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8/13/2019 Data Rates Gate Works 2
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GATE / HOIST AND ALLIED WORKS
Total : 37 67 76 240
Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision
is considered for welder for stitch welding.
b. Workforce for painting 2 coats primer and 3 coats finishing paint consists of 30 Painters Cl-II
at 15 sqm / day and 6 helpers to assist painters.
7. Excise duty on supply :
Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all
taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.
8. Use rate of materials :
Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 4.50
Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00
Life of gas cutting set : 600 hours
Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50
RATE ANALYSIS UNIT : 15.440 tonne wt
A. MATERIALS: 90.00 t capacity
Sl No Unit Amount
in Rs.1 Structural steel
Angles / beams / channels / bars kg 2571.00 37.95 97569.45
Plates / flats kg 3632.00 40.00 145280.00
2 Cast steel components :
Rope drums 2 Nos / Gears 4 Nos kg 3680.00 145.00 533600.00
Pinions kg 218.00 150.00 32700.00
Pulleys 720 PCD 6 Nos kg 1080.00 125.00 135000.00
Plummer blocks / Hubs kg 322.00 125.00 40250.00
3 Alloy steel components
Shafts kg 557.00 175.00 97475.00
Pins kg 546.00 215.00 117390.00
4 Bronze alloy components :
Bronze bearings / bush kg 144.00 635.00 91440.00
5 Wire rope 36 mm dia 6/37 construction kg 448.00 105.00 47040.00
6 MS Bolt / Nut / Washer kg 85.00 55.00 4675.00
7 Worm reducer No. 1.00 120000.00
8 Electric motor 20 hp No. 1.00 60000.00 60000.00
9 Floating shaft 300 mm dia kg 1000.00 45.00 45000.00
10 Manual operating system No. 1.00 22500.00 22500.00
Contd
A. MATERIALS ( Contd ) : Sl No Unit Amount
in Rs.
Contd
11 Gate position indicator No. 1.00 9000.00 9000.00
12 Ele-magnetic brake No. 1.00 15000.00 15000.00
13 Electric cable /switch /control panel etc LS 1.00 18000.00 18000.00
14 Oxygen gas cum 216.00 48.00 10368.00
15 Acetyline gas cum 72.00 258.00 18576.00
Perticulars Quantity
in Rs.
120000.00
in Rs.
Rate
Perticulars Quantity Rate
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GATE / HOIST AND ALLIED WORKS
16 Welding electrodes ( general purpose ) Nos 584.00 6.00 3504.00
17 Welding electrodes ( low hydrogen ) Nos 5250.00 12.00 63000.00
18 Zinc chromate red oxide primer ltr 21.00 140.00 2940.00
19 Synthetic enamel ( 1st quality ) paint ltr 31.00 176.00 5456.00
20 Rust cleaner / inhibitor ltr 16.00 240.00 3840.00
21 Grease kg 50.00 194.00 9700.00
22 Use rate welding holder set Hour 623.00 4.50 2803.50
23 Use rate gas cutting torch set Hour 90.00 2.50 225.00
24 Wire brush Nos 3.00 30.00 90.00
25 Sundries ( hand rail /staircase / gate etc ) LS 1000.00 30.00 30000.00
Total Rs: 1782421.95
Add for small Tools and Plants @ 1% Rs: 17824.22
Add for Contractor's Profit @ 10% Rs: 178242.20
Add for Contractor's Overheads @ 5% Rs: 89121.10
Total cost of Materials : Rs: 2067609.46
B. MACHINERY:
Sl No Unit Amount
in Rs.
1 Welding transformer Hour 623.00 12.00 7476.00
Fuel / Energy charges Hour 390.00 60.00 23400.002 Tower crane 5 t capacity Hour 4.00 994.00 3976.00
Fuel / Energy charges Hour 4.00 130.00 520.00
3 Pug cutting machine Hour 53.00 16.00 848.00
Fuel / Energy charges Hour 53.00 3.00 159.00
4 Mobile crane 25 t Hour 40.00 3804.00 152160.00
Fuel / Energy charges Hour 20.00 1375.00 27500.00
5 Mobile crane 8 t Hour 40.00 362.00 14480.00
Fuel / Energy charges Hour 20.00 495.00 9900.00
6 Grinding machine Hour 32.00 18.00 576.00
Fuel / Energy charges Hour 32.00 25.00 800.00
7 Drilling machines Hour 16.00 18.00 288.00
Fuel / Energy charges Hour 16.00 25.00 400.00
8 Sundries LS 600.00 30.00 18000.00
Total Rs: 260483.00
Add for small Tools and Plants @ 1% Rs: 2604.83
Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 7077.90
Add for Contractor's Overheads @ 5% Rs: 13024.15
Total hire charges of Machinery : Rs: 283189.88
C. LABOUR:
Sl No Unit Amountin Rs.
