o.

ru|oq gs oTfttidr (dfi)

qd ssttn ftqm, gm rrqq,
fr-6 its q. e, otdn tw erss d Od, r1q.
RRils mqo 07ss-2424038, 2426s2s $-m c. o7ss, 2424833,
E-ma il. eincbod h i (d gm a il.com

w fr. .............. / /ile /ffi/zots *||Y ,,rq,

"I , ^ ..
tq'1t(, / 10 / 2o1e
cfr,
nuw gc< etft-tiol,

v-d €sTsrq fulrtr,

qlvt.a (q!..)

ftEq:- Design series Technical circurar No. 33 sff,il{ (Gate) i *nrrw gu uo,ffi g$qzoTFqd
qckl I

sqt-tr fr!-q n d* t fu' Design *n", ,""n""t circurar No. 33 "qd-ff{" or} fu
wq
sTftridT, d$ arr qd rsgr ii qfo fuqr.tqr err, i Tfrrc
fu-qr r|qr ir Design series technical
circular No. :: { s-oait + qqEd qqrn qrq+rfr qFm-mq
ig ux .runr dtdT, q-dfli} d
+Ci{T tg oTicrrqiD RqT ft{eT Vq eEqlFqi wddTti d ftqfuT d sqq q,1 qd qd
nfu.r sTd f_g
GTF'.{f, frar frdeT G q.*fu \'q tfuT od ig Gil.-{rr* fipr ftdeT sq o,qqrfui gq faft--q
q-f,drit d Erqr ffi or qqrisr fu-al q-qr g,
gwcretri ilqrfiifr erftvoTgsio z ftqs d ,ff-d-{ rffi or oE 6t I

qExtrr:-1 ri o+ gw e-o

*- €lOt -
frra rM)
gw efivn (dtfr)
qEI wgrtrq frqrJT, r1}qrd
-- 3'' SD
a.Y'. ....... .Y...,,/ / 1\e /q\tfr/zojs +nqn. ft-ri"F
qftftfr- \a/ 7rc7zots
r. pr erFuor, q-a evltrl frqrT, qtw of ork qqflef €.ift-dt
\_7rqq i;fqq, qa risnrq frqTq, dq.ld of 3r)R nd.flr{-c n s-oTRrd ori tg r

I r gq oTNn (defi)
fttTFr, ,Tlqrd
 MADIIYA PRADESH WATER RESOURCES DEPARTMENT
DESIGN SERIES TECHNICAL CIRCULARNO 33 (Revised)

(Issued vide memo no. 22 1 /BODHI/R&CITCI1 I lDt. 30t12tr991)

0Ig

SELECTION OF TYPE OF GATE

ilriNfi_SJlt-G".uO,N#
A hydraulic gate is a equipment used for conholling the flow of water through any
component of the inigation system. Generally it holds the
water on the upstream side
though. Some gates deal with a reversible water flow
in special cases.

i':e$.rE-r:
2.1 According to purpose and location of gafe:_

2.i.1 Spillway gates: - A gate used to regulate flow over a spillway.

2'i 2 Sluice gate:- A gate which controls or regulates flow. Through

an opening where
the upsueam water level is above the top ofthe opening.

2'7'3 Draft tube gate:- A gate used to permit dewatering of the draft tubes
for inspection
and repair of turbine parls and draft tubes and is placed
over the draft tube portal
under-no-flow condition, although there may be considerable
tail, race turburence at
the time.

2.r.4 Banage gate: - These are a series of gates across the river to regulate water
surface
level and pattern of flow upsream.

2.1.5 Pick-up-weil gate: - These are the gates provided

on the prck_up_weir.

2'1 6 cross-regulator gate: - A gate in an irrigation chanaer

for the purpose of raising the
water level.

2'1'7 Head Regulator gate: - A gate provided at

the head of canar off-taking from a river
to regulate the supplies enter.ing the canal and to control
silt entry into the canal.
2 1 8 canal escape gate: - The gate pro'ided in the canal escape,
to escape sulrrus or
excess water from the canal.

2 1 9 Penstock gate:- The gate provided in the penstock to

regurate the flow of water to
the turbine in a hydro electtic power house.

2 1'10 By pass tunner gate:- During construction of

dam the river water is diverled
through a tururel and the gate rocated in the tunnel to regulate
the flow of river
water.

t1l
2.2 According to the shape of the Gate:-

2-2.1 Radtal Gates:- A hinged gate, the leaf of which is usualiy a circular are with the
centre of curvature at on very near the hinge or turn-on.

2.2.2 Cyltndrical gate:- A gate in the form of a hollow cylinder placed in a vertical shaft.

2.2.3 Drwn Gate:- A movable crest in the form of a sector of a circle hinged at the
gate
crest are face effect a water soak with the edge ofa recess into which the gate may
be lowered. The gate is raised and held up by the pressure of water admitted to the
recess form the head water. It is lowered by closing the inlet port to the recess and
draining the water form it. The top surface of the drum matches with the curve of the
spill-way.

2.2.4 Rectangular gate:- These are rectangular in shape and hence called rectangular gates

2.3 According to the made of movement of the gate:-

2.3.1 Vertical lift gates:- A gate operating in vertical grooves.

2.3.2 Gates rctaling about a fixed exunion point e-g. radial gates, drum gates etc.

2.3.3 Automatic gates:- A gate which functions without extemal manual attendance.

2.4 According to water head acting on the gate:-

2,4.1 High head gates:- A gate which is subjected to a water head of 30m. or more above
the gate siil.

2.4.2 Medium head gates:- A gate which is subjected to a water head exceeding 15m but
less than 30 m. over sill.

2.4.3 Low head gates:- A gate which is subjected to a water head upto and including 15m
above siil.

2.4.4 Differential water head gate: - In this the head of water is at different level acting on
both the sides ofthe gate.

2.5 According to the function of the gate:-

2.5.1 Service Gates:- A gate which operates under unbalanced conditions at palt gate
openmg.

2.5.2 Emergency gate:- A gate provided on the upstream of a service or a regulating gate
to shut off the flow under unbalanced head.

2.5.3 Stop-log gate:- A 1og, plank, cut timber, steel or concrete beam fitting into end
grooves between walls or piers to close an opening under balanced condition

t2l
 rvater surface at a predetetmined constant
automatically the upstream/down stream
Ievel.

3.1 Spillway crest gates selection:-

for which vertical lift and radial gates
Many types ot gates are in use for spillways
are mosl popular in modem practice'
gates are generally used when it is necessary to
3.1.1 Vertical lift gates:- Vertical lift
gates and where it is required to obtain
large
store a high head of water behinJ level is
used in locations where the tail water
I

discharges ln narow confines' It is also

gate cannot be located conveniently'
so high that the trunton pin for the radial
spillways when the elevation of the full
Vertical lift gates will also be suitable for
so that excessive long piers would the
reservoir level is high above the sill level
at a sufhcient height in case of radial
required to te extenOeJ on the downstream tensile load
taken by the piers as concentrated
gates. In radial gates tf'" tut"' load is
gates there
the gate size' where as in verlical
at the gate anchorages which may limit
isnosuchlimitation.Verticalliftgatesconbeerectedspeedily.

typ
3.1.2 Raclial Gates:- Among the vartous
gate is the most economical and us
simplicity, light weight and low hoist c
becoming popular for spillways tn mo
for this type of gate is that the trunion s'
debris etc'
spillway discharge to avoid contact wi h floating
Further, the trunlons of the gate shall
be so located that under conditions of
these should preferably remaln at
maximum discharge over the spillway barrage'
leastl'5mclearofthewuterprofile.Withgateshavingthetrunionsontheupstream
side, the trunions have to remain submerged
ir water' but suitable of the trunnion
Pafis under such condition'

Gates/ Shutters: - Installation of automatic

3.1.3 Automatic Titting Gate/ Automatic
gates is the most economical solution for
raising the storage capacity of existing
dams and resolving water crises'

Automatlc gates are cost effective and

time saving and do not need any
hoisting arangement' We are facing
gates are useful to mitigate addition
and installing the automatic gates Ex
modification and extra land acquisition'
structures and can be used on
These gates are also useful for water harvesting
and in percolation tanks'
bridge cum barrage, Aqueduct cum barrage

I?]
 \
Techno economical feasibility is required for installation of these gates
considering availability of yield, structual safety and stability of the stn"lcture and
resolve of land acquisition rssues.

In case of an ungated weir of dam where there is low head of water the
additional storage capacity between full reservoir level and maximum water level
can be between 20 to 60Vo ofthe existing live storage. By installing automatic tilting
gates this capacity can be usefully employed without encroaching on the free board.

The principle on which the automatic tilting gate function is that of common
balance. Water pressure on the gate itself is utilized to provide the opening moment
while self weight of the gate provides the closing moment. The water pressure acts
on one lover arm while self weight of the gate acts on the other. with a movable
fulcrum between the centre of water pressure and centre of gravity. The gate is
manufactured out of mild steel, supported on end girders and canies ho,rizontal and
cross girders which in turn supports the skin plates. These types of gates are useful in
remote places also.
3.2 Gates for reservoir out lets:-

Vertical lift gates, either sliding or fixed wheel type are extensively used in outlets.
The Selection ofhigh head outlet gate mainly depends upon the functional requirements.

3.2.1 Depending upon the functions thgy perform, closed conduit gates can be classified
as:-
a) Regulating gates.
b) Non-regulating gates.
Regulating gates are those which are used for regulation of flow at partial gate
openings'Nonregulationgatesalekepteitherincompletelyopenorclosed
position.

of the
3 .2.2 Onthe basis of disposition of seals and skin plate, closed conduit gates can be
following types.

a) Gates with upstream skin plate and down-stream seals'

b,) Gates with upstream skin plate and upstream seals'
the latter is of
The former can be either offixed wheel type or slide type' where as
fixed wheel tYPe.
Inhighearthdamswherelargedischargesarereleasedthroughconduitsortunnels
ofexceptionallylargesize'economiesinthedesignwarrantusageoflargevertical
lift gates of rolling type in preference to slide gates because ofpractical limitations
in the size of hoist.
The majority ofhigh head gates capable or part opening in closed conduits belong
to vertical lift gate of rolling fpe. Since the rolling to verlical lift gate of rolling
type.Sincetherollingislow,thehoistingcapacityrequiredisrelativelysmall,and

t4l
 il

as the gate is capable of lowering by its orvn rveight' rope drum or chain hoist can
also be emploYed.

3.3 Selection of canal gates:-

The control mechanism provided to regulate the flow of water

in canal is by means of a
gate. The main functional aspect ofthe canal gates is ofregulation
of water flowing
through the canal.

The main tyPes of canal gates are:-

(i) Sliding tYPe gates

liit Fixed wheel tYPe gates.
Itisfoundthatvenrcalliftgatesalemolesuitablefortheregulationofwaterin
Radial Gate can
canals in comparlson to other types of gates' However Automatic
also be used in canals.
For most of the canals where the head of water is quite low sliding
tlpe of vertical
lifts gates are used. For high head canal gates fixed wheel type ofvertical
gates are

also used.

3.4 Selection of Penstock gates:-

Penstock gates are generally vertical lift gates of fixed wheel type'

For operation of penstock gate hydraulic hoist are mainly used ln

penstock gates
and is expected
the time required for opening and closing the gate is kept minimum
thatgatewillopenandcloseinaveryshortperiod.Thisrequirementofoperationis
positive
only possible with hydraulic hoists Hydraulic hoist is also used when a
thrust is required for closing ofthe gate.

3.5 Selection of Draft tube gate:-

Draft tube gates are generally vertical lift gates of sliding type with sealing
arrangementonbothsidesofgateduetowaterheadonupstreamanddownstream
ofthe sate.

Hoists are provided for operations of gates, which are used of regulate
flow from
reservoirs for flood control, Inigation and power generation lf there
are a number

of gates in a project, either travelling or gantry cranes may be used for their
operation. While this system is cheaper than ptovision of separate hoist for
each

gut", th. period required for the operation of gates is greater' Hence quite often
gates
individual hoists are provided. Different types ofhoists are used for operating
The
depending upon the hoist capacity required and the operating consideration
following are some of the tYPes.

tsl
.tt Screrv lift hoist:-

This type of hoist is used when positive thrust is required to close the gate, though
elficiency of this hoist is low, there is overall economy because, it is more compact
than other type ofhoists. Due to the preference to single point suspension is more in
case of small gates or narrow ones like sluice gates etc. screw hoist in limited to l5
tones capaclty.

4.2 Rope drum hoist:-

This is the most commonly used type of hoist for soillway gates, because it enables
a wide gate being suspended at the two ends with common driving unit at the centre
or at one end. This type of hoist is also used for sluice and penstock gates, when
these are of self closing type and when there is no vibration of the gate' Since
vibration of gate decreases the life of ropes considerably and hence this type is not
suitable. Rope drum hoist can be manually operated or electrically operated
depending upon the capacity of hoist and period taken for opening and closing of
the gate. Rope drum hoists are normally used for spillway gates, sluice gates,

emergency gates etc.

4.3 Hydraulic hoists:-

This type of hoist is mainly used for penstock gates whele the time required for
closing is kept a minimum. It is also used where positive thust is required for
closing of the gate of in the installations where vibration is experienced' With this
type ofhoist, the oil in the cylinder acts as a buffer and dampens vibration'

4.4 Automatic hoist with float operations:-

canal gates
These types of hoists are generally used for operation of spillway and
available so
located in remote places. Where the operating personnel are not always
that the water can be let down when the reservoir level is above F.R.L. the
water

level in canal is above F.S'L.

5.0 HOIST CAPACITY OF GATE:

the following
5.1 The hoist capacity shall be determined by taking into consideration
forces which might be required to be overcome'

a) Weight of the gate along with all its components'

b) Al1 frictional forces comprising of:

(1) Wheel friction

(2) Guide friction
(3) Seal friction and
(4) Pulley friction.

I61
 c) Any hydro-dynamic load, like down pull force/uptiit
etc.
d) Silt and ice load wherever en_countered
e) Lifting beam, if used.
0 Any other consideration specific to a particular
site.
5'2 The worst combination of the above
forces, during either lowering cycre or raising
cycle, shall be considered.

