data rates gate works 3
TRANSCRIPT
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TOTAL Rs: 318794.52
Add for excise duty on 75 percent cost of
Machinery / Labour components @ 8.24% Rs: 3143.52
Add for insurance charges @ 1.00% Rs: 3187.95
Add for designs and drawings @ 2.50% Rs: 7969.86
Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 7969.86
Add for power supply arrangements @ 2.00% Rs: 6375.89
Add for enabling works @ 1.40% Rs: 4463.12
Total Rs: 351904.72
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2 x 3.528 tonnes @ Rs: 129.10 / tonne Rs: 910.93
Add for transportation upto work site @ 3.00% Rs: 10557.14
Total cost for 3.528 tonne Rs: 363372.80
Rate per tonne Rs: 103000.00
Rate approved per tonne Rs: 103000.00
SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 8
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 actual weight for data rate analysis.
Consider details of Material / Gas cutting / Welding based on fabrication drawings of moving
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gantry crane for operating spillway stoplog gate elements and river sluice emergency gate
provided for one of the dam for rate analysis ( for details refer item : 8 of Annexure-2 ).
1. Requirement of materials :
a. Structural steel conforming to IS : 2062 :
Angles/ beams/ channels/ bars with 2.5 % wastage ( 1700x1.025 ) : 1743.00 kg
Plates / flats with 2.5 % wastage ( 19219 x 1.025 ) : 19700.00 kg
Chequered plate with 2.5 % wastage ( 800 x 1.025 ) : 820 kg
b. Cast steel components conforming to IS : 1030 :
Rope drums 2 Nos / Gears : 2336.00 kg
Pinions : 149.00 kg
Wheels and Pulleys : 2255.00 kg
Plummer blocks / Couplings : 817.00 kg
c. Forged steel components conforming to IS : 2004 :
Hook / Shackle : 127.00 kg
d. Alloy steel steel components conforming to IS: 1570 :
Shafts : 556.00 kg
Pins : 524.00 kg
e. Alluminium/ Bronze alloy components conforming to IS : 305 :
Bearings / Bush : 181.00 kg
f. Bolt / Nut / Washers conforming to IS : 1363 :
MS Bolts / Nuts / Washers with 2.5 % wastage ( 61 x 1.025 ) : 63.00 kgg. Steel wire rope conforming to IS : 2266 :
28 mm dia 6 / 37 construction 150 Rm @ 2.71 kg / m : 406 .00 kg
h. Other components :
Worm reducers : 4 Nos
Electric motor 17.5 hp : 1 No.
Electric motor 5 hp : 2 Nos
Electric motor 3 hp : 1 No.
Ele-magnetic / Thruster brakes : 4 No.
MS pipe 32 mm dia : 50 Rm
Electric cable / switches / control panels etc : 3 sets
i. Welding electrodes ( General purpose / Low hydrogen ) :
GP / LH electrodes as per data sheet ( Item:8 Annexure-2 ) : 16651 Nos
Add for variations / wastage / misc welding @ 10 % ( 16651 x 0.1 ) : 1665 Nos
Total requirement of GP / LH electrodes : 18316 Nos
for stitch weld GP electrodes @t 10 % of total ( 18316 x 0.10 ) : 1832 Nos
for run welding LH electrodes @ 90 % of total ( 18316 x 0.90 ) : 16484 Nos
2. Cutting :
Length of cutting assuming cutting for 2 sides as per data sheet : 761 Rm
Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 76 Rm
Total : 837 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas cutting torch manually : 250 mLength of steel to be cut by gas using pug cutting machine : 587 m
Time for gas cutting manually at ( av ) 2 m cutting / hour : 125 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 196 hours
Acetelyne gas @ 0.6 cum / hour ( 125 + 196 ) x 0.60 : 193 cum
Oxygen gas @ 1.8 cum / hour ( 125 + 196 ) x 1.80 : 579 cum
Use of gas cutting torch with 50 min / hr working ( 125 x 60 / 50 ) : 150 hours
Use of pug cutting machine with 50 min/hr working ( 196 x 60 / 50 ) : 235 hours
3. Welding :
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Length of welding as per data sheet : 1260 Rm
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 1832 / 15 ) x 8 / 2 : 489 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 16484 / 15 ) x 8 / 6 : 1465 hours
Total : 1954 hours
Deploy welding transformer for 1954 hours.
Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.
( 489 x 0.25 + 1465 x 0.75 ) : 1221 hours
4. Surface cleaning and painting :
Painting area for crane at 25 sqm / t of str steel ( 21.443 x 25 ) say : 540 sqm
2 coats of zinc chromate red oxide primer.
Quantity of primer paint for 540 sqm @ 12 sqm / ltr / coat : 90 ltr
3 coats of synthetic enamel paint.
Quantity of synthetic enamel paint for 540 sqm @ 12 sqm / ltr / coat : 135 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 540 sqm @ 8 sqm / ltr : 68 ltr
5. Requirement of other machinery :
For handling and erection of portals use of 25 t mobile crane for 16 hours with energy chargesfor 8 hours and 8 t momile crane for 40 hours considered
For drilling holes for bolts 16 hours use of drilling machine considered.
For grinding and finishing weld joints 64 hours use of grinding machine considered.
6. Requirement of work force :
Work component Foreman Helper /
Painter Cl-II
Cutting sections 385 hours 24 48 48 96
Drilling holes for pins / bolts fixing 1 2 --- 2
Fabricating by stitch welding 489 hours 30 61 --- 122
Run welding 1465 hours 18 --- 183 183
Assembly/Erection of wheels/ base frame 4 8 --- 16
Assembly/Erection of portals 4 8 --- 16
Assembly/Erection of top frame 4 8 --- 16
Assembly/Erection of CT trolley 2 4 --- 8
Assembly/Erection of drums / drive units 2 4 --- 8
Assembly/Erection of CT drive units 1 2 --- 4
Assembly/Erection of LT drive units 1 2 --- 4
Erection of cabin / railings etc 2 2 --- 4
Erection of control panel / cabling 1 1 --- 2
Checking and trial running without rope 2 4 --- 4
Rope fixing and checking 1 2 --- 2Cleaning surface 540 sqm @ 15 sqm/day --- --- --- 36
Painting ( 5 x 540 ) sqm @ 15 sqm / day --- --- --- 162
Trial running by lifting / lowering gate 1 2 --- 2
Finishing / cleaning --- 1 --- 2
Total : 98 159 231 689
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 135 Painters Cl-II
Erector /
Fabricator /
Marker /
Welder
Gas cutter /
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at 15 sqm / day and 27 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 : 30.856 tonne
A. MATERIALS: 25 t capacity
Sl No Unit Amount
in Rs.
