GATE / HOIST AND ALLIED WORKS

13 14 15

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

70.00 158.00 10.00

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

141.50 141.50 143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

9905.00 22357.00 1430.00 204083.80 2040.84 20408.38 30612.57 30612.57 10204.19 297962.35

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 @

Rs: Rs: Rs: TOTAL Rs: 8.24% 1.00% 2.50% 2.50% Rs: Rs: Rs: Rs:

2224489.54 284211.28 297962.35 2806663.17 35978.33 28066.63 70166.58 70166.58

Add for power supply arrangements @ Add for enabling works @

2.00% 1.40%

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

56133.26 39293.28 3106467.84 8527.06 93194.04 3208188.93 97100.00 97100.00 ITEM No: 21

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2x33.025 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 33.025 tonne Rate per tonne Rate approved per tonne SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

ITEM: Design, fabrication, supply, erection and commissioning of structural steel hoist bridge consisting of columns, beams, bracings, stiffeners, ties, chequered plate covering, hand railing, ladder etc., with all accessories for supporting rope drum hoist for operating barrage gates including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying two coats of zinc chromate red oxide primer and three coats of synthetic enamel paint etc., complete with all leads and lifts. DATA: Structural steel hoist bridge for supporting rope drum hoist for operating barrage gates consists of steel columns and beams with cross beams, ties, bracings, stiffeners, hand railing, ladder, chequered plate covering, anchorages etc., with all accessories. The size of the steel hoist bridge depends on the size of the gate and hoist capacity required to operate the gate. Generally the hoist capacity will be 1.5 times the weight of the gate and the weight of hoist bridge will be about 400 kg per metre height of column or per metre span of beam. Consider vertical lift roller gate for 13.72 m x 8.26 m opening for analysis. For vent opening of 13.72 x 8.26 m the approximate size of gate leaf will be 14.7 x 8.6 m. Head of water above sill level considered : 8.26 m Weight of gate leaf in tonne for vertical lift roller gate based on empirical formula :

100

GATE / HOIST AND ALLIED WORKS

= 0.0335 ( L 2 x H x h ) 0.716 Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm. = 0.0335 x( 14.7 x 14.7 x 8.6 x 8.26 ) 0.716 : 33.289 Consider hoist capacity including 25 % reserve @ 1.5 times the weight of gate : ( 1.5 x 33.289 ) : 49.9335 Round off the hoist capacity to next 10 tonne : 50 tonnes Consider 15 m span and 10 m over all height ( 9 m columns and 1 m beams ) for bridge. Assessment of weight of structural steel for bridge: Columns with bracings, anchors, stiffeners etc @ 400 kg / m for 9 m ht : : 3600.00 kg Beams with cross beams, stiffeners etc @ 400 kg / m for 15 m span : : 6000.00 kg Total : 9600.00 kg Other accessories such as railing, chequered plate, ladder etc @ 10 % : 960.00 kg Total : 10560.00 kg The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings of hoist bridge structure for vertical lift barrage gate of same size provided for one of the barrage. Actual weight of hoist supporting bridge as per data in Item : 21 of Annexure-2 : 10239.00 kg Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of hoist bridge structure for vertical lift barrage gate provided for one of the barrage for rate analysis ( for details refer Item : 21 of Annexure-2 ).

1. Requirement of materials: a. Structural steel conforming to IS : 2062 : Angles / beams / channels with 2.5 % wastage ( 4453 x 1.025 ) Plates / flats with 2.5 % wastage ( 5431 x 1.025 ) Chequered plate with 2.5 % wastage ( 133 x 1.025 ) b. MS pipes 32 mm dia ( 30.86 x 1.025 ) MS pipes 25 mm dia ( 61.72 x 1.025 ) c. Bolt / Nut / Washer MS bolt / Nut / Washers with 2.5 % wastage ( 18 x 1.025 ) d. Welding electrodes ( General purpose / Low hydrogen ) : GP / LH electrodes as per data sheet ( Item:21 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 4731 x 0.1 ) Total requirement of GP / LH electrodes for stitch weld GP electrodes @t 10 % of total ( 5204 x 0.10 ) for run welding LH electrodes @ 90 % of total ( 5204 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 ( 50 + 73 ) x 0.60 Oxygen gas @ 1.8 cum / hour ( 50 + 73 ) x 1.80 Use of gas cutting torch with 50 min / hr working ( 50 x 60 / 50 ) Use of pug cutting machine with 50 min / hr working ( 73 x 60 / 50 ) 3. Welding :

: : : : :

4564 kg 5567 kg 136 kg 32 Rm 64 Rm

: 18.5 kg : : : : : 4731 Nos 473 Nos 5204 Nos 520 Nos 4684 Nos

: 290 Rm : 29 Rm : 319 Rm : : : : : : : : 100 m 219 m 50 hours 73 hours 74 cum 222 cum 60 hours 88 hours

101

GATE / HOIST AND ALLIED WORKS

Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 520 / 15 ) x 8 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 4684 / 15 ) x 8 / 6 Total

: 473 Rm : 139 hours : 416 hours : 553 hours

Deploy welding transformer for 553 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 139 x 0.25 + 416 x 0.75 ) : 347 hours 4. Surface cleaning and painting : Painting area for hoist bridge @ 20 sqm per tonne ( 10.239 x 20 ) : 205 sqm 2 coats of zinc chromate red oxide primer . Quantity of primer paint for 205 sqm @ 12 sqm / ltr / coat : 35 ltr 3 coats of synthetic enamel paint. Quantity of synthetic enamel paint for 205 sqm @ 12 sqm / ltr / coat : 51 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 205 sqm @ 8 sqm / ltr : 26 ltr 5. Requirement of other machinery : For handling of parts during fabrication and erection 8 t mobile crane for 12 hours and stationery

6.

