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www.fullertonengineering.com
Engineer Training Series – Towers & Foundation Mods
Reinforcement Project Examples:
Monopole - Self Supporter - Guyed Tower
Fred Teichman 04/2014
Part 4 - Design Practices by Others presented from a Construction perspective on
Tower & Foundation Modifications
www.fullertonengineering.com
Part 4 – Mods/Reinforcements with Project Examples
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. FredTeichmanHTH@gmail.com
In This module we cover typical reinforcement projects for each of the three
structure types:
A. Monopole Tower
B. Self Supporting Tower (SST)
C. Guyed Tower
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
www.fullertonengineering.com
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
Portable Water Tank
www.fullertonengineering.com
Many Projects require special equipment
Welding blankets
for all welding jobs
to protect existing
coax and cables
Fire extinguishers
are required on all
welding and drilling
projects.
CCI – Marshalltown IA
Water
refill
used
during
warm
months
www.fullertonengineering.com
Complex Projects Require more – Leg Mod “Welding”
Needs options (3)
2 Spider baskets
equipped with:
Climbers,
Welders,
and
Miller SuitCase
mig welder.
Extra hands are
needed to assist in
steel positioning,
prepping and
protection of existing
equipment
CCI – Crawfordsville IN
A Climbers job is to
also be the extra set of
eyes for any signs of
fire hazards
www.fullertonengineering.com
Question(s) - Towers Mods
Why is the Tower being modified ?
What’s on the tower now ?
Fred Teichman 04/2014
www.fullertonengineering.com
Question – How... To add reinforcement
Do you see a clear
path ?
How easy do you
think it would be
to install
continuous plate,
½ pipe or angle ?
Look up ...
Take a look at the
tower leg in the
center of this picture
www.fullertonengineering.com
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.
The #1 problem when
tower reinforcement
projects require the legs
to be strengthened... is
getting around, under, or
thru the existing mounts.
Often existing equipment
is not considered in the
modification design.
Simple point – every
structure being modified has
equipment on it.
www.fullertonengineering.com
Part 4 – Monopole Mods (Reinforcements)
Monopole Mods
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. FredTeichmanHTH@gmail.com
www.fullertonengineering.com
Monopole Reinforcement Areas on the structure
Reasons to modify or reinforce a
monopole structure:
A. Adding a Carrier
B. Existing Carrier is adding or
changing equipment
Areas of a monopole that
commonly require
reinforcement :
A. Base Flange
B. Shaft (s)
C. Entry /Exit ports (new)
D. Splice flanges
E. Foundations
www.fullertonengineering.com
Part 4 – Monopole Mods (Reinforcements)
Monopole Mods
Examples
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. FredTeichmanHTH@gmail.com
www.fullertonengineering.com
Monopole Reinforcement Projects
Customer & Projects Names:
(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
Drawings Provided
www.fullertonengineering.com
Base Plate Reinforcement –Gussets Step 1
Layout project, protect bolts and
remove existing galvanizing
CCI – Westerville OH
Remove all debris and clean inside of pole
of any material that could start a fire
www.fullertonengineering.com
Per the design, the material layout
and welding is underway
CCI – Westerville OH
Base Plate Reinforcement –Gussets Step 2
Key point – Crew on site is always watching for
any signs of fire from both grinding and welding
www.fullertonengineering.com
ZRC coating on all new steel, welds
and existing surfaces effected by
welding
CCI – Westerville OH
Base Plate Reinforcement –Gussets Step 3
Once the welding is complete – Field applied
Cold galvanizing by “ ZRC “ is used to re-coat
the factory applied galvanizing
Inside Pole
www.fullertonengineering.com
Monopole baseplate/Foundation mod
CCI Plush Horse – Huntsville AL
Weld on new DYWIDAG bracket and core drill
Core drill 11’ 6” into existing
foundation
www.fullertonengineering.com
Monopole baseplate/Foundation mod
CCI Plush Horse – Huntsville AL
Before
After
Note – the complete
project area has been
recoated with gold
galvanizing (ZRC) to
protect existing surface
Most of the projects
require grouting of the
base plate
www.fullertonengineering.com
Monopole Reinforcement – Core drilling Base Plate
CCI/Aero
Sweet MI
After
During
project.
