frangible safety approach light masts lattice masts with hinge tool installation

Frangible Safety Approach Light Masts

LATTICE MASTS WITH HINGE TOOL INSTALLATION MANUAL

LATTICE MAST WITH HINGE TOOL Revision 4.3 Page 1 (40) INSTALLATION MANUAL 25.2.2014 LatticeHingeToolREV4-3.docx

CONTENTS

1 GENERAL INFORMATION ................................................................................. 3 1.1 Symbols used in this manual ..................................................................... 3 1.2 Requirements of ICAO ............................................................................... 3 1.3 Mast family of Exel Composites Oyj ........................................................... 4 1.4 Exel lattice masts ....................................................................................... 5

2 FOUNDATION .................................................................................................... 6 2.1 Foundation design ..................................................................................... 6 2.2 Preparation of foundation ........................................................................... 8

2.2.1 Equipment needed for preparation of foundation .......................... 9 2.2.2 Work instruction for casting of foundation ..................................... 9

3 LATTICE MAST ASSEMBLY ............................................................................ 11 3.1 Main dimensions of approach light mast .................................................. 11 3.2 Tightening torques of approach mast ....................................................... 12 3.3 Unpacking and handling of mast .............................................................. 13 3.4 Joining of mast modules .......................................................................... 13

3.4.1 Equipment needed for joining mast modules .............................. 13 3.4.2 Tightening torque in joining mast modules .................................. 14 3.4.3 Work instruction for joining mast modules ................................... 14

3.5 Mounting of base frame to the mast......................................................... 16 3.5.1 Equipment needed for mounting the base frame ........................ 18 3.5.2 Tightening torque for base frame screws .................................... 18 3.5.3 Work instruction for mounting the base frame ............................. 18

3.6 Installations of the top section of the mast ............................................... 19 3.6.1 Tools and tightening torque for mounting the top section ............ 20 3.6.2 Top frame .................................................................................... 20 3.6.3 Work instruction for installation of cross bar tube ........................ 20 3.6.4 Work instruction for installation of strut arm pair ......................... 21 3.6.5 Fitting strut arms to a short mast ................................................. 22

3.7 Installation of approach lights................................................................... 23 3.7.1 Equipment needed for installation of approach lights .................. 23 3.7.2 Adjustment tube clamps .............................................................. 23 3.7.3 Fitting and adjustment of approach lights .................................... 24

3.8 Installation of electrical wires ................................................................... 25 3.8.1 Equipment needed for installation of cables ................................ 25 3.8.2 Work instruction for wiring ........................................................... 25

4 MOUNTING AND ERECTING THE MAST ....................................................... 28 4.1 Tools needed for mounting the mast ........................................................ 28 4.2 Tightening torque applied in mounting the mast ...................................... 29 4.3 Movingthe lattice mast to its’ final position ............................................... 29 4.4 Preparation of foundation for erection of the mast ................................... 29 4.5 Work instruction for fixing the hinge tool .................................................. 30 4.6 Work instruction for erecting the lattice mast ........................................... 31 4.7 Work instruction for alignment of approach lights .................................... 34

5 USE AND MAINTENANCE OF LATTICE MAST .............................................. 35 5.1 Lowering and raising of lattice mast ......................................................... 35


5.1.1 Tools needed for lowering and raising the mast, tightening torque35 5.1.2 Work instruction for lowering and raising of lattice mast .............. 36

5.2 Repair painting ......................................................................................... 37 5.2.1 Material needed for repair painting .............................................. 37 5.2.2 Repair painting ............................................................................ 37

5.3 Glass fibre tube repair .............................................................................. 38 5.3.1 Material needed for glass fibre tube repair .................................. 38 5.3.2 Repairing the damage ................................................................. 38

6 ILLUSTRATIONS AND TABLES ...................................................................... 40 APPENDICES


1 GENERAL INFORMATION

1.1 Symbols used in this manual

Specific symbols are used in this manual in order to attract readers’ attention to information of special importance. These symbols, their referents and explanations are presented in the table below. Symbol Referent Explanation

INFO A useful hint to facilitate installation.

NOTE In case of incorrect action, the structures are in danger of being broken. When performing this action, please exercise extreme caution.

Note related to the matter.

DANGER In case of incorrect action, fitters or persons in the proximity are in danger of accident. Please exercise extreme caution when performing this action.

REFERENCE

Further information about the subject elsewhere in the manual

Table 1: Symbols

1.2 Requirements of ICAO

According to the requirements of ICAO (International Civil Aviation Organisation) frangible safety approach light masts shall be used in all installations. The protection period of non-complying installations ended on 1st January, 2005. Below is an extract from Aerodrome Design Manual Part 6, Frangibility, First Edition – 2006 “Chapter 1 INTRODUCTION 1.3 OBSTACLES TO BE MADE FRANGIBLE 1.3.2 Annex 14 — Aerodormes, Volume I — Aerodorme Design and Operations, Chapter 5,

specifies that elevated approach lights and their supporting structures should be frangible except that, in that portion of the approach lighting system beyond 300 m from the threshold:

a) where the height of the supporting structure exceeds 12 m, the frangibility requirements should apply to the top of 12 m only; and

b) where a supporting structure is surrounded by non-frangible objects, only that part of the structure that extends above the surrounding objects shall be frangible.

Chapter 5 TESTING FOR FRANGIBILITY 5.1 GENERAL


5.1.2 The frangibility of any aid should always be proven before the aid is considered for installation. High-speed, full-scale testing is a proven method for verification of frangibility. Results of the numerical simulation show this approach to be capable of demonstrating frangibility. Hoewver, as for any numerical simulation methods, the model and simulation approach used must be validated for this purpose by comparison with representative test data. Numerica simulation methods are discussed in Chapter 6.

5.1.4 Static tests, as opposed to dynamic tests , are considered adequate for verification of frangibility of visual aids of low mass having an overall height equal to or less than 1.2 m, such as elevated runway and taxiway lights, taxiing guidance signs and visual approach indicator systems.

5.1.5 Dynamic test are recommended for verification of frangibility of navigational aids having an overall height in excess of 1.2 m and located in positions where they are likely to be impacted by an aircraft in flight. Such aids are approach lighting towers, wind direction indicators, transmissometers, ILS localizer and glide path antennas and MLS approach azimuth and elevation equipment. ILS glide path antenna and the MLS aaproach azimuth and elevation equipment provide a unique situation due to their size and mass of the instrument and support structure. While frangibility requirements should be applied to this equipment in general, these requirements may be too restrictive for such large structures.”

