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Process Name:

TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

Tower
Preventive
Maintenance
Manual

Prepared by Reviewed by Approved by

AHMAD ZAIRE IR. NALINI IR. NALINI


BIN MOHAMAD KUMARI KUMARI

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History Record

Date Version Item Change record Requester Approval

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Table of Contents

History Record ................................................................................................................ 2


1. Glossary ................................................................................................................. 4
2. Objective ................................................................................................................ 5
3. Roles & Responsibility............................................................................................ 6
4. Process Flow.......................................................................................................... 7
5. Procedures, Guidance and Requirement ............................................................... 9
6. Forms ................................................................................................................... 26
7. Appendix .............................................................................................................. 37

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1. Glossary

Short
Full Form
Form
BS British Standard (i.e BS8100, BS8110)
DCA Department of Civil Aviation
GBT Ground Based Tower
IBS In-Building System
ICAO International Civial Aviation Organization
NTC National Tower Company
OSHA Occupational Safety and Health Administration
PPE Personnel Protective Equipment
RTC Regional Tower Company
RTT Roof Top Tower
TIA Telecommunication Industry Association
TPM Tower Preventive Manual

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2. Objective

This TPM Manual is to be used by all employees working for or on behalf of edotco to
standardize all tower preventive maintenance practices during operational and maintenance
activities. The purpose of this TPM Manual is to:
Define TPM specification and requirements.
Lay down the basic TPM Rules to be complied by all employees and persons on
edotcos behalf.
Provide Specific TPM related practices and procedures to ensure our tower and site
are compliance with rules, regulations and standard.
Whenever there is a need for deviation from the specific guidelines outlined in this TPM
Manual, it has to be in accordance with the each countrys requirement, rules, regulations and
standard.

Based on the TIA guideline, major routine inspections shall be performed at least once in every
3 years for guyed towers and every 5 years for self-supporting towers PROVIDED that the first
thorough check of the structure should be carried out 6 months after its installation and
erection. Shorter inspection intervals of 2 years for guyed towers and three years for self-
supporting towers shall be obligatory for structures in coastal salt water environments, in
corrosive atmospheres, and in areas that are prone to vandalism. Nevertheless, basic inspection
for preventive maintenance is still be required to be carried out on annual basis.
This TPM Manual is based on TIA-222-G: Structural Standard for Antenna Supporting Structures
and Antennas, relevant design codes, edotco OSHA policy, governance and good practices.

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3. Roles & Responsibility

Accountable /
Dept/Unit/PIC Responsible / Recommend Inform
Approve
Director of
Regional Head of Asset To revise and alter the TPM All NTC Director
Engineering
Integrity (Group) Manual of Operations
(Group)
Regional Head of
Director of Engineering To review and approve the Chief Executive
Asset Integrity
(Group) TPM Manual Officer (Group)
(Group)
To plan and manage TPM to
Director of Operations All NTC NTC Country
be executed at NTC level
(NTC) Operations Teams Manager
based on TPM manual

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4. Process Flow

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5. Procedures, Guidance and Requirement

5.1 General Requirement

5.1.1 THE CODE AND THE IMPORTANCE OF MAINTENANCE EXECUTION

In order to select appropriate safety factors to be applied in design to the loadings defined in
the design code, consideration should be given to the reliability required of a tower during its
intended period of service. The factors adopted should take into account the risk to life in the
event of a collapse and the potential economic or strategic consequences of failure.

For the purposes of the design code, the design service life, is, in years, is taken as the intended
period of service of the tower. A tower designed in accordance with BS8100, if adequately
maintained, provide consistent reliability beyond the period of its design service life, that
period being used only as a basis for the economic assessment of the appropriate annual risk of
failure. It is also depend on the quality of materials and workmanship specified and achieved in
construction. In other words, the reliability of a tower depends in part on the quality of the
materials and workmanship used in its construction, and or the adequacy of the maintenance
after its erection.

For towers entirely of bolted or riveted construction of steel of up to 450 N/mm2 yield stress,
the fatigue life may be assumed to exceed 50 years.

For towers containing welded details, the fatigue life should be evaluated when either:
(a) the design life is greater than 30 years; or
(b) the tower is constructed of steel of yield stress greater than 355 N/mm2.

However, caution should be exercised in the design of all welded structures and due account
taken of the welded details adopted. For towers constructed of other metallic materials,
specialist advice should be sought with regard to fatigue life.

The Telecommunications Industry Association produced the Structural Standard for Antenna
Supporting Structures and Antennas (TIA-222-G is the current revision) which, in addition to

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TOWER PREVENTIVE MAINTENANCE MANUAL

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procedure, outlines a recommended schedule for tower inspections. This is typically every
three years for a guyed tower and five years for a self-support tower, but is recommended
annually for coastal areas that are subject to corrosive salt air and high winds. In general,
proper tower maintenance will significantly influence to maximize the lifespan of the tower.

5.1.2 LOCAL RULES AND REGULATIONS

Building a new tower or collocating an antenna on an existing structure requires compliance


with the local authoritys governing rules and regulation. This TPM Manual is to be taken as a
guideline for each country operational and engineering teams to follow. It will however subject
to each countrys legal and technical requirement.

All country managers are required to ensure that the organization they led to follow these
regulatory processes ensure that appropriate measures are taken to protect the company from
any safety, environmental and legal issues. Also, the country managers are required to take all
necessary actions and plans to ensure that all activities carried out at country level are in line
with the group policy and best practices.

5.1.3 ASSET INTEGRITY COMPLIANCE

All structures and infrastructures should be in safe operation condition including load
requirement. Any changes and new information are required to be recorded. All employees and
contractors are required to report any defect condition and not limited to unused/ malfunction
items or structures that can lead to any harm/ site injuries/ safety issues.

Prior to the installation of a tower, mast and antenna support structure on any building or roof
the Commission shall be provided with a structural engineer's certification that the structure
will support and not be adversely affected by the proposed mast, tower, antenna and
associated equipment.

5.1.4 TOWER SAFETY

Safety is a primary consideration to which all personnel including the edotco employees,
contractors, clients and others must devote their complete attention whenever they are
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climbing a tower or are in the immediate vicinity of a tower of any height. The elevation and
potential electrical hazards associated with tower inspection, maintenance, and repair require
adoption of extraordinary safety measures in order to protect the climbers from avoidable
accidents.

Towers are classified as elevated structures as defined by OSHA. All personnel engaging in
construction, maintenance, repair or inspection shall use fall protection when working on any
telecommunication structure. Safety precautions also include the use of appropriate personnel
protective equipment (PPE) to include the wearing of safety helmets, safety footwear, eye
protection, and protective clothing to protect personnel from injury while in the vicinity of a
tower. A safety helmet is required to be worn by any person within the tower drop zone, which
is an area whose radius is 1/2 the height of the tower and centered on the tower axis. In
addition, precautionary measures must be taken to protect the tower structure itself from
damage.

Any type of works including the routine inspection and maintenance work are required to be
carried out in accordance with edotco safety policy, guidelines and manual.

5.2 Routine Inspection and Assessment

5.2.1 INSPECTION FREQUENCY AND EFFORT

Inspection on a periodic basis is the most effective way to protect the towers/ structures. All
country managers should consider it their first priority, where the antenna system is concerned,
to establish a sound inspection program utilizing all of the expertise available. In this way it will
be possible to provide for the timely detection and correction of deficiencies before major
tower maintenance or repair become necessary. With early detection and correction, both
costs and off-air time will be minimized. Therefore, it is highly recommended that the annual
inspection for the preventive maintenance purposes should be carried out for each country.

