TECHNICAL SPECIFICATION FOR MANUFACTURE OF ANGLE … - 372_1.pdf · 2019. 11. 17. · Round bars according to EN 10060, square bars according to EN 10059. Hollow Profiles (such as

Israel Electric Corp. Ltd.

Grid Engineering Division

Distribution Engineering Unit

Network Design & Construction

Specification NPS - 372

FOR MANUFACTURE OF ANGLE AND

CHANNEL TOWERS, THEIR PARTS

AND STEEL GRID ITEMS

Edition no.: 0

Issue date: SEPTEMBER 2019

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TECHNICAL SPECIFICATION

FOR MANUFACTURE OF ANGLE

AND CHANNEL TOWERS, THEIR

PARTS AND STEEL GRID ITEMS

Prepared by : E. Berkover - signed -

Checked by: A. Dolkin - signed -

approved by : N. Grinberg - signed -

SEPTEMBER 2019









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Table of contents

Paragraph Page 1.General 2.Threshold conditions 3.Other conditions 4.Documents for the proposal 5. Materials and standards 6. Technical demands 6.1 Tolerances 6.2 Cold forming 6.3 Welding 6.4 Coating 6.5 Items marking 7. Packing, packages marking, storing at the manufacturer yard, transporting 7.1 Welded towers and extensions 7.2 Assembled and disassembled arms 7.3 Other items (Legs etc.) 8. Demands from the winning supplier 9. Demands for prototype approval, control for the continuous production and

transportation

9.1 Demands for prototype approval 9.2 Control of continuous production 10. Appendixes Appendix "A-1" – Two angles connected with back plate Appendix "A-2" – Angle and plate connection Appendix "A-3" – Angles connection with angle Appendix "A-4" – Profiles U connection Appendix "A-5" – Directive for penetration and fillet weld check Appendix "A-6B" – Marking pattern for channel tower and extension Appendix "A-6G" – Marking pattern for High and Low voltage crossarms Appendix "A-6D" – Marking pattern for angle tower or extension Appendix "A-7" – Instructions for connecting steel structures connection with

bolts

Appendix "A-8" – Internal connection between two angles by welding a

connection angle

Appendix "A-9" – Connection of channel profile to angle profile in angle









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tower

Appendix "A-11" – Process Control for the " Hot Zinc Coating" chapter Appendix "A-13" – Manufacturer's experience statement form Appendix "A-14" – Screws and nuts

1. General:

This specification describes the requirements pertaining to the manufacture of welded

towers (Angle and Channel) and their parts, different steel grid items, including arms,

legs Etc. The specification also describes the different work stages which includes

welding, Cold forming, galvanizing, marking, packing and storing.

Important note:

In the production of trench pillars after coating in hot zinc, safe painting is needed, as

required on drawings and in specification K-2590. There will be no separate payment for

this painting, the painting and materials cost must be taken in consideration at the time

of filing the commercial proposals.

At the end of the specification there is an appendix chapter containing: welding details,

instructions for joining steel structures with bolts, welding test instructions and marking

examples.

The manufacturer will supply the raw materials to manufacture and manufacture the

items according to the drawings, according to this specification, European standards,

Israeli standards and the proper ATSM standards.

Security and quality assurance requirements will be based on IEC specifications for

quality control Q-App-02 REV4..

Any change or deviation from specification requirements and production drawings must

have pre approval of the national network or a qualified representative of IEC.

In case of incompatibility or discrepancy between the various documents, follow the

order of precedence as follows: programs to perform this specification from other specifications and standards.

2. Threshold conditions:

In accordance with the attached documents of the I.E.C "Supply and storage division".

3. Other conditions:









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3.1 The bidder will have the equipment, manpower and proper storage areas as

requested in the tender.

3.2 According to IEC request and according to its decision at the technical stage of the tender, the company's representatives may visit the bidder's factory for the purpose of an

impression to provide technical opinion on his proposal.

In coordination, the bidder will allow the visit and present the factory to IEC

representatives.

4. Documents for the proposal:

The bidder will submit together with his offer the following Documents:

4.1 The manufacturer, as a required proven experience, will convey a statement from a

senior position in the factory, as detailed in Appendix A-13, on the production

experience, for at least three years out of the last 5 years.

4.2 The manufacturer will attach the sketch/sketches, signed by the manufacturer; next

to every catalog number in the sketch will indicate its P/N.

4.3 In the tender for angle towers and their parts – the bidder will deliver the name of the

manufacturer with the automatic computerized machine for drilling and punching

the towers legs, that will do the job.

If the bidder does not have a machine, the manufacturer will submit an approval

having the right machine, and willing to do the job required if the bidder wins the

tender.

4.4 In the tender for channel towers, the type of paint offered to be used for painting will

be delivered by the bidder (As required in specification K-2590).

4.5 The manufacturer must fill out the attached questionnaire and submit it with the

offer.









