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GOVERNMENT OF INDIA
MINISTRY OF RAIL'W"&YS

Technical Specification
for
Spun Prestressed Cement Concrete ( .PSC )
OHE Traction Mast

Specification No. ETI/C/2 ( 8/94 )

RESEARCH DESIGNS .tr. [Link].A RDS [Link]:M

LUCX"NO'W" • 226011
 4
REFERENCE COPY

..
GOVERNMENT OF INDIA
Ml'NISTRY OF RAILWAYS
/

TECHNICAL SPECIFJ:CATION FOR

1 SPUN PRESTRESSED CEMENT CONCRETE (PSC)
OHE TRACTION
~ . MAST

SPECIFICATION [Link]/C/2(8/94}

ISSUED BY
'RESEARCH DESIGNS & s·TANDA~DS ORGANISATION
MANAK NAGAR, LUCKNOW 22~ 011 (INDXA)

(psc 1)
 Specification N·o. ETI/C/2(8/94)

TECHNICAL'SPECIFICATION FOR SPUN PRESTR~SSED CEMENT

CONCRETE (PSC) QHE TRACTION MAST
1. 0 SCOPE-
1.1 This specification c6vets t~e manufacture,_ testing ~nd
Sl~pply of· .spun prestressed concrete (PSC) traction
masts 1 for Railway E1 ectr if icat ion.
1. 2. This [Link]~tion supersedes the earlier specification
[Link]/C/2 {1~82)'

GENERAL

2. 1 Governing Specifications:·

[Link] ·[Link]. [Link] [Link]·[Link] has

been derived from the following Standards and Codes of
Practices (latest version) wherever applicabla. ·
2. 1 . 1 IS;383 Specification f\Ot coarse and fine
., I
aggregates·. ·
2. 1. 2 . rs·:432(Part I) Specification .for mild steel .
.. " ;'
·'
2. 1. 3 IS:456 -Code of practice· for plain and.
reinforced ctincrete. eo
C>
l ~
2. 1. 4 IS:518 - Methods ~f tests. for strength
.of concrete.
'"
0
Q
2. 1. s· IS.: 650- - Standard sand for testing ceme~t Q
'Q
2. ~. 6 IS: 1343 .• - Code of practic~ for pRestress~d •
concrete •.
. . .
2.1.7 IS:1785~Part'I) - [Link]~drawn steel wire for
prestressed concrete.
2. "1.. 8 IS; 1}86 - High strength ~formed steel bars
& wires for co~ctete reinforcement
' . ~ .
2.,. 9. IS; 2.905_ . ~.Conc~ete poli~ for overhead power
•'
I
;;.nd,,telecp~[Link] ion 1 ines
- metho·d o+' test.
' >

2 .1·. 10 IS:6006
'
- Sp~cificati?n for unGQated st~a:~
relieved •trand,for prestrssoad
concrete.

1
 2. 1. 11 IS:9103 - Specification for admixtures for
concrete.
2. 1. 12 IS: 10262 - RecommJ~ded =guidelines for
·concrete mix de~ign.
'.

2. 1. 13 IS~12269 Spe·ci.f icat·ion for 53 grade

6rdinary portland cement.
2. 1. 14 IS:\~3158 :... Prest·r~ssed ·concrete· circular sptm
Doles for ov~rh~ad power.,traction
and t.e ·1 ~COffiffiUn i Cat i On• 1 i neS, I
2. 1. 15 S.P 23 (S&T) - Hand book _on [Link] mixes.
. .
2. 2 In case of [Link] conf'l ict [Link] the contents of the
~bove specifications and this speci~ication, th~ latter
· sha 11 preva i 1 .
2.3 The manufacturer shall submit to the Purchaser the
design of· the· mast for approv~l of [Link] General
'(T~action Instal~ation) Research Oes~gns. & Standards
[Link] sat ion, Manak Nagar, ,Luck now 225 011 (India) or
indicate. his acceptanc~ of cQnc~pt~onal/~etailed
designs of o·; rector Genera 1 (Traction Insta 11 at ion)
·R~search Designs & Stanadards Orgariisation, Manak
Nagar, Luckn6w 226 011 (India)/ Purchaser.·Designs may
get upgraded with better knowledge and manufact0rer
shall incorporate such change$ ,and improvements in
d~signs a$ are foun9 necessary after evaluation and
discussion with the Director Ganeral(Traction
Lnstall~tion) ~eseirch DesignG & sfanadards
Organisation, Manak ·Nagar, ·Luckno-w 226 011 (India)
/Purchaser.
..
'··J 2' . 4 '
[Link] manufacturing process to be adopted for production
~hall ~e with the ~rior approval of the Purcha~8r.

