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ARE Short Towers Installation Manual

For the awp3.6 wind generator
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SHORT TOWER INSTALLATION MANUAL
ARE
ARE110
AWP-3.6
Tilt-up, Guyed, Pipe Towers for
&
Wind Generators
Short Towers – 43, 64, and 85 feet tall

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Summary of Contents for ARE Short Towers

  • Page 1 SHORT TOWER INSTALLATION MANUAL ARE110 AWP-3.6 Tilt-up, Guyed, Pipe Towers for & Wind Generators Short Towers – 43, 64, and 85 feet tall...

  • Page 2: Table Of Contents

    Contents 1) Introduction 2) Site Selection and Preparation 3) Tools List 4) Parts List 5) Tower Foundations 6) Tower Section Preparation 7) Lightning and Grounding Protection 8) Tower Raising Options 9) Tower Assembly Step 1 (Base Installation and Anchor Setup) Step 2 (First Tower Section Installation &...

  • Page 3: Introduction

    43 to 127 feet tall. This manual will only cover towers which are 43, 64 and 85 feet tall. The 106 and 127 foot towers are covered in the “Tall Towers” Manual. All of the towers are based on 4-inch, schedule-10 pipe.

  • Page 4: Tools List

    3) Tools & Materials List Foundation: • Gloves • Shovel • Tape measure (50-100 ft.) • Leveling tool • Laser level or string • Site level or transit • Masonry mortar type “S” • Clamps • Rebar bender • Wire mesh or rebar (see section “5. Tower Foundations”, subsection “Center Foundation”) •...

  • Page 5: Parts List

    4) Parts List The complete tower kits contents are listed in the tables below. PART 43’ 64’ 85’ Foundation Kit: Anchors J Bolts 5/8” x 8” Nuts and Washers 5/8” galv. (# of each) Eye Bolts 1/2” x 6” Nuts and Washers 1/2” galv. (# of each)
  • Page 6 Hoist Rigging PART 43’ 64’ 85’ 3/16” Cable 65’ 100’ 135’ Pulleys 3” Shackles 3/8” Saddle Clamps 3/16” Thimbles 5/16 for Ø3/16” wire Gin Pole Guy Wires with Crimped Eyes (Qty 2) Tower Height 3/16” 43 foot 35’ 64 foot 35’...

  • Page 7: Tower Foundations

    The outer foundations support anchors for the tower and gin pole guy wires. The steel anchors for the tower guy wires are cast in the concrete at the angle ‘A’ indicated in Table 1.
  • Page 8 Down Side Anchor The downside anchor eye height is not as critical as the hoist side. The anchor may vary up to a foot higher or lower than the tower base. Please consult ARE for larger variations. - 7 -...

  • Page 9: Tower Section Preparation

    This allows the side guy wires to become slack during the lowering of the tower reducing the possibility of over tensioning the wires. The eyebolts for the gin pole guy wires are located on the left and right side foundations. They are offset 4 inches toward the hoist side anchor from the centerline of the center foundation for the same reason.

  • Page 10: Lightning And Grounding Protection

    The following procedure is suggested for drilling holes in the pipe ends that attach to the gusset plates. The holes must be aligned in order to work properly. • Lay a piece of angle iron at least 2 feet long on the pipe lengthwise. Mark a line on the pipe along one side of the angle iron.
  • Page 11 Lightning arresters – It is advised that lightning arrestors be installed in the wiring of the system. We recommend that one be installed in a junction box at the base of the tower and one in the power room. Consult ARE for available lightning protection packages.

  • Page 12: Tower Raising Options

    There are various options for the raising and lowering of a tilt-up tower. The towers are equipped to be raised and lowered with a vehicle, such as a truck or tractor. They come with a hoist cable and pulleys for raising with a vehicle. The ideal vehicle is a heavy pickup with 4 wheel drive and an automatic transmission.
  • Page 13 Adjustment Tower Holes Base Section Pivot Bolt Shrinking Grout Pole Figure 2 Figure 3 - 12 -...

  • Page 14: Step 2 (First Tower Section Installation & Raising)

    Step 2 (First Tower Section Installation & Raising) Start with the Tower Base Section laid out between down side anchor and the tower base foundation. Install the Tower Coupler with the 35’ guy wires in the top of the tower section. Note: this is the only coupler with all four wires already attached.
  • Page 15 Table 2 Tower Number Hoist Cable End Attach Point Number of Number of Height Pulleys Pulleys Pulleys Attached to Attached to Equalizer Gin Pole Plate End Fitting 43 foot Equalizer Plate 64 foot Gin Pole End Fitting 85 foot Equalizer Plate Gin Pole Guy Wires Hoist cable...
  • Page 16 Attach the remaining 3/16” guy wires that are not attached to the tower couplers to the remaining turnbuckle eyes using 5/16” open thimbles. Secure with three 3/16” saddle clamps per guy wire. Install the shortest closest to the tower base and then work outward with successively longer wires.

  • Page 17: Step 4 (Raising The Gin Pole)

    Step 4 (Raising the Gin Pole) Attach the guy wires between the first coupler on the Tower Base Section and the Left, Right and Down Side foundations. Use a 5/16” open thimble through the eye of the turnbuckle. After placing this and all other thimbles, squeeze it closed before installing the wire and saddle clamps.

  • Page 18: Step 7 (Top Guy Wire Attachment)

    Step 7 (Top Guy Wire Attachment) The top guy wires are attached 4 feet from the end of the top section with tangs. Install the short leg of the tangs to the tower in 2 locations with 5/8” X 7” bolts.

  • Page 19: Step 8 (Hoist Guy Wire Attachment)

    Use a 1/2" thimble, three 5/16” saddle clamps and a 1/2" shackle for the 5/16” guy wire. Lift or block each section, so they are level, and then pull the guy wire tight. This will allow the tower to lift evenly.

  • Page 20: Step 9 (First Tower Raising)

    If there is no visible slack, there is no way to tell if they are getting too tight. If a guy wire gets too tight it can break and the tower can fall.
  • Page 21 1/2” chain and a 7/16” shackle is offered to attach the retaining turnbuckle to the gin pole end fitting. Also, a set of holes are provided in the gusset plates to adjust for higher or lower placement of the anchor. Each hole is a 5 degree adjustment and moves the end of the gin pole 1 foot 9 inches at the hoist anchor.

  • Page 22: Step 10 (Tower Adjustment)

    The lowest hoist and down side guy wires are unique in that they hold the gin pole from falling into the hoist foundation. The result is that they are tight with little or no sag compared to the other guy wires.

  • Page 23: Step 12 (Re-Raising The Tower)

    (see Figure 9). While we recommend that the gin pole guy wires be left in place, they are a tripping hazard and should be marked with surveyors tape. If they must be removed, please mark the lengths for accurate reassembly.

  • Page 24: Tower Maintenance

    Guy wire dead end weaved through the turnbuckle eyes and bodies Figure 9 10) Tower Maintenance The tower should be inspected every 6 months at a minimum. • Ensure that all hardware is tight. • Ensure proper tension exists in the guy wires. •...

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