2002 Jun 60' SS Cambria.pdf

Tower Inspection Report

INSPECTORS:

Mike Shade Pat Hunter

DEPARTMENT OF TRANSPORTATION

UNITED STATES COAST GUARD

Contract No. DTCG83-99-D-3WF050

Delivery Order No. DTCG83-02-F-623130 FY02 Tower Inspections and Maintenance

60' Self Supporting Tower Cambria, California

INSPECTION DATE: June 29, 2002

Barry R. Bayless, Registered Professional Engineer

UNITED STATES COAST GUARD

Delivery Order No. DTCG83-02-F-623130

60' Self Supporting Tower Cambria, California

C O N T E N T S

Page LIST OF PHOTOGRAPHS ....................................................................................i

EXECUTIVE SUMMARY

INSPECTION PHOTOS AND NOTES

RECOMMENDED MAINTENANCE

ESTIMATED MAINTENANCE COST

DESCRIPTIVE DRAWING AND PHOTO REFERENCE

LOCATION MAP

APPENDIX A:

CHRONOLOGICAL NARRATIVE .................................................................. I

60' Self Supporting Tower Cambria, California i

LIST OF PHOTOGRAPHS

√ A photo reference is checked if there is a related work item in the Recommended Maintenance section of the report.

No. Description Page

1 Overall 2, 3 √ Improperly installed coax grounding cables 4, 5 Overall views of the base area 6, 7 Mechanically cleaned and coated areas of corrosion 8, 9 √ Heavily corroded Leg B anchor nuts 10 Welded ground connection 11 √ Mechanical ground connection 12 √ Deficient safety climbing device 13 Typical leg splice connection 14 Typical safety rail clamp 15 Coax properly secured 16 Lower antenna 17 Weathered connection bolts 18 Antenna ground connection 19 Antenna mount 20 Upper antenna 21 Antenna mounting hardware 22 √ Safety climb rail not equipped with a stop bolt 23 View down from the top of the tower

60' Self Supporting Tower Cambria, California

EXECUTIVE SUMMARY

The 60' Self Supporting communications tower near Cambria, California was inspected on June 29, 2002 by Mike Shade and Pat Hunter. The weather was clear with light northwest winds and temperatures in the 70's. The tower supports communications antennas.

STRUCTURAL MEMBERS — Connection bolts throughout the tower were beginning to corrode (Photo No. 17). No action is necessary at this time.

ANTENNA SYSTEM — Communication cables were improperly grounded prior to their entry into the transmitter building (Photos No. 2 and 3). The cables should be installed in a manner that provides a constant path to ground within one year.

MISCELLANEOUS — Leg B anchor nuts (3 out of 4) were heavily corroded (Photos No. 8 and 9). This corrosion appeared to be the result of debris build-up around the tower base. The nuts should be replaced within one year. Legs A and C were grounded at the tower base using mechanical connectors (Photo No. 11). A better ground connection could be achieved using an exothermic weld. The mechanical connectors on Legs A and C should be replaced with exothermic welds within one year.

MAINTENANCE ACCOMPLISHED — Areas of corrosion were mechanically cleaned and coated with a cold galvanizing compound (Photos No. 6 and 7).

OSHA STANDARDS — The safety climb rail was not easily accessible in the first 20' of the tower (Photo No. 12). Installation of climbing members in the tower face in the first 20' of the tower or installation of a safety rail for the step bolts is recommended. The safety climb rail was not equipped with a stop bolt (Photo No. 22). A stop bolt should be installed.

60' Self Supporting Tower Cambria, California

Photo No. 1

60' Self Supporting Tower Cambria, California

Photo No. 2

Photo No. 3

Communication cables were improperly grounded prior to their entry into the transmitter building (Photos No. 2 and 3). The cables should be installed in a manner that provides a constant path to ground within one year.

60' Self Supporting Tower Cambria, California

Photo No. 4

Photo No. 5

Overall views of the tower base area are shown in Photos No. 4 and 5.

60' Self Supporting Tower Cambria, California

Photo No. 6

Photo No. 7

Areas of corrosion were mechanically cleaned and coated with a cold galvanizing compound (Photos No. 6 and 7).

60' Self Supporting Tower Cambria, California

Photo No. 8

Photo No. 9

Leg B anchor nuts (3 out of 4) were heavily corroded (Photos No. 8 and 9). This corrosion appeared to be the result of debris build-up around the tower base. The nuts should be replaced within one year.

60' Self Supporting Tower Cambria, California

Photo No. 10

Photo No. 11

A welded ground connection is shown in Photo No. 10. Legs A and C were grounded at the tower base using mechanical connectors (Photo No. 11). A better ground connection could be achieved using an exothermic weld. The mechanical connectors on Legs A and C should be replaced with exothermic welds within one year.

60' Self Supporting Tower Cambria, California

Photo No. 12

Photo No. 13

The safety climb rail was not easily accessible in the first 20' of the tower (Photo No. 12).

Installation of climbing members in the tower face in the first 20' of the tower or installation of a safety climb rail along the step bolts is recommended. A typical leg splice connection is shown in Photo No. 13.

60' Self Supporting Tower Cambria, California

Photo No. 14

Photo No. 15

A safety rail clamp is shown in Photo No. 14. The coaxial cable was properly secured to the tower (Photo No. 15).

