Technical Specification of Rolling Shutter for ACDFS building

Design, fabrication, supply and fixing of extruded aluminum alloy rolling shutters
with side one operator drive unit and Direct drive option, confirming to IS 6248
(1979) . Extrusion for the components of rolling shutters shall be conforming to
53000 (NE5) or 64430 (HE30) of IS: 733.
A. Scope of supply
a) The scope supply includes Design, fabrication, supply unloading and
fixing of extruded aluminum alloy rolling shutter, including all general
accessories/components .It also include control and safety equipment for
proper functioning of rolling shutter ensuring safety of operator & shutter.
b) It also includes all the work related to unloading and installation of shutter,
including civil, mechanical, electrical & other allied Works, if any.
c) Supplier shall make the arrangement to bring the consignment at the
installation location.
d) C-channel / Support / Hydra (if required) for installation will be in the
supplier’s scope & ladder / scaffolding (if required) for installation at their
expense.
e) Further, if due to storage at site / warehouse for prolonged periods, the
refurbishment from the weather deterioration like rust removal, re-painting
etc. will be in supplier’s account.
f) Client shall provide a stabilized, uninterrupted power supply with a voltage
stabilizer / spike buster to the automation system.
g) During the period of installation, any shortage of material due to pilferage,
misplacement etc. at site would be in client’s account.
h) Cables, Conduit & Cable trays required for installation of accessories will be
supplied & laid by the supplier.
i) Supplier may visit RRCAT to see the site location and work involved, before
 submission of quotation.
B. Work in the scope of RRCAT
RRCAT will provide
1. Safe storage of rolling shutter on the site until installation will be in the
client’s scope.
2. Electrical wiring for providing single / three-phase AC supply through a
separate MCB up to point of installation will be done by the RRCAT.
C. Codes, Documents and relevant standards
S. No. Applicable code Description
01 IS 733 Codes and standard for aluminum alloy extrusions
02 EN 13241-1 Codes and standard for safety brake and limit switch
03 IS 6248 (1979) Code and standard for metal rolling shutter and
rolling grills

D. Bidder’s qualification
a) The quotations are invited and accepted only from ISO 9001-2008 certified
reputed rolling shutter manufacturers not from dealers or traders.
b) The bidders should provide satisfactory evidence, acceptable to the
Purchaser, to prove that they are licensed manufacturer and possess adequate
plant and manufacturing capacity/facilities. They should furnish a statement
that they have manufactured and supplied 5nos. of metal rolling shutter
fabricated from steel/aluminum of similar or higher size supplied by him
during the last 5 years. Bidder should also provide information along with
quotations regarding, Purchaser’s name and address, order number, date and
quantity supplied, also their comments on their performance, also statement
regarding the supplies that it was made within the delivery period etc.
c) In the absence of the above information, the offer is liable to be rejected.
 Purchaser reserves right to evaluate bidder’s fabrication facility, to see its
competence for this work.
E. Size of rolling shutters
S.No. Clear Width (approx.) Clear Height (approx.) Quantity
01 4500 mm 6900 mm 01 No.
02 4100 mm 4320 mm 01 No.

