TECHNICAL SPECIFICATION FOR
'REFURBISHMENT OF ELECTRICAL & INSTRUMENTATION CABLE TRAYS AT ZOP
This document covers the detailed technical specification for r e mo va l o f e xi s t i ng ca b l e
tr a ys i n N F C ; s up p l y, inspection and er e ct i on of n e w FRP cable trays along with
accessories.
I.
SCOPE OF WORK: Scope of work includes
1. Supply of FRP cable trays with FRP supports
2. Removing of dressing and lifting of Cables on existing cable trays
3. Removing of existing GI or Al Cable Trays (ladder or perforated type)
4. Erection of FRP Cable Trays (ladder or perforated type) along with clamping, jointing
and fixing
5. Fabrication and Erection of FRP Cable tray Supports with all consumables
6. Re-laying and redressing of cables on FRP trays
II. SCOPE OF SUPPLY: The scope of supply through this specification includes FRP
perforated type cable trays, FRP accessories such as bends, tees, crosses, reducers,
Connector plates, cable tray supports and accessories like bolts, nuts, etc.
III. SCHEDULE OF QUANTITIES: The Schedule of Quantities for the work is enclosed as
Annexure – I.
IV. TECHNICAL SPECIFICATIONS: Technical Specifications of the FRP Cable Trays
(ladder and perforated type) are attached as Annexure – II.
V. GENERAL REQUIREMENT:
1. The bidder shall quote indicating cost towards:
a) Supply (FRP cable trays - ladder/perforated, FRP supports, FRP fittings, SS
hardware)
b) Erection (Removing of dressing, Removing of existing Cable Trays, Erection of
FRP Cable Trays, Re-laying and redressing of cables)
2. Composite FRP cable trays shall be manufactured in accordance with NEMA FG-1 and
ASTM –E84 /IS-6746 standards.
3. All Cable trays shall be made of Glass reinforced Flame retardant vinylester (minimum
Glass content 60%) and should be corrosion resistant and Fire retardant (Class 1, Fire
rating) in accordance with the latest ASTM E-84/IS-6746. It shall have flame spread
rating of 25 or less (class 1 rating) when tested in accordance with ASTM E 84/ASTM D635.
4. All FRP cable trays shall be manufactured using the PULTRUSION technology
5. Glass content shall be maintained between 6 0 % to 65% by weight in all
pultruded components except in flat sheet where it shall be 35 to 45% and all molded
components where it shall be 25 to 45%.
6. All composite material shall have ultraviolet light inhibiting chemical additive to
resist UV degradation. All pultruded material shall be Nexus (or equivalent) surfacing
veil to provide maximum chemical and UV protection.
7. The Pultruded Cable Bearers should have a minimum thickness of 4.0 mm for all sizes
of 100 mm & above. Perforated type cable Bearers 50mm width is to be provided in 3.0
mm minimum thickness.
Page 1 of 10
8. The Composite FRP perforted Cable trays shall be supplied with Drilling / Perforation
of 8 mm Dia. Holes/ Perforations staggered @ 150 mm lengthwise and minimum 25
mm crosswise.
9. The Cable trays (both ladder and perforated type) shall be supplied in standard lengths
of 3000 mm.
10. The tray construction shall have high degree of finish and shall be such as to facilitate
easy handling as also to ensure easy laying of cables without causing damage to cables.
The inside surface shall be perfectly smooth and free from sharp edges, burrs or
projections, etc. Only machine Molding is acceptable in both the sides.
11. The cable bearers shall have holes on each end for fixing of coupler plates to join
individual cable bearer sections.
12. Each section of tray shall be complete with necessary FRP coupler plates and associated
stainless steel hardware for joining of trays bends etc.
13. The hardware shall conform to NEMA FG-1 and shall be able to withstand the loading.
14. The coupling plate shall also be manufactured of the same material & using the same
process (Pultrusion). The minimum thickness shall be 4 mm, minimum length 200 mm
& minimum width should be as per width of the joining face of the cable tray.
15. Tolerance on width and length shall be +/- 6mm and height +/- 2mm for cable trays of
150mm and above. For lower size cable trays, tolerance shall be ± 2mm.
16. All rung to side member connection shall have both a mechanical and chemical
(adhesive) Lock. Trays shall be assembled by use of locking pin.
17. Required horizontal, vertical bends, tees, crosses, reducers shall be fabricated out of
pultruded sections.
18. The Color of cable bearers, beds, tees, crosses, coupler plates, etc. and all other
accessories shall be smoke Grey.
19. The inside depth of the cable trays shall be as follows
i. 25mm for 50mm wide tray.
ii. 50mm upto 300mm wide trays.
iii. 100mm for 500mm and 600mm wide trays.
