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BONATRANS PRODUCTION FACILITY IN INDIA
Brief summary:
On of the biggest world producer of railway wheel sets, Czech
company BONATRANS, is going to built some production/assembly
facility for railway wheel sets in India. The development project
locality is in the city of Shendra in the Aurangabad region (near
Mumbai). The land is part of an industrial zone and has a
rectangular shape of an area of approximately 40 000 m2, unburdened
by any previous construction. Plant will generally consist from
following main parts:
Production hall housing technology & testing (structural
hall rough dimensions 130 x 30 x 10m with overhead manipulation
cranes)
Transformer station (power input ca 3 500 kW), switch room
Covered storage place for finished wheels
Open concrete storage space for 4000 wheels
Closed storage building for 1000 axles
Warehouses for paints, bearings, assembly parts etc.
Ramp + concrete manipulation space for unloading of
containers
Ramp + concrete manipulation space for loading of production to
the containers or trucks
Storage area for containers
Maintenance workshop + storage
Administrative building and amenities for 15 blue collars
Amenities for workers (changing rooms, toilets, showers, canteen
etc.), expected ca 65 workers
Parking place for cars and bikes
Waste system handling
Environmental facility (VOC filters & their regeneration,
cutting fluid cleaning & recirculation, waste water handling
etc.)
Internal roads
Connection to utilities & electricity and internal utilities
& power distribution
Other necessary facility (ventilation, air-conditioning, Fire
& safety facility, computer room, compressor station etc.
etc.)
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Note: detailed description of technology and equipment is listed
in attached file Technical specification TZ-13-012-PM in chapters
1.-3.
Scope of Tender:
To make a design of such a plant
o Architectural study, layouts, ground investigation
o Basic design documentation based on which can be obtained
Authority approvals
o Contractor selection documentation documentation based on
which BONATRANS company will tender the company(-ies) which will
execute the project and build-up the plant
o Detail design documentation based on which the plant will be
built-up
o As-built documentation
All procedures, formalities and discussions with Authorities in
India which are necessary to obtain a Permit for building-up such a
designed plant
Authors supervision during erection
Commissioning of the plant (not the technology)
Authority Approval of the completed works for permanent use (if
required)
Note: scope of documentation is described in attached file
Technical specification TZ-13-012-PM in chapter 5. The scope
division is as per European habits, may undergo change as per
Indian practice and requirements.
Time Schedule:
By 10.4.2013 Submitting of the Offer By 15.4.2013 Signing a
Works Contract with a principal architect, commencement
of design works By 30.6.2013 Architectural design By 30.9.2013
Architectural design of the selected variant By 31.3.2014 Building
permit design documentation By 30.4.2014 Contractor selection
design documentation By 30.6.2014 Building permit, signing a Works
Contract with the selected contractor By 01.07.2014 Commencement of
construction works
2015 Official commissioning and installation of machinery
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What is requested MBE:
TEKNOLINK will make all documentation as per European standards.
However documentation shall finally correspond to all Indian
standards and norms which may differ and are unknown to TEKNOLINK
(e.g. civil standards, structural standards, electrical standards,
FISA standards, Health standards etc. etc.)
So that MBE shall:
To adopt/modify or supplement drawings/documentation elaborated
by TEKNOLINK to fully conform to Indian standards, norms and
requirements.
To carry out all formalities, discussions, procedures and all
other related items with Authorities in order to finally get an
Authority Approval for building-up designed plant
To make Authors supervision during erection
To carry out commissioning of the facilities (not the
technology)
To get an final Authority Approval of the completed works for
permanent use (if required)
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Item Activities Term Responsible
1 EIA - announcement - if required MBE / TEKNOLINK
1a Leakage study (air pollution study) - if required MBE
1b Noise study - if required MBE
1c Technical expertise (Law No. 86/2002) MBE
1d Architectural study (variants) 30-09-2013 TEKNOLINK
2 Planning permit documentation TEKNOLINK / MBE
3 Plannig permit engineering (dealing with authorities) MBE
4 Building permit design documentation (BPDD) 31-03-2014
TEKNOLINK / MBE
5 Building permit engineering (dealing with authorities) -
Authority Approval 30-06-2014 MBE
6 Project execution documentation (PEDD) 30-06-2014 TEKNOLINK /
MBE
7 Contractor selection design documentation 30-04-2014 TEKNOLINK
/ MBE
8 Commencement of construction works 01-07-2014 TEKNOLINK /
MBE
9 Architects supervision TEKNOLINK / MBE
10 Technical supervision MBE
11 As-build documentation 30-04-2015 TEKNOLINK / MBE
12 Individual tests MBE
13 Operationg regulations MBE
14 Official commissioning TEKNOLINK / MBE
15 Approval of the completed works for pernament use MBE
16 Geodetic survey of territory MBE
17 Geological + other surveys if any (radon, etc.) MBE
BONANTRANS Shendra MIDC India
Responsibility Matrix
green colour - if necesary for permition as per Indian law,
standards etc.
