POLY-QUAL (INDIA) PVT.LTD.

ENGINEERS ٠TOWER MANUFACTURERS ٠ERECTORS

A-210, OKHLA INDUSTRIAL AREA, PHASE – I,

NEW DELHI – 110020, INDIA

Tel. : +91-(011) 26817236, 26814137

Fax : +91-(011) 26812231, 26811397

Email: polyqual@eth.net Website: http\\www.polyqual.com

Buying a Telecommunication TowerTower is a Capital expenditure with operational life of several decades. Hence buying a tower needs careful determination of requirements or

specifications. Important specification include 1. Survival wind Speed.

2. Physical size, Type, Number and levels of Antennas. 3. Twist & Sway requirements.

While offering a product, almost all bidders, uniformly say “Complied” against all the required specifications including above i.e. wind speed,

antenna loading etc.While compliance for some of the specifications is easily confirmable,

the requirement of wind speed and antenna loading cannot be checked without looking into detailed design calculations. Hence experienced

and shrewd buyers always insist on design calculations, before finalization of purchase contract.

Unfortunately these two parameters are main parameters, which determine suitability of tower and are responsible for cost of tower also.

Factors like size of antennas, type of antenna, level of antenna have considerable effect on the required strength (read cost) of tower.

Placing antenna at mid height of tower will reduce the loading on tower by 50%. On the other hand, if the wind speed is double, the forces

acting on tower are 4 times.Buying a communication tower is not the same as buying a bunch of

steel angle, pipes, plates etc. Tower is matched set of its various components.

Each component of this set has a vital role to play in the strength of WHOLE tower, for example, if One small segment of the leg is slightly weaker than required, that the entire tower’s strength will be determined by this small component, because tower will fail from this point only when full loading occurs. Moreover, putting extra strength at any non-required point is wastage of materials, because strength of the tower is determined by weakest link in the structure only. Hence it becomes imperative that all members should be capable of resisting the applied loads to the same extent uniformly.To ensure that all these things have been considered properly, availability of design competency with the tower supplier is the most desirable eligibility criterion. Design competency in supplier is a must for copying also. For example, if bolt grade changes, the joints have to be redesigned. If any member is replaced due to non availability of any section then also detailing of all adjoining members has to be changed.

Approx.95% of price paid by buyer for tower, consists of materials cost. In today’s competitive world, all bidders work on small margins. Hence material cost is the all encompassing component of total cost. Anybody can reduce the cost by reducing the materials. That reduction is normally not without compromising on the performance or strength. The buyer has no way to recognize this compromise without looking into detailed calculations and verify that the product is as per design calculations.

Poly-Qual (India) Pvt.Ltd.

• Poly-Qual is one of very few companies in world who offers design & construction of towers under one roof, Poly Qual USP is tailor made tower of any type as per individual need & requirement. Poly-Qual has in house designing system to design of towers. We use “State of the Art” designing software for static & dynamic analysis of the tower models. Computerized modeling - We do 3D modeling of our towers before actual production is taken up . This modeling helps us to carry out the detailing of the tower with a very high degree of accuracy, optimization of space with same strength, very less turn around time and also help full for cost cutting (value for money).

• Poly-Qual provides complete turnkey solutions which include engineering, manufacturing and construction

services or any combination of individual services related to construction and continuing operation of

communication towers.

• From an initial project consulting & system design to implementation, installation and testing through maintenance & support, Poly-Qual provides performance proven expertise & technological foresight upon which long term customer partnership are built.

• Tailor Made Towers – Poly-Qual USP is tailor made tower of any type as per individual need & requirement. We have commissioned several tailor made towers, for example. Towers with 2 legs on rooftop & two legs on ground. Triangular towers on square bases Ultra Slim Towers made out of Solid Rods. Platforms as big as 30 square Meters on tower top. Towers with very small base width i.e. up to height/12.

Product & Services Offered by Poly Qual

Product Range Poly-Qual product range includes self-supporting

tower, guyed masts, monopole for telecommunications,

microwave, television, radio, defense, windmill, for security and other diverse application. Poly-Qual manufactures Square /Triangular towers. These could be fabricated out of angles/ pipes or could be hybrid construction. The construction of tower could be welded or bolted. Each type has its own merits & demerits

depending on application.

