295' DGPS Klamath Falls OR.pdf

UNITED STATES COAST GUARD

Delivery Order No. HSCG88-08-J-623223

Site No. 226 Klamath Falls 295' Guyed DGPS Antenna

Klamath Falls, OR

C O N T E N T S

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

EXECUTIVE SUMMARY

INSPECTION PHOTOS AND NOTES

RECOMMENDED MAINTENANCE

ESTIMATED MAINTENANCE COST

VERTICALITY TABULATION AND PLOTS

GUY TENSION TABULATIONS

TOWER TWIST PLOTS

APPENDIX A:

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

Site No. 226 Klamath Falls 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 Overall of base insulator 3 Overall of tower base area 4, 5 Minor cracks on surface of isolation transformer rings, no action 6 View up tower along climbing face 7 Antenna feed in satisfactory condition 8 √ Leg splice bolt marked for replacement, between Section 1 and 2 9 Typical diagonal connection to leg in satisfactory condition 10, 11 Typical guy connection and strain insulators in satisfactory condition 12 View looking up the tower 13 Typical member connection in satisfactory condition 14 √ Leg splice bolt marked for replacement, between Section 3 and 4 15 √ Leg splice bolt marked for replacement, between Section 4 and 5 16 √ Leg splice bolt marked for replacement, between Section 6 and 7 17 √ Deflected diagonal, Panel 10-1, Face A 18 Typical fourth level guy connection in satisfactory condition 19 √ Reinforcing member is not attached to the tower legs 20 View up the tower from the top section 21 Typical TLE connection in good condition, free of corrosion 22 Overall of strobe fixture at the top of the tower 23 Close up of the strobe tag 24 View down the tower from the top 25 Overall of site entrance, equipment shelter, reference masts 26 √ C2 anchor rod has slipped and was held in place by its ground wire 27 √ Overall of C2 anchor, anchor rod has failed below grade 28 √ Close up of C2 ground wire connection 29 √ Corroded areas of C2 anchor rod, above grade 30, 31 √ Different views of the temporary rigging installed at the C2 anchor 32, 33 √ C3 anchor, corrosion on rod below grade, water encountered 34 Typical TLE anchor connection, satisfactory condition

Site No. 226 Klamath Falls ii

No. Description Page

35 √ Light corrosion on C10 anchor rod, water encountered 36 √ C8 anchor rod, light corrosion at 2' below grade 37 √ C9 anchor rod, light corrosion at 2.5' below grade 38 √ A1 anchor rod, light corrosion, 2.5' below grade, water encountered 39 Overall view of A1 anchor 40 √ Light rust on B3 anchor rod 41 Overall of B1 anchor 42 Overall of Reference Mast #1 43 Overall of Reference Mast #2 44, 45 Cleaned and painted corroded areas on reference mast 46 √ Coax ground leads bonded upside down to reference mast legs 47 √ No caps at top of reference masts 48, 49 Typical break up insulators in satisfactory condition 50, 51 Typical strain insulators in satisfactory condition

Site No. 226 Klamath Falls

EXECUTIVE SUMMARY

The 295' guyed DGPS antenna near Klamath Falls, OR was inspected on 18 and 20 April 2009 by Philip Nickels and Jody O'Neal. The weather for both days was sunny with temperatures in the 60s°F and 0-3 mph winds.

NOTE: The TLE C2 anchor rod was broken below grade. The rod had failed below grade and slipped some 6" above ground. The anchor was being held in place by its ground wire.

According to the Raytheon technicians, this condition has existed for over one year. A new anchor should be installed immediately. See Guy System Section for additional details.

The DGPS antenna consists of a 295' Stainless G-25 guyed tower and two 10' self-supporting reference masts. The two 10' reference masts are similar to a Rohn 45G. The Stainless tower is guyed in three directions at five levels and in twelve directions at the top. The lacing consists of solid members welded to the tower legs. This tower is an energized tower and sits on top of a base insulator. Downtime is required to climb this tower.

