14.7.4 Matimba-Spitskop 2 400kV Loop-In and Out Transmission Line Specification Rev0 PDF

TRANSMISSION LINE SPECIFICATION
Title: Matimba Spitskop 2 400kV Template Unique Identifier: 240-86978162

Loop-in and Out of Medupi.
Bay repositioning
Project Unique Number: LES0019
Area of Applicability: Engineering
Documentation Type: Report
Revision: 0
Total Pages: 120
Next Review Date: N/A
Disclosure Classification: CONTROLLED

DISCLOSURE
LES0019 Revision 0 November 2014 Page 1

MATIMBA SPITSKOP 2 400KV LOOP-IN AND OUT
OF MEDUPI. BAY REPOSITIONING
MATIMBA SPITSKOP 2 400KV LOOP-IN AND OUT OF MEDUPI. BAY REPOSITIONING
Transmission Line Specification

Signatures of design team of Eskom Lines Engineering Services (LES)
Revision Control
Lines Engineering document no. Revision no. Date
LES0019 0 November 2014
Copyright Warning
COPYRIGHT ESKOM HOLDINGS LIMITED
NO PUBLICATION OR DISSEMINATION OF ITS CONTENTS IS ALLOWED WITHOUT
WRITTEN PERMISSION

REVISION CONTROL
Revision Change Log Date
0 First revision Nov 2014

TABLE OF CONTENTS
PAGE
REVISION CONTROL ................................................................................................................. 3
TABLE OF CONTENTS .............................................................................................................. 4
1. EXECUTIVE SUMMARY................................................................................................ 8
2. PROJECT DESCRIPTION ............................................................................................. 8
2.1. TOWER AND HARDWARE DRAWINGS ...................................................................................... 11
2.2. TECHNICAL TENDER EVALUATION CRITERIA ......................................................................... 11
3. MECHANICAL SPECIFICATIONS .............................................................................. 12

3.1. TOWER ......................................................................................................................................... 12
3.2. GENERAL LINE DETAILS ............................................................................................................ 12
3.3. CORROSION PROTECTION ........................................................................................................ 12
3.4. PHASE CONDUCTOR AND GROUNDWIRE DETAILS ............................................................... 12
3.5. DETAILS OF TOWERS TO BE USED........................................................................................... 13
3.6. PROFILING DETAILS ................................................................................................................... 15
3.7. TOWER TEST LOADS .................................................................................................................. 15
3.8. TOWER SHACKLES FOR TOWER ATTACHMENTS .................................................................. 16
4. FOUNDATIONS, CIVIL AND GEOTECHNICAL SPECIFICATIONS............................ 17

4.1. FOUNDATION LOAD FACTORS .................................................................................................. 17
4.2. FOUNDATION LOADS.................................................................................................................. 17
4.3. GENERIC SPECIFICATION INFORMATION ............................................................................... 18
5. EARTHING REQUIREMENTS ..................................................................................... 18

5.1. CONNECTIONS BETWEEN EARTH AND A SELF-SUPPORTING TOWER LEG...................... 18
5.3 CONNECTIONS BETWEEN A TERMINAL TOWER AND A SUBSTATION ............................... 20
5.4 CONNECTIONS BETWEEN EARTH AND A CROSSROPE TOWER LEG ................................. 21
5.5 TOWER FOOTING RESISTANCE REQUIREMENTS ................................................................. 22
5.6 ADDITIONAL EARTHING REQUIREMENTS ............................................................................... 22
5.7 FITTING REQUIREMENTS .......................................................................................................... 23
5.8 EXCEPTIONAL CASES ................................................................................................................ 24
6. INSULATOR REQUIREMENTS ................................................................................... 24

7. HARDWARE REQUIREMENTS .................................................................................. 26
7.1. HARDWARE ASSEMBLIES .......................................................................................................... 26
7.2. SPACER DAMPERS ..................................................................................................................... 26
7.3. RIGID SPACERS FOR JUMPERS ................................................................................................ 26
7.4. VIBRATION DAMPERS FOR EARTH WIRES .............................................................................. 26
8.1. LINE DESIGNATION LABELS LAYOUT AND WORDING ............................................................ 27
8.2. PHASE DISK LABELS................................................................................................................... 27
9. CONSTRUCTION METHODOLOGY ........................................................................... 27

10. APPENDIX A: STANDARDS, SPECIFICATIONS ....................................................... 29
10.1. STANDARDS ................................................................................................................................ 29
10.2. SPECIFICATIONS .............................................................................................................................................................. 31
APPENDIX B: TOWER OUTLINE DRAWING ........................................................................... 31

11. APPENDIX C: HARDWARE ASSEMBLY DRAWINGS AND INFORMATION ............ 35
11.1. HARDWARE ADDITIONAL INFORMATION ................................................................................. 35
11.2. HARDWARE SPECIFICATONS ................................................................................................... 36
11.3. COMMON HARDWARE ................................................................................................................ 36
11.4. AERIAL WARNING SPHERES ..................................................................................................... 37
11.5. TRANSPORTING AND PACKAGING ........................................................................................... 39
11.6. HARDWARE ASSEMBLY DRAWINGS ........................................................................................ 40
12. APPENDIX D: STRUCTURES ADDITIONAL INFORMATION .................................... 46

12.1. TEMPERATURE ........................................................................................................................... 47
12.2. CONDUCTOR, GROUNDWIRE TENSIONS ................................................................................ 47
12.3. GUY WIRES .................................................................................................................................. 47
12.4. MATERIAL .................................................................................................................................... 48
12.5. TESTING ....................................................................................................................................... 48
12.6. LIVE LINE MAINTENANCE OF CROSS ROPE STRUCTURES................................................... 49
12.7. ANTI-THEFT MEASURES ............................................................................................................ 49
12.8. SAFETY MEASURES ................................................................................................................... 49
13. APPENDIX E: FOUNDATIONS ADDITIONAL INFORMATION ................................... 51

13.1. FOUNDATION DESIGNS ............................................................................................................ 51
13.2. CONSTRUCTION SPECIFICATIONS .......................................................................................... 54
13.3. PROOF LOAD TESTING............................................................................................................... 55
13.4. SPECIAL CONDITIONS AND DESIGNS ...................................................................................... 56
14. APPENDIX I: TECHNICAL TENDER SCHEDULE AND RETURNABLES .................. 62

14.1. SCHEDULE A: PURCHASERS SPECIFIC REQUIREMENTS .................................................... 62
14.2. LIST OF RETURNABLES ............................................................................................................. 62
15. APPENDIX J: AS BUILT INFORMATION REQUIREMENTS ...................................... 67

16. APPENDIX K: METHOD STATEMENTS ..................................................................... 83
GENERAL ................................................................................................................................. 83
16.1. TERMS, DEFINITIONS AND ABBREVIATIONS ........................................................................... 83
16.2. INTRODUCTION ........................................................................................................................... 85

16.3. PURPOSE ..................................................................................................................................... 85
16.4. GENERAL CONSTRUCTION REGULATIONS ROLES AND RESPONSIBILITIES .................... 85
16.5. EQUIPMENT ................................................................................................................................. 86
16.6. INSPECTIONS .............................................................................................................................. 86
17. FOUNDATION CONSTRUCTION METHOD STATEMENT ......................................... 87

17.1. SETTING OUT .............................................................................................................................. 87
17.2. SOIL CLASSIFICATION ................................................................................................................ 87
17.3. EXCAVATION AND PILE OR ROCK ANCHOR DRILLING........................................................... 88
17.4. PLACEMENT OF REINFORCING STEEL, SHUTTERING, STUBS AND ANCHOR LINKS ..... 88
17.5. FORMWORK................................................................................................................................. 89
17.6. SLUMP TEST AND CONCRETE CUBE SAMPLES ...................................................................... 89
17.7. CONCRETE PLACEMENT, CURING AND FINISH ...................................................................... 89
17.8. BACKFILLING ............................................................................................................................... 90
17.9. POTENTIAL RISKS ....................................................................................................................... 90
17.10. SAFETY MEASURES ................................................................................................................... 90
18. TOWER ERECTION METHOD STATEMENT .............................................................. 91

18.1. GENERAL ..................................................................................................................................... 91
18.2. ASSEMBLING OF TOWERS ........................................................................................................ 91
18.3. ERECTION .................................................................................................................................... 91
18.4. METHODOLOGY FOR THE ERECTION OF SELF-SUPPORTING TOWERS ............................ 92
18.5. METHOD FOR ERECTION OF GUYED CROSSROPE STRUCTURES ...................................... 95
18.6. QUALITY ASSURANCE/QUALITY CONTROL MONITORING .................................................... 97
18.7. HAZARDS ..................................................................................................................................... 97
19. DRESSING, STRINGING AND REGULATING METHOD STATEMENT ..................... 99

19.1. ATTACHING OF INSULATOR STRINGS AND RUNNING BLOCKS DRESSING ................... 99
19.2. SELF-SUPPORTING SUSPENSION STRUCTURES / GUYED V................................................ 99
19.3. SELF-SUPPORTING STRAIN STRUCTURES ........................................................................... 100
19.4. EARTH WIRE .............................................................................................................................. 100
19.5. OTHER WAYS OF DRESSING ................................................................................................... 101
19.6. TEMPORARY BACK STAYING OF STRUCTURES ................................................................... 101
19.7. STRINGING OF CONDUCTORS ................................................................................................ 101
19.8. SAGGING / REGULATING ......................................................................................................... 103
19.9. CLAMPING IN OF CONDUCTORS / DEAD-ENDING ................................................................. 104
19.10. VIBRATION DAMPER INSTALLATION ...................................................................................... 104
19.11. SPACER DAMPER INSTALLATION ........................................................................................... 104
19.12. GENERAL ................................................................................................................................... 104

19.13. FORMWORK AND SUPPORT WORK ........................................................................................ 105
19.14. TOWER BOLTS .......................................................................................................................... 106
20. CONSTRUCTION EARTHING METHOD STATEMENT ............................................ 106

20.1. PRELIMINARY INSPECTIONS ................................................................................................... 106
20.2. GENERAL ................................................................................................................................... 107
20.3. EQUIPMENT DETAILS ............................................................................................................... 107
20.4. INDUCED VOLTAGES AND CURRENTS THAT POSE A RISK ................................................. 108
20.5. METHOD FOR AVOIDING INDUCED VOLTAGE AND CURRENT EFFECTS DURING CONSTRUCTION ACTIVITIES110
20.6. QUALITY ASSURANCE/QUALITY CONTROL MONITORING .................................................. 110
20.7. HAZARDS ................................................................................................................................... 111
20.8. DEFECT/NONCONFORMITY MANAGEMENT .......................................................................... 111

1. EXECUTIVE SUMMARY
The Matimba Spitskop 2 400kV line was looped in and out of Medupi in order to connect Medupi
to the existing Eskom Transmission network. The loop-in and out was constructed and Medupi
was then connected to the network, it later became feasible to rearrange the bay positions for the
loop-ins and use the existing loop-ins for the Masa - Medupi 400kV line.
The new loop-in and out will be discussed in this report. The line is designed to have similar
specifications as the existing loop-in and out.
2. PROJECT DESCRIPTION
The Matimba Spitskop 2 400kV loop-in and out of Medupi overhead transmission lines have the
following characteristics:
Line route The Loop In and out of Matimba Spitskop 2 will take place within 2km of
Medupi.
Line length 2 x 2km lines
Quad Tern (IEC: 403.77-A1S1A-45/3.35+7/2.25) will be utilised on the loop in

Conductor
and out of Medupi from Matimba Spitskop 2.
Sub-conductor spacing: 450 mm
Conductor templating temperature: 80C.
Thermal Limits at 80 degrees Celsius:
Rate A = 2655 MVA
Rate B = 3536 MVA
Rate C = 5135 MVA
Matimba Medupi:
1 16kA - 48 Core OPGW

1 x Panther ACSR
Groundwire Medupi Spitskop 3:
2 x Panther
Insulators Composite long rod (31mm/kV creepage).

Standard I-assembly and strain structure hardware
Hardware
Modified V-assembly including extension link (as per SANS 10280:1998)
Live line fitting to be placed on all assemblies.
Grading rings to be inline and as small as possible.
Corona free fittings to be used.
Bellville washers to be used on all hardware for additional locking of
components subjected to vibration.
The following tower family will be used:

Towers types
518 C self-supporting strain towers (0- 45)
518 D self-supporting strain towers (45- 70) / terminal (0)
518 H self-supporting heavy suspension tower
Straight leg shackles to be supplied as the tower shackle.
Swage type anti-vandal bolts to be used on all towers.
All members to be marked with Eskom name.
Live line maintenance hole must be included at the bottom of the
crossarm.
Self-Supporting type towers:

Foundations
Spreader type: Pad and Column foundations
Galvanizing of 105 m on Towers and Hardware

Corrosion
protection Defined by SANS 121.
As built information to be provided as per Eskom requirements, see Appendix J

As built
This must include ALS.
Line is to be labelled as per Eskom transmission spec TSP 41-604

Line labels
Install danger signs for towers.
Tower footing resistance to be below 30 for 400kV towers.

Earthing
Line Impedance Measurements to be done prior to energising utilising

Line Impedance
specification 474-9428
Measurement
Anti-Theft Spec 474-285 & Technical Instruction 12TI-013

Anti-Theft
Anti-vandal bolts fitted up to anti-climb device
Flatwrap razorwire to be installed

As-Built Survey See appendix J for as built specification also refer to LiDAR Specification 32-
1109.
Fall Arrest Fall arrest system must be removed after construction.

Systems
Make use of horizontal fall arrest system.
Use latest method statements available, if different method statements are

Method used, contractor will have to get approval from Eskom.
Statements
Rigging equipment must be tested timeously and valid certificates must be
available.
Ground
Minimum of 10m ground clearance.
Clearance and
templating

2.1. TOWER AND HARDWARE DRAWINGS
Self-Supporting Suspension Structure 400kV Tower Type

2103
518H (outline drawing)
Self-Supporting 0 - 45 Angle Strain 400kV Tower Type

2105
518C (outline drawing)
Self-Supporting 45 - 70 Angle Strain & 0 Terminal 400kV

2106
Tower Type 518D (outline drawing)
400kV Strain assy Conceptual 400kV Strain Assembly with double attachment
double att 4xXXXX for Quad Conductor
518H/520B 400kV V- Conceptual 400kV 518H & 520B V-Suspension Assembly for
susp assy 4xXXXX Quad Conductor
400kV Bolted Slack
Conceptual 400kV Bolted Slack Span Assembly with single
Span assy single att
attachment for Quad Conductor
4xXXXX
30-120kN_ESUS1-001 Suspension earth wire assemblies
30-120kN_ESTR1-001 Strain earth wire assemblies
The tower and hardware drawings can be found in Appendix C.
2.2. TECHNICAL TENDER EVALUATION CRITERIA

For the technical tender evaluation, the criteria sheet in APPENDIX I will be used to evaluate each
tenderer with pass/fail criteria for each discipline in multidisciplinary packages.
Each package will be broken down as to what criteria will constitute a pass.
Method statements focuses on equipment and equipment capacity to be used on the assembly,
erection and stringing of all type of structures as well as the methodology used to bring together
the different elements of the system. All method statements are gatekeepers (non-compliance
leads to disqualification).
For a tenderer to qualify they need to pass all the criteria within the multidisciplinary packages in
APPENDIX I technical tender evaluation form.

3. MECHANICAL SPECIFICATIONS
3.1. TOWER
The Medupi 400kV loop-ins overhead transmission lines have been designed and profiled
using the 518 series of towers.
3.2. GENERAL LINE DETAILS
Line voltage phase-to-phase 400 kV

Three-phase; single or double circuit Single circuit
Phase configuration Flat
Number of conductors per phase Four
Number of earth conductors Two
Minimum clearance from lowest conductor to
10 m
earth:
Minimum clearance from conductor envelope to earthed metal:
(a) Under still air conditions: 3.2 m
(b) Under every day wind conditions to tower
2.9 m
steelwork:
(c) Under high wind conditions to tower
1.0 m
steelwork:
Dimensions of hardware assembly: See separate hardware drawing
3.2.1. Wind Loading
A 10 minute wind speed of 29 m/s at a height of 10m will be used with recurrence interval
of 150 years and terrain category B, to determine the pressures on the components of the
line.
3.3. CORROSION PROTECTION

All towers and hardware shall be protected by galvanizing to a minimum of 105 m (see
SANS 121:2000).
As an alternative to galvanized bolts and nuts corrosion protection in the form of

specialized electroplated coatings may be considered acceptable, subject to the Clients
prior approval. Standard galvanized bolts are accepted.
3.4. PHASE CONDUCTOR AND GROUNDWIRE DETAILS
3.4.1. Phase Conductor
The phase conductor and jumpers used on the Medupi 400kV loop-ins will be quad Tern

4 x Tern ACSR, IEC Code -/A1S1A-
Conductor type
403.77/45/2.25 7/3.387
Conductor overall diameter (mm) 27.00
Area aluminium (mm) 403.77
Area Total (mm) 431.60
Aluminium wires (mm) 45/3.38
Steel wires (mm) 7/2.25
Conductor linear mass (kg/km) 1340.00
Ultimate Tensile strength (kN) 98.70
Resistance dc @ 20 C (ohms/km) 0.0718
Modulus elasticity final (GPa) 66.6
Coefficient of Linear expansion (1/C) 21.12 x 10-6
3.4.2. Earth wire
Panther ACSR, IEC Code A1/S1A-

Conductor type 212.06/30/3 7/3
Conductor overall diameter (mm) 21

Area aluminium (mm) 212.06
Area Total (mm) 261.54
Aluminium wires (mm) 30/3

Steel wires (mm) 7/3
Conductor linear mass (kg/km) 970
Ultimate Tensile strength (kN) 90.8
Resistance dc @ 20 C (ohms/km) 0.13630
Modulus elasticity final (GPa) 83.4
Coefficient of Linear expansion (1/C) 1.84E-05
Greased conductor requirements Non greased
3.5. DETAILS OF TOWERS TO BE USED

DETAILS OF SUSPENSION AND STRAIN TOWERS FOR 518 SERIES
(As per original the design specification for 518 tower series)
Nominal design span: 400 m

Final phase conductor sag at 50C for design span : 12.6 m

Minimum clearance from lowest phase conductor to ground: 8.4 m
Height of lowest phase conductor attachment point above 21.0 m
ground:
Minimum clearance from conductor envelope to earthed metal:
(a) Under still air conditions: 3.2 m
(b) Under 15 swing conditions to tower steelwork: 2.9 m
(c) Under 55 swing conditions to tower steelwork: 1.0 m
Design angle of swing of single suspension assembly from n/a

vertical :
Dimensions of V suspension assembly for phase conductors : See hardware
drawing.
Length of strain insulator assembly : See hardware
drawing.
Design maximum swing angle from vertical of jumpers at strain 15
towers or clearance checks :
Length of earth conductor suspension hardware assembly : See hardware
drawing.
Maximum cover angle at tower in still air from vertical through 15
earth conductor to line through earth conductor and outer phase
conductor:
Maximum cover angle at tower in still air from earth conductor to 60
inner phase conductor:
Vertical angle between the phase conductor and the horizontal at
the attachment point for which clearance to earthed metal should
be checked:
a) Above the horizontal: 5
b) Below the horizontal: 15
Jumper clearances on 0 terminal tower to be provided for the
following conditions:
a) angle between the normal to the tower cross-arm and 0
incoming line:
b) angle between the normal to the tower cross-arm and 35
closing span:
TOWER INSTALLATION
According to the Test and Inspection Plan witnessing of the first installation of each tower
type is necessary and witnessed by an Eskom design engineer. Full method statements of
erection and stringing for the installation of each of the towers need to be developed and
submitted at the tender stage.

