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IS : 802 ( PartII ) 1978(Reaffirmed 2010 ).

Indian Standard

CODE OF PRACTICE FORUSE OF STRUCTURAL STEEL IN OVERHEAD

TRANSMISSION LINE TOWERS

PART II FABRICATION, GALVANIZING, INSPECTIONAND PACKING

( Fourth Reprint APRIL 2000 )

UDC 621.315.668.2:006.76

Copyright 1979BUREAU OF INDIAN STANDARDS

BHAVAN, 9 BAHADURSHAH ZAFARMARG

NEW DELHI 110002

Gr3 February 1979

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IS I 802 Part II ) 1978 C . . i ~ t l from d 1 )

Director Q.eneral, BIS{ x tJfficio M,mber

Bombay Port Trust , BombayEngineers India Ltd, New Delhi

Hindustan Steel Works Construction Ltd, CalcuttaRichardson Cruddas Ltd, Bombay

Mtmb,rs R,prls,nt; ,SHRI P. K. MAJ.LICK: Jeuop Co Ltd, CalcuttaSURI P. K. MUJ tHnJBE Braithwaite Co India) Ltd, CalcuttaSURI P. T. PATEL II mal )5BBI S. MUJtHBRJEE Hindustan Steel Ltd , DurgapurSHIl l S. K. MUXBERJEl : Bridge Roof Co India) Ltd, Howrah

SBJU B. K. CH TTERJEE Alurnat )SBBI P. N. BBAIKARAN NAm Rail India Techni ca l and Economics Services,New Delhi

SBBI A. B. RIBEIRO lumau )SURI R. NARAYANAN Structural Engineering Research Centre (CSIR) ,RoorkeeEngineer-in-Chief Branch. Ministry of DefenceRO) H C. PARME8HWARAM

SKRI C. S. S. RAO Ait,rn t, )SURI DILIP PAUL Industrial Fasteners Association of India, CalcuttaREPRESENTATIVB Burn Standard Co L td , How rah

SHRI A. P. KAYAL All,rnat,RXPRB:SENTATIVF.:RURESJNTATIVE

SHRI p. V. NAIl AlternateSUR I P, SKNOUPT Stewarts Lloyds of India Ltd, Calcutta

SHRI M M GHOSH A.lternat,SHIU G. SRINIVAS. N Bharat Heavy Electricals Ltd, Tiruchirapalli

SURI G. L. NARA8AIAIi Alurnau )SH RI D. SRINIVASAN Joint Plant Committee, C.aJcutta

SHRI B. P. GHOSB Alt4r1lat. )Snnr M. D. THAMBEXARSURJ L. D. WADHWA

SHRI R. R. NAG Alternau )Sl IRJ C. R. I{AMA RAO,Director Struc Met)

Sterl/tJrySrmr S. S. SETHIAssistant Director Struc Met), HIS

Subcommittee for Code of Practice for Use of Steel in OverheadTransmission Line Towers, 5MBDC 7 : 1C01lvnu,

SUBI V. D. ANAND Central Electricity Authority, New DelhiM.mb,rs

SHftJ H. S. SERR .Alt4,,.al4 toShri V. D. Anand)Snnr M, ARUMUHAMAS818TANT DIRECTOR ST ND RDS(B 5 ) 1

DEPUTY DIRECTOR S T ND- C-OHE) Alt,rnal, )Tamil Nadu Electr icity Board, MadrasMinistry of Railways

i tUin_d ' ~ Q I 10 )2

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AMENDl\1ENT NO. 1 AUGUST 1992TOIS 802 Part 2 ) : 1978 CODE OF PRACTICE FOfC USEOF STRUCTURJ- l.L STEEL I OVERHEAD

T R N S ~ ~ I S S I O N LINE TovVVERSPART2 FABRICATiON, G A L V A N I Z l r ~ G l ~ ~ S ? E C T I O N ~PACKIf IG

age7, clause 5.9) line 3 ) - Substitu. - SP 6 Part 1 ) : 9 6 ~ , for SP 6(1): 1969 . age8, clause 6.3, line 2 ) - Substitute 2 rum and 1 mm respectivelyfor O 5 mm

age 8. clause6.4, line 1 ) - Substitute 2 nun) for 1.6 mm . age8, cli US 6.5, line 2 ) - Substitute 1 mm for 0.5 mm