5'3 The hoist capacity thus anived at shal

be increased by 20 percent to add for the
reserve hoist capacity unless otherwise specified
by the purchaser.
5 4 The gate sha be designed for closing under its
own weight (without any positive
thrust to the same) and to achieve the san e,
downward rbrces closing the gate whire
lowering shall be at least 20 percent higher
than the frictional ro..., opio.ing trr.
doqT rward motion The necessary crosing/seating
load shall be obtained, .,'t .n tnJgut"
is about to seat on the bottom seal. The values
of closing/seating load shall be greater
than those given below.

Type of Gate Minimum seating load

Fixed wheel gates or radial

Gates for spillway crest. 250 kg f/m length ofgate.
High head sluice gates. 1000 kg f/m length of gate.

5'5 The usual lifting speed for such hoist shalr be 30 to

70 cm per minute. However, other
values may be adopted depending upon the requirements.

5 6 Note:- Generally electromechanical hoist should be provided for

spillway gates.
However if the condition of frequent opening/shutting and urgent
ope.atio.,
occurs, hydraulic hoist with prior written permission of Chief
Engineer E&M
WRD/Chief Engineer, BODHI WRD& E_in_C WRD may be
obtained.

17)
 FORMULA FOIT CALCULATION OF GATE WEIGHT
F'OR ES''IMATION I'T,]IIt'OSI.-
BY BOOK OF DESIGN OF HYDRAULIC GATE

By : paul C.F. Erbishti

I. WEIGHT OF RADIAL GATE / SEGMENT GATE

G= 0.64(BrhH)068r
For spillway gates, and
G:3,688(B'?hH)0 52r (For subme.ged segment gates)
(ln equations. B, i and Hare expressed ilr merers
and the weight G is given in kN. For spiluar
gates. it can be assumed H-i, rvithout
incurring any substantial error.
2. FIXED-WHEEL GATES

G: 0.735(B2hH)o 6e7

For H>2000 mr, and

B2h
G=0.886 (BthH;oosr
For B2hH<2000 m4.
3. STOPLOGS GATE
The weight ofone complete set ofstoplogs for
one opening is given by the 6quation

G= 0.60t (B)hH)oro:
For spillway stop logs, and
G= 0.667 (BrhH;oore
For sLrbr.nerged stop Iogs.
4. FLAP GATES
The weight of fl.ap gares is estirnated by the
expression
G=2.387 B(ht-t)064r
By the above 1'ornrula the u'eight calculation lbr gate
leal'orrlv r.c- excluding cnrbccjdccl parrs lirr
weighL of errbedded par1s, lbllowing ratjo can
be uscrj.
WEIGHT OF EMBEDDED PARTS

Gate Typc Ratio bchvecn rv t ol cmbcdded and rvcisht of

Minimum Maximum
Spillrva t (Red ia I Gate
S u brlelRed seqntent

Fixed-l heel ruith B,hHji000,,,

Fixed-u hee I ,,virh B.hH<2000r,,
Spillway stoo lo
S u brnelged stoo lo

Legend:
B- span of gate, rr
h=he ight of gare. m
H:Head on sill, m
G=Weight of the gate leaf in kN (excluding
enrbedded pans)
 IS 13623:1993
Table 1 Gates anrl Hosits Commonly
Usetl and Their Location
(Clause 4)
Type of Gate Type of Eoist
Remarls
(D Crest a) Fixed wheel Ropb drum/Hydaulic rhese gates iiei--i1 fillf,lllfrlJ:ro,
hoist discharge of^are
flood. V"rti.d
gate: should be chosen ;;i"r7iJ;
from the
consideration of factors like head-
supersfuchre height and availabje
width oi
pret e1c. However, the limiting
height of
vertlcal trtt gate should be gm.
b) Automatic gates Float operatecV
Counterweight operated
hoist. (Autonratically
operates when water
level reaches the
required level).
c) Stop log gates Gantry crane,Monorail These gates
which are facilitate the maintenance of
fixed srane with. automatically main crest gates.
wheel vertical gates operated lifting beam.
oi slide type i"
number of elements
(iD
Serv'ice,Emergency Screw hoist or rope
gate of fixed wheel drum hoist or hydraulic
tSrpe or slide t5rpe or hoist.
radial gates orjet flow
gate

(iii) Constructiou sluice, Fixed wheel

vertical Rope drum hoist/cbain
diversion tunnel, lift gares
pulley
etc. itociisiwinches/-ovubt"
(iv) Power House
a) Intake Fixed vheel vertical Rope drum hoisV EOT
|ln gate crane
b) Penstock Fixed wheel vertical Rope drum hoist/ Hydraulic hoist is used for. quick closure
lift gate Hydraulic hoist of
c) Surge sha{t gate.
Fixed wheel vertical Rope drum hoist Surge shafi gares are used for the rnspeciion
Iift gate
d) Draft tube ofturmel/pensrock.
Fixed-wheei tyne or Rone drum hoisti Gantry Gates are meant for tlte
sllde qPe crane
maintenance of
turbines by preventing the entry of tail
race
watei.
Gates are used for regulating water
form
reservoir to main canal. Capacitv of screw
(v)CanalSystemhoistshouldbelimitedtotit.-
These gates are used for the maintenance
of
c hoist constant upstrear/dowlstream water
levels.
 INSPECTION AND MAINTENANCE OF GATES & THEIR PARTS
Components ofthe gates to be inspected are as below:-

1.0 Vertical Lift Gates:

i. Embedded Parts: ii. Gate Parts

. Sill beam assembly . Skin plate Assembly

. Roller track . End Verticals
. Seal seat/Upstream Guide . Horizontal griders
. Top seal seat and side guide . Vertical Stiffeners
. Dogging anangement . Roller assembly
. Side guide assembly

. Lifting Arrangement

1.1 The aspects to be inspected and maintained periodically for ensuring proper operation of
these are as under-

1. Clean the gate slot and bottom platform,/sill remove Scales formed over the embedded
parts. Check Second stage concrete for any development of cracks/leakages

2. Check the gate leaf cleaned and repainted as and when necessary according to the

procedure or guidelines-indicated in 15"14177

3. Check the Rubber seals smoothness for proper alignment. Check all nuts and bolts fixing
the seal to lhe gate.

4. Check the free movement of wheel shell Gate roller bearings and guide roller bushes
properly Iubricated.
5. Check the lubrication in the Hosting connection of the gate leaf
6. Examine lubrication and greased in all the components
7. Adjust the Roller assembly by the eccentricity arrangement to ensure all rollers rest

uniformly on the tack particularly in the closed position ofthe gate.

8. Check all welds for cracks/damages

9. Clear grit, sand or any other foreign material form guide-assemblies, wheel assemblies
and sealing-assemblies

10. Check the wheel pin coating with corrosion resistant compound

L0
2.0 Radial Gates:

Radial Gate Leaf:

Embedded Parts:
(Common anchorages
(Common anchorages
Bonded Anchorases)
Bonded Anchoraees)
Skin plate
Sill beam assemblY
Side guide and seal assemblY
Wall plate AssemblY
Vertical stiffeners
Horizontal Anchor Rods
Horizontal Girder Bracings
Trunnion Girder
Arm AssemblY
Trunnion girder chairs
Trunnion
Vertical rods
Trunnion Pin
Thrust block
(Independent anchorage Trunnion Bracket
Tie between trunnion or Tluust block
Unbonded anchorage)
Lifting Bracket
Sill beam assemblY
Independent anchora ges
Wall Plate AssemblY
(Un-bonded anchorages)
Anchor girders
Skin plate, Side guide and seal assembly
Load Anchors/Tie flats
Vertical stiffeners
Yoke girders
Horizontal Girders
Rest plate
Horizontal Girder Bracings
Vertical rods etc.
Arm AssemblY
Trunnion
Trunnion Pin
Trurrnion Bush
Trururion Bracket
Tie between trunnion or Thrust block
Lifting Bracket

2.2 Rope Drum Hoist for Radial Gates:

Drive unit assemblY
Upstream SusDension
Gear box assemblY
. Drive Unit AssemblY
Fixed end suPPott
. Gear box assemblY
Hoist chassis
. Hoist bridge
Line shaft suPPort girder
. Lifting arrangement
'Down Stream SusDension Diai and Dial AssemblY etc'

t\
 :' 2.2.1The aspects to
be it and maintained periodically
rhese gares for ensuring proper
"." ^.
;tj;:t"o operation of

(i) Rubber Seals

1. Check the seals for
leakages.
2. Check the seal for r
t ifdamaged, then repiaced. ,l
3. Ifreakage,.
""""r,'ive & immediate repair is consid ered necessary then use
repaired or reprac.. stop log gates tbr
4. Check the seal for wear
and tear and deterioration.

Note:- During monsoon

period, ---('"6
' stop log gates
sdr.s sha
snall NEVI
1\.1-vtrR be lorvered
through seals. inspite ofheary reakage

(ii) Trunnion block assemb y its anchorages

l. Check utt ,t nu,'
" checked f.r,ish,ness
"nd
; nl _*;{JHH:::H:i":;J;;:;,,
he Yoke girder and
thrust block rs covered
prate on cover it with mird steer l

4. Check all the wel, rounoness and rectifu

defect
5. Cover the t ,nn,oo' 'or
6. Remove ,,",
",
gate with
JitilHffiff#bry ana iub,icate
trunnion bearings orthe
suitable water resisting
grease as recommended
recommended by bea'ng by bearing grease as
manufactures.
(iii) Gate structure

l. Check all the weld

r soundness and rectisr
defects.
2. Check .,'"ta;ng u"t'
ween arns and horizontal
i

girders as r.vell as between latching bracket

and skin
3 Latching bracket and
skin plate with the help
of magnifoing glass for cracks/defects
rectifu the defect and

4. Clean all drain holes including those

in end arms and horizontal girders.
5. Check all the nuts bolts and tighten
ar
I

them Replace damage dons'

6 check uo*..ur fu",n
scaring and corrosion' Scaring
mav be nrred
witri werd and
,.,"r:;:::ffi:':,T:j-'-
(iv) Embedded parts
jl
t. Check all the sill bea
ll
ii
2 check the suir".",,J:;;:'rJ1#::1;j:--*
ror crack, pitting etc. and
derects.
l

(lz) General maintenance

on Radial Gate,/Vertical gate IS:f0096 (part3)
l. Check defective weld
2 check damag",_,,';;:::J;::,:,i:.,.
to reprace
 and finished by grinding
if necessary
3. Any pitting filled up by welding and firrished structure
parts' hoists and hoist supporting
4. Check the gate leaf, exposed ernbeddeil metal
etc.
trunnion beartngs tn
grease and when required keeping
5; Covers Trunnion bearing with
bolted connections checked
perfect working condition is
very important Check all other

uP lor ProPer tightness'

6.CheckBoltsandtrunnionbearinghousirrgfortightnesswhereverrequired.
them it if necessary'
7. Check the wall plates' sill beams and repaired
8. Check the wire ropes for lubrication'
9. Check the Flexible couPlings to'
ofall electrical relays and controls should be attended
10. Repairs and replacements sets and
of Power such as Diesel Generating
11. Maintenance of alternative sources
provided should be canied out'
alternative drive wherever
be reviewed and updated
list of essential spare parts to be kept available should
12 The
and protective
periodically lt'" of spares should be checked periodically
"ondition
coating given for use'

for Radial Gates

2.3 Electrically Operated Fixed floists
radicons' etc shall be carried
of brought out items like motor' brakes' '
The periodical maintenance
advice/maintenance schedule'
out as per the manufacturer's

a) DailY InsPection:
remain with the
to all hoist platforms are keep lock. Check all keys
1. Check entrance

shift suPervisor'
ensure that there are no
daily inspection made of hoist and gate to
2. Check the cursory
operation when called for'
unusual happenings and ensure

b) MonthlYMaintenance:
l.Cleanthedustofallhoistingmachineryandhoistplatform.
wherever required with oil of
proper
2. Check oil level rn gear boxes and replenish
grade.
grease gun through alt the
greasing niPPIes and
3. Apply grease of suitable grade by
replace grease niPPle if missing'
pins' linkages' etc'
4. Lubricate all bearings, bushings'
power lines and ensure closing
of panel board covers not of
5. Check all the fuses on

entry of dust and motst'

gear boxed' hoist drum and
check shaft couplings for tightness'
b. All bolts and nuts on
per standard'
Check the supply voltage' As
anchorages'
1. Check the expansion
provision in case of independent
dirt
8. Check all Starters are
clean and free of moisture and

IJ
 9. Check each individual contactor to examined to make sure
that it operated freely.
l0 check arr rvearing parts are examined and uke remediar
actron to avoid reoccurrence.
I l. Check the magnet faces are clean if the contacted Hum.
l2
Examine alr connections to see that no wires are
broken and no connections are roose.
13. Clean the surface ofthe moving armature
and magnet cone which comes together
14. When the contractor closes, free ofdust or grease
ofany kind.
15. Check the contact tips keep free from burns
or p)ts by smoothening with fine sand
paper or emery paper.

