COMPANY STANDARDS

ISSUE NO : 08
ISSUE DATE : 01.10.2007
REVISION NO : 05

REVISION DATE : 01.09.2011

CORPORATE OFFICE:
KEC INTERNATIONAL LIMITED
463, Ceat Mahal, Dr. Annie Besant Road,
Worli, Mumbai – 400 030
India
TEL: (022) 66670200
FAX: (022) 66670299

This Company Standard is a property of KEC International Limited. Making copies or even an
extract from this is not permitted.

Page 1 of 101
 COMPANY STANDARD CCH
ISSUE NO. 8 01.10.07

CONTROLLED COPY HOLDERS REV. NO. 5 01.09.11

SHEET NO. 1 OF 1

LIST OF CONTROLLED COPY HOLDERS

Copy No. Controlled Copy Holders Location

1 Head CQA – Corporate Quality Assurance Butibori

2 Plant Head – Butibori Butibori

3 Plant Head – Jabalpur Jabalpur

4 Plant Head – Jaipur Jaipur

5 Head Production – Butibori Butibori

6 Head Production – Jabalpur Jabalpur

7 Head Production – Jaipur Jaipur

8 Head Production – Mumbai Mumbai

9 Head QA – Butibori Butibori

10 Head QA – Jabalpur Jabalpur

11 Head QA – Jaipur Jaipur

12 Head QA – Mumbai Mumbai

13 Head Materials – Butibori Butibori

14 Head Materials – Jaipur Jaipur

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 2 of 101
 COMPANY STANDARD CS – LCS
ISSUE NO. 8 01.10.07

LIST OF COMPANY STANDARDS REV. NO. 5 01.09.11

SHEET NO. 1 OF 1

Page Revision Revision

CS No Name of Company Standards
No. No. Date
CS 1 Specification for Structural Steel Sections 4 1 30.12.08

CS 2 Specification for Structural Steel Plates 18

CS 3 Color Codification for Steel Grade Identification 20 1 20.09.10

CS 4 Fabrication Tolerances 22

CS 5 Stamping Specifications 26

CS 6 Specification for Bending Operation 29 1 20.09.10

CS 7 Specification for Plugging of Holes by Welding 31

CS 8 Galvanizing Inspection Tests 32

CS 9 Specification for Stenciling of Item Numbers 36

CS 10 Hot Dip Galvanizing Zinc Grades 40

CS 11 Packaging of Tower Parts for Domestic Projects 42 1 31.07.09

CS 12 Packing of Tower Parts for Export Projects 46 3 01.02.11

CS 13 Bundles and Boxes Packaging Material Specifications 55

CS 14 Packaging of Bolts, Nuts and Accessories 59

CS 15 Specification for Pack Washers 61

CS 16 Specification for Spring Washers 67

CS 17 Specification for Bolts and Nuts 75

CS 18 Specification For Anti Theft Bolt and Nuts 92

CS 19 Sampling Plan for Inspection and Testing 94 2 01.09.11

The Company Standards are issued and approved by Corporate Quality and Assurance, Butibori.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 3 of 101
 COMPANY STANDARD CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 1 OF 14

1.0 SCOPE
This standard covers the requirement of Structural Steel Angles of Mild Steel & High Tensile Steel
generally used, for manufacturing of Transmission Line Tower Parts.
(All inspection specification/parameters are taken from repsective standards for reference purpose.
Final decision for acceptance / rejection shall be based on the requirements of the respective
standards and / or Customer Manufacturing Quality Plan.)

2.0 The Structural Steel shall be suitable for Hot Dip Galvanizing after fabricating the steel angles of
MS and HT grades into tower parts.

3.0 RAW MATERIAL

3.1 The manufacturing / rolling of Steel Angles shall be done from Billets, Blooms and Slabs. Ingots
shall be used only when special permission is obtained from WORKS.
3.2 The Grades of Raw Material used, shall be as per the respective applicable standards, suitable to
obtain the required Mechanical and Chemical Properties.

4.0 GRADES
The Material Grade shall be as mentioned in the Purchase Order and in specifications.

5.0 SAMPLING PLAN

5.1 Refer Company standard CS – 19 for sampling plan of following tests:
a) Visual test – Surface finish, Raw Material and rolling defects
b) Dimensional test – Flange width, Flange Thickness, Root Radius, Squareness, Straightness
c) Mechanical test - Yield stress, Ultimate Tensile stress, % of Elongation, Bend test, Charpy
Impact test
d) Chemical test – presence of elements in %, % of nitrogen, % of hydrogen and % of oxygen
e) Austenite grain size and Microstructure one sample per grade, per heat and per size.
f) Inclusion test – one sample per grade, per heat and per size.
5.2 The Sampling Plan 3.1.3 of CS-19 shall be changed to normal or tightened sampling plan if two
consecutive lots gets reworked / rejected at Supplier inspection. Refer IS 2500 (Part I) for sampling
plan for Normal / Tighten.

6.0 VISUAL INSPECTION

6.1 All Steel Angles & Plates shall be free from:
1) Lamination / Fold / Tongue
2) Piping
3) Pitting
4) Cracks
5) Roll Marks
6) Scaling / Scabbing
7) Toe Projection
8) Fin

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 4 of 101
 COMPANY STANDARD CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 2 OF 14

6.2 If any of the above Surface Defects removed by grinding the thickness should not be reduced
locally by more than 4% of the nominal thickness value.

7.0 CAMBER & SWEEP:

The purpose of checking the camber and sweep is to ensure the adequate straightening of the rolled
angles and fabricated item members, for desired fitment in the tower structure.

7.1 Procedure to check:

7.1.1 The Items under verifications shall be put in Apex-up position on reasonably leveled supports
and a thread shall be used (at equi-distance of three meters and minimum two at both ends) to
measures the camber which is directly proportional to the segment of the Angle with respect to thread.
7.1.2 The straightness mostly measured in two ways as shown below as Camber and Sweep and the
minimum value permissible for Camber and Sweep shall be as given below in the table:

SWEEP CAMBER
CAMBER:

Flange width / Allowable Tolerance

Name of Specification
Leg Length Camber Sweep
< 3” / 76.2 mm 0.4% of length
ASTM A6 Not specified
≤ 3” / 76.2 mm 0.2% of length
≥ 150 mm 0.4% of length
> 150 to ≤ 200 mm 0.2% of length Not Specified
> 200 mm 0.1% of length
BSEN 10056 Part II
 150mm **6mm on 1.5m L
> 150 to  200mm **3mm on 2m L Not Specified
> 200mm **3mm on 3m L
< 100 mm 0.2% of length
IS 802 Part II Not Specified
≥ 100 mm 0.2% of length
KEC Specifications All sizes 0.2% of total length Not allowed

Note: ** Tolerance over any part of bar (L) on given Flange width or Leg Length.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 5 of 101
 COMPANY STANDARD CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 3 OF 14

8.0 Sampling for Unit Weight Test:

Refer 6.0 of CS – 19 for sampling plan for sectional weight test.

9.0 TOLERANCES

9.1 FOR ANGLE

9.1.1 Leg Length / Flange Width: The Tolerance on Leg Length shall be as follows:

Table – 1: As per IS 808 Flange Width variation - Angles

Flange Width Allowable Tolerance
Up to 45 mm  1.5 mm
> 45 to 100 mm  2.0 mm
> 100 mm  2 % of flange width

Note: As per IS 808 Difference between the Leg Lengths of equal leg angle shall be limited to 75 %
of total tolerance on leg length.

Table – 2: As per ASTM A6 Flange width variation - Angles

Section Sizes
Under (mm) Over (mm)
(mm)
25.4 and under 0.79 0.79
Over 25.4 to 50.8 incl. 1.19 1.19
Over 50.8 to 76.2 excl 1.59 1.59
76.2 to 101.6 incl. 2.38 3.18
Over 101.6 to 152.4 incl. 3.18 3.18
Over 152.4 3.18 4.76

Table – 3: As per BSEN 10056-II Flange Width Tolerance - Angles

Flange Width Allowable Tolerance
≤ 50 mm  1.0 mm
> 50 to ≤ 100 mm  2.0 mm
> 100 to ≤ 150 mm  3.0 mm
> 150 to ≤ 200 mm  4.0 mm
> 200 mm + 6.0 mm & - 4.0 mm

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 6 of 101
 COMPANY STANDARD CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 4 OF 14

9.1.2 Leg Thickness / Flange Thickness: The Tolerance on Flange Thickness of Angles as follows:
Thickness shall be measured in the middle 1/3 rd portion of the flange width. In case of any
ambiguity, measurement by Micrometer shall be considered as final.
Table–4: As per BSEN 10056-II Flange Thickness Tolerance - Angles
Thickness Allowable Tolerance
≤ 5 mm  0.5 mm
> 5 to ≤ 10 mm  0.75 mm
> 10 to ≤ 15 mm  1.0 mm
> 15 mm  1.2 mm

Table–5: As per ASTM A6 Flange Thickness Tolerance - Angles

Section Sizes (mm) Upto 4.76 (mm) Over 4.76 to 9.53 incl. (mm) Over 9.53 (mm)
25.4 and under 0.20 0.25 0.30
Over 25.4 to 50.8 incl. 0.25 0.25 0.30
Over 50.8 to 76.2 excl 0.30 0.38 0.38
76.2 to 101.6 incl. 0.30 0.38 0.38
Over 101.6 to 152.4 incl. 0.30 0.38 0.38
Over 152.4 0.30 0.38 0.38

Indian standard does not specify any tolerance on flange thickness. This is to be controlled by all
sectional weight parameters.

10.0 UNIT WEIGHT, ROOT RADIUS AND HEEL ROUND

10.1 Unit Weight / Sectional Weight:
For ANGLE:
Tolerance on the sectional weight per meter given in Annexure -2 for material shall be as given below
in the table:
Table – 6: Unit Weight of Angles as per following standards
As per IS: 808 As per ASTM A6 As per BSEN: 10056 part 1
Thickness upto 3mm: ± 5% Leg length upto 3’/76.2mm: + 5%, - 3% Thickness upto 4mm: ± 6%
Thickness above 3mm: + 5%, - 3% Leg length above 3’/76.2mm: ± 2.5% Thickness above 4mm: ± 4%

10.2 ROOT RADIUS: + 0.5 mm

10.3 HEEL ROUND

Tolerance on Heel round of Steel Shapes shall be as follows:
Table - 7
Leg lengths Tolerance
Leg Length Upto 100 mm 2 mm Maximum
Leg Length more than 100 mm 3 mm Maximum

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 7 of 101
 COMPANY STANDARD CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 5 OF 14

11.0 SQUARENESS
The legs shall be perpendicular to each other within the permissible tolerance given below:
k k

Table – 8
Specification Leg Length, mm Tolerance on out–of-Squareness
0
IS 1852 All sizes 1
0
ASTM A6 All sizes 1 1/2
≤ 100 k = 1.0mm
> 100 to ≤ 150 k = 1.5mm
BSEN 10056 Part II
> 150 to ≤ 200 k = 2.0mm
> 200 k = 3.0mm

12.0 SAMPLE PIECE LOCATION, PREPARATION, SHAPE AND SIZE FOR MECHANICAL TESTS
12.1 Tensile Test Sample
12.1.1 Location Of Test Samples
a) The Tensile Strength, Yield Stress and Percentage Elongation of Steel shall be determined from
the standard sample piece cut lengthwise or crosswise from Plates and lengthwise from Angles.
b) The recommended location for taking Test Sample for Angles and Plates are indicated in Fig.1.

2/3 1/3 2/3 1/3

Figure 1
12.1.2 Preparation Of Test Piece
a) The test piece cut from the standard sample as mentioned above in the Fig 1 shall be machined on
shaper machine.
b) The Machining of Test Piece shall be done on thickness only.

12.1.3 For Shape, Size and Dimensions Of Test Piece for tensile testing refer IS 1608, ASTM A6 and
BSEN 10002-1.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 8 of 101
 COMPANY STANDARD CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 6 OF 14

13.0 TENSILE TEST:

Tensile Strength, Yield Stress and Percentage Elongation shall be determined in accordance with IS:
1608, BSEN 10002 Part 1 & ASTM A6 and shall be as per respective specification and grade. Refer
Annexure 4.

14.0 BEND TEST:

Bend Test shall be carried out as required and stated in applicable Standards. Test shall be
conducted in accordance with IS 1599, JIS G 3192 and ASTM A370. Refer Annexure 4.

15.0 CHARPY / IMPACT TEST:

Impact Test shall be conducted in accordance with IS 1757, IS 2062, BSEN 10025 Part II, ASTM A6
and ASTM A370. Refer Annexure 4.

16.0 CHEMICAL COMPOSITION (PRODUCT ANALYSIS)

16.1 Chemical composition is an analysis (manually or on spectro machine) to know the presence of
elements as per the relevant specification in a product / sample. The presence of elements shall be
governed and decided by the specification. Presence of elements shall be mentioned in percentage.
Refer Annexure 4.
16.2 The test results observed shall meet the values specified in the relevant standards like IS 2062,
BSEN 10025 Part II, ASTM A 6, JIS G 3101 etc.

17.0 INCLUSION RATING :

17.1 Inclusions refer to a defect when particles of nonmetallic impurities, usually oxides, sulfides,
silicates, refractories and such, which are the products of deoxidation, are insoluble in the matrix and
are mechanically held in steel during solidification.
Inclusion count/rating means determination of the number, kind, size and distribution of non-metallic
inclusions.

17.2 Microscopical methods shall be used to characterize the size, distribution, number and type of
inclusions on a polished specimen surface.

17.3 Inclusion test shall be conducted by Method A (Worst Field) in accordance with ASTM E45.

This test method requires a survey of a 160 mm² polished surface area of the specimen at 100X.
The field size (size selected for image under microscope) shall equal an area equivalent to 0.50
mm² on the specimen surface as defined by a square with 0.71 mm long sides. Each 0.50 mm²
field is compared to the square fields depicted in Plate I-r in a search for the worst field, that is the
highest severity rating, of each inclusion Type A,B,C and D (Inclusion type A-sulphide, B-Alumina,
C-Silicate, D- Oxide) for both the Thin and Heavy Series. The severity level of these worst fields
shall be reported for every specimen examined.

Individual Inclusion Rating for Steel Sections shall not be more than 2.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 9 of 101
 COMPANY STANDARD CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 7 OF 14

18.0 PACKING AND BUNDLING OF STEEL SECTIONS

18.1 Each bundle shall have only one size, length, and grade of section in a bundle.
18.2 Sections shall be bundled size, length and heatwise. If heat traceability is not available then
sections shall be bundled lotwise. (Lot means sections rolled at one time).
18.3 Sections upto 120mm size shall be bundled and weight of bundle shall not exceed 3000 kgs.
Sections above 120mm can be in sent in loose condition.
18.4 Each bundle shall have identification on one of the top section in a bundle. Identification marking
shall be done with permanent marking pen and shall be legible. Identification mark shall have
information about section size and length, number of pieces, grade of steel and customer name and
destination.
18.5 Each bundle shall be tied with MS wire or steel straps at two ends and at distance of 3 mtrs each
from one end. The ends of MS wire are twisted together to hold the sections firmly in a bundle.
18.6 Grade identification colour (CS -3) shall be applied at one end of the each section in a bundle or
on each section above 120mm size.
18.7 Sections shall be transported preferably on flat bed trucks and if flat bed trucks are not available
then proper size wooden rafters shall be used to avoid bending / sagging and deformation of sections
during transportation.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 10 of 101
 COMPANY STANDARD Annexure 1 of CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 8 OF 14

Chart of Sectional weight and Root Radius for IS and BSEN Specification:

IS 808 BSEN10056-I&II IS 808 BSEN10056-I&II

Section Root Root Section Root Root
Kg/m Kg/m Kg/m Kg/m
Radius Radius Radius Radius
20X20X3 4 0.9 3.5 0.88 65X65X6 6.5 5.8 9* 5.91*
25X25X3 5 1.1 3.5 1.12 65X65X7 6.5* 6.79* 9 6.83
25X25X4 5 1.4 3.5 1.45 65X65X8 6.5 7.7 9* 7.73*
30X30X3 5 1.4 5 1.36 70X70X5 7 5.3 9* 5.37*
30X30X4 5 1.8 5 1.78 70X70X6 7 6.3 9 6.38
35X35X4 5 2.1 5 2.09 70X70X7 7* 7.35* 9 7.38
45X30X3 5 1.7 4.5* 1.72* 75X75X5 7 5.7 9* 5.76*
45X30X4 5 2.2 4.5 2.25 75X75X6 7 6.8 9 6.85
45X30X5 5 2.8 4.5* 2.77* 75X75X8 8 8.9 9 8.99
40X40X3 5.5 1.8 6* 1.84* 80X80X6 8 7.3 10* 7.34*
40X40X4 5.5 2.4 6 2.42 80X80X8 8 9.6 10 9.63
40X40X5 5.5 3 6 2.97 80X80X10 8.5 11.8 10 11.90
45X45X3 5.5 2.1 7* 2.09* 90X90X6 8.5 8.2 11* 8.30*
45X45X4 5.5 2.7 7* 2.74* 90X90X7 8.5* 9.57* 11 9.61
45X45X4.5 5.5* 3.06* 7 3.06 90X90X8 8.5 10.8 11 10.90
45X45X5 5.5 3.4 7* 3.38* 90X90X9 8.5* 12.14* 11 12.20
45X45X6 5.5 4 7* 3.99* 90X90X10 8.5 13.4 11 13.40
50X50X3 6 2.3 7* 2.33* 100X100X6 12 9.2 12 NS
50X50X4 6 3 7 3.06 100X100X7 8.5 10.7 12* 10.73*
50X50X5 6 3.8 7 3.77 100X100X8 8.5 12.1 12 12.20
50X50X6 6 4.5 7 4.47 100X100X10 8.5 14.9 12 15.00
55X55X4 6.5 3.3 7* 3.38* 100X100X12 10 17.7 12 17.80
55X55X5 6.5 4.1 7* 4.17* 110X110X8 10 13.4 12.5* 13.45*
60X60X4 8 3.7 8* 3.69* 110X110X9 10* 14.99* 12.5* 15.04*
60X60X5 6.5 4.5 8 4.57 110X110X10 10 16.6 12.5* 16.62*
60X60X6 6.5 5.4 8 5.42 110X110X11 10* 18.13* 12.5* 18.18*
60X60X8 6.5 7 8 7.09 110X110X12 13 19.7 12.5* 19.73*
65X65X4 6.5 4 9* 4.03* 120X120X8 13 14.7 13* 14.71*
65X65X5 6.5 4.9 9* 4.97* 120X120X9 13* 16.46* 13* 16.46*

Note * - Sections whose sectional weights are not specified in standard is calculated by formula given
in specification and Root Radius shall be that of same flange size of section.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 11 of 101
 COMPANY STANDARD Annexure 1 of CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 9 OF 14

Chart of Sectional weight and Root Radius for IS and BSEN Specification:

IS 808 BSEN 10056-I&II

Section
Root Radius Kg/m Root Radius Kg/m
120X120X10 13 18.20 13 18.20
120X120X11 13* 19.92* 13* 19.92*
120X120X12 10 21.60 13 21.60
130X130X10 10 19.70 14* 19.79*
130X130X11 10* 21.59* 14* 21.67*
130X130X12 10 23.50 14 23.60
150X150X10 12 22.90 16 23.00
150X150X12 12 27.30 16 27.30
150X150X14 12* 31.56* 16* 31.65*
150X150X15 16 33.80 16 33.80
150X150X16 12 35.80 16* 35.89*
150X150X18 16 40.10 16* 40.06*
150X150X20 12 44.10 16* 44.18*
160X160X15 16* 36.13* 17 36.20
175X175X15 16* 39.67* 17* 39.65*
180X180X14 18* 38.22* 18* 38.30*
180X180X16 18* 43.40* 18 43.50
180X180X18 18 48.60 18 48.60
200X200X16 15 48.50 18 48.50
200X200X18 18* 54.17* 18 54.30
200X200X20 15 60.00 18 59.90
200X200X24 18 71.10 18 71.10
200X200X25 15 73.90 18* 73.87*
250X250X25 18 93.70 18* 93.50*
250X250X28 18* 104.02* 18 104.00
250X250X32 18* 117.84* 18* 117.84*
250X250X35 18* 128.04* 18 128.00

Note * - Sections whose sectional weights are not specified in standard is calculated by formula given
in specification and Root Radius shall be that of same flange size of section.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 12 of 101
 COMPANY STANDARD Annexure 2 of CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 10 OF 14

Chart of Sectional weight for ASTM A6 Standard:

L - Shapes Equal Leg Angles

Unit wt *Unit wt Unit wt *Unit wt
Section (inches) Section (mm) Section (inches) Section (mm)
(lb/ft) (Kg/m) (lb/ft) (Kg/m)
8'x8'x1' 1/8' 56.90 203.2x203.2x28.58 84.70 3 1/2'x3 1/2'x5/16' 7.20 88.9x88.9x7.94 10.70
8'x8'x1' 51.00 203.2x203.2x25.4 75.90 3 1/2'x3 1/2'x1/4' 5.80 88.9x88.9x6.35 8.60
8'x8'x7/8' 45.00 203.2x203.2x22.23 67.00 3'x3'x1/2' 9.40 76.2x76.2x12.7 14.00
8'x8'x3/4' 38.90 203.2x203.2x19.05 57.90 3'x3'x7/16' 8.30 76.2x76.2x11.11 12.40
8'x8'x5/8' 32.70 203.2x203.2x15.88 48.70 3'x3'x3/8' 7.20 76.2x76.2x9.53 10.70
8'x8'x9/16' 29.60 203.2x203.2x14.29 44.00 3'x3'x5/16' 6.10 76.2x76.2x7.94 9.10
8'x8'x1/2' 26.40 203.2x203.2x12.7 39.30 3'x3'x1/4' 4.90 76.2x76.2x6.35 7.30
6'x6'x1' 37.40 152.4x152.4x25.4 55.70 3'x3'x3/16' 3.71 76.2x76.2x4.76 5.50
6'x6'x7/8' 33.10 152.4x152.4x22.23 49.30 2 1/2'x2 1/2'x1/2' 7.70 63.5x63.5x12.7 11.40
6'x6'x3/4' 28.70 152.4x152.4x19.05 42.70 2 1/2'x2 1/2'x3/8' 5.90 63.5x63.5x9.53 8.70
6'x6'x5/8' 24.20 152.4x152.4x15.88 36.00 2 1/2'x2 1/2'x5/16' 5.00 63.5x63.5x7.94 7.40
6'x6'x9/16' 21.90 152.4x152.4x14.29 32.60 2 1/2'x2 1/2'x1/4' 4.10 63.5x63.5x6.35 6.10
6'x6'x1/2' 19.60 152.4x152.4x12.7 29.20 2 1/2'x2 1/2'x3/16' 3.07 63.5x63.5x4.76 4.60
6'x6'x7/16' 17.20 152.4x152.4x11.11 25.60 2'x2'x3/8' 4.70 50.8x50.8x9.53 7.00
6'x6'x3/8' 14.90 152.4x152.4x9.53 22.20 2'x2'x5/16' 3.92 50.8x50.8x7.94 5.80
6'x6'x5/16' 12.40 152.4x152.4x7.94 18.50 2'x2'x1/4' 3.19 50.8x50.8x6.35 4.70
5'x5'x7/8' 27.20 127x127x22.23 40.50 2'x2'x3/16' 2.44 50.8x50.8x4.76 3.60
5'x5'x3/4' 23.60 127x127x19.05 35.10 2'x2'x1/8' 1.65 50.8x50.8x3.18 2.40
5'x5'x5/8' 20.00 127x127x15.88 29.80 1 3/4'x1 3/4'x1/4' 2.77 44.45x44.45x6.35 4.10
5'x5'x1/2' 16.20 127x127x12.7 24.10 1 3/4'x1 3/4'x3/16' 2.12 44.45x44.45x4.76 3.10
5'x5'x7/16' 14.30 127x127x11.11 21.30 1 3/4'x1 3/4'x1/8' 1.44 44.45x44.45x3.18 2.10
5'x5'x3/8' 12.30 127x127x9.53 18.30 1 1/2'x1 1/2'x1/4' 2.34 38.1x38.1x6.35 3.40
5'x5'x5/16' 10.30 127x127x7.94 15.30 1 1/2'x1 1/2'x3/16' 1.80 38.1x38.1x4.76 2.70
4'x4'x3/4' 18.50 101.6x101.6x19.05 27.50 1 1/2'x1 1/2'x5/32' 1.52 38.1x38.1x3.97 2.20
4'x4'x5/8' 15.70 101.6x101.6x15.88 23.40 1 1/2'x1 1/2'x1/8' 1.23 38.1x38.1x3.18 1.80
4'x4'x1/2' 12.80 101.6x101.6x12.7 19.00 1 1/4'x1 1/4'x1/4' 1.92 31.75x31.75x6.35 2.80
4'x4'x7/16' 11.30 101.6x101.6x11.11 16.80 1 1/4'x1 1/4'x3/16' 1.48 31.75x31.75x4.76 2.20
4'x4'x3/8' 9.80 101.6x101.6x9.53 14.60 1 1/4'x1 1/4'x1/8' 1.01 31.75x31.75x3.18 1.50
4'x4'x5/16' 8.20 101.6x101.6x7.94 12.20 1'x1'x1/4' 1.49 25.4x25.4x6.35 2.20
4'x4'x1/4' 6.60 101.6x101.6x6.35 9.80 1'x1'x3/16' 1.16 25.4x25.4x4.76 1.80
3 1/2'x3 1/2'x1/2' 11.10 88.9x88.9x12.7 16.50 1'x1'x1/8' 0.80 25.4x25.4x3.18 1.20
3 1/2'x3 1/2'x7/16' 9.80 88.9x88.9x11.11 14.60 3/4'x3/4'x1/8' 0.59 19.05x19.05x3.18 0.90
3 1/2'x3 1/2'x3/8' 8.50 88.9x88.9x9.53 12.60

Note: * Sectional weight in Kg/m for reference only.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 13 of 101
 COMPANY STANDARD Annexure 2 of CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 11 OF 14