1 Crew for Mobile crane 25 t Hour 40.00 72.60 2904.00
2 Crew for Mobile crane 8 t Hour 40.00 75.70 3028.00
3 Crew for Tower crane Hour 4.00 62.00 248.00
4 Crew for Drilling machine Hour 16.00 59.50 952.00
5 Crew for Grinding machine Hour 32.00 59.50 1904.00
6 Foreman Day 37.00 177.00 6549.00
7 Marker / Fabricator / Erector / Mechanic Day 67.00 157.50 10552.50
Quantity
Description
Description
Quantity Rate
Ratein Rs.
in Rs.
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8 Gas cutter Day 18.00 157.50 2835.00
9 Welder ( General ) Day 58.00 157.50 9135.00
10 Khalasi Day 100.00 145.50 14550.00
11 Helper fabrication / erection Day 196.00 141.50 27734.00
12 Helper for cleaning / painting Day 14.00 141.50 1981.00
13 Painter Cl - II Day 30.00 141.50 4245.00
14 Electrician Day 3.00 143.00 429.00
Total Rs: 87046.50
Add for small Tools and Plants @ 1% Rs: 870.47
Add for Contractor's Profit @ 10% Rs: 8704.65
Add for hidden cost on Labour @ 15% Rs: 13056.98
Add for additional hidden cost on labour @ 15% Rs: 13056.98
Add for Contractor's Overheads @ 5% Rs: 4352.33
Total cost of Labour : Rs: 127087.89
ABSTRACT:
A. Cost of Materials Rs: 2067609.46
B. Hire charges of Machinery Rs: 283189.88
C. Cost of Labour Rs: 127087.89
TOTAL Rs: 2477887.23
Add for excise duty on 75 percent cost ofMachinery / Labour components @ 8.24% Rs: 25355.17
Add for insurance charges @ 1.00% Rs: 24778.87
Add for designs and drawings @ 2.50% Rs: 61947.18
Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 61947.18
Add for power supply arrangements @ 2.00% Rs: 49557.74
Add for enabling works @ 1.40% Rs: 34690.42
Total Rs: 2736163.80
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2 x 15.44 tonnes @ Rs: 129.10 / tonne Rs: 3986.61
Add for transportation upto work site @ 3.00% Rs: 82084.91
Total cost for 15.440 tonne weight Rs: 2822235.32
90.000 tonne capacity
Rate per tonne wiegt Rs: 182790.00
Rate per tonne capacity Rs: 31400.00
Rate approved per tonne capacity Rs: 31400.00
SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 4
ITEM: Design, fabrication, supply, erection and commissioning of 1 metre wide catwalkconnecting
spillway piers / abutments at trunnion platform level including cost of all materials,
machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat
of zinc rich epoxy primer and two coats of cold applied coal tar epoxy paint etc., complete asper specifications and approved drawings with all leads and lifts.
DATA:Catwalk at trunnion level generally consists of 1 m wide structural steel bridge spanning across
piers / abutments for inspection and maintenance of gate parts at trunnion level.
Consider 1 m wide catwalk for a clear span of 15 m and 3 m wide piers.
Generally weight of 1 m wide steel catwalk will be about 300 kg / m lenght.
Weight of catwalk for 18 m length ( C / C of piers ) @ 0.3 t / m : 5.400 tonnes
The weight of catwalk ( foot bridge ) computed as above based on empirical formula is further
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GATE / HOIST AND ALLIED WORKS
checked by computing the actual weight as per fabrication drawings of a catwalk of same size
provided for one of the dam work.
Actual weight of catwalk as per data in Item : 4 of Annexure-2 : 5.318 tonnes
Consider actual weight for data rate analysis.
Consider details of Material / Gas cutting / Welding based on fabrication drawings of catwalk
provided for one of the dam for rate analysis ( for details refer Item : 4 of Annexure-2 ).