(Aerodrome Design Manual Part 6, Frangibility; First Edition — 2006: International

Civil Aviation Organisation, Doc 9157 AN/901.)According to the requirements of ICAO (International Civil Aviation Organisation) frangible safety approach light masts shall be used in all new installations. Existing installations have a protection period that ends at the end of 2004. Below is an extract from International Standards and Recommended practices, Annex 14 Vol.1, fourth edition July 2004, § 5.3.1.4

1.3 Mast family of Exel Composites Oyj

Exel Composites Oyj has accepted the challenge of ICAO requirements by designing a light, frangible, approach light mast family based on composite materials. The Exel mast has passed a full-scale impact test as a proof of meeting the requirements of ICAO. In Exel masts, frangibility is a unique built-in feature and no break-away points at regular intervals used by other manufacturers are needed. If case of a collision, the mast will break down at the point of impact, and there is no danger of the broken pieces of the mast wrapping around the wing of the aircraft. Due to its design and materials, an Exel mast is light but at the same time very stiff and strong, and can thus well withstand wind loads and jet blast loads caused by aircraft jet engines. In case of a side impact, however, the mast will break down safely to small pieces. Exel masts are in practice maintenance-free and the composite materials used in them resist fatigue and corrosion. The masts will maintain their physical properties regardless of the weather and temperature. They can be safely used in maritime or other climate conditions causing corrosion. Exel-masts have been painted with visible aviation yellow colour, and therefor they do not need to be marked separately for visibility. The chosen materials make the masts transparent to electromagnetic signals. Exel masts do not distort ILS signals and as a result, the need for calibration of ILS antenna system is decreased. The shape and dimensions of Exel masts will not be deformed when the masts are


lowered down for light maintenance, and consequently, re-aligning of lights is not necessary.

1.4 Exel lattice masts

Exel lattice masts have a modular construction. Medium-tall masts consist of a single module of 400 mm, and the cross bar tube for fixing the lights is mounted on top of the 400 mm module. The maximum height of single-module masts is approximately 6,5 m. In tall masts, the lower section consists of a module of 500 mm, and the top section of a module of 400 mm. The cross bar tube is mounted on top of the 400 mm module. The maximum height of two-module masts is approximately 14 m. The extra tall masts can reach even the height of 25 m.

Illustration 1: Exel lattice mast

The design of lattice masts has been explained more in detail in the assembly drawings and in the mast list.


2 FOUNDATION

2.1 Foundation design

The factors affecting the foundation design are: Height of the mast Quantity of lights / mast (in lattice masts 1-5 pcs) Wind load (including jet blast loads caused by the aircraft engines in the proximity

of the threshold) Soil quality The following tables describe some typical examples of mast foundations. The calculations have been made for tubular masts carrying single luminaires and lattice masts carrying barrettes of four luminaires. The maximum wind speed used in the calculations is 40 m/s. Dimensioning of the foundations has been done according to DIN V 4017-100. Two types of foundations have been calculated, slab foundation and drum foundation.

Illustration 2: Slab foundation and drum foundation


Slab foundation SOIL TYPE 1 SOIL TYPE 2 SOIL TYPE 3

Mast height

Type L=W H Mass L=W H Mass L H Mass

Meters - mm mm kg mm mm kg mm mm kg H = 2,5 Pole 600 200 170 600 200 170 700 200 250 H = 4 Pole 700 300 350 600 300 260 800 400 620 H = 4 Lattice 1200 400 1400 1100 400 1200 1300 500 2100 H = 7 Lattice 1400 600 2900 1300 600 2500 1600 700 4400 H = 10 Lattice 1700 700 5000 1600 700 4400 1900 800 7100 H = 13 Lattice 1900 800 7100 1800 800 6350 2300 800 10400 H = 16 Lattice 2300 800 10400 2200 800 9500 2600 900 14900

Table 2: Dimensioning of the concrete slab foundation for mast heights up to 16 m.

Drum foundation

SOIL TYPE 1 SOIL TYPE 2 SOIL TYPE 3

Mast height

Type D H Mass D H Mass D H Mass

Meters - mm mm kg mm mm kg mm mm kg H = 2,5 Pole 500 800 390 500 600 280 H = 4 Pole 500 1000 480 500 800 390 H = 4 Lattice 1200 1100 3000 1200 900 2500 H = 7 Lattice 1200 1500 4150 1200 1200 3350 H = 10 Lattice 1200 1900 5260 1200 1500 4200 H = 13 Lattice 1200 2200 6100 1200 1700 4700 H = 16 Lattice 1200 2600 7200 1200 2000 5600

Table 3: Dimensioning of the concrete drum foundation for mast heights up to 16 m. Soil type 1: Sand, sandy soil

angle of friction = 25 weight by volume = 17 kN/m³ cohesion c = 0 kN/m²

Soil type 2: Compacted coarse sand and moraine angle of friction = 40 weight by volume = 21 kN/m³ cohesion c = 0 kN/m²

Soil type 3: Hard clay (drum foundation should not be used!) angle of friction = 0 weight by volume = 19 kN/m³ cohesion c = 20 kN/m²

Concrete: > K30


In a groundwater area the foundation shall be deeper. In a soil frost area, the foundation shall reach below the soil frost penetration

depth.

All design values mentioned in this instruction are purely indicative. Exel Composites Oyj shall not take responsibility for their applicability to the area in question.

It is highly recommended to always consult a local civil engineer about the dimensioning of the foundation.

Exel Composites Oyj will provide the necessary load calculations (shear force and bending moment), when requested.

Positioning of masts has been dimensioned in the layout-drawing. The heights of the top of foundation have been listed separately for each

position in the mast list, if this information has originally been provided to Exel Composites Oyj.

2.2 Preparation of foundation

Fixed base plate Part of foundation bolt remaining visible 150 +5 mm Allowed deviation of the position of the jig/base frame from the approach light centre line.

± 0,5 =8,7mm/1000mm

Allowed deviation of the position of the jig/base frame from the horizontal level.

± 1 =17mm/1000mm

Correct position of the base frame Even side up Table 4: Essential information necessary for preparation of foundation.

Plywood jigs (option) are available to facilitate concrete casting. The position of foundation bolts is the same for both 400 mm and 500 mm

module masts. Both mast modules (400 and 500 mm) have their own base frame.

Hot dip galvanised foundation bolts shall in no case be welded to the steel reinforcement of the foundation. Fasten the foundation bolts with wire.

Protect the thread of the foundation bolts during the casting for example with tape.

See: ”Preparation of foundation for the erection of the mast”. See: ”Installation of cable”. See Appendix: ”Assembly drawings”. See Appendix: ”Foundation drawings”.


2.2.1 Equipment needed for preparation of foundation

Measure Instrument Size - Foundation bolt, 4 pcs

641019 / 641861 M20-350(1000) M24-430(1160)

Fastening of foundation bolts to the jig

Nut, 8 pcs M20 M24

-:- Washer Ø60/Ø20x10 Washer Ø60/M20x10

L400 mast

-:- Washer Ø60/Ø24x10 Washer Ø60/M24x10

L500 mast

-:- Wrench S=30 mm (S=36 mm)

Positioning of foundation bolts (alternative 1)

Template 641830B 1 pc or template 641934

L400 mast L500 mast

Protection of screw thread Masking tape - Fastening of screws to steel reinforcement

Wire -

Casting of foundation Normal casting accessories (moulds and steel re-inf.)

-

Verification of straightness / angle of the jig

A stiff ruler L > 1000 mm

-:- Water level - Table 5: Equipment needed for preparation of foundation.

