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GATE / HOIST AND ALLIED WORKS

= 0.0335 ( L2 x H x h )

0.716

Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm.

= 0.0335 x( 14.7 x 14.7 x 8.6 x 8.26 )0.716

: 33.289

Consider hoist capacity including 25 % reserve @ 1.5 times the weight of gate :

( 1.5 x 33.289 ) : 49.9335

Round off the hoist capacity to next 10 tonne : 50 tonnes

Consider 15 m span and 10 m over all height ( 9 m columns and 1 m beams ) for bridge. Assessment of weight of structural steel for bridge:

Columns with bracings, anchors, stiffeners etc @ 400 kg / m for 9 m ht : 3600.00 kg

Beams with cross beams, stiffeners etc @ 400 kg / m for 15 m span : 6000.00 kg

Total : 9600.00 kg

Other accessories such as railing, chequered plate, ladder etc @ 10 % : 960.00 kg

Total : 10560.00 kg

The weight computed as above based on empirical formula is further checked by computing the

actual weight as per fabrication drawings of hoist bridge structure for vertical lift barrage gate of

same size provided for one of the barrage.

Actual weight of hoist supporting bridge as per data in Item : 21 of Annexure-2 : 10239.00 kg

Consider actual weight for data rate analysis.

Consider details of Material / Gas cutting / Welding based on fabrication drawings of hoist

bridge structure for vertical lift barrage gate provided for one of the barrage for rate analysis

( for details refer Item : 21 of Annexure-2 ).

1. Requirement of materials:

a. Structural steel conforming to IS : 2062 :

Angles / beams / channels with 2.5 % wastage ( 4453 x 1.025 ) : 4564 kg

Plates / flats with 2.5 % wastage ( 5431 x 1.025 ) : 5567 kg

Chequered plate with 2.5 % wastage ( 133 x 1.025 ) : 136 kg

b. MS pipes 32 mm dia ( 30.86 x 1.025 ) : 32 Rm

MS pipes 25 mm dia ( 61.72 x 1.025 ) : 64 Rm

c. Bolt / Nut / Washer MS bolt / Nut / Washers with 2.5 % wastage ( 18 x 1.025 ) : 18.5 kg

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

GP / LH electrodes as per data sheet ( Item:21 Annexure-2 ) : 4731 Nos

Add for variations / wastage / misc welding @ 10 % ( 4731 x 0.1 ) : 473 Nos

Total requirement of GP / LH electrodes : 5204 Nos

for stitch weld GP electrodes @t 10 % of total ( 5204 x 0.10 ) : 520 Nos

for run welding LH electrodes @ 90 % of total ( 5204 x 0.90 ) : 4684 Nos

2. Cutting :

Length of cutting assuming cutting for 2 sides as per data sheet : 290 Rm

Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 29 Rm

Total : 319 Rm

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

Length of steel to be cut by using gas manually : 100 m

Length of steel to be cut by gas using pug cutting machine : 219 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 50 hours

Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 73 hours

Acetelyne gas @ 0.6 cum / hour ( 50 + 73 ) x 0.60 : 74 cum

Oxygen gas @ 1.8 cum / hour ( 50 + 73 ) x 1.80 : 222 cum

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

Use of pug cutting machine with 50 min / hr working ( 73 x 60 / 50 ) : 88 hours

3. Welding :

101




Length of welding as per data sheet : 473 Rm

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

( 520 / 15 ) x 8 / 2 : 139 hours

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

( 4684 / 15 ) x 8 / 6 : 416 hours

Total : 553 hours

Deploy welding transformer for 553 hours.

Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 139 x 0.25 + 416 x 0.75 ) : 347 hours

4. Surface cleaning and painting :

Painting area for hoist bridge @ 20 sqm per tonne ( 10.239 x 20 ) : 205 sqm

2 coats of zinc chromate red oxide primer .

Quantity of primer paint for 205 sqm @ 12 sqm / ltr / coat : 35 ltr

3 coats of synthetic enamel paint.

Quantity of synthetic enamel paint for 205 sqm @ 12 sqm / ltr / coat : 51 ltr

As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment

to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting

before applying primer painting.

Quantity of rust cleaner / inhibitor for 205 sqm @ 8 sqm / ltr : 26 ltr

5. Requirement of other machinery :

For handling of parts during fabrication and erection 8 t mobile crane for 12 hours and stationery

derric crane for 40 hours considered.

For drilling holes in plates 8 hours use of drilling machine considered.

For grinding and finishing weld joints in liner plates 8 hours use of grinding machine considered.

