Steel Tube Tower Manufacturing and Processing Technique Measures
Steel Tube Tower Manufacturing and Processing Technique Measures
2016
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ZSST Technical specification for steel tube tower
Chapter 1 General
1.2 Manufacturing and testing of all the steel tower components shall meet the
technical agreement, design drawings requirements and provisions of technical
measures. All the required steel tube (seamless tube, straight seam tube) and other
components of the procurement, manufacturing, hot-dip galvanizing, except of
specified requirements in drawings should be followed technical standards and
requirements in Table 1 below. When there is inconsistency between the provisions of
standards, it should use the more stringent standard. If there is anything not clear-cut
in this provision, it should be consistent with national and industry standards
requirements.
Table 1 Standards
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ZSST Technical specification for steel tube tower
1.3 Except in special indicated, all technical documents are used in the length of
millimeters (mm) as a unit.
1.4 The equipment, tools and test meter used must have certification, which are
substandard or over-week review period will be prohibit to use in order to ensure
value delivery accurate and reliable.
1.5 All parts are implemented process inspection, only passed inspection of last
working procedure can it be in next working procedure process, emergency release is
not allowed.
1.6 When the production problems do need to modify the design, it should be
obtained by the engineer in charge and has a written record. Major changes of the
project should be approvalled by the Chief Engineer. All modify the design institute to
obtain approval in writing and submitted to the owners, the content of the need for
submission of documents (but not limited to) the names, titles, ready date, document
number, the signature of the engineer in charge.
1.7 Testing, measurement should use the certified measurement apparatus, all the
one-time use tape and steel ruler must be bought from the same group and same
manufacturer.
1.9 This project use code "XXX", tower-type code is " ", use our factory mark
1.10 When there is any part repeat or conflict in this criteria, it should conform to
the to higher requirement standard.
1.11 This technique measures has binding force on the processing of this steel tube
tower.
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ZSST Technical specification for steel tube tower
2.1 Technical Center according to the design drawings of steel specifications, quantity,
length statistic the quantity each specifications of steel provided to the stock
preparation and supplies department. Then this department purchase the material form
qualified sub-contractor side in accordance with approved plans to the amount of steel
utilization rates.
(2) Welding should in strict accordance with drawings weld grades require and
supply relevant provisions of the inspection and inspection reports.
2.2.2 Test sample should no less than 20% in principle, can also refer to SD-015
"Sampling methods and quality testing determine rules of steel tower".
2.4 Products in the loading and unloading, transportation should be properly fixed,
so as to avoid distortion.
2.5 Warehouse quality inspector inspect the appearance of the raw materials
according to the the certificate of furnace batch.
2.5.1 Dimension of steel must meet the standards and requirments in Genaral 1.2.
Appearance may not have Alice leather, double leather, bending, rust, pitting, rolling
tust piont, pattern does not allow more than 10% of the total area of steel, 10% of the
defects in the depth can be no more than 0.3mm; before hysical and chemical test
appearance should passed the inspection. It will be refuse treatment if the appearance
test is not passed.
2.5.2 Appearance of welding rod should be no skin off, welding defects such as core
rust, flux should not be wet agglomeration or melting burnt, wire should not be rusty.
And it should be consistent with the standards in General1.2.
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ZSST Technical specification for steel tube tower
2.6 Purchased materials (steel, welding rod, fasteners, etc.) should be consistent
with current standards or design requirements with appropriate quality certificate.
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ZSST Technical specification for steel tube tower
Allowable deviation of height, leg width, waist thickness of steel channel (mm)
2.7.1 Except for seamless pipe, all other pipes should be fabricated as per
DL/T646-2006.
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ZSST Technical specification for steel tube tower
Allowable
Project deviation( Legend
mm)
+0.5
Thickness
0
Outer diameter of flange +0.5
ΦA -0.5
+0.4
Central hole of flange ΦB
-0.4
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ZSST Technical specification for steel tube tower
Note: In the course of drawings review and lofting, if we find there are some
questions in the drawings, we will contact with the designers for modification by
contacting sheet. Our engineers have right to modify some parts for structural
detailing On the premise of conforming to relevant standards and designing drawings.
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ZSST Technical specification for steel tube tower
4.2.1 Steel severing (the general name of machinery severing and flame severing)
shall priority adopt machinery severing, second adopt flame severing.
4.2.2 The permissible deviation of severing satisfies the demands in the following
table.
Basic size
Length L or width ±2.0
B
Uprightness of the
±(2b/100)<±3.0
ends t
Uprightness of the
±(S/8)
severing P
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ZSST Technical specification for steel tube tower
The specification is L63×5 and above, adopt angle automatic line to cut material and
synchronous drill.