DYWIDAG
rods drilled
before
welding
bracket
Core Drilling
track for long
depth
www.fullertonengineering.com
Before - Monopole Shaft/baseplate/Foundation Mod
CCI /Aero – Cedar Road MI
Existing base plate and shaft
prior to project start
Typical existing site conditions
include multiple cable bridge posts
and other obstacles
www.fullertonengineering.com
During - Monopole Baseplate Mod
CCI /Aero – Cedar Road MI
Temperature gauge used
to confirm metal is
heated prior to welding
Extensive welding to lower portion of shaft for Base plate reinforcement thru foundation
Confirming weld size
www.fullertonengineering.com
After - Monopole baseplate/Foundation mod
CCI /Aero – Cedar Road MI
Shaft reinforcement
Baseplate extension
Dywidag Rod
Gusset
www.fullertonengineering.com
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.
Typical method to determine if specified epoxy is
working
www.fullertonengineering.com
Base Plate Solution ?
Learn more at: www.structuralcomponents.net
www.fullertonengineering.com
Monopole Shaft reinforcement
Crown /Aero - Westerville IN
Concern: A lot of
drilling resulting
in disturbing the
galvanized coating
in multiple areas.
Many areas not
easy to inspect.
Inside and behind
Aero
Solutions
MP3 design
www.fullertonengineering.com
Monopole Shaft reinforcement – Special Equipment
Mag Drills & Spiders
baskets
CCI /Aero – Cedar Road MI
Moving from
one flat to
another
www.fullertonengineering.com
Monopole Mod - Shaft Reinforcement
CCI /Aero – Cedar Road MI
Shaft Reinforcement
MP3 designed provided
by Aero Solutions
Shaft reinforcement
From view upstairs
Installing Ajax bolts
www.fullertonengineering.com
Monopole Shaft reinforcement – Ajax Bolt
Blind bolt connection for steel – the washer is split and folds in half prior to inserting
Standard installation tool and sample bolts
Installation on channels around the pole require
special equipment so access to drilling and bolting is
possible
AJAX Bolts
www.fullertonengineering.com
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
Gusset plates 3’ – 6’ in length
CCI/Aero – Westville IN
www.fullertonengineering.com
Monopole Exit and Entry Ports
ATC – Bristol IL
Ports are
installed by
grinding the
opening,
inserting the
port and
welding it in
place
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
www.fullertonengineering.com
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
Dent
(Existing Damage)
www.fullertonengineering.com
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.
ATC – Sugar Creek OH
Before
During After
www.fullertonengineering.com
Part 4 – SST Mods (Reinforcements)
Self Supporting
Mods
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. FredTeichmanHTH@gmail.com
www.fullertonengineering.com
SST Reinforcement Areas on the structure
Basic areas to Reinforce
• Leg
• Horizontal members
• Diagonal members
• Flanges
• Base Plate
• Foundations
www.fullertonengineering.com
Part 4 – SST Mods (Reinforcements)
Self Supporting Tower
Mods Examples
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. FredTeichmanHTH@gmail.com
www.fullertonengineering.com
SST Reinforcement Projects
Customer & Projects Names:
(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
Drawings Provided
www.fullertonengineering.com
SST Reinforcements - Horizontal Bolt on Mod
CCI – Howard
Lake MN
Bolt on
Horizontal
attachments
This project was
challenged with
having cable
ladders on each
of the 3 faces.
www.fullertonengineering.com
SST Horizontal Bolt on Mod
CCI – Howard Lake MN
Standard bolt on leg
application
Horizontal connected to existing stitch plate
Unfortunately the J bolt hardware length was incorrect for
the 3 existing cable ladders.
www.fullertonengineering.com
SST Leg Reinforcement
CCI – Lafayette IN
Bolt on PiRod leg
reinforcement – Yes
that is a lot of
hardware and tough
on your cloths !
www.fullertonengineering.com
Note – design drawings not available
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
www.fullertonengineering.com
Installing extensions on existing structures used
to be common, but as the network continues to
develop they are less and less.
