Pre-Bid Conference Civil Engineering Issues• Building - PEB• Standards- AISC American Institute of Steel Construction (Hot Rolled ,Built Sec.), AISI (American Iron and steel institute) (Light Gauge Cold worked) IS:8750- 1987(Design Load) IS: 800-1984 Construction in Steel IS: 801-1975 Cold Formed Light gauge steel steel structural members • Electrical Issues.• Firefighting• Lightening Protection• General Issues

Pre-Bid Conference

• Approval of Building Plan from Government Authorities/ BMC/ IIT ?

• PEB Construction : Which Specification is to be followed ? IS or AES ?

• Canopy and it’s location ?

• Surface Finish for the structural Members- Weather Shot Blasting or wire brush ?

• Type of Paint to be used : Polyurethane or Enamel ?

Painting

• Painting for the a. Pallets : PU

b. Racks : PU after

shot blasting

a. Crane, Transfer Car :Poly Urethane

b. Structural members :Poly Urethane

c. Wall cladding :Poly urethane

Roof

Type of Ventilators : Graven type or powerless ventilators ? Powerless turbo ventilators to be used

• Safety on the roof approach•Safety Net / fall protection requirement

•Tolerance code ?•Stiffeners for columns ?• •

General • Supply of Steel & Cement: Contractor shall arrange

his own steel and cement.• Water and Electricity: Shall be provided by

Railways but charged from the contractor at actual based on standard railway tariff.

• Approval of Building Plan : The approval may be obtained from government authorities/ BMC/ IIT or BMC Licensed engineers or Chartered engineers of repute.

• Concrete: RMC or Site Mixed Concrete ?• Tax Structure: Works Contract or Supply ?• Provisioning of Lightening arrestor

• R/R Masonry below plinth : Plaster or pointing to be done ?

• IS 456 of 1978 or of 2000 ? M-25 is specified 2000 edition .

• Emergency Door – HMPS- Aluminium ?

• Approved makes of welding electrode, anti termite chemical, Hardonite ?

• No of Windows per bay ?6

• Integrity between old building and the new building ?

• Chajja over only the window or over the entire course ?

• Roads and drains around the building ?

• Office area details

• Lightening above the racking area?

• Toilet/Change Rooms ?

• Aluminum wire mesh around the well of the ASRS ?

PEB Design

Pre Engineered Metal Building(Major Components)

• Main framing or vertical columns• Purlins, girts and eave struts• Sheeting and insulation or prefab panels• Brick & Cement Board Walls• Flooring• Paints and finishes• False Ceiling• Miscellaneous services

MAIN FRAMING

• Main framing : It includes the rigid steel frames of the building. The PEB rigid frame comprises of tapered columns and tapered rafters. The tapered sections are fabricated wherein the flanges are welded to the web. Splice plates are welded to the ends of the tapered sections. The frame is erected by bolting the splice plates of connecting sections together.

PURLINS, GIRTS AND EAVE STRUTS

• Purlins, girts and eave struts are also known as secondary cold-formed members.

• There is no welding involved in their preparation. They are prepared by just bending the steel coil giving it the desired shape (Z-shape for purlins and girts, and C-shape for eave struts).

• Purlins : Purlins are the secondary members are for supporting the roof panels & wall cladding.

•

PANELS AND INSULATION • Single skin profile or ribbed steel sheets are used as roof and wall sheeting,

roof and wall liners, partition sheeting. The steel sheets are generally made from steel coils. Minimum thickness of steel coils used is 0.5mm high tensile steel.

• The steel sheets are normally of zincalume or galvanized bare and permanently colour coated or plain which can be coated at site after installation.

• These buildings can be properly insulated by providing fibrous insulation slabs / rolls of non- combustible Rockwool, Aluminium foil laminated, placed over a metal mesh bed created between the purlins, and then the roofing steel sheet fixed over it. The siding walls can also be insulated by providing a double skin profile or ribbed steel sheet or cement board sheets on inner side wall cladding having Rockwool Insulation slab sandwiched in between and held in position with the help of ‘Z’ spacers in between the two steel sheets. In similar pattern a double skin insulated roofing system can also be erected. The cement boards will give a conventional white finish after paining.