Based on the TIA guideline, major routine inspections shall be performed at least once in every
3 years for guyed towers and every 5 years for self-supporting towers PROVIDED that the first
thorough check of the structure should be carried out 6 months after its installation and
erection. Shorter inspection intervals of 2 years for guyed towers and three years for self-

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Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

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Document Revision No: 00


supporting towers shall be obligatory for structures in coastal salt water environments, in
corrosive atmospheres, and in areas that are prone to vandalism.

However, because of seasonal storm cycles, antenna systems should be carefully inspected
about once per year, making allowances for local conditions, expenses involved, expertise
availability, and the magnitude of the original capital investment. The quality of an inspection is
only as good as the personnel performing the inspection. Almost complete reliance is placed
on visual inspection methods. A hurried or superficial inspection cannot produce the desired
result, regardless of the ability of the inspector. Inspectors should be guided by detailed
information contained in this Manual.

5.2.2 ANNUAL INSPECTION FOR PREVENTIVE MAINTENANCE

The following annual inspection guidelines for preventive maintenance shall be carried out
annually :

(i) Main structure


Check geometry of the structure and structural members
Check that there are no structural components missing
Check that bars are neither warped, holed nor spitted and replace all defective parts.
Check all structural components are not broken or oxidized
Check that draining holes on pipe leg members, pipe lattice parts are not blocked.

(ii) Base foundation and concrete blocks


Check general site condition (standing water, drainage, etc.) and condition of the
structural supports or plumb. There must not be any water collection, cracking or
splitting, chipped or broken concrete.
Check the condition of aboveground concrete block parts. There must not be any
stagnant water.
Check for ground settlement or movement
Check anchor-bolt and connection erosion and corrosion.
Check bolts, nuts and lock nuts for tightness
Ensure that there is no structural deterioration to concrete bases and/or anchorages
which affects structural integrity.

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(iii) Connection and bolting parts


Check that the main structure and its connections are in the right position and all bolts
are adequately tightened and neither the connecting components are missing
Check that no bolts or nuts or any bolting part like washers, pins, etc is missing. Replace
these immediately.
Check all bolts, nuts and bolting parts for corrosion.

(iv) Guy wires (for guy wired towers/structures)


Check that each cable that is part of the guy wire is neither broken nor warped
Check guy wires condition (corrosion, breaks, nicks, kinks, etc)
Check for signs of corrosion and take remedial timely steps
Check that the guy wire tightening system is properly greased.
Check for loose or missing fasteners
Ensure anchor head is clear of earth
Check base for settlement, movement or earth cracks
Check backfill heaped over concrete for water shedding

(v) Antennas and Accessories


Inspect that microwave dish, antenna, accessories and its supports are in good condition
and right direction. Check that fixing clamps are in good condition
Inspect that coaxial cables/feeders cables are in good condition.
Check the number of antenna and accessories to review the status of ownership and
tenancy for the colocation.
Please check and report if there is any unused equipment or antenna or its parts have
been left installed.

(vi) Salty environment (for the coastal salt water environment)


Wash the structure and accessories with clean water once every six months to eliminate
residue salt particles which may not be washed away by rain.
Check the condition of structural members for corrosion, erosion and coating.

(vii) Safety components


Check the climbing facilities, platforms, catwalks for safety and integrity

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Check rest and work platforms for defects, wear and tear
Ensure that anti climb door can open and close. Clean and grease all hinges.
Ensure the work platform's trap can open and close. Clean and grease all door hinges.
Check that access ladder is in good repair and condition; without any obstruction. Check
if there is enough space and it must be safe for maneuvering and movement purposes.
Check tower ladder for any signs of weakness, re-tighten all bolts
Check the functioning of the fall arrestor system. Check if the climbing system is
properly installed, maintained and in good condition.
For a fall arrestor system with cable, check that the cable has not been over tightened.
Check that the anti-climbing mechanical tool is functioning.
Check if there is any safety, emergency and hazardous signs are provided
Check all site security elements and components are existing, complete and in good
condition. (including fencing, locking system, etc). Please report if there is any damage,
malfunction or defects?
Address any safety concerns or hazards prior to proceeding especially with regards to
the access to our asset/site. No known safety hazards before service personnel are
allowed to access towers/structure.
Check if there is any unused, malfunction, faulty and defective items or structures that
can lead to any harm or site injuries or safety issues.

(viii) Lightning and Earthing system


Check that all lightning and earthing components are existing and complete including
lightning arrestor, copper strip, and connection plate.
Check the earthing connection of coaxial cables
Check the physical condition of the lightning rod and lightning arrestor
Check the physical condition and installation of the copper strip
Check the connection of the concrete block copper belting onto the copper strip the
connection of coaxial cables earthing onto the copper strip
Check the connection between the bottom coaxial cable earthing and the collection
copper bar fixed on the concrete block
Check the tightening of the brass bolts of the lightning protection electrodes

(ix) Aviation Safety Light


Check that all components are in place,

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Check condition and well-functioning of components (Light bulb, energy cables, fixing
parts, photoelectric cell, connections)
Check the functionality of controllers, flashers, alarms and photo control
Check the condition of electrical wires, connectors and earthing cables
Check the condition and fixing of energy cables
Check the condition of conduit, junction boxes, and fasteners weather tight and secure
Check bulb condition - change all bulbs at the same time immediately before the rated
service hours is achieved.
Condition and fidelity of the power supply systems

(x) Coating and anti corrosion protection


Inspect the paint condition of the structure (if applicable)
Check all galvanized members for integrity
Check for signs of rust and corrosion on the structure, of the bolts, bolting accessories,
harnesses, antenna supports, etc.
Check oxidization of the structure, bolting parts, and accessories.
For guyed masts, check for corrosion on the entire guy assembly.
For masts with guidewires, check oxidization of wires.
Check ICAO Colour marking conditions

(xi) General Site Condition


Check the condition of the site surrounding, lawn and grass growing area. Have they
been properly maintained?
Do we have any unused wires, equipments parts or waste items scattered in our
boundary/area?
Please check and report if there is any vandalism act and theft activities.
Please check and report if there is any malfunction, faulty and defective items which
have not been replaced.
Please address if there is any areas or aspects which related to the site condition which
require our attention for asset integrity, security or safety reasons.

(xii) Log Book


A Log Book shall be maintained in which all maintenance checks made will be
documented.

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The contents of the Log Book shall include: date of checks, what was checked,
observations of the check, and name and signature of the personnel that conducted the
check.
The Log Book shall be made available to the Commission or its due representative on
demand.
Failure to keep or make a Log Book available to the Commission as above shall
constitute an offence.

5.2.3 ROUTINE CONSECUTIVE INSPECTION

The routine consecutive inspection shall be carried out during the service life of the Structure
based on the table below which is showing a cycle of years required for inspection :

Self-Supporting
No Type of environment Guyed Towers / Structures
Towers / Structures
1 Normal environment 5 years 3 years
Coastal salt water environments
2 / in corrosive atmospheres / in 3 years 2 years
areas prone to vandalism

The same procedures which have already been stated in the annual inspection routine are
applied for the routine consecutive inspection but with supplementary guideline checklist. The
following guidelines are supplement to the annual preventive maintenance inspection checklist:

(i) Main structure


Execute the checklist of the annual preventive maintenance inspection.
Check tower/structures verticality with the appropriate devices such as theodolite that
the structure stands in a vertical position.
Check the member sizing of the structural members. If no information available; take
site and member sizing measurement including the main legs/structure, bracing system,
platform, support, etc. Please produce a single drawings that are showing the member
sizing and details.