Note :

7.

8.

derric crane for 40 hours considered. For drilling holes in plates 8 hours use of drilling machine considered. For grinding and finishing weld joints in liner plates 8 hours use of grinding machine considered. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections 148 hours 9 18 18 36 Fabricating by stitch welding 139 hours 9 17 --34 Run welding 416 hours 5 --52 52 For erection of columns & bracings 2 4 --16 For erection of beams / cross beams 4 8 --16 For erection of railing / covering etc 1 2 --4 Cleaning surface 205 sqm @ 15 sqm/day ------14 Painting ( 5 x 205 ) sqm @ 15 sqm / day ------61 Finishing / Cleaning 1 1 --1 Total : 31 50 70 234 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 coat primer and 3 coats finishing paint consists of 51 Painters Cl-II at 15 sqm / day and 10 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. 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

102

GATE / HOIST AND ALLIED WORKS

Life of gas cutting set Use rate of gas cutting set per hr RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars Unit

( cost / life ) UNIT : Quantity

: 600 hours Rs: 2.50 10.239 tonne Rate in Rs. 37.95 40.00 42.00 127.00 95.25 55.00 48.00 258.00 6.00 12.00 140.00 Contd Amount in Rs. 173203.80 222680.00 5712.00 4064.00 6096.00 1017.50 10656.00 19092.00 3120.00 56208.00 4900.00

2 3 4 5 6 7 8

Structural steel Angles / beams / channels / bars Plates / flats Chequered plate MS pipe 32 mm dia MS pipe 25 mm dia Bolt / Nut / Washers Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen ) Zinc chromate red oxide primer

kg kg kg Rm Rm kg cum cum Nos Nos ltr

4564.00 5567.00 136.00 32.00 64.00 18.50 222.00 74.00 520.00 4684.00 35.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

9 10 11 12 13 14

Synthetic enamel paint ( 1st quality ) 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 @

ltr ltr Hour Hour Nos LS

51.00 26.00 553.00 60.00 5.00 20.00

1% 10% 5% Total cost of Materials :

Rate in Rs. Contd 176.00 240.00 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 8976.00 6240.00 2488.50 150.00 150.00 600.00 525353.80 5253.54 52535.38 26267.69 609410.41

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

Description

Unit Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour

Quantity 553.00 347.00 88.00 88.00 12.00 12.00 40.00 40.00 8.00 8.00 8.00 8.00

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

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

Amount in Rs. 6636.00 20820.00 1408.00 264.00 4344.00 5940.00 2640.00 360.00 144.00 200.00 144.00 200.00

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GATE / HOIST AND ALLIED WORKS

Sundries

LS

20.00

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

30.00 Total Rs: Rs: Rs: Rs: Rs:

600.00 43700.00 437.00 2838.40 2185.00 49160.40

Description

Unit Hour Hour Hour Day Day Day Day

Quantity 12.00 8.00 8.00 31.00 50.00 18.00 52.00

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

Rate in Rs. 75.70 59.50 59.50 177.00 157.50 157.50 157.50 Contd

Amount in Rs. 908.40 476.00 476.00 5487.00 7875.00 2835.00 8190.00

C. LABOUR ( Contd ) : Sl No Description

Unit

Quantity

8 9 10 11

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

159.00 24.00 51.00 5.00

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

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

Amount in Rs. 22498.50 3396.00 7216.50 715.00 60073.40 600.73 6007.34 9011.01 9011.01 3003.67 87707.16

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:

609410.41 49160.40 87707.16 746277.97 8458.42 7462.78 18656.95 18656.95 14925.56 10447.89 824886.52 2643.71 24746.60

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2x10.239 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00%

104

GATE / HOIST AND ALLIED WORKS

Total cost for

10.239 tonne Rate per tonne Rate approved per tonne YEAR : 2010-11

Rs: Rs: Rs:

852276.82 83200.00 83200.00 ITEM No: 22

SECTION: GATE / HOIST & ALLIED WORKS.

ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity rope drum hoist consisting of hoist platform, rope drum, pulleys, gear system, electri c motor, electro-magnetic brake system, manual operation assembly, position indicator, control panel, wire rope etc., with all accessories for operating vertical lift roller gates for barrage 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 vertical lift barrage gate consists of hoist supporting frames, pulley supports, 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.