2.2.2 Work instruction for casting of foundation

A plywood template has been supplied to assure accurate positioning of the anchor bolts in the foundation. Please make sure that you have the template with the sticker “this side up” facing up. The template cannot be used upside down, the bolts will not align correctly for the base frame. Make a cast mould with its steel reinforcements in accordance with the design of

a local civil engineer. The cable conduit is drawn under the ground from the transformer housing

through the foundation up to and as close as possible to either inside corner of the base plate that is facing the felling direction of the mast. See drawing 641011B/641892B at the drawings-section of tehis manual.

Fasten the foundation bolts to the template Protect the threads in the anchor bolts by using for example masking tape. Place the template with the bolts at its’ position. Fasten the bolts to the steel

reinforcement with wire if necessary. The foundation bolts shall remain for the length of 150 mm above the concrete surface

Make sure that the template is in straight angle towards the approach light centre line. The allowed deviation of the position of the template from the approach light centre line. ± 0,5, which corresponds to 8,7 mm/1000 mm. Correct if necessary.

Cast concrete in the foundation mould.


Make sure that the template is in a horizontal position. Correct the position before the concrete hardens.

When the concrete is hard, remove the template.

HPM20/L KZN, L=350 mm (13.8")

HPM20/P KZN, L=1100 mm (43.3")

ALTERNATIVE FOUNDATION BOLTS

Concrete foundation

Concrete foundation

Foundation bolt

Threaded washer

Casting template

Washer

Hex nut

Foundation bolt

Using a casting template

Approach C/L

Positioning of the anchor bolts

2

4

3

5

Tilting direction

of the mast

One additional hex nut M20 and

washer Ø37/22x3 on both foundation

bolts to hold the hinge tool in place

on the tilting side of the mast.

Ød

min. 115 mmmin. 10d

Protrution of

anchor bolts 150+5-0

4xM20 bolts

450.0

450.0

(455.4)

70.0

70.0

(644.0)

(level of base

frame 110.0)

80200

Position of

cable duct

Reinforcing to match

capacity of anchor bolts;

minimum mesh Ø8#200

Reinforcing to match


minimum mesh Ø8#200

HPM24/L KZN, L=430 mm (16.9")

HPM24/P KZN, L=900 mm (35.4")

ALTERNATIVE FOUNDATION BOLTS

Concrete foundation

Concrete foundation

Foundation bolt

Threaded washer

Casting template

Washer

Hex nut

Foundation bolt

Using a casting template

Approach C/L

Positioning of the anchor bolts

1

2

4

3

5

Tilting direction

of the mast

One additional hex nut M24 and

washer Ø44/26x4 on both foundation

bolts to hold the hinge tool in place

on the tilting side of the mast.

Ød

min. 115 mmmin. 10d

protrution of anchor

bolts 150+5-0

(level of base

frame 110.0)

450

450

(455.4)

(644

)

70

70

4xM24 bolts

Position of

cable duct

150

300

Reinforcing to match the


minimum: mesh Ø8#150

Reinforcing to match the


minimum: mesh Ø8#150

Illustration 3: Principal draft of foundation, template and foundation bolts of the mast.


3 LATTICE MAST ASSEMBLY

3.1 Main dimensions of approach light mast

Illustration 4: Main dimensions of an approach light mast. Dimension Explanation H1 Light height from top of foundation. H2 Height of lattice section H3 Light height from top of lattice section H4 Height of the base frame top from top of foundation. H5 Height of 400 mm mast module H6 Height of 500 mm mast module L1 Horizontal spacing of approach lights L2 Length of the cross bar

Table 6: Explanations of the main dimensions of an approach light mast


3.2 Tightening torques of approach mast Item Size Torque Strut arms to cross member

clamp M8 13 Nm

Cross member clamps M8 13 Nm Top frame to leg beams M16 80 Nm

Horizontal support to leg beams M6 5 Nm Strut arms to horizontal support M8 13 Nm

L400 leg beams to joining

element M16 130 Nm

Joining element to L500 leg beams

M24 200 Nm

L400 leg beams to base frame M16 150 Nm Base frame to anchor bolt M20 200 Nm L500 leg beams to base frame M24 250 Nm Base frame to anchor bolts M24 300 Nm


3.3 Unpacking and handling of mast

Unpack the mast carefully on the assembly site. Handle mast modules with care. Be sure not to damage the glass fibre structures, because they are designed to be frangible. Masts are delivered as assembled modules, which will then be connected on the assembly site. The 400 mm mast module is packed inside the 500 mm module. They have been numbered by positions according to a separate mast list. A joint element is mounted on top of the 500 mm module. This joint element is used for connecting modules of different sizes. On top of the 400 mm module is the top frame, on which the cross bar tube is mounted. All necessary screws, nuts, washers and shims have been fitted. When unpacking, arrange modules so that different elements of the mast will not get mixed with each other during assembly.

If any damage is found in the masts, contact the representative of Exel Composites Oyj. Exel will either repair the damaged parts or provide the repairing instructions.

Make sure that the masts have not been damaged during transportation. Recommended lifting points of a mast are the top frame, the joint element

and the base frame. In addition to those points, mast modules may only be lifted from leg beams. Never lift a mast from diagonal beams!

Be careful not to damage masts during transportation, because they are designed to be frangible.

Mast modules have been numbered according to their positions. The numbers refer to a separate mast list.

3.4 Joining of mast modules

3.4.1 Equipment needed for joining mast modules

Mast module

Object Part Size Qty

500 mm Lower module Mast module 641068

500 mm 1

400 mm Upper module Mast module 641027

400 mm 1

- Joint element of modules

Exel joint element 641000A

- 1

500 mm Connection to joint element

Hex screw M24x50 4

400 mm Connection to joint element

Hex screw M16x40 4


500 mm Upper and lower washers

Exel washer 641085

ø56/24 x5 8

400 mm Upper washers Exel washer 641087

ø55/16 x5 4

400 mm Lower washer Exel washer 641086

ø34/16 x5 4

400 mm Load adjustment Exel shim ø32/17 x0.5 n 500 mm Load adjustment Exel shim ø50/25 x0.5 n

Table 7: Equipment needed for connecting lattice mast modules and joint element Mast module

Action Tool Size

Both modules

Final tightening of screws Torque wrench M=300 Nm

500 mm Tightening of M24 fastening screw

Plug spanner S=36 mm



Both Applying torque against tightening

Hook wrench 32 / 50 mm

-:- Support of lattice masts Trestles - 400 mm -:- Blocks of wood -

Table 8: Tools for connecting lattice mast modules and joint element.

3.4.2 Tightening torque in joining mast modules

Mast Module

Action Size Torque

500 mm Tightening of module to joint element

M24 200 Nm

400 mm Tightening of module to joint element

M16 130 Nm

Table 9: Tightening torque in joining mast modules.

3.4.3 Work instruction for joining mast modules

Tall masts consist of two modules. The modules of 400 mm and 500 mm are joined by using a joint element.