6. Requirement of work force :

Work component Foreman Helper /

Painter Cl-II

Cutting sections 148 hours 9 18 18 36

Fabricating by stitch welding 139 hours 9 17 --- 34

Run welding 416 hours 5 --- 52 52

For erection of columns & bracings 2 4 --- 16

For erection of beams / cross beams 4 8 --- 16

For erection of railing / covering etc 1 2 --- 4

Cleaning surface 205 sqm @ 15 sqm/day --- --- --- 14

Painting ( 5 x 205 ) sqm @ 15 sqm / day --- --- --- 61

Finishing / Cleaning 1 1 --- 1

Total : 31 50 70 234

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 51 Painters Cl-II

at 15 sqm / day and 10 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

Fabricator / Welder

Erector /

Marker / Gas cutter /

102




7 Sundries LS 20.00 30.00 600.00

Total Rs: 43700.00

Add for small Tools and Plants @ 1% Rs: 437.00

Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 2838.40

Add for Contractor's Overheads @ 5% Rs: 2185.00

Total hire charges of Machinery : Rs: 49160.40

C. LABOUR:

Sl No Unit Amount

in Rs.

1 Crew for Mobile crane Hour 12.00 75.70 908.40

2 Crew for Drilling machine Hour 8.00 59.50 476.00

3 Crew for Grinding machine Hour 8.00 59.50 476.00

4 Foreman Day 31.00 177.00 5487.00

5 Marker / Fabricator / Erector Day 50.00 157.50 7875.00

6 Gas cutter Day 18.00 157.50 2835.00

7 Welder ( General ) Day 52.00 157.50 8190.00

Contd

C. LABOUR ( Contd ) :

Sl No Unit Amount

in Rs.

Contd

8 Helper fabrication / erection Day 159.00 141.50 22498.50

9 Helper for cleaning / painting Day 24.00 141.50 3396.00

10 Painter Cl - II Day 51.00 141.50 7216.50

11 Electrician Day 5.00 143.00 715.00

Total Rs: 60073.40


Add for Contractor's Profit @ 10% Rs: 6007.34

Add for hidden cost on Labour @ 15% Rs: 9011.01

Add for additional hidden cost on labour @ 15% Rs: 9011.01


Total cost of Labour : Rs: 87707.16

ABSTRACT:

A. Cost of Materials Rs: 609410.41

B. Hire charges of Machinery Rs: 49160.40

C. Cost of Labour Rs: 87707.16

TOTAL Rs: 746277.97

Add for excise duty on 75 percent cost of

Machinery / Labour components @ 8.24% Rs: 8458.42

Add for insurance charges @ 1.00% Rs: 7462.78 Add for designs and drawings @ 2.50% Rs: 18656.95

Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 18656.95

Add for power supply arrangements @ 2.00% Rs: 14925.56

Add for enabling works @ 1.40% Rs: 10447.89

Total Rs: 824886.52

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

Fabricated parts 2x10.239 tonnes @ Rs: 129.10 / tonne Rs: 2643.71

Add for transportation upto work site @ 3.00% Rs: 24746.60

Rate

in Rs.

QuantityDescription

QuantityDescription

in Rs.

Rate

104




Total cost for 10.239 tonne Rs: 852276.82

Rate per tonne Rs: 83200.00

Rate approved per tonne Rs: 83200.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 22

ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity rope

drum hoist consisting of hoist platform, rope drum, pulleys, gear system, electri c motor,

electro-magnetic brake system, manual operation assembly, position indicator, control panel,

wire rope etc., with all accessories for operating vertical lift roller gates for barrage

including cost of all materials, machinery, labour, cutting, bending, aligning, anchoring, welding,

finishing, cleaning, applying two coats of zinc chromate red oxide primer and three coats of

approved synthetic enamel paint etc., complete with all leads and lifts.

DATA:Rope drum hoist for vertical lift barrage gate consists of hoist supporting frames, pulley

supports, pulleys, drive stool, rope drums, shafts, couplings, gears and pinions, plummer

blocks, gear box, electric motor, hand operation assembly, brake, wire rope, gate position

indicator, switch box etc. with related accessories.

Consider rope drum hoist for operating barrage gate for clear opening of 13.72 m x 8.26 m.

For vent opening of 13.72 x 8.26 m the approximate size of gate leaf will be 14.7 x 8.6 m.

Head of water above sill level considered : 8.26 m

Generally the capacity of hoist required for barrage gate will be 1.5 times the weight of gate.

Weight of hoist with all accessories is assumed at 0.1 tonne per tonne capacity of hoist as the

hoist is supported on steel bridge and no anchorages and base frames are required.

Weight of gate leaf in tonnes based on empirical formula :

= 0.0335 ( L2 x H x h )

0.716

Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm.

