with dedication and serving the world with … · 2018-02-06 · 6 production solution engineering...

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[email protected]

Ciğir Köyü Köy Sokak No:101 Kazan - Ankara / TURKEYTel:+90.312.814 44 76 (Pbx) • Fax:+90.312.814 44 79

www.er-san.com

TECHNOLOGY TECHNOLOGY

TECHNOLOGY

TECHNOLOGYSERVING THE WORLD

SERVING THE WORLD

SERVING THE WORLD

WITH DEDICATION AND

WITH DEDICATION AND

WITH DEDICATION AND

WITH DEDICATION AND

serving the world withdedication and

technology

engineering

06

energysector

48

manufacturing

08telecomunication sector

52

galvanizing

14

lightingsystems

54

packing

16

quality

18

HSSE

22

references &certification

23

products

26

high voltage energy transmission lines / 48substations / 49LV+MV electrical distribution networks / 50

26 / OHL towers

32 / antenna towers

38 / substation structure

42 / poles

turnkey GSM solutions / 52turnkey telecom solutions / 53

city & road lighting, floodlighting / 54

TURNKEY SOLUTIONPRODUCTION SOLUTION

TURN

KEY

tons for manufacturing

ERSAN is a steel design and construction company with its main office and factory located in Kazan, 45 km away from Ankara.

Energy and Telecommunication Sector with the annual capacity of

tons for galvanizing.

New investments are going on to increase the capacity of production parallel to the market demand.

ERSAN has emerged as a leader in steel structures design and production. With an expert design group and experienced production team, ERSAN is determined to give its customers quality products and services.

ERSAN with a target of becoming best in local and international competition aims the customer satisfaction as major.

42,00080,000

Floodlighting and Street Lighting Poles

productionsolution

briefintroduction

• engineering• manufacturing• galvanizing• packing• quality• hsse• references & certification• products - OHL towers

- antenna towers

- substation structure

- poles

Energy Transmission Line TowersTransformer Substation Steel ConstructionsGSM Antenna Towers

Radio & Television Broadcasting Towers

Monopoles

production solution6 engineering production solution 7engineering

ERSAN’s experienced, dynamic and motivated Design Group responds to customer needs with innovative engineering designs, always keeping aesthetics in mind and with the basic understanding that knowledge is universal.

For each proposal a full structural design is done first. The design is made according to national or international standards listed on the next page as desired by the clients. Specially prepared computer programs are used for the structural analysis and member designs. ERSAN engineers stay in constant contact with the client to be able to respond to customer requests quickly in case any change in design and drawings is needed due to site conditions or any other reasons.

engineering

Analysis and Design of Steel Latticed Towers Used in Transmission Lines and Communication Facilities

Analysis and Design of Single Shaft Steel Pole Tranmission Lines and Communication Facilities

Analysis and Design of Steel Latticed Towers Used in Transmission Lines and Communication Facilities

Analysis And Designs Spread Footing Foundations For Steel Lattice Towers

ANALYSIS PROGRAMS USED

TOWER

SPOLE

SAFE

SAP2000

Design of Lattice Steel Transmission Structures

Guide for Design of Steel Transmission Towers

Steel Radio Towers and Masts

Design of Steel Structures

Lattice Towers and Masts

Building Code for Steel Structures

Requirements for Design and Construction of Reinforced Concrete Structures

Structural Steelwork

Design Loads for Buildings

Specification for the Use of Structural Steel in Buildings

Code of Basic Data for the Design of Buildings-Chapter 5/2

Structural Standards for Steel Antenna Towersand Antenna Supporting Structures

ASCE 10-90

ASCE No.52

ANSI/TIA/EIA-222

BS 8100, Part B

BS 449, Part 2

DIN 18800

TS 648

TS 500

TS 498

DIN 4131

EUROCODE3

BSI CP 3

3D Drawing Program For All Steel Structures

Drawing Program For All Steel Structures

DRAWING PROGRAMS USED

BOCAD

AUTOCAD

production solution8 production solution 9manufacturingmanufacturing

ERSAN has an annual manufacturing capacity of 42.000 tons. Manufacturing mainly consist of steel angle and steel plate. Due to the demands, channels, square bars, gratings, flat bars, round bars, pipes, hollow sections, hexagon bars and beams are also produced.

Following the completion of the design work, ERSAN Manufacturing Team comes into action. To minimize errors and increase quality, ERSAN utilized the maximum of computer technology in the field. Production is mainly done by highly automated machines and CNC (Computer Numerical Control) Machines take the head for manufacturing.