Chart of Sectional weight for ASTM A6 Standard:

L - Shapes Un-Equal Leg Angles
Unit wt Unit wt Unit wt Unit wt
Section (inches) Section (mm) Section (inches) Section (mm)
(lb/ft) (Kg/m) (lb/ft) (Kg/m)
8'x6'x1' 44.20 203.2x152.4x25.4 65.50 5'x3'x1/4' 6.60 127x76.2x6.35 9.80
8'x6'x7/8' 39.10 203.2x152.4x22.23 57.90 4'x3 1/2'x1/2' 11.90 101.6x88.9x12.7 17.60
8'x6'x3/4' 33.80 203.2x152.4x19.05 50.10 4'x3 1/2'x3/8' 9.10 101.6x88.9x9.53 13.50
8'x6'x5/8' 28.50 203.2x152.4x15.88 42.20 4'x3 1/2'x5/16' 7.70 101.6x88.9x7.94 11.40
8'x6'x9/16' 25.70 203.2x152.4x14.29 38.10 4'x3 1/2'x1/4' 6.20 101.6x88.9x6.35 9.20
8'x6'x1/2' 23.00 203.2x152.4x12.7 34.10 4'x3'x5/8' 13.60 101.6x76.2x15.88 20.20
8'x6'x7/16' 20.20 203.2x152.4x11.11 29.90 4'x3'x1/2' 11.10 101.6x76.2x12.7 16.40
8'x4'x1' 37.40 203.2x101.6x25.4 55.40 4'x3'x3/8' 8.50 101.6x76.2x9.53 12.60
8'x4'x7/8' 33.10 203.2x101.6x22.23 49.30 4'x3'x5/16' 7.20 101.6x76.2x7.94 10.70
8'x4'x3/4' 28.70 203.2x101.6x19.05 42.50 4'x3'x1/4' 5.80 101.6x76.2x6.35 8.60
8'x4'x5/8' 24.20 203.2x101.6x15.88 36.00 3 1/2'x3'x1/2' 10.20 88.9x76.2x12.7 15.10
8'x4'x9/16' 21.90 203.2x101.6x14.29 32.40 3 1/2'x3'x7/16' 9.10 88.9x76.2x11.11 13.50
8'x4'x1/2' 19.60 203.2x101.6x12.7 29.00 3 1/2'x3'x3/8' 7.90 88.9x76.2x9.53 11.70
8'x4'x7/16' 17.20 203.2x101.6x11.11 25.60 3 1/2'x3'x5/16' 6.60 88.9x76.2x7.94 9.80
7'x4'x3/4' 26.20 177.8x101.6x19.05 38.80 3 1/2'x3'x1/4' 5.40 88.9x76.2x6.35 8.00
7'x4'x5/8' 22.10 177.8x101.6x15.88 32.70 3 1/2'x2 1/2'x1/2' 9.40 88.9x63.5x12.7 13.90
7'x4'x1/2' 17.90 177.8x101.6x12.7 26.50 3 1/2'x2 1/2'x3/8' 7.20 88.9x63.5x9.53 10.70
7'x4'x7/16' 15.70 177.8x101.6x11.11 23.40 3 1/2'x2 1/2'x5/16' 6.10 88.9x63.5x7.94 9.00
7'x4'x3/8' 13.60 177.8x101.6x9.53 20.20 3 1/2'x2 1/2'x1/4' 4.90 88.9x63.5x6.35 7.30
6'x4'x7/8' 27.20 152.4x101.6x22.23 40.30 3'x2 1/2'x1/2' 8.50 76.2x63.5x12.7 12.60
6'x4'x3/4' 23.60 152.4x101.6x19.05 35.00 3'x2 1/2'x7/16' 7.60 76.2x63.5x11.11 11.30
6'x4'x5/8' 20.00 152.4x101.6x15.88 29.60 3'x2 1/2'x3/8' 6.60 76.2x63.5x9.53 9.80
6'x4'x9/16' 18.10 152.4x101.6x14.29 26.80 3'x2 1/2'x5/16' 5.60 76.2x63.5x7.94 8.30
6'x4'x1/2' 16.20 152.4x101.6x12.7 24.00 3'x2 1/2'x1/4' 4.50 76.2x63.5x6.35 6.70
6'x4'x7/16' 14.30 152.4x101.6x11.11 21.20 3'x2 1/2'x3/16' 3.39 76.2x63.5x4.76 5.10
6'x4'x3/8' 12.30 152.4x101.6x9.53 18.20 3'x2'x1/2' 7.70 76.2x50.8x12.7 11.50
6'x4'x5/16' 10.30 152.4x101.6x7.94 15.30 3'x2'x3/8' 5.90 76.2x50.8x9.53 8.80
6'x3 1/2'x1/2' 15.30 152.4x88.9x12.7 22.70 3'x2'x5/16' 5.00 76.2x50.8x7.94 7.40
6'x3 1/2'x3/8' 11.70 152.4x88.9x9.53 17.30 3'x2'x1/4' 4.10 76.2x50.8x6.35 6.10
6'x3 1/2'x5/16' 9.80 152.4x88.9x7.94 14.50 3'x2'x3/16' 3.07 76.2x50.8x4.76 4.60
5'x3 1/2'x3/4' 19.80 127x88.9x19.05 29.30 2 1/2'x2'x3/8' 5.30 63.5x50.8x9.53 7.90
5'x3 1/2'x5/8' 16.80 127x88.9x15.88 24.90 2 1/2'x2'x5/16' 4.50 63.5x50.8x7.94 6.70
5'x3 1/2'x1/2' 13.60 127x88.9x12.7 20.20 2 1/2'x2'x1/4' 3.62 63.5x50.8x6.35 5.40
5'x3 1/2'x3/8' 10.40 127x88.9x9.53 15.40 2 1/2'x2'x3/16' 2.75 63.5x50.8x4.76 4.20
5'x3 1/2'x5/16' 8.70 127x88.9x7.94 12.90 2 1/2'x1 1/2'x1/4' 3.19 63.5x38.1x6.35 4.80
5'x3 1/2'x1/4' 7.00 127x88.9x6.35 10.40 2 1/2'x1 1/2'x3/16' 2.44 63.5x38.1x4.76 3.60
5'x3'x1/2' 12.80 127x76.2x12.7 19.00 2'x1 1/2'x1/4' 2.77 50.8x38.1x6.35 4.20
5'x3'x7/16' 11.30 127x76.2x11.11 16.70 2'x1 1/2'x3/16' 2.12 50.8x38.1x4.76 3.10
5'x3'x3/8' 9.80 127x76.2x9.53 14.50 2'x1 1/2'x1/8' 1.44 50.8x38.1x3.18 2.10
5'x3'x5/16' 8.20 127x76.2x7.94 12.10

Note: * Sectional weight in Kg/m for reference only.

RAJESH MOTGHARE YASHWANT DANGE
ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 14 of 101
 COMPANY STANDARD Annexure 3 of CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 12 OF 14

MECHANICAL PROPERTIES - MINIMUM OR RANGE SPECIFIED

Yield Stress (min) UTS (min) % Elongation (min) Bend Test 1800 on Charpy ’V’ Notch
Grade
N/mm2 N/mm2 Lo=5.65 So Diameter Impact Test ☻
MILD STEEL
E 250 A / Thk < 20 mm : 250 Thk ≤ 25 mm: 3t NS
410 23 Thk > 25 mm: 2t
Fe 410 WA Thk 20-40 mm : 240 NS
E 250 B / Thk < 20 mm : 250 Thk ≤ 25 mm: 2t 27J at 25o C
410 23
Fe 410 WB Thk 20-40 mm : 240 Thk > 25 mm: 3 t 27J at -20o C *
E 250 C / Thk < 20 mm : 250 Thk ≤ 25 mm: 2t 27J at 25o C
410 23
Fe 410 WC Thk 20-40 mm : 240 Thk > 25 mm: 3t 27J at -20o C *
BSEN 10025 Thk ≤ 16 : 235 Thk < 3: 360-510 26 NS 27J at 200 C*
S235 JR 16<Thk ≤ 40 : 225
BSEN 10025 Thk ≤ 16 : 235 Thk ≥ 3 to ≤ 100
: 360-510 26 NS 27J at 0o C
S235 JO 16<Thk ≤ 40 : 225
BSEN 10025 Thk ≤ 16 : 275 Thk < 3: 430-580 23 NS 27J at 20o C *
S275 JR 16<Thk ≤ 40 : 265
BSEN 10025 Thk ≤ 16 : 275 Thk ≥ 3 to ≤ 100
: 410-560 23 NS 27J at 0o C
S275 JO 16<Thk ≤ 40 : 265
Thk ≤ 5: 21
JIS G 3101 Thk ≤ 16 : 245 400-510 5< Thk ≤ 16: 17 1.5t NS
SS 400 16 < Thk ≤ 40 : 235
16<Thk ≤ 50: 21

23 For Plates &

ASTM A36 21 For Shapes on
250 400-550 NS NS
A36 50GL
20 on 200GL

HIGH TENSILE STEEL

IS 2062 Thk < 20 mm : 350 Thk ≤ 25 mm: 2t 50J at 25o C
490 22
E 350 / Fe 490 Thk 20-40 mm : 330 Thk > 25 mm: 3t 25J at –20o C
IS 2062 Thk < 20 mm : 410 Thk ≤ 25 mm: 2t 50J at 25o C
540 20
E 410 / Fe 540 Thk 20-40 mm : 390 Thk > 25 mm: 3t 25J at –20o C
IS 2062 Thk < 20 mm : 450 Thk ≤ 25 mm: 2t 50J at 25o C
570 20
E450D / Fe 570 Thk 20-40 mm : 430 Thk > 25 mm: 3t 25J at -20o C
BSEN10025 Thk ≤16 : 355 Thk < 3: 510-680 22 NS 27J at 20o C *
S 355 JR 16< Thk ≤40 : 345
BSEN 10025 Thk ≤16 : 355 Thk ≥ 3 to ≤ 100
: 470-630 22 NS 27J at 0o C *
S 355 JO 16< Thk ≤40 : 345
Thk ≤ 5:16
JIS G 3101 Thk ≤16 : 400 540 5 < Thk ≤ 16: 13 2.0t NS
SS 540
16< Thk <40 : 390 16<Thk ≤ 40:17
ASTM A 572 On 200 GL – 18
345 450 NS NS
Grade 50 On 50 GL – 21
ASTM A 572 On 200 GL – 16
415 520 NS NS
Grade 60 On 50 GL – 18
ASTM A572 On 200 GL – 15
450 550 NS NS
Grade 65 On 50 GL – 17
Where as - NS Not Specified and
* Optional, if value is not specified, it is to be specified by the purchaser.
☻ Impact test shall be required for thickness 6mm and above incase of BSEN and Impact test shall
be required for thickness 12mm and above incase of IS Standard.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 15 of 101
 COMPANY STANDARD Annexure 4 of CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 13 OF 14

CHEMICAL COMPOSITION (LADDLE ANALYSIS)-MAXIMUM OR RANGE SPECIFIED

Method of
Grade C% S% P% Si% Mn% N% CEV
deoxidation
MILD STEEL
IS 2062
E 250 A / Fe 410 WA Semi Killed / Killed 0.23 0.045 0.045 0.40 1.50 0.012* 0.42
E 250 B / Fe 410 WB Killed 0.22 0.045 0.045 0.40 1.50 0.012* 0.41
E 250 C / Fe 410 WC Killed 0.20 0.040 0.040 0.40 1.50 0.012 0.39
BSEN 10025
S 235 JR - 0.17 0.040 0.040 NS 1.40 0.012 0.35
S 235 JO - 0.17 0.035 0.035 NS 1.40 0.012 0.35
S 275 JR - 0.21 0.040 0.040 NS 1.50 0.012 0.40
S 275JO - 0.18 0.035 0.035 NS 1.50 0.012 0.40
JIS G 3101
SS 400 - NS 0.050 0.050 NS NS NS NS
ASTM A 36 - 0.26 0.050 0.040 0.40 NS NS NS
HIGH TENSILE STEEL
IS 2062
E 350 / Fe 490 Semi Killed / Killed 0.20 0.045 0.045 0.45 1.50 0.009 0.42
E 410 / Fe 540 Semi Killed / Killed 0.20 0.045 0.045 0.45 1.60 0.009 0.44
E 450 D / Fe 570 D Semi Killed / Killed 0.22 0.045 0.045 0.45 1.60 0.009 0.46
BSEN 10025
S 355 JR - 0.24 0.040 0.040 0.55 1.60 0.012 0.45
S 355 JO - 0.20 0.035 0.035 0.55 1.60 0.012 0.45
JIS G 3101
SS 540 - 0.30 0.040 0.040 NS 1.60 NS NS
ASTM A572
Grade 50 Semi Killed / Killed 0.23 0.050 0.040 0.40 1.35 NS NS
Grade 60 Semi Killed / Killed 0.26 0.050 0.040 0.40 1.35 NS NS
Grade 65 Semi Killed / Killed 0.23 0.050 0.040 0.40 1.65 NS NS

Where as -
NS Not Specified
* Optional, It should be verified only if stated in order.

All High Tensile steel shall contain the presence of micro-alloying elements as follows:
EITHER - Vanadium = 0.025% min. OR Niobium = 0.015% min
AND
ADDITION OF - Vanadium + Niobium + Titanium = 0.25% max.
For specific chemistry or elements presence shall be strictly as per the relevant specification. Customer’s
special requirements shall be included as and when approved.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 16 of 101
 COMPANY STANDARD Annexure 4 of CS – 1
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. 1 30.12.08
STEEL SECTIONS
SHEET NO. 14 OF 14

CHEMICAL COMPOSITION (PRODUCT ANALYSIS)-MAXIMUM OR RANGE SPECIFIED

Grade C% S% P% Si% Mn% N% CEV

MILD STEEL
IS 2062
E 250 A / Fe 410 WA 0.25 0.050 0.050 0.43 1.55 0.012* 0.42
E 250 B / Fe 410 WB 0.24 0.050 0.050 0.43 1.55 0.012* 0.41
E 250 C / Fe 410 WC 0.22 0.045 0.045 0.43 1.55 0.012 0.39
BSEN 10025
S 235 JR 0.19 0.050 0.050 NS 1.50 0.014 0.35
S 235 JO 0.19 0.045 0.045 NS 1.50 0.014 0.35
S 275 JR 0.24 0.050 0.050 NS 1.60 0.014 0.40
S 275JO 0.21 0.045 0.045 NS 1.60 0.014 0.40
JIS G 3101
SS 400 NS 0.050 0.050 NS NS NS NS
ASTM A 36 ۞ 0.30 0.060 0.050 0.45 NS NS NS

HIGH TENSILE STEEL

IS 2062
E 350 / Fe 490 0.22 0.050 0.050 0.48 1.55 0.009 0.42
E 410 / Fe 540 0.22 0.050 0.050 0.48 1.65 0.009 0.44
E 450 D / Fe 570 D 0.24 0.050 0.050 0.48 1.65 0.009 0.46
BSEN 10025
S 355 JR 0.27 0.050 0.050 0.60 1.70 0.014 0.45
S 355 JO 0.23 0.045 0.045 0.60 1.70 0.014 0.45
JIS G 3101
SS 540 0.30 0.040 0.040 NS 1.60 NS NS
ASTM A572 ۞
D
Grade 50 0.27 0.060 0.050 0.45 1.35 NS NS
D
Grade 60 0.30 0.060 0.050 0.45 1.35 NS NS
D
Grade 65 0.27 0.060 0.050 0.45 1.35 NS NS

Where as -
NS Not Specified
* Optional, It should be verified only if stated in order.
D For each reduction of 0.01% point below the specified carbon maximum, an increase of 0.06% point
manganese above the specified maximum is permitted, up to a maximum of 1.60%
RAJESH MOTGHARE YASHWANT DANGE
ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 17 of 101
 COMPANY STANDARD CS – 2
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. - -
STEEL PLATES
SHEET NO. 1 OF 2

1.0 SCOPE
This standard covers the requirement of Structural Steel Plates of Mild Steel & High Tensile Steel
generally used, for manufacturing of Transmission Line Tower Parts.
(All inspection specification/parameters are taken from repsective standards for reference purpose.
Final decision for acceptance / rejection shall be based on the requirements of the respective
standards and / or Customer Manufacturing Quality Plan.)

2.0 The Structural Steel shall be suitable for Hot Dip Galvanizing after fabricating the steel plates of
MS and HT grades into tower parts.

3.0 Refer CS - 1 for Raw Material, Grades, Sampling Plan, Visual Inspection and Dimensional
Inspection of Steel Plate.

4.0 TOLERANCES ON THICKNESS OF PLATES:

4.1 As per IS 1852 - The thickness shall be measured at the following points:
a) One at each corner of the plate,
b) One in the middle of the width, and
c) One in the middle of the length
These measurements shall be 25 mm away from edges at points randomly chosen. The thickness
measured at each of these points shall satisfy the tolerance specified below in the Table - 1
Table – 11: As per IS 1852 - Plates
Thickness Allowable Tolerance
< 8.0 mm + 12.5 % and – 5.0 %
8.0 to ≤ 12.0 mm + 7.5 % and – 5.0 %
> 12.0 mm  5.0 %

4.2 As per ASTM A6 - The Thickness shall be measures at the following points:
1) The Thickness shall be measured at 9.53mm (3/8”) to 19.05mm (¾”) from the longitudinal edge.
2) Thickness measured at any location other than point 1 the permitted variation over specified
thickness shall be 1.75 times the amount in this table, rounded to the nearest 0.25mm (0.01”).
3) Permitted variation Under specified Thickness is 0.254mm (0.01”)
Table-12: As per ASTM A6 - Permitted Variations Over Specified Thickness for Given Widths
Width of Plate
Thickness mm (inch) Under 1219 to 1524 to 1829 to 2134 to 2438 to
1219 1524 1829 2134 2438 2743
Under 6.35 (1/4”) 0.76 0.76 0.76 0.76 0.76 0.76
6.35 (1/4”) to 7.94 (5/16”) excl 0.76 0.76 0.76 0.76 0.76 0.76
7.94 (5/16”) to 9.53 (3/8”) excl 0.76 0.76 0.76 0.76 0.76 0.76
9.53 (3/8”) to 11.11 (7/16”) excl 0.76 0.76 0.76 0.76 0.76 0.76
11.11 (7/16”) to 12.7 (1/2”) excl 0.76 0.76 0.76 0.76 0.76 0.76
12.7 (1/2”) to 15.88 (5/8”) excl 0.76 0.76 0.76 0.76 0.76 0.76
15.88 (5/8”) to 19.05 (3/4”) excl 0.76 0.76 0.76 0.76 0.76 1.02
19.05 (3/4”) to 25.4 (1”) excl 0.76 0.76 0.76 0.76 1.02 1.02
25.4 (1”) to 50.8 (2”) excl 1.52 1.52 1.52 1.52 1.52 1.78
50.8 (2”) to 76.2 (3”) excl 2.29 2.29 2.29 3.30 3.30 2.79
76.2 (3”) to 101.6 (4”) excl 2.79 2.79 2.79 2.79 2.79 3.30

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 18 of 101
 COMPANY STANDARD CS – 2
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STRUCTURAL
REV. NO. - -
STEEL PLATES
SHEET NO. 2 OF 2

4.3 The Thickness shall be measured at any point situated more than 25mm from the transverse or
longitudinal edges of the plate, other than locally ground areas.
Table – 13: As per BSEN 10029 – Plates, Class A
Nominal Thickness Allowable Lower Allowable Upper
 3 mm < 5 mm Tolerance
- 0.4 mm Tolerance
+ 0.8 mm
 5 mm < 8 mm - 0.4 mm + 1.1 mm
 8 mm < 15 mm - 0.5 mm + 1.2 mm
 15 mm < 25 mm - 0.6 mm + 1.3 mm
 25 mm < 40 mm - 0.8 mm + 1.4 mm
 40 mm < 80 mm - 1.0 mm + 1.8 mm
 80 mm < 150 mm - 1.0 mm + 2.2 mm

5.0 UNIT WEIGHT OF PLATES:

5.1 Unit weight as per IS 1852 The Consignment Weight shall not vary from the Theoretical Weight
specified in Table 3 of IS 1730 Part-1 by more than + 5%, -2.5.
Table - 14
Thickness, mm Weight, Kg/m2 Thickness, mm Weight, Kg/m2 Thickness, mm Weight, Kg/m2
5 39.25 10 78.50 16 125.60
6 47.10 12 94.20 18 141.30
8 62.80 14 109.90 20 157.00

5.2 As per ASTM A6 permitted sectional weight variation is given below in the Table-1
Table-15: Permitted % of Variations in Average Weight/Square foot of Lots for Widths Given Below
Over 48 to 60
48 and under 60 to 72 excl 72 to 84 excl 84 to 96 excl 96 to 108 excl
2 excl
Specified Weights, lb/ft
Upto 1232 1232 to <1524 1524 to <1829 1829 to <2134 2134 to <2438 2438 to <2743
Over Under Over Under Over Under Over Under Over Under Over Under
To 10, excl 4.00 3.00 4.50 3.00 5.00 3.00 5.50 3.00 6.00 3.00 7.50 3.00
10 to 12.5, excl 4.00 3.00 4.50 3.00 4.50 3.00 5.00 3.00 5.50 3.00 6.50 3.00
12.5 to 15.0, excl 4.00 3.00 4.00 3.00 4.50 3.00 4.50 3.00 5.00 3.00 5.50 3.00
15 to 17.5, excl 3.50 3.00 3.50 3.00 4.00 3.00 4.50 3.00 4.50 3.00 5.00 3.00
17.5 to 20, excl 3.50 2.50 3.50 2.50 3.50 3.00 4.00 3.00 4.50 3.00 4.50 3.00
20 to 25, excl 3.50 2.50 3.50 2.50 3.50 3.00 3.50 3.00 4.00 3.00 4.00 3.00
25 to 30, excl 3.00 2.50 3.50 2.50 3.50 2.50 3.50 3.00 3.50 3.00 3.50 3.00
30 to 40, excl 3.00 2.00 3.00 2.00 3.00 2.00 3.00 2.00 3.50 2.00 3.50 2.50
40 to 81.7, excl 2.50 2.00 3.00 2.00 3.00 2.00 3.00 2.00 3.50 2.00 3.50 2.00
81.7 to 122.6, excl 2.50 2.00 3.00 2.00 3.00 2.00 3.00 2.00 3.50 2.00 3.50 2.00
122.6 to 163.4, excl 2.50 1.50 2.50 1.50 2.50 1.50 2.50 1.50 2.50 2.00 2.50 2.00
163.4 to 245.1, excl 2.50 1.00 2.50 1.00 2.50 1.00 2.50 1.00 2.50 1.00 2.50 1.00

6.0 Refer clause 12.0 on page 5 of CS - 1 for sample piece location, preparation, shape and size.

7.0 Conduct Tensile test, Bend test, Charpy test & chemical test as given on Page 6 of CS - 1.

8.0 For Yield Stress, Ultimate Tensile Strength, % of Elongation, Bend, Charpy and Chemical values
refer Annexure 3 & 4 on page 11, 12 and 13 of CS - 1.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 19 of 101
 COMPANY STANDARD CS – 3
ISSUE NO. 8 01.10.07
COLOUR CODIFICATION FOR STEEL
REV. NO. 1 20.09.10
GRADE IDENTIFICATION
SHEET NO. 1 OF 2

1.0 SCOPE
This standard is applicable to all specifications and grades of steel presently being used for tower
structures.

2.0 PROCEDURE
Color-coding shall be done on all material at Re-Roller or Vendor premises. Incase material received
without color then color shall be applied at KEC Raw Yard before unloading. Color-coding scheme
shall be used to identify the steel specification and grade for angle, plate, flats and channel sections.

ANGLE, PLATE, FLAT and CHANNEL SECTION:

Color Code shall be applied on cropped edge/end of an Angle, Plate, Flat & Channel, as illustrated in
Fig. I to Fig. IV.

3.0 COLOR CODES

The Color Codes shall be as per Table-1 and shall be applied with non-washable enamel paint. The
paint shall not spread more than 10mm on the flange of the section.

4.0 COLOR SHADES

The shades of the Color shall be purchased from Shalimar Paints, Asian Paints, Bombay Paints or
from any standard reputed company.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 20 of 101
 COMPANY STANDARD CS – 3
ISSUE NO. 8 01.10.07
COLOUR CODIFICATION FOR STEEL
REV. NO. 1 20.09.10
GRADE IDENTIFICATION
SHEET NO. 2 OF 2

TABLE - 1 COLOUR CODE CHART

Sr. PG / Colour Code
Specification Source Grade
No NPG L-Side R-Side L-side R-Side
Steel Angle- Mild Steel (MS)
1 IS 2062 PG E 250A Green Green
2 IS 2062 NPG E 250A Green Pink
3 BSEN 10025 - S 275 JR Green Grey
4 BSEN 10025 - S 275 JO Green Brown
5 ASTM - A 36 Green Black
6 JIS G 3101 - SS 400 Green Dark Blue
7 Chinese China - Q 235 Green White
8 Telecom - E 250A Green Sky Blue
Steel Plates- Mild Steel (MS)
9 IS 2062 SAIL PG E 250A Green Dark Blue
10 IS 2062 ESSAR PG E 250A Green Violet
11 IS 2062 LLOYDS PG E 250A Green White
12 IS 2062 JINDAL PG E 250A Green Black
13 IS 2062 Any Sources NPG E 250A Green Pink
14 Telecom - E 250A Green Sky Blue
15 BSEN 10025 Any Sources NPG S 275 JR Green Grey
16 BSEN 10025 Any Sources NPG S 275 JO Green Brown
Steel Flats - Mild Steel (MS)
1 IS 2062 PG E 250A Green Green
2 IS 2062 NPG E 250A Dark Blue Dark Blue
Steel Angle- High Tensile Steel (HT)
1 IS 2062 PG E 350 A Yellow Yellow
2 IS 2062 NPG E 350A Yellow Pink
3 BSEN 10025 NPG S 355 JR Yellow Grey
4 BSEN 10025 NPG S 355 JO Yellow Brown
5 ASTM NPG A 50 Yellow Violet
6 Chinese NPG Q 345 Yellow White
7 Telecom NPG E 350 A Yellow Sky Blue
Steel Plates- High Tensile Steel (HT)
8 IS 2062 SAIL PG E350 A / SAILMA Yellow Dark Blue
9 IS 2062 ESSAR PG E 350 A Yellow Violet
10 IS 2062 LLOYDS PG E 350 A Yellow White
11 IS 2062 JINDAL PG E 350 A Yellow Black
12 IS 2062 Any Sources NPG E 350A Yellow Pink
13 Telecom - E 350 A Yellow Sky Blue
14 BSEN 10025 Any Sources NPG S 355 JR Yellow Grey
15 BSEN 10025 Any Sources NPG S 355 JO Yellow Brown
Steel Angles & Plates - Super High Tensile Steel (HT)
1 ASTM NPG A 60 Orange Black
2 ASTM NPG A 65 Orange Violet
3 JIS G 3101 NPG SS 540 Orange Dark Blue
4 BSEN 10025 NPG S 450JO Orange White

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 21 of 101
 COMPANY STANDARD CS – 4
ISSUE NO. 8 01.10.07

FABRICATION TOLERANCES REV. NO. - -

SHEET NO. 1 OF 4

1.0 SCOPE
This standard covers the Tolerances on Dimensions for fabrication of tower parts.
Note: Company Standards shall be applicable when the Standards like National and International are
not available or the customer does not state the reference standard or specific requirements.

