Jharkhand Industrial Infrastructure Development Corporation Tender
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Jharkhand Industrial Infrastructure Development Corporation - JIIDC Tender
Electrical and Electronics
Eprocure
Opening Date11 Jun 2018
Closing Date29 Jun 2018
Tender Amount₹ 10,99,41,119
Costs
EMD
₹ 10,99,500Document Cost
Refer DocumentsTender Fee
Refer Documents
Summary
Construction of PCC road and RCC culvert Street light and high mast light
Description
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Contact
Tender Id
2018_JIIDC_31661_1Bid Award Id
ViewTender No
JIIDCO/03/ SBD/AIADA3rd and 8th /2018-19Tender Authority
Jharkhand Industrial Infrastructure Development Corporation ViewPurchaser Address
-Website
http://jharkhandtenders.gov.in
GEM & Bid Advisory Services
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Documents
BOQ Items
(c) Girth 0.9m to 1.8 m
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(d) Girth 1.8 m
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Excavation for roadwork in soil with hydraulic excavator of 0.9 cum bucket capacity including cutting and loading in tippers, trimming bottom and side slopes, in accordance with requirements of lines, grades and cross sections, and transporting to the embankment location within all lifts and lead upto 1000m
1649.45
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Construction of embankment with approved material obtained from borrow pits with all lifts and leads, transporting to site, spreading, grading to required slope and compacting to meet requirement of table 300-2.Rolling with vibratory roller
1066.62
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Construction of embankment with approved materials deposited at site from roadway cutting and excavation from drain and foundation of other structures graded and compacted to meet requirement of table 300-2.Rolling with vibratory roller
1484.51
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Furnishing and laying of the live sods of preennial turf forming grass on embankment slope, verges or other locations shown on the drawing or as direted by the engineer including reparation of ground, fetching of sods and watering.
1156.69
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Construction of granular sub-base by providing coarse graded material, spreading in uniform layers with motor grader on prepared surface, mixing by mix in place method with rotavator at OMC, and compacting with vibratory roller to achieve the desired density, complete as per clause 401.
for grading -I material
527.83
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for grading -II material
175.94
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Wet Mix Macadam
Providing, laying, spreading and compacting graded stone aggregate to wet mix macadam specification including premixing the Material with water at OMC in mechanical mix plant carriage of mixed Material by tipper to site, laying in uniform layers with paver in sub- base / base course on well prepared surface and compacting with vibratory roller to achieve the desired density.
879.71
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Bituminous surfacing prime coat
Porviding and applying primer coat with bitumen emulsion on prepared surface of granular Base inculding cleaning of road sufface and spraying primer at the rate of 0.60 kg/sqm using mechanical means.
1935.36
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Tack Coat
Providing and applying tack coat with bitumen emulsion usig emulsion pressure distributor at the rate of 0.20 kg per sqm on the prepared bituminous/granular surface cleaned with mechanical broom.
3870.72
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Bituminous Macadam
Providing and laying bituminous macadam with 100-120 TPH hot mix plant producing an average output if 75 tonnes per hour using crushed aggregates of specified grading premixed with bituminous binder, transported to site, laid over a previously prepared surface with paver finisher to the required grade, level and alignmnent and rolled as per clauses 501.7 to achieve the desired compaction.
For grading- II (19mm nominal size)
96.77
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Bituminous Concrete
Providing and laying bituminous concrete with 100-120 TPH batch type hot mix plant producing an average output of 75 tonnes per hour using crushed aggregates of specified grading, premixed with bituminous binder @ 5.4 to 5.6 per cent of mix and filler, transporting the hot mix to work site, laying with a hydrostatic paver finisher with sensor control to the required grade, level and alignment, rolling with smooth wheeled, vibratory and tandem rollers to achieve the desired compaction as per MORTH specification clause No. 509 complete in all respects
58.06
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Culvert (2mx2m) carriage width 12m-6 nos.
Earth work in excavation inall kinds of soil including moorum soil, soil mixed with kankar, pebbles and boulders upto 300mm size and disposal of the same along with all organic materials within intial lead of 150m and all lifts as pe specification and direction of E/I.
1670.22
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Providing laying and compacting filter material behind abutment and wing wall/return wall etc. as per MOST sp. Cl. 2502.2.1
352.62
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Providing laying and casting insitu cement concrete grade M10 below flooring and approach slabe complete as per MOST Sp. CL. 1700 with necessary formwork.
37.02
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Providing laying and casting insitu cement concrete grade m15 below of foundation of abutment, W/L, C/W etc complete as per MOST Sp. CL. 1700 with necessary formwork.
273.06
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Providing R.D.R.R. stone masonary with c.m.(1:3) in foundation and plinth -do-do-all complete
952.02
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Providing and casting insitu cement concrete grade M20 in cap of pier and abutment as well as dirt wall complete as per MOST Sp.Cl. 1700 including necessary formwork but excluding reinforcement.
