GATE / HOIST AND ALLIED WORKS

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

Rs:

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

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

RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars

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

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

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

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

1% 10% 5% Total cost of Materials :

B. MACHINERY: Sl No 1 2

Description

Unit Hour Hour Hour Hour

Quantity 701.00 438.00 7.00 7.00

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

Rate in Rs. 12.00 60.00 62.00 100.00 Contd

Amount in Rs. 8412.00 26280.00 434.00 700.00

B. MACHINERY ( Contd ) : Sl No Description

Unit

Quantity

3 4 5 6

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

Hour Hour Hour Hour Hour Hour Hour

84.00 84.00 69.00 69.00 4.00 4.00 40.00

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

Amount in Rs. 1344.00 252.00 6072.00 5175.00 1448.00 1980.00 2640.00

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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

40.00 25.00 25.00 50.00 50.00 25.00

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

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

360.00 450.00 625.00 900.00 1250.00 750.00 59072.00 590.72 3737.20 2953.60 66353.52

Description

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

Quantity 4.00 7.00 69.00 50.00 25.00 42.00 68.00 16.00 59.00 7.00 186.00 12.00 30.00 2.00

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

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

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

Amount in Rs. 302.80 321.30 5064.60 2975.00 1487.50 7434.00 10710.00 2520.00 9292.50 1212.75 26319.00 1698.00 4245.00 286.00 73868.45 738.68 7386.85 11080.27 11080.27 3693.42 107847.94

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:

648537.03 66353.52 107847.94 822738.49 10765.65 8227.38 20568.46 20568.46 16454.77 11518.34

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GATE / HOIST AND ALLIED WORKS

Total Rs: Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 9.088 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 9.088 tonne Rate per tonne Rate approved per tonne SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 Rs: Rs: Rs: Rs: Rs:

910841.56 2346.52 27325.25 940513.33 103500.00 103500.00 ITEM No: 17

ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type vertical lift emergency gate consisting of skin plate, horizontal and vertical girders, wheels, stiffeners, lifting brackets, guide rollers, ballast blocks, teflon claded rubber seals etc., with all accessories for river sluice / canal sluice vent including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with all leads and lifts. DATA: Consider upstream seal vertical lift roller gate. The gate leaf consists of skin plate, horizontal girders, vertical end girders, stiffeners, wheels, gate guide rollers, brackets for hooks, seals etc., with all accessories. Consider river / canal sluice emergency gate for 2.5 m x 3 m sluice opening for analysis. For vent opening of 2.5 x 3.0 m approximate size of gate leaf will be : 3.2 m x 3.3 m Head of water above sill level considered : 34 m Weight of vertical lift roller gate in tonnes including ballast based on empirical formula : = 0.0888 ( L x H x h ) Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm. = 0.0888 ( 3.2 x 3.2 x 3.3 x 34 ) : 9.229 The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings for river sluice emergency gate of same size provided for one of the dam. Actual wt of river sluice emergency gate as per data in Item :17 of Annexure-2 : 9.215 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of river sluice gate provided for one of the dam for rate analysis ( for details refer Item:17 of Annexure-2 ).
0.659 2 0.659

1. Requirement of materials : a. Structural steel conforming to IS : 2062 : Plates / flats with 2.5 % wastage ( 4301 x 1.025 ) b. Cast iron components conforming to IS : 210 : Cast iron blocks for counter weight ( 4000 x 1.025 ) c. Alloy steel components conforming to IS : 1570 : Wheel axles / Pins d. Cast steel components conforming to IS : 1030 : Wheels / guide rollers e. Alluminium / Bronze alloy components conforming to IS : 305 : Bearings / Bushes f. Bolts / Nuts / Washers conforming to IS : 1363 : SS bolts / nuts / washers with 2.5 % wastage ( 54 x 1.025 )

: 4409 kg : 4100 kg : 144 kg : 492 kg : 76 kg : 55 kg

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GATE / HOIST AND ALLIED WORKS

GI bolts / nuts / washers with 2.5 % wastage ( 144 x 1.025 ) MS bolts / nuts / washers with 2.5 % wastage ( 4 x 1.025 ) g. Rubber seal conforming to IS : 11855 : Bottom seal ( flat uncladed ) ( 2.76 x 1.025 ) Top seal ( bulb type teflon claded ) ( 2.2 x 1.025 ) Side seals ( bulb type teflon claded ) ( 5.71 x 1.025 ) Corner seal ( bulb teflon claded ) h. Welding electrodes ( General purpose / Low hydrogen ) : GP / LH electrodes as per data sheet ( Item:17 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 3017 x 0.1 ) Total requirement of GP / LH electrodes for stitch weld GP electrodes @t 10 % of total ( 3319 x 0.10 ) for run welding LH electrodes @ 90 % of total ( 3319 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 %

: 148 kg : 4 kg : : : : : : : : : 2.8 Rm 2.25 Rm 5.85 Rm 2 Nos 3017 Nos 302 Nos 3319 Nos 332 Nos 2987 Nos

