K-600 MAST - E-Tech Components · K-600 MAST INSTALLATION MANUAL 3&7 t%3"8*/(/3 $% ERECTION USING A...

CUE DEE ”YOUR INNOVATIVE PARTNER” 1

Visit our homepage for more information and manual downloads.www.cuedee.com • [email protected]

K-600 MAST INSTALLATION MANUAL REV: 1.7 • DRAWING NR: CD 430000

K-600 MAST

Consists of square 2 m high sections. The side of the sections range from 600 mm to 1050 mm. Tapered sections are used to connect 2 different section sizes. To support the mast, guy wires are used at multiple levels depending on the height of the mast.

All Enquiries: | tel: +44 (0)1744 762 929 | email: [email protected] | web: www.etechcomponents.com


2 CUE DEE ”YOUR INNOVATIVE PARTNER”


CONTENTS

GENERAL .................................................................................................................................... 3

THE K-600 MAST SYSTEM ......................................................................................................... 4

GENERAL LAYOUT OF A K-600 MAST .......................................................................................... 5

BOLT DIMENSIONS AND TIGHTENING TORQUE ............................................................................. 6

ERECTING AND ASSEMBLY OF THE K-600 MAST ........................................................................ 8

GUY PLACEMENT AND ADJUSTMENT .......................................................................................... 15

DIMENSIONS AND WEIGHTS ........................................................................................................ 19

ACCESSORIES ............................................................................................................................ 20

SLACKPULLER ............................................................................................................................ 27

CONTACT INFORMATION ............................................................................................................ 32





GENERALThis assembly instruction is in accordance with SS-EN 1090-2 and intended for professional mast and tower installers as an installation guide.

A triangle with an exclamation mark indicates a warning. This means that there is a potential risk for personal injuries. The text beside it will explain how to avoid the risk.

An exclamation mark indicates a potential risk for material damages or economic loss. The text beside it will explain how to avoid the risk.

A light bulb indicates a suggestion of how to solve a specific task more efficiently.

The K-600 hot-dip galvanized solid-rod steel mast is built using 2 m long mast sections and a K-type framework. The mast is climba-ble on all four sides, including the inside and the outside. The K-600 mast system can be erected on a roof, on top of a shelter or on the ground.

Guyed masts erected on the ground can be assembled to a height of approximately 100 - 140 m depending on the wind conditions, icy conditions and installed equipment. The masts can be erected by crane, gin pole or helicopter. Antennas can be attached to the mast before or after the mast has been erected.

Warning! The delivered mast is dimensioned to carry specific equipment and be placed on a specific location. Therefore, it is not permitted to use the mast for other purposes without consulting CUE DEE!





REF. DENOMINATION: QUANTITY DESCRIPTION: COMMENTS:

1 CD 431100 K-600 mast section Qt. depending on configuration. 8 M16x 90 Hex head bolt 8 M16 Hex head nut 16 Washer

2 CD 431101 K-600 mast section with manhole At least 1 per mast 8 M16 x 90 Hex head bolt 8 M16 Hex head nut 16 Washer

3 CD 431142 Guy attachment K-600 1 per guying level 8 M16 x 150 Hex head bolt 8 M16 Hex head nut 16 Washer

4 CD 431146 Torsion attachment K-600 1 per torsion level 8 M16 x 150 Hex head bolt 8 M16 Hex head nut 16 Washer Set of guys Depending on load and height. Installation instruction

THE K-600 MAST SYSTEMESSENTIAL PARTS OF A K-600 MAST

Below are the standard parts included in a K-600 mast. Apart from these, there are a number of accessories which are used de-pending on the site configuration. Please refer to the Packing List included in the hardware pallet of your shipment for the proper configuration of your specified mast.

THE K-600 SECTIONS ARE 2 M IN HEIGHT. THE WIDTH IS 600 MM CC.

K-600 SECTIONCD 431100

K-600 SECTION WITH MANHOLECD 431101

GUY ATTACHMENT K-600CD 431142

TORSION ATTACHMENT K-600CD 431146

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Example of a 60 m K-600 Mast erected on the ground.

GENERAL LAYOUT OF A K-600 MASTTo the left is an example of a mast layout. Please refer to the included drawings in the hardware pallet of your shipment for the proper configuration of your mast.

