Contents

Foreword

Preface

Chapter1 Introduction

Chapter2 BasicTowerTypes

Chapter3 IntheAir:TheRealitiesofClimbing

Chapter4 TowerBasesandGuyAnchors

Chapter5 TheTowerItself

Chapter6 InstallingTowerAccessories

Chapter7 WorkingwithCranesandLifts

Chapter8 GettingAntennasUpintheAir

Chapter9 CoaxialCablesandConnections

Chapter10 InspectionsandMaintenance

Chapter11 PuttingItAllTogether

Chapter12 Insurance

Chapter13 WorkingwithProfessionals

AppendixA ToolsandGadgets

AppendixB Fasteners

AppendixC RandomThoughtsandTips

AppendixD CommercialProducts—ApplicationNotes

Foreword

Althoughmanyamateursrelyonwireantennashungintreesorverticalsontheirroofs,sometimestheurgestrikestoputupsomethingmore.“Somethingmore”mightbearotatablemultibandYagi,orahigherperchforyour2metervertical,orevenastackedarrayofmonobandbeamsforyourfavoriteHForVHFbands.Inanyevent,“somethingmore”usuallyinvolvesatowertosupportyournewantennasystem,andthat’sthefocusofthisbook.Author Don Daso, K4ZA, presents practical information and techniques gained from decades of

experiencedesigningandbuildingAmateurRadiotowersforhimselfandothers.Aseasonedprofessionaltowerclimber,Donhasworkedoneverythingfromsmallcrank-upandlightdutyfreestandingtowersto200+footrotatingmonsterswithstacksofgiantYagis.AntennaTowersforRadioAmateursdiscussestheprosandconsofvarioustypesoftowersandguides

thereaderthroughtheinstallationprocessfromdiggingholestopouringconcretetostackingsectionstoassemblingguywires to installingantennasandaccessories.Dondiscusses the safetyequipment, toolsandskillsneeded fora successfulproject:What is apersonal fall arrest system,andhowdo Iuse it?Whathand toolsareuseful?What ropesandpulleys tobuy?What specialized toolswillmake the jobeasier?Laterchapterscovermaintenanceandinsuranceissues.Noteveryoneiswillingorabletoinstallor work on their tower, so there is a chapter describing considerations for those who decide to hireprofessionalhelp.Wehopethatthisbookwillinspireyoutoimproveyourantennasystem.Pleaseworksafely,followthe

manufacturer’sinstructions,anddon’thesitatetoaskaknowledgeablehamorprofessionaltowerclimberforhelpifyouhaveanydoubtsorquestions.

DavidSumner,K1ZZChiefExecutiveOfficerNewington,ConnecticutAugust2010

Preface

When the ARRL called and asked me if I would be interested in writing a book about ham radiotowers,Iwasbothflatteredandworried.Flatteredtohavebeenasked—Iassumedtheirquerywasmotivatedbysomeofmyearlierarticles

publishedinQSTandmyNCJ“WorkshopChronicles”column.Worried that I wouldn’t be able to complete the task— both because of my own expanding work

schedule,andbecauseIdidn’tyetknowenoughtocreatesomethingmeaningful.IfindIlearnsomethingnewand/ordifferentoneverytowerjobIdo,soIwasn'tsureIcouldcovereverythinginsufficientdetailtomeeteveryone'sneed.Ihavelotsofpeopletothank—myparents,firstofall,wholetmeputupmyfirsttoweronthefamily

farmat15.Ipouredtheconcreteoneeveningaftermychores,thenclimbeduptheverynextday,carefullyscrunchedmyKedsaroundthetowerlegsforsecurity,leaneddownandhauledupthenextsectionwithashorthunkofrope,lifteditoverheadandintoplace,andthenboltedittogether.Ididthattwomoretimes,andthereitwas,myfirsttower,uponwhichIlatermounteda6meterYagi!I’vecomeawayssincethen.Lotsofverticalmilesofsteelhavebeenclimbed.Lotsofaluminumhung.

Lotsofhoursspentintheair.Lotsoffriends,lotsofclients,haveallcontributedtowhatIknowtoday,andhavetriedtopassalonginthepagesthatfollow.RogerBurt,N4ZC;LennyChertok,W3GRF(SK);FrankDonovan,W3LPL;HankLonberg,KR7X;andJohnCrovelli,W2GD,alldeservespecialmention—forinspiration,perspiration,edificationandmotivationrequiredtocontinueclimbinganddoingtowerwork!SpecialthankstoKimHinceman,K4ATX,forhelpingwithproof-reading.Andveryspecialthanksmustgotomywife,Marti,wholovesandsupportsmeinthis,thegreatestof

hobbyadventures,andwatchesovermyhealth,bothmentalandphysical.

Introduction

Tower...thewordconjuresupimmediateimages.Beingbothnounandverb,it’spowerful.Thoughtsofatowercancreateexcitementforanyhambecausethatoldurgetotransmitandreceivefurther(toworkDX) is still as strong as ever and amotivating force behindmany station improvements.This chapterpresents an overview of Amateur Radio towers and some things to consider if you’re thinking aboutaddingonetoyourstation.

SomeHistoryAt the close of the 19th century, America found itself replicating the European optical telegraphy

system,aline-of-sightsystem.Poles,modestones20or30feetinheight,heldflagsandothersignalingdevices.In1844,SamuelF.B.Morsesetupasuccessfultelegraphlineof30footpolesalongsideroadsandraillines.BythetimeMarconiwasdemonstratinghis“wireless,”in1899,mostmajorUScitieswerealreadysurroundedbyhorizonsfilledwithwiresandpoles(Figure1-1).

Within the first twodecadesofwireless, the race to reachand receive furtherpushedantennaseverhigher.Amateurs,governmentsandseeminglyeveryentrepreneurwantedthenewwirelessinsomeway.Alongwith thiswidespread interestcamecomplaints that thesepolesandwireswerebad—reducingproperty values, creating interference and destroying views and peace of mind for residents. Soundfamiliar?Sure,thatcouldbealeadstoryforyourlocalTVnewstodayorinyourlocalnewspaperorontheInternet.Historically,hamshavealwayssearchedforwaysinwhichtoraisetheirantennaseverhigher.Early

efforts included tallwoodenpoles, usuallymade fromcedar.Themetal structureswe take forgranted

todaycameintomorewidespreadpopularityinthe1920sand1930s,atfirstcommercially.BytheendofWorld War II, as surplus electronics became widely available, ham radio’s growth followed theburgeoning technologyevolution thatAmericawasundergoing.Aquickglance throughQSTmagazinesfromthatperiodshowsadsforsomeoftheearliestcommercialYagiantennas,rotatorsandmetaltowers,alongwithaveritable treasure troveofwarsurplus itemsadvertisedforsale.Figure1-2 shows someexamplesofwhatwasavailabletohamsinthepost-WWIIera.

It’sbecomeincreasinglychallengingfortoday’shamtoputupatower,butstilltheneedanddesireforan effective antenna system persist among active amateurs. I hope that this book will give youencouragementandideastohelpovercomethechallengesandmakeyourtowerareality.

AboutthisBookThisbookwillconsidersomeofthereasonsatypicalhammightwantorneedatower.Ifyoutakethe

timetoanswersomebasicquestionsaboutwhatyouwanttodowithyourhamgear(thesortsofactivitiesyouenjoyandpursue),you’llbeevenfurtheraheadofthegame.Whetheryou’reaDXer,oracontester,oracasualrag-chewer,aVHFoperator,orevenaninveteratetinkeringbuilder,youcanprobablybenefitin

somewayfromhavingatowertosupportwhateversortofantenna(s)youeventuallychoosetouse.Therearerealbenefits,afterall,tohavinganantennauphighandintheclear.Informationinthesechapterswillhelpyoudecidewhetherornotit’spracticaltoconsiderputtingsuch

atowerupbyyourself(perhapswiththehelpoflocalamateurfriends),orwhetheryoushouldcalluponprofessionalhelp.We’llalsoexaminesomeoftheprosandconstovariousapproaches.Thisvolume isnot intended tobeacookbook—meaning,having read it,youwon’tnecessarilybe

immediately,innatelyqualifiedtobuyandinstallyourowntower.Itisintendedtoguideyouthroughsomeof thepitfallsandpossiblestumblingblocks toowningandmaintaininga tower. (Maintenanceremainsoneofthemoremisunderstoodaspectsofthetypicalhamtowerinstallation.)The followingchapterswilldescribe someprofessional solutions to typicalham installations, along

withadvantagesanddisadvantagestovariousapproaches.There’saconsiderableamountof“handson”informationinthisbook,astheauthorhasmadehislivingworkingonhamradiotowersandantennasforthepastfewyears,muchtohisownsurprise!Thisfocusonthepractical,attheexpenseofabstracttheory,isnotmeanttoslightorotherwiselessenitsimportance.Indeed,Ioftencallonfriendsforhelpintheseareas,asmydegreesandexperienceareintheliberalarts,notengineering.TheARRLAntennaBookhasalsolongbeenaprimaryguideonthis incrediblejourney,andit’shopedthat thisbookwillserveasausefulcompanionpiecetothatvolume.

SafetyThroughout this book, you’ll find references and remarks pertaining to safety. In planning and

performingtowerwork,youcannotstresssafetyenough!Towerworkisdangerous.Thesimplelinethatappearson the little label thatRohnputsona tower section—YOUCANBEKILLED—cannotbetakenforgranted.Ifyou’renotsureofwhattodo,ifyou’refrightened,ifyou’reoutofshapeorotherwisephysicallyincapableofluggingnotonlyyourself,butalsoabunchoftoolsandhardwareupintheair,ifyou’renotcarefulandconcernedwithsafetyateverystepoftheprocess—youcanbekilled.There’sareasontowerworkhasbeendeclaredthemostdangerousoccupationinAmerica,andithas

nothingtodowithyourhamradiolicenseclassorexperiencelevelorattitudeorphysicalabilities.It’sthatworkingatheightsisdangerous,pureandsimple.Fallingmorethanafewfeetcankillyou!Whilemosteverythingelseinhamradiocanbetakenforgranted(onlyhighvoltagesfoundinamplifier

buildingorequipmentrepairscomeclosetothislevelofserious,potentiallife-threateningdanger),towerwork cannot be taken for granted. Everything must be evaluated, examined, and an exhaustive set ofchecksandbalancesmustbemet.That’snecessaryeachandeverytimeyouconsiderworkingonatower,regardlessofwhether it’s20feet tallor200feet tall.Andbytheway, thisbookwillassumethatyourhamtowerwillnotexceed200feetinheight.ThosetowersrequireFAAapprovalandmustmeetratherrigorouslightingandpaintingstandards.Althoughtherearesomehamradioinstallationsutilizinghighertowers,wewon’tbeclimbinghigherthan200feetwithinthesepages!Thislevelofseriousnessandemphasisonsafetyisnotmeanttofrightenorotherwisedeteryoufrom

suchwork.Whileit’ssometimesgruelinglabor,towerworkcanalsoberewardingandevenfun.Itcanprovidesomerealhighs,ifyou’llpardonthepun.There’salottobesaidforproblemsolvingatheights,andthere’ssomethingtobesaidfordoingsuchworkonourown.Indeed, tower and antenna work represent one of the areas where the individual experimenter or

buildercanstillshineintoday’sultra-modern,high-tech,surface-mountworld.Andif,withinthesepages,youthinkthere’salotofemphasisplacedonactuallyclimbing—workingaloft—you’reright.Iadmittothinkingthata“realtower”isoneyoucanclimb,notmerelycrankupordownandtiltover,oratubular

design,andsoforth.Iadmitto liking thoselattice-likestructures thatallowyoutoclamberup,wrapalanyardaround,leanbackandgazeatthehorizon!Itneverfailstopleaseandexciteme,insomesmallway,everytimeI’m“upthere.”

TowerHeightandMakingChoices

Of course, one of the major factors you should consider is the height of your antenna(s). Mostantennasaredesignedinwhat’sknownasa“freespace”environment,meaningtheeffectsoftheearthare not considered during modeling. Once the design is finalized, the effects of real earth areconsidered. Effects of real earth vary from location to location, of course. The relatively poorconductivityoftheearthabsorbsRFenergy,whichcausesloss.Antennasthatare“close”totheearth(meaninglessthana¼wavelengthattheiroperatingfrequency),especiallysufferfromsuchlosses.Forgettingbudgetaryconcernsforthemoment,it’spossibletohaveantennasthataretoohigh,justas

itistohaveantennasthataretoolowtobeeffective.Theoldadage“ifitstayedupthroughthewinter,it’s not tall enough,” has been proven wrong, not only through modern modeling programs, but inpracticeaswell.RunningaprogramlikeHFTA(HighFrequencyTerrainAnalysis),bundledwith theARRLAntennaBook, isasolidrecommendationforanyaspiringtowerbuilder!Figures1-Aand1-BshowanHFTAanalysisofperformanceofa20meterYagiat100feetbasedonsurroundingterrainataspecificlocation.Armedwithresultsforyourlocation,youcanmakebetterdecisionsaboutyourtowerandwhatantennasyoumightchoosetoputonit—decisionsthatwillserveyouwellthroughoutyourhamcareer.So,howhighishighenough?Igetaskedthisquestionallthetime,andbyalltypesofoperators.Your

budget, local ordinances and homeowner’s association guidelines, esthetics and what materials youhave on hand are all factors that drive the answer to this question. There is no easy, simple, singleanswer.Buthere’sastartingpoint:Howseriouslydoyoutakehamradio?I always recommend you begin simply— let experience (time) guide your decision-making once

you’vegottenaccustomedtowhatyouwanttodowiththishobby.

DreamingofTowersIt’sprobablynot too far from the truth toconsider thateveryham, ifheor shecould,wouldhavea

tower.Afterall,theantennaisthemostimportantlinkinthecommunicationschain,andgettingituphighandintheclearisalwaysagoodthing.In1910,earlyradiopioneerEdwinArmstrongbuilthimselfa125-foothighantennatower(wooden)at

hisfamilyhomeinYonkers,NewYork,whilestillinhighschool.Soyoucanseethatthisurge(andneed)existedfromradio’sverybeginnings.Suchurgesarealwaystemperedbytheabilitytonotonlyrealizethem,buttopayforthem.Everything

has a price. Some things that go into a tower installation that today’s ham radio urge-holders shouldconsiderarelistedbelow.Ifyou’renotfamiliarwithsomeoftheitems,don’tworryaboutit.We’llgointodetailinthefollowingchapters.thetoweritself,whetherneworusedengineeringdrawingsand/orpermitsexcavationforthebaseand/orguyanchorholesrebar(reinforcingsteel)fortowerbaseand/orguyanchorslumberforbaseformsbasesectionorplateconcrete(andpossibletransporttogetconcretetothebase/anchorholes)guyanchors(ifneeded)guywire(ifneeded) guy hardware (tower bracket, insulators, grips or cable clamps, shackles, thimbles, turnbuckles,equalizerplates)

hardwarerequired(bolts,groundrods/wire,clamps,lightningprotection,etc.)accessoriesrequired(stepbolts,rotatorplate,toporbearingplate,thrustbearingetc)mastanti-climbpanelsshippingcostsformaterialnotpurchasedlocally(thisstuffisheavy!)craneorotherheavyequipment(ifneededorused)

installationlabor(oneormoreworkersasneeded,ifyoucannotclimbyourself)specialtoolsrequiredforinstallation(ropes,ginpole[erectionfixture],capstanwinch,otherclimbingaccessoriesandtools)Note that this list is just items needed to install the tower structure itself. It does not include your

antenna(s)orrotator(s),coaxialcableorcontrolcables,orthemethodofsecuringthosetothetower.Anditdoesn’tincludethemethodofgettingcablesfromtheradiotothetower,orprovidingaccessforthemintoyourradioshack,orprotectingthemfromlightning-induceddamage.Maintenance,whichshouldbeanannualconsideration,isnotmentioned.Thislistispresentedhere,attheverybeginningofthisbook,todemonstratetheseriousnessofsuchan

undertaking.Acquiringasuitableradio tower,and thenraising that tower, isa formidable task. It’snotsomethingtobeundertakenlightly,nottobeconsideredasimple,walk-in-the-parksortofjob.Thisdoesnotmeanyoushouldnotconsider it.Thisdoesnotmeanyoucannotdoit,workingwitha

groupofhamradiopals. It is simply intended to show the scopeof the things thatmustbeconsideredbefore you break ground, the kinds of materials needed, and the somewhat specialized system ofknowledgetowersrequire.Ifyou’resuccessful,attheendoftheprocessyoumighthaveatowerliketheonesshowninFigures1-

3through1-5.

Towers,theRealityYour radio tower represents a considerable investment, in time, money and physical labor. Done

properly,yourtowerisalong-terminvestmentthatyoucanenjoythroughoutyourAmateurRadiocareer.

TowersandLocalGovernmentRegulationsOnceupona time, ifyouwanteda tower foryourhamstation,you justwent aheadandputoneup.

That’s it. End of story.But today,with the rapid proliferation of the cell phone andwireless industryacrossthecountry,thingshavechangeddramatically.EvenaninstallationassimpleastheoneshowninFigure1-6requirescarefulplanning.

Towersaresometimes,perhapsevenoftentimes,perceived—byindividuals,byneighborhoods,bylocalgovernments,bycompaniesandcorporations,andevenbymanyinthemedia—asnegativeorbadthings, literalblightsupon the landscape.So…whatcanahamdo?Theanswer isnotassimpleaswewouldperhapslikeittobe.You have to learn, to know, to understand and to appreciate (even though it may be difficult), any

numberoflegalaspectsoferectingthatprideandjoyinyourownbackyard.Therearezoningordinancesandbuildingcodestofollow.You’lllearnaboutsetbackrequirements(distancetoyourpropertyline),aswellaswindandiceloadingrequirements.Therearemeetings,hearingsandotherhurdlesyoumayberequiredtojumpover.Allofthemaredoneinordertoobtainapermit—whichisanecessarystepforevery potential tower project, without exception. It’s necessary so that you are protected should any“trouble” ever arise.Without a permit, you are subject not only to legal action, but also fines and thepossibilityofbeingforcedtoremovethetoweryouworkedsohardtoerect.Every community (whether we’re talking local, county-wide or state-wide) is different. Building

permitsandregulationsvarywidely.Thebestway toproceed is toactuallyvisit theappropriate localzoningofficeandaskforacopyof therelevantregulations. Ifnecessary,buyacopy—youmusthavethemathandforreviewandstudy.Simplyaskingquestions,orreviewingtheregulationsintheoffice,isnot enough.Not onlywill these regulations describe the permit application process, but the basis andprocessforappealswillalsobespelledout(incaseyourapplicationisdeniedinitially).

Donotbesurprisedifyouhavetoexplainhamradio,hamradiotowersandthelike.Mostzoningandregulatoryoffices(andofficials)areusedtodealingwithapplicationsforstructureswherefolkswillliveorreside.Astructurestrictlyforahobbypurpose,andnotforhabitation,willlikelybenewtothem.Donotbesurprisedifyouarerequiredtohavearegisteredprofessionalengineerwithknowledgeoftowersandantennassignoffonadetaileddesignanddrawingsforyourspecifictowerandantennainstallation(notjustcopiesofpagesfromthemanufacturer’scatalog).Besuretounderstandandfollowallthestepsrequiredbythebuildingofficials.Ifyouskipsome,you

mayfindyourselfpresentedwitha“stopwork”orderwhileyouresolveoutstandingissues.Worstcase,youmaybeforcedtore-doworkwiththepaperworkandinspections.

PRB—HowDoesItApply?TheFCChasaninterestinensuringthatthestationsitlicensescanhaveantennasthatareappropriate

fortheservicestheyareexpectedtorender.InthecaseoftheAmateurRadioservice,theFCCformallyexpressedthatinterestin1985inanFCCdeclarationoflimitedpreemptionofstateandlocalregulations.Commonly known as “PRB-1,” the FCC declaration says that local governments must reasonablyaccommodateAmateurRadiooperations,buttheymaystillzoneforheight,safetyandaestheticconcerns.FulldetailsmaybefoundatontheARRLWebsite.PRB-1doesnot specify aminimumheight belowwhich local governments cannot regulate, but they

mustbe“reasonable”intheiraccommodations.Somestateshaveadoptedstatestatutes,whichcodifyPRB-1.Fiveofthosestates—Alaska,Wyoming,

Virginia,NorthCarolinaandOregon—specifyheightsbelowwhich localgovernments in thosestatesmaynotregulate.ThisactuallygoesfurtherthanPRB-1.Amateursinotherstatesaretryingtoconvincetheirlegislatorstosponsorsimilarlegislation.Thefollowingstateshaveadoptedstatestatutes:Alaska,California,Florida,Idaho,Indiana,Kansas,

Louisiana,Maine,Massachusetts,Mississippi,Missouri,Nevada,NewHampshire,NewMexico,NorthCarolina,Oklahoma,Oregon,Pennsylvania,Tennessee,Texas,Utah,Vermont,Virginia,Washington,WestVirginia,WisconsinandWyoming.This listmayhavechangedsinceIpreparedthisbook,sochecktheARRL’sPRB-1Webpageforthelatestdetails.

OrganizationsAgainstTowersI was surprised, when researching various topics for this book, to encounter so many organized,

apparentlywell-funded(lotsoflawyersrepresented),andwell-writtentreatisesagainsttowers.Granted,muchofthefocusisontheburgeoningcelltowergrowthacrosstheUS,butthepointis,there’salotofresistance out there and it’s growing! This is something you need to be prepared for as you lay thegroundwork for your tower project. For example, Scenic America’s booklet, Taming WirelessTelecommunicationsTowers, remainsoneof thebestoverall argumentsagainst radio towers.Learningabout thecommonobjections isusefulbecauseyouneed tobeprepared toaddress themwhenmakingyourcase.

ResourcesTowermanufacturerspublisha lotof technical informationabout installingandusing theirproducts.

Yourvendormaybeabletosupplyenoughdesigninformationanddrawingstohelpyousatisfyyourlocalbuilding department. As mentioned previously, it’s common for building officials to require that aProfessionalEngineerlicensedinyourstatesignoffonyourdesign.Ifthat’sthecase,otherhamsinyourareamayhavearecommendation.ARRLsponsorstheVolunteerConsultingEngineer(VCE)programand

maylistsomeoneinyourarea.VCEsarefamiliarwithhamradioandwithtypicaltowerinstallations,sothey’llknowaboutandhaveagoodideaofwhatyouarehopingtoaccomplish.SeetheARRLWebsitefordetails.ARRL publishes quite a bit of information that may be useful in developing your tower permit

application on the ARRLWeb site. In addition, the ARRL publishes Antenna Zoning for the RadioAmateurbyFredHopengarten,K1VR.Thesecondedition,revisedandexpanded,hadjustbeenreleasedwhenIwrotethischapter.Fred’sbookissimplyinvaluableinhelpingyounavigatethroughtheredtape!AnothervaluableresourceisK1VR’sWebsite,www.antennazoning.com.If you encounter antenna restrictions or zoning issues that require professional legal assistance, an

ARRLVolunteerCounselmaybeabletohelp.VolunteerCounsels(VCs)areattorneyswhoarefamiliarwithAmateurRadioandantennarestrictions.VCswillprovideaninitialconsultationfreeofcharge,butexpect to pay a fee if you hire one to represent you. As with Volunteer Consulting Engineers, theadvantage is thatVCs are familiarwith ham radio and tower regulations, so youwon’t have to spendvaluabletimebringingthemuptospeed.FormoreinformationandalistofVCs,seetheARRLWebsite.

TIA/EIAStandardThere is an industry standard that applies to commercial tower construction and manufacture.

Introducedin1949,it’scurrentlypublishedbytheTelecommunicationsIndustryAssociation,althoughitwasoriginallypublishedbytheElectronicIndustriesAssociation—whichishowitcametobereferredtoastheTIA/EIAstandard.HamsandtheirattendanttowermanufacturersdonothavetofollowTIA/EIAguidelines,butthere’sawealthofinformation,includingdesigndata,thatanyenterprisingtowerbuilder(orpotentialbuilder)wouldbewisetoconsultandconsider.Thecurrentversion(orrevision,ifyouwill)ofthisstandardisRevisionG,whichbecameeffectivein

January 2006. There were significant changes in this latest release, one example being a moreinternational focus.And another changewas the shift away fromAllowable StressDesign (ASD), theprevailingmethodologyusedintheUSformanyyears,toLoadResistanceFactorDesign(LRFD),whichiswidelyacceptedasmoreaccurate.Revision G is twice the size of Revision F, comprising 15 chapters, supported by 14 annexes,

providinguserswiththeminimumcriteriaforspecifyingandchoosingsteelantennatowers.Windloads,aswellasiceloads,aredramaticallydifferentfromthoseusedinpreviouspublications.Windusedtobeconsideredintermsof“fastestmileperhour,”andnowit’saveragedasathree-secondgust.Iceusedtobeconsideredtobethesameeverywhere,andnowit’sknown(andshown)tobedifferentfordifferentlocations.DetailedmapsillustrateiceandwindconditionsthroughouttheUSAanditsterritories.Anotherchange is the acknowledgment that location determines how towers are designed, built and erected.Previously,towersweresimplybuilttothesamestandards,regardlessoflocation.RevisionGintroducedaclassificationsystemfortowersthatdependsupontheirproximitytopeopleandtheservicesthattowersupports.ThethreeclassesoftowersfoundinthisRevisioninclude:ClassI:Structuresthatduetoheight,use,and/orlocationpresentalowrisktohumanlifeandproperty

damageintheeventoffailure,orthatareusedforservicesthatcanbeconsideredoptional,orwhereadelay in returning such services to operation would be acceptable. Such services might includeresidentialwireless,TV,radioorscannerreception,wirelesscableservice,andAmateurRadio.ClassII:Structuresthatduetoheight,use,and/orlocationpresentasubstantialrisktohumanlifeand

propertydamageintheeventoffailure,andareusedforservicesthatmaybeprovidedbyothermeans.

Suchservicesmight includecommercialwirelesscommunications,TVandradiobroadcasting,cellularandpersonalcommunicationservices,CATVandmicrowavecommunications.ClassIII:Structures thatdue toheight,use, and/or locationpresentahigh risk tohuman lifeand/or

damagetopropertyintheeventoffailureandthatareusedprimarilyforessentialcommunications.Suchservices include communications supporting civil or national defense, emergency, rescue or disastercommunications,andmilitaryandnavigationalservicesRevision G is the first time Amateur Radio services have been considered within the TIA/EIA

standard.Despitebeingrankedasthelowestclassofservice,thereareavarietyofissuesanyhamevenconsideringhavingatowershouldfindofvalue.Suchtopicsinclude:towerloadingandstressesfoundationstoweranchorsguyinggroundingmaintenanceinspectionsiceloading(updatedinRevisionGtoincludeeveryUScounty)minimumwindspeedratings(foreveryUScounty)Obviously,thefirstthinganyhamshouldconsiderforhis/herinstallationisthelastlisteditem—the

windspeedratingwithinhisorherlocale.Youthenreadthemanufacturer’sguidelinespublishedforthetoweryou’reconsideringor intending touse,alongwith theappropriate loadyou intend toputon thattower.MoreinformationontheTIA/EIAstandardmaybefoundintheAppendixtothisbook.

SomeThingsI’veLearnedAlongtheWayHavingafairamountofexperienceinthefieldofhamradiotowerandantennawork,I’dberemissifI

did not share some of themore common tower buildingmistakes encountered throughout the years ofdoing suchwork.Nonamesor call signswill bepresentedhere (toprotect theguiltyparties), but allthesegeneralizationswerederived fromactual casehistories!These aregeneral ideas thatyou shouldkeepinmindthroughouttheprocessofplanningyourtower,assemblingthepieces,andputtingeverythingtogether.

TheTwoBiggestMistakesThe single biggest error encountered is not following directions. Not doing what the manufacturer

wants you to do ranks as the number one mistake on the part of builders, both newly licensed andexperiencedhams,probablynowandforever.It’ssimple:readandfollowthemanufacturer’sdirections!The secondbiggestmistake isnot inspecting the installation— either often enough, or sometimes

never!I’veseenRohnbases(evenonesbuiltabovegrade)wheretwoofthethreetowerlegshadrustedtotallythrough.Whilethat’sacritical(anddangerous)situation,otherexamplesabound:coaxconnectorsunprotected or about to fail, rotation loops that have come undone, coax runs that have come apart incrankupsystems...thelistgoeson.Yousimplycannothaveamechanical/electrical“system”suchasatowerandantennainstallation,whichyoudonotinspectwithsomeregularity.Otherwise,you’resimplylivingonborrowedtimeuntilthefirst,orthenext,failure.AndweallknowthatMurphy’sLawpostulates

suchfailureswilloccurat themost inopportunetime.We’lldealwithinspectionsinsomedetail in thechapteronmaintenance.

OtherFactorsOthermistakesaredifficulttorank,intermsofsomethinglikepriorityororder.Butheretheyare:Improperguytension.Inover20yearsoftowerjobs,I’veencounteredexactlyonetowerinstallation

where the guys were “too tight.” In all other instances, they were simply way too loose. You couldpracticallyseethemoscillate!Thisallowsthetower,theguysthemselves,andespeciallytheloadatthetop,tomoveexcessively.It’saneasyfix,coveredindetailinalaterchapter.Overloading.Hamsdothisallthetime.Andtheyoftengetlucky.Manufacturersbuildinsomesecurity,

for obvious, potential litigation issues. Sometimes, too, the actual tower is stronger than specified.Sometimes,too,thelocationshieldsthetowerfromdamagingwinds,andsoforth.Butjustdon’tdoit—keepinmindthesinglebiggestmistake,previouslymentioned.Andkeepinmindwhattheintendedloadshouldbe.Choosinganimpropermast.IfIhadadollarforeverypieceofwaterpipeI’vereplaced...well,you

knowtherest—I’dbelivingintheCaribbean,hammingupastorm.Theyieldmomentofasomewhattypicalinstallation,sayatwoelementshortened40meterbeammounted10to12feetaboveatribander,canput tremendous stresses onyourmast. So, it stands to reason thatwater pipemade fromunknownmaterials, intended only to transport liquids, is not what we want up there on the tower. Do thecalculations, talk to your local steel supplier or towerhardware supplier—whatever it takes—andinstallaproper,suitablestrengthmast.Failuretoinstallapropergroundsystem.Thisisanecessaryiteminordertoprotectyourhomefrom

lightningstrikes,ofcourse.ButitcanalsopreventRFinterference.Entirebookshavebeenwrittenanddevotedtothistopic.We’llcoveritindetailinthechapteronbases.Hardware issues.This final category refers tonot using “the right stuff” inyour tower and antenna

work.Stainlesssteeland/orgalvanizedfastenersare really theonlychoicewhen itcomes to longevitywhenconfrontingMotherNature.Knowingwhathardwaretouse,when,andhowtoinstallitallcorrectly...allcoveredindetailinlaterchapters.

BasicTowerTypes

Thereare twobroad typesof tower fromwhichyoucanchoose:guyed towers and self-supportingtowers.Thecategoryofself-supportingtowers,alsoreferredtoasfreestanding,isalsobrokendownintotwoclasses:crank-uptowermodelsthatcanberaisedandlowered,andthemoreclassic,taperedself-supportingmodelsatfixedheights.Eachoftheseversionscanbeconstructedfromaluminumorsteel.There are only threemajor considerations in choosing the correct tower style for your station: load

requirement,towerfootprintandcost.First,youneedtodeterminetheantennaloadrequirementsoftheinstallation.Thisisafunctionofthe

antenna’sprojectedwindarea,alongwithallthecoaxialcablesandcontrollines,brackets,rotatorsandthe like that are mounted on your tower. All towers have load ratings (in square feet) under variousconditionsofwindspeedandiceload.Youmustknowhowmuchloadyourplannedantennaspresenttoselectanappropriatetowerandinstallitproperly.It’sagoodideatoaccountforpossiblechangesinyourantennasystemlateronsoyouhavetheflexibilitytoaddantennasorputuplargeronesasyourinterestsevolve.For example, if you’re newly licensed, you probably do not yet know exactly all of the areas that

interest you in the hobby. A tower that’s tall enough and strong enough to support HF antennas isconsiderablymoreeffortandexpensethanonetosupportafewVHF/UHFantennas.Ifyou’rejuststartingoutonVHF,butplantoaddHFcapabilityatsomepoint, it’seasiertoplanforthatnow—ratherthanputtingupalightdutytowerandthendismantlingandreplacingitwithabiggeroneinayearortwo.Second, you need to determine the tower footprint; that’s the amount of land required for your

installation. Considerations include the location of trees and buildings that could interfere with theconstruction of the tower and installation of antennas; property line or building setback requirementsimposedby local regulation; placement of guywires (if needed); and aesthetic concerns expressed byfamilymemberswhomaynotseethesamebeautyinthetowerasyoudo.Forreasonsdiscussedinthefollowingsections,thesmallerthefootprint,themorecostlythetoweritselfandinstallationwillusuallybe. Freestanding towers have the smallest footprint, but they usemore steel in their construction andrequireamoresubstantialconcretebase.Speakingofcosts,that’sthethirdandfinalconsideration.Whatwillyourbudgetallow?Yes,heightis,ofcourse,alsoafactortoconsider.AsexplainedinthesidebarinChapter1,Isuggest

running an HFTA (High Frequency Terrain Analysis) prediction for your location before startingconstruction. The analysis includes those bands that hold your interest and the antenna(s) you’reconsidering,andinaperfectworldwillhelpyoudetermineoptimumantennaheights.AnHFTAanalysisworksverywell,butsometimesthat’snottheyardstickthestationownerisusing.

Forexample,let’ssayyouhavea70foottoweravailable,sothat’swhatyou’regoingtoputupregardless

ofwhat thesoftwarepredicts.Orperhapsyouhave limitedspaceorother requirements thatkeepyourmaximumto40feet.That’sfine—goaheadandplantoputupwhattoweryoucan.Getyourantennaupintheair,andenjoyoperating.

FreestandingTowersTheamountofconcreteusedinthetower’sbaseisrelatedtohowfarapartthelegsarespaced,along

with the overall height of the tower. Freestanding towers with their legs set relatively close togetherrequirelargerconcretebases,alongwithlargersteel.Guyedtowers,incontrast,havegeometryworkingintheirfavor,withthewidespacingoftheguywires.Theendresultofallthis(simplistic)physicsisthatguyedtowersrequirelesssteelintheirstructure

andlessconcreteintheground.Freestandingtowersrequiresignificantlymoresteelandconcrete.Thiscanmeanamoreexpensivetower,aswellashigherinstallationcosts.There are two types of freestanding tower— the monopole and the lattice tower. Monopoles are

structural tubes, tapering from large at the base to smaller at the top. (Rohn’smonopole takes uponlythreesquarefeetatthebase,whilestillrisingto100feet.)Monopolescanbeaestheticallypleasing,buttheyusemoresteelandconcretecompared toanyother tower.Assuch, theyarerelativelyrareamongamateurinstallations,althoughtheyareverycommonincellphoneinstallations.Freestandinglatticetowers(eitherthreeorfour-leggedvarieties)aremorecommon.Atypicalexample

isshowninFigure2-1.Theytakeuprelativelylittlegroundspace,whichis theirprimaryattractiontomost users. Some people are simply turned off by guywires orwould have to install the tower in alocationwhereguywireswouldinterferewithhouseholdactivities.Thecrank-upvarietyoffreestandingtowerwillbediscussedseparately.

BXSeriesTowersFormanyhams,theBXseriesofself-supportingtowerrepresentsaratherlowcostintroductiontoham

towers. Indeed,many people start outwith this class of tower, and the one shown inFigure 2-2 willprovidemanyyearsofenjoymentforitsowner.TheBXtower(referredtoastheStandardmodel)isthesimplestversionofthisseries.TheHBX(referredtoasHeavyDuty)isaheavier-dutyversion,andtheHDBX(referred toasExtraHeavyDuty) isevenheavier-duty.Manufactured formanyyearsbyRohn,thesetowersarenowmadebyThomasShelby&Companyandarestillwidelyavailabletohams.

All versions of BX series tower use sections of various sizes and configurations, all eight feet inlength, to achieve the desired height. All versions use X-bracing. The legs are neither round, tubularmembers nor angle stock, but rather use a stamped, channel steel style construction.TheX-braces arerivetedtogether,andthenrivetedtothechannellegs.Thisconstruction,combinedwiththerelativelymildsteel,makesthemratherlightweighttowers.Again,considerthemasintroductory,“firsttower”models,andyou’llappreciatenotonlytheireconomy,butalsotheirfunctionality.Whendisassembled,eachtowersectiontelescopesinsidethenextlargersection,makingthemeasytotransport.The X-braced legs can be difficult to climb. They are certainly difficult to stand on for extended

periodsoftime,especiallyatthetop,onthesmallestsection,whichisexactlywhereyou’llbeworkingforlongperiods!Sincethelegsarestampedsteel,theywillnotwithstandthetorsionalforcesofamoretypicalroundlegtower.And,sincethebracingisriveted,andnotwelded,thesectionsarenotasstrong.Thesmallsizeofthetopmostsectioncanmakeinsertingarotatorsomewhatdifficult.Forexample,the

popularHy-GainT2XTailtwistermodelwon’tfitinsidethetopsectionatall,althoughIhavehadgoodluckinusingalongmast,withtherotatormountedwelldowninsidethetowerinmodelsfromthelight-dutyBX-40(40feet)totheheavierHBX56-footer.None of these points should discourage you fromusing or putting up one of these towers.They are

inexpensive, unobtrusive (especially if painted flat black!), and more importantly, they can be foundseeminglyeverywhere.

AluminumTowersSelf-supporting towers constructed of aluminum are also available. These towers are made by the

HeightsandUniversalcompanies,andtheyareavailableinvariousconfigurationsandheights.Popularbecauseoftheirlightweight,aluminumtowersaresimplynotasstiffassteeltowers,andwillnotcarrysimilarloads.ConsiderthemforVHFantennasorsmallerHFYagis.Special mention should also be made of some products offered by the Glen Martin Engineering

Company—specifically,theirallaluminum-angle,bolt-togetherdesigntower.Theyalsooffera“Hazer”system,whichisatrackingdevicedesignedtoallowyoutotakeanantennaupanddown50feetofRohn25Gwithoutclimbing.

HeavierDutyFreestandingTowersSayyouwantatowerthatcanhandlelargerantennasoristallerthanthe40to60feettypicalofthe

light duty BX or aluminum freestanding towers. If a guyed tower is not an option, a heavy dutyfreestandingtowerisanotherconsideration.HeavydutytowersfromANWireless,TrylonandRohnarealsoreadilyavailabletohams.Thesearetapereddesigns(goingfromlargerbasesectionstosmallertopsections)availableinawiderangeofheightsandloadratings.Theyoffersomedistinctadvantages.

ANWIRELESSTOWERSLet’sfirstconsidertheANWireless(ANW)towers.AllANWtowersuse50ksisteelthroughoutthe

entirestructure(ksiisaratingforkilo-poundsforcepersquareinch;1ksi=1000psi).ANWusesthissteelforaddedstrengthandweightsavingfeaturesinsteadofthetypical36ksimaterial that’sfoundinmanytowerdesigns.Thetowersreceivefullhot-dipgalvanizingtreatmentafterfabricationtopreventrustontheedgesoratjoints.ANWtowersprovidesignificantwindloadingspecifications,includingatowerandfoundationwithasustained120MPHwindzonerating.With24boltsateachsection-to-sectionintersection,alongwithheavysteelplatesoneachsideofthe

jointforsupport,thisisaruggedtower.Boltdiametersarethesameatthetopofthetowerastheyareatthebottom,too.Thetowerisstrongenoughtobefullyassembled,thenliftedintoplacebycranewithoutworryingaboutstressingthejoints.ANWtowersdon’tloseheightduringconstruction,sincetherearenooverlappingjoints—a100-foottoweris100feettall.ANWoffersoptional⅝-inchstepbolts,spacedevery18inches,soyou’renotclimbingbracesinstalledatawkwardangles.Figure2-3showsa60footANWtowerunderconstruction.

The standard foundation includes a half-section of the next largest tower section, complete withhorizontal bracing that’s embedded in concrete for added strength.Customhardware such asmountingplates, beacon plates, side arms, work platforms, rooftop mounting kits, ice shields and waveguidebridges canbebuilt to order.Spareparts are readily available, and are field replaceableusing just awrench.Fallarrestoptionsareavailableforoneface,orallthree.Figure 2-4 shows a 90 foot ANWireless freestanding tower with two large and heavy multiband

Yagis.Clearly,aheavydutyfreestandingtowercanofferheightandantennaloadcapabilitiesthatrivalguyedtowers.

TRYLONTOWERSAnothersupplierofheavydutyfreestanding towers isTrylonTSF,aCanadian-basedcompany.They

began in 1932,manufacturingwind turbine generators and the towers required to support them.WorldWarIIsawahugegrowthforthecompany,withtheredesignoftheirtowersforcommunicationsusebytheUSSignalCorps.Today, Trylonmakes andmarkets awide range of towers, but is perhaps best known among radio

amateursfortheirfreestandingTitanself-supportingtowers.TheTitantowersoccupyaminimalfootprintareaandcomeinheightsrangingfrom16to96feet.TheirSuperTitanmodelscontinueupwardinheightandheavierload-carryingcapabilities.The Titan towers offer excellent flexibility for awide range of applications.Models are available

supportingupto300pounds,andamaximumantennaarearatingof99squarefeet.Thetowersareratedto 100MPH.They’re usually in-stock at authorized distributors, providing fast lead times and qualityproductinonetidypackage.

ROHNSSVRohn’sSSVtowersaredesignedforbroadcast,commercialandindustrialclientsneedingtowersupto

500feettall.Obviously,anSSVtowerisprobablygoingtobecapableofhandlinganyamateur’sneed!Eventhemostbasicmodelisdesignedtohandle30squarefeetofantennaarea,sohigherloadsarenoproblem.Theknock-downconstructionallowson-siteassembly,whichcanreducetransportationcosts.SSVtowersareintendedforcommercialuse,sotherearetradeoffsforhamuse.Namely,the“typical”

hamhardwareweassociatewithourtowersandantennas(arotatormountingshelf,forexample)willnotbe available. Some custom fabrication is usually required.Theirmassive size and continual taper canmake side-mounting antennas difficult, although straight, non-tapered sections are also available. Thatmassivesizemeansasizableinvestmentinconcreteintheground!Because SSV towers have been around for a while and used extensively in the broadcast and

commercial arenas, it is sometimes possible to find them for sale or auction at what appear to beastonishingly lowprices.Of course, youdohave the problemof transporting themor even sometimesactually takingsuchabehemothdown!Onceyougetyour treasurehome, there’s theconsiderableangstand anguish required to re-erect it, again not a trivial task. Yet, if you have a unique and demandinglocation(say,onamountaintoporridgeline),thesebabiescanhandlethewindandiceloadsalldaylongwithoutworryorquestion.

Crank-UpTowersCrank-uptowersarethedouble-edgedswordofthetowerworld—theirinstallationanduserepresent

realconsequencesfortheowner.Here’swhy.Not everyone resides in the countryor on a suburban lot large enough to allowaguyed toweror a

large, self-supporting tower.Most people do have the room to allow installation of a crank-up tower.Crank-upsaretypicallylatticeconstruction,althoughtherearetubulardesignsaswell.Theprincipleandoperationarethesameforeach.Bothkindsusesectionsthattelescope(Figure2-5).Multiplesectionsoftowerarenested,oneinside

another,andarepulledupandheldinplacebythecrank-upcable.Somecrank-upmodelsusemultiplecables (oftencalledpositive pull down design) that literally haul a sectiondownaswell as up.Theydon’tsimplyrelyongravityfordownwardmovement.SeeFigure2-6.

It should be apparent (having read this far) that suchmechanized designs are limited in their load-carryingability.Theentiretower(alongwithalltherotator,mast,cablesandantennas)willbecarried,movedandheldbythatsinglecablealone.Bydesign,thetelescopingcrank-uptowersectionsuseever-decreasing sizes of lattice tower or tubular steel. The smaller sections near the top ofmost crank-uptowersmeanlower load-carryingcapacities thanfixedtowers.Still, their limitedfootprint, lackofguywiresandabilitytobeloweredwhennotinuse(presumablylessnoticeabletoneighbors)makecrank-uptowersapopularchoiceformanyhams.

SpecialPrecautionsIt’seasytosimplyassumethatthecrankupwillsolvemanyproblems,butyoumusttakesomespecial

precautionsintoconsideration.Forexample:Deliveryandoff-loadingofthetoweratyourlocation.Baseandconcreterequirements.Antennaandtowermaintenance.Let’stakeacloserlook.It’salltooeasytoforgetthatthecrankuptowerwillarriveatyourhousefullyassembled—allthe

sectionswillbetelescopedtogether,withappropriatesheaves,bearingsandcablesalreadyassembled.The tower will weigh from several hundred to perhaps a couple of thousand pounds! Unless otherarrangementshavebeenmade,youwillberesponsibleforunloadingthatheavy,awkwardtowerfromtheshipper’s truck.Whenthedrivercallsorknocksonyourdoor isnot the time tobe thinkingabouthowyou’llunloadyournewtower.Youmustplanaheadandbeprepared.I’veusedeverythingfromacrewoffriendstoall-terrainforkliftstoautomotivewreckerstoA-frames

andchainhoists todealwith takingacrank-up toweroffa truck.Planningandpreparationarecriticalfactorstoavoiddamagenotonlytothetower,butalsotoyou,yourhelpersoryourproperty.It’swisetorememberthatusingthetowervendor’srecommendedcommercialmotorfreightcompany

for shipping provides you with some insurance, should the unthinkable happen and your tower sufferdamageintransit.Ifyou’vearrangedpickuporprovidedforyourownshipping,you’reusuallyonyourownifsomethinggoeswrong.Whenyou’redealingwithsuchlarge,heavyobjectsandtheequipmentrequiredtoliftandmovethem,

it’salsowisetokeepinmindwherethatequipmentisgoingtohavetotravel.Aretheresprinklerheadsembedded in the lawn, for example?Theywon’t survive being run over. Is the lawn itself capable ofsupportingvehiculartraffic?Again,pre-planningiscrucialinthisregard.Acrank-uptowerderivesitsstrengthfromalargechunkofconcrete(thetowerbase)intheground.Of

course,crankuptowersrequirelargeconcretefoundationbases.Nocompromisesarepossible.Thesize

of the base and the amount of reinforcing steel required, alongwith the concrete (and the finishing itrequires)mustallfollowthemanufacturer’sguidelinestotheletter.Ifyouhaveanyquestionsordoubtsaboutyourabilitytodothat,hireitdoneprofessionally.We’lldiscussbuildingabaseandworkingwithconcreteindetailinalaterchapter.Whileitmayseemunreasonabletotalkaboutmaintenance—evenbeforethetowerispurchased,let

aloneerected—it’smoreimportantandnecessarywithacrank-upthanwithotherdesigns.Thenumberofmoving parts alone dictate this degree of attention.Many hams choose a crank-up, thinking that thenested positionwill provide easy access to their antenna system, or allow an added degree of safetyduringapproachingstorms,butcrank-upshavespecialissuesthatmustbetakenintoaccount.

Crank-UpTowers:ThingstoConsiderCrank-upsoffer theadvantageofbeingable to lower theantenna(s)whentheweather is threatening.

Some suggest that the ability towork on the antenna once it’s lowered is also an advantage, butmostcrank-upsleavetheantennarestingat20feetormoreabovetheground—nottrulyconvenient.Physicallycrankingthetowerupanddowncansometimesbeproblematic.Ittakesalotofenergyto

crank by hand, so motorized towers have come to be more and more popular. But with this simpleelegance(pushabutton,watchyourprideandjoysoarupwardorreturntoearth),comesaheftypricetag.Anddespitetheurge,Isuggestyouonlydotheraisingand/orloweringwhenyoucanactuallywatchthetowermoving!Onesolutiontotherequirementthatyouclimbuptoworkontheantennaisallowingthecrank-uptower

totiltover.Again,thiscleversolutioncomeswithasignificantpricetag.Theforcesencounteredwhileraisingandloweringthetower(evencrankeddown)withantennasmountedonitcanbetremendous.Asdiscussed inChapter1, themost troublesomeaspectof installinganewtower thesedayscanbe

dealing with bureaucratic issues and securing the required permit. This process can be particularlydifficultwithcrank-uptowers,sincemostofthemareratedat50to60MPHwindloads.Buildingcodesusuallyrequirehigherratings,sopermitsmaybedifficulttoobtainwithoutcarefulplanning.Howmuchloadwillthetowercarryatthewindspeedratingforyourarea?Evenifyoudogetadrawingfromthemanufacturer,gettinganeededanalysisandapprovalfromaProfessionalEngineer(PE)licensedinyourstate can sometimesbedifficult. Somemanufacturers are able to provide a design thatwillmeet yourneedsandcanhelpwiththePEstampofapproval.Keep in mind that load specifications are normally given for a fully extended (cranked up) tower.

Variablesincludethewindspeed,theheight,theloadandthebendingmoment.Leavingthetowercrankeddown(sectionsnestedinsideeachother),evenasmallamount,willincreasethewindloadcapabilitiesconsiderably.Again,checkwiththemanufacturerregardingyourneeds.

WorkingonCrank-UpTowersWorkingoncrank-uptowerscanbedangerous.Neverclimbacrank-uptowerthat’sextended.Figure

2-7 shows a crank-up tower that collapsed after a cable failure. Nobodywas injured, but imagine ifsomeonehadbeenonthetoweratthetime!

Iftelescopingsectionsbindorhardwaregetscaught,acrank-upcanappeartobefullynestedwheninfact it’s not. There are horror stories of fingers and toes being jammed between sections as they sliddownwardbecausenotallsectionsofthetowerhadnested.Thesolutiontothisproblemistoinsertasectionofpipeorsturdymaterialbetweeneachofthenested

sections, near the bottom of the tower, before you even think about climbing the nested tower to doanything. Use as large a piece of pipe as can be maneuvered between the sections. If the tower ismotorized,removeallpowerfromthemotor,eitherbyflippingthebreakerofforbyremovingthepowerleads from themotor itself. Then, and only then, should you consider climbing the tower.Figure 2-8showsaclimberdoingittherightway.

Climbingthosenestedsectionswillbedifficult,since there’snowprecious littlespaceforyourfeetandhands!All thesecautionary talesand troublesomeaspectsareanotherargument forusinga simplebuckettruckoramanlifttogetyouthe20orsofeetintheairnecessarytoworkontheantennasorrotator.Manliftsmakegoodsense,andthey’renotonlycheaptorent,they’reeasytooperate.Iconsideriteasyinsuranceforthissortoftowerwork.Manliftsarediscussedinmoredetailinalaterchapter.

MaintenanceMaintenanceoncrank-ups(sincetheyaremoving,mechanicalsystems)consistsofcheckingoillevels

inthemotor’stransmissionorgearbox,greasinganybearingsorfittingsyousee,andexaminingthecablefornicks,cuts,loosestrandsandthelike.Mostcrank-upsuseeitherstainlessorgalvanizedaircraftcable(7×19 strand, most commonly), and you’ll easily see if your cable is damaged. You shouldmark thepulleysonyour tower.Asimplepainted-onstripewillallowyoutoseeif they’re turning,evenfromadistance.Watchforsmooth,freerotationasyouraiseandlowerthetower.Thatcablewillprobablyneedreplacingatsomepoint,andwhileyoucando itvertically, it’smore

easilydonewiththetowerrestingontheground.Thatmeanseverythinghastobedismantled,andthisisnot a job tobe taken lightly.Somemanufacturers are reluctant toprovide the requiredcable sizesandspecificationsordirectionsonhowtore-stringthem—apparentlybecauseoflitigationconcerns.Seekprofessionalhelpifyoumustperformthismaintenance.

Greasing the cables is always a topic that generates considerable conversation. Some suggest thegreaseattractsdirtanddust,whichcanthencauseabnormalwear.Iusuallyleavestainlesscablesalone,choosingtolubricateonlythegalvanizedversions.USTowerrecommendsreplacementafterthreeyears.Atthistime,theyaretheonlymanufacturerI’mawareofthatpubliclyrecommendscablereplacement.Somecrank-uptowervendorsofferaraisingfixture,whichwillallowthetowertotiltovertoprovide

easieraccess(Figure2-9).Still,you’relikelytobeworkingfromaladderatsome30-degreesorsoofangle.Eventhoughtheraisingfixtureisratedtoholdthetower,it’salwaysagoodideatoputsomesortofstandorjackunderthetowertotaketheweightwhileyou’reworkingonthings.

GuyedTowersGuyedtowersofferthewidestvarietyofconfigurations.Theyarebuiltfromsections(typically10feet

long)andcanbeanywherefromamodest30or40feet toseveralhundredfeet inheight.Theyrequirelessconcreteinthebasethanfreestandingtowers,buttheydorequiresomeroomforguywiresasshowninFigure2-10.

Rohn’sG-modelseriesof towers—Rohn20G,25G,45G,55Gand65G—representprobably themostwidelyusedtowerinhamradiocircles,with25Gand45Gthemostpopular.(Andyes,thereisa35G,sometimesreferredtoas“Motorola”tower,sinceitwasmanufacturedundercontracttoMotorola;35Gishalfwaybetween25and45,butisrarelyseenorused.)Eachtriangularsectionis10feetinlength.Sections bolt togetherwith two bolts per leg, simply stacking one above the other.Awide variety ofaccessories are available. Various style top sections, plates, accessory shelves, guy brackets, baseoptions,andsoforthprovideextremeversatility—indeed,it’sperhapsthemostversatiletowersystemeverengineered.G series towers are designed for efficiency, strength and versatility. They are entirely welded and

fabricatedwithprecisionequipmentandare suited tomeet awidevarietyof loadsandneeds.All thetowers in theG series are constructedwith high strength steel tubing for the legs and feature Rohn’sexclusive Zigzag solid rod bracing to provide exceptional strength. They are hot dip galvanizedafterfabrication.Inthisprocess,eachsectionofthetoweristotallyimmersedinmoltenzinc,allowingeverysquareinchofthetower,insideandout,tobecompletelycovered.Hotdipgalvanizingprotectsallpointsofweldingandconstructionagainstrustandcorrosion,whileprovidinganattractivefinish.TheRohncatalog,availableonRohn’sWebsite,representsavirtual“Bible”oftowerdesigndataand

layoutandloadconsiderations.Forthatreasonalone,it’sworthhaving.IfyouintendtoputupanyoftheGseriestowers,it’snecessarytoatleastconsultthefactoryspecificationstoensureyouaredoingwhatthemanufacturer intended.That shouldalwaysbeyourmantra inany towerconstructionproject.Quitesimply,Iconsiderthismanualinvaluable.AsseeninFigure2-11,guyedtowerscanbedesignedtocarryincredibleloads.

Here’sabreakdownofsomepopularchoicesfromRohn.Rohn25GTower.Rohn25Gisbuiltona12inchequilateraltriangledesignwith1¼inchODlegs.

Sectionsareavailable in thestandard10 foot lengthanda7 foot length,which isUPSshippable.The25Gtowercanbeusedinguyed,self-supportingorbracketedconfigurationsaccordingtospecificationsintheRohncatalog.Asaguyedstructure,the25Gcanrisetoamaximumof190feet.Self-supportingandbracketedheightsdependonloading.Rohn45GTower. 45Gprovides excellent strength for applicationsup to300 feet. It’sofferedwith

eitherheavysteeltubeorsolidsteelrodlegstosatisfyawidevarietyofneedsundervariedconditions.When properly installed, the standard tower will support loads as shown on various guyed and self-supportinginformationsheets.Builtonan18inchequilateraltriangledesignwith1¼inchODlegs,Rohn45Gisavailablein10footsections.Rohn55GTower.Becauseofitsruggeddesign,55Glendsitselftoawidevarietyofuseswithinthe

communications field,particularlywhereunusualwind loadingandheight requirementsexist.The55Gwasdesignedtoprovideexcellentstrengthinheightsupto400feet.Whenproperlyinstalled,thestandardtowerwillsupportloadsasshowninthecatalogonvariousguyedandself-supportinginformationsheets.Like45G,55Gisbuiltonan18inchequilateraltriangledesignandcomesin10footsections,butthelegsarelarger—1½inchesOD.

SomeSimpleTowerPhysicsThephysicsofradiotowersisnotthatcomplex,butasimple,yetsolidunderstandingofwhat’s“going

on”isnecessaryifyourinstallationistobesuccessful.Thatoldjokeconcerningtowersandantennasthatgoes“Ifitdidn’tfalldown,thenitwasn’tbigenough,”whilehumorous,trulydoesn’tapplyinthisdayandageofusingasolid, systemsengineeringapproach to thedesign,constructionand installationofatraditionalhamradiotower.Wewanttoputthingsupsothattheysurvive.Weputthemuptostayup.First,let’sconsiderthetoweritself—theactualphysicalstructure.Itmustbestrongenough,inandof

itself,towithstandthewindforcesthatwillwanttocauseittobend(whatwecallbendingmoment).Thetowerbase(whereandhowitisattachedtotheground)willhavetobelargeenoughsothatthetowerwillnottiltorfalloverasaresultofthosebendingmomentforces.The stabilityof any tower is a functionof the spreadof its legs.Thinkof somethingas simple as a

cameratripod.Bringingthelegsclosertogethercausesthetripodtobecomelessstable.Spreadthelegsoutandthetripodbecomesmorestable.Withfreestandingtowers,thethreelegs(wideratthebase)areanalogoustothetripodlegs.Withguyedtowers,theguywiresareanalogoustothetripodlegs.

