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FOR THE YEAR : 2018-19

CONTENTS PAGES

REFERENCE DATA 1 -- 3

NOTES ON BASIC RATES 4 -- 4

DATA FOR SCHEDULE OF RATES 5 -- 179

ANNEXURE-1 ( Data for Enabling works ) 180 -- 186

ANNEXURE-2 ( Details of Materials / Cutting / Welding ) 187 -- 258

CHAPTER - WRD: 7

WATER RESOURCES DEPARTMENT

SCHEDULE OF RATES

zÀgÀ¥ÀnÖ ¸À«Äw¬ÄAzÀ ¥ÀjµÀÌj¸À®ànÖzÉREVISED BY SCHEDULE OF RATES COMMITTEE

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GATE / HOIST AND ALLIED WORKS


FOR THE YEAR : 2018-19

COST OF MATERIALS :1 Acytelene gas per cum `: 404.002 Alloy steel ( Corbon steel : IS : 1570 ) Shafts per kg `: 280.003 Alloy steel ( Stainless steel : IS : 1570 ) Pins per kg `: 345.004 Bolt / Nut / Washer ( hot dipped galvanized ) per kg `: 108.005 Bolt / Nut / Washer ( mild steel ) per kg `: 90.006 Bolt / Nut / Washer ( stainless steel ) per kg `: 182.007 Bronze / Alluminium alloy ( IS : 305 ) Bearings / Bushes per kg `: 810.008 Cast iron blocks per kg `: 54.009 Cast steel Drums / Gears per kg `: 190.00

10 Cast steel Pinions per kg `: 190.0011 Cast steel Wheels / Pulleys / Hubs / Rollers / Retainers per kg `: 155.0012 Chequered plate per kg `: 41.5213 Coaltar epoxy paint per ltr `: 226.0014 Degreasing / derusting / phasphate coating chemical per ltr `: 311.0015 Forged steel Hooks / Shackles per kg `: 210.0016 Gas cutting set ( 2 Nos 15 m hose and nozzle unit ) `: 2250.0017 Grease per kg `: 233.0018 MS pipe 300 mm dia per kg `: 63.0019 MS pipe 32 mm dia per Rm `: 208.0020 Oxygen gas per cum `: 84.0021 Rails 45 kg / m per tonne `: 47458.0022 Rubber bottom seal ( flat type ) IS : 11855 per Rm `: 219.0023 Rubber corner seal ( music note teflon claded ) IS : 11855 per Rm `: 1158.0024 Rubber corner seal ( music note uncladed ) IS : 11855 per Rm `: 441.0025 Rubber side seal ( music note teflon claded ) IS : 11855 per Rm `: 1049.0026 Rubber side seal ( music note uncladed ) IS : 11855 per Rm `: 368.0027 Rubber side seal ( Z - type ) IS : 11855 per Rm `: 411.0028 Stainless steel plate / flats per kg `: 231.0029 Steel wire rope 6x37 construction per kg `: 163.0030 Structural steel angle / channel / beam / bars per kg `: 39.5531 Structural steel plate / flats per kg `: 39.5532 Synthetic enamel paint ( 1st quality ) per ltr `: 233.0033 Welding electrodes 4 mm x 450 mm ( general purpose ) per No. `: 10.0034 Welding electrodes 4 mm x 450 mm ( low hydrogen ) / No. `: 21.0035 Welding electrodes 4 mm x 450 mm ( stainless steel ) per No. `: 62.0036 Welding holder set ( cable / holder / gloves / mask etc ) per set `: 6750.0037 Wire brush per Each `: 53.0038 Zinc per kg `: 222.0039 Zinc rich ( zinc content : 85 % ) epoxy primer paint per ltr `: 244.0040 Zinc chromate red oxide primer per ltr `: 139.00

LEAD, LOADING & UNLOADING CHARGES: Unloading1 Steel per tonne `: 78.80 139.70 139.70

1 km lead Loading

GATE / HOIST AND ALLIED WORKS -- REFERENCE DATA

1


HIRE CHARGES OF MACHINERY: Crew charge1 Bending machine per hour `: 26.00 111.00 131.002 Diesel generating set 50 kVA per hour `: 69.00 1139.00 134.003 Grinder per hour `: 13.00 37.00 164.004 Mobile crane 8 t ( pick & carry ) per hour `: 289.00 854.00 231.005 Mobile crane 25 t ( revolving ) per hour `: 2623.00 2372.00 222.006 Planing machine per hour `: 58.00 111.00 210.007 Plate shearing machine per hour `: 41.00 148.00 131.008 Pug cutting machine per hour `: 11.00 4.00 ---9 Stationery Derric crane ( revolving ) per hour `: 44.00 12.00 ---

10 Tower crane 5 tonne per hour `: 660.00 192.00 178.0011 Transformer 250 kVA per month `: 2301.00 --- ---12 Upright / Hand drilling machine per hour `: 13.00 37.00 164.0013 Welding transformer per hour `: 8.00 89.00 ---

WAGES OF WORKERS: Per day1 Electrician `: 436.002 Foreman `: 436.003 Gas cutter `: 436.004 Heavy mazdoor `: 411.005 Helper fabrication / erection `: 421.006 Khalasi `: 436.007 Marker / Erector / Fabricator / Machanic `: 436.008 Painter Class-II `: 421.009 Welder ( General ) `: 436.00

10 Welder ( X-ray quality ) ( 10 % extra over Welder ) `: 479.60

ELECTRIC SUB-STATION MATERIALS:1 RCC Pole 8m length (145kg/WL) including earth work, erection etc., `: 5125.002 Flood light 250/450 W ( HPMH/HPSodium vapour lamp ) `: 762.003 Flood light luminaire set (250W HPMH/HPSV with control gear box) `: 4876.004 Fluoscent tube light ( 2'/4'-36/40W) `: 34.005 Fluoscent tube light set ( Patti type with electronic ballast 1 x 4'-28W) `: 473.006 Moulded case Circuit breaker (four pole 700-800Amps 50kA) `: 35262.007 HT/LT Rabbit Conductor (6/3.15mm AI+6/3.15mm steel) `: 39831.008 PVC Armoured cable 10 sqmm and below (4 core-1.1KV LTUG cable) `: 101.009 PVC Armoured cable 16 sqmm (4 core-1.1KV LTUG cable) `: 119.00

10 PVC Armoured cable 25 sqmm (3.5 core-1.1KV LTUG cable) `: 140.0011 PVC Armoured cable 70 sqmm (3.5 core-1.1KV LTUG cable) `: 229.00

Hire charge Fuel charge

2


OTHER DATA :1 Contractor's Overheads on Materials / Machinery / Labour % 5.002 Contractor's Profit on Materials / Fuel & Energy charges / Labour % 10.003 Demand charges per kVA / month `: 216.004 Electric power kWhr 8.245 Excise duty on cost of supplies % 0.006 Insurance charges on gate / hoist parts % on cost 1.007 Interest on average capital cost % / annum 9.008 Hidden cost on Labour % 15.00

Hidden cost on Labour ( additional for Gate / Hoist works ) % 15.009 Small Tools & Plant on Materials / Machinery / Labour % 1.00

10 Sundries ( Lump sum rate for unquantified inputs ) `: 45.0011 Cost of Power supply arrangements ( Annexure-1.a ) % 2.3012 Cost of Other enabling works ( Annexure-1.b ) % 1.30

3


NOTES ON SCHEDULE OF RATES GATE / HOIST AND ALLIED WORKS FOR THE YEAR : 2018-19

1. All notes under ' General Notes on Schedule of Rates ' are applicable to ' Gate / Hoist and Allied Works ' also to the extent they are relevant.

2. All materials / bought out components for embedded parts, gates, hoists and allied worksshall conform to relevant Indian standards / technical specifications and approved drawings.

3. The basic rates are inclusive of preparation of designs / drawings / material schedules etc., as per specifications and other technical data including revisions.

4. The basic rates are inclusive of cost of all materials, machinery, labour, fabrication, erection,commissioning and testing of gates, hoists and other related components as per technicalspecifications.

5. The basic rates are inclusive of taxes, duties, levies and all other incidental charges exceptsales tax on works contract. Separate provision shall be made in the estimate towards salestax on works contract at the rate prevailing at the time of preparation of estimate.

6. The basic rates are inclusive of rehandling at fabrication and erection sites.

7.a. The basic rates are inclusive of 1 km lead and all lifts for structural steel and all leads and lifts for other materials. For working out additional lead charges for structural steel 1 km leadincluded in basic rate shall be deducted from total lead. The quantity of structural steelfor working out additional lead, loading and un-loading charges shall be as per Note: 2 undereach item.

7.b. The basic rates are inclusive of 3 percent provision towards cost of packing, forwarding andtransportation of all materials other than structural steel from their source of supply upto work site. No lead charges shall be added for materials other than structural steel.

8. Unless otherwise specified the basic rates are inclusive of standard finish required for all thefabricated and bought out gate and hoist components.

9. The basic rates are inclusive of preparatory works such as rectification of damages, repairingshop painting, cleaning, positioning and anchoring first stage embedments, cleaning surfacefor field painting etc.

10. The basic rates are exclusive of cost of river diversion arrangements, dewatering, desilting etc.

11. Unless otherwise specified the basic rates for items are on per tonne basis. The rate per setor per number shall be worked out on the basis of rate per tonne and the tonnage computedas per detailed designs / empirical formulae furnished in the ' Note ' under each item.

12. Minimum dry film thickness for zinc rich epoxy primer paint and coal tar epoxy paint shall be40 microns per coat and 100 microns per coat respectively.

4


SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2018-19 ITEM No: WRD: 7.1

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sillbeam, wall plates, seal seats, anchors, anchor girders, yoke girders, tie flats, trunnion supports, rope and pulley supports etc., with all accessories for spillway radial gates including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Embedded parts for radial gate consist of sill beam / wall plates / anchor girders / yoke girders /tie flats / trunnion supports etc., with all accessories. The weight of embedded parts for radialgate will be generally at about 25 to 30 percent of weight of radial gate leaf.Consider embedded parts for radial gate for spillway opening of size 15 m x 9 m at crest.Size of gate for 15 x 9 m opening at crest with gate sill on d /s 0.6 m below crest level.Length of gate : 15 m Head of water at sill level : 9.60 m Height of gate : 9.75 mWeight of radial gate leaf in tonne with end shield and hood based on empirical formula :

Weight of radial gate in tonnes = 0.0710 x ( L 2 x H x h ) 0.673

Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.Consider weight of embedded parts in tonnes @ 25% of weight of radial gate.

= 0.25 x 0.710 x ( L 2 x H x h ) 0.673

= 0.0177 x ( 15 x 15 x 9.75 x 9.6 ) 0.673 : 14.377The weight computed as above based on empirical formula is further checked by computing theactual weight as per embedded parts fabrication drawings for gate of same size provided for oneof the dam work.Actual weight of embedded parts as per data in Item :1 of Annexure-2 : 14.334 tonnesConsider actual weight of embedded parts for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of embeddedparts for radial gate provided for one of the dam having 15 m x 9 m spillway opening at crest forrate analysis ( for details refer Item :1 of Annexure-2 ).

1. Requirement of materials : a. Structural steel conforming to IS : 2062 :

Angles / beams / channels / bars with 2.5 % wastage ( 679x1.025) : 696 kgPlates / flats with 2.5 % wastage ( 13356 x 1.025 ) : 13690 kg

b. Alloy steel conforming to IS : 1570 :Stainless steel plates / flats with 2.5 % wastage ( 190 x 1.025 ) : 195.00 kg

c. Bolt / Nut / Washer conforming to IS : 1363 :MS bolts / nuts with 2.5 % wastage ( 109 x 1.025 ) : 112 kg

d. Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) :GP / LH electrodes as per data sheet ( Item:1 Annexure-2 ) : 7539 NosAdd for variations / wastage / misc welding @ 10 % ( 7539 x 0.1 ) : 754 NosTotal requirement of GP / LH electrodes : 8293 Nos for stitch welding GP electrodes @t 10 % of total ( 8293 x 0.10 ) : 829 Nos for run welding LH electrodes @ 90 % of total ( 8293 x 0.90 ) : 7464 NosStainless steel electrodes as per data sheet ( Item:1 Annexure-2 ) : 876 Nos

5

GATE / HOIST AND ALLIED WORKS - DATA RATES


Add for variations / wastage @ 5 % ( 876 x 0.05 ) : 44 NosTotal requirement of Stainless steel ( SS ) electrodes : 920 Nos for stitch welding SS electrodes @t 10 % of total ( 920 x 0.10 ) : 92 Nos for run welding SS electrodes @t 90 % of total ( 920 x 0.90 ) : 828 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides as per data sheet : 428 RmAdd for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 43 Rm

Total : 471 Rm

For cutting structural steel sections to required size gas cutting is assumed for cutting angles /beams / channels / round bars. For plates / flats less than 12 mm in thickness plate shearing machine and for the remaining sections pug cutting machine is considered.

Length of steel to be cut by using gas manually : 60 mLength of steel to be cut by gas using pug cutting machine : 371 mLength of steel to be cut by using plate shearing machine : 40 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 30 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 124 hoursTime for cutting by shearing machine at ( av ) 10 m cutting / hour : 4 hoursAcetelyne gas @ 0.6 cum / hour ( 30 + 124 ) x 0.60 : 93 cumOxygen gas @ 1.8 cum / hour ( 30 + 124 ) x 1.80 : 279 cumUse of gas cutting torch with 50 min / hour working ( 30 x 60 / 50 ) : 36 hoursUse of pug cutting machine with 50 min/hr working ( 124 x 60 / 50 ) : 149 hoursUse of shearing machine with 50 min / hour working ( 4 x 60 / 50 ) : 5 hours

3. Welding :Length of welding as per data sheet : 600 mFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 829 + 92 ) x 8 / 15 / 2 : 246 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 7464 + 828 ) x 8 / 15 / 6 : 737 hoursTotal : 983 hours

Deploy welding transformer for 983 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 246 x 0.25 + 737 x 0.75 ) : 614 hours 4. Planing SS plates for seal seats :

For surface finishing of stainless steel plates for seal seats planing machine is considered.Length of SS plate for surface finishing by planing machine : 56 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 56 m SS plates ( 56 x 8 / 3 ) : 150 hours

5. Surface cleaning and painting :Painting area for embedded parts at 10 sqm / tonne ( 14.33 x 10 ) : 143 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 143 sqm @ 9 sqm / ltr / coat : 16 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 143 sqm @ 6 sqm / ltr / coat : 96 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 143 sqm @ 8 sqm / ltr : 18 ltr

6


6. Requirement of other machinery :Hiring of tower crane for 4 hours considered for handling yoke / anchor girder parts from river bed to pier / abutment at trunnion level.For drilling holes for anchor bolts and for grinding surface / edges of parts requiring finishing 8 hours use of drilling machine and 24 hours grinding machine considered.For handling of parts during fabrication and erection use of 8 t mobile crane for 32 hours and stationery derric crane for 64 hours considered.

7. Requirement of work force :Work component Foreman Helper /

Painter Cl-II

Cutting sections 190 hours 12 48Drilling holes for anchors / supports 2 4Fabricating by stitch welding 246 hours 15 62Run welding 737 hours 9 92Erection of Anchor / Yoke girders 13 52Erection of tie flats( anchor bars ) 2 4Erection of first stage anchors 5 20Erection of Sill beam / Wall plates 3 12Cleaning surface 143 sqm @ 15 sqm/day --- 10Painting ( 5 x 143 ) sqm @ 15 sqm / day --- 56Finishing / cleaning / checking 5 10 Total : 66 370

Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.b. Workforce for painting 1 coat primer and 4 coats finishing paint consists of 48 Painters Cl-II at 15 sqm / day and 8 helpers to assist painters.

8. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes / duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.

9. Use rate of materials :Cost of welding set @ `: 6750.00 / Each `: 6750.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) `: 6.75Cost of gas cutting set @ `: 2250.00 / Each `: 2250.00Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) `: 3.75

RATE ANALYSIS UNIT : 14.334 tonneA. MATERIALS: Sl No Unit Amount

in `:1 Structural steel

Angles / beams / channels / bars kg 696.00 39.55 27524.71Plates / flats kg 13690.00 39.55 541398.43

2 Stainless steel plate / flats kg 195.00 231.00 45045.003 MS bolts and nuts kg 112.00 90.00 10080.004 Oxygen gas cum 279.00 84.00 23436.00

Contd

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116115

---

Perticulars

26

10

4---

Quantity Rate

------

10 ---

---6 ---

9231---

24------

24Erector /

Gas cutter / Marker /

4

---

Fabricator / Welder

in `:

7


A. MATERIALS ( Contd ) : Sl No Unit Amount

in `:Contd

5 Acetyline gas cum 93.00 404.00 37572.006 Welding electrodes ( general purpose ) Nos 829.00 10.00 8290.007 Welding electrodes ( low hydrogen ) Nos 7464.00 21.00 156744.008 Welding electrodes ( stainless steel ) Nos 920.00 62.00 57040.009 Zinc rich epoxy primer ltr 16.00 244.00 3904.00

10 Coal tar epoxy paint ltr 96.00 226.00 21696.0011 Rust cleaner / inhibitor ltr 18.00 311.00 5598.0012 Wire brush Nos 2.00 53.00 106.0013 Use rate welding holder set Hour 983.00 6.75 6635.2514 Use rate gas cutting torch set Hour 36.00 3.75 135.0015 Sundries LS 250.00 45.00 11250.00

Total `: 956454.39Add for small Tools and Plants @ 1% `: 9564.54Add for Contractor's Profit @ 10% `: 95645.44Add for Contractor's Overheads @ 5% `: 47822.72

Total cost of Materials : `: 1109487.09

B. MACHINERY: Sl No Unit Amount

in `:1 Welding transformer Hour 983.00 8.00 7864.00

Fuel / Energy charges Hour 614.00 89.00 54646.002 Tower crane Hour 4.00 660.00 2640.00

Fuel / Energy charges Hour 4.00 192.00 768.003 Plate shearing machine Hour 5.00 41.00 205.00

Fuel / Energy charges Hour 5.00 148.00 740.004 Pug cutting machine Hour 149.00 5.00 745.00

Fuel / Energy charges Hour 149.00 4.00 596.005 Mobile crane 8 t Hour 32.00 289.00 9248.00

Fuel / Energy charges Hour 32.00 854.00 27328.006 Stationery derric crane Hour 64.00 44.00 2816.00

Fuel / Energy charges Hour 64.00 12.00 768.007 Grinding machine Hour 24.00 13.00 312.00

Fuel / Energy charges Hour 24.00 37.00 888.008 Drilling machines Hour 8.00 13.00 104.00

Fuel / Energy charges Hour 8.00 37.00 296.009 Planing machine Hour 150.00 58.00 8700.00

Fuel / Energy charges Hour 150.00 111.00 16650.0010 Sundries LS 200.00 45.00 9000.00

Total `: 144314.00Add for small Tools and Plants @ 1% `: 1443.14Add for Contractor's Profit on DPOL / Energy @ 10% `: 11168.00Add for Contractor's Overheads @ 5% `: 7215.70

Total hire charges of Machinery : `: 164140.84

Rate

Rate

in `:

in `:

8

Description Quantity

Perticulars Quantity


C. LABOUR: Sl No Unit Amount

in `:1 Crew for Tower crane Hour 4.00 178.00 712.002 Crew for Mobile crane Hour 32.00 231.00 7392.003 Crew for Shearing machine Hour 5.00 131.00 655.004 Crew for Planing machine Hour 150.00 210.00 31500.005 Crew for Drilling machine Hour 8.00 164.00 1312.006 Crew for Grinding machine Hour 24.00 164.00 3936.007 Foreman Day 66.00 436.00 28776.008 Marker / Fabricator / Erector Day 115.00 436.00 50140.009 Gas cutter Day 24.00 436.00 10464.00

10 Welder ( General ) Day 83.00 436.00 36188.0011 Welder ( X - ray ) Day 9.00 479.60 4316.4012 Khalasi Day 65.00 436.00 28340.0013 Helper fabrication / erection Day 304.00 421.00 127984.0014 Helper for cleaning / painting Day 18.00 421.00 7578.0015 Painter Cl - II Day 48.00 421.00 20208.0016 Electrician Day 5.00 436.00 2180.00

Total `: 361681.40Add for small Tools and Plants @ 1% `: 3616.81Add for Contractor's Profit @ 10% `: 36168.14Add for hidden cost on Labour @ 15% `: 54252.21Add for additional hidden cost on labour @ 15% `: 54252.21Add for Contractor's Overheads @ 5% `: 18084.07

Total cost of Labour : `: 528054.84

ABSTRACT:A. Cost of Materials `: 1109487.09B. Hire charges of Machinery `: 164140.84C. Cost of Labour `: 528054.84

TOTAL `: 1801682.78Add for excise duty on 75 percent cost of Machinery / Labour components @ 0.00% `: 0.00Add for insurance charges @ 1.00% `: 18016.83Add for designs and drawings @ 2.50% `: 45042.07Add for zigs / supports / winches / chain-pulley @ 2.50% `: 45042.07Add for stress relieving of anchor girders @ 1.50% `: 27025.24Add for power supply arrangements @ 2.30% `: 41438.70Add for enabling works @ 1.30% `: 23421.88

Total `: 2001669.57Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x14.334 tonnes @ `: 358.20 / tonne `: 10268.88Add for packing, forwarding and transportation upto work site on cost of materials other than structural steel ( on cost of Sl No. 2 to 12 ) @ 3.00% `: 11085.33 Total cost for 14.334 tonne `: 2011938.44

Rate per tonne `: 140361.27Rate approved per tonne `: 140400.00

Ratein `:

QuantityDescription

9



ITEM: Design, fabrication, supply, erection, testing and commissioning of radial gate consistingof skin plate, stiffeners, horizontal girders, sector arms, trunnion assemblies, tie beam, pulleysupports, bracings, rubber seals, clamps etc., with all accessories for spillway including cost of all materials, machinery, labour, cutting, bending, aligning, anchoring, welding, finishing,cleaning, applying one coat of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with leadupto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Spillway radial gate consists of trunnions / sector arms / horizontal girders / Tee- supports / skin plate / tie beam / bracings for horizontal girders and sector arms / pulley blocks / seals /end shields etc., with all accessories.Sector arms are connected to trunions by bolts and nuts with zinc padding in between.Horizontal girders generally spaced at about 3 m apart are joined to sector arms by welding andare stiffened by vertical and diagonal stiffeners to form the main frame. Tee- sections are weldedto horizontal girders to make the frame regid and to support the skin plate. Skin plate is weldedto Tee-supports generally spaced vertically at about 40 cm apart.Consider radial gate for spillway opening of size 15 m x 9 m at crest.Size of gate for 15 x 9 m opening at crest with gate sill on d /s 0.6 m below crest level :Length of gate : 15 m Head of water at sill level : 9.60 m Height of gate : 9.75 mWeight of gate leaf in tonne with end shield and hood based on empirical formula :

= 0.0710 x ( L 2 x H x h ) 0.673

Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.

= 0.0710 x ( 15 2 x 9.75 x 9.6 ) 0.673 : 57.669The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings for gate of same size provided for one of the dam work.Actual weight as per data in Item : 2 of Annexure-2 : 57.457 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of radial gate provided for one of the dam having spillway opening of 15 m x 9 m at crest for rate analysis ( fordetails refer Item : 2 of Annexure-2 ).


Angles/ beams/ channels/ bars with 2.5% wastage ( 15421x1.025 ) : 15806 kgPlates / flats with 2.5 % wastage ( 37729 x 1.025 ) : 38672 kg

b. Alloy steel components conforming to IS : 1570 :Stainless steel plates : 6 kgLifting pins : 1098 kg

c. Cast steel components conforming to IS : 1030 :Trunnion hub / Guide roller : 1895 kg

d. Alluminium / Bronze alloy components conforming to IS : 305 :Trunnion bush / Guide roller bush : 1155 kg

e. Bolts / Nuts / Washers conforming to IS : 1363 :GI bolts / nuts / washers with 2.5 % wastage ( 76 x 1.025 ) : 78 kgMS bolts / nuts / washers with 2.5 % wastage ( 77 x 1.025 ) : 79 kg

f. Zinc at 70 kg / trunnion ( 2 x 70 ) : 140 kgg. Rubber seal conforming to IS : 11855 :

Bottom seal ( flat type ) with wastage ( 15 x 1.025 ) : 15.5 Rm

10


Side seals ( Z - type ) with wastage ( 24.2 x 1.025 ) : 25 Rmh. Welding electrodes ( General purpose / Low hydrogen ) :

GP / LH electrodes as per data sheet ( Item:2 Annexure-2 ) : 31038 NosAdd for variations / wastage / misc welding @ 10 % ( 31038 x 0.1 ) : 3104 NosTotal requirement of GP / LH electrodes : 34142 Nos for stitch welding GP electrodes @t 10 % of total ( 34142 x 0.10 ) : 3414 Nos for run welding LH electrodes @ 90 % of total ( 34142 x 0.90 ) : 30728 Nos


Total : 1067 RmFor cutting structural steel sections to required sizes gas cutting is assumed for cutting angles/beams / channels / round bars and for thick plates / flats. For plate / flats less than 12 mmthick use of shearing machine is assumed to the extent feasible.Length of steel to be cut by using gas manually : 396 mLength of steel to be cut by gas using pug cutting machine : 571 mLength of steel to be cut by using shearing machine : 100 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 198 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 190 hoursTime for cutting by shearing machine at ( av ) 10 m cutting / hour : 10 hoursAcetelyne gas @ 0.6 cum / hour ( 198 + 190 ) x 0.60 : 233 cumOxygen gas @ 1.8 cum / hour ( 198 + 190 ) x 1.80 : 699 cumUse of gas cutting torch with 50 min / hr working ( 198 x 60 / 50 ) : 238 hoursUse of pug cutting machine with 50min/ hr working ( 190 x 60 / 50 ) : 228 hoursUse of shearing machine with 50 min / hr working ( 10 x60 / 50 ) : 12 hours

3. Bending :Curved length of plates / tee for bending for 9.75 m height gate : 11.00 mFor 1.2 m wide plates, length of plate for bending ( 15 x 11/ 1.2 ) : 137.50 mLength of Tee sections @ 0.4 m spacing ( 15 x 11 / 0.4 ) : 412.50 mLength of side seal base and cover flats ( 11 x 2 x 2 ) : 44.00 m

Total : 594.00 mAssuming 3 m bending / hour, time for bending 594 m ( 594 / 3 ) : 198 hoursWith 50 min / hr working use bending machine for ( 198 x 60 / 50 ) : 238 hours

4. Welding :Length of welding as per data sheet : 2294 RmFor radial gates where field welding is more hourly progress is assumed at 12 electrodes / hour.For stich welding @ 2 hrs usage / shift & @ 12 electrodes / hr

( 3414 / 12 ) x 8 / 2 : 1138 hoursFor run welding @ 6 hrs usage / shift & @ 12 electrodes / hr

( 30728 / 12 ) x 8 / 6 : 3414 hoursTotal : 4552 hours


( 1138 x 0.25 + 3414 x 0.75 ) : 2845 hours 5. Surface cleaning and painting :

Painting area for radial gate at 20 sqm / tonne ( 57.457 x 20 ) : 1150 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 1150 sqm @ 9 sqm / ltr / coat : 128 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 1150 sqm @ 6 sqm / ltr / coat : 575 ltr

11


As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 1150 sqm at 8 sqm / ltr : 144 ltr

6. Requirement of other machinery :For lifting and placing in position sector arms / horizontal girders / tie beam 10 hours use of tower crane considered.For drilling holes in skin plate and seal clamps for seal fixing 50 hours use of drilling machine considered. For grinding and finishing weld joints in skin plate and other locations 200 hours use of grinding machine considered.For handling during fabrication and erection of gate parts 25 t mobile crane for 75 hours and8 t mobile crane for 100 hours and stationery derric for 200 hours considered.


Painter Cl-II

Cutting sections 478 hours 30 60 60 120Drilling holes for seal fixing 3 6 --- 12Fabricating by stitch welding 1138 hours 71 142 --- 568Run welding 3414 hours 43 --- 427 427Erection of trunnion and tie beam 4 15 --- 60Erection of Horizontal girders 3 10 --- 20Erection of sector arms 3 10 --- 20Erection of vertical stiffeners 5 20 --- 40Erection of skin plates 3 15 --- 30Erection of end sheilds and hood 4 20 --- 40Erection of bracings 6 10 --- 20Molten zinc filling for trunnion supports 2 2 --- 2Seal fixing 2 5 --- 10Cleaning surface1150 sqm @15 sqm/day --- --- --- 77Painting ( 4x1150 ) sqm @ 15 sqm / day --- --- --- 383Finishing / cleaning / checking 1 5 --- 5 Total : 180 320 487 1834


8. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost of materials ( assuming 25 % of machinery and labour components for erection ) is considered for assessing excise duty.

9. Use rate of materials :Cost of welding set @ `: 6750.00 / Each : 6750.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) `: 6.75Cost of gas cutting set @ `: 2250.00 / Each `: 2250.00Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) `: 3.75

Gas cutter /

12

WelderMarker /

Fabricator /Erector /



in `:1 Structural steel :


2 Cast steel components :Trunnion hubs / Guide rollers kg 1895.00 155.00 293725.00

3 Alloy steel components :Stainless steel plate kg 6.00 231.00 1386.00Trunnion pins kg 1098.00 345.00 378810.00

4 Alluminium / Bronze alloy components:Bush for Trunnion / Guide roller kg 1155.00 810.00 935550.00

5 Bolt / Nut / Washer :GI bolts / nuts / washers kg 78.00 108.00 8424.00MS bolts / nuts / washers kg 79.00 90.00 7110.00

6 Zinc kg 140.00 222.00 31080.007 Rubber seals :

Bottom seal Rm 15.50 219.00 3394.50Side seals ( Z - type ) Rm 25.00 411.00 10275.00

8 Oxygen gas cum 699.00 84.00 58716.009 Acetyline gas cum 233.00 404.00 94132.00

10 Welding electrodes ( general purpose ) Nos 3414.00 10.00 34140.0011 Welding electrodes ( low hydrogen ) Nos 30728.00 21.00 645288.0012 Zinc rich epoxy primer ltr 128.00 244.00 31232.0013 Coal tar epoxy paint ltr 575.00 226.00 129950.0014 Rust cleaner / inhibitor ltr 144.00 311.00 44784.0015 Wire brush Nos 20.00 53.00 1060.0016 Use rate welding holder set Hour 4552.00 6.75 30726.0017 Use rate gas cutting torch set Hour 238.00 3.75 892.5018 Sundries LS 300.00 45.00 13500.00







Fuel / Energy charges Hour 228.00 4.00 912.004 Bending machine Hour 238.00 26.00 6188.00

Fuel / Energy charges Hour 238.00 111.00 26418.00Contd

in `:Quantity

in `:

Perticulars Rate


13

Rate


B. MACHINERY ( Contd ) : Sl No Unit Amount

in `:Contd

5 Tower crane 5 t cpacity Hour 10.00 660.00 6600.00Fuel / Energy charges Hour 10.00 192.00 1920.00

6 Mobile crane ( pick & carry ) 8 t Hour 100.00 289.00 28900.00Fuel / Energy charges Hour 100.00 854.00 85400.00

7 Mobile crane ( revolving ) 25 t Hour 75.00 2623.00 196725.00Fuel / Energy charges Hour 75.00 2372.00 177900.00

8 Stationery derric crane Hour 200.00 44.00 8800.00Fuel / Energy charges Hour 200.00 12.00 2400.00

9 Grinding machine Hour 200.00 13.00 2600.00Fuel / Energy charges Hour 200.00 37.00 7400.00

10 Drilling machines Hour 50.00 13.00 650.00Fuel / Energy charges Hour 50.00 37.00 1850.00

11 Sundries LS 400.00 45.00 18000.00Total `: 867060.00

Add for small Tools and Plants @ 1% `: 8670.60Add for Contractor's Profit on DPOL / Energy @ 10% `: 57718.10Add for Contractor's Overheads @ 5% `: 43353.00



in `:1 Crew for Mobile crane 8 t Hour 100.00 231.00 23100.002 Crew for Mobile crane 25 t Hour 75.00 222.00 16650.003 Crew for Tower crane Hour 10.00 178.00 1780.004 Crew for Bending machine Hour 238.00 131.00 31178.005 Crew for Drilling machine Hour 50.00 164.00 8200.006 Crew for Grinding machine Hour 200.00 164.00 32800.007 Foreman Day 180.00 436.00 78480.008 Marker / Fabricator / Erector Day 320.00 436.00 139520.009 Gas cutter Day 60.00 436.00 26160.00

10 Welder ( General ) Day 384.00 436.00 167424.0011 Welder ( X - ray ) Day 43.00 479.60 20622.8012 Khalasi Day 200.00 436.00 87200.0013 Helper fabrication / erection Day 1374.00 421.00 578454.0014 Helper for cleaning / painting Day 154.00 421.00 64834.0015 Painter Cl - II Day 306.00 421.00 128826.0016 Electrician Day 30.00 436.00 13080.00



Rate

RateDescription


Quantityin `:

14

in `:



TOTAL `: 8741527.65Add for excise duty on 75 percent cost of Machinery / Labour components @ 0.00% `: 0.00Add for insurance charges @ 1.00% `: 87415.28Add for designs and drawings @ 2.50% `: 218538.19Add for zigs / supports / winches / chain-pulley @ 2.50% `: 218538.19Add for power supply arrangements @ 2.30% `: 201055.14Add for enabling works @ 1.30% `: 113639.86




ITEM: Design, fabrication, supply, erection, testing and commissioning of electrically operated ropedrum hoist of adequate capacity consisting of base frames, rope drums,connecting shaft, gearsystem, brake system, electric motor, wire ropes, gate position indicator, manual operationarrangement etc., with all accessories for spillway radial gate including cost of all materials,machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, greasing, providing hand railing and approach staircase with gate to hoist platform, applying two coats of zinc chromate red oxide primer and three coats of approved synthetic enamel paint etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for and lifts including

DATA:Rope drum hoist for radial gate consists of embedded parts for anchorages, hoist supporting structure, pulley supporting structures, pulleys, drive stool, rope drums, couplings, shafts,gears and pinions, plummer blocks, worm reducer, floating shaft, electric motor, hand operation assembly, brake, wire rope, gate position indicator, switch box etc. with related accessories.Consider rope drum hoist for radial gate for spillway opening of size 15 m x 9 m at crest.Generally the rope drum hoist capacity in tonnes with 25 % reserve will be about 1.50 times the weight of radial gate in tonnes.Size of gate for 15 x 9 m opening at crest with gate sill on d /s 0.6 m below crest level :Length of gate : 15 m Head of water at sill level : 9.60 m Height of gate : 9.75 mWeight of radial gate leaf in tonne for 9.6 m water head based on empirical formula :

= 0.0710 x ( L 2 x H x h ) 0.673


= 0.0710 x ( 15 2 x 9.75 x 9.6 ) 0.673 : 57.669Consider capacity of hoist including 25 % reserve capacity @ 1.5 times the weight of gate :

( 1.50 x 57.669 ) : 86.504 tonnes

15


Round off the rope drum hoist capacity to next 10 tonne : 90.00 tonnesConsider weight of hoist with all accessories @ 0.175 tonne per tonne capacity of hoist :

( 0.175 x 90 ) : 15.750 tonnesThe hoist capacity and hoist weight computed as above based on empirical formulae are furtherchecked by varifying / computing the actual capacity and weight as per fabrication drawings forradial gate rope drum hoist of same capacity provided for one of the dam work.Actual capacity of hoist provided : 90.00 tonnesActual weight of rope drum hoist as per data in Item : 3 of Annexure-2 : : 15.440 tonnesConsider actual capacity and weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of 90 tonne capacity rope drum hoist provided for spillway radial gate for one of the dam for rate analysis( for details refer Item : 3 of Annexure- 2 ).

1. Requirement of materials :a. Structural steel conforming to IS : 2062 :

Angles/ beams/ channels/ bars with 2.5 % wastage ( 2508x1.025 ) : 2571.00 kgPlates / flats with 2.5 % wastage ( 3543 x 1.025 ) : 3632.00 kg

b. Cast steel components conforming to IS : 1030 :Rope drums 2 Nos / Gears 4 Nos : 3680.00 kgPinions : 218.00 kgPulleys 720 PCD 6 Nos : 1080.00 kgPlummer blocks / Hubs : 322.00 kg

c. Alloy steel components conforming to IS : 1570 :Shafts ( carbon steel ) : 557.00 kgPins ( stainless steel ) : 546.00 kg

d. Alluminium / Bronze alloy components conforming to IS : 305 :Bearings / Bush : 144.00 kg

e. Bolt / Nut / Washers conforming to IS : 1363 :MS Bolts / Nuts / Washers with 2.5 % wastage ( 83 x 1.025 ) : 85.00 kg

f. Steel wire rope conforming to IS : 2266 :36 mm dia 6 / 37 construction 2 Nos 50 m each @ 4.48 kg / Rm : 448 kg

g. Other components :Manual operation assembly : 1 No.Worm reducer : 1 NosElectric motor 20 hp : 1 No.Gate position indicator : 1 No.Ele-magnetic brake : 1 No.Wire rope sockets : 2 NosMS pipe 300 mm dia 13.32 Rm @ 75 kg / Rm : 1000 kgElectric cable / switch / control panel etc : 1 set

h. Welding electrodes ( General purpose / Low hydrogen ) :GP / LH electrodes as per data sheet ( Item:3 Annexure-2 ) : 5304 NosAdd for variations / wastage / misc welding @ 10 % ( 5304 x 0.1 ) : 530 NosTotal requirement of GP / LH electrodes : 5834 Nos for stitch welding GP electrodes @t 10 % of total ( 5834 x 0.10 ) : 584 Nos for run welding LH electrodes @ 90 % of total ( 5834 x 0.90 ) : 5250 Nos


Total : 280 RmFor cutting structural steel sections to required sizes gas cutting is assumed.

16


Length of steel to be cut by using gas manually : 150 mLength of steel to be cut by gas using pug cutting machine : 130 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 75 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 44 hoursAcetelyne gas @ 0.6 cum / hour ( 75 + 44 ) x 0.60 : 72 cumOxygen gas @ 1.8 cum / hour ( 75 + 44 ) x 1.80 : 216 cumUse of gas cutting torch with 50 min / hr working ( 75 x 60 / 50 ) : 90 hoursUse of pug cutting machine with 50 min / hr working ( 44 x 60 / 50 ) : 53 hours

3. Welding :Length of welding as per data sheet : 447 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr





Quantity of structural steel requiring cleaning for painting : 6.2 tonnesPainting area for hoist at 20 sqm / t of str steel ( 6.2 x 20 ) : 124 sqm2 coats of zinc chromate red oxide primer.Quantity of primer paint for 124 sqm @ 12 sqm / ltr / coat : 21 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 124 sqm @ 12 sqm / ltr / coat : 31 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 124 sqm at 8 sqm / ltr : 16 ltr

5. Requirement of other machinery :For lifting and placing in position hoist drums, worm reducers, gears, floating shafts etc use oftower crane for 4 hours considered.For handling and erection 25 t mobile crane for 48 hrs with energy charges for 24 hrs considered.For drilling holes for bolts 16 hours use of drilling machine considered. For grinding and finishing weld joints 32 hours use of grinding machine considered


Painter Cl-II

Cutting sections 143 hours 9 18 18 36Drilling holes for pins / bolts fixing 1 2 --- 4Fabricating by stitch welding 156 hours 10 20 --- 40Run welding 467 hours 6 --- 58 58Erection of anchors 2 4 --- 8Erection of drums and gears 2 4 --- 16Erection of floating shaft / pulleys 1 2 --- 4Erection of worm reducers / brake / motor 1 4 --- 8Erection of other accessories 1 2 --- 2Erection of control panel / cabling 1 1 --- 2

Contd

WelderErector /

17

Marker / Gas cutter / Fabricator /


6. Requirement of work force ( Contd ) :Work component Foreman Helper /

Painter Cl-II

ContdChecking and trial running without ropes 1 2 --- 4Rope fixing and checking 1 4 --- 8Cleaning surface 124 sqm @ 15 sqm/day --- --- --- 8Painting ( 5 x 124 ) sqm @ 15 sqm / day --- --- --- 36Finishing / cleaning --- 2 --- 2Trial running for lifting / lowering gate 1 2 --- 4 Total : 37 67 76 240

Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.b. Workforce for painting 2 coats primer and 3 coats finishing paint consists of 30 Painters Cl-II at 15 sqm / day and 6 helpers to assist painters.

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.


RATE ANALYSIS UNIT : 15.440 tonne wtA. MATERIALS: 90.00 t capacity Sl No Unit Amount



2 Cast steel components :Rope drums 2 Nos / Gears 4 Nos kg 3680.00 190.00 699200.00Pinions kg 218.00 190.00 41420.00Pulleys 720 PCD 6 Nos kg 1080.00 155.00 167400.00Plummer blocks / Hubs kg 322.00 155.00 49910.00

3 Alloy steel componentsShafts kg 557.00 280.00 155960.00Pins kg 546.00 345.00 188370.00

4 Bronze alloy components :Bronze bearings / bush kg 144.00 810.00 116640.00

5 Wire rope 36 mm dia 6/37 construction kg 448.00 163.00 73024.006 MS Bolt / Nut / Washer kg 85.00 90.00 7650.007 Worm reducer No. 1.00 180000.008 Electric motor 20 hp No. 1.00 90000.00 90000.00

Contd

Rate

18

in `:

180000.00

WelderErector /

Fabricator /Gas cutter /

QuantityPerticulars

Marker /



in `:Contd

9 Floating shaft 300 mm dia kg 1000.00 63.00 63000.0010 Manual operating system No. 1.00 33750.00 33750.0011 Gate position indicator No. 1.00 13500.00 13500.0012 Ele-magnetic brake No. 1.00 22500.00 22500.0013 Electric cable /switch /control panel etc LS 1.00 27000.00 27000.0014 Oxygen gas cum 216.00 84.00 18144.0015 Acetyline gas cum 72.00 404.00 29088.0016 Welding electrodes ( general purpose ) Nos 584.00 10.00 5840.0017 Welding electrodes ( low hydrogen ) Nos 5250.00 21.00 110250.0018 Zinc chromate red oxide primer ltr 21.00 139.00 2919.0019 Synthetic enamel ( 1st quality ) paint ltr 31.00 233.00 7223.0020 Rust cleaner / inhibitor ltr 16.00 311.00 4976.0021 Grease kg 50.00 233.00 11650.0022 Wire brush Nos 3.00 53.00 159.0023 Use rate welding holder set Hour 623.00 6.75 4205.2524 Use rate gas cutting torch set Hour 90.00 3.75 337.5025 Sundries ( hand rail /staircase / gate etc ) LS 1000.00 45.00 45000.00





Fuel / Energy charges Hour 390.00 89.00 34710.002 Tower crane 5 t capacity Hour 4.00 660.00 2640.00









in `:Rate

19

Quantityin `:RateDescription

QuantityPerticulars



in `:1 Crew for Mobile crane 25 t Hour 40.00 222.00 8880.002 Crew for Mobile crane 8 t Hour 40.00 231.00 9240.003 Crew for Tower crane Hour 4.00 178.00 712.004 Crew for Drilling machine Hour 16.00 164.00 2624.005 Crew for Grinding machine Hour 32.00 164.00 5248.006 Foreman Day 37.00 436.00 16132.007 Marker / Fabricator / Erector / Mechanic Day 67.00 436.00 29212.008 Gas cutter Day 18.00 436.00 7848.009 Welder ( General ) Day 58.00 436.00 25288.00

10 Khalasi Day 100.00 436.00 43600.0011 Helper fabrication / erection Day 196.00 421.00 82516.0012 Helper for cleaning / painting Day 14.00 421.00 5894.0013 Painter Cl - II Day 30.00 421.00 12630.0014 Electrician Day 3.00 436.00 1308.00





Total `: 3779152.74Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2 x 15.44 tonnes @ `: 358.20 / tonne `: 11061.22Add for packing, forwarding and transportation upto work site on cost of materials other than structural steel ( on cost of Sl No. 2 to 22 ) @ 3.00% `: 63587.19 Total cost for 15.440 tonne weight `: 3853801.14

90.000 tonne capacityRate per tonne wiegt `: 249600.00Rate per tonne capacity `: 42820.01

Rate approved per tonne capacity `: 42800.00

RateDescriptionin `:

Quantity

20



ITEM: Design, fabrication, supply, erection and commissioning of 1 metre wide catwalk connectingspillway piers / abutments at trunnion platform level including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coatof zinc rich epoxy primer and two coats of cold applied coal tar epoxy paint etc., complete asper specifications and approved drawings with lead upto 1 km and all lifts for structural steelcomponents and all leads and lifts including packing / forwarding charges for other materials.

DATA:Catwalk at trunnion level generally consists of 1 m wide structural steel bridge spanning acrosspiers / abutments for inspection and maintenance of gate parts at trunnion level.Consider 1 m wide catwalk for a clear span of 15 m and 3 m wide piers.Generally weight of 1 m wide steel catwalk will be about 300 kg / m lenght.Weight of catwalk for 18 m length ( C / C of piers ) @ 0.3 t / m : 5.400 tonnesThe weight of catwalk ( foot bridge ) computed as above based on empirical formula is furtherchecked by computing the actual weight as per fabrication drawings of a catwalk of same sizeprovided for one of the dam work.Actual weight of catwalk as per data in Item : 4 of Annexure-2 : 5.318 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of catwalk provided for one of the dam for rate analysis ( for details refer Item : 4 of Annexure-2 ).


Angles/ beams/ channels/ bars with 2.5 % wastage ( 4154x1.025 ) : 4258 kgPlates / flats with 2.5 % wastage ( 96 x 1.025 ) : 98 kgChequered plates with 2.5 % wastage ( 835 x 1.025 ) : 856 kg

b. Bolts / Nuts / Washers conforming to IS : 1363 :MS bolts / nuts / washers with 2.5 % wastage ( 8 x 1.025 ) : 8 kg

c. Welding electrodes ( General purpose ) :GP electrodes as per data sheet ( Item:4 Annexure-2 ) : 1387 NosAdd for variations / wastage / misc welding @ 10 % ( 1387 x 0.1 ) : 139 NosTotal requirement of GP electrodes : 1526 Nos for stitch weld GP electrodes @t 10 % of total ( 1526 x 0.10 ) : 153 Nos for run welding GP electrodes @ 90 % of total ( 1526 x 0.90 ) : 1373 Nos


Total : 63 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 40 mLength of steel to be cut by gas using pug cutting machine : 23 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 20 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 8 hoursAcetelyne gas @ 0.6 cum / hour ( 20 + 8 ) x 0.60 : 17 cumOxygen gas @ 1.8 cum / hour ( 20 + 8 ) x 1.80 : 51 cumUse of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) : 24 hoursUse of pug cutting machine with 50 min / hr working ( 8 x 60 / 50 ) : 10 hours

21







Painting area for catwalk at 25 sqm / tonne ( 5.318 x 25 ) : 133 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 133 sqm @ 9 sqm / ltr / coat : 15 ltr2 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 133 sqm @ 6 sqm / ltr / coat : 44 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 133 sqm at 8 sqm / ltr : 16 ltr

5. Requirement of other machinery :For erection of fabricated catwalk 1 hour use of tower crane considered.For handling during fabrication 8 t mobile crane for 2 hours considered.For drilling holes for bolts 2 hours use of drilling machine considered. For grinding and finishing weld joints 8 hours use of grinding machine considered


Painter Cl-II

Cutting sections / drilling holes 34 hours 2 4 4 8Fabricating by stitch welding 41 hours 2 5 --- 10Run welding 122 hours 1 --- 15 15Cleaning surface 132 sqm @ 15 sqm/day --- --- --- 9Painting ( 3 x 133 ) sqm @ 15 sqm / day --- --- --- 33Erection / anchoring / finishing / checking 1 2 --- 2 Total : 6 11 19 77



8. Use rate of materials :Cost of welding set @ `: 6750.00 / Each `: 6750.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) `: 6.75

Gas cutter / Welder

Marker /Fabricator /

Erector /

22


Cost of gas cutting set @ `: 2250.00 / Each `: 2250.00Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) `: 3.75

RATE ANALYSIS UNIT : 18.000 RmA. MATERIALS: Sl No Unit Amount


Angles / beams / channels / bars kg 4258.00 39.55 168391.13Plates / flats kg 98.00 39.55 3875.61Chequered plates kg 856.00 41.52 35544.84

2 MS bolts / nuts / washers kg 8.00 90.00 720.003 Oxygen gas cum 51.00 84.00 4284.004 Acetyline gas cum 17.00 404.00 6868.005 Welding electrodes ( general purpose ) Nos 1526.00 10.00 15260.006 Zinc rich epoxy primer ltr 15.00 244.00 3660.007 Coal tar epoxy paint ltr 44.00 226.00 9944.008 Rust cleaner / inhibitor ltr 16.00 311.00 4976.009 Wire brush Nos 1.00 53.00 53.00

10 Use rate welding holder set Hour 163.00 6.75 1100.2511 Use rate gas cutting torch set Hour 24.00 3.75 90.0012 Sundries LS 10.00 45.00 450.00













in `:

Quantity

RateQuantity

RatePerticularsin `:

23

Description



in `:1 Crew for Mobile crane Hour 2.00 231.00 462.002 Crew for Tower crane Hour 1.00 178.00 178.003 Crew for Drilling machine Hour 2.00 164.00 328.004 Crew for Grinding machine Hour 8.00 164.00 1312.005 Foreman Day 6.00 436.00 2616.006 Marker / Fabricator / Erector Day 11.00 436.00 4796.007 Gas cutter Day 4.00 436.00 1744.008 Welder ( General ) Day 15.00 436.00 6540.009 Helper fabrication / erection Day 35.00 421.00 14735.00

10 Helper for cleaning / painting Day 16.00 421.00 6736.0011 Painter Cl - II Day 26.00 421.00 10946.0012 Electrician Day 1.00 436.00 436.00





Total `: 424089.37Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2 x 5.318 tonnes @ `: 358.20 / tonne `: 3809.82Add for packing, forwarding and transportation upto work site on cost of materials other than structural steel ( on cost of Sl No. 2 to 9 ) @ 3.00% `: 1372.95 Total cost for 18.000 Rm `: 429272.14

Rate per Rm `: 23848.45Rate approved per Rm `: 23800.00


ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sill beam, slide tracks, seal seats, guide rails, dogging sets for storage of stoplog elementsetc., with all accessories for spillway stop log gate elements including cost of all materials,machinery, labour, cutting, aligning, welding, anchoring, finishing, cleaning, applying one coat

in `:Rate

24

QuantityDescription


of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete asper specifications and approved drawings with lead upto 1 km and all lifts for structural steelcomponents and all leads and lifts including packing / forwarding charges for other materials.

DATA:Spillway stoplog gate embedded parts consist of sill beam, slide tracks / seal tracks and gate guides and dogging sets for storage of elements with accessories such as first stage anchors.Weight of embedded parts with dogging sets will be about 4 to 5 percent of stop log gate weight.Consider embedded parts for stoplog gate for spillway opening of size 15 m x 9 m for analysis.Size of stoplog gate for 15 x 9 m opening at crest with gate sill 0.4 m below crest level :Length of gate in m : Clear opening + 0.65 m : 15.00 + 0.65 : 15.65 mHeight of gate ( total height of gate elements ) in m : FRL - Sill level + 0.2 : 9.60 mHead of water in m : FRL - Sill level : 9.40 mWeight of stoplog gate elements in tonne for 15 m x 9 m opening based on empirical formula :

= 0.0553 x ( L 2 x H x h ) 0.716

Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.Consider weight of embedded parts for stoplog gate @ 4.50 % of weight of gate elements.

= 0.045 x 0.0553 x ( L 2 x H x h ) 0.716

= 0.0025 x ( 15.65 2 x 9.6 x 9.4 ) 0.716 : 3.225The weight computed as above based on empirical formula is further checked by computing theactual weight as per embedded parts fabrication drawings for stoplog gate of same size providedfor one of the dam.Actual weight of embedded parts as per data in Item : 5 of Annexure-2 : 3.179 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of spillway stoplog gate embedded parts provided for one of the dam for rate analysis ( for details referItem : 5 of Annexure-2 ).


Angles/ beams/ channels/ bars with 2.5 % wastage ( 421x1.025 ) : 432 kgPlates / flats with 2.5 % wastage ( 2245 x 1.025 ) : 2301 kg

b. Alloy steel conforming to IS : 1570 :Stainless steel plates / flats ( 235+166 ) x 1.025 : 411.00 kg

c. Bolt / Nut / Washer conforming to IS : 1363 :MS bolts and nuts with 2.5 % wastage ( 112 x 1.025 ) : 115 kg

d. Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) :GP / LH electrodes as per data sheet ( Item:5 Annexure-2 ) : 1973 NosAdd for variations / wastage / misc welding @ 10 % ( 1973 x 0.1 ) : 197 NosTotal requirement of GP / LH electrodes : 2170 Nos for stitch welding GP electrodes @t 10 % of total ( 2170 x 0.10 ) : 217 Nos for run welding LH electrodes @ 90 % of total ( 2170 x 0.90 ) : 1953 NosStainless steel electrodes as per data sheet ( Item:5 Annexure-2 ) : 1095 NosAdd for variations / wastage @ 5 % ( 1095 x 0.05 ) : 55 NosTotal requirement of Stainless steel ( SS ) electrodes : 1150 Nos for stitch welding SS electrodes @t 10 % of total ( 1150 x 0.10 ) : 115 Nos for run welding SS electrodes @t 90 % of total ( 1150 x 0.90 ) : 1035 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides as per data sheet : 163 Rm

25


Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 16 RmTotal length of cutting : 179 RmFor cutting structural steel sections to required size gas cutting is assumed for cutting angles /beams / channels / round bars. For plates / flats less than 12 mm in thickness plate shearing machine and for the remaining sections pug cutting machine is considered.Length of steel to be cut by using gas manually : 29 mLength of steel to be cut by gas using pug cutting machine : 120 mLength of steel to be cut by using shearing machine : 30 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 15 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 40 hoursTime for cutting by shearing machine at ( av ) 10 m cutting / hour : 3 hoursAcetelyne gas @ 0.6 cum / hour ( 15 + 40 ) x 0.60 : 33 cumOxygen gas @ 1.8 cum / hour ( 15 + 40 ) x 1.80 : 99 cumUse of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hoursUse of pug cutting machine with 50 min / hr working ( 40 x 60 / 50 ) : 48 hoursUse of shearing machine with 50 min / hr working ( 3 x60 / 50 ) : 4 hours





( 89 x 0.25 + 266 x 0.75 ) : 222 hours 4. Planing SS plates for slide block / seal tracks : :

For surface finishing of SS plates for wheel / seal tracks planing machine is considered.Length of SS plate for surface finishing by planing machine : 50.4 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 50.4 m SS plates ( 50.4 x 8 / 3 ) : 135 hours

5. Surface cleaning and painting :Painting area for embedded parts at 7 sqm / tonne ( 3.179 x 7 ) : 22 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 22 sqm @ 9 sqm / ltr / coat : 2.5 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 22 sqm @ 6 sqm / ltr / coat : 15 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 22 sqm at 8 sqm / ltr : 3 ltr

6. Requirement of other machinery :For drilling holes for anchor bolts and for grinding surface / edges of parts requiring finishing 16 hours use of drilling machine and 16 hours use of grinding machine considered.For handling and erection 25 t mobile crane for 4 hours and stationery derric crane for 50 hoursconsidered.

26



Painter Cl-II

Cutting sections 70 hours 5 9 9 18Drilling holes for anchors / supports 1 2 --- 2Fabricating by stitch welding 89 hours 6 11 --- 22Run welding 266 hours 3 --- 33 33Erection of anchors / dogging set 6 12 --- 12Erection of Sill beam / Tracks / Guide 3 3 --- 6Cleaning surface 20 sqm @ 15 sqm/day --- --- --- 2Painting ( 5 x 20 ) sqm @ 15 sqm / day --- --- --- 8Finishing / cleaning / checking 1 1 --- 2 Total : 25 38 42 105







2 Stainless steel plate / flats kg 411.00 231.00 94941.003 MS bolts and nuts kg 115.00 90.00 10350.004 Oxygen gas cum 99.00 84.00 8316.005 Acetyline gas cum 33.00 404.00 13332.006 Welding electrodes ( general purpose ) Nos 217.00 10.00 2170.007 Welding electrodes ( low hydrogen ) Nos 1953.00 21.00 41013.008 Welding electrodes ( stainless steel ) Nos 1150.00 62.00 71300.009 Zinc rich epoxy primer ltr 2.50 244.00 610.00

10 Coal tar epoxy paint ltr 15.00 226.00 3390.0011 Rust cleaner / inhibitor ltr 3.00 311.00 933.0012 Wire brush Nos 3.00 53.00 159.0013 Use rate welding holder set Hour 355.00 6.75 2396.25

Contd

Erector /

in `:

Gas cutter / Welder

Quantity

Marker /

Perticulars Rate

Fabricator /

27



in `:Contd

14 Use rate gas cutting torch set Hour 18.00 3.75 67.5015 Sundries LS 72.00 45.00 3240.00
















in `:1 Crew for Mobile crane Hour 4.00 222.00 888.002 Crew for Shearing machine Hour 4.00 131.00 524.003 Crew for Planing machine Hour 135.00 210.00 28350.004 Crew for Drilling machine Hour 16.00 164.00 2624.005 Crew for Grinding machine Hour 16.00 164.00 2624.006 Foreman Day 25.00 436.00 10900.007 Marker / Fabricator / Erector Day 38.00 436.00 16568.008 Gas cutter Day 9.00 436.00 3924.00

Contd

Rate

Rate

in `:

in `:

Rate

in `:


28

QuantityDescription



C. LABOUR ( Contd ) : Sl No Unit Amount

in `:Contd

9 Welder ( General ) Day 30.00 436.00 13080.0010 Welder ( X - ray ) Day 3.00 479.60 1438.8011 Helper fabrication / erection Day 95.00 421.00 39995.0012 Helper for cleaning / painting Day 3.00 421.00 1263.0013 Painter Cl - II Day 7.00 421.00 2947.0014 Electrician Day 2.00 436.00 872.00





Total `: 751275.43Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2 x 3.179 tonnes @ `: 358.20 / tonne `: 2277.44Add for packing, forwarding and transportation upto work site on cost of materials other than structural steel ( on cost of Sl No. 2 to 12 ) @ 3.00% `: 7395.42 Total cost for 3.179 tonne `: 760948.28



ITEM: Design, fabrication, supply, erection, testing and commissioning of vertical lift sliding type all interchangeable ( except bottom element ) stoplog gate elements consisting of skin plate, horizontal and vertical girders, stiffeners, lifting pins, bronze padded slide blocks, guide shoes, rubber seals, clamps etc., with all accessories for spillway including cost of all materials,machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coat of zincrich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc.,complete as per specifications and approved drawings with lead upto 1 km and all lifts forstructural steel components and all leads and lifts including packing / forwarding charges for other materials.