Before starting the production of the shutter, fabricator or his representative will
visit the site to RRCAT, and physically take the dimensions of the available clear
opening for the shutter
F. Fabrication requirements of the rolling shutter
1. Curtain
This shall be built up from interlocking lath sections of aluminum alloy
conforming to 53000 (NE5) or 64430 (HE30) of IS: 733. The lath sections shall be
from 18 gauge (1.25 mm) section with 78mm Profile Height for curtains The lath
section shall be rolled so as to have interlocking curls at both edges and a deep
corrugation at the centre with a bridge depth of 16 mm to provide sufficient curtain
stiffness for resisting manual pressure and normal wind pressure. Each lath section
shall be continuous single piece without any welded joint. When interlocked, the
lath section shall have a distance of 75 mm between rolling centres. Each alternate
lath section shall be fitted with a malleable cast iron or mild steel clips securely
riveted at either end, thus locking the lath section at both ends and preventing
lateral movement of the individual lath sections. The clips shall be so designed as
to fit the contour of the lath sections. Bottom Profile shall be Bend-resistant
double-skinned extruded Aluminum profile for additional strength. The bottom rail
shall be fitted with extruded rubber bottom seal that should be suitable to seal
against the floor when the door is fully closed.
 2. Lock Plate
The Lock Plate provided at the bottom of the shutter, shall be composed of a mild
steel plate 3.15 mm thick, reinforced with mild steel angle 35 x 35 x 5 mm at
bottom of the plate. The lock plate shall be fitted with sliding bolts at either end to
engage with suitable receiving pockets at the bottom of the guide channel. The
sliding bolts shall be capable of being locked by means of padlocks both from
outside and inside. The lock plate shall also be provided with pulling handles, one
handle for 2.5 m width and 2 handles for widths above 2.5 m. Pulling handles shall
be fixed on both inside and outside faces of the lock plate.
3. Guide Channels
These shall be of mild steel deep channel section of rolled, pressed or built up
(fabricated) construction. The thickness of the sheet used shall not be less than 3.15
mm. The depth of the guide should be such that there is sufficient clearance
between curtain and inner surface of guide. The curtain shall project into the guide
at least 40 mm for shutters up to 3.5 m width and 60 mm for greater widths. There
shall be a clearance of 10 mm between guide wall and the end clips of the curtain.
Where the shutter is installed in heavy windy zones, special wind locking
arrangements shall be provided to prevent the curtain coming out of the guide. The
clear gap on either side of the curtain and inner faces of the guide channel shall be
5 mm. The depth and width of the guide channel shall be as follows: Clear Width
of Depth of Guide Channel shall be 75 mm. Width of Guide Channel shall be 25
mm for lath sections with bridge depth of about 12 mm and 32 mm for lath
sections with bridge depth of 16 mm.
4. Fixing Cleats
Each guide shall have a minimum of 3 fixing cleats. The spacing of cleats shall not
exceed 0.75 m. Alternatively, the guide channels may also be provided with
suitable dowels hooks or pins for embedding in the walls. The guide channel shall
be attached to the wall plumb and true.
5. Bracket Plate
This shall be fabricated out of mild steel plate of 3.15 mm thick. Thicker plates
may be used depending upon the height of the shutter. Dimensions shall be as
given in IS: 6248. The bracket plate may be square, circular or hexagonal with a
U-shaped cast iron or mild steel clamp riveted or welded to it at the centre. The
bracket plate should have sufficient cross sectional area to resist the shear arising
out of the weight of the curtain, suspension shaft etc. and shall be held rigidly by
suitable foundation bolts.
6. Roller
The suspension shaft of the roller shall be made of steel pipe conforming to heavy
duty of IS: 1161. The diameter shall be sufficient to limit deflection of shaft under
the weight of the rolling shutter. The deflection of the shaft shall not exceed 5 mm
per metre width of the shutter. Diameters of the steel pipe shall be suitably selected
and shall be as per IS: 6248. Sizing of pipe diameter for greater widths and heights
shall be designed giving due consideration for deflection limit mentioned above.
The pipes of the suspension shaft which are clamped to the brackets shall be fitted
with rotatable cast iron pulleys to which the curtain is attached. The pulleys and the
pipe shaft shall be connected by means of pretensioned helical springs to
counterbalance the weight of the curtain and to keep the shutter in equilibrium in
any partly opened position.
7. Hood Covers
These shall be made of mild steel sheets not less than 0.9 mm thick, and shall be
hexagonal, square or circular contour depending on the contour of the bracket
plate. The hood cover shall be stiffened with angle or flat stiffeners at top and
bottom edges to retain shape. The hood cover shall be fixed to the bracket plate by
means of angle cleats. The hood cover shall also be supported all along the top at
suitable intervals to prevent sagging.
8. Central Hasp and Staple
This shall be provided at the centre of the bottom lock plate. The hasp shall be
embedded in the floor at the centre. The staple shall be fitted at the centre of the
bottom lock plate outside in an accurate position so that the hasp may properly
engage with staple when the shutter is in a closed position. The hasp shall be
embedded within the floor so as not to cause any obstruction. Normally one central
hasp and outside staple will be sufficient for any width of shutter.
G. Operation requirement of the rolling shutter
1. Operation of lock plate
Push Pull Type shall be operated manually by pulling hooks with appropriate
pulling handles in the lock plate. The length of the pulling handle shall be
sufficient to push the lock plate up to the top most position.
2. Electrically Operated Side one operated drive unit type
These shall be operated by an electric motor operating on 400/440V3 phase 50
cycles A.C. supply with CE Certified Side One Operated Drive Unit with Direct
drive option, This unit shall be in accordance to the EEC standards EN 12453, as
plug-on drive unit System, power supply wired with industrial plug, push button
integrated in the housing lid Safety mechanism It should have provision for an
integrated safety brake and double circuit limit switch which comply with the EN
13241-1 standards. Control Switch shall have provision for three station push
button with Deadman control feature which allows shutter to move as long as the
operating button is being pressed. The motor shall have a push button control,
with a minimum of 3 buttons marked “Up”, “Down” and “Stop”. Limit switches
shall also be provided to cut off current to the motor when the shutter reaches the
limit of its travel in the “Up” or “Down” directions. Along with this, provision for
Wireless remote operation for shutter operation is also required. This remote will
operate the shutter and will also be used for switching ON/OFF for two 250 W
Metal Halide luminaries, These metal Halide luminaries will be fixed at the
suitable position, near the cover hood of the rolling shutter. This Wireless remote
control shall be able to operate within 100 meters range. The wireless remote
control transmitter shall be impact resistant. The receiver of remote control may
be fixed at any suitable position. The remote transmitter, should be powered with
rechargeable batteries.
Preferred make - Stromag / Siemens /ABB make.
One spare remote transmitter and two nos. of spare batteries along with charger
shall be supplied with the shutter should be supplied with the shutter.
Arrangements shall also be made for emergency mechanical operation of the
rolling shutter in the event of failure of the electric equipment or electricity. The
emergency mechanical operation shall be by an auxiliary chain wheel drive.
3. Rolling Shutter cum Grill
These shall be provision of small grill be of about 500 mm. somewhere in top 1/4
th portion of rolling shutter for ventilation and safety point of view as specified in
the drawing (for item no.1).
4. Ease of Maintenance.
The rolling shutter should be so designed and constructed that normal adjustments,
repair and overhaul can be readily accomplished by means of general purpose tools
with a minimum removal or disturbance of other elements of the rolling shutter.
Ease of maintenance provisions shall ensure operating clearances for facilitating
maintenance and servicing. Lubrication fittings shall be accessible without the
removal or adjustment of accessories or parts.
 5. Safety
All rotating/reciprocating parts, and all parts subject to high operational
temperatures, that should be of such a nature or so located to be or become a
hazard to the safety of the operating personnel and shall be insulated, enclosed or
guarded to the extent necessary to eliminate the hazard.
4. Anodizing of shutter curtain
All aluminum components and curtain of rolling shutter shall be colored anodized
or suitably painted. Similarly all steel parts shall have two coats of approved epoxy
finish paint. Painting work on steel parts shall be applied after installation. Painting
of shutter curtain or any other sub assembly of the shutter, which got damaged
during transportation or installation work shall be rectified with matching color,
quality and painting scheme.
H. Marking
Each shutter shall be clearly and legibly marked with the following information:
i. Manufacturer’s Name or Trade Mark
ii. Size
iii. Year of Manufacture.
I. Spares/Additional Accessories
Spares/Additional Accessories of the rolling shutter should be quoted separately.
Procurement of spare is not added in this indent, but the list of required spares and
its price can be used as reference for future procurement.
 Guaranteed technical parameters
(Technical data sheet to be submitted by the bidder along with the quotation)
S. Technical parameters Bidder to confirm with specified values Remark,
No wherever applicable if any