REF. DENOMINATION QUANTITY DESCRIPTION COMMENTS 1 CD 431100 29 K-600 mast section2 CD 431101 1 K-600 mast section with manhole3 CD 431142 4 Guy attachment K-6004 CD 339000 1 Lightning rod5 CD 5052830 1 Guy wire (wire strand) 52mm2 830 m6 CD 50351 32 Slackpuller M16 x 3007 M6S M16x90 HTG 8.8 200 M16 Hex head bolt8 M6S M16x150 HTG 8.8 32 M16 Hex head bolt9 BRB M16 HTG 464 Washer10 M6M M16 HTG KL8 232 Hex head nut





BOLT DIMENSIONS AND TIGHTENING TORQUEBelow are the tightening torques for the section connection bolts and most common accessories.

8.8 BoltSurface treatment

M12HTG

M16HTG

M20HTG

M24HTG

M27HTG

M30HTG

Tightening moment (Nm) 87 211 385 665 961 1310

RECOMMENDED TIGHTENING TORQUE FOR PRE-LOADED BOLTS

The section joints are Pre-loaded bolt connections according to SS-EN 1090-2.

Torque tightening methods according to the methods described in SS-EN 1090-2. The nuts and bolts have a specific delivery friction to ensure the correct preloading force in the joint. The connection should be tightened on the nut side.

No additional wax or lubricant should be used. Keep the nuts and bolts in their bags as long as possible to prevent the lubricant to be washed away by rain etc.

Pre-loaded bolts does not need additional locking. Nut locking where necessary by punch mark, lock nut or double nut.

WRONG RIGHT

If the bolt box has a label specifying the tightening tourqe,use the box lable tourqe insteed of the tourqe in the table above.

10.9 BoltSurface treatment

M12HTG

M16HTG

M20HTG

M24HTG

M27HTG

M30HTG

Tightening moment (Nm) 85 250 430 750 1100 1500





Due to the change in the strength class for incoming bolted joints from 8.8 to 10.9, the section joints in K-600 strong only need to be bolted with 2 x 10.9 bolts, compared with the previous 4 x 8.8 bolts. The bolts are placed diagonally on the base block. The bolted joint is tightened according to the torque specified on the bolt packaging.





ASSEMBLY AND ERECTION OF THE K-600 MAST

GENERAL SAFETY PRECAUTIONS

• MAKE SURE THAT THE CREW ALWAYS WEARS PROTECTIVE HELMETS WHEN ERECTING THE MAST.

• NEVER ALLOW THE CREW TO WALK UNDER THE MAST WHILE IT IS BEING LIFTED.

• BEAR IN MIND THAT IF OBJECTS ARE DROPPED FROM HEIGHT ,THEY CAN BOUNCE AWAY A GREAT DISTANCE FROM THE MAST. ALWAYS BE ALERT FOR DROPPED OBJECTS.

• CHECK ALL SAFETY EQUIPMENT FOR DAMAGES AND FAULTS BEFORE USE.

• KEEP SPECTATORS AT A SAFE DISTANCE.

• FOLLOW THE INSTRUCTIONS GIVEN IN THE PARAGRAPHS DESCRIBING THE ERECTING METHODS.

• MAKE SURE THAT ALL PERSONNEL INVOLVED ARE INFORMED OF THESE SAFETY INSTRUCTIONS.

PREPARATIONS

• At least 4 workers with proper skills are required for the erection of the mast. 2 of them should have advan ced climbing skills.

• Make sure that the shipment contains all the parts according to the configuration, including accessories, of your specific mast.

EQUIPMENT

The equipment described in the table below is not part of the delivery but is required for the assembly of the mast.

REQUIRED EQUIPMENT

QTY: DESCRITPTION: COMMENT:2 13 mm Box-end wrench or equivalent2 18 and 19 mm Box-end wrench or equivalent2 24 mm Box-end wrench1 41 mm open-end wrench (If a mast base is used)1 Torque wrench Up to 200 Nm (1000 Nm if a mast base is used)1 Steel Wire or Rope* Length: 2 times mast height + 10 m. See warning below!

* If gin pole is used for lifting.

WARNING! THE ROPE MUST BE AN INDUSTRIAL STATIC ROPE (MAX 4% ELASTIC DEFORMATION) OR A STEEL WIRE ROPE THAT IS DIMENSIONED FOR THE HEAVIEST PART LIFTED.





USEFUL EQUIPMENT

QTY: DESCRITPTION: COMMENT: Lever Hoist Hammer Slings Pulley Steel rod For alignment of bolt holes. Ø15 or tapered end. Rope Extra rope for steering when lifting.