= 0.0335 ( 14.7 x 14.7 x 8.6 x 8.26 )0.716

: 33.289

Consider capacity of hoist including 25 % reserve capacity at 1.5 times the weight of gate :( 1.50 x 33.289 ) : 49.933 tonnes

Round off the capacity of hoist to next 10 tonne : 50.00 tonne

Consider Weight of hoist with all accessories @ 0.1 t / tonne capacity of hoist :

( 50 x 0.10 ) : 5.00 tonnes

The hoist capacity and hoist weight computed as above based on empirical formulae are further

checked by varifying / computing the actual capacity and weight as per fabrication drawings for

vertical lift barrage gate rope drum hoist of same capacity provided for one of the barrage.

Actual capacity of rope drum hoist as per data sheet : 50.000 tonnes

Actual wt of barrage gate rope drum hoist as per data in Item :22 of Annexure-2 : 5.069 tonnes


Consider details of Material / Gas cutting / Welding based on fabrication drawings of rope drum

hoist for vertical lift barrage gate provided for one of the barrage for rate analysis ( for details

refer Item : 22 of Annexure-2 ).

1. Requirement of materials:a. Structural steel conforming to IS : 2062 :

Angles / beams / channels / bars with 2.5 % wastage ( 410x1.025 ) : 420.00 kg

Plates / flats with 2.5 % wastage ( 219 x 1.025 ) : 225.00 kg

b. Cast steel components conforming to IS : 1030 :

Rope drums 2 Nos / Gears : 1290.00 kg

Pinions : 98.00 kg

Pulleys 8 Nos / Couplings 2 Nos : 650.00 kg

105




Plummer blocks / Hubs : 250.00 kg

c. Alloy steel steel components conforming to IS : 1570 :

Shafts / Keys : 350.00 kg

Pins : 96.00 kg

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

Bearings / Bush : 100.00 kg

e. Bolt / Nut / Washers conforming to IS : 1363 :

MS Bolts / Nuts / Washers with 2.5 % wastage ( 25 x 1.025 ) : 26.00 kg

f. Steel wire rope conforming ti IS 2266 :

28 mm dia 6 / 37 construction 1 No 120 Rm @ 2.71 kg / m : 435.00 kg

g. Other components :

Manual operation assembly : 1 No.

Worm reducer ( size 800 ) : 1 No

Electric motor 12.5 hp : 1 No.

Gate position indicator : 1 No.

Ele-magnetic brake : 1 No.

Electric cable / switch / control panel etc : 1 set

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




for stitch weld GP electrodes @ 10 % of total ( 608 x 0.10 ) : 61 Nos


2. Cutting :

Length of cutting assuming cutting for 2 sides as per data sheet : 37 Rm


Total : 41 Rm

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


Length of steel to be cut by gas using pug cutting machine : 21 m

Time for gas cutting manually at ( av ) 2 m cutting / hour : 10 hours






3. Welding :

Length of welding as per data sheet : 53 Rm


( 61 / 15 ) x 8 / 2 : 16 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 547 / 15 ) x 8 / 6 : 49 hours

Total : 65 hours



( 16 x 0.25 + 49 x 0.75 ) : 41 hours


106




Painting area for hoist at 20 sqm / tonne of str steel ( 0.645 x 20 ) : 13 sqm

2 coats of zinc chromate red oxide primer.


3 coats of synthetic enamel paint.

Quantity of synthetic enamel paint for 13 sqm @ 12 sqm / ltr /coat : 3.5 ltr




Quantity of rust cleaner / inhibitor for 13 sqm @ 8 sqm / ltr : 1.5 ltr


For lifting and placing in position hoist drums, worm reducers, gears, floating shafts etc use of

25 t mobile crane for 56 hours with energy charges for 28 hours considered.

For handling of parts during fabrication and transportation use of 8 t mobile crane for 40 hours

with energy charges for 20 hours considered.

For drilling holes for bolts 16 hours use of drilling machine considered.

For grinding and finishing weld joints 8 hours use of grinding machine considered



Painter Cl-II

Cutting sections/ drilling holes 21 hours 1 3 3 6



Erection of hoist frame 2 2 --- 8

Erection of drums / gears / shafts 4 8 --- 16

Erection of pulleys / plummer blocks 2 4 --- 8

Erection of worm reducers / brake / motor 2 4 --- 8

Erection of other accessories 1 2 --- 2

Erection of control panel / cabling 1 1 --- 2

Checking and running without rope 1 2 --- 4



Rope fixing and checking 2 4 --- 8

Trial running by lowering / lifting gate 1 2 --- 4

Final checking / Finishing / cleaning 1 1 --- 2

Total : 20 35 9 83


is considered for welder for stitch welding.


