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Assembling your antenna system

Assembling an antenna on an XXTower.

Assembling a low band HF antenna on an XXTower equipped with a ringrotor.

Installing of the antenna system (VI)

Like the tower building, you must plan and think seriously about the way that you or maybe with your team will proceed to the assembling and installation of the antenna system, what includes the rotator, the supporting mast , the antenna and the cabling system.

This procedure is probably useless to place a light antenna that you can carry alone in one hand and that does not require hours of preparation to know how to process, even if you have to place it on a sloping roof. This procedure rather concerns a typical bulky and large antenna that you cannot raise on top of a tower without assistance (both mechanical like adding a pulley, and human).

See first if the tower or the antenna manufacturer has not left some instructions. In all cases, here also simulate at ground level the full installation. It is by far preferable to be warned before than have to say sorry after ! 

If you work with a team begin by assigning to each people a determined role according to their skills : what element of the antenna with what tool each people must assemble, who stands on ground, why for, who climbs on the tower, at what time, who install the rotator, the antenna, who check the security and clean the ground, etc, and repeat also who is the chief !

The job must be divided in several steps : 

- Assembling the antenna on the ground

- Preparation of the area to raise the antenna and accessories

- Installing the rotator and the mast

- Installing the antenna

- Connection and fixing of the cabling system (rotator and antenna).

Assembling of an antenna is never a difficult task if you follow strictly the instruction manual. With a screwdriver, pliers and a wrench this a job that last between a few hours or two days.

When your antenna is assembled it is time to simulate the installation and imagine how you will raise this bulky antenna there up as well as its accessories.

We will take the example of a standard antenna assembled on top of a mast. There are other solutions among which the installation of a rotating ring at any heigth of the tower coupled with a TIC ringrotor like on the picture displayed at left taken at N3RR. The antenna in fixed on the ring and all the tower rotates.

For a ordinary pylon, begin first by installing a gin pole or a simple pulley on top of the mast. If necessary, to avoid to lift a load too heavy (over 30 kg, 60 lbs.) attach a second pulley at the base of the antenna so that you can use all your weight when pulling, rather than the sole strengh of your arms. In all cases use a rope at least twice as long as the height of the tower.

Then install the rotator on its platform and place the mast as described in the instruction manual. To increase the resistance to wind and reduce the lateral force endured by the rotator you can add just above the rotator a thrust bearing as explained previously. You will attach all required cables later. Remember than the lower is the rotator the weaker are the constraints that it will have to support.

At left, blue print of the main elements and sizings of an antenna system. At center the rotator and the thrust bearing installed at N0RQ. At right the installation of a typical rotator and its thrust bearing.

Raising and fixing of the antenna

At last take the antenna. Tie a rope around the balance point of the boom (60 cm to 1m on each side or 2-3ft) so that the antenna will be lift in horizontal position using the pulley(s). If it is a long Yagi you can also lift it with the boom parallel to the tower but you will have more difficulties once arrived on top to rotate it in position in both the vertical and the horizontal planes.

Before raising the antenna verify that during the ascent it will not hit the tower or will not be blocked by any obstacle like the guy wires or the insulators. In this case you can build a "track" made of two ropes joined over the tower (near the pulley) and tight more far than the guy anchors, thus forming a L over them, on which the antenna boom will slide to the top of the tower. But it is maybe easier to attach two additional ropes to both ends of the antenna boom so that you can pull on them to move the antenna away for any obstacle.

When all is ready, clear the tower area from all useless tool and potential obstacle. Check that the ropes are not intermingled and place them well apart, out of the antenna area and the people's feet. Then lift the antenna just one meter up to see if the balance is correct. If necessary, let it back down and adjust the ropes. When all is safely attached and verify, start pulling the antenna up the tower. With a large antenna it is careful to ask someone to climb on top of the tower to check the climb and that the elements are not caught or jammed here or there. 