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Questionnaire for filling by the manufacturer

The manufacturer is asked to fill out the required details in the body of the questionnaire

and to add comments if necessary.

1. General

Manufacturer's name:_____________________________________________________

Manufacturer's address: ___________________________________________________

Phone number: __________________________________________________________

Fax number: ____________________________________________________________

Details of the questionnaire fill: Name, position and date of the questionnaire's fill:

_______________________________________________________________________

_______________________________________________________________________

2. Storage areas for raw materials and finished products:

A. Specify area size for storing raw materials and finished products

_______________________________________________________________________

_______________________________________________________________________

B. Specify size of space for assembling prototype

_______________________________________________________________________

_______________________________________________________________________

C. Specify whether these areas are owned by you or at your possession (paragraphs

A&B)

_______________________________________________________________________

_______________________________________________________________________

3. Technical and engineering production capacity









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A. List customer names for which steel constructions were manufactured in similar or

large sizes or similar steel products in the next 3 years

_______________________________________________________________________

_______________________________________________________________________

B. Quantity/tonnes production capacity per month

_______________________________________________________________________

_______________________________________________________________________

C. Marking/ /manufacturer's mark for embedding on items to be provided

_______________________________________________________________________

_______________________________________________________________________

D. List number of employees/ manpower to perform the work

_______________________________________________________________________

_______________________________________________________________________

E. List of engineering manpower at the factory (Technical headquarters, Engineer,

Engineering)

_______________________________________________________________________

_______________________________________________________________________

F. Computerized automatic machine for drilling and punching of angle towers and their

parts–(In tenders for angle towers) is it owned by the bidder or owned by someone else

by agreement? (In case of an agreement, the agreement must be attached)

_______________________________________________________________________

_______________________________________________________________________

G. Detail and describe the types of machines and equipment you own to perform the

works (machines for punching, cutting, drilling, welding, marking, embedding, , etc.)

_______________________________________________________________________

_______________________________________________________________________









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H. Write down the the proposed type of galvanic and the galvanic factories in which the

galvanizing will be performed

_______________________________________________________________________

_______________________________________________________________________

I. Write down the proposed color type for safe painting of channel towers (only channel

towers)

_______________________________________________________________________

_______________________________________________________________________

4. Quality assurance and control:

Is there a quality assurance guide or your own quality control guide in the factory

(specify and append certificates).

Whether procedures and quality control instructions are implemented (such as ISO 9001)

in the issues of procurement, acceptance testing, raw materials, equipment Maintenance,

materials and products storage, planning and production processes, delivery and final

product testing - please describe briefly.

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

5. Materials and standards

The steel to manufacture is S355J0 (ST 52.3) or S235JR (RST 37.2) according to EN

10025:2004. As shown in the drawings.

Quality control Documents by standard 2.2 / 50049 DIN, EN 10204 3.1B.

“C” shaped steel profiles (Channel) - EN 10279.

Pipes by Israeli standard 530 "Welded pipes for general use".

Flat profiles according to EN 10058.

Sheets metal according to EN 10029, EN10131.









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Round bars according to EN 10060, square bars according to EN 10059.

Hollow Profiles (such as RHS) according to EN 10210-2.

"H" and "I" shaped profiles according to EN 10034.

Silicon content (Si) in steel profiles and in sheets will be according to European

standard EN 10025:2004 -3 as follows:

Lower than 0.004 or between 0.14 to 0.25.

Degree of Bolts strength will be 50 kg/mm

2 according to ASTM – A-394, Type 0.

Bolts hardness will be Rockwell B Min. 80, Max 100, measurements according to

Appendix "A-14".

Nuts will be acc. ASTM-A 563 GrA. Material shall be from carbon steel.

Nuts hardness will be Brinell MIN 116, MAX 302. Measurements according to

Appendix "A-14".

Spring washer will be acc. ASME B18.21.1- 2009 (regular table 1).

Material shall be from carbon steel. Hardness requirements shall be: HRC 38-46,

372-458 HV.

All raw materials as well as nuts screws and spring washers will be provided by the

manufacturer.

The manufacturer must present suitable and satisfying test certificates of the steel

manufacturer, or of a certified Testing Institute for the quality of matter.

I.E.C has the right to perform strength tests and the chemical composition of steel in the

materials laboratory of I.E.C.

Note: Can be offered other raw materials with equivalent properties (not listed in this

specification) for the approval of I.E.C.

6. Technical demands

6.1 Tolerances

6.1.1 Angle and channel towers tolerances

The pieces must be manufactured according to the dimensions that appear on the

blueprints.