Consider rope drum hoist for operating barrage gate for clear opening of 13.72 m x 8.26 m. For vent opening of 13.72 x 8.26 m the approximate size of gate leaf will be 14.7 x 8.6 m. Head of water above sill level considered : 8.26 m Generally the capacity of hoist required for barrage gate will be 1.5 times the weight of gate. Weight of hoist with all accessories is assumed at 0.1 tonne per tonne capacity of hoist as the hoist is supported on steel bridge and no anchorages and base frames are required. Weight of gate leaf in tonnes based on empirical formula : = 0.0335 ( L 2 x H x h ) 0.716 Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm. = 0.0335 ( 14.7 x 14.7 x 8.6 x 8.26 ) 0.716 : 33.289 Consider capacity of hoist including 25 % reserve capacity at 1.5 times the weight of gate : ( 1.50 x 33.289 ) : 49.933 tonnes Round off the capacity of hoist to next 10 tonne : 50.00 tonne Consider Weight of hoist with all accessories @ 0.1 t / tonne capacity of hoist : ( 50 x 0.10 ) : 5.00 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 for vertical lift barrage gate rope drum hoist of same capacity provided for one of the barrage. Actual capacity of rope drum hoist as per data sheet : 50.000 tonnes Actual wt of barrage gate rope drum hoist as per data in Item :22 of Annexure-2 : 5.069 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of rope drum hoist for vertical lift barrage gate provided for one of the barrage for rate analysis ( for details refer Item : 22 of Annexure-2 ). 1. Requirement of materials: a. Structural steel conforming to IS : 2062 : Angles / beams / channels / bars with 2.5 % wastage ( 410x1.025 ) : 420.00 kg Plates / flats with 2.5 % wastage ( 219 x 1.025 ) : 225.00 kg b. Cast steel components conforming to IS : 1030 : Rope drums 2 Nos / Gears : 1290.00 kg Pinions : 98.00 kg Pulleys 8 Nos / Couplings 2 Nos : 650.00 kg

105

GATE / HOIST AND ALLIED WORKS

Plummer blocks / Hubs c. Alloy steel steel components conforming to IS : 1570 : Shafts / Keys Pins d. Alluminium/ Bronze alloy components conforming to IS : 305 : Bearings / Bush e. Bolt / Nut / Washers conforming to IS : 1363 : MS Bolts / Nuts / Washers with 2.5 % wastage ( 25 x 1.025 ) f. Steel wire rope conforming ti IS 2266 : 28 mm dia 6 / 37 construction 1 No 120 Rm @ 2.71 kg / m g. Other components : Manual operation assembly Worm reducer ( size 800 ) Electric motor 12.5 hp Gate position indicator Ele-magnetic brake Electric cable / switch / control panel etc

: 250.00 kg : 350.00 kg : 96.00 kg : 100.00 kg : 26.00 kg : 435.00 kg : : : : : : 1 No. 1 No 1 No. 1 No. 1 No. 1 set

h. Welding electrodes ( General purpose / Low hydrogen ) : GP / LH electrodes as per data sheet ( Item:22 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 553 x 0.1 ) Total requirement of GP / LH electrodes for stitch weld GP electrodes @ 10 % of total ( 608 x 0.10 ) for run welding LH electrodes @ 90 % of total ( 608 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 ( 10 + 7 ) x 0.60 Oxygen gas @ 1.8 cum / hour ( 10 + 7 ) x 1.80 Use of gas cutting torch with 50 min / hr working ( 10 x 60 / 50 ) Use of pug cutting machine with 50 min / hr working ( 7 x 60 / 50 ) 3. Welding : Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 61 / 15 ) x 8 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 547 / 15 ) x 8 / 6 Total

: : : : :

553 Nos 55 Nos 608 Nos 61 Nos 547 Nos

: 37 Rm : 4 Rm : 41 Rm : : : : : : : : 20 m 21 m 10 hours 7 hours 10 cum 30 cum 12 hours 9 hours

: 53 Rm : 16 hours : 49 hours : 65 hours

Deploy welding transformer for 65 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 16 x 0.25 + 49 x 0.75 ) : 41 hours 4. Surface cleaning and painting :

106

GATE / HOIST AND ALLIED WORKS

Painting area for hoist at 20 sqm / tonne of str steel ( 0.645 x 20 ) : 13 sqm 2 coats of zinc chromate red oxide primer. Quantity of primer paint for 13 sqm @ 12 sqm / ltr / coat : 2 ltr 3 coats of synthetic enamel paint. Quantity of synthetic enamel paint for 13 sqm @ 12 sqm / ltr /coat : 3.5 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 13 sqm @ 8 sqm / ltr : 1.5 ltr 5. Requirement of other machinery : For lifting and placing in position hoist drums, worm reducers, gears, floating shafts etc use of 25 t mobile crane for 56 hours with energy charges for 28 hours considered. For handling of parts during fabrication and transportation use of 8 t mobile crane for 40 hours with energy charges for 20 hours considered. For drilling holes for bolts 16 hours use of drilling machine considered. For grinding and finishing weld joints 8 hours use of grinding machine considered

6. Requirement of work force : Work component

Foreman

Marker / Fabricator / Erector /

Gas cutter / Welder

Helper / Painter Cl-II

Cutting sections/ drilling holes 21 hours 1 3 3 6 Fabricating by stitch welding 16 hours 1 2 --4 Run welding 49 hours 1 --6 6 Erection of hoist frame 2 2 --8 Erection of drums / gears / shafts 4 8 --16 Erection of pulleys / plummer blocks 2 4 --8 Erection of worm reducers / brake / motor 2 4 --8 Erection of other accessories 1 2 --2 Erection of control panel / cabling 1 1 --2 Checking and running without rope 1 2 --4 Cleaning surface 13 sqm @ 15 sqm/day ------1 Painting ( 5 x 13 ) sqm @ 15 sqm / day ------4 Rope fixing and checking 2 4 --8 Trial running by lowering / lifting gate 1 2 --4 Final checking / Finishing / cleaning 1 1 --2 Total : 20 35 9 83 Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding. b. Workforce for painting 2 coat primer and 3 coats finishing paint consists of 3 Painters Cl-II at 15 sqm / day and 1 helper to assist painters. 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