77.4
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Providing R.C.C. M-25 in deck slabkerb, girder, bed block and footpath complete as per MOST Sp. Cl. 1700 with necessary formwork but excluding reinforcement
67.5
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Providingrenforcement for deck slab girder, bed block, pier, abutment cap, wing wall, curtain wall and approach slab complete as pr MOST Sp.Cl. 1600 with HYSD steel bars conforming to IS1786
5.24
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Providing laying and casting insitu cement concrete in grade M15 for imprevious floor as per MOST Sp. Cl. 1700
55.5
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Providing and filling sand behind abutment and wing wall/return walls layers not exceeding 150mm thick complete including inundating each layer by profuse amount of water and ramming layer by layer as poer most Sp. Cl. 305
323.28
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Providing 75mm x75mm weep holes @1000mm C/C both horizontally and vertically -do-do-all complete job
264
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Plastering with cement mortar (1:4) on brick work in sub-structure as per technical specifications
85.86
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Painting two coats after filling the surface with synthetic enamel paint in all shades on new plastered concrete surfaces.
85.86
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supplying of 9 m high street lighting system--
TECHNICAL SPECIFICATIONS
1. APPLICABLE STANDARDS The tendered materials should confirm to the following Indian standard specification. Sl No. IS No. Specification
1 IS 16102(Part I and II) Performance and safety requirement for self –ballasted LED lamps for
General Lighting Services
2 IS 16105 Measurement of lumen maintenance of LED sources
3 IS 15885(Part I & II) Safety of Lamp control gear
4 IS 16104 Performance requirement for Electronic control gear for LED modules
5 IS 16106 Method of electrical and photometric measurements of solid state lighting
products
6 IS 16108 Photo biological safety of lamps and lamp systems
Materials meeting with the requirements of other authoritative standards, which ensure equal or better quality than the standards mentioned above, shall also be considered. In such case the salient points of difference along with advantages between the standards adopted and the specified standards shall be clearly brought out in a schedule.
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Components for which no IS is available, relevant International Standard may be considered.
For values not available in relevant IS values indicated in the GTP/ Tender specification shall be valid. In
case of discrepancies between values of IS and GTP the better will prevail.
2. TECHNICAL REQUIREMENT FOR LED STREET LIGHTS 2.1. GENERAL:
Application : Street lighting
Rated voltage (V.ref) : 230 volts 1 ph AC
Rated frequency : 50 Hz
Usage : 12 hours
Color : White
However, the materials should be robust enough to withstand and work satisfactorily with the
following system variations:
Voltage : V.ref + 40% to – 40%
Frequency : 50 Hz +/- 5%
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2.2. CONSTRUCTION:
The lamps should be robustly built with adequate mechanical strength, heat resistance, insulation resistance, flame resistant and corrosion resistant material complying with relevant clauses of IS 16102. It should be made of Die cast Aluminium/ Aluminium extrusion with toughened glass or poly carbonate cover suitable for mounting on a pole pipe bracket with complete locking arrangement. The complete housing of the lamp should have an ingress protection level of IP 65 and IP 66 for the lamp compartment as well as the driver circuit. The luminaries shall have separate optical and electrical part for maintainability. The luminaire shall use an asymmetric secondary optics of Type-I Viewing angle(153x107degrees) along the horizontal and vertical axis respectively making it Suitable for street lighting applications to achieve the required uniformity. Lead wire of minimum length of 1 meter or as necessary is to be provided for electrical connection.
2.3. MARKING ON THE LAMP:
The lamps should be clearly and durably marked with the following mandatory
markings:
a. Manufacturer’s name
b. Rated voltage (marked “V” or volt)
c. Rated wattage(marked “W” or watts)
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d. Rated lumen
e. Rated frequency(marked “Hz”)
2.4. TOTAL HARMONIC DISTORTION:
Should be less than 10% 2.5. LAMP EFFICIENCY:
Should not be less than 130 lumens per watt.
2.6. POWER FACTOR:
Should be greater than 90% including the driver circuit. Luminaries with high power factor
shall be preferred at the same cost. 2.7. COLOUR RENDERING INDEX:
Minimum CRI of 80
2.8. DRIVER CIRCUIT EFFICIENCY,PROTECTION & THERMAL SHUTDOWN:
I. Should be 90% with 05 years warranty.
II. Surge Voltage protection of Min. 5 KV and above in differential mode
III. Driver to have a Min. 440V AC withstand
IV. Driver to have 300V AC Overvoltage Cut-Off feature
V. Main Device IC to have an in-built thermal shut-down feature 2.9. CORRELATED COLOUR TEMPERATURE
Should be between 5500° K to 7000° K
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2.10. POWER CONSUMPTION: Should be maximum 135 watt including the driver circuit so that the lux level of the road of is not less than 20 lux measured using a 9 point or appropriate method with uniformity ratio of 0.4 and transverse uniformity of 0.33. 2.11. LIFE EXPECTANCY:
I. Should be 50000 glow hours at normal ambient conditions and lumen maintenance of category 3 or better for L70 as per IS 16102 (Part-2):2012 for the LEDs.
II. Driver circuit life should be mentioned in BID. Its warranty should not be less than 5 yrs. 2.12. WORKING CONDITIONS:
Temperature: - 5 to 50° C
Humidity: 10% to 90% RH 2.13. SWITCHING:
To be operated through group switching device for operation during night hours only. 2.14. Aux. Lighting Panel (ALP)
ALP having incoming SF unit of 63 Amps, 440 Volt connected to 63 Amp Aluminium Bus Bar and
having 05 numbers outgoing single pole 10 Amp,
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250 Volt MCB per phase (IP 54 Protection with
Canopy provision and Double Door System and locking facility) with incoming and outgoing cable termination and cable gland and providing all required accessories. The make of SFU&MCB should be L&T/Legrand/C&S/Siemens/Hager.