red colour - Bonatrans requests see tender documentation
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The price shall cover:
Close co-operation with TEKNOLINK on this project, collection of
requirements of local authorities for this project, explanation of
Indian formal procedures/documentation for getting an authority
approvals for such a project.
Survey and judgement of chosen construction site from
acceptability point of view (e.g. Hydrogeological survey if needed,
environmental suitability, architectural applicability, survey of
local wider layouts in connection with other nearby buildings,
roads, utility connections etc.), general acceptability of project
from local authority point of view.
To carry out all formalities, discussions, procedures and all
other related items with
authorities in order to finally get an authority approval for
building-up of designed plant, to supplement some
documents/documentation if required as per local Indian standards
or authority requirements.
To adopt/modify or supplement drawings/documentation elaborated
by TEKNOLINK to fully
conform to Indian standards, norms and authority requirements
(e.g. Civil, electrical, FISA, environmental, health & hygiene
etc.), to work out some local documents if required as per local
standards, procedures or authority requirements.
To make authors supervision during erection
To carry out commissioning of the facilities (not the
technology)
To get an final authority approval of the completed works for
permanent use (if required as
per Indian procedures)
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TECHNICAL SPECIFICATION No. TZ/13/012/PM
Technical specification for selecting an architect to design a
railway wheel and
axle machining plant and railway wheelset assembly plant in
India.
Related Call for Tenders No.: INV/13/012/PM
Compiled by: Radim Zima, Martin Plach Jan Zdail Ji Vodk Joachim
Marreck
Approved by: Jakub Weimann
Bohumn, March 19, 2013
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1. Brief description of the production process and envisaged
capacities Production and production halls including facilities in
addition to main and auxiliary technologies must be designed and
adapted to match the given productions character, but also to be
suitable for the given climatic zone and construction projects
locality, and to comply with all legislative standards concerning
the construction of industrial buildings and halls in India from
the safety point of view. Part of the production and storage
facilities will be also social amenities for the personnel
according to the local standards, and offices for management and
administration staff. Expected dimension of production hall: 2 x
120m x 25m. Halls are equipped one beam crane with lifting capacity
5t.
A cornerstone of the production will be mechanical machining of
railway wheels supplied in a raw rolled condition after final heat
treatment from the Czech Republic. Thus supplied raw wheels will be
shipped in closed containers with their full surfaces jet-blasted
and without conservation. At the place of destination the wheels
will be offloaded from the containers and stored in a warehouse
awaiting further machining. Mechanical machining of wheels takes
place in several operations on vertical lathes carousels; these
operations involve classic cut turning in which metal waste is
generated steel shavings. The machining technology uses tools with
replaceable blades made of cemented carbides (CDs). Some tools are
also made of standard high speed steel. Most machining involves wet
technology using a cutting fluid with a maximum 5% concentration of
cutting oils, a system of circulation and collection of the cutting
fluid in a closed loop system. Railway axles are supplied final
machined, with only left material allowance for grinding of the
axle seats. Therefore the axles are fully covered with conservation
oil, packed and palletised. As with wheels, the pallets are stacked
and transported from Bohumn to India in closed containers. After
being offloaded from the containers at the place of destination in
India, the axles are stowed in a warehouse. Before finishing
operations are performed, axles are unpacked and de-conserved. The
axle finishing operation comprises grinding axle seats on an NC
cylindrical grinder in a wet process. After the final machining,
the wheels and axles undergo ultrasound and magnetoscopy tests to
identify any defects. After these tests, compliant wheels and axles
are moved to a manual measuring and visual inspection station.
After a final dimension check, the wheels and axles are stowed
either in an intermediate storage facility before being
press-fitted into wheelsets, or, in case of wheels to be supplied
as free wheel, in an intermediate wheels storage facility, from
where they are moved to a final painting and packaging station.