2.5 The design and manufacture of the mast sha41 be

of type- 3 m~~b~~ ~ith 1i~~ting crack width 6f'0.1 mm
genera ll·y in accordance with IS: 1.343 and IS: 13158. The
data .for ?~sign of' mast .is [Link] i·n 'Annexure-!.
2.6 Any· devi~tio~ from this specificati6n proposed by the'
manufacturer, intended to improve"::·. the performance,
uti 1 ity and efficiency of the [Link]. wi 11 ·be givt;;n ·due
considerat~on' · provided full particulars of the
devi~tion ~iih justification thereof are furnished. In
SUCh ·a CaSe, the [Link] .sha1l Ql..-10te aCCOrding tO
this specification and the devlatiein;· if any,· proposed
:by·. him Shall be [Link]
. an alt~rnative(s). . ;

. 3.0 TERMINOLOGY: F'or the purpose [Link] specification, the

•.
' '
following definitions in addition to those given in the
specification meht1oned in Clause· 2.1 shall apply.

2
 3. 1

This is the equivalent .shear acting at 7000 mm height

[Link] the top of foundation level (i.e. 8350 mm ·fr·om
the bottom end of the mast).

3.2 Ultimate failure

I

The copditions·~xistin~ ~hen the mast ce~ses to sustain

a load increment owing to ~ither cru~hing of concrete
or Shapping of' the prestressing te~don or permanent
stretching of the steel in any part of the mast.
''f
4.0 DIMENSIONS OF~ THE ~·1AST

4., The ove~all length of ~ast shall be 9500 mm or as

desired by the purchaser.

4 ',r_
'} The _outside diameter at the top ~nd of mast shall be
250 ffim or as· tjesired by the purchaser.

'4. 3 Tolerances:
/

4.3.1 The permissible toler~nces f6r the finished masts shall

be as follows:

(i) length: + 10 mm or
-- 10 mm,
('11. -) Diameter: + 2 mm or -· 2 mm,
(iii) Thickness: + 2 mm or - 1
f'mm,
(iv) Up-rightness: \ 0.1%
~
C\l
5.0 MATERIALS <:>
<::)-
5 .'1 Cement Q
Q
Th~ ce~ent used shall conform to IS:12269
(Specification for 53 ~rade ordinary portland cement)
except for the following mini~um requir~ments for
setting time. I
a.) Initial Not less than 90 minutes.
b) Final Not more than· 600 m{nutes.
5. , . 1 As far as p-ssible, the cement shall be obtained from
Ol'l~
source
con~ignmen'
,o
minimise 'variations in the ·qt.~ality. Each
sha·n be·covered by a test .certificate.
which shan be submitteq to the Pur·chaser or Inspectin~
Officer ~r check. E~ch consianment of cement shall be
stockeds~parately and shall be clearly identified.

5. 1. 2 If ~quired by the Inspec~[Link] Officer, before using a

par~bular batch of cement, a minimum of 3 ttial cubes
·sh~l be made With aggregat~ gradin~ as followed frr
t~ approv-ed .design mix an'd the a verage
· ' compre~s1· .
•trength results at 7 days shall be determined ~ 0

3
 assess the suitability of the cement. An~ other
suitable quick testing method may be adopted with the
approval of the Inspecting Officer.

5.2 ~Arigregates

Coarse and fine aggregates used for the casting of

mast ·shall conform to JS;383 and test certificates from
a reputed testing laboratory shall be sub~itted to the
Purchaser for approval. A sample of aggregates sha.11
b.,.e .submitted by the f'1anufacturer to. the d~urchaser for
appr ova 1 i f requ i r·ed. The nomina 1 · maxi mum size of
aggrega~es [Link] ';n no c~~e e~ceed 20 mm or 6ne · fou~th
of the minimL~m thic~.ness of the [Link] ·whichever is less.
Eac~ ~ize of ~raded ~gg~egate shall be stocked in
different storag~ bins or stock piles .and shall be
mixed only after the quantity required for each size
has been separately weighed. The storage bins or stock
Pi·les shall be under cover to protect them from
weather.

5.3 Steel

The properties of. the mild, the high strength

deformed and high tensile steel, along with test
certificates shall be submitted, to. the. Inspecting
Officer for approva.l be~fore commehc i ng. f!lanufacture. In
the absence of test reports, three .samples shall be
selected in ·the pr~sence·of the Inspecting Officer and
tests conducted in an approved laboratory. .The
,.,: ~ Purchaser has the right to have the steel in stock
tested periodically at the cost of the Manufacturer.
,. The· ~igh tensiie steel to be used shall . conform to
. ' 15:1785-(Pt.I) or IS:6006 the mild steel shall
(.· conform to IS;432 (Part.I) and high strength deformed
steel shall conform to IS:1786 [Link] far as specified
in the drawings.

5.4 Water

Water used for mixing ~nd curing shall be clean and

free. from injurious amounts of oils, acids, alkalis,
salt, sugar, ·organic materials or other substances [Link]
I

may be deleterious to [Link] steel. Potable water

is generally· considered satisfactory . for mixing
concrete. The requ [Link]·nt of water sha 11 conform to
IS:456~ The use of sea ~ater is ~rohibited.

