data rates gate works 2

8/13/2019 Data Rates Gate Works 2

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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 UNIT : 15.440 tonne wt

A. MATERIALS: 90.00 t capacity

Sl No Unit Amount

in Rs.1 Structural steel

Angles / beams / channels / bars kg 2571.00 37.95 97569.45

Plates / flats kg 3632.00 40.00 145280.00

2 Cast steel components :

Rope drums 2 Nos / Gears 4 Nos kg 3680.00 145.00 533600.00

Pinions kg 218.00 150.00 32700.00

Pulleys 720 PCD 6 Nos kg 1080.00 125.00 135000.00

Plummer blocks / Hubs kg 322.00 125.00 40250.00

3 Alloy steel components

Shafts kg 557.00 175.00 97475.00

Pins kg 546.00 215.00 117390.00

4 Bronze alloy components :

Bronze bearings / bush kg 144.00 635.00 91440.00

5 Wire rope 36 mm dia 6/37 construction kg 448.00 105.00 47040.00

6 MS Bolt / Nut / Washer kg 85.00 55.00 4675.00

7 Worm reducer No. 1.00 120000.00

8 Electric motor 20 hp No. 1.00 60000.00 60000.00

9 Floating shaft 300 mm dia kg 1000.00 45.00 45000.00

10 Manual operating system No. 1.00 22500.00 22500.00

Contd

A. MATERIALS ( Contd ) : Sl No Unit Amount

in Rs.

Contd

11 Gate position indicator No. 1.00 9000.00 9000.00

12 Ele-magnetic brake No. 1.00 15000.00 15000.00

13 Electric cable /switch /control panel etc LS 1.00 18000.00 18000.00

14 Oxygen gas cum 216.00 48.00 10368.00

15 Acetyline gas cum 72.00 258.00 18576.00

Perticulars Quantity

in Rs.

120000.00

in Rs.

Rate

Perticulars Quantity Rate

20


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16 Welding electrodes ( general purpose ) Nos 584.00 6.00 3504.00

17 Welding electrodes ( low hydrogen ) Nos 5250.00 12.00 63000.00

18 Zinc chromate red oxide primer ltr 21.00 140.00 2940.00

19 Synthetic enamel ( 1st quality ) paint ltr 31.00 176.00 5456.00

20 Rust cleaner / inhibitor ltr 16.00 240.00 3840.00

21 Grease kg 50.00 194.00 9700.00

22 Use rate welding holder set Hour 623.00 4.50 2803.50

23 Use rate gas cutting torch set Hour 90.00 2.50 225.00

24 Wire brush Nos 3.00 30.00 90.00

25 Sundries ( hand rail /staircase / gate etc ) LS 1000.00 30.00 30000.00

Total Rs: 1782421.95

Add for small Tools and Plants @ 1% Rs: 17824.22

Add for Contractor's Profit @ 10% Rs: 178242.20

Add for Contractor's Overheads @ 5% Rs: 89121.10

Total cost of Materials : Rs: 2067609.46

B. MACHINERY:

Sl No Unit Amount

in Rs.

1 Welding transformer Hour 623.00 12.00 7476.00

Fuel / Energy charges Hour 390.00 60.00 23400.002 Tower crane 5 t capacity Hour 4.00 994.00 3976.00

Fuel / Energy charges Hour 4.00 130.00 520.00

3 Pug cutting machine Hour 53.00 16.00 848.00


4 Mobile crane 25 t Hour 40.00 3804.00 152160.00




6 Grinding machine Hour 32.00 18.00 576.00


7 Drilling machines Hour 16.00 18.00 288.00


8 Sundries LS 600.00 30.00 18000.00

Total Rs: 260483.00


Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 7077.90


Total hire charges of Machinery : Rs: 283189.88

C. LABOUR:

Sl No Unit Amountin Rs.

1 Crew for Mobile crane 25 t Hour 40.00 72.60 2904.00

2 Crew for Mobile crane 8 t Hour 40.00 75.70 3028.00

3 Crew for Tower crane Hour 4.00 62.00 248.00

4 Crew for Drilling machine Hour 16.00 59.50 952.00

5 Crew for Grinding machine Hour 32.00 59.50 1904.00

6 Foreman Day 37.00 177.00 6549.00

7 Marker / Fabricator / Erector / Mechanic Day 67.00 157.50 10552.50

Quantity

Description

Description

Quantity Rate

Ratein Rs.

in Rs.