Assembled wheelsets are moved to a bearing fitting station and then
to a final paint station. Finished products, after being painted,
conserved and packed, will be stored in an outdoor covered finished
product storage facility, from where they will be shipped to end
users throughout India (mainly IR repair centres or municipal
transport and underground transport operators in Delhi, Bangalore,
Mumbai, etc.). Finished products in India will be transported on
covered trucks, either on wooden pallets or in metal racks.
The plan is to produce annually in a three-shift operation the
following products and quantities: - complete wheelsets (WS) 4,000
units (8,000 wheels and 4,000 axles) - wheels for repairs and for
building new rolling stock, locomotives, coaches and metro
cars for the Indian home market up to 8,000 units - wheels for
rolling stock repairs intended for re-export to Asia up to 4,000
units
TOTAL CAPACITY: 16,000 20,000 railway wheels and 4,000 axles
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Main wheel and axle parameters: Wheels:
- nominal wheel diameter on tread after machining from 700 to
1,250 mm - nominal height of wheel rim after machining from 130 to
140 mm - nominal wheel weight after machining from 280 to 750
kg
Axles: - nominal diameter of axle seat after machining from 160
mm to 230 mm - nominal axle length from 2,000 mm to 2,500 mm -
nominal axle weight after machining from 300 kg to 650 kg
2. Description of the used technology and plant equipment 2.1
Wheel machining technology For wheel machining mechanical
machining, are used vertical lathes type SKI/SKIT/SKJ/SKIQ 12-16
NC. Wheels are first machined on carousels on the outside and the
inside (so-called first operation and second operation), followed
by finishing operation (final turning of the hub hole, boring and
threading an oil-injection hole, drilling holes in wheel webs,
machining shock absorber connection points, etc. (so-called third
and fourth operation). The last operation performed on wheels
before they are released for a finalisation process is static
balancing. Static balancing is done on a dedicated equipment type
CEMB VUBS 1500. At this plant products are also marked by manual
stamping, including indicating position of residual imbalance.
Oil-injection hole will be drilled outside of the vertical lathes,
at a workplace equipped for this purpose with a radial drilling
machine, either VO 50 or VO 80. The radial drilling machine will be
equipped with a fixed table on which the wheel is to be placed in a
horizontal position (for deburring and bevelling operations in the
wheel web holes) and with a tilting table for drilling skew holes
in the wheel web (oil-injection hole). Wheels will be manipulated
from machine-to-machine by manually controlled electric
manipulators type MH 90. The wheels will be stacked in piles of
four to five units in a horizontal position see the photo No 1 with
showing also transportation by fork lift. Photo No.2 Transport of
black wheels.
- Total number of vertical lathes: 8 - Built-up area including
manipulators: x sq.m - Built-up area with auxiliary machines
(drilling machine, balancing machine, etc.): x sq.m - Total
estimated electricity input: 1500 kW
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Photo No.1
Photo No.2
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2.2 Axle machining technology Axles are delivered to India
already finally machined, except for the seat for mounting wheels
or brake disc or parts of drives. These parts of an axle will be
ground to their final press-fitting dimension on a CNC cylindrical
grinder type BUC 63. The axles are manipulated to the grinder and
from the grinder by a special hook suspended on a manually
controlled electric block and tackle moving along a special
structure above the grinder and the surrounding tables on which the
axles are placed after the grinding operation and from which they
are also picked up and moved to the grinder for the grinding
operation. The tables are welded steel frames fixed to the floor by
chemical anchoring bolts. Those table sections which are in contact
with axles when being placed there and rolled, have plastic laths
fitted to prevent the axle surface from being knocked and
damaged.
- Total number of grinders: 2 - Built-up area including
manipulation and tables: x sq.m - Total estimated electricity
input: 200 kW
2.3 Wheelset assembly technology Wheels are press-fitted to
axles with a CDR/CDRA 500 NC hydraulic press. Axles are manipulated
to the press held by cord slings with a gantry crane or by manually
controlled electric block and tackle which moves along a special
structure above the press and its surroundings. Part of the press
facility are tables on which axles are placed and prepared for the
press-fitting operation. These are identical tables as the ones
used at the axle grinding plant. Furthermore, part of this plant
are rails installed in the halls floor, used for stowing and
manipulating already assembled wheelsets. Part of the facility is
also a free space where manual dimension measurements of the
wheelsets after the press-fitting operation are performed.