CCI – Lafayette IN
SST Tower Extension
Top of tower before
Dual beacon
light temp
installed off to
the side but
remains
functional
Removing beacon plate and prepping
welding points
www.fullertonengineering.com
CCI – Lafayette IN
SST Tower Extension
Manufacture provided template painted and welded in place on existing tower section
Weld per design
and installation
specifications
www.fullertonengineering.com
Installing the 10’ extension on existing tower
CCI – Lafayette IN
SST Tower Extension
Installing new solid leg tower extension
www.fullertonengineering.com
SST Angle Leg Reinforcement
Angle Leg
Reinforcement
with tabbed
solid rod
attachments
ATC -
Florence
OH
Sky Climber like a
Spider basket
www.fullertonengineering.com
SST Angle Leg Reinforcement & Diagonal Bracing
ATC - Florence OH
Interior wind lacing
(bracing) required field
modifications due to
material shipped. Angle
was coped, bent, drilled,
coated and then installed
www.fullertonengineering.com
Extreme/Odd Mods – 4 leg SST
C channel screw
mounted to top and
bottom side of back
to back angles
CCI – Lake Zurich IL
www.fullertonengineering.com
Extreme/Odd Mods – Diagonal and Horizontal
C channel screwed - (yes screwed) ...
to the existing back to back angle
CCI – Lake Zurich IL
Raw Galvanized material on site
provided in stock lengths.
Cut and drilled on site
www.fullertonengineering.com
Extreme/Odd Mods – Diagonal and Horizontal
CCI – Lake Zurich IL
Triangle bracing
Difficult access and nasty
painting
Man lift used for
interior lacing
due to span and
access. Spider
baskets in upper
portion of the
tower
www.fullertonengineering.com
Part 4 – Guyed Tower Mods (Reinforcements)
Guyed Tower
Mods
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. FredTeichmanHTH@gmail.com
www.fullertonengineering.com
Guyed Tower - Reinforcement Areas
A. Modifications to the Sections
Members & Flanges
Diagonals
Legs
Horizontals
B. Modifications to
the Foundations
ATC Patent # US8250817
Inverted U Anchor reinforcement
www.fullertonengineering.com
Guyed Tower - Reinforcement Areas
C. Simply Adding additional Guyed points
www.fullertonengineering.com
Part 4 – Guyed Towers (Reinforcements)
Guyed Tower
Reinforcement
Examples
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. FredTeichmanHTH@gmail.com
www.fullertonengineering.com
Guyed Tower Reinforcement Projects
Customer & Projects Names:
1. BCI/Structural Components – Lincoln NE
2. CCI – Crawfordsville IN
3. CCI – Lafayette IN
4. CCI – Marshalltown IA
Drawings Provided
www.fullertonengineering.com
Guyed Tower – Leg Reinforcement Pipe on Angle
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
www.fullertonengineering.com
Guyed Tower – Leg Reinforcement details
Needs options (2)
BCI/Structural Components – Lincoln NE
Pipe to pipe extension sleeve
L brackets u-bolted
and bolted directly to
the vertical pipe
www.fullertonengineering.com
Guyed Tower Leg Reinforcement – Angle on Pipe
CCI – Crawfordsville IN
All Weld application
with angle on pipe to
reinforce the tower
leg.
Crew using Spider
basket for welding
and extra climber is
keeping an eye for fire
hazards.
www.fullertonengineering.com
Guyed Tower Leg and Flange Reinforcement
CCI – Crawfordsville IN
Transition stiffeners used to carry the load around the towers
existing flange
Stiffeners
on each
side of the
angle
www.fullertonengineering.com
Guyed Tower Flange Reinforcement ... Mounts ?
CCI – Crawfordsville IN
CCI – Lafayette IN
View of
completed
transition
stiffeners
prior to FAA
painting
Question ?