2.15. Supply and laying of cable including electric pole painting
a) 4C x 16 sq.mm armoured 1100 V grade aluminium PVC Cable
b) 2C x 10 sq.mm armoured 1100 V grade aluminium PVC Cable
c) 2Cx 2.5 sq.mm 1100 V grade Flexible Copper Cable
Above Cables shall be of Make: Finolex/Lapp/Polycab/V-Guard/Havells/RR Cable.
The party shall be responsible for laying of cable having earth excavation of approx 1 meter depth, with sand filling, brick layings and back filling of earth with both end termination of cables including required accessories. There shall be 2 coats of red oxide and 2 coats of aluminum paints. 2.16. Supply and Erection of Coil Earthing to Lighting Pole as per IS spec.
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2.17. Supply and Erection of 40 mm dia, 3 mtr length, 3mm thickness GI Pipe for Earthing as per IS spec. 2.18. Supply and Installation of JB (GI thickness: 2.5 mm) at Lighting Pole:
JB shall have the provision of fuse protection for pole lighting supply and connector for incoming and outgoing cable termination and cable gland for accommodating 2Cx10 sq.mm armoured cable termination.
3. GENERAL REQUIREMENTS FOR STREET LIGHTING:
I. Only NICHIA/ OSRAM/ LUMILEDS/CREE LED’s shall be used for the street lights.
II. The luminaire casing/housing shall be of stainless sheet steel SS304 grade or aluminium having high conductivity preferably to grade 5000 or similar to high conductivity heat sink material.
III. The electronic components used shall be as follows:-
• IC (Integrated circuit) shall be of industrial grade or above.
• Metallic film / Paper/Polyester Capacitor shall be rated for a sustained operating temperature of 105ºC.
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• The resistors should be preferably made of metal film of adequate rating. The actual rating versus loading shall be by a factor of 3.
• The junction temperature of the Switching devices such as transistors and MOSFETs etc. shall not exceed 125ºC (allowing thermal margin of 25 ºC).
• The protective cum adhesive coating used on PCBs should be cleared and transparent and should not affect colour code of electronic components or the product code of the company.
• The construction of PCBs and the assembly for components for PCBs should be as per IS standards.
• The electronics covered for this equipment shall pass all the tests called for in the above specification. The bidder shall indicate the deviation or compliance otherwise the offer shall not be considered for evaluation.
• The infrastructure for Quality Assurance facilities as called for in the above specification must be available at the manufacturing facility. In-house testing facility for Quality Assurance should be present. The compliance shall be indicated clearly in the tender itself.
IV. The connecting wires used inside the luminaire, shall be low smoke halogen free, fire retardant ebeam cable and fuse protection shall be provided
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in input side.
V. Care shall be taken in the design that there is no water stagnation anywhere and entire housing shall be dust and water proof having IP65 and IP66 protection as per IEC 60529.
VI. The LED Module(s), Driver gear, etc. shall be designed in such a way so that temperature of heat sink shall not exceed 150C above the ambient temperature.
VII. All the material used in the luminaire shall be halogen free and fire retardant confirming to UL94.
VIII. Lumen maintenance of 70% for at least 50000 hours. LM 79 Data sheet showing lumen maintenance in the LED shall also be submitted.
IX. The manufacturer /firm should also offer Comprehensive Maintenance Contract (CMC) for the post Warranty period.
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4. General requirements for Microprocessor Controller
Technical Specification of Microprocessor based Switching Panel.
i) Enclosed in 14/16 G CRCA sheet steel fabricated box, outdoor type, self-standing and easily
attachable to the existing panels (feeder pillars).
ii) Microprocessor based system and control suitable for unmanned operations.
iii) Input power redundancy. (i.e. unit should operate in single-phase healthy condition. )
iv) Overload & short circuit protection.
v) Real time clock with 5 years battery life.
vi) EPROM for data storage and communication
vii) Auto computation of sunrise and sun set timings.
viii) Twilight time forward and reverse delays for turning lights ON/OFF settable for Jharsuguda
ix) Individual day profile settable for 365 days of the year.
x) Digital controller with 8/16 bit DSP based micro controller operating as an intelligent unit to
monitor and measure the electrical parameter
xi) LCD display with backlit function
xii) Single Phase, 2 Wires, 50 Hz (Aux. Supply)
xiii) 230V+/- 30%, AC, 50Hz
xiv)Ratings 10 kVA, 20A Single Phase or as applicable
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xv) Mounting suitable for Indoor & Outdoor, pole/foot Mounted, IP 65
5. TEST AND TEST CONDITIONS: 5.1. Type Test:
The materials offered shall be fully type tested at independent accredited/ Govt. certified
laboratories by the bidder as per the relevant standards referred to in this document. The test
reports should not be more than one year old from the date of opening of bid. The bidder
shall furnish two sets of type test reports along with the bid. Test Report Required: IES LM-79-2008, ANSI C78.377-2008, ANSI C82.77, CIE 13.3-1995, CIE 15-2004.