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(ii) Base foundation and concrete blocks
Execute the checklist of the annual preventive maintenance inspection.
Check the grout condition.
Check the condition of anchor setting in the concrete block.
Check the size and measurement of the foundation / concrete block. If no information
available; take site and measurement to produce a single drawings that are showing the
details.

(iii) Connection and bolting parts


Execute the checklist of the annual preventive maintenance inspection.
Check the anchorage rod in the concrete.

(iv) Guy wires (for guy wired towers/structures)


Execute the checklist of the annual preventive maintenance inspection.
Check anchor rod condition below earth
Check and measure the tension of each guy wire using a strand dynamometer and
compare result with the installer's stated values.
Ensure that the structural cable tensions to be kept within manufacturer
recommendations (if applicable)

(v) Antennas and Accessories


Execute the checklist of the annual preventive maintenance inspection.
Check structural condition, azimuth and rigidity for all antennas, antenna supports and
accessories (i.e coaxial cables, RRU, etc)
Check types, numbers and installed heights of all antennas currently on the structure
and confirm that the loading does not exceed structure design load.

(vi) Salty environment (for the coastal salt water environment)


Execute the checklist of the annual preventive maintenance inspection.

(vii) Safety components


Execute the checklist of the annual preventive maintenance inspection.
Check the positioning and installation of safety components.
Test the fall arrestor system with individual equipment.

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(viii) Lightning and Earthing system
Execute the checklist of the annual preventive maintenance inspection.
Check the resistivity of the lightning protection electrodes
Measure the resistivity of the Earth and confirm conformity to expected values.

(ix) Aviation Safety Lights


Execute the checklist of the annual preventive maintenance inspection.

(x) Coating and anti corrosion protection


Execute the checklist of the annual preventive maintenance inspection.
Check if there is any requirement for re-painting for coating.
Check if there is any requirement for replacement for any structural members affected
by the severe corrosion.

(xi) General Site Condition


Execute the checklist of the annual preventive maintenance inspection.

(xii) Log Book


Execute the checklist of the annual preventive maintenance inspection.

5.2.4 POST SEVERE WEATHER CONDITION INSPECTION

Communication towers are constantly exposed to the weather, which can be severe and may
cause damage. As a regular assessment and maintenance is not only required but essential to
ensuring the structural stability of our tower/structure as well as the adequate performance of
feed lines and antennas.

TIA-222-G states that maintenance and condition assessment shall be performed, at a


minimum, once every three years for guyed towers and once every five years for self-
supporting towers. Towers used for essential communications or those that represent a high
hazard in the event of failure (Class III structures), towers in coastal regions or corrosive
environments, or towers subjected to frequent vandalism require more frequent assessment
and maintenance. Towers should also be assessed after severe seismic events, wind and/or ice
storms.

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The immediate action to carry out structural assessment to respond to any severe weather
conditions (i.e earthquake, typhoon, flood) could reduce the risk of having structural or tower
failure which could give worse impact or even towards a catastrophic failure to the structure.

The inspection checklist for the post severe weather condition shall follow the routine
consecutive inspection checklist. The following guidelines are for the supplement :

(i) Post Severe Weather Condition


Check and record any damage, broken, defect and malfunction item caused by the
severe weather condition (earthquake, typhoon, flood, etc)
Check the status and condition of the signal and transmission system. Check the azimuth
and line of sight for all active equipment.
Check condition of the structural supports, connections, base and foundation.
Prepare a complete report to state the structural condition and record the incident.

5.3 Building Structural Assessment


5.3.1 GENERAL REQUIREMENT

More than half of the total structures/towers which are belongs to Edotco built off of an
existing building. A lot of those existing buildings/structures have been constructed and used
for more than 50 years. As structures are aging, the structural assessment of buildings or
structures is becoming increasingly important; required to be carried out to analyze the current
structural capacity and reliability.

Most of the periodic structural inspections are carried out based on the following frequency:

a) Every 10 years for buildings where at least 90% of its floor area is used solely for residential
purposes; and
b) Every 5 years for all other buildings

The inspection consists of one or both of the following stages:


Stage 1: Visual inspection.
Stage 2: Full/Detailed structural investigation.
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The structural engineer who is appointed/assigned by edotco is required to carry out a


comprehensive visual inspection that relies largely on his/her professional engineering
assessment, judgement and advice. He shall exercise reasonable diligence and take active and
personal interest in the planning and carrying out of the inspection of the building; and advise if
full/detailed structural investigation is required to be carried out.

Prior to the commencement of any inspection (visual or detailed), the structural engineer is
required to obtain a set of the buildings structural layout plans. The availability of the
structural layout plan will help the structural engineer:
(a) To understand the structural system and layout of the building;
(b) To identify critical areas for inspection;
(c) To identify the allowable imposed loads, in order to assess the usage and possibility of
overloading; and
(d) To verify if unauthorized addition or alteration works that affect the structure of the
building have been carried out.

Two main principles are usually accepted when assessing existing buildings: -

I. Currently valid codes for verification of structural reliability should be applied, codes valid
in the period when the structure was designed should be used only as guidance
documents.
II. Actual (estimated) characteristics of structural materials, actions, geometric data and
structural behavior should be considered, the original design documentation including
drawings should be used as guidance documents only.

The building structural assessment guideline and form for structural audit are provided in the
Appendix for reference.

5.3.2 VISUAL INSPECTION

In general, the structural engineer is expected to carry out, with reasonable diligence, a visual
inspection of:
a) the condition of the structure of the building

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to identify the types of structural defects
to identify any signs of structural distress and deformation
to identify any signs of material deterioration

b) the loading on the structure of the building


to identify any deviation from intended use, misuse and abuse which can result in
overloading

c) any addition or alteration works affecting the structure of the building


to identify any addition or alteration works which can result in overloading or adverse
effects on the structure.

If there are no signs of any structural deterioration or defects, the visual inspection should
suffice and unless the structural engineer otherwise advises, no further action needs to be
taken. If, on the other hand, signs of significant structural deterioration or defects are present,
the structural engineer should make a professional assessment of the deterioration or defect
and recommend appropriate actions to be taken. Such actions may involve repair works or full
structural investigation to parts or whole of the building.

There could be some difficulties in the conduct of a visual inspection as some of the main
structural elements in a building may have been covered up by architectural finishes. It is
therefore important that professional judgement is exercised by the structural engineer to
determine which areas that are covered up should be exposed for inspection. Reference to
structural layout plans to determine the presence of critical structural elements would be
crucial under such circumstances.

5.3.3 DETAILED STRUCTURAL INVESTIGATION

On the recommendation of the structural engineer who carries out the visual inspection, each
NTCs Head/country manager may grant approval for a full structural investigation to be carried
out. If the structural deficiencies are of a localised nature, the structural engineer may
recommend a full structural investigation for that area in the first instance.

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The scope and extent of the investigation should be clearly defined and subject to the approval
of each NTCs Head/country manager. The outcome of this investigation may lead to a full
structural investigation for the whole building.

The scope of the full structural investigation includes the following:


(a) obtaining information relating to the design, construction, maintenance and history of the
building;
(b) assessing the structural adequacy of the building by checking the structural plans and
calculations and reconstructing the structural plans if they are not available;
(c) carrying out tests on the materials used and structural elements of the building;
(d) carrying out load test on parts of the building if necessary;
(e) recommending appropriate safety precautionary and remedial measures to restore the
structural stability and integrity of the building structure.