$.5 CQncrete.

5.5.1 The granulometric curves for aggregates shall be

plotted by the Manufacturer showing the limits of
grading according ·to the. ty·pes and s'izes of the
I agg~egates proposed to be used to achieve the requisite

4
 -.

strength of concrete. These curves and the [Link].

water cement .ratio she. 11 be got· ·approyed by. (lie
Inspect·ing Officer before commencing manufacture. The
actual granulometric·c~rves d~ring. ma~ufactur~ shall
'lie [Link] l,irnits. To ensure compliance with this
·' requirement,.,th~ grahulomet~ic curves shall be plotted
· · and. · checked 1 every dtw, before commer;tcement of
cone ret i ng. Whenever ther.e is cmange in source and or
quality of a~gr~~~tes and cement, fresh granulometric
curves shall be plotted and got ap~roved by the
Inspect1ng Officer. ·
•
.. 5.!? .2 ~e ceme~t cont~t~t shall be ,kept as low ·as possible to
• minimise ~hrinkage and creep of concrete. However, it
, shall· be ensured- .[Link] cement content sha 11 not be less
t,han .3:80 kg/m3 and preferably not· more than. 500 kg/m3
[Link] compacted conc~ete.

5.5.3 The mi.x design [Link] be in accordance wi t.h the IS: 10262
and- standard deviatio~ shall be derived from not less
than 40 [Link];:fual cube results prepared under ful 1
e~ale· conditions during the mix design stage before
'finalising· · the·· mix for ~egular production. For
statistical ·calcu,lation C?f standard 'deviation and
quality ·control, a,general gl/idance may-be taken from
Handbook of concrete mixes· SP:23(S&T). ·

5.5.4· The strength of concrete sha)i be' as aiven'below:

i) [Link] strength at F.8 days;- The:minimum works

test cube crushing strength of.. the concrete shal~
.. normally be not 1ess tpan 51. 5· MPa. In occas; ona 1 case'W
where th.e minimL~m works test cubes crushing strengt~
falls be 1 ow· 51 . 5 MPa but not below >48 f\1Pa, mast fro""
such ·batches may be accepted .[Link] to their passinD
the. increase.d frequency of testing· specified 1n ClausO
8.2.'2. 0
c:.
ii) Compressive strength at transfer:~ The works test
cubes streng(h at t~ansfer pf prestress shall not be
les~ than ~o MPa.

5,5.5 A minimum 3 test specimen~ of 15 em cubes shall

determine .the compressive .strength of concrete a.t each
:_.stage .. The compressive strength stiplqated abo\/e sha'il
be based on the lowest cube test result of the 3 test
specimens. This shall ,however,· be relaxed to the sec·>nd
lowest cube test [Link]. in case the number of test··
SP®.'ilnens .are .. increased to a minimum of 6 ai· PaC;..i ·
; st~fj~'·. ·

5.6 Admixture may be used with the approval· of the

Purchaser. However use of any ad~ixture · CJntaining
6hlori~es in any form is prohibited. The admixt~re
shall ·conform to IS:9103.

5
 6.0 MANUFACTURE
'Only after ·all the designs, drawings and t~st
·certificates of raw mat~rials have been· ~pprovo~ and
clearance given by purchaser to ·the effect, the
manufactu~er shall take up the ma~~factur~ of the
prototfpe. The manufac~u~a of masts shall be done under
sui'table 'cover and not in the open~ It i.s to be clearJ.y
understood that .any changes reauired to be done in the
design after approval of. the prototype .as required ·by'
purchaser shall be don~ expeditioUsly.

5. 1 Mou 1 ds: . l.

t-1oulds · [Link] be of steel. arid -of rigid. construct ion to

prevent distort ion ·and so arr-~mged
. &.s to
provide smooth
surfaces. The moulds shall not allow any leakage of
.
cement grout during castin~. The holes in the end
plates,· for the high tens11e steel wires shall be
accu~~tely drilled by Jlgs to ensure
interchange~bility. These ehd plat~s shall be designed
to [Link]$. for~es ~rising out of the change in
dire¢tion of prestressing ·wir~s:during tensioning.
• 'l '

6. 1. 1 In the case of long lin~ method of manufacture, the

casting bed sha~l have provision to ansure correct
alignment· of the moulds. the-moulds shall be free to
' move/slide along the lon~ line to permit ~ransfei of
prestressing force along the line without restraint .