PANELS AND INSULATION

• Another alternative is to provide pre-fabricated insulated panels, which comprises of two single skin panels (plain steel sheets galvanized / zincalume colour coated) with polyurethane foam insulation in between.

• These panels are intended for use as thermally efficient roof and wall claddings for buildings e.g. in high altitude areas and hilly terrains. Roof is of profile steel sheet with or without insulation fixed underneath.

• False Ceiling of particle / rigid board is fixed to a steel frame work hung from the trusses. Insulation can also placed over the false ceiling packed in polythene. Here a 2 ft. high brick wall is required to be given on the outside for protection.

• For walls a second alternative can be by way of normal brick work

PANELS AND INSULATION 2 • The latest trend developed for construction of pre-

fab single storeyed residential houses does not involve any steel structure (columns & purlins).

• The walls are constructed with profiled GI sheet of high crest height and faced with cement particle boards and the crest depths filled with either high density Rockwool or Rigid insulation material like Polyurethane Foam or Expanded Polystyrene.

• The roof is erected with trusses placed over the walls and profile sheet fixed to purlins and bolted to the trusses.

• The corners of the walls are provided with steel flashings fixed to the profiled GI sheet on both sides before fixing of the cement particle boards.

PAINTS AND FINISHES

• Normally the primary and secondary steel are coated with one coat (35 microns) of redoxide paint without any special treatment to steel. However, if some special paint has to be applied to steel in order to give better anti-corrosion properties etc. then the steel members have to be shot-blasted and then coated with the special paints.

DOORS AND WINDOWS

• Steel or aluminum framed doors and windows are fixed to the purlins or the supporting profiled steel either by welding or bolted to the flanges already fixed to the purlins..

Design Codes• Design codes that govern the design

procedures and calculations are as follows :-• Frame members (hot rolled or built-up) are in

accordance with AISC (American Institute of Steel Construction) Specifications for the design, fabrication and erection of structural steel.

• Light gauge cold-formed members are designed in accordance with AISI (American Iron and Steel Institute) Specification for the design of light gauge cold formed steel structural members.

Design Codes 2

• IS : 8750 - 1987 : Code of practice for design loads of buildings & structures.

• IS : 800 -1984 : Code of practice for general construction in steel.

• IS : 801- 1975 : Code of practice for use of Cold formed light gauge Steel Structural Members in general building Construction

Guidelines for PEB design 1

• All designs shall be as per MBMA American standards unless specified as per IS code

• Live load as per American code = 0.57 kn/m^2  and as per IS code = 0.75 kn/m^2.

• As per American code :horizontal deflection = l/180 & vertical deflection=eh/100 for main frames.

• Wind terrain category 3 is to be selected unless more data is available.

Guidelines for PEB design 2

• In American design , wind coefficients to be followed as given in MBMA.

• In is design, internal & external building wind coefficients as per IS -875 (part-3).

• Generally buildings are to be designed as pinned except for building span >30m or crane capacity of more than 5 tons or height greater than 9 m.

• Standard purlin laps shall be 385 mm

PEB

• STRUCTURAL PLANNING• FRAME CONFIGURATIONS• TYPES OF LOADS & ASSESSMENT• END CONDITIONS• CRANES• MEZANINES• LOAD COMBINATIONS

PEB

Load 1X

YZ TCCS = TAPERED COLUMN CLEAR SPAN

Steps in design of PEB

• Wind load calculation• Purline Design• Girt Design• Design of Main Frame• Base Plate• Anchor Bolt design for Moment Condition• Anchor Bolt design for Shear Condition• Gable column design• Design of connection plate• Cranes Design

Erection System 1

• Wind load calculation• Purlin Design• Girt Design• Design of Main Frame• Base Plate• Anchor Bolt design for Moment Condition• Anchor Bolt design for Shear Condition• Gable column design• Design of connection plate• Cranes Design

Erection System 2

• Preparation for Erection1.Pre Erection checks2.Receiving Materials at site3.Unloading Containers

• Erection of the Framing1.Preparation of the First Bay2.Main frames3.Mezzanine floors4.Crane Beams

Erection System 3

Sheeting & Trimming• Sheeting preparation• Sheeting the walls• Sheeting the roofs• Miscellaneous trimmings• Fascia

