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Engineer Training Series – Towers & Foundation Mods Part 4 - Design Practices by Others presented from a Construction perspective on Tower & Foundation Modifications

Monopole - Self Supporter - Guyed Tower

Fred Teichman

www. f u l l e r t o n e n g i n e e r i n g . co m

Reinforcement Project Examples:

04/2014

Part 4 – Mods/Reinforcements with Project Examples In This module we cover typical reinforcement projects for each of the three structure types:

You will see both “Bolt on” applications as well as “Weld on” applications . Each of the slides that reference a Customer and Site Name indicates that the original modification drawings has been provided for additional review

First we cover Standard issued equipment & Safety 80% of the photos used in this material are from actual projects and referenced by customer & site. Project drawings and costs information is available upon request. [email protected]

www. f u l l e r t o n e n g i n e e r i n g . co m

A. Monopole Tower B. Self Supporting Tower (SST) C. Guyed Tower

The Key = Planning, Safety, & Communications All crews are equipped with Radios, First Aid, Fall Protection and Fire Safety equipment .

Fire Extinguishers, Water & Welding Blankets for all welding and drilling projects

www. f u l l e r t o n e n g i n e e r i n g . co m

Portable Water Tank

Many Projects require special equipment Welding blankets for all welding jobs to protect existing coax and cables

Water refill used during warm months CCI – Marshalltown IA

www. f u l l e r t o n e n g i n e e r i n g . co m

Fire extinguishers are required on all welding and drilling projects.

Complex Projects Require more – Leg Mod “Welding” A Climbers job is to also be the extra set of eyes for any signs of fire hazards

2 Spider baskets equipped with:

Extra hands are needed to assist in steel positioning, prepping and protection of existing equipment

CCI – Crawfordsville IN

Needs options (3)

www. f u l l e r t o n e n g i n e e r i n g . co m

Climbers, Welders, and Miller SuitCase mig welder.

Question(s) - Towers Mods

What’s on the tower now ?

Fred Teichman

www. f u l l e r t o n e n g i n e e r i n g . co m

Why is the Tower being modified ?

04/2014

Question – How... To add reinforcement Look up ... Take a look at the tower leg in the center of this picture

How easy do you think it would be to install continuous plate, ½ pipe or angle ?

www. f u l l e r t o n e n g i n e e r i n g . co m

Do you see a clear path ?

Be Aware of Existing Equipment and ... 90% of the towers you see today have one primary purpose – to securely position an antenna at a certain height . 95% of the total mounts used to hold those antennas in place are secured to the tower leg.

Often existing equipment is not considered in the modification design.

Simple point – every structure being modified has equipment on it.

www. f u l l e r t o n e n g i n e e r i n g . co m

The #1 problem when tower reinforcement projects require the legs to be strengthened... is getting around, under, or thru the existing mounts.

Part 4 – Monopole Mods (Reinforcements)

80% of the photos used in this material are from actual projects and referenced by customer & site. Project drawings and costs information is available upon request. [email protected]

www. f u l l e r t o n e n g i n e e r i n g . co m

Monopole Mods

Monopole Reinforcement Areas on the structure Reasons to modify or reinforce a monopole structure:

Areas of a monopole that commonly require reinforcement : A. B. C. D. E.

Base Flange Shaft (s) Entry /Exit ports (new) Splice flanges Foundations

www. f u l l e r t o n e n g i n e e r i n g . co m

A. Adding a Carrier B. Existing Carrier is adding or changing equipment

Part 4 – Monopole Mods (Reinforcements)

80% of the photos used in this material are from actual projects and referenced by customer & site. Project drawings and costs information is available upon request. [email protected]

www. f u l l e r t o n e n g i n e e r i n g . co m

Monopole Mods Examples

Monopole Reinforcement Projects

Customer & Projects Names:

Drawings Provided

www. f u l l e r t o n e n g i n e e r i n g . co m

(1) Crown Castle International (CCI) – Westerville OH (2) CCI- Plush Horse, Huntsville AL (3) CCI /Aero – Sweet MI (4) CCI /Aero – Cedar Road MI (5) CCI /Aero - Westerville IN (6) ATC – Bristol IL (7) ATC – Sugar Creek OH

Base Plate Reinforcement –Gussets Step 1

Layout project, protect bolts and remove existing galvanizing

CCI – Westerville OH

www. f u l l e r t o n e n g i n e e r i n g . co m

Remove all debris and clean inside of pole of any material that could start a fire