5.4 Tower Maintenance

5.4.1 PRECAUTIONARY AWARENESS FOR MAINTENANCE

When carrying out first line of maintenance, due awareness shall always be taken of the
following factors:
(i) The worst case scenario of a total structural or mechanical failure is assumed in tower
design.
(ii) A failure can be caused by stress, extreme overload, use of defective and poor quality
materials, fatigue, corrosion, poor workmanship, insufficient maintenance, sabotage, as well as
any combination of these factors.
(iii) Every design must attempt to foresee all possible combinations of these that can occur in
the installation environment and incorporate protective answers to them in the design.

5.4.2 KEY ELEMENT FOR TOWER MAINTENANCE

In the maintenance of towers, attention shall be given to the following key elements:

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(i) Towers require regular maintenance for purposes of early detection of deterioration and as a
mandatory measure to prevent breakdowns and the attendant consequences.
(ii) Regular maintenance is especially important for the purposes of public safety, network
availability, environmental aesthetics and life time quality of the structures.
(iii) Maintenance and inspection of steel towers and antenna supporting structures should be
performed by the owner on a routine basis.
(iv) Ground and aerial procedures should be performed only by authorized personnel,
experienced in climbing and tower adjustments.
(vii) All structures shall be inspected after severe winds conditions like tempest, hurricane,
typhoon, and after the installation of an additional load like antennas on the structure loading
conditions.
(viii) A maintenance log book should be prepared for every site/tower. The log shall be readily
accessible to inspectors from the commission or any duly authorized person and shall contain
the following information:
a. Installation Date
b. Inspection due dates
c. Painting due dates
d. Minor Maintenance due dates
e. Major Maintenance due dates
f. Name and address of Inspector
(ix) For each of the due dates, the log should show that the inspection or the maintenance was
carried out and by whom.

5.4.3 REPAIR AND MODIFICATION


While an adequate tower maintenance program will lengthen useful tower life, it cannot be
expected to entirely eliminate the eventual requirement for repair or replacement due to
damage, premature failures, or normal wear.

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Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

4.3.1. Replacement Materials

Materials and equipment used for repairs or replacements will be of the same size and type as
used in the original design. Higher quality replacement materials which would provide longer
life may be substituted for the original materials provided there is long-term economic
justification.

4.3.2. Timely Corrective Repairs

The maintenance program should not only be concerned with maintenance and repair of
superficial failures or damage, but with the timely correction of the basic cause of failure. Some
damage may be due to normal wear and weathering, but many failures may be traced to other
causes. Correction of these underlying causes will be justified by decreased maintenance as
well as improved tower longevity and safety.

A. Causes of Failure
Premature failures of tower structural components, materials, and other parts may be caused
by one or more of the following:

(1) Lack of proper maintenance.


(2) Defective materials or parts.
(3) Incorrect installation or application.
(4) Failure of related, connected, or adjacent components.
(5) Unusual or extreme climatic conditions exceeding design considerations.
(6) Faulty design.
(7) Damage done during construction or maintenance activities.

B. Investigation and Reporting of Failures


Component failures should be carefully investigated and the basic defects corrected before
superficial repairs are accomplished. Prompt reporting of failures to higher command authority

Page 24 of 39
Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00


should immediately follow detection so that preventive measures can be taken on similar
towers. Major component failures should be reported to related Director of
Engineering/Operations at country (NTC) and group (RTC) level with a detailed description of
the circumstances and conclusions as to the cause of the failure.

C. Technical Assistance
Unless the cause of a particular failure is immediately detectable and corrective measures are
not complicated, a higher command level should be consulted for advice on corrective action.

D. Tower Design's Instructions


In the case of some specific materials and equipment, the tower erection and maintenance
manual and/or original drawings may provide sufficient information for corrective measures.

e. External Tower Design Consultants


In vital structural matters or in complex circumstances, consultation with qualified tower design
engineers may be necessary. If still available, the tower manufacturer is normally a good source
of information on design queries.

4.3.3 Modifications
Any tower modification should be evaluated by a structural engineer with specific knowledge in
tower design and construction. Additions of any antennas or appurtenances, beyond those
contemplated in the original tower design, must be evaluated by a structural engineer. The
source of information from the tower manufacturer should be kept available at all times.
Proposed tower modifications such as communication dishes, antennas, or a change to the
structural components must consider the types and compatibility of materials. Modifications
which will not economically extend tower life or reduce the maintenance effort should be
avoided.

Page 25 of 39
Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

6. Forms
THE CHECKLIST FOR ANNUAL INSPECTION FOR TOWER PREVENTIVE MAINTENANCE
PHOTO
SECT NO. DESCRIPTION REMARKS ( )

1 Check geometry of the structure and structural members

2 Check that there are no structural components missing


STRUCTURAL

Check that bars are neither warped, holed nor spitted and replace all
3
defective parts.

4 Check all structural components are not broken or oxidized

Check that draining holes on pipe leg members, pipe lattice parts are
5
not blocked.
Check general site condition (standing water, drainage, etc.) and
1 condition of the structural supports or plumb. There must not be any
BASE FOUNDATION & CONCRETE

water collection, cracking or splitting, chipped or broken concrete.


Check the condition of aboveground concrete block parts. There must
2
not be any stagnant water.
BLOCKS

3 Check for ground settlement or movement

4 Check anchor-bolt and connection erosion and corrosion.

5 Check bolts, nuts and lock nuts for tightness


Ensure that there is no structural deterioration to concrete bases and/or
6
anchorages which affects structural integrity.
Check that the main structure and its connections are in the right
1 position and all bolts are adequately tightened and neither the
CONNECTIONS

connecting components are missing


Check that no bolts or nuts or any bolting part like washers, pins, etc is
2
missing. Replace these immediately.

3 Check all bolts, nuts and bolting parts for corrosion.

Check that each cable that is part of the guy wire is neither broken nor
1
warped
GUY WIRES (FOR GUY WIRED TOWERS)

2 Check guy wires condition (corrosion, breaks, nicks, kinks, etc)

3 Check for signs of corrosion and take remedial timely steps

4 Check that the guy wire tightening system is properly greased.

5 Check for loose or missing fasteners

6 Ensure anchor head is clear of earth

7 Check base for settlement, movement or earth cracks

8 Check backfill heaped over concrete for water shedding

Inspect that microwave dish, antenna, accessories and its supports are
ANTENNA & ACCESSORIES

1 in good condition and right direction. Check that fixing clamps are in
good condition

2 Inspect that coaxial cables/feeders cables are in good condition.

Check the number of antenna and accessories to review the status of


3
ownership and tenancy for the colocation.
Please check and report if there is any unused equipment or antenna or
4
its parts have been left installed.
Wash the structure and accessories with clean water once every six
SALTY ENV.

1 months to eliminate residue salt particles which may not be washed


away by rain.
Check the condition of structural members for corrosion, erosion and
2
coating.
NOTE : PLEASE USE ADDITIONAL SHEETS OF PAPERS IF REQUIRED. THE CHECKER/S IS RECOMMENDED TO TAKE PHOTOS AS THEIR
SUPPORTING DOCUMENTS FOR THEIR RESULT FINDINGS/REPORTS.