2.0 REFERENCES:
IS: 802 Part 2, IS: 7215, & IS: 1852

3.0 RAW MATERIAL

Inspect steel Angles, Plates and Flats for fabrication as given below in the table:
TESTS PARAMETERS CS REFERENCE
Grade - Color code CS - 3
Visual Raw material Defects - Embossing, Piping, Scaling, Cracks, Roll CS – 1
marks, pitting, fin, toe projections, round heel, lamination etc CS – 2
Straightness, Camber, Sweep CS – 1
Dimensions
Flange width, Thickness, Squareness, Root radius CS – 1 & 2

4.0 FABRICATION TOLERANCES

4.1 Total Length of member (any size) shall be acceptable within  2.0 mm.
4.2 Taper Cut Tolerances:
Taper Cut for leg length upto 100 mm (Fig - 1) =  1 mm
Taper Cut for leg length over 100 mm & up to 250 mm (Fig - 2) =  2 mm

-1mm +1mm -2mm +2mm

Fig - 1 Flange upto 100 mm Fig – 2 Flange above 100 mm
4.2.1 Flange cutting shall be done by shearing upto 8 mm thickness and above 8 mm thickness Band
saw cutting or Controlled / Pug flame cutting machine to be used.
4.2.2 Free hand flame cutting is not acceptable.
4.3 Flange Cuts - Notches, Corner Cuts, Bevel Cuts etc. The tolerances on dimensions for flange
cuts shall be as below:

Dimension (Along with Toe/Apex) Nominal Tolerance

Upto 100 mm + 2.0, - 0
Above 100 mm + 3.0, - 0

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 22 of 101
 COMPANY STANDARD CS – 4
ISSUE NO. 8 01.10.07

FABRICATION TOLERANCES REV. NO. - -

SHEET NO. 2 OF 4

4.4 Hole (Punching / Drilling):

4.4.1 Holes shall be punched or drilled for material upto thickness 12mm (For metric size sections)
and ½ inch thickness (For inch size sections).
4.4.2 Holes above 17.5mm diameter and thickness above 12mm shall be drilled.
4.4.3 Holes above 12mm or 1/2 inch thickness shall be drilled only.
4.4.4 Punched or drilled holes shall be perpendicular to the flange / plate surface.
4.4.5 Nominal hole sizes and tolerances shall be as below:
Bolt Size Nominal Hole Size Tolerance (in mm)
M: 12 13.5 mm + 0.4, - 0.0
M: 16 17.5 mm + 0.4, - 0.0
M: 20 21.5 mm + 0.4, - 0.0
M: 25 26.5 mm + 0.4, - 0.0

4.4.6 For all critical parts the hole diameter of connecting cleat and plates shall be increased by 1mm
than normal hole diameter. These items will be identified on the fabrication sketch.
4.4.7 Angle members / leg members holes shall be maintain as per specified tolerance only.
4.4.8 The diametrical clearance between hole diameter and bolt-nominal diameter shall be diametrical
1.5mm or as specified by the customer.
4.4.9 Hole ovality (difference between minimum & maximum diameter of a hole) shall be permitted
upto + 0.4 mm and - 0 mm.
4.4.10 Hole taperness (difference between diameter of hole at both the face of thickness) shall be
permissible max 0.8mm.
4.5 End Security Of Holes
To Suit Bolt Size Cut Edge Security Subject to Minimum Rolled Edge Minimum
M: 12  2 or min 20 min 16 mm
M: 16  2 or min 23 min 20 mm
M: 20  2 or min 28 min 25 mm
M: 24  2 or min 38 min 33 mm

4.6 Hole Positions

Tolerance on Hole Spacing (distance between centers of two holes) shall be as follows:
Tolerances for Hole Distances
Consecutive Hole Distance + 1mm
Cumulative Hole Distance + 2mm
Hole Back Mark (Gauge line) + 1mm

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 23 of 101
 COMPANY STANDARD CS – 4
ISSUE NO. 8 01.10.07

FABRICATION TOLERANCES REV. NO. - -

SHEET NO. 3 OF 4

NOTE: ** Tolerance for Critical Joint Hole Distances – Where joints have 3 or more than 3 items
joined together. These joints shall be specified on shop sketches.
Tolerances for **Critical Joint Hole Distances
Joint Consecutive Hole Distance + 0.75mm
Joint Cumulative Hole Distance + 1.50mm
Joint Hole Back Mark (Gauge line) + 0.75mm
4.7 For making hole sizes following size of punch and drill shall be used
Bolt size Size of Punch / Drill
16mm 17.75mm
20mm 21.75mm
5/8” or 15.88mm 17.75
¾” or 19.05mm 20.75

5.0 STAMPING
5.1 Stamping of item mark number shall be done on each piece of the tower item before hot dip
galvanizing. Stamping shall be done as per Company Standard CS - 5.
5.2 The stamping has Nine alphanumeric characters. The stamping generally has project number,
tower type and mark number. All high tensile members shall have ‘H’ as prefix in stamping. The logic /
sequence of stamping characters can be kept as per customer requirement.

6.0 HEEL CUTTING / GRINDING

6.1 Heel shall be removed as per Drawing / Sketches by heel cutting machine.
6.2 Heel cutting tolerance on length shall be + 5 mm, - 0 and Heel cutting tolerance on width shall be
+/- 1mm up to 6mm width heel cut and +/- 2mm above 6mm width heel cut.
6.3 Heel cutting up to 10mm width shall be cut on heel cutting machine and heel cutting width above
10mm shall be removed by controlled Flame cutting / Pug cutting machine. After flame cutting the
heel shall be ground to remove the flame cutting burrs.
6.4 Free hand flame cutting is not acceptable.
6.5 Table for Heel cutting and tolerance on Width (W) shall be as below:
S. No. SECTION W TOLERANCE
1. 45x45 5 mm + 1 mm
2. 50x50 and 55x55 6 mm + 1 mm
4. 60x60 7 mm + 2 mm
5. 65x65 8 mm + 2 mm
6. 70x70 and 75x75 9 mm + 2 mm
8. 80x80 and 90x90 10 mm + 2 mm
10. 100x100 to 120x120 11 mm + 2 mm
13. 130x130 14 mm + 2 mm
14. 150x150 18 mm + 2 mm
15. 200x200 20 mm + 2 mm
16. 250x250 24 mm + 2 mm

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 24 of 101
 COMPANY STANDARD CS – 4
ISSUE NO. 8 01.10.07

FABRICATION TOLERANCES REV. NO. - -

SHEET NO. 4 OF 4

7.0 BENDING
The Bending of tower parts shall be done as per the Company Standard CS - 6.

8.0 BURRS
8.1 The Burrs due to Cropping, Punching, Drilling, Cutting, Gas Cutting etc., shall be ground
completely. All Fabricated items shall be free from burrs.
8.2 Grinding of burrs shall be done on the item so that grinding marks should not appear on the
surface of item. Only area of burrs shall be ground.

9.0 PLUGGING OF HOLES

9.1 Hole plugging shall be done only after approval of QA.
9.2 Hole plugging by welding shall be done as per Company Standard CS – 7.
9.3 In case specification of the customer prohibits the blocking of hole by welding, the same shall not
be done.

10.0 SURFACE DEFECTS

Scaling, Scabbing, Hammer Marks, Excess Burning at Hot Bend, Punch & Die Marks, Rolling marks,
Grooves, Deep scratches shall not be permitted.

Note: All measuring and testing equipments used for dimensional verification shall be calibrated as
per calibration plan

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 25 of 101
 COMPANY STANDARD CS – 5
ISSUE NO. 8 01.10.07

STAMPING SPECIFICATIONS REV. NO. - -

SHEET NO. 1 OF 3

1.0 SCOPE
This specification covers the shapes and sizes of Letters and Digits stamped on Tower Parts before
Galvanizing.

2.0 SHAPES
The shape of letters and digits shall be as shown in Annexure 1.

3.0 DIMENSIONS AND TOLERANCES

3.1 The overall size and the tolerances of stamping on items:
Parameters Dimensions Tolerances
Width 9.0 mm  0.3 mm
Height 16.0 mm  0.5 mm
Depth 0.45 mm  0.1 mm
Thickness 1.0 mm  0.2 mm

3.2 The Marking of Item Number shall be stamped on tower parts before Hot Dip Galvanizing. The
marking shall be clearly visible after hot dip galvanizing.

4.0 STAMPING
4.1 Stamping of Item Number shall be done on each piece of the item before hot dip galvanizing. The
letters and digits of the stamping should be completed and care should be taken that stamping is not
done on any hole or notching.
4.2 Stamping shall be done in one row for complete item number along the length of angle or along
the longer edge of Gusset Item.
4.3 In case sufficient space is not available the stamping of item number may be broken and done in
two rows.

5.0 LOCATION OF STAMPING

5.1 Stamping On Angle Items:
Stamping shall be done on outer surface of the flange (leg length) of the angle. The bottom of letters
and digits shall be towards the toe of the angle. Stamping should be done near one end of the angle
member. Stamping should be done in the area which is between 100 mm and 400 mm away from the
last hole of the end joint of the piece, as shown below:

x xxx x xxxx

X X> 100 mm
Y Y< 400 mm

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 26 of 101
 COMPANY STANDARD CS – 5
ISSUE NO. 8 01.10.07

STAMPING SPECIFICATIONS REV. NO. - -

SHEET NO. 2 OF 3

In case of any hole occurring in between 100 mm and 400 mm from the last hole of end joint the
stamping shall be adjusted on the flange width such that its letters and digits are not cut by the hole or
it may even go beyond 400 mm from the last hole of the end joint.

5.2 STAMPING ON CLEATS

Stamping shall be done on outer surface of the flange in such a way that the bottom of letters and
digits is towards the toe of angle. Stamping shall be done on any area available on outer flange even
in between the holes.

5.3 STAMPING ON GUSSETS

Stamping shall be done on any available area preferably near the longer edge or in between the holes
along the longer edge of the gusset.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 27 of 101
 COMPANY STANDARD Annexure 1 of CS – 5
ISSUE NO. 8 01.10.07

STAMPING SPECIFICATIONS REV. NO. - -

SHEET NO. 3 OF 3

LETTERS & FIGURES FOR HANDS & MACHINE STAMPS

(16X9 mm-T-160)
SKETCH No. QA-001 (CHAWLA-23*9/96)

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 28 of 101
 COMPANY STANDARD CS – 6
ISSUE NO. 8 01.10.07
SPECIFICATION FOR BENDING
REV. NO. 1 20.09.10
OPERATION
SHEET NO. 1 OF 2

1.0 SCOPE
This Standard covers the requirement of Bending Operation for all tower parts for Mild Steel and High
Tensile Steel grades.

2.0 PURPOSE
To define the process parameters for Bending Operation and Tolerance for acceptance.

3.0 PROCESS CONTROL

3.1 The bending shall be done either in Hot Condition or in Cold Condition.
3.2 The Bending shall be done with the help of Bending Dies. Slope of Bending Dies shall be verified
by Bending Gauges. Hammer shall not be used for bending operation.
3.3 The criteria for bending shall be as follows:

Bending condition Steel Section / Plate

FOR MILD STEEL

Cold Bend Steel sections Upto 75x75x6 mm – Bending Upto 100

Cold Bend Steel sections Upto 100x100x8 mm – Bending Upto 50

Cold Bend Steel Plates Upto 12 mm thick – Bending Upto 150

Hot Bend Steel sections Above 75x75x6 mm - Above 100

Hot Bend Steel Plates Above 12 mm thick – Bending above 150

FOR HIGH TENSILE STEEL

Hot Bend All steel section shapes & sizes

(angles, plates, flats, channels etc.)

4.0 TEMPERATURE RANGE FOR BENDING OPERATION

For Mild Steel and High Tensile Steel -
4.1 Hot bending is done at temperature range 7500 C to 8500 Celsius.
4.2 The temperature shall be measured at the Surface of the Material by pyrometer, thermochalk or
an appropriate device.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 29 of 101
 COMPANY STANDARD CS – 6
ISSUE NO. 8 01.10.07
SPECIFICATION FOR BENDING
REV. NO. 1 20.09.10
OPERATION
SHEET NO. 2 OF 2

5.0 THE ACCEPTANCE NORMS FOR BENDING SHALL BE AS FOLLOWS

5.1 Bending Items shall be verified with the help of validated Bending Slope Gauge.
5.2 The maximum permissible deviation in Bending Slope shall be 3.0 mm per 300 mm.
5.3 The maximum permissible shifting of Bending Line on either side of bend line shall be 2 mm.
5.4 The maximum permissible deviation in angle for Opening & Closing Operation shall be ±1°.
5.5 Waviness / Folds at bend area permissible up to 0.5mm
5.6 100% pieces are to be checked for following bending quality parameters after bending operation –
 Scaling
 Bend degree
 Folds on bend portion
 Waiviness
 Cracks
 Carbon deposit on surface
 Hole after bend
5.7 After bend reduction up to 5% in flange thickness / flange width is acceptable.
5.8 After bend reduction up to 7% in cross section area is acceptable

6.0 GENERAL
6.1 All Hot Bend material shall be air-cooled.
6.2 The Bend shall be of even profile and free from any Surface Damages.
6.3 Scaling, Hammer Marks, Excessive Burning and Die Marks on hot bend material shall not be
permitted.
6.4 Only skilled operator to be deployed for bending operation.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 30 of 101
 COMPANY STANDARD CS – 7
ISSUE NO. 8 01.10.07
SPECIFICATION FOR PLUGGING OF
REV. NO. - -
HOLES BY WELDING
SHEET NO. 1 OF 1

1.0 SCOPE
This is applicable for all types/sizes of Holes, which require Hole Plugging.
(Hole plugging by welding shall be done only after prior approval from QA)

2.0 SELECTION OF WELDING ELECTRODES BASED ON PARENT MATERIAL

PARENT MATERIAL ELECTRODE
MILD STEEL As per IS: 814-ER4 XXX
Type Overcord-S (Advani Oerlikon)
Ferrosped (Esab/IOL), Regular (Honavar)
Normal (DH Secherom)
HIGH TENSILE STEEL As per IS: 914-EXS XXX
Low Hydrogen Type
Supercito/Tenacito (Advani Oerlikon)
Supratheme (DH Secheron)
0
For welding with Low Hydrogen Electrodes, the electrodes shall be kept in Drying Oven at 250 C
0 0
+20 C for one hour and then left at 100 C till the time of welding.

3.0 WELDING PROCESS AND POSITION OF WELDING FOR PLUGGING

Welding Process: Manual Metal Arc / MIG Welding
Welding Position: Plugging Flat

4.0 WELDING PROCEDURE

Welding Procedure as per Specification No. IS: 9595 / as laid down during the Qualification
Procedure.

5.0 HOLE PLUGGING

5.1 Hole Plugging shall be done by completely depositing the Weld metal only.
5.2 More than one hole in group of holes of same joint and more than two hole in any piece shall not
be plugged.
6.2 5.3 In case of blocking of holes in Critical Members like Leg, Main Lattice and X-arms permission from
Quality Assurance/Design Department shall be taken.

6.0 GRINDING
The welded surface after plugging shall be thoroughly ground using a grinder to obtain a smooth
surface and make it flush with parent metal.

7.0 STRESS RELIEVING

In case of Hole Plugging in High Tensile Steel, the surface to be heat-treated after plugging, in order
to relieve the Welding Stresses and to make top surface homogeneous.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 31 of 101
 COMPANY STANDARD CS – 8
ISSUE NO. 8 01.10.07

GALVANZING INSPECTION TESTS REV. NO. - -

SHEET NO. 1 OF 4

1.0 SCOPE
The standard covers all types of galvanizing tests for galvanized tower parts / structures.

2.0 Visual defects in galvanizing coating, acceptance criteria and methods of rework

TABLE-1

Code Reference Is: 2629 Acceptance Criteria For Visible Defects In Galvanizing Coating And Method Of
Plant Practice Rectification

Re-Galvanizing (By
No Defects Manual Rectification Tolerance stripping complete piece /
item)

No
Bare Spots/ Max Permitted 4mm
1 Except Tiny Yes*
Black Spots Across
Spots upto 4mm

Yes
Yes
2 Flux Marks Marks Can Be Removed --
Only When In Big Patches
By Wire Brushing

Yes Yes
Rough Surface (Only
3 Roughness Can Be -- Only When Roughness Is
During Galvanizing)
Smoothened By Filing Too Widespread

Yes Yes
4 Pimples If In Small Quantity By -- Only When Dross
Filing Contamination Is Heavy

Yes Yes
5 Lumpiness If Affected Area Is Less, -- Only When Observed In
By Filing Widespread Areas

Hard Zinc
6 No -- Yes
Contamination

Minor Peeling Off Due Yes

Peeling Off No
7 To Mechanical Only When Poor
Damage Adherence

Yes
Ash / Oxide Yes
8 Generally Removed By --
Contamination Only When In Gross Lumps
Filing & Brushing

Yes
9 Blisters No Few Small Blisters
Only When Widespread

* As Far As Possible Rectification Of Bare / Black Spots Shall Be Avoided.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 32 of 101
 COMPANY STANDARD CS – 8
ISSUE NO. 8 01.10.07

GALVANZING INSPECTION TESTS REV. NO. - -

SHEET NO. 2 OF 4

3.0 VISUAL INSPECTION

3.1 After galvanizing zinc coating on tower parts shall be adherent, smooth, reasonably bright,
continuous and free from such imperfections as flux, ash and dross inclusions, bare and black spots,
pimples, lumpiness and runs, rust stains, bulky white deposits and blisters.
3.2 Galvanized item shall be checked for spikes, excess zinc and hard zinc on the items.

4.0 GALVANIZING TESTS

Zinc Coating Thickness -
4.1 In Process –
4.1.1 Every rack shall be inspected for zinc coating thickness by Elcometer and for surface defects
after galvanizing and before unloading from rack. If rack found acceptable unload for filing.
Acceptance of Zinc coating thickness shall be as per applicable standard or customer specification.
4.1.2 Item on Rack shows less zinc coating thickness, rough surface or galvanized defects the whole
rack shall be send back without unloading for rework / re- galvanization.
4.2 Galvanized Steel Items shall be tested for following tests with applicable standards as mentioned
below in the Table –
Test of Zinc Mass / Stripping Test for Adhesion Test for Uniformity of Test for
Coating Thickness Test of Zinc coating Zinc Coating Embrittlement
IS 4759 IS 6745 IS 2629 IS 2633 IS 2629
BS 729 BS 729 BS 729 BS 729 BS 729
ASTM A 123 ASTM A 123 ASTM A 123 ASTM A 239 ASTM A 123
ISO 1461 ISO 1460 ISO 1461 ISO 1461 ISO 1461

As per ISO 1461 Zinc coating thickness shall be as given below in Table 1 for Steel and Table 1A for
Fasteners
Table – 1: Zinc coating thickness as per ISO 1461 (Samples that are not centrifuged)
Article and its Local coating thickness (min) Mean coating thickness µm (min)
2 2
thickness µm ‘g/m µm ‘g/m
≥ 6 mm 70 505 85 610
≥ 3 mm to < 6 mm 55 395 70 505
≥ 1.5 mm to < 3 mm 45 325 55 395
< 1.5 mm 35 250 45 325
Castings ≥ 70 505 80 575
Castings < 6 mm 60 430 70 505

Table – 1A: Zinc coating thickness as per ISO 1461 (Samples that are centrifuged)
Local coating thickness (min) Mean coating thickness µm (min)
Article and its thickness 2 2
µm ‘g/m µm ‘g/m
Articles with threads
≥ 20 mm 45 325 55 395
≥ 6 mm to < 20 mm diameter 35 250 45 325
< 6 mm diameter 20 145 25 180
Other articles (including castings):
≥ 3 mm 45 325 55 395
< 3 mm 35 250 45 325

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 33 of 101
 COMPANY STANDARD CS – 8
ISSUE NO. 8 01.10.07

GALVANZING INSPECTION TESTS REV. NO. - -

SHEET NO. 3 OF 4

As per ASTM 123 & ASTM 153 Zinc coating thickness for Steel – Table 2 and Fasteners – Table 2A
Table – 2: Zinc coating thickness as per ASTM 123
Steel Thickness inch, mm
<1/16 1/16 to <1/8 1/8 to 3/16 >3/16 to <1/4 ≥¼
Material category
(<1.6) (1.6 to <3.2) (3.2 to 4.8) > 4.8 to <6.4) (≥ 6.4)
2 2 2 2 2
µm ‘g/m µm ‘g/m µm ‘g/m µm ‘g/m µm ‘g/m
Structural Shape & Plate 45 320 65 460 75 530 85 600 100 705
Strip and Bar 45 320 65 460 75 530 85 600 100 705
Pipe and Tubing 45 320 45 320 75 530 75 530 75 530
Wire 35 245 50 355 60 425 65 460 80 565

Table – 2A: Zinc coating thickness as per ASTM 153

2 2
Mass of Zn coating oz/ft (g.m ), Zinc coating Thickness, mils
minimum (microns), minimum
Average of Average of
Class of Material Any individual Any individual
specimens specimens
specimen specimen
tested tested
2 2 2 2 2 2 2 2
oz/ft ‘g/m oz/ft ‘g/m oz/ft ‘g/m oz/ft ‘g/m
Class A – Castings – Malleable Iron, Steel
Class B – Rolled, pressed, and forged articles
1.80 550 2.00 610 3.1 79 3.4 86
(except those which would be included under
classes C and D)
B-1 – 3/16” (4.76mm) and over in thickness and
1.80 550 2.00 610 3.1 79 3.4 86
over 15” (381mm) in length
B-2 – under 3/16” (4.76mm) in thickness and
1.25 381 1.50 458 2.1 53 2.6 66
over 15” (381mm) in length
B-3 – any thickness and 15” (381mm) and
1.10 336 1.30 397 1.9 48 2.2 56
under in length
Class C – Fasteners over 3/8” (9.52mm) in
diameter and similar articles. Washers 3/16” 1.00 305 1.25 381 1.7 43 2.1 53
and ¼” (4.76 and 6.35mm) in thickness
Class D – Fasteners 3/8” (9.52mm) and under
in diameter, rivets, nails and similar articles. 0.85 259 1.00 305 1.4 36 1.7 43
Washers under 3/16” (4.76 mm) in thickness.

As per IS 4759 Zinc coating thickness for steel and fasteners shall be as given below in the Table 3:
Table 3: Zn coating Thickness as per IS 4759 Minimum Value or Average Mass of
Coating
Product 2
‘g/m Microns
i) Castings grey iron, malleable iron 610 86
ii) Fabricated steel articles
5mm thick and over 610 86
Under 5mm but not less than 2mm 460 65
Under 2mm but not less than 1.2mm 340 48
iii) Threaded work other than tubes and tube fittings
10mm diameter and over 300 43
Under 10mm diameter 270 38

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 34 of 101
 COMPANY STANDARD CS – 8
ISSUE NO. 8 01.10.07

GALVANZING INSPECTION TESTS REV. NO. - -

SHEET NO. 4 OF 4

As per BS 729 Zinc coating thickness for steel and fasteners shall be as given below in the Table 4:
Table 4: Zn coating Thickness as per BS 729 Minimum average coating weight
for any individual test area
Category
‘g/m2 Microns
Steel articles 5mm thick and over 610 85
which are not Under 5mm but not less than 2mm 460 64
centrifuged Under 2mm but not less than 1mm 335 47
Grey and Malleable iron castings 610 85
Threaded work and other articles which are centrifuged 305 43
Note: –
1) 1 g/m2 = 0.14 microns
2) For structural steel sections the minimum coating weight referred to in Table 4 shall be the average
of determinations over a test area of 600 to 1200 mm2
3) The nuts are tapped up to 0.4 mm oversize after galvanizing and the threads are oiled.

5.0 STENCILING
5.1 Item Number shall be stenciled on every piece on the top of the bundle or if loose, on every piece
of item number.
5.2 Stenciling shall be done on outer surface of the tower parts after galvanizing. Stenciling shall be
done as per Company Standard CS-9.
5.3 In case of customer specification stenciling on tower parts shall be done as per their requirements.

6.0 REWORK / REGALVANISATION

6.1 Rack send back for less zinc coating thickness, rough surface or galvanized defects shall be
stripped in the pickling solution till all zinc gets removed from the item in the rack.
6.2 After pickling, the item in rack shall be re-galvanized following the process of galvanizing. After
galvanizing the item in the rack shall be inspected and checked again for quality.
6.3 Rack / item found with spikes, excess zinc or hard zinc on the galvanized items then it shall be
removed or filed. If it could not get removed by filing then it shall given sent for re-galvanization.