3.6. PROFILING DETAILS
The profiling details of the towers as used in this contract are as follows:
MAXIMUM MAXIMUM MINIMUM MAXIMUM

TOWER WIND WEIGHT WEIGHT UPLIFT
DESCRIPTION OF TOWER
TYPE SPAN SPAN SPAN SPAN
TYPE
NAME
(m) (m) (m) (m)
SUSPENSION,SELF-
518H 500 900 -
SUPPORTING
0- 15 ANGLE STRAIN 518C 500 1200 200
518D 500 1200 200

15-35 ANGLE STRAIN &
TERMINAL
375 900 200
The table above shows the wind and weight spans for the tower types utilised in the
Matimba Spitskop 2 400kV loop-in and out of Medupi design, the spans given refer to the
use of Quad Tern conductor. The 518 Series was strengthened to handle Panther earthwire
and is used as a standard tower type irrespective of the earthwire chosen for the design.
A margin of safety has been applied in the determination of these spans, but it is the
contractors responsibility to check the loads applied during his erection and stringing
procedures in order to ensure that the test loads are not exceeded, including his safety
margin, which should not be less than 1.5.
3.7. TOWER TEST LOADS
The structure test loads are shown in the table below and should be used for calculating
back-stay requirements as per method statement instructions.
Note: The structure loads below for transverse, longitudinal and vertical loads should not be
applied simultaneously at any given time. These loads represent the maximum loads applied
during different load cases and was never applied all at once on any structure. If additional
information is required it is advised that the design engineer be contacted for further
information.

Transverse Loads Longitudinal Vertical
Tower Type
(kN) Loads(kN) Loads(kN)
Earth 11.07 30 18.3

518H Peak
Phase 91 75.4 159
Earth 37.32 28.1 15

518C Peak
Phase 290.2 218 128
Earth 50.4 39 15
518D Peak
Phase 364 312 128
The contractor is to ensure that the following accessories are applied to all structures:
Safety step bolts
3.8. TOWER SHACKLES FOR TOWER ATTACHMENTS

The shackles shall be of the bolted type and shall be provided with a stainless steel split pin
fitted to the bolt so as to prevent the nut from working loose. All tower shackles are
considered part of the tower and have to be supplied with the tower. The tower shackle
supplied shall be the straight leg shackle not a standard (bowed leg) shackle. These are
indicated in the table below:
BOLT
TOWER TYPE CONDUCTOR CAPACITY
DIAMETER
Earth conductor 120 kN 16 mm
Suspension Self-Supported 518 H
Phase conductor 210 kN 20 mm
Earth conductor 210 kN 20 mm
Strain Self-Supported 518 C, D
Phase conductor 450 kN 30 mm

4. FOUNDATIONS, CIVIL AND GEOTECHNICAL SPECIFICATIONS
All foundations shall BE CONSTRUCTED in accordance with Eskom Technical
InstructionTechnical InstructionTechnical Instruction 240-47172520 (TRMSCAAC5.2).
4.1. FOUNDATION LOAD FACTORS

To ensure the reliability of the line as well as a predictable failure sequence in the unlikely
event of a line support structure failure, factored loads (which include a geotechnical partial
load factor) as supplied shall be applied to the strength of the foundations as listed.
Apart from what is a factored load as described above, the foundation designer shall, at
his/her professional discretion, apply additional partial load factors in calculating the
Ultimate design load to ensure satisfactory performance in service with respect to
strength and durability requirements.
These additional partial load factors could, for example, allow for strength and performance
inconsistencies in the various construction materials used, associated construction
difficulties and human error, impairment of long-term performance due to creep,
inconsistencies within the soil or rock to which the applied load will be transferred, etc.
When considering the severe impact of foundation failure, the general objective is to ensure
that foundations are designed to be the last component to fail in a power line.
Additional load safety factors are incorporated for the new designs allowing for increased
everyday loads and performance inconsistencies. The long-term performance is affected
by:
a) Creep and variations within the soil or rock, and

b) Inconsistencies in the various construction materials used, which are associated
with construction difficulties, soil erosion, chemically aggressive founding material,
human error, etc.
4.2. FOUNDATION LOADS
518 series
Factored Foundation Reactions for Critical Loading Conditions
Factored Loads (All loads in kN)
SELF-SUPPORTING TOWERS (ALL LOADS IN kN)
TOWER TYPE
518C 518D 518H 518H (21m body)

COMPRESSION
C = 1608 C = 1792 C = 754 C = 868
X = 40 X = 92 X = 30 X = 190
Y = 29 Y = 68 Y = 25 Y = 181
UPLIFT
U = 1337 U = 1573 U = 592 U = 560

Applied factor for loads on self-supporting tower foundations: 1.2
+ +
+ + X
4.3. GENERIC SPECIFICATION INFORMATION

See appendix E.
5. EARTHING REQUIREMENTS
On completion of all towers, tower footing resistance shall be measured with an approved
earth tester and the measurements must be submitted to the Project Manager. Resistance
shall be measured when foundations and earth straps are all electrically connected which
includes any counterpoise that may have been added. Should a null balance insulation
tester be used, the footing resistance of the tower shall be measured before the overhead
groundwires are connected to the tower or the overhead groundwires can be temporarily
isolated. Reference must be made to TST41-321 Earthing of Transmission Line Towers
standard for the method of testing to be employed.
The maximum fault current is 16kA as per Table 5.1 in Section 3, GROUNDWIRE
SELECTION. During a fault, 20% of fault current is assumed to flow through the tower to
ground. The 19/2.7mm steel conductor will be adequate as its rating is 8.1kA for 1 second.
5.1. CONNECTIONS BETWEEN EARTH AND A SELF-SUPPORTING TOWER LEG

For a self-supporting tower, a connection must be made at each block of the foundation
system between the steel tower leg and the main reinforcing bar (rebar). That is, the
connection between each of the four legs of a self-supporting tower and earth will be
achieved with the use of a 19/2.7 steel conductor.
One end of the conductor must be bolted to the tower leg and the other end must be
clamped to the foundation rebar. Both connections must be made before the foundation is
cast and must be within concrete. The end of the conductor that is to be bolted must first
be crimped onto a hole of a suitable lug before it can be bolted to a dedicated hole on the
tower leg. Figure 5.1 shows the crimped end of an earth electrode that must be bolted to a
tower leg and the end that must be clamped to the foundation rebar.
A suitable lug with an 18mm-diameter hole must be crimped onto the loose end of the
conductor. The lug must be bolted to the tower leg using a bolt of a minimum diameter of
16 mm

FIGURE 5.1: Connection between Self Supporting Tower Steel and Main Reinforcing Bar
5.2 CONNECTIONS BETWEEN EARTH AND A GUYED-VEE TOWER LEG
For a guyed vee tower, a connection shall be made within concrete between the main foundation
rebar and one of the anchor bolts as shown in figure 1.2. The connection shall be made using a
19/2.7 steel conductor, which will be fastened to the anchor bolt and to the foundation rebar using
Crosby clamps. The two masts of a guyed vee tower will be bolted together using a 40 mm x 3 mm
galvanised mild steel strap.
FIGURE 5.2: Tower Leg (Guyed Vee) And Rebar Connection

5.3 CONNECTIONS BETWEEN A TERMINAL TOWER AND A SUBSTATION
There must be an underground electrical connection between the terminal structure and the
main earth-mat of a substation. The substation earth-mat consists of copper rods, thus the
connection at each of the two legs of a terminal structure that are nearest to the substation
must make use of two solid copper conductors, each with an approximate diameter of 10
mm.
The connection between the two conductors and the leg of a steel lattice terminal structure
must make use of an earth-tail clamp as shown in Figure 5.3. The connection of each
conductor to the tower must be in accordance with Eskom 0.54/393 drawings. The
exposed part of the conductor must be painted with two coats of a suitable bitumastic
compound.
The connection of each of the conductors to the main earth-mat of the substation must
make use compression joints. The joints must be made using a 12 ton hydraulic
compression tool. The tool must be of a type that will not release until full compression
force is achieved. Each conductor must be buried 800 mm below the ground level.
The earth-wires (ground-wires) of a terminal structure are always bonded to the earth-
peaks of a substation. In addition to bonding tower top geometries, the footing resistances
of the terminal structures should be less than 10.
FIGURE 5.3: Terminal Tower Leg and Copper Conductor Connections

5.4 CONNECTIONS BETWEEN EARTH AND A CROSSROPE TOWER LEG
For a crossrope tower, there should be a connection between a tower leg and the top of a
locating pin and there should be another connection within concrete between the cast-in
end of the locating pin and the main foundation re-enforcing bar (rebar). Figure 5.4 shows
the connections between the tower leg, the locating pin and foundation rebar.
FIGURE 5.4: Tower Leg, Locating Pin and Foundation Rebar Connection
The connection between the tower leg and the top of the locating pin should be made with the use
of a galvanised mild steel strap with dimensions of 40 mm 3 mm such that the strap is bolted to
the tower leg. The top of the locating pin, which protrudes from the foundation, should be tapped
with a 12 mm hole to be a depth of 30 mm.
The connection between the cast-in end of the locating pin and the main foundation rebar should
be made with the use of a 19/2.7mm steel conductor. The conductor should be connected to the
locating pin with a lug and should be connected to the rebar with a Crosby clamp.
For guy anchors, a proper connection shall be made at each foundation between the link and the
reinforcing steel. The earth electrode that is recommended to be used for the connection is a
19/2.7mm steel conductor. The conductor should be bolted to the link and it should be connected
to the reinforcing steel using a Crosby clamp.

5.5 TOWER FOOTING RESISTANCE REQUIREMENTS
Upon complete installation of all planned connections between foundations, bonding
conductors and any counterpoise that may have been added, the tower footing resistance
of each structure is to be measured with an approved earth tester and the measurements
are to be submitted to the relevant Eskom project manager. However, if a null balance
insulation tester is to be used, the footing resistance of each structure is to be measured
either before connecting the bonding straps to the structure or after temporarily isolating the
bonding straps from the structure. The required nominal resistance for 400kV lines is 30.
The footing resistances of the second, third, fourth and fifth towers from the substation
should be greater than equal to 10 but less than equal to 20 . If however, an
unfavourable case in encountered, where the footing resistance of such a structure of a
strain type is less than 10 , then jumper leads must be fitted across the structure.
5.6 ADDITIONAL EARTHING REQUIREMENTS

The main path of an earthing system is between the main base of the structure and earth.
In situations where the main earthing path is inadequate, the need to enhance the earthing
system by ensuring broad and deep contact between every structure and earth should be
considered. Where the required tower footing resistances cannot be achieved additional
earthing in the form of counterpoise may be required.
Prior to installing counterpoise soil resistivity tests should be taken to determine a suitable
system for additional earthing. Additional earthing can be installed in three basic ways. It
can either consist of: 15 m radial counterpoise, buried 600 mm below ground level; deep
drilled electrodes; or, a combination of 15 m radial counterpoise and deep drilled
electrodes. All counterpoise must be configured as 40 mm x 3 mm galvanized mild steel
straps.
For example, Figure 5.5 shows that counterpoise must be added on either side of the base
of a guyed tower in the direction of the guys using brazed copper joints and it must be
added to two opposite legs of a self-supporting tower [3]. If further reduction in the footing
resistance is required, additional 15m-long counterpoise must be added either to each of
the other two tower legs or at right angles to the counterpoise that would already be
installed.
The choice of whether to lay counterpoise in trenches or in drilled holes depends on the
resistivity of the soil layers which will be determined from soil resistivity tests. All holes
must be backfilled with soil. In rocky areas and areas with high resistivity, a conductive
mixture of carbonaceous aggregate shall be used as a backfill.
Counterpoise must be painted with two coats of an approved bitumastic compound from the
attachment at the tower leg to approximately 450 mm below ground level. Figure 1.6
shows the parts of the tower and of the foundations that the bitumastic compound must be
applied to.

5.7 FITTING REQUIREMENTS
The SCSASACB1 Eskom standard states that measures must be taken to ensure that no
current flows through fittings and assemblies that are not designed to carry current, even
during fault conditions. Thus, all earth-electrode connections must make use of
internationally acceptable clamps that are specifically designed to carry current.
A combinational use of external, visible conductors and embedded bonding electrodes will
be used for the earthing system of the line. It should also be noted that all construction work
must comply with the TRMSCAAC 5.2 Eskom specification.
Suitable Earth
conductor
Connection between guy anchors and central foundation
15 m
counterpoise
Alternate position for

counterpoise
15 m
counterpoise
Alternate position for

counterpoise
FIGURE 5.5: Additional Earthing for Guyed V and Cross Rope Suspension Towers.

: Paint Detailing of Counterpoise
5.8 EXCEPTIONAL CASES

Structures which are within 800 m of, and that either cross or run parallel to, electrified
railway tracks or metal pipelines are to be protected from galvanic corrosion by insulating
the ground-wires from the structures. If such structures are of a strain type, then jumper
leads must be fitted across the insulated ground-wire assemblies.
6. INSULATOR REQUIREMENTS
Table 6.1: The requirements for composite insulators for the Medupi 400kV Loop-ins will
use
Longrod Composite
INSULATOR MATERIAL
Requirements
Insulator strength [kN] 210 300
Dry-arcing distance [mm] 3200
Specific creepage [mm/kV] 31
Total creepage distance

13020
[mm]
Connecting length [mm] shortest possible
BIL (+) ( @1500 m

1425
altitude) [kV]
SIL (+) (@ 1500 m

1050
altitude) [kV]
End fitting size [mm] 20 24

Table 6.2: Earthwire composite insulator characteristics
INSULATOR TYPE OPGW / EARTHWIRE INSULATOR
PARAMETER USER REQUIREMENTS
Shed Material Silicone-based
Standards Comply with IEC60815, IEC61109
Corecover Thickness 3 mm
Insulator Class Class A
Connecting Length 375 (12) mm
Creepage length 174 mm
Pf. Dry, one minute withstand 50 kV (without arcing horns)
Pf. Wet, one minute withstand 25 kV (without arcing horns)
Lightning positive impulse

80 kV (without arcing horns)
withstand
Minimum mechanical strength 120 kN
In-line tongue and clevis caps in accordance

Coupling method
with IEC 60471 size 16L
Jacobs Ladder with minimum strait horn

Arcing horn shape lengths of 50mm and an angle of 605
degrees between them
2 times the arcing horn rod/bar diameter at

Arcing horn bending radius
base
Arcing horn material Hot dipped galvanized forged steel
Arcing horn cross sectional area > 18 mm2 each
Arcing horn gap size 8 ( 2) mm fixed
The insulator and hardware drawings are shown in APPENDIX C.

7. HARDWARE REQUIREMENTS
7.1. HARDWARE ASSEMBLIES
Hardware requirements should be assembled as per assembly drawings form the approved
supplier. The strength rating for the strain and bolted slack span assemblies (400kV Strain
assy double att 4xXXXX and 400kV Bolted Slack Span assy single att 4xXXXX) is
stipulated in column Breaking Load 1. The strength rating for the V-Suspension assemblies
(518H/520B 400kV V-susp assy 4xXXXX) is stipulated in column Breaking Load 2. An
example of each type should be assembled in the site camp for inspection before use. Spacer
dampers, rigid spacers, vibration dampers and jumper flags/dead ends should be fitted with
Bellville washers as an additional locking mechanism.
7.2. SPACER DAMPERS

The conductor spacing is 450mm for the quad tern conductor and this should be maintained
throughout the spans. Suitable spacer dampers should be installed as or the suppliers
recommendations and corresponding spacing for the specified conductor.
The schedule for the spacing should include spans of 100m to 1500m for the product offered.
The phase conductor will be strung to a C value of 1800m.
Where:
C=H/W
H = Final horizontal tension (N)
W = Vertical weight of conductor (N/m)
7.3. RIGID SPACERS FOR JUMPERS

The jumper spacing is 450mm (Tern) and should be kept throughout the jumper. Suitable rigid
spacers should be offered to keep the sub-jumper spacing to required distance for the
specified conductor type.
7.4. VIBRATION DAMPERS FOR EARTH WIRES

Only Stockbridge type vibration dampers will be accepted. Vibration dampers should be
installed as per the suppliers recommendations for spans of 100m to 1500m for the product
offered. The earth wires will be strung to a C value of 2100m.
8. LINE LABELS
The Matimba Spitskop 2 400kV line has already been looped in and therefore the lines have
been relabelled as Matimba Medupi 400kV and Medupi Spitskop 3 400kV. The portions
that are being rebuilt are meant to match the existing loop-in and out as far as possible and
therefore the labelling should match the existing labels.
All labels shall be designed, manufactured and installed in strict accordance with the following
Eskom Specification: TSP41-604 REV.1
The Grid must advise on the preferred material within the material approved by Eskom. All
tower labels shall be made of a material approved by Eskom. Preference is given to the use of
Iscor Chromadek and vitreous enamel, but if any other material offers the same or higher
quality than the preferred listed above, then this new material will be considered.

8.1. LINE DESIGNATION LABELS LAYOUT AND WORDING
TOWER LABELS
Matimba Medupi 400 kV Line
Figure 8.1 Tower Labels
8.2. PHASE DISK LABELS

a) All Terminal Tower shall be fitted with phase disk labels.
b) All Transposition Towers shall be fitted with phase disk labels on one side.
c) All bypass terminal structures shall be fitted with phase disk labels.
R W B
9. CONSTRUCTION METHODOLOGY
The new sections will be built near other lines which are evacuating power from Medupi Power Station. The
necessary clearances must be maintained to any live lines in the immediate vicinity of the lines being
constructed.