6.2 .!::[Link] and Consolidation of

: . ;I
Concrete: ·

. <
6.2.1 Provision shall b~ ~ade to measure the quantities . of
cement and of 'firie and c~arse aggregates by weight
only. The accuracy ~f the measuring· equipment shall be
+ 3% or -3% All the·· measuring equipment· shall be·
maintained in ·clean, serviceable condition· and "its
accuracy checked regularly. Modern high speed mixers. I
preferably Pan or Turbine Type approved by the
Purchaser, shall be used for mixing the concrete.
6.2.2 Mixing and placing of c~ncrete shall be as far as
possible be avoided dw·ing 'the extreme temperatures in
·summer and winter. The concrete once placed in the
moulds shall be spun within 60 minutes of its mixing or
as required by the inspectirtg 6fficer.
6.2.3 The concrete shall be thoroughly mi~ed and cdnsolidated
in the mould by spi~ning method.
6.2.4 The freshly c-ast ma·sts s·hall be protected during the
first stage of hardening from the ha~mful effect.s
sunshine, dry wind, ~old and rain.

6
 Stretching Qi ~G.s;
The prestressing ·wires shall be· stretched sy an
approved method. The anchor ins of. the stretched wires
sha 1 J. be :s'uch that dur tng manufac-ture and unt i 1 the
wires ar~ released, no Slipping occurs. The force at
the time of initial stretching should ih add1t~on to
imparting of designed ·pre'stress should also be
~uffic~ent to .ov~rcome the .fricti~~~on account of any
change· in the inclination of wires and slippage that
might occur during the anchoring process which will
have to be suitably compensated.
The tensioning of prestressing steel shall .be. carried
out in a manner that wi11 induce a smooth and even rate
of increase of s~ress in the wires.

6.3.3 The force induced in .the prestr•ssing·~iras shall be

determined .· by means. of . gauge~ a~tached to the
tensioning apparatus arid ~ross·checked by extension of
·the wires observed. [Link] to be .achieved .shal1
be determined in advance, l;)ased on
trials C9nducted. on ,
reRresentative samples of the wires as -used in the
masts. The accuracy of the,.[Link] for measuring of the
ten•ioning force shall be within + 5% or -5% ......
.....,
~
6.4 [Link]; C\.1.
Q
The concrete sha11 be cured by steam curing at 0
atrnospher. ic ·pressure t i 11 tran.s..fer of pres~.ress. Prior 0
appraval of Inspecting Officer shall .be obtained for~
the. process and detans .such as temperature, duration
etc. for t~e steam curing cycle. After detensioning the
masts shall be cured for a further period of not less
than 14 days by submerging jn water tank~.
Alternatively, the masts may be cured bY submerging
them in Water tanks for a pariod Of 7·days followed by
curing for a further period of 7 days ~ith mechanical
water sprayin$ ~rrangements which shall be invariably
ca·rried o•o.~t under cover and [Link] fu11 h1..1midity
conditions.
6,5 Detensjoning .Qf. wires:
6.5. 1 The anchoring system shall pr6vide a dev1ce fop gradual
detensio~ihg of the wire~. No b~ck pulling of the wires
shall . be ~er~itted in th~ gradual detensioning device
for the purpose of ~ei~ase of any wedge or other parts
of the detensioning device. [Link] cutting of the '~-tires
before release of the full t•nsion shall be strictly
· prohib1ted. ·

1
6.5.2 The transfer of' pre~tress shall not bo effected· until
the concrete in the mast has ~ttained the strength
specified in clause 5.5.4 above as established by
control tests on cubes specified in clause 8.1.3.

6.6 Earthing

Suitable arrangements shall be made for prOviding

[Link] for the [Link].s a.s· per the drawing or as
desired by the Purchaser.

6.7 Supervision:

6.7.1 A competent and ~ualified person shall be employed by

the Manufacturer whose duty ~ill be to supervise at'all
stages, the placement of doncrete. All te·t~ o~
materials, the making and. testing ·of cubsG. l~v
maintenance and calibration of all mixing c;.nd iiH~·~r:~\!.-li·ing
plants and gauges shall b~ cafried ou~ unde~ his d1rect
supervision. He sh~ll also ~aintain a direct record of
the quantitiesi proportions and source of supply of
aggregates used, ~rastressing·force actually applied,
th& actual measure~ent of extension of the prestressing
wires, na~ure and duration of cu~jng 'actually done and
the results on internal a.s well as Inspecting Officer's
tests. These records shall be kept available for
scrutiny by the Inspecting Officer at all times. The
name of the compet~nt person shall be intimate~ t6 the
Inspecting Officer before commencing manufacture.
'.6.8 Finish;

Ma~t& shall be. free .from surface defects including hair

cracks. The surfaces of the masts in contact with the
steel moulds shall be smooth and regular in shape ·.and
sha11, as far as·[Link], be free from .. pores. Water
retaining p6ckets or honey-combing formation shall not
be admiss~ble. 25 mm thick 1;2 cement mortar cover
shall be p~ovided on:the full ar~a of the top of m~st.

6.8.2 The ends of the pr~stressing wires shall. be cut as

' • r:1 •
close to the surface of the mast as possible and in any
case sha 11 not; project more tha.n 3 mm.

The ends of the prestr~ssing wir~s shall be given two

coats of suita~le anticorrosive paints approved by the
Purchaser or Inspecting Officer.

