AU2017365705A1

AU2017365705A1 - Radio towers, and systems and methods for the construction thereof

Info

Publication number: AU2017365705A1
Application number: AU2017365705A
Authority: AU
Inventors: Andrew Price
Original assignee: Australian Radio Towers Assets Pty Ltd
Current assignee: Australian Radio Towers Assets Pty Ltd
Priority date: 2016-11-22
Filing date: 2017-11-22
Publication date: 2019-06-13
Also published as: WO2018094456A1

Abstract

A monopole radio tower comprises a plurality of skins, including an outer skin and one or more internal skins, each skin comprising a plurality of monopole sections coupled together via splice joints comprising an internal splice plate and a plurality of external splice plates. The internal splice plate can have a cross-sectional shape that corresponds to a cross-sectional shape of the monopole section connected thereto. The splice joints between monopole sections of one or more of the internal skins can be offset from the splice joints between monopole sections of the outer skin. One or more of the internal skins can comprise one or more corrugations.

Description

RADIO TOWERS, AND SYSTEMS AND METHODS FOR THE CONSTRUCTION THEREOF

FIELD OF THE INVENTION [0001] The present invention relates to radio towers and/or masts, and systems and methods for the construction thereof. In particular, the present invention relates to monopoles, and systems and methods for the construction thereof.

BACKGROUND TO THE INVENTION [0002] Radio towers and masts are typically tall self-supporting structures upon which antennae for telecommunications and/or broadcasting are mounted. One type of radio tower is a monopole. Typically, monopoles comprise a self-supporting pole. In the prior art, monopoles are usually formed from tubular galvanized steel.

[0003] For some applications monopoles can be 30m high or taller. Traditional monopole designs are based on black raw steel that is formed and then hot dipped galvanised for corrosion protection. This provides a heavy wall thickness material. The walls of the monopole are typically 6-9mm thick, for example, to support the weight of the monopole and to resist buckling of the monopole in windy conditions.

[0004] Due to the heavy weight of such monopoles, they can be difficult to transport and erect. For example, monopoles typically require a large truck to transport them and heavy machinery such as cranes to unload the monopoles after transportation and to erect them.

OBJECT OF THE INVENTION [0005] It is a preferred object of the invention to provide an improved radio tower and/or mast, and/or systems and/or methods for the construction thereof that addresses or at least ameliorates one or more of the aforementioned problems of the prior art or provides a useful commercial alternative.

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SUMMARY OF THE INVENTION [0006] The present invention relates to radio towers and/or masts, and systems and methods for the construction thereof. In particular, the present invention relates to monopoles, and systems and methods for the construction thereof [0007] In one form, although not necessarily the broadest form, the invention resides in a monopole radio tower comprising a plurality of skins, including an outer skin and one or more internal skins.

[0008] In some embodiments, each skin comprises a plurality of monopole sections coupled together.

[0009] In some embodiments, the monopole sections are coupled together via splice joints.

[0010] Suitably, the splice joints between monopole sections of one or more of the internal skins are offset from the splice joints between monopole sections of the outer skin.

[0011] Suitably, each splice joint comprises an internal splice plate. For example, the internal splice plate can have a cross-sectional shape that corresponds to the crosssectional shape of the monopole section connected thereto.

[0012] Suitably, each splice joint comprises a plurality of external splice plates. For example, an external splice plate can be used for each lateral side of the monopole section.

[0013] In some embodiments, one or more fasteners, such as bolts, couple one of the external splice plates to a corresponding one of the internal splice plates.

[0014] In some embodiments, each skin and/or section comprises a plurality of portions coupled together, for example, via fasteners such as pins.

[0015] Suitably, one or more of the internal skins comprise one or more corrugations.

[0016] Suitably, the outer skin comprises one or more sides adjacent the corrugations of the internal skins. For example, the outer skin can have an octagonal or substantially octagonal cross-section.

[0017] Suitably, the outer skin is coupled to one of the internal skins at one or more of the corrugations.

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PCT/AU2017/051284 [0018] In some embodiments, adjacent portions of the outer skin are coupled via a lateral butt joint, wherein the adjacent portions are coupled to one of the internal skins adjacent the butt joint.