1 Structural steel
Angles / beams / channels / bars kg 1743.00 37.95 66146.85
Plates / flats kg 19700.00 40.00 788000.00
Contd
A. MATERIALS ( Contd ) :
Sl No Unit Amount
in Rs.
Contd
Chequered plates kg 820.00 42.00 34440.00
2 Cast steel components :
Rope drums 2 Nos / Gears kg 2336.00 145.00 338720.00
Pinions kg 149.00 150.00 22350.00
Wheels / Pulleys kg 2255.00 125.00 281875.00
Plummer blocks / Couplings kg 817.00 125.00 102125.00
3 Forged steel components
Hook / Shackle kg 127.00 165.00 20955.00
4 Alloy steel components
Shafts kg 556.00 175.00 97300.00
Pins kg 524.00 215.00 112660.00
5 Bronze alloy components :
Bronze bearings / bush kg 181.00 635.00 114935.00
6 Wire rope 28 mm dia 6 / 37 construction kg 406.00 105.00 42630.00
7 MS Bolt / Nut / Washer kg 63.00 55.00 3465.00
8 MS pipe 32 mm dia for railing Rm 50.00 127.00 6350.00
9 Worm reducers Nos. 4.00 52500.00 210000.00
10 Electric motor 17.5 hp No. 1.00 37500.00 37500.00Electric motor 5 hp Nos. 2.00 15000.00 30000.00
Electric motor 3 hp No. 1.00 9000.00 9000.00
11 Ele-magnetic / Thruster brakes Nos. 4.00 11250.00 45000.00
12 Electric cable / switch / control panel etc LS 3.00 7500.00 22500.00
13 Oxygen gas cum 579.00 48.00 27792.00
14 Acetyline gas cum 193.00 258.00 49794.00
15 Welding electrodes ( general purpose ) Nos 1832.00 6.00 10992.00
16 Welding electrodes ( low hydrogen ) Nos 16484.00 12.00 197808.00
in Rs.
Quantity Rate
RatePerticulars Quantity
Perticulars
in Rs.
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17 Zinc chromate red oxide primer ltr 90.00 140.00 12600.00
18 Synthetic enamel ( 1st quality ) paint ltr 135.00 176.00 23760.00
19 Rust cleaner / inhibitor ltr 68.00 240.00 16320.00
20 Grease kg 50.00 194.00 9700.00
21 Use rate welding holder set Hour 1954.00 4.50 8793.00
22 Use rate gas cutting torch set Hour 150.00 2.50 375.00
23 Wire brush Nos 6.00 30.00 180.00
24 Sundries ( scrap for counter wt etc ) LS 200.00 30.00 6000.00
Total Rs: 2750065.85
Add for small Tools and Plants @ 1% Rs: 27500.66
Add for Contractor's Profit @ 10% Rs: 275006.59
Add for Contractor's Overheads @ 5% Rs: 137503.29
Total cost of Materials : Rs: 3190076.39
B. MACHINERY:
Sl No Unit Amount
in Rs.
1 Welding transformer Hour 1954.00 12.00 23448.00
Fuel / Energy charges Hour 1221.00 60.00 73260.00
Contd
B. MACHINERY ( Contd ) :
Sl No Unit Amount
in Rs.
Contd
2 Pug cutting machine Hour 235.00 16.00 3760.00
Fuel / Energy charges Hour 235.00 3.00 705.00
3 Mobile crane 25 t Hour 16.00 3804.00 60864.00
Fuel / Energy charges Hour 8.00 1375.00 11000.00
4 Mobile crane 8 t Hour 40.00 362.00 14480.00
Fuel / Energy charges Hour 40.00 495.00 19800.00
5 Grinding machine Hour 64.00 18.00 1152.00
Fuel / Energy charges Hour 64.00 25.00 1600.00
6 Drilling machines Hour 16.00 18.00 288.00
Fuel / Energy charges Hour 16.00 25.00 400.00
7 Sundries LS 150.00 30.00 4500.00
Total Rs: 215257.00
Add for small Tools and Plants @ 1% Rs: 2152.57
Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 11126.50
Add for Contractor's Overheads @ 5% Rs: 10762.85
Total hire charges of Machinery : Rs: 239298.92
C. LABOUR:
Sl No Unit Amountin Rs.
1 Crew for Mobile crane 25 t Hour 16.00 72.60 1161.60
2 Crew for Mobile crane 8 t Hour 40.00 75.70 3028.00
3 Crew for Drilling machine Hour 16.00 59.50 952.00
4 Crew for Grinding machine Hour 64.00 59.50 3808.00
5 Foreman Day 98.00 177.00 17346.00
6 Marker / Fabricator / Erector Day 159.00 157.50 25042.50
7 Gas cutter Day 48.00 157.50 7560.00
Description
Description Quantity Ratein Rs.
in Rs.
in Rs.
Description Quantity Rate
RateQuantity
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8 Welder ( General ) Day 183.00 157.50 28822.50
9 Khalasi Day 20.00 145.50 2910.00
10 Helper fabrication / erection Day 491.00 141.50 69476.50
11 Helper for cleaning / painting Day 63.00 141.50 8914.50
12 Painter Cl - II Day 135.00 141.50 19102.50
13 Electrician Day 5.00 143.00 715.00
Total Rs: 188839.10
Add for small Tools and Plants @ 1% Rs: 1888.39
Add for Contractor's Profit @ 10% Rs: 18883.91
Add for hidden cost on Labour @ 15% Rs: 28325.87
Add for additional hidden cost on labour @ 15% Rs: 28325.87
Add for Contractor's Overheads @ 5% Rs: 9441.96
Total cost of Labour : Rs: 275705.09
ABSTRACT:
A. Cost of Materials Rs: 3190076.39
B. Hire charges of Machinery Rs: 239298.92
C. Cost of Labour Rs: 275705.09
TOTAL Rs: 3705080.39
Add for excise duty on 75 percent cost of
Machinery / Labour components @ 8.24% Rs: 31827.25
Add for insurance charges @ 1.00% Rs: 37050.80
Add for designs and drawings @ 2.50% Rs: 92627.01
Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 92627.01
Add for power supply arrangements @ 2.00% Rs: 74101.61
Add for enabling works @ 1.40% Rs: 51871.13
Total Rs: 4085185.20
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x30.856 tonnes @ Rs: 129.10 / tonne Rs: 7967.02
Add for transportation upto work site @ 3.00% Rs: 122555.56
Total cost for 30.856 tonne weight Rs: 4215707.77
25.000 tonne capacity
Rate per tonne weight Rs: 136630.00
Rate per tonne capacity Rs: 168600.00
Rate approved per tonne capacity Rs: 168600.00
SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 9
ITEM: Design, fabrication, supply, erection and commissioning of rail trackusing 45 kg / m standard
rails on spillway bridge for movement of gantry cranefor handling and operating spillway
stoplog gate elements / river sluice / canal sluice emergency gate including cost of all materials,
machinery, labour, aligning, anchoring, welding, cleaning etc., complete as per specifications
and approved drawings with all leads and lifts.