GuyedTowersvsFreestandingTowersClients, or potential clients, or folkswho are simply considering towers, often askme point blank:

“What’s best, andwhy?”or, “What’s the strongest tower I can put up?”Thebottom line is that guyedtowershavelargerantennaareasupportcapacitythandofreestanding(cantilevered,orself-supporting)towers having similar sectional properties. Now…here’s why — from a professional engineeringperspective,courtesyofHankLonberg,KR7X:Thisincreasedcapacitycomesfromthewayinwhichlateralloadsfromthewindareconveyedtothe

ground.Structuralengineerscall this loadpath.Thismechanismof load transfershouldbecontinuous,andthemoredirectitis,thebetter.LookingatFigure2-12,weseethatonthefreestandingtower,thetowersectionitselfistheprincipal

loadpathtotheground.Intheguyedtowerexample,theprincipalloadpathforthelateralloadwillbetheindividualguywires.The tower sectionprovidesa loadpath for the lateral load itdevelops from thewindonitssurface.Inaddition,theverticalcomponentoftheguyforce,developedfromtheresistancetothelateralloading,willhaveitsloadpathtothegroundthroughthetowerinaxialforce.

Inthecaseofafreestandingtower,theforcesdevelopedatthebaseareaxialforce(P),lateralshearforce(V)andbendingmoment(M).Theseareresistedbythetowersection,andinturnresistedbythefoundationorbasestructure.Iftheywerenot,thenthefreestandingsystemwouldnotbeinequilibrium.Itwould go sailing off into space. Sir Isaac Newton developed the mathematics and theorems fordeterminingtheseforces.Lookingat theguyedtowersketch,youwillseethatthelateral loadfromtheantenna(abovetheguy

point),istransferredtothegroundbytheguywires.Thisloadistransferreddowntotheguypointbythetowerandthemast,whichisattachedtothetower.Belowtheguypoint,thetoweronlyseesthelateralloaddevelopedby thewind—not the lateral forcedevelopedby the antenna (which is usuallymuchlarger than the wind load on the tower). Each guy, if activated by the force direction, develops ahorizontalresistancetothelateralloadandalsodevelopsaverticalcomponentbasedonthegeometricarrangementoftheguyinspace.Theaxialloadontheguyintensionisthesumofthevectorcomponents.Inshort,thelateralloadistransferredtothegroundanchorpointthroughthetensionforceintheguys.

Remember,theguysaretensionforcecapableonly.Dependingonthewinddirection,onlytwoguyswillbeactiveatanyonetime.Inmostcases,thereissomemomentatthebaseoftheguyedtower,butit’ssmallwhencomparedtothe

freestandingtower.Thereisalsolesshorizontalshear,sincemostofthelateralloadistakentothegroundthrough the guys. The axial load is larger than that of a freestanding tower, due to the vertical vectorcomponentsdevelopedintheguysresistingthelateralload.Thinkofitthisway:Freestandingtower—onlyoneloadpath

Guyedtower—twotothreeloadpathsMultipleloadpathstranslatestosmallercomponentsorlargerload(antennaarea)capacity—allother

thingsbeingequal.

WhatAboutUsedTowers?Havingpresentedsome tubular legged towersspecifications, it’sagood time to introduceaconcept

familiar to hams everywhere— that of buying or utilizing used towers. The obvious question is, ofcourse,doesthistowerrepresentabargain,ornot?Ifyou’reinjured(orworse,killed)bychoosingandtryingtoerectausedtower,thenthesavingswerenot,inaword,worthit.Howcanyoudeterminethevalueofausedtower?Thefirst(andsimplest)choiceistoexaminethelegboltsfromanyRohntower.Iftheboltsarerusted

on the inside, then Iwouldsuspect that the interiorof thosesame legscould includedamagingrust,aswell.I’dpass.I’veseenboltssorustythattheywerelessthanonehalftheiroriginaldiameter.I’vealsoseen20-year-old towerswith legsbolts thatappeared“likenew”on the inside. It’s this situationwithtubularleggedtowersthatshouldbeyourfirstconcern—theintegrityofthesteelontheinteriorofthelegs.Makeeveryefforttodeterminetheircondition.Typically,theZ-bracingwillrustbeforethetubularlegs.TheZ-bracesreceivemorewear(fromclimbingandhandling),andbeingsolidrod,seemtoacquirelesszincthanthelegs.Hams are often concerned about surface rust on the steel of tower legs. It’s not usually a problem.

Simplypaintingover itwithgood, coldgalvanizingpaintwillworkwell. It isnotnecessary to spendhoursgrindingawaytheoriginalhotdipgalvanizedcoating!Indeed,that’sprobablyabadidea.Sometimes, enterprising hams will find a local plant providing re-galvanizing services, often

“pickling”ordippingthesectionsinanacidbathfirst,beforecoatingthem.Thiscanworksurprisinglywell. Or it can be problematic, especially if the re-galvanizing is a little sloppy. The bolt holes andsection jointscanbecomefilledwithexcessgalvanizing(sometimescalledslag filled).Or the coatingcanbetoothick,andsectionswillnolongermatetogether.Thisisadifficultdecision,asmostplantswillrequireaminimumorder—soyoucannottryoutafewsectionsbeforehandtoseehowwellitworks.I’vebeenlucky,withbothtubulartowerdesignsandAB-105style(bolttogether)sections,however,inhavingsuchworkdonemyself.Iftheboltsarenotavailable(whichisoftenthecasewithtowersectionsthathavebeentakenapart),

thenit’sarealcrapshootintermsofknowingexactlywhat’sontheinside.Trytopayparticularattentiontothetowerlegs,lookingcloselyattheends.It’snotunheardoftoshineasmallspotlightdowntheleg,tryingtogaugetheamountofrustorwearthat’stakenplace.Again,it’syourlifethat’satriskhere.Don’tbeafraidorashamedtobesuper-critical!I’vealsoencounteredRohn25Gtowerswhich,althoughthey’dbeenupforyears,stillcontainedthe

original,factory-packed,legsboltstuckedinside!Thiscansometimesbeaproblemaswatercancollect,freeze,andthensplitthetubularlegatthispoint.Anothermorecommonproblemisfoundwithabasesectionthatisburiedinconcrete.Thebaseburial

sectioncandevelopacrackbecausetheoriginalinstallerdidnotprovideagravelbedunderthelegsfordrainage.Ifyoudon’tallowfordrainageincoldclimates,watercancollectinsidethelegsandfreeze,expandingandcracking thesteel tubing.Dependingupontheirsize(they’reusuallysmall), thesefreezecrackscanbeaproblem.I’verepairedmanyofthem,andthesectionhasgoneontoserveme(oraclient)well formanymore years. The solution is to drill two small holes, one at each end of the crack (topreventthecrackfromspreading),andthencloseupthecrack.Thisinvolvescarefulworkwithahammer

andapunch,andthencarefullyweldingthecrackclosed.Then,afewcoatswithacoldgalvanizingspraypaint,andthesectioncanbere-used.Ihavealsothrownsectionsaway—oneswithcracksordamageIconsideredtooserioustoattemptrepair.Again, it’s false economy tobet your lifeon this stuff, especiallywhen it’s thevery first sectionof

towerinastack,reachingupward, towardtheheavens—holdingyourhard-earnedinvestment insteelandaluminum!More informationon inspectionsandmaintenanceandworkingwithused tower ispresented in later

chapters.

IntheAir:TheRealitiesofClimbing

Althoughmoststatesregulateprofessionsthatinvolvehealthandsafety(barber,electricianandsoon),theyrequirenolicenseorcertificationtoclimbatower.AndwhiletherearesuchthingsasOSHA(OccupationalSafetyHealthAdministration)guidelinesfor

commercial climbers andworkers, for the radio amateur there exist only the good intentions andwellwishesofhisorherfriendsandrelatives.That’srisk,personified,indeed!Whatcanyoudo?Howcanyouknoworensureorevendetermineyou’redoing“therightthing”when

it comes to doing work on your own tower— whether it’s erecting the tower or making repairs orstackingavarietyofantennasonit?Whoareyougoingtocall?This chapter will attempt to provide you with not only the answers to these questions, but some

guidelines—aprocessorsetofproceduresthatwillallowyoutodosuchworknotonlysafely,butwithconfidence.Withexperience,you’llbeascomfortableatopthetowerastheclimberinFigure3-1.First,though,we’llgooversomeofthegearthatwillhelpyouworksafelyandcomfortablyonthetower.

DressforSuccessClothingchoicesfortowerworkarenotasarbitraryasyoumightthink.Safetyconsiderationsshould

alwaysdriveyourdecision-making.Exceptintheveryhottestweather,longpantsandlongsleeveshirtsmakesenseandtheyshouldbemadeofheavymaterialsuchasdenim.I’vespentlongdaysworkinginthehighheatofsummerinSouthTexas,whereevenshortsandteeshirtsseemedoppressive.Uponreachingthe ground, I’ve found enough nicks, scrapes and scars to warrant such heavier clothing. Think ofappropriateclothingasaninvestment.Let’s begin, keeping in mind ’tis better to feel good than to look good, contradicting Fernando’s

comedicsuggestionotherwise.(ForthosewhoarenotSaturdayNightLivefans,BillyCrystalplayedthehilarious andoutlandish characterFernando, inspiredby the real-life actorFernandoLamas.Fernandowasknownforsaying,“’Tisbettertolookgoodthantofeelgood.”)

FootwearAlthoughI’veseenfriendsclimbwearingsimpleflip-flops,zippingrightupRohn25’stinyZ-bracing

(yes!),thesimplefactofthematteristhatyouneednotonlyadequateprotectionforyourfeet,butsomesupportaswell.Asteelshankinsoleisaverygoodfeatureifyou’llbespendinganyextendedtimeatallaloft.Ipreferwhattheindustrytermslinemen’shigh-topbootssuchasthebootshowninFigure3-2.Their

heavy leather construction withstands the rigors of climbing, and their heavy steel shanks (originallydesigned for the bolt steps of utility poles) provide plenty of support. I bought a pair years ago to becompatiblewithmyclimbinggaffs (spikesused toclimbwoodenpolesor trees), andbynow, they’resecond nature with me. Even these rugged boots will do little to mitigate against the wear, tear andextremeawkwardnessofX-bracedtowers—RohnBX-series,theoldTrylonAB-nomenclaturetowersinstalledwithoutclimbingsteps,andsimilardesigns.Afewyearsago,IinvestedinsomeCarolinaBootsbrandprofessionalpole-climbingboots.Myfirst

pairIfoundatSportsman’sParadise,asurplushouse,for$90.Thatseemedcostlyatthetime.Whenmyentirejob-boxwasstolenfromthebedofmypickup,Ilostthemandhadtobuydirectlyfromthefactory.At$200for thenewboots, thefirstpairwasanobviousbargain.Theyarenot toohotforsummertimewear;they’recomfortable.

I’vealsoinvestedinsomehighdollarsockswithmoisture-wickingabilitiesandpaddedsoles.Again,

I’venotregrettedit.Iwearsocklinersunderneathhightop(overthecalf)socks.Irollthesocksdownover the loops of the boot laces, helping to ensure they don’t snag on something while I’mworking.Again,thesearewortheverypenny.

AClothingEnsembleMyapproach to clothinghas always followed the ensemble idea (no laughingnow, from thosewho

knowmeoutsideoftowerwork).Theensembleideaincorporatesclothingandequipmentitemsthatofferprotectionwhile still providing for functionality.Here’s a quickoverview, followedby somedetailedsuggestions.Protectionisjustthat,andshouldcoveryoufromheadtotoe:hardhat,shirt,jacket,gloves,pantsand

appropriatefootwear.Weatherandseasonalconditionswill,ofcourse,dictatesomeofyourchoices.We’vementionedlongpants,specificallydenimorjeans.IliketheCarharttbrandworkpants,aswell

astypicalbluejeans.I’vealwaysbeenabigCarharttclothingfan,eversincegettingmyfirst“chore”coatas an Ohio farm boy. I remember being pretty disappointed when I outgrew the coat— it was thatcomfortableandfunctional.Itrulyliketheir12ouncecanvasmaterialpants.Theadcopyisrightonthemoney: “The relaxed room legs and large, gusseted crotch of the pants offer unparalleled freedom ofmovement…”WhereIlive,summerscanbebrutallyhot,andwhileIdon’tliketheidea,shortssometimesmakegood

sense.Carharttmakesshortswiththesamematerial,butwithoutthelonglegs,meaningI’vegotshortsIseeminglycannotwearout.IwearthemalotinthehotdaysofJuly,AugustandSeptember,evenwhilenotonatower.AnothergoodchoiceiscargostyleshortsfromCabelassportinggoodsstores.Theyhaveangled, slash-stylepockets,making insertingand retrieving thingsespeciallyeasy. (I remove thehook-and-loopfastenerstomakegettinginthoserearpocketsaseasyaspossible.)

GlovesGlovesremainasoresubjectwithme.Istartedwearingglovesseveralyearsago—oneveryclimbing

job,despitetheweather.(Mostly,Igottiredofthecutsandscrapes.)And,whileIcontinuetoseekoutthe“best”gloveforthistypeofwork,I’mcurrentlypartialtothemechanic’sstyle—withtheindex,middlefingerandthumbtipsremoved,providingtheneededlevelofdexteritywhendealingwithsmallscrewsandthelike.Figure3-3showsawellusedpair.

Prices typically rangearound$25perpair. I’ve tried themall and found fewwinners.The Ironclad

brandisfairlygood,buteverypairseemsdifferent.I’vewornsomeformonths;othershavecomeapartafteracoupleofjobs.TheMechanixbrandFramermodelglovesareprettygood,ifyoucangetpastthegiganticletteringemblazonedonthebackofyourhands.They’rethecoolestinthesummerandhavenotripped at the seams, but the fingertips have disintegrated over time.Somebrands have paddedpalms,which are helpful, especially as you’re playing out a long rope through your hand. Duluth TradingCompanyoftenhasgoodinformationandgooddealsonnotonlygloves,butalsootherconstructionwear-suitedclothing.Isometimesgetaskedabout“waterproof”glovesandsometimessuggestPlaytexas theanswer.This

attemptatwitoftenfailstowork,butfolksareseeminglyseriousinaskingthis—thinkingthereissuchathing.Butguys,there’sabigholeinoneendoftheglove,sonoamountofspace-agematerialorcomputeraideddesign isgoing tomakeanyglovewaterproof.Yes, ifyou’regoing todipyourhands in thesinkthereareoptions,butworkingintherealworldmeansyou’regoingtogetyourhandswet.It’sjustthatsimple. I know, we’re not supposed to be working in the rain or other compromising conditions, butsometimescircumstances(anddemandingclients)dictatethatweworkininclementweather.

UndergarmentsPerspirationcanleaveyouchilled,nomatterhowwellyouroutershellfendsofffallingmoisture.Of

course,suchlanguageispartofthebasicconceptoflayeringclothing.Sincecottondoesagoodjobofretaining perspiration, it makes sense towear underwear (“base layer”) that’smade from some othermaterial,totransportthemoistureawayfromyourskin.Youstaywarmerevenasyousweat.Fortunatelythereisawidevarietyofunderweardesignedforpeopleengagedinallformsofoutdoor

activity. Garments made from silk, wool and synthetic fabrics are available in various weights andshapes.REI’sMTS,orPatagoniaCapilene,orPolartecPowerDryaresomesuitablebrandnames.CheckstoresorWebsitesthatcatertooutdoororwintersportsenthusiasts.Inputtingtogetheryourlayeringsystem,rememberthatwhatyouaretryingtodoiscreateasystemthat

effectively allows for breathability (wicking away sweat), rapid drying, insulation, durability, wind-resistanceandwater-repellence,whilestillbeinglightweightandallowingfreedomofmovement.Whatyou chooseon anyparticular daywill dependonyour intendedworkload andMotherNature.Choosewiselyandyou’llfoolhereverytime!

HardHatsThemostoverlookedareaofthebodyis,ofcourse,theonethat’smosteasilydamaged—yourhead.

Hardhats(Figure3-4)areafactoflifearoundconstructionsites,yetIrarely(ifever)encounterhamswho own them, let alone use or wear them. They’re not that expensive, and well worth the effort toacquireanduse.Here’showtheyworkandwhyyoushouldwearone.

Aconventionalhardhatconsistsoftwocomponents,theshellandthesuspension,thatworktogetherasasystem.Thermoplastics(polyethylene,polycarbonate)andthermosetmaterials(fiberglassandphenolic-impregnatedtextiles)arecommonlyusedasshellsofindustrialhardhats.Thesematerialshaveproventobe durable, reliable and lightweight, while still providing effective protection. The shell should beinspectedroutinelyfordents,cracks,nicks,gougesordamagefromimpact,penetration,abrasions,roughtreatmentandwearthatmightreducethedegreeofprotectionoriginallyprovided.Anyhardhatshowingsignsofwornordamagedpartsshouldberemovedfromserviceandreplaced.All hard hats are susceptible to ultraviolet light damage, temperature extremes and chemical

degradation. Thus, userswhowork in excessive exposure to sunlight, heat, cold or chemicals, shouldreplacetheirhardhatsmorefrequently.Degradationofthermoplasticmaterialsmaybeapparentwhentheshellbecomesstiff,brittle,fadedanddullincolororexhibitsachalkyappearance.Ahardhatshouldbereplaced immediately at the first sign of any such condition. A simple field test can be performed todeterminepossibledegradationofpolyethyleneshells.Compresstheshellinwardfromthesidesaboutaninchwithbothhands,andthenreleasethepressurewithoutdroppingtheshell.Theshellshouldquicklyreturntoitsnormal,originalshape,exhibitinggoodelasticity.Compare(ifyoucan)thatelasticitywithanewshell.Ifyourhardhatdoesnotmatch,replaceitatonce.Thehardhat’ssuspensionsystem(Figure3-5)isjustasimportantastheshell.Itsmainpurposeisto

helpabsorbtheshockfromablow.Therefore,itmustbeingoodconditionatalltimes.Liketheshell,thesuspensionmust also be inspected and replaced periodically. Over time, the suspensionwill becomewornandmaybedamaged.Thesuspensionshouldalsobeinspectedforcracks,frayedorcutstraps,tornheadbandsorsize-adjustmentslots,lossofpliabilityorothersignsofwear.Perspirationandscalpoilsbothhelpcontributetothissortofwear.Anysuspensionthat’sdamagedshouldberemovedfromserviceandreplacedimmediately.

It’s impossible to predict a specific time frame for hard hat replacement. Some large corporationsreplace their hard hats every five years, regardless of outward appearance.Where environments areknown to include higher exposure to temperature extremes, sunlight or chemicals, hard hats should bereplacedaftertwoorthreeyearsofuse.We’veall heardor read thatheat losshappensmostly throughourhead.Debate continues about the

amountofheatlostthatway,butit’sundeniablethatabout15%ofthebody’sbloodvolumeisinthehead,andthebrain(whichregulateseverythingourbodydoes)needsnotonlytherightamountofblood,butbloodatthecorrecttemperature.So,theMerckManualtellsus,30%ofourbodytemperaturecanbelostthroughtheheadandneck.Forthetowerworker,who’softenwearingahardhat,thiscanbeaproblem.Butit’sanissueworthresolving—typically,throughanappropriateliner,whichcanpreventheatlossandalsoaidwithcoolinginthesummer.Inthewinter,I’vetakentowearingasimplebalaclavaundermyhardhat—ablacknylonhoodthat

some ham pals (jokingly?) refer to as my attempt to appear Ninja-like. But the simple cloth facialcoveringtrulyworksandkeepsmewarmwellintofreezingtemperatures.

TheClimbingHarnessAswithmany things, tower climbing times have changed, and thematerials and tools used in those

dutieshavechanged,aswell.Today, the synthetic-webbingharness rules.Thedaysof theold, simplelineman’sbelt(Figure3-6)areover.AsyoucanseefromFigure3-7,themodernharnessisquiteabitmoreinvolvedthanasimplebelt.

Alongwiththesechanges,confusionseemsrampant,especiallyamonghams,whohaveheardorreador otherwise received some information or partial details concerning rules or “certification” or someotherregulations.Let’strytoclearuptheconfusion.First of all, there are no OSHA certifications for anything. What OSHA does have are training

requirements, which are included or embedded in many of their standards. It’s an employer’sresponsibilitytotrainemployeeswhererequiredbyOSHA.Iftheemployerprovidessuchsafetytraining,it is documented and then these trainees are considered “certified.” OSHA does not actually certifyanyone.Theemployeessimplyreceiveacardsayingthey’vereceivedsuchtraining.For tower climbers, employersmust have awritten fall protection plan. Employersmust train their

employeeswhowillworkatheightandusesuchfallprotection.OSHArequires theuseofafullbodyharness,notjustasimplebelt.Here’stheactualregulationwording:1)Theemployershallensurethateachemployeeunderthefallprotectionplanhasbeentrainedasa

qualifiedclimber.2)Thefallprotectionplanshallbemadeavailableandcommunicatedtoexposedemployee(s)priorto

theemployee(s)beginningwork,andsuchcommunicationshallbedocumented.3) The fall protection plan shall identify each location on the tower structurewhere fall protection

methodsasdescribedcannotbeused.As soonas adequate tie-off anchoragepointsorother fallprotectionsystemscanbeestablished,theemployershallutilizeanyofthefallprotectionsystems.

Thecriticalthingyoushouldtakeawayfromreadingtheregulationisthatthisrathersimple-soundingharness is, in fact, part of a system— an entire set of tools or gear designed to keep you safe. It’sreferredtoasaPersonalFallArrestSystem(PFAS).

ElementsofaPFASSystemPFASgear isacriticalcomponentforsafeandproductive towerwork.Youinspect thatgearbefore

climbing, every time (following the manufacturer’s supplied guidelines)! There are three criticalcomponentsforanyPFAS:Theanchorpointsyouselectonthetower.Bodyharness—properlyfittedandinspected.Connectingdevices—properlyselectedandinspected.Typically,harnesseswillstillallowhookinginalanyardtoDringsatthehips(holdingtheworkerin

placeonatower).There’salsoanotherDringinthemiddleoftheback,whereasecondlanyardconnects—ashockabsorbingfallarrestlanyard.Thelanyardatthehipsisonlya“positioningdevice.”Itisnotfallprotection!Figure3-8showsaclose-upofthebackD-ringwithtwofallarrestlanyardsattached.Theotherendof

theselanyardsareconnectedtolockingcarabiners(Figure3-9).Thelockingcarabinerscanbeattachedquickly to toweranchorpoints.Figure3-10 shows thePFAS system inuse, protecting a climberon atowersohecanusebothhandstowork.

AllPFASharnessesaredesignedtosaveyourlife,shouldtheunthinkablehappenwhileatheight.Thisis where and how times (and thinking) have changed— no one climbs a tower intending to have anaccident.Butaccidentscananddohappen.Weallknow that.Fortunately, for today’sclimbers, shouldthatunthinkablethinghappen,theycanbeprotected.Choosingaharnesswillprimarilymeanpickingonethat’scomfortable.Andthebestwaytodothatis,

of course, by actually trying the harness on. Unless you live near a large metropolitan area, that’sprobably impossible.You’re lookingforcomfort in theshoulders,upper thighandseatareas,adequateadjustabilitywiththelegstraps,andsomegoodpaddingintheshoulders,thebeltandthesaddle.Otherthingstoconsider(whichwillquicklybecomeessential,onceyouactuallystartusingyourharness)are:Howmanytoolspouchescanyouattachtothebelt?Doyouwantabuilt-intoolbeltorfloatingtoolbelt?Doyouwantatwin-leglanyard?This is a goodplace to cautionyounot tobe taken inor swayedbygear that claims tobe “OSHA

Certified.”Because,onceagain,OSHAdoesn’tcertifyanyequipment.Youwon’tgowrongbuyingyourclimbingsafetyequipmentfrommanufacturerssuchasDBI/Sala,Miller,MSAandsoforth.Bepreparedtopayfortheirqualityandreputation.Butit’scheapinsurance,plainandsimple.

AboutthatOldLineman’sBeltYou may wonder about that shift from the old lineman’s belt. The reasons are numerous and

overwhelminglysimple.Studieshaveshown(proven,infact)thatthesimple,singlebelt,wornsecurelyat the waist, can cause serious problems and damage to a climber should an accident occur and thatclimberfalls.Iftheclimberdoesnotfalloff thetower,butissecuredtoit(bythetypicalpositioninglanyard), the

beltcanslipup,ontothechestarea.Thatcanconstrictthediaphragm,makingbreathingdifficultorevenimpossible.Plus,thephysicsoffalling“into”thatwaist-levelsecuredbeltcanharmotherpartsofyourbody.Damagetoyourinternalorgansislikely.Of course, noone ever expects orwants to fall froma tower.Of course, nooneplans an accident,

either. It’s just this simple: the shift in thinking and these applications toward amore safety consciousworkplacemakeverygoodsense.Whatworksfor industryprofessionalscanworkforushams, too.Theideaof“100%connected”or

always being tied off to the tower is a good one.ButwithRohn 25G and 45G, the tie-off pointmustincludetwoweldsandthesiderail(thetower leg) inorder tobesecuredto thatrequired5000-poundstructurally-ratedmember—somethingthat’snotonlynotnecessarilyeasy,butsometimesimpractical,aswell.SimplyclippingontotheZ-bracingisnotananswer—it’ssimplynotstrongenough!

Climbing—SafetyisAlwaysthePrimaryConcern!Onceyou’re ready toclimb,andyou reachout,grasp the towerandstepup, it’s time to removeall

otherthoughts,worriesorconcernsfromyourmind.Yourconcentrationonclimbingshouldbecompleteand total.Youshouldbe focusedonwhat’s right there in frontofyou: the steel, theplacementofyourhandsandfeetonit,andyoursafetygearanditsattachmenttothattower.Itmakes sense to climba short distance, stop andget acclimated toyour surroundings. Itmay seem

overwhelminglyobvious,butbeingofftheground(evenafewfeet)isaverydifferentenvironmentfromsimplywalkingaroundorstandingerect.Yourbodyandmindbothneedsome time toadjust to it.Thehigheryougo,themorethisistrue,ofcourse.Payingattentioniscritical!There’sreallyno“boss”orsupervisortotellyouwhattodowhileclimbing.Itis,inthebestsenseof

theword,a liberatingexperience.Climberswillbecalledupon tosolveproblemsanddo things inanenvironmentwhere theaveragepersonwillnevergo—that freedomcanbecomeanaddictingwayoflife. Doing such work successfully is strong motivation, along with a very positive form of self-expression,yetthat’snotsomethingmostclimberswouldadmittoorevenperhapsconsider.Climbingisastrenuousphysicalactivity.Itrequirespractice,someseriousskillsandpayingattention.

Youclimbwithyourlegs;youdon’tclimbwithyourarms.That’snottosaythatupperbodystrengthisn’tgoodtohave(especiallyiforwhenyou’repullingyourselfupandaroundstarguysorringrotators),butthesheerworkofclimbingupanddownisdonebyhavingyourlegsdriveyourhands.Asyouclimb,yourbodyshouldberelaxedandlimber.Thereareno“rules”regardinghowtogripor

grasp the tower (overhand, underhand or a combination of the two). The critical factor is to dowhatworksforyou.Developsomething,callitasystemorwhatever,andthenstickwithit,climbingthatwayeachandeverytime.IfthissoundslikeI’msuggestingyouactuallypracticeclimbingyourtower,you’reright.Youshouldbefamiliarwithwhereyou’llgraspwhatonyourowntower—intimatelyso—beforeyou decide to go up there to perform some work. Practice, of course, is also strenuous, but it paysdividendsinthelongrun.Theoldmantra“trainlikeyouwork,worklikeyoutrain”justmakesverygoodsense.Climbingneeds

tobecomealmostsecondnatureifyouaregoingtosucceeddoingit.

MakingtheClimbAsyouclimb,alwayslooktoconfirmthatyoursafetyhookisclosed.Neverrelyonjustthesoundthe

latchesmake, regardless ofwhat youmay have been told or read someplace.Always check visually!Figure3-11showshowtousetwolanyardstogetsafelyaroundanobstructionandFigure3-12 showshowtomakesureyou’reattachedtothetowerwhileyou’reclimbing.

Alwaysthinkaboutyournextmove,beforeyoumakeit.Alwaystakeyourtime.Climbingisn’tarace,andwhatworksforoneclimbermayseemhorriblyfast(orslow)foranother.Thinkofitasyourcommutetowork,whichwillstillbethereonceyouarrive.Theideaistogetthererelaxedandreadytowork,andnotbesotiredyoucannotdowhatyouclimbedupthereforinthefirstplace!Asyouworkyourwayupward,youshouldbekeepingasimilarspacingbetweenyourbodyandthe

tower itself.Aboutnine to12 inches fromyourbeltbuckle is agoodworkingdistance.Again, asyouclimb,yourlegsdriveyourhands—yourhandsshouldbethelastthingsyoumoveasyouascendfromsteptostep.(Whendescending,workingyourwaydown,yourhandsleadyourfeet—theymovefirst.And,whendescending,yousimplyletyourlegsandfeet“fall”intoplace;don’tpushthemdownward.)

Ifyouclimbyourtower(orsimilartowers)oftenenough,youwilldevelopwhat’softencalledasenseormusclememory.Yourbodywillrecognizewherethingsshouldbeandhowtheyshouldfeel.Thisdoesnotmeanyoushouldn’torwon’tbewatchingwhatyou’redoingorpayingattention.It’smerelyonemoremethodofknowingwhereyouareatalltimes.Onceyoureachthetoporwhereveryouwillbeworking, it’swisetostopforamomentandrestor

catchyourbreath.Thisisanidealopportunitytolookaround,toscopeoutwhereyou’llbeworking,todetermineifyoucandoexactlywhateverworkyoupre-visualizedontheground.Anytalkaboutclimbingwouldbeincompleteif itdidnotaddressthefollowing:Onceupthere,you

must be able to let go, to release your grip on the tower and have both hands free to dowork. I’veclimbedwithguyswhocouldn’tdo thatandwebothfound it frustrating, trying toaccomplisheven thesimplesttaskswithonlythreehandsavailable.Youmusthaveconfidenceinyourharness—notonlytoprotect you from falling, but to secure andpositionyourbodyperfectly, so that you canmove around,workandfullyfunctionupthere.Thisisalsoanappropriateplacetosaythere’snothingwrongwithnotbeingabletodoanyofthat.Not

everyoneiscutoutorequippedorabletoclimbandworkatheights.(PlentyofpeoplesayImustbenutstobedoingsuchworkasIapproachretirementage!)But,ifyouwishtodosuchworksuccessfully,youmustbeabletoputyourtrustinyourgear,inyourownphysicalandmentalabilitiesandcondition,andyourknowledgeandperceptionofthatvastspaceyoufindyourselfin.Youmustbeabletosimplyletgoanddoit.AsIsay,it’saliberatingexperience.

GroundCrewConsiderationsThosewhoremainonthegroundareessentialpartsofanysuccessfultowerorantennaproject.What

makes for a good ground crewmember? The ability to assess and analyze situations quickly and theabilitytoanticipatewhatthetowerclimber(s)willwantorneed.Crewmembersalsoneedtobeadeptatworkingwithavarietyofropes,toolsandriggingsituationsbasedonthoseneeds.(A“retired”climbermakesanexcellentgroundcrewperson!)

Ground crew personnel need to realize theirworkwill be filledwith long periods of interminableboredom—juststandingaroundwaiting.Waitingfortheclimber(s)todosomething,tofinishsomething(whichwillthenrequireactionfromthem),towantsomethingortoneedsomething.Whenthathappens,theymustworkquicklyandcorrectly.(Forthegroundcrew,standingaroundtalkinganddoingnothingisfine, up to a point. But when the crew aloft wants or needs something, their perception will be thatstandingaroundisallthegroundcrewdoesifthey’renotreceptivetorequestsandnotquickresponders.)During the pre-climb “tailgatemeeting” it’s important tomake sure everyone’s on the same page in

regardtotheworkthatneedstobedoneandhowitwillbeaccomplished.It’sespeciallyimportanttotalkabouttheverbalcommandsusedbythecrewonthetower.Andbytheway,thosewhoareonthetowerarealwaysincharge—theyareclosesttotheaction,canseebetterthananyonewhat’sgoingonandit’stheirlivesatrisk.Theycalltheshots.Always.HerearethevoicecommandsIuse:Slackmeanstoloosentheline.Tensionmeanstotightentheline.(Onceyouhavetensionontheline,simpleupanddowncommandstakeover).

Onthetowermeanstheloadhasbeensafelysecuredtothetower(groundcrewcanletgooftherope).Standby means hold the load or line— to just keep doing what they’re doing when they hear thecommand.

Headsuporheadachemeansyou’vedroppedsomething.Ofcourse,therealgoalisnevertodropanything,butsuchthingsdohappenfromtimetotime.Proper

riggingandexperiencedpersonnelwillhelpensurethatthegroundcrewfolksarenotstandingnexttoornearthetower’sbaseanyway.

CommunicationCommunication between climber(s) and ground crew is the name of the game, of course. That can

sometimesbecomeproblematic,especiallywhenthetowercrewisworkinguphigh—above100feet.Windnoiserisesquicklyabovetheaveragetreeline.Vehiculartrafficcanbeaprobleminsomeurbanenvironments,ascanairplanes(whichusuallygoawayquickly,butMurphyoftenplansfortheirarrival,or so it seems).Dogs, chainsaws and lawnmowers and other assorted household noisemakers can betroublesomeorannoying.I’vetriedallthetypicalsolutionsincludingFRSradios,2meterhand-helds,thoselittleVOX-headset

47MHzradios.Theyallwork,tosomeextent,buttheyallhaveshortcomings.Shouting,however,isn’tthebestanswer—butit’softenused,especiallyasalastresortorinmomentsofextremeexasperationorinfinalfrustration.Whateveryoudo,trytocomeupwithsomethingthatworksforyouandyourcrew.

CrewSizeGroundcrewsizewillbedeterminedbythescopeofwork.Largerjobs,suchasmaneuveringthelarge

beaminFigure3-13, requiremorehands.Sometimes, towerworkcanbecomedangerouslyclose to asocialevent,withallthegroundcrewfolksstandingaround,chattingawayorsharingstories.Whilethisisnotnecessarilybad, itcanbedistracting to the towercrew. Itcanevenhinderprogress if the towercrewhastowaitforthegroundcrewtocatchupwiththeirneeds.

It’s important thatallworkerspayattention towaterandfoodneeds.Dehydrationcanoccurquickerthanyoumightthink,especiallyinhotanddrysummermonths.Makecertainyouprovideplentyofdrinksandfuelforeveryone.Waterisbetterthansodaandeventhehigh-electrolytesportdrinks.Byallmeans,savethebeerforwhenthejobisfinished,neverduringorbeforetheworkitself!Whateveryoudo,donotclimborworkalone!Notonlyisitunwisefromasafetystandpoint(someone

needstocallforhelpifyouareinjured),butalsoit’salmostcertainthatatsomepointyouwillneedthatsecondpairofhandsatgroundlevel.Groundcrewssurebeatclimbingdownandbackup!Andfinally,afewwordsontheideaoftower/antennapartiesatafellowclubmember’shouseoverthe

weekend.This oft-usedphrase (and activity) givesmepausewhenever I hear itmentionedon some2meterrepeaterorataclubmeeting.Theimportanceofgoodhelpwhendoingtowerjobscannotbetakenforgranted.Onceagain,towerworkisdangerous,andyourlifedependsonthosegroundassistants.It’saCatch-22,foreveryonehastostartsomewhere,buttakecarewhenchoosingyourhelpers.Surprisesarenotgoodinsuchworksessions,andinexperiencedhelpcancreatesomedandies.Again,thewatchwordis safety. Experience can go a long way towardmaking sure everyone, on the ground and in the air,remainssafe.

SafetyWrap-upThischapterisintendedtofocusyourattentiononsafety,whichissooftenoverlooked.OSHAhasno

jurisdiction over your ham tower, and they won’t investigate you should an accident occur. Nogovernmentofficialwillcomebytocheckonyou,toseeifyouarequalifiedtoclimbyourtower,orifaclimberyou’vehiredis,either.It’suptoyoutolearnaboutsafetowerworkpractices,toequipyourselfwiththerightclothingandtools,andtopayattentionandperformtheclimbcarefully.Regarding insurance, if you have someonework on your tower, you are not required tomake sure

they’retrained.Aswithhiringanycontractor,itdoesmakesensetoensuretheyhaveliabilitycoverage.It’sokaytorequestacopyoftheircertificateofinsurance—toprovetheyhavesuchcoverage.Again,thisallsoundslikesomuchcommonsenseinmanyways…andinmanywaysitis.Yet, the simple fact is that these safety concerns are all-too-often overlooked. Within industry,

employersandworkersbothseemtosharethemisconceptionthatsimplyhavingtherightsafetygearandfallprotectionhardwareisenoughtokeepeveryonesafe.Trainingfallsbythewaysidealltoooften.Fortheoccasionaltowerclimber—thetypicalhamradiotowerownercertainlyapplieshere—trainingmayeasilybeforgone,ormorelikely,simplyforgotten.Workingatheightisdangerous—somuchsothatsafetyshouldalwaysbeyourmainconcern!Safety

shoulddriveeveryaction,bothuponthetower,andamongthoseworkersaidingyouontheground.Theideaistoaccomplishthework,andthenbeabletoenjoythefruitsofthatlabor,backontheground,intheshack,andontheair.Safety—thinkingaboutit,practicingit,andreviewingit—makesthatpossible.

TowerBasesandGuyAnchors

Onceyouhave your tower plan finalized, it’s time to start digging dirt and pouring concrete— thesubjectsofthischapter.

BaseTypesThebaseforyourhamradiotowerisliterallyitsfoundation—whatsupportsandcarriestheweightof

thetoweritself,alongwithforcesdirecteddownthelegsfromthewinds.Basesvary,accordingto thetypeoftower.FourcommonlyusedguyedtowerbasedesignsareshowninFigure4-1:thetaperedtowerbase,thepivotedtowerbase,thecompositebaseandthepierpinbase.

Hamsoftenuseavariationof thecompositebase,where theyburya sectionorpartofa section.Aspecial “base burial” section is simply a smaller-than-normal section sized to bury in concrete.Hamsalsocommonlyusethepierpinbase.Apininthecenteroftheconcretepierprotrudesthroughaholeinthecenterof thebaseplateandholdsit inplace.Thebaseplateisnotbolteddownoranchoredtotheconcrete, though,allowingsomeside-to-sidemovement.The tapered towerbase is seenon largerhamtowerssuchasRohn65.Pivotedbasesaren’ttoocommoninhaminstallations.

Freestandingtowersutilizeheavierconstructionthanguyedtowersandtaperintowardthetopfromawide, spread apart base section. Freestanding towers exert larger weight-bearing forces on theirfoundations than the typicalguyed tower.So, largeranddeeperbasesare required.Somebasedesignshaveeachlegsupportedbyanindividualfoundation,forexample.

BuriedSectionvsPierPinThemostcommonlyusedbaseforguyedtowersisprobablytheburiedsection.Alotofhamsdon’tlike

the ideaofburyingaperfectlygood,workingsectionof tower inachunkofconcrete. Icanappreciatethat. But the buried sectionwill simply feelmore solid than any othermethod, and it’s oh-so-easy toinstall.Pierpinbases,whethertheyuseataperedtowersectionorasquarebaseplateandstandardsection,

requirefurtherattentiontodetail.Theconcreteforthebaseplate(ifused)mustbeperfectlylevel.Thepinmustbe theproperone—designed for this application.Youdon’t simply insert abolt from the localhardware store in the concrete and consider it ready. Any tower with a pier pin base will requiretemporarilyguyingthesectionsasyouerectthem,asthere’snosupportfromthebase.Thiscansometimesprovetroublesome,certainlytime-consuming.(Therearenoshortcutshere—donotthinkyoucansimplyuseropestotemporarilyguythetowerinplaceasyouworkyourwayupward.Onlystandardsteelguywireshouldbeused.)

SafetyTipsRegardlessofyour tower type, it’s important tokeep safety inmindwhendigging thehole foryour

towerbase.Donottakesuchworkforgranted.Eachyearpeopledieorareinjuredfrombeingtrappedinaholewhensoilcollapses.Thefollowingsimpleoverviewofsoilmechanicsmayhelpyouunderstandsomethingstowatchoutforwhendiggingthetypicaltowerbasehole.Soilisagenerouslyvagueterm.Itcanmeanweatheredrockandhumus,whichweusuallyrefertoas

clays,siltsandloams.Butsoilcanalsoincludegravel,sandandotherrock.Soilcanbeextremelyheavy,weighingmore than100poundspercubic foot.Onecubicyardof soil (3 feet×3 feet×3 feet,or27cubicfeet)canweighmorethan2700pounds.Ifthatsoiliswetorcontainsrocks,itwillbeevenheavier.That’slikehavingacarfallontopofyouwhenyou’redowninthattowerbasehole!Keepingthat100-poundpercubicfootweightinmind,werealizethatnotonlydoesthesoilexertthis

downwardpressure,it’sexertingsomepressuresideways,orhorizontally,aswell.Thatpressureisonehalfthedownwardforce.So,ifyou’redowninthegroundfivefeet,standingnexttoawall,there’s250poundsofpressurecoming“atyou.”Unlessyoudothisprofessionally,you’renodoubtunawareof thepressureandprobablyhavenotshoreduporotherwiseattemptedtosecurethesidesofthehole.Mostofthetime,that’snotaproblem.Butdiggingtowerholescanbeapotentiallydangerousjob,andyoushouldbeprepared.In undisturbed soil, equilibrium is maintained by having all the horizontal forces push against the

vertical forces. Inahole,or trench, thatequilibriumis lostbecause thehorizontal forcesare removed.The soilmaynotbe able to support itsownweight, andmaycollapse.The first failurewill be at thebottom,thenslowly(overtime)workitswayupward.Thetypical“bellcutting”weoftendoatthebottomof a tower’s base hole (making the bottom wider than the top in a bell shape) only compounds thispotentiallydangerouscondition.Shoringupthewallsorsidesofanunusuallylargeholecanbeausefulsafetytechnique.Digging holes that are larger than you need, then building a form inside, and then back filling, is

sometimes necessary — especially in very sandy soil. It’s truly time-consuming, and requiresconsiderableattentiontodetail.Don’tbeafraidtoaskforadviceifyou’renotcertainwhattypesoilyouhaveorarediggingin,asthiscanbecritical.Yourcountyextensionagentcanusuallyhelpanswersuchquestions.Afewsimple rules:Any timeyou findyourself further than four feetdown in theground,a suitable

ladder or set of steps should be used to provide an exit. The ladder should extend at least six inchesabovethesurroundingexcavationgrade.Whileworkinginthehole,bracingorshoringisagoodidea.Ofcourse,theinstallationofthetowerbasesectionandsteelreinforcingcagesintheholeoftenpreventsthisor makes such work highly impractical. And, it almost goes without saying — never work in suchconditionsalone.

DiggingtheHolesYour towermanufacturerwill have specifications and drawings for the required tower base.We’re

talkingaboutaprettybighole—typically4feetdeepand3to4feetsquareforasmallRohn25guyedtower. Base holes go up in size from there; 5 or 6 feet square and 5 feet deep is not unusual for afreestandingfixedorcrank-uptower.Beforediggingthefirstshovelfullofdirt,layoutthelocationanddimensionsofthebasehole(Figure4-2).Double-checkthelocationandorientationofguyanchors.Thesimple,homebrewtowerlayouttoolshowninFigure4-3canhelpwiththistask.

Diggingalmostany towerbaseholecanbenefit frommechanicalhelpsuchasabackhoe,excavator,tractorwithbackhoeattachmentorotherearthmovingequipment(Figure4-4).Withrockysoil, ledgeorsimilar challenges it may be your only choice. If the site is accessible and the right equipment isavailable,hiringequipmenttodigtheholesmaybelessexpensivethanyouexpect.Callaround,havetheplansreadyandbepreparedtoexplainexactlywhatyouneed.Showtheoperatorthelocationofsepticsystems,undergroundpipesorelectricallinesandotherobstacles.Dependingonwhereyoulive,youmayneedtonotifythelocalutilitycompanyorhaveaservicesuchasDigSafemarklocationstoavoid.

Equipmentoperatorsusuallychargebythehour,andexpectachargefortransportingtheequipmenttothejobsite(called“portaltoportal”).Machinescomeinawidevarietyofsizesandcapabilities—onethatcanmoveaboulder thesizeofacar isn’tagoodmatchfordiggingyour3 to4-foot-square towerbase.Machinesmayhaverubbertracks,cleatedmetaltracksortires.Thetrackedmachinescangomoreplaces,butthosewithcleatedtrackscanquicklymakeamessofyourlawnorblacktopdriveway.Besureto discuss all of your expectations with the operator and understand any potential collateral damagebeforestartingthejob.The critical factor, always, is the size and depth of the hole. A smaller bucket is almost always

preferred,foritallowsformoreprecision.Thisprecisioncomesattheexpenseoflongerdiggingtimes.Ifyou’rerentingequipmentorpayinganoperatorbythehour,timecansometimesbeafactor,butIalmostalwaysoptfor the tightercontrol.Typical towerholesarenot thatbiga jobcomparedto,say,ahousefoundationorsepticsystem.Itwon’ttakeaskilledoperatorthatmuchlongertomakeapreciseholeforyou.ThebestmachineoperatorsI’veeverfound(andused)havebeengravediggers,literally!Theycandig

youaverypreciselysquared-uphole,withoutthebottombeingbell-shaped.Buttypicallyyoushouldplanon“finishing”almostanymachine-madeholebyhand.Traditionally,digginginthedirthasbeenconsideredapejorativeterm—thatifyoufailateverything

else,you’llendupdiggingditches.Byhand.Slowly,painfullyandmindlessly.Punishinghardlabor.Soitsometimesseemswithtowerbasesandguyanchorholesintheground.Youmayhavetodoit thehardway if site access is too restrictive for powered tools, for instance.Or perhaps you cannot lo-cate orafford to hire equipment and/or an experienced operator. Something—whatever it is—means thoseholesmustbedugbyhand.

UsingHandToolsForlargerholes,suchasatowerbase,thetraditionalshovelandpickaxecanbeusedincombination.

Manyfolksaresurprisedtolearnthatvariousversionsofthesemostbasicdirt-movingtoolsexist.Herearesomesuggestionstoincreasethespeed,easethepain,andmakediggingbyhandfarlessfrustrating.

MakingaSquareHoleThetrenchingshovelorspadeisverysimilartotheroundpointshovel(whichmostofusknow),only

it’sverynarrow— typicallyonly four incheswide. It’sused to remove loosedirt from thebottomoftrenchesdugbyamachineorfordiggingholesandtrenchesinsoftsoil.Getonewithalonghandleandyoucaneasilyexpandthesidesofholesandsoon.Whileonthesubjectofexpandingholes,letmesuggestacleversolutionto“squaringup”dirt.(Amass

ofsquareconcrete ismore resistant tomovement thanrounded-off lumpspoured in theground.Yet thetraditional round point shovel leaves exactly that— rounded-off cuts.) A simple six-inch steel floorscraperwillworkwonders(especiallyinCarolinaclay)insquaringupthesidesofholes,allowingyouto put a precise corner or edge in a tower base hole. I’m pretty sure clientRickLow,N6CY, is stillwonderinghow,workingentirelybyhand,IwasabletomakeaperfectlysquareholeinthesoilofhisReston,Virginia,backyard(thetowerbasewasinaccessibletoanymechanizedhardware).Thescraperallowedmetocreateperfectlysquarecorners(IlaidaframingsquareagainstthemasIworkedmywayaround)andperfectlystraightedges.Again,mosteveryoneknowsthepickaxe.Butconsider,instead,themattock,whichisacrossbetween

apickandashovel.Ithasanarrowbladeononeside(somewhatlikeatrenchingshovel,onlysmaller),withapickaxepointontheotherside.Youuseitlikeanax.Iuseamattockfordiggingshorttrenchesandremovingrocks.Withamattockbladeononesideandapickontheother,amattockwilldigtwiceasfastandtwiceaseasilyasashovel.Anotherindispensabletoolisthedigger/tamper,whichissimplyaheavysteelbaraboutfivefeetlong.

Onthetamperend,thebarhasahead(similartoahugenailhead)that’susedtocompactsoil.Thediggerend has a wide, flattened point like a large chisel. Don’t struggle with rocks and debris when thedigger/tamper/prybarwillhelpyoutoremovethemeasily.

ThePostholeDiggerNow,thetruetestofthededicateddirtmover—themaintoolinhis/herarsenal—thepostholedigger.

Again,manyfolksknowandhaveusedthestandardtwo-handlemodel.Butnottoomanyknow(orhaveused)anaugermodel (Figure4-5).Theauger is faster (inmyopinion) andmakes a cleanerhole. It’ssometimesdifficulttoplungethetwo-handlemodelperfectlystraightdown,repeatedly,especiallywhenyou’retired.Therealbenefitoftheaugermodelisthatyoucanchangethedepthofyourholebysimplychangingthelengthofthehandle.Forinstance,byaddinga3-footpipenipplebetweentheaugerandtheexisting handle, you’re now digging a 6-foot deep hole by hand. Take it off, and you’re back to thestandardthree-footdeepholesuitableforfencepostsandclotheslinepoles.

Thetwo-handlemodelhasanotheruseintowerwork.Ifthebaseholeislargeenough,youcancontinuetodigwiththeshovel,butwillfinditdifficulttoremovethedirt.Thetwo-handlediggercanbeusedlikegiantchopstickstoliftoutthedirtyourshovelhasloosened.Eachmodelhasitsplaceindiggingholes.InmyOhiofarmboyyouth,Isimplyhatedthepostholeauger.Itmeanthoursofhard,physical labor,

usuallyduringsummervacations,whenitwashot,too!I’mamazedtofindI’vesearchedoutandownone(Seymourmakesthebestauger,inmyopinion).YetIfindmyselfgrinningwhenIsuccessfullydigwhatsomeclientsthoughtwasgoingtobeimpossibleorimpracticalholesintheground.

ReinforcingSteelOnce the hole is dug, it’s time to think aboutwhat goes in it. And no, we’re not yet ready for the

concrete—we’retalkingaboutrebar.Rebarreferstothosesteelreinforcingbarsusedinconcreteconstruction.Thetermdatesfromthepost-

warAmericanbuildingboomof the1950s, although reinforcing steelhasbeen inuse since the1920s.Ridgesarerolledintoitbecauseit’smilledtomechanicallyanchorintheconcrete.Rebarisdarkgraywhennew,butrustyorangeandscalyafterexposuretotheweather.It’smadefromavarietyofrecycledmaterials,anditscompositionisquitevariable,whichistheprimaryreasonweldingofrebarcagesisnotallowedbybuildingcodes.Wire tiesare thepreferredmethodof securingsuchstructures.Your towermanufacturerwill specify the type, size, amount and configurationof rebar required in thedesignof atowerbaseorguyanchorforyourapplication.Figures4-6and4-7showatowerbaserebarcageunderconstruction.

Rebarissizedby“the8ths,”meaningincrementsof⅛inch.Forexample,#8rebarwouldbe1inchinsize.Themostcommonsizesfortypicaltowerbaseapplicationsare#3(⅜inch),#4(4⁄8or½-inch),and#5(⅝inch).Theoverallrebardiameterisabout1⁄16-inchlargerthanthenominalsizebecausetheridgesprojectslightly.Forexample,#4rebarmightfita½-inchholeinthinmaterial,butitmightbeaverytightfit.Rebar isavailable invariousgrades,orstrengths.Grade60rebar is themostcommonforhomeuse

andlandscaping.It isusuallysold in20-foot lengths(oftencut inhalfby thebigboxhomestores),butshorterlengthsarealsoavailable.Itcanalsooftenbecutatthestore.Takeadvantageofthatserviceifit’savailable.Rebarcanbetoughtocutwithouttherighttools.Reinforcing steel is incorporated into concrete construction because concrete, while very strong in

compression,cantakeverylittletensionforce.Thereinforcingsteel(rebar)takesthetensionforceandlets theconcrete take thecompression force.This force sharing ishow reinforcedconcretebeamsandslabscantakethelargeloadsthat theydo.Thestrengthofthereinforcingbarisdevelopedbyitsbondlinkintheconcretemass.Eachsizebarhasacode-specificlength(developmentlength)that’snecessarytoallowthereinforcingbartodevelopitsfullstrengthintension.Hooksattheendsofbarsareusedto

help create this link when the physical size of the concrete mass precludes it being developed by astraightbar.Table4-1showssomekeyrebarspecifications.

Towerbasebuildersmay encounter the following terminology, especially if they are dealingwith astructural steelcompany, insteadofahome improvementsupplystore.Understanding the languageputseveryoneonthesamepage.Dowels.TheseareusuallyL-shaped,witha90°bendononeend,orstraightlengthsofrebar.Cornerbars.ThesearealsoL-shaped,butwitheachsideoftheLthesamelength.Offset bends. These range from a simple Z shape to complex angles and are used in reinforcingconcretewalkwaystepsorotherchangesinelevationwithinthefooting.

Hairpins.TheseU-shapedrebarsareusedtointerlocktwoormoreindividualmatsof rebar togivelateralstrengthtotheconcrete.

PreparingtheBaseHoleWiththerebarundercontrol,it’stimetopreparethehardwarethatwillattachthebottomtowersection

tothefinishedbase.Dependingonyourparticular typeof tower, thismightbeashortsectionof towerburiedintheconcrete,apierpinandflatsteelplate,anchorboltsorbracketsofsometype.It’salwaysagoodideatostudythetowermanufacturer’sdrawingsandspecificationsandget therighthardwareforyourapplication.Obviouslyit’sveryimportanttomakesurethatthebasesectionislinedupandlevelsothat your installed towerwill be truly vertical. In some cases youmight install the first above-groundtowersectionwithtemporaryguystoaidthisprocess.Besuretosecurethebasesectionorhardwaresothatitdoesnotmoveasyoupourtheconcrete.Figures4-8through4-10showseveralwaysofpreparingbasehardwareforconcrete.

Thebottomoftheholeiscoveredwithagravelbedtofacilitatedrainingwaterfromthetubulartowerlegs(ifapplicable)andhelppreventfreezecracksinthesteel.Rohnrecommendsthatthegravelbesixinchesdeepfortheirtypical25Gor45Gseriesbases,butcheckyourtowermanufacturer’sspecificationsandfollowthem.Although I’ve seen concrete simply poured into an “empty” hole, it’s always better to have a form

surroundthetopofthebasehole.Thismeans,ofcourse,it’snowtimetochangefromtheditch-diggingmentalitytothatofacarpenter.Rememberingthatconcretetypicallyweighsabout4000poundsperyard,yourwoodworkingskillswillhavetoproduceafinishedformthat’ssturdyaswellasstraight.Dependingon the type of tower you’re erecting, along with the terrain surrounding your base, you’ll have someoptions.Crank-uptowerbaseformsusuallysupporttheerectionfixturehardwareorsimpleT-barbracketover

thehole,suspended,ifyouwill,downintotheconcrete.Guyedtowerbaseformsaresimplesurroundsifthere’sabaseburialsection.Ifyou’reusingapierpinbase,it’sasimple,perfectlyflatandlevelboxto

holdtheconcrete.Ineithercase, two-headednailswillmake it fasterandeasier to takeyourbaseformapartonce the

concretehascured.Greasingoroilingtheinsidesofthewoodwillalsomakeforasmoothersurfaceandeasier disassembly (I use oldmotor oil). I use 2 × 6 lumber for the forms,mostly as a convenience,becausesixinchesabovegrade(abovethesoil)isthespecificationRohncallsforintheircatalog.Thecatalogwillalsoprovideyouwiththeallneededdimensionsforthebase,ofcourse.Yes,alittletimeandattentiontodetailherewillpreventproblemsfromdevelopinglater.I’msimplya

firmbelieverthatanytowerbaseshouldbeabovegrade—higherthanthesurroundingsoil.Iknowthearguments formaking thembelowgrade (youmayone day sell the house, and so on), but the risks ofstructuraldamageandlossofsteelfromconstantcontactwithdirtandmoisturearetoogreat.I’veseentoo many bases left unattended, sometimes for years, with legs totally rusted through, to ever buildanything like this!Base inspection,ofcourse,shouldbepartofany tower’sannual inspectionprocess,regardlessofwhetherthetopofthetowerbaseisaboveorbelowgrade.I like to coat the tower legs andbracingorother steelparts rightwhere theyexit the concretewith

rubberizedautoundercoatspray.I’vefoundthattobeaninexpensiveandterrifictooltohelpprotectthesteelfromwateranddebristhatinevitablycollectsonthebasepad.Now,havingdoneeverything,you’rereadytopourconcreteintothatbasehole.

ConcreteI’ve discovered over the past few years that concrete is one of the more misunderstood building

materialsintheworld.TheexplanationsandtalltalesI’veencounteredhavebeenmind-boggling,tosaytheleast.So,letmepresentabrieftreatiseonconcreteanditsapplicationtotowerbases.Thefollowingsectionspresentsomefacts, fallaciesand tipsonworkingwith itproperly,whetheryoubuyreadymixconcreteormakeityourself.

TheBasicsInitssimplestform,concreteisamixtureofapasteandcertainaggregates—fineaggregate(suchas

sand)andcoarseaggregate(suchasgravelorcrushedstone).Thepaste,whichiscomposedofPortlandcement and water, coats the surface of the aggregates. Then, through a chemical reaction known ashydration, the paste hardens and gains strength, becoming what we know as concrete. This hydrationprocess is the key, the real “magic” of concrete— it’s pliable, plastic andmalleable when it’s firstmixed,butincrediblystronganddurableoncehardened.Thissimple,often-overlookedfactoriswhythismaterialcanbeusedtobuildanythingfromyoursidewalkorpatio,tobridges,damsandskyscrapers,toyourtowerbase.