01 Extrusion for the components of rolling shutters shall be conforming to

53000 (NE5) or 64430 (HE30) of IS: 733.

02 C-channel / Support / Hydra (if required) for installation will be in the

supplier’s scope & ladder / scaffolding (if required) for installation at
their expense.

03 Offer confirms all Codes, Documents and relevant standards specified

in the specification

04 The lath sections of shutter curtain shall be from 18 gauge (1.25 mm)
section with 78 mm Profile Height for curtains

05 The bottom rail shall be fitted with extruded rubber bottom seal

06 Shutter guide channels shall be mild steel deep channel section of

rolled, pressed or built up (fabricated) construction. The thickness of
the sheet used shall not be less than 3.15 mm.

07 Each shutter guide shall have sufficient no. of fixing cleats

08 The suspension shaft of the roller shall be made of heavy duty steel
pipe.

09 The deflection of the shutter suspension shaft shall not exceed 5 mm

per meter foe the size of the specified shutter.
10 Shutter hood covers shall be made of mild steel sheets, not less than
0.9 mm thick

11 Shutter shall have direct drive inline electrically operated drive unit
located at Side one only

12 Shutter direct drive unit shall be in accordance to the EEC standards EN

12453

13 Shutter direct drive unit shall have provision for all safety features,
specified in the specification

14 Shutter direct drive unit shall have provision for wireless remote
operation along with conventional push button control

15 Shutter shall have arrangements for emergency mechanical operation,

in the event of failure of the electric equipment or electricity. This
emergency mechanical operation shall be by an auxiliary chain wheel
drive mechanism.

16 Please also provide information about orders for the fabrication and
installation of aluminum shutter executed by the company within last
five years.

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