HIGHMAST LIGHTING NEW SIZE 11 singal...

Stadia, City Junctions, Airports, Sea Ports, Industries.We reach faster than anyone else.

H I G H M A S T L I G H T I N G

VARIANT INFRATECH PRIVATE LIMITED

Facilities offered at-a-glance

Why BAJAJ highmast is preferred?

BEL has inhouse facilities for :

Pioneer : BEL is in the field of high mast since last 25 years and has unmatched

experience in design, development, manufacturing and site erection.

Illumination Design

BEL has a team of illumination design engineers, who are well qualified and

experienced. They prepare designs with the help of the best available software.

BEL illumination design engineers are equipped to offer optimum designs for all

lighting applications like stadiums, traffic junctions, airports, sea ports, container

yards, railway marshaling yards, etc. Several lighting projects confirming to Indian /

international standards, have been designed and successfully executed.

Civil / Structure design

BEL has an in house set up for structural and foundation design for the masts.

Designs generally conform to ILE TR No.7 and IS 875 part 3. Masts confirming to

various terrains, wind zones and heights have been designed by BEL over these

years. BEL has designed manufactured and installed masts of heights upto 60 M.

BEL designs have already been approved by various Institutions/consultants like IIT

Mumbai, IIT Chennai, Engineers India Limited, Bectel Limited, PDIL, Meccon, etc.

Mechanical Design

BEL has in-house team of engineers with latest mechanical design software to

design the complete raising / lowering system. This also enables BEL to cater to

customer specific requirements.

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Highmasts for Places of Tourist Attractions


1.3Bajaj Highmasts being Installed at Ras-Al-Khaima, UAE.

Manufacturing:

BEL's manufacturing plant is one of the best in the world and is fully

equipped with all state-of-the-art machineries.

With these facilities BEL is capable of manufacturing high masts confirming

to international standards and as per the requirement of the user.

The plant is ISO 9001 and 14001 certified.

Marketing, Sales and service set-up

BEL has 19 offices in India to cater its clientele. These offices help

customers for their requirements from the conceptual to commissioning

stage. BEL engineers stationed at these offices provide optimum designs,

competitive prices, installation services and efficient after sales services.

BEL offices at Mumbai and Sharjah cater to its international customers.

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Introduction

Advantages Applications

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Designs

BEL has been supplying this type of masts for more than two decades. Normally designed for a life of 25 years, these masts are the best solution available for external illumination requirements.

These masts will accommodate any lighting system and are also ideal for mounting CCTV cameras. BEL's manufacturing facility is one of the best of its kind in the world. With this facility, BEL can offer masts of various types and capacities suiting the customers' requirement.

Best space utilisation. Airports & sea ports

Perfect suspension. Railway sidings & yards

Maintenance friendly. Car parks & junctions

Double drum winches Highways & express ways

Motorised operation. Industrial flood lighting

Sleek and aesthetic. Top security zones.

Available upto 60 M height

Masts are designed to ILE Technical Report No. 7. Wind velocity as per IS 875 part.3 in India and as per the relevant local standards in other countries. The method of construction using overlapping joints provides good damping and greatly resists resonance caused by wind induced oscillations. The mechanical and electrical systems incorporated within the mast also conform to the requirements of ILE T R No.7.

BEL has successfully conducted “Wind Tunnel Testing” for the mast sample. The test was conducted at Wichita State University USA. Crucial parameters used for preparing individual designs are taken from this test results.

Raising and loweringWinch Lighting masts

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India's only 60 M Highmasts - Installed at Chennai Container Terminal

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Mast Construction

Mast Head Assembly

'BAJAJ' raising and lowering winch masts are made from continuously tapered folded

steel sections. The polygonal cross section is usually 20 sided, although other shapes

can be offered on request.

The material is steel confirming to BSEN 10025 grade S 355. the plate is plasma cut and

folded to form polygon of required shapes and then welded along longitudinal seams.

