Concrete cable cover products
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This document provides specifications for concrete products including Hatari slabs and stay blocks. It outlines requirements for the design, composition, dimensions, testing, and markings of the concrete products. The concrete products are to be used in tropical conditions for underground power cables and overhead power lines. Tolerances and load strength requirements are provided for the different product sizes and applications.
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Concrete cable cover products
- 1. TITLE: Doc. No. Issue No. SPECIFICATION FOR CONCRETE PRODUCTS Revision No. (Hatari Slabs & Stay Date of Issue Blocks) Page 1 of 9 FOREWORD This specification lays down requirements for Concrete Products (Hatari Slabs and Stay Blocks). It shall be the responsibility of the manufacturer to ensure adequacy of the design and good engineering practice in the manufacture of the Hatari Slabs and Stay Blocks for KPLC/REA. The manufacturer shall submit information which confirms satisfactory service experience with products which fall within the scope of this specification. 1. SCOPE 1.1 This specification is for Concrete Products Hatari Slabs (concrete cable covers) and Stay Blocks. 1.2 This specification covers the following sizes: 1.2.1 Hatari slab, LV 1.2.2 Hatari slab, HT 1.2.3 Stay block, 1/2" (12.5mm) 1.2.4 Stay block, 3/4" (19mm) 1.2.5 Stay block, 1" (25mm) 2. REFERENCES The following documents were referred to during the preparation of this specification. In case of conflict, the requirements of this specification shall take precedence. ESI 43 – 91 Stay Strands and Stay Fittings for Overhead Lines. IS 5820 Indian Standard Specification for Precast Concrete Cable Covers. BS 2484 British Standard Specification for Straight Concrete and Clayware Cable Covers. BS 4483 Steel Fabric for the Reinforcement of Concrete. KS 02-95 Kenya Standard Specification for Natural Aggregates for Concrete KS 1725 Kenya Standard Specification for Cement Part1: Composition, Specifications and Conformity Criteria for Common Cement 3. TERMS AND DEFINITIONS
- 2. TITLE: Doc. No. Issue No. SPECIFICATION FOR CONCRETE PRODUCTS Revision No. (Hatari Slabs & Stay Date of Issue Blocks) Page 2 of 9 The definitions given in the reference standards shall apply. 4. REQUIREMENTS 4.1 OPERATING CONDITIONS 4.1.1 The concrete products shall be suitable for use in tropical conditions with temperatures of –1 °C to 40 °C and humidities of up to 95%. 4.1.2 The stay block shall be buried at depths of up to 1.8m in soils of various types to act as an anchor for stay wire on overhead lines. The concrete stay blocks designated ½’’ shall be used with stay rod size 6ft x 5/8” & 6ft x ½’’ of 36.8kN minimum failing load, those designated 3/4" shall be used with stay rod size 8ft x 3/4" of 64kN minimum failing load while those designated 1" shall be used with stay rod size 9ft x 1" of 131.6kN minimum failing load. 4.1.3 The Hatari Slabs (cable covers) shall be laid above power cables buried underground in soils of various types. High voltage cables are buried at depths of up to 1.6m while low voltage cables are buried at depths of 0.5m. The cable covers designated LV shall be used to cover cables operating at 240/415V (low voltage) while those designated HT shall be used to cover cables operating at higher voltages up to 66kV. 4.2. DESIGN AND CONSTRUCTION 4.2.1. General 4.2.1.1 The products shall be made using Portland Cement conforming to KS1725, course aggregates not exceeding 10mm nominal size and conforming to KS02- 95, clean river sand and drinking quality water free from any visual contamination. The products shall not contain additional admixtures and pigments. The composition of cement, sand and course aggregates shall be such as to satisfy the requirement for transverse strength and ultimate failing load. The concrete stay blocks shall be reinforced while the cable covers shall contain no steel reinforcement. 4.2.1.2 Steel moulds shall be used in the manufacture of the products so as to ensure a smooth texture externally. The mould shall be accurately made to produce units of the dimensions, profiles and shapes shown in the drawings.