4.4.1 The steel plate thickness is 12mm and below, line shaped plate adopt shearing
machine, curve shaped plate adopt numerical-control flame cutting machine.
4.4.2 The steel plate thickness is 14mm and above, which adopt automatic flame
shearing machine or numerical-control flame cutting machine.
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ZSST Technical specification for steel tube tower
5.1.1 Unless design documents and drawings indication, drilling method: if thickness
is bigger than 16mm, method must adopt drill; if thickness is no bigger than 16mm,
manufacture satisfies the following rules priority to adopt punch.
5.1.2 There should lack edges or fallen angles that are no bigger than 0.5mm. There
should be no obvious concave near the holes, the burrs that are longer than 0.5 mm
should be cleaned.
Table 5-1
Permissible
Item Figure
deviation
Distance Two
between neighboring ±0.7
lines of holes
steel
angle Two
and non-neighboring ±1.0
steel holes
Holes
plateε
location
Angle steel standard
±0.7
distance a
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ZSST Technical specification for steel tube tower
Note: Position measurement of holes should be done on the plane of the small
diameter.
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ZSST Technical specification for steel tube tower
The parts of this project should be marked with project code, tower type, and part
number using steel character pressing stamps. The project code is XXX, tower type is
XXX.
6.3 The size of letter is 12×12. The steel stamps should not be covered.
6.4 The location of the steel stamps should not near the rolling side and cutting side.
The distance between the stamps and the side should keep more than 5mm.
6.5 For some small pieces the steel stamps can be pressed on the positive side and
negative side respectively.
6.6 For two or one flanged steel pipe, the steel stamps brand is welded on the pipe
inside wall. The size of the brand general is 5*60*120.
6.7 There are connecting plates on both side of the steel pipe, the steel stamps should
be pressed on the main connecting plate.
6.8 The steel stamps must according to the stamp code of single piece, sample plate or
detailed list to ensure to deliver and check finished production.
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ZSST Technical specification for steel tube tower
7.1.1 Before assembling, the rusts, burrs and oil fouling on the connecting surface and
within the scope of 30~50mm on each side of the weld seams should be cleaned.
7.1.2 The tack welding adopts the CO2 gas shielded arc welding method and use the
relevant CO2 gas-shielded welding wire. The spot welding height should not exceed
2/3 of the designed height of weld seams. And it should be operated by the welders
who obtain the certification of welder approval.
7.1.3 The allowable deviations of incline between flange face and main axis,
displacement of connecting plates and deflection of connecting plates should
according to the Table 7-1.
Table 7-1
Allowable
No. Deviation Item deviation Figure
(mm)
7.2.1 For tack welding it is to forbid to arc in the parent metal outside the weld seam.
And the welding material which is used for spot welding should be same with
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ZSST Technical specification for steel tube tower
7.2.2 If there are gas holes or cracks, they should be cleaned and then re-weld.
If the shapes of elements are symmetric, their tack welding bead should be symmetric.
There isn’t tack weld seam on where the elements have the crossing weld seam, and
the distance between tack weld bead and crossing should be more than 50mm. If the
direction of weld seam changes sharply, the tack welding cannot be done.
Current of tack welding is 15%~20% larger than normal welding current to avoid
lacking of penetration. Both ends of tack welding should be smoothly to avoid lacking
of penetration or cracks during the formal welding.
7.2.5 The tack welding should have certain strength to ensure the safety of assembly.
If the tower will be vertical or horizontal assembled, the tack welding should be
reinforced according to the actual situation. The welding pieces which are not be
reinforced shouldn’t be entered into the trial assembling process.
The Allowable deviation value in the following table will used for inspection.
Allowable
Item deviation value Figure
(mm)
Element full length
±2
(L)
Maximum Tilt
deformation of ±1 Δ
flange plate (△)
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ZSST Technical specification for steel tube tower
Allowable deviation
+0.5
of bolt holes(d)
End distance of
±1.5
bolts hole(e)
Roundness of steel
tube(D means the
(D1-D2)≤2D/1000
standard diameter
of steel tube)
Allowable
Item deviation value Figure
(mm)
Installation angle of
0.5°
connecting plate A2
Maximum deviation of
±2
connecting plate L1
Maximum deviation of
±2
plate L2
Opening Width of steel tube 0
S +2
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ZSST Technical specification for steel tube tower
Allowable
deviation
Item Figure
value
(mm)
lateral deviation of
±1
joint plate X1
lengthwise deviation of
±1
joint plateX2
Rotary deviation of
±1
ring flange E
Centerline radius of
bolt hole in the ring ±0.5
flange R
Outside diameter of
±0.2
ring flange
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ZSST Technical specification for steel tube tower
7.4 Others
7.4.1 It should use the mould during all the weldments being assembled. And the
flanges will be fixed by dowel pin.