Descriptionin `:RateQuantity

29


DATA:Spillway stoplog gate consists of number of vertical lift slide gate elements. Each gate element consists of skin plate, horizontal girders, vertical end girders, stiffeners, slide blocks, gate guide shoes, lifting pins and seals with all accessories.Consider spillway stoplog elements for 15 m x 9 m spillway opening for analysis.Size of stoplog gate for 15 x 9 m opening at crest with gate sill 0.4 m below crest level :Length of gate in m : Clear opening + 0.65 m : 15.00 + 0.65 : 15.65 mHeight of gate ( total height of gate elements ) in m : FRL - Sill level + 0.2 :9.60 mHead of water in m : FRL - Sill level : 9.40 mGenerally, the height of each stoplog element will be in the range of 1.00 to 1.20 m.For 9.60 m total height consider 8 stoplog elements of 1.20 m height each.Weight of stoplog gate elements in tonne for 15 m x 9 m opening based on empirical formula :

= 0.0553 x ( L 2 x H x h ) 0.716


= 0.0553 x ( 15.65 x 15.65 x 9.6 x 9.4 ) 0.716 : 71.340The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings for stoplog gate of same size provided for one of dam.Actual weight of spillway stoplog elements as per data in Item :6 of Annexure-2 : 71.157 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of spillway stoplog gate elements provided for one of the dam for rate analysis ( for details refer Item : 6of Annexure-2 ).



b. Alloy steel components conforming to IS : 1570 :Lifting pins : 104 kg

c. Alluminium / Bronze alloy components conforming to IS : 305 :Bronze pads for slide blocks : 48 kg

d. Bolts / Nuts / Washers conforming to IS : 1363 :GI bolts / nuts / washers with 2.5 % wastage ( 288 x 1.025 ) : 295 kgMS bolts / nuts / washers with 2.5 % wastage ( 48 x 1.025 ) : 49 kg

e. Rubber seal conforming to IS : 11855 :Bottom seal ( 120 x 1.025 ) : 123 RmSide seals ( music note type uncladed ) ( 19.2 x 1.025 ) : 20 Rm

f. Welding electrodes ( General purpose / Low hydrogen ) :GP / LH electrodes as per data sheet ( Item:6 Annexure-2 ) : 33626 NosAdd for variations / wastage / misc welding @ 10 % ( 33626 x 0.1 ) : 3363 NosTotal requirement of GP / LH electrodes : 36989 Nos for stitch weld GP electrodes @t 10 % of total ( 36989 x 0.10 ) : 3699 Nos for run welding LH electrodes @ 90 % of total ( 36989 x 0.90 ) : 33290 Nos


Total : 1078 RmFor cutting structural steel sections to required sizes gas cutting is assumed since most of thesections are above 10 mm thick.Length of steel to be cut by using gas manually : 50 m

30


Length of steel to be cut by gas using pug cutting machine : 1028 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 25 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 343 hoursAcetelyne gas @ 0.6 cum / hour ( 25 +343 ) x 0.60 : 221 cumOxygen gas @ 1.8 cum / hour ( 25 + 343 ) x 1.80 : 663 cumUse of gas cutting torch with 50 min / hr working ( 25 x 60 / 50 ) : 30 hoursUse of pug cutting machine with 50 min/ hr working ( 343 x 60 / 50 ) : 412 hours






Painting area for stoplog elements at 18 sqm / tonne ( 71.157x18 ) : 1280 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 1280 sqm @ 9 sqm / ltr / coat : 142 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 1280 sqm @ 6 sqm / ltr / coat : 640 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 1280 sqm at 8 sqm / ltr : 160 ltr

5. Requirement of other machinery :For handling during fabrication 25 t mobile crane for 100 hours and stationery derric crane for 100 hours considered.For drilling holes in skin plate and seal clamps for seal fixing 100 hours use of drilling machine considered. For grinding and finishing weld joints in skin plate and other locations 200 hours use of grinding machine considered.


Painter Cl-II

Cutting sections 442 hours 28 56 56 112Drilling holes for seal fixing 6 12 --- 12Fabricating by stitch welding 986 hours 62 124 --- 248Run welding 2959 hours 37 --- 370 370Seal fixing 8 elements @ 2 per day 8 8 --- 16Cleaning surface1280 sqm @15 sqm/day --- --- --- 85Painting ( 4x1280 ) sqm @ 15 sqm / day --- --- --- 409Finishing / cleaning / guide shoe fixing 1 2 --- 4Trial operation and checking 2 2 --- 4 Total : 144 204 426 1260

Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.

Erector /

Gas cutter /

31

WelderMarker /

Fabricator /


b. Workforce for painting 1 coat primer and 3 coats finishing paint consists of 341 Painters Cl-II at 15 sqm / day and 68 helpers to assist painters.






2 Alloy steel componentsLifting pins kg 104.00 345.00 35880.00

3 Alluminium / Bronze alloy components Bronze pads kg 48.00 810.00 38880.00

4 Bolt / Nut / WasherGI bolts / nuts / washers kg 295.00 108.00 31860.00MS bolts / nuts / washers kg 49.00 90.00 4410.00

5 Rubber sealsBottom seal Rm 123.00 219.00 26937.00Side seals ( uncladed ) Rm 20.00 368.00 7360.00

6 Oxygen gas cum 663.00 84.00 55692.007 Acetyline gas cum 221.00 404.00 89284.008 Welding electrodes ( general purpose ) Nos 3699.00 10.00 36990.009 Welding electrodes ( low hydrogen ) Nos 33290.00 21.00 699090.00

10 Zinc rich epoxy primer ltr 142.00 244.00 34648.0011 Coal tar epoxy paint ltr 640.00 226.00 144640.0012 Rust cleaner / inhibitor ltr 160.00 311.00 49760.0013 Wire brush Nos 13.00 53.00 689.0014 Use rate welding holder set Hour 3945.00 6.75 26628.7515 Use rate gas cutting torch set Hour 30.00 3.75 112.5016 Sundries LS 150.00 45.00 6750.00



32

Ratein `:

QuantityPerticulars













in `:1 Crew for Mobile crane Hour 100.00 231.00 23100.002 Crew for Drilling machine Hour 100.00 164.00 16400.003 Crew for Grinding machine Hour 200.00 164.00 32800.004 Foreman Day 144.00 436.00 62784.005 Marker / Fabricator / Erector Day 204.00 436.00 88944.006 Gas cutter Day 56.00 436.00 24416.007 Welder ( General ) Day 333.00 436.00 145188.008 Welder ( X - ray ) Day 37.00 479.60 17745.209 Khalasi Day 150.00 436.00 65400.00

10 Helper fabrication / erection Day 766.00 421.00 322486.0011 Helper cleaning / painting Day 153.00 421.00 64413.0012 Painter Cl - II Day 341.00 421.00 143561.0013 Electrician Day 5.00 436.00 2180.00



ABSTRACT:A. Cost of Materials `: 4818915.78B. Hire charges of Machinery `: 878845.04

Quantity

in `:Quantity Rate

in `:Description Rate

33

Description


C. Cost of Labour `: 1473749.11TOTAL `: 7171509.93

Add for excise duty on 75 percent cost of Machinery / Labour components @ 0.00% `: 0.00Add for insurance charges @ 1.00% `: 71715.10Add for designs and drawings @ 2.50% `: 179287.75Add for zigs / supports / winches / chain-pulley @ 2.50% `: 179287.75Add for power supply arrangements @ 2.30% `: 164944.73Add for enabling works @ 1.30% `: 93229.63




ITEM: Design, fabrication, supply, erection, testing and commissioning of automatic lifting beam with all accessories for handling, lowering and lifting of spillway stop log gate elementsincluding cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning,applying one coat of zinc rich epoxy primer and two coats of cold applied coal tar epoxy paint etc., complete as per specifications and drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Automatic lifting beam for lifting spillway stop log elements consists of fabricated beam withlifting bracket and automatic engaging / dis-engaging type hooks for under water hooking / de-hooking of gate element. Lifting beam is an independent attachment to moving gantry crane.Consider lifting beam for stoplog element for spillway opening of size 15 m x 9 m for analysis.Spillway stoplog gate consists of number of elements of convenient height. Generally the heightof each stoplog element will be in the range of 1.00 to 1.20 m.For 9.60 m height of stoplog gate the number of elements of 1.2 m each will be 8.Generally the weight of lifting beam for spillway stoplog element will be about 40 percent of theweight of one stoplog element.Size of stoplog gate for 15 x 9 m opening at crest with gate sill 0.4 m below crest level :Length of gate in m : Clear opening + 0.65 m : 15.00 + 0.65 : 15.65 mHeight of gate ( total height of gate elements ) in m : FRL - Sill level + 0.2 : 9.60 mHead of water in m : FRL - Sill level : 9.40 mWeight of stoplog gate elements in tonne for 15 m x 9 m opening based on empirical formula :

= 0.0553 x ( L 2 x H x h ) 0.716

Consider weight of lifting beam in tonnes @ 40 % of weight of one stoplog element: = 0.40 x 0.0553 x ( L 2 x H x h ) 0.716 / n

Where ( L ) is length and ( H ) is total height and ( h ) is head of water in metres and ( n ) is the number of stoplog gate elements.

= 0.0221 x ( 15.65 x 15.65 x 9.6 x 9.4 ) 0.716 / 8 : 3.567The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings for lifting beam for stoplog gate of same size provided

34


for one of the dam.Actual weight of stoplog gate lifting beam as per data in Item : 7 of Annexure-2 : 3.528 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of lifting beam for spillway stoplog elements provided for one of the dam for rate analysis ( for detailsrefer Item : 7 of Annexure-2 ).


Angles / beams / channels / bars with 2.5 % wastage ( 13 x 1.025 ) : 13 kgPlates / flats with 2.5 % wastage ( 3306 x 1.025 ) : 3389 kg

b. Alloy steel components conforming to IS : 1570 :Lifting pins : 101 kg

c. Alluminium / Bronze alloy components conforming to IS : 305 :Bronze Bush : 5 kg

d. Forged steel components conforming to IS : 2004 :Lifting hooks : 130 kg

e. Bolts / Nuts / Washers conforming to IS : 1363 :MS bolts / nuts / washers with 2.5 % wastage : 3 kgMS pipe 100 mm dia : 11 kg

f. Welding electrodes ( General purpose / Low hydrogen ) :GP / LH electrodes as per data sheet ( Item:7 Annexure-2 ) : 2121 NosAdd for variations / wastage / misc welding @ 10 % ( 2121 x 0.1 ) : 212 NosTotal requirement of GP / LH electrodes : 2333 Nos for stitch weld GP electrodes @t 10 % of total ( 2333 x 0.10 ) : 233 Nos for run welding LH electrodes @ 90 % of total ( 2333 x 0.90 ) : 2100 Nos








Painting area for lifting beam at 12 sqm / tonne ( 3.528 x 12 ) : 42 sqm

35


1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 42 sqm @ 9 sqm / ltr / coat : 5 ltr2 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 42 sqm @ 6 sqm / ltr / coat : 14 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 42 sqm @ 8 sqm / ltr : 5 ltr

5. Requirement of other machinery :For handling during fabrication 8 t mobile crane for 2 hours and stationery derric crane for 4 hours considered.For drilling holes for pins / guide shoes 2 hours use of drilling machine considered. For grinding and finishing weld joints 2 hours use of grinding machine considered.


Painter Cl-II

Cutting sections 84 hours 6 11 11 22Drilling holes for pins / bolts fixing --- 1 --- 1Fabricating by stitch welding 62 hours 4 8 --- 16Run welding 187 hours 2 --- 24 24Cleaning surface 42 sqm @ 15 sqm/day --- --- --- 3Painting ( 3 x 42 ) sqm @ 15 sqm / day --- --- --- 10Finishing / guide shoe fixing / checking --- 1 --- 1 Total : 12 21 35 77







Contd

Gas cutter /

Rate

Fabricator /

in `:Quantity

Marker /

Erector /

Perticulars

36

Welder


A. MATERIALS ( Contd ): Sl No Unit Amount

in `:Contd

Lifting pins kg 101.00 345.00 34845.003 Bronze alloy components :

Bronze bush kg 5.00 810.00 4050.004 Forged steel components :

Lifting hooks kg 103.00 210.00 21630.005 MS pipe 100 mm dia kg 11.00 63.00 693.006 Bolt / Nut / Washer

MS bolts / nuts / washers kg 3.00 90.00 270.007 Oxygen gas cum 126.00 84.00 10584.008 Acetyline gas cum 42.00 404.00 16968.009 Welding electrodes ( general purpose ) Nos 233.00 10.00 2330.00

10 Welding electrodes ( low hydrogen ) Nos 2100.00 21.00 44100.0011 Zinc rich epoxy primer ltr 5.00 244.00 1220.0012 Coal tar epoxy paint ltr 14.00 226.00 3164.0013 Rust cleaner / inhibitor ltr 5.00 311.00 1555.0014 Wire brush Nos 1.00 53.00 53.0015 Use rate welding holder set Hour 249.00 6.75 1680.7516 Use rate gas cutting torch set Hour 24.00 3.75 90.0017 Sundries LS 20.00 45.00 900.00













Perticulars

Quantity

in `:

Description Rate

37

Quantity

in `:

Rate



in `:1 Crew for Mobile crane Hour 2.00 231.00 462.002 Crew for Drilling machine Hour 2.00 164.00 328.003 Crew for Grinding machine Hour 2.00 164.00 328.004 Foreman Day 12.00 436.00 5232.005 Marker / Fabricator / Erector Day 21.00 436.00 9156.006 Gas cutter Day 11.00 436.00 4796.007 Welder ( General ) Day 24.00 436.00 10464.008 Helper fabrication / erection Day 64.00 421.00 26944.009 Helper for cleaning / painting Day 5.00 421.00 2105.00

10 Painter Cl - II Day 8.00 421.00 3368.0011 Electrician Day 1.00 436.00 436.00








ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity Class- IItype moving gantry crane consisting of rail mounted gantry frame, top platform with handrailing, long / cross travel arrangements, rope drums, gear systems, electric motors, electro-magnetic brake system, cabin, control panel, wire rope, ladder, motorised cable reeling drumetc., with all accessories for operating spillway stop log gate elements and river sluice /

in `:

38

RateDescription Quantity


canal sluice emergency gates including cost of all materials, machinery, labour, cutting,bending, aligning, anchoring, welding, finishing, cleaning, greasing, applying two coats of zinc chromate red oxide primer and three coats of approved synthetic enamel paint etc., complete with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Moving gantry crane consists of rail mounted gantry frame with long travel arrangement, crosstravel trolley with track arrangement mounted on gantry frame top platform, rope drum hoistwith all accessories mounted on cross travel trolley for operating stoplog gate elements.Generally, same moving gantry crane is utilised for operating river sluice emergency gate also.Therefore, the hoisting capacity of the gantry crane depends on the requirement of hoistingcapacity for spillway stoplog element or river sluice emergency gate whichever is higher.Consider moving gantry crane for operating spillway stoplog gate element for analysis.The capacity of moving gantry crane may be considered at 2.5 times wt of 1 stoplog element.Total weight of spillway stoplog gate elements as per item 6 ( W ) : 71.34 tonnesNumber of stoplog gate elements as per item 6 ( n ) : 8 NosCapacity of moving gantry crane in tonnes with 25% reserve capacity : 2.5 x ( W / n ) Where ( W ) is weight of 1 set of stoplog elements and ( n ) is number of stoplog elements. Capacity of moving gantry crane required 2.50 x ( 71.34 / 8 ) : 24.97 tonnesRound off the capacity to next 5 tonne say : 25 tonneThe weight of moving gantry crane may be considered at 1.25 t per tonne capacity of crane.Wt of moving gantry crane @ 1.25 t / tonne capacity ( 1.25 x 25 ) : 31.25 tonnesThe hoist capacity and hoist weight computed as above based on empirical formulae are furtherchecked by varifying / computing the actual capacity and weight as per fabrication drawings of moving gantry crane for operating spillway stoplogs provided for one of the dam.Actual capacity of moving gantry crane as per data considered : 25 tonneActual weight of moving gantry crane as per data in Item : 8 of Annexure-2 : 30.856 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of moving gantry crane for operating spillway stoplog gate elements and river sluice emergency gateprovided for one of the dam for rate analysis ( for details refer item : 8 of Annexure-2 ).


Angles/ beams/ channels/ bars with 2.5 % wastage ( 1700x1.025 ) : 1743.00 kgPlates / flats with 2.5 % wastage ( 19219 x 1.025 ) : 19700.00 kgChequered plate with 2.5 % wastage ( 800 x 1.025 ) : 820 kg

b. Cast steel components conforming to IS : 1030 :Rope drums 2 Nos / Gears : 2336.00 kgPinions : 149.00 kgWheels and Pulleys : 2255.00 kgPlummer blocks / Couplings : 817.00 kg

c. Forged steel components conforming to IS : 2004 :Hook / Shackle : 127.00 kg

d. Alloy steel steel components conforming to IS: 1570 :Shafts : 556.00 kgPins : 524.00 kg

e. Alluminium/ Bronze alloy components conforming to IS : 305 :Bearings / Bush : 181.00 kg

f. Bolt / Nut / Washers conforming to IS : 1363 :MS Bolts / Nuts / Washers with 2.5 % wastage ( 61 x 1.025 ) : 63.00 kg

39


g. Steel wire rope conforming to IS : 2266 :28 mm dia 6 / 37 construction 150 Rm @ 2.71 kg / m : 406 .00 kg

h. Other components :Worm reducers : 4 NosElectric motor 17.5 hp : 1 No.Electric motor 5 hp : 2 NosElectric motor 3 hp : 1 No.Ele-magnetic / Thruster brakes : 4 No.MS pipe 32 mm dia : 50 RmElectric cable / switches / control panels etc : 3 sets

i. Welding electrodes ( General purpose / Low hydrogen ) :GP / LH electrodes as per data sheet ( Item:8 Annexure-2 ) : 16651 NosAdd for variations / wastage / misc welding @ 10 % ( 16651 x 0.1 ) : 1665 NosTotal requirement of GP / LH electrodes : 18316 Nos for stitch weld GP electrodes @t 10 % of total ( 18316 x 0.10 ) : 1832 Nos for run welding LH electrodes @ 90 % of total ( 18316 x 0.90 ) : 16484 Nos


Total : 837 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas cutting torch manually : 250 mLength of steel to be cut by gas using pug cutting machine : 587 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 125 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 196 hoursAcetelyne gas @ 0.6 cum / hour ( 125 + 196 ) x 0.60 : 193 cumOxygen gas @ 1.8 cum / hour ( 125 + 196 ) x 1.80 : 579 cumUse of gas cutting torch with 50 min / hr working ( 125 x 60 / 50 ) : 150 hoursUse of pug cutting machine with 50 min/hr working ( 196 x 60 / 50 ) : 235 hours





( 489 x 0.25 + 1465 x 0.75 ) : 1221 hours

4. Surface cleaning and painting :Painting area for crane at 25 sqm / t of str steel ( 21.443 x 25 ) say : 540 sqm2 coats of zinc chromate red oxide primer.Quantity of primer paint for 540 sqm @ 12 sqm / ltr / coat : 90 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 540 sqm @ 12 sqm / ltr / coat : 135 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting

40


before applying primer painting.Quantity of rust cleaner / inhibitor for 540 sqm @ 8 sqm / ltr : 68 ltr

5. Requirement of other machinery :For handling and erection of portals use of 25 t mobile crane for 16 hours with energy chargesfor 8 hours and 8 t momile crane for 40 hours consideredFor drilling holes for bolts 16 hours use of drilling machine considered. For grinding and finishing weld joints 64 hours use of grinding machine considered.


Painter Cl-II

Cutting sections 385 hours 24 48 48 96Drilling holes for pins / bolts fixing 1 2 --- 2Fabricating by stitch welding 489 hours 30 61 --- 122Run welding 1465 hours 18 --- 183 183Assembly/Erection of wheels/ base frame 4 8 --- 16Assembly/Erection of portals 4 8 --- 16Assembly/Erection of top frame 4 8 --- 16Assembly/Erection of CT trolley 2 4 --- 8Assembly/Erection of drums / drive units 2 4 --- 8Assembly/Erection of CT drive units 1 2 --- 4Assembly/Erection of LT drive units 1 2 --- 4Erection of cabin / railings etc 2 2 --- 4Erection of control panel / cabling 1 1 --- 2Checking and trial running without rope 2 4 --- 4Rope fixing and checking 1 2 --- 2Cleaning surface 540 sqm @ 15 sqm/day --- --- --- 36Painting ( 5 x 540 ) sqm @ 15 sqm / day --- --- --- 162Trial running by lifting / lowering gate 1 2 --- 2Finishing / cleaning --- 1 --- 2 Total : 98 159 231 689




Marker /

Erector /

41

Gas cutter / WelderFabricator /


RATE ANALYSIS UNIT : 30.856 tonneA. MATERIALS: 25 t capacity Sl No Unit Amount


Angles / beams / channels / bars kg 1743.00 39.55 68930.42Plates / flats kg 19700.00 39.55 779075.90Chequered plates kg 820.00 41.52 34049.97

2 Cast steel components :Rope drums 2 Nos / Gears kg 2336.00 190.00 443840.00Pinions kg 149.00 190.00 28310.00Wheels / Pulleys kg 2255.00 155.00 349525.00Plummer blocks / Couplings kg 817.00 155.00 126635.00

3 Forged steel componentsHook / Shackle kg 127.00 210.00 26670.00



6 Wire rope 28 mm dia 6 / 37 construction kg 406.00 163.00 66178.007 MS Bolt / Nut / Washer kg 63.00 90.00 5670.008 MS pipe 32 mm dia for railing Rm 50.00 208.00 10400.009 Worm reducers Nos. 4.00 78750.00 315000.00

10 Electric motor 17.5 hp No. 1.00 56250.00 56250.00Electric motor 5 hp Nos. 2.00 22500.00 45000.00Electric motor 3 hp No. 1.00 13500.00 13500.00

11 Ele-magnetic / Thruster brakes Nos. 4.00 16875.00 67500.0012 Electric cable / switch / control panel etc LS 3.00 11250.00 33750.0013 Oxygen gas cum 579.00 84.00 48636.0014 Acetyline gas cum 193.00 404.00 77972.0015 Welding electrodes ( general purpose ) Nos 1832.00 10.00 18320.0016 Welding electrodes ( low hydrogen ) Nos 16484.00 21.00 346164.0017 Zinc chromate red oxide primer ltr 90.00 139.00 12510.0018 Synthetic enamel ( 1st quality ) paint ltr 135.00 233.00 31455.0019 Rust cleaner / inhibitor ltr 68.00 311.00 21148.0020 Grease kg 50.00 233.00 11650.0021 Wire brush Nos 6.00 53.00 318.0022 Use rate welding holder set Hour 1954.00 6.75 13189.5023 Use rate gas cutting torch set Hour 150.00 3.75 562.5024 Sundries ( scrap for counter wt etc ) LS 200.00 45.00 9000.00



42

Perticularsin `:

Quantity Rate













in `:1 Crew for Mobile crane 25 t Hour 16.00 222.00 3552.002 Crew for Mobile crane 8 t Hour 40.00 231.00 9240.003 Crew for Drilling machine Hour 16.00 164.00 2624.004 Crew for Grinding machine Hour 64.00 164.00 10496.005 Foreman Day 98.00 436.00 42728.006 Marker / Fabricator / Erector Day 159.00 436.00 69324.007 Gas cutter Day 48.00 436.00 20928.008 Welder ( General ) Day 183.00 436.00 79788.009 Khalasi Day 20.00 436.00 8720.00

10 Helper fabrication / erection Day 491.00 421.00 206711.0011 Helper for cleaning / painting Day 63.00 421.00 26523.0012 Painter Cl - II Day 135.00 421.00 56835.0013 Electrician Day 5.00 436.00 2180.00



ABSTRACT:A. Cost of Materials `: 4111363.97B. Hire charges of Machinery `: 277199.90

Quantity

in `:Rate

Description

Description

in `:Rate

43

Quantity


C. Cost of Labour `: 787887.54TOTAL `: 5176451.41


Total `: 5673390.75Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x30.856 tonnes @ `: 358.20 / tonne `: 22105.24Add for packing, forwarding and transportation upto work site on cost of materials other than structural steel ( on cost of Sl No. 2 to 21 ) @ 3.00% `: 79184.13 Total cost for 30.856 tonne weight `: 5774680.12

25.000 tonne capacityRate per tonne weight `: 187150.00Rate per tonne capacity `: 230987.20



ITEM: Design, fabrication, supply, erection and commissioning of rail track using 45 kg / m standard rails on spillway bridge for movement of gantry crane for handling and operating spillwaystoplog gate elements / river sluice / canal sluice emergency gate including cost of all materials,machinery, labour, aligning, anchoring, welding, cleaning, applying one coat of zinc rich epoxy primer and two coats of cold applied coal tar epoxy paint for buffers and rail supporting plates etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Rail track for moving gantry crane consists of 45 kg / m standard rails fixed by welding and bolting to anchors embedded in concrete at intervals. The width of track shall be as per therequirement of gantry long travel specifications.Consider track length of 200 m for rate analysis.Weight of 45 kg / m rails in tonnes ( 2 x 200 x 45 ) / 1000 : 18.00Add for anchors and fixtures @ 15 % including wastage : 2.70

Total weight in tonnes : 20.70The weight computed as above based on percentage provision for fixtures is further checked bycomputing the actual weight as per fabrication drawings for gantry track provided for one of dam.Actual weight of materials as per data in Item : 9 of Annexure-2 : 20.722 tConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of gantry track provided for one of the dam for rate analysis ( for details refer Item : 9 of Annexure-2 ).



b. Bolt / Nut / Washer conforming to IS : 1363 :MS bolts and nuts with 2.5 % wastage ( 240 x 1.025 ) : 246 kg

44


c. Standard Rails 45 kg / m with 2.5 % wastage ( 18000 x 1.025 ) : 18450 kgd. Welding electrodes ( General purpose ) :

GP electrodes as per data sheet ( Item:9 Annexure-2 ) : 1710 NosAdd for variations / wastage / misc welding @ 10 % ( 1710 x 0.1 ) : 171 NosTotal requirement of GP electrodes : 1881 Nos for stitch weld GP electrodes @t 10 % of total ( 1881 x 0.10 ) : 188 Nos for run welding GP electrodes @ 90 % of total ( 1881 x 0.90 ) : 1693 Nos

2. Cutting :Total length of cutting assuming cutting for 2 sides as per data sheet : 222 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas cutting torch manually : 222 mTime for gas cutting manually at average cutting progress of 2 m / hour : 111 hoursAcetelyne gas @ 0.6 cum / hour ( 111 x 0.60 ) : 67 cumOxygen gas @ 1.8 cum / hour ( 111 x 1.80 ) : 201 cumUse of gas cutting torch with 50 min / hr working ( 111 x 60 / 50 ) : 133 hours





4. Surface cleaning and painting :For painting buffers and supporting plates 0.5 ltr zinc rich epoxy primer and 1 ltr coal tar epoxypaint considered.

5. Requirement of other machinery :For drilling holes for anchor bolts 24 hours use of drilling machine considered.For grinding edges of parts requiring finishing 8 hours use of grinding machine considered.For handling and erection use of 8 t mobile crane for 2 hours considered.


Painter Cl-II

Cutting sections 133 hours --- 17 17 17Drilling holes for anchors / supports --- 6 --- 6Erection /stitch welding anchors 50 hours 3 6 --- 6Erection of rails & fixing clamps 2 2 --- 4Run welding 150 hours 2 --- 19 19Cleaning surface 3 sqm @ 15 sqm/day --- --- --- ---Painting ( 3 x 3 ) sqm @ 15 sqm / day --- --- --- 1Finishing / checking / cleaning 1 1 --- 1 Total : 8 32 36 54

Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.b. 1 Painter Cl- II considered or cleaning and painting.

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all

Welder

45

Erector /


Gas cutter /


taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.


RATE ANALYSIS UNIT : 200.000 RmA. MATERIALS: Sl No Unit Amount


Angles / channels / beams / bars kg 1570.00 39.55 62088.79Plates / flats kg 975.00 39.55 38558.33

2 Rails kg 18450.00 47.46 875600.103 MS bolts and nuts kg 246.00 90.00 22140.004 Oxygen gas cum 201.00 84.00 16884.005 Acetyline gas cum 67.00 404.00 27068.006 Welding electrodes ( general purpose ) Nos 1881.00 10.00 18810.007 Zinc rich epoxy primer ltr 0.50 244.00 122.008 Coal tar epoxy paint ltr 1.00 226.00 226.009 Use rate welding holder set Hour 200.00 6.75 1350.00












Quantity

Ratein `:

Quantity

Ratein `:

Description

Perticulars

46



in `:1 Crew for Mobile crane Hour 2.00 231.00 462.002 Crew for Drilling machine Hour 24.00 164.00 3936.003 Crew for Grinding machine Hour 8.00 164.00 1312.004 Foreman Day 8.00 436.00 3488.005 Marker / Fabricator / Erector Day 32.00 436.00 13952.006 Gas cutter Day 17.00 436.00 7412.007 Welder ( General ) Day 19.00 436.00 8284.008 Helper fabrication / erection Day 53.00 421.00 22313.009 Painter Cl- II Day 1.00 421.00 421.00

10 Electrician Day 1.00 436.00 436.00Total `: 62016.00

Add for small Tools and Plants @ 1% `: 620.16Add for Contractor's Profit @ 10% `: 6201.60Add for hidden cost on Labour @ 15% `: 9302.40Add for additional hidden cost on labour @ 15% `: 9302.40Add for Contractor's Overheads @ 5% `: 3100.80




Total `: 1473109.53Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x20.722 tonnes @ `: 358.20 / tonne `: 14845.24Add for packing, forwarding and transportation upto work site on cost of materials other than structural steel ( on cost of Sl No. 2 to 8 ) @ 3.00% `: 28825.50 Total cost for 200.000 Rm `: 1516780.27

Rate per Rm `: 7583.90Rate approved per Rm `: 7600.00


ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( without grooveliner ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner ( upto one vent height plus 1 m above the roof of vent ) etc., with all accessories for river / canal sluiceservice gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with

Ratein `:

47



lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Embedded parts for river / canal sluice service gate without groove lining consist of sill beam,wheel / seal tracks, breast wall lining and gate guide with accessories such as first / secondstage anchors.The weight of embedded parts depends on the height of gate groove and height upto which breast wall lining is to be provided. Weight of embedded parts will be about 50% of wt of gate.Consider embedded parts for river sluice service gate for sluice opening of size 1.5 m x 3 m. Weight of breast wall lining for 20 mm MS plate and 6 mm SS plate including stiffeners and anchors will be about 250 kg per sqm area of breast wall.Size of gate for 1.5 m x 3 m opening : Length : 2.2 m Height : 3.3 mHead of water above sill level considered : 16 mWeight of vertical lift roller gate in tonne for 1.5 m x 3 m opening based on empirical formula :

= 0.0888 x ( L 2 x H x h ) 0.659

Consider weight of embedded parts in tonnes @ 50 % of weight of gate leaf :

= 0.50 x 0.0888 x ( L 2 x H x h ) 0.659


= 0.0444 x ( 2.2 x 2.2 x 3.3 x 16 ) 0.659 : 1.714 tonnesWeight of breast wall lining about 7 sqm @ 250 kg / sqm : 1.750 tonnes

Total : 3.464 tonnesThe weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of embedded parts for river sluice service gate of samesize provided for one of the dam.Actual weight of embedded parts as per data in Item :10 of Annexure-2 : 3.172 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on embedded parts drawings for river sluice service gate provided for one of the dam for rate analysis ( for details refer Item : 10of Annexure - 2 ).



b. Alloy steel components conforming to IS : 1570 :Stainless steel plates / flats ( 414 x 1.025 ) : 424.00 kg

c. Bolt / Nut / Washer conforming ti IS : 1363 :MS bolts and nuts with 2.5 % wastage ( 61 x 1.025 ) : 62.5 kg

d. Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) :GP / LH electrodes as per data sheet ( Item:10 Annexure-2 ) : 1359 NosAdd for variations / wastage / misc welding @ 10 % ( 1359 x 0.1 ) : 136 NosTotal requirement of GP / LH electrodes : 1495 Nos for stitch welding GP electrodes @t 10 % of total ( 1495 x 0.10 ) : 150 Nos for run welding LH electrodes @ 90 % of total ( 1495 x 0.90 ) : 1345 NosStainless steel electrodes as per data sheet ( Item:10 Annexure-2 ) : 417 NosAdd for variations / wastage @ 5 % ( 417 x 0.05 ) : 21 NosTotal requirement of Stainless steel ( SS ) electrodes : 438 Nos for stitch weld SS electrodes @t 10 % of total ( 438 x 0.10 ) : 44 Nos for run weld SS electrodes @t 90 % of total ( 438 x 0.90 ) : 394 Nos

48


2. Cutting :Length of cutting assuming cutting for 2 sides as per data sheet : 152 RmAdd for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 15 RmTotal length of cutting Total : 167 RmFor cutting structural steel sections to required size gas cutting is assumed for cutting angles /beams / channels / round bars. For plates / flats less than 12 mm in thickness plate shearing machine and for the remaining sections pug cutting machine is considered.Length of steel to be cut by using gas manually : 30 mLength of steel to be cut by gas using pug cutting machine : 107 mLength of steel to be cut by using shearing machine : 30 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 15 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 36 hoursTime for cutting by shearing machine at ( av ) 10 m cutting / hour : 3 hoursAcetelyne gas @ 0.6 cum / hour ( 15 + 36 ) x 0.60 : 31 cumOxygen gas @ 1.8 cum / hour ( 15 + 36 ) x 1.80 : 93 cumUse of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hoursUse of pug cutting machine with 50 min / hr working ( 36 x 60 / 50 ) : 43 hoursUse of shearing machine with 50 min / hr working ( 3 x 60 / 50 ) : 4 hours





( 52 x 0.25 + 154 x 0.75 ) : 129 hours 4. Planing SS plates for wheel / seal tracks :

For surface finishing of SS plates for wheel / seal tracks planing machine is considered.Length of SS plate for surface finishing by planing machine : 30 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 30 m SS plates ( 30 x 8 / 3 ) : 80 hours

5. Surface cleaning and painting :Painting area for embedded parts at 10 sqm / tonne ( 3.172 x 10 ) : 32 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 32 sqm @ 9 sqm / ltr / coat : 4 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 32 sqm @ 6 sqm / ltr / coat : 22 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor @ 8 sqm / ltr : 4 ltr

6. Requirement of other machinery :For drilling holes for anchor bolts use of drilling machine for 8 hours considered.For grinding weld joints and edges requiring finishing use of grinding machine for 8 hours considered.For handling parts during fabrication and erection use of 8 t mobile crane for 4 hours andstationery derric crane for 8 hours considered

49



Painter Cl-II

Cutting sections 65 hours 4 8 8 16Drilling holes for anchors / supports 1 1 --- 2Fbricating by stitch welding 52 hours 3 6 --- 12Run welding 154 hours 2 --- 19 19Erection of first stage anchors 3 6 --- 6Erection of Sill beam / Tracks / Guide 2 4 --- 8Erection of Breast wall 2 4 --- 8Cleaning surface 32 sqm @ 15 sqm/day --- --- --- 2Painting ( 5 x 32 ) sqm @ 15 sqm / day --- --- --- 13Finishing / checking / cleaning 1 1 --- 2 Total : 18 30 27 88








10 Coal tar epoxy paint ltr 22.00 226.00 4972.0011 Rust cleaner / inhibitor ltr 4.00 311.00 1244.0012 Wire brush Nos 1.00 53.00 53.00

Contd


Marker / Gas cutter /

Erector /

50

in `:Rate

Fabricator / Welder



in `:Contd

















in `:1 Crew for Mobile crane Hour 4.00 231.00 924.002 Crew for Shearing machine Hour 4.00 131.00 524.003 Crew for Planing machine Hour 80.00 210.00 16800.004 Crew for Drilling machine Hour 8.00 164.00 1312.005 Crew for Grinding machine Hour 8.00 164.00 1312.006 Foreman Day 18.00 436.00 7848.007 Marker / Fabricator / Erector Day 30.00 436.00 13080.00

Contd

in `:

Rate

QuantityDescription


Rate


in `:

in `:Rate

51



in `:Contd

8 Gas cutter Day 8.00 436.00 3488.009 Welder ( General ) Day 17.00 436.00 7412.00

10 Welder ( X - ray ) Day 2.00 479.60 959.2011 Helper fabrication / erection Day 73.00 421.00 30733.0012 Helper for cleaning / painting Day 4.00 421.00 1684.0013 Painter Cl - II Day 11.00 421.00 4631.0014 Electrician Day 2.00 436.00 872.00








ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( with grooveliner upto breast wall level ) consisting of sill beam, wheel tracks, seal seats, guide rails,breast wall liner ( upto one vent height plus 1 m above the roof of vent ) etc., with all accessoriesfor river / canal sluice service gate including cost of all materials, machinery, labour,cutting, aligning, anchoring, welding, finishing, cleaning, applying ne coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

in `:

52

Description Quantity Rate


DATA:Embedded parts for river sluice service gate consist of sill beam, wheel / seal tracks, groovelining upto breast wall level, breast wall lining upto 1 vent plus 1 m above top of vent, gate guideetc., with all accessories such as first stage anchors.The wt of embedded parts depends on the height of gate groove and height upto which breast wall lining is to be provided. Generally wt of embedded parts will be about 50% of wt of gate.Weight of breast wall lining for 20 mm MS plate and 6 mm SS plate including stiffeners and anchors will be about 250 kg per sqm area of breast wall.Weight of groove liner for 20 mm MS plate including stiffeners and anchors will be about200 kg / sqm area of groove liner.Consider embedded parts for river sluice service gate for sluice opening of size 2.5 m x 3 m. Size of gate for 2.5 m x 3 m opening : Length : 3.2 m Height : 3.3 mHead of water above sill level considered : 34 mWeight of vertical lift roller in tonne for 2.5 m x 3 m opening based on empirical formula :

= 0.0888 x ( L 2 x H x h ) 0.659

Consider weight of embedded parts in tonnes @ 50 % of weight of gate leaf :

= 0.50 x 0.0888 x ( L 2 x H x h ) 0.659


= 0.0444 x ( 3.2 x 3.2 x 3.3 x 34 ) 0.659 : 4.615 tonnesWeight of breast wall lining about 12 sqm @ 250 kg / sqm : 3.000 tonnesWeight of groove liner about 15 sqm @ 200 kg / sqm : 3.000 tonnes

Total : 10.615 tonnesThe weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of embedded parts with groove liners for river sluiceservice gate of same size provided for one of the dam.Actual weight of embedded parts as per data in Item : 11 of Annexure-2 : : 10.657 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on embedded parts and gate grooveliner drawings for river sluice service gate provided for one of the dam work for rate analysis ( fordetails refer Item : 11 of Annexure - 2 ).



b. Alloy steel components conforming to IS : 1570 :Stainless steel plates / flats ( 825 x 1.025 ) : 846 kg

c. Bolt / Nut / Washer conforming ti IS : 1363 :MS bolts and nuts with 2.5 % wastage ( 180 x 1.025 ) : 185 kg


53








For surface finishing of SS plates for wheel / seal tracks planing machine is considered.Length of SS plate for surface finishing by planing machine : 30 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 30 m SS plates ( 30 x 8 / 3 ) : 80 hours


6. Requirement of other machinery :For drilling holes for anchor bolts use of drilling machine for 50 hours considered.For grinding weld joints and edges requiring finishing use of grinding machine for 25 hours considered.For handling of parts during fabrication and erection 8 t mobile crane for 10 hours and stationeryderric crane for 40 hours considered.

54



Painter Cl-II

Cutting sections 127 hours 8 16 16 32Drilling holes for anchors / supports 3 6 --- 6Fbricating by stitch welding 176 hours 11 22 --- 44Run welding 528 hours 7 --- 66 66Erection of first stage anchors 5 10 --- 10Erection of Sill beam / Tracks / Guide 2 4 --- 8Erection of Breast wall liner 2 4 --- 8Erection of groove liners 3 6 --- 12Cleaning surface 107 sqm @ 15 sqm/day --- --- --- 7Painting ( 5 x 107 ) sqm @ 15 sqm / day --- --- --- 42Finishing / cleaning 1 2 --- 4 Total : 42 70 82 239


8. Excise duty on supply : Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.






10 Coal tar epoxy paint ltr 72.00 226.00 16272.0011 Rust cleaner / inhibitor ltr 14.00 311.00 4354.00

Contd

55

WelderErector /

Gas cutter /

Quantity Ratein `:

Perticulars

Fabricator /Marker /



in `:Contd

12 Wire brush Nos 2.00 53.00 106.0013 Use rate welding holder set Hour 704.00 6.75 4752.0014 Use rate gas cutting torch set Hour 36.00 3.75 135.0015 Sundries LS 40.00 45.00 1800.00
















in `:1 Crew for Mobile crane Hour 10.00 231.00 2310.002 Crew for Shearing machine Hour 7.00 131.00 917.003 Crew for Planing machine Hour 80.00 210.00 16800.004 Crew for Drilling machine Hour 50.00 164.00 8200.005 Crew for Grinding machine Hour 25.00 164.00 4100.006 Foreman Day 42.00 436.00 18312.00

Contd

Descriptionin `:

in `:Quantity Rate

Quantity

Quantity

56

Ratein `:

Rate

Perticulars

Description



in `:Contd

7 Marker / Fabricator / Erector Day 70.00 436.00 30520.008 Gas cutter Day 16.00 436.00 6976.009 Welder ( General ) Day 59.00 436.00 25724.00









ITEM: Design, fabrication, supply, erection and commissioning of vent liner using 20 mm thickplates with stiffeners and anchors for river sluice / canal sluice vents including cost of allmaterials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applyingone coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc.,complete with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

57

in `:RateQuantityDescription


DATA:Vent lining consists of forming river / canal sluice of specified size using 20 mm thick structural steel plates for the specified length. The liner plates are stiffened on the back side and anchorsare provided for embedment in concrete.Consider vent lining for river / canal sluice of size 2.5 m x 3 m for analysis.Consider vent lining for 3.40 m length of vent.Finished area of lining : ( 2 x 3 x 3.4 + 2 x 2.5 x 3.4 ) : 37.40 sqmWeight of 20 mm thick MS plate per sqm : 157.00 kgAdd 25 % for stiffeners / anchors / projections etc : 39.25 kgTotal requirement of steel for vent lining of sluice per sqm area Total : 196.25 kg

say : 196 kgQuantity of steel required for 37.40 sqm ( 37.40 x 0.196 ) : 7.330 tonnesThe weight computed as above on percentage basis for stiffeners / anchors is further checkedby computing the actual weight as per fabrication drawings of vent liner for river sluice servicegate vent of same size provided for one of the dam.Actual weight of liner for 37.4 sqm as per data in Item : 12 of Annexure-2 : 7.281 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on vent liner drawings for river sluiceservice gate vent provided for one of the dam for rate analysis ( for details refer Item : 12 ofAnnexure - 2 ).


Plates / flats with 2.5 % wastage ( 7281 x 1.025 ) : 7463 kgb. Welding electrodes ( General purpose / Low hydrogen ) :

GP / LH electrodes as per data sheet ( Item:12 Annexure-2 ) : 4194 NosAdd for variations / wastage / misc welding @ 10 % ( 4194 x 0.1 ) : 419 NosTotal requirement of GP / LH electrodes : 4613 Nos for stitch weld GP electrodes @ 10 % of total ( 4613 x 0.10 ) : 461 Nos for run welding LH electrodes @ 90 % of total ( 4613 x 0.90 ) : 4152 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 203 RmAdd for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 20 Rm

Total : 223 RmFor cutting structural steel sections to required sizes gas cutting is assumed since most of thesections are above 10 mm thick.Length of steel to be cut by using gas manually : 30 mLength of steel to be cut by gas using pug cutting machine : 193 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 15 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 64 hoursAcetelyne gas @ 0.6 cum / hour ( 15 + 64 ) x 0.60 : 47 cumOxygen gas @ 1.8 cum / hour ( 15 + 64 ) x 1.80 : 141 cumUse of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hoursUse of pug cutting machine with 50 min / hr working :( 64 x 60 / 50 ) : 77 hours

3. Welding :Length of welding : 420 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr



Deploy welding transformer for 492 hours.

58


Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.( 123 x 0.25 + 369 x 0.75 ) : 308 hours

4. Surface cleaning and painting :Painting area for liner : 37.5 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 37.5 sqm @ 9 sqm / ltr / coat : 4 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 37.5 sqm @ 6 sqm / ltr / coat : 25 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 37.5 sqm @ 8 sqm / ltr : 5 ltr

5. Requirement of other machinery :For handling during fabrication and erection 8 t mobile crane for 4 hours and stationery derric crane for 16 hours considered.For grinding and finishing weld joints in liner plates 12 hours use of grinding machine considered.


Painter Cl-II

Cutting sections 95 hours 6 12 12 24Fabricating by stitch welding 123 hours 8 15 --- 30Run welding 369 hours 5 --- 46 46Cleaning surface 37.4 sqm @15 sqm/day --- --- --- 2Painting ( 5x37.4 ) sqm @ 15 sqm / day --- --- --- 14Finishing / Cleaning 1 1 --- 1 Total : 20 28 58 117




RATE ANALYSIS UNIT : 37.400 sqmA. MATERIALS: Sl No Unit Amount

in `:1 Structural steel plates / flats kg 7463.00 39.55 295139.262 Oxygen gas cum 168.00 84.00 14112.00

Contd

in `:

59

Rate

Gas cutter / Welder


Erector /




in `:Contd

3 Acetyline gas cum 56.00 404.00 22624.004 Welding electrodes ( general purpose ) Nos 461.00 10.00 4610.005 Welding electrodes ( low hydrogen ) Nos 4152.00 21.00 87192.006 Zinc rich epoxy primer ltr 4.00 244.00 976.007 Coal tar epoxy paint ltr 25.00 226.00 5650.008 Rust cleaner / inhibitor ltr 5.00 311.00 1555.009 Wire brush Nos 1.00 53.00 53.00














in `:1 Crew for Mobile crane Hour 4.00 231.00 924.002 Crew for Grinding machine Hour 12.00 164.00 1968.003 Foreman Day 20.00 436.00 8720.004 Marker / Fabricator / Erector Day 28.00 436.00 12208.005 Gas cutter Day 12.00 436.00 5232.006 Welder ( General ) Day 46.00 436.00 20056.00

Contd

Quantity

in `:Description RateQuantity

Rate

in `:

in `:Description

Rate

60




in `:Contd

7 Helper fabrication / erection Day 101.00 421.00 42521.008 Helper for cleaning / painting Day 4.00 421.00 1684.009 Painter Cl - II Day 12.00 421.00 5052.00






Total `: 760384.68Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2 x 7.281 tonnes @ `: 358.20 / tonne `: 5216.11Add for packing, forwarding and transportation upto work site on cost of materials other than structural steel ( on cost of Sl No. 2 to 9 ) @ 3.00% `: 4103.16 Total cost for 37.400 sqm `: 769703.95

Rate per sqm `: 20580.32Rate approved per sqm `: 20600.00


ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type verticallift service gate consisting of skin plate, vertical and horizontal girders, wheels, stiffeners, liftingbrackets, guide rollers, ballast blocks, teflon claded rubber seals etc., with all accessories for river sluice / canal sluice vent including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and threecoats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Consider upstream seal vertical lift roller gate. The gate leaf consists of skin plate, horizontalgirders, vertical end girders, stiffeners, wheels, gate guide rollers, brackets for pulleys, seals

61

Ratein `:



etc., with all accessories.Consider river / canal sluice service gate for 2.5 m x 3 m sluice opening for analysis.For vent opening of 2.5 x 3.0 m the approximate size of gate leaf will be 3.2 x 3.3 m.Head of water considered above sill of gate : 34 m Weight of gate leaf in tonne for vertical lift roller gate based on empirical formula :

= 0.0888 ( L 2 x H x h ) 0.659

Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm.

= 0.0888 ( 3.2 x 3.2 x 3.3 x 34 ) 0.659 : 9.229The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings for river sluice service gate of same size provided for one of the dam.Actual weight of river sluice service gate as per data in Item : 13 of Annexure-2 : 9.202 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of river sluicegate provided for one of the dam for rate analysis ( for details refer Item : 13 of Annexure-2 ).


Plates / flats with 2.5 % wastage ( 4370 x 1.025 ) : 4479 kgb. Cast iron components conforming to IS : 210 :

Cast iron blocks for counter weight ( 4000 x 1.025 ) : 4100 kgc. Alloy steel components conforming to IS : 1570 :

Wheel axles / Pins : 132 kgd. Cast steel components conforming to IS : 1030 :

Wheels / guide rollers : 492 kge. Alluminium / Bronze alloy components conforming to IS : 305 :

Bearings / Bushes : 76 kgf. Bolts / Nuts / Washers conforming to IS : 1363 :

SS bolts / nuts / washers with 2.5 % wastage ( 54 x 1.025 ) : 55 kgGI bolts / nuts / washers with 2.5 % wastage ( 74 x 1.025 ) : 76 kgMS bolts / nuts / washers with 2.5 % wastage ( 4 x 1.025 ) : 4 kg

g. Rubber seal conforming to IS : 11855 :Bottom seal ( flat type ) ( 2.76 x 1.025 ) : 2.8 RmSide seals ( music note type teflon claded ) ( 5.71 x 1.025 ) : 5.85 RmTop seal ( music note type teflon claded ) ( 2.2 x 1.025 ) : 2.25 RmCorner seal ( teflon claded ) : 2 Nos

h. Welding electrodes ( General purpose / Low hydrogen ) :GP / LH electrodes as per data sheet ( Item:13 Annexure-2 ) : 3265 NosAdd for variations / wastage / misc welding @ 10 % ( 3265 x 0.1 ) : 326 NosTotal requirement of GP / LH electrodes : 3591 Nos for stitch weld GP electrodes @t 10 % of total ( 3591 x 0.10 ) : 359 Nos for run welding LH electrodes @ 90 % of total ( 3591 x 0.90 ) : 3232 Nos


Total : 151 RmFor cutting structural steel sections to required sizes gas cutting is assumed since most of thesections are above 10 mm thick.Length of steel to be cut by using gas manually : 30 m

62


Length of steel to be cut by gas using pug cutting machine : 121 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 15 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 40 hoursAcetelyne gas @ 0.6 cum / hour ( 15 + 40 ) x 0.60 : 33 cumOxygen gas @ 1.8 cum / hour ( 15 + 40 ) x 1.80 : 99 cumUse of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hoursUse of pug cutting machine with 50 min / hr working ( 40 x 60 / 50 ) : 48 hours






Painting area for river sluice gate at 10 sqm / tonne ( 9.202 x 10 ) : 92 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 92 sqm @ 9 sqm / ltr / coat : 10 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 92 sqm @ 6 sqm / ltr / coat : 46 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 92 sqm @ 8 sqm / ltr : 12 ltr

5. Requirement of other machinery :For lowering gate leaf from hoist chamber use of tower crane for 1 hour considered.For handling and erection 8 t mobile crane for 4 hours and stationery derric crane for 10 hoursconsidered.For drilling holes in skin plate, counter weight blocks, horizontal girders and seal clamps use of drilling machine for 8 hours considered. For grinding and finishing weld joints in skin plate and other locations 8 hours use of grinding machine considered.


Painter Cl-II

Cutting sections 66 hours 4 8 8 16Drilling holes for seal fixing 1 2 --- 2Fabricating by stitch welding 96 hours 6 12 --- 24Run welding 287 hours 3 --- 36 36Fixing counter weight blocks --- 2 --- 4Seal fixing 1 1 --- 2Cleaning surface 92 sqm @ 15 sqm/day --- --- --- 6Painting ( 4 x 92 ) sqm @ 15 sqm / day --- --- --- 30Guide roller fixing / Cleaning / Lowering 1 2 --- 2 Total : 16 27 44 122

Gas cutter / Fabricator / Welder

Marker /

63

Erector /


Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision considered for welder for stitch welding.b. Workforce for painting 1 coat primer and 3 coats finishing paint consists of 25 Painters Cl-II at 15 sqm / day and 5 helpers to assist painters.





Plates / flats kg 4479.00 39.55 177131.012 Cast iron components

CI blocks for counter wt kg 4100.00 54.00 221400.003 Alloy steel components

Wheel axles / Pins kg 132.00 345.00 45540.004 Cast steel components

Wheels / Guide rollers kg 492.00 155.00 76260.005 Alluminium / Bronze alloy components

Bearings / Bushes kg 76.00 810.00 61560.006 Bolt / Nut / Washer

SS bolts / nuts / washers kg 55.00 182.00 10010.00GI bolts / nuts / washers kg 76.00 108.00 8208.00MS bolts / nuts / washers kg 4.00 90.00 360.00

7 Rubber sealsBottom seal ( flat uncladed ) Rm 2.80 219.00 613.20Side seals ( bulb teflon claded ) Rm 5.85 1049.00 6136.65Top seal ( bulb teflon claded ) Rm 2.25 1049.00 2360.25Corner seals ( bulb teflon claded ) Nos 2.00 1158.00 2316.00


10 Welding electrodes ( general purpose ) Nos 359.00 10.00 3590.0011 Welding electrodes ( low hydrogen ) Nos 3232.00 21.00 67872.0012 Zinc rich epoxy primer ltr 10.00 244.00 2440.0013 Coal tar epoxy paint ltr 46.00 226.00 10396.0014 Rust cleaner / inhibitor ltr 12.00 311.00 3732.0015 Wire brush Nos 1.00 53.00 53.0016 Use rate welding holder set Hour 383.00 6.75 2585.25

Contd

Perticulars Quantity Ratein `:

64



in `:Contd
















in `:1 Crew for Mobile crane Hour 4.00 231.00 924.002 Crew for Tower crane Hour 1.00 178.00 178.003 Crew for Drilling machine Hour 12.00 164.00 1968.004 Crew for Grinding machine Hour 8.00 164.00 1312.005 Foreman Day 16.00 436.00 6976.006 Marker / Fabricator / Erector Day 27.00 436.00 11772.007 Gas cutter Day 8.00 436.00 3488.008 Welder ( General ) Day 32.00 436.00 13952.009 Welder ( X - ray grade ) Day 4.00 479.60 1918.40

10 Helper fabrication / erection Day 86.00 421.00 36206.00Contd

QuantityDescription

Rate

Rate

in `:

in `:

Quantityin `:RateDescription

65



C. LABOUR ( Contd ): Sl No Unit Amount

in `:Contd









ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity ropedrum hoist consisting of hoist platform, rope drum, gear system, electric motor, electro- magnetic brake system, hand operation assembly, control panel, wire rope, pulleys, ladder etc.,with all accessories for operating river sluice / canal sluice service gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, greasing, applying two coats of zinc chromate red oxide primer and three coats of approved synthetic enamel paint etc., complete with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Rope drum hoist for river / canal sluice service gate consists of embedded parts for anchorage, hoist supporting structure, pulley support, pulleys, drive stool, rope drums, shafts, couplings,

in `:

66



gears and pinions, plummer blocks, gear box, electric motor, hand operation assembly, brake,wire rope, gate position indicator, switch box etc. with related accessories.Generally the hoist capacity will be 2.5 times the weight of gate including weight of ballast.Consider rope drum hoist for river / canal sluice service gate for vent of size 2.5 m x 3 m.Capacity of hoist in tonnes :Size of gate for 2.5 x 3 m opening : 3.2 m x 3.3 mHead of water above sill level considered : 34 mWeight of gate leaf in tonne including weight of ballast based on empirical formula :

= 0.0888 x ( L 2 x H x h ) 0.659


= 0.0888 x ( 3.2 x 3.2 x x 3.3 x 34 ) 0.659 : 9.229Capacity of hoist in tonnes with 25% reserve capacity at 2.5 times wt of gate with ballast.

( 2.50 x 9.229 ) : 23.073 tonnesRound off the capacity of hoist to next 5 tonne say : 25.00 tonnesWeight of hoist with all accessories is considered at 0.25 tonne per tonne capacity of hoist.Weight of hoist with all accessories ( 0.25 x 25 ) : 6.250 tonnesThe hoist capacity and hoist weight computed as above based on empirical formulae are furtherchecked by varifying / computing the actual capacity and weight as per fabrication drawings forsluice gate rope drum hoist of same capacity provided for one of the dam.Actual capacity of hoist as per data sheet : 25.00 tonnesActual weight of rope drum hoist as per data in Item :14 of Annexure-2 : 6.243 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of 25 tonne capacity rope drum hoist provided for river sluice service gate for one of the dam work for rate analysis ( for details refer Item : 14 of Annexure- 2 ).


Angles/ beams/ channels/ bars with 2.5 % wastage ( 1451x1.025 ) : 1487.00 kgPlates / flats with 2.5 % wastage ( 392 x 1.025 ) : 402.00 kgChequered plates with 2.5 % wastage ( 283 x 1.025 ) : 290.00 kg

b. Cast steel components conforming to IS : 1030 :Rope drums 2 Nos / Gears ( 1420 +506 ) : 1926.00 kgPinions : 79.00 kgPulleys 3 Nos / Couplings 2 Nos : 306.00 kgPlummer blocks / Hubs : 72.00 kg

c. Alloy steel steel components conforming to IS : 1570 :Shafts : 346.00 kgPins : 73.00 kg

d. Alluminium/ Bronze alloy components conforming to IS : 305 :Bearings / Bush : 57.00 kg


f. Steel wire rope conforming ti IS 2266 :28 mm dia 6 / 37 construction 1 No 120 Rm @ 2.71 kg / m : 325 kg

g. Other components :Manual operating system : 1 No.Worm reducer : 1 NoElectric motor 5 hp : 1 No.Gate position indicator : 1 No.Ele-magnetic brake : 1 No.

67


Electric cable / switch / control panel etc : 1 seth. Welding electrodes ( General purpose / Low hydrogen ) :

GP / LH electrodes as per data sheet ( Item:14 Annexure-2 ) : 1005 NosAdd for variations / wastage / misc welding @ 10 % ( 1005 x 0.1 ) : 100 NosTotal requirement of GP / LH electrodes : 1105 Nos for stitch weld GP electrodes @t 10 % of total ( 1105 x 0.10 ) : 110 Nos for run welding LH electrodes @ 90 % of total ( 1105 x 0.90 ) : 995 Nos








Painting area at 20 sqm / tonne of str steel (1487+402+290 ) x 20 : 43 sqm2 coats of zinc chromate red oxide primer.Quantity of primer paint for 43 sqm @ 12 sqm / ltr / coat : 7 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 43 sqm @ 12 sqm / ltr /coat : 11 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 43 sqm @ 8 sqm / ltr : 5 ltr

5. Requirement of other machinery :For handling during fabrication and erection 8 t mobile crane considered for 2 hours.For drilling holes for bolts 2 hours use of drilling machine considered. For grinding and finishing weld joints 2 hours use of grinding machine considered.


Painter Cl-II

Cutting sections/ drilling holes 31 hours 2 4 4 8Contd

WelderErector /

68

Fabricator /Marker / Gas cutter /


Requirement of work force ( Contd ):Work component Foreman Helper /

Painter Cl-II

ContdFabricating by stitch welding 29 hours 2 4 --- 8Run welding 88 hours 1 --- 11 11Erection of anchors 1 1 --- 2Erection of hoist frame 1 1 --- 4Erection of drums / gears / shafts 1 2 --- 4Erection of pulleys / plummer blocks 1 1 --- 2Erection of worm reducers / brake / motor 1 2 --- 4Erection of other accessories --- 1 --- 2Erection of control panel / cabling --- 1 --- 1Checking and running without rope 1 1 --- 2Rope fixing and checking 1 1 --- 2Cleaning surface 43 sqm @ 15 sqm/day --- --- --- 3Painting ( 5 x 43 ) sqm @ 15 sqm / day --- --- --- 13Trial running by lowering / lifting gate 1 1 --- 4Final checking / Finishing / cleaning 1 1 --- 1 Total : 14 21 15 71

Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.b. Workforce for painting 2 coats primer and 3 coats finishing paint consists of 11 Painters Cl-II at 15 sqm / day and 2 helpers to assist painters.



