GATE / HOIST AND ALLIED WORKS

Total : 492 hours Deploy welding transformer for 492 hours. 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 sqm 1 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 ltr 4 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 ltr 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 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. 6. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections 95 hours 6 12 12 24 Fabricating by stitch welding 123 hours 8 15 --30 Run welding 369 hours 5 --46 46 Cleaning surface 37.4 sqm @15 sqm/day ------2 Painting ( 5x37.4 ) sqm @ 15 sqm / day ------14 Finishing / Cleaning 1 1 --1 Total : 20 28 58 117 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 12 Painters Cl-II at 15 sqm / day and 2 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 all 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. 8. Use rate of materials : Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00 Life of welding set : 1000 hours Use rate of welding set per hour ( cost / life ) Rs: 4.50 Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00 Life of gas cutting set : 600 hours Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50 RATE ANALYSIS A. MATERIALS: Sl No 1 2 Perticulars Unit kg cum Quantity 7463.00 168.00 UNIT : 37.400 sqm Rate in Rs. 40.00 48.00 Amount in Rs. 298520.00 8064.00

Structural steel plates / flats Oxygen gas

60

GATE / HOIST AND ALLIED WORKS

3 4

Acetyline gas Welding electrodes ( general purpose )

cum Nos

56.00 461.00

258.00 6.00 Contd

14448.00 2766.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

5 6 7 8 9 10 11 12

Welding electrodes ( low hydrogen ) Zinc rich epoxy primer Coal tar epoxy paint Rust cleaner / inhibitor Use rate welding holder set Use rate gas cutting torch set Wire brush Sundries Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @

Nos ltr ltr ltr Hour Hour Nos LS

4152.00 4.00 25.00 5.00 492.00 18.00 1.00 5.00

1% 10% 5% Total cost of Materials :

Rate in Rs. Contd 12.00 594.00 208.00 240.00 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 49824.00 2376.00 5200.00 1200.00 2214.00 45.00 30.00 150.00 384837.00 3848.37 38483.70 19241.85 446410.92

B. MACHINERY: Sl No 1 2 3 4 5 6

Description

Unit Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour LS

Quantity 492.00 308.00 77.00 77.00 4.00 4.00 16.00 16.00 12.00 12.00 5.00

Welding transformer Fuel / Energy charges Pug cutting machine Fuel / Energy charges Mobile crane 8 t Fuel / Energy charges Stationery derric crane Fuel / Energy charges Grinding machine Fuel / Energy charges Sundries

Add for small Tools and Plants @ 1% Add for Contractor's Profit on DPOL / Energy @ 10% Add for Contractor's Overheads @ 5% Total hire charges of Machinery : C. LABOUR: Sl No 1 2 3 4 5 6 7

Rate in Rs. 12.00 60.00 16.00 3.00 362.00 495.00 66.00 9.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 5904.00 18480.00 1232.00 231.00 1448.00 1980.00 1056.00 144.00 216.00 300.00 150.00 31141.00 311.41 2128.50 1557.05 35137.96

Description

Unit Hour Hour Day Day Day Day Day

Quantity 4.00 12.00 20.00 28.00 12.00 46.00 101.00

Crew for Mobile crane Crew for Grinding machine Foreman Marker / Fabricator / Erector Gas cutter Welder ( General ) Helper fabrication / erection

Rate in Rs. 75.70 59.50 177.00 157.50 157.50 157.50 141.50

Amount in Rs. 302.80 714.00 3540.00 4410.00 1890.00 7245.00 14291.50

61

GATE / HOIST AND ALLIED WORKS

Helper for cleaning / painting

Day

4.00

141.50 Contd

566.00

C. LABOUR ( Contd ) : Sl No Description

Unit

Quantity

9 10

Painter Cl - II Electrician Add for small Tools and Plants @ Add for Contractor's Profit @ Add for hidden cost on Labour @ Add for additional hidden cost on labour @ Add for Contractor's Overheads @

Day Day

12.00 1.00

1% 10% 15% 15% 5% Total cost of Labour :

Rate in Rs. Contd 141.50 143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 1698.00 143.00 34800.30 348.00 3480.03 5220.05 5220.05 1740.02 50808.44

ABSTRACT: A. Cost of Materials B. Hire charges of Machinery C. Cost of Labour Add for excise duty on 75 percent cost of Machinery / Labour components @ Add for insurance charges @ Add for designs and drawings @ Add for zigs / supports / winches / chain-pulley @ Add for power supply arrangements @ Add for enabling works @

Rs: Rs: Rs: TOTAL Rs: 8.24% 1.00% 2.50% 2.50% 2.00% 1.40% Rs: Rs: Rs: Rs: Rs: Rs: Total Rs: Rs: Rs: Rs: Rs: Rs:

446410.92 35137.96 50808.44 532357.32 5311.49 5323.57 13308.93 13308.93 10647.15 7453.00 587710.39 1879.95 17631.31 607221.66 16200.00 16200.00 ITEM No: 13

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 7.281 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 37.400 sqm Rate per sqm Rate approved per sqm SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type vertical lift service gate consisting of skin plate, vertical and horizontal 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 three coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with all leads and lifts. DATA: Consider upstream seal vertical lift roller gate. The gate leaf consists of skin plate, horizontal girders, vertical end girders, stiffeners, wheels, gate guide rollers, brackets for pulleys, seals 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.