Base Plate Reinforcement –Gussets Step 2 Key point – Crew on site is always watching for any signs of fire from both grinding and welding Per the design, the material layout and welding is underway www. f u l l e r t o n e n g i n e e r i n g . co m

CCI – Westerville OH

Base Plate Reinforcement –Gussets Step 3

ZRC coating on all new steel, welds and existing surfaces effected by welding

Once the welding is complete – Field applied Cold galvanizing by “ ZRC “ is used to re-coat the factory applied galvanizing

CCI – Westerville OH

www. f u l l e r t o n e n g i n e e r i n g . co m

Inside Pole

Monopole baseplate/Foundation mod Weld on new DYWIDAG bracket and core drill

CCI Plush Horse – Huntsville AL

www. f u l l e r t o n e n g i n e e r i n g . co m

Core drill 11’ 6” into existing foundation

Monopole baseplate/Foundation mod Before

Most of the projects require grouting of the base plate CCI Plush Horse – Huntsville AL

After

www. f u l l e r t o n e n g i n e e r i n g . co m

Note – the complete project area has been recoated with gold galvanizing (ZRC) to protect existing surface

Monopole Reinforcement – Core drilling Base Plate During project.

Core Drilling track for long depth After

CCI/Aero Sweet MI

www. f u l l e r t o n e n g i n e e r i n g . co m

DYWIDAG rods drilled before welding bracket

Before - Monopole Shaft/baseplate/Foundation Mod

Existing base plate and shaft prior to project start CCI /Aero – Cedar Road MI

www. f u l l e r t o n e n g i n e e r i n g . co m

Typical existing site conditions include multiple cable bridge posts and other obstacles

During - Monopole Baseplate Mod Extensive welding to lower portion of shaft for Base plate reinforcement thru foundation

CCI /Aero – Cedar Road MI

www. f u l l e r t o n e n g i n e e r i n g . co m

Confirming weld size

Temperature gauge used to confirm metal is heated prior to welding

After - Monopole baseplate/Foundation mod Shaft reinforcement

Dywidag Rod

CCI /Aero – Cedar Road MI

Baseplate extension

www. f u l l e r t o n e n g i n e e r i n g . co m

Gusset

Testing the Installation – DYWIDAG Pull testing is performed after installation of DYWIGDAG rods and the epoxy has cured. Hydraulic jacks are used to provide sufficient lifting pressure during test.

www. f u l l e r t o n e n g i n e e r i n g . co m

Typical method to determine if specified epoxy is working

Base Plate Solution ?

www. f u l l e r t o n e n g i n e e r i n g . co m

Learn more at:

www.structuralcomponents.net

Monopole Shaft reinforcement Aero Solutions MP3 design

Concern: A lot of drilling resulting in disturbing the galvanized coating in multiple areas. www. f u l l e r t o n e n g i n e e r i n g . co m

Many areas not easy to inspect. Inside and behind

Crown /Aero - Westerville IN

Monopole Shaft reinforcement – Special Equipment

Moving from one flat to another

CCI /Aero – Cedar Road MI

www. f u l l e r t o n e n g i n e e r i n g . co m

Mag Drills & Spiders baskets

Monopole Mod - Shaft Reinforcement Shaft reinforcement From view upstairs

Installing Ajax bolts

CCI /Aero – Cedar Road MI

www. f u l l e r t o n e n g i n e e r i n g . co m

Shaft Reinforcement MP3 designed provided by Aero Solutions

Monopole Shaft reinforcement – Ajax Bolt Installation on channels around the pole require special equipment so access to drilling and bolting is possible AJAX Bolts

Blind bolt connection for steel – the washer is split and folds in half prior to inserting

www. f u l l e r t o n e n g i n e e r i n g . co m

Standard installation tool and sample bolts

Monopole Base plate & Shaft reinforcement Most Non weld pole mods require some welding ... And in some cases a lot Welds have been highlighted in yellow

CCI/Aero – Westville IN

www. f u l l e r t o n e n g i n e e r i n g . co m

Gusset plates 3’ – 6’ in length

Monopole Exit and Entry Ports

Increased concerns are addressed to prevent fire hazards during all grinding and welding activity due to existing coax inside monopole structure

Exit port is upstairs

Entry port is downstairs ATC – Bristol IL

www. f u l l e r t o n e n g i n e e r i n g . co m

Ports are installed by grinding the opening, inserting the port and welding it in place

Extreme/Odd Mods – How to repair a dent Pole was dented 131’ in the air by others ... How ? Not sure but we fixed it

ATC – Sugar Creek OH

www. f u l l e r t o n e n g i n e e r i n g . co m

Dent (Existing Damage)

Extreme/Odd Mods – Dent has been corrected Area was prepped by removing galvanizing and existing step bolts . Split sleeve was installed (welded) and step bolts re-welded in place. Complete area was primed and painted.

