

ii) Tests have been conducted not prior to 5 (five) years from the date of NOA.

iii) In case the test have been conducted earlier than the above stipulated
period or in the event of any discrepancy in the test report (i.e., any test not
applicable due to any design/manufacturing change including substitution
of components or due to non-compliance with the requirement stipulated
in the Technical Specifications), the tests shall be conducted by the Supplier
at no extra cost to the Purchaser.

Sl. Type test Description Applicable Test Standard/

No. Procedure
1 Ozone Resistance Test on ASTM D1149*
Insulation Sleeve and Tape
2 Power Frequency Voltage The test sample consisting of
Withstand Test on Insulation Insulation sleeve along with
Sleeve and Tape Insulating tape (as per the
installation condition) shall
withstand 66 kV for 1 minute
3 Arc Resistance on Insulation ASTM D495*
Sleeve and Tape
4 UV Resistance on Insulation 1000 hrs as per IEC 62217*
Sleeve and Tape
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5 Hardness test on Insulation ASTM D2240*

Sleeve
6 Tensile Strength test on ASTM D 412*
Insulation Sleeve & tape
7 Elongation test on Insulation ASTM D 412*
sleeve and Tape
8 Dielectric Strength test on ASTM D 149*
Insulation sleeve and Tape
9 Silicone Content test on Minimum content of silicone
Insulation sleeve and Tape as guaranteed by supplier
shall be verified through FT-IR
spectroscopy & TGA analysis
or any other suitable method
mutually agreed between
Purchaser& Supplier in Quality
Assurance Programme
10 Tracking and Erosion Resistance ASTM D2303*
on Insulation sleeve and Tape
11 Flammability test on Insulation IEC 62217*
sleeve and Tape
12 Temperature test for 1800 for Sample shall not develop any
Insulation sleeve and Tape cracks/ fissures after
subjecting to 1800for 4 hours.
* Equivalent Indian Standards shall also be acceptable.
Acceptance Tests on Insulated Conductor sleeve:
1. Verification of dimensions of Insulation sleeve and Insulating Tape
2. Tensile Strength test of Insulation sleeve and Insulating Tape
3. Elongation test of Insulation sleeve and Insulating Tape
4. Hardness test of Insulation sleeve
5. Silicone Content Test on Insulation sleeve and Insulating Tape

3.12 Replacement
If any replacement is to be affected after stringing and tensioning or during
maintenance, leg member and bracing shall not be removed without first
reducing the tension on the tower by proper guying techniques or releasing of the
conductor. For replacement of cross arms, the conductor shall be suitably tied to
the tower at tension points or transferred to suitable roller pulleys at suspension
points.
3.13 Permitted Extra Consumption of Line materials
3.13.1 The quantity of conductor and earth wire to be incorporated in the line shall be
worked as per the following norms.
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Quantify of Conductor = Line length* as per detailed survey x 3 phases x Nos.

of conductor per phase (for Single Circuit Line)
= Line Length* as per detailed survey x 3 phases x
Nos. of conductor per phase x 2 (for Double Circuit
Line)
Quantity of Earthwire = Line length* as per detailed survey x nos. of earthwire
Quantity of OPGW = Line length* as per detailed survey x no. of OPGW
* For calculation of conductor & Earth wire requirement in hilly stretches, inclined
distance between the towers shall be considered instead of horizontal distance
(considered for line length).
3.13.2 The Contractor shall make every effort to minimise breakage, losses and wastage
of the line materials during erection. However, the Contractor shall be permitted
and extra consumption of line materials up to the limits specified in the table
below and shall be permitted to dispose of the scrap, if any at the end.
Table: Permitted extra consumption of line materials
Item % of permitted extra consumption
Conductor & earth wire 1
Insulators 1*
OPGW (in Plain area) 5
OPGW (in Hilly area) 7
* will be applicable whenever insulators are supplied by owner.
In case of Composite Long Rod Insulators, permitted extra consumption will be
subject to physical evidence of damaged insulators otherwise excess insulators
are required to be returned to POWERGRID.
3.13.3 In case of conductor and earth wire, the maximum permitted extra consumption
limit of one percent is inclusive of sag, jumpering, damage, loss and wastage etc.
3.13.4 The Conductor can be supplied in Wooden drums/ steel drums and hybrid drums
and the following methodology/ procedure to be followed: -
In case of wooden drums for conductor and earthwire, the Contractor shall not
be required to return empty wooden drums to the Employer. The empty drums
shall dispose-off by the contractor at his cost.
In case of steel drums and hybrid drums for conductor, the Ownership of the
empty conductor drums shall lie with the conductor supplier who shall ultimately
take back the empty conductor drum from the Project site(s). Accordingly,
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erection Contractor is required to return the drums to the Conductor Supplier at