6.8.4 No touching up or finishing by cement grout etc .. shall

.
be done on the mast after it is removed from the mou d
6.9 Stacking in lots:
. 6. 9.1 After the masts have initially been checked, both
dimensionally and from the point of view of finish [Link]

8
 straightness, ~hey ~hall .be stored at a convenient
place in lots, each lot 6omprising of -

i) A1 ! masts' cast together · and [Link]

sim~ltaneously in one long line in·~h~ case o~ long·
_line· product ion.,
. - I
;

50 conseclit_;:.;e mast·$ or a day~ s product ion to the

· i i)
same drawihg when production is not on 1ong 1ine
subject to·~ ma;imum
,, of 50.
.,
The ma.s'ts shall be stacked ;'n a convenient order on
leveled an,d conso1ipat~d-ground, over one·another. upto
a co~venien~ h~ight .. Each ~ast sh~11 be separated from
.[Link]
'
vertically
.
by wooden- battens of size suitable
to- ensure that ·earthing e.r re_ngement etc. , .are not
damaged and ~he masts ~re stacked evenly.

7..0 Inspect ion

7. 1 The .manufacturei-shall supply at his expense, all the

masts reQui~e~ f6t ~ests and those for r~tests; samples
of materials and all la-b'our, suitable testing rig
machines, too1,s, _gauges, [Link].s, forms qf· test
reports, etc.,·r· .0;nd · all otljer t'l"l;ngs which may be
considered necesaary or req~ir~~ by the Inspecting
Officer for. car·rying out any' or all of the checks and
te~ts mentioned 'in t~ese; ~pacifications and shall
render all assistaric~ in making such cheeks and tests.
7. 2. All pressure gauges and measuring dials on the
"""""'
"'
• compression test machines, preterision~ng equipment, .~
~
weigh batching machine and any other equjpments shall (",..:)
be got 9heck~d and caltbYated reg~larly (as ~i~ected by c::;:,
the Inspe~ting Otficer) by an in~ependent agency and 0
the adjustment certificates shall be ·furnished to the Q
Inspect·_ing Officer.· The cost of all such check-s and
calibrations shall be bbrne by the manufact~re~.

7.3 The Inspecting· Officer and the Purchaser shall have

free [Link] ·rat a11 reasonabJe times to the Works in
which the masts are manufactured. He shall be at
1iberty·t6 insp~ct the man~facture at any stage and to
reject any mater i·a1 or supplies that do not conform to
the terms of this specification.
8,.0·

8. 1 ~ Tests
8. 1., Befor~ giving a call to the Purchaser/Director General
(Traction Installations)/ Resea~ch Designs&· Standards
Organisation, Lucknow for inspection and testing of
the prototype, the manufacturer shall submit a detailed
test schedul~ coneisting of sche~atic ar~angement of

.•
 the tests and the numb~r 6f days ~equired to complete
a11 the tests. Once the schedule is approved, the tests
shall invariably be done accordingly. However, ~uring
· the ·process of . t)lpe , testing or . even 1ater,: · the·
purchaser reserves the [Link]' to conduct anx additional
test(s) besides those [Link] herein. 'on [Link]·st. so
as to test the mast to his sattsfaction or for g~ining
additional information and knowledge. In case. any
dispute or disagreement [Link].s between the manufa:cturer
and representative of 'the Purchaser~Director General
:(Traction Installationi)/ Res~arch Designs & . Standards
Orga~isation, LuCknow during the process of te~tirig as
re~ards the procedur~ for type tests and/6r ihe
interpret•tion and acceptability of the results of type
test, it 1 sha 11 be · brought to the notice of the
·Purchaser/Director Geheral (Traction I~stallation),
RDSO/Lucknow as the ~ase may be~ whose decision .shall
be final [Link]. · ·

8.,. 2 All the tests specifi~d in the specificatioK shall be

carried ~ut at the manufact~rer's· works. The
.manufacturer shall ar~ange all the necessary machinery,
apparatu~. labour ~nd ·assistance . required f6t
conducting the tests ~ithout taking any claim on · th~
purchaser. The tests . for which the facilities are not
avai 1able at the manufacturer' .s ·[Link] may be carried
out at any other reputed or gove~nment laboratory with·
~rior approval of-the purchaser and the cost of such
tests shall be borne 6y· the manutacturer.
'1!1' ' ... • ~

.8. 1.3 In addition to the control checks exercised on tn~

materials and manufacturing process specified in
clauses 5 & 6 above, the eoncrete ~nd the [Link]
shall be subjected ~o the:following checks ~nd type
te.s,ts .

.; ) [Link] strehgth fest of conc're,te· at transfer

of prestress and at [Link]~s.

ii) Flexural strength test of co~crete.

•I •

iii) Check. for dimensiona 1 [Link], straightfles.s and

surface finish of mast.

iv) Bend test of [Link]

,,. for dest.n~ction.