Before

www. f u l l e r t o n e n g i n e e r i n g . co m

ATC – Sugar Creek OH

During

After

Part 4 – SST Mods (Reinforcements)

Simple & Complex

80% of the photos used in this material are from actual projects and referenced by customer & site. Project drawings and costs information is available upon request. [email protected]

www. f u l l e r t o n e n g i n e e r i n g . co m

Self Supporting Mods

SST Reinforcement Areas on the structure

www. f u l l e r t o n e n g i n e e r i n g . co m

Basic areas to Reinforce • Leg • Horizontal members • Diagonal members • Flanges • Base Plate • Foundations

Part 4 – SST Mods (Reinforcements)

80% of the photos used in this material are from actual projects and referenced by customer & site. Project drawings and costs information is available upon request. [email protected]

www. f u l l e r t o n e n g i n e e r i n g . co m

Self Supporting Tower Mods Examples

SST Reinforcement Projects

Customer & Projects Names:

Drawings Provided

www. f u l l e r t o n e n g i n e e r i n g . co m

(1) Crown Castle International (CCI) – Howard Lake MN (2) CCI – Lafayette IN (3) ATC – Florence OH (4) MNDOT – Wykoff MN (5) CCI – Lake Zurich IL

SST Reinforcements - Horizontal Bolt on Mod

This project was challenged with having cable ladders on each of the 3 faces.

CCI – Howard Lake MN

www. f u l l e r t o n e n g i n e e r i n g . co m

Bolt on Horizontal attachments

SST Horizontal Bolt on Mod

Horizontal connected to existing stitch plate

CCI – Howard Lake MN

Unfortunately the J bolt hardware length was incorrect for the 3 existing cable ladders.

www. f u l l e r t o n e n g i n e e r i n g . co m

Standard bolt on leg application

SST Leg Reinforcement Bolt on PiRod leg reinforcement – Yes that is a lot of hardware and tough on your cloths ! www. f u l l e r t o n e n g i n e e r i n g . co m

CCI – Lafayette IN

SST Leg & Flange Reinforcement + Extension Angle welded to solid round leg needs to be continuous up the leg... Oops – M/W mount in the way

Weld on Bridge stiffener transitions around the existing PiRod flange CCI – Lafayette IN

www. f u l l e r t o n e n g i n e e r i n g . co m

Note – design drawings not available

SST Tower Extension Top of tower before

Removing beacon plate and prepping welding points www. f u l l e r t o n e n g i n e e r i n g . co m

CCI – Lafayette IN

Dual beacon light temp installed off to the side but remains functional Installing extensions on existing structures used to be common, but as the network continues to develop they are less and less.

SST Tower Extension

Manufacture provided template painted and welded in place on existing tower section CCI – Lafayette IN

www. f u l l e r t o n e n g i n e e r i n g . co m

Weld per design and installation specifications

SST Tower Extension Installing new solid leg tower extension

www. f u l l e r t o n e n g i n e e r i n g . co m

Installing the 10’ extension on existing tower

CCI – Lafayette IN

SST Angle Leg Reinforcement Angle Leg Reinforcement with tabbed solid rod attachments

Sky Climber like a Spider basket

www. f u l l e r t o n e n g i n e e r i n g . co m

ATC Florence OH

SST Angle Leg Reinforcement & Diagonal Bracing Interior wind lacing (bracing) required field modifications due to material shipped. Angle was coped, bent, drilled, coated and then installed www. f u l l e r t o n e n g i n e e r i n g . co m

ATC - Florence OH

Extreme/Odd Mods – 4 leg SST C channel screw mounted to top and bottom side of back to back angles

www. f u l l e r t o n e n g i n e e r i n g . co m

CCI – Lake Zurich IL

Extreme/Odd Mods – Diagonal and Horizontal

C channel screwed - (yes screwed) ... to the existing back to back angle

CCI – Lake Zurich IL

Cut and drilled on site

www. f u l l e r t o n e n g i n e e r i n g . co m

Raw Galvanized material on site provided in stock lengths.