1. Requirement of materials :
a. Structural steel conforming to IS : 2062 :
Angles/ beams/ channels/ bars with 2.5 % wastage ( 4154x1.025 ) : 4258 kg
Plates / flats with 2.5 % wastage ( 96 x 1.025 ) : 98 kg
Chequered plates with 2.5 % wastage ( 835 x 1.025 ) : 856 kg
b. Bolts / Nuts / Washers conforming to IS : 1363 :
MS bolts / nuts / washers with 2.5 % wastage ( 8 x 1.025 ) : 8 kg
c. Welding electrodes ( General purpose ) :
GP electrodes as per data sheet ( Item:4 Annexure-2 ) : 1387 Nos
Add for variations / wastage / misc welding @ 10 % ( 1387 x 0.1 ) : 139 Nos
Total requirement of GP electrodes : 1526 Nos
for stitch weld GP electrodes @t 10 % of total ( 1526 x 0.10 ) : 153 Nos
for run welding GP electrodes @ 90 % of total ( 1526 x 0.90 ) : 1373 Nos
2. Cutting :
Length of cutting assuming cutting for 2 sides as per data sheet : 57 Rm
Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 6 Rm
Total : 63 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas manually : 40 m
Length of steel to be cut by gas using pug cutting machine : 23 m
Time for gas cutting manually at ( av ) 2 m cutting / hour : 20 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 8 hours
Acetelyne gas @ 0.6 cum / hour ( 20 + 8 ) x 0.60 : 17 cum
Oxygen gas @ 1.8 cum / hour ( 20 + 8 ) x 1.80 : 51 cum
Use of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) : 24 hours
Use of pug cutting machine with 50 min / hr working ( 8 x 60 / 50 ) : 10 hours
3. Welding :
Length of welding as per data sheet : 151 Rm
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 153 / 15 ) x 8 / 2 : 41 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 1373 / 15 ) x 8 / 6 : 122 hours
Total : 163 hours
Deploy welding transformer for 163 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.
( 41 x 0.25 + 122 x 0.75 ) : 102 hours
4. Surface cleaning and painting :
Painting area for catwalk at 25 sqm / tonne ( 5.318 x 25 ) : 133 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 133 sqm @ 9 sqm / ltr / coat : 15 ltr
2 coats of coal tar epoxy paint 100 micron dry film each coat.
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3 Oxygen gas cum 51.00 48.00 2448.00
4 Acetyline gas cum 17.00 258.00 4386.00
5 Welding electrodes ( general purpose ) Nos 1526.00 6.00 9156.00
6 Zinc rich epoxy primer ltr 15.00 594.00 8910.00
7 Coal tar epoxy paint ltr 44.00 208.00 9152.00
8 Rust cleaner / inhibitor ltr 16.00 240.00 3840.00
9 Use rate welding holder set Hour 163.00 4.50 733.50
10 Use rate gas cutting torch set Hour 24.00 2.50 60.00
11 Wire brush Nos 1.00 30.00 30.00
12 Sundries LS 10.00 30.00 300.00
Total Rs: 240918.60
Add for small Tools and Plants @ 1% Rs: 2409.19
Add for Contractor's Profit @ 10% Rs: 24091.86
Add for Contractor's Overheads @ 5% Rs: 12045.93
Total cost of Materials : Rs: 279465.58
B. MACHINERY:
Sl No Unit Amount
in Rs.
1 Welding transformer Hour 163.00 12.00 1956.00
Fuel / Energy charges Hour 102.00 60.00 6120.002 Tower crane Hour 1.00 994.00 994.00
Fuel / Energy charges Hour 1.00 130.00 130.00
3 Pug cutting machine Hour 10.00 16.00 160.00
Fuel / Energy charges Hour 10.00 3.00 30.00
4 Mobile crane 8 t Hour 2.00 362.00 724.00
Fuel / Energy charges Hour 2.00 495.00 990.00
5 Grinding machine Hour 8.00 18.00 144.00
Fuel / Energy charges Hour 8.00 25.00 200.00
6 Drilling machines Hour 2.00 18.00 36.00
Fuel / Energy charges Hour 2.00 25.00 50.00
7 Sundries LS 10.00 30.00 300.00
Total Rs: 11834.00
Add for small Tools and Plants @ 1% Rs: 118.34
Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 782.00
Add for Contractor's Overheads @ 5% Rs: 591.70
Total hire charges of Machinery : Rs: 13326.04
C. LABOUR:
Sl No Unit Amount
in Rs.
1 Crew for Mobile crane Hour 2.00 75.70 151.40
2 Crew for Tower crane Hour 1.00 62.00 62.00
3 Crew for Drilling machine Hour 2.00 59.50 119.004 Crew for Grinding machine Hour 8.00 59.50 476.00
5 Foreman Day 6.00 177.00 1062.00
6 Marker / Fabricator / Erector Day 11.00 157.50 1732.50
7 Gas cutter Day 4.00 157.50 630.00
8 Welder ( General ) Day 15.00 157.50 2362.50
9 Helper fabrication / erection Day 35.00 141.50 4952.50
10 Helper for cleaning / painting Day 16.00 141.50 2264.00
11 Painter Cl - II Day 26.00 141.50 3679.00
Description
Description
Rate
in Rs.
in Rs.