erection contractor’s designated stores after the running out of conductor from
the drum.
The erection contractor shall intimate the Conductor supplier and Employer
regarding empty steel drums at their designated stores. Necessary coordination
for taking back the empty steel/ hybrid drums in this regard shall be carried out
by the Conductor Supplier with the erection Contractor. The erection Contractor
shall handle the Steel/ Hybrid Drums in a manner so that these drums can be
reused. All efforts shall be made by the erection Contractor to use the Conductor
at the earliest.
Erection Contractor is required to return all the empty steel/ hybrid drums.
However, 2% wastage due to transportation & handling etc. of steel/ hybrid
drums is allowed. The wastage beyond 2% has to be reimbursed by Erection
Contractor.
3.13.5 Any conductor and earth wire drum which has been opened by the Contractor
shall not be taken back by Employer and the unused conductor or earth wire in
such drums may be treated as waste permissible within the overall limits specified
in the Table above under clause 3.1.3.2.
3.13.6 The Contractor shall return to the Employer all Employer supplied material not
incorporated in the works, except those permitted by Employer as scrap in terms
of Table above under clause 3.1.3.2. Otherwise, the Contractor shall either
replenish the excess material from approved source or pay in respect of such
excess materials which he is unable to return at rates corresponding to the actual
cost of procurement plus (i) 15% for OSM procured under domestically funded
packages; and (ii) 26.5% for OSM procured against packages funded by
multilateral funding agencies. The “cost of procurement” for the above purpose
shall be F O R destination site cost of OSM as per LOA of the respective packages
plus taxes & duties plus price variation (if positive) applicable as on the date of
issuance of TOC for Tower Package. In case of contract in Foreign currency, Bills
clearing (BC) Selling, Market Rate of Exchange (MRE) established by State Bank of
India (SBI) as prevalent on date of TOC shall be applicable for converting into
Indian Rupees.
3.13.7 The quantities of line materials to be supplied by the contractor (i.e. earth wire
and/or OPGW, Hardware fittings & accessories) as indicated in the bill of
quantities are provisional and the actual quantity shall depend upon detailed
survey. Contractor shall be responsible for regulating the supplies of contractor
supplied materials on the basis of actual requirements. The Employer shall have
right, not to take any surplus contractor supplied line materials.
3.13.8 OPGW shall be supplied as per standard length of 5 km in plain area and 3 km in
hilly area.

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3.14 Final checking, Testing and Commissioning

After completion of the works, final checking of the line shall be carried out by the
Contractor to ensure that all foundation works, tower erection and stringing have
been done strictly according to the specifications and as approved by the
Employer. All the works shall be thoroughly inspected in order to ensure that:
a) Sufficient backfilled earth covers each foundation pit and is adequately
compacted;
b) Concrete chimneys and their copings are in good condition and finely
shaped.
c) All tower members are used strictly according to final approved drawing and
are free of any defect or damage whatsoever.
d) All bolts are properly tightened, punched, tack welded and painted with zinc
rich paint;
e) The stringing of the conductors and earth wire has been done as per the
approved sag and tension charts and desired clearances are clearly
available;
f) All conductor and earth wire accessories are properly installed;
g) All other requirements for completion of works such as fixing of danger
plate, phase plate, number plate, anti-climbing device and aviation signal
have been fulfilled.
h) Wherever required, that proper revetment (erosion protection) is provided;
i) The original tracings of profile and route alignment as well as tower design,
structural drawings, bill of material and shop drawings of all towers are
submitted to the Employer for reference and record.
j) The insulation of the line as a whole is tested by the Supplier through
provision of his own equipment, labour etc., to the satisfaction of the
Employer.
k) All towers are properly grounded.
l) The line is tested satisfactorily for commissioning purpose.
3.14.1 The contractor shall submit minimum 4 nos. of high resolution (min. 20MP) geo
tagged photographs of each tower after completion of stringing. Stringing shall
not be considered completed without submission of soft copy of following
photographs of each tower.
i) Complete tower
ii) Close up on Cross arms covering insulators, Hardware etc.
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iii) Forward span focusing on Conductor & corridor

