Bus Body Material Specification

Specification of the Bus Body material to be used for fabrication of Bus Bodies of P R T C
Patiala as per AIS : 052

Sr.No. Name of Item Specification

1 C.R.G.I. Pipe As Per ISI: 4923:1997 or latest.
2 CRERW Pipe As Per ISI: 3601: 1990 or latest.
3 M.S. Angle As Per ISI Specification No. IS: 2062.
4 G P Sheet As Per ISI Specification No. 277GR 120.
5 Alu Sheet, Alu. Chequered Alu Sheet Coil-As Per ISI specification No.
Plate AS8011H14 Alu Chequered Plate - As per
IS specification no. AA3105F
6 Bus Passenger Seat As per ISO & ARAI Approved specification
and drawings, specification of the material
used in seats will be as under:
PU Moulded Foam: As per ASTRU
Specification No. AS:329:70 Feb 2006. PU
moulded Foam should meet flammability
requirement as per IS 15061:2002
CRERW Pipe: As per ASTRU specification -
IS 3601:1990 PVC Foam Leather Cloth: As
per ASTRU specification AS:209: Type-A
Grade -I, Class -A
Orthopallic Fire Retardant Polyester Resin
:
AS6746:1994
For Miscellaneous items: As per prevalent
and existing specification as mentioned in
the drawing and specification
8 Front Wind screen Front Wind Screen Laminated as per IS:
laminated curved glass of 2553 (part2) -2008 or latest (50"x53")
'AA' quality curved and clear as per
drawings/Template. Gold plus/ Duratuf
make.
9 Roof Light Assy. Inverter and complete LED assembly
(24V)/AS:261:68 Dec-04 or ARAI
approved or latest/LED Light Assembly
24V
10 PVC Sleeve 3mm thick (Branded).
11 Fasteners AS per ASTRU Specification No.
AS:212:65: June 2003.
12 Chassis U Bolt AS per drawing, specification as per
ASTRU No.AS:166:65:june 2003 or latest.
13 Fire Extinguisher Two numbers of 6 kgs+4kgs fire
extinguisher shall comply with IS:13849 or
or IS : 2171 fitted in one number at last
two pass seat back side flooring and
another one fitted in driver cabin.
14 Thermocol Fire Retardant Density 12 kg./m3 Random Tolerance 6%
Sheet in thickness 21/2% in length & width. Other
specifications as per IS No. 4671.
15 L.T. Wire AS per ASTRU specification
AS:84/61/Oct.2000 for conductor.
16 Electric Welding Rod M.S. Welding Elect. Rod as per AWS 6013
3.15mm and 814:4211 Radiographic quality.
17 PU Paint As per the detailed specifications of PRTC
with LE system Paint
18 Tool Box Tool Box to be fitted inside at the front of
Driver seat.
19 Toe Hook Toe Hook (one) be fixed at the centre of
rear bumper be bolted with the chassis
cross bearer
20 Floor longitudes There will be five lengths of floor
longitudes of floor 10 x 75 x 10 section
10G, provided each and every joints of
floor chequered plates, each and every
step of seat legs and extra supports of
floor at the passenger standing area will
be provided.
21 To avoid Water leakage Top quality Sikka flux shall be provided
on the each and every joint of roof top
to prevent water leakage.
22 Foot board and Mud- Plane GI sheet 16G and extra Chequered
guards plates provided at the foot board and also
at the mud-guards
23 Convenience of the Provide PVC Grip handles (14 pcs per
passengers bus) along with rod for the convenience
of the passengers
24 Side Exterior Panelling 1. Stretch panel 1mm GP sheet
IS:277:1985 (up to latest)
2. Sole bar to skirt rail 1.1 GP sheet
IS:277:1985 (up to latest)
25 Roof Exterior Panelling Roof exterior panel shall be of 1 mm GP
sheet IS: 277 : 1985 (up to latest).
26 Interior Panelling Interior roof and side panel shall be done
with 0.50 mm GP sheet IS: 277 :1985
27 Interior Front roof tool FRP with 2 layers 350 csm Mat of FR grade
28 Interior Rear cover FRP with 2 layers 350 csm Mat of FR grade
29 Body Insulation Thermocol (F.R) of 50 mm packing in
between outside and inside paneling for
the insulation.
30 Flooring 3.15 mm chequered Aluminium sheet shall
be used.
31 Foot Board Fabricated with suitable MS structure with
35X35X3mm MS angle. Step will be
covered with 3.15 mm chequared
Aluminiuum. Rises of the steps and Side
portion to be covered with Aluminium
chequred plate with suitable
reinforcement. Yellow FRP angle 50mm
foot step beading to be provided. The
structure will be as per drawing attached.
32 Front FRP Two layers 450 GSM C.S. Mat and third
Layer of 650 CSM WR with overlaying
surface mat on the top roof for leak proof.
With approx. thickness of 8 mm. ( Material
used will be of FR grade ,viz, Resin of
Revex and Mat of owens cornering)