Page 26 of 39
Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

THE CHECKLIST FOR ANNUAL INSPECTION FOR TOWER PREVENTIVE MAINTENANCE


PHOTO
SECT NO. DESCRIPTION REMARKS ()
1 Check the climbing facilities, platforms, catwalks for safety and integrity

2 Check rest and work platforms for defects, wear and tear
Ensure that anti climb door can open and close. Clean and grease all
3
hinges.
Ensure the work platform's trap can open and close. Clean and grease all
4
door hinges.
Check that access ladder is in good repair and condition; without any
obstruction. Check if there is enough space and it must be safe for
5
maneuvering and movement purposes. Check tower ladder for any signs
SAFETY COMPONENTS

of weakness, re-tighten all bolts


Check the functioning of the fall arrestor system. Check if the climbing
6
system is properly installed, maintained and in good condition.
For a fall arrestor system with cable, check that the cable has not been
7
over tightened.
8 Check that the anti-climbing mechanical tool is functioning.
Check if there is any safety, emergency and hazardous signs are
9
provided
Check all site security elements and components are existing, complete
10 and in good condition. (including fencing, locking system, etc). Please
report if there is any damage, malfunction or defects?
Address any safety concerns or hazards prior to proceeding especially
11 with regards to the access to our asset/site. No known safety hazards
before service personnel are allowed to access towers/structure.
Check if there is any unused, malfunction, faulty and defective items or
12
structures that can lead to any harm or site injuries or safety issues.

Check that all lightning and earthing components are existing and
1
complete including lightning arrestor, copper strip, and connection plate.
LIGHTNING AND EARTHING SYSTEM

2 Check the earthing connection of coaxial cables

3 Check the physical condition of the lightning rod and lightning arrestor

4 Check the physical condition and installation of the copper strip


Check the connection of the concrete block copper belting onto the
5 copper strip the connection of coaxial cables earthing onto the copper
strip
Check the connection between the bottom coaxial cable earthing and the
6
collection copper bar fixed on the concrete block
Check the tightening of the brass bolts of the lightning protection
7
electrodes
1 Check that all components are in place
Check condition and well-functioning of components (Light bulb, energy
2
cables, fixing parts, photoelectric cell, connections)
AVIATION SAFETY LIGHT

3 Check the functionality of controllers, flashers, alarms and photo control

4 Check the condition of electrical wires, connectors and earthing cables

5 Check the condition and fixing of energy cables


Check the condition of conduit, junction boxes, and fasteners weather
6
tight and secure
Check bulb condition - change all bulbs at the same time immediately
7
before the rated service hours is achieved.
8 Condition and fidelity of the power supply systems

NOTE : PLEASE USE ADDITIONAL SHEETS OF PAPERS IF REQUIRED. THE CHECKER/S IS RECOMMENDED TO TAKE PHOTOS AS THEIR
SUPPORTING DOCUMENTS FOR THEIR RESULT FINDINGS/REPORTS.

Page 27 of 39
Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

THE CHECKLIST FOR ANNUAL INSPECTION FOR TOWER PREVENTIVE MAINTENANCE


PHOTO
SECT NO. DESCRIPTION REMARKS ()
1 Inspect the paint condition of the structure (if applicable)
COATING AND ANTI CORROSION

2 Check all galvanized members for integrity


Check for signs of rust and corrosion on the structure, of the bolts,
3
PROTECTION

bolting accessories, harnesses, antenna supports, etc.


4 Check oxidization of the structure, bolting parts, and accessories.

5 For guyed masts, check for corrosion on the entire guy assembly.

6 For masts with guidewires, check oxidization of wires.

7 Check ICAO Colour marking conditions


Check the condition of the site surrounding, lawn and grass growing
1
area. Have they been properly maintained?
GENERAL SITE CONDITION

Do we have any unused wires, equipments parts or waste items


2
scattered in our boundary/area?
3 Please check and report if there is any vandalism act and theft activities.
Please check and report if there is any malfunction, faulty and defective
4
items which have not been replaced.
Please address if there is any areas or aspects which related to the site
5 condition which require our attention for asset integrity, security or
safety reasons.

1 A Log Book is available


LOG BOOK

The contents of the Log Book shall include: date of checks, what was
2 checked, observations of the check, and name and signature of the
personnel that conducted the check.
NOTE : PLEASE USE ADDITIONAL SHEETS OF PAPERS IF REQUIRED. THE CHECKER/S IS RECOMMENDED TO TAKE PHOTOS AS THEIR
SUPPORTING DOCUMENTS FOR THEIR RESULT FINDINGS/REPORTS.

Page 28 of 39
Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

THE CHECKLIST FOR ROUTINE INSPECTION FOR TOWER PREVENTIVE MAINTENANCE


PHOTO
SECT NO. DESCRIPTION REMARKS ( )

1 Check geometry of the structure and structural members


2 Check that there are no structural components missing
3 Check that bars are neither warped, holed nor spitted and replace all defective parts.
STRUCTURAL

4 Check all structural components are not broken or oxidized


5 Check that draining holes on pipe leg members, pipe lattice parts are not blocked.
Check tower/structures verticality with the appropriate devices such as theodolite
6
that the structure stands in a vertical position.
Check the member sizing of the structural members. If no information available; take
7 site and member sizing measurement including the main legs/structure, bracing
system, platform, support, etc. Please produce a single drawings that are showing the
Check general site condition (standing water, drainage, etc.) and condition of the
1 structural supports or plumb. There must not be any water collection, cracking or
BASE FOUNDATION & CONCRETE BLOCKS

splitting, chipped or broken concrete.


Check the condition of aboveground concrete block parts. There must not be any
2
stagnant water.
3 Check for ground settlement or movement
4 Check anchor-bolt and connection erosion and corrosion.
5 Check bolts, nuts and lock nuts for tightness
Ensure that there is no structural deterioration to concrete bases and/or anchorages
6
which affects structural integrity.
7 Check the grout condition
8 Check the condition of anchor setting in the concrete block.
Check the size and measurement of the foundation / concrete block. If no information
9 available; take site and measurement to produce a single drawings that are showing
the details.
Check that the main structure and its connections are in the right position and all
1
CONNECTIONS

bolts are adequately tightened and neither the connecting components are missing
Check that no bolts or nuts or any bolting part like washers, pins, etc is missing.
2
Replace these immediately.
3 Check all bolts, nuts and bolting parts for corrosion.
4 Check the anchorage rod in the concrete.
1 Check that each cable that is part of the guy wire is neither broken nor warped
2 Check guy wires condition (corrosion, breaks, nicks, kinks, etc)
3 Check for signs of corrosion and take remedial timely steps
(FOR GUY WIRED TOWERS)

4 Check that the guy wire tightening system is properly greased.


5 Check for loose or missing fasteners
GUY WIRES

6 Ensure anchor head is clear of earth


7 Check base for settlement, movement or earth cracks
8 Check backfill heaped over concrete for water shedding
9 Check anchor rod condition below earth
Check and measure the tension of each guy wire using a strand dynamometer and compare
10
result with the installer's stated values.
Ensure that the structural cable tensions to be kept within manufacturer recommendations
11
(if applicable)
Inspect that microwave dish, antenna, accessories and its supports are in good
1
condition and right direction. Check that fixing clamps are in good condition
ANTENNA & ACCESSORIES

2 Inspect that coaxial cables/feeders cables are in good condition.


Check the number of antenna and accessories to review the status of ownership and
3
tenancy for the colocation.
Please check and report if there is any unused equipment or antenna or its parts have
4
been left installed.
Check structural condition, azimuth and rigidity for all antennas, antenna supports and
5
accessories (i.e coaxial cables, RRU, etc)
Check types, numbers and installed heights of all antennas currently on the structure and
6
confirm that the loading does not exceed structure design load.
Wash the structure and accessories with clean water once every six months to
1
SALTY
ENV.

eliminate residue salt particles which may not be washed away by rain.
2 Check the condition of structural members for corrosion, erosion and coating.