VI. FACTORY ACCEPTANCE TEST
1. All cable trays and accessories shall be offered for inspection. A notice of readiness
2.
3.
4.
5.
6.
for inspection shall be given minimum 15 days in advance.
All offered cable trays or those of similar designs manufactured by the same supplier
shall have been type tested by an authority approved by the Company and the test
reports witnessed by an independent testing laboratory in accordance with the latest
revision of NEMA FG-1 and other relevant standards shall be furnished during
inspection.
Manufacturer should have facility to test trays as per NEMA FG-1 for load test, IS
10661 for Glass Content and IS 6746 for Flammability Test at their works.
Raw material test certificates for polyester resin, glass fiber and additives used for
production shall be furnished during inspection.
The following tests shall b e carried out in presence of NFC’s representative.
i. Dimensional Check
ii. Deflection Load Test
iii. Burn Test and Flammability Test
iv. The minimum glass content should be 60%.
No material shall be dispatched until clearance for dispatch has been obtained in
writing from the purchaser.
Page 2 of 10
All the type test reports should be submitted along with the tender documents only,
failing which the offer will be rejected.
8. All required documentary proof is compulsory for the comparison of Tender documents.
7.
VII. PACKING: The cable tray shall be suitably protected by proper and adequate
packing for shipment and weather conditions involved. Cable trays shall be dispatched
in standard length of each cable tray section as decided by purchaser. Vendor shall clearly
indicate method of packing in the offer.
PERFORMANCE GUARANTEE
Vendor shall guarantee the material supply by him for twelve months from the date of
installation of eighteen months from the date of supply, whichever is earlier. In case
of failure of any of supplied items/equipment, the same shall be replaced with new
one or repaired within the period of guarantee. Moreover the purchaser reserves the
right to use rejected/failed material till it is replaced.
2. Payment will be made on 50% of the supply cost on receiving the material at site.
Balance 50% of the supply cost and erection cost on pro-rata basis will be paid on
completion of the work.
VIII.
1.
IX. SPARES:
1. Vendor shall supply 20% hardware such as nuts, bolts, splice/connector plate for each
type and size of cable trays and accessories. These shall be properly wrapped and
packed separately, clearly marked as “spare hardware” for cable trays and shipped along
with trays. Packing list shall be furnished so that the parts can be handled without
uncrating, if required.
X. PROCEDURE FOR REMOVING EXISTING CABLE TRAYS / SUPPORTS AND
REPLACING WITH FRP CABLE TRAYS AND FRP SUPPORTS:
1.
All cable Trays have to be replaced with suitable FRP Cable Trays and FRP Supports.
2.
Necessary care has to be taken while replacing existing Cable Trays with FRP Cable
Trays.
3.
Proper alignment and fixing/clamping (with SS/FRP clamps and SS
nuts/bolts/washer) shall be carried out for all trays.
4.
Any bends, elbows, tees, etc., as required for FRP tray as per site conditions shall be
pre-fabricated and shall not fabricate at site unless it is straight run only.
5.
Supply, fabrication and painting of all structural supports for the cable tray is in the
scope of supplier.
6.
Cables shall properly be laid in perforated trays of suitable size FRP. There shall be
no multi tier laying in any of the cable trays. All cables shall be laid in parallel in
side-by-side in single layer/tier only.
7.
Cables shall not be bent to radius less than manufacturer’s recommendations (i.e., 10
times the cable O.D.).
8.
The cable laid on the cable tray shall be properly dressed in such a manner that the
crossing of cables shall be minimized. The cable in the cable tray shall be clamped
with suitable pre-fabricated clamps/thick PVC straps at every 0.5 m in vertical trays
and 1 m in horizontal cable tray.
9.
Necessary permission will be given for drilling walls for the purpose of bolting the
supports or welding to MS Pillers or MS Beams to FRP Cable Trays.
Page 3 of 10
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Wherever necessary, power should be put off before start of work to ensure safety to
the personnel working.
All people working should use necessary safety gadgets like Safety Shoes, Safety
Helmets, Safety Gloves and Safety Belts. Personnel working on FRP Cable Trays or
FRP Supports should use safety goggles, Chest Mask, Apron, Gloves when sawing,
machining, etc. and Safety Ladders will be provided by NFC.
The contractor shall produce Police verification certificate, Medical fitness
Certificate, ESI & EPF for all the personnel employed by him for erection of cable
trays. The age of the personnel employed for erection shall not be less than 18 years
and shall not be more than 55 years.
Wherever required NFC will provide Power for cutting or any other operation free of
cost.
