GATE / HOIST AND ALLIED WORKS

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 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 : 15.440 tonne wt 90.00 t capacity Rate Amount in Rs. in Rs. 37.95 40.00 145.00 150.00 125.00 125.00 175.00 215.00 635.00 105.00 55.00 120000.00 60000.00 45.00 22500.00 Contd 97569.45 145280.00 533600.00 32700.00 135000.00 40250.00 97475.00 117390.00 91440.00 47040.00 4675.00 120000.00 60000.00 45000.00 22500.00

4 5 6 7 8 9 10

Structural steel Angles / beams / channels / bars Plates / flats Cast steel components : Rope drums 2 Nos / Gears 4 Nos Pinions Pulleys 720 PCD 6 Nos Plummer blocks / Hubs Alloy steel components Shafts Pins Bronze alloy components : Bronze bearings / bush Wire rope 36 mm dia 6/37 construction MS Bolt / Nut / Washer Worm reducer Electric motor 20 hp Floating shaft 300 mm dia Manual operating system

kg kg kg kg kg kg kg kg kg kg kg No. No. kg No.

2571.00 3632.00 3680.00 218.00 1080.00 322.00 557.00 546.00 144.00 448.00 85.00 1.00 1.00 1000.00 1.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

11 12 13 14 15

Gate position indicator Ele-magnetic brake Electric cable /switch /control panel etc Oxygen gas Acetyline gas

No. No. LS cum cum

1.00 1.00 1.00 216.00 72.00

Rate in Rs. Contd 9000.00 15000.00 18000.00 48.00 258.00

Amount in Rs. 9000.00 15000.00 18000.00 10368.00 18576.00

20

GATE / HOIST AND ALLIED WORKS

16 17 18 19 20 21 22 23 24 25

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 Use rate gas cutting torch set Wire brush Sundries ( hand rail /staircase / gate etc ) Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @

Nos Nos ltr ltr ltr kg Hour Hour Nos LS

584.00 5250.00 21.00 31.00 16.00 50.00 623.00 90.00 3.00 1000.00

1% 10% 5% Total cost of Materials :

6.00 12.00 140.00 176.00 240.00 194.00 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

3504.00 63000.00 2940.00 5456.00 3840.00 9700.00 2803.50 225.00 90.00 30000.00 1782421.95 17824.22 178242.20 89121.10 2067609.46

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 623.00 390.00 4.00 4.00 53.00 53.00 40.00 20.00 40.00 20.00 32.00 32.00 16.00 16.00 600.00

Welding transformer Fuel / Energy charges Tower crane 5 t capacity Fuel / Energy charges Pug cutting machine Fuel / Energy charges Mobile crane 25 t 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 :

Rate in Rs. 12.00 60.00 994.00 130.00 16.00 3.00 3804.00 1375.00 362.00 495.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 7476.00 23400.00 3976.00 520.00 848.00 159.00 152160.00 27500.00 14480.00 9900.00 576.00 800.00 288.00 400.00 18000.00 260483.00 2604.83 7077.90 13024.15 283189.88

C. LABOUR: Sl No 1 2 3 4 5 6 7

Description

Unit Hour Hour Hour Hour Hour Day Day

Quantity 40.00 40.00 4.00 16.00 32.00 37.00 67.00

Crew for Mobile crane 25 t Crew for Mobile crane 8 t Crew for Tower crane Crew for Drilling machine Crew for Grinding machine Foreman Marker / Fabricator / Erector / Mechanic

Rate in Rs. 72.60 75.70 62.00 59.50 59.50 177.00 157.50

Amount in Rs. 2904.00 3028.00 248.00 952.00 1904.00 6549.00 10552.50

21

GATE / HOIST AND ALLIED WORKS

8 9 10 11 12 13 14

Gas cutter Welder ( General ) Khalasi 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 @

Day Day Day Day Day Day Day

18.00 58.00 100.00 196.00 14.00 30.00 3.00

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

157.50 157.50 145.50 141.50 141.50 141.50 143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

2835.00 9135.00 14550.00 27734.00 1981.00 4245.00 429.00 87046.50 870.47 8704.65 13056.98 13056.98 4352.33 127087.89

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:

2067609.46 283189.88 127087.89 2477887.23 25355.17 24778.87 61947.18 61947.18 49557.74 34690.42 2736163.80 3986.61 82084.91 2822235.32 182790.00 31400.00 31400.00 ITEM No: 4

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 15.44 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 15.440 tonne weight 90.000 tonne capacity Rate per tonne wiegt 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 1 metre wide catwalk connecting

spillway piers / abutments at trunnion platform level including cost of all materials, machinery, labour, cutting, aligning, anchoring, 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 approved drawings with all leads and lifts. DATA: Catwalk at trunnion level generally consists of 1 m wide structural steel bridge spanning across piers / 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 tonnes The weight of catwalk ( foot bridge ) computed as above based on empirical formula is further

22

GATE / HOIST AND ALLIED WORKS

checked by computing the actual weight as per fabrication drawings of a catwalk of same size provided for one of the dam work. Actual weight of catwalk as per data in Item : 4 of Annexure-2 : 5.318 tonnes Consider 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 ). 1. Requirement of materials : a. Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5 % wastage ( 4154x1.025 ) Plates / flats with 2.5 % wastage ( 96 x 1.025 ) Chequered plates with 2.5 % wastage ( 835 x 1.025 ) b. Bolts / Nuts / Washers conforming to IS : 1363 : MS bolts / nuts / washers with 2.5 % wastage ( 8 x 1.025 ) c. Welding electrodes ( General purpose ) : GP electrodes as per data sheet ( Item:4 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 1387 x 0.1 ) Total requirement of GP electrodes for stitch weld GP electrodes @t 10 % of total ( 1526 x 0.10 ) for run welding GP electrodes @ 90 % of total ( 1526 x 0.90 ) 2. Cutting : Length of cutting assuming cutting for 2 sides as per data sheet Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % Total For cutting structural steel sections to required sizes gas cutting is assumed. Length of steel to be cut by using gas manually Length of steel to be cut by gas using pug cutting machine Time for gas cutting manually at ( av ) 2 m cutting / hour Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour Acetelyne gas @ 0.6 cum / hour ( 20 + 8 ) x 0.60 Oxygen gas @ 1.8 cum / hour ( 20 + 8 ) x 1.80 Use of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) Use of pug cutting machine with 50 min / hr working ( 8 x 60 / 50 ) 3. Welding : Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 153 / 15 ) x 8 / 2

: 4258 kg : 98 kg : 856 kg : 8 kg : : : : : 1387 Nos 139 Nos 1526 Nos 153 Nos 1373 Nos

: 57 Rm : 6 Rm : 63 Rm : : : : : : : : 40 m 23 m 20 hours 8 hours 17 cum 51 cum 24 hours 10 hours

: 151 Rm : 41 hours

For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 1373 / 15 ) x 8 / 6 Total

: 122 hours : 163 hours

Deploy welding transformer for 163 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 41 x 0.25 + 122 x 0.75 ) : 102 hours 4. Surface cleaning and painting : Painting area for catwalk at 25 sqm / tonne ( 5.318 x 25 ) 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 133 sqm @ 9 sqm / ltr / coat 2 coats of coal tar epoxy paint 100 micron dry film each coat.

: 133 sqm : 15 ltr

23

GATE / HOIST AND ALLIED WORKS

Quantity of coal tar epoxy paint for 133 sqm @ 6 sqm / ltr / coat : 44 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 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 6. Requirement of work force : Work component

Foreman

Marker / Fabricator / Erector /

Gas cutter / Welder

Helper / Painter Cl-II 8 10 15 9 33 2 77

Cutting sections / drilling holes 34 hours 2 4 4 Fabricating by stitch welding 41 hours 2 5 --Run welding 122 hours 1 --15 Cleaning surface 132 sqm @ 15 sqm/day ------Painting ( 3 x 133 ) sqm @ 15 sqm / day ------Erection / anchoring / finishing / checking 1 2 --Total : 6 11 19 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 26 Painters Cl-II at 15 sqm / day and 7 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 @ Life of welding set Use rate of welding set per hour

Rs:

4500.00 / Each ( cost / life )

Rs: 4500.00 : 1000 hours Rs: 4.50

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 18.000 Rm Rate in Rs. 37.95 40.00 42.00 55.00 Amount in Rs. 161591.10 3920.00 35952.00 440.00

RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars

Structural steel Angles / beams / channels / bars Plates / flats Chequered plates MS bolts / nuts / washers

kg kg kg kg

4258.00 98.00 856.00 8.00

24

GATE / HOIST AND ALLIED WORKS

3 4 5 6 7 8 9 10 11 12

Oxygen gas Acetyline gas Welding electrodes ( general purpose ) 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 @

cum cum Nos ltr ltr ltr Hour Hour Nos LS

51.00 17.00 1526.00 15.00 44.00 16.00 163.00 24.00 1.00 10.00

1% 10% 5% Total cost of Materials :

48.00 258.00 6.00 594.00 208.00 240.00 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

2448.00 4386.00 9156.00 8910.00 9152.00 3840.00 733.50 60.00 30.00 300.00 240918.60 2409.19 24091.86 12045.93 279465.58

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

Description

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

Quantity 163.00 102.00 1.00 1.00 10.00 10.00 2.00 2.00 8.00 8.00 2.00 2.00 10.00

Welding transformer Fuel / Energy charges Tower crane 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 :

Rate in Rs. 12.00 60.00 994.00 130.00 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. 1956.00 6120.00 994.00 130.00 160.00 30.00 724.00 990.00 144.00 200.00 36.00 50.00 300.00 11834.00 118.34 782.00 591.70 13326.04

C. LABOUR: Sl No 1 2 3 4 5 6 7 8 9 10 11

Description

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

Quantity 2.00 1.00 2.00 8.00 6.00 11.00 4.00 15.00 35.00 16.00 26.00

Crew for Mobile crane Crew for Tower crane Crew for Drilling machine Crew for Grinding machine Foreman Marker / Fabricator / Erector Gas cutter Welder ( General ) Helper fabrication / erection Helper for cleaning / painting Painter Cl - II

Rate in Rs. 75.70 62.00 59.50 59.50 177.00 157.50 157.50 157.50 141.50 141.50 141.50

Amount in Rs. 151.40 62.00 119.00 476.00 1062.00 1732.50 630.00 2362.50 4952.50 2264.00 3679.00

25

GATE / HOIST AND ALLIED WORKS

12

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

1.00

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

143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

143.00 17633.90 176.34 1763.39 2645.09 2645.09 881.70 25745.49

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:

279465.58 13326.04 25745.49 318537.11 2414.62 3185.37 7963.43 7963.43 6370.74 4459.52 350894.22 1373.11 10526.83 362794.15 20200.00 20200.00 ITEM No: 5

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 5.318 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 18.000 Rm Rate per Rm Rate approved per Rm SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

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 elements etc., with all accessories for spillway stop log gate elements including cost of all materials, machinery, labour, cutting, welding, aligning, anchoring, 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: 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 m Height of gate ( total height of gate elements ) in m : FRL - Sill level + 0.2 : 9.60 m Head of water in m : FRL - Sill level : 9.40 m Weight of stoplog gate elements in tonne for 15 m x 9 m opening based on empirical formula : = 0.0553 x ( L x H x h ) 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.
2 0.716

26

GATE / HOIST AND ALLIED WORKS

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

0.716 0.716

1. a.

b. c. d.

2.

= 0.0025 x ( 15.65 x 9.6 x 9.4 ) : 3.225 The weight computed as above based on empirical formula is further checked by computing the actual weight as per embedded parts fabrication drawings for stoplog gate of same size provided for one of the dam. Actual weight of embedded parts as per data in Item : 5 of Annexure-2 : 3.179 tonnes Consider 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 refer Item : 5 of Annexure-2 ). Requirement of materials : Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5 % wastage ( 421x1.025 ) : 432 kg Plates / flats with 2.5 % wastage ( 2245 x 1.025 ) : 2301 kg Alloy steel conforming to IS : 1570 : Stainless steel plates / flats ( 235+166 ) x 1.025 : 411.00 kg Bolt / Nut / Washer conforming to IS : 1363 : MS bolts and nuts with 2.5 % wastage ( 112 x 1.025 ) : 115 kg Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) : GP / LH electrodes as per data sheet ( Item:5 Annexure-2 ) : 1973 Nos Add for variations / wastage / misc welding @ 10 % ( 1973 x 0.1 ) : 197 Nos Total 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 Nos Stainless steel electrodes as per data sheet ( Item:5 Annexure-2 ) : 1095 Nos Add for variations / wastage @ 5 % ( 1095 x 0.05 ) : 55 Nos Total 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 Cutting : Length of cutting assuming cutting for 2 sides as per data sheet : 163 Rm Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 16 Rm Total length of cutting : 179 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 Length of steel to be cut by gas using pug cutting machine Length of steel to be cut by using shearing machine Time for gas cutting manually at ( av ) 2 m cutting / hour Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour Time for cutting by shearing machine at ( av ) 10 m cutting / hour Acetelyne gas @ 0.6 cum / hour ( 15 + 40 ) x 0.60 Oxygen gas @ 1.8 cum / hour ( 15 + 40 ) x 1.80 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 ) Use of shearing machine with 50 min / hr working ( 3 x60 / 50 ) 3. Welding : Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

: : : : : : : : : : :

29 m 120 m 30 m 15 hours 40 hours 3 hours 33 cum 99 cum 18 hours 48 hours 4 hours

: 303 m

27

GATE / HOIST AND ALLIED WORKS

( 217 + 115 ) x 8 / 15 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 1953 + 1035 ) x 8 / 15 / 6 Total

: 89 hours : 266 hours : 355 hours

4.

5.

6.

7.

Deploy welding transformer for 355 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 89 x 0.25 + 266 x 0.75 ) : 222 hours 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 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 50.4 m SS plates ( 50.4 x 8 / 3 ) : 135 hours Surface cleaning and painting : Painting area for embedded parts at 7 sqm / tonne ( 3.179 x 7 ) : 22 sqm 1 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 ltr 4 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 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 22 sqm at 8 sqm / ltr : 3 ltr 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 hours considered. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections 70 hours 5 9 9 18 Drilling holes for anchors / supports 1 2 --2 Contd

Requirement of work force ( Contd ): Work component

Foreman

Marker / Fabricator / Erector /

Gas cutter / Welder

Helper / Painter Cl-II

Contd Fabricating by stitch welding 89 hours 6 11 --Run welding 266 hours 3 --33 Erection of anchors / dogging set 6 12 --Erection of Sill beam / Tracks / Guide 3 3 --Cleaning surface 20 sqm @ 15 sqm/day ------Painting ( 5 x 20 ) sqm @ 15 sqm / day ------Finishing / cleaning / checking 1 1 --Total : 25 38 42 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 7 Painters Cl-II

22 33 12 6 2 8 2 105

28

GATE / HOIST AND ALLIED WORKS

at 15 sqm / day and 1 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 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 : 3.179 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 Contd Amount in Rs. 16394.40 92040.00 49320.00 6325.00 4752.00 8514.00 1302.00 23436.00 49450.00 1485.00 3120.00 720.00 1597.50 45.00

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

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

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

432.00 2301.00 411.00 115.00 99.00 33.00 217.00 1953.00 1150.00 2.50 15.00 3.00 355.00 18.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

14 15

Wire brush Sundries Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @

Nos LS

3.00 72.00

1% 10% 5% Total cost of Materials :

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

Amount in Rs. 90.00 2160.00 260750.90 2607.51 26075.09 13037.55 302471.04

B. MACHINERY: Sl No 1

Description

Unit Hour Hour

Quantity 355.00 222.00

Welding transformer Fuel / Energy charges

Rate in Rs. 12.00 60.00

Amount in Rs. 4260.00 13320.00

29

GATE / HOIST AND ALLIED WORKS

2 3 4 5 6 7 8 9

Plate shearing machine Fuel / Energy charges Pug cutting machine Fuel / Energy charges Planing machine Fuel / Energy charges Mobile crane 25 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 Hour LS

4.00 4.00 48.00 48.00 135.00 135.00 4.00 4.00 50.00 50.00 16.00 16.00 16.00 16.00 64.00

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

62.00 100.00 16.00 3.00 88.00 75.00 3804.00 1375.00 66.00 9.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

248.00 400.00 768.00 144.00 11880.00 10125.00 15216.00 5500.00 3300.00 450.00 288.00 400.00 288.00 400.00 1920.00 68907.00 689.07 3265.90 3445.35 76307.32

Description

Unit Hour Hour Hour Hour Hour Day Day Day

Quantity 4.00 4.00 135.00 16.00 16.00 25.00 38.00 9.00

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

Rate in Rs. 72.60 45.90 73.40 59.50 59.50 177.00 157.50 157.50 Contd

Amount in Rs. 290.40 183.60 9909.00 952.00 952.00 4425.00 5985.00 1417.50

C. LABOUR ( Contd ) : Sl No Description

Unit

Quantity

9 10 11 12 13 14

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 @

Day Day Day Day Day Day

30.00 3.00 95.00 3.00 7.00 2.00

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

Rate in Rs. Contd 157.50 173.25 141.50 141.50 141.50 143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 4725.00 519.75 13442.50 424.50 990.50 286.00 44502.75 445.03 4450.28 6675.41 6675.41 2225.14 64974.02

30

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:

302471.04 76307.32 64974.02 443752.38 8731.19 4437.52 11093.81 11093.81 8875.05 6212.53 494196.29 820.82 14825.89 509843.00 160400.00 160400.00 ITEM No: 6

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 3.179 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 3.179 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 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 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: 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 m Height of gate ( total height of gate elements ) in m : FRL - Sill level + 0.2 : 9.60 m Head of water in m : FRL - Sill level : 9.40 m Generally, 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 x H x h ) Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0553 x ( 15.65 x 15.65 x 9.6 x 9.4 ) : 71.340 The weight computed as above based on empirical formula is further checked by computing the actual 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 tonnes Consider 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 : 6
0.716 2 0.716

31

GATE / HOIST AND ALLIED WORKS

of Annexure-2 ). 1. Requirement of materials : a. Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5 % wastage ( 461x1.025 ) Plates / flats with 2.5 % wastage ( 70208 x 1.025 ) b. Alloy steel components conforming to IS : 1570 : Lifting pins c. Alluminium / Bronze alloy components conforming to IS : 305 : Bronze pads for slide blocks d. Bolts / Nuts / Washers conforming to IS : 1363 : GI bolts / nuts / washers with 2.5 % wastage ( 288 x 1.025 ) MS bolts / nuts / washers with 2.5 % wastage ( 48 x 1.025 ) e. Rubber seal conforming to IS : 11855 : Bottom seal ( 120 x 1.025 ) Side seals ( music note type uncladed ) ( 19.2 x 1.025 ) f. Welding electrodes ( General purpose / Low hydrogen ) : GP / LH electrodes as per data sheet ( Item:6 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 33626 x 0.1 ) Total requirement of GP / LH electrodes for stitch weld GP electrodes @t 10 % of total ( 36989 x 0.10 ) for run welding LH electrodes @ 90 % of total ( 36989 x 0.90 ) 2. Cutting : Length of cutting assuming cutting for 2 sides as per data sheet Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 %

: 473 kg : 71963 kg : 104 kg : 48 kg : 295 kg : 49 kg : 123 Rm : 20 Rm : : : : : 33626 Nos 3363 Nos 36989 Nos 3699 Nos 33290 Nos

: 980 Rm : 98 Rm Total : 1078 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 : 50 m Length of steel to be cut by gas using pug cutting machine : 1028 m Time for gas cutting manually at ( av ) 2 m cutting / hour : 25 hours Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 343 hours Acetelyne gas @ 0.6 cum / hour ( 25 +343 ) x 0.60 : 221 cum

Oxygen gas @ 1.8 cum / hour ( 25 + 343 ) x 1.80 Use of gas cutting torch with 50 min / hr working ( 25 x 60 / 50 ) Use of pug cutting machine with 50 min/ hr working ( 343 x 60 / 50 ) 3. Welding : Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 3699 / 15 ) x 8 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 33290 / 15 ) x 8 / 6 Total

: 663 cum : 30 hours : 412 hours : 3228 Rm : 986 hours : 2959 hours : 3945 hours

Deploy welding transformer for 3945 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 986 x 0.25 + 2959 x 0.75 ) : 4. Surface cleaning and painting : Painting area for stoplog elements at 18 sqm / tonne ( 71.157x18 ) : 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 1280 sqm @ 9 sqm / ltr / coat : 3 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 :

2466 hours 1280 sqm 142 ltr 640 ltr

32

GATE / HOIST AND ALLIED WORKS

5.

6.

Note :

7.

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 1280 sqm at 8 sqm / ltr : 160 ltr 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. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections 442 hours 28 56 56 112 Drilling holes for seal fixing 6 12 --12 Fabricating by stitch welding 986 hours 62 124 --248 Run welding 2959 hours 37 --370 370 Seal fixing 8 elements @ 2 per day 8 8 --16 Cleaning surface1280 sqm @15 sqm/day ------85 Painting ( 4x1280 ) sqm @ 15 sqm / day ------409 Finishing / cleaning / guide shoe fixing 1 2 --4 Trial operation and checking 2 2 --4 Total : 144 204 426 1260 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 341 Painters Cl-II at 15 sqm / day and 68 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

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 : 71.157 tonne Rate in Rs. 37.95 40.00 215.00 Amount in Rs. 17950.35 2878520.00 22360.00

2 3

Structural steel Angles / beams / channels / bars Plates / flats Alloy steel components Lifting pins Alluminium / Bronze alloy components

kg kg kg

473.00 71963.00 104.00

33

GATE / HOIST AND ALLIED WORKS

6 7 8 9 10 11 12 13 14 15 16

Bronze pads Bolt / Nut / Washer GI bolts / nuts / washers MS bolts / nuts / washers Rubber seals Bottom seal Side seals ( uncladed ) 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 Rm Rm cum cum Nos Nos ltr ltr ltr Hour Hour Nos LS

48.00 295.00 49.00 123.00 20.00 663.00 221.00 3699.00 33290.00 142.00 640.00 160.00 3945.00 30.00 13.00 150.00

635.00 95.00 55.00 147.00 235.00 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:

30480.00 28025.00 2695.00 18081.00 4700.00 31824.00 57018.00 22194.00 399480.00 84348.00 133120.00 38400.00 17752.50 75.00 390.00 4500.00 3791912.85 37919.13 379191.29 189595.64 4398618.91

1% 10% 5% Total cost of Materials :

B. MACHINERY: Sl No 1

Description

Unit Hour Hour

Quantity 3945.00 2466.00

Welding transformer Fuel / Energy charges

Rate in Rs. 12.00 60.00 Contd

Amount in Rs. 47340.00 147960.00

B. MACHINERY ( Contd ) : Sl No Description

Unit

Quantity

2 3 4 5 6 7

Pug cutting machine Fuel / Energy charges Mobile crane 25 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 LS

412.00 412.00 100.00 100.00 100.00 100.00 200.00 200.00 100.00 100.00 150.00

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 :

Rate in Rs. Contd 16.00 3.00 3804.00 1375.00 66.00 9.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 6592.00 1236.00 380400.00 137500.00 6600.00 900.00 3600.00 5000.00 1800.00 2500.00 4500.00 745928.00 7459.28 29959.60 37296.40 820643.28

34

GATE / HOIST AND ALLIED WORKS

C. LABOUR: Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13

Description

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

Quantity 100.00 100.00 200.00 144.00 204.00 56.00 333.00 37.00 150.00 766.00 153.00 341.00 5.00

Crew for Mobile crane Crew for Drilling machine Crew for Grinding machine Foreman Marker / Fabricator / Erector Gas cutter Welder ( General ) Welder ( X - ray ) Khalasi Helper fabrication / erection Helper 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 59.50 59.50 177.00 157.50 157.50 157.50 173.25 145.50 141.50 141.50 141.50 143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 7570.00 5950.00 11900.00 25488.00 32130.00 8820.00 52447.50 6410.25 21825.00 108389.00 21649.50 48251.50 715.00 351545.75 3515.46 35154.58 52731.86 52731.86 17577.29 513256.80

ABSTRACT: A. Cost of Materials B. Hire charges of Machinery C. Cost of Labour

Rs: Rs: Rs: TOTAL Rs:

4398618.91 820643.28 513256.80 5732518.98

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 @

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:

82435.02 57325.19 143312.97 143312.97 114650.38 80255.27 6353810.79 18372.74 190614.32 6562797.85 92200.00 92200.00 ITEM No: 7

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2x71.157 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 71.157 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 automatic lifting beam with all accessories for handling, lowering and lifting of spillway stop log gate elements 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 leads and lifts.

35

GATE / HOIST AND ALLIED WORKS

DATA: Automatic lifting beam for lifting spillway stop log elements consists of fabricated beam with lifting 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 height of 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 the weight 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 m Height of gate ( total height of gate elements ) in m : FRL - Sill level + 0.2 : 9.60 m Head of water in m : FRL - Sill level : 9.40 m Weight of stoplog gate elements in tonne for 15 m x 9 m opening based on empirical formula : = 0.0553 x ( L x H x h ) Consider weight of lifting beam in tonnes @ 40 % of weight of one stoplog element: /n = 0.40 x 0.0553 x ( L x H x h ) 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 ) /8 : 3.567 The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings for lifting beam for stoplog gate of same size provided for one of the dam. Actual weight of stoplog gate lifting beam as per data in Item : 7 of Annexure-2 : 3.528 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of lifting
0.716 2 0.716 2 0.716

1. a.

b. c. d. e.

f.

2.

beam for spillway stoplog elements provided for one of the dam for rate analysis ( for details refer Item : 7 of Annexure-2 ). Requirement of materials : Structural steel conforming to IS : 2062 : Angles / beams / channels / bars with 2.5 % wastage ( 13 x 1.025 ) : 13 kg Plates / flats with 2.5 % wastage ( 3306 x 1.025 ) : 3389 kg Alloy steel components conforming to IS : 1570 : Lifting pins : 101 kg Alluminium / Bronze alloy components conforming to IS : 305 : Bronze Bush : 5 kg Forged steel components conforming to IS : 2004 : Lifting hooks : 130 kg Bolts / Nuts / Washers conforming to IS : 1363 : MS bolts / nuts / washers with 2.5 % wastage : 3 kg MS pipe 100 mm dia : 11 kg Welding electrodes ( General purpose / Low hydrogen ) : GP / LH electrodes as per data sheet ( Item:7 Annexure-2 ) : 2121 Nos Add for variations / wastage / misc welding @ 10 % ( 2121 x 0.1 ) : 212 Nos Total 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 Cutting : Length of cutting assuming cutting for 2 sides as per data sheet : 172 Rm

36

GATE / HOIST AND ALLIED WORKS

: Total : For cutting structural steel sections to required sizes gas cutting is assumed. Length of steel to be cut by using gas manually : Length of steel to be cut by gas using pug cutting machine : Time for gas cutting manually at ( av ) 2 m cutting / hour : Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : Acetelyne gas @ 0.6 cum / hour ( 20 + 50 ) x 0.60 : Oxygen gas @ 1.8 cum / hour ( 20 + 50 ) x 1.80 : Use of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) : Use of pug cutting machine with 50 min / hr working ( 50 x 60 / 50 ) : 3. Welding : Length of welding as per data sheet : For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 233 / 15 ) x 8 / 2 : For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 2100 / 15 ) x 8 / 6 : Total : Deploy welding transformer for 249 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 62 x 0.25 + 187 x 0.75 ) : 4. Surface cleaning and painting : Painting area for lifting beam at 12 sqm / tonne ( 3.528 x 12 ) : 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 42 sqm @ 9 sqm / ltr / coat : 2 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 :

Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 %

17 Rm 189 Rm 40 m 149 m 20 hours 50 hours 42 cum 126 cum 24 hours 60 hours 211 Rm 62 hours 187 hours 249 hours

156 hours 42 sqm 5 ltr 14 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 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. 6. Requirement of work force : Work component

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

Foreman

37

GATE / HOIST AND ALLIED WORKS

b. Workforce for painting 1 coat primer and 2 coats finishing paint consists of 8 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 @ Life of welding set Use rate of welding set per hour Cost of gas cutting set @ Life of gas cutting set Use rate of gas cutting set per hr

Rs:

4500.00 / Each ( cost / life ) 1500.00 / Each ( cost / life ) UNIT : Unit Quantity

Rs:

Rs: 4500.00 : 1000 hours Rs: 4.50 Rs: 1500.00 : 600 hours Rs: 2.50 3.528 tonne Rate in Rs. 37.95 40.00 215.00 Contd Amount in Rs. 493.35 135560.00 21715.00

RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars

Structural steel Angles / beams / channels / bars Plates / flats Alloy steel components Lifting pins

kg kg kg

13.00 3389.00 101.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

Rate in Rs. Contd 635.00 165.00 45.00 55.00 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:

Amount in Rs.

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Bronze alloy components : Bronze bush Forged steel components : Lifting hooks MS pipe 100 mm dia Bolt / Nut / Washer MS bolts / nuts / washers 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 @

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

5.00 103.00 11.00 3.00 126.00 42.00 233.00 2100.00 5.00 14.00 5.00 249.00 24.00 1.00 20.00 1% 10%

3175.00 16995.00 495.00 165.00 6048.00 10836.00 1398.00 25200.00 2970.00 2912.00 1200.00 1120.50 60.00 30.00 600.00 230972.85 2309.73 23097.29

38

GATE / HOIST AND ALLIED WORKS

Add for Contractor's Overheads @

5% Total cost of Materials :

Rs: Rs:

11548.64 267928.51

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

Description

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

Quantity 249.00 156.00 60.00 60.00 2.00 2.00 4.00 4.00 2.00 2.00 2.00 2.00 15.00

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 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 :

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

Amount in Rs. 2988.00 9360.00 960.00 180.00 724.00 990.00 264.00 36.00 36.00 50.00 36.00 50.00 450.00 16124.00 161.24 1111.60 806.20 18203.04

C. LABOUR: Sl No 1 2 3 4 5 6 7 8 9 10 11

Description

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

Quantity 2.00 2.00 2.00 12.00 21.00 11.00 24.00 64.00 5.00 8.00 1.00

Crew for Mobile crane 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 @ 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 59.50 59.50 177.00 157.50 157.50 157.50 141.50 141.50 141.50 143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 151.40 119.00 119.00 2124.00 3307.50 1732.50 3780.00 9056.00 707.50 1132.00 143.00 22371.90 223.72 2237.19 3355.79 3355.79 1118.60 32662.97

ABSTRACT: A. Cost of Materials B. Hire charges of Machinery C. Cost of Labour

Rs: Rs: Rs:

267928.51 18203.04 32662.97

39

GATE / HOIST AND ALLIED WORKS

TOTAL Rs: 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 @ 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:

318794.52 3143.52 3187.95 7969.86 7969.86 6375.89 4463.12 351904.72 910.93 10557.14 363372.80 103000.00 103000.00 ITEM No: 8

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 3.528 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 3.528 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 Class- II type moving gantry crane consisting of rail mounted gantry frame, top platform with hand railing, long / cross travel arrangements, rope drums, gear systems, electric motors, electromagnetic brake system, cabin, control panel, wire rope, ladder, motorised cable reeling drum etc., with all accessories for operating spillway stop log gate elements and river sluice / canal sluice emergency gates 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: Moving gantry crane consists of rail mounted gantry frame with long travel arrangement, cross travel trolley with track arrangement mounted on gantry frame top platform, rope drum hoist with 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 hoisting capacity 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 tonnes Number of stoplog gate elements as per item 6 (n) : 8 Nos Capacity 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 tonnes Round off the capacity to next 5 tonne say : 25 tonne The 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 tonnes The hoist capacity and hoist weight computed as above based on empirical formulae are further checked 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 tonne Actual weight of moving gantry crane as per data in Item : 8 of Annexure-2 : 30.856 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of moving

40