- Total tolerances in the long direction of the part will be: for ribs and diagonals +2/-

1mm

- Tolerance to General dimensions (Length, width, diagonals) for welded structures

+2/-1mm









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- Tolerance between two adjacent holes will be 1mm, not cumulative

- Tolerance from the last hole to the end of the iron will be in the range of 2mm

- Tolerance for the diameter of the hole will be +0.5/-0mm

- Tolerance for the length and width of the sheet metal will be +1/-1mm

- Tolerance for the dimensions of bending sheet metal or bars will be +1/-1mm

- Tolerance for the dimensions of the welding length will be +1/-1mm

- Tolerance for the dimensions of connecting the joints in the cross arms will be

+1/-0mm

- Tolerance for the dimensions of connecting the cross arms to the towers will be

+2/-1mm

In order to ensure standing in the mentioned tolerances in angle towers, channel

towers and their parts, the manufacturer must use appropriate templates at the time of

production.

- Tolerance for the hole-dividing axis from profile end will be:

+1/-0mm for profile in external connection

+0/-0.5mm for profile in internal connection

+0.5/-0.5mm for holes in Diagonals

6.1.2 Tolerance for steel grid items:

The tolerance of the scale and won't be mentioned in the drawing according to ISO

2768-C/M.

6.2 Cold forming

6.2.1 General

Manufacturing of angled towers legs and their parts (extensions, upper extensions)

will be done using automatic machine for drilling and punching only, production will

be performed by those offered at the tender stage only, changing the place of

production – under I.E.C approval.

Cold forming includes: bending, cutting, punching and drilling.

Any deviation from the following requirements requires the pre-approval of I.E.C.

At the time of production take the precautions listed in:

“Standard Practice for Safeguarding Against Embrittelment of Hot – Dip

Galvanized Structural Steel Products and Procedure for Detecting

Embrittlement” – A 143 – Latest edition.









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6.2.2 Punching and drilling

The manufacturer must carry out the drilling and punching with CNC machines.

Holes are to be punched with racks and jigs employed to ensure accuracy throughout.

The punches and dies for this work must be maintained sufficiently sharp so as to

produce clean round holes.

Holes may be punched and drilled in high-strength structural steel under 11 mm thick.

Over 11 mm holes can be punched to preliminary hole and then be finished by drilling to

final dimension and reamed.

Table no.1 shows the dimensions of preliminary and final holes

Table no.1

Bolt

Preliminary

hole (mm)

(punching or

drilling)

Final hole

(drilling)

1/2" 10 14.5

5/8” 14 17.5

3/4” 17 21

7/8” 20 24

1” 23 27

Holes in elements with welded reinforcement plates will be done only after welding.

Thickness of such element will be calculated according the sum of thickness of element

and reinforcement.

Holes in bent members which may be affected by the bending operation shall be laid out

and punched or drilled after bending. Holes which are elongated or otherwise distorted

by bending will not be accepted.

Special care is to be exercised to ensure exact spacing of holes and their distance from

back of angle and to end of piece.

No welding, filling or plugging will be permitted unless otherwise approved by IEC.

Plates can be produced using computerized machines laser or water, provided that plate

edges and holes will be clean and smooth and on condition that would not cause damage.









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6.2.3 Bending

The possibility of cold bending normally depends on the shape of part (angle, plate,

channel, etc.), type of steel, angle and radius of bending and equipment for bending.

The radius of the bend will be not less than 3 times of part thickness and the bending

equipment will match this requirement.

For angle and channel profiles the manufacturer will choose between the following two

bending methods:

1. Cold bending, if the manufacturer has the right equipment.

2. Cutting sides and welding in accordance with the production drawings.

6.2.4 Cutting

Materials with thickness of more than 18mm must be cut with a saw or burning torch.

Cutting with burning torch will require cleaning and smoothing before connection

operations, welding and galvanization.

Materials with thickness of less than 18 mm may be cut with a suitable guillotine on

condition that no distortion is caused.

Note: Other method cutting only with the prior approval of the I.E.C

6.2.5 Repairs during the production

Repairs during the production will only be performed according to the instructions

and guidelines of I.E.C. These repairs will include, among other things, hole

corrections (Wrong location, wrong diameter, non-circular shape, the need for blockage, etc.), bending, cuttings etc.

6.3 Welding

6.3.1 General

This chapter describes the method of welding and the testing method of welded steel

structures to ensure that the quality of the welding will be controlled, fixed and subject

to demand.

All welding will meet the requirements of this chapter and standard AWS D1.1.

Welding marking according to Israel Standard 1061.

Definitions and Terms according to Israel Standard 1133.









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6.3.2 Welding process

6.3.2.1 Welding method: This specification is based on a welding method (SMAW)

with coated electrode.

Using other welding processes requires written approval by I.E.C material laboratory,

which will determine whether welding processes qualification is needed. Granting this

approval will be conditioned that the quality of the welding and the control of the

performance will be at least as required in this specification.

6.3.2.2 Welding specification: The manufacturer will prepare a representative welding

specification (WPS) for all shapes of the connectors in the towers production.

6.3.2.3 Proof of welding capability: The manufacturer will make a representative

welding model which will be welded in the presence of I.E.C representative (Quality

control or welding engineer from the I.E.C materials laboratory).

