W5 Shelters Towers

EETP/BSNL
SILVER
CERTIFICATION COURSE
TELECOM SUPPORT INFRASTRUCTURE
PRE-FAB SHELTERS AND TOWERS
Version 2 June 2014
Telecom Support Infrastructure (TSI)
Pre-FAB Shelters and Towers
PRE-FAB SHELTERS AND TOWERS
INDEX
5.1
Introduction .................................................................. 2
5.2
Objective ....................................................................... 3
5.3
Various Components Of Ground Based Bts ..................... 3
5.4
Site Selection For Bts ..................................................... 3
5.5
Telecom Shelters ............................................................ 4
5.6
Technical Specifications For Pre Fabricated Shelters ........ 6
5.7
Dimensions Of Shelter .................................................... 7
5.8
Communication Towers ............................................... 10
5.9
Evolution Of Towers .................................................... 12
5.10
Infrastructure For Mobile Communication Tower ......... 14
5.11
Overview Of Tower Material & Tower Specifications ..... 18
5.12
Erection Of Tower ....................................................... 21
5.13
Summary .................................................................... 24
5.14
Self Assessment Questions ............................................ 24
5.15
References & Suggested Further Readings..................... 24
EETP/ BSNL Silver Certification Course /Ver.02/June2014

For Restricted Circulation
Page 1 of 26
5 PRE-FAB SHELTERS AND TOWERS
STRUCTURE
5.1
INTRODUCTION
5.2
OBJECTIVE
5.3
VARIOUS COMPONENTS OF GROUND BASED BTS
5.4
SITE SELECTION FOR BTS
5.5
TELECOM SHELTERS
5.6
TECHNICAL SPECIFICATIONS FOR PRE FABRICATED

SHELTERS
5.7
DIMENSIONS OF SHELTER
5.8
COMMUNICATION TOWERS
5.9
GUYED TOWER
5.10
EVOLUTION OF TOWERS
5.11
INFRASTRUCTURE FOR MOBILE COMMUNICATION

TOWER
5.12
OVERVIEW OF TOWER MATERIAL & TOWER

SPECIFICATIONS
5.13
ERECTION OF TOWER
5.14
SUMMARY
5.15
SELF ASSESSMENT QUESTIONS
5.16
REFERENCES & SUGGESTED FURTHER READINGS
5.1 INTRODUCTION
Telecom Shelters are to provide protection to the high value telecom equipment .
Any closed structure which can house the communication equipments is called Telecom
shelter. Tower is used to achieve the elevation or height for better communication of
radio waves or Microwaves. Steel towers are widely used for communication.
Communication towers were being used in the field of radio communication since
thirties. In the field of telephony, use of towers was extensively started, in the then P&T
department in the era of Microwave Communication superseding the co-axial technology
for long distance communication somewhere in 1975.
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5.2
OBJECTIVE
After reading this, the participant will be able to:
Learn about the purpose and requirements of Shelter.

Learn about important aspects of shelter planning & construction.
List the Classification of Communication Towers
Enumerate the Infrastructure requirements of Mobile Communication Towers
Explain the Layout of Towers
Learn about the Tower Material Specifications
5.3 VARIOUS COMPONENTS OF GROUND BASED BTS

Various components of ground based BTS are
(i)
(ii)
(iii)
Tower Foundation and Tower.

Pre-Fab Shelter.
Canopy Type Engine/Alternator.
5.3.1 Layout Planning:Since the area of the land available & provided for BTS is very small (Hardly
About 20m x 15m), meticulous planning of each component is must.
a) Engine/Alternator:It should preferably be provided in front or near the main gate of BTS site so that
unloading of E/A can be done easily with the help of crane or chain pulley.
This location will also be very helpful for maintenance operations of E/A.
b) Tower Foundation & Tower:(i)It can be located in the rear side of the plot. Because once tower is erected, it
will not create any problem subsequently, if it is provided in the rear side.
(ii) Rather if it is provided in the front side, it will hinder the other components for
their functioning.
c) Pre-Fab Shelter:It may be planned near the gate for convenient installation & maintenance
operations.
5.4 SITE SELECTION FOR BTS
Site should be suitable as per RF survey.

Size of the plot should be about 20m x 15m. Sufficient place for locating
the earth & storage of tower material should also be available.
Position of adjacent foundation, U/G tank, W/S & Sewer Line etc. should
not foul with tower foundation.
Overhead high tension wire should not cross the site.
There should be proper approach to the site for transportation of
equipment & tower material.
Land should be generally leveled.
Land should not be low lying.

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Land having rocky strata should be avoided.

Power supply should be available nearby.
5.5 TELECOM SHELTERS

Any closed structure which can house the communication equipments is called
Telecom shelter. It is also popularly known as BTS/WLL/GSM shelter.
Figure 1. Types of Shelters
Figure 2. Prefab shelter
Figure 3. Security room

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5.5.1 General Requirements of a Telecom Shelter:(i)

(ii)
(iii)
(iv)
(v)
(vi)
Closed Chamber.
Heat Resistant.
Weather Resistant.
Sound / Noise Insulation.
Sealed from external environment.
Easy to install.
5.5.2 Locations for Telecom Shelter:(i)

(ii)
Roof Top Sites.