NOTE : PLEASE USE ADDITIONAL SHEETS OF PAPERS IF REQUIRED. THE CHECKER/S IS RECOMMENDED TO TAKE PHOTOS AS THEIR
SUPPORTING DOCUMENTS FOR THEIR RESULT FINDINGS/REPORTS.

Page 29 of 39
Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

THE CHECKLIST FOR ROUTINE INSPECTION FOR TOWER PREVENTIVE MAINTENANCE


PHOTO
SECT NO. DESCRIPTION REMARKS ( )

1 Check the climbing facilities, platforms, catwalks for safety and integrity

2 Check rest and work platforms for defects, wear and tear

3 Ensure that anti climb door can open and close. Clean and grease all hinges.

Ensure the work platform's trap can open and close. Clean and grease all door
4
hinges.
Check that access ladder is in good repair and condition; without any
obstruction. Check if there is enough space and it must be safe for
5
maneuvering and movement purposes. Check tower ladder for any signs of
weakness, re-tighten all bolts
Check the functioning of the fall arrestor system. Check if the climbing system
SAFETY COMPONENTS

6
is properly installed, maintained and in good condition.
For a fall arrestor system with cable, check that the cable has not been over
7
tightened.
8 Check that the anti-climbing mechanical tool is functioning.

9 Check if there is any safety, emergency and hazardous signs are provided

Check all site security elements and components are existing, complete and in
10 good condition. (including fencing, locking system, etc). Please report if there
is any damage, malfunction or defects?
Address any safety concerns or hazards prior to proceeding especially with
11 regards to the access to our asset/site. No known safety hazards before
service personnel are allowed to access towers/structure.
Check if there is any unused, malfunction, faulty and defective items or
12
structures that can lead to any harm or site injuries or safety issues.
13 Check the positioning and installation of safety components.

14 Test the fall arrestor system with individual equipment.

Check that all lightning and earthing components are existing and complete
1
including lightning arrestor, copper strip, and connection plate.
LIGHTNING AND EARTHING SYSTEM

2 Check the earthing connection of coaxial cables

3 Check the physical condition of the lightning rod and lightning arrestor

4 Check the physical condition and installation of the copper strip


Check the connection of the concrete block copper belting onto the copper
5
strip the connection of coaxial cables earthing onto the copper strip
Check the connection between the bottom coaxial cable earthing and the
6
collection copper bar fixed on the concrete block
7 Check the tightening of the brass bolts of the lightning protection electrodes

8 Check the resistivity of the lightning protection electrodes


Measure the resistivity of the Earth and confirm conformity to expected
9
values.
1 Check that all components are in place
Check condition and well-functioning of components (Light bulb, energy
2
cables, fixing parts, photoelectric cell, connections)
AVIATION SAFETY LIGHT

3 Check the functionality of controllers, flashers, alarms and photo control

4 Check the condition of electrical wires, connectors and earthing cables

5 Check the condition and fixing of energy cables


Check the condition of conduit, junction boxes, and fasteners weather tight
6
and secure
Check bulb condition - change all bulbs at the same time immediately before
7
the rated service hours is achieved.
8 Condition and fidelity of the power supply systems

NOTE : PLEASE USE ADDITIONAL SHEETS OF PAPERS IF REQUIRED. THE CHECKER/S IS RECOMMENDED TO TAKE PHOTOS AS THEIR
SUPPORTING DOCUMENTS FOR THEIR RESULT FINDINGS/REPORTS.

Page 30 of 39
Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

THE CHECKLIST FOR ROUTINE INSPECTION FOR TOWER PREVENTIVE MAINTENANCE


PHOTO
SECT NO. DESCRIPTION REMARKS ()
1 Inspect the paint condition of the structure (if applicable)
COATING AND ANTI CORROSION PROTECTION

2 Check all galvanized members for integrity


Check for signs of rust and corrosion on the structure, of the bolts, bolting
3
accessories, harnesses, antenna supports, etc.
4 Check oxidization of the structure, bolting parts, and accessories.

5 For guyed masts, check for corrosion on the entire guy assembly.

6 For masts with guidewires, check oxidization of wires.

7 Check ICAO Colour marking conditions

8 Check if there is any requirement for re-painting for coating.


Check if there is any requirement for replacement for any structural members
9
affected by the severe corrosion.
Check the condition of the site surrounding, lawn and grass growing area.
1
Have they been properly maintained?
GENERAL SITE CONDITION

Do we have any unused wires, equipments parts or waste items scattered in


2
our boundary/area?
3 Please check and report if there is any vandalism act and theft activities.
Please check and report if there is any malfunction, faulty and defective items
4
which have not been replaced.
Please address if there is any areas or aspects which related to the site
5 condition which require our attention for asset integrity, security or safety
reasons.

1 A Log Book is available


LOG BOOK

The contents of the Log Book shall include: date of checks, what was checked,
2 observations of the check, and name and signature of the personnel that
conducted the check.
NOTE : PLEASE USE ADDITIONAL SHEETS OF PAPERS IF REQUIRED. THE CHECKER/S IS RECOMMENDED TO TAKE PHOTOS AS THEIR
SUPPORTING DOCUMENTS FOR THEIR RESULT FINDINGS/REPORTS.

Page 31 of 39
Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

THE CHECKLIST FOR POST SEVERE WEATHER FOR TOWER PREVENTIVE MAINTENANCE
PHOTO
SECT NO. DESCRIPTION REMARKS ( )

1 Check geometry of the structure and structural members


2 Check that there are no structural components missing
3 Check that bars are neither warped, holed nor spitted and replace all defective parts.
STRUCTURAL

4 Check all structural components are not broken or oxidized


5 Check that draining holes on pipe leg members, pipe lattice parts are not blocked.
Check tower/structures verticality with the appropriate devices such as theodolite
6
that the structure stands in a vertical position.
Check the member sizing of the structural members. If no information available; take
7 site and member sizing measurement including the main legs/structure, bracing
system, platform, support, etc. Please produce a single drawings that are showing the
Check general site condition (standing water, drainage, etc.) and condition of the
1 structural supports or plumb. There must not be any water collection, cracking or
BASE FOUNDATION & CONCRETE BLOCKS

splitting, chipped or broken concrete.


Check the condition of aboveground concrete block parts. There must not be any
2
stagnant water.
3 Check for ground settlement or movement
4 Check anchor-bolt and connection erosion and corrosion.
5 Check bolts, nuts and lock nuts for tightness
Ensure that there is no structural deterioration to concrete bases and/or anchorages
6
which affects structural integrity.
7 Check the grout condition
8 Check the condition of anchor setting in the concrete block.
Check the size and measurement of the foundation / concrete block. If no information
9 available; take site and measurement to produce a single drawings that are showing
the details.
Check that the main structure and its connections are in the right position and all
1
CONNECTIONS

bolts are adequately tightened and neither the connecting components are missing
Check that no bolts or nuts or any bolting part like washers, pins, etc is missing.
2
Replace these immediately.
3 Check all bolts, nuts and bolting parts for corrosion.
4 Check the anchorage rod in the concrete.
1 Check that each cable that is part of the guy wire is neither broken nor warped
2 Check guy wires condition (corrosion, breaks, nicks, kinks, etc)
3 Check for signs of corrosion and take remedial timely steps
(FOR GUY WIRED TOWERS)

4 Check that the guy wire tightening system is properly greased.


5 Check for loose or missing fasteners
GUY WIRES

6 Ensure anchor head is clear of earth


7 Check base for settlement, movement or earth cracks
8 Check backfill heaped over concrete for water shedding
9 Check anchor rod condition below earth
Check and measure the tension of each guy wire using a strand dynamometer and
10
compare result with the installer's stated values.
Ensure that the structural cable tensions to be kept within manufacturer
11
recommendations (if applicable)
Inspect that microwave dish, antenna, accessories and its supports are in good
1
condition and right direction. Check that fixing clamps are in good condition
ANTENNA & ACCESSORIES

2 Inspect that coaxial cables/feeders cables are in good condition.


Check the number of antenna and accessories to review the status of ownership and
3
tenancy for the colocation.
Please check and report if there is any unused equipment or antenna or its parts have
4
been left installed.
Check structural condition, azimuth and rigidity for all antennas, antenna supports
5
and accessories (i.e coaxial cables, RRU, etc)
Check types, numbers and installed heights of all antennas currently on the structure
6
and confirm that the loading does not exceed structure design load.
Wash the structure and accessories with clean water once every six months to
1
SALTY
ENV.

eliminate residue salt particles which may not be washed away by rain.
2 Check the condition of structural members for corrosion, erosion and coating.