The same
approach is
used for
going
around
existing
mounts
www.fullertonengineering.com
Towers with lots of Mounts require ... Bridge Stiffeners
CCI – Marshalltown IA
Transition Stiffeners, Bridge Stiffeners, same idea ... Just
much larger do to the area or space being skipped
So a tower with a lot of
mounts will require a
lot stiffeners
Project material
prepared by removing
the galvanizing prior
to welding
www.fullertonengineering.com
Tower Leg Reinforcement around existing mounts – Detail
CCI – Marshalltown IA
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
www.fullertonengineering.com
Welding projects – Bridge Stiffener
CCI – Marshalltown IA
Yes –
sometimes it
seams
impossible to
see how
everything
will fit.
www.fullertonengineering.com
Welding projects – Bridge Stiffener
CCI – Marshalltown IA
Size needed per engineer
to transfer the load
around the existing
mounts
Great weld
looking even
better when
finished with
galv and FAA
paint
www.fullertonengineering.com
Guyed Tower Foundations - Guyed Anchors
Crown Castle – Marshalltown IA
Typical straight forward dead-
man anchor install turns into
engineered changes due to
poor soil conditions
Walls collapse causing over excavation
www.fullertonengineering.com
Guyed Tower Foundations - Guyed Anchors
The soil
conditions
varied from
one new
install anchor
point to
another
CCI – Marshalltown IA
Existing
guy
Anchor
Installing steel
casing to form
the concrete
block as per
the design
www.fullertonengineering.com
Guyed Tower Foundation - Guy Anchor
Poor soil conditions (walls collapsed) - required engineered steel casing &
oversizing of anchor block
CCI – Marshalltown IA
Over excavation , steel framing, increased rebar and
oversized block.
Change Orders (costs)
available for review
www.fullertonengineering.com
Guyed Tower – Adding Guy Wire
Adding and changing out guy
wires require special equipment
to pull and release tension during
the process
Cable Grip
Come-Along
www.fullertonengineering.com
Guyed Tower – Reinforcement – Guy Change-out
Top View of Guy pull-off (existing
for guy replacement)
CCI – Marshalltown IA
Preform
Bailing wire
Thimble
Truck
www.fullertonengineering.com
Guyed Tower Foundation – Center Pier
Needs details and info
Just the beginning
Before
CCI – Marshalltown IA
Helical Screw Anchors project!
www.fullertonengineering.com
Guyed Tower Foundation – Center Pier
First the area is cleared around the base of
the tower. Then the anchors are installed
using special attachments
CCI – Marshalltown IA
Skid steer using hydraulic attachment
Special note: Site remains live and existing coax
equipment is protected and watched during all
activity
www.fullertonengineering.com
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
Drilled into
existing pier,
the rebar is
secured with
epoxy
www.fullertonengineering.com
Guyed Tower - Center Pier Reinforcement
Needs detail
CCI – Marshalltown IA
Extensive work required to tie in new
rebar to existing foundation pier and to
newly installed helical screw anchors
www.fullertonengineering.com
Guyed Tower - Center Pier Reinforcement
Need details
CCI – Marshalltown IA
Concrete is poured and finished
Foundation mod for center pier completed and
includes capping off screw anchors and
installing required cable support structures
www.fullertonengineering.com
Towers & Foundation Reinforcement – Summary
Fred Teichman 04/2014
• 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
www.fullertonengineering.com
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.fullertonengineering.com
CCI Welding - Safety Guidelines
Sample Guidelines provided by Crown Castle (CCUSA)
www.fullertonengineering.com
CCI Cutting - Safety Guidelines
Sample Guidelines provided by Crown Castle (CCUSA)
www.fullertonengineering.com
Specialized Suppliers & Resources – Mods
abchance.com
dywidag-systems.com
sabretowersandpoles.com/Tower-Modifications
valmont.com/valmont-structures/products/wireless-communication
wirelesscomponents.com
Specialty Manufacturing LLC
ep-ind.com
Fred Teichman
linkedin.com/in/fredteichman
commstructures.com
vikinghelicalanchors.com
zrcworldwide.com
structuralcomponents.net
aerosolutionsllc.com

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Part 4 Mods - Tower and Foundation Modifications on vertical structures

