Stadia, City Junctions, Airports, Sea Ports, Industries.We reach faster than anyone else.
H I G H M A S T L I G H T I N G
VARIANT INFRATECH PRIVATE LIMITED
VARIANT INFRATECH PRIVATE LIMITED
Facilities offered at-a-glance
Why BAJAJ highmast is preferred?
BEL has inhouse facilities for :
Pioneer : BEL is in the field of high mast since last 25 years and has unmatched
experience in design, development, manufacturing and site erection.
Illumination Design
BEL has a team of illumination design engineers, who are well qualified and
experienced. They prepare designs with the help of the best available software.
BEL illumination design engineers are equipped to offer optimum designs for all
lighting applications like stadiums, traffic junctions, airports, sea ports, container
yards, railway marshaling yards, etc. Several lighting projects confirming to Indian /
international standards, have been designed and successfully executed.
Civil / Structure design
BEL has an in house set up for structural and foundation design for the masts.
Designs generally conform to ILE TR No.7 and IS 875 part 3. Masts confirming to
various terrains, wind zones and heights have been designed by BEL over these
years. BEL has designed manufactured and installed masts of heights upto 60 M.
BEL designs have already been approved by various Institutions/consultants like IIT
Mumbai, IIT Chennai, Engineers India Limited, Bectel Limited, PDIL, Meccon, etc.
Mechanical Design
BEL has in-house team of engineers with latest mechanical design software to
design the complete raising / lowering system. This also enables BEL to cater to
customer specific requirements.
highmast systems
1.2
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EN ISO 9001
Highmasts for Places of Tourist Attractions
VARIANT INFRATECH PRIVATE LIMITED
1.3Bajaj Highmasts being Installed at Ras-Al-Khaima, UAE.
Manufacturing:
BEL's manufacturing plant is one of the best in the world and is fully
equipped with all state-of-the-art machineries.
With these facilities BEL is capable of manufacturing high masts confirming
to international standards and as per the requirement of the user.
The plant is ISO 9001 and 14001 certified.
Marketing, Sales and service set-up
BEL has 19 offices in India to cater its clientele. These offices help
customers for their requirements from the conceptual to commissioning
stage. BEL engineers stationed at these offices provide optimum designs,
competitive prices, installation services and efficient after sales services.
BEL offices at Mumbai and Sharjah cater to its international customers.
highmast systems CERTTUV
EN ISO 9001
VARIANT INFRATECH PRIVATE LIMITED
Introduction
Advantages Applications
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Designs
BEL has been supplying this type of masts for more than two decades. Normally designed for a life of 25 years, these masts are the best solution available for external illumination requirements.
These masts will accommodate any lighting system and are also ideal for mounting CCTV cameras. BEL's manufacturing facility is one of the best of its kind in the world. With this facility, BEL can offer masts of various types and capacities suiting the customers' requirement.
Best space utilisation. Airports & sea ports
Perfect suspension. Railway sidings & yards
Maintenance friendly. Car parks & junctions
Double drum winches Highways & express ways
Motorised operation. Industrial flood lighting
Sleek and aesthetic. Top security zones.
Available upto 60 M height
Masts are designed to ILE Technical Report No. 7. Wind velocity as per IS 875 part.3 in India and as per the relevant local standards in other countries. The method of construction using overlapping joints provides good damping and greatly resists resonance caused by wind induced oscillations. The mechanical and electrical systems incorporated within the mast also conform to the requirements of ILE T R No.7.
BEL has successfully conducted “Wind Tunnel Testing” for the mast sample. The test was conducted at Wichita State University USA. Crucial parameters used for preparing individual designs are taken from this test results.
Raising and loweringWinch Lighting masts
1.4
highmast systems
India's only 60 M Highmasts - Installed at Chennai Container Terminal
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EN ISO 9001
VARIANT INFRATECH PRIVATE LIMITED
Mast Construction
Mast Head Assembly
'BAJAJ' raising and lowering winch masts are made from continuously tapered folded
steel sections. The polygonal cross section is usually 20 sided, although other shapes
can be offered on request.
The material is steel confirming to BSEN 10025 grade S 355. the plate is plasma cut and
folded to form polygon of required shapes and then welded along longitudinal seams.
BAJAJ section lengths are typically designed and are such that transverse welding is
not required. Sections are designed in such a way that the overlap length shall be more
than 1.5 times the diameter at penetration.