7.0 REJECTION
Material shall be rejected if item during galvanizing gets over pickled causing reduction in material
thickness or flange width or visible surface defect.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 35 of 101
 COMPANY STANDARD CS – 9
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STENCILING
REV. NO. - -
OF ITEM NUMBERS
SHEET NO. 1 OF 2

1.0 SCOPE
This specification covers stenciling of Item Number on tower parts and the Shapes and Sizes of
letters and digits used for the same.

2.0 STENCILING
2.1 Stenciling shall be done in such a way that letters and digits of stenciling are complete and care
shall be taken to avoid elimination of any part of stenciled letters and digits due to Hole/Notch on the
surface.
2.2 Stenciling shall be done in one row for complete item number, along the length of angle or longer
edge of the Gusset Item.
2.3 In case sufficient space is not available the stenciling of Item Number may be broken and shall be
done in two rows at one location only.

3.0 PLACE OF STENCILING

3.1 ON ANGLE MEMBERS
3.1.1 Stenciling shall always be done on Outer Flange Surface of the angle, such that bottom of
letters and digits shall be towards the toe of the angle.
3.1.2 Stenciling shall be done at a single location on all pieces of one item OR Stenciling shall be
done near stamping.
3.1.3 Stenciling shall be done near one end of the angle.
3.1.4 Stenciling shall start at least 100 mm away from the last hole of the end joint of the piece. If
there is no other hole coming in between, the stenciling shall be completed within 400 mm of the last
hole of the joint on that end. In case of any other hole between 100 mm and 400 mm of the last hole
of the end joint, the stenciling may be adjusted accordingly and may go beyond 400 mm of the last
hole of the joint at that end.

THT 515A 234X

3.2 ON CLEATS
3.2.1 Stenciling shall be done on Outer Flange surface of the angle such that bottom of letters and
digits is towards the toe of the angle.
3.2.2 Stenciling shall be done on any space available on the outer flange surface.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 36 of 101
 COMPANY STANDARD CS – 9
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STENCILING
REV. NO. - -
OF ITEM NUMBERS
SHEET NO. 2 OF 2

3.3 ON GUSSETS
Stenciling shall be done on any available space preferably near the longer edge or in between the
holes along the longer edge of the gusset.

4.0 STENCILING ON SHORTER LENGTH ITEMS

For shorter length items where it is not possible to stencil due to less available length, the Item Number
shall be marked on the item using a Permanent ink Marker in BLACK COLOUR. The marker ink shall
have characteristics mentioned in Clause 8.0.

5.0 NUMBER OF PIECES TO BE STENCILED

5.1 In case of material for Export Projects each and every piece shall be stenciled with its Item
Number.
5.2 In case of material for Domestic Projects the top piece in the bundle shall be stenciled with Item
Number.
5.3 In case item weighing more than equal to 25kgs shall be stenciled on each piece.

6.0 SHAPES
The shapes of the letters and digits shall be as shown in Figure-1 and Figure-2 of this specification.

7.0 DIMENSIONS AND TOLERANCES

7.1 The overall dimensions and tolerance of letters and digits shall be as follows:
Dimensions and Tolerances on Letters and Digits for stenciling
Parameters Dimensions Tolerances
Width 15.5 mm ± 0.4 mm
Height 25.0 mm ± 0.7 mm
Thickness 3.50 mm ± 0.2 mm

7.2 The tolerances on other dimensions forming the shape of the letters and digits stenciled on the
material shall be ± 5.0 percent.

8.0 STENCIL INK

Stenciling Ink shall be as per IS: 1369-1985. The required characteristics for the following ink are listed
below:
A) Black Color or Red Color if specified by customer
B) Suitable for stenciling on Hot Dip Galvanized Non-porous Metal Surface. Should not
spread or flow on Non-porous Metal Surface.
C) Water Proof
D) Indelible (permanent marking which cannot be wiped easily).
E) Resistant to withstand all variations on climatic temperature.
F) Suitable for self-inking stenciling brushes.

9.0 Letters, Digits or Signs other than those given in Figure-1 & Figure-2 of Annexure 5 shall not
be used unless and otherwise required by the customer.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 37 of 101
 COMPANY STANDARD Annexure 5 to CS – 9
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STENCILING
REV. NO. - -
OF ITEM NUMBERS
SHEET NO. 1 OF 2

FIGURE-1 - DIGITS FOR STENCILING

All Dimensions are in mm

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 38 of 101
 COMPANY STANDARD Annexure 5 to CS – 9
ISSUE NO. 8 01.10.07
SPECIFICATION FOR STENCILING
REV. NO. - -
OF ITEM NUMBERS
SHEET NO. 2 OF 2

FIGURE-2 - LETTERS FOR STENCILING

All Dimensions are in mm

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 39 of 101
 COMPANY STANDARD CS - 10
ISSUE NO. 8 01.10.07
HOT DIP GALVANIZING ZINC
REV. NO. - -
GRADES
SHEET NO. 1 OF 2

1.0 SCOPE
This Standard covers the Zinc to be used for Hot Dip Galvanizing.

2.0 REFERENCE
IS: 209, IS: 13229; ASTM B6; ISO R752; DIN 1706

3.0 GRADE
3.1 The grade of Zinc used for Hot Dip Galvanizing shall be as per IS 209, IS 13229, ISO R752, DIN
1706 and ASTM B6.
3.2 In case this grade is not available, grade Zn 98.5 as per IS: 13229 or Prime Western Z19001 as
per ASTM B6 may be used with prior approval of Works.

4.0 CHEMICAL COMPOSITION

As per national and international standards Chemical composition of Zinc of various grades shall be
as given below in the Table 1: -

Table – 1: Chemical Composition of various grade of Zinc

Grade Standard Pb% Cd% Fe% Sn% Cu% % Other % Total
Zn% max max max max max elements Impurities
99.995 ISO R752 0.003 0.003 0.002 0.001 0.001 0.004 0.005
SHG DIN 1706 0.003 0.003 0.002 0.001 0.001 0.004 0.05

ISO R752 0.003 0.003 0.003 0.001 0.002 0.006 0.010

99.990 DIN 1706 0.005 0.003 0.003 0.001 0.002 0.006 0.010
SHG ASTM B6 0.003 0.003 0.003 0.001 0.002 0.002 0.010
IS 209 0.003 0.003 0.003 0.001 0.002 0.015 0.010

ISO R752 0.03 0.02 0.02 0.001 0.002 0.050

99.950
DIN 1706 0.03 0.02 0.02 0.001 0.002 0.03 0.050
HG
IS 209 0.025 0.02 0.01 0.001 0.002 0.050

99.900
ASTM B6 0.03 0.02 0.02 0.01 0.100
HG

98.500 IS 13229 1.25 0.05 0.05 0.020 0.020 0.11

98.000
ASTM B6 0.5-1.4 0.20 0.05 0.20 Al - 0.01 0.14-1.04
PW

5.0 FREEDOM FROM DEFECTS

The surface of ingots slab shall be checked visually and it shall not show oxide inclusions, slag or
foreign matter and shall be clean.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 40 of 101
 COMPANY STANDARD CS - 10
ISSUE NO. 8 01.10.07
HOT DIP GALVANIZING ZINC
REV. NO. - -
GRADES
SHEET NO. 2 OF 2

6.0 MANUFACTURER’S TEST CERTIFICATE

For all receipts of Zinc, Manufacturer’s TC showing Chemical Analysis shall be available. 7.0

7.0 VERIFICATION OF QUALITY OF ZINC

7.1 The Manufacturer’s Test Certificate received for the receipt of the Zinc shall be verified for its
conformity to Chemical Composition shown in Table - 1.
7.2 Verification of Quality of Zinc by third party laboratory shall be at the discretion of the In charge
Quality Control Department based on the criteria stipulated below:
I) If quantity in the lot supplied is more than 75 MT.
II) If the Sub-contractor of the lot is new.
III) If there have been some quality problem regarding quality of the Zinc in the previous supplies of
the same Sub-contractor.
The point has been decided on the experience so far that the third party testing results of the Zinc
have consistently shown conformance to acceptable limits.
7.3 Based on satisfactory conformity of Quality of Zinc as per Clause No.7.1 and / or 7.2 above, the
receipt of Zinc shall be released for utilization for Hot Dip Galvanizing.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 41 of 101
 COMPANY STANDARD CS – 11
ISSUE NO. 8 01.10.07
PACKAGING OF TOWER PARTS FOR
REV. NO. 1 31.07.09
DOMESTIC PROJECTS
SHEET NO. 1 OF 4

1.0 SCOPE
This specification covers the bundling and packaging for Domestic projects.

2.0 PROCEDURE FOR BUNDLING / PACKAGING (Itemwise)

2.1 Pieces of the same Item / mark number shall be packed together in one bundle.
2.2 The pieces shall be packed with heel at top. (Reverse V). Some pieces in the bundle shall be
packed with heel down for interlocking of pieces in a bundle.
2.3 To provide stability to a bundle, height of a bundle shall not be more than the width of a bundle.
2.4 Maximum weight of bundle shall not exceed 1000 Kgs however in case of left over items in the lot,
the bundle weight may exceed upto 1200 Kgs.
2.5 The wire used for bundles reeving shall be 4mm (8 swg) hot dip galvanized.
2.6 The double wires passing through the end holes of all pieces in a bundle shall be twisted and bent
back to prevent opening during handling.
2.7 Wire reeving shall be done at one end of the bundle and at the other end bundle is tied with wire
of 4mm (8 swg) and ends are twisted together at the top.
2.8 Bundles shall be strapped or tied up with the wire at three meters each from one end for more
than 6 meters long bundles.

3.0 PACKAGING OF GUSSETS, CLEATS & SMALL BRACING ITEMS

Wooden box packaging:
3.1 Gussets, cleats and items which are less than 600 mm length are packed in wooden box.
3.2 All pieces of the same item / Mark number shall be packed together by galvanized steel wire of
4mm (8 swg).
3.3 Box may contain more than one item in a box.
3.4 Box shall contain billable lot wise or tower panel wise items as per the bundle plan.
3.5 A transparent polythene sheet of 180 gauge is used to cover all six faces of the boxes to arrest
water seepage inside the box.
3.6 Size of wooden box shall be as per approved drawing. Wood for wooden box shall be jungle wood
or mango wood.

Packaging without wooden box by making a loop

Smaller items can be packed without wooden box if approved by customer
3.7 All pieces of the same item / Mark number shall be packed together by galvanized steel wire of
4mm (8 swg).
3.8 These individual item bundles are wired together in a loop. Different items can be looped together
based on weight of the loop.

RAJESH YASHWANT DANGE

MOTGHARE
ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 42 of 101
 COMPANY STANDARD CS – 11
ISSUE NO. 8 01.10.07
PACKAGING OF TOWER PARTS FOR
REV. NO. 1 31.07.09
DOMESTIC PROJECTS
SHEET NO. 2 OF 4

3.9 Two galvanized wires of 4mm (8 swg) shall be used to make a loop of different items. The end of
the wires shall be twisted together to avoid misplacement of an items during handling / transit.

Packaging by making a bundle of plates, cleats / gussets and small bracings incase of tower
wise packaging:

3.10 Bundling shall consist of all plates, cleats and small bracings up to 600mm length
3.11 For bundling, items shall belong to a single tower. No mixing of other tower items in one bundle
3.12 The items shall be reeve together to form a bundle. Steel wire shall pass from minimum one hole
each of every item to form a bundle. Enclosed photo for reference. For photo refer Page 8 of 8 of
Annexure I to CS – 12
3.13 Depending upon the size variations of items, weight of bundle / bundle type shall be decided -
600Kg, 400kg, 200kg and 60kg
3.14 Following table shall be followed for bundling (for clarity see enclosed photo on page 8 of 8 in
annexure I to CS-12) –

Size of wire to be No. of wires No. of strands

Bundle type
used passing a hole after reeving

Up to 600 kg 8SWG (4.06mm) double eight

Up to 400 kg 10SWG (3.25mm) double eight

Up to 200kg 8SWG (4.06mm) single four

Up to 60 kg 10SWG (3.25mm) single four

3.15 Wires shall be tightened in such a manner that bundles shall have in-built lifting hooks made
from same bundle wires. Enclosed photo for reference on page 8 of 8 in annexure I to CS-12
3.16 Maintain the bundle height less than the width of bundle for bundles stability.
3.17 In case of special requirements specified by customer, the same shall be followed

4.0 STENCILING
4.1 Item Number shall be stenciled on every piece in the top layer of bundle or on every piece in
bundle if specified by customer.
4.2 Package Number and Number of Pieces shall be stenciled on any one piece on top layer of
bundle.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 43 of 101
 COMPANY STANDARD CS – 11
ISSUE NO. 8 01.10.07
PACKAGING OF TOWER PARTS FOR
REV. NO. 1 31.07.09
DOMESTIC PROJECTS
SHEET NO. 3 OF 4

5.0 COLOR CODING ON ANGLE & PLATES

5.1 Color coding shall be provided for identifying the tower type and project. One flange is color coded
for tower type and another for project as mentioned below in Figure - 1.
5.2 Tower type shall be identified by providing color code on edge / face of each bundle/ box.
5.3 Project and tower type color code code shall be done as per instruction of colors codes given by
plant head / works or if specified by customer.
5.4 For Tower Type color code shall be –

Tower Tower Type Color Code

Suspension ‘A’ / ‘P’ Green
Tangent ‘B’ / ‘Q’ Yellow
Angle ‘C’ / ‘R’ Dark Blue
Big Angle ‘D’ / ‘S’ Orange

Figure - 1

Project Tower
Color Type Color

Project Tower
Color Type Color

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 44 of 101
 COMPANY STANDARD Annexure I to CS - 11
ISSUE NO. 8 01.10.07
PACKAGING OF TOWER PARTS FOR
REV. NO. 1 31.07.09
EXPORT PROJECTS
SHEET NO. 4 OF 4

Below pictures shows the arrangement of small plate and cleat items for
bundling. This is a tower wise bundling.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 45 of 101
 COMPANY STANDARD CS - 12
ISSUE NO. 8 01.10.07
PACKAGING OF TOWER PARTS
REV. NO. 3 01.09.11
FOR EXPORT PROJECTS
SHEET NO. 1 OF 9

1.0 SCOPE
This specification covers bundling, packaging of tower parts, bolts, nuts, washers and tower
accessories for export projects.

2.0 MATERIAL
Refer CS – 13 for material specifications used for packaging.

3.0 TYPE OF BUNDLING / PACKAGING

3.1 Bundles - Angle members having length above 600 mm shall be packed in bundles.
3.2 Wooden Boxes (Cleat/Gusset items) - Material like gussets, cleats, platform plates, small bracings
(less than 600 mm) shall be reeved and packed in wooden boxes.
3.3 Wooden Boxes (BNA with gunny bags) - Bolts, nuts, washers and tower accessories shall be
packed in wooden boxes.

4.0 PROCEDURE FOR BUNDLING / PACKAGING:

4.1 The bundling shall be done either item wise or tower wise as specified by customer.
4.2 The pieces shall be packed with heel at top. (Reverse V). Some pieces in the bundle shall be
packed with heel down for interlocking of pieces in a bundle.
4.3 To provide stability to a bundle, height of a bundle shall not be more than the width of a bundle.
4.4 Minimum two wooden rafters shall be provided for bundles upto 8000mm length and for more than
8000mm length one additional rafter to be provided at the center of a bundle.
4.5 In absence of customer specification size of wooden rafter shall be 75mm X 75mm and its length
shall be based on the width of bundle. The length of wooden rafter shall be kept upto 30mm more
than the width of a bundle.
4.6 Maximum weight of bundle shall not exceed 1250 Kgs however in case of left over items in the lot,
the bundle weight may exceed upto 1450 Kgs.
4.7 The wire used for bundles reeving shall be 4mm (8 swg) hot dip galvanized.
4.8 The reeving wire passing through the end security holes of all pieces in a bundle shall be twisted
and bent back to prevent opening during handling.
4.9 Nylon rope of 6mm diameter shall be put between all layers of bundles at equidistant
(refer table-1) for proper ventilation and prevention of white rust formation on pieces.
4.10 All bundles shall be strapped by galvanized / black painted steel straps. Tighten the strap by
tensioner and seal the ends by clamp seals using a sealer. (Refer CS 13 for specification of strap and
clamp seal)
4.11 Two end strapping of a bundle shall pass through the clips nailed on wooden rafters
4.12 Each strapping shall have a strip of Niwar / Hessian cloth underneath throughout the perimeter
of the bundle. Refer CS – 13 for specification of Niwar / Hessian Cloth.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 46 of 101
 COMPANY STANDARD CS - 12
ISSUE NO. 8 01.10.07
PACKAGING OF TOWER PARTS FOR
REV. NO. 3 01.09.11
EXPORT PROJECTS
SHEET NO. 2 OF 9

4.13 The number of straps and nylon ropes on a length of bundle shall be as follows:
Table – 1: For Number of Nylon ropes and Straps on a Bundle
Length of Bundle No. of Straps No. of Nylon ropes
Upto 2000 mm 2 2
Above 2000 – 4000 mm 3 3
Above 4000 – 6000 mm 4 4
Above 6000 – 8000 mm 5 4
Above 8000 – 10000 mm 6 5
Above 10000 – 12000 mm 7 6
Above 12000 – 14000 mm 8 7

4.14 Color code on bundles -

4.14.1 Color coding shall be provided for identifying the tower type and project. One flange is color
coded for tower type and another for project as mentioned below in Figure - 1.
4.14.2 Tower Type shall be identified by providing Color Code on Edge / Face of each Bundle/ Box.
4.14.3 Project and Tower Type color code code shall be done as per instruction of colors codes given
by Plant Head / Works or if specified by Customer.

Figure - 1.
Project Tower Type
Color Color

Project Tower
Color Type
Color
4.15 Labeling – Labels shall be made of resin or metal as specified by the customer. Contents on the
label shall consist of manufacturer, PO reference number, bundle / box number, shipping mark,
destination, net weight, gross weight, number of pieces and any other information specified by the
customer.

5.0 TOWER WISE BUNDLING

5.1 The bundling shall be done Tower Type wise and the members of two different types of towers
shall not be put in same bundle.
5.2 Tower wise bundles shall be tower panel wise (stubs, body below waist, body above waist, cross
arms, beam, peak, body or leg extensions etc) or as specified by customer.
5.3 Pieces in a bundle shall be arranged lengthwise in descending order. Shorter length pieces shall
be kept at the top of the bundle.
5.4 Bundles shall be strapped in such a way that pieces in a bundle should not bend due to straps
tightening.
5.5 For supply projects all pieces in a bundle shall be aligned at one end of the bundle for ease in
tightening and counting at customer warehouse.
RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 47 of 101
 COMPANY STANDARD CS - 12
ISSUE NO. 8 01.10.07
PACKAGING OF TOWER PARTS FOR
REV. NO. 3 01.09.11
EXPORT PROJECTS
SHEET NO. 3 OF 9

5.6 For supply and construction projects pieces shall be distributed from both the ends of bundle to
maintain the bundle stability and minimise the bundle height. All pieces in a bundle shall be reeved
together even though they are put at both the ends of a bundle.
5.7 Open ends of pieces on top of bundle (normally in midlength
of bundles) will be tightened by strap and the strap will be
maximum 100mm away from the end of top piece (practice was
to put strap at 200-500mm away from the end as shown in the
photograph).

Wrong practice -

6.0 IMPROPER BUNDLING PATTERNS

Following types of improper bundling shall be avoided: (Refer Annexure for pictures)
6.1 Plates and angles shall not be packed in same bundle (Refer picture)
6.2 Bundles with only one or two angles projecting out from the other pieces by more than 500 mm
shall be avoided as these pieces are highly susceptible for bend and damages during transportation
and shipment (Refer picture)
6.3 Too many smaller sections shall not be kept on heavy section as more heighten bundles get
collapsed and straps get loose during transportation. (Refer picture)
6.4 Shorter pieces shall not be kept in two longer pieces. In this type of arrangement unsupported end
of longer top pieces in a bundle gets deflected downward and it is likely to develop permanent
deformation if bundle is stored for a long time in strapped condition (Refer picture)

7.0 PACKAGING OF WOODEN BOXES (Cleats/ Gussets and Bolt, Nuts & Accessories)
7.1 All Gussets, cleats and small bracings upto 600 mm length shall be reeved itemwise and packed
in wooden boxes.
7.2 All bolt, nuts, step bolts, pack washers, spring washers and tower accessories packed in gunny
bags shall be packed in wooden box.
7.3 A transparent polythene sheet of 180 gauge is used to cover all six faces of the boxes to arrest
water seepage inside the box.
7.4 The gross weight of wooden box shall not exceed 1000 Kgs or weight per box shall be as
specified by the customer.
7.5 Size of the wooden box shall be as per approved drawings.
7.6 Box shall be strapped at minimum two places along the periphery of the box.
7.7 Box labels shall be made of resin or metal as specified by the customer. Contents on the label
shall consist of manufacturer, PO reference number, bundle / box number, shipping mark, destination,
net weigth, gross weight, number of pieces and any other information specified by the customer.
7.8 A list containing the items and pieces packed in the box shall be put inside the box. The list shall
be put in sealed polythene bag.
RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 48 of 101
 COMPANY STANDARD CS - 12
ISSUE NO. 8 01.10.07
PACKAGING OF TOWER PARTS FOR
REV. NO. 3 01.09.11
EXPORT PROJECTS
SHEET NO. 4 OF 9

8.0 BUNDLING OF PLATES, CLEATS / GUSSETS AND SMALL BRACINGS INCASE OF TOWER
WISE PACKAGING
8.1 Bundling shall consist of all plates, cleats and small bracings up to 600mm length
8.2 For bundling, items shall belong to a single tower. No mixing of other tower items in one bundle
8.3 The items shall be reeve together to form a bundle. Steel wire shall pass from minimum one hole
each of every item to form a bundle. Enclosed photo for reference. For photo refer Page 8 of 8 of
Annexure I to CS – 12
8.4 Depending upon the size variations of items, weight of bundle / bundle type shall be decided -
600Kg, 400kg, 200kg and 60kg
8.5 Following table shall be followed for bundling (for clarity see enclosed photo on page 8 of 8 in
annexure I to CS-12) –

Size of wire to be No. of wires No. of strands

Bundle type
used passing a hole after reeving

Up to 600 kg 8SWG (4.06mm) double eight

Up to 400 kg 10SWG (3.25mm) double eight

Up to 200kg 8SWG (4.06mm) single four

Up to 60 kg 10SWG (3.25mm) single four

8.6 Wires shall be tightened in such a manner that bundles shall have in-built lifting hooks made from
same bundle wires. Enclosed photo for reference on page 8 of 8 in annexure I to CS-12
8.7 Maintain the bundle height less than the width of bundle for bundles stability.
8.8 In case of special requirements specified by customer, the same shall be followed

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 49 of 101
 COMPANY STANDARD Annexure I to CS - 12
ISSUE NO. 8 01.10.07
PACKAGING OF TOWER PARTS FOR
REV. NO. 3 01.09.11
EXPORT PROJECTS
SHEET NO. 5 OF 9

Following type of bundling shall be avoided

Angles and plates are not to be bundled together.

Different profile plates are not be bundled together

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 50 of 101
 COMPANY STANDARD Annexure I to CS - 12
ISSUE NO. 8 01.10.07
PACKAGING OF TOWER PARTS FOR
REV. NO. 3 01.09.11
EXPORT PROJECTS
SHEET NO. 6 OF 9

Angles and plates are not to be bundled together.

Unsupported end of top pieces in bundles are deflected downward as shorter pieces are put
between two longer pieces and strapped on unsupported length.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 51 of 101
 COMPANY STANDARD Annexure I to CS - 12
ISSUE NO. 8 01.10.07
PACKAGING OF TOWER PARTS FOR
REV. NO. 3 01.09.11
EXPORT PROJECTS
SHEET NO. 7 OF 9

One or two longer pieces projecting out of the bundle by more than 500 mm. These projecting
pieces are susceptible for transit damage / bend

Too many smaller pieces bundled together making bundle height more than width and make the
bundle and unstable. Pieces on top of the bundle are likely to get collapsed during transit making
straps loose.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 52 of 101
 COMPANY STANDARD Annexure I to CS - 12
ISSUE NO. 8 01.10.07
PACKAGING OF TOWER PARTS FOR
REV. NO. 3 01.09.11
EXPORT PROJECTS
SHEET NO. 8 OF 9

Below pictures shows the arrangement of small plate and cleat items for
bundling. This is a tower wise bundling.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 53 of 101
 COMPANY STANDARD CS - 12
ISSUE NO. 8 01.10.07
PACKAGING OF TOWER PARTS FOR
REV. NO. 3 01.09.11
EXPORT PROJECTS
SHEET NO. 9 OF 9

9.0 LASHING OF CANTAINER -

9.1 Lashing of container to be decided on demand of customer
9.2 Lashing to be done from approved agency by using provision inside container as shown below.
9.3 Lashing to be done to fix the positions of bundles and boxes from vertical, horizontal movement
inside container while shipment or tansit.
9.4 Ensure the lashing before sealing the container. This is to be cross checked by Dispatch or Finish
Goods yard department.
9.5 If customer demands then provide photographs of lashing done.

10.0 The above Standard Packaging Specification shall be followed unless otherwise specified by the
Purchaser / Customer. In case of special requirements specified by the customer, the same shall be
followed.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 54 of 101
 COMPANY STANDARD CS – 13
ISSUE NO. 8 01.10.07
BUNDLES AND BOXES PACKAGING
REV. NO. - -
MATERIAL SPECIFICATIONS
SHEET NO. 1 OF 4

1.0 SCOPE
This standard covers specifications for Steel Strapping, Steel Clamps/Seal, Steel Wires, Nylon Rope,
Wooden Rafters, Niwar/Hessian Cloth, Labels and Wooden Box used for packaging Tower Parts.