  • 1. www.fullertonengineering.com Engineer Training Series – Towers & Foundation Mods Reinforcement Project Examples: Monopole - Self Supporter - Guyed Tower Fred Teichman 04/2014 Part 4 - Design Practices by Others presented from a Construction perspective on Tower & Foundation Modifications
  • 2. www.fullertonengineering.com Part 4 – Mods/Reinforcements with Project Examples 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. FredTeichmanHTH@gmail.com In This module we cover typical reinforcement projects for each of the three structure types: A. Monopole Tower B. Self Supporting Tower (SST) C. Guyed Tower 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
  • 3. www.fullertonengineering.com 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 Portable Water Tank
  • 4. www.fullertonengineering.com Many Projects require special equipment Welding blankets for all welding jobs to protect existing coax and cables Fire extinguishers are required on all welding and drilling projects. CCI – Marshalltown IA Water refill used during warm months
  • 5. www.fullertonengineering.com Complex Projects Require more – Leg Mod “Welding” Needs options (3) 2 Spider baskets equipped with: Climbers, Welders, and Miller SuitCase mig welder. Extra hands are needed to assist in steel positioning, prepping and protection of existing equipment CCI – Crawfordsville IN A Climbers job is to also be the extra set of eyes for any signs of fire hazards
  • 6. www.fullertonengineering.com Question(s) - Towers Mods Why is the Tower being modified ? What’s on the tower now ? Fred Teichman 04/2014
  • 7. www.fullertonengineering.com Question – How... To add reinforcement Do you see a clear path ? How easy do you think it would be to install continuous plate, ½ pipe or angle ? Look up ... Take a look at the tower leg in the center of this picture
  • 8. www.fullertonengineering.com 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. The #1 problem when tower reinforcement projects require the legs to be strengthened... is getting around, under, or thru the existing mounts. Often existing equipment is not considered in the modification design. Simple point – every structure being modified has equipment on it.
  • 9. www.fullertonengineering.com Part 4 – Monopole Mods (Reinforcements) Monopole Mods 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. FredTeichmanHTH@gmail.com
  • 10. www.fullertonengineering.com Monopole Reinforcement Areas on the structure Reasons to modify or reinforce a monopole structure: A. Adding a Carrier B. Existing Carrier is adding or changing equipment Areas of a monopole that commonly require reinforcement : A. Base Flange B. Shaft (s) C. Entry /Exit ports (new) D. Splice flanges E. Foundations
  • 11. www.fullertonengineering.com Part 4 – Monopole Mods (Reinforcements) Monopole Mods Examples 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. FredTeichmanHTH@gmail.com
  • 12. www.fullertonengineering.com Monopole Reinforcement Projects Customer & Projects Names: (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 Drawings Provided
  • 13. www.fullertonengineering.com Base Plate Reinforcement –Gussets Step 1 Layout project, protect bolts and remove existing galvanizing CCI – Westerville OH Remove all debris and clean inside of pole of any material that could start a fire
  • 14. www.fullertonengineering.com Per the design, the material layout and welding is underway CCI – Westerville OH Base Plate Reinforcement –Gussets Step 2 Key point – Crew on site is always watching for any signs of fire from both grinding and welding
  • 15. www.fullertonengineering.com ZRC coating on all new steel, welds and existing surfaces effected by welding CCI – Westerville OH Base Plate Reinforcement –Gussets Step 3 Once the welding is complete – Field applied Cold galvanizing by “ ZRC “ is used to re-coat the factory applied galvanizing Inside Pole
  • 16. www.fullertonengineering.com Monopole baseplate/Foundation mod CCI Plush Horse – Huntsville AL Weld on new DYWIDAG bracket and core drill Core drill 11’ 6” into existing foundation