RATE ANALYSIS UNIT : 6.243 tonne wtA. MATERIALS: 25 t capacity Sl No Unit Amount


Angles / beams / channels / bars kg 1487.00 39.55 58806.39Plates / flats kg 402.00 39.55 15897.89Chequered plate kg 290.00 41.52 12042.06

2 Cast steel components :Rope drums 2 Nos / Gears kg 1926.00 190.00 365940.00Pinions kg 79.00 190.00 15010.00Pulleys 3 Nos / Couplings 2 Nos kg 306.00 155.00 47430.00

Contd

Erector /

in `:

Fabricator / Welder

QuantityPerticulars

Marker / Gas cutter /

Rate

69



in `:Contd

Plummer blocks / Hubs kg 72.00 155.00 11160.003 Alloy steel components

Shafts kg 346.00 280.00 96880.00Pins kg 73.00 345.00 25185.00


5 Wire rope 28 mm dia 6/37 construction kg 325.00 163.00 52975.006 MS Bolt / Nut / Washer kg 32.00 90.00 2880.007 Worm reducers No. 1.00 78750.00 78750.008 Electric motor 5 hp No. 1.00 18000.00 18000.009 Manual operating system No. 1.00 16875.00 16875.00

10 Gate position indicator No. 1.00 16875.00 16875.0011 Ele-magnetic brake No. 1.00 16875.00 16875.0012 Electric cable / switch / control panel etc LS 1.00 11250.00 11250.0013 Oxygen gas cum 45.00 84.00 3780.0014 Acetyline gas cum 15.00 404.00 6060.0015 Welding electrodes ( general purpose ) Nos 110.00 10.00 1100.0016 Welding electrodes ( low hydrogen ) Nos 995.00 21.00 20895.0017 Zinc chromate red oxide primer ltr 7.00 139.00 973.0018 Synthetic enamel ( 1st quality ) paint ltr 11.00 233.00 2563.0019 Rust cleaner / inhibitor ltr 5.00 311.00 1555.0020 Grease kg 25.00 233.00 5825.0021 Wire brush Nos 1.00 53.00 53.0022 Use rate welding holder set Hour 117.00 6.75 789.7523 Use rate gas cutting torch set Hour 16.00 3.75 60.0024 Sundries LS 5.00 45.00 225.00










Perticulars

Description

Quantity

Quantity

70

Ratein `:

in `:Rate


B. MACHINERY ( Contd ): Sl No Unit Amount

in `:Contd





in `:1 Crew for Mobile crane 8 t Hour 2.00 231.00 462.002 Crew for Drilling machine Hour 2.00 164.00 328.003 Crew for Grinding machine Hour 2.00 164.00 328.004 Foreman Day 14.00 436.00 6104.005 Marker / Fabricator / Erector Day 21.00 436.00 9156.006 Gas cutter Day 4.00 436.00 1744.007 Welder ( General ) Day 11.00 436.00 4796.008 Helper fabrication / erection Day 55.00 421.00 23155.009 Helper for cleaning / painting Day 5.00 421.00 2105.00






Total `: 1310344.84Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2 x 6.243 tonnes @ `: 358.20 / tonne `: 4472.49

71

Quantity

Ratein `:

in `:Rate


Description


Add for packing, forwarding and transportation upto work site on cost of materials other than structural steel ( on cost of Sl No. 2 to 21 ) @ 3.00% `: 25951.77 Total cost for 6.243 tonne weight `: 1340769.10




ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( without grooveliners ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner upto1m height above the roof of vent etc., with all accessories for river / canal sluice emergencygate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding,finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold appliedcoal tar epoxy paint etc., complete as per specifications and approved drawings with leadupto 1 km and all lifts for structural steel components and all leads and lifts includingpacking / forwarding charges for other materials.

DATA:Embedded parts for river sluice emergency gate consist of sill beam, wheel / seal tracks, breastwall lining upto 1 m height above vent top, gate guide etc., with all accessories such as f irst stage anchors. The weight of embedded parts depends on the height of gate groove and heightupto which breast wall lining is to be provided.Generally wt of embedded parts for sluice gate will be 50% of wt of gate including ballast.Weight of breast wall lining for 20 mm MS plate and 6 mm SS plate including stiffeners and anchors will be about 250 kg per sqm area of breast wall.Consider embedded parts for river sluice emergency gate for sluice opening of size 1.5 m x 3 m. Weight of embedded parts in tonne for 1.5 m x 3 m opening based on empirical formula : Size of gate for 1.5 m x 3 m opening : Length : 2.2 m Height : 3.3 mHead of water considered above sill level : 16 m

Weight of gate with ballast in tonnes = 0.0888 x ( L 2 x H x h ) 0.659

Consider weight of embedded parts at 50 % of weight of gate including ballast:

Weight of embedded parts in tonnes = 0.50 x 0.0888 x ( L 2 x H x h ) 0.659


= 0.0444 x ( 2.2 x 2.2 x 3.3 x 16 ) 0.659 : 1.714 tonnesWeight of breast wall lining about 2 sqm @ 250 kg / sqm : 0.500 tonnes

Total : 2.214 tonnesThe weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of embedded parts for river sluice emergency gate ofsame size provided for one of the dam.Actual weight of embedded parts as per data in Item : 15 of Annexure-2 : 2.180 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on embedded parts drawings for riversluice emergency gate provided for one of the dam for rate analysis ( for details refer Item 15 ofAnnexure - 2 ).



72










( 40 x 0.25 + 118 x 0.75 ) : 99 hours

4. Planing SS plates for wheel / seal tracks :For surface finishing of SS plates for wheel / seal tracks planing machine is considered.Length of SS plate for surface finishing by planing machine : 26 RmLength of planing at a time for 4 m stroke planing machine : 3 Rm

73


Time for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 26 m SS plates ( 26 x 8 / 3 ) : 72 hours


6. Requirement of other machinery :For drilling holes for anchor bolts use of drilling machine for 10 hours considered.For grinding weld joints and edges requiring finishing use of grinding machine for 8 hours considered.For handling of parts during fabrication and erection use of mobile crane for 2 hours and stationery derric crane for 4 hours considered.


Painter Cl-II

Cutting sections 58 hours 4 7 7 14Drilling holes for anchors / supports 1 1 --- 1Fbricating by stitch welding 40 hours 2 5 --- 10Run welding 118 hours 2 --- 14 14Erection of first stage anchors 2 4 --- 8Erection of Sill beam / Tracks / Guide 2 4 --- 8Erection of Breast wall liners 1 2 --- 4Cleaning surface 26 sqm @ 15 sqm/day --- --- --- 2Painting ( 5 x 26 ) sqm @ 15 sqm / day --- --- --- 10Finishing / cleaning 1 1 --- 2 Total : 15 24 21 73

Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.b. Workforce for painting 1 coat primer and 4 coats finishing paint consists of 9 Painters Cl-II at 15 sqm / day and 1 helper to assist painters.


9. Use rate of materials :Cost of welding set @ `: 6750.00 / Each `: 6750.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) `: 6.75

Gas cutter /

74

WelderMarker /



Cost of gas cutting set @ `: 2250.00 / Each `: 2250.00Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) `: 3.75








B. MACHINERY : Sl No Unit Amount









in `:RateQuantity

75

Perticulars Quantityin `:Rate

Description



in `:Contd






in `:1 Crew for Mobile crane Hour 2.00 231.00 462.002 Crew for Shearing machine Hour 4.00 131.00 524.003 Crew for Planing machine Hour 72.00 210.00 15120.004 Crew for Drilling machine Hour 8.00 164.00 1312.005 Crew for Grinding machine Hour 12.00 164.00 1968.006 Foreman Day 15.00 436.00 6540.007 Marker / Fabricator / Erector Day 24.00 436.00 10464.008 Gas cutter Day 7.00 436.00 3052.009 Welder ( General ) Day 12.00 436.00 5232.00





TOTAL `: 385117.79Add for excise duty on 75 percent cost of Machinery / Labour components @ 0.00% `: 0.00Add for insurance charges @ 1.00% `: 3851.18Add for designs and drawings @ 2.50% `: 9627.94Add for zigs / supports / winches / chain-pulley @ 2.50% `: 9627.94Add for power supply arrangements @ 2.30% `: 8857.71

Quantityin `:Rate

in `:

Description


76

Rate


Add for enabling works @ 1.30% `: 5006.53Total `: 422089.10

Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2 x 2.180 tonnes @ `: 358.20 / tonne `: 1561.75Add for packing, forwarding and transportation upto work site on cost of materials other than structural steel ( on cost of Sl No. 2 to 12 ) @ 3.00% `: 3904.83 Total cost for 2.180 tonne `: 427555.68



ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( with grooveliners ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner ( upto1 m above the roof of vent ), groove liner upto breast wall level etc., with all accessories for river / canal sluice emergency gate including cost of all materials, machinery, labour,cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primerand four coats of cold applied coal tar epoxy paint etc., complete as per specifications andapproved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Embedded parts for river sluice emergency gate consist of sill beam, wheel /seal tracks, groovelining upto breast wall level, breast wall lining upto 1 m above top of vent, gate guide etc., withall accessories such as first stage anchors. The weight of embedded parts depends on the height of gate groove and height upto which breast wall lining is to be provided.Weight of embedded parts for emergency gate will be about 65 to 70 % of gate wt with ballast.Weight of breast wall lining for 20 mm MS plate and 6 mm SS plate including stiffeners and anchors will be about 250 kg per sqm area of breast wall.Weight of groove liner for 20 mm MS plate including stiffeners and anchors will be about 200 kg / sqm area of groove liner.Consider embedded parts for river sluice emergency gate for sluice opening of size 2.5 m x 3 m. Size of gate for 2.5 m x 3 m opening : Length : 3.2 m Height : 3.3 mHead of water considered above sill level : 34 mWeight of embedded parts in tonne including weight of ballast based on empirical formula :

= 0.0888 x ( L 2 x H x h ) 0.659

Consider weight of embedded parts at 67.5 % og weight of gate including ballast:

= 0.675 x 0.0888 x ( L 2 x H x h ) 0.659


= 0.0600 x ( 3.2 x 3.2 x 3.3 x 34 ) 0.659 : 6.236 tonnesWeight of breast wall lining about 3.5 sqm @ 250 kg / sqm : 0.875 tonnesWeight of groove liner about 10 sqm @ 200 kg / sqm : 2.000 tonnes

Total : 9.111 tonnesThe weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of embedded parts and groove liner for river sluiceemergency gate of same size provided for one of the dam.Actual weight of embedded parts as per data in Item :16 of Annexure-2 : 9.088 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on embedded parts and groove linerdrawings for river sluice emergency gate provided for one of the dam work for rate analysis ( for

77


details refer Item : 16 of Annexure - 2 ).



b. Alloy steel components conforming to IS : 1570 :Stainless steel plates / flats ( 431 x 1.025 ) : 442 kg








( 175 x 0.25 + 526 x 0.75 ) : 438 hours

78


4. Planing SS plates for wheel / seal tracks :For surface finishing of SS plates for wheel / seal tracks planing machine is considered.Length of SS plate for surface finishing by planing machine : 26 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 26 m SS plates ( 26 x 8 / 3 ) : 69 hours


6. Requirement of other machinery :For drilling holes for anchor bolts use of drilling machine for 50 hours considered.For grinding weld joints and edges requiring finishing use of grinding machine for 25 hours considered.For handling of parts during fabrication and erection 8 t mobile crane for 4 hours and stationery derric crane for 40 hours considered.


Painter Cl-II

Cutting sections 127 hours 8 16 16 32Drilling holes for anchors / supports 3 6 --- 6Fbricating by stitch welding 175 hours 12 22 --- 44Run welding 526 hours 7 --- 66 66Erection of first stage anchors 5 10 --- 10Erection of Sill beam / Tracks / Guide 2 4 --- 8Erection of Breast wall liner 1 2 --- 4Erection of groove liners 3 6 --- 12Cleaning surface 91 sqm @ 15 sqm/day --- --- --- 6Painting ( 5 x 91 ) sqm @ 15 sqm / day --- --- --- 36Finishing / cleaning 1 2 --- 4 Total : 42 68 82 228



Fabricator /Gas cutter /

WelderErector /

Marker /

79
















Fuel / Energy charges Hour 4.00 854.00 3416.00

Contd

Description

80

in `:

Quantity Rate

RatePerticulars Quantity

in `:



in `:Contd








in `:1 Crew for Mobile crane Hour 4.00 231.00 924.002 Crew for Shearing machine Hour 7.00 131.00 917.003 Crew for Planing machine Hour 69.00 210.00 14490.004 Crew for Drilling machine Hour 50.00 164.00 8200.005 Crew for Grinding machine Hour 25.00 164.00 4100.006 Foreman Day 42.00 436.00 18312.007 Marker / Fabricator / Erector Day 68.00 436.00 29648.008 Gas cutter Day 16.00 436.00 6976.009 Welder ( General ) Day 59.00 436.00 25724.00





TOTAL `: 1191963.37Add for excise duty on 75 percent cost of Machinery / Labour components @ 0.00% `: 0.00Add for insurance charges @ 1.00% `: 11919.63

Rate

81

Quantity

Quantity Rate

in `:

Descriptionin `:

Description


Add for designs and drawings @ 2.50% `: 29799.08Add for zigs / supports / winches / chain-pulley @ 2.50% `: 29799.08Add for power supply arrangements @ 2.30% `: 27415.16Add for enabling works @ 1.30% `: 15495.52




ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type vertical liftemergency gate consisting of skin plate, horizontal and vertical girders, wheels, stiffeners,lifting brackets, guide rollers, ballast blocks, teflon claded rubber seals etc., with all accessories for river sluice / canal sluice vent including cost of all materials, machinery, labour, cutting,aligning, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and threecoats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel componentsand all leads and lifts including packing / forwarding charges for other materials.

DATA:Consider upstream seal vertical lift roller gate. The gate leaf consists of skin plate, horizontalgirders, vertical end girders, stiffeners, wheels, gate guide rollers, brackets for hooks, seals etc., with all accessories.Consider river / canal sluice emergency gate for 2.5 m x 3 m sluice opening for analysis.For vent opening of 2.5 x 3.0 m approximate size of gate leaf will be : 3.2 m x 3.3 mHead of water above sill level considered : 34 mWeight of vertical lift roller gate in tonnes including ballast based on empirical formula :

= 0.0888 ( L 2 x H x h ) 0.659

Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm.

= 0.0888 ( 3.2 x 3.2 x 3.3 x 34 ) 0.659 : 9.229The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings for river sluice emergency gate of same size providedfor one of the dam.Actual wt of river sluice emergency gate as per data in Item :17 of Annexure-2 : 9.215 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of river sluicegate provided for one of the dam for rate analysis ( for details refer Item:17 of Annexure-2 ).


Plates / flats with 2.5 % wastage ( 4301 x 1.025 ) : 4409 kgb. Cast iron components conforming to IS : 210 :

Cast iron blocks for counter weight ( 4000 x 1.025 ) : 4100 kg

82


c. Alloy steel components conforming to IS : 1570 :Wheel axles / Pins : 144 kg

d. Cast steel components conforming to IS : 1030 :Wheels / guide rollers : 492 kg

e. Alluminium / Bronze alloy components conforming to IS : 305 :Bearings / Bushes : 76 kg

f. Bolts / Nuts / Washers conforming to IS : 1363 :SS bolts / nuts / washers with 2.5 % wastage ( 54 x 1.025 ) : 55 kgGI bolts / nuts / washers with 2.5 % wastage ( 144 x 1.025 ) : 148 kgMS bolts / nuts / washers with 2.5 % wastage ( 4 x 1.025 ) : 4 kg

g. Rubber seal conforming to IS : 11855 :Bottom seal ( flat uncladed ) ( 2.76 x 1.025 ) : 2.8 RmTop seal ( bulb type teflon claded ) ( 2.2 x 1.025 ) : 2.25 RmSide seals ( bulb type teflon claded ) ( 5.71 x 1.025 ) : 5.85 RmCorner seal ( bulb teflon claded ) : 2 Nos



Total : 147 RmFor cutting structural steel sections to required sizes gas cutting is assumed since most of thesections are above 10 mm thick.Length of steel to be cut by using gas manually : 29 mLength of steel to be cut by gas using pug cutting machine : 118 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 15 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 39 hoursAcetelyne gas @ 0.6 cum / hour ( 15 + 39 ) x 0.60 : 32 cumOxygen gas @ 1.8 cum / hour ( 15 + 39 ) x 1.80 : 96 cumUse of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hoursUse of pug cutting machine with 50 min / hr working ( 39 x 60 / 50 ) : 47 hours





( 89 x 0.25 + 265 x 0.75 ) : 221 hours

4. Surface cleaning and painting :Painting area for river sluice gate at 10 sqm / tonne ( 9.215 x 10 ) : 92 sqm

83


1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 92 sqm @ 9 sqm / ltr / coat : 10 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 92 sqm @ 6 sqm / ltr / coat : 46 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 92 sqm @ 8 sqm / ltr : 12 ltr

5. Requirement of other machinery :For lowering gate leaf from hoist chamber use of tower crane for 1 hour considered.For handling of gate parts during fabrication and erection 8 t mobile crane for 4 hours and stationery derric crane for 10 hours considered.For drilling holes in skin plate, counter weight blocks, horizontal girders and seal clamps use of drilling machine for 8 hours considered. For grinding and finishing weld joints in skin plate and other locations 8 hours use of grinding machine considered.


Painter Cl-II

Cutting sections 65 hours 4 8 8 16Drilling holes for seal fixing 1 2 --- 2Fabricating by stitch welding 89 hours 6 11 --- 22Run welding 265 hours 3 --- 33 33Fixing counter weight blocks 1 1 --- 2Seal fixing 1 1 --- 2Cleaning surface 92 sqm @ 15 sqm/day --- --- --- 6Painting ( 4 x 92 ) sqm @ 15 sqm / day --- --- --- 30Guide roller fixing / Cleaning / Lowering 1 2 --- 2 Total : 17 25 41 115





Gas cutter /

84

Marker /Welder




Plates / flats kg 4409.00 39.55 174362.722 Cast iron components

CI blocks for counter wt kg 4100.00 54.00 221400.003 Alloy steel components

Wheel axles / Pins kg 144.00 345.00 49680.004 Cast steel components

Wheels / Guide rollers kg 492.00 155.00 76260.005 Alluminium / Bronze alloy components

Bearings / Bushes kg 76.00 810.00 61560.006 Bolt / Nut / Washer

SS bolts / nuts / washers kg 55.00 182.00 10010.00GI bolts / nuts / washers kg 148.00 108.00 15984.00MS bolts / nuts / washers kg 4.00 90.00 360.00

7 Rubber sealsBottom seal ( flat uncladed ) Rm 2.80 219.00 613.20Side seals ( bulb teflon claded ) Rm 5.85 1049.00 6136.65Top seal ( bulb teflon claded ) Rm 2.25 1049.00 2360.25Corner seals ( bulb teflon claded ) Nos 2.00 1158.00 2316.00










Quantity

in `:

Ratein `:

Quantity RateDescription

Perticulars

85



in `:Contd

4 Mobile crane 8 t Hour 4.00 289.00 1156.00Fuel / Energy charges Hour 4.00 854.00 3416.00








in `:1 Crew for Mobile crane Hour 4.00 231.00 924.002 Crew for Tower crane Hour 1.00 178.00 178.003 Crew for Drilling machine Hour 8.00 164.00 1312.004 Crew for Grinding machine Hour 8.00 164.00 1312.005 Foreman Day 17.00 436.00 7412.006 Marker / Fabricator / Erector Day 25.00 436.00 10900.007 Gas cutter Day 8.00 436.00 3488.008 Welder ( General ) Day 29.00 436.00 12644.009 Welder ( X - ray grade ) Day 4.00 479.60 1918.40

10 Khalasi Day 4.00 436.00 1744.0011 Helper fabrication / erection Day 79.00 421.00 33259.0012 Helper for cleaning / painting Day 11.00 421.00 4631.0013 Painter Cl - II Day 25.00 421.00 10525.0014 Electrician Day 2.00 436.00 872.00




TOTAL `: 1011268.82

86

RateQuantityin `:

in `:Rate

Description

QuantityDescription






ITEM: Design, fabrication, supply, erection, testing and commissioning of automatic lifting beam with all accessories for handling, lowering and lifting of river sluice / canal sluice emergencygate including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and two coats of cold applied coal tar epoxy paint etc., complete as per specifications and drawings with all lead upto 1 km and alllifts for structural steel components and all leads and lifts including packing /forwardingcharges for other materials.

DATA:Automatic lifting beam for lifting river sluice emergency gate consists of fabricated beam withlifting bracket and automatic engaging / dis-engaging type hooks for under water hooking / de-hooking of gate leaf. Lifting beam is an independent attachment to moving gantry crane.Generally the weight of lifting beam for river sluice emergency gate will be about 10 percent of the weight of gate leaf with ballast.Consider river sluice emergency gate for sluice opening of size 2.5 m x 3 m for analysis.For vent opening of 2.5 x 3.0 m approximate size of gate leaf will be : 3.2 m x 3.3 mHead of water above sill level considered : 34 mWeight of vertical lift roller gate in tonnes including weight of ballast as per empirical formula :

= 0.0888 ( L 2 x H x h ) 0.659

Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm.Consider weight of lifting beam @ 10 % of weight of gate including ballast:

= 0.10 x 0.0888 ( L 2 x H x h ) 0.659

= 0.0089 ( 3.2 x 3.2 x 3.3 x 34 ) 0.659 : 0.925 tonneThe weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of lifting beam for river sluice emergency gate of samesize provided for one of the dam.Actual weight of lifting beam as per data in Item : 18 of Annexure-2 : 0.922 tonneConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of lifting beam for river sluice emergency gate provided for one of the dam for rate analysis ( for detailsrefer Item : 18 of Annexure-2 ).

87


1. Requirement of materials : a. Structural steel :


b. Alloy steel components :Pins : 71 kg

c. Bronze alloy components :Bush : 4 kg

d. Forged steel components :Hooks : 130 kg

e. Bolts / Nuts / Washers :MS bolts / nuts / washers with 2.5 % wastage ( 2 x 1.025 ) : 2 kg

f. MS pipe 100 mm dia : 11 kg g. Welding electrodes ( General purpose / Low hydrogen ) :

GP / LH electrodes as per data sheet ( Item:18 Annexure-2 ) : 508 NosAdd for variations / wastage / misc welding @ 10 % ( 508 x 0.1 ) : 51 NosTotal requirement of GP / LH electrodes : 559 Nos for stitch weld GP electrodes @t 10 % of total ( 559 x 0.10 ) : 56 Nos for run welding LH electrodes @ 90 % of total ( 559 x 0.90 ) : 503 Nos








Painting area for lifting beam at 12 sqm / tonne ( 0.922 x 12 ) : 11 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 11 sqm @ 9 sqm / ltr / coat : 1.25 ltr2 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 11 sqm @ 6 sqm / ltr / coat : 4 ltr

88


As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 11 sqm @ 8 sqm / ltr : 1.5 ltr

5. Requirement of other machinery :For drilling holes for pins / guide shoes 2 hours use of drilling machine considered. For grinding and finishing weld joints 2 hour use of grinding machine considered.


Painter Cl-II

Cutting sections 21 hours 1 3 3 6Drilling holes for pins / bolts fixing --- 1 --- 1Fabricating by stitch welding 15 hours 1 2 --- 4Run welding 45 hours 1 --- 6 6Cleaning surface 11 sqm @ 15 sqm/day --- --- --- 1Painting ( 3 x 11 ) sqm @ 15 sqm / day --- --- --- 3Finishing / guide shoe fixing / checking --- 1 --- 1 Total : 3 7 9 22







2 Alloy steel componentsLifting pins kg 71.00 345.00 24495.00

3 Bronze alloy components :Bronze bush kg 4.00 810.00 3240.00

4 Forged steel components :Lifting hooks kg 130.00 210.00 27300.00

Contd

Rate


in `:QuantityPerticulars


89

Welder



in `:Contd

5 MS pipe 100 mm dia kg 11.00 63.00 693.006 Bolt / Nut / Washer

MS bolts / nuts / washers kg 2.00 90.00 180.007 Oxygen gas cum 30.00 84.00 2520.008 Acetyline gas cum 10.00 404.00 4040.009 Welding electrodes ( general purpose ) Nos 56.00 10.00 560.00













in `:1 Crew for Drilling machine Hour 2.00 164.00 328.002 Crew for Grinding machine Hour 2.00 164.00 328.003 Foreman Day 3.00 436.00 1308.004 Marker / Fabricator / Erector Day 7.00 436.00 3052.00

Contd

in `:

in `:

Rate

in `:

Description

Quantity

Rate

90

Description Rate

Quantity

QuantityPerticulars



in `:Contd

5 Gas cutter Day 3.00 436.00 1308.006 Welder ( General ) Day 6.00 436.00 2616.007 Helper fabrication / erection Day 18.00 421.00 7578.008 Helper for cleaning / painting Day 2.00 421.00 842.009 Painter Cl - II Day 2.00 421.00 842.00









ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sill beam, wheel tracks, seal seats, guide rails etc., with all accessories for vertical liftbarrage gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of coldapplied coal tar epoxy paint etc.,complete as per specifications and aproved drawings with leadupto 1 km and all lifts for structural steel components and all leads and lifts includingpacking / forwarding charges for other materials.

DATA:Barrage gate embedded parts consist of sill beam, wheel tracks / seal tracks and gate guides

in `:

91

Description RateQuantity


with accessories such as first / second stage anchors.Weight of embedded parts for barrage gate will be about 15 to 20 percent of gate weight.Consider embedded parts for vertical lift gate for barrage opening of size 13.7 m x 8.26 m.For vent opening of 13.72 x 8.26 m the approximate size of gate leaf will be 14.7 x 8.6 m.Head of water above sill level considered : 8.26 mWeight of vertical lift barrage gate in tonnes based on empirical formula :

= 0.0335 ( L 2 x H x h ) 0.716

Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm.Consider weight of embedded parts @ 17.5 % of weight of gate leaf :

= 0.175 x 0.0335 ( L 2 x H x h ) 0.716

= 0.0058 ( 14.7 x 14.7 x 8.6 x 8.26 ) 0.716 : 5.763 tonnesThe weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of embedded parts for vertical lift barrage gate of samesize provided for one of the barrage.Actual weight of embedded parts as per data in Item :19 of Annexure-2 : 5.193 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of embeddedparts for vertical lift barrage gate provided for one of the barrage for rate analysis ( for detailsrefer Item : 19 of Annexure-2 ).



b. Alloy steel components conforming to IS : 1570 :Stainless steel plates / flats ( 620 + 133 ) x 1.025 : 772.00 kg



2. Cutting :Length of cutting assuming cutting for 2 sides as per data sheet : 210 RmAdd for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 21 RmTotal length of cutting Total : 231 RmFor cutting structural steel sections to required size gas cutting and use of plate shearingmachine is considered.Length of steel to be cut by using gas manually : 50 mLength of steel to be cut by gas using pug cutting machine : 151 mLength of steel to be cut by using shearing machine : 30 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 25 hours

92


Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 50 hoursTime for cutting by shearing machine at ( av ) 10 m cutting / hour : 3 hoursAcetelyne gas @ 0.6 cum / hour ( 25 + 50 ) x 0.60 : 45 cumOxygen gas @ 1.8 cum / hour ( 25 + 50 ) x 1.80 : 135 cumUse of gas cutting torch with 50 min / hr working ( 25 x 60 / 50 ) : 30 hoursUse of pug cutting machine with 50 min / hr working ( 50 x 60 / 50 ) : 60 hoursUse of shearing machine with 50 min / hr working ( 3 x 60 / 50) : 4 hours






For surface finishing of SS plates for wheel / seal tracks planing machine is considered.Length of SS plate for surface finishing by planing machine : 63.00 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 63 m SS plates ( 63 x 8 / 3 ) : 168 hours

5. Surface cleaning and painting :Painting area for embedded parts at 10 sqm / tonne ( 5.193 x 10 ) : 52 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 52 sqm @ 9 sqm / ltr / coat : 6 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 52 sqm @ 6 sqm / ltr / coat : 35 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 52 sqm @ 8 sqm / ltr : 6.5 ltr

6. Requirement of other machinery :For drilling holes for anchor bolts use of drilling machine for 24 hours considered.For grinding weld joints and edges requiring finishing use of grinding machine for 16 hours considered.For handling during fabrication and erection 25 t mobile crane for 24 hours with energy chargesfor 12 hours and stationery derric crane for 75 hours considered.


Painter Cl-II

Cutting sections 94 hours 6 12 12 24Drilling holes for anchors / supports 3 6 --- 12Fabricating by stitch welding 87 hours 6 11 --- 22

Contd

Gas cutter / Welder

Erector /Fabricator /

Marker /

93


7. Requirement of work force ( Contd ) :Work component Foreman Helper /

Painter Cl-II

ContdRun welding 260 hours 4 --- 32 32Erection of first stage anchors 10 20 --- 40Erection of Sill beam / Tracks / Guide 10 10 --- 20Cleaning surface 52 sqm @ 15 sqm/day --- --- --- 3Painting ( 5 x 52 ) sqm @ 15 sqm / day --- --- --- 20Finishing / cleaning 1 4 --- 4 Total : 40 63 44 177








10 Coal tar epoxy paint ltr 35.00 226.00 7910.0011 Rust cleaner / inhibitor ltr 6.50 311.00 2021.5012 Wire brush Nos 4.00 53.00 212.0013 Use rate welding holder set Hour 347.00 6.75 2342.25

Contd

94

Quantityin `:

Erector /

Marker /

Rate

WelderGas cutter /

Fabricator /

Perticulars



in `:Contd

















in `:1 Crew for Mobile crane 25 t Hour 24.00 231.00 5544.002 Crew for Plate shearing machine Hour 4.00 131.00 524.003 Crew for Planing machine Hour 168.00 210.00 35280.004 Crew for Drilling machine Hour 24.00 164.00 3936.005 Crew for Grinding machine Hour 24.00 164.00 3936.006 Foreman Day 40.00 436.00 17440.007 Marker / Fabricator / Erector Day 63.00 436.00 27468.008 Gas cutter Day 12.00 436.00 5232.00

Contd

in `:

95

Quantity Rate

in `:

RateQuantityPerticularsin `:

RateQuantity

Description

Description



in `:Contd

9 Welder ( General ) Day 29.00 436.00 12644.0010 Welder ( X - ray ) Day 3.00 479.60 1438.8011 Helper fabrication / erection Day 154.00 421.00 64834.0012 Helper for cleaning / painting Day 6.00 421.00 2526.0013 Painter Cl - II Day 17.00 421.00 7157.0014 Electrician Day 2.00 436.00 872.00








ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type verticallift gate consisting of skin plate, vertical and horizontal girders, wheels, stiffeners, liftingbrackets, guide shoes, rubber seals etc., with all accessories for barrage including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coatof zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc.,complete as per specifications and approved drawings with lead upto 1 km and all lifts forstructural steel components and all leads and lifts including packing / forwardingcharges for other materials.

in `:Rate

96

QuantityDescription


DATA:Consider upstream seal vertical lift roller gate. The gate leaf consists of skin plate, horizontalgirders, vertical end girders, stiffeners, wheels, gate guide shoes, brackets for pulleys, seals etc., with all accessories.Consider vertical lift roller gate for 13.72 m x 8.26 m opening for analysis.For vent opening of 13.72 x 8.26 m the approximate size of gate leaf will be 14.7 x 8.6 m.Head of water above sill level considered : 8.26 mWeight of gate leaf in tonne for vertical lift roller gate based on empirical formula :

= 0.0335 ( L 2 x H x h ) 0.716

Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm. = 0.0335 x( 14.7 x 14.7 x 8.6 x 8.26 ) 0.716 : 33.289

The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of vertical lift barrage gate of same size provided forone of the barrage.Actual weight of vertical lift barrage gate as per data in Item : 20 of Annexure-2 : 33.025 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of vertical liftgate provided for one of the barrage for rate analysis ( for details refer Item : 20 of Annexure-2 ).


Angles/ beams/ channels with 2.5 % wastage ( 3299x1.025 ) : 3382 kgPlates / flats with 2.5 % wastage ( 28655 x 1.025 ) : 29372 kg

b. Alloy steel components conforming to IS : 1570 :Wheel axles / Pins : 176 kg

c. Cast steel components conforming to IS : 1030 :Wheels : 656 kg

d. Alluminium / Bronze alloy components conforming to IS : 305 :Bearings / Bushes : 80 kg

e. Bolts / Nuts / Washers conforming to IS : 1363 :GI bolts / nuts / washers with 2.5 % wastage ( 91 x 1.025 ) : 93 kgMS bolts / nuts / washers with 2.5 % wastage ( 68 x 1.025 ) : 70 kg

f. Rubber seal conforming to IS : 11855 :Bottom seal ( flat uncladed ) ( 14 x 1.025 ) : 14.5 RmSide seals ( bulb uncladed ) ( 17.2 x 1.025 ) : 18 Rm

g. Welding electrodes ( General purpose / Low hydrogen ) :GP / LH electrodes as per data sheet ( Item:20 Annexure-2 ) : 18400 NosAdd for variations / wastage / misc welding @ 10 % ( 18400 x 0.1 ) : 1840 NosTotal requirement of GP / LH electrodes : 20240 Nos for stitch weld GP electrodes @t 10 % of total ( 20240 x 0.10 ) : 2024 Nos for run welding LH electrodes @ 90 % of total ( 20240 x 0.90 ) : 18216 Nos


Total : 765 RmFor cutting structural steel sections to required sizes gas cutting and plate shearing machinefor plates less than 12 mm thick are considered.Length of steel to be cut by using gas manually : 200 mLength of steel to be cut by gas using pug cutting machine : 465 mLength of steel to be cut by gas using plate shearing machine : 100 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 100 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 155 hours

97


Time for cutting by shearing machine at ( av ) 10 m cutting / hour : 10 hoursAcetelyne gas @ 0.6 cum / hour ( 100 + 155 ) x 0.60 : 153 cumOxygen gas @ 1.8 cum / hour ( 100 + 155 ) x 1.80 : 459 cumUse of gas cutting torch with 50 min / hr working ( 100 x 60 / 50 ) : 120 hoursUse of pug cutting machine with 50 min/hr working ( 155 x 60 / 50 ) : 186 hoursUse of plate shearing machine with 50 min/hr work ( 10 x 60 / 50 ) : 12 hours






Painting area for barrage gate at 18 sqm / tonne ( 33.025 x 18 ) : 595 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 595 sqm @ 9 sqm / ltr / coat : 66 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 595 sqm @ 6 sqm / ltr / coat : 298 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 595 sqm @ 8 sqm / ltr : 75 ltr

5. Requirement of other machinery :For handling of gate parts during fabrication and erection 25 t mobile crane for 20 hours withenergy charges for 10 hours and 8 t mobile crane for 40 hours and stationery derric crane for150 hours considered.For drilling holes in skin plate and seal base / clamps use of drilling machine for 50 hoursconsidered. For grinding and finishing weld joints in skin plate and other locations 50 hours use of grinding machine considered.


Painter Cl-II

Cutting sections 318 hours 20 40 40 80Drilling holes for seal fixing 3 6 --- 6Fabricating by stitch welding 540 hours 34 68 --- 136Run welding 1620 hours 20 --- 203 203Joining units & wheel fixing 4 8 --- 32Seal fixing & guide shoe fixing 1 2 --- 4Cleaning surface 595 sqm @ 15 sqm/day --- --- --- 40Painting ( 4 x 595 ) sqm @ 15 sqm / day --- --- --- 188Aligning and lowering in position 2 4 --- 16Cleaning / checking 1 2 --- 2 Total : 85 130 243 707

Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision

Fabricator / WelderGas cutter /

98

Marker /

Erector /


considered for welder for stitch welding.b. Workforce for painting 1 coat primer and 3 coats finishing paint consists of 158 Painters Cl-II at 15 sqm / day and 30 helpers to assist painters.






2 Alloy steel componentsWheel axles / Pins kg 176.00 345.00 60720.00

3 Cast steel componentsWheels kg 656.00 155.00 101680.00

4 Alluminium / Bronze alloy componentsBearings / Bushes kg 80.00 810.00 64800.00


6 Rubber sealsBottom seal ( flat uncladed ) Rm 14.50 219.00 3175.50Side seals ( bulb uncladed ) Rm 18.00 368.00 6624.00

7 Oxygen gas cum 459.00 84.00 38556.008 Acetyline gas cum 153.00 404.00 61812.009 Welding electrodes ( general purpose ) Nos 2024.00 10.00 20240.00




99

Perticulars Ratein `:

Quantity















in `:1 Crew for Mobile crane 25 t Hour 20.00 222.00 4440.002 Crew for Mobile crane 8 t Hour 40.00 231.00 9240.003 Crew for Plate shearing machine Hour 12.00 131.00 1572.004 Crew for Drilling machine Hour 50.00 164.00 8200.005 Crew for Grinding machine Hour 100.00 164.00 16400.006 Foreman Day 85.00 436.00 37060.007 Marker / Fabricator / Erector Day 130.00 436.00 56680.008 Gas cutter Day 40.00 436.00 17440.009 Welder ( General ) Day 183.00 436.00 79788.00

10 Welder ( X - ray grade ) Day 20.00 479.60 9592.0011 Khalasi Day 100.00 436.00 43600.0012 Helper fabrication / erection Day 479.00 421.00 201659.0013 Helper for cleaning / painting Day 70.00 421.00 29470.0014 Painter Cl - II Day 158.00 421.00 66518.0015 Electrician Day 10.00 436.00 4360.00

Total `: 586019.00Add for small Tools and Plants @ 1% `: 5860.19Add for Contractor's Profit @ 10% `: 58601.90Add for hidden cost on Labour @ 15% `: 87902.85

Contd

in `:RateQuantity

in `:

100


Description



in `:Contd

Add for additional hidden cost on labour @ 15% `: 87902.85Add for Contractor's Overheads @ 5% `: 29300.95







ITEM: Design, fabrication, supply, erection and commissioning of structural steel hoist bridge consisting of columns, beams, bracings, stiffeners, ties, chequered plate covering, hand railing,ladder etc., with all other accessories for supporting rope drum hoist for operating barrage gates including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying two coats of zinc chromate red oxide primer and three coats of approved synthetic enamel paint etc.,complete with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Structural steel hoist bridge for supporting rope drum hoist for operating barrage gates consistsof steel columns and beams with cross beams, ties, bracings, stiffeners, hand railing, ladder,chequered plate covering, anchorages etc., with all accessories.

The size of the steel hoist bridge depends on the size of the gate and hoist capacity required to operate the gate. Generally the hoist capacity will be 1.5 times the weight of the gate and theweight of hoist bridge will be about 400 kg per metre height of column or per metre span of beam.Consider vertical lift roller gate for 13.72 m x 8.26 m opening for analysis.For vent opening of 13.72 x 8.26 m the approximate size of gate leaf will be 14.7 x 8.6 m.Head of water above sill level considered : 8.26 m

in `:

101



Weight of gate leaf in tonne for vertical lift roller gate based on empirical formula : = 0.0335 ( L 2 x H x h ) 0.716

Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm. = 0.0335 x( 14.7 x 14.7 x 8.6 x 8.26 ) 0.716 : 33.289

Consider hoist capacity including 25 % reserve @ 1.5 times the weight of gate :( 1.5 x 33.289 ) : 49.9335

Round off the hoist capacity to next 10 tonne : 50 tonnesConsider 15 m span and 10 m over all height ( 9 m columns and 1 m beams ) for bridge.Assessment of weight of structural steel for bridge:Columns with bracings, anchors, stiffeners etc @ 400 kg / m for 9 m ht : : 3600.00 kgBeams with cross beams, stiffeners etc @ 400 kg / m for 15 m span : : 6000.00 kg

Total : 9600.00 kgOther accessories such as railing, chequered plate, ladder etc @ 10 % : 960.00 kg

Total : 10560.00 kgThe weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of hoist bridge structure for vertical lift barrage gate ofsame size provided for one of the barrage.Actual weight of hoist supporting bridge as per data in Item : 21 of Annexure-2 : 10239.00 kgConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of hoistbridge structure for vertical lift barrage gate provided for one of the barrage for rate analysis( for details refer Item : 21 of Annexure-2 ).

1. Requirement of materials:a. Structural steel conforming to IS : 2062 :

Angles / beams / channels with 2.5 % wastage ( 4453 x 1.025 ) : 4564 kgPlates / flats with 2.5 % wastage ( 5431 x 1.025 ) : 5567 kgChequered plate with 2.5 % wastage ( 133 x 1.025 ) : 136 kg

b. MS pipes 32 mm dia ( 30.86 x 1.025 ) : 32 RmMS pipes 25 mm dia ( 61.72 x 1.025 ) : 64 Rm

c. Bolt / Nut / WasherMS bolt / Nut / Washers with 2.5 % wastage ( 18 x 1.025 ) : 18.5 kg

d. Welding electrodes ( General purpose / Low hydrogen ) :GP / LH electrodes as per data sheet ( Item:21 Annexure-2 ) : 4731 NosAdd for variations / wastage / misc welding @ 10 % ( 4731 x 0.1 ) : 473 NosTotal requirement of GP / LH electrodes : 5204 Nos for stitch weld GP electrodes @t 10 % of total ( 5204 x 0.10 ) : 520 Nos for run welding LH electrodes @ 90 % of total ( 5204 x 0.90 ) : 4684 Nos


Total : 319 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 100 mLength of steel to be cut by gas using pug cutting machine : 219 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 50 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 73 hoursAcetelyne gas @ 0.6 cum / hour ( 50 + 73 ) x 0.60 : 74 cumOxygen gas @ 1.8 cum / hour ( 50 + 73 ) x 1.80 : 222 cum

102


Use of gas cutting torch with 50 min / hr working ( 50 x 60 / 50 ) : 60 hoursUse of pug cutting machine with 50 min / hr working ( 73 x 60 / 50 ) : 88 hours





( 139 x 0.25 + 416 x 0.75 ) : 347 hours

4. Surface cleaning and painting :Painting area for hoist bridge @ 20 sqm per tonne ( 10.239 x 20 ) : 205 sqm2 coats of zinc chromate red oxide primer .Quantity of primer paint for 205 sqm @ 12 sqm / ltr / coat : 35 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 205 sqm @ 12 sqm / ltr / coat : 51 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 205 sqm @ 8 sqm / ltr : 26 ltr

5. Requirement of other machinery :For handling of parts during fabrication and erection 8 t mobile crane for 12 hours and stationeryderric crane for 40 hours considered.For drilling holes in plates 8 hours use of drilling machine considered.For grinding and finishing weld joints in liner plates 8 hours use of grinding machine considered.


Painter Cl-II

Cutting sections 148 hours 9 18 18 36Fabricating by stitch welding 139 hours 9 17 --- 34Run welding 416 hours 5 --- 52 52For erection of columns & bracings 2 4 --- 16For erection of beams / cross beams 4 8 --- 16For erection of railing / covering etc 1 2 --- 4Cleaning surface 205 sqm @ 15 sqm/day --- --- --- 14Painting ( 5 x 205 ) sqm @ 15 sqm / day --- --- --- 61Finishing / Cleaning 1 1 --- 1 Total : 31 50 70 234


Gas cutter / Welder

Marker /

Erector /

103

Fabricator /







2 MS pipe 32 mm dia Rm 32.00 208.00 6656.00MS pipe 25 mm dia Rm 64.00 156.00 9984.00

3 Bolt / Nut / Washers kg 18.50 90.00 1665.004 Oxygen gas cum 222.00 84.00 18648.005 Acetyline gas cum 74.00 404.00 29896.006 Welding electrodes ( general purpose ) Nos 520.00 10.00 5200.007 Welding electrodes ( low hydrogen ) Nos 4684.00 21.00 98364.008 Zinc chromate red oxide primer ltr 35.00 139.00 4865.009 Synthetic enamel paint ( 1st quality ) ltr 51.00 233.00 11883.00

10 Rust cleaner / inhibitor ltr 26.00 311.00 8086.0011 Wire brush Nos 5.00 53.00 265.0012 Use rate welding holder set Hour 553.00 6.75 3732.7513 Use rate gas cutting torch set Hour 60.00 3.75 225.0014 Sundries LS 20.00 45.00 900.00








104


in `:

in `:




in `:Contd


5 Drilling machine Hour 8.00 13.00 104.00Fuel / Energy charges Hour 8.00 37.00 296.00











TOTAL `: 1016631.99Add for excise duty on 75 percent cost of Machinery / Labour components @ 0.00% `: 0.00Add for insurance charges @ 1.00% `: 10166.32Add for designs and drawings @ 2.50% `: 25415.80Add for zigs / supports / winches / chain-pulley @ 2.50% `: 25415.80

105

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in `:Quantity

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Add for power supply arrangements @ 2.30% `: 23382.54Add for enabling works @ 1.30% `: 13216.22




ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity ropedrum hoist consisting of hoist platform, rope drum, pulleys, gear system, electri c motor, electro-magnetic brake system, manual operation assembly, position indicator, control panel, wire rope etc., with all accessories for operating vertical lift roller gates for barrageincluding cost of all materials, machinery, labour, cutting, bending, aligning, anchoring, welding,finishing, cleaning, greasing, applying two coats of zinc chromate red oxide primer and three coats of approved synthetic enamel paint etc., complete with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Rope drum hoist for vertical lift barrage gate consists of hoist supporting frames, pulleysupports, pulleys, drive stool, rope drums, shafts, couplings, gears and pinions, plummerblocks, gear box, electric motor, hand operation assembly, brake, wire rope, gate positionindicator, switch box etc. with related accessories.Consider rope drum hoist for operating barrage gate for clear opening of 13.72 m x 8.26 m.For vent opening of 13.72 x 8.26 m the approximate size of gate leaf will be 14.7 x 8.6 m.Head of water above sill level considered : 8.26 mGenerally the capacity of hoist required for barrage gate will be 1.5 times the weight of gate.Weight of hoist with all accessories is assumed at 0.1 tonne per tonne capacity of hoist as thehoist is supported on steel bridge and no anchorages and base frames are required.Weight of gate leaf in tonnes based on empirical formula :

= 0.0335 ( L 2 x H x h ) 0.716

Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm. = 0.0335 ( 14.7 x 14.7 x 8.6 x 8.26 ) 0.716 : 33.289

Consider capacity of hoist including 25 % reserve capacity at 1.5 times the weight of gate :( 1.50 x 33.289 ) : 49.933 tonnes

Round off the capacity of hoist to next 10 tonne : 50.00 tonneConsider Weight of hoist with all accessories @ 0.1 t / tonne capacity of hoist :

( 50 x 0.10 ) : 5.00 tonnesThe hoist capacity and hoist weight computed as above based on empirical formulae are furtherchecked by varifying / computing the actual capacity and weight as per fabrication drawings forvertical lift barrage gate rope drum hoist of same capacity provided for one of the barrage.Actual capacity of rope drum hoist as per data sheet : 50.000 tonnesActual wt of barrage gate rope drum hoist as per data in Item :22 of Annexure-2 : 5.069 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of rope drumhoist for vertical lift barrage gate provided for one of the barrage for rate analysis ( for details

106


refer Item : 22 of Annexure-2 ).


Angles / beams / channels / bars with 2.5 % wastage ( 410x1.025 ) : 420.00 kgPlates / flats with 2.5 % wastage ( 219 x 1.025 ) : 225.00 kg

b. Cast steel components conforming to IS : 1030 :Rope drums 2 Nos / Gears : 1290.00 kgPinions : 98.00 kgPulleys 8 Nos / Couplings 2 Nos : 650.00 kgPlummer blocks / Hubs : 250.00 kg

c. Alloy steel steel components conforming to IS : 1570 :Shafts / Keys : 350.00 kgPins : 96.00 kg



f. Steel wire rope conforming ti IS 2266 :28 mm dia 6 / 37 construction 1 No 120 Rm @ 2.71 kg / m : 435.00 kg

g. Other components :Manual operation assembly : 1 No.Worm reducer ( size 800 ) : 1 NoElectric motor 12.5 hp : 1 No.Gate position indicator : 1 No.Ele-magnetic brake : 1 No.Electric cable / switch / control panel etc : 1 set

h. Welding electrodes ( General purpose / Low hydrogen ) :GP / LH electrodes as per data sheet ( Item:22 Annexure-2 ) : 553 NosAdd for variations / wastage / misc welding @ 10 % ( 553 x 0.1 ) : 55 NosTotal requirement of GP / LH electrodes : 608 Nos for stitch weld GP electrodes @ 10 % of total ( 608 x 0.10 ) : 61 Nos for run welding LH electrodes @ 90 % of total ( 608 x 0.90 ) : 547 Nos



3. Welding :Length of welding as per data sheet : 53 Rm

107


For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 61 / 15 ) x 8 / 2 : 16 hours

For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 547 / 15 ) x 8 / 6 : 49 hours

Total : 65 hoursDeploy welding transformer for 65 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 16 x 0.25 + 49 x 0.75 ) : 41 hours

4. Surface cleaning and painting :Painting area for hoist at 20 sqm / tonne of str steel ( 0.645 x 20 ) : 13 sqm2 coats of zinc chromate red oxide primer.Quantity of primer paint for 13 sqm @ 12 sqm / ltr / coat : 2 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 13 sqm @ 12 sqm / ltr /coat : 3.5 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 13 sqm @ 8 sqm / ltr : 1.5 ltr

5. Requirement of other machinery :For lifting and placing in position hoist drums, worm reducers, gears, floating shafts etc use of 25 t mobile crane for 56 hours with energy charges for 28 hours considered.For handling of parts during fabrication and transportation use of 8 t mobile crane for 40 hourswith energy charges for 20 hours considered.For drilling holes for bolts 16 hours use of drilling machine considered. For grinding and finishing weld joints 8 hours use of grinding machine considered


Painter Cl-II

Cutting sections/ drilling holes 21 hours 1 3 3 6Fabricating by stitch welding 16 hours 1 2 --- 4Run welding 49 hours 1 --- 6 6Erection of hoist frame 2 2 --- 8Erection of drums / gears / shafts 4 8 --- 16Erection of pulleys / plummer blocks 2 4 --- 8Erection of worm reducers / brake / motor 2 4 --- 8Erection of other accessories 1 2 --- 2Erection of control panel / cabling 1 1 --- 2Checking and running without rope 1 2 --- 4Cleaning surface 13 sqm @ 15 sqm/day --- --- --- 1Painting ( 5 x 13 ) sqm @ 15 sqm / day --- --- --- 4Rope fixing and checking 2 4 --- 8Trial running by lowering / lifting gate 1 2 --- 4Final checking / Finishing / cleaning 1 1 --- 2 Total : 20 35 9 83

Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.

108

WelderGas cutter /


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b. Workforce for painting 2 coat primer and 3 coats finishing paint consists of 3 Painters Cl-II at 15 sqm / day and 1 helper to assist painters.



RATE ANALYSIS UNIT : 5.069 tonne wtA. MATERIALS: 50.00 t capacity Sl No Unit Amount



2 Cast steel components :Rope drums 2 Nos / Gears kg 1290.00 190.00 245100.00Pinions kg 98.00 190.00 18620.00Pulleys 3 Nos / Couplings 2 Nos kg 650.00 155.00 100750.00Plummer blocks / Hubs kg 250.00 155.00 38750.00

3 Alloy steel componentsShafts / Keys kg 350.00 280.00 98000.00Pins kg 96.00 345.00 33120.00


5 Wire rope 28 mm dia 6/37 construction kg 435.00 163.00 70905.006 MS Bolt / Nut / Washer kg 26.00 90.00 2340.007 Worm reducers No. 1.00 180000.008 Electric motor 12.5 hp No. 1.00 90000.00 90000.009 Manual operating system No. 1.00 33750.00 33750.00

10 Gate position indicator No. 1.00 13500.00 13500.0011 Ele-magnetic brake No. 1.00 22500.00 22500.0012 Electric cable / switch / control panel etc LS 1.00 27000.00 27000.0013 Oxygen gas cum 30.00 84.00 2520.0014 Acetyline gas cum 10.00 404.00 4040.0015 Welding electrodes ( general purpose ) Nos 61.00 10.00 610.0016 Welding electrodes ( low hydrogen ) Nos 547.00 21.00 11487.0017 Zinc chromate red oxide primer ltr 2.00 139.00 278.0018 Synthetic enamel ( 1st quality ) paint ltr 3.50 233.00 815.5019 Rust cleaner / inhibitor ltr 1.50 311.00 466.5020 Grease kg 50.00 233.00 11650.0021 Wire brush Nos 2.00 53.00 106.0022 Use rate welding holder set Hour 65.00 6.75 438.75

Contd

in `:

109

180000.00

Perticulars RateQuantity



in `:Contd















in `:1 Crew for Mobile crane 8 t Hour 40.00 231.00 9240.002 Crew for Mobile crane 25 t Hour 56.00 222.00 12432.003 Crew for Drilling machine Hour 8.00 164.00 1312.004 Crew for Grinding machine Hour 16.00 164.00 2624.005 Foreman Day 20.00 436.00 8720.006 Marker / Fabricator / Erector Day 35.00 436.00 15260.007 Gas cutter Day 3.00 436.00 1308.008 Welder ( General ) Day 6.00 436.00 2616.009 Khalasi Day 90.00 436.00 39240.00

10 Helper fabrication / erection Day 78.00 421.00 32838.0011 Helper for cleaning / painting Day 2.00 421.00 842.00

Contd

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Quantity

110

Description

Perticulars

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Rate

in `:

in `:



in `:Contd










ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sillbeam, wall plates, seal seats, first stage anchors, anchor girders, anchor bars,trunnion supports etc., with all accessories for outflow regulating automatic gates for barrage / escape including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning,applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Embedded parts for automatic outflow regulating gate consist of sill beam / wall plates / anchor /girders / anchor bars trunnion supports etc., with all accessories. The weight of embedded parts

in `:Quantity Rate

111

Description


for automatic gate will be about 35 to 40 percent of weight of gate leaf with fulcrum assembly.Consider embedded parts for automatic outflow regulating gate for barrage opening of size8.0 m x 3.5 m.Size of gate : 8.00 m x 3.50 m Head of water : 3.50 mWeight of automatic outflow regulating gate with fulcrum assembly in tonne for the openingbased on empirical formula = 0.1325 x ( L 2 x H x h ) 0.673

Consider Weight of embedded parts in tonne @ av. 55 % of weight of gate : = 0.375 x 0.1325 x ( L 2 x H x h ) 0.673

Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.049 x ( 8 x 8 x 3.5 x 3.3 ) 0.673 : 4.177

The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of embedded parts for barrage outflow regulating radialgate of same size furnished by the designer.Actual weight of embedded parts : : 3.910 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of embeddedparts for automatic outflow regulating gate as provided by the designer. ( for details referItem : 23 of Annexure-2 ).

1. Requirement of materials:a. Structural steel conforming ti IS : 2062 :

Total weight of structural steel excluding wastage : 3800 kgWeight of Angles / Channels / Beams @ 20 % : 760 kgWeight of Plates / Flats @ 80 % : 3040 kgAngles / beams / channels / bars with 2.5 % wastage ( 760x1.025 ) : 779 kgPlates / flats with 2.5 % wastage ( 3040 x 1.025 ) : 3116 kg

b. Alloy steel conforming to IS : 1570 :Stainless steel plates / flats AISI 410 ( 49 x 1.025 ) say: 50.00 kgStainless steel plates / flats AISI 304L ( 62 x 1.025 ) say: 64.00 kg

c. Bolt / Nut / Washer conforming to IS : 1363 :MS bolts and nuts with 2.5 % wastage ( 129 x 1.025 ) : 132 kg


2. Cutting :Length of cutting assuming cutting for 2 sides as per data sheet : 168.00 RmAdd for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 17.00 Rm

Total : 185.00 RmFor cutting structural steel sections to required sizes plate shearing machine and gas cutting isassumed.Length of steel to be cut by using plate shearing machine : 30 m

112


Length of steel to be cut by using gas manually : 40 mLength of steel to be cut by gas using pug cutting machine : 115 mTime for cutting by shearing machine @ ( av ) 10 m cutting / hour : 3 hoursTime for gas cutting manually at ( av ) 2 m cutting / hour : 20 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 38 hoursAcetelyne gas @ 0.6 cum / hour ( 20 + 38 ) x 0.60 : 35 cumOxygen gas @ 1.8 cum / hour ( 20 + 38 ) x 1.80 : 105 cumUse of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) : 23 hoursUse of pug cutting machine with 50 min / hr working ( 38 x 60 / 50 ) : 45 hours

3. Welding :For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr





For surface finishing of SS plates for seal tracks planing machine is considered.Length of SS plate for surface finishing by planing machine : 47 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 47 m SS plates ( 47 x 8 / 3 ) : 126 hours


6. Requirement of other machinery :For drilling holes for anchor bolts 16 hours use of drilling machine considered.For finishing weld joints / edges 12 hours use of grinding machine considered.For handling of parts during fabrication and erection use of 8 t mobile crane for 18 hours and stationery derric crane for 56 hours considered.


Painter Cl-II

Cutting sections 68 hours 4 8 8 24Drilling holes for anchors / supports --- 2 --- 4Fabricating by stitch welding 32 hours 4 8 --- 24Run welding 95 hours 6 --- 12 12Erection of Anchor girders / anchor bars 2 4 --- 12

Contd

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113


7. Requirement of work force ( Contd ):Work component Foreman Helper /

Painter Cl-II

ContdErection of first stage anchors 1 2 --- 4Erection of Sill beam / Wall plates 2 4 --- 12Cleaning surface 40 sqm @ 15 sqm/day --- --- --- 3Painting ( 5 x 40 ) sqm @ 15 sqm / day 2 --- --- 15Finishing / Checking 1 2 --- 2 Total : 22 30 20 112

Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision considered for welder for stitch welding.b. Workforce for painting 1 coat primer and 4 coats finishing paint consists of 13 Painters Cl-II at 15 sqm / day and 2 helpers to assist painters.For surface finishing of stainless steel plates for seal seats planing machine is considered.






2 Stainless steel plates / flats AISI 410 kg 50.00 231.00 11550.00Stainless steel plates / flats AISI 304L kg 64.00 462.00 29568.00

3 MS bolts and nuts kg 132.00 90.00 11880.004 Oxygen gas cum 105.00 84.00 8820.005 Acetyline gas cum 35.00 404.00 14140.006 Welding electrodes ( general purpose ) Nos 15.00 10.00 150.007 Welding electrodes ( low hydrogen ) Nos 132.00 21.00 2772.008 Welding electrodes ( stainless steel ) Nos 1036.00 62.00 64232.009 Zinc rich epoxy primer ltr 5.00 244.00 1220.00

10 Coal tar epoxy paint ltr 27.00 226.00 6102.0011 Rust cleaner / inhibitor ltr 5.00 311.00 1555.0012 Wire brush Nos 3.00 53.00 159.00

Contd

in `:Rate

Gas cutter /

114

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Erector /

Marker /Fabricator / Welder

Perticulars



in `:Contd

















in `:1 Crew for Mobile crane Hour 18.00 231.00 4158.002 Crew for plate shearing machine Hour 3.00 131.00 393.003 Crew for Planing machine Hour 127.00 210.00 26670.004 Crew for Drilling machine Hour 12.00 164.00 1968.005 Crew for Grinding machine Hour 16.00 164.00 2624.006 Foreman Day 22.00 436.00 9592.007 Marker / Fabricator / Erector Day 30.00 436.00 13080.00

Contd

in `:Description

Description

Quantity Rate

Quantity Rate

Quantity Rate

115

Perticularsin `:

in `:



in `:Contd

8 Gas cutter Day 8.00 436.00 3488.009 Welder ( General ) Day 10.00 436.00 4360.00





TOTAL `: 594946.97Add for excise duty on 75 percent cost of Machinery / Labour components @ 0.00% `: 0.00Add for insurance charges @ 1.00% `: 5949.47Add for patent royalty charges @ 4.40% `: 26177.67Add for designs and drawings @ 2.50% `: 14873.67Add for zigs / supports / winches / chain-pulley @ 2.50% `: 14873.67Add for power supply arrangements @ 2.30% `: 13683.78Add for enabling works @ 1.30% `: 7734.31




ITEM: Design, fabrication, supply, erection, testing and commissioning of automatic outflow regulating gate and fulcrum assembly consisting of skin plate, stiffeners, horizontal girders, trunnion assemblies, gate bracket, base plate, rolling surface assembly, link brackets, link assembly, rubber seals, seal clamps etc., with all accessories for barrage including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with lead upto 1 km and

in `:Description Quantity Rate

116


all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Automatic outflow regulating gate and fulcrum assembly consisting of skin plate, stiffeners, horizontal girders, trunnion assemblies, gate bracket, base plate, rolling surface assembly, link , brackets, link assembly rubber seals, seal clamps etc., with all accessories.Consider automatic outflow regulating gate for barrage opening of size 8 m x 3.5 m for analysis.Size of gate : 8.00 m x 3.50 m Head of water : 3.30 mWeight of automatic gate leaf in tonnes based on empirical formula :

= 0.1325 x ( L 2 x H x h ) 0.673


The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of automatic outflow regulating gate of same size furnished by the designer for one of the gate.Actual weight of radial gate leaf as per data in Item :24 of Annexure-2 : : 11.270 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of canalregulator radial gate provided for one of the canal regulator for rate analysis ( for details referItem : 24 of Annexure-2 ).