16. Replace the contact tips which have worn

half_way.
lT Do not rubricate the contacts. Normal. If so, stop tbe hoist and investigate the cause
and rectify.

l8' check for condition of painting of various comporonrs ano remove rust wherever
noticed and repaint the portion after proper cleaning
schedule.
c) Check Electrical connection and wiring:_
a. From supply point to main switch.
b. Main switch to starter.
c. Starter to moto.
d. Contact points ofstarter.
e. From starter to all lighting points, availability of bulbs and its glowing.
d) Annual Maintenance:
1. Check the annual maintenance is combined with one of the quarterly
2. Check all trash, sediments and any foreign material cleared off the
lifting rope
3. And lifting attachment. ,

4. Check all ropes for wear and tear and ifbroken wires more than.
5. Permissible of mark corrosion is notice, Check the rope is replace.
Refer is IS Code
for maintenance of wrre ropes.
6. Check all wire ropes check and rernove all visible oxidation
7. Check all wire ropes grease with corium compound or equivalent brand.
8. Adjust the rope tension ofwire ifunequal.
9. Check the overload relays and limit switches for proper functioning.
l0 check tightening ofat nuts & borts, soundness ofwelds. A, borts shall
be tightened
and defective welding must be rectified.

ll. Check the pulleys, sheaves and turn buckle for soundness.
12. Check the limit switches and adjust for design
limits duty operating.
13. Check the effectiveness of the brakes, check
by stopplng the gate in intermediate
operation duly rising and lowering operation. Check
the brakes and adjust ifneeded.
14. When the gate is operated, Check there is
no noise or chafter in the gears.
15. Check for all gears and pinions for proper
match, uneven wear and adjust for proper
contact and grease the gears.
!4
 structures after a
hoisting platform and its supporting
16. Repaint the holst components'
painting schedule'
time interval depending upon the

of Fixed Rope Drum Hoists:

2.4 Maintenance of Electrical components
are as under'
inspected and maintained periodically
The electrical components to be
arld dust'
1. Check Starters are cleaned' free of moisture
sure that it operates rreery.
2. contactor try by hand to make
check each individuar
wear which may have
parrs are examined in order to take note of any
3. Check all wearrng

occurred during oPeratton'

are cleaned'
4. It the contactor hums' Check the contact faces are loose'
wlres are broken and no connections
5. Examine all connectlons to see that no when the
of the moving armature and magnet core which comestogether
6. clean the surface
or grease of any kind'
contactor closes, free for dust
and seewhen the contact
interlock between the reversing contactor
7. Examine the mechanrcal
are touching'
tips of one of the conhcror units
with fine sand paper
g. should be kept free from burns and pits by smoothening
The contact tips
or emery paper.
have worn away half-way'
9. Replace the contact tips which

10. Do not lubricate the contacts'

in the stator and the
and dry air to clear air passage
11. Blow out windings thoroughly by clean
pressure shall not be too high
to damage the
rotor for any accumulated difi' The air

insulation.
and motor leads'
12. Examine earth connections

13. Examine motor windings

for overheating

14. Examine Control equiPment's

for burnt contacts'
15. Examine starting equipment
burnt contacts bolts
16. Check and tighten all nuts and
and burnt contacts bolts'
17. Clean and tighten all nuts

18. Lubricate the bearlngs'

19. Overhaul the controllers'

20. Inspect and clean circuit breakers'

bedding ofbrushes'
21. Wipe brush holders and check
22.Blowoutwindingsthoroughlybycleananddryair.Thepressuresnotbesohigh.
and the frame
insulation resistance ofthe motor between any terminal
23. Check the

Solenoids 0Perated Brakes

1. Check all fixing bots

wear'
2. Reset the magnet stroKe to compensate for
given on the instruction plate
when the magn"t strt'ke t"uches the value
3. Re-adjust the brake
If
 4. Check Brake lining and
replace when required.
5. Examine all electricai Ieads
and connectrons.
6 Check Rubber bushes or
couplings and replace ifrequired.
L Tighten the pins.
8. Check the Brake drum, clean
to remove any dust or grease.

3.0 Stop Logs. Lifting Beam and

Gantry Crane
3.1 a) Stop Logs for Spillway Radial
Gate
Generaty one or two sets of
spitway stop Jog are pranned for Spiirway
Radiar Gates
depending upon the number of
spi,way gate instatation. The set of
stop rogs sha'comprise of nrore
than one unit pranned to cover
around 200-250 mm above the FRL
or the top of spirway gate. Under
balanced head conditions (both for
these stop Jogs shalr be operate raising
& iowering) by Gantry
crane to be located at the top
of dam over the rails fixe on tne roadway
over the dam with the
provision ofan automatic angering o/o
disengaging lifting beam.
The Stop log units being in places,
the top non-interchangeable unit wrth
unique features as
weil as the other inrercrlangeabre
units is stored in rhe groores in various
spans/bays. the torowing
aspects are to be considered and
attended during maintenance:
l. Check defective/damaged/cracked welding
2. Damaged nuts, bolts, screws etc.
3. Examine the gate leafcleaned and repainted
whenever necessary
4' Rubber sears should be grinded, if required
to bring it in arignment. At nuts and bolts for
fixing
5. Check all components greased and lubricated with the recommended
Oil and grease only.
6 Adjust the roller assembly by the eccentricity provision to
ensure that all the rollers resr
uniformly on track plates particularly in the closed position
ot the stop log gate.
7. Clean the drain holes in horizontal girders

8. Examine that no bearings overheated.

9. Cleaned the gate slots and remove scaling over embedded pan.

a) Lifting Beam

1. Examine Lifting beam for both raising &lowering

of Spilrway stop log units with the use of
Gantry crane.
2. Lifting Beam shall mainry comprise of two number structural
steer channers or fabricated
channels with back to back connection to make it a single
fabricated structural frame.
3. Two side guide rorlers/Shore shal be provided on each side of the
lifting beam. The depth of
lifting beam/frame sufficient to accommodate to ro ers on
each side located at sufficient
distance from one another to enable proper guided movement.

16
4. The depth of lifting beam should not be less than one tenth
of the length/sPan of the liiling
of the
beam or 500 mm whichever is more Lifting beam hook mechanism by the movement

hookblock'Thetwohooksaremechanicallylinkedtogetherforsimu|taneousoperation.
with corrosion resistant 0steel
5. Check all the rotating part of the lifting bearn Shall be provided
pins and aluminum bronze bushing/roller bearings'

Following issues need to be considered and att€nded during maintenance:

(i) Bush bearing of lifting attachment and various pulleys/sheaves wheel'
(ii) Check the lifting aftachment and various pulleys/sheaves wheel

b) Gantry Crane
gantry struclure travelling
Hoisting trolley of the Gantry Cranes built on top of a wheeled mobile
workspace
over fixed rails and is used to straddle an object or load overa

buffers' mechanical
Cabin, walkways, ladders and railings, end buffers, mechanical' end
equipment, wheels and axles, gantry drive unit, wire rope' rope
drum' gears and pinions'
pulleys' bearings' flexible couplings'
reduction gear box, shafts for gear and pinions, sheaves and
lifting hook and block, sockets for wire " gearbox covers' keys & key ways' counter weight'

wrenches and tools, electrical equipment, . "'motor, master control equipment' cables and cable

reel, wiring, limit switches,

't)

1. Oil level in the gear b'oxes. It is very important to ensure that the corect oil level is
maintained. Over filling causes overheating and leakage'

2. Check the insulation resistance ofmotor winding'

3. Checking ofall the electrical connectlons'
4. Lubrication ifeach parl ofcrane
5. Removal ofany loose/foreign material along the rail track
6- Actuating tests of limit switches
7. Actuating tests of brakes.
8. Check all fuses in the control panel.
9. Necessary terminal connections ofmotors brakes etc' is to be checked'
10. Check Overload relaY.

11. CheckVisual inspection ofwire ropes

12. Checking of rope clamps on the drum snapped loose
wire and its proper lubrication and

ofbolts ifrequired. Check unusual noise/vibration before operation'

tightening

17
 4.0 Surface preparation and painting
of HM Worl$ IS: CODE 14177(par3):

4.1 Introduction:

and its supporting structures

reaction and abrasion
due to

Painting of hydro mechanical

works parl shall be caried
o 14177- tgrT or larest the
painting svste' for gates
and equipment sha, be
I. Appling paint as fresh at the time
artended a::il::]t
ofmanufacture.
II Removar oford paint, rust
and repainting during mainrenance.

4.2 A] Surface preparation:

After the equipmeut has been

fabricated, it is essential
that befiore any primer and
applied, the surface is properly coat of paint is
prepared.
The procedures for surface
preparatlon are as follows:

l. All oilgrease and dirt shall

be removed from the surface
by the use of clean materiar spirits,
Xylor or white gasoline and
crean wipingmaterials.
2 Following the solvent cleaning,
the surfaces to be painted shal
be creaned of alr rust, milr
scale and other lightly adhering
obiectionable substances by sand
blasting. Blast clean to a
minimum of Sa zllrswedish
standard Jl)
,vro,, rldru.lru SIS )yuu with a
5900 wrth a surface profile not exceeding
65
microns.
3. The fig. B Sa zl7, is given.

4.2.1 Bl Shop painting:

I. Embedded parts which come into contact

ofconcrete:

clean all embedded parts which come

in contact with concrete as detailed above
and given two coats
ofcement la|{ to prevent rusting during
the shipment while awaiting installation.

II. Embedded parts which are not in

contact with concrete and gate parts:

'Two coats ofzinc rich primer with epoxy resin applied to

al embedded parts Surface which are
nor rn
contact with concrete.

18
 painted unless or otherrvise specified:
The following surfaces are not to be

a) Machine finished or similar surface

with concrete
b) Surfaces which will be in contact
c) Stainless steel overlay surfaces'
d) Surfaces in sliding or rolling contact
and bronze surfaces'
e) Galvanized surfaces, brass

f) Aluminum alloY surfaces

that will expose during
of f'errous metal including bolts' screw threads etc '
All finished surfaces
unifortn coating of gasoline
shall be cleaned and given heavy
shipment or while awaiting rnstallation
or equivalent'
soluble rust preventive compound

Cl Gates:
silicate primer giving a dry film
Coat: Over the prepared surface one coat of inorganic zinc
Primer
be applied Alternatively two coats
ofzinc rich primer' contain not
thickness of70t5 microns should
of 75 t5 microns'
less than 850/o zinc on dry frlm
applied to giv€ a total dry film thickness

Dl Hoist and suPPorting structure:

a) Structural comPonents: PrimarY
dry film thickness of40t5 microns'
primer shall be applied to give a
Primer coats ofzinc phosphate
FinalCoats:onecoatofalkydbasedmicaceousironoxidepainttogiveadryfilmthicknessof65+5
synthetic enamel paint
microns followed by two coats of
all surfaces of machinery including gearing' houstng'
b) Machinery: Except machlned surfaces
shafting, bearing Pedestals etc'
paint Confirming to lS
coats: One coat of zinc phosphate priming paint to give minimum
Primary
give a dry film thickness of
19630r synthetic enamel paint confirming ro lS 2932-19'11 to
2339-
film thickness of 125 microns'
2515 microns to obtain a minimum dry

c) Machined surfaces:
threads which will be exposed during
All machined surfaces of f.errous metal including screw
uniform coating of gasoline
suitable solvent and given a heavy
shipment or installation cleaned by
shall be protected with
rust preventive compound or equivalent Machined surfaces
soluble removable
the cleaning and painting operation of
other
. the adhesive tapes or other suitable means during

components.
from the data
if film thickness are to be taken anived
alternatives are chosen the guaranteed
Note:
thickness considering the
and incorporated the total film
sheets of leading paint manufacturers
of project'
Iocation and atmospheric conditions

19
 Application of paint:
The contents shourd be checked
thoroughiy as directed by the paint
manufacturer before and during

a) Brush/roller

b) Conventional spray

c) Airless spray etc.

Painting at shop can be done in any

ofthe above three methods so that the paint
can be made
to suit the convenient direction

5.0 Electrical System

Electricity is rypica,y used at a dam

for righting and to operate the gates, hoists,
and recording
equlpment, and other misceraneous
equipment. rt is important that the
Erectricar system is we,
maintained, incruding a thorough check
of fuses and a test of the system to ensure that
a, parts are
properly functioning

1) Check the system is free from moisture

and dirt.
2) Check Wiring for conosion and mineral
deposit.
3) Check all electrical fittings like bulbs, lights, loose wires
4) Maintain generator to be as used for emergency auxiliary
power.

5.1 Metal Component Maintenance

check all exposed' bare ferrous metal ofan

outlet instalration, whether submerged or exposed
to air, will tend to rust.
check the grease on movi||g parts. on surlaces like guides
& track seats on which rhere rs
movement of gates they should be greased heavily.

Check the grease on friction sufaces to avoid

binding.

5.2 Operation and Maintenance

' Day to-day experience on operatior and difficulties faced should

be recorded in the log book
of gates
o check for special repairs to of gates, it is advisable to refer to Experts
to execute it.
o Inspection and maintenance experience are to be compiled
in the form of History register of
any installation so as to be usefur for future designs, investigation
of any failure, improper
and unusual operation of gares.

5.3 The follorving precautions are to be taken before dry testing of

Gates:
l. checking of all criticar dimensions and proper seating of gate over embedded parts is to be
ensured. Record of readings

2. Lubricated Worm reducer, plumber blocks, trunnion pin, gate wheels

and gear wheels
20
3. Removal of temPorary suPPorts
arms and trunnions' tees and hbrizontal
girders'
A
Checking of weld between horizontal girders,
welding of lifting bracket etc' and are to be
cross girders and hoist bridge girders, final
to be maintained'
welded if left over' A comprehensive check list is
horizontal Girders'
trunnion with arms and trunnion with
5. Checking tightness of bolts between
bolts and other bolts
lock plate bolts oftrunnion pin, wire rope clamp
yoke girder
to ensure the expansion of tie flats and
b. Increase ofunbounded anchorage one has

under load.
in the
The gates are to be inspected thoroughry
for projection, temporary supports coming
7.
are to be removed
way of gate movement and excess concrete
the gate preferably with water to
8. All the rubber seals are to be made wet before lowering
seal seat and ensure fixing of all
bolts and mouldings
reduce heat generated between seal and

of site joints.
gap between seal and seal seat'
9. Light test may be conducted for checking

10. All weld tests are to be conducted'

z!
 Design ofhydraulic
gates, 2nd edition
ITEFBRENCES

ilI Knapp, F.H., Ausjtuss,

--, Ub,
--erfall und Durchfluss im ll/asserbau,
Ug60). verlage G. Braun,
Karlsruhc

cates. U.S. Dept.

lil:*" or
ternational llater power
and
P., Downpull on Vertical
Lift G ates, International
ty6J). waler power
G^INEERS, Hydraut
ic isn
t)J)
Des
- oif Reservoir outlet strucnris,
:,"Lyo,,I
at i'
Hvdrodvnamic-Analysis
oJ the Hydraurics
ror High-Head Leaf
Division, proceedinss
Er"iit,"iit.iti,
Hydraulic Design Criteria,
Hydraulic Design Chart
ents (1961).