2.0 REFERENCE
For Straps IS 5872, Strap Clamp / Seals IS: 2062, For Steel Wires IS 280 & IS 4826

3.0 STEEL STRAPS:

3.1 Material – Material shall be Steel Strap complying to following requirements.
3.2 Dimensions - The width of Strap shall be 32 mm and thickness shall be 0.8mm.
3.3 Tolerances – On width +/- 0.50 mm and On thickness +/- 0.04 mm.
3.4 Coating – Straps shall be Hot Dip Galvanized with coating of 25 microns minimum / Electro
Galvanized with coating thickness of 15 microns minimum OR Straps shall be painted either black or
gray with coating thickness of min. 20 microns.
3.5 Tensile Properties:
3.5.1 Sampling – Sample shall be selected one number from each consignment.
3.5.2 The tensile test samples shall be taken from any end of the straps and shall be at least 1.5 m in
length.
3.5.3 The Tensile Strength shall be minimum 900 Mpa and percentage of elongation 5% minimum.
3.6 Reverse Bend Test – One sample from each lot shall be bend at 1800 and again make flat to its
original shape. Sample shall not break or develop major cracks during this test.
3.7 Peel Off test - Coated surface shall be scratched by a pointed \ Sharp knife scratching horizontal
and vertical line 2-3mm apart on one inch square of area. One inch width adhesive tape shall be
pasted on scratched area firmly and pulled off at a stretch. Coating material shall not get peel off.
3.8 Salt Spray test - Two samples from each lot shall be tested in salt spray test for minimum 24
hours. Samples shall not develop white rust within 24 hours. (Refer CS-8 for Salt spray test).
3.9 The Steel Straps shall be free from defects such as Scales, Rust, Blisters, Lamination, Pitting,
Porosity and other harmful defects such as Sharp Cracked or Torn Edges or any other defects that
may impair the service ability of the strips.

4.0 STEEL WIRES:

4.1 Material – Material for Steel Wires shall comply with IS 280 and IS 4826.
4.2 Dimensions and Tolerances -

Size of Wire (Gauge) Diameter (mm) Tolerance (mm)

8 SWG 4.06 + 0.10
10 SWG 3.25 + 0.08
14 SWG 1.99 + 0.05
4.3 The Yield Stress shall be minimum 300 Mpa and Tensile Strength shall be minimum 550 Mpa.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 55 of 101
 COMPANY STANDARD CS – 13
ISSUE NO. 8 01.10.07
BUNDLES AND BOXES PACKAGING
REV. NO. - -
MATERIALSPECIFICATIONS
SHEET NO. 2 OF 4

Size of Wire (Gauge) Diameter (mm) Mass of Zn coating (gms/m2)

8 SWG 4.06 130
10 SWG 3.25 100
14 SWG 1.99 70
4.4 Galvanizing – Steel wires shall be Hot Dip Galvanized with minimum of zinc coating thickness as
mentioned below in the table –
4.5 The Steel Wire shall be circular and free from scales, irregularities, imperfections, surface flaws,
splits and other harmful defects. The joining of wires by welding shall not be permitted.

5.0 STRAP CLAMPS / SEALS:

5.1 Material – Material for Strap Clamps shall conform to IS 2062 2006 Grade E 250 / Fe 410WA.
5.2 Dimensions – Width of Clamp shall be 32 mm and length shall be 80mm.
5.3 Tolerances – On width +/- 0.50 mm and On length +/- 1.0 mm.
5.4 Coating – Clamps / Seals shall be Zinc electro-plated with minimum coating thickness 15 microns.
5.5 Peel Off test - Coated surface shall be scratched by a pointed \ Sharp knife scratching horizontal
and vertical line 2-3mm apart on one inch square of area. One inch width adhesive tape shall be
pasted on scratched area firmly and pulled off at a stretch. Coating material shall not get peel off.
5.6 Salt Spray test - Two samples from each lot shall be tested in salt spray test for minimum 24
hours. Samples shall not develop white rust within 24 hours. (Refer CS-8 for Salt spray test).

6.0 NYLON ROPES:

The diameter of nylon rope used for spacing the two members in the bundles shall have its outside
diameter of 6mm minimum.

7.0 WOODEN RAFTERS:

7.1 Wooden rafters are used for providing support bundle and for tying the bundle with strap.
7.2 Material for rafters shall be of Jungle wood / Mango wood.
7.3 Size of wooden rafters shall be 75mm X 75mm with a tolerance of +/- 5mm or as specified by
customer.
7.4 Length of wooden rafter shall depend on width of bundle and shall be decided accordingly.
7.5 Wooden rafters shall not have defects like knots, cracks, termites etc.
7.6 Wooden rafters shall have a Steel Clips at both the end nailed with 3 nails at each side.
7.7 Steel Clip shall have following dimensions and tolerances –
1. Width of Clip shall be 32mm with tolerance of +/- 0.5mm
2. Thickness of Clip shall be 0.8mm with tolerance of +/- 0.04mm
3. Height of Clip shall be 5mm with tolerance of +/- 1mm

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 56 of 101
 COMPANY STANDARD CS – 13
ISSUE NO. 8 01.10.07
BUNDLES AND BOXES PACKAGING
REV. NO. - -
MATERIALSPECIFICATIONS
SHEET NO. 3 OF 4

4. Length of Clip shall be 65mm with tolerance of +/- 1mm

5. Web of Clip shall be 12mm with tolerance of +/- 0.5mm

8.0 NIWAR / HESSIAN CLOTH:

8.1 Niwar shall be made from oven cloth or fabric material. These are used underneath the steel strap
to prevent the marks due to steel strap on bundled items.
8.2 Grade – 28 to 30 Kg per meter
8.3 Width – 65mm +/- 5mm

9.0 LABELS:
9.1 Labels shall be made of Resins or Metal
9.2 Dimensions and Tolerance of Labels as given below in the tables:
Metal Label -
Table – 1: Dimension and Tolerance for Metal Label
Parameters Dimensions (mm) Tolerances (mm)
Width 100 +/- 2
Length 150 +/- 2
Thickness 0.4 +/- 0.04
Slot (LXW) 45 X 3 +/- 1 on L & +/- 0.4 on W
Distance of slot from ends (Length) 11.5 +/- 0.5
Distance of slot from ends (Width) 27.5 +/- 0.5
Distance between the slots 127 +/- 1

Resin Label –
Table – 2: Dimension and Tolerance for Resin Label
Parameters Dimensions (mm) Tolerances (mm)
Width 80 +/- 2
Length 145 +/- 2
Thickness 0.6 +/- 0.04
Slot (LXW) 40 X 0.1 +/- 1 on L & +/- 0.02 on W
Distance of slot from ends (Length) 20 +/- 1
Distance of slot from ends (Width) 20 +/- 1
Distance between the slots 105 +/- 1

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 57 of 101
 COMPANY STANDARD CS – 13
ISSUE NO. 8 01.10.07
BUNDLES AND BOXES PACKAGING
REV. NO. - -
MATERIALSPECIFICATIONS
SHEET NO. 4 OF 4

10.0 NAILING –
10.1 All nails shall be of 8 to 10 Gauges.
10.2 Rust free nails shall be used for nailing.
10.3 Length and gauge of nails shall be selected on the thickness of joint.
10.4 Each nail shall have proper head at top. Half or broken head nails shall not be used for nailing.
10.5 Nailing shall follow zigzag pattern at maximum of 75mm in length.
10.6 Nailing shall be straight and should not be nailed in bend condition. Only head of nail shall be
visible on the surface.
10.7 Nailing shall be done properly so its head or end should not protrude out from either side.
10.8 All corners of box shall be nailed with plated or painted metallic strip. The length and width of
strip shall not protrude out at joints.
10.9 Proper care shall be taken during nailing Planks or Ribs so that crack due to hammering or
nailing pressure can be prevented.

11.0 WOODEN BOXES -

11.1 The dimensions of wooden boxes shall be as per approved drawing or customer specification.
11.2 Material for boxes shall be Jungle wood, Mango wood or Rubber wood.
11.3 The wood shall be free from detrimental cracks, insect attack, any kind of decay, warping, splits
and any other defect, which may reduce the strength, or usefulness of the packing case. Pin holes
(dead infestation) shall not be permitted.
11.4 As far as possible, only one type of wood shall be used to manufacture a packing case.
11.5 Boxes shall be checked on sampling basis for overall dimensions and visual characteristics.
11.6 Crack preventive clamps shall be used wherever necessary.
11.7 Surface of Top Planks, Side Planks shall b e straight.

12.0 SAMPLING PLAN (Visual & Dimension)

Single Sampling Plan as per IS 2500 Part II, Inspection Level II, AQL 4 given below shall be followed
–

Lot Size Sample Acceptance No Rejection No

2 to 150 3 0 1
151 to 3200 13 1 2
3201 to 35000 20 2 3
35001 to 150000 32 3 4
150001 to 500000 50 5 6

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 58 of 101
 COMPANY STANDARD CS – 14
ISSUE NO. 8 01.10.07
PACKAGING OF BOLTS, NUTS AND
REV. NO. - -
ACCESSORIES
SHEET NO. 1 OF 2

1.0 SCOPE
This standard covers the packaging of Bolts, Nuts, Washers and Accessories at supplier’s premises.

2.0 PACKING GUIDELINES

2.1 All tower bolts and nuts shall be packed in buttoned condition unless specified otherwise
2.2 One bag shall contain only one size and one grade of bolts, nuts and accessories
2.3 Quantity per bag shall be limited to 50 Kgs or as specified by customer.

3.0 IDENTIFICATION TAGS:

3.1 Size of the Tag shall be 9 cm x 6 cm
3.2 The tag paper shall be 300 to 400 gsm white paper.
3.3 Font shall be Times New Roman and uniform. Item and Grade font shall be in Bold.
3.4 Month and year of packing shall be mentioned on tag.
3.5 Contents of tag shall be printed as below. Supplier, Item, Size and Grade shall necessarily be
printed and not hand written. Color of printing ink is mentioned in the Table 1.
3.6 Tag shall be put in 150-gauge transparent polythene bag size 12 x 7 cms with opening on 7 cm
side.
3.7 Tag polythene bag shall be stitched along with gunny bag. Stitching shall be at minimum 20 mm
from the edge of the ploythene bag
3.8 All other bolts like step bolts, U bolts, accessories tag shall be printed in black color only

Table 1 Chart for printing color on tags:

Sr No Grade of the Bolt-Nuts Tag Printing Color

1 Grade 5.6 / 5 Black
2 Grade 5.8 / 5 Grey
3 Grade 6.8 / 6 Brown
4 Grade 8.8 / 8 Orange
5 ASTM T0 Blue
6 ASTM T1 Green

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 59 of 101
 COMPANY STANDARD CS – 14
ISSUE NO. 8 01.10.07
PACKAGING OF BOLTS, NUTS AND
REV. NO. - -
ACCESSORIES
SHEET NO. 2 OF 2

SAMPLE TAG

Supplier:
Items: Bolts and Nuts
Size: M ----- x ------
Grade: 5.6 / 5
Quantity: Nos. Weight: Kgs.
Batch no: Month/year:

4.0 PACKAGING
4.1 All bolts, nuts and accessories shall be packed in woven HDPE bags coated with LDPE lining
from inside.
4.2 Woven HDPE bags shall be 100 to 120 GSM and thickness shall be in the range of 600 to 700
Microns
4.3 HDPE bags shall be waterproof and shall be checked for 20 minutes under water showers for
verification of water seepage in the bags.
4.4 HDPE bags shall be put inside gunny bags.
4.5 Gunny bags shall be free from oil stains and dirty spots.
4.6 Gunny bags shall be 0.8 to 1.0 mm thick.
4.7 Gunny bags and HDPE bags shall be stitched together with polyester thread. Stitching shall be at
a distance of minimum 20 mm from the edge of the bag.
4.8 Identification tags polythene bags shall be stitched along with gunny bags at right hand corner of
the bag.
4.9 Gunny bags shall be printed with supplier’s identification and product identification.
4.10 The packed items gunny bags shall not get wet in rainwater or any other source of water.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 60 of 101
 COMPANY STANDARD CS – 15
ISSUE NO. 8 01.10.07
SPECIFICATION FOR PACK
REV. NO. - -
WASHERS
SHEET NO. 1 OF 6

1.0 SCOPE
This standard covers the specifications for Pack Washers and Hardened Washers used as a packing
while fastening the joints in Galvanized Transmission Towers.
(All inspection specification/parameters are taken from repsective standards for reference purpose.
Final decision for acceptance / rejection shall be based on the requirements of the respective
standards and / or Customer Manufacturing Quality Plan.)

2.0 REFERENCE:
Indian Standard – IS 2016, IS 5639, IS 2629
Deutsche Institut Fur Normung – DIN 126, DIN 267 Part 10
American Standard – ANSI B18.22.1, ASTM F 436, ASTM A153

3.0 MATERIAL
3.1 The Washers shall be made of steel, brass, aluminium or any other suitable metal specified in the
standard or purchaser specification. For chemistry of raw material review the manufacturers mill test
certificate.
3.2 As per ASTM F 436 Washers upto and including 1 ½ inch in bolt size shall be hardened and
washers over 1 ½ inch may be either hardened or carburized at the option of the manufacturer.

4.0 TYPES OF WASHERS:

4.1 As per IS 2016 and DIN 126 - there are two types of washers as follows:
a. Machined washers – For Precision and Semi Precision grade - Diameter range 1.7 to 155 mm
b. Punched washers, Type A – For black grade general purpose - Diameter range 1.8 to 52 mm
4.2 As per ANSI B18.22.1 - Plain Washers there are two types of washers as follows:
a. Type A – To minimize embedding and aid torquing – light, medium, heavy & extra heavy series
b. Type B – For distributing load over large area of lower strength material – Narrow & Regular
4.3 As per ASTM F 436 Hardened Steel Washers:
a. Type 1 – Carbon Steel – Style – Circular, Beveled, Clipped and Extra Thick
b. Type 3 – Weathering Steel (Uncoated) – Style – Circular, Beveled, Clipped and Extra Thick

5.0 WORKMANSHIP
The washers shall be free from cracks, burrs, pits and other defects. The holes shall be reasonably
concentric with the outer periphery. All sharp edges shall be removed. There should be no Cup
Formation or Steel Marks on any surface of Washers

6.0 CHEMICAL COMPOSITION

6.1 Chemical composition of washer Type 1 and Type 3 as per ASTM F 436: Product analysis may be
made by the purchaser from finished material representing each lot of washers.
Type Elements P% S% Si % Cr % Ni % Cu %

0.04 0.05
Type 1 -- -- -- --
Heat 0.05 0.06
Product 0.040 0.050 0.15-0.35 0.45-0.65 0.25-0.45 0.25-0.45
Type 3
0.045 0.055 0.13-0.37 0.52-0.68 0.22-0.48 0.22-0.48

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 61 of 101
 COMPANY STANDARD CS – 15
ISSUE NO. 8 01.10.07
SPECIFICATION FOR PACK
REV. NO. - -
WASHERS
SHEET NO. 2 OF 6

6.2 If customer does not specifies the Chemical composition of pack washers then the results shall
conform to IS 2062 E 250 A / Fe 410WA as mentioned below in Table 2:

Table 2: Chemical composition of Pack Washers

C% P% S% Si % Mn %
Item
max max max max max
Pack
0.25 0.050 0.050 0.43 1.55
Washer

6.3 Chemical composition of finish material shall conform to grade of specification mentioned in the
purchase order.

7.0 DIMENSIONS AND TOLERANCES

7.1 For Dimensions and Tolerances of washers for IS 2016 & IS 5639, DIN 126 & DIN 267 Part 10
and ASTM F 436, ANSI B18.22.1
7.2 The tolerance allowed for the difference between the diameters of two faces of washers shall 0.8
mm or Taperness of the punched hole shall not exceed 0.8 mm on diameter.
7.3 The difference in thickness measured on washers maximum and minimum side shall not exceed
0.5 mm for washers of 5 mm & 6 mm thickness and 0.6 mm in case of washer of 8 mm & 10 mm.
7.4 Flatness of washer shall be measured and it should not exceed the specified tolerance. The
permissible deviation for Flatness of washer shall be as given below in the table:
Washer Tolerance Washer Tolerance
Thickness Thickness
Upto 1 mm 0.1 mm 4 to < 6 mm 0.4 mm
1 to < 2.5 mm 0.2 mm 6 to < 10 mm 0.6 mm
2.5 to < 4 mm 0.3 mm 10 to < 18 mm 1.0 mm

8.0 MECHANICAL PROPERTIES:

8.1 For Hardened washers as per ASTM F 436:
8.1.1 Hardness of washers shall be 38 to 45 HRC in black stage and after HOT DIP GALVANIZED
hardness shall be 26 to 45 HRC
8.1.2 For Carburised washers: Washers shall be carburised to a min depth of 0.015 inch and shall
have a surface hardness of 69 to 73 HRA in black stage and after Hot Dip Galvanized 63 to 73 HRA.
8.1.3 Carburised and Hardened washers shall have a minimum core hardness of 30 HRC to 65 HRA.
8.2 If customer does not specifies the hardness then MS washer shall be supplied.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 62 of 101
 COMPANY STANDARD CS – 15
ISSUE NO. 8 01.10.07
SPECIFICATION FOR PACK
REV. NO. - -
WASHERS
SHEET NO. 3 OF 6

9.0 SAMPLING PLAN

9.1 For sampling plan refer company standard CS-19.
9.2 As per ASTM F 436 Sampling plan for each required property shall be as follows:
No. of Pcs in lot No. of specimens samples
800 and under 1
801 to 8000 2
8001 to 22000 3
Over 22000 5

10.0 GALVANISING
10.1 In case customer does not specify the requirements then the washers shall be Galvanized, as
per IS 1367 Part XIII with 54 microns in average for domestic projects and ASTM A 153 Class C with
53 microns in average for export projects.
10.2 In case Washers are required to be supplied Hot Dip Galvanized, the galvanizing requirements
shall conform to IS 2629, IS 2633, IS 4759, IS 6745 or ASTM A-153 Class C, ASTM A-239.
10.3 As per LOA and Technical Specification of PGCIL, washers shall be supplied to PGCIL projects
conforming to IS 2629, IS 2633, IS 4759 and IS 6745 with Zinc coating thickness of 86 microns.

11.0 FINISH
11.1 Washers shall be supplied in natural finish unless otherwise specified in Purchase Order.
11.2 Washers surface should not bear any thick Oil or Paint Marks.
11.3 Washers shall be free of excess mill scale, excess coatings and foreign material on bearing
surfaces.
11.4 Arc and Flame cut washers shall be free of metal spatter.

12.0 PACKAGING
For Packaging details refer CS 14 OR As per customer requirements.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 63 of 101
 COMPANY STANDARD Annexure 1 to CS – 15
ISSUE NO. 8 01.10.07
SPECIFICATION FOR PACK
REV. NO. - -
WASHERS
SHEET NO. 4 OF 6

As per IS 2016, IS 5639 and DIN 126 Dimensions of Pack Washers:

Table 1: Dimensions For Machined Washers

Side, d D S Bolt or
Basic Tol Basic Tol Screw size
8.4 17 +0, - 0.4 1.6 ± 0.2 M8
10.5 21 +0, - 0.5 2.0 ± 0.2 M10
13 24 +0, - 0.5 2.5 ± 0.3 M12
17 30 +0, - 0.5 3.0 ± 0.3 M16
19 34 +0, - 0.8 3.0 ± 0.3 M18
21 37 +0, - 0.8 3.0 ± 0.3 M20
23 39 +0, - 0.8 3.0 ± 0.3 M22
25 44 +0, - 0.8 4.0 ± 0.3 M24
28 50 +0, - 0.8 4.0 ± 0.3 M27
31 56 +0, - 1.0 4.0 ± 0.3 M30
37 66 +0, - 1.0 5.0 ± 0.6 M36
40 72 +0, - 1.0 6.0 ± 0.6 M39
43 78 +0, - 1.0 7.0 ± 1.0 M42
46 85 +0, - 1.5 7.0 ± 1.0 M45
104 175 +0, -1.8 14 ± 1.2 M100
124 210 +0, -2.0 16 ± 1.2 M120

Table – 2 Dimensions For Punched Washers, Type A

Nominal For thread Inner diameter, d Outer Diameter, D Thickness, S
size size, M min max max min Over Upto Tol.
6.6 6 6.6 6.96 12 10.9 0 1.0 ± 0.2
9 8 9 9.36 16 14.9 1.0 2.5 ± 0.3
11 10 11 11.43 20 18.7 2.5 4.0 ± 0.6
13.5 12 13.5 13.93 24 22.7 4.0 6.0 ± 1.0
17.5 16 17.5 17.93 30 28.7 6.0 10.0 ± 1.2
20 18 20 20.52 34 32.4 10.0 18.0 ± 1.5
22 20 22 22.52 37 35.4
24 22 24 24.52 39 37.4
26 24 26 26.52 44 42.4
30 27 30 30.52 50 48.4
33 30 33 33.62 56 54.1
39 36 39 40 66 64.1
42 39 42 43 72 70.1
45 42 45 46 78 76.1
48 45 48 49 85 82.8
107 100 107 108.4 175 172.5
127 120 127 128.6 210 207.1

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 64 of 101
 COMPANY STANDARD Annexure 2 to CS – 15
ISSUE NO. 8 01.10.07
SPECIFICATION FOR PACK
REV. NO. - -
WASHERS
SHEET NO. 5 OF 6

As per ASTM F436 - Dimensions of Hardened Square Beveled and Square Clipped Washers:

ID A A

A T T
A
SQUARE BEVELED SQUARE CLIPPED
Square Beveled and Clipped Square BeveledA Clipped
Slope or Nominal Edge
Bolt size Dimension 'A' Dimension 'ID' Dimension 'T'
Taper in Distance (E)B,
inch (mm) inch (mm) Inch (mm) Inch (mm)
Thickness inch (mm)
1/2" (12.7) 1 3/4" (44.45) 17/32" (13.49) 5/16" (7.94) 1:6 7/16" (11.11)
5/8" (15.88) 1 3/4" (44.45) 11/16" (17.46) 5/16" (7.94) 1:6 9/16" (14.29)
3/4" (19.05) 1 3/4" (44.45) 13/16" (20.64) 5/16" (7.94) 1:6 21/32" (16.67)
7/8" (22.23) 1 3/4" (44.45) 15/16" (23.81) 5/16" (7.94) 1:6 25/32" (19.94)
1" (25.40) 1 3/4" (44.45) 1 1/8" (28.58) 5/16" (7.94) 1:6 7/8" (22.23)
1 1/8" (28.58) 2 1/4" (57.15) 1 1/4" (31.75) 5/16" (7.94) 1:6 1" (25.40)
1 1/4" (31.75) 2 1/4" (57.15) 1 3/8" (34.93) 5/16" (7.94) 1:6 1 3/32" (27.78)
1 3/8" (34.925) 2 1/4" (57.15) 1 1/2" (38.10) 5/16" (7.94) 1:6 1 7/32" (30.96)
1 1/2" (38.10) 2 1/4" (57.15) 1 5/8" (41.28) 5/16" (7.94) 1:6 1 5/16" (33.34)
A
- Rectangular beveled washers shall conform to the dimensions shown above, except that one side
may be longer than that shown for the A dimension.
B
- Clipped edge E shall not be closer than 7/8" of the bolt diameter from the center of the washer.