Illustration 5: Mast modules in assembly position Choose modules to be joined according to the position numbers. Place modules in a lying position on wooden support frames placed on an even

base. The joint element has been mounted by the manufacturer on top of the module of

500 mm with M24x50 mm screws. Make sure that the bolts of the joint element have been tightened to correct

torque. Use a hook wrench when applying torque against tightening. There is a hole in the aluminium bush at the end of the leg beam. This way no torsion stress will be directed to the glass fibre construction of the leg beam.

Adjust the position of trestles under the module of 400 mm in order to locate the threaded holes in the leg beams of the module to the holes in the joint element

Join the module of 400 mm to the joint element with M16x40 mm screws. Place a washer ø34/16 x5 (total 4 pcs) under each fastening screw head. Place a washer ø55/16 x5 (total 4 pcs) under each leg beam.

Compensate the length differences of leg beams by using shims under a shorter leg beam.

Tighten the M16 screws to their torque. Use a hook wrench as described above.

Illustration 6: Joining a mast module to the joint element.


No. Part name Size / model /ref. Qty 1 Washer ø55/16x5 4 2 Shim ø50/24x0.5 n 3 Hex screw M24x50 4 4 Washer ø56/24x5 8 5 Washer ø34/16x5 4 6 Hex screw M16x40 4 7 Mast module 500mm 1 8 Joint element 500/400mm 1 9 Mast module 400mm 1

Table 10: List of connection parts of the joint element.

Tightening torques for installation screws can be found also on page 12 .

Recommended lifting points of a mast are for example the top frame, the

joint element and the base frame. In addition to those points, mast modules shall be lifted only from the leg beams. Never lift a mast from the diagonal beams!

Be careful not to damage masts when handling them, because they are designed to be frangible.

Shims must be used for all leg beams in order to even the torsion load. Never tighten the leg beams to the level of the joint element by force.

A hook wrench must be used for applying torque against tightening. Torsion stress caused by tightening shall not be directed to the glass fibre structure of the leg beam.

The right mast segments can be found according to the position numbers. See the layout drawing, the mast list and the identification plates on the masts.

3.5 Mounting of base frame to the mast

Remember to prepare the foundation for erection before mounting the base frame to the mast. Instructions of the preparation of foundation for erection are given later in this manual The base frame is manufactured of steel profile and it is finished with hot dip galvanising. Both mast modules (400 mm and 500 mm) have their own fixed base frame. The holes of the foundation bolts in the base frame are slightly oversized. This enables the necessary adjustment of deflection ± 0,5 of the masts.


Illustration 7: Fixed base frames of 400 mm and 500 mm masts


3.5.1 Equipment needed for mounting the base frame

Mast module

Object Part Size Qty

500 mm - Mast module 641068

500 mm 1

400 mm - Mast module 641027

400 mm 1

400 mm - Fixed base frame 641133A

- 1

500 mm - Fixed base frame 641891A

- 1

500 mm Connecting of mast to base frame

Hex screw Washer

M24x50 M24

4 4

500 mm Load adjustment Exel shim ø50/25 x0.5 N 400 mm

Connecting of mast to base frame

Hex screw Washer

M16x40 M16

4 4

400 mm Load adjustment Exel shim ø32/17 x0.5 N Table 11: Accessories needed for mounting the base frame. Mast Action Tool Size Both Final tightening of screws Torque wrench M=300 Nm 500 mm Tightening of M24

fastening screw Plug spanner S=36 mm



Both Applying torque against tightening

Hook spanner 32 / 50 mm

Table 12: Tools needed for mounting the base frame.

3.5.2 Tightening torque for base frame screws

Mast size Screw size Torque 500 mm M24 250 Nm 400 mm M16 150 Nm

Table 13: Tightening torque for base frame screws.

3.5.3 Work instruction for mounting the base frame

The necessary bolts and washers have been fitted to the lower end of the mast. The 400 mm mast module will be fixed with M16x40 bolts and the 500 mm mast module with M24x50 bolts. Detach the bolts and the washer from the mast.

Mount the frame to the lower end of the mast. Compensate length differences of the leg beams by using 0.5 mm shims under the shorter leg beam, in order to distribute the stress caused by tightening as evenly as possible to all leg beams.


It is recommended to apply liquid thread locker (blue Loctite 242 or equivalent) to the threads of the mounting screws. Tighten the screws of the base frame to their torque setting. Use a hook wrench to apply torque against tightening. There is a hole for the hook wrench in the aluminium bush in the end of the leg beam. This way no torsion stress is directed to the glass fibre construction of the leg beam.

Prepare the foundation before mounting the base frame to the mast.. The mass of the base frame of 400 mm mast module is approximately

26 kg. The mass of the base frame of 500 mm mast module is approximately

34 kg.

Shims must be used in order to distribute the tightening load equally between all leg beams. Leg beams shall in no case be tightened to the level of the base frame by force.

A hook wrench must be used to apply torque against tightening. No torsion stress created by tightening shall be directed to the glass fibre construction of the leg beam.

Exel Composites recommends the use of liquid thread locker in the threads of the mounting screws when the base frame is attached to the bottom of the mast. For example blue Loctite 242 or equivalent is good for the purpose as the screws can be opened if needed.

3.6 Installations of the top section of the mast

The installations of the top section of the mast include mounting of cross bars, strut arm supports and approach lights. See the enclosed illustration.

Illustration 8: Installations of the top section of the mast.


3.6.1 Tools and tightening torque for mounting the top section

Action Tool Size Final tightening of screws Torque wrench M=20 Nm Cross bar tube clamp, tightening of M8 screw

Allen key S=6 mm

Horizontal support of strut arms, tightening of M8 screw

Allen key S=6 mm

Horizontal support of strut arms, tightening of M6 screw

Allen key S=5 mm

Table 14: Tools needed for mounting the top section of the mast. Object Screw size Torque Cross bar tube clamp M8 13 Nm Strut arm clamp M8 13 Nm Horizontal support of strut arms M6 5 Nm

Table 15: Tightening torque applied in the installation of the top section of the mast.

3.6.2 Top frame

A top frame has been mounted to the top of the mast for installation of the cross bar. The cross bar tube will be mounted on the mast with clamps in the top frame. Check that the clamps and the cross bar are on the centre line of the mast.

3.6.3 Work instruction for installation of cross bar tube

The cross bar tube will be mounted on the top frame with cross bar tube clamps. The misalignment of the tube is prevented with the ribs in the tube. There are grooves for the ribs in the clamp frame and in the crossbow. Check during installation that the ribs fit in their grooves. Tighten the clamps to their torque setting.

Illustration 9: Top frame, clamp and cross bar tube


3.6.4 Work instruction for installation of strut arm pair

Do the preliminary installation of the adjustment tube clamps in connection with the installation of the strut arms. See ”Installation of approach lights”. Attach the upper ends of the strut arms to the cross bar tube with the crossbow

clamps. Open the clamp by removing the hex socket head screws, check that the clamps have a rubber lining on the inside and fasten the clamp around the cross bar tube.