PEB

BUILT UP LINE COLD FORM LINE SHEETING

PRIMARY MEMBERS

CKD

C & Z PURLINS LINE

HR SECTIONS &

MISCELLANEOUS PARTS

ROOF & WALL SHEETING

GUTTER, FLASHINGS, TRIMS, ETC

CKD CKD CKD ACCESSORIES

SHIPMENT

PROCESSES

•Welding : Single side welding or double side welding for PEB Members ?•Thickness of hot rolled and cold rolled sections ? 4 mm or 6mm ?•Support condition to be considered in design as fixed based or Pin based ?•Structural Analysis – 2 or 3 dimensional ?•?

Electrical Issues• Power requirement of the entire ASRS

system shall be broadly 100 KW.

• 70 KW for the ASRS and balance 30 KW for the office requirement.

• 440 AC supply is to be arranged.

• Underground cable (LT) to be laid from wheel shop to ASRS location and another LT Cable from timber ward SS to ASRS arena.

Fire Fighting-1• Comprehensive fire fighting system including fire/

smoke detection, piping, fire hoses, water sump to be provided by the contractor.

• Nature of material in the ASRS.• Steel components : Steel pins, hangers, nuts and

bolts, bearings etc.• Rubber components : water and air hose pipes,

rubber pads, rubber washers, • Paints: Approx. 300 Tons• Chemicals: H2SO4 , trichloroethylene, bleaching

powder, soda ash, HCL• Cloth: Duster cotton, dungri cloth, waste cotton, • Leather: Safety Boots, Hand gloves

Fire Fighting-2• One Aisle to be kept separate for paints ,chemicals

or other fire prone material.

• Underground sump to be created with adequate capacity by contractor.

• Pumps and motors of adequate capacity to be provided by the contractor for water pumping.

• Water point shall be provided by the Railways near the sump.

• Provisioning of traditional fire extinguishers along with two number high powered pressurized water mist system.

Bar-coding and RFID 1

• Bar-coding is to be used for all the components stored in the ASRS i.e individual components for bigger items such as BSS Hanger, buffer plunger etc. and also packets for smaller items such as nuts, screws , bolts etc.

• RFID is to be used for each pallet which shall help in tracking the pallets within the workshop.

Bar-coding and RFID- 2

• Material received at CRD Parel shall have Bar code labels pasted on them. These labels shall be printed by the vendor supplying material to railways.

• In case Bar codes are not available on the received material, provision of printing the bar codes and pasting on the consignment should be incorporated in the system.

Interfacing of WMS, LMS, ICMS & MMIS

• Contractor shall integrate the Warehouse Management system, Location Management system, Inventory control system with that of the Western Railways Materials Management System( MMIS).

Office area , Wash Rooms ,Change Rooms

• Office area :

• Offices presently available.a. Ledger Section

b. Progress, receipt, Cash Purchase, Dispatch

c. Computer Room

d. Chambers of Dy.CMM & AMM

e. Chambers of CDMS & DMS

Location of Offices in the new setup

• Integrated offices shall be located at the “ Non Dismantled Area” on the ground floor.

• This complex shall have all the offices mentioned in the previous slide.

• The layout plan of the offices shall be as under.

Layout of New Office Complex.

Dy. CMM

DMSCDMS

Computer Center

AMM

Office Complex

DMS DMS

CA Visitors Area

•Granamite Tile flooring with 2’X2’ tiles.•Walls with polished veneer 6 mm.•False ceiling.•Modular doors.•CFL Lightening.•Particle board partition for office

Soil test report

Modernization of Carriage Repairs Depot at Carriage Repair Workshop

• Stores depots on the Indian Railways are housed in a dilapidated structures released from the old steam loco sheds or abandoned carriage depots.

• Hence the structural strength as well as mechanization is almost nil in the old stores depots.

• In the estimate for new workshops or Diesel/Electric Loco Sheds, few

godowns are provided in the name of stores depot without M&P & material handling equipment.

• The entire gamut of activities in the workshops have been mechanized with the inclusion of new technology.

• The material storage , handling and transportation in a stores depots

needs to be modernized so that instead of just acting as a warehouse , the stores become a part of the supply chain management and the production process .