Washer Dimensional Tolerances

<1 inch 1" to 1 1/2" >1 1/2" to 3" >3 "
Dimensional Characteristics
Nominal Size Nominal Size Nominal Size Nominal Size
Nominal dia of hole, (inch) -0 to +0.032 -0 to +0.063 -0 to +0.063 -0 to +0.0125
Nominal outside dia of hole, (inch) +/- 0.032 +/- 0.063 +/- 0.063 +/- 0.0125
Flatness max deviation from
straightedge placed on cut side shall 0.01 0.015 0.02 0.032
not exceed, (inch)
Concentricity, center of hole to A A A A
0.030 FIR 0.060 FIR 0.090 FIR 0.25 FIR
outside diameter, (inch)
Burr shall not project above
immediately adjacent washer surface 0.01 0.015 0.02 0.025
more than, (inch)
A
- Full Indicator Runout

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 65 of 101
 COMPANY STANDARD Annexure 3 to CS – 15
ISSUE NO. 8 01.10.07
SPECIFICATION FOR PACK
REV. NO. - -
WASHERS
SHEET NO. 6 OF 6

As per ASTM F436 Dimensions of Hardened Circular, Clipped Circular & Extra-Thick Washers
CIRCULAR AND EXTRA THICK CLIPPED CIRCULAR

I OD
O IDI OO
I D
D
. . . .
D D D D
E
TT
Table 4 E- TT
Circular, Clipped & Extra Thick Circular and Clipped Extra Thick Clipped
Nominal size, Nominal O.D, Nominal I.D, Thickness (T), inch (mm) Min Edge
in (mm) in (mm) in (mm) distance (E)A ,
Minimum Maximum Minimum) Maximum
inch (mm)
1/4" (6.35) 0.625 (15.88) 0.281 (7.14) 0.051 (1.3) 0.08 (2.03) … … 0.219 (5.56)
5/16" (7.94) 0.688 (17.48) 0.344 (8.74) 0.051 (1.3) 0.08 (2.03) … … 0.281 (7.14)
3/8" (8.53) 0.813 (20.65) 0.406 (10.31) 0.051 (1.3) 0.08 (2.03) … … 0.344 (8.74)
7/16" (11.11) 0.922 (23.42) 0.469 (11.91) 0.051 (1.3) 0.08 (2.03) … … 0.406 (10.31)
1/2" (12.7) 1.063 (27) 0.531 (13.49) 0.097 (2.46) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 0.438 (11.13)
9/16" (14.29) 1.188 (30.18) 0.625 (15.88) 0.11 (2.79) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 0.5 (12.7)
5/8" (15.88) 1.313 (33.35) 0.688 (17.48) 0.122 (3.1) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 0.563 (14.3)
3/4" (19.05) 1.468 (37.29) 0.813 (20.65) 0.122 (3.1) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 0.656 (16.66)
7/8" (22.23) 1.75 (44.45) 0.938 (23.83) 0.136 (3.45) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 0.781 (19.84)
1" (25.4) 2 (50.8) 1.063 (27) 0.136 (3.45) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 0.875 (22.23)
1 1/8" (28.58) 2.25 (57.15) 1.188 (30.18) 0.136 (3.45) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 1 (25.4)
1 1/4" (31.75) 2.5 (63.5) 1.375 (34.93) 0.136 (3.45) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 1.094 (27.79)
1 3/8" (34.93) 2.75 (69.85) 1.5 (38.1) 0.136 (3.45) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 1.219 (30.93)
1 1/2" (38.1) 3 (76.2) 1.625 (41.28) 0.136 (3.45) 0.177 (4.5) 0.305 (7.75) 0.375 (9.53) 1.313 (33.35)
1 3/4" (44.45) 3.375 (85.73) 1.875 (47.63) 0.178B (4.52) 0.28B (7.11) 0.305 (7.75) 0.375 (9.53) 1.531 (38.89)
B B
2" (50.8) 3.75 (95.25) 2.125 (53.98) 0.178 (4.52) 0.28 (7.11) 0.305 (7.75) 0.375 (9.53) 1.75 (44.45)
2 1/4" (57.15) 4 (101.6) 2.375 (60.33) 0.24C (6.1) 0.34C (8.64) 0.305 (7.75) 0.375 (9.53) 2 (50.8)
C C
2 1/2" (63.5) 4.5 (114.3) 2.625 (66.68) 0.24 (6.1) 0.34 (8.64) 0.313 (7.95) 0.375 (9.53) 2.188 (55.58)
C C
2 3/4" (69.85) 5 (127) 2.875 (73.03) 0.24 (6.1) 0.34 (8.64) 0.313 (7.95) 0.375 (9.53) 2.406 (61.11)
3" (76.2) 5.5 (139.7) 3.125 (79.38) 0.24C (6.1) 0.34C (8.64) 0.313 (7.95) 0.375 (9.53) 2.625 (66.68)
C C
3 1/4" (82.55) 6 (152.4) 3.375 (85.73) 0.24 (6.1) 0.34 (8.64) 0.313 (7.95) 0.375 (9.53) 2.875 (73.03)
3 1/2" (88.9) 6.5 (165.1) 3.625 (92.08) 0.24C (6.1) 0.34C (8.64) 0.313 (7.95) 0.375 (9.53) 3.036 (77.11)
C C
3 3/4" (95.25) 7 (177.8) 3.875 (98.43) 0.24 (6.1) 0.34 (8.64) 0.313 (7.95) 0.375 (9.53) 3.313 (84.15)
C C
4" (101.6) 7.5 (190.5) 4.125 (104.78) 0.24 (6.1) 0.34 (8.64) 0.313 (7.95) 0.375 (9.53) 3.5 (88.9)
A
- Clipped edge E shall be not closer than 7/8" of the bolt diameter from the center of the washer.
B
- 3/16 inch nominal
C
- 1/4 inch nominal

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 66 of 101
 COMPANY STANDARD CS – 16
ISSUE NO. 8 01.10.07
SPECIFICATION FOR SPRING
REV. NO. - -
WASHERS
SHEET NO. 1 OF 8

1.0 SCOPE
This specification covers the dimensions, physical properties and method of testing for helical spring
washers as per national and international standards for various bolt sizes.
(All inspection specification/parameters are taken from repsective standards for reference purpose.
Final decision for acceptance / rejection shall be based on the requirements of the respective
standards and / or Customer Manufacturing Quality Plan.)

2.0 REFERENCE SPECIFICATIONS

Indian Specification - IS: 3063, IS: 4072, IS: 6821, IS: 1573, IS: 1367(Part XIII), IS 1501,
American Specification - ASME B18.21.1, ASTM A153, ASTM A143
Deutsches Specification - DIN 127, DIN 267 Part 26, DIN 17222/17221, DIN 267 Part 10,

3.0 RAW MATERIAL

3.1 The raw material used for manufacturing Spring Washers shall conform to relevant standards.
3.2 For requirement in Indian standard refer IS: 4072, American Standard refer ASME B18.21.1 and
Deutsches Institut for Normung refer DIN 267 Part 26.
3.3 Supplier shall make the manufacturers Test Certificates correlating with raw material used during
finished material inspection.

4.0 WORKMANSHIP
4.1 The flat faces of washers and the inner and outer peripheries shall be smooth and free from
knurling, serrations, die marks, deep scratches, etc, although slight feed roll marks shall be
permissible.
4.2 Washers shall also be free from burrs, rust, pit marks, loose scale and defects that might affect
their serviceability.
4.3 The clearances and angles of the cut ends shall be in such degree so that the washers do not
cause lapping when they are completely compressed and shall not be liable to tangle or link together
when in the free condition.

5.0 TYPES OF SPRING WASHERS

5.1.1 As per IS 3063 there are two types of spring washers
a) Type A - Spring lock washers with bent Deflected or tang ends.
b) Type B – Spring lock washers with flat (square) ends
5.1.2 As per ASME B18.21.1 following are the types
a) Helical Spring-Lock Washers:
In the standard this type covers the sections – Regular, Heavy, Extra-duty and High Collar.
b) Tooth Lock Washers
This standard covers following types – Internal tooth, External tooth, Countersunk tooth, Internal
/external tooth, and of two constructions, designated Types A and B.
5.1.3 As per DIN 127 there are two types of spring washers
a) Type A - Spring lock washers with tang ends
b) Type B - Spring lock washers with square ends

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 67 of 101
 COMPANY STANDARD CS – 16
ISSUE NO. 8 01.10.07
SPECIFICATION FOR SPRING
REV. NO. - -
WASHERS
SHEET NO. 2 OF 8

6.0 COILING
As per ASME B18.21.1 Washers shall be coiled so that the free height is equivalent to twice the
thickness of the washer section. The gap and relationship of the severed ends shall be such as to
prevent washers from tangling and to ensure that washers compress flatly.

7.0 DIMENSIONS AND TOLERANCES:

7.1 Refer Annexure 1 and Annexure 2 for dimensions and tolerances of spring washers required in
Indian Standard, Deutsches Institut for Normung and American Standard.
7.2 Dimensions and tolerances of spring washers after tests like Permanent set test, Permanent Load
test etc refer respective tests specification and tables.

8.0 CHEMICAL COMPOSITION

8.1 As per ASME B18.21.1 washers shall be made from material meeting the chemical composition
requirements of one of the following standards:
a) Carbon Steel – SAE J403 1055-1065 (UNS G10550-G10650)
b) Boron Steel – SAE J411 10B55-10B65
c) Stainless Steel – SAE J405 302-305 (UNS S30200-S30500) or SAE J405 316 (UNS S31600)
d) Aluminium Alloy – ASTM B 211, Alloy 7075 (UNS A97075)
e) Phosphor-Bronze – ASTM B 159, Copper Alloy No. 510 (UNS C51000)
f) Silicon-Bronze 0 ASTM B 99, Copper Alloy No. 651 or 655 (UNS C65100 or C65500)
g) Nickel-Copper-Aluminium – Federal Specification QQ-N-286 (UNS N05500)
h) Alloy Steel – SAE J404 4037 (UNS G40370)
i) Other materials and grades shall be as agreed upon by the manufacturer and purchaser
Table – 1: Chemical composition of Carbon Steel – SAE J403 1055-1065 (UNS G10550-G10650):
UNS No. SAE No. C% Mn % P% S%
G10550 1055 0.50 – 0.60 0.60 – 0.90 0.030 0.050
G10600 1060 0.55 – 0.65 0.60 – 0.90 0.030 0.050
G10650 1065 0.60 – 0.70 0.60 – 0.90 0.030 0.050

8.2 Spring washers shall be made of spring steel complying with the specifications of DIN 17221 or
DIN 17222, or for spring steel with equivalent properties, the grade being at the manufacturers
discretion.
Table – 2: As per DIN 17222 chemical composition of Spring steel shall be as follows:

Size Range Grade C% Mn % P % max S % max Si % max

Width range C55 0.50 – 0.60 0.60 – 0.90 0.035 0.025 0.35
6-325mm, and
C62 0.60 – 0.67 0.60 – 0.90 0.035 0.025 0.35
Thickness
0.40-3.0mm. C80 0.75 – 0.85 0.60 – 0.90 0.035 0.025 0.35

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 68 of 101
 COMPANY STANDARD CS – 16
ISSUE NO. 8 01.10.07
SPECIFICATION FOR SPRING
REV. NO. - -
WASHERS
SHEET NO. 3 OF 8

8.3 As per IS 4072 chemical composition for steel of spring washers shall be as given below in the
table:
Grade Designation C% Si % Mn % S% P% Cr % V%
(max) (max)
1 55C6 0.50-0.60 0.10-0.35 0.50-0.65 0.050 0.050 - -
2 65C6 0.60-0.70 0.10-0.35 0.50-0.80 0.050 0.050 - -
3 70C6 0.65-0.75 0.10-0.35 0.50-0.80 0.050 0.050 - -
4 80C6 0.75-0.85 0.10-0.35 0.50-0.80 0.050 0.050 - -
5 38Si7 0.35-0.42 1.50-1.90 0.60-0.80 0.040 0.040 - -
6 50Si7 0.45-0.55 1.50-2.00 0.50-0.80 0.050 0.050 - -
7 55Si7 0.50-0.60 1.50-2.00 0.70-1.00 0.050 0.050 - -
8 60Si7 0.55-0.65 1.50-2.00 0.70-1.00 0.050 0.050 - -
9 50CrV4 0.47-0.55 0.15-0.35 0.80-1.10 0.035 0.035 0.90-1.20 0.07-0.12

8.4 Chemical composition of Finished Product after check analysis shall not exceed the limits
specified above in the table by more than the following permissible variation:
Constituent Permissible variation over the maximum or under
minimum specified limits, in percent
C, Carbon 0.02
Mn, Manganese:
Upto 0.9% 0.03
Over 0.9% 0.04
Si, Silicon:
Upto 0.35% 0.02
Over 0.35% 0.05
S, Sulphur 0.005
P, Phosphorus 0.005

9.0 MECHANICAL TESTS

9.1 Hardness Test -
9.1.1 The Washer after coiling shall be suitably heat-treated to a hardness of HV 430 (HRC 43.6) to
HV 530 (HRC 51.1).
9.1.2 Hardness Test on Spring Washer shall be conducted in accordance with IS: 1501(Part 1).
9.1.3 For checking hardness, the Washers shall be lightly ground to assure the removal of a
decarburized or plated surface.
9.1.4 During grinding care shall be exercised to prevent the surface temperature of the washer from
exceeding 2500 F.
9.1.5 The values shall be measured, where possible, in the middle of the washer surface at the point
of contact with the supporting surface.
9.1.6 Hardness requirements as per ASME B18.21.1 of spring washers for usage of Carbon Steel
shall be 38 to 46 HRC or 372 to 458 HV. Refer to ASTM E 140 for hardness conversions.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 69 of 101
 COMPANY STANDARD CS – 16
ISSUE NO. 8 01.10.07
SPECIFICATION FOR SPRING
REV. NO. - -
WASHERS
SHEET NO. 4 OF 8

9.2 PERMANENT SET TEST

The Spring Washer to be tested shall be compressed between two hardened Flat Ground Washers
with a hardness of not less than 60 HRC for two minutes at given loads in Table-1. After releasing the
compression load the free height of the spring washers shall not be less than the values in Table-1.
Reference standard is IS 3063 and DIN 267 Part 26.

9.3 PERMANENT LOAD TEST

Ten Spring Washers shall be arranged on a bolt and separated from one another by parallel-faced
washers with minimum hardness of 500 HV (HRC 49.1). This assembly shall then be subjected to
compression loads as specified in Table - 1, for duration of 48 hours at ambient temperature. There
shall be no crack or fracture on the washers. Reference standard is DIN 267 Part 26.

9.4 EMBRITTLEMENT TEST

As per ASME B18.21.1 Carbon and Boron steel lock washers that are electroplated or coated may be
subject to embrittlement. Plated washers shall not fracture after having been compressed flat for
minimum of 48hrs.
Table – 1: As per IS 3063 & DIN 267 Part 26
Bolt Size (mm) Compression Load (N) Minimum Free Height (mm)
4 3050 1.4
5 5050 1.9
6 7050 2.6
8 12900 3.2
10 20600 3.5
12 30000 4
16 56300 5.6
20 88000 6.4
22 110000 6.4
24 127000 8
30 204000 9.6
36 298000 9.6

9.5 TWIST TEST

A portion of the Spring Washer parallel to the end shall be gripped in a vice jaw to a depth of one
fourth of the Washer Outer Diameter and the other portion shall be symmetrically gripped in Wrench
Jaws such that the edge of the Wrench Jaws are parallel to that of the vice jaws. The Wrench Jaw
shall be rotated to twist the washer through 90 º in a direction that increases the free height. The
washer shall show no signs of cracks or fracture. Reference standard is ASME B18.21.1

10.0 GALVANISING:
10.1 The Spring Washer shall have Electro galvanized or Hot Dip galvanized coating (unless
otherwise specified in Purchase Order).
10.2 Electro galvanizing shall be in accordance with Grade 4 (Fe/Zn 25) as per IS: 1573, BS 3382
Hot Dip Galvanizing shall be in accordance with IS: 1367(Part XIII), BS 729, DIN 267 Part 10, ASTM
A 153.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 70 of 101
 COMPANY STANDARD CS – 16
ISSUE NO. 8 01.10.07
SPECIFICATION FOR SPRING
REV. NO. - -
WASHERS
SHEET NO. 5 OF 8

10.2.1 The Electro Galvanized Spring washers shall have a minimum of coating thickness of 25
microns. Test shall be done in accordance with testing method as per IS: 3203.
10.2.2 Average coating thickness shall be minimum 38 microns. Each individual piece of spring
washer shall meet this requirement.
10.3 Hot Dip Galvanizing shall be done meeting the requirements specified in IS 1367 Part XIII, ASTM
153 and DIN 267 Part 10.
10.4 Hot Dip Galvanizing shall not entail the loss of hardness property of Spring Washers due to hot
dip galvanizing process (if specified in Purchase Order).
10.5 In case the Spring Washers are hot dip galvanized the minimum Inner diameter shall be 0.2 mm
more than specified above in order to accommodate the Zinc Coating.
10.6 In case spring washers are Hot Dip Galvanized then the galvanizing requirement shall be as
mentioned below for relevant specifications –
10.6.1 As per IS 1367 Part XIII
2
1) Each individual sample shall meet the requirement of 300 g/m (43 µ) when tested by Stripping
Method or by Coating Thickness Gauge.
2
2) The average of individual samples tested shall meet the requirement of minimum 375 g/m (54 µ)
when tested by Stripping Method or by Coating Thickness Gauge.
3) Uniformity of coating thickness shall be carried out as per IS: 2633. Samples shall withstand
minimum four dips of one minute each.
4) The Adhesion of Zinc Coating shall be carried out as per IS 2629. Zinc on sample should not be
flake off after prying the surface with a Stout Knife.

10.6.2 As per DIN 267 Part 10

The minimum zinc coating thickness for spring washer shall be 40 microns (285 gms/m2).

10.6.3 As per ASTM A153

1) The minimum Zinc coating thickness of any individual spring washer whose thickness is below
4.76mm shall be 36 μ min (1.4oz/ft2 / 259 gms/m2) and 43 μ min. (1.7oz/ft2 / 305 gms/m2) in average.
2) The minimum Zinc coating thickness of any individual spring washer whose thickness is 4.76mm to
6.35mm shall be 43 μ min (1.7oz/ft2 / 305 gms/m2) and 53 μ min. (2.1oz/ft2 / 381 gms/m2) in average.

11.0 SURFACE FINISH

11.1 The Zinc coated articles shall be free from uncoated areas, blisters, flux deposits, dross
inclusions and other types of projections that would interfere with the intended use of the articles or
other defects not consistent with good galvanizing practice.

11.2 The zinc coating shall be smooth and reasonably uniform in thickness.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 71 of 101
 COMPANY STANDARD CS – 16
ISSUE NO. 8 01.10.07
SPECIFICATION FOR SPRING
REV. NO. - -
WASHERS
SHEET NO. 6 OF 8

12.0 RETEST
If any one of the samples selected fail to meet the requirements, then twice the number of samples
first taken shall be so tested, and if any one of these fails the batch represented by the samples shall
be rejected or the batch may be re-galvanized and re-submitted for testing.

13.0 PACKAGING
For Packing details refer CS – 14 or As per customer requirements.

14.0 INSPECTION
14.1 The entire quantity ordered shall be packed and kept ready in all respects prior to inspection by
Inspecting Engineer.
14.2 The material shall be cleared for dispatch on satisfactory conformance to all requirements.
14.3 For acceptance or rejection or dispatch clearance MICC shall be issued with remarks and sign
on the documents.

15.0 SAMPLING PLAN

For Visual, Dimensional, Mechanical, Chemical & Galvanizing inspection refer Company Standard
CS-19.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 72 of 101
 COMPANY STANDARD Annexure 1 to CS – 16
ISSUE NO. 8 01.10.07
SPECIFICATION FOR SPRING
REV. NO. - -
WASHERS
SHEET NO. 7 OF 8

16.0 DIMENSIONS
16.1 As per IS 3063 & DIN 127 Dimensions of Type A and Type B Washers of nominal sizes 12 mm,
16 mm and 20 mm to suit M12, M16 and M 20 Bolts shall be as follows:
s s

600 r
d1
d2 d2
b
k

h‘
h
TYPE A TYPE B
d1 d2 b s r' k* h' - Type A h - Type B
Bolt size
Basic Tol + max Basic Tol + Basic Tol + Nom Min Max Min Max
10 10.2 0.5 18.1 3.5 0.2 2.2 0.15 0.5 0.3 5 5.9 4.4 5.2
12 12.2 0.5 21.1 4 0.2 2.5 0.15 1 0.4 5.8 6.8 5 5.9
16 16.2 0.8 27.4 5 0.2 3.5 0.2 1 0.4 7.8 9.2 7 8.3
20 20.2 1 33.6 6 0.2 4 0.2 1 0.4 8.8 10.4 8 9.4
24 24.5 1 40 7 0.25 5 0.2 1.6 0.5 11 13 10 11.8
30 30.5 1.2 48.2 8 0.25 6 0.2 1.6 0.8 13.6 16.1 12 14.2
36 36.5 1.2 58.2 10 0.25 6 0.2 1.6 0.8 13.6 16.1 12 14.2
1) 2)
42 42.5 1.2 68.2 12 0.25 7 0.25 2 0.8 15.6 18.4 14 16.5
1) 2)
48 49 1.5 75 12 0.25 7 0.25 2 0.8 15.6 18.4 14 16.5
1) 2)
52 53 1.5 83 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
56 57 1.5 87 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
60 61 1.5 91 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
64 65 1.5 95 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
68 69 1.5 99 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
72 73 1.5 103 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
80 81 1.5 111 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
90 91 1.5 121 14 0.25 8 0.25 2 1 18 21.2 16 18.9
1) 2)
100 101 1.5 131 14 0.25 8 0.25 2 1 18 21.2 16 18.9

Note:
1) Test values for spring force test as described in specification is not been specified for this sizes.
2) Test values for the test for permanent set as described in speification is not been specified for this
size.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 73 of 101
 COMPANY STANDARD Annexure 2 to CS – 16
ISSUE NO. 8 01.10.07
SPECIFICATION FOR SPRING
REV. NO. - -
WASHERS
SHEET NO. 8 OF 8

As per ASME B18.21.1Dimensions of Spring Washers of nominal sizes ½”, 5/8”, ¾” 7/8” and 1” to suit
½”, 5/8”, ¾” 7/8” and 1” Bolts shall be as follows:

T to ti
A B
B
W
W

Inside Diameter 'A' Outside Mean Section

Section width, Bearing Width,
Nominal washer As per ASME Diameter 'B' Thickness
'W' min 'BW' min
size B18.21.1 max (ti+to)/2, min
max min
mm(inch) mm(inch) mm(inch) mm(inch) mm(inch) mm(inch)
1/2" (0.500) 13.00(0.512") 12.75(0.502") 22.07(0.869") 3.18(0.125") 4.34(0.171") 3.05(0.120")
9/16" (0.5625) 14.58(0.574") 14.33(0.564") 24.51(0.965") 3.58(0.141") 4.78(0.188") 3.35(0.132")
5/8" (0.625) Table-1 16.28(0.641") 15.95(0.628") 27.25(1.073") 3.96(0.156") 5.16(0.203") 3.61(0.142")
11/16" (0.6875) Dimensions 17.88(0.704") 17.55(0.691") 29.72(1.170") 4.37(0.172") 5.56(0.219") 3.89(0.153")
of Regular
3/4" (0.750) Helical Spring 19.46(0.766") 19.13(0.753") 32.13(1.265") 4.78(0.188") 5.94(0.234") 4.17(0.164")
13/16" (0.8125) - Lock 21.13(0.832") 20.73(0.816") 34.62(1.363") 5.16(0.203") 6.35(0.250") 4.45(0.175")
Washers
7/8" (0.875) 22.71(0.894") 22.30(0.878") 37.06(1.459") 5.56(0.219") 6.76(0.266") 4.72(0.186")
15/16" (0.9375) 24.33(0.958") 23.90(0.941") 39.52(1.556") 5.94(0.234") 7.14(0.281") 5.00(0.197")
1" (1.000) 26.01(1.024") 25.48(1.003") 42.06(1.656") 6.35(0.250") 7.54(0.297") 5.28(0.208")
1/2" (0.500) 13.00(0.512") 12.75(0.502") 22.33(0.879") 3.84(0.151") 4.47(0.176") 3.12(0.123")
9/16" (0.5625) 14.58(0.574") 14.33(0.564") 24.77(0.975") 4.32(0.170") 4.90(0.193") 3.43(0.135")
5/8" (0.625) Table-2 16.28(0.641") 15.95(0.628") 27.61(1.087") 4.80(0.189") 5.33(0.210") 3.73(0.147")
11/16" (0.6875) Dimensions 17.88(0.704") 17.55(0.691") 30.12(1.186") 5.26(0.207") 5.77(0.227") 4.04(0.159")
of Heavy
3/4" (0.750) Helical Spring 19.46(0.766") 19.13(0.753") 32.64(1.285") 5.74(0.226") 6.20(0.244") 4.34(0.171")
13/16" (0.8125) - Lock 21.13(0.832") 20.73(0.816") 35.23(1.387") 6.25(0.246") 6.65(0.262") 4.65(0.183")
Washers
7/8" (0.875) 22.71(0.894") 22.30(0.878") 37.82(1.489") 6.76(0.266") 7.14(0.281") 5.00(0.197")
15/16" (0.9375) 24.33(0.958") 23.90(0.941") 40.39(1.590") 7.21(0.284") 7.57(0.298") 5.31(0.209")
1" (1.000) 26.01(1.024") 25.48(1.003") 43.18(1.700") 7.77(0.306") 8.10(0.319") 5.66(0.223")
1/2" (0.500) 13.00(0.512") 12.75(0.502") 23.75(0.935") 4.11(0.162") 5.18(0.204") 3.63(0.143")
9/16" (0.5625) 14.58(0.574") 14.33(0.564") 26.29(1.035") 4.62(0.182") 5.66(0.223") 3.96(0.156")
5/8" (0.625) Table-3 16.28(0.641") 15.95(0.628") 29.24(1.151") 5.13(0.202") 6.15(0.242") 4.29(0.169")
11/16" (0.6875) Dimensions 17.88(0.704") 17.55(0.691") 31.80(1.252") 5.61(0.221") 6.60(0.260") 4.62(0.182")
of Extra -
3/4" (0.750) Duty Helical 19.46(0.766") 19.13(0.753") 34.42(1.355") 6.12(0.241") 7.09(0.279") 4.95(0.195")
13/16" (0.8125) Spring - Lock 21.13(0.832") 20.73(0.816") 37.03(1.458") 6.63(0.261") 7.57(0.298") 5.31(0.209")
Washers
7/8" (0.875) 22.71(0.894") 22.30(0.878") 39.90(1.571") 7.24(0.285") 8.18(0.322") 5.72(0.225")
15/16" (0.9375) 24.33(0.958") 23.90(0.941") 42.77(1.684") 7.82(0.308") 8.76(0.345") 6.12(0.241")
1" (1.000) 26.01(1.024") 25.48(1.003") 45.57(1.794") 8.38(0.330") 9.30(0.366") 6.50(0.256")

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 74 of 101
 COMPANY STANDARD CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 1 OF 17

1.0 SCOPE
This standard covers the chemical, visual, dimensional, mechanical and galvanizing requirements for
hot dip galvanized Hexagon and Square Head Transmission Bolts in the size range M12, M16, M20 &
M24 (as per IS, ISO, DIN) and inch series sizes ½”, 5/8”, ¾”, 7/8”, 1” (as per ASTM).
(All inspection specification/parameters are taken from repsective standards for reference purpose.
Final decision for acceptance / rejecton shall be based on the requirements of the respective
standards and / or Customer Manufacturing Quality Plan.)

2.0 REFERENCE SPECIFICATIONS

IS: 1363 (Part-I to III) IS: 14394 ISO 898(Part I ) ASTM A 143
IS: 1367 (Part-I to III) BS: 4190 ISO 898 (Part II) ASTM A 153
IS: 1367 (Part-VI) DIN 267 (Part 10) ISO 4014 ASTM F 606
IS: 1367 (Part-IX/Sec 1) DIN 7990 ISO 4016 ASTM A 370
IS: 1367 (Part-IX/Sec 2) DIN 267 (Part 4) ISO 4034 ASTM A 394
IS: 1367 (Part X) DIN EN 20898 (Part 1 & 2) ISO 1459 ASTM A 563
IS: 1367 (Part-XIII) DIN EN 20898 (Part 6 & 7) ISO 1460 ASME B18.2.1
IS: 12427 DIN EN 24034 ISO 1461 ASME B18.2.2
IS: 4218 (Part VI) DIN EN 24016 ASTM F 788
IS: 10238 DIN EN 26157-1 ASTM F 812

3.0 RAW MATERIAL

The Raw Material shall be tested by the manufacturer and shall conform to the Chemical & Physical
properties as per relevant specifications so as to suit the process of manufacture. Any additional test
required for checking suitability to the process of manufacture shall be conducted. All Test Certificates
shall be made available during Finished Material Inspection.