Place the horizontal supports carefully to opposite sides of the lattice section. The distance from the top of the mast should be approximately the same as the distance of the strut arm top clamps from the mast center line. This way the strut arms are set in a 45º angle. Use green plastic clamps for fastening. Do not tighten the fastening screws of the clamps.

Fit the lower ends of the strut arms to their positions in the horizontal support. Place bonded washers against the glass fiber profiles.

Illustration 10: Installation drawing of strut arms No. Part Size Qty

1 Strut arm - 2+2 2 Allen screw M8x45 2+2 3 Horizontal support - 1+1 4 Clamp with rubber lining ø72 2+2 5 Allen screw M8x35 2+2 6 Washer M8 2+2 7 Bonded washer ø19/8,7 4+4

Table 16: Parts list of the installation drawing of strut arms

The quantities given in the parts list above are needed for mounting the strut arms to one mast.


3.6.5 Fitting strut arms to a short mast

If the mast with strut arms is short and the strut arms cannot be mounted at a normal angle of 45, they can be mounted at an angle of approximately 60 according to the illustration below.

Illustration 11: Mounting strut arms to a short mast No. Part Size Qty

1 Strut arm - 2+2 2 Angle screw M8 4+4 3 Horizontal support - 1+1 4 Clamp with rubber lining ø72 2+2 5 Lock nut M8 12+12 6 Washer M8 8+8 7 Bonded washer ø19/8,7 4+4

Table 17: Parts list for installation of strut arms to a short mast

The quantities given in the parts list above are needed for installation of strut arms to one mast.

When mounting strut arms at an angle of 60, use angle screws and M8 nuts instead of M8 screws.


3.7 Installation of approach lights

3.7.1 Equipment needed for installation of approach lights

Action Tool Size Final tightening of screws Torque wrench M=20 Nm Clamp, tightening of M8 screw Allen key S=6 mm Strut arm clamp, tightening of M8 screw Allen key S=6 mm

Table 18: Tools needed for installation of approach lights. Object Screw size Torque Clamp of adjustment tube M8 13 Nm Strut arm clamp M8 13 Nm

Table 19: Tightening torque applied in installation of approach lights.

3.7.2 Adjustment tube clamps

The adjustment tube clamps are similar to the cross bar tube clamps. Install adjustment tube clamps in connection with the installation of strut arms. Fix the adjustment tube clamps to their positions and tighten them lightly.

Illustration 11: Exploded view of a clamp No. Part Size Qty 1 Allen screw M8 x 40 mm 8 2 Washer M8 8 3 Crossbow of clamp ø 51 tai ø 72 2+2 4 Clamp frame - 1 (5) (Adjustment tube) (ø 51 x 780 mm) (1) (6) (Cross bar tube, with ribs) (ø 72 mm) (1)

Table 20: Part list of clamp


3.7.3 Fitting and adjustment of approach lights

Fit the approach lights to their sleeves. Check the light height and the light spacing in the mast list. Measure light height from the mast base. Adjust the light height roughly. The final adjustment will be done at the erection

site by using an optic device. Check also the light spacing in the mast list. Measure the distances between lights. Adjust the light spacing and the position of the centre line of lights roughly. The

final adjustment will be done at the erection site by using an optic device. Tighten all screws of the approach lights and strut arms.


3.8 Installation of electrical wires

3.8.1 Equipment needed for installation of cables

Object Equipment Size Wiring of cross bar tubes Rubber cable VSB

2x2,5 mm Wiring of lattice section Conduct wire or lead 2,5 mm2 Cover tube for cross bar Plastic tube, UV-

protected Ø 25 mm

Cover tube of lattice section Plastic tube, UV-protected

Ø 25-50 mm

Cover tube over joint element and base frame

Flexible plastic tube, UV-protected

Ø 25-50 mm

Fastening of cover tubes UV-protected plastic straps

Suitable

Cover tube from transformer housing to foundation

Plastic tube IR 65

Connection between cables Secondary connector KD 501, 502 tai 503R

Sealing of cover tubes in the bottom section

Sealing compound or tape

Table 21: Equipment needed for installation of cables.

3.8.2 Work instruction for wiring

ICAO’s recommendation for wiring of an approach mast encourages the designer to provide points of disconnection for the wires to ensure that segmentation is not hindered in case of a collision. The wiring method presented in this document satisfies that recommendation and has been found practical. These cable installation instructions can be considered a recommendation. Installation can be carried out also by using another method. Wiring at the foundation site Place the cable duct tubes between the transformer housing and the foundation

prior to casting the foundation. Recommended duct tube IR 65.The cable conduit is drawn under the ground from the transformer housing through the foundation up to and as close as possible to either inside corner of the base plate that is facing the felling direction of the mast.

Pass cables from the transformer housing to the foundation. Wiring to be carried out at the mast assembly site It is recommended to cable the mast to the greatest possible extent at the mast assembly site. Only the connection of the leads in the mast to the cables drawn from the transformer housing will be carried out at the erection site. Draw a rubber cable (recommendation: VSB 2x2,5) from the joint between the

lattice section and the cross bar tube to all approach lights. Fix the rubber cables to the cross bar tube either directly or inside ø 25 mm cover tube with UV-


protected plastic straps. Fix the rubber cables only to the cross bar tube, and not at all to the lattice section.

Connect the rubber cable leads to the approach lights. Fit the rubber cable leads at the other end of the rubber cable with the KD-connectors.

Fix a UV-protected cover tube to the lattice sections. Choose an appropriate size ø 25–50 mm of the cover tube according to the quantity of cables. Fix with UV-protected plastic straps to the leg beams.

Pass by the joint element with a UV-protected, flexible cover tube. Use matching cover tube joints in the connection between cover tubes.

Fix a similar flexible cover tube also to the lower end of the cover tube. The flexible tube will be connected later to the cover tube coming from the foundation. Leave enough length to the flexible cover tube.to compensate the tilting of the mast

Pass the leads (recommendation: MK 2,5) through the cover tube. Leave extra length to the leads for felling of the mast. Connect the upper ends of the leads to the KD connectors, which are connected to the leads of the rubber cable. Connect the lower ends of the leads to the KD connectors, which will be connected later to the cable passed through the foundation.

Illustration 12: Wiring of the mast


No. Part Size 1 Rubber cable VSB 2x2,5 mm 2 Secondary connector KD 501, 502 or 503-R 3 Conduct wire 2,5 mm 4 UV-protected plastic tube ø 25-50 mm 5 UV-protected plastic straps - 6 UV-protected flexible plastic tube 25–50 7 Plastic tube IR 65

Table 22: Part list of the illustration ”Wiring of mast”

IR 65 tube is similar to a drainage pipe, but there are no holes in it.

Use only leads, not rubber cable, in the cabling of the lattice part. The lattice part is frangible and will break safely in case of anaircraft impact, and frangibility must not be compromised by using too strong cables. The cover tubes will be fitted to the leg beams. Avoid fitting to the diagonal beams. Provide the upper and lower ends of the leads with secondary connections, which will be detached in a collision. Seal the joint between the IR65 tube and the lower flexible plastic tube to get it water-proof.