The taper fit friction joints can be assembled at site with equipments usually available at
construction sites. No site fabrication work is required during assembly. The edge of
the door opening is reinforced to guard against buckling. The door cover is provided
with vandal resistant locking device.
The mast is mounted on the foundation using a flange. The shaft is attached to the
flange using full strength butt welds with supplementary gussets provided between
bolt holes. All steel work is galvanised to BS EN ISO 1461.
The mast head assembly is fitted with a four pulley system which can accommodate 2
wire ropes and 2 electric cables. The pulley is of large diameter appropriate to the multi
core flexible cable being used. They are of non-corrodible material and run on self
lubricating bearings with stainless steel spindles. Arrangements are provided to ensure
that the electric cables and steel wire ropes are separated before passing over their
respective pulleys to prevent ropes and cables leaving the pulley's grooves.
Pulleys are housed in a chassis integral with a sleeve which slips over the top of the
mast and is secured axially and in azimuth. Guides and stops are provided for docking
the lantern carriage. The complete chassis assembly is hot dip galvanised after
fabrication. The pulley assembly is protected with a weatherproof cover.Typical General Arrangement Details of Base Compartment
1.5
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EN ISO 9001
VARIANT INFRATECH PRIVATE LIMITED
Other designs of head frames can also be supplied against specific requirements.
The lantern carriage is fabricated from durable steel pipes designed to act as electric
conduit with cable holes. It is fitted with junction box mounting bracket (s) and is in two
halves joined by bolted flanges to permit removal from an erected mast. Lantern fixing
arms and plates are welded to the carriage. Carriage is fitted with a buffer
arrangements to prevent damage to the mast finish during movement. Rollers or other
moving parts are not required
Lantern Carriages
Raising and loweringWinch Lighting Masts
1.6
Typical General Arrangement Details of Head Frame
highmast systems CERTTUV
EN ISO 9001
Highway Lighting with Highmast at Surat, Gujrat.
VARIANT INFRATECH PRIVATE LIMITED
Winches
Suspension System
Electrical System
Winches are completely self sustaining type with a gear ratio of 53:1. Winches
are of self lubricating type by means of an oil bath. Lubricant recommended by
the supplier is to be used. Single gear and double gear design of winches are
available in 'bajaj' range. Winches can be operated by a motor or manual
handle. Power tools for operating the winch are available in 'integral' or
'common' versions. Bajaj winches have been rigorously type tested based on
the relevant standards under the guidance and presence of experts from
Indian Institute of Technology, Mumbai. Test certificates for the safe working
load is submitted along with all winches.
Suspension wires are 'marine grade' (AISI 316) stainless steel of 7/19
construction and are provided with pre-formed thimbles and terminals. Normal
suspension systems are with two continuous wire ropes without any
intermediate joints in between. One end of the rope shall be fixed on the winch
and the other end on the lantern carriage. Suspension systems supplied by
'bajaj' are properly designed with suitable clamps to prevent entangling of wire
ropes and cables. This unique arrangement increases the life of the wire ropes
and cables. Other types of suspension systems can also be supplied against
specific requirements.
Multicore flexible power cables are provided for power supply. Cables are with EPR insulation, PCP sheathing and cotton braiding to get the required strength and flexibility. These cables terminate in the base compartment through specially designed metal clad plugs and sockets. At the mast head cables are connected to weather proof cast aluminium junction box on the lantern ring. The power cables are factory cut for ease of installation.
An MCB box is provided inside the base compartment of the mast for local isolation of the power supply. Masts shall have facility for testing the luminaries at the bottom level (this facility is not provided for masts located in hazardous area for safety reasons). Masts in hazardous areas are with a flame proof plug socket unit at the bottom.
A 12 mm diameter GI bolt is provided at a convenient location in the base compartment as earthing point. All standard masts are provided with a single spike lightning finial on the head frame at the top most point.
Foundation bolts are fabricated from MS rods of high yield strength. As foundation bolts are very important in the structural safety of the system, 'bajaj' supply these bolts as part of the total system. Exposed portion of the bolts is hot dipped galvanised to increase resistance against corrosion. Foundation bolts are supplied as a complete set with bolts, anchor plates and templates.