Ma Me 22 to Ma Me 25, Me Spi 1 to Me Spi 5 and Me Spi 6 to Me Spi 7 must be built and strung
completely. This work will be carried out within close proximity to the existing loop-in and out which would
most likely be energized during this construction work. If the work cannot be done with the adjacent lines
energized system operators will have to advise if at least one of the lines can be switched out at a time.
Ma Me 21 to Ma Me 22 and Me Spi 5 to Me Spi 6 which cross the existing loop in and out
underpasses will have to be strung during an outage.

10. APPENDIX A: STANDARDS, SPECIFICATIONS
10.1. STANDARDS
The standards within this section provide for the design and technical requirements of the
line:
IEC 60652 Load tests of transmission towers.
Transmission Line Loading Part 1: Recommendations and
CSIR: 1990
commentary - 1990
ASCE 10 Guide for design of steel transmission towers.
Methods of testing cement Part 21: Determination of the
SANS 50196-21 - 1989
chloride, carbon dioxide and alkali content of cement
IEC 60888 Ed. 1.0 b:1987 Zinc-coated steel wires for stranded conductors
SANS 10111-1 Engineering drawing Part 1: General principles 1993 3.01
SANS 1556-1,2,3 - 1994 ISO Metric screw threads
SANS 1491-1,2,3 - 1989 Portland cement extenders
ISO metric machine screws and nuts, hexagon socket
SANS 1355-3 - 1989 screws and set-screws (coarse thread series) Part 3: Set-
screws
SANS 10044-1,2,3,4,5
Welding
1973 1983
SANS 1391-1 - 1983 Thermally sprayed metal coatings
ISO 1461 / SANS Specification for hot dip galvanized coatings on iron and
121:2000 steel articles.
SANS 935 - 1993 Hot-dip (galvanized) zinc coatings on steel wire
Continuous hot-dip zinc-coated carbon steel sheet of
SANS ISO 4998 - 1996
structural quality
SANS 10144 (1995) Detailing of steel reinforcement for concrete
BS 5835: 1980 Compatibility test for graded aggregates.
Specification for bitumen based coatings for cold application
BS 6949: 1991
excluding use in contact with potable water.
SABS EN 795
Code of practice for ground anchorages.
SABS EN 353-1
SANS ISO 9001:2000 Quality Management Systems Requirements.
Hot rolled products of non-alloy structural steels. Technical
SANS EN 10025
delivery conditions.
Hot finished structural hollow sections of non-alloy and fine
BS EN 10210:
grain structural steels.
SABS ISO 5177 Approval testing of welders for fusion welding. Part 1:
SABS ISO 6520 Essential variables, range of approval examination and
testing, acceptance requirements, re-tests, period of validity.
SABS ISO 4136 Annexes on steel groups, welders test certificates,
SABS 0443-3 (1987) procedure specification and job knowledge.
SABS 0443-6 (1985)
SABS 1033 ( 1982 )
SABS 864, Specification and approval of welding procedures for metallic
materials. Part 3: Welding procedure tests for the arc welding
SABS 1293, of steels.
SABS 1370 (1982)
Specification for cold reduced steel wire for the
BS4482: 1985
reinforcement of concrete.
Cement composition specification and conformity criteria
SANS 50197-1,2 - 2000
Part 1: Common cements
SANS 5860, 5861, 5862,
Concrete tests
5863, 5865 - 1994
SANS 10162 - 2005 The structural use of steel
SANS 1431 - 1997 Weldable structural steels
Part I: The structural use of concrete. Part II: Materials and
SABS 0100
execution of work
Live-line equipment is to be as per IEC standards 743, 895, 900, etc.

10.2. SPECIFICATIONS
This line specification shall take precedence if there is any conflict between it and the following
specifications:
PHASE CONDUCTOR AND GROUNDWIRE
IEC 60888 Zinc-coated steel wires for stranded conductors.
Quality requirements for the procurement of quality

TST41-168
related assets, goods and services.
HARDWARE
Code of practice for overhead power lines for

SANS 10280
conditions prevailing in South Africa.
Compression accessories for phase and earth
NWS 1019 Rev 1
conductors for transmission lines.
Design, manufacture and installation specification
TSP41-604
for transmission line labels
EARTHING REQUIREMENTS
TST41-321 Earthing of transmission line towers
TOWERS
TRMSCAAC5 Rev 2 240-

Transmission line towers and line construction.
47172520
AS BUILT LiDAR SCAN
32 -1109 LiDAR Specification
NOTE: Wherever reference is made to supplier(s), vendor(s), etc, it shall mean the
Contractor.
10. APPENDIX B: TOWER OUTLINE DRAWING




11. APPENDIX C: HARDWARE ASSEMBLY DRAWINGS AND INFORMATION
11.1. HARDWARE ADDITIONAL INFORMATION
Hardware Standards
The standards within this section provide for the design and technical requirements of the line:
IEC 60120: Dimensions of ball and socket couplings of string insulator units.
IEC 61089: Round wire concentric lay overhead electrical stranded conductors.
IEC 61284: Overhead lines Requirements and tests for fittings.
IEC 60372: Locking devices for ball and socket couplings of string insulator units.
IEC 60383: Insulators for overhead lines with nominal voltage above 1000V.
IEC 60471: Dimensions of clevis and tongue couplings of string insulator units.
IEC 60826: Loading and strength of overhead transmission lines.
BS 2874: Specification for wrought steel for mechanical and applied engineering
purposes.
ISO 14399: ISO Metric screw threads.
BS 4190: Specification for ISO metric black hexagon bolts, screws and nuts.
BS 7668: Specification for weld able structural steels. Hot finished structural hollow
sections in weather resistant steels.
BS EN Plates and wide flats made of high yield structural steels in quenched
10137: and tempered or precipitation hardened conditions.
BS EN Specification for tolerances on dimensions, shape and mass for hot

10029: rolled steel plates 3mm thick or above.
ISO 1461: Specification for hot dip galvanized coatings on iron and steel articles.
BS 970: Specification for wrought steel for mechanical and applied engineering
purposes.
BS EN ISO Quality systems model of quality assurance in design, development,

9001: 9002 production, installation and servicing.
BS EN Hot rolled products of non-alloy structural steels. Technical delivery

10025: conditions.
BS EN Specification for delivery requirements for surface conditions of hot rolled

10163: steel plates, wide flats and sections.
BS EN Hot finished structural hollow sections of non-alloy and fine grain

10210: structural steels.
BS EN 287- Approval testing of welders for fusion welding. Part 1: Essential

variables, range of approval examination and testing, acceptance

1:1992: requirements, re-tests, period of validity. Annexes on steel groups,
welders test certificates, procedure specification and job knowledge.
BS EN 288- Specification and approval of welding procedures for metallic materials

3:1992 Part 3: Welding procedure tests for the arc welding of steels.
11.2. HARDWARE SPECIFICATONS

This line specification shall take precedence if there is any conflict between it and the following
specifications:
TST41-168 Quality requirements for the procurement of quality related assets, goods
and services.
SANS 10280 Code of practice for overhead power lines for conditions prevailing in
South Africa.
TSP 41-452 Ceramic and Glass Cap and Pin Insulators
TSP 41-619 Specification for polymeric long rod insulators for Transmission voltages
of 220kV and above
(TRMSCABS
9 Rev1)
TRMSCAAI3 Spacer or spacer damper assemblies for conductor bundles for

: transmission lines.
TRMSCAAC Transmission line towers and line construction.

5 Rev 2:
TSP 41-264 Phase conductor for transmission lines.
TRMSCAAH Specification for suspension and strain assemblies and for hardware for
2 Rev 5: transmission lines.
TRMSCAAJ2 Requirements and tests for Stockbridge type Aeolian vibration dampers.
Rev 0:
TSP 41-604 Design, Manufacture and Installation specification for transmission line
labels.
TGL41-332 Transmission Bird Perch Guidelines
NOTE: Wherever reference is made to supplier(s), vendor(s), etc, it shall mean the
Contractor.
11.3. COMMON HARDWARE

Hardware Fitting
The hardware fittings are to be corona free.
The corona rings on either end of the insulators for the 518H (extended hardware assembly)
are to be decreased in diameter to increase the air gap between the live end and the tower
top.

The assembly is to be tested with and without grading rings, if the test yields results that show
that there is no significant difference in performance then the grading rings can be discarded
from the assembly thereby increasing the air gap.
Grading rings should be fitted in line with the span and not perpendicular thereby increasing
the air gap between the live end and the tower top. This will decrease the risk of flashover
from bird streamers.
Bird Guards
All self-supporting towers as well as guyed vee towers must be fitted with the approved Eskom
bird guards as per Eskoms specification- TGL41-332 (Transmission Bird Perch Guidelines).
Bird Diverters
The construction and design of the Bird Flight Diverter must be such that:
There are no moving parts and the attachment to the Ground wire/OPGW shall be rigid.
It is highly visible. Colours required are solid black and solid white
The attachment to the ground wire/OPGW is a preformed type, and rigid with no
movement between the clamp and the ground wire
The attachment device facilitates quick, easy installation and removal of the Bird Flight
Diverter.
The attachment device will cause no damage or stress concentration to the ground wire or
OPGW
All other suggested attachment methods offered, will be subject to Eskoms approval.
Installation of Bird Flight Diverters on Earth Wires / O.P.G.W,
The Bird Flight Diverters should be installed on both the earth wires / O.P.G.W, in the case of
a line having two earth wires, in a staggered alternating configuration as indicated in the figure
below.
FIGURE: 10.1 TYPICAL INSTALLATION OF A BIRD FLIGHT DIVERTER
11.4. AERIAL WARNING SPHERES

All Aerial Warning Spheres shall be manufactured from UV stabilized material such as, low
density polyethylene (LLPDE), or aluminium of uniform thickness not less than 1.6mm. Any
other material shall be subject to approval by Eskom.

The Aerial Warning Sphere must be spherical in shape, with a minimum diameter of 600mm.
No deviation to this will be accepted. The colour of these spheres must be solid white, solid
red or solid orange. The colour of the sphere must be visible from a distance and should not
fade with time. Aluminium type spheres shall be powder coated on all external surfaces.
The Aerial Warning Sphere may consist of two halves (hemispheres), provided that a lip or
similar feature will be incorporated in the design of the top hemisphere, to reduce water
ingress and to facilitate the assembling of the two hemispheres. Stainless steel screws or
bolts and nuts, shall be used.
Adequate water drainage holes of at least 10mm diameter shall be located on the bottom end
of the Aerial Warning Sphere. The device for attaching the Aerial Warning Sphere to the earth
wire shall be located at the top of the sphere or in such a way that the earth wire passes
through the centre of the Aerial Warning Sphere.
The design of the attachment device shall facilitate quick and easy installation and removal of
the Aerial Warning Sphere. The attachment shall be such that, in case of aluminium spheres
electrical contact shall exist between sphere and ground wire.
The design of the device shall prevent the Aerial Warning Sphere from sliding along the earth
wire after installation. Design of the attachment clamp of the Aerial Warning Sphere, shall be
as such that it will cause no damage or stress concentration to the earth wire.
If necessary to install on O.P.G.W conductor, the use of suitable armour rods will be required.
Installation of Aerial Warning Spheres on Ground Wires
For the installation of Aerial Warning Spheres, it is recommended to use the following
procedure:
Install the Aerial Warning Spheres on a single ground wire, but alternate the colours
(white and red or orange)
The Aerial Warning Spheres have to be installed on the highest wire of the affected line
spans, typically on the ground wires
They are to be located 30m from the tower, and 30m from each other along the span.
White and Red/Orange Aerial Warning Spheres should alternate along the span, as
shown in the figure below. This method will guarantee that the pilot sees the alternating
affect from any approach angle.
If bird flight diverters are required on the same span, they will be installed as usual with
the ones clashing with the position of the Aerial warning spheres omitted.
Ground Wire / OPGW

Tower 1 Tower 2
Red
or
Orange Ground Wire
30m
60m
FIGURE: 10.2 TYPICAL INSTALLATION OF AN AERIAL WARNING SPHERE
11.5. TRANSPORTING AND PACKAGING

All hardware components should be packed in suitable crates which are rigid enough to
withstand loading and shipping conditions. If timber is used as packing material, it should be
treated with suitable preservatives that will not lead to timber rot during shipping and storage
of material for a period of up to one year. The crates should be clearly marked with the
contents indicating which hardware components are inside. The design of the crates should
be such that standard off-loading equipment like fork-lifts and cranes can readily off-load the
material without damaging the crates.

11.6. HARDWARE ASSEMBLY DRAWINGS






12. APPENDIX D: STRUCTURES ADDITIONAL INFORMATION
Eskom owns copyright on the designs of all these towers and full fabrication drawings of the
structures will be supplied to the successful tenderer.
All towers are to be fabricated using S355JR steel, in accordance with recent industry changes.
Thus all references to the use of 300WA or lower grade of steel shall be taken to read S355JR.
(The towers were designed for either grade 300WA or 350WA for the main members). Where
300WA steel was originally specified - this requirement is however subject to the availability of
S355JR steel. The contractor shall confirm availability and notify the project manager regarding the
steel grade to be used. If the tower consists of mixed grades of steel then the higher grade steels
must be marked with H as a suffix after the member label. If a tenderer wishes to propose the use
of other grades of steel, the towers may need to be redesigned and re-tested.
A prototype of each type of tower with all body and leg extensions shall be assembled at the
manufacturing premises for inspection by the Design Engineer prior to start full fabrication. The
contractor shall do pilot installation on site of all type of towers according to accepted method
statement procedure and in presence of the Design Engineer.
For the alternative designs, the tenderers are free to design their own towers, to suit the steel
grade and section sizes available to them, based on the outline drawings, attachment heights and
clearance dimensions provided and in accordance with the required loading schedules. All steel
shall be in accordance with BS EN 10025 or BS EN 10210 and the quality of finished steel to BS
EN 10163. Bolts for lattice structures shall be metric to SABS 136-1991 grade 6.8 with thread
length 1,5 as per SABS 135-1991.
On the lattice structures anti climb devices shall be of the spike or palisade type.
Mechanical properties of grade S355JR steel for flat bars and sections are to be used where:
J refers to the Charpy impact test withstand value of 27J and

R refers to the test temperature (24 deg Celsius temperature)

12.1. TEMPERATURE
The maximum wind loads will be applied at an ambient temperature of 15C. Conductor loads
will be checked at maximum and minimum temperatures. A maximum templating temperature
of 60C will be used. A minimum temperature of -5C should be considered.
12.2. CONDUCTOR, GROUNDWIRE TENSIONS

Sag-tension tables will be compiled for a range of spans, considering the erection conditions
and the tower capacities. Final tension will be governed by vibration limits. Equation 1 below
relates catenary, C, to horizontal tension, H, and weight, W.
H
C [m] (1)
W
Where:
H = final horizontal tension (N); and
W = vertical unit weight of conductor (N/m).
For the conductor, the final tension at 15C will be governed by a C-value of 1800 m; for the
earth wire, the final tensions at 15C will be governed by C-values of 2100 m unless
reduced by the table presented in the profiling section above.
Sag tension limits:
PHASE
CASE EARTH WIRE
CONDUCTOR
Final C value at 15C 1800 2100
Maximum conductor temperature 60C 40C
Minimum conductor temperature -5C -5C
Final condition at 15C and wind
70% UTS 70% UTS
pressure at 1000 Pa
12.3. GUY WIRES

All guy wires shall conform to Eskom specification NWS 1074 Guy strand grips for
transmission lines.
As part of the towers the steel guy strands (single strands), end fittings, shackles, etc shall be
included for the installation of the suspension towers. Guys for the Cross-rope suspension
towers shall be pre-cut and compression end fittings shall be installed prior to testing and
shipping the guys to site.
For the cross rope towers three of the guys of each tower shall have no adjustment
whatsoever. Only one of the four guys shall have tension adjustment, at the bottom
connection only. The adjustable end on the fourth guy shall be simple. It is suggested that a
U-bolt be connected to the end of the anchor rod, and that a steel plate be installed on the U-
bolt for guy-length regulation.

After installation of the mast foundations and anchors, the position and elevation of each tower
shall be measured, and the required length of the guys shall be calculated with respect to the
known height of the tower as per the tower drawing. Then the four guys shall be cut and the
end fittings installed.
Further to 240-47172520 (TRMSCAAC5.2), adjustment of 350mm for the guy length shall be
provided on all guys at the bottom end only for Guyed V towers and not for cross-rope
towers.
The tolerance for the complete length of the guys (calculated distance between centres of top
and bottom attachment points) shall be 20 mm from the calculated length. All guys shall be
permanently marked, including the number of the tower and the pre-established position of
each guy in each tower.
The bidders shall propose convenient attachment configurations between guys and tower, and
guys and anchor rods.
All ropes with compression end fittings shall be tested individually to a tensile load
equal to 83% of the ultimate strength of the steel rope in each case. Due to the testing,
which causes permanent stretch, a reduction of 0,2% of total length shall be applied to the
calculated length of all ropes, which are to be tested.
12.4. MATERIAL
The material and manufacture processes selected for each component of the guy strand grip
assemblies shall be subject to Eskoms approval. The approval procedure will consider the
material strength characteristics, ductility and fracture toughness.
12.5. TESTING
Qualifying design tests
Before the closing date for tendering, all tenderers shall satisfactorily perform the following
tests, where applicable, to qualify their guy strand grips and compression guy assemblies as
acceptable for Eskoms transmission system.
The contractor shall submit proposals to Eskom for acceptable test procedures, test
equipment and recording devices. The contractor shall communicate in writing to Eskom, in
good time, the site and the date of the tests.
No testing of cables shall take place without a representative from Eskom being present. The
contractor shall identify each individual cable and shall keep records of all the test results.
Copies of these records shall be submitted to Eskom.
Test to include testing foundation link and tower attachment plate that can fit 450kN shackles.
Tests shall be conducted on a minimum of two identical guy assemblies. If the guy assemblies
successfully complete the tests, no further testing needs to be performed. If any component
fails a test, the guy assembly cannot be retested until Eskom has approved the design
modifications.
Three copies of each test certificate showing the results of the tests shall be submitted.
Visual and dimensional tests
Material properties test

Production routine tests
Production routine tests shall be performed as specified in NWS 1074
12.6. LIVE LINE MAINTENANCE OF CROSS ROPE STRUCTURES

All inverted clamps on cross rope towers are to have a hole to fit a live line pin.
12.7. ANTI-THEFT MEASURES

All steel members up to anti-climb except for main members in lattice structures shall be
equipped with anti-theft fasteners.
The anti-theft fasteners will be of minimum 8.8 grade strength bolts and shall involve metal
deformation during installation. Break-away nut systems will not be acceptable (unless similar
performance to the latter type systems can be demonstrated satisfactorily.)
All steel members up to anti-climb device level shall be stamped with the word ESKOM at
300mm - 500mm intervals.
Ensure that all members are striped ( 2 x 1mm wide parallel grooves, 4mm apart, 1mm deep)
All U-bolts of guys on ground level will be fitted with anti-vandal caps or other suitable
methods subjected to Eskoms approval, to ensure that the bolts arent loosened.
The anti-vandal specification, TSP_474-285 1 Anti-Theft Measure Tx and Dx Towers must be

adhered to.
12.8. SAFETY MEASURES

FALL ARREST SYSTEM
All tenderers are to be aware that a guide type fall arrest system on a rigid anchorage line, in
accordance with requirements of the attached Standard EN 353-1:2002 will be supplied and
installed by the contractor. This will be a temporary fall arrest system and is to be removed
when all construction activities are complete.
KEY COMPONENTS
The system supplied and installed by the Contractor will comprise five key components; the
top anchor, energy absorber, intermediate wire guides, bottom anchor and the cable.
Tenderers should allow for a sufficient quantity of cable attachment units to suit its own
workforce.
INSTALLATION
The system will be installed vertically on each of the tower climbing legs, i.e. two per tower,
with compatible brackets to ensure that top, intermediate and bottom anchors can be clamped
into place on the main steel angles to support the main cable. The system shall run from
above the anti-climbing device to the top of the earth wire peak, and temporarily attached on
each tower for the duration of the construction period.
An additional cable will also be installed for self-supporting towers, mounted horizontally along
the tower bridge between the two outer conductor phases.