4 MOUNTING AND ERECTING THE MAST

If the masts are located near to the sea, or in some other corrosive environment, spread grease “Molykote Cu-7439 Plus” to aluminium and steel surfaces to prevent corrosion. Spread the grease on dry and clean surfaces.

Check that the mast sections have not been damages in the previoushandling.

Be careful not to damage the masts, they are frangible.

The mast positioning has been presented in the mast lists and in the lay-out

drawing (if supplied).

4.1 Tools needed for mounting the mast

Action Tool Size Final tightening Torque wrench M=20 Nm Final tightening Torque wrench M=300 Nm Lowering and raising of a mast shorter than 7 m

Hinge tool 641887B

Lowering and raising of a mast taller than 9 m

Hinge tool 641886

M20/M24 nuts of foundation bolts (nuts A and E)

1 pc fork spanner 1 pc plug spanner

S=30 mm (S=36 mm)

Threaded washer ø60/M20 (ø60/M24) Hook wrench 60 mm M20/M24 nuts of hinge tool (nut B) 1 pc fork spanner S=30 mm

(S=36 mm) Nut M10 of hinge tool (nut C) 2 pcs

fork spanner S=17 mm

Screw of hinge tool (screw D) 1 pc -:- -:- Adjustment of upright position of mast Water level Adjustment of the alignment Optic device Adjustment of light height and of light alignment

Allen key S=6 mm

Adjustment of light height Optic device Table 23: Tools needed for mounting of the mast.


4.2 Tightening torque applied in mounting the mast

Object Size Torque Nuts of foundation bolts (nuts A and E) M20 hex nut 200 Nm Nuts of foundation bolts (nuts A and E) M24 hex nut 300 Nm Nut of hinge tool (nut B) M20/24 hex nut 180 Nm Nut of hinge tool (nut C) M10 hex nut 30 Nm Screw of hinge tool (screw D) M10 hex screw 30 Nm Clamp of adjustment tube M8 hex socket

screw 13 Nm

Table 24: Tightening torque applied in mounting the mast

4.3 Movingthe lattice mast to its’ final position

When the mast modules have been connected to each other, the mast will be moved from the assembly site to its’ final position for erection. Place the mast in a horizontal position beside its’ concrete foundation to wait for erection.

Lift the mast from the top frame, joint element, base frame or leg beams. Never lift the mast from the diagonal beams.

4.4 Preparation of foundation for erection of the mast

This phase is to be effectuated before mounting the base frame to the mast. Remove protective tapes from foundation bolts. The foundation bolts have been supplied with one fitted.. Screw an extra nut for

fitting of the hinge tool to the two foundation bolts on the side of the felling direction. So before continuing there must be two nuts fitted to both foundation bolts on the side of the felling direction and one nut to both foundation bolts on the other side.

Screw a threaded washer to each foundation bolt. The top surface of the washer should be approximately 100 mm from the top of the foundation, and approximately 45 – 55 mm of the thread shall remain above the washer.

Adjust the washers to horizontal position with a water level. Tighten the nut of the foundation bolt from below to the threaded washer. Hold the washer at its’ place during tightening with a hook wrench.


4.5 Work instruction for fixing the hinge tool

A hinge tool is used for erecting and felling a mast. With the hinge tool erecting and felling the mast can be done as if the base frame was joined to the foundation with a hinge. Two different sizes of hinge tool are available. The smaller hinge tool is used for the erection of masts shorter than 7 m and the bigger for masts taller than 7 m.

Nut E

Washer

Nut C

Washer

Screw D

Washer

Hinge tool

Nut B

Nut A

Threaded

washer

Washer

Illustration 13: Fixing of hinge tool Loosen the screws D of the hinge tool and adjust the hinge tool to its’ upper

position. Tighten the screws D. Attach the hinge tool to the base frame of the mast with the nuts C. Turn nuts B high enough that the hinge tool will fit between the washer and the

foundation. Lift the mast up and locate the slots at the hinge tool to the foundation bolts on the side of the felling direction. Tighten the hinge tool to the foundation with the nuts B.

Check the tightness of all screws and nuts of the hinge tool.

Make sure you will not damage the threads of the foundation bolts when tilting the mast by verifying the correct fixing position of the hinge tool and the correct height of the nuts A.


4.6 Work instruction for erecting the lattice mast

The mast can be erected by using manual power, or by using a crane when lifting without the hinge tool. If a crane is used, it has to be equipped with soft lifting straps. Erecting the mast with a hinge tool Place the mast in a horizontal position beside the foundation on the side of the

felling direction so that the base of the mast is pointed towards the foundation. Fix the hinge tool.

Connect the KD-connector of the lower leads of the mast to the electric cable drawn through the foundation earlier.

Join the flexible cover tube to the cover tube coming through the foundation with cover tube joint. Seal the joint so that it is water-proof.

Erect the mast carefully by hand. Remember to grab the mast only from the recommended lifting points. Make sure that the edges of the holes in the base frame do not damage the foundation bolt threads. Place the mast down again if necessary and correct the position of the hinge tool.

When the mast is standing, place a washer and a nut to each foundation bolt on top of the base frame. Tighten the nuts lightly.

Remove the hinge tool. Adjust the mast position:

- Alignment with respect to approach light line

Loosen the foundation bolt nuts, and turn the mast manually. Adjustment margin ± 0,5

- Vertical alignment Check with a water level that the mast is vertical. Adjust the position by opening the lock nut of the threaded washer and turning the washer up- or downward if necessary. Lock the washers according to the point 4.4 after adjustment.

Tighten the foundation bolt nuts to the torque.


Nut E

Washer

Nut C

Washer

Screw D

Washer

Hinge tool

Nut B

Nut A

Threaded

washer

Washer

Illustration 14: Erecting the mast with a hinge tool. Symbols in the illustration

Part Size Qty

Nuts A and E Hex nut M20/M24 4+4 Threaded washer of nut A Threaded

washer ø60/M20 ø60/M24

4

Washer of nut E Washer ø60/20mm ø60/24mm

4

Nut B Hex nut M20/M24 4 Washer of nut B Washer M20/M24 2 Nut C Hex nut M10 2 Washer of nut C Washer ø 10,5 mm 2 Screw D Hex screw M10x25 2 Washer of screw D Washer ø 10,5 mm 2

Table 25: Part list of the illustration ”Erection of the mast”.


Erecting the mast with a crane If you use a crane to erect the mast, do not use the hinge tool. Fasten soft hoisting straps to the top frame of the mast. Lift the mast from the ground and lower down on the foundation steering the base

frame in the correct position over the foundation bolts. Tighten the nuts lightly. Connect the electrical wires, take into consideration the supplementary cable

length required by lowering and raising of the mast. Adjust the mast position and tighten the foundation bolt nuts to the torque.

Illustration 15: Erecting the mast with a crane.