[0019] In some embodiments, the monopole comprises a base section.

[0020] Suitably, the base section comprises a base plate.

[0021] Suitably, the base section comprises an outer connecting section and one or more internal connecting sections coupled to, or integrally formed with, the base plate.

[0022] In some embodiments, the monopole is tapered upwardly.

[0023] In some embodiments, the monopole is formed of a sheet metal material, such as, sheet steel.

[0024] Suitably, the sheet metal material is pre-coated, for example, with a protective coating, such as, colour bond, zincalume, galvanised and/or one or more Zam® coating products.

[0025] In another form, although not necessarily the broadest form, the invention resides in a method for constructing a monopole radio tower comprising a plurality of skins, the method comprising:

coupling together a plurality of first monopole sections to form an internal skin; and coupling together a plurality of second monopole sections to form an outer skin.

[0026] In some embodiments, the method comprises coupling together a plurality of portions of the internal skin to form a section of the internal skin.

[0027] In some embodiments, the method comprises coupling together a plurality of portions of the outer skin to form a section of the outer skin.

[0028] Suitably, coupling together the plurality of portions of the outer skin comprises coupling adjacent portions of the outer skin together via the internal skin.

[0029] Suitably, the method further comprises coupling a corrugation in the internal skin to a side of the outer skin to mitigate buckling.

[0030] In a further form, although not necessarily the broadest form, the invention resides in a method of manufacturing a monopole radio tower comprising a plurality of skins, including an outer skin and one or more internal skins, the method comprising forming a plurality of monopole sections for each skin from sheet metal.

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PCT/AU2017/051284 [0031] Suitably, the sheet metal comprises a pre-applied protective coating.

[0032] Further forms and/or features of the present invention will become apparent from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS [0033] In order that the invention may be readily understood and put into practical effect, reference will now be made to preferred embodiments of the present invention with reference to the accompanying drawings, wherein like reference numbers refer to identical elements. The drawings are provided by way of example only, wherein:

[0034] Fig. 1 illustrates a monopole comprising a plurality of monopole sections coupled together;

[0035] Fig. 2 illustrates an exploded view of a monopole comprising a plurality of skins according to one embodiment of the invention;

[0036] Fig. 3 illustrates a cross-sectional view of the monopole according to one embodiment of the invention;

[0037] Fig. 4 illustrates a butt joint according to one embodiment of the invention;

[0038] Fig. 5 illustrates part of a monopole according to one embodiment of the invention;

[0039] Fig. 6 illustrates a cross-sectional view of the monopole of Fig. 5 according to one embodiment of the invention;

[0040] Fig. 7 illustrates a butt joint of the monopole of Fig. 5 according to one embodiment of the invention;

[0041] Fig. 8 illustrates a ladder section of the monopole of Fig. 5 according to one embodiment of the invention;

[0042] Fig. 9 illustrates an example monopole according to one embodiment of the invention;

[0043] Fig. 10 illustrates another example monopole according to one embodiment of the invention;

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PCT/AU2017/051284 [0044] Fig. 11 illustrates a first fastener arrangement according to one embodiment of the invention;

[0045] Fig. 12 illustrates a second fastener arrangement according to one embodiment of the invention;

[0046] Fig. 13 illustrates a fastener connection according to one embodiment of the invention;

[0047] Fig. 14 illustrates a third fastener arrangement according to one embodiment of the invention;

[0048] Fig. 15 illustrates a fourth fastener arrangement according to one embodiment of the invention;

[0049] Fig. 16 illustrates a cross-sectional view of a monopole comprising three skins according to one embodiment of the invention;

[0050] Fig. 17 illustrates a perspective view of a mounting structure for mounting aerials to a monopole according to one embodiment of the invention;

[0051] Fig. 18 illustrates a perspective view of one or more aerials mounted to a monopole according to one embodiment of the invention;

[0052] Fig. 19 illustrates a perspective view of a monopole section according to one embodiment of the invention; and [0053] Fig. 20 illustrates a cross sectional view of a monopole according to one embodiment of the invention.

[0054] Skilled addressees will appreciate that elements in the drawings are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the relative dimensions of some of the elements in the drawings may be distorted to help improve understanding of embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION [0055] The present invention relates to radio towers and/or masts, and systems and methods for the construction thereof. In particular, the present invention relates to monopoles, and systems and methods for the construction thereof [0056] Embodiments of the present invention include a monopole radio tower comprising a plurality of sections, which, for example, enable the monopole radio tower

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PCT/AU2017/051284 to be transported more easily and constructed on site. In preferred embodiments, the monopole radio tower comprises a plurality of skins. In preferred embodiments of the invention, the monopole is tapered upwardly and/or an outer skin of the monopole comprises: three or more lateral sides.

[0057] Fig. 1 illustrates a monopole 100 comprising a plurality of monopole sections 110 coupled together. A lowest monopole section 110A is coupled to a surface, such as a concrete footing, for example, via a base plate.

[0058] Fig. 2 illustrates an exploded view of a monopole 200, according to one embodiment of the invention. The monopole 200 comprises an outer skin 210 and an internal skin 250. Each skin 210, 250 comprises a plurality of monopole sections 220, 260 coupled together. In the embodiment shown, the joints 270 between the monopole sections 260 of the internal skin 250 are offset from the joints 230 between monopole sections 220 of the outer skin 210. A base monopole section 220A of the outer skin 210 is shorter than a base monopole section 260A of the internal skin 250 to enable the joints 230, 270 to be offset. An uppermost monopole section 260B of the internal skin 250 is also shorter than the uppermost section 220B of the outer skin 210 such that the outer skin 210 and the internal skin 250 have a similar length. For example, the internal skin 250 and the outer skin 210 can be made from high tensile steel and can have a thickness of about 3mm.

[0059] Fig. 3 illustrates a cross-sectional view of the monopole 200 according to one embodiment of the invention. The internal skin 250 comprises corrugations 255. The outer skin 210 comprises sides 215 adjacent the corrugations 255 of the internal skin 250. In the embodiment shown, the outer skin has an octagonal cross-section, i.e. eight sides 215. The outer skin 210 is coupled to the internal skin 250 at the corrugations 255, for example, via one or more fasteners 310 between each corrugation 255 of the internal skin 250 and the adjacent side 215 of the outer skin 210. In the embodiment shown, a width of the corrugation is about a third of a width of the side and the corrugation divides the side into three substantially equal sections. This reduces a buckling width of the side and mitigates buckling of the monopole 200. The design shown in Fig. 3 is used, for example, for sections of the monopole 200 having a width of 660mm - 1010mm.

[0060] The outer skin 210, and/or each monopole section 220 of the outer skin 210, comprises a plurality of portions 240. In the embodiment shown, each portion 240

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PCT/AU2017/051284 comprises two sides 215 of the outer skin 210. The internal skin 250, and/or each monopole section 260 of the internal skin 250, comprises a plurality of portions 280. In the embodiment shown, each portion 240 includes two corrugations 255 which are fixed to the corresponding two sides 215 of the outer skin 210.

[0061] The plurality of portions 240, 280 of each skin 210, 250 are coupled together, for example, via fasteners such as pins. In the embodiment shown, adjacent portions 240 of the outer skin 210 are coupled together via a lateral butt joint 290.

[0062] A corner 242 of each potion 240 of the outer skin 210 stiffens the monopole 200 to mitigate buckling. The smaller the internal angle of the corner 242, the more buckling is mitigated. For example, the internal angle of the corner can be increased or decreased by changing the number of sides 215 of the outer skin 210.

[0063] Fig. 4 illustrates the butt joint 290 according to one embodiment of the invention. The portions 280 of the internal skin 250 comprise a first flange 282 at a first end of each portion 280 and a second flange 284 at a second end of each portion 280. The first flange 282 of each portion 280 couples to a parallel surface of the second flange 284 of an adjacent portion 280, for example, via fasteners 310. A corner flange 286 extends from the first flange 282. Adjacent portions 240 of the outer skin 210 are coupled to the corner flange 286 of the internal skin 250, for example, via fasteners 310, on either side of a corner 288 of the corner flange 286 to form the butt joint 290.

[0064] Fig. 5 illustrates part of a monopole 400 according to one embodiment of the invention. The monopole 400 has an outer skin 410 and an internal skin 420. The monopole 400 comprises a plurality of monopole sections 430 coupled together via splice joints 450.

[0065] Each splice joint 450 comprises an internal splice plate 470. The internal splice plate 470 can have a cross-sectional shape that corresponds to the cross-sectional shape of the monopole section 430. For example, in the embodiment shown, the internal splice plate 470 has an octagonal cross section. The internal splice plate 470 comprises a plurality of apertures 472 to receive fasteners to fasten the internal splice plate 470 to the adjacent monopole sections 430. In the embodiment shown, two staggered rows of apertures are provided for connection to each section 430. The rows of apertures can be spaced, for example, by 100mm vertically. The fasteners can be, for example, M16 class 8.8 bolts. In some embodiments, the bolts are tack welded to

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PCT/AU2017/051284 the internal skin 410. The internal splice plate 470 can be, for example, approximately 6mm thick and approximately 400mm high.

[0066] Each splice joint 450 also comprises a plurality of external splice plates 460. For example, the external splice plates 460 include a splice plate for each lateral side of the monopole section 430. In the embodiment shown, there are eight external splice plates 460 for each splice joint 450. The external splice plates 460 comprise each comprises a plurality of apertures 472 to receive fasteners to fasten the external splice plate 460 to the adjacent monopole sections 430. In the embodiment shown, two staggered rows of apertures are provided for connection to each section 430. The rows of apertures can be spaced, for example, by 100mm vertically. The fasteners can be, for example, M16 class 8.8 bolts. In some embodiments, the bolts are tack welded to the outer skin 410. Each external splice plate 460 can be, for example, approximately 6mm thick and approximately 400mm high. A width of each external splice plate 460 can be based on a width of each side of the monopole 400 at the splice joint 450.

[0067] The monopole 400 comprises a base section 440, which comprises a base, a base plate 445, an outer connecting section 465 and an internal connecting section 475. The base plate 445 comprises apertures 442 to fix the monopole 400 to a surface to support the monopole 400 in an upright position. The outer connecting section 465 and the internal connecting section 475 are coupled to, or integrally formed with, the base plate 445. For example, in some embodiments, the outer connecting section 465 and the internal connecting section 475 are welded to the base plate 445. The internal connecting section 475 and the outer connecting section 465 each comprise a joint including a plurality of apertures 462, 472 to receive fasteners to couple a monopole section 430 to the connecting section 465, 475. The fasteners can be, for example M16, grade 8.8 bolts. In some embodiments, the fasteners used for the outer connecting section 465 are “hollo-bolts”. In the embodiment shown, the internal connecting section 475 and the outer connecting section 465 are octagonal. The internal connecting section 475 and/or the outer connecting section 465 can be about 8mm thick. The based plate can be, for example, about 25mm-40mm thick and can be fastened, for example, to footings via M36, class 8.8 bolts.

[0068] The internal connecting section 475 protrudes beyond the outer connecting section 465 such the joint of the internal connecting section 475 is accessible. The internal skin 420 of the monopole section 430 is coupled to the outside of the internal

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PCT/AU2017/051284 connecting section 475 via fasteners. The outer skin 410 of the monopole section 430 is coupled to the outside of outer connecting section 465 via fasteners.

[0069] In some embodiments, the monopole is made of steel. The above measurements of parts of the monopole are based on the use of USO grade steel.

[0070] Fig. 6 illustrates a cross-sectional view of the monopole 400 according to one embodiment of the invention. The outer skin 410 is coupled to the internal skin 420 via fasteners 415, as described above. The portions of the outer skin 410 and the internal skin 420 are coupled together via butt joints 480 including fasteners 415, as described above. For example, the fasteners 415 can be rivets or heavy duty pins, such as Pulsa™ pins made by Ramset™. The fasteners can be spaced, for example, by 100mm vertically along the section 430. Each portion of the internal skin 420 comprises a corrugation 425 adjacent each face of the outer skin 410. The corrugation 425 stiffens each side of the outer skin 410 to mitigate buckling. The internal skin 420 and the outer skin 410 are spaced apart by approximately 50mm.

[0071] The internal skin 420 is mounted over the internal splice plate 470. The contour of the outer surface of the internal splice plate 470 corresponds substantially to the contour of the inner surface of the internal skin 420. The external splice plates 460 are fixed to the outside of the outer skin 410 on each side of the outer skin 410 to join adjacent monopole sections 430.

[0072] One or more fasteners 464, such as bolts, couple the adjacent monopole sections 430 to the internal splice plate 470 and/or the external splice plate 460. In the embodiment shown, the fasteners 464 extend through the external splice plate 460, the outer skin 410, the internal skin 420 and the internal splice plate 470.

[0073] In some embodiments, the monopole 400 can include step pegs or a ladder up at least one side of the monopole, for example, in accordance with Australian standards or other national/international standards. Fig. 6 illustrates an optional ladder section 490 coupled to one side of the outer skin 410 and/or to one of the external splice plates 460. For example, the ladder can be offset from the outer skin 410 or the external splice plate 460 a distance of 0 to 200mm.

[0074] The monopole 400 optionally comprises cable clamps 405. For example, the cable clamps 405 are attached to the outside of the monopole 400.

[0075] Fig. 7 illustrates the butt joint 480 according to one embodiment of the invention. A first flange 424 is provided at a first end of each portion 422 of the internal

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PCT/AU2017/051284 skin 420 and a second flange 426 at a second end of each portion 422. Adjacent portions 422 of the internal skin 420 are coupled together via fasteners 415 which couple the first flange 424 of one portion 422 to the second flange 426 of an adjacent portion 422. Adjacent portions 412 of the outer skin 410 are coupled via fasteners 415 to a corner flange 428 of the internal skin 420 that extends from the first flange 424. [0076] The butt joint 480 is covered by the internal joint plate 470 and the adjacent external joint plates 460. The external joint plates 460 cover the fasteners 415, for example, to protect the fasteners 415 from tempering and/or to mitigate the fasteners 415 from being a hazard on the outside of the monopole 400.

[0077] Fig. 8 illustrates the ladder section 490 according to one embodiment of the invention. The ladder section 490 comprises a fixing plate 495. The fixing plate 495 is coupled, via fasteners 497, to one side of the outer skin 410 and/or to one of the connecting plates 460. Similar ladder sections 490 can be coupled to each section 430 and/or joint 450 of the monopole 400 to form a ladder up the outside of the monopole 400. For example, the fixing plate can be about 8mm thick, about 150mm long and about 150mm high. The fasteners 497 can be M12, class 5.6 bolts and can be spaced vertically along the monopole 400 in accordance with Australian or other national/international spacing standards. For example, the fasteners 497 can be spaced by 1500mm vertically along the monopole 400.

[0078] Fig. 9 illustrates an example monopole 400 according to one embodiment of the invention. The monopole 400 is 25m high. Fig. 9 shows the displacement of the end of each monopole section from the base of the monopole and a diameter of the monopole 400 at the end of each monopole section. The monopole sections are about 3.3m high, except the top monopole section which is 3.2m high and the connecting section adjacent the base which is 2m high.

[0079] Fig. 10 illustrates another example monopole 400 according to one embodiment of the invention. The monopole 400 is 30m high. Fig. 10 shows the displacement of the end of each monopole section from the base of the monopole and a diameter of the monopole 400 at the end of each monopole section. The monopole sections are about 3.3m high, except the top monopole section which is 3.6m high.

[0080] Fig. 11 illustrates a first fastener arrangement 500 according to one embodiment of the invention. The first fastener arrangement 500 comprises three vertical lines or columns of fasteners 464 for each external joint plate 460. One of the io

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PCT/AU2017/051284 three columns of fasteners 464 is aligned with the corrugation 425 on the respective side of the monopole 400. The other two columns of fasteners 464 are either side of the corrugation 425.

[0081] The first fastener arrangement 500 can be used, for example, for monopole sections 430 having a diameter in the range of 660mm-1010mm. For example, the monopole section 430 can have a diameter of about 800mm. The corrugation 425 divides each side of the monopole section 430 into thirds. Each third can be, for example, about 112mm wide. This width can be considered to be a width of a stress zone for potential buckling.

[0082] Fig. 12 illustrates a second fastener arrangement 510 according to one embodiment of the invention. The second fastener arrangement 510 comprises two vertical lines or columns of fasteners 464 for each external joint plate 460. The two columns of fasteners 464 are located on either side of the corrugation 425.

[0083] The second fastener arrangement 510 can be used, for example, for monopole sections 430 having a diameter that is smaller than the monopole sections for which the first fastener arrangement 500 is used. For example, the second fastener arrangement 510 can be used for monopole sections 430 having a diameter in the range of 450mm590mm. The corrugation 425 divides each side of the monopole 400 approximately into halves having a stress zone that is, for example, about 124mm wide. In some embodiments, the fasteners 464 are M16 or M20, class 8.8 bolts.

[0084] Fig. 13 illustrates a fastener connection 550 according to one embodiment of the invention. The fastener connection 550 comprises a spacer 552 between the outer skin 410 and the inner skin 420. For fasteners adjacent corrugations, the spacer 552 can be between the inner skin 420 and the internal splice plate 470. In embodiments where the monopole has more than two skins, spacers can be used between internal skins.

[0085] Fig. 14 illustrates a third fastener arrangement 520 according to one embodiment of the invention. The fasteners 464 are arranged in three columns 522 across the external splice plate 460. Three rows 524 of fasteners 464 are provided for coupling to each of the adjacent monopole sections 430. For example, Fig. 12 shows a side of a monopole section 430 having a diameter of 800mm. Each row 524 is spaced apart vertically by about 70mm and each column 522 is spaced apart horizontally by

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PCT/AU2017/051284 about 98mm. The top and bottom rows are vertically offset by about 60mm from the edge of the external splice plate 460.

[0086] Fig. 15 illustrates a fourth fastener arrangement 530 according to one embodiment of the invention. The fasteners 464 are arranged in a staggered or zigzag arrangement with offset rows 534 of three fasteners 464. Four rows 534 of fasteners 464 are provided for coupling to each of the adjacent monopole sections 430. For example, the third fastener arrangement 520 is used between narrower sections 430 of the monopole 400 than the fourth joint arrangement 530. For example, Fig. 13 shows a side of a monopole section 430 having a diameter of 870mm. Each row 534 is spaced apart vertically by about 60mm and the fasteners 464 in each row 534 are spaced apart horizontally by about 108mm. The top and bottom rows are vertically offset by about 60mm from the edge of the external splice plate 460.

[0087] While monopoles described above have two skins, some embodiments of the present invention comprise an outer skin and two or more internal skins.

[0088] Fig. 16 illustrates a cross-sectional view of a monopole 600 according to one embodiment of the invention. The monopole 600 comprises an outer skin 610 and two internal skins 620, 630. The outer skin 610 and a first internal skin 620 are arranged as described above for the monopole 400. However, a second internal skin 630 is coupled to the first internal skin 620 via fasteners 640. The second internal skin 630 comprises a plurality of portions 635 which are coupled together. For example, in the embodiment shown, ends of adjacent portions 635 overlap and are coupled together via fasteners 640. In other embodiments, where a fourth internal skin is added, the portions of the second internal skin 630 may be coupled together via a butt joint, as described above, by fastening the ends of the portions 635 to the fourth internal skin.

[0089] In the embodiment shown, the fasteners 464 extend through the external splice plate 460, the outer skin 610, the first internal skin 620, the second internal skin 630 and the internal splice plate 470. Spacers 552 are used with the fasteners 464 as described above.

[0090] Fig. 17 illustrates a perspective view of a mounting structure 700 for mounting aerials to the monopole according to one embodiment of the invention. The mounting structure 700 comprises a ring 710 upon which aerials can be mounted. Radial members 720 couple the ring to the monopole 100. The radial members 720 each comprise a first mounting bracket 730 for fixing the radial member 720 to the monopole

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100 via fasteners 750 and a second mounting bracket 740 for fixing the radial member 720 to the ring 710.

[0091] Fig. 18 illustrates a perspective view of one or more aerials 760 mounted to a monopole 100 according to one embodiment of the invention. Two mounting structures 700 are coupled to the monopole 100. One or more aerial mounts 760 are coupled to the rings 710 of the two mounting structures 700 such that they extend between the mounting structures 700. An aerial 770 can be coupled to each aerial mounts 760 [0092] In some embodiments, the monopole can support a weight of up to 1000kg. In some embodiments, the monopole can support a weight of up to 500kg.

[0093] Fig. 19 illustrates a perspective view of a monopole section 800 according to one embodiment of the invention. The monopole section 800 is similar to the monopole section 430 described above. However, an outer skin 810 of the monopole section 800 comprises two portions 815 and an internal skin 820 of the monopole section 800 comprises four portions 825. Each portion 825 of the internal skin 820 includes a first flange 830 at a first end and a second flange 840 at a second end. The first flange 830 and the second flange 840 each form a corner and have a complementary shape such that the first flange 830 can be received within the second flange 840 and fastened to the second flange 840.

[0094] Fig. 20 illustrates a cross sectional view of a monopole 900 according to one embodiment of the invention. The monopole 900 comprises an outer skin 910, a first internal skin 920 and a second internal skin 930. The second internal skin 930 has a similar design to the first internal skin 920. In the embodiment shown, the corner flange 928, 938 extends from the second flange 926, 936 of each portion 922, 932 of the internal skins 920, 930. The corner flange 938 of the second internal skin 930 is aligned with a corner 923 at a middle of the portion 922 of the first internal skin 920.

[0095] Fig. 21 illustrates a method 1000 for constructing a monopole radio tower comprising a plurality of skins according to one embodiment of the invention. The method 1000 comprises the following steps.

[0096] At step 1010, the method 1000 comprises coupling together a plurality of first monopole sections to form an internal skin. In some embodiments, the method 1000 comprises coupling together a plurality of portions of the internal skin to form a section of the internal skin.

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PCT/AU2017/051284 [0097] At step 1020, the method 1000 comprises coupling together a plurality of second monopole sections to form an outer skin. In some embodiments, the method 1000 comprises coupling together a plurality of portions of the outer skin to form a section of the outer skin. The adjacent portions of the outer skin can be coupled together via the internal skin. A corrugation in the internal skin can be coupled to each side of the outer skin to mitigate buckling.

[0098] In preferred embodiments of the invention, the monopole is formed of a sheet metal material, such as, sheet steel. In some embodiments, the sheet metal material is pre-coated, for example, with a protective coating, such as one or more of the following: colour bond, zincalume, galvanised and/or one or more Zam® coating products.

[0099] Embodiments of the present invention can provide strength using light weight materials. In contrast to prior art monopoles which must be transported on large trucks and erected via heavy machinery, the monopole portions, sections and/or skins of embodiments of the present invention may be transported via smaller vehicles and can be more easily lifted. For example, a 30m monopole that would traditionally be transported on a large semi trailer and unloaded with a crane could be delivered using the present invention on a trailer behind a car and unloaded by hand.

[0100] The present invention can reduce transportation and construction costs and enable the monopole to be transported more easily and transported to difficult to access places.

[0101] Furthermore, monopole sections no longer need to be welded during production and the fabrication process can be fully automated. The monopole sections can be attached more simply using fasteners such as screws, rivets, glue and/or bolts without the need for special equipment.

[0102] The monopole of embodiments of the present invention is also adaptable in that skins can be added to increase the capacity of the monopole radio tower, potentially further than traditional designs. Such layering of skins can be alternated and repeated, for example, flat skin (layer 1), skin with corrugation (layer 2), flat skin (layer 3), skin with corrugation (layer 4), etc. Therefore, the design of the present invention can be adapted to achieve the strength needed for the monopole.

[0103] The monopoles of the present invention can use pre-coated material, or material that is produced in coils with pre applied protective coatings such as colour bond, zincalume, galvanised and/or Zam® coating products. One advantage of this is

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PCT/AU2017/051284 that higher tensile strength material can be used while not requiring further protective coating applications after the manufacture or forming process. This can enable full automation from programming through to packaging allowing most of the assembly to be carried out completely on site with small manageable components.

[0104] The use of sheet metal materials also enables coloured monopoles to be produced using coloured bond coated products.

[0105] In this specification, the terms “comprises”, “comprising” or similar terms are intended to mean a non-exclusive inclusion, such that an apparatus that comprises a list of elements does not include those elements solely, but may well include other elements not listed.

[0106] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

[0107] Throughout the specification the aim has been to describe the invention without limiting the invention to any one embodiment or specific collection of features. Persons skilled in the relevant art may realize variations from the specific embodiments that will nonetheless fall within the scope of the invention. For example, while embodiments of the invention have been described separately, a skilled addressee will appreciate that the features of such embodiments may be combined where possible.

Claims

1. A monopole radio tower comprising a plurality of skins, including an outer skin and one or more internal skins.

2. The monopole radio tower as claimed in claim 1, wherein each skin comprises a plurality of monopole sections coupled together.

3. The monopole radio tower as claimed in claim 2, wherein the plurality of monopole sections are coupled together via splice joints.

4. The monopole radio tower as claimed in claim 3, wherein the splice joints between monopole sections of one or more of the internal skins are offset from the splice joints between monopole sections of the outer skin.

5. The monopole radio tower as claimed in claim 3 or 4, wherein each splice joint comprises an internal splice plate.

6. The monopole radio tower as claimed in claim 5, wherein the internal splice plate has a cross-sectional shape that corresponds to a cross-sectional shape of the monopole section connected thereto.

7. The monopole radio tower as claimed in any one of claims 3 to 5, wherein each splice joint comprises a plurality of external splice plates.

8. The monopole radio tower as claimed in claim 7, wherein at least one of the plurality of external splice plates is coupled to a lateral side of a respective monopole section.

9. The monopole radio tower as claimed in claim 7 or 8, wherein one of the external splice plates is coupled to a corresponding one of the internal splice plates with one or more fasteners.

10. The monopole radio tower as claimed in any preceding claim, wherein each skin and/or monopole section comprises a plurality of portions coupled together.

11. The monopole radio tower as claimed in any preceding claim, wherein one or more of the internal skins comprises one or more corrugations.

12. The monopole radio tower as claimed in claim 11, wherein the outer skin comprises one or more sides adjacent the one or more corrugations of the one or more internal skins.

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13. The monopole radio tower as claimed in claim 11 or 12, wherein the outer skin is coupled to one of the internal skins at one or more of the corrugations.

14. The monopole radio tower as claimed in any preceding claim, wherein adjacent portions of the outer skin are coupled via a lateral butt joint.

15. The monopole radio tower as claimed in claim 14, wherein the adjacent portions are coupled to one of the internal skins adjacent the butt joint.

16. The monopole radio tower as claimed in any preceding claim, wherein the outer skin has an octagonal, or substantially octagonal cross-section.

17. The monopole radio tower as claimed in any preceding claim, wherein the monopole comprises a base section.

18. The monopole radio tower as claimed in claim 17, wherein the base section comprises a base plate.

19. The monopole radio tower as claimed in claim 17 or 18, wherein the base section comprises an outer connecting section and one or more internal connecting sections coupled to, or integrally formed with, the base plate.

20. The monopole radio tower as claimed in any preceding claim, wherein the monopole is tapered upwardly.

21. The monopole radio tower as claimed in any preceding claim, wherein the monopole is formed of a sheet metal material, such as, sheet steel.

22. The monopole radio tower as claimed in claim 21, wherein the sheet metal material is pre-coated with a protective coating selected from one or more of the following: colour bond; zincalume; galvanised; one or more Zam® coating products.

23. A method for constructing a monopole radio tower comprising a plurality of skins, the method comprising:

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24. The method as claimed in claim 23, comprising coupling together a plurality of portions of the internal skin to form a section of the internal skin.

25. The method as claimed in claim 23 or 24, comprising coupling together a plurality of portions of the outer skin to form a section of the outer skin.

26. The method as claimed in claim 25, wherein coupling together the plurality of portions of the outer skin comprises coupling adjacent portions of the outer skin together via the internal skin.

27. The method as claimed in any one of claims 23 to 26, further comprising coupling a corrugation in the internal skin to a side of the outer skin to mitigate buckling.

28. A method of manufacturing a monopole radio tower comprising a plurality of skins, including an outer skin and one or more internal skins, the method comprising forming a plurality of monopole sections for each skin from sheet metal.

29. The method of claim 28, wherein the sheet metal comprises a pre-applied protective coating.