No climbing to the structures shall be done prior to the installation to the fall arrester system
unless absolutely necessary, and, in that case, the climbing shall be done under the
supervision of site manager.
SAFETY STEP BOLT
Safety step bolt should be installed on all lattice towers, as per standard Eskom drawing.
Drawing number 0.69/10-1.
TRAINING
The Contractors appointed supplier will provide relevant training in the use and practical
application of the fall arrester system. Tenderer to ensure that applicable workforce undergo
the required training.

13. APPENDIX E: FOUNDATIONS ADDITIONAL INFORMATION
13.1. FOUNDATION DESIGNS
Eskom will supply preliminary drawings for tender purposes only to enable easier pricing
across all tenders. These Standard designs issued with the tender will consist only of
preliminary drawings and foundation material requirements, excluding stubs and layouts.
If these Standard designs are to be utilised by contractors, such designs will only be
adopted if the following conditions are met:
1) All foundation designs must be thoroughly checked and signed off by the contractors
Professional Engineer, before being submitted for Eskom acceptance and
implementation as final designs for construction.
2) The design, appropriate use of foundation types and quality of construction is the
contractors responsibility.
3) Contractors will be advised to submit alternative designs if standard designs are not
acceptable or suitable to their construction equipment or if alternative types of
foundations (e.g. drilled footings) are proposed.
4) Whether the contractors submit their own designs, or make use of standard designs,
tenderers will continue to price only the rates for common cost components (including
material and labour costs) of:
Excavation Volume conventional excavation(for each of six soil / rock types)
Excavation Volume drilled excavation (for relevant soil / rock types)
Reinforcing weight
Embedded Mild Steel weight (e.g. stubs)
Concrete and Grout Volumes
FOUNDATION SYSTEMS AND DESIGNS
All foundations shall be designed in accordance with Eskom Technical InstructionTechnical

InstructionTechnical Instruction 240-47172520 (TRMSCAAC5.2).
Tables 13.1, 13.2 and 13.3 show the foundation systems that can be designed and optimised
for load performance and cost effectiveness for the lines.
Table 13.1 : Standard designs foundations

TOWER TYPE FOUNDATION TYPE APPLICABLE SOIL TYPE
Self-supporting Pad and column foundations Soil types 1 4
towers Rock anchors Soft rock & Hard rock
Guyed towers Mast foundations: pad and plinth All soil types
Deadman anchors All soil types
Rock anchors Soft rock & Hard rock

Table 13.2 : Alternative acceptance - pile foundations
TOWER TYPE FOUNDATION TYPE APPLICABLE SOIL

TYPE
Self-supporting Multiple piles and cap Soil types 1 , 2 &
towers soft rock
Rock anchor systems consisting of
anchors and a connecting cap Hard and soft rock
Specialised pile systems Collapsing / waterlogged

soil
Guyed towers Inclined anchor piles or vertical Soil types 1 and 2 &
multiple pile systems soft rock
Table 13.3 : Alternative acceptance - Titan anchors foundations
APPLICABLE SOIL
TOWER TYPE FOUNDATION TYPE
TYPE
Soil anchor systems consisting of
Soil types 1 to 4
anchors and a connecting cap
Self-supporting
Rock anchor systems consisting of
towers Hard and soft rock
anchors and a connecting cap
Inclined anchor/s system or Soil types 1 to 4

Guyed towers
vertical multiple pile systems Hard and soft rock
Micropile (grout injected anchor) Foundation System
The micropile grout injected (Titan type or similar) system is suitable for all soil conditions
ranging from saturated soils to hard rock and is therefore very suitable for use on power
line construction as it can deal with any foundation condition experienced. The added
advantage is that from a logistic point of view very little material has to be brought in as the
drill shafts act as tension/compression reinforcement in the constructed piles and the pile
caps are smaller than conventional foundations. Furthermore, the system only requires a
light drilling rig and a cement grout pump system as far as equipment is concerned.

These micropiles are formed by drilling a threaded hollow drill shaft into soil or rock and
mixing the loosened virgin material with a high strength cement grout which is pumped
simultaneously at high pressure through the hollow centre of the drill bar. As it is not
always known how deep one needs to drill the micropile in order to get the desired load
capacity from the micropile, the drill shaft can be extended by adding multiple drill shaft
sections of 3m. The new section is coupled to the previous section by means of a threaded
hollow coupling. The bars can also be cut into shorter pieces if a shorter section is required.
Cement grout is pumped in under pressure to form a grout bubble to ensure good contact
between the pile and the virgin soil in order to ensure good transfer of the load forces from
the pile to the virgin soil. As the micropile stabilizes the in situ virgin material there is no
chance of the drill hole collapsing and the drill shaft is covered by a layer of high strength
cement grout to give it corrosion protection. Once the desired depth is reached the grout is
pumped continuously until fresh grout emerges at the top surface.
Figure 13.1: The micropile system cross-section and plan section
From an environmental point of view the system is extremely suitable as the natural
surrounding at the foundation positions is hardly disturbed apart from the small excavations
required for the pile and anchor caps. Different drill bit types and sizes and drill shaft sizes
are available to suite different load requirements. Because the system constructs the
micropiles in a single process and the pile caps require far less material than conventional
foundations the foundation construction process has been found to be faster than the
conventional approach (in the order of 3-5 times faster). Depending on the depth of
bedrock on site, substantial savings in foundation costs can be accrued (up to 50%).

Guy anchor design
the use of linked metal components in direct contact with soil is not acceptable.
All steel below ground line must be encased in concrete.
13.2. CONSTRUCTION SPECIFICATIONS

All foundations shall be constructed in accordance with Eskom Technical InstructionTechnical
InstructionTechnical Instruction 240-47172520 (TRMSCAAC5.2).
Soil Classifications
A geotechnical investigation (for soil/rock type nomination) must be done by the contractor
before foundation construction (as per the Eskom Technical InstructionTechnical
InstructionTechnical Instruction 240-47172520-TRMSCAAC5.2, at which point the prevailing
soil or rock type classification is determined, and a suitable foundation system for this material
is selected.
These investigations allow foundations to be designed more precisely for the type of soil or
rock encountered, rather than adopting a conservative design approach for foundations.
Foundation-Soil nominations will be performed by suitably qualified professionals, as

appointed by the contractor. This change in practice is in keeping with international practice,
and will greatly reduce the risk of foundation failure due to inappropriate foundation selection,
which is one the most common causes of foundation failure in South Africa.
A typical geotechnical investigation to determine the soil classification will involve observation
of surface and sub-surface drainage patterns, a trial pit excavation, manual inspection of the
side walls using a geologists hammer, in-situ tests with a shear vane and a hand
penetrometer and logging of soil consistency down the excavation sides.
As the contractor progresses with the soil/rock nominations he must provide ESKOM with a
list of all the proposed foundation type/systems he plans to install with the corresponding soil
profile log sheets of each geotechnical investigation pit. (tower position) This is a hold point on
the contractors construction program (test plan) where approval of ESKOM must first be
obtained prior to constructing the foundation.
Where rock boulders/pinacles are encountred not revealed in the Geotechnical investigation
slight foundation alterations is needed. Large rock volumes must not be removed to be
replaced by a large foundation designed for soil. Rock foundation solutions is possible for
most rock/soil conditions.
If large a boulder/rock is encountered and the TLB is not able to move or disloged the rock/
boulder, then the rock must form part of the foundation, for example by dowelling / anchoring
or keying the foundation to the rock.
In selected cases or specialized designs, more thorough geotechnical investigations must be

carried out in accordance with accepted, geotechnical engineering practices.
Where specialised grout injected anchor foundation systems (Titan type) is being used an
initial more applicable geotechnical investigation for the Titan type anchor requirements must
be done. Soil and rock characteristics i.e. layer depths, rock depths, water tables, soil
consistencies etc. or any other geotechnical conditions influencing the anchor performance
shall be determine by drilling (core drilling where required). Soil frictional/shear values and
anchor strengths shall be confirmed by anchor tests as per specification.

The final part of geotechnical investigation (Titan applicable) is done during the installation
drilling confirming the applicable Titan anchor type requirements. The rate of drilling
progress will be recorded for each drilling, as also all the installation information that is:
anchor type, size, diameter, depth, etc.
Soil Types
Type 1 Hard engineering strong granular soil.

Type 2 Less competent soil, stiff clay or dense sand.
Type 3 Very engineering incompetent soil i.e. loose sand or soft clay.
Type 4 Saturated or submerged soft ground below the seasonal water table.
Rock Types
Hard rock solid continuous moderately fractured.

Soft rock very fractured, weathered or decomposed rock.
13.3. PROOF LOAD TESTING

In keeping with increased quality assurance measures, the proof loading of guy anchor
foundations will be done on a minimum of 5% of deadman anchors and 5% of all installed
piled/Micropile guy anchors. These will be proof tested to a value of 90% of the unfactored
design load or 70% of the ultimate design load for pile anchors and deadman anchors.
To achieve proof load tests, use can be made of newer, more practical foundation testing
equipment. Such equipment was made available since the use of the conventional test rigs
that are shown in Figure 13.1. As shown in Figure 13.2, new equipment includes semi-
portable, lighter test rigs that are mounted on vehicles that are equipped with a hydraulic
power take-off.
The advantage of this type of system is that it can perform tests at high rate, with minimum
set up time. The disadvantage of the system is that the testing system is relatively
expensive to produce and requires a heavy transporter to be relocated to different
construction sites

Figure 13.2: Conventional proof load test rig
Figure 13.3 Proof load testing rig.
13.4. SPECIAL CONDITIONS AND DESIGNS
If the EIA or geo-technical findings reveal any severe findings or extreme conditions
applicable to the line construction it will be integrated in the line profiles and foundation
designs. However, at this stage the best information available does not indicate severe or
extreme conditions.
The conditions that influence the geotechnical and constructional aspects will be identified
with the geotechnical investigation during construction. Some typical geotechnical
conditions that are difficult to handle are as follows:
a) Type 4 soils which have shallow water tables or seasonal flooded areas.
b) Shallow and outcropping boulders spaced apart.
c) Land or rock slide prone areas or unstable slopes.
d) Sinkholes areas, mined areas or seismically active areas.
The following constructional conditions are difficult to handle:
I. Topography extremes such as elevation variations i.e. steep slopes, cliffs, valleys and
dongas.

II. Difficult access areas and surfaces: forests, floodplains, erodible soils, loose sands and
soft and wet clayey soils.
If the Geotechnical Investigation reveal any other severe or extreme conditions applicable to the
construction of the foundations, special designs may be required. This may be necessary in
instances where for example the integrity of foundation installations could be threatened by rapidly
flowing water and the resultant effects thereof, such as undermining and/or increased lateral loads.
These tower positions will be identified during the geo-technical investigation.
Any severe or extreme conditions detected during the geotechnical investigations will be dealt with
as a compensation event.

FOUNDATION CONSTRUCTION
Project No: Project description
ESKOM / ENGINEERING
NON DESTRUCTIVE
Quality preformed by Signature
ESKOM / CLIENT
EXAMINATION
DIMENSIONAL
CONTRACTOR
TOWER AND FOUNDATION NUMBER
DOCUMENT
Remarks, Deficiency
VISUAL
or
Activity No and description
Nonconformance Report
Instruction / Procedure / Drawing numbers
/ Inspection / Template or
Description Specification Reference LEG A LEG B LEG C LEG D Mast F Mast E
Method Statements (MS) and Specification:
1 Foundations Type of Control Signature Date Signature Date Signature Date
TRMSCAAC1 rev 3 and amendments
1.1 Tower centre peg position and Foundations setting out clear of any objects Foundation set out drawings X X X I S S
Geotech investigation report together with Contractor's

Soil classification for foundation nomination for every tower position (professional's
1.2 proposed foundation type to be approved by ESKOM. X X H H+A H +A
geotec report with foundation type proposals)
TRMSCAAC1 cl 6.2.1 Photographs of each pit profile
1.3 Excavations and Pile or Rock Anchor drilling M S and TRMSCAAC1 cl 6.2.2 X X X I S S
1.4 Excavation Barricading M S and TRMSCAAC1 cl 6.2.2 X X X I I I
1.5 For the following activity (1.6) LES must be notified one week in advance.
Check rebar, Shuttering Stubs and Anchor Links (The first of each foundation type to be M S , Works information and TRMSCAAC1 cl 6.2.4.8-9.
1.6* X X H+I H + W+ A H+W+A
witnessed by LES) Photographs must be taken at this point
1.7 Check rebar, Shuttering Stubs and Anchor Links (rest of the line) M S and drawings X X I I I
Check concrete delivery time, slump tests and take concrete cube samples M S and TRMSCAAC1 cl 6.2.4.6-7 X I W W
1.8
Casting and concrete compaction(vibration), Grouting of Anchors Piles M S and TRMSCAAC1 cl 6.2.4.10-13 X I W W
1.9
1.10 Concrete finishing and curing M S and TRMSCAAC1 cl 6.2.4.12-13 X I S S
1.11 Check backfilling and compaction and re-establish top soil M S and TRMSCAAC1 cl 6.2.3 X I S S
1.12 Clean tower site Environmental requirements X I S S

1.13 Test cube results 7 and 28 day results M S and TRMSCAAC1 cl 6.2.4.6 X X X T W W
1.14 Construction proof load test on Guy anchors M S and TRMSCAAC1 cl 6.2.5 X X T W W
1.15 Ultimate Load test -block anchor(deadman), pile or rock anchor M S and TRMSCAAC1 cl 6.1.6.4e X X T W W
1.16 Tower footing resistance measurement X X I S S

1.17 Review all relevant inspection and test records X X I I W
Definitions:
H - Hold Point: A predetermined stage beyond which work shall not proceed without the attendance of and written authorizati on of a GBE representati ve and photographs must be taken at this point
I - Inspection Point A predetermined stage in the Quality product/process plan where a check or measurement must be preform to verify parameters and specification requirements
Inspection agency: An organization or person appointed by GBE for the purpose of performing quality assurance/quality control, monitoring or inspection services.
T - Test to be preformed S - Surveillance -general observation
A - Approval by client and LES
* - GBE must be notified one week in advance.

Note:
For guyed v tower central foundation use Mast F column

TOWER ASSEMBLY AND ERECTION
ESKOM / ENGINEERING
ESKOM / CLIENT
EXAMINATION
DIMENSIONAL
CONTRACTOR
DESTRUCTIVE
DOCUMENT
VISUAL
TOWER NAME
NON
Activity No and description Instruction / Procedure / Drawing / AND NUMBER Remarks, Deficiency or
Inspection / Template or Specification Nonconformance Report
Description Reference numbers
2 Tower Assembly and Erection Type of Control Signature Date Signature Date Signature Date Name Number
2.1 Steel assembly configuration as per tower drawing M S and TRMSCAAC1 cl 7.4.2c and d/Tower drawings X X I S S
Tower, foundation and earthing functional specification and
2.2 Steelwork condition and galvanising X X I I S
TRMSCAAC1 cl 7.2.4
2.3 Hole and member alignment M S and TRMSCAAC1 cl 7.4.2f, g and h X I S S
2.4 Bolt size and orienation M S and TRMSCAAC1 cl 7.4.2d and e X I S S
2.5 Tightening , punching and painting of bolts and nuts M S and TRMSCAAC1 cl 7.4.2j X I S S
2.6
For the following activity (2.7) GBE must be notified one week in advance.
First tower assembly of each type (TO BE WITNESSED BY ESKOM ENGINEERING AFTER
2.7* M S and TRMSCAAC1 cl 7.4.2 X H H + W+ A H+W+A
COMPLETION OF ASSEMBLY)
2.8 Tower Assembly (rest of the line) M S and TRMSCAAC1 cl 7.4.2 X I I S
2.9
For the following activity (2.10) GBE must be notified one week in advance.
2.10.* First tower erection of each type ( TO BE WITNESSED BY LES) M S and TRMSCAAC1 cl 7.4.2/3 X H H + W+ A H+W+A
2.11 Tower erection M S and TRMSCAAC1 cl 7.4.2/3 X I S S
2.12 Fall arrest installation MS X I S S

2.14 Review all relevant site inspection and test records X X H H H
Definitions:
H - Hold Point: A predetermined stage beyond which work shall not proceed without the attendance of and written authorization of a GBE representative and photographs must be taken at this point
W - Witness Point: A predetermined stage in the Quality product/process plan beyond which work may proceed, provided GBE or their authority/agency have been notified according to the requirements of the contractor/order.