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 alltaxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost







Life of gas cutting set : 600 hours

Gas cutter /

Welder Fabricator /

Marker /

Erector /

107




Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50

RATE ANALYSIS UNIT : 5.069 tonne wt

A. MATERIALS: 50.00 t capacity

Sl No Unit Amount

in Rs.

1 Structural steel

Angles / beams / channels / bars kg 420.00 37.95 15939.00

Plates / flats kg 225.00 40.00 9000.00

2 Cast steel components :

Rope drums 2 Nos / Gears kg 1290.00 145.00 187050.00

Pinions kg 98.00 150.00 14700.00

Pulleys 3 Nos / Couplings 2 Nos kg 650.00 125.00 81250.00

Plummer blocks / Hubs kg 250.00 125.00 31250.00

Contd

A. MATERIALS ( Contd ) : Sl No Unit Amount

in Rs.

Contd

3 Alloy steel components

Shafts / Keys kg 350.00 175.00 61250.00

Pins kg 96.00 215.00 20640.00

4 Bronze alloy components :

Bronze bearings / bush kg 100.00 635.00 63500.00

5 Wire rope 28 mm dia 6/37 construction kg 435.00 105.00 45675.00

6 MS Bolt / Nut / Washer kg 26.00 55.00 1430.00

7 Worm reducers No. 1.00 120000.00

8 Electric motor 12.5 hp No. 1.00 60000.00 60000.00

9 Manual operating system No. 1.00 22500.00 22500.00

10 Gate position indicator No. 1.00 9000.00 9000.00

11 Ele-magnetic brake No. 1.00 15000.00 15000.00

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

13 Oxygen gas cum 30.00 48.00 1440.00

14 Acetyline gas cum 10.00 258.00 2580.00

15 Welding electrodes ( general purpose ) Nos 61.00 6.00 366.00

16 Welding electrodes ( low hydrogen ) Nos 547.00 12.00 6564.00

17 Zinc chromate red oxide primer ltr 2.00 140.00 280.00

18 Synthetic enamel ( 1st quality ) paint ltr 3.50 176.00 616.00

19 Rust cleaner / inhibitor ltr 1.50 240.00 360.00

20 Grease kg 50.00 194.00 9700.00

21 Use rate welding holder set Hour 65.00 4.50 292.50

22 Use rate gas cutting torch set Hour 12.00 2.50 30.00

23 Wire brush Nos 2.00 30.00 60.0024 Sundries LS 1000.00 30.00 30000.00

Total Rs: 828472.50




Total cost of Materials : Rs: 961028.10

B. MACHINERY:

Perticulars

in Rs.

in Rs.

Quantity Rate

Perticulars RateQuantity

120000.00

108




Sl No Unit Amount

in Rs.

1 Welding transformer Hour 65.00 12.00 780.00

Fuel / Energy charges Hour 41.00 60.00 2460.00

2 Mobile crane 25 t Hour 56.00 3804.00 213024.00


3 Pug cutting machine Hour 9.00 16.00 144.00




5 Grinding machine Hour 16.00 18.00 288.00


Contd

B. MACHINERY ( Contd ) : Sl No Unit Amount

in Rs.

Contd

6 Drilling machines Hour 8.00 18.00 144.00


7 Sundries LS 600.00 30.00 18000.00

Total Rs: 298347.00





C. LABOUR:

Sl No Unit Amount

in Rs.

1 Crew for Mobile crane 8 t Hour 40.00 75.70 3028.00




5 Foreman Day 20.00 177.00 3540.00


7 Gas cutter Day 3.00 157.50 472.50


9 Khalasi Day 90.00 145.50 13095.00



12 Painter Cl - II Day 3.00 141.50 424.5013 Electrician Day 3.00 143.00 429.00

Total Rs: 44260.10







Description

in Rs.

Quantity RateDescription

in Rs.

Description RateQuantity

RateQuantity

in Rs.

109




ABSTRACT:




TOTAL Rs: 1348844.37



Add for insurance charges @ 1.00% Rs: 13488.44

Add for designs and drawings @ 2.50% Rs: 33721.11




Total Rs: 1499602.78


Fabricated parts 2 x 5.069 tonnes @ Rs: 129.10 / tonne Rs: 1308.82 Add for transportation upto work site @ 3.00% Rs: 44988.08

Total cost for 5.069 tonne weight Rs: 1545899.68

50.000 tonne capacity

Rate per tonne weight Rs: 304970.00

Rate per tonne capacity Rs: 30900.00

Rate approved per tonne capacity Rs: 30900.00


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

beam, wall plates, first stage anchors, anchor girders, anchor bars, trunnion supports etc., with

all accessories for outflow regulating automatic gates for barrage/ escape including cost of

all materials, labour, machinery, cutting, aligning, anchoring, welding, finishing, cleaning,applying

one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc.,

complete as per specifications and approved drawings with all leads and lifts.