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8 Gas cutter Day 18.00 157.50 2835.00

9 Welder ( General ) Day 58.00 157.50 9135.00

10 Khalasi Day 100.00 145.50 14550.00

11 Helper fabrication / erection Day 196.00 141.50 27734.00

12 Helper for cleaning / painting Day 14.00 141.50 1981.00

13 Painter Cl - II Day 30.00 141.50 4245.00

14 Electrician Day 3.00 143.00 429.00

Total Rs: 87046.50



Add for hidden cost on Labour @ 15% Rs: 13056.98

Add for additional hidden cost on labour @ 15% Rs: 13056.98


Total cost of Labour : Rs: 127087.89

ABSTRACT:

A. Cost of Materials Rs: 2067609.46

B. Hire charges of Machinery Rs: 283189.88

C. Cost of Labour Rs: 127087.89

TOTAL Rs: 2477887.23

Add for excise duty on 75 percent cost ofMachinery / Labour components @ 8.24% Rs: 25355.17

Add for insurance charges @ 1.00% Rs: 24778.87

Add for designs and drawings @ 2.50% Rs: 61947.18

Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 61947.18

Add for power supply arrangements @ 2.00% Rs: 49557.74

Add for enabling works @ 1.40% Rs: 34690.42

Total Rs: 2736163.80

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

Fabricated parts 2 x 15.44 tonnes @ Rs: 129.10 / tonne Rs: 3986.61

Add for transportation upto work site @ 3.00% Rs: 82084.91

Total cost for 15.440 tonne weight Rs: 2822235.32

90.000 tonne capacity

Rate per tonne wiegt Rs: 182790.00

Rate per tonne capacity Rs: 31400.00

Rate approved per tonne capacity Rs: 31400.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 4

ITEM: Design, fabrication, supply, erection and commissioning of 1 metre wide catwalkconnecting

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 asper 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

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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 ) : 4258 kg

Plates / flats with 2.5 % wastage ( 96 x 1.025 ) : 98 kg

Chequered plates with 2.5 % wastage ( 835 x 1.025 ) : 856 kg

b. Bolts / Nuts / Washers conforming to IS : 1363 :

MS bolts / nuts / washers with 2.5 % wastage ( 8 x 1.025 ) : 8 kg

c. Welding electrodes ( General purpose ) :

GP electrodes as per data sheet ( Item:4 Annexure-2 ) : 1387 Nos

Add for variations / wastage / misc welding @ 10 % ( 1387 x 0.1 ) : 139 Nos

Total requirement of GP electrodes : 1526 Nos

for stitch weld GP electrodes @t 10 % of total ( 1526 x 0.10 ) : 153 Nos

for run welding GP electrodes @ 90 % of total ( 1526 x 0.90 ) : 1373 Nos

2. Cutting :

Length of cutting assuming cutting for 2 sides as per data sheet : 57 Rm

Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 6 Rm

Total : 63 Rm

For cutting structural steel sections to required sizes gas cutting is assumed.

Length of steel to be cut by using gas manually : 40 m

Length of steel to be cut by gas using pug cutting machine : 23 m

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 : 8 hours

Acetelyne gas @ 0.6 cum / hour ( 20 + 8 ) x 0.60 : 17 cum

Oxygen gas @ 1.8 cum / hour ( 20 + 8 ) x 1.80 : 51 cum

Use of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) : 24 hours

Use of pug cutting machine with 50 min / hr working ( 8 x 60 / 50 ) : 10 hours

3. Welding :

Length of welding as per data sheet : 151 Rm

For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 153 / 15 ) x 8 / 2 : 41 hours

For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 1373 / 15 ) x 8 / 6 : 122 hours

Total : 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 ) : 133 sqm

1 coat of zinc rich epoxy primer 40 micron dry film each coat.

Quantity of primer paint for 133 sqm @ 9 sqm / ltr / coat : 15 ltr

2 coats of coal tar epoxy paint 100 micron dry film each coat.