STRINGING AND REGULATING

ESKOM / ENGINEERING
ESKOM / CLIENT
EXAMINATION
DIMENSIONAL
CONTRACTOR
DESTRUCTIVE
DOCUMENT
Activity No and description
Instruction / Procedure / Drawing
VISUAL
NON
/ Inspection / Template or Section Name
Specification Reference Remarks, Deficiency or
Nonconformance Report
Description numbers
3 Stringing and Regulation Type of Control Signature Date Signature Date Signature Date Name
3.1 Location of crossing M S and TRMSCAAC1 cl 8.2.1 X I S S
3.2 Inspection of the first hardware assembly for a every tower type ( including groundwire) Hardware Specification/ Hardware drawings X H H + W+ A H+W+A
3.3 For the following activity(3.4) LES must be notified one week in advance.
3.4* Conductor and earthwire joints and tests at CSIR M S and TRMSCAAC1 cl 8.2.3 X X H H + W+ A H+W+A
3.5 Conductor and earthwire joints MS X I S S
3.6 Dead ending all conductors MS X I S S
3.7* For the following activities (3.7, 3.8, 3.9, 3.10 and 3.11)LESmust be notified one week in advance.
3.8* Lifting of assembly for each tower type MS X H H+W+A H+W+A
3.9* String Earthwire (LES to witness first section stringing) M S and TRMSCAAC1 cl 8.2.2 X X I S S
3.10.* String Conductor (LES to witness first section stringing) M S and TRMSCAAC1 cl 8.2.2 X X I S W
M S and TRMSCAAC1 cl 8.3/ TRMASACB2 Standard for the

3.11* String OPGW (LES to witness first section stringing) installation of overhead ground wire with optical fibre X X I W W
(OPGW)
3.12 Regulation of all conductors M S and TRMSCAAC1 cl 8.2.6/Sag and tension charts/Profiles X I S S
3.13 Clamping all conductors M S and TRMSCAAC1 cl 8.2.7 X I S S

3.14 Spacer / spacer damper installation M S and TRMSCAAC1 cl 8.2.9 X I S S
3.15 For the following activity(3.16) LES must be notified one week in advance.
3.16* Jumper installation (LES to witness first jumper installation)) M S and TRMSCAAC1 cl 8.2.10 X I W W
3.17 Aerial warning spheres installation MS X I S S

3.18 Aerial bird flight diverters M S and TRMSCAAC1 cl 4.3b X I S S
3.20. Review all relevant inspection and test records X H H H
Definitions:
H - Hold Point: A predetermined stage beyond which work shall not proceed without the attendance of and written authorizati on of a GBE representati ve and photographs must be taken at this point
W - Witness Point: A predetermined stage in the Quality product/process plan beyond which work may proceed, provided GBE or their authority/agency have been noti fied according to the requirements of the contractor/order.
MISCELLANEOUS
SKOM / ENGINEERING
Quality preformed by Signature LES0019 Revision 0 November 2014 Page 60
SKOM / CLIENT
EXAMINATION
DIMENSIONAL
CONTRACTOR
DESTRUCTIVE
Remarks,
DOCUMENT
VISUAL
Activity No and description TOWER NAME Deficiency or

NON
Instruction / Procedure / Drawing AND NUMBER Nonconformance

/ Inspection / Template or Report

14. APPENDIX I: TECHNICAL TENDER SCHEDULE AND RETURNABLES

14.1. SCHEDULE A: PURCHASERS SPECIFIC REQUIREMENTS
Description Schedule A Schedule B
Structures
List of subcontractors to No
be used on this project Yes
supplied?
Name of tower No
manufacturer supplied? Yes
Name of steel supplier No
supplied? Yes
Steel Lattice Structures 518C, 518D, 518H, As specified
Other (provide details)
Steel grade S355JR used on all As specified
steel lattice structures Other (provide details)
Conductor tension limits As specified As specified
Tower shackles As specified As specified
Bolts As specified As specified
Guys N/A As specified
Description Schedule A Schedule B
Earthing Requirements
Compliance to specification as described in No
Section 4 : Earthing Requirements Yes
Subcontractors utilized? No
Yes
If yes, please provide
details of subcontractor.
Will exoweld or Brazing techniques be employed No
for electrical connections? Exoweld
Brazing
Are qualified personnel available to perform the No
work required (exoweld/Brazing)? Yes
If exoweld technique is to be used, is validation No
certificate provided? Yes
Is earth tester equipment calibration certificate No
provided? Yes
Alternative earthing designs are to be submitted No
with drawings for acceptance Yes
14.2. LIST OF RETURNABLES

Please submit all Engineering documentation described in the tables below in a separate file.

The file must be clearly marked Engineering Tender Returnables Matimba Spitskop
2 400kV Loop-in and Out of Medupi. Bay repositioning.
The documents must be submitted in a numbering sequence as described in the tables.
Please note that the minimum score to qualify for further evaluation is 70%. This evaluation will be
done purely on the documentation provided.
Certain documents are compulsory, and indicated as such in the table. The percentage score
allocated to each section are shown in brackets.
Please note the following are Free-issue items:
Phase conductor
Groundwire
Insulators
Hardware
Hardware fittings including aircraft warning spheres, bird diverters and bird guards
OPGW
OPGW Hardware
The listed free issue items are as per LES (Eskom Line Engineering Services) Transmission
Line Specification LES0019
OPGW hardware will be as per OPGW Spec. Eskom will select an OPGW supplier and the OEM
will appoint the contractor to install the OPGW, under their supervision or may provide his own
approved installer.
The following items are to be Supplied and Installed by contractor:
Towers and foundations as per LES Transmission Line Specification LES0019

1. List of Suppliers and Sub-Contractors Reference Document Compulsory
1.1 Provide a list of proposed suppliers and N/A Yes

subcontractors for the following:
Guy-wire and guy-wire fittings

Earthing
Fall arrestor
Scaffolding
1.2 Provide letters of undertaking stating their N/A Yes

willingness and availability to be involved on the
project should the bidder be successful.
2. FOUNDATIONS Reference Document Compulsory
2.1 Provide a statement indicating whether LES0019 Yes

Eskom designs will be utilised (contractor to
take responsibility for the designs). If Eskom
designs are not utilised, provide a statement of
compliance stating that the alternative
foundation designs will be suitable to meet the
specified loads as per LES Transmission Line
Specification.
2.2 Provide method statement for all aspects of Yes

foundation construction, namely the evaluation
and determination of the foundation material, the
excavation of the foundation, the placing of
rebar and pouring of concrete, curing and
backfilling, etc
2.3 Provide a statement to indicate adherence to

Yes
the engineering requirement that all test shall be
done by a laboratory that is independent of the
supplier of the item being tested.
3. TOWERS Reference Document Compulsory
3.1 Provide the completed tower section of LES0019 Yes

Schedules A and B of the Transmission Line
Specification

3.2 Provide the name of the tower steel Yes

manufacturer and a letter of undertaking that
states the willingness and availability of the
manufacturer to be involved on the project should
the bidder get the project.
3.3 Provide method statements for the assembly

and erection of all tower types used on this Yes
project, including pictures or drawings to clarify
these processes. As part of the assembly and
erection method statement describe the method
used to treat bolts and nuts after punching and
also describe the method used for cutting,
installation and tensioning of guy wire and its
attachments for the guyed towers. Provide details
of method for temporary back staying when
needed.
3.4 Specify the type of anti-vandalism fasteners Yes

that will be utilised.
LES0019
Yes
4. EARTHING Reference Document Compulsory
4.1 Provide the completed earthing section of LES0019 Yes

Schedules A and B of the Transmission Line
Specification.
5. Dressing, Stringing and Regulating Reference Document Compulsory

5.1 Provide method statements for stringing and LES0019 Yes

regulating phase conductor and groundwire
including figures or pictures.
5.2 Provide method statements for dressing of all LES0019 Yes

tower types related to this project. Including
figures or pictures.
6. Fall arrest and scaffolding precautions Reference Document Compulsory
6.1 Provide method statements for fall arrestor N/A Yes

installation including figures or pictures.
6.2 Provide method statements for erecting

scaffolding or other acceptable support structures N/A Yes
and processes including figures or pictures. This
applies to crossings over other power lines, roads
and railways.
7. Feedback from contractors Client Reference Document Compulsory
7.1 Provide letter of reference from contractors N/A No

client in the last 3 years indicating performance on
previous similar projects.
8. Inspection and test plan Reference Document Compulsory
8.1 Provide a statement to indicate adherence to the LES0019 Yes

engineering hold points, witness points and
surveillance points as described in Appendix H of
the Transmission Line Specification.

15. APPENDIX J: AS BUILT INFORMATION REQUIREMENTS
Latest version of As-built document must be acquired when construction begins.
Outline of Requirements
1. General Line Data
2. Summary of Project (Towers, Foundations and Earthing Specification)
3. Foundation and Tower Schedules

3.1. Foundation Checking Lists
3.2. Earth Resistance Checking Lists (Must include recording of soil and weather
conditions)
3.3. Tower Assembly and Erection Checking Lists
4. Stringing Records
5. Electrical Line Parameters (Measurements to be carried out as per specification 474-9428

Transmission Line Impedance Measurement Specification)
6. Drawings
7.1. Foundation Drawings
7.2. Tower Outline Drawings
7.3. Hardware Drawings
7.4. Insulator Drawings
7. Line Profiles
8. ALS survey

MATIMBA SPITSKOP 2 400KV LOOP-IN AND OUT OF MEDUPI. BAY
REPOSITIONING
Contract No.:
Contractor:
SOIL/ROCK CLASSIFICATION RECORD
Rev. 0
Tower Tower Proposed Date of Site Inspected by Witnessed Details of Soil/Rock/Water Table Approx. Position of Remark
No. Type Soil Class Inspection (Contractor) by (Eskom) and/or Other Significant Details the Trial Pit
S1 Soil type 1, S2 Soil type 2, S3 Soil type 3, S4 Soil type 4, SR Soft rock, HR Hard rock

REPOSITIONING
Unique PDPNEG-IRP-
Identifier 01
Document Inspection
Tower Foundation Inspection - Self Supporting Tower
Type Report
Revision 0
Total Pages 1
Project: Tower No.: Tower Type:
Foundation preparation for concrete
A - B - C - D -
A - 1st A - 2nd B - 1st B - 2nd C - 1st C - 2nd D - 1st D - 2nd
Tower Leg Chimn Chimn Chimn Chimn
Pad Pad Pad Pad Pad Pad Pad Pad
ey ey ey ey
Type of foundation
nominated & approved?
(Indicate Type)
Foundation set out
checked?
Foundation safe to work in?
Excavation dimensions
checked?
Reinforcing installation
checked?
Earthing checked?
Shuttering checked?
Date Inspected
Foundation excavation and reinforcing inspected, accepted and released for casting of concrete.
Contractor: Date: ESKOM Representative

REPOSITIONING
Name: Signature: Name: Signature:
Concrete batch number

(Cube test piece prepaired
and identified)
Concrete delivery time
Slump record
Casting of concrete
checked?
Date Inspected
Concrete inspected, accepted and released for backfilling.

Backfilling of foundations
checked?
Compaction checked?
Date Inspected
Completed backfilling and compaction of foundations inspected


REPOSITIONING
Unique PDPNEG-
Identifier IRP-02
Document Inspection
Tower Foundation Inspection - Guyed Tower
Tyoe Report
Revision 0
Total Pages 1
Project: Tower No.: Tower Type:
Foundation preparation for concrete

Tower Leg A B C D E - Pad E - F Pad F -
Chimney Chimney
Type of foundation nominated & N/A N/A
approved? (Indicate Type)
Foundation set out checked? N/A N/A
Foundation safe to work in? N/A N/A
Excavation dimensions checked? N/A N/A
Reinforcing installation checked?
Earthing checked? N/A N/A N/A N/A N/A N/A
Shuttering checked?

REPOSITIONING
Date Inspected
Foundation excavation and reinforcing inspected, accepted and released for casting of concrete.
Name: Name: Signature:
Signature:
Concrete batch number (Cube test piece
prepaired and identified)
Concrete delivery time
Slump record
Casting of concrete checked?
Date Inspected
Concrete inspected, accepted and released for backfilling.

Contractor: Date ESKOM Representative
Signature:
Backfilling of foundations checked?
Compaction checked?
Date Inspected

REPOSITIONING
Completed backfilling and compaction of foundations inspected

Contractor: Date ESKOM Representative
Signature:

Concrete Sampling Record

Project: Contractor:
1. Slump Test
No Tower Resul Statu Done Sample Marking
Date Time
. No. t s By
1
3
Tower No. HG49
4
Leg C
5
Date DD/MM/YY
6
2P
7
8
Mark (Sample no. and part
9 of foundation, See note
10
2. Cube Samples
No 3. Comments
Mark Tower No. Leg Date Done By
.
1
Note: P Pad
PL Plinth
AB Anchor Block
Status: OK As specified/within limits
X Not Acceptable

Unique PDPNEG-
Assembly & Erection Inspection for Self-
Identifier IRP-03
Supporting Tower
Revision 0
Project: Contractor:
Tower Type: Tower No.:
Drawing No.: Rev. Leg Extensions (m)
Attachment Height Body Extension A B C D
(m)
Activity and inspection aspects as per Acceptable

Comments
specification Yes / No
Tower Assembly (Pre-Erection)
Tower Assembly as per correct drawing?
Stubs/Links in good order / no visible damaged?
Members damaged / bend?
Bolts Tightened, Punched and Painted correctly
(Bolts that are not Painted, must be hand
tightened)?
No Missing steel members?
Anti-Vandalism Bolts (Only if required) Installed?
Are all Bolts that are tightened, punched and
painted at least 3mm thread clearance?
Are the correct packers and washers used
Galvanizing visually inspected?
Name: Signature: Date:
Released for erection by Contractors
Supervisor

Witnessed by ESKOM Site Representative
Erection
All members installed?
Tower vertical/plumb and aligned (Guys
adjusted and anti-tampering protection
installed)?
Section joint bolts tightened, punched &
painted?
Fall arrest system installed (If applicable)?

Declaration by Contractor:
In terms of Construction Regulation Section 9 - Structures paragraph (1), I, the undersigned
Contractors Supervisor, duly appointed in terms of Construction Regulation section 6,
Supervision of Construction Work, paragraphs 6 (1) or (2), hereby declare that I have ensured
that
(a) all reasonably practicable steps have been taken to prevent the uncontrolled collapse of this
structure or any part thereof, which may become unstable or is in a temporary state of weakness
or instability due to the carrying out of construction work; and
(b) this structure is complete in every respect and is therefore released for stringing.
Released for stringing by Contractors
Supervisor
Name: Signature Date:

Witnessed by ESKOM Site Representative
Unique PDPNEG-
Earth Resistance Measurements
Identifier IRP-04
Project:
TEST EQUIPMENT INFORMATION
Test Equipment Description: ____________________________ Serial No.: ______________________
Calibration Date: ______________________ Next Calibration Due Date: _______________________
Calibration Certificate No.: _____________________________
Earth
Tower Foundation Tester Weather
Remarks
No. Type Readings Condition
(Ohms)
Tested By Witnessed By
Name: Designation: Name: Designation:
Signature: Date: Signature: Date:

ESKOM Representative Verified
Name: Designation:
Signature: Date:

Assembly & Erection Inspection for Guyed Unique PDPNEG-

Tower Identifier IRP-10
Revision 1
Project: Date:
Tower Type: Tower No.:
General
Ye No
Comments
s
ITP Completed by contractor?
Contractor Inspection done?
Tower Assembly as per correct drawing? Drng. No.:
Are all Split-pins used, bended correctly?
Fall Arrest system attached as specification
(Drawing available)?
Spacer Cable Number.
Anchor Points in good order / no visible
damaged?
Anchor Points - Are the holes closest to the
concrete, have at least 180-200mm clearance
from the concrete?
Masts E F Comments
Ye N Ye No
s o s
Members damaged / bend?
Bolts Tightened, Punced and Painted
correctly (Bolts that are not Painted,
must be handtightened)?
Step Bolts Tightened?
Anti-Vandalism Bolts (Only if
required) Used?
Are all Bolts that are tightened,
punched and painted at least 3mm
thread clearance?
Are the correct packers and washers
used
Damaged Galvanizing repaired with
Zinc Fix or Galvpatch?
Central Mast Footings in good order /
no visible damaged?
Additional Hardware correct as per
approved drawing?
No Missing steel members?
Inspected By:
Contractor Representative Name: ESKOM Representative Name:

Signature: Signature:
Date: Date:

Conductor and E/W Drum Record Unique PDPNEG-

Identifier IRP-09
Revision 0
Stringing Section: Tower: To Tower: Pulling Direction: Tower: Tower:
Phase 1 1TL 1TR Phase 2 2TL 2TR Phase 3 3TL 3TR
Phase Conductors-
Configuration:
1B 2B 3B
Earth Wire Configuration: Earth Wire #1 Earth Wire #2

Drum Allocation:
Phase 1:
Sub- Used Used Used
Conductor 1TL Length/Balance 1TR Length/Balance 1B Length/Balance REMARKS
No. [M] [M] [M]
1st Drum No. No. No.
2nd Drum No. No. No.
3rd Drum No. No. No.
Phase 2:
Sub- Used Used Used
No. [M] [M] [M]
Phase 3:
Sub- Used Used Used
No. [M] [M] [M]


Earthwire:
Earthwire Used Length Balance [M] Used Length Balance Recorded
1 2 Remarks
No. [M] [M] [M] (Contractor):
1st Drum No. No.
Date:
2nd Drum No. No. Checked (Eskom):
3rd Drum No. No.
Date

Electrical Line Parameters

Project Name:
Contractor:
Line Details
Length: _______________km Voltage: ___________kV
Conductor Type: ________________________ No. of Sub-Conductors: __________
Earth Wire Type(s): ______________________ No. of Earth Wires: ______________
Tower Type: ____________________________ Sub-Conductor Spacing:

__________mm
Transposed Line
Other:

.
Test Equipment Details
Company: ___________________________ Representative:

________________________________
Equipment Specifications:
______________________________________________________________________________
Signature: _____________________________
Measurement Results 1
Final measurements:
Positive Sequence Impedance:
R = ___________________ X = _____________________ B =
______________________
Units: /km
Zero Sequence Impedance:
R = ___________________ X = _____________________ B =
______________________
Units: /km
Impedance Matrix:

[ ] [ ]
Date: _________________________ Time: ______________________
Ambient Temperature: ___________ C
Weather Conditions:
____________________________________________________________________
16. APPENDIX K: METHOD STATEMENTS