Line of Sight Surveys To get communication between 2 points, it is necessary

that that the height of the tower be adequate at both ends.

Height of tower required at each end is determined by considering    * Earth Curvature. * Height of Fresnel Zone for frequency of Communication. * Heights of man made obstructions on way. * Degree of reliability required with the proposed equipment.

Above determination involves map study, physical survey of

obstructions & elaborate calculations. Poly Qual carries out

LOS surveys between any defined points. Normally money

spent in survey is more than compensated in savings in

tower heights & reliable communications.

Soil Investigations

It is necessary that the foundation design be done according to the soil conditions available at site. Poly Qual determines the strength of the soil, height of the water table and other desired properties of the soil for safe & economic design of the foundation.

The process involves transport of drilling equipment to site , drilling boreholes at the site and laboratory analysis of disturbed & undisturbed samples collected from site and according to the result final soil test report is made.

Tower Designing Poly Qual undertakes to design towers tailor made to the needs of the buyer, so that the design meets the parameters of ·  Space available. ·  Wind Speed Applicable. · Antenna Loads to be applied. ·  Facilities required on tower. · Twist and sway required by the communication system or any other requirement. · Latest “State of The Art” software is used to carry out the design.

Detailing of Design After design, Poly Qual offers the services of making a production drawing for each member, gusset, joint of the tower. The drawings are prepared in Auto-cad. All applicable standards regarding pitch, edge distance etc are followed. All dimensions are given to the nearest millimeter.

• We have a well equipped tool room to facilitate maintenance of our dies, tools etc. We employ modern techniques of fabrication e.g. our gusset templates are computer generated to eliminate all drawing errors.• Above in-house facilities result in following advantages to the customer.A new design of tower, having different geometry or different loads is developed in a very short time. The detailing of the towers has a very high level of precision, which results in fast & easy erection.• Our production is never held up due to no availability of any section. Our design team is always able to recommend us an alternative for the section not available.• Poly Qual's biggest strength lies in its ability to manufacture, a new design of any tower without going through the process of first making a prototype for that design. This means that a customer gets a very fast delivery for any new design of tower. Alterations or variations in any existing design are accomplished very fast. Poly Qual has in-house designing facility for towers & tower foundations. To the customer, it means that the supplies will never be delayed due to non availability of any section.

Materials Used Our tower designs are based on strengths of Indian Steels. Certificate from a Govt. approved test laboratory certifying the strength of material is as specified in design, can also be provided with material supply. All materials are hot dip galvanized after fabrication. The length of all members is maintained less than 6 meters, so that transportation of material by truck or containers is not a problem.

Fabrication of Tower Materials

Tower material is fabricated using precision machinery. Accuracy of all drilled or punched holes are maintained as per engineering drawing. Buyer can choose any type of tower. Each type will be guaranteed to meet the performance specifications laid out by buyer. The design will be certified to meet the performance requirements by chartered engineer /Govt. Approved Authority. Certificates, showing. ● The strength of materials as per design. ● Thickness of zinc coating as per standards will be enclosed with supply of materials, if desired. ●An erection manual, showing location of all members & their code is provided, when only tower materials are ordered. All members in the supply carry code in permanent punch and permanent ink as per erection manual.

Galvanizing of Fabricated Materials All material is hot dip galvanized as per applicable standards after the fabrication. All holes are coated through. All weld joints are coated. The thickness of coating is checked for each lot of galvanizing.

Foundation DesignThe foundation design is done on the basis of soil parameters and the forces generated by the tower on the foundation. Indian Code IS 456 is followed for concrete. Adequate factoring is done for loads during design.

Construction of Foundations Foundations are constructed as per design. The concrete mixture is maintained as per design. Proper curing is done to achieve desired strength of concrete.

Erection And Painting of Towers An erection manual, showing location of all members & their code is provided, when only tower materials are ordered. All members in the supply carry code in permanent ink as per erection manual. Poly Qual undertakes erection and painting of towers as per erection manual. All safety procedures are followed. Nut & bolts are properly tightened. Painting is done as desired by the customer.

Quality Poly-Qual’s Commitment To Quality

• Poly-Qual is a ISO 9000-2001 company and has a well documented quality manual.