BAJAJ section lengths are typically designed and are such that transverse welding is

not required. Sections are designed in such a way that the overlap length shall be more

than 1.5 times the diameter at penetration.

The taper fit friction joints can be assembled at site with equipments usually available at

construction sites. No site fabrication work is required during assembly. The edge of

the door opening is reinforced to guard against buckling. The door cover is provided

with vandal resistant locking device.

The mast is mounted on the foundation using a flange. The shaft is attached to the

flange using full strength butt welds with supplementary gussets provided between

bolt holes. All steel work is galvanised to BS EN ISO 1461.

The mast head assembly is fitted with a four pulley system which can accommodate 2

wire ropes and 2 electric cables. The pulley is of large diameter appropriate to the multi

core flexible cable being used. They are of non-corrodible material and run on self

lubricating bearings with stainless steel spindles. Arrangements are provided to ensure

that the electric cables and steel wire ropes are separated before passing over their

respective pulleys to prevent ropes and cables leaving the pulley's grooves.

Pulleys are housed in a chassis integral with a sleeve which slips over the top of the

mast and is secured axially and in azimuth. Guides and stops are provided for docking

the lantern carriage. The complete chassis assembly is hot dip galvanised after

fabrication. The pulley assembly is protected with a weatherproof cover.Typical General Arrangement Details of Base Compartment

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Other designs of head frames can also be supplied against specific requirements.

The lantern carriage is fabricated from durable steel pipes designed to act as electric

conduit with cable holes. It is fitted with junction box mounting bracket (s) and is in two

halves joined by bolted flanges to permit removal from an erected mast. Lantern fixing

arms and plates are welded to the carriage. Carriage is fitted with a buffer

arrangements to prevent damage to the mast finish during movement. Rollers or other

moving parts are not required

Lantern Carriages

Raising and loweringWinch Lighting Masts

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Typical General Arrangement Details of Head Frame


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Highway Lighting with Highmast at Surat, Gujrat.


Winches

Suspension System

Electrical System

Winches are completely self sustaining type with a gear ratio of 53:1. Winches

are of self lubricating type by means of an oil bath. Lubricant recommended by

the supplier is to be used. Single gear and double gear design of winches are

available in 'bajaj' range. Winches can be operated by a motor or manual

handle. Power tools for operating the winch are available in 'integral' or

'common' versions. Bajaj winches have been rigorously type tested based on

the relevant standards under the guidance and presence of experts from

Indian Institute of Technology, Mumbai. Test certificates for the safe working

load is submitted along with all winches.

Suspension wires are 'marine grade' (AISI 316) stainless steel of 7/19

construction and are provided with pre-formed thimbles and terminals. Normal

suspension systems are with two continuous wire ropes without any

intermediate joints in between. One end of the rope shall be fixed on the winch

and the other end on the lantern carriage. Suspension systems supplied by

'bajaj' are properly designed with suitable clamps to prevent entangling of wire

ropes and cables. This unique arrangement increases the life of the wire ropes

and cables. Other types of suspension systems can also be supplied against

specific requirements.

Multicore flexible power cables are provided for power supply. Cables are with EPR insulation, PCP sheathing and cotton braiding to get the required strength and flexibility. These cables terminate in the base compartment through specially designed metal clad plugs and sockets. At the mast head cables are connected to weather proof cast aluminium junction box on the lantern ring. The power cables are factory cut for ease of installation.

An MCB box is provided inside the base compartment of the mast for local isolation of the power supply. Masts shall have facility for testing the luminaries at the bottom level (this facility is not provided for masts located in hazardous area for safety reasons). Masts in hazardous areas are with a flame proof plug socket unit at the bottom.

A 12 mm diameter GI bolt is provided at a convenient location in the base compartment as earthing point. All standard masts are provided with a single spike lightning finial on the head frame at the top most point.

Foundation bolts are fabricated from MS rods of high yield strength. As foundation bolts are very important in the structural safety of the system, 'bajaj' supply these bolts as part of the total system. Exposed portion of the bolts is hot dipped galvanised to increase resistance against corrosion. Foundation bolts are supplied as a complete set with bolts, anchor plates and templates.