FIELDS OF WORK

LATTICE STRUCTURE

a) Power Transmission Line Towersb) GSM and Broadcast Antenna Towersc) Substation Steel Construction

POLYGONAL STRUCTURE

a) Lighting and Floodlighting Polesb) Telecommunication Polesc) Power Transmission & Distribution Linesd) Advertisement and Flag poles

manufacturing


CNC Machine

Laser Cutting Machine

Laser Cutting Machine

CNC Machine

CNC Machine

production solution14 production solution 15

Pickling

Rinsing

SURFACE PREPARATION GALVANIZING INSPECTION

FluxSolution

MoltenZinc Bath

Cooling &Cleaning

galvanizinggalvanizing

Surface pre-treated items will be dipped into the galvanizing bath for the period required for specified coating thickness.

The coating thickness on articles is in accordance with EN ISO 1461 standard.

galvanizing

All steel structures are hot-dip galvanized in accordance with international galvanizing standards. The items are subjected to surface pre-treatment in the following sequence for removal of grease, oil, paint, rust and any other surface contaminants prior to galvanizing:

GALVANIZING STANDARDS | EN ISO 1461 | ASTM A123 | ASTM A153 | DIN 50976 | NF A 91-121

MaterialThickness

(mm)

t < 1,51,5 ≤ t < 33 ≤ t ≤ 6t ≥ 6

250325395305

325395505610

35455570

45557085

MinimumWeight(gr/m2)

Weight(gr/m2)

Thickness(µm)

Thickness(µm)

Average

Galvanizing Pool

production solution16 production solution 17packingpacking

packing

All handling, packing, storage and shipment of the steel work are carried out diligently and carefully to reduce the risk of damage to the zinc coated articles to a minimum.

The steel work is packed in bundles containing articles in accordance with the prepared packing list.

The parcels are bundled with polyester bands of suitable strength which are evenly distributed along the lenght of the parcels.

The galvanised items are stacked such that water and moisture can run off them and the surfaces are able to dry out.

production solution18 production solution 19qualityquality

quality

One of its prime concerns being quality, ERSAN practices an ISO-9001:2008 Quality System, ISO-14001:2004 Management System and OHSAS 18001:2007 convering the whole process from checking the material entering the factory to packing of the finished poduct during which any reported fault is immediately corrected.

Before and during working of the individual structural parts, the raw material is subjected to visual and dimensional inpection especially at the points of working or assembly to check if any deviations in dimensions or shape or other defects that can impair the structure are present. Any deviations or defects that can impair the structure are present. Any deviations or defectes observed are treated in accordance with ERSAN quality control procedures.

The fabrication is carried out in a thoroughly reliable and workmanlike way in other to assure satisfactory assembly and erection, interchangeability of similar members, accuracy of dimensions, position and alignment of holes.

The structural parts are fabricated accurately so that the tolerances given in quality plan for the maximum deviations from workshop drawings of the completed steelwork are complied with.

Angles, Equal : DIN 1028 (DINEN 10056-2)Angles, Unequal : DIN 1029 (DINEN 10056-2)Plates : EN 10029Sheets : EN 10051Channels : DIN 1026Square Bars : DIN 1014Gratings : DIN 24537Beams : DIN 1025Flat Bars : DIN 1017Round Bars : DIN 1013Pipes : DIN 2458Hollow Sections : DIN 59410Hexagon Bars : DIN 1015Beams (HE-A) : EN 10034

PRODUCT DIMENSIONAL STANDARDS

Fasteners

Washers

Spring Washers

Anchor Bolts

ISO 898/1-2 (The strength class of the bolts will be 5.8, 6.8, 8.8 or 10.9. The class 5.8 is recommended)

Structural Steel

Spring Steel

AISI 1020, 1030, 1040, 1050

The steel materials will comply with theequivalent material definitions in thefollowing table:

QUALITY STANDARDS

STANDARD

International / ISO

European / EN 10025

American / ASTM/AISI

MILD STEEL

Fe 360 B

S235-J0-JR-J2

A36

HIGH STRENGTH STEEL

Fe 510 C

S355-J0-JR-J2

A572

production solution20 production solution 21qualityquality

DIMENSIONAL STANDARDS FOR FASTENERS

DIN 7990DIN 933 (DINEN 24017)DIN 931 (DINEN 24014)DIN 961 (DINEN 28676)

BOLTS DIN 6914DIN 607DIN 960 (DINEN 28765)ASA-B-18.2.1

ASA-B-18.2.2DIN 6921

DIN 555 (DINEN 24034)DIN 934 (DINEN 24032)DIN 439-1 (DINEN 24036 - unchamfered)DIN 439-2 (DINEN 24035 - chamfered)DIN 439-2 (DINEN 28675 - fine pitch)

NUTS DIN 7967DIN 6915

DIN 7989DIN 126

WASHERS DIN 6916DIN 434

SPRING WASHERS DIN 127DIN 128

production solution22 production solution 23human safety security & environment - HSSEHSSE - human safety security & environment

HSSE - human safetysecurity & environment

Today’s world, the importance given to health and safety of work is assessed as a modernity criteria. The health and safety of work have been institutionalised in societies where have been appreciated first of all the value of humanity and the respect to the effort.