CEO 7 ReprugtQphy U,li:, SIS. NewDelhi. India

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IS 802 Part n 1978Indian Standard

CODE OF PRACTICE FORUSE OF STRUCTURAL STEEL IN OVERHEADTRANSMISSION IJINE TOWERSPART II FABRICATION. GALVANIZING t INSPECTIONAND PACKING

R E W R D0.1 This Indian Standard Part II was adopted by the Indian StandardsInstitution on 25 October 1978, after the draft finalized by the StructuralEngineering Sectional Committee had been approved by the Struc tu ra land Metals Division Council and the Civil Engineering Division Council.0.2 With the publication of IS : 802 Part I -1977*, provisions regardingloads, material, permissible stresses and design aspect have been covered.In this part requirements regarding fabrication, galvanizing, inspectionand packing of overhead transmission line towers have been covered.0.3 This s tandard keeps in view the practices being followed in thecountry in this field. Asaistance has been derived from the Guide fordesign of steel transmission line towers t issued by the American Societyof Civil Engineers.0.4 For the purpose of deciding whether a particular requirement of thisstandard is complied with, the final value, observed or calculated,expressing the result of a test, shall be rounded off in accordance withIS : 2 196 t. The number of significant places retained in the roundedoff value should be the same as that of the specified value in thisstandard.I. SCOPE1.1 This standard Part II covers the provisions relating to the fabrication, galvanizing, inspection and packing requirements of self-supportingIteellattice towers for overhead transmission lines.

1.1.1 Provisions regarding loads, permissible stresses and designconsiderations have been covered in Part I of this standard .Code of pract ice for use of structural steel in overhead transmission line towers:P.rt I Loada and permiuible allellCl Slt tJ pasion .tRules for rounding oft numerical values r iSld .

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II Par tD 19781.1.2 Pr )visiofts regarding testing of tower. have b e ~ n covered inPart III of this standard.1.1.3 For provisions regardiDI erection of towers, r eference shall bemade to IS: 5613 P a rt II/S e c 2 )-1976*.

1. 2 This code does not cover guyed towers and special towers for rivercroning or other long spans. These wil] be covered by separate codes.2 PL N N R WING2.1 Plan. an d drawings shall be prepared according to IS : 696-1972tand IS : 9 6 2 1 9 6 1 ~2.2 Strllctaral Ae m b ly D ra w l_

2.2.1 The drawings shall show th e complete design dimensions, memberlength, slope acton or triangles, section sizes, bend lines, gauge lines,diameter, length and number of bolts, spacers, washers, sizes of gussetplates, position of holes, etc, and relative location of various members.

2.2.1.1 Sufficient number of elevation, cr S section and plan views.hall be presented to clearly indicate the details ofjoints and arrangemento f member.2.2.2 All members shal l be clearly shown and th e respective identification mark allotted to each member.2.2.3 The drawings shall be drawn to a scale large enough to conveythe information adequately.2.2.4 All connections shall be detailed to minimize eccentricity of theconnection.

NOTII- Du e consid. . . .tion shan be riven to th e ad ditio n al stresses introduced inth e member. on account oreccentricity of th e connection.2. 3 5laop D r a w i D I - Shop drawings, containing complete informationnecessary for fabrication of th e component part. of the structures shall beprepared. These drawings shall clearly show the member sizes, lengthand marks, hole positionl, gauge lines, bend Jines, edge distances, amountof clipping, notching, etc.

2. .1 In the case of members to be bent, the shop d ra wi ng s s ha llindicate provision for th e variation in length to be made.2. 4 Bill o f M ate r i . l- Bill of material for each type of tower shall beprepared separately. This shall indicate grade of steel, mark numbers,

*Code or practice for design, jllltallation an d m:\intnance o f overb..ad power Iines ;Part II Lines above 11 kV up to a nd i nc lu di o. 220 kV. Section 2 Installat ion an dmaintenance.fCode of practice for general cn.incerin, drawiDls e tI 61J; iD*Code of p, ,ctice for architectural an d buildinl drawin.