1. Requirement of materials: a. Structural steel :

Angles / beams / channels / bars with 2.5 % wastage ( 3122x1.025 ) : 3200 kgPlates / flats with 2.5 % wastage ( 7561x1.025 ) : 7750 kg

b. Alloy steel components :Pins / Axles : 74 kgStainless plate / flats AISI 410 ( 49x1.025 ) : 50 kg

c. Cast steel components :Trunnion hub / Guide roller : 443 kg

d. Alluminium / Bronze alloy components :Trunnion / Guide roller bush : 33 kg

e. Bolts / Nuts / Washers :Stainless steel bolts /nuts /washers with 2.5 % wastage ( 31 x 1.025 ) : 32 kgMS bolts / nuts / washers with 2.5 % wastage ( 23.5x1.025 ) : 24 kg

f. Rubber seal :Bottom seal ( flat type ) ( 8 x 1.025 ) : 8.5 RmSide seals ( Z - type ) (2 x 4 x 1.025 ) : 8.5 Rm

g. Welding electrodes ( Ordinary / Low hydrogen ) :GP / LH electrodes as per data sheet ( Item:24 Annexure-2 ) : 6125 NosAdd for variations / wastage / misc welding @ 10 % ( 6125 x 0.1 ) : 613 NosTotal requirement of GP / LH electrodes : 6738 Nos for stitch weld GP electrodes @t 10 % of total (6738 x 0.10 ) : 674 Nos for run welding LH electrodes @ 90 % of total (6738 x 0.90 ) : 6064 Nos

h. Welding electrodes ( Stainless steel ) :SS electrodes as per data sheet ( Item:24 Annexure-2 ) : 150 NosAdd for variations / wastage / misc welding @ 10 % ( 6900 x 0.1 ) : 15 NosTotal requirement of SS electrodes : 165 Nos for stitch weld SS electrodes @t 10 % of total (165 x 0.10 ) : 15 Nos for run welding SS electrodes @ 90 % of total (165 x 0.90 ) : 160 Nos

117


2. Cutting :Total length of cutting assuming cutting for 2 sides : 195 RmAdd for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 20 Rm

Total : 215 RmFor cutting structural steel sections to required sizes use of plate shearing machine and gas cutting is assumed.Length of steel to be cut by using plate shearing machine 40 mLength of steel to be cut by using gas manually : 62 mLength of steel to be cut by gas using pug cutting machine : 113 mTime for cutting by plate shearing machine at ( av ) 10 m cutting / hour : 4 hoursTime for gas cutting manually at ( av ) 2 m cutting / hour : 31 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 38 hoursAcetelyne gas @ 0.6 cum / hour ( 31 + 38 ) x 0.60 : 42 cumOxygen gas @ 1.8 cum / hour ( 31 + 38 ) x 1.80 : 126 cumUse of gas cutting torch with 50 min / hr working ( 31 x 60 / 50 ) : 37 hoursUse of pug cutting machine with 50 min / hr working ( 38 x 60 / 50 ) : 46 hours


( 674 + 15 ) x 8 / ( 15 x 2 ) : 184 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 6064 + 160 ) x 8 / ( 15 x 6 ) : 553 hoursTotal : 737 hours



For surface finishing of SS plates planing machine is considered.Length of SS plate for surface finishing by planing machine : 3 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 3 m SS plates ( 3 x 8 / 3 ) : 8 hours

6. Surface cleaning and painting : Painting area for gate at 20 sqm / tonne ( 11.27 x 20 ) : 225 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 225 sqm @ 9 sqm / ltr / coat : 25 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 225 sqm @ 6 sqm / ltr / coat : 112 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 225 sqm @ 8 sqm / ltr : 28 ltr

7. Requirement of other machinery :For drilling holes in skin plate and seal clamps for seal fixing 16 hours use of drilling machine considered. For grinding and finishing weld joints in skin plate and other locations 16 hours use of grinding machine considered.For handling of parts during fabrication and erection use of 8 t mobile crane for 16 hours and stationery derric crane 50 hours considered.

118



Painter Cl-II

Cutting sections 87 hours 2 4 9 18Drilling holes for seal fixing 1 2 --- 2Erection of trunnions/H -girders /stiffeners 4 4 --- 8Fabricating and stitch welding 184 hours 11 23 --- 46Run welding 553 hours 5 --- 69 69Erection of links / other accessories 2 4 --- 8Erection of fulcrum assembly 2 4 --- 8Cleaning surface 225 sqm @ 15 sqm/day --- --- --- 15Painting ( 4 x 225 ) sqm @ 15 sqm / day --- --- --- 66Seal fixing 1 2 --- 2Finishing / checking / cleaning 1 1 --- 1 Total : 29 44 78 243







2 Cast steel components :Hub / Rollers kg 443.00 155.00 68665.00

3 Alloy steel components :Stainless steel plate kg 50.00 231.00 11550.00Pins / Axles kg 74.00 345.00 25530.00

4 Alluminium / Bronze alloy components:Bearings / Bush kg 33.00 810.00 26730.00

Contd

Gas cutter /

Ratein `:

Erector /



119

Welder



in `:Contd

5 Bolt / Nut / Washer :Stainless steel bolts / nuts / washers kg 32.00 182.00 5824.00MS bolts / nuts / washers kg 24.00 90.00 2160.00

6 Rubber seals :Bottom seal Rm 8.50 219.00 1861.50Side seals ( Z - type ) Rm 8.50 411.00 3493.50


10 Welding electrodes ( general purpose ) Nos 674.00 10.00 6740.0011 Welding electrodes ( low hydrogen ) Nos 6064.00 21.00 127344.0012 Welding electrodes ( stainless steel ) Nos 165.00 62.00 10230.0013 Zinc rich epoxy primer ltr 25.00 244.00 6100.0014 Coal tar epoxy paint ltr 112.00 226.00 25312.0015 Rust cleaner / inhibitor ltr 28.00 311.00 8708.0016 Wire brush Nos 5.00 53.00 265.0017 Use rate welding holder set Hour 737.00 6.75 4974.7518 Use rate gas cutting torch set Hour 37.00 3.75 138.7519 Sundries LS 100.00 45.00 4500.00








Fuel / Energy charges Hour 8.00 111.00 888.007 Mobile crane ( revolving ) 8 t Hour 16.00 289.00 4624.00





Total `: 77711.00Contd

in `:QuantityDescription

in `:Perticulars

Rate

RateQuantity

120



in `:Contd




in `:1 Crew for Mobile crane 8 t Hour 16.00 231.00 3696.002 Crew for plate shearing machine Hour 4.00 131.00 524.003 Crew for planing machine Hour 8.00 210.00 1680.004 Crew for Drilling machine Hour 16.00 164.00 2624.005 Crew for Grinding machine Hour 32.00 164.00 5248.006 Foreman Day 29.00 436.00 12644.007 Marker / Fabricator / Erector Day 44.00 436.00 19184.008 Gas cutter Day 9.00 436.00 3924.009 Welder ( General ) Day 62.00 436.00 27032.00

10 Welder ( X - ray ) Day 7.00 479.60 3357.2011 Khalasi Day 34.00 436.00 14824.0012 Helper fabrication / erection Day 162.00 421.00 68202.0013 Helper for cleaning / painting Day 21.00 421.00 8841.0014 Painter Cl - II Day 60.00 421.00 25260.0015 Electrician Day 3.00 436.00 1308.00




TOTAL `: 1307118.39Add for excise duty on 75 percent cost of Machinery / Labour components @ 0.00% `: 0.00Add for insurance charges @ 1.00% `: 13071.18Add for Patent royalty charges @ 4.40% `: 57513.21Add for designs and drawings @ 2.50% `: 32677.96Add for zigs / supports / winches / chain-pulley @ 2.50% `: 32677.96Add for power supply arrangements @ 2.30% `: 30063.72Add for enabling works @ 1.30% `: 16992.54

Total `: 1490114.96

Quantity

in `:

Ratein `:

Perticulars


121


Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x11.27 tonnes @ `: 358.20 / tonne `: 8073.83Add for packing, forwarding and transportation upto work site on cost of materials other than structural steel ( on cost of Sl No. 2 to 16 ) @ 3.00% `: 10741.95 Total cost for 11.270 tonne `: 1508930.74



ITEM: Design, fabrication, supply, erection, testing and commissioning of hoisting cum damping system consisting of low level horizontal lever link, low level long actuating lever, high level vertical lever link, high level short actuating lever, high level hoisting bracket, axle for lever system, friction shoes, supporting box for shoes, track assembly, ratchet pawl, supporting structure, bracket plate etc., with all accessories for outflow regulating automatic gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Hoisting cum damping system for automatic outflow regulating gate consists of low levelhorizontal lever link, low level long actuating lever, high level vertical lever link, high level short actuating lever, high level hoisting bracket, axles for lever system, friction shoes, track assembly, support box for shoes, ratchet pawl, support structure, bracket plate etc.Consider hoisting cum damping system for automatic outflow regulating gate of size 8 x 3.50 mfor analysis.Weight of the hoisting cum damping system will be about 50 to 55 percent of the weight of theautomatic outflow regulating gate.Consider automatic outflow regulating gate for barrage opening of size 8 m x 3.5 m for analysis.Size of gate : 8.00 m x 3.50 m Head of water : 3.30 mWeight of automatic gate leaf in tonnes based on empirical formula :

= 0.1325 x ( L 2 x H x h ) 0.673


Weight of hoisting cum damping system = 0.525 x 11.295 : 5.93 tonnesThe weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings.Actual weight of radial gate leaf as per data in Item :25 of Annexure-2 : : 5.81 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of hoistinglcum damping system as furnished by the designer for one of the automatic outflow regulating gate of size 8.0 x 3.5 m for rate analysis ( for details referItem : 25 of Annexure-2 ).


Angles / beams / channels / bars with 2.5 % wastage ( 1483x1.025 ) : 1520 kgPlates / flats with 2.5 % wastage ( 3622x1.025 ) : 3712 kg

b. Alloy steel components :Stainless steel plates / flats : 435 kgAxles / Pins : 59 kg

122


c. Cast steel components :Wheels / Hubs / Rollers : 76 kg

d. Alluminium / Bronze alloy components :Bearings / Bush : 118 kgPipe 50 NB : 28 kg

e. Bolts / Nuts / Washers :Stainless steel bolts /nuts /washers with 2.5 % wastage ( 15.5 x 1.025 ) : 16 kgMS bolts / nuts / washers with 2.5 % wastage ( 14.5x1.025 ) : 15 kg

f. Disc springs : 64 Nos h. Welding electrodes ( Ordinary / Low hydrogen ) :

GP / LH electrodes as per data sheet ( Item:25 Annexure-2 ) : 2911 NosAdd for variations / wastage / misc welding @ 10 % ( 2911 x 0.1 ) : 291 NosTotal requirement of GP / LH electrodes : 3202 Nos for stitch weld GP electrodes @t 10 % of total (3202 x 0.10 ) : 320 Nos for run welding LH electrodes @ 90 % of total (3202 x 0.90 ) : 2882 Nos

i. Welding electrodes ( Stainless steel ) :SS electrodes as per data sheet ( Item:25 Annexure-2 ) : 324 NosAdd for variations / wastage / misc welding @ 10 % ( 324 x 0.1 ) : 32 NosTotal requirement of SS electrodes : 356 Nos for stitch weld SS electrodes @t 10 % of total (356 x 0.10 ) : 36 Nos for run welding SS electrodes @ 90 % of total (356 x 0.90 ) : 320 Nos

2. Cutting :Total length of cutting assuming cutting for 2 sides : 124 RmAdd for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 12 Rm

Total : 136 RmFor cutting structural steel sections to required sizes plate shearing machine and gas cutting by manually and by pug cutting machine is assumed.Length of steel to be cut by using plate shearing machine : 20 mLength of steel to be cut by using gas manually : 34 mLength of steel to be cut by gas using pug cutting machine : 82 mTime for cutting by shearing machine at ( av ) 10 m cutting / hour : 2 hoursTime for gas cutting manually at ( av ) 2 m cutting / hour : 17 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 27 hoursAcetelyne gas @ 0.6 cum / hour ( 17 + 27 ) x 0.60 : 27 cumOxygen gas @ 1.8 cum / hour ( 17 + 27 ) x 1.80 : 81 cumUse of gas cutting torch with 50 min / hr working ( 17 x 60 / 50 ) : 21 hoursUse of pug cutting machine with 50 min / hr working ( 27 x 60 / 50 ) : 33 hours

4. Welding :Length of welding :For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr





Painting area for radial gate at 18 sqm / tonne ( 5.81 x 18 ) : 105 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.

123


Quantity of primer paint for 105 sqm @ 9 sqm / ltr / coat : 12 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 105 sqm @ 6 sqm / ltr / coat : 52 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 105 sqm @ 8 sqm / ltr : 13 ltr

6. Requirement of other machinery :For drilling holes in skin plate and seal clamps for seal fixing 16 hours use of drilling machine considered. For grinding and finishing weld joints in skin plate and other locations 16 hours use of grinding machine considered.For handling of parts during fabrication and erection use of 8 t mobile crane for 16 hours and stationery derric crane for 50 hours considered.


Painter Cl-II

Cutting sections 56 hours 2 2 7 11Drilling holes for bolt fixing 1 2 --- 2Fabricating by stitch welding 95 hours 2 12 --- 12Run welding 285 hours 2 --- 36 36Erection of low level lever links 2 2 --- 4Erection of high level lever links 2 2 --- 4Erection of support structure 1 2 --- 4Erection of hoist bracket 1 2 --- 4Erection of other accessories 1 2 --- 4Cleaning surface 105 sqm @ 15 sqm/day --- --- --- 7Painting ( 4 x 105 ) sqm @ 15 sqm / day --- --- --- 35Finishing / checking / cleaning 1 1 --- 1 Total : 15 27 43 124




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124





2 Cast steel components :Trunnion hubs / Guide rollers kg 76.00 155.00 11780.00

3 Alloy steel components :Stainless steel plate kg 435.00 231.00 100485.00Axles / Pins kg 59.00 345.00 20355.00

4 Alluminium / Bronze alloy components:Bearings / Bush kg 118.00 810.00 95580.00Pipe 50 NB kg 28.00 810.00 22680.00

5 Bolt / Nut / Washer :Stainless steel bolts / nuts / washers kg 16.00 182.00 2912.00MS bolts / nuts / washers kg 15.00 90.00 1350.00

6 Disc spring Nos 64.00 585.00 37440.007 Oxygen gas cum 81.00 84.00 6804.008 Acetyline gas cum 27.00 404.00 10908.009 Welding electrodes ( general purpose ) Nos 320.00 10.00 3200.00

10 Welding electrodes ( low hydrogen ) Nos 2882.00 21.00 60522.0011 Welding electrodes ( stainless steel ) Nos 356.00 62.00 22072.0012 Zinc rich epoxy primer ltr 12.00 244.00 2928.0013 Coal tar epoxy paint ltr 52.00 226.00 11752.0014 Rust cleaner / inhibitor ltr 13.00 311.00 4043.0015 Wire brush Nos 2.00 53.00 106.0016 Use rate welding holder set Hour 380.00 6.75 2565.0017 Use rate gas cutting torch set Hour 21.00 3.75 78.7518 Sundries LS 100.00 45.00 4500.00



B. MACHINERY : Sl No Unit Amount





Fuel / Energy charges Hour 4.00 111.00 444.00

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125


Quantityin `:

Description

in `:Rate

Rate



in `:Contd

5 Mobile crane ( pick & carry ) 8 t Hour 16.00 289.00 4624.00Fuel / Energy charges Hour 16.00 854.00 13664.00








in `:1 Crew for Mobile crane 8 t Hour 16.00 231.00 3696.002 Crew for plate shearing machine Hour 2.00 131.00 262.003 Crew for planing machine Hour 4.00 210.00 840.004 Crew for Drilling machine Hour 16.00 164.00 2624.005 Crew for Grinding machine Hour 16.00 164.00 2624.006 Foreman Day 15.00 436.00 6540.007 Marker / Fabricator / Erector Day 27.00 436.00 11772.008 Gas cutter Day 7.00 436.00 3052.009 Welder ( General ) Day 33.00 436.00 14388.00

10 Welder ( X - ray ) Day 3.00 479.60 1438.8011 Khalasi Day 18.00 436.00 7848.0012 Helper fabrication / erection Day 84.00 421.00 35364.0013 Helper for cleaning / painting Day 12.00 421.00 5052.0014 Painter Cl - II Day 28.00 421.00 11788.0015 Electrician Day 2.00 436.00 872.00




TOTAL `: 946552.47

in `:

RateQuantity

Description

126

Quantity

Description

Rate

in `:


Add for excise duty on 75 percent cost of Machinery / Labour components @ 0.00% `: 0.00Add for insurance charges @ 1.00% `: 9465.52Add for Patent royalty charges @ 4.40% `: 41648.31Add for designs and drawings @ 2.50% `: 23663.81Add for zigs / supports / winches / chain-pulley @ 2.50% `: 23663.81Add for power supply arrangements @ 2.30% `: 21770.71Add for enabling works @ 1.30% `: 12305.18




ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sillbeam, wall plates, first stage anchors, anchor girders, anchor bars, trunnion supports,wire rope/ pulley supports etc., with all accessories for canal regulator radial gates including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for othermaterials.

DATA:Embedded parts for radial gate consist of sill beam / wall plates / anchor girders / anchor bars /trunnion supports etc., with all accessories. The weight of embedded parts for small radial gate will be generally at about 50 to 60 percent of weight of radial gate leaf.Consider embedded parts for radial gate for canal cross regulator opening of size 3 m x 3.7 m.Size of radial gate : 3.00 m x 3.90 m Head of water : 3.70 mWeight of radial gate in tonne for canal regulator opening based on empirical formula :

= 0.1690 x ( L 2 x H x h ) 0.673

Consider Weight of embedded parts in tonne @ av. 55 % of weight of gate : = 0.55 x 0.1690 x ( L 2 x H x h ) 0.673


The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of embedded parts for canal regulator radial gate ofsame size provided for one of the canal regulator.Actual weight of embedded parts as per data in Item :26 of Annexure-2 : : 2.404 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of embeddedparts for canal regulator radial gate provided for one of the canal regulator for rate analysis ( fordetails refer Item : 26 of Annexure-2 ).

1. Requirement of materials:a. Structural steel conforming ti IS : 2062 :

Angles / beams / channels / bars with 2.5 % wastage ( 812x1.025 ) : 832 kg

127


Plates / flats with 2.5 % wastage ( 1475 x 1.025 ) : 1512 kgb. Alloy steel conforming to IS : 1570 :

Stainless steel plates / flats ( 52 x 1.025 ) : 53.00 kgc. Bolt / Nut / Washer conforming to IS : 1363 :

MS bolts and nuts with 2.5 % wastage ( 65 x 1.025 ) : 67 kgd. Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) :

GP / LH electrodes as per data sheet ( Item:26 Annexure-2 ) : 1272 NosAdd for variations / wastage / misc welding @ 10 % ( 1272 x 0.1 ) : 127 NosTotal requirement of GP / LH electrodes : 1399 Nos for stitch welding GP electrodes @t 10 % of total ( 1399 x 0.10 ) : 140 Nos for run welding LH electrodes @ 90 % of total ( 1399 x 0.90 ) : 1259 NosStainless steel electrodes as per data sheet ( Item:26 Annexure-2 ) : 185 NosAdd for variations / wastage @ 5 % ( 185 x 0.05 ) : 10 NosTotal requirement of Stainless steel ( SS ) electrodes : 195 Nos for stitch weld SS electrodes @t 10 % of total ( 195 x 0.10 ) : 20 Nos for run weld SS electrodes @t 90 % of total ( 195 x 0.90 ) : 175 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides as per data sheet : 97.00 RmAdd for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 10.00 Rm

Total : 107.00 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 40 mLength of steel to be cut by gas using pug cutting machine : 67 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 20 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 22 hoursAcetelyne gas @ 0.6 cum / hour ( 20 + 22 ) x 0.60 : 25 cumOxygen gas @ 1.8 cum / hour ( 20 + 22 ) x 1.80 : 75 cumUse of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) : 24 hoursUse of pug cutting machine with 50 min / hr working ( 22 x 60 / 50 ) : 26 hours







5. Surface cleaning and painting :Painting area for embedded parts at 5 sqm / tonne ( 2.404 x 5 ) : 12 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 12 sqm @ 9 sqm / ltr / coat : 1.5 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.

128


Quantity of coal tar epoxy paint for 12 sqm @ 6 sqm / ltr / coat : 8 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 12 sqm @ 8 sqm / ltr : 1.5 ltr

6. Requirement of other machinery :For drilling holes for anchor bolts 8 hours use of drilling machine considered.For finishing weld joints / edges 8 hours use of grinding machine considered.For handling of parts during fabrication and erection use of mobile crane for 2 hours and stationery derric crane for 8 hours considered.


Painter Cl-II

Cutting sections 50 hours 3 6 6 12Drilling holes for anchors / supports --- 1 --- 1Fabricating by stitch welding 43 hours 2 5 --- 10Run welding 127 hours 1 --- 16 16Erection of Anchor girders / anchor bars 2 4 --- 8Erection of first stage anchors --- 2 --- 2Erection of Sill beam / Wall plates 1 2 --- 2Cleaning surface 12 sqm @ 15 sqm/day --- --- --- 1Painting ( 5 x 12 ) sqm @ 15 sqm / day --- --- --- 5Finishing / Checking 1 1 --- 1 Total : 10 21 22 58

Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision considered for welder for stitch welding.b. Workforce for painting 1 coat primer and 4 coats finishing paint consists of 4 Painters Cl-II at 15 sqm / day and 1 helper to assist painters.For surface finishing of stainless steel plates for seal seats planing machine is considered.






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Rate

Gas cutter / Welder

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Perticulars

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in `:Contd

2 Stainless steel plates / flats kg 53.00 231.00 12243.003 MS bolts and nuts kg 67.00 90.00 6030.004 Oxygen gas cum 75.00 84.00 6300.005 Acetyline gas cum 25.00 404.00 10100.006 Welding electrodes ( general purpose ) Nos 140.00 10.00 1400.007 Welding electrodes ( low hydrogen ) Nos 1259.00 21.00 26439.008 Welding electrodes ( stainless steel ) Nos 195.00 62.00 12090.009 Zinc rich epoxy primer ltr 1.50 244.00 366.00















in `:Quantity

Rate

Rate

130

Perticulars

Descriptionin `:

Quantity



in `:1 Crew for Mobile crane Hour 2.00 231.00 462.002 Crew for Planing machine Hour 36.00 210.00 7560.003 Crew for Drilling machine Hour 8.00 164.00 1312.004 Crew for Grinding machine Hour 8.00 164.00 1312.005 Foreman Day 10.00 436.00 4360.006 Marker / Fabricator / Erector Day 21.00 436.00 9156.007 Gas cutter Day 6.00 436.00 2616.008 Welder ( General ) Day 14.00 436.00 6104.009 Welder ( X - ray ) Day 2.00 479.60 959.20









ITEM: Design, fabrication, supply, erection, testing and commissioning of radial gate consistingof skin plate, stiffeners, horizontal girders, sector arms, trunnion assemblies, tie beam, pulleysupports, bracings, rubber seals, seal clamps etc., with all accessories for canal regulator

in `:RateDescription Quantity

131


including cost of all materials, machinery, labour, cutting, bending, aligning, anchoring, welding,finishing, cleaning, applying one coat of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and liftsincluding packing / forwarding charges for other materials.

DATA:Regulator radial gate consists of trunnions / sector arms / horizontal girders / Tee- supports / skin plate / tie beam / bracings for horizontal girders and sector arms / pulley blocks / sealswith all accessories.Sector arms are connected to trunions by bolts and nuts.Horizontal girders generally spaced at about 3 m apart are joined to sector arms by welding andare stiffened by vertical and diagonal stiffeners to form the main frame. Tee- sections are weldedto horizontal girders to make the frame regid and to support the skin plate. Skin plate is weldedto Tee-supports generally spaced vertically at about 40 cm apart.Consider radial gate for canal cross regulator opening of size 3 m x 3.7 m for analysis.Size of radial gate : 3.00 m x 3.90 m Head of water : 3.70 mWeight of regulator radial gate leaf in tonnes based on empirical formula :

= 0.1690 x ( L 2 x H x h ) 0.673


The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of canal regulator radial gate of same size providedfor one of the canal regulator.Actual weight of radial gate leaf as per data in Item :27 of Annexure-2 : : 4.455 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of canalregulator radial gate provided for one of the canal regulator for rate analysis ( for details referItem : 27 of Annexure-2 ).


Angles / beams / channels / bars with 2.5 % wastage ( 2116x1.025 ) : 2215 kgPlates / flats with 2.5 % wastage ( 2042 x 1.025 ) : 2093 kg

b. Alloy steel components :Pins : 41 kg

c. Cast steel components :Trunnion hub / Guide roller : 122 kg

d. Alluminium / Bronze alloy components :Trunnion / Guide roller bush : 19 kg

e. Bolts / Nuts / Washers :GI bolts / nuts / washers with 2.5 % wastage ( 16 x 1.025 ) : 16.5 kgMS bolts / nuts / washers with 2.5 % wastage ( 54 x 1.025 ) : 55 kg

f. Zinc at 20 kg / trunnion ( 2 x 20 ) : 40 kg g. Rubber seal :

Bottom seal ( flat type ) ( 3 x 1.025 ) : 3.1 RmSide seals ( Z - type ) ( 10 x 1.025 ) : 10.2 Rm

h. Welding electrodes ( Ordinary / Low hydrogen ) :GP / LH electrodes as per data sheet ( Item:24 Annexure-2 ) : 1955 NosAdd for variations / wastage / misc welding @ 10 % ( 1369 x 0.1 ) : 195 NosTotal requirement of GP / LH electrodes : 2150 Nos for stitch weld GP electrodes @t 10 % of total ( 2150 x 0.10 ) : 215 Nos

132


for run welding LH electrodes @ 90 % of total ( 2150 x 0.90 ) : 1935 Nos 2. Cutting :

Total length of cutting assuming cutting for 2 sides : 108 RmAdd for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 11 Rm


3. Bending machine:For 1.5 m wide plates, length of plate for bending ( 3 x 5 / 1.5 ) : 10.00 mLength of Tee sections : 30.00 mLength of side seal cover angles ( 5 x 2 ) : 10.00 m

Total : 50.00 mAssuming 3 m bending / hour, time for bending 50 m ( 50 / 3 ) : 17 hoursWith 50 minutes / hour working deploy bending machine for : 20 hours





( 72 x 0.25 + 215 x 0.75 ) : 179 hours

5. Surface cleaning and painting : Painting area for radial gate at 20 sqm / tonne ( 4.455 x 20 ) : 89 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 89 sqm @ 9 sqm / ltr / coat : 10 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 89 sqm @ 6 sqm / ltr / coat : 45 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 89 sqm @ 8 sqm / ltr : 11 ltr

6. Requirement of other machinery :For drilling holes in skin plate and seal clamps for seal fixing 16 hours use of drilling machine considered. For grinding and finishing weld joints in skin plate and other locations 8 hours use of grinding machine considered.For handling of parts during fabrication and erection use of 8 t mobile crane for 10 hours and stationery derric crane 20 hours considered.

133



Painter Cl-II

Cutting sections 60 hours 4 8 8 16Bending sections 20 hours 1 2 --- 4Drilling holes for seal fixing 1 2 --- 2Fabricating by stitch welding 72 hours 4 9 --- 18Run welding 215 hours 3 --- 27 27Erection of trunnion and tie beam 1 2 --- 4Erection of H -girders / Sector arms 1 2 --- 4Erection of vertical stiffeners 1 2 --- 4Erection of skin plates 1 2 --- 4Erection of bracings / Zinc filling 1 2 --- 4Cleaning surface 89 sqm @ 15 sqm/day --- --- --- 6Painting ( 4 x 89 ) sqm @ 15 sqm / day --- --- --- 30Seal fixing 1 2 --- 2Finishing / checking / cleaning 1 1 --- 1 Total : 20 34 35 126







2 Cast steel componentsTrunnion hubs / Guide rollers kg 122.00 155.00 18910.00

3 Alloy steel componentsTrunnion pins kg 41.00 345.00 14145.00

4 Alluminium / Bronze alloy componentsBush for Trunnion / Guide roller kg 19.00 810.00 15390.00

Contd

Erector /

134

in `:



WelderFabricator /



in `:Contd


6 Zinc for trunnion seating kg 40.00 222.00 8880.007 Rubber seals

Bottom seal Rm 3.10 219.00 678.90Side seals ( Z type ) Rm 10.20 411.00 4192.20








Fuel / Energy charges Hour 24.00 4.00 96.003 Bending machine Hour 20.00 26.00 520.00








135

in `:

in `:Quantity RatePerticulars




in `:1 Crew for Mobile crane Hour 10.00 231.00 2310.002 Crew for Bending machine Hour 20.00 131.00 2620.003 Crew for Drilling machine Hour 16.00 164.00 2624.004 Crew for Grinding machine Hour 8.00 164.00 1312.005 Foreman Day 20.00 436.00 8720.006 Marker / Fabricator / Erector Day 34.00 436.00 14824.007 Gas cutter Day 8.00 436.00 3488.008 Welder ( General ) Day 24.00 436.00 10464.009 Welder ( X - ray ) Day 3.00 479.60 1438.80









ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacityelectrically operated rope drum hoist consisting of hoist platform, rope drums, connecting shaft, gear system, electric motor, electro- magnetic brake system, control panel, pulleys, wire

136

Description RateQuantityin `:


rope, manual operating system, railing, ladder etc., with all accessories for operating canal regulator radial gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, greasing, applying two coats of zinc chromate red oxide primer and three coats of approved synthetic ename paint etc., complete with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Rope drum hoist for radial gate consists of embedded parts for anchorage, hoist supporting structure, pulley supporting structures, pulleys, drive stool, rope drums, couplings, shafts,gears and pinions, plummer blocks, worm reducer, floating shaft, electric motor, hand operation assembly, brake, wire rope, gate position indicator, switch box etc. with related accessories.Generally the capacity of rope drum hoist for small radial gate will be about 2 times the weightof radial gate and the weight of hoist with all accessories is assumed at 0.30 tonne per tonnecapacity of the rope drum hoist.Consider rope drum hoist for radial gate for canal regulator opening of size 3 m x 3.7 m.Size of radial gate : 3.00 m x 3.90 m Head of water : 3.70 mWeight of regulator radial gate leaf in tonne based on empirical formula :

= 0.1690 x ( L 2 x H x h ) 0.673


Consider Capacity of hoist with 25% reserve capacity at 2 times the weight of gate :( 2 x 4.470 ) : 8.940 tonnes

Round off the capacity of hoist to next 5 tonne : 10 tonnesConsider weight of hoist @ 0.3 tonne per tonne capacity of hoist :

( 0.30 x 10 ) : 3.000 tonnesThe hoist capacity and hoist weight computed as above based on empirical formulae are furtherchecked by varifying / computing the actual capacity and weight as per fabrication drawings forcanal regulator radial gate rope drum hoist of same capacity provided for one of the canal work.Actual capacity of hoist as per data in Item : 28 of Annexure-2 : 10 tonnesActual weight of gate rope drum hoist as per data in Item :28 of Annexure-2 : 3.002 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of ropedrum hoist for canal regulator radial gate provided for one of the canal work for rate analysis( for details refer Item : 28 of Annexure-2 ).


Angles/ beams/ channels/ bars with 2.5 % wastage ( 1238x1.025 ) : 1269 kgPlates / flats with 2.5 % wastage ( 531 x 1.025 ) : 544 kgChequered plate ( 190 x 1.025 ) : 195 kg

b. Cast steel components conforming to IS : 1030 :Rope drums 2 Nos / Gears : 384 kgPinions : 14 kgPulleys 6 Nos : 108 kgPlummer blocks / Hubs : 47 kg

c. Alloy steel components conforming to IS : 1570 :Shafts : 75 kgPins : 24 kg

d. Alluminium/ Bronze alloy components conforming to IS : 305 :Bearings / Bush : 11 kg

137


e. Bolt / Nut / Washers conforming to IS : 1363 :MS Bolts / Nuts / Washers with 2.5 % wastage ( 66 x 1.025 ) : 68 kg


g. Other components :Manual operating system : 1 No.Worm reducers : 1 No.Electric motor 2 hp : 1 No.Ele-magnetic brake : 1 No.Wire rope sockets : 2 NosMS pipe 32 mm dia : 10.5 RmElectric cable / switch / control panel etc : 1 set



Total : 95 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 78 RmLength of steel to be cut by gas using pug cutting machine : 17 RmTime for gas cutting manually at ( av ) 2 m cutting / hour : 39 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 6 hoursAcetelyne gas @ 0.6 cum / hour ( 39 + 6 ) x 0.60 : 27 cumOxygen gas @ 1.8 cum / hour ( 39 + 6 ) x 1.80 : 81 cumUse of gas cutting torch with 50 min / hr working ( 39 x 60 / 50 ) : 47 hoursUse of pug cutting machine with 50 min / hr working ( 6 x 60 / 50 ) : 7 hours






Painting area at 20 sqm / t of str steel ( 1.96 x 20 ) : 39 sqm2 coats of zinc chromate red oxide primer.Quantity of primer paint for 39 sqm @ 12 sqm / ltr / coat : 6.5 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 39 sqm @ 12 sqm / ltr / coat : 10 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.

138


Quantity of rust cleaner / inhibitor for 39 sqm @ 8 sqm / ltr : 5 ltr 5. Requirement of other machinery :

For handling of parts during fabrication and erection use of 8 t mobile crane for 16 hours andstationery derric crane for 16 hours considered.For drilling holes for bolts 16 hours use of drilling machine considered. For grinding and finishing weld joints 8 hours use of grinding machine considered


Painter Cl-II

Cutting sections 54 hours 3 7 7 14Drilling holes for pins / bolts fixing 0 1 --- 1Fabricating by stitch welding 24 hours 1 3 --- 6Run welding 73 hours 0 --- 9 9Erection of anchors 1 1 --- 1Erection of drums and gears 1 1 --- 2Erection of floating shaft / pulleys 1 1 --- 2Erection of worm reducers / brake / motor 1 1 --- 2Erection of other accessories / cabling 1 1 --- 2Checking and trial running without ropes 1 1 --- 2Cleaning surface 39 sqm @ 15 sqm / day --- --- --- 3Painting ( 5 x 39 ) sqm @ 15 sqm / day --- --- --- 12Rope fixing and checking 1 1 --- 2Finishing / cleaning --- 1 --- 1Trial running for lifting / lowering gate 1 1 --- 1 Total : 12 20 16 60




RATE ANALYSIS UNIT : 3.002 tonneA. MATERIALS: 10.00 t capacity Sl No Unit Amount



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139

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A. MATERIALS ( Contd ) : 10.00 t capacity Sl No Unit Amount

in `:Contd

Chequered plate kg 195.00 41.52 8097.2532 mm dia MS pipe Rm 10.50 208.00 2184.00

2 Cast steel components :Rope drums 2 Nos / Gears kg 384.00 190.00 72960.00Pinions kg 14.00 190.00 2660.00Pulleys 6 Nos kg 108.00 155.00 16740.00Plummer blocks / Couplings kg 47.00 155.00 7285.00



5 Wire rope 12 mm dia 6 / 36 construction kg 42.00 163.00 6846.006 MS Bolt / Nut / Washer kg 68.00 90.00 6120.007 Worm reducers No. 1.00 67500.00 67500.008 Electric motor 2 hp No. 1.00 18000.00 18000.009 Manual operating system No. 1.00 13500.00 13500.00

10 Ele-magnetic brake No. 1.00 9000.00 9000.0011 Wire rope sockets No 2.00 1125.00 2250.0012 Electric cable/ switch/ control panel etc LS 1.00 9000.00 9000.0013 Oxygen gas cum 81.00 84.00 6804.0014 Acetyline gas cum 27.00 404.00 10908.0015 Welding electrodes ( general purpose ) Nos 91.00 10.00 910.0016 Welding electrodes ( low hydrogen ) Nos 816.00 21.00 17136.0017 Zinc chromate red oxide primer ltr 6.50 139.00 903.5018 Synthetic enamel ( 1st quality ) paint ltr 10.00 233.00 2330.0019 Rust cleaner / inhibitor ltr 5.00 311.00 1555.0020 Grease kg 10.00 233.00 2330.0021 Wire brush Nos 1.00 53.00 53.0022 Use rate welding holder set Hour 97.00 6.75 654.7523 Use rate gas cutting torch set Hour 47.00 3.75 176.2524 Sundries LS 70.00 45.00 3150.00







in `:

Quantity

140

Rate

in `:

QuantityDescription

RatePerticulars



in `:Contd

3 Mobile crane 8 t Hour 16.00 289.00 4624.00Fuel / Energy charges Hour 8.00 854.00 6832.00













TOTAL `: 565775.91Add for excise duty on 75 percent cost of Machinery / Labour components @ 0.00% `: 0.00Add for insurance charges @ 1.00% `: 5657.76Add for designs and drawings @ 2.50% `: 14144.40

Rate

Quantity

Description

in `:

in `:

Rate

Quantity

141

Description


Add for zigs / supports / winches / chain-pulley @ 2.50% `: 14144.40Add for power supply arrangements @ 2.30% `: 13012.85Add for enabling works @ 1.30% `: 7355.09





ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacitymanually operated rope drum hoist consisting of hoist platforms, rope drums, connecting shaft, gear system, brake system, pulleys, wire rope, manual operation system, railing, ladder etc., with all accessories for operating canal regulator radial gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, greasing, applying two coats of zinc chromate red oxide primer and three coats of approved synthetic enamel paint etc., complete as per specifications and approved drawings with lead upto 1 km and all liftsfor structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Rope drum hoist for radial gate consists of embedded parts for anchorage, hoist supporting structure, pulley supporting structures, pulleys, drive stool, rope drums, couplings, shafts,gears and pinions, plummer blocks, worm reducer, floating shaft, hand operation assembly,brake, wire rope, gate position indicator etc. with related accessories.Generally the capacity of rope drum hoist for small radial gate will be about 2 times the weightof radial gate and the weight of the hoist with all accessories is assumed at 0.30 tonne pertonne capacity of the rope drum hoist.Consider rope drum hoist for radial gate for canal regulator opening of size 3 m x 3.7 m.Size of radial gate : 3.00 m x 3.90 m Head of water : 3.70 mWeight of regulator radial gate leaf in tonne based on empirical formula :

= 0.1690 x ( L 2 x H x h ) 0.673


Consider Capacity of hoist with 25% reserve capacity at 2 times the weight of gate :( 2 x 4.470 ) : 8.940 tonnes

Round off the capacity of hoist to next 5 tonne : 10 tonnesConsider weight of hoist @ 0.3 tonne per tonne capacity of hoist :

( 0.30 x 10 ) : 3.000 tonnesLess weight of drive unit ( electric motor / cover etc ) : 0.200 tonneWeight of manually operated hoist : 2.800 tonnesThe hoist capacity and hoist weight computed as above based on empirical formulae are furtherchecked by varifying / computing the actual capacity and weight as per fabrication drawings forcanal regulator radial gate rope drum hoist of same capacity provided for one of the canal work.Actual capacity of hoist as per data In Item :29 of Annexure-2 : 10 tonnes

142


Actual weight of rope drum hoist as per data in Item : 29 of Annexure-2 : 2.804 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of rope drumhoist for canal regulator radial gate provided for one of the canal work for rate analysis ( fordetails refer Item : 29 of Annexure-2 ).


Angles/ beams/ channels/ bars with 2.5 % wastage ( 1193x1.025 ) : 1223 kgPlates / flats with 2.5 % wastage ( 442 x 1.025 ) : 453 kgChequered plate ( 190 x 1.025 ) : 195 kg

b. Cast steel components conforming to IS : 1030 :Rope drums 2 Nos / Gears : 384 kgPinions : 14 kgPulleys 6 Nos : 108 kgPlummer blocks / Hubs : 47 kg

c. Alloy steel components conforming to IS : 1570 :Shafts : 75 kgPins : 24 kg

d. Alluminium/ Bronze alloy components conforming to IS : 305 :Bearings / Bush : 11 kg

e. Bolt / Nut / Washers conforming to IS : 1363 :MS Bolts / Nuts / Washers with 2.5 % wastage ( 63 x 1.025 ) : 65 kg


g. Other components :Manual operating system : 1 No.Worm reducers : 1 No.Wire rope sockets : 2 NosMS pipe 32 mm dia : 10.5 Rm



Total : 80 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 60 RmLength of steel to be cut by gas using pug cutting machine : 20 RmTime for gas cutting manually at ( av ) 2 m cutting / hour : 30 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 7 hoursAcetelyne gas @ 0.6 cum / hour ( 30 + 7 ) x 0.60 : 22 cumOxygen gas @ 1.8 cum / hour ( 30 + 7 ) x 1.80 : 66 cumUse of gas cutting torch with 50 min / hr working ( 30 x 60 / 50 ) : 36 hoursUse of pug cutting machine with 50 min / hr working ( 7 x 60 / 50 ) : 8 hours

143






( 22 x 0.25 + 66 x 0.75 ) : 55 hours

4. Surface cleaning and painting :Painting area at 20 sqm / t of str steel ( 1.82 x 20 ) : 36 sqm2 coats of zinc chromate red oxide primer.Quantity of primer paint for 36 sqm @ 12 sqm / ltr / coat : 6 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 36 sqm @ 12 sqm / ltr / coat : 9 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 36 sqm @ 8 sqm / ltr : 4.5 ltr

5. Requirement of other machinery :For handling of parts during fabrication and erection use of 8 t mobile crane for 16 hours andstationery derric crane for 16 hours considered.For drilling holes for bolts 16 hours use of drilling machine considered. For grinding and finishing weld joints 8 hours use of grinding machine considered


Painter Cl-II

Cutting sections 44 hours 2 5 6 10Drilling holes for pins / bolts fixing --- 1 --- 1Fabricating by stitch welding 22 hours 1 3 --- 6Run welding 66 hours 1 --- 8 8Erection of anchors 1 1 --- 1Erection of drums and gears 1 2 --- 4Erection of floating shaft / pulleys 1 1 --- 2Erection of worm reducers / brake 1 2 --- 4Erection of other accessories 1 1 --- 2Checking and trial running without ropes 1 1 --- 2Cleaning surface 36 sqm @ 15 sqm/day --- --- --- 2Painting ( 5 x 36 ) sqm @ 15 sqm / day --- --- --- 11Rope fixing and checking 1 1 --- 2Finishing / cleaning --- 1 --- 1Trial running for lifting / lowering gate 1 1 --- 2 Total : 12 20 14 58


Gas cutter /

144

Fabricator / WelderMarker /

Erector /






Angles / beams / channels / bars kg 1223.00 39.55 48365.98Plates / flats kg 453.00 39.55 17914.79Chequered plate kg 195.00 41.52 8097.2532 mm dia MS pipe Rm 10.50 208.00 2184.00

2 Cast steel components :Rope drums 2 Nos / Gears kg 384.00 190.00 72960.00Pinions kg 14.00 190.00 2660.00Pulleys 6 Nos kg 108.00 155.00 16740.00Plummer blocks / Couplings kg 47.00 155.00 7285.00



5 Wire rope 12 mm dia 6/36 construction kg 42.00 163.00 6846.006 MS Bolt / Nut / Washer kg 65.00 90.00 5850.007 Worm reducers No. 1.00 67500.00 67500.009 Manual operating system No. 1.00 13500.00 13500.00

10 Brake No. 1.00 9000.00 9000.0011 Wire rope sockets No 2.00 1125.00 2250.0013 Oxygen gas cum 66.00 84.00 5544.0014 Acetyline gas cum 22.00 404.00 8888.0015 Welding electrodes ( general purpose ) Nos 83.00 10.00 830.0016 Welding electrodes ( low hydrogen ) Nos 747.00 21.00 15687.0017 Zinc chromate red oxide primer ltr 6.00 139.00 834.0018 Synthetic enamel ( 1st quality ) paint ltr 9.00 233.00 2097.0019 Rust cleaner / inhibitor ltr 4.50 311.00 1399.5020 Grease kg 10.00 233.00 2330.0021 Wire brush Nos 1.00 53.00 53.0022 Use rate welding holder set Hour 88.00 6.75 594.00

Contd

145

Ratein `:

QuantityPerticulars



in `:Contd


















Rate

RateQuantity

in `:

146

Quantity

in `:

Quantity

Rate

Description

in `:Description

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TOTAL `: 514343.16Machinery / Labour components @ 0.00% `: 0.00Add for insurance charges @ 1.00% `: 5143.43Add for designs and drawings @ 2.50% `: 12858.58Add for zigs / supports / winches / chain-pulley @ 2.50% `: 12858.58Add for power supply arrangements @ 2.30% `: 11829.89Add for enabling works @ 1.30% `: 6686.46





ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( with top sealseat ) consisting of sill beam, wheel tracks, seal seats, guide rails, groove lining upto top etc.,with all accessories for vertical lift roller gate for canal escape / regulator including costof all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning,applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paintetc., complets as per specifications and approved drawings with lead upto 1 km and all liftsfor structural steel components and all leads and lifts including packing / forwardingcharges for other materials.

DATA:Embedded parts for canal escape / regulator gate consist of sill beam, wheel / seal tracks, groove lining upto top, gate guide with all accessories such as first stage anchors.Weight of embedded parts with groove lining for such small gates will be about 150 percent of gate weight.Consider embedded parts for canal escape / regulator gate for opening of size 2 m x 2 m. For 2 m x 2 m opening approximate size of gate : 2.5 m x 2.2 m

147

Description Quantity Ratein `:


Head of water above sill level : 3.7 mWeight of vertical lift roller gate in tonne for regulator / escape based on empirical formula :

= 0.0888 x ( L 2 x H x h ) 0.659

Consider weight of embedded parts in tonnes @ 150 % of weight of gate : = 1.50 x 0.0888 x ( L 2 x H x h ) 0.659

Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.1332 x ( 2.5 x 2.5 x 2.2 x 3.7 ) 0.659 : 1.775 tonnes

The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of embedded parts for canal escape vertical lift rollergate of same size provided for one of the canal escape structure.Actual weight of embedded parts as per data in Item : 30 of Annexure-2 : 1.784 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of embeddedparts for canal escape vertical lift roller gate provided for one of the canal escape structure forrate analysis ( for details refer Item : 30 of Annexure-2 ).


Angles/ beams/ channels/ bars with 2.5% wastage ( 1189.5x1.025 ) : 1219 kgPlates / flats with 2.5 % wastage ( 514.5 x 1.025 ) : 527 kg

b. Alloy steel components conforming to IS : 1570 :Stainless steel plates / flats ( 79.5 x 1.025 ) : 82.00 kg

c. Bolt / Nut / Washer conforming to IS : 1363 :MS bolts and nuts with 2.5 % wastage : 1 kg


2. Cutting :Total length of cutting assuming cutting for 2 sides as per data sheet : 40 RmAdd for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 4 Rm


3. Welding :Length of welding as per data sheet : 207 m

148


For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 130 + 23 ) x 8 / 15 / 2 : 41 hours

For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 1170 + 205 ) x 8 / 15 / 6 : 122 hours

Total : 163 hoursDeploy welding transformer for 163 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.



5. Surface cleaning and painting :Painting area for embedded parts at 5 sqm / tonne ( 1.784 x 5 ) : 9 sqm1 coats of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 15 sqm @ 9 sqm / ltr / coat : 1 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 15 sqm @ 6 sqm / ltr / coat : 6 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 9 sqm @ 8 sqm / ltr : 1 ltr

6. Requirement of other machinery :For handling during fabrication and erection use of 8 t mobile crane for 2 hours considered.For drilling holes for anchor bolts use of drilling machine for 1 hour considered.For finishing weld joints / edges 2 hours use of grinding machine considered.


Painter Cl-II

Cutting sections / Drilling holes 24 hours 2 3 3 6Fabricating by stitch welding 41 hours 2 5 --- 10Run welding 122 hours 1 --- 15 15Erection of first stage anchors --- 1 --- 2Erection of Sill beam / Tracks / Guide 1 2 --- 4Cleaning surface 9 sqm @ 15 sqm/day --- --- --- 1Painting ( 5 x 9 ) sqm @ 15 sqm / day --- --- --- 4Finishing / cleaning --- 1 --- 1 Total : 6 12 18 43




Welder

149

Gas cutter /

Erector /

















150

Perticulars Rate

Quantity

in `:

Ratein `:

Quantity

Description



in `:Contd






in `:1 Crew for Planing machine Hour 48.00 210.00 10080.002 Crew for Drilling machine Hour 1.00 164.00 164.003 Crew for Grinding machine Hour 2.00 164.00 328.004 Crew for Mobile crane Hour 2.00 231.00 462.005 Foreman Day 6.00 436.00 2616.006 Marker / Fabricator / Erector Day 12.00 436.00 5232.007 Gas cutter Day 3.00 436.00 1308.008 Welder ( General ) Day 13.00 436.00 5668.009 Welder ( X - ray ) Day 2.00 479.60 959.20






Total `: 275275.73

Description


Rate

151

in `:

in `:

Quantity


Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2 x 1.784 tonnes @ `: 358.20 / tonne `: 1278.06Add for packing, forwarding and transportation upto work site on cost of materials other than structural steel ( on cost of Sl No. 2 to 12 ) @ 3.00% `: 2046.54 Total cost for 1.784 tonne `: 278600.32



ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type vertical lift gate ( with top seal ) consisting of skin plate, stiffeners, horizontal and vertical girders, wheels, guide rollers, rubber seals etc., with all accessories for canal escape / regulator ventincluding cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning,applying one coat of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing /forwarding charges for other materials.

DATA:Consider down stream sealing vertical lift roller gate. The gate leaf consists of skin plate, horizontal girders, vertical end girders, stiffeners, wheels, gate guide rollers, brackets, pins, seals etc., with all accessories.Consider canal escape / regulator gate for 2 m x 2 m vent opening for analysis.For 2 m x 2 m opening approximate size of gate : 2.5 m x 2.2 mHead of water above sill level : 3.7 mWeight of vertical lift roller gate in tonne for regulator / escape based on empirical formula :

= 0.0888 ( L 2 x H x h ) 0.659

Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water in metre. = 0.0888 ( 2.5 x 2.5 x 2.2 x 3.7 ) 0.659 : 1.183

The weight computed as above based on empirical formula is further checked by computingthe actual weight as per fabrication drawings of fixed wheel vertical lift roller gate of same sizeprovided for one of the canal escape structurer.Actual weight of canal escape gate as per data in Item : 31 of Annexure-2 : 1.217 tonnesConsider actual weight for data rate analysis.Consider details of Material /Gas cutting / Welding based on fabrication drawings of fixed wheelvertical lift roller gate provided for one of the canal escape structure for rate analysis ( for detailsrefer Item : 31 of Annexure-2 ).


Angles / beams / channels / bars with 2.5 % wastage ( 244x1.025 ) : 250 kgPlates / flats with 2.5 % wastage ( 877 x 1.025 ) : 899 kg

b. Alloy steel components conforming to IS : 1570 :Wheel axles / Pins : 30 kg

c. Cast steel components conforming to IS : 1030 :Wheels / guide rollers : 50 kg

d. Alluminium / Bronze alloy components conforming to IS : 305 :Bearings / Bushes : 5 kg

e. Bolts / Nuts / Washers conforming to IS : 1363 :GI bolts / nuts / washers with 2.5 % wastage ( 7.5 x 1.025 ) : 8 kgMS bolts / nuts / washers with 2.5 % wastage ( 3.5 x 1.025 ) : 4 kg

152


f. Rubber seal conforming to IS : 11855 :Bottom seal ( uncladed ) ( 2.25 x 1.025 ) : 2.3 RmSide seals ( uncladed ) ( 3.95 x 1.025 ) : 4.0 RmTop seal ( uncladed ) ( 1.85 x 1.025 ) : 1.9 Rm

g. Welding electrodes ( General purpose / Low hydrogen ) :GP / LH electrodes as per data sheet ( Item:31 Annexure-2 ) : 658 NosAdd for variations / wastage / misc welding @ 10 % ( 658 x 0.1 ) : 66 NosTotal requirement of GP / LH electrodes : 724 Nos for stitch weld GP electrodes @t 10 % of total ( 724 x 0.10 ) : 72 Nos for run welding LH electrodes @ 90 % of total ( 724 x 0.90 ) : 652 Nos








Painting area for canal escape gate at 18 sqm / tonne ( 1.217 x 18 ) : 22 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 22 sqm @ 9 sqm / ltr / coat : 2.5 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 22 sqm @ 6 sqm / ltr / coat : 11 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 22 sqm @ 8 sqm / ltr : 3 ltr

5. Requirement of other machinery :For handling of parts during fabrication and erection use of 8 t mobile crane for 2 hours andstationery derric crane for 2 hours considered.For drilling holes in skin plate, girders and clamps use of drilling machine for 2 hrs considered. For grinding and finishing weld joints in skin plate and other locations 2 hours use of grinding machine considered.

153



Painter Cl-II

Cutting sections / Drilling holes 24 hours 1 3 3 6Fabricating by stitch welding 19 hours 1 2 --- 4Run welding 58 hours 1 --- 7 7Wheel fixing / Seal fixing 1 1 --- 2Cleaning surface 22 sqm @ 15 sqm/day --- --- --- 1.5Painting ( 4 x 22 ) sqm @ 15 sqm / day --- --- --- 7.5Guide roller fixing / Finishing / Erecting 1 1 --- 2 Total : 5 7 10 30

Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.b. Workforce for painting 1 coat primer and 3 coats finishing paint consists of 6 Painters Cl-II at 15 sqm / day and 1.5 helpers to assist painters.





Angles / Channels / Beams / Bars kg 250.00 39.55 9886.75Plates / flats kg 899.00 39.55 35552.75

2 Alloy steel componentsWheel axles / Pins kg 30.00 345.00 10350.00

3 Cast steel componentsWheels / Guide rollers kg 50.00 155.00 7750.00

4 Alluminium / Bronze alloy componentsBearings / Bushes kg 5.00 810.00 4050.00


6 Rubber sealsBottom seal ( uncladed ) Rm 2.30 219.00 503.70Side seals ( uncladed ) Rm 3.60 368.00 1324.80Top seal ( uncladed ) Rm 1.50 368.00 552.00Corner seal ( uncladed ) Nos 2.00 441.00 882.00

Contd

Gas cutter /

Rate

154

Erector /Welder

in `:

Marker /

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Fabricator /

Perticulars



in `:Contd

7 Oxygen gas cum 36.00 84.00 3024.008 Acetyline gas cum 12.00 404.00 4848.009 Welding electrodes ( general purpose ) Nos 72.00 10.00 720.00















in `:1 Crew for Mobile crane Hour 2.00 231.00 462.002 Crew for Drilling machine Hour 1.00 164.00 164.003 Crew for Grinding machine Hour 2.00 164.00 328.00

Contd

in `:Perticulars Quantity Rate

Rate

Rate

in `:

155

Quantityin `:

Quantity

Description

Description



in `:Contd

4 Foreman Day 5.00 436.00 2180.005 Marker / Fabricator / Erector Day 7.00 436.00 3052.006 Gas cutter Day 3.00 436.00 1308.007 Welder ( General ) Day 6.00 436.00 2616.008 Welder ( X - ray grade ) Day 1.00 479.60 479.609 Helper fabrication / erection Day 21.00 421.00 8841.00









ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity screwtype hoist consisting of supporting structure, platform, railing, ladder etc., with all accessories for operating canal escape / regulator gate including cost of all materials, machinery,labour,cutting, aligning, anchoring, welding, finishing, cleaning, greasing, applying two coats of zinc chromate red oxide primer and three coats of approved synthetic enamel paint etc., complete with lead upto 1 km and all lifts for structural steel components and all leads and lifts

156

Ratein `:



including packing / forwarding charges for other materials.

DATA:Screw type hoist for operating gate consists of supporting structure, hoist body, hoist stem, thrust bearings, operating wheel / handle with related accessories.The capacity of screw hoist for canal gate may be considered at 2.5 times the weight of gate.Consider screw type hoist for canal escape / regulator gate for vent opening of size 2 m x 2 m. For 2 m x 2 m opening approximate size of gate : 2.5 m x 2.2 mHead of water above sill level : 3.7 mWeight of vertical lift gate in tonnes for regulator / escape based on empirical formula :

= 0.0888 x ( L 2 x H x h ) 0.659

Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0888 x ( 2.5 x 2.5 x 2.2 x 3.7 ) 0.659 : 1.183

Consider capacity of screw hoist with 25 % reserve capacity @ 2.5 times the weight of gate : ( 2.5 x 1.183) : 2.957 tonnes

Round off the capacity of hoist to next 1 tonne : 3.00 tonnesConsider weight of hoist with all accessories at 0.3 tonne per tonne capacity of hoist :

( 0.3 x 3 ) : 0.900 tonneThe hoist capacity and hoist weight computed as above based on empirical formulae are furtherchecked by varifying / computing the actual capacity and weight as per fabrication drawings ofscrew type hoist of same capacity for vertical lift roller gate provided for one of the canal escape.Actual capacity of hoist as per data : 3.00 tonnesActual weight of screw hoist as per data in Item : 32 of Annexure-2 : 0.871 tonneConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of screw typehoist for canal escape vertical lift roller gate provided for one of the canal escape structure ( fordetails refer Item : 32 of Annexure-2 ).


