Tower Light: Mast Pole Installation

IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

1. Scope:
The practical purpose of the following procedure is at ease to naturally provide a comprehensive technical
guide; to conveniently provide the adequate awareness of all the necessary procedures for a formal
installation and proper maintenance of the tower; and to be made aware of those appropriate precautions
to which it must strictly adhere to personal safety.
2. Application:
The practical application of premium services under this work procedure appropriately includes, but is not
limited to, the following functions for proper Installation / maintenance activities of:

• Mast Pole,
• Elevated Platform and key Ladders, and
• Projectors.

3. Objective:
The key objective of this established guideline is invariably to ensure the standard procedure and keep safe
installation jobs and necessary electrical maintenance jobs typically performed on Tower Lights.
On top of that, the Industrial Electric Department is responsible for the electrical maintenances involve the
fault diagnosis, routine servicing, and necessary repair of electrical components of a tower.
4. Skills and Competency:
Based on occupational purpose and specific context; electric maintenance jobs shall be operated efficiently,
cleaned and maintained by adequately trained electrical workers; accordingly to the outlined
standard procedures.
5. Activities:
5.1. Considerable Space Required for Practical Use and Proper Maintenance:
In correctly positioning the completed tower, an area susceptible to the lifting and handling means shall
be guaranteed and must typically allow the proper emplacement of the trunk (mast) length.
The surrounding knowledge must knowingly allow possible freedom of active movement to the principal
tower mounted both horizontally and vertically.
5.2. Foundation Plinth:
The foundation plinth can be instantly realized in two distinctive systems:
1. For infix towers (comfortably installing at the center of the plinth circular hole) see
precisely in fig. 1.
2. For towers equipped with the base flange (with anchor bolts embedded in the
foundation plinth) see fig. 2.

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 Tower Light: Mast Pole Installation
IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

• The foundation plinth must be made as accurately foreseen by the practical calculation, the cable entry hole
and the anchoring set must be highlighted in the comprehensive plan.
Each anchor bolt must be accompanied by three (3) nuts and of two (2) flat washers.
Before typically casting the concrete, the anchor bolts must be tightened to the assembly template and
properly kept in a vertical position during casting.
The threaded part of the anchor bolt must be properly preserved and adequately protected.
Once the casting has been carried out and the finishing work has been sufficiently completed, all the fillets of
the anchor bolts must be clean and greased.
The mounting template can only be retrieved after the concrete socket or before the tower is assembled.
For typically fixing on the specific hole at the center, it must be broader in apparent diameter than the
tower diameters of about 10/15 cm.
It is therefore advisable to exploit a bottom hole at the base of the plinth, approximately Ø50mm, for water
drainage.

N.B.:
• Plinths must be highlighted for visibility issues and shall be sufficiently protected with adequate barriers
typically granting to the applicable laws and safety regulations.

5.3. Tubular Mast Pole Assembly:

The completed tower can be typically composed of two or more trunks and they shall
be strategically positioned near the foundation plinth horizontally on trestles or wood
structures; two for each trunk; see fig. 3, carefully keeping the longitudinal weld aligned.

 Before typically performing the grafting, the male trunks shall be sufficiently marked with
notches; typically executed with felt-tip pen; which precisely correspond to the overlapping
dimensions; see fig.4.

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 Tower Light: Mast Pole Installation
IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

 To typically, find out the real graft allocation when the ‘b’ specific quota is exceeded,
precisely calculate:

1.0 – X =

 Specific areas of engagement shall be carefully examined that there are no protrusions, zinc
residues or dirt.

 Inside the logs, carefully insert a pilot rope of; at least one, in extent lengthwise of the grand
tower; for the upcoming towing of electric cables, as shown in fig. 5.

 Grafting shall be typically begun from the base trunk; heave the upper log; move gradually
towards the topmost part of the base trunk with intensive care to sustain a straight
alignment of the established joint. Besides, wire rope hoists shall be engaged as shown in
fig. 6. Strategically.