ConcreteTerminology

Aggregates.Materialssuchassand,gravelorcrushedstonethat,alongwithwaterandcement,areessential ingredients in concrete. Aggregates account for 60 to 75 percent of the total volume ofconcrete.Theyaredividedintotwocategories—fineandcoarse.Fineaggregatesgenerallyconsistofnatural sand or crushed stone with most particles that will pass through a ⅜-inch sieve. Coarseaggregates are anyparticles greater than0.19 inch, but generally range between⅜ and1½ inches in

diameter.ReadyMix.Themixtureofcement,water,sandandcoarsematerial.Readymixisplacedinaplastic

state(stiffbutworkable)andwillbegintohardenorcurewithinafewhours.Reinforcement.Concreteisreinforcedwitheitherwiremeshorsteelbars(rebar)placedinagrid

pattern. In either case,blocks shouldbeused tokeep the reinforcement in the centerof the concrete.Notethatreinforcementdoesnoteliminatecracks—itsimplyholdsthemtogether.Slump.Ameasurementdescribingtheliquidityorviscosityofreadymixconcrete.Lowslumpmeans

themixhas lowwater content; high slumpmeans highwater content.Low slump concrete is usuallystrongerthanhighslumpconcrete,butislessworkableandmoredifficulttoplace.

Havingsaidthis,it’sprobablyobviousthatthekeytosuccessinsucha“mix”istheproportionsandmixingprocess,andthat’sexactlyright.Amixturewithoutenoughpastetofill inall thevoidsbetweenaggregateswillbehardtoplacecorrectly,anditwillberoughandporouswhenhardened.Amixturewithtoomuchpastewillmoveeasilyandbeexceedinglysmooth,butwillmostlikelyshrinkTypically,themixshouldbearound10to15percentPortlandcement,60to75percentaggregate,and

15to20percentwater.Trappedairmaymakeupfivepercentofthemix.Again,it’sthePortlandcementthat’sthecriticalingredient.Why’s it called that?Because JosephAspdin, anEnglishmason,whopatented theproduct in1824,

named it that, after the color of the natural limestone quarried on the Isle of Portland, in the EnglishChannel.Portlandcementismanufacturedbyheatingaslurryoflimestoneorchalkwithclayinakiln,andthengrindingtheresultantclinkertoafinepowderandaddinggypsum.

OptionsforConcreteMixingyourownconcretewithPortlandcement andcoarse and fineaggregates isperhaps themost

economical method, but you must have the separate materials on hand and you must measure themaccurately.Bagsofpremixedconcreteavailableathomecentersareconvenientforsmallprojectsandavailablein

variousstrengthsfrom3000to5000psi.Justmixwithwaterfollowingthedirectionsonthebagandpourinplace.Premixedbagswillsaveyoutheeffortofbuyingandmeasuringcementandaggregates,butthisconveniencecomesataprice.For either of these options, a powered mixer is a good idea, and they are usually available for a

nominalfeeatthelocaltoolrentalcenter.You’llalsoneedwaterformixingtheconcrete(alongwiththesubsequentfinalcleanup),asourceofpowerforthemixer,andawaytogetthemixedmaterialstothetowersite.Ready mix means just that — the concrete is delivered to you already mixed, per your supplied

instructionsregardingstrengthandslump(seetheConcreteTerminologysidebar),readytogointoyourpreparedbaseandanchorholes.You’llstillneedtogettheconcreteintothehole,andthatcanbeachoreifthetruckcan’tgetclose.Priceitout,andyoumayfindthatreadymixisreasonablypricedcomparedtobuyingtheingredientsandrentingamixer.Thenconsider thehardlabor involvedinmixingityourself,especiallyifyouneedacoupleofyardsormore.Thereadymixplanthasalotmoreexperienceinmixingtheingredients,too.Regardlessofwhattypeconcreteyouchoose,thekeytosuccessisintheproportionsandinthemixing

process.Asnotedpreviously,amixturewithoutenoughpastetofillinallthevoidsbetweenaggregateswillbehardtoplacecorrectly,andwillberoughandporouswhenhardened.Amixturewithtoomuchpaste will move easily and be exceedingly smooth, but will most likely shrink. Concrete’s strength

dependsonthewater/cementratio.Peoplewhodon’tworkwithconcreteregularlytendtousetoomuchwatertomakeitflowbetter,whichcanresultinweakerconcrete.

CuringConcreteAfteryourconcreteismixedandplaced(pouredintoyourbasehole),satisfactorymoisturecontentand

temperatureshouldbemaintainedwhentheconcreteiscuring.Propercuringguaranteesqualityconcrete,andthecuringdeterminesdurability,strength,waterandabrasionresistanceandstability,alongwiththeabilitytowithstandfreezingandthawingandchemicals.Curingaidsthehydrationprocess.Mostfreshlymixedconcretecontainsconsiderablymorewaterthan

requiredforhydration,butevaporation(onthosehotsummerdays,forinstance,justwhenyou’relikelytobeputtinginatowerbase)candelayhydration.Theprocessisrelativelyrapidduringthefirstfewdays,when it’s most important to keep the curing concrete moist. (This is why you’ll see burlap bags orsheetingor straw strewnacross forms, alongwithperiodic spray applicationsofwater, and so forth.)Goodcuringmeansyoushouldtrytopreventorreducesuchevaporation.Andyes,curingtakestime—therecommendedwaitingperiodtoreachfullstrengthis28days!Bythesametoken,ifitistoocold,thecementwillnothydratefastenoughandthewaterinthemixmay

freeze.Ifthathappens,theconcretewillnotsetanddevelopthedesiredstrength.Insulatingwithplasticsheetingorstrawwillhelptocontainheatgivenoffduringhydration.

OrderingConcreteforTowerBasesHere’swhat theRohn catalog (which is also their technicalmanual) says about concrete for tower

bases:

1) Concrete materials shall conform to the appropriate state requirements for exposed structuralconcrete.

2) Proportions of concretematerials shall be suitable for the installationmethod utilized and shallresult in durable concrete for resistance to local anticipated aggressive actions. The durabilityrequirements of ACI 318 shall be satisfied based on the conditions expected at the site. As aminimum,concreteshalldevelopaminimumcompressivestrengthof3000PSIin28days.

3)Maximumsizeofaggregateshallnotexceed¾inch;sizesuitablefor installationutilized;orone-thirdcleardistancebehindorbetweenreinforcing.

4)Minimumconcretecoverforreinforcementshallbe3inchesunlessotherwisenoted.

Here’swhatyouneedtoknow,orwhatyouneedtodo,tocomplywiththoseRohnspecifications.First,you’ll need todecide if you’regoing touse ready-mixed concrete— recommended for threeyardsormore.You’llneedtotellthesupplierhowmanyyardsyourequire(concreteismeasuredincubicyards).Youcandeterminethatfrom:

Cubicfeet=Length(ft)×Width(ft)×Depth(ft)

Cubicyards=cubicfeet/27

Forexample,sayyourtowerbaseis4ft×4ft×6ft=96cubicfeet.Andthus,96/27=3.6cubicyardsrequired.Beprepared—ayardofconcreteweighsaround4000pounds!Thedispatcherwillaskyoufortherating.“Normal”concrete(sidewalks,patiosandsoon)isusually

rated at 3000 pounds per square inch (PSI). For most tower bases, 4000 to 5000 PSI concrete will

suffice,butchecktoseewhatyourtowermanufacturerspecifies,andorderaccordingly.Thedispatcherwillaskyouwhatslumpyourequire(remember,slumpreferstoawayofmeasuringthe

workabilityoftheconcretemixture).Theslumptestisdonetomeasuretheconsistencyfromtruckloadtotruckload.Goodpracticeistohavearounda4-inchslumpfortowerbasepours.Themorewaterthat’sadded to the concretemixture, the higher the slump, then the lower the concrete’s strength and so on.Waterreducingagentscanbeaddedtomaketheconcreteeasiertoworkwithoutaddingwater.Concreteisnormallypricedbythecubicyard,withtheper-yardpricebasedontheassumptionofafull

load.Notethatatypicalconcretetruckcarries8to10cubicyards,morethanyou’llneedforatypicalhamtowerbaseandguyanchors.Bepreparedforminimumchargesora“shortload”feeifyou’reonlygettingafewyards.

TipsforaSuccessfulPourYouwere careful if and/orwhen inserting or installing any needed rebar cage.Youmade sure you

proppedthecageup,offthesoil,usingsuitablespacers.Youmadesuretubulartowerlegs(ifapplicable)were resting on some drainage material, such as pea gravel or other small stone. And while it’ssometimesthelogicalchoice(duringyoursummervacation,forexample),concreteshouldnotbepouredonextremelyhot,drydays,asitwilldryoutbeforeitcancureproperly.Concreteisaperishableproduct—itstartstocureassoonasit’smadeandneedstobepouredwithin

abouttwohoursat60to80°F.You’llneedtogetyourconcreteoffthetruckandintothehole(s)promptly,soplantobereadytogoassoonasthetruckarrives.Considerrentingamotorizedorpush-type“Georgiabuggy” made for transporting concrete or enlist the help of several friends with heavy-dutywheelbarrows.Concreteshouldnotbeoverworked,meaningmovingitaroundexcessivelywithtrowelsortools,for

example.Ifit’soverworked,toomuchwaterwillbebroughttothesurface,whichcancausescalingoncecured.Trytospreaditevenlyandquicklyonceyourpourbegins.Overfilltheformsslightly.Iliketouseavibratingtooltoworktheconcreteintocornersandsoforth,buta2×4canbepressedintoserviceforthis,too.Bepreparedforhardwork;concreteisheavy!Whenworking the concrete, I like to leave the center of the base higher than the edges to facilitate

waterrunoffandpreventwateranddebrisfrompoolingaroundthelegs.Calledcrowning,it’ssometimeshardtoaccomplishwithsmaller-sizedtowers,suchasRohn25,butveryworthwhileifyoucandoit.Ascreedboard(usedtolevelmostforms)cannotbeusedforthetypicaltowerbase—there’susually

somethingin theway, likeaburialsection,orbolts,orapierpin.So,youmustworkwitha trowel tofinishthebase.Concretefinishingprovideseitheraroughorasmoothsurface.Butyourfirststepistouseapointingtroweltoseparatetheedgeoftheconcretefromyourform.Then,useanedgerallalongthetopedgeoftheform.Theroundededgeleftbythistoolwon’tchipoffasyouremoveyourform.Holdthetoolflat,keepingthefrontedgetiltedupwhenmovingforward,ortherearedgetiltedupifmovingbackward.Keepingtheconcretedampforfivetosevendaysafterpouringhelpsthecuringprocess.Donotallow

ittodryout.Coveritwithplastic,anddampenthesurfacetwiceadayorso.Inmid-July,clientsaresometimessurprisedtoseemewearinglongpantsandlong-sleevedshirtsand

glovesdoingthiswork.Iadmittosweatingupastorm,butconcreteisquiteabrasive,andthePortlandcementishighlyalkaline,ascaustictoskinasanacid.AndPortlandcementishygroscopic,meaningitdrawsmoisturefromwhateveritcontacts—includingyourskin.Ihopethisbriefoverviewhelpsyouunderstandthisterrifictoolalittlebetter.Figures4-11through4-

14showtheconstructionofalargepadandpierbasefora70footselfsupportingtower.Figures4-15through4-18showconstructionofabaseforalargecrank-uptowerusingdifferentmaterials.Figures4-19and4-20showthemuchmoremodestbaserequirementsforaRohn25Gguyedtower.

GroundsandGroundingProtectingyourinvestment(tower,beams,feedlines,rotatorsandcontrollines,switchboxes,andthe

like)fromlightninginduceddamageisacriticalaspectofanyinstallation.Thebasicidea,always,istodirectthecurrentinducedbythestriketogroundasquicklyaspossible.Quicklymeansthepathofleastresistance—sothechargeisdissipatedbeforeitenterstheshack.Theideaistoprovideasingle,verylowinductanceground(asystem,ifyouwill),sonocurrentcan

flow“across”orthroughourgear,searchingforthatlowestpotential.Todothat,strappingworksbetterthanwire and solid conductors are preferred over stranded.But evenwith the best protection system,somecurrentcanflowonfeed lines,acandcontrol lines,soprotectiondevicesshouldbe installedontheselines.Startingatthetowerbase,it’swisetoinstallaseriesofgroundrodsattachedtoeachtowerlegwith

bondingwires. Separate these rods by twice their length. Eight-foot rodswould be 16 feet apart, forexample.Keepingthesewiresandrodsafewinchesunder thesurfaceof thesoil isfine; infact, it’sagood idea.Butclampedconnectionsshouldbe inspectedperiodically,agoodargumentagainstburyingthem.IliketouseCadweldOneShots(Figures4-21and4-22)asaconvenientway toattach thebonding

wires to theground rods,althoughstrappingcanbeusedwithappropriateclamps.Here’sa tipgainedfromexperience: Igniting theOneShotscanbe troublesome.Anordinary torchwon’twork, asunusedpropanegas formsa“cone”around the flame,whichprevents the ignitionmaterial fromstarting.So, Isimplyuseanordinarychildren’sfireworkssparklertolighttheOneShot.Cadweldedconnectionswon’trequireinspectionasoftenasclampedconnections.

Thenextstepiswheremanyhamsgetintotrouble—bondingthosewirestotheirtower.Whenbondingcoppertogalvanizedsteel(oraluminum)towerlegs,youmustinsertsomethingbetweenthesetwometalstopreventagalvanicreaction.Iliketousestainlesssteelshimstock,forinstance.Caremustalsobetakenincleaningeachsurface.It’simportanttouseafreshcleaningpadormaterial

on each surface to avoid contaminating them. It’s also important to use a light coating of Penetrox orsimilarconductivepasteonthejointbeforejoiningthem.Usetheproperlysizedclampsonthetowerlegsand tighten them verywell. If possible, allow them to go through a temperature cycle (overnight, forexample,thencomebackandre-tightenagain.

ProtectionforCablesWhenthetowertakesalightningstrike(noticewe’renotsaying“if”here),muchoftheenergycanbe

inducedintothefeedlinesandcontrollines,whichwilltypicallybetapedorsecuredtothetowerlegs.To reduce thepotential, the feed line(s) shouldbebonded to the tower.Typically, they’regroundedatboththetopandbottom.Towerstallerthan100feetshouldhavemultiplebonds.Mostofthefeedlinesusedbyhamswillhaveeitherbarecopperortinnedcopperjacketsfortheshield.ThestandardgroundingkitsavailablefromPolyPhaser,Andrewandothermanufacturers,willhavethe

necessaryshimsandconductivepastetoensuresolid,reliableconnections.ThePolyPhaserkitcontainslotsofillustrationstoguideyouthroughtheinstallation(usepartnumberPPC-UNI-KIT-2CT,forcoppershield to galvanized tower). It’s important to note here that all of these connections aremechanical innature.Youdonotwant touse solderedconnectionsanywhere.While fine foranRFground, solderedconnectionswillsimplyevaporatefromtheintenseheatinanylightningstrike.Thegroundstrapbondstothetoweritselfwillusestainlesssteelhoseclamps,withbothstainlessband

andscrew.Orifyouhaveanangle-legtower,thegroundstrapwill likelyuseexistinghardwareholes.Again,cleanallsurfacesanduseconductivepaste.PolyPhaser,ICEandArraySolutionsallofferprotectiondevicesforrotatorcontrolcables.Theseare

shunt-typeprotectiondevices,goingtogroundifasurgeexceeds82Vdc.Mountedtoa tower leg justabovethetowerpointground,thesearealsousefuldevicestohaveinyourprotectionarsenal.Movingtotheshackentrance,it’swisetoinstallabulkheadtypepanel(aluminum,copper,orstainless

are all typically used),which simplifies themounting of a variety of lightning arrestors and allows asimplemethodforattachingthecopperstraptoagoodground.Thearrestorsshouldbemountedinaweatherproofbox.PolyPhaserIS-50-seriesprotectorsare50Ω

devicesdesignedtomountonthatbulkhead.Notethattheyaredirectional—antennaandequipmentportsareclearlymarked,andinstallingthembackwardwillnotprovideprotection.ModelswithUHFandN-styleconnectorsareavailable,aswellasa3kWunit.Forinstallationswherethetowerislocatedsomedistance(over100feet)fromtheshack,Ipreferto

havetheIS-50deviceslocatedbothatthetowerbase,andthenagainatthebulkheadpanel.Thisisagoodplacetotalkabouttheactualshacklocationitself.Basementlocationsarebest—froma

lightningprotectionpointofview,notnecessarilyjustforaesthetics,economics,orfamilyrelations.Butthebasement’sclosenesstogroundcanenhanceprotectionpossibilities.Firstfloorlocationsarethenextobviouschoice,andshacklocationsgoingeverhigherprovidelessenedprotectionpotentials.Thisoverviewintroducesyoutothebasicsofgrounding—asystemsapproachthat’strulynecessaryif

yourinstallationistosurvivetherigorsofalightningstrike.It’sawiseapproachtofollow,providingnotonlysome“insurance,”butprotectionforyourhome,aswell.Forfurtherdetails,thereisalotofusefulinformationonthePolyPhaserWebsite.

AFewWordsAboutGuyAnchorsHolesarealsoneededforguyanchors,aswell,especiallyifwefollowtheguidelinesprovidedinthe

Rohncatalogforaversionofthe“deadman”anchor.AsshowninFigure4-23, that’sbasicallyalargechunkofconcretesuitablyburiedintheground.TheRohncatalogcontainsdrawingsandspecificationsforanchorssuitablefortypical25G,45Gand55Gtowers.Youcan’tgowrongbyinstallingaconcreteanchor following the manufacturer’s guidelines. The techniques for building tower bases — diggingholes,constructingrebarcages,pouringconcrete—arethesamefordeadmanguyanchors.

Questionsinvariablyariseonhamreflectorsandincorrespondence,concerningothertypesofanchors

—theubiquitous screw-inearthanchor, elevatedguypostanchors, anchoring to trees, andsometimes,even“temporary”anchors,whichIhavetoassumemeansthetowerinstallationwillbetemporary,sayforaFieldDayoutingorsomethingsimilar.Inanycase,let’sexaminesomeofthese.

Screw-InAnchorsScrew in earth anchors (Figure 4-24) are widely used in the commercial world, anchoring utility

poles,forexample.Thereareavastvarietyofthemoutthere,rangingfromsimple,shortshafted,smallscrewaugers,toserious,heavy-duty,largescrewanchors.Thesmalleranchorsarenotsuitedtoholdupyourtower,toputitbluntly.But,onceuponatime,eventheRohncatalogcarriedasimpledrawingoftwoguys,screwinginoneofRohn’sownearthanchors,whichwererathersmall—onlyfourfeetinlength,withasix-inchhelicalscrew.

Thelarger,heavy-dutyanchors,especiallythosemadebyABChance,designedtobeinstalledwithahydraulicdriver,willholdupa tower—providedyouhave somethingakin to“normal” soil.Chanceoffersaseriesofanchors,alongwithawealthofdataontheholdingpowerofsuchscrew-inaugers,ontheirWeb site. Look for theABChanceEncyclopedia of Anchoring, available for download in PDFformat.Ratingtheseanchorsishighlydependentonthepropertiesofthesoil.Table4-2showsasamplingof

ABChance’sratingsforsomescrew-anchormodelsusedinClass6soil(definedas“loosetomediumdensefinetocoarsesandstostiffclaysandsiltsloosesandysoilorfill”).Densesandorgravelorsoilswithhigherclaycontentwillhavehigherstrength;loosesandysoilorfillwillhavelowerstrength.SeetheEncyclopediaofAnchoringfordetails.

There’sobviouslyadirectcorrelationbetweenthescrewdiameter,depthandpulloutstrength.What’sasuitablescrew-inanchorforhamradiotoweruse?Somethingwithatleasta⅝-inchshaft,weldedhelicalscrews,andatleast5to6feetlong,aresomeofthethingsyoushouldlookforwhensearchingvarioussuppliers or catalogs—but check the ratings, consultwith an engineer and consider having your soiltested.Longer, larger,biggerareall,ofcourse,goodattributes,although thesevery featureswillmakegettingtheanchorsinthegroundmoredifficult,aswell.Theheaviestdutymodelshavetwooreventhreehelicalscrewsona7footshaft,areprofessionally

installed by machine, and are capable of handling huge loads. The AB Chance square shaft anchors(professionallyinstalled)wereusedextensivelyatK4JA’sinstallationofhis160meter4-squareverticalarray inCallao,Virginia.Pictures andbrief captionscan stillbe foundatwww.k4za.com. Iwas veryimpressedbythemwhenIdismantledPaul’sstation.Ihavescrewed4-inchscrewhelicalanchorsintotheNCclaysoilbyhand,butIhavealsobentasolid

¾-inchsteelbarattemptingtodothat,too.Moisteningthesoilhelps,butittakesanamazingamountofwatertodothat,alongwithconsiderabletimeforthewatertosoakdowntowheretheaugerislocated.Althoughyou’llreadaboutthisontheInternetorhearaboutit,theprocedureshouldnotbepracticed.Thestrengthorholdingpowerofsuchscrewinanchorsisderivedfromthemassoftheearthresisting

beingpulledoutoftheground.I’vehadclientstellmetheydrilledaholeandfilleditwithconcrete,usingthe same screw in anchor theywere unsuccessful at screwing in the ground. That’s not an acceptablesolutioneither,asthatsmallcylinderofconcretecaneasilypulloutofthegroundwithonly1000poundsofpull.Iknow—I’vetriedit!Inanycase,it’sagoodideatohavetheinstallertestascrew-inanchortomakesurethatitworkswiththeexpectedload.Thatwillavoidsurpriseslateron.Ifyoucannotgettheanchorscrewedtospecifications,it’sbesttosimplyreverttothedeadmanstyleof

concreteanchor.It’salsotruethatyoushouldbeleeryofanyanchoryoucaneasilyscrewin,aswell.Ifitgoes in easily, itmay comeout equally easily! Soils that contain lots ofmoisture (near creek beds orponds, for instance) shouldbe avoided.Wet soil can slip around the screw.Any screwanchor’s shaftshouldbemarkedwhereitleavesthegroundsoyoucantellataglancewhetherit’smoved—especiallyduringthefirstmonthorsoafterinstallation.

ExpandingEarthAnchorAnothertypeofanchorworthyourattentioniswhat’sknownasthe“expandingearthanchor”shownin

Figure4-25(ABChancecallsita“Bust”ExpandingAnchor).Thesebell-shapedanchorsrequireyoutodrilladeephole,atanangleorinserieswiththeguyline.Then,theanchorispusheddowntothebottom

oftheholebytheanchorrod.Asuitablelengthofpipeisthensliddown,overthatrod,andthensmashedwithasledgehammer!Youwillfeel(andhear)theanchor“bustopen”astheexpandingfingersextendoutintoundisturbedsoil.Removethepipe, thenbackfill thehole, tamping thedirtdownasyouworkyourwayupward.Then,simplybeginattachingtheguywires,asneeded.

Theseanchorsareterrifictouseinproblemareasandprovidesuperbholdingpower.Anchorrodsareavailableinlengthsfrom5to10feetanddiametersfrom½to1¼inches.Forexample,inClass6soila6-inchexpandinganchorwith⅝-inchrodisratedtohold8500pounds.An8-inchanchorwith⅝or¾-inchrodisratedfor15,000pounds.Many of these screw in anchors and the shaft rods for the expanding earth anchors have a large

“knuckle”headontheend.Thediameterofthisheadislargeenoughtoacceptguycablewithoutanextrathimblebeingadded,butittypicallyonlyacceptstwosuchlines.Ifyouwishtoinstallmorethanthat,youcan add an equalizer plate with a suitably sized shackle. Guy wire hardware is covered in detail inChapter5.

TheTowerItself

Withthebaseandguyanchorsinstalled,it’stimetotakeacloselookatthetoweritselfandthetoolsrequiredtoworkwithitandonit.

PlanningtheWorkEachday’s towerworkalwaysstarts thesameway—with the“tailgatemeeting,”whichmeans the

crew(climbersandgroundcrew)gathersaroundthetruck’stailgateanddiscussestheworkthat’sabouttohappen.Thismeeting isvitally important. Itensures thateveryonehasagood ideaofwhat’sgoingon,what’sneeded,whatstepseveryonewillfollow,whatwillhappenfirst,andsoon.Donotattempttodoanythingwithouthavingsuchasimplemeeting.Ifyou’reagroundcrewmember

andyouhave a question, don’t be afraid to ask. If you’re a climber, don’t be afraid to ask or tell thegroundcrewwhatyouexpectorwillneed.The idea is tocommunicate the sequenceofevents for theday’sworkclearlyenoughsotherearenosurprises,letaloneaccidents.Notonlywilltheclimberssortouttheirneededtools(whichonesthey’llclimbwith,whichonestheywillhavethegroundcrewhaulup,andsoon),they’llplanoutthejobsthatneedtobeperformed.Someonewill bedesignated as a safetyperson, the “just in case”guywith theworking cell phone.

Perhapssomeonewillbe takingphotographs.Makesure thatdoesn’t interferewith thework.How theclimbers and ground crew communicatewith each otherwill be discussed—whether radioswill beused, or other alternatives, and so on. Again, the issue is to have no surprises, and no confusion,disruptingtheworkflow.

PreliminaryInspectionWhenwebegintoseriouslyconsidertheactualtowerwe’regoingtoputup,thingsgettrulyinteresting.

Thereare,aswehavepreviouslycovered,twotypesoftowerstoconsider—theguyedtowerandtheself-supportingtower.Let’sconsidertheguyedtowerfirst.Andlet’sconsiderthevariouskindsofconstructionusedinthem.

We’llbeginwithtubularlegconstruction,asusedinthepopularRohnG-seriestowers.These triangular towers are assembled from steel tubing, with the legs or siderails held together

throughaseriesofZ-bracingrods,weldedtothattubingateachintersection.Towersectionsaretypically10feetinlength,andtheybolttogetherwithafive-inchoverlap.The25Gserieslosesthesefiveinchesateachjoint.The45and55G-seriesaretruly10-footsections,evenafterassembly.TheG-seriestoweristheclosestthingtoa“universal”towerthatwehaveintheUSA.The Rohn guyed towers (even the small 25G) are an amazing design— very strong for their size,

weightandconstruction.Hamsareknownfortheirabilitytooverloadthistowerbeyondmanufacturer’sspecifications and get away with it. A quick Google search will bring up any number of installationstories,picturesandguidelines.Thereare some limitations, somepossiblynegativeaspects to thisdesign,whichmanyhams tend to

overlook.Themostcommonissueistheabilitytorustfromtheinsideout,whichisalmostimpossibletoseeordetectbutismostcertainlydangerous.Experienceisprobablythebestdefensehere—knowingwhat you’re looking at, knowingwhat you’re dealingwith and knowingwhen towalk away. In harshenvironmentssuchassaltair,rustdamagecanbeobviousandsevere(Figure5-1).It’squitecommonforthefactory-appliedhotdipgalvanizingfinishtolast20yearsormore.It’squite

commonfortheretobepatchesofrustatsomepointonthetowerwheresomethinghasbeenattached—asidemount,arotatororasmallantenna.Theseareusuallystainsfromtheassociatedhardware,andnotafailure of the original finish. Tower sections that have been stored on the ground may suffer somedeterioration to their finish from soil minerals and the extended exposure to groundmoisture. Again,experiencewillbeyourbestguide.Ifthesteelisstillsound,havingsectionsre-galvanizedisanoptioninlocationswhereyouhaveaccess

tosuchafacility.Thesectionsaredippedinanacidbathforcleaning,andthenre-galvanizingcantakeplace.Typically,youpay“bythepound”tohavesuchworkdone.Itcanbeacosteffectivewaytorestoresectionsandguaranteethelifeofyourtower,whetheritistubularorangleironconstruction.For smaller jobs there are “cold galvanizing” coatings you can apply. These are typically spray-on

applications.Thebetterbrands(ZRC,BriteKote)arezincrichandrequirerepeatedshakingtokeepthenozzle clear.Multiple, thin coatswork best. It isnot necessary to use a grinder,wire brush, or otherabrasivetoolonthesectionbeforeapplication.Simplyensurethesteelisclean,grease-free,anddry.

TakedownsHamsareknownforthrift—youseethisatanyandallhamfests,hearaboutitontheairandreadabout

inthepagesofanyhammagazine.Nothingnewthere.Butsometimes,it’ssopervasive,Ithinkweallmustpossesssomespecificgeneticmakeupthatallowsustopassthelicenseexam.Normally,thisisn’tanissue.Indeed,it’ssomewhatadefiningquality—partoftheindefinablemagic

thatmakesthishobbysomuchfun.Butwhenitcomestoissuesthatcanthreatenlifeorproperty,economyhastobeforgotten.Safety,securityandseriousnessmustprevail.A used tower can be a bargain. But it can also be an accidentwaiting to happen.Again, if you’re

consideringtakingdownatowerforlateruseatyourownstation,seekoutnotonlysomeadvice,butalsosomerealhelpfromsomeonewho’sdonethissortofthingbefore.Towerworkisn’tforbeginners.Andwhileit’simpossibletogainexperiencesimplybyreadingaboutit,climbingatowertodoatakedownisdangerousterritoryforabeginner.Weallhavetostartsomewhere,sometime,somehow—butit’sbestnottobeginbytakingdownanexistingtowerwithanunknownsetofissues.

TemporaryGuysLet’sassumeyou’retakingdownwhatappearstobeasimple,easyjob—some25Gtower.Themost

commonmistakeisnottoinstalltemporaryguysortouseropeinsteadofproperguywireastemporaryguys.Ilearnedthislessonthehardway.Ioncehad30feetof25Gfalloverwithmeattachedtoit,alongwithsometemporaryropeguys.Withinseconds,Ifoundmyselflayingflatonmyback,stillclutchingthesiderails,stillbeltedin,butstaringupatthebrightblueMarylandsky,unabletobreathe.Foracoupleofminutes,mymindwasracing:Wow,whathappened?Whycan’t Ibreathe?AmIdying?Howdid theropebreak? Icanmovemy

fingersandtoes,whycan’tIbreathe?Actually,thisprinteddescriptiondoesn’tbegintocomeclosetowhatIwastrulythinkingandfeeling,

butthisis,afterall,afamilypublication,forgeneralaudiences.Sufficeittosay,Iwasscaredwitless.Fortunately,thetowerfellwhenI’donlyreachedthe25footmark.Thelandingspotwasonaperfectly

flat,manicured lawn, and the towerwas just 25G, light enoughnot to seriously injureor killme.Theropesdidnotfail.Twoofthemmerelystretchedoutcompletely—enoughsothatthethirdrope(thesideofthetowerIwasclimbingon)simplycollapsedorfoldedup.Thepierpinbaseofthetowerwaslooseenoughtoallowtheplatetoshiftenoughsothetowercouldlean,thenfall.Inafewshortminutes,Iregainedmybreath,andwewerereadytostandthetowerupagain.Thistime,

weinstalledsomereal,steelguys,andusedsomemorehelptoraiseitupright.Iwillneveragainworkonanother towerwith temporaryguysmade from rope.Yet, you read andhear about this practice all thetime,especiallyregardingtakingdownthetypicalRohnguyedtower.Yes,it’ssomewhattroublesometoinstall,hookup,andsecuretemporarysteelguys.Butthesimplefact

ofthematteris,Ibelievemylife(andthatofmyco-workersontheground)tobeworththattrouble!

TimeMarchesOnThesecondaspectoftakingthingsdownthatyoumustconsideristhemarchoftime—thingswillhave

changedconsiderablyat thetowersitesinceitwasfirsterected.Somechangesmaybeminor;someofthemmaybeveryserious.Youmustconsidersuchchanges,anddealwiththemaccordingly.Rustandthelossofsteelshouldbeyourprimaryconcern,asthesewillaffectyoursafety.Then,ask

yourself:Doyouhavespaceorroomtoallowthetakedowntoproceedwithoutendangeringyourselfandthecrew?Doyouhave room to loweror tramdownantennasandother thingsmountedon the tower?(Naturehasawayofclosinginonthetowersiteandtakingthelandback!)!SomeoftheNorthCarolinalocalsenjoyedashotofmewithasectionof45GhungupinanoakatN4XO’shome,wherethegrowthdidnotallowquiteenoughroomtolowerdismantledtowersectionseasily.

Lossofsteelespeciallyappliestothebaseofthetowerandtheguywireanchors.Youmust inspectthem,andcarefully!It’swisetohaveadiggingtool(Icarryamilitarysurplusentrenchingtoolwithme),toallowyoutoremovesomesoilatandaroundthetowerbase,andalsoatandaroundeachoftheguyanchors.Makesurethesteelhasnoterodedsomuchthatit’snowdangerous.I’veencounteredRohn45GwiththesiderailsandtheZ-bracingtotallyrustedthroughafter30yearsofneglect(Figure5-2).

TheTowerJackTool

WorkingwithRohn’spopularG-seriestower(20G,25G,45G,55G),isrelativelyeasy.Mostofthetime.With someattention todetails (suchaspre-assembling sectionson theground, checking legs toensure they’re clear and that the bolt holes are free of slag from galvanizing),most tower assemblyproceedsfairlyquickly.Afterthetowerhasbeenupafewyearsorevenforalongertime,itwillusuallycomeaparteasily

and can be taken downwithout many problems. But sometimes…there’s that one, stubborn, stickingsection…thatsimplyrefusestocomeapart.Manyofushavecarriedupsmallscissorsjacksorhydraulicjacks,withblocksofwoodandsmall

ropestosecureeverything,andstruggledwithtakingsectionsapart.Sometimes,wealsohadproblemsgettingthemtomate,whenputtingthe towerup.Weacceptedthis,assimplystandardprocedurewiththistypetower,andwenton.Enter theTowerJack, inventedbyJeaneneGill,N5UHL,andmarketedbyJeaneneandherhusband

Kenny,WB5HLZ.TheTowerJackisabasiclever-typedevice(madeofhingedbarstock),withhooksandnotches located at appropriatepoints to facilitate assemblyordisassemblyofRohn20G through55Gsections(dependingonwhichmodelyouneed).SeeFigure5-A.

Thissimpleleverwillsaveyoufromworkingsohardwhenputtinguportakingdownsuchsections.Theforce this leverexerts is significant—yetanotherappreciationofsomesimple lawsofphysics.TheonlycautionneededistokeepthejacktotheleftorrightedgeoftheZ-bracingtopreventbendingthesteelbracing.TryingtodescribetheprocessofusingtheTowerJackmakesitseemoverlycomplicated.Inuse,you

eitheruseahookornotch,andyoueitherpulldownorpushupontheleverhandle.It’sjustthatsimple.It’s a very clever, andverypractical tool to have for anyoneworkingwith this style ofRohn tower.Indispensable,really.

GuyedTowersOnceyou’vedeterminedtherearenoissuesorproblems,andthetowerissafetoclimb,youcandoso.

Cutcabletiesand/ortapeonthecontrollinesandfeedlinesasyougoup.Inspecteachsectionjoint,andthetoweringeneral,asyoumakeyourclimb.Onceat the top, it’s time todecidehowyou’ll proceedwith taking thingsdown.Multiple (stacked)

antennasonthemastwillrequireyoutodismantlethemoneatatime,workingyourwayup.Thatmeansyoumusttakedownthelowestbeam,thenperhapsremovetherotator(aftersecuringthemast),andthenlowerthemast toallowaccesstoandremovalof thenextbeam,andsoon.Thesearenot jobs for thefaintatheart,orforinexperiencedorfirst-timeclimbers,inmyopinion.When thecables,antennas,mastandrotatorareon theground, it’s time toconsider taking the tower

apart.Thisisanotherplacewhereexperiencecounts!You’llhavetoremovetheguystotakethesectionsapart.Dependinguponhowandwhere the tower isguyedyoumayfindyourselfworkingon30feetofunguyed tower above the next lower set of guys. Temporary guys are always a good idea.And thosetemporaryguysshouldbesteel—justlikethepermanentguys.Norope!Yes,installingtemporaryguysslowsthingsdown,butI’dratherdrivemyselfhomeattheendoftheday

andnotbetakenawayfromthejobsiteinanambulance.Oneofthenicethingsabouthamradioisthatit’stypicallynotdrivenbyatimeclock.Takeyourtime,andworksafely.Thepropertoolsaremoreimportantindismantlingandtakingantennasandtowersdownthanputting

themup,Ibelieve.AcquireaTowerJacktool(seethesidebar)forseparatingtowersections,Kleingrips

forgrabbingontosteelEHSguywireandsomePBBlastertosoakandloosenrustyhardware,alongwithsomesuitablysizedwrenches,andyou’regoodtogointakingdownmostanythingintheguyedhamradiotowercategory.

Self-SupportingandCrank-UpTowersSelf-supporting towers need to be inspected and cleared of cables, antennas and perhapsmast and

rotatorjustlikeguyedtowers.Themajorchangeinworkingwithlargerself-supportingtowersissimplyscale.Big,self-supportingtowerswillprobablybetakendownusingacrane—theentiretowerinonepick,afterremovingtheantennas,forexample.Smallself-supportingtowers,liketheBX-series,requirecloserattention.Theirsteelissmaller,andtheirrivetedjointscancomelooseovertime.Usually,ifatallpossible,Ialsoprefertakingthemdownwithamanlift,insections,orinonepick,afterhavingremovedtheantennas.WorkingwithcranesandmanliftsisdiscussedindetailinChapter7.Takingdowncrankuptowerscanbeevenmoredifficult.Younowhavemovingpartstoconsider,parts

thatmayhavesufferedfromyearsofneglectorinattentionandthatmaybeindangerouscondition.Thecardinalrule:NeverClimbACrankUpTower,certainlyappliesevenmorewhenitcomestousedcrankups.Again,Iprefertouseamanlift.Takeofftheantenna(s),andthenlowerthetowertotheground.Forthosemodelswithanerectionfixture,payparticularlycloseattentiontothewinchandcableusedbeforeattemptingtouseittolowerthetowertotheground.Iwasquitesurprised,onceuponatime,tofindthatthecenterportionofthehingepinonanEZWaytowerhadsimplydissolvedintorustafter30years!Safetyisalwaysthewatchword,andthisfactisnevertruerthanwhenworkingwithusedtower.Work

slowly,payingparticularattentiontothosepartsthatcanwearorweaken,andplanyourwork.

ToolsTherearesometoolsthatareuniquetotowerwork,andI’llspendsometimetalkingaboutthemhere.

Beforethat,letmesimplysaythattheusualshadetreemechanicorhandyman’sselectionofwrenchesandassortedshoptoolswillcoverprobably95%oftheworkassociatedwithtowers.Thereareanynumberofbrandnames—Craftsmantoolsarefine,forexample.Figure5-3showspartofwhatI’dconsiderabasictowerworktoolkit:

Deepwellsocketwrenchset—⅜-inchor½-inchdrive,socketsfrom7⁄16-inchonupCombinationwrenches—7⁄16-inchto11⁄16-inch(openendandboxend)Screwdrivers—both#2PhillipsandstraightbladeNutdriverset—qualityones,withrubbergripsPliers—Channel-Lock,RoboGriporKleinlinemanstyleNeedle-nosepliers—largersizepreferredDiagonalcuttersDriftpinpunch—taperpunch(¼-inchonup)Adjustablewrench—10inchKnife—adjustableorretractingbladestylepreferredHammer—somethinglikeasmall-handled9poundsledgehammerKleingrip—theonlytooldesignedtoholdEHSguycableComeAlong—usedtotakeuporloosenthatEHSguycable

That simple selection should get you started. Over time, if you continue to work on your owninstallation, you’ll grow accustomed to or prefer some tools to others, and you’ll develop your ownpersonalchoices.Nowwe’ll get into somemore specialized tools and accessories that I’ve found indispensable for

towerwork.

ClimbingAccessoriesToday’swell-equippedclimbertakessomecuesfromtherock-climbingfolksandutilizessomeofthe

unique and specialized tools developed by and for them.Table5-1 lists several sources for climbingequipmentdiscussedhere.

Table5-1RopeandClimbingGearSourcesGearExpress—www.gearexpress.comSterlingRope—www.sterlingrope.comTheGearshop—www.gearshop.comNewRiverNets—www.newrivernets.com

Whyclimbinggear,anyway?Primarilybecause it’s lightweightanddesigned tosafelyholdorcarryhumanloads,sothesafetyfactorinhelpingferryyourantennaorrotatorortoolstothetopofthetowerissignificant.

CarabinersThe primary tool, of course, is the carabiner. Carabiners are lightweight metal links (usually

aluminum)thatcanbeclosedandopenedquicklyandeasily.Climbers,parasailgliders,spelunkersandrescuepersonnelusetheminawidevarietyoftasks.Theycomeinarangeofstyles,sizesanddesigns.Figure5-4showsacouplefrommycollection.Foragoodreferenceandstartingpoint,lookatthisWebsite:www.uhartrescue.com.

Intypicalclimbinguse,carabinershavebothaconnectingandasafetyfunction.Connectingtoarope,connectingarope toanotherpieceofgearorconnectingarope toafallprotectiondeviceareprimaryuses. Carabiners must withstand extreme forces, as a climber’s life often depends on them, so it’sprobably safe to clip your tool bag to the tower using one.As hams,we’ll bemore interested in theconveniencefactor—Ineverrelyonacarbineerforanyprotectiveuse.But,asinclimbing,differentactivitiesandtasksrequiredifferentkindsofcarabiners.Characteristics

suchasshape,gatetype,strength,material,weightandsizewilldeterminetherighttypeofcarabinerforeachtaskandbudget.Inchoosingcarabiners,simplylookattheintendedusefirst.Ifyoucan,buyafewcarabiners of different styles to seewhich you prefer. If your budget is restricted, the simple designs(oval,non-locking)willprobablycovermostofyourneeds,althoughsizecanbeanissue.Thestandardsizecarabinerswillnotfitlarger-sizedtowers,forinstance,likeAB-105orSSVtowers.Forthat,you’llshifttothelarger,rescue-work-orientedtypes(Figure5-5).

Knowinghowtoclipacarabinerisextremelyimportant.Basically,thebottomgateshouldalwaysfaceawayfromthedirectionyouareworking.Second,yourropeshouldneverrunacrossthecarabinergate.Andwhen clipping, the ropemust end up running out of the carabiner toward the climber. Finally, acarabinermustrestevenlyagainstsomesupport;unevenpressureonpartofthecarabinerwillreduceitsstrength. (Again, in normal towerwork, these factors are not an issue—most of our towers are notsituatedamongrocksorboulders.)

PulleysPulleysareusedoneverytowerjob.Mountedatthetopofthetoweraswellasthebase,theymake

haulingup tools,equipmentorantennas relativelyeasy.Youwill findavarietyofpulleysatanywell-equipped hardware store, but these steelmodels are heavy. Tower climbers are always searching forwaystomakethingslighter.

IhavetwostylesIuse.Oneisaplasticmodel(Figure5-6),ratedat1000pounds,whichhasahingedopeningthatallowseasyaccess.Rescuepulleysarethenextconsiderationfromtherockclimbingtoolkitworth the tower climber’s attention (Figure5-7). These aluminum-bodied gadgets are ideal for towerwork.They come in a variety of sizes,with ultra-smooth bearings, and best of all, they swivel apart,enablingthemtobeputonalineatanypointalongits length.Lookforpulleyswithaminimum2-inchsheave size — that’s the grooved wheel that spins between the pulley halves. Anything less willcontributetoomuchfrictionordragonyourpullropes.

Severalpeoplehaveaskedaboutacouplegadgetsthey’veseenmeusingduringtowerjobs,namely,asimpleswivelattachedtoaropeorcarabiner.Butit’snotjustanordinaryswivel—thisisaPetzlballbearing-equippedswivelthatmakestrammingbeamsororientingarope’sdirectionsmoothandpainless.Asealedballbearingmakes theactionon thisswivelsilkysmooth,evenafteryearsofuse.Use itanyplacewhere twistingmightbeaproblem.The topof theswivelcanholdup to threecarabiners.Petzlswivelsarepricey,butareanenergyandtime-savingadditiontomytoolbox.Ineverclimbwithoutatleastonerescuepulley.Ialsoalwaysuseoneatthebaseofthetower(witha

swivel),allowinggroundcrewpersonneltoruntheropethroughitandbackawayfromthetower.Thesecondpulleyallowsthemtohandletheropehorizontally,whichmanypeoplefindeasier,andtheydon’thavetoworryaboutwhetherornottheropeisgoingtosnagonthegroundorisclearofobstructionsatthetowerbase.Also,oncesafelyawayfromthetowerbasethereislesschancethatthecrewwillbehitbyfallingobjectsiftheclimberaccidentallydropstoolsorhardware.Andawayfromthetowerbaseit’s

alsoeasiertolookupandseewhattheclimberisdoing.

SlingsFinally,afewthoughtsonslings.Thesearetypicallyloopsofnylonthataresewntogether(Figure5-

8).The“norm”orstandardis25mmwide(about1inch)sewnslings,manufacturedfromFrench-madeFaure-roux webbing. These general-purpose slings have impressive strength, typically a rating of 25kilonewtons(kN)andanactualstrengthusuallyover30kN.(1kN=224.8lbs-force;4000lbs-force=17.8 kN.)When the webbing is made into a sling and tested, a strength of around 25-30 kN can beobtained. Generally, a particular length of sling is made a certain color, to assist in distinguishingdifferentlengths.(Ihaveslingsinavarietyoflengths.The4-footlength,forexample,isaversatilesling—agoodlengthforattachingtoanantennaboomtohoistbeams.)

Therealmagicoftheslingisthatit’slikethatsimplekid’stoy,theChinesefingerpuzzle—wherethetighterorharderyoupull, the tighter andharder the littlepaper tubegripsyour fingers.Relaxingyourhandsmakesthepaperloose,andyoucaneasilyremoveyourfingers.Slingsworkthesameway.Afewwrapsandyoucanhoistamastorotherverticalmemberwithoutthehassleofboltingonamufflerclamporotherdeviceontheend.Somefolkswonderaboutthesafetyandsecurityofslings,orwhyyoucan’tuseropetodothesamething.It is themakeupof thatspecialnylonmaterial thatuniquelyqualifies thewebbingasthewinner—ropeslips,andtheslingsholdfast.If you’re familiarwith cranes, you’ve seen different versions of these climbing tools in use. “Open

slings”arealengthofwebbingwithasmallloopateachend.“Closedslings”arethestandardcircularslingswith a stitched joint.These slings are usually heavier andwidermaterial, and are designed forliftingdeadweights.Theconfigurationsareusuallydifferentaswell.The importantpoint to rememberabouteachtypeis that thesurfacearoundwhichtheslingissecurediscritical tosafety.Ifanyslingisworkedaroundaroughsurface,a lowerstrength thannormalfor thewebbingwillbeobtained.And,asquareedgeorthreadedbar,forexample,willdrasticallyreduceanywebbing’sstrength.Ienjoythespeedandeaseofuseof theseclimbingaccessories—that’swhythey’re inmytoolbox.

Next,herearesomeideasandguidelinesforsafeliftingwithslings.

SafeLiftingTherearefourprimaryfactorstoconsiderbeforeliftingaload:1)Thesize,weight,andcenterofgravity(CG)oftheload

2)Thenumberoflegsandtheangletheslingmakeswiththehorizontalline3)Theratedcapacityofthesling4)ThehistoryofcareandusageoftheslingThe center of gravity of an object is that point where the entire weight may be considered as

concentrated.Tomake level lifts, the lifting connection point (from a rope or a hook from a crane orwherever)mustbedirectlyabovetheCG.Somesmallvariationsareusuallypermissible,butiftheliftingpointistoofartoonesideofthecenterofgravity,theobjectwilltiltover.As theangleformedby thesling legand thehorizondecreases, theratedcapacityofyourslingalso

decreases.Inotherwords,thesmallertheanglebetweentheslinglegandthehorizontal,thegreaterthestress on that sling, and the smaller the load itwill safely support.Hamswill not normally encounterloads that even approach the limit of the typical 1-inch or 2-inchweb slings. But, knowwhat you’reworkingwith—readthesling’slabel.Thevalueslistedarefornewslings;olderslingsshouldbeusedwithadditionalcaution.Neverexceedasling’sratedcapacity!Themostcommonhitchesweusetoliftitemsaretheverticalhitch,chokerhitchandbaskethitch.A

verticalhitchismadedirectlyfromtheliftinghooktotheload,usuallyattachedbymeansofanotherhook.Achokerhitchmeanstheslingpassesentirelyaroundtheloadwithonelooppassingthroughanotheronthesling’soppositeend,formingasimplenooseor“choke”hitch.Thebaskethitchmeansyoupasstheslingunder and around the load,withboth eyesor endsgoingbackup to the liftingpoint.Figure 5-9showsaslinginuse.

Slinganglesareimportant.Theydirectlyimpacttheratedcapacityofthesling.Thisangleismeasuredbetweenhorizontalandtheslingleg,regardlessofhitch.Wheneverpullisexertedatanangleonaleg,thetensiononthelegisincreased.Forexample,eachslingleginaverticalbaskethitchabsorbs500poundsof stress from a 1000 pound load. That same load, lifted using a 60-degree basket hitch, exerts 577poundsof tensiononeachsling leg.Withoutconsultingsomechart tellingyouwhat the increased loadwillbe,followthissimplerule:Ifthelengthoftheslinglegisgreaterthanthespanorwidth,theliftingangleisokay.You’ll quickly realize that angles less than 45 degrees should be avoided. If you have trouble

remembering,simplythinkabouthoistingtwobucketsofwater—oneineachhand.It’sveryhardtoliftandholdthemwithyourarmsoutspread,butyoucanpickupandholdthebucketsquiteeasilywithyourhandsandarmsbyyoursides.Keepyourloadsasverticalaspossible,that’stheidea.Table5-2 showstheeffectsofangleonslingcapacity.Notethatatsomeangles,ratedslingcapacityiscutinhalf!

Slings are swell tools, and they can make lifting our sometimes heavy and cumbersome three-dimensionalYagissomucheasier.Combinedwithsomemodernclimbingaccessories,riggingandliftingcanactuallybefun.Italwaystakesfarlongertosettheriggingthantoactuallydotheworkofraisingtheantennas!Understandingslingsand thoseclimbing toolswillmake trammingantennas relativelyeasy.Whether

it’s a small tribander or somemonster Yagi, hauling antennas up and into place can be one of thosemomentsofappliedscience thatawesandamazeseven theexperiencedrigger.Forfurtherreadingandmoredetailedrigginginformation,takesometimetoperusetheWebsitewww.fdlake.com.

RopeRopeisoneofthosethingswesimplytakeforgranted.It’sasimplefactthatifyou’regoingtobedoing

towerandantennawork,you’regoingtoneedandbeusingrope.Whetherit’sfortaglines,haulropes,ortramlines,thereareliterallydozensofoptionsandguidelinesyoushouldconsider.You’ll find ropemade fromnaturalmaterials today (manila, sisal andcottonare themost common),

alongwithlotsofsynthetics(nylon,Dacron,polypropylene,andsoon).You’llfindlotsofsizes,prices,claimsandcomments,too,regardingeachandeveryoneofthesematerials.Figure5-10showssomeoftheropeIuse.

SizeYourfirstpriorityshouldbedecidingexactlywhattask(ortasks)youwanttodowithyourrope,asthe

useshoulddictatewhatyoubuy.Sizeisthefirstfactor,ofcourse,andthisincludesnotonlylength,butalsodiameter.Materialselectionshouldbenext.Priceprobablyshouldn’tbeafactor,asonceyoustartsearching,youmaybestunnedbywhatyoufind.Theoldsong,“yougetwhatyoupayfor,”iscertainlytrue with rope, and thus, your budget for this item may require some rethinking. Good rope will beexpensive.Thinkingaboutsizeiseasywhenspeakingoflength—you’llneedtogetupyourtowerandthenback

down,withacomfortable“handling”margin(say25%tobesure)leftover.So,ifyouhavea100-foottower,you’llneeda225to250-footrope.Thinking about size ismoredifficultwhen speakingof diameter—you’re into the arcaneworldof

“working load” and “ultimate breaking strength,” and almost no one understands these. If you plan onusingyour rope for lifting loads (towersections,beams,and the like), thenanyropehavingaworkingloadof100to300poundsshouldhandlealmostanythingahamwouldcommonlyputup.Obviously,therearesomeniftysyntheticropesoutthereofverysmalldiameterstrongenoughtoliftthisload,butconsiderhaving(andusing)somethingthatwillbecomfortableinyourgrip.Smallerropeshurtyourhandsmorereadily than larger ropes. Smaller lines (sometimes called cords)work great for “tag” lines, but oncethey’rehaulingaheavyload,theybecomedifficulttohold.I’dsaythata⅜-inchlineisthesmallestsizeIwoulduseformostanytowerwork.Ipreferalarger,½-inchropeforthiswork,myself.

MaterialandConstructionThinkingaboutmaterial is also relativelyeasy, as the syntheticmaterial’sadvantagesoutweigh their

disadvantages.(Allthenaturalfiberssoakupwateraboutaswellasspongesdo—theyroteasilyandmustbestoredproperlyatalltimes.)Nylonisthestrongestrope.Itstretches,butbecauseofthis,nyloncanabsorbsuddenshockloadsthatwouldcauseotherfiberstobreak.It’sextremelyresistanttowear,andcaneasilyoutlastnaturalfiberropes.It’sessentiallyrotproof,unaffectedbymostcommonchemicals,andmostimportantly,itknotseasily.Allropeisconstructedfromsmallfiberseithertwistedorbraidedtogether.Thistwist,calledthelayof

the rope, isusuallya simple three-twist construction,verycommon inanyhardware store inAmerica.Ropeconstructionhasevolvedovertheyears,becomingmoretask-specific,andconcernswithsafetyand

good engineering practices from today’s manufacturers provide several great choices. Braidingtechniques, developed inWWII, should lead your rope selection process. Those choices are hollowbraided,doublebraidandkernmantleropes.Hollowbraidmeansthefibersarelaidaroundahollowcorein“maypole”fashion.Assuch,thisropeissubjecttoflatteningunderstrain,meaningit’snolongerround.

Doublebraidropesareconstructedwitha“cover”overa“core,”oftenofthesamematerial.Ruggedandsmooth.

Kernmantle ropes (kernmeanscore;mantlemeans sheath) are usuallymadewith an inner syntheticmaterials core, covered with a braided sheath. The core provides the strength, while the sheathprotectsthatcorefromabrasion.Doublebraidedandkernmantleropeswillprobablybethebestoverallvalue.

StrengthNow,whataboutworking load,or limits,orstrength?Obviously,wearenowspeakingofsafety,so

knowingthemaximumsafeworkingloadforyourropecanhelpkeepyououtoftrouble.Neverstressarope (or line) anywherenear itsbreaking strength.As ropes age,or as theyare spliced, stretchedandsubjectedtosustainedloadsorshock,orastheyareexposedtoultravioletlight(inotherwords,asropesareused),theywillalsolosesomeoftheirstrength.Theratedbreakingstrengthofseemingly-identical ropefromdifferentsupplierscanvaryby10%or

more,anddifferentsuppliersalsospecifyarope’ssafeworkingloadatanythingfrom1⁄5toaslittleas1⁄15ofitsbreakingstrength,sobesuretocheckonthesespecificationsbeforebuying.Thisisanothergoodargumentforusingropeof⅜-inchorlargerdiameter—assuchropehasahigh-enoughbreakingstrengththat even conservative calculations of a safe working load provide some leewaywhen working withtypicalamateurantennas.This is a good point at which to talk aboutworking loads, a term that is often misunderstood or

misused.It’sreallyimpossibletopositanabsolutesafeworkingloadforanyropeorline.Calculationsshouldbebasedonapplication,theconditionsofuse,andpotentialdangertopersonnelorproperty.Youcandetermineaworkingload,alongwithsomesafetyfactor,usingyour judgment,personalexperienceandthemanufacturer’spublishedrating.I always assess the risks involved when using a rope to do any task, taking that factor into

consideration. Shock loading or heavy, sustained loads, and so forth, along with the physical factorspreviouslymentioned, all contribute to a rope’s service life. (TheCordage Institute considers the safeworking limit to be derived by dividing theMinimumTensile Strength of the rope by a safety factor,whichrangesfrom5to12fornoncriticaluses.Thefactorrisesto15whenphysicalsafetyisanissue.)

StorageRememberingthatcommentaboutexposuretoultravioletlightpossiblyweakeningrope,it’simportant

tostoreyourropesproperly.Youhavetorelyonyourropes,anddamagefromUVlightormoisturemaynot be obvious. That’swhy I store allmy ropes in Rubbermaid or other plastic tubs (Figure 5-11). Isimplylaythemin,dry,whenfinishedwithajob.Theyalwayscomeouteasily,too,whichsavestimeonthenext job.Each tub is labeledwith information concerning thatparticular rope,usuallyprompting aquestionortwofrommyclients!