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3 Oxygen gas cum 51.00 48.00 2448.00



6 Zinc rich epoxy primer ltr 15.00 594.00 8910.00

7 Coal tar epoxy paint ltr 44.00 208.00 9152.00




11 Wire brush Nos 1.00 30.00 30.00

12 Sundries LS 10.00 30.00 300.00

Total Rs: 240918.60





B. MACHINERY:

Sl No Unit Amount

in Rs.


Fuel / Energy charges Hour 102.00 60.00 6120.002 Tower crane Hour 1.00 994.00 994.00










7 Sundries LS 10.00 30.00 300.00

Total Rs: 11834.00





C. LABOUR:

Sl No Unit Amount

in Rs.

1 Crew for Mobile crane Hour 2.00 75.70 151.40

2 Crew for Tower crane Hour 1.00 62.00 62.00

3 Crew for Drilling machine Hour 2.00 59.50 119.004 Crew for Grinding machine Hour 8.00 59.50 476.00

5 Foreman Day 6.00 177.00 1062.00

6 Marker / Fabricator / Erector Day 11.00 157.50 1732.50

7 Gas cutter Day 4.00 157.50 630.00




11 Painter Cl - II Day 26.00 141.50 3679.00

Description

Description

Rate

in Rs.

in Rs.

Quantity

Quantity Rate

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12 Electrician Day 1.00 143.00 143.00

Total Rs: 17633.90







ABSTRACT:




TOTAL Rs: 318537.11

Add for excise duty on 75 percent cost of

Machinery / Labour components @ 8.24% Rs: 2414.62





Add for enabling works @ 1.40% Rs: 4459.52Total Rs: 350894.22




Total cost for 18.000 Rm Rs: 362794.15

Rate per Rm Rs: 20200.00

Rate approved per Rm Rs: 20200.00


ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of

sill beam, slide tracks, seal seats, guide rails, dogging sets for storage of stoplog elements

etc., with all accessories for spillway stop log gateelements 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 withall 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 ( L2

x H x h )0.716

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

Consider weight of embedded parts for stoplog gate @ 4.50 % of weight of gate elements.

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= 0.045 x 0.0553 x ( L2

x H x h )0.716

= 0.0025 x ( 15.652

x 9.6 x 9.4 )0.716

: 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 ).





b. Alloy steel conforming to IS : 1570 :

Stainless steel plates / flats ( 235+166 ) x 1.025 : 411.00 kg

c. Bolt / Nut / Washer conforming to IS : 1363 :

MS bolts and nuts with 2.5 % wastage ( 112 x 1.025 ) : 115 kg

d. Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) :

GP / LH electrodes as per data sheet ( Item:5 Annexure-2 ) : 1973 NosAdd for variations / wastage / misc welding @ 10 % ( 1973 x 0.1 ) : 197 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

2. Cutting :



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 shearing machine : 30 m



Time for cutting by shearing machine at ( av ) 10 m cutting / hour : 3 hoursAcetelyne gas @ 0.6 cum / hour ( 15 + 40 ) x 0.60 : 33 cum




Use of shearing machine with 50 min / hr working ( 3 x60 / 50 ) : 4 hours

3. Welding :

Length of welding as per data sheet : 303 m


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( 217 + 115 ) x 8 / 15 / 2 : 89 hours


( 1953 + 1035 ) x 8 / 15 / 6 : 266 hours

Total : 355 hours

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

4. Planing SS plates for slide block / seal tracks : :

For surface finishing of SS plates for wheel / seal tracks planing machine is considered.

Length of SS plate for surface finishing by planing machine : 50.4 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


Painting area for embedded parts at 7 sqm / tonne ( 3.179 x 7 ) : 22 sqm


Quantity of primer paint for 22 sqm @ 9 sqm / ltr / coat : 2.5 ltr


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 rustingbefore applying primer painting.

Quantity of rust cleaner / inhibitor for 22 sqm at 8 sqm / ltr : 3 ltr

6. Requirement of other machinery :

For drilling holes for anchor bolts and for grinding surface / edges of parts requiring finishing

16 hours use of drilling machine and 16 hours use of grinding machine considered.

For handling and erection 25 t mobile crane for 4 hours and stationery derric crane for 50 hours

considered.