DATA:Embedded parts for automatic outflow regulating gate consist of sill beam / wall plates / anchor /

girders / anchor bars trunnion supports etc., with all accessories. The weight of embedded parts

for automatic gate will be generally about 35 to 40 percent of weight of gate leaf with fulcrum

assembly.

Consider embedded parts for automatic outflow regulating gate for barrage opening of size

8.0 m x 3.5 m.

Size of gate : 8.00 m x 3.50 m Head of water : 3.50 m

Weight of automatic outflow regulating gate with fulcrum assembly in tonne for the opening

based on empirical formula = 0.1325 x ( L2 x H x h )

0.673

Consider Weight of embedded parts in tonne @ av. 55 % of weight of gate :

= 0.375 x 0.1325 x ( L 2 x H x h ) 0.673

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

= 0.049 x ( 8 x 8 x 3.5 x 3.3 )0.673

: 4.177


actual weight as per fabrication drawings of embedded parts for barrage outflow regulating radial

gate of same size furnished by the designer.

Actual weight of embedded parts : 3.910 tonnes


110




Consider details of Material / Gas cutting / Welding based on fabrication drawings of embedded

parts for automatic outflow regulating gate as provided by the designer. ( for details refer

Item : 23 of Annexure-2 ).


a. Structural steel conforming ti IS : 2062 :

Total weight of structural steel excluding wastage : 3800 kg

Weight of Angles / Channels / Beams @ 20 % : 760 kg

Weight of Plates / Flats @ 80 % : 3040 kg

Angles / beams / channels / bars with 2.5 % wastage ( 760x1.025 ) : 779 kg

Plates / flats with 2.5 % wastage ( 3040 x 1.025 ) : 3116 kg

b. Alloy steel conforming to IS : 1570 :

Stainless steel plates / flats AISI 410 ( 49 x 1.025 ) say: 50.00 kg

Stainless steel plates / flats AISI 304L ( 62 x 1.025 ) say: 64.00 kg

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

MS bolts and nuts with 2.5 % wastage ( 129 x 1.025 ) : 132 kgd. Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) :




for stitch welding GP electrodes @t 10 % of total ( 147 x 0.10 ) : 15 Nos


Stainless steel electrodes as per data sheet ( Item:23 Annexure-2 ) : 987 Nos

Add for variations / wastage @ 5 % ( 987 x 0.05 ) : 49 Nos

Total requirement of Stainless steel ( SS ) electrodes : 1036 Nos

for stitch weld SS electrodes @t 10 % of total ( 1036 x 0.10 ) : 104 Nos

for run weld SS electrodes @t 90 % of total ( 1036 x 0.90 ) : 932 Nos

2. Cutting :

Length of cutting assuming cutting for 2 sides as per data sheet : 168.00 Rm

Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 17.00 Rm

Total : 185.00 Rm

For cutting structural steel sections to required sizes plate shearing machine and gas cutting is

assumed.

Length of steel to be cut by using plate shearing machine : 30 m



Time for cutting by shearing machine @ ( av ) 10 m cutting / hour : 3 hours






Use of pug cutting machine with 50 min / hr working ( 38 x 60 / 50 ) : 45 hours 3. Welding :


( 15 + 104 ) x 8 / 15 / 2 : 32 hours


( 932 + 132 ) x 8 / 15 / 6 : 95 hours

Total : 127 hours



111




( 32 x 0.25 + 95 x 0.75 ) : 80 hours

4. Planing SS plates for seal seats :

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

Length of SS plate for surface finishing by planing machine : 47 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 47 m SS plates ( 47 x 8 / 3 ) : 126 hours


Painting area for embedded parts at 10 sqm / tonne ( 3.9 x 10 ) : 40 sqm

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


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

Quantity of coal tar epoxy paint for 40 sqm @ 6 sqm / ltr / coat : 27 ltr



before applying primer painting.Quantity of rust cleaner / inhibitor for 40 sqm @ 8 sqm / ltr : 5 ltr


For drilling holes for anchor bolts 16 hours use of drilling machine considered.

For finishing weld joints / edges 12 hours use of grinding machine considered.

For handling of parts during fabrication and erection use of 8 t mobile crane for 18 hours and

stationery derric crane for 56 hours considered.