WhatRopetoBuy?So,whatshouldyoudo?Whatshouldyoubuy?Yourdecisionwilldependuponyourultimateuse,the

sizeofyourtower,andhowyouintendtousethatrope,ofcourse.Obviously,havingreadthisfar,you’llrealizeyoushouldprobablyhavemore thanone rope,basedoneachof thepreviouspoints.Forsheerstrength,easeofuseandworkingabilities,I’drecommendadouble-braidednylonrope.I’drecommendatwisted(orbetteryet,braided)polycordorropefortaglineuses.Irecommendbuyingthebestropeyoucan,thencaringforitproperly—sometimesmoreeasilysaidthandone.Using rope as a tram to haul beams up the tower always generates considerable traffic on various

Internet reflectors,mostlyall related to safety, the lawsofphysics,and the rightandwrongway todosuchwork.(Trammingissuchausefultechniqueforraisingantennasthatit’scoveredindetailinChapter8.)Mylargestropeisa⅝-inchdoublebraidednylon.It’sservedmewell,andthelargestbeamI’veeverhauledwith itwasa200+pound20meterTelrexmonobander. Ifyou’reunsureofyourneedsorhavequestionsabouttherequirementsforstrengthorsafetywhenworkingwithrope,simplyaskononeofthetowerorantennareflectorsorbulletinboards.Therearelegionsofpeoplewillingtohelpandsupplytheanswers.Buyingropecanbeexpensive,especiallygoodrope.Withtheincreasingpopularityofrockclimbing,

some interesting synthetic ropes can be found (be prepared, however, since all their dimensions aremetric, asmany ropes aremade in Europe). Gear Express is one good source for climbing rope andhardwareatconsiderablesavings.(Mentionyourcall,orwhatyouintendtodowiththerope;oneoftheownersisaham.)SterlingRopeandGearShopandNewRiverNetsarealsogoodsources.Iwouldn’tbuyusedrope.Iwouldn’tbuyropeoneBay.Iwouldn’tborrowrope.Iwouldn’tsuggesta

club pool its resources to buy rope. I say this simply because the unknown variables increaseexponentially, and it’s not worth the risk. Why put yourself, anyone who’s helping you, and/or theequipmentyou’reworkingwith,inanydanger?Iconsidermyropesaninvestment,andIhavevarioussizesanddiametersinmytoolkittoallowmeto

workontowersupto200feetinheight.

GinPoleTheusualtoolassociatedwithpulleysandropeistheginpole,atowererectiontoolthatconsistsofa

longpolewithapulleyatthetopasshowninFigure5-12.Ineveryinstance,theginpoleisdesignedtoattachtothetower,withahaulropepassingthroughthepole,aroundthepulley(calledaroosterhead,in

the commercial world) and down to the ground. It’s wise to install another pulley at the tower base,allowinggroundcrewworkerstowalkawayfromthetower,astheyhaulmaterialsupthetower.

Theprincipleofginpoleuseistosecurethepoleclamptoasection’stowerleg,ashighasphysicallypossible,thenslidethepoleupasfarasneededandsecuretheclamp.Thatusuallylocatesthepulleyatthetopafootortwohigherthantheworkarea,whichisdeterminedbythelengthoftowersectionstobepulledintoplaceandassembled.Thegroundcrewattachestheropetothenexttowersectionsomewhereabovethebalancepointand

usuallyashighaspossiblewithout runningoutofworkareaat the topof the tower.Thegroundcrewhaulsthesectionuptotheclimber,whousesthe“reacharea”tomaneuverthenewtowersectionupandintoplace.Figure5-13showsaginpoleinuse.

Whenerectingtowersections,thenextsectionispulledpastthetopofthematingsection—sothelegsclear the topof the section—and then loweredon to those legs.Thisallows themostcontrol, as thetower climber guides the mating sections together. This also ensures that the ground crew personnelalwaysmaintains“control”ofthetowersectionattachedtotheginpole,untilit’sfullymated.Adriftpinpunchisusedtoaligntheholes,andthentheboltsarepushedinandtightened.Then, the

climbercangoup,releasetheattachedginpolerope,collapsethepole,andmoveitup,ontothisnewsection.Theropeendisthensentbacktoearth,andtheprocessisrepeated,asnecessary.Rohnmakesaginpolespecificallyintendedforusewiththeir25Gand45Gmodels.Theirdesignation

isEF2545(erectionfixture).Itis,however,veryexpensive.WBØWsellsaginpolewithclampssuitableforboth theG-series tower,aswellas theBX-series. IIXEquipmentalsosellginpoles.TheWBØWmodelisveryrugged,andsuitablefor55G,aswellasthesmallertowers.Luggingitaroundwilltaxeventhebiggestandbesttowerworker!Folksoftenask(inperson,aswellasonvariousInternetreflectors),exactlyhowtomovetheginpole

up,ontothenexthighersection.IfI’musingtheRohnpole,I’llusuallysimplywrapasmallslingaroundthepole,attachittomybeltandclimbtothenextattachmentpoint.IfI’musingaheavierdutyversion,I’lluseasecondworkropeandallowthegroundcrewtopullthepoleintoposition.Theginpolecanalsobeusedtoliftrotatorsorothertoweraccessoriesorotherhardwareupandinto

place.Itcanbecumbersometouse,though,andthepulleysdescribedpreviouslymaybeabetterchoiceforhaulinghardware.Theginpoleworksbestfortowersectionsormastswherethepulleyneedstobewellabovetowertopandinlinewiththetowersections.

GinPoleWisdom(Rohn’sEF2545)

Theginpoleisyourfriend,justkeeptellingyourselfthat,asyoustruggle(especiallythefirsttime)toraiseitororientitontoatowersectionrightnexttoaguybracket.Itcanbeanawkwardmoment,andaseeminglycumbersome,clumsytool.Theclampistheimportantpart,ofcourse,andslidingtheclamptotheend(wherethepulleyis)will

allowyoutomaneuverthepolearoundthetowermoreeasily.That’sthefirstthingtoremember.Ihaveclimbedwiththeginpoleonmybeltforyears,butthesedaysIoftenrigittoaslingandhave

thegroundcrewmove itupanddown,savingmyself thestruggle.Onnew installations, this requiresclimbingupandriggingthehaullinebeforehand,soit’ssometimeseasierjusttomoveitmyself.Regardless,it’simportanttokeepaclearpathtothegroundfortheginpolerope—somountingthe

polearoundornearthoseguybracketscanbeproblematic.Theroosterhead(thepulley)mustclearthebracketasthepoleisextended,forexample,anoftenoverlookederrorwhenfirstusingaginpole.Thepulleyitselfshouldextendoutandover,andin—towardthecenterofthetower—whenlifting

to installor removesections.Thatpositionprovides thebestbalanceand themost lifting force.Thismeans the haul linewill come up one side of the tower, and down the opposite side. This providesplentyofclearanceforthesection,cominguporgoingdown,too,toclearanyguybracketsorguywiresthatmayalreadybeinplace.Easeofuseisobviouslyyourfirstneedonthetower,soit’salwayswisetostoretheclampindoors,

outoftheweather,topreventrusting.Ialwayslubricatetheclamphingesbeforeeachuse,too.Thepoleitselfcanbestoredanywhereconvenient,solongasit’sfreefromgettingbent,dentedordamaged.

AGinPoleMod

WhiletheRohnginpoleisnotexceedinglyheavy,itcanbeawkwardtouse.TheWBØWandW9IIXpoleandclampsareheavy.So,ineachcase,asecondclimber,alongwithashortrope,canhelpyoumaneuverthepoleupandintoplaceonthenextsection.Or,asecondworkropecanberundowntheoppositesideofthetowersections,allowingthegroundcrewtoliftandhaultheginpoleupandintoplaceasneeded.Ashortsling,securedaroundthepole itself,makesattachingaropeandmovingthepolemucheasier.Havingfoundmyselfatoptowersnumeroustimes,attemptingtoguide, insert,orotherwiseinstalla

long,heavymastintoatowertoporthrustbearing,Ialwaysfoundmyselfthinking,“There’sgottobeabetterwaytodothis.”Theproblemiscompoundedbytheginpole’s12-foot length.A24-footmast isdifficult topickup

andkeepbalanced—ifyourigthe“heavyend”down,thepole’stooshort.Ifyourigthe“heavyend”up,nomatterhowmuchofabruteyouare,themastcangetawayfromyou.Andyes,Iknowyoucanuseropesandturnthemastupsidedown,intheair.Whilethereare,admittedly,otherriggingsolutionstotheproblem,Iwantedsomethingabitmoreelegant,alongwithacertainsafetyfactor.Drivinghomeoneafternoon,thesolutioncametomindasIwatchedsomeneighborhoodkidsplaying

basketball.Whynot simplymountahoop (likeabasketballhoop, that is), at the topof theginpole?Then,regardlessofrigging,regardlessofwheretheheavymast’sbalancepointfalls,itcannotgetawayfromtheclimberorgroundcrewastheyworktogethertoguidethemastintoplace.Aquick trip tomy local sports emporiumproved theplan tobe economically feasible. I bought a

hoopfor$20.Afterpurchasingit,andafewminuteswithmytrustyDeWaltgrinder,I’dremovedallthelittleweldedorbrazed-onhooksandloopsdesignedtosupportthenetting.Ithendrilledsomeholesto

accept a couple of 2-inch U-bolts on the plate for mounting to the gin pole, and then sanded andrepaintedthewholehoop.Figure5-Bshowstheresult.

Naturallyenough,onthenextjobrequiringmetoinstall21feetofChrome-Molymastinsidea100-footRohn25Gtower,mygroundcrewgotquiteachucklefromthisnewestgadgetintheK4ZAtoolkit.Amidstcriesof“BelikeMike,”and“Goforthree,”andsoforth,weslowlyraisedtheheavymastintoplace.But all the cries and catcalls ceasedwhen themast slid into placewithout incident, not onlysavingustimeandenergy,butalsoremovingoneofthoselingeringdoubtsaboutanotherdangerousjob.It’sasimpleandelegantsolutiontothisoldproblem.Thehoop is relatively light, inexpensive,and theclimbercan install and remove it inminutes. It’s

anotherwelcomeadditiontomytoolbox.

How-ToTipsHerearesometipsforstackingtowersectionsthatI’vepickedupovertheyears.Checkingeachtowersectioncarefullybeforeattemptingassemblymakesperfectsense.Thisappliesto

new tower sections aswell as used. Tubular legsmust be clear of debris and obstructions. Look forexcessivegalvanizingandmakesurethattheboltsfittheholes.Ifalegisblocked,slidingagroundrodthrough the siderailworkswell. It has enough “mass” to force out any debris,while still being smallenoughtoeasilyslidethrough.Pre-fittingthesectionsonthegroundmayseemoverlycautiousand/ortroublesome,butit’sfareasier

to find problems on the ground than while in the air. Granted, neither place may provide an easy,immediate solution, but the tower crew will appreciate and applaud your efforts. Even brand newsectionsmayhavebeenbangedaroundintransit,bendingtheendsofthelegs.TheTowerJacktool,ratchetstraps,evenlong“breakerbars”haveallbeenusedtosuccessfullyshift

stubbornlegsintoalignment.Asalastresortsolution,I’veevenbenttheZ-bracing,whichhastheeffectofmovingtheopposite-facingsiderailleg.Beatingituporintowardthecenterofthesectionshiftsthelegsinward;beatingitdownoroutshiftsitoutward.Forthosetrulystubbornmomentsonthetower,I’ve

alsoinstalledthematingsectiononthemisalignedleg,andthenusedthatsectionitselfasalongleverarmtoshiftthelegwhereIneededit.Theseare,asIsay,solutionsthatwork,butshouldn’tbetriedbytowernovicesorthosefaintofheart.Lubricatingthelegsisalwaysagoodidea.Iliketousewhitelithiumgrease,mostlybecauseitcomes

in a convenient-to-use tube. For those towers thatwill be used as 160 or 80meter verticals, I’ll usePenetroxorNoaloxantioxidantcompounds.Towerboltsarecontroversial.IadmittousingstainlesssteelinassemblingRohntubulartowers.Yes,

thisviolatesthe“DoWhatTheManufacturerSays”rule.Yes,stainlessisnotasstrongasothermaterial.Yes,thismakesdisassemblymucheasierlateron.And,Iadmit,Isimplyhaterust.IfinditoffensivetolookupatatowerI’veputupandseeitstainedwithrustateachsectionjoint,seeminglywithinafewshortweeks after assembly. In 30 years of towerwork, I’ve not encountered one problemwith usingstainlessbolts.

GuysForGuysWhoHaveToGuyIbelieveguywirestobeoneofthemostmisunderstoodpiecesoftowerhardwarearound.Isaythis

because I’ve encountered everything from simple clothesline to PVC-jacketed aluminum CATV cableused toguy towers! (No, IdidNOTclimb the tower supportedwith theCATVcable.Theownerwasquiteupset;assuringmethattowerhadgonethroughHurricaneHugowithoutmishap.)Youneedtoconsiderthemaximumloadthatwillbeputontheguysduringoperation,alongwithsome

safetymargin.Considermaximumuplift forces theguyanchorsmustsustain.Havingdone this,youcanthendesignorengineeraguy“system”basedupon:ANSI/EIA/TIA-222-GSoilconditionsWindloadofeverythingthat’sgoingonthetowerIt’simportanttothinkaboutwhatyou“mightdo”onedayanddesignaguysystemthatnotonlyworks

today,butalsolater—ifandwhenyouaddthingstothetower.Thiswillhappen.Inotherwords,you’renotjustputtingup“50feetofRohn25”or“100feetofRohn45.”You’realsoputtingupaguyingsystem.Rohn and other manufacturers publish information about guy requirements for various tower

configurations,loadsandenvironmentalconditions.Figure5-14showsacoupleofexamples.Ifyouneedhelp in determining how to adequately support or guy your tower, the ARRL’s Volunteer ConsultingEngineerprogramcansteeryoutoaknowledgeableengineer.Table5-3showsspecificationsforsomeoftheguycablematerialsdiscussedinthefollowingsections.

EHSSteelGuyWireEHS(ExtraHighStrength)steelcableiseverymanufacturer’srecommendedguyingcable.Sizesstart

at3⁄16inchandgoup,nextto¼-inchEHS,andthenfortrulytallhamtowersinhigherwindzones,5⁄16-inchor ⅜-inch EHS.Most ham towers will use the 3⁄16 or ¼ inch cable (Figure 5-15). EHS guy wire isstrandedandeachstrandisgalvanized.It’stoughstuffandrequiressomeknowledgeandspecialtoolstoworkwith.

ThepropertoolstousewhenworkingwithEHSguycableareKleingrips(Figure5-16),specificallywhat’s called a “Chicago”grip or the “Haven”grip.These tools allowyou to grip theEHS securely,applytension,andthenattachthePreformorCrosbyClips,andassociatedhardwareasdescribedinthefollowingsections.

TheChicagogrip#1613-40isthemodeltolookfor,asitsparallelV-shapedjawsprovidefourlongpointsofcontactonthecable,allowingittobetensioneduntilterminated.TheHaven grip is smaller and lighter, but its curved jaws grip the cable for only¼-inch, possibly

deformingitundertension.The#1604-20Listhemodeltolookfor,asithasaswinginglatchtohelpholdthecableinthejaws.

CABLECLAMPSAttachingEHScabletoyourtowerandtotheguyanchoriswherethefunbegins.Theleastexpensive

solutionistousewhatarecommonlycalledcableclamps.Cableclampshavebeenaroundforeverandyou can find some at the local hardware store. Those hardware store clamps are usually made ofmalleable iron, and not forged material, and therefore are not that strong. They are prone to rustingquicklyoutdoors,andarethusnotrecommendedfortoweruse.Thefirstcluethathardwarestorecableclampsarenot suitable for towerguywire applications shouldbe the cheapprice,usually less thanadollar!Theclampswe’retalkingaboutarespeciallydesignedforusewithEHSguywire.CrosbyClipsisa

popularbrandnamethatyoumayhaveheardof,andthat’sthetermI’lluseheretodistinguishtheproper

clampsfromthehardwarestorevariety.Theseclampsareheavyduty,madeofdropforgedconstructionandgalvanized for long life out in the elements.Figure5-17 showsCrosbyClips and hardware storecableclampsside-by-side.Thedifferencesaresubtlebutimportant.

InolongerusewireropeclipsorcableclampsexceptonsomeshortendsofEHSguycableusedassafety wires on the turnbuckles, and so forth. I encounter them on the job, and they are often usedincorrectly.Here’sthepropermethod:RefertoFigure5-18.TheclampconsistsofasaddleandaU-shapedcliporsaddle.Theendoftheguy

cableisturnedaroundathimbleanddoubledbackonitself,creatingtwo“ends.”Oneofthemistermedthe liveend, and theother termed thedeadend (that’s the short piece that terminates or ends past thethimble).Tighteningcableclipstothemanufacturer’srequiredratingisdonewithatorquewrench.

Applythefirstcliponebasewidthfromthedeadendofthecable.PuttheU-boltoverthedeadendofthe wire and the saddle over the live end (“never saddle a dead horse”). Tighten the nuts evenly,alternatingfromonenuttotheother,untilyoureachtherequiredtorque.Applythesecondclipasnearthethimble loop as possible. Tighten the nuts appropriately, alternating again on the nuts, to the requiredtorque. Put the third clip equal distance between the two, and tighten as before.Wire rope clipswillloosenovertime,socheckthemperiodically.Thetypicalclipwilldeformthecable,sousingadoublesaddleclampmakessense.Crosby’sbrand

nameforthemis“FistGrip”clamps.They’reespeciallyusefulinthattheyallowyoutotightenthemusingafullarcwithyourwrench.

PREFORMEDLINEPRODUCTSBIGGRIPDEAD-ENDSTheguycableendfittingofchoice thesedays in towerwork isadevicehamscommonlycallaguy

griporabiggriporapreform.MadebythePreformedLineProductsCompany(www.preformed.com),theirofficialnameisGuyGripDead-endorBigGripDead-end.Thesegripscomeinavarietyofsizes

(allcolorcoded),designedtofitallthepopularguymaterialsinusetoday.GripsforEHSguywiresizescommonly used by hams are available from a number of vendors such as TESSCOorTexasTowers.Figure5-19showsaBigGrippartiallyinstalledonEHSguycable.(BigGripsarethePreformswewanttouseinguyingourtowers.AstandardortypicalGuyGripisjustslightlyshorter,andisintendedforusebyutilitycompanies inguying theirpoles.The loads imposedbyawoodenpolearedifferent—muchmore “static” compared to the dynamic load imposed by a tower.That slightly longer length providessignificantlymoreholdingpower!)

TheBigGripDead-endworksbyapplyinganevenandconstantradialforceonthestrand.Thisforceisachievedbecausetheinsidediameterofthegripis80%oftheoutsidediameterofthecableorstrand.Thegrippingpoweralsocomes,inpart,fromthealuminumoxidecoatingonthegrip’swraps(that’sthecrystallinecoatingonthewire).Thegriphasashortsideandalongside,andyoubeginwrappingusingtheshortside.Beginwiththe

end of the guywire just coming past the paintmarks.Wrap the short side completely. Then, insert orinstallthethimble,andbeginwrappingthelongside.Youlineupthefirstsetofpaintmarksandcontinuewrapping,righttotheend.Thefinalwrapwillbedifficult,andaquicktwistwithapairofplierswillprobablybeneededto“click”thewrapsintoplace.(IfindthatRoboGrippliersworkgreatforthisuse.)Anotheroptionistosplitopenthelegsofthedead-endandwraptheresultingsubsetsindividually,whichrequireslessforcetosnap-in.Thesecondsetofpaintmarksareusedwhenthegripispassedthroughaninsulator.Simplylinethem

up,asyoudidwhenbeginningtowraptheEHS.OnceyouuseaPLPGuyGriporBigGripDead-end,youwillprobablyneverwanttogobacktoacableclamptypegrip.Ever!Thesegripsareclearlythewinningtoolofchoice.Figure5-20showsaBigGripinstalledwithathimble.

Questionsoftenariseabouttheabilityto“re-use”thesegrips,sincethey’resoconvenientandeasyto

use.Andtheycanbeappliedthreetimes,butonlywithinathree-monthtimespan.Anylongerthanthat,andyoumustsimplytossthegripout.Andno,thegripsshouldnotbeappliedas“pullingtools”orusedforothernon-guyingpurposes.PreformedBigGripDead-endsarealsoavailable to fitotherguymaterial, suchasvarious sizesof

nonmetallicPhillystranandPolygonroddescribedlaterinthischapter.

SWAGEDFITTINGSAnotherendfittingisaswagedfitting,usuallyaNicopressfitting.Theselowprofilefittingslookneat,

andeachcrimponthefittinghasbeendeterminedtobeaseffectiveasasinglecableclamp(typically,therearethreecrimpsperfitting),sothey’reobviouslyalsostrong.Theyarerelativelyinexpensive,butthetoolneededtoinstall themisquiteexpensive.Onceinstalled, theycannotbere-used,andthereforemustbecutoff.Figure5-21showsatypicalNicopressfittinginstalledonaboomtruss.

GuyHardwareInadditiontoCrosbyClipsorBigGripDead-ends,therearesomeotherpiecesofguylinehardware

youshouldknowaboutanduse.ThimblesandshacklesshouldalwaysbeusedwithBigGrips—thimblestoassurethegripdoesnot

collapse,andshacklestoallowyoutomoveorremoveorchangetheconfigurationwithoutdestroyingtheBigGrip.Inshort,theanchorshacklesprovideamethodforeasymaintenance.Figure5-22showssomeheavydutyshacklessuitablefortoweruse.Onceagain,agalvanizedfinishwillprovidemanyyearsofservice.

A3⁄16-inchBigGriprequiresa7⁄16to⅜-inchthimble.A¼-inchBigGriprequiresa½-inchthimbletoproperlymatchitsbendradius.And,therearedifferentkindsofthimbles.Youdonotwantthe“teardrop”shapedones—withtheclosedend.Youwantheavyduty(HD)thimbles,suitablyhotdipgalvanizedorotherwiseprotectedfromtheelements.TheyshouldbeU-shaped,expandedones,withplentyofroomtofit the Big Grip’s end. Such thimbles will likely not be available at your local hardware store, butsuppliersandvendorsoftowerhardwarewillhavethem.Figure5-23showsavarietyofthimblesusefulintowerwork.Allthismayseemoverlycriticalanddetailed,butanyjobworthdoingisdoingright.

Ateachguyanchor,youwillneedsomewaytoadjustthetensionontheguycable.Forthat,weuseaturnbuckle.Butonceagainnotjustanyordinaryhardwarestoreitem(Figure5-24).(Indeed,hardlyanyhardwaresuitablefortowerworkwillbefoundatahardwarestore!)Tosupporttheloadgeneratedbyatower, you want something made from forged materials, not stamped or rolled, and galvanized orotherwiseweatherproofed.Youwantsomethingwithatleastnineinchesofadjustment(thethreadedpart).Youwanteithereye-to-jaworeye-to-eyeconfigurations.(SeeFigure5-25.)TheturnbucklesattachtotheanchorandtotheEHSguywithanchorshackles.

If you have only one guy line (on a small tower, for instance), youmight choose to simply use theknuckleendoftheGAR-30Rohngroundanchor,attachingtoitwithananchorshackle.Butifyouhaveatallertower,andmultipleguys,youmightwonderoraskhowyouattachthosemultipleguywirestotheanchor.Ifyou’rereallyclever,you’llhaverealizedthattighteningthelowerguywire,forexample,willthentightentheupperline.Tohelpspreadoutordistributetheseloads,thecommonwaytoattachthemistousewhat’sknownasanequalizerplate,orEQplate.(SeeFigure5-26.)TheEQplateallowsmultipleguystoattachtotheguyanchor.

Aslongaswe’rementioningshacklesandthimbles,it’stimetomentionguybracketsaswell.Istronglyrecommendusing them.Whileyoucansimplywrap theBigGriparound the tower leg (even thesmallRohn 25’s 1.25-inch diameter siderail is large enough to ensure the Big Grip doesn’t collapse), thismethodofmountingdoesnothing tomitigateagainst tower torque inducedbywindor thestoppingandstartingofthetowerloads.SuchtwistingtorquecanbeoffsetwiththestandardRohnguybrackets,whichtransfertheforcestomultipletowerlegs.(Besides,whyputsomethingaroundthelegsofthetowerwhichwillrubcontinuouslyandeventuallyremovethegalvanizing?)TherearenewstyleandoldstylebracketsforRohnGseriestowers(Figures5-27and5-28).You’ll

nodoubtencounterthembotheventually.FortheRohnG-series,there’sbeenlotsofdiscussionregardingtheuseof torquearmguybrackets.Rohnactuallydiscontinued thisold style forawhile,but“populardemand” seemed to bring them back. Personally, I’ve always liked using them. Here’s why: the guybracketdesigndistributestheloadevenlyamongthetowerlegs.Thebracketprovidesaconvenientandproperlydesignedguyattachmentpoint.Andthebracketmustprovidesomemechanicaladvantage.WithRohn25, forexample, the tower’s radiuswillbe justover seven inches.That12-inch torquebarwillincreasethatradiusbyabitmorethan8.5inches,surelyagoodthing.Youcan“feel”thedifference.

DeterminingGuyWireTension

Once you’ve got your tower up, and reasonably plumb, you’ll inevitably ask yourself, as you turnawayonyourturnbuckles….howtightdoImakethis?Properguywiretensionisimportantforthelifeofthetowersystem.Stabilityisthekey.Youwantto

transferwindforcestotheguysandguyanchors.Toomuchtension,andyouputexcessivecompressiveforcesonthetowerlegs.Toolittletension,andthingsmovearound,inevitablyleadingtootherproblemslateron.Afteryears

oftowerworkI’velearnedthatmostfolkswithtowersintheirbackyardshavenoideawhatthetensionactuallyisontheirguywires.Icanalsoassureyoumostoftheseguywiresaretooloose.So,what’stheanswer?Usingasimpletooldesignedformarineuse(tosettensiononsailboatrigging),wecaneasily

andaccuratelymeasureourguywiretension.ThattoolistheLOOStensiongauge.The LOOS gauge (model PT-2) measures 3⁄16 to ¼ inch EHS guy wire easily. See Figure 5-C.

Availableatmostmarineshopsoronline,thegaugecouldeasilybeaclubpurchaseoranadditiontoyourowntoolboxifyouwishtoincludeguytensioninyourownyearlyinspectionplans.(TheirmodelPT-3measuresupto⅜-inchcable.)

PlumbingaTower

One of themoremisunderstand aspects of tower erection ismaking sure the tower is vertical, orplumb.Asusual, thereareavarietyofmethodsavailable toyou.Herearesome thoughtsonsomeoftypicalwaystoensurestraightness.

TheTransitMethodThechoiceoftheprofessional,atransitisaspecialformofmovabletelescopemountedwithintwo

perpendicularaxes—horizontalandvertical.Transitscame intowidespreaduseduring19thcenturysurveying,allowinggreateraccuracyinlayingoutrailroadlinesintheAmericanWestforexample.A simple builder’s transit (not a builder’s level),which canmeasure both vertical and horizontal

angles,willallowyoutopreciselylineupyourtower.Theycanoftenberentedlocally.Thisismerelyanabbreviatedoutlineofhowtousethistooltoplumbyourtower.Usingthetransittakessomepractice,butit’snotdifficult.SeeFigure5-D.Pickaspot that’sasfar

awayasyourtoweristall.Setupthetripod100feetback,ifyourtoweris100feethigh,forinstance.Pushthetripod’sfeetfirmlyintothesoil,aimingtohavethetopplatemore-or-lesslevel.Then,attachthe transit head to the tripod (keepingonehandon the instrument until it’s secure!).Use the levelingscrews, and level the instrument, checking through 360 degrees of rotation.You beginwith the plate

bubbleparalleltothetwolevelingscrews.Usethe“lefthandrule,”meaningturningyourleftthumbtotheleftandyourrightthumbtotheright,willmovethebubbletotheleft.Theinverseisalsotrue,ifyouneedtoshiftthebubbletotheright.Oncethetransitislevel,rotatethetelescope90degrees.Checkandre-level. Rotate 90 degrees again. Continue this process until the plate bubble remains in the samepositionthroughouttheentire360degrees.Checkthelevelbubblebeforeeachreading.

Now, it’s a simple matter to line up the crosshairs on the tower leg near the bottom, lock thehorizontalscrews,loosentheverticalscrews,andtilttheeyepieceupthetowerleg.Thefirsttimeyoudo this,you’ll likelybeamazedand thinkyour tower is totallyoutofplumb.Butyou’re lookingatamagnifiedviewintheeyepiece.Tototallycheck,movethetransit90degreesawayfromyourfirstlocation,andrepeattheprocedure.

(Youseewhyusingtwotransitsisfaster?)Adjusttheguywireturnbucklesaccordinglytobringthetowerintoplumb.

WorkingWithoutaTransitIfyoudonothaveaccesstoatransit,it’spossibletouseasimplebuilder’sorcarpenter’sleveland

achievesuccess.It’swisetousealongerlevel—afour-footmodel,forexample—inordertoensureaccuracy.Plumb thebase sectionbefore pouring the concrete.This requires holding thebase sectionsteady,ofcourse.(Iwilloftenmixandpourabagor twoofpremixedconcretearoundthesectiontoensurethebasedoesn’tmove.Thishasalwaysworkedwellforme.)Oncethebaseisplumb,theotherbolted-togethersectionswillfollowtheverticalpathrathereasily.

Sightinguptheassembledsectionswillimmediatelytellyouifsomethingiswrong.Asimpleplumbbobhung from the towerwill aid in alignment.Andwhile I’veheardaboutusing

pianowireandcementblocks,I’veneverfoundthatnecessary.Asimplestringplumbbobhasalwaysworkedforme.Ifthere’swind,andthebobwillnot“settledown,”puttingitinsideabucketofwaterplacedatthetowerbaseworks.Youcanmakeyourownplumbbobusingstringandasuitableweight.(I’veusedeverythingfromalargenuttoahammerorwrenchtoabrick—the“line”iswhatprovidesyourreference,notthe“bob”orweightontheline’send.)Simplysightthelineagainstonetowerleg,thenmovearoundandsightitagainstanother.Thiswillbeamazinglyaccurate.Laser levelshavecome intowidespreadusewithin thepast fewyears,and Iownone. It isnotas

handyasIfirstthoughtitwouldbe,butitworkedgreatstuckonatripod(onceleveled)toestablishthethreeanchorlegpointsforalarge,taperedfreestandingtower,replacingmyoldhomemadewaterlevel.Theproblemwiththelaserisseeingitinbrightsunlightmuchabove50feet.

Clients often wonder (and ask) howmuch the tower can be out of plumb and still be okay. TheEIA/TIAguidelineforguyedtowers,forexample,allowsnomorethan1partin400,orthreeinchesin100 feet. For self supporting towers, the deviation allows nomore than 1 part in 250, or about 4.8inchesfor199feet.Thislevelofaccuracyiseasytoobtain,ifyoubeginwithalevelandplumbbase!

AlternativestoSteelGuyCableWeallknow(andhaveseenatvariousvenues)thattheantennapatternofaYagicanresemblealarge

donutsurroundingourtower.Obviously,someofthatRFmustpassthroughthesteelcableguywiresifwe’reusingaguyedtower—exactlythecaseifwe’veputupatalltowerutilizingstackedYagis,andsoforth.Suddenly, the issueof interactionarises.Wedon’twant interactionwithguywires tochange theperformanceofourantennas,sotheimmediatequestionbecomes:Whattodo?Foryears,hamshaveusedinsulatorstobreakupsteelguywiresintononresonantlengths.TheARRLAntennaBookevenincludesachartshowinglengthstoavoid.Withtheadditionof12,17,30and60meters,findingasuitablelengthhasgottenharder.Nonconductive guy cable is the other alternative popular with hams. The choices are Phillystran

(Figure5-29), a flexible nonmetallic cable basedon aramid fiber, orPolygon fiberglass rod.Aquickperusalofthevariousavailablecatalogswillshowthatbothnonconductivechoicesaresomewhatmorecostlywhencomparedtosteel.Butisthattheendofthestory?Arethereotherfactorstoconsider?Yes.

If you intend to break up EHS guy wires into nonresonant lengths with an appropriate number ofinsulators,youshouldconsiderthecostoflabor,whetheryouhiresomeoneortakeyourtimeawayfromother things. You should consider the cost of those insulators, which must be of a size and strengthappropriatefortheapplication.YoushouldconsiderthecostoftheextraGuy-GripDead-endsneededtoattachthewiretotheinsulators(Figure5-30).Youshouldconsiderthetimeandeffortrequiredtohaulupaheavylengthofsteelcableholdingsomeheavyceramicballs,undoubtedlymoredifficultthanhaulingupasimplehunkoflightweightPhillystran.Todojusticetoyourinstallation,youneedtositdownanddoaline-by-lineanalysisofallthenecessarymaterialsandlabor.

Ifyouarebuildinga largestation,Polygonrodcanbeacost-effectivealternative,providedyoucanutilizetheminimumordersizeof5000feetofthematerial.Groupbuyscanbeonewayaroundthis,butbeawarethematerial(shippedrolledin10-footdiameterreels),mustbeunrolledverysoonafterdeliveryinordertopreserveitsintegrity.Andtherodcanbeproblematictohandle,requiringasimplemask,longsleevesandgoodgloves,topreventthefibersfromgettinginsideyou!It’simportanttorememberthatbothPhillystranandPolygonrodarefragile—easilydamagedbyfire.

Theycanbe cutor scoredwith simplehand tools.For these reasons, theseguy lines are typicallynotbroughtall theway toground level.They receivesteel“stingers”usually from15 to30 feet in length,whichthenconnecttotheguyanchor.Atthetowerendoftheguycable,it’scommonpractice(aswellasagoodidea)toaddanothershort

stinger of steel EHS guywire at the guy bracket whenworkingwith Phillystran or Polygon Rod guymaterial. Simply install two Big Grips back-to-back. Then attach the nonconductive guymaterial andcontinuetotheground,ortothesteelstingeronthatendasdescribedabove.Shouldsomethingbadhappen,suchasabeamgetsdroppedduringhandlingorfailsandfallslateron,

damage would most likely occur close to the tower. Protecting nonconductive material from beingcrushed,cutorotherwisedamagedfromsuchanincidentisagoodinsurancepolicy—bothlongtermandwhileworkingonthetowertoo.PreformedLineProductsmakesaseriesofBigGripDead-endsspecificallyforusewiththevarious

sizes of Phillystran and Polygon rod guy cables.Appropriate thimbles and anchor shackles should beused,asdescribedpreviously.

HouseBracketsHouse brackets are often used, especiallywithRohn 25G or other small cross-section towers. The

housebracketinstallationtakestheplaceofasetofguywiresatsomeconvenientheightonastructure.Housebracketsareoftenattachedwithlagscrews,butabettersolutionisboltsthatpassthroughthe

siding to thick “backer boards”mounted behind structural framing timbers inside the wall or ceiling.Remember, too, that lumber dries out over time. It oftenmoves or changes size and sometimes losesstrengthorresiliency.That’sagoodargumentformakingthebackingplatefromsteelinsteadofwood.Ifyouhaveanyquestionsabouthowtosecureahousebracket,consultyourhomebuilder,oraframing

carpenter,orotherstructuralexpertbeforeriskingdamage.Theforcestransmittedfromatowertoyourbuildingcanbeconsiderable.Remember,too,thattheinstallationofthehousebracketwill“drive”theactualtowerinstallation—

thedistance thehousebracket’s clampsextendout from the structurewill determine towerplumb, andwhereandhowthebaseshouldbesituated.

StarGuyedTowersOnceagain,HankLonberg,KR7X,providesuswithaprofessionalengineeringperspective.Thistime

thetopicisstarguys(usingtwoguywiresperanchorpoint—Figure5-31)versusconventionalsingle-wireguys.AsHankexplains:

The advantageof star guyed towers versusnormal guyed towers is the significantly larger torsionalforcecapacitythestarguyedtowerhasgoingforit.Youmaywonderwhythisisimportant,sincetherearecountlessnormallyguyed towers inuse.Hams, in theirquest for larger,higherormore,havebeenknowntoputupstackedantennaarraysonasingleguyedtower.Evenmoreamazingisthattheythenwantthemtoturneitherindependentlyorintandem,inordertocoverawiderangeofazimuths.Indoingso,theysubject their towerstoforcesotherthanweightandwindloading.Thestartingandstoppingoftherotatingmechanisms,antennaattachmenteccentricityandtheuseofside-mountedrotationalsupportsallimpart torsional forces into the tower.These torsional forces cause the twistingof the tower about itsverticalaxis.Referring toFigure 5-32, you can see that the normal guyed tower has guys spaced at 120 degree

intervalsinplan.Theguysareconnectedfromthetowersectionapextoaguyanchorthatissomeradialdistance out from the center of the tower. The star guyed tower also has guy anchors at 120 degreeincrements,buttheyhavebeenshiftedto60degreesinplan.Theradialextensionisbetweentheapexesofthetriangulartower.Inaddition,youseethattherearetwoguystoeachanchorpoint.

Thesedoubleguysaretypicallyusedatalltheverticalguylocationsonthetower.Ataminimum(tobethe most effective), the star guys should be located at or near the application of the torsional loadattachmentpoints.Thesepointsincludetherotatorbaseattachment,sideorswinginggateattachmentsandsoforth.Thisallowsfortheshortestloadpaththroughthetowertotheguys,andthendowntotheground.Ifyoustudythediagram,youwillseehowtheincreasedtorsionalresistanceisaccomplishedbythe

starguyedsystem.Inthenormalguyedsystem,thetowersectionshavetorotateinorderfortheguystodevelopaforceresistingvectortocounteractthetorsionalforceapplied.Sincetheforceisperpendicularto theguy initially, theguycannot resist the forceuntil someangle isdeveloped tocreate the resistingvector.Thestarguyedsystem,becauseofthedoubleguyarrangementandlocationoftheanchorpointsrelative

totheattachmentpointonthetower,initiallyhasananglebetweenthetorsionalforceandtheguyforcevectordirections.Thismeans that the towerdoesnothave to rotate initially todevelopavector forceresistance to the torsion. Infact, thereare threesuchguys thatwouldbeactive initially,anddue to thesymmetricallayoutinplan,theguysystemiseffectiveineitherdirection.If you are contemplating a large stacked array, either concentric or eccentric,with a swinging gate

mechanism,orevenanextremelylargesingleYagi(likeafullsized3-element80meterbeam),theuseofstarguyingwillletyouresteasyabouttheloadingsonthetower.(Designingsuchamonster,well,that’sanotherstory!)Thanksforsharingthatexplanation,Hank.Nowwe’lltakealookatsomepracticalissuestoconsider

whenworkingwithguywires.

MechanicalIssueswithStarGuysIf you take a look at a commercial tower using star guys, youwill notice that they typically simply

“stack”theguywiresoneabovetheotherontheequalizerplates.Ofcourse,I’veseenasmanyas12guysterminatingononeplate—notsomethingmosthaminstallationsaregoingtoemulate.Recently,whilerebuildingthemulti-multiconteststationatNR5MdowninTexas,W2GDandIwere

facedwith installingstarguysonavarietyofRohn45Gand55G towers.AllwereguyedusingeitherPhillystranorPolygon rod,butmore importantly, allutilizedstandardRohnhardware.Theoptions forterminatingthoseguyendswere,ofcourse,limited.Thesolutionwastomakeuparathersimpleadapter.Thesolutioninvolvedweldingtogethertwosteelplates,whichwouldallowustoattachtwoguylines

toeachoftheexistingequalizerplate’sbolts.Oncetheadapterswereweldedtogether,wehadthemhotdipgalvanizedatalocalplant.TheseadaptersareshowninFigures5-33and5-34.

ClearanceIssueswithGuysHavingguywiressometimesmeanshavingtodealwiththemclearingthings.Sometimesyouhaveno

choicebuttorunaguywireacrossadrivewayoroverthefootpathleadingtoyourgarden.Another consideration is when an antenna must clear the guy wires. This becomes particularly

importantifyouintendtostackandperhapsrotateoneormoreantennasloweronthetower.Theelements

of that lower antennamust clear the guys coming down from above, allowing suitable rotation of theantenna.YoubecomeconcernedabouttheturningradiusofeachYagi;youbecomemoreconcernedabouttheguywireinteractionwiththatYagi.Computing the clearance or the required turning radius can be done by carefully sketching your

installationoutongraphpaper,providingyouwithascalemodelofyourtowerandbeams.Or,youcanfigureouttheclearancemathematically.I’veusedasimpleformulaforyears,butoneofmyclients,TomWarren,K3TW,modifiedtheformulasuchthatitalsotakeselevatedguypostanchorsintoconsideration,allowingmetolayoutordesignsuchinstallationsmuchmoreeasily.Here’stheformula:

where

TR=turningradiusatanypointonthetower(measuredabovetowergroundlevel)belowanobstructingguywire

d=thedistancefromthetowerbasetotheguypoint(atgroundlevel)p=theheightoftheguypole(usezeroifguysterminateintheground)g=theguypointonthetowermeasuredfromgroundlevela=heightoftherotatingantennaonthetowermeasuredfromthegroundThanksTom!

Ice—ConsideringIt,DesigningForIt,DealingWithItAlmosteverytowercanwithstandsomeiceaccumulation.Formanyyears,towershavebeenspecified

anddesignedwithoutrealformalconsiderationforiceloading.Buticecanpresentaserioushazardfortowersurvival,especiallyifitoccursatthesametimeashighwinds,oriftheiceloadisexcessive.It’spossible, forexample, for iceaccumulation to increase thesizeofguywiresby fiveorsix times—aseriousload,indeed!Insomeareasofthecountry,buildingcodesrequirethetowerdesigntoassumeacertainamountoficeloading.Figure5-35showsactualicechunksfrombuilduponanantenna.Figures5-36through5-38showthepowerofanicestorm.

Ificingcanoccurinyourlocation,amoreconservativedesigniscalledfor—somethingyoumayonlybenefit from once, but that one time may mean the survival of your entire installation. Some designsconsiderthaticingdoesnotoccurwithfullwindspeeds,andlookattowerloadswithradialiceat75%oftherequiredwindloading.Somedesignsconsiderradialicesimultaneouslywithmaximumwind.Butyoumustconsiderit.Forexample,sayan80mphwindhitsa2inchdiametertowerleg.Thewind

loadonthelegisabout18.5lbs/squarefoot,or3.1pounds/foot.Addacoupleinchesoficeandthatloadincreasesto9.3pounds/foot!It’sjustnottheweightoftheicealone(althoughthat’sconsiderable),it’showthestressesonthetower

maychangeduetothatload.Afewyearsago,twoverytallTVtowersinRaleigh,NorthCarolina,camedown.Thesewererelativelynew,verystrong,welldesignedandguyed2000-foottowers.Extremeicingconditions,whichlastedthroughoutthedayandnight,metthelowwintersunthenextday,meltingenoughiceoffonlyonesideofthetowersothatalegbuckledontheoppositeside.Fortunately,someonecalledtheownersofthesecondtower,andpersonnelwerewarnedandevacuated.Noonewasinjuredlaterthatday when the second tower came down for the exact same reason. These conditions were abnormal,certainly;onecannotreasonablydesignforthem.Workingonthetowerinconditionsliketheseisvirtuallyimpossible.It’sobviouslymoredangerous,

worktakeslonger,it’smoreexpensiveandsoforth.Soitobviouslymakesgoodsensetotryplanningforiceandtryingtohaveguyingandothertower-attachedhardwaresituatedandorientedproperlytomitigateproblems.

IceLoadDanger:NearTowerFailureatW3LPL

Twentyfourhoursbeforethe1994ARRLDXPhoneContest,forabout12hoursonThursdaybeforethecontestthetemperaturewas31degrees.Alightmistwasfallingcontinuously,freezingonalloftheantennas,towers,wires,guycablesandropesatW3LPL.Thiswasfollowedbystrong40mphwinds.WhenIarrivedhomearound6PM,itwasveryapparentthatthreeofthe200-foottowerswereleaningoverbyseveralfeet,andmanyoftheelementsontheYagishadflippedfromhorizontaltovertical.Theicehadstartedtofallasthetemperaturewentabove32degreesandthepartiallymeltedicefoundlyingonthegroundwasoneinchthick!Onlyoneantennawasdestroyed,a56-footboom20meterbeamthathad accumulated a tremendous amountof ice.Theboomdrooped somuch that theguys supporting itdroppedunderthethenbow-shapedboomandcollapsedit!Severalinsulatorssupportingwireantennassnapped,reducingthestressonthetowerssomewhat.Thenearcollapseofthetowerswascausedbyfailingtoevenconsiderthepossibilityofmassiveice

loadinginselectingtheheightofthetopsetoftowerguys,alongwiththeinstallationofthousandsoffeetofwireantennasandropeshangingoffthetowers—withoutconsideringthetremendousiceloadtheycouldalsoapplytothetowers.The fourth 200 foot heavy duty AB-105 tower was completely unaffected by the massive load

becauseofseveralfactors:■The heavy duty tower had considerable additional strength compared to the three lighter duty

towers.■Thetopguyswereonly10feetfromthetopofthetower.ThethreelighterdutyAB-105shadtheir

topguys16-18feetfromthetop.■Theropessupportingthemanywireantennashungfromthistowerpassedthrupulleys,thenaway

fromthewireantennas,notback in thesamedirectionas thewireantennas (and ice) load,ason theothertowers.Lessonslearned?1)Ificeisevenaremotepossibility,designyourantennasandtowersforit!Ineverthoughtoneinch

radialicewasevenaremotepossibilityatmyQTH.Don’tforgeticeloadsfromwireantennasattachedtothetowers!2)Icedoesnotnecessarilydropoffantennaelementssymmetrically!Whenitdropsoffonesidefirst,

theelementislikelytofliptoverticalfromthetremendousweightoficeontheotherside!Theelementsmustbe fastened to theboomattachment stronglyenough to successfully resist thisvery large torque.Verticalelementscouldcollapsetheboom.3)Guy placement should consider ice loads!Mineweremuch too far below the top of the tower

wheneverythingwascoatedinoneinchofice!4)Ropesshouldattachtoapulleyonthetower, thenpullawayfromtheantennastheysupport,not

backtowardtheload.5)Ropesshouldattach to the towernearaguypoint so theguys take the ice load to themaximum

extentpossible.Thetowersdidnotfalldown,andwemanagedtorepairthemostcriticalantennas,soourscoreinthe

1994ARRLDXPhoneContestwasonlyminimallyaffected.Then, theguyingwas totally redesignedandredone.Sixweekslater,a120mphmicroburststruck,destroyingmostoftheantennasandtwistingthetopsof

twoofthetowers,butthat’sanotherstory!—FrankDonovan,W3LPL

InstallingTowerAccessories

Oncethetowerisinstalled,therearesomeaccessoriestoconsiderinadditiontoyourantennas.Thischaptercoversrotators,thrustbearingsandremoteantennaswitchboxes.

RotatorsAquick search on the Internet for “rotators” or “rotator repair” and you’re suddenly thrust into the

worldofmedicine—rotatorcuffsandshoulderinjuriesandoperatingroomscenariosofaseriousandscarynature.Youreallyjustwantedtofindouthowtoturnthatbeamantennauponyourtower....The history of directionalAmateurRadio antennas is a fascinating fieldwithin our hobby’s general

history.Earlyversionsincludedthetriedandtrue“Armstrong”method—whereinyousimplyturnedtheantennabyhand(requiringastrongarm...).OldQSTmagazinesshowhamshackswithasteeringwheelorsomethingsimilarcomingdownthroughtheceiling—connectedtotherotaryantennaatoptheroof.Later,afterWorldWarIIandtheintroductionofsurpluselectronicsandequipment,theubiquitousprop

pitch motor became a de facto antenna rotator standard, along with the ever-popular selsyn synchromotors for indicating antenna direction. Prop pitchmotorswere originally used to change the pitch ofairplane propellers, and selsynswere used in gun turrets and other placeswhere direction ormotionindicatorswereneededinwartime.Figure6-1showsaproppitchadfromJanuary1948QST.

With its high ratio gearbox (the “small” prop pitch gearbox is 9576:1),whichwill allow it to turnpracticallyanything,theproppitchrotatorstillservessomeuserswelltoday,particularlythosewithfull-size40meterYagis.Partsarebecominghardertofind,andmoreimportantly,soarepeoplewhoknowtheirwayaroundthesemechanicalengineeringmarvels.Theproppitchmotorisn’taplug-and-playhamrotatorsolution.Itrequiresuserstobepartdesigner,partmachinistandpartelectricianinordertorealizethetruepotentialofthispowerhouse.Whentelevisionbecamewidelypopular in the1950s,outdoorTV“aerials”appearedon theroofof

seemingly every suburbanhome, alongwith theneed to rotate that antenna andpoint it toward theTVstation’ssignal.Tomeetthisneed,Cornell-DubilierElectronics(CDE)begantomanufactureandmarketthebelltyperotator.EarlyTR-2andTR-4modelrotatorswerefairlylightdutyandoftencalled“clackerboxes”becauseof theclickingnoise thecontrolboxmadeas the rotatorworked itswayaround to thedesireddirection.Introduced in late 1957, the CDRHam-M rotator featured a stronger case, heavier gears, a wedge

brake to hold the antenna in place when not rotating, and an improved indicating system using aD’Arsonval meter movement as a direction indicator (Figure 6-2). Over the years, the Ham-M wasupdatedand improved, resulting in theHam-II,Ham-IIIandHam-IVaswellasaheavierdutyversioncalled theTailtwisterorT2X.CDEsold the rotator line toTelex/Hy-Gain in1981,and itwassold toMFJin1999.

CurrentlymanufacturedbyMFJundertheHy-Gainbrand,thebasicHam-MdesignisstillwithustodayastheHam-IVandT2Xmodels.It’savailablewiththestandardanalogmetercontrolboxorwithaDCU-1digitalcontrolboxasshowninFigure6-3.It’sprobablythemostpopularandsuccessfulrotatoreverproducedandcancertainlyserveasastandardofcomparison,regardlessofyourpersonalfeelingsabouthowwellthedesignworks.Andit’sstoodthetestoftime—beingthe“model”forothermanufacturerstofollow,albeitwithfancierbraking,orimprovedindicatorsystemsandthelike,yetwhilefollowingtheoriginal,basicCDEdesign.

Figures6-4to6-6showsomeof theotherrotatorsavailabletohams.TheseunitswerereviewedinSeptember2005QST.

RotatorConsiderationsLet’sgothroughsomerotatorbasics,hopefullyansweringsomequestions,providingsomeguidelines,

andensuringsuccessinturningyourantennasystem.Today’s amateur has a relatively limited number of choiceswhen it comes to rotators.Most tower

manufacturersprovidepre-drilledmountingplatesforthechoicesthatareavailable.Rotatorplatesmaybeweldedinplace,ortheymaybesecuredwithclampsthatallowsomechoiceinplacement.InsomeRohnGseriestowers,forexample,therotatorshelffitslooselyinsideasection,restingonZ-bracingandheldinplacebyU-bolts.Thisabilitytosimplyboltthingstogethercanbeproblematic,however.One potential problem is that most hams simply do not take the centering of their mast into

consideration.Therotatormountingplatemustbecentered(levelandplumb)withinthetowerstructureitself.Formosthams, this issomethingofaguessinggame,compoundedbytheneedto tightenU-boltsequallyaroundtubulartowerlegsorotherwiseensuretheplateisperpendiculartothemast’scenter.OnsmalltowersectionssuchasRohn25,yourownweightononesideofthetowerisoftenenoughto

offset any attempt at eyeballing the accessory shelf into some semblance of being level (even using asmalllevelontheshelf).Thisisasituationwhereexperiencecounts—knowingwhentheshelfislevelor no further adjustment is needed. There are some tricks you can use to assure that the plate isperpendiculartothemast,suchaspickingasecondaryobjectinthebackgroundagainstwhichyoulineuptheshelf.Oryoucantryusingasmallleveltoensurethattheplateisindeedparalleltothehorizon.Manyhamsdonottakeintoconsiderationtheactualwindloadpresentedtotherotatorbytheirmast,

antennas and feed lines. I once encountered an 80meter beamwith a Tailtwister rotator under it, forexample.Itwasfreewheelingon60feetofRohn25G.Iaskedtheclienthowmanytimeshe’dturnedit.“Once,”hereplied.“Ittookanawfullongtimetogetstarted,thenitcamearoundjustfine,andwhenitgottowhereIwanted,Ireleasedthebrake.Andthebeamjustkeptonturning.”Thisincidentpresentsagoodexampleoftheabilityofgearingtoprovideamechanicaladvantage,and

alsoagoodexampleoftherequirementofamodernrotatortoholdanantennainplaceonceit’sgottenwhereyouwantittogo.Thatholdingpowerisquiteoftenmorecriticalthanturningpower.

TestingandInstallationAnother aspect of working with rotators that I’ve encountered is the lack of testing everything

beforehand!You shouldmake a point of hooking up the rotator to the control box, turning the rotatorthrough a complete set of clockwise (CW) and counter-clockwise (CCW) rotations. Watch forsluggishnessorerraticmetermovementsandthelike.Ofcoursethereshouldn’tbeany,butit’sbetterto

encounterthemnow,ontheground,thanatheight.LeavetherotatororientedNorth!(Yes,Virginia,we’regoingtotalkabout“findingtrueNorth,”injustalittlebit.)Oncetherotatorisorientedcorrectly(toNorth),it’stimetothinkaboutmountingitinsidethetower.

Usually, this won’t be a problem — the tower manufacturer can provide a suitable (pre-drilled)accessoryshelfonwhichyoumounttherotator,simplyboltingitinplace.But…becareful.Useonlythesuppliedbolts,orifyouwishtochangetostainlesshardware,makesureyouuseonlytheexactsamesizebolts!Thelengthisoftencritical.Usetoolongafastener,andyoucandamagepartsinsidethehousing.Whenyou’recertaintheplateorshelfislevel,youcanslidetherotatorintoposition.Onmosttowers,

thiswon’tbe(orshouldn’tbe)aproblem.WithRohn25G,theaccessoryshelfcanreallyonlygoatoneplace—atasectionjoint.Otherwise,theZ-bracingrodsgetintheway.So,ofcourse,yourmastlengthmustbeconsideredcarefullybeforehand.(Rohn25GtopsectionsincludeaspotnearthetopwithoutZ-bracingfortheaccessoryshelf.Thisplacestherotatoronlyacouplefeetbelowthetowertop,whichmaynotbethebestsolution.)Intheprevioussection,Imentionedtheneedtocenterthemast.WithHam-Mtyperotatorsthereisa

special consideration that hams often overlook. For years, the CDE/Telex/Hy-Gain rotator manualscautionedownersthatthegeometryofthemastandrotatorhousingaccommodatesonlya21⁄16-inchmast.Forthetypical2-inchODmast,shimstock(1⁄32-inch)isrequiredforaperfectfit.Ifyouareusinga2-inchmast,andyouwishtoshimthattothecorrectdimension,it’srelativelyeasytoinserttheshimstocknow—beforeyoutightendowntheU-clampsintherotator.(I liketousestainlesssteelmaterial,availablefromMcMaster-Carr.)InserttheshimstockrightattheU-clampjoints,suchthatit’ssnuggedupsecurelyby the clamps as you tighten them.Don’t just drop it into place and hope for the best. The idea is to“expand”the2-inchmastdiametereversoslightlyfortheproperfit.Figure6-7showsaHam-IVrotatorbeinginstalledinRohn25G.

ManyrotatordesignsutilizeaU-clamptoprovidetheholdingpowerforthemastandantennaload,andmanyoftheseclampsuseonly¼inchdiameterhardware.Forseriousloads,Iprefersomethingalittlelargerandstronger,at least 5⁄16 inch,andI’lluse the largersize ifpossible. I’veevendrilledoutsomerotatorcasestoallowmetousebiggerU-bolts.Inanycase,especiallyifthehardwareisstainlesssteel,don’tforgettouseanti-seizelubricantonthe

threadsbeforeyoubegintightening.AndmakesureyoutightentheseU-boltsasevenlyasyoucan.Andit’sevenagoodideatotightenthemtoday,andthencomebackandre-tightenthemagainacoupleofdayslater.Irealizethisisoftenimpractical(ifnotimpossible),soaquickrecheckisoftentheverylastthingI’lldoattheendoftheday—beforeIclimbdown.Believeme,theseboltsdohaveawayofrequiringthiskindofattentiontodetail.

KeepingThingsLinedUpRegarding“pinningthemast”(drillingaholeandboltingthemasttotherotatorhousingorclamps),I

havealwayssubscribedtothenotionthatit’smucheasiertoclimbupandrealignanantennaormastthanit is to be climbing the tower and taking broken things down. If themast canmove inside the rotatorclamp,thingsusuallywillnotbreak.Ihaveclientswhobelievein(andinsiston)pinningthemast,andtheresultshavebeenalmostexactly50/50whenthereisaproblem.Halfthetimewemerelyhadtoclimbupandreadjustthings.Theothertimes,wefoundourselvesreplacingabrokenrotator(andoftengoingupinsize, to a larger rotator). I always recommendwenot pin themast,which can seem like I’m trying toguaranteefutureworkformyself.That’snotthecase.Isimplythinkitmakesmoresensenottoforcetherotator“guts”toworkquitesohard.Auniqueandwell-designedrotatoraccessoryistheSlipp-Nott,availablefromTennadyne.Thisclamp,

whichprovidesconsiderablymoresurfaceareathantheusualmufflerclamp,workswondersatholdingbigbeamsinplace.I’veinstalledseveralofthemovertheyears,andalwaysfoundthemtoprovidetheholdingpowertheyclaim.Yaesurotatorsareuniqueinthisregard—theyprovidetheboltanddirectionsonhowtopinthemast.

I’ve alwaysbelieved this tobe adirect result of their using a fragilemast-to-rotator clamp. It’s a potmetalmaterialthat’seasilybrokenifyoutorquedownontheboltstoohardortightentheminanunevenfashion.Tightentheclampboltssnugly,drillandinsertthemastbolt,andyou’redone.Shouldtheantennamoveoutofalignment,Yaesurotatorscanberealignedfrominsidetheshack,withoutclimbing.(Andbytheway,beprepared—Yaesurotatorsusemetrichardware.TheveryfirsttimeIinstalledone,Ifoundmyselfat120feet,withwrenchesthatwouldn’tfitanything.Nordidtheclienthavemetrictools.SoherantoSearswhileIhungoutuptopandenjoyedwatchingthesailboatsinAnnapolisBay!)