Angles/ beams/ channels/ bars with 2.5% wastage ( 392.5x1.025 ) : 402.00 kgPlates / flats with 2.5 % wastage ( 141.5 x 1.025 ) : 145.00 kgChequered plates with 2.5 % wastage ( 172 x 1.025 ) : 176.00 kg

b. Cast iron components conforming to IS : 210 :Hoist body / Lock nut / Main nut : 55.00 kg

c. Alloy steel components conforming to IS : 1570 :Hoist stem : 75.00 kg


e. Bolt / Nut / Washers conforming to IS : 1363 :MS Bolts / Nuts / Washers with 2.5 % wastage ( 8 x 1.025 ) : 8.00 kgMS pipe 32 mm dia : 8.8 Rm

f. Welding electrodes ( General purpose ) :GP / LH electrodes as per data sheet ( Item:32 Annexure-2 ) : 71 NosAdd for variations / wastage / misc welding @ 10 % ( 71 x 0.1 ) : 7 NosTotal requirement of GP / LH electrodes : 78 Nos for stitch weld GP electrodes @t 10 % of total ( 78 x 0.10 ) : 8 Nos for run welding GP electrodes @ 90 % of total ( 78 x 0.90 ) : 70 Nos


157


For cutting structural steel sections to required sizes gas cutting is assumed.Time for gas cutting manually at average cutting progress of 2 m / hour : 10 hoursAcetelyne gas @ 0.6 cum / hour ( 10 x 0.60 ) : 6 cumOxygen gas @ 1.8 cum / hour ( 10 x 1.80 ) : 18 cumUse of gas cutting torch with 50 min / hr working ( 10 x 60 / 50 ) : 12 hours






Painting area for hoist at 20 sqm / tonne of str steel ( 0.723 x 20 ) : 15 sqm2 coats of zinc chromate red oxide primer.Quantity of primer paint for 15 sqm @ 12 sqm / ltr / coat : 3 ltr3 coats of synthetic enamel paint.Quantity of coal tar epoxy paint for 15 sqm @ 12 sqm / ltr / coat : 4 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 15 sqm @ 8 sqm / ltr : 2 ltr

5. Requirement of other machinery :For handling of parts during fabrication / erection use of 8 t mobile crane for 1 hour considered.For drilling holes for bolts 1 hours use of drilling machine considered. For grinding and finishing weld joints 2 hours use of grinding machine considered


Painter Cl-II

Cutting sections / Drilling holes 14 hours 1 2 2 4Fabricating / welding 8 hours --- 1 1 2Erection of hoist frame / body 1 1 --- 2Cleaning surface 15 sqm @ 15 sqm/day --- --- --- 1Painting ( 5 x 15 ) sqm @ 15 sqm / day --- --- --- 6Trial operation and final adjustments 1 1 --- 1 Total : 3 5 3 16



Gas cutter /

158

WelderMarker /







2 32 mm dia MS pipe Rm 8.80 208.00 1830.403 Cast iron components :

Hoist body / Lock nut / Main nut kg 55.00 155.00 8525.004 Alloy steel components

Hoist stem kg 75.00 280.00 21000.005 Bronze alloy components :

Thrust bearings kg 4.00 810.00 3240.006 MS Bolt / Nut / Washer kg 8.00 90.00 720.007 Oxygen gas cum 18.00 84.00 1512.008 Acetyline gas cum 6.00 404.00 2424.009 Welding electrodes ( general purpose ) Nos 8.00 10.00 80.00

10 Welding electrodes ( low hydrogen ) Nos 70.00 21.00 1470.0011 Zinc chromate red oxide primer ltr 3.00 139.00 417.0012 Synthetic enamel ( 1st quality ) paint ltr 4.50 233.00 1048.5013 Rust cleaner / inhibitor ltr 2.00 311.00 622.0014 Grease kg 2.00 233.00 466.0015 Wire brush Nos 0.50 53.00 26.5016 Use rate welding holder set Hour 8.00 6.75 54.0017 Use rate gas cutting torch set Hour 12.00 3.75 45.0018 Sundries LS 1.00 45.00 45.00







Rate

Rate

in `:

159

in `:





in `:Contd







in `:1 Crew for Drilling machine Hour 1.00 164.00 164.002 Crew for Grinding machine Hour 2.00 164.00 328.003 Crew for Mobile crane Hour 1.00 231.00 231.004 Foreman Day 3.00 436.00 1308.005 Marker / Fabricator / Erector Day 5.00 436.00 2180.006 Gas cutter Day 2.00 436.00 872.007 Welder ( General ) Day 1.00 436.00 436.008 Helper fabrication / erection Day 9.00 421.00 3789.009 Helper for cleaning / painting Day 2.00 421.00 842.00






Total `: 113627.01

160

Rate

Rate

Description

QuantityDescription

Quantityin `:

in `:


Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2 x 0.871 tonnes @ `: 358.20 / tonne `: 623.98Add for packing, forwarding and transportation upto work site on cost of materials other than structural steel ( on cost of Sl No. 2 to 15 ) @ 3.00% `: 1301.44 Total cost for 0.871 tonne weight `: 115552.43




ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sillbeam, wheel tracks, seal seats, guide rails, gate groove liners etc., with all accessories forcanal escape / regulator stoplog gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Embedded parts for canal escape / regulator stop log gate consist of sill beam, wheel / sealtracks, groove lining upto top, gate guide with all accessories such as first stage anchors. Weight of embedded parts for such small gates will be in the range of 65 to 70 % of gate weight.Consider embedded parts for canal escape / regulator stoplog gate for 2 m wide vent opening. Length of stoplog element for 2 m wide opening : 2.50 mHead of water above sill level : 3.70 mTotal height of stoplog gate considering 4 elements of 1 m height each : 4.00 mWeight of embedded parts for stoplog gate in tonnes based on empirical formula :

= 0.0995 x ( L 2 x H x h ) 0.716

Where ( L ) is length and ( H ) is total height and ( h ) is head of water in metres.Consider weight of embedded parts @ 67.5 % of weight of stoplog gate :

= 0.675 x 0.0995 x ( L 2 x H x h ) 0.716

= 0.0671 x ( 2.5 x 2.5 x 4 x 3.7 ) 0.716 : 1.716The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of embedded parts for canal escape/ regulator stoploggate of same size provided for one of the canal escape / regulator structure.Actual weight of embedded parts as per data in Item :33 of Annexure-2 : 1.685 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of embeddedparts for canal escape / regulator stoplog gate provided for one of the canal escape / regulatorstructure ( for details refer Item : 33 of Annexure-2 ).

1. Requirement of materials: a. Structural steel conforming to IS : 2062 :

Angles/ beams/ channels/ bars with 2.5% wastage ( 1106.5x1.025 ) : 1134 kgPlates / flats with 2.5 % wastage ( 510 x 1.025 ) : 523 kg


c. Bolt / Nut / Washer conforming to IS : 1363 :MS bolts and nuts with 2.5 % wastage : 1 kg

161











5. Surface cleaning and painting :Painting area for embedded parts at 5 sqm / tonne ( 1.685 x 5 ) : 8 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 8 sqm @ 9 sqm / ltr / coat : 1 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 8 sqm @ 6 sqm / ltr / coat : 5.5 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 8 sqm @ 8 sqm / ltr : 1 ltr

162


6. Requirement of other machinery :For finishing weld joints / edges 2 hours use of grinding machine considered.


Painter Cl-II

Cutting sections 20 hours 1 2 2 5Fabricating by stitch welding 39 hours 2 5 --- 10Run welding 116 hours 2 --- 15 15Erection of Sill beam / Tracks / Guide 1 2 --- 4Cleaning surface 8 sqm @ 15 sqm/day --- --- --- 0.5Painting ( 5 x 8 ) sqm @ 15 sqm / day --- --- --- 3.5Finishing / cleaning --- 1 --- 1 Total : 6 10 17 39

Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.b. Workforce for painting 1 coat primer and 4 coats finishing paint consists of 3 Painters Cl-II at 15 sqm / day and 0.5 helper to assist painters.






2 Stainless steel plate / flats kg 70.00 231.00 16170.003 Bolt / Nut / Washer ( MS ) kg 1.00 90.00 90.004 Oxygen gas cum 30.00 84.00 2520.005 Acetyline gas cum 10.00 404.00 4040.006 Welding electrodes ( general purpose ) Nos 124.00 10.00 1240.007 Welding electrodes ( low hydrogen ) Nos 1120.00 21.00 23520.008 Welding electrodes ( stainless steel ) Nos 209.00 62.00 12958.009 Zinc rich epoxy primer ltr 1.00 244.00 244.00

10 Coal tar epoxy paint ltr 5.50 226.00 1243.00Contd

163

Welder

Rate


in `:


QuantityPerticulars



in `:Contd













in `:1 Crew for Planing machine Hour 44.00 210.00 9240.002 Crew for Grinding machine Hour 2.00 164.00 328.003 Foreman Day 6.00 436.00 2616.004 Marker / Fabricator / Erector Day 10.00 436.00 4360.005 Gas cutter Day 2.00 436.00 872.006 Welder ( General ) Day 13.00 436.00 5668.007 Welder ( X - ray ) Day 2.00 479.60 959.208 Helper fabrication / erection Day 35.00 421.00 14735.009 Helper for cleaning / painting Day 1.00 421.00 421.00


Total `: 40898.20Add for small Tools and Plants @ 1% `: 408.98

Contd

164

Description

RateQuantity

Rate

in `:

Ratein `:

Quantity

Quantity

in `:Perticulars

Description



in `:Contd

Add for Contractor's Profit @ 10% `: 4089.82Add for hidden cost on Labour @ 15% `: 6134.73Add for additional hidden cost on labour @ 15% `: 6134.73Add for Contractor's Overheads @ 5% `: 2044.91







ITEM: Design, fabrication, supply, erection, testing and commissioning of sliding type interchangeable stoplog gate elements consisting of skin plate, stiffeners, horizontal and vertical girders, lifting hooks, bronze padded slide blocks, guide shoes, rubber seals etc., with all accessories for canal regulator vent including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coats of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Consider down stream sealing vertical lift slide gate. The stoplog gate consists of number of inter-changeable elements having height of each element in the range of 0.9 to 1.2 m. Eachelement consists of skin plate, horizontal girders, vertical end girders, stiffeners, slide blocks, gate guide shoes, brackets, lifting pins,seals etc., with all accessories.Consider canal escape / regulator gate for 2 m vent opening and 3.7 m depth of water.Consider 4 elements of size 2.50 m length x 1.00 m height each.Weight of 1 set of stoplog gate elements in tonne based on empirical formula :

= 0.0995 ( L 2 x H x h ) 0.716

165

in `:Quantity RateDescription


Where ( L ) is length and ( H ) is total height of gate and ( h ) is head of water in metres. = 0.0995 ( 2.5 x 2.5 x 4.0 x 3.7 ) 0.716 : 2.544

The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of canal escape / regulator stoplog gate elements ofsize provided for one of the canal escape / regulator structure.Actual wt of 1set of stoplog elements as per data in Item : 34 of Annexure-2 : 2.534 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of canal escape / regulator stoplog gate elements provided for one of the canal escape / regulator ( for details refer Item : 34 of Annexure-2 ).



b. Alluminium/ Bronze alloy components conforming to IS : 305 :Bronze pads : 16.00 kg

c. Bolts / Nuts / Washers conforming to IS : 1363 :GI bolts / nuts / washers with 2.5 % wastage ( 20 x 1.025 ) : 20.5 kgMS bolts / nuts / washers with 2.5 % wastage ( 6 x 1.025 ) : 6 kg

d. Rubber seal conforming to IS : 11855 :Bottom seal ( uncladed ) ( 8 x 1.025 ) : 8.2 RmSide seals ( uncladed ) ( 8.05 x 1.025 ) : 8.25 Rm

e. Welding electrodes ( General purpose / Low hydrogen ) :GP / LH electrodes as per data sheet ( Item:34 Annexure-2 ) : 1588 NosAdd for variations / wastage / misc welding @ 10 % ( 1588 x 0.1 ) : 159 NosTotal requirement of GP / LH electrodes : 1747 Nos for stitch weld GP electrodes @t 10 % of total ( 1747 x 0.10 ) : 175 Nos for run welding LH electrodes @ 90 % of total ( 1747 x 0.90 ) : 1572 Nos






Deploy welding transformer for 187 hours.

166


Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.( 47 x 0.25 + 140 x 0.75 ) : 117 hours

4. Surface cleaning and painting :Painting area for stoplog gate at 18 sqm / tonne ( 2.534 x 18 ) : 45 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 45 sqm @ 9 sqm / ltr / coat : 5 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 45 sqm @ 6 sqm / ltr / coat : 23 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 45 sqm @ 8 sqm / ltr : 6 ltr

5. Requirement of other machinery :For handling of parts during fabrication and erection use of mobile derric crane for 2 hours andstationery derric crane for 4 hours considered.For drilling holes in skin plate, end girders and seal clamps use of drilling machine for 8 hours considered. For grinding and finishing weld joints in skin plate and other locations 8 hours use of grinding machine considered.


Painter Cl-II

Cutting sections 38 hours 2 5 5 10Drilling holes 8 hours 1 1 --- 1Fabricating by stitch welding 47 hours 3 6 --- 12Run welding 140 hours 2 --- 18 18Slide blocks fixing / Seal fixing 1 2 --- 2Cleaning surface 45 sqm @ 15 sqm/day --- --- --- 3Painting ( 4 x 45 ) sqm @ 15 sqm / day --- --- --- 15Guide shoe fixing / Finishing / Erecting 1 1 --- 2 Total : 10 15 23 63




Welder

167

Fabricator /Gas cutter / Marker /

Erector /




Angles / Channels / Beams / Bars kg 1195.00 39.55 47258.67Plates / flats kg 1376.00 39.55 54416.67

2 Alluminium / Bronze alloy componentsBronze pads kg 16.00 810.00 12960.00


4 Rubber sealsBottom seal ( uncladed ) Rm 8.20 219.00 1795.80Side seals ( uncladed ) Rm 8.25 368.00 3036.00

5 Oxygen gas cum 57.00 84.00 4788.006 Acetyline gas cum 19.00 404.00 7676.007 Welding electrodes ( general purpose ) Nos 175.00 10.00 1750.008 Welding electrodes ( low hydrogen ) Nos 1572.00 21.00 33012.009 Zinc rich epoxy primer ltr 5.00 244.00 1220.00













168

Ratein `:


Ratein `:




in `:Contd




in `:1 Crew for Mobile crane Hour 2.00 231.00 462.002 Crew for Drilling machine Hour 8.00 164.00 1312.003 Crew for Grinding machine Hour 12.00 164.00 1968.004 Foreman Day 10.00 436.00 4360.005 Marker / Fabricator / Erector Day 15.00 436.00 6540.006 Gas cutter Day 5.00 436.00 2180.007 Welder ( General ) Day 16.00 436.00 6976.008 Welder ( X - ray grade ) Day 2.00 479.60 959.209 Helper fabrication / erection Day 45.00 421.00 18945.00






Total `: 330651.25Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2 x 2.534 tonnes @ `: 358.20 / tonne `: 1815.36

169

in `:Quantity Rate

Description Ratein `:

Quantity

Description


Add for packing, forwarding and transportation upto work site on cost of materials other than structural steel ( on cost of Sl No. 2 to 12 ) @ 3.00% `: 2283.26 Total cost for 2.534 tonne `: 334749.88



ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of liners for trash rack grooves ( for coarse and fine screens ) with all accessories for pump houseintake structure including cost of all materials, machinery, cutting, labour, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with lead upto 1 km for structural steel components and all leads and lifts including packing/forwarding charges for other materials.

DATA:Embedded parts for trash rack groove of pump house intake structure consist of groove linerswith anchors.Weight of one set embedded parts for trash rack groove will be in the range of 100 to 125 kg / mheight of the trash rack groove for one vent.Consider embedded parts for trash rack groove of pump house intake for 3.55 m wide and 12 m height vent.Weight of embedded parts for 12 m height in tonnes based on empirical rule :

( 12 x 112.50 ) : 1350.00 kgThe weight computed as above based on empirical rule is further checked by computing theactual weight as per fabrication drawings of embedded parts for trash rack groove for one vent of one of the pump house intake structure.Actual weight of embedded parts as per data in Item :35 of Annexure-2 : 1.322 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of embeddedparts for one vent of trash rack groove of one of the pump house intake structure ( for detailsrefer Item : 35 of Annexure-2 ).


Plates / flats with 2.5 % wastage ( 1322 x 1.025 ) : 1355 kg b. Welding electrodes ( General purpose / Low hydrogen ) :



Total : 86 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 10 mLength of steel to be cut by gas using pug cutting machine : 76 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 5 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 10 hours

170


Acetelyne gas @ 0.6 cum / hour ( 5 + 25 ) x 0.60 : 18 cumOxygen gas @ 1.8 cum / hour ( 5 + 25 ) x 1.80 : 54 cumUse of gas cutting torch with 50 min / hr working ( 5 x 60 / 50 ) : 6 hoursUse of pug cutting machine with 50 min / hr working ( 25 x 60 / 50 ) : 30 hours

3. Welding :Length of welding as per data sheet : 98.3 mFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 108 x 8 / 15 / 2 ) : 29 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 973 x 8 / 15 / 6 ) : 86 hoursTotal : 115 hours


( 29 x 0.25 + 86 x 0.75 ) : 72 hours

4. Surface cleaning and painting :Painting area for embedded parts at 12 sqm / tonne ( 1.322 x 12 ) : 16 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 16 sqm @ 9 sqm / ltr / coat : 1.75 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 16 sqm @ 6 sqm / ltr / coat : 10.5 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 16 sqm @ 8 sqm / ltr : 2 ltr

5. Requirement of other machinery :For handling parts during fabrication and erection use 8 t mobile crane for 4 hours.For holding in position during erection use stationery derric for 8 hours.For finishing weld joints / edges 4 hours use of grinding machine considered.


Painter Cl-II

Cutting sections 36 hours 2 4 4 8Fabricating by stitch welding 29 hours 2 4 --- 8Run welding 86 hours 1 --- 11 11Erection of liners 1 2 --- 4Cleaning surface 16 sqm @ 15 sqm/day --- --- --- 1Painting ( 5 x 16 ) sqm @ 15 sqm / day --- --- --- 9Finishing / cleaning --- 1 --- 1 Total : 6 11 15 42



171

Fabricator / WelderGas cutter / Marker /

Erector /





Plates / flats kg 1355.00 39.55 53586.192 Oxygen gas cum 54.00 84.00 4536.003 Acetyline gas cum 18.00 404.00 7272.004 Welding electrodes ( general purpose ) Nos 108.00 10.00 1080.005 Welding electrodes ( low hydrogen ) Nos 973.00 21.00 20433.006 Zinc rich epoxy primer ltr 1.75 244.00 427.007 Coal tar epoxy paint ltr 10.50 226.00 2373.008 Rust cleaner / inhibitor ltr 2.00 311.00 622.009 Wire brush Nos 1.00 53.00 53.00













Rate

172

RateQuantityin `:

Description

in `:QuantityPerticulars



in `:1 Crew for Mobile crane Hour 4.00 231.00 924.002 Crew for Grinding machine Hour 4.00 164.00 656.003 Foreman Day 6.00 436.00 2616.004 Marker / Fabricator / Erector Day 11.00 436.00 4796.005 Gas cutter Day 4.00 436.00 1744.006 Welder ( General ) Day 11.00 436.00 4796.007 Helper fabrication / erection Day 32.00 421.00 13472.008 Helper for cleaning / painting Day 4.00 421.00 1684.009 Painter Cl - II Day 6.00 421.00 2526.00









ITEM: Design, fabrication, supply, erection and commissioning of trash racks consisting of a numberof panels of suitable height with vertical trash bars welded to structural steel frame at wider interval and provided with weld mesh frame for pump house intake structure including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts

QuantityDescription Ratein `:

173


for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:Tracsh rack consists of a number of panels of suitable size. Each panel consists of structuralsteel frame with horizontal stiffeners at interval and vertical trash bars at closer or wider interval.Where the trash bars are spaced at wider interval a weld mesh frame is attached to main frame.Consider trash rack panels for pump house intake structure for 3.55 m wide vent opening. Length of each panel : 3.75 mHeight of each panel : 2.70 mNumber of panels for one vent : 3.00 NosTotal height of trash rack ( 3 x 2.70 ) : 8.10 mHead of water : 7.50 mWeight of trash rack in tonnes based on empirical formula :

= 0.0375 x ( L 2 x H x h ) 0.716

Where ( L ) is length and ( H ) is total height and ( h ) is head of water in metres. = 0.0375 x ( 3.75 x 3.75 x 8.1 x 7.5 ) 0.716 : 4.710 tonnes

The weight computed as above based on empirical formula is further checked by computing theactual weight as per fabrication drawings of trash rack panels for 1 vent for pump house intakestructure having same vent size provided for one of the pump house.Actual weight of embedded parts as per data in Item :36 of Annexure-2 : 4.686 tonnesConsider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of trash rackprovided for one vent of one of the pump house intake structure.structure ( for details refer Item : 36 of Annexure-2 ).


Angles/ beams/ channels/ bars with 2.5% wastage ( 3246.1x1.025 ) : 3327 kgPlates / flats with 2.5 % wastage ( 1359.3 x 1.025 ) : 1393 kg

b. Weld mesh (2 mm dia 25x25 mm opening ) ( 3.44x2.7x3x1.025 ) : 28.50 sqm c. Bolt / Nut / Washer conforming to IS : 1363 :

GI bolts / Nuts / Washers with 2.5 % wastage ( 6.7 x 3 x 1.025 ) : 20.6 kg d. Welding electrodes ( General purpose / Low hydrogen ) :



Total : 84 RmFor cutting structural steel sections to required sizes gas cutting is assumed.As the work involves use angles / channels / beams cutting using cutting torch is considered.Length of steel to be cut by using gas manually : 84 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 42 hoursAcetelyne gas @ 0.6 cum / hour ( 42 ) x 0.60 : 25 cumOxygen gas @ 1.8 cum / hour ( 42 ) x 1.80 : 75 cumUse of gas cutting torch with 50 min / hr working ( 42 x 60 / 50 ) : 50 hours

174



( 164 x 8 / 15 / 2 ) : 44 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 1473 x 8 / 15 / 6 ) : 131 hoursTotal : 175 hours



Painting area for trash rack panels at 30 sqm / tonne ( 4.686 x 30 ) : 140 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 140 sqm @ 9 sqm / ltr / coat : 16.0 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 140 sqm @ 6 sqm / ltr / coat : 94 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor for 140 sqm @ 8 sqm / ltr : 18 ltrFor handling parts during fabrication and erection use 8 t mobile crane for 8 hours.For drilling holes for fixing bolts use drilling machine for 8 hours.For finishing weld joints / edges 4 hours use of grinding machine considered.


Painter Cl-II

Cutting sections 50 hours 1 6 6 12Fabricating by stitch welding 39 hours 2 5 --- 10Run welding 131 hours 2 --- 16 16Erection of panels 1 2 --- 4Cleaning surface 140 sqm @ 15 sqm/day --- --- --- 10Painting ( 5 x 140 ) sqm @ 15 sqm / day --- --- --- 59Finishing / cleaning --- 1 --- 1 Total : 6 14 22 112




Marker /

175

Erector /Welder

Gas cutter / Fabricator /





2 Weld mesh 25x25 mm opening sqm 28.50 150.00 4275.003 Bolt / Nut / Washer ( GI ) kg 20.60 108.00 2224.804 Oxygen gas cum 75.00 84.00 6300.005 Acetyline gas cum 25.00 404.00 10100.006 Welding electrodes ( general purpose ) Nos 164.00 10.00 1640.007 Welding electrodes ( low hydrogen ) Nos 1473.00 21.00 30933.008 Zinc rich epoxy primer ltr 16.00 244.00 3904.009 Coal tar epoxy paint ltr 94.00 226.00 21244.00







Fuel / Energy charges Hour 8.00 854.00 6832.003 Drilling machine Hour 4.00 13.00 52.00






in `:1 Crew for Mobile crane Hour 8.00 231.00 1848.002 Crew for Drilling machine Hour 4.00 164.00 656.00

Contd

Descriptionin `:

in `:

Rate

176

RateQuantityin `:


Description

Quantity



in `:Contd

3 Crew for Grinding machine Hour 8.00 164.00 1312.004 Foreman Day 6.00 436.00 2616.005 Marker / Fabricator / Erector Day 14.00 436.00 6104.006 Gas cutter Day 6.00 436.00 2616.007 Welder ( General ) Day 16.00 436.00 6976.008 Helper fabrication / erection Day 43.00 421.00 18103.009 Helper for cleaning / painting Day 22.00 421.00 9262.00









ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting ofsill beam, wheel tracks, seal seats, guide rails, gate groove liners etc., with all accessoriesfor pump house intake stoplog gate including cost of all materials, machinery, labour,cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications

Quantity Rate

177

in `:Description


and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:The nature of work involved is similar to the embedded parts for stoplog gate proposed for canal regulator stop-log gate under ' Gate / Hoist and allied works '. Therefore same unit rate as proposed under ' Gate / Hoist and allied works ' is proposed for this item.

Item : 33 Gate / Hoist and allied works Rate per tonne `: 151100.00

Note: Wt of 1 set of embedded parts in tonnes = 0.0665 x ( L2 x H x h )

0.716

Where ( L ) is length = Clear distance between piers in m + 0.50 m. ( H ) is total height of stoplog gate in m = FSL - Sill level + 0.30 m ( h ) is head of water above sill of gate in m = FSL - Sill level


ITEM: Design, fabrication, supply, erection, testing and commissioning of sliding type stoplog gateconsisting of skin plate, horizontal and vertical girders, lifting hooks, bronze padded slide blocks, stiffeners, guide shoes, rubber seals etc., with all accessories for pump house intake vent including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with lead upto 1 km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:The nature of work involved is similar to the stoplog gate proposed for canal regulator underunder ' Gate / Hoist and allied works '. Therefore same unit rate as proposed under ' Gate /Hoist and allied works ' is proposed for this item.

Item : 34 Gate / Hoist and allied works Rate per tonne `: 132100.00

Note: Wt of 1 stoplog gate in tonnes = 0.0995 ( L2 x H x h )

0.716

Where ( L ) is length = Clear distance between piers in m + 0.50 m. ( H ) is total height of stoplog gate in m = FSL - Sill level + 0.30 m ( h ) is head of water above sill of gate in m = FSL - Sill level


ITEM: Design, fabrication, supply, erection and commissioning of electrically operated mono-rail hoist assembly consisting of electric motor, rope drum, gear system, wire rope with lifting attachment, festoon cabling etc., with all accessories for operating pump house stop-log gate including cost of all materials ( excluding providing mono-rail hoist supporting structure and mono-rail with fixtures ), machinery, labour, cleaning, greasing etc., complete as per specifications and approved drawings with all leads and lifts.

DATA:Mono-rail hoist with accessories Rate / tonne hoist capacity `: 45000.00Add for erection, jointing and commissioning at 15 % `: 6800.00

Rate / tonne hoist capacity `: 51800.00Rate approved / tonne capacity `: 51800.00

Note: i. Hoist capacity = 1.50 x weight of stop-gate

178



ITEM: Design, fabrication, supply, erection and commissioning of structural steel hoist supporting structure consisting of columns, cross beams, bracings, stiffeners, mono-rail with fixtures etc.,with all accessories for electrically operated mono-rail rope drum hoist for operating pump house intake vertical lift gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying two coats of zinc chromate red primer and three coats of synthetic enamel paint etc., complete as per specifications and approved drawings with lead upto I km and all lifts for structural steel components and all leads and lifts including packing / forwarding charges for other materials.

DATA:The nature of work involved is similar to the hoist supporting structure proposed for barrage gaterope drum hoists under ' Gate / Hoist and allied works '. Therefore same unit rate as proposedunder ' Gate / Hoist and allied works ' is proposed for this item.

Item : 21 Gate / Hoist and allied works Rate per tonne `: 110100.00Note: i. Columns with bracings/anchors/stiffeners:150 kg per metre height.

ii. Weight proposed above is for each intake ventiii. Mono rail beam with cross beams :100 kg per metre length


ITEM: Design, fabrication, supply, erection, testing and commissioning EOT crane consisting ofdouble girder box type construction, rail mounted end carraiges with long and cross travel arrangement, main and auxiliary hoists of specified capacity, rails, pendant control, gear boxes, electric motors, brakes, rope drums, wire ropes, sheaves, end buffer stoppers, pendant operated DSL bus bars with all accessories for main and auxiliary hoists for handling pumpsand accessories in pump house including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, greasing, applying two coats of zinc chromate red oxideprimer and three coats of synthetic enamel paint etc., complete as perspecifications and approved drawings with all leads and lifts .

DATA:The basic requirements of EOT crane are similar to out door moving gantry crane except forgantry portal legs. The reduction in quantity of portal legs is assumed to off-set to some extent increase in span for EOT crane base frame and cost of additional auxiliary hoist.Therefore, similar rate per tonne capacity as provided for out-door moving gantry crane with about 25 percent reduction per tonne capacity is proposed for EOT crane.Rate per tonne capacity ( vide Item: 8 under ' Gates & Hoists ' )EOT crane Rate / tonne hoist capacity `: 173300.00

Note: i. EOT crane Main hoist capacity = 1.25 x Maximum lifting load(round off to next 5 t)ii. EOT crane Auxiliary hoist capacity = Approximately 10 % of main hoist capacityiii. Rate for EOT crane shall be based on capacity of main hoist.

179


DATA FOR PERCENTAGE PROVISIONS

ENABLING WORKS

FOR

ANNEXURE-1


SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2018-19 Annexure-1.a

ITEM: Provision for Electric sub-station / Demand charges / Lighting fabrication & work areas :

DATA:Generally, contracts provide for arranging HT / LT electric power line within about 1 km distancefrom work site by the department. From the departmental bulk supply point laying of further transmission lines, erection of sub-station, erecting distribution lines and other arrangementsfor power supply to various installations will be the responsibility of the contractors requiringelectric power for their works.For gate / hoist works, generally, cutting / bending / welding operations for most of the partsare carried out at the contractor's central fabrication yard and fabrcated parts along with the bought out parts are transported to site of work. Fabrication of some matching parts and minormodifications to shop fabricated parts / erection / field welding / commissioning are carried outat specified work site. Therefore, electric power supply arrangements are necessary both atcentral fabrication place and erection / commissioning place for gate / hoist works.Estimation of electric power load for sub-station for gate / hoist works:

Erectionplace ( in hp )

Plate shearing machine 20.00 ---Bending machine 15.00 15.00Pug cutting machine 4.00 2.00Planing machine 15.00 ---Drilling machine 5.00 5.00Grinding machine 5.00 5.00Welding transformers 120.00 120.00Work shop equipments / miscellaneous 20.00 20.00

Total : 204.00 167.00Requirement of power in Kw 152.184 124.58Add for lighting fabrication area & trial running etc @ 5 % 7.61 ---Add for lighting erection areas & trial running etc @ 10 % --- 12.46Add for lighting & domestic use for camp @ 5 % 0.00 6.23Add for reserve capacity @ 5 % 7.61 6.23

Total : 167.40 149.50Capacity of sub-station required hp / 0.85 196.94 175.88

200 kVA 175 kVAFor working out demand charges sanctioned power requirement is assumed to vary from100 KVA to 200 kVA ( average 150 kVA ) for fabrication place and from 75 kVA to 175 kVA( average 125 kVA ) for erection site.Av. demand for electric power is considered for 2 years each for fabrication and erection sites.Consider 1 Transformer of 250 KVA at each place.Capital cost of other sub-station equipments & distribution lines:( for each place )HT / LT Circuit breaker 3 Nos @ `: 35262.00 / Each `: 105786.00Poles with fixtures 10 Nos @ `: 5125.00 / Each `: 51250.00HT / LT Line conductor 2 km @ `: 39831.00 / km `: 79662.00Other accessories / controls / junctions LS `: 45000.00

Total `: 281698.00Life of sub-station equipments ( average ) : 20 yearsSalvage value : 10 percentMaintenance & Repairs as % of Capital cost : 25 percentMiscellaneous charges as % of Repair charges : 10 percent

180

place ( in hp )

181

say :

Fabrication


Interest on av. capital cost per annum : 9.00%Insurance charges as % of av. capital cost per annum : 1%Average capital cost 281698 x ( 20+1 ) / 40 `: 147891.45Hire charges of sub-station equipments / year :Depreciation per year 281698 x 0.9 / 20 `: 12676.41Interest on av. Capital cost per year 147891 x 0.09 `: 13310.23Maintenance & repairs per year 281698 x 0.25 / 20 `: 3521.23Miscellaneous charges per year 3521.23 x 0.1 `: 352.12Insurance charges per year 147891 x 0.01 `: 1478.91

Total hire charges / year Rs: `: 31338.90

Total cost of sub-station equipments :Transformers 1 Nos @ `: 209694 / Each `: 209694.00Other sub-station equipments `: 281698.00

Total `: 491392.00

Cables & Fittings: ( for fabrication place and erection place ) :PVC cable 70 sqmm 200 m @ `: 229.00 / Rm `: 45800.00PVC cable 25 sqmm 200 m @ `: 140.00 / Rm `: 28000.00PVC cable 16 sqmm 500 m @ `: 119.00 / Rm `: 59500.00PVC cable 10 sqmm & below 1000 m `: 101.00 / Rm `: 101000.00Miscellaneous fittings / switches etc LS `: 200.00

Total `: 234500.00Assume use of cables for 10 years with 10 percent salvage value.Use rate of cables per year with 10 % salvage value `: 21105.00Data for cost of Lighting : ( for fabrication place and erection place ) :Lighting facilities are to be provided for plants and work areas during night time.Provision of flood lights near work areas and tube lights at other locations is assumed.No. of tube lights for fabrication and erection areas assumed: : (10+10) Nos.No. of hours of use and energy requirement for 2 years No. of hours of usage ( 20 x 12 x 300 x 2 ) : 144000.00Energy requirement in Kwhr ( 20x 12x 300x 2x 40 / 1000) : 5760.00No. of flood lights for fabrication / erection areas assumed: : (10+10) NosNo. of hours of use and energy requirement for 2 years No. of hours of usage ( 20 x 12 x 300 x 2 ) : 144000.00Energy requirement in Kwhr (20x 12x 300x2x 500/ 1000 ) : 72000.00Flood / Tube light fittings:Flood light sets 20 Nos @ `: 4876.00 / set `: 97520.00Tube light sets (plant area) 20 Nos @ `: 473.00 / set `: 9460.00Accessories for light fittings / repairs / replacements etc LS `: 2250.00

Total `: 109230.00Assume use of light fittings for 10 years with 50 percent salvage value.Use rate of light fittings / year with 50 % salvage value `: 5461.50 ( 109230.00 x 0.5 / 10 )Cost of flood lights 500 W `: 762.00 / Each `: 762.00Life of flood light in hours : 1500.00Use rate of flood lights per hour 762.00 / 1500 `: 0.51Cost of tube lights 40 W `: 34.00 / Each `: 34.00Life of fluorescent tube light in hours : 1500.00Use rate of tube lights per hour 34.00 / 1500 `: 0.02

182


Running 50 KVA DG set is assumed for 1 hour daily for fabrication place and 2 hours daily for erection site to ensure minimum power supply for lighting and works during break down of mainpower supply from grid.

RATE ANALYSIS UNIT: 1.00 No.A. MATERIALS:( fabrication & erection sites combined ) Sl No Perticulars Unit Amount

in `:1 Use rate of cables Year 2.00 21105.00 42210.002 Anchors / supports for cables / lights LS 200.00 45.00 9000.003 Use rate of flood/ tube light sets Year 2.00 5461.50 10923.004 Use rate of flood lights Hour 0.51 73152.00

Energy charges Kwhr 72000.00 8.24 593280.005 Use rate of fluorescent tubes Hour 0.02 3264.00

Energy charges Kwhr 5760.00 8.24 47462.406 Sundries ( tapes & consumeables ) LS 200.00 45.00 9000.00



B. MACHINERY: ( fabrication & erection site combined ) : Sl No Unit Amount

in `:1 Sub-station at fabrication place Year 2.00 62677.81

Sub-station at erection place Year 2.00 62677.812 Transformer 250 KVA 1 No.( fabrication ) Month 24.00 2301.00 55224.00

Transformer 250 KVA 1 No. ( erection ) Month 24.00 2301.00 55224.003 Demand charges for 2 years: 150 KVA

at 85 % PF ( 150x2x12x0.85 ) KVA 3060.00 216.00 660960.00Demand charges for 2 years: 125 KVAat 85 % PF ( 125x2x12x0.85 ) KVA 2550.00 216.00 550800.00

4 DG set 50 KVA at fabrication place Hour 600.00 69.00 41400.00Fuel / Energy charges Hour 600.00 1139.00 683400.00DG set 50 KVA at erection place Hour 1200.00 69.00 82800.00Fuel / Energy charges Hour 1200.00 1139.00 1366800.00




C. LABOUR: ( fabrication & erection sites combined ) : Sl No Unit Amount

in `:1 Crew for DG set at fabrication place Hour 600.00 134.00 80400.00

Crew for DG set at erection place Hour 1200.00 134.00 160800.00Contd

183

144000.00

144000.00

31338.90

Quantity

Descriptionin `:

in `:

Ratein `:

31338.90

Quantity

Rate

Rate



C. LABOUR( Contd ) : ( fabrication & erection sites combined ) : Sl No Unit Amount

in `:Contd

2 Electrician 1 No. x 2 x 12 x 26 days Day 624.00 436.00 272064.00Electrician 1 No. x 2 x 12 x 26 days Day 624.00 436.00 272064.00

3 Heavy mazdoor 1 No x 2 x 12 x 26 days Day 624.00 411.00 256464.00Heavy mazdoor 1 No x 2 x 12 x 26 days Day 624.00 411.00 256464.00



D. ENABLING WORKS AT ERECTION SITE :1 Shed for DG set & office 50 sqm @ `: 6750.00 / sqm `: 337500.002 Fensing for sub-station 100 Rm @ `: 1125.00 / Rm `: 225000.003 Civil works for foundations / pedastals / duct etc LS `: 90000.00

Total `: 652500.00Add interest for ( 1 + 1 ) years @ 9% `: 117450.00Add for transportation / erection / dismantling cost @ 12% `: 58967.04Deduct salvage value on shed & fensing @ 25% ( - ) `: -140625.00

Total `: 688292.04

ABSTRACT:A. Cost of Materials `: 914418.02B. Hire charges of Machinery `: 4175917.43C. Cost of Labour `: 1895453.76D. Cost of enabling works `: 688292.04

TOTAL `: 7674081.25 Less requirement for camp use at site @ 5% ( - ) `: -383704.06 Total cost for work 1.00 No. `: 7290377.19Approximate quantity of gate / hoist work is assumed at 2000 tonnes.As radial gates are major components of work, the basic unit rates worked out for radial gateand hoist are considered for estimating the approximate cost of gate / hoist works.The quantity distribution for embedded parts / gate / hoist is assumed as under:Embedded parts with all accessories : 260 tonnesGates with all accessories : 1460 tonnesHoists with all accessories : 280 tonnes

Total : : 2000 tonnesBasic cost of embedded parts / tonne `: 1801683 / 14.334 ( Item-1) `: 125692.95Basic cost of radial gate / tonne `: 8741528 / 57.457 ( Item-2) `: 152140.34Basic cost of radial gate hoist / tonne `: 3448132 / 15.440 ( Item-3) `: 223324.62Total cost of embedded parts / gates / hoists:Total cost of embedded parts x 260 `: 32680168Total cost of gates x 1460 `: 222124900Total cost of hoists x 280 `: 62530892

Total `: 317335960

Quantity

184

Rate

223324.62

125692.95152140.34

Descriptionin `:


Cost of power supply arrangements including lighting and demand charges as percentage of basic cost of embedded parts / gates / hoists works out to:

x 100 / : 2.30 say : 2.30

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2018-19 Annexure-1.b

ITEM: Provision for other Enabling works:

DATA:Stores / work shop / guarage / fuel depot / power supply arrangements / lighting / sheds forplant and machinery are necessary both at main fabrication place and field erection place forgate / hoist and allied works. Plant and machinery required for field erection works requiretransportation / erection / dismantling / re-transportation to main work shop or else where.The cost of enabling works at fabrication place is ignored as the aportioned cost is negligiblein view of long duration use of these enabling works.This data rate is for other enabling works for erection / commissioning of gate / hoists works.

1 Store for boughtout items 100 sqm @ `: 6750.00 / sqm `: 675000.002 General store 100 sqm @ `: 7875.00 / sqm `: 787500.003 Work shop 100 sqm @ `: 7875.00 / sqm `: 787500.004 Guarage 75 sqm @ `: 5625.00 / sqm `: 421875.005 Sheds for machinery 150 sqm @ `: 5625.00 / sqm `: 843750.006 Fuel depot 25 sqm @ `: 6750.00 / sqm `: 168750.007 Site levelling / field offices etc LS `: 225000.008 Local haul roads / fensing store yard etc LS `: 225000.00

Total `: 4134375.00Add interest for 1 years @ 9% `: 372093.75Add for maintenance for 2 years @ 2.00% `: 82687.50Less salvage value @ 25 % for ( 1 ) to ( 6 ) ( - ) `: -921093.75

Total ( A ) `: 3668062.50Transportation / Erection / Dismantling of plant & machinery for erection:Bending machine / derric cranes / welding transformers / D.G. set / work shop equipments are the major plant & machinery requiring erection and dismantling services at work site.Capital cost of equipments for field erection works:

1 Stationery derric cranes 2 Nos `: 7061462 Mobile crane 8 t 1 No `: 753475

Mobile crane 25 t 1 No `: 118561263 Welding transformers 10 Nos `: 2495104 Truck 1 No ( exclusive transportation not considered ) `: 05 Bending machine 1 No. `: 3450306 D.G set 50 kVA 1 No. `: 5413707 Transformer 250 kVA 1 No. `: 2096948 Work shop equipments / fuel pump / Misc LS `: 225000

Total `: 14886351Transportation to site for ( 1 ) to ( 8 ) @ 1.50% `: 223295.27Erection cost for ( 5 ) to ( 8 ) @ 6.00% `: 79265.64

Total `: 302560.91Add interest for 1 year @ 9% `: 27230.48Add dismantling cost for ( 5 ) to ( 8 ) @ 3.00% `: 39632.82Add transportation from site for ( 1 ) to ( 8 ) 1.50% `: 223295.27

Total( Total ( B ) `: 592719.47

185

3173359607290377.19


Total cost of other enabling works ( A + B ) `: 4260782Approximate basic cost of gate / hoist works as per data in annexure-1:Total cost of embedded parts x 260 `: 32680168Total cost of gates x 1460 `: 222124900Total cost of hoists x 280 `: 62530892

Total `: 317335960Cost of other enabling works as percentage of total basic cost:

x 100 / : 1.34 say : 1.30

125692.95

223324.62152140.34

4260782 317335960

186


187

GATES / HOIST WORKS

DETAILS OF

MATERIALS / CUTTING / WELDING

ANNEXURE-2


GATES AND HOISTS : REQUIREMENT OF MATERIALS -

SECTION: GATE / HOIST & ALLIED WORKS. Item No.1

Item: Embedded parts for spillway radial gates:Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on embedded parts fabrication drawings of 15 m x 9.75 m radial gates provided for Kodasalli dam spillway under Kali Stage-II Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard weiding tables.

Sl No. DESCRIPTION OF MATERIALS Weight Number of in kg electrodes

Sill beam / wall plates:1 Flats 100x100x10 mm 152 Nos 120.00 15.2 1.5 152 Flats 100x250x10 mm 26 Nos 43.00 9.1 0.3 33 Anchor rods 12 dia 350 mm 152 Nos 48.00 1.8 5.3 534 Anchor rods 12 dia 350 mm 52 Nos 16.00 0.6 1.8 185 Sill beam ISMB 300 half 2820 mm 2 Nos 130.00 5.6 0.5 56 Sill beam ISMB 300 half 2400 mm 4 Nos 221.00 9.6 1.5 157 Anchor plate 80x200x10 mm 26 Nos 33.00 2.1 4.2 428 Anchor bolts 16 dia 180 mm 52 Nos 15.00 --- 2.6 269 Stiffeners 60x135x10 mm 12 Nos 8.00 3.6 6.5 65

10 Stiffeners 60x135x10 mm 12 Nos 8.00 3.6 6.5 6511 Stiffeners 125x125x10 mm 2 Nos 3.00 0.8 1.2 1212 Stiffeners 125x125x10 mm 2 Nos 3.00 0.8 1.2 1213 Anchor bolts 16 dia 190 mm 108 Nos 32.00 --- 5.4 5414 Anchor bolts 16 dia 430 mm 36 Nos 24.00 --- 1.8 1815 Seal base 190x200x10 mm 2 Nos 6.00 0.8 SV 0.8 1016 Seal base 130x200x10 mm 2 Nos 4.00 0.7 SV 1.1 1317 Seal seat SS 80x420x6 mm 2 Nos 3.00 1.0 2.0 2018 Seal seat SS 100x2640x6 mm 2 Nos 25.00 5.5 10.8 10819 Seal seat SS 100x2400x6 mm 4 Nos 45.00 10.0 19.6 19620 Seal seat SS 100x1232x6 mm 16 Nos 93.00 21.3 41.0 41021 Seal seat SS 100x1208x6 mm 2 Nos 11.00 2.6 5.0 5022 Seal seat SS 100x350x6 mm 2 Nos 3.00 0.9 1.6 1623 Cleats ISA 75x75x8 mm 80 mm 108 Nos 77.00 16.2 17.3 17324 Wall plate base 360x1232x12 mm 16 Nos 668.00 25.5 SV 5.8 7025 Wall plate base 360x1365x12 mm 2 Nos 93.00 3.5 SV 0.8 1026 Stiffener 80x126x8 mm 16 Nos 99.00 1.3 40.5 40527 Stiffener 80x1202x8 mm 16 Nos 97.00 1.3 39.8 39828 Stiffener 80x1173x8 mm 2 Nos 12.00 0.2 4.9 4929 Stiffener 80x1308x8 mm 2 Nos 13.00 0.2 5.4 5430 Stiffener 70x222x8 mm 52 Nos 51.00 3.6 37.7 37731 Stiffener 80x315x8 mm 2 Nos 3.00 0.2 1.9 1932 Wall plate 350x360x12 mm 2 Nos 24.00 1.4 SV 0.7 8

Contd

188

length in mWeld length

in mGas cutting



Contd33 Splice plate 120x320x6 mm 10 Nos 18.00 4.4 3.2 3234 Nuts / Washers 16 dia 392 Nos each 17.00 --- --- ---35 Bolts / Nuts / Washers 16 dia 55 mm 40 6.00 --- --- ---

Anchors / Anchor girders / Yoke girders :36 Anchor bars 275x8900x40 mm 8 Nos 6148.00 73.4 F16 33.8 240037 Anchor girder web 950xx2760x20 mm 2 823.00 7.4 --- ---38 Flange U / S 200x2760x20 mm 2 Nos 173.00 9.4 F8 11.0 19839 Flange D / S 350x2760x25 mm 2 Nos 379.00 9.7 F8 11.0 19840 Yoke girder web 1160x2440x20 mm 2 Nos 889.00 7.2 --- ---41 Flange U / S 1000x2440x28 mm 2 Nos 1073.00 10.3 F8 9.8 17642 Flange D / S 250x2440x20 mm 2 Nos 192.00 8.8 F8 9.8 17643 Stiffeners 150x950x12 mm 20 Nos 268.00 32.0 48.0 48044 Stiffeners 150x200x10 mm 48 Nos 113.00 21.6 33.6 33645 Stiffeners 475x1160x16 mm 8 Nos 554.00 18.7 28.2 28246 Stiffeners 475x450x12 mm 24 Nos 483.00 29.4 44.4 44447 Stiffeners 105x150x10 mm 8 Nos 10.00 3.2 1.9 1948 Stiffeners 100x1160x12 mm 8 Nos 87.00 0.8 21.8 21849 Stiffeners 425x1160x12 mm 4 Nos 186.00 8.3 13.7 13750 Pad plates 380x430x20 mm 4 Nos 103.00 3.2 6.5 6551 Bolts / Nuts 24 dia 16 Nos 9.00 --- --- ---

Trunnion supports :52 Thrust plates 700x731x20 mm 2 Nos 166.00 2.9 --- ---53 Stiffeners 110x288x12 mm 8 Nos 24.00 3.2 6.4 6454 Stiffeners 120x700x12 mm 6 Nos 47.00 4.9 8.4 8455 Cleats ISA 75x75x8 mm 80 mm 8 Nos 6.00 1.2 1.4 1456 Base plate 650x940x20 mm 2 Nos 192.00 3.2 --- ---57 SS sliding plates 60x570x6 mm 6 Nos 10.00 0.4 7.6 7658 Stiffeners 140x538x12 mm 6 Nos 43.00 4.1 8.1 8159 Stiffeners 150x940x12 mm 4 Nos 53.00 4.4 7.5 7560 Align plate 120x800x12 mm 4 Nos 36.00 3.6 6.4 6461 Align rod 16 dia 180 mm 8 Nos 2.00 0.4 0.4 462 Nuts / Washers 16 dia 16 Nos each 2.00 --- --- ---63 Align plate 100x100x12 mm 8 Nos 8.00 1.6 --- ---64 Align rod 45 dia 1778 mm 8 Nos 178.00 1.0 --- ---65 Nuts / Washers 45 dia 24 Nos / 8 Nos 2.00 --- --- ---66 Align rod 12 dia 360 mm 8 Nos 3.00 0.5 0.3 3

Total : 14334.00 428.1 600.0 8415 kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angles / Beams / Channels / Bars : 679.00 kgStructural steel Plates / Flats : 13356.00 kg

2. Alloy steel components : IS : 1570Stainless steel plates / flats : 190.00 kg

3. Bolt / Nut / Washer : IS : 1363MS Bolts / Nuts / Washers : 109.00 kg

189

Gas cutting in m

Weld lengthlength in m


4. Other details :Length of cutting : 428.10 RmLength of welding : 600.00 RmNumber of electrodes ( for structural steel ) : 7539 NosNumber of electrodes ( for stainless steel ) : 876 Nos


Item: Spillway radial gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of 15 m x 9.75 m radial gates provided for Kodasalli dam spillway under Kali Stage-II Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard weiding tables.


Trunnion assembly :1 Side plate(FS) 1177x1437x25 mm 2 Nos 664.00 6.2 F16 2.0 1422 Side plate(NS) 1177x1272x25 mm 2 Nos 588.00 5.9 F16 2.0 1423 Web plate 490x1119x14 mm 4 Nos 241.00 9.0 23.8 2384 Web plate 490x969x12 mm 2 Nos 90.00 4.9 10.7 1075 Hub 590 / 390 / 340 dia 680 mm 2 Nos 1865.00 --- --- ---6 Stiffener 170x200x16 mm 6 Nos 26.00 2.3 4.5 457 Con. Plate 397x720x 25 mm 4 Nos 224.00 5.0 --- ---8 Con. Plate 260x720x 20 mm 2 Nos 59.00 2.0 --- ---9 Stiffener 100x200x10 mm 4 Nos 6.00 1.2 2.4 24

10 Stiffener 170x250x 10 mm 4 Nos 13.00 1.7 3.4 3411 Stiffener 400x250x10 mm 2 Nos 16.00 1.3 3.6 3612 Back strip 25x1119x6 mm 4 Nos 5.00 0.1 4.5 4513 Back strip 25x962x6 mm 4 Nos 5.00 0.1 3.9 3914 Back strip 25x432x6 mm 4 Nos 2.00 0.1 1.8 1815 Back strip 25x460x6 mm 4 Nos 2.00 0.1 1.9 1816 Bracket pl 725x745x36 mm 4 Nos 610.00 11.8 F16 12.0 85217 Plate 775x850x25 mm 2 Nos 259.00 3.3 --- ---18 Plate 610x850x20 mm 2 Nos 163.00 3.0 --- ---19 R / F plate 620 dia x 10 mm 2 Nos 47.00 6.0 4.0 4020 Stiffener 160x716x12 mm 4 Nos 43.00 3.5 8.3 8321 Stiffener 90x716x16 mm 6 Nos 49.00 0.6 10.8 10822 Stiffener 60x200x16 mm 4 Nos 6.00 0.3 2.1 2123 SS plate 40x555x6 mm 6 Nos 6.00 0.3 6.7 6724 Bush 330/390/620 dia 2 Nos 1128.00 --- --- ---25 Pin 330 dia x 815 mm 2 Nos 1094.00 --- --- ---26 Brass washers 590 dia x5 mm 2 Nos 21.00 --- --- ---27 Keeper pl 120x530x20 mm 2 Nos 20.00 0.3 --- ---28 Hex screws 24 dia x50 mm 4 Nos 1.00 --- --- ---

Contd

Weld length

190

in mlength in mGas cutting



Contd29 Plate washer 100x100x25 mm 8 Nos 16.00 1.6 --- ---30 Tie holder 390x500x32 mm 2 Nos 98.00 2.6 F16 4.0 28431 Stiffener 230x515x16 mm 2 Nos 60.00 3.0 7.8 7832 Stiffener 165x515x16 mm 2 Nos 21.00 1.5 5.5 5533 Stiffener 130x515x16 mm 2 Nos 17.00 1.3 5.2 5234 R/F plate 650 dia 10 mm 2 Nos 6.00 6.0 4.0 40

Trunnion tie beam :35 ISMC-300 : 6652 mm 2 Nos 483.00 1.2 --- ---36 ISMC-300 : 8652 mm 2 Nos 628.00 1.2 2.4 2437 Plate 160x6302x10 mm 2 Nos 158.00 12.9 25.5 25538 Plate 160x8302x10 mm 2 Nos 196.00 16.9 33.6 33639 Plate 240x300x8 mm 4 Nos 18.00 2.2 4.3 4340 Plate 160x700x12 mm 4 Nos 42.00 6.7 6.2 6241 Plate 55x300x12 mm 4 Nos 6.00 1.5 2.9 2942 Plate 240x370x12 mm 4 Nos 33.00 2.5 4.9 4943 Bolts 22 dia x 100 mm 40 Nos 20.00 --- --- ---

Sector arms and bracings :44 Web plate 500x9716x12 mm 2 Nos 915.00 20.5 --- ---45 Web plate 500x9766x10 mm 2 Mos 767.00 20.5 --- ---46 Web plate 516x10286x10 mm 2 Nos 833.00 21.6 --- ---47 Flange plate 360x9556x20 mm 2 Nos 1080.00 19.9 F10 39.7 111248 Flange plate 340x9606x20 mm 2 Nos 1026.00 19.9 F10 39.7 111249 Flange plate 180x10126x12 mm 2 Nos 344.00 20.6 41.3 41350 Flange plate 360x9723x20 mm 2 Nos 1099.00 20.2 F10 40.4 113151 Flange plate 340x9773x20 mm 2 Nos 1043.00 20.3 F10 40.5 113452 Flange plate 180x10293x12 mm 2 Nos 349.00 21.0 41.9 41953 Pad plate 360x760x25 mm 2 Nos 107.00 2.3 F10 5.0 14054 Pad plate 340x760x25 mm 2 Nos 101.00 2.2 F10 5.0 14055 Pad plate 210x750x20 mm 2 Nos 49.00 2.0 F10 5.0 14056 Pad plate 370x690x25 mm 2 Nos 100.00 2.2 F10 4.8 13457 Pad plate 350x690x25 mm 2 Nos 95.00 2.1 F10 4.8 13458 Pad plate 220x690x20 mm 2 Nos 48.00 1.8 F10 4.8 13459 Stiffener 150x250x10 mm 8 Nos 24.00 3.2 6.4 6460 Stiffener 90x200x10 mm 4 Nos 6.00 1.2 2.3 2361 Stiffener 80x150x10 mm 6 Nos 6.00 1.4 2.8 2862 Stiffener 128x150x10 mm 6 Nos 9.00 1.7 2.8 2863 Bracing L 100x100x6 - 3530 mm 4 Nos 130.00 0.8 4.0 4064 Bracing L 100x100x6 - 3776 mm 4 Nos 139.00 0.8 4.0 4065 Bracing L 75x75x6 - 2642 mm 4 Nos 72.00 0.6 3.5 3566 Bracing L 75x75x6 - 2995 mm 4 Nos 81.00 0.6 3.5 3567 Bracing L 75x75x6 - 1714 mm 4 Nos 47.00 0.6 3.5 3568 Bracing L 75x75x6 - 2161 mm 4 Nos 59.00 0.6 3.5 3569 Bracing L 75x75x6 - 786 mm 4 Nos 21.00 0.6 3.5 3570 Bracing L 100x100x6 - 2762 mm 4 Nos 102.00 0.8 4.0 4071 Bracing L 100x100x6 - 3175 mm 4 Nos 117.00 0.8 4.0 4072 Bracing L 75x75x6 - 2010 mm 4 Nos 55.00 0.6 3.5 35

Contd

191

Weld lengthGas cutting in mlength in m



Contd73 Bracing L 75x75x6 - 2534 mm 4 Nos 69.00 0.6 3.5 3574 Bracing L 75x75x6 - 1258 mm 4 Nos 34.00 0.6 3.5 3575 Bracing L 75x75x6 - 1810 mm 4 Nos 49.00 0.6 3.5 3576 Bracing L 75x75x6 - 496 mm 4 Nos 13.00 0.6 3.5 3577 Gusset pl 160x220x8 mm 8 Nos 18.00 4.3 3.5 3578 Gusset pl 160x280x8 mm 4 Nos 11.00 1.8 2.3 2379 Gusset pl 160x300x8 mm 4 Nos 12.00 10.9 2.4 2480 Gusset pl 160x360x8 mm 4 Nos 14.00 2.1 2.9 2981 Gusset pl 170x410x8 mm 4 Nos 18.00 2.4 3.3 3382 Gusset pl 170x430x8 mm 4 Nos 18.00 2.4 3.4 3483 Gusset pl 170x520x8 mm 4 Nos 22.00 2.8 4.1 4184 Gusset pl 170x500x8 mm 4 Nos 21.00 2.7 4.0 4085 Gusset pl 160x200x8 mm 8 Nos 16.00 2.9 3.2 3286 Gusset pl 160x160x8 mm 8 Nos 13.00 2.6 2.5 2587 Gusset pl 160x270x8 mm 8 Nos 22.00 1.8 4.3 4388 Gusset pl 170x350x8 mm 4 Nos 15.00 2.1 2.8 2889 Gusset pl 170x430x8 mm 4 Nos 18.00 2.4 3.4 3490 Gusset pl 170x540x8 mm 4 Nos 23.00 2.9 4.3 4391 Stiffener 40x450x8 mm 118 Nos 133.00 4.7 35.4 35492 Bolts 22 dia x 75 mm Nos 7.00 --- --- ---93 Bolts 22 dia x 80 mm 17.00 --- --- ---94 Bolts 27 dia x 100 mm 18.00 --- --- ---95 Bolts 24 dia x 90 mm 12.00 --- --- ---

Horizontal girders and bracings :96 Web plate 1200x14840x10 mm 1 No. 1398.00 4.0 --- ---97 Flange plate 450x14840x20 mm 1 No. 1048.00 15.3 F10 29.7 83298 Flange plate 340x14938x20 mm 1 No. 797.00 15.3 F10 29.9 83799 Flange plate 370x2750x10 mm 2 Nos 159.00 6.3 12.4 124100 Bracket 700x1085x20 mm 2 Nos 238.00 5.0 F10 6.0 168101 Bracket 700x1200x20 mm 2 Nos 264.00 5.4 F10 6.0 168102 Stiffener 200x900x12 mm 4 Nos 68.00 4.4 8.8 88103 Stiffener 428x1300x10 mm 2 Nos 87.00 3.5 2.6 26104 Stiffener 125x1200x10 mm 6 Nos 70.00 8.0 17.4 174105 Stiffener 155x1260x20 mm 8 Nos 245.00 11.3 25.1 251106 Stiffener 150x300x10 mm 12 Nos 42.00 5.4 10.8 108107 Web plate 1200x14840x10 mm 1 No. 1398.00 4.0 --- ---108 Flange plate 380x14840x20 mm 1 No 885.00 15.2 F10 29.7 832109 Flange plate 320x13122x20 mm 1 No. 659.00 13.5 F10 26.3 736110 Flange plate 320x1000x20 mm 2 Nos 100.00 2.7 F10 4.7 132111 Flange plate 350x2752x10 mm 2 Nos 151.00 6.2 12.4 124112 Stiffener 145x1200x10 mm 6 Nos 82.00 8.1 17.9 179113 Stiffener 145x1260x20 mm 8 Nos 229.00 11.3 24.8 248114 Stiffener 100x700x10 mm 4 Nos 22.00 3.2 7.2 72115 Stiffener 100x950x10 mm 4 Nos 30.00 4.2 9.2 92116 Web plate 800x14840x10 mm 1 No. 932.00 4.0 --- ---117 Flange plate 300x14840x16 mm 1 No. 559.00 15.2 F10 29.7 832

Contd

192

in mGas cutting Weld lengthlength in m



Contd118 Flange plate 240x12888x16 mm 1 No. 389.00 13.2 F10 25.8 722119 Flange plate 240x1000x16 mm 2 Nos 60.00 2.5 F10 4.5 126120 Flange plate 280x2280x10 mm 2 Nos 100.00 5.1 10.3 103121 Stiffener 115x800x10 mm 6 Nos 43.00 5.5 12.4 124122 Stiffener 115x840x16 mm 8 Nos 97.00 7.7 17.1 171123 Stiffener 120x895x10 mm 2 Nos 17.00 2.1 4.6 46124 Stiffener 120x1020x10 mm 2 Nos 19.00 2.3 5.0 50125 Stiffener 100x600x10 mm 4 Nos 19.00 2.8 6.4 64126 Stiffener 300x300x10 mm 4 Nos 28.00 2.4 4.8 48127 Bracing L 110x110x8 - 4560 mm 2 Nos 122.00 0.5 1.4 14128 Bracing L 110x110x8 - 2360 mm 2 Nos 63.00 0.5 1.4 14129 Bracing L 110x110x8 - 2041 mm 2 Nos 54.00 0.5 1.4 14130 Bracing L 110x110x8 - 3879 mm 2 Nos 104.00 0.5 1.4 14131 Bracing L 110x110x8 - 1968 mm 2 Nos 53.00 0.5 1.4 14132 Bracing L 110x110x8 - 1608 mm 2 Nos 43.00 0.5 1.4 14133 Bracing L 130x130x8 - 5575 mm 2 Nos 177.00 0.5 1.8 18134 Bracing L 130x130x8 - 2798 mm 2 Nos 88.00 0.5 1.8 18135 Bracing L 130x130x8 - 2638 mm 2 Nos 83.00 0.5 1.8 18136 Bracing L 130x130x8 - 4968 mm 2 Nos 158.00 0.5 1.8 18137 Bracing L 130x130x8 - 2395 mm 2 Nos 76.00 0.5 1.8 18138 Bracing L 130x130x8 - 2255 mm 2 Nos 72.00 0.5 1.8 18139 Bracing L 110x110x8 - 3210 mm 5 Nos 215.00 1.2 3.5 35140 Bracing L 110x110x8 - 3970 mm 5 Nos 266.00 1.2 3.5 35141 Bracing L 75x75x8 - 1200 mm 5 Nos 53.00 0.8 2.5 25142 Bracing L 75x75x8 - 1986 mm 10 Nos 177.00 1.5 5.0 50143 Bracing L 75x75x8 - 1100 mm 5 Nos 49.00 0.8 2.5 25144 Bracing L 75x75x8 - 2390 mm 10 Nos 213.00 1.5 5.0 50145 Gusset pl 180x500x10 mm 5 Nos 35.00 3.4 2.5 25146 Gusset pl 180x440x10 mm 5 Nos 31.00 3.1 2.2 22147 Gusset pl 180x570x10 mm 2 Nos 16.00 1.5 1.2 12148 Gusset pl 200x700x10 mm 1 No. 11.00 0.9 0.7 7149 Gusset pl 210x700x10 mm 2 Nos 23.00 1.8 1.4 14150 Gusset pl 180x730x10 mm 2 Nos 21.00 1.9 1.5 15151 Gusset pl 230x420x10 mm 2 Nos 15.00 1.3 0.9 9152 Gusset pl 230x400x10 mm 2 Nos 15.00 1.3 0.9 9153 Gusset pl 230x330x10 mm 2 Nos 12.00 1.2 0.7 7154 Gusset pl 230x460x10 mm 2 Nos 17.00 1.5 0.9 9155 Gusset pl 240x460x10 mm 2 Nos 17.00 1.6 0.9 9156 Gusset pl 200x500x10 mm 4 Nos 31.00 3.0 2.4 24157 Gusset pl 220x580x10 mm 4 Nos 40.00 3.4 2.8 28

Skin plate and stiffeners :158 Skin plate 2980x1800x12 mm 2 Nos 1011.00 6.0 8.9 89159 Skin plate 2100x1600x12 mm 2 Nos 633.00 4.2 6.8 68160 Skin plate 2400x1800x12 mm 2 Nos 814.00 4.8 7.7 77161 Skin plate 2980x8415x10 mm 2 Nos 3937.00 6.0 19.6 196162 Skin plate 2100x9076x10 mm 2 Nos 2992.00 4.2 18.9 189

Contd

193


in mGas cutting



Contd163 Skin plate 2400x8876x10 mm 2 Nos 3345.00 4.8 19.1 191164 Stiffener 1/2 ISMB 350-10155 mm 14 Nos 3725.00 71.0 284.0 2840165 Stiffener 1/2 ISMB 350-10646 mm 22 Nos 6136.00 117.0 468.4 4684166 Web plate 158x10215x10 mm 2 Nos 253.00 20.8 40.9 409167 Flange 100x10015x12 mm 2 Nos 189.00 0.2 20.0 200168 Seal base 25x2980x16 mm 2 Nos 19.00 0.1 11.9 119169 Seal base 25x2100x16 mm 2 Nos 13.00 0.1 8.4 84170 Seal base 25x2400x16 mm 2 Nos 15.00 0.1 9.6 96171 Back strip 40x10215x6 mm 5 Nos 96.00 0.2 102.0 1020172 Stiffener 60x160x8 mm 204 Nos 123.00 12.3 114.2 1142173 Stiffener 80x158x8 mm 6 Nos 5.00 0.5 3.8 38174 Diaphragm 170x391x10 mm 6 Nos 31.00 3.4 8.8 88

End shields :175 Skin plate 2200x3010x10 mm 2 Nos 1040.00 5.0 6.0 60176 Stiffener L 150x75x8 - 2400 mm 16 Nos 525.00 3.6 6.4 64177 Shield plate 150 / 715x2300x8mm 2 Nos 125.00 6.9 11.8 118178 Stiffener L 65x65x6 - 1350 mm 6 Nos 470.00 0.8 16.2 162179 Stiffener L 65x65x6 - 3450 mm 2 Nos 400.00 0.3 1.6 16

Guide rollers 4 Nos180 Plates for guide roller assembly 48.00 5.2 2.9 29181 Guide roller 4 Nos 30.00 --- --- ---182 Bronze bush 4 Nos 6.00 --- --- ---183 Pins 4 Nos 4.00 --- --- ---184 Bolt/Nut/Washer 2.00 --- --- ---

Seal assembly :185 Bottom seal 100x15000x20 mm 1 No. --- --- --- ---186 Side seal 12110x20 mm 2 Nos --- --- --- ---187 Seal clamp 75x1984x16 mm 2 Nos 37.00 0.2 --- ---188 Seal clamp 75x1998x16 mm 4 Nos 75.00 0.3 --- ---189 Seal clamp 75x1398x16 mm 2 Nos 26.00 0.2 --- ---190 Seal clamp 60x1969x16 mm 2 Nos 30.00 0.1 --- ---191 Seal clamp 60x1998x16 mm 10 Nos 151.00 0.6 --- ---192 Lock plate 30x120x27 mm 24 Nos 18.00 3.6 --- ---193 GI Bolts 16 dia x 70 mm 388 Nos 67.00 --- --- ---194 GI Washers 16 dia 388 Nos 9.00 --- --- ---

Total : 57457.00 927.5 2293.7 31038kg Rm Rm Nos


Angles / Beams / Channels / Bars : 15421.00 kgPlates / Flats : 37729.00 kg

2. Cast steel components : IS : 1030Trunnion hub / Guide roller : 1895.00 kg

3. Alloy steel components : IS : 1570SS plates / Flats : 6.00 kgPins : 1098.00 kg

194

Gas cutting in mlength in m

Weld length


4. Alluminium / Bronze alloy components : IS : 305Trunnion & Guide roller bush : 1155.00 kg

5. Bolt / Nut / Washer IS :1363GI Bolts / Nuts / Washers : 76.00 kgMS Bolts / Nuts / Washers / Screws : 77.00 kg

6. Rubber seals : IS : 11855Bottom seal : 15.00 RmSide seals : 24.22 Rm

7. Other details :Length of cutting : 927.50 RmLength of welding : 2293.70 RmNumber of electrodes ( for structural steel ) : 31038 Nos


Item Rope drum hoist for spillway radial gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of 90 t capacity rope drum hoist provided for operating 15 m x 9.75 m radial gates of Kodasalli dam under Kali Stage-II Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard weiding tables.