GENERAL
16.1. TERMS, DEFINITIONS AND ABBREVIATIONS
e.g.: Definitions:
Term Definition
Toolbox talk A daily short discussion of a supervisor to convey safety issues, work
methods etc. surrounding a specific procedure or task to be done.
Competent Any person having the knowledge, training and experience specific to
person the work or task being performed: Provided that where appropriate
qualifications and training are registered in terms of the provisions of
the South African Qualifications Authority Act, 1995 (Act No. 58 of
1995), these qualifications and training shall be deemed to be the
required qualifications and training;
Construction The erection, maintenance, alteration, renovation, repair, demolition or
work dismantling of or addition to a building or any similar structure
The installation, erection, dismantling or maintenance of a fixed plant
where such work includes the risk of a person falling
The construction, maintenance, demolition or dismantling of any
bridge, dam, canal, road, railway, runway, sewer or water reticulation
system or any similar civil engineering structure
Construction Means a vehicle used for means of conveyance for transporting
vehicle persons or material or both such persons and material, as the case
may be, both on and off the construction site for the purposes of
performing construction work
Contractor An employer who performs construction work and includes principal
contractors
Design In relation to any structure includes drawings, calculations, design
details and specifications;
Designer any Prepares a design
person who-
Checks and approves a design
Arranges for any person at work under his control (including an
employee of his, where he is the employer) to prepare a design
Architects and engineers contributing to, or having overall
responsibility for the design
Build services engineers designing details for fixed plant
Contractors carrying out design work as part of a design and build
project

Fall prevention Means equipment used to prevent persons from falling from an
equipment elevated position, including personal equipment, body harness, body
belts, lanyards, lifelines or physical equipment, guardrails, screens,
barricades, anchorages or similar equipment
Health and Means a documented plan which addresses hazards identified and
safety plan includes safe work procedures to mitigate, reduce or control the
hazards identified
Material hoist Means a hoist used to lower or raise material and equipment, and
includes cantilevered platform hoists, mobile hoists, friction drive
hoists, scaffold hoists, rack and pinion hoists and combination hoists
Method Means a written document detailing the key activities to be performed
statement in order to reduce as reasonably as practicable the hazards identified
in any risk assessment
Mobile Plant Means machinery, appliances or other similar devices that is able to
move independently, for the purpose of performing construction work
on the construction site
Principal Means an employer, as defined in section 1 of the Act who performs
contractor construction work and is appointed by the client to be in overall control
and management of a part of or the whole of a construction site
Professional Means any person holding registration as either a Professional
engineer or Engineer or Professional Certificated Engineer under the Engineering
Professional Profession Act, 2000 (Act No. 46 of 2000);
certificated
engineer
Risk Means a programme to determine any risk associated with any hazard
assessment at a construction site , in order to identify the steps needed to be taken
to remove, reduce or control such hazard;
Structure any building, steel or reinforced concrete structure (not being a
means- building), railway line or siding, bridge, waterworks, reservoir, pipe or
pipeline, cable, sewer, sewage works, fixed vessels , road, drainage
works, earthworks, dam, wall, mast, tower, tower crane, batching
plants, pylon, surface and underground tanks, earth retaining
structure or any structure designed to preserve or alter any natural
feature, and any other similar structure
any formwork, false work, scaffold or other structure designed or used
to provide support or means of access during construction work
any fixed plant in respect of work which includes the installation,
commissioning, decommissioning or dismantling and where any such
work involves a risk of a person falling two meters or more
e.g.: Abbreviations in alphabetical order:

Abbreviation Description
EMP Environmental management plan
HIRA Hazard identification and Risk analysis
PPE Personal protective equipment
RoD Record of decision
UTS Ultimate tensile strength
ITP Inspection and test plan

16.2. INTRODUCTION
The method statements provided below are to be used for the construction of transmission
lines, as it is the responsibility of the designer, as set out in the construction regulations. It
is however still the responsibility of the contractor to provide and demonstrate to the client a
suitable and sufficiently documented health and safety plan which includes safe work
procedures/method statements to mitigate, reduce or control the hazards identified.
16.3. PURPOSE
The procedure contained below is to be used as an informative reference for the
contractors; it will provide a starting place for the contractors to compile their own safe work
procedures.
The safe work procedure will conform to the legislation and specifically the Construction
Regulations as part of a Health and Safety Plan.
16.4. GENERAL CONSTRUCTION REGULATIONS ROLES AND RESPONSIBILITIES

16.4.1. Responsibility of the contractor:
According to the construction regulations
9. Structures (1) a contractor shall ensure that
(a) all reasonably practicable steps are taken to prevent the uncontrolled collapse of any
new or existing structure or any part thereof, which may become unstable or is in a
temporary state of weakness or instability due to the carrying out of construction work; and
(b) no structure or part of a structure is loaded in a manner which would render it unsafe.
16.4.2. Responsibility of the designer:
(2) The designer of a structure shall
(a) before the contract is put out to tender, make available to the client all relevant
information about the design of the relevant structure that may affect the pricing of the
construction work;
(b) inform the contractor in writing of any known or anticipated dangers or hazards relating
to the construction work, and make available all relevant information required for the safe
execution of the work upon being designed or when the design is subsequently altered;
(c) subject to the provisions of paragraph (a) and (b) ensure that the following information is
included in a report and made available to the contractor
(i) a geo-science technical report where appropriate;

(ii) the loading the structure is designed to withstand; and
(iii) the methods and sequence of construction.
(d) not include anything in the design of the structure necessitating the use of dangerous
procedures or materials hazardous to the health and safety of persons, which could be
avoided by modifying the design or by substituting materials;

(e) take into account the hazards relating to any subsequent maintenance of the relevant
structure and should make provision in the design for that work to be performed to minimize
the risk;
(f) carry out sufficient inspections at appropriate times of the construction work involving the
design of the relevant structure in order to ensure compliance with the design and a record
of those inspections is to be kept on site;
(g) stop any contractor from executing any construction work which is not in accordance
with the relevant design;
(h) conduct a final inspection of the completed structure prior to its commissioning in order
to render it safe for use and issue a completion certificate to the contractor; and
(i) ensure that when preparing the design, cognizance is taken of ergonomic design
principles in order to minimize ergonomic related hazards in all phases of the life cycle of a
structure.
-These and all other aspects of the construction regulations should be adhered to under all
circumstances.
16.5. EQUIPMENT
For each activity type, the Safe work procedure should contain an equipment list with the
type of equipment and the capacity - clearly distinguish between safe working load (SWL)
and ultimate breaking load (UBL).
16.6. INSPECTIONS
Foundations and the dimensions between tower leg attachment points i.e. Back to Back
and Diagonals and stub angles shall be checked prior to structure erection. Once this is
inspected it will be signed off on the corresponding check sheet by the supervisor appointed
in terms of the Construction regulations act as an on-site representative of the
designer/client as well as by the contractor (first of each type of foundation should also be a
hold point for LES to inspect):
PDPNEG-IRP-01 Foundation inspection self-supporting tower

PDPNEG-IRP-02 Foundation inspection guyed tower
After the tower has been assembled in the different sections as stipulated in the
corresponding method as stated below, it should be inspected and signed off on the
corresponding check sheet by the supervisor appointed in terms of the Construction
regulations act as an on-site representative of the designer/client as well as by the
contractor:
PDPNEG-IRP-06 Guyed tower inspection

PDPNEG-IRP-07 Self-supporting suspension tower inspection
PDPNEG-IRP-08 Self-supporting strain tower inspection
These two forms together with the inspection notification form should be sent to the
designer with seven days notice:
PDPNEG-FM-03 Inspection notification

This is to inspect the first off tower erection for each type of tower so as to comply with the
construction regulations point 9. Structures (2) The designer of a structure shall (f) carry
out sufficient inspections at appropriate times of the construction work involving the design
of the relevant structure in order to ensure compliance with the design and a record of
those inspections is to be kept on site.
Although the designer only inspects the first off each tower type, the supervisor should
inspect and complete the same form with inspection for each tower and file on site and form
part of the as-built documents.
Once this first off inspection is carried out by the designer the construction of similar
structures/foundations/stringing/dressing processes can continue.
The ITP and check sheets signed by LES and the Eskom site supervision team is to ensure
quality of their designs is delivered as required in the specifications.
The ITP and check sheets submitted by the contractor as part of their contract quality plan
is to ensure quality of their construction techniques and should refer to their submitted
method statements (not to LES Specifications). Their method statements should be a
detailed execution plan abiding by the high level sequence of events laid out in the LES
Line Specification Method Statements and mitigating the risks highlighted by the line
engineers.
The contractors method statements and corresponding ITPs should be signed off by an
ECSA registered professional engineer and he should periodically visit the site to ensure
conformance to his methods by means of inspection.
17. FOUNDATION CONSTRUCTION METHOD STATEMENT

This section covers the various activities to be undertaken in the construction of
transmission line foundations.
17.1. SETTING OUT

The Eskom and the Contractor site supervisor shall identify the tower position and
verify the peg positions.
The setting out of foundations shall be done according to the foundation setting out
drawings.
17.2. SOIL CLASSIFICATION

Care shall be taken in choosing the position of trial pit, by ensuring that soil strata of
the selected location represent soil conditions of whole tower site. The position and
the number of trial pits should be :
o For cross rope towers: three (3) trial pits per tower - one pit between
foundations A & B, another one between foundations E & F , and the third
one between foundations C & D.
o For self-supporting towers: two (2) trial pits per tower - one pit between
foundations A & B, and another one between foundations C & D.
An experienced registered professional shall execute the soil investigation. The
registered professional shall accept the responsibility for the investigations and
shall sign all the soil profile log sheets. The soil nominations shall be submitted to
the Project Manager. The soil nomination shall be done according to the soil
classification as explained in TRMSCAAC5.2 (240-47172520)

All soil profiling shall be done in the presence of the ESKOM Site representative.
The test pits shall be excavated outside the zone of influence of the appropriate
foundation, and shall be taken down to a depth equal to the lesser of the depth of
the foundation systems to be constructed or 3m.
The responsible person (registered professional) doing the test pit investigation shall
decide where shoring is necessary in the case of unstable test pit ground sides as
to BOHSS Construction Regulation No 11. The responsible person shall also ensure
the safe operating procedures of the TLB.
A photograph of each test pit shall be taken.
The test pit shall be suitably backfilled immediately after the relevant inspections
and tests have been completed
This is a hold point (i.e. no foundation construction) in the Quality Plan until the
foundation soil type nominations list has been approved by the Project Manager.
The accepted soil / foundation nomination sheets shall be present at site.
17.3. EXCAVATION AND PILE OR ROCK ANCHOR DRILLING

Excavations shall be made to the full dimensions required, and shall be finished to
the prescribed lines and levels
Topsoil shall be stockpiled separately.
Over-excavation shall be avoided. If it occurs, the over-excavated section shall be
filled with 10Mpa concrete and not backfilled with soil.
If the bottom of the excavation is below the water table, the water shall be pumped
out and the excavation kept dry and free from water during foundation construction.
When the material at foundation depth is found to be partly rock or incompressible
material, and partly a soil or material that is compressible, all compressible material
shall be removed for an additional depth of 200mm and filled with 10mPa concrete
The excavations shall be protected so as to maintain a clean subgrade
Excavations shall be concreted within seventy two hours. Excavations that remain
unconcreted for longer than seventy two hours may, at the option of the supervisor,
be required to be enlarged by 150mm in all directions
Excavation shall be covered or barricaded to prevent injury to people or livestock
17.4. PLACEMENT OF REINFORCING STEEL, SHUTTERING, STUBS AND ANCHOR

LINKS
Reinforcing steel shall be fabricated and bent according to drawings and SABS 82
Before placement, the steel shall be thoroughly cleaned of mill scale and any
coatings that may destroy or weaken the bond.
The reinforcing steel shall be placed according to the drawings
The minimum cover to main reinforcing bars shall be 50mm.
The minimum cover to all embedded items, but excluding stubs, shall be 150mm.
The minimum cover to angle stubs and cleats shall be 75mm unless otherwise
shown on the drawings
A concrete slab of 300 x 300 x 75 mm shall be placed in the bottom of the
excavation in the position where the tower leg stub or anchor link plate should sit.
The stub or link shall be fixed to the rebar so that its position does not change
during the pouring of the concrete.
Cover blocks (75mm thick) shall be placed in bottom of excavation and the bottom
steel reinforcing placed on top of these blocks to ensure a minimum of 50 mm
concrete cover.

The reinforcing frame shall be properly constructed according the design and tied
together with no. 18 gauge annealed wire.
The foundation earthing strip shall be fixed between the stub or link plate and the
rebar with clamps to ensure that the foundation is properly earthed.
The vertical and horizontal angles of the stub or link plate shall be corrected and
fixed in place so that the top end of the stub or link plate will also be fixed during the
pouring of the concrete.
In the case of deadman anchors the link plate shall be covered with a PVC pipe with
a minimum concrete cover of 50 mm. This pipe must penetrate at least 100 mm
into the anchor block. This pipe shall also be fixed in position so that it will remain in
the correct position during the pouring of the concrete.
Cover blocks of 50 mm thickness are fixed to the top rebar layer in order to ensure
that concrete cover is thick enough at the top. The side cover should also be at least
50 mm of concrete.
17.5. FORMWORK
The forms will be mortar-tight and will withstand the pressure of concrete, the effect
of vibration as the concrete is being placed and all loads incidental to the
construction operations without distortion or displacement.
Where the bottom of the form is inaccessible, provision will be made to clean out
extraneous material before placing the formwork and pouring the concrete.
All exposed corners of the concrete will be chamfered approximately 20mm.
All form work dimensions will be checked, and if necessary, corrected before any
concrete is placed and approved by the Eskom Supervisor.
All forms will be treated with a form-release agent accepted by the Eskom
Supervisor before concrete is placed.
17.6. SLUMP TEST AND CONCRETE CUBE SAMPLES

Slump test shall be done in accordance with SABS Method 862
Test cubes shall be prepared in accordance with SABS Method 863 at the initiation
of concrete placement of each mix design and every day that concrete is batched
thereafter. Each set of test cubes shall consist of four cubes. One cube to be
crushed at seven days, two to be crushed at twenty eight days and one to be held
as spare in the event of a suspect result from one of the other three cubes.
17.7. CONCRETE PLACEMENT, CURING AND FINISH

All surfaces of the foundation upon or against which concrete is to be placed shall
be free from mud and/or loose or disturbed material
The surfaces of absorptive material, against which concrete is to be placed, shall be
moistened prior to the placing of concrete to prevent moisture being drawn from
fresh concrete TRMSCAAC5.2 (240-47172520) clause 6.6.10 C
The maximum discharge height shall be three meters, and for heights in excess of
this shall, a tremie pipe shall be used
If concrete must be placed under water, a suitable tremie, accepted but the
Supervisor, of sufficient length to reach the bottom of the excavation shall be used
Concrete shall be thoroughly settled and compacted onto a dense homogeneous
mass throughout the whole depth of each layer being consolidated, using internal
vibrators
Construction joint are to be avoided. If construction joints cannot be avoided and are
accepted by the Supervisor, the contractor may be permitted to make a construction
joint if the condition stipulated in TRMSCAAC5.2 (240-47172520) clause 6.6.11 A

are met.
The top surface of the foundation shall be at least a wood float finish, and shall be
contoured to shed water
The contractor shall provide means of maintaining concrete in a moist condition for
at least seven days after the placement of concrete. Exposed surfaces shall be kept
thoroughly wet 24 hours a day for this period. Formwork shall not be removed at
least 36hours after final placement of concrete after such formwork
17.8. BACKFILLING
The material to be used for compacted backfill shall be deposited in horizontal
layers, having a thickness of not more than 300mm before being compacted. The
material to be compacted shall contain no stones more than 150mm in diameter,
and be free from organic material such as trees, brush, and scraps etc.
The distribution of materials shall be such that the compacted material will be
homogeneous to secure the best practicable degree of compaction, impermeability
and stability
The surface around the backfill shall be carried to such an elevation that water will
not accumulate
17.9. POTENTIAL RISKS

Wrong soil type nomination - too conservative or too lenient resulting in the wrong
foundation for the soil type
Wrong pegging of foundation positions, foundation out of position
Poor construction of foundation concrete due to breakdown of equipment such as
poker vibrators, poor preparation of formwork, that is leaking of water and cement at
shutter joints. etc.
Problems with the delivery of concrete to site in time, with the concrete not casted in
the concrete setting time, resulting in under strength concrete.
Wrong steel reinforcement
Wrong angle or position anchor link plate or stub
Wrong tower stub or anchor link plate
Sides of foundation excavation collapsing - unprotected, excavated too early , water
washing into the excavation, unstable soils not shored
Poor quality control of concrete
Link plate not protected against corrosion
Personnel hurt while entering excavation because no ladder was available to enter
into excavation
Animals and people falling into the unprotected excavations
Poor curing of concrete
Wrong size excavation too large , too small, too deep
Wrong concrete strength delivered to site
17.10. SAFETY MEASURES

Good safety measures to be put in place for entering into or exiting the foundation
excavation
Excavated material to be stockpiled away from the edge of the foundation
excavation.

Large excavated boulders or rock pieces must be placed in a location or manner

that will prevent them from rolling or rolling back into the excavation.
In the case of unstable soils the side walls of the excavation are to be back-sloped
or shored to prevent the side walls from caving in or slipping.
All excavations must be properly barricaded to prevent injury to people or animals.
18. TOWER ERECTION METHOD STATEMENT

This section covers the various methods and practices to be employed in assembling and
erecting self-supporting lattice towers.
18.1. GENERAL
Only winches will be allowed to secure the Safety and Construction ropes when erecting
the structures and hoisting of hardware and other equipment. No vehicle may pull or lift any
equipment or structure member by any means other than with a vehicle mounted winch.
The pulling/lifting or tightening of stay ropes by driving the vehicle onto which the cable is
mounted is strictly prohibited.
During assembly and erection, members shall not be bent or overstressed to force them
into place.
The rest of the regulations with regard to point 21 of the construction regulations with
regards to vehicles should be adhered to at all times.
The field assembly and erection methods chosen will be influenced by such variables as
line and tower design, line route, terrain, climatic and seasonal weather conditions, the
impact of any environmental restrictions, line route access, schedule requirements and the
availability of critical resources in both man-power and equipment. Deviation of the method
statement is permitted if the contractor submits a concession request with a complete
method statement detailing the erection method.
18.2. ASSEMBLING OF TOWERS

The structures shall be assembled in strict accordance with the design drawings.
It is recommended that when assembling the self-supporting structures as many as

possible bolts shall be fitted finger tight with all connection faces touching to assemble the
part members and only bolts which present difficulties will be left over for the revision team
to complete the assembly. A minimum of 50% of bolts have to be installed in any member
in all cases.
Mud, dirt, white rust and other foreign material shall be removed from the contact surfaces
of joints prior to assembly. Steel members shall not be dragged over the ground or
otherwise handled in such a manner as to damage the galvanizing.
18.3. ERECTION
The following general points should be adhered to at all times to ensure that structures are
erected safely:
Cross arms and earth peak shall be lifted and attached to the structures only after
all bolts are fitted and tightened.