As a result of scientists have been carrying on the scientifical studies from the industrial revolution to now, the health and safety of work have become a science and have been globalised. The foundation of International Labor Organization in 1919 is a result of the globalisation of the health and safety at work.

UN-Declaration of Human Rights in 1948 declared the principle of "All individuals have the rights of working, free selecting of their job, working in the suitable conditions and the right of protection against unemployment."

The 1961 dated European Social Charter have adopted the principle of "All employers have the rights of having safe and healthy working conditions."

The health and safety at work can be defined as "These are scientific and systematic studies with the aim of protection against the conditions which may be harming on health because of the several reasons during the process of work in the working places."

The first aim of the studies of the health and safety at work is providing comfortable and safety workplaces for employers; attendantly, protecting the employers against working accidents and ilnesses by providing their physical and mental integrity.

The losses of labor force and work day will be decrease by protecting the employers; because of working accidents and illnesses; and consequently the production will be protected. The productivity will also increase with the trust of the more comfortable and safe workplace that is given to the employer.

The enterprise safety is being provided with measurements of work safety and health through preventing the machine breaks, explosions and fire because of the work accidents or dangerous and unhealthy work conditions. Historically, our country has been developped with legislation on the health and safety at work, the law no 1475 Working Law, the law no 4857 Working Law, the law no 6331 Work Safety and Work Health, Regulations, Legislations, Notices and Case Laws of Supreme Court. The legislation defines that the legal requirements and standards of work health and safety. Fulfilling the legal requirements and implementing the standards underlie the works of health and safety at work.

We have to settle the culture of work health and safety in co-operation with employee, labor and government to ensure its continuity. The health and safety of workers can be protected in this way. Our 1700 workers have been passed away in 69227 working accidents occured in our country in the year of 2011. The cases of working illnesses have also increased. Eliminating those negative statistics must be the first and urgent duty of all related parties, organizations and institutions.

Work Safety and Health Studies in Factory of Kazan, ERSAN Galvanise Energy Ind. And Trade Inc.

• The staff of health and safety unit maintain their studies with an A Class Work Safety Specialist, a work place doctor and a health officer.

• 3 of representatives have been chosen for each of 50 employers. Representatives of employers have chosen a first representative among them. Representatives of employers have been educated in order to subjects of their duties and rights.

• The work safety and health committee which is composed of the deputy of employee, health and safety staff, representatives of workers, foreman representative and staff official maintain their studies and their monthly stated meetings.

• Personal protective equipments have been determined after the risk assessment and the PPEs in conformity with standards have been given to the workers.

A) General work health and safety,

B) General health rules and principles of working hygiene,

C) Safe using of work equipments education are given to the workers in line with prepared programs by A Class Work Safety Specialist, Workplace Doctor and engineers.

• Fire, sabotage, earthquake, environmental pollution, work accident, machine damage, first-aid emergency plansa re revised and emergency teams have been programmed for emergency teams and workers.

• The risk assessment revision studies are continuing with attendance of related individuals.

• The medical examinations of the workers have been making annualy and at starting recruitment.

• The lung x-rays and hearing examinations of the workers have been making and they have been vaccinating against tetanus.

• The more of 10% of the workers have taken certificated first-aid education.

• The service vehicles and the cafeteria have been inspecting continuously with regard of the workers and equipments, and improvement works have been maintaining.

• The ways and methods of suggestion, complaint and communication on the subject of work safety and health in workplace have been determined and have announced to the workers.

• The announcement have been made in case of sudden and close danger, the workers have to quit their works and have to g oto the emergency post.