Good work man ship and practice shall be maintained throughout the fabrication and
assembly. Edges shall be removed after field cuts are made. Sealant shall be used for
sealing surfaces. When adhesives used, prepare the surface properly before applying.
Follow Label instructions carefully. A combination of mechanical fasteners and
adhesive make the strongest most reliable connection.
Specifications and drawings are for assistance and guidance, but exact routing,
locations, distances and levels will be governed by actual field conditions. Contractor
is directed to make field surveys as part of his work prior to submitting offer &
system layout drawings.
Installation shall be in accordance with equipment manufacturer's instructions, and
with recognized industry practices to ensure that cable tray equipment comply with
requirements of NEC and applicable portions of NFPA 70B & NEMA publications
FG-1.
As per NEMA FG-1, splice plate is recommended to be located at 1/4th of the span
from support, where the bending moment is zero.
Manufacturing and erection of cable trays shall be in accordance with relevant
national /international standards.
On completion of the entire work, the contractor shall submit as built cable schedule
tracing to standards/standard industrial practices in triplicate along with soft copies.
XI. COMPLIANCE STATEMENT: The bidders shall submit compliance statement for the
tender in the format attached as Annexure - III.
---------------------------------------------------------------X--------------------------------------------------------
Page 4 of 10
Annexure – I
Schedule of Quantities
S. No.
I
1
2
3
4
5
6
Description
Supply of FRP Ladder Type Cable Tray With FRP Coupler Plate and
SS316 hardware. The Side Runners are of FRP ‘C’ Channel 100 X 30 X
4 mm, Rung dimension 25 X 25 mm Hollow Square, Rung Spacing: 300
mm, FRP Coupler Plate (Flat) dimension: 200(L) X 70(B) X 4(T) mm,
FRP coupler plate should be with 8 set. of bolts & nuts.
150mm(W) x 100mm(H) x 3mm(T)
200mm(W) x 100mm(H) x 3mm(T)
300mm(W) x 100mm(H) x 3mm(T)
450mm(W) x 100mm(H) x 4mm(T)
600mm(W) x 100mm(H) x 4mm(T)
750mm(W) x 100mm(H) x 4mm(T)
II
Supply of FRP Perforated Cable Tray With FRP Coupler Plate and
SS316 hardware. FRP Coupler Plate (Flat) dimension: 200(B) X 4(T)
mm, FRP coupler plate should be with 8 set. of bolts & nuts.
1
2
3
50mm(W) x 25mm(H) x 3mm(T)
100mm(W) x 50mm(H) x 3mm(T)
200mm(W) x 50mm(H) x 3mm(T)
III
100
150
250
200
200
100
Meter
Meter
Meter
Meter
Meter
Meter
300
600
250
Meter
Meter
Meter
100
100
Nos.
Nos.
50
50
Nos.
Nos.
50
50
Nos.
Nos.
100
100
100
Nos.
Nos.
Nos.
25
25
25
Nos.
Nos.
Nos.
Supply of FRP fittings for ladder type cable tray, radius 300mm
1
90 deg Inward/Outward Bends, Horizontal Bends, Horizontal Reducers
- Left / Right / Straight (radius 300mm)
a
b
2
a
b
3
a
b
From 150mm(W) CT to 300 mm (W) CT
From 450mm(W) CT to 750 mm (W) CT
Horizontal Tee, radius 300mm
From 150mm(W) CT to 300 mm (W) CT
From 450mm(W) CT to 750 mm (W) CT
Horizontal Cross, radius 300mm
From 150mm(W) CT to 300 mm (W) CT
From 450mm(W) CT to 750 mm (W) CT
IV
Qty. UOM
Supply of FRP fittings for perforated type cable tray, radius 300mm
1
90 deg Inward/Outward Bends, Horizontal Bends, Horizontal Reducers
- Left / Right / Straight (radius 300mm)
a
b
c
2
a
b
c
For 50 mm(W) CT
For 100 mm(W) CT
For 200 mm(W) CT
Horizontal Tee, radius 300mm
For 50 mm(W) CT
For 100 mm(W) CT
For 200 mm(W) CT
Page 5 of 10
3
a
b
c
V
a
b
c
d
e
f
g
h
VI
a
b
c
d
e
f
g
h
VII
VIII
Horizontal Cross, radius 300mm
For 50 mm(W) CT
For 100 mm(W) CT
For 200 mm(W) CT
Removing existing Cable Tray (ladder/perforated type) including
Removing of Dressing and Lifting Cables on Below Trays
50 mm tray
100 mm tray
150 mm tray
200 mm tray
300 mm tray
450 mm tray
600 mm tray
700 mm tray
Erection of FRP Cable Tray (ladder/ perforated type) including
clamping, jointing and fixing, Relaying and Redressing of Cables on
FRP Trays
50 mm tray
100 mm tray
150 mm tray
200 mm tray
300 mm tray
450 mm tray
600 mm tray
700 mm tray
Removing of Un necessary Structural Steel
Supply, Fabrication and Erection of FRP Cable tray Supports with all
consumables
**************************
Page 6 of 10
10
10
10
Nos.