- Total number of presses: 1 - Built-up area including
manipulation and tables: x sq.m - Estimated total electricity
input: 300 kW
2.4 Bearing system fitting technology Bearing systems are
installed at a workplace separated from the production premises in
order to maintain the environment required for bearing fitting
works (dust and temperature). Here the wheelsets will be placed on
an elevated rail track in such a way that the wheelset axle is
positioned 700 mm above the floor level. Inner bearing rings and
labyrinth rings will be heated by induction heaters of appropriate
size and output depending on the ring size (weight). This station
will be equipped with tables on which components are prepared prior
to be assembled (unpacked, de-conserved, etc.). The station will be
also equipped with manipulators for handling bearing boxes overhead
pneumatic manipulators or balancers moving along an overhead steel
structure. Maximum manipulated weight of the bearing box is 100 kg.
Part of the workplace are separate intermediate storage rooms with
bearing system parts (bearings, bearing box casings, front and rear
covers, end plates, bolts and nuts). These parts are stowed on
shelves and on pallets manipulated by a manually controlled
electric car with slide bars.
- Built-up area including manipulation operation workplaces: x
sq.m - Estimated total electricity input: 150 kW
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2.6 Shavings removal and cutting fluid management system Metal
shavings generated during machining operations will be removed by
steel link conveyers to a central channel running below the floor
level to the end of the hall and from there by a conveyor outdoors,
where the shavings will be discharged into metal crates, containers
or railway trucks. As the shavings are being transported, remnants
of the cutting fluid is separated and collected in a central
collection tank and from there transported to a central cooling
emulsion tank common for all the vertical lathes. A minimum width
link conveyor is 800 mm, preferably made of hard material with high
resistance against wear and hence also of long service life
(Hardox).
2.7 NDT test technologies After the last machining operation,
wheels and axles are delivered to a testing station with automatic
ultrasound equipment to test them for potential internal defects in
the rim or the wheel web and hub. The ultrasound test equipment is
the first part of the NDT line. When entering the ultrasound test
equipment, the wheels are placed in a loading position on a link or
roller conveyor in a horizontal position, four or five wheels
stacked on top of each other. During the scanning process the test
probes move automatically. Also the transport and handling in the
line by means of conveyers and manipulators is automatic. Deployed
is an immersion method when the wheel is immersed in a fluid. The
other part of the line is a magnetoscope for identifying wheel
surface defects. After the test completion the wheels are
demagnetised to the level of permitted residual magnetism. Part of
the line is a cabin for the line operator. After leaving the
magnetoscopy test equipment, the wheels are again stowed in a
horizontal position, stacked up to five units on top of each other
on the exit position of a link or roller conveyor of the same
construction and concept as the line entry conveyor.
- Built-up area including manipulation and service facilities :
x sq.m - Estimated total electricity input: 500 kW
2. 8 Dimension checks 2.8.1 Dimension checks of wheels. Wheel
dimensions are checked with hand-held measuring devices at a
separate station with a manually controlled electric rotation
manipulator. During the check the wheels are placed on a work
table. Part of the wheel measurement process using hand-held
devices such as a slide calliper, depth gauge, cavity meter,
special template, etc., is measuring the surface roughness and a
visual inspection of the wheel. After checking the wheel on one
side, the wheel is grabbed by the manipulator, turned over, put
back on the table, and the remaining dimensions are checked. After
being measured, the wheels are again stowed in a horizontal
position, stacked up four-to-five units on top of each other.
2.8.2 Dimension checks of axles Similarly as with wheels,
dimensions of axles are checked with hand-held measuring devices at
a separate workplace. This workplace has metal tables (a structure
welded from rolled sections), on which the axles are manually
rolled by the shank. This part of the table surface is lined with
plastic inserts to prevent the surface from being damaged. The
axles are placed on the tables either by crane or by a forklift
with slide bars. Above the tables is a steel structure with a
manually controlled block and tackle with an attached special
manipulation hook to hold the axle by the shank.
- Built-up area including manipulation and service facilities :
x sq.m
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2.9 Painting, conservation, packing and palletisation Wheels are
painted either manually with a brush or with a hand-held air spray
gun while they are rotating in a horizontal position on guiding
rollers. Upstream the spray painting station is located a station
where the surfaces of wheel webs are cleaned before the products
are painted. A manual line will be built for this operation, where
the wheel is transported on a link conveyor in a vertical position.
The first work position comprises cleaning and degreasing the
wheels before they are painted. The wheel rotates here. Product
called Simple Green is used for degreasing, in a 5 10% water
solution; the manual cleaning process takes place while the wheel
is rotating. A second work position is again with a wheel rotating,
in which the wheel is painted, either with a brush or a hand-held
air gun. This position and the following evaporation station has an
extraction fan capturing volatile organic compounds (VOC) by active
coal. Part of this facility will be also equipment for cleaning and
desorption of active coal cartridges. The wheels are then moved out
of the line by a forklift and stowed on premises where the paint
dries in free air. Following that, the wheels are packed on wooden
pallets and prepared for shipping.