  • 17. www.fullertonengineering.com Monopole baseplate/Foundation mod CCI Plush Horse – Huntsville AL Before After Note – the complete project area has been recoated with gold galvanizing (ZRC) to protect existing surface Most of the projects require grouting of the base plate
  • 18. www.fullertonengineering.com Monopole Reinforcement – Core drilling Base Plate CCI/Aero Sweet MI After During project. DYWIDAG rods drilled before welding bracket Core Drilling track for long depth
  • 19. www.fullertonengineering.com Before - Monopole Shaft/baseplate/Foundation Mod CCI /Aero – Cedar Road MI Existing base plate and shaft prior to project start Typical existing site conditions include multiple cable bridge posts and other obstacles
  • 20. www.fullertonengineering.com During - Monopole Baseplate Mod CCI /Aero – Cedar Road MI Temperature gauge used to confirm metal is heated prior to welding Extensive welding to lower portion of shaft for Base plate reinforcement thru foundation Confirming weld size
  • 21. www.fullertonengineering.com After - Monopole baseplate/Foundation mod CCI /Aero – Cedar Road MI Shaft reinforcement Baseplate extension Dywidag Rod Gusset
  • 22. www.fullertonengineering.com 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. Typical method to determine if specified epoxy is working
  • 23. www.fullertonengineering.com Base Plate Solution ? Learn more at: www.structuralcomponents.net
  • 24. www.fullertonengineering.com Monopole Shaft reinforcement Crown /Aero - Westerville IN Concern: A lot of drilling resulting in disturbing the galvanized coating in multiple areas. Many areas not easy to inspect. Inside and behind Aero Solutions MP3 design
  • 25. www.fullertonengineering.com Monopole Shaft reinforcement – Special Equipment Mag Drills & Spiders baskets CCI /Aero – Cedar Road MI Moving from one flat to another
  • 26. www.fullertonengineering.com Monopole Mod - Shaft Reinforcement CCI /Aero – Cedar Road MI Shaft Reinforcement MP3 designed provided by Aero Solutions Shaft reinforcement From view upstairs Installing Ajax bolts
  • 27. www.fullertonengineering.com Monopole Shaft reinforcement – Ajax Bolt Blind bolt connection for steel – the washer is split and folds in half prior to inserting Standard installation tool and sample bolts Installation on channels around the pole require special equipment so access to drilling and bolting is possible AJAX Bolts
  • 28. www.fullertonengineering.com 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 Gusset plates 3’ – 6’ in length CCI/Aero – Westville IN
  • 29. www.fullertonengineering.com Monopole Exit and Entry Ports ATC – Bristol IL Ports are installed by grinding the opening, inserting the port and welding it in place 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
  • 30. www.fullertonengineering.com 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 Dent (Existing Damage)
  • 31. www.fullertonengineering.com 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. ATC – Sugar Creek OH Before During After
  • 32. www.fullertonengineering.com Part 4 – SST Mods (Reinforcements) Self Supporting Mods 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. FredTeichmanHTH@gmail.com
  • 33. www.fullertonengineering.com SST Reinforcement Areas on the structure Basic areas to Reinforce • Leg • Horizontal members • Diagonal members • Flanges • Base Plate • Foundations
  • 34. www.fullertonengineering.com Part 4 – SST Mods (Reinforcements) Self Supporting Tower Mods Examples 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. FredTeichmanHTH@gmail.com
  • 35. www.fullertonengineering.com SST Reinforcement Projects Customer & Projects Names: (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 Drawings Provided
  • 36. www.fullertonengineering.com SST Reinforcements - Horizontal Bolt on Mod CCI – Howard Lake MN Bolt on Horizontal attachments This project was challenged with having cable ladders on each of the 3 faces.
  • 37. www.fullertonengineering.com SST Horizontal Bolt on Mod CCI – Howard Lake MN Standard bolt on leg application Horizontal connected to existing stitch plate Unfortunately the J bolt hardware length was incorrect for the 3 existing cable ladders.
  • 38. www.fullertonengineering.com SST Leg Reinforcement CCI – Lafayette IN Bolt on PiRod leg reinforcement – Yes that is a lot of hardware and tough on your cloths !