The GPS coordinates for this site are:

42° - 17.306' N

121° - 40.237' W

STRUCTURAL MEMBERS — The Face A diagonal in Panel 10-1 was deflected 1/8" and should be reinforced within one year (Photo No. 17). The reinforcing member installed in Panel

11-1 should be replaced within one year using a member that attaches to the tower legs rather than to the member in distress (Photo No. 19).

The inspectors checked all the leg splice bolts for tightness. There were four loose leg splice bolts which should be replaced with 1" diameter x 2.5" long A325 bolts. The bolts were painted red for future identification. Since this is a one bolt connection, the splice plates will need to be temporarily clamped while the bolt is replaced. Their locations are located in the following table:

Site No. 226 Klamath Falls

Table 1: Leg Splice Bolt Replacement Schedule Location Leg Photo No.

Between Section 1 and 2 B 8

Between Section 3 and 4 B 14

Between Section 4 and 5 B 15

Between Section 6 and 7 A 16

All tower members were hot dipped galvanized and all members were free of corrosion. The inspectors took coating thickness readings in each of the sections. The average thickness for all sections varied between 7.6 and 13.1 mils with an overall average of 9.9 mils.

OBSTRUCTION MARKING AND LIGHTING — The 295' tower was equipped with one white flashing strobe at the top of the tower. The light fixture was a Flash Technology Electro

Flash FH 308 manufactured in 11-2000. The power to the light is fed through an isolation transformer at the base of the tower. There were minor cracks on the surface of the isolation transformer rings (Photos No. 4 and 5). No action is required.

GUY SUBSYSTEM — The 295' tower is guyed in 12 directions at the top of the tower. The anchor for the C2 TLE wire had failed below grade. The anchor had slipped out of the ground some 6" and was caught by its copper ground wire which is under considerable tension for its size (Photos No. 26-29). Raytheon technicians indicated this anchor had been broken for over a year and had used rope to tie the TLE back to fence posts. As a precautionary measure, we installed a 4x5 wooden timber across the back fence posts of the TLE enclosure (Photos No. 30 and 31). Using 5/16" galvanized steel cable, we connected the TLE to the wooden brace. This is a temporary correction.

We measured all the tensions on the TLE wires except the C2 wire. The required tension for these wires was 800 lbs. Based on the amount of anchor rod slippage, we estimated the C2 tension was near 300 to 400 lbs. The broken C2 anchor had no affect on the tower's alignment.

On initial inspection, the alignment was less than ½" out at the top of the tower. The adjacent

TLE wires to the C2 wire were over tensioned and rested near 1000 lbs and the opposing C2

Site No. 226 Klamath Falls wire, C8, was 780 lbs. The remaining wires were near 800 lbs. See the TLE Tension Tabulations for a complete listing of each wire tension. We did not adjust any of the TLE tensions because of the condition of the C2 anchor. Even though one TLE wire is not a structural concern, its sudden failure could produce a damaging shock to the system and could send the upper portion of the

TLE wire crashing into the tower. This may result in damage to the TLE's corona ring and insulators. It could also damage the tower. A new anchor should be installed immediately to prevent such an occurrence. To prevent corrosion of the new anchor rod, the entire rod should be encased in concrete below grade.

The SOW required that we inspect all anchor rods 12" below grade. We did not excavate the C2 anchor because of its fragile condition. Given that one anchor rod was broken, we excavated at least 2' below grade for the other anchors. At the C3 anchor we excavated down until we encountered water at 3' below grade (Photos No. 32) Each anchor rod had the same condition of light corrosion bleeding through a black coating (we assume was bituminous tar) (Photo No. 33, 35-38, 40).

It is important to note that at the DGPS antenna in Essex, CA, all the anchor rods were replaced due to severe corrosion occurring more than 5' below grade. It is likely that all the anchor rods here at Klamath Falls may eventually corrode and fail like the C2 anchor. When the C2 anchor is replaced, we recommend all the anchors be excavated down to their concrete to determine their condition. Note that a sump pump will be required to remove water during the excavation.

Aside from the anchor rods, all other guy connection components were in satisfactory condition.