- Built-up area including manipulation and service facilities: x
sq.m - Estimated total electricity input: 450 kW - Annual paint
consumption synthetic (average VOC content 40%) or water
soluble
(average VOC content 10%) is estimated at 10 tonnes
2.9 Wastes their specification and volumes Metal shavings from
machining operations: in total 3000 tonnes per year Grinding dust
metal shavings mixed with grinding material: in total Machining
emulsion: a 2% solution of cutting oil type xxx, in total xxx
litres per year Hydraulic and gear oil: in total xxx litres per
year Packaging material: base timber, wooden pallets, etc.: in
total xxx tonnes per year Packaging material: polyethylene sheets,
Myrelon, Lamiflex boards: in total xxx kg per year Cleaning cloths
and paper wipes: in total xxx kg per year Ordinary communal waste,
paper, plastics: in total xxx kg per year
The designs of machines and operating equipment must meet all
Indian national regulations concerning work health, occupational
safety, environment and fire safety. If any of the Indian
regulations are more benevolent, than the design shall be done
according to European standards.
All documentation must be drafted in English, with dimensions
shown in both Imperial and metric units.
2.10 Data networks Data networks in production plants as well as
offices will be controlled from a single location and using UTP
Category 5e or 6 cabling. If the length of installation routes
exceeds 100 m, another distribution branch must be installed
directly in the production plant. At least two UTP cables must lead
to every place and be terminated there. Because of the size of the
networks and the length of the routes, using fibre optic cables is
not envisaged.
A central distribution rack will be located in a separate room
(width 19, height 42 U-units, depth 800 mm), with an appropriate
network switch (48 ports, 100/1000 Mbit/s) with virtual server
environment on a VMware platform (2 servers, a disk array),
firewall and Internet
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and telephone service access technology. Room temperature must
be maintained at maximum 25C and hence two air-conditioning units
will be installed there (to provide redundancy for case that one
air-conditioning unit fails). If only one air-conditioning unit
were to be installed, a 24/7 service with a four-hour response time
would have to be guaranteed. Relative humidity in the room should
not exceed 70%. The power supply must be backed by at least a 2000
VA UPC and minimum backup time 15 minutes. Total server room
consumption will be around 7 KVA @ 230 V. It is envisaged that in
the future a diesel-generator may be installed, initially only an
installation place and a supply route to be prepared (outdoors).
The room must be protected by fire alarm system and security system
(smoke, temperature, water). Main cable to the server room must be
terminated with a RJ-45 connector.
In the production plants product data (operations, measurements,
acceptance procedures, etc.) will be acquired at each machine
through barcode readers and laptops. In the production facilities
installed will be three to four PC terminal stations (mini PCs with
SSD disks). Communication will be secured through a server in India
(cache) to servers in the parent company in Bohumn and into its
information system. Information about completed production will be
available similarly as in Bohumn via BTGs IS or intranet.
Electronic mail will be based on the MS Exchange platform, at the
beginning using BTG facilities, with a copy available at the Indian
locality. Telecommunication services will be provided via a small
switchboard or by IP telephony. Between 20 and 25 extensions are
assumed. For Internet connection and for remote connection to
Bohumn, a 10 Mbit/s symmetrical line will be sufficient. Servers in
the Indian locality will be administered remotely from Bohumn.
3. Logistics, transport, manipulation and storage system It is
envisaged that raw wheels and axles will be imported from the
parent company in Bohumn, Czech Republic, in containers.
Manipulation with these products will require a ramp, both for
offloading from containers and for final shipping in containers or
on the truck semitrailers. Imports and exports will take place only
on trucks.
Raw wheels can be stored outside on an open paved (concrete)
surface. Max. capacity 4000 wheels. Axles (rough-machined) will be
stored in a warehouse of a capacity 1000 axles.
Work in progress stored in halls.
Shipping warehouse finished products can be stored outside the
hall, but under cover.
Storage paints, bearings, WS assembly parts, etc.
Manipulation with products is by approximately 6 electric fork
lifts with lifting capacity 2,5 tons. It necessary to plan charging
place for these fork lifts.
4. Construction project locality in India The development
project locality is in the city of Shendra in the Aurangabad
region. The land is part of an industrial zone and has a
rectangular shape of an area of approximately 4 ha, unburdened by
any previous construction.