Quantity
Quantity Rate
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GATE / HOIST AND ALLIED WORKS
12 Electrician Day 1.00 143.00 143.00
Total Rs: 17633.90
Add for small Tools and Plants @ 1% Rs: 176.34
Add for Contractor's Profit @ 10% Rs: 1763.39
Add for hidden cost on Labour @ 15% Rs: 2645.09
Add for additional hidden cost on labour @ 15% Rs: 2645.09
Add for Contractor's Overheads @ 5% Rs: 881.70
Total cost of Labour : Rs: 25745.49
ABSTRACT:
A. Cost of Materials Rs: 279465.58
B. Hire charges of Machinery Rs: 13326.04
C. Cost of Labour Rs: 25745.49
TOTAL Rs: 318537.11
Add for excise duty on 75 percent cost of
Machinery / Labour components @ 8.24% Rs: 2414.62
Add for insurance charges @ 1.00% Rs: 3185.37
Add for designs and drawings @ 2.50% Rs: 7963.43
Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 7963.43
Add for power supply arrangements @ 2.00% Rs: 6370.74
Add for enabling works @ 1.40% Rs: 4459.52Total Rs: 350894.22
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2 x 5.318 tonnes @ Rs: 129.10 / tonne Rs: 1373.11
Add for transportation upto work site @ 3.00% Rs: 10526.83
Total cost for 18.000 Rm Rs: 362794.15
Rate per Rm Rs: 20200.00
Rate approved per Rm Rs: 20200.00
SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 5
ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of
sill beam, slide tracks, seal seats, guide rails, dogging sets for storage of stoplog elements
etc., with all accessories for spillway stop log gateelements including cost of all materials,
machinery, labour, cutting, welding, aligning, anchoring, finishing, cleaning, applying one coat
of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as
per specifications and approved drawings withall leads and lifts.
DATA:Spillway stoplog gate embedded parts consist of sill beam, slide tracks / seal tracks and gate
guides and dogging sets for storage of elements with accessories such as first stage anchors.
Weight of embedded parts with dogging sets will be about 4 to 5 percent of stop log gate weight.
Consider embedded parts for stoplog gate for spillway opening of size 15 m x 9 m for analysis.
Size of stoplog gate for 15 x 9 m opening at crest with gate sill 0.4 m below crest level :Length of gate in m : Clear opening + 0.65 m : 15.00 + 0.65 : 15.65 m
Height of gate ( total height of gate elements ) in m : FRL - Sill level + 0.2 : 9.60 m
Head of water in m : FRL - Sill level : 9.40 m
Weight of stoplog gate elements in tonne for 15 m x 9 m opening based on empirical formula :
= 0.0553 x ( L2
x H x h )0.716
Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.
Consider weight of embedded parts for stoplog gate @ 4.50 % of weight of gate elements.
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= 0.045 x 0.0553 x ( L2
x H x h )0.716
= 0.0025 x ( 15.652
x 9.6 x 9.4 )0.716
: 3.225
The weight computed as above based on empirical formula is further checked by computing the
actual weight as per embedded parts fabrication drawings for stoplog gate of same size provided
for one of the dam.
Actual weight of embedded parts as per data in Item : 5 of Annexure-2 : 3.179 tonnes
Consider actual weight for data rate analysis.Consider details of Material / Gas cutting / Welding based on fabrication drawings of spillway
stoplog gate embedded parts provided for one of the dam for rate analysis ( for details refer
Item : 5 of Annexure-2 ).