• Presently, they work more as godowns rather than modern warehouses.

Plan of Parel Workshop

CENTRAL WARD

MAIN GATE

PAREL WORKSHOP LAYOUT

PROPOSED SITE FOR ASRS

Present Status

What and where is the central What and where is the central ward ?ward ?

• The location of ASRS shall be the central ward.

• Central ward measures 60m X 45 m ETE.

• On the north end of CW is CR2 Shop.

• On the South of CW is macadam road.

• On the east of CW is fitting shop

• On the south of CW is rail line

Layout of C ward

Dy.CMM-PL ChamberCA/TA to

Dy.CMM

lift

AMM, Ledger Section & computer cell

NF Ward

DMS

Returned stores

& platform

Survey Plot &

Loading platform

LAYOUT FOR THE PROPOSED ASRS AT THE CENTRAL WARD

Installation of IW-ASRS• Transport the material to the prepared ASRS

site.• Provide Bill of Material along with WTC.• Get Payment for 80% of material cost.• Install the racks.• Cranes, Transfer Car, Pallets etc.• Integrated with Warehouse Management

System• Integrate with Depot Module of MMIS

Existing Plan of Roof for Central Ward

Dy.CMM-PL ChamberCA/TA to

Dy.CMM

lift

AMM, Ledger Section & computer cell

NF Ward

DMS

Returned stores

& platform

Survey Plot &

Loading platform Existing Elevation of Roof for

Central Ward

Future elevation of Roof for Future elevation of Roof for Central WardCentral Ward

Dy.CMM-PL ChamberCA/TA to

Dy.CMM

lift

AMM, Ledger Section & computer cell

NF Ward

DMS

Returned stores

& platform

Survey Plot &

Loading platform

Layout of C wardLayout of C ward

Dy.CMM-PL ChamberCA/TA to

Dy.CMM

lift

AMM, Ledger Section & computer cell

NF Ward

DMS

Returned stores

& platform

Survey Plot &

Loading platform

• • Working Capacity: 1.50 Ton Payload

• 100% duty cycle

• • End-of-Aisle Run-out Required: 15 ft.

• • Height Requirements: 60 ft. to 80 ft.

• • S/R Machine Length: 15 ft.

• • Aisle Width: 80" Pallet to Pallet

• • Vertical Speed: 90 FPM

• • Horizontal Speed: 700 FPM

• • Forks Rotation: 180 deg.

Broad Design Parameter

General Specifications of IW-ASRS

• S/R Machine:• Construction: Modular component design. All parts designed

for 100% duty cycle. Welded steel frame. Single mast tube, strut braced. Structural steel base.

• Drive and Idler Wheels: Flanged forged alloy steel. Case Hardened to 55 Rockwell C. Reground for concentricity. Heavy-duty pillow block bearing support.

• Fork Extractor Mechanism:• • Construction: Precession fabricated steel• • Load Capacity: 1500 Kg.• • Load Support: Industrial Standard Forks• • Extractor Drive: Patented ball screw and rotator with

variable frequency drives, industrial gear reducers, and    brake.

Crane Rail with V-H Drives• Crane Rail:• • Rail mounted .

• Vertical & Horizontal Drives:

• High performance sine-coded, pulse width modulated AC vector motor drives which generates an adjustable voltage/ frequency three phase output for complete speed control. Automatic stall prevention and voltage boost prevents nuisance tripping during load or line side transient conditions. The drives will not induce any voltage or distortion back into the utility line and maintains a displacement power factor of not less than 0.98 throughout its speed range.

Communication & Controls• Communication:• • Infrared Modem

• S/R Machine Controls:• Electrical Components: IEEE code compliance

throughout. IEEE rated enclosure, sensors, and wiring. Panel-mounted diagnostic indicator lights. Panel-mounted maintenance controls.

• Logistics and Positioning: Onboard programmable controller A-B SLC-500® communication by infrared modem. Steel code bar, optical address readers. Fine positioning, motor-mounted resolvers with 1/16'' accuracy or 1 deg. Accurate positioning on start-up.

Rack & Pallets

• Safeguards:• Front and rear aisle-obstruction detectors. Onboard

and off-board emergency stops. Load and centering sensors and interlocks.