GUY TENSIONS AND VERTICALITY — Upon initial inspection the structural guy tensions ranged from -14% to +31% from the design tensions. Upon final inspection the structural guy tensions were ±5% from the required tensions and the largest deviation from true vertical was

1.13" at the 5th guy level. See the Guy Tension and Verticality Tabulations for a full listing of values. See notes above regarding the TLE tensions.

ANTENNA SYSTEM — The inspectors examined all TLE break up insulators with a high power scope. All insulators were in satisfactory condition.

Site No. 226 Klamath Falls

REFERENCE MASTS — Neither of the masts were equipped with top caps (Photo No. 47).

To prevent precipitation from entering the legs, the legs should be capped immediately. The leg size was 1.5" diameter.

The coax ground kits for the mast antennas were exothermically bonded upside down to the tower legs (Photo No. 46). Coax ground leads are normally attached to tower structures with mechanical connectors. We recommend installing mechanical connectors to the coax ground kits and connecting them to the structure in a smooth path to ground within one year.

MAINTENANCE ACCOMPLISHED — Installed temporary rigging as a safety precaution to secure the C2 radial wire. The inspectors mechanically cleaned isolated corrosion on the reference masts (Photos No. 44 and 45).

OSHA STANDARDS — This tower was not equipped with a ladder but it did have horizontal lacing members and a safety cable climb system. The safety climb system was in satisfactory condition.

Site No. 226 Klamath Falls

Photo No. 1

Site No. 226 Klamath Falls

Photo No. 2

Photo No. 3

Photo No. 2 shows the base insulator in satisfactory condition. Photo No. 3 is an overall view of the tower base area.

Site No. 226 Klamath Falls

Photo No. 4 Photo No. 5

There were minor cracks on the surface of the isolation transformer rings (Photos No. 4 and 5).

No action is required.

Site No. 226 Klamath Falls

Photo No. 6

Photo No. 7

Photo No. 6 is a view looking up the climbing face (Face A). Photo No. 7 shows the antenna feed in satisfactory condition.

Site No. 226 Klamath Falls

Photo No. 8

Photo No. 9

The leg splice bolt between Sections 1 and 2 on Leg B was found loose and painted red by the inspectors (Photo No. 8). The bolt should be replaced in one year. Photo No. 9 shows a typical diagonal connection in satisfactory condition.

Site No. 226 Klamath Falls

Photo No. 10

Photo No. 11

Photos No. 10 and 11 show a typical guy connection and strain insulators in satisfactory condition.

Site No. 226 Klamath Falls

Photo No. 12

Photo No. 13

Photo No. 12 is a view looking up the tower from the base. Photo No. 13 shows a typical horizontal and diagonal leg connection in satisfactory condition.

Site No. 226 Klamath Falls

Photo No. 14

Photo No. 15

The Leg B splice bolts at Sections 3/4 and 4/5 were found loose and painted red by the inspectors (Photos No. 14 and 15). The bolts should be replaced in one year.

Site No. 226 Klamath Falls

Photo No. 16

Photo No. 17

The leg splice bolt between Sections 6 and 7 on Leg A was found loose and painted red by the inspectors (Photo No. 16). The bolt should be replaced in one year. The Face A diagonal in Panel 10-1 was deflected 1/8" and should be reinforced within one year (Photo No. 17).

Site No. 226 Klamath Falls

Photo No. 18

Photo No. 19

Photo No. 18 shows a typical fourth level guy connection in satisfactory condition. The reinforcing member installed in Panel 11-1 should be replaced within one year using a member that attaches to the tower legs rather than to the member in distress (Photo No. 19).

Site No. 226 Klamath Falls

Photo No. 20

Photo No. 21

Photo No. 20 is a view up the tower in the top section. Photo No. 21 shows a typical TLE connection in good condition free of corrosion.

Site No. 226 Klamath Falls

Photo No. 22

Photo No. 23

Photo No. 22 is an overall view of the top strobe fixture. Photo No. 23 is a close up of the strobe tag.

Site No. 226 Klamath Falls

Photo No. 24

Photo No. 25

Photo No. 24 is a view down the tower from the top. Photo No. 25 is a view showing the site entrance, equipment shelters, and reference masts.