: 134 Rm : 13 Rm Total : 147 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 : 29 m Length of steel to be cut by gas using pug cutting machine : 118 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 : 39 hours Acetelyne gas @ 0.6 cum / hour ( 15 + 39 ) x 0.60 : 32 cum Oxygen gas @ 1.8 cum / hour ( 15 + 39 ) x 1.80 : 96 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 ( 39 x 60 / 50 ) : 47 hours 3. Welding : Length of welding as per data sheet : 271 Rm For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 332 / 15 ) x 8 / 2 : 89 hours For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 2987 / 15 ) x 8 / 6 : 265 hours Total : 354 hours Deploy welding transformer for 354 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 89 x 0.25 + 265 x 0.75 ) : 221 hours

4. Surface cleaning and painting : Painting area for river sluice gate at 10 sqm / tonne ( 9.215 x 10 ) : 92 sqm 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 92 sqm @ 9 sqm / ltr / coat : 10 ltr 3 coats of coal tar epoxy paint 100 micron dry film each coat. Quantity of coal tar epoxy paint for 92 sqm @ 6 sqm / ltr / coat : 46 ltr As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting. Quantity of rust cleaner / inhibitor for 92 sqm @ 8 sqm / ltr : 12 ltr 5. Requirement of other machinery : For lowering gate leaf from hoist chamber use of tower crane for 1 hour considered. For handling of gate parts during fabrication and erection 8 t mobile crane for 4 hours and stationery derric crane for 10 hours considered.

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GATE / HOIST AND ALLIED WORKS

For drilling holes in skin plate, counter weight blocks, horizontal girders and seal clamps use of drilling machine for 8 hours considered. For grinding and finishing weld joints in skin plate and other locations 8 hours use of grinding machine considered. 6. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections 65 hours 4 8 8 16 Drilling holes for seal fixing 1 2 --2 Fabricating by stitch welding 89 hours 6 11 --22 Run welding 265 hours 3 --33 33 Fixing counter weight blocks 1 1 --2 Seal fixing 1 1 --2 Cleaning surface 92 sqm @ 15 sqm/day ------6 Painting ( 4 x 92 ) sqm @ 15 sqm / day ------30 Guide roller fixing / Cleaning / Lowering 1 2 --2 Total : 17 25 41 115 Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding. b. Workforce for painting 1 coat primer and 3 coats finishing paint consists of 25 Painters Cl-II at 15 sqm / day and 5 helpers to assist painters. 7. Excise duty on supply : Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost of materials ( assuming 25 % erection cost ) is considered for assessing excise duty. 8. Use rate of materials : Cost of welding set @ Life of welding set Use rate of welding set per hour Cost of gas cutting set @ Life of gas cutting set Use rate of gas cutting set per hr

Rs:

4500.00 / Each ( cost / life ) 1500.00 / Each ( cost / life )

Rs:

Rs: 4500.00 : 1000 hours Rs: 4.50 Rs: 1500.00 : 600 hours Rs: 2.50

RATE ANALYSIS A. MATERIALS: Sl No 1 2 3 4 5 6 Perticulars Unit Quantity

UNIT :

9.215 tonne Rate in Rs. 40.00 32.00 215.00 125.00 635.00 Amount in Rs. 176360.00 131200.00 30960.00 61500.00 48260.00

Structural steel Plates / flats Cast iron components CI blocks for counter wt Alloy steel components Wheel axles / Pins Cast steel components Wheels / Guide rollers Alluminium / Bronze alloy components Bearings / Bushes Bolt / Nut / Washer

kg kg kg kg kg

4409.00 4100.00 144.00 492.00 76.00

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GATE / HOIST AND ALLIED WORKS

8 9 10 11 12 13 14 15 16 17 18

SS bolts / nuts / washers GI bolts / nuts / washers MS bolts / nuts / washers Rubber seals Bottom seal ( flat uncladed ) Side seals ( bulb teflon claded ) Top seal ( bulb teflon claded ) Corner seals ( bulb teflon claded ) Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen ) Zinc rich epoxy primer Coal tar epoxy paint Rust cleaner / inhibitor Use rate welding holder set Use rate gas cutting torch set Wire brush Sundries Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @

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

55.00 148.00 4.00 2.80 5.85 2.25 2.00 96.00 32.00 332.00 2987.00 10.00 46.00 12.00 354.00 18.00 1.00 5.00

150.00 95.00 55.00 147.00 675.00 675.00 740.00 48.00 258.00 6.00 12.00 594.00 208.00 240.00 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

8250.00 14060.00 220.00 411.60 3948.75 1518.75 1480.00 4608.00 8256.00 1992.00 35844.00 5940.00 9568.00 2880.00 1593.00 45.00 30.00 150.00 549075.10 5490.75 54907.51 27453.76 636927.12

1% 10% 5% Total cost of Materials :