iv) Foundation

3.14.2 The Contractor should also fulfill the requirements of pre-commissioning

procedure as given in Appendix–II to this Specification
3.14.3 After commissioning of the line, thermos-vision scanning of jumper connections,
dead end joints and mid span compression joints of the complete line shall be
completed by the Contractor by deploying third party agency within three months
of commissioning of the line using minimum 640x480 pixel resolution day time
thermos-vision Camera alongwith suitable lenses. Details of the proposed third-
party agency (including past experience) shall be submitted by the Contractor to
POWERGRID site-in-charge/ RHQ. The thermos-vision scanning shall be carried
out under supervision of Contractor & POWERGRID site engineers. Location and
span wise report of thermos-vision scanning shall be submitted by the Contractor
to POWERGRID site-in-charge. Identified defects, if any, shall be rectified by the
Contractor within contractual defect liability period.
4.0 Field Quality Plan
The Contractor shall execute the work in accordance with the Field Quality Plan
which is available on the POWERGRID Website 7 (seven) days prior to the actual
date of bid opening

5.0 Manufacturing Quality Plan

Tower manufacturing shall be carried out in accordance with
Standardized Manufacturing Quality plan as given in Appendix-III to this section
of the Specification.

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Annexure-I

Test Procedures for Bird Flight Diverters

1 Visual Examination Test

Bird diverter assemblies shall be visually examined for general finish and good
workmanship.

2 Verification of Dimensions

The dimensions of the bird diverter assembly, including area of warning disc, reflective
area and glow-in-dark area, shall be checked against approved drawings and
requirements given in the technical specification.

3 Mechanical Strength Test

Following Mechanical Strength Tests shall be carried out: -

a) Direct Pull test

The clamp of the completely assembled Bird diverters shall be subjected to a load
equal to 50% of the specified load of 500 N (using Universal Testing machine) which
shall then be increased at a steady rate to 67% of the specified load. The load shall
be held for five minutes and then removed. After removal of the load, the assembly
and its components shall not show any visual deformation and it shall be possible
to disassemble them. The clamp shall then be re-assembled and loaded to 50% of
specified load. The load shall be further increased at a steady rate to the maximum
load of 500 N and shall be held for one minute. No damage /deformation should
occur during this period. The applied load shall then be gradually increased until the
failing load is reached and the value shall be recorded.

b) Clamp Slip Test/Grip Retaining Strength test

The test shall be carried out as per IEC 61854 (Fig. 1a). The tests shall be performed
separately using earthwire, and OPGW. The earthwire/ OPGW, free of any defects or
damage, shall be tensioned to 20% of its rated tensile strength. By means of a suitable
device (see fig. 1a of IEC 61854), load shall be applied to the clamp along the axis of the
earthwire/OPGW and shall be gradually increased (not faster than 100 N/s) until it
reaches the specified minimum slip load of 250 N. The load shall be kept constant for
one minute. The movement of the clamp relative to its original position on the
earthwire/ OPGW shall be observed. The clamp should not slip more than 10 mm and
there should not be any damage / deformation of the bird diverter and the earth
wire/OPGW. Thereafter, the load shall be increased gradually in steps of 25 N and shall
be kept constant for one minute at each step. The slippage at each step shall be

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recorded. The process shall be continued till the slippage is observed to be more than
10 mm from its previous position and the corresponding load shall be recorded.

4 Vibration Test

The tests shall be conducted in a laboratory set up with a minimum effective span length
of 30 m for earthwire and OPGW separately. The earthwire/ OPGW shall be tensioned
at 25% of its Ultimate Tensile Strength (UTS). Constant tension shall be maintained
within the span by means of lever arm arrangement. The span shall be equipped with
vibration inducing equipment suitable for producing steady standing vibration. The
inducing equipment shall have facilities for stepless speed control as well as stepless
amplitude arrangement. Equipment shall be able to measure the frequency, cumulative
number of cycles and amplitude of vibration at any point along the span.

Four number of Bird Diverters shall be clamped to the earthwire/ OPGW in and around
the middle of the test span. These bird diverters shall be free to vibrate and shall not
be re-torqued or adjusted between the tests. The frequency of vibration is so chosen
as to get an odd number of loops. The shaker shall be positioned at least two loops
away from the test specimens to allow free movement of the earthwire/ OPGW close
to the test specimens. The earthwire/ OPGW shall be connected to the shaker and
vibrated to an amplitude such that

f1.8 Ymax > 1000 mm/sec.

