data rates gate works 3

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GATE / HOIST AND ALLIED WORKS

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


3 Mobile crane 25 t Hour 16.00 3804.00 60864.00




5 Grinding machine Hour 64.00 18.00 1152.00


6 Drilling machines Hour 16.00 18.00 288.00


7 Sundries LS 150.00 30.00 4500.00

Total Rs: 215257.00


Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 11126.50


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 hidden cost on Labour @ 15% Rs: 28325.87

Add for additional hidden cost on labour @ 15% Rs: 28325.87


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








Total Rs: 4085185.20


Fabricated parts 2x30.856 tonnes @ Rs: 129.10 / tonne Rs: 7967.02


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


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 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 ).



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


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


3. Welding :

Length of welding as per data sheet : 210 m


( 188 / 15 ) x 8 / 2 : 50 hours


( 1693 / 15 ) x 8 / 6 : 150 hours

Total : 200 hours



( 50 x 0.25 + 150 x 0.75 ) : 125 hours


For painting buffers and supporting plates 0.5 ltr zinc rich epoxy primer and 1 ltr coal tar epoxy

paint considered.


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.



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


Cleaning surface 3 sqm @ 15 sqm/day --- --- --- ---


Finishing / checking / cleaning 1 1 --- 1

Total : 8 32 36 54



b. 1 Painter Cl- II considered or cleaning and painting.












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



7 Zinc rich epoxy primer ltr 0.50 594.00 297.00

8 Coal tar epoxy paint ltr 1.00 208.00 208.00



11 Sundries LS 10.00 30.00 300.00

Total Rs: 927269.00Add for small Tools and Plants @ 1% Rs: 9272.69




B. MACHINERY:

Sl No Unit Amount

in Rs.

Erector /

Description

Perticulars Rate

Quantity

Quantity

in Rs.

in Rs.

Rate

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5 Sundries LS 10.00 30.00 300.00

Total Rs: 13290.00





C. LABOUR:

Sl No Unit Amount

in Rs.

1 Crew for Mobile crane Hour 2.00 75.70 151.40



4 Foreman Day 8.00 177.00 1416.00


6 Gas cutter Day 17.00 157.50 2677.50



9 Painter Cl- II Day 1.00 141.50 141.50

10 Electrician Day 1.00 143.00 143.00

Total Rs: 21965.40







ABSTRACT:




TOTAL Rs: 1122747.92

Add for excise duty on 75 percent cost ofMachinery / Labour components @ 8.24% Rs: 2911.76






Total Rs: 1231197.99


Description

in Rs.

Quantity Rate

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Total cost for 200.000 Rm Rs: 1273484.35

Rate per Rm Rs: 6400.00

Rate approved per Rm Rs: 6400.00


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 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


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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for stitch welding GP electrodes @t 10 % of total ( 1495 x 0.10 ) : 150 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


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 cutting by shearing machine at ( av ) 10 m cutting / hour : 3 hours


Oxygen gas @ 1.8 cum / hour ( 15 + 36 ) x 1.80 : 93 cum


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


( 150 + 44 ) x 8 / 15 / 2 : 52 hours


( 1345 + 394 ) x 8 / 15 / 6 : 154 hours

Total : 206 hours



( 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


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




Quantity of rust cleaner / inhibitor @ 8 sqm / ltr : 4 ltr


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



Painter Cl-II


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

Fbricating by stitch welding 52 hours 3 6 --- 12


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


Finishing / checking / cleaning 1 1 --- 2

Total : 18 30 27 88

















A. MATERIALS:

Sl No Unit Amount

in Rs.

1 Structural steel


Plates / flats kg 2162.00 40.00 86480.00

Erector /

Marker /

Perticulars

Fabricator /

in Rs.