B. MACHINERY: Sl No 1 2 3

Description

Unit Hour Hour Hour Hour Hour Hour

Quantity 354.00 221.00 47.00 47.00 1.00 1.00

Welding transformer Fuel / Energy charges Pug cutting machine Fuel / Energy charges Tower crane Fuel / Energy charges

Rate in Rs. 12.00 60.00 16.00 3.00 994.00 130.00 Contd

Amount in Rs. 4248.00 13260.00 752.00 141.00 994.00 130.00

B. MACHINERY ( Contd ) : Sl No Description

Unit

Quantity

4 5 6 7 8

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

Hour Hour Hour Hour Hour Hour Hour Hour LS

4.00 4.00 10.00 10.00 8.00 8.00 8.00 8.00 5.00 1% 10%

Add for small Tools and Plants @ Add for Contractor's Profit on DPOL / Energy @

Rate in Rs. Contd 362.00 495.00 66.00 9.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs:

Amount in Rs. 1448.00 1980.00 660.00 90.00 144.00 200.00 144.00 200.00 150.00 24541.00 245.41 1615.10

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GATE / HOIST AND ALLIED WORKS

Add for Contractor's Overheads @

5% Total hire charges of Machinery :

Rs: Rs:

1227.05 27628.56

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

Description

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

Quantity 4.00 1.00 8.00 8.00 17.00 25.00 8.00 29.00 4.00 4.00 79.00 11.00 25.00 2.00

Crew for Mobile crane Crew for Tower crane Crew for Drilling machine Crew for Grinding machine Foreman Marker / Fabricator / Erector Gas cutter Welder ( General ) Welder ( X - ray grade ) 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 62.00 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. 302.80 62.00 476.00 476.00 3009.00 3937.50 1260.00 4567.50 693.00 582.00 11178.50 1556.50 3537.50 286.00 31924.30 319.24 3192.43 4788.65 4788.65 1596.22 46609.48

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

Rs: Rs: Rs: TOTAL Rs:

636927.12 27628.56 46609.48 711165.15

Add for excise duty on 75 percent cost of Machinery / Labour components @ Add for insurance charges @ Add for designs and drawings @ Add for zigs / supports / winches / chain-pulley @ Add for power supply arrangements @ Add for enabling works @

8.24% 1.00% 2.50% 2.50% 2.00% 1.40%

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

4587.91 7111.65 17779.13 17779.13 14223.30 9956.31 782602.59 2379.31 23478.08 808459.98 87700.00 87700.00 ITEM No: 18

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 9.215 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 9.215 tonne Rate per tonne Rate approved per tonne SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

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GATE / HOIST AND ALLIED WORKS

ITEM: Design, fabrication, supply, erection, testing and commissioning of automatic lifting beam with all accessories for handling, lowering and lifting of river sluice / canal sluice emergency gate including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and two coats of cold applied coal tar epoxy paint etc., complete as per specifications and drawings with all leads and lifts. DATA: Automatic lifting beam for lifting river sluice emergency gate consists of fabricated beam with lifting bracket and automatic engaging / dis-engaging type hooks for under water hooking / de-hooking of gate leaf. Lifting beam is an independent attachment to moving gantry crane. Generally the weight of lifting beam for river sluice emergency gate will be about 10 percent of the weight of gate leaf with ballast. Consider river sluice emergency gate for sluice opening of size 2.5 m x 3 m for analysis. For vent opening of 2.5 x 3.0 m approximate size of gate leaf will be : 3.2 m x 3.3 m Head of water above sill level considered : 34 m Weight of vertical lift roller gate in tonnes including weight of ballast as per empirical formula : = 0.0888 ( L x H x h ) Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm. Consider weight of lifting beam @ 10 % of weight of gate including ballast: = 0.10 x 0.0888 ( L x H x h )
2 0.659 0.659 2 0.659

= 0.0089 ( 3.2 x 3.2 x 3.3 x 34 ) : 0.925 tonne The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings of lifting beam for river sluice emergency gate of same size provided for one of the dam. Actual weight of lifting beam as per data in Item : 18 of Annexure-2 : 0.922 tonne Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of lifting beam for river sluice emergency gate provided for one of the dam for rate analysis ( for details refer Item : 18 of Annexure-2 ). 1. Requirement of materials : a. Structural steel : Angles/ beams/ channels/ bars with 2.5 % wastage ( 228x1.025 ) : 234 kg Plates / flats with 2.5 % wastage ( 476 x 1.025 ) : 488 kg

b. Alloy steel components : Pins c. Bronze alloy components : Bush d. Forged steel components : Hooks e. Bolts / Nuts / Washers : MS bolts / nuts / washers with 2.5 % wastage ( 2 x 1.025 ) f. MS pipe 100 mm dia g. Welding electrodes ( General purpose / Low hydrogen ) : GP / LH electrodes as per data sheet ( Item:18 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 508 x 0.1 ) Total requirement of GP / LH electrodes for stitch weld GP electrodes @t 10 % of total ( 559 x 0.10 ) for run welding LH electrodes @ 90 % of total ( 559 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 %