BiggerAntennas=BiggerRotatorsAswemoveupinsize,withbiggertowers,biggerbeamsandsoforth,theturningrequirementsgoup

aswell.For largeantennas(longboomHFYagis,40meterbeamsandeven80meterbeams), reliablyturning them can become problematic, even downright troublesome, as the rotator choices are morelimited.Withpropergearing,mostanysmallmotorcouldbemadetoturnsuchantennas,butholdingtheminplace,especiallythroughanysortofwind,iswheretheproblemsarise.That’satoughtask;indeed,it’sanespeciallytoughtask.Thetorquerequirementscanbecomequitehighveryquickly.What’sonetodo?Usually,thefirstchoicewillbeanorbitalringrotator.Thechoicesherebasicallycomedowntotwo.

ThosechoicesaretheTICringrotator,ortheKØXGorbitingring.I’veinstalledaboutadozenTICringsovertheyears.Theyrepresentgoodvalue.TimDuffy,K3LR,hasanumberofTICringsathislargemulti-

towerconteststationinwesternPennsylvaniaandspeakshighlyofthem.Ibelieveit’sfairtosaythatJohnCrovelli,W2GD,andIhavemoreexperiencewith theKØXGorbital ringrotators thananyotherUSAinstallers.Thesemassiverotatorsaretrulybig,heavyandsimplysuperbatturninglargeantennas.TheyareusedextensivelytorotatestackedOWAantennasatNR5M(Figure6-8).

Or,youcouldbuildyourownrotator.Thedetailsonhowtodojustthatwereoutlinedverywellinhamradiomagazinewayback in Juneof 1986. In “Turning thatBigArray,”VictorMozarowski,VE3AIA,presentedadesignoutline thatwas remarkably similar toacommercial rotator soldbyHy-Gain, theirmodel3501.The3501was, inaddition,verysimilar totheR9100rotatoroncesoldbytheshort-livedAdvancedRadioDevicescompany.MostARDproductswerewellaheadoftheirtime,andveryruggedandwellmade. TheR9100, for example, boasted 10,000 inch lbs of rotational torque, had a brakingtorqueof24,000inchlbs,supported2000lbs,acceptedmastsfrom2to3.5inches,andweighedinat230pounds.Or,youcouldrelyonsomethingliketheonce-popularTelrexrotatorthatsometimesshowsuponthe

usedmarket.Butmounting theTelrex rotators (theygooutside the tower, andmove themast throughachaindrive)canbeaproblem.Or,youcouldutilizeanotherold,butheavy-dutyworkhorse—theproppitchmotor.ButasI’vesaid,

findingsomeonewhotrulyknowsandunderstandstheintricaciesofthesemechanicalmarvelsisgettingharderandharder.KurtAndress,K7NV,offersarebuildingservice(asofthiswriting)that’simpossibleto beat on your own; Kurt probably has more experience than anyone currently working with thesebeauties.Ihighlyrecommendhisservices.When you reach the summit— theworld of big towers and big beams— youwill probably have

enoughknowledgeablecontactstoallowyoutobuildorbuyasuitablesolutiontotheproblemofturningthatbigarray.CheckoutthemassiveOH8XrotatorgearboxinFigure6-9.

TroubleshootingWhenwespeakaboutturningbeams,we’reusuallytalkingaboutaproblem—somethinghasstopped

turning!Ham radio antenna rotators are one of those itemswe typically take for granted, never givingthemmuchthoughtorconsideration.Let’sspendsometimetalkingaboutrotatorsingeneral,andthenmoveontomorespecificareasand

aspects.Not onlywill this allow us to diagnose potential problemsmore easily and quickly (perhapswithout climbing), but it will also provide a better understanding of what these simple mechanicalmarvelsshoulddo.Mostrotatorsystemshavethreemajorparts:acontrolunitatthestationend,amotoronthetowerand

acontrolcabletoconnectthetwo.The control unit contains a power supply, a switching system and a direction indicator. The power

supply usually works from commercial power, of course, and contains a low voltage dc supply. Theswitchingsystemallowsyoutoturnclockwiseorcounter-clockwise,andtostaystopped.Thedirectionindicatorshowsyouwheretheantennaispointed.Troubleshootingsuchasystemisnotthatdifficult.If we take a look at some simplified schematics, we can quickly see that there’s nothing overly

complicated.We should be able to determinewhat’swrong using some simple voltage and resistancemeasurements.Andthat’sexactlythecase.Thekeyistoknowwheretostart.

Ifyousubscribetothenotionofkeepingastationnotebook,thenyouhaveanexcellentstartingpoint.Yousimplycomparetheresistanceandvoltagemeasurementsonthecontrolcable(disconnectedfromthecontrol box) to those you recordedwhen you initially installed the system (andwhen it wasworkingcorrectly). Lower-than-normal voltages are often signs of corrosion related problems. ResistancemeasurementsthataresuspectarealsooftenconnectedtoterminalsorscrewsorjointsthathavesufferedfromtheravagesofMotherNature.Table6-1showssomesamplereadingsforHAMseriesrotators.

SomeRotatorHints&KinksWhile many of us unplug our station from the ac line and disconnect antenna feed lines when

thunderstorms approach, it’s easy to forget about the rotator control lines. Consequences can includedamagetothecontrolboxorotherequipmentinthestation.AcommonproblemisthattheZenerdiodeinHy-Gain controllers can fail from a voltage spike (proving that fuses alone are not suited for suchprotection).Otherissuescancropup,aswell.Ihadaclientwhose⅛ampfuseinsidethecontrolboxwasactually

intermittent!Apparently,theweldinsidethefuse’sglasscasehadbeendamaged.Needlesstosay,thisonetooksometimetotrackdown,asjustwhenwethoughttheunitwasdead,andwe’dmovethecontrolboxtolookforsomething,itwouldcomebacktolife!

ConnectionsandConnectorsWhileonthesubjectoftheHy-Gainbellrotators,someremarksontheterminalstriporthenewerpin-

plug connectors are in order. I still like the terminal strip,myself,mostly because of allmy years ofaccumulatedexperience.Forweatherproofingpurposes, I’vealwayssimply removed the terminal strip

screws and replaced them with suitably sized stainless steel ones. For some folks, this provestroublesomebecausetheoriginalscrewsare“captivethread”design.Thatmeanstheyonlyscrewoutsofar, then stop.You simplykeep turning the screwandyou can easily force themoutwithout damaginganything.Thenit’sasimplemattertoreplacethemwiththesamesizepanheadstainless-steelscrews.I’veneversufferedanotherfailureusingthissimpletechnique.Idonot recommendcovering the screwsor terminal stripwith silicone seal,CoaxSeal,or anything

else.I’veencounteredthisquickfixonvariousjobsovertheyears,andineveryinstance,itwasmoreofanuisancethanasolution.I’ve also always enjoyed using a short pigtail (utilizing a suitable plug/jack), which allowsme to

troubleshoottherotatoratopthetowerwithoutbendingmyheadhalfupsidedowninordertoaccesstheterminal strip. Ordinary eight-pin trailer light plugs and jacks serve this purpose quite well, in myexperience.Anumberofvendors,suchasTheWireman,carrythem.The new pin plugs seem to be fine, but I admit the tiny pins are not my favorite things to install,

especiallyifyou’reattheendofaratherlongrunoflargecable.Thenyou’reofteninstallingasmaller-sizedwire pigtail anyway.Or you’re carefully clipping out individualwires from the stranded cable.Neithertaskisfun.WithYaesurotators,theconnectingplug(whichmountsnearthebottom,ononesideoftherotatorcase)

sticksoutaconsiderabledistance.Onsomecrankupinstallations,thiswillbeaproblem,asloweringthetopsectionallthewaydownwillcausetheZ-bracingtobreaktheplugoff,requiringyoutobuya$50replacement.Otherthannotcrankingthetowerallthewaydown,I’venotfoundasolutiontothisone.Usually, rotators do not pose problems, but when they do, it’s quite often an easy troubleshooting

situation.Binding issuesusuallyrelate tosomethingbeingoutofplumbornot level. Intermittent issuesusuallyrelatetoimproperconnections,ortorustyorcorrodedconnections.Directionindicatorissuesarealmostalwaysrelatedtothepotentiometerorthelittlemagnetmountedinsidethehousingoronthemotorshaftthatsendpositioninformationtothecontrolunit.

PlanforMaintenanceIfyourinstallationhasbeenplannedandthencarriedoutcorrectly,youshouldbeabletoremovethe

rotator, take it to ground level and repair it, all without creating a potential hazard atop your tower.Planning,ofcourse,istheoperativewordintheprevioussentence.Planningformaintenanceisalwaysagood idea, as electro-mechanical things come with an unwritten guarantee: “It’s not a question of ifsomethingwillbreakorfail;it’saquestionofwhen.”So,youshouldhavesomesystemplanned,built,andonhand,whichwillallowyoutodoexactlythat

—removetherotatorwithoutproblemswhenitfails.

CuttingCableCostsIf you’ve priced any of the commercial rotator cable lately, you know it can be expensive. That’s

especiallytruefortheheaviergauges,whichyouneedifyourrunislong.OnealternativeistouseRomexelectricalcable—theUForoutdoorkind—insteadofthatexpensiverotatorcable.Two runs of taped-together Romex will provide you with six wires. Then, you simply mount the

startingcapacitorattherotator(whereitdoesmoregoodanyhow,ratherthanbeingdowninyourshack,inside the control box), and voila, this six-conductor cable works perfectly. You will need to payparticularattentiontothewiring,sincethecolorswillbelimitedtoblack,white,andabaregroundleadoneachrun,butthat’seasyenough.

FindingTrueNorthThisisnecessarybecausenorth,asindicatedbyacompass,isnotwherewewanttopointourbeams,

ofcourse.Thesimplestmethod,orold-fashionedway,isnottouseacomputeroronlineresources.Youwillneed

toknowyour local sunnoon time.That’s easilydoneby lookingupyour sunrise/sunset times (use analmanac),andifthesunisbrightenough,theshadowcreatedbyaverticalstakeorpoleatlocalsunnoontimewilllietruenorth.Here’s anothermethod,not requiring local sunnoon timing.Using thatplumbed stake in theground,

marktheendofthestake’sshadowinthemorning.Laterthatday,marktheendoftheshadowonceagain.Drawalinethroughthesetwopoints,whichwillbeeast-west.Alinedrawnatarightangletothislinewill,ofcourse,benorth-south.Ifyou’reinthenorthernhemisphere,anothertrickistolineuptheNorthStar—Polaris,thatbrightstar

at the endof theLittleDipper—soyou are looking at it throughyour tower.Mark the spot.You arestandingduesouthofyourtower.Alinedrawnfromthatspotthroughthetowerwillpointtruenorth.Ofcourse,ifthisallsoundstoosillyandcomplicated,youcanlookitup,oruseanynumberofWeb

sites to provide the required data and information. One good resource iswww.ngdc.noaa.gov/seg/geomag/declination.shtml.Ifyouhaven’tgotalocalpaperanylonger,youcanusethissitetohelpyoufindordetermineyourlocalsunnoon:www.weatherunderground.com.

GettingYourBearingonBearingsIfyoustopandconsiderhowmanythingsinourlivesturnorrotate,anewappreciationforthehumble

bearingwilllikelyevolve.Hams,ofcourse,areconcernedwithturningantennas.Bearingscanmakesuchataskeasier,morereliable,morepreciseorlesslimitedbysize.Oneveryusefultoweraccessoryisthethrustbearing.Athrustbearingmountsatthetopofthetower,

usuallyboltedtoaflatplateatthetopofthetopsectionoronashelfinsidethetowernearthetop.Themast passes through the center of the thrust bearing and extends downward to the rotator. The thrustbearingclampstothemast,centeringitinthetowerandholdingtheweight.Withoutathrustbearing,alltheweightofthemastandantennaswouldrestontherotatorhousing.Thatmayormaynotbeanissue,dependingonthesizeoftheantennaloadandtherotatorratings.Bearingsworkbyusingeitherhardballsorrollers thatmoveor turn inside smooth inner andouter

surfaces (called races). SeeFigure6-10. These balls or rollers support the load, allowing objects tomovesmoothly.Ballbearingstypicallydealwithtwotypesofload—radialandthrust—usuallyoneatatime,oracombinationofboth.Thetypicaltowerthrustbearing,asyoumightimagine,dealswithbothforces, but we aremostly concerned with the vertical load that themast and antenna(s) place on therotator.

Mentionbearings toanyactivestationbuilder, andyou’llgetanopinionor twoandperhapsevenahorrorstory.Thisisonetopicthat’ssuretodrawavarietyofreactions,dependingonwhoyouask.Let’strytoclearthingsup,justabit,andanswersomecommonquestions.

Grease?NoGrease?ShouldIgreasemythrustbearingornot?ThetypicalRohnthrustbearingsdesignedspecificallyfor

toweruse (modelTB-3 andTB-4) aredesigned to rundry—without lubrication. (SeeFigure 6-11.)Their turningspeed issoslowthatnoheatwillbegeneratedas thebearingmoves.Remember,heat iswhatlubricantstakeaway.

Atopourtowers,let’sconsidersomebasicphysics.Whenaballinathrustbearingismotionless,theloadisdistributedsymmetricallyontheballandtherace.Whenatangentialloadisapplied,causingtheballtoroll,thematerialintheracewill“bulge”infrontoftheball,while“flatteningout”behindit.Sincenotenoughheatisgeneratedfromslidingfrictioninatypicalthrustbearing,metalpickuporweldingdoes

notoccur.But,theracecanshowevidenceofwear.Becauseit’smadefromasoftermetalthantheballbearings,theracewilldeformfirst—sometimestothepointofseizure.Lubricationwillnotsolvethatproblem.Anotherpitfall:Ifthegreaseholdsdebris,itcoulddamagetherace.Youcanencounterproblemsfromlargeloadsonthrustbearingsthathavesetidleforextendedperiods.

Thehardersteelballswillsimplymovethesofteraluminumoftheraceastheyrockbackandforthinthewind.Overtime,thebearingdevelopsa“bump”orirregularityintherace,oftenenoughsothatwhenitdoesturnormove,thebearingwillbind,causingfurtherproblems.

MultipleBearings?Anothercommonquestion:Whataboutusingtwobearings?Whileit’sagoodwaytoallowtheeasy

removal of the rotator (the mast/antennas remain supported as you take out the rotator), alignment iscritical.Mastalignmentinsidethetowerisoneofthemoreimportantmeasurementswehamsface,yetnearly

everyone takes it forgranted.Mostly, I believe, that’sbecause there is simply somuch room to adjustthings.For instance, in 20years of towerwork I haveonly encounteredone clientwho’s asked aboutshimmingtheHam-IV/T2Xrotatormastclampout to thespecified2.062inchesasdescribedearlier inthis chapter, even though it’s clearly spelled out in the manual. Everyone assumes there won’t be aproblemusingatypical2.0inchODmast.Usuallythey’reright,orlucky,orbothandit’snotaproblem.Addingasecondthrustbearingmagnifiestheissueofevenslightmisalignment,whichcancausedrastic

loadconcentrations.So,thosetwothrustbearingsmustbekeptplumbwiththemast.Iusuallyindicatethattwothrustbearingsmeansalignmentistwiceascriticaltomyclients.

CarryingtheWeight?Onefurthercommonquestion:ShouldIputweightontherotator,orusethethrustbearingtohold

theweight?My experience indicates itmakesmore sense to put theweight on the rotator, instead ofusingtheTB-3orTB-4thrustbearingtocarrytheload.Mostmodernrotatorsaredesignedtocarryweightloadsthatexceedthecombinedweightofatypical

mast and antenna(s). The bearingworks best at dealingwith side-to-side forces. This doesn’tmean Iwon’tusethebearingtosupportthemastwhenIremovearotator,butfornormalday-to-dayoperationIprefertohavetherotatorcarryingtheload.Thisalsoseemstohelpmitigatethatmetalmigrationproblemsometimes experiencedwith very large arrays (such as at large contest stations), where the load setsstationaryforextendedperiods.Intheplanningstages,it’sagoodideatoadduptheweightofyourmastandantennasandcheckthe

rotatorratings.

OtherChoices?Next, that inevitable query: What about using something other than Rohn bearings? And the

immediateansweris,ofcourse,it’scertainlypossible.Suchbearingsusuallyonlyhaveone,oratmost,two,setscrews—notthreeevenlyspacedonesasusedintheRohndesign.Themajorlimitationofmostbearings is theyare intended forshopuse—indoors.Theywill rustquicklywhenusedoutside in theweather. Yet, I continue to see them used by clients and supplied by various vendors and towermanufacturers.HerearesomepreventativemeasuresI’veusedsuccessfullyinprotectingshopbearings:Painttheentirebearing—flangeandbearingsurfaces—withRustoleumRustyMetalPrimer.Useaminimumoftwocoats.

ReplacetheAllenheadsetscrewswithhex-headbolts.Thesewillbefinethread(NF)boltsandwillprobably require some searching.But replace themnow, before installing the bearing, or you’ll bedrillingoutsetscrewsoneday,atopyourtower,certainlysomethingthat’sneverafuntask!

Bepreparedtoclimbandgreasesuchbearings,usuallytwiceayear.Rememberthatwatercanmigrateintothegreaseandfreeze.Remember,too,thatthissamegreasecanholdotherdebrisorcontaminants,someofwhichmayleadtoprematurefailure.Keepsuchbearingsclean!

Try to cover the bearingwith a suitable boot or cover of some kind.Each installationwill requiresomething different, but the business end of a plumber’s friend, some vent stack covers, or otherbuildingpartscananddowork.Iusuallyusealargeremnantfromatrucktireinnertube,cuttoshapeandheldtothemastbyahoseclamp.

BushingsYoumaynot needorwant a real bearing (required for supportingvertical loads), but just a simple

bushing.Thisworksespeciallywellifyourememberthatyoucanreducebendingmomentforcesifyourmastextendsbelowthetopofyourtoweraboutasfarasitextendsabovethetop.Mostmodernrotatorscansupporttypicalheavymastandantennaloadseasilyenough.Abushingcan

be used to properly align themast and provide an appropriate surface for themast to rub against topreventwearas itcontacts the tower topsection.Figure6-12 showsabushingmadeatK4VV’sQTHwithsomeDelrinstockandinstalledonhisPirodtower,supportinghis40meterbeam.

FurtherReadingIntruehamspirit,whentalkingabouttowersandthrustbearingsI’malwaysremindedofanarticleby

FredHopengarten,K1VR.PublishedontheYankeeClipperContestClubWebpage(www.yccc.org)andlistedunder“Articles,”it’scalled,simply,FAQ:ThrustBearings.Thisdocumentisfilledwithneat,oftenwitty,butalwaysusefulfactsandideas.Itendswithastep-by-stepdescriptionofhowtorefurbishaRohnthrust bearing on your own. (Another good resource comes from Jim Idelson, K1IR, and was alsopublished as “Refurbishing Your Rohn TB-3 Thrust Bearing” in the Sep/Oct 1999National ContestJournal.)

TurningEverythingAtOnceTurningtheentire towerhasbecomemorepopularwithin thepast fewyears—asstationsgetmore

advanced(orcomplicated,ifyoulike).Therearesomedefiniteadvantages.You can install bearings and rotating rings on a lattice-style tower, or you can take the rotating

monopole approach if guy wires are an issue for your installation. In either case, you’ll be turningeverythingatonce!Asstackedarraysincreaseinpopularityanduse,turningthemcanbecomesomewhattroublesome.A

rotatingtowermovesalltheantennastogether,atonce,inechelon.Whileanavidconteststationmightnotwanttoturneverythingatonetime(antennaspointingindifferentdirectionscanbeanadvantage),aDXermightwant tomaximize forwardgainat all times.AVHF/UHFstationcouldalsobenefit from turningeverythingatonce to takeadvantageof stackedantennasor to lineupantennas forvariousbandsonadistantstation.Tomorefullyutilizethebenefitsofarotatingtowersystem,asingletowercanbeseparated.Typically,

the lower half remains stationary and the top half rotates — providing some variety in directions.Assemblyof rotating towerhardware isusuallynomoredifficult thansimplybuilding the tower itself.MostrotatingtowersystemsarebuiltonnothinglessthanRohn45Gand55G,bothofwhichareheavy-dutyhardware.So,beprepared—it’sheavystuff!While rotating the entire tower is a specialized approach to rotating your antennas, there are some

commercial options or accessories that make the process easier. I’ve installed both Rotating TowerSystems(RTS)andKØXGhardware.Bothareextremelywellmadeandheavilygalvanized.Despitethemassandweight,theyareeasytoinstallandmaintain.RTSringsmustbeinstalledasthetowerisbeingconstructed(atsectionjoints);KØXG’sringscanbeputonthetoweratanypoint.Boltingtheantennasontothetower(side-mounting)canalsobesimplifiedifyouutilizesomeoftheKØXGmountinghardware,forexample.Havingtherotatorlocatedatthebottomofthetowerallowsforeasyservicing,eveneasyreplacement,

shouldthateverbenecessary,anotheradvantageofarotatingtowersetup.Andyou’llbeamazedwhenyoufindyoucanturntheentiretowerbyhandpriortoinstallingthebeamsandrotator!

StackingAntennasIf you have a heavy enough tower, youmay wish to utilize some of the space available and stack

antennasloweronthetower.Thereareanumberofswitching/matchingdevicesonthemarketthatwillallowyoutofeedantennasseparatelyorincombination.Youcankeeptheloweronesallpointedinone,fixed direction, or you can aim different antennas toward various population dense areas. A popularapproach is to rotate the top antenna(s) andpoint the lower antenna(s) toward an areaof interest (sayEuropeorJapan).MentionedpreviouslyasasolutionforlargeYagis,orbitalringrotatorsareagreatsolutionforrotating

lowerantennasofanykindaroundtheoutsideofthetower.They’llhandleYagislargeandsmall;themainconcernisclearingguywires.Anotherapproachtorotatinglowerantennasisasidearmmount.Theswinginggatesidearmenjoyed

somepopularityinthe1970s/80s,anditisstillaviableapproach,especiallyforthecleverhomebrewer.Themaindrawbackisthatthemountorantennaboomwillhitthetowerateachendofrotation,soyou’relimitedtoabouta300°sweepdependingondesign.WBØWsellsapopularsidearmmount.ArraySolutionsmarketsacleverswinginggatesidearm,and

Max-GainSystemssellstheIDCTechnologySidewinderswinginggate.IIXEquipmentoffersaswinging

sidearmmountaswell.So,thereareoptionsifyouhavetheroomonyourtowerandwishtobenefitfromstacksofantennas.

RemoteAntennaSwitchesOnce you have a tower, it’s a natural inclination to utilize it not only for that HF rotary beam (or

beams),butalsoasahighsupportforwireantennasandperhapsevenaVHForUHFantenna(ortwo).So it’s natural, aswell, that you then find yourself confrontedwith the need to run several coaxial

cablestofeedyourgrowingcropofantennas.Ratherthanrunanindividualfeedlinetoeachantenna,itmakes good economic sense to run oneverygood feed line (large diameter flexible coaxial cable, orhardline,orAndrewHeliax, forexample),and thenremotelyswitch thevariousantennas inandoutofconnection to that feed line as needed.This arrangementmaymakepractical sense aswell, comparedwithroutingmultiplefeedlinestoyourstationandconsideringtheeaseofaddingorchangingantennas.If youwant to go this route, that obviouslymeans you’re now in need of a switch.Remote antenna

switchesmust be designed for outdoor use.The cover ormounting box should beweatherproof (evenwaterproof),andyetalloweasyaccesstotheappropriatejackstoattachfeedlinesgoingtothevariousantennas. If the enclosure is not weatherproof, eventually the switch will become intermittent or failcompletely.Hamsarefortunatetohavearatherlargenumberofpotentialchoices.Typicalmodelsallowthechoice

offourormoreantennas(Figure6-13).TheytypicallyuserelayswithratingssuitableforhighpowerRFoperationandrequireamulticonductorcontrolcable.Mostoffermanualantennaselectorswitches;somearedesignedtotakeadvantageofstationautomationandcomputercontrol.Somespecializedmodelsaredesignedforstackingandswitchingamongtwoormoreantennasforadditionalgain.

It’simpossibletopickonemanufacturer’sproductoveranother,astherequirementsandoptionswillvarywidely from station to station. Some things to consider are power and frequency ratings, control

optionsandrequirementsandconnectorstyle.It’sagoodideatobuyaremoteswitchwithextrapositionsincaseyouwanttoaddantennasinthefuture.I’vehadverygoodresultswithunitsmadebyHeathandDrake(availableused),Ameritron,DXEngineeringandArraySolutions,atmyownstationaswellasattheinstallationsofvariousclients.ChecktheadsinQSTfortheseandotheroptions.Wheninstallingaswitchbox,Iusuallymakesurethemountinghardwareisstainlesssteelandchangeit

ifneedbe.IusuallytrytomounttheswitchsuchthatthecableaccessiseasywhenI’mstandingonthetower.It’softendifficulttoweatherproofSO-239connectorsclusteredtogetherontheundersideofabox,butmaketheeffort.It’spossibletowindsometapebackward(withthestickysideout,woundcarefully)aroundasmalldowelordrillbit,andthenunwinditontotheconnection.Thisprocessismuchhardertodescribe than to actually do, but it takes real practice before you can succeed with this old-timeelectrician’strick.Theswitchboxisalsoagoodplacetoutilizeanunder-usedtool—thecoaxboot,arubberorvinyl

cover that slides right over the entire coax connector. This upside-down location is already partiallyshielded,andthebootsprovidejusttheneededmeasureofprotection,easilyandquickly.Justremember,you’llneedtoinstallbootsbeforeyouinstallyourconnectorsonthecoaxialcable!I’vefoundthebootswilllastfourtofiveyearsbeforedryingoutandcracking,evenlongerifyoucancoverthemsuitably.

WorkingwithCranesandLifts

Usingacrane tohelperect towersand/orantennas isnotasexpensiveordifficultasyoumaythink.Youmightconsiderhiringacranewhenthemechanicaladvantageissimplytoogreat(comparedtoliftingbig,heavyobjectsmanually),orsafetyfactorsoutweightheextraexpense,ortimesavingsalonemakesitworthwhile.Sometimesadamagedtowerorantennaissimplynotsafetoworkonandacraneistheonlypracticalsolution.Whatever thereason,sometimesusingacrane issimply thebetter, safersolutionwhenputtingupor

takingdowntowersorbigbeams.Accordingly,somethoughtsarepresentedhereonworkingwithcranesandlifts.

CraneBackgroundIfyou’veneverworkedwithorusedacrane,it’simportanttounderstandthatcranesaremainlyusedto

hoistheavyloadsandmovethemshortdistances.Acraneisasteelboom(usually)mountedonahingedhydraulicplatformwithacablerunningthroughitonpulleys.Thiscableendsinahookandisraisedorlowered by a winch attached to the platform. The boom can be raised and lowered, and the entireplatformcanturn,orslew.Mostcranestodayarehydraulic.Mostofuswillusemobilecranes,whichcanvaryinsizeandshape,

dependingontheirliftingcapacityorboomlength.Truck-mountedcranessuchastheoneshowninFigure7-1canbecost-effective.Theyhaveboomlengthsgoingto120feet,yetarestillsmallenoughtofitintoanormalbackyard.Mostofthetime,weightlimitswillnotbeaproblemforcranes,asthey’redesignedforconstructionuseandhamtowersorantennasareextremelylightweightincomparison.Thecraneisheavy,soyou’llneedtoensurethattheequipmentcanreachyourtowersitewithoutgettingstuckinsoftgroundorruiningyourflowerbedsorsprinklerheadsorsepticsystem.

Likeotherheavyequipment,cranesarerentedbysize(capability),bythehour,withhigherratesformore capable equipment.Rental almost always alsomeans “portal-to-portal,”whichmeans that you’llpay for time required toget theequipment toyour locationandback to thevendor’s shop.Also, somestates(suchasMaryland)imposefeesfortransportingsuchheavyvehiclesonthehighway.Whengettinganestimatefromvendors,makesuretoaskaboutallapplicablefees,taxesandothercharges.

PuttingaCranetoWorkThefirsttimeyouuseacraneonajob,itcanbeasoberingandfrighteningexperience.Onceyoudoit,

you’llbehooked(punintended)—nomoreheavylifting,nomorelaboriousriggingoftramlinesorbackguys,andsoforth.Acranecanmakeeasyworkofsettingaheavycrank-uptowerinplaceasshowninFigure7-2.Guyedtowerconstructioncanbenefitfromuseofacranetoliftlongassembledsectionsoftower,completewithguywires,mastandotherhardware,intoplaceasshowninFigure7-3.Itcanalsomakeshortworkofliftingalarge,fullyassembledYagiintoplace(Figure7-4).

Ofcourse,thecraneoperatormaynotbefamiliarwithhamtowersorantennas.They’reusedtoliftinglarge,heavyitems,notdelicatefixturesofaluminum.Planonspendingsometimegoingovertheworktobeperformed.Ialwaysincludesometalkaboutourterminologywiththecraneoperatorbeforehand,too.If he’s suddenly confrontedwith someone yelling about the beam orYagi (terms he’s probably never

heardbefore), itmaybetoolatetosavetheiteminquestionfromdamage.Ialmostalwaysspendwaymore time talkingabout the jobwe’re about todo than it actually takes todo thework.But, asusual,safety first is the key to thiswork, and such discussions help ensure a safe experience by getting theclimber(s)andcraneoperatoronthesamepage.Thisisagoodtimetopointoutthatthetowerclimber(s)directtheoperation.They’retheonesatrisk,

andmoreimportantly,theyaretheoneswhoaretheclosesttotheaction.Theycantrulydeterminewhat’sgoingonandwhatneedstobedonenext.It’svitallyimportantthatclimberscommunicatecorrectlywiththecraneoperator,whetherthat’sviaradio(suchasapairofFRShandhelds)orthroughthetypicalhandsignals. In either case, a brief meeting of minds is called for before starting work so everyone is inagreementonwhat’stobedoneandhowtheworkwillprogress.Riggingisalwaysafactortoconsider—howdoyouattachthatdelicateYagitothathugesteelball

(300to600pounds,typically)hangingtherewithasimplehookattheendoftheheavysteelcable?Iliketorigtheloadmyself,andthenclimb.Iusemyusualassortmentofslingsandcarabinerstorigantennas,using techniquesdescribed in earlier chapters forworkingwith ropes andgroundcrewmuscle.Thesetoolsaremuchsmallerand lighterweight thanwhat thecraneoperator isused to seeingandusing, sodiscussingthembeforehandisanothergoodidea.Time spent rigging and testing by lifting the antenna or tower section a literal few incheswill help

showeveryonethatyourloadisbalanced,secureandreadyto“fly”onceyou’reatopthetower waitingforit.Afteryouandtheloadleavetheground,you’llneedtocommunicatewiththeoperatorviaradioorhandsignals.Ifyoudon’thaveasuitableradio,youmustrelyonhandsignals.AsimpleInternetsearchwillprovidethehalfdozenmostcommonones(theyarestandardized).Learnandusethem.Again,safetyfirst!

HumanCargoSometimes, liftinganantenna intoplace isn’tneeded.What’sneeded isa fixor repair toanantenna

alreadymountedandinpositiononthetower.Theobviousoptionisremovingtheantennaandtakingittoground,effectingtherepair(s),andthenhaulingitbackintoplace.Anotherwayisrepairingtheantennaintheair. Ifyourboom-to-mastmountdoesn’tallowyoutoeasilymovetheantennasoyoucanreachthedamagedpartfromthetower,whatcanyoudo?Onesolutionisusingacranetobringtherepairmantotheproblem.Basically,therearetwooptions.First,andthesimplest,fromahardwarepointofview,istheso-calledbosun’schair(Figures7-5and

7-6).Thetechnicaldefinitionofabosun’schair(sometimesspelledboatswain’schair)isadeviceusedtosuspendapersonfromaropetoperformworkaloft.Oftenlittlemorethanaboardandsomerigginginthesailingworld, thebosun’schairallowstheclimber toaccess theantennawhilesuspendedfromtheheadache ball of the crane.Working from a bosun’s chair limitsmaneuverability.One hand is usuallyneededtoholdoneselfinplace,forexample—especiallyatrealheightswherethewindisoftenafactor,even on calm days. But for quick and simple repair or adjustment tasks, it’s sometimes a workablesolution.

Amoreseriousapproachtobeinghoistedintoworkingpositionbythecraneinvolveswhat’sknownasamanbasket,cranebasketorpersonnelplatform.Theserugged,steelcagesarealsosuspendedfromtheheadacheball.Thereareonemanandtwomanbaskets,andifyou’rerequiredtospendmorethanafewminutesintheair,it’stheonlylogicalchoice.Ioncespenthalfadayinone,goingaroundandaroundthe3-element 80 meter Yagi at NR5M, when we were in the final tuning stages, literally adjusting eachelementbyinches.Manbasketrental isusuallyanadditionalexpenseandmustbeorderedwiththecranewhenplacing

yourorder.Forcertainjobs,it’sthemostpracticalanswertothequestionofhowtosolvetheproblemof

workingsuccessfullywhile“hangingout”inspace.

LesserLiftsSay youwant to work on your antenna,mounted on a crank up tower that is cranked down to 20-

something feet. In that case, you don’t really need the height or lifting power of a crane.Consider anaeriallift,instead.Oftenreferredtoasmanlifts,theseaerialplatformshavebecomeincreasinglypopularover the years and are used at nearly every construction site these days. These lifts can be foundseeminglyeverywheretoday,atreasonablerentalrates.Theyprovideasafeplatformfromwhichyoucanperformavarietyoftasksandjobs.They’remuchsaferthanladdersorscaffolding.Fromthestraightboomlift(Figure7-7)tothearticulatingarmlift(sometimescalledaknuckleboom),

tothescissorsliftandthepersonnellift,thereareavarietyofoptionsdesignedtogetyouworkingsafelyupintheair.Allwithoutclimbing!

Theboomliftisastraight,telescopinglengthofboom.Typicallyavailableatsomelargerrentalhousesup to120 feet,onanall-terrain, self-propelledmount, these liftscansolveavarietyofproblems.Thearticulatingarm lift,which isusually in two sections, can shift aroundobjects (gettingyou inbetweenelementsofa longboomYagi,orunderandaroundguywires,forexample),puttingyouexactlywhereyouneedtobetowork.Figure7-8showshowusefulthistoolcanbe.Theseboomsareusuallynotquiteaslong,butagain,themountsareusuallyallterrain,sotheycanbedrivenvirtuallyanywhere.Boththeboomandarticulatingarmliftscanusuallycarry500pounds.

Thescissors lifthas tremendous liftingpower (oftenup to2500pounds),butallof it isconfined tostraightupanddowndirections.They’reusuallyavailableoninteriorsurface(smooth)mountsonly.Thepersonnelliftisintendedtoliftonepersonstraightupanddown,andagain,theseareintendedmostlyforinterioruse.Buttheycanbeverylightweight,oftenwheeledintopositionbyhand.Mostof the larger,self-propelledunitsarequiteeasytooperate,andtherentalcompanywillgladly

provideyouwiththesimpleinstructionneeded.Thetow-behindliftcanbemovedontoyourjobsite,outriggersplacedandreadytohaulyouupinthe

air,allliterallywithinjustafewminutes.Batterypowered,theseliftscanreachupto60feetinworkingheight.Theonlydownsideisyoualmostalwaysneedtobewellversedinthefineartofbackingupwithatrailerinordertomaneuvertheliftintotheproperworkingposition.Ifyouneedtowork“upintheair,”aerialliftsofferasafe,relativelyinexpensivealternativetoold-

fashionedmethods.Theyareoftenavailableatlargeequipmentrentalfacilities.

LIFTSAFETY—AFewSimpleRules

Likeanytool,manliftsaresafeonlywhentheyareusedcorrectly.Falls or tipovers and electrocutions are the main cause of death in manlift accidents. So, pay

attentiontowhat’soverheadornearby,justasyoudowhenworkingontowers.WhileOSHArequirescommercialworkerstowearasafetybeltinthebaskettopreventfalls,asamateurs,wecanoptnottodo so. I’venever foundwearing the safetybelt tobe ahindrance toworkingquickly andeasily, andrecommendwearingoneanytimeyougoaloft.Always be certain of the terrain. Never work on sloping ground. Never work on extremely wet

ground.Alwaysuseoutriggers,ifsupplied.Ifuncertainoftheterrain,chockthewheelsforsafety.Don’tclimbuponorleanovertheguardrailofthemanbasket.

Don’texceedtheloadcapacitylimit(considertheweightoftoolsandequipment,plusyourself).Ifworkinganywherenearvehiculartrafficareas,setoutconesorwarningtapetokeeptrafficaway.Donotexceedtheverticalorhorizontalreachlimitofthelift.Do not move the platform with the boom extended. Always orient the lift so it’s moving in the

directionyou’refacing.Communication is critically important. The person in the basket should always communicate with

groundpersonnelbeforemovingthebasket.

GettingAntennasUpintheAir

Atsomepoint,unlessyouhavesomeonetodotheworkforyou,you’llfindyourselfneedingtogetanantennaupoffthegroundandontothetower.Ifit’ssomethingyou’veneverdonebefore,youmaywonderexactlywhatthebest,andsafest,methodisfordoingthejob.Thereareseveralpossibilities.Picking therightonewilldependsomewhaton thespecificsofyour

installation,yourexperienceandcomfortlevel,theavailabletoolsandequipment,andyourbudget.Youcoulduseacraneasdescribed inChapter7—provided there’s roominyourbudget,aswellasyouryard.YoucouldassembletheYagiupintheair—atthetopofthetowerorabovethelowerguywires,perhaps.You’vereadorheardabouttrammingantennasintopositiononthetower.Butwhat,exactly,areyouroptions?HowcanyouaccomplishthisoftenseeminglyHerculeantask—especiallywithaguyedtower?We’llbrieflydescribeotheroptions,buttrammingisthemaintopicorfocusforthischapter.IsuggesttrammingasthemaintopicbecauseIbelieveit’stheoneofthemoreefficientwaystomove

antennasupandontoyour tower.Yes, thereareavarietyof stepsandprocedures required inorder toaccomplishthetask.Yes,therearesomespecializedtools.Yes,therearesomespacerequirements—youmust have room tomaneuver, not only theYagi(s), but the ground crew, aswell.Yet, the benefits faroutweighalltheserequirementsinmyopinion.As always, if you ever have any doubts or questions about rigging, about procedures, about safety

issues,alwaysaskthembeforelife,propertyandpeaceofmindareatrisk.

TrammingAntennasTrammingisoftenmisunderstood.WheneversomeonebringsuptrammingonInternetdiscussiongroups

(suchasTowertalk,accessiblefromwww.contesting.com)italwaysgeneratesalotoftraffic.Figure8-1showsthegeneralidea:Theassembledantennaridestothetopofthetoweronatramlineaffixedtothemast.Thetramlineisanchorednearortothegroundatanappropriatedistancefromthetowerbase,andriggedsothattheantennaboomandelementsavoidcontactwithguywires.

First,let’sgetonthesamepagewithourdefinitions.Trammingmeanstheantennaissuspendedbeneaththetramline.Trolleyingmeanstheantennarestsupontheline.Thereareconsiderabledifferencesinapproachandinusingthetwomethods.Imuchprefertramming,

myself,althoughI’vefoundmyselfinsituationswhereusingatrolleywasthebettersolution.Thischapterwill, however, focus on the trammingmethod. It seemsmore practical andmore useful for nearly allapplications.For me, successful tramming depends upon the use of many of the climbing gadgets discussed in

previouschapters—slings,carabiners,properropesandpulleys.Withoutthem,I’dbelost.Withthem,Icanaccomplishmyriggingsafely,securely,easilyandrelativelyquickly,too.

BalanceisKeyThefirstthingtodowhensettingupatrammingjobistoensuretheload(theantenna)isdynamically

balanced.Thecenterofgravityshouldbeasneartotheboom-to-mastclampaspossible.Iftheantennaisnotbalanced,notonlywillriggingbeextremelydifficult,butalsotheantennawillnotwantto“flyflat

andlevel”onitsupwardjourney.So,thefirstthingItrytodoisbalancetheantenna.Thefirstandeasiestthingtotryissimplyshiftingtheboom-to-mastclamp’slocation.Thismaynotbe

possibleonsomeantennasbecauseofelementlocationsortheclampdesign.Ifyoucannotbalancetheantennabymovingtheclamp,thenextstepisofteninsertinganappropriate

weight inside the boom. I always try to add anyweight as near to the boom truss attachment point aspossible(mostlongerboomYagisuseaboomsupporttrussofsomekind).Iusegalvanizedwaterpipeofan appropriate size inserted inside the boom.For example, 2 inch galvanizedwater pipeweighs 3.65poundsperfoot.Thepipeisusuallysecuredwithastainlesssteelbolt,passedthroughtheboom.Iftheweightitselfissmallenough,simplysquirtinginsomeexpandingpolyurethanefoamwillholditinplace.SeeFigure8-2.

Balancing theantenna requires thatyoubeable to lift theentirebeamhighenoughoff theground toallowyoutojudgewhenyou’vereachedthecenterofgravity.Thismeansliftingithighenoughtoensureelementtipsarenotdraggingontheground,andsoforth.Todeterminetheamountofweightrequiredforbalance,Ipulldownonthelightend,usingastraingaugethatregistersupto50pounds.(Straingaugeisa fancy name for a scale used toweigh fish, available from sporting goods stores. SeeAppendixA.)Havingsomeonesightalongtheboomandtellingyouwhenit’s levelmakesthis jobrelativelyeasy,ofcourse.Then,yousimplyreadouttheweightneededtoreachthatbalance,andinsertthatamountintothelight end of the boom, again, as near to a truss attachment point as possible. Thismay require somejudiciousjockeyingbackandforth,asthetrussattachmentpointwillnotbeexactlyattheboomend.Timeandexperiencepayoffhere,andit’seasyenoughtogetthebeamintobalancewithalittlepatience.Remember, adding thecoax that runsalong theboom to theantenna feedpointwilloftenupsetyour

carefullyplannedbalancepointifit’snotinstalledduringweigh-in,butthatcanoftenbecompensatedforthroughcarefulrigging.

RiggingtheAntennaAtthispoint,manyfolksthinktheyarereadytobegintramming.Notquite.There’snoguarantee(even

ifyou’vebalancedthebeam)thattheantennaelementswon’t“rollover”orshiftdirectionasyoubeginlifting (aperennial problemwithKLMantennas, for example).The first timeyou try this, youmaybedismayed todiscover thebeam’s element tips suddenly catching inyourguywireson thewayup.Or,perhapsyourboomslowlyslides to the rightor left,wanderingaway from theattachmentpointon themast.

Somefolkswilltryusingtaglinesthatarepulledasnecessarytocontrolthisside-to-sidemovement.And,taglinescananddowork,buttheirremoval(oncethebeamisinplace)sometimesleavesalottobedesired.There’salwaysthechanceataglinemaygetcaughtorsnaggedduringtheremovalprocess,forexample.That’sneverfun.Here’sonesolutiontonotusingtaglines.Usingslings,suspendthebeamjustbelowthetramline—rightunder theupside-downpulleythat’s

restingonthetramline.Orient theelements towardthetower,ofcourse.Again, theideais tokeepthebeamlevel.Next,toconnecttheantennatotheropeyou’llusetopullituptothetower,youneedtobuildonesmalladditionalpieceofhardwareoftenreferredtoasatiller.It’sreallymoreofatorquearm,anditworks likea lever. (Glenn,K6NA, isoftencreditedwith this idea.His remarksabout trammingon theTowertalkreflectorarewellworthsomeresearchtime!)Thetorquearmisasimplepieceofangleiron(oranglealuminum),about2feetlongand⅛inchthick

by1.5or2incheswide.Drilloneendforamufflerclampthatwillfityourbeam’sboom;drilltheotherendtoacceptashackleorcarabiner.Attachthistorquearmontheboomasneartothatcenterofgravityaspossible,whichputsitveryclose

totheboom-to-mastplate.Withthetorquearmpointingtowardyourtower,you’llfindthatyoucannow“set”theangleoftheelementsthemselvesastheygoup(relativetothetower),bysimplymovingthearm.Pushingiteversoslightlylower(belowtheplaneoftheelements),forexample,willcausetheelement

tipstorisehigher,andsoforth.Ideally,you’llfindasmalldegreeofshiftrelativetothetramlinewillprobablybeaboutperfect,whichistheeffectyou’llfindifthearmisparalleltotheelements.Thisarmwill keep the elements away from the guys, and you’ll find it provides the control you need whentramming.Toomuchangleofattack,andtheelementscancollidewiththoseofanotherantennathatmayalreadybeinplaceonyourmast!I think you’ll find this method of tramming works quite well, and it even makes a one-man tram

operationpossible,albeitonerequiringlotsofclimbing.Youwillstillhaveyourhandsfullwithsomeoftoday’slonger-boomYagis,punintended!

TheTramLineTrammingdoes require some roomaround the tower andmaybedifficult or impossible inwooded

areasoronatightlot.Whenlocatingtheanchorpoint,it’sadvantageoustokeeptheangleoftheloadtothetowerasshallowaspossible.Ashallowerangleprovidesmorecontroloverthat“angleofattack”oftheloadgoingup.Ialwaysprefertorigthetopofthetramlinerightontothemastitself.Anotherchoiceistorigittothe

tower,abovethetopsetofguys,andthenpull theloadupintoitsfinalposition,onthemast,eitherbyhand orwith a come-along if needed.Again, the climbing slings and associated hardwaremake shortworkofthesetasks.They’relightweight,small,andsolvemanyriggingissuesquicklyandeasily.Idonotattempttousemyginpolefortrammingunlessit’swithverysmallloadssuchasVHF/UHF

antennas,smalltribanders,orthelike.Themastitselfsimplyworksmuchbetter.Back-guyingthemastisagoodideaiftheloadislarge,orifthemastisaluminum,forexample.Materialforthetramlineitselfvarieswiththeloadyou’regoingtolift.Ilike3⁄16-inchEHSguywire

forbigYagis,althoughI’veused⅝-inchrope, too.WithEHSguywire,aPreformedLineProductGuyGrip (discussed in Chapter 5) makes an ideal attachment method at each end, of course. I also likestainlesssteelaircraftcable,asit’sveryflexibleandsomewhateasiertomaneuveraroundthantheEHS,butyou’rebacktofussingwithcableclampsoncemoretosecuretheendsofthetramline.Whateveryouchoose,makecertainyouaresecuringthetramlinetosomethingsolidatthegroundend.Thecriticalfactorhereistouseanappropriatepulleyforwhichevermaterialyouchooseasyourtram

line.Thebeautifulnylonandaluminumrescuepulleyswillnotworkon theEHSoraircraft cable, forexample, onlyon rope.Figures8-3 and8-4 show two pulleys suitable for tramming onwire rope orcable.

Don’tsetup the tramlineso thatyou’reunable to lift the load(theantenna)upandonto the tramlineitself.Oncetheloadisontheline,it’sagoodideatoallowittosettle,againmakingcertainit’sbalanced.

LiftingtheAntennaOncetheriggingisinplaceandtheantennabalancedandsecured,it’stimetohaultheantennaupthe

tramline (Figure 8-5). Usually that’s done by hand, with that old standby — manpower — pullingcarefullyonthehaulline.Whenpossible,Iprefertouseacapstanwinch(seethesidebar)tohandlethelifting.Forsomereallybigandheavyloads,thewinchrepresentstheonlylogicalsolution.

TheCapstanWinch

If you’re going to be doing any serious towerwork, at somepoint you’ll eventually encounter thecapstanwinch.Alogicalapplicationistrammingantennasorhaulingheavyhardware,suchasrotatingtower bearings or orbital ring rotators, up the tower. Probably no single mechanized tool is more

misunderstoodormisusedthanthissimpledevice.AsseeninFigure8-A,acapstanwinchisamotor-drivenspoolordrumaroundwhichyouwrap3to

4turnsofyourhaulrope.Thetensionyouputonthatrope(literallyfingertippressure)determinestheamountofpullappliedtotheload.Theropeneveraccumulatesonthedrum,sothere’saconstantrateofpull—perfectforhaulingstuffupatower.

Capstanwinches aredesigned touse small diameter synthetic ropes— materialswith low stretchcharacteristics.Thewinch itselfneeds tobemounted securely, in linewith the towerbase. It’softenconvenienttomountthewincheitheronthetowerbaseitselforonatrailerreceiverhitchonatruck.Eitherway,makecertaintheanglegoingupwardonthetowerisfreeandstraight.Ifyouusethetruckmount, a separate sheaveorpulleymountedat the towerbase is required.Makecertain that thehaulropegoesonandcomesoffthecapstandrumatarightangle—sothatitcannotbespooledoffthedrumduringuse.Ifthisdiscussionsoundssomewhatvague,andyou’dlikespecific,detaileddirectionsonsettingupa

capstanwinch,pleaserealizethatthisisoneareainwhichthere’snosubstituteforexperience.Foreachinstallation, setupwill require that the rigger draw upon not only common sense, but on his own, -personalexperienceandtechniques.Layoutthehaulropesonosnagsarepossible.Theropebetweenthepulleyatthetowerbaseandthe

winchdrumshouldnevertouchthegroundduringlifting,forinstance.Don’tstandsoclosetothedrumthatyou(oryourclothing)couldpossiblygetsnaggedortangledintheline.Neverwraptheropearoundyourhand,armorbody.Mostwinchesutilizea“deadman”styleswitchforpower—usuallyafootpedaltype.Neverdefeat

suchswitches.Ifthewinchisspinning,buttheloadisn’tmoving,stopimmediatelyanddeterminewhy.Youmaysimplyhavechosenthewrongkindofrope—onethathassimplyreacheditselongationorstretchpoint.Ortheloadmaybesnagged.Stop,securetherope,andfigureoutwhat’sgoingon.Tostopduringalift,simplystepoffthedeadmanswitchandholdtheline.Donotsimplyallowthemotorto

turnwhilelooseningtheline—thatcausesfriction,heatingupandpossiblyburningtherope.Propercareandinspectionofthecapstanwinchropeismorecriticalthanforotherropesfoundinthe

towerclimber’stoolkit.(Ihavearopededicatedsolelytomywinch.)Avoidkinks,dirt,knotsandsnagsinthecapstanrope.Anyofthosecouldcausethedrumtolosesolidcontactwiththehaulrope,makingyoulosecontrol,whichcouldbedisastrous.Acapstanwinchisasimple,usefultool.It’snotusedeveryday,oroneveryjob,obviously,butit’sa

trulyvaluabletoolforsavinglaborandtime.

Idonot likeusinggarden tractors, pickup trucksorothervehicles topull thehaul line.Othersmayview the use ofmechanized help or vehicles differently, but inmy opinion, they isolate and limit thecontrol entirely toomuch.Quick and accurate communications arevital during the tramoperation, andshoutingtobeheardoveratractormotorandexhaustisn’tverypractical.Also,thesemechanizedpowersourceswillkeepontugging,regardlessofconditions,andpossiblytoyourdismayifnotstoppedintime.Keepingahandonthehaulrope,orevenstandinginlinewithit,isnotagoodideaifyoudoresortto

machinerytolifttheload.Shouldtroubledevelop(forexample,apulleybindsortheantennacatchesonguywires)andyoudonotstopintime,thewhiplashactionofabreakingropecoulddorealdamagetoanyoneoranythingnearby.Regardlessofyoursetup,it’simportanttokeepawatchfuleyeonthehaulropethroughouttheprocess.

Itsmovement(orlackofmovement)canprovideyouwithcluesthatwillpreventdisastermuchfasterthananythingelse.Thisisanotherreasonwhytheclimbersuponthetowercanbetterjudgewhat’sgoingonatalltimes,simplybykeepingawatchfuleyeonthehaulrope.If all this talk about rigging suggests that tramming is overly complicated, I’ve given the wrong

impression.Itdoesrequiresomeextrasetuptime,somesmallamountofexperienceandsomespecializedtools.Butthesepotentialdisadvantagesarefaroutweighedbytheeaseingettingyourantenna(s)upintheair and safely onto your tower.Onceyouget used to it, or evengood at it, you’ll findyourself in theenviable (or dubious) position of being asked to help do it for your ham friends and their owninstallations.Followthesesuggestedguidelinesandyou’llindeedbesuccessful!

OptionstoTrammingWith self-supporting towers, it’s usually a simplematter to simplyhoist the antennas straight up the

tower and into place on the mast. Sometimes the process is more complicated because the tower istapered.Or,ifit’sacrank-uptower,standoffstosupportthecoaxandcontrollinesorwinchesandotherhardware located directly at or on the base may be in the way. A simple tool can help with thesesituations.It’sasimplegantrytypedevicethatguaranteesthattheloadwillbeheldout,awayfromthetower,andcanthenbepulledstraightup.DetailsonthistoolmaybefoundintheAppendixA.

TrolleyingWorkingwith a trolley, where the antenna is suspended on the line rather than underneath, ismore

difficult.Itrequirestwocablesorlines,notone,whichmeansyouneedmorecabletobeginwith,alongwiththehardwaretoattachthem.Settingandmaintainingequal tensionon these lines is critical to success, too.And then, there’s the

actualtrolleyitself—somethingyouwillhavetoconstructormake.Thetrolleywillhavetobestrongenoughtosecurelycarrytheantenna’sweight,rigidenoughnottoflexitselfapartastheliftingandpullingforcesexertpressureonitsupwardjourney,andsimpleenoughtoallowyoutodetachthebeamfromthe

trolleyandattachittothemastonceatthetopofthetower.Ifthissoundscomplicated,I’dagree.Allfurtherreasonsforchoosingtramming!

WorkingAroundGuyWiresSometimes,trammingisn’tpossibleandanotherwaymustbefoundtomoveanantennaupandontoa

guyed tower. Sometimes, it’s possible to accomplish this by using a procedure commonly calledcorkscrewing,whichmeanstheantennaissimplyturned(inacorkscrewfashion)aroundeachindividualguywire,oneatatime,untiltheelementsallclearthoseguys.Then,thebeamisagainpulledup,andtheprocedureisrepeated.Figure8-6showsabigYaginearingthetopofthetower.

Thehaulropeisattachedtotheantennaboomattheboom-to-mastclamp(balanceisagainextremelyhelpful), run throughapulley at the topof the tower, andbackdown to thegroundcrew.The climbermovesupward—withtheantenna—whilethegroundcrewcarriestheweightandliftstheantenna.Themomentofsomebiggerbeamswillbegreat,andeventhoughthegroundcrewwillbedoingtheheavyhauling,theclimberwillbetaskedwithsomemonumentalmovingofhisowntopushtheantennaaroundtheguysandtowersections.Antennadesigncomesintoplayaswell.Youmusthaveadequateclearancebetweentheelementsnear

theboom-to-mastclamp,forexample,forthisproceduretosucceed.Ifthecenterelementsaretooclose,youmay not have enough range ofmovement to thread the elements around the tower itself, let aloneobstacleslikeguybracketsandguywires.Temporarilyremovingsomeelementsmaybenecessaryifyoudon’thavetherequiredclearanceontheboom.Aswithtramming,awell-balancedantennawillmakethisproceduremuch,mucheasier.I’veinstalledbigtribanders,fourelement20metermonobandersandshortenedtwoelement40meter

beamsusingthismethod.It’sslow,heavywork.Ineachcase,therewassimplynotenoughroomtotram

themupintoplace.Anotheroptionthat’ssometimesusedbytrulyexperiencedtowerworkersistohaultheYagiupashigh

aspossible,secureit,andthenattachtemporary(steel)guysbelowit.ThenremovethepermanentguysabovetheYagi,haulthebeamuppasttheguyhardwareandsecureit.Thenreplacethepermanentguys,remove the temporary guys, and repeat, as needed, moving up the tower. This option is best left toprofessionals.

BuildingtheAntennaontheTowerAnotheroptionistobuildtheantennaonthetowerandthenswingitintoposition.Dependingonthe

sizeoftheantennaandelementlocations,theantennamaybebuiltalongsidethetower,belowthetopsetofguys,oratthetopofthetower.It’sagoodideatoassembletheantennaontheground,checkbalanceand become familiarwith the hardware pieces and parts before hauling everything up the tower. Thegroundcrewwillneedtohelptheclimberaligntheelements.Thisprocedureworkswellwhentheboomlengthislessthanthespacingbetweentheguybrackets.Figures8-7and8-8showtwowaysofbuildinganantennaonthetower.