The model will be submitted to the I.E.C for "Micro" testing to determine the quality of

the welding in the metallographic tests.

6.3.2.4 Model rejection: If the micrographic testing will prove discontent, the

manufacturer will change the welding specification according to the defects discovered

in the model and prepare a new model as described in paragraph 6.3.2.3.

6.3.2.5 Receiving the model: If the model was tested and was found suitable, the

manufacturer will weld all types of connectors according to the approved welding

specification.

6.3.3 The filler materials (Electrodes)

High and low voltage towers, extensions and other grid items

Coated electrodes for manual welding in diameter of 2.5-4.0mm.

Butt welds – according to standard E7018 ASME SFA – 5.1 or equal.

For fillet welds - must be done with coated electrodes, according to 7024 CLASS E

5.1 – SFA. Seal welds up to 3 mm possible to perform – welding process GMAW with CO2 backup

gas.

Note – electrodes E 7024 will be used only for fillet welds.

Any change of electrodes requires written approval by I.E.C material laboratory.









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6.3.4 Cleaning the base material

Base material in the area next to welding, up to a distance of 50mm from each side of

the welding groove, will be cleaned of all foreign material such as: Grease, paint,

moisture, slags and metal oxides.

The welding groove and adjacent area up to 20mm from each side of the welding groove

will be cleaned until there’s a shiny metal.

The cleaning will be performed with mechanical brushes, by sharpening or by hand

brush as needed.

6.3.5 Connections types

In case there is no detailed demand for connection by welding, do not use welding

without the national Network certification. In any case, it is not allowed to have more

than one connection in a profile.

The connections will be: single sided butt, single sided butt with a backup strip, double

sided butt and fillet. The connections types according to the production drawings:

6.3.6 Preparation of compilations (phases)

The phases will be made by chipping or sharpening.

A gaseous or electric crop is allowed on the condition that the cut will be smooth and

evenly precise in its form without bumps or “teeth” and that all the oxides and the slags

at were created during the cutting are cleaned carefully.

The phases will be according to the drawings and details in the appendixes.

6.3.7 Storing welding electrodes

Welding electrodes will be stored in closed boxes and sealed. open boxes to be kept

according to the following table:

Storing conditions Electrode type Coating type

In a heated oven at a

temperature of

C1200

7018 E Low hydrogen (base)

In an oven at the

temperature of the

environment with

6013 E

7024 E

Rutile









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relative humidity of

50%

Low hydrogen electrodes exposed to air over 4 hours will be considered as wet and will

need to be dried according to standard 1.1 D AWS.

Storing conditions Electrode type

At a temperature of 2500 C for 2 hours 7018 E

No need for drying 6013 E

7024 E

Electrodes will be kept away from contact with moisture damage or dirt.

Wet electrodes will be disqualified for use.

6.3.8 Environmental conditions

The welds will be performed in a protected place from rain, humidity, strong winds and

all abnormal conditions that may harm the quality of the welds.

6.3.9 Welding technology

General Welding in the horizontal position (sheet is vertical and the weld is horizontal) will be

done, exclusively, in the pull technique. Weave technique is permitted in the other positions, at rate not exceeding 3d.

Fillet welds in vertical position will be in the weave technique, in other positions only

pull technique.

Welding cleaning After every weld bead, weld material and the phase side must be cleaned of any oxide slags foam and sparkling. Any defect found in the welding, such as pores, cracks, sharp

transitions and excessive arches must be eliminated by sharpening or chisel. In two-sided

welds, welding root must be sharpened until you get free material from any defect before

welding from the opposite side. Once the welding has finished, the welding and the surrounding area must be cleaned.

Distortion Prevention Weld beads must be deposited in a fashion such that distortion is kept to a minimum

level. Double sided welds must be deposited in a balanced manner from both sides of the sheet such that a flush transition between sheet and weld area is maintained.

Welds direction









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Vertical position welds will be deposited, exclusively, from bottom to top (up).

6.3.10 Welding control

Welding Inspector I.E. Corp. will appoint a welding inspector, whom will ensure all welds are deposited

according to the instructions in this procedure. The inspector will authorize deposition of

welds by IEC qualified and documented welders only. In the event that welding is done

not in according to this procedure, the inspector may order the job be ceased.

If the weld quality of any given welder does not satisfy the inspector, the later may order

the former (the welder) to successfully repeat the qualification exam or his removal from

the job.

Welders Qualification All welding subject to this procedure must be done exclusively by welders that passed

the qualification exam described below and were granted a written approval by the IEC

materials lab. For tack welds will be examined according to the examination I.E.C. of

Welders of tack welds K1.

The welders depositing the tack welds will be tested to K2. K1 tack welders are only

certified to make simple carbon steel welds. Tack welders will not be permitted to

deposit beads that will constitute part of the final weld.