Earthing Point & Lightning Finial

Foundation Bolts

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"Stars" of bajaj at CFS Mundhra - 65 Nos. 40 M Highmast at one location

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Raising and loweringWinch Lighting Masts

Client Profile

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We are proud that 'BAJAJ' raising and lowering masts are providing the leading

light to the industrial and infrastructural development in India.

BEL entered into the field of raising and lowering winch masts more than two decades

ago. Since then BEL has been the undisputed leader in the Indian market.

During this period more than 8000 masts of different designs were installed in India. List

of our esteemed clientele is exorbitant, but include

Indian Railways Haldia Dock Complex

Durgapur Projects Ltd. Chennai Port Trust

Container Corporation of India Jawaharlal Nehru Port Trust

Chennai International Airport. Mormugao Port Trust

Hyderabad International Airport. Vishakhapatanam Port Trust

Kochi International Airport. P&O Ports (India) Ltd.

CSI Airport, Mumbai. Bharat Petroleum Corporation Ltd.

IGI Airport, New Delhi. Indian Oil Corporation Ltd.

SAIL Bokaro Steel Plant. Hindustan Petroleum Corporation Ltd.

SAIL Bhilai Steel Plant. Oil & Natural Gas Corporation Ltd.

SAIL Rourkela Steel Plant. Reliance Industries Ltd.

Various Municipal Corporations. OTDC Bhuvaneshwar.

National Thermal Power Corporation Ltd. Hill Temple, Palani.

Nuclear Power Corporation Ltd. Bharat Heavy Electricals Ltd.

National Highway Authority of India. Neyveli Lignite Corporation Ltd.

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Flyover Lighting with Highmasts


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Standard Mast Dimensions

MAST MAST HT TOP DIA BOT DIA PLATE THK PCD FOUNDATION LUM CAPACITY atRef. (M) (mm) (mm) (mm) (mm) BOLTS 50 M/S 44 M/S

BJRLMW11L 11 100 360 3 445 M24/850 X 4 6 6

BJRLMW16L 16 150 360 3,3 445 M24/850 X 6 6 6

BJRLMW16M 16 150 410 3,4 490 M30/850 X 8 12 16

BJRLMW20L 20 150 360 3,3 445 M30/850 X 8 NA 6

BJRLMW20M 20 150 460 3,4 590 M30/850 X 8 12 16

BJRLMW25L 25 150 460 3,4,4 590 M30/850 X 8 8 12

BJRLMW25M 25 150 540 3,4,5 650 M30/850 X 12 12 16

BJRLMW30L 30 150 460 3,4,5 590 M30/850 X 8 NA 8

BJRLMW30M 30 150 540 4,4,5 650 M30/850 X 12 9 12

BJRLMW30H 30 150 610 4,4,6 740 M30/850 X 12 12 16

Luminaries for Highmasts

Following are the most frequently used 'bajaj' luminaries on high masts.

BGENF 22 R BJEF 21 S BGENF 14 BJEF 28 S

Exports

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Apart from the Indian market, BEL caters to

international markets also. BEL has exported

high mast systems to the following countries till

date.

Libya

Nigeria

Mauritius

Oman

Zambia

United Arab Emirates

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BJEF 2KW MH DE BJHM 22 SS

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Monopoles forTelecommunications

Monopole structures are ideal for mounting antennas for telecommunication. It has

several advantages over the traditional lattice structures. Space consumed by a

monopole compared to a lattice structure of the same capacity is much less. Hence

monopole structures become suitable for heavily populated and congested areas like

metros and other cities. Monopoles provide more flexibility for installation of required

antennas. Thus it can provide a better utility for the service provider. With its sleek and

elegant look monopoles can improve the aesthetics of the whole installation.