Ground Fields proximity to the communication tower.
5.5.3 Material for Shelter

Sandwich Construction
Insulated panels with high insulation properties are used for such type of shelters.
Advantages of Sandwich Panels:(i)
(ii)
(iii)
(iv)
(v)
(vi)
Light Weight.
Structurally Stable.
Easy to Maintain.
Easy to Replace.
Available in desired thicknesses.
Flexibility of surface laminate.
Typical Telecom Shelter Details:
4 walls.
Roof.
Floor.
Door. (with perfect sealing).

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Figure 4. Parts of Telecom Shelter

5.5.4 Brief Specifications of a Typical Shelter Work Executed
The contractor shall be responsible for:(i)
Supply of complete shelter including base frame as per specifications in

knockdown conditions.
(ii) Construction of Suitable foundation for distribution of shelter load.
(iii) Erection and fixing of shelter on the foundation constructed (on ground or roof
top as the case may be).
(iv) Delivery, off-loading and lifting to final location.
(v) Site survey(s), design and its approval, drawings, specifications etc, as
required.
(vi) The shelter shall be made of sandwich insulated panels 80 mm thick with
PU foam as filler material between galvanized pre-coated steel sheets. The
sheet on inner-side of shelter shall have thickness of 0.8 mm (min.) and outer
sheet shall have thickness of 0.6 mm.
(vii) The colour shall be off white on both sides. The density of foam shall be
minimum of 40 +/- 2 Kg/cum with K value of 0.023 W/m-deg. K. The foam
should be fire retarding and self-extinguishing as per relevant IS codes.
5.6
TECHNICAL SPECIFICATIONS FOR PRE FABRICATED

SHELTERS
(i)
Roof structure & cover:-Pre painted galvanized sheets (PPGI) of 0.4 mm
thick trapezoidal sheets laid over a framework of trusses, columns and purling (made out
of rectangular hollow sections of size suitable as per design requirements fixed using
suitable HSD screws. A pre painted galvanized ridge cover to be fixed on top junction of
the roof using suitable fasteners / HSD screws. PPGI end flashings or drain water gutters
considered as per drawing. Insulated roof sheets can be supplied as per requirement.
(ii) Wall:- Providing & fixing of wall using 50 / 75 mm thick interlocking
aerated concrete wall panels made out of two 5mm thick cement fiber boards (Asbestos
free) conforming to IS 14276 - 1995 and with fill by aerated concrete and expandable
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polystyrene granules/ Polyurethane foam (PUF). The boards shall be fixed on floor and
top using 25/52c 1mm thick GI Channels.
(iii) Wall finish:- Further 12mm thick plaster (gypsum) board layer on all internal
exposed surfaces of walls fixed directly on the wall panels complete with joint finish
using jointing compound & fiber tape to give smooth joint less finish. Alternative wall
papers shall be considered.
(iv) False Ceiling :-Providing & fixing of false ceiling using 595x595x12mm
mineral fiber board / gypsum board. The false ceiling panels should be placed on a
suspended grid frame made of pre painted GI steel consisting interlocking main runner,
intermediate tee sections and wall L angles to form 600 x 600mm grid suspended from
ceiling using GI wire of required thickness from roofing structure.
(v) Doors:-Frame shall be made of pressed steel using powder coated CR coil
1.25mm thick, shutter will be made out of 32 mm thick wooden / ERP flush door with
necessary hardware and approved shade oil paint / laminated finish.
(vi) Windows:- Frame made from Pressed steel using powder coated CR 1.25mm
Thick C Channels of size 30x52 or 77mm ( as per wall thickness) and MS / aluminum /
UPVC window frame with glazed panel using 6mm thick float glass & necessary
hardware
(vii) Painting:-Outside walls are painted with 2 coats of acrylic paint and inside
walls are applied with 2 coats of oil bound distemper or any other paint as per choice.
5.6.1 Aluminum Prefabricated Shelter:Aluminum prefab shelters are uniquely pre-engineered using special Aluminum
Alloy profiled roofing sheet for roof & side wall anchored on column and roof beam also
made of preformed Aluminum alloy plain sheet. Aesthetically pleasing appearance, high
resale value after prolonged use and semi permanent living space have wide usage &
application.Light weight yet structurally sturdy, maintenance free long service life, easy
transportation to high altitude camps and also preferred for application under extreme of
cold as the properties of Aluminum enhances to sub zero temperature.
5.7
DIMENSIONS OF SHELTER
The shelters generally shall have the following internal dimensions (all in mm):
(i)
(ii)
4000 L x 3500 W x 3000 H and

5000 L x 3500 W x 3000 H
5.7.1 Steel Work in Base Frame of Shelters etc.
All structural steel shall conform to IS 2062 & IS-226

All structural MS pipes shall conform to IS 1239 pt. 2
All steel work shall be hot dip galvanized after full fabrication as per IS4759 and the minimum coating thickness to be greater than or equal to 127
micron.
All welding shall be as per IS-816
All hardware used shall be galvanized as per relevant IS Code
/specifications.

