1ns rocla poles & piles · lifting for final placement. . . . . . . . . . . . .9 ... the...

DuraspunPoles & Piles

®

H A N D L I N G & I N S T A L L A T I O N G U I D E

POLES & PILES

CONTENTS

P O L E S & P I L E H A N D L I N G & I N S T A L L A T I O N G U I D E

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . 3

2. TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1. Rail Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2. Road Transport . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.3. Poles of Equal Size . . . . . . . . . . . . . . . . . . . . . 4

2.4. Poles of Different Sizes . . . . . . . . . . . . . . . . 5

2.5. Longer Poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1. Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.3. Moving Poles to Difficult Places . . . . . . 9

3.4. Lifting for Final Placement . . . . . . . . . . . . . 9

3.5. Pole Dressing . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 11

4.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.2. Installation Methods . . . . . . . . . . . . . . . . . . 11

5. JOINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.1. Standard Joint (Lug Joint) . . . . . . . . . . . . 15

5.2. High Strength Joint . . . . . . . . . . . . . . . . . . . . 16

6. DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . 17

INTRODUCTION


This guide is intended for electrical contractors andothers involved in the transport and installation ofRocla Duraspun® concrete poles and piles.

Since so many authorities now use Duraspun®

concrete poles, handling practices vary to somedegree between users. Recommendations in thisdocument should therefore be treated as a guide only.Authorities with experience of Duraspun® concretepoles confirm they are as easy to handle and erect asequivalent timber or steel poles.

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TRANSPORT


2.1 RAIL TRANSPORT

Where rail transport is employed, arrangementshould be made with the rail authority to providesuitable wagons, fitted with timber bearers atappropriate spacing. For second and subsequentlayers of poles above the bottom layer, supports suchas used car tyres can be used. It is important,however, that car tyres used as supports are placedvertically above the bottom row of timber supports.

The wagons should be fitted with side posts (orpanels) of appropriate height. Chains must be usedto secure the load. The chains must secure the loadat the points where the timber bearers and tyressupport the poles.

2.2 ROAD TRANSPORT

Unless the vehicle is specifically designed to carryconcrete poles, timber bearers not less than 100mm x75mm should be placed across the tray of the vehicleat the appropriate spacing to ensure no poleoverhangs the end bearer by more than 4.5m.

A sufficient number of timbers must be employed tosatisfy statutory transport regulations such as theminimum number of chains, pole overhang andmaximum axle loads. Timbers and chains should bearranged in such a way as to avoid inducing bendingforces in the pole, i.e. prior to tensioning the chains,there must not be any gaps between the timbers andthe pole.

The two outside poles of each layer must have steelchocks in place on the outside of each butt end. Thesteel chock must have a rubber pad placed over thecontact surface to protect the concrete from beingdamaged by the steel chock.

2.3 POLES OF EQUAL SIZE

Poles with the same tip diameter should be groupedtogether and placed in butt-to-butt contact only (seephoto). To prevent relative movement between polesin any one layer, the butts should be in contact,without packing material. Loosening or compactionof packing material during transport can lead tomovement of the load.

The tip of each pole should be restrained, on bothsides, by tapered wedges or cut-outs in the timberbearer. These cut-out timbers are referred to as"scalloped timbers".

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Poles with same tip diameter are placed together butt-to-butt

Butts

Tips

ScallopedTimber

Steel Chock

TRANSPORT


When poles are loaded in more than one layer,timber spacers/bearers not less than 100mm x 75mmshould be placed between each layer, verticallyabove the bottom row supports.

Poles in the second and subsequent layers must havesteel chocks placed at the butt ends of the twooutside poles, with the tips of the poles resting inscalloped timber bearers.

When there are two or more layers, the poles in thesecond and subsequent layers should alternate indirection, with the tips above the butts of thepreceding layer, to provide the best load sharingbetween axle. (see illustration above).

The completed load of concrete poles should befastened down using a minimum of four sets ofchains and load binders only. The fastening pointsshould always be over the timber bearers (see photo).All fastening points must have a rubber pad placedbetween the chains and contact point of the concretepole, to prevent the chains damaging the externalsurface of the poles.

No loads are to be secured with nylon load restraintsonly. Loads will not be permitted to leave any RoclaConcrete Poles yard unless secured by a minimum offour chains and load binders.

2.4 POLES OF DIFFERENTSIZES

Poles of mixed sizes should be arranged to providethe best possible sharing of weight across the tray ofthe vehicle.