DATA:Rail track for moving gantry crane consists of 45 kg / m standard rails fixed by welding and
bolting to anchors embedded in concrete at intervals. The width of track shall be as per the
requirement of gantry long travel specifications.
Consider track length of 200 m for rate analysis.
Weight of 45 kg / m rails in tonnes ( 2 x 200 x 45 ) / 1000 : 18.00
Add for anchors and fixtures @ 15 % including wastage : 2.70
Total weight in tonnes : 20.70
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The weight computed as above based on percentage provision for fixtures is further checked by
computing the actual weight as per fabrication drawings for gantry track provided for one of dam.
Actual weight of materials as per data in Item : 9 of Annexure-2 : 20.722 t
Consider actual weight for data rate analysis.
Consider details of Material / Gas cutting / Welding based on fabrication drawings of gantry
track provided for one of the dam for rate analysis ( for details refer Item : 9 of Annexure-2 ).
1. Requirement of materials :
a. Structural steel conforming to IS : 2062 :
Angles/ beams/ channels/ bars with 2.5 % wastage ( 1531x1.025 ) : 1570 kg
Plates / flats with 2.5 % wastage ( 951 x 1.025 ) : 975 kg
b. Bolt / Nut / Washer conforming to IS : 1363 :
MS bolts and nuts with 2.5 % wastage ( 240 x 1.025 ) : 246 kg
c. Standard Rails 45 kg / m with 2.5 % wastage ( 18000 x 1.025 ) : 18450 kg
d. Welding electrodes ( General purpose ) :
GP electrodes as per data sheet ( Item:9 Annexure-2 ) : 1710 Nos
Add for variations / wastage / misc welding @ 10 % ( 1710 x 0.1 ) : 171 Nos
Total requirement of GP electrodes : 1881 Nos
for stitch weld GP electrodes @t 10 % of total ( 1881 x 0.10 ) : 188 Nos
for run welding GP electrodes @ 90 % of total ( 1881 x 0.90 ) : 1693 Nos
2. Cutting :
Total length of cutting assuming cutting for 2 sides as per data sheet : 222 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas cutting torch manually : 222 m
Time for gas cutting manually at average cutting progress of 2 m / hour : 111 hours
Acetelyne gas @ 0.6 cum / hour ( 111 x 0.60 ) : 67 cum
Oxygen gas @ 1.8 cum / hour ( 111 x 1.80 ) : 201 cum
Use of gas cutting torch with 50 min / hr working ( 111 x 60 / 50 ) : 133 hours
3. Welding :
Length of welding as per data sheet : 210 m
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 188 / 15 ) x 8 / 2 : 50 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 1693 / 15 ) x 8 / 6 : 150 hours
Total : 200 hours
Deploy welding transformer for 200 hours.
Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.
( 50 x 0.25 + 150 x 0.75 ) : 125 hours
4. Surface cleaning and painting :
For painting buffers and supporting plates 0.5 ltr zinc rich epoxy primer and 1 ltr coal tar epoxy
paint considered.
5. Requirement of other machinery :
For drilling holes for anchor bolts 24 hours use of drilling machine considered.
For grinding edges of parts requiring finishing 8 hours use of grinding machine considered.
For handling and erection use of 8 t mobile crane for 2 hours considered.
6. Requirement of work force :
Work component Foreman Helper /
Painter Cl-II
Gas cutter /
Fabricator /
Marker /
Welder
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Cutting sections 133 hours --- 17 17 17
Drilling holes for anchors / supports --- 6 --- 6
Erection /stitch welding anchors 50 hours 3 6 --- 6
Erection of rails & fixing clamps 2 2 --- 4
Run welding 150 hours 2 --- 19 19
Cleaning surface 3 sqm @ 15 sqm/day --- --- --- ---
Painting ( 3 x 3 ) sqm @ 15 sqm / day --- --- --- 1
Finishing / checking / cleaning 1 1 --- 1
Total : 8 32 36 54
Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision
is considered for welder for stitch welding.
b. 1 Painter Cl- II considered or cleaning and painting.
7. Excise duty on supply :
Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all
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 : 200.000 Rm
A. MATERIALS:
Sl No Unit Amount
in Rs.
1 Structural steel
Angles / channels / beams / bars kg 1570.00 37.95 59581.50
Plates / flats kg 975.00 40.00 39000.00
2 Rails kg 18450.00 42.00 774900.00
3 MS bolts and nuts kg 246.00 55.00 13530.00
4 Oxygen gas cum 201.00 48.00 9648.00
5 Acetyline gas cum 67.00 258.00 17286.00
6 Welding electrodes ( general purpose ) Nos 1881.00 6.00 11286.00
7 Zinc rich epoxy primer ltr 0.50 594.00 297.00
8 Coal tar epoxy paint ltr 1.00 208.00 208.00
9 Use rate welding holder set Hour 200.00 4.50 900.00
10 Use rate gas cutting torch set Hour 133.00 2.50 332.50
11 Sundries LS 10.00 30.00 300.00
Total Rs: 927269.00Add for small Tools and Plants @ 1% Rs: 9272.69
Add for Contractor's Profit @ 10% Rs: 92726.90
Add for Contractor's Overheads @ 5% Rs: 46363.45
Total cost of Materials : Rs: 1075632.04
B. MACHINERY:
Sl No Unit Amount
in Rs.