Painter Cl-II


Drilling holes for anchors / supports --- 2 --- 4



Erection of Anchor girders / anchor bars 2 4 --- 12

Erection of first stage anchors 1 2 --- 4

Erection of Sill beam / Wall plates 2 4 --- 12


Painting ( 5 x 40 ) sqm @ 15 sqm / day 2 --- --- 15

Finishing / Checking 1 2 --- 2

Total : 22 30 20 112


considered for welder for stitch welding.



For surface finishing of stainless steel plates for seal seats planing machine is considered.

8. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all








Fabricator / Welder

Erector /

Marker / Gas cutter /

112






RATE ANALYSIS UNIT : 3.910 tonne

A. MATERIALS:

Sl No Unit Amount

in Rs.

1 Structural steel


Plates / flats kg 3116.00 40.00 124640.00

Contd

A. MATERIALS ( Contd ) :

Sl No Unit Amount

in Rs.

Contd 2 Stainless steel plates / flats AISI 410 kg 50.00 120.00 6000.00

Stainless steel plates / flats AISI 304L kg 64.00 240.00 15360.00

3 MS bolts and nuts kg 132.00 55.00 7260.00

4 Oxygen gas cum 105.00 48.00 5040.00




8 Welding electrodes ( stainless steel ) Nos 1036.00 43.00 44548.00

9 Zinc rich epoxy primer ltr 5.00 594.00 2970.00

10 Coal tar epoxy paint ltr 27.00 208.00 5616.00




14 Wire brush Nos 3.00 30.00 90.00

15 Sundries LS 70.00 30.00 2100.00

Total Rs: 255720.05





B. MACHINERY:

Sl No Unit Amount

in Rs.



2 Plate shearing machine Hour 3.00 62.00 186.00Fuel / Energy charges Hour 3.00 100.00 300.00

3 Pug cutting machine Hour 45.00 16.00 720.00


4 Planing machine Hour 126.00 88.00 11088.00




6 Stationery derric crane Hour 56.00 66.00 3696.00

Rate

in Rs.

Perticulars Quantity Rate

QuantityDescription

Perticulars Quantity

in Rs.

Rate

in Rs.

113









9 Sundries LS 70.00 30.00 2100.00

Total Rs: 51133.00





C. LABOUR:

Sl No Unit Amount

in Rs.

1 Crew for Mobile crane Hour 18.00 75.70 1362.60

2 Crew for plate shearing machine Hour 3.00 45.90 137.703 Crew for Planing machine Hour 127.00 73.40 9321.80



6 Foreman Day 22.00 177.00 3894.00


8 Gas cutter Day 8.00 157.50 1260.00


10 Welder ( X - ray ) Day 2.00 173.25 346.50



13 Painter Cl - II Day 13.00 141.50 1839.50

14 Electrician Day 2.00 143.00 286.00

Total Rs: 40422.60







ABSTRACT:




TOTAL Rs: 412543.13


Machinery / Labour components @ 8.24% Rs: 7163.11 Add for insurance charges @ 1.00% Rs: 4125.43

Add for patent royalty charges @ 4.40% Rs: 18151.90





Total Rs: 476637.19


in Rs.

Description Quantity Rate

114




Fabricated parts 2 x 3.910 tonnes @ Rs: 129.10 / tonne Rs: 1009.56






ITEM: Design, fabrication, supply, erection, testing and commissioning of automatic outflow regulating

gate and fulcrum assembly consisting of skin plate, stiffeners, horizontal girders, trunnion

assemblies, gate bracket, base plate, rolling surface assembly, link brackets, link assembly,

rubber seals, seal clamps etc., with all accessories for barrage including cost of all materials,

machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of

zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc.,

complete as per specifications and approved drawings with all leads and lifts.

DATA: Automatic outflow regulating gate and fulcrum assembly consisting of skin plate, stiffeners,

horizontal girders, trunnion assemblies, gate bracket, base plate, rolling surface assembly, link ,

brackets, link assembly rubber seals, seal clamps etc., with all accessories.

Consider automatic outflow regulating gate for barrage opening of size 8 m x 3.5 m for analysis.


Weight of automatic gate leaf in tonnes based on empirical formula :

= 0.1325 x ( L2 x H x h )

0.673


= 0.1325 x ( 8 x 8 x 3.5 x 3.3 )0.673

: 11.295


actual weight as per fabrication drawings of automatic outflow regulating gate of same size

furnished by the designer for one of the gate.

Actual weight of radial gate leaf as per data in Item :24 of Annexure-2 : 11.270 tonnesConsider actual weight for data rate analysis.

