CTB C O M M U N I C AT I O N S T E C H N O LO G Y B R O AD C AS T I N G c a s e s t u d y In 2003, these seventeen men performed the impossible. C o m m u n i c a t i o n s Te c h n o l o g y Broadcasting here demonstrates how their formidable and uncontested experience in the broadcast technology industry enabled them to literally achieve the impossible: to relocate a TCI 611 SW antenna system originally installed in the 1980's. Published by Communications Technology Broadcasting 2011 C O M M U N I C AT I O N S T E C H N O LO G Y B R O AD C AS T I N G c a s e s t u d y CUSTOMER PROFILE The scope of work was as follows: Customer: Official carrier of Broadcasting signals in South Africa Location: 1. Lower the three SW antenna curtain arrays suspended between the four 100m lattice masts. THE CHALLENGE 2. Package, transport and store antenna materials for reinstallation approximately 2km from the existing site. To dismantle, relocate by 2 kilometres and re-install a TCI 611 SW antenna system originally installed in the 1980's 3. Dismantle the four the 100m masts, transport and store at new site. THE RESULTS 4. Dismantle approximately 1000m of open wire feed-line, transport and store for re-installation at the new site. The project was deemed to have been a huge success, and what was thought to not be possible was achieved. The antenna manufacture described the success as a modern engineering marvel and congratulated Communications Technology Broadcasting (Pty) Ltd on a job very well done. 5. Dismantle three slew switches, transport to the new Site. 6. Survey new site for antenna placement, taking into account the desired target area (central and northern Africa). The antenna system is directional so the correct placement of the foundations of the antenna curtain and masts was of critical importance. Incorrect surveying would result in the broadcast signal missing the desired target area and as a result making the entire relocation process worthless. 7. Excavate for foundations, manufacture of foundation hardware, preparation of re-enforcing and casting of all concrete (in total 350 cubic metres of concrete) 8. Survey in of new antenna feed-line positioning, complete all civil works including re-bar, foundation hardware, shuttering and concrete pouring. 9. Re-paint the 4 x 100m masts and re-install in their new location taking into account the ground level to achieve the same “balance” as the old site. 10. Raise the 3 SW antenna curtains, ensuring that the dipoles are horizontal and the correct height from the ground. Project description: In 2003, Communications Technology Broadcasting (Pty) Ltd was approached by the official carrier of Broadcasting signals in South Africa to evaluate and report back on the possibility of dismantling, relocating and re-installing and TCI 611 SW antenna system originally installed in the 1980’s (also by Communications Technology Broadcasting (Pty) Ltd). After due consideration Communications Technology Broadcasting (Pty) Ltd decided that the project was feasible and together with the customer decided to take on a very ambitious project, deemed to be not possible by many since the antenna system was almost 20 years old. 11. Re-install the feed-line 12. Re-install slew switches, transformers and horizontal feed-lines. 13. Install new aviation lighting and wire all lights and switches to transmitter building 14. Test and commission antenna system. Published by Communications Technology Broadcasting 2011 C O M M U N I C AT I O N S T E C H N O LO G Y B R O AD C AS T I N G c a s e s t u d y OVERVIEW PROJECT DURATION During the dismantling, transportation, storage and installation phases, many hurdles had to be overcome. The project duration spanned over two years. Due to the age of the antenna many components had become brittle and special care had to be taken to eliminate the degree of breakages, which were inevitable. As a result the dismantling was kept to a minimum and an ingenious storage facility was created to house complete dipole sections. Mast sections were kept complete and the 1000m of feed-line was transported using hundreds of labourers carrying it by hand through the field. This could have been greatly reduced had it not been due to delays beyond the control of Communications Technology Broadcasting (Pty) Ltd. Design issues, theft and other technical issues forced delays here and there. Nevertheless the project was deemed to have been a huge success, and what was thought to not be possible was achieved. The antenna manufacture described the success as a modern engineering marvel and congratulated Communications Technology Broadcasting (Pty) Ltd on a job very well done. By successfully completing this project Communications Technology Broadcasting (Pty) Ltd has made its mark on the Broadcasting industry. Our reputation as Broadcasting and Communications specialists was given yet another boost and put us into different league where SW installations are concerned. Communications Technology Broadcasting (Pty) Ltd can say with confidence that no job is too big and if it is possible, we can do it, we have done it! Manual Labourers carrying feed line. Although there were some breakages, this was kept to a minimum and Communications Technology Broadcasting (Pty) Ltd was able to manufacture and replace all damaged items. PLEASE PROCEED OVERLEAF TO OUR GALLERY CONTACTS Tel Nr : +27 11 425 6656 Fax Nr: +27 11 425 6845 / +27 86 693 1417 E-mail: [email protected] Grant Chambers - Tel: +27 82 453 5216 Postal Address: Box 13299 Northmead Benoni 1511 Physical Address: 237/1 Robin Road Rynfield Agricultural Holdings Benoni 1501 Typical replacement part made by CTB. Published by Communications Technology Broadcasting 2011 C O M M U N I C AT I O N S T E C H N O LO G Y B R O AD C AS T I N G c a s e s t u d y GALLERY Our Gallery represents a sequential visual display of the entire project. 1. SW Antennae prior to relocation 2. Entire SW array that was relocated 3. Start of SW mast dismantling 4. Lower of top section of SW mast 5. Lowering of 1st section of SW mast 6. Mast dismantling in process 7. Winches in action used for antenna lowering and raising 8. Loading of SW slew switch for SW antenna system 9. Escorted transport of Slew Switch 10. Moving of antenna counterweights 11. Pegging out of Mast base 12. SW mast guy re-bar cages Published by Communications Technology Broadcasting 2011 C O M M U N I C AT I O N S T E C H N O LO G Y B R O AD C AS T I N G c a s e s t u d y GALLERY Our Gallery represents a sequential visual display of the entire project. 13. Placing of re-bar cages 14. Casting of mast base foundation for SW mast 15. Typical guy anchor for SW mast 16. Complete mast base for SW mast 17. Placing of 1st Section of SW mast 18. Preparing to lift a section of the SW mast 19. Crane being used for 1st section of SW mast erection 20. Mast section being rasied on SW Mast Published by Communications Technology Broadcasting 2011