Reinforced with GI tubular Structure.

33 Rear of the Bus Strucre will be as per drawing attached
and cover with GP sheets.
34. Structure Platform The platform channel to be provided with
100X50mm ISMC MS channel. The MS
channel to be mounted on 8mm thick MS
plate over the 6mm Balatt. M.M. Base plate
of size minimum 150mmX150mmX8mm to
be welded to the M.S. channels at the
bottom. Diagonal holes or straight holes of
16mm diameter to be drilled for these base
plate for fitment of EN8 U Bolts. The main
cross bearer ends should be fully welded
with MS end plates of thickness 6mm on
either ends of the channel for mounting of
main and stump pillars. The platform
channels are to be provided without any
drilling on the chassis with heavy duty self
locking nylon nuts. The U bolts should not
 project more than 6mm above the nylon
nuts when fully tightened. Necessary
aluminum die cast packing and tubular
inter postings of specified dimensions be
provided while clamping the U bolts.
Wherever not possible to provide die cast,
6mm transmission belt alone can be used.
The platform channels should be spaced at
specified interval.

35 Structure details Drawings for RHS, LHS, Roof and floor are
attached herewithin.

Main Pillars Comprise of 50x50x2.60 mm

36 Passenger Dooors Exit & Entrance to be Jack and Knife

folding type door with heavy duty hinges
provided with suitable 50x25x2mm GI
frame with GP paneling and with locking
arrangement. The hinges are to be
provided as per drawing. Two point
mechanism to lock the door from the
inside. Passenger door structure spacing
beaded by rubber beeding . Door hinges
will be as per IS 13942:1994, as amended
from time to time.