• Our mission statement includes “.. to build towers, which excel or match the best in world ......... at a right cost to the customer “

● Poly-Qual controls the quality of their towers at each stage of manufacture i.e. a)  Raw material stages – Inspection is done on arrival

of raw material for visual surface defects like slivers, blowholes , pit tings & hairlines cracks etc. Before commencing fabrication, various properties which are tested these include tensile strength, bending strength of steel. Chemical analysis is done to determine various micro components

b) During processing stages – all the dimensions of various components are first tested in virtual space by 3D modeling. Then each component is checked against the physical dimensions generated by computer model. Welded component are subjected to DP test for checking quality of welding. Random sampling of members is done to measure physical distances between holes and total length.

 

c) On finished stage.- Poly-Qual towers are hot dip galvanized after fabrication to make sure that there are no rust starting points. In hot dip galvanizing, each section of the tower is totally immersed in molten zinc allowing every square mm of the tower, inside and out, to be completely covered. Hot dip galvanizing protects all points of welding and construction against rust and corrosion.

Thickness of coating is routinely checked by non destructive tests. Some samples are subjected to destructive tests also to ensure.

i)  Proper thickness of coating. ii)  Proper adhesion of coating. iii)  Proper quality of zinc used.d) Pre-dispatch Stage – All members are checked for

erection codes marked on them , Checking is done for punched marking as well as permanent ink marking . All critical subassemblies are subject to proof of prototype assembly.

No of pieces/packing & member of packing are checked with

the packing list to ensure the completeness of material being

dispatched. Note: All the above mentioned tests are done by

govt. certified independent labs. All the certificate issued for

material testing/quantity are properly filed & maintained.

Poly-Qual quality standards  a)  IS 2062 or IS 630 or BS 4360 for quality of steel. b) IS 800/ IS 802 for fabrication of towers. c) IS 875 for wind loading on towers. d) IS 1461 for zinc coating. e) Permissible stress as per IS 802. f) ISO 9001:2000 for quality management systems. g) IS : 2074 Nut bolts used are grade 5.6/5. Dimensions as per IS 6639-72. Physical properties as per IS 1367. Physical properties as per IS 1367.

Tower Design approval. Tower designs are generated by Poly-Qual engineers

who have decades of Experience in designing. However

third party approval by IIT/ Govt. department of the tower design, foundation design are also organized, if the

customer so requires.

Experience

Benefits Of Working With Poly-Qual

We have been in the field of making communication towers

For more than 30 years. Our products are being used in

diverse fields like cellular telephony, Micro-wave communication

links Wireless, Paging, Lighting towers etc.

Poly-Qual’s Core Strengths:

Time Delivery

Poly Qual’s biggest strength lies in its ability to manufacture

a new design of any tower without going through the process

of first making a prototype for that design. This means that a customer gets a very fast delivery for any new design

of tower. Alterations or variations in any existing design

are accomplished very fast. Poly Qual has in-house

designing facility for towers & tower foundations.

Benchmark

a) 150 meter Tower Poly-Qual has commissioned a tower in affna, Sri Lanka which is the tallest tower with height of 150M. The tower commissioning took just 2 weeks & was installed by the simple user friendly help of our erection manual. The installation of such towers not only offers tremendous connectivity on LOS basis but also saves cost for successive smaller installations accordingly.

b) We have supplied about more than 500 towers to Bharti Cellular from 15M to 70M height Limited which includes the first ever tower purchased by Airtel which is installed in Okhla head office.

c) Radar Tower - We have supplied around 45 towers of 45M to 70M height to metrological department of Kenya, this tower is designed with internal stair case so that climbing on tower is quite easy Compact Profile.

Awards won

Poly-Qual, in stewardship of Mr. D K Bansal has won several

awards which includes the following: • Century International Quality Era Awards. • Tamra Patra Award by the Honorable President of India. • Business Sphere Awards. • IEDRA Awards. • Export Excellence award from EEPC for last consecutive

4 years. • All India Achievers Conference Awards. • Poly-Qual has also been awarded a “Gold Medal” in recognition of excellent work done in developing new products like Coaxial Connectors.

Partial List of Clients We have a long list of satisfied customers in India as well

as outside India.

Partial list of our clients which includes the following.