1. Requirement of materials :
a. Structural steel conforming to IS : 2062 :
Angles/ beams/ channels/ bars with 2.5 % wastage ( 421x1.025 ) : 432 kg
Plates / flats with 2.5 % wastage ( 2245 x 1.025 ) : 2301 kg
b. Alloy steel conforming to IS : 1570 :
Stainless steel plates / flats ( 235+166 ) x 1.025 : 411.00 kg
c. Bolt / Nut / Washer conforming to IS : 1363 :
MS bolts and nuts with 2.5 % wastage ( 112 x 1.025 ) : 115 kg
d. Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) :
GP / LH electrodes as per data sheet ( Item:5 Annexure-2 ) : 1973 NosAdd for variations / wastage / misc welding @ 10 % ( 1973 x 0.1 ) : 197 Nos
Total requirement of GP / LH electrodes : 2170 Nos
for stitch welding GP electrodes @t 10 % of total ( 2170 x 0.10 ) : 217 Nos
for run welding LH electrodes @ 90 % of total ( 2170 x 0.90 ) : 1953 Nos
Stainless steel electrodes as per data sheet ( Item:5 Annexure-2 ) : 1095 Nos
Add for variations / wastage @ 5 % ( 1095 x 0.05 ) : 55 Nos
Total requirement of Stainless steel ( SS ) electrodes : 1150 Nos
for stitch welding SS electrodes @t 10 % of total ( 1150 x 0.10 ) : 115 Nos
for run welding SS electrodes @t 90 % of total ( 1150 x 0.90 ) : 1035 Nos
2. Cutting :
Length of cutting assuming cutting for 2 sides as per data sheet : 163 Rm
Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 16 Rm
Total length of cutting : 179 Rm
For cutting structural steel sections to required size gas cutting is assumed for cutting angles /beams / channels / round bars. For plates / flats less than 12 mm in thickness plate shearing
machine and for the remaining sections pug cutting machine is considered.
Length of steel to be cut by using gas manually : 29 m
Length of steel to be cut by gas using pug cutting machine : 120 m
Length of steel to be cut by using shearing machine : 30 m
Time for gas cutting manually at ( av ) 2 m cutting / hour : 15 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 40 hours
Time for cutting by shearing machine at ( av ) 10 m cutting / hour : 3 hoursAcetelyne gas @ 0.6 cum / hour ( 15 + 40 ) x 0.60 : 33 cum
Oxygen gas @ 1.8 cum / hour ( 15 + 40 ) x 1.80 : 99 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 ( 40 x 60 / 50 ) : 48 hours
Use of shearing machine with 50 min / hr working ( 3 x60 / 50 ) : 4 hours
3. Welding :
Length of welding as per data sheet : 303 m
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
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( 217 + 115 ) x 8 / 15 / 2 : 89 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 1953 + 1035 ) x 8 / 15 / 6 : 266 hours
Total : 355 hours
Deploy welding transformer for 355 hours.
Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.
( 89 x 0.25 + 266 x 0.75 ) : 222 hours
4. Planing SS plates for slide block / seal tracks : :
For surface finishing of SS plates for wheel / seal tracks planing machine is considered.
Length of SS plate for surface finishing by planing machine : 50.4 Rm
Length of planing at a time for 4 m stroke planing machine : 3 Rm
Time for planing 3 m length section with 50 min / hour working : 8 hours
Time for planing 50.4 m SS plates ( 50.4 x 8 / 3 ) : 135 hours
5. Surface cleaning and painting :
Painting area for embedded parts at 7 sqm / tonne ( 3.179 x 7 ) : 22 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 22 sqm @ 9 sqm / ltr / coat : 2.5 ltr
4 coats of coal tar epoxy paint 100 micron dry film each coat.
Quantity of coal tar epoxy paint for 22 sqm @ 6 sqm / ltr / coat : 15 ltr
As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment
to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rustingbefore applying primer painting.
Quantity of rust cleaner / inhibitor for 22 sqm at 8 sqm / ltr : 3 ltr
6. Requirement of other machinery :
For drilling holes for anchor bolts and for grinding surface / edges of parts requiring finishing
16 hours use of drilling machine and 16 hours use of grinding machine considered.
For handling and erection 25 t mobile crane for 4 hours and stationery derric crane for 50 hours
considered.
7. Requirement of work force :
Work component Foreman Helper /
Painter Cl-II
Cutting sections 70 hours 5 9 9 18
Drilling holes for anchors / supports 1 2 --- 2
Contd
Requirement of work force ( Contd ):
Work component Foreman Helper /
Painter Cl-II
Contd
Fabricating by stitch welding 89 hours 6 11 --- 22
Run welding 266 hours 3 --- 33 33
Erection of anchors / dogging set 6 12 --- 12Erection of Sill beam / Tracks / Guide 3 3 --- 6
Cleaning surface 20 sqm @ 15 sqm/day --- --- --- 2
Painting ( 5 x 20 ) sqm @ 15 sqm / day --- --- --- 8
Finishing / cleaning / checking 1 1 --- 2
Total : 25 38 42 105
Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision
is considered for welder for stitch welding.
b. Workforce for painting 1 coat primer and 4 coats finishing paint consists of 7 Painters Cl-II
Marker /
Erector /
Gas cutter /
Fabricator /
Fabricator /
Marker /
Gas cutter /
Welder
Welder
Erector /
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at 15 sqm / day and 1 helpers to assist painters.
8. Excise duty on