  • 39. www.fullertonengineering.com Note – design drawings not available 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
  • 40. www.fullertonengineering.com Installing extensions on existing structures used to be common, but as the network continues to develop they are less and less. CCI – Lafayette IN SST Tower Extension Top of tower before Dual beacon light temp installed off to the side but remains functional Removing beacon plate and prepping welding points
  • 41. www.fullertonengineering.com CCI – Lafayette IN SST Tower Extension Manufacture provided template painted and welded in place on existing tower section Weld per design and installation specifications
  • 42. www.fullertonengineering.com Installing the 10’ extension on existing tower CCI – Lafayette IN SST Tower Extension Installing new solid leg tower extension
  • 43. www.fullertonengineering.com SST Angle Leg Reinforcement Angle Leg Reinforcement with tabbed solid rod attachments ATC - Florence OH Sky Climber like a Spider basket
  • 44. www.fullertonengineering.com SST Angle Leg Reinforcement & Diagonal Bracing ATC - Florence OH Interior wind lacing (bracing) required field modifications due to material shipped. Angle was coped, bent, drilled, coated and then installed
  • 45. www.fullertonengineering.com Extreme/Odd Mods – 4 leg SST C channel screw mounted to top and bottom side of back to back angles CCI – Lake Zurich IL
  • 46. www.fullertonengineering.com Extreme/Odd Mods – Diagonal and Horizontal C channel screwed - (yes screwed) ... to the existing back to back angle CCI – Lake Zurich IL Raw Galvanized material on site provided in stock lengths. Cut and drilled on site
  • 47. www.fullertonengineering.com Extreme/Odd Mods – Diagonal and Horizontal CCI – Lake Zurich IL Triangle bracing Difficult access and nasty painting Man lift used for interior lacing due to span and access. Spider baskets in upper portion of the tower
  • 48. www.fullertonengineering.com Part 4 – Guyed Tower Mods (Reinforcements) Guyed Tower Mods 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. FredTeichmanHTH@gmail.com
  • 49. www.fullertonengineering.com Guyed Tower - Reinforcement Areas A. Modifications to the Sections Members & Flanges Diagonals Legs Horizontals B. Modifications to the Foundations ATC Patent # US8250817 Inverted U Anchor reinforcement
  • 50. www.fullertonengineering.com Guyed Tower - Reinforcement Areas C. Simply Adding additional Guyed points
  • 51. www.fullertonengineering.com Part 4 – Guyed Towers (Reinforcements) Guyed Tower Reinforcement Examples 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. FredTeichmanHTH@gmail.com
  • 52. www.fullertonengineering.com Guyed Tower Reinforcement Projects Customer & Projects Names: 1. BCI/Structural Components – Lincoln NE 2. CCI – Crawfordsville IN 3. CCI – Lafayette IN 4. CCI – Marshalltown IA Drawings Provided
  • 53. www.fullertonengineering.com Guyed Tower – Leg Reinforcement Pipe on Angle 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
  • 54. www.fullertonengineering.com Guyed Tower – Leg Reinforcement details Needs options (2) BCI/Structural Components – Lincoln NE Pipe to pipe extension sleeve L brackets u-bolted and bolted directly to the vertical pipe
  • 55. www.fullertonengineering.com Guyed Tower Leg Reinforcement – Angle on Pipe CCI – Crawfordsville IN All Weld application with angle on pipe to reinforce the tower leg. Crew using Spider basket for welding and extra climber is keeping an eye for fire hazards.