Nos.
Nos.
200
450
75
250
175
130
175
75
Rmtr
Rmtr
Rmtr
Rmtr
Rmtr
Rmtr
Rmtr
Rmtr
300
500
100
400
250
150
175
100
0.5
Rmtr
Rmtr
Rmtr
Rmtr
Rmtr
Rmtr
Rmtr
Rmtr
MT
2
MT
Annexure – II
TECHNICAL SPECIFICATIONS
Specifications for FRP Ladder Cable Trays:
S. No.
Description
Parameters
1
Standard
As per NEMA FG-1, 1993
2
Material
Ultra Violet Resistant, Corrosion Resistant & Fire
Retardant and antistatic FRP using premium vinylester
Resin and shall have a resin rich surface veil.
3
Manufacturing Process
Pultrusion using automated Pultrusion Machines
4
Std. Length of Cable Tray
3000mm±6mm
5
Width of Cable Ladder
100mm to 1000mm
6
Height of Cable Ladder
100mm with cable loading depth of 65mm
7
Thickness of Cable Trays
To be decided by manufacturer to meet loading
conditions and support spans.
8
Design of Trays
Cable Ladders must have rungs fixed to the side runner
without any metal, the adhesive bonded rung fixing must
also have mechanical locking without any metal
hardware to prevent rung roll over or dismantling during
handling or overloading.
9
Radius of Bends
300 mm as specified in BOQ.
10
Material of Coupler Plates
Coupler Plates of FRP and Bolts, Nuts washers of SS 316
and Hardware for Coupler
of M6 x 20 size
Plates
11
Material of Adjustable
FRP
Coupler Plates
12
Colour
DARK GREY
13a
RUNGS (Ladder Cable tray) Rungs should also be of pultruded section free of any
sharp projection to avoid damage to cable & joined to the
web of side runner channel with rigid mechanical locking
without any metal & suitable to withstand specified
loading. Cables Can be tied to rungs using Cable ties,
across the rungs and cables
13b
Rung spacing
300 mm
13c
Rung shape
25 mm x 25 mm Square tube
14
ROUTINE TEST:
14a
Loading:
14b
14c
14d
14e
14f
Deflection
Support Span
Fire Retardancy
Glass Content
Oxygen Index Test
Width of Tray
UDL Load
900mm
150Kg/m
750mm
120 Kg/m
600mmW
90 Kg/m
450mmW
75Kg/m
300mmW
60 Kg/m
150mmW
30 Kg/m
100mmW
20 Kg/m
An additional conc. load of 70 Kg with a safety factor
of 2 should be placed at mid span for each size and the
cable tray should not break or crack.
Must not be more than Span/200
Max. 2m for 100 mmH.
As per UL 94 V0
Min. 55% as per IS: 10661 – 1983
As per ASTM D2863- min 29%
Page 7 of 10
Specifications for FRP Perforated Cable Trays:
S. No.
1
2
Description
Standard
Material
3
4
5
6
Manufacturing Process
Std. Length of Cable Tray
Width of Cable Tray
Height of Cable Tray
7
8
Thickness of Cable Trays
Design of Trays
9
10
12
Radius of Bends
Material of Coupler Plates
and Hardware for Coupler
Plates
Material of Adjustable
Coupler Plates
Colour
13
ROUTINE TEST:
13a
Loading:
13b
13c
13d
13e
13f
Deflection
Support Span
Fire Retardancy
Glass Content
Oxygen Index test
11
Parameters
As per NEMA FG-1, 1993
Ultra Violet Resistant, Corrosion Resistant & Fire Retardant
and antistatic FRP using premium grade vinyl ester Resin and
shall have a resin rich surface veil.
Pultrusion using automated Pultrusion Machines
3000mm±6mm
50mm to 200mm
25mm (for 50 mm W cable tray)
50 mm (for 100 mm & 200 mm W cable tray)
Min 3 mm
The Cable Trays should be single section pultruded,
(assembled cable trays are not acceptable.)