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18 802 Part U ) 1978section sizes, member lengths, their calculated weights, number of bolts,nuts and washers and their sizes, total quantities required and structuraldrawing numbers.2.4.1 No reduction in weight due to drilling, punching of bolt holes,screw cuts, clipping, notching, chamfering, etc, shall be made whilecomputing the calculated weight of the members.3. FABRICATION3.1 GeDeral- The fabrication of transmission line towers shall be donein accordance with this code A reference may, however, be made toIS : 800-1962 in case of non-stipulation of some particular provision inthis standard.3.2 Material Quality COlltrol- In cases where more than one gradeof steel is used in the structural members, proper identification marks ofthe various grades of steel being used shall be made on the mater ia l toensure their ultimate use in the proper location in the towers before takingup the fabrication.4. OPERATIONS IN FABRICATION4.1 StraightemD, - All material shall be reasonably straight and, ifnecessary, before being worked shall be straightened and/or f lat tened bypressure, unless required to be of curvilinear form and shall be free fromtwists. Straighten ing shall not damage the material. The adjacentsurfaces of the parts when assembled, shall be in close contact throughout keeping in view the tolerances specified. Hammering shall not bepermitted for straightening and/or flattening of members. Sharp bendsshall be cause for rejection.4.2 Cuttiag - Cutting may be effected by shearing, cropping, flamecutting or sawing. The surfaces so cut shall be clean, smooth, reasonably square and free from y distortion.4.3 BeDdiDI

f.3.1 Mild steel angle sections up to 75 75 mm up to 6 mm thickshall be bent cold up to and including bend angle of 10; angles above75 75 mm thicknesl up to 6 mm and up to and including100 100 mm thickness up to 8 mm ) may also be bent cold up to thebend angle of 5. All other angle sections and bend angles not coveredabove shall be bent hot .

4.3.2 All plates up to 12 mm thickness shall be bent cold up to amaximum bend angle of 15. Greater bends and other thicknesses shallbe bent hot.4.3.3 Bends on all high tensile steel sections shall be done hot.Code or practice for usc of structural steel in general building conltruction l I i s , ~ ).

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1 1 . _ h re D ) . 11 71 All hot beDtmaterial hall be air cooled. S 5 The bends lhall be of even profile and Cree from any surface

clamaB BeHq

4.4.1 Holes in the memben Ihall either be drilled or punched to jigand shall Dot be formed by flame cutting process. All burn left bypunching or drilling ahall be completely removed...4.2 Punching may be ~ p t e Cor sectionI up to 12 mm thick. Forthicker lecnon. drilling shall be done.4.4.3 The boles near the bend line o f . bent member on both sides ofbend line shall be pUDched/drilled after bending and relative poaition of

t h _ boles .ball be maintained with the Ule proper template/jiga andhtura . P . IUNDS AND JOINTS5.1 0 . It Iball be .IUred that the futenen provisle politiveattachment at .11 times and under the conditioDi when the toweratructur. . are lubjected to vibratory load U .1 . - Boltl used for erection of transmiaion line tower shallpreferably be 12 16 and 20 mm diam.er and in no cue bolt diameter.hall be leu than 12mm.

5.2.1 Only ODe diameter of bolts sball preferably be wed in one towertype.5.2.2 The leDlth of the bolt .ball be luch that the threaded portiondoes not lie in the plaae of contact ofmembe. . .5.2.3 It thall alia be ensured that the threaded portion of the boltprotrudu Dot len than 3 mID and not more than 8 mm over the nut afterIt i fully dahtened.

U Ho i . ... Boltial - Holes Ihall be cylindrical. Oval or lobed(orml hola Ihall Dot be permitted. The diameter the hole aball beequal to the diameter of the bolt plua 1-5 mm.

5.3.1 Hoi Ihall be perpendicular to the platel or augles.5.S.2 The accuracy the location of hoI...hall be sueh that for anygroup ofmemben when . . .embled the holes .haJl admit tbe bolt at rightangle to the plane orconnection.