  • 56. www.fullertonengineering.com Guyed Tower Leg and Flange Reinforcement CCI – Crawfordsville IN Transition stiffeners used to carry the load around the towers existing flange Stiffeners on each side of the angle
  • 57. www.fullertonengineering.com Guyed Tower Flange Reinforcement ... Mounts ? CCI – Crawfordsville IN CCI – Lafayette IN View of completed transition stiffeners prior to FAA painting Question ? The same approach is used for going around existing mounts
  • 58. www.fullertonengineering.com Towers with lots of Mounts require ... Bridge Stiffeners CCI – Marshalltown IA Transition Stiffeners, Bridge Stiffeners, same idea ... Just much larger do to the area or space being skipped So a tower with a lot of mounts will require a lot stiffeners Project material prepared by removing the galvanizing prior to welding
  • 59. www.fullertonengineering.com Tower Leg Reinforcement around existing mounts – Detail CCI – Marshalltown IA 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
  • 60. www.fullertonengineering.com Welding projects – Bridge Stiffener CCI – Marshalltown IA Yes – sometimes it seams impossible to see how everything will fit.
  • 61. www.fullertonengineering.com Welding projects – Bridge Stiffener CCI – Marshalltown IA Size needed per engineer to transfer the load around the existing mounts Great weld looking even better when finished with galv and FAA paint
  • 62. www.fullertonengineering.com Guyed Tower Foundations - Guyed Anchors Crown Castle – Marshalltown IA Typical straight forward dead- man anchor install turns into engineered changes due to poor soil conditions Walls collapse causing over excavation
  • 63. www.fullertonengineering.com Guyed Tower Foundations - Guyed Anchors The soil conditions varied from one new install anchor point to another CCI – Marshalltown IA Existing guy Anchor Installing steel casing to form the concrete block as per the design
  • 64. www.fullertonengineering.com Guyed Tower Foundation - Guy Anchor Poor soil conditions (walls collapsed) - required engineered steel casing & oversizing of anchor block CCI – Marshalltown IA Over excavation , steel framing, increased rebar and oversized block. Change Orders (costs) available for review
  • 65. www.fullertonengineering.com Guyed Tower – Adding Guy Wire Adding and changing out guy wires require special equipment to pull and release tension during the process Cable Grip Come-Along
  • 66. www.fullertonengineering.com Guyed Tower – Reinforcement – Guy Change-out Top View of Guy pull-off (existing for guy replacement) CCI – Marshalltown IA Preform Bailing wire Thimble Truck
  • 67. www.fullertonengineering.com Guyed Tower Foundation – Center Pier Needs details and info Just the beginning Before CCI – Marshalltown IA Helical Screw Anchors project!
  • 68. www.fullertonengineering.com Guyed Tower Foundation – Center Pier First the area is cleared around the base of the tower. Then the anchors are installed using special attachments CCI – Marshalltown IA Skid steer using hydraulic attachment Special note: Site remains live and existing coax equipment is protected and watched during all activity
  • 69. www.fullertonengineering.com 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 Drilled into existing pier, the rebar is secured with epoxy
  • 70. www.fullertonengineering.com Guyed Tower - Center Pier Reinforcement Needs detail CCI – Marshalltown IA Extensive work required to tie in new rebar to existing foundation pier and to newly installed helical screw anchors
  • 71. www.fullertonengineering.com Guyed Tower - Center Pier Reinforcement Need details CCI – Marshalltown IA Concrete is poured and finished Foundation mod for center pier completed and includes capping off screw anchors and installing required cable support structures
  • 72. www.fullertonengineering.com Towers & Foundation Reinforcement – Summary Fred Teichman 04/2014 • 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
  • 73. www.fullertonengineering.com 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.
  • 74. www.fullertonengineering.com CCI Welding - Safety Guidelines Sample Guidelines provided by Crown Castle (CCUSA)
  • 75. www.fullertonengineering.com CCI Cutting - Safety Guidelines Sample Guidelines provided by Crown Castle (CCUSA)
  • 76. www.fullertonengineering.com Specialized Suppliers & Resources – Mods abchance.com dywidag-systems.com sabretowersandpoles.com/Tower-Modifications valmont.com/valmont-structures/products/wireless-communication wirelesscomponents.com Specialty Manufacturing LLC ep-ind.com Fred Teichman linkedin.com/in/fredteichman commstructures.com vikinghelicalanchors.com zrcworldwide.com structuralcomponents.net aerosolutionsllc.com