Extreme/Odd Mods – Diagonal and Horizontal

Triangle bracing

Difficult access and nasty painting

CCI – Lake Zurich IL

www. f u l l e r t o n e n g i n e e r i n g . co m

Man lift used for interior lacing due to span and access. Spider baskets in upper portion of the tower

Part 4 – Guyed Tower Mods (Reinforcements)

80% of the photos used in this material are from actual projects and referenced by customer & site. Project drawings and costs information is available upon request. [email protected]

www. f u l l e r t o n e n g i n e e r i n g . co m

Guyed Tower Mods

Guyed Tower - Reinforcement Areas A. Modifications to the Sections Members & Flanges B. Modifications to the Foundations

www. f u l l e r t o n e n g i n e e r i n g . co m

ATC Patent # US8250817 Inverted U Anchor reinforcement

Diagonals Legs Horizontals

Guyed Tower - Reinforcement Areas C. Simply Adding additional Guyed points

www. f u l l e r t o n e n g i n e e r i n g . co m

Part 4 – Guyed Towers (Reinforcements)

80% of the photos used in this material are from actual projects and referenced by customer & site. Project drawings and costs information is available upon request. [email protected]

www. f u l l e r t o n e n g i n e e r i n g . co m

Guyed Tower Reinforcement Examples

Guyed Tower Reinforcement Projects

Customer & Projects Names: BCI/Structural Components – Lincoln NE CCI – Crawfordsville IN CCI – Lafayette IN CCI – Marshalltown IA

Drawings Provided

www. f u l l e r t o n e n g i n e e r i n g . co m

1. 2. 3. 4.

Guyed Tower – Leg Reinforcement Pipe on Angle

www. f u l l e r t o n e n g i n e e r i n g . co m

All bolted angle leg reinforcement using galv pipe designed by BCI (now known as Structural Components

BCI/Structural Components – Lincoln NE

Transition around guy pull-off

Guyed Tower – Leg Reinforcement details

Pipe to pipe extension sleeve BCI/Structural Components – Lincoln NE

www. f u l l e r t o n e n g i n e e r i n g . co m

Needs options (2)

L brackets u-bolted and bolted directly to the vertical pipe

Guyed Tower Leg Reinforcement – Angle on Pipe

CCI – Crawfordsville IN

Crew using Spider basket for welding and extra climber is keeping an eye for fire hazards.

www. f u l l e r t o n e n g i n e e r i n g . co m

All Weld application with angle on pipe to reinforce the tower leg.

Guyed Tower Leg and Flange Reinforcement

Transition stiffeners used to carry the load around the towers existing flange CCI – Crawfordsville IN

www. f u l l e r t o n e n g i n e e r i n g . co m

Stiffeners on each side of the angle

Guyed Tower Flange Reinforcement ... Mounts ? View of completed transition stiffeners prior to FAA painting www. f u l l e r t o n e n g i n e e r i n g . co m

CCI – Crawfordsville IN

Question ? The same approach is used for going around existing mounts CCI – Lafayette IN

Towers with lots of Mounts require ... Bridge Stiffeners Transition Stiffeners, Bridge Stiffeners, same idea ... Just much larger do to the area or space being skipped

Project material prepared by removing the galvanizing prior to welding CCI – Marshalltown IA

www. f u l l e r t o n e n g i n e e r i n g . co m

So a tower with a lot of mounts will require a lot stiffeners

Tower Leg Reinforcement around existing mounts – Detail

CCI – Marshalltown IA

www. f u l l e r t o n e n g i n e e r i n g . co m

Round leg tower with angle reinforcement requires continuous lengths of certain areas on the tower. Antenna mounts are always bolted to the legs of the tower. Here is one way to transition or “Bridge” the existing mount

Welding projects – Bridge Stiffener

www. f u l l e r t o n e n g i n e e r i n g . co m

Yes – sometimes it seams impossible to see how everything will fit.