Welder

Gas cutter /

RateQuantity

51


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2 Stainless steel plate / flats kg 424.00 120.00 50880.00


4 Oxygen gas cum 93.00 48.00 4464.00




8 Welding electrodes ( stainless steel ) Nos 438.00 43.00 18834.00





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





B. MACHINERY:

Sl No Unit Amount

in Rs.



2 Plate shearing machine Hour 4.00 62.00 248.00




4 Planing machine Hour 80.00 88.00 7040.00




6 Stationery derric crane Hour 8.00 66.00 528.00




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





Description

Perticulars Quantity

in Rs.

Rate

Quantity Rate

in Rs.

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C. LABOUR:

Sl No Unit Amount

in Rs.


2 Crew for Shearing machine Hour 4.00 45.90 183.60

3 Crew for Planing machine Hour 80.00 73.40 5872.00



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


10 Welder ( X - ray ) Day 2.00 173.25 346.50


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







ABSTRACT:




TOTAL Rs: 337270.81







Add for enabling works @ 1.40% Rs: 4721.79Total Rs: 373936.46


Fabricated parts 2 x 3.172 tonnes @ Rs: 129.10 / tonne Rs: 819.01


Total cost for 3.172 tonne Rs: 385973.57

Rate per tonne Rs: 121700.00


Description

Description Quantity Rate

in Rs.

Quantity Rate

in Rs.

53


15/21



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 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 ).



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 ) :



54


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17/21



Quantity of rust cleaner / inhibitor for 107 sqm @ 8 sqm / ltr : 14 ltr


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.



Painter Cl-II


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


Finishing / cleaning 1 2 --- 4

Total : 42 70 82 239

















A. MATERIALS:

Sl No Unit Amountin Rs.

1 Structural steel


Plates / flats kg 9195.00 40.00 367800.00

2 Stainless steel plate / flats kg 846.00 120.00 101520.00


4 Oxygen gas cum 180.00 48.00 8640.00


Perticulars

Fabricator /

Marker /

Quantity

Gas cutter /

Ratein Rs.

Welder

Erector /

56


18/21




8 Welding electrodes ( stainless steel ) Nos 480.00 43.00 20640.00




Contd


Sl No Unit Amount

in Rs.

Contd



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




B. MACHINERY:

Sl No Unit Amount

in Rs.



2 Plate shearing machine Hour 7.00 62.00 434.00




4 Planing machine Hour 80.00 88.00 7040.00




6 Stationery derric crane Hour 40.00 66.00 2640.00






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



C. LABOUR:

Sl No Unit Amount

in Rs.


Description

Description Quantity

in Rs.

Rate

Quantity

in Rs.

Rate

Perticulars Quantity Rate

in Rs.

57


19/21


2 Crew for Shearing machine Hour 7.00 45.90 321.30

3 Crew for Planing machine Hour 80.00 73.40 5872.00



6 Foreman Day 42.00 177.00 7434.00

Contd

C. LABOUR ( Contd ) :

Sl No Unit Amount

in Rs.

Contd


8 Gas cutter Day 16.00 157.50 2520.00


10 Welder ( X - ray ) Day 7.00 173.25 1212.75


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







ABSTRACT:




TOTAL Rs: 942481.80








Total Rs: 1042683.11




Total cost for 10.657 tonne Rs: 1076715.24Rate per tonne Rs: 101000.00



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

58


20/21


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 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 ).




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




for stitch weld GP electrodes @ 10 % of total ( 4613 x 0.10 ) : 461 Nos


2. Cutting :

Length of cutting assuming cutting for 2 sides : 203 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




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


( 461 / 15 ) x 8 / 2 : 123 hours


( 4152 / 15 ) x 8 / 6 : 369 hours

59


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Total : 492 hours



( 123 x 0.25 + 369 x 0.75 ) : 308 hours


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




Quantity of rust cleaner / inhibitor for 37.5 sqm @ 8 sqm / ltr : 5 ltr


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.



Painter Cl-II


Fabricating by stitch welding 123 hours 8 15 --- 30


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














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

data rates gate works 3

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