7. Requirement of work force :

Work component Foreman Helper /

Painter Cl-II

Cutting sections 70 hours 5 9 9 18

Drilling holes for anchors / supports 1 2 --- 2

Contd

Requirement of work force ( Contd ):


Painter Cl-II

Contd

Fabricating by stitch welding 89 hours 6 11 --- 22

Run welding 266 hours 3 --- 33 33

Erection of anchors / dogging set 6 12 --- 12Erection of Sill beam / Tracks / Guide 3 3 --- 6

Cleaning surface 20 sqm @ 15 sqm/day --- --- --- 2

Painting ( 5 x 20 ) sqm @ 15 sqm / day --- --- --- 8

Finishing / cleaning / checking 1 1 --- 2

Total : 25 38 42 105



b. Workforce for painting 1 coat primer and 4 coats finishing paint consists of 7 Painters Cl-II

Marker /

Erector /

Gas cutter /

Fabricator /

Fabricator /

Marker /

Gas cutter /

Welder

Welder

Erector /

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RATE ANALYSIS UNIT : 3.179 tonne

A. MATERIALS:

Sl No Unit Amount

in Rs.

1 Structural steel


Plates / flats kg 2301.00 40.00 92040.00

2 Stainless steel plate / flats kg 411.00 120.00 49320.003 MS bolts and nuts kg 115.00 55.00 6325.00

4 Oxygen gas cum 99.00 48.00 4752.00




8 Welding electrodes ( stainless steel ) Nos 1150.00 43.00 49450.00






Contd

A. MATERIALS ( Contd ) :

Sl No Unit Amount

in Rs.

Contd

14 Wire brush Nos 3.00 30.00 90.00

15 Sundries LS 72.00 30.00 2160.00

Total Rs: 260750.90


Add for Contractor's Profit @ 10% Rs: 26075.09Add for Contractor's Overheads @ 5% Rs: 13037.55


B. MACHINERY:

Sl No Unit Amount

in Rs.



Perticulars

Quantity

Quantity

in Rs.

Rate

in Rs.

in Rs.

Rate


Description

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2 Plate shearing machine Hour 4.00 62.00 248.00




4 Planing machine Hour 135.00 88.00 11880.00




6 Stationery derric crane Hour 50.00 66.00 3300.00






9 Sundries LS 64.00 30.00 1920.00

Total Rs: 68907.00





C. LABOUR:

Sl No Unit Amount

in Rs.


2 Crew for Shearing machine Hour 4.00 45.90 183.60

3 Crew for Planing machine Hour 135.00 73.40 9909.00



6 Foreman Day 25.00 177.00 4425.00


8 Gas cutter Day 9.00 157.50 1417.50

Contd

C. LABOUR ( Contd ) :

Sl No Unit Amount

in Rs.

Contd


10 Welder ( X - ray ) Day 3.00 173.25 519.75



13 Painter Cl - II Day 7.00 141.50 990.50

14 Electrician Day 2.00 143.00 286.00Total Rs: 44502.75







Description Quantity

Description

in Rs.

Rate

in Rs.

Rate

Quantity

30


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ABSTRACT:




TOTAL Rs: 443752.38








Total Rs: 494196.29




Total cost for 3.179 tonne Rs: 509843.00

Rate per tonne Rs: 160400.00

Rate approved per tonne Rs: 160400.00


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 allleads 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



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.


= 0.0553 x ( L2

x H x h )0.716

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 )0.716

: 71.340


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 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

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of Annexure-2 ).





b. Alloy steel components conforming to IS : 1570 :

Lifting pins : 104 kg

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

Bronze pads for slide blocks : 48 kg

d. Bolts / Nuts / Washers conforming to IS : 1363 :

GI bolts / nuts / washers with 2.5 % wastage ( 288 x 1.025 ) : 295 kg

MS bolts / nuts / washers with 2.5 % wastage ( 48 x 1.025 ) : 49 kg

e. Rubber seal conforming to IS : 11855 :

Bottom seal ( 120 x 1.025 ) : 123 Rm

Side seals ( music note type uncladed ) ( 19.2 x 1.025 ) : 20 Rm

f. Welding electrodes ( General purpose / Low hydrogen ) :

GP / LH electrodes as per data sheet ( Item:6 Annexure-2 ) : 33626 Nos




for run welding LH electrodes @ 90 % of total ( 36989 x 0.90 ) : 33290 Nos 2. Cutting :



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.