Consider details of Material / Gas cutting / Welding based on fabrication drawings of canal

regulator radial gate provided for one of the canal regulator for rate analysis ( for details refer

Item : 24 of Annexure-2 ).


a. Structural steel :


Plates / flats with 2.5 % wastage ( 7561x1.025 ) : 7750 kg

b. Alloy steel components :

Pins / Axles : 74 kg

Stainless plate / flats AISI 410 ( 49x1.025 ) : 50 kg

c. Cast steel components :

Trunnion hub / Guide roller : 443 kg

d. Alluminium / Bronze alloy components :Trunnion / Guide roller bush : 33 kg

e. Bolts / Nuts / Washers :

Stainless steel bolts /nuts /washers with 2.5 % wastage ( 31 x 1.025 ) : 32 kg

MS bolts / nuts / washers with 2.5 % wastage ( 23.5x1.025 ) : 24 kg

f. Rubber seal :

Bottom seal ( flat type ) ( 8 x 1.025 ) : 8.5 Rm

Side seals ( Z - type ) (2 x 4 x 1.025 ) : 8.5 Rm

g. Welding electrodes ( Ordinary / Low hydrogen ) :

115







for stitch weld GP electrodes @t 10 % of total (6738 x 0.10 ) : 674 Nos

for run welding LH electrodes @ 90 % of total (6738 x 0.90 ) : 6064 Nos

h. Welding electrodes ( Stainless steel ) :

SS electrodes as per data sheet ( Item:24 Annexure-2 ) : 150 Nos


Total requirement of SS electrodes : 165 Nos

for stitch weld SS electrodes @t 10 % of total (165 x 0.10 ) : 15 Nos

for run welding SS electrodes @ 90 % of total (165 x 0.90 ) : 160 Nos

2. Cutting :

Total length of cutting assuming cutting for 2 sides : 195 Rm


Total : 215 Rm

For cutting structural steel sections to required sizes use of plate shearing machine and gascutting is assumed.

Length of steel to be cut by using plate shearing machine 40 m



Time for cutting by plate shearing machine at ( av ) 10 m cutting / hour : 4 hours







4. Welding :

Length of welding : 196 Rm


( 674 + 15 ) x 8 / ( 15 x 2 ) : 184 hours


( 6064 + 160 ) x 8 / ( 15 x 6 ) : 553 hours

Total : 737 hours



( 184 x 0.25 + 553 x 0.75 ) : 461 hours

5. Planing SS plates for seal seats :

For surface finishing of SS plates planing machine is considered.

Length of SS plate for surface finishing by planing machine : 3 Rm

Length of planing at a time for 4 m stroke planing machine : 3 Rm

Time for planing 3 m length section with 50 min / hour working : 8 hours

Time for planing 3 m SS plates ( 3 x 8 / 3 ) : 8 hours 6. Surface cleaning and painting :

Painting area for gate at 20 sqm / tonne ( 11.27 x 20 ) : 225 sqm

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


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

Quantity of coal tar epoxy paint for 225 sqm @ 6 sqm / ltr / coat : 112 ltr



116





Quantity of rust cleaner / inhibitor for 225 sqm @ 8 sqm / ltr : 28 ltr


For drilling holes in skin plate and seal clamps for seal fixing 16 hours use of drilling machine

considered.

For grinding and finishing weld joints in skin plate and other locations 16 hours use of grinding

machine considered.

For handling of parts during fabrication and erection use of 8 t mobile crane for 16 hours and

stationery derric crane 50 hours considered.



Painter Cl-II


Drilling holes for seal fixing 1 2 --- 2Erection of trunnions/H -girders /stiffeners 4 4 --- 8

Fabricating and stitch welding 184 hours 11 23 --- 46


Erection of links / other accessories 2 4 --- 8

Erection of fulcrum assembly 2 4 --- 8



Seal fixing 1 2 --- 2

Finishing / checking / cleaning 1 1 --- 1

Total : 29 44 78 243


considered for welder for stitch welding.



9. Excise duty on supply :

Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all










RATE ANALYSIS UNIT : 11.270 tonneA. MATERIALS:

Sl No Unit Amount

in Rs.

1 Structural steel :


Plates / flats kg 7750.00 40.00 310000.00

2 Cast steel components :

Hub / Rollers kg 443.00 125.00 55375.00

in Rs.

Marker /

Fabricator /

Perticulars Quantity Rate

Welder

Erector /

Gas cutter /

117




3 Alloy steel components :

Stainless steel plate kg 50.00 120.00 6000.00

Pins / Axles kg 74.00 215.00 15910.00

4 Alluminium / Bronze alloy components:

Bearings / Bush kg 33.00 635.00 20955.00

Contd

A. MATERIALS ( Contd ) :

Sl No Unit Amount

in Rs.