: 71 kg : 4 kg : 130 kg : 2 kg : 11 kg : : : : : 508 Nos 51 Nos 559 Nos 56 Nos 503 Nos

: 43 Rm : 4 Rm

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GATE / HOIST AND ALLIED WORKS

Total : 47 Rm For cutting structural steel sections to required sizes gas cutting is assumed. Length of steel to be cut by using gas manually : 10 m Length of steel to be cut by gas using pug cutting machine : 37 m Time for gas cutting manually at ( av ) 2 m cutting / hour : 5 hours Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 12 hours Acetelyne gas @ 0.6 cum / hour ( 5 + 12 ) x 0.60 : 10 cum Oxygen gas @ 1.8 cum / hour ( 5 + 12 ) x 1.80 : 30 cum Use of gas cutting torch with 50 min / hr working ( 5 x 60 / 50 ) : 6 hours Use of pug cutting machine with 50 min / hr working ( 12 x 60 / 50 ) : 15 hours 3. Welding : Length of welding as per data sheet : 49 Rm For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 56 / 15 ) x 8 / 2 : 15 hours For run welding @ 6 hrs usage / shift & @ 12 electrodes / hr ( 503 / 15 ) x 8 / 6 : 45 hours Total : 60 hours Deploy welding transformer for 60 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 15 x 0.25 + 45 x 0.75 ) : 38 hours 4. Surface cleaning and painting : Painting area for lifting beam at 12 sqm / tonne ( 0.922 x 12 ) : 11 sqm 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 11 sqm @ 9 sqm / ltr / coat : 1.25 ltr 2 coats of coal tar epoxy paint 100 micron dry film each coat. Quantity of coal tar epoxy paint for 11 sqm @ 6 sqm / ltr / coat : 4 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 11 sqm @ 8 sqm / ltr : 1.5 ltr 5. Requirement of other machinery : For drilling holes for pins / guide shoes 2 hours use of drilling machine considered.

For grinding and finishing weld joints 2 hour use of grinding machine considered. 6. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections 21 hours 1 3 3 6 Drilling holes for pins / bolts fixing --1 --1 Fabricating by stitch welding 15 hours 1 2 --4 Run welding 45 hours 1 --6 6 Cleaning surface 11 sqm @ 15 sqm/day ------1 Painting ( 3 x 11 ) sqm @ 15 sqm / day ------3 Finishing / guide shoe fixing / checking --1 --1 Total : 3 7 9 22 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 2 coats finishing paint consists of 2 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

88

GATE / HOIST AND ALLIED WORKS

taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost of materials ( assuming 25 % erection cost ) is considered for assessing excise duty. 8. Use rate of materials : Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00 Life of welding set : 1000 hours Use rate of welding set per hour ( cost / life ) Rs: 4.50 Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00 Life of gas cutting set : 600 hours Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50 RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars Unit Quantity UNIT : 0.922 tonne Rate in Rs. 37.95 40.00 215.00 635.00 165.00 45.00 55.00 48.00 258.00 6.00 12.00 Contd Amount in Rs. 8880.30 19520.00 15265.00 2540.00 21450.00 495.00 110.00 1440.00 2580.00 336.00 6036.00

2 3 4 5 6 7 8 9 10

Structural steel Angles / beams / channels / bars Plates / flats Alloy steel components Lifting pins Bronze alloy components : Bronze bush Forged steel components : Lifting hooks MS pipe 100 mm dia Bolt / Nut / Washer MS bolts / nuts / washers Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen )

kg kg kg kg kg kg kg cum cum Nos Nos

234.00 488.00 71.00 4.00 130.00 11.00 2.00 30.00 10.00 56.00 503.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

11 12 13 14 15 16 17

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 @

ltr ltr ltr Hour Hour Nos LS

1.25 4.00 1.50 60.00 6.00 1.00 5.00

1% 10% 5% Total cost of Materials :

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

Amount in Rs. 742.50 832.00 360.00 270.00 15.00 30.00 150.00 81051.80 810.52 8105.18 4052.59 94020.09

B. MACHINERY: Sl No

Description

Unit

Quantity

Rate in Rs.

Amount in Rs.

89

GATE / HOIST AND ALLIED WORKS

1 2 3 4 5

Welding transformer Fuel / Energy charges Pug cutting machine Fuel / Energy charges Grinding machine Fuel / Energy charges Drilling machines Fuel / Energy charges Sundries

Hour Hour Hour Hour Hour Hour Hour Hour LS

60.00 38.00 15.00 15.00 2.00 2.00 2.00 2.00 3.00

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

12.00 60.00 16.00 3.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

720.00 2280.00 240.00 45.00 36.00 50.00 36.00 50.00 90.00 3547.00 35.47 251.50 177.35 4011.32