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Use rate of gas cutting set per hr RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars Unit

( cost / life ) UNIT : Quantity

Rs:

2.50

5.069 tonne wt 50.00 t capacity Rate Amount in Rs. in Rs. 37.95 40.00 145.00 150.00 125.00 125.00 Contd 15939.00 9000.00 187050.00 14700.00 81250.00 31250.00

Structural steel Angles / beams / channels / bars Plates / flats Cast steel components : Rope drums 2 Nos / Gears Pinions Pulleys 3 Nos / Couplings 2 Nos Plummer blocks / Hubs

kg kg kg kg kg kg

420.00 225.00 1290.00 98.00 650.00 250.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

Rate in Rs. Contd 175.00 215.00 635.00 105.00 55.00 120000.00 60000.00 22500.00 9000.00 15000.00 18000.00 48.00 258.00 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:

Amount in Rs.

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Alloy steel components Shafts / Keys Pins Bronze alloy components : Bronze bearings / bush Wire rope 28 mm dia 6/37 construction MS Bolt / Nut / Washer Worm reducers Electric motor 12.5 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 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 No. No. No. No. No. LS cum cum Nos Nos ltr ltr ltr kg Hour Hour Nos LS

350.00 96.00 100.00 435.00 26.00 1.00 1.00 1.00 1.00 1.00 1.00 30.00 10.00 61.00 547.00 2.00 3.50 1.50 50.00 65.00 12.00 2.00 1000.00

61250.00 20640.00 63500.00 45675.00 1430.00 120000.00 60000.00 22500.00 9000.00 15000.00 18000.00 1440.00 2580.00 366.00 6564.00 280.00 616.00 360.00 9700.00 292.50 30.00 60.00 30000.00 828472.50 8284.73 82847.25 41423.63 961028.10

1% 10% 5% Total cost of Materials :

B. MACHINERY:

108

GATE / HOIST AND ALLIED WORKS

Sl No 1 2 3 4 5

Description Welding transformer Fuel / Energy charges Mobile crane 25 t Fuel / Energy charges Pug cutting machine Fuel / Energy charges Mobile crane 8 t Fuel / Energy charges Grinding machine Fuel / Energy charges

Unit Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour

Quantity 65.00 41.00 56.00 28.00 9.00 9.00 40.00 20.00 16.00 16.00

Rate in Rs. 12.00 60.00 3804.00 1375.00 16.00 3.00 362.00 495.00 18.00 25.00 Contd

Amount in Rs. 780.00 2460.00 213024.00 38500.00 144.00 27.00 14480.00 9900.00 288.00 400.00

B. MACHINERY ( Contd ) : Sl No Description

Unit

Quantity

6 7

Drilling machines Fuel / Energy charges Sundries

Hour Hour LS

8.00 8.00 600.00

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

Rate in Rs. Contd 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 144.00 200.00 18000.00 298347.00 2983.47 6948.70 14917.35 323196.52

Description

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

Quantity 40.00 56.00 8.00 16.00 20.00 35.00 3.00 6.00 90.00 78.00 2.00 3.00 3.00

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

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

Rate in Rs. 75.70 72.60 59.50 59.50 177.00 157.50 157.50 157.50 145.50 141.50 141.50 141.50 143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 3028.00 4065.60 476.00 952.00 3540.00 5512.50 472.50 945.00 13095.00 11037.00 283.00 424.50 429.00 44260.10 442.60 4426.01 6639.02 6639.02 2213.01 64619.75

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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:

961028.10 323196.52 64619.75 1348844.37 23967.05 13488.44 33721.11 33721.11 26976.89 18883.82 1499602.78

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 5.069 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 5.069 tonne weight 50.000 tonne capacity Rate per tonne weight Rate per tonne capacity Rate approved per tonne capacity SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

Rs: Rs: Rs: Rs: Rs: Rs:

1308.82 44988.08 1545899.68 304970.00 30900.00 30900.00 ITEM No: 23

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sill beam, wall plates, first stage anchors, anchor girders, anchor bars, trunnion supports etc., with all accessories for outflow regulating automatic gates for barrage/ escape including cost of all materials, labour, machinery, 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 automatic outflow regulating gate consist of sill beam / wall plates / anchor / girders / anchor bars trunnion supports etc., with all accessories. The weight of embedded parts for automatic gate will be generally about 35 to 40 percent of weight of gate leaf with fulcrum assembly. Consider embedded parts for automatic outflow regulating gate for barrage opening of size 8.0 m x 3.5 m. Size of gate : 8.00 m x 3.50 m Head of water : 3.50 m Weight of automatic outflow regulating gate with fulcrum assembly in tonne for the opening = 0.1325 x ( L 2 x H x h ) 0.673 based on empirical formula Consider Weight of embedded parts in tonne @ av. 55 % of weight of gate : 2 0.673 = 0.375 x 0.1325 x ( L x H x h ) Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.049 x ( 8 x 8 x 3.5 x 3.3 ) 0.673 : 4.177 The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings of embedded parts for barrage outflow regulating radial gate of same size furnished by the designer. Actual weight of embedded parts : : 3.910 tonnes Consider actual weight for data rate analysis.