- Escotel Mobile Communications Ltd: - A leading cellular phone service provider in - States of UP, Haryana & Kerala in India - All India Radio & Doordarshan: - India’s National Television Brodcaster - Bharti Cellular Communications Ltd: - Spice Telecom - REI Systems, US - Tata Telecom - Idea Cellulars Limited - Hexacom India Ltd. (Oasis Cellulars) - Bhutan Telecom - Modi Telecom Ltd. - Telecommunication Consultant India Ltd. - Public Telecommunication Corporation Yemen - Bharat Electronics Limited - American Express - DCM Daewoo Motors - Motorola Communication Ltd. - Delhi Jal Board - O.N.G.C. - Punwire, Communication Limited - Dakshe Services Pvt. Ltd. - Software Technology Park of India - Police Wireless. - Polaris and many others.

Capacity

Production Capacity

We have total capacity of approx 700 tons per Month. We have erected self supporting towers in thousands all over the country and in foreign countries. All our customers are very much satisfied with our products. To read their comments on our products, please visit our website www.polyqual.com. We have also exported approximately 1500 towers of varying heights from 15 meters to 150 meters to countries in South East Asia, Middle East, U.K., Africa, USA, Nepal, Bhutan and 2500 towers within the India.

Work Space The manufacturing unit of Poly-Qual is located in prime industrial area in India’s capital, New Delhi. The facility consists of 10000 sq ft, 3 floors, equipped with all modern tools & equipment for tower manufacture. A new unit in

Hathin, Haryana in a area of 20000 sq.ft.

Financial capacity Poly Qual has a strong financial capacity to supply any quantity of towers and capable to run non stop production with continuous flow of raw materials.

Registrations and Empanelment Govt authorities give recognition to establishments after verifying that all norms/procedures required by the Govt. are followed. Important buyers empanel competent suppliers to save the vendor evaluation effort, each time a purchase is made. Above registration & empanelment are done on the basis of evaluation of manufacturing facilities by personal visits & assessment of machinery/production procedure followed:

• Evaluation of technical competence.• Evaluation of financial competence by getting references from banks & past performances.• Evaluation of methods employed to achieve consistent quality. • By cross checking all relevant documents ensuring that the laws of the land are being followed. We are registered empanelled with - Director of Industries, Delhi Administration, Delhi. - National Small Industries Corporation, Govt of India. - Directorate of Quality Assurance, Ministry of Defense, Govt

of India. - Engineering Export Promotion Council (EEPC). - Ministry of Railways, Govt of India and many more ........... We always evaluate company’s financial position by outside third party i.e. M/s Dun & Bradstreet Information Services India Pvt. Ltd., FB-01, NSIC STP Centre, NSIC Bhawan, Okhla Industrial Estate, New Delhi-110020, India. Website: www.dnb.com

Team Poly-Qual

Mr. Bansal Sh. D.K Bansal Managing Director of Poly-Qual (India) Pvt Ltd is a Gold Medallist Post Graduate Engineer from IIT (Kharagpur) and has experience of industry for more than 40 years. Poly Qual, in stewardship of Mr. Bansal has won several awards which includes the following. · Century International Quality Era Awards. · Tamra Patra Award. • Business Sphere Awards. •IEDRA

Awards. · Export Excellence award from EEPC for last consecutive 4

years.

· All India Achievers Conference Awards.

Mrs R.D.Kumar Mrs Rekha Dev has done Mechanical engineering from

BITS Pilani has experience of industry for more than 25 years.

Civil Engineers We have about 10 diploma holders in civil engineering who

take cares of site supervision during foundation & erection of

towers.

Supervisors We have about 15 Production supervisors with diploma in welding, cutting, lathe machine etc from ITI. Our supervisors looks after the mass production.

Technicians We have about 8 technicians diploma holders, who takes

cares after the maintenance of Machines, jigs & dies.

Skilled workers We have about team of 75 workers who works in two shifts in various activities like cutting, drilling, punching,

marking, grinding inspection of material, dispatch of material etc.

Marketing Department : A very focused, dynamic marketing team that understands the needs of each customers installations and advices on the project. This not only promotes the clients trust but also enables our continual partnering with each of them.

Designing Department : A full Fledged Computer based designing team engaged in tower designing & foundation of tower.