22
 S.No
1 l)r.|NT'a

)
"v''rvorrJ quaured or trained
-
op€rators should be allowed should not be
to operate
3
gates.
H "li;ilil##'Ju|"#n'"uut
"ivrsrw urc_BaLes onty when required l\oI tn
power supply as per ^har-+^ ^^.^ -
rvrule 6arcis r
uunng low voltage period
rhe desisn is
avartable.

ro
A
.-r qJ! u,r i1l(es wnen
the gate Is /\OI lar 2d"rcf +L^
.ur lrrv L-^r
vt.LNE5 wncn gates
ls not
oogged
5 ....-r,u I14 (cflance ounng pre_
monsoon season
H
6 vJr y,upcr roors tor
#.-
K
attendins

7 urY test oelore puttng into

^: :,:".
operatlon --,, vfvrulv 641tr5 wlrnout Dry testing
8
or hoisr plarform. Norr;I";;;;r-i-'.--
;ffiil,,,;:ij#ess q'r JrrPPsry malerlal on Hoist
9 H
^.,eqrqrv u4ll|aBco etectflcal wiflnp
*utt*ui'"
which are exnosed r.,
rrH
1.0
ffii,-
I IIn ralns
F
"'*^--;^--"' -
_- : ": ^""p ts,rdr uux cover open aller daily
malntenance
71
"..rqw wlls rupc ugntness on either # Edr.e wnen tne wrre
1,2 ru stded equallv hefnrc n^.*^+:-_ _^-
^;_.1."
stacKed
#
"y",o,s rope is

ruube urosses ourrng operation

gates of
l5 !9, v' puwqr suppiy aner operation
n" "^t;:-::--- ,
oI gates yuwcr suppty
* ^::;,,"* Lo motors when it is
r4 H
i*l)^
I
":,1'."1ons and lunctioning of
lrnll Swrtches before ol.,".or;^-
;"i.:'i++i5d
_

not tunctioning
,
^:,:"* 'ur LU uperare gate li, llmit
.
switches are
15
!nrnr t^ rwrLlu
ivL Lv .- i^L urr n- _..__-
^ nolsr motors rf fbreign
materral found in between teeth
ofgei
to H
v!wv^ LrErluess or rtummer WHEEI,
H
block, upsrdrs Bare tr any bolts ol.plummer
dnve unit. line shaft cn,,nli-^ r-^r.^
L7 EH si riu loretgn parllcles
Lrr.rur
olocK and couolinB holrq e.o f^,,-.r
\H{'vru\.,ss
r

Stuck rrn in
bi :tween roller and roller
track/wall
pr
18 l::''ll tluer"+:9.=
u1,'rdLv gares wrm low oi.l level in gear
19
box
a-:-
Lrr,!!r\ 'Burrcss ot wtre rope clamps !u,uysrare Bare rr wrre rope
oerore
ooeration ;,v! clamps are
20 Hvprr.lrc. Bare onty when round loOSe
clean wlthout Anv
grooves are H rrwr u1,lrdLe tsare rr rnere rs any projection,
vv
n,^r;^ ^. in
zt ^her the grooves which ohstnrcr
N
"t r'arr/ra fope/wrre ropes as approach
;^:.-::
ror auendlng maintenance works at Tnmurions,
trunruon girders etc.

23
 LUBRICATION SCHEDULE
S.No
Mode of LUBRICAM
Lubricatin,' r requency
1
rressure grease gun
rcrvo gear_20 or
2
""", lu uuee months
rressure grease gun learing Grease as per Site condirin-"
oervo gear-20 or
,rr rruce months
5 bearing Grease qr Pcr slae con.tr t'i^h
rressure grease gun
]J,eanng Urease .;;--:i<
4 ",.", ,u Lruee months
as per site condiri^-.
n1.;^::-:-
_"wu rlr d ycal Detore
5

#T:Y::rs+.--
-.rsrv4l\l lvvel to be
6
rressure grease gun Inaintained alwawc
IJeanng urease n=l-;--+
_.."" ,rr uuee months
7 Lme shalt rressure grease gun as per siteconditin.o
bearinss Deanng Urease .r;^^l:-:r
rr I ---
srx months a<
8 uear Wheels H;il;;;ll.,l--.__-
,,]-r'vs Lnassls Grease
yLr Jrts Con0tnnn
I v'vw ur rrA rnonths as
urum shaft
@d."*
9

#-++{rr!___
",,,, uuEe months
_,.u
10
n:uro apphed as per site condiri^."
rvl.r. urease /-\--
r,zqce tn stx months
as
per site condition
11
nano applted
mechanism and oervo rn _ 140 ;---.-_:---
\Juce ln thlee months
other relating as per site conditions
parts

24
 nart for maintenance Schedule for Gates
IS: 7718 Part III-1975
IS: 10096 Part III-1982

Every Quarterly At Ever At Every At Every six years

Year three years
General cleanliness of in addition of In addition Check welds for damages at:
embedded pa1ts, Gate hoist Quarterly
components marntenance maintenance
schedule the schedul'e the
following are following
to be are to be
checked checked
Check for oil level in Check the Check the . Skin plate joints
radicons tightness of condition of . Tee girders to Horizontal
foundation wrre rope, Girders
bolts of pulleys, . Horizontal girders to arm
Motors, sheaves, o Arm Bracings
Radicons, limit switch, . Horizontal girder bracings
Plummer brakes, and . End boxes
blocks, gear wheels.
. Gate stiffeners
coupling
joints
Greasing ofpulleys and Check for Check gate Check wheel assemblies for
pins smooth seals for any
operation of damages. Breakage
Frnz in o
raising and Conosion
lowering Misalignment
Trumion pin, Rope drum Check for Check for sill beam, side
hoist, Gear wheels, Hand condition of guide, roller tracks for
operation of shaft, guide painting of damages, conosion, pitting
rollers, Gate wheels all
components
guide rollers,
wheels
Check for peration of Check Hoist Bridge for
Brakes foundation bolts for
tightening.
Check for loose electrical
connections
In case offixed wheel
gates)
i, Wheels are to be
greased properly
ii. Movement of
wheels should be
smooth and it can
" be rotated by hand

25
 DETAIL OF GATE
RADIAL GATES:

Introduction:

After Independence most of the

Majo
resources and supply of water
for irrigation
etc., Radial gates are playing major
role in reg
in canals and other channels.

ot of problems were faced and the

same were
has brought some of the limitations
for the
ne of planning and design stages
structures. of Hydraulic

Gates are preferred compared

to vertical lift gates due to the following
uou.nr.]""r, ^toial

- No grooves are required in the

piers to accommodate road bearing
wheers. This
results in simple construction
and its arrangement.
- The construction of gates is simple
and easy to maintain.
- Due to configuration vis-d-vis its
rotating axis about trunnion of the gate
that load
bearing members are protected
from damage by debris.
- The only disadvantage is that it requires accurate construction of piers
with required
shape at trunnion rever for movement
of arms (in case of Independent Anchorages).

The Radial Gate and its operating system

are divided into three groups ie.,

i) Embedded parts- which are fixed in the

concrete to transmit the load to civil construction.

ii) Gate Leaf- curved prate and its supporting

structures which transfer the water thrusr to
embedded parts.

iii) operating system- Rope drum Hoists

/ Hydrauric hoists used for operation ofgate.

26
 Radial Gates and its operatinR
svstem:

Embedded parts:

Typel: Common anchorage system (bonded

anchorages)

Type2: Independent anchorage system (Unbonded)

anchorage system)
Type3: Achorages with post_ tensioned
anchor rods.

Type4: Post-tensioned prestressed concrete

anchorages.

Gate Leaf:

Typel: Gate reaf with curved skin prate supported

by verticar stiffeners, Horizontal
girders, Arms, trunnions, trunnion
Bearings, Trunnion Bracket etc.

Type2: Gate reaf with curved skin prate

supported by horizontar stiffeners, vertical
girders and Horizontal girders, arms
trunnion bearings and anchor rods.
Hoisting Arrangement:

Typel: Rope drum hoist with U/S rope suspension

Type2: Rope drum hoist with D/S rope suspension.

Type3: Hydraulic Hoists.

Radial Gates with Common Anchoraees:

The Radial gate with common (bounded) anchorages: -

The hydrauric thrust on the gate is
transmitted to the trunnion girder through brackets.

The trunnion Girder is designed to withstand the lbad of water thrust transmitted
bV trunnion
on either side and the road is transmitted through
the anchor bars as bonded anchorages ro
concrete piers.

- The rods are used as road carrying anchorages.

The anchors are not werded to trunnion girder
but are fixed with nuts and pre-tensioning can be carried
out. Arternativery werding of
additional flats also can be done after pre_tensioning
of roos.

77
 "ii
rlil
iiil
'i\
:\
"u-i'. '-
t'!,i\

l!\!-/

El.EYAii ON s€c - aa
DE TAIL- 8

COIISOd A'GHOFAG€ SYST

GPII i WAY FIDIII GAIFq

Limitations:
1. Advantageous for construction of piers since no accurate pier shape is fequired at
tru nnion.

2. Since there is a limitation on the size and iength of rods available, it is advisable to
use the type of arrangement upto gate size of 12M width x 1oM height max. In case
of bigger gates it may not be economical.

3. The disadvantage is, since the trunnion girder is common for two adjacent gates rn
case of failure of anchorages of one gate due to any reason, there are chances
of
successive failure of all gates.
The deviation in pier construction is to be carefully compensated while erection of trunnion
girder to maintain the distance between centre to centre of vents.

@
Independent Anchoraqe Svstem:
The Radial gates with independent anchorage system the hydraulic thrust on the gate is
transmitted from Trunnion Bracket to Yoke Girder and to anchor girder through unbounded
tie flats. The Anchor girder is embedded in the concrete which transmits the load to pier.

'!HC€P€I'OAXT A{CHORAGE
5Y5TEi.I
SPItIWAY RADIAL CATE
ECAO lRANgen rO COi€A-IE
sTa4,ErLltE TlFc.r:+i Et€€al€il paqls

) ::
The advantages in Independent ancnoiages are:
- The gates can be made to suit the vent width even there is a variation in Civil
construction.
- There is no successive failure of gates in case of failure of one anchorage.

The disao'vantages are:

- Care shall be taken to provide clearance between the tie flats and trunnion arms
when gate is belng lifted.
-- Pier is to be provided with shape during construction for movement of arms_
 -l:F:ar-J

Thorough checking is required regarding

soundness of weld between anchor girder
and tie flats. Once thjs weld fails
rectiflcation will be impossibie / difficult.
Proper erection sequence and accuracies
are to be aoopted to achieve good
performance.
Arrangement requires larger width
of piers to accommodate anchorages assembly
when compared to common anchorages.
The Inoependent anchorage JJr,.s,
systems dr c iruopreo
r rs are adopted for
Tor targer size gates. The max. size
of
gaie executed in our country is 18.228
M wdth X 18.228M heioht .

Anchoraqes with post _ Tensioned

Anchor Rods:

The arrangement of post

-
tensioned Anchor Bars, the hydraulic thrust
is transmitted
from trunnion girder to anchor pratq through
high - tensire ancnor bars. These anchor
bars
are housed in Galvanised seteer tubes.
After instalation three rods are to be pre{ensioned
on D/S of trunnion Girder to snare the
equal load.

This type of Anchorages have been used

for the rarges gate and the advangates are:

) considerabry ress steer is required for

the bars which resurts in more compact beam.
) Anchorage movement due to extension
of anchor bars are virtually eliminated.
> Piers may be narrower

The disadvantages in larges gates:

) The rods aj-e to be joined by couplers, the-failure of anchorages
were noticed on
account of failure of couplers.
F The trunnion girder is generary provided
across the vent hence heavy handring ano
eTectton facilities are required.
This type of anchorages are not in practice
in our country. This system is provided onry in
Chamera proiect.
 1

IRUtr,{10\ GrnDEr

-1
F
0i r ri!,\.itii i}J

FL OW

r
A
J.

sEqtpq_rHqllqHlelllrla.L
i
E OF TiiUNi:'N

OF Tl(ir iJ r'i3;i

5Ei ftoN-AA
POSTIENSION ANCiIOR RODS

Post - tensioned prestressed Concrete anchoraqes:

To obtain best arround periormance of Radiar
Gates the use of post - Tensioned,
Prestressed concrete anchorages (pTpS)
are used.
In this system the water thrust is transmitted l\"
to the common trunnion girder through
bracket- The trunniofi girder shal be anchored
to the spiflway prer by a post - tensioned
anchor system ri consrsts of rendons,
Anchors, sheaths, Anchor prate, Bearing prares,
snrms, duplicate grout and vent fitting and
a[ equipment and devrces required for instarratron
and tensioning the anchors. Arternativery post-tensioned
pre-stressed concrete beam arso
rn use for longer gate to mount the
trunnion bracket.
Tendons sha, be formed from murtipre strands
of uncoated steer wire, row reraxatron
stress rerieved steer strand conflrming to
ASTM A. 416 and having UTS 1860Mpa.
Anchorages formed by transfer of roads
through the curved portion of anchor roop
will develop the furr urtimate design strength
of tendon when tested in an unbounoeo
e

/.-:.>_
tr)
 condition without exceeding allowable bearing
stress on the concrete. After tensioning
and
seattng, anchorages will sustain applied
loads without distorsion or other changes
which
result in loss of prestress.

q'

RAO'A[.6Ai- - DETAILS OF IOS'I :FTCJONI D

PRE,5'IAESSED CONCR€-IE
ANCHORS

Large gates can be supported by

narrow spillway piers.
The frictional forces due to movement
of trunnion brackets are elrminated
The prestressed Anchorages put pier
concrete in compression.
The prestressed anchorages are
ress burky than conventionar anchoraoes.
When post -
tensioning force is applied at the ends of cables, the
force decreases alonq rne
cabtes as a result of the following factors.
- Loss of prestress due to creep in concrete.
- Loss of prestress due to shrinkage of concrete.
- Loss of prestress due to relaxation of steel.
- Loss of prestress due to elastic shortening of concrete.
- Loss of prestress due to slip ip anchorages_
- Loss of prestress due to friction along the able(profile) and the anchorages_

Limitation: Initial cosi of anchorage system in totai is higher than ihe conveniionar
svstem
and not adopted for many projects.in our country.

Gate Leaf : .

i) Conventional: This type consists of skin plate with vertical stiffeners, horizontar
grrders, horizontar girder bracings, arms with bracings, trunnions
with bearing tre
between trunnions ( option), trunnion pins, trunnion brackets and rifting
arrangement.