FOUNDATIONThis instruction manual does not cover the construction of the foundation. The foundation must be built according to the applied legal standards of the country where the mast will be placed. The delivered documentation should contain technical requirements for the foundation such as applied forces. Otherwise, contact CUE DEE.

CLIMBINGAt least two workers should be certified for advanced climbing. •DONOTCLIMBTHEMASTINHEAVYRAINORSTRONGWIND. •ALWAYSUSEPROPERSAFETYEQUIPMENT •DONOTCLIMBTHEMASTIFYOUDON’THAVETHEPROPEREDUCATIONANDEXPERIENCE.

Bear in mind that the work being done up on the mast is slower than on the ground. Always prepare the parts as much as possible before they are lifted. Check the mounting holes and deburr them if necessary.

ERECTION USING A GIN POLEThe mast can be erected section by section by using a gin pole. Please refer to separate gin pole instructions.





ERECTION USING A CRANE

1. Mount the manhole section to the mast base or the concrete foundation depending on foundation type. Make sure that it is plumb.

2. Wrap two lifting straps around two leg members close to the joining plates of the mast, at the top or at two thirds of the total height of the mast assembly (more than 40 m should not be lifted at one time). Always put the straps as close as possible to the joining plates of two sections.

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Proper Sling Attachment Positions

WARNING! THE MAST MUST NOT BE LIFTED BY A LIFTING SLING WHICH IS ONLY WRAPPEDAROUND ONE SINGLE FRAME MEMBER. DOING SO WILL CAUSE DAMAGE TO THE MAST SECTION.

Secure the straps to the two frame members to prevent them from sliding during erection.

Roll the guys together and tape them to the bottom of the mast to prevent them from getting tangled during erection.

When everything is prepared and the hook of the crane is connected to the lifting straps, start by lifting the mast approx-imately 1 m above the ground. Check to make sure that no cables or guys obstruct the lifting of the mast.

Lift the mast into position and secure it to the section already fitted to the base. During the entire lifting procedure the mast should be carefully watched and if anything is obstructing the operation the work should be halted.

While the crane holds the mast in position secure the guys to the anchors.

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CONCRETE FOUNDATION ANCHOR BOLTSWhen the mast is erected on a concrete foundation, the lowest mast section can be mounted directly to the foundation without the use of a mast base.

Mount the manhole section to the mast base or the concrete foundation depending on foundation type. Make sure that it is plumb.

Wrap two lifting straps around two leg members close to the joining plates of the mast, at the top or at two thirds of the total height of the mast assembly (more than 40 m should not be lifted at one time). Always put the straps as close as possible to the joining plates of two sections.

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Template for M16 Anchor Bolts.





GROUTINGGrouting of the space between the concrete and the base plates (flanges) of the lowest section is always recommended and neces-sary if the clearance between the concrete and base section exceeds twice the anchor bolt diameter. Grouting can be done when the base section is leveled and tightened but it’s recommended that you erect a number of sections before grouting. Clean all contact surfaces. All surfaces in contact with grout must be free from dirt, oil, grime and other contaminants. If the concrete surface is loose, defective or has laitance, it should be cleaned to a sound base. Prior to placement of grout, thoroughly saturate the concrete surface with cement water. Remove surface water just prior to grout placement.

Place a framework around the foot plate of the base section. The framework should be higher than the distance between the concrete and the foot plate. To achieve an adequate size of the grout, the size of the framework box should be = w+2d, where w is the width of the foot plate and d is the distance between the concrete and the foot-plate. The framework should be well fixed and tight.

Mix the grout in accordance with the instructions given by the grout manufacturer. Use a premixed non-shrink, noncorrosive/ non-metallic cement based product, i.e. SikaGrout-212, Masterflow 520 or equivalent.

Forms may be removed when grout is self-supporting.

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Grouting with Straight Sides Excessive Concrete cut away.

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5

For best results, grout should extend downward at a 45° angle from the lower edge of the base-plate as shown in the right-hand figure below. Cut back excessive areas. Keep exposed areas wet for 3 days.

WARNING! THE MAST MUST NOT BE LIFTED BY A LIFTING SLING WHICH IS ONLY WRAPPED AROUND ONE SINGLE FRAME MEMBER. DOING SO WILL CAUSE DAMAGE TO THE MAST SECTION.