NOTE : PLEASE USE ADDITIONAL SHEETS OF PAPERS IF REQUIRED. THE CHECKER/S IS RECOMMENDED TO TAKE PHOTOS AS THEIR
SUPPORTING DOCUMENTS FOR THEIR RESULT FINDINGS/REPORTS.

Page 32 of 39
Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

THE CHECKLIST FOR POST SEVERE WEATHER FOR TOWER PREVENTIVE MAINTENANCE
PHOTO
SECT NO. DESCRIPTION REMARKS ( )
1 Check the climbing facilities, platforms, catwalks for safety and integrity

2 Check rest and work platforms for defects, wear and tear

3 Ensure that anti climb door can open and close. Clean and grease all hinges.

Ensure the work platform's trap can open and close. Clean and grease all door
4
hinges.
Check that access ladder is in good repair and condition; without any
obstruction. Check if there is enough space and it must be safe for
5
maneuvering and movement purposes. Check tower ladder for any signs of
weakness, re-tighten all bolts
Check the functioning of the fall arrestor system. Check if the climbing system
SAFETY COMPONENTS

6
is properly installed, maintained and in good condition.
For a fall arrestor system with cable, check that the cable has not been over
7
tightened.
8 Check that the anti-climbing mechanical tool is functioning.

9 Check if there is any safety, emergency and hazardous signs are provided

Check all site security elements and components are existing, complete and in
10 good condition. (including fencing, locking system, etc). Please report if there
is any damage, malfunction or defects?
Address any safety concerns or hazards prior to proceeding especially with
11 regards to the access to our asset/site. No known safety hazards before
service personnel are allowed to access towers/structure.
Check if there is any unused, malfunction, faulty and defective items or
12
structures that can lead to any harm or site injuries or safety issues.
13 Check the positioning and installation of safety components.

14 Test the fall arrestor system with individual equipment.

Check that all lightning and earthing components are existing and complete
1
including lightning arrestor, copper strip, and connection plate.
LIGHTNING AND EARTHING SYSTEM

2 Check the earthing connection of coaxial cables

3 Check the physical condition of the lightning rod and lightning arrestor

4 Check the physical condition and installation of the copper strip


Check the connection of the concrete block copper belting onto the copper
5
strip the connection of coaxial cables earthing onto the copper strip
Check the connection between the bottom coaxial cable earthing and the
6
collection copper bar fixed on the concrete block
7 Check the tightening of the brass bolts of the lightning protection electrodes

8 Check the resistivity of the lightning protection electrodes


Measure the resistivity of the Earth and confirm conformity to expected
9
values.
1 Check that all components are in place
Check condition and well-functioning of components (Light bulb, energy
2
cables, fixing parts, photoelectric cell, connections)
AVIATION SAFETY LIGHT

3 Check the functionality of controllers, flashers, alarms and photo control

4 Check the condition of electrical wires, connectors and earthing cables

5 Check the condition and fixing of energy cables


Check the condition of conduit, junction boxes, and fasteners weather tight
6
and secure
Check bulb condition - change all bulbs at the same time immediately before
7
the rated service hours is achieved.
8 Condition and fidelity of the power supply systems

NOTE : PLEASE USE ADDITIONAL SHEETS OF PAPERS IF REQUIRED. THE CHECKER/S IS RECOMMENDED TO TAKE PHOTOS AS THEIR
SUPPORTING DOCUMENTS FOR THEIR RESULT FINDINGS/REPORTS.

Page 33 of 39
Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

THE CHECKLIST FOR POST SEVERE WEATHER FOR TOWER PREVENTIVE MAINTENANCE
PHOTO
SECT NO. DESCRIPTION REMARKS ()
1 Inspect the paint condition of the structure (if applicable)
COATING AND ANTI CORROSION PROTECTION

2 Check all galvanized members for integrity


Check for signs of rust and corrosion on the structure, of the bolts, bolting
3
accessories, harnesses, antenna supports, etc.
4 Check oxidization of the structure, bolting parts, and accessories.

5 For guyed masts, check for corrosion on the entire guy assembly.

6 For masts with guidewires, check oxidization of wires.

7 Check ICAO Colour marking conditions

8 Check if there is any requirement for re-painting for coating.


Check if there is any requirement for replacement for any structural members
9
affected by the severe corrosion.
Check the condition of the site surrounding, lawn and grass growing area.
1
Have they been properly maintained?
GENERAL SITE CONDITION

Do we have any unused wires, equipments parts or waste items scattered in


2
our boundary/area?
3 Please check and report if there is any vandalism act and theft activities.
Please check and report if there is any malfunction, faulty and defective items
4
which have not been replaced.
Please address if there is any areas or aspects which related to the site
5 condition which require our attention for asset integrity, security or safety
reasons.

1 A Log Book is available


LOG BOOK

The contents of the Log Book shall include: date of checks, what was checked,
2 observations of the check, and name and signature of the personnel that
conducted the check.
Check and record any damage, broken, defect and malfunction item caused by
POST SEVERE WEATHER

1
the severe weather condition (earthquake, typhoon, flood, etc)
Check the status and condition of the signal and transmission system. Check
2
the azimuth and line of sight for all active equipment.
3 Check condition of the structural supports, connections, base and foundation.
Prepare a complete report to state the structural condition and record the
4
incident.
NOTE : PLEASE USE ADDITIONAL SHEETS OF PAPERS IF REQUIRED. THE CHECKER/S IS RECOMMENDED TO TAKE PHOTOS AS THEIR
SUPPORTING DOCUMENTS FOR THEIR RESULT FINDINGS/REPORTS.

Page 34 of 39
Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

BUILDING STRUCTURAL ASSESSMENT GUIDELINES

ELEMENT No. Description Remarks / Comments Photo

1 Name and address of the building.

2 Height of the building. How many storey and building dimensions.

What is the altitude of the location? What is the building surrounding


3 landscape/condition? Is there any building/construction next to the existing
structure?
GENERAL

Is there any historical data including construction related info, calculations,


drawings and reports for super and substructure? This shall include any
4
maintenance, modification, alteration, repairs, renovation and
refurbishment works

Any relevant information and details with regards to soil condition and
5
investigation.

Type of Structure (concrete/steel framed structure, etc). What is the use of


1
the building?

Check if there is any initial drawings provided


(architectural/construction/as-built drawing). If no, please provide
2
drawings/sketches for floor plan and specify the functional type of
STRUCTURAL DETAILS

occupancy/ies for room/space.