Embedments :1 Anchor bars 25 dia x 1670 mm 24 Nos 154.00 0.6 --- ---2 Template 180x1290x12 mm 4 Nos 44.00 5.9 --- ---3 Anchor plate 180x220x20 mm 4 Nos 25.00 1.6 F10 1.2 344 Anchor plate 100x180x20 mm 4 Nos 11.00 0.7 F10 0.6 175 Anchor bars 20 dia x 490 mm 4 Nos 5.00 0.1 --- ---6 Washers & Nuts for anchor bars 8.00 --- --- ---7 Bolts / Washers / Nuts 20 dia 4 Nos 1.00 --- --- ---8 Pack plate 180x180x6 mm 1 No. 2.00 --- --- ---

Hoist supporting structure :9 Girder ISMB-450 x 2950 mm 4 Nos 854.00 3.0 --- ---

10 Girder ISMB-300 x 1670 mm 4 Nos 295.00 2.4 --- ---11 Girder ISMB-300 x 1230 mm 2 Nos 109.00 1.2 --- ---12 Bracing L 75x75x8 - 1780 mm 2 Nos 32.00 0.3 0.6 613 Bracing L 75x75x8 - 1650 mm 6 Nos 88.00 0.9 2.7 2714 Bracing L 90x90x8 - 2130 mm 2 Nos 46.00 0.4 1.2 1215 Bracing L 90x90x8 - 1020 mm 2 Nos 22.00 0.4 1.2 1216 Bracing L 90x90x8 - 970 mm 2 Nos 21.00 0.4 1.2 1217 Cleats L 75x75x10 - 220 mm 24 Nos 58.00 3.6 17.8 17818 Stiffener 60x280x10 mm 4 Nos 5.00 0.3 3.2 3219 Stiffener 65x424x12 mm 48 Nos 125.00 23.5 53.2 53220 Stiffener 65x137x12 mm 8 Nos 7.00 1.6 4.3 43

Contd

195

in mlength in mWeld lengthGas cutting



Contd21 R / F plate 180x300x16 mm 4 Nos 26.00 1.9 F10 3.5 9822 R / F plate 250x250x16 mm 4 Nos 31.00 2.0 F10 4.0 11223 Gusset plate 170x430x10 mm 2 Nos 12.00 2.0 1.0 1024 Gusset plate 150x230x8 mm 8 Nos 17.00 3.0 4.3 43

Pulley supporting structure :25 Girder ISMB-500 - 2040 mm 4 Nos 709.00 4.0 --- ---26 Flange 500x750x20 mm 4 Nos 236.00 4.8 7.8 7827 Diaphragm 590x488x12 mm 2 Nos 54.00 2.2 6.3 6328 Stiffener 80x476x12 mm 18 Nos 65.00 1.5 25.0 25029 Stiffener 120x510x12 mm 18 Nos 104.00 11.4 27.0 27030 Diaphragm 545x590x36 mm 2 Nos 182.00 2.3 F10 6.4 17931 Diaphragm 590x769x20 mm 2 Nos 141.00 2.7 F10 6.4 17932 R / F plate 200 dia x 16 mm 4 Nos 20.00 2.5 F10 2.5 7033 Pin 190 dia x 800 mm 2 Nos 356.00 --- --- ---34 Nuts 130 dia 4 Nos 1.00 --- --- ---35 Washers 250/132 dia x 10 mm 2 Nos 6.00 2.4 --- ---36 Washers 250/120 dia x 10 mm 2 Nos 4.00 2.6 --- ---37 Pin 170 dia x 534 mm 2 Nos 190.00 --- --- ---38 Keeper pl 60x250x16 mm 4 Nos 8.00 0.3 --- ---39 Washer 280/172 dia x16 mm 2 Nos 10.00 2.9 --- ---40 Washer 250/172 dia x 2 mm 2 Nos 2.00 2.6 --- ---41 Washer 280/172 dia x 2 mm 4 Nos 5.00 2.9 --- ---42 Plate 200x750x16 mm 2 Nos 38.00 1.9 1.8 1843 Plate 380x750x16 mm 2 Nos 72.00 2.3 1.8 1844 Plate 425x1220x10 mm 4 Nos 163.00 6.6 6.6 66

Drive stool :45 Pad plate 340x340x12 mm 1 No. 11.00 0.7 1.4 1446 Pad plate 220x620x12 mm 1 No. 13.00 0.8 0.9 947 Pad plate 430x620x12 mm 1 No. 25.00 1.1 2.5 2548 Pad plate 260x400x12 mm 1 No. 16.00 0.7 1.0 1049 Web plate 259x1890x8 mm 2 Nos 60.00 2.5 --- ---50 Flange 90 x 1890x12 mm 2 Nos 31.00 4.0 7.6 7651 Stiffener 60x251x8 mm 2 Nos 2.00 0.1 1.5 1552 Stiffener 192x251x8 mm 1 No. 3.00 0.5 1.3 1353 Stiffener 177x200x8 mm 2 Nos 8.00 0.8 1.8 1854 Stiffener 177x192x8 mm 1 No. 4.00 0.4 1.1 1155 Stiffener 100x259x8 mm 4 Nos 7.00 1.4 3.4 3456 Stiffener 192x259x8 mm 2 Nos 6.00 0.9 2.9 2957 Stiffener 50x136x8 mm 4 Nos 2.00 0.2 1.9 1958 Stiffener 136x192x8 mm 2 Nos 3.00 0.7 1.9 1959 Shim plates 340x340x2/2/1 mm 1 each 5.00 --- --- ---60 Shim plate 220x620x2/2/1 mm 1 each 5.00 --- --- ---61 Shim plate 430x620x2/2/1 mm 1 each 10.00 --- --- ---62 Bolts / Washers / Nuts 6.00 --- --- ---

Gear box :63 Web plate 532x2358x10 mm 2 Nos 196.00 5.8 9.5 95

Contd

length in m

196

Weld lengthGas cutting in m



Contd64 Web plate 532x410x10 mm 2 Nos 34.00 1.9 1.6 1665 Web plate 532x1178x10 mm 2 Nos 98.00 3.5 4.7 4766 Web plate 532x1230x10 mm 2 Nos 102.00 3.5 4.9 4967 Web plate 532x1300x10 mm 2 Nos 108.00 3.7 5.2 5268 Web plate 532x1230x10 mm 2 Nos 102.00 3.5 4.7 4769 Flange pl 140x2358x16 mm 2 Nos 82.00 5.0 9.4 9470 Flange pl 140x416x16 mm 2 Nos 14.00 1.1 1.6 1671 Flange pl 140x1178x16 mm 2 Nos 42.00 2.6 4.7 4772 Flange pl 140x670x16 mm 2 Nos 24.00 1.6 2.7 2773 Flange pl 140x1300x16 mm 2 Nos 46.00 2.9 5.2 5274 Flange pl 100x1230x16 mm 2 Nos 44.00 2.5 4.9 4975 Flange pl 150x2238x12 mm 2 Nos 66.00 4.8 9.3 9376 Flange pl 150x370x12 mm 2 Nos 10.00 0.8 1.5 1577 Flange pl 150x1058x12 mm 2 Nos 30.00 2.4 4.3 4378 Flange pl 150x1280x12 mm 2 Nos 36.00 2.9 5.2 5279 Flange pl 150x1190x12 mm 2 Nos 68.00 5.4 10.0 10080 Drum support 400x570x20 mm 4 Nos 144.00 4.5 F10 4.0 11281 Pad plate 100x380x45 mm 4 Nos 56.00 0.4 F16 3.9 10982 Pad plate 120x430x10 mm 4 Nos 16.00 2.2 4.4 4483 Stiffener 140x240x10 mm 8 Nos 22.00 3.0 8.3 8384 Stiffener 140x532x10 mm 8 Nos 40.00 5.4 13.0 13085 Stiffener 100x532x10 mm 24 Nos 100.00 2.4 35.2 35286 Stiffener 200x200x8 mm 12 Nos 30.00 4.8 14.4 14487 Flange pl 100x180x12 mm 2 Nos 4.00 0.2 0.7 788 Flange pl 100x600x10 mm 2 Nos 1.00 0.2 2.4 2489 Bolts / Nuts / Washers 10.00 --- --- ---

Floating shaft :90 Pipe 300 dia x 6671 mm 2 Nos 983.00 --- --- ---91 Flange pl 440/325 dia x 25 mm 4 Nos 54.00 9.6 F16 4.0 28492 Plate 440 dia x 14 mm 1 No. 17.00 1.4 --- ---93 Stiffeners 55x100x10 mm 24 Nos 10.00 3.8 3.8 3894 Plate 300 dia x 8 mm 2 Nos 9.00 2.0 2.0 2095 Bolts / Nuts / Washers 13.00 --- --- ---

Gear box coupling :96 Plate 440/153 dia x 25 mm 2 Nos 54.00 3.7 F10 1.9 1997 Hub 150 dia x 83 mm 2 Nos 20.00 --- --- ---98 Stiffener 60x140x10 mm 12 Nos 8.00 0.7 4.8 48

Other components :99 Plummer blocks for drums 4 Nos 192.00 --- --- ---100 Bronze bush for plummers 4 Nos 32.00 --- --- ---101 Bolts / Nuts / Washers 12.00 --- --- ---102 Plummer blocks for gears 4 Nos 110.00 --- --- ---103 Bronze bush for plummers 4 Nos 28.00 --- --- ---104 Bolts / Nuts / Washers 7.00 --- --- ---105 Pulleys 720 PCD 6 Nos 1080.00 --- --- ---106 Bush for pulleys 6 Nos 84.00 --- --- ---

Contd

197

Weld lengthlength in m in mGas cutting



Contd107 Roap drums 290 dia x 1170 mm 2 Nos 2370.00 --- --- ---108 Shafts for drums / pinions 557.00 --- --- ---109 Gears 1310.00 --- --- ---110 Pinions 218.00 --- ---

Covers for gear and drive units :111 ISA 45x45x5 mm 100.00 4.0 4.0 40112 Plates / Flats 250.00 16.0 20.0 200113 Round bars 15.00 0.1 0.5 5114 Bolt/Nut/Washers 10.00 --- --- ---

Other components :115 Manual operation assembly 124.00 10.0 10.0 100116 Gate position indicator 25.00 --- --- ---117 Wire rope 36 mm dia 448.00 --- --- ---118 Elecon gear units 1000.00 --- --- ---119 Electric motor 20 hp 1 No. 150.00 --- --- ---120 Ele-magnetic brake 29.00 --- --- ---121 Bolts / Nuts / Washers for above 15.00 --- --- ---

Total : 15440.00 254.6 447.2 5304kg Rm Rm Nos



2. Cast steel components : IS : 1030Rope drums 2 Nos / Gears 4 Nos : 3680.00 kgPinions : 218.00 kgPulleys 720 PCD 6 Nos : 1080.00 kgPlummer blocks / Hubs : 322.00 kg

3. Alloy steel steel components : IS : 1570Shafts : 557.00 kgPins : 546.00 kg

4. Alluminium/ Bronze alloy components : IS : 305Bearings / Bush : 144.00 kgBolt / Nut / Washers IS : 1363MS Bolts / Nuts / Washers : 83.00 kg

5. Wire rope : IS : 226636 mm dia 6 / 37 construction 2 Nos : 100 Rm

6. Other components :Manual operating system : 1 No.Elecon gears : 2 NosElectric motor 20 hp : 1 No.Gate position indicator : 1 No.Ele-magnetic brake : 1 No.MS pipe 300 mm dia : 13.32 Rm

7. Other details :Length of cutting : 254.60 Rm

Gas cutting Weld lengthlength in m in m

198


Length of welding : 447.20 RmNumber of electrodes ( for structural steel ) : 5304 Nos


Item: Foot bridge ( catwalk ) at spillway trunnion level : Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of 15 m clear span and 1 m wide catwalk provided for Alamatti dam spillway under Upper Krishna Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard weiding tables.


1 ISMB 500 x 17900 mm 2 Nos 3111.00 5.2 2.0 202 ISMB 200 x 990 mm 15 Nos 377.00 10.0 6.0 603 ISA 75x75x8 x 150 mm 60 Nos 80.00 9.0 36.0 3604 ISA 75x75x8 x 17900 mm 2 Nos 319.00 1.0 72.0 7205 ISA 75x75x8 x 1000 mm 30 Nos 267.00 4.5 4.5 456 Chequered pl 990 x 17900 mm 1 No. 835.00 20.0 F3 20.0 807 32 dia pipe 17900 mm 4 Nos 225.00 --- --- ---8 Plate 300x300x12 mm 8 Nos 68.00 5.0 5.0 509 Plate 250x400x12 mm 4 Nos 28.00 2.5 5.2 52

10 Bolt/Nut/Washer 20 dia x 60 mm 16 Nos 8.00 --- --- --- Total : 5318.00 57.2 150.7 1387

kg Rm Rm Nos


Angles / Beams / Channels / Bars : 4154.00 kgStructural steel plates / flats : 96.00 kg

2. Chequered plates : 835.00 kg 3. Bolts / Nuts / Washers : IS : 1363

MS Bolts / Nuts / Washers : 8.00 kg 4. Other components :

MS pipes 32 mm dia : 71.60 Rm 5. Other details :

Length of cutting : 57.2 RmLength of welding : 150.7 RmNumber of electrodes ( for structural steel ) : 1387 Nos


Item: Embedded parts for spillway stoplog gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on embedded parts fabrication drawings of stoplog gates provided Kodasalli dam spillway under Kali Stage-II Project in Karnataka.

Weld lengthGas cutting

199

in mlength in m


2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


First stage anchors :1 Anchor plate 80x280x10 mm 36 Nos 63.00 2.9 --- ---2 Anchor bars dia 12 x 360 mm 72 Nos 26.00 0.9 2.7 273 Anchor plate 80x220x10 mm 70 Nos 97.00 5.6 --- ---4 Anchor bars dia 12 x 360 mm 140 Nos 50.00 1.7 5.3 535 Anchor plate 250x250x12 mm 3 Nos 18.00 1.5 --- ---6 Anchor bars dia 12 x 360 mm 6 Nos 2.00 0.1 0.2 2

Embedded parts :7 SS plate 100x2400x6 mm 4 Nos 45.00 0.4 F4 19.6 888 SS plate 100x2900x6 mm 2 Nos 27.00 0.2 F4 11.8 539 SS plate 100x2300x6 mm 2 Nos 22.00 0.2 F4 9.4 42

10 SS plate 120x2400x12 mm 4 Nos 108.00 10.1 F8 19.7 35511 SS plate 120x2900x12 mm 2 Nos 66.00 6.0 F8 11.8 21212 SS plate 120x2700x12 mm 2 Nos 61.00 5.6 F8 11.1 20013 Track plate 180x2400x32 mm 4 Nos 434.00 10.3 DV 0.8 5314 Track plate 180x2900x28 mm 2 Nos 230.00 6.2 DV 0.4 2115 Track plate 180x2800x28 mm 2 Nos 222.00 6.0 DV 0.4 2116 Tr Angle 150x75x8 x 2400 mm 4 Nos 132.00 0.9 20.1 20117 Tr Angle 150x75x8 x 2900 mm 2 Nos 79.00 0.5 12.1 12118 Tr Angle 150x75x8 x 2400 mm 2 Nos 66.00 0.5 10.0 10019 Stiffener 70x120x8 mm 36 Nos 19.00 2.5 18.7 18720 Stiffener 85x312x8 mm 24 Nos 40.00 9.5 18.6 18621 Cleat ISA 75x75x8 x 100 mm 72 Nos 64.00 10.8 14.4 14422 SS plate 100x2160x6 mm 2 Nos 20.00 0.2 F4 8.9 4023 SS plate 100x2650x6 mm 4 Nos 50.00 0.4 F4 22.0 9924 Sill beam flange 130x2600x12 mm 2 Nos 64.00 5.5 DV 0.5 625 Sill beam flange 130x2650x12 mm 4 Nos 130.00 11.1 DV 1.0 1226 Sill beam web 150x2600x10 mm 2 Nos 61.00 5.5 11.0 11027 Sill beam web 150x2650x10 mm 4 Nos 125.00 11.2 22.4 22428 Stiffener 60x150x8 mm 12 Nos 7.00 0.7 5.1 5129 Stiffener 60x180x8 mm 12 Nos 8.00 0.7 5.1 5130 Anchor plate 80x200x10 mm 30 Nos 38.00 3.0 6.0 6031 SS plate 112x175x6 mm 2 Nos 2.00 0.6 F4 1.2 632 Guide plate 140x2625x16 mm 6 Nos 277.00 16.6 DV 1.7 3333 Anchor plate 100x220x12 mm 42 Nos 87.00 4.2 8.4 8434 Anchor bolt dia 16 x 200 mm 144 Nos 46.00 2.3 7.3 7335 Anchor bolt dia 16 x 185 mm 144 Nos 42.00 2.3 7.3 7336 Nuts / Washers dia 16 mm 576 each 24.00 --- --- ---37 Anchor plate 40x250x6 mm 24 Nos 11.00 2.4 3.6 3638 Guide plate 140x3225x16 mm 2 Nos 113.00 6.7 DV 0.5 9

Contd

in m

200

Weld lengthGas cutting length in m



ContdDogging set :

39 Bearing pl 150x200x25 mm 2 Nos 12.00 0.7 --- ---40 Anchors 60x250x10 mm 4 Nos 5.00 0.3 0.5 541 Diaphragm pl 596x790x12 mm 2 Nos 89.00 2.8 1.2 1242 Beam 150x750x36 mm 2 Nos 64.00 0.9 --- ---43 R / F plates 130x290x16 mm 4 Nos 19.00 1.7 1.0 1044 Guide plate 140x220x25 mm 2 Nos 12.00 0.7 SV 0.5 645 Handle / stopper 2.00 --- 0.2 2

Total : 3179.00 162.9 302.5 3068kg Rm Rm Nos



2. Alloy steel components : IS : 1570SS plates for wheel track : 235.00 kgSS plates for seal seat : 166.00 kg

3. Bolts / Nuts / Washers : IS : 1363MS Bolts / Nuts / Washers : 112.00 kg



Item: Spillway stoplog gate elements :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of stoplog gate elements provided Kodasalli dam spillway under Kali Stage-II Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard weiding tables. Data for 1 element ( size 15 m x 1.2 m ) : 8 elements considered.


Gate leaf :1 Skin plate 1200x15620x16 mm 1 No. 2354.00 2.4 DV 2.4 462 Stiffener 80x790x10 mm 36 Nos 179.00 2.9 68.4 6843 Web plate 1400x15488x10 mm 2 Nos 3404.00 21.6 123.9 12394 Stiffener 120x1320x10 mm 20 Nos 249.00 28.8 62.4 624

Contd

in m

Weld length

201

length in mWeld lengthGas cutting

Gas cutting in mlength in m



Contd5 Flange 345x15816x20 mm 2 Nos 1713.00 33.0 --- ---6 Bracing ISA 65x65x6 x 730 mm 4 Nos 17.00 0.5 3.0 307 Bracing ISA 65x65x6 x 1339 mm 4 Nos 31.00 0.5 2.5 258 Plate 550x1200x16 mm 2 Nos 166.00 3.5 8.0 809 Slide block 40x1200x40 mm 2 Nos 30.00 0.1 F8 4.8 86

10 Bronze padding for slide blocks 6.00 --- --- ---11 Seal base 45x1105x12 mm 2 Nos 9.00 2.3 4.4 4412 Seal support 25x14955x16 mm 1 Nos 47.00 --- 30.0 30013 Plate 140x140x12 mm 4 Nos 7.00 1.1 2.3 2314 Pin support 300x523x16 mm 4 Nos 79.00 3.4 6.0 6015 Pin 80 dia x 160 mm 2 Nos 13.00 --- --- ---16 Stiffener 340x528x10 mm 2 Nos 28.00 1.8 4.3 4317 Stiffener 340x740x10 mm 2 Nos 40.00 2.2 5.1 5118 Cleat ISA 65x65x6 x 150 mm 6 Nos 5.00 0.8 2.2 2219 Plate 150x150x10 mm 6 Nos 11.00 1.8 2.7 2720 Stiffener 50x550x12 mm 4 Nos 10.00 0.2 5.2 5221 Plate 100x14965x10 mm 1 No 117.00 0.2 30.0 30022 Stiffener 80x150x8 mm 40 Nos 30.00 3.2 18.4 18423 Plate 120x1004x10 mm 8 Nos 76.00 9.0 19.9 199

Guide Shoe :24 Plate 200x220x12 mm 4 Nos 17.00 1.7 --- ---25 Plate 97x220x12 mm 8 Nos 16.00 0.8 1.8 1826 Plate 28x220x12 mm 4 Nos 2.00 0.6 SV 1.8 3627 Plate 92x70x10 mm 8 Nos 4.00 --- 2.9 2928 Shims 7.00 --- --- ---29 Bolt/Nut/Washer 20 dia x60 mm 16 Nos 6.00 --- --- ---

Seal assembly :30 Bottom seal 100x15000x16 mm 1 No --- --- --- ---31 Side seals 100x1200x12 mm 2 Nos --- --- --- ---32 Seal clamp 90x1566x16 mm 2 Nos 35.00 --- --- ---33 Seal clamp 90x1598x16 mm 6 Nos 108.00 --- --- ---34 Seal clamp 90x1108x16 mm 2 Nos 25.00 --- --- ---35 Seal clamp 45x1190x16 mm 2 Nos 13.00 --- --- ---36 GI Bolts / Nuts 16 dia x 80 mm 24 Nos 5.00 --- --- ---37 GI Bolt / Nuts 16 dia x 75 mm 152 Nos 29.00 --- --- ---38 Washers 16 dia 176 Nos 2.00 --- --- ---

Total for 1 element 8890.00 122.4 412.4 4202Total for 8 elements 71120.00 979.2 3299.2 33616Additional supports for bottom element :

39 ISA 65x65x6 x 1000 mm 3 Nos 37.00 0.4 1.0 10 Total : 71157.00 979.6 3300.2 33626

kg Rm Rm Nos

ABSTRACT :( For 8 Elements ) 1. Structural steel : IS : 2062

Angles / Beams / Channels : 461.00 kgPlates / Flats : 70208.00 kg

length in m

202

Gas cutting Weld lengthin m


2. Alloy steel components : IS : 1570Pin : 104.00 kg

3. Alluminium / Bronze alloy components : IS : 305Bronze pads : 48.00 kg

4. Bolt / Nut / Washer : IS : 1363GI Bolts / Nuts / Washers : 288.00 kgMS Bolts / Nuts / Washers : 48.00 kg

5. Rubber seal : IS : 11855Bottom seal ( uncladed ) : 120.00 RmSide seal ( uncladed ) : 19.20 Rm



Item: Lifting beam for spillway stoplog gate elements :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of lifting beam for operating the stoplog gate elements provided for Kodasalli dam spillway under Kali Stage-II Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard weiding tables.


1 Web plate 540x15476x8 mm 2 Nos 1050.00 33.0 ---2 Flange plate 150x15476x16 mm 4 Nos 1166.00 62.8 123.8 12383 Stiffener 100x400x10 mm 28 Nos 88.00 2.8 8.7 874 End plate 560x1120x12 mm 2 Nos 118.00 3.4 2.3 235 Stiffener 250x525x10 mm 4 Nos 41.00 3.1 6.2 626 Hook plate 350x625x20 mm 4 Nos 137.00 3.9 4.6 467 Stiffener 120x540x10 mm 20 Nos 102.00 13.2 31.2 3128 Plate 120x125x10 mm 8 Nos 9.00 2.0 3.9 399 Plate 200x200x16 mm 4 Nos 20.00 1.6 3.2 32

10 Plate 160x1130x10 mm 4 Nos 57.00 9.5 --- ---11 Plate 122x165x20 mm 2 Nos 6.00 0.6 0.5 512 Plate 60x162x10 mm 4 Nos 3.00 0.9 1.0 1013 Plate 140x140x20 mm 10 Nos 31.00 2.8 --- ---14 Plate 200x2071x20 mm 48 Nos 260.00 17.0 --- ---15 Plate 427x604x25 mm 2 Nos 101.00 3.0 --- ---16 Hook 315x815x60 mm 2 Nos 100.00 --- --- ---17 Plate 100x160x20 mm 2 Nos 5.00 0.2 0.5 518 Bush dia 105 / 85 x 120 mm 2 Nos 5.00 --- --- ---19 Pin dia 85 x 268 mm 2 Nos 24.00 --- --- ---20 Keeper pl 40x140x10 mm 4 Nos 2.00 --- --- ---

Contd

203

in mWeld lengthGas cutting

length in m



Contd21 Pin dia 90 x 285 mm 2 Nos 29.00 --- --- ---22 Pin dia 120 x 252 mm 1 Nos 22.00 --- --- ---23 Pin dia 85 x 300 mm 2 Nos 26.00 --- --- ---24 Guide shoe pl 150x150x12 mm 4 Nos 8.00 1.2 --- ---25 Guide shoe pl 103x150x12 mm 8 Nos 12.00 2.0 1.2 1226 Plate 26x150x12 mm 4 Nos 2.00 0.7 SV 1.2 2427 Stiffener 40x93x8 mm 8 Nos 2.00 0.5 2.1 2128 Stiffener 140x120x10 mm 4 Nos 5.00 1.0 1.0 1029 Stiffener 120x250x10 mm 2 Nos 5.00 0.8 1.0 1030 Rod dia 60 x 300 mm 2 Nos 13.00 0.2 0.7 731 Stopper pl 60x210x20 mm 2 Nos 4.00 0.2 0.5 532 Plate 40x150x12 mm 1 No. 1.00 --- --- ---33 Bolt/Nut/Washer dia 24 x150 mm 2 Nos 1.00 --- --- ---34 Bolt/Nut/Washer dia 16 x35 mm 16 Nos 2.00 --- --- ---35 Plate 210x540x10 mm 8 Nos 71.00 6.0 17.3 173

Total : 3528.00 172.4 210.9 2121kg Rm Rm Nos


Angle / Channel / Beam / Bar : 13.00 kgPlates / Flats : 3306.00 kg

2. Alloy steel components : IS : 1570Pin : 101.00 kg

3. Forged steel components : IS : 2004Hook : 103.00 kg

4. Alluminium / Bronze alloy components : IS : 305Bush : 5.00 kg

5. Bolts / Nuts / Washers IS : 1363MS Bolts / Nuts / Washers : 3.00 kg



Item: Spillway gantry crane :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of 25 t moving gantry crane for operating the stoplog gate elements provided for Alamatti dam spillway under Upper Krishna Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard weiding tables.

204




Gantry portal :1 Plate 850/450x2650x10 mm 4 Nos 544.00 16.0 --- ---2 Plate 1500/850x2800x10 mm 4 Nos 858.00 20.0 DV 6.8 613 Plate 850/650x2700x10 mm 4 Nos 638.00 17.0 DV 2.6 254 Plate 1500/650x2650x10 mm 4 Nos 651.00 18.0 --- ---5 Plate 320x10700x20 mm 2 Nos 1076.00 22.0 F10 86.0 24086 Plate 320x2589x20 mm 2 Nos 260.00 5.8 F10 22.0 6167 Plate 320x1300x20 mm 2 Nos 131.00 3.3 F10 10.4 2918 Plate 320x1050x20 mm 2 Nos 106.00 2.8 F10 9.7 2729 Plate 320x2757x20 mm 2 Nos 277.00 6.2 F10 23.4 655

10 Plate 320x1050x20 mm 2 Nos 106.00 2.8 F10 9.7 27211 Plate 320x282x20 mm 8 Nos 114.00 4.8 DV 19.3 56012 Plate 320x728x20 mm 2 Nos 73.00 2.1 6.8 6813 Plate 320x450x16 mm 4 Nos 73.00 3.1 9.8 9814 Plate 320x650x16 mm 4 Nos 105.00 3.9 13.0 13015 Plate 320x500x10 mm 4 Nos 50.00 3.3 6.5 6516 Plate 280x489x8 mm 2 Nos 17.00 1.5 5.0 5017 Plate 280x584x8 mm 2 Nos 21.00 1.8 5.8 5818 Plate 280x725x8 mm 2 Nos 25.00 2.0 6.9 6919 Plate 280x850x8 mm 6 Nos 90.00 6.8 23.8 23820 Plate 280x839x8 mm 2 Nos 29.00 2.3 7.8 7821 Stiffener 280x774x8 mm 2 Nos 27.00 2.1 7.3 7322 Stiffener 280x768x8 mm 2 Nos 27.00 2.1 7.3 7323 Stiffener 280x650x8 mm 2 Nos 23.00 1.9 6.3 6324 Stiffener 280x635x8 mm 2 Nos 22.00 1.8 6.2 6225 Stiffener 150x892x10 mm 2 Nos 21.00 2.1 4.8 4826 Plate 320x4231x16 mm 8 Nos 1361.00 36.4 --- ---27 Plate 500/380x4230x10 mm 8 Nos 1328.00 40.0 135.4 135428 Plate 240x240x10 mm 8 Nos 36.00 3.9 7.7 7729 Washer dia 160x10 mm 4 Nos 8.00 2.0 2.0 2030 Stiffener 280x500x8 mm 4 Nos 35.00 3.1 10.2 10231 Plate 280x468x8 mm 4 Nos 33.00 3.0 9.7 9732 Plate 280x431x8 mm 4 Nos 30.00 2.9 9.1 9133 Plate 280x393x8 mm 4 Nos 28.00 2.7 8.5 8534 Plate 280x380x8 mm 4 Nos 27.00 2.6 8.3 8335 Flange pl 380x7176x8 mm 2 Nos 342.00 15.1 --- ---36 Web plate 250x7176x8 mm 2 Nos 225.00 14.9 SV 28.7 34437 Stiffener 220x380x8 mm 8 Nos 42.00 4.8 16.2 16238 Flange pl 412x7176x10 mm 2 Nos 464.00 15.2 --- ---39 Stiffener 396x450x10 mm 2 Nos 28.00 1.7 3.4 3440 Web plate 450x7176x8 mm 2 Nos 406.00 15.3 SV 28.7 25941 Stiffener 396x450x8 mm 8 Nos 89.00 6.8 20.7 20742 Web plate 320x7176x10 mm 2 Nos 361.00 15.0 57.4 57443 Flange pl 510x7176x8 mm 2 Nos 460.00 15.4 --- ---44 End plate 430x630x12 mm 2 Nos 51.00 2.2 3.4 3445 Stiffener 284x510x8 mm 2 Nos 18.00 1.6 20.9 20946 Plate 400x7140x14 mm 2 Nos 628.00 15.0 --- ---

Contd

205

Weld lengthGas cutting in mlength in m



Contd47 Plate 1000x7140x10 mm 2 Nos 1121.00 16.3 SV 28.6 42948 Plate 360x1000x8 mm 10 Nos 226.00 13.6 47.2 47249 Plate 350x460x10 mm 4 Nos 51.00 3.3 6.5 6550 Pin dia 80 x 520 mm 2 Nos 41.00 --- --- ---51 Keeper pl 40x130x10 mm 4 Nos 2.00 0.2 --- ---52 Screw dia 12 x 50 mm 8 Nos 2.00 --- --- ---53 Plate 255x320x12 mm 16 Nos 123.00 9.2 --- ---54 Plate 180x450x8 mm 16 Nos 81.00 10.0 --- ---55 Bolt/Nut/Washer dia 10x40 mm 160 Nos 6.00 --- --- ---56 Bolt/Nut/Washer dia 16x80 mm 192 Nos 26.00 --- --- ---57 Plate 350x450x12 mm 4 Nos 60.00 3.2 6.4 6458 Plate 400x540x16 mm 4 Nos 108.00 3.8 F10 7.5 21059 Plate 270x500x12 mm 4 Nos 52.00 3.1 6.2 62

Long travel wheel bogie :60 Plate 520x1400x16 mm 4 Nos 366.00 7.7 --- ---61 Plate 520x1556x16 mm 4 Nos 407.00 8.3 --- ---62 Plate 500x562x16 mm 4 Nos 141.00 4.3 F8 4.5 8163 Plate 350x430x16 mm 6 Nos 113.00 4.1 F8 7.3 13164 Plate 325x606x16 mm 2 Nos 50.00 1.9 F8 3.0 5465 Plate 176x386x10 mm 6 Nos 32.00 3.4 13.5 13566 Plate 395x386x10 mm 6 Nos 72.00 4.7 9.5 9567 Plate 386x520x10 mm 2 Nos 31.00 1.8 2.8 2868 Plate 100x386x10 mm 4 Nos 12.00 0.4 0.1 169 Plate 75x370x10 mm 4 Nos 9.00 0.3 0.8 870 Plate 100x370x10 mm 12 Nos 35.00 1.2 13.7 13771 Plate 85x125x10 mm 24 Nos 20.00 5.0 10.1 10172 Plate 240x240x10 mm 16 Nos 72.00 7.7 15.4 15473 Plate 400x515x20 mm 4 Nos 129.00 3.7 F8 7.3 13174 Plate 314x350x20 mm 8 Nos 138.00 5.3 F8 5.6 10175 Plate 120x120x10 mm 8 Nos 9.00 2.0 3.9 3976 Plate 125x475x10 mm 8 Nos 37.00 4.8 11.6 11677 ISMC100 x 845 mm 2 Nos 16.00 0.4 1.5 1578 ISMC100 x 845 mm 3 Nos 23.00 0.6 1.0 1079 ISA 75x75x6 x 560 mm 4 Nos 15.00 0.6 0.6 680 Plate 230x440x10 mm 1 No 8.00 0.7 2.0 2081 Plate 130x360x10 mm 1 No 4.00 0.5 1.0 1082 Plate 230x270x10 mm 1 No 5.00 0.5 0.8 883 Keeper pl 60x200x12 mm 8 Nos 9.00 0.5 --- ---84 Pin dia 100x515 mm 4 Nos 127.00 --- --- ---

Long travel wheel / gear / pinion / shafts :85 LT wheel 500 mm dia 8 Nos 1600.00 --- --- ---86 Wheel pin dia 120 x 442 mm 8 Nos 314.00 --- --- ---87 Sleeve for pin 150/115 dia x 340 mm 8 No 156.00 --- --- ---88 Wheel retainer 16 Nos 32.00 --- --- ---89 Gear 320 PCD x 75 mm 2 Nos 90.00 --- --- ---90 Sleeve for gear 2 Nos 3.00 --- --- ---

Contd

206




Contd91 Gear shaft 75/60 dia x 440 mm 2 Nos 30.00 --- --- ---92 Gear retainer 4 Nos 6.00 --- --- ---93 Rim gear 400 PCD x 80 mm 4 Nos 280.00 --- --- ---94 Pinion 136 PCD x 80 mm 2 Nos 16.00 --- --- ---95 Pinion retainer 2 Nos 2.00 --- --- ---96 Keeper pl 60x190x12 mm 16 Nos 17.00 --- --- ---97 Plate 50x180x12 mm 16 Nos 14.00 0.8 --- ---98 Plate 40x130x10 mm 2 Nos 1.00 0.1 --- ---99 Plate 40x120x10 mm 2 Nos 1.00 0.1 --- ---100 Bolt/Nut/Washer dia 20x160 mm 48 Nos 22.00 --- --- ---101 Wheel bearing 16 Nos 80.00 --- --- ---102 Gear bearing 4 Nos 16.00 --- --- ---

Long travel drive assembly :103 Motor 5 hp 2 Nos 75.00 --- --- ---104 Solenoid operated brake 2 Nos 25.00 --- --- ---105 Worm reducer 2 Nos 500.00 --- --- ---

Trolley structure :106 ISMB 400 x 1990 mm 2 Nos 246.00 3.0 6.0 60107 ISMC 300 x 1990 mm 2 Nos 143.00 1.0 4.5 45108 ISMC 150 x 1980 mm 2 Nos 65.00 0.6 2.4 24109 ISMC 150 x 1685 mm 4 Nos 111.00 1.2 2.4 24110 ISMC 150 x 1230 mm 2 Nos 41.00 0.6 2.4 24111 ISMC 150 x 990 mm 2 Nos 32.00 0.6 2.4 24112 ISMC 250 x 1265 mm 2 Nos 77.00 0.8 2.8 28113 ISA 100x100x6 x 1265 mm 8 Nos 94.00 1.6 3.2 32114 Plate 430x590x10 mm 1 No. 20.00 1.0 1.2 12115 Plate 360x360x10 mm 1 No. 10.00 0.7 1.1 11116 Plate 300x500x12 mm 2 Nos 28.00 1.6 2.0 20117 Web plate 800x7800x10 mm 2 Nos 980.00 17.2 --- ---118 Flange pl 240x7800x20 mm 2 Nos 588.00 16.1 31.2 312119 Flange pl 240x6708x20 mm 2 Nos 506.00 13.9 26.9 269120 Plate 240x457x20 mm 4 Nos 69.00 2.8 4.6 46121 Plate 240x325x20 mm 4 Nos 49.00 2.3 3.6 36122 Plate 110x400x10 mm 24 Nos 83.00 12.3 29.8 298123 Plate 110x800x10 mm 12 Nos 83.00 10.9 24.5 245124 Plate 110x394x10 mm 10 Nos 14.00 2.0 4.9 49125 ISA 75x75x6 x 200 mm 4 Nos 6.00 0.6 1.4 14126 Web plate 400x3550x10 mm 4 Nos 446.00 15.8 --- ---127 Flange pl 70x3550x16 mm 4 Nos 125.00 14.5 28.4 284128 Flange pl 70x2778x16 mm 4 Nos 98.00 11.4 22.2 222129 Flange pl 70x295x16 mm 8 Nos 21.00 3.0 5.3 53130 Flange pl 70x370x16 mm 8 Nos 26.00 3.5 6.5 65131 Plate 100x160x16 mm 16 Nos 32.00 4.2 6.4 64132 Plate 300x160x16 mm 4 Nos 24.00 1.9 3.7 37133 End plate 200x320x16 mm 4 Nos 32.00 2.1 4.2 42134 Stiffener 220x400x8 mm 10 Nos 55.00 6.2 8.0 80

Contd

Weld length

207

in mlength in mGas cutting



Contd135 Stiffener 90x220x10 mm 4 Nos 6.00 1.3 3.2 32136 Plate 280x280x20 mm 4 Nos 49.00 2.3 3.4 34137 Plate 230x380x8 mm 2 Nos 11.00 1.2 2.4 24138 ISA 100x100x6 x 770 mm 4 Nos 28.00 0.8 1.6 16139 ISA 100x100x6 x 425 mm 4 Nos 16.00 0.8 1.6 16140 ISA 100x100x6 x 440 mm 4 Nos 16.00 0.8 1.6 16141 ISA 100x100x8 x 800 mm 2 Nos 19.00 0.4 3.5 35142 Plate 85x90x8 mm 4 Nos 2.00 0.7 2.1 21143 ISA 75x75x6 x 475 mm 2 Nos 7.00 0.3 0.6 6144 ISMC 150 x 440 mm 2 Nos 15.00 0.6 1.2 12145 Plate 200x250x10 mm 1 No. 4.00 0.5 0.6 6

End gear box base frame :146 ISMC 300 x 1750 mm 2 Nos 126.00 1.0 4.8 48147 ISMC 300 x 1425 mm 2 Nos 103.00 1.0 --- ---148 ISMC 300 x 1020 mm 2 Nos 74.00 1.0 4.8 48149 ISMC 300 x 1072 mm 2 Nos 77.00 1.0 4.8 48150 ISMC 300 x 830 mm 2 Nos 60.00 1.0 4.8 48151 ISMC 300 x 345 mm 2 Nos 25.00 1.0 4.8 48152 Plate 110x1750x12 mm 2 Nos 36.00 3.7 1.8 18153 Plate 110x730x12 mm 2 Nos 15.00 1.7 0.8 8154 Plate 60x1020x12 mm 2 Nos 12.00 0.2 1.4 14155 Plate 305x500x20 mm 3 Nos 72.00 2.4 2.7 27156 Plate 110x325x10 mm 4 Nos 11.00 1.8 2.5 25157 Plate 180x285x10 mm 12 Nos 48.00 5.6 13.3 133158 Plate 130x285x10 mm 6 Nos 18.00 2.5 6.1 61159 Plate 70x160x10 mm 8 Nos 7.00 1.9 3.7 37160 Plate 70x120x10 mm 4 Nos 3.00 0.8 1.5 15161 Plate 100x350x10 mm 2 Nos 6.00 0.9 0.8 8162 Plate 110x1750x20 mm 2 Nos 61.00 3.7 F10 7.0 196163 Plate 110x1020x20 mm 2 Nos 35.00 2.3 F10 4.1 115164 Plate 110x830x20 mm 2 Nos 29.00 1.9 F10 3.3 92

Cross travel assembly :165 Cross travel wheels 450 mm dia 4 Nos 320.00 --- --- ---166 CT wheel gear 498 PCD x 80 mm 2 Nos 150.00 --- --- ---167 Pinion and shaft dia 60 x 535 mm 2 Nos 30.00 --- --- ---168 Driving wheel shaft 435 mm long 2 Nos 48.00 --- --- ---169 Floating shaft 60 dia x 2536 mm 2 Nos 116.00 --- --- ---170 Bearing journals 8 Nos 344.00 --- --- ---171 Idle wheel shaft 270 long mm 2 Nos 32.00 --- --- ---172 Wheel gear shaft 485 mm long 2 Nos 30.00 --- --- ---173 Outer retainer dia 220/92x6 mm 8 Nos 16.00 --- --- ---174 Inner retainer dia 220/117x6 mm 8 Nos 12.00 --- --- ---175 Pillow block with bronze bush 4 Nos 60.00 --- --- ---176 Collars dia 115x32 mm 2 Nos 5.00 --- --- ---177 Flexible coupling 2 Nos 25.00 --- --- ---178 Flanged coupling 2 Nos 30.00 --- --- ---

Contd

Gas cutting Weld length

208

in mlength in m



Contd179 Flanged coupling 2 Nos 70.00 --- --- ---

Drum and gear assembly :180 Rope drum 600 PCD x 1095 mm 2 Nos 1320.00 --- --- ---181 Drum hub bush 2 Nos 10.00 --- --- ---182 Drum gear 876 PCD x 1351 mm 2 Nos 330.00 --- --- ---183 Second gear 570 PCD x 60 mm 2 Nos 160.00 --- --- ---184 Bearing bush 2 Nos 4.00 --- --- ---185 Pinion 1st reduction 216 PCD 2 Nos 64.00 --- --- ---186 Pinion 2nd reduction 190 PCD 2 Nos 26.00 --- --- ---187 Drum shaft 2 Nos 146.00 --- --- ---188 Pinion shaft 2 Nos 76.00 --- --- ---189 Third shaft 2 Nos 48.00 --- --- ---190 Plummer blocks 8 Nos 120.00 --- ---191 Flexible coupling 2 Nos 25.00 --- --- ---192 Drum spacers 4 Nos 28.00 --- --- ---193 Clamp 100x150x25 mm 4 Nos 12.00 0.4 --- ---194 Bolt / Nut dia 20 x 100 mm 12 Nos 3.00 --- --- ---195 Bolt / Nut dia 20 x 80 mm 8 Nos 2.00 --- --- ---198 Keys ( various size ) 8 Nos 3.00 --- --- ---199 Keeper pl 50x295x12 mm 4 Nos 6.00 0.2 --- ---

Sheave assembly :200 Plate 760x1680x12 mm 2 Nos 200.00 6.0 --- ---201 Plate dia 300 x 8 mm 4 Nos 18.00 3.8 3.8 38202 Plate 50x210x10 mm 1 No. 1.00 --- --- ---203 ISA 75x75x6 x 75 mm 2 Nos 1.00 0.3 0.6 6204 Plate 232/126x 950x3 mm 2 Nos 10.00 2.0 2.0 8205 Main sheave 500 mm dia 2 Nos 200.00 --- --- ---206 Balancing sheave 320 mm dia 1 No. 75.00 --- --- ---207 Sheave bearing bush 6 Nos 50.00 --- --- ---208 Main sheave pin 2 Nos 57.00 --- --- ---209 Balancing sheave pin 1 No. 26.00 --- --- ---210 Hook cross piece 1 No. 10.00 --- --- ---211 Shanh hook 1 No. 100.00 --- --- ---212 Hook nut 1 No. 17.00 --- --- ---213 Hook lock pl 1 No. 20.00 --- --- ---214 Keeper plates 8 Nos 5.00 0.4 --- ---215 Plate 230x230x8 mm 2 Nos 7.00 1.8 1.8 18216 Thruster bearing for hook 1 No. 5.00 --- --- ---217 Wire rope 28 mm dia 6/37 con 150 m 406.00 --- --- ---

Trolley drive :218 Motor 3 hp for cross travel drive 1 No. 25.00 --- --- ---219 Motor 17.5 hp for load 1 No. 75.00 --- --- ---220 Worm reducer 2 Nos 800.00 --- --- ---221 Thruster brake 1 No. 25.00 --- --- ---222 Solenoid operated brake 1 No. 25.00 --- --- ---223 Brake for CT 1 No. 25.00 --- --- ---

Contd

209


in mGas cutting



ContdPlatform / Ladder :

224 Chequered pl 6 mm th 16 sqm 800.00 18.0 2.0 14225 ISA 60x60x6 mm Hand railing 12 Rm 64.00 1.5 2.5 25226 Pipe 32 mm dia for railing/ ladder 50 Rm 150.00 --- --- ---227 Angles for cabin / ladder / covers etc 200.00 1.0 2.0 20228 Plates for cabin / covers 270.00 17.5 12.6 57

30856.00 760.6 1260.0 16561kg Rm Rm Nos


Angle / Channel / Beam / Bars : 1700.00 kgPlates / Flats : 19219.00 kgChequered plate for platform covering : 800.00 kg

2. Cast steel components : IS : 1030Rope drums : 1320.00 kgGears : 1016.00 kgWheels with retainers : 1980.00 kgPinions : 149.00 kgPulley / sheave : 275.00 kgPlummer blocks / Bearing journals : 508.00 kgCouplings / Sleeves : 309.00 kg

3. Alloy steel components : IS : 1570Pins : 524.00 kgShafts : 556.00 kg

4. Forged steel components : IS : 2004Hook : 127.00 kg

5. Alluminium / Bronze alloy components : IS : 305Bearings / Bushes : 181.00 kg

6. Wire rope : IS : 226628 mm dia 6/37 construction : 150 Rm


8. Other components :Electric motor 3 hp : 1 No.Electric motor 5 hp : 2 Nos.Electric motor 17.5 hp : 1 No.Worm reducer : 4 NosBrakes 4 Nos : 4 NosPipe 32 mm dia for railing / ladder : 50 Rm


210

Gas cutting in m

Weld lengthlength in m



Item: Rail track for Spillway gantry crane : Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of 200 metre length rail track for moving gantry crane provided for Kodasalli dam spillway under Kali Stage-II Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard weiding tables.