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5.7.2 Floor and Roof:(i)The floor shall consist of standard PUF Sandwich Panels over which 19 mm
Marine Plywood covered with antistatic PVC flooring shall be laid .
(ii)A base frame consisting of Galvanized steel channels /square tubes and ISMB
or suitable alternatives as per manufacturers approved design to carry and transfer load of
shelter and superimposed floor loads to foundations pedestals /columns /beams /joists etc.
shall be provided.
(iii)Anti static flooring shall be done by using anti-static vinyl robust rolls of 2
mm thickness. Floor operation and adhesive used shall be as per manufacturers
recommendations.
(iv) Design loads for :Floor: 1000 Kg/Sq.m. (Superimposed Load)
Roof: 200 Kg/Sq.m. (Superimposed Load)
(a) Roof
(i)Roof shall be made of the panels same as used for walls. A secondary sloping
roof of pre-coated sheet shall be provided to protect the primary roof from direct sunlight
and water.
(ii)A down slope of 1:50 to be maintained from front to back. The secondary roof
shall not have any projections and shall be hidden by rectangular profiles on roof top to
decrease the aerodynamic affect and improve on aesthetics.
(b) Door of Shelter
Shelter shall have one door for main entrance. The door dimensions shall be
approx. 1000 W x 2000 H (mm). Main door opening outwards and shall be provided with
external, internal handles/knob respectively. Door sealed by a peripheral (double) sealing
frame with silicon rubber gaskets. Locking mechanism with cylinders or number lock.
The locking should be of approved make like Godrej or equivalent make. The door is to
be hinged with heavy duty hinges (stainless steel/brass). Gaskets shall be provided on all
sides of the door to ensure perfect sealing. The door shall be equipped with a hydraulic
closer. A canopy is to be fixed above external light/door.
5.7.3 Joints of Panels:The joining of panels shall be done with the use of eccentric cam locks (preferably
cam-lock pin should be metallic). All panel joints shall be sealed silicon sealant. Silicon
sealant shall be used for waterproofing in the panel joints or wherever necessary.
Flashing shall be provided on the inner and outer side corner joints between vertical walls
and roof/floor.
5.7.4
Shelter Openings:-
The shelter shall have provision for opening for air conditioner, piping cabling on
wall, etc. Cable entry ports in the wall panel for AC power supply cabling, DG cable and
earthing. Suitable wall opening in side wall for entrance of wave guides and feeder
cables. All openings shall be custom built and cutting shall be typically done on site.
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5.7.5 Temperature Range:(i)Internal temperature
+25 + 2degree C
(ii)Maximum outside temp.
+50 degree C (avg. + 45 degree C)
(iii)Minimum outside temp.

5.7.6
+5 degree C
Environmental Conditions:(i)Humidity 100 %

(ii)The shelter shall have heat transmission coefficient K less than or equal to 0.3
5.7.7 Earthing and Electrical Conductivity:All metal parts shall be interconnected for good electrical conductivity. Inside the
shelter a long Copper bar of size 400 x 35 x 6 mm with M 8 bolt size rounded holes in it
shall be provided near the door for earthing of equipment.
5.7.8 Structural Stability:(i)
Design of shelter shall be in accordance to the relevant Indian Standard

Codes.
(ii) Resistant to various volumes of rain, dust and sand with different speeds.
(iii) Resistant to corrosion against water, industrial air and saline air.
(iv) Resistant to vegetation, termites and micro organisms.
5.7.9 Outdoor Installation:(i ) Survival wind speed
: 160 Km/h
(ii) To cope with these conditions, provision is to be made for threaded bolts,
connecting the shelters to the base frame & foundations respectively.
5.7.10 Installation:(i)The shelter is to be installed on the base frame supported on RCC foundation or
on suitable supporting structures.
(ii)The construction of shelters shall be such that it can be transported in a
dismantled form to the site and assembled there.
5.7.11 Foundation System for Shelter:(i)Foundation made of RCC isolated footing & columns should be properly
designed as per superimposed load (Dead Load + Live Load) of shelter & soil conditions
of site.
(ii)The base frame shall be fabricated and mounted on the constructed columns
and properly leveled to support the shelter.

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5.7.12 Steps for Entrance:(i)Brick steps (3 nos) or MS bolted/welded Steel stairs with treads of 25 cm and
riser of 15 cm in front of door, supported on suitable foundation, should be provided for
entry.
5.7.13 Base Frame of Shelter:(i)All the panels will rest on a galvanized steel floor which will further rest on
base frame consisting of ISMB 150x75mm grid.
(ii)All the sections used for base frame shall be hot dip galvanized to provide a
zinc coating of minimum 127 microns.
(iii)The galvanized base shall be placed on four to six RCC columns of size not
less than 400 x 400 of mix 1:1.5:3 and bolted on to the concrete structure to provide
stability.
(iv)The length of I-beams used in base frame may vary for roof top sites, however,
based on column grid pattern.
5.7.14 Guarantee /Life Periods of Shelters:The manufacturer shall submit a guarantee bond of 20 years life period of shelter.
5.8 COMMUNICATION TOWERS

5.8.1 Classification of Towers:Classification of Towers Based on Structural Behavior:Based on structural behavior, steel towers are of two types:
Free standing or self supporting or Lattice towers (e.g. Eiffel Tower).

Guyed Towers.
5.8.2 Self Supporting Tower:Following are the characteristics of self supporting towers:
Self supporting towers transfer the load to ground by cantilever action.

Moments due to wind in case of self supporting towers are very high.
These towers are supported on ground or on tall buildings by four /three
legs.
Weight of tower, in these towers is high, due to which these are costly.
These towers occupy less space.
These towers are used for heavy antenna loads.
These towers are used in microwave & mobile communications.