Site No. 226 Klamath Falls

Photo No. 26

Photo No. 27

Photos No. 26 and 27 are different views of the C2 anchor. The anchor had slipped out of the ground some 6" and was caught by its copper ground wire. See Executive Summary.

Site No. 226 Klamath Falls

Photo No. 28 Photo No. 29

There was considerable stress on the C2 anchor rod ground wire (Photo No. 28). Photo No. 29 shows the C2 rod with corrosion on portions of the rod that were once below grade.

Site No. 226 Klamath Falls

Photo No. 30

Photo No. 31

Photos No. 30 and 31 are different views of the temporary rigging installed at the C2 anchor rod as a safety precaution in the event the ground wire fails. See Executive Summary.

Site No. 226 Klamath Falls

Photo No. 32

Photo No. 33

The inspectors excavated the C3 anchor along its rod until they encountered water at 3' below grade (Photo No. 32). The anchor rod had corrosion bleeding through its tar coating (Photo No.

33). See Executive Summary.

Site No. 226 Klamath Falls

Photo No. 34

Photo No. 35

Photo No. 34 shows a typical TLE anchor connection in satisfactory condition. Photo No. 35 shows a close up view of light corrosion on the C10 anchor rod. Water was encountered at this anchor rod at 2'-4" below grade. See Executive Summary.

Site No. 226 Klamath Falls

Photo No. 36 Photo No. 37

Photos No. 36 and 37 show the condition of the C8 and C9 anchor, respectively. Light corrosion was on both of these rods at depths of 2' and 2.5' below grade. See Executive Summary.

Site No. 226 Klamath Falls

Photo No. 38

Photo No. 39

Photo No. 38 is a close up view of the A1 anchor rod at 2.5' below grade. Note that water was encountered at this depth. The rod was lightly corroded (Photo No. 38). See Executive Summary.

Photo No. 39 is an overall view of the A1 anchor.

Site No. 226 Klamath Falls

Photo No. 40

Photo No. 41

Photo No. 40 shows typical light rust on the B3 anchor rod. See Executive Summary. Photo No.

41 is an overall view of a typical B anchor.

Site No. 226 Klamath Falls

Photo No. 42 – Reference Mast #1

Site No. 226 Klamath Falls

Photo No. 43 – Reference Mast #2

Site No. 226 Klamath Falls

Photo No. 44

Photo No. 45

The inspectors cleaned isolated areas of corroded areas on the reference masts and coated the prepped areas with a cold galvanizing compound (Photo No. 44 and 45).

Site No. 226 Klamath Falls

Photo No. 46 Photo No. 47

The coax ground kits for the reference mast antennas were exothermically bonded upside down to the tower legs. (Photo No. 46). Coax ground leads are normally attached to tower structures with mechanical connectors. We recommend installing mechanical connectors to the coax ground kits and connecting them to the structure in a smooth path to ground within one year.

Neither of the reference masts were equipped with top caps (Photo No. 47). To prevent precipitation from entering the legs, the legs should be capped within one year. The leg size was 1.5" diameter.

Site No. 226 Klamath Falls

Photo No. 48

Photo No. 49

Photos No. 48 and 49 show typical break up insulators in satisfactory condition.

Site No. 226 Klamath Falls

Photo No. 50

Photo No. 51

Photos No. 50 and 51 show typical strain insulators in satisfactory condition.

Site No. 226 Klamath Falls

RECOMMENDED MAINTENANCE

Deficiencies observed on this tower could have an effect on the structural integrity. It is necessary to perform the recommendations outlined below in the suggested time frame to avoid more serious and costly repairs in the future.

IMMEDIATELY:

1) Replace the C2 anchor (Photos No. 26-31). To prevent corrosion of the new anchor rod, the entire rod should be encased in concrete below grade. Excavate the other 17 anchors down to the their concrete to ascertain their condition (Photos No. 32, 33, 35-38, 40).

WITHIN ONE YEAR:

1) Replace 4 leg splice bolts as identified in Table No. 1. Each bolt is 1" x 2.5" A325 hot dipped galvanized. Note this is a single bolt connection and the connection will need to be temporarily clamped during the bolt replacement.