This bonstruction is simple in design and easy in controlling the dimensions

during manufacture and instarration with the rimited facirities of handring. Due to
this advantage, most of the projects are provided with this system
wherever inclined arms are used tie between trunnion rs provided between
trunnions to take care of ihe lateral load. Based on the experience it is found that
tie between trunnion is not advisable for larger spans, since it has no expansion
facility and also cause failure due to development of cracks in welding at the joint
between trunnion arms and tie between trunnion at a later date. Need constant
watch and maintenance. To avoid this it is befter to go for ihrusi pad
arrangement for bigger gates ( i.e., 15M X 10M size gate onwards) to get good
performance.

ii) Orthotropic Desiqn : ln this arrangement the skin plate is being built in with
horizontal stiffener, verticar girders and horizontar girders. The other components
are same as conventional type.

l0
 calculation for
the combined
stresses,
andling systern
is required to
,.int"in
Some times controlling
of d
not widery adopJ;;;;ilensions wirl be arso dirficurt task. ihis method js

The radial gates

are self clos,ed
{. used. one and hence
the followjng
handling system
are

pe drum hoist.
e drum hoist.
rc hoist.

l1
 c9
H; FF
g;EeeEieEiC EO
=o
ip
<E
o<
iSFs; FFg iE; iffo r IIJ
gFgEiEE:;iiE 4.(
lSE d6
<(L
;FS
0a=
r;Ef;F Eru; *r*;E 6do
"=e
QE(J
90.
glsH;g
fs;r;s SIFEH E BHz

J]

A
 t3

/,_\\"
I.-? f' !
go_i
 i:EiDLHExs cNs AFE rN MM 4D

gEI:qC

t4
i5
 Handlinq Equipments For Hvdraulic
Structures

Gates are io be operated for water regulation i.e., water release

Industriarizatjon, rrrigatron, power for drinking,
generation and frood contror
etc.,

These are two types of operating

sysiems by positron. I

Fixed type Hoisting systems:

These are independent hoists provided
for operating
the gates individually and used
for all types of service gates.

Under this group the main

types used are:
1. Screw Hoists
2. Ropedrum Hoists
3. Hydraulic Hoists

Movable hoisting devices: These

are mainiy for operation of stoplogs,
bulk heads
emergency gates and draft tube gates.

The main types used are: Gantry

Orane, Monorail Cranes and movable hbists
etc.,
In case of singie vent better to go
for ropedrum hoist or hydraulic hoist.

For more details refer the following

lS codes for details of specification design
etc,,

lS:l l22SRecommendation for design of

Screw hoisis for Hydraulic gates
2. lS:6938 Code of practice for design
of Rope drum hoists for hydraulic gates
lS:10210 Design criteria of Hydraulic
hoists for gates
4. ls:11733' Guide rines for design of
float di'iven hoisting mechanisms for automatic
gates control.
ls:3177code of praciice for Erectric over head
tfavering cranes and Gantry cranes
ls:807 Code of practice for design, manufacture
and testing ( structurar portion of
Glanes and Hoists)

16
r.

Selt 9lqEIns_qf-Eelg:
that the self
The first step in deciding handling system for hydraulic gaie is io ensure
closing (gravity lowering) or not.

positive
The gate shall be checked for closing under its own weight (without any
n thrust) and downward forces closing the gate while lowering shall be atleast 20% higher
compared to upward forces. The necessary closing / seating load shall be
calculated
pressure
considering the net cross sectional area of the bottom seal and maximum water
acting on it such that the lowering force is more than seating load However' the values of
i closing/seating load shall be greater than those given below:

Tvpe of qate: Minimum seatinq load

Low head gate: 2-5KN/m length of gate
Medium head gates: 5.OKN/m length of gate

. In case of gate is not self closing even by providing ballast accomrnodated in gaie then
one has to go for screw hoist or doubte acting hydraulic hoist for positive thrust to close
ihe gate-
Ex: Sluice gates and Conduit gaies.
. Self closing gates are being operated by Rope drum hoists, Gantry crane, Monorail

A hoist, single acting Hydraulic hoists-

Hoist Gapacitv: The hoist capacity shall be determined taking into consideration the
following forces which might be required to overcome
a) weight of gate leaf along with all its components including the weight of wire rope
and attachments and ballast etc.,
b) All frictional forces comprising of
. Wheel friction
. Seal friction including friction due to initial compression
. Guide friction etc.,

17
 Note: L Consider init
compressive force rs
l Kg/cm length oi seal
or gate Gujde friction is 5%
weignl
Note : 2. In case of
slide gates, sliding friction
may be considered.

. Any hydrodynamic load, jike

down pull / uptift force
. Silt and ice load wherever
etc.,
encountered
. Weight of lifting beam,
if used or
. Any other consideration
specific to a particuiar
site / project.

rces during either lowering

cycle or rarsrng
hus arrived ai shall be
increased by 2OT" to
rwise speciiied by the purchaser,

Note: No direct form

availdble for arriving Hydrodynamic
uplift because ihese load like down pull /
are o.''""'t
rpending on flow
velocity, shape of gaie, position
of gate, siot
tuoy results for accuracy
other wise nearest
en_ Based on the expedences
for low and
ch effective and considered_
For high nead

speed for Hvdraulic

n"*"""1n,*Jr";::ff: sats are 0.3oM/minute to 0.7oM/minute.
the requirement Generarry
most or our sates workins
;
::,.1l"Jjil ::j::#il;t:' the
t t on' In case of large gates,
capacities the speed adopted
is o.3M/min to contror .,n'n
smooth operation wiih out rribration
rherowe*o""or;;:]:":#:::;:ilTi::il:
ressdemandofair

18
 1. Screw Hoists:
Sciew hoists are used generally for smaller vertical lift gates subjected to low and
medium head. Most of the applications manually operaied screw hoists are used. The
power operated can also be adopted if required for sluices. \ /here ever screw hoists
are used the self closing of gaies by applying positive thrusi. The arrangement is shown
in the drawing.
The main parts are: Stem, Nut, Capsten with spiral bevel or worm and worm wheel
{ mechanism for operation of the gate. This system can also be provided with position
indicator, and limit switbhes controlling to gate travel extreme position'
Theavai|abi|ityofstemrodsize,|engihandfaci|ityofmakingsquarethreads
- is governing factor or usage, the capaciti€s normally used fof screw hoist is limited to
15t. Some are using higher capacities on special occasions.

n
 DETAILS OF STEI1
RON

!9E
It fl g,H^T,";itrA,,eiSHyif,:StiJ"T5i*

0E4l!:€

:-T+?;m

. .- . .-
-.r"}.Jr-.'...- -;
I
2- Ropedrum Hoists:
Ropedrum hoists are used extensively for operation of Hydraulic gates for all types of
self closed gates by gravity. Before going for different types and the type of hoist
selected one has to study the following :

Speed required.

Lift of gate vent width available .

Power source available.

Balancing operation'of gate maintaining the lead angle of ropes etc',

Over load protection of hoist required.

Power operation / manual operation or both.

Space availability, working clearances etc.,

Space restriction for movement of pulley blocks/ lifting beams'

 TVpe of hoists
:

ystem for c

. br","
"
;:;'ffi.J;::::::::;j:*",
lift gates generaily
all
in less space.
ll. For operation of Radial
gates
" Ropedrum hoist with upstream
rope suspension.
. Ropedrum wiih dowri
stream rope suspension.

Difference between
U/S and D/.S rope
suspension

UP Sheam sGpensio;

Type oiEFaionGctr-.on More srnce leter ;rnirb

GC

Dalancing is crittcal.
Gears advantage
capacity and reduction is used. The
rat,o capacity of gears, and gear
required is more
wainteJanEe oiRope- ratto required js less.
.Sin^a
-,' ,es r.:::--------
upes are always under-
water, applvino vpc .^--
, , .J .. .v ,rnnF
. r,ut pOUI_)d
and replacempni nr ur .^^^
rOpeS tS water on the gate
ornlcult
Hoist Bridge-
Hoist brrog;l;;;;essat
foi best
rayout

InterferGnie of ropes--.--.--_--
gtrder is required
ttre tocation EinoEt
selected after working
rs to G
vo,crur slrjdy and locate out
rne necessary
clearance of Hoist
, r.. I ne rope shall be alWays
,vrr
tangent to components with movinq
-, the c!r;^ praie
e,u o^irr ^r^+^ Olher parts gates of
wrse the gate top
will bend

Maximum-ipaiities
executed in India

22
'.i

*E*,: E=o:li o+*=t;li

-iEEEiF
eSelg
?=z iElle
Ekis'
"E; h;56 P5!E:
I"E5i!
$: gn* i+ ;e!4e
Ee;_!e
=!
6q
aa
Yii
iEe
1t:-
ra-
R
3
't!Ecj;)
ai
:E
;=5
FgF
EE big
QE
iiz =ee
9+;
3E 6 S r=io
'!',:

c,a

t
B
I
 rS
N
)

))
t
j
AE9r

d ga
r 5l+
R> '":
I
! 5lE t=iF
JF:
9; !, gi :ra'g;
9! :l !
t^
5i Ei 591g
i.6
=;'
6: i al
6e=,i i. ; 1o-

@
 ROPE.

=== 329 WRE ROPE + CONSTRUCTION, RIGHT

HAND LAY UNGALVANIZED MAIN
UTS '180 KG/MI\42 HAVING MIN. BRAKING LOAD
60958 KGS, CONFORT\4tNG TO lS 2266 1989
LENGHT REOUIRED 80 M -2 LENGTHS
WEIGHT = 622.0 KGS

-MOTORi
--J +-- 10KW(15 H P)975RPM SQ.CAGE tNDUCTION
MOTOR,CONTINUOS DUTY,TEFC,CALSS "B'
INSULATION FOOT MOUNTED WORKING ON
4OO/440 V A,C 3 PH,50 CYC/SEC OUT PUT
SHAFT EXTENDED ON BOTH SIDES,FMIME
SIZE ND.]6OL CONFIRI\,4ING TO 15 325 -1NO.

E,M.BRAKE.
25OO AC ELECTROMAGNETIC SOLINOID
OPERATED SINGLE PHASE BRAKE, 1OO% COIL
RATING, CLASS :'B'INSULATION, WORKING ON
4OO /440V AC ,50 C/S WITH BREAKING TORQUE
CAP= 19.30 KGltl.-1NO-

WORII REDUCER:
RATIO 60:1,TYPE "U", SIZE 10" INPUT H.P:15,
INPUT SPEED S75 RPM, OUT PUT TOROUE
530 KGM OUTPUT SHAFT EXTENSION ON
EiTHER SIDE WTH SELF LOCKING.INO

SNA 513: TC PLUIVIMER BLOCK

WITH 2213K BEARING AND H 318 SLEEVE
STATIC CAP = 57 2KN,DYNANIIC CAP :20.0KN

TECHNICAL DETAILS:

NO OF HOISTS : 19NOS
CAPACITY OF HOIST ' 7OT
. SPEED : 0.50M/min
t10%
TYPE :ROPE DRUM HOIST
D/S SUSPENSION
I
- LIFT : 9-50 M
. DESIGNED : AS PFR lS 6938 -

2-5

@
 F l!>
-I trco
(,E
YS
s93 (/)
6*@
@iiE =
>a
i<az
P<
coo-:z
ootrR ^4o
\rm
ttr9 n Ule
o,i;o =<IIJ
<
E ;>s9 To:9
o s!Jo<
,x< he
> @.t) * t)
=(y:

il

=l
E
.-l
6i
trl
6i
z

il
<i
E
Main Sub assemblies :

The ropedrum hoist consists of the following:

1. Drive unit assembly: consists of motor, brake, worm reducer and manual operation.
2. End Gear Box assembly: consists of ropedrum, gear reducers, shafts and bearing
blocks etc.,
3. Dial and Dial assembly
4. Bottom pulley block and rope
5. Supporting structure
6. Electrical controls wiring etc.,

Note : only worm reducers of 50:1 , 60:1 and 70:i ratios are self locking and hence gate is
once lifted, it's never lowered by gravity even when brake is not effective or brare
fails . Therefore if s more safe even for manual operation

The other gear drives are not self locking and hence the moment brake is loose the
gate will be dropped. For manual operation rachet and fall system shall be added for
safety. Also a limit switch arrangement shall be provided to cut off the supply during
manual for safety.
-operation

7. Layout of Hoist: after arriving c.G of gate and lifting centers in the gate, the location
of drums are fixed. considering the pier thicknesses ihe hoist supporting centers are
to be arrived and layout is to be made.

The following points are to be considered while finalizing the layout:

o The iayout is to be made such that the gate shall be easily maintained in the
maintenance chamber at desired level. The lead angle of the rope interference
of wire rope with structure balanced operation shall be considered.
Necessary reference distances, levels and clearances shall be specified.
Safety regulation, poweT supply and operation of gate, dogging posiiion etc.,
shall be considered for fixing the column heights for hoist function and
maintenance of gates.
In case of monorail hoists and crane, hook approach and end clearances are to
be ensured
It is beiter to provide concrete columns than structural steel columns to reduce
vibration while operation.

z1-

\_-;/
8.

ration of ropedrum
hoist to Iift or lower
the

All equipments shall

be conforming to
relevant Indian standards.

Separate locai control

panelr s shall
be_ provided
r.vy,wsu for
,ur eacn
each gate hoist
motor and shall
Sha, be enclosed
ha 6^^r^^^ -, located nedr the
i.e-,
i.e., IPs4
rps4 or rp55_ Foroutdoo. rl€tdl
metat c'l
cabinets with desired
,,";;.;:
",,".u .",-,*1"^lji::":::i"r,"ted
. vury iJ^^ ts
0,n,, rl-oc ,]"torcu
the best suited
red protection

Each control panel

shall contain :

+
+
*
+

be included
Per the

28
 _":-'- _'. _-.:.

t.
Hydrauric hoists are used for operating
various types of gates instared in nydrauiic
structure.
Hydraulic hoists have a number of
advantaoes
) Large force can be appried at desired
speed without the need for gear boxes
having
with several reductjon siages_
F High overall efficiency.
) Absence of over head structure instatatron is more
flexibre for Jocating a bridge
spanning a spillway or werr.
) The speed can be varied i e., different
desired speeds can be adopted separatery
for
hoisting, normal lowering and emergency
lowering. Example: for penstock gates and
lntake gates
) where ever positive thrust is required
for gate crosing the same can be achieved
by
hydraulic hoists_. For example : Sluice
slide gates

Disadvantaqes or detrimental aspects

are:
sensitivity to communication of hydrauric
fluid contamination of fluid when changing
orl can resurt in a common cause
fairure, an event which affects the whore
system.
First few years maintenance is very
ress and after 10 to 12 years operation,
the
replacement of parts cost is more.
Dust free cabinet are needed for effective performance_
Initial cost is moTe.