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Figure 5. Self supporting Tower and Guyed tower
5.9
GUYED TOWER
Following are the characteristics of guyed towers:
These towers are supported by the tensile stress of guy wires which
transmits the wind loads to the ground.
Moments due to wind are quite less at the base of the mast.
Supported on ground as well by the guy wires.
Weight of tower, in these towers is less, due to which these towers are
cheaper as compared to self supporting towers.
These towers require large space to anchor guy wires.
These towers are used for light antenna loads.
These towers are used in Radio/mobile communication & wireless
communication.
5.9.1 Classification of towers based upon shape:Based upon shape, steel towers are of three types:
Four legged towers.

Triangular Towers.
Guyed Masts.
5.9.2 Delta structures.

A) Four Legged Towers:Four legged towers have four legs. They may be of following type:(a) Angular Towers:- M.S. angles are used as structural members connected by
gusset plates, nuts & bolts.
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(b) Tubular Towers:- In tubular towers, M.S. pipes are used as structural
members.
(c) Hybrid Towers:- M.S. angles and pipes, both are used as structural members.
B) Triangular Towers:Triangular towers have three legs. They may be of following type:(a) Angular Towers:- M.S. angles are used as structural members connected by
gusset plates, nuts & bolts.
(b) Tubular Towers:- In tubular towers, M.S. pipes are used as structural
members.
C) Guyed Mast:Structural mast is supported by guy wires of high tensile strength.:(a) Angular Towers:- M.S. angles are used as mast.
(b) Tubular Towers with rods:- M.S. pipes and MS rods are used for mast.
D) Delta structures:Delta shape structures are vertical in height and not tapered. Generally made of
M.S. pipes & used in RTT (roof top towers).
5.10 EVOLUTION OF TOWERS

5.10.1 Guyed towers/Mast:Guyed towers/masts were being used by the, the then P&T department in India for
radio and wireless communication since pre-independence era.
5.10.2 Microwave Towers:(i) With the induction of Microwave Technology for long distance communication
obsoleting the co-axial technology. Use of Microwave tower was started somewhere in
1975.
(ii) Four legged towers, self supporting angular towers were used for the same.
(iii)Height of these towers was ranging from 30m to 100m.100m high towers were
predominantly used in those days.
(iv)Depending upon the number of parabolic (solid or grid) antenna, these towers
were categorized as:EETP/ BSNL Silver Certification Course /Ver.02/June2014
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Light Weight Tower.

Heavy Weight Tower.
Special heavy Weight Tower.
5.10.3 Triangular Tubular Hybrid Towers (T.T.H. Towers):(i) In the year 1992-93, Govt. of India started a massive programme for rural
communication through UHF/VHF systems in Deptt of Telecom.
(ii) For rural communication programme, large number of light weight towers
were required, hence TTH (Triangular Tubular Hybrid) towers were introduced.
(iii) These towers were in triangular in plan and design was standardized for 40m,
60m, 80m & 100m.
(iv) In TTH towers both MS pipes and MS angles were used. Main leg members
were made of pipes and bracings, were made of MS angles. Joints of main leg was
welded with connecting plates and also to accommodate the bracing members.
(iv) TTH towers are light in weight and cheaper as compared to 4 legged angular
towers. However perfection is required in welding of joints.
5.10.4 15m Mast:For rural communication, 15m high masts were introduced somewhere in 1992. It
was triangular mast (base width of triangle was 70cm). It was made by MS pipes and MS
rods. This mast was made of 5 panels of 3m height each.
5.10.5 Mobile Technology Towers:(i) For GSM mobile Technology, era of 40 meter high towers was started.
(ii) Tower of mobile technology was to be provided in the populated areas,
therefore, space for tower was restricted and base width of tower was reduced
substantially.
(iii) Accordingly era of narrow base 40 metre towers was started. Base width of
these towers was restricted to 2.0m only. Following type of 40m high Narrow Base
Towers were developed by Telecom Factories:
40m Narrow Base Tower ( Wt. 16T)

40m Narrow Base Light Weight Tower (Wt.- 10T)
40m Narrow Base Feather Light Weight Tower (Wt.- 8T)
5.10.6 Roof Top Towers (RTT):(i) RTT is used in congested city areas to use the height of building as additional
elevation.RTT is supported on tall buildings by its legs.The following types of RTT are
generally used.
4/3 legged, Angular Self Supporting Tower.

TTH Tower.
Delta Structure.
Guyed Mast.