Thefirststepistohaultheboomupontothetower,withasmuchhardwareontheboomalreadyasispractical—meaningtheboom-to-mastclampandperhapstheelement-to-boomplatesorclamps.Swingtheboomvertical,usingeitheraginpoleoraseparateropeandpulleymountedhigher thanwhere thebeamwilleventuallygoonthetowerandriggednearthecenteroftheboom.Thensecuretheboomtothetower.Onceagain,thosemountainclimbingslingsworkwondersforthis;makesuretheboomcannotslipoutofitsverticalorientation.Mountthelargest/longestelementfirst(thereflector)atthebottomoftheboom,thenworkyourwayto

thefinaldirector.It’seasytoaligntheelementsifyouinserta“dummymast”(ashortpostorevenapieceof PVC, to keep theweight down) into the boom-to-mast clamp, allowing the ground crew to line upelementsagainstit.Astheassembler,you’llfindyou’resimplytooclosetoaccuratelyjudgewhat’swhat.Withtheelementsmountedandaligned,removetheriggingatthedirectorendoftheboomandallow

theantennatoswingfreely.Movetheboomsotheelementsarevertical,andwiththegroundcrew’shelp,swing themaroundand into thehorizontalplane.Then, thegroundcrewcan lift thebeam into its finalrestingplaceonthetowerasyouguideitintoplaceandmountit.Thisproceduremaybe followed if the antenna is side-mountedon the tower,ormountedonamast

abovethetowertop.Themainconsiderationinthissecondinstance,isthattheelementsattheheadorinfrontoftheboom-to-mastclampmustbeabletobemovedorswungaroundthemast.Keepthatinmindasyoubuildthebeam.Youmaybeabletoaccomplishthisbyrotatingtheelementsvertically,thenswingingthembackhorizontal,oryoumaywishtotilttheboombeforeinstallingtheforwardelements.This narrative all perhaps sounds overly difficult, and it does involve a far amount of climbing up,

down,thenoverandaroundtheelements,butit’softenthebestanswertogettingthingsonthetowerwhenthere simply is not a large amount of open ground space surrounding the tower, which you need fortramming.

ThePVRCMountThePVRCMount isa tool thatprovidesyouaway tobuilda largeantennaat the topof the tower.

NamedafterthePotomacValleyRadioClub(atopcontestclubcenteredintheWashington,DCarea),ithasbeenpresentedintheARRLAntennaBookandotherpublicationsformany,manyyears.ItshistoryhasbeenlostamongthePVRCbrethren,too,althoughI’vetriedtoresearchitasbestaspossible.Creditiscertainly due Silent Key members Ed Bissell, W3MSK (W3AU), Lenny Chertok, W3GRF, and TomPeruzzi,W4BVV, for contributing to its development.These legendary contest pioneerswere all earlyadoptersofmassiveantennahardware.Basically,thePVRCMountallowsyounotonlytobuildlargebeamsupintheair,onthetower,piece-

by-piece,butalsototiltthemoverformaintenancepurposes.ExceptforsomeoftheMaryland/Virginialocals,IhaveneverencounteredthePVRCMountinwidespreaduse.Havingworkedwithitmany,manytimes(FrankDonovan,W3LPL,usesitextensively),Icansayittrulyisauniqueandlabor-savingdevice,worthy of any serious antenna builder’s attention. See the “Antenna Supports” chapter of the ARRLAntennaBookforfurtherconstructiondetails.

CoaxialCablesandConnections

Onceyouhaveatowerwithamast,beamandrotatorinstalled,it’stimetothinkaboutconnectingittotheradiointheshack,ofcourse.Choosingtherightmaterialandinstallingitproperlywillhelpensurelongandtrouble-freeoperationofyourantennasystem.Thischapterisnotanexhaustivestudyofcoaxialcable,butratherpresentssometipsI’vepickedupovertheyears.Figure9-1showstheconstructionofvarioustypesofcabledescribedinthefollowingsections.

CoaxialCableHistory—WhattheLetters/NumbersMeanBack when the military drove the development of coaxial cable, they designated the cables by

descriptionsrelativetopagesinamanual.RGreferredto“radioguide.”RG-1wasthefirstcabledesign,onpageone,butthefirsttrulypopularcablewasRG-6,whichisstillwithus.Thedesignationsfollow

neitherlogic,nororder,asshowninafewexamplesinTable9-1.

SinceweknowthattheRGnumbersaresomewhatarbitrarynow,canweassumethatsay,allRG-58cables are the same, or might there be differences? If you guessed the latter, you’re doing well. Forexample,isthecenterconductorsolidorstranded?Ifit’ssolid,isitbarecopperwire,tinnedcopperwireorsilverplatedcopperwire?Ifit’sstranded,howmanystrandsofwhatgauge,andfromwhatmaterialarethosestrandsmade?Other issues to question: Is the shield bare copper, single or double braid, or braid and foil?How

denseisthebraid?Howmanyconductors,andofwhatsize?Differentouter jackets call fordifferentdesignations, too.Acablemighthavea jacketmade so that

chemicalswithinitwillnotcontaminatethedielectricunderneathit—knownasa“non-contaminating”jacket.Finally,aftertheendofWorldWarII,thewholeRGsystemwassimplychanged.Coaxialcabletoday

isreferredtoasC17.Tothisday,hamshavecontinuedtousetheoldRGnumbers,mostlyoutofhabit,althoughinrecentyearsmanufacturershaveintroducedawidevarietyofcoaxwiththeirownnumberingsystems.

WhyDoWeUse50ΩCoax?Lotsoffolkswonderwhyorhow50Ωbecamepopular.Thenumberswerenotarbitrarilychosen.For pure power handling capabilities, 30Ω cablewould the best choice.We should all know that

impedanceis theratiobetweenthecenterconductor’ssizeandthedistance to theshield(braid),alongwiththedielectricconstantoftheinsulatorinbetweenthem.Itturnsoutthatthisswell30Ωcableprovedexceedingly difficult to manufacture. Another group wanted extremely low signal loss, and it wasdetermined that77Ωcablemet that requirement.Standardwire sizesanddimensions turnedout75Ωcable,asuitablecompromise.Forthosefolkswhowantedtosendveryhighvoltagesdownthecable,60Ωwasagoodchoice.But

highvoltageuserswerealsolikelytobehighpowerusers,aswell.Thecompromisebetweenvoltageandcurrent?Ourever-popular50Ωcable.

HardlineIn today’s technology-driven environment, lots of “serious” hams are using large-diameter, low-loss

rigidcable—“hardline”—tofeedtheirantennas.It’ssomethingtoconsiderifyouhavetocoveralongdistance between your station and antennas, or if you want to maximize performance at the higherfrequencies.AsmentionedinChapter6,somehamshavefounditmakessensetorunoneverygoodfeedlinetotheirtowerandthenusearemoteantennaswitchtoselectvariousantennas.YoucanfinddataonvarioustransmissionlinesintheARRLHandbook,theARRLAntennaBookoratvendorWebsites.It’sworth taking a look at power handling and loss characteristics and considering options for your

installation.Hardlinesizesusedbyamateursrangefrom½inch(slightlylargerthanRG-8sizecoax)to1⅝inchor

larger diameter. Construction varies. Some versions have solid aluminum jacket, while others have acorrugated copper jacket (Figure 9-2). You’ll probably want to look at hardline with foamedpolyethylenedielectric.Someversionsuse“airdielectric”andaredesignedtobepressurizedtokeepoutmoisture.Thatrequiresspecialconnectorsandequipmentandaddsalevelofcomplexitynotworththeeffort formost ham radio applications. Another alternative is coax such as Times LMR600 (0.6 inchdiameter)orLMR1200(1.2 inchesdiameter),which isbuilt similarly toRG-8 typecable, simply toalargerscale.

Ifyou’reused toRG-8prices, theper-footcostof thesecablesand theirconnectorsmaycomeasashock.PerfectlygoodsurplusandusedcableisoftenavailableatattractivepricesthroughInternetswapandauctionsites.Also, remember thatcable television(CATV)hardline isvery lowloss,and isoftenavailable free just for hauling it away.You’ll still need to come upwith connectors andmay need toaddressits75Ωimpedance,though.I’llpresentmoreonusingCATVhardlinelaterinthischapter.Askaround—someoneinyourclubmayhaveagoodsourceforcable.

WorkingwithHardlineSomeoftheserigidhardlineshaveacorrugatedoutershieldthatmakesthemeasiertoworkwith.The

two brands you’ll most likely encounter are Heliax from Andrew Corporation and Flexwell fromCablewave. (They’re the largestmanufacturers in theUS).Corrugatedcablesare intended for agentlebend,butnotforcontinuedflexing.Inotherwords,theywillbend,butonlythroughaspecificradius,andonly fora limitednumberof times.Once that limitednumberof“flexes”hasbeen reached, thecopperjacketwillwork-hardenandthenbreak!Therotationloopwillhavetobesomethingflexible,likeouroldfaithful friendRG-213.So, run thehardlineup the tower legandstopnear the toporat anantennaorswitchbox. It sounds pretty simple, but here are some areas to consider before, during and after suchinstallation.

HANDLINGITONTHEGROUNDFirst, remember the cable will be most prone to damage before you ever get it installed. It’s not

unheard of for over-zealous forklift drivers to damage the cable unloading it. In case youdon’t know,hardlinecomesonspoolsthatarelargeandheavy.Thetwoendsareoftennotaccessibleonnewspools,unlessyouspecifythat.Andthespoolsareoftenstoredthewrongway—lyingflat,insteadofbeingkeptupright, andwithout the factory-installed protective cover,making them susceptible to damage. That’swhyprofessionalsalwaysuseatimedomainreflectometer(TDR)tocheckthecableonthespoolbeforetheybeginworkingwithit.Because this cable is so fragile, it’s important to consider how you’re going to dealwith it on the

ground.Knowwhereit’sgoingtogoandwhereit’sgoingtocomefromasit’sunwoundfromthespool.Andyes,thiscableisdelicateandcanbekinked,ifyou’renotcareful.Haveaplan,andworkslowlyandcarefully,followingthatplan.

HAULINGITUPSecond,theissueofsupportforthecableasyouhoistitmustbeconsidered.Naturally,mosthamswill

not have themanufacturer’s recommendedhoistinggrips. (However, this is one thing that canoftenbefound,cheaply,oneBay.)They’llhavetoimprovise.Theonethingyoudonotwant todo is install theconnector,thenusethatasapullingpoint.(Yes,I’veseenthisdone.)Hardlineispronetodamagefromjury-riggedclampsandmaybepermanentlydeformedorcrimpedby

yourattemptstofastenaline.Thesimplest,easiestandleastdamagingsystemIhavefound(anduse)isachokersling(Figure9-3).Ahundredfeetorsoofthisstuffisheavy.Ifyou’renervousabouttheabilityofasimplepieceofnylontosafelyholdthismuchcable,Isuggestyoutalktoaseriousclimber—someonewhotrustshisorherlifetosuchtools.Then(foryourpeaceofmind),securetheslingwithsomegoodelectricaltape,suchasScotch88,andhaulaway.(Moreonelectricaltapeinalatersection.)

SECURINGITINPLACEThird,onceyouhavepulledyourhardlineup intoplaceand it’shanging thereagainst the tower, the

issueofsecuringithastobeaddressed.WithRG-8sizecable,you’reprobablyusedtowrappingafewturnsofelectricaltapeatregularintervalstoholdittothetower.Withhardline,eventhebesttapeoftenwill not hold this much weight over time. Like most hams, I cannot always use the manufacturer’shangers.SomesolutionsI’veusedincludestainlesssteelhoseclamps(boththeclampandwormscrewarestainless),spacedliberallythroughoutthelengthofthecable,generallyevery50feet.Inbetween,Iuseblacknyloncableties—thosewitha120poundrating—coveredwithScotch88tape.I’veneverobserved an interaction problem between the galvanized tower leg and aluminum or copper jacketedcables. (Imake a point to ground the cables separately at the bottomof the tower, too.)Andyes, youshould take this cable’s outer dimension into consideration when computing the wind loading you’veplacedonyourtower.Finally, a fewwords aboutmaintenance, onceyou’vegot the cable installed.Althoughgoodquality

cable canprovidemanyyearsof trouble-free service, it doesneeda little attention from time to time.Afteryearsofuse,withconstanttemperatureshifting,thedielectricmaterialscanharden,evenbreak.Thecenterconductorcanmigrateoutofcenter,withobviousbadresults.Thetighterthebendinyourcable,themorelikelysuchproblemsaregoingtobe.Inotherwords,watchtheradiusofthosebends!Climb the towerat leastonceayearand inspecteachclampand tape joint,and re-doany that look

weakorsuspect.ChecktheSWRatperiodicintervalsforeachantenna,andcomparetheresultstowhatyouhadwhenyouoriginally installed it.Check all yourgroundconnections.And finally, if you sufferdamage,replacethecable.Don’ttrysimplycuttingoutthe“bad”section.Residuefromarcingcanmovedownintothecableandcreatetheproblemagain.

UsingCATVHardline

Hamsarealwayssearchingforabargain,whetherit’sapieceofgearfortheshackorawaytosavemoneyonthetower.CATVhardlinerepresentsonesuchbargain.Thisaluminum-jacketedcableisruggedand low loss. Formanyyears, short ends (usually anything less than300 feet)were often free for theaskingfromthe localcablecompany.Thissource isdryingup,however,asmoreandmorecompanieschangeovertofiber.It’sworthcheckingwithyourlocalcablecompany,orperhapssomeoneinyourclubhasastockpile.Manyhamsoverlookthiscable,however,becausetheyknowit’s75Ωcoax,andbelieveusingitwill

causeSWRproblemsorissues.EvenifyouuseCATVcablewithnoattemptatimpedancematching,theSWRfromthemismatchwillonlybe1.4:1,whichisprettyinsignificant.Oneeasysolutiontoachievingamatchto50Ωistouseanasynchronoustransformerateachendofthe

75Ω hardline. For thosewith extensive libraries, an explanatory article is “Matching 75-OhmCATVHardlineto50-OhmSystems,”byCharlesJ.Carroll,K1XX,HamRadioMagazine,Sep1978,pp31-33.Here’showyousolvetheproblemformonobandantennas(seeFigure9-4):

1) Start at the last piece of equipment in your station before the antenna feed line (transceiver oramplifier antenna jack, wattmeter, switchbox or whatever) where you’re expecting to see 50Ωimpedance.

2)Installa0.0815wavelengthsectionof75Ωcoax(usuallyRG-11).3)Next,installa0.0815wavelengthsectionof50Ωcoax(usuallyRG-213).4)Nextcomesthe75ΩCATVhardline,anylengthnecessarytogetwhereyouwanttogo.5)Next,another0.0815wavelengthof50Ωcoax(again,usuallyRG-213).6)Next,another0.0815wavelengthof75Ωcoax(again,usuallyRG-11).7)Endatyour50Ωantenna.Note that these are not physicalwavelengths, but electrical wavelengths,whichmust be calculated

usingthecorrectvelocityfactorforyourRG-11andRG-213cables.

L(inches)=(961.7×VF)/f(MHz)

whereVFisthelinevelocityfactor.Solidpolyethylene(PE)is0.66;foamPEvariesfrom0.78to0.86forpopularRG-8sizecable;Teflonis0.695.

Forexample,at14.15MHzwithPE-dielectricRG-11andRG-213:

L=(961.7×0.66)/14.15=44.9inches

Consultthemanufacturer’sdatasheetforthespecificcablechosen,orbetteryet,measure.

ConnectingtoCATVCableOver theyears,anumberofmethodsofmakingconnectors forCATVhardlinehavebeenpublished.

Here’showIconnectto¾inchCATVhardline,whichis(orwas)verycommon.SeeFigure9-5.

ThefirststeptobuildingaconnectoristoobtainsomeAmphenolPL-258doublefemaleconnectors.(Cheapimportswillnotwork.)OneendofthePL-258isheldonwithasnap-retainingring,insidetheconnector.Usingasharppointedtool,removethisring.(Iusetwodentalpicks.Becareful—theseringscansometimesflyacrosstheroom.Patienceandpracticemakeperfect.)InsertthePL-258metalshellintoacopperplumbingfittingusedtojoin¾-inchODtubingto½-inch

threadedpipe.LeaveasmallamountofthePL-258’sshoulder(about1⁄32-inch)abovethecopperfitting.Now,solderthePL-258andpipeadaptertogether.(Iusesilversolder,butordinaryrosincorewillworkfine.)TurnyourattentiontothepartsremovedfromthePL-258.Usingasuitabledrillbitorreamer,reamout

oneof the insulators.Goslow; theplastic isbrittle.A lathe is ideal for this,althoughnotnecessary ifyou’re careful. Spread the prongs of one end of the PL-258 center conductor so it’s a snug fit on thehardlinecenterconductor.Don’tdoanythingtotheoppositeend.Insertthesmallerendofthereamed-outinsulatorintothenewconnector,followedbythespreadendof

theconductor.Inserttheotherinsulator,smallendup,andre-installthesnapring.Onthehardline,withasharptubingcutter,cutoff⅝-inchofthealuminumjacket.Donotcutthefoam

insulation.Using a¾-inchpipedie, thread approximately¾-inchof threadsonto the jacket.Clean thethreads,and then trimoff the foam(asharpsingle-edgerazorbladeworkswell).Becarefulyoudon’tnickthecopperplatedaluminumcenterconductor.Carefully round off the end of the center conductor. Fill the threads with Noalox or other joint

compoundandthreadyourconnectorontoyourhardline.Installandweatherproofyournewlow-losscable.

LoopingtheLoopsHere are some solutions to theproblemofdealingwithmovingcoax— the sometimesproblematic

“rotatorloop.”Probablythemostcommonwaytohandletheissueofallowingenoughroomforthecoaxtoturnwith

thebeamisasimple,danglinghunkofcable.Manybeams(atypicalthreeelementtribander,forexample)

willhavetheirdrivenelementnearenoughtothemasttoallowyoutosimplysecurethecoaxtotheboom,thenleaveithanginglooselystraightdownsothatittravelsfreelyaroundthemastasyoumovethebeam.Theloophangsoutawayfromthemastortower,drawingitselfupasthebeammoves.The same sort of loopwill alsoworkwell on long boomYagiswhere the driven element is well

removedfromthemast.Inthatcase,securethecoaxalongtheboomuntilyoureachanappropriatespotclosetothetowertoformtheloop.Anotheroption,onethatworkswellonflat-topstyletowers,istocoil thecoaxinalooparoundthe

mast,such that this loopwindsandunwindsas therotator turns.Ofcourse, thismeans theouter jacketwillactuallyberubbingagainstitselfandalsorubbingagainstthetowertopasitturns.Ifthecoaxrubsagainstanything(suchasthethrustbearingbolts,ortheactualedgeofthetowertopplate),abrasioncanoccur.Continuedabrasioncancausethejackettotearorwearaway,leadingtomoisturecontamination,brokenconductorsorotherproblems. Ihave installed“jackets”over thecoax topreventsuchdamage,usingoldgardenhoseorcableloomandthelike.Temperature cycles (winter to summer, for instance) can cause the loop size to change, leading to

trouble,too.Obviously,theideathatyouhaveamovingobjectupatthetowertopshouldcauseyoutothinkverycarefullyaboutthissimple“loop”thatyou’reinstalling.Questions abound on what type of coax to use for the loop. I still prefer RG-213 or BuryFlex, as

they’retriedandtrueperformers.I’vehadclientstellmetheywanttouseAndrewSuperFlexhardline,astheybelievethenameimplies“superflexibility,”butthat’samisnomer.SuperFlexreallymeansthecoaxhasasmaller-than-normalbendingradius.Allhelicalhardlineshavea finitenumberofbendspossible(Andrew says 1000 bends).After toomany bends, the corrugated jacketwork-hardens and eventuallybreaks.Soareal,braidedcableiswhatyouwanttoinstallforanyloopuse.

SideMountedAntennasSide-mounted antennas, whether on a swinging gate or an orbital ring rotator, also present special

problems.Typically,thesimplestsolutionistousethetrusssupportonlongboomYagistoholdthecoaxupandawayfromthemovingpartsofthering.Donotallowanypieceofthelooptocomeincontactwithmovingparts.Forrotatingtowers,Ihavehadverygoodluckusinganactualgatehingeholdinga“yardarm”outand

awayatthetowerbase.Thearmisfreetoturnorrotatewiththetower,whichhelpstorelieveanystressputonthecoaxcables.SeeFigure9-6.Thisisespeciallyhelpfulonrotatingtowers,whichareusually“stacked”fullofavarietyofantennas,meaningtherearenumerouscablesleavingthetowerbase.W3LPLusesasimplevertical“post”toholdhisrotatingloopupandawayfromhisrotatingAB-105towers.SeeFigure9-7.

Regardlessof thekindof installationyouhave, it’svery important toactually try it— to install the

loop,thenhavesomeonerotatetheantennathroughacouplecycles(stoptostop),asyouobservewhathappens.Doestheloopmovefreely,nottouchinganything?Isthereenoughcoax(especiallyneartheendsofrotation)?Onlythendoyouwanttofinalizetheinstall—securingthelooppermanently.Remember,sincethesepartswillbemoving,securethingssothatonlywhatyouwanttomovecanandwillmove.Thatmeansusinggood,heavy(120poundrating)UV-ratedcabletiesorwireties,forexample.IliketocoverthetieswithScotch88tapeforfurtherprotectionfromtheelements.

WeatherproofingThoseConnectionsYou’vestudiedtheoptionsandpickedthebestcoaxialcableforyourapplication,gottenitupthetower

andconnectedittoyourantenna.Toprotectyourinvestmentandkeepyourstationworkingoverthelonghaul,it’sagoodtimetolearnaboutweatherproofing.

TapeTipsOnce,oneofmyclients,watchingfromtheground,askedmewhatIwasdoingwhileweatherproofing

his cables. “What’s thatwhite stuff?” he asked. If you’ve heard this lecture before, I apologize, but itseemsthesubjectiscyclical.Everyfewyears,itcomesbackintorotation,showinguponreflectorsandthelocalrepeater,inprintandconversation.Weatherproofing(noticeIdidnotsaywaterproofing)connectorsisaforeignconcepttosomehams.I

encounterunprotectedconnectorsallthetime,fromsimplescrewterminalstoRFconnections.Therearelotsandlotsofwaystoprotectandweatherproofconnectionsthatwillbeexposedtotheelements.Let’sbeginwithtape.VinylelectricaltapecameintowidespreaduseafterWorldWarII.Beforethat,

theprimarysealingproductwasarubbery,stickysubstancecalled“frictiontape.”Irememberusingitasaboyonthefarm.Ialsorememberdiscoveringthenew,vinyltapeandbeingimpressed.Today,wehaveavarietyofvinyltapesfromwhichtochoose.Ibelieve3Mmakesthebest,sothisarticlewillfocusontheirproducts,someofwhichareshowninFigure9-8.Theyare readilyavailableathardwarestores,homecentersorontheInternetandyoushouldhavenotroublefindinganyoftheproductsdiscussedhere.

TapeCharacteristicsAmongtapeaficionados,you’llsometimeshearcertaintermsorcharacteristicsdiscussed:adhesionto

backing, adhesive transfer, conformability, elastic memory, elongation and flagging. But first, let’sconsidersomerealworldapplicationorusesforthesetapes.Vinyltapeisusedtojacket(insulate),splice(lowvoltageconnections)andmechanicallyprotect(just

whatitsays)jointsorconnections.Mostofthecommonlyfoundtapesareratedupto600V.Thestrappingorbundlingorholdingusesareoftentakenforgranted.Forinsulationpurposes,alwaysuseaminimumoftwohalf-lappedlayers—meaningeachlayeroftapeoverlapsitselfbyhalfthetapewidth.Thefinallayeriswrappedinamore“relaxed”manner—withoutasmuchtensionorstretchbeingput

on the tape.We’vealldone thiswhenwe’vewrappedconnectors,butchancesare,you’venot thoughtmuchaboutthischaracteristic.Thisabilitytofitsnugly,makingcompletecontactwiththesurfaceofanirregularobjectwithoutcreasing,iscalledconformability.Thisabilityto“stretchtofit”andthen“stayinplace”iscalledelasticmemoryandelongationby3M.Allmanufacturersgradetheir tapesaccordingtothickness.Super33(7mil),Super88(8.5mil)and

Super35(colorcodingtapes,also7mil)arethemorepopularScotchproductsusedbyhams.Thinnertapesareveryeasytoapplyandwillconformreadily;theyalsobreakortearquiteeasily.Thickertapesprovidefasterbuildup,betterdielectricandmechanicalstrength,andcanbehardertocutthrough.Scotch88canbeappliedfrom0-100°F,extremesunderwhichfewofuswouldwanttobeworking.

Scotch88 alsooffers excellent elasticmemory and elongation, soyou canget a good snug fit under awidevarietyofconditions.Butisitreallyandtrulywaterproof?Theanswerisno,notalways,ifusedbyitself.

TheNextLevel:WaterproofThereare,however,solutions—additionalproductsthatmoveyoufromweatherprooftowaterproof.

Rubber tapes (not vinyl), which provide electrical insulation and mechanical sealing, can also sealconnectionsagainsttheenvironment.Theyreadilystretchtoconformtoirregularsurfaces.Quitesimply,they form a gasket around cables, connectors orwires. Two readily available products I’ve used areScotch130Cor2242,calledlinerlessrubbertape.Linerlesssimplymeansthere isnoadhesiveonthis tape.Itwillnot stick toconnections. Indeed,as

you peel it off the roll, it hangs limp in your fingers, and you’re not sure it’s going to be any usewhatsoever. It does, however, stick to itself (called self-amalgamating). It should be wound tightlyaroundconnectors—startingfromthebottomuplikeroofshingles—keepingitundertension,asyougo.Scotchrecommendsa50%stretch,andwithsomepractice,you’llgetthehangofhowmuchstretchthismeans.Experiencewillbeyourguide,butonegoodruletofollowiswhenthetapeturnsfromblacktogray,youshouldstopstretching.Itstretchesandmoldsitselfeasilyaroundconnectors,likePL-259s.

BuildingaWaterproofConnectionFigure9-9showsthestepstomakingalong-lastingwaterproofconnection.Inpractice,Iliketowrap

connectors with some special Teflon tape first. It’s 0.003 inch thick. At first glance it looks like theordinary pipe thread tape plumbers use, but it’s tougher stuff and conforms to literally anything! It’savailable fromMcMaster-Carr.Thencomesa layerofScotch130Clinerless rubber tape, followedbytwolayersofScotch88.AnalternativeistouseScotch88ratherthanTeflontapeforthebaselayer.

As to technique, it’soldnews,but thekey is tomake sure there arenogapsor air cavities inyourwraps.Where there is air, therewill bewater, plain and simple. The super-flexible Teflon tapewillliterallyconformtoanything,solvingthatproblem.OnthatlastwrapofScotch88tape,lettheendrelax,andthencutit.Don’tsimplygrabthetape,tug,

stretchand tear it.Over time, theelasticmemorywill cause the tape tobecome looseand flag (that’swhatthosenastylittleflappingendsarecalled).Thinkabouteachjointbeinglaidliketheshinglesonyourroof—eachoverlappedlayerisoverthe

nextlayer,asyoumovethejoint.Wherepractical,Ialsoliketoputa tie-wrapaboveeachconnection,wherecapillaryactionwillpullthewaterawaybeforeitgetstorundownintothetapedjoint.Howwelldoesthistechniquework?Itwilltakeafewmomentsofefforttogetaknifeorbladesawing

throughthatconnectorafteracoupleofyears,butonceyougetanendloose,youcanpeelthewholemessaway and be surprised with a brand-new-looking connector. It’s somewhat expensive (I buy mine atHome Depot), but the ability to truly waterproof a connector over an extended period of time isinvaluable.Figure9-10showswhatacoaxconnectionprotectedthiswaylookslikeaftermanyyearsofservice.

ScotchLiquidElectricalTapeLiquidelectrical tapeisanotherqualityScotchproduct,althoughI’veonlyrecentlybegunusingit. If

youhavethetimetowaitforit tosetup,andtheabilitytobrushitontotheconnector(forinstance,ifyou’renothangingupsidedownandbackward120feetintheair),itworksperfectlytosealthe130C-tape-covered connector. It’s also a good choice for covering normally exposed antenna electricalconnections—suchassmallfeedpointhardware.I’vebeenimpressedintheshorttimeI’vebeenusingit.Trythisliquidelectricaltapeforsuchjoints.

InspectionsandMaintenance

Onceyourtowerisstandingtallandtheantennasareup,goaheadandenjoythefruitsofyourlabor.Keepinmind,though,thatyourjobisnotfinished.Regularinspectionsandmaintenancearethebestwaytokeepyour stationoperatingat topperformanceandheadoff smallproblems that could turn intobigheadaches.Pleaseunderstand that this is anongoingcommitment, and this chapteroffers some tips forkeepingyourantennasystemworkingefficiently.I suggest to my clients that they perform an inspection (or have such work done) twice annually.

Springtime is one obvious choice of an opportune time— the tower(s) and antenna(s) have just gonethroughthe temperaturecyclesofwinter,alongwithstressfrompossible ice loads,highwindsandthelike.Fallisasecondobviouschoice—rightbeforethestartofcontestseason.Regardlessofwhenyoudoit,inspectingyourinstallationshouldbeappearsomewhereonyourownpersonal“todo”list.

AChecklistApproachWhileI’veoftenjoked,sayingthatthisis“onejobwhereyoucanstartatthetop,”thatisnotliterally

true.Anytowerinspectionhastobeginontheground,ofcourse.Andyoubeginbyexaminingthetowerbaseandguyanchors(ifapplicable).Youarelookingforanyhardwarethatmighthavecomeloosesincethe last inspectionand fallen to theground.Youare lookingat theconcreteandbasearea for signsofwinterweatherdamage(cracksandthelike).Youarelookingattheanchorswheretheyleavetheground.It’snotabadideatoactuallydigupthesoilsurroundingthoseanchorsjustabit,toseeifthere’sevidenceofcorrosionorloststeelbelowgrade.Figures10-1through10-4showsomeoftheproblemsthatmaybelurkingbelowthesurface.

Withthegroundinspectioncomplete,I’mclimbingtothetopofthetowerandworkingmywaydown.AllRFandcontrolcablesfastenedtothetowerwillbeinspected.Electricalconnectionstorotatorsandantennaswillbeinspected.Towerboltsandnutswillbevisuallyinspectedfortightness.Ifneeded,I’llretapeorsecurelines,alongwithcoaxandcontrolcablesasIgo.While thismay soundoverly complicated, once you’ve done it, it becomes almost secondnature to

climbup,takeaquicklookaround,tugandpullonvariousthings, thenbeginworkingyourwaydown.Evenatalltowercanbecompletedrelativelyquickly,onceyou’refamiliarwiththings.Andifit’syourownstuff,youwillbe,orshouldbe,familiarwithit!

KeepingTrackAllthissearchingandlookingshouldberecorded,preferablyintheStationNotebook(youdohavea

stationnotebook,don’tyou?). If there is evidenceofpossiblephysicaldamage,or if something showsearlysignsofdeterioration,it’sagoodideatodocumentitwithsomepicturessoavisualrecordexistsforlatercomparison.ThesidebardetailsmythoughtsforaStationNotebook.ThesectiondedicatedtoTowershasentries

forvariousmeasurementsanddata,alongwithsomeproceduresandguidelines. Table10-1showssometopicstoinclude.

Table10-1TowerandAntennaInspectionChecklist

TowerBaseConcrete:YardsusedinconstructionMaintenanceperformed

AnchorsConcrete:YardsusedinconstructionMaintenanceperformed

GuyWireTensionsSet1Set2Set3

TurnbucklesSafetywiresPreformGuyGripsorCrosbyClips

GroundSystemCondition&LightningProtectionSystemGroundrods&wires

TowerHardwareChecktowerforplumbGuybrackets

AntennasInstallationdate(s)SWRrecordings/band

Cables&ElectronicsInstallationdatesLength,colorcodes,connectors

TheStationNotebookshouldbefleshedoutwithdetailsforyourinstallation.Forexample,someoftheactivitiesorproceduresmightread:1)Eachtowerbasewillbecheckedforrustorotherdeteriorationofsteelandanyaccumulateddirtor

otherdebriswillbetotallyremoved.2)Towerplumbtobecheckedfromtoptobottom(usingatransit,orapairofthem),andcorrectedby

re-tensioningtheguysasneeded.3)Alltowergroundwiresandgroundrodstobeinspected.While the simple list presented here is not as complete as what you should have in your Station

Notebook,youcanseewhatwe’regettingatwiththissortofrecordeddetail.Whatwe’relookingforisasystematic examination of various mechanical and electrical items, with places to describe what’s

happenedovertimeandnotewhatneedsattention.Writingitdownmakessense.Youwillforgetdetailsastimepasses,sohavingawrittenrecordmakesyourjobmuch,mucheasier.Andwhile the example shownhere ismyold,originalpersonalNotebook, collected in a three-ring

binder,there’ssomethingtobesaidforkeepingsuchfilesonacomputerinstead.Isuggestthismostlyduetotheeaseandconvenienceofdigitalphotographsthesedays.Documentingthingshasneverbeeneasier,andsinceI’veacquiredalaptop,ostensiblytouseinwritingthisbook,I’vetakentostoringandrecordingawiderangeofthingsonit.IimagineI’llhavetheStationNotebooktherebythistimenextyear!

SomeThoughtsonTowerSteelMaintenanceMost towers hams own are made from steel. Most are protected from environmentally induced

corrosion in one of threeways: paint, hot dip galvanizing, zinc coating or some combination of these.Paintisconsideredtheleasteffective.Itdependsuponthepaintformingaprotectivecoatingtosealthesteelfrommoistureandothercorrosiveagents.Ifchipped,thesteelunderneathwillbegintocorrode.Hotdipgalvanizingisthemostwidelyusedprotectivemethod.You’veheardofit—itwaspartofRohn’smagazineadvertisingforyears.Hotdipgalvanizingmeansthoroughlycleaningthesteel,thensubmersingitinamoltenzincbath.When

removed,thezincformsathick,abrasion-resistantcoatingthatismetallurgicallybondedtothesteel.Thezinc coating protects threeways. First, the coating is an effective barrier againstwater and corrosiveagents.Second,thezincdissolvestoprovidecathodicprotectiontoanyexposedsteel.Third,overtime,the zinc forms zinc carbonate, which seals over any damaged areas in the coating. It’s this cathodicprotection that differentiates this coatingmethod from all others. Zinc ismore anodic than the steel itcovers.Smallscratchesorcuts in thecoatingmeancorrosionproductsprecipitateon thesteelsurface.Corrosionwillnotoccurbetweenthezincandthebasesteel.(Ifyourememberhighschoolchemistry,youknowwe’retalkingaboutagalvaniccell.)Inhotdipping,severallayersofzincform—100%zincatthesurface,rangingthroughvariouslayersofalloysto100%steelatthebase.

TheStationNotebook

WithapologiestoHenryDavidThoreauI’m often surprised to discover that fellow hams (or clients) do not have, nor keep, notebooks

concerningtheirstations.Somethinglikeanaturalist’ssetofobservations,ifyouwill.Now,ahurdlefortoday’sactivehamcanbethehighcostofgear, includingtestorrecordingequipment.Yet,oneofthemostusefultoolsavailablecostsnexttonothing—thesimplestationnotebook.Whybother?Anumberofreasons,ofcourse,buthereareafew:1)Youcanandwillforgetthings.2)Youwillhavedatatocomparewhenthingsgowrong.3)Youwill learnmoreaboutyourstationbecausenote-takingwillactuallyimproveyourabilityto

observe.I’veoftenheardfolkssaytheyliketousethebacksoftheirstationlogbookpagesforthissortofthing,

andIusedtodothatmyself.Butitquicklybecameapparentthissortofrecordkeepingwassimplytoorandom—therewasnoeasywaytofindorretrieveanyinformationonceI’drecordedit.Obviously,whatIneededwassomethingabitmoreorganizedandserious.

And thiswill probably comeas a shock in today’sdigital-everythingworld, but I still like ahardcopyinsteadofelectronicformats.Ifindit’sfaster,moreconvenient,lesspronetolossortheft,andwaymoreportablethananycomputer-orientedsystem.Useindexcards,loose-leafnotebooks,asketchpad,or whatever works for you. Check out stores that sell artist, school or office supplies for suitablesolutions.Ilikethethree-ringloose-leafnotebookapproach(Figure10-A).Iuseregularlinedpaperfornotes,

alongwithgraphpaperfordrawingsorsketches.Thestandard8½×11sizemeansIcaninsertcopiesofarticles(whererelevant),too.Useawaterproofinkpen,notpencil,fornotesandsuch.

Whataresomethingstoinclude,orhowcansuchanotebookbetrulyuseful?Innoparticularorder,considerseveraltabsforvarioustopicsorsubjects.Ihavesectionsfor:Serial numbers. When I purchase gear, I record relevant data here, including model and serial

numbers.Everythingisinoneplace,whichmakespreparingalistpriortooverseastravelsimpleandfast.Andit’salsoagreatinsurancetool(althoughoneIhopeyouneverhavetouse,andI’mspeakingfromexperiencehere!).Iincludeinformationfromthesuppliedmanualaswell,incaseit’slaterlostormisplaced.Antennasystem.Thisisthelargestfile,andperhapsthemostimportant.BesidestheusualSWRor

impedance readings and descriptions, I include data on the type of coax or feed line, including dateinstalled,informationonconnectorsandthecolorcodeused.Aschangesoccur, thesegetrecordedaswell.Towers. This is the second largest file, with installation data and maintenance data. It includes

recordingsofguytensions,hardwareused,relevantdataontowerbasesandguyanchors,andsoforth.Onceor twiceayear,when the tower inspectionrollsaround, it’sespeciallyhandy tobeable toseewhat changeshaveoccurredorwhat repairsneed tobedone.Again, as changes takeplace, theygetrecordedhere.Rotatorsystem.Similar totheantennafile,withvoltageandresistancereadings,colorcodes,and

otherpertinentdata.Stationsignalflow-chart.Ablockdiagramofeverysignal(RF,AF,logicandkeyingorcontrol)or

circuitpathinyoursetup,thisisthetypeofthingyouoftenseeinNCJorQSTarticles.It’samazinglyhelpful when things go wrong or stop working to be able to know exactly (especially when you’re

suddenlyfrustrated)whateachboxissupposedtodo.AllthecableIDsorlabeltagsgetrecordedhere,too.Work list. The one area where I’ll allowmyself to throw things out afterward, or otherwise be

sloppy.It’soneham’sapproachtothosesilly“thingsIgottado”notebooksyouseeforsaleindiscountstores.Inoneplace,Icanmapoutorwritedownprojectideas,vendorinformation,contactinformation,reactionsfromfellowcontestersorideasgleanedfromarticlesortheInternet.Inshort,it’sacatch-allarea,aplacewhereIplanforthefuture.Thekeyfactorforthistabisthat,onceit’swrittendown,Ihaveamuchgreatertendencytorecallorrememberit!Such recordkeeping and summaries of your station building, along with operational notes, will

increaseyourability to troubleshootandrepair thesystemwhenitbreaks.Trustme—this isagoodidea.And,I’mwillingtowager,you’ll feelsomefurthermanifestationofprideoraccomplishment inmakingsuchjournalentriesorsummaries.Alittleglancebackward,towardThoreau,whosaid,“IfeelasifmylifehadgrownmoreoutwardwhenIcanexpressit.”It’saperfectmetaphorforradio’sabilitytoexpressandexplore,aswell.

Hams often attempt painting maintenance on hot dip galvanized towers, with varying degrees ofsuccess. Here’s why. Upon removal from the dip, the zinc coating begins a variety of chemicaltransformations.Theouterlayer(that100%zinc)oxidizes.Zincoxide,zinchydroxideandothersurfaceconditions can be present from48 hours up to several years after galvanizing. In any case, this oxideprevents paint fromadhering to your tower.Light sandblastingor a high-pressurewash followedby ametalconditionerisrequiredforproperpreparation—usuallynottoopractical,regardlessofwhetheryou’vegota200footor50footbeautyinyourbackyard.Asimplecleaningwithvinegarwillprovidethesimplestandcheapestapproachtohelpingyourpaintadheretoahotdipgalvanizedsurface,though.Trythat,beforegivingup.ASTM standardA123 covers hot dip galvanizing. Basically, your inland-USA tower should last at

least30yearswith a typical3.4 to3.9mil thick zinc coating.At aminimum,your towerwill requiretouch-upaftererection.Overtime,youmaynoticeruststainsorcorrosion.Whatyou’reprobablyseeingisrustfromlegboltsorotherhardwareyou’vefastenedtothetower.Orsomethingmayhavedamagedthegalvanizedcoatinginsomefashion.What should you do? Touch up those parts or areas of your towerwith zinc-rich paint such as the

Rustoleum,ZRCorBriteZincproductsfoundinmanyhardwarestoresandhomecenters(Figure10-5).Readthelabeltoguaranteeyou’regettinggoodpaintandexpecttopaymorefortheproperpaint.Readthelabelagainregardingpreparationandapplication.Mostofthesepaintsarenotintendedtobeappliedor used in periods of high humidity — usually just when we’re thinking about doing this sort ofmaintenance.However,there’sreallynoalternative.

Most experts will tell you that quality paint, properly applied, will adhere well and will furnishprotection,assumingsomezincremainstoprovidecathodiccoveragetothesteelbaseofthetower.So,with somesurfacecleaning,agoodzinc-richpaint is indeeda solidmaintenancemethod.Figure 10-6showstouch-upofboltholesatthebottomofatowersection.

PuttingitallTogether

Thepreviouschaptershavecoveredthevariousconsiderations,techniquesandtoolsforplanningandinstalling a ham radio tower. The narrative, or story, of this chapter suggests how it might all cometogetherforyourfirsttower.

ATowerfortheTakingOnenight,aftersupper,yourphonerings,andthecallerisEd,yourhambuddyacrosstown.Heknows

you’ve beenwanting a tower, and he has a line on a tower that’s available free, providedyou take itdown.It’slocatedatanoldtaxicompany,andtheownerofthebuildingwouldlikeitremovedwithinthemonth.Ed’snot toosurehowhighit is,buthethinksit’s50or60feet tall.Hepromisestohelpyoutakeit

down,andheissuresomeotherclubmemberswouldbewillingtohelpwiththiswork,aswell.Yourquestion:Isitworthpursuingthis,ornot?Acoupleofnightslater,youstopattheaddressonyourwayhome.ThetowerappearstobeRohn25

with two small vertical antennas, onemounted on the very top of the tapered top section, and anotherabout10feetdown.Heliaxfeedlinerunsupthetowertobothantennas;you’reprettysureyoucouldusethat,too.Youcountthesections.It’sa50-foottower,allright.There’sahousebracketneartheeavesofthebuilding,about25 feethigh.And thereare threeguywires, atwhatyou’ve read is theappropriate120-degreespacing.Theylookliketherightstuff,EHS(ExtraHighStrengthcable).Twogotoelevatedguyposts,madefromI-beammaterial.Onegoestoautilitypoleandisattachedtoaverylargeeyebolt,securedthroughthepole,apparentlytoallowclearanceoverthedriveway.Thesectionsalllookstraight.Norustisvisible;indeed,thegalvanizinglooksgood,consideringthis

towerhasbeenhereforatleast10to15years.Edsaidthebuilding’sownertoldhimthetowerhadbeenputupbyacompanyhereintownthathassincegoneoutofbusiness,buttheywererealprofessionals,havinghadsomethingtodowiththelocalAMbroadcaststationandtheirtower.

WhatWillYouNeed?Youhavetodecide,andsoon,whetheryoushouldpursuethis,ornot.Havingreadabitabouttowers,

youknowtherearecertainsomewhatspecializedtoolsyouwillneedtotakethistowerdown.Aginpole,firstofall,allowsyoutostackorremovethe10-footsectionsoneatatime.Togetthesectionsapart,everyonerecommendssomethingcalledaTowerJack.Thenthere’stherope

required—at least 150 feet of it, toworkup anddown the tower, in andout of the gin pole,with acomfortableworking length on the ground.You’ll probably need somepulleys, somehand tools and a

smalltrailertohaulthesectionshome(youknowyoucanborrowEd’s).Thenthere’sthequestionoftime,gasusedinferryingthingshereandthere,andsoforth.

“Neverhavinghadatowerbefore,yourealizeyoudon’thavethenecessarysafetyequipment,northe

knowledgerequired.”

Neverhavinghadatowerbefore,yourealizeyoudon’thavethenecessarysafetyequipment,northeknowledge required.You’re probably not ready to climb this one.At least notwithin the span of onemonth—thetimerequiredinwhichyoumustremovethetower.So,youdecidetogetsomeoneelsetohelpyou,todotheworkyouarenotyetpreparedtodo.YoucontactGary,oneof the“biggun”DXers inyour local radioclub,whohas three towersathis

home. Even though Gary’s retired, a distinguished-looking white haired gentleman, you know he stillclimbshistowers.Youaskhimforhelp.Garyspendsnearlyanhourwithyouon the telephone,goingover theentireprocessof takingdown

suchatoweracoupleoftimes,explainingnotonlyhowtheworkshouldproceed,butexplainingthewhybehind several of the procedures. He agrees to help you on Saturdaymorning, providing theweathercooperates.

WorkDayArrivesSaturdaydawnswithtempsinthe50s,theskyalreadyblueandbright.Gary calls while you’re grabbing a bite to eat, to assure you he’ll be heading to the tower site

momentarily.Yourealize it’sevenfurtherawayfromhisQTHthanyours,whichmakesyoufeelguilty.Youmakeanotetostopbyadonutshopforcoffeeandgoodiesonyourwaytothesite.Whenyouarrive,Gary,Edandacoupleotherhelpersarealreadythere.Gary’saretiredmanagerata

local electrical utility, and his calm command presence puts you at ease right away. He’s alreadyexplainedtoEdandtheotherswhat they’llbedoingtoday; it’s justwhathedescribedtoyoutheothernightonthetelephone.Gary digs at the basewith a small shovel, telling you hewants to confirm the base is not only the

proper size anddepth, but also still solid.Then, hewalksover and inspects each anchorpost, payingparticular attention to the utility pole. He tugs on an elaborate-looking bright blue-colored webcontraption, festoonedwithhooks and rings, then stepsup andonto the tower.He reachesup, snaps alargehookoverhisheadandclimbsup,repeatingtheprocessashegoes.Younoticehehasanotherlooparoundthetowerathiswaist.Youalsonoticehe’scarryingathinropeattachedtothatbelt.Hestopsandspendsconsiderabletimeatthehousebracket,obviouslyinspectingitclosely,too.Then,heclimbstotheguybracket,andstopsthere.Satisfied,hedropsthethinropetotheground.Ed

takesthealreadyattachedclipandhooksontotheginpolelyingontheground,thenpassestheothersideoftheropeintoapulleythat’sclippedtothetower.Waitaminute…howwasthatpossible—withouthavingtheendoftherope?Edsmiles,andshowsyouthepulley,whichrotatesapart,allowingyoutoattachitatanypointontherope.“Garyhassomereallycooltools,”hesays.Thenhestepsbackawayfromthetower,pullingthepoleup,slowlyandsteadily.WhenGaryhollers,Edstops,andsoontheginpoleisattachednearthetopofthetower.Next up the tower is a small bag of tools, and before you know it, Ed has you carrying a small

stepladdertooneoftheelevatedguyposts.Garyhasleftaspraycanoflubricant,withinstructionstouseit on the turnbuckles and bolts.You do, and then slowlywork the turnbuckle back and forth, until it’sturningfreely,andloose,untilGarysaysstop.Yourepeatthisprocesstwicemoreattheotheranchors.Bythen,youseeEd’sat thebaseof the tower,helpingGaryloweroneof theverticalantennas.The

secondone follows in short order, then theHeliax feed line.Youdidn’t notice it, but apparentlyGaryloosenedorcutthetapesecuringittothetowerlegsasheclimbedup.Everyoneworkscarefullytomakecertainthefragilefeedlineisn’tdamagedorkinked,coilingitintolarge-diameterreelsonceit’sontheground.YouseeEdandtheothertwohelpersworkingattakingoneguywireloosetotally.Youwalkbacknear

thetowerbase,relativelyfrightenedwhenyourealizethatGary’shangingonuptherewithnoguywiresattached.Butyounoticethatthetower’snotmovingverymuch,andyoufigurehemustknowwhathe’sdoing.Asifhe’sreadingyourmind,Garysays,“Sincewe’veonlygottwoun-guyedsectionsabovethehousebracket,wecansafelytakedownthetopsectionaftertakingofftheseguys.”Andseeminglybeforeyouknowit,that’sexactlywhat’shappening.Withverylittleapparentefforton

anyone’spart,thetopmostsectionisupandseparatedfromtheothersections,danglingthereontheginpolerope.Threeofyoucarefullylowerittotheground.You’resurprisedathoweasythisis,butthen,Gary’sprobablydonethisdozens,perhapshundredsoftimes,andhehasthetools.Besides,thesectiononlyweighs35pounds…butyou’reexcited.Itis,afterall,yourfirsttower!Thetakedownproceedsquitesmoothly,andsoonyou’restaringatfivepiecesoftowerloadedonEd’s

trailer.Heevenofferstohaulittoyourhouse.Garyasksifyou’vefiguredoutwhereit’sgoinginyourbackyard, andyouownup that, no, you’ve looked around theyard several times, but reachedno finaldecision.Heofferstocomeoverandlookatthings,andyouofferhimlunch.Heacceptsandyoureachforyourcellphone,checkingwithyourwife….

PlanningYourNewTowerOnMondayevening,afterwork,Garydrivesovertoyourhouse.Youchatabouttheyarditself,your

shacklocation,andwhatyourfamilyhastoldyou.Hehasafiberglasstapemeasure,andasimplelayouttool,apieceofplywoodthathasatoweranditsassociated120-degreeguyspacingdrawnonit.Usingit,he paces out the orientation possible (behind the garage) and thenmeasures the distances for the guyanchors.Heputsyouatease,talkingabouthisownfirsttowerandbeamyearsago,sharingsomestoriesandaskingwhatyouwanttodowithyourownfirst tower.WhileyoufeelabitawkwardtalkingaboutDXingwithsomeonewho’sworkedeverything,everywhere,severaltimesoveritseems,Garyispleasedwithyourenthusiasmandassuresyouthere’llbegreattimesahead,oncethebeamgoesup.Heoutlineswhatyoushoulddonext,thethingstohavewithyouandsoforth,whenapplyingfortheusagepermit(allyourcountyrequires)forthetower.So,withallthatinmind,youarrangewithyourmanagertopossiblycomebackabitlatefromlunchon

Wednesday,anddrivetoyourcountyzoningoffice.Ittakesafewminutestofindtherightdepartment,but

yougo inandaskwhatyouneed todo toobtainapermit forahamradio tower. Inyourbriefcaseareseveral items Gary suggested you bring along— the relevant pages copied from his Rohn technicalcatalog,showingthebaseconstructionforyourtower, theguyingrequirements,andtheplatdrawingofyour property, along with another drawing showing where and how the tower will be placed on theproperty. The guy behind the counter yawns, tells you that you don’t need a building permit. But youpersist,andexplainexactlywhatyoudoneedorwant,andbeforelong,theusepermitisissuedtoyou.

You’reonyourway!

WorkingintheDirtHavingsecuredthenecessarypermit,youknowthenextstepwillbediggingaholeforthetowerbase

andguyanchors,andthenpouringconcrete.Garyhasmentionedtoyouthattheoriginalinstallationusedabasesectiondesignedspecificallytobeburiedinconcrete,whichyou’veleftinthegroundattheoldtaxiservicecompanylocation.Therefore,you’llneedsomethingtoreplace thatandalsoyou’llneedtobuythreeguyanchorrods.YouaresurprisedtofindasectionofRohntowerlyingnexttoyourgarageoneeveningafterwork.E-

mail fromGary explains that you’ll simply bury part of this section in the ground as your new base,replacingtheoriginally-buriedRohnbasesection.Theman’sgenerosityandwillingnesstoshareamazesyouonceagain.His e-mail contained thephonenumberof a backhoeguy, soyou call, and arrange tomeet himone

evening afterwork. Turns out he’s not a stranger to digging tower base and guy anchor holes, havingworked forGary previously.He understands the importance of creating a smaller hole, and one that’ssquare.Hementionshe’ll beusinga smallerbucket todigyourbase.Youarrange that for the comingweekend.Garydoesn’tleaveyouhangingonthisproject,comingoveroncetheholeisdugtoguideyouthrough

theconstructionof a simple timber2×6 framed formsurrounding thehole.Withhishelp,youvisit thelocalhomecenterandpurchasesomerebar,alongwithsomeother“essentials,”fromalisthe’scarrying.Laterthatday,heshowsyouhowtomakeasimplecageforthebaseandanchorholes,andbeforeyouknowit,you’rereadyforconcrete.Turnsout,oneofthoseextrahelpersfromthetakedownprojectisamason.Hegetsyouabetterdealon

the concrete— using a Ready-Mix factory truck to deliver some 4000 PSI mix. You’ve done someInternet research and you think you can smooth out the concrete.Gary has set and plumbed the towersectioninthehole,includingseveralinchesofgravelatthebottomofthebasehole,fordrainageofthetubularlegs.Then,he’dsecuredit(wiredtosome2×4s),soitcannotmoveoutofplumb.TheReady-Mixdriveriscautious,andeasestheheavyconcreteintothehole.Beforelong,youhavethebasesmoothandlookingfairlyprofessional(evenifyoudosaysoyourself).Nextarethethreeearthanchors,whicharesmallerandeasier.Youpaythedriver,andheasksyouwhatyou’rebuilding.“It’saradiotower.Myfirst,”youexplain.Thatnight,Garycallsonthephone.Youtalkabouttheprocessofallowingconcretetocure,andhowto

proceedwiththeremainderoftheproject.

StackingSteelOnenight,Garycallsandsaysit’stimetoactuallybeginputtingthetowersectionstogether.Again,he’s

alreadyorganizedthings,ifyourschedulewillpermit,andsoforth.

Youagree,andtheweekendbringshelpfromthesamefellowswhohelpedwiththetakedown.Garyhasasmallsectionofplywoodonthegroundnearthebasesection,andhe’sexaminingeachleg

ofeachsection—peeringdown,saying it’s important therearenoobstructions(wasporspidernests,clumpsofdirt,andsoforth)lodgedthere.Anythingthatcouldallowwatertocollectandpossiblyfreezeandcrackthetowerlegmustberemovedbeforeassembly.Manyofthesametoolsusedatthetakedownareinevidence,eventheTowerJack.Youthoughtthatwas

used to separate sections, but in a few deftmoves,Gary shows you how it alsoworks in reverse—pulling theRohnsections togetherusing theZ-bracing.Prettyclever.Soon,hehasput together the foursections,andmarked themwith somecolored tapebands,assuring thatwhatmateswellon thegroundwillgoeasilytogetherintheair.Again,simplebutprettyclever.Soon,he’sonceagainsteppingupandontothefirstsection,cementedinplace,attachinghisginpole,

andalmostbeforeyouknow it, there’syourvery first sectionof tower, bolted intoplace, and lookingmighty good. Garymentions that the piece of plywood helps keep each section out of the dirt as it’sprepped to behauledupon the gin pole.He showsyouhowheputs a small amount of grease on theswagedsideraillegs,andhowhedoesnottightentheboltssomuchthatthetubingiscrushed.Thiswillensurethetowercaneasilybetakenapartlater,ifneedbe.Yourealize,onceagain,you’relearningalot.Thegroundcrewguysareusedtothisprocess,obviously,andtheyhaveaneasy-goingrhythmtothe

work,layingouttheshinynewEHSguycable,thenpullingituptoGaryonthetower.YouwatchastheyinstallthePreformBigGripDead-ends,marvelingattheeaseandspeedwithwhichthesedevicesmakeshortworkofgettingtheguysonthetowerandattachedtotheguyanchors.Thebronze-lookingclampsused tohold theguywires inplace temporarily,you learn,arecalledKleinGrips,and they’reanotherclevertool.Shortlyafterlunchtime,yourtowerisfinished,atleastintermsofhavingallthesectionsassembled,

theguysattached,andeverythingtensionedandsecured.Garysuggests thatwaitingaweekwouldbeagoodidea—givingtheguysachancetostretch,thehardwaretocyclethroughsometemperaturechanges,andsoforth.Staringnumblyupatwhatseemsaverytalltower,youmumblesomethingthatsoundslikethankyou.Then,yourealizethatmaybeitwouldbeagoodideanotonlytothankeveryone,buttoprovidelunch(asintended),soyouhurriedlysuggestsomeburgersandfranksfromthegrillwillbeforthcominginshortorder.

SomeFinalThoughtsHavingputupyourveryfirsttower,withthehelpoflocalradioclubfriends,especiallyGary’s,which

includedevenbuyingand installingoneofhisold tribandYagis,you’ve learneda tremendousamount.You’vebeenontheairmoreoften(despitesomedisappointingpropagation),includingexperiencingsomesuccess on the low bands from the wires mounted on the tower. You’ve even experienced your firstcontest,somethingyou’dnevertriedbefore(andhadfun!).One night, after dinner and the local news, you found yourself sitting in your armchair, looking out

towardthetowerandantennas,contemplatingsomeofwhattheexperiencehastaughtyou.

“Indeed,thewholeprocessofknowingwhencertainbands

areopenandwhyhasbecometotallyfascinatingtoyou.”

You’ve learned something about mechanics. You’ve learned something about construction. You’velearnedsomethingaboutthephysicsofradiosignals.Indeed,thewholeprocessofknowingwhencertainbands are open and why has become totally fascinating to you (Gary suggested all along this wouldhappen.). You’ve learned something about several of your local radio club friends, too.Without theirhelp, the entire projectwould never have happened, after all.You’ve learned some things about yourneighbors,yourlocalgovernment(notallofthatwaspleasant,butlearningissometimespainful).You’velearned(youthink),evenmoreaboutwhatitmeanstobeaham,andfeelmoreconnectedtothehistorybehindthat,insomesmallway.The very process of putting up the tower, learning how to climb it and work on it, and using the

antennasyouputup—allofthathasmadeyou,ifnotabetterhamorperson,atleastmoreawareofagreatmanymorethingsthanyoufirstthoughtpossible.That’sprettyamazing,yourealize.Prettyamazing,andspecial, too.Youwonderwhat’sonthebands

rightnow,andheaddowntoyourbasementhamshack....