62

GATE / HOIST AND ALLIED WORKS

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 x H x h ) 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 ) : 9.229 The weight computed as above based on empirical formula is further checked by computing the actual 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 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of river sluice gate provided for one of the dam for rate analysis ( for details refer Item : 13 of Annexure-2 ). Requirement of materials : Structural steel conforming to IS : 2062 : Plates / flats with 2.5 % wastage ( 4370 x 1.025 ) : 4479 kg Cast iron components conforming to IS : 210 : Cast iron blocks for counter weight ( 4000 x 1.025 ) : 4100 kg Alloy steel components conforming to IS : 1570 : Wheel axles / Pins : 132 kg Cast steel components conforming to IS : 1030 : Wheels / guide rollers : 492 kg Alluminium / Bronze alloy components conforming to IS : 305 : Bearings / Bushes : 76 kg Bolts / Nuts / Washers conforming to IS : 1363 : SS bolts / nuts / washers with 2.5 % wastage ( 54 x 1.025 ) : 55 kg GI bolts / nuts / washers with 2.5 % wastage ( 74 x 1.025 ) : 76 kg MS bolts / nuts / washers with 2.5 % wastage ( 4 x 1.025 ) : 4 kg Rubber seal conforming to IS : 11855 : Bottom seal ( flat type ) ( 2.76 x 1.025 ) : 2.8 Rm Side seals ( music note type teflon claded ) ( 5.71 x 1.025 ) : 5.85 Rm Top seal ( music note type teflon claded ) ( 2.2 x 1.025 ) : 2.25 Rm Corner seal ( teflon claded ) : 2 Nos Welding electrodes ( General purpose / Low hydrogen ) : GP / LH electrodes as per data sheet ( Item:13 Annexure-2 ) : 3265 Nos Add for variations / wastage / misc welding @ 10 % ( 3265 x 0.1 ) : 326 Nos Total 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 Cutting : Length of cutting assuming cutting for 2 sides as per data sheet : 137 Rm Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 14 Rm Total : 151 Rm For cutting structural steel sections to required sizes gas cutting is assumed since most of the sections are above 10 mm thick. Length of steel to be cut by using gas manually : 30 m Length of steel to be cut by gas using pug cutting machine : 121 m Time for gas cutting manually at ( av ) 2 m cutting / hour : 15 hours Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 40 hours Acetelyne gas @ 0.6 cum / hour ( 15 + 40 ) x 0.60 : 33 cum Oxygen gas @ 1.8 cum / hour ( 15 + 40 ) x 1.80 : 99 cum
0.659 2 0.659

1. a. b. c. d. e. f.

g.

h.

2.

63

GATE / HOIST AND ALLIED WORKS

Use of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) Use of pug cutting machine with 50 min / hr working ( 40 x 60 / 50 ) 3. Welding : Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 359 / 15 ) x 8 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 3232 / 15 ) x 8 / 6 Total

: 18 hours : 48 hours : 281 Rm : 96 hours : 287 hours : 383 hours

4.

5.

6.

Note :

7.

Deploy welding transformer for 383 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 96 x 0.25 + 287 x 0.75 ) : 239 hours Surface cleaning and painting : Painting area for river sluice gate at 10 sqm / tonne ( 9.202 x 10 ) : 92 sqm 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 ltr 3 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 ltr 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 92 sqm @ 8 sqm / ltr : 12 ltr 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 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. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections 66 hours 4 8 8 16 Drilling holes for seal fixing 1 2 --2 Fabricating by stitch welding 96 hours 6 12 --24 Run welding 287 hours 3 --36 36 Fixing counter weight blocks --2 --4 Seal fixing 1 1 --2 Cleaning surface 92 sqm @ 15 sqm/day ------6 Painting ( 4 x 92 ) sqm @ 15 sqm / day ------30 Guide roller fixing / Cleaning / Lowering 1 2 --2 Total : 16 27 44 122 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. Excise duty on supply : Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all

64

GATE / HOIST AND ALLIED WORKS

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. 8. Use rate of materials : Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00 Life of welding set : 1000 hours Use rate of welding set per hour ( cost / life ) Rs: 4.50 Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00 Life of gas cutting set : 600 hours Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50 RATE ANALYSIS A. MATERIALS: Sl No 1 2 3 4 5 6 Perticulars Unit Quantity UNIT : 9.202 tonne Rate in Rs. 40.00 32.00 215.00 125.00 635.00 150.00 95.00 55.00 147.00 675.00 675.00 740.00 48.00 258.00 6.00 12.00 594.00 208.00 240.00 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs: Amount in Rs. 179160.00 131200.00 28380.00 61500.00 48260.00 8250.00 7220.00 220.00 411.60 3948.75 1518.75 1480.00 4752.00 8514.00 2154.00 38784.00 5940.00 9568.00 2880.00 1723.50 45.00 30.00 150.00 546089.60 5460.90 54608.96 27304.48 633463.94

8 9 10 11 12 13 14 15 16 17 18

Structural steel Plates / flats Cast iron components CI blocks for counter wt Alloy steel components Wheel axles / Pins Cast steel components Wheels / Guide rollers Alluminium / Bronze alloy components Bearings / Bushes Bolt / Nut / Washer SS bolts / nuts / washers GI bolts / nuts / washers MS bolts / nuts / washers Rubber seals Bottom seal ( flat uncladed ) Side seals ( bulb teflon claded ) Top seal ( bulb teflon claded ) Corner seals ( bulb teflon claded ) Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen ) Zinc rich epoxy primer Coal tar epoxy paint Rust cleaner / inhibitor Use rate welding holder set Use rate gas cutting torch set Wire brush Sundries Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @

kg kg kg kg kg kg kg kg Rm Rm Rm Nos cum cum Nos Nos ltr ltr ltr Hour Hour Nos LS