ASSEMBLY OF THE K-600 SYSTEMThe procedure described below is intended for erection by using a gin pole. If a crane or helicopter is used, the process is basically the same except that the mast sections can be preassembled prior to lifting. Tighten all bolts to the required torque according to the table on page 6.

Mount the manhole section to the mast base or the concrete foundation depending on foundation type.Make sure that it is plumb.

Erect standard K-600 sections up to the first guy attachment. Place a washer on each side of the section foot plates as shown at (A) in the figure below. Place the nut on the top side to simplify tightening.

Make sure that the sections are turned so that the K-framework forms a ladder.The arrow-like diagonal members shall point upwards.

Do not use iron sledges for hammering galvanized parts of the mast.Hammers of plastic, lead or other soft material should be used.

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M16x90 BOLT HTGM16 WASHER HTG

M16 NUT HTG

A

B

M16x150 BOLT HTGM16 WASHER HTGM16 NUT HTG

SLACK PULLER

Standard guy attachment CD 431142

GUY WIRE





Mount the guy attachment. For determination of suitable height refer to the Mast drawing included in the delivered docu mentation. Place a washer on each side of the section joining plates as shown at (B) in K-600 Assembly.

Fit the guys to the guy attachment with the slack pullers as show in the figure on the previous page. Make sure that the guy is properly secured to the slack puller.

If the mast is equipped with a torsion attachment proceed assembling up to it.

Mount the torsion attachment. For determination of suitable height refer to the Mast drawing included in the delivered docu mentation.

Fit the guys to the torsion attachment with the slack pullers. Every other guy must be mounted in the upper hole, and every other in the lower hole as shown in the figure below. Make sure there is no contact between crossingwires. See note below!

Proceed with the rest of the mast.

NOTE! Every other guy must be mounted in the upper hole, and the rest in the lower hole as shown in the figure above. If not, the strands may collide and cause wearing of the strands.

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Torsion Attachment CD431146

GUY WIRE

SLACK PULLER

M16x130 BOLT HTGM16 WASHER HTGM16 NUT HTG

CD 431146 TORSIONALGUY ATTATCHMENT

SEE NOTE!





GUY PLACEMENT AND ADJUSTMENT

GENERAL The Guys are dimensioned and delivered with the mast.

Please refer to the Mast drawing included in the delivered documentation for proper configuration.

Warning! It is very important that you read and follow the instructions for guy placement and adjustment. An incorrect mounted guy can result in collapsing of the mast.

Accurate adjustment can be measured by using a Theodolite.

•Donotadjustormeasurethemastduringwindspeedgreaterthan5m/satgroundlevelorifthereis ice present on the mast.

•Theinitialtensionsmaydifferduetodifferencesintheelevationsoftheguyanchorsandtwistinthe mast shaft. It is important that the mast is plumb before the guys are tensioned.

GENERAL POSITIONING OF GUY ANCHOR POINTSThe position of the anchor points for the guys is determined by the number of guys per level and the guy radius. A K-600 mast has 4 guys per level which results in a 90° angle between the anchor points. The torsion attachment has 8 guys but because they are con-nected to the anchor points in pairs, the anchor placement is the same.

Normal Guy Arrangement Guy Arrangement for TorsionAttachment





Example with a Guying Radius of 30 m

View from above

The guying radius can be configured in two ways depending on the ground conditions on the site.

The normal configuration is to have one or two guying radii depending on the mast height. The guys from several guying levels can then share the same guy supports.

The other configuration alternative is to have one guying radius per guying level.

Please refer to the Mast drawing included in the delivered documentation for proper positioning of anchor points.

It is important that the positions of the anchor points are accurate. • If the guying radius is 25 m the anchor position must not differ more than 1 m from the correct position. • If the guying radius is 50 m the anchor position must not differ more than 2 m from the correct position. • If the accuracy is not possible, contact CUE DEE to verify alternative anchor points.

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The tables below show the recommended initial pretension of

guys depending on the difference between temperature on the

specific occasion of pretension and the average annual tempera-

ture at the site.

The guy pretension according to the tables will be 13 % of the guy

breaking strength when the site temperature is 20° C lower, and

8 % when the site temperature is 20° C higher than the average

temperature at the site. The steeper the guy, the smaller is the

temperature correction.

RECOMMENDED GUY PRETENSION AT DIFFERENT SITE TEMPERATURES. CUE DEE MAST K - 600

ANCHORING THE GUYSAnchoring can be done in bedrock or in soil. For more information about anchoring.