ACCEPTANCE CRITERIA FOR PROTOTYP.E:

8.,. 4. 1 The sample offered for type tests in accordance w1th
:61ause 8.1.3 shall b•ss all the type tests st1pulated
in c1a.w;;e 8 .,1. 3 hereof.

10
8.·1.4.2 · The mast ·shall be deemed not to have passed the tes~,
if:-

i) Cracks Wider t~an 0.1 mm appear at a stage prior

to. the application of the design load (1.0 Dt.)
i i )The cr'acks appear~d at a stage· prior. to the
app1ication of· the desisn load (1.0 Dt) do not
c1ose af>ter release
l
of
.
all loads.
iii) The deflection ob~erved at the top of the mast
Lmder design load ( 1.0 Dt) is more th'an 80 mm.
/

·iv) The .observed ·load at failure is less than the

respect~ve_designed· ultimate lo~d (2.0 Dt).

8.1.4. 3 Only after clear written approval of the results of the

tests oh the prototype is communicated by
Purchaser/Director Genera( (Traction [Link])/
Research Designs & Standa·rds or·ganisation, Lucknow to
the manGfacturer, shall hf take ~P bulk manufacture of
the mast which· sh~ll be s~rtetl~ with the same
mat~rials and [Link] 'of [Link] as adopted for the
prototype .. In" . no c irCU!1St'ances sha 11 mater i e.l other
than ihose adopted' durin§ the m~rlufactur~ of prototype
be used·for bu'lk manufaccure on tl'H~\ p'lea that they had
been obtai ned prior 'to the ·ap'prova l of. the prototype.
~

[Link] If the prototype 6f a mast confo~~ing to this

speCification ,has alretdy been approv~d. in connection
with previous ·supplies to Indian Railways, fresh
testing of prototype cf the mast may be·waived at the
discretion of the ~~r~haser, provided that n~ cha~~es:
whatsoever~ in the m~i~rial o~ process' o¥ manufacture
·have been mad~. 'Ho~etef~· the. Purchaser reserves the
right to t~st·any ma~ if he deem~ i t nec~ssary to do
so in the light of e<per'·ience gained from previous
supp 1 ies.
Q
[Link] Notwithstand~ng ao~oval having been accorded to, ~
manufacture th~'bUlk'df the masts on the basis of the
~esGlts of th~ typetests, the purch~se~ reserves the
right to conduct my type arid number of tests,
including destructi1e te~ts at any time durino the
process of [Link]. mamiacture without prior advice to the
manvfacturer. Al'l [Link]-sha·ll be mage available to
the purchaser ,to coJduct ·such tests without any charge.
8.2 Acceptance test

All the.t~sts me~[Link] clau~e 8.1.3 an~ bend test

of mast shall con~ itute the
.,
acce'ptance fests .
8.2.1 For the purpose if testing and acceptance of masts each
lot shall be as ~fined in clause 6.9.1 above. Masts to

.n
 be tested shall be se1ected at random py the Inspecting
Officer. Only masts which are 28 days old shall be
selected for tests:
·8. 2. 2 freq·uency and number of ·tests

The number of masts td be~~~lected fro~ a lot shall be

in accordance with columns 1 and 2 of the ro:llowing
. ' .
. table: . . .·. . .. .
------------------------ -.-~ ~- - - - - - - - - ----~;--- - - - - : - - - - - - ~~ ,.._,!..... - · - -

Size of -Dimensional Permissible Number of ma.s"t-s· ·.for

lot- sample s,ize defect ; ve ' ' -.... -:... _;_·-; ----:. -_-·-- ._._.::_..J ~-~-----i.-f-.--
sample· 1 bend te·st.· .bend test for
::,f· .. ::de~tf-uc.t ion
.' . . . . '.,
-------~---------------------------------------~---~---------
' ~:. :, '

( 1) ( 2) ( 3) . ' ( 4} ( 5)
·..,
~~;~-;~-------~;----------~---:-~-:~-----~---~~--,~~~-:;_;;~--------

-- do -:-- 30 . i · -J 2 . ~": 2 ( liC)

----------------~---------~~-~-------------~-~---~-~~~------
(l!C) for [Link] co~cr~te c~be'strength is between
51.5 MPa and 48 MPa.t.·

8. 2 ..3 The mast~ sh~ll be selected ~t random. In· order tp

ensure randomness. a 1 l the ma's·ts in one lot may be- ·
numbered in•serial order and starting from any random
mast every rth mast ~ay. be 'ncluded [Link] sample. r
being the integral pcart of N/[Link] N. is the size of
the lot and n is the sample siz~_.