When poles of different diameters are placed in onelayer, a short support bearer, in conjunction withpacking timbers, can be used to support the overlyingbearer (see photo).

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Align fastening with timber bearers

Poles of different diameters require support bearersand timber packing

Poles or piles must not be secured via joint lugs

TRANSPORT


When poles of different lengths need to be carried,the longest poles should be placed on the bottomlayer. Shorter poles can be supported on bearersspaced according to the pole length (see photo).

2.5 LONGER POLES

It is recommended that an extendable trailer be usedfor transporting poles longer than 14m. These polescan be transported using the same techniquesdescribed above. However, particular attention mustbe given to poles overhanging the trailer. No poleshould be transported with more than 4.5m overhangfrom the end bearer.

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Longer poles should be placed on bottom layer

Use extendable trailer for poles or piles longer than 14m

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3.1 UNLOADING

While unloading, it is paramount that the followingguidelines are followed to maintain the integrity ofthe product and, most importantly, to ensure thehighest level of safety.

When unloading, it may be necessary to roll a polesideways to gain access for fitting a lifting chain orsling. Before removing the chocks, ensure that asecond set of chocks is in place, to limit themovement of the pole. Until lifting chains or slingsare fitted to a pole and secured, the pole and everyother pole remaining on the truck should be chockedon both sides to prevent accidental side movement.

Before unloading the poles, the vehicle must bepositioned with a minimum of cross-fall to preventthe load from moving. If the transport operatorconsiders the cross-fall too excessive to allow safeunloading, a more suitable area or positioning of thetruck must be sought, at the discretion of theoperator.

If a cross-fall cannot be avoided, the pole on thehigher side must be the first pole of each layer to beunloaded. Even when on level ground, always unloadthe outer pole first - never take an inner pole.

The vehicle must not be moved while any part of theload is unsecured. If the vehicle is required to moveonly a short distance and the speed does not exceed8 km/h on smooth and level ground, the poles can besecured with a single chain and chocks on the twooutside poles on each layer.

When unloading by crane on site, a dual-point liftusing double-legged chain slings must be used. Thebalance point is marked on the pole or pile (atapproximately 0.4 x length) from the butt of a taperedpole or at the midpoint of a parallel-sided pile. Achain sling is normally used, but a fabric sling can beused as an alternative (see photo).

HANDLING


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Unload this

pole first

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Unloading poles with chain sling

Dual-point lift

HANDLING


All poles and piles have their cartage mass stampedon the name plate so the appropriately rated safeworking load (SWL) for chains and slings can beselected to safely lift the products.

The use of forklifts for loading or unloading concretepoles or piles is considered unsafe and is notrecommended.

3.2 STORAGE

3.2.1 Long term storage

If poles or piles are to be stored on site for anextended period of time, they should be laid ontimbers at spacings shown in the diagram below.

Example:

18.5m/24kN Concrete Pole

L = 18.5m

X = 0.2 x 18.5 = 3.7m

Bearers are placed 3.7m from each end of the pole

Note:

Regardless of the terrain, there should only ever betwo (2) contact points between the pole and theground.

3.2.2 Short term storage

If the poles are to be stored at peg sites, thefollowing instructions should be followed toeliminate any potential damage to poles before theyare erected.

Two timber supports should always be used totemporarily support poles or piles on site. It isimportant to ensure the timber bearers are the onlycontact points supporting the pole. The bearers mustbe positioned such that the pole or pile does notmake contact with the ground at any point.Permanent deflections in the pole or pile can result ifthey are stored for an extended period of time in aninappropriate manner.

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Store poles on two bearers placed 0.2 x pole length from ends

There should be only twocontact points between thepole and the ground,regardless of terrain

HANDLING


3.3 MOVING POLES TODIFFICULT PLACES

Rocla Duraspun® concrete poles can easily be used indifficult terrain or other situations where access maybe restricted. They can be unloaded from trucks insmall stockpiles near the final positions in the line,then transported to their final position by twomethods, using a 4-wheel drive vehicle.

In the first method, the tip of the pole is attached tothe vehicle and dolly wheels are placed at about one-third the distance from the butt of the pole.

The second method, which eliminates the dollywheels, can be used when the ground is soft orsandy. The pole is simply dragged by the tip to itsfinal position.

