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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)
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
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 25
th
May 1905, and the lowest one, at
2C, was recorded on 2
nd
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" #$%& '#%( ')%* '$ '$%$ '+%$ ',%' #$%* ',%+ '#%) ',%$ #$%' '#%$
Average lo- !C" *+%# *)%' #,%# #'%& #+%) #' #*%. #*%* #,%$ *$%& *)%+ *+ *$%&
/recipitation mm" #%# #%$ (%* )%' #(%( *'*%+ *)& *)( *'(%' (#%) #$%' .%+ &'*

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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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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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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

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: mplachy@bonatrans.cz.

9. Procurers contact persons:

Martin Plach Head, Division of Technical Development
tel.: +420 602 730 171
e-mail: mplachy@bonatrans.cz

Radim Zima Technical Director (TD)
tel.:+420 602 730 022
e-mail: rzima@bonatrans.cz

Ji Vodk Project manager
tel.:+420 606 201 214,
e-mail: jvodak@bonatrans.cz

Joachim Marreck Managing Director of BONATRANS INDIA Pvt.Ltd.
Tel. Indie: +91 976 438 2223
Tel. esko: +420 733 789 691
e-mail: jmarreck@bonatrans.in

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AMENITIES FOR WORKERS
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PRODUCTION HALL
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2
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TRANSFORMER
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3
10M
COVERED STORAGE PLACE FOR FINISHED WHEELS
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5
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AREA 40 000 M2
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7800m
3900m
250m
540m
1200m
2160m
1150m
580m
860m
1150m
360m
30m