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Climate classification: Climate in the Aurangabad region
according to the Kppen scale is medium dry.
Temperature: an average temperature in Aurangabad ranges between
14 and 40C. A maximum temperature of 46C was recorded on 25th May
1905, and the lowest one, at 2C, was recorded on 2nd February 1911.
During the cold season the region is occasionally hit by a cold
front wave from the north of India, when temperatures can drop to
as low as 4C.
Rainfall: maximum rainfall occurs during the monsoon season from
June to September. An average annual rainfall is 731 mm. For more
detailed information see the following table.
Humidity: An average humidity during the main three periods
(before monsoon season, during monsoon season and after monsoon
season) is 35%, 80% and 55%, respectively. For more detailed
information see the diagram below.
5. Subject matter of the Tender The subject matter of the Tender
is drafting design documentation (DD) for the construction of a
railway wheel machining production plant in the specified locality,
Shendra MIDC in India. The DD documentation must cover completely
the entire complex, including all the bellow listed buildings,
engineering structures and production technology facilities. The DD
must also cover all buildings, engineering structures and
production technology facilities not named in the Technical
Specification, the necessity of which, however, will have arisen
when this DD documentation is being prepared or discussed with the
Procurer or with relevant authorities in India. The DD of all
levels must meet all Indian laws and other regulations concerning
buildings and land zoning proceedings, work safety, protection of
health, environment and fire safety, or any other to the Procures
as yet unknown, but by Indian authorities and organisations
required, parts of the DD. If any Indian regulation is more
benevolent than the corresponding European standard, the design
must meet the European standard.
5.1. Different variants of architectural and construction design
solution
Climate data for Aurangabad
Month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Year
Average high (C) 29,7 32,5 36,1 39 39,9 34,9 30,3 29,1 30,4 32,6
30,9 29,3 32,9
Average low (C) 14,2 16,3 20,2 23,7 24,6 23 21,8 21,1 20,9 19,7
16,4 14 19,7
Precipitation (mm) 2,2 2,9 5,1 6,3 25,5 131,4 167 165 135,3 52,6
29,3 8,4 731
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Submitted shall be an architectural and construction design
solution of the production facility in at least three different
variants in 3D images, all of which must be during the design
process consulted on an on-going basis with the Procurer. The
selected architectural and construction design variant will be then
completed and shall contain the following:
- An accompanying and summary report containing: o
Identification data of the development project, the Investor, the
Architect and the
construction project location. o Information about any hitherto
use and build-up of the construction site and about
proprietorship relations, and a construction site review. o
Information about any surveys conducted and about the sites
connection to traffic
and technical infrastructures, an outcome of a hydrogeological
survey and if none is available, the architect shall arrange for
one to be carried out.
o Information concerning the requirements of relevant Indian
authorities in this locality.
o Information whether general requirements on construction in
the region have been met.
o Material and time links of the construction project to any
related and prerequisite structures, and other measures required in
the territory.
o Anticipated construction project dates and deadlines,
including a preliminary project time schedule.
o Urban and architectural design of the project in relation to
any already existing buildings in the locality.
o Impacts of the construction project on the environment and
proposed protection measures.
o Breakdown of the project to individual buildings and
engineering structures and production technology facilities.
o Measures to protect the health and safety of personnel. o Fire
safety of the production complex and its buildings and structures,
fire brigade
action options. o Protection of the buildings against harmful
effects of external environment. o Description of the wider
greenery area plan.
- Design drawings shall include: o A wider area situation plan
showing connections to traffic and technical
infrastructures and the sites position within the countryside. o
Breakdown of the complex to different zones, building structures
and engineering
structures in 3D images, and production technology facilities. o
General plan of the complex greeneries. o Coordination situation
plan including a summary schematic drawing of
technologies, schematic diagram of reticulation systems of
energies and a basic schematic diagram of water reticulation system
and waste water purification system.
o Furthermore, included shall be a disposition drawing of
operation and social amenity facilities, production buildings and
all utility connections and production technology facilities
plotted in layouts.
o Cross and longitudinal sections and elevations of the
buildings. o Situation drawings including 3D models; elevations
will be in colour. o The documentation shall be submitted in six
sets in Czech and six sets in English,
plus in an electronic form (drawings in format dwg, tables in
xls, texts in doc, and any other in pdf).