Erector /
Description
Perticulars Rate
Quantity
Quantity
in Rs.
in Rs.
Rate
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1 Welding transformer Hour 200.00 12.00 2400.00
Fuel / Energy charges Hour 125.00 60.00 7500.00
2 Mobile crane 8 t Hour 2.00 362.00 724.00
Fuel / Energy charges Hour 2.00 495.00 990.00
3 Grinding machine Hour 8.00 18.00 144.00
Fuel / Energy charges Hour 8.00 25.00 200.00
4 Drilling machines Hour 24.00 18.00 432.00
Fuel / Energy charges Hour 24.00 25.00 600.00
5 Sundries LS 10.00 30.00 300.00
Total Rs: 13290.00
Add for small Tools and Plants @ 1% Rs: 132.90
Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 959.00
Add for Contractor's Overheads @ 5% Rs: 664.50
Total hire charges of Machinery : Rs: 15046.40
C. LABOUR:
Sl No Unit Amount
in Rs.
1 Crew for Mobile crane Hour 2.00 75.70 151.40
2 Crew for Drilling machine Hour 24.00 59.50 1428.00
3 Crew for Grinding machine Hour 8.00 59.50 476.00
4 Foreman Day 8.00 177.00 1416.00
5 Marker / Fabricator / Erector Day 32.00 157.50 5040.00
6 Gas cutter Day 17.00 157.50 2677.50
7 Welder ( General ) Day 19.00 157.50 2992.50
8 Helper fabrication / erection Day 53.00 141.50 7499.50
9 Painter Cl- II Day 1.00 141.50 141.50
10 Electrician Day 1.00 143.00 143.00
Total Rs: 21965.40
Add for small Tools and Plants @ 1% Rs: 219.65
Add for Contractor's Profit @ 10% Rs: 2196.54
Add for hidden cost on Labour @ 15% Rs: 3294.81
Add for additional hidden cost on labour @ 15% Rs: 3294.81
Add for Contractor's Overheads @ 5% Rs: 1098.27
Total cost of Labour : Rs: 32069.48
ABSTRACT:
A. Cost of Materials Rs: 1075632.04
B. Hire charges of Machinery Rs: 15046.40
C. Cost of Labour Rs: 32069.48
TOTAL Rs: 1122747.92
Add for excise duty on 75 percent cost ofMachinery / Labour components @ 8.24% Rs: 2911.76
Add for insurance charges @ 1.00% Rs: 11227.48
Add for designs and drawings @ 2.50% Rs: 28068.70
Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 28068.70
Add for power supply arrangements @ 2.00% Rs: 22454.96
Add for enabling works @ 1.40% Rs: 15718.47
Total Rs: 1231197.99
Add for 2 rehandling leads for 1 km including loading and unloading :
Description
in Rs.
Quantity Rate
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Fabricated parts 2x20.722 tonnes @ Rs: 129.10 / tonne Rs: 5350.42
Add for transportation upto work site @ 3.00% Rs: 36935.94
Total cost for 200.000 Rm Rs: 1273484.35
Rate per Rm Rs: 6400.00
Rate approved per Rm Rs: 6400.00
SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 10
ITEM: Design, fabrication, supply, erection and commissioning of embedded parts( without groove
liner )consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner ( upto one
vent height plus 1 m above the roof of vent ) etc., with all accessoriesfor river / canal sluice
service gateincluding cost of all materials, machinery, labour, aligning, anchoring, welding,
finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied
coal tar epoxy paint etc., complete as per specifications and approved drawings with all leads
and lifts.
DATA:Embedded parts for river / canal sluice service gate without groove lining consist of sill beam,wheel / seal tracks, breast wall lining and gate guide with accessories such as first / second
stage anchors.
The weight of embedded parts depends on the height of gate groove and height upto which
breast wall lining is to be provided. Weight of embedded parts will be about 50% of wt of gate.
Consider embedded parts for river sluice service gate for sluice opening of size 1.5 m x 3 m.
Weight of breast wall lining for 20 mm MS plate and 6 mm SS plate including stiffeners and
anchors will be about 250 kg per sqm area of breast wall.
Size of gate for 1.5 m x 3 m opening : Length : 2.2 m Height : 3.3 m
Head of water above sill level considered : 16 m
Weight of vertical lift roller gate in tonne for 1.5 m x 3 m opening based on empirical formula :
= 0.0888 x ( L2x H x h )
0.659
Consider weight of embedded parts in tonnes @ 50 % of weight of gate leaf :
= 0.50 x 0.0888 x ( L2x H x h ) 0.659
Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.
= 0.0444 x ( 2.2 x 2.2 x 3.3 x 16 )0.659
: 1.714 tonnes
Weight of breast wall lining about 7 sqm @ 250 kg / sqm : 1.750 tonnes
Total : 3.464 tonnes
The weight computed as above based on empirical formula is further checked by computing the
actual weight as per fabrication drawings of embedded parts for river sluice service gate of same
size provided for one of the dam.
Actual weight of embedded parts as per data in Item :10 of Annexure-2 : 3.172 tonnes
Consider actual weight for data rate analysis.
Consider details of Material / Gas cutting / Welding based on embedded parts drawings for
river sluice service gate provided for one of the dam for rate analysis ( for details refer Item : 10
of Annexure - 2 ).
1. Requirement of materials :a. Structural steel conforming to IS : 2062 :
Angles/ beams/ channels/ bars with 2.5 % wastage ( 588x1.025 ) : 603 kg
Plates / flats with 2.5 % wastage ( 2109 x 1.025 ) : 2162 kg
b. Alloy steel components conforming to IS : 1570 :
Stainless steel plates / flats ( 414 x 1.025 ) : 424.00 kg
c. Bolt / Nut / Washer conforming ti IS : 1363 :
MS bolts and nuts with 2.5 % wastage ( 61 x 1.025 ) : 62.5 kg
d. Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) :
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GP / LH electrodes as per data sheet ( Item:10 Annexure-2 ) : 1359 Nos
Add for variations / wastage / misc welding @ 10 % ( 1359 x 0.1 ) : 136 Nos
Total requirement of GP / LH electrodes : 1495 Nos
for stitch welding GP electrodes @t 10 % of total ( 1495 x 0.10 ) : 150 Nos
for run welding LH electrodes @ 90 % of total ( 1495 x 0.90 ) : 1345 Nos
Stainless steel electrodes as per data sheet ( Item:10 Annexure-2 ) : 417 Nos
Add for variations / wastage @ 5 % ( 417 x 0.05 ) : 21 Nos
Total requirement of Stainless steel ( SS ) electrodes : 438 Nos
for stitch weld SS electrodes @t 10 % of total ( 438 x 0.10 ) : 44 Nos
for run weld SS electrodes @t 90 % of total ( 438 x 0.90 ) : 394 Nos
2. Cutting :
Length of cutting assuming cutting for 2 sides as per data sheet : 152 Rm
Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 15 Rm
Total length of cutting Total : 167 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 shearingmachine and for the remaining sections pug cutting machine is considered.