Usage
useo onty rn gravity_ closing gates.
. Generally used for penstock gates for variable speed
for hoisting by
power pack and lowering by gravity i.e.,
normal lowering and
emefgency lowering,
The radial gates are being operated with
two number of hydraulic hoists
connected on either side.
Generally rr"O -
,_". the
sates. Generaily the capacity wiil be on hisher side
::::i1"1 :':"eThe gates
with less stroke. which are working are in the order of upto 625t
max_ capacity for operation of sluice
slide gates
The hoisiing arrangement
ar(e shown in
reH
the drawings encrosed.
r- --

@
@@
 ls 10210 : Design criteria of hydrauric hoists for gates
gives the generar parameters under
which the hydraulic hoists are designed.

Lifting of gate is carried out by oir pressure

suppried by pumping unit. oir uRder pressure is
.rrected to the interior of the cyrinder on the
stem side, pushing up the piston. The upward
movement of the piston forces the oir on
the other side of the cylinder to return to the tank_

q The hydraulic hoist consists of following parts:

1. Cylinder/ tube
2. Upper cylinder head
3. Lower cylinder head / rod end head
4. Piston
5. piston stem
6. piston seals / rings
7. Eye end
8, Mounting details:.
. Top eye end
. Flange mounting
.
Trunnion mounreo
The materiars serection and design procedure shal
be folowed as per rs 10210.

Hvdraulic operatinq svstem :

cornponents cf hydrauric erectricar system consists
- of ihe foriowing components
. Oil tank
. Filters
. rumps
" Electrical Motors
. FIow direction valves

" Pressure _ relief valves

pressuTe switches
"
o pressure gauges
. Piping
o Control components( relays, push buttons etc.,)

schematic diagram of hydrauric power pack circuit used

for the system is shown in the drawing.
 ,o.r**uwHffiffi",,,."

*...'",J",?,,t,""';:T"l'_",:?:"",T:"f
Most widely used pio
i:Tff;:,"#:T.:,;",ffi?:.":? ffi1.il:""f,":1,:

ectrode type size and current

and can be
e operator.

Specification:

g:'i:* sha' be carried out in accordance

with the speciflcations mentioned
in some of the
ing
I are welding of structural steel.
metal arc welding for general construction
in
!?2 - 1970: Code of procedure for inspection of weros
llIS - 9595
- - 1996 : Code of metal arc wetding
oi c"iUon"r"ng"nuse steels
Some of the precauiions to be borne
in the mind while weldinq are

ine flame cutting_ All oil, grease, paint,

loose
f the weld prior to welding. Notches
or otner
be ground smooth before joint is welJeo.

. shearing of prates
"Tl.T,],0:
permitted on edges of secondary materiar which wirl
materiar must be machine name o.it
ffiX#:i:: !:lii':,"J#'ary cut
"t'"liJc,'r,.t o"

than 4omm and up to 6omm shall be preheated

Yrt"JlSl,llicker to 65'c before flame
"rn'"n

34

@@
' Material ihjcker than 60mm shalj be preheated
welding. to 104"C before flame cuttrng and or
Assemblv:

arried out as per the drawings. Wherever

emoved and grounded wherever necessary.
of girders during assembly and handling
braces to the flanges.
Weldinq Processes :

The welding shall be carried out as per the

.
methods flnalized with the in nouse expertise.
code of practrces of ls standards and the

most widely used welding process in sites is shielded

,arO*lnu metal arc welding

Weld Consumables :
Weld ing of Carbon steel to ca rbon steel :

E7018 low hydrogen electrodes, confirming to specification

CSA W48. i must be used.

(lS 2062 to iS t SzO I SOCrrsy

E 308 - 16 or E 30BL - 16 Stainless steet electrodes confirming to specification

CSA 48 2
must be used. Alternatively E 309 - 16 or E 309 L * '16 stainless steel
electrodes can be
used for Ni - B to 10 steel

E 308 - 16 or 308 L - 16 stainress steer electrodes confirming to specification csA w4g.2

must be used.

An electrode comparson chart is enclosed. The consumption of electrodes per

meter length for fillet and butt welds is also enclosed.

Storaqe of Electrodes :

All electrodes are to be handled as explained below

. All eleclrode c6ntainers arriving at the site shall be examined for damage. Damaged
containers shall be returned to the supplier_

. lmmediately upon opening each can of electrodes the contents shall be placed in a
holding oven held at a temperature of 90. to 120"C
A) DOWN HEAD

b) VERTICAL

c) i{oRlzONTAL

d) OVER HEAD
 e wetotng current costs from a verv smati
is enough if data of current consumpiion
are
have been determjned for definitely typrcal

Some of standard values for current

consumpijon per elecrrode are as belo\ru
below.

Electrode lenoth (nrm

0.340

0 372

Tack Welds:
Tack welds shall be made by qualified fitters,
tackers, or welders and are sublect to the
same quality and preheat requirements as finai
weros.

fack welds shall be held to the minimum srTe necessary

orrentation during
to hold the memoeTs tn proper
welding but shall not be less than 4Omm and more than
70mm rong
Tack welds and temporary welds which are not incorporated
into the frnar werd sha|| be
removed and the surface made flush with origtnal sudace

P recautions for Qualitv welds:

Each bead and layer sha[ be thoroughry creaned of a| srag and spatter before the next
bead or layer is deposited

weids shall be free from cracks, tears and gross porosity Defective werds shal
be
removed..by gaugrng, chipping or grinding and the joint re welded
in accordance witn the
specificaiion where complete penetration welds are to b e welded from both sides, rne
root of the first side werded shal be gauged to sound metar before the
second sioe rs
welded.

when welding in the verticar position, the pr:ogression shal be upwards for a[
oasses.
 l

Limitation of fillet weld: As per iS 9595 : 1996

The f.ilbi welds connecting parts, the fusion faces of which form an angle of more than
128 or less than 60. should not 5e relied upon to transmit calculaled loads at the full working
stresses unless permitted to do so by the standards of the parlicular application

The design throat thickness of the flat or convex fillel weld connecling parts the {uston
faces of which form an angie between 60' and 120", may be derived by.multiplying the leg
length by the approximate facior as follows:

Angle between fusion faces Factor by which leg length is multiplied

in Deqrees to oive design throat thickness
60"-90' 0.70
91"-1 00" 0.65
.1
01.-1 06" 0.60
107.-113' 055
114.-120" 0.50

Minlmum sizes of fillet welds shall be as given below to avoid cracking-

Thickness of thicker Part Size of fillet Weld

Over in mm Up to and including in mm tn mm
6 3

12 4
6
'18 6
12
36 8
18
56 10

150 12
56
16
150

ocations of hvdraulic qates:

and sectio s were difficult task and are
For any fabrication getting full length plates
Bv lolning two pads
to u" rJra"l'L ;;;;; dJsired length and size bv metal arc werdins.
by welding always have some deficiency
though we take lot of precautions

The joints are cnosen at safe zones even

in case of 90% efflciency of ioint th(
desired factor of safeiy can be achieved'
 Some of the trps wherre
the joints are proposed
are as follows:.

important and hence

fuil strengrh
:::roru

e minimized or eliminated.
possible:
of span or near by with
a varjation of
ano bendrng is.moder€te,
No joj.nt js
ng moment occur.

a L-.- -- |
-_i

. No joint shall be providec

n^ flange at point (A) and (B)
because the project r",,"o 1^ 111'on for safety. This is
In our country is mostiy
hence advised. due to the failure of tnis joint
anO
. The joints in flange and
web e t0 be staggered
. ln assembly the weldingjoin
as shown
ts In the girders are atso staggerecl while welding.

'@!
i

ALL BUTI WELDS ARE i

AND
Y WELD

Horizontal Girder

SECTIoN"_AA

@
3. Welding of horizontal girders to end vertical or end box:

GIRDER

Theweldismoreimportanttotransfertheshear|oadfromhorizonta|glrdertoendbox-
DuetoVibraiionunderpartla]operationthisWe|dgenera|lydevelopscracksinaspanof
3 to 5 years operation. One is to be careful in doing this
weld and also the welds are to '

be checked durlng maintenance.

4. Lifting Arrangement:
gate where in the total load takes full
Lifting arrangement ls very importani part in
for at least two girders.
load while lifting. Hence the load is to be transmitted

F+

load under normal

shall be sufflcient to take care of
" The weld strength
conditionandalsoUnderbreak_downtorqueconditionofmotorloading. additional
shown to avotd
. The bracket ls to be located over full depth stiffener as
girder'
bending on YY direction to horizontal

'-err:-ii:l:r.-idrffi
 '
.l}*tler performance the liftjng bracket
shall be fixed matchlng the C.G of the
F duly cneckrng the C. G of gate afler qompletjon of mainufacture and
All othcr welds are atso more important
and continuous one to control
the

in hydraulic
struclures because at the poinrs
e no weld corrosion:i: ::j:_r^,:"d
::
Wher
- -' r rs rusreo n"t o"'n"o
ano got ;:;t"]i:::Til:tT;:
damaged.. In case if one wants
' jhent
rntermitlenr
Inlerm the .,^l^:1t:1,:10
weld rhtr
wercr
" matching plates at jointare to
,"0,,,J;;;Jl::ilt"ffi:;;:"J,il:
rhe other as ,.^ .^,t:-:,,^"1
over the
to go ?:;
for
be machined and sei one
""
B. Radial Gates:

be proposed For larger gates

the skin prate shal be made
shall be taken that joints q(E
with Il as horizontal joints and care
rL/ utr
r,,,,!r ate to be crucily joints (
used. + ) shall not be

-r--{-- l

--r€-+-
ll
IT
ll

All weids welded in jig shall

bre prepared with D/S opening
as shown.

" wfth werdins from U/s open ro faciritare

]f':::"":i:ililir""^::::,ed
after alignment with down hand
positjon
werdins

The skin plate jojnt is so located

that there wjll be atleast 50 75 mm
gap from Tee weld. .
- minimum

VERTICAL TEE
 D/S ELEVATION

,]

@
 The location of horizontar
l0int is made where bending moment rs ress for safety.
No joint is provided at centre of
span / support where max. bending moment
occurs

Where ever the X-ray or UT is not possible

it is betier to go for backing plate.

SKIN PLATE

,I

@
 The thickness of backing plate may be up to 8mm to mm and width of
may be 80 to 1oo mm. Alternaiively if the skin plate manufacture is carried out
shop assembly the joint may be proposed as follows for easy assembly at slte
sealing run is to be made for leak proof .
WELD AT SIDES AFTER
Y AND ALIGNIVIENT

Note: where ever shop assembly of skin.plate care shall be exercised to get accurate
width in construction otherwise gate cannot be matched to suit the vent'

t' . 2. Horizontal girders:

. For loining the rqquired size of plate butt welds of full strength 100% X-ray
q

r'l weldsaretobeprovided'Forbiggergatesconsideringihemateria|availabi
handling facilities etc-, one or two site ioints are provided to suit the
requirement"
l;:l .ForallpracticatpurposesavoidingtheSitejointwillbesafestmeihod'The
l,:.
of joint may be adopted at minimum bending moment zone and
irl

1i

:
3

The typicaljoint for

Horizontal girder is as follows
:

ALI. B UTT WELDS ARE

FLJLL STRENGTH BUTT

Y OUALITY WELD WELD

sIl.IIq& 8!

joints w*h continue werds.

JffiH::T=r:::"n:"nJ",o"o And the sizes or werd ma,

3. Tie between trunn ion:

The re between
'|rre tie oetween trunnion is provided
to take care of raterar roads as tensions
between trunnions,
No of projects (Radiar gates were
faired on account of farrure oi rie
The tie between trunnion is to between welds..
be welded to cast steel trunnlon
. The history speaks that these weids
are Oevetoping cracks after few years
operatron rn some projects the of
werd provrded is insufficient and there
record of we jd inspectjon. is no
. ln some projects the welding has done
only on top and no weld is provjded
bottom and sides. people are at the
takrng advantage if quajtty checks are
At the same time one has to not made.
remember these structures have to withstand
water loads. the
 -ia=,

By experience it is better to provide tie between tiunnion to the gate size max
15.0M X 10.0M and for bigger gates ii ls better to go for the thrust block, so that
the lateral load can be transferred directly to pier through brackei flange'

TIE BETWEEN TRUNNION

-t
-1,
,f-

ol
i,'
ELEVATION
ll1
FLOW
--,J TRUNNION RH
TRUNN ON

l,A

_J
z-t

I
 The sequence
of weldi nq shall
be as fo/lows:

hydrogen elecirode (7018).

ct reguired and lower the same

over bottom
shown'
cker Plate '

r ne ma jn oolective
is io obtajn sound
defect free welded jojnts

inclusions or porosiiy as revealed

in non _
variaiions in the
normal
Hfi:;il"
aflecl Ihe functjon of the joint, it is termed
as

. Sub_standard welding
. consumables.
Inefficient workman
shio.
r Lack of cleanliness
' Un favourable properties
of the base metaj.
 ' Low ambient temperature and humid atmosphere.

Every fabricator must strive to prevent the occurrence of

weld defects in the
instance and to rectjfy them if they have occurred. Rectification
welding
increases fabricaiion costs considerably.
Typical Defects which can occur in arc Welds :
1. Incomplete Penetrations :
This defect occurs at the root of the joint when the werd metar fairs
to reach
or weld metal fails to fuse compretery with the root faces of the joint.
As a resurt,
void remains ai the root zone which may contain slag, inclusions. In
a fillei
poor penetrations at the root zone can give rise to cracking of
singre butt werd.

i,
ilir' Incomptete penetration in a single Vee butt weld
In a weld adequate root penetration is ensured by using :

. ' Correct size of elecirode.

i' . Sufflciently high current.
ll . Directing the arc towards the root during deposition of the root pass.
li,, Rectification of this defect is a very costly proposition because it
il
removal of the entire thickness of the weld and re weldino.
iri
i,
2. Lack of Fusion :
l
LACK OF FUSION is deflned as a condition where boundanes removal of
j
entire thickness of the weld metal and base metal or betvveen adjacent layers
lt
I weld metal.