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 Tower Light: Mast Pole Installation
IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

N.B.:
• The superior traction shall be carried out in an equitable manner on both sides; so that the two distinct
sections are properly aligned correctly. When the joint is completed and the leading ropes are typically
pulled; by means of a wad typically hit the engagement zone and intervene a suitable timber; so as to
overcome any considerable friction, refer fig. 7.

 The accurate throw shall be continued gently until the joint becomes aligned totally under
the combined action of the rope hoist and of the sledgehammer. Subsequently, checking the
overlap length shall be performed accordingly to fig. 4.
N.B.

• A maximum tolerance of - 4% is allowed on Quota "b".

• The grafting of the trunk must be considered concluded when turndown is reached, or the impossibility of
continuing the joint with the traction equipment in use.
• The force necessary for the engagement is a theoretical value, which must be kept ideal due to the
suitability of the traction equipment.

 The upper remaining trunks are grafted and all the operations described above are
performed.

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 Tower Light: Mast Pole Installation
IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

 It shall not be engage more than two logs at the same time. On top of that, the new joint
shall merely be performed after satisfactorily completing the previous one.

N.B.:
• The grafting forces are decreasing towards the summit trunks.
• Even if the joint is a perfect joint and difficult to remove, it is necessary, as a precaution, a connection to
be made between the lifting groove hook and the tower base when raising the tower.

5.4. Assembly Scale Ascent and Accessories

N.B.:
• The instructions below are valid for both the towers, towers on base plate and anchor bolts.

 The Tower shall be strategically positioned to the scale fixing attachment flanges upwards
consistent direction on the visible top of the completed tower. Afterwards, the first 10 –step
staircase typically starting from the third specific hole shall be properly installed, as shown in
the key figure underneath; fig. 8.

Attention!
• The stairs are designed to fit together, the enlarged part shall be towards the base of the tower fig. 8.

 The first movable bracket shall be typically mounted as purportedly shown in fig. 8; all other
scales shall be assembled afterwards as shown in the key figure underneath, fig.9.

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 Tower Light: Mast Pole Installation
IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

 The last three brackets; to properly, compensate for the large tower base diameter, are
wider.

 Appropriate tower collars shall be manually shaped to naturally adapt the proper diameter
of the tower; which are necessary to precisely fix the ladder as shown in the key figure;
fig. 11, underneath. What's more, the fastening hooks shall be appropriately positioned to
the keyway on the crosspiece; invariably following that, the detachable collar shall be
tensioned until it is adequately affixed to the tower.

N.B.:
• During this distinct phase, it shall be instantly confirmed that the ladder and the tower are naturally
aligned.

 The assembly of the body guard shall be assembled starting from the top of the ladder;
manufacturer construction drawing shall be referred here.

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 Tower Light: Mast Pole Installation
IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

 The intermediate terrace shall be assembled on the ground and positioned on the scale by
referring the specific manufacturer’s assembly drawing; as shown in the figure underneath,
fig.14.

 During strategically positioning the intermediate terrace, the upper connection shall be
comfortably fixed to a crosspiece; which was already installed as carefully outlined in the
previous section; for the mutual support of the principal staircase and the bottom
connection as intended positioned properly using another crossbar; as shown in fig.15.

 Before promptly proceeding with properly assembling the elevated platform, all assembled
components shall be instantly confirmed; properly tightened and adequately secured the
tower, so as to intentionally avoid any rotation; as shown in fig.17.

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 Tower Light: Mast Pole Installation
IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

5.5. Assemblage Platform

 The tower shall be placed on the ground with plates facing upwards; wedges shall be used to
block rotation, as shown in fig. 17.

N.B.:
• The general assembly of the platform shall be in accordance with manufacturer’s assembly drawing.

 Tripods shall be typically used to embrace the elevated platform aligned and safe during
properly assembling; as shown in the key figure underneath, fig.18. Moreover the platform
installation shall be completed accordingly to details adequately provided by
the manufacturer.

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 Tower Light: Mast Pole Installation
IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

 Sliding ladders for necessary maintenance of the floodlights shall run on

two racks; additionally initial regulation shall be properly established with the elevated
platform on the ground; as shown in figure underneath, fig. 19.

N.B.:
• Final adjustments to optimize shall be performed after raising the tower.