Length of steel to be cut by using gas manually : 30 m
Length of steel to be cut by gas using pug cutting machine : 107 m
Length of steel to be cut by using shearing machine : 30 m
Time for gas cutting manually at ( av ) 2 m cutting / hour : 15 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 36 hours
Time for cutting by shearing machine at ( av ) 10 m cutting / hour : 3 hours
Acetelyne gas @ 0.6 cum / hour ( 15 + 36 ) x 0.60 : 31 cum
Oxygen gas @ 1.8 cum / hour ( 15 + 36 ) x 1.80 : 93 cum
Use of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hours
Use of pug cutting machine with 50 min / hr working ( 36 x 60 / 50 ) : 43 hours
Use of shearing machine with 50 min / hr working ( 3 x 60 / 50 ) : 4 hours
3. Welding :
Length of welding as per data sheet : 191 m
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 150 + 44 ) x 8 / 15 / 2 : 52 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 1345 + 394 ) x 8 / 15 / 6 : 154 hours
Total : 206 hours
Deploy welding transformer for 206 hours.
Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.
( 52 x 0.25 + 154 x 0.75 ) : 129 hours
4. Planing SS plates for wheel / seal tracks :
For surface finishing of SS plates for wheel / seal tracks planing machine is considered.
Length of SS plate for surface finishing by planing machine : 30 RmLength of planing at a time for 4 m stroke planing machine : 3 Rm
Time for planing 3 m length section with 50 min / hour working : 8 hours
Time for planing 30 m SS plates ( 30 x 8 / 3 ) : 80 hours
5. Surface cleaning and painting :
Painting area for embedded parts at 10 sqm / tonne ( 3.172 x 10 ) : 32 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 32 sqm @ 9 sqm / ltr / coat : 4 ltr
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4 coats of coal tar epoxy paint 100 micron dry film each coat.
Quantity of coal tar epoxy paint for 32 sqm @ 6 sqm / ltr / coat : 22 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 @ 8 sqm / ltr : 4 ltr
6. Requirement of other machinery :
For drilling holes for anchor bolts use of drilling machine for 8 hours considered.
For grinding weld joints and edges requiring finishing use of grinding machine for 8 hours
considered.
For handling parts during fabrication and erection use of 8 t mobile crane for 4 hours and
stationery derric crane for 8 hours considered
7. Requirement of work force :
Work component Foreman Helper /
Painter Cl-II
Cutting sections 65 hours 4 8 8 16
Drilling holes for anchors / supports 1 1 --- 2
Fbricating by stitch welding 52 hours 3 6 --- 12
Run welding 154 hours 2 --- 19 19
Erection of first stage anchors 3 6 --- 6
Erection of Sill beam / Tracks / Guide 2 4 --- 8
Erection of Breast wall 2 4 --- 8
Cleaning surface 32 sqm @ 15 sqm/day --- --- --- 2
Painting ( 5 x 32 ) sqm @ 15 sqm / day --- --- --- 13
Finishing / checking / cleaning 1 1 --- 2
Total : 18 30 27 88
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 11 Painters Cl-II
at 15 sqm / day and 2 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 UNIT : 3.172 tonne
A. MATERIALS:
Sl No Unit Amount
in Rs.
1 Structural steel
Angles / beams / channels / bars kg 603.00 37.95 22883.85
Plates / flats kg 2162.00 40.00 86480.00
Erector /
Marker /
Perticulars
Fabricator /
in Rs.
Welder
Gas cutter /
RateQuantity
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2 Stainless steel plate / flats kg 424.00 120.00 50880.00
3 MS bolts and nuts kg 62.50 55.00 3437.50
4 Oxygen gas cum 93.00 48.00 4464.00
5 Acetyline gas cum 31.00 258.00 7998.00
6 Welding electrodes ( general purpose ) Nos 150.00 6.00 900.00
7 Welding electrodes ( low hydrogen ) Nos 1345.00 12.00 16140.00
8 Welding electrodes ( stainless steel ) Nos 438.00 43.00 18834.00
9 Zinc rich epoxy primer ltr 4.00 594.00 2376.00
10 Coal tar epoxy paint ltr 22.00 208.00 4576.00
11 Rust cleaner / inhibitor ltr 4.00 240.00 960.00
12 Use rate welding holder set Hour 206.00 4.50 927.00
Contd
A. MATERIALS ( Contd ) :
Sl No Unit Amount
in Rs.
Contd 13 Use rate gas cutting torch set Hour 18.00 2.50 45.00
14 Wire brush Nos 1.00 30.00 30.00
15 Sundries LS 20.00 30.00 600.00
Total Rs: 221531.35
Add for small Tools and Plants @ 1% Rs: 2215.31
Add for Contractor's Profit @ 10% Rs: 22153.14
Add for Contractor's Overheads @ 5% Rs: 11076.57
Total cost of Materials : Rs: 256976.37
B. MACHINERY:
Sl No Unit Amount
in Rs.
1 Welding transformer Hour 206.00 12.00 2472.00
Fuel / Energy charges Hour 129.00 60.00 7740.00
2 Plate shearing machine Hour 4.00 62.00 248.00
Fuel / Energy charges Hour 4.00 100.00 400.00
3 Pug cutting machine Hour 43.00 16.00 688.00
Fuel / Energy charges Hour 43.00 3.00 129.00
4 Planing machine Hour 80.00 88.00 7040.00
Fuel / Energy charges Hour 80.00 75.00 6000.00
5 Mobile crane 8 t Hour 4.00 362.00 1448.00
Fuel / Energy charges Hour 4.00 495.00 1980.00
6 Stationery derric crane Hour 8.00 66.00 528.00
Fuel / Energy charges Hour 8.00 9.00 72.00
7 Grinding machine Hour 8.00 18.00 144.00
Fuel / Energy charges Hour 8.00 25.00 200.00
8 Drilling machines Hour 8.00 18.00 144.00Fuel / Energy charges Hour 8.00 25.00 200.00
9 Sundries LS 10.00 30.00 300.00
Total Rs: 29733.00
Add for small Tools and Plants @ 1% Rs: 297.33
Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 1702.10
Add for Contractor's Overheads @ 5% Rs: 1486.65
Total hire charges of Machinery : Rs: 33219.08
Description
Perticulars Quantity
in Rs.