This defect is caused by tl.re presence of :

' Scale ((rusting)

' Dirt
' Oxide
' Slag
. Other non metallic substances which prevent the underlying metal from reachi
metallic temperature.

To prevent the occurrence of this defect, the following steps should be iaken :

Keep the joint surface clean

Use adequate welding cunent
De slag each Weld pass thoroughly
 Place weld passes
correc y nex to each
other
Lack of fusion is
rectified in Ure same
way as lack of preventton.
3. Undercut:
This defect appears
a or dis - continuous
werd pass .ro
;ffi:;fi""J-"JT::f sroove ar the toes of
'.

Undercut in the vertical

leg of a horizontal and
vertical filel weld.
It occufs prominentiy
on the edge of a flret
werd deposrted in the horizoniar
. This defect is usually
caused by :
position.
. Excessive we,ding
current
, Too high speed of arc
travel
' Wrong electrode angle
or excessive side manrpulation
. Also causes due ,o o.ro
or improperly formuiated
electrodes.
Note : In the case o, statically
|oaded structures the presence
intermlttent under of small and
cutting wirr reduce fatigue
endurance of the werded joint
and hence it should not be permitted.

Rectification:

g should correspond to the recornmended

procedure for partrcular
steel.
4. Over lap:
The defect occurs at the
toes of weld and consists of weld _
over flowed on the base metal whrch has
iso,atedintermit,"",;;;;"ili:i j',T1;JJIT:Ti:HHJ',llrf
an apparent jncrease in
the weld s jze.
i"i;J":il,7
 Cause:
I lt is occurred
metal flows by the wetd

an electrode in relation to
the welding position,
coupled with a too low and
welding speed also promote
its

rn leg length rs made

in the
sag and causes overlapping
in
ln the figure.

Overlap in a horizontal_vertical
fillet weld
Rectification:
Slight and intermitteni over lapping
may be ignoreo rn statjcally loaded
srructures, but it should not
b
acr as stress _ raises,
";J:'T.'H;.J ilTffiilil ;lr?H'::::ffi:J,,il:
excess infused weld metal. Care
should be taken to leave rne smooth
surface.

Non meta,ic particres of comparaiivery

rarge size enrrapped in the weld
are termed as slag inclusion. metai

Slag inclusions in a single-Vee butt wetd

Slag inclusions are detected by the

normal non destructive testing methods.
While non - metaliic inclusions are
observed in the weid micro structure
magnification. at high

Causes:
 SIag jnclusions usually
occurs
the slag between the
disposiiion of su
also be caused by heavy
mill scale
present on the surface

ff :lT:ffi :tx;f ':fi Tiil"T;T.Til::::';[;ff ']:ilil::;

The melting chz
v s cos ty o'he rust n g :#:::: :; j:ililJil"::T:T:,: T,.:' H,l',i:;
freety to the surface or ti e wuro pool
::#l""f];l and easily removabje on

.'Prevention:
I Use proper welding consumables.
I Keep joint surf'aces (especraty
gas cut surfaces) ano oare
fi,er wires perfectiy c,ean
ano ctean the base metal
thoroughly before welding.
r Avoid under cuts and gaps
between deposited perfec,y
ciean and crean the base
metal thoroughly before welding.
r Avoid under cuts and gaps
Detween deposited passes.
r Clean the slag thoroughly
between weld passes.

The strength of welded joint

may be considere
rncrusions or eronsated
rines or incrusions
sometrmes give rise to radiatrng
a*he _Jilff::":.jtrffi;T:.l
hajr line cracks. The presence
globurar incrusion may
of small, isojated
not however, seriousry affect the
static strength of a joint and
rnese may normally be disregarded.

Rectification:
The portions of werd.metar
which contain srag rncrusrons must
and then filled wiih sound be removed
wero metal

6. Porositv:
The presence of a group of gas
pores rn a weld caused by the
entrapment of
gas dunng solidification is
termed as porosity.
 The pores are in the form of smat
sphericar cavities erther crustered rbcary
or
scattered through out the werd
deposit. sometimes entrapped gas gives
rise to
srngle large cavity, which is
termed as a brow hore. In some rarer
cases, erongated
or tubular gas cavities are presented
these are referred to as prprng or worm
holes.
The gases are evolved by the chemical
reactions In fie welding are these
gases may have high sorubirity
in the morten werd metar, but as the
metar soridifies
and cools, their solubility decreases
rapidly and they are revolved from the
metal,
sometrmes'if the werd meiar soridification
and cooring rs too rapid, the gas gets
entrapped in the form of porositv.

Causes:
I
chemicaly imperfect werding consumabres
for exampre deficient in deoxidizers
E
Faulty composition of the base metal
or electrode wire for example, high sulphur
content.
!
Oil, grease moisture and mill scale on the joint
surface.
I
Excessive moisture jn the eiectrode coating or submerged _
are flux.
1 Inadequaie gas shielding or rmpure gas rn a gas shielded process.
. Low welding current or too long an arc.
Quick freezing of the weld deposit.

Puddling of the weld metal and use of preheat or higher current allow
sufficient time for the dissorved gases to escape from the werd metar. presence
of
small, finally dispersed porosity is norma|y not expected to affeci the static and even
dynamic properties of a wetded joint. However excessive porosity blow hores or
ptptng must be guarded against as they seriously impair ihese properiies
Their
presence is detected by the conventional NDT methods. The defective portions must
be removed and re-welded.

'7 Crack :

crack is defined as a discontinuity caused by ihe tearing of the metar while in

a plastic condition (hot crack) or by fracturing of the metal when cold (cold crack). lt
represents a faiiure under stress of a metal when it is behaving in a britfle manner
ie., it is inclined to fracture without deformation.
 Cracking can occur in the
weJd metalj
may be classifred according or rn the base metal. Cracks
-'-',,v ro tocatid of Jine
srze trom large cracks and they may range in
which can be
exkemely smail fissures eye (called macro cracks) to
which are d,
mrcro cracks) Typical aro ol a microscope (cailed
cracks occurnng
are as shown.

found to be coated with """""u rr'r r/rs surrace'

the b,,rue ^^-, or possibly black
^ scate scale.

Classification of cracking according

to location in a weldment :

1) Weld metal crater cracKtng.

2) Weld metal transverse cracKrng.
3) Base metal heat affected zone transverse
cracking
4) Weld metal longitudinal cracking
5) Toe crackrng
6) Underbead cracking
7) Fuslon line cracking
8) Weld metal root cracking.

Hot cracking occurs in a soridifying

metar at the end of the soridification range,
when this last portion is still liquid
and the mass of the metar is unable to deform
without cracking. At this stage when vibratjonal
or contractJon stresses are imposed

@
 I

indicated by arrows

Sbrinkage stress--

Shrinkag€ stress
Stage'1 Stage 2

while hot cracking propensity increases wiih increasing joint restraint, it is

really the presence of certain undesirable low
- freezing compounds formed bV strav
elements which promotes the phenomenon

Causes:
The hot cracking iendency caused by phosphorous, sulphur and silicon
increases with carbon and alloy content of the steel and hence high tensile steels
must have lower percentage of these elements than in the case of mild steel. This
applies as much to the weld metal as the base metal
 STANDARD TIME
FOR FILLET WELDIN

;rze o
eld In
mm Horizontal fillet weld Down hand fillet weid \ /

Time in min/m Electrode Dia J consumption in

in mm I Electrodes/m Time in Erectrodei
minlm
"on"t*o,,on
I tength
Dia in mm I Elecirodes/m
_11.28l8.53 _____ _.1____lelsth
3.15 I 4 oo
4.0 | 2.7 9.02 3.15
/ 16 92 | 12.64 I 3.2
3.15 / 4.0 | 5.0
11 94 6.0t40/32 14_38 / 10 74 315t4.O 51t34
c 26 23 I 19.59 3.15 / 4.A
9.3t62 22.84 / 11.a6 3.15 l4n 8.1 I 5.4
34 69 I 25.91 / 24_6 3.15t40/50 12.3/8.2/6.6 21 04 4.A I 5.0 3.0/31
8
_ 4.0 / 5.0 liteo
26 31
l

5.0 / 6.30 30/40

10
?o a/4
5.0/63r)
12 3.0 / 7.5

55.04 5.0 / 6.30 3.0i 1161

v_
73.94 50/6.30
16
3.0/166
95.86 5.0/630 3.A | 22.4

"'"' Sffit;ierectrode
length
:
: 450mm
50mm
inctudes the fotrowins
r. "o:1.
In" ii-:s
Jet up elements:
tl
A. 1. Electrode burn-ng time
1. E rectrode changing
time.
2. srag removal time.

E- Machine set up
1.
a ,?iffi; :ff ,y;iiT,'J,*:i,," the wo rk s por
 OJ (r) N) NJ
O (, N l\)
O_) N) N O co Jo) NJ O o_)

:=
-D
q) ilo
I lo
o it:
Ilr
(t < F-l
NJ N) NJ N) N) I! NJ
J
ltr
f cz
(, (, a-
(, (,
.:< o f o
o O
^= (o
n) m
o;=
-.DOJ
@
!
OJ IL
t1 ru (o Co co co co
-D -n
o o (<lo
ta
o o a
l +l-llf, |
-J

o) (,
tl c
:l
mt
rol
ol i
I
z
@ OJ G t\.: -! Tl I

!.
!i l 3l 1"{
-vlN) f.J (o C -o m ^

f 3iiI
co C' o
O') I r"r
A N.) J
CN
3
(D
(o m
tlll -m
q) Nltul\ N N
ac lrll -i
l/_\ r-
t:lx. !ljl\
I lo) IO) p (J) N] so 19,
N N.\'
-U
o o J
E
t@i
illi
iolio
l- /S ^-
tt\ I\J N) ctl CI)
N)
3 llll
liil m
lo
ltu lo
ia-
lf
loj
to;
.?
-a (!
N)
N) N]
\ -! (o --l O)
(Jl Cr) O (,)
C'I
ti!
1/L
U)

m
t6 o) O @
O O
N] o)
O O O N) NJ
Co P€€l TI
o :r oo i il) m
f,
-J
n oE-; m
'0Jl
t-
N) IJ NJ N IJ IN l\)
(Jl i-n (, -t-li fl
f/o ltu m
z
I t< o
-{
-U
o I !.)
I /-
II
l! IP
f @ co co co
'n
lo_
90 @lx
ola
N
(, :JI \t- z
-U 1f, =l-\
<JF h
o qr (,IN o
@ \ N (ols -U =
: N) N) N (n
O) co lco Cr) o) N
IO) O') t\ o T m o.
l- o N) N) J o
(Jl
f (D o f
o
5
=n c-
(o O I

N) N) N] j:
N) gn (o @ -D q
O O O :.1
co
li O'r A N-) O')
O
N) ()) o E
c il
F (n
N) 3 1 f

I
(,r
(o N) N t\) @ --l (,
O O O
O O o
o) O --l ())
o)
! O
O O O O O @
CI
o) (o
l\)
N)
@ co
@
(.c)

3
T{€m
; -:i.+
o6;o
0Jl
 -,,a1 .q
t-- G
lullal o a.)
eq)
IlilEs_
ll> - tr I
I llo o _ F /
I lt.!) ! (o
I
O /
q)J E (o o cv o tv O
lllu = =
i>.l T--r---
C')
Ot |r)
cr)
LO
ro N o l(o o)
tr)

c
UI
o @ co (o c')
a'l o O !- c\i (o
n
cN
Id c')
tx cCJ E
IY
lo tL
=. uJ
(J c! t; ql(o E :lvl Yl
lq)
o_ C\i (o :/= (\ co l(o ot
a
- lc! N 9l

li
(J
lL'J E o, -l a)l ccl
lo f rf)
l> o E N
(t
lG (I()
olo
\ql
:l I
tf,
o-
s-
--t v l'$ .C
Kl-i :l
I

I
o
o)
() ll ".tl
\t Vl "rl
$l
I
o
o E q
I
t E N *l^ N N c\l
EG
;.gP*
E*cY c
H o'o t O
o
LO (o O O o) O
LU}}Lb (o O
(r) (o (o ro c.)
(o
(o @ cr,
o- 6l !l
ol ol Sl
|r)
Itr -l -cl
i; N
(f)
.l_ ;El
= bl
:t
otd (o <.r lcci o c!
(o |f) ro
o =xl !t \Jl

t-
to)
c
QJ E LO
l(, a? lo
ql+
t:
uJ D- ^i ol- 9l- lr) d (\
lr! Lr)
't\
f
Lal
E ol
o
o co
E o_ \t !4)
.=( .:xX
m (E\uL
/t! rF
,: -l-
- a)

O h ;p
(f) E LO (EO*
! E N c{ N
c(g C\t N N
Lr >a
I
3 :j
E
o E (o co
O N (o @ o l(

N rl

@
 lntroduction:

parts, gate Jeal

hoists and its supporting
^?:ou:o due
corrosion strucrures
to climaiic condition' biochemical
s acting on it. otherwisu reactionand
ment of pafts may o"""r"tT^t^:^111'pments may deteriorate
necessary and such replacement
stlY' Therefor; *';;":
equrpment and to increase
main purposes. ,,:he rire. or o"*.. *"Li,.H,i"fini;:tff;[ij"l:TJ:
. The first one is to protect
the sieel from corrosion.
. The second for decorative
appearance_

Painting for hydro mechanice

;i; '-,
ri' u p"inti n g
; #1 r"
j:",:H
;, "'
r, ates t
n :ffi i"" :ffi"T :: ; ii lJ
o

L Applying paint as fresi

rI Removar or o o
o;.;:.,:l'l;o''ffi:ffiiT::l,,i"int"
"n."

The procedure for sufrace preparation

shail be as forows:

' weld spatters or any other surface

irregurarities shalr be removed
before cleaning. by any suitabre means

' All oir grease and dirt sha, be

removed from the surface
spirits, Xylol or white gasoiine by the use of crean materiar
and ctean iping *"i.ri"f r.
"

exceeding 65 microns.
 ,"\-J.
. The fig_ B Sa 2/z is
given.

tr

@
 FoTmore details of cleaning method
refer lS 1477 (paft-j _ 1g71
----- - -----_sudaec-ofslaiRie-ss
ste'er, nicker, bronze and
)
machined surface adjacent to metar
being creaned or painted shat work
be protected by maki g tape or by other
during the cleaning and painting suitabre means
operations.
Primers shat be appried as soon
as the surface preparation is comprete
deveropment of surface rusting. and prior to the
In case there is considerabre time gap,
shall.be cleaned prior to prjming. the surface

of concrete:
with concrete shall be cleaned as
detaireo
Io prevent rusting during the shipment
awaiting installation. while

ll. Embedded parts whieh are

not in contact with concrete and gate parts:
. Two coats of zinc rich
su rr"
"e wr,iii .; il' ; ::n :i"# J":}:5i':"T'jT,",#T.:l:::":"
atmosphere or subme T;
s ha' be ro owed
||
J'""i
pait so as to get',a dry firm
J]If: jT::l :iffil,:r"., H;_:: ;: il ":"r:,#:
thickness of go microns in each coai.
thickness of paint Totar dry flrm
shall be 3OO microns.

' surfaces not to be painted: The

fotowing surfaces are noi to be painted
other wise specified unress or
a) Machine finished or slmilar sudace
b) Surfaces whlch will be rn contact with
concrete
c) Stainless steel overlay surfaces
d) Surfaces in sliding or rolling contact
e) Galvanized surfd.ces, brass and bronze
surfaces.
f) Aluminum alloy surfaces
All finished surfaces of fr
dur ng sh pment *h
",
coating of gasoline "'i;:;ffl:,ff1,::'.::ii=;::::.r:ff ]il;J?.1lll,illl;;
soluble rust preventive compound
or equivalent
'Gates:

' Primer coat: over the prepared

surface one coat of inorganic zinc siricate
giving a dry pnmer
t 5 microns shourd be appried. Arternativery two coats
firm thickness of 70
of zinc rich primer, whrch shourd
contain not ress than E5% zinc on dry
applied to give a total dry film thickness firm shourd be
of 75 t 5 microns.
 *ryi,;
_______________appl jed-.af Two coats of solven
r ress coai tar epoxv paints rhese
,ro*, ,,.r11ottt"l d"b;;;;r:;;::t sharl be

,r,
" no t o
"
lli" Jff *L,f;ill Tff
".T T :; T, :,:" ffi #. ;#:T#;
J,

hail be applied to give

a dry film thickness
of

machinery incruding gearing'

i|']Tl?""i
ospnate priming paint to give
necessary. joiher bought out items
minimum flim
.tr.,, i; o.'."6"'i

c) Machined surfaces:
AIr machined sudaces of ferrous
metar incruding screw threads
exposed during shipmeni which wi, be
or instaration sha, be.cieaned
by suitabre sorvent and

ranteed film thickness are to

be arrived from
tufacturers and incorpofated the
totat film
. tmospheric conditions of project.

@*,
 Ui4[-s4flLc thoroughty as directed
by pain manufactu rer before
a) Brush / and during use
roller
b) Conventional spray

1971

ses and remedies

The carrying oti'"rn

o"ffilwing
. The rusting is noticed conoitions:
ajl over the surface or
. Rusiing is severe or
. has damased the primer
:i1.,::?r:ldu::::::, coat exposing the metar
and is norrced
. The laint film has
erod ed badly' the scrap
carry outfresh paintino. of entire paint fiim to the
base metal and
Note: In case of mainten-an
tce and renovation:
repainting. Refer lS 14 7 (part Il) 1971
and - for checkinq

moving the old paint fhe

and descaled by either surfaces shail ire derusred
mect by one or more of the methods'
a) wire brushing , a"r",t"n'"""u
rt rg' and chipping
sand paperi g or cleaning
or abr.asive paper with steel wool
b) power tool cleaning
c) Elame cleaning
d) Sand blasting or shot flasting
and
e) Chemical rust femovat.

):::'.rt['ff1,""t"T""::l*tiono" shalr be decided based on conditions existins. After

originaily proposed
some are painted without ""
,.",'"0 and rusting this will amounts
and deteriorate fasterthan,tlffi[l :'1"*'"t to no painting
 I ne following steps
involved tn.
Inspection of painting
1
1. Generar . " v"'t tttr ts dre
are
^-^^-_, inspection b";;.) and dufing painting
2. viseneih,
Viscosity r^^.
test of^,paints
3, rhickness test _
using Elcometer
;pection gf general
appearance of flnished work.
General: The aim
of ir

Idli
' in
;*r, ::,:ffi
progress. Any test
."","0
:il',,
ried out l"^':::j':"'"
fl *t":l:i
H'-# :i,l: ?il Hfi :
rneans a close supervision
should be non d(
while the work is
nsture, should be
either
",n - nature or' if of destructive
general appearances,
to areas *n'"n
or brestricted ":t"u""ue
n ,"""il;":::r:,: :"""T;T,#ilT:"lil,t"jt:
comprere repet*ion
**"
*l,.*nu"n ""t ''
In.:lection of surfaces
prior to painting:
.' adicle lnspection
will depend on whether
is to be painted for I

the first time or is an

to be ,.uo",nJtJ.'noo"

-":,T;::H::,ilT:l painted): rhe roirowing

shail be decided by
inspection:
feasible or recommended:
b) The iniermeo,"r"
oro"un'nn treatments to
be applied'
c) The painting ."h"dul " if found necessary;
the specifications for
performance.or,*olj,T the paint for
th" particurar
"n.rring
d) The method of application,
whether by brush, roller
or spray.

OId Work (Which

requires r
The following shali
a) whether the un,,ru be decided by inspection:
r''|'vvqu'
ur,'"o"tn*ing):
b) whetherrepainting**
:;l]:::::;;J,"J:":::.,,.

'@
\::-/'

,
r_:--_
',j
 For ascertaining whether the old paint
has deteriorated@!@ e*t"nt that its
complete removal_ts necessary, "n
th,e following test for embritflement should
em ployed; be

A square coin such as a 5 paisa

coin shair be pressed with the straight
edge on an
angle of 45' againsi the paint
firm. This wiir resurt in a chip of paint breaking
roose from the
surface if the paint has embrit
ed, lacks adhersion and
.l:,T:H
"* ;il:-il"t;:::':"
embritted, ii wir curr o,., nnu"r
combined with an examrnaJion
up i,-n;J
of the paint fiJm through a magnifying
I l:
grass to observe rne
extent of cracking and a paint
firm which does not show fine hair
cracks under it may be
considered as perfecfly sound.

Inspection during prqparation of

surfaces:

1. Cleaning and Degreasing. At

the work _ site a visual and physical
inspection is
aoequate A degreased steer surfaie
is duter in appearanie than one which is
even
slightly oily
wiping the surface with a piece of white cloth
will show if minute traces of
grease and dust have been
refi on the surface. when steer is
being degreased by wiping
the surface with mineral turpentine
(or any other solveni), it is important to watch
cteanjng rags afe washed or the
changed regularly.

2. Derusting and Descaling:

a) sand brasting: the most
saiisfactory method of removing rust and
scare is by sand
blasting The criterion of inspection
shourd be that the steel after sandbrasting
grayish white meta|ic appearance. has a
The surface shouid be uniform in coror
and srighry
rough only such a uniform appearance
ensures that the surface has been thorougnry
cleaned.

b) Hand Scraping; No defnite method

of inspection may be ,aid down for hand
scraping. rt
is unreasonabre to expeci hand
scraped surfaces to be perfecty crean,
and for purposes of
inspection, air Ioose rust or scare
( and al roose paint in case of repainting) shaI
have been
removed.
 c) Chemical rust removal: ,n".:r." of chemical ,ur(
rusr rcriovar
removal ( ptckling),
shall
shali make sure that
ih,+ \,,.6h;^^ ll pickling), inspection
i
washino .116.
after ^;^r_,j__
:r "'::lr'r]s pickling has removed aii traces
J be inspected n",ti.rturty in
shall of acid. AilI work pieces
nrono-
in""""rriit" corners.
.o

rt is important to inspect
the work to make sure that
or. other contaminaiion no time is arowed for fresh
to take place between the rust
protective .treatment.
protective - - recleaning
P'vv'sqrrrrrg and rne
drlq the Intermediate
intermediate
trearman+ Insoectinn
r*^* - -,. ^r +r-.^ ..__!

;x,;:nim:itr"J;,::"::,#ili:::::J".rff::,::"::1t;
n accordance with
manufacturer,s recommendations.

while in progress, it should

: When inspecting general painting
work
be ensured:

" lff::i::[: ilil'::":"*t arter pre creanins or pre treatments;

may occur in the interim period
thar any
precautions are taken
is removed,
-" vv' that
,"qr -' rspecial
.
when painting after galvanizing;
b) That no painting is carried
out when there is danger of
dew;

c) That tools used are clean

and not excessively worn:

cl) That the paint in the (

prior ro apprication; that drums
inspected to make aTe
",,H;;:,:"j:J:|]1.H::
e) Thai if paint has thickened because of rong siorage or because
of the evaporation of
the soivents, iis vrscosity is
adjusted as recommended by the paint
manufacturel

I That each coat is a'owed to

dry sufficienty but not excessivery
before apprying the
forlowing coat; that manufaciurer's
instructions for drying time are
property; and adhereo io

g) That every individuar coat is properry appried, reasonabry

rever and smooth and free
from runs and,holidays, (minute
uncovered areas).

66

.r
)
 1. Viscosity
Test of paint
A.simplecheck
orisinar va/ue is toverirl the
", ;":;';::t
viscositv of the paint
cornparins the
o"lng n" .ou;; ;"1 with its
times o, u"lL9
d m e ns on s
* o.",o"o *,1i ::,H: ::::":J
" 11*il;;] ;:[h;*il::rT
2. Thickness
test: The- thi(
alr coats apprie;.;fiIi:::ess or primer paints as w as
the total film thickness
senins of the
rhickness Jllo"o.
*,,n
" ;;;Jerl lt is impoftant that
of
is checked ihe
srandardized
rest b*s '^utno ;r;;';';t""'
test and for this
wth every,""nurtnu purpose
rnstruments
ljke "r" the Eicomsr'rppiied

": il''; "':,:,"j;: ::l

ha nd I ns o,
",.n,n*,ilff";::: ;
"'i#",J*ff their accuracy.
retain :Y

(-l;
 1.0 Defects in finish
:

PossibGJauG
oirtvai% suggesTeaEmeo.es.----

cun stronGa too

&G tolGGurracJ Strokethes@
rrigser@
(when stroke does
not .go beyond Operator should release the trigger after
object) every stroke.
oun"trok% Gunshouldffi
surface.
the surface.
Caint appileO-too nEffi Regulate flow-f plipi
Paini thinned too much, Addtheco@
measure.

s.tlo | --FossibE canse Suggested rGmEEGi

rty air cap anO-nurC-tip--lCEiortEO
Removeairc@
spray pattern)
I nsufficient oiEcorreFovErlapping
ot Follow the previous stroke accuEGiy
t,o
deposit a wet coat.
Gun stroked toJ rap;l1y
16ffi1lg !f Avoid 'whipping anO Ge Tef inerate
sf ow

Gun *troked atrrwong--ingG-

t,c lir"- Gun should be stroT{ at righa;;o6
to
su rface.
Shoking too tarlromGurfaio
Stroke tSO toZSOmm GEGurfacJ
I oo much air pressure.
Use less air presiure as neceGarn

I
g,
- 4,

PossibtEEuG
susgestedEmEEiG
Paint not thinned
out sufficienfly. Addthe"%
solvent by measure.
Not depositing
a wet coat. cnects%
Gunstr@ and stroke.

the paint.
Avoic'w6
strokes.
air pressuE
or reduce nuia pressura-
Using wrong air
cap or fluid irozzle. setectc%
and feed.
cunstroTedroo-f
a--rfiihe-.-s,fieC
overs% Str"k.t.t%
sprayed surface. Spray detail parts first.
End.\,vith a wet coat_

l. Excessiv"-Fiilt Loss _-
PossibteiiuG
Suggesteo
Not'tris-erinfl thelfi-aG;ch- ltshould% renredr.es--.---.----

Stroking at wrong angle

Stroking gG-toqEafrom
dErface Gunshouto@
Wrong airJlF oirrLrr-o
the surfa;A stroketne@
tip. Ascertain anO uGiorrect
Air pressuEGEo h[h. iet uo
Useiheteaffi
 PossibteJauGE
suggested reEEEG
Too high air pressure useteas@
necessary.
seratms pasr suffaFof
G;roEuct Reteasetri@
Wrons arr;torluEj,p.-
Ascertain?nd' uGiorEEt
eun stroteo too Ei}6m-lE6!uEce.- Gluu
Materiat tF-lfied ou=-t
Stroketne@
iofiuch Add the corrGGmEunt

Too humid an atmosphere

sprayourin@
slow syspepsllng solvents
as advised by.the
manufacturers.

Possible cause-
Suggested remeOG
_e, h^;;;-;-.:-;---i-----'-:-----.-
,, v, pc,r
r. luun oegtns to spuiter).
'. 'r ^r
SettleO, cat<eC pr-fiE-ent
Add paint, corr.fi out and strained.
ntGking gfitip. Removeobstrffi
crit. dirt, pa;flG-efclocktng
sun Cteansprayg@
tip, fluid valve or skarner_
paint. Always strain pa jnt before
using it.

lv. painrwilno@
PossibteiiuG
suggesteoiemEEes
Lack ot air pressur.n preGure
tink Check for leaks or lack o--f air ently
Air intake opdins jlEeoi
pressure Thisisacomffi
tank lid, clogged by dried
up palnt. periodically.
Leaking Gsled on tanGvel
eplace wiih a ne@askA

' fj-.r'
@
L_ Sglgftpf._ co n_sta nfl y.

Possible cause Suggested remedies

Fluid nozzle not tightened to spray gun Tighten securely, using good
a gasket.
Leaky connection on fluid ruoe or
Tighien connections. Lubricate packjng.
needle packing (suction gun).
Fluid pipe not tighiened m tne
pressure tank lid.

Vl. Paint leaks from spray gun

Suggested remedies
Fluid needle pacing nut too tignr. Loosen nut. Lubricaie packing.
Packing for fluid needle dry. Lubricate this part daily.
Foreign particle blocks fluid tip, Remove the tip and clean.
Damaged fluid tip or ne€dle. Replace both tip and needle.

*****

e!
*a-

{
!
f
I
!

J
i!
A:

i-:,ib