300mm
Coupler Plates of FRP and Bolts, Nuts washers of SS 316 of
M6 x 20 size
FRP
DARK GREY
Width of Tray
UDL Load
200mmW
45 Kg/m
100mmW
20 Kg/m
50mmW
10 Kg/m
No Concentrated Load applicable on Perforated Cable Trays
Uniform Distributed Load Design is for support Span of 1.5
meters
Must not be more than Span/150
Max. 1.5m
As per UL 94 V0
Min. 55% as per IS: 10661 – 1983
Min 29 as per ASTM D-2863
Covers, Bends, Tees, Reducers:
1. Covers, Bends, Tees, Reducers must be made of Pultruded FRP material only and no metal
couplers should be used in fabricated bends.
2. Fasteners: All hardware (Bolt & Nuts) should be of SS 316 quality only.
3. All straight lengths & accessories to be supplied with pre-drilled holes for coupler plates
connections, material of coupler plates Bends & accessories should be same as that of cable
ladders.
Support Brackets and Beams:
1. The supports for cable trays must be made form FRP Pultruded structural sections. It is
preferable to use FRP single unistrut channels/angles of size 42x42x4 mm thick or double
unistrut channel of size 82x41x4 mm thick using SS base plates or Gusset plates, Rivets, etc.
as per site requirement.
2. For fixing trays to support, SS or FRP hold down clamps can be used with SS 316 M8 size
spring nuts and bolts.
3. Horizontal wall brackets, Vertical supports with cantilever brackets, etc. all to be made in
above manner.
Page 8 of 10
TYPE TESTS: The following type test certificates shall be furnished along with the offer and
during inspection, for the FRP cable trays being supplied.
TYPE TESTS:
1a
Fire Retardancy
Class 1 as per BS-476, Part 7
1b
Flame Spread
< 25 as per ASTM E84
1c
Self-Extinguishing
UL 94 V0
2
Oxygen Index Test
Min. 29 as per ASTM D-2863
3
UV Resistance
for 1000 Hours accelerated weather test, with reduction in Tensile
Strength of not more than 7% after exposure to UV As per ASTM
G154.
4
Antistatic Property
Resistivity < 106 As per ASTM D257
5
Glow wire Test
As per IEC 60695-2-12-2000 for 960 deg C
6
Moisture absorption
Max. 0.6% - 24 hrs test as per ASTM D 570/ IS 6746 Annexure K
Charges for carrying the above type tests at national accredited laboratories may be quoted
separately.
***
Page 9 of 10
Annexure – III
Compliance Statement
Compliance
1. The entire scope of work encompassing Supply of FRP cable trays with FRP
supports & accessories, Removing/lifting of Cables on existing cable trays,
Removing of existing Cable Trays, Erection of FRP Cable Trays & Supports,
Re-laying and redressing of cables on FRP trays is considered.
2. Cost towards Supply (FRP cable trays - ladder/perforated, FRP supports, FRP
fittings, SS hardware) and Erection (Removing of dressing, Removing of
existing Cable Trays, Erection of FRP Cable Trays, Re-laying and redressing
of cables) is indicated separately.
3. All Cable trays will be made of Glass reinforced Flame retardant vinylester
with minimum Glass content of 60%.
4. All FRP cable trays, accessories & coupler plates will be manufactured using
PULTRUSION technology.
5. All pultruded material will provided with surfacing veil to provide maximum
chemical and UV protection.
6. The Pultruded Cable Bearers have a minimum thickness of 4.0 mm for all
sizes of 100 mm & above.
7. Perforated type cable Bearers 50mm width is provided in 3.0 mm minimum
thickness.
8. The Cable trays will be supplied in standard lengths of 3000 mm.
9. Stainless steel hardware (SS316) such as bolts, nuts, etc. will be provided for
joining of trays, bends, etc.
10. 20% SS hardware such as nuts, bolts, splice/connector plate for each type and
size of cable trays and accessories will be supplied as spare.
11. The inside depth of the cable trays is 25 mm for 50 mm wide tray, 50 mm
upto 300 mm wide trays & 100 mm for 500 mm & 600 mm wide trays.
12. All cable trays and accessories will be offered for inspection at
Manufacturer's works.
13. Manufacturer has facility to test trays as per NEMA FG-1 for load test, IS
10661 for Glass Content and IS 6746 for Flammability Test at their works.
14. All the type test reports are submitted along with the tender.
15. Charges for carrying the type tests at national accredited laboratories is
quoted separately.
16. Personnel will use necessary safety gadgets & PPEs during erection of cable
trays at site.
17. Police verification certificate, Medical fitness Certificate, ESI & EPF will be
produced for all the personnel employed for erection of cable trays.
18. As-built Cable schedule tracing to standards/standard industrial practices will
be submitted in triplicate along with soft copies.
****
Page 10 of 10
Yes / No