Rate
Quantity Rate
in Rs.
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C. LABOUR:
Sl No Unit Amount
in Rs.
1 Crew for Mobile crane Hour 4.00 75.70 302.80
2 Crew for Shearing machine Hour 4.00 45.90 183.60
3 Crew for Planing machine Hour 80.00 73.40 5872.00
4 Crew for Drilling machine Hour 8.00 59.50 476.00
5 Crew for Grinding machine Hour 8.00 59.50 476.00
6 Foreman Day 18.00 177.00 3186.00
Contd
C. LABOUR ( Contd ) :
Sl No Unit Amount
in Rs.
Contd
7 Marker / Fabricator / Erector Day 30.00 157.50 4725.008 Gas cutter Day 8.00 157.50 1260.00
9 Welder ( General ) Day 17.00 157.50 2677.50
10 Welder ( X - ray ) Day 2.00 173.25 346.50
11 Helper fabrication / erection Day 73.00 141.50 10329.50
12 Helper for cleaning / painting Day 4.00 141.50 566.00
13 Painter Cl - II Day 11.00 141.50 1556.50
14 Electrician Day 2.00 143.00 286.00
Total Rs: 32243.40
Add for small Tools and Plants @ 1% Rs: 322.43
Add for Contractor's Profit @ 10% Rs: 3224.34
Add for hidden cost on Labour @ 15% Rs: 4836.51
Add for additional hidden cost on labour @ 15% Rs: 4836.51
Add for Contractor's Overheads @ 5% Rs: 1612.17
Total cost of Labour : Rs: 47075.36
ABSTRACT:
A. Cost of Materials Rs: 256976.37
B. Hire charges of Machinery Rs: 33219.08
C. Cost of Labour Rs: 47075.36
TOTAL Rs: 337270.81
Add for excise duty on 75 percent cost of
Machinery / Labour components @ 8.24% Rs: 4962.20
Add for insurance charges @ 1.00% Rs: 3372.71
Add for designs and drawings @ 2.50% Rs: 8431.77
Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 8431.77
Add for power supply arrangements @ 2.00% Rs: 6745.42
Add for enabling works @ 1.40% Rs: 4721.79Total Rs: 373936.46
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2 x 3.172 tonnes @ Rs: 129.10 / tonne Rs: 819.01
Add for transportation upto work site @ 3.00% Rs: 11218.09
Total cost for 3.172 tonne Rs: 385973.57
Rate per tonne Rs: 121700.00
Rate approved per tonne Rs: 121700.00
Description
Description Quantity Rate
in Rs.
Quantity Rate
in Rs.
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SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 11
ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( with groove
liner upto breast wall level ) consisting of sill beam, wheel tracks, seal seats, guide rails,
breast wall liner ( upto one vent height plus 1 m above the roof of vent ) etc., with all accessories
for river / canal sluice service gate including cost of all materials, machinery, labour,
aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer
and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and
approved drawings withall leads and lifts.
DATA:Embedded parts for river sluice service gate consist of sill beam, wheel / seal tracks, groove
lining upto breast wall level, breast wall lining upto 1 vent plus 1 m above top of vent, gate guide
etc., with all accessories such as first stage anchors.
The wt of embedded parts depends on the height of gate groove and height upto which breast
wall lining is to be provided. Generally wt of embedded parts will be about 50% of wt of gate.
Weight of breast wall lining for 20 mm MS plate and 6 mm SS plate including stiffeners andanchors will be about 250 kg per sqm area of breast wall.
Weight of groove liner for 20 mm MS plate including stiffeners and anchors will be about
200 kg / sqm area of groove liner.
Consider embedded parts for river sluice service gate for sluice opening of size 2.5 m x 3 m.
Size of gate for 2.5 m x 3 m opening : Length : 3.2 m Height : 3.3 m
Head of water above sill level considered : 34 m
Weight of vertical lift roller in tonne for 2.5 m x 3 m opening based on empirical formula :
= 0.0888 x ( L2
x H x h )0.659
Consider weight of embedded parts in tonnes @ 50 % of weight of gate leaf :
= 0.50 x 0.0888 x ( L2
x H x h )0.659
Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.
= 0.0444 x ( 3.2 x 3.2 x 3.3 x 34 )0.659
: 4.615 tonnes
Weight of breast wall lining about 12 sqm @ 250 kg / sqm : 3.000 tonnes
Weight of groove liner about 15 sqm @ 200 kg / sqm : 3.000 tonnes
Total : 10.615 tonnes
The weight computed as above based on empirical formula is further checked by computing the
actual weight as per fabrication drawings of embedded parts with groove liners for river sluice
service gate of same size provided for one of the dam.
Actual weight of embedded parts as per data in Item : 11 of Annexure-2 : 10.657 tonnes
Consider actual weight for data rate analysis.
Consider details of Material / Gas cutting / Welding based on embedded parts and gate groove
liner drawings for river sluice service gate provided for one of the dam work for rate analysis ( for
details refer Item : 11 of Annexure - 2 ).
1. Requirement of materials :
a. Structural steel conforming to IS : 2062 :
Angles/ beams/ channels/ bars with 2.5 % wastage ( 681x1.025 ) : 698 kgPlates / flats with 2.5 % wastage ( 8971 x 1.025 ) : 9195 kg
b. Alloy steel components conforming to IS : 1570 :
Stainless steel plates / flats ( 825 x 1.025 ) : 846 kg
c. Bolt / Nut / Washer conforming ti IS : 1363 :
MS bolts and nuts with 2.5 % wastage ( 180 x 1.025 ) : 185 kg
d. Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) :
GP / LH electrodes as per data sheet ( Item:11 Annexure-2 ) : 5569 Nos
Add for variations / wastage / misc welding @ 10 % ( 5569 x 0.1 ) : 557 Nos
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before applying primer painting.