2) Reinforce the deflected diagonal on Face A, Panel 10-1 (Photo No. 17). Replace the reinforcing member in Panel 11-1 using a member that attaches to the tower legs rather than to the member in distress (Photo No. 19).

3) Install caps at the top of the legs for both of the reference masts (Photo No. 47).

4) Mechanically connect the coax ground leads on the reference masts to the mast legs in a smooth path to ground (Photo No. 46).

COST ESTIMATING Sheet 1 of 1

WORKSHEET CONTRACT NUMBER:

HSCG88-08-D-623111

ACTIVITY: LOCATION: TOWER HEIGHT & DESIGNATION:

ESD Astoria Site No. 226 Klamath Falls 295' Guyed DGPS Antenna

PROJECT:

ITEM (OR FEATURE) DESCRIPTION NO. OF UNIT UNIT

UNITS UNIT COST COST COST COST

1) Replace the C2 Anchor, excavate and acertain the condition of the other 11 54 MH $95.00 $5,130

Concrete 1 CYD $115.00 $115

Rebar 1 LOT $50.00 $50

Guy rod 1 EA $250.00 $250

Project Management $1,500

Mobilization $5,000

Equipment $4,000

APPROVED BY: TITLE: DATE:

LABOR COST $5,130

Neal Bayless 10-Jun-09

MATERIAL COST $415

TOTAL COST (EST.) $16,045

Vice President

To Be Completed Immediately

D13 Tower inspection and Minor Maintenance

DEPARTMENT OF HOMELAND SECURITY

LABOR COSTQUANTITIES MATERIAL COST

COST ESTIMATING Sheet 2 of 2

WORKSHEET CONTRACT NUMBER:

HSCG88-08-D-623111

ACTIVITY: LOCATION: TOWER HEIGHT & DESIGNATION:

ESD Astoria Site No. 226 Klamath Falls 295' Guyed DGPS Antenna

PROJECT:

ITEM (OR FEATURE) DESCRIPTION NO. OF UNIT UNIT

UNITS UNIT COST COST COST COST

1) Replace four leg splice bolts 6 MH $99.75 $599

1" x 2 1/2" galvanized (A325) bolt, nut, lw 4 EA $3.00 $12

2) Reinforce deflected diagonal on Face A, panel 10-1 & panel 11-1 8 MH $99.75 $798

L 2 x 2 x 3/16" 2 EA $50.00 $100

1/2" u-bolts 3 EA $5.00 $15

3) Install leg caps on top of both reference masts 4 MH $99.75 $399

Leg caps 6 EA $5.00 $30

4) Mechanically reconnect coax ground leads 4 MH $99.75 $399

Mechanical ground clamp 2 EA $20.00 $40

Project Management $500

Mobilization $5,000

Equipment $1,500

APPROVED BY: TITLE: DATE:

LABOR COST $2,195

Neal Bayless 10-Jun-09

MATERIAL COST $197

TOTAL COST (EST.) $9,392

Vice President

DEPARTMENT OF HOMELAND SECURITY

To Be Completed Within One Year

D13 Tower inspection and Minor Maintenance

QUANTITIES MATERIAL COST LABOR COST

Drawn By: PEN Sheet No. 35D ate: 04-20-09 Delivery Order No: HSCG88-08-J-623223

DHS, UNITED STATES COAST GUARD

CIVIL ENGINEERING UNIT - OAKLAND

OAKLAND, CA

VERTICALITY TABULATIONS

295ʼ DGPS GUYED TOWER

KLAMATH FALLS, WAPO Box 709 Muskogee, Oklahoma 74401 Telephone: (918) 683-8915 Fax: (918) 683-0888

DATE:

TIME:

TEMP:

WIND:

WEATHER:

INSPECTORS:

FINAL READINGS

Elevation Description1 2

DATE:

TIME:

TEMP:

WIND:

WEATHER:

INSPECTORS:

18 April 2009 10:00 am 60°F 0-3 mph Sunny P. Nickels, J. O’Neal

INITIAL READINGS

Elevation Description

Transit Position Deviation (in.)