Acetelyne gas @ 0.6 cum / hour ( 25 +343 ) x 0.60 : 221 cum



Use of pug cutting machine with 50 min/ hr working ( 343 x 60 / 50 ) : 412 hours

3. Welding :



( 3699 / 15 ) x 8 / 2 : 986 hours


( 33290 / 15 ) x 8 / 6 : 2959 hours

Total : 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 ) : 2466 hours


Painting area for stoplog elements at 18 sqm / tonne ( 71.157x18 ) : 1280 sqm





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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


For handling during fabrication 25 t mobile crane for 100 hours and stationery derric crane for

100 hours considered.

For drilling holes in skin plate and seal clamps for seal fixing 100 hours use of drilling machine

considered.

For grinding and finishing weld joints in skin plate and other locations 200 hours use of grinding

machine considered.



Painter Cl-II


Drilling holes for seal fixing 6 12 --- 12

Fabricating by stitch welding 986 hours 62 124 --- 248


Seal fixing 8 elements @ 2 per day 8 8 --- 16

Cleaning surface1280 sqm @15 sqm/day --- --- --- 85Painting ( 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. MATERIALS: Sl No Unit Amount

in Rs.

1 Structural steel


Plates / flats kg 71963.00 40.00 2878520.00


Lifting pins kg 104.00 215.00 22360.00

3 Alluminium / Bronze alloy components

Perticulars

Fabricator /

Marker /

Erector /

Welder

Gas cutter /

Quantity Rate

in Rs.

33


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Bronze pads kg 48.00 635.00 30480.00

4 Bolt / Nut / Washer

GI bolts / nuts / washers kg 295.00 95.00 28025.00

MS bolts / nuts / washers kg 49.00 55.00 2695.00

5 Rubber seals

Bottom seal Rm 123.00 147.00 18081.00

Side seals ( uncladed ) Rm 20.00 235.00 4700.00

6 Oxygen gas cum 663.00 48.00 31824.00









15 Wire brush Nos 13.00 30.00 390.00

16 Sundries LS 150.00 30.00 4500.00

Total Rs: 3791912.85


Add for Contractor's Profit @ 10% Rs: 379191.29Add for Contractor's Overheads @ 5% Rs: 189595.64


B. MACHINERY:

Sl No Unit Amount

in Rs.



Contd

B. MACHINERY ( Contd ) :

Sl No Unit Amount

in Rs.

Contd









6 Drilling machines Hour 100.00 18.00 1800.00Fuel / Energy charges Hour 100.00 25.00 2500.00

7 Sundries LS 150.00 30.00 4500.00

Total Rs: 745928.00





Description Quantity

in Rs.

Rate

Description Quantity Rate

in Rs.

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C. LABOUR:

Sl No Unit Amount

in Rs.




4 Foreman Day 144.00 177.00 25488.00


6 Gas cutter Day 56.00 157.50 8820.00


8 Welder ( X - ray ) Day 37.00 173.25 6410.25

9 Khalasi Day 150.00 145.50 21825.00


11 Helper cleaning / painting Day 153.00 141.50 21649.50

12 Painter Cl - II Day 341.00 141.50 48251.50

13 Electrician Day 5.00 143.00 715.00

Total Rs: 351545.75




Add for additional hidden cost on labour @ 15% Rs: 52731.86Add for Contractor's Overheads @ 5% Rs: 17577.29


ABSTRACT:




TOTAL Rs: 5732518.98








Total Rs: 6353810.79


Fabricated parts 2x71.157 tonnes @ Rs: 129.10 / tonne Rs: 18372.74






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 withallleads and lifts.

in Rs.