8.2.4 Acceotance criteria i.Q.t. acQeptance test;

8. 2 .4·.1 All masts as selected according to Clause 8.2.2 shall
be tested for length, dimension and uprightness as per
Clause 4.3. The number of masts to be tested for bend
t~st and bend test ior destructi9n shall be in
accordance with column (4) and column (5) respectively
of table 8.2.2 and shall be selected from those
accepted after dimensional checks.
..
•

[Link] A lot shall · be crinsidered conforming to the

specification if the dondition~ of clause [Link] and
[Link] are satisfied.
. \

8.2.4.:_) The number of masts w:hich do not satisfy the

requirements. Of .l~ngth ,. · straightne~s and dimension of
section, sha 11 not exce,ed the figure. in column (3) of
table in 8.2.2.

If the _number of such masts exceeds this figur8.

all the masts in. the lot sh,ll be ~osted for these
reQuirement-s and those not satisfying the requ i rt:Jment. s
reject~d. 100% of the masts shall be checke~ Visually
and satisfy the requirements as per clause 6.8.

12
 . '
. : '.

. -(" ( ·-·~
8 .. 2 '4' 4 A'l.T, ./ffi~13t.s
tested 'for bend test and bend test for
destfuction shall [Link] the requirement of the ~est.
as · specified in c 1&.use 8. 1. 4 ..2. 'If one or more masts
f&.il, twice f.'he number of mas~-s or1gin&.liy tested sha11.
be selected from those already [Link] for dimensional
accur~cy and subject~d to the test. I f there· is no·
failure &.mong these [Link], .the . 1 ot sha 11 be considered
to_ have satisfied the requirements of the test. I f one
) or. more [Link] of thet second [Link]· fai 1, th~ lot
repre$[Link] by the samples shall be Considered not to .•

hay~ b~ssed the test ~nd will be r~jected .

. '"·

. 8.2 .5 '·

8. 2, 5. 1 ·~~·6·r· ·.~each
lot ·of masts "'compressive st [Link] tests on
.. :·,"eH.~t:rete,. ,both· at 28'"days and at ·transfe~._, shall be
' . e'~fitied out on a 'mini~um of .. 3 cubes .each time .
.... , ...
a.. ~ .5. 2 Th,,i1~xural strehsth test•of concrete· shall be carried
. otit·,,·~b.;'·ihe rate of one beam for each lot.

'1i~l ~Et~bos
1
9.0 .
•
'•.. ' t ~ . '
9.1 G:Q'ft:il>t!'?[Link]'test Qf. concrete 1.(

,.
j :t~·~
Te~~t .. :·cub~s
/\'. ' ,., . '.
of size 15 em x 15 em· x 15 em sha.11 be made
. .
"''[Link]~d·
"· !'" ' "'(I:
'[Link]
• ,
.[Link]
' -
to IS;·516
· t
~ · .
[Link]· the same ~ ~·

c'tJ:nttete
,: .
~. ' t •
cast.
simultaneously with' the masts in the same
manh'et:,. [Link] of the· cubes (minim'l~m- [Link] cubes ) shall
ba ·~·-~~fed along w\t.h· .the masts·'and tes'ted prior . to
tr~fi~f~r of~ p_re$tre~.s ,' t.o· check \hat th<7 concrete has
developed the requisite minimum compressive strength
specified at transfer. The remainder (minimum three
· cubes ) s'ha 11 1 be, cw:~d s..s specified i n'·'the C 1ause 6. 4 ..
[Link]. [Link] at t'he end of 28 day's . 'fo determine the
compres~ i ve ,[Link] o(
concr:-ete at that age .
. ,
9.2 F1exuraL.. [Link] test g_f concrete
~
The f lexura 1 strength test of concrete sha 11 be carried ~
out on conqrete [Link] as specified in IS:516. ~~
;. ' ~

9.3· ChecJs .i21:. dimerisi0i1~1 to1eranc~

,.
and finish: 0
c:.)
The mas~~ shall b~ [Link] visually· for finish and::
[Link] from surface defe~ts: r. The dimensional
toJerance~ specified·sha-11 be checked by any suitable
rneans as directed by- t~e-Insp~·cting Officer·.:
~ .., ..
'

' .•

13
 .' ..
--.I .~ ·~ '

:i
9.4.1 Arranpemeot for bend ~~

[Link] The mast may be ~ested either. in the vertical or as

desired by the manufacturer in the horizontal position
with the approval of the Purchaser. It shall be fixed
in a crib which ~h~ll chetk all movements of th~
clamped [Link]·of the mast, The c}[Link] portion of the
mast is 1.35 m of the bottom end of the mast.

It t~ste~ in the horizontal position, provision

shall be made by suitable supports to compen~ate for
the overhanging ~eight of the mast. For this p~rpose,
the overhanging portion of the mast may be ~upported on
a movable trolley or·aimilar device. The frictional
resistance of th~ supporting devices should be
sep~rate1y determined and deduct~d from the total final
loa~ applied on the mast.

[Link] To minimise vertical movement at the point·· of load

application and to reduce the stresses.'·due to dead
weight of mast. a rai) supbort shall be ~~ovided near
the point of . load applfcation,· or alternatively a
number of frictionless 8l~pport.s 'in the form of t.ro11eys
may be provided near the support or · other forms of
supports shall be such that any [Link] ~s~ociated
with the deflecti~n of. the _mast under lo~d shall not be
significant portion .,of the measured load on ffi(.ist.

