Madhya Gujarat Vij Co. Ltd. An ISO 9001:2008 Certified Company Regd. Office:- 3 RD Floor, S.P. Vidyut Bhavan Race Course, Vadodara 390 007, EXPRESSION OF INTEREST Ref. No. MGVCL/Civil/PF s/11/01 Entrepreneurs / Businessmen interested in setting up of readymade 8M long Prestressed Concrete Pole Manufacturing Unit are invited for Submitting Expression of Interest. Similarly, existing pole manufacturers desirous of expanding the installed capacity or setting up a unit in another location can also Submit Expression of Interest. Specifications and technical details are available on web site URL www.gseb.com Tenders MGVCL Corporate Office and www.mgvcl.com Application with full details of manufacturer along with financial status, facilities available and time required for establishing the factory must be submitted in physical form and sent by Registered post/speed post so as to reach the office of the undersigned latest by 11-11- 2011 by 14:00 Hrs. In order to provide the entrepreneurs with required information to understand the product and fulfill the necessary requirements of 8M/200 Kg PSC Poles, information is furnished in form of Annexure 1 to 5. All interested bidders should apply considering fulfillment of the conditions stipulated in Annexures is necessary for implementation. For & On behalf of MGVCL Sd/- Chief Engineer (T&O) EOI_New PF's-2011.doc Page 1
ANNEXURE - 1 STANDARD REQUIREMENTS FOR A POLE FACTORY 1. Non Agricultural Land admeasuring approx. 2 Hectares located at least 30 Kms away from nearest existing pole factory. Location should be accessible in all seasons. 2. Water Potable water in sufficient quantity for use in concrete and curing ponds should be available. 3. Electrical Connection of required Electrical load is required at site. 4. Casting bed for manufacturing poles to required capacity. 5. Cement Godown suitable to store at least 500 bags. 6. Site laboratory equipped with Cube testing machine. 7. Site office with Computer and operator. 8. Labour colony with toilet facilities. 9. Test bed with all testing facilities. 10. Storage space for H.T. Wires, M.S. Rounds, Fine and Coarse Aggregates. 11. Mobile crane for handling of poles. 12. Steel Formwork of suitable capacity. 13. Pan mixer / Mini Batching Plant for manufacturing M45 grade Concrete. 14. Labour License and Factory License to be arranged by manufacturer. 15. Hand cart for handling poles and fresh concrete. 16. Vibrator of suitable capacity. EOI_New PF's-2011.doc Page 2
ANNEXURE - 2 GENERAL TERMS AND CONDITIONS [1] GENERAL: The subject covers the manufacture and supply of Prestressed Concrete Poles for Overhead Power Traction Lines 8 meters in length and capable of sustaining working load of 200Kgs (as stipulated in Cl. 3.7 of IS: 1678-1998). The offer is for supply of Ready-made PSC poles manufactured in accordance with the specifications and the drawing mentioned in tender. Alternate design / specifications shall not be considered. [2] DRAWING: The work shall be carried out as per the Drawing Prestressed Concrete Pole-8 Mtrs / 200 Kg showing detailed dimensions" bearing No. C - 583 Rev.2 [3] ONLY FOR NEW FACTORY: The work covered under this tender being of specialised nature, the tenderer is expected to know the procedure of manufacturing activities of Prestressed Concrete Poles and have a clear understanding of the various problems connected with the smooth running of the factory and also to study carefully design, drawing, specifications etc. For new pole factory, the activity of pole manufacturing shall be arranged in such a manner keeping in mind that the pole manufacturing is to be commenced with immediate effect and that supply can commence within 30 days of issue of Letter of Intent (L.O.I.)/ Work Order as intimated. [4] ORDER: The Company reserves the right to place order for any quantity it deems fit depending on the requirement of Poles by respective Circle. However attempt shall be to utilise the availability of poles up to minimum guaranteed quantity but not exceeding the maximum supply capacity of the pole factory. [5] LABOUR WAGES: Terms and conditions regarding industrial laws and other related matters like wages payment to the labours, compliance of the labour laws including payment of workman compensation etc, shall be the responsibility of the PSC Pole suppliers. [ [6] WORKMANSHIP: The contractor will be responsible for the general soundness as well as good finish of each pole. The workmanship shall be of a high degree and poles having flaws and defects will be rejected in accordance with applicable Indian Standards. EOI_New PF's-2011.doc Page 3
[7] WATER AND ELECTRICITY: The contractor shall have to make his own arrangement for water and Electricity required for manufacturing work of PSC pole along with statutory approval, if any, the Company does not take any responsibility for the same. [8] TOOLS PLANTS & MACHINERY: The contractor shall make his own arrangement for all the tools, plants & machineries such as formwork, electrically / mechanically operated mixer, vibrator, pump, cube testing machine, gauges, chain pulley block, gantries, measuring instruments, tension test assembly etc. required for manufacturing, inspection and testing of PSC poles. I/We confirm having read the above Conditions and also accept the same without any deviations. Signature & Stamp of Supplier/ Manufacturer Name of P.F. Name of Authorised Signatory Date: EOI_New PF's-2011.doc Page 4
ANNEXURE - 3 TECHNICAL TERMS AND CONDITIONS: [1]SCOPE OF WORK: The scope of the work covers fabrication and supply of PSC Poles of 8 meter long and 200 Kgs. working (transverse) load in accordance with the technical terms and drawing of this specification. Alternate design / specifications shall not be considered which may be noted. [2] DIMENSIONS AND TOLERANCES: SR NO DESCRIPTION STANDARD IN MM MAXIMUM IN MM MINIMUM IN MM 1 LENGTH 8000 8015 7985 2 WIDTH - TOP - BOTTOM 114.3 336.55 117.3 339.55 111.3 333.55 3 THICKNESS 139.7 142.7 136.7 4 UP RIGHTNESS 1 TO 72 0.5 % 0.5 % 5 PLANTING DEPTH 1381 - - NOTE: All dimensions are in mm. [3]WORKMANSHIP: The contractor will be responsible for the general soundness as well as good finish of each pole. The workmanship should be of high degree and poles having flaws and defects will be rejected. [4] STANDARDS: The poles shall comply with the relevant provisions made in the following Indian standard specifications with latest amendment. Sr. No. IS: No. Title 1 IS: 1678/1998 Specification for Prestressed concrete poles for overhead Power and telecommunication lines 2 IS: 2905/1989 Method of test for concrete poles for overhead Power and telecommunication lines. 3 IS:1343 & IS: 456 Code of practice for Prestressed and plain / reinforced Concrete. EOI_New PF's-2011.doc Page 5
[5] MATERIALS: The materials shall conform to this specification and be in accordance with the guaranteed particulars given. The quality of materials to be used for manufacturing of PSC poles shall be as under: [A] CEMENT: The Ordinary Portland Cement used in manufacture of prestressed concrete poles shall be relevant to IS: 8112 for 43-Grade and IS: 12269 for 53 - Grade Cement to get 28 days strength of 450 Kg/ cm 2. [B] STEEL: The prestressing steel used shall be 4mm dia. Cold drawn indented wire (H.T. Steel wires) conforming to IS: 6003/1983. [C] AGGREGATE: Aggregate used for the manufacturing of Prestressed Concrete poles shall conform to IS: 383-1963. Coarse aggregates shall be hard, strong, dense, durable, clear and free from veins and adherent coating, and free from injurious amount of disintegrated pieces, alkali, vegetable material, and other deleterious substances. It should not contain organic or other admixture that may cause corrosion of the reinforcement or impair the strength or durability of the concrete. The aggregates of 20 mm or smaller are generally considered satisfactory. Coarse and fine aggregates shall be batched separately. The sand used shall be clean and free of silt. If necessary it shall be washed before use by installing a sand washing machine in the factory. [D] WATER: Water to be used for process of manufacturing PSC poles like concrete mix and curing should be free from chlorides, other salts and organic materials and it should be got tested in Govt. Laboratory at lest once in a year by the supplier. Potable water only can be used in concrete. [6] STORAGE OF MATERIALS The cement shall be stored at the work site in such a manner as to prevent deterioration due to moisture or intrusion of foreign matter. Steel reinforcement shall be stacked in such a way so as to avoid distortion and to prevent deterioration and corrosion. It is good practice to coat reinforcement with cement wash before stacking to prevent scale and rust. The aggregates shall be stored in such a way as to prevent mixing of foreign materials. The heaps of fine and coarse aggregates shall be kept separately. When different sizes of fine or coarse aggregate are procured separately, they shall be stored in separate stockpiles, to prevent the material at the edges of the piles from getting intermixed. Any material, which has deteriorated or has been damaged or is otherwise considered defective shall not be used for the concrete. Rejected materials shall be removed from the P.F. premises immediately. EOI_New PF's-2011.doc Page 6
[7] TESTING OF MATERIALS: The contractor shall arrange for the necessary testing of the material like Metal, Sand, Water etc. and see that the materials to be used in the manufacturing conform to relevant IS. [8] METHOD OF MANUFACTURING OF PSC POLES: The Prestressed concrete poles are generally manufactured by long line multiple bed method for mass production. (A) BED AND MOULD: The length and number of rows of concrete casting bed shall be according to the production capacity of pole factory. Preferably one pole bed separately should be provided to minimise wastage of H.T.Steel wire. The prestressed poles are to be cast in a steel mould having accurately machined bottom bed and side faces. The steel mould should be strong enough to resist distortion. The bed should be absolutely horizontally levelled and free from any undulation. The mould should be capable of being opened in such a way that edges of the poles are not damaged. At both the ends of row of concrete casting bed, the anchor blocks are provided for fixing and stretching of H.T. Steel Wire. (B) STIRRUPS: The stirrups shall be prepared as per the design / drawing of the MGVCL from 4 MM dia. H.T. Steel wire/ 6MM dia. M.S. Bars. The stirrups shall be tied up with main bar i.e. Tension Wire with binding wire of 18 gauges. The contractor at his cost shall procure the binding wire. The binding with the help of cotton or any other means will not be permitted. (C) PREPARATION OF REINFORCEMENT: All the reinforcement and window boxes shall be accurately placed and maintained in position during the fabrication. As per the Design / Drawing all the stirrups made out of M.S. Bars, H.T. Steel wire shall be placed in respective position of the mould and thereafter continuous H.T. Steel wires are arranged through holes and plates of the mould. The welded joints in H.T. Steel wire will not be permitted. The H.T. Steel wires are stretched up to the required tension as specified in relevant I.S. code with the help of Jacks and anchor blocks. All the wires shall be accurately stretched with uniform prestress in each wire. Each wire shall be anchored positively during the casting. The tension applied shall be checked with the help of suitable Gauge/Meter. (D) CONCRETE MIX: The concrete mix to be used for manufacturing of P.S.C.Poles shall be prepared by weigh batching only in such a manner and proportion so as to achieve the EOI_New PF's-2011.doc Page 7
compressive strength of the concrete mix of any individual test result not less than 225 and 450 KG/CM 2 after 3 and 28 days respectively. The cement concrete shall be mixed only in electrically / mechanically operated concrete mixer machine. Gradation of the aggregate used in concrete mix shall be checked in regular interval and required adjustment shall be done at site. Water in concrete shall be added with proper measurement to maintain required water cement ratio. The hand broken metal shall not be permitted. The 3 day strength actually corresponds to the concrete strength at transfer. However average of four consecutive test results shall be not less than strength specified plus 0.825 x established standard deviation or specified strength + 40 Kg/cm 2. (E) PLACING OF CONCRETE MIX: The mould / formwork should be free from Dust, Dirt and other organic materials. The face of formwork in contact with the concrete shall be cleaned and treated with Form Release agent. The machine mixed concrete is, thereafter poured in the mould and shall be compacted by vibrating, shocking or other suitable mechanical means. Over-vibration or under-vibration or vibration of very wet mix is harmful and should be avoided. The Hand compaction shall not be permitted. On application of vibrator the concrete Mix will compact & get to 2 to 3 mm below form/mould level. This gap shall also be filled up with prepared concrete Mix only & re-vibrated. The mixture of cement & sand for filling up the gap as well as finishing work will not be permitted. Finishing work shall be done only with cement slurry. Care should be taken to see that anchorages do not yield before concrete attains necessary strength. Proper cover for concrete should be maintained throughout process of pouring, compacting etc. of concrete mix. On achieving setting time, the side faces of the mould shall be removed from the bed and watered at intervals to prevent the surface cracking of the pole. The concrete shall be covered with a layer of sacking, canvas, Hessian or similar absorbent materials and kept constantly wet up to the time when the strength of the concrete reaches to the minimum strength of the concrete at transfer of pre-stress i.e. for about 72 hours. The Steam curing may be permitted in exigency or emergency cases with the approval of the competent authority only. (F) DETENSIONING, CUTTING OF WIRE, AND REMOVING OF THE POLES FROM THE BED: Detensioning has to be done when concrete has attained strength not less than 225 Kg/ cm 2 which usually is attained within 48 to 72 hours of placing the concrete. Detensioning has to be carried out only after ascertaining the strength of concrete. The cutting shall be started only from the centre of the bed length. The pole is then removed from the bed by lifting at 2 points using gantry and moved to the Curing Pond. EOI_New PF's-2011.doc Page 8
(G) CURING: The curing of the pole on the beds shall commence after setting of the concrete and such curing on bed should be done till concrete attains strength of more than 225 Kg/ cm 2. Water sprinkling shall be done at intervals to keep the poles constantly wet. After de-tensioning, the poles are removed from the beds and immersed in curing water ponds. The curing pond shall be full of water and each pole must be immersed in the water for a period of at least 14-21 days. (H) STORING OF POLES READY FOR INSPECTION: The poles prepared vide method stated above shall be stacked in well defined Lots. It is preferable to put up a sign board indicating the lot no. and the period of manufacturing the lot. This shall enable easy identification of the lot by inspecting officer. Similarly lots already tested need to be differentiated from the poles yet to be tested. 9] MARKING: The poles shall be clearly and indelibly marked with MGVCL, <Date of manufacture>, <Pole identification No.> and <the Cumulative sr. no. of production>, during manufacture, at positions shown in drawing. The mark shall be done by pressing embossed figures / letters of 50 mm height and 20 mm width with gap of 5 mm between two figures. The sample drawing No. - C 583 - A is attached with the tender. The pole shall also be suitably marked for the planting depth i.e. 1381 mm from bottom. On both the ends of pole the anti corrosive paint i.e. epoxy based bituminous paints two coats are to be applied, one before putting in curing pond and second after removing from the pond. [10]CUBE TESTING: Total 6 Nos. Cubes of 150mm X 150mm X 150mm size concrete shall be cast daily, cured and tested as under. Three cubes are to be tested at intervals prior to release of tension, Average strength of the three cubes should comprise one test result and it shall be not less than 225 Kg/cm 2. The results of strength shall be recorded along with its age at time of test, in the Cube testing register. Similarly 3 cubes must be tested after 28 days of casting of concrete, in accordance with Indian Standard specification at contractor s own expense. The average strength of three cubes shall be such as to give cube strength not less than 225Kg/cm 2 at release (usually 2-3 days) and 450 Kg/cm 2 at 28 days. Standard Deviation shall be calculated for a set of 30 test results. Cube testing machine shall always be kept in the working condition and regular cube tests shall be taken by responsible and experienced personnel appointed by the supplier/ tenderer and results be recorded in the Cube Testing registers duly signed by the person testing the cubes. The cubes shall be tested in presence of Company s engineer as far as possible. Recording results in Register is essential. EOI_New PF's-2011.doc Page 9
I/We confirm having read the above Conditions and also accept the same without any deviations. Signature & Stamp of Supplier/ Manufacturer Name of P.F. Name of Authorised Signatory Date: EOI_New PF's-2011.doc Page 10
ANNEXURE - 4 TECHNICAL DATA OF PSC POLES The Guaranteed Particulars of Poles 8 Mt. 200 Kg. 01. Working load : 200 Kg. 02. Factor of safety : 2.5 03. Ultimate Load : 500 Kgs. 04. Dimensions : (a) Bottom Cross-Section : 336.55 x 139.7 mm. (b) Top Cross-Section : 114.3 x 139.7 mm. (c) Total height : 8000 mm. (d) Uprightness(Taper) : 1 to 72 (mm or inch). (e) Web thickness. : 57.15 mm (2.25 inch). (f) Planting Depth : 1381 mm. 05. No. of Windows : 09 nos. 06. No. of 20mm dia holes. (i) On Front face : 02 nos. (100 mm apart). (ii) Side face : 05 nos. (300 mm apart). 07. Minimum requirement: (a) Cube Test : 450 Kg/Cm 2 (28 days). : 225 Kg/Cm 2 (3 days). (b) Initial tension in HT Steel Wire/Pole. : 70% of 175.00 Kg/mm 2 as specified in related I.S.Code EOI_New PF's-2011.doc Page 11
Addresses of existing pole factories: ANNEXURE - 5 Sr.No. Name of Firm /Pole Factory ADDRESS 1. M/s. A.K. Patel (Santrampur P.F.) At PO: Barikota, Opp. Hanuman Temple Santrampur 389 260 Dist Godhra. 2. M/s. Usha Prestressed (Santroad P.F) At PO.: Morva, Opp: GEB Substation, Santrampur Road, Vill: Saliya, Santroad 389120 Taluka: Godhra Dist Godhra. 3. M/s. Urja Power PTE Ltd. (Asoj P.F.) (F) Baroda-Halol Highway. (O) 1-Bira Venus Apptt. ProductivityRoad, Alkapuri, Vadodara 390 007 4. M/s. Dipak kumar Chauhan (Chota Udaipur P.F) Nr. Killa Chota Udaipur 5. M/s. Prestressed Concrete(Bodeli P.F) At: Khandivav Taluka: Jambughoda Dist.Pancmahals 6. M/s. D. A.Chauhan(Nimeta P.F) At PO: Rasulabad, B/h Saibaba Temple Ajwa Nimeta Road Taluka : Waghodiya Dist: Vadodara Resi: B-4, Heritage Home. Opp: Nilamber Township, B/h Sarthi Society, Dabhoi-Waghodia ring road, Vadodara. 7. Shri Maruti Pole Industries(Masar P.F.) At PO: Masar, Padra-Jambusar Road Taluka: PadraDist: Vadodara 391421 8. M/s. S.V.Trust (V.V Nagar P.F) Nr. Charutar Vidyamandal Office, Vidyanagar Anand Road Vallabh Vidyanagar.388 120 9. M/s. Anand Prestressed (Mogar P.F.) (F) N. Highway No.8 Mogar Nr. Fountain, Sardar Chawk, Borsad 10 M/S Urja Infra Structure (India) Pvt Ltd, Kathlal P.F. 15, Srinagar B/h Maharaja Landmark, Opp: Sarvoday Hospital, Kalol (NG) 382 721. 11 M/S ACME Prestressed & Allied Industries.Karjan P.F. 2, Sayona Vihar, Nr. C.P. Nagar, Ghatlodia, Ahmedabad: 380061 12 M/S Jivanlal Joitaram Patel (Udalpur P.F.) Patel Estate, Station Road, Thasra 388250, Dist: Kheda. EOI_New PF's-2011.doc Page 12