Technical Specification of Tubular Steel Poles for Tension Ministry of Electricity (MoE) /IRAQ

Ministry of Electricity
Power Distribution Office
Baghdad – Iraq

Specification No. D-46

TECHNICAL SPECIFICATION OF
TUBULAR STEEL POLES FOR
TENSION

REVISION YEAR 2001 YEAR 2009 YEAR 2012 YEAR 2021

 1- Scope of supply

This specification covers the provision of tubular steel poles, cross arms, fittings and
accessories suitable for 11kV overhead lines with maximum conductor size (120/20 mm2) ACSR and
LV lines with maximum conductor size (120 mm2) AAC on distribution networks. Suppliers are called
upon to deliver tubular steel poles to MoE which are required for the installation of medium voltage
(11 kV) and low voltage (0.4kv) Electricity Distribution Network but the poles shall be used in between
for the following purposes: -
a- Tensioning of the Network.
b- At corners of Network.
c- At end of Network.

2- General Requirements
The materials shall be of first-class quality and designed for continuous satisfactory operation
as continuity of supply is of prime importance and to operate satisfactorily under variation of load,
voltage and short circuit or other conditions which may occur on the system provided that these
variations are within the assigned rating of the apparatus. The materials used shall be suitable for the
following climatic conditions.

2 -1-Ambient temperatures
Highest maximum (in the shade) 55°C for about 6 hours a day
Lowest minimum -10°C
Maximum yearly average +30°C
Maximum daily average +40°C
2-2- Sun Shine temperature

Black objects under direct sunshine attain a temperature of 80°C

2-3- Air humidity
Maximum 92% at 40°C
Minimum 12%
Yearly average 44%

2-4- Altitudes
From sea level up to (1000m).
2-5- Sand storm
The equipment’s shall be suitable for outdoor installations and subjected to frequent sand
storms and heavily polluted atmosphere.
2-6- Wind Velocity
Max velocity (for design purpose) (140 km/hr) or 39m/sec.

2-7- Composition of Soil

The soil consists mainly of hard clay containing deposit gravel.

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 3- Technical Requirement
3-1 System Data: - Shall be according to Table below:
Table 1:

a.11 KV System
Nominal voltage 11000 volts
Highest system voltage 12000 volts
System 3-phase,3wire neutral earthed through resistance of 21.1 Ohm
Short circuit breaking current limiting the earth fault current to 300A
b. 0.416 KV System
Nominal voltage 400 Volts
3phases, 6 wires (4 wires with neutral solidly grounded +
System
1 wire light + 1 wire grounded system)
Frequency 50 Hz

4- Materials and Process:

The poles shall be made from longitudinally welded tube sections of hot rolled structural carbon
steel in accordance with DIN 17100 (ST-52) or in accordance with BS-4360 or in accordance with any
international equivalent standards with considering the design factor of safety for design of the poles
shall be considered (1.5).

5-Construction and Fittings:

5-1-Tubular Steel Supports:
poles shall be manufactured using the following methods: -
Medium Voltage Poles and Low Voltage Poles – Welded Sections

The supplier shall submit a welding procedure detailing joint configuration and welding parameters
with the tender, provided that the tubular pieces for pole are welded with using two circular iron rings
between each of the two tubes with a thickness equal to the difference between their inner and outer
diameters, or welded by using any equivalent method

a- Medium Voltage Poles

Medium Voltage Poles shall be used as a tension, angle (0-65˚) and end-pole for (11 kV) power
transmission lines together with straight line tubular poles. Referring to drawing (No.1) this pole has
to withstand the max. working loads (700 Kgf). Planting depth shall be (2m) for (11 m) poles. The rest
of dimension, parameters, locations of hole shall be as per drawing (No.1) attached. (‘A’ clamp) as per
drawing (No.1) shall be welded to the top of each pole

b- Low Voltage poles:

Low Voltage poles which is shown in drawing (No.2) shall serve as a tension, angle and end- pole
for low voltage network using straight-line tubular poles. The pole should be capable of withstanding
a working load of (600 Kgf). Planting depth shall be (1.8 m) for (9 m) poles. The rest of dimensions and
parameters as per drawing (No.2) attached and also for locations of holes.