Conducting an examination of the welders is based on examination requirements K4 of

I.E.C, or according to standard AWS D1.1.

In welding work, in a fillet welding connection only, it is permitted to weld for welders

with K2 certified.

6.3.11 Weld Repairs

Any welding defect that has been disqualified will be removed by a chisel, grinding,

Cutting with an arc air system or by gas cutting (oxyacetylene) and welded again.

The ruling of the I.E.C welding inspector will be decisive in regard to the repair method.

6.3.12 Inspections

Visual inspection (according to standard AWS D1.1) The manufacturer will examine each and every weld visually in order to determine

compatibility with standard AWS D1.1 requirements.

Tolerance in the weld shape of the welds: The weld shape: the inside of the fillet welds can be slightly convex, flat or slightly concave as described in appendix A-5 in pic no.1 and no.2.









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Welds with profile as described in pic no.3 will not be accepted.

Detail for external corner welds, the convex ratio will not exceed 0.1S where the letter S

marks the actual amount of welding (See pic no.2). Fillet welds with a "toe length" (S)

1.5 mm short of the required value, will be accepted providing the total length of such

sections does not exceed 10% of the weld length.

Groove welds should be preferred with light or minimum reinforcement, except for a

case when the work needs dictate a different shape.

In case of butt joints and corner joints, the weld reinforcement will not be more than

2mm and the transition between the weld reinforcement and the base material will be

gradual and continuous, as shown in picture no.4.

There will not be any discontinuities in the welds as described in pictures no. 5 and 6.

Weld Dimensions The weld material must fill the weld groove and exceed the rim by no more than 5 mm

from the edge of the weld groove.

The weld reinforcement may not exceed 3 mm. The weld groove is to be filled to the

surface level or beyond.

Undercuts and Overlap Undercuts not exceeding a depth of 0.5 mm and a maximum length of 50 mm will be

tolerated. Any faulty weld section, exceeding the criteria above, must be separated from

a neighboring faulty section by a defect free section with a length of at least twice the

size of the longer faulty section amongst the two. If this condition is not met, the

undercut will be considered continuous.

No accept cold overlapping defects.

Penetration and melting It is necessary to have full penetration and melting of the welding. When the welding is

done against a backup bandwidth, there must be a perfect meltdown between the weld

and the backup bandwidth.

Cracks Not accept cracks in the welding.

Unfastened backup bandwidth The backup bandwidth must be fastened to both sheet metal.

The maximum allowable gap between the backup bandwidth and sheet metal is 1mm.

Porousness and slags According to standard AWS D1.1.









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Cleaning at the completion of the welding Clean the remains of the slags on the surface of the welding to avoid defects during welding.

Other tests I.E.C has the right to demand additional laboratory tests as needed.

6.3.13 Changing the welding method

In case the towers manufacturer wants to change the welding method, it should be

brought to the attention of the laboratory at the tender stage. The contractor needs to

demonstrate and present welding specifications for the process, as well as the process

certifications and welders certifications for the desired method.

Changing the welding method is under the responsibility of the materials laboratory

only.

6.4 Coating

Towers and their parts will be coated in hot zinc galvanizing. The rest of the items

are provided as an alternative, coating by a thermo diffusion method (Sherardizing,)

the manufacturer will determine in advance how it does the coating, Any change

requires pre-approval of I.E.C, bolts and washers coating has 3 possible alternatives.

6.4.1 Hot Zinc Galvanizing

6.4.1.1 General

This section refers to the protective coating of steel products by dipping them in a

warm zinc bath - Different profiles, different sheet metal thicknesses, screws and

nuts.

Coating with hot zinc will be according to Israel Standard 918 with the following

disclaimers:

Paragraph 202 - Repairing the coating – instead of the above required: "Any repair should be in the approval of a Distribution Engineering Unit

representative or other authorized representative of I.E.C".

Paragraph 203.1 - The outer surface – instead of the above required:

"In a zinc-coated area, there will be no coating defects such as: bubbles, places that

are not coated, stains, spots, Cracks or roughness caused by the coating operations









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etc. The product will be clean and there will be no signs of any damage. The coating

will be continuous, smooth and without stains from the coating material.

Do not leave any sharp tips as a result of the zinc spill on the iron areas, especially in

the corners.

Steel details with such defects will not be accepted by I.E.C.

Paragraph 204- Coating thickness– instead of the above required:

Steel with thickness of 8mm or more - The minimum coating thickness will be

0.085mm.

Steel with thickness between 5mm to 8mm - The minimum coating thickness will be

0.07mm.

Steel with thickness between 3mm to 5mm - The minimum coating thickness will be

0.055mm.

Steel with thickness of 3mm or less - The minimum coating thickness will be

0.050mm.