4.0 SAMPLING PLAN

For sampling plan for required tests refer company standard CS-19.

5.0 GRADE & TOLERANCE

Grade and tolerance of bolts & nuts shall conform to the standards as given in Purchase order and
dimensional tolerances shall be maintained accordingly.
5.1 Bolt Eccentricity
5.1.1 As per ASME B18.2.1 Shifting of the head axis with respect to the axis of body shall be within a
tolerance zone having diameter equivalent to 6% of the maximum WAF. This tolerance shall be
determined and allowed to the length of body below head upto one diameter of bolt size.
5.1.2 The maximum difference (X1-X2) between the measurement from one Flat Face of the Bolt
Head to the Shank & same on the symmetrically opposite face of the Bolt shall not exceed 0.84 mm
Figure No. 1
X1

X2

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 75 of 101
 COMPANY STANDARD CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 2 OF 17

5.2 Nut Eccentricity

The maximum difference (Y1-Y2) between the wall thicknesses of two symmetrically opposite faces of
the Nut shall not exceed 0.30 mm (Refer Figure-2).
As per ASME B18.2.2 Bearing surface shall be perpendicular to the axis of the threaded hole within a
tolerance of 3° upto 1” size and 2° for nut sizes larger than 1” size.

Figure 2
Y1
Y222

Y11

Y2

5.3 Squareness Of Bolt

The Bearing Face of the Bolt shall be perpendicular to the Shank Length with a max tolerance of 2°.
As per ASME B18.2.1 Bearing surface shall be perpendicular to the axis of the body within a
tolerance of 3° upto 1” size and 2° for sizes larger than 1” size.

6.0 DIMENSIONS
6.1 Dimensions of the Bolts shall be as per IS: 12427 / ISO: 4016 / DIN: 7990 / BS: 4190 / ASME
B18.2.1 or as Specified in Purchase Orders. For Dimensions see Annexure -2 and Symbols for
Dimensions as per Figure 3
o o
15 to 30
x
x
d e
Ø a w
Ød
d Øds
gl sl b
c k S
l
Figure 3

6.2 The effective Thread Length shall be measured as given below and shown in Figure 4:
6.2.1 The Bolt Length (l) shall first be measured.
6.2.2 A Screw Ring Gauge shall then be fitted on to the Bolt by hand, to the fullest extent.
6.2.3 Distance between Bearing Faces of Bolt Head and Ring Gauge shall then be measured (ls).
6.2.4 Difference of lengths (l-ls) shall be the effective Thread Length and shall be controlled in the
limits as indicated (Refer Figure-4).

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 76 of 101
 COMPANY STANDARD CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 3 OF 17

Figure 4
l
ls

Screw Ring
Gauge
6.3 Dimensions of the Nut shall be as per IS: 1363 Part-3 / ISO: 4034 / DIN EN 24034 / ASME
B18.2.2 as Specified in Purchase Order. For Dimensions & Tolerances of the nuts comply with the
values given in Annexure - 2 & Symbols of Dimensions are as per Figure 5.
0 0
15 to 30

d e
dw

m’ s
m Figure 5

7.0 SCREW THREADS

7.1 Bolts & Nuts shall conform to ISO Metric Screw Threads. The Basic dimensions design profile &
tolerances of screw thread shall conform to the coarse tolerance class of IS: 4218 (Part I to VI).
7.2 The coarse tolerance class for Bolt shall be 8g and for Nut it shall be 7H.
7.3 The Tolerances of ISO metric Bolts and Nuts threads with tolerance class 8g and 7H shall be as
per Annexure – 1
7.4 Checking Of Screw Threads:
1. The Tolerances on Bolt & Nut threads shall apply prior to galvanizing.
2. For inspecting the same on galvanized material, the coating shall first be stripped.
3. The Bolt Thread shall be checked with standard Screw Ring Gauge with 8g tolerances.
4. The Nut Threads shall be PREPARED BY Screw Plug Gauge having oversize as per clause 11.3.
5. The thread dimensions of Bolt & Nut shall be maintained in tolerance limit so that it shall be
possible to tighten nut by hand and shall not have any excessive loose or tight fit over the bolt thread.
6. The fitting shall be such that the nut does not rattle on the bolt.

8.0 CHAMFERING & FACING

0 0
8.1 The periphery of the upper face of the Bolt Head shall be Chamfered at an angle of 15 to 30 .
8.2 The lower or bearing face of the bolt shall not be machined.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 77 of 101
 COMPANY STANDARD CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 4 OF 17

8.3 The diameter of the circle so formed on the head due to the chamfering shall not be less than
90% of the minimum width across the flats distance.
0 0
8.4 Nuts shall be chamfered on both faces at an angle of 15 to 30 so that the diameter of the circle
so formed is not less than 90% of the minimum width across the flats.

9. PROPERTY CLASS
9.1 Property Class of Bolt shall be 4.6/5.6/5.8/6.8 or 8.8 as per ISO: 898 Part I/Specified in Purchase
Order.
9.2 Property Class of Nut shall be 4/5/6 or 8 as per ISO: 898 Part II/Specified in Purchase Order.

10 CHEMICAL COMPOSITION
10.1 Bolt-Nut shall be manufactured from Carbon Steel with Chemical Composition as per Anexure-1.
10.2 The Manufacturer shall carry out Chemical Analysis for each size of Raw Material (wire rods)
used for manufacture of Bolts & Nuts.
10.3 The result shall meet the requirement of the relevant specification and shall be suitable for the
process of manufacture adopted.
10.4 One sample shall be drawn for Chemical Analysis for each Grade & Size of raw material for each
20 MT and part thereof by the manufacturer.
10.5 KEC Representative shall do the verification of Chemical Properties on the basis of one sample
for each Grade & Size of Bolts & Nuts.

10.0 MECHANICAL PROPERTIES

10.1 Mechanical Properties Of Bolts:
10.1.1 Test Methods for Bolts shall be as per Test Programme ‘B’ of ISO: 898 Part-I and
10.1.2 Mechanical properties as per Annexure - 3.
10.2 Mechanical Values –
10.2.1 M12, M16, M20 & M24 Bolts of Grades 5.6 & 5.8 shall meet the following values for the
Mechanical Tests.
10.2.2 The values for minimum shear load shall be calculated based on the Nominal Shear Stress
Area of 113 mm2 for M12, 201 mm2 for M16, 314 mm2 for M20 and 452 mm2 M20 Bolts respectively.
However, in case of marginal values the actual Shank Area shall be taken to calculate the Shear
Stress.
10.2.3 During Wedge Load or Tensile Test and Proof Load Test the length of the Bolt thread engaged
with the hardened fixture or Nut shall be such that minimum three threads of the Bolt shall remain
unengaged i.e., Free. For values of tests refer Annexure – 3.
10.2.4 If the Wedge Loading test is satisfactory, the Tensile test may not be conducted on Bolts.
10.2.5 For Wedge Load test bolt shall be tested at 100 wedge angle.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 78 of 101
 COMPANY STANDARD CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 5 OF 17

10.2.6 The Angle of Wedge used for the Wedge Loading Test for M12, M16, M20 and M24 Bolts shall
be as follows:
Property Class for
Nominal dia. of
Bolt with plain shank length ls  2d Bolt with plain shank length ls  2d
Bolt ‘d’ mm
4.6, 5.6, 5.8 & 8.8 6.8 4.6, 5.6, 5.8 & 8.8 6.8
d  20 10 6 6 4
20  d  39 6 4 4 10
The Hardness of the Wedge shall be minimum 45 HRC.
10.2.7 Head Soundness Test
1) Test shall be conducted on Bolts having diameter less than or equal to 16 mm and lengths less
than 2.5 times the diameter.
2) The Test Plate shall have a thickness above 32 mm and the value of ‘’ (Refer Figure-6) shall be
0 0
60 for testing bolts of Grade 4.6 & 5.6 and 80 for testing bolts of Grade 5.8, 6.8 & 8.8.
3) There shall be no crack on the Shank Head fillet after the head is hammered.

Figure - 6


10.2.8 Hardness Test shall be conducted on Bolt Head for bolts grade 5.6 and on Shank End for bolts
of grade 5.8 after stripping the bolt of galvanized coating and polishing thoroughly the Test Surface to
smoothness.

10.2.9 Shear Test:

1) The shear test consists of a test bolt placed laterally between two fixtures placed vertically.
2) The bolt is then arrested with a plain washer of suitable thickness and a nut.
3) The bolt has to be finger tightened by nut so as to allow the fixture plates to move freely.
4) The holes provided in the fixture shear plates are kept 1.0 mm larger than the nominal thread
diameter of the test bolt and the holes are chamfered 0.5 mm to relive sharp edges.
5) The test specimen is so mounted to ensure that the load is transmitted in a slight line transversely
through the bolt.
6) Load is applied gradually until failures of bolts occur.
7) The bolt has to be sheared at the unthreaded portion of the shank only.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 79 of 101
 COMPANY STANDARD CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 6 OF 17

10.3 Mechanical Properties Of Nuts:

10.3.1 Mechanical Test method for Nuts shall be as per IS: 1367(Part 6) or ISO: 898 Part 2 and
Mechanical Properties as per Annexure - 3.

10.3.2 Proof Load Test:

1. The Nut shall be assembled on a Hardened and threaded test mandrel having minimum hardness
of 45 HRC and Mandrels used shall be threaded to tolerance class of 5h6g except that the tolerance
of the major diameter shall be the last quarter of 6g range on the minimum material side.
2. The proof load shall be applied on the nut in axial direction and shall be held for 15 seconds.
3. The nut shall resist the load without failure by stripping or rupture.
4. Nut shall be removable by the fingers after releasing the load.
5. If the thread of the mandrel gets damaged during testing then test shall be discarded.

10.3.3 Hardness Test

1. Hardness tests shall be carried out on one Bearing Face of the Nut. Mean of three readings at
0
angular separation of 120 shall be taken.
2. Incase of dispute hardness shall be carried out on longitudinal section of nut axis with the
impressions placed as close as possible to the nominal major diameter of the nut thread.

10.4 Torque Test:

Assembly of Bolt & Nut gripped in a vice shall be subjected to Torque Test whereby the Torque
Values specified as per the following table shall be applied to the bolt and there shall be no damage
on the Bolt Head and thread of the bolt & nut.

BOLT SIZE TORQUE (Nm)

5.6 5.8
M 12 47.6 64.0
M 16 118.0 158.0
M 20 231.0 308.0

11.0 SURFACE DISCONTINUITIES

11.1 Surface Discontinuities can occur either during manufacturing or due to defect in the raw
material.
11.2 The Surface Discontinuities can be in the form of Cracks, Seams, Bursts, Shear Bursts, Folds,
Voids, Tool Marks Nicks & Gauges.
11.3 The Nuts shall be examined for these defects according to the Sampling Plan and acceptability
criteria mentioned in IS: 1367(Part X) for Nuts.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 80 of 101
 COMPANY STANDARD CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. 0 -

SHEET NO. 7 OF 17

12.0 GALVANIZING
Bolt nuts shall be galvanized as per requirement mentioned in Purchase order or with respect to
relevant standards.
12.1 The Fasteners shall be Hot Dip Galvanized as per IS: 1367 Part XIII or ASTM A: 153
12.2 The galvanized coating requirements on the Bolts & Nuts shall be as per IS: 1367(Part XIII) or
ASTM A: 153.
12.3 Nut Thread shall be tapped oversize according to the following diametric allowances in order to
accommodate the galvanizing on Bolt Threads
As per IS 1367 Part XIII As per ASTM A 563
NUT SIZE OVER TAPPING NUT SIZE OVER TAPPING
M 12 +0.3 mm M ½ inch ± 0.018 inch / 0.46 mm
M 16 +0.4 mm M 5/8 inch ± 0.020 inch / 0.51 mm
M 20 +0.5 mm M ¾ inch ± 0.020 inch / 0.51 mm
12.4 The Bolt Threads shall not be Re-died, Re-cut or Re-rolled after galvanizing.
12.5 Bolt-Nuts shall be oiled at the time of Buttoning i.e., assembling.
12.6 Zinc Coating Requirements:
12.6.1 Weight Of Zinc Coating:
Test to determine the weight of Zinc Coating per unit area of the Bolts, Nuts shall be as per Appendix-
B of IS: 1367(Part XIII) and shall meet the following requirements as per IS: 1367(Part XIII) or ASTM
A: 153 as required.
Specification Min. Wt. (gm/m2) Thickness (micron)
IS: 1367 (Part XII) Individual 300 43
Average 375 54
ASTM A: 153 Individual 305 43
Average 381 54

12.6.2 Uniformity Of Coating (Preece Test):

Uniformity of Zinc Coating shall be tested in accordance with IS: 2633 or ASTM A239 by dipping a
specimen in Copper Sulphate Solution.
Bolts & Nuts shall withstand four dips of one minute each without showing any adherence of red
deposition of Copper Metal upon the Base Metal.
12.6.3 Adhesion Of Coating:
The Galvanized Coating shall be Pried Off with a Stout Knife by applying a considerable pressure.
There should not be any Flake off of Zinc Layer from the specimen and it shall be acceptable only if
small particles of zinc get removed.
12.6.4 Freedom From Defects:
The coating shall be uniform, smooth and free from imperfections such as Flux, Ash & Dross
Inclusions, Black Spots, Bare Patches, Pimples, Lumpiness, Runs, Rust Stains and Blisters.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 81 of 101
 COMPANY STANDARD CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 8 OF 17

Note: In addition to Inspection & Testing of Raw Material and Process Material, the Manufacturer
shall conduct inspection & testing on Finished Material after drawing samples for, Mechanical Test as
per Table-1 as per IS: 2614 and Table-2 for Galvanizing Tests as per IS: 1367(Part XIII).

13.0 SAMPLING PLAN

Refer CS – 19 for sampling plan of Visual, Dimensional, Mechanical, Chemical and Galvanizing
inspection and tests.

14.0 RETEST
Should any one the specimen fails a galvanizing test then a sample of double the number of the; first
sample shall be drawn and the test re-conducted. If any single specimen from the second sample
fails the test, then the entire lot represented by the samples shall be deemed Rejected due to
improper galvanizing and may be re-galvanized for Inspection & Testing again.

15.0 MARKING
The Bolt Heads shall bear embossed markings to indicate the grade of the Bolt and name of the
manufacturer. If customer specifies the marking then it shall be done as per customer specification.

16.0 PACKAGING
Refer CS – 14 for Packing of Bolt and Nuts or As per customer requirements / specification.

16.0 INSPECTION
16.1 The full consignment of Bolts/Nuts shall be kept ready in all respects and packed prior to
inspection by KEC Representative.
16.2 Once the material is found acceptable on satisfactory inspection results, all the bags shall be
sealed for dispatch to the destination specified.
16.3 KEC inspector shall issue MICC after inspection stating the status of inspection. MICC shall be
issued for accepted and rejected lot.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 82 of 101
 COMPANY STANDARD Annexure 1 to CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 9 OF 17

MECHANICAL PROPERTIES OF STEEL BOLTS AS PER IS 1367 PART 3, IS 12427 / ISO 898
PART 1 / DIN: 20898 Part I:

Wedge Load/ Ultimate Proof Shear Strength Hardness

Size Grade
Tensile Load in N Load in N in Mpa** in Range
M 12 33700 19000
M 16 62800 35300
4.6 250 67-99.5 HRB
M 20 98000 55100
M 24 141000 79400

M 12 42200 23600
M 16 78500 44000
5.6 310 79-99.5 HRB
M 20 122000 68600
M 24 176000 98800

M 12 43800 32000
M 16 81600 59700
5.8 322 82-99.5 HRB
M 20 127000 93100
M 24 184000 134000

M 12 50600 37100
M 16 94000 69100
6.8 375 89-99.5 HRB
M 20 147000 108000
M 24 212000 155000

M 12 70000* 50700*
M 16 130000* 91500*
8.8 515 22-32 HRC
M 20 203000 147000
M 24 293000 212000
* For Structural Bolting
Note: ** All grade, size and specification of bolts shall be mandatory shear tested and it shall meet the
minimum shear load value mentioned above in the table.

MECHANICAL PROPERTIES OF STEEL NUTS AS PER IS 1367 PART 6, ISO 898 PART 2 and
DIN: 20898 Part 2:
Property Class 5 Property Class 6 Property Class 8
Nominal
Size of Nut Proof Load Hardness Proof Load Hardness Proof Load Hardness
in N in HV in N in HV in N in HV
M12 51400 59000 74200
130 - 302 150 - 302 200 - 302
M16 95800 109900 138200
M20 154400 176400 225400
146 - 302 170 - 302 233 - 302
M24 222400 254200 324800

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 83 of 101
 COMPANY STANDARD Annexure 2 to CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 10 OF 17

MECHANICAL PROPERTIES OF STEEL BOLTS AS PER ASTM A 394:

Tensile Load -
Minimum Tensile / Wedge Load
Type 1 and 3 Tensile
Nominal size Type 0 Tensile strength
strength
Inch mm lbf kgf KN lbf kgf KN
1/2 12.70 10500 4763 46723 17050 7734 75869
5/8 15.88 16700 7575 74312 27100 12293 120590
3/4 19.05 24700 11204 109910 40100 18189 178438
7/8 22.23 34200 15513 152184 55450 25152 246742
1 25.40 44850 20344 199574 72700 32977 323502
Shear Load -
Minimum Shear Load (lbf)
Nominal size
Type 0 Type 1 and 3
Thru Thru Thru Thru Thru Thru Thru Thru Thru Thru Thru Thru
Inch mm Threads Threads Threads body body body Threads Threads Threads body body body
(lbf) (kgf) (KN) (lbf) (kgf) (KN) (lbf) (kgf) (KN) (lbf) (kgf) (KN)
1/2 12.70 6950 3153 30926 9000 4082 40048 9350 4241 41606 14600 6623 64967
5/8 15.88 11150 5058 49615 14100 6396 62742 15050 6827 66970 22850 10365 101678
3/4 19.05 16650 7552 74089 20250 9185 90109 22450 10183 99898 32850 14901 146176
7/8 22.23 23150 10501 103013 27600 12519 122815 31150 14130 138612 44750 20299 199129
1 25.40 30400 13789 135274 36050 16352 160416 41000 18598 182442 58450 26513 260092

Hardness -
Grade Scale of Hardness Minimum Maximum
Type 0 Rockwell B 80 100
Type 1,2, 3 Rockwell C 25 34

MECHANICAL PROPERTIES OF STEEL NUTS AS PER ASTM A 563:

Hex Nuts, Proof Load (lbf) Heavy Hex Nuts, Proof Load (lbf)
Grade O A D DH A D DH
Dia, 52 69 68 90 135 150 75 100 150 150 175
½” 7379 9791 9649 12771 19157 21285 10643 14190 21285 21285 24833
5/8” 11752 15594 15368 20340 30510 33900 16950 22600 33900 33900 39550
¾” 17368 23046 22712 30060 45090 50100 25050 33400 50100 50100 58450
7/8” 24024 31878 31416 41580 62370 69300 34650 46200 69300 69300 80850
1” 31512 41814 41208 54540 81810 90900 45450 60600 90900 90900 106050
1 3/8” 60060 79695 78540 103950 155925 173250 86625 115500 173250 173250 202125
Hardness Of Nuts -
HRB 55 min 68 min 84 - 68 min 84 -
HRC 32 max 32 max 38 24 - 38 32 max 38 24 - 38

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 84 of 101
 COMPANY STANDARD Annexure 3 to CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 11 OF 17

CHEMICAL COMPOSITION OF STEEL BOLTS ISO: 898 Part I, DIN: 20898 Part I & IS: 1367 Part III
Chemical Composition Limits (Check Analysis) % Tempering
Property Class C% P% S% Temp. C
Min. Max. Max. Max. Min.
4.6 -- 0.55 0.05 0.06 --
5.6 0.13 0.55 0.05 0.06 --
5.8 -- 0.55 0.05 0.06 --
6.8 -- 0.55 0.05 0.06 --
Carbon steel with B. Mn / Cr.
Quenched and tempered
0.15 0.40 0.035 0.035 425
8.8
Carbon steel quenched and
tempered
0.25 0.55 0.035 0.035 425

1. Free cutting steel is allowed for Property class 4.6, 5.8 & 6.8 with the following composition:
S - 0.34% Max, P - 0.11% Max & Pb - 0.35% Max
2. For the nominal diameter above 20mm the steel specified for property class 10.9 may be necessary
in order to achieve sufficient hardenability.

CHEMICAL COMPOSITION OF STEEL NUTS ISO: 898 Part II, DIN: 20898 Part II & IS: 1367 Part VI
Chemical Composition Limits (Check Analysis) %
Property C% Mn % P% S%
Class Max. Max. Max. Max.
4, 5 & 6 0.50 -- 0.06 0.15
8 0.58 0.25 0.06 0.15
Nuts of Property Class 4, 5 & 6 may be manufactured from free cutting steel unless otherwise agreed
between the manufacturer and purchaser. In such case following are permissible. S - 0.34% Max, P -
0.11% Max & Pb - 0.35% Max

TOLERANCE OF ISO METRIC BOLTS THREADS CLASS 8g

Nominal Length of threads Major Pitch Minor
size engagement
From Upto Diameter
Max. Min. Diameter
Max. Min. Diameter
Max. Min.
M 12 6 18 11.986 11.541 10.829 10.593 9.819 9.457
M 16 8 24 15.962 15.512 14.663 14.413 13.508 13.114
M 20 10 30 19.958 19.428 18.334 18.068 16.891 16.446
M 24 12 36 23.952 23.352 22.003 21.668 20.271 19.740

Length of threads Major Pitch Minor

Nominal engagement Diameter Diameter Diameter
size
From Upto Min. Max. Min. Max. Min.
M 12 6 18 12.00 11.113 10.863 10.531 10.106
M 16 8 24 16.00 14.966 14.701 14.310 13.835
M 20 10 30 20.00 18.656 18.378 17.854 17.294
M 24 12 36 24.00 22.386 22.051 21.382 20.752

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 85 of 101
 COMPANY STANDARD Annexure 4 to CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 12 OF 17

CHEMICAL COMPOSITION OF STEEL BOLTS AS PER ASTM A 394:

Head Marking Bolt Type Steel material C% Mn % P% S% B%

T-0 Low or Med 0.55 0.48 0.058

0 - -
Carbon Steel max max max

T-1 Medium 0.28 / 0.60 0.48 0.058

1 -
Carbon Steel 0.55 min max max

T-3 Weathering A,B,C,D,E and F classes of material used for

3
steel type 3 bolts (Refer table 2 in standard)

CHEMICAL COMPOSITION OF STEEL NUTS AS PER ASTM A 563:

Grade Analysis C% Mn% P% S%

O, A, B, Heat 0.55 - 0.12 0.15A
C Product 0.58 - 0.13B -
Heat 0.55 0.30 0.04 0.05
DC
Product 0.58 0.27 0.048 0.058
Heat 0.20-0.55 0.60 0.04 0.05
DHC
Product 0.18-0.58 0.57 0.048 0.058
Note:
A
- For Grades O, A and B a sulfur content of 0.23% max is acceptable with the purchasers approval
B
- Acid bessemer steel only
C
- For Grades D and DH a sulfur content of 0.05-0.15% is acceptable provided the manganese is
1.35% minimum

OVERTAPPING ALLOWANCE FOR NUTS AFTER HDG ZINC COATED AS PER ASTM A 563

Diameter Allowance Pitch Diameter

Nominal size
Inch mm Inch, min Inch, max mm, min. mm, max.
½” – 0.500 0.018 0.46 0.4680 0.4745 11.89 12.05
5/8” – 0.625 0.020 0.51 0.5860 0.5932 14.88 15.07
¾” – 0.750 0.020 0.51 0.7050 0.7127 17.91 18.10
7/8” – 0.875 0.022 0.56 0.8248 0.8330 20.95 21.16
1” – 1.000 0.024 0.61 0.9428 0.9516 23.95 24.17
1 3/8” – 1.375 0.027 0.69 1.2937 1.3041 32.86 33.12

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 86 of 101
 COMPANY STANDARD Annexure 5 to CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 13 OF 17

DIMENSIONS OF BOLTS AS PER IS: 12427 / ISO: 4016 / DIN EN: 24016:

o o
15 to 30
x
x
d e
Ø a w
Ød
d Øds
gl sl b
c k S
l
Figure 3

DIMENSIONS OF BOLTS AS PER IS: 12427 / ISO: 4016 / DIN EN: 24016

M12 M16 M20 M22 M24

Dimensions for
Min Max Min Max Min Max Min Max Min Max

Pitch of thread p 1.75 2.00 2.50 2.5 3.0

Washer face thickness C 0.6 0.8 0.8 0.8 0.8

Root diameter da 14.7 18.7 24.4 26.4 28.4

Shank diameter ds 11.3 12.7 15.3 16.7 19.16 20.84 21.16 22.84 23.16 24.84

Washer face dw 16.47 18.0* 22.0 24.0* 27.7 30.0* 31.35 34.0* 33.25 36.0*

Width across corner e 19.85 26.17 32.95 37.29 39.55

Head thickness k 7.05 7.95 9.25 10.75 11.6 13.4 13.1 14.9 14.1 15.9

Root radius r 0.6 0.6 0.8 0.8 0.8

Width across flat s 17.57 18.00 23.16 24.0 29.16 30.0 33.0 34.0 35.0 36.0

Thread Length b AS PER PURCHASE ORDER

Upto 30 mm  1.05 mm 125 mm to 150 mm  2.0 mm
35 mm to 50 mm  1.25 mm 155 mm to 180 mm  4.0 mm
Length l
55 mm to 80 mm  1.50 mm 185 mm to 240 mm  4.6 mm
85 mm to 120 mm  1.75 mm 245 mm to 300 mm  5.2 mm
Note: * indicates that these maximum values are mentioned in IS 12427 only.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 87 of 101
 COMPANY STANDARD Annexure 6 to CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 14 OF 17