Operating mechanism : Manual

Position and size of Doors: as per drawing

The service door(s) shall be situated on

the side of the vehicle that is nearer to the
side of the road corresponding to the
direction of traffic. This dimension shall be
reduced by 100 mm for single door when
the measurement is made at the level of
the hand holds A double service door shall
be counted as two doors. Guarding of
Stepwells Wherever a seated passenger is
likely to be thrown into a stepwell as a
result of heavy braking, a guard shall be
provided. The guard height shall be
minimum 800 mm from the floor, and the
guard shall extend inward from the wall at
least 100 mm more than the center line of
the seating position of the passenger who
is prone to this risk or upto the edge of the
riser of the innermost step, whichever is
higher in dimension. Access to Service
Doors Height and width as per drawing
Hand Rails and Hand Holds They shall be
designed and installed as to present no
risk of injury to passengers. (There shall
be no relative movement between the rail
and mounting bracket) Hand rails and
hand holds section dimensions shall be
such that the passengers can grasp them
easily and firmly. Hand rail length shall be
at least 100 mm to accommodate a hand
or this requirement shall be in accordance
with AIS-046, as amended from time to
time. Diameter of the section shall not be
less than 20 mm and not more than 45
mm. Or this requirement for the diameter
of the section shall be in accordance with
AIS-046, as amended from time to time,
for the specifications of hand holds.
The clearance between a hand rail or a
handhold and adjacent part of the vehicle
body or lateral wall shall be at least 40
mm. However in case of a handrail on a
door or seat a minimum clearance of 35
mm shall be permitted. The lateral
clearance shall be 150 mm minimum or
this requirement shall be in accordance
with AIS-046, as amended from time to
time. Handrails and /or handholds shall be
provided with sufficient number for each
point of the floor Area intended, for the
standing passengers. This requirement
shall be deemed to be full filled if at least
two handrails and/ or handholds can be
reached is inside the envelope inscribed by
the moving arm of the testing device. The
testing device is designed to rotate freely
about its vertical axis. Hand-rails
and handholds above 800 mm and not
 greater than 1900 mm shall be considered
to meet the above requirement. For every
position that can be occupied by a
standing passenger, at least one of the
two required. Areas which are occupied by
the standing passengers and are not
separated by seats from the side walls or
rear wall of the vehicle shall be provided
with at least two horizontal handrails
parallel to the walls Hand Rails and Hand
Holds for Service Doors Door
apertures shall be fitted with Hand Rails
and/or Hand Holds on each side. Handrails
and Handholds provided for service doors
shall be such that they include a grasping
point available to a person standing on the
ground and adjacent to the service door or
any of the successive door steps. Such
point shall be situated, vertically, between
800 to 1000mm above the ground or from
the surface of each step, and horizontally,
a) For position appropriate to the person
standing on the ground, not more than
400 mm inwards from the outer edge of
the first step, and b) For position
appropriate to the particular step not more
than 400 mm inward from the inboard
edge of that step and not outwards from
the outer edge of the step considered.
37 Driver Door Hinged type door – door to be provided on
the off side in the foremost front bay.
Frame with 50x25x2mm Tube structures
with GI paneling and suitable MS structure
for fixing heavy duty door locking as per IS
14225:1995 and sliding glass frame to be
used . Climb facility to be provided as per
drawing enclosed.
38 Battery Box Battery box provided in the right side body
at the near of front tyre with door (Heavy
duty door lock). And also fitted fixed
battery box frame. Covered with G.I.
sheets with proper ventilation. As per
drawing enclosed.
39 Stephaney Carrier box / Stephaney Carrier box provided in the left
Luagge box side body between the two doors (Heavy
duty door lock). Proper to be welded to
flooring channel.

Same can be replaced by luggae box

covered with GI sheets and single door .

Drawings are enclosed for both.

40 Tool Box Tools box provided with necessary locking
arrangement to be placed inside of bus
below the rear most seat. Leaving space
for fire Extinguisher.
41 Tool Box for Driver FRP moulded Tool box will be provide in
belongings front side of driver cabin as per drivers
requirement or on the left side of the
cabin.
42 Dashboard The dash board to be extended and
connected to the front end structure. The
dash board to be fabricated with
35X35X6mm MS angle and with other
structural members to the full width of the
body and upto the front end structure.
Dash board covered by FRP Doom as per
drawing enclosed. Dash board instruments
to be provided rigidly in the dash board. It
should be clearly viewed by driver.
Provision for water filling for radiator.
Meter board to be fitted on the dash board
with removal type property.
43 Route Board One route board on the front and one on
the rear as per AIS 052 norms
44 Grab rails With 1” ERW pipe 14G thick coverd with
PVC sleeve provided one single lines with
hanging grip handles. The distance
between ceiling and the pipe is minimum
40mm i.e handhold is 40mm
45 Side window Guard Rails Windows with sliding glass shall be fitted
with guard rails. Fitment of guard rails on
emergency windows is prohibited. The first
guard rail shall be provided at a height of
75 mm from the lower window sill. The
distance between two guard rails shall be
75 to 100 mm.with 19mm ERW pipe 14G
 thick painted and to be fixed outside of the
window – 2 rows in each side as per the
drawing enclosed.
46 Windows Window
Window is fixed by pasting and screws
Window Glazing.
The window glass shall be made of safety
glass as specified in IS 2553 Part 2 and
4mm thickness shall readily break on
impact when hit by a hammer in the event
of an accident.

Edges
The edge shall be crown edge, satin
finish for all the exposed edges that is
likely to come in touch with the passenger’
s body.).
Window Frames
Constructed from aluminum
extrusions coated sections. Alternately
directly, sliding on flocked rubber channels
supported by aluminum section.The
window frames shall be mounted such that
distortions and change of aperture
dimensions due to forces on the structure
does not deform the guideways. The
window glass/glass and frame shall slide
smoothly when subjected to normal pull
force (50 to 75N) .The window frame shall
be attached to the structure by bonded
with adhesive and additional screws
The mounting shall meet requirement
specified in BIS Standard- Window
retention and release system for Buses
Safety Requirement IS 13944-1994.
The window frame fitted on buses shall
meet the requirements specified in AIS-
068 as amended from time to time
however AIS-068 shall not be applicable
for pasted or fixed glass windows.