Quantity of rust cleaner / inhibitor for 107 sqm @ 8 sqm / ltr : 14 ltr
6. Requirement of other machinery :
For drilling holes for anchor bolts use of drilling machine for 50 hours considered.
For grinding weld joints and edges requiring finishing use of grinding machine for 25 hours
considered.
For handling of parts during fabrication and erection 8 t mobile crane for 10 hours and stationery
derric crane for 40 hours considered.
7. Requirement of work force :
Work component Foreman Helper /
Painter Cl-II
Cutting sections 127 hours 8 16 16 32
Drilling holes for anchors / supports 3 6 --- 6
Fbricating by stitch welding 176 hours 11 22 --- 44
Run welding 528 hours 7 --- 66 66Erection of first stage anchors 5 10 --- 10
Erection of Sill beam / Tracks / Guide 2 4 --- 8
Erection of Breast wall liner 2 4 --- 8
Erection of groove liners 3 6 --- 12
Cleaning surface 107 sqm @ 15 sqm/day --- --- --- 7
Painting ( 5 x 107 ) sqm @ 15 sqm / day --- --- --- 42
Finishing / cleaning 1 2 --- 4
Total : 42 70 82 239
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 36 Painters Cl-II
at 15 sqm / day and 6 helpers to assist painters.
8. Excise duty on supply :
Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all
taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.
9. Use rate of materials :
Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 4.50
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 : 10.657 tonne
A. MATERIALS:
Sl No Unit Amountin Rs.
1 Structural steel
Angles / beams / channels / bars kg 698.00 37.95 26489.10
Plates / flats kg 9195.00 40.00 367800.00
2 Stainless steel plate / flats kg 846.00 120.00 101520.00
3 MS bolts and nuts kg 185.00 55.00 10175.00
4 Oxygen gas cum 180.00 48.00 8640.00
5 Acetyline gas cum 60.00 258.00 15480.00
Perticulars
Fabricator /
Marker /
Quantity
Gas cutter /
Ratein Rs.
Welder
Erector /
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6 Welding electrodes ( general purpose ) Nos 613.00 6.00 3678.00
7 Welding electrodes ( low hydrogen ) Nos 5513.00 12.00 66156.00
8 Welding electrodes ( stainless steel ) Nos 480.00 43.00 20640.00
9 Zinc rich epoxy primer ltr 12.00 594.00 7128.00
10 Coal tar epoxy paint ltr 72.00 208.00 14976.00
11 Rust cleaner / inhibitor ltr 14.00 240.00 3360.00
Contd
A. MATERIALS ( Contd ) :
Sl No Unit Amount
in Rs.
Contd
12 Use rate welding holder set Hour 704.00 4.50 3168.00
13 Use rate gas cutting torch set Hour 36.00 2.50 90.00
14 Wire brush Nos 2.00 30.00 60.00
15 Sundries LS 40.00 30.00 1200.00
Total Rs: 650560.10Add for small Tools and Plants @ 1% Rs: 6505.60
Add for Contractor's Profit @ 10% Rs: 65056.01
Add for Contractor's Overheads @ 5% Rs: 32528.01
Total cost of Materials : Rs: 754649.72
B. MACHINERY:
Sl No Unit Amount
in Rs.
1 Welding transformer Hour 704.00 12.00 8448.00
Fuel / Energy charges Hour 440.00 60.00 26400.00
2 Plate shearing machine Hour 7.00 62.00 434.00
Fuel / Energy charges Hour 7.00 100.00 700.00
3 Pug cutting machine Hour 84.00 16.00 1344.00
Fuel / Energy charges Hour 84.00 3.00 252.00
4 Planing machine Hour 80.00 88.00 7040.00
Fuel / Energy charges Hour 80.00 75.00 6000.00
5 Mobile crane 8 t Hour 10.00 362.00 3620.00
Fuel / Energy charges Hour 10.00 495.00 4950.00
6 Stationery derric crane Hour 40.00 66.00 2640.00
Fuel / Energy charges Hour 40.00 9.00 360.00
7 Grinding machine Hour 25.00 18.00 450.00
Fuel / Energy charges Hour 25.00 25.00 625.00
8 Drilling machines Hour 50.00 18.00 900.00
Fuel / Energy charges Hour 50.00 25.00 1250.00
9 Sundries LS 40.00 30.00 1200.00
Total Rs: 66613.00
Add for small Tools and Plants @ 1% Rs: 666.13Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 4173.70
Add for Contractor's Overheads @ 5% Rs: 3330.65
Total hire charges of Machinery : Rs: 74783.48
C. LABOUR:
Sl No Unit Amount
in Rs.
1 Crew for Mobile crane Hour 10.00 75.70 757.00
Description
Description Quantity
in Rs.
Rate
Quantity
in Rs.
Rate
Perticulars Quantity Rate
in Rs.
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2 Crew for Shearing machine Hour 7.00 45.90 321.30
3 Crew for Planing machine Hour 80.00 73.40 5872.00
4 Crew for Drilling machine Hour 50.00 59.50 2975.00
5 Crew for Grinding machine Hour 25.00 59.50 1487.50
6 Foreman Day 42.00 177.00 7434.00
Contd
C. LABOUR ( Contd ) :
Sl No Unit Amount
in Rs.