When lifting the mast, 1 – 3 persons or a crane with its’ driver and 1 person are needed.

Use a water level to verify the vertical position of the mast. Use an optic device to measure the adjustment of alignment of the mast.

Check always in the mast list (and in the lay-out drawing) before erection of the mast that you have chosen the right mast for each base.

Verify before the erection that the masts have not been damaged during handling.

Recommended lifting points are the top frame, the joint element and the base frame. Never lift the mast from the diagonal beams.

Be especially careful not to let the mast base damage the anchor bolt threads during the erection.


4.7 Work instruction for alignment of approach lights

Carry out the final aligning of the approach lights when all lights of the approach light line have been fitted. Use an optic device to verify the correct position and alignment of the approach

lights. Loosen the fastening screws of the light. Move the light to the correct position and direct correctly. Tighten the fastening screws of the light.


5 USE AND MAINTENANCE OF LATTICE MAST

An Exel lattice mast is normally service- and maintenance-free. To achieve this, however, all screws and bolts which have not been locked at the assembly with liquid thread locker should be retightened to torques given on page 12 approximately three months after the assembly. A visual inspection of masts should be done once every 12 months to detect any scratches on the painting, damages on the mast’s structure and screws or bolts coming loose. ICAO Doc 9157 Aerodrome Design Manual Part 6 – Frangibility provides instructions in implementing an inspection programme of masts in accordance with these instructions to ensure the continued operation as a frangible device. The inspection process should form part of the aerodrome safety management system and should ensure that all hardware and associated structures are inspected and maintained to the highest standards of safety. For maintenance of the approach lights, the mast has to be tilted. When the mast has been assembled according to the instructions and all screw joints have been tightened to the torque given in the instruction, the structure from the base frame to the adjustment tube is rigid. By following the instructions, the mast can be tilted without the need to re-align the lights after the operation. The mast will return to the same position where it was before lowering.

5.1 Lowering and raising of lattice mast

5.1.1 Tools needed for lowering and raising the mast, tightening torque

Action Tool Size Lowering and raising of a mast shorter than 7 m

Hinge tool 641887A

Lowering and raising of a mast taller than 7 m

Hinge tool 641886

Final tightening Torque wrench M=300 Nm M20/M24 nuts of foundation bolts (nuts A and E)

1 pc fork spanner 1 pc plug spanner

S=30 mm S=36 mm

M20/M24 nuts of hinge tool (nut B) 1 pc fork spanner -:- M10 nut of hinge tool (nut C) 2 pcs

fork spanner S=17 mm

Screw of hinge tool (screw D) 1 pc -:- -:- Verification of upright position of mast Water level Adjustment of alignment of mast Optic device Adjustment of light height Allen key S=6 mm Adjustment of light height Optic device

Table 26: Tools needed for lowering and raising the mast.


Object Size Torque Nuts of foundation bolts (nuts A and E) M20 hex nut 200 Nm Nuts of foundation bolts (nuts A and E) M24 hex nut 300 Nm Nut of hinge tool (nut B) M20/24 hex nut 180 Nm Nut of hinge tool (nut C) M10 hex nut 30 Nm Screw of hinge tool (screw D) M10 hex screw 30 Nm Clamp of adjustment tube M8 hex socket

screw 13 Nm

Table 27: Torque applied when locking the mast in the upright position.

5.1.2 Work instruction for lowering and raising of lattice mast

Depending on the mast height, 1 – 3 persons are needed for lowering and raising the mast. Lowering Check that no obstacles exist in the felling area. Fix the hinge tool according to the instruction. Make sure you have fastened all

screws and nuts of the hinge tool, in order not to change the adjustments when raising the mast to the upright position.

Loosen the nuts of the foundation bolts from above the base frame while one person is supporting the mast. Do not touch the lower nuts, because that would change the mast position when it is raised back to the upright position.

Lower the mast down carefully. Raising Raise the mast with the hinge tool back to the upright position. Make sure that the upper holes of the base are placed at the point of the anchor

bolts when raising the mast. Fasten the lock nuts. Tighten the lock nuts. Remove the hinge tool.

Observe especially that the mast base does not damage the anchor bolt threads during lowering/raising of the mast.

See the previous instructions ”Work instruction for erection of lattice mast” for

more detailed instructions related to mounting of the hinge tool and erection of the mast.


5.2 Repair painting

5.2.1 Material needed for repair painting

Description Quality/colour/size Sand paper Fine, 200-400 Acetone Paper or cloth towel Two-component polyurethane paint Aviation yellow (RAL 1021 or

NCS 0580-Y05R) Brush Width app. 20-50 mm Tape Polypropylene, PP Mixing stick Wood, plastic etc. Rubber gloves

Table 28: Material needed for repair painting of lattice mast.

5.2.2 Repair painting

Clean all surfaces with sand paper. Wipe the dust off with acetone and paper/towel. Mix the paint carefully. Follow the paint manufacturer’s instructions. Brush the paint on the clean surface.

Repair paint kit is available from the mast supplier. Read the instructions of the paint manufacturer for painting conditions. Recommended temperature during painting work: minimum 18 C

Read and follow the manufacturer’s safety instructions. Wear safety glasses all the time. Use rubber gloves all the time. Wear a dust respirator filter when necessary. Assure good ventilation. Avoid skin contact. Acetone is flammable.


51100

B ComponentA Component

,

5.3 Glass fibre tube repair

5.3.1 Material needed for glass fibre tube repair

Description Quality/colour/size Sand paper Fine, 200-400 Acetone Paper or cloth towel Pre-accelerated Epoxy Vinyl Ester Resin (Component A)

Derakane 411-45/ the Dow Chemical Company

Hardener (Component B) Butanox 50/Neste Oy Syringe 20 ml Glass fibre mat reel Reel B=35-50 mm.

For example Weight 425g/m² Ward 70x320 Weft 53x272 Thickness 0,32 Weave Plain.

Two-component polyurethane paint Aviation yellow (RAL 1021 or NCS 0580-Y05R)

Brush Width app. 20-50 mm Tape Polypropylene, PP Mixing pots PE/PP-plastic, 1litre Mixing sticks Wood, plastic etc. Rubber gloves

Table 29: Material needed for glass fibre tube repair.

Glass fibre tube repair kit is available from the mast supplier. Due to the flammability of the components special packaging is required.

Be prepared for higher air freight cost than normal. Arrange the repair conditions as instructed by the resin/hardener producer. Recommended minimum temperature for repair and painting +18 C

5.3.2 Repairing the damage

Pre-treatment Remove dirt and old paint with acetone and paper. Abrade and clean the surfaces with sand paper. Wipe off the dust with acetone and paper/towel.

Mixing the components Read carefully the manufacturer’s instructions and follow them. Use a syringe and/or a scale to measure the quantities of different components. Do not mix more than 100 g at a time, you have only about 25 min to work.


Normal mixing ratio: Doing the repair Spread the mixed resin on the damaged area. Try to soak the damaged area with the resin. Wind glass fibre mat tightly around the damaged area spreading more resin over

the mat at the same time. Make sure that the mat is fully soaked, this is to obtain as much strength as possible.

