Industry Overview
Towers and masts are structural systems designed to position equipment, objects, or personnel at elevated levels above the ground. They are widely used for antenna installations, floodlighting, inspection and observation platforms, ski lifts, ropeways, and electrical power transmission lines. The principal design characteristic of a tower is its height, which is generally considerably greater than its horizontal dimensions, making slender structural configurations common where ground space is limited.
Wind loading is a major consideration in tower design because forces act on the structure, installed equipment, conductors, and suspended wires. Lattice structures are therefore widely preferred because they provide flexural rigidity while reducing exposed surface area and allowing wind to pass through the framework. Lattice steel towers consist of interconnected structural members, generally fabricated from angle-profiled steel sections and joined by bolting or welding.
These self-supporting structures are extensively used for high-voltage transmission lines and can be assembled at the erection site, enabling the construction of very tall towers and transportation to locations with difficult access. Their relatively low material requirement, stiffness, reliability, ease of transportation, and cost-effectiveness make lattice towers an important solution for power transmission infrastructure. Key project considerations include load requirements, tower configuration, member detailing, fabrication, galvanizing, quality control, transportation, erection, and maintenance.
Cost Estimation
| Particulars | Cost / Value |
|---|---|
| Plant Capacity | 100 Ton/Day |
| Land & Building (15000 sq.mt.) | US$ 17.33 Lac |
| Plant & Machinery | US$ 6 Lac |
| Working Capital for 2 Months | US$ 30.86 Lac |
| Total Capital Investment | US$ 56.11 Lac |
| Rate of Return | 52% |
| Break Even Point | 39% |
Content Index
- INTRODUCTION
- MAIN PARTS OF LATTICE TOWER
- PEAK
- HIGH VOLTAGE TRANSMISSION TOWERS
- TYPES OF TOWERS ALONG TRANSMISSION LINES
- EXAMPLES OF OVERALL DESIGN OF SUSPENSION TOWERS FROM DIFFERENT COUNTRIES
- FREE STANDING LATTICE TOWERS
- THIS TOWER FACE IS 1100MM WIDE FROM CENTRE-TO-CENTRE OF VERTICAL PIPES.
- AIRCRAFT WARNING LIGHTS CAN BE SUPPLIED AND INSTALLED TO THE TOWER ON REQUEST.
- TOWER TYPES
- CLASSIFICATION ACCORDING TO USE
- ANGLE TOWERS
- PILOT SUSPENSION INSULATOR STRING
- UNEQUAL CROSS ARMS
- NORMALLY 4 TYPES OF SINGLE CIRCUIT TOWERS ARE USED AS DETAILED BELOW
- A) "A" TYPE TOWERS :
- B) "B" TYPE TOWERS :
- C) "C" TYPE TOWERS
- D) "D" TYPE TOWERS :
- 400 KV DOUBLE CIRCUIT TOWERS
- RIVER-CROSSING TOWER
- RAILWAY CROSSING TOWER
- HIGH WAY CROSSING TOWER
- TRANSPOSITION TOWER
- MULTI CIRCUIT TOWERS.
- WEIGHT OF DIFFERENT TYPES OF TOWERS
- WEIGHTS OF TOWERS USED ON VARIOUS VOLTAGE CATEGORIES
- FABRICATION
- BOLTING
- SPACING OF BOLTS AND EDGE DISTANCES
- MAXIMUM EDGE DISTANCE POSSIBLE WITH MINIMUM ANGLE SIZE
- WASHERS
- THICKNESSES OF SPRING WASHERS
- LAP AND BUTT JOINT
- GUSSET PLATES
- BRACING TO LEG CONNECTIONS
- CROSS-ARM CONNECTIONS
- STEP BOLTS AND LADDERS
- ANTI-CLIMBING DEVICES
- DANGER AND NUMBER PLATES
- PHASE AND CIRCUIT PLATES
- BIRD GUARD
- AVIATION REQUIREMENTS:-
- NUMBER PLATE
- CIRCUIT PLATE
- DANGER PLATE
- MATERIALS FOR TOWER CONSTRUCTION
- TOWER MAINTENANCE
- USES AND APPLICATION
- LIGHTING DESIGN
- DIMENSIONS AND SPACING
- TECHNICAL REQUIREMNT OF TUBULER POLES
- SYSTEM DATA
- MATERIALS AND PROCESS:
- POLES SHALL BE DELIVERED IN A SWAGED OF STEPPED FORM.