Contd

5 Bolt / Nut / Washer :

Stainless steel bolts / nuts / washers kg 32.00 150.00 4800.00

MS bolts / nuts / washers kg 24.00 55.00 1320.00

6 Rubber seals :

Bottom seal Rm 8.50 147.00 1249.50Side seals ( Z - type ) Rm 8.50 295.00 2507.50

8 Oxygen gas cum 126.00 48.00 6048.00




12 Welding electrodes ( stainless steel ) Nos 165.00 43.00 7095.00

13 Zinc rich epoxy primer ltr 25.00 594.00 14850.00

14 Coal tar epoxy paint ltr 112.00 208.00 23296.00




18 Wire brush Nos 5.00 30.00 150.00

19 Sundries LS 100.00 30.00 3000.00

Total Rs: 691773.00





B. MACHINERY:

Sl No Unit Amount

in Rs.



2 Plate shearing machine Hour 4.00 62.00 248.00


3 Pug cutting machine Hour 46.00 16.00 736.00Fuel / Energy charges Hour 46.00 3.00 138.00

5 Planing machine Hour 8.00 88.00 704.00


7 Mobile crane ( revolving ) 8 t Hour 16.00 362.00 5792.00


8 Stationery derric crane Hour 50.00 66.00 3300.00



Rate

Description

Perticulars Quantity

in Rs.

Quantity Rate

in Rs.

118







11 Sundries LS 100.00 30.00 3000.00

Total Rs: 61856.00

Contd

B. MACHINERY ( Contd ) :

Sl No Unit Amount

in Rs.

Contd





C. LABOUR: Sl No Unit Amount

in Rs.


2 Crew for plate shearing machine Hour 4.00 45.90 183.60

3 Crew for planing machine Hour 8.00 73.40 587.20



6 Foreman Day 29.00 177.00 5133.00


8 Gas cutter Day 9.00 157.50 1417.50


10 Welder ( X - ray ) Day 7.00 173.25 1212.75

11 Khalasi Day 34.00 145.50 4947.00



14 Painter Cl - II Day 60.00 141.50 8490.00

15 Electrician Day 3.00 143.00 429.00

Total Rs: 69056.75







ABSTRACT:

A. Cost of Materials Rs: 802456.68B. Hire charges of Machinery Rs: 69704.16


TOTAL Rs: 972983.70



Add for insurance charges @ 1.00% Rs: 9729.84

Add for Patent royalty charges @ 4.40% Rs: 42811.28


Perticulars

Description

in Rs.

Quantity

in Rs.

Rate

Quantity Rate

119







Total Rs: 1117794.01


Fabricated parts 2x11.27 tonnes @ Rs: 129.10 / tonne Rs: 2909.91






ITEM: Design, fabrication, supply, erection, testing and commissioning of hoisting cum damping

system consisting of low level horizontal lever link, low level long actuating lever, high levelvertical lever link, high level short actuating lever, high level hoisting bracket, axle for lever

system, friction shoes, support box for shoes, track assembly, ratchet pawl, support structure,

bracket plate etc., with all accessories for outflow regulating automatic gate including cost of all

materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying

one coat of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal

fixing etc., complete as per specifications and approved drawings with all leads and lifts.

DATA:Hoisting cum damping system for automatic outflow regulating gate consists of low level

horizontal lever link, low level long actuating lever, high level vertical lever link, high level short

actuating lever, high level hoisting bracket, axles for lever system, friction shoes, track assembly,

support box for shoes, ratchet pawl, support structure, bracket plate etc.

Consider hoisting cum damping system for automatic outflow regulating gate of size 8 x 3.50 m

for analysis.

Weight of the hoisting cum damping system will be about 50 to 55 percent of the weight of the

automatic outflow regulating gate.

Consider automatic outflow regulating gate for barrage opening of size 8 m x 3.5 m for analysis.


Weight of automatic gate leaf in tonnes based on empirical formula :

= 0.1325 x ( L2 x H x h )

0.673


= 0.1325 x ( 8 x 8 x 3.5 x 3.3 )0.673

: 11.295

Weight of hoisting cum damping system = 0.525 x 11.295 : 5.93 tonnes


actual weight as per fabrication drawings.

Actual weight of radial gate leaf as per data in Item :25 of Annexure-2 : 5.81 tonnes


Consider details of Material / Gas cutting / Welding based on fabrication drawings of hoistinglcum damping system as furnished by the designer for one of the automatic outflow regulating

gate of size 8.0 x 3.5 m for rate analysis ( for details referItem : 25 of Annexure-2 ).


a. Structural steel :


Plates / flats with 2.5 % wastage ( 3622x1.025 ) : 3712 kg

b. Alloy steel components :

Stainless steel plates / flats : 435 kg

data rates gate works 6

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