- 3. TITLE: Doc. No. Issue No. SPECIFICATION FOR CONCRETE PRODUCTS Revision No. (Hatari Slabs & Stay Date of Issue Blocks) Page 3 of 9 The product shall be vibrated while on mould to ensure a dense mass free from honeycombs or segregation and fill the forms and spaces between reinforcement (for concrete stay blocks) compactly and without voids. The vibrator used shall have a frequency of not less than 5000 cycles/minute and shall not be attached to or allowed to touch reinforcement during compacting. Lettering shown on the drawings (for cable covers) shall be formed using accurately placed formers securely fixed in position. Cutting either uncured or hardened concrete shall not be permitted. 4.2.1.3 Freshly placed concrete shall be suitably protected and shall be kept constantly damp for a period of at least four days after concreting. The concrete shall be allowed to dry slowly over a period of at least three days after wet curing is completed. 4.2.1.4 Steel reinforcement rods shall be welded at all points of crossing and all dimensions shall be as per the drawings. Alternatively, a welded reinforcing fabric of No. 5 SWG x 75mm square with the wires symmetrically placed about the centre would be accepted. 4.2.1.5 The underside of the cable cover and stay block shall be flat while the upper sides shall be peaked as shown on drawings. The concrete cable cover shall have one end concave, the other convex (as shown in drawings) to provide a concave/convex joint resisting lateral displacement. 4.2.2. Dimensions 4.2.2.1 The cable covers are required in two sizes with dimensions as shown in table 1 and drawing SK No. 08424/1 and 2. Tolerances on length (L), width (W) and thickness at outer edges (H) shall be ±3mm and ±2mm respectively. 4.2.2.2 When tested in accordance with IS5820: 1970 (clause 8.3) the Hatari Slabs (concrete cable covers) shall withstand, without breaking, the loads given in table 1 below. Table 1: Cable Cover Sizes and Transverse Strength Category Dimensions(LxWxH) Average Breaking Load mm (kg) HT 610 x 230 x 50 750 LV 305 x 150 x 40 300 4.2.2.3 The concrete stay blocks are required in three sizes with dimensions (including hole size) as shown in table 2 and drawing number 3 & 4. Tolerances on length
- 4. TITLE: Doc. No. Issue No. SPECIFICATION FOR CONCRETE PRODUCTS Revision No. (Hatari Slabs & Stay Date of Issue Blocks) Page 4 of 9 (L), width (W) and thickness at outer edges (H) shall be ±3mm and ±2mm respectively. 4.2.2.4 When tested in accordance with ESI 43 - 91 the concrete stay blocks shall withstand, for a period of 1 minute, the ultimate failing loads given in table 2 below. Table 2: Concrete Stay Blocks- Sizes and Ultimate Failing Load. Category (size Dimensions(LxWxH) Ultimate failing load (kN) of center hole) mm ½’’ (12.5mm) 500 x 380 x 50, Drg No. 3 65 3/4" (19mm) 500 x 380 x 50, Drg No. 3 65 1" (25mm) 660 x 480 x 60, Drg No. 4 65 5. TESTS AND INSPECTION 5.1 Tests for the concrete stay blocks shall be in accordance with ESI 43-91 while cable covers shall be tested in accordance with IS 5820. 5.2 Certified true copies of previous test reports by the National Testing/Standards Authority of the country of manufacture shall be submitted with the offer for evaluation (all in English Language). 5.3 Routine and sample test reports for the concrete products to be supplied shall be submitted to KPLC/REA for approval before delivery of the goods. 6. MARKING AND LABELLING 6.1 The upper side of each cable cover shall be marked longitudinally by means of impression with the words “HATARI REA” in accordance with drawing SK No. 08424/1 and 2. The word ‘HATARI’ shall be impressed on one inclined face and the name REA on the other. The lettering shall be symmetrically spaced, 4mm deep and 20mm minimum height for LV cable covers and 40mm minimum height for HT cable covers. Each cable cover and stay block shall carry an impression or embossment of the manufacturer’s name or identifying mark. 6.2 The following information shall be marked on the manufacturer’s certificate supplied with the cable covers and stay blocks: Name or trademark of manufacturer; The number and date of standard to which the concrete product complies; Type of binder constituent (s) used;