1 Track rail 45 kg / m 2 x 200 m 18000.00 --- --- ---2 Anchor rod dia 16 x 430 mm 1068 Nos. 726.00 17.0 F5 53.6 3753 Cleat ISA 65x65x6 x 260 mm 534 Nos. 805.00 69.5 --- ---4 Packing plate 50x50x10 mm 1068 Nos 210.00 53.4 F5 53.4 3745 Clamp 50x90x8 mm 1068 Nos 302.00 53.4 F5 53.4 3746 Bolt 60 mm / Nut / Washer 16 dia 1068 240.00 --- --- ---7 Plate 180x1200x12 mm 20 Nos 407.00 27.6 48.0 4808 Buffers 150x190x36 mm 4 Nos 32.00 1.4 F16 1.5 107

Total : 20722.00 222.3 209.9 1710.00kg Rm Rm Nos




3. Other components :Rails 45 kg / m : 18000.00 kg



Item: Embedded parts without groove lining for river / canal sluice service gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on emedded parts ( with out groove liner ) fabrication drawings for river sluice service gate provided for Tunga dam under Upper Tunga Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard weiding tables.

in m

211

Gas cutting Weld lengthlength in m



First stage anchors :1 Anchor plate 100x210x10 mm 28 Nos 46.00 8.7 5.6 562 Anchor bar 12 dia x 350 mm 56 Nos 18.00 0.7 1.0 103 Anchor plate 100x180x10 mm 24 Nos 34.00 6.7 4.8 484 Anchor bar 12 dia x 350 mm 48 Nos 15.00 0.6 1.8 185 Anchor plate 80x515x8 mm 10 Nos 26.00 6.0 3.6 366 Anchor bar 12 dia x 350 mm 20 Nos 6.00 0.3 0.8 87 Anchor plate 80x150x10 mm 20 Nos 19.00 1.6 --- ---8 Anchor bar 12 dia x 350 mm 40 Nos 13.00 0.5 1.5 159 Anchor plate 80x150x10 mm 24 Nos 23.00 1.9 --- ---

10 Anchor bar 12 dia x 350 mm 48 Nos 15.00 0.6 1.8 1811 Anchor plate 100x210x10 mm 20 Nos 33.00 2.0 --- ---12 Anchor bar 12 dia x 350 mm 40 Nos 13.00 0.5 1.5 15

Embedded parts :13 Anchor bolt 16 dia x 285 mm 48 Nos 22.00 0.8 F8 2.4 4314 Anchor bolt 16 dia x 200 mm 8 Nos 2.00 0.1 F8 0.4 715 Anchor bolt 16 dia x 185 mm 20 Nos 6.00 0.3 F8 1.0 1816 Anchor bolt 16 dia x 500 mm 24 Nos 18.00 0.4 F8 1.2 2217 Alignment plate 100x210x10 mm 28 Nos 46.00 2.8 --- ---18 Alignment plate 100x180x10 mm 24 Nos 34.00 2.4 --- ---19 Alignment plate 80x515x8 mm 10 Nos 26.00 0.8 --- ---20 Split anchor plate 60x400x6 mm 20 Nos 23.00 10.4 3.6 3621 Nut / Washer for anchor bolts 200 Nos 10.00 --- --- ---22 SS track 115x6750x10 mm 2 Nos 122.00 13.7 27.5 27523 Track base 130x7100x12 mm 2 Nos 174.00 14.5 28.4 28424 Track base ISMB 200x7100 mm 2 Nos 360.00 0.6 --- ---25 Sill beam ISMB 200x2300 mm 1 No. 58.00 0.3 --- ---26 SS seal seat 115x2300x6 mm 1 No. 12.00 2.4 F4 4.6 2127 SS seal seat 80x3035x5 mm 2 Nos. 19.00 6.3 F4 12.2 5528 Seal base ISA100x100x8 x3020 mm 2 No 73.00 0.4 --- ---29 SS seal seat 1680x1985x5 mm 1 No. 131.00 3.7 F4 7.4 3330 SS seal seat 1680x1975xx5 mm 1 No. 130.00 3.7 F4 7.3 3331 Seal base 1700x2000x20 mm 2 Nos 1068.00 7.4 --- ---32 Guide 120x2200x20 mm 2 Nos 82.00 4.7 --- ---33 Guide 120x2400x20 mm 4 Nos 180.00 10.1 --- ---34 Stiffener 130x1700x20 mm 1 No. 35.00 2.0 3.4 3435 Stiffener 120x390x8 mm 8 Nos 24.00 4.1 10.1 10136 Stiffener 130x1700x10 mm 3 Nos 52.00 5.5 10.2 10237 Stiffener 120x1960x10 mm 10 Nos 184.00 20.8 44.0 44038 Cleat ISA75x75x8 x 80 mm 24 Nos 17.00 3.6 4.8 4839 Spacer pipe/ washer 20 dia x 20 mm 1.00 --- --- ---40 Bolt / Nut / Washer 16 dia x 60 mm 8 No 2.00 --- --- ---

Total : 3172.00 151.9 190.9 1776.0kg Rm Rm Nos


Angle / Channel / Beam / Bars : 588.00 kg


212

length in m in m


Plates / Flats : 2109.00 kg 2. Alloy steel components : IS : 1570

Stainless steel plates : 414.00 kg 3. Bolt / Nut / Washer : IS : 1363

MS Bolt / Nut / Washer : 61.00 kg 4. Other details :

Length of cutting : 152.00 RmLength of welding : 191 RmNumber of electrodes ( for structural steel ) : 1359 NosNumber of electrodes ( for stainless steel ) : 417 Nos


Item: Embedded parts with groove lining for river / canal sluice service gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on emedded parts ( with groove liner ) fabrication drawings for river sluice service gate provided for Kodasalli dam under Kali Stage- II Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


First stage anchors :1 Plate 80x210x10 mm 162 Nos 214.00 13.0 --- ---2 Anchor bar 12 dia x 350 mm 324 Nos 100.00 3.9 12.2 1223 Plate 80x80x10 mm 82 Nos 41.00 6.6 --- ---4 Anchor bar 12 dia x 350 mm 82 Nos 25.00 1.0 3.1 31

Embedded parts :5 SS seal seat 100x2800x6 mm 1 No. 13.00 0.1 F4 5.8 266 Liner plate 666x3550x20 mm 1 No. 371.00 4.2 --- ---7 Stiffener 220x3520x10 mm 1 Nos 61.00 3.8 7.0 708 Stiffener 120x3520x10 mm 1 Nos 33.00 3.7 7.0 709 Stiffener 155x420x8 mm 3 Nos 12.00 1.7 4.4 44

10 Cleat ISA 75x75x8 x 80 mm 44 Nos 31.00 6.6 8.3 8311 SS B/W seat 1300x2720x6 mm 1 No. 167.00 4.0 F4 8.0 3612 SS B/W seat 1976x2720x6 mm 1 No. 253.00 4.7 F4 9.4 4213 Base plate 2000x2750x20 mm 1 No. 864.00 4.8 DV 2.8 8714 base plate 2000x3640x20 mm 1 No. 1143.00 5.7 --- ---15 Bottom liner Gr 484x2600x20 mm 1 No. 198.00 3.1 5.2 5216 Stiffener 180x1898x10 mm 7 Nos 188.00 14.5 26.6 26617 Stiffener 180x1960x10 mm 7 Nos 194.00 15.0 27.4 27418 Stiffener 100x2570x10 mm 1 No. 20.00 0.1 5.2 5219 Stiffener 100x410x10 mm 30 Nos 97.00 3.0 36.6 36620 SS track plate 150x3000x20 mm 2 Nos 141.00 6.3 12.3 12321 Track base pl 200x3000x40 mm 2 Nos 377.00 6.4 DV 0.4 5622 Web plate 320x3000x20 mm 2 Nos 301.00 6.7 12.7 127

Contd

in mlength in m

213




Contd23 Track ISMB 150 x 4200 mm 8 Nos 504.00 2.4 DV 2.4 3624 Anchor plate 80x200x10 mm 66 Nos 83.00 5.3 10.5 10525 Anchor plate 80x200x12 mm 80 Nos 121.00 6.4 F8 12.8 23026 Guide 110x2050x16 mm 20 Nos 566.00 43.2 DV 2.2 3627 Anchor bolt 16 dia x 300 mm 12 Nos 6.00 0.2 0.6 628 Anchor bolt 16 dia x 185 mm 180 Nos 53.00 2.9 9.0 9029 Anchor bolt 16 dia x 135 mm 112 Nos 24.00 0.4 5.6 5630 Anchor bolt 16 dia x 380 mm 32 Nos 20.00 0.5 1.6 1631 Nut / Washer for 16 dia bolt 672 Nos 29.00 --- --- ---32 Cover plate 270x290x10 mm 4 Nos 25.00 2.3 --- ---33 Back strip 40x2610x6 mm 2 Nos 10.00 0.1 5.2 5234 Split anchor 80x400x8 mm 25 Nos 50.00 4.0 5.5 5535 Bolt/Nut/Washer 25 diax65 mm 24 Nos 7.00 --- --- ---36 Track base pl 220x4767x40 mm 2 Nos 659.00 10.0 --- ---37 Track web pl 320x4767x20 mm 2 Nos 479.00 10.2 DV 19.0 58938 SS track plate 170x4150x20 mm 2 Nos 222.00 8.7 17.3 17339 Side plate 210x3917x20 mm 2 Nos 258.00 8.3 15.7 15740 Side plate 115x3029x20 mm 2 Nos 109.00 6.3 12.1 12141 Stiffener 260x295x8 mm 8 Nos 39.00 4.5 8.9 8942 Stiffener 210x260x8 mm 4 Nos 14.00 1.9 3.8 3843 Stiffener 210x260x10 mm 2 Nos 9.00 1.5 F8 2.6 4744 Anchor plate 80x200x10 mm 16 Nos 20.00 1.3 2.6 2645 Groove lining 560x3915x20 mm 2 Nos 688.00 9.0 17.9 17946 Guide 40x3878x16 mm 2 Nos 39.00 0.1 15.5 15547 Stiffener 100x3915x10 mm 2 Nos 61.00 0.2 16.0 16048 Stiffener 100x3841x10 mm 2 Nos 60.00 0.2 15.8 15849 Stiffener 120x3878x10 mm 2 Nos 73.00 8.0 15.5 15550 Stiffener 110x265x8 mm 16 Nos 29.00 6.0 12.0 12051 Cleat ISA 75x75x6 x 80 mm 28 Nos 15.00 4.0 7.5 7552 SS seal seat 100x3052x6 mm 2 Nos 29.00 0.2 F4 12.6 5753 Liner plate 570x3029x20 mm 2 Nos 542.00 7.2 SV 1.2 6054 Stiffener 120x3024x10 mm 2 Nos 57.00 6.3 12.5 12555 Stiffener 330x220x10 mm 6 Nos 34.00 3.3 7.9 7956 Stiffener 460x820x10 mm 3 Nos 89.00 3.9 7.3 7357 Stiffener 80x975x10 mm 8 Nos 49.00 0.7 16.9 16958 Stiffener 80x988x10 mm 4 Nos 25.00 0.3 8.8 8859 B/W liner 800x2780x20 mm 1 No. 349.00 3.6 7.2 7260 B/W liner 484x2780x20 mm 1 No. 211.00 3.3 6.5 6561 Stiffener 100x2740x10 mm 1 No. 43.00 0.2 5.5 5562 Stiffener 100x1245x10 mm 2 Nos 10.00 0.1 5.8 5863 Anchor bolt 16 dia x 185 mm 32 Nos 9.00 0.5 1.6 1664 Anchor bolt 16 dia x 355 mm 28 Nos 16.00 0.5 1.4 1465 Anchor bolt 16 dia x 450 mm 12 Nos 9.00 0.2 0.6 666 Nut / Washer for 16 dia bolt 144 Nos 7.00 --- --- ---67 Back strip 40x3027x8 mm 6 Nos 46.00 0.3 18.2 182

Contd

Gas cutting length in m

Weld length

214

in m



Contd68 Cleat ISA 75x75x6 x 80 mm 12 Nos 6.00 1.8 1.9 1969 Stiffener 110x195x10 mm 6 Nos 10.00 1.8 3.7 37

Total : 10657.00 301.0 551.6 6026kg Rm Rm Nos


Angle / Channel / Beam / Bars : 681.00 kgPlates / Flats : 8971.00 kg

2. Alloy steel components : IS : 1570Stainless steel plates : 825.00 kg

3. Bolt / Nut / Washer : IS : 1363MS Bolt / Nut / Washer : 180.00 kg

4. Other details :Length of cutting : 301.00 RmLength of welding : 552 RmNumber of electrodes ( for structural steel ) : 5569 NosNumber of electrodes ( for stainless steel ) : 457 Nos


Item: Vent lining for river / canal sluice vents.Details of materials / Gas cutting / Welding for rate analysis :( For 38.50 sqm finished lining area )

Note : 1. Data based on groove / vent lining fabrication drawings for 2 m x 3 m size river sluice vents for Kodasalli dam under Kali Stage- II Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


1 Liner plate 454x2610x20 mm 1 No. 186.00 3.1 5.2 522 Liner plate 429x2610x20 mm 1 No. 176.00 3.1 5.2 523 Stiffener 110x2580x10 mm 4 Nos 89.00 10.8 20.6 2064 Stiffener 139x294x8 mm 3 Nos 8.00 1.3 3.4 345 Stiffener 139x299x8 mm 3 Nos 8.00 1.3 3.5 356 Side plate 225x3062x20 mm 2 Nos 216.00 6.6 12.3 1237 Liner plate 250x3064x20 mm 2 Nos 240.00 6.7 25.0 2508 Stiffener 70x80x8 mm 48 Nos 17.00 3.9 14.4 1449 Side liner 230x1020x20 mm 8 Nos 295.00 10.0 20.0 200

10 Plate 230x1018x20 mm 4 Nos 147.00 5.0 10.0 10011 Side lining D/S 2525x3358x20 mm 2 Nos 2662.00 11.8 33.6 33612 Top/bottom liner 2547x2580x20 mm 2 No. 2063.00 10.3 10.3 103

Contd


length in m in m

in m

215

Weld length

length in m

Gas cutting



Contd13 Stiffener 120x2780x10 mm 12 Nos 314.00 34.8 66.7 66714 Stiffener 120x3066x10 mm 12 Nos 347.00 38.3 73.6 73615 Stiffener 160x455x8 mm 60 Nos 274.00 36.9 93.0 93016 Split anchor 80x400x8 mm 119 Nos 239.00 19.0 22.6 226

Total : 7281.00 202.9 419.4 4194.0kg Rm Rm Nos


Plates / Flats : 7281.00 kg 2. Other details :

Length of cutting : 203 RmLength of welding : 420 RmNumber of electrodes ( for structural steel ) : 4194 Nos


Item: River / canal sluice service gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of river sluice service gate for 2 m x 3 m sluice opening of Kodasalli dam under Kali Stage- II Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


Gate leaf :1 Skin plate 3220x3372x18 mm 1 No. 1534.00 6.6 --- ---2 Ver stiffener 140x688x10 mm 28 Nos 212.00 23.2 54.2 5423 Web plate 350x688x10 mm 6 Nos 114.00 6.2 16.7 1674 Web plate 350x688x10 mm 2 Nos 38.00 2.0 5.8 585 Girder web 350x2788x12 mm 4 Nos 368.00 12.5 50.2 5026 Girder web 390x2788x12 mm 1 No 102.00 3.2 7.1 717 Flange plate 320x2788x20 mm 4 Nos 560.00 12.5 SV 2.6 1308 Flange plate 250x2788x20 mm 1 No. 109.00 3.0 SV 3.3 1659 End plate 370x3251x12 mm 4 Nos 453.00 14.5 26.0 260

10 Flange plate 150x380x12 mm 6 Nos 32.00 3.2 6.4 6411 Flange plate 150x152x12 mm 2 Nos 4.00 0.6 1.2 1212 Flange plate 80x380x18 mm 6 Nos 26.00 0.5 SV 3.2 10013 Flange plate 80x152x18 mm 2 Nos 4.00 0.2 SV 1.0 3114 End ver plate 80x3170x18 mm 2 Nos 72.00 0.2 SV 6.4 19915 Diaphragm plate 188x360x12 mm 10 Nos 64.00 5.5 18.2 18216 End stiffener 50x352x12 mm 24 Nos 40.00 1.2 21.7 217

Contd

216


length in m in mGas cutting Weld length

length in m in m



Contd17 Pad plate 250x300x16 mm 8 Nos 75.00 4.4 8.8 8818 Stiffener 80x130x10 mm 8 Nos 7.00 0.7 3.4 3419 Support plate 20x2540x16 mm 1 No. 6.00 2.6 5.1 5120 Seal support 65x2905x12 mm 2 Nos 36.00 5.9 --- ---21 Support plate 20x3105x12 mm 2 Nos. 12.00 6.3 12.5 12522 Sealing frame 65x2795x12 mm 1 No. 17.00 2.8 --- ---23 Sealing frame 20x2755x12 mm 1 No. 5.00 2.8 5.5 5524 Seal support 65x1965x12 mm 1 No. 12.00 2.0 --- ---25 Seal support 65x375x12 mm 2 Nos 5.00 0.9 --- ---26 Stopper 20x2540x12 mm 1 No. 5.00 2.5 5.1 5127 Plate 50x70x12 mm 2 Nos 1.00 0.1 0.2 228 Bracket plate 400x570x16 mm 4 Nos 115.00 3.9 3.2 3229 Bracket plate 180x785x6 mm 2 Nos 13.00 2.0 1.0 1030 Stiffener 172x350x12 mm 4 Nos 23.00 2.0 5.5 5531 Stiffener 56x250x12 mm 4 Nos 5.00 1.2 4.4 4432 Counter weight ( CI blocks ) 4000.00 --- --- ---33 GI Bolt/Nut/Washer 24 diax280 mm 60 No 72.00 --- --- ---34 Plates for guide roller 4 sets 72.00 1.4 1.8 1835 Guide roller 4 Nos 8.00 --- --- ---

Wheel assembly :36 Wheels 484.00 --- --- ---37 Bearings 76.00 --- --- ---38 Bearing retainer plate 80.00 --- --- ---39 Cover plate 8.00 --- --- ---40 Spacer plates 16.00 --- --- ---41 Stainless steel pin 132.00 --- --- ---42 Keeper plate 8.00 0.1 --- ---43 GI Bolt / Nut / Screw / Washer 2.00 --- --- ---44 MS Bolt / Nut / Screw / Washer 4.00 --- --- ---

Seal assembly :45 Flat bottom seal 2755 mm 1 No. --- --- --- ---46 Music note side seal 2855 mm 2 Nos --- --- --- ---47 Double flange top seal 2199 mm 1 No. --- --- --- ---48 Corner seal 2 Nos --- --- --- ---49 Seal clamp 90x2545x20 mm 1 No. 36.00 0.1 --- ---50 Seal clamp 45x1495x20 mm 2 Nos 21.00 0.1 --- ---51 Seal clamp 45x1628x20 mm 2 Nos 23.00 0.1 --- ---52 Seal clamp 45x2545x20 mm 1 No. 18.00 --- --- ---53 Seal clamp 45x2660x20 mm 1 No. 19.00 0.1 --- ---54 SS Bolt / Nut / Washer 20 dia x 80 mm 10.00 --- --- ---55 SS Bolt / Nut / Washer 20 dia x 100 mm 44.00 --- --- ---

Total : 9202.00 137.1 280.5 3265kg Rm Rm Nos


Plates / Flats : 4370.00 kg

217



2. Cast steel components : IS : 1030Wheels / Guide roller : 492.00 kg


4. Alloy steel components : IS : 1570Wheel axle / lifting pin : 132.00 kg

5. Rubber seals : IS : 11855Bottom rubber seal ( uncladed ) : 2.76 RmSide rubber seal ( teflon claded ) : 5.71 RmTop rubber seal ( teflon claded ) : 2.20 RmCorner seal : 2 Nos

6. Bolt / Nut / Washer IS : 1363SS Bolt / Nut / Washer / Screws : 54.00 kgGI Bolt / Nut / Washer / Screws : 74.00 kgMS Bolt / Nut / Washer : 4.00 kg

7. Other components :CI counter weight : 4000.00 kg



Item: Rope drum hoist for river / canal sluice service gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of 25 t rope drum hoist provided for operating river sluice service gate of Kodasalli dam under Kali Stage- II Project in Karnataka. 2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


Hoist frame :1 ISMC 400 x 3900 mm 4 Nos 782.00 2.4 --- ---2 ISMC 250 x 935 mm 3 Nos 80.00 1.2 --- ---3 ISMC 250 x 1236 mm 2 Nos 76.00 0.8 --- ---4 ISMC 200 x 1330 mm 8 Nos 237.00 2.8 --- ---5 ISMC 200 x 440 mm 2 Nos 20.00 0.7 --- ---6 ISMC 150 x 1330 mm 6 Nos 134.00 1.8 --- ---7 Bracket plate 300x560x16 mm 4 Nos 84.00 2.4 F8 4.8 868 Stiffener 95x160x10 mm 8 Nos 10.00 2.0 4.1 419 Stiffener 85x378x10 mm 24 Nos 61.00 11.1 26.3 263

10 Base plate 145x370x30 mm 2 Nos 25.00 1.0 1.1 1111 Stiffener 120x399x10 mm 2 Nos 8.00 1.1 2.1 2112 Base plate 110x430x10 mm 2 Nos 8.00 1.0 1.2 12

Contd

218

length in m in mWeld lengthGas cutting



Contd13 ISMC 400 x 110 mm 2 Nos 14.00 1.2 0.5 514 Base plate 336x340x10 mm 1 No. 9.00 0.7 0.5 515 Base plate 160x390x10 mm 1 No. 5.00 0.6 0.5 516 Base plate 210x300x10 mm 1 No. 5.00 0.5 0.5 517 Cleat ISA 50x50x6 x 150 mm 36 Nos 22.00 3.6 18.0 18018 Cleat ISA 65x65x6 x 180 mm 20 Nos 21.00 2.6 12.4 12419 Cleat ISA 50x50x6 x 100 mm 24 Nos 11.00 2.4 9.6 9620 Cleat ISA 50x50x6 x 121 mm 2 Nos 1.00 0.2 0.9 921 Cleat ISA 50x50x6 x 116 mm 2 Nos 1.00 0.2 0.9 922 Base plate 200x250x20 mm 8 Nos 63.00 3.6 --- ---23 Bracket plate 300x500x12 mm 2 Nos 28.00 1.6 1.4 1424 Stiffener 260 dia x 12 mm 2 Nos 13.00 1.6 1.6 1625 Anchor bolt 20 dia x 350 mm 16 Nos 14.00 0.3 1.0 1026 Nut / Washer 20 dia 16 Nos 1.00 --- --- ---27 Anchor plate 60x60x12 mm 16 Nos 5.00 1.0 --- ---28 Bolt/Nut/Washer dia 22 x 85 mm 4 Nos 2.00 --- --- ---29 Bolt/Nut/Washer dia 10 x 65 mm 4 Nos 1.00 --- --- ---30 Bolt/Nut/Washer dia 14 x 65 mm 4 Nos 1.00 --- --- ---31 Bolt/Nut/Washer dia 16 x 65 mm 4 Nos 1.00 --- --- ---32 Bolt/Nut/Washer dia 24 x 110 mm 4 Nos 3.00 --- --- ---33 ISMC 150 x 935 mm 2 Nos 31.00 0.6 --- ---34 ISMC 200 x 935 mm 1 No. 21.00 0.4 --- ---35 Plate 80x2250x10 mm 2 Nos 28.00 0.2 9.3 9336 Chequered plate 6 mm th 6 sqm 283.00 6.0 --- ---

Plummer blocks :37 Plummer body 2 Nos 72.00 --- --- ---38 Bronze bush 2 Nos 13.00 --- --- ---39 Shims 2 Nos 2.00 --- --- ---40 Bolt/Nut/Washer 4 Nos 1.00 --- --- ---

Shafts :41 Drum shaft 110 dia x 1381 mm 2 Nos 206.00 --- --- ---42 1st pinion shaft 70 dia x 650 mm 1 No. 20.00 --- --- ---43 2nd pinion shaft 120 dia x 1350 mm 1 No. 120.00 --- --- ---

Drum assembly :44 Drum 560 PCD 2 Nos 1420.00 --- --- ---45 Bronze bush 140/110 diax140 mm 2 Nos 12.00 --- --- ---46 Bronze bush 140/110 diax100 mm 2 Nos 10.00 --- --- ---47 Spacers 240/112 x 10 mm 2 Nos 6.00 --- --- ---48 Spacers 240/112 x 6 mm 2 Nos 4.00 --- --- ---49 Clamping plate 100x150x32 mm 4 Nos 16.00 0.4 --- ---50 Lock plate 50x210x12 mm 4 Nos 4.00 0.2 --- ---51 Bolt/Nut/Washer 12 Nos 5.00 --- --- ---

Gears and pinions :52 Drum gear 980 PCD 2 Nos 350.00 --- --- ---53 Gear 800 PCD 1 No. 156.00 --- --- ---

Contd

219




Contd54 1st reduction pinion 1 No. 19.00 --- --- ---55 2nd reduction pinion 2 No. 60.00 --- --- ---

Pulleys and sheaves :56 Pulley 672 PCD 2 Nos 180.00 --- --- ---57 Pin 120 dia x 262 mm 2 Nos 46.00 --- --- ---58 Bronze bush 145/120 dia x 160 mm 2 14.00 --- --- ---59 Spacer 170/123 dia 2.00 --- --- ---60 Lock plate 50x190x12 mm 4 Nos 4.00 0.2 --- ---61 Pulley 350 PCD 1 No. 76.00 --- --- ---62 Pin 130 dia x 258 mm 1 No. 27.00 --- --- ---63 Bronze bush 1 No. 8.00 --- --- ---64 Brass Washer 180/132x8 mm 2 Nos 2.00 --- --- ---65 Keeper plate 50x190x12 mm 2 Nos 2.00 0.1 --- ---

Hoist drive :66 Electric motor 5 hp 1 No. 50.00 --- --- ---67 Worm reducer 1 No. 500.00 --- --- ---68 Flexible coupling 2 Nos 50.00 --- --- ---69 Wire rope 28 dia 6x37 constn 120 m 500.00 --- --- ---70 Manual operation assembly 1 No. 120.00 --- --- ---71 Position indicator 1 No. 32.00 --- --- ---72 EM brake 1 No. 25.00 --- --- ---

Total : 6243.00 56.5 96.7 1005.0kg Rm Rm Nos


Angle / Channel / Beam / Bars : 1451.00 kgPlates / Flats : 392.00 kgChequered plate for platform covering : 283.00 kg

2. Cast steel components : IS : 1030Rope drums 2 Nos : 1420.00 kgGears 3 Nos : 506.00 kgPinions : 79.00 kgPulleys 3 Nos / Couplings 2 Nos : 306.00 kgPlummer blocks : 72.00 kg

3. Alloy steel components : IS : 1570Shafts : 346.00 kgPins : 73.00 kg


5. Wire rope : IS : 226628 mm dia 6/37 construction rope : 120 Rm

6. Bolts / Nuts / Washers : IS : 1363Bolts / Nuts / Washers ( various size ) : 31.00 kg

7. Other components :Electric motor 5 hp Standard : 1 No.Worm reducer Standard : 1 No

220



Electro-megnatic brake Standard : 1 NoManual operation assembly : 1 No.Position indicator : 1 No.



Item: Embedded parts without groove lining for river / canal sluice emergency gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of emedded parts ( with out groove liner ) for river sluice emergency gate provoded for Tunga dam under Upper Tunga Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


First stage anchors :1 Anchor plate 100x210x10 mm 28 Nos 46.00 8.7 5.6 562 Anchor bar 12 dia x 350 mm 56 Nos 18.00 0.7 1.0 103 Anchor plate 100x180x10 mm 40 Nos 56.00 11.1 8.0 804 Anchor bar 12 dia x 350 mm 48 Nos 15.00 0.6 1.8 185 Anchor plate 80x515x8 mm 10 Nos 26.00 6.0 3.6 366 Anchor bar 12 dia x 350 mm 36 Nos 11.00 0.5 1.4 147 Anchor plate 80x150x10 mm 20 Nos 19.00 1.6 --- ---8 Anchor bar 12 dia x 350 mm 40 Nos 13.00 0.5 1.5 159 Anchor plate 80x150x10 mm 24 Nos 23.00 1.9 --- ---

10 Anchor bar 12 dia x 350 mm 48 Nos 15.00 0.6 1.8 1811 Anchor plate 100x210x10 mm 20 Nos 33.00 2.0 --- ---12 Anchor bar 12 dia x 350 mm 40 Nos 13.00 0.5 1.5 15

Embedded parts :13 Anchor bolt 16 dia x 285 mm 48 Nos 22.00 0.8 2.4 2414 Anchor bolt 16 dia x 200 mm 8 Nos 2.00 0.1 0.4 415 Anchor bolt 16 dia x 185 mm 36 Nos 11.00 0.5 1.8 1816 Anchor bolt 16 dia x 500 mm 24 Nos 18.00 0.4 1.2 1217 Alignment plate 100x210x10 mm 28 Nos 46.00 2.8 --- ---18 Alignment plate 100x180x10 mm 24 Nos 34.00 2.4 --- ---19 Alignment plate 80x515x8 mm 10 Nos 26.00 0.8 --- ---20 Split anchor plate 60x400x6 mm 20 Nos 23.00 10.4 3.6 3621 Nut / Washer for anchor bolts 200 Nos 10.00 --- --- ---22 SS track 115x6750x10 mm 2 Nos 122.00 13.7 27.5 27523 Track base 130x7100x12 mm 2 Nos 174.00 14.5 28.4 28424 Track base ISMB 200x7100 mm 2 Nos 360.00 0.6 --- ---25 Sill beam ISMB 200x2300 mm 1 No. 58.00 0.3 --- ---

Contd


221



Contd26 SS seal seat 115x2300x6 mm 1 No. 12.00 2.4 F4 4.6 3227 SS seal seat 80x3035x5 mm 2 Nos. 19.00 6.3 F4 12.2 8528 Seal base ISA100x100x8 x3020 mm 2 No 73.00 0.4 --- ---29 SS seal seat 1680x990x5 mm 1 No. 66.00 1.8 F4 5.4 3830 Seal base 1700x1000x20 mm 1 Nos 267.00 2.7 --- ---31 Guide 120x2200x20 mm 6 Nos 246.00 14.1 --- ---32 Guide 120x2400x20 mm 4 Nos 180.00 10.1 --- ---33 Stiffener 130x1700x20 mm 1 No. 35.00 2.0 3.4 3434 Stiffener 120x390x8 mm 8 Nos 24.00 4.1 10.1 10135 Stiffener 120x980x10 mm 5 Nos 46.00 5.2 11.0 11036 Cleat ISA75x75x8 x 80 mm 24 Nos 17.00 3.6 4.8 4837 Spacer pipe/ washer 20 dia x 20 mm 1.00 --- --- ---

Total : 2180.00 134.7 143.0 1363kg Rm Rm Nos





4. Other details :Length of cutting : 135 RmLength of welding : 143 RmNumber of electrodes ( for structural steel ) : 933 NosNumber of electrodes ( for stainless steel ) : 430 Nos


Item: Embedded parts with groove lining for river / canal sluice emergency gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on emedded parts ( with groove liner ) fabrication drawings for river sluice emergency gate provided for Kodasalli dam under Kali Stage- II Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


First stage anchors :1 Plate 80x210x10 mm 234 Nos 309.00 18.7 --- ---2 Anchor bar 12 dia x 350 mm 468 Nos 145.00 5.6 17.6 176

Contd

Gas cutting Weld lengthin m

Gas cutting length in m in m

length in m

Weld length

222



Contd3 Plate 80x80x10 mm 58 Nos 29.00 4.7 --- ---4 Anchor bar 12 dia x 350 mm 58 Nos 18.00 0.7 2.2 22

Embedded parts :5 SS seal seat 100x2800x6 mm 1 No. 13.00 0.1 F4 5.8 416 Liner plate 666x3550x20 mm 1 No. 371.00 4.2 --- ---7 Stiffener 220x3520x10 mm 1 Nos 61.00 3.8 7.0 708 Stiffener 120x3520x10 mm 1 Nos 33.00 3.7 7.0 709 Stiffener 155x420x8 mm 3 Nos 12.00 1.7 4.4 44

10 Cleat ISA 75x75x8 x 80 mm 20 Nos 14.00 3.0 3.8 3811 SS seal seat 180x2720x6 mm 1 No. 23.00 2.9 F4 5.8 4112 Liner plate 814x3640x20 mm 1 No. 465.00 4.5 --- ---13 Liner plate 484x2600x20 mm 1 No. 198.00 3.1 5.2 5214 Stiffener 120x814x12 mm 7 Nos 64.00 6.5 17.8 17815 SS track plate 150x3000x20 mm 2 Nos 141.00 6.3 F8 12.6 26516 Track base 200x3000x40 mm 2 Nos 377.00 6.4 --- ---17 Track web pl 320x3000x20 mm 2 Nos 301.00 6.6 24.0 24018 Anchor plate 80x200x10 mm 98 Nos 123.00 7.8 15.7 15719 Track ISMB 150 x 4200 mm 12 Nos 751.00 3.6 6.0 6020 Track ISMB 150 x 1200 mm 2 Nos 36.00 0.6 1.0 1021 Guide 110x2000x16 mm 30 Nos 829.00 63.3 126.6 126622 Guide anchor pl 80x200x12 mm 120 Nos 181.00 9.6 --- ---23 Anchor bolt 16 dia x 185 mm 436 Nos 127.00 7.0 21.9 21924 Anchor bolt 16 dia x 300 mm 12 Nos 6.00 0.2 0.6 625 Anchor bolt 16 dia x 380 mm 8 Nos 5.00 0.1 0.4 426 Nut / Washer for 16 dia bolts 912 Nos 38.00 --- --- ---27 Anchor plate 80x400x8 mm 7 Nos 14.00 0.6 1.6 1628 Stiffener 120x2600x10 mm 2 Nos 49.00 5.5 10.4 10429 Cover plate 270x290x10 mm 4 Nos 25.00 2.3 --- ---30 Back strip 40x2580x6 mm 2 Nos 10.00 0.1 2.0 2031 Bolt/Nut/Washer 20 diax65 mm 24 Nos 8.00 --- --- ---32 Track base pl 220x4767x40 mm 2 Nos 659.00 10.0 --- ---33 Track web pl 320x4767x20 mm 2 Nos 479.00 10.2 19.0 19034 SS track plate 170x4217x20 mm 2 Nos 225.00 8.8 F8 17.6 31735 Side plate 210x3917x20 mm 2 Nos 258.00 8.3 16.5 16536 Side plate 115x3026x20 mm 2 Nos 109.00 6.3 12.6 12637 Stiffener 260x295x8 mm 8 Nos 39.00 4.5 8.9 8938 Stiffener 210x260x8 mm 4 Nos 14.00 1.9 3.8 3839 Stiffener 210x260x10 mm 2 Nos 9.00 1.0 1.9 1940 Anchor plate 80x200x10 mm 16 Nos 20.00 1.3 2.6 2641 Groove lining 560x3915x20 mm 2 Nos 688.00 9.0 --- ---42 Guide 40x3878x16 mm 2 Nos 39.00 0.1 7.8 7843 Stiffener 100x3915x10 mm 2 Nos 61.00 0.2 16.0 16044 Stiffener 100x3841x10 mm 2 Nos 60.00 0.2 15.8 15845 Stiffener 120x3878x10 mm 2 Nos 73.00 8.0 16.0 16046 Stiffener 110x265x8 mm 16 Nos 29.00 6.0 12.0 12047 Cleat ISA 75x75x6 x 80 mm 40 Nos 22.00 6.0 8.0 80

Contd

223




Contd48 SS seal seat 100x3050x6 mm 2 Nos 29.00 0.2 F4 12.6 8849 Liner plate 570x3026x20 mm 2 Nos 542.00 7.2 --- ---50 Stiffener 120x3024x10 mm 2 Nos 57.00 6.3 12.1 12151 Stiffener 330x220x10 mm 6 Nos 34.00 4.5 6.6 6652 Stiffener 760x350x10 mm 3 Nos 69.00 4.0 8.2 8253 Stiffener 80x975x10 mm 8 Nos 49.00 0.7 15.6 15654 Stiffener 80x988x10 mm 4 Nos 25.00 0.3 7.9 7955 B/W liner 800x2780x20 mm 1 No. 349.00 3.6 5.5 15456 B/W liner 484x2780x20 mm 1 No. 211.00 3.3 5.6 15757 Stiffener 100x2740x10 mm 2 No. 43.00 0.2 11.0 11058 Stiffener 100x1245x10 mm 2 Nos 20.00 0.2 5.8 5859 Anchor bolt 16 dia x 185 mm 32 Nos 10.00 0.5 1.6 1660 Anchor bolt 16 dia x 355 mm 28 Nos 16.00 0.5 1.4 1461 Anchor bolt 16 dia x 450 mm 12 Nos 9.00 0.2 0.6 662 Nut / Washer for 16 dia bolt 144 Nos 7.00 --- --- ---63 Back strip 40x3027x6 mm 6 Nos 34.00 0.3 2.0 2064 Cleat ISA 75x75x6 x 80 mm 12 Nos 6.00 1.8 1.9 1965 Bolt/Nut/Washer 20 diax65 mm 28 Nos 8.00 --- --- ---66 Stiffener 110x195x10 mm 6 Nos 10.00 1.8 3.7 37

Total : 9088.00 300.6 560.0 6008.0kg Rm Rm Nos





4. Other details :Length of cutting : 301 RmLength of welding : 560 RmNumber of electrodes ( for structural steel ) : 5256 NosNumber of electrodes ( for stainless steel ) : 752 Nos


Item: River / canal sluice emergency gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of river sluice emergency gate for 2 m x 3 m river sluice opening of Kodasalli dam under Kali Stage- II Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.

224




Gate leaf :1 Skin plate 3220x3372x18 mm 1 No. 1534.00 6.6 --- ---2 Ver stiffener 140x688x10 mm 28 Nos 212.00 23.2 54.2 5423 Web plate 350x688x10 mm 6 Nos 114.00 6.2 16.7 1674 Web plate 350x688x10 mm 2 Nos 38.00 2.0 5.8 585 Girder web 350x2788x12 mm 4 Nos 368.00 12.5 50.2 5026 Girder web 390x2788x12 mm 1 No 102.00 3.2 7.1 717 Flange plate 320x2788x20 mm 4 Nos 560.00 12.5 SV 2.6 1308 Flange plate 250x2788x20 mm 1 No. 109.00 3.0 SV 3.3 1659 End plate 370x3251x12 mm 4 Nos 453.00 14.5 26.0 260

10 Flange plate 150x380x12 mm 6 Nos 32.00 3.2 6.4 6411 Flange plate 150x152x12 mm 2 Nos 4.00 0.6 1.2 1212 Flange plate 80x380x18 mm 6 Nos 26.00 0.5 SV 3.2 10013 Flange plate 80x152x18 mm 2 Nos 4.00 0.2 1.0 1014 End ver plate 80x3170x18 mm 2 Nos 72.00 0.2 6.4 6415 Diaphragm plate 188x360x12 mm 10 Nos 64.00 5.5 18.2 18216 End stiffener 50x352x12 mm 16 Nos 27.00 0.8 14.5 14517 Pad plate 250x300x16 mm 8 Nos 75.00 4.4 8.8 8818 Stiffener 80x130x10 mm 8 Nos 7.00 0.7 3.4 3419 Support plate 20x2540x16 mm 1 No. 6.00 2.6 5.1 5120 Seal support 65x2905x12 mm 2 Nos 36.00 5.9 --- ---21 Support plate 20x3105x12 mm 2 Nos. 12.00 6.3 12.5 12522 Sealing frame 65x2795x12 mm 1 No. 17.00 2.8 --- ---23 Sealing frame 20x2755x12 mm 1 No. 5.00 2.8 5.5 5524 Seal support 65x1965x12 mm 1 No. 12.00 2.0 --- ---25 Seal support 65x375x12 mm 2 Nos 5.00 0.9 --- ---26 Stopper 20x2540x12 mm 1 No. 5.00 2.6 5.1 5127 Plate 50x70x12 mm 2 Nos 1.00 0.1 0.3 328 Bracket plate 300x500x16 mm 4 Nos 75.00 3.2 2.4 2429 GI Bolt/Nut/Washer 24 diax280 mm 118 142.00 --- --- ---30 Stiffener 148x300x12 mm 4 Nos 17.00 1.8 4.9 4931 Stiffener 90x250x12 mm 4 Nos 8.00 1.4 4.7 4732 Counter weight ( CI blocks ) 4000.00 --- --- ---33 Pin 80 dia x 150 mm 2 Nos 12.00 --- --- ---34 Plates for guide roller 4 sets 72.00 1.4 1.8 1835 Guide roller 4 Nos 8.00 --- --- ---

Wheel assembly :36 Wheels 484.00 --- --- ---37 Bearings 76.00 --- --- ---38 Bearing retainer plate 80.00 --- --- ---39 Cover plate 8.00 --- --- ---40 Spacer plates 16.00 --- --- ---41 Stainless steel pin 132.00 --- --- ---42 Keeper plate 8.00 0.1 --- ---43 GI Bolt / Nut / Screw / Washer 2.00 --- --- ---44 MS Bolt / Nut / Screw / Washer 4.00 --- --- ---

Contd

225




ContdSeal assembly :

45 Flat bottom seal 2755 mm 1 No. --- --- --- ---46 Music note side seal 2855 mm 2 Nos --- --- --- ---47 Double flange top seal 2199 mm 1 No. --- --- --- ---48 Corner seal 2 Nos --- --- --- ---49 seal clamp 90x2545x20 mm 1 No. 36.00 0.1 --- ---50 Seal clamp 45x1495x20 mm 2 Nos 21.00 0.1 --- ---51 Seal clamp 45x1628x20 mm 2 Nos 23.00 0.1 --- ---52 Seal clamp 45x2545x20 mm 1 No. 18.00 --- --- ---53 Seal clamp 45x2660x20 mm 1 No. 19.00 0.1 --- ---54 SS Bolt / Nut / Washer 20 dia x 80 mm 10.00 --- --- ---55 SS Bolt / Nut / Washer 20 dia x 100 mm 44.00 --- --- ---

Total : 9215.00 134.1 271.3 3017.0kg Rm Rm Nos


Plates / Flats : 4301.00 kg 2. Cast steel components : IS : 1030

Wheels / Guide roller : 492.00 kg 3. Alluminium / Bronze alloy components : IS : 305

Bearings / Bushes : 76.00 kg 4. Alloy steel components : IS : 1570

Wheel axle / lifting pin : 144.00 kg 5 Rubber seals : IS : 11855

Bottom rubber seal ( uncladed ) : 2.76 RmSide rubber seal ( teflon claded ) : 5.71 RmTop rubber seal ( teflon claded ) : 2.20 RmCorner seal : 2 Nos

6. Bolt / Nut / Washer IS : 1363SS Bolt / Nut / Washer : 54.00 kgGI Bolt / Nut / Washer : 144.00 kgMS Bolt / Nut / Washer : 4.00 kg

7. Other components :CI counter weight : 4000.00 kg



Item: Lifting beam for river / canal sluice emergency gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of lifting beam for operating river sluice emergency gate provided for Kodasalli dam under Kali Stage- II Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.

226



3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


1 ISMC 300 x 3186 mm 2 Nos 228.00 1.2 3.8 382 Plate 250x450x20 mm 4 Nos 71.00 2.8 4.0 403 Plate 190x300x10 mm 7 Nos 31.00 3.5 8.4 844 Stiffener 75x278x10 mm 14 Nos 23.00 5.0 12.3 1235 Stiffener 80x100x10 mm 8 Nos 5.00 0.8 2.9 296 Stiffener 80x330x10 mm 10 Nos 21.00 0.8 4.4 447 Stiffener 140x330x10 mm 2 Nos 7.00 1.0 1.2 128 Pipe 100 dia x 540 mm 2 Nos 11.00 --- 0.6 69 Plate 400x720x12 mm 2 Nos 54.00 2.3 --- ---

10 Plate 200x390x10 mm 4 Nos 24.00 2.0 4.7 4711 Plate 50x190x20 mm 2 Nos 3.00 0.3 0.6 612 Hook 2 Nos 130.00 --- --- ---13 Plate 80x150x20 mm 2 Nos 4.00 0.2 0.3 314 Bronze bush 110/90/70 dia x 100 mm 2 4.00 --- --- ---15 SS pin 70 dia x 250 mm 2 Nos 15.00 --- --- ---16 Plate 120x700x10 mm 4 Nos 26.00 6.0 --- ---17 Plate 104x145x20 mm 2 Nos 5.00 0.5 0.3 318 Plate 120x120x25 mm 8 Nos 23.00 1.9 --- ---19 Plate 180x766x20 mm 4 Nos 87.00 7.5 --- ---20 Plate 331x462x25 mm 2 Nos 60.00 2.0 --- ---21 SS pin 85 dia x 65 mm 4 Nos 11.00 --- --- ---22 SS pin 110 dia x 231 mm 1 No. 17.00 --- --- ---23 SS pin 90 dia x 280 mm 2 Nos 28.00 --- --- ---24 Plate 150x190x12 mm 4 Nos 11.00 1.4 --- ---25 Plate 83x150x12 mm 8 Nos 9.00 1.9 2.4 2426 Plate 26x150x16 mm 4 Nos 2.00 0.7 SV 1.2 2827 Plate 40x73x8 mm 4 Nos 1.00 0.5 0.9 928 Shims 4.00 --- --- ---29 Keeper plate 40x140x12 mm 1 No. 1.00 --- --- ---30 Keeper plate 40x140x10 mm 4 Nos 2.00 0.2 --- ---31 Plate 73x80x8 mm 4 Nos 2.00 0.6 1.2 1232 Bolt/Nut/Washer 20 dia x 150 mm 2 Nos 1.00 --- --- ---33 Bolt/Nut/Washer 16 dia x 35 mm 16 Nos 1.00 --- --- ---

Total : 922.00 43.1 49.2 508kg Rm Rm Nos



2. Forged steel components IS : 2004Lifting hooks : 130.00 kg

227




4. Alloy steel components : IS : 1570Stainless steel pins : 71.00 kg

5. Bolt / Nut / Washer IS : 1363Bolt / Nut / Washer : 2.00 kg

6. Other components :Pipe 100 mm dia : 1.08 Rm



Item: Embedded parts for Barrage gates :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of embedded parts for vertical lift roller gate provided for Hipparagi Barrage in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


1 SS track plate 130x8100x20 mm 2 Nos. 331.00 16.5 33.0 3302 SS track plate 130x7090x20 mm 2 Nos. 289.00 14.5 29.4 2943 Track base 220x8500x25 mm 2 Nos. 734.00 17.5 --- ---4 Track base 220x7190x25 mm 2 Nos. 621.00 15.0 --- ---5 Track web 360x8500x16 mm 2 Nos. 769.00 17.8 F8 34.0 6126 Track web 360x7190x16 mm 2 Nos. 650.00 15.1 F8 28.8 5187 Sill beam ISMB 200 x 3750 mm 2 Nos 191.00 0.8 --- ---8 Sill beam ISMB 200 x 3600 mm 2 Nos 183.00 0.8 --- ---9 SS seal seat 80x3750x6.5 mm 2 Nos 31.00 7.7 15.2 152

10 SS seal seat 80x3600x6.5 mm 2 Nos 29.00 7.4 14.6 14611 SS seal seat 20x140x6.5 mm 2 Nos 1.00 0.3 0.4 412 SS seal seat 80x4200x6.5 mm 2 Nos 34.00 8.6 17.0 17013 SS seal seat 80x4600x6.5 mm 2 Nos 38.00 9.4 18.6 18614 Seal base ISA100x100x8x4200 mm 2 No 102.00 0.2 --- ---15 Seal base ISA100x100x8x4630 mm 2 No 112.00 0.2 --- ---16 Seal base 75x515x8 mm 30 Nos. 73.00 17.7 8.3 8317 Guide 110x3000x20 mm 8 Nos. 414.00 24.9 --- ---18 Guide 110x3690x20 mm 2 Nos. 127.00 7.6 --- ---19 Anchor pl 100x220x10 mm 76 Nos. 131.00 7.6 15.2 15220 Anchor pl 100x200x12 mm 52 Nos. 98.00 5.0 10.4 10421 Anchor bolt 16 dia x 200 mm 52 Nos. 16.00 0.8 2.6 2622 Anchor bolt 16 dia x 290 mm 74 Nos. 34.00 1.2 3.7 37

Contd

228




Contd23 Anchor bolt 16 dia x 185 mm 60 Nos. 18.00 1.0 3.0 3024 Anchor bolt 16 dia x 295 mm 104 Nos. 48.00 1.7 5.2 5225 Nuts & Washer 16 dia 580 Nos 33.00 --- --- ---26 Stiffener 90x210x8 mm 20 Nos. 24.00 6.0 12.0 12027 Splice pl 210x320x12 mm 4 Nos. 22.00 2.2 --- ---28 Splice pl 150x260x12 mm 6 Nos. 22.00 2.5 --- ---29 Bolt/Nut/Washer 16 dia x 60 mm 36 Nos 8.00 --- --- ---30 Bolt/Nut/Washer 20 dia x 70 mm 24 Nos 10.00 --- --- ---

Total : 5193.00 210.0 251.4 3016kg Rm Rm Nos


Angles / Beams / Channels / Bars : 588.00 kgStructural steel Plates / Flats : 3685.00 kg

2. Alloy steel components : IS : 1570Stainless steel plates / flats for track : 620.00 kgStainless steel plates / flats for seal seat : 133.00 kg

3. Bolt / Nut / Washer : IS : 1363MS Bolts / Nuts / Washers : 167.00 kg



Item: Vertical lift roller gate for barrageDetails of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of vertical lift roller gate provided for Hipparagi barrage in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


Gate leaf bottom unit :1 Skin plate 2420x14700x16 mm 1 No. 4468.00 17.4 24.2 2422 Stiffener ISA100x75x8x295 mm 35 Nos. 108.00 6.1 32.9 3293 Stiffener ISA100x75x8x1730 mm 35 Nos. 634.00 6.1 145.6 14564 Stiffener ISA100x75x8x265 mm 33 Nos. 92.00 5.8 24.0 2405 Web plate 1320x12820x10 mm 1 No. 1223.00 14.2 52.6 526

Contd

Gas cutting Weld lengthin mlength in m

length in m in m

229




Contd6 Web plate 1335x12820x10 mm 1 No. 1237.00 14.3 52.7 5277 Web plate 650x718x10 mm 4 No. 293.00 9.0 20.6 2068 Flange 300x8820x32 mm 2 Nos. 1329.00 18.5 --- ---9 Flange 300x2852x32 mm 2 Nos. 430.00 6.3 1.2 12

10 Flange 300x2584x32 mm 2 Nos. 389.00 6.2 1.2 1211 Flange 268x300x32 mm 2 Nos. 40.00 1.1 0.6 612 Flange 250x8000x12 mm 1 Nos. 188.00 8.5 16.5 16513 Flange 270x8000x12 mm 1 Nos. 203.00 8.6 16.6 16614 End girder 532x2410x12 mm 4 Nos. 483.00 11.8 19.3 19315 Diaphragm 140x532x20 mm 6 Nos. 70.00 4.0 16.1 16116 Flange 60x2320x16 mm 2 Nos. 35.00 5.6 9.3 9317 Flange 60x235x16 mm 2 Nos. 4.00 0.6 1.2 1218 Flange 60x1255x16 mm 2 Nos. 19.00 2.7 2.8 2819 Flange 60x220x16 mm 2 Nos. 3.00 2.5 1.0 1020 Pad plate 230x230x16 mm 8 Nos. 53.00 6.7 7.4 7421 Stiffener 365x1210x10 mm 2 Nos. 69.00 3.2 7.8 7822 Stiffener 150x980x10 mm 2 Nos. 23.00 2.3 5.1 5123 Stiffener 150x1225x10 mm 2 Nos. 29.00 2.8 6.1 6124 Stiffener 100x1320x10 mm 18 Nos. 186.00 1.8 54.7 54725 Gusset pl 210x250x10 mm 3 Nos. 12.00 1.5 2.8 2826 Bracing ISA90x90x8x1520 mm 3 Nos 49.00 0.6 2.3 2327 Bracing ISA90x90x8x1904 mm 1 Nos 21.00 0.2 0.7 728 Bracing ISA90x90x8x1830 mm 2 Nos 40.00 0.4 1.4 1429 Seal guard 20x2345x12 mm 2 Nos. 9.00 --- 9.4 9430 Seal guard 20x13770x20 mm 1 No. 43.00 --- 27.5 27531 Seal base 65x2345x10 mm 2 Nos. 24.00 4.8 9.4 9432 Stiffener 500x1220x10 mm 4 Nos. 191.00 6.9 14.6 14633 Stiffener 150x200x10 mm 6 Nos. 14.00 2.1 3.6 3634 Stiffener 150x1090x10 mm 1 Nos. 13.00 1.2 2.5 2535 Stiffener 50x506x10 mm 6 Nos. 12.00 0.3 7.2 7236 Splice pl 120x6879x8 mm 4 Nos. 207.00 28.0 --- ---

Gate leaf top unit : ---37 Skin plate 3203x3810x10 mm 2 Nos. 1915.00 14.0 --- ---38 Skin plate 2435x8295x10 mm 1 No. 1586.00 10.7 13.2 13239 Skin plate 3705x8295x10 mm 1 No. 2412.00 12.0 7.4 7440 Skin plate 2330x3203x10 mm 2 Nos. 1171.00 11.1 6.4 6441 Stiffener ISA 75x75x8x1990 mm 35 Nos. 731.00 6.1 163.8 163842 Stiffener ISA 75x75x8x2590 mm 33 Nos. 893.00 5.8 194.0 194043 Stiffener ISA 75x75x8x1095 mm 35 Nos. 402.00 6.1 88.9 88944 Stiffener 100x1130x10 mm 24 Nos. 213.00 2.4 63.8 63845 Stiffener 100x970x10 mm 5 Nos. 38.00 0.5 11.7 11746 Stiffener 150x995x10 mm 2 Nos. 23.00 2.3 5.2 5247 Stiffener 150x833x10 mm 8 Nos. 78.00 7.9 18.1 18148 Stiffener 150x755x10 mm 1 No. 9.00 0.9 2.1 2149 Stiffener 100x880x10 mm 13 Nos. 90.00 1.3 28.0 28050 Diaphragm 1062/848x2590x8 mm 2 Nos. 310.00 7.4 28.4 284

Contd

230




Contd51 Web plate 1150x8295x10 mm 2 Nos. 1498.00 9.5 8.5 8552 Web plate 1150/566x2981x10 mm 4 Nos. 663.00 14.2 28.4 28453 Web plate 900x8295x10 mm 1 No. 586.00 9.2 18.4 18454 Web plate 900/512x2981x10 mm 2 Nos. 330.00 7.0 14.0 14055 Flange pl 300x8820x32 mm 2 Nos. 1329.00 18.3 36.5 36556 Flange pl 300x2803x32 mm 4 Nos. 845.00 12.4 24.8 24857 Flange pl 250x8820x20 mm 1 Nos. 346.00 9.5 18.6 18658 Flange pl 250x2750x20 mm 2 Nos. 216.00 6.0 13.0 13059 Flange pl 270x8000x12 mm 2 Nos. 406.00 16.5 34.2 34260 Flange pl 150x2336x12 mm 2 Nos. 66.00 5.0 10.5 10561 Stiffener 100x882x10 mm 4 Nos. 28.00 3.9 8.6 8662 End girder 532x6140x12 mm 4 Nos. 1231.00 26.7 --- ---63 Diaphragm 140x532x10 mm 10 Nos. 58.00 6.7 26.7 26764 Pad plate 230x230x16 mm 8 Nos. 53.00 5.7 7.4 7465 Seal base 65x6140x10 mm 2 Nos. 63.00 12.4 24.8 24866 Seal base 20x6140x12 mm 2 Nos. 23.00 12.3 24.6 24667 Cover plate 120x8175x8 mm 1 No. 62.00 8.3 16.4 16468 Cover plate 120x6040x8 mm 2 Nos. 91.00 13.4 24.6 24669 Cover plate 120x310x8 mm 2 No. 5.00 0.9 1.8 1870 Cover plate 120x1960x8 mm 2 No. 30.00 4.2 8.4 8471 Cover plate 120x2560x8 mm 2 No. 39.00 5.4 10.7 10772 Cover plate 120x1090x8 mm 2 No. 16.00 2.5 5.0 5073 Splice pl 120x1100x8 mm 8 Nos. 66.00 9.8 19.5 19574 Splice pl 120x850x8 mm 8 Nos. 51.00 7.8 15.5 15575 Splice pl 120x1022x10 mm 2 Nos 19.00 2.3 4.6 4676 Stiffener 425x1062x10 mm 2 Nos. 71.00 3.0 5.9 5977 Stiffener 120x8145x12 mm 1 No. 92.00 8.5 16.5 16578 Flange plate 60x6140x16 mm 2 Nos. 93.00 12.4 24.6 24679 Flange plate 60x985x16 mm 2 Nos. 15.00 2.1 4.0 4080 Flange plate 60x2325x16 mm 2 Nos. 35.00 4.8 9.3 9381 Flange plate 60x1700x16 mm 2 Nos. 26.00 3.5 6.8 6882 Flange plate 60x280x16 mm 2 Nos. 4.00 0.7 1.4 1483 Stiffener 50x506x10 mm 20 Nos. 40.00 11.1 24.2 24284 Bracing ISA90x90x8x1960 mm 3 Nos. 64.00 0.6 2.0 2085 Bracing ISA90x90x8x2047 mm 1 Nos. 22.00 0.2 0.7 786 Bracing ISA90x90x8x2572 mm 2 Nos. 55.00 0.4 1.4 1487 Stiffener ISA100x75x8x325 mm 35 Nos. 119.00 6.1 9.6 9688 Gusset pl 125x265x10 mm 1 No. 3.00 0.4 0.8 889 Gusset pl 125x210x10 mm 1 No. 2.00 0.3 0.7 790 Gusset pl 135x250x10 mm 3 Nos. 8.00 1.2 2.3 2391 Gusset pl 140x200x10 mm 3 No. 7.00 1.0 2.0 2092 Gusset pl 130x270x12 mm 2 No. 7.00 0.8 1.6 1693 Gusset ISA100x100x6x895 mm 4 Nos. 33.00 0.8 2.8 2894 Pack plate 60x13760x6 mm 1 No. 26.00 13.9 --- ---95 Diaphragm 140x532x12 mm 4 Nos. 28.00 2.7 10.8 108

Contd

Weld lengthlength in m in m

231

Gas cutting



Contd96 Lifting lug 400x400x20 mm 4 Nos. 100.00 3.5 F10 1.6 4597 Lifting pl 670x1040x16 mm 4 Nos. 250.00 6.9 --- ---98 Stiffener 146x1005x10 mm 4 Nos. 46.00 4.6 16.0 16099 R / F plate 220/80 dia x 12 mm 4 Nos. 12.00 3.8 2.8 28100 Stiffener 250x300x10 mm 4 Nos. 24.00 2.2 6.4 64101 Stiffener 250x250x10 mm 4 Nos. 20.00 2.0 5.2 52102 Stiffener 120x879x10 mm 2 Nos. 14.00 2.0 4.5 45103 Stiffener 120x819x10 mm 2 Nos. 13.00 1.9 4.2 42104 Bracing ISA75x75x8x2004 mm 2 Nos. 36.00 0.3 1.1 11105 Bolts 16 diax 60 mm 4.00 --- --- ---106 Bolts 16 dia x 35 mm 4.00 --- --- ---107 Bolts 16 dia x 50 mm 40 Nos 7.00 --- --- ---108 Bolts 16 dia x 75 mm 276 Nos 53.00 --- --- ---109 Flange 190x600x10 mm 4 Nos. 36.00 3.2 6.3 63110 Web plate 518x566x12 mm 4 Nos. 110.00 4.4 8.8 88111 Stiffener 120x703x10 mm 4 Nos. 22.00 3.3 7.5 75

Seal assembly :112 Bottom seal 14.00 Rm --- --- --- ---113 Side seal 17.20 Rm --- --- --- ---114 Seal clamp 70x3503x12 mm 2 Nos. 46.00 7.0 --- ---115 Seal clamp 70x3389x12 mm 2 Nos. 45.00 6.8 --- ---116 Seal clamp 45x3068x12 mm 4 Nos. 52.00 12.3 --- ---117 Seal clamp 45x2414x12 mm 2 Nos. 20.00 4.8 --- ---118 GI Bolt/Nut/Washer 12 diax65 mm 310 62.00 --- --- ---

Wheel assembly :119 Wheels 410 mm dia x 200 mm 8 Nos. 528.00 --- --- ---120 Bearings 8 Nos 80.00 --- --- ---121 SS Pins 125/110/95 dia 8 Nos 176.00 --- --- ---122 Bearing retainers 16 Nos. 128.00 --- --- ---123 Spacers 8 Nos 8.00 2.0 --- ---124 Spacers 8 Nos 8.00 2.0 --- ---125 Cover 16 Nos 32.00 7.5 --- ---126 GI Screws 15.00 --- --- ---127 Keeper pl 60x210x10 mm 8 Nos. 8.00 2.2 --- ---128 GI bolts 16 dia x 80 mm 16 Nos 4.00 --- --- ---129 GI washers 4.00 --- --- ---

Guide shoe : ---130 Base pl 220x220x20 mm 4 Nos. 32.00 1.8 --- ---131 Guide pl 103x220x16 mm 8 Nos 24.00 2.6 3.5 35132 Guide pl 32x220x20 mm 4 Nos 4.00 1.0 1.8 18133 Stiffener 70x95x10 mm 8 Nos 4.00 1.4 2.6 26134 Pack plate 4 Nos 4.00 --- --- ---135 GI Bolts 20 dia x 65 mm 16 Nos 6.00 --- --- ---

Total : 33025.00 694.5 1837.1 18400kg Rm Rm Nos

232








5. Rubber seals : IS : 11855Bottom rubber seal ( uncladed ) : 14.00 RmSide rubber seal ( uncladed ) : 17.20 Rm

6. Bolt / Nut / Washer IS : 1363GI Bolt / Nut / Washer : 91.00 kgMS Bolt / Nut / Washer : 68.00 kg



Item: Hoist supporting bridge for barrage gates .Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of 10 m height & 15 m span hoist supporting bridge provided for Hipparagi Barrage in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


Columns :1 ISMB350 x 9918 mm 4 Nos. 2079.00 2.6 16.0 1602 Base pl 340x550x20 mm 4 Nos. 179.00 3.6 5.0 503 Stiffener 100x550x20 mm 6 Nos. 52.00 3.9 6.6 664 Stiffener 300x530x12 mm 6 Nos. 90.00 5.0 6.4 645 Stiffener 90x300x12 mm 20 Nos. 51.00 7.8 15.6 1566 Stiffener 100x326x20 mm 2 Nos. 10.00 0.9 2.1 217 Stiffener 100x100x20 mm 4 Nos. 6.00 1.2 2.4 248 Stiffener 78x300x12 mm 12 Nos. 26.00 4.5 9.1 919 Stiffener 210x430x12 mm 4 Nos. 34.00 2.6 2.7 27

10 Bracings ISA65x65x6x2127 mm 16 Nos. 197.00 2.1 8.5 8511 Bracings ISA65x65x6x1120 mm 20 Nos. 130.00 2.6 10.6 10612 Bracings ISA65x65x6x1781 mm 4 Nos. 41.00 0.6 2.1 2113 Lacing ISA40x40x5x450 mm 30 Nos. 41.00 2.7 9.0 90

Contd

233




Contd14 Tie beam ISMB300 x 2026 mm 6 Nos. 537.00 3.5 --- ---15 Column cap 280x410x16 mm 4 Nos. 58.00 2.8 5.0 5016 Gusset pl 170x330x12 mm 12 Nos. 63.00 6.0 13.9 13917 Gusset pl 200x280x10 mm 20 Nos. 88.00 12.0 19.2 19218 Stiffener 60x328x10 mm 40 Nos. 62.00 2.4 35.8 35819 Anchor bolt 25 dia x 1200 mm 24 Nos 111.00 0.6 --- ---20 Nuts 24 dia 48 Nos 4.00 --- --- ---21 Plate washer 70x70x16 mm 24 Nos. 15.00 3.4 --- ---22 Bolt/Washer 20 dia x 70 mm 24 Nos 8.00 --- --- ---23 Bolt/Washer 20 dia x 60 mm 16 Nos 4.00 --- --- ---24 Stiffener 300x326x12 mm 2 Nos 19.00 1.3 3.7 3725 Stiffener 60x159x10 mm 16 Nos. 12.00 3.5 8.9 8926 Gusset pl 125x330x10 mm 8 Nos. 26.00 3.7 7.3 73