Please refer to the “Soil Anchor” or the “Rock Anchor” part in the Accessories chapter.

GUY TENSIONINGAfter erection, the mast must be adjusted and the guys tensioned.

•5,4kN±10%for52mm2 strand. •7,1kN±10%for68mm2 strand. •9,3kN±10%for89mm2 strand. •10,9kN±10%for105mm2 strand. •14,1kN±10%for135mm2 strand. •19,3kN±10%for185mm2 strand.

Apply the tightening torque mentioned on page 6 to the locking screws of the slack puller wedges. Start by tensioning the guys on the

lowest guying level and proceed upwards to the highest guying level.

Note it is important to have equal tension on the wire to the same guy attachment. Difference in guy tension in between guy levels is less important and will always occur due to different shrinkage for different wire heigths.





PRETENSION OF 135 mm2 GUY (kN)

Slope of guy to the horizontal Temperature difference from average (ºC) -20 -10 0 +10 +20

20º 22,7 20,5 18,4 16,2 14,1

30º 21,3 19,5 17,7 15,9 14,1

40º 19,7 18,3 16,9 15,5 14,1

50º 18,1 17,1 16,1 15,1 14,1

60º 16,5 15,9 15,3 14,7 14,1

70º 15,2 14,9 14,6 14,4 14,1

80º 14,4 14,3 14,2 14,1 14,1



20º 30,8 27,9 25,0 22,1 19,3

30º 28,9 26,5 24,1 21,7 19,3

40º 26,8 24,9 23,0 21,1 19,3

50º 24,6 23,3 22,0 20,6 19,3

60º 22,6 21,8 20,9 20,1 19,3

70º 20,9 20,5 20,1 19,7 19,3

80º 19,7 19,6 19,5 19,4 19,3

REMARKS ON GUY TENSIONINGThe measurement of guy tensions should be made at a time when the wind velocity is less than 5 m/s at ground level.Final plumbing and tensioning of guys should normally proceed from the lowest guy level upward.



20º 8.9 8.1 7.2 6.3 5.4

30º 8.4 7.6 6.9 6.2 5.4

40º 7.7 7.1 6.6 6.0 5.4

50º 7.0 6.6 6.2 5.8 5.4

60º 6.4 6.1 5.9 5.6 5.4

70º 5.9 5.7 5.6 5.5 5.4

80º 5.5 5.5 5.5 5.4 5.4



20º 11.7 10.5 9.4 8.2 7.1

30º 10.9 10.0 9.0 8.0 7.1

40º 10.1 9.3 8.6 7.8 7.1

50º 9.1 8.6 8.1 7.6 7.1

60º 8.3 8.0 7.7 7.4 7.1

70º 7.6 7.5 7.4 7.2 7.1

80º 7.2 7.2 7.2 7.1 7.1

PRETENSIONOF89mm2 GUY (kN)


20º 15,1 13,6 12,2 10.7 9,3

30º 14,1 12,9 11,7 10,5 9,3

40º 13,1 12,1 11,2 10,2 9,3

50º 12,0 11,3 10,6 9,9 9,3

60º 10,9 10,5 10,1 9,7 9,3

70º 10,0 9,9 9,7 9,5 9,3

80º 9,5 9,4 9,4 9,3 9,3



20º 17.9 16.2 14.4 12.7 10.9

30º 16.9 15.4 13.9 12.4 10.9

40º 15.5 14.3 13.2 12.1 10.9

50º 14.0 13.3 12.5 11.7 10.9

60º 12.8 12.3 11.8 11.4 10.9

70º 11.8 11.6 11.3 11.1 10.9

80º 11.1 11.1 11.0 11.0 10.9





TOLERANCES

The final position of the centre line of the mast should all lie within a vertical cone with its apex at the mast base and with a radius of 1/1500 of the height above the mast base.

The resultant horizontal component of the initial guy tensions of all the guys at a given level should not exceed 5% of the average hori-zontal component of the initial guy tension for that level.

The initial tension in any individual guy at a level should in no case vary more than 10 % from the design value.

Maximum initial deflection of the mast column between two guy levels, where L is the distance between the guy levels in question, should be L/1000. After erection the tolerance on the alignment of 3 consecutive guy connections on the shaft is limited to (L1 + L2)/2000, where L1 and L2 are the lengths of the two consecutive spans of the shaft.