5.4 Sp a ' of t cI.e OI.t - The minimum Ipacinlofbolta aad eel . diltaaC8 mall be u liYeD in Table I.e

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.1 802 Part D ) 1171TABLE 1 SPACING OF BOLTS AND EDGE DUTANCB

Cl4u, 5.4BoLT HOL. BoLT SPAOIHO, EDOB DtftAB oz. MittDUJOTBB U l f t Mia , A Hole Centre Hole Centreto Rolled or to Sheared orSawn Edge Flame Cut

d e 1) 2) 3) 4) 5)mm mm mm mm mID12 135 2 16 2016 175 40 20 2320 21-5 48 25 28

5.5 In dimensioning gauge lines, allowance shall be made or the milltolerance in width of flange in accordance with IS: 1852-1973- as toensure minimum edge distance specified in 5.4.5.6 LocldDI DeYlce. -Spring washers of positive lock type of thefollowing thicknesses shall be provided for insertion under all nuts.

Bou Di hi kness of Sprin Wahmm mm121620

5.7 To obviate bending stress in bolts or to reduce the same to minimum, no bolt ,h.ll connect aggregate thickness of more than threetimes the bolt diameter and also the Dumber or memben carryingstress to be connected by a single bolt shall not generally exceed threeexcluding gussets and packing ).5.1 The gap between the ends of two connected member. in a but t jointshall not be more than 6 mm and lesl than 4 mm,5.t Bolt G _ Dl.taDc I 1 A_.I - The bolt gaupdistances in f t n ~ s of angle sections .hall generaJly be in accordancewith Table XXXI of SP : 6 1)-1969t.

Specification fur roUins aDd cuuins tolaancn for hot rolled ateel product. I n d r rtili . tlSI HaDdbook for structural en,iDeera - Structural Itcel acctiO . . ~ ) .7

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II I 802 (PArt II 1976. TOLERANCES1.1 Fabrication tolerances shall conform to those specified in 6.2 to 6.5.Tolerances not specified in this code shall in general conform toIS : 7215e1974*.6.2 The maximum allowable difference in diameter of the holes on thetwo sides of. plate or angle shall be 0-8 mm, that is, the allowable taperin a punched hole shall not exceed 08 mm on diameter.6.3 Tolerance cumulative and between consecutive holes shall bewithin ::I: 0-5 mm,6.4 Tolerance on the overall length of a member shall be within 16 mm.6.5 Tolerance on gauge distance shall be within :I: 05 mm7. MARKING1.1 The identification mark allotted to each member shall be distinctlystamped before galvanizing with marking dies of 16mm size.L SHOP BRECTION1.1 The steel work sball be temporarily shop erected complete inhorizontal or vertical position one tower of each type including everycombination of leg extensions) so that accuracy of the memben maybe checked before commencing mas. fabrication.I . PAINTING AND GALVANIZING9.1 Pa l aU - Preparation of surface for painting pretreatment) andapplication of primer and finilhing coats shall be done in accordancewith the relevant clauses of IS : 1477 (Part I -1971t and IS : 1477 Part II -1971: respectively.

9.1.1 The pretreatment to the members and application of primer coat.hall be done immediately after fabrication. Another primer coatfollowed by two coati of finishing paint sball be given at site after thefabricated -Iteel work iJ erected. In cue the primer coat I i scrapedduring transportatioD, the member .urface Iball be cleaned before applying the primer coat in the field. 2 Gal - Boltl and other rastenerl .hall be ,.Ivaniaed inaccordance with IS : 5358-19691 galvanizin. of melDben of the tower.h.11 conform to IS : 4759 196811 and prill wasbers .hall be 1.lvanizedin accordance with IS : 1573-1970,.

ToI aCel for .bricadoD or Iteel ItruetUreI.tOode of practice paiDtiD, 01 la-roUi mctaJa ia buiJcIiDp: Part I PretnatmeaIJr I,. . . . . ). . pracdce 01 palDdDa or rerroUi met iD buUd1Dp: Part n Paiatial, I I . , , . . . . . .I8Peci catioD lor 1Iot-dlp plYaDbcd coatiDp _ ruteaen.lSiMd lor Iao clip aiDecoatill. OD I iuct IraI ucI II ali i_ 8,- ,. electroplated coatiap far .bae _ ina aD ....

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IS 802 P a r t II 197810. INSPECTION10.1 T h e inspector s ha ll h av e free access at all reasonable times to thoseparts of the manufacturer s works which are concerned with th efabrication of th e steel work and shall be afforded all reasonable facilitiesfor satisfying himself that th e fabrication is being done in accordancewith th e provisions of this standard.10.2 Unless specified otherwise inspection shall be made at the placeof manufacture prior to despatch and shall be conducted so as not tointerfere unnecessarily with th e o p eration of th e work.10.3 The manufacturer shall guarantee co mp lian ce w ith the provisionsof this standard if required to do so by the p u rch aser.10.4 Should any member of th e structure be found not to comply withany of the provisions of this standard it shall be liable to rejection. Nomember once rejected shall be resubmitted for inspection except in caseswhere th e purchaser or his authorized representative considers t he d ef ec tas rectifiable.10.5 Defects which may a pp ea r during f ab ri ca ti on s ha ll be made goodwith the consent of and according to th e procedure laid down by th einspector.10.6 All gauges and templates necessary to satisfy th e inspector shall besupplied by th e m an ufactu rer.10.7 The correct grade and quality of steel shall be used by th e manu-facturer. To ascertain the qu alit y o f st ee l us ed th e inspector at hisdiscretio n m ay get the material tested at a suitable or approvedlaboratory.11. PACKING11.1 Angle sections shall be wire bundled or despatched loose as ma y bemutually agreed upon.11.2 Cleat angles gusset plates brackets fillet plate h an ge r a nd similarloose pieces shall be nested and bolted together in rnutiples or securelywire-d together through holes.11.3 Bolts, nuts washers and o th er a tt ac hm en ts shall be packed ind ou bl e g un ny bags accu rately tagg ed in a cc or da nc e w it h t he contents.11.4 The packings shall avoid losses/damages during transit. Eachbundle or package shal l be appropriately marked.

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IS I 802 Part I I 1.78

Kamataka State Electricity Board, BanploreStructural EDliDeeriDg Rnearch CeDtre (CSIR.),RoorkeeSIUU R. NUAYAlfAB Al ma. )

S J T. K. RAIIA ATIUX TriVeDi Struccurall Ltd, NalDi, Allahabad8 1 K. V. S. MUaTHY AllmtiIllmr rATn JD Bhakra MaDasemeat Board. Chudiluh

SBBI Nm I DD Suro. AI ..S I A. P. SR Madhya Pradesh Electricity Board. JabalpurS.BI N. S t n Bihar State Electricity Board, PatD.S I S. N. Vo IDapection in., Directorate General Suppliaand Di.poulJ, New Delhi

C.,, inutd/,. , I 2 )M .w R / t IIIi_SO l S. K. BBATTAOBABJ.. SAE India) Ltd. CalcuttaSaRI V. NABAYANAlf ~ l l

CRIE.. ENGman Andhra Pradesh Electricity Board, HyderabadSVPDJ:NTENDt1fO ENo lnEB All .,.)

SR I K. R. Do Damodar Valley Corporation, CalcuttaSRBI SWABA GUPTA Al tn l l . )

SRJlI J. C. GUPl . Be ConltructiOD Board. ChandiprbSRILI J. C. GUtTA U. P. State Electricity Board, Lucbow

SHRI V. B. SmOB AlIImat )SHRI O KHOSLA EMC Steeb) Ltd, Calcutta

Ssa l S. N. SINOH Allmltlll )SBRI S. N. MISRA Mabarashtra State Electricity Board, Bomba,S lI al S. R. Jo eBI AII .,. , S8 NI AlB SINOH Punjab State Electricity Board. ChandiprhSuaJ N. D. PAalKR Kamani EnlineeriDI Corporation Ltd, Bombay

5 S. D. D dD AI,,,,..,, Smu R. N. Pmrl>8. Tata Hydro Electric Power Supply Co Ltd, BombayDRR Roll AX ll )SO l P. V. RAMAIA.SBIU N. V. RAMAl

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