Beams and hoist supports :27 Web plate 1000x15430x8 mm 1 No. 969.00 17.5 --- ---28 Web plate 1008x15430x8 mm 1 No. 977.00 17.6 --- ---29 Flange 150x15430x16 mm 2 Nos. 581.00 15.7 31.5 31530 Flange 250x15430x20 mm 2 Nos. 1211.00 16.0 31.8 31831 Bearing pl 250x380x16 mm 4 Nos. 48.00 2.6 2.0 2032 Stiffener 180x1000x10 mm 4 Nos. 57.00 4.7 10.0 10033 Stiffener 180x1008x10 mm 4 Nos. 60.00 4.8 10.1 10134 Stiffener 130x1000x10 mm 11 Nos. 155.00 12.5 25.3 25335 Stiffener 130x1008x10 mm 11 Nos. 113.00 13.0 25.5 25536 Cross beam ISMC150x2392 mm 6 Nos 235.00 1.8 3.6 3637 Cross beam ISMC200x2392 mm 2 Nos 106.00 0.8 3.2 3238 Cross beam ISMC300x2392 mm 6 Nos 515.00 3.6 14.4 14439 Cross beam ISMC200x1418 mm 4 Nos 126.00 1.6 6.4 6440 Bracket 240x685x12 mm 4 Nos. 62.00 3.7 3.4 3441 Bracket 240x555x12 mm 4 Nos. 50.00 3.2 3.4 3442 R / F plate 220 dia x 12 mm 8 Nos. 29.00 5.5 5.5 5543 Bracing ISA65x65x6x1437 mm 4 Nos. 33.00 0.5 2.1 2144 Stiffener 75x808x10 mm 2 Nos. 10.00 1.8 3.8 3845 Stiffener 100x800x10 mm 2 Nos. 13.00 1.8 4.0 4046 Stiffener 75x708x10 mm 4 Nos. 17.00 3.1 6.9 6947 Stiffener 100x700x10 mm 4 Nos. 22.00 3.2 7.2 7248 Stiffener 75x858x10 mm 4 Nos. 20.00 3.7 7.3 7349 Stiffener 100x850x10 mm 4 Nos. 27.00 3.8 8.4 8450 Railing post ISA50x50x6x1160 mm 26 136.00 2.6 5.2 5251 Railing plate 75x15430x6 mm 2 Nos. 109.00 31.0 2.6 2652 Railing pipe 32 dia x15430 mm 2 Nos 80.00 --- 0.5 553 Railing pipe 25 dia x15430 mm 4 Nos 124.00 --- --- ---54 Plate 70x2000x8 mm 4 Nos. 35.00 8.3 16.6 16655 Splice plate 120x900x8 mm 4 Nos. 27.00 4.1 8.2 8256 Splice plate 120x300x8 mm 2 Nos. 5.00 0.8 1.7 1757 Splice plate 220x300x8 mm 2 Nos. 10.00 1.0 2.1 2158 Splice plate 45x300x8 mm 4 Nos. 3.00 1.4 2.8 28

Contd

234




Contd59 Splice plate 90x300x10 mm 4 Nos. 8.00 1.6 3.1 3160 Chequered plate 25 sqm 133.00 10.0 5.0 5061 Stiffener 65x184x8 mm 8 Nos. 6.00 2.0 5.0 5062 Stiffener 75x278x10 mm 4 Nos. 7.00 1.4 3.4 3463 Batten 100x300x10 mm 4 Nos. 9.00 1.6 0.8 864 Cross beam ISMC200x2392 mm 2 Nos 106.00 0.8 3.2 3265 Cross beam ISMC200x600 mm 3 Nos 40.00 1.2 4.8 4866 Cross beam ISMC150x600 mm 2 Nos 20.00 0.6 2.4 2467 Bolts 26 & 16 dia 2.00 --- --- ---

Total : 10239.00 290.2 473.1 4731kg Rm Rm Nos


Angles / Beams / Channels / Bars : 4453.00 kgStructural steel Plates / Flats : 5431.00 kgChequered plate : 133.00 kg

2 Bolt / Nut / Washer : IS : 1363MS Bolts / Nuts / Washers : 18.00 kgMS pipes :32 mm dia pipe : 30.86 Rm25 mm dia pipe : 61.72 Rm

3 Other details :Length of cutting : 290.20 RmLength of welding : 473.10 RmNumber of electrodes ( for structural steel ) : 4731 Nos


Item: Rope drum hoist for barrage gates .Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of rope drum hoist for vertical lift roller gate provided for Hipparagi Barrage in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


Gear box :1 Frame ISMC250x1800 mm 2 No. 104.00 1.0 --- ---2 Frame ISMC250x1094 mm 2 No. 66.00 1.0 --- ---3 Frame ISMC250x1432 mm 4 No. 174.00 2.0 8.0 804 Frame ISMC250x780 mm 2 No. 44.00 1.0 2.0 20

Contd

235

Gas cutting


Weld lengthlength in m in m



Contd5 Frame ISMC250x330 mm 2 No. 22.00 1.0 4.0 406 Drum support 260x550x16 mm 4 Nos. 72.00 3.2 2.8 287 Stiffener 70x305x10 mm 8 Nos. 14.00 3.0 6.0 608 Stiffener 65x228x10 mm 12 Nos. 14.00 3.6 8.6 869 Stiffener 110x350x10 mm 4 Nos. 12.00 1.8 3.6 36

10 Stiffener 110x320x16 mm 4 Nos. 10.00 1.8 2.8 2811 Bolts / Screws 3.00 --- --- ---

Rope drums :12 Drum ( 632/566 dia )x1310 mm 2 Nos 680.00 --- --- ---13 Bronze bush 125/100 diax130 mm 2 Nos 10.00 --- --- ---14 Bronze bush 125/100 diax100 mm 2 Nos 8.00 --- --- ---15 Spacers 4.00 --- --- ---16 Clamping pl 33x150x100 4 Nos 16.00 --- --- ---17 Bolts 24 dia x 90 mm 8 Nos 5.00 --- --- ---18 Bolts 24 dia x 80 mm 12 Nos 8.00 --- --- ---

Gears and pinions :19 Drum gear 2 Nos. 480.00 --- --- ---20 1st gear 2 Nos 130.00 --- --- ---21 1st pinion 2 Nos 76.00 --- --- ---22 2nd pinion 2 Nos 22.00 --- --- ---

Shafts :23 Drum shaft 100 diax1480 mm 2 Nos 182.00 --- --- ---24 2nd pinion shaft 110 diax695 mm 1 Nos 52.00 --- --- ---25 2nd pinion shaft 110 diax595 mm 1 Nos 44.00 --- --- ---26 1st pinion shaft 75 diax763 mm 2 Nos 53.00 --- --- ---27 Keys 28x150x16 mm 2 Nos. 1.00 --- --- ---28 Keys 28x130x16 mm 2 Nos. 1.00 --- --- ---29 Keys 20x115x12 mm 2 Nos. 1.00 --- --- ---

Pipe shaft :30 MS pipe 200 dia x 4601 mm 2 Nos 391.00 --- --- ---31 Flange 355/200 dia x12 mm 4 Nos 25.00 7.0 2.5 2532 Flange 355/140 dia x12 mm 4 Nos 20.00 6.2 2.5 2533 Hub 140/68 dia x 85 mm 2 Nos 16.00 --- 0.9 934 Stiffener 62x65x6 mm 16 Nos 3.00 2.0 4.0 4035 Stiffener 68x100x6 mm 16 Nos 5.00 2.7 5.4 5436 Bolt/Nut/Washer 20 dia x50 mm 24 Nos 7.00 --- --- ---

Pulleys :37 Pulley 622 mm dia 6 Nos 480.00 --- --- ---38 Pulley 400 mm dia 2 Nos 120.00 --- --- ---39 Bronze bush 115/90 mm dia 6 Nos 24.00 --- --- ---40 Bronze bush 115/90 mm dia 2 Nos 8.00 --- --- ---41 Pin 90 dia x 244 mm 6 Nos 72.00 --- --- ---42 Pin 90 dia x 244 mm 2 Nos 24.00 --- --- ---43 Spacers 16 Nos 16.00 --- --- ---44 Keeper pl 40x140x10 mm 16 Nos 8.00 --- --- ---45 Screws 2.00 --- --- ---

Contd

236




ContdOther components :

46 Worm reducer 60 :1 ( size 800 ) 1 No. 500.00 --- --- ---47 Electric motor 12.5 hp 1000 rpm 1 No. 60.00 --- --- ---48 Electro-megnatic brake 1 No. 25.00 --- --- ---49 Manual operation unit 1 No. 120.00 --- --- ---50 Plummer block body 10 Nos 250.00 --- --- ---51 Bronze bush 10 Nos 50.00 --- --- ---52 Fexible couplings 2 Nos 50.00 --- --- ---53 Position indicator unit 1 No. 50.00 --- --- ---54 Wire rope 6/36 construction 160 Rm 435.00 --- --- ---

Total : 5069.00 37.3 53.1 531.0kg Rm Rm Nos



2. Cast steel components : IS : 1030Rope drums 2 Nos / Gears : 1290.00 kgPinions : 98.00 kgPulleys 8 Nos / Couplings 2 Nos : 650.00 kgPlummer blocks : 250.00 kg

3. Alloy steel components : IS : 1570Shafts / Keys : 350.00 kgPins : 96.00 kg


5. Wire rope : IS : 226628 mm dia 6/36 construction rope : 160 Rm

6. Bolts / Nuts / Washers : IS : 1363Bolts / Nuts / Washers ( various size ) : 25.00 kg

7. Other components :Electric motor 12.5 hp Standard : 1 No.Worm reducer 60 :1 ( size 800 ) 1 No. Standard : 1 NoElectro-megnatic brake Standard : 1 NoManual operation assembly : 1 No.Position indicator : 1 No.



Item: Embedded parts for out-flow regulating automatic gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on details made available by the designer of ebedded parts for 8.00 x 3.50 m size

237



out-flow regulating automatic gate.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 5 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.

ABSTRACT : 1. Structural steel : IS :2062

Angle / Channel / Beam / Bars 0.94059 : 760.00 kgPlates / Flats : 3040.00 kg

2. Alloy steel components : IS : 1570Stainless steel plates AISI-410 : 49.00 kgStainless steel plates AISI-304L : 62.00 kg

3. Bolt / Nut / Washer : IS :1363MS Bolt / Nut / Washer : 129.00 kg

4. Other details :Length of cutting : 168.00 RmNumber of electrodes ( for structural steel ) : 133 NosNumber of electrodes ( for stainless steel ) : 987 Nos


Item: Out-flow regulating automatic gate and fulcrum assembly:Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on details made available by the designer of gate for 8.00 x 3.50 m size out-flow regulating automatic gate.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 5 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.



2. Cast steel components : IS : 1030 94.23%Trunnion hub / Guide roller : 443.00 kg

3. Alloy steel components : IS : 1570Pins : 74.00 kgStainless steel plate : 49.00 kg


5. Bolt / Nut / Washer IS :1363SS Bolts / Nuts / Washers : 31.00 kgMS Bolts / Nuts / Washers / Screws : 23.50 kg


238




Item: Hoisting and damping system for out-flow regulating automatic gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on details made available by the designer of gate for 8.00 x 3.50 m size out-flow regulating automatic gate.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 5 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.



2. Cast steel components : IS : 1030 81.38%Wheels / Trunnion hub : 76.00 kgTrunnion / Guide roller : 443.00 kg

3. Alloy steel components : IS : 1570Pins / Axles : 59.00 kgStainless steel plate : 435.00 kg

4. Alluminium / Bronze alloy components : IS : 305Trunnion & Guide roller bearings / bush : 118.00 kg50 NB pipe : 28.00 kg

5. Bolt / Nut / Washer IS :1363SS Bolts / Nuts / Washers : 15.50 kgMS Bolts / Nuts / Washers / Screws : 14.50 kg

6 Disc springs : 64 Nos 7. Other details :

Length of cutting : 124.00 RmLength of welding :Number of electrodes ( for structural steel ) : 2911 NosNumber of electrodes ( for stainless steel ) : 324 Nos


Item: Embedded parts for Cross regulator radial gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of embedded parts for cross regulator radial gate provided for Alamatti Left Bank Canal under Upper Krishna Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 5 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.

239


4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


First stage anchors :1 Anchor plate 300x100x10 mm 7 Nos 16.00 0.7 --- ---2 Anchor rod 20 dia x 615 mm 7 Nos 11.00 0.1 0.9 63 Anchor plate 300x100x10 mm 34 Nos 94.00 3.4 --- ---4 Anchor rod 20 dia x 740 mm 34 Nos 63.00 0.7 4.3 43

Sill beam :5 ISMB 200 x 3500 mm 1 No. 89.00 0.4 --- ---6 SS plate 80x6x3100 mm 1 No. 12.00 0.1 6.3 447 Stiffener 200x190x10 mm 14 Nos 42.00 5.5 10.9 768 Plate 150x3500x10 mm 2 Nos 83.00 7.3 SV 7.0 1059 Plate 300x100x10 mm 7 Nos 17.00 0.7 1.4 10

10 Anchor bolts 20 dia x 300 mm 14 Nos 10.00 --- 0.9 611 SS plate 120x100x6 mm 2 Nos. 2.00 0.2 0.2 1

Wall plates :12 Plate 500x350x10 mm 2 Nos 27.00 1.7 SV 0.7 1013 Plate 1500x350x10 mm 10 Nos 412.00 18.5 SV 3.5 5214 Plate 600x350x10 mm 2 Nos 33.00 1.9 SV 0.7 1015 SS plate 80x5000x6 mm 2 Nos 38.00 0.2 20.0 14016 ISA 75x75x8 mm x 100 mm 68 Nos 60.00 10.2 13.6 9517 Anchor bolts 20 dia x 190 mm 68 Nos 32.00 --- 4.4 31

Anchor girders : ( All welds 6 mm fillet )18 Plate 450x2226x12 mm 2 Nos 189.00 5.4 --- ---19 Plate 276x2226x12 mm 2 Nos 116.00 4.9 13.6 13620 Stiffener 138x276x12 mm 6 Nos 22.00 2.5 6.6 6621 Stiffener 144x276x12 mm 12 Nos 45.00 5.0 13.5 13522 End plate 450x300x12 mm 2 Nos 25.00 1.5 2.4 2423 Stiffener 138x200x12 mm 6 Nos 16.00 2.0 4.0 4024 Stiffener 144x200x12 mm 12 Nos 33.00 4.1 8.2 8225 Bolt/Nut/Washer 24 diax60 mm 16 Nos 8.00 --- --- ---

Anchor bar and chairs : ( All welds 8 mm fillet )26 Anchor bars 40 dia x 4500 mm 12 Nos 533.00 0.5 --- ---27 Anchor plate 200x200x20 mm 24 Nos 151.00 9.6 6.0 10828 Anchor bars 25 dia x 1200 mm 12 Nos 56.00 0.3 --- ---29 Anchor plate 80x80x16 mm 12 Nos 10.00 2.0 1.9 3430 Plate 250x325x20 mm 4 Nos 52.00 2.3 --- ---31 Plate 130x250x20 mm 2 Nos 11.00 0.8 2.0 3632 Plate 250x325x20 mm 2 Nos 25.00 1.2 2.0 3633 Stiffener 195x325x20 mm 2 Nos 20.00 1.0 3.4 6134 Plate 250x340x20 mm 2 Nos 27.00 1.2 2.0 3635 Stiffener 90x325x20 mm 2 Nos 9.00 0.8 1.9 3436 Nuts / Washers for anchor bars 15.00 --- --- ---

Total : 2404.00 96.7 142.3 1457kg Rm Rm Nos


240





3. Bolt / Nut / Washer : IS :1363MS Bolt / Nut / Washer : 65.00 kg



Item: Radial gate for Cross regulator :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of cross regulator radial gate provided for Alamatti Left Bank Canal under Upper Krishna Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


Trunnions / Brackets / Tie beam :1 Tie beam ISMB 250 x 2200 mm 1 No. 82.00 0.5 1.6 162 Plate 250x400x12 mm 4 Nos 38.00 4.2 2.6 263 Pin 90 dia x 370 mm 2 Nos 37.00 --- --- ---4 Trunnion hub 180/110x250 mm 2 Nos 92.00 --- --- ---5 Trunnion bush 110/90 x 260 mm 2 Nos 13.00 --- --- ---6 Plate 350x450x20 mm 4 Nos 99.00 6.2 2.3 237 Stiffener 220x450x20 mm 4 Nos 62.00 2.7 9.0 908 Plate 300x160x20 mm 4 Nos 30.00 1.9 2.9 299 Bolt/Nut/Washer 20 dia x 100 mm 24 Nos 16.00 --- --- ---

10 Bracket base pl 450x400x20 mm 2 Nos 57.00 1.7 --- ---11 Bracket pl 350x350x20 mm 4 Nos 77.00 4.5 2.8 2812 Stiffener 280x80x20 mm 6 Nos 21.00 0.5 5.3 5313 Stiffener 130x80x20 mm 4 Nos 7.00 0.3 2.3 2314 Keeper pl 140x60x20 mm 4 Nos 3.00 0.3 --- ---15 Screws 16 dia x 30 mm 8 Nos 1.00 --- --- ---16 Bolt/Nut/Washer 20 dia x 100 mm 16 Nos 10.00 --- --- ---

Sector arms and Horizontal girders :17 Sector arm ISMB 250 x 5150 mm 4 Nos 768.00 2.0 --- ---18 Bracing ISMB 250 x 2200 mm 2 Nos 164.00 1.0 4.0 4019 ISA 75x75x8 x 1900 mm 4 Nos 68.00 0.6 1.8 18

Contd

241




Contd20 ISA 75x75x8 x 1400 mm 4 Nos 50.00 0.6 1.8 1821 ISA 75x75x8 x 1900 mm 4 Nos 68.00 0.6 1.8 1822 ISA 75x75x8 x 550 mm 4 Nos 20.00 0.6 1.8 1823 Gusset pl 250x150x10 mm 4 Nos 12.00 1.6 1.6 1624 Gusset pl 200x150x10 mm 4 Nos 10.00 1.4 1.4 1425 Gusset pl 250x200x10 mm 4 Nos 16.00 1.8 1.8 1826 Gusset pl 200x200x10 mm 4 Nos 13.00 1.6 1.6 1627 Gusset pl 250x200x10 mm 4 Nos 16.00 1.8 1.8 1828 Plate 280x160x20 mm 4 Nos 28.00 1.8 4.0 4029 Plate 300x160x20 mm 4 Nos 30.00 1.8 4.0 4030 Bolt/Nut/Washer 20 dia x 70 mm 24 Nos 12.00 --- --- ---31 H-Girder ISMB 300 x 2900 mm 2 Nos 256.00 1.8 --- ---32 Stiffener 70x320x20 mm 16 Nos 56.00 6.3 14.7 14733 Plate 300x160x20 mm 4 Nos 30.00 1.8 3.7 3734 Bolt/Nut/Washer 20 dia x 100 mm 24 Nos 15.00 --- --- ---35 ISA 75x75x8 x 1994 mm 3 Nos 53.00 0.5 1.3 1336 ISA 75x75x8 x 2150 mm 2 Nos 38.00 0.3 0.9 937 Gusset pl 200x200x10 mm 3 Nos 9.00 1.2 1.2 1238 Gusset pl 240x200x10 mm 2 Nos 8.00 0.9 0.8 839 Gusset pl 300x200x10 mm 1 Nos 5.00 0.5 0.5 5

Skin plate assembly :40 Skin plate 2880x4950x10 mm 1 No. 1119.00 12.8 5.0 5041 Tee ISMB 250/2 x 4950 mm 6 Nos 554.00 14.9 59.4 59442 Top plate 150x2880x10 mm 1 Nos 34.00 3.0 6.0 6043 Stiffener 120x120x10 mm 14 Nos 16.00 3.4 6.7 6744 Bottom pl 150x2880x10 mm 1 No. 34.00 3.0 3.8 3845 Seal support 10x10x2880 1 No. 2.00 --- 5.8 5846 Side clamp ISA 45x45x6x5000 mm 2 Nos 40.00 0.2 --- ---47 Bottom clamp 70x2880x10 mm 1 No 16.00 3.0 --- ---48 Z - seal 5000 mm 2 Nos --- --- --- ---49 Flat seal 3000 mm 1 No. --- --- --- ---50 Back plate 60x5000x10 mm 1 No. 24.00 --- 10.0 10051 GI Bolt/Nut/Washer 12 dia x 50 mm 140 14.00 --- --- ---

Guide roller assembly :52 Plates 48.00 5.2 2.9 2953 Guide roller 4 Nos 30.00 --- --- ---54 Bronze bush 4 Nos 6.00 --- --- ---55 Pins 4 Nos 4.00 --- --- ---56 GI Bolt/Nut/Washer 12 dia x 50 mm 16 2.00 --- --- ---

Pulley supports in gate :57 Bracket pl 300x350x20 mm 4 Nos 66.00 2.7 5.2 5258 Plate 160x400x6 mm 2 Nos 6.00 1.1 3.2 3259 Plate 300x360x20 mm 2 Nos 34.00 1.3 1.9 1960 Stiffener 70x150x10 mm 8 Nos 7.00 2.0 3.5 3561 Stiffener 123x220x10 mm 4 Nos 9.00 1.4 2.8 28

4455.00 107.3 195.5 1955 Total : kg Rm Rm Nos

242





2. Cast steel components : IS : 1030Trunnion hub / Guide roller : 122.00 kg

3. Alloy steel components : IS : 1570Pins : 41.00 kg


5. Bolt / Nut / Washer IS :1363GI Bolts / Nuts / Washers : 16.00 kgMS Bolts / Nuts / Washers / Screws : 54.00 kg




Item: Rope drum hoist for regulator radial gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of rope drum hoist for cross regulator radial gate provided for Alamatti Left Bank Canal under Upper Krishna Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 5 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


Embedments :1 Anchor bolts 20 dia x 750 mm 16 Nos 30.00 0.4 1.0 72 Bolt / Nut / Washers 2.00 --- --- ---3 Plate 220x280x20 mm 8 Nos 77.00 4.0 --- ---

Hoist supporting structure :4 Girder ISMB-250 x 3600 mm 2 Nos 269.00 1.0 --- ---5 Rib plate 225x250x10 mm 8 Nos 35.00 3.8 1.8 136 ISMC- 150 x 500 mm 2 Nos 17.00 0.6 2.4 177 ISMC- 150 x 1990 mm 2 Nos 61.00 0.6 2.4 178 ISMC- 250 x 790 mm 2 Nos 54.00 0.8 4.0 289 ISMC- 250 x 1990 mm 4 Nos 272.00 1.6 8.0 56

10 ISMC- 250 x 570 mm 4 Nos 78.00 1.7 8.0 5611 MS pipe 32 dia x 5250 mm 2 Nos 42.00 --- 0.5 412 Flat 50x3100x8 mm 2 Nos 20.00 0.1 0.8 6

Contd

Gas cutting

243

Weld lengthin mlength in m



Contd13 ISA 65x65x6 mm x 1130 mm 6 Nos 39.00 0.8 --- ---14 ISA 65x65x6 mm x 3600 mm 2 Nos 42.00 0.3 14.4 10115 Bolt/Nut/Washer 12 diax50 mm 12 Nos 2.00 --- --- ---16 Rib plate 200x250x10 mm 6 Nos 14.00 2.7 4.6 3217 Chequered pl 400x687x6 mm 2 Nos 29.00 2.2 2.2 1518 Chequered pl 525x1935x6 mm 2 Nos 109.00 4.9 4.9 3419 Chequered pl 247x560x6 mm 1 No. 7.00 0.8 0.8 620 Chequered pl 587x630x6 mm 2 Nos 40.00 2.4 2.4 1721 Chequered pl 162x560x6 mm 1 No. 5.00 0.8 0.8 622 Plate 250x350x16 mm 4 Nos 44.00 2.4 3.2 2223 R/F plate 120/62 dia x 8 mm 4 Nos 1.00 2.3 1.5 1124 Plate 120x470x20 mm 2 Nos 18.00 1.2 0.8 625 Plate 80x80x10 mm 4 Nos 2.00 0.6 1.3 9

Pulleys and accessories :26 CI Pulley 300 dia 2 Nos 36.00 --- --- ---27 Pin 60 dia x 200 mm 2 Nos 16.00 --- --- ---28 Bronz bush 80/60 dia x 50 mm 2 Nos 2.00 --- --- ---29 Plate 40x90x8 mm 4 Nos 2.00 0.5 --- ---30 Bolt/Nut/Washer 12 diax30 mm 16 Nos 2.00 --- --- ---31 Pulley pin 50 dia x 250 mm 2 Nos 8.00 --- --- ---32 Lock plate 50x90x10 mm 8 Nos 8.00 --- --- ---33 Spacer 130/60 dia x 25 mm 2 Nos 6.00 --- --- ---34 Spacer 130/60 dia x 8 mm 4 Nos 2.50 --- --- ---35 CI Pulley 276 dia 4 Nos 72.00 --- --- ---36 Bronz bush 80/60 dia x 60 mm 4 Nos 4.50 --- --- ---

Gear box :37 ISMC 250 x 880 mm 2 Nos. 60.00 1.0 --- ---38 ISMC 250 x 570 mm 2 Nos. 39.00 1.0 0.8 639 ISMC 250 x 660 mm 2 Nos. 45.00 1.0 0.8 640 ISMC 250 x 450 mm 2 Nos. 31.00 1.0 0.8 641 ISMC 250 x 260 mm 2 Nos. 14.00 1.0 0.8 642 ISMC 250 x 400 mm 2 Nos. 27.00 1.0 1.6 1143 Plate 60x880x10 mm 2 Nos 8.00 0.2 1.8 1344 Plate 60x220x10 mm 2 Nos 2.00 0.2 0.7 545 Stiffener 75x90x10 mm 12 Nos 4.00 2.0 3.9 2746 Plate 250x400x20 mm 4 Nos 63.00 2.6 4.0 2847 Plate 75x240x10 mm 2 Nos 3.00 0.6 1.6 1148 Plate 130x240x10 mm 8 Nos 20.00 3.0 6.4 4549 Plate 80x290x20 mm 4 Nos 15.00 1.5 3.0 21

Drive stool :50 ISMC 150 x 1525 mm 2 Nos 51.00 0.6 --- ---51 ISMC 150 x 500 mm 3 Nos 25.00 0.9 3.0 2152 ISA 75x75x8 mm x 500 mm 4 Nos 14.00 0.6 2.4 1753 Plate 230x280x8 mm 1 No 4.00 0.6 0.5 454 Plate 312x330x8 mm 1 No 7.00 0.7 0.7 555 ISA 75x75x8 mm x 500 mm 2 Nos 7.00 0.3 0.2 2

Contd


244



Contd56 Plate 65x100x8 mm 3 Nos 1.00 --- --- ---57 Bolt/Nut/Washer 16 dia x 60 mm 10 Nos 3.50 --- --- ---58 Bolt/Nut/Washer 20 dia x 100 mm 4 Nos 2.00 --- --- ---59 Bolt/Nut/Washer 10 dia x 50 mm 4 Nos 0.50 --- --- ---60 Bolt/Nut/Washer 12 dia x 50 mm 4 Nos 0.50 --- --- ---61 Bolt/Nut/Washer 12 dia x 50 mm 12 Nos 1.50 --- --- ---

Drums / Gears / Pinions / Shafts :62 Rope drum 300 dia x 470 mm 2 Nos 240.00 --- --- ---63 Drum gear 2 Nos 144.00 --- --- ---64 Drum shaft 60 dia x 610 mm 2 Nos 31.00 --- --- ---65 First pinion 2 Nos 14.00 --- --- ---66 Pinion shaft 60 dia x 540 mm 2 Nos 28.00 --- --- ---67 Bearings 4 Nos 4.00 --- --- ---68 Plummer blocks for pinions 4 Nos 20.00 --- --- ---69 Line shaft 50 dia x 431 mm 2 Nos 16.00 --- --- ---70 Flexible coupling 50 dia 4 Nos 20.00 --- --- ---71 Lock plate 180x50x8 mm 4 Nos 3.00 0.2 --- ---72 Bolt/Nut/Washer 16 diax30 mm 8 Nos 1.00 --- --- ---73 Bolt/Nut/Washer 16 diax75 mm 24 Nos 6.00 --- --- ---74 Bolt/Nut/Washer 10 diax40 mm 100 Nos 10.00 --- --- ---75 Bolt/Nut/Washer 16 diax100 mm 8 Nos 2.00 --- --- ---76 Spacer pl 150/62 dia x 8 mm 4 Nos 2.00 2.6 1.9 13

Gear box cover :77 Plate 50x416x5 mm 2 Nos 2.00 0.1 0.9 478 IAS 45x45x5 mm x1920 mm 2 Nos 17.00 0.2 0.2 179 IAS 45x45x5 mm x1900 mm 4 Nos 35.00 0.4 0.4 280 Plate 50x600x5 mm 2 Nos 2.00 0.1 1.3 581 Plate 340x1600x3 mm 2 Nos 27.00 3.9 2.0 682 Plate 420x850x3 mm 2 Nos 18.00 3.8 2.0 683 Plate 420x850x3 mm 2 Nos 18.00 4.0 2.0 684 Plate 50x1600x5 mm 2 Nos 7.00 0.1 1.5 685 Plate 50x1200x5 mm 2 Nos 5.00 0.1 1.0 486 Inspection cover 200x200x3 mm 2 Nos 2.00 0.8 --- ---87 Handle 16 dia 250 mm 6 Nos 3.00 0.1 0.6 6

Drive unit cover :88 IAS 45x45x5 mm x590 mm 2 Nos 4.00 0.2 0.2 189 IAS 45x45x5 mm x247 mm 2 Nos 2.00 0.2 0.2 190 IAS 45x45x5 mm x1037 mm 2 Nos 7.00 0.2 0.2 191 IAS 45x45x5 mm x940 mm 2 Nos 6.00 0.2 0.2 192 IAS 45x45x5 mm x1570 mm 2 Nos 11.00 0.2 0.2 193 IAS 45x45x5 mm x520 mm 2 Nos 4.00 0.2 0.2 194 Plate 550x580x3 mm 1 No. 8.00 1.1 1.1 395 Plate 930x1495x3 mm 2 Nos 34.00 4.9 4.5 1496 Plate 550x930x3 mm 1 No 13.00 1.5 1.5 497 Plate 50x715x3 mm 2 Nos 2.00 0.1 1.5 498 Plate 620x1600x3 mm 1 No 25.00 2.3 2.0 6

Contd

245


length in m



Contd99 Plate 200x200x3 mm 1 No 1.00 0.4 --- ---100 Plate 250x400x3 mm 1 No 2.00 0.7 1.0 3101 Plate 100x100x3 mm 1 No 0.50 0.2 0.4 2102 Flat 50x350x5 mm 2 Nos 1.00 0.10 1.4 6103 Flat 50x100x5 mm 2 Nos 1.00 0.10 0.4 2104 Flat 50x350x5 mm 2 Nos 1.00 0.10 0.7 4105 Handle 16 dia x 450 mm 4 Nos 3.00 0.10 0.8 10106 Handle 16 dia x 350 mm 2 Nos 1.00 --- 0.4 5107 Bolt/Nut/Washer 20 dia x 30 mm 30 Nos 2.00 --- --- ---108 Bolt/Nut/Washer 12 diax40 mm 12 Nos 1.00 --- --- ---

Other components :109 Steel wire rope 12 dia 6x36 - 2 x 35 m 40.00 --- --- ---110 Rope socket with pin 2 Nos 14.00 --- --- ---111 Elecon gear unit 1 No 102.00 --- --- ---112 Electric motor 2 hp 1 No. 44.00 --- --- ---113 Ele-magnetic brake 18.00 --- --- ---114 Brake drum coupling 150 dia 7.00 --- --- ---

Total : 2947.50 85.5 129.5 825kg Rm Rm Nos


Angles / Beams / Channels / Bars : 1238.00 kgPlates / Flats : 531.00 kgChequered plate : 190.00 kg

2. Cast steel components : IS : 1030Rope drums 2 Nos Gears 2 Nos : 384.00 kgPinions : 14.00 kgPulleys 6 Nos : 108.00 kgPlummer blocks 6 Nos / couplings : 47.00 kg



5. Wire rope : IS : 226612 mm dia 6 / 36 construction 2 x 35 Rm : 40.00 kg

6. Other components :Manual operating system : 1 No.Worm reducer : 1 NosElectric motor 2 hp : 1 No.Ele-magnetic brake : 1 No.Rope socket with pin : 2 NosMS pipe 32 mm dia : 10.50 Rm


246

length in m in m



Manual operation assembly :Note: For this assembly a lumpsum rate is proposed in the data rate analysis. The details furnished

below for this assembly are only for information to assess approximate cost of the assembly.Therefore, the quantity details of this assembly are not included in the abstract of materials.


1 IAS 50x50x5 mm x 775 mm 4 Nos 14.00 0.4 0.6 42 Plummer blocks - sprocket shafts 3 Nos 6.00 --- --- ---3 Handle 1.50 --- --- ---4 Round 32 dia x 500 m / c 3.00 --- --- ---5 ISA 50x50x6 mm x 300 mm 2 Nos 3.00 0.2 0.4 56 ISA 75x75x8 mm x 210 mm 1 No 2.00 0.2 0.6 77 Round 32 dia x 361 m / c 2.00 --- --- ---8 Dog clutch 45 dia and lever 15.00 --- --- ---9 Sprocket 30 theeth 4.50 --- --- ---

10 Sprocket 15 theeth 1.00 --- --- ---11 Sprocket chain 2.50 --- --- ---12 Bolt/Nut/Washer 10 dia x 40 mm 6 Nos 0.50 --- --- ---

55.00 0.80 1.60 16kg Rm Rm Nos


Item: Manually operated Rope drum hoist for regulator radial gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of rope drum hoist without considering drive unit for cross regulator radial gate for Alamatti Left Bank Canal under Upper Krishna Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


Embedments :1 Anchor bolts 20 dia x 750 mm 16 Nos 30.00 0.4 1.0 72 Bolt / Nut / Washers 2.00 --- --- ---3 Plate 220x280x20 mm 8 Nos 77.00 4.0 --- ---

Hoist supporting structure :4 Girder ISMB-250 x 3600 mm 2 Nos 269.00 1.0 --- ---5 Rib plate 225x250x10 mm 8 Nos 35.00 3.8 1.8 136 ISMC- 150 x 500 mm 2 Nos 17.00 0.6 2.4 17

Contd


247

length in m in m




Contd7 ISMC- 150 x 1990 mm 2 Nos 61.00 0.6 2.4 178 ISMC- 250 x 790 mm 2 Nos 54.00 0.8 4.0 289 ISMC- 250 x 1990 mm 4 Nos 272.00 1.6 8.0 56

10 ISMC- 250 x 570 mm 4 Nos 78.00 1.7 8.0 5611 MS pipe 32 dia x 5250 mm 2 Nos 42.00 --- 0.5 412 Flat 50x3100x8 mm 2 Nos 20.00 0.1 0.8 613 ISA 65x65x6 mm x 1130 mm 6 Nos 39.00 0.8 --- ---14 ISA 65x65x6 mm x 3600 mm 2 Nos 42.00 0.3 14.4 10115 Bolt/Nut/Washer 12 diax50 mm 12 Nos 2.00 --- --- ---16 Rib plate 200x250x10 mm 6 Nos 14.00 2.7 4.6 3217 Chequered pl 400x687x6 mm 2 Nos 29.00 2.2 2.2 1518 Chequered pl 525x1935x6 mm 2 Nos 109.00 4.9 4.9 3419 Chequered pl 247x560x6 mm 1 No. 7.00 0.8 0.8 620 Chequered pl 587x630x6 mm 2 Nos 40.00 2.4 2.4 1721 Chequered pl 162x560x6 mm 1 No. 5.00 0.8 0.8 622 Plate 250x350x16 mm 4 Nos 44.00 2.4 3.2 2223 R/F plate 120/62 dia x 8 mm 4 Nos 1.00 2.3 1.5 1124 Plate 120x470x20 mm 2 Nos 18.00 1.2 0.8 625 Plate 80x80x10 mm 4 Nos 2.00 0.6 1.3 9

Pulleys and accessories :26 CI Pulley 300 dia 2 Nos 36.00 --- --- ---27 Pin 60 dia x 200 mm 2 Nos 16.00 --- --- ---28 Bronz bush 80/60 dia x 50 mm 2 Nos 2.00 --- --- ---29 Plate 40x90x8 mm 4 Nos 2.00 0.5 --- ---30 Bolt/Nut/Washer 12 diax30 mm 16 Nos 2.00 --- --- ---31 Pulley pin 50 dia x 250 mm 2 Nos 8.00 --- --- ---32 Lock plate 50x90x10 mm 8 Nos 8.00 --- --- ---33 Spacer 130/60 dia x 25 mm 2 Nos 6.00 --- --- ---34 Spacer 130/60 dia x 8 mm 4 Nos 2.50 --- --- ---35 CI Pulley 276 dia 4 Nos 72.00 --- --- ---36 Bronz bush 80/60 dia x 60 mm 4 Nos 4.50 --- --- ---

Gear box :37 ISMC 250 x 880 mm 2 Nos. 60.00 1.0 --- ---38 ISMC 250 x 570 mm 2 Nos. 39.00 1.0 0.8 639 ISMC 250 x 660 mm 2 Nos. 45.00 1.0 0.8 640 ISMC 250 x 450 mm 2 Nos. 31.00 1.0 0.8 641 ISMC 250 x 260 mm 2 Nos. 14.00 1.0 0.8 642 ISMC 250 x 400 mm 2 Nos. 27.00 1.0 1.6 1143 Plate 60x880x10 mm 2 Nos 8.00 0.2 1.8 1344 Plate 60x220x10 mm 2 Nos 2.00 0.2 0.7 545 Stiffener 75x90x10 mm 12 Nos 4.00 2.0 3.9 2746 Plate 250x400x20 mm 4 Nos 63.00 2.6 4.0 2847 Plate 75x240x10 mm 2 Nos 3.00 0.6 1.6 1148 Plate 130x240x10 mm 8 Nos 20.00 3.0 6.4 4549 Plate 80x290x20 mm 4 Nos 15.00 1.5 3.0 21

Contd

248


length in m



ContdDrive stool :

50 ISMC 150 x 1525 mm 2 Nos 51.00 0.6 --- ---51 ISMC 150 x 500 mm 3 Nos 25.00 0.9 3.0 2152 ISA 75x75x8 mm x 500 mm 4 Nos 14.00 0.6 2.4 1753 Plate 230x280x8 mm 1 No 4.00 0.6 0.5 454 Plate 312x330x8 mm 1 No 7.00 0.7 0.7 555 ISA 75x75x8 mm x 500 mm 2 Nos 7.00 0.3 0.2 256 Plate 65x100x8 mm 3 Nos 1.00 --- --- ---57 Bolt/Nut/Washer 16 dia x 60 mm 10 Nos 3.50 --- --- ---58 Bolt/Nut/Washer 20 dia x 100 mm 4 Nos 2.00 --- --- ---59 Bolt/Nut/Washer 10 dia x 50 mm 4 Nos 0.50 --- --- ---60 Bolt/Nut/Washer 12 dia x 50 mm 4 Nos 0.50 --- --- ---61 Bolt/Nut/Washer 12 dia x 50 mm 12 Nos 1.50 --- --- ---

Drums / Gears / Pinions / Shafts :62 Rope drum 300 dia x 470 mm 2 Nos 240.00 --- --- ---63 Drum gear 2 Nos 144.00 --- --- ---64 Drum shaft 60 dia x 610 mm 2 Nos 31.00 --- --- ---65 First pinion 2 Nos 14.00 --- --- ---66 Pinion shaft 60 dia x 540 mm 2 Nos 28.00 --- --- ---67 Bearings 4 Nos 4.00 --- --- ---68 Plummer blocks for pinions 4 Nos 20.00 --- --- ---69 Line shaft 50 dia x 431 mm 2 Nos 16.00 --- --- ---70 Flexible coupling 50 dia 4 Nos 20.00 --- --- ---71 Lock plate 180x50x8 mm 4 Nos 3.00 0.2 --- ---72 Bolt/Nut/Washer 16 diax30 mm 8 Nos 1.00 --- --- ---73 Bolt/Nut/Washer 16 diax75 mm 24 Nos 6.00 --- --- ---74 Bolt/Nut/Washer 10 diax40 mm 100 Nos 10.00 --- --- ---75 Bolt/Nut/Washer 16 diax100 mm 8 Nos 2.00 --- --- ---76 Spacer pl 150/62 dia x 8 mm 4 Nos 2.00 2.6 1.9 13

Gear box cover :77 Plate 50x416x5 mm 2 Nos 2.00 0.1 0.9 478 IAS 45x45x5 mm x1920 mm 2 Nos 17.00 0.2 0.2 179 IAS 45x45x5 mm x1900 mm 4 Nos 35.00 0.4 0.4 280 Plate 50x600x5 mm 2 Nos 2.00 0.1 1.3 581 Plate 340x1600x3 mm 2 Nos 27.00 3.9 2.0 682 Plate 420x850x3 mm 2 Nos 18.00 3.8 2.0 683 Plate 420x850x3 mm 2 Nos 18.00 4.0 2.0 684 Plate 50x1600x5 mm 2 Nos 7.00 0.1 1.5 685 Plate 50x1200x5 mm 2 Nos 5.00 0.1 1.0 586 Inspection cover 200x200x3 mm 2 Nos 2.00 0.8 --- ---87 Handle 16 dia 250 mm 6 Nos 3.00 0.1 0.6 4

Other components :88 Steel wire rope 12 dia 6x36 - 2 x 35 m 40.00 --- --- ---89 Rope socket with pin 2 Nos 14.00 --- --- ---90 Elecon gear unit 1 No 102.00 --- --- ---

Total : 2749.00 72.7 112.6 755kg Rm Rm Nos

249

Gas cutting Weld lengthin mlength in m



Angles / Beams / Channels / Bars : 1193.00 kgPlates / Flats : 442.00 kgChequered plate : 190.00 kg

2. Cast steel components : IS : 1030Rope drums 2 Nos Gears 2 Nos : 384.00 kgPinions : 14.00 kgPulleys 6 Nos : 108.00 kgPlummer blocks 6 Nos / couplings : 47.00 kg



5. Wire rope : IS : 226612 mm dia 6 / 36 construction 2 x 35 Rm : 40.00 kg

6. Other components :Manual operating system : 1 No.Worm reducer : 1 NosRope socket with pin : 2 NosMS pipe 32 mm dia : 10.50 Rm

7. Other details :Length of cutting : 73 RmLength of welding : 113 RmNumber of electrodes ( for structural steel ) : 755 NosManual operation assembly :

Note: For this assembly a lumpsum rate is proposed in the data rate analysis. The details furnishedbelow for this assembly are only for information to assess approximate cost of the assembly.Therefore, the quantity details of this assembly are not included in the abstract of materials.


1 IAS 50x50x5 mm x 775 mm 4 Nos 14.00 0.4 0.6 42 Plummer blocks - sprocket shafts 3 Nos 6.00 --- --- ---3 Handle 1.50 --- --- ---4 Round 32 dia x 500 m / c 3.00 --- --- ---5 ISA 50x50x6 mm x 300 mm 2 Nos 3.00 0.2 0.4 26 ISA 75x75x8 mm x 210 mm 1 No 2.00 0.2 0.6 47 Round 32 dia x 361 m / c 2.00 --- --- ---8 Dog clutch 45 dia and lever 15.00 --- --- ---9 Sprocket 30 theeth 4.50 --- --- ---

10 Sprocket 15 theeth 1.00 --- --- ---11 Sprocket chain 2.50 --- --- ---12 Bolt/Nut/Washer 10 dia x 40 mm 6 Nos 0.50 --- --- ---

55.00 0.80 1.60 10kg Rm Rm Nos

250

Weld lengthGas cutting length in m in m



Item: Embedded parts for vertical lift Regulator / Escape gate :( With top seal seat arrangement )Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of embedded parts for vertical lift roller gate provided for Alamatti Left Bank Canal Escape structure under Upper Krishna Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 5 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


Sill beam :1 SS seal seat 60x2200x6 mm 1 No. 6.50 0.1 F4 4.5 202 Plate 400x2600x10 mm 1 No. 82.00 3.0 --- ---3 ISA 75x75x8 x 2600 mm 2 Nos 46.50 0.3 10.4 734 Anchor rod 16 dia x 300 mm 10 Nos 5.00 0.2 0.5 4

Roller track :5 SS track plate 80x4800x8 mm 2 Nos 48.50 0.2 19.5 1376 ISMC 300 x 4800 mm 2 Nos 349.00 1.0 1.6 117 Half ISMB 250 x 4800 mm 2 Nos 180.00 5.3 19.2 1348 Stiffener 110x120x10 mm 20 Nos 19.00 4.6 13.4 949 Stiffener 110x170x10 mm 20 Nos 32.00 5.6 15.4 108

10 Anchor rod 16 dia x 300 mm 40 Nos 19.00 0.6 2.0 14Side seal track :

11 SS seal seat 60x2250x6 mm 2 Nos 13.00 0.1 F4 9.2 4112 ISMC 300 x 4800 mm 2 Nos 349.00 1.0 1.6 1113 ISA 75x75x8 x 300 mm 20 Nos 53.50 3.0 18.0 12614 Anchor rod 16 dia x 300 mm 40 Nos 19.00 0.6 2.0 14

Guide :15 Plate 400x4800x10 mm 2 Nos 301.50 10.4 39.2 27416 ISA 75x75x8 x 4800 mm 2 Nos 85.50 0.3 19.2 13417 Plate 40x4800x25 mm 2 Nos 75.50 0.1 19.2 134

Top seal track :18 SS seal seat 120x2040x6 mm 1 No. 11.50 2.1 F4 4.3 1919 ISMC 300 x 2000 mm 1 No. 73.00 0.5 1.2 820 Plate 90x300x10 mm 2 Nos 4.50 0.2 1.9 1321 ISA 75x75x8 x 300 mm 4 Nos 6.00 0.6 3.8 2722 Anchor rod 16 dia x 300 mm 8 Nos 4.00 0.1 0.4 323 Bolt/Nut/Washer 20 dia x 80 mm 4 Nos 0.50 --- --- ---

Total : 1784.00 39.9 206.5 1399kg Rm Rm Nos



251

in mlength in mGas cutting Weld length






Item: Vertical lift roller gate for Regulator / Escape :( With top seal arrangement )Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of vertical lift roller gate provided for Alamatti Left Bank Canal Escape structure under Upper Krishna Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 5 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


1 Skin plate 2200x2480x10 mm 1 No. 428.00 4.7 --- ---2 End girder pl 230x2200x10 mm 4 Nos 159.00 9.8 17.6 1233 H-girder half ISMB 450 x 2260 mm 2 Nos 163.50 2.6 10.2 714 Stiffener ISA 75x75x8 x 2260 mm 1 No. 20.00 0.2 5.1 365 Ver stiffener half ISMB450 x 340 mm 1 12.00 0.5 2.2 156 Ver stiffener half ISMB450 x 1340 mm 1 48.50 2.0 4.0 287 Stiffener 340x150x10 mm 4 Nos 16.00 2.0 5.1 368 Stiffener 150x1340x10 mm 4 Nos 63.00 6.9 13.1 929 Stiffener 150x490x10 mm 4 Nos 23.00 2.6 5.1 36

10 Stiffener 150x200x10 mm 2 Nos 5.00 0.8 1.6 1111 Stiffener 150x250x10 mm 2 Nos 6.00 0.8 1.6 1112 Plate 230x500x10 mm 2 Nos 18.00 1.5 3.5 2513 Stiffener 80x230x10 mm 6 Nos 5.00 0.5 5.5 3914 Cover plate 160x160x10 mm 8 Nos 16.00 3.8 --- ---15 Cover plate 80x160x10 mm 4 Nos 4.00 0.6 --- ---16 Cover plate 160 dia x 10 mm 4 Nos 6.50 2.0 --- ---17 Seal base pl 40x2130x10 mm 2 Nos 13.50 0.1 8.7 6118 Clamp plate 40x2175x10 mm 2 Nos 13.50 0.1 --- ---19 Side seal 30 diax90 x 1975 mm 2 Nos --- --- ---20 Clamp plate 70x2060x10 mm 1 No 11.50 0.1 --- ---21 Seal support 12x2060x12 mm 1 No. 2.50 2.1 4.1 2922 Bottom seal 76x2250x10 mm 1 No. --- --- ---23 Top seal 30 diax90 x 1850 mm 1 No. --- --- ---24 Clamp plate 40x2160x10 mm 1 No. 7.00 --- --- ---

Contd

252




Contd25 Seal base pl 40x2250x10 mm 1 No. 7.00 --- 4.5 3226 Plate for guide rollers 72.00 1.4 1.8 1327 Guide roller 4 Nos 8.00 --- --- ---28 Wheel bush 4 Nos 5.00 --- --- ---29 Lifting pin 90 dia x150 mm 1 No. 9.00 --- --- ---30 Keeper plate 50x110x10 mm 1 No. 0.50 --- --- ---31 Bolt/Nut/Washer 12 dia x 20 mm 28 Nos 2.00 --- --- ---32 Corner seal 200x200 mm 2 Nos --- --- ---33 Bolt/Nut/Washer 12 dia x 20 mm 16 Nos 0.50 --- --- ---34 Bolt/Nut/Washer 12 dia x 40 mm 16 Nos 1.00 --- --- ---35 Wheel 200/80 dia x 50 mm 4 Nos 41.50 --- --- ---36 Wheel axle 60 dia x 176 mm 4 Nos 21.00 --- --- ---37 Seal bolts/nuts 12 dia x 40 mm 110 Nos 7.50 --- --- ---

Total : 1216.50 45.1 93.7 658kg Rm Rm Nos






5. Rubber seals : IS : 11855Bottom rubber seal ( uncladed ) : 2.25 RmSide rubber seal ( uncladed ) : 3.95 RmTop rubber seal ( uncladed ) : 1.85 Rm

6. Bolt / Nut / Washer IS : 1363GI Bolt / Nut / Washer : 7.50 kgMS Bolt / Nut / Washer : 3.50 kg



Item: 3 t capacity screw hoist for vertical lift roller gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of embedded parts for vertical lift roller gate for Alamatti Left Bank Canal Escape structure under Upper Krishna Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 5 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.

253

Weld lengthGas cutting length in m in m


4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


Hoist platform :1 ISMB 250 x 2600 mm 2 Nos 194.00 1.0 --- ---2 ISMC 200 x 2125 mm 2 Nos 95.00 0.7 --- ---3 Chequered plate 1000x1900x5 mm 2 Nos 172.00 3.8 --- ---4 ISA 65x65x6 x 1990 mm 2 Nos 23.00 0.3 0.4 35 ISA 50x50x6 x 2600 mm 2 Nos 23.50 0.2 0.4 36 ISA 50x50x6 x 1255 mm 6 Nos 34.00 0.6 --- ---7 Plate 50x2000x5 mm 2 Nos 8.00 0.1 0.2 28 Plate 135x250x10 mm 8 Nos 21.00 3.1 6.0 429 Plate 300x300x16 mm 8 Nos 90.50 4.8 --- ---

10 Plate 200x205x10 mm 6 Nos 19.00 2.4 3.0 2111 Pipe 32 dia x 4400 mm 2 Nos 23.00 --- --- ---12 Anchor rod 20 dia x 500 mm 16 Nos 23.00 0.3 --- ---13 Bolt/Nut/Washer 8.00 --- --- ---

Hoist parts :14 Hoist body 1 No. 36.00 --- --- ---15 Hoist stem 60 dia x 3400 mm 1 No. 75.50 --- --- ---16 Lock nut 1 No. 3.00 --- --- ---17 Main nut 1 No. 16.00 --- --- ---18 Thrust bearing 2 Nos 4.00 --- --- ---19 Plate 120x150x10 mm 2 Nos 2.50 0.5 --- ---20 Plate 40x40x10 mm 4 Nos 0.50 0.2 --- ---

Total : 871.50 18.0 10.0 71kg Rm Rm Nos


Angle / Channel / Beam / Bars : 392.50 kgPlates / Flats : 141.50 kgChequered plate : 172.00 kg

2. Cast iron components : IS : 1030Hoist body / Lock nut / Main nut : 55.00 kg


4. Alloy steel components : IS : 1570Hoist stem : 75.50 kg


6. Other components :Pipe 32 mm dia : 8.80 Rm

7. Other details :Length of cutting : 18.00 RmLength of weld : 10.00 RmNumber of electrodes ( for structural steel ) : 71 Nos

254




Item: Embedded parts for Regulator / Escape stoplog gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of embedded parts for cross regulator stoplog gate for Alamatti Left Bank Canal cross regulator under Upper Krishna Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 5 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


Sill beam :1 SS seal seat 60x2200x6 mm 1 No. 6.50 0.1 F4 4.5 202 Plate 400x2600x10 mm 1 No. 82.00 3.0 --- ---3 ISA 75x75x8 x 2600 mm 2 Nos 46.50 0.3 10.4 734 Anchor rod 16 dia x 300 mm 10 Nos 5.00 0.2 0.5 4

Roller track :5 SS track plate 80x4800x8 mm 2 Nos 48.50 0.2 19.5 1376 ISMC 300 x 4800 mm 2 Nos 349.00 1.0 1.6 117 Half ISMB 250 x 4800 mm 2 Nos 180.00 5.3 19.2 1348 Stiffener 110x120x10 mm 20 Nos 19.00 4.6 13.4 949 Stiffener 110x170x10 mm 20 Nos 32.00 5.6 15.4 108

10 Anchor rod 16 dia x 300 mm 40 Nos 19.00 0.6 2.0 14Side seal track :

11 SS seal seat 60x2250x6 mm 2 Nos 13.00 0.1 F4 9.3 4212 ISMC 300 x 4800 mm 2 Nos 349.00 1.0 1.6 1113 ISA 75x75x8 x 300 mm 20 Nos 53.50 3.0 18.0 12614 Anchor rod 16 dia x 300 mm 40 Nos 19.00 0.6 2.0 14

Guide :15 Plate 400x4800x10 mm 2 Nos 301.50 10.4 39.2 27416 ISA 75x75x8 x 4800 mm 2 Nos 85.50 0.3 19.2 13417 Plate 40x4800x25 mm 2 Nos 75.50 0.1 19.2 134

Total : 1684.50 36.4 195.0 1330kg Rm Rm Nos





255

in mWeld length

length in mGas cutting



Item: Stoplog gate for Regulator :( Data for one element )Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of stoplog gate elements for cross regulator of Alamatti Left Bank Canal under Upper Krishna Project in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 5 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


1 Skin plate 990x2450x10 mm 1 No. 190.00 3.4 --- ---2 ISMB 250 x 2293 mm 2 Nos 171.00 1.0 9.6 673 ISMB 250 x 980 mm 2 Nos 73.00 1.0 4.4 314 Plate 150x250x10 mm 2 Nos 4.00 0.7 0.4 35 ISMB 250 x 237 mm 2 Nos 18.00 1.0 1.4 106 ISMB 250 x 493 mm 1 No. 18.50 0.5 1.2 87 Plate 150x493x10 mm 2 Nos 11.50 1.3 2.0 148 Plate 150x237x10 mm 4 Nos 11.50 1.6 4.3 309 Plate 200x237x10 mm 4 Nos 15.00 1.8 5.1 36

10 Plate 200x493x10 mm 2 Nos 15.50 1.4 3.6 2511 Plate 100x260x10 mm 5 Nos 10.00 0.5 --- ---12 Plate 50x1000x10 mm 2 Nos 8.00 0.1 4.0 2813 Slide blocks 50x25x20 mm 4 Nos 1.00 0.1 F8 0.6 1114 Plate 50x2200x10 mm 1 Nos 8.50 --- 4.4 3115 Plate 70x250x10 mm 2 Nos 3.00 0.2 2.3 1616 Plate 150x300x10 mm 4 Nos 14.00 1.8 1.2 817 Plate 110x250x10 mm 2 Nos 4.50 0.7 1.5 1118 Pin 50 dia x 100 mm 2 Nos 3.00 --- --- ---19 Seal base 50x980x10 mm 2 Nos 9.50 0.1 4.0 2820 ISA 45x45x6 x 1000 mm 2 Nos 8.00 0.1 --- ---21 Side seal 1005 mm 2 Nos --- --- --- ---22 Plate 10x1860x10 mm 1 No. 1.50 --- 3.9 2723 Seal clamp 70x1860x10 mm 1 No. 10.00 0.1 --- ---24 Bottom seal 76x2000 mm 1 No. --- --- --- ---25 Plates for 4 Guide shoe assembly 18.00 1.3 1.8 1326 Bolt/Nut/Washer 12 dia x 65 mm 16 Nos 1.50 --- --- ---27 GI Bolt/Nut/Washer 12 dia x 50 mm 28 2.50 --- --- ---28 GI Bolt/Nut/Washer 12 dia x 60 mm 30 2.50 --- --- ---

Total for 1 element : 633.50 18.7 55.7 397 Total for 4 elements : 2534.00 74.8 222.8 1588

kg Rm Rm NosABSTRACT :

1. Structural steel : IS :2062Angle / Channel / Beam / Bars : 1154.00 kgPlates / Flats : 1342.00 kg

length in m in m

256



2. Alloy steel components : IS : 1570Hook pins : 12.00 kg

3. Rubber seal : IS : 11855Bottom rubber seal ( uncladded ) : 8.00 RmSide rubber seal ( uncladded ) : 8.04 Rm

4. Bolt / Nut / Washer : IS :1363GI Bolt / Nut / Washer : 20.00 kgMS Bolt / Nut / Washer : 6.00 kg



Item: Embedded parts for trash rack structure of pump hpuse / penstock intake.( Data for one vent / bay )Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of embedded parts for coarse screen for pump house intake of Maralihalla pump house for Bellary Thermal station in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


1 Plate 350x12000x10 mm 2Nos. 659.4 24.72 Plate 170x12000x10 mm 4 Nos 640.56 48.7 96 9603 Flat 50x150x8 mm 46 Nos 21.66 4.6 2.3 23

Total for 1 vent : 1321.62 78.0 98.3 983kg Rm Rm Nos


Plates / Flats : 1322.00 kg 2. Other details :



Item: Coarse and Fine screens for pump house intake ( Data for one vent ).Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on fabrication drawings of coarse and fine screens for pump house intake of Maralihalla pump house for Bellary Thermal station in Karnataka.2. Plate cutting considered for 2 sides assuming other 2 sides free face.

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3. Unless otherwise specified 6 mm thick fillet weld considered for computing requirement of welding electrodes and 450 mm long electrodes are considered for computing the quantity.4. Number of welding electrodes computed is based on length, type and thickness of weld and the requirement of electrodes per metre length of weld is based on standard welding tables.


For one panel :Coarse screen ( Trash rack ) :

1 ISMC 250x80x3750 mm 2 Nos 228.00 0.82 ISMC 250x80x3750 mm 2 Nos 164.16 0.8 1.8 183 ISMB 250x125x3736 mm 3 Nos 418.05 3.9 4.8 484 Flat 50x2680x10 mm 28 Nos 294.53 1.4 1.1 115 Plate 200x200x10 mm 4Nos 12.56 2.6 2.6 266 Plate 320x370x12 mm 2 Nos 11.15 3.4 2.6 267 Plate 170x300x12 mm 2 Nos 9.60 1.7 1.6 16

Fine screen frame :8 Angle 65x65x8x2700 mm 8 Nos 166.32 1.8 4.0 409 Angle 65x65x8x235 mm 42 Nos 76.00 5.5 16.8 168

10 Angle 65x65x8x3430 mm 2 Nos 26.50 0.311 Flat 50x2680x10 mm 7 Nos 73.60 0.4 2.8 2812 Flat 50x235x10 mm 56 Nos 51.65 2.8 11.2 11213 Weld mesh 2700x3440 mm 1 No 20.00

( 2 mm dia 25x25 mm opening )14 Bolt/Nut/Washer 16 dia x 45 mm 38 6.7015 40 dia x 150 mm rod 2 Nos 3.00 0.3 3

Total for 1 panel : 1561.82 25.3 49.6 496 Total for 3 panels of 1 vent : 4685.46 76.0 148.7 1488

kg Rm Rm Nos



2. Weld mesh ( 2 mm dia 25x25 mm opening ) : 27.86 sqm 3. GI Bolt / Nut / Washer : 20.10 kg 4. Other details :


length in m in m

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Weld lengthGas cutting

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