Some steps of the installation of the 3 stacked and phased Bencher Skyhawk Yagis on top of a 40m tower in Rohn No.45 at W0YVA. Guys are a combination of 0.25" EHS steel and 6700# Phillystran.

Do never exert antagonist forces in the same time, like pulling strongly the boom toward you to avoid an obstacle and in the same time pulling it vertically. Balance your strains because the boom is vulnerable to horizontal forces and might break apart, all the more if it is made of fiber glass. Avoid also that the antenna rotates during the climb in using the two additional ropes tied and the ends of the boom to stabilize the antenna. Once arrived on top, one people is enough to place the antenna and bolt it on its mast.

When the antenna system is properly attached you can proceed to the installation of the cabling system, the cables to power and control the rotator and the antenna feed line or coaxial. Reserve the installation of the ground system and the lightning protection for another day, but as soon as possible.

After this first installation attach slightly the cabling system on top of the tower then let it runs freely to the ground. Take the time to place your cabling system in a flexible pipe 10-20 cm wide (4-8"), the ends being protected with a piece of insulation. Drive a narrow trench (excavation) less than 30 cm depth (<1') in the ground and bury inside the pipe to make it emerge near your station. Before stopping up properly the trench and fixing all cables make a first transmission test.

At left an US Tower supporting a CAL-AV 2-element beam for the 40-m band. At right F5RRS 12m high tower supporting a 5-element Tri-band Create 318B Yagi.

Do a first test of your installation before continuing. Test the rotator in all directions and check if the direction indicated on the control box and the heading of the beam are the same. In case of problem verify the rotator and the mast clamping. Make also some QSOs on each band covered by the antenna to check the transmission line SWR and other potential troubles. If all works properly it is time to achieve the job. Weatherproof all coaxials and connections (and optionally paint or coat unprotected hardware). Then secure all cables with fixings placed each 30 cm (1') all the way to the tower base. Fixings can be made either in wrapping tape along the cables running along the antenna boom and the tower rungs or better, using tie-wraps (autolocking plastic strips). Leave enough coax so that the antenna can rotate freely over 360° without pulling or binding the cable. But conversely to not let the cables flap in the wind as they can be damaged under high winds. 

Voilą, there we are, the antenna system and the tower are in place and work as expected ! I think having nothing forgot.

Additional security

Construction of a shield made of aluminium panels 1.5m long equipped of Z-brackets (a Z-bracket and a double-L versions are shown). They are installed on the low part of the tower between the rungs (see explanations below).

For security reasons, to prevent kids to climb on the tower, shield its lower part. ARRL published an article in the '80s suggesting to install panels between the base and about 1.5m (5 ft) high, and on a width as wide as the interval between two corners (say 50 cm, 20" between the structural rungs). 

These panels are made of galvanized steel sheets in 18-gauge size that are jammed in the tubular structure as displayed at right thanks to brackets in shape of Z. These brackets are made of aluminium or steel of about 15 cm long (6") and 3 cm wide (1.2"). They are fixed each 50 cm (20") on the left vertical side and inside each panel. Their size must be suited to the diameter of your rungs. You can also build these brackets in bolting together two L-brackets upside down. So, for a square tower your need either of 12 Z-brackets or 24 L-brackets. Then drill one hole in each plate and stick inside a bolt in order to screw a removable door-knob from the outside. 

To put the panels in place in the tower, move them from right to left and slightly tilted to you to jam the brackets around the vertical rungs then push them in position, they will stand up on their own weight. Then unscrew the door-knob. The panels must be difficult to extract for a kid although detachable in screwing the door-knob in the panels and taking the brackets out of rungs in moving the panels to the side opposite to the brackets (right) and slightly tilted to the outside.

Do not forget also to ground your tower and the antenna, and to install a lightning protection. "Playing" with high voltage and current, this time this is not a job that has room for experimentation...