North

= Transit Position

1 2

Transit Position Deviation (in.)

18 April 2009 1:00 Pm 65°F 0-3 mph Sunny P. Nickels, J. O’Neal

PLOT PLANGUY LEVELS

Drawn By: PEN Sheet No. 36Date: 04-20-09 Delivery Order No: HSCG88-08-J-623223

DHS, UNITED STATES COAST GUARD

CIVIL ENGINEERING UNIT - OAKLAND

OAKLAND, CA

STRUCTURAL GUY TENSION TABULATIONS

295' DGPS GUYED TOWER

KLAMATH FALLS, OR

PO Box 709 Muskogee, Oklahoma 74401 Telephone: (918) 683-8915 Fax: (918) 683-0888

DATE:

TIME:

TEMP:

WIND:

WEATHER:

INSPECTORS:

FINAL READINGS

DATE:

TIME:

TEMP:

WIND:

WEATHER:

INSPECTORS:

INITIAL READINGS

18 April 2009 8:00 am 55°F 0-3 mph Sunny P. Nickels, J. O’Neal

20 April 2009 12:30 pm 65°F 0-3 mph

PLOT PLANGUY LEVELS

Drawn By: PEN Sheet No. 37Date: 04-20-09 Delivery Order No: HSCG88-08-J-623223

DHS, UNITED STATES COAST GUARD

CIVIL ENGINEERING UNIT - OAKLAND

OAKLAND, CA

TLE TENSION TABULATIONS

295' DGPS GUYED TOWER

KLAMATH FALLS, OR

PO Box 709 Muskogee, Oklahoma 74401 Telephone: (918) 683-8915 Fax: (918) 683-0888

DATE:

TIME:

TEMP:

WIND:

WEATHER:

INSPECTORS:

FINAL READINGS

DATE:

TIME:

TEMP:

WIND:

WEATHER:

INSPECTORS:

INITIAL READINGS

18 April 2009 8:00 am 55°F 0-3 mph Sunny P. Nickels, J. O’Neal

20 April 2009 12:30 pm 65°F 0-3 mph

PO Box 709 Muskogee, Oklahoma 74401 Telephone: (918) 683-8915 Fax: (918) 683-0888

Level: Twist:

positive values = clockwise twist negative values = counter clockwise twist

Level: Twist:

Level: Twist:

Drawn By: PEN Sheet No. 38

DHS, UNITED STATES COAST GUARD

CIVIL ENGINEERING UNIT - OAKLAND

OAKLAND, CA

TWIST PLOTS

295ʼ DGPS GUYED TOWER

KLAMATH FALLS, WA

= Tower position at specified level

= Tower position at base x y

Twist = = arctan(x/y)

Elevation Description

Elevation (ft.) x (ft.) y (ft.) (°)

Twist Elevation Description

Elevation (ft.) x (ft.) y (ft.) (°)

Twist

Date: 04-20-09 Delivery Order No: HSCG88-08-J-623223

Level: Twist:

Level: Twist:

Level: Twist:

DATE:

TIME:

TEMP:

WIND:

WEATHER:

INSPECTORS:

02 APRIL 2009

10:00 am 45°F W 10 mph Overcast

Site No. 226 Klamath Falls

I

Appendix A: Chronological Narrative

Date: 18 April 2009 Weather Conditions: Sunny, 58-68°F, 0-3 mph winds

Time Work Performed 7:15 am – 1:00 pm Measured and adjusted tensions. Measured verticality. Did not adjust TLE tensions because of the broken C2 anchor 1:30 pm – 4:30 pm Bought supplies at Home Depot and installed temporary rigging as a safety to prevent the C2 anchor from being released from the ground. Note: The anchor ground wire is holding the anchor rod in the ground.

Date: 20 April 2009 Weather Conditions: Sunny, 60-70°F, calm winds

Time Work Performed 7:30 am – 9:00 am Performed TLE anchor excavations.

9:00 am – 12:00 pm Performed climbing inspection.

12:00 pm – 2:00 pm Continued with anchor excavations.