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 5-2-Scheduled Equipment:

a- The pole design shall be in accordance with Table below: -

Table 2:

Medium Voltage Low Voltage

Effective length (m) 11.00 9.00
Top Section
Length x outside diameter (mm) 3400 x 168.3 2000 x 114.3
Minimum wall thickness (mm) 4.5 4.5
Middle Section
Length x outside diameter (mm) 2850 x 219.1 2300 x 168.3
Minimum wall thickness (mm) 4.5 4.5
Bottom Section
Length x outside diameter (mm) 4750 x 273.1 4700 x 219.1
Minimum wall thickness (mm) 5 5
Planting depth (m) 2 1.8
Working Load (kgf) 700 600
Point of load application from top(m) 1.2 0.6
Safety Factor 1.5 1.5
Minimum yield strength (N/mm²) 355 355

b - All (11 m) pole shall be fitted with (‘A’) shaped clamped welded to the poles top and having an
approximate height of (25 cm). The clamp which shall be fixing the upper (11kv) pin insulator, is to be
manufactured from steel (ST-41) or (ST-42). The plate shall have a width of (75 mm) and (6 mm)
thickness with two holes (25mm) diameter, each drilled at center coincident with the centerline of the
pole. The extra length of ‘A’ clamp shall not be considered in the effective length of the (11m)
pole.
c- six nos.(17.5mm) dia. Through holes shall be drilled at the top sections of poles for the purpose of
fixing low tension shackle insulators. All holes shall be located on two faces with different angle 90°,
more details are shown in Drawing (No. 1) and Drawing (No. 2) for pole 11m and pole 9m respectively.

For earthing purposes, a (20mm) dia. Hole shall be drilled at the bottom of each pole at a distance
of(20cm) there from and a suitable length (M-18) galvanized bolt, nut & washer shall be supplied with
each pole.

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 5-3 Galvanization:
The poles shall be hot-dip galvanized thoroughly internally and externally. The zinc coating shall
not be less than 610 g/m2 and minimum thickness in any one place shall be 85 microns.

Poles and other hollow items shall be galvanized both inside and out. The zinc coating shall be
smooth, continuous and uniform. It shall be free from acid spots and shall not scale, blister or be
removable by handling or packing. There shall be no impurities in the zinc or additives to the smelter
bath that could have a detrimental effect on the durability of the zinc coating. Before pickling, all
welding, drilling, cutting and grinding shall be completed and all grease, paint, varnish, oil and welding
slag shall be completely removed. All protuberances which could affect the life of galvanizing shall
also be removed. To avoid the formation of white rust all galvanized material shall be packaged in
such a way to ensure adequate ventilation between parts during shipping and storage.

5-4- Drillings:

Poles shall be drilled according to the dimensions given in Drawing (No.1, No.2). All holes shall
be drilled prior to the galvanizing process and have smooth uniform finish after galvanizing.

5-5- Pole Cap:

Each pole shall be supplied with a pole cap, to seal the aperture at the top of the pole. The cap
shall be manufactured according to the dimensions given in Drawing (No.1, No.2).

5-6- ‘A’ Clamps:

Medium Voltage Poles shall have welded to the top, an ‘A’ clamp for the purpose of supporting the
pin stalk of a top phase insulator. The additional height due to the attachment of the clamp shall not
be considered as part of the effective length of the pole and, where measurements are quoted “from
the pole top”, they refer to the top of the main pole structure. The A shaped clamp shall be
manufactured according to the dimensions in Drawing (No.1) and the completed clamp shall be
welded to the pole before galvanizing. All welding and drilling involved in the manufacture of the ‘A’
Clamp will be carried out prior to the galvanizing process.

5-7-Identification Marks:
A line of dimension (5x150) mm shall be engraved/punched/embossed on each pole. The line shall
be perpendicular to the longitudinal axis at a distance of 3m from bottom edge of the pole before
galvanizing. The following text shall be engraved/punched/embossed (20) mm below the line: -

1- Manufacturers name/Trade mark,

2- Year of manufacturing,
3- Batch or Order Number.
The text shall be at least (10) mm in height and the depth of engraving/height of embossing
shall be such that the text remains legible after galvanizing.