• Rack Structure:• Virtually any post and beam (conventional) existing or

new racks capable of safely bearing the pallet loads (pushback and flow rack). Continuity of vertical shelf distance from floor NOT REQUIRED. Common depth dimension recommended, but differing depths can often be accommodated. Racks must be attached to the floor but no shimming is needed except with extreme floor conditions.

• Maximum Height: 18 m approx.• Pallets:• Any two or four way pallet capable of being used.

.

Automated Control:Automated Control:The Stacker Cranes should be linked to central computer The Stacker Cranes should be linked to central computer control through WMS ( Warehouse Management System) control through WMS ( Warehouse Management System) within the warehouse & should include the following within the warehouse & should include the following operations operations Inventory Control Software (ICS): Inventory Control Software (ICS): This module shall manage the inventory of the entire material This module shall manage the inventory of the entire material stored in AS/RS and has the database of all transactions.stored in AS/RS and has the database of all transactions.

Location Management Software Module (LMS):Location Management Software Module (LMS): The Location of each pallet and its status shall be continuously The Location of each pallet and its status shall be continuously monitored and controlled by the location Management software monitored and controlled by the location Management software module.module.

Handling Control Software Module (HCS):Handling Control Software Module (HCS): Handling Control software shall monitors the movement of the Handling Control software shall monitors the movement of the equipment and controls the functions of actual process of equipment and controls the functions of actual process of traveling, hoisting, forking etctraveling, hoisting, forking etc

Automated ControlsAutomated Controls

CIVIL CONSTRUCTION• Remove the roof asbestos sheets.• Transport to BMC dumping ground.• Provide additional colums to take the load of columns

to be removed at 4,1 to 4,6.• Dismantle truss and purlins.• Weigh them and transport to W. R Scrap Yard at

Mahim.• Dismantle west end wall of CW.• Transport the debris to BMC Dumping Ground.• Dismantle the Ledger and computer center• Transport the debris to BMC DG.

Civil Work (Cont.)• Dismantle the south end wall of CW.

• Transport the debris to BMC DG.

• Provide roof for the non-dismantled area.

• Dismantle the columns.

• Weigh the columns.

• Transport them to WR Scrap Yard at Mahim.

Civil Work (Cont.)• Prepare the foundation

• Foundation for columns.

• Prepare the ASRS working area.

• Construct the platform.

• Construct superstructure to house ASRS

S/ASRS/LPL/2008/01 DATED 07.07.2008 opening ON 07.10.2008 AT 11.00 HRS

SCOPE: Design , fabrication, supply, commissioning and testing of automated storage and retrieval system at carriage repair stores depot, lower Parel, Mumbai

EMD: 7.70 Lakhs.

Expected time of completion: 12 TO 15 Months from the date of issue of signing of contract

Tender Details

Major work involved

a.Dismantling of exiting central ward building and construction

b.Provisioning of ASRS with crane, racks, pallets, electrical controls etc.

CIVIL WORK INVOLVES

Demolishing /dismantling of existing structure/building and segregation of dismantled debris along with their transportation to nominated Scrap Yards.

Construction of concrete platform of approximate height 1 Mtr For supporting entire ASRS structure.

Erection of pre-engineered modular steel structure/building for housing the ASRS . Provision of High Rise Racking System with minimum 3840 racking Locations  

Provision of cage and plain pallets for keeping material. Provision of High rise Fully Automated, Computer Controlled, StackerCrane and Transfer Car system along with necessary Aisle Equipment0.

Provision of comprehensive Warehouse Management System.

Provision of Electricals, screened partition and fire protection system forcomplete ASRS system.

CIVIL WORK . CONT.

Two bid system

•TECHNICAL BID•Part I for Civil Engineering Work•Part- II for Mechanical and Electrical Work•COMMERCIAL BID•In prescribed format as given in Annexure B of tender Document

PAYMENT TERMS1. Mechanical and Electrical Work: 50 per cent on proof of inspection and dispatch of documents . For

dispatches by Road, 50% payment will be made on receipt of material duly pre-inspected and receipted at site by the consignee in good condition

ii) Balance 40 % payment shall be made after successful installation &commissioning of the ASRS i.e. Cranes , Transfer cars ,racks, pallets

etc.iii) Balance 10 per cent payment within 90 days of commissioning of the

entire project on furnishing a Bank Guarantee . If a Tenderer requests a variation in the payment terms and if such variation is acceptable to the Purchaser, the same would be evaluated at an interest rate of 12 percent per annum for purposes of comparison with other tenders.