Description

Unit Hour Hour Day Day Day Day Day Day Day Day

Quantity 2.00 2.00 3.00 7.00 3.00 6.00 18.00 2.00 2.00 1.00

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

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

Amount in Rs. 119.00 119.00 531.00 1102.50 472.50 945.00 2547.00 283.00 283.00 143.00 6545.00

C. LABOUR ( Contd ) : Sl No Description

Unit

Quantity

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

Amount in Rs. 65.45 654.50 981.75 981.75 327.25 9555.70

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:

94020.09 4011.32 9555.70 107587.11 838.44 1075.87 2689.68 2689.68

90

GATE / HOIST AND ALLIED WORKS

Add for power supply arrangements @ Add for enabling works @

2.00% 1.40%

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

2151.74 1506.22 118538.74 238.06 3556.16 122332.96 132700.00 132700.00 ITEM No: 19

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 0.922 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 0.922 tonne Rate per tonne Rate approved per tonne SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sill beam, wheel tracks, seal seats / tracks, guide rails, etc., with all accessories for vertical lift barrage gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint, etc., complete as per specifications and aproved drawings with all leads and lifts. DATA: Barrage gate embedded parts consist of sill beam, wheel tracks / seal tracks and gate guides with accessories such as first / second stage anchors. Weight of embedded parts for barrage gate will be about 15 to 20 percent of gate weight. Consider embedded parts for vertical lift gate for barrage opening of size 13.7 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 Weight of vertical lift barrage gate in tonnes based on empirical formula : = 0.0335 ( L x H x h ) Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm.
2 0.716

Consider weight of embedded parts @ 17.5 % of weight of gate leaf : = 0.175 x 0.0335 ( L x H x h )
2 0.716 0.716

1. a.

b. c. d.

= 0.0058 ( 14.7 x 14.7 x 8.6 x 8.26 ) : 5.763 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 vertical lift barrage gate of same size provided for one of the barrage. Actual weight of embedded parts as per data in Item :19 of Annexure-2 : 5.193 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of embedded parts for vertical lift barrage gate provided for one of the barrage for rate analysis ( for details refer Item : 19 of Annexure-2 ). Requirement of materials : Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5 % wastage ( 588x1.025 ) : 603 kg Plates / flats with 2.5 % wastage ( 3685 x 1.025 ) : 3777 kg Alloy steel components conforming to IS : 1570 : Stainless steel plates / flats ( 620 + 133 ) x 1.025 : 772.00 kg Bolt / Nut / Washer conforming ti IS : 1363 : MS bolts and nuts with 2.5 % wastage ( 167 x 1.025 ) : 171 kg Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) : GP / LH electrodes as per data sheet ( Item:19 Annexure-2 ) : 1734 Nos

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GATE / HOIST AND ALLIED WORKS

Add for variations / wastage / misc welding @ 10 % ( 1734 x 0.1 ) : 173 Nos Total requirement of GP / LH electrodes : 1907 Nos for stitch welding GP electrodes @t 10 % of total ( 1907 x 0.10 ) : 191 Nos for run welding LH electrodes @ 90 % of total ( 1907 x 0.90 ) : 1716 Nos Stainless steel electrodes as per data sheet ( Item:19 Annexure-2 ) : 1282 Nos Add for variations / wastage @ 5 % ( 1282 x 0.05 ) : 64 Nos Total requirement of Stainless steel ( SS ) electrodes : 1346 Nos for stitch weld SS electrodes @t 10 % of total ( 1346 x 0.10 ) : 135 Nos for run weld SS electrodes @t 90 % of total ( 1346 x 0.90 ) : 1211 Nos 2. Cutting : Length of cutting assuming cutting for 2 sides as per data sheet : 210 Rm Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 21 Rm Total length of cutting Total : 231 Rm For cutting structural steel sections to required size gas cutting and use of plate shearing machine is considered. Length of steel to be cut by using gas manually : 50 m Length of steel to be cut by gas using pug cutting machine : 151 m Length of steel to be cut by using shearing machine : 30 m Time for gas cutting manually at ( av ) 2 m cutting / hour : 25 hours Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 50 hours Time for cutting by shearing machine at ( av ) 10 m cutting / hour : 3 hours Acetelyne gas @ 0.6 cum / hour ( 25 + 50 ) x 0.60 : 45 cum Oxygen gas @ 1.8 cum / hour ( 25 + 50 ) x 1.80 : 135 cum Use of gas cutting torch with 50 min / hr working ( 25 x 60 / 50 ) : 30 hours Use of pug cutting machine with 50 min / hr working ( 50 x 60 / 50 ) : 60 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 : 252 m

For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 191 + 135 ) x 8 / 15 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 1716 + 1211 ) x 8 / 15 / 6 Total

: 87 hours : 260 hours : 347 hours

Deploy welding transformer for 347 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 87 x 0.25 + 260 x 0.75 ) : 217 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 : 63.00 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 63 m SS plates ( 63 x 8 / 3 ) : 168 hours 5. Surface cleaning and painting : Painting area for embedded parts at 10 sqm / tonne ( 5.193 x 10 ) : 52 sqm 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 52 sqm @ 9 sqm / ltr / coat : 6 ltr 4 coats of coal tar epoxy paint 100 micron dry film each coat. Quantity of coal tar epoxy paint for 52 sqm @ 6 sqm / ltr / coat : 35 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

92

GATE / HOIST AND ALLIED WORKS

6.

