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Anchor Design & Maintenance Manual - ECP Utility Products PDF

96 Pages·2014·17.21 MB·English
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“Designed and Engineered to Perform” 11..112255 22..443388 11..662255 00..884444 11 11//22 RR..CC.. SSQQ.. BBAARR 22..443388 11..662255 RR00..006622 TTYYPP.. 00..118888 TTYYPP.. 00..440066 TTYYPP.. 3300..00°° TTYYPP.. 11..550000 TTAAHH--115500--1122 33..000000 33..000000 33//88 5500KK 8844..000000 00..887755 3300..000000 TTAAHH--115500--1100 33//88 5500KK 33..000000 112200..000000 4455°° 22..550000 TYP TYP 1.094 3/8 1-1/2 (cid:1)(cid:1)00..887755 TTYYPP.. 1.094 11..112255 2.188 11..550000 RRCCSS RR33..000000 RR77..000000 RR00..331133 Utility Industry Anchor Design 1 11//44 11//44and Maintenance Manual LEGT OYNP; H1U/4B 1/8 x 1/4 11//44 11..337755 11..008811 ─ Second Edition ─ 2 11..443388 1/4 TYP 1/4 0.250 11..000000 00..662255 33..668888 www.getecp.com 1-866-327-0007 ©2013 Earth Contact Products Utility Industry Anchor Design and Maintenance Manual By: Donald J. Clayton, PE “Designed and Engineered to Perform” © 2013 Earth Contact Products, LLC. All Rights Reserved. This material may not be reproduced in any form without the written permission of Earth Contact Products, LLC. Any unauthorized uses of the material and inventions disclosed herein or reproductions or copies of the pages of this document are hereby prohibited. Such uses would be deemed infringement of Earth Contact Products’ intellectual property rights and will be prosecuted to the full extent of the law. ECPUTILITY Is a division of Earth Contact Products, LLC Company Office and Manufacturing Facility 15612 South Keeler Terrace, Olathe, Kansas 66062 913 393-0007- FAX 913 393-0008 Toll Free– 866 327-0007 www.earthcontactproducts.com Earth Contact Products, LLC reserves the right to change design features, specifications and products without notice, consistent with our efforts toward continuous product improvement. We also make changes and corrections to the technical design text consistent with the state of the art. Please check with Engineering Department, Earth Contact Products to verify that you are using the most recent design information and product specifications. First Printing–07/2011 Second Printing–12/2013 (revised edition) Preface Earth Contract Products designs and manufactures quality foundation anchors and support products at competitive prices. The purpose of this manual is to assist the reader to prepare preliminary designs for ECP product selections that will most economically fit a given application. The manual also provides installation guidance and product selection. In this manual we have attempted to take the highly technical engineering theories and distill them into a veryuser friendly format. We have reduced many complicated equations into simpler terms that relate to the most typical applications where our products have been used. In addition, we have included many graphs and tables that can help the reader to obtain solutions with a minimum of mathematical effort. The reader will find clear and simple explanations, data tables, and many relevant examples in this manual. By taking some knowledge of basic theory to arrive at a relatively accurate product design by following step by step instructions, tables and graphs when using this manual. This manual is in no way intended to replace professional engineering input and judgment; in addition, we require incorporating a factor of safety suitable to the project for each and every preliminary design. We highly recommend that you seek professional engineering input on complicated applications. We also consider it good practice to perform a field load test on any heavily loaded anchorsorfor placements incritical applications. Utility Industry Anchor Design and MaintenanceManual © 2013 Earth Contact Products, L.L.C 2013-11 Pagei All rights reserved Table of Contents Chapter 1 – Introduction to ECP Helical Torque Anchors™ for Electric Utility Applications 1 Introduction 3 ECP Torque Anchors™ 3 Torque Anchor™ Components 4 Product Benefits 4 Product Limitations 5 Soil Types 5 Table 1–Torque Anchor™ Product Designations 5 Table2–Capacities of ECP Torque Anchors™ 5 Product Data 6 Power Installed Torque Anchors™ (PITA) 6 Extreme Power Installed Torque Anchors™ (PITA) 6 HD Extreme Power Installed Torque Anchors™ (PITA) 6 Cable Attachment Eyes 7 Pita Accessories 7 Round Corner Square Bar ECP Torque Anchors™ 8 Product Limitations 9 Soil Types 9 Table 3–Soil Classification Table 9 Effects of Water Table Fluctuation and Freeze Thaw Cycle 10 Anchor Holding Capacity 10 Chapter 2 – Tension Design for ECP Helical Torque Anchors™ 13 Table4–Symbols Used in this Manual 14 Design Criteria 14 Preliminary Design Guidelines 15 Deep Foundations 15 Equation1(Ultimate Theoretical Capacity) 16 Soil Behavior 16 Cohesive Soil (Clay) 16 Table 5- Cohesive Soil Classification 16 Undrained Shear Strength 17 Cohesive Bearing Capacity Factor– “N” 17 c Equation 1a(Ultimate Capacity– Cohesive Soil) 17 Cohesionless Soil (Sand and Gravel) 17 Soil Overburden Pressure– “q” 17 Table 6-Properties of Cohesive Soil 17 Table7-CohesionlessSoil Classification 17 Cohesionless Bearing Capacity Factor– “N ” 18 q Table8-Properties of Cohesionless Soil 18 Utility Industry Anchor Design and Maintenance Manual © 2013 Earth Contact Products, L.L.C 2013-11 Pageii All rights reserved Equation1b(Ultimate Capacity– Cohesionless Soil) 18 Helical Torque Anchor™Design Considerations 18 Projected Areas of Helical Plates 18 Allowable Helical Plate Capacity 18 Table9-Projected Areas of Helical Torque Anchor™ Plates 18 Table 10-Average Ultimate Mechanical Helical Plate Capacities 19 Installation Torque 19 Figure 1– Torque Efficiency 19 Torque Efficiency Factor– “k” 19 Table 11- TorqueEfficiencyFactor– “k” 19 Equation 2(Helical Installation Torque) 20 Equation 2a(Torque Efficiency Factor) 20 Minimum Embedment Depth 20 Figure 2. Minimum Embedment depth to insure sufficient soil overburden for resistance to pull out. 20 Preventing “Pull Out” in Tension Applications 21 Torque Anchor™ Installation Limits 21 Shaft Strength 21 Graph 1–Ultimate Capacities for Structural Applications 22 Guy Anchoring Design 23 Introduction to Guy Anchoring 23 Guy Loads 23 Angle Line Loads 23 Equation3(Dead End Load on Pole) 23 Torque anchor™ Holding Capacity Estimates 23 Graph 2–Guy Anchor Holding Capacity 25 Graph 3–Ultimate Guy Anchor Capacities 26 Design Example 1– Guy Load 27 Design Example 2– Guy Anchor in Cohesive (Clay) Soil 28 Design Example 3– Guy Anchor in Cohesionless (Granular) Soil 31 Table 12-Ultimate Strength of Conductors 33 Table 13- Bisected Line Load to Be Guyed 34 Table 14-Guy Load 35 Table 15-Breaking Strength of Stranded Guy Wire 36 Chapter 3 – Compressive Design for ECP Helical Torque Anchors™ 37 Compressive Helical Torque Anchor™ Design Considerations 38 Table16- ECP Torque Anchor™ Product Designations 38 Table 17– Capacities of ECP Torque Anchor™ 38 Product Data 39 Round Corner Square Bar ECP Torque Anchor™ Lead Sections 39 Tubular Shaft ECP Torque Anchors™ 40 Light Pole Anchor Configurations 41 Utility Industry Anchor Design and Maintenance Manual © 2013 Earth Contact Products, L.L.C 2013-11 Pageiii All rights reserved Foundation Grillages 42 Tubular Pile Caps 42 Preventing “Punch Through” in Compression 42 Minimum Embedment Depth 42 Torque Anchor™ Compressive Installation Limits 43 Shaft Strength 43 Buckling Loads in Weak Soil 43 Table 18–Torque Anchor™ Shaft Stiffness Comparison 44 Table 19–Conservative Critical Buckling Load Estimates 44 Equation4(Critical Buckling Load) 44 Shaft Stiffness 44 Graph4– Ultimate loads–Piles in air orwater with no lateral support to the grout filledshaft 45 Torque Anchor™ Compressive Capacity Estimates 45 Graph 5– Torque Anchor™ Holding Capacity (8”, 10”, 12” & 14” dia.) 47 Graph 6– Torque Anchor™ Holding Capacity (8-8”, 8-10”, 10-10” & 10-12” dia.) 47 Graph 7– Torque Anchor™ Holding Capacity (12-14”, 8-10-12”, 10-12-14” & 12-14-14” dia.) 48 Graph 8– Torque Anchor™ Holding Capacity (8-10-12-14”, 10-12-14-14”, & 12-14-14-14” dia.) 48 Design Example 4–Transmission Tower in Cohesive (Clay) Soil 49 Design Example 5– Transmission Tower in Cohesionless (Granular) Soil 52 Design Example 6– Transmission Tower in Wetland Soil 54 Chapter 4 – Installation Guidelines and Testing Procedures for ECP Helical Torque Anchors™ 57 Hydraulic Torque Motors 58 Installation Torque 58 TorqueEfficiency Factor – “k” 58 Equation 5(Helical Installation Torque) 59 Equation 5a(Torque Efficiency Factor) 59 Table 15– Installation Torque Factor– “k” 59 Determining Installation Torque 59 Twisting of the Solid Square Bar 59 Shear Pin Hub 59 Single Pressure Gauge 59 Dual Pressure Gauges 60 Strain Gauge Monitor 60 Converting Motor Pressure to Shaft Torque 60 Equation 7 (Installation Motor Output Torque) 60 Table 20–Hydraulic Torque Motor Specifications 61 Graph9–Motor Output Torque vs Ultimate Capacity 61 Torque Motor Accessories 62 ECP Smart Anchor Monitor (SAM) and Assembly Configuration 62 Utility Industry Anchor Design and Maintenance Manual © 2013 Earth Contact Products, L.L.C 2013-11 Pageiv All rights reserved ECP Hydraulic Torque Motor Performance Curves 63 Graph10–Pro-Dig PDU78 Two Speed Gear Motor Differential Pressure at Motor vs. Motor Output Torque 63 Graph11– Pro-Dig PDU78 Two Speed Gear Motor Hydraulic Flowthrough Motor vs.Output Shaft Speed 63 Graph12– Pro-Dig PDU76 & PDU 76B Single Speed Gear Motors Differential Pressure at Motor vs. Motor Output Torque 64 Graph13– Pro-Dig PDU76 & PDU 76B Single Speed Gear Motors Hydraulic Flowthrough Motorvs. Output Shaft Speed 64 Design Example7–Motor Output Torque 65 Design Example8–Estimated Ultimate Capacity 65 ECP Helical Guy Anchor Installation Procedure 67 ECP PITA Anchor & Extreme PITA Anchor Installation Procedure 69 Structural CompressivePileand/or Tensile Helical Anchor InstallationProcedure 71 Torque Anchor™ Installation Record (Sample Form) 73 Field Test Procedures for Static Axial Compression and Tensile Loads 74 Basic Procedure for Quick Tension or Compression Tests 75 Field Load Test Report (Sample Form) 76 Chapter5 – Corrosion Considerations 77 Corrosion Life Expectancies 78 Steel Underground– How Long Will It Last? 78 Soil Resistivity 78 Table 21–Soil Classification Table- Resistivity 78 Table 22–Soil Resistivity and Relative Corrosivity Rating 78 Soil pH 78 Graph13–The Effect of pH on Corrosion of Iron 79 Zinc Galvanizing for Corrosion Protection 79 Zinc Galvanizingfor Corrosion Protection 79 Graph 14– The Effect of pH on Corrosion of Zinc life of Galvanized Coating 79 Life of Galvanized Coating 79 Graph 15– Corrosion Life of Galvanized Steel in Neutral Soil (pH = 7) 80 Graph 16– Corrosion Life of Galvanized Steel in Corrosive Soil (pH< 4.5 or pH > 10.5) 80 Graph 17–Estimated Life of Galvanized Coating PITA Rods & Adapters Hot Dip Galvanizing 81 Table 23– ECP Torque Anchor™ Estimated Average Life Expectancy at Full Load 82 Hot Dip Galvanizing 83 Design Example 7– Corrosion Life of Tubular Shaft 83 Manufacturer’s Warranty 87 Earth Contact Products, LLC reserves the right to change design features, specifications and products without notice, consistent with our efforts toward continuous product improvement. We also make changes and corrections to the technical design text consistent with the state of the art. Please check with Engineering Department, Earth Contact Products to verify that you are using the most recent design information and product specifications. Utility Industry Anchor Design and Maintenance Manual © 2013 Earth Contact Products, L.L.C 2013-11 Pagev All rights reserved oe tu nq™ Chapter 1 ors tior cTo ul h dac ocn rliA te nH I Introduction to ™ ECP Helical Torque Anchors for Electric Utility Applications  PITA Helical Torque Anchors™  HD Extreme PITA Torque Anchors™  Solid Square Shaft Torque Anchors™  Tubular Shaft Torque Anchors™ “Designed and Engineered to Perform” Introduction toUtility Industry Anchor Design © 2013 Earth Contact Products, L.L.C. 2013-11 Page1 All rights reserved © 2013 Earth Contact Products, LLC. All Rights Reserved. This material may not be reproduced in any form without the written permission of Earth Contact Products, LLC. Any unauthorized uses of the material and inventions disclosed herein or reproductions or copies of the pages of this document are hereby prohibited. Such uses would be deemed infringement of Earth Contact Products’ intellectual property rights and will be prosecuted to the full extent of the law. Earth Contact Products, LLC Corporate Office and Manufacturing Facility 15612 South Keeler Terrace, Olathe, Kansas 66062 913 393-0007- FAX 913 393-0008 Toll Free– 866 327-0007 www.earthcontactproducts.com Earth Contact Products, LLC reserves the right to change design features, specifications and products without notice, consistent with our efforts toward continuous product improvement. Please check with Engineering Department, Earth Contact Products to verify that you are using the most recent information and specifications. Technical Design Assistance Earth Contact Products, LLC. has a knowledgeable staff that stands ready to help you with understanding how to prepare preliminary designs, installation procedures, load testing, and documentation of each placement when using ECP Torque Anchors™. If you have questions or require engineering assistance in evaluating, designing, and/or specifying Earth Contact Products, please contact us at 913 393-0007, Fax at 913 393-0008. Introduction toUtility Industry Anchor Design © 2013 Earth Contact Products, L.L.C. 2013-11 Page2 All rights reserved oe tu Introduction nq™ ors Screw piles have been in use for more than 162 19th and early 20th centuries. They mainly ctiToor years. In 1838 a lighthouse was built upon screw supported structures and bridges over weak or wet ul h dac piles designed by an Irish engineer, Alexander soil. ocn rliA Mitchell. In 1863, Eugenius Birch designed the Hydraulic torque motors became available in the ntHe Brighton West Pier in Brighton, England. These 1960’s, which allowed for easy and fast I piers are still in use 140 years later. The original installation of screw piles. Screw piles soon screw piles were installed at 10 feet per hour using became the favored product for resisting tensile eight 20 foot long torque bars with the force of 32 forces. Soon electric utility companies began to to 40 men. use screw piles for tie down anchors on In the United States, the Thomas Point Shoal transmission towers and for guy wires on utility Lighthouse on Chesapeake Bay, Maryland is the poles. After implementing helical gear motors in only remaining lighthouse built upon helical screw the 1960's, the electric utility companies became a piles that is still situated at its original location leading consumer of helical anchors due to the near Annapolis, Maryland. The lighthouse has a easy and fast installation of helical screw piles. hexagonal shape measuring 35 feet across, and it Initially the helical screw piles were used as guy is still supported by seven original helical screw wire anchors for utility poles and subsequently as piles. The Thomas Point Shoal Lighthouse was tie down anchors for transmission towers. The first put into operation on November 20, 1875. combination of the gear motor and the helical anchor provided excellent foundation support for utility infrastructures. Such applications are particularly beneficial in times of major storm damage where a rapid foundation support system is necessary to restore power to customers. Helical screw piles are ideal for applications where there is a need to resist both tensile and axial compressive forces. Some examples of structures having such combination forces are metal building foundations, canopy supports and monopole telecommunication tower foundations. Current uses for helical screw pile foundations include foundations for commercial and residential structures, lighting standards, retaining walls Thomas Point Shoal Lighthouse tieback anchors, guy wire anchors, failed The helical screw piles that support the structure foundation restorations, pipeline and pumping consist of ten inch diameter wrought iron shafts equipment supports, elevated walkways, bridge with cast iron helical abutments, and numerous other uses in the electric screw flanges at the utility industry. end of the shafts. At Thomas Point, the ECP Torque Anchors™ screw piles were ECP Torque Anchors™ are a part of the complete advanced into to sandy product line of screw piles, steel piers and bottom of Chesapeake foundation support products manufactured by Bay a distance of 11- Earth Contact Products, LLC, a family owned 1/2 feet. The light is company based in Olathe, Kansas. mounted 43 feet above the surface of the Our 100,000 square foot state of the art water. manufacturing facility produces all components and steel assemblies. Earth Contact Products uses Sporadic use of screw only certified welders and robotics for quality piles has been docu- Cast iron coupling at fabrication. The only processes not done in our mented throughout the Thomas Point facility are galvanization and hot forge upsetting Lighthouse Introduction toUtility Industry Anchor Design © 2013 Earth Contact Products, L.L.C. 2013-11 Page3 All rights reserved

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Utility Industry Anchor Design and Maintenance Manual © 2011 Earth Contact Products, L.L.C. manufacturing facility of Earth Contact Products,
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