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Consider details of Material / Gas cutting / Welding based on fabrication drawings of embedded parts for automatic outflow regulating gate as provided by the designer. ( for details refer Item : 23 of Annexure-2 ). 1. Requirement of materials: a. Structural steel conforming ti IS : 2062 : Total weight of structural steel excluding wastage : 3800 kg Weight of Angles / Channels / Beams @ 20 % : 760 kg Weight of Plates / Flats @ 80 % : 3040 kg Angles / beams / channels / bars with 2.5 % wastage ( 760x1.025 ) : 779 kg Plates / flats with 2.5 % wastage ( 3040 x 1.025 ) : 3116 kg b. Alloy steel conforming to IS : 1570 : Stainless steel plates / flats AISI 410 ( 49 x 1.025 ) say: 50.00 kg Stainless steel plates / flats AISI 304L ( 62 x 1.025 ) say: 64.00 kg

c. Bolt / Nut / Washer conforming to IS : 1363 : MS bolts and nuts with 2.5 % wastage ( 129 x 1.025 ) d. Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) : GP / LH electrodes as per data sheet ( Item:23 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 133 x 0.1 ) Total requirement of GP / LH electrodes for stitch welding GP electrodes @t 10 % of total ( 147 x 0.10 ) for run welding LH electrodes @ 90 % of total ( 147 x 0.90 ) Stainless steel electrodes as per data sheet ( Item:23 Annexure-2 ) Add for variations / wastage @ 5 % ( 987 x 0.05 ) Total requirement of Stainless steel ( SS ) electrodes for stitch weld SS electrodes @t 10 % of total ( 1036 x 0.10 ) for run weld SS electrodes @t 90 % of total ( 1036 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 %

: 132 kg : : : : : : : : : : 133 Nos 14 Nos 147 Nos 15 Nos 132 Nos 987 Nos 49 Nos 1036 Nos 104 Nos 932 Nos

: 168.00 Rm : 17.00 Rm Total : 185.00 Rm For cutting structural steel sections to required sizes plate shearing machine and gas cutting is assumed. Length of steel to be cut by using plate shearing machine : 30 m Length of steel to be cut by using gas manually : 40 m Length of steel to be cut by gas using pug cutting machine : 115 m Time for cutting by shearing machine @ ( av ) 10 m cutting / hour : 3 hours Time for gas cutting manually at ( av ) 2 m cutting / hour : 20 hours Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 38 hours Acetelyne gas @ 0.6 cum / hour ( 20 + 38 ) x 0.60 : 35 cum Oxygen gas @ 1.8 cum / hour ( 20 + 38 ) x 1.80 : 105 cum Use of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) : 23 hours Use of pug cutting machine with 50 min / hr working ( 38 x 60 / 50 ) : 45 hours 3. Welding : For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 15 + 104 ) x 8 / 15 / 2 : 32 hours For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 932 + 132 ) x 8 / 15 / 6 : 95 hours Total : 127 hours Deploy welding transformer for 127 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

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GATE / HOIST AND ALLIED WORKS

( 32 x 0.25 + 95 x 0.75 ) 4. Planing SS plates for seal seats : For surface finishing of SS plates for seal tracks planing machine is considered. Length of SS plate for surface finishing by planing machine Length of planing at a time for 4 m stroke planing machine Time for planing 3 m length section with 50 min / hour working Time for planing 47 m SS plates ( 47 x 8 / 3 ) 5. Surface cleaning and painting : Painting area for embedded parts at 10 sqm / tonne ( 3.9 x 10 ) 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 40 sqm @ 9 sqm / ltr / coat 4 coats of coal tar epoxy paint 100 micron dry film each coat. Quantity of coal tar epoxy paint for 40 sqm @ 6 sqm / ltr / coat

: 80 hours

: : : :

47 Rm 3 Rm 8 hours 126 hours

: 40 sqm : 5 ltr : 27 ltr

6.

7.

Note :

8.

9.

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 40 sqm @ 8 sqm / ltr : 5 ltr Requirement of other machinery : For drilling holes for anchor bolts 16 hours use of drilling machine considered. For finishing weld joints / edges 12 hours use of grinding machine considered. For handling of parts during fabrication and erection use of 8 t mobile crane for 18 hours and stationery derric crane for 56 hours considered. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Painter Cl-II Fabricator / Welder Erector / Cutting sections 68 hours 4 8 8 24 Drilling holes for anchors / supports --2 --4 Fabricating by stitch welding 32 hours 4 8 --24 Run welding 95 hours 6 --12 12 Erection of Anchor girders / anchor bars 2 4 --12 Erection of first stage anchors 1 2 --4 Erection of Sill beam / Wall plates 2 4 --12 Cleaning surface 40 sqm @ 15 sqm/day ------3 Painting ( 5 x 40 ) sqm @ 15 sqm / day 2 ----15 Finishing / Checking 1 2 --2 Total : 22 30 20 112 a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision considered for welder for stitch welding. b. Workforce for painting 1 coat primer and 4 coats finishing paint consists of 13 Painters Cl-II at 15 sqm / day and 2 helpers to assist painters. For surface finishing of stainless steel plates for seal seats planing machine is considered. 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. 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

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Life of gas cutting set Use rate of gas cutting set per hr RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars Unit

( cost / life ) UNIT : Quantity

: 600 hours Rs: 2.50 3.910 tonne Rate in Rs. 37.95 40.00 Contd Amount in Rs. 29563.05 124640.00