Wind minimum of 2 full layers, 3-4 layers where possible. Direct the layers in 30-45˚ angle to each other.

Finish the repair by winding Polypropylene tape around the repaired area to squeeze air out and to penetrate the resin into the tube structure.

Hardening Let the resin cure in the instructed temperature for 24 hours. Surface finishing Remove the Polypropylene tape. Abrade the surface with sand paper. Paint the repaired area as instructed earlier in this manual.

The damage can be repaired as long as it is less than half of the circumference of the tube.

If the tube is fully broken, contact the representative of Exel Composites Oyj.

Read the manufacturer’s safety instructions and follow them carefully. Wear safety glasses all the time. Use rubber gloves all the time. Wear a dust respirator filter. Assure good ventilation. Avoid skin contact. Acetone is flammable.


6 ILLUSTRATIONS AND TABLES

List of illustrations Illustration 1: Exel lattice mast ..................................................................................................... 5 Illustration 2: Slab foundation and drum foundation ..................................................................... 6 Illustration 3: Principal draft of foundation, casting jig and foundation bolts of the mast. ........... 10 Illustration 4: Main dimensions of an approach light mast. ......................................................... 11 Illustration 5: Mast modules in assembly position ...................................................................... 15 Illustration 6: Joining a mast module to the joint element. .......................................................... 15 Illustration 7: Fixed base frames of 400 mm and 500 mm masts ............................................... 17 Illustration 8: Installations of the top section of the mast. ........................................................... 19 Illustration 9: Top frame, clamp and cross bar tube ................................................................... 20 Illustration 10: Installation drawing of strut arms .......................................................................... 21 Illustration 11: Mounting strut arms to a short mast ..................................................................... 22 Illustration 11: Exploded view of a clamp ..................................................................................... 23 Illustration 12: Wiring of the mast ................................................................................................. 26 Illustration 13: Fixing of hinge tool................................................................................................ 30 Illustration 14: Erecting the mast with a hinge tool. ...................................................................... 32 Illustration 15: Erecting the mast with a crane. ............................................................................ 33

Tables Table 1: Symbols .................................................................................................................. 3 Table 2: Dimensioning of the concrete slab foundation for mast heights up to 16 m. ........... 7 Table 3: Dimensioning of the concrete drum foundation for mast heights up to 16 m. ......... 7 Table 4: Essential information necessary for preparation of foundation. .............................. 8 Table 5: Equipment needed for preparation of foundation. ................................................... 9 Table 6: Explanations of the main dimensions of an approach light mast .......................... 11 Table 7: Equipment needed for connecting lattice mast modules and joint element........... 14 Table 8: Tools for connecting lattice mast modules and joint element. ............................... 14 Table 9: Tightening torque in joining mast modules. .......................................................... 14 Table 10: List of connection parts of the joint element. ......................................................... 16 Table 11: Accessories needed for mounting the base frame. ............................................... 18 Table 12: Tools needed for mounting the base frame. ......................................................... 18 Table 13: Tightening torque for base frame screws. ............................................................. 18 Table 14: Tools needed for mounting the top section of the mast. ....................................... 20 Table 15: Tightening torque applied in the installation of the top section of the mast. .......... 20 Table 16: Parts list of the installation drawing of strut arms .................................................. 21 Table 17: Parts list for installation of strut arms to a short mast ........................................... 22 Table 18: Tools needed for installation of approach lights. ................................................... 23 Table 19: Tightening torque applied in installation of approach lights................................... 23 Table 20: Part list of clamp ................................................................................................... 23 Table 21: Equipment needed for installation of cables. ........................................................ 25 Table 22: Part list of the illustration ”Wiring of mast” ............................................................ 27 Table 23: Tools needed for mounting of the mast. ............................................................... 28 Table 24: Tightening torque applied in mounting the mast ................................................... 29 Table 25: Part list of the illustration ”Erection of the mast”. .................................................. 32 Table 26: Tools needed for lowering and raising the mast. .................................................. 35 Table 27: Torque applied when locking the mast in the upright position. .............................. 36 Table 28: Material needed for repair painting of lattice mast. ............................................... 37 Table 29: Material needed for glass fibre tube repair. .......................................................... 38

LATTICE MAST WITH HINGE TOOL Revision 3.2

INSTALLATION MANUAL 2.9.2011 LIST OF APPENDICES LatticeHingeToolREV4-3.docx

Page 1 (2)

APPENDICES

Name of document .................................................... Number and revision Mast list ...................................................................................................... Adjustment of light height ............................................................... 642074 Approach light mast 500/400/5 assembly ....................................... 641001 Approach light mast 500/400/4 assembly ....................................... 641002 Approach light mast 500/400/3 assembly ....................................... 641003 Approach light mast 500/400/3 assembly ....................................... 641188 Approach light mast 500/400/2 assembly ....................................... 641004 Approach light mast 500/400/1 assembly ....................................... 641005 Joint element .................................................................................. 641000A Approach light mast 400/5 assembly .............................................. 641006 Approach light mast 400/4 assembly .............................................. 641007 Approach light mast 400/3 assembly .............................................. 641008 Approach light mast 400/3 assembly .............................................. 641187 Approach light mast 400/2 assembly .............................................. 641009 Approach light mast 400/1 assembly .............................................. 641010 Adjustment tube and clamp ............................................................ 641171 Cross bar tube ................................................................................ 641174 Strut arm pair ................................................................................. 641199 Strut arm ........................................................................................ 641198A Horizontal support of strut arm pair ................................................ 641179 Installation of strut arm pair to a short mast ................................... 641907A Angle screw .................................................................................... 641906 Cross bow Ø72 for 60º strut arm .................................................... 641908 Top frame ....................................................................................... 641183 Cross barIadjustment tube clamp ................................................... 641184 Base frame for 400 mm mast ......................................................... 641133A Base frame for 500 mm mast ......................................................... 641891A Foundation parts for 400 mm mast ................................................ 641011B Casting template for 400 mm mast ................................................ 641830B Foundation parts for 500 mm mast ................................................ 641892B Casting template for 500 mm mast ................................................ 641934 Erection hinge tool for 400 mm mast ............................................. 641887B Erection hinge tool for 500 mm mast ............................................. 641886

LATTICE MAST WITH HINGE TOOL Revision 3.2

INSTALLATION MANUAL 2.9.2011 LIST OF APPENDICES LatticeHingeToolREV4-3.docx

Page 2 (2)

Name of document .................................................... Number and revision These articles are supplied, when included in the order: Bracket for installation of flasher below HI light fitting .................... 641746H Anti-climbing guard 400 mm ........................................................... 641837A Panel 470x2500 mm ...................................................................... 641847 Profile 4x60x100 mm ...................................................................... 641848 Anti-climbing guard 500 mm ........................................................... 641849B Panel 590x2500 mm ...................................................................... 641847B Profile 4x60x100 mm ...................................................................... 641848B

frangible safety approach light masts lattice masts with hinge tool installation

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