7.

Note :

8.

before applying primer painting. Quantity of rust cleaner / inhibitor for 52 sqm @ 8 sqm / ltr : 6.5 ltr Requirement of other machinery : For drilling holes for anchor bolts use of drilling machine for 24 hours considered. For grinding weld joints and edges requiring finishing use of grinding machine for 16 hours considered. For handling during fabrication and erection 25 t mobile crane for 24 hours with energy charges for 12 hours and stationery derric crane for 75 hours considered. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Painter Cl-II Fabricator / Welder Erector / Cutting sections 94 hours 6 12 12 24 Drilling holes for anchors / supports 3 6 --12 Fabricating by stitch welding 87 hours 6 11 --22 Run welding 260 hours 4 --32 32 Erection of first stage anchors 10 20 --40 Erection of Sill beam / Tracks / Guide 10 10 --20 Cleaning surface 52 sqm @ 15 sqm/day ------3 Painting ( 5 x 52 ) sqm @ 15 sqm / day ------20 Finishing / cleaning 1 4 --4 Total : 40 63 44 177 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 17 Painters Cl-II at 15 sqm / day and 3 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. 9. Use rate of materials : Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00 Life of welding set : 1000 hours Use rate of welding set per hour ( cost / life ) Rs: 4.50 Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00 Life of gas cutting set : 600 hours Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50 RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars Unit Quantity UNIT : 5.193 tonne Rate in Rs. 37.95 40.00 120.00 55.00 48.00 258.00 6.00 12.00 Amount in Rs. 22883.85 151080.00 92640.00 9405.00 6480.00 11610.00 1146.00 20592.00

2 3 4 5 6 7

Structural steel Angles / beams / channels / bars Plates / flats Stainless steel plate / flats MS bolts and nuts Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen )

kg kg kg kg cum cum Nos Nos

603.00 3777.00 772.00 171.00 135.00 45.00 191.00 1716.00

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GATE / HOIST AND ALLIED WORKS

8 9 10 11 12 13 14 15

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 @

Nos ltr ltr ltr Hour Hour Nos LS

1346.00 6.00 35.00 6.50 347.00 30.00 4.00 70.00

1% 10% 5% Total cost of Materials :

43.00 594.00 208.00 240.00 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

57878.00 3564.00 7280.00 1560.00 1561.50 75.00 120.00 2100.00 389975.35 3899.75 38997.54 19498.77 452371.41

B. MACHINERY: Sl No 1 2 3 4

Description

Unit Hour Hour Hour Hour Hour Hour Hour Hour

Quantity 347.00 217.00 4.00 4.00 60.00 60.00 168.00 168.00

Welding transformer Fuel / Energy charges Plate shearing machine Fuel / Energy charges Pug cutting machine Fuel / Energy charges Planing machine Fuel / Energy charges

Rate in Rs. 12.00 60.00 62.00 100.00 16.00 3.00 88.00 75.00 Contd

Amount in Rs. 4164.00 13020.00 248.00 400.00 960.00 180.00 14784.00 12600.00

B. MACHINERY ( Contd ) : Sl No Description

Unit

Quantity

5 6 7 8 9

Mobile crane 25 t Fuel / Energy charges Stationery derric crane Fuel / Energy charges Grinding machine Fuel / Energy charges Drilling machines Fuel / Energy charges Sundries

Hour Hour Hour Hour Hour Hour Hour Hour LS

24.00 12.00 75.00 75.00 24.00 24.00 24.00 24.00 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 : C. LABOUR: Sl No 1 2

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

Amount in Rs. 91296.00 16500.00 4950.00 675.00 432.00 600.00 432.00 600.00 2100.00 163941.00 1639.41 4667.50 8197.05 178444.96

Description

Unit Hour Hour

Quantity 24.00 4.00

Crew for Mobile crane 25 t Crew for Plate shearing machine

Rate in Rs. 75.70 45.90

Amount in Rs. 1816.80 183.60

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GATE / HOIST AND ALLIED WORKS

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

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 @

Hour Hour Hour Day Day Day Day Day Day Day Day Day

168.00 24.00 24.00 40.00 63.00 12.00 29.00 3.00 154.00 6.00 17.00 2.00

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

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:

12331.20 1428.00 1428.00 7080.00 9922.50 1890.00 4567.50 519.75 21791.00 849.00 2405.50 286.00 66498.85 664.99 6649.89 9974.83 9974.83 3324.94 97088.32

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

Rs: Rs: Rs: TOTAL Rs:

452371.41 178444.96 97088.32 727904.69

Add for excise duty on 75 percent cost of Machinery / Labour components @ Add for insurance charges @ Add for designs and drawings @ Add for zigs / supports / winches / chain-pulley @ Add for power supply arrangements @ Add for enabling works @

8.24% 1.00% 2.50% 2.50% 2.00% 1.40%

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

17027.96 7279.05 18197.62 18197.62 14558.09 10190.67 813355.68 1340.83 24400.67 839097.19 161600.00 161600.00 ITEM No: 20

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 5.193 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 5.193 tonne Rate per tonne Rate approved per tonne SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type vertical lift gate consisting of skin plate, vertical and horizontal girders, wheels, stiffeners, lifting brackets, guide shoes, rubber seals etc., with all accessories for barrage including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with all leads and lifts. DATA: Consider upstream seal vertical lift roller gate. The gate leaf consists of skin plate, horizontal

95

GATE / HOIST AND ALLIED WORKS

girders, vertical end girders, stiffeners, wheels, gate guide shoes, brackets for pulleys, seals etc., with all accessories. 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 : = 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 The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings of vertical lift barrage gate of same size provided for one of the barrage. Actual weight of vertical lift barrage gate as per data in Item : 20 of Annexure-2 : 33.025 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of vertical lift gate provided for one of the barrage for rate analysis ( for details refer Item : 20 of Annexure-2 ). Requirement of materials : Structural steel conforming to IS : 2062 : Angles/ beams/ channels with 2.5 % wastage ( 3299x1.025 ) : 3382 kg Plates / flats with 2.5 % wastage ( 28655 x 1.025 ) : 29372 kg Alloy steel components conforming to IS : 1570 : Wheel axles / Pins : 176 kg Cast steel components conforming to IS : 1030 : Wheels : 656 kg

1. a.

b. c.

d. Alluminium / Bronze alloy components conforming to IS : 305 : Bearings / Bushes e. Bolts / Nuts / Washers conforming to IS : 1363 : GI bolts / nuts / washers with 2.5 % wastage ( 91 x 1.025 ) MS bolts / nuts / washers with 2.5 % wastage ( 68 x 1.025 ) f. Rubber seal conforming to IS : 11855 : Bottom seal ( flat uncladed ) ( 14 x 1.025 ) Side seals ( bulb uncladed ) ( 17.2 x 1.025 ) g. Welding electrodes ( General purpose / Low hydrogen ) : GP / LH electrodes as per data sheet ( Item:20 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 18400 x 0.1 ) Total requirement of GP / LH electrodes for stitch weld GP electrodes @t 10 % of total ( 20240 x 0.10 ) for run welding LH electrodes @ 90 % of total ( 20240 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 %

: 80 kg : 93 kg : 70 kg : 14.5 Rm : 18 Rm : : : : : 18400 Nos 1840 Nos 20240 Nos 2024 Nos 18216 Nos

: 695 Rm : 70 Rm Total : 765 Rm For cutting structural steel sections to required sizes gas cutting and plate shearing machine for plates less than 12 mm thick are considered. Length of steel to be cut by using gas manually : 200 m Length of steel to be cut by gas using pug cutting machine : 465 m Length of steel to be cut by gas using plate shearing machine : 100 m Time for gas cutting manually at ( av ) 2 m cutting / hour : 100 hours Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 155 hours

96

GATE / HOIST AND ALLIED WORKS

Time for cutting by shearing machine at ( av ) 10 m cutting / hour Acetelyne gas @ 0.6 cum / hour ( 100 + 155 ) x 0.60 Oxygen gas @ 1.8 cum / hour ( 100 + 155 ) x 1.80 Use of gas cutting torch with 50 min / hr working ( 100 x 60 / 50 ) Use of pug cutting machine with 50 min/hr working ( 155 x 60 / 50 ) Use of plate shearing machine with 50 min/hr work ( 10 x 60 / 50 ) 3. Welding : Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 2024 / 15 ) x 8 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 18216 / 15 ) x 8 / 6 Total

: : : : : :

10 hours 153 cum 459 cum 120 hours 186 hours 12 hours

: 1837 Rm : 540 hours : 1620 hours : 2160 hours

Deploy welding transformer for 2160 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 540 x 0.25 + 1620 x 0.75 ) : 1350 hours 4. Surface cleaning and painting : Painting area for barrage gate at 18 sqm / tonne ( 33.025 x 18 ) : 595 sqm 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 595 sqm @ 9 sqm / ltr / coat : 66 ltr 3 coats of coal tar epoxy paint 100 micron dry film each coat. Quantity of coal tar epoxy paint for 595 sqm @ 6 sqm / ltr / coat : 298 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 595 sqm @ 8 sqm / ltr : 75 ltr 5. Requirement of other machinery : For handling of gate parts during fabrication and erection 25 t mobile crane for 20 hours with energy charges for 10 hours and 8 t mobile crane for 40 hours and stationery derric crane for 150 hours considered. For drilling holes in skin plate and seal base / clamps use of drilling machine for 50 hours considered. For grinding and finishing weld joints in skin plate and other locations 50 hours use of grinding machine considered. 6. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections 318 hours 20 40 40 80 Drilling holes for seal fixing 3 6 --6 Fabricating by stitch welding 540 hours 34 68 --136 Run welding 1620 hours 20 --203 203 Joining units & wheel fixing 4 8 --32 Seal fixing & guide shoe fixing 1 2 --4 Cleaning surface 595 sqm @ 15 sqm/day ------40 Painting ( 4 x 595 ) sqm @ 15 sqm / day ------188 Aligning and lowering in position 2 4 --16 Cleaning / checking 1 2 --2 Total : 85 130 243 707 Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision considered for welder for stitch welding.