PAYMENT TERMSPayment will be made for the actual work done at site on pro-rata basis. Thetendered is free to submit its stage payment schedule based on the activitiesinvolved such as dismantling of building, removal of debris, construction of ASRS platform, erection of columns, construction of roof etc.

Advance payment of accepted rate/structural steel of bars, HTS wires, neoprene bearings, anchorages, sheathing etc. shall be made after bringing to the site of work and on production of necessary purchase voucher/Test certificates, an insurance policy covering losses due to thefts & floods and against indemnity bond submitted by the contractors and accepted by competent authority. This advance is recoverable from running bills to the extant quantity of above material are consumed up to the running bills stage. Sr.No Work Payment to be made Remarks.(a) Supply of reinforced steel 70%(b) Supply of material otherthan reinforced steel 60%(c) Fabrication & Erection 90%(d) On commissioning 100%

EMD & SD

EMD.Deposit Receipt, Pay order, Demand Draft, Guarantee Bonds.

Performance Guarantee/Security DepositTo. Be deposited

Excise Duty & Modvat

Technical Specification 1One Single Mast Stacker Crane for 1000 mm (W) X 1200 mm (D) X 1200 mm (H) Pallets of one ton capacity and capable of serving a height of 18 meters or more

Transfer Car –Racking System

Plain Steel Pallets -: Qty 1920 Numbers of Four way entry Plain Steel pallets of size – 1000 mm (W) X 1200 mm(D) X 1200 mm (H)

Cage Steel Pallets : Qty. 1920 Numbers of Four way entry four sidewire mesh cage steel pallets of size – 1000 mm (W) X 1200 mm(D) X 1200 mmMechanical Aisle Equipments: Railway railwith adjustable clamps for holding the rails inposition & to ensure alignment. Top rail shall be mounted on the racking system through clamps

Electrical Aisle Equipments: The Electrical aisle equipment shall consist of Power rail (fully enclosed Bus Bar), which is mounted on the racking system below the first loading level with necessary protection as feature as per Indian Electricity Act.

Controls & Hardware – All necessary controls, PLC, Hardware etc. Software – Warehouse Management System and inverter control system

OPERATION CYCLE

Technical Specification 2

The Stacker Cranes should be linked to central computer control through WMS

•Warehouse Management System(WMS)•Inventory Control Software (ICS)Location Management Software Module (LMS •Handling Control Software Module (HCS)

Automated Controls and Software

DESIGN STANDARDS 1

The design of the AS/RS should conform to Indian and International standards, ensuring that best of the System is supplied. Following Indian and International Standards should be followed. IS 800 – 1984 General Construction on steelIS 801 – 1975 Code of practice for use of cold formed light gauge steel structural members in general building construction IS 10748 – 1984 Hot-rolled Steel Strip for Welded Tubes and Pipes – Specification IS 3655 – 1966 Recommended practice for electroplating IS 101 – 1964 Methods of Sampling and test for paints, varnishes and related Products

DESIGN STANDARDS 2 IS 2074 – 1992 Ready Mixed Paint, Air Drying, Red Oxide Zinc Chrome, Priming– Specification IS 513 : Cold Rolled Low Carbon Steel Sheets & Strips IS 325 : 3-Phase induction motor – specifications. IS 1363 : Hexagon Head Bolts, Screws and Nuts IS 2062 : 1999 Steel for General Structural Purposes – SpecificationIS 4923 : 1997 Hollow Steel Sections for structural use IS 2266 : Steel Wire Rope for engineering purpose. IS 4923 : Hollow steel section for structural use. FEM 9.311 – 1978: Rules for Design of Storage & retrieval Machines – Structures.5.1.15 FEM 9.831 – 1995 : Basis of calculation for Storage & retrieval Machines –Tolerances & Clearances within warehouse.5.1.16 FEM 9.851 – 2003 : Performance Data of S/R Machines – Cycle Time.