DIMENSIONS AND WEIGHTS

PARTS

DENOMINATION DESCRIPTION HxWxL [mm] WEIGHT [KG]

CD 431100 K-600 Section 2000 x 600 x 600 (CC) 70CD 431101 K-600 Section with manhole 2000 x 600 x 600 (CC) 70CD 431170 K-600 Strong 82 K-600 Climbing barrier 1600 x 1600 25.5CD 431142 K-600 Guy attachment 60 x 750 x 750 30CD 431146 K-600 Torsion attachment 200 x 850 x 850 55CD 339000 K-600 Lightning rod 2000 x Ø25 10 K-600 Obstruction light fitting 900 8.5CD 431117 Cable support 310 x 66 x 27 0.4 Guy 52 mm2 Ø9,2 0.41 Kg/m Guy 68 mm2 Ø10,6 0.54 Kg/m Guy 105 mm2 Ø13,1 0.82 Kg/m3700210 Soil Anchor 2200 x Ø 475 11.2 Rock Anchor for Concreting See under Accessories See under AccessoriesCD 431153 Mastbase 800 x 800 x 140 60





MAST BASE

ARTICLE NR: 5162, CD 431153 To mount the mast on bedrock a mast base is required.

ACCESSORIES

Bedrock mounting

Remove loose material from bedrock.

Drill 4 holes Ø50 mm in square spaced 750 mm to approx-

imately 800 mm depth. Use mast base as a drilling template.

Clear the holes thoroughly from water, drilling residues and

contaminations.

Use a premixed non-shrink, non-corrosive/non-metallic

cement based product, i.e. SikaGrout-212, Masterflow 520 or

equivalent. Mix it in accordance with the instructions given by

the manufacturer.

Fill the holes with the mixture (grout) and insert the M27 an-

chor bolts. Anchor bolts should extend approximately 300mm

above ground.

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Mast base assembly

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Mount the mast base (1) on the M 27 rods (4) with a washer

(3) on the upper side and a nut (5) on each side of the mast

base and keep it mounted during hardening to fix the rods´

position.

When the grout is hardened attach the first mast section and

adjust it plumb.

If the distance D from the bedrock to the mast base exceeds

two times the bolt diameter, apply grout between the bedrock

and the mast base, see page 12 for grouting instructions.

ca 3

00 m

m





SÖLL FALL PROTECTIONSöll fall protection system is the prefered fall protection amongst mast climbers. (several) other fall protection

systems available upon request

Make sure that all parts are included in the shipment according to the packing list.

Assemble the Söll Fall Protection according to the söll instructions that are delivered with the fall

protection system.

Lift the fall protection in place at the centre of one of the mast sides as shown in the figure below.

If erecting is done by crane or Gin pole, the fall protection can be mounted before erecting.

Mount a Söll information sign on the mast and sign it.

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Söll Fall Protection system mounted on a K-600 section Söll Fall Protection Sign





CLIMBING BARRIER

ARTICLE NR: 1583When the climbing barrier is open it is possible to climb past the barrier on both in and outside of the mast.

The Climbing Barrier consists of two parts and four U-bolts:

• Door (1)

• Side Barriers (2)

• U-bolts (3)

Climbing barrier for K-600Door closed

Climbing barrier for K-600Door open

Begin by determining the height you wish to fit the climbing barrier on. It must however be positioned in level with a horizontal

member of the mast.

Fit the 3-side barrier (2) to the mast with its vertical rods leaning along the mast´s vertical members. Use four U-bolts (3) to

mount the side barrier as shown in the figure above. Tighten the Ubolts to 22 Nm.

Place the door with its hooks on the horizontal member of the mast on the same level as the rest of the climbing barrier.

The door should be resting on the opposite horizontal member when closed.

When the climbing barrier is aligned and the door can be opened without any problems, damage the threads of the Ubolts at the

nut by using a centre punch. This prevents unauthorized persons from breaching through the climbing barrier.

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To lock the barrier, use a padlock large enough to reach across the climbing barrier door and the horizontal member of the mast.

To open the door, pull it backwards toward the hooks and lower it to a vertical position or remove it completely while accessing the mast.

The mast can then be climbed on the inside and the outside.

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MAST FOUNDATION FSK600-6021

ARTICLENR:2019Standard mast foundation for K-600 masts. Install according to foun-

dation drawing. Foundation can be shipped prefabricated or in situ.

Weight: 2,7 ton

ARTICLE NR: 4050 Foundation bolts kit.