Structural steel Angles / beams / channels / bars Plates / flats

kg kg

779.00 3116.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

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

Stainless steel plates / flats AISI 410 Stainless steel plates / flats AISI 304L 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 cum cum Nos Nos Nos ltr ltr ltr Hour Hour Nos LS

50.00 64.00 132.00 105.00 35.00 15.00 132.00 1036.00 5.00 27.00 5.00 127.00 23.00 3.00 70.00

1% 10% 5% Total cost of Materials :

Rate in Rs. Contd 120.00 240.00 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. 6000.00 15360.00 7260.00 5040.00 9030.00 90.00 1584.00 44548.00 2970.00 5616.00 1200.00 571.50 57.50 90.00 2100.00 255720.05 2557.20 25572.01 12786.00 296635.26

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

Description

Unit Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour

Quantity 127.00 80.00 3.00 3.00 45.00 45.00 126.00 126.00 18.00 18.00 56.00

Welding transformer Fuel / Energy charges Plate shearing machine Fuel / Energy charges Pug cutting machine Fuel / Energy charges Planing machine Fuel / Energy charges Mobile crane 8 t Fuel / Energy charges Stationery derric crane

Rate in Rs. 12.00 60.00 62.00 100.00 16.00 3.00 88.00 75.00 362.00 495.00 66.00

Amount in Rs. 1524.00 4800.00 186.00 300.00 720.00 135.00 11088.00 9450.00 6516.00 8910.00 3696.00

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GATE / HOIST AND ALLIED WORKS

7 8 9

Fuel / Energy charges Grinding machine Fuel / Energy charges Drilling machines Fuel / Energy charges Sundries

Hour Hour Hour Hour Hour LS

56.00 16.00 16.00 12.00 12.00 70.00

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 :

9.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

504.00 288.00 400.00 216.00 300.00 2100.00 51133.00 511.33 2689.90 2556.65 56890.88

C. LABOUR: Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Description

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

Quantity 18.00 3.00 127.00 12.00 16.00 22.00 30.00 8.00 10.00 2.00 94.00 5.00 13.00 2.00

Crew for Mobile crane Crew for plate 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. 1362.60 137.70 9321.80 714.00 952.00 3894.00 4725.00 1260.00 1575.00 346.50 13301.00 707.50 1839.50 286.00 40422.60 404.23 4042.26 6063.39 6063.39 2021.13 59017.00

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 patent royalty 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% 4.40% 2.50% 2.50% 2.00% 1.40% Rs: Rs: Rs: Rs: Rs: Rs: Rs: Total Rs:

296635.26 56890.88 59017.00 412543.13 7163.11 4125.43 18151.90 10313.58 10313.58 8250.86 5775.60 476637.19

Add for 2 rehandling leads for 1 km including loading and unloading :

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GATE / HOIST AND ALLIED WORKS

Fabricated parts 2 x 3.910 tonnes @ Rs: Add for transportation upto work site @ Total cost for

129.10 / tonne 3.00% 3.910 tonne Rate per tonne Rate approved per tonne YEAR : 2010-11

Rs: Rs: Rs: Rs: Rs:

1009.56 14299.12 491945.87 125800.00 125800.00 ITEM No: 24

SECTION: GATE / HOIST & ALLIED WORKS.

ITEM: Design, fabrication, supply, erection, testing and commissioning of automatic outflow regulating gate and fulcrum assembly consisting of skin plate, stiffeners, horizontal girders, trunnion

assemblies, gate bracket, base plate, rolling surface assembly, link brackets, link assembly, rubber seals, seal clamps etc., with all accessories for barrage including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with all leads and lifts. DATA: Automatic outflow regulating gate and fulcrum assembly consisting of skin plate, stiffeners, horizontal girders, trunnion assemblies, gate bracket, base plate, rolling surface assembly, link , brackets, link assembly rubber seals, seal clamps etc., with all accessories. Consider automatic outflow regulating gate for barrage opening of size 8 m x 3.5 m for analysis. Size of gate : 8.00 m x 3.50 m Head of water : 3.30 m Weight of automatic gate leaf in tonnes based on empirical formula : = 0.1325 x ( L 2 x H x h ) 0.673 Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.1325 x ( 8 x 8 x 3.5 x 3.3 ) 0.673 : 11.295 The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings of automatic outflow regulating gate of same size furnished by the designer for one of the gate. Actual weight of radial gate leaf as per data in Item :24 of Annexure-2 : : 11.270 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of canal regulator radial gate provided for one of the canal regulator for rate analysis ( for details refer Item : 24 of Annexure-2 ). 1. Requirement of materials: a. Structural steel : Angles / beams / channels / bars with 2.5 % wastage ( 3122x1.025 ) : 3200 kg Plates / flats with 2.5 % wastage ( 7561x1.025 ) : 7750 kg b. Alloy steel components : Pins / Axles : 74 kg Stainless plate / flats AISI 410 ( 49x1.025 ) : 50 kg c. Cast steel components : Trunnion hub / Guide roller : 443 kg d. Alluminium / Bronze alloy components : Trunnion / Guide roller bush : 33 kg e. Bolts / Nuts / Washers : Stainless steel bolts /nuts /washers with 2.5 % wastage ( 31 x 1.025 ) : 32 kg MS bolts / nuts / washers with 2.5 % wastage ( 23.5x1.025 ) : 24 kg f. Rubber seal : Bottom seal ( flat type ) ( 8 x 1.025 ) : 8.5 Rm Side seals ( Z - type ) (2 x 4 x 1.025 ) : 8.5 Rm g. Welding electrodes ( Ordinary / Low hydrogen ) :

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GATE / HOIST AND ALLIED WORKS

GP / LH electrodes as per data sheet ( Item:24 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 6125 x 0.1 ) Total requirement of GP / LH electrodes for stitch weld GP electrodes @t 10 % of total (6738 x 0.10 ) for run welding LH electrodes @ 90 % of total (6738 x 0.90 ) h. Welding electrodes ( Stainless steel ) : SS electrodes as per data sheet ( Item:24 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 6900 x 0.1 ) Total requirement of SS electrodes

: : : : :

6125 Nos 613 Nos 6738 Nos 674 Nos 6064 Nos

: 150 Nos : 15 Nos : 165 Nos

for stitch weld SS electrodes @t 10 % of total (165 x 0.10 ) for run welding SS electrodes @ 90 % of total (165 x 0.90 ) 2. Cutting : Total length of cutting assuming cutting for 2 sides Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 %

: 15 Nos : 160 Nos

: 195 Rm : 20 Rm Total : 215 Rm For cutting structural steel sections to required sizes use of plate shearing machine and gas cutting is assumed. Length of steel to be cut by using plate shearing machine 40 m Length of steel to be cut by using gas manually : 62 m Length of steel to be cut by gas using pug cutting machine : 113 m Time for cutting by plate shearing machine at ( av ) 10 m cutting / hour : 4 hours Time for gas cutting manually at ( av ) 2 m cutting / hour : 31 hours Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 38 hours Acetelyne gas @ 0.6 cum / hour ( 31 + 38 ) x 0.60 : 42 cum Oxygen gas @ 1.8 cum / hour ( 31 + 38 ) x 1.80 : 126 cum Use of gas cutting torch with 50 min / hr working ( 31 x 60 / 50 ) : 37 hours Use of pug cutting machine with 50 min / hr working ( 38 x 60 / 50 ) : 46 hours 4. Welding : Length of welding : 196 Rm For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 674 + 15 ) x 8 / ( 15 x 2 ) : 184 hours For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 6064 + 160 ) x 8 / ( 15 x 6 ) : 553 hours Total : 737 hours Deploy welding transformer for 737 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 184 x 0.25 + 553 x 0.75 ) : 461 hours 5. Planing SS plates for seal seats : For surface finishing of SS plates planing machine is considered. Length of SS plate for surface finishing by planing machine : 3 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 3 m SS plates (3x8/3) : 8 hours 6. Surface cleaning and painting : Painting area for gate at 20 sqm / tonne ( 11.27 x 20 ) : 225 sqm 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 225 sqm @ 9 sqm / ltr / coat : 25 ltr 3 coats of coal tar epoxy paint 100 micron dry film each coat. Quantity of coal tar epoxy paint for 225 sqm @ 6 sqm / ltr / coat : 112 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

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GATE / HOIST AND ALLIED WORKS

before applying primer painting. Quantity of rust cleaner / inhibitor for 225 sqm @ 8 sqm / ltr : 28 ltr 7. Requirement of other machinery : For drilling holes in skin plate and seal clamps for seal fixing 16 hours use of drilling machine considered. For grinding and finishing weld joints in skin plate and other locations 16 hours use of grinding machine considered.

8.

Note :

9.

10.

For handling of parts during fabrication and erection use of 8 t mobile crane for 16 hours and stationery derric crane 50 hours considered. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Painter Cl-II Fabricator / Welder Erector / Cutting sections 87 hours 2 4 9 18 Drilling holes for seal fixing 1 2 --2 Erection of trunnions/H -girders /stiffeners 4 4 --8 Fabricating and stitch welding 184 hours 11 23 --46 Run welding 553 hours 5 --69 69 Erection of links / other accessories 2 4 --8 Erection of fulcrum assembly 2 4 --8 Cleaning surface 225 sqm @ 15 sqm/day ------15 Painting ( 4 x 225 ) sqm @ 15 sqm / day ------66 Seal fixing 1 2 --2 Finishing / checking / cleaning 1 1 --1 Total : 29 44 78 243 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 60 Painters Cl-II at 15 sqm / day and 6 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. 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 UNIT : Unit Quantity 11.270 tonne Rate in Rs. 37.95 40.00 125.00 Amount in Rs. 121440.00 310000.00 55375.00

A. MATERIALS: Sl No 1

Perticulars

Structural steel : Angles / beams / channels / bars Plates / flats Cast steel components : Hub / Rollers

kg kg kg

3200.00 7750.00 443.00

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GATE / HOIST AND ALLIED WORKS

Alloy steel components : Stainless steel plate Pins / Axles Alluminium / Bronze alloy components: Bearings / Bush

kg kg kg

50.00 74.00 33.00

120.00 215.00 635.00 Contd

6000.00 15910.00 20955.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

Rate in Rs. Contd 150.00 55.00 147.00 295.00 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.

8 9 10 11 12 13 14 15 16 17 18 19

Bolt / Nut / Washer : Stainless steel bolts / nuts / washers MS bolts / nuts / washers Rubber seals : Bottom seal Side seals ( Z - type ) 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 Rm Rm cum cum Nos Nos Nos ltr ltr ltr Hour Hour Nos LS

32.00 24.00 8.50 8.50 126.00 42.00 674.00 6064.00 165.00 25.00 112.00 28.00 737.00 37.00 5.00 100.00

4800.00 1320.00 1249.50 2507.50 6048.00 10836.00 4044.00 72768.00 7095.00 14850.00 23296.00 6720.00 3316.50 92.50 150.00 3000.00 691773.00 6917.73 69177.30 34588.65 802456.68

1% 10% 5% Total cost of Materials :

B. MACHINERY: Sl No 1 2 3 5 7 8 9

Description

Unit Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour

Quantity 737.00 461.00 4.00 4.00 46.00 46.00 8.00 8.00 16.00 16.00 50.00 50.00 32.00

Welding transformer Fuel / Energy charges Plate shearing machine Fuel / Energy charges Pug cutting machine Fuel / Energy charges Planing machine Fuel / Energy charges Mobile crane ( revolving ) 8 t Fuel / Energy charges Stationery derric crane Fuel / Energy charges Grinding machine

Rate in Rs. 12.00 60.00 62.00 100.00 16.00 3.00 88.00 75.00 362.00 495.00 66.00 9.00 18.00

Amount in Rs. 8844.00 27660.00 248.00 400.00 736.00 138.00 704.00 600.00 5792.00 7920.00 3300.00 450.00 576.00

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GATE / HOIST AND ALLIED WORKS

10 11

Fuel / Energy charges Drilling machines Fuel / Energy charges Sundries

Hour Hour Hour LS

32.00 16.00 16.00 100.00

25.00 18.00 25.00 30.00 Total Rs: Contd

800.00 288.00 400.00 3000.00 61856.00

B. MACHINERY ( Contd ) : Sl No Perticulars

Unit

Quantity

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 15

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

Amount in Rs. 618.56 4136.80 3092.80 69704.16

Description

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

Quantity 16.00 4.00 8.00 16.00 32.00 29.00 44.00 9.00 62.00 7.00 34.00 162.00 21.00 60.00 3.00

Crew for Mobile crane 8 t Crew for plate 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 ) 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 @

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

Rate in Rs. 75.70 45.90 73.40 59.50 59.50 177.00 157.50 157.50 157.50 173.25 145.50 141.50 141.50 141.50 143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 1211.20 183.60 587.20 952.00 1904.00 5133.00 6930.00 1417.50 9765.00 1212.75 4947.00 22923.00 2971.50 8490.00 429.00 69056.75 690.57 6905.68 10358.51 10358.51 3452.84 100822.86

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 Patent royalty charges @ Add for designs and drawings @

Rs: Rs: Rs: TOTAL Rs: 8.24% 1.00% 4.40% 2.50% Rs: Rs: Rs: Rs:

802456.68 69704.16 100822.86 972983.70 10538.57 9729.84 42811.28 24324.59

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Add for zigs / supports / winches / chain-pulley @ Add for power supply arrangements @ Add for enabling works @

2.50% 2.00% 1.40%

Rs: Rs: Rs: Total Rs:

24324.59 19459.67 13621.77 1117794.01

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2x11.27 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 11.270 tonne Rate per tonne Rate approved per tonne SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

Rs: Rs: Rs: Rs: Rs:

2909.91 33533.82 1154237.75 102400.00 102400.00 ITEM No: 25

ITEM: Design, fabrication, supply, erection, testing and commissioning of hoisting cum damping system consisting of low level horizontal lever link, low level long actuating lever, high level vertical lever link, high level short actuating lever, high level hoisting bracket, axle for lever system, friction shoes, support box for shoes, track assembly, ratchet pawl, support structure, bracket plate etc., with all accessories for outflow regulating automatic gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with all leads and lifts. DATA: Hoisting cum damping system for automatic outflow regulating gate consists of low level horizontal lever link, low level long actuating lever, high level vertical lever link, high level short actuating lever, high level hoisting bracket, axles for lever system, friction shoes, track assembly, support box for shoes, ratchet pawl, support structure, bracket plate etc. Consider hoisting cum damping system for automatic outflow regulating gate of size 8 x 3.50 m for analysis. Weight of the hoisting cum damping system will be about 50 to 55 percent of the weight of the automatic outflow regulating gate. Consider automatic outflow regulating gate for barrage opening of size 8 m x 3.5 m for analysis. Size of gate : 8.00 m x 3.50 m Head of water : 3.30 m Weight of automatic gate leaf in tonnes based on empirical formula : = 0.1325 x ( L 2 x H x h ) 0.673 Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.1325 x ( 8 x 8 x 3.5 x 3.3 ) 0.673 : 11.295 Weight of hoisting cum damping system = 0.525 x 11.295 : 5.93 tonnes The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings. Actual weight of radial gate leaf as per data in Item :25 of Annexure-2 : : 5.81 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of hoistingl cum damping system as furnished by the designer for one of the automatic outflow regulating gate of size 8.0 x 3.5 m for rate analysis ( for details referItem : 25 of Annexure-2 ). 1. Requirement of materials: a. Structural steel : Angles / beams / channels / bars with 2.5 % wastage ( 1483x1.025 ) : 1520 kg Plates / flats with 2.5 % wastage ( 3622x1.025 ) : 3712 kg b. Alloy steel components : Stainless steel plates / flats : 435 kg

120