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5.11
INFRASTRUCTURE FOR MOBILE COMMUNICATION

TOWER
They are basically of two types.
Self supporting type

And the Guy- wire supported type.
These can be either ground based or roof top towers. Now a days, depending upon
the requirement, mostly ground based towers are being executed for 40 m & 60 m height.
They are designed for different heights & varying wind speeds. Generic Requirement
(G.R.s) for light weight and medium weight ground based towers & roof top towers are
available and contain all the details for execution of a particular tower including
foundation and erection both.
5.11.1 B.T.S Plinth / Bed + B.T.S Shelter:For outdoor sites, where towers are not, near to telephone exchange building, BTS
equipment has to be located in an open site. Thus, to support the BTS, a structural R.C.C.
slab is required to be constructed supported by R.C.C beams & columns as per standard
drawing/design worked out on the basis of size, dimensions and weight of BTS
equipment. Further to protect the costly and sophisticated BTS equipment from external
agents like Sun, Rains, etc, its desirable to make a shelter preferably of F.R.P.(Fiber
Reinforced Plastic) sheets of minimum 3mm thickness or even G.I sheet roofing
supported by M.S angles frame-work embedded in the concrete bed blocks well below the
Ground level up to 45 cm depth. The sides should be covered with thick M.S. wire mesh
for at least up to 5ft above the plinth bed for dissipation of heat & effective air circulation.
5.11.2 E/A (Engine Alternator) Bed for Generator/Engine Alternator (E/A):Due to heavy vibration of the Engine, a suitable foundation for dynamic loading is
designed for the engine bed to support the Engine Alternator. For this, P.C.C. platform
with light steel reinforcement is constructed over the bed of Earth/Moorum, filling
retained by suitable Random Rubble or Brick masonry of 30 cm to 45 cm height above
the ground or formation level. Angle nosing should be provided on the edges of the E/A
bed to protect the edges. Earlier, there was a practice of making a trench of sand bed,
made all around the engine bed for containing and absorbing dynamic vibrations.
However, now-a-days, Engines are coming with rubberized pads beneath them, and so
there is no need to provide the sand bed any more.
5.11.3 Compound wall or Fencing for site protection:As per standard practice and guide lines issued in this regard, the compound walls
are constructed.
5.11.4 NameBoard:Depicting the name of the site location & date of commissioning of B.T.S etc.
along with other relevant details, is required to be fixed on to the tower at a suitable
height so that it is conveniently visible.
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5.11.5 Earthing:This is required to pass on electric charge due to Electric- Lightening received by
the lightening conductor fixed on the top of the tower into the earth with minimum
possible resistance of 0.5 ohms and thus save the Tower/ BTS/Antenna/ Human life etc.
from any electric hazard.
5.11.6 . Lightening Conductor:To absorb all the electric charges from lightening and pass it to the earth for safety
of the tower and other associated equipments from any damages; due to electrical hazard.
The lightening conductor is fixed at top of tower. The copper-lightening conductor is
1500 mm long and 25mm dia hollow tube of minimum wall thickness of 1.6 mm. The
lightning spike shall be fixed to the tower with Teflon Sleeve to avoid direct contact with
tower. The spike is connected to plate earth by 70 sqmm. insulated multistrand copper
wire. The copper wire shall be fixed to the tower with necessary lugs.
5.11.7 . Aviation Lamp:This is the mandatory requirement as per Civil Aviation bye laws in order to keep
the top of the tower visible in Night/Darkness to protect it from any untoward happening
due to aviation services by maintaining safe distances of the air services from the tower
location. 230V AC LED aviation obstruction lamp (Saraj, Binoy, Aviads, Litten or
equivalent) with Light Dependent Resistance Sensor (day night automatic timer) with
necessary MCB switches shall be provided at top of the tower.
5.11.8 Vertical Gantry & Horizontal Gantry:For carrying 3 pairs of the R.F. cables, each pair (one for inward and the other for
outward communication), being for one of the three antennas in a secured & supported
way from Antenna at top of the tower to B.T.S (Base Transmission System). This
structure is made of M.S. angles properly galvanized and painted to prevent them from
rusting, in a ladder type fashion.
5.11.9 Vertical Ladder:Vertical ladder is provided with protection rings for climbing the tower safely.
5.11.10Resting Platform & Operative Platforms of mild steel:
For attending to the antenna fixing/adjustment at desired altitude (38.5 m for 40 m
Tower), operation platform made of mild steel is provided & a resting platform is fixed at
mid height of tower (Ground based) for the workers and technicians to take rest. A ladder
from roof top up to top of platform at tower is provided with safety rings. Width of ladder
shall be minimum 300 mm and safety ring of 750 mm shall be provided. Entry from
ladder up to top of platform shall be such that no extra efforts will require to reach at the
platform. Width of platform should be minimum 600mm.
5.11.11. Wave Guide:Waveguide is provided in towers to carry the feeder cables from Antenna, fixed at
top of tower up to Transmission room. It is a tray of galvanized M.S. angles and Flats of
600 mm width. This should not bend sharp at right angles at turning points to avoid
damage to running feeder cables.
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5.11.12. Providing & Fixing of Antenna mount on which antennas are fixed /
supported:Three antenna mounts are provided spaced at 1200 apart for covering signal from
all the directions.
5.11.13. Security Huts for Remote Tower Locations:Provided particularly in rural areas.
Figure 6. Lay out of Tower site

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Figure 7. Mobile Call-Route Network

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5.12
OVERVIEW OF
SPECIFICATIONS
TOWER
MATERIAL
&
TOWER
Steel tower works shall be carried out as per the following specifications:5.12.1
MATERIALS:-
(i) The tower materials consisting of legs/bracings shall be of M.S. angles of grade
A as per IS: 2062-1999 & IS: 808-1989 and satisfy the relevant tests as per IS codes.
(ii)The material for gusset/splice plates shall be of M.S. angles of grade A as per
IS: 2062 & IS 3502-1994.
(iii) The materials for nuts, bolts shall be of grade 4.6 and as per 6639-1972, IS
1364(Part I toV) 2002, IS 1367(Part VIII) 1992, plain washers as per IS 6610-1972 and
spring washers of Type-B as per IS 3063-1994, IS 1148-1982, IS 2015-1977.
(iv) A test certificate bearing IS certification marks for materials are acceptable.
If test certificates are not available, the materials shall be tested in the approved lab or
where authorized by the Engineer-in-Charge.
(v) Two or more pieces shall not be welded or joined to make up for the required
length of member. If required, properly designed joint should be provided.
5.12.2
FABRICATION:(i) The fabrication of towers shall be done in accordance with IS 800-1984.
(ii) The fabrication of various components of the tower shall be done in