RateDescription Quantity

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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




= 0.0553 x ( L2x H x h )

0.716

Consider weight of lifting beam in tonnes @ 40 % of weight of one stoplog element:

= 0.40 x 0.0553 x ( L2

x H x h )0.716

/ n

Where ( L ) is length and ( H ) is total height and ( h ) is head of water in metres and ( n ) is the

number of stoplog gate elements. = 0.0221 x ( 15.65 x 15.65 x 9.6 x 9.4 )

0.716/ 8 : 3.567


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 details of Material / Gas cutting / Welding based on fabrication drawings of lifting

beam for spillway stoplog elements provided for one of the dam for rate analysis ( for details

refer Item : 7 of Annexure-2 ).



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


b. Alloy steel components conforming to IS : 1570 :

Lifting pins : 101 kg

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

Bronze Bush : 5 kg

d. Forged steel components conforming to IS : 2004 :

Lifting hooks : 130 kg

e. Bolts / Nuts / Washers conforming to IS : 1363 :

MS bolts / nuts / washers with 2.5 % wastage : 3 kg

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

GP / LH electrodes as per data sheet ( Item:7 Annexure-2 ) : 2121 Nos




for run welding LH electrodes @ 90 % of total ( 2333 x 0.90 ) : 2100 Nos

2. Cutting :


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Total : 189 Rm

For cutting structural steel sections to required sizes gas cutting is assumed.





Acetelyne gas @ 0.6 cum / hour ( 20 + 50 ) x 0.60 : 42 cum




3. Welding :



( 233 / 15 ) x 8 / 2 : 62 hours


( 2100 / 15 ) x 8 / 6 : 187 hours

Total : 249 hours

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 ) : 156 hours 4. Surface cleaning and painting :

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






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


For handling during fabrication 8 t mobile crane for 2 hours and stationery derric crane for

4 hours considered.

For drilling holes for pins / guide shoes 2 hours use of drilling machine considered.

For grinding and finishing weld joints 2 hours use of grinding machine considered.



Painter Cl-II


Drilling holes for pins / bolts fixing --- 1 --- 1Fabricating by stitch welding 62 hours 4 8 --- 16


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



Gas cutter /

Fabricator /

Erector /

Marker /

Welder

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A. MATERIALS:

Sl No Unit Amount

in Rs.

1 Structural steel

Angles / beams / channels / bars kg 13.00 37.95 493.35Plates / flats kg 3389.00 40.00 135560.00


Lifting pins kg 101.00 215.00 21715.00

Contd

A. MATERIALS ( Contd ) :

Sl No Unit Amount

in Rs.

Contd

3 Bronze alloy components :

Bronze bush kg 5.00 635.00 3175.00

4 Forged steel components :

Lifting hooks kg 103.00 165.00 16995.00

5 MS pipe 100 mm dia kg 11.00 45.00 495.00

6 Bolt / Nut / Washer

MS bolts / nuts / washers kg 3.00 55.00 165.00

7 Oxygen gas cum 126.00 48.00 6048.00





12 Coal tar epoxy paint ltr 14.00 208.00 2912.0013 Rust cleaner / inhibitor ltr 5.00 240.00 1200.00



16 Wire brush Nos 1.00 30.00 30.00

17 Sundries LS 20.00 30.00 600.00

Total Rs: 230972.85



Quantity Rate

in Rs.

in Rs.


Perticulars

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B. MACHINERY:

Sl No Unit Amount

in Rs.













7 Sundries LS 15.00 30.00 450.00

Total Rs: 16124.00

Add for small Tools and Plants @ 1% Rs: 161.24Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 1111.60



C. LABOUR:

Sl No Unit Amount

in Rs.




4 Foreman Day 12.00 177.00 2124.00


6 Gas cutter Day 11.00 157.50 1732.50




10 Painter Cl - II Day 8.00 141.50 1132.00

11 Electrician Day 1.00 143.00 143.00

Total Rs: 22371.90



Add for hidden cost on Labour @ 15% Rs: 3355.79Add for additional hidden cost on labour @ 15% Rs: 3355.79



ABSTRACT:




QuantityDescription

in Rs.

Rate

in Rs.

Rate

QuantityDescription

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TOTAL Rs: 318794.52








Total Rs: 351904.72








ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity Class- II

type moving gantry craneconsisting of rail mounted gantry frame, top platform with hand

railing, long / cross travel arrangements, rope drums, gear systems, electric motors, electro-magnetic 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 details of Material / Gas cutting / Welding based on fabrication drawings of moving

data rates gate works 2

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