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 5-8- Cross arm (Strain):
Each Medium Voltage Poles shall be supplied with a cross arm and its associated clamp
according to the dimensions in Drawing (No. 1). The cross-arm is intended to be fixed to the pole by
means of the clamp at a distance of 600mm below the pole top. Every set shall include the following:
• One galvanized steel channel cross arm (100x50x6 mm) with length of (1410 mm) according
to the dimensions given in Drawing (No. 1) and manufactured from steel (ST-41) or (ST-42).
• One galvanized steel clamp according to the dimensions given in Drawing (No.1) and
manufactured from steel (ST-41) or (ST-42).
• Two galvanized high-tensile steel (M16 x 60) bolts with a minimum threaded length of (75 mm).
Each bolt shall be supplied complete with a galvanized nut, plain washer and spring washer.

5-9 D-iron Bracket:

galvanized steel D-iron bracket for porcelain shackle insulator according to the dimensions
given in Drawing (No.2) and manufactured from steel (ST-41) or (ST-42), with galvanized high-tensile
steel bolt (M16) install in poles, with a minimum threaded length of (160 mm) for 9m pole and
(200 mm) for 11m pole, Each bolt shall be supplied complete with a galvanized nut, plain washer and
spring washer

6- Quality Control: -
The supplier shall submit evidence of ISO 9001 accreditation with his tender. The supplier shall
also submit detailed quality control procedures with his tender. Any potential supplier that does not
submit these documents shall be disqualified from the evaluation process. All materials under
contract shall be tested at the manufacturing works to verify compliance to our specifications. The
MoE shall appoint an inspector for this purpose and paid accordingly, but the manufacturer shall
supply all equipment and facilities to our inspector necessary for conducting all such tests without
extra charge
Random samples from each batch shall be inspected by the purchaser’s engineers or the
purchaser’s nominated inspector. The minimum quantities for sampling from each batch are listed in
the table below
a -Number of poles selected for conducting tensile test and chemical analysis shall be as given Table
below.
Table 4:
Batch Size Number of Poles
up to 500 1
501 – 1000 2
1001 – 2000 3
2001 – 3000 4
3001 and above 5

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 a- Number of poles selected for conducting the deflection, permanent set, Dimensions tests,
Galvanization tests and drop tests specified in Table below:

Table 5:
Batch Size Number of Poles
up to 500 5
501 – 1000 8
1001 – 2000 13
2001 – 3000 18
3001 and above 20

The Supplier shall aid the work of the Purchaser’s inspector by providing copies of all relevant
standards, and allowing the inspector full use of the necessary tools, instruments and laboratory
equipment, together with ample space and assistance in the handling of poles for inspection. Any
costs incurred in assisting with the inspections shall be borne by the supplier.
The following parameters shall be examined: -
a. General appearance
b. Finishing
c. Dimensions
d. Tensile test
e. Chemical analysis test
f. Sweep
g. Thickness and appearance of galvanizing

As a minimum requirement, the following dimensional checks for poles shall be witnessed
by the inspector shall be as given below Table: -

Table 6:
Dimension Tolerance
Length ±0.25%
diameter and circumference ±0.25%
Wall thickness +10%
Concentricity ±1%
Accuracy of drillings ±0.5%
Sweep, where appropriate ±1%

Cross arms, clamps and fittings shall have the following parameters examined: -
h. General appearance
i. Finishing
j. Dimensions
k. Tensile test
l. Chemical analysis test
m. Straightness
n. Appropriate markings
o. Accuracy of drillings
p. Thickness and appearance of galvanizing

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 As a minimum requirement the following dimensional checks for fitting and accessories shall
be witnessed by the inspector shall be as given Table below: -

Table 7:

Dimension Tolerance
Length ±0.25%
Cross section of cross arm +10%
Dimensions of clamp +2.5%
Position and size of suspension holes ±0.5%
Verticality of all through holes ±0.5%
The group of poles or fittings offered at any one time shall constitute a batch. Within a batch,
poles and fittings presented for inspection shall be segregated on a size basis. If the inspected items
have damage or deviations on a quantity greater than 5% of the batch, then the entire batch shall
be unconditionally rejected without further sorting. Poles delivered to stores or sites shall be free of
all damage to protective zinc coating, and shall not be out of straight by more than one thousandth
of the length of the pole.