Where Ymax being the antinode displacement (mm) and f is the test frequency (Hz).

The test frequency shall be greater than 24 Hz and the total number of cycles shall be
more than 10 million. The bird diverter shall withstand the vibration test without
slipping on the earthwre/ OPGW, loosening, damage or failure of components parts.

After the completion of test, the same bird diverter shall be subjected to mechanical
strength test (direct pull test & clamp slip test) as per the procedure given above and
the sample shall be able to withstand the tests without damage/ deformation.

A representative diagram of test assembly is given below.

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5 Temperature Cycle Test

The complete bird diverter assembly shall be quickly and completely immersed,
without being placed in an intermediate container, in a water bath maintained at a
temperature of 85°C and left submerged at this temperature for 15 minutes. The
sample then shall be withdrawn and quickly & completely immersed, without being
placed in an intermediate container, in the cold water bath maintained at a
temperature of -15°C where it shall remain for 15 minutes. The sample shall be
subjected to 10 such cycles.

The time taken to transfer from either bath to the other shall be as short as possible
and never exceed 30 seconds. The quantity of water in the test tanks shall be
sufficiently large for the immersion of the samples so as not to cause a temperature
variation of more than ±5°C in the water.

After completion of 10 cycles, the sample shall be examined to verify that the samples
have not deformed/ damage.

After the completion of test, the same bird diverter shall be subjected to mechanical
strength test (direct pull test & clamp slip test) as per the procedure given above and
the sample shall be able to withstand the tests without damage/ deformation.

6 Corrosion Resistance Test

Salt fog (at 5% salt solution) and Humidity test (at 90% Rh) as per procedure in
accordance with MIL-STD 810F (method 509.4 and Method 507.4).

After the completion of test, the same bird diverter shall be subjected to mechanical
strength test (direct pull test & clamp slip test) as per the procedure given above and
the sample shall be able to withstand the tests without damage/ deformation.

7 Ageing Test

Solar radiation test & sand and dust test as per procedure in accordance with MIL-
STD 810F (Method 505.4 proc II and 510.4 proc I).

After the completion of test, the same bird diverter shall be subjected to mechanical
strength test (direct pull test & clamp slip test) as per the procedure given above and
the sample shall be able to withstand the tests without damage/ deformation.

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Annexure-II

Site Acceptance Testing (SAT) for FO Cabling

1.0 Site Acceptance Test

Prior to installation, every spooled fibre optic cable segment shall be tested for
compliance with the Pre-shipment data previously received from the manufacturer.
This requirement will preclude the installation of out of specification cable segments
that may have been damaged during shipment.

SAT shall be carried out link by link from FODP to FODP. SAT may be performed in
parts in case of long links.

Sag and tension of OPGW shall generally be as per approved sag-tension chart and
during installation, sag and tension of OPGW shall be documented. Upon completion
of a continuous cable path, all fibres within the cable path shall be demonstrated for
acceptance of the cable path. Fibre Optic cable site testing minimum requirements
are provided in Table 1(a) through 1 (c) below:

Table 1(a)
Fibre Optic Cable Pre-Installation Testing
Sl. No. Description
1 Physical Inspection of the cable assembly for damage
2 Optical fibre continuity and fibre attenuation with OTDR at 1550
nm
3 Fibre Optic Cable length measurement using OTDR

Table 1(b)
Fibre Optic Cable Splicing Testing
Sl. No. Description
1 Per splice bi-directional average attenuation with OTDR
2 Physical inspection of splice box/enclosure for proper fibre /
cable routing techniques
3 Physical inspection of sealing techniques, weather proofing, etc

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Table 1(c)
Fibre Optic Cable Commissioning Testing
Sl. No. Description
1 End to End (FODP to FODP) bi-directional average attenuation of
each fibre at 1310 nm and 1550 nm by OTDR
2 End to End (FODP to FODP) bi-directional average attenuation of
each fibre at 1310 nm and 1550 nm by Power meter
3 Bi-directional average splice loss by OTDR of each splice as well as
for all splices in the link (including at FODP also)
4 Proper termination and labelling of fibres & fibre optic cables at
FODP as per approved labelling plan

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