.9.4.1,3 Dynamometer or any ~ther satisfactory method of load

measurement may be ~dopted. The load measuring device
sha 11 be cal ib'rated ·at reeu 1ar i nterv~.l s. The
frictional /resistance of the supporting devices and
rope line pulleys shall be separately determined and
necessary correction applied to the readings of the
load measuring device .
••
... . 9 .4. 1.4 The 1oads acting on the mast should simulate the
•..
~ .. design loading conditions on the mast and are to be.
applied as indicat~d in the Annexure-!. · The design
load (Dt) shall be applied at 8350 mm from the
bottom end of the ~ast in the transverse direction.

[Link] .Deflection of the mast, development of .crack if any and

the load applied shail be observed ·simultaneously, The
measurement of deflection of top [Link] shall be made
in a direction perpendicular to the unloaded position
of the. mast axis.
[Link] One hour before the test, the mast shall be given a
coat of lime wash ~n order to make cracks visible
clearly.

14
·[Link] .The above arrangements should be made to the full
:satisfaction of the purchaser. The manufacturer should
set [Link] approved by pu~chaser.
9.4.2 Proceduq~ for bend tJi3..t. .Qf mast-:

[Link] The loading in tiansvers~ dir~6tion shall be commenced

at 0.5.0t where Dt is the design load and is specified
in Ahnexure-I and shall .be increased in steps of o. 1 Dt
tc 0.7 Dt. The load of ~.7 Dt shall be kept constant
for ·two hours, after· which it .shall be increased to 1.0
Ot(in. steps of 0.1 Ot). The load. i~all then be brought
back to zero. Each time the load is app1ied or
increased it shall be held for two minutes .
.·
9.5 · Procedur§ for Bend-~ of mast for destruction:

[Link] in transverse,direction shall be commenced

at 0.5 Ot and shall be in-Greased. in steps of 0.1 Dt to
0.7Dt. The load of. 0.7 Ot shall be kept constant for 24
hours, after which ii ·shall. be i~creased·to 1.0 Dt (in
steps of ·o.1 pt) and kept constant for 2 hours. The
'load shall then be brought back to zero and thereafter
increased in steps of 0.1 Dt to destruction in type
test and to destruction or 2.5Dt whichever i·s earlier
in ac~eptance test. Ea~h time the load is applied or
increased it shall be held for two minutes .

.9.6 The method-of recording the observations shall be as

specified by the Inspecting Officer.
9.7 T~e masts which are tested ~o failure should be checked
~or reinforcement and cover.

10.0 Marking

Th& ·~ast~ shall be clearly embossed or indelibly

marked wit~ the follo~ing particulars either during or
after manufactuf~ but before testing at~ location so
as to be clearly read after erection in position:

i) Year of manufacture.
ii) Class of mast as per purchaser's requirement.
iii) Manufacturer's se~i~l number and mark.
iv) Position of ~enter of gravit~ of the mast with the
'CG'.
10.2 Masts which are .considered not passed in any of the
above tests should be cleatly marked with indelible ink
o.s "FAILED"'. ·

15
 ANNEXURE-I

DATA FO~ DESIGN OF-SPUN PRESTRESSED CONCRETE OHE MAST.

S 1. No. Oeser ipt ion ;1 Unit Loa_d

.. --------------------------------------------------------
•
I 1. Vertical load a.t top of mast. l<.g 700

2. Design .bending moment at top kgm 4200

of [Link].

3. Design load (Dt)7

Equivalent shear act~ng at 7000mm
height abov4 the to~ of foundation.
(ie. 8350 m~ from bottom end of
[Link]-) kg 600

4, Permissible_•deflec~ionat top of
mast at design load (Dt). mm 80
c
.J. Torsion acting at 7000 mm height. kgm
from top of·foundation.
"
6. Load factor for ultimate bending
mom~ checking.
;!
2.0

------------------------------------------------------------
- . li

@ 400 (D/2.0 + 0.15) where Dis the diameter of mast

in metre at 7000 mm height from tqp of foundation.

NOTE:- 1he abbve data is applicable for a particular

type of mast (i~. fcir a design bending moment of 4200
kgm and vertical load of 700 kg.). The above data
shall vary for other types of mast with different
design bendin~ moments 1 vertica1 loads and torsion as
desired by the; purchaser . -

16
 ·--- ! ij

.
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J I.
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11.50
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t
I
... ,¥' ,l
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i
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,. EQUIVAI...ENT LOAD
\ I \
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I
I
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7000
'

'
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9 00 I i
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I .FOUNDAT,:QN LEVEL
:
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13.50 j
;

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'

BOTTOM< PLAN

ALL DIAMENSIONS ARE IN ·nun

17