6.4.1.2 Holes

After the galvanization, the holes should be free for bolts transition, free minimum

diameter:

14.0mm for 1/2“bolt



23.5mm for 7/8 bolt

26.5mm for 1“bolt

6.4.2 Galvanizing metals in a thermo diffusion method (Sherardizing)

6.4.2.1 General

Before galvanizing must be blasting with steel grains on the parts.

The galvanizing is done through a thermo diffusion process in an oven containing

zinc powder at a temperature of 420ºC or 400ºC for bolts. As a result of the special

process, the diffusion of zinc powder is formed into the outer layer of the steel and

forming a layer of zinc that penetrates into the steel.

After galvanization, zinc phosphate phosphatizations are performed in the stones

vibrator.

Suitable for parts that enter the drum (530mm in diameter and length of 2100mm):

cross arms, bolts, sheet metal, filling etc.

6.4.2.2 Galvanic thickness:

Steel with thickness of less than 3mm – Minimal galvanic thickness will be

0.050mm.









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Steel with thickness of 3mm or more but less than 5mm - Minimal galvanic

thickness will be 0.055mm.

Steel with thickness of 5mm up to 8mm or more - Minimal galvanic thickness will

be 0.070mm.

The thickness of galvanic thickness for screws bigger than 1/2'' – will be 0.040mm.

6.4.2.3 Quality of the galvanization and tests

Quality tests to be performed according to British Standard BS 4921,

BSEN13811:2003.

6.4.3 Coating of bolts, nuts and spring washers: The bolts, nuts and spring washers will be coated with one of the following methods:

6.4.3.1 Hot zinc, coating thickness at least 40micron.

6.4.3.2 Cyanide-based electrolytic zinc, coating thickness at least 40micron with

passivation, according to paragraph 5.2.

6.4.3. 3 Thermo diffusion zinc coating (Sherardizing), coating thickness at least

40micron with passivation, according to paragraph 5.2.

6.4.3.4 Electrolytic zinc coating, coating thickness at least 12micron with

passivation, according to specification K-2503.

6.4.4 Safe painting of channel towers. Safe painting of channel towers will be made according to the drawings and

specification K-2590.

6.5 Marking Items

6.5.1 General

This chapter discusses the marking of welded angle and channel towers and their parts,

high and low voltage crossarms, legs, templates and small grid items.

In order to facilitate the identification of the products, their marking must be embedded

before galvanizing.

The items will be marked so that it will be possible to identify the manufacturer, the

item, and the item's serial number for it's assembling.

In case some details have specific requirements in the drawing - this requirement will

determine for marking purposes.

For different items that are not specified in this chapter, the manufacturer needs to

contact the "Distribution Engineering Unit" in I.E.C for marking instructions.

6.5.2 The marking method of welded towers, extensions and crossarms









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This paragraph discusses marking welded towers: angle towers, channel towers, high

and low voltage crossarms, extensions for angle and channel towers.

Manufacturer symbol, tower type, length and year of manufacture, must be marked in

welding, imprint or imprint on a welded plate. The marking sample can be seen in

appendixes A-6B, A-6G and A-6D.

6.5.2.1 Manufacturer's mark

Each tower will be marked with a welding or embedding of an agreed marking of the

manufacturer.

6.5.2.2 Tower type, cross arms - will be marked as followed:

In angle towers and steel extensions S235J0 (RST 37.2): tower type: 70/80, 80/90,

90/110, 120/130, 140/150 and it's length.

In angle towers and steel extensions S355J0 (ST52.3): tower type: st52 70/80, st52

80/90, st52 100/120, st52 120/140 and it's length. A narrow tower will be marked –

110/130 narrow and it's length.

On angle towers and extensions, partly disassembled, manufacturer mark, tower type or

extension, serial number of the item must be marked.

On channel towers and extensions: tower type U10, U12, U14, U16, U18, U20 and it's

length.

In high and low voltage crossarms: drawing number, or according to the demands in the

drawing.

6.5.3 Marking method

6.5.3.1 Marking size

The size of the numbers and letters will be 12-20mm. The imprint depth will be

sufficient so that after the galvanizing it will be possible to clearly read the imprinted

marking.

6.5.3.1 Marking position

Angle towers:

The markup will be on the outside of each leg and begin at a distance of 3.2m from

the bottom of the tower. The marking will be imprinted on 2 opposite legs.

For angle tower - at 10cm below the welded connection on the side.









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Channel towers:

The markup will be on a broad or short exterior side of the channel profile, and edge

will start at a distance of 3m from the leg above the painted area.

For channel towers - at 1.9m from the bottom of extension.

Crossarms for high and low voltage:

The markup will be in the middle of the crossarm.

All dismantled tower members are to be stamped with distinguishing numbers or letters

corresponding to the information below. These marks shall be impressed before

galvanizing and are to be clearly readable afterwards.

The following information shall be stamped on each item:

- Trademark of manufacturer - Type of tower (for example TMH2 T) - Item number

The height of letters or numbers will be 12 – 20 mm.