97

GATE / HOIST AND ALLIED WORKS

b. Workforce for painting 1 coat primer and 3 coats finishing paint consists of 158 Painters Cl-II at 15 sqm / day and 30 helpers to assist painters. 7. Excise duty on supply : Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost of materials ( assuming 25 % erection cost ) is considered for assessing excise duty. 8. Use rate of materials : Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00 Life of welding set : 1000 hours Use rate of welding set per hour ( cost / life ) Rs: 4.50 Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00 Life of gas cutting set : 600 hours Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50 RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars Unit Quantity UNIT : 33.025 tonne Rate in Rs. 37.95 40.00 215.00 Contd Amount in Rs. 128346.90 1174880.00 37840.00

Structural steel Angles / beams / channels / bars Plates / flats Alloy steel components Wheel axles / Pins

kg kg kg

3382.00 29372.00 176.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

Rate in Rs. Contd 125.00 635.00 95.00 55.00 147.00 235.00 48.00 258.00 6.00 12.00 594.00 208.00 240.00 4.50 2.50 30.00 30.00 Total Rs: Rs:

Amount in Rs.

3 4 5

7 8 9 10 11 12 13 14 15 16 17

Cast steel components Wheels Alluminium / Bronze alloy components Bearings / Bushes Bolt / Nut / Washer GI bolts / nuts / washers MS bolts / nuts / washers Rubber seals Bottom seal ( flat uncladed ) Side seals ( bulb uncladed ) Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen ) Zinc rich epoxy primer Coal tar epoxy paint Rust cleaner / inhibitor Use rate welding holder set Use rate gas cutting torch set Wire brush Sundries Add for small Tools and Plants @

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

656.00 80.00 93.00 70.00 14.50 18.00 459.00 153.00 2024.00 18216.00 66.00 298.00 75.00 2160.00 120.00 10.00 100.00 1%

82000.00 50800.00 8835.00 3850.00 2131.50 4230.00 22032.00 39474.00 12144.00 218592.00 39204.00 61984.00 18000.00 9720.00 300.00 300.00 3000.00 1917663.40 19176.63

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GATE / HOIST AND ALLIED WORKS

Add for Contractor's Profit @ Add for Contractor's Overheads @

10% 5% Total cost of Materials :

Rs: Rs: Rs:

191766.34 95883.17 2224489.54

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

Description

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

Quantity 2160.00 1350.00 186.00 186.00 12.00 12.00 20.00 10.00 40.00 40.00 150.00 150.00 100.00 100.00

Welding transformer Fuel / Energy charges Pug cutting machine Fuel / Energy charges Plate shearing machine Fuel / Energy charges Mobile crane 25 t Fuel / Energy charges Mobile crane 8 t Fuel / Energy charges Stationery derric crane Fuel / Energy charges Grinding machine Fuel / Energy charges

Rate in Rs. 12.00 60.00 16.00 3.00 62.00 100.00 3804.00 1375.00 362.00 495.00 66.00 9.00 18.00 25.00 Contd

Amount in Rs. 25920.00 81000.00 2976.00 558.00 744.00 1200.00 76080.00 13750.00 14480.00 19800.00 9900.00 1350.00 1800.00 2500.00

B. MACHINERY ( Contd ) : Sl No Description

Unit

Quantity

8 9

Drilling machines Fuel / Energy charges Sundries

Hour Hour LS

50.00 50.00 75.00

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

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

Amount in Rs. 900.00 1250.00 2250.00 256458.00 2564.58 12365.80 12822.90 284211.28

Description

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

Quantity 20.00 40.00 12.00 50.00 100.00 85.00 130.00 40.00 183.00 20.00 100.00 479.00

Crew for Mobile crane 25 t Crew for Mobile crane 8 t Crew for Plate shearing machine Crew for Drilling machine Crew for Grinding machine Foreman Marker / Fabricator / Erector Gas cutter Welder ( General ) Welder ( X - ray grade ) Khalasi Helper fabrication / erection

Rate in Rs. 72.60 75.70 45.90 59.50 59.50 177.00 157.50 157.50 157.50 173.25 145.50 141.50

Amount in Rs. 1452.00 3028.00 550.80 2975.00 5950.00 15045.00 20475.00 6300.00 28822.50 3465.00 14550.00 67778.50

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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