To read: All about Lightning protection

Remain the maintenance. Check the state of your installation regularly from top to bottom, the antenna of course, but also the rotator housing, the fixings (bolts, anchors, etc), the base of the tower and the tension of guy wires. Check whether an hardware is missing, spots of rust, structural defects like cracks or bindings. Fix immediately any problem, reinforce if necessary the concerned element before it becomes a danger.

At last, think also to the dismantling of your tower. Proceed like we did but in reverse order. For the bulkiest installations it is preferable to entrust this task to a specialized company that will do the job using a crane to minimize the risks of accident.

  Good luck !

Take care assembling an antenna system

If you are not confident and used to erect antenna towers, do not entrust the job to close friends or so-called skilled radio amateurs... Your life and the one of your friends is more important that sparing a few money in doing the job yourself without competences.

Here is the comments of Jack, an ironworker in this regard : "there are some places and some jobs where if you make a mistake, people, either yourself or others or both, will be killed. Amateur Radio is not defined as one of these occupations, and no amateur has any business working aloft with rigging and equipment unless he was properly trained in that field. That certainly doesn't stop many from doing it, but it doesn't make it safer because they survive it. The skills sets that seem to congregate in radio are amazing for sure, and the field-expediant thinking and can-do attitudes are good for all involved in the hobby. 

But there are some things better left to professionals. Anyone who doesn't think a lot of Ironworkers die doing what they do better than anyone else could, is just delusional. The bravado I've witnessed from so called antenna-tower experts far outweighs their knowledge of safety, strength of materials, rigging principles, or safe working aloft. Even the better ones at it are not properly qualified to train others, and so often enlist any brave soul they can find as riggers, connectors, ground support, etc

When a home-made and low quality gin pole breaks...

Nobody was injured. Pļctures by LX4SKY.

Radio amateurs are not riggers! You are old men who have no business up in the air. You belong ON THE AIR, not in it ;-) Paste those pictures of your rigging days upon the club walls and stop your friends from believing they can think these jobs out. They can't erect an antenna tower in certifying at 100% that they will never incur the least risk. One or another day you will have to discover a new principle, strength/weakeness, fault, improper manufacturing or material failure, improper tools, breakage of tools, physical exhaustion of a team member at a critical time, unexpected wind condition, improper response to a command or order at a winch, line, etc. And each time those things happen, your fingers, hands, feet and possibly life will be at risk. It comes with the understanding that all injuries happen between 0-10 meters (0-40 ft). After that, you're either dead, or wish death would release you from the disfiguring and crippling pain.You better get used to the fact that you can and will have injuries so bad from a 2-10 meter fall into or around steel that you will never be the same again, if you live

All the blind leading the blind. I happen to know better than to work with untrained people at the effort of erecting antenna towers. I knew better when I erected steel as a professional and I still know better 20 years later. But some people's purpose in life is to serve as a warning to others. Don't let one of your friend's falling to his death make your club that purpose. Hire a professional company and take pictures from a safe distance."

Jack, Journeyman Ironworker.

Regularly ham magazines highlight similar accidents, sometimes involving a crane and a truck... So think twice to the risk you incur is doing such a job alone or with friends but without know-how.

For more information

Images of assembling

K4JA's construction of the contesting station

K6NR's crank-up tower installation

K7EM's shack and antennas farm

N0RQ's tower project

N3RR's tower and lightning protection installation

VK2VA's tower installation

W0YVA's tower installation

WX3K's amateur radio station

ComTrain LLC gallery


Anchor Guard

AN Wireless

Antenna Systems


Custom Metalworks

De Kerf (Bazel, Belgium)

Galvatech 2000

Glen Martin

Rohn Industries, Inc.

Thomas Global Register Europe

TIC ringrotor

US Tower


Books and technical info

Application Notes, Array Solution

Tower Climbing Safety & Rescue, ARRL bookshop
The Antenna File, RSGB or ARRL bookshop

QST Magazine, ARRL

The website of major manufacturers of rotators and towers (see ads in ham magazines).

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