4479.00 4100.00 132.00 492.00 76.00 55.00 76.00 4.00 2.80 5.85 2.25 2.00 99.00 33.00 359.00 3232.00 10.00 46.00 12.00 383.00 18.00 1.00 5.00

1% 10% 5% Total cost of Materials :

65

GATE / HOIST AND ALLIED WORKS

B. MACHINERY: Sl No 1 2 3 4 5 6 7 8

Description

Unit Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour LS

Quantity 383.00 239.00 48.00 48.00 1.00 1.00 4.00 4.00 10.00 10.00 8.00 8.00 12.00 12.00 5.00

Welding transformer Fuel / Energy charges Pug cutting machine Fuel / Energy charges Tower crane Fuel / Energy charges Mobile crane 8 t Fuel / Energy charges Stationery derric crane Fuel / Energy charges Grinding machine Fuel / Energy charges Drilling machines Fuel / Energy charges Sundries

Add for small Tools and Plants @ 1% Add for Contractor's Profit on DPOL / Energy @ 10% Add for Contractor's Overheads @ 5% Total hire charges of Machinery : C. LABOUR: Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13

Rate in Rs. 12.00 60.00 16.00 3.00 994.00 130.00 362.00 495.00 66.00 9.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 4596.00 14340.00 768.00 144.00 994.00 130.00 1448.00 1980.00 660.00 90.00 144.00 200.00 216.00 300.00 150.00 26160.00 261.60 1733.40 1308.00 29463.00

Description

Unit Hour Hour Hour Hour Day Day Day Day Day Day Day Day Day

Quantity 4.00 1.00 12.00 8.00 16.00 27.00 8.00 32.00 4.00 86.00 11.00 25.00 2.00

Crew for Mobile crane Crew for Tower crane Crew for Drilling machine Crew for Grinding machine Foreman Marker / Fabricator / Erector Gas cutter Welder ( General ) Welder ( X - ray grade ) Helper fabrication / erection Helper for cleaning / painting Painter Cl - II Electrician Add for small Tools and Plants @ Add for Contractor's Profit @ Add for hidden cost on Labour @ Add for additional hidden cost on labour @ Add for Contractor's Overheads @

1% 10% 15% 15% 5% Total cost of Labour :

Rate in Rs. 75.70 62.00 59.50 59.50 177.00 157.50 157.50 157.50 173.25 141.50 141.50 141.50 143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 302.80 62.00 714.00 476.00 2832.00 4252.50 1260.00 5040.00 693.00 12169.00 1556.50 3537.50 286.00 33181.30 331.81 3318.13 4977.20 4977.20 1659.07 48444.70

66

GATE / HOIST AND ALLIED WORKS

ABSTRACT: A. Cost of Materials B. Hire charges of Machinery C. Cost of Labour Add for excise duty on 75 percent cost of Machinery / Labour components @ Add for insurance charges @ Add for designs and drawings @ Add for zigs / supports / winches / chain-pulley @ Add for power supply arrangements @ Add for enabling works @

Rs: Rs: Rs: TOTAL Rs: 8.24% 1.00% 2.50% 2.50% 2.00% 1.40% Rs: Rs: Rs: Rs: Rs: Rs: Total Rs: Rs: Rs: Rs: Rs: Rs:

633463.94 29463.00 48444.70 711371.63 4814.70 7113.72 17784.29 17784.29 14227.43 9959.20 783055.26 2375.96 23491.66 808922.88 87900.00 87900.00 ITEM No: 14

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2x9.202 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 9.202 tonne Rate per tonne Rate approved per tonne SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity rope drum hoist consisting of hoist platform, rope drum, gear system, electric motor, electromagnetic 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, bending, 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 all leads and lifts. 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, 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 m Head of water above sill level considered : 34 m Weight of gate leaf in tonne including weight of ballast based on empirical formula : = 0.0888 x ( L x H x h ) Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0888 x ( 3.2 x 3.2 x x 3.3 x 34 ) : 9.229 Capacity of hoist in tonnes with 25% reserve capacity at 2.5 times wt of gate with ballast. ( 2.50 x 9.229 ) : 23.073 tonnes Round off the capacity of hoist to next 5 tonne say : 25.00 tonnes Weight 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 tonnes The hoist capacity and hoist weight computed as above based on empirical formulae are further
0.659 2 0.659

67

GATE / HOIST AND ALLIED WORKS

1. a.

b.

c.

d. e. f. g.

h.

2.