Earthing Point & Lightning Finial
Foundation Bolts
1.7
highmast systems
"Stars" of bajaj at CFS Mundhra - 65 Nos. 40 M Highmast at one location
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EN ISO 9001
VARIANT INFRATECH PRIVATE LIMITED
Raising and loweringWinch Lighting Masts
Client Profile
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We are proud that 'BAJAJ' raising and lowering masts are providing the leading
light to the industrial and infrastructural development in India.
BEL entered into the field of raising and lowering winch masts more than two decades
ago. Since then BEL has been the undisputed leader in the Indian market.
During this period more than 8000 masts of different designs were installed in India. List
of our esteemed clientele is exorbitant, but include
Indian Railways Haldia Dock Complex
Durgapur Projects Ltd. Chennai Port Trust
Container Corporation of India Jawaharlal Nehru Port Trust
Chennai International Airport. Mormugao Port Trust
Hyderabad International Airport. Vishakhapatanam Port Trust
Kochi International Airport. P&O Ports (India) Ltd.
CSI Airport, Mumbai. Bharat Petroleum Corporation Ltd.
IGI Airport, New Delhi. Indian Oil Corporation Ltd.
SAIL Bokaro Steel Plant. Hindustan Petroleum Corporation Ltd.
SAIL Bhilai Steel Plant. Oil & Natural Gas Corporation Ltd.
SAIL Rourkela Steel Plant. Reliance Industries Ltd.
Various Municipal Corporations. OTDC Bhuvaneshwar.
National Thermal Power Corporation Ltd. Hill Temple, Palani.
Nuclear Power Corporation Ltd. Bharat Heavy Electricals Ltd.
National Highway Authority of India. Neyveli Lignite Corporation Ltd.
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highmast systems CERTTUV
EN ISO 9001
Flyover Lighting with Highmasts
VARIANT INFRATECH PRIVATE LIMITED
highmast systems
Standard Mast Dimensions
MAST MAST HT TOP DIA BOT DIA PLATE THK PCD FOUNDATION LUM CAPACITY atRef. (M) (mm) (mm) (mm) (mm) BOLTS 50 M/S 44 M/S
BJRLMW11L 11 100 360 3 445 M24/850 X 4 6 6
BJRLMW16L 16 150 360 3,3 445 M24/850 X 6 6 6
BJRLMW16M 16 150 410 3,4 490 M30/850 X 8 12 16
BJRLMW20L 20 150 360 3,3 445 M30/850 X 8 NA 6
BJRLMW20M 20 150 460 3,4 590 M30/850 X 8 12 16
BJRLMW25L 25 150 460 3,4,4 590 M30/850 X 8 8 12
BJRLMW25M 25 150 540 3,4,5 650 M30/850 X 12 12 16
BJRLMW30L 30 150 460 3,4,5 590 M30/850 X 8 NA 8
BJRLMW30M 30 150 540 4,4,5 650 M30/850 X 12 9 12
BJRLMW30H 30 150 610 4,4,6 740 M30/850 X 12 12 16
Luminaries for Highmasts
Following are the most frequently used 'bajaj' luminaries on high masts.
BGENF 22 R BJEF 21 S BGENF 14 BJEF 28 S
Exports
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Apart from the Indian market, BEL caters to
international markets also. BEL has exported
high mast systems to the following countries till
date.
Libya
Nigeria
Mauritius
Oman
Zambia
United Arab Emirates
1.9
BJEF 2KW MH DE BJHM 22 SS
CERTTUV
EN ISO 9001
VARIANT INFRATECH PRIVATE LIMITED
highmast systems
Monopoles forTelecommunications
Monopole structures are ideal for mounting antennas for telecommunication. It has
several advantages over the traditional lattice structures. Space consumed by a
monopole compared to a lattice structure of the same capacity is much less. Hence
monopole structures become suitable for heavily populated and congested areas like
metros and other cities. Monopoles provide more flexibility for installation of required
antennas. Thus it can provide a better utility for the service provider. With its sleek and
elegant look monopoles can improve the aesthetics of the whole installation.
Due to its advantages developed countries are using monopoles extensively for
telecommunication purposes. However, its use in India was limited till recently. BEL
introduced Monopole antenna masts in India few years back. BEL have so far supplied
such masts to Bharat Sanchar Nigam Limited and Reliance Infocomm Limited.