The example of marking, see annexure 6a.

Bolts marking:

The bolts will be marked according to ASTM-A 394 Type 0 and in addition

manufacturer name or trade mark

7. Packing, Marking the packaging, Storage in the manufacturer's

yard and transportation

7.1 Welded towers and extensions:

Angel towers

Towers will be provided related - 3 towers together, extensions will be provided bundled

– 2 extensions together.

Channel towers

Channel tower 12m U140 will be provided 4 units bundled together with galvanized iron

wire.

Extension 2.12 m - each extension will be provided bundled with galvanized iron wire.

All the items required in the drawings and all 5 extensions of this type tied together with

galvanized iron wire.









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1m extensions – Any extension system that makes up the extension will be bundled by

galvanized iron wire. Every 20 extensions will be bundled together properly on top of

strong wooden 1.20mX1.0m board pallet with a forklift access option from all directions.

7.2 Assembled and disassembled crossarms:

All crossarms surfaces for the towers will be provided assembled except for those in the production drawing are otherwise indicated.

The crossarms surfaces must be assembled with bolts, nuts and spring washers as required in drawings. Use the appropriate bolts for each part (Length and diameter) as

required in the drawings and according to the instructions for connecting with bolts see

appendix A-7.

Steel items which aren't connecting to the crossarm surface (such as hangers and the

connectors) will be tied together as a bundle with 2 tying ribbons. The bundle must be

tied properly to the assembled crossarm surface so that it won't come loose during the

transportation.

This steel item will be placed in the space inside the crossarms adjacent to one of the

legs. With at least 4 mm diameter steel wire pass between the steel item holes and the arm leg holes at two points and in addition tighten the steel item with 2 extra tying

ribbons.

A crossarm provided disassembled must be provided as a package of items. The bundles

will be marked and will be according to the manufacture drawings.

Packages marking will include the manufacturer name, order number, catalog number,

amount etc.

7.3 The rest of the items

The packages will be packed so that the long "L" shape profiles are facing down and the

small "L" shape profiles facing up in the order of the lengths, placed on top of each

other.

When placing the "L" shape profiles on top of each other is not possible, they must be

pinned in s them in the sets according to the catalog numbers.

Each package must be tied in 3 places with galvanized iron wire, in case the package has

with large difference in length or large amount, extra wires must be added in ברזלים

order to prevent the loosening of the package.

Each package will have an identification label and a marking for the list of parts in the

package, as well as a copy of the manufacture drawing of that package. The

identification label will be put in a sealed plastic bag, in a way that it will be possible to

read the label without opening the plastic bag. The plastic bag will be well tied to the

package with iron wire.









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The package's marking will include order number, P/N serial number as required,

amount etc.

7.4 Storing at the manufacturer's yard and transportation

Finished products will be stored in the supplier's or galvanized factory yard and

improper products will be stored separately with appropriate signage. The transportation

to the sites or company's warehouses will be made by the manufacturer and on the

manufacturer’s account in quantities and times as required by the contract.

Product transfer will be done in a controlled manner according to product types.

8. Demands from the winning supplier:

* Coordination with I.E.C quality control and approval of examination and testing

program.

* Execution of testing and controls programs as required in the chapter 9.

9. Demands for prototype approval, control for the continuous

production and transportation

9.1 Demands for prototype examination

General – Examination of prototype will be under the responsibility of the representatives of the National Network and quality control.

Only after the prototype has been tested and approved, the manufacturer can move into

continuous production.

The examination will be required in the following cases and at I.E.C decision:

• Manufacturer who hadn’t previously created the required item. • New product or updated product. • In every production of templates for setting up tower legs.

Assembling a prototype is the assembly of all parts connected together as a single unit.

In prototype assembling screws, washers and spring rings must be use in sizes according

to the drawings. The screws must be fastened as required.

Instructions for connecting steel structures in screws see appendix A-7.









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As a rule, the assembly of an angle and channel tower will be made at manufacturer's

yard, the examination of the rest of the grid items can be of a submitted sample sent to

I.E.C.

Manufacturer required to perform a prototype examination, will invite I.E.C

representatives for that examination with advance notice as follow:

Abroad (out of Israel) - 60 advance notice days prior to examination.

In Israel - 10 advance notice days prior to examination.

Final schedule for the examination will be made close to the scheduled time.

In the production of angle and channel towers and their parts, the prototype examination

can be done before galvanizing, all other items in final mode ready for delivery.

At the end of the examination, the I.E.C inspector will write a protocol with the steps

required to continue the supplies.

Prototype examination will be without extra charge and will be taken in consideration

during the bids stage by the bidder, these tests will not affect the delivery times indicated

in the order.

9.2 Manufacturer control on continuous production

The manufacturer must perform tests to ensure the quality of the products provided by

the.