Insurance

Havinginvestedsometime(justingettingtoChapter12,aswellasinthebuildingofyourstation!)andperhaps some considerable funds in your antenna system, it’s only logical to consider insurance.As ahomeowner(orevenasarenter),youdohavesomechoiceswhenitcomestoinsurance.Thefirstplacetostartiswithyourownpersonalinsuranceagent.I’veinterviewedsomeagents(locally,onlineandattheDaytonHamvention),andtheiroverwhelming

reactionwasdisbeliefthatthehomeownerdidnotread,understandorappreciatetheirowncoverage.Inevery instance, thoseagentshadhorrorstoriesaboutownerswho thought theywerecovered,butwerenot.Ineveryinstance,thislackofknowledgeamongpolicyholdersnotonlydisappointedthem,butalsosaddenedthem.(Alloftheagentsmentionedtheywanttofinalizeanyandallclaimsquicklyandsmoothly—theywanttogetthemoverwith!)So,talkwithyourlocalagent,andfollowhisorheradvice.Don’tguess,orsimplyhopethatyou’recovered.Afterallthisresearch,itbecameapparentIneededsomeprofessionalassistancetoadequatelyprepare

thischapter.Iwasdeterminedtomakethischapternotonlytechnicallyaccurate,butalsousefulinsomeadvisoryorpreparatoryway—mygoalfortherestofthebook.Withthatinmind,IcontactedRayFallen,ND8L,aStateFarmInsuranceagentinHubbard,Ohio.Ray

wroteanarticleoninsurancethatappearedintheFebruary2009issueofQST.Afteraseriesofemails,andanextendeddiscussionatDayton,IaskedRaytoexpandonsomeofthetopicsfromthatarticleforthisbook.I’mpleasedthatheobliged.

Homeowner’sInsurance:

YourAntennaSystemandYourGearByRayFallen,ND8LManyyearsago,Iwasjustlikeyou.I’dbuyaninsurancepolicytoprotectmyhome,mycar,mylifeor

myhealth.Whiletheagenttriedtoexplainit,myeyeswouldglazeoverandmybreathingwouldslow.Iwouldnodmyheadknowingly,makealloftheappropriate“WhyYes,Mr.InsuranceAgent,yourAmazingExplanationjustcouldn’tbeclearer”noises…andinmyheadavoicewaswhisperingtheNovenaoftheNewlyInsured:“Ifsomethinghappens…Isurehopeit’scovered…forIhavenotonesinglecluewhatthisguyistryingtotellme.”Then,onFebruary1,1988,IwentovertotheDarkSide.Ibecameaninsuranceagent.This chapter in Don’s book shares some of what I’ve learned in that time about homeowner’s

insurance,yourantennasystemandotherhamgear.

CaveatsandStuffLikeeverythingfrombulldozerstoyourmorningoatmeal,thischaptercomeswithsomedisclaimers:1)Mosthomeowner’sinsurancepolicieswrittenintheUS(exceptinTexas,andnobodyknowswhy)

arebasedonstandardlanguageprovidedbytheInsuranceServicesOffice.Eachinsurancecompanymodifies that language to comply with individual state insurance statutes … so coverage thatappliestotowersinOhiomaynotnecessarilyapplytotowersinFlorida.

2)Coveragevariesfromcompanytocompany,statetostateandcountrytocountry.3)Becauseofthesevariations,thischaptercan’ttellyouexactlyhowyourantennainstallationwillbe

covered.Icangiveyousometalkingpointstofollowwhenyouvisitwithyourinsuranceagent.Andyouaregoingtodothatrealsoon,aren’tyou?Let’sbeginatthebeginning.Aninsurancepolicyisalegalcontractbetweenyou(TheInsur-ed)andthe

company (The Insur-er). The contract is quite specific in its definitions, coverage, and the duties andresponsibilitiesofbothparties.Forexample:1)What’scoveredinthepolicyisinthepolicycontract.2)What’snotcoveredinthepolicyisinthepolicycontract.3)Yourdutiesfollowingalossareinthepolicycontract.4)Howthelosswillbepaidis,youguessedit,inthepolicycontract.Ifyou’restartingtoseeapatternhere,gototheheadoftheclass.Here’s the problem: I said the policy was specific…I didn’t say it was always easily understood.

Insurancepolicies are legaldocumentswritten in anobscureOldeEnglishdialect calledLawyer.Youneed tovisit your agent,whocan translateLawyer intoEnglish. If you’replanning an installation, seeyour agent before you start. If your tower’s already up…what are you reading this for? Go see yourinsuranceagent…rightnow!

PropertyCoverageDamage to towers, guy wires, rotators, tower-mounted antennas and related cabling is covered by

DwellingExtensions,OtherStructuresorAppurtenantStructurescoveragelistedontheDeclarationPagesofyourHomeowner’sPolicy. (Thespecificnameandamountof thecoveragevariesbycompany.)Forexample, State Farm’s Ohio Insurance Homeowner’s Policy defines Dwelling Extensions as “otherstructureson the residencepremises, separated from thedwellingbyclear space.”Hmmm…starting tosoundlikeLawyer,again.DwellingExtensionsarepermanentlyattachedtoorotherwiseformapartofyourproperty,butthey

arenotphysicallyattachedtoyourhome(dwelling).DwellingExtensionsaretypicallycoveredfor10%ofthedwellingcoverageamount.Forwemeremortals,thismaybemorethanadequate.Atlargeconteststationswithmulti-kilobucktowerandantennasystemssuchasK3LR,K8AZ,W3LPLorNR5M,thatmaybeanentirelydifferentstory.If your tower is physically attached toyourhome (dwelling), then the cost of the tower and related

equipment should be added to dwelling coverage on your policy,not dwelling extension coverage. Iftherearequestionsinyourmind,thiswouldbeanexcellenttimetohaveyourinsuranceagentdropbythehouseandtakealook.Remember, tower replacement costs should include professional help in removal, repair or

replacement, in addition to the replacement cost of the damaged gear. Also, consider other dwelling

extensionitems:fences,sheds,polebarns,gazebos,detachedgarages,flagpolesandin-groundswimmingpools,forexample.Addupthereplacementcostofthosestructuresandifyouneedmorecoverage,buyit…now.Ifyou’renotsureofthereplacementcostofthosestructures,youragentcanhelp.

Wireantennasintreesand/orground-mountedverticalsaregenerallynotpermanentlyaffixedtoyourproperty (sometimesmuch lesspermanently thanwe’d like)andareconsideredpersonalproperty.Thegoodnewsispersonalpropertyiscoveredfor50%to75%ofthedwellingamount…thebadnewsisthe

coverageisnotasbroadasdwellingextensions,butwind,ice,vandalismorlightningdamageisusuallycovered.(ReviewthediscussionofnamedperilsintheARRLHamRadioEquipmentInsurancesectionwhichfollows.)Thedistinctionbetweendwelling(anddwellingextensions)andpersonalpropertyis:Ifsomething’s“naileddown”andnoteasilymoved,it’sdwellingordwellingextensioncoverage.Ifit’seasilymoved(evenifit’s“naileddown”),it’spersonalproperty.Believeitornot,mostinsurancecompanieslookatin-groundswimmingpoolsasdwellingcoverage,

butabovegroundpoolsareconsideredpersonalproperty,sincetheycanbetakendownandmoved.Hey,Idon’tmakethisstuffup!

Let’sreview,shallwe?ACushcraftR-7000verticalmountedonapieceofpipepoundedinthegroundis personal property. Eighty feet of guyed Rohn 55G in 15 cubic yards of reinforced concrete is adwellingextension.Noclaimsadjusterwilleverconfusethetwo.Oneotherthing.Ifyouhavetowersandequipmentonpropertyyouownorrentawayfromyourprimary

residence, make sure your agent knows. Some homeowner’s and renter’s policies have significantcoveragelimitationsforoff-premisesstructures(towersandantennas)andpersonalproperty(radiogear,computersandthelike).

ARRLHamRadioEquipmentInsuranceAveryviablealternativetoyourhomeowner’spolicyistheARRLsponsoredHamRadioEquipment

InsurancePlan.MoredetailsonthisplanareavailablefromtheARRLWebsite(www.arrl.org).Thisprogramprovidesprotectionfromthepropertyhazardsweall faceandtheaccompanyingcosts

thatcanfollowfromlossordamagetoyouramateurstationandmobileequipmentbytheft,accident,fire,flood,tornadoandothernaturaldisasters.Antennas,rotatorsandtowerscanbeinsuredtoo.And,unlikemosthomeowner’spolicies,yourequipmentiscoveredifdamagedbyanearthquakeorflood.You’reevencoveredforthereplacementcostofcomputersoftwaresuchasdisksandtapes,including

reimbursement of the expense of reprogramming for up to $1000 per claim, if you have computerhardware scheduled on your policy.Computer equipmentmay include televisions, recorders andothermonitoring systems that are related ham radio accessories. And, your equipment and accessories arecoveredinyourcar,truckorRV,aswellasyourhome.YoushouldcompareotherinsurancecoveragewiththeARRLplan.You’llfindthisplanlessexpensive

withbroadercoveragethansimilarplansavailable.Infact,theARRL“All-Risk”HamRadioEquipmentInsurancePlanisoneofthemostcomprehensivepoliciesyoucanbuy.

ARRLInsurancevsYourHomeowner’sPolicyMosthomeowner’s insurancepolicieswill providewhat is called “namedperil” coverage for your

accidentaldirectphysicallosstoyourcontentsorpersonalproperty.Thecoveragecanvaryfrompolicytopolicy…buthereisapartiallistofnamedperilsfromStateFarm’sOhioHomeownersPolicy:1)FireandLightning2)WindstormorHail3)Explosion4)Riotorcivilcommotion5)Aircraft6)Vehicles7)Smoke8)Vandalismormaliciousmischief9)Theft(withlimitationsonspecificproperty,suchasjewelryandfirearms)10)Fallingobjects11)Weightofice,snoworsleet12) Sudden and accidental discharge or overflow of water or steam from plumbing, heating, air

conditioningorfiresprinklers13)Freezingofplumbing,heating,airconditioningandhouseholdappliances14)Suddenandaccidentaldamage toelectricalappliancesandsystemsfromvariations inelectrical

current15)Glassbreakage.Each of these perils comeswith some limitations that are defined in your policy. For example, you

can’tgotoFloridafor thewinter, turnoff theheat inyourhomeandthenfileaclaimforfrozenpipes.Again, there may be significant variations from policy to policy, insurance company to insurancecompanyandstatetostate.Makesureyoucontactyouragentforclarification.Somehomeowner’spoliciesstillprovidenamedperilcoveragefordwellingextensions(towersand

related equipment), butmost cover accidental directly physical loss (an insurance policy term), again,withsomeexclusions.Typicalexclusionswouldbedamageresultingfromflood,normalwearandtearandearthquake.

TheARRL’s plan provides accidental directly physical loss coverage on all ham radio equipment,computers, towers and antennas.Thatmeans, unless the damagewas causedby something specificallyexcludedinthepolicy,yourclaimwillbepaid.OneexclusionintheARRL’splanisequipmentdamagedwhileyou’rerepairingit.Soifyou’rehardat

workontheLoudenboomer9000amplifierwiththepoweronandyoudropascrewdriverinthepowersupplycageanditdestroystheamp…sorry,nocoverage.Anotherexclusionwouldbenormalwearandtear.Ifyourcoaxialcablebreaksdownafterbeinguponthetowerfor15years…sorry,nocoverage.Dependingonyourhomeownersinsurer,ifyoufileaclaim—evenasmallone—yourpolicymaybe

surchargedfor the loss. Ifyoustarthavingahigher thanaveragenumberofclaims(whatpeople in theinsurancebusinesscall a loss frequencyproblem)youmay findyourselfgettingnon-renewedandwillprobably find it difficult or impossible to purchase homeowner’s insurance from any carrier, at anyprice.InOhio,whereIlive,theaveragehomeownerhasapropertyclaimthatexceedsthepolicydeductible

every12to15years,dependingonthecompanyprovidingtheinsuranceandwherethehomeownerlives.Ifyouturninahomeowner’sinsuranceclaimeverycoupleofyears,soonerorlateryouwillgetaletterfromyourinsurancecompanythatwon’tmakeyouoryourmortgagecompanyor,mostimportantly,yourspouse,veryhappy.Now if you’re asking yourself, why should I consider the ARRL’s plan when I already have a

homeowner’spolicy,let’sreview:1)Broadercoverageonallhamradiogearthanyourhomeowner’spolicy.2)Lowerdeductiblesthanthetypicalhomeowner’spolicy.3)Claimsactivitywon’taffectyourhomeowner’spolicy.4)Happyspouse...happyhouse.Everybody’ssituationisdifferent,buthereIam,aninsuranceagent,tellingyoutheARRL’splanmight

be a pretty good idea for you to consider. Hey…if I were you, I’d listen tome. It could insure yourdomestictranquility.

IfYouRentHamswho rent houses or apartments also need coverage. Some renter’s policies provide personal

property coverageonly.Others provide10%of the contents coverage amount for dwelling extensions,

likeahomeowner’spolicy.Again,seeyouragentforclarification.Ifyoudon’thaverenter’sinsurance,getsome.That’sespeciallyimportantifyouhaveatower,ifforno

otherreasonthantohaveliabilitycoverage.Whichbringsustothenextbigtopic

LiabilityInsurance(Don’tForgetYourUmbrella)ThefirstthingIlearnedinInsuranceSchoolis:eitheryoueitherbuyaninsurancepolicyforthoserisks

oritemsofpersonalpropertythatyoucan’taffordtolose(transferringtheriskofloss)oryouself-insure(assumingtheriskoflossyourself).People driving 1983Yugos don’t buy collision coverage.Those driving newCorvettes do. (Do the

math.)Like a swimmingpoolor trampoline,your tower iswhat attorneys call anattractivenuisance. If a

neighborhoodkidclimbsyour toweronadareandfalls…you’regoing togetsued…forahugepileofcash...and you’re probably going to lose.This is called bodily injury liability. If your tower falls anddamages your neighbor’s home, car or other property, his insurance company may try to recover thedamagecausedfromyou.Thisis,duh,propertydamageliability.The good news is there’s some protection in your homeowner’s policy, typicallyonly $100,000 to

$300,000ofpersonalliabilitycoverage.Theinsurancecompanywillhireanattorneytodefendyouandwriteacheckfordamagesuptothepolicylimits.Thebadnewsiswhenanattorneyparadesateenagerinawheelchairinfrontofajury,policylimitsof

$100,000to$300,000arejustadownpayment.(Yourargumentthatthiskidwastrespassingwillalmostsurelyfallonthejury’sdeafears.)Youareresponsiblefortherestofthedamages,ifyou’recollectible.You’recollectibleifyou(oryourspouse)havewagesorotherincome,equityinyourhomeorbusiness,bankaccounts,investments,retirementplans,futureinheritancesoranyotherassetsthatcanbeattachedbycourtjudgment.If you can afford to lose these things, fine. If you can’t, you need to purchase a personal liability

umbrella policy (PLUP) with coverage of at least $1,000,000 per occurrence. It doesn’t cost a lot,typicallylessthanadollaradayandwillprovidegreatpieceofmind.TherearemanyotherbenefitstoowningaPLUP;seeyouragentfordetails.What’sthebottomlineonjustifyingaPLUPpurchase?Ifyou’resuedforeverythingyouearnorown,

nowand in the future and if you lose…who do youwant towrite that check?You or your insurancecompany?Ithoughtso.By theway, that check for everythingyou’vegot is theminimumamount of coverageyour umbrella

should provide.A little extrawouldn’t hurt. Typically, personal umbrella policies are sold inmilliondollarincrements.Now…gobackandreadthissectionagain.It’svery,very,veryimportant.Afteryou’vedonethat,get

toaphoneandcallyourInsuranceAgentandtellhimyouneedanewumbrella…today!Here’saquick,butvery importantnote.TheARRL’sInsurancePlandoesnot includeanypersonal

liabilityprotectionatall.Thisisanareayouwillneedtodiscussandreviewwithyourinsuranceagent.

FilinganInsuranceClaim“Honey,didyourtoweralwayslooklikethat?”Itmighthavebeenatornadoorotherwindstorm,lightningstrike,iceorvandalism,butyourtowerand

antennas are damaged.Aren’twe feeling better thatwe discussed thingswith our agent before aBad

Thinghappened?Now,it’stimetogetbusy.Your primary duty after a loss is to protect your property and the property of others from further

damageor loss, thenmakereasonableandnecessarytemporaryrepairs.Youobviouslywant topreventadditionaldamage,butyourinsurancecompanydoesn’texpectyoutokillyourselfdoingit.Itmightalsobeagoodideatotakesomepictures.Notify your agent of the loss as soon as possible. Many agents and companies have 24/7 claims

service,soifthelosshappenedonSundaymorningmakethecall.Itwouldbeappropriatetofollowupwithashortletter,faxore-mailtoyouragent,justtomakesuretheclaimwasfiledcorrectly,requestingtheclaimnumberandtheclaimrepresentative’snameandphonenumber.After filing theclaim,youragent’s involvementwillprobablybeminimal,unless there’ssome issue

youandtheclaimrepcan’tworkout.Whenyourclaimissettled,an“attaboy”e-mailtotheagentandtheclaimrepwouldbeawelcome,appreciatedandveryunexpectedsurprise.

OrganizeYourPaperworkStartaclaimfile,whichshouldinclude:1)Notesonconversationswithyouragentandclaimrepresentative,includingdatesandtimes.2)Costestimatesonitemstoberepairedorreplaced.3)Anytimeyou,yourfriendsorfamilyspendonrepairsorclean-up.Yourclaimrepmay“pay”youfor

thistimebyallowingyoutooffsetitagainstyourpolicydeductible.Thisisnegotiableandshouldbediscussedearlyintheprocess.

4)Photographsand inventoryofdamagedordestroyed items.Donot throwanything awayuntil theclaimrepsaysto.Damagedpropertythattheinsurancecompanypaysyouforbecomestheirsandtheymayelecttosellitforsalvagevalue.

5)Relatedclaimdata:theclaimnumber,claimrep’sname,postalmailande-mailaddresses,office,cellandfaxnumbers.

Get prices from several vendors. If the items destroyed are no longer available, most insurancepoliciesprovideforreplacementwithitemsof“likekindandquality.”Documenttheseitemsanddiscussthemwithyourclaimrep.Rememberthatyourclaimrepisprobablywayoutofhisorherelement.Yourdamagedtowermaybe

thefirstonethey’veeverseen,sothey’llasklotsofquestionsandneedsomedocumentation.That’sokay.Claimadjustersaretrainedtopayeverypennythecompanyowes—notapennymore,notapennyless.Theclaimrepwillprobablyhavetojustifyyoursettlementchecktoasupervisor.Makethatjobaseasyasyoucan.TrustmewhenItellyouthattherepwantsthisclaimresolvedjustasmuchasyouwanttobebackontheair.Also,asmysaintedGrandmotherusedtosay,“Pigsgetfat,hogsgetslaughtered.”Somepeoplethinkan

insuranceclaimislikehittingthelottery.Notso,Bucko.Ifyoucanbuynewgearatagreatprice,turnthatpricein—notthelistprice.Claimspeoplegetrealcranky(andrightfullyso)iftheyfeelaclaimisbeing“padded.”InthisdayofWebsitesandsearchengines,trustbutverifyiseasilyaccomplished.Yourclaimrepmay

notknowaForce-12C31XRfromnextTuesday,butGoogledoes.Atbest,paddingslowstheprocessandmightleaveyouwitheggonyourfaceandsomeexplainingtodo.Atworst,youmayfindyourselffacingfelonyinsurancefraudcharges.Awordtothewiseshouldbesufficient.One other thing to remember.Your damaged tower is not as high on the claim rep’s priority list as

someone’shomewithmajorstructuralorfiredamage,norshoulditbe.Whenbadthingshappen,thereisnever enough time and people to get things done as quickly as peoplewould like. Be patient and be

reasonable.

MakingtheRepairsMostinsurancecompanieswriteacheckforthetotaldamages(lessyourdeductible)whentheworkis

completedandalldamaged/destroyeditemsarereplaced.Ifyouwantacheckpriortothestartofwork,theclaimrepmayreducethepaymentfordepreciationofthedamagedproperty,payingthebalancewhenthedamageditemsareactuallypurchasedorworkiscompleted.Thisisconsistentwithcontractlanguageinmosthomeowner’spoliciesandkeepseverybodyhonest.Also,don’tbesurprised ifyourcontractorasksyoutopayyourdeductibledirectlytohimbeforehestartswork.Paybycheck,getareceiptandtellyourclaimrep.Mosthomeowner’spoliciessettlelossesonareplacementcostbasis,meaningyougetnewstuff for

old,whenthenewstuffispurchased.Makesureyouhavereplacementcostcoverageonyourdwelling,dwellingextensionsandyourpersonalpropertybeforeyouhavea loss.This isanothergoodreasontoseeyouragentrealsoon.Ifyouhireacontractortorepairorreplaceyourtower,insistheprovideyouwithacurrentcertificate

ofcontractor’sliabilityinsurance(hismalpracticepolicy),acurrentcertificateofworker’scompensationcoverageand local references. Ifhe’saprofessional, thiswon’tbeaproblem. Ifhe’sa fly-by-nighter,he’s probably not insured, and you just don’t need those headaches. If the contractor tells you hisemployeesare“subcontractors,”you’llneedtoseethesubcontractors’insurancedocumentation.Donotevenconsiderbendingonthis.Ever!Yourcontractormayaskforsomepaymentupfront.Itwouldbewisetoincludeyourclaimrepinthat

discussionsincehe’llbewritingthechecks.

SeekProfessionalAdviceHere’sthebottomline:Don’trelyonyourhamradiobuddies,yourneighbororyourbrother-in-lawfor

advice on insurancematters. Call your agent right now, update him on your installation and ask hardquestions. “Ifmy tower andantennas aredamaged,howwillmypolicy cover the loss?” If your agentdoesn’tknow,makesurehefindsoutandthenshowsyouinwriting(inthepolicy)howlosseswillbecovered or why they won’t be. If there are gaps in coverage, what will it cost for what you need?

Photographyour installationandgiveyour agent an accurate inventoryofyourgear.Get toknowyouragent—afterall,ontheworstdayyoumighteverhave,he’llbestandingbesideyou.Here’sanotherlittlesecret…everytimeyourpayyourpremium,youragentgetspaid.(Allright,Isaid

itwas a little secret.) If your agent can’t orwon’t provideyouwith the serviceyoudeserve, he’snotearninghiskeep.It’stimetogoshoppingforanewcompanyoranewagentwithyouroldcompany.Everyinsuranceagentworthhissalthassomewarstoriestoshare.Here’soneofmine.Notlongafter

myarticlewaspublished in theFebruary2009QST, I got an e-mail froma ham inNorthCarolina. Itseems thathe followedmysuggestions, spokewithhisagentandupgradedhishomeowner’s insurancepolicyforhistowerinstallation.Everythingwasjustpeachy.Acoupleofmonthslater,hegotaletterfromhisagentadvisinghimthatduetohistowerandantenna

system,hiscurrentcarrierwasnon-renewinghishomeowner’spolicy.Thehamsentmeaphotoofhishome and his tower installation. I could see absolutely no reason for the company’s decision. In fact,much tomychagrin, this guydid abetter job securing and climb-proofinghis tower than I did formytower.I referred this gentleman to an acquaintance ofmine,who is an agent for a largeGoodNeighborly

InsuranceCompanywithanofficenearhishome.Anewhomeowner’spolicywaswrittenwiththatun-namedinsurancecompanythatveryday.Themoralof thisstoryis:Therearehundredsofthousandsofhamswhoarehomeowners,with towers, beams andother antennas,whohavenoproblemgetting andkeepinghomeowner’sinsurancecoverage.IfmygoodfriendsTimDuffy,K3LR,andTomLee,K8AZcangetahomeowner’spolicyfortheirhomesandantennaplantations,believeme,youcantoo.Finally,andfor the last time,pleasemake it apriority tovisityouragentand reviewyourpolicies.

Insuranceagentsarejustlikeyou.Wedon’tlikesurprisesandwedon’tlikeconflict.Wedofeelreallygoodwhenwetakecareofaclient’sclaimandputhimbacktowherehewasbeforethelosshappened.Asmyteenagesonwouldsay,“it’s,like,ourjob.”

RayFallen,ND8L, has been an agent for The StateFarmCompanies sinceFebruary, 1988. Theopinions expressed in this chapter are solely his and are not necessarily those of the State FarmInsuranceCompanies.Thecoveragesdescribedinthischaptermaynotbeavailableorapplyinyourstate,provinceorcountry.Youarestronglyencouragedtoreviewyourhomeowner’spolicyandtowerinstallationwithyourinsuranceagenttodetermineappropriatecoveragesandcoverageamounts.Thewords“he/his/him/guy/attaboy”areusedinagender-neutralbasis.Ray’s been licensed since 1964, anExtraClass Licensee since 1983 and amember of theNorth

CoastContesters and theK8AZmultiop team. Ray’s a confirmed appliance operator, contester andDXerandhasearned5BDXCCandDXCCHonorRoll(Mixed).

WorkingwithProfessionals

Youmightarguethatthisisamateurradio,soyoushouldbeabletopreparethesite,buildyourtower,install theantennasandmaintaineverythingyourself.Or ifnotbyyourself, thatyoucouldget theworkdonebysimplyusingtheresourcesfoundwithinyourlocalhamclub,orwithhelpfromotherhamfriends.Andthesetrulyareoptions,viableandreal,usedbycountlesshamstoinstallandmaintaintheirantennas.Theyare,however,notalwaysavailableoptions,noralwaysthebestoptions.Sometimesthebestand

safestwaytodothejobisbyusingprofessionalhelp.Climbing and working aloft requires special tools. Building a tower is sheer physical labor —

somethingsomeever-aging(andoftenout-of-shape)hamsarenotcapableofdoing.At leastnotsafely.Andthat’sthesingle,largestfactoryoushouldconsider—doingthistypeofworksafely!Thatrequiresnot only special tools, along with some solid physical conditioning, but also practical, very realisticlevelsofexperience.Experience is, of course, the basis of all knowledge, wisdom, understanding andmeaning. There’s

simply no substitute for it. When your life hangs in the balance, experience is what you need tosuccessfully complete the task. So hiring an experiencedworker to build, climb or repair your towermakessense,inmany,manyways.

“Choosesomeonewhowillcompletethejobquickly,efficiently,correctlyandsafely.”

Conventionalwisdompositsthatthelessmoneyyoupayforsomething,thebetteryou’llfeelaboutit.Inmyexperience,theconventionalwisdomiswrong,atleastwhenitcomestotowerwork.Yougetwhatyoupayfor.Howdoyouputapriceonavoidinganaccident?Howyouknowyourinstaller’sproposeddesignfor

yournewtowermeetsyourneeds?HowdoyouknowhisideaorsolutionforputtingyourbigYagiupintheairisright?Howcanyoudecidewhat’sfair?The answers to such questions cannot, and will not, apply to each and every situation. Every

installationisdifferent,evenifit’sjustonesmall,seeminglyinsignificantway.So,experienceandsome

history—withthetypeoftower,thetypeormanufacturerofantenna,thebrandofrotator—allcountforalot.You’rehiringsomeonetoprovideaspecializedservice,notshoppingpriceonaboxofpencils.Buyersshouldchoosetheirvendororsupplierbasedontheonewhooffersthemnotonlyafairprice,

but someone they think will be able to complete their work quickly, efficiently, correctly and safely.While this ismore-or-less common sense, it’s also the basis of the legal aspect ofwhat constitutes abargain (a mutually-agreed upon arrangement between buyer and seller) instead of the more commonlayman’slanguage—somethingthat’smerely“agooddeal.”

TheRightExperienceCountsNBC’sproductionofanepisodeoftheTVshowDateline,entitled“TowerDogs,”generatedalotof

traffic andconversationamonghams.Andprobablymore conversation spunuparounda thrown-awayline referring to the worker’s $14 per hour pay rate than any other aspect that was presented on theprogram.Within thepast fewyears, I’vemore-or-lessmademy livingbydoingham radio towerandantenna

work.(NooneismoreamazedbythisthanIam!)Andinthattime,I’vemadeapointofmeeting,talkingwithandevenhiringsomeprofessionaltowerguystohelpmewithvariousprojectsinvariouslocales.Inevery instance, theprofessionalswanted toknowhowIgot into thebusinessofdoing thissortof

towerworkbecausetheratewasbetterthanwhattheywerebeingpaid.Ineveryinstance,noneofthemtruly understoodwhat aYagi (or any other ham antenna)was,why and howwe use rotators, how tosolder,whatHFradiomeanstous,ormanyothertopicsthatwehamsalltakeforgranted.Noneofthissurprisedme.On theotherhand, in every instance, theyhad farmoreexperience than Idowith largeHeliax feed

lines,withcranes, andwithworkingon reallybig towers andbighardware.Beingyoungerguys, theyclimbedalotfaster.Even though theymayhavegotten to the topof the towerfaster thanIdid, Iendedup teaching these

non-hamprofessionalsa lot about theworkweneeded todoup there.That’s simplybecause theyhadvirtuallyno ham-related experience and were unfamiliar with the types of antennas and rotators weneededtoworkwith.Andthisremainsacriticalfactor,inmyopinion.Clientsshouldconsidertheexperiencelevelofany

potentialvendororworker.Youwantsomeonewho’sexperienced;thatgoesalmostwithoutsaying.Buthowdoyoudeterminethattheyhaveenoughoftherightexperience?Inotherwords,ifyoufeelyouneedtohireprofessionalhelp,howcanyoujudgethequalificationsthatvendorpresentstoyou?

FindingandEvaluatingProfessionalHelpIntheworldoftowerdogs,thereareover500membercompanieslocatedthroughouttheUnitedStates,

PuertoRico,Bahamas,CanadaandCaymanIslands.That’swithintheareaservedbyNATE(theNationalAssociationofTowerErectors),totalingabout95,000individualworkersinvolvedintheindustry.Intheworldofhamradio,asthisiswrittentherearefewerthantwodozenindividualsorcompanies

providingantennaandtowerservicesrepresentedonthereviewpageatwww.eham.net.Andof those,onlyahandfulhavehadrecentreviews.That’sastaggeringlysmallnumber,consideringwe’vegotover650,000licenseesspanningallareasofthecountry.Sure,noteveryoneisactiveorwillneedorwantorcanevenhaveatower,butstill,theresourcepoolofqualifiedtowerpersonnelisverylimited.

“Safetowerworkersalwaysthink

aboutwheretheyare.”

Given the safety concerns (both during the initial installation and over the life of the tower andantennas),andgivenyoursubstantialinvestmentintimeandmoney,itonlymakessensetohiretherightcontractorforthejob.Thisrequiresyou,asthecustomer,tobemoreproactiveinchoosingsomeonetodosuchwork,inordertomakeameaningfulevaluation.Youcangaugethatlevelofexperiencebyreadingthosewww.eham.netreviews,forexample.Youcansimplyaskwhetherornotthevendorhasdoneworklikeyoursbefore,andsoforth.Mostvendorswillsupplyyouwithreferences,ifyouask.Mostvendorswillhavetheneededtools,sotheexperiencelevelistheonlyrealvariableleftforyoutoconsider.Again,safetyshouldalwaysbeyourmainconcern.It’sbeensaidoftenenoughthatitdoesnotrequire

realsmartsorbraverytoclimbatower.Itdoestaketrust—trustinyourequipmentandyourabilities.Climbing experience doesn’t mean someone isn’t afraid of heights, either. (My climbing partner JohnCrovelli,W2GD, knowshe can alwaysmakeme smile by saying, at someopportunemoment, usuallywhenwe’reabove100feet:“I’mafraidofheights.”)Safetowerworkersalwaysthinkaboutwheretheyare(whetherthat’s20feetor200feetupatower),howtheygottothatlevel,andhowthey’regoingtogetdown from that level. They always respect the fact that amistake and fall from any height can causeseriousinjuryordeath.Thismostlyallmeanswe’recomparingapples tooranges ifwecompare theTowerDog’sworld to

what we do. We can learn things from them, of course (anytime you encounter guys with that muchexperience,youshouldtrytobenefitfromit).Butifyousawtheshow,youmayhavenoticedthatnearlyevery single structure theyworked onwas unique. That’s amajor difference.Much ofwhatwe do isconfinedtosimilartowers,usingsimilarantennas,usingsimilarhardware—alotofthesamestuff,overandover,againandagain.Much of what we do is not governed by deadlines—we can work at our own pace, regardless,

weatherpermitting.Muchofwhatwedoisnotdrivenbyabusinessplan—it’sonlyahobby,afterall.Andwhatwedoisnotregulated—there’snoOSHAstipulatingwhatequipmentweuse.Buteverythingsaidaboutsafetycertainlyapplies.Always.

HamversusCommercialTowers:AProfessional’sViewpointAsisoftenthecase,thereisa“professional”sidetotowerworkandinstallations.Indeed,commercial

towersoftendwarfhaminstallations.Andwhileone’sfirstreactiontothesetoweringbeautiesmightbetoignorethem,itmakesmoresensetometostudythem.Andtoanalyzeandinquireaboutthem.Indeed,Idecided to ask someonewho’s been in that business for a number of years if itwould be possible tocompareandcontrastthetwofields—thinkingitwouldbeprofitabletolearnfromthepros.Afterall,it’sprobablymorethanasimplequestionofscalewhenitcomestocomparingcommercialinstallationstowhatyouhaveinyourbackyard.So, I went to Norm Jeweler, W4NRS, who owns United States Tower Services, in Frederick,

Maryland,whichhasbeeninbusinessfor40years.USTShasneverhadafatality,neverhadatowerfall

orcollapse,andisaleaderinthetowerindustry’ssafetyprogram.IaskedNormafewbasicquestions.Herearehisanswers.

Q.Takeamomenttocompareandcontrasta“typical”commercialtowerinstallationtoa“typical”hamradioinstallation.A. There is really not much difference between a ham tower installation and a commercial tower

installation.Commercialtowersarejustusuallybiggerandtallerwithbiggerantennasonthem.Atowerisatowerisatower!But,theyallrequireknowledgeoftheproductandhowtoinstallitsafelywithoutgetting hurt, so the owner ends up with a quality installation that will last throughout the years. Acommercialtowerinstallationusuallylasts30to50yearswiththerightkindofmaintenance.

Q.What’sthemostobviousorcommonmistake(s)you’veseenorencounteredovertheyearswiththattypicalham’stowerinstallation?A.ThebiggestmistakesIseeinhamtowerinstallationsarenotusingthecorrectsafetyequipment—

likeanapprovedclimbingharness.Otherproblemsincludeusingthewrongequipmenttoraiseorlowertower sections and antennas (gin pole), notwearing a hard hat, free climbing orworking by yourselfwithoutsomeoneonthegroundtobethereifyouneedhelp.Workingwithoutasafetyplanbeforeyoustarttheprojectisanotherthingmanyhamsforgetordon’tdo.Ornotcheckingtheareaforobstaclessuchastrees,powerlines,rooflinesandanythingelsethatwillbeinthewaywhileinstallingatowerorantenna.And, of course, not following the manufacturer’s directions, that’s always a factor. When a

manufacturersaysthebaseof thetowershouldbe3×3×3feetwithoneyardofreinforcedconcrete,thereisareason.Don’tunderestimatetheirknowledgeanduseless.Orwhen½-inchreinforcingbarsarecalledforandyouusewiremeshtoholdtheconcretetogether.Thingslikethat.And,Ishouldsaytoalwaysfinishtheconcreteatthebaseofatowersowaterwillrunawayfromthe

legsandnotpooluparoundthem.Wheninstallinghollowleggedtowers,besuretoputthelegsinatleastsix inchesofgravel toallow fordrainageofcondensation.Never stepon thebase sectionandpush itthroughthegravel,whichplugsthelegswithdirt.AndIcan’tforget,usingwaterpipeorfencepipeformast.Bracketingatowertothesideofahouseor

buildingwithoutreinforcingtheareaontheothersideofthebracket.Hamsoftenoverlookthingslikethattotryandsavemoney,butit’sfalseeconomy.

Q. What steps should hams take in order to work as safely as possible on their own towerinstallations?A.Again,themostimportantthingsareusinganapprovedharness(notsomeusedleatherclimbingbelt

that’sdryrotted).Theonlytrulysafebeltisanylonwebsitharnessstylebeltwithapprovedsafetystraps(yes,atleasttwo).Then,stayawayfromoverheadelectricallines,wearahardhat,makesureyouhaveagroundobserverwhocancall911ifyougetintotrouble.Useonlyapprovedequipment.Thedaysofusing2×4lumberorconduitforginpolesarehopefullylonggone.UseanylonorDacronropeonatowerjob,notmanilaorpolyropes.

Q. Since it is, after all, “amateur” radio, should a hamwhowants a tower ever consider hiringsomeonetodothework—suchassettingthetowerandguys,buildingantennasandtheninstallingthem,andsoforth?Orshouldsuchworkbedonebytheowner,perhapswiththehelpoflocalhambuddiesorsomeradioclubpals?Inotherwords,isthereaplacefortower“professionals”withinthehamradioranks?A.Inmyestimation,theanswertothisquestionisabsolutely.Ifonedoesn’tfeelcomfortableclimbing

ordoingallthelabortodigtheholesandinstallingtheconcreteforatower,thensimplyleavethattoaprofessional.Youcaneasilyoverstressyourselfbydiggingthebaseoranchorholesanddiefromaheartattack.Pushingyourselftoclimbatowerifyou’renot110%comfortabledoingsomeansyoucouldfall.Onemustask:Ispayingaprofessionaltodoaguaranteedjobworthmylifeandlimb?WillIsleepbetteratnightknowingthatsuchworkwasdoneproperlyandwilllastfor30ormoreyears?Towersinstalledbyprofessionals(byprofessionalImeansomeoneinthebusinessatleast15yearsor

more,whobelongstotheNationalAssociationofTowerErectors)willprovidethatpeaceofmind.And,ifyouwantthisprofessionaltoinstallyourantennasandrotators,getsomeonewhohasdonethismanytimesbefore—not just onceor twice, andwhoknowswhat they’re doing.You’dbe surprised at thenumberofprofessionaltowercompanyownersandclimberswhoareknowledgeablehams.I’m64yearsoldandIhavean80-footfreestandingtoweratmyFloridahome.Iknowbetterthanto

climbmytoweranymore.I’moverweight,havesomehealthissues,andIwanttolivetoenjoymyhobbyformanymoreyears.Sosure,IgladlynegotiatewithmylocalprofessionaltowercompanytodoworkwhenIneedit.It’sveryreasonable.Remember: if you ask friends or members of your local club to come over and help you on your

propertytoworkonyourtowerandtheygethurt,guesswhopaysfortheirinjuries,orheavenforbidtheirdeath.Onemorething.Yourhomeowner’sinsurancelikelywillnotrepresentyouorpayadimeinyourdefense,muchlesspayaclaimforsomethinglikethis.

Q.Ifonealreadyhasatower,talkabitaboutmaintenance—whatitmeansandmightinclude.A.Maintenanceisthekeytohavingatowerthat’ssafe,reliable,andwillsurvivewindsandiceand

lastfor30ormoreyears.Atminimum,guyedtowersshouldbeinspectedatleasttwiceayear,includingcheckingguy tensions, checking legs for splittingat thebasedue towater in them,verticality, andanyloose or missing hardware. Grounding should also be inspected twice a year, too, and this includescheckingtheconnectiontothegroundrod.

Q&AWithProfessionalTowerInstallersWhatbeganasacoupleofrathersimplequestionsfromtheeditorworkingonmymanuscriptfor the

ARRLquicklymorphedintoalargergroupofquestions,whichfurtherfueledtheideaofaskinganumberoftowerinstallersfortheiropinions!So, I polled several of my fellow tower climbers who have a lot of positive reviews on

www.eham.net, and all agreed that the idea hadmerit.Everyone respondedwithin a fewdays of oneanother.WhiletheseareallEastCoastworkers,Idon’tbelievethere’stoomuchdifferencebetweenworking

hereaboutsandworkinginsouthernCalifornia,let’ssay,exceptfortheweatherinmid-January….So, here are six general questions and the answers from not onlyme, but also from JohnCrovelli,

W2GD, Dan Street, K1TO, and Ray Higgins, W2RE. I’ve provided everyone’s relevant contactinformation,aswell.

TowerWorksDonDaso,K4ZA515WithershinnDriveCharlotteNC28262Phone:704-408-7948Email:k4za@juno.com

JohnCrovelli,W2GDPOBox10SoleburyPA18963-0010Phone:908-391-5611Email:w2gd@hotmail.com

A1TowerServiceDanStreet,K1TO9933289thStreetEastMyakkaCityFL34251Phone:941-780-0073Email:A1TowerService@aol.com

HudsonValleyTowersRayHiggins,W2REwww.hudsonvalleytowers.comPhone:888-528-6937Fax:866-509-0843

1)Doyouworkwithclientswhoarejuststartingoutandhaveabsolutelynothing?(Thatis,wouldyoudoanentireprojectfromconcepttoconnectingthelastcable?)K4ZA: I’ve done numerous projects for “first time” tower owners! I enjoy the teaching aspect of

explainingandlayingoutthevariousoptionsforclients.Infact,Itrulylikeplanning,andthenbuilding,astation.So,sure,I’vestartedwithadrawingandworkedthroughtheprocess,rightuptohandinganewly-finishedhunkofcoaxtoaclient,saying,“Hereyougo…havefun!”W2GD:IworkwithclientsrangingfromnewbiestocontestorDXingfanatics,providingconsultative

services at whatever level is requested or felt to be necessary to move a project from concept tocompletion.K1TO: Yes. Site andmaterials planning is often very helpful to them, since there are a number of

factorstheytypicallyarenotthinkingofinitially.W2RE:Weall rememberwhat it is likewhenstartingoutwithanythingnew. Itcanbe trying to find

peopletohelpand“Elmer”youalongtheway.Wetrytokeepanopendoorpolicyfornewcomersinthehobby,andeventhoughtheymightnothavethebudget tohireprofessionals,wefeelafewphonecallsandemailspushingthemintherightdirectionalwaysseemstobetherightthing.Weunderstandthere’salot to learn from thisgreathobbyandwedoourbest tohelpeven ifmonetarycompensation isnotanoption.Soreally,wehavedonesmalljobs—fromthenewhamwhojustgothisticketandweinstalledaverticalonhischimney—tofulloutsoup-to-nutsinstallswithstacks.

2) Along those lines, if the client needs professional engineering drawings for local buildingofficials,doyougivereferences?Ordoyouonlycomeinaftertheplanningorpermitsaredone?K4ZA: I’veworkedwith a variety of professional engineers (PEs) for clientswho needed that.My

favoriteisHankLonberg,KR7X,whocontributedinformationonfreestandingversusguyedtowersandstarguysversusnormalguysforotherchaptersofthisbook.Beinglicensed,andhavingexperiencewithcontestingandbigstations,he’strulyavaluableresource.W2GD:Ingeneral,Idon’tbecomedirectlyinvolvedwithzoningorpermits.However,it’scertainlyin

my best interest to explain the process to a prospective client. I guide the client onwhat to do,with

whom,andwhen.InsomecasesIpointthemtowardlocalgovernmentWebsites,wheretheycanresearchtheirzoninglaws.Othertimes,ImaydirectthemtoaPEforassistance,andinthemostdifficultcases,tospecializedlegalassistance.K1TO: I prefer not getting involved in local permitting. I always use referrals for professional

engineeringdrawings.W2RE:Wetrytogivereferencesasmuchaspossible,beingproactiveandhelpingwithtowerspecs

andreferringlegalcouncilwhendealingwithzoningboards.

3)Doyouchargeclientsby thehourorby the job?Anddoyouhavedifferent rates fordifferentwork?(Forinstance,buildingarebarcageandinstallingan80meterbeamat200feetwouldseemtocommanddifferentrates,butmaybenot.)K4ZA:Iworkbythehour.Withhams,therearetoomanyvariables,andanyotherwayistoorisky!The

levelofknowledgeneededtodotheworkyoudescribedoesnotrelatedirectlytothelaborrequiredinyourexamples.Wire-tiesonsomerebarsoundsridiculouslysimple,whileputtingupan80meterYagisoundsterriblycomplex.But there’s lotsof informationandknowledgeneededtocorrectlyaccomplisheachofthoseprojects,forinstance.I’mnotadversetodiscountingwork,though.Crank-upinstallations,whichsometimesdon’trequiremuchclimbing,oftencomeincheaperthanfull-blown,guyedtowerjobs,whereI’mspendingalotoftimeclimbingandhangingonthetower.W2GD:Inalmostallcases,myworkisdoneonaperhourbasis,atthesamehourlyrateregardlessof

taskperformed.Somediscounting is given, atmydiscretion,when I feel theworkdoesn’t support theamountcharged.Ihaveafourhourminimumcharge,whichissometimeswaivedifthejobtakesfarlesstime.Fixedpricingistoorisky.K1TO:Typically,bythehour,usuallywithanup-frontestimatesoweareboth“calibrated.”Butafew

jobshavebeen“fixedbid”projects.Andwedefinitelychargelessforgroundwork.W2RE:Italldependsonthescopeofwork—ifthequoteiseitherhourlyoronesetpricetocomplete.

Sometimesit’sverydifficulttoquoteoutlargerjobsbecauseofunforeseenissuesthatmayarise.Anotherfactorthataffectsarateislevelofdifficulty,orifanyspecialprecautionsneedtobefollowed.Usually,onevery request forwork,we spendsome timegatheringasmuch informationaspossiblebeforehand(pictures,eitherGoogleEarthorsiteinspection)togetagoodhandleonwhatneedstobedoneandwhatobstaclesmaybeencountered.

4)Howdoyoudecidehowmanypaidhelpersareneeded(andtheclientpaysfor)?K4ZA:Iftheworkloadislargeenough—saywe’reputtingupa40meterbeam,I’llbringahelper.Or

quiteoftenthesedays,asourpopulationisgettingolder,myclientcannothelpoutdirectly,forhealthorphysicalreasons,sothenI’llbringalongahelper.That’sfairlycommon.That’salldiscussedbeforehand,sotherearenosurprises.W2GD:Theworkdictateshowmuchmanpowerisneededtocompletetheproject.Typically,nomore

thanonehelperisneeded.It’stherigger’sdecision,nottheclient’s...always!K1TO:Iftheclientiscompetentandwilling,wehavenoproblemworkingwiththemdirectlyinlieuof

bringingourownpersonnel.Scopeoftheprojectdictatespersonnelneeds.Onoccasion,I’veusedfewerresourcesforalongertimetoaccomplishthesameresult.W2RE:Oncewe’vedeterminedhowwe’regoingtocompletetherequest,therategivenwillinclude

everythingandeverybodyonthejob.Ifwefeelthatatsomepointwemayneedaextrahandortwo,therewouldbenoextra charge to the customer.Theprice for thewhole joborby thehourwill not changedependingonifwebringmorepeopleintocompleteit.Thisway,theclientdoesn’thavetoworryabout

extracostatjobcompletion.Atnotimedowewanttheclienttofeeltheremaybeunknownchargesthathavenotbeendiscussedaheadoftime.

5)Iftheclientortheirfriendswanttohelpontheground,isthatokay?Encouraged?Whatiftheclientwantstoclimbandworkwithyou?K4ZA:Sure!I’veactually“taught”someclientshowtoclimb.Boughtthemtheirfallarrestsystemand

everything.Butnotmanyclientsclimb. Icertainlydon’tmind if theclientwants towork. I think that’sgreat.Frankly,I’msurprisedwhentheydon’tgetinvolved—wantingonlyaturnkeyjob.Butthat’sjustme. I’m a nuts and bolts person,who likesmaking stuff. So I think everyone should be excited aboutbuildingabeaminthebackyard!ButthenIremembereverybody’sdifferent,andthat’swhytheyhiredmein thefirstplace! It isvery,verycommonforme tobe theclimber,andfor theclient tobe thegroundcrew.Alotofclientssimplydon’t,won’t,orcan’tclimbtheir tower.But theystilldoeverythingelse.Whateverittakes…I’mablue-collarguy.Workiswork.W2GD:Ihavenoproblemswithaclientclimbing.Idon’tgenerallyencouragethis(franklyit’squite

rare),unlessthere’ssomesignificantadvantagetohavingtwoonthetowertodoagiventask.Ofcourse,youmustusegoodjudgment,andmakethedecisiononacase-by-casebasis.K1TO:Again,iftheclientiscompetentandwilling,wehavenoproblemworkingwiththemdirectlyin

lieuofbringingourownpersonnel.Buttypically,iftheclientclimbs,he/sheisn’tinthemarketfortowerservices.Manyclientsareex-climbersandthusarequitecompetentontheground.W2RE: This isn’t encouraged andwe very rarely allow it. First and foremost is safety. Things can

happenveryquicklyandunexpectedlyandthelastthingweneedtoworryaboutistheclientbeinginthewrong place at the wrong time. The ultimate goal is for the job to be completed above the client’sexpectationandmostofall,withoutinjuryordamagetoanyoneorproperty.It’sjustlikehiringanytypeofprofessional—likeaplumberoranelectrician.It’sbesttoleavetheworktotheprofessionals.

6)Whoarrangesforlocalequipment,suchasabackhoe,theconcrete,craneandsoon?K4ZA:Goodquestion.Somelocalesaresosmallthatthereisn’taSunbeltoranRSCorothernational

chainnearby,sotheclientwillnotonlyhavetosupplythenameorsource,butdotheactualrental,too.Ihaveaccountsatbothplaces,butnotatJoe’sToolSupply,youknow?SoI’lljusttelltheclientwhatweneed,whattoget,andsoforth.W2GD:SinceIdon’tgenerallydiginthedirt(sinceit’snotcosteffectiveformyclients),foundation

work is almost always left to the client, which includes arranging for a local general contractor,equipmentandmaterials.I’veneverarrangedforamanliftorcrane;again, theseitemsareorderedandpaidforbytheclient(althoughIwillhelpthemmakeequipmentselections).K1TO:Iprefertheclientlineuplocalresources,especiallyforout-of-townjobs.Thisgivesthemthe

opportunitytouseapreferredresourceandtoshoparoundifdesired.Thisisusuallyhowitworksout,butagain,onoccasion,we’llhavetolineupeverythingremotely.W2RE:Wetrytohandleasmuchofthejobaspossible.Asamatteroffact,weencouragelettingus

takefullcontroloftheproject.Thisallowsustocoordinateallpartiesinvolvedandhaveasolidtimelineofallthepartsoftheproject.Iftoomanypeoplearetryingtocoordinatethevariousvendorsneededforajob, then the riskofmiscommunicationanderrorwilloccur.Theworstpartof this is lossof timeandproductivity.Nevertheless,iftheclientwantstohandlesomepartofthejob—forinstance,takingcareofthebase,concreteandgettingthefirstfewsectionsin—wehavenoproblemswiththataslongastheclientfollowsthemanufacturer’sspecifications.Wealsoaskfordigitalpicturesbeforehandtomakesurenothingwasmissedandthatthestructureissafeandsecurebeforeweshowuptofinish.

ToolsandGadgets

Sometimesproblemsdemanduniquesolutions,which iswherePlato’s observation that“necessity isthemotherofinvention”probablycamefrom.Towerworkisn’tanydifferent.

AFixtureforCrank-UpTowersThefirst toolherewassuggestedtomeetaneedduringaninstallationforRickKourey,K4KL,near

Charlotte. Rick had selected an 89-foot ITS crank-up tower from Array Solutions, along with anOptiBeamYagifor20/17/15/12/10metersandM2antennasfor30/40metersandVHF.SomephotosofRick’sinstallationareshowninotherchaptersofthisbook.Theapproachwasfairlystraightforward, involvingaGenie50-footman-lift to installa3-inchhigh-

strengthmast,alongwiththetopmost2meterverticalandthe30/40meterand6meterYagis.But,bythen,we’drunoutofdaylight.Wehad,however,alsocarriedtheOptiBeamintopositionnexttothetower.Allhandspressedforaquickraisingusingthegoodoldginpole,butIwantedtoensurethebeamitselfwaswellawayfromthetowerbase.Itwasprettycrowdedtherewiththecrank-up’smotor,thecontrolbox,thetowergroundingitemsandsoforth.Ioptedtoconstructthesimplecantileverrigdescribedhere,andinstallthe5-bandYagibyhandonanotherday.Selectingsome1-inchsquaretubing, themainarmwasweldedup,usingtwosections; then,suitable

braceswerecutandweldedtoit,usingthesamestock.Thesewerethenboltedtoaplateof¼-inchthick6061alloyaluminum.AllmaterialscamefromtheK4ZAcollectionofmetal“IknewI’dfindauseforoneday,”whichseemstogrowexponentiallyastimegoesby.FigureA-1showsthissimpledevice’sconstruction.Theabilitytokeepthebeamawayfromthemotor

andhardwarenearthegroundmakesraisingthebeamoncrank-upsoronbigtaperselfsupportingtowersaneasytask.Onceatthetopofthetower,Isimplyattachacome-along(mountedtothemast,thistime)andswingthebeamintoitsfinalposition.

LevelsandMeasuringTapesLevelsareuseful toany towerbuilder,with the48-inchcarpenter’s levelbeing thestandard.Pocket

levels are sometimes useful, even on the tower, just to give yourself some advantage over eyeballingthings.Notmany folkspayattention to theangleof theirguyanchors,even thoughRohnspecifies theangle

relativetotheground.Greenleemakesatrulyhandylevel,withamagneticbase, thatmakessettingtheanchors and aligning masts easier. Designed for electrical contractors (who must often bend conduit,usuallyat30,45and90°angles),thislightweightlevelnowalwaysgoesoncertaintowerjobs.Anotherusefulleveliswhat’sknownasaPostLevel.It’stheidealtoolforlevelinggroundpoles,roof

mounts,wallmountsorevenfenceordeckposts,whichmakesitidealforradiomasts,too.Mostmodelsaremagnetic,andit’stheonlylevelallowingyoutocheckforplumbwithoutmovingthelevel.It’sperfectfor installing tower bases, elevated guy posts, and the like. Check your local hardware emporium orAmazonforsomegreatdeals.Hansomhas comeoutwith a new level design that uses a ball insteadof themore commonbubble

(FigureA-2).Thedesignmakesreadingplumborlevel,aswellasangles,easierthantheold-fashionedbubbledesigns.Itseemstomaketowerplumbingmucheasier,forsomereason!

TheWixeyGauge(FigureA-3)isacleverandhandywoodshoptoolnormallyusedtosetsawbladeangles.It’sperfectformeasuringthetaperofself-supportingtowerbaselegs.

Measuringtapesareusuallytakenforgranted,unlessyoubuildlotsofstuff.Stanley’slatestFatMaxlineofferssomeuniqueapproaches.Advertisedtostandoutunsupportedto11feet,mineonlygoesatadpast10feet—stillwaypastanyothertapeI’veowned.Itmakessingle-handedconstructionmucheasier.Thebulkycasemightbeaproblemforsomeonewithsmallhands,andtheblack,rubberizedcasecoatingcangetawfullyhotifleftoutinthesun.Andthespringreturnisrapid,andthecurvatureoftheblade(acontributingfactortothatsuperiorstandoutlength)cansliceyourfingerquiteeasily.They’reabitpricey,

too,comparedtoothertapes.ButeverytimeIactuallyusemine,Iadmiremostoftheprosanddecidetheconsaren’tsobadafterall.

ProjectCalculatorEverynowand then, somethingcomesyourway that’s so simple,yet refined, so inexpensive (okay,

cheap)yetversatile,andsoimpressesyouthatyousimplyhavetohaveit.TheProjectCalcPluspocketcalculatorshowninFigureA-4has tobeoneof theneatest tools I’ve

foundin thepastfewyears.Yes, it’syetanotherexampleofcomputersbeingfoundineverything,fromyourtoastertothefamilycar.It’ssocoolthatyouquicklyforgetthatpart,andlookaroundforcleverandcoolproblemstosolve.Andwhilethereareseveralsuchcalculatorsonthemarket,thisoneimpressedmefirstwithitsprice.

Ifyouneedtofigureout:Paintcoverage(surfacearea,orgallons,quartsorpints)Wallpaper(rollsof)Tiles(thenumberneeded)Concrete(numberofbagsormixerloadsneeded,fortowerbasesordrivewaysorfences)Gravel(shovelsortruckloads)Bricksorblocks(numberforawall,driveway,whatever)Carpet(lengthorsurfacearea)Fences(numberofpostsandrails,boards,wire)Cost(usingcustomordedicatedsettings)Conversions(forthemetrically-challengedornon-USusers;itworksbothways)Well…you get the idea.This is one handy gadget! It’s the size of your typical pocket calculator—

meaningitwill,literally,fiteasilyintoyourshirtpocket.Theinstructionsareprinted(inthatannoyinglysmall type)ononesheetofmulti-foldedpaper,which isbothersomeat first,but thenyoudiscover thatusingtheProjectCalcisfairlyintuitive.And,thepaperfoldssmallenoughandisthinenough,thatitfitsinside the fold over lid or cover. You can take it out, store it safely in your shirt pocket, do all thefunctions(probablywithouteverreferringtoit),andthenput itback.Butit’salwaysnicetoknowyoucanlooksomethingupshoulditbenecessary.It’ssimpleandeasytousethecalculator.Youenterthingsjustasyou’dsaythemaloud,andsuddenly,

there’syouranswer,inthesameformat.Forinstance,ifyouwanttoadd3feet4½inchesand5feet9¼inches,yousimplytype

3FEET4INCHES½+5FEET9INCHES¼=andthen9FEET1¾INCHESmagicallyappearsonthescreen.WanttodescribeyourtoweraccuratelyinyournextDXQSO?Type

100FEETCONVMETERSand30.48METERSpopsrightuponscreen.Thesearebuttwoverysimpleexamples.Thecalculatorfunctionsarecapableofholdingspecificor

dedicated amounts in memory, along with standard-of-the-industry default values for bricks, block,concrete,plywoodandsoforth.Forinstance,itwillfigurecostperbag,paintcoverage,size,boardorpostcenters,studs,settingspertileorblockandsoforth.Itwillfigureboardorposton-centerspacing(theactualboardorpostwidthplusspacingbetweenthem).TheProjectCalc is obviously designed for theDo-It-Yourselfmarket,where themath isn’t somuch

hardasitistediousandatypical.NeveragainwillIfindmyselfre-checkingthemathbeforecallingtheconcretesupplierforatowerbasepour.(I’msureI’llstillmeasuretwice,butwon’tbemultiplyingthedimensionsmorethanonce.)

