Stadia, City Junctions, Airports, Sea Ports, Industries. We reach faster than anyone else. HIGHMAST LIGHTING VARIANT INFRATECH PRIVATE LIMITED

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1 Stadia, City Junctions, Airports, Sea Ports, Industries. We reach faster than anyone else. HIGHMAST LIGHTING VARIANT INFRATECH PRIVATE LIMITED

BEL has inhouse facilities for : Illumination Design BEL has a team of illumination design engineers, who are well qualified and experienced.

3 Facilities offered at-a-glance Why BAJAJ highmast is preferred? Pioneer : BEL is in the field of high mast since last 25 years and has unmatched experience in design, development, manufacturing and site erection. BEL has inhouse facilities for : 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. Highmasts for Places of Tourist Attractions 1.2

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.

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

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.

5 Raising and lowering Winch Lighting masts Introduction 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. Advantages Best space utilisation. Perfect suspension. Maintenance friendly. Double drum winches Motorised operation. Sleek and aesthetic. Available upto 60 M height Applications Airports & sea ports Railway sidings & yards Car parks & junctions Highways & express ways Industrial flood lighting Top security zones. Designs 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. India's only 60 M Highmasts - Installed at Chennai Container Terminal 1.4

6 Mast Construction '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 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 Mast Head Assembly 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. Typical General Arrangement Details of Base Compartment 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. 1.5

Raising and lowering Winch Lighting Masts Typical General Arrangement Details of Head Frame Other designs of head

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

It is fitted with junction box mounting bracket (s) and is in two halves joined by bolted flanges to permit removal

7 Raising and lowering Winch Lighting Masts Typical General Arrangement Details of Head Frame Other designs of head frames can also be supplied against specific requirements. Lantern Carriages 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 Highway Lighting with Highmast at Surat, Gujrat. 1.6

Winches 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.

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

8 Winches 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 System 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. Electrical System 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. Earthing Point & Lightning Finial 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 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. "Stars" of bajaj at CFS Mundhra - 65 Nos. 40 M Highmast at one location 1.7

List of our esteemed clientele is exorbitant, but include Indian Railways Haldia Dock Complex Durgapur Projects Ltd.

9 Raising and lowering Winch Lighting Masts Client Profile 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. We are proud that 'BAJAJ' raising and lowering masts are providing the leading light to the industrial and infrastructural development in India. Flyover Lighting with Highmasts 1.8

10 Exports 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 Standard Mast Dimensions MAST MAST HT TOP DIA BOT DIA PLATE THK PCD FOUNDATION LUM CAPACITY at Ref. (M) (mm) (mm) (mm) (mm) BOLTS 50 M/S 44 M/S BJRLMW11L M24/850 X BJRLMW16L ,3 445 M24/850 X BJRLMW16M ,4 490 M30/850 X BJRLMW20L ,3 445 M30/850 X 8 NA 6 BJRLMW20M ,4 590 M30/850 X BJRLMW25L ,4,4 590 M30/850 X BJRLMW25M ,4,5 650 M30/850 X BJRLMW30L ,4,5 590 M30/850 X 8 NA 8 BJRLMW30M ,4,5 650 M30/850 X BJRLMW30H ,4,6 740 M30/850 X 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 BJEF 2KW MH DE BJHM 22 SS 1.9

Monopoles for Telecommunications Monopole structures are ideal for mounting antennas for telecommunication. It has several advantages over the traditional lattice structures.

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.

11 Monopoles for Telecommunications 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. Antenna Masts for Telecommunication 1.10

Fixed Head Masts for Sports Lighting 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.

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.

12 Fixed Head Masts for Sports Lighting 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. Stadium Lighting - GMC Balayogi Stadium at Hyderabad. 1.11

Signage Masts & Midhinged Lighting Masts Signage Masts Utility of raising and lowering winch masts in advertising was also introduced in the Indian market by BEL.

Today, all Petroleum companies like IOCL, BPCL, HPCL and RIL are using these masts as their main means of advertising in high way outlets.

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.

13 Signage Masts & Midhinged Lighting Masts Signage 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. Mid hinged type masts 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. Mid Hinged Masts Highmasts for Advertisement - Sinage Mast Installed for IOCL 1.12

Manufacturing Facilities 2 3 1 4 State of the art

Welding Machines - Bode, England make 4.

14 Manufacturing Facilities 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 'bajaj' Highmasts Manufacturing Unit at Ranjangaon, Near Pune 1.13

Branch Ahmedabad Bangalore Bhubaneshwar Kolkata Chandigarh Chennai Cochin Delhi Guwahati Hyderabad Indore Jaipur Lucknow Nagpur Noida Patna Pune Raipur Email ID

com ccn_epd1@bajajelectricals.com del_epd@bajajelectricals.com guw_epd@bajajelectricals.com hyd_epd1@bajajelectricals.com ind_epd@bajajelectricals.com jai_epd1@bajajelectricals.

15 Branch Ahmedabad Bangalore Bhubaneshwar Kolkata Chandigarh Chennai Cochin Delhi Guwahati Hyderabad Indore Jaipur Lucknow Nagpur Noida Patna Pune Raipur ID E003EP01JUL11

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