These two methods are intended to be carried outwith care to protect the integrity of the entire pole.The poles should not be handled in an unduly roughmanner; for example, dragging the poles over rockyoutcrops or through washouts and gullies.

3.4 LIFTING FOR FINALPLACEMENT

Three different methods can be used to lift Duraspun®

poles and piles, depending on the type of section tobe lifted and the specific application. They are:

• Choke chain (or sling)• Lifting bar• Lifting lug

3.4.1 Choke chain or sling

For smaller size Duraspun® concrete poles, such asthe power distribution and lighting pole ranges, thequickest and easiest method of lifting the pole forinstallation is by using a choke chain or sling. Thiscan be achieved by wrapping a chain or sling aroundthe pole at least 600mm from the tip of the pole.Most power distribution and lighting poles include athrough-tube in this area that can be used to securea bolt above the chain or sling to prevent slip.

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Min. 600mm

Choke chain (or sling)

Lifting bar Lifting lug

Poles or piles must not be lifted via joint lugs

HANDLING


3.4.2 Lifting bar or lifting lug

For larger poles, or where more precise placement isrequired, pole sections can be lifted either using asolid lifting bar or via the joint studs using speciallifting lugs. The lower sections of jointed poles havejoint studs protruding from the concrete that can beused to pitch the section and lower it into thefooting. Rocla's special lifting lug attachment isbolted on to diametrically opposite studs to providesecure lifting points for installation.

3.5 POLE DRESSING

Duraspun® poles can be supplied with all necessarytubes, ferrules and earth points precast into the poleto enable rapid dressing on site. It is usual practiceto dress as many fittings as possible on to the polewhile it is on the ground. To facilitate this, a polecradle may be used (see photo). Even complicatedsubstation or communication poles can be fullydressed on the ground, with all the brackets neededto mount specific equipment.

In the case of twin pole transmission lines, fittingssuch as step irons can be added before erection. Toavoid the use of cross-bracing, poles are usuallylifted separately. Steel cross-arms, with insulatorsalready attached, can then be lifted to the pole headand connected.

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Lifting lugs

Installing fittings before erection

Installing fittings on a pole cradle

Minimum Lifting Bar DiameterSWL (t) Grade 300 Grade 400 Grade 4.6

Round Bar Round Bar Bolt

2.0 39 36 363.0 45 42 424.0 50 45 485.0 56 50 566.0 60 56 567.0 65 56 568.0 65 60 649.0 70 65 6410.0 70 65 64

Minimum Lifting Bar Diameter

INSTALLATION


4.1 GENERAL

This section provides details of the various methodsthat can be employed to install Rocla Duraspun®concrete poles.

These guidelines are intended for generalinformation only. Footing design is a specialist fieldrequiring geotechnical and structural engineeringexpertise and is not addressed in this guide.Specific aspects of footing design (such asembedment depth, pad footing size and steel design)are the responsibility of the foundation designer.

4.2 INSTALLATION METHODS

Duraspun® concrete poles can be installed using fourdifferent methods. The most economical method ofinstallation will depend on the sub-soil conditions,access to site for plant and equipment and the designcriteria applicable to the pole. For example, theantennas mounted on communication poles can besensitive to even slight rotation of the pole and footingand therefore require a more rigid installation than atypical transmission pole.

4.2.1 Direct embedment

A hole for the concrete poles is augered to therequired depth. Nominal setting depths forDuraspun® power poles, communications poles andlighting poles are specified in the relevant productbrochure. Nominal setting depths quoted are basedon a standard set of soil strength parameters andhole diameters. Care should be taken to determinewhether the site conditions meet the minimumrequirements applicable to the specified embedmentdepth.

The auger size should allow sufficient room to eitheradequately place and ram solid the backfill, or pourand vibrate the concrete backfill. As a rule of thumb,the hole diameter should be a minimum of the polebutt diameter plus 200mm, rounded up to the neareststandard auger diameter (typically in increments of150mm, i.e. 300, 450, 600, 750, 900, 1050, 1200,1350, 1500, etc).The concrete pole is placed in the hole and lined upusing either a plumb bob or spirit level thatcompensates for the taper of the pole (15mm permetre reduction in diameter). When the pole is inposition, the void between the pole and the hole canbe backfilled.