CCI – Marshalltown IA

Welding projects – Bridge Stiffener

CCI – Marshalltown IA

www. f u l l e r t o n e n g i n e e r i n g . co m

Size needed per engineer to transfer the load around the existing mounts

Great weld looking even better when finished with galv and FAA paint

Guyed Tower Foundations - Guyed Anchors

Typical straight forward deadman anchor install turns into engineered changes due to poor soil conditions Crown Castle – Marshalltown IA

www. f u l l e r t o n e n g i n e e r i n g . co m

Walls collapse causing over excavation

Guyed Tower Foundations - Guyed Anchors

Installing steel casing to form the concrete block as per the design

CCI – Marshalltown IA

Existing guy Anchor

www. f u l l e r t o n e n g i n e e r i n g . co m

The soil conditions varied from one new install anchor point to another

Guyed Tower Foundation - Guy Anchor Poor soil conditions (walls collapsed) - required engineered steel casing & oversizing of anchor block

CCI – Marshalltown IA

www. f u l l e r t o n e n g i n e e r i n g . co m

Over excavation , steel framing, increased rebar and oversized block. Change Orders (costs) available for review

Guyed Tower – Adding Guy Wire Adding and changing out guy wires require special equipment to pull and release tension during the process

Come-Along

www. f u l l e r t o n e n g i n e e r i n g . co m

Cable Grip

Guyed Tower – Reinforcement – Guy Change-out Truck

Bailing wire Thimble

CCI – Marshalltown IA

www. f u l l e r t o n e n g i n e e r i n g . co m

Preform

Top View of Guy pull-off (existing for guy replacement)

Guyed Tower Foundation – Center Pier

Just the beginning

Needs details and info

Helical Screw Anchors project! CCI – Marshalltown IA

www. f u l l e r t o n e n g i n e e r i n g . co m

Before

Guyed Tower Foundation – Center Pier First the area is cleared around the base of the tower. Then the anchors are installed using special attachments

Skid steer using hydraulic attachment

CCI – Marshalltown IA

www. f u l l e r t o n e n g i n e e r i n g . co m

Special note: Site remains live and existing coax equipment is protected and watched during all activity

Guyed Tower Center Pier – Mod with Screw Anchors Once the helical anchors are all installed, the remaining excavation begins to expose the existing foundation and to prep surface to dowel in the rebar

CCI – Marshalltown IA

www. f u l l e r t o n e n g i n e e r i n g . co m

Drilled into existing pier, the rebar is secured with epoxy

Guyed Tower - Center Pier Reinforcement

Needs detail

Extensive work required to tie in new rebar to existing foundation pier and to newly installed helical screw anchors

www. f u l l e r t o n e n g i n e e r i n g . co m

CCI – Marshalltown IA

Guyed Tower - Center Pier Reinforcement

Concrete is poured and finished CCI – Marshalltown IA

Foundation mod for center pier completed and includes capping off screw anchors and installing required cable support structures

www. f u l l e r t o n e n g i n e e r i n g . co m

Need details

Towers & Foundation Reinforcement – Summary

Safety Special Equipment Bolt on – Weld on Inspections & Certifications Remember the existing Equipment Library of Mod drawings by others

Next 3 slides cover basic Safety guidelines issued by Crown Castle International on all mod projects Fred Teichman

www. f u l l e r t o n e n g i n e e r i n g . co m

• • • • • •

04/2014

CCI - Safety Guidelines The Following Safety Guidelines are For Installation Contractors Performing Structural Modifications on Towers Where Cutting and Welding of Steel is Required; Such as Cutting New Portholes in Monopoles and Reinforcing Structural Tower Members and Sections. Refer to CCUSA Cutting, Welding, and Safety Policy.

www. f u l l e r t o n e n g i n e e r i n g . co m

CCI Welding - Safety Guidelines Sample Guidelines provided by Crown Castle (CCUSA)

www. f u l l e r t o n e n g i n e e r i n g . co m

CCI Cutting - Safety Guidelines Sample Guidelines provided by Crown Castle (CCUSA)

www. f u l l e r t o n e n g i n e e r i n g . co m

Specialized Suppliers & Resources – Mods ep-ind.com

zrcworldwide.com structuralcomponents.net commstructures.com

aerosolutionsllc.com

sabretowersandpoles.com/Tower-Modifications

valmont.com/valmont-structures/products/wireless-communication wirelesscomponents.com Specialty Manufacturing LLC abchance.com

vikinghelicalanchors.com

Fred Teichman linkedin.com/in/fredteichman

www. f u l l e r t o n e n g i n e e r i n g . co m

dywidag-systems.com