accordance with the approved drawings. Suitable markings for manufacturers identity
shall be done. Item marking for each section shall be done for easy assembling and
traceability at site. All dimensions shall be checked on the template floor with reference
to drawings before manufacturing and if, any deviation is required after check, and the
same shall be done only with the approval of the Engineer-in-charge.
(iii) The contractor shall maintain a master steel tape of an approved make besides
other measuring instruments.
5.12.3
STRAIGHTENING:-
All materials shall be straightened and or flattened by pressure unless required for
a shape of curvilinear form before fabrication and shall be free from twists. Straightening
should not damage the material. The parts when assembled; adjacent surfaces should be
in close contact. Hammering shall not be permitted for straightening. Sharp kinks or
bends shall be rejected.
5.12.4
CUTTING:-
Cutting may be affected by shearing, flame cutting or sawing. The surface so cut
shall be clean, smooth, square and free from any distortion.
5.12.5
BENDING AND WELDING:-
Mild steel angle sections up to 75x75 mm (up to 6mm thick) may be bent cold and
(up to and including) bend angle of 10 degree. Angles above 75x75 mm (thickness up to
6mm) and up to and including 100x100mm (thickness up to 8mm) may also be bent cold,
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up to the bend angle of 5 degree. All other angle sections not covered above shall be hot
bent. Butt-welding, if used, in members shall be carried out either by submerged arc or
shielded arc welding. Welding shall be free from cracks, discontinuity in welding, undersize, over-size or under cutting. It should be cleaned off slag and other deposit. Welds
shall be adequately tested using radiography or other well-known methods of nondestructive testing.
5.12.6
HOLES:-
(i)Holes for bolts shall be drilled using jigs provided with hardened steel bushes
and shall not be punched or formed by flame cuttings process. All drill burns shall be
completely removed. Drilling of holes shall be done before galvanizing.
(ii)Holes on both sides of the bend line in a bent member shall be drilled after
bending. The relative position of these holes shall be checked using proper templates.
(iii) Holes shall be circular and of a diameter 1.5 mm more than the dia of the bolt.
(iv) Holes shall be drilled at right angles to the surface of the plates or angles,
unless otherwise specified.
(v)The accuracy of location of hole shall be such that for any group when
assembled they shall admit the bolt at right angles to the plane of the connection.
(vi)Spacing of bolts and edge distances shall be in accordance with IS 800-1984.
(vii) Butting ends of main leg members shall be cut with saw. Flame cutting or
shearing shall not be permitted.
5.12.7
MARKING:-
Identification marks allotted to each member shall be distinctly stamped with

marking dyes of 16mm size before galvanizing.
5.12.8
TOLERANCES:-
Fabrication tolerance shall not exceed those specified in IS 7215-1974 as

applicable to group B structure.
5.12.9
GALVANIZING:-
(i) Hot dip galvanizing protects steel from corrosion by providing a thick, tough
metallic zinc coating, which completely covers the steel surface and seals it from the
corrosive action of environment. The galvanized coating provides outstanding abrasion
resistance. Where there is damage or minor discontinuity in the coating of zinc,
protection of the steel is maintained by the cathodic action of the surrounding galvanized
coating. Metallic zinc is strongly resistant to the corrosive action of normal environments
and hot dip galvanized coatings therefore provide long-term protection for steel.
(ii) Zinc for galvanizing should conform to IS 13229-1991.
(iii) All members and fasteners of tower structures are to be hot dip galvanized.
Galvanizing of members of the tower shall conform to IS 4759 and 2629. Bolts and other
fasteners shall be galvanized in accordance with IS 1367 (part 13). The total mass of
galvanizing coating shall not be less than 610gm/sqm (i.e.85 micron) thickness.

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5.12.10
PAINTING:-
Painting of galvanized steel towers is required to give additional protection and to

give Day warning as per additional protection and civil aviation specifications.
5.12.11
COASTAL AREA:-
All steel galvanized sections like L angles, flats, tubular sections, bolts and nuts
etc. shall be given a coat of ETCH primer. Zinc Chromate primer shall be applied over
ETCH primer. Synthetic enamel paint of two or more coat thickness shall be applied over
the above.
5.12.12
NON COASTAL AREA:-
In the non-coastal area zinc chromate may be applied instead of zinc phosphate.
Painting shall be done in accordance with IS 1477 Part I & II.Priming coat of zinc
chromate/phosphate shall conform to IS 104.
5.12.13
CLEANING:-
Dust, grease and rust on galvanized tower members namely angles, tees, plates,
railing, ladders, racks etc. shall be removed by wire brushing and cleaned with a piece of
cloth.
5.12.14
APPLICATION OF ETCH PRIMER:-
After cleaning the tower members, first coat of an etch primer has to be applied to
the tower structure members. The etch primer consists of polyvinyl butyral phosphoric
acid catalyst and zinc chromate base and are supplied separately. They
should
be
mixed before use in the specified ratio of four parts base to one part catalyst or as
specified by the manufacturer. The primer is to be applied uniformly to get a very thin
and almost invisible coat and every part of the tower structure should be treated with this
primer. Subsequent painting of the zinc chromate primer should be commenced within
two hours of application of the primer. The etch primer once mixed should be used up
immediately.
5.12.15
APPLICATION OF PAINT:-
After 48 hours of application of primer, the first coat of the paint should be
applied carefully, well brushed into the surface, corners, crevices etc. Should be uniform
and even. The second coat of paint should be applied after 48 hours of the application of
the first coat. Care should be taken to see that the painting is not carried out at the hottest
time of the day and air pockets should be avoided.
5.12.16
SPECIAL REMARKS:-
The painting shall be done carefully so that all corners and crevices of the mast
receive the paint and no base surface is left exposed anywhere. Special care is to be taken
in applying paint at the places where galvanized coating has got removed. No driers
such as Litharge or Turpentine are to be used. The practice of mixing kerosene oil with
paint is strictly forbidden.
5.12.17
PAINTS:-
Paints shall be synthetic enamel of the best quality and anticorrosive and should
withstand exposures to outside conditions. They should be of standard quality equivalent
to synthetic enamel paint of Shalimar or Berger paints or Asian paints.
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5.12.18
ORANGE AND WHITE BANDS (DAY MARKINGS):-
To conform to Civil Aviation regulations, the towers shall be painted in alternate

bands of international orange and international white, terminating with orange at top and
the bottom, Height of each band should be not exceeding 6 metres and should not be
less than 0.5 meters. The correct shade for the international orange corresponds to ISI
shade 592 as given in the Indian Standard Institution Publication (Colours for ready
mixed paint).
5.12.19
RECTIFICATION/REPAIRS TO DAMAGED PARTS:-
Damaged components of the steel work should be rectified as per directions of the
Engineer-in-charge. Minor damages to the galvanizing shall be made good by cleaning
the damaged portion, free of all rust and applying a zinc rich paste to the same thickness
as the original coat of galvanizing. Members of components, which are dented, bent or
twisted in transit or by handling during erection shall not be used on work but shall be
replaced as directed by the Engineer-in-Charge.
5.13 ERECTION OF TOWER

It shall be ensured that structural components with correct markings as indicated
in drawings are used in correct position. At the base connection, the foundation bolts shall
be located correctly using templates and grouted ensuring; that all templates are in one
horizontal plane. After erection of the first panel, its verticality shall be checked and
corrected if necessary.
Further erection work shall proceed panel by panel, bolts and nuts shall be finally
be tightened up to the specified torque using torque wrenches. Verticality of the tower
shall be checked after complete erection of each panel. Each panel shall be completed in
all respects and shall have the approval of the Engineer-in-charge before proceeding to
the next panel.If a panel is to be left incomplete, it shall be ensured if necessary; by
erection of temporary bracings, that all the members erected form a stale configuration;
sufficient to withstand dead and wind loads.
The joint shall be made by drawing the light members into position with barrel
drifts. Drifts may be used on the heavier members only to secure them in correct
position. No member shall be force fitted. Any error in steel work, which prevents the
assembly and fitting up to the parts by the proper use of drifts, shall be investigated
immediately. If any defect or deficiency in the member comes to notice, the same shall be
rectified As per directions of the Engineer-in-Charge.
Packing plates shall be provided at the joints as shown in approved drawings in
order to make up the change in the thickness of the parts, jointed. No other packing plates
shall be used. Hot dip galvanized bolts and nuts and washers of class 5.6 shall be
provided in all connections involving leg members, main diagonals as well as horizontal
through inter- section of the main diagonals in k brace, panels and plain bracings
Hot dip galvanized contact surfaces of joints providing with hot dip galvanized
bolts nuts and washers shall be free of oil, paint and lacquer or other coatings and shall be
scored by wire brushing or light blasting after galvanization and prior to assembly.
Bolts used for connections shall not be not less than 12mm in diameter. and the
length shall be such that not more than half of the pitch of the thread lies inside the grip
26
Page 21 of
length. The threaded portion of the bolt shall protrude by not less than 3mm beyond the
lock nut after it has been fully tightened.
Bolts and nuts shall be tightened by using the part turn method. The nut shall be
brought to the snug tight position after which it will be given a further half to one turn
depending upon the length of the bolt. In joints with several fasteners, all the nuts, bolts
shall be brought to the snug tight position, before tightening further systematically. The
nut rotation from snug tight condition is given in the table below:5.13.1 NUT ROTATION FROM SNUG TIGHT CONDITION:-
Bolt length(As measured Boltsfaces One face normalto

from underside of head to normal to bolt axis & other face
extreme end of point)
bolt axis.
sloped not more than
1:20 (bevel washer
not used)
Bolt faces slope not

more than 1:20 from
normal to bolt axis
(bevel washers not
used).
Upto including 4 dia.
1/3turn
1/2 turn
2/3 turn
Over 4 dia. But

exceeding 8 dia.
not 1/2 turn
2/3 turn
5/6 turn
Over 8 dia. But

exceeding 12 dia.
not 2/3 turn
5/6 turn
1 turn.
(xi) Alternatively nuts may be tightened using a calibrated wrench so that the
proof load of the bolt specified in IS 1367 is achieved. Snug tight is defined as the
tightness
attained by a few impacts of an impact wrench or the full effort of a man
using an ordinary spud wrench. Following this initial operation, bolts shall be placed in
remaining holes in the connection and brought to snug tight position.
5.13.2 VERTICALITY TOLERANCES:The verticality for towers of different heights shall be within the provisions of
Table 1 (III) (b) of IS 12843:1989 viz., + H/1000 or +/- 20mm (whichever is less) for
towers up to and including 30 mtrs height and H/1500 or +/- 25mm (whichever is less)
for towers over 30mtrs height respectively. (H Refers to the height of tower).

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Figure 8. Excavation of tower foundation

26
Page 23 of
5.14
SUMMARY
Telecom shelter is popularly known as BTS/WLL/GSM shelter. Prefab shelter is

an important component of Ground Based BTS system. Prefab shelter should be planned
near the gate of compound for convenience in installation & maintenance. Prefab shelter
should be heat and weather resistant as well as should have sound/noise insulation. Now a
days sandwich panel construction is used for construction of Prefab shelters.
Communication Towers can be Ground based or Roof top towers and are classified on the
basis of structural behavior, shape and sections used in the tower. Proper planning of
tower layout site and installation of Civil/Electrical Infrastructure of Towers is necessary.
Fabrication of towers is done in accordance with IS 800-1984. Proper erection of Tower
with snug tight jointing of connections and verticality needs to be ensured.
5.15 SELF ASSESSMENT QUESTIONS

1 General requirement of Telecom Shelter are____________________
2 For convenience of installation & maintenance operations, Pre-Fab shelter should
be located___________
3 Jointing of panels in Prefab Shelter shall be done with the use of machine lock
((T/F)
4 For outdoor installations of Telecom Shelter, the design survival wind speed taken
is___
5 Foundation of Telecom shelter, made of R.C.C. isolated footing & columns, shall
be properly designed for__________________
6 All structural steel work in Base Frame of Shelters shall conform to________ .
7 Towers are designed to withstand _______,_______ &________ loads
8 The material of lightening conductor of Tower is ________
9 In hybrid towers only M.S. angles are used as structural members (T /F)
10 Based on shape, the towers can be classified as_________
11 The erection work of tower proceeds_____ (bottom to top / Panel by panel)
5.16
REFERENCES & SUGGESTED FURTHER READINGS

www.tec.gov.in
www.tnd.bsnl.co.in
intranet.bsnl.co.in/digital library
www.wikipedia.org
BIS codes mentioned in the text above
BSNL Handbook On Tower Infrastructure

26
Page 24 of
Answers to Self Assessment Questions.

1. Should be heat resistant and Sound/Noise insulated.
2. Near to the Gate of Compound.
3. False
4. 160 Km/Hr
5. Dead Load plus Live Load
6. 127 Micron
7. Dead Load, Self Weight And Wind Load
8. Copper
9. False
10. Four Legged, Three Leged And Delta Structure
11. Panel By Panel

26
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EETP/BSNL

Telecom Support Infrastructure (TSI)

Pre-FAB Shelters and Towers

PRE-FAB SHELTERS AND TOWERS

Various Components Of Ground Based Bts ..................... 3

Site Selection For Bts ..................................................... 3

Telecom Shelters ............................................................ 4

Technical Specifications For Pre Fabricated Shelters ........ 6

Dimensions Of Shelter .................................................... 7

Communication Towers ............................................... 10

Evolution Of Towers .................................................... 12

Infrastructure For Mobile Communication Tower ......... 14

Overview Of Tower Material & Tower Specifications ..... 18

Erection Of Tower ....................................................... 21

Self Assessment Questions ............................................ 24

References & Suggested Further Readings..................... 24

EETP/ BSNL Silver Certification Course /Ver.02/June2014

Telecom Support Infrastructure (TSI)

Pre-FAB Shelters and Towers

5 PRE-FAB SHELTERS AND TOWERS

VARIOUS COMPONENTS OF GROUND BASED BTS

SITE SELECTION FOR BTS

TECHNICAL SPECIFICATIONS FOR PRE FABRICATED

INFRASTRUCTURE FOR MOBILE COMMUNICATION

OVERVIEW OF TOWER MATERIAL & TOWER

SELF ASSESSMENT QUESTIONS

REFERENCES & SUGGESTED FURTHER READINGS

Telecom Support Infrastructure (TSI)

Pre-FAB Shelters and Towers

Learn about the purpose and requirements of Shelter.

5.3 VARIOUS COMPONENTS OF GROUND BASED BTS

Tower Foundation and Tower.

5.4 SITE SELECTION FOR BTS

Site should be suitable as per RF survey.

EETP/ BSNL Silver Certification Course /Ver.02/June2014

Telecom Support Infrastructure (TSI)

Pre-FAB Shelters and Towers

Land having rocky strata should be avoided.

5.5 TELECOM SHELTERS

Figure 1. Types of Shelters

Figure 2. Prefab shelter

Figure 3. Security room

EETP/ BSNL Silver Certification Course /Ver.02/June2014

Telecom Support Infrastructure (TSI)

Pre-FAB Shelters and Towers

5.5.1 General Requirements of a Telecom Shelter:(i)

5.5.2 Locations for Telecom Shelter:(i)

Roof Top Sites.

5.5.3 Material for Shelter

Typical Telecom Shelter Details:

EETP/ BSNL Silver Certification Course /Ver.02/June2014

Telecom Support Infrastructure (TSI)

Pre-FAB Shelters and Towers

Figure 4. Parts of Telecom Shelter

Supply of complete shelter including base frame as per specifications in

TECHNICAL SPECIFICATIONS FOR PRE FABRICATED

Telecom Support Infrastructure (TSI)

Pre-FAB Shelters and Towers

4000 L x 3500 W x 3000 H and

5.7.1 Steel Work in Base Frame of Shelters etc.

All structural steel shall conform to IS 2062 & IS-226

EETP/ BSNL Silver Certification Course /Ver.02/June2014

Telecom Support Infrastructure (TSI)

Pre-FAB Shelters and Towers