checked by varifying / computing the actual capacity and weight as per fabrication drawings for sluice gate rope drum hoist of same capacity provided for one of the dam. Actual capacity of hoist as per data sheet : 25.00 tonnes Actual weight of rope drum hoist as per data in Item :14 of Annexure-2 : 6.243 tonnes Consider 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 ). Requirement of materials : Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5 % wastage ( 1451x1.025 ) : 1487.00 kg Plates / flats with 2.5 % wastage ( 392 x 1.025 ) : 402.00 kg Chequered plates with 2.5 % wastage ( 283 x 1.025 ) : 290.00 kg Cast steel components conforming to IS : 1030 : Rope drums 2 Nos / Gears ( 1420 +506 ) : 1926.00 kg Pinions : 79.00 kg Pulleys 3 Nos / Couplings 2 Nos : 306.00 kg Plummer blocks / Hubs : 72.00 kg Alloy steel steel components conforming to IS : 1570 : Shafts : 346.00 kg Pins : 73.00 kg Alluminium/ Bronze alloy components conforming to IS : 305 : Bearings / Bush : 57.00 kg Bolt / Nut / Washers conforming to IS : 1363 : MS Bolts / Nuts / Washers with 2.5 % wastage ( 31 x 1.025 ) : 32.00 kg Steel wire rope conforming ti IS 2266 : 28 mm dia 6 / 37 construction 1 No 120 Rm @ 2.71 kg / m : 325 kg Other components : Manual operating system : 1 No. Worm reducer : 1 No Electric motor 5 hp : 1 No. Gate position indicator : 1 No. Ele-magnetic brake : 1 No. Electric cable / switch / control panel etc : 1 set Welding electrodes ( General purpose / Low hydrogen ) : GP / LH electrodes as per data sheet ( Item:14 Annexure-2 ) : 1005 Nos Add for variations / wastage / misc welding @ 10 % ( 1005 x 0.1 ) : 100 Nos Total 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 Cutting : Length of cutting assuming cutting for 2 sides as per data sheet : 57 Rm Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 6 Rm Total : 63 Rm For cutting structural steel sections to required sizes gas cutting is assumed. Length of steel to be cut by using gas manually : 26 m Length of steel to be cut by gas using pug cutting machine : 37 m Time for gas cutting manually at ( av ) 2 m cutting / hour : 13 hours Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 12 hours Acetelyne gas @ 0.6 cum / hour ( 13 + 12 ) x 0.60 : 15 cum

68

GATE / HOIST AND ALLIED WORKS

Oxygen gas @ 1.8 cum / hour ( 13 + 12 ) x 1.80 Use of gas cutting torch with 50 min / hr working ( 13 x 60 / 50 ) Use of pug cutting machine with 50 min / hr working ( 12 x 60 / 50 ) 3. Welding : Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 110 / 15 ) x 8 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 995 / 15 ) x 8 / 6 Total

: 45 cum : 16 hours : 15 hours : 97 Rm : 29 hours : 88 hours : 117 hours

4.

5.

6.

Note :

Deploy welding transformer for 117 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 29 x 0.25 + 88 x 0.75 ) : 73 hours Surface cleaning and painting : Painting area at 20 sqm / tonne of str steel (1487+402+290 ) x 20 : 43 sqm 2 coats of zinc chromate red oxide primer. Quantity of primer paint for 43 sqm @ 12 sqm / ltr / coat : 7 ltr 3 coats of synthetic enamel paint. Quantity of synthetic enamel paint for 43 sqm @ 12 sqm / ltr /coat : 11 ltr 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 43 sqm @ 8 sqm / ltr : 5 ltr 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. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections/ drilling holes 31 hours 2 4 4 8 Fabricating by stitch welding 29 hours 2 4 --8 Run welding 88 hours 1 --11 11 Erection of anchors 1 1 --2 Erection of hoist frame 1 1 --4 Erection of drums / gears / shafts 1 2 --4 Erection of pulleys / plummer blocks 1 1 --2 Erection of worm reducers / brake / motor 1 2 --4 Erection of other accessories --1 --2 Erection of control panel / cabling --1 --1 Checking and running without rope 1 1 --2 Rope fixing and checking 1 1 --2 Cleaning surface 43 sqm @ 15 sqm/day ------3 Painting ( 5 x 43 ) sqm @ 15 sqm / day ------13 Trial running by lowering / lifting gate 1 1 --4 Final checking / Finishing / cleaning 1 1 --1 Total : 14 21 15 71 a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.

69

GATE / HOIST AND ALLIED WORKS

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. 7. Excise duty on supply : Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all 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. 8. Use rate of materials : Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00 Life of welding set : 1000 hours Use rate of welding set per hour ( cost / life ) Rs: 4.50 Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00 Life of gas cutting set : 600 hours Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50 RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars Unit Quantity UNIT : 6.243 tonne wt 25 t capacity Rate Amount in Rs. in Rs. 37.95 40.00 42.00 145.00 150.00 125.00 125.00 175.00 215.00 635.00 105.00 55.00 52500.00 12000.00 11250.00 11250.00 11250.00 7500.00 48.00 258.00 6.00 12.00 140.00 176.00 240.00 194.00 4.50 Contd 56431.65 16080.00 12180.00 279270.00 11850.00 38250.00 9000.00 60550.00 15695.00 36195.00 34125.00 1760.00 52500.00 12000.00 11250.00 11250.00 11250.00 7500.00 2160.00 3870.00 660.00 11940.00 980.00 1936.00 1200.00 4850.00 526.50

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Structural steel Angles / beams / channels / bars Plates / flats Chequered plate Cast steel components : Rope drums 2 Nos / Gears Pinions Pulleys 3 Nos / Couplings 2 Nos Plummer blocks / Hubs Alloy steel components Shafts Pins Bronze alloy components : Bronze bearings / bush Wire rope 28 mm dia 6/37 construction MS Bolt / Nut / Washer Worm reducers Electric motor 5 hp Manual operating system Gate position indicator Ele-magnetic brake Electric cable / switch / control panel etc Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen ) Zinc chromate red oxide primer Synthetic enamel ( 1st quality ) paint Rust cleaner / inhibitor Grease Use rate welding holder set

kg kg kg kg kg kg kg kg kg kg kg kg No. No. No. No. No. LS cum cum Nos Nos ltr ltr ltr kg Hour