- B.I.S. SPECIFICATION
- FACTORS GOVERNING TOWER CONFIGURATION
- TOWER HEIGHT
- MINIMUM PERMISSIBLE GROUND CLEARANCE
- MAXIMUM SAG OF LOWERMOST CONDUCTOR
- SPACING OF CONDUCTORS
- VERTICAL CLEARANCE BETWEEN GROUND WIRE AND TOP CONDUCTOR.
- ROLE OF WIND PRESSURE
- VARIATION OF WIND SPEED WITH HEIGHT
- WIND FORCE ON STRUCTURE
- THESE ARE :
- MAXIMUM & MINIMUM TEMPERATURE
- COMPUTATION OF VARIOUS LOADS ON TOWERS
- TRANSVERSE LOAD DUE TO LINE DEVIATION
- WIND LOAD ON TOWER
- LONGITUDINAL LOAD
- TORSIONAL LOAD:
- VERTICAL LOAD
- WEIGHT OF STRUCTURE
- MARKET SURVEY
- GLOBAL POWER TRANSMISSION TOWERS AND CABLES MARKET SEGMENTATION:
- SEGMENTATION BY VOLTAGE RANGE:
- SEGMENTATION BY CURRENT:
- SEGMENTATION BY TYPE:
- SEGMENTATION BY REGION:
- BY CONDUCTOR
- HIGH TEMPERATURE
- BY INSULATION
- REGIONAL OUTLOOK OF LIGHT TOWER MARKET
- COVID-19 IMPACT ON LIGHT TOWER MARKET
- POWER TRANSMISSION LINES & TOWERS MARKET, BY REGION
- MANUFACTURERS/SUPPLIERS OF LATTICE STEEL TOWER
- FABRICATION PROCESS
- (1) PROCUREMENT OF RAW MATERIAL
- (2) FABRICATION
- THE VARIOUS PROCESSES INVOLVED IN THE FABRICATION ARE AS FOLLOWS:
- (A) FOR ANGLE
- STRAIGHTENING
- CUTTING
- BENDING
- PUNCHING AND DRILLING
- HOLING
- (B) FOR PLATES
- TOLERANCES
- (3) GALVANIZING
- 4) QUALITY CONTROL
- (A) FOR RAW MATERIAL
- TOLERANCE:
- (B) FOR FABRICATION
- STRAIGHTENING:
- CUTTING:
- PUNCHING AND DRILLING:
- WELDING:
- (C) FOR GALVANISING:
- (5) MARKING OF MEMBERS FOR IDENTIFICATION
- (6) PACKING TRANSPORTATION AND DELIVERY
- FOR THIS PROJECT:-
- RAW MATERIAL SUPPLIERS
- M.S CHANNELS AND ANGLES
- M.S PLATE
- MIG WELDING WIRE ELECTRODE
- GRINDING AND FINISHING WHEEL
- ZINC INGOT
- PICKLING CHEMICALS
- SULFURIC ACID
- (HCL) PICKLING ACIDS
- PLANT AND MACHINERIES
- COMPLETE PLANT AND MACHINERY
- INDIVIDUAL :-
- CNC ANGLE DRILLING MACHINE
- CNC PLASMA PLATE CUTTING MACHINE
- CNC MACHINES, CNC MACHINE TOOLS & LATHES
- MILLING MACHINE
- POWER HACSAW
- GRINDING MACHINE
- PUNCHING PRESS
- POWER PRESS
- SHEARING MACHINE
- BENDING MACHINE
- WELDING MACHINE
- MIG WELDING MACHINE
- HOT DIP GALVANISING PLANT
- PRECISION MEASURING TOOLS
- EOT CRANE
- POWER TRANSFORMERS
- ELECTRICAL PANEL
- PLATFORM WEIGHING MACHINE
- MATERIAL HANDLING EQUIPMENTS
- JIGS AND FIXTURE
- RAW MATERIAL PHOTOGRAPHS
- M.S CHANNELS AND ANGLES
- M.S PLATE
- MIG WELDING WIRE ELECTRODE
- GRINDING AND FINISHING WHEEL
- ZINC INGOT
- PICKLING CHEMICALS
- SULFURIC ACID
- PRODUCT PHOTOGRAPHS
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
A lattice steel tower is a self-supporting framework structure assembled from interconnected steel structural members. These towers are commonly used for electricity transmission lines and other elevated applications where structural stiffness and reduced wind resistance are important. Members are generally connected through bolts or welding, while galvanized steel is commonly used to improve corrosion resistance. The lattice arrangement also permits wind to pass through the framework, reducing the exposed surface area compared with more compact structures.
Lattice towers are primarily used for power transmission lines, antenna support, floodlighting, observation platforms, and other elevated installations. In power infrastructure, they support conductors and ground wires while maintaining the required electrical and ground clearances. Specialized configurations can also be used for river crossings, railway crossings, highway crossings, transposition arrangements, and multi-circuit transmission systems. Their self-supporting construction makes them suitable for locations where a strong but comparatively lightweight framework is required.