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5.2 Design documentation for a building permit (BPDD) or similar
building administrative ruling allowing the project to be legally
constructed, including issuing an official commissioning
certificate, and including a bill of quantities for selecting a
contractor
For this part of the Tender applies that the BPDD must meet all
requirements of Indian laws and other regulations concerning
building and land zoning rulings, work safety, protection of health
and environment and fires safety, as well as any other requirements
by Indian authorities and organisations on DD, as yet unknown to
the Procurer.
o The scope and content of the BPDD shall, as a minimum, meet
the requirement of Annex 1 to Public Notice No. 499/2006 and of
preamble of section 5.2.
o This notwithstanding, it must always contain the following
information: o Identification of the construction project, the
investor and the architect, plus
identification data of the construction projects location. o
Information about any hitherto use and build-up of the territory,
the construction
land and legal proprietorship relations, and a review of the
construction site. o Detailed description of the new use of the
building complex, including all building
and engineering structures and production technology facilities.
o Information about any surveys made and how the complex is going
to be
connected to traffic and technical infrastructures, results of a
hydrogeological survey and its impact on the design of the
buildings and engineering structures and production technology
facilities.
o Dealing with the requirements of relevant Indian authorities
on construction works in the territory.
o Adherence to general requirements in relation to construction
works in the locality. o Material and time links of the
construction project to any related and prerequisite
structures and other measures required in the territory. o
Construction project dates and deadlines, including a detailed
project time
schedule. o Urban and architectural design of the project in
relation to any already existing
buildings in the locality. o Impacts of the construction project
on the environment and proposed protection
measures, a comprehensive waste management solution. o Breakdown
of the project to individual buildings and engineering structures
and
production technology facilities. o Measures to protect the
health and safety of personnel. o Fire safety of the production
complex and its buildings and structures, fire brigade
action options. o Protection of the buildings against harmful
effects of external environment and
earthquakes. o Complete structural design of all buildings and
engineering structures and
production technology facilities. o General plan of the complexs
greeneries. o Connection to existing engineering services and
sources of energies. o Heating, ventilation and lighting according
to work hygiene standards in all
buildings and engineering structures and production technology
facilities. o Design of staff amenities including social amenities
(dayroom, first-aid room with
room for doctor, canteen, change rooms, showers, toilets,
offices, a conference room, etc.). An assumed number of production
workers is 61, technicians 14.
o The gate to the company with social building for security
people, room for visitors o Parking place in front of the company
(gate) for cars and motorbikes. o Sanitary plumbing, electro
installation, day and artificial lights in all buildings and
engineering structures and production technology facilities. o
The following requirements apply to the drawing part of the BPDD,
plus Preamble
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12
section 5.2: o All layouts and sections shall be drawn in scale
1:100, elevations and situation
plans in scale 1:200; other scale can be used subject to the
Procurers approval. o A situation plan shall include utility lines
plotted in colour. o Elevations shall include a faade colour
scheme. o Project budgets shall be in all variants broken down
along the normal budget
systems, the Procurer requires RS Praha. o Part of the budgets
must be also a bill of quantities for each individual building
structure, supply, installation and specification, broken down
by building. Use of complete set, kit and other items without a
concrete size parameters will be avoided in budgets, as far as
possible.
o The BPDD shall be submitted in six sets in Czech and six sets
in English, plus in an electronic form (drawings in format dwg,
tables in xls, texts in doc, and any other in pdf).
5.3. Project execution design documentation (PEDD)
For this part of the Tender applies too that the PEDD must meet
all requirements of Indian laws and other regulations concerning
building and land zoning rulings, work safety, protection of health
and environment and fire safety, as well as any other requirements
by Indian authorities and organisations on DD, as yet unknown to
the Procurer. If any Indian regulations are more benevolent that
European standards, the design shall meet the European standards. o
The scope and content of the PEDD shall, as a minimum, meet the
requirement of
Annex 2 to Public Notice No. 499/2006 and of preamble of section
5.3. o Project budgets shall be in all variants broken down along
the normal budget
systems, the Procurer requires RS Praha. o Part of the budgets
must be also a bill of quantities for each individual building
structure, supply, installation and specification, broken down
by building. Use of complete set, kit and other items without a
concrete size parameters will be avoided in budgets, as far as
possible.
o The PEDD shall be submitted in six sets in Czech and six sets
in English, plus in an electronic form (drawings in format dwg,
tables in xls, texts in doc, and any other in pdf).