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 Tower Light: Mast Pole Installation
IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

5.6. Fixing the Platform on the Tower:

 Proper nylon straps shall be typically used to harness at the specific points; typically marked
on the tower; and the platform shall be moved closer to the assembled tower section and
fixed together using sixteen TE M24 X 140 bolts and nuts; which shall be galvanized steel 8.8
and proper tightening torque for this joint shall be precisely 650Nm on the first nut; as
shown in the figure underneath, fig.19.
N.B.:
• Proper lifting equipment shall be typically utilized to gently lift up the complete platform without lighting
projectors. (Typically refer to the responsible manufacturer’s standard manual for the total kg.)

N.B.:
• The proper installation of floodlights shall be precisely on the ground; as recommended by the responsible
manufacturer for more convenient assembly and wiring. Besides, on the completed tower at the towering
height of each crosspiece, cable exit slots are adequately provide; in notable addition to the inner part of
the crosspiece, there is precisely a welded rod for efficiently storing cables using cable ties.

• The glass of the lamps shall not be touched with hands.

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 Tower Light: Mast Pole Installation
IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

5.7. Lifting the Tower:

Installation on the foundation plinth:
 Relatively more notable adjustments on the nuts shall be performed properly keeping 90° of
the installed bolts; on top of that, the practical manual leveling shall be performed
correctly on the opposite side corresponding nuts; as shown in the key
figure underneath, fig.22; A-A and B-B.

 To sling the choke tower in the upper gravity point, anti-slip safety rope shall be fitted
comfortably; as shown in key figure underneath, fig.23.
Moreover, it shall be tensioned with a rope hoist. Subsequently, the completed
tower shall be raised gradually to it over the plinth; at that fundamental point its proper
orientation shall be checked well.

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 Tower Light: Mast Pole Installation
IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

N.B.:
• Even if the joint typically consists of an exact entry and difficult to remove, for necessary
precautions; that is precisely in the tower rising phase, a consistent link shall be intentionally made to
frail hooking of the lifting crane and the principal base of the Tower.

 Once the tower is suspended on the air straight upwards over the plinth, the utmost
attention shall be undoubtedly given; to insert gradually the key holes of tower base flanges
on to the anchor bolts; projecting from the plinth; as shown in the key figure underneath, fig
24.

 The tower shall be slightly suspended until at least four (4) nuts placed at 90° have been
partly screwed; subsequently, the base flange shall be gently placed on the four slightly
higher screwed nuts. Ultimately, fix all the remaining nuts and washers and fasten them for
an optimum ratio on the anchor bolts.

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 Tower Light: Mast Pole Installation
IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

5.8. Tower Sealing:

Proceed to the sealing of the completed tower naturally following the following
procedure:
1. After the base flange of the tower is carefully inserted into the anchor bolts and rests on
the four (4) nuts at 90°; afterwards on, the lifting crane tune shall be loosened safely in
accordance without any possible effect on the tower structure.

2. Now install two leads with considerable length at 90° in-line with the principal axis of the
four adjustment nuts at a distance from the completed tower; to typically cover and
carefully inspect the entire longitudinal alignment of the tower; as shown in the figure
underneath, fig. 26.

N.B.:
• This operation must be performed first on one axis and then on that placed at 90°.

3. Once the vertically is reached on both axis, place all the flange nuts on the flange and
tighten the topmost ones. Carefully fit the upper lock nuts; typically referring fig. 25; and
free the mobile crane from the completed tower.
4. The created space under the base plate shall be pervaded to adequately protect the
exposed parts of the log bolts. The protruding threaded part of the log bolts shall be
properly protected with suitable bituminous or zinc-based paints.
5. Once the adequate cover of the concrete flange is properly completed, gentle slope shall
be created so as to typically avoid water stagnation at the established base; as shown in
the key figure underneath, fig. 27.

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 Tower Light: Mast Pole Installation
IE MPIP 1.2019
Procedure

GERDP: Industrial Electric

6. Finally, earthing rods shall be installed in soils; Soil shall be treated and tested and shall
have a resistivity value in ohm-meter with in the acceptable range; naturally it shall be
≤ 50 Ωm; as shown in the key figure underneath, fig. 28.

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