DIMENSIONS OF BOLTS AS PER DIN 7990:

o o
15 to 30
x
x
d e
Ø a w
Ød
d Øds
gl sl b
c k S
l
Figure 3

DIMENSIONS OF BOLTS AS PER DIN 7990

M12 M16 M20 M24

Dimensions for
Min Max Min Max Min Max Min Max
Pitch of thread P 1.75 2.00 2.50 3.00
Washer face thickness C 0.6 0.8 0.8 0.8
Root diameter da 14.7 18.7 24.4 28.4
Shank diameter ds 11.3 12.7 15.3 16.7 19.16 20.84 23.16 24.84
Washer face dimensions dw 16.4 22.0 27.7 33.2
Width across the corner e 19.85 26.17 32.95 39.55
Head thickness k 7.55 8.45 9.25 10.75 12.1 13.9 14.1 15.9
Root radius r 0.6 0.6 0.8 0.8
Width across the flat s 17.57 18.00 23.16 24.00 29.16 30.00 35.00 36.00
Thread Length b AS PER PURCHASE ORDER

Upto 30 mm  1.05 mm 35 mm to 50 mm  1.25 mm

55 mm to 80 mm  1.50 mm 85 mm to 120 mm  1.75 mm
Length l
125 mm to 150 mm  2.00 mm 155 mm to 180 mm  4.00 mm
185 mm to 200 mm  4.60 mm

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 88 of 101
 COMPANY STANDARD Annexure 7 to CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 15 OF 17

DIMENSIONS OF STEEL BOLTS AS PER ASME B18.2.1:

0 0
15 to 30

E d G

LT
LG F
H L
Figure 3

Dimensions in Millimeters -
LT - Thread Length
Length Length
Nominal E' - Shank F' - Width Across G' - Width Across H' - Head Height, R' - Radius of
Less than Above
Dia Diameter, mm Flats, mm Corners, mm mm Fillet, mm
152.4mm 152.4mm
mm max min max min max min Max min max min max min
12.70 13.081 12.243 19.050 18.415 21.996 20.980 9.246 7.671 0.762 0.254 31.75 38.10
15.88 16.307 15.367 23.825 23.012 27.508 26.238 11.278 9.601 1.524 0.508 38.10 44.45
19.05 19.507 18.517 28.575 27.635 32.995 31.496 13.310 11.557 1.524 0.508 44.45 50.80
22.23 22.733 21.641 33.325 32.233 38.506 36.754 15.342 13.487 1.524 0.508 50.80 57.15
25.40 25.959 24.790 38.100 36.830 43.993 41.986 17.780 15.011 2.286 0.762 57.15 63.50

Dimensions in Inches -
LT - Thread Length
E' - Shank G' - Width Length
F' - Width Across R' - Radius of Length
Nominal Diameter, Across Corners, H' - Head Height, inch Less
Flats, inch Fillet, inch Above 6"
Dia, inch inch inch than 6"
max min Basic max min max min Basic max min max min max min
1/2 0.500 0.515 0.482 3/4 0.75 0.73 0.87 0.83 11/32 0.36 0.30 0.03 0.01 1.25 1.50
5/8 0.625 0.642 0.605 15/16 0.94 0.91 1.08 1.03 27/64 0.44 0.38 0.06 0.02 1.50 1.75
3/4 0.750 0.768 0.729 1-1/8 1.13 1.09 1.30 1.24 1/2 0.52 0.46 0.06 0.02 1.75 2.00
7/8 0.875 0.895 0.852 1-5/16 1.31 1.27 1.52 1.45 37/64 0.60 0.53 0.06 0.02 2.00 2.25
1 1 1.022 0.976 1-1/2 1.50 1.45 1.73 1.65 43/64 0.70 0.59 0.09 0.03 2.25 2.50

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 89 of 101
 COMPANY STANDARD Annexure 8 to CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 16 OF 17

Tolerance on Total Length Of Bolts:

Full body is the distance from the underside of the head to the first scratch of thread for bolts with
machine-cut threads or top of the extrusion angle for bolts with rolled threads with a tolerance of ± 1/32
inch for sizes 1/2 inch to 3/4 inch (including) and ± 1/16 inch for size 7/8 inch and 1 inch.
Length of Bolt - Bolt Diameter
'L' Inch MM Inch MM Inch MM Inch MM Inch MM
Inch MM 1/2 12.70 5/8 15.88 3/4 19.05 7/8 22.23 1 25.4
1 25.40 3/32 2.38 1/16 1.59 … … … … … …
1 1/4 31.75 5/32 3.97 1/16 1.59 1/16 1.59 … … … …
1 1/2 38.10 13/32 10.32 1/4 6.35 1/8 3.18 3/16 4.76 … …
1 3/4 44.45 21/32 33.34 1/2 12.70 3/8 9.53 1/4 6.35 3/16 4.76
L minus L minus L minus L minus L minus
≤2 50.80 27.781 31.750 34.925 38.100 41.275
1 3/32 1 1/4 1 3/8 1 1/2 1 5/8

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 90 of 101
 COMPANY STANDARD Annexure 9 to CS – 17
ISSUE NO. 8 01.10.07

SPECIFICATION FOR BOLTS & NUTS REV. NO. - -

SHEET NO. 17 OF 17

DIMENSIONS OF NUTS AS PER ASME B18.2.2:

150 - 300 150 - 300

H H
F

Dimensions in Inches
Runout of Runout of
Bearing Bearing
G' - Width Face FIM - Face FIM -
F' - Width Across
Nominal Dia, Across H' - Head Height, inch for specific for specific
Flats, inch
Inch Corners, inch proof load proof load
Upto 150000 psi
150000 psi & above
Basic max min max min Basic max min inch inch
1/2 0.500 3/4 0.750 0.736 0.866 0.840 7/16 0.448 0.427 0.019 0.014
9/16 0.563 7/8 0.875 0.861 1.010 0.982 31/64 0.496 0.473 0.020 0.015
5/8 0.625 15/16 0.938 0.922 1.083 1.051 35/64 0.559 0.535 0.021 0.016
3/4 0.750 1-1/8 1.125 1.088 1.299 1.240 41/64 0.665 0.617 0.023 0.018
7/8 0.875 1-5/16 1.312 1.269 1.516 1.447 3/4 0.776 0.724 0.025 0.020
1 1.000 1-1/2 1.500 1.450 1.732 1.653 55/64 0.887 0.831 0.027 0.022

Dimensions in Millimeters
Runout of Runout of
Bearing Face Bearing Face
Nominal F' - Width Across G' - Width Across H' - Head Height,
FIM for specific FIM for specific
Dia, mm Flats, mm Corners, mm mm
proof load Upto proof load 1034
2 2
1034 N/mm N/mm & above
mm max min max min max min mm mm
12.700 19.050 18.694 21.996 21.336 11.379 10.846 0.4826 0.3556
14.288 22.225 21.869 25.654 24.943 12.598 12.014 0.5080 0.3810
15.875 23.825 23.419 27.508 26.695 14.199 13.589 0.5334 0.4064
19.050 28.575 27.635 32.995 31.496 16.891 15.672 0.5842 0.4572
22.225 33.325 32.233 38.506 36.754 19.710 18.390 0.6350 0.5080
25.400 38.100 36.830 43.993 41.986 22.530 21.107 0.6858 0.5588

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 91 of 101
 COMPANY STANDARD CS – 18
ISSUE NO. 8 01.10.07
SPECIFICATION FOR ANTI THEFT
REV. NO. - -
BOLT AND NUTS
SHEET NO. 1 OF 2

1.0 SCOPE:
This standard covers the requirements of inspection & testing of galvanized Anti-Theft Bolt Nuts.

2. 0 REFERENCE SPECIFICATIONS:
As per drawing mentioned in Purchase order and following standards as applicable
IS: 1363 (Part-I to III) IS: 10238 ISO / DIN EN 2 4034
IS: 1367 (Part-I to III) BS: 4190 ISO / DIN EN 2 4016
IS: 1367 (Part-VI) DIN 267 (Part 10) ISO 898(Part I & II)
IS: 1367 (Part-XIII) DIN EN 20898 (Part 1 & 2) ASTM A 153
IS: 12427 DIN EN 20898 (Part 6 & 7) ASTM F 812 & 788
ASTM A 394 ASTM 563 ASME B18.2.1

3.0 RAW MATERIAL:

The Raw Material shall be tested by the manufacturer and shall conform to relevant specification and
grade for all test parameters.

4.0 GRADE / PROPERTY CLASS & TOLERANCE:

Property Class of Bolt shall be 4.6/5.6/5.8/6.8 or 8.8 as per IS 1367 Part III, ISO: 898 Part I / Specified
in purchase order or as mentioned in the drawing.

5.0 INSPECTION TESTS

Following inspection tests are applicable for AT bolts and nuts. Refer CS-19 for the sampling plan of
all these tests.
Tests for AT bolts and nuts Applicable for CS reference
Visual and dimensions Bolts and Nuts CS – 17 and drawings
Hardness tests Bolts and Nuts CS – 17
Proof Load test Bolts and Nuts CS – 17
Shear test Bolts CS – 17
Tensile test Bolts CS – 17
Torque test Nuts CS – 18
Galvanizing test Bolts and Nuts CS – 8

6.0 SHANK LENGTH OF BOLT:

6.1 Shank lengths of bolts shall be as per the tolerance given on the drawing.
6.2 The tolerance for shank length shall be  0.5mm. If the shank length of bolt is not within tolerance
then reject the whole lot without testing. If shank length is more then nuts rotates along with the bolt
and doesn’t get tightened fully.
RAJESH MOTGHARE YASHWANT DANGE
ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 92 of 101
 COMPANY STANDARD CS – 18
ISSUE NO. 8 01.10.07
SPECIFICATION FOR ANTI THEFT
REV. NO. - -
BOLT AND NUTS
SHEET NO. 2 OF 2

7.0 TORQUE TEST:

7.1 Torque test value of ATB nuts shall be as per approved drawing. If torque value is not specified on
the drawing then it shall be 10 Kgm to 16 Kgm for M16 size and 4 Kgm to 6 Kgm for M12 size.
7.2 Torque test procedure -
7.2.1 Grip the anti-theft bolt and nut on the steel plate. Decide plate thickness on the basis of shank
length of the bolt.
7.2.2 Plate and spring washers used for testing to be in galvanized condition.
7.2.3 Tighten the nut with one spring washer between plate and nut.
7.2.4 Hold the plate in vice and tighten the nut by calibrated torque wrench.
7.2.5 Select a Torque wrench having torque range required for the size to be tested
7.2.6 Initially set the torque wrench at 1 Kgm less than minimum value of the nut (as mentioned on
drawing) and apply the torque. If torque wrench ratchet slips and nut doesn’t break then increase the
torque by 0.5 kgm. Follow the step till nuts breaks.
7.2.7 While applying torque, if assembly starts rotating then recheck it again by dismantling/
reassembling and still rotation repeats then reject the entire lot.
7.2.8 If a nut breaks in the torque range specified on the drawing the lot is accepted.
7.2.9 Follow the above step till it reaches at maximum value of the nut (mentioned on the drawing). If
nut doesn’t break at maximum value then the lot is treated as rejected.

8.0 MARKING:
Bolt Heads shall have marking of manufacturer and grade of bolt.

9.0 PACKING:
For Packaging of Anti Theft Bolt Nuts shall be as per bolts and nuts packing CS-14

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 93 of 101
 COMPANY STANDARD CS – 19
ISSUE NO. 8 01.10.07
SPECIFICATION OF SAMPLING PLAN
REV. NO. 2 01.09.11
FOR INSPECTION AND TESTING
SHEET NO. 1 OF 8

1.0 SCOPE
This Standard covers sampling plan for inspecting and testing the Raw Material, In-Process Material,
Fabricated Material, Galvanized Material and Finished Material under various National and
International standards.

2.0 REFERENCE
2.1 For Raw Material, Fabricated Material & Galvanized Material - IS 2062, IS 2500, IS 2629, IS 4759,
BSEN 10025, ASTM A6, A36, A572, A123 and applicable standards
2.2 For Bolt, Nuts, Washers and Accessories - IS 2614, IS 1367 Part XIII, A153, A307, A394, A563

3.0 SAMPLING PLAN AS PER INDIAN SPECIFICATION:

3.1 FOR STEEL SHAPES, PLATES & FLATS,

3.1.1 For Visual and Dimensional Test number of samples as per IS 2500 (Part-I):
Lot size Sample size Acceptance No. Rejection No.
1 to 8 100% 0 1
9 to 15 8 0 1
16 to 25 8 0 1
26 to 50 8 0 1
51 to 90 8 0 1
91 to 150 32 1 2
151 to 280 32 1 2
281 to 500 50 2 3
501 to 1200 80 3 4
1201 to 3200 125 5 6
3201 to 10000 200 7 8
10001 to 35000 315 10 11
35001 to 150000 500 14 15
150001 and over 800 21 22
3.1.2 For Mechanical and Chemical Testing of Steel Shapes, Plates and Flats number of samples
as per IS 2062:
Tests Sampling
Mechanical test: Yield Stress Number of test
Ultimate Tensile samples shall be 2
% of Elongation per cast / heat and a
Bend test class of steel product
Charpy / Impact irrespective of cast /
Chemical test heat size.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 94 of 101
 COMPANY STANDARD CS – 19
ISSUE NO. 8 01.10.07
SPECIFICATION OF SAMPLING PLAN
REV. NO. 2 01.09.11
FOR INSPECTION AND TESTING
SHEET NO. 2 OF 8

3.1.3 For Galvanizing Tests (Mass test, Uniformity test, Adhesion test) of Tower Members
number of samples as per IS 2629 & IS 4759:1
All the material of the same type in a coating bath having uniform coating characteristics shall be
grouped together to constitute a lot. Sampling shall be done as given below in the table:
No. of units in No. of units to be Acceptance
thetoLot
Up 25 selected in
3 a sample No.
0
26 to 100 5 0
101 to 150 8 1
151 to 500 13 1
501 to 1000 20 2
1001 to 10000 32 3
Over 10000 50 5

3.2 FOR BOLT, NUTS, WASHERS AND ACCESSORIES

3.2.1 For Visual and Dimensional Tests of Fasteners number of samples as per IS 2614:
Lot size Sample Size Acceptance No. Rejection No.
Upto 100 8 0 2
101 to 300 13 0 2
301 to 500 20 0 2
501 to 1000 32 0 3
1001 to 3000 50 1 4
3001 to 10000 80 2 5
10001 to 35000 125 3 7
Over 35000 200 5 9

3.2.2 For Mechanical Tests (Hardness, Proof, Shear, Wedge, Head soundness) of Fasteners
number samples as per IS 2614:
Lot size Sample Size Acceptance No.
Upto 1000 5 0
1001 to 3000 8 0
3001 to 10000 13 0
10001 to 35000 20 0
Over 35000 32 1

3.2.3 For Galvanizing Tests (Mass test, Uniformity test, Adhesion test) of Fasteners number of
samples as per IS 1367 Part XIII:
Total Number of Fasteners in Number of Test Samples
Upto andBatch
including 500 3
501 Up to and including 35000 5
Over 35000 8
If any one of the samples selected fail to meet the requirements then twice the number of samples first
taken shall be so tested, and if any one of these fails the batch represented by the samples shall be
rejected. Refer CS-19 clause 6.0 Procedure for Re-test.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 95 of 101
 COMPANY STANDARD CS – 19
ISSUE NO. 8 01.10.07
SPECIFICATION OF SAMPLING PLAN
REV. NO. 2 01.09.11
FOR INSPECTION AND TESTING
SHEET NO. 3 OF 8

4.0 SAMPLING PLAN AS PER ASTM SPECIFICATION:

4.1 FOR STEEL SHAPES AND PLATES

4.1.1 For Visual and Dimensional Tests refer CS-19 clause no. 3.1.1 for number of samples.

4.1.2 For Mechanical and Chemical Tests number of samples as per ASTM A6:
Test Parameters Sampling
Mechanical test: Yield Stress
Ultimate Tensile
% of Elongation Two sample per heat / cast
Bend test
Charpy / Impact
Chemical tests Two sample per heat / cast

4.1.3 For Galvanizing Tests (Mass test, Uniformity test, Adhesion test) of Tower Members
number of samples as per ASTM A 123:
Number of pieces in lot Number of specimens
3 or less 100%
4 to 500 3
501 to 1200 5
1201 to 3200 8
3201 to 10000 13
10001 and over 20

4.2 FOR BOLT, NUTS AND WASHERS

4.2.1 For Visual and Dimensional Tests of Fasteners number of samples as per ASME B18.2.1 and
ASTM F1470:
Lot size Sample Size Acceptance No. Rejection No.
Upto 50 1 0 1
51 to 280 2 0 1
281 to 3200 3 0 1
3201 to 35000 4 0 1
35001 to 150000 5 0 1
150001 to 500000 6 0 1
Over 500000 7 0 1

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 96 of 101
 COMPANY STANDARD CS – 19
ISSUE NO. 8 01.10.07
SPECIFICATION OF SAMPLING
PLAN FOR INSPECTION AND REV. NO. 2 01.09.11
TESTING SHEET NO. 4 OF 8

4.2.2 For Mechanical Tests number of samples for items as per ASTM A 394 (Bolts), A 563 (Nuts), F
436 (Washers), A 307 (Step Bolts):

Number of pieces in lot Number of specimens

800 and under 1
801 to 8000 2
8001 to 22000 3
Over 22000 5

4.2.3 For Chemical Test number of samples for items as per specifications ASTM A 394 (Bolts), A
563 (Nuts), F 436 (Washers), A 307 (Step Bolts) shall be:
One sample for each grade, size, lot / batch and raw material used.

4.2.4 For Galvanizing Tests (Mass test, Uniformity test, Adhesion test) number of samples as per
ASTM A 153:
Number of pieces in lot Number of specimens
3 or less 100%
4 to 500 3
501 to 1200 5
1201 to 3200 8
3201 to 10000 13
10001 and over 20

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 97 of 101
 COMPANY STANDARD CS – 19
ISSUE NO. 8 01.10.07
SPECIFICATION OF SAMPLING PLAN
REV. NO. 2 01.09.11
FOR INSPECTION AND TESTING
SHEET NO. 5 OF 8

5.0 SAMPLING PLAN AS PER BSEN SPECIFICATION:

5.1 FOR STEEL SHAPES AND PLATES
5.1.1 For sampling plan of Visual and Dimensional Tests refer CS-19 clause no. 3.1.1.
5.1.2 For Mechanical and Chemical Tests number of samples as per BSEN 10025 Part I & II:
Test Parameters Sampling
Mechanical test: Yield Stress
Ultimate Tensile
By Lot – 20MT or part thereof
% of Elongation
By Cast / Heat – 40MT or part thereof
Bend test
Charpy / Impact
Chemical tests One sample for one heat / cast

5.1.3 For Galvanizing Tests (Mass test, Uniformity test, Adhesion test) of Tower Members and
Bolt Nuts and Washers number of samples as per ISO 1461 (BS729 is replaced by ISO1461):
Lot size Sample size
1–3 All
4 – 500 3
501 – 1200 5
1201 – 3200 8
3201 – 10000 13
>10000 20

6.0 PROCEDURE OF RE-TESTING:

6.1 Procedure for re-testing shall be followed as specified in applicable standard/ Client specifications
6.2 If specimen/sample re-tested found meeting the required results as specified in re-test clause of
applicable standard then material to be accepted and if it does not meets the required test results then
sample representating the heat / lot / sizes / quantity to be rejected
6.3 If material is rejected apply red paint at cross section of material
6.4 If standard does not specifies about re-test then follow below steps:
6.4.1 Criteria for Re-testing - samples failing with substantial amount of difference in values or
marginal cases/values or abnormal results or manual error or machine breakdown or power shut down
or wrong selection of sample. This all will be considered on proper identification and traceability of test
specimen/sample with representating lot/sample and proper evidence of reasoning
6.4.2 For each specimen / sample failure two additional specimen / samples shall be drawn. One from
same failed piece and other from same bundle/bag/heat/lot.
6.4.3 Samples / specimen drawn to be signed before cutting and visible after readiness for testing.
6.4.4 If specimen/sample re-tested found meeting the required results as specified in re-test clause of
applicable standard then material to be accepted and if it does not meets the required test results then
sample representating the heat / lot / sizes / quantity to be rejected
6.4.5 If material is rejected apply red paint at cross section of material

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 98 of 101
 COMPANY STANDARD CS – 19
ISSUE NO. 8 01.10.07
SPECIFICATION OF SAMPLING PLAN
REV. NO. 2 01.09.11
FOR INSPECTION AND TESTING
SHEET NO. 6 OF 8

6.0 SAMPLING FOR IN-PROCESS INSPECTION OF STEEL SHAPES & PLATES IN ABSENCE OF
HEAT/CAST IDENTIFICATION:
6.1 FOR STEEL SHAPES AND PLATES
6.1.1 For Visual and Dimensional Tests refer CS-19 clause no. 3.1.1 for number of samples.
6.1.2 For Sectional weight, Mechanical and Chemical Tests number of samples shall be mentioned
below:
Test Parameters Sampling
a) Sectional weight test If material is not as per cast / heat wise then it shall be
b) Mechanical test: Yield Stress treated as lot. Sampling of lot shall be done as mentioned
Ultimate Tensile below.
% of Elongation
Bend test If lot is: 0MT to 10MT – 1 sample
Charpy / Impact Above 10MT and below 40MT – 2 samples
40MT & Above – 3 samples, and
c) Chemical test For every additional 20MT – 1 sample

6.2 Inclusion rating, grain size, microstructure shall be per grade, per size, per heat and per lot.

6.3 Sampling plan for sectional weight test:

6.3.1 Below sampling plan shall be followed for all steel standards for testing sectional weight of
angles and plates:
If lot is: 0MT to 20MT – 2 samples
20MT & Above – 3 samples, and
For every additional 20MT – 1 sample
6.3.2 For sectional weight test sample size shall be 300mm to 1000mm or as specified by customer.
6.3.3 No retest incase of failure of sample in sectional weight test
6.3.4 Lot represented by the failed sample to be sorted and re-offered for inspection

7.0 SAMPLING PLAN FOR ZINC INGOTS & MOLTEN ZINC FROM GALVANIZING BATH -
7.1 Incoming zinc to be tested/verified for each receipt of consignment and inline with CS-10.
7.2 Weekly molten zinc in bath to be tested and recorded. Compliance as per applicable standard.

8.0 SAMPLING PLAN INCASE OF CUSTOMER SPECIFIC REQUIREMENT:

Incase customer specifies a sampling plan to conduct tests, KEC shall follow the given sampling plan
as specified in their technical specification or ITP or contract. This shall be followed for steel shapes &
plates, bolts, nuts, spring washers, pack washers, step bolts and other tower item under supply scope.

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 99 of 101
 COMPANY STANDARD CS – 19
ISSUE NO. 8 01.10.07
SPECIFICATION OF SAMPLING PLAN
REV. NO. 2 01.09.11
FOR INSPECTION AND TESTING
SHEET NO. 7 OF 8

9.0 SAMPLING FOR IN-PROCESS INSPECTION

9.1 For In-process Inspection (Galvanizing)

9.1.1 Sampling Plan For Inspection Of Process Parameters (Galvanizing Process Tanks):
Description/Tank Parameters Frequency
Degreasing solution Strength, pH
Pickling solution Strength & Iron content After 100MT or 24hrs
Pre-flux/Flux solution Sp. Gravity, pH & Iron content Whichever is earlier
Sodium Dichromate / Deoxidant X100 VNS Strength, pH
Drying oven Temperature On line monitoring
Zinc bath Temperature On line monitoring

9.1.2 Sampling for testing the process of galvanizing tower parts:

9.1.3 Preece Test - 3 Samples in a shift
9.1.4 Adhesion Test - 3 Samples in a shift

9.1.5 Zinc coating thickness Test –

Sample size per rack/dip and Procedure of zinc coating thickness as follows -
The thickness of the coating determined by the magnetic thickness gauge meter i.e. With the help of
Elcometer minimum five reading shall be taken in the peripherally about 100 mm location near both
ends & in the approximate middle of each piece being tested. The average coating thickness for the
item shall be the average of the values obtained in three locations &shall not be less than the
required/standard values.

Minimum 5 Points In Shaded Area (Shaded Cluster around 100mm)

Avg.5points Avg.5 Points Avg.5 points

Flange 1

Flange2

Total No of Readings on one Angle is 30 Points from both the Flanges. (Inside & Outside both)

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 100 of 101

 COMPANY STANDARD CS – 19
ISSUE NO. 8 01.10.07
SPECIFICATION OF SAMPLING PLAN
REV. NO. 2 01.09.11
FOR INSPECTION AND TESTING
SHEET NO. 8 OF 8

9.1.6 For Calculation of average Coating minimum local thickness on sample:-

For Mean coating thickness (min) µm Local coating thickness (min) µm

130 110
100 86
86 70
70 55
55 45

9.2 For In-process Inspection (Fabrication)

Sampling for inspecting the process of fabrication shall be done as mentioned in IRS (Inspection
Record Sheet) - First piece, Second piece, Each Fiftieth piece and Last piece.

9.3 Sampling Plan for Visual and Dimensional Audit Inspection of Fabricated and Galvanized
Tower Members
Acceptance Rejection
Lot Size Sample Size
Number Number
Up to 500 nos. 03 00 01

For every additional 100 nos. (when

route sheet / job card is more than 500 01 00 01
nos.)

10.0 FINAL PRODUCT AUDIT INSPECTION:

10.1 Sampling Plan For Visual and Dimensional Inspection, Mechanical, Chemical etc., Test of
Finished Tower Members shall be as per customer Manufacturing Quality Plan.
10.2 If this is not specified in ITP / MQP then following table shall be followed as a sampling plan:
Test Description Reference of Sampling Plan
Visual & Dimensional CS 19 Clause 3.1.1
Galvanized Tower Members Mechanical & Chemical CS 19 Clause 3.1.2
Galvanizing CS 19 Clause 3.1.3
Visual & Dimensional CS 19 Clause 3.2.1
Galvanized Tower Bolt &
Mechanical & Chemical CS 19 Clause 3.2.2
Nuts
Galvanizing CS 19 Clause 3.2.3

RAJESH MOTGHARE YASHWANT DANGE

ISSUED BY SIGNATURE APPROVED BY SIGNATURE

Page 101 of 101