No tower shall be erected with a known shortage of members, unless consultation

with the line engineer capable of assessing the risk of the shortage.
Structures shall be completely erected with all members in place, all bolts installed
and tightened, punched and painted, and the entire structure inspected in
accordance with ITP forms to confirm conformance with the design prior to the
installation of conductors and ground wires.
When erecting structures in the vicinity of energized lines, care shall be taken to
ground these un-energized structures before any worker come in contact with them.
Structures can generally be erected in three ways:
Crane Method:
o The use of a crane is generally an efficient method for erecting lattice and
steel poles which were pre-assembled as a unit or in sections.
o Cranes with telescopic booms will be preferred over rigid cranes in rough
terrain.
o Pre-planning of the crane location at the structure site will allow for any
necessary grading or preparation of the ground for crane stability.
o The contractor must ensure that the position and capacity of the crane used
on the job is adequate to execute safely the lifting procedure.
Gin Pole Method
o This method will be used when tower heights and weights exceed the
capacity of the crane or where access to the site is restricted.
o The erection of the structure using a Gin Pole can be done piece by piece,
section by section or lifted as a complete structure.
o Safety precautions shall be taken when using this lifting method due to the
instability of the auxiliary structure.
Helicopter Method
o This method will be used when access to tower position is constrained and
the method has been approved by the Project Manager.
o Erection procedure with this method shall be prepared by the Contractor and
approved by the project manager prior to execution.
o The contractor must ensure that the capacity of the helicopter used on the
job is adequate to execute the lifting procedure safely.
o Special safety precautions shall be taken when using this lifting method.
18.4. METHODOLOGY FOR THE ERECTION OF SELF-SUPPORTING TOWERS

Verify that assembly has been inspected and released for erection by the client as per ITP
document:
PDPNEG-IRP-03 CR 9(1)(a)&(b) Assembly and Erection Inspection
Properly plan the lift to ensure:
All parts are assembled correctly as per the appropriate tower drawing.
All pieces of the tower are assembled in a layout so that the pieces can be lifted
easily in the correct order with a clear lifting path, all parts are assembled so that the
attachment points of the slings are accessible and the COG of the part is below the
sling attachment point.

o The reach of the crane as well as its capacity at the required extension of
the beam to lift each piece should be incorporated in the lifting plan and the
SWP.
All stubs are checked and measured to ensure they are in the correct position and
angle.
Position the crane on the outside of the stubs.
The legs can be lifted into place using the mobile crane / or truck mounted crane will be
used to erect the legs of towers on site before the rest of the tower erection begins.
Crane lifts leg onto stubs where it is fastened. Please refer to Appendix B: Tower weight
Table
After lifting the legs into position the individual legs will be stayed by means of at least two
stay wires until all four legs are connected to each other and the structure is stable.
Distances, heights and component strength ratings should be captured in the Safe Work
Procedure.
The body of the structure can be lifted in two ways:
The body is lifted as one piece and attached.

The crane lifts half the body using slings, once the half is lifted into place it will be
back-stayed temporarily until both pieces of the body is attached and creates a
stable structure. The back stay should be done through a lever operated hoist so
that the stay can be tightened or slackened slightly to help with the piecing together
of the two halves.
o Suitable anchors (e.g. heavy vehicle with proper blocks installed at wheels to
ensure it doesnt roll, concrete blocks, etc.)
o Only steel ropes are acceptable for use as a back-stay.
Equipment ratings should be sufficient to complete the work safely and should be
captured on the SWP.

The top parts of the body to which the K-frames attach are quite loose and should be
connected to a back-stay so that the members can be held in place until the K-frame is
lifted.
The K- Frames are raised towards the body and is then secured to the body through these
members.

The Crane lifts the beam complete with earth peaks into place, where it is secured by the
climbers. Because of the weight of the K-frames, they will sag outwards and make the
fitting of the beam difficult. To avoid this, lever operated hoists should be attached on an
appropriate joint from which the beam can be connected to the K-frame and the K-frame
pulled closer to the beam attachment points. The beam can then be bolted into place.
After erection ensure that:
Installation of all bolts is completed ensuring correct orientation of nuts as per

TRMSCAAC5 Rev 2.
Punch and paint all bolts.
Fix all minor galvanizing damage that may have been caused during erection.
18.5. METHOD FOR ERECTION OF GUYED CROSSROPE STRUCTURES

Verify that assembly has been inspected and released for erection by the client as per ITP
document:
PDPNEG-IRP-03 CR 9(1)(a)&(b) Assembly and Erection Inspection
Properly plan the lift to ensure:
Both masts are assembled correctly as per the appropriate tower drawing.

Both masts are assembled in a layout so that they can be lifted easily with a clear
lifting path, both masts are assembled so that the attachment points of the slings
are accessible and the COG of the mast is below the sling attachment point.
o The reach of the crane as well as its capacity at the required extension of
the beam to lift each mast should be incorporated in the lifting plan and the
SWP.
All stubs are checked and measured to ensure they are in the correct position and
angle.
Two options exist for lifting the crossrope structure.
a. Using a crossbeam to lift both masts and crossrope with insulators at the same time.
b. Pick up the first mast and secure it to the pin on the foundation. The guys can then be
pulled and connected to the stubs on the outer foundations as well as the temporary
stay which can be connected to a temporary anchor point or opposite guy foundation
anchors. Only once the mast is fixed on all three/four points can a climber ascend the
tower and disconnect the crane slings.
*Note: The service rope should be attached to the second mast together with a nylon
rope so that a climber can climb the first structure which is stable with the three/four
attachments to secure the service rope.
Pick up the second mast and secure it to the pin on the foundation. A climber can
ascend the first mast with the nylon rope attached to the service rope on the second
mast and pull it across to attach it to the first mast (While the crane is holding it slightly
straighter upwards it will be easier to attach). Once the crane lowers it further and the
mast leans backwards the guy wires can be attached. Once the guy wires are attached
a climber can ascend the mast and disconnect the crane slings.

Tensioning of the guy wire (guy wire with adjustable U-bolt) should be done by tightening it
to the required tension (check tower drawing but typically 10% of guy wire UTS) using a
come-along clamp connected to the guy anchor link service hole through a dynamometer.
Tension the dynamometer to half the required tension and then tighten the bolts on the U-
bolt until the tension reading on the dynamometer drops to zero. A too tight guy wire can be
easily recognized by a miss-aligned mast (rotation of the mast due to higher tension in the
adjustable guy wire), slight bending of the mast in a banana-like shape when checking the
straightness of the mast along the length looking upwards or a tight service rope after the
conductor is strung (weight of the conductor on the structure should allow for slight sag in
the service rope).
After erection ensure that:
Installation of all bolts is completed ensuring correct orientation of nuts as per

TRMSCAAC5 Rev 2.
Punch and paint all bolts.
Fix all minor galvanizing damage that may have been caused during erection.
18.6. QUALITY ASSURANCE/QUALITY CONTROL MONITORING

For all aspects of the construction, the contractor will comply with the design and method
statement as set out by the designer.
All relevant ITP documentation should be signed off, for each aspect of the design, after
inspection by the appointed site representative of both the contractor and the client as set
out in the construction regulations on the relevant ITP forms.
18.7. HAZARDS
Environmental:
Sharp objects like tower steel, conductor ends, planks with nails etc.
Nip points on ring views, block and tackles, press etc.
Noise from equipment.
Mud, wet steel, long grass, loose stones, soil and uneven surfaces, excessive wind.
Crane can sink into the ground.
Moving trucks and LDVs.
Human:

Miscommunication between winch/tensioner/crane operators.

Falling objects like tools, bolts and nuts etc.
Working at heights on towers and conductors.
Climber attaches to a portion of the tower suspended by the crane.
Poor rigging practice incorrect use of shackles, attachment below center of gravity,
overloading of crane etc.
Employees not using PPE / climbing equipment correctly.
Equipment:
Lifting of equipment and materials with slings / cranes slings can break / crane faulty etc.
Sudden release of tension in slings/conductor/stay-wires.
Winching of the conductor/moving wires.
Overloading of the structure in a temporary state of weakness because of loose bolts etc.
during erection / loading during stringing.

19. DRESSING, STRINGING AND REGULATING METHOD STATEMENT

19.1. ATTACHING OF INSULATOR STRINGS AND RUNNING BLOCKS DRESSING
A sample of each hardware assembly should be assembled together with its corresponding
insulator and tower shackle (all with split pins fitted) for inspection in the site camp. These
can be hoisted onto planted wood poles. The importance of this is to ensure that all
components fit as per the approved hardware drawings and doesnt create a hold-up once
the stringing can start. The design engineer should be notified for inspection and correct
assembly inspection can be signed off.
To dress the structures, the corresponding hardware and insulator assemblies should be
assembled at the tower position. The insulators should be inspected for damage like cracks
/ chipping and the surface cleaned of any foreign matter before hoisting the assembly to the
tower attachment point. The split pins should also be fitted and opened to secure all
components except the conductor clamps which are not fitted at this stage.
A running block is also fitted to the hardware yoke plate or to the bottom of the insulator
together with a rope for pulling through the pilot wire. Once all this is fitted and checked, a
climber can ascend the structure and attach a pulley to a suitable service hole on the
landing plate or a structural joint (attaching this to a member in the middle of two joints will
cause bending of the member) close to the attachment point.
A steel rope is fed through the pulley and attached to the assembly below the first few
insulators (to allow for movement of the attachment point) and the steel rope is also fed
through a pulley secured to the tower leg and to a winch. The assembly can then be
winched up to the hardware landing plate on the structure while the climber guides the
lifting process by giving hand signals to the winch operator.
19.2. SELF-SUPPORTING SUSPENSION STRUCTURES / GUYED V

For self-supporting structures with a VVV and IVI hardware configuration the assemblies
with insulators should be assembled on the ground (as per the hardware suppliers
drawing), and the running blocks attached to the bottom of the assembly where the yoke
plate would normally be installed.
A nylon rope should be fed through the center pulley of the running block, long enough so
that the two ends that are connected with a 120kN shackle have sufficient slag on the
ground after the Vstring has been installed to use it to pull the pilot cable through the
running block. This rope will also be used as a tag line to pull the assembly away from the
tower steel while it is hoisted into position.
Two winches will be placed about 10m away from the tower base in-line with the
attachment point of the assembly being lifted.
Two climbers will ascend the tower and attach snatch blocks to the service holes or other
appropriate rigging point near the assembly attachment point and feed a steel rope through
the snatch block of which one end will be attached to the assembly and the other will be fed
through another snatch block secured to the bottom of each leg before being attached to
the winches.
To attach the steel rope to the assembly, it can be wrapped around the base of a glass disc
with a gag method to prevent slippage, leaving enough slack discs for a worker to lift and
attach the assembly to the landing plate. Alternatively for a composite insulator, the steel
rope should be attached to the running block or alternative attachment point below the
composite insulator, and the top of the insulator tied to the steel rope with a nylon rope so
as not to damage the silicone of the insulator and so that the worker on the tower can easily
untie the insulator and attach it to the landing plate.
The assembly and running block can now be lifted by pulling simultaneously with both
winches, keeping the top attachments level, the assembly will at the same time be pulled
away from the structure by the workers pulling on the tag line.
When the assembly attachment points reaches an appropriate distance from the landing
plate, the workers on the structure will instruct the lifting operation to stop by
communicating with hand signals to the supervisor and then attach the assembly to the
landing plate before loosening the steel lifting wire.
When the assembly reaches the attachment point, the free end of the hardware assembly
point can be attached manually to the hardware landing plate.
While lifting the assembly for the center phase on a self-supporting structure or a guyed V
structure, the tower members could obscure the path that the assembly would normally
follow during lifting and workers should pull the assembly away from the structure using the
rope fed through the running block to keep the assembly from hitting the structure which
could damage the structure, assembly and insulators.
19.3. SELF-SUPPORTING STRAIN STRUCTURES

At a strain structure, depending on the angle of deviation, a running block should be hoisted
and attached to the landing plate. If the angle is large, two running blocks may be needed
to accommodate for the angle of deviation so that bending of the parts passing over the
running block doesnt occur because of the large angle of deviation.
19.4. EARTH WIRE

Similarly the dressing of the earth wire running blocks should occur. The earth wire has to
be strung before the stringing of the conductors occurs. Special care should be taken
to ensure that the pilot wire is not pulled underneath the guy wire on the Crossrope
structure. Only nylon ropes are to be used as pilot wires when crossrope structures are
dressed.
19.5. OTHER WAYS OF DRESSING

It is encouraged that safer and faster ways of lifting assemblies should be explored by the
contractor with the proper acceptance from the client. These include and are not limited to:
Lifting of the Crossrope and assemblies using a spreader bar attached to the crane.
Planning should be done so that the spreader bar and assemblies are on site during
the tower erection while the crane is available on site.
Using a sliding ladder which moves on the service rope to allow access to the
crossrope and assemblies.
Lifting the whole structure as one with both masts and crossrope with assemblies
attached to a single spreader bar.
19.6. TEMPORARY BACK STAYING OF STRUCTURES

The contractor is responsible to ensure that all structures can cope with the loads that he
imparts on the structure during construction. Temporary back-stays should be installed first
before loading on the opposite side of the structure commences.
During construction the conductors may be dead-ended on an angle strain structure

temporarily only on one side. The contractor should then provide temporary back-stays /
anchors on the cross arms and earth peaks to counter these loads.
It might be necessary to install double stays to counter the loads imparted by the conductor.
It is therefore necessary that the contractor calculate the loads, check if the structure can
handle these on the tower test loads, and design an appropriate anchor to counter these
loads.
Standing trees or legs of towers should not be used as anchors for the stay wires.
Stays should be fixed at approximately 30 degrees to the ground or a distance of 1.5 times
the attachment height of the respective cross arm.
19.7. STRINGING OF CONDUCTORS

The conductor is one of the most expensive components of any transmission line and
should be treated with care to avoid damage.
The sequence of stringing should be:
Earth wire first

Middle phase
Outer phases.
All conductors (earth wire included) will be tension strung; keeping the conductor off the
ground during the entire stringing process, minimizing surface damage and facilitating
overcoming obstacles such as road crossings.
A pilot line should be used to pull the conductors by attaching it to a swivel, a head board
and then to the conductors with a woven grip sock and then pulling the conductor from a
drum station through a bull wheel type tensioner, to the pulling station.

The process consists of four main processes namely:
Pulling the pilot cable

Stringing of the conductor / earth wire
Regulating the conductor / earth wire
Clamping in of the conductor
*Note: Reference should be made to TRMSCAAC5 Rev 2 for specifications regarding
stringing tensions, sag, creep, etc.
Equipment required for tension stringing include:
Reel/drum stands which can pay out the conductor by supporting the drum off the
ground behind the tensioner. It should be equipped with brakes to prevent the drum
from turning when stringing is stopped
Tensioner made up of urethane or neoprene coated bullwheels which is designed to
hold tension against a pulling conductor by friction of the conductor reeved around
the grooves of the bullwheels.
Pulling vehicle to pull the pilot wire along an accessible servitude (in inaccessible
places a helicopter or other accepted methods may be used to pull the pilot wire).
Puller made up of bullwheels similar to that of a tensioner to pull the pilot wire
through onto a pilot wire winder drum. It should be mounted with an engine to drive
the drum mechanically.
Conductor running blocks which is sized correctly for the size of conductor being
pulled and should be lined with neoprene or urethane to prevent damage to the
conductor. Sheaves should be able to turn freely or it will adversely affect
stringing/regulating.
Grounded running blocks which is the same as a normal running block but have
additional unlined rollers that make electrical contact with the conductor and is
connected to the ground.
Running grounds are spring loaded unlined rollers that ensure electrical contact with
the conductor and can be connected directly to a suitable ground and then placed
between the tensioner and the first structure and between the last structure and the
puller.
Pulling lines / pilot cables which are non-rotating, i.e., the rope will not imply twisting
or torque to the conductor.
Swivels are devices used to connect pilot cables to the conductor and is constructed
so that each end will rotate independently thus preventing a transfer of torque from
the pilot cable to the conductor or between different conductors.
Woven grip / socks are a loosely woven sock which fits over a conductor and then
constricts under tension to grip the conductor.
Running board / headboard is commonly referred to as a crocodile/gator and is
used to connect multiple conductors to a single pilot cable.
Once pull-sections are identified, the puller, tensioner and drum stand placement can be
done. The placement of the equipment is of the utmost importance because of its effect on
the loading on the structures. Distance from the first structure to the puller / tensioner
should be at least three times the conductor attachment height as measured to the
attachment point of the running block.
All equipment at both ends (puller and tensioner) should be grounded and bonded together
to ensure that no difference in ground potential exists.

Pull sections should be chosen to maximize use of conductor lengths in order to reduce the
number of joints. The use of drums should be planned such that minimum short lengths of
conductor / earth wire remain on the drum. These short pieces can then later be used for
the making of jumpers.
The pilot cable can be pulled from the puller drum stand with a pulling vehicle such as a
tractor. It should be pulled approximately 1.5 times the attachment height of the conductor
past the structure and then disconnected from the pulling vehicle. It can then be tied to the
rope passing through the running block and pulled through the running block before then
being attached to the pulling vehicle again. This should be repeated until the pilot wire
passes through all structures and can be connected to the running board on the tensioner
side of the pull.
The puller can now gently take up the slack on the pilot wire and pull through the conductor
which is attached to the head board.
Running blocks may become stuck during the stringing process and therefore cause
problems. A running block that swings in the direction of the pull is a clear visual indication
of a stuck or defective roller.
A person should follow the running board in a vehicle as it passes through the running
blocks so that he can stop the process using radio communication with the puller and
tensioner should anything become stuck.
19.8. SAGGING / REGULATING

After installation of the conductor it will not be allowed to hang in the running block for more
than 72 hours before being sagged / regulated.
For sagging of the conductor a few methods can be employed:
The basic principle is that a come-along clamp is fitted onto each conductor at a distance
far enough from the tower to allow for enough slack of the conductor to be taken up while
still allowing a fair section of slack conductor (lead) from the come along clamp and the
tower to allow (after final sagging) for the lead to be taken up to the attachment point for
purpose of measurement. To do this, two methods can be employed:
19.8.1. The come along clamp can be connected through a pulley arrangement
connected to the structure members onto a winch anchored at the bottom of the
structure to a dead-man anchor (or concrete block etc.).
The attachment to the structure can be through a series of slings connected at

appropriate joints or to a specially purpose fit yoke plate which allows for the
attachment of the pulley blocks and attaches to the structure landing plate at the
service holes.
19.8.2. The come along clamp can be connected through a pulley arrangement
connected to the front of the hardware assembly and from there onto a winch
anchored at the bottom of the structure to a dead-man anchor (or concrete block
etc.).
The attachment to the hardware can be through a series of slings connected at

appropriate service holes which leaves the hardware attachment point open for
attachment of the dead-end after crimping.