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BlindingLayer

Backfill

GroundLevel

Backfill

ConcreteInfill

ReinforcedConcreteCollar

Holding downbolt assemblyby Rocla

Reinforcedconcrete slabfoundation

PoleMounted toDriven PoleBoltedConnections

Driven Pile

Direct embedment Collared footing

Pad footing Driven pile footing

Augering the hole

INSTALLATION


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Typically, the cuttings generated from augering thehole are considered satisfactory backfill material. Itis regarded as good practice to use a concretebackfill at the base of the pole for at least 300mm.This increases the bearing area, provides aconsolidated bearing material and ensures thatdesign load capability will be achieved.

Dry bagged pre-mixed concrete is a convenient wayto backfill the hole. As the backfill concrete strengthis not critical, it can have water added on site, bepoured down dry and then have water poured in. Inwet conditions there may be no need for any addedwater at all. In all cases some compaction isnecessary.

Any backfill material that has significant clay contentor that may form a slurry when wet should beavoided even if that requires the provision of crushedrock or gravel.

Placing the pole

Backfilling with concrete

INSTALLATION


4.2.2 Collared installation

This is an adaptation of the direct embedmentinstallation to suit situations where either the requiredembedment depth cannot be achieved (because ofunexpected rock) or where added restraint on rotationis required at ground level. The method of installationis similar to the direct embedment method in that ahole is bored to the desired or maximum depthpractical and then a typically square excavation ismade around the top of the hole to provide additionallateral resistance to overturning.

4.2.3 Pad footing

The pad footing option is typically used in rock, whereaugering is considered impossible or impractical.Typically, it is easier to excavate rock using anexcavator equipped with a rock breaker than to augeror core the rock using a pier-boring machine. RoclaConcrete Poles can provide custom hold-down boltassemblies to suit any Duraspun® concrete pole thatcan be used in conjunction with a pad footing.Contact Rocla Concrete Poles to find out more aboutthe footing design service.

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Square excavation around bored hole for collared footing Concrete pad footing for installation on rock

INSTALLATION


4.2.4 Piled footing (pole-pile)

A piled footing for Duraspun® concrete poles isavailable to allow poles to be installed in situations ofvery low soil strength. The pole-pile method involvesdriving a hollow-spun concrete pile into the ground,leaving the head of the pile approximately 1.5m aboveground level. The pole top is then jointed to the pile inthe same way as a pad footing.

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Piled footing for soft ground

5.1 STANDARD JOINT (LUG JOINT)

Suitable for bolting together jointed pole sections which use "joint lugs". Refer to Drawing 89228 at the back of this guide for lug assembly details.

5.1.2 Coating joint interface

On one of the surfaces to be jointed, apply an even coating of Megapoxy P1 epoxy. This is a two-part epoxy that should be mixed thoroughly in even proportions of Part A and Part B. It is important that the joint surfaces are free of dust and loose material and are completely dry. The epoxy should be applied in a layer approximately 10mm thick.

5.1.3 Nut tightening

Refer to drawing 8384.

Standard lug joint

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JOINTING


5.2 HIGH STRENGTH JOINT

The Rocla® high strength joint is used in specialistapplications to provide a higher capacity mechanicaljoint between pole sections. Both concrete sections tobe jointed have protruding joint studs. The method ofattachment is via a fabricated steel connecting ring(pictured). Usually this ring will be connected to oneside of the joint in the factory so that jointing on sitecan be carried out in the same manner as describedabove for the standard lug joint.

Note that the high strength joint uses 1.5-inch jointstuds instead of the smaller 1.25-inch joint studs.

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High strength joint

DRAWINGS


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®DuraspunPoles & Piles

For further information on Rocla Duraspun® powerpoles, lighting poles, communications poles and spunconcrete piles

E-mail your inquiry

[email protected] visit our website

www.rocla.com.au

Rocla Pty Limited

ABN 31 000 032 191

Trading as Rocla Concrete Poles

A member of the Fletcher Building Group

® Trade mark of Rocla Pty Limited

© Rocla Pty Limited June 2006

The contents of this brochure are copyright and may not be reproduced in anyform without the prior written consent of Rocla Pty Limited. Recommendations andadvice regarding the use of the products described in this brochure are to be takenas a guide only, and are given without responsibility on the part of the company orits employees. Individual designs involving the use of these products should beundertaken by a competent engineer.

Melbourne(03) 9549 4540

Wodonga(02) 6024 7566

Sydney(02) 9721 5221

Rockhampton(07) 4936 1233

1ns rocla poles & piles · lifting for final placement. . . . . . . . . . . . .9 ... the...

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