Please specify/provide the structural arrangement/layout that shall include


3
the column, slab and beam position.
Please specify if there any bracing system information available either via
4
data collection or observation.

Please provide the structural description of tower on the existing building


5 including the location, height of the tower, position, base support, type of
tower structure and any relevant details.

Visually inspect overall condition of the building/structure noting any


1 potential problems especially for any circumstances which will affect
structural integrity or lead to a structural failure or collapse.
STRUCTURAL SURVEY/INVESTIGATIONS

Check if there is any presence of structure immersed in water (eg. ground


floor water tank,sea water, lakes, etc) or aggressive chemical which may
2
accelerate the deterioration of structural elements, particularly in industrial
buildings. There must not be any stagnant water.

Check and observe if there is any sign of structural deterioration, defection


3 or failure (including cracks, excessive deflection, structural deformation,
connection failure, instability, corrosion of steel. etc)

4 Check and observe if there is any sign of settlement (floor or foundation).

Survey of retaining walls and slope protection structures if any - Evidence


5 of wall movement, inadequate surface drainage, unintended
imposed loading behind wall, tension cracks, etc.

NOTE : PLEASE USE ADDITIONAL SHEETS OF PAPERS IF REQUIRED. THE CHECKER/S IS RECOMMENDED TO TAKE PHOTOS AS THEIR
SUPPORTING DOCUMENTS FOR THEIR RESULT FINDINGS/REPORTS.

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Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

Building Assessment Checklist Form For Structural Audit


Structural Assessor Company Name:
Name & Contact of Assessor: Date:
Site Code: Site Name:
Site Address:

GPS Coordinates (if recorded): Lat: Long:


Site Assessment History:
Previous Structural Assessor Company Name:
Previously Assessed? Yes No
Result (if yes):
Previous Findings & Recommendation:
Site Assessment Findings:
Building Usage Type: Residential/Hotel/Market/Mosque/School/Collage/University/Commercial/Other:
Specify: Is it changed from earlier: Yes No
Number of Floor: Any new extension (vertical/horizontal):
Comments (give details of extension):
Site Loading Condition: New addition (compared previous audit): Yes No
Comments (specify additional equipment, battery etc. installed at site & their quantity):
Crack Found at site: Yes No Crack Type (Beam/column/slab etc.):
Criticality of the crack (share/load etc.):
Pictures taken for the crack: Crack History: New Old
Crack Details (measurement W & L in mm):
Crack length & depth condition compared to last audit (Yes/No & remarks):
Recommendations:
Need detail structural audit by Professional Vendor Need maintenance for the crack
Do Periodic check after 6/12 months Need immediate relocation (very critical)
Assessment Remarks (if any):

Page 36 of 39
Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

7. Appendix

Tower Structure

TOWER MATERIALS AND COATING

Inspection and maintenance of structural metal will be concerned with corrosion, wear,
deformation and premature failures. Corrosion control normally requires the most attention.

Galvanized Steels
Protection of the galvanizing by maintaining the protective coating system over the galvanizing
should be the thrust of the corrosion control effort for galvanized steels. Once corrosion of the
steel has begun in such a severe environment, it cannot be stopped without a surface
preparation that removes the rust completely. This requires intensive grinding (which is
discouraged) or abrasive blasting. Efforts to slow the corrosion process by accepting a surface
preparation method which removes only the worst rust are very costly over time and the
success of these efforts is questionable at best.

The galvanized surface will first show signs of corrosion by the formation of a bulky white
substance. The next stage will be the formation of a bright yellow product resulting from
corrosion of the zinc-iron alloy layer formed on the surface of the base metal. Since most
galvanized surfaces are painted, the loss of the galvanized coating and the occurrence of rust
because of an improperly maintained protective coating system over the galvanizing may not
be apparent. If there is a fracture of sufficient size in the paint coating, the rust will appear at
the surface.

Where the paint film appears to be intact, but is minutely cracked, rusting can occur beneath
the paint film. This condition can be detected by the appearance of blistering or buckling of the
paint surface. Since this condition can also be caused by the loss of adhesion of the paint film,
the coating should be scraped off to the extent necessary to determine if rusting is taking place.
Dissimilar metal contact points should always be closely examined.

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Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00


The accumulation of dirt and other foreign matter inside hollow members is a good breeding
ground for corrosion. In some cases, open-end members have been sealed after tower
erection. Depending on the quality of the seal, this effort may eliminate the cause of internal
corrosion.

Wear, Deformation, and Failures


Most forms of wear, deformation, and failures of parts and welds can usually be detected
through close examination during periodic tower inspections.

(1) Wear
Wear or abrasion on major tower structural members will rarely be a problem. This condition
can occur at bolted connections where the bolts are not properly tightened and at the guy
connection points. Where this condition is found at bolted connections, the bolts should be
renewed. Minor wearing at guy shackle connections can be expected due to movement of the
guys and should not require action unless the condition becomes progressively worse.

(2) Deformation
Permanent deformation of a structural member indicates that it has been stressed beyond the
elastic limit; if this deformation is significant, the tower may be in jeopardy. Deformations of
this kind may or may not be detectable through an instrument check or binocular inspection.
When bends are observed, a straightedge should be placed parallel to the affected member
and the amount of deflection measured as accurately as possible. Subsequent straightedge
checks should then be periodically performed in order to determine the degree of any further
deflection. If the deflection is found to be progressive, immediate corrective action must be
taken.

(3) Cracks
Cracks can be detected by close examination. Structural components are usually prefabricated
by welding. Fillet welds are the most common in tower fabrication. Cracks can occur in any
portion of a weld, but are most likely along the line of contact with the joined members. Cracks
in pinned and bolted plates can occur if the stresses at a hole exceed the ultimate strength of
the plate material. Immediate corrective action must be taken when cracks are found, and
proper and safe repair techniques must be applied.

Page 38 of 39
Process Name:
TOWER PREVENTIVE MAINTENANCE MANUAL

Process Owner:
NTC DIRECTOR OF ENGINEERING / OPERATIONS

Document Revision No: 00

TOWER PAINTING

Tower painting is accomplished for three reasons:


To provide obstruction marking, if required by the Civil Aviation Authority (i.e DCA);
To extend the life of galvanizing;
To help prevent corrosion.

The use of galvanized steel for all towers and similar coatings or materials for guys, hardware,
and other components in some cases precludes the need to paint to preserve the surface. The
reason for painting with the red and white color bands is to meet the visibility requirements of
the ICAO

Repainting is required "when the color changes noticeably or its effectiveness is impaired by
scaling, oxidation, chipping, or layers of industrial contamination". Any decision to repaint
should take into account other factors, such as the condition of the paint, the need to repaint
for protective purposes, and the anticipated life of the tower.

Towers should not be repainted to improve appearance if they have adequate visibility and for
no reason to paint for surface protection. Complete repainting should be governed by the
overall condition of the existing paint coating and not by premature localized failures. Normally
the best time to repaint is when the old paint evidences general erosion or deadening of the
coating. It is always better to repaint with the same type of material originally used unless
there are clear indications that different materials will be compatible with the old system.
Some of the newer coatings contain solvents that may act as efficient paint removers on old
conventional paints. It is often necessary to completely remove the old paint from all surfaces
to avoid problems of incompatible paints and to ensure proper adhesion of the new paint.
When severe corrosion of the galvanizing layer of the tower is attributable to the sand blast
effect; it is important to use a paint based on a penetrating type vehicle so as to get into the
small pores created. The same paint should also be heavily pigmented with an abrasion
resistant pigment to counteract such future erosion.

Page 39 of 39