5.2. Acceptance Test:
All acceptance tests as stipulated in the relevant standard shall be carried out by the supplier in the presence of the JIIDCO/ AIADA representative. 6. INSPECTION:
6.1. The supplier will keep JIIDCO/ JIADA informed in advance of the time of the starting and the progress of manufacture of equipment in its various stages so that arrangement could be made for inspection if necessary. JIIDCO/ AIADA or his authorized representative(s) will have access to
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the supplier’s or his subcontractor’s work at any time during working hours for the purpose of inspecting the materials during manufacturing of the materials / equipment and testing and may select test samples from the materials going into plant and equipment. The supplier will provide the facilities for testing such samples at any time including access to drawings and production data at no charge to JIIDCO/ AIADA . As soon as the materials are ready, the supplier will duly send intimation to JIIDCO/ AIADA by Regd. Post/Speed Post and e-mail and carry out the tests in the presence of representative(s) of JIIDCO/ JIADA if felt necessary. If JIIDCO/ JIADA feels necessary, it may select one sample from the lot at factory to send for testing at CPRI/NTL or any other standard NABL accredited laboratory.
6.2. JIIDCO/ JIADA may at its option get the materials inspected by the third party if it feels necessary. The cost of third party inspection shall be borne by the bidder.
6.3. The dispatches will be affected only if the test results comply with the specification. The
dispatches will be made only after the inspection by the JIIDCO/ JIADA ’s representative is completed to the satisfaction of the JIIDCO/ JIADA or such inspection is waived by the competent authority.
6.4. The acceptance of any quantity of materials
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will in no way relieve the supplier of its
responsibility for meeting all the requirements of this specification and will not prevent
subsequent rejection if such materials are later found to be defective or deviation from
specification/IS.
6.5. The supplier will give 15 days advance intimation to enable JIIDCO/ AIADA to depute its representative for witnessing the acceptance tests If necessary.
6.6. Should any inspected or tested materials / equipment fail to conform to the specification, JIIDCO/ AIADA may reject the materials and supplier will either replace the rejected materials or make alterations necessary to meet specifications requirements free of costs.
6.7. After delivery of materials at Store the materials may be verified/retested if necessary in full or taking one random sample before acceptance. In case of any deviation to the specification,
Guaranteed technical parameters and IS during the tests the lot will be rejected or will be replaced by supplier without any additional cost.
6.8. JIIDCO/ AIADA may waive inspection at its own discretion if it so desires.
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7. GENERAL:
7.1. Technical deviations:
All deviations to the technical specifications and commercial terms and conditions should be
specifically and clearly brought out in the deviation form.
8. RELAXATION OF TECHNICAL REQUIREMENT:
JIIDCO/ JIADA reserves the right to ignore/ relax minor deviations in the technical specifications mentioned above, if it does not materially affect the quality of material to be supplied. The decision of JIIDCO/ AIADA on such matters shall be final and binding on the supplier.
SCOPE OF WORK
The scope of work will include the following:
a) Design, supply, installation, commissioning of LED street light systems as per specification with all fixtures, fittings compatible with 9.0 high poles and other related works.
b) Supply and installation of microprocessor based light sensitive and astronomical ON OFF timers to switch and control the street lights at predetermined time and as per ambient lighting level.
c) Five years warrantee from the date of successful installation of the project.
d) The equipments design and supply shall fully
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conform to the specifications as outlined in Technical Specification for LED as per specification mentioned in this document.
e) Packing and transportation from the manufacturer’s works to the Site including insurance.
f) Receipt, storage, preservation and conservation of equipment at the Site.
g) Pre-assembly, if any, erection, testing and commissioning of all the equipments.
h) Reliability tests and performance and guarantee tests on completion of commissioning.
i) The installation of equipments to be taken up as per the directive of JIIDCO/ JIADA .
j) Undertake measurement of the energy usage and lighting level of the street lighting segment after successful installation of the project.
k) The bidder shall also supply and install the protectitive guard for LED lights to prevent against any type of damages by anti-social elements.
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APPENDIX -I
PART A
GUARANTEED TECHNICAL PARTICULARS (TO BE SUBMITTED BY THE BIDDER)
LED STREET LIGHTS
Sl no Parameters Details 1 Make of LED NICHIA/ OSRAM /LUMILEDS/CREE
2 LED Street Light operating voltage 230v +40%to -40%
3 LED Street Light operating frequency 50 Hz+/- 5%
4 Beam Angle of luminaire 153X107 degrees
5 Luminous efficacy in lumens per watt 100
6 Total LED power consumption including driver circuit per unit Maximum 135 watt
7 Avg. illuminance at road surface 20 lux
10 Uniformity ratio and transverse uniformity 0.4 and 0.33
11 Driver circuit Efficiency 90%
12 Total harmonic distortion 10%
13 Colour rendering index 80
14 Lumen maintenance 80% or better
15 Insulation resistance between live and Accessible parts of the lamp Not less than 4MΩ as per IS
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16 Conformity with IP-65, IP-66 Fixtures Yes
17 LED Life 50000 hrs
18 Power factor 0.9
19 Switching through group controller Yes
20 Driver life Minimum 50% of LED life
21 Color temperature 55000K-70000K
22 Average LED viewing angle 120
23 Working temperature -5 to 500 C
24 Working humidity 10-90% RH
(NB: All details are to be filled in by the bidder failing which the bid may treated as non responsive and liable for rejection) Bidder’s Signature with Seal 1. For values not available in relevant IS; values indicated in the GTP/ Tender specification shall be valid.
2. In case of discrepancies between values of IS and GTP, the better will prevail.
3. Pertinent type test reports, literatures, catalogue, photometry etc. as required to substantiate the above and index for comprehensive reference should be attached.
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APPENDIX -I
PART B
GUARANTEED TECHNICAL PARTICULARS (TO BE SUBMITTED BY THE BIDDER)
Microprocessor Timer
Sl .No Parameters Guaranteed Value offered by the bidder
1 14/16 G CRCA sheet steel fabricated box 2 Make/ Brand of the Microprocessor Timer 3 Ratings ( Min.10 kVA, 20A Single Phase) 4 Overload & short circuit protection. ( should be provided) 5 Real time clock with 5 years battery life ( should be provided) 6 Light sensitive control (Lux based control for automatic
switching on/off control based on ambient lighting condition so that
the lights operate only during nights) 7. EPROM for data storage ( should be provided)
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8 Auto computation of Sunrise & Sun set timings ( should be
provided) 9. Individual day profile settable for 365 days of the year 10. LCD display with backlit function 11. IP 65/66 compliant for outdoor usage Bidder’s Signature with Seal
N.B:
1) Bidder shall also submit the technical particulars for the microprocessor based light sensitive and astronomical ON OFF timer & the Cables with make, IS Standard etc. with Technical Part of the Bid.
2) For values not available in relevant IS; values indicated in the GTP/ Tender specification shall be valid.
3) In case of discrepancies between values of IS and GTP, the better will prevail.
4) Pertinent type test reports, literatures, catalogue, etc. as required to substantiate the above, and List and index for comprehensive reference should be attached.
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APPENDIX -I
PART C
GUARANTEED TECHNICAL PARTICULARS (TO BE SUBMITTED BY THE BIDDER)
Static Check Energy Meter: the rating of kWh meter should be as follows:-
Sl .No Parameters Details Guaranteed Value offered by the bidder
1. Supply voltage Three Phase, 240V AC (Phase to
Neutral),415V AC (Between phases)
2. Current range(basic) 10 A 3. Max. current 600% of Basic Current 4. Current rating 10-60A 5. Class of accuracy 1.0(No drift in tolerance of accuracy for
10 years)
6. Starting current 0.2% of Basic Current at unity power factor 7. Power factor range 0 to 1 (Lagging & Leading) 8. Power loss As per ISS-13779
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9. Resistance to surge voltage 6kV peak As per ISS-13779 10. 1.2/50Micro sec. IEC-62053-21:2003/CBIP-88
11. Test voltage of 50Hz for 1
Min. 2kV rms
12. Clock time accuracy +/- 5 ppm at 25°C
13. Temperature rise As per ISS-13779
14. Power consumption by
Meter As per ISS-13779
Bidder’s Signature with Seal
N.B:
1. Bidder shall also submit the technical particulars for the microprocessor based light sensitive and astronomical ON
OFF timer & the Cables with make, IS Standard etc. with Technical Part of the Bid.
2. For values not available in relevant IS; values indicated in the GTP/ Tender specification shall be valid.
3. In case of discrepancies between values of IS and GTP, the better will prevail.
4. Pertinent type test reports, literatures, catalogue, etc. as required to substantiate the above, and List and index for
comprehensive reference should be attached.
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Supply for high mast lighting system complete with all fitting and fixing materials with interconnection etc. including light fixtures as required and cabling wiring, switching all complete job as per direction of E/I and as per specification given below.
SPECIFICATION FOR HIGH MAST LIGHTING SYSTEM 1.0 SCOPE This specification covers the technical requirements of design of system, manufacture, testing at works, supply in well packed condition of high masts lighting structure, light fittings, lamps, control gears for movement / maintenance of light fitting, earthing / lightning protection of units, aviation lights for towers / supply of spares for commissioning etc. for JIIDCO works at various sites in Jharkhand. The scope shall also include the erection including testing and
testing and commissioning of the complete lighting system, using Raising and Lowering type of High mast towers, including the civil works in foundation. All items required for the safe and efficient operation and maintenance of the lighting system, including the high mast, whether explicitly stated hereunder or not, shall be included by the Contractor. Control Panel at base including timer,
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cabling from control panel to the control gears / fittings as per price bid and aviation lamp / lightning protection shall be part of high mast item. Llightening protection shall be part of high mast item. Control Panel shall have facility to terminate two numbers of cables as specified in SLD.
2. APPLICABLE STANDARDS:
The following shall be the Reference Standards for the loading of the high mast:-
a. BS Code of Practice, CP-3, Gradient of wind related to height Chapter-V, Pt-II above ground
b. BS 4360 Grades of MS Plates
c. BS 5135 Welding
d. BD 729 Galvanising
e. Technical Report (TR) No.7 – 1996 S pecification for Mast and Foundation
f. IS 875 (Pt-III) 1987 Code of Practice for Design Loads for structure 3. HIGH MAST: 3.1. Structure:
The High mast shall be of continuously tapered, polygonal cross section, at least 16 sided, presenting a pleasing appearance and shall be based on proven In- Tension design conforming to the Standards referred to above, to give an assured performance and reliable service
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3.2. Construction The mast height shall be 30 meters, with minimum diameters of 152mm at the top and 612mm at the bottom. Minimum plate thickness of bottom section shall be 5mm and other sections 4mm. The PCD of the mast flange shall be minimum 740 mm. The structure shall be suitable for wind loading as per IS-875, pt-3, 1987. The mast shall be capable of safely withstanding the strong winds prevailing at site. The deflection at the top during heavy monsoon periods shall therefore be considered in the design and the mast designed in such way that the above deflection during worst periods is kept to a minimum value. The mast shall be fabricated from special steel plates, conforming to BS-EN10- 025, cut and folded to form a polygonal section as stated above and shall be telescopically jointed and fillets welded. The welding shall be in
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accordance with BS – 5135.
The procedural weld geometry and the workmanship shall be exhaustively tested on the completed welds. The 30 meter size mast shall be delivered only in three sections, and shall be jointed together by slip-stressed-fit method at site. No site welding or bolted joint shall be done on the mast. The minimum over lap distance shall be 1.5 times the diameter at penetration.
The mast shall be provided with full penetrated flange which shall be free from any lamination or incursion. The welded connection of the base flange shall be provided with supplementary gussets between the bolt holes to ensure elimination of helical stress concentration. For the environmental protection of the mast, the entire fabricated mast shall be hot dip galvanized, internally and externally, having a uniform thickness of 65 microns.
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3.3. Door Opening: An adequate door opening approximately 1000 mm x 300 mm shall be provided at the base of the mast and the opening shall be such that it permits clear access to equipment like winches, cables, plug and socket, etc. and also facilitate easy removal of the winch. The door opening shall be complete with a close fitting, vandal resistant, weather proof door, provided with a heavy duty double internal lock with special paddle key. The door opening shall be carefully designed and reinforced with welded steel section, so that the mast section at the base shall be unaffected and undue buckling of the cut portion is prevented. 3.4. 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 a minimum of 25 years. 4. LANTERN CARRIAGE: 4.1. Fabrication:
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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 wires, with holes fully protected by grommets. The Lantern Carriage shall be so designed and fabricated to hold the required number of flood light fittings and the control gear boxes, and also to have a perfect self balance.
The Lantern Carriage shall be fabricated in two halves and joined by bolted flanges with stainless steel bolts and plastic lock type stainless steel nuts to enable easy installation or removal from the erected mast. 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 the raising and lowering operation of the carriage. The entire Lantern Carriage shall be hot dip galvanised after fabrication
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4.2. Junction Box: Weather proof junction box with IP55 enclosure, made of Cast Aluminium shall be provided on the Carriage Assembly as required, from which the interconnections to the designed number of the flood light luminaries and associated control gear fixed on the carriage shall be made. 4.3. Raising and Lowering Mechanism: For the installation and maintenance of the luminaries and lamps, it will be necessary to lower and raise the Lantern Carriage Assembly. To enable this, a suitable Winch Arrangement shall be provided, with winch fixed at the base of the mast and the specially designed head frame assembly at the top. 4.4. Winch: The winch shall be of 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, gravity activated PAWLS. Individual drum also should be operated for fine adjustment of lantern carriage. The capacity, operating speed, safe working load of the recommended lubrication and serial number of
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winch shall be clearly marked on each winch.
The gear ratio may be according to manufacturer’s standard. However, the minimum working load shall be not less than 750Kg. The Winch shall be self lubricating type by means of an oil bath and the oil shall be readily available grades of reputed producers.
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 atleast 5 to 6 runs of rope remains on the drum even when lantern carriage is fully lowered and rested on the rest pads.
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It should be possible to operate the winch manually by a suitable handle and / or by an external power tool. It shall be possible to remove the double drum after dismantling, through the door opening provided at the base of mast. Also a winch gear box for simultaneous and reversible operation of the double drum winch shall be provided as part of the contract.
The winch shall be type tested in presence of reputed Institution and the certificate shall be furnished before supply of material. A test certificate shall be test furnished by the contractor from the original equipment manufacturer, for each winch in support of the maximum load operated by the winch.
4.5. Head Frame:
The head frame which is to be designed as a capping unit of the mast, shall be of welded steel construction, galvanized both internally and externally after the assembly.
The top pulley shall be appropriate diameter, large enough to accommodate the stainless steel wire ropes and the multi-core electric cable. The pulley block shall be made of non-corrodable material, and shall be of die cast aluminum alloy (LM-6).
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Pulley made of synthetic material such as plastic or PVC are not acceptable. Self lubricating bearings and stainless steel shaft shall be provided to facilitate smooth and maintenance free operation for a long period. The pully assembly shall be fully protected by a canopy galvanized externally and internally
Close fittings guides and sleeves shall be provided to ensure that the ropes and cables do not dislodged from their respective positions in the grooves. The head frame shall be provided with guides and stops with PVC buffer for docking the lantern carriage.
4.6. Stainless Steel Wire Ropes:
The stainless steel wire ropes shall be of 7/19 construction, the central core being of the same material. The overall diameter of the rope shall not be less than 6 mm. The breaking load of each rope shall not be less than 2350kg individually, giving factor of safety or over 5 for system at full load, the minimum recommended value as per the TR-7 referred to in the beginning of the talurit.
The thimbles shall be secured on ropes by compression splices. Two continuous lengths of stainless steel wire ropes shall be used in the system and no intermediate joints are acceptable in view of the required safety. No intermediate joints, either bolted or else is provided on the wire ropes between winch and lantern carriage.
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4.7. Electrical System, Cable And Cable Connection: The electrical connections from bottom to top shall made by special trailing cable. The cable shall be EPR insulated and PCP sheathed to get flexibility and endurance. Size of the cable shall be 5 core, 4 mm², copper conductor. The cable shall be of approved make. A suitable FLP socket arrangement shall be provided at the bottom section of the Mast. The trailing cable also shall have FLP plug connected at the bottom end. Also suitable provision shall be made at the base compartment of the Mast to facilitate the operation of externally mounted, electrically operated FLP power
tool for raising and lowering of the lantern carriage assembly. The trailing cables FLP plug connected at the bottom end.
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Also suitable provision shall be made at the base compartment of the Mast to facilitate the operation of externally mounted, electrically operated FLP power tool for raising and lowering of the lantern carriage assembly. The trailing cables at the top shall be terminated in the weatherproof junction box
Control Panel at the base shall be suitable to terminate cables as specified in SLD & cable schedule. Control Panel shall be flameproof. Control Panel shall be provided with timer, Auto manual off switch, start push button. The fittings including control gear shall be supplied by High Mast supplier. The wiring from control panel up to lighting fitting shall be done by High Mast supplier. Junction box shall be provided at the top of Mast. 3 core x 2.5 mm2 FRLS cable shall be used from junction box to lighting fitting. 5. POWER TOOL FOR THE WINCH
A suitable, high powered, electrically driven, externally mounted, flameproof (FLP) power tool, with manual operating handle, together with an operating stand shall be supplied for raising and
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lowering of the lantern carriage for maintenance purpose. The speed of power tool may preferably be of slow speed, of 1.5 to 1.8 mtr / minute, so that vibrations associated with high speed are avoided. The power tool shall be single speed, provided with a motor of required rating, suitable for trolley mounting. The power tool shall be supplied complete with flame proof push button type remote control switch, together with 6 (six) meters of power cable, so that the operation can be carried out from a safe distance of 5 (five) meters. The capacity and speed of the electric motor used in the power tool shall be suitable for lifting of the designed load installed on the lantern carriage
The power tool trolley shall be so designed that it will not only be self supporting but also align the power tool perfectly with respect to the winch spindle during the operations. Also, a handle for the manual operation of the winches, in case
of problems with electrically operated tool, shall be provided and shall incorporate a torque limiting device There shall be a separate torque limiting device to protect the wire ropes from over stretching. It shall
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be mechanical with suitable load adjusting device. The torque limiter shall trip the load when it exceeds the adjusted limits. There shall be suitable provision for warning the operator once the load is tripped off. The torque limiter is a requirement as per the relevant standards in view of the overall safety of the system. Internal built-in type power tools shall not be acceptable It is utmost importance that the complete power tool, including trolley, motor, PB station and lead etc. shall be designed, assembled / built and supplied as one unit by the original equipment manufacturer (OEM), to the Dept, through the Contractor. Locally assembled / built make-shift contraption, in lieu of the above, to be called as power tool by the Contractor, shall under no circumstances be accepted
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5.1. LIGHTNING CONDUCTOR: One number heavy duty, hot dip galvanized lightning finial shall be provided for each mast. The finial shall be minimum 1.2 M in length and shall be provided at the centre of the head-frame. It shall be bolted solidly to the head frame to get a direct conducting path to the earth through the Mast body. The lightning finial shall, under no circumstances, be provided on the lantern carriage, in view of the safety of the system. Other lightning arrestor of the installation shall take into existence of these lightning arrestors and cone effect to be taken into account. 6. LUMINAIRES:
The number of fittings on each mast shall be as per schedule given 6.1. Aviation Obstruction Lights:
A set of Two Neon Aviation Obstruction shall be provided on top of each mast.
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7. EARTHING TERMINAL:
Three numbers earthing terminals, using 12mm dia stainless steel bolts, shall be provided at a convenient location on the base of the mast, one exclusively for the lightening conductor and other two for earthing the mast. 8. TESTS:
Routine tests shall be carried out as per relevant British Standards. Following routine tests shall be carried out on all components as per relevant standards Functional test. Checking of dimensions, paint shade, bill of materilas, circuit diagram etc The measuring instruments used during the shop testing of panels shall be calibrated and their calibration must be valid. The calibration should be got done from any Govt. approved test house. The calibration reports must be furnished before conducting the shop test for our approval. 7 copies of routine and type test certificates shall be submitted for Purchaser’s approval before dispatch of panels.
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9. TEST & GUARANTEE CERTIFICATE: Test certificate shall be furnished by the contractor, obtained from the original equipment manufacturer (OEM), for each winch including wire rope, in support of the maximum load operated by the winch. A separate guarantee certificate shall also be furnished by the Contractor, obtained from the OEM, for the quality and reliability of the total Mast system including the mast, accessories and associated civil works in foundation. 10. DRAWINGS AND INSTRUCTION MANUALS: Vendor shall submit seven copies of the following drawings for approval after award of contract.
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General arrangement of the high mast indicating dimensions and foundation details.
Wiring diagram of light fittings Bill of materials / part list Foundation details
Design calculations
Data sheet
Vendor shall submit five copies of installation and maintenance manual. One print of each drawing shall be returned to vendor after making necessary corrections, changes and required clarification. Vendor shall incorporate these and resubmit the drawings within fifteen (15) days for final approval/reference.
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Culvert 1mx1m- 10m length (77 nos)
Earth work in excavation inall kinds of soil including moorum soil, soil mixed with kankar, pebbles and boulders upto 300mm size and disposal of the same along with all organic materials within intial lead of 150m and all lifts as pe specification and direction of E/I.
3037.65
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Providing coarse clean sand in filling in foundation trenches or in 150mm thick with all leads and lifts including cost of all materials, labour, royalty and taxe all complete as per building specification and direction of E/I. (mode of measurement compacted volume)
279.51
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Providing 75A B/F soling in bed & joints filled with local sand including cost of watering taxes royalty all complete as per building specification and direction of E/I.
1270.5
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Providing shuttering including strutting proping etc. And its removal after use in foundation as per specification and direction of E/I.
348.04
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Providing shuttering including strutting proping etc. And its removal after use in various componemts of structure or embankment structure as per specification and direction of E/I.
3080
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Providing M.S. reinforcement in RCC work with cutting bending & binding with all complete job.
57.21
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Providing RCC (1:11/2:3) in bed wall & deck slab with approved quality of graded stone chips (20mm and down) and coarse granular sand of requisite F.M. (2.5 to 3.0) in lig slab cross and longitudinal sleepers for lining of canals including cost of form work and its removal, curing, royalty and all other taxes etc. all complete job as per specification and direction of E/I.
804.65
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Providing RCC (1:11/2:3) in bed wall & deck slab with approved quality of graded stone chips (20mm and down) and coarse granular sand of requisite F.M. (2.5 to 3.0) in lig slab cross and longitudinal sleepers for lining of canals including cost of form work and its removal, curing, royalty and all other taxes etc. all complete job as per specification and direction of E/I.
1118.04
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Dewatering during execution with all complete job.
154
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Carriage of materials
Cement (lead 5km)
3060.62
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Sand (lead 5km)
5821.64
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Stone metal (lead 30 km)
4494.03
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Stone chips (lead 30km)
14562.05
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Bricks(lead 8km)
217.36
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Steel (lead 5km)
132.22
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Muroom (lead5km)
706.8
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PCC ROAD IN 8TH PHASE (678m+1678m)
Excavation in soil using Hydraullic excavator ck 90 and tippers with disposal upto 1000 meters. (Excavation for road work in soil with hydraulic excavator of 0.9 cum bucket capacity including cutting and loading in tippers ,trimming bottom and side slopes in accordance with requirements of lines grades and cross section and transporting to the embankment location with all lifts and lead upto 1000 m).
10203.7
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Construction of granular sub-base by providing coarse graded material, spreading in uniform layers with motor grader on prepared surface, mixing by mix in place method with rotavator at OMC, and compacting with vibratory roller to achieve the desired density, complete as per clause 401.
for grading -I material (2642.85+1745.85)
4388.7
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Wet Mix Macadam Providing, laying, spreading and compacting graded stone aggregate to wet mix macadam specification including premixing the Material with water at OMC in mechanical mix plant carriage of mixed Material by tipper to site, laying in uniform layers with paver in sub- base / base course on well prepared surface and compacting with vibratory roller to achieve the desired density.(1745.83+2642.85)
4388.7
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Providing dry lean cement concrete sub base over aprepared sub graded with coarse and fine aggregate confirming to is 383 the size of coarse aggregate not exceeding 25mm size. Aggregate cement ratio not to exceed 15:1 aggregrade gradation after blending to be as per table 600-1 cement content not to be less than 150 kg/cum optimum moisture content to be determined during trial length construction concrete strength not to be less than 10 mpa at 7 days mixed in abatching plant transported to site laid with a paver with electronic censor compacting with 8-10 tones vibratory roller finishing and curring ..(684.78+1023.58)
1708.36
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Construction of unreinforced dowel jointed cement concrete pavement with all complete job.
4212
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Providing muroom filling in both side…..do….
471.2
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RCC DRAIN 1MX1M IN 3RD & 8TH PHASE
Earthwork in excavation in foundation trenches in ordinary soil (vide classification of soil item-A and disposal of excavated earth as obtained to a distance upto 50m including all lift, levelling ramming the foundation trenches, removing roots of trees, shurbs all complete as per approved design, building specification and direction of E/I.
3277.5
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Cleaning of mud & slush with all complete job.
404
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Providing coarse clean sand in filling in foundation trenches or in 150mm thick with all leads and lifts including cost of all materials, labour, royalty and taxe all complete as per building specification and direction of E/I. (mode of measurement compacted volume)
441.62
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Providing 75A B/F soling in bed & joints filled with local sand including cost of watering taxes royalty all complete as per building specification and direction of E/I.
5462.5
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Providing RCC (1:11/2:3) in bed wall with approved quality of stone chips 20mm to 6mm size graded and clean coarse sandd of F.M. 2.5 to 3 including screening, shuttering, mixing cement concrete in mixer and placing in position, birating, striking, curing (but excluding the cost of reinforcement, taxes and royalty all complete, as per buolding specification and direction of E/I.
1911.88
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Providing M.S. reinforcement in RCC work with cutting, bending & bending with all complete job
75.01
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Filling in foundation trenches and plenth in layers not exceeding 150mm thick well watered from excavaion of foundation trenches within a iead of 50 m and lift of 1.5m all complete as per building specification and direction of E/I. (mode of measurement compacted volume)
6992
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