7- Testing and inspection:

Test frequency shall conform to the inspection frequency listed in table 5. Testing shall conducted
by the supplier as follows: -

- Drop Test:

The pole shall be dropped vertically from a height of 3m above arm surface. The test will be deemed
successful if no welds crack or break.

- Loading Tests (type test):

Table 8:

Load Type of Load Acceptance Criteria

Ps Working load No deflection
Pb Ps x 1.5 Destruction

Where: -
Ps = Specified working load.
Pb = Breaking load.

All test loads shall be applied at a distance 600mm(9m) and 1200mm(11m), from the pole top
with the direction of force being perpendicular to the longitudinal axis of the pole. The bottom of
the pole shall be securely fixed during testing at a distance equal to the sinking depth as shown
in table 2. Loads shall be applied gradually and held constant at the final value for a period of
2 minutes after which the load will be released gradually. The purchaser reserves the right to
witness the testing at the expense of the supplier.

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 8- Handling:
Poles and cross arms shall be handled with due care. Specifically, poles shall not be dragged
along the ground and care shall be taken not to cause damage to the protective coating.
9. STAY SET
a. General
This specification covers the supply of the stay set assembled with the following
accessories for use to guy overhead 11 kV line at deviates from the loading angle points and
dead-end points, See Drawing (No.3). All the accessories shall be galvanized as per the relevant
standards.
b. Stay Rods
Stay rods shall be made of mild steel of ultimate tensile strength of 4200 kg/sq. cm. as
per IS 432 Part 1.
c. Turn Buckle
The stay turnbuckle shall be (bow or Tubular) type with ratchet nut adjuster. The
turnbuckle shall be made of steel of 4200 kgf/sq. cm. as per IS 432 Part 1. Bow type part of
the turnbuckle shall be made of the 18 mm. steel rod. A thimble made of 18 SWG G.I., steel
shall be coupled with bow. The thimble shall be suitable for diameter SWG stay wire.
d. Stay Plate
The stay plate shall be square type galvanized M.S. plate of 5 mm. thick. The plate shall
have suitable square shape hole of (40×40) mm. at the center. The dimension of the plate
shall be of (400×400) mm. for 11 kV line. Stay plate rod assembled with stay rod.
e. Galvanizing
All the stay set assembly must include rod, plate, turnbuckle, nut and bolts, washers,
thimble, etc. and they should be hot dip zinc galvanized conforming to IS 2629.

f. Stay Wire
The stay wire shall be zinc coated steel wire strand type generally used for guying the
Stay Set used on poles for the construction of overhead power line.
a. Description of strands
The steel strand shall be fabricated in accordance with ASTM specification A-475 or and
equivalent international standard, the any steel strand shall have the following features:
Quality of individual wire Class B with high strength
Quoting on the wire Zinc
Minimum Total Sectional Area 95 mm2
Laying of the strand Left hand lay
Minimum Ultimate Tensile Strength 77 KN
b. Packaging
The steel wire strand shall be furnished in 250 m(min). reels. Each reels shall have a weather
resistance tag securely attached the length, nominal diameter, number of individual wires,
grade of the strand, and the class of zinc coating.
g. Other Accessories

The Stay Set shall also include all other accessories such as nut, bolts, washers, thimble,
etc. that are necessary to assemble and fit the complete Stay Set

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 h. Rating of Stay Set

Length of stay rod 2m (min)

Diameter of rod 18 mm.
Ultimate tensile strength of stay rod and turn buckle 4200 kg/sq.cm
Length of threaded portion Min 300 mm
Thimble section 18 SWG min
Stay plate section 400×400×5 mm.
Elbow 18 mm. dia. M.S. rod(min)
Galvanization Confirm to IS - 2629
Applicable standard for steel IS – 432
10- Packing:

The manufacturer shall state clearly in his offer the proposed packing of the materials under
contract mainly for the poles and how many poles in each bundle. The cross arms and
accessories shall be supplied in suitable bundles as well. All poles shall be packed suitably to
provide full protection during multiple loading/offloading and storage, as the poles will be
redistributed several times to various destinations.

Note:
a. All drawings of the pole and its accessories subjected to our approval before start manufacturing.
b. The type of poles (galvanized) will be fixed by the tenderer.

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 D-Iron Bracket
Hot dip galvanized
 11-MV-STAY ARRANGEMENT

Drawing (No.3)

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