MovingHeavyObjectsIsometimesfindmyselffacedwithtakingdowncrank-uptowers.Then,I’mfacedwithmovingthem.Thesearealwaysheavy,awkwardtowers,andtheydon’teasilycomeapartintomanageablesections.

Moving them requires planning and preparation. Part of that prep work is bringing along my towerdollies.Oneisasimple“wagonstyle”dolly,withten-inchpneumatictires,capableofsupporting1200pounds.Ihavea10-foothandleforit,whichallowsmetowalkandsteerwithacollapsedtowerhangingoverthefront.Theotherdollyisamodified“trailerhitch”dolly,whichwasintendedtoallowonepersontorollatraileraround.Iweldedsomeplatetothehitchpoint,andthisdollynowslidesunderheavystuffandletsmerollitaround.Thisdollyusuallybringsuptherearendofwhateverlong,heavyobjectIammaneuveringaroundsomeremoteplace.AndIcanstillscrewaballontoit,andthenusethisdollyasoriginallyintended.Together, thesesmalldolliesallowmetohaulcrankupsaroundrelativelyeasily.IpurchasedthewagondollyfromTEKSupplyandthetrailerdollyfromNorthernTools.Formovingheavyobjectsshortdistances,it’shardtobeataLug-Allleverratchethoist(whichnearly

everyonecallsacomealong)showninFigureA-5.TheveryfirsttimeIusedone,Iknewitwasthebestcomealong in theworld.Compared to theusualhardware storeversion, they’remuchbettermadeandeasiertouse(theydon’tsnag).Inowhavethreeofthem.

Ifyouthinkyou’reinterestedinmovingheavythingsaroundwithouthurtingyourself,orspendinglargeamountsofmoneytorentmechanizedequipment,youmightenjoywhatoneenterprisingretiredcarpenterinMichiganhasbeenabletoaccomplish.Visitwww.theforgottentechnology.comforatrulyfascinatinglookatsomeoldmethodsandtechniquesformovingheavystuffaroundbyhand!Sometimes, a professional tool or gadget gets replicated and offered for sale to the general public.

That’sthecasewiththeAccu-Chutewheelbarrow.Thisheavydutywheelbarrowwasdesignedfromthegrounduptobeusedtotransportconcrete—withitsheavier-than-usualbase,largepneumatictire,andataperedchute(pouringspout)onitsnose.Now,youcanwalkintoahomecenterandbuyaknockoffthat’lldo the same thing at half the Accu-Chute’s price tag. This design is perfect for moving concrete andpouring it into towerbaseholes, anchorholes, and so forth. (Beprepared, however—when full, thewheelbarrowwillweighover200pounds.)

WrenchesandPliersFolks sometimes askme about brands of tools, specificallywrenches.Here’smy opinion: Snap-On

makesthebestwrenches,period.Theyarealsothemostexpensive.AndyoumusttrackdowntheSnap-Onsalesmanservicingyourarea—that’stherollingdisplaytruckyoucanspotatautodealershipsandotherprofessionalserviceareas.Thattruckcansupplyeverythingyou’lleverneed.Youcanorderonline,aswell,butIurgeyoutotakeapeekinsideoneofthetrucks.Youwillbeamazed!Mac,MatcoandCornwellareotherprofessionalbrands—alsoavailablefromsimilardisplaytrucks.

Craftsmantools,availableatSears,willsufficefortheaverageham,shadetreemechanicorhomeowner.Theirlifetimewarrantymakesthemattractive,asdotheirsaleprices.SKtoolsareanotherbrandworthyourconsideration.Socket wrenches come in 6-point and 12-point styles. The 12-point wrenches are more useful for

generalwork,but6-pointwrencheshavemoregrippingpower.IfIhadtochooseonestyleoveranother,Iwouldpick12-pointwrenches, although I’vegot complete setsofboth inmy toolbox. I normallyonlycarry“deep”socketsupthetower,simplybecausethey’remoreversatile,whenworkingwithU-boltsandthelike.UnlessI’mworkingonreallybighardware,a⅜-inchratchetdriveshouldworkfine.(Again,Ihaveratchetsandsocketsetsrangingfrom¼-inchupto¾-inch-drives,butIdomoreofthisworkthantheaverageham,sodon’tthinkyouhavetohaveeverythinginyourtoolboxthatIdo.)Occasionallyyoumayneedsocketwrenchaccessoriessuchasextensions,swivelsorbreakerbars.Oneofmymore interestingsetsof tools remainsmyratchetingbox/open-endcombinationwrenches.

What’suniqueaboutthem(besidesthenoveltyofaratchetingbox-endwrench)isthattheratchetworksinonly5°of rotation.Whenyou’reworkingatopa tower, sometimes incrampedconditions, that smallerratchetanglecanmakeabigdifferenceandsaveyou time.Plus, thebox-endwrenchgivesyoua littlemore torquecompared toa typicalsocketwrench.GearWrench,Craftsman,Husky,Snap-Onandothersallmarketthesewrenches.MinehaveprovensousefulthatInowhavetwosets,soeventhegroundcrewcanbenefitfromthem.GearWrench(andprobablyothers,bythetimeyoureadthis)nowhavesomevariationsonthisdesign.

Youcangetaflex-headedset(greatfortightspaces)andanX-boxdesign,whichallowsyoutoputmoreforceontheboltornut.FiguresA-6andA-7showsomeofthehandtoolsIuse.

Foryears,IreliedonKleinlineman’splierstosolvelotsofgrippingandcuttingproblems.Recently,IhavefoundtheCraftsmanRobo-Gripplierstobemoreusefulwhenfacedwithaluminumelements,largerconnectorsonbaluns,Preformedguygrips,andsoforth.Theycanmakethedifferencewhentakingdownsomeoldbeams, for instance—providinga solidgriponhardware that’s so rusted regularwrencheswon’t fit. Severalmanufacturers nowmake similar pliers, alongwith Craftsman. I’m carrying a littlemoreweightinthepouch,butagain,theycansavetime.FigureA-8showsthespecializedtoolofchoiceifyouneedtorotateaboomormastwhileintheair.

TheViseGripchaingriptakesagoodbiteontubingwithoutdamagingit.

OtherHandyToolsIusedtocarrymultiplescrewdriverswithmeupthetower.Butafewyearsago,Iswitchedtooneof

thosecheapmulti-bitscrewdrivers—twosizesofstraightbladesandtwosizesofPhillipsblades.OnlyonceduringthosetwoyearsdidIneedascrewdriverthatwouldprovideabitmoretorque.Sonowmypouchislighterbynotcarryingsomanyscrewdrivers.IlikedthisideasowellthatIrecentlywenttoanIrwinmodelofferingninetoolsinone—screwdriversandnutdrivers,aswell.It’sahit!Another indispensable tool for tower work is a cutting tool, a knife. Most everyone chooses the

standardboxcutterversion.Butmakesureyouuseonewitharetractableblade,andkeepsparebladesstoredinthehandle.I’vehadgreatsuccesswiththeIrwinmodelandtheirTitaniumblades,bytheway.I’dberemissintalkingaboutold,rustyhardwareifIdidnotmentiontheonlywaytodealwithit—a

productcalledPBBlaster(achemicalcatalyst)showninFigureA-9.Thisstuffworksbetter to loosenlong-rustedhardwarethananythingI’veevertried.Whileitwasscarceforawhile,it’snowseeminglyavailableeverywhere,includingWal-Mart.

Tohaulassortedstuffupthetower(what’snotcarriedinoneofmybelt-sidepouches),IusetheoldfaithfulKleinLineman’scanvasbuckets.Ihavetheovalversion(#5144,usefulforhandtools—FigureA-10),andthemoretypical,straight-sidedbucket(#5103,usefulforrotators,andlargeritems—FigureA-11).Lotsoffolkssuggestormentiontheyusefivegallonbuckets.But,they’renotthatpractical,inmyhumbleopinion.Theirrigidnature,andthatpeskymetalbailhandle,neverseemtofunctionwellaloft.Forstoringorcarryingitemstoajoblocation,sure,buttheydon’tworkwellintheair.

White lithiumgreasehasmanyuses.Carryasmall tube(FigureA-12)up the tower togrease towerlegs during assembly. Thatmaymake the sections easier to take apart if you need to disassemble thetower.

AsdescribedinChapter8,astraingaugeorscaleusedtoweighfish(FigureA-13)makesiteasytobalanceantennabooms.Justsuspendtheantennaattheboom-to-mastplate,attachthegaugetothelightendandpulldownuntiltheboomislevel.Thegaugewilltellyouhowmuchweighttosecureinsidethatendoftheboom.

Fasteners

Therearebolts,andtherearescrews.Boltsareheldinplacebynuts;screwsarethreadedintooneofthe pieces being fastened together. The bolt is held stationary, and tightened by turning down the nut.Screws, of course, are tightened by turning the screw head itself. In other words, the applicationdeterminesthecorrectterminology.

PlainTalkAboutThreadsThehelicalscrewthreadisamazinglyversatile—severaldifferenttypesarefoundinwidespreaduse.

TheAcme thread, for instance, isa square form threadusedon lathesandmillingmachines toprovidestraight, directionalmotion to various sliding rods and cutting heads.Abuttress thread is designed towithstandseverestressesparalleltotheaxisofthethreaditself.Youcanfindthisthreadonhoseclamps,forinstance.Self-tappingsheetmetalscrewsandwoodscrewscomeinavarietyofthreads—withoutanysortofstandardization.Allarespecializedtosuitdifferentmaterialsaswellasassemblymethods.Oneofthefirstthingsyounoticeaboutboltthreadsisthattheycomeintwobasictypes:finepitchand

coarsepitch.Eachhasitsplaceintheworldoffasteners.Butthereisnomeasurabledifferenceinfatigueresistancebetweencoarseandfinethreads.(Asusual,aWorldWarwasrequiredtoachievesomethingakin to standardization among nations regarding screw threads, along with calibers of weapons.Interesting history, if you like that sort of thing.By1948, themilitary-derivedunified fine andunifiedcoarsethreadedseries,whichincludedathreadangleof60°,hadbecomestandard.)

BoltFunctionsAfter a fewwords on threads, let’s examine the function of the bolt.Let’s startwithwhat a bolt is

designed to do. First and foremost, bolts are meant to hold parts together. That’s all. They are notdesignedtoserveaspivots,rotationalaxles,fulcrumsoranythingelse.Theyshouldnotbeusedtoholdpartsinplace,either.Inotherwords,boltsshouldnotbeusedtopreventclamped-togetherpiecesfromslidingormovingonoragainstoneanother.(Fortherecord,thisiswhatdowels,pilotpinsorkeysareintendedtodo.)Boltsaremeanttobeusedasclamps.Andonlyclamps.Clamps,ofcourse,must remain tight,underall sortsof loads,vibrationandstresses.A loosebolt’s

obviously a poor clamp. A loose bolt will fail, and fail quickly. Youmay ask: “Okay, what keeps abolted-togetherjointtight?”First,herearesomethingsthatdonotkeepbolted-togetherjointstight:lockwashers,threadlockingcompounds,safetywires,cotterpinsorevenelasticstopnuts.Thisisnotmeanttodemeanthosepartsorproducts.Oreventocondemnmodernengineeringpractices.Whichmightleadyoutoinferthemechanicalworldisabouttocollapse—ifyoutakemystatementliterally.

WhatImeanisthatintheworkadayworld,it’ssimplynotpracticaltocleanandtorqueeverysinglebolttoprecisestandards.Often,it’snotnecessary,either.Butifboltsaremeanttoclampthingstogether,then theboltwillbe internallystressed in tension.Tighteningabolt toaspecific torquevalueactuallystretchesitandloadsitintensiontoasetlevelofstress.Thus,aproperlytorquedboltwillhavethemostresistancetoagivenloadforthegreatestamountoffatiguecycles.Under-stressedboltswillloosenunderloadandfail.Over-tightenedboltswillfailduringinstallationorprematurelyunderstress.

What’sThisMean,inPracticalTerms?As you tighten the nut onto the bolt, the bolt itself stretches.Male threads elongate; female threads

compress. This creates an interference condition, which resists loosening. (Plating, the lack oflubrication,lengthofthethreadedarea,allthesefactorinandcontributetomakingthisseeminglysimpletask, in aword,difficult.)Normally, thiswon’t affect your toweror antennaproject.But, if you’re anenginebuilder,youbetterbelieveyou’llbemeasuring things likeconnecting rodbolts for stretchafterinstallation.

IdentificationHamsoftenwalkintotheirfriendlylocalhardwareorhomesupplystore,buysomefastenerstosolve

theirinstallationproblem,andhappilygoonhamming.Sometimes,they’redisappointed—eitherwiththestrengthofthematerials,theplating(orlackof),thewearorsomethingelse.Mostly,thisissimplyacaseof“bolteducation,”whichwe’retryingtoovercomehere.CheckoutTableB-1,whichgivesinformationaboutboltsusedinindustry.TheSocietyofAutomotive

Engineers(SAE)standardJ429,whichdefinesboltstrength,identifiesvariousgrades.TheSAEgradeofaboltismarkedonitshead,usingshortradiallines.ForGrade5andup,thenumberoflinesistwolessthan theSAEgrade (three lines indicateGrade5, six lines indicateGrade8).Nomarking is used forGrade 4 and lower. These grades are typically used for bolts ranging from ¼ inch up 1½ inches indiameter.

Whenever possible, you shouldn’t be using anything less thanGrade 5 bolts on towers, beams androtators.Thathardwarestorestuffisn’theat-treated,andtypicallytheplatingwillrustthroughinafewmonthsofoutdoorexposure.Stainlesssteelfasteners(moreonstainlesslater)areoftenrecommendedformanyapplications.Enterprisinghams,believing they’re“using theverybest.”will searchoutGrade8bolts.Theseare

verystrong,indeed,buttheirheat-treatingmakesthembrittle.Unlessspecifiedbythemanufacturer(forbasemountinguse,forinstance),Iwouldn’tbotherwiththem.Whataboutbuyingsurplusfasteners?It’snotworthit.Unlessyouknowwhatyou’redoing(thisincludeshavingamicrometerinyourhand),it’snot

worthittorisklifeandlimbtosaveafewcents,literally.Counterfeitfastenersarebigoffshorebusiness.Ifbigcompaniescanbetakenin(andtheyhavebeen),consumerscaneasilybeconfusedinthesurplusstore.

StainlessSteelNow, those fewwordson stainless steel...a ferrous alloy.TheAmericanSociety forMetals (ASM)

defines stainless steel as any alloy containing at least 10%chromium,with orwithout other elements.Alloy 304 is an austenitic stainless alloy (one of the most common of the four types), and the non-magneticalloyyou’llusuallyfind.Alloy304hasexcellentresistancetocorrosion.TheASMpublishesvolumesonmetals;it’savasttopic,ifyou’reinterested.Whatmosthamsdon’tknow(havingrundowntothelocalhardwarestoreforsomestainlesshardware)

ishowtoinstallitproperly.Stainlesswill“gall”asyoutightenit—meaningthethreadswillbind(seethe next section). Stainless isn’t very strong. For critical uses (like a tower itself) stickwithGrade 5hardware.

SomeTipsforWorkingWithNutsandBoltsQuiteoften,Ispendconsiderabletimeassemblingantennas,whereIworkwithlotsandlotsofvarious

typesofhardware.Thequestiononcearose,“Howlongshouldaboltbe?”Ithoughtthatwasaprettygoodquestionforaclienttoask—rightuptherewith,“Howlongshouldmy

feedlinebe?”Aswiththequickanswertothefeedlinequestion(“longenoughtoreachtheshack”),asimple answer to the bolt questionmay not cover everything you need to consider for your particularinstallation.Simplyput, there’slittlepointtohavingmorethansixthreadsonanything.NationalCoarsethreaded

nutsusuallyhavefivethreadsinthem;NationalFinethreadednutshaveabouteight.Why?Becausethenutisstrongerthanthebolt,whichwillbreakbeforethenutwillstrip.It’sjustthatsimple.Someofyoumayhaveheardtheoldshopadage,“Youshouldhavetwothreadsexposedaboveanut.”

Why?Simplybecausethefirsttwothreadsofaboltaresometimespoorlyformed.Theymaynotengagethenutproperly,overloadingthenut,weakeningitandcausingittostrip.Ifthefirsttwothreadsarenotholdingtheirshareoftheload,theotherthreadsinthenutwillbeoverstressed,andthenutmaystrip.

GallingEveryonceinawhile,therecomethoseinevitablequestionsormomentsthatwillyieldanideaformy

NCJcolumn,alongwithachuckleorheadshakeinwonderment.Galling—aperennialpeskyproblemwithstainlesssteelhardware—isacaseinpoint.“Whyisit

calledgalling?”oneofmyclientswantedtoknow.IadmittedthatwhileIdidn’tknowtheanswertothat,Icould explain theprocess, andwhyandhow it happens. It turnsout hedidn’t care about that; heonlywanted to knowwhy itwas calledwhat it’s called. Saying it’s also known as “coldwelding,” a trueoxymoron,swungourconversationbacktotheprocess,whereIwasabletoofferanexplanation.Gallingtakesplacewhenstainlesssteelconnectionsseemingly“fuse”toandwitheachother—whena

boltandnutjamorfreezetogether,forinstance.Youshouldknowthatit’snotjuststainlesshardwarethatexhibitsthis.Aluminum,titaniumandotheralloysthatnaturallyformanoxidesurfacefilmcanalsogall.(But when’s the last time you used a bolt made from one of those materials?) This film preventscorrosion, one of themajor advantages of such fasteners. But as you assemble them, surface pressurebuildsupbetweenthethreads,andtheoxidesarebroken.Theoxideshavingsbuildup,andlocktogether,

whichfurtherincreasesheatandfriction,whichfurtherexpandsthemetals,andvoila….galling.Thesimplestsolutionistokeepalubricantathandduringassembly.Adropofitappliedtothethreads

shouldcompletelyeliminategalling.Yes,adrop!Youdon’tneedtoliterallylatherupthethreads.Iliketouse a tube of lubricant gel (“LubeGel”) that contains Teflon. It’s small and easily carried inmy toolpouch.Thegeldoesn’tgetallovereverything,likespraylubricants,either.Anylubricantwillwork—evenWD-40,inapinch,ifyou’llexcusethepun.ThespecialNo-Gallstainlesssteelnutsandboltsarefine,too,althoughexpensive.Keepingthehardwarecoolcanhelp,too.That’softendifficultinourwork,asyoumightbesurprised

to realize how hot hardware can get simply by being out in the sun.You can also slow down as youassembletheboltsandnuts.

RivetsSomehamsfrownontheuseofrivets.However,anyfastenersuitableforaviationandaerospaceuse

(glanceoutthewindowthenexttimeyou’resittingonsomerunway,waitingtotakeoff)canbeusedonabeam,inmyopinion.Pop rivets (themost common variety) are available in various combinations. I recommend the all-

aluminumorall-stainlessrivetsuchasthoseshowninFigureB-1.Investinaqualityrivettool—asyoushould with all tools.What makes blind or “pop” rivets work so well in fastening element or boomsectionstogether,forinstance,isthattheyexpandtofillthehole.Unlikebolts,whichmustpassthroughslightlyoversizedholes,rivetswillexpand.Irecommendnotbuyingrivetsfromthelocalhardwarestore.The blister pack-variety are not very strong. I recommendbuyingCherry orAvex brand rivets from afastenersupplier.

Theholesforrivetsshouldbedeburred(admittedly,thisisdifficulttodoinsideanelementorboom)toensureproperseating.Moreimportantly,ifyouwanttorealizethefullstrengthofarivet,themaximumrivetdiametershouldbetwotothreetimestheworkthickness.

DrillsOfcourse,allthistalkofscrewsandnutsandrivets,andusingthem,wouldnotbecompletewithout

mentioningsomethingabouttheholestheygointo,orthethreadsthatreceivethem,tobespecific.Togetstarted,weneedadrill(I’mreferringtodrillbits).Drillsizesarecommonlydenotedinthree

ways:smallerdrillscomeinnumberedsizesfrom1to60,withthelargestbeingnumberl,whichis0.228inchindiameter,andthesmallest,number60, is0.040inch.(That’sa lotofdrills,Don!Dowereallyneedsuchaset?Andtheanswerisno,probablynot.I’dbuyseveralofthemost-commonsizes,instead.TableB-2listssuchsizes)Youmayhaveseendrillslistedwithlettersizes,whicharecommonlycalledjobbersizes,runningfromAtoZ,from0.234inchto0.413inch.Athirdsystemoverlapsthenumberedandletteredsizes.It’scalledfractionalsizes.Thisisthesystemyou’llseeatyourlocalhardwarestoreifyoutrytogooutandbuydrillbits.Sizesrangefrom1⁄16to½inch.

Thebaneofdrills(likeelectronics)isheat.Avoidpressurewhendrilling.Letthebitdothedrilling;don’ttrypushingyourwaythrough.Burningthecuttingedgesofthedrillruinsthebitormaycauseittobreak or bend. Obviously, for best results, any drill should be sharp. Sharpening a drill bit can bedifficult,butwithpracticeandthepropertool(severalarenowavailabletoholdthebitwiththeproperorientation and angle), you can learn to sharpen bits yourself— just in time to learn something aboutcuttingthreads.

TapsandDiesTocutsthreadsinmaterial,youuseatap.Toputthreadsontomaterial,youuseadie.SeeFigureB-2.

Internalversusexternalthreads is thewayyouremember thedistinction.Tapscanbepurchasedthreeways—taper,plugandbottomingtaps.Tapertapsareusedtostartthreads;thetipisgroundawayforagradualstart.Ifthematerial’sthick,aplugtapshouldbeusedonceyou’vestartedthreadingitwithatapertap.Bottomingtaps,astheirnameimplies,areusedtofinishthreadstothebottomofaholethatdoesn’tgoallthewaythroughmaterial.

Tapsareusuallyheldinatapwrench(varioustypesholdvarioussizes).Butthemostimportantthingto remember is that lubrication isvital to the tap’s life. (Youmaypurchasecommercial lubricants,butkeroseneworkswellonaluminumasalubricant.Alwaysusecareandcommonsensewithanymachineshopwork,butespeciallywhendrillingandtapping.)Holesdrilledinthematerialtoreceiveatapmustleaveenoughmaterialinwhichtocutthethreads.(TableB-2liststheproperdrillsizesusedforvariouscommontaps.)Movethetapback-and-forth.Thebackwardmotionclearsthecutmetalfromthetap.Goslowanddon’tforcethetap.Haveyoueverhadadinged-upboltorcross-threadedholethatjustwouldn’twork?Tapsanddiesare

usefulforcleaningupdamagedthreadsaswell.Itwon’talwayswork,butcarefulapplicationofatapordiemayallowyoutosaveahard-to-findboltormachinedfitting.Thereare,asyoumightexpect,avarietyofotherfasteners,applications,proceduresandmethodsused

inholdingthingstogether.Indeed,it’sanindustry,asabitofWebsearchingorawalkthroughtheYellowPageswilltellyou.Myremarksaremerelyanoverview,toacquaintyouwiththebasics.

WorkingwithAluminumTubingMaterials suitable for building antennas are available from severalQST advertisers who cater to

antenna builders with a variety of tubing, clamps, plates and other hardware. If you live in a largemetropolitanarea,youmaybeabletofindtubingsuppliersintheYellowPages.Suppliercatalogscanbeaneducation.IntheUSA,tubingisavailable(in12-footlengths)indiameters

thatincreaseby0.125inch(⅛inch)—⅜,½,⅝inchouterdiameter(OD)andsoon.Tubingisavailableinavarietyofwallthicknesses.Thesecretistoselecttubingwithawallthicknessof0.058inch,whichprovidesperfecttelescopingfits(FigureB-3).TableB-3showsstandardtubingsizes.Catalogswilllistthe various alloys available. Usually, you’ll be looking for 6061-T6 or “aircraft aluminum” types ofalloys.

Joiningmetalssuchasaluminumcanbeajoy.Itsprecisionnatureandabilitytobecutormachinedtosizeispartofthatjoy.Butjoiningdissimilarmetalscanbewithoutjoy.Allmetalshaveanelectrolyticpotential. Joining them requiresyoucounteract thispotential—otherwiseyou’ve installed a “battery”(possibly high in the air), which gradually loses material and strength (see the section on Corrosionbelow).TheuseofNoalox,Penetroxorotherantioxidantcompound(FigureB-4)isstandardprocedurewhenbuildingbeamsortowersections.Suchlubricantspreventcorrosionandwillmakeiteasiertogetpiecesorsectionsapartlaterifyouhaveto.

HoseClampsHamswhobuildanytypeofHFbeamantennawillinevitablyhavetoanswerthequestionofhowto

fasten aluminum tubing pieces together. Joints in the tubing used for booms or elements, which cantelescope together quite nicely if the correct tubing sizes are used, must be made solid — bothmechanicallyandelectrically.Myfirstchoice is tousestainlesssteelmachinescrewsateachjoint.Somemanufacturersandhome

builders like to cut slots in the larger tubing and then clamp it tightly around the smaller piece thattelescopes inside with hose clamps. In this case, I recommend only top-quality worm-gear-type hoseclampswiththroughslots(FigureB-5).Clampswith“formed”slotsareworthless; they’llstripeasily.Stainlesssteelistheonlywaytogo—forboththeclampandthescrewmechanism.(IdealandTridentarebothqualitybrandnames.)

Lookforhex-headscrewsthatcanbeturnedeitherwithascrewdriveror(betteryet)witha5⁄16-inchnut-driver.Iusuallytrytoputthescrewitselfdirectlyovertheslotinthelargertubingbeforetightening.And,Iusuallydonottrytoover-tightentheseclamps.Aircraftmanualsspecify15inch-poundsoftorqueforhoseclamps.Andthat’sforapressurizedsystem.Somethinglessthanthatwillworkfineforholdingelementstogether.Obviously,Ibelievethemechanicaljointisthefundamentalbuildingblock.Electricalcontinuity can be obtained by driving a stainless steel sheet metal screw through the mechanicalconnection,ifyou’retrulyworried.

CorrosionSometimes,whenyoutakeapartoneofthoseniftyaluminumantennajoints,you’lldiscoversomefine

whitepowderattheconnection.Sinceittakesalotofenergytoextractaluminumorefromtheearth,thencreatethatswelltubingwetakeforgranted,it’seasytoseehow,overtime,thismetalwilltrytoreturntoitsnatural,corrodedstate—asit“releases”alltheenergywe’veputintoit.Intheair,aluminumoxidizeseasily,formingaluminumoxide,thatwhitepoweryouencounter.Another typeofcorrosionhamsencounter frequently isbi-metalliccorrosion.Thisoccurswhen two

metalswiththerightpropertiesconnect,andanelectrolyteispresent.It’sachemicalprocess(whichissometimeshardforfolkstograsp,sincewe’retalkingmetals,butthat’swhatitis)—justlikeabattery.Simplyput,electronsflowfromonemetal(calledtheanode)acrossthejointtothesecondmetal(calledthecathode).Hydrogengas formsat thesurfaceof thecathodicmetal junction.Positive ions left in theanodic metal then oxidize. In bi-metallic joints, the more anodic metal always corrodes away. Theelectrolytecanbesomekindofsalt—anythingthatmakesthejointconductive.Acidrain,evendeworsaltsdepositedfromyourhands,aresufficienttostarttheprocess.I’veincludedachartofgalvanicmetalactivity (TableB-4), which shows the electro-potential of these metals or alloys. They are listed bydecreasingpotential—frommostanodictomostcathodic.Generally, it’sbest tochoosethosethatareclosetogetheronthechartfortrouble-freeresults.

For instance, you can see that a junction of aluminum and zinc would be good, while a joint ofaluminum and copperwould be bad.Remember that electrical connectionmeansmating surfaceswillhavemicroscopicbumpsandpointswherethesemetalsmeet.Thejointimpedanceisproportionaltothenumberofsuchpoints.Lotsofpointswithlittlegettinginthewaymeansagoodjoint.Foraluminum,I’vefoundit’sbesttocleanjointsasdescribedinthenextsection.Donotcontaminate

thecleansurfacewithyourfingersaftercleaning.Jointpressureisimportantbecauseoxidesstarttoformimmediatelyaftercleaning—thepressuremustbegreatenoughtobreakthroughthislayer.Asthemetalsflex, a phenomenon called “fretting corrosion” occurs, whereby the clean metal part of the openconnectionoxidizesandbuildsup.Thisiswhyantennas(whichworkedjustfinewhenyouputthemup)sometimesseeminglyfailallbythemselveswhenupintheair.JointcompoundssuchasNoaloxorPenetroxcanhelpseal theseconnectionsand inhibitelectrolytic

activity.Theyareavailablefromelectricalsupplyhouses,hardwarestores,somehomecenters,evenacoupleofantennamanufacturersshipthem.Thesecompoundswillnotlastforever,though.Theydryout;theyhardenandcrack.Over timeand throughtemperaturevariations, theywillsimplyflowawayfromjoints. Some sort of finish or overcoat can also be a good idea. Choose something thatwill flex andresistsultravioletlight.

CleaningAluminumMentioncleaningaluminumandyouneverfail torousesomerabbleamongyouraudience.Everyone

has anopinion.Severalmethods involve steelwool.Alas, this is not agood idea.Thewool (even in0000,veryfinegrade)willleavebehindtracesofsteel,whichwilloxidizeandrust,creatingafarworseproblem.Therearechemicalproductsthatwillaidincleaning.NeverDullorGord’sCleaner/PolishareacoupleI’veusedsuccessfully.Thesimplestsolutionis touseScotch-BriteIndustrialHandPads(6×9inches).Thesepads(which

arecolor-coded)aregreatcleaningtools,andnotjustforaluminum.Iboughtarollofthegraypadsfiveyearsagoandamnotyetathirdthroughit.Here’stheindustrialpadbreakdown:Scotch-BriteHeavyDutyHandPad(tancolor)—Mostdurableandaggressivepadforquickremovalofdirtandoxidation.

Scotch Blending Pad (gray color) — Slightly finer abrasive than heavy duty pads. Excellent forremovingscratchesonmetal,woodorsyntheticsurfaces.

Scotch-BriteGeneralPurposeHandPad (marooncolor)—ThemostpopularScotch-Briteabrasivebecauseit’scoarseenoughforcleaningandfinishing,butfineenoughtoproducegoodsurfacefinishes.

Scotch-BriteUltra-FineHandPad(lightgraycolor)—Finetexturedforfinefinishingofmetal,wood,plasticsandcomposites.

Scotch-Brite Light Duty Hand Pad (white color)— A very mild abrasive for gentle, yet thoroughcleaning.Commonlyusedwithliquiddetergent.

RandomThoughtsandTips

TowerStandardsYou could purchase the EIA/TIARevisionG standard from TIA, but it’s ridiculously expensive. It

makes more sense to review the differences included within the version, compared to earlier ones.There’s a PDF file available listing those differences online at www.mei1inc.com/NAB-2003presentation.pdf.Incaseyouareinterested,herearethetopicscoveredinRevisionG,bychapter:1)General2)Loads3)Analysis4)Designedstrengthofstructuralsteel5)Manufacturing6)Otherstructuralmaterials7)GuyAssemblers8)Insulators9)Foundationsandanchorages10)Protectivegrounding11)Obstructionandmarking12)Climbingandworkingfacilities13)Plans,assemblytolerancesandmarking14)Maintenanceandconditionassessment15)ExistingstructuresThereare14annexesthatformprocurementanduserguidelines.Theseareintendedtohelpengineers

intheirprocurementofantennasupportingstructuresandantennasdesignedinaccordancewiththenewstandard.Annexesprovideamplificationandclarificationofmanyofthespecifications.Theannexlistingfollows:A)ProcurementandtheuserguidelinesB)U.S.CountylistingsofdesigncriteriaC)WindforceontypicalantennasD)TwistandswaylimitationsformicrowaveantennasE)GuyruptureF)PresumptivesoilparametersG)GeotechnicalinvestigationsH)Additionalcorrosioncontrol

I)ClimberattachmentanchoragesJ)MaintenanceandconditionassessmentK)MeasuringguytensionsL)WindspeedconfessionsM)SIconversionfactorsN)References

SomeNot-So-TechnicalThoughtsonAntennasandHamminginGeneralAntennasremainoneareawherehamscanbothdesignorcreateandbuildsomethingtheycanconsider

state-of-the-art.Nottoomanyofuscanmakesomethinglikeamoderntransceiverinahomeworkshop,but somesimplepiecesofwireor aluminumcancontribute significantly to the successof thatmoderntransceiver insideyour station.Allyouneed is someknowledge,enthusiasmandperseverance.Here’showyoucandoit.

KnowledgeBooksremainthesingleeasiestandmostaccessiblesourceofantennainformation.Themostpopular

source for this favorite topicofham radio lore is theARRLAntennaBook. It’s updated regularly, andwhile the lawsofphysicshaven’t changed, I believe it’s agood idea topurchase a copywhenaneweditioncomesout.Today’seditionhasover700pages;itevencomeswithsoftware.Another great source for design ideas isThe ARRLAntennaCompendium series. There are seven

volumes available; each contains a wealth of previously unpublished designs. Antennas, transmissionlinesandpropagationareallcovered.BillOrr’sRadioHandbookisanothermust-havetitle.IalsorecommendOrr’sotherantennabooks—

specifically his works on verticals, quads, beams and wire antennas. Paul Lee’s Vertical AntennaHandbook is a wealth of information. Jim Lawson’s Yagi Antenna Design, Dave Leeson’s PhysicalDesignofYagiAntennas,L.A.Moxon’sHFAntennasForAllLocations,ErwinDavid’sHFAntennaCollection,Jacobs&Cohen’sShortwavePropagationHandbookandtheCommercialProductscatalogfrom Rohn are also must-have items in the modem DXer and contester’s library. Some of thesepublicationsareoutofprintbutoftencanbefoundonInternetauctionsites,hamradioclassifiedswapsites,fleamarkets,orthroughAmazon.com’susedbooklocatorservice.The Internet is a virtual library. A surprising number of ham radio links can provide you with

fascinatingreading,alongwithawealthofinformationandsomesurprisingmisinformation.Alwaysseekoutasecondopinion,especiallyforadvicereceivedfromvariousreflectors.

EnthusiasmThisoughtnotbeaproblemforhams,butIdoencounterconversationson2meterFMthatsurpriseme.

(Isometimessimplyswitchtoscanningthechannelswhiledrivingaroundthecountry,goingfromjobtojob.)Andwhilethisisacomplexissue(whywouldn’tanyonebeexcitedaboutourhobby?),Ithinktheanswerisasimpleone.Oursocietyandcultureinsulatesusfromthe“oldway”ofsharing,whichwastypicallyviaanElmerorfromthenecessary“poolingofresources”thatclubactivityentailed.IthinkthebestwaytocombatthislethargyistohavededicatedElmersforeachnewcomertoourhobby.Meaninglocalclubswillhavetobecomemoreinvolved.Once you have the enthusiasm, the best way to guarantee its continuing existence is to promote

operating.AndbythatImeanHFoperating.Thereisalotofinterestingandexcitingstufftodoinhamradiobeyondtalkingwiththeusualcrowdonthelocal2meterrepeater.Andwhatgetsone’senergyandenthusiasm up more than DXing or experiencing an unusual band opening or trying a new mode?Contestingisabigoneforme,butthat’sanotherstory.IbelieveI’menthusiasticenoughfortwohams!

PerseveranceDictionaries tell us that perseverance means that one continues, steadfast, even when something is

difficult or tedious.Ham radio,without amentor or Elmer, can seem difficult. Certainly, some of theconversations you might encounter can seem tedious. But I would urge anyone reading these lines toconsiderStanhope’s idea: “Whatever isworthdoingat all, isworthdoingwell.”This line from1746certainlyholdstruemorethan250yearslater.Try tobe agoodham radiooperator—whichmeans learningasmuchasyoucanaboutoperating,

somethingwealltoooftentakeforgrantedinourhobby.Havethebestsignalyoucan,onwhateverband,usingwhatevermode,wheneveryou’reontheair.Andmakesureyoudothat—getontheair.You’llfindthat these three areas inter-relate and drive each other. As your knowledge grows, so will yourenthusiasm.Ifyoupersevere,you’llfindyourknowledgeincreasing,whichwillcreatemoreenthusiasm,andyou’lladvancethroughtheranks.Seehowitworks?Ihopeso!

Wasps…theFlyingKindIfyouspendanytimeonatower,you’lleventuallyencounterthesecritters,especiallyduringthefall

months,whentheheat-absorbingsteelseemstoattractthemingreatnumbers.It’salwaysdisconcertingtobeclimbing,glanceupward,andseeaswirlingswarmofthemsurroundingthespacewhereyou’llsoonfindyourself.Likemanyofus,you’llprobablykeepclimbing,hoping theydon’tbotheryou.Mostof the time, this

will be true.But I havebeen stung, andprobablywill be again.Thequestionofwhat attracts them isunknown, and no so-calledwasp expert has stepped forward or providedmewith an answer, despitenumerousqueries.Weallsimplyassumeit’sthewarmingeffectfromthesteeltowerthatseemstoattractthem.Rumorsaboundabouttheeffectsoftheirstings,however.Let’strytocorrectthesemistakes,someof

whichcanactuallybelife-threatening.Youoftenhearthattakinganantihistamine(Benadrylisatypicalexample)willstopanallergicreaction.Butthatreaction(anaphylaxis)isveryrapid,andyou’dbedeadwell before the tablet dissolved in your system. If you’re allergic to bee stings, you probably alreadyknowthis.Ifyouareallergicandmustclimb,youprobablyhaveseenyourdoctorandhaveaprescriptionforan

epinephrineself-injector.Ofcourse,youcarrythatinjectorwithyouatalltimes.You’llhaveonlyminutestoreact,hopefullyallowingyourselftimetoclimbdownandgettoanER.Theepinephrinewillwearoff,andtheanaphylacticshockmayreoccur,butonceintheER,youcanreceivepropertreatment.Indeed,ifyou’vehadanallergicreactiontoinsectbitesorstings,I’davoiddoingtowerworkduring

thefallwhenwaspsarearound.

StationDesign

AnEngineeredApproachForToday’sDX/ContestingAmateurPaul Rockwell,W3AFM,wrote a series of articles that influenced theway hams thought, not only

aboutDXingingeneral,butspecificallyaboutdesigningtheirstationstorealizethatgoal—successfullyworkingDX.Thefourpartseries,“StationDesignforDX,”waspublishedinQST,September throughDecember1966,andremainsusefulandenjoyablereadingtoday.What W3AFM set forth was a simplified, yet structured, approach to station design. I believe he

borrowedsometechniquesandterminologyfromhisprofessionallife.JimAhlgren,W4RX,whowasayoungengineeringgraduateat the timeandworkedwithPaul,agreeswith thisassessment.Regardless,continuingtofollowandusesomeofhisprinciples,andexpandingorenlargingothers,wecanreadilymeetsomeoftoday’smodernstation-buildingneeds.

DesignThe key word in W3AFM’s approach is design, something most hams overlook or simply don’t

consider.Instead,theybuygear(individualpiecesandcomponents)andsetupstations,oftenseeminglyatrandom,andthendecidewhattheywanttodowithit.Suchanapproachisunderstandable;indeed,it’sprobablyinevitableasyourfocuswithinthehobbyandyourneedsdevelopandchange.ForDXing,W3AFM’sapproachrankedthefocusondesignasfollows:1)Antennatopics2)Economics3)Stationconfiguration(andreceivertopics)4)Propagationquirksandoperatingtips

Thatclassicapproachisjustasviable,andjustasvaluable,totoday’sham.Inbusiness,weusuallyconsiderSystemsEngineeringtobeaninterdisciplinaryapproach—ameans

wherein we realize some success. The focus is on defining “customer needs.” Functionality,documentation, alongwith design synthesis and system validation, all while considering the completeproblem,willbecomekeyelements.Forindustry,thisprocessusuallyincludes:OperationsPerformanceTestingManufacturingCostandScheduleTrainingandSupport

Obviously,suchanapproachintegratesdisciplinesandspecialtygroupsintoateameffort.Developmentcanproceedfromconcepttoproductiontooperation.Ashams,wedon’tneed(usually)toconsiderthemanufacturingsequence(saveforaone-timeeffort).

Cost,schedule,trainingandsupportareimportant,butwehavemoreflexibilityintheseareasthanmightbefoundincommercialproductdevelopment.Yettheideasbehindtheprocess—thecriticalthinkingandanalysis— can be not only time-saving, but helpful in reducing costs and guaranteeing performance.However,weshouldrememberthatthisapproachwouldhavebothPROandCONsides:

PRO Those with an engineering background (some hams) are usually very comfortable with the systemsapproach.

Theapproachisverysuccessfulwhereit’spossibletospecifytherequirementstoahighdegree. The systems engineering approach requires thorough documentation (after all, it was developed byNATO’scommand-and-controlstructureandNASA).

CONTheprocessrequiresheavydocumentation.The process assumes it’s possible to arrive at near-perfect documentation that’s complete. It furtherassumessuchdocumentationtrulyrepresentstheultimate“requirements.”

Theprocessassumesthefinaldesigncanbefrozenatsomepointinitsdevelopment.So,let’sconsidersomewayswemightutilizethisapproachindesigningastationtobesuccessfultoday—withanemphasisonantennasforDXingandcontestwork.

OutsidetheShackTower(s), antenna(s), rotators and associated hardware should be your primary consideration —

realizingthemostmeasurableROI(returnoninvestment).ForaDXer/contester,anglesof radiationarecritical—theprimaryadvantages fromstacking,orat

leasthavingmultipleantennasfromwhichtochoose.Or,astheoldclichesays,“Youcanneverhavetoomanyantennas.”Reliabilityisanothercriticalfactor.Asispeaceofmind—notworryingaboutfailures!Expenseoftenseems,atfirstglance,nottohavebeenafactorforsomeoperators.(Butappearancescan

often be deceiving — there often are budgets and limits at work even at the largest super-stations,regardlessofwhatyoumaythink)Volumescouldbewrittenonhowtobudgetforstationbuilding.Havingoneisprobablythesimplestandbestadvicepossible!Itwillhelpyoufocusyourprioritiesandgetthemostbangforyourbuck.

InsidetheShackErgonomics— relaxed and comfortable posture and positioning. Simply put, thismeans nowasted

motionduringthe4hoursor48hoursyou’reseatedatyourradio!Whileit’softenconsidered“new”orcontemporary thinking, Katashi Nose, KH6IJ, pointed out, way back in 1958, the fallacy of sendingwithouthavingyourpenorpencilinyourhand!Consideroperatingtechniquesortactics,justforamoment.Remember,thetransceiverandtheCPUare

probablythetwogreatestinfluencesorfactorsthathavechangedthewayweoperatetoday.Howmanyreaders,forinstance,haveheard,letalonetakenpart,inanAMpileup?Onceuponatime,we’dtune“thewholeband,”afterCQing!Onceuponatime,theMulti-operator,Multi-transmittercategorydidnotexist!Onceuponatime,aquotasystemwasusedinARRL’sDXcontest.MeaningtherewerelimitstothenumberofDLsorJAsyoucouldwork.

Obviously,thetimestheyhavechanged(andarestilla-changin’),asthatpopularsongtolduswaybackinthe1960s.So,historyshouldalsocontributetoourthinking.AsGeorgeSantayanasaid:“Thosewhodonotlearnfrommistakesofthepastarecondemnedtorepeatthem...”Andyet, some things remain the same.We just have somemoremodern tools to analyze things and

understand how we’re doing things, how change is occurring and how we can measure or gauge itseffects. For instance: antenna and terrain modeling, databases of scores/rates/multipliers, historicalrecords(ifwecaretoaccessandusethem),andfar,farmoresophisticatedorbettergear—usuallyallcontainedinoneboxorseamlesslyintegratedandautomated.Consider some specifics as you operate— especially some considerations for using that computer.

Notethatwhilethe“box”maybeawhiz-bangtool,we’renowreallytalkingaboutsomeprettymundane,basicthings—achair,adesk,lightingandsoforth.Thesehavebeenpartofthehamstationforever,butnotalwaysusedwiththatwhiz-bangcomputer!

1)Monitorscreenisateyelevel(±10°)2)Elbowsrestattheside3)Elbowsarebentbetween60to90°4)Wristsareinaneutral(straight)position5)Wristsrestonaroundedtabletopedge6)Kneesarelevelwithorslightlylowerthanhips7)Softseatedge(behindknees)8)Feetrestonthefloororonafootrest9)Lowandmiddlebacksupportisprovided10)Seatwidth18inches11)Seatdepth15to17inches12)Chairheight13)Deskheight14)Lighting—noshadowsoroverlybrightspots/areas15)Audio—neithertoolownortooloud,sothelevelisalwaysconstant(preferheadphoneusewith

attachedmicrophone)Bynow,youshouldhaveconcluded thatdesign is, indeed, thecriticalword inourentireapproach.

AskGoogle“whatisdesign?”andyou’llonlygetsomethinglike26,700answersordefinitions.Sinceourfocusishighperformanceradio,ourneedswilllimitsomeofthem—furthersharpeningourfocus.For instance,wewill only have a finite amount of space to use, both outside and inside the shack.

Economicswill furtherdefine and limitour selectionof resources.Our “personal” choices (thingswefavor,suchasphoneversusCWversusdigitalmodes)willdriveour thinkinganddecisions.Variablesoutsideourcontrol(propagation)willalsomotivateourthinkingandchoices.Butthen,voila,someofthosedefinitionsuncoveredbyGooglestarttomakesense:theactofworkingouttheformofsomething...anarrangement,ascheme...ablueprint...adecorativeorartisticwork...aninvention...aplan...So,ultimately,werealizethatdesignisconcernedwithhowthingsoughttobeinordertoattaingoals

and to achieve some higher function. In constructive design, a specific artifact is designed. Inargumentativedesign, thedesignspaceandthedesigntrade-offsofaclassofdesignsarediscussed.Indesigning our stations— for DX and/or contesting success—wemust share and use processes andfactorsfrombothconstructiveandargumentativedesigninatrue,structured-engineeringapproach.Efficiencyshoulddriveourthinkingwhenbuildingourstations,frominsidetheshack,tothetower(s)

and antenna(s) up in the air. Economics (the practical realities ofwhatwe can afford) always furtherfocusthosethoughts.It’sanapproachpioneeredbyPaulRockwell,W3AFM,over40yearsago!

ReferenceandInspirationThevirtuallibraryaspectsoftheWorldWideWebremainunsurpassed,allowingyoutovisitandsee

whatyourfellowhamshavedonetosolveproblemsintheirownstation-buildingefforts.Over the years, I’ve searched for ideas and solutions (especially good, clear pictures) for various

clientsandtheirjobs,andfoundsomeofthebestonesonthefollowingpersonalpages.

www.ab7e.com—DavidGilbert,AB7E,ofHereford,Arizona(rightontheArizona/Mexicoborder),hasanexcellentwrite-upofhisANWirelessHD-70towerinstallation,alongwithsometrulyterrificpicturesdetailingtheproject,fromstarttofinish.

roode.com/k6nr/tower/—DanaRoode,K6NR, of Irvine,California, has awebsitewith excellentpicturesdocumentingthetowererectionathisremotestationinthedesert.Ofspecialnote(trulyworthstudying)arehis“towerpermitbuildingnotes,”whichcanbefoundonaseparatelinkatthebottomofthehomepage.

www.comdac.com—DuaneDurflinger,KX8D, ofHillman,Michigan, has aWeb sitewith lots ofexcellentpicturesdetailinghiscrank-uptowerinstallationinthelowerUpperPeninsulaofMichigan.Ofspecialnotearethemethodsheusedinovercomingtheverysandysoilconditionsencountered.

www.n0hr.com — Pat Rundall, NØHR, of Ames, Iowa, runs a Web site dedicated to ham radioresources,includingavastvarietyoflinksandsoforth.Hisownpersonaltowerprojectpagescontainawealth of information, from start to finish, including some excellent pictures of hisANWirelessinstallation. Pat’s project is typical, in that he relied on local helpers, ham buddies, family andneighborstomakethingshappen.

k7nv.com—KurtAndress,K7NV,ofMinden,Nevada,hasaveryinterestinganddetailedWebpage.Of special interest are his studies of guy wires and guyed towers, all found within “The K7NVNotebook”pages.OtherlinksprovidevaluableinformationonKurt’srebuildingofproppitchmotors,aswell.

www.k7vc.com—DickFlanagan,K7VC,out inwesternNevada,hassomeexcellentpicturesofhisUSTower72-footcrankupinstallation,doneusingaman-lift,alongwithlotsofhamfriendshelpinghimstackavarietyofbeams.

www.k4ja.com—Andalthoughit’ssincebeendismantled(Ispentaweektakingdowntheantennasandtowers,aheart-breakingjob),theconstructionphotographsofPaulHellenberg,K4JA’sstationinCallao, Virginia, are all still up and very worthwhile viewing. They are truly awe-inspiring andinspirationalstation-buildingshots,alongwithsomecontestinginformation!

users.erols.com/n3rr/ — Bill Hider, N3RR, of Rockville, Maryland, took a systems engineeringapproach to building his tower and antenna setup. As a contester, Bill was focused on safety andreliability.Severalofhissolutionsareworthalook.

www.k3lr.com.TimDuffy,K3LR,inWestMiddlesex,Pennsylvania(almostinOhio),hasalargemulti-multiorientedconteststation.Therearelotsofscores,lotsofpictures,lotsofconteststuff.Butagain,don’t let all that enthusiasm for competition scare you away if you’re not interested in contesting.What’sreallyvaluableandusefulisexamininghowTimhasdesigned,andthenfollowedthroughinbuildinghisstation.Iguaranteeavisitherewillprovideyouwithsomeideas!

www.anwireless.com—WebsiteofANWirelessCompany,ofSomerset,Pennsylvania,completewithfull technical specifications and descriptions of their self-supporting towers,which are rugged andreliable designs. Perhaps of most interest and use to hams will be the vast arrays of photographsshowing (in detail) awide variety of installations around theworld. Procedures and solutions caneasilybegleanedfromviewinghowotherfolksdidwhatyoumaywishtodo!

www.nr5m.com—GeorgeDeMontrond,NR5M’sstationinHempstead,Texas,iswellonthewaytobecomingoneof thepremieremulti-opstations in theUSA.JohnCrovelli,W2GD,andIhavebeenworking there together since fall of 2007, rebuilding George’s station. Again, the focus is oncontesting,butthelevelofseriousness,enthusiasmanddesignparticularsareworthalook.

www.k4za.com—Shameless self-promotion, I suppose,but thisWeb site, designedas ablog,mayprovideyouwithsomeinterestingreadingasIworkonvariousjobsaroundthecountry.

CommercialProducts—ApplicationNotes

PreformedLineProductsBigGripDeadEndsaretheproductofchoicefortoday’stowerworker,whetheryou’reusingEHS(steel)oranon-conductiveguyline(suchasPhillystranorPolygonRod).ThefollowingdocumentsfromthePreformedLineProductscatalogarereprinted

withpermission.Formoreinformation,seewww.preformed.com.

GUY-GRIP®Dead-end

GUY-GRIPDead-ends, installed at the top, the breaker and the anchor, provide today’smost effectivemethodforsecuringguystrand.Thisunique,one-piecedead-endisneatinappearanceandfreefromboltsorhigh-stressholdingdevices.TheGUY-GRIPDead-endwasthefirsttoofferthecabledloop,afeaturethatprovidesmoredurability,easiertensioningandadaptabilitytomultipleguying.

GUY-GRIPDead-endsaremadeofthesamematerialasthestrandtowhichtheyareapplied.Theyshouldbeusedonhardwarethatisheldinafixedposition.Thefittingshouldnotbeallowedtorotateorspinabouttheaxisofthestrand.Theyshouldnotbeusedastoolsincludingcome-alongs,pulling-ingrips,etc.

NOMENCLATURE

Cross-overMarks:(A)—Indicatesstartingpointforapplicationonsmallerdiameterfittings.(B)—Indicatesalternatestartingpointforapplicationonlargerdiameterfittings.

CabledLoop:Furnishedasstandard,allsizes.PitchLength:Onecompletewrap.

ShortLeg-LongLeg:Identifiesrodsbelongingtoeachleg,afterapplication.

ColorCodeandLength:Assists in identificationof strand size, corresponding to tabular informationappearingonpricepage.

IdentificationTape:Showscatalognumber,nominalsizes.

Big-GripDead-end

Big-GripDead-endsaredesignedforusewithantenna,communications tower,microwaveandvariousguyedstructuresthatrequireuseoflargeguystrand.Theyareeffectiveatboththestructuretopandtheanchorbottom.

Big-GripDead-endsarelefthandlaystandardandareappliedtothesamebasicmaterialsasthestrand(galvanizedstrand,aluminumcoveredstrand,exceptwherenoteddifferently).

TheBig-GripDead-endisdesignedtobeappliedquicklyinthefield,withouttools,andusuallybyoneperson.

Concentratedstressesintheanchorareaareminimizedbythecabledloop.Longlengthhelicalgrippingdistributesotherstressesuniformlyandevenly.

FormoredetailedinformationconcerninginstallationguidelinescontactPreformedLineProducts.

GalvanizedStrandForuseon:•ExtraHighStrength•SiemensMartin•HighStrength•UtilitiesGrade

Phillystranisanexcellentchoicefornonconductiveguylinesforyourhamtower.

BigGripsareavailable,andprovideaneasywaytoattachthisline.Hereistherelevantdatasheetcoveringtheproducts.Thefollowing

PhillystranTechnicalBulletinisreprintedwithpermission.Formoreinformation,

seewww.phillystran.com.

TheRohnProductCatalogcanservemore-or-lessasyour“Bible,”intermsofguyedtowerconstruction.It’swellworththeexpenseofbuyingacopy,aswellasthetimeandtroubleofsittingdownandreadingthroughthevarioussections.You’lllearnalotjustbydoingso.Formoreinformation,seewww.rohnnet.com.

Herearesomerelevantillustrations,reprintedwithpermission,pertainingtosometypicalham

installationsof25Gand45Gtowers:

AbouttheARRL

TheseedforAmateurRadiowasplantedinthe1890s,whenGuglielmoMarconibeganhisexperimentsinwireless telegraphy.Soonhewas joinedbydozens, thenhundreds, ofotherswhowere enthusiasticaboutsendingandreceivingmessagesthroughtheair—somewithacommercialinterest,butotherssolelyout of a love for this new communications medium. The United States government began licensingAmateurRadiooperatorsin1912.By1914,therewerethousandsofAmateurRadiooperators—hams—intheUnitedStates.HiramPercy

Maxim, a leadingHartford,Connecticut inventor and industrialist, saw the need for an organization tobandtogetherthisfledglinggroupofradioexperimenters.InMay1914hefoundedtheAmericanRadioRelayLeague(ARRL)tomeetthatneed.TodayARRL,withapproximately155,000members, is the largestorganizationof radioamateurs in

theUnitedStates.TheARRLisanot-for-profitorganizationthat:promotesinterestinAmateurRadiocommunicationsandexperimentationrepresentsUSradioamateursinlegislativematters,andmaintainsfraternalismandahighstandardofconductamongAmateurRadiooperators.At ARRL headquarters in the Hartford suburb of Newington, the staff helps serve the needs of

members.ARRL is also International Secretariat for the InternationalAmateur RadioUnion,which ismadeupofsimilarsocietiesin150countriesaroundtheworld.ARRLpublishesthemonthlyjournalQST,aswellasnewslettersandmanypublicationscoveringall

aspects of Amateur Radio. Its headquarters station, W1AW, transmits bulletins of interest to radioamateursandMorsecodepracticesessions.TheARRLalsocoordinatesanextensivefieldorganization,which includes volunteers who provide technical information and other support services for radioamateurs as well as communications for public-service activities. In addition, ARRL represents USamateurswith the FederalCommunicationsCommission and other government agencies in theUS andabroad.Membership inARRLmeansmuchmore than receivingQST eachmonth. Inaddition to the services

already described, ARRL offers membership services on a personal level, such as the TechnicalInformationService—wherememberscangetanswersbyphone,emailortheARRLwebsite,toalltheirtechnicalandoperatingquestions.Full ARRLmembership (available only to licensed radio amateurs) gives you a voice in how the

affairsoftheorganizationaregoverned.ARRLpolicyissetbyaBoardofDirectors(onefromeachof15Divisions).Eachyear,one-thirdoftheARRLBoardofDirectorsstandsforelectionbythefullmemberstheyrepresent.Theday-to-dayoperationofARRLHQismanagedbyanExecutiveVicePresidentandhisstaff.Nomatterwhat aspectofAmateurRadioattractsyou,ARRLmembership is relevant and important.

TherewouldbenoAmateurRadioasweknowittodaywereitnotfortheARRL.Wewouldbehappytowelcomeyouasamember!(AnAmateurRadiolicenseisnotrequiredforAssociateMembership.)FormoreinformationaboutARRLandanswerstoanyquestionsyoumayhaveaboutAmateurRadio,writeorcall: