Municipal Corporation Tender

The High Mast & head frame shall be structurally suitable to accommodate the 6 Nos.LED flood light fittings & its control gear boxes.

The entire high mast structure (Internally & externally) and all MS parts shall be hot dip galvanized as per BSEN ISO 1461.

Construction of the Mast: The mast shaft shall be manufactured from high tensile steel plates confirming to BS EN 10025 having minimum yield strength of 355N/Sq. mm. Each mast shaft section shall be without any circumferential weld joint except base flange. The mast base flange shall be free from any lamination or incursion and provided with supplementary gussets between the bolt-holes to ensure elimination of helical stress concentration. The minimum A/F dimension of top shall be 150 mm (min.) and bottom 360 mm (min.). The mast should have two sections and the sections shall be joined at site by slip-stress-fit method and the sections shall be joined at site by slip-stress-fit method and minimum overlap distance shall be 1.5 times the diameter at penetration. A door reinforced with welded steel section, vandal resistant, weather proof with Allen bolts and pad locking facility of dimension not less than 1200 mm x 250 mm shall be provided at a height 2 times the width of door from the base of mast to provide clear access to base compartment Equipments winch, motor, cable, connector etc. For the environmental protection of the mast, the entire fabricated mast shall be hot dip galvanized internally and externally in single dip having a uniform average thickness of 85 microns for plates more than 5 mm and 70 microns for 5 mm and less thickness.

Code No.: I.S. 875 (Part III) 1987 Amended up to date Title: Code and practice for design loads for structures under

Code No.: BSEN 10025 Title: Grades of M.S. plates

Code No.: BS 5135/AWS D 1.1 Title: Welding

Code No.: BSEN ISO 1461 Title: Hot dip galvanizing

Code No.: TR. No. 7 (2000 addition) of ILE, UK. Title: Specification of Mast and foundation.

Code No.: IS 3459 / 2266 Title: Stainless steel Wire rope

Code No.: IS 9968 Part – 1 Title: Trailing Cable

Code No. IS 325 Title: Motor

Dynamic Loading for the Mast: The mast structure shall be suitable to sustain an assumed maximum reaction arising from a wind speed as per IS 875 (three second gust), and shall be measured at a height of 10 meters above ground level. The design life of the mast shall be 25 years. The force co-efficient taken for design of the twenty sided polygonal structure is to be established from the wind tunnel test data.

Luminaries Carriage: A fabricated Lantern Carriage shall be provided for fixing and holding the flood light fitting and control gear boxes. The Lantern Carriage shall be of special design and shall be of steel tube construction, the tubes acting as conduits for wire, with holes fully protected by grommets. The Lantern Carriage shall be so designed and fabricated to hold the required number of flood light fitting and control gear boxes, and also have a perfect self balance. The Lantern Carriage shall be fabricated in two / three halves and joined by bolted flanges with steel nuts to enable easy installation or removal from the erected mast. The entire lantern carriage shall be hot dip galvanized after fabrication. The inner lining of the carriage shall be provided with protective PVC arrangement, so that no damage is caused to the surface of the mast during raising and lowering operation of the carriage. Weather proof junction box, made of cast Aluminum shall be provided on the Carriage Assembly as required, from which the inter-connections to the designed number of the flood light luminaries and associated control gears fixed on the carriage shall be made.

RAISING AND LOWERING MECHANISM: For the installation and maintenance of the luminaries and lamps, it shall be necessary to lower and raise the Lantern Carriage Assembly. To enable this, a suitable Winch Arrangement shall be provided, with the winch fixed at the base of the mast the specially designed head frame assembly at the top Winch: The winch shall be of “Integral Power Tool” type with motor. The winch shall have provision for manual operation in case of failure of the motor. The winch shall be double drum and completely self sustaining type, without the need for brake shoe, springs or clutches. Each driving spindle of the winch shall be positively locked when not in use. The capacity, operating speed, safe working load, recommended lubrication and serial number of the winch shall be clearly marked on each winch. The winch drums shall be grooved to ensure perfect seat for stable and tidy rope lay, with no chances of rope slippage. The rope termination in the winch shall be such that distortion or twisting is eliminated and at least 5 to 6 turns of rope remains on the drum even when the lantern carriage is fully lowered and rested on the rest pads. It shall be possible to remove the hoisting mechanism after dismantling through the door opening provided at the base of the mast. The winch shall be type tested at a reputed institution and the test certificate shall be furnished before supply of materials. The test certificate shall include the maximum load operated by the winch.

Head Frame: The head frame is to be designed as a capping unit of the mast, shall be of welded steel construction, galvanized both internally and externally after assembly. The top pulley shall be of appropriate diameter, large enough to accommodate the steel wire ropes and the multi-core electric cable. The pulley block shall be made of no corrodible material, and shall be of die cast Aluminum Alloy (LM-6). Pulley made of synthetic materials such as plastic or PVC are not acceptable. Self-lubricating bearings and steel shaft shall be provided to facilitate smooth and maintenance free operation for a long period. The pulley assembly shall be fully protected by a canopy galvanized internally and externally. The head frame shall be provided with guides and stops with PVC buffer for docking the lantern carriage.

Stainless Steel Wire Ropes: The stainless steel wire ropes shall be in AISI 316 grade, 7/19 construction with central core in the same material of diameter and the breaking load of rope shall not be less than 2x1450 Kg. giving a factor of safety of over 5 for the system at full load as per the TR7 referred to in the beginning of this specification. The end construction of rope for the winch drum shall be fitted with talurit and for three continuous ropes the end termination in luminary’s carriage shall be with stainless steel thimble and copper splicing and for others with stainless steel thimble and bull dog grips.

Electrical System, Cable and Cable Connections: Suitable terminal box shall be provided as part of the contract at the base compartment of the high mast for terminating the incoming cable. The electrical connections from the bottom to the top shall be made by special trailing cable. The cable shall be EPR / PVC insulated and PCP sheathed to get flexibility and endurance. At the top there shall be weather proof junction box to terminate the trailing cable. The system shall have in-built facilities for testing the luminaries while in lowered position. Also, suitable provision shall be made at the base compartment of the mast to facilitate the operation of internally mounted, electrically operated power tool for raising and lowering of the lantern carriage assembly. The trailing cables of the lantern carriage rings shall be terminated by means of specially designed, metal clad, multi pin plug and socket provided in the base compartment to enable easy disconnection when required. Also including Supplying and layig of 3 core x 4 sq. mm Copper Conductor flexible cable inside the highmast according to the no. of fittings.

Power Tool for the Winch: Three phase, single speed, 6 pole high-powered motor of rating 2 HP suitable to lift the load mounted on adjustable plate to adjust the length of winch motor coupling chain is to be provided in base compartment. Mechanical torque limiter is to be mounted on motor shaft to stop transmission of motion from motor to winch in case of excess load and thus prevent the damage to winch and breakage of rope.

Lighting Finial: One number heavy duty hot dip galvanized lightning finial shall be provided for each mast. The lightning finial shall be minimum 1.2 M in length and shall be provided at the center of the head frame. It shall be solidly bolted to the head frame to get a direct conducting path to the center of the earth through the mast. The lightning finial shall not be provided on the lantern carriage under any circumstances in view of the safety of the system. 2 Nos. LED type single dome aviation obstruction light shall be provided each high mast.

Earthing Terminals: Earth terminal using 12mm diameter hot dip galvanized bolts shall be provided on the door stiffener of the mast for lightning and electrical earthing of the mast.

The firm will give the high mast parameters as given below:

Height of the High Mast. = 12.5 Mtr.

Nos. of sections = Two Nos.

Thickness of each section in mm. = Top: 3 mm & Bottom 3 mm minimum

Bottom plate thickness = 25 mm (Minimum)

No. of rag bolts along with Anchor plate = 6 Nos. (Minimum)

Makes of High Mast = Valmount/ Bajaj/ Transrail only.

The manufacturer should be ISO 9001 certified having their own marketing division and project cell with adequate qualified and experienced Engineers to carry out the job and must have experience of handling similar turnkey jobs in past and the proof of the same is to be furnished for issue of tender documents. The bidder has to conduct wind tunnel test on a specimen to establish the force coefficients of the 20 side polygon and the value received from the wind tunnel test is to be taken in design. Further type test is to be done on a full size mast at SERC or other reputed institutions to validate the structural program. The winches are to be type tested through reputed institutions like IIT as consultants. The high mast manufacturer should have in-house civil, structural and product design facilities. Also the shaft is to be manufactured from ISO 9001, ISO 14001 and ISO 18001 certified factory taking care of all aspects of design, quality, environment and safety.

FOUNDATION FOR 12.5 Mtr.LONG HIGH MAST: Design & casting of foundation with M20 cement Concrete & steel reinforcement suitable for installation of 12.5 Mtr. / 16mtr high mast:

DSR ITEM NO. 2.8.1 (CIVIL WORK) Earth work in excavation by mechanical means (Hydraulic excavator) / manual means in foundation trenches or drains (not exceeding 1.5m in width or 10 sqm on plan), including dressing of sides and ramming of bottoms, lift upto 1.5 m, including getting out the excavated soil and disposal of surplus excavated soil as directed, within a lead of 50m. All kinds of soil (Size 1600mmx2300mmx2300mm) (Total 1.6mx2.3mx2.3m)= 8.46 cum (1 no. x 8.46= 8.46 cum)

DSR ITEM NO. 5.9.1 (CIVIL WORK) Centering and shuttering including strutting, propping etc. and removal of form for : Foundations, footings, bases of columns, etc. for mass concrete Size 1x2 (3.100+3.100) 0.45 = 5.58 sq.mtr. or Size 1 - 1550mm x 900mm = (1.55mx0.9m) = (1.395x4=5.58 sq. mtr.) Size 2 - 250mmx2300mm = (2.3mx0.25m) = (0.515x4=2.3 sq. mtr.) Total (5.58+2.3= 7.88 Sq. mtr.) (1 no. x 7.88= 7.88 sq. mtr.)

DSR ITEM NO. 5.2.2 (CIVIL WORK) Reinforced cement concrete work in walls (any thickness), including attached pilasters, buttresses, plinth and string courses, fillets, columns, pillars, piers, abutments, posts and struts etc. up to floor five level, excluding cost of centering, shuttering, finishing and reinforcement: 1:1.5:3 (1 cement : 1.5 coarse sand : 3 graded stone aggregate 20 mm nominal size) Size 1 - 250mmx2300mmx2300mm = (0.25mx2.3mx2.3m) = 1.3225 cum Size 2 - 1550mmx900mmx900mm = (1.55mx0.9mx0.9m)= 1.25 cum Total (1.3225+1.25= 2.57 cum) (1 no. x 2.57= 2.57 cum)

DSR ITEM NO. 4.1.11 (CIVIL WORK) b) Providing and laying in position cement concrete of specified grade excluding the cost of centering and shuttering - All work up to plinth level : 1:5:10 (1 cement : 5 fine sand : 10 graded stone aggregate 40mm nominal size) (0.1mx2.3x2.3m =0.52 cum) (1 no.x0.52= .52 cum)

DSR ITEM NO. 5.22.6 (CIVIL WORK) Steel reinforcement for R.C.C. work including straightening, cutting, bending, placing in position and binding all complete upto plinth level. Thermo-Mechanically Treated bars 1.Horizontal Bar10mm dia = 48 nos.x 2400mm= 115.2 r.mtr @ 0.62 Kg per mtr.= 71.42 kg 2.Vertical Bar 12mm dia =20 nos.x2400mm= 48 r.mtr. @ 0.89 kg/mtr. =42.72 kg 3.Horizontal Ring 8mm dia =10 nos.x3200mm=32 r.mtr.@ 0.390kg per mtr.=12.48kg Total (71.42+42.72+12.48=126.62+5% wastage = 132.95 kg) (1 no.x132.95= 132.95)

Supply & Laying of Earthing with G.l. earth plate 600 mm X 600 mm X 6 mm thick tape riveted to 25 mm X 5 mm· G.l. strip at 4.5 below the ground level including connection with G.l. nut, bolt, spring, washer excavation and refilling etc.with charcoal/ coke and salt as required and providing masonry enclosure with cover plate having locking arrangement and watering pipe of 2.7 metre long etc. The work shall be executed to the entire satisfaction of Engineer-in-Charge.

S&E of Outdoor type both side openable M.S. Cubical Pedestal of size 1200mmx 900mm x350mm fabricated from 16 G.M.S. sheet welded on M.S. angle iron frame of size 50mmx 50mm x6mm with 4 Nos. legs of angle iron of same size each of length 600mm with M.S. sheet of size 100mm x 100mm x 6mm thick at the bottom of the legs. The front side and the back side of the pedestal should be openable with hiunged door provided with Godrej type locking arrangements. A 'U' type support made from M.S. sheet of 16 G having width 75mmx 6mm be welded vertically in the inner side of the door to avoid entry of water. The door of the pedestal should be provided with rubber gasket to avoid entry of other insects etc. The top of the pedestal shall be covered with canopy made out of 16 G M.S. sheet projected outside to avoid entry of water. Four No. supporting members each of size 50mm x 6mm thick according to cubical size shall be welded for mounting switcher gear i.e. ICTPN, BBC, Timer and energy meter etc. The Pedestal shall be painted with two coats of P.O. red paint after applying one coat of red oxide. One No. The legs of the pedestal shall be embedded in the 1:2:4 C.C. mixture by digging 1' deep pit of 1' dia.The letter 'M.C.C.' in 4" size shall be written on the front door of the Pedestal. The job also included supply and erection one no. wooden plank/ board of size 1’-6’’ x 1’-6’’ and 25mm thick suitable for fixing energy mater including cost of screw, nuts and bolts in cubical pedestal complete in all respect. The pedestal will be housed on RCC foundation platform of size 900mm deep (450mm underground and 450 mm above ground x 910 mm long x 360 mm wide including sufficient number of DWC pipe size of 51/63mm pieces to facility to entire the main cable and the circuit cable. The work shall be executed to the entire satisfaction of Engineer-in-Charge.

G.I. Earth pipe electrode: Supply and laying of earth electrode made out of ISI marked 'B' class G.I. pipe 4.5 Mtr. long 40 mm dia including accessories. G.I. pipe electrode shall be cut tapered at the bottom, and provided with holes of 12mm dia, drilled not less than 7.5 cm from each other upto 2 Mtr. of length from bottom. The earth electode shall be laid in ground after boring as per CPWD specifications complete in all respect and to the entire satisfaction of the engineer-in-charge.

P/F 6 SWG GI earth wire in pipe: Providing & laying earth connection from earth electrode with 6 SWG dia G.I. wire in 15 mm dia G.I. pipe from earth electrode, as required.

Supply & Laying of DWC pipe 50/63mm with hand bockey:- Supply and laying of 50/63 mm (I/D& O/D) Double Wall Corrugated (DWC) High Density Polyethylene pipe (HDPE Density 240 to 958 KG/Cm3) having corrugation on the outer wall and plain surface inner wall with average wall thickness for outer layer as 1.1+0.1mm and for inside layer 1.2+0.1mm conforming to IS 14930 (P-II) and PSEN-50086 (P-I & II) of Make Gemini/Mohindra eco/Supreme. The pipe should be laid 3 feet below ground/road level with hand bockey without cutting of road for laying cables etc. including cost of digging and refilling of pits complete in all respects to the entire satisfaction of Engineer-in-Charge.

Supply & Laying of DWC pipe 50/63mm with out hand bockey:- Supply and laying of 50/63 mm (I/D& O/D) Double Wall Corrugated (DWC) High Density Polyethylene pipe (HDPE Density 240 to 958 KG/Cm3) having corrugation on the outer wall and plain surface inner wall with average wall thickness for outer layer as 1.1+0.1mm and for inside layer 1.2+0.1mm conforming to IS 14930 (P-II) and PSEN-50086 (P-I & II) of Make Gemini/Mohindra eco/Supreme. The pipe should be laid 3 feet below ground/road level by digging the ground upto 3 feet or cutting the road/paver blocks upto required level & laying of DWC pipe for laying L.T. (up to 1.1 KV grade) cables etc. including cost of digging and refilling of pits/Trench complete in all respects to the entire satisfaction of Engineer-in-Charge of work.

Supply & laying of ISI marked 4 core 16 mm sq PVC INSULATED Aluminium armoured cable loose in trench/ pipe:- Supply & laying of ISI marked 4 core 16 mm sq Aluminum conductor armoured cable of make Havell's/ Finolex/ Ecko/ Lapp/ Cirtina/ Polycab/ KEI conforming IS:1554 (Pt.1) amended. The cable shall be laid as per DSR Code 7.1 MV CBPIP (external). The job included all Connections, Commissioning and testing of phase. Supply complete in all respective to the entire satisfaction of the Engineer in charge. The specification of the cable as below:- i) Conductor – Aluminum ii) Core – 4 iii) Working Voltage – 1100 V iv) Nominal Cross Section – 16mm2 v) Minimum No. of Wire – 7/6 vi) Insulation Thickness – 1.0mm (Nominal) vii) Inner Sheath Minimum Thickness – 0.3mm viii) Outer Sheath Minimum Thickness – 1.40mm ix) Nominal size of Armoured Wire/Strip – 4x0.8mm x) Approximate O.D. – 22mm Maximum d.c. Resistance at 20 Deg. C – 1.91 ohm/km The work shall be executed to the entire satisfaction of Engineer-in-Charge.

Supply & Erection of Three Phase Aluminum Bus Bar Supply & Erection of Single Phase Aluminum Bus Bar of size 600mmx40mmx4mm with L type fuse unit covered with the heat shrink insulation sheet to be fixed on Porcelein insulators in the existing pedestal with required material. The fuse links should be equal to the number of out going circuits. The work shall be executed to the entire satisfaction of Engineer-in-Charge.

S&E of Sheet metal/iron clad triple pole switch with neutral link 100Amp.415 Volts. Supply & Erection of 100 A/415 Volts ISI marked sheet metal iron clad switch of make Havell's/ Standard/ L&T on existing surface with GI Bolts & Nuts/rag bolts and nuts etc., according to the size of holes in the body of the switch including bonding to the existing earth. The work shall be executed to the entire satisfaction of Engineer-in-Charge.

Supply & erection of Three Phase Sensor based Timer and Contactor assembled in 22 gauge CRCA sheet enclosure duly powder coated with the following accessories of Make Amsons/ L&T/ Scheinder as approved by the Engineer-in-Charge. It should conform to latest relevant IS Code:- 1. It shall have Contactor 25 Amp. 220 Volts of BCH, Legrand, L&T of siemons Make. 2. It shall have Auto/Manual switch, light activated switching system to Switch ON/OFF the lights Automatically with allied accessories as required. 3. It shall have kit-kat fuse unit of 20 Amp capacity. The fuse unit shall conform to latest relevant IS code for protection of timers, bakelite sheet & other components as per requirement at site. 4. It shall be housed in a powder coated 22 gauge M.S. Sheet cabinet for its protection 5. The device shall be provided/ fixed in the existing pedestal box in such a way so that it operates at correct time i.e. at rising/setting of Sun. The Sensor shall be included time watch to operate as required. The work shall be executed to the entire satisfaction of Engineer-in-Charge Warranty:- IT SHOULD STAND WARRANTY FOR ONE YEAR TOWARDS ANY MANUFACTURING DEFECTS.

Erection of high power LED 180-200 Watt Flood Light luminaries. The work shall be executed to the entire satisfaction of Engineer-in-Charge.