1487.00 402.00 290.00 1926.00 79.00 306.00 72.00 346.00 73.00 57.00 325.00 32.00 1.00 1.00 1.00 1.00 1.00 1.00 45.00 15.00 110.00 995.00 7.00 11.00 5.00 25.00 117.00

A. MATERIALS ( Contd ) :

70

GATE / HOIST AND ALLIED WORKS

Sl No

Perticulars

Unit

Quantity

22 23 24

Use rate gas cutting torch set Wire brush Sundries Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @

Hour Nos LS

16.00 1.00 5.00

1% 10% 5% Total cost of Materials :

Rate in Rs. Contd 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 40.00 30.00 150.00 705479.15 7054.79 70547.92 35273.96 818355.81

B. MACHINERY: Sl No 1 2 3 4 5 6

Description

Unit Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour LS

Quantity 117.00 73.00 15.00 15.00 2.00 2.00 2.00 2.00 2.00 2.00 5.00

Welding transformer Fuel / Energy charges Pug cutting machine Fuel / Energy charges Mobile crane 8 t Fuel / Energy charges Grinding machine Fuel / Energy charges Drilling machines Fuel / Energy charges Sundries

Add for small Tools and Plants @ 1% Add for Contractor's Profit on DPOL / Energy @ 10% Add for Contractor's Overheads @ 5% Total hire charges of Machinery : C. LABOUR: Sl No 1 2 3 4 5 6 7 8 9 10 11

Rate in Rs. 12.00 60.00 16.00 3.00 362.00 495.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 1404.00 4380.00 240.00 45.00 724.00 990.00 36.00 50.00 36.00 50.00 150.00 8105.00 81.05 566.50 405.25 9157.80

Description

Unit Hour Hour Hour Day Day Day Day Day Day Day Day

Quantity 2.00 2.00 2.00 14.00 21.00 4.00 11.00 55.00 5.00 11.00 2.00 1%

Crew for Mobile crane 8 t Crew for Drilling machine Crew for Grinding machine Foreman Marker / Fabricator / Erector Gas cutter Welder ( General ) Helper fabrication / erection Helper for cleaning / painting Painter Cl - II Electrician Add for small Tools and Plants @

Rate in Rs. 75.70 59.50 59.50 177.00 157.50 157.50 157.50 141.50 141.50 141.50 143.00 Total Rs: Rs: Contd

Amount in Rs. 151.40 119.00 119.00 2478.00 3307.50 630.00 1732.50 7782.50 707.50 1556.50 286.00 18869.90 188.70

C. LABOUR ( Contd ) : Sl No Description

Unit

Quantity

Rate

Amount

71

GATE / HOIST AND ALLIED WORKS

Add for Contractor's Profit @ Add for hidden cost on Labour @ Add for additional hidden cost on labour @ Add for Contractor's Overheads @

10% 15% 15% 5% Total cost of Labour :

in Rs. Contd Rs: Rs: Rs: Rs: Rs:

in Rs. 1886.99 2830.49 2830.49 943.50 27550.05

ABSTRACT: A. Cost of Materials B. Hire charges of Machinery C. Cost of Labour Add for excise duty on 75 percent cost of Machinery / Labour components @ Add for insurance charges @ Add for designs and drawings @ Add for zigs / supports / winches / chain-pulley @ Add for power supply arrangements @ Add for enabling works @

Rs: Rs: Rs: TOTAL Rs: 8.24% 1.00% 2.50% 2.50% 2.00% 1.40% Rs: Rs: Rs: Rs: Rs: Rs: Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

818355.81 9157.80 27550.05 855063.67 2268.55 8550.64 21376.59 21376.59 17101.27 11970.89 937708.20 1611.94 28131.25 967451.39 154970.00 38700.00 38700.00 ITEM No: 15

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 6.243 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 6.243 tonne weight 25.000 tonne capacity Rate per tonne weight Rate per tonne capacity Rate approved per tonne capacity SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( without groove liners ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner upto 1m height above the roof of vent 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 primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with all leads and lifts. DATA: Embedded parts for river sluice emergency gate consist of sill beam, wheel / seal tracks, breast wall 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 height upto 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 m Head of water considered above sill level : 16 m

72

GATE / HOIST AND ALLIED WORKS

Weight of gate with ballast in tonnes = 0.0888 x ( L x H x h ) 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 x H x h ) Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0444 x ( 2.2 x 2.2 x 3.3 x 16 ) Weight of breast wall lining about 2 sqm @ 250 kg / sqm
0.659 2 0.659

0.659

1. a.

b. c. d.

2.