Contd
7 Marker / Fabricator / Erector Day 70.00 157.50 11025.00
8 Gas cutter Day 16.00 157.50 2520.00
9 Welder ( General ) Day 59.00 157.50 9292.50
10 Welder ( X - ray ) Day 7.00 173.25 1212.75
11 Helper fabrication / erection Day 190.00 141.50 26885.00
12 Helper for cleaning / painting Day 13.00 141.50 1839.5013 Painter Cl - II Day 36.00 141.50 5094.00
14 Electrician Day 5.00 143.00 715.00
Total Rs: 77430.55
Add for small Tools and Plants @ 1% Rs: 774.31
Add for Contractor's Profit @ 10% Rs: 7743.06
Add for hidden cost on Labour @ 15% Rs: 11614.58
Add for additional hidden cost on labour @ 15% Rs: 11614.58
Add for Contractor's Overheads @ 5% Rs: 3871.53
Total cost of Labour : Rs: 113048.60
ABSTRACT:
A. Cost of Materials Rs: 754649.72
B. Hire charges of Machinery Rs: 74783.48
C. Cost of Labour Rs: 113048.60
TOTAL Rs: 942481.80
Add for excise duty on 75 percent cost of
Machinery / Labour components @ 8.24% Rs: 11608.02
Add for insurance charges @ 1.00% Rs: 9424.82
Add for designs and drawings @ 2.50% Rs: 23562.04
Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 23562.04
Add for power supply arrangements @ 2.00% Rs: 18849.64
Add for enabling works @ 1.40% Rs: 13194.75
Total Rs: 1042683.11
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x10.657 tonnes @ Rs: 129.10 / tonne Rs: 2751.64
Add for transportation upto work site @ 3.00% Rs: 31280.49
Total cost for 10.657 tonne Rs: 1076715.24Rate per tonne Rs: 101000.00
Rate approved per tonne Rs: 101000.00
SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 12
ITEM: Design, fabrication, supply, erection and commissioning of vent liner using 20 mm thick MS
plates with stiffeners and anchors for river sluice / canal sluice vents including cost of all
materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying
QuantityDescription
in Rs.
Rate
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one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc.,
complete withall leads and lifts.
DATA:Vent lining consists of forming river / canal sluice of specified size using 20 mm thick structural
steel plates for the specified length. The liner plates are stiffened on the back side and anchors
are provided for embedment in concrete.
Consider vent lining for river / canal sluice of size 2.5 m x 3 m for analysis.
Consider vent lining for 3.40 m length of vent.
Finished area of lining : ( 2 x 3 x 3.4 + 2 x 2.5 x 3.4 ) : 37.40 sqm
Weight of 20 mm thick MS plate per sqm : 157.00 kg
Add 25 % for stiffeners / anchors / projections etc : 39.25 kg
Total requirement of steel for vent lining of sluice per sqm area Total : 196.25 kg
say : 196 kg
Quantity of steel required for 37.40 sqm ( 37.40 x 0.196 ) : 7.330 tonnes
The weight computed as above on percentage basis for stiffeners / anchors is further checked
by computing the actual weight as per fabrication drawings of vent liner for river sluice servicegate vent of same size provided for one of the dam.
Actual weight of liner for 37.4 sqm as per data in Item : 12 of Annexure-2 : 7.281 tonnes
Consider actual weight for data rate analysis.
Consider details of Material / Gas cutting / Welding based on vent liner drawings for river sluice
service gate vent provided for one of the dam for rate analysis ( for details refer Item : 12 of
Annexure - 2 ).
1. Requirement of materials :
a. Structural steel conforming to IS : 2062 :
Plates / flats with 2.5 % wastage ( 7281 x 1.025 ) : 7463 kg
b. Welding electrodes ( General purpose / Low hydrogen ) :
GP / LH electrodes as per data sheet ( Item:12 Annexure-2 ) : 4194 Nos
Add for variations / wastage / misc welding @ 10 % ( 4194 x 0.1 ) : 419 Nos
Total requirement of GP / LH electrodes : 4613 Nos
for stitch weld GP electrodes @ 10 % of total ( 4613 x 0.10 ) : 461 Nos
for run welding LH electrodes @ 90 % of total ( 4613 x 0.90 ) : 4152 Nos
2. Cutting :
Length of cutting assuming cutting for 2 sides : 203 Rm
Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 20 Rm
Total : 223 Rm
For cutting structural steel sections to required sizes gas cutting is assumed since most of the
sections are above 10 mm thick.
Length of steel to be cut by using gas manually : 30 m
Length of steel to be cut by gas using pug cutting machine : 193 m
Time for gas cutting manually at ( av ) 2 m cutting / hour : 15 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 64 hours
Acetelyne gas @ 0.6 cum / hour ( 15 + 64 ) x 0.60 : 47 cum
Oxygen gas @ 1.8 cum / hour ( 15 + 64 ) x 1.80 : 141 cumUse of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hours
Use of pug cutting machine with 50 min / hr working ( 64 x 60 / 50 ) : 77 hours
3. Welding :
Length of welding : 420 Rm
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 461 / 15 ) x 8 / 2 : 123 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 4152 / 15 ) x 8 / 6 : 369 hours
59
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8/13/2019 Data Rates Gate Works 3
21/21
GATE / HOIST AND ALLIED WORKS
Total : 492 hours
Deploy welding transformer for 492 hours.
Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.
( 123 x 0.25 + 369 x 0.75 ) : 308 hours
4. Surface cleaning and painting :
Painting area for liner : 37.5 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 37.5 sqm @ 9 sqm / ltr / coat : 4 ltr
4 coats of coal tar epoxy paint 100 micron dry film each coat.
Quantity of coal tar epoxy paint for 37.5 sqm @ 6 sqm / ltr / coat : 25 ltr
As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment
to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting
before applying primer painting.
Quantity of rust cleaner / inhibitor for 37.5 sqm @ 8 sqm / ltr : 5 ltr
5. Requirement of other machinery :
For handling during fabrication and erection 8 t mobile crane for 4 hours and stationery derriccrane for 16 hours considered.
For grinding and finishing weld joints in liner plates 12 hours use of grinding machine considered.
6. Requirement of work force :
Work component Foreman Helper /
Painter Cl-II
Cutting sections 95 hours 6 12 12 24
Fabricating by stitch welding 123 hours 8 15 --- 30
Run welding 369 hours 5 --- 46 46
Cleaning surface 37.4 sqm @15 sqm/day --- --- --- 2
Painting ( 5x37.4 ) sqm @ 15 sqm / day --- --- --- 14
Finishing / Cleaning 1 1 --- 1
Total : 20 28 58 117
Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision
is considered for welder for stitch welding.
b. Workforce for painting 1 coat primer and 4 coats finishing paint consists of 12 Painters Cl-II
at 15 sqm / day and 2 helpers to assist painters.
7. Excise duty on supply :
Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all
taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.
8. Use rate of materials :
Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 4.50
Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00
Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 2.50
RATE ANALYSIS UNIT : 37.400 sqm
A. MATERIALS:
Sl No Unit Amount
in Rs.
1 Structural steel plates / flats kg 7463.00 40.00 298520.00
2 Oxygen gas cum 168.00 48.00 8064.00
Fabricator /
Erector /
Welder
Marker / Gas cutter /
Quantity Rate
in Rs.
Perticulars