For the production test, the manufacturer will perform ongoing production checks during

production and document the results of the tests and deliver them to I.E.C inspector

according to the inspector’s demand. In any case, the manufacturer will deliver the test

certificates before the shipping.

9.2.1 Materials examination

The manufacturer will deliver raw material’s certificates to I.E.C for all types of steel

required in the tender (Steel profiles, sheet metal etc.). The certificates will include:

chemical properties, ultimate tensile strength, yield strength and percentage elongation.

The manufacturer will analyze the raw material in the lab (J355JO only), screws, nuts

and spring washers, the results will be submitted to quality control of I.E.C.

• S355JO steels – material type, chemical properties, ultimate tensile strength, yield strength and percentage elongation.

• Screws – according to ASTMA394. • Nuts – according to ASTMA563. • Spring washers – according to ASME B18.21.1-1999.









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9.2.2 Manufacturing Phase Tests

The manufacturer will prepare a factory test form which defines the tests to be

performed during production and in the end before shipping to galvanizing. The form

will include:

Dimensions, welding, phases, drills and marking.

In angle towers and their parts – the manufacturer is required to manufacture light

templates for examining connection of 2 adjacent parts, which includes adjusting the

holes in the legs and the measurements between the legs, these templates will be used by

the manufacturer and quality control personnel of I.E.C.

9.2.3 Coating examination

In angle towers and their parts, quality tests must be performed according to Israel

standard 918 or British standard BS 4921, BSEN13811:2003.

The documentation will include:

• The number of items tested, galvanization thickness including maximum and minimum and average results.

• Number of items examined in the pasting/coating test and results. • Tests of screws, nuts and spring washers will be made according to standards and

requirements in Chapter 6 of the specification.

9.2.4 Packing and marking examination

The manufacturer will examine each shipment that it is packaged as required in the

specification:

How it is packaged and its content, labels and their order and equipment details.

Including serial number, P/N, quantity etc.

The examination must be documented.

9.2.5 Painting tests in channel towers

Tests will be made according to specification K-2590.









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10. Appendixes:









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Appendix A-11 - Process Control for the " Hot Zinc Coating" chapter

Goal This appendix is intended to define the way of the treatment and control parts on which

have been galvanizied to ensure the quality of the final product and its durability over

time in corrosion conditions.

1. General In order to secure the success of the treatment, there must be a system of quality

assurance and documentation of all phases and the course of treatment of any portions

submitted to galvanizing. The factory will appoint a trustee to be responsible for the

existence of the system and the concentration of all the actions designed to ensure the

quality of the final product that is provided to I.E.C as described below.

2. Process Control The manufacturer will submit quality control of the customer full documentation of all

stages of the process. The documentation will include the following information for each

step:

A. Type and concentration of materials. The measurement and Control methods. B. The application temperature including the way of the measurement. C. The application's duration. Time measurement method. D. Criteria for defining the stage's proper finish and passing the part for following

treatment.

E. Procedures for maintenance the line, testing methods and the analysis of the concentration of active materials and documentation of the finds, time between the

tests and documentation of adding materials, etc.

3. documentation 3.1 Documentation must be performed using a ROUTE CARD, which will be near the

portion, for each stage in the process of handling the portion: Cleaning, washing and

fluxing, drying, zinc dip, cooling, etc. Verification of matching between the marking and

identifying the specific portion and its accompanying documentation.

3.2 The factory representative shall sign the suitable line for the completion of the fine

and quality performance of the specific phase.

3.3 The signed certificates will be transferred to I.E.C quality representatives before

submitting the portion for approval.

4. Final inspection 4.1 The manufacturer will consolidate and record criteria based on valid and qualified

standards (Such as Israel standard 918, 265 etc.) for accept/reject of the finished product.

4.2 Checked-out products are marked with a stamp or labeled "Approved", “For repair”

etc. The label will include date of a portion number and a clear identity stamp of the

inspector.

4.3 Corrective action - The manufacturer will consolidate procedures to perform

corrective action in the event of defects discovered in the final product inspection









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including detection that causes the procedure to malfunction and the course of repair, its

approval and documentation.

Edited by: material laboratory









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APPENDIX A-13

STATEMENT OF STRUCTURAL/STEEL MANUFACTURING

EXPERIENCE

1. I______________________ (enter name), am authorized to sign this

statement on behalf of ___________________ (the Structural/Steel

Manufacturer).

2. I hold the position of ______________________________ (enter job

title and description, i.e. partner, production manager, sales manager,

etc.) at the Structural/Steel Manufacturer.

3. I have been in this position since ____________ (enter date).

4. I am providing this statement with regards to I.E.C. tender №.

____________ .

5. The facts/details given in this statement have been checked and

verified by me.

6. _________________ (the Structural/Steel Manufacturer) has

experience in production of __________ (enter field) requested in

this Tender at the time of Tender proposal submission and for at least

________ years prior to submission.

Signature: __________

Stamp:









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Screws and nutes: – 41-AAPPENDIX