7.4.2 The centerline of connecting plate should through the axial lead.
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ZSST Technical specification for steel tube tower
8.1 Usually, steel tube tower will use the horizontal trial assembling method, for
special structure will adopt the vertical trial assembling methods (Such as top of the
tower).
8.1.1 During trial assembling, it should be connected smoothly and the controlling
sizes are correct. Forbid to assemble by force.
8.1.2 During trial assembling, all the quantity of holes, diameter of holes and material
size in the joints should be checked as per the drawings.
8.1.3 The ground used for trial assembling should be smooth. There isn’t obstacle
around ground and in the upper air. If there are difficulties, it should report in time,
and then provide the correct treatment after thorough investigation, forbid to assemble
by force. Trial assembling staff should use the bolts according to the drawings. If
there are two or more than two diameters for the coordinating holes, should report and
solve it, forbid to use the small diameter bolts for the big holes.
8.1.4 During trial assembling, each piece should be assembled according to the
Construction drawings. If there is any maladjustment, should find out the reason,
forbid to assemble by force. The bolts quantity which used for assembling should
more than 75% of design quantity, at least 3 bolts. All the bolts should be fixed. The
bolts used for trial assembling can be Grade 4.8.
8.1.5 It should consider the direction to wear the bolts when decide to deal with the
structure problems. For the horizontal and declining bolts should be (according to
situation after tower erection) wore inside out, and for the vertical bolts should be
wore top-to-bottom.
8.1.6 The bolts in the important joint should be screw up. The screw should be
perpendicular to the surface of elements. The outside thread should be more than 2
rings.
8.1.7 There isn’t any collision between elements and elements, elements and bolts.
The gap between them should be more than 5mm.
8.1.8 There should be inspection record and recheck records which are confirmed and
signed. After all the problem being solved, it can enter into the welding and
galvanization process.
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ZSST Technical specification for steel tube tower
8.1.9 During trial assembling must pay attention to safety. Before working,
responsible person should preach the content of safe operation. It should use the 25T
crane to assemble the top section. The 50T crane will be used for assembling the body
section and leg section. Before dismantling bolts, should use the crane to lift the
elements at first to avoid the elements falling and injuring. There should be clear
marks in the ground and not allow non-staff enter into. Forbid to get out of line.
During working, should note the stance to avoid Accident injury. Guardian is
responsible for monitoring the implementation
8.1.10 According to the assembly for detailed location should provide detailed test
assembly plan separately.
8.1.11 The top surface of each flange of main tube of tower foot should be marked
and provided the size to convenient for inspection after assembling.
9.2 Inspection standards of trial assembling please see the following table (Mainly on
the overall size):
Allowable
Item deviation value Figure
(mm)
Open Size L ±2
Height H ±5
verticality△ ≤0.065%
Verticality between
L/150 only can hog out
cross arm and
upwards
centerline of tower X
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ZSST Technical specification for steel tube tower
L/1500
Height of bending f
And ≤10mm
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ZSST Technical Specification for Steel Tube Tower
9.1.1 After assembling the weldments and trial assembling being qualified, will start
welding. The welding should according to the relevant regulation to ensure the height
of weld seam meet design requirements. The weldments which cannot be Welded
penetration should be beveled at first, then start welding to ensure the height of weld
seam to meet the weld seam quality which listed in the drawings.
9.1.2 The welding of steel tubular tower meets requirements of design drawings and
DL/T646-2006 <Manufacturing Technical Requirements for Transmission and
Substation Steel Tubular Structures >.
Materials selection should according to the welding procedure sheet. The welding rod,
welding wire and welding flux should have the Mill certificates or inspection report.
9.4 Preheat
If the thicknesses of welding plates are equal or more than 40mm (The material of
base plates is Q345, thickness is 40mm), according to the welding process
specification, the plates should be preheat before welding by the appointed staff.
9.5.1 Before welding, the rust, oil fouling and slag should be cleaned until the metal
surface is revealed.
9.5.2 Before welding, it should check the quality of spot welding. If there are any
cracks, gas holes or slag inclusion, the defects should be cleaned then start welding.
9.5.3 If the assembly of groove and gap is not meet requirements, it should be
repaired by the assembler, and then will start welding.
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ZSST Technical Specification for Steel Tube Tower
9.5.4 During multi-layer welding, only cleaning the surface slag, then do the next
welding.