Due to its advantages developed countries are using monopoles extensively for

telecommunication purposes. However, its use in India was limited till recently. BEL

introduced Monopole antenna masts in India few years back. BEL have so far supplied

such masts to Bharat Sanchar Nigam Limited and Reliance Infocomm Limited.

Monopole structures are also used for mounting antennas for railway signalling.

Recently commissioned Delhi Metro Rail system is using monopoles for their signalling

requirements. All towers required for DMRC were provided by BEL. Height of these

towers varies from 40 M to 50 M.

Telecommunication masts are designed with a fixed platform at the top. Provision for

required number of microwave or GSM antennas can be provided on the top platform. If

required, masts with multiple platforms can also be supplied.

Design parameters for telecommunication masts are more stringent compared to

normal lighting masts. Allowable deflection during wind is very low for these types of

masts. BEL with a team of experienced designers can design and execute towers as

per the customer requirements.

Another important use for monopoles is for mounting CCTV cameras. CCTV masts

have several applications like monitoring the safety of sensitive installations,

monitoring of traffic on highways, etc.

1.10Antenna Masts for Telecommunication

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Stadium Lighting

Development in technology has

changed the way of life in sports arena

also. Matches are played at night with the

same ease as that in the day. Efficient

floodlighting is the main requirement to

make this possible.

Fixed head polygonal masts are the ideal

means to flood lit stadiums to

international standards. These masts are

normally manufactured in polygonal

tapered sections and assembled at site.

The top platform and the mast are

designed to carry required number of

flood light luminaries.

BEL is the market leader in India for

stadium lighting with fixed head

polygonal structures. With all in house

facilities for lighting design, structural

design, manufacturing and installation,

BEL can offer flood lighting solutions for

any sports activities.

BEL has executed sports lighting work at

Delhi, Chandigarh, Hyderabad, Jaipur,

Guwahati, Kanpur, Banglore, Chennai,

Ras-al-khaima (UAE), Hatta (UAE),

Muscat etc.

Fixed Head Masts for Sports Lighting

1.11Stadium Lighting - GMC Balayogi Stadium at Hyderabad.

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Signage Masts

Mid hinged type masts

Utility of raising and lowering winch masts in advertising was also introduced in the

Indian market by BEL. This innovative idea, mooted by BEL gathered its momentum

very fast.

Today, all Petroleum companies like IOCL, BPCL, HPCL and RIL are using these masts

as their main means of advertising in high way outlets.

This is another type of raising and lowering

type masts. These masts are fitted with a

heavy duty hinging arrangement at the

middle. The luminaries mounted at the top

can be lowered down using this hinge for

installation / maintenance.

Mid hinged masts have a jacket extending

from the middle to the bottom. The operator

can tie a rope at the end of this jacket and

raise / lower the luminaries. These masts

can be operated manually by a single

operator. Due to operational limitations,

these masts are normally designed to

accommodate upto six luminaries only.

Mid hinged masts are suitable for

illuminating open areas, parks, high ways,

car parkings etc.

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Signage Masts & Mid-hinged Lighting Masts

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Highmasts for Advertisement - Sinage Mast Installed for IOCL

Mid Hinged Masts


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Manufacturing Facilities

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State of the art machineries installed at bajaj plant

1. Plasma Cutting Machines - Messer, Germany make

2. Press Break LVD - Belgium make

3. Welding Machines - Bode, England make

4. Galvanising Plant - Gimeco, Italy make

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'bajaj' Highmasts Manufacturing Unit at Ranjangaon, Near Pune

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Branch Email ID

Ahmedabad [email protected]

Bangalore [email protected]

Bhubaneshwar [email protected]

Kolkata [email protected]

Chandigarh [email protected]

Chennai [email protected]

Cochin [email protected]

Delhi [email protected]

Guwahati [email protected]

Hyderabad [email protected]

Indore [email protected]

Jaipur [email protected]

Lucknow [email protected]

Nagpur [email protected]

Noida [email protected]

Patna [email protected]

Pune [email protected]

Raipur [email protected]

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