DETAILED TECHNICAL SPECIFICATION FOR 30 M HIGH MAST LIGHTING

1.

SCOPE:
The scope of this specification covers supply, installation, 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, 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.
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:-

3.

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 Specification for Mast and Foundation.
f. IS 875 (Pt-III) 1987
Code of Practice for Design Loads
for structure.
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 InTension design conforming to the Standards referred to above, to give an
assured performance and reliable service.

The mast height shall be 30 me ters, 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.
3.2.

Construction:
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-EN10025, cut and folded to form a polygonal section as st ated above and shall be
telescopically jointed and fillets welded. The welding shall be in 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
fully developed to the strength of the entire section. 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 galvanised, internally and
externally, having a uniform thickness of 65 microns.

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, ca bles, 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 pe r 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:
A fabricated Lantern Carriage shall be pr ovided 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 t wo 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.

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 the top.

4.4.

Winch:
The winch shall be of completely self sustaining type, without the need for brake
shoe, springs or cl utches. Each driving spindle of the winch shall be positively
locked when not in use, gravity activated PAWLS. Individual drum also sh ould
be operated for fine adjustment of lantern carriage. The capacity, operating
speed, safe working load of the recommended lubrication and serial number of
the winch shall be clearly marked on each winch.

The gear ratio may be according to manufacturers standard. However, the

minimum working load shall be not less than 750Kg. The Winch shall be self
lubricating type by me ans 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 e liminated 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.
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 pr esence of reputed Institution and the test
certificate shall be furnished before supply of material. A test certificate shall be
furnished by th e 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, galvanised both internally and externally after
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 diecaste aluminium alloy
(LM-6). Pulley made of synthetic material such as plastic or PVC a re not
acceptable. Self lu bricating 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 can opy galvanised 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 suspension system shall be essentially be without intermediate joint and
shall consist of any non-corrodable stainless steel of AISI 316 or better grade.

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 th e
specification. The end construction of rope to winch drum shall be fitted with
talurit.
The thimbles shall be secured on ropes by compression splices. Two continuous
lengths of stainless steel wire ropes shall be u sed in the system and no
intermediate joints are acceptable in view of the required safety. No intermediate
joints, either bolted or else is p rovided on the wire ropes between winch and
lantern carriage.
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 mm , copper conductor. The
cable shall be of approved make. A su itable FLP socket arrangement shall be
provided at th e 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 po wer
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 sup plied by High Mast supplier. The wiring from
control panel upto 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 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 be mechanical with suitable load adjusting device. The
torque limitor shall trip the load when it exceeds the adjusted limits. There shall
be suitable provision for warning the operator once the load is tr ipped off. The
torque limitor 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.
5.1.

LIGHTNING CONDUCTOR:
One number heavy duty, hot dip galvanised 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. O ther 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.

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 Indian 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.

9.

TEST & GUARANTEE CERTIFICATE:

Test certificate shall be furnished by t he 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 re liability 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.
General arrangement of the high mast indicating dimensions and foundation
details.
Wiring diagram of light fittings
Bill of materilas/part list
Foundation details
Design calculations
Data sheet

11. TECHNICAL DATA FOR 30 MTR HIGH MAST AND COMPONENTS

(To be obtained from the OEM and must be filled in by the bidders)
1
HIGH MAST LIGHTINGS STRUCTURE
a. Cross section of mast in polygon (no of sides)
b. Overall height of mast (mm)
c. No. of sections of mast
d. Individual section, thickness /dia /length(mm)
i. Top
ii. Middle
iii. Bottom
e. Type of joints & length of overlap joints
f. Weight in Kgs of mast(including base plate,
door and head frame etc.,)
g. Material construction
h. Pollution treatment
i. Thickness of galvanisation (min)
j. Size of base opening door
k. Locking arrangement of base opening door
l. Size of base plate dia. / thickness
m. Lighting protection device
n. Aviation lighting deice
o. Make / Enclosed Drawing reference
2.
a.
b.
c.
d.
e.

Civil Design Consideration

Max. wind speed (as per IS:875 1987)
Max. gust speed time
Factor of safety for wind load
Factor of safety for other load
Factor of safety of tower

3. Foundation Details
a. Type of foundation
b. Size of foundation
c. Designed load bearing capacity
d. Design safety factor
e. Considered wind pressure (Kg/Mt)
f. Consider wind speed (Km/Hr)
g. Depth of foundation
h. Average soil bearing capacity
i. No. of foundation bolts

j.
k.
l.

PCD of Foundation bolts

Type of foundation bolts / dia.
Bolt Diameter

4.
a.
b.
c.
d.
e.
f.
g.
h.
i.

LANTERN CARRIAGE
Material of construction
Type of construction
Diameter of carriage ring (m)
Number of joints
Buffer arrangement for carriage and mast
Load carrying capacity (kg)
Total weight of assembly with fittings(kg)
Number of fittings
Type of fittings/fixture

5.
a.
b.
c.
d.
e.
f.
g.
h.
g.

WINCH
Make of winch & No. of winch / drums
Gear ratio
Capacity (kg)
Operating Speed on full load
Individual drum rotation
Method of Operation
Lubrication arrangement / type of lubricant
Tested load per drum (kg) i. Kgs per drum
ii. Kgs per winch
SWL of winch at 200 rpm (Kg)

6.
a.
b.
c.
d.
e.
f.
g.
h.
i.

STAINLESS STEEL WIRE ROPE

Make
Grade
Number of ropes
Material and construction
Centre core material
Diameter (mm)
Thimbles & Terminals
Breaking load capacity (kg)
Factor of safety (specified not less than 5)

7. CABLE
a. Conductor, insulation/No. of cores
b. Type
c. Make
d. Conductor Size / Current Capacity
8.
a.
b.
c.
d.
e.
f.

POWER TOOL
Mode / Type
Input Supply (Volts)
KW / HP
Operating speed
i) Remote control switch PB station
ii) Length of control cable provided
Max. Time taken for:
i) Raising
ii) lowering

9.
a.
b.
c.

TORQUE LIMITER
Model
Lifting capacity (kg)
Adjustability / non-adjustable

10.
a.
b.
c.

AVIATION FITTINGS
Type
Type of lamps
No. of Lamps/fittings