9.5.5 It should stop welding and find the reasons if the arc is not stable or
performance of welding rod is not well or there are any cracks, gas holes etc. After
resolving all the problems, the continued welding will be allowed.
9.5.6 Welders shall do the welding work as specified in the certificate, and prohibit
doing beyond of the scope.
9.5.7 Size of weld seam should conform to the drawings and specification.
9.5.8 During welding between steel tubes, tube and flanges, should use the
symmetrical skip welding method. If necessary, should adopt the treatment to avoid
distortion.
9.5.9 All the seams should be welded all around and totally enclosed.
9.1.10 It is not allowed to arcing outside of seam area. Inside the bevel, local area of
arcing should be melting welded once and the craters are not allowed existing.
It should use the file to remove all the slag, including various the dead angles, and
then polished by steel wire wheel brush to ensure the surface quality.
9.7.1 For whole weldments, their appearance quality should be checked by the
unaided eyes, and their seam sizes should be checked by Weld Height Gauges
9.7.2 For the main seams of hanging wires plates, should do the 100% ultrasonic
examination.
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ZSST Technical Specification for Steel Tube Tower
Chapter 10 Galvanization
10.1 All the elements including the connecting bolts should be hot-dip galvanized to
anticorrosive. The hot-dip galvanization should meet the quality requirements
specified in standard GB2694-2003 < Transmission line tower-Technical requirements
for manufacturing > clause 2.5.
10.3 After galvanization, the elements should be checked whether the distortion is out
of the scope. For the failed test elements, should be corrected, or else cannot be
passed. On the premise of the steel seal depth is enough, the steel seal on the
galvanized elements should be clear. And then make the large font marks on the
galvanized elements for providing convenience, which the same content with steel
seal.
10.5 The average attachment of zinc layer is thickness and surface density, always
measured with metal layer thickness measuring instruments. If there is a dispute,
method of delamination test method can be used to measure surface density as the
arbitration test.
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ZSST Technical Specification for Steel Tube Tower
Table 10-1
Item Requirements
Thickness <5 65
(μm) Thickness of ≥5 86
Average attachment element
of zinc layer Surface <5 460
density (mm)
≥5 610
(g/m2)
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ZSST Technical Specification for Steel Tube Tower
11.1 It should avoid falling and colliding during the semi-finished products (including
the pieces) are lifted in the workshops and shoveled in the factory, to ensure the safety
of transit and right size of welding pieces.
11.2 The external thread parts and flanges should be packed up by gunny, to avoid
being colliding the thread parts and flanges. During transporting, loading and
unloading them, it should avoid be distorted and ensure the bolts, washers and
accessories form a complete set.
11.3 It should use the appropriate lifting method to avoid colliding the steel tube and
members to impact the quality when the pieces are loaded and unloaded. During the
transportation, the projecting parts of steel tube towers should be fixed properly to
avoid distortion; between the galvanized pieces should use the wood block to separate
them, and fix tightly to avoid sliding and destroying the galvanization coating. It
should use the packaging of Adequate strength to ensure the packages not be
separated and the galvanization not be destroyed during the short transit, storage of
products, loading and unloading.
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ZSST Technical Specification for Steel Tube Tower
11.5 Packaging should be marked with our company name and the project’s name,
variety, quantity, weight, destination and other necessary information in order to avoid
loss of product or possibility of error packaging.
11.6 For transporting large size and overweight components of the Ultra High tower,
it need be transported by transportation company which is professional and has
extensive experience in large cargo transportation. Zhejiang Shengda steel tower
company relies on its sister company (Zhejiaang Suda large cargo transportation
company) which supplies sufficient availability and the all tonnage of cranes and
transport vehicles, transport equipment resources are adequate. Zhejiang Suda large
cargo transportation company has extensive experience in transporting large
equipment and has outstanding performances, which has been transporting our
company’s steel tube tower especially in last year they excellent completed the
transportation the tower material of 370 meters high tower in Zhoushan networking
project.
11.7 To ensure the size of containers as per the outline size of pieces. Generally, the
total weight of each container will be around 23 tons. According to the length of
pieces to loading container reasonably, besides use the wood block to separate pieces
and fix tightly to avoid sliding and destroying the galvanization coating
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ZSST Technical Specification for Steel Tube Tower
11.8 After receiving the approval of designing, our company will finish the fabrication
within 4 months then delivery them. The galvanized pieces should be stocked
separately as per the section No. which will convenient for delivery.
11.9 Truck shipments must have a loading list, and after the transfer of Party A, the
list should be signed and recognized by Part A .The products should be delivered with
a packing list.
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