Lattice towers are preferred for many transmission applications because they combine structural stiffness, relatively low material consumption, and effective resistance to wind loading. Their open framework allows wind to pass through the structure, reducing wind pressure and resistance. Individual members can also be transported conveniently and assembled at the erection location, which is useful for difficult or inaccessible sites. Proper structural design, member detailing, bolting, fabrication, galvanizing, and quality control remain essential for reliable long-term performance.
The main manufacturing processes include raw-material procurement, straightening, cutting, bending, punching and drilling, plate processing, fabrication, galvanizing, quality control, marking, packing, transportation, and delivery. Angle sections and plates are processed according to their intended application and required dimensions. Quality checks address raw materials and fabrication operations such as straightening, cutting, punching, drilling, and welding. Hot-dip galvanizing is then used to provide corrosion protection, followed by identification marking and preparation for transportation and erection.
Transmission tower design is influenced by height, ground clearance, conductor spacing, conductor sag, wind pressure, temperature, and the different loads imposed on the structure. Designers must consider transverse, longitudinal, torsional, and vertical loads, together with the weight of the structure and supported electrical components. The overall configuration, number of legs, bracing arrangement, connections, sectioning for transportation, and erection requirements must also be coordinated so that the completed structure provides the required strength, stiffness, stability, and service performance.
A lattice steel tower fabrication facility can require equipment for cutting, drilling, punching, bending, welding, grinding, lifting, measurement, and corrosion protection. The project report lists CNC angle drilling machines, CNC plasma plate cutting machines, milling machines, power hacksaws, grinding machines, punching and power presses, shearing and bending machines, welding and MIG welding machines, a hot-dip galvanising plant, precision measuring tools, EOT cranes, electrical panels, platform weighing machines, material-handling equipment, and jigs and fixtures. The actual equipment configuration depends on the production process and product requirements.
Galvanizing is important because it provides steel tower components with a protective zinc coating that helps resist atmospheric corrosion. Transmission towers are normally installed outdoors and are exposed to moisture and varying environmental conditions throughout their service life. Hot-dip galvanizing is therefore an important stage of tower manufacturing and is followed by quality control to verify the required finish. Proper preparation, pickling, galvanizing, inspection, marking, and handling help maintain the protective quality of fabricated tower members during storage, transportation, erection, and operation.
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