The Drawing of window frame is enclosed.

47 Electrification Electrification BIS marked copper
conductor with fire retardant as per IS/ISO
6722:2006 as per appropriate class

Front Head Lamps: 2nos each side head

lamps(total 4 nos) as per HLLD test
approved

Blinkers : On front & rear sides as per bus

code norms
Saloon Lightings : Quality led Tube light on
roof to be provided to meet PRTC
requirement

Tail Lamps: OEM fitted lamps

Head Marker Lamps: 2 nos. front, 2 nos.

at rear
Side marker lamps: each side as per AIS
052 specification

Battery Box: Underneath the

flooring(outside of the passenger saloon)

Fan: One fan in the driver cabin area for

driver comfort

Bus with Fitment of Destination Boards:

900mm at front top, 900mm at rear wind
screen glass as per AIS-052 code.

Speakers & Mic System: One mic & 2

speakers to be provided. (As per AIS 052)
48 Wiper Motor As Per AIS 052 approved
49 Horn As per AIS 052 single TT horn / OEM fitted
50 Driver Seat The driver seat supplied with chassis to be
modified for comforts to the driver with
adjustable type wire knitted/ loose covers.
51 First Aid Box One first aid box to be provided at driver
partition along with basic medicines. The
lid be provided with hasp and staple with
good quality lock and two keys. The box to
be provided with lettering and red cross
mark sticker.
 52 Conductor Ticket Box Provision to be given in the dashboard with
lock and key arrangement for keeping
conductor ticket.
53 Rear View Mirrors 2 Nos. Rear view Mirror supplied along
with the chassis to be provided.

The rear view mirrors shall meet the

requirements specified in AIS Standards
AIS-001 and AIS-002 as amended from
time to time
54 Mud Flaps 8 numbers Mud guard flaps with flaps 4
numbers to be provided with 18G GI sheet
pieces for full width of the wheels.
55 Seats As per AIS 023
56 Seat Layout Strictly as per AIS 052 / specially proposed
for PRTC , drawings are enclosed.
57 Cabin Luggae Rack Width from side wall : 360 mm(Min)
Height from roof : 260 mm( Min)

Hatracks made of ERW 19 mm tubes .

Photographs has been attached.
58 Driver Door Lock M/s Mobility Solutions Limited

Identification Mark : 600C0335-000-00.2

TAC No. CB00882

1. PRTC bus bodies will be fabricated strictly as per AIS: 052 norms and as per
approved parameters.
2. Front FRP .
3. Aluminium Chequered Sheet-3.15 mm tank.
4. Toughened Glass Clear Glass.
5. Luggage Carrier will not be provided ( AIS:052 doesnot allow RLC)
6. PVC handles shall be fitted on the top of each passenger seats.
7. Back of last six seats should be folding type so that it can be used as sleeper for
driver/conductor rest.
8. One 12 litre water tank (Rehbar) shall be provided in the Driver cabin.
9. Reflective tape: Front should be white, Rear should be Red and Sides should be
of Yellow colour (as per the CMVR).
10. Graphics:
a) Insignia at both sides.
 b) PRTC – Front & Rear wind screens.
c) Emergency Door, In & Out door.
11.One mirror shall be provided at the front of Driver seat inside the bus.
Fire extinguisher 2kg of ISI approved shall be fitted near the front seat at
suitable place.
11. All structure welding to be done with MIG welding / arc welding.
12. Top quality Sikka flux shall be provided on the each and every joint and each
rivets of roof top to prevent water leakage.
13. Shower test shall be done in the presence of PRTC inspection team.
14. There shall be no water leakage from the window frames.
15. Seat number shall be written.

Note: If there is any variation in specification and drawing of PRTC with AIS052 code
in dimension then the material will be used as per the approved code only.