5.4. Securing building permit proceedings, obtaining a building
permit or an equivalent administrative permit allowing construction
works to be carried out legally, including issue of an official
commissioning certificate
o Submitting and discussing the documentation with relevant
state administration authorities, organisations, societies and
parties to the building permit proceedings in India. Obtaining
their reactions and subsequently all building permits, land permits
and land zoning rulings and building works notifications necessary
for the construction of all building and engineering structures and
production technology facilities in accordance with Indian
regulations. The names of the relevant administrative proceedings
in India are unknown to the Procurer, hence terminology used in the
Czech Republic has been applied in this point as a demonstrative
and substitute term.
5.5. Consultations o Consultation services will be provided
through Procurers representatives who will
be named in the relevant Works Contract.
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13
5.6. Architects supervision o Architects supervision will be
carried on an ad-hoc basis at the Procurers request
in the Czech Republic. In justifiable cases, when the Architects
presence on the construction site is required, the DD author shall,
at the Procurers request, carry out forthwith an architects
supervision on the construction site in India. Unless the
architects presence on the site in India has been invoked by errors
in the DD, direct costs of this activity will be paid for by the
Procurer.
6. Time schedule Envisaged project milestones and deadlines By
15.4.2013 Signing a Works Contract with a principal architect,
commencement of design works By 30.6.2013 Architectural design By
30.9.2013 Architectural design of the selected variant By 31.3.2014
Building permit design documentation By 30.4.2014 Contractor
selection design documentation By 30.6.2014 Building permit,
signing a Works Contract with the selected contractor By 1.7.2014
Commencement of construction works 2015 Official commissioning and
installation of machinery
7. Bid scope Scope of documentation and activities as required
by Indian laws and regulations. The following is an assumed
minimum:
Architectural design in variants Building permit design
documentation Contractor selection design documentation Project
execution design documentation Architects supervision Dealing with
authorities Official commissioning Approval of the completed works
for permanent use As-built documentation
Deadlines for the following milestones: o Preparation phase time
schedule
Building permit design documentation Contractor selection design
documentation As-built documentation
o Construction phases time schedule
Price broken down as per Clause 5 of this Specification Minimum
60-month warranty on the project Sanctions for missed deadlines
References, preferably for projects in India Bids shall be
submitted in Czech, alternatively in English Bids must be valid at
least until 30.6.2013.
8. Bid evaluation criteria Deadlines Warranties References
Price
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14
9. Method and deadline for bid submission By post in a sealed
envelope, mailed so that the bid arrives before the stipulated
submission deadline (mailing address: Ing. Martin Plach,
BONATRANS GROUP a.s., Revolun 1234, 735 94 Bohumn, Czech
Republic);
The bids must be submitted in a sealed non-transparent envelope.
The envelope must bear the Tender title, PROJECT INDIA and the text
NEOTVRAT VBROV ZEN . INV/13/012/PM [DO NOT OPEN TENDER No.
INV/13/012/PM];
Bid submission deadline APRIL 10, 2013.
10. Other terms and conditions - The Procures does not
reimburses bidders the costs of preparing their bids; - The
delivery sought by the Tender shall be carried out in accordance
with
applicable legal regulations and provisions. Bids must be
prepared in accordance with generally binding regulations and in
line with the Procurers specification and requirements;
- The Procurer has the right to cancel the Tender at any stage
and not to any winner, and has no obligation after the Tender
conclusion to enter into a works contract or reimburse the bidder
the costs of participating in the Tender. The bidder fully accepts
the Tender terms and conditions.
- If you do not wish to take part in the Tender or are unable to
meet the stipulated deadline for bid submission, please let us know
by sending a message to the following e-mail address:
[email protected].
9. Procurers contact persons:
Martin Plach Head, Division of Technical Development tel.: +420
602 730 171 e-mail: [email protected]
Radim Zima Technical Director (TD) tel.:+420 602 730 022 e-mail:
[email protected]
Ji Vodk Project manager tel.:+420 606 201 214, e-mail:
[email protected]
Joachim Marreck Managing Director of BONATRANS INDIA Pvt.Ltd.
Tel. Indie: +91 976 438 2223 Tel. esko: +420 733 789 691 e-mail:
[email protected]
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ADMINISTRATIVE BUILDINGAMENITIES FOR WORKERS
1
PRODUCTION HALL
10M
24M
TRANSFORMERSTATION
310M
COVERED STORAGE PLACE FOR FINISHED WHEELS
13
53M
CLOSED STORAGEFOR 1000 AXLES 6
WARE HOUSEFOR PAINTS
MAINTENANCE WORKSHOPS+STORAGE
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OPEN CONCRETE STORAGEFOR 4000 WHEELSPARKING PLACE
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AREA 40 000 M2
5M
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