| 1 | 1 | Supply, erection, testing & commissioning of High Mast based on the following parameters/ requirements of the Deptt. Height of Mast: 16 meter with power tool based. The power tool 3 phase motorized 1.1 KW complete in all respect should be installed in the pole Reputed ISI marked only. Wind speed: 180 Km/hour as per IS-875 (Part-III). The High Mast & head frame shall be structurally suitable to accommodate the 8 Nos. 240 Watt. 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.\nThe 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 minimum overlap distance shall be 1.5 times the diameter at penetration.\nA 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. \nFor 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. \n\nCode No. (Title) I.S. 875 (Part III) 1987 Amended up to date (Code and practice for design loads for structures under ) BSEN 10025 (Grades of M.S. plates ) BS. 5135/AWS D 1.1 (Welding) BSEN ISO 1461 (Hot dip galvanizing) TR. No. 7 (2000 Edition) of ILE, UK (Specification of Mast and foundation.) IS 3459 / 2266 (Stainless steel Wire rope) IS 9968 Part – 1 (Trailing Cable) IS 325 (Motor) Dynamic Loading for the Mast:\nThe 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 metres 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:\nA 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\nafter 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.\nWeather 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\nshall 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\nWinch: \nThe 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. \nThe 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. \nThe 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\nload operated by the winch.\nHead Frame:\nThe 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.Head Frame:\nThe 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:\nThe 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 2x2350 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 two 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:\nSuitable 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\ndisconnection when required ,Power Tool for the Winch:\nThree phase, single speed, 6 pole high-powered motor of rating 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. \nMechanical 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:\nOne 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 Earthing Terminals:\nEarth terminal using 12 mm diameter hot dip galvanized bolts shall be provided on the door stiffener of the mast for lightning and electrical earthing of the mast.Feeder Pillar:\nEach mast shall be provided with a feeder pillar housing Suitable TPN MCB incomer, single dial time switch and outgoing contactor for automatic switching on and off luminaries, 9A two contactors and raise lower push buttons for motor operation, incoming terminals of 50 sq. m and outgoing terminals of 16 sq. mm for power cable and 2.5 sq. mm for motor.Incoming Power Cable:\n1.1 KV grade, PVC insulated, PVC sheathed, Aluminium conductor, armoured cable for power supply shall be provided from feeder pillar to the base compartment of the high mast. Cable shall be taken to the base compartment of the high mast through the provision made in the foundation. Power cable of suitable size up to the feeder pillar from supply point shall be provided by purchaser.The firm will give the high mast parameters as given below:Height of the High Mast. (16 Mtr.)Nos. of sections (Two Nos. ) Thickness of each section in mm. (Top: 3 mm & Bottom 4 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 / Utkarsh 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.\n\n\n\n\n\n\n\n\n\n | | 8 | Each |
| 2 | 2 | FOUNDATION FOR 16/12.5 MTR. LONG HIGH MAST:\nDesign & casting of foundation with M20 cement Concrete & steel reinforcement suitable for installation of 16 Mtr high mast:\n | | | |
| 3 | 2.1 | DSR ITEM NO. 2.8.1 (CIVIL WORK)\nEarth 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 3.5mx3.5mx1.6m= 19.60 cum (8 Nos. x 19.60= 156.80 cum)\n | | 156.8 | Cum |
| 4 | 2.2 | DSR ITEM NO. 4.1.11 (CIVIL WORK)\nProviding 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)\n(3.3mx3.3mx0.10m =1.089 cum.)\n8 Nos. x1.089= 8.71cum)\n | | 8.71 | Cum |
| 5 | 2.3 | DSR ITEM NO. 5.22.6 (CIVIL WORK)\nSteel reinforcement ( TATA/TISCON/ SAIL for R.C.C. work including straightening, cutting, bending, placing in position, overlaps etc and binding all complete upto plinth level. Thermo-Mechanically Treated bars\n1. Horizontal Bar10mm dia =52 nos.x3.200=166.40 [email protected] Kg per mtr.= 103.16 kg\n2. Vertical Bar 12mm dia =24 nos.x1.995=47.88 r.mtr. @0.89 kg per mtr. =42.61 kg\n3.Horizontal Ring 8mm dia =9 nos.x3.792=34.12 [email protected] per mtr.=13.30kg\nTotal (103.16+42.16+13.30=159.07+5% wastage = 167.02 kg)\n8 Nos. x167.02= 1336.16 cum)\n | | 1336.16 | P/Kg |
| 6 | 2.4 | DSR ITEM NO. 5.2 (CIVIL WORK)\nReinforced 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 (Zone III) : 3 graded stone aggregate 20 mm nominal size)\nSize 3.100x3.100x0.300 = 2.88 cum\nSize 1.000x1.000x1.400 = 1.40 cum\nTotal (2.88+1.40= 4.28 cum.)\n8 Nos. x4.28= 34.24 cum)\n\n | | 34.24 | P Cum |
| 7 | 2.5 | DSR ITEM NO. 5.9.1 (CIVIL WORK)\nCentering and shuttering including strutting, propping etc. and removal of form for : Foundations, footings, bases of columns, etc. for mass concrete\nSize 1x2 (3.100+3.100) 0.45 = 5.58 sq.mtr.\nSize 1x2 (1.400+1.400) 1.000 =5.60 sq.mtr.\nTotal (5.58+5.60= 11.18 sq.mtr.)\n(8 Nos. x11.18= 89.44 sq.mtr)\n\n | | 89.44 | P/Sqm |
| 8 | 3 | S/E of High Power LED Flood light luminaries of Philips / Bajaj / Wipro / Crompton / LT make only. The job includes the cost of testing, commissioning and making connection with 3 x 4 sq. mm. copper wire from adjacent junction box, other petty material and labour etc. as required to complete the job to the entire satisfaction of Engineer In Charge.\nSpecification of LED fittings:\n | | | |
| 9 | 3.1 | Wattage of LED fittings ( Code and practice for design loads for structures under )Total lumens of the LED fittings (Code and practice for design loads for structures under )Ingress protection level of fittings (IP 65 or better.)Body of fittings ( Extruded aluminium housing/ pressure die cast with toughen glass diffuser)Operating voltage ( 140 V to 270 V AC supply or better )Input frequency (50 Hz + 1 Hz)Power factor (Minimum 0.95) Luminaire efficacy ( Minimum 110 lm/w)Color rendering index (CRI shall 70 (minimum))Working/ operating temperature ( 00 to + 450c or better )Color temperature (55000 K to 65000K) Electronic Driver, Drive current (LED) ( Constant current less than 750 MA) Operating voltage ( 140 V to 270 V AC supply or better )Type of driver (Constant current output driver) Surge Protection ( 10 KV minimum) Efficiency Driver (>85%) Protection ( Shall have under voltage and over voltage protection.) Guarantee of LED fittings including LED driver (2 years against manufacturing defect.) Fixture ( Should comply with LM 79 test from NABL lab approved Lab.) LED Type/ Make/ Model ( Power CREE/ OSRAM/ NICHIA/ Philips LUMILED with life more than 50,000 burning hour’s @70% lumen maintenance complying with LM 80 test report from the original manufacturer.) Life of LED ( 50000 burning hours at 70% lumen maintenance ) | | 64 | Each |
| 10 | 3.2 | S/E of sheet metal 3 phase bus-bur chamber on existing surface with required no. of bus-bar strips of suitable 1.6 mm thick with detachable cover fitted with dust excluding gasket and secured with sufficient no. of cadmium plated iron screws and of given overall dimensions and to be fixed with GI bolts and nuts/rag bolts and nuts etc. complete with all accessories including connections with suitable size tin coated copper thimbles, bonding to the existing earth & painting etc as desired by the EIC.Sheet metal bus-bar chamber 100 amp 415 V capacity with 4 copper strip of Suitable size. | | 12 | P/Rn.Ft. |
| 11 | 4 | Providing and fixing following rating MCCB 4 pole 415 Volt (Thermal magnetic / microprocessor release) without MS enclosure for Over load and short circuit protection, 25 KA (Min.) Breaking capacity (Ics=100% Icu) with positive isolation. The overload & short circuit release shall be of Adjustable Type. The MCCB is to be installed in MS enclosure (Fixed in existing pedestal with nut and bolt) with suitable arrangement and making connections with suitable rating of copper wire / copper strip etc. as required. The MCCB should be of make L&T (D Sine)/Schneider (Compact NSX) / Siemens (3VL)/ ABB(T-max) / Legrand (DPX3) make only. The job also includes the cost of suitable size of MS enclosure for installation of MCCB of the same make as proposed for the MCCB. 100Amp. 25 KA 4 pole MCCB (Thermal Magnetic) | | 8 | Each |
| 12 | 5 | Supply and erection of sheet metal cubical pedestal of suitable dimensions made from 50 mm X 50 mm X 6 mm thick M.S angle iron frame, covered with 1.6 mm thick M.S. sheet duly welded on five sides and front side hinged complete with locking arrangement with 4 Nos. switchgear supporting members each of M.S. flat 50 mm X 6 mm thick of suitable length duly welded. The cubical pedestal shall have 4 Nos. legs of 50 mm X 50 mm X 6 mm each 60 cm long M.S. angle iron each long including painting, bonding to the existing earth etc. the same shall be erected in the 1:2:4 cement concrete plat-form of suitable dimensions 15cm high form ground level and 45 mm thick. The cubical pedestal shall be 15 cm from the top of cement concrete platform. Cubical size 1200 mm X 900 mm X 350 mm | | 8 | Each |
| 13 | 6 | DSR-15.4 Supplying, installation, testing and commissioning of Astronomical time switch of following configuration to be mounted in feeder pillars / Lighting DBs for automatic switching On & OFF of street lights at sun set & sun rise or twilight (Auto ON, Auto OFF, Auto modes) with manual override facility with 12/24 hour display format with suitable battery and indication for relay status i/c programming at site complete as required. 3 output (1output per phase) and suitable for three phase supply | | 8 | Each |
| 14 | 7 | S/I/T/C of Single dome integral LED aviation obstruction light (IP-65) comprising of aluminium housing with polycarbonate enclosure to be installed on the top of existing High mast including making necessary connections, testing and commissioning etc. to the entire satisfaction of Engineer In Charge. The LED aviation light should be of Bajaj / Philips / Wipro only. | | 8 | Each |
| 15 | 8 | DSR 2.3 Supplying and fixing following way, single pole and neutral, sheet steel, MCB distribution board, 240 V, on surface/ recess, complete with tinned copper bus bar, neutral bus bar, earth bar, din bar, interconnections, powder painted including earthing etc. as required. (But without MCB/RCCB/Isolator) 6 way , Double door | | 8 | Each |
| 16 | 9 | DSR Item No. 2.10\nSupplying and fixing 5 A to 32 A rating, 240/415 V, 10 kA, “C” curve, miniature circuit breaker suitable for inductive load of following poles in the existing MCB DB complete with connections, testing and commissioning etc. as required. Single pole\n | | 48 | Each |
| 17 | 10 | DSR Item No.5.1\nEarthing with G.I. earth pipe 4.5 metre long, 40 mm dia including accessories, and providing masonry enclosure with cover plate having locking arrangement and watering pipe etc. (but without charcoal/ coke and salt) as required.\n | | 16 | Each |
| 18 | 11 | DSR Item No 5.7\nSupplying and laying 6 SWG G.I. wire at 0.50 meter below ground level for conductor earth electrode, including connection/ termination with GI thimble etc. as required.\n | | 900 | P/Mtr |
| 19 | 12 | DSR Item No 14.16\nSupplying and laying of following size DWC HDPE pipe ISI marked along with all accessories like socket, bend, couplers etc. conforming to IS 14930, Part II complete with fitting and cutting, jointing etc. direct in ground (75 cm below ground level) including excavation and refilling the trench but excluding sand cushioning and protective covering etc. complete as required. 3 mm dia (OD-63 mm & ID-51 mm nominal)\n | | 900 | P/Mtr |
| 20 | 13 | DSR 14.15 Supplying and laying of following size DWC HDPE pipe ISI marked along with all accessories like socket, bend, couplers etc. conforming to IS 14930, Part II complete with fitting and cutting, jointing etc. in the existing trench, complete as required. 63 mm dia (OD-63 mm & ID-51 mm nominal) | | 80 | P/Rmt |
| 21 | 14 | Labour charges for horizontal boring 1 mtr. Below ground level including cost of 2 nos. pit digging and refilling complete in all respects upto entire satisfaction of the EIC of the work. | | 80 | P/Rmt |
| 22 | 15 | Supply and laying of XLPE insulated PVC sheathed Aluminium conductor cable of 1.1 KV grade as per IS 7098 (Part-I) 1988 (amended up to date) of the following sizes to be laid in existing RCC/HUME/DWC pipe/on surface as required. The job includes labour charges of laying the cable and making connections etc. (For Campus & security light) Makes of Cable: - KEI / Havells / Polycab / RR Kables / Finolex only. PVC Armoured Aluminium conductor cable Size 4 core x 16 Sq. mm | | 1100 | P/Mtr |
| 23 | 16 | Provision of Electricity connection charges | | 18.16 | P/KW |
| 24 | 17 | Aviation light and connector wire twins core 2.5 mm for LED light. | | 8 | Each |
| 25 | 18 | Control panel with timer MCB, BUS BAR connector auto switch etc. | | 8 | Each |