- 5. TITLE: Doc. No. Issue No. SPECIFICATION FOR CONCRETE PRODUCTS Revision No. (Hatari Slabs & Stay Date of Issue Blocks) Page 5 of 9 Dimensions of the product; Instructions; (all in English Language) ANNEX A: Statement of Compliance and Technical Particulars (to be filled and signed by the Manufacturer for all clauses and submitted for tender evaluation) Clause Number Bidder’s offer Reference page on Manufacturer’s catalogue, drawing, technical data or tests certificate to support the offer. NB: - This schedule does not in any way substitute for detailed information required elsewhere in the specification. ……………………………………………………………………………………………. Manufacturer’s Name, Signature, Stamp and Date
- 6. TITLE: Doc. No. Issue No. SPECIFICATION FOR CONCRETE PRODUCTS Revision No. (Hatari Slabs & Stay Date of Issue Blocks) Page 6 of 9 NOTES 1. ALL DIMENSIONS ARE IN mm. 2. WHEN MANUFUCTURING, THE MOULDS ARE TO BE ACCURATELY MADE TO PRODUCE UNITS OF THE DIMENSIONS PROFILES AND SHAPE SHOWN ON THE DRAWINGS. 3. LETTERING SHOWN ON THE DRAWING MUST BE FORMED USING ACCURATELY PLACED FORMERS SECURELY FIXED IN POSITION. CUTTING EITHER UNCURED OR HARDENED CONCRETE WILL NOT BE PERMITTED. ISOMETRIC VIEW 50 25 75 610 230 SIDE VIEW END VIEW K.P.L.C. 115 230 HATARI 115 100 410 100 610 PLAN FIG :1 CONCRETE HATARI SLAB TO COVER H.T. CABLES DATE SIGN ISSUE DESCRIPTION DATE SIGN APPROVED K. P. & L. Co LTD CHECKED 26 /03/ 02 S.K.K. DRAWN 17 /11/ 01 J.M.K. SK. NO. 08424 / 1 SCALE
- 7. TITLE: Doc. No. Issue No. SPECIFICATION FOR CONCRETE PRODUCTS Revision No. (Hatari Slabs & Stay Date of Issue Blocks) Page 7 of 9 NOTES 1. ALL DIMENSIONS ARE IN mm. 2. WHEN MANUFUCTURING, THE MOULDS ARE TO BE ACCURATELY MADE TO PRODUCE UNITS OF THE DIMENSIONS PROFILES AND SHAPE SHOWN ON THE DRAWINGS. 3. LETTERING SHOWN ON THE DRAWING MUST BE FORMED USING ACCURATELY PLACED FORMERS SECURELY FIXED IN POSITION CUTTING EITHER UNCURED OR HARDENED CONCRETE WILL NOT BE PERMITTED. ISOMETRIC VIEW 40 25 65 305 150 SIDE VIEW END VIEW K.P.L.C. 75 150 HATARI 75 40 225 40 305 PLAN FIG: 2 CONCRETE HATARI SLAB TO COVER L.V. CABLES DATE SIGN ISSUE DESCRIPTION DATE SIGN APPROVED K. P. & L. Co LTD CHECKED 26 /03/ 02 S.K.K. DRAWN 16 /11/ 01 J.M.K. SCALE SK. NO. 08424 / 2
- 8. TITLE: Doc. No. Issue No. SPECIFICATION FOR CONCRETE PRODUCTS Revision No. (Hatari Slabs & Stay Date of Issue Blocks) Page 8 of 9 REINFORCED CONCRETE STAY BLOCK FOR M.V. O/H LINE 65 65 30 50 80 25 Reinforcing Bars SIDE ELEVATION 65 65 30 50 80 25 Reinforcing Bars FRONT ELEVATION 50 Reinforcing Bars 50 90 1 380 90 1 250 250 500 PLAN VIEW SCALE : 1: 5 Not es Drg. No. 3 MANUFAC TURING 1 All dimensions are in mm. . FAILING REINFORCEMENT LOAD 2.Reinforcement rods should be welded at all point s of point s of crossing. Alt ernat ively a welded reinforcing fabric of NUMBER No. 5 gauge x 3'' square would be accept ed. 3. Concret e t o be vibrat ed during manufact ure. LENGHT ACROSS 1 '' /4 4 6 6 .5 KN TONs
- 9. TITLE: Doc. No. Issue No. SPECIFICATION FOR CONCRETE PRODUCTS Revision No. (Hatari Slabs & Stay Date of Issue Blocks) Page 9 of 9 REINFORCED CONCRETE STAY BLOCK FOR H.T. LINE mm 25 15 6 75 75 15 6 5x 2 le ho 40 1 00 60 Reinforcing Bars SIDE ELEVATION 255 75 75 255 PERSPECTIVE VIEW 40 1 00 60 Reinforcing Bars FRONT ELEVATION Reinforcing Bars 0 1 50 50 15 6 90 60 25mm SQ hole 50 380 480 60 1 255 1 50 255 60 90 15 6 50 50 0 1 1 0 50 90 90 60 60 60 90 90 50 1 0 50 56 0 50 660 SCALE : 1: 5 PLAN VIEW Not es Drg. No. 4 1 All dimensions are in mm. . REINFORCEMENT 2.Reinforcement rods should be welded at all point s of point s of crossing. Alt ernat ively a welded reinforcing fabric of NUMBER A No. 5 gauge x 3'' square would be accept ed. LENGHT ACROSS 3. Concret e t o be vibrat ed during manufact ure. 1 '' /4 8 6