• The health and safety inspections of workers and workplace are continuing.

antenna

AfghanistanAlbaniaAlgeriaAngolaArgentinaArmeniaAzebaijanBelgiumBeninBosnia And HerzegovinaBrazilBulgariaBurkina FasoCambodiaCameroonCape VerdeChadCongoCongo, Democratic Republic OfCyprusDenmarkDjiboutiDominican RepublicEgyptEthiopiaFinlandFranceGabon

GambiaGeorgiaGermanyGhanaGreeceGuineaIndonesiaIran, Islamic Republic OfIraqIsraelItalyIvory CoastJordanKazakhstanKenyaKyrgyzstanLaosLebanonLiberiaLibyaMacedonia, Republic OfMadagascarMaltaMontenegroMoroccoMyanmarNakhichevanNepal

HolladNigerNigeriaNorwayOmanPakistanPeruQatarRwandaSenegalSierra LeoneSomaliaSpainSri LankaSudanSyria, Arab RepublicSwedenSwitzerlandTanzania, United Republic OfTogoTunisiaTurkmenistanTürkiyeUgandaUkraineUnited Arab EmiratesUzbekistanYemen

references &certification

energy

Indonesia

Laos

Dominican Republic

Türkiye

PakistanEgypt

Sudan

Cyprus

TunisiaMalta

Libya

Senegal

AlgeriaMorocco

Gambia

Sierra Leone

Liberia

GuineaIvoryCoast

Ethiopia

Tanzania

Gabon

GhanaBenin

Nigeria

NigerChad

Congo

DemocraticRepublic of Congo

Yemen

UAEQatar

Oman

Afghanistan

Turkmenistan

Kazakhstan

UzbekistanAzebaijanGeorgia

SyriaArmenia

Nakhichevan

Iraq Iran

Bulgaria

Ukraine

Italy

Holland

Norway

Germany

Angola

Argentina

Peru

Nepal

Somalia

Madagascar

Sri Lanka

Switzerland

Belgium

France

Sweden

Finland

Denmark

Djibouti

Cape Verde

CambodiaTogo

Burkina Faso

Brazil

Montenegro

Bosnia AndHerzegovina

JordanIsrael

Uganda

KenyaRwanda

Myanmar

Lebanon

KyrgyzstanAlbania

Greece

MacedoniaSpain

Cameroon

serving the world with dedication and

technology

production solution26 production solution 27OHL towers / productsproducts / OHL towers

ERSAN has supplied towers for and built under turnkey contracts many energy transmission line projects ranging from 11kV to 500kV all over the world.

products /OHL towers

154 Kv Transmission LineTower

154 Kv Transmission Line Tower





154 Kv Transmission Line Tower154 Kv Transmission Line Tower 380 Kv Transmission Line Tower




220 Kv Transmission Line Tower220 Kv Transmission LineTower



production solution32 production solution 33antenna towers / productsproducts / antenna towers

Many Television and Radio channels in Turkey are being broadcasted from towers designed, manufactured and erected by ERSAN heights of which range from 50 to 150 meters.

ERSAN has played an important role in the telecommunication boom in Turkey. This covers the design and manufacture of towers with heights ranging from 10 to 250 meters.

products /antenna towers

GSM Antenna Tower (Lattice Type)

production solution34 production solution 35

Angular Triangular Tower Three Leg Antenna Tower

(New Design)

antenna towers / productsproducts / antenna towers

Polygonal Antenna Tower

Antenna Tower

production solution36 production solution 37antenna towers / productsproducts / antenna towers

PolygonalAntennaTowerGuyed Tower

production solution38 production solution 39products / substation structureproducts / substation structure

ERSAN has an annual production capacity of 42.000 tons. Production mainly consists of angle iron and sheet metal. Due to the demands, channels, square bars, gratings, beams, flat bars, round bars, pipes, hollow sections, hexagon bars and beams are also produced.

products /substation structure

production solution40 production solution 41products / substation structureproducts / substation structure

production solution42 production solution 43poles / productspoles / products

ERSAN has also manufactured and erected many lighting poles of heights ranging from 6 to 50 meters for street and stadium lighting as well as monopoles for GSM antenna towers.

products /poles

Floodlighting Tower(With Elevator)

Floodlighting Tower (With Platform - Manual Type)

PolygonalAntenna Tower

production solution44 production solution 45poles / productspoles / products

turnkeysolution

• energy sector - high voltage energy transmission lines

- substations

- LV+MV electrical distribution networks

• telecomunication sector - turnkey GSM solutions

- turnkey telecom solutions

• lighting systems - city & road lighting, floodlighting

ERSAN has completed many turnkey projects of

Low and High Voltage Energy Transmission Lines

ERSAN as acontractor

in Turkey and abroad.Substations

Turnkey GSM SolutionsRoad and City Lighting Solutions

TURN

KEY

48 49

ERSAN has experience delivering substation projects for customers in Turkey and fully understand the requirements and demands of the power industry since 2000. This experience and the diversity of projects undertaken leaves us well experienced to deliver complex and large-scale projects. We offer our clients bespoke innovative solutions delivered safely and to their precise specifications. Services include:

• Turnkey substations from 11kV to 500kV

• Electrical design

• Civil design

• Civil engineering works

• Condition assessment of substation equipment

• Maintenance

• Procurement of high voltage electrical equipment

• Installation of high voltage electrical equipment

• Design and installation of control and protection schemes

• Design risk analysis

• Underground cabling and jointing

• Installation of multi-core cabling

• Commissioning and testing

• Construction management

• Site health and safety management

energy sector /substations

substation / energy sectorenergy sector / high voltage energy transmission lines turnkey solutionturnkey solution

energy sector /high voltage energy transmission lines

engineering design, structural solutions, supply of all necessary equipments, project management and site implementation.

Construction of transmission lines is an individual and complex business. Each project requires different national and corporate standards and specifications. These are challenges that ERSAN is fully equipped to meet with its expertise and maximum flexibility.

For this reasons, our customers choose to take advantage of the capable services and resources of ERSAN, as the following reference projects demonstrate;

50 51OHL construction referencesenergy sector / LV+MV electrical distribution networks turnkey solutionturnkey solution

energy sector /LV+MV electrical distribution networks

ERSAN can provide all the necessary supervision, tools and construction equipment to install up to 36 kV city electricity networks and primaryunderground distribution systems from the transformer to the demanded areas.

HIGH-VOLTAGETRANSMISSION

LINES

SUBSTATIONTRANSFORMER

DISTRIBUTIONTRANSFORMER

60

LOW VOLTAGEPREMISE

NETWORK

Low VoltagePower Line

Medium VoltagePower Line

Customer Premise 40

Aggregation Point 20

Backhaul Point 10

Power LineInterface Device

50

Bypass Device30

154 kV Energy Transmission Line between Camlibel-Guneskoy and Kalecik-Bafra in Cyprus

380 kV Energy Transmission Line between Erzin S/S and Toscelik S/S

154 kV Energy Transmission Line between Uzuncayir Hydroelectric Power Station and Tunceli-Elazig OHL

154 kV Energy Transmission Line between Seyrantepe Hydroelectric Power Station and Ozluce S/S

52 53turnkey solutiontelecomunication sector / turnkey telecom solutionstelecomunication sector / turnkey GSM solutionsturnkey solution

Mobile TeleSystems OJSC (MTS)-TurkmenistanSupply and erection of GSM Towers and Shelters. ERSAN serve fully site implementation for MTS in Turkmenistan. We have supplied 111 towers and we have completed 66 sites in 2009Total Contract Value: 10.000.000 $

Anel Telecommunication Systems-TurkeySupply and erection of TV Broadcasting Towers. ERSAN has supplied and erected TV Broadcasting towers on new sites in Istanbul . Total Contract Value: 2.000.000 $

Sotelco Ltd (Beeline)-CambodiaSupply and erection of GSM Towers and Shelters. ERSAN serve fully site implementation for Beeline in Cambodia. We have supplied 91 towers and we have completed 91 sites in 2009Total Contract Value: 15.000.000 $

Nortel Networks NETAS-TurkeySupply and erection of Telecommunication Towers. ERSAN has supplied and erected towers for JEMUS (New Telecommunication System for Army) project. Total Contract Value: 5.600.000 $

Motorola-TurkeySupply and erection of GSM Towers. ERSAN has supplied 750 towers and erected 92 towers until 2009Total Contract Value: 13.360.000 $

ERSAN is an international leader in the provision of telecommunication turnkey projects and end toend solutions. ERSAN serve following solutions to his customers with his huge experience and well educated stuffs;

• Complete Turnkey for Site Infrastructure,

• Site Engineering Design,

• Structural Solutions,

• Supply of Infrastructure equipments,

• Project Management,

• Field Implementation.

ERSAN can design and deliver almost any element;

• Variety of Self-Supported Towers 3 and 4 legged

• Monopole Towers and Guyed Masts

• Rooftop Solutions

• Prefabricated Shelters

• Cell-on-Wheels

• Innovative solutions;

• Slim towers - a breakthrough development by ERSAN,

• Decorative sites,

• Fast implementation sites,

• Unique solutions tailored to customer’s needs.

telecomunication sector /turnkey GSM solutions

telecomunication sector /turnkey telecom solutions

54 lighting systems / city & road lightingturnkey solution

lighting systems /city & road lighting

ERSAN has been deal with installation of lighting poles and armatures in roads, streets, parking areas, seaports, airports, stadiums and motorways etc.

with dedication and serving the world with … · 2018-02-06 · 6 production solution engineering...

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