Monopole structures are also used for mounting antennas for railway signalling.
Recently commissioned Delhi Metro Rail system is using monopoles for their signalling
requirements. All towers required for DMRC were provided by BEL. Height of these
towers varies from 40 M to 50 M.
Telecommunication masts are designed with a fixed platform at the top. Provision for
required number of microwave or GSM antennas can be provided on the top platform. If
required, masts with multiple platforms can also be supplied.
Design parameters for telecommunication masts are more stringent compared to
normal lighting masts. Allowable deflection during wind is very low for these types of
masts. BEL with a team of experienced designers can design and execute towers as
per the customer requirements.
Another important use for monopoles is for mounting CCTV cameras. CCTV masts
have several applications like monitoring the safety of sensitive installations,
monitoring of traffic on highways, etc.
1.10Antenna Masts for Telecommunication
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EN ISO 9001
VARIANT INFRATECH PRIVATE LIMITED
highmast systems
Stadium Lighting
Development in technology has
changed the way of life in sports arena
also. Matches are played at night with the
same ease as that in the day. Efficient
floodlighting is the main requirement to
make this possible.
Fixed head polygonal masts are the ideal
means to flood lit stadiums to
international standards. These masts are
normally manufactured in polygonal
tapered sections and assembled at site.
The top platform and the mast are
designed to carry required number of
flood light luminaries.
BEL is the market leader in India for
stadium lighting with fixed head
polygonal structures. With all in house
facilities for lighting design, structural
design, manufacturing and installation,
BEL can offer flood lighting solutions for
any sports activities.
BEL has executed sports lighting work at
Delhi, Chandigarh, Hyderabad, Jaipur,
Guwahati, Kanpur, Banglore, Chennai,
Ras-al-khaima (UAE), Hatta (UAE),
Muscat etc.
Fixed Head Masts for Sports Lighting
1.11Stadium Lighting - GMC Balayogi Stadium at Hyderabad.
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EN ISO 9001
VARIANT INFRATECH PRIVATE LIMITED
Signage Masts
Mid hinged type masts
Utility of raising and lowering winch masts in advertising was also introduced in the
Indian market by BEL. This innovative idea, mooted by BEL gathered its momentum
very fast.
Today, all Petroleum companies like IOCL, BPCL, HPCL and RIL are using these masts
as their main means of advertising in high way outlets.
This is another type of raising and lowering
type masts. These masts are fitted with a
heavy duty hinging arrangement at the
middle. The luminaries mounted at the top
can be lowered down using this hinge for
installation / maintenance.
Mid hinged masts have a jacket extending
from the middle to the bottom. The operator
can tie a rope at the end of this jacket and
raise / lower the luminaries. These masts
can be operated manually by a single
operator. Due to operational limitations,
these masts are normally designed to
accommodate upto six luminaries only.
Mid hinged masts are suitable for
illuminating open areas, parks, high ways,
car parkings etc.
highmast systems
Signage Masts & Mid-hinged Lighting Masts
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EN ISO 9001
Highmasts for Advertisement - Sinage Mast Installed for IOCL
Mid Hinged Masts
VARIANT INFRATECH PRIVATE LIMITED
highmast systems
Manufacturing Facilities
1.13
State of the art machineries installed at bajaj plant
1. Plasma Cutting Machines - Messer, Germany make
2. Press Break LVD - Belgium make
3. Welding Machines - Bode, England make
4. Galvanising Plant - Gimeco, Italy make
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EN ISO 9001
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EN ISO 9001
'bajaj' Highmasts Manufacturing Unit at Ranjangaon, Near Pune
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VARIANT INFRATECH PRIVATE LIMITED
Branch Email ID
Ahmedabad [email protected]
Bangalore [email protected]
Bhubaneshwar [email protected]
Kolkata [email protected]
Chandigarh [email protected]
Chennai [email protected]
Cochin [email protected]
Delhi [email protected]
Guwahati [email protected]
Hyderabad [email protected]
Indore [email protected]
Jaipur [email protected]
Lucknow [email protected]
Nagpur [email protected]
Noida [email protected]
Patna [email protected]
Pune [email protected]
Raipur [email protected]
CERTTUV
EN ISO 9001highmast systems
E003
EP01
JUL1
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VARIANT INFRATECH PRIVATE LIMITED
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