: 1.714 tonnes : 0.500 tonnes Total : 2.214 tonnes The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings of embedded parts for river sluice emergency gate of same size provided for one of the dam. Actual weight of embedded parts as per data in Item : 15 of Annexure-2 : 2.180 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on embedded parts drawings for river sluice emergency gate provided for one of the dam for rate analysis ( for details refer Item 15 of Annexure - 2 ). Requirement of materials : Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5 % wastage ( 593x1.025 ) : 608 kg Plates / flats with 2.5 % wastage ( 1304 x 1.025 ) : 1337 kg Alloy steel components conforming to IS : 1570 : Stainless steel plates / flats ( 219 x 1.025 ) : 225.00 kg Bolt / Nut / Washer conforming ti IS : 1363 : MS bolts and nuts with 2.5 % wastage ( 64 x 1.025 ) : 66 kg Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) : GP / LH electrodes as per data sheet ( Item:15 Annexure-2 ) : 933 Nos Add for variations / wastage / misc welding @ 10 % ( 933 x 0.1 ) : 93 Nos Total requirement of GP / LH electrodes : 1026 Nos for stitch welding GP electrodes @t 10 % of total ( 1026 x 0.10 ) : 103 Nos for run welding LH electrodes @ 90 % of total ( 1026 x 0.90 ) : 923 Nos Stainless steel electrodes as per data sheet ( Item:15 Annexure-2 ) : 430 Nos Add for variations / wastage @ 5 % ( 430 x 0.05 ) : 22 Nos Total requirement of Stainless steel ( SS ) electrodes : 452 Nos for stitch weld SS electrodes @t 10 % of total ( 452 x 0.10 ) : 45 Nos for run weld SS electrodes @t 90 % of total ( 452 x 0.90 ) : 407 Nos Cutting : Length of cutting assuming cutting for 2 sides as per data sheet : 135 Rm Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 14 Rm Total length of cutting Total : 149 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 : 30 m Length of steel to be cut by gas using pug cutting machine : 89 m Length of steel to be cut by using shearing machine : 30 m Time for gas cutting manually at ( av ) 2 m cutting / hour : 15 hours Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 30 hours

Time for cutting by shearing machine at ( av ) 10 m cutting / hour Acetelyne gas @ 0.6 cum / hour ( 15 + 30 ) x 0.60 Oxygen gas @ 1.8 cum / hour ( 15 + 30 ) x 1.80 Use of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 )

: : : :

3 hours 27 cum 81 cum 18 hours

73

GATE / HOIST AND ALLIED WORKS

Use of pug cutting machine with 50 min / hr working ( 30 x 60 / 50 ) Use of shearing machine with 50 min / hr working ( 3 x 60 / 50 ) 3. Welding : Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 103 + 45 ) x 8 / 15 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 923 + 407 ) x 8 / 15 / 6 Total

: 36 hours : 4 hours : 143 m : 40 hours : 118 hours : 158 hours

4.

5.

6.

7.

Deploy welding transformer for 158 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 40 x 0.25 + 118 x 0.75 ) : 99 hours 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 Rm Length of planing at a time for 4 m stroke planing machine : 3 Rm Time for planing 3 m length section with 50 min / hour working : 8 hours Time for planing 26 m SS plates ( 26 x 8 / 3 ) : 72 hours Surface cleaning and painting : Painting area for embedded parts at 12 sqm / tonne ( 2.18 x 12 ) : 26 sqm 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 26 sqm @ 9 sqm / ltr / coat : 3 ltr 4 coats of coal tar epoxy paint 100 micron dry film each coat. Quantity of coal tar epoxy paint for 26 sqm @ 6 sqm / ltr / coat : 18 ltr 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 43 sqm @ 8 sqm / ltr : 4 ltr 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. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections 58 hours 4 7 7 14 Drilling holes for anchors / supports 1 1 --1 Fbricating by stitch welding 40 hours 2 5 --10 Run welding 118 hours 2 --14 14 Erection of first stage anchors 2 4 --8 Erection of Sill beam / Tracks / Guide 2 4 --8 Erection of Breast wall liners 1 2 --4 Contd

Requirement of work force ( Contd ) : Work component

Foreman

Cleaning surface 26 sqm @ 15 sqm/day

---

Marker / Fabricator / Erector / ---

Gas cutter / Welder ---

Helper / Painter Cl-II 2

74

GATE / HOIST AND ALLIED WORKS

Painting ( 5 x 26 ) sqm @ 15 sqm / day ------10 Finishing / 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. 8. Excise duty on supply : Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all 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. 9. Use rate of materials : Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00 Life of welding set : 1000 hours Use rate of welding set per hour ( cost / life ) Rs: 4.50 Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00 Life of gas cutting set : 600 hours Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50 RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars Unit Quantity UNIT : 2.180 tonne Rate in Rs. 37.95 40.00 120.00 55.00 48.00 258.00 6.00 12.00 43.00 594.00 208.00 240.00 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs: Amount in Rs. 23073.60 53480.00 27000.00 3630.00 3888.00 6966.00 618.00 11076.00 19436.00 1782.00 3744.00 960.00 711.00 45.00 30.00 150.00 156589.60 1565.90 15658.96 7829.48 181643.94

2 3 4 5 6 7 8 9 10 11 12 13 14 15

Structural steel Angles / beams / channels / bars Plates / flats Stainless steel plate / flats MS bolts and nuts Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen ) Welding electrodes ( stainless steel ) Zinc rich epoxy primer Coal tar epoxy paint Rust cleaner / inhibitor Use rate welding holder set Use rate gas cutting torch set Wire brush Sundries Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @

kg kg kg kg cum cum Nos Nos Nos ltr ltr ltr Hour Hour Nos LS

608.00 1337.00 225.00 66.00 81.00 27.00 103.00 923.00 452.00 3.00 18.00 4.00 158.00 18.00 1.00 5.00

1% 10% 5% Total cost of Materials :

B. MACHINERY: Sl No 1 2

Description

Unit Hour Hour Hour

Quantity 158.00 99.00 4.00

Welding transformer Fuel / Energy charges Plate shearing machine

Rate in Rs. 12.00 60.00 62.00

Amount in Rs. 1896.00 5940.00 248.00

75

GATE / HOIST AND ALLIED WORKS

3 4 5 6 7 8 9

Fuel / Energy charges Pug cutting machine Fuel / Energy charges Planing machine Fuel / Energy charges Mobile crane 8 t Fuel / Energy charges Stationery derric crane Fuel / Energy charges Grinding machine Fuel / Energy charges Drilling machines Fuel / Energy charges Sundries

Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour LS

4.00 36.00 36.00 72.00 72.00 2.00 2.00 4.00 4.00 12.00 12.00 8.00 8.00 10.00

Add for small Tools and Plants @ 1% Add for Contractor's Profit on DPOL / Energy @ 10% Add for Contractor's Overheads @ 5% Total hire charges of Machinery : C. LABOUR: Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13 14

100.00 16.00 3.00 88.00 75.00 362.00 495.00 66.00 9.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

400.00 576.00 108.00 6336.00 5400.00 724.00 990.00 264.00 36.00 216.00 300.00 144.00 200.00 300.00 24078.00 240.78 1367.40 1203.90 26890.08

Description

Unit Hour Hour Hour Hour Hour Day Day Day Day Day Day Day Day Day

Quantity 2.00 4.00 72.00 8.00 12.00 15.00 24.00 7.00 12.00 2.00 61.00 3.00 9.00 1.00

Crew for Mobile crane Crew for Shearing machine Crew for Planing machine Crew for Drilling machine Crew for Grinding machine Foreman Marker / Fabricator / Erector Gas cutter Welder ( General ) Welder ( X - ray ) Helper fabrication / erection Helper for cleaning / painting Painter Cl - II Electrician Add for small Tools and Plants @ Add for Contractor's Profit @ Add for hidden cost on Labour @ Add for additional hidden cost on labour @ Add for Contractor's Overheads @

1% 10% 15% 15% 5% Total cost of Labour :

Rate in Rs. 75.70 45.90 73.40 59.50 59.50 177.00 157.50 157.50 157.50 173.25 141.50 141.50 141.50 143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 151.40 183.60 5284.80 476.00 714.00 2655.00 3780.00 1102.50 1890.00 346.50 8631.50 424.50 1273.50 143.00 27056.30 270.56 2705.63 4058.45 4058.45 1352.82 39502.20

ABSTRACT: A. Cost of Materials B. Hire charges of Machinery C. Cost of Labour Add for excise duty on 75 percent cost of Machinery / Labour components @

Rs: Rs: Rs: TOTAL Rs: 8.24% Rs:

181643.94 26890.08 39502.20 248036.21 4103.04

76

GATE / HOIST AND ALLIED WORKS

Add for insurance charges @ Add for designs and drawings @ Add for zigs / supports / winches / chain-pulley @ Add for power supply arrangements @ Add for enabling works @

1.00% 2.50% 2.50% 2.00% 1.40%

Rs: Rs: Rs: Rs: Rs: Total Rs: Rs: Rs: Rs: Rs: Rs:

2480.36 6200.91 6200.91 4960.72 3472.51 275454.66 562.88 8263.64 284281.18 130400.00 130400.00 ITEM No: 16

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 2.180 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 2.180 tonne Rate per tonne Rate approved per tonne SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( with groove liner ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner ( upto 1 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, 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 all leads and lifts. DATA: Embedded parts for river sluice emergency gate consist of sill beam, wheel /seal tracks, groove lining upto breast wall level, breast wall lining upto 1 m above top of vent, gate guide etc., with all 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 m Head of water considered above sill level : 34 m Weight of embedded parts in tonne including weight of ballast based on empirical formula : = 0.0888 x ( L x H x h ) Consider weight of embedded parts at 67.5 % og weight of gate including ballast: = 0.675 x 0.0888 x ( L x H x h ) Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0600 x ( 3.2 x 3.2 x 3.3 x 34 )
0.659 2 0.659 2 0.659

: 6.236 tonnes

: 0.875 tonnes : 2.000 tonnes Total : 9.111 tonnes The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings of embedded parts and groove liner for river sluice emergency 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 tonnes Consider actual weight for data rate analysis.

Weight of breast wall lining about 3.5 sqm @ 250 kg / sqm Weight of groove liner about 10 sqm @ 200 kg / sqm

77

GATE / HOIST AND ALLIED WORKS

1. a.

b. c. d.

2.

Consider details of Material / Gas cutting / Welding based on embedded parts and groove liner drawings for river sluice emergency gate provided for one of the dam work for rate analysis ( for details refer Item : 16 of Annexure - 2 ). Requirement of materials : Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5 % wastage ( 992x1.025 ) : 1017 kg Plates / flats with 2.5 % wastage ( 7431 x 1.025 ) : 7617 kg Alloy steel components conforming to IS : 1570 : Stainless steel plates / flats ( 431 x 1.025 ) : 442 kg Bolt / Nut / Washer conforming ti IS : 1363 : MS bolts and nuts with 2.5 % wastage ( 234 x 1.025 ) : 240 kg Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) : GP / LH electrodes as per data sheet ( Item:16 Annexure-2 ) : 5256 Nos Add for variations / wastage / misc welding @ 10 % ( 5256 x 0.1 ) : 526 Nos Total requirement of GP / LH electrodes : 5782 Nos for stitch welding GP electrodes @t 10 % of total ( 5782 x 0.10 ) : 578 Nos for run welding LH electrodes @ 90 % of total ( 5782 x 0.90 ) : 5204 Nos Stainless steel electrodes as per data sheet ( Item:16 Annexure-2 ) : 752 Nos Add for variations / wastage @ 5 % ( 752 x 0.05 ) : 38 Nos Total requirement of Stainless steel ( SS ) electrodes : 790 Nos for stitch weld SS electrodes @t 10 % of total ( 790 x 0.10 ) : 79 Nos for run weld SS electrodes @t 90 % of total ( 790 x 0.90 ) : 711 Nos Cutting : Length of cutting assuming cutting for 2 sides as per data sheet : 301 Rm Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 30 Rm Total length of cutting Total : 331 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 m Length of steel to be cut by gas using pug cutting machine : 211 m Length of steel to be cut by using shearing machine : 60 m Time for gas cutting manually at ( av ) 2 m cutting / hour : 30 hours Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 70 hours Time for cutting by shearing machine at ( av ) 10 m cutting / hour : 6 hours Acetelyne gas @ 0.6 cum / hour ( 30 + 70 ) x 0.60 : 60 cum Oxygen gas @ 1.8 cum / hour ( 30 + 70 ) x 1.80 : 180 cum Use of gas cutting torch with 50 min / hr working ( 30 x 60 / 50 ) : 36 hours Use of pug cutting machine with 50 min / hr working ( 70 x 60 / 50 ) : 84 hours Use of shearing machine with 50 min / hr working ( 6 x 60 / 50 ) : 7 hours

3. Welding : Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 578 + 79 ) x 8 / 15 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 5204 + 711 ) x 8 / 15 / 6 Total Deploy welding transformer for 701 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

: 560 m : 175 hours : 526 hours : 701 hours

78

GATE / HOIST AND ALLIED WORKS

( 175 x 0.25 + 526 x 0.75 ) : 438 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 Rm Length of planing at a time for 4 m stroke planing machine : 3 Rm Time for planing 3 m length section with 50 min / hour working : 8 hours Time for planing 26 m SS plates ( 26 x 8 / 3 ) : 69 hours 5. Surface cleaning and painting : Painting area for embedded parts at 10 sqm / tonne ( 9.088 x 10 ) : 91 sqm 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 91 sqm @ 9 sqm / ltr / coat : 10 ltr 4 coats of coal tar epoxy paint 100 micron dry film each coat. Quantity of coal tar epoxy paint for 91 sqm @ 6 sqm / ltr / coat : 61 ltr 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 91 sqm @ 8 sqm / ltr : 12 ltr 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. 7. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections 127 hours 8 16 16 32 Drilling holes for anchors / supports 3 6 --6 Fbricating by stitch welding 175 hours 12 22 --44 Run welding 526 hours 7 --66 66 Erection of first stage anchors 5 10 --10 Erection of Sill beam / Tracks / Guide 2 4 --8 Erection of Breast wall liner 1 2 --4 Erection of groove liners 3 6 --12 Cleaning surface 91 sqm @ 15 sqm/day ------6 Painting ( 5 x 91 ) sqm @ 15 sqm / day ------36 Finishing / cleaning 1 2 --4 Total : 42 68 82 228 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 30 Painters Cl-II at 15 sqm / day and 6 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 all 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. 9. Use rate of materials : Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00 Life of welding set : 1000 hours Use rate of welding set per hour ( cost / life ) Rs: 4.50

79

GATE / HOIST AND ALLIED WORKS

Cost of gas cutting set @ Life of gas cutting set Use rate of gas cutting set per hr

Rs:

1500.00 / Each ( cost / life ) UNIT : Unit Quantity

Rs: 1500.00 : 600 hours Rs: 2.50 9.088 tonne Rate in Rs. 37.95 40.00 120.00 55.00 48.00 258.00 6.00 12.00 43.00 594.00 208.00 240.00 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs: Amount in Rs. 38595.15 304680.00 53040.00 13200.00 8640.00 15480.00 3468.00 62448.00 33970.00 5940.00 12688.00 2880.00 3154.50 90.00 60.00 750.00 559083.65 5590.84 55908.37 27954.18 648537.03

RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars

2 3 4 5 6 7 8 9 10 11 12 13 14 15

Structural steel Angles / beams / channels / bars Plates / flats Stainless steel plate / flats MS bolts and nuts Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen ) Welding electrodes ( stainless steel ) Zinc rich epoxy primer Coal tar epoxy paint Rust cleaner / inhibitor Use rate welding holder set Use rate gas cutting torch set Wire brush Sundries Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @

kg kg kg kg cum cum Nos Nos Nos ltr ltr ltr Hour Hour Nos LS

1017.00 7617.00 442.00 240.00 180.00 60.00 578.00 5204.00 790.00 10.00 61.00 12.00 701.00 36.00 2.00 25.00

1% 10% 5% Total cost of Materials :

B. MACHINERY: Sl No 1 2

Description

Unit Hour Hour Hour Hour

Quantity 701.00 438.00 7.00 7.00

Welding transformer Fuel / Energy charges Plate shearing machine Fuel / Energy charges

Rate in Rs. 12.00 60.00 62.00 100.00 Contd

Amount in Rs. 8412.00 26280.00 434.00 700.00

B. MACHINERY ( Contd ) : Sl No Description

Unit

Quantity

3 4 5 6

Pug cutting machine Fuel / Energy charges Planing machine Fuel / Energy charges Mobile crane 8 t Fuel / Energy charges Stationery derric crane

Hour Hour Hour Hour Hour Hour Hour

84.00 84.00 69.00 69.00 4.00 4.00 40.00

Rate in Rs. Contd 16.00 3.00 88.00 75.00 362.00 495.00 66.00

Amount in Rs. 1344.00 252.00 6072.00 5175.00 1448.00 1980.00 2640.00

80