60' Self Supporting Tower Cambria, California

Photo No. 16

Photo No. 17

The lower antenna was in satisfactory condition (Photo No. 16). Connection bolts throughout the tower were beginning to corrode (Photo No. 17). No action is necessary at this time.

60' Self Supporting Tower Cambria, California

Photo No. 18

Photo No. 19

The lower antenna ground connection is shown in Photo No. 18. The lower antenna mount is shown in Photo No. 19.

60' Self Supporting Tower Cambria, California

Photo No. 20

Photo No. 21

The upper antenna is shown in Photo No. 20. Antenna mounting hardware is shown in Photo No.

21.

60' Self Supporting Tower Cambria, California

Photo No. 22

Photo No. 23

The safety climb rail was not equipped with a stop bolt (Photo No. 22). A stop bolt should be installed. A view down from the top of the tower is shown in Photo No. 23.

60' Self Supporting Tower Cambria, California

RECOMMENDED MAINTENANCE

Deficiencies observed on this tower have no effect on the structural integrity and present no problems to the tower's function at the present time. It is, however, necessary to perform the recommendations outlined below in the suggested time frame to avoid more serious and costly repairs in the future.

OSHA STANDARDS: This tower does not fully comply with OSHA standards. The items required to upgrade the tower for compliance are outlined below. This requirement has no effect on the tower structure or its function. It is suggested that this upgrade is accomplished within two years for the purpose of cost estimating only, and it is not meant to imply that this work should be deferred.

Estimated maintenance costs for the following recommended maintenance is based on an estimated ironworker rate. Rates are computed including 20% overhead and 12% profit. Labor rates for work to be accomplished within one year have been escalated 5%; 10% for two years; 15% for three years. Equipment costs are included in these rates unless specified.

WITHIN ONE YEAR:

1) Install grounds in a constantly descending manner on the cables prior to their entry into the transmitter building (Photos No. 2 and 3).

2) Replace the heavily corroded (3) nuts on the Leg B base pad (Photos No. 8 and 9).

3) Replace mechanical ground connectors at the tower base (2) with exothermic welds (Photo No.

11).

WITHIN TWO YEARS:

OSHA STANDARDS:

1) Install climbing members in the tower face on the first 20' of the tower to provide access to the safety climb rail or install a safety climb rail along the leg where step bolts are mounted (Photo No. 12).

2) Install a stop bolt at the top of the tower (Photo No. 22).

COST ESTIMATING FORM DOT UNITED STATES COAST GUARD Sheet 1 of 2

WORKSHEET CONTRACT NUMBER:

DTCG83-99-D-3WF050

ACTIVITY: LOCATION: TOWER HEIGHT & DESIGNATION:

USCG Communication Tower Cambria, California 60' Self Supporting Tower

PROJECT:

FY02 Tower Inspections and Maintenance

QUANTITIES MATERIAL COST LABOR COST

ITEM (OR FEATURE) DESCRIPTION NO. OF UNIT UNIT

UNITS UNIT COST COST COST COST

1) Install coax grounds at entry into transmitter building. 8 MH $99.75 $798

Ground kits 2 EA 40 $80

Buss bar assy 1 EA $150.00 $150

Ground wire 15 FT $0.87 $13

Misc Materials 1 LS $50.00 $50

2) Replace base anchor bolt nuts 4 MH $98.43 $394

Nuts 3 EA $5.00 $15

3) Replace mechanical ground connections using exothermic welds 4 MH $98.43 $394

Exothermic weld materials 1 LS $169.00 $169

Project Management $1,000

Mobilization $8,000

Equipment $2,000

APPROVED BY: TITLE: DATE:

LABOR COST $1,586

W. Michael Byers Vice President 15-Jan-03

MATERIAL COST $477

TOTAL COST (EST.) $13,063

To Be Completed Within One Year

COST ESTIMATING FORM DOT UNITED STATES COAST GUARD Sheet 2 of 2

WORKSHEET CONTRACT NUMBER:

DTCG83-99-D-3WF050

ACTIVITY: LOCATION: TOWER HEIGHT & DESIGNATION:

USCG Communication Tower Cambria, California 60' Self Supporting Tower

PROJECT:

FY02 Tower Inspections and Maintenance

QUANTITIES MATERIAL COST LABOR COST

ITEM (OR FEATURE) DESCRIPTION NO. OF UNIT UNIT

UNITS UNIT COST COST COST COST

OSHA

1) Install climbing members 18 MH $103.35 $1,860

Material design & fabrication 1 LS $1,000.00 $1,000

2) Install safety climb stop bolt 4 MH $103.35 $413

Bolt 1 EA $5.00 $5

Project Management $1,000

Mobilization $8,000

Equipment $2,000

APPROVED BY: TITLE: DATE:

LABOR COST $2,273

W. Michael Byers Vice President 15-Jan-03

MATERIAL COST $1,005

TOTAL COST (EST.) $14,278

To Be Completed Within Two Year

Drawn By: SJH Order No.: DTCG83-02-F-623130 Sheet No.

DOT, UNITED STATES COAST GUARD

CIVIL ENGINEERING UNIT-OAKLAND

OAKLAND, CALIFORNIA

Date: 7/31/02

DESCRIPTIVE DRAWING

60' SELF SUPPORTING TOWER

CAMBRIA, CALIFORNIA

P.O. BOX 709 MUSKOGEE, OKLAHOMA 74401

TELEPHONE (918) 683-8915 FACSIMILE (918) 683-0888

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