Advantages of this arrangement are:

Easy attachment of slings with pulleys at dedicated service holes.
Better measure of exact conductor length before cutting of the conductor.
19.9. CLAMPING IN OF CONDUCTORS / DEAD-ENDING

The clamping in portion of the stringing operation involves the work following the sagging
and plumb marking of the conductors. This entails removing the conductors from the
travelers and placing them in their permanent suspension clamps attached to the insulator
assemblies.
Clamping begins once the conductor has been brought to sag and is initiated by placing
plumb marks on the conductor directly below the insulator attachment points on the
structures with a plumb marker pole. This marking is done as soon as possible after
reaching sag to minimize the effect of creep and possible movement of the conductor
between spans. In rugged terrain, clamping offsets may be used whereby the suspension
clamp, rather than being placed at the plumb marks, is offset a calculated distance from the
mark to compensate for the unevenness of the terrain and to allow the insulator assemblies
to hang vertically when all structures have been clamped in. When clamping is being done
care must be taken to ensure that conductors are grounded prior to clamping, despite the
fact that the lines being clamped are not attached to any electrical source. This is explained
in the earthing method statement.
After the conductors have been marked, personnel lift the weight of the conductor, allowing
the running blocks to be removed and the suspension clamps and armor rod, if used, to be
placed on the conductors. Lifting is normally done by using a hoist suspended from the
structure and a conductor lifting hook that is designed not to damage the conductor. After
placing the suspension clamps on the conductor, the hooks are lowered, thereby placing
the weight of the conductor on the suspension clamp and completing the assembly. Where
bundled conductors are used, the multiple conductors may be lifted simultaneously by use
of a yoke arrangement supporting the hooks and a single hoist.
19.10. VIBRATION DAMPER INSTALLATION
Vibration dampers should be placed on the conductors immediately following clamping in to

prevent any possible Aeolian vibration damage. Damage can occur in a matter of a few
hours at initial tensions and the personnel has already ascended the structure to do the
clamping in and is therefore in the correct place and properly earthed.
19.11. SPACER DAMPER INSTALLATION

Spacer dampers should also be installed immediately following the clamping in operation.
Spacer dampers can be installed using a bicycle / conductor car. The location and
spacing of the spacer dampers vary with manufacturer and should be installed according to
their recommendations regarding spacing, unequal spacing and tolerance.
19.12. GENERAL
Only winches will be allowed to secure the Safety and Construction ropes when dressing
the structures and hoisting of hardware and other equipment. No vehicle may pull or lift any
equipment by any means other than with a vehicle mounted winch. The pulling/lifting or
tightening of stay ropes by driving the vehicle onto which the cable is mounted is strictly
prohibited.

During dressing or regulating, members shall not be bent or overstressed by attaching

equipment or slings to members in the middle of two attachment points. Lifting equipment
or slings should always be attached to a joint or landing plate.
The rest of the regulations with regard to point 21 of the construction regulations with
regards to vehicles should be adhered to at all times.
The field assembly and erection methods chosen will be influenced by such variables as
line and tower design, line route, terrain, climatic and seasonal weather conditions, the
impact of any environmental restrictions, line route access, schedule requirements and the
availability of critical resources in both man-power and equipment.
19.13. FORMWORK AND SUPPORT WORK

Temporary guying may be required to support certain parts of a structure while the
stringing/regulating is taking place. The contractor is responsible to check the loads
imposed on the structure during his stringing/regulating procedure and to check if the
structure can handle these loads or if temporary guying is required and the strength of this.
The design loads of the structures will be given to the contractor by the designer.
Both temporary bracing and temporary guying or back-staying shall be treated as formwork
as set out in the construction regulations:
10. A contractor shall ensure that
(a) all formwork and support work operations are carried out under the supervision of a
competent person who has been appointed in writing for that purpose;
(b) all formwork and support work structures are adequately designed, erected, supported,
braced and maintained so that they will be capable of supporting all anticipated vertical and
lateral loads that may be applied to them and also that no loads are imposed onto the
structure that the structure is not designed to withstand;
(c) the designs of formwork and support work structures are done upon close reference to
the structural design drawings and where any uncertainty exists, the structural designer
should be consulted;
(d) all drawings pertaining to the design of formwork or support work structures are kept on
the site and are available on request by an inspector, contractor, client, clients agent or
employee;
(e) all equipment used in the formwork or support work structure are carefully examined
and checked for suitability by a competent person, before being used;
(g) if, after erection, any formwork and support work structure is found to be damaged or
weakened to such a degree that its integrity is affected, it shall be safely removed or
reinforced immediately;
(h) adequate precautionary measures are taken in order to
(i) secure any deck panels against displacement; and
(ii) prevent any person from slipping on support work or formwork due to the
application of formwork or support work release agents;

(k) provision is made for safe access by means of secured ladders or staircases for all
work to be carried out above the foundation bearing level;
(l) all employees required to erect, move or dismantle formwork and support work
structures are provided with adequate training and instruction to perform these operations
safely.
19.14. TOWER BOLTS
The diameter, type and length of bolts as shown on the structure drawings shall be used for
each connection.
Bolts on the legs, body and superstructure K frame of self-supporting towers close to
joints shall not be tightened, punched and painted before erection of the tower to facilitate
assembly and avoid having to force members into position or struggling to assemble parts
while the load is suspended from a crane.
Tower bolts shall be installed so that the nuts are to the outside of the tower or, in the case
of horizontal members, to the top of the connection. For long slender columns, the nuts will
be tightened before lifting to minimize deflections during lifting. Washers shall be put on
bolts so that the flat slightly concave surfaces are against the tower steel members. Bolts
shall not be driven in any manner that will distort them or damage the threads.
20. CONSTRUCTION EARTHING METHOD STATEMENT

This section covers the various methods and practices to be employed in earthing of the
conductors during the stringing-, regulating- and clamping-in procedures.
20.1. PRELIMINARY INSPECTIONS

All earthing components, earth leads, etc. should be checked and inspected for proper
installation. Once this is inspected it will be signed off on the corresponding ITP form by the
supervisor appointed in terms of the Construction regulations act as an on-site
representative of the designer/client as well as by the contractor:
PDPNEG-IRP-09 Stringing report
After the inspection of the proper application of the various earthing practices by the
supervisor, the corresponding practice of stringing-, regulating-, clamping-in can occur.
A notification of inspection should be sent to the designer on the following form:
PDPNEG-FM-03 Inspection notification
This is to inspect the first off application of the earthing so as to comply with the
construction regulations point 9. Structures (2) The designer of a structure shall (f) carry
out sufficient inspections at appropriate times of the construction work involving the design
of the relevant structure in order to ensure compliance with the design and a record of
those inspections is to be kept on site.
*Note: The entire line, including conductors, is deemed a structure and the safe
construction thereof requires sufficient inspection by the designer.
Although the designer only inspects the first off each type, the supervisor should inspect
and complete the same form with inspection for each activity.

Once this first off inspection is carried out by the designer the construction can continue.
20.2. GENERAL
When stringing and regulating conductors close to a parallel energized line(s), and when
transferring conductor onto suspension and strain hardware and when fitting jumpers at
strain towers, there is a real risk for workers to get injured or killed as a result of induced
voltage and current.
This risk can be avoided by applying safety earthing in two levels, namely 1 set of working
earths on either side of the work sites, and a fall-back set of earths further away (master
earth) that can act as a backup should anything go wrong with the earths closer to the
worksite. It is also assumed that proper earthing tools are used, and that earthing will
always be applied and be removed using an insulated earth stick.
The main aim of the earthing described above is to create a preferred path for induced
energy (described in engineering terms as electrostatic and electromagnetic induction
which leads to measurable voltage and current levels). It is further implied that the worker
should never become part of the electrical circuit through the rigorous application of the
working earths.
Note that the earthing system that is designed and intended to be part of the operation of
the line during its lifecycle is to be seen as a separate earthing system.
Internationally, line construction contractors are required to apply the safety earthing
principles as laid down in in the following standards, including the adherence to earthing
equipment specifications:
IEC 61328-2003 Live working Guidelines for the installation of transmission line
conductors and earthwires stringing equipment and accessory items.
IEC 61230-2008 Live working Portable equipment for earthing or earthing and short-
circuiting
ITEE Std 524- Guide to the installation of overhead transmission line conductors
1992
IEEE Std 524a- Guide to grounding during the installation of overhead transmission
1993 line conductors.
Of particular interest is the IEEE Standard 524 which explains in good detail how the safety
earthing principles are working and how the contractor should proceed to do the various
activities from the stringing phase until the conductor installation work is finished.
20.3. EQUIPMENT DETAILS

The equipment details that are most pertinent can be summarized as follows: Minimum
20mm2 copper cable, or aluminum cable equivalent to 20mm2 copper.
Working Earth Master Earth

Minimum 20mm2 copper cable, or aluminum Minimum 70mm2 copper cable, or aluminum
cable equivalent to 20mm2 copper. cable equivalent to 70mm2 copper.

Figure 20.1 : Example of insulated earth sticks

*Note: All earths should be applied using an insulated earthing stick.
20.4. INDUCED VOLTAGES AND CURRENTS THAT POSE A RISK

If either the master earths or the working earths cannot be connected to a towers steel (to
use the towers earthing system), it is specified that rod earths be driven into the ground
and tested to see that a low enough resistance is achieved for it to be effective. This is an
area where contractors should be strictly monitored to make sure that the correct technique
and equipment is used to verify the effectiveness of drive rod temporary earth electrodes.
Although it will not always be possible to achieve low ohm values, there is a suggestion on
the table that a value below 100 ohms be achieved. If this value is not achieved by the first
driven rod, it implies that more rods be driven in a crows foot arrangement and
interconnected with leads.
The two figures below demonstrate the capacitive coupling and magnetic coupling
situations. In practice, a mix of the two coupling mechanisms will be present. The magnetic
coupling mechanism can be more dangerous especially if the workers on site do not
understand how it actually manifests itself. A single earth applied to a conductor which is
subjected to magnetic coupling phenomena is a death-trap waiting for the worker to touch it
to complete and set the circuit up to conduct electrical current.

Figure 20.2: Electrostatic coupling mechanism

With a single earth in place, the electrostatic induction (which would be present if energized
parallel lines are energized but not carrying current) can be dealt with quite effectively using
only 1 earth (instead of the worker providing that path to earth).
Figure 20.3: Electromagnetic coupling mechanism

When there is no voltage on the parallel energized lines but if they carry current, which is
admittedly an unlikely scenario but used here for explanatory purposes, the worker is facing
a lower risk when no earths are applied than when 1 earth is applied. If only 1 earth is in
place, the worker becomes the second earth which completes the electrical circuit for
current to be conducted.
As soon as more than 2 earths are applied, the chances of the worker becoming a
preferred path for electrical current are reduced. When two working earths are applied on
both sides of the work site, and two master earths further away, redundancy in the
temporary earthing system is provided and the risk to the worker is reduced to a very low
level.
20.5. Method for avoiding induced voltage and current effects during construction
activities
The use of running blocks with a traveler ground is suggested by the IEEE 524 standard
and provides a very good security system against accidental electrocution when
transferring conductors from running blocks onto insulator assemblies. These devices also
provide an additional remote earth connection at each suspension tower.
Figure 20.4: Application of traveller ground

In summary, the following activities and procedures are potentially risky in terms of steady
state (50Hz) induced electrocution:
Stringing a new line close to parallel energized lines or when crossing them
Regulating and fitting of dead-ends, and transferring conductors from running blocks on
suspension towers to the insulator hardware
Fitting of jumpers on strain towers
Dismantling of conductor from an old line that runs in parallel or crossing existing
energized lines
Transient coupling, from lightning or switching impulses, although far less likely to occur at
a critical moment in time, will also be limited to a large extent if the 50Hz steady state
induction risk is properly eliminated.
20.6. QUALITY ASSURANCE/QUALITY CONTROL MONITORING

For all aspects of the construction, the contractor will comply with the design and method
statement as set out by the designer.
All relevant ITP documentation should be signed off, for each aspect of the design, after
inspection by the appointed site representative of both the contractor and the client as set
out in the construction regulations on the relevant ITP forms.
20.7. HAZARDS
Environmental:
Sharp objects like tower steel, conductor ends, planks with nails etc.
Nip points on ring views, block and tackles, press etc.
Noise from equipment.
Mud, wet steel, long grass, loose stones, soil and uneven surfaces, excessive wind.
Crane can sink into the ground.
Moving trucks and LDVs.
Electrostatic coupling emanating from capacitive coupling (voltage on energized parallel
line inducing voltage and current on the conductor being strung or modified or removed on
the line being worked on.
o Main risk is that the worker will put him/herself in a position to become part of the
discharge current which will flow into earth to drain the electrostatically induced
energy.
Magnetic coupling (current flowing in the phase conductors of the parallel energized
line(s) inducing voltage and current on the conductor being strung or modified or removed
on the line being worked on.
o Main risk is that the worker will place him/herself in a position to become part of the
current which will flow back through a ground loop.
Human:
Miscommunication between winch/tensioner/crane operators.

Falling objects like tools, bolts and nuts etc.
Working at heights on towers and conductors.
Climber attaches to a portion of the tower suspended by the crane.
Poor rigging practice incorrect use of shackles, attachment below center of gravity,
overloading of crane etc.
Employees not using PPE / climbing equipment correctly.
Electrocution due to improper earthing attachment method
Equipment:
Lifting of equipment and materials with slings / cranes slings can break / crane faulty etc.
Sudden release of tension in slings/conductor/stay-wires.
Winching of the conductor/moving wires.
Overloading of the structure in a temporary state of weakness because of loose bolts etc. during
erection / loading during stringing.
20.8. DEFECT/NONCONFORMITY MANAGEMENT
Any deviation from this method statement or design without the notification of the project
manager and designer in writing (on the relevant ITP form for concession request
PDPMAN-FM-143) will be recorded by a defect/non-conformity (PDPMAN-FM-127 and
PDPMAN-FM-128) which forms part of the record of non-compliance with the Occupational
Health and Safety Act and Regulations (85 of 1993).

On the non-conformance/defect report reference should be made to the contractors non-

conformance to the design which breaches point 5. (1) A principal contractor shall provide
and demonstrate to the client a suitable and sufficiently documented health and safety plan,
based on the clients documented health and safety specification contemplated in regulation
4(1)(a), which shall be applied from the date of commencement of and for the duration of
the construction work and shall therefore be subject to point 30 of the act: Offences and
penalties: Any person who contravenes or fails to comply with any of the provisions of
regulations 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25,
26, 27 and 28, shall be guilty of an offence and liable upon conviction to a fine or to
imprisonment for a maximum of 12 months.

14.7.4 Matimba-Spitskop 2 400kV Loop-In and Out Transmission Line Specification Rev0 PDF

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14.7.4 Matimba-Spitskop 2 400kV Loop-In and Out Transmission Line Specification Rev0 PDF

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TRANSMISSION LINE SPECIFICATION

Title: Matimba Spitskop 2 400kV Template Unique Identifier: 240-86978162

Area of Applicability: Engineering

Documentation Type: Report

Total Pages: 120

Next Review Date: N/A

Disclosure Classification: CONTROLLED

LES0019 Revision 0 November 2014 Page 1

MATIMBA SPITSKOP 2 400KV LOOP-IN AND OUT OF MEDUPI. BAY REPOSITIONING

Transmission Line Specification

Lines Engineering document no. Revision no. Date

LES0019 0 November 2014

LES0019 Revision 0 November 2014 Page 2

0 First revision Nov 2014

LES0019 Revision 0 November 2014 Page 3

3. MECHANICAL SPECIFICATIONS .............................................................................. 12

4. FOUNDATIONS, CIVIL AND GEOTECHNICAL SPECIFICATIONS............................ 17

5. EARTHING REQUIREMENTS ..................................................................................... 18

6. INSULATOR REQUIREMENTS ................................................................................... 24

9. CONSTRUCTION METHODOLOGY ........................................................................... 27

APPENDIX B: TOWER OUTLINE DRAWING ........................................................................... 31

12. APPENDIX D: STRUCTURES ADDITIONAL INFORMATION .................................... 46

13. APPENDIX E: FOUNDATIONS ADDITIONAL INFORMATION ................................... 51

14. APPENDIX I: TECHNICAL TENDER SCHEDULE AND RETURNABLES .................. 62

15. APPENDIX J: AS BUILT INFORMATION REQUIREMENTS ...................................... 67

LES0019 Revision 0 November 2014 Page 5

17. FOUNDATION CONSTRUCTION METHOD STATEMENT ......................................... 87

18. TOWER ERECTION METHOD STATEMENT .............................................................. 91

19. DRESSING, STRINGING AND REGULATING METHOD STATEMENT ..................... 99

LES0019 Revision 0 November 2014 Page 6

20. CONSTRUCTION EARTHING METHOD STATEMENT ............................................ 106

LES0019 Revision 0 November 2014 Page 7

Line length 2 x 2km lines

Quad Tern (IEC: 403.77-A1S1A-45/3.35+7/2.25) will be utilised on the loop in

1 16kA - 48 Core OPGW

Insulators Composite long rod (31mm/kV creepage).

LES0019 Revision 0 November 2014 Page 8

The following tower family will be used:

Self-Supporting type towers:

Galvanizing of 105 m on Towers and Hardware

As built information to be provided as per Eskom requirements, see Appendix J

Line is to be labelled as per Eskom transmission spec TSP 41-604

Tower footing resistance to be below 30 for 400kV towers.

Line Impedance Measurements to be done prior to energising utilising

Anti-Theft Spec 474-285 & Technical Instruction 12TI-013

LES0019 Revision 0 November 2014 Page 9

Fall Arrest Fall arrest system must be removed after construction.

Use latest method statements available, if different method statements are

LES0019 Revision 0 November 2014 Page 10

Self-Supporting Suspension Structure 400kV Tower Type

Self-Supporting 0 - 45 Angle Strain 400kV Tower Type

Self-Supporting 45 - 70 Angle Strain & 0 Terminal 400kV

30-120kN_ESUS1-001 Suspension earth wire assemblies

30-120kN_ESTR1-001 Strain earth wire assemblies

The tower and hardware drawings can be found in Appendix C.

2.2. TECHNICAL TENDER EVALUATION CRITERIA

LES0019 Revision 0 November 2014 Page 11

3.2. GENERAL LINE DETAILS

Line voltage phase-to-phase 400 kV

3.2.1. Wind Loading

3.3. CORROSION PROTECTION

As an alternative to galvanized bolts and nuts corrosion protection in the form of

3.4. PHASE CONDUCTOR AND GROUNDWIRE DETAILS