For in situ installations order a foundation bolts kit.

Other foundation designs are available.

GUY FOUNDATION GP170-2012

ARTICLENR:5905Concrete guy foundation for masts. Install according to foundation drawing. Specify number of guy connections.

Weight: 1230 kg





Soil anchor

SOIL ANCHOR

ARTICLE NR: 5544A guy wire can be anchored in the soil by using a soil anchor. Place the anchor in the

ground at depth and tilting angle according to the table below. If the mast is located at

a place where there can be frost in the ground, the soil anchor must be placed under

ground frost level.

Note! The backfill must be friction material, well compactedand not contain clay, organic material or ice.

Stagplattan i plåt monteras med den kupade sida uppåt.(se märkning)

Nedgrävningsdjupet anpassas till markslag och staglutning enligt

tabell i EBR KJ10:96. (Normalt 1,5-2,0 m)

Förankringen skall i framkanten vila mot orörd mark. Urschaktning sker

i stagets riktning för staglänk och eventuellt tillkommande bergöglelänkar.

Återfyllnad sker med den uppschaktade massorna.

AVAILABLE ROCK ANCHOR DIMENSIONS

ARTICLE: MAX GUYAREA: [mm2] DIAMETER: [mm] LENGTH: [mm] WEIGHT: [kg]1544 68 20 2200 17

* For anchoring in poor quality bedrock





ROCK ANCHOR FOR CONCRETING

ARTICLE NR: 3018 A guy wire can be anchored in the bedrock using a rock anchor. Check the bedrock for cracks and determine its quality.

Chose anchor length based on the rock quality. Contact www.necks.se for detailed instructions.

Locate the anchor point according to the mast drawing.

Remove loose material from the bedrock.

Drill a vertical hole in the ground according to the table below.

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Rock Anchor for Concreting

AVAILABLE ROCK ANCHOR DIMENSIONS

ARTICLE: MAX GUYAREA: [mm2] DIAMETER: [mm] LENGTH: [mm] WEIGHT: [kg] DRILL HOLE: [mm]2971 68 20 1000 0,72 Ø26-29 x 1050

3018 142 25 1500 6.7 Ø32-36 x 1550

* For anchoring in poor quality bedrock

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Clear the hole thoroughly from water, drilling residues and contaminations.

Use a premixed non-shrink, non-corrosive/non-metallic cement based product, i.e. SikaGrout-212, Masterflow 520 or equivalent.

Mix it in accordance with the instructions given by the manufacturer.

Fill the hole with the mixture (grout) and insert the rock anchor so that only the ring is above the rock surface.





ANCHOR ROD EXTENSION 1000 mm

ARTICLENR:2971If necessary extend rock or soil anchors to get the slack puller above ground.

Length: 1000 mm. For wire area 52-68 mm2

ROCK ANCHOR CD 30505023

ARTICLE NR: 4081Anchoring point for up to six guy wires. Includes two M27x1000 8.8 threaded rods with

nuts and washers.

Remove loose material from bedrock.

Drill 2 holes Ø50 mm to approximately 1000 mm depth.

Clear the holes thoroughly from water, drilling residues and contaminations.

Use a premixed non-shrink, noncorrosive/ non-metallic cement based product,

i.e. SikaGrout-212, Masterflow 520 or equivalent. Mix it in accordance

with the instructions given by the manufacturer.

Fill the holes with the mixture (grout) and insert the M27 anchor bolts. Apply

grout to get an even surface for the rock anchor.

Mount the rock anchor on the M 27 rods with a washer and a nut. Keep it

mounted during hardening to affix the rods’ position.

Tighten the M 27 Nuts to 500 Nm and punch the threads

When the grout is hardened attach the guy wires. If less than 6 wires are at-

tached, arrange the wires as symmetrically as possible.

1

2

3

4

5

6

7

8





SLACK PULLER

SLACK PULLER FOR 25-52 mm2 WIREARTICLE NR: 1471A= 50 mm B= 300 mm D= M16 Weight 1.5 kg

Wedge locking screw tightening torque= 45 Nm

The slackpuller is designed for 25-68 mm2 wire, but Cue Dee recommend

using the larger Slack Puller for the 68 mm2 wire for easier installation.

SLACKPULLERFOR68-89mm2 WIREARTICLE NR: 1472A= 60 mm B= 350 mm D= M20 Weight 2.7 kg


The slackpuller is designed for 68-105 mm2 wire, but Cue Dee recommend

using the larger Slack Puller for the 105 mm2 wire easier installation.

SLACK PULLER FOR 105-142 mm2 WIREARTICLE NR: 2182A= 75 mm B= 425 mm D= M24 Weight 5,4 kg


SLACK PULLER FOR 185-284 mm2 WIREARTICLE NR: 5358A= 90 mm B= 425 mm D= M27 Weight 9 kg


If anything is unclear please contact Cue Dee.





SLACK PULLERS FOR GUYS (Short version)

ART.NR GUY AREA: [mm2] SLACK PULLER SIZE: WEDGE LOCKING SCREW TIGHTENING TORQUE [NM]1471 52 mm2 M16 451472 68 mm2 M20 751472 89 mm2 M20 752182 105 mm2 M24 752182 135 mm2 M24 755358 185 mm2 M27 100

SLACKPULLER





MAXIMUM INTERVALSMaintenance and condition assessment shall be performed in accordance with national

standards. Cue Dee recommend:

a) One-year interval for wind measurement masts. Three-year intervals for permanent

masts and five-year intervals for self-supporting structures.

b) After severe wind and /or ice storms or other extreme conditions.

c) Shorter inspection intervals may be required for Class III structures and structures in

coastal regions, in corrosive environments, and in areas subject to frequent vandalism.

MAINTENANCE AND CONDITION ASSESSMENT ON CUE DEE K-SYSTEM

A STRUCTURE CONDITION

1) Damaged members (legs and bracing)

2) Loose members

3) Missing members

4) Climbing facilities, platforms – all secure

5) Loose and/or missing bolts

6) Visible cracks in welded connections

B FINISH

1) Paint and/or galvanizing condition

2) Rust and/or corrosion condition including mounts and accessories

C LIGHTING

1) Conduit, junction boxes, and fasteners (weather tight and secure)

2) Drain and vent openings (unobstructed)

3) Wiring condition

4) Light lenses

5) Bulb condition

D GROUNDING

1) Connections

2) Corrosion

3) Lightning protection (secured to structure)





E ANTENNAS AND LINES

1) Antenna condition

2) Mount and/or ice shield condition

3) Feed line condition

4) Hanger condition

5) Secured to structure

F OTHER APPURTENANCES (walkways, platforms, sensors, floodlights, etc.)

1) Condition

2) Secured to structure

G INSULATOR CONDITION

1) Cracking and chipping

2) Cleanliness of insulators

3) Spark gaps set properly

4) Isolation transformer condition

5) Bolts and connection secure

H GUYS

1) Strand condition (corrosion, breaks, nicks, kinks, etc.)

2) Guy Hardware Conditions

a) Slack pullers

(i) applied properly and bolts tight

(ii) No signs of slippage or damaged strands

3) Measure guy tensions

4) Record temperature, wind speed and wind direction

NOTES:

1) Minor variations in guy tensions are to be expected due to temperature and low wind speed conditions. The cause of significant changes should be determined immediately and proper remedial action taken. Possible causes may be initial construction loosening, previously experienced extreme wind or ice, anchor movements, base settlement, or connection slippage.

2) Tension variations at a single level are to be expected because of anchor elevation differences, construction deviations, and wind effects.





I CONCRETE FOUNDATIONS

1) Ground condition

a) Settlement, movement or earth cracks

b) Erosion

c) Site condition (standing water, drainage, trees, etc.)

2) Anchorage condition

a) Nuts and/or nut locking device (tightened)

b) Grout condition

c) Anchorages and/or anchor rod condition

3) Concrete condition

a) Cracking, spalling, or splitting

b) Chipped or broken concrete

c) Honeycombing

d) Low spots to collect moisture

J GUYED MAST ANCHORS

1) Settlement, movement or earth cracks

2) Backfill heaped over concrete for water shedding

3) Anchor rod condition below earth (Maintain required structural capacity of anchor during exploration. Attachment to temporary

anchorage may be required)

4) Corrosion control measures (galvanizing, coating, concrete encasement, etc.)

5) Anchor heads clear of earth





CUE DEE AB, Industrihuset Spiran Sikeå SE-915 93 Robertsfors Sweden Phone: +46 934 153 10, Fax: +46 934 150 72, E-mail: [email protected], Website: www.cuedee.com

THANKS FOR YOUR

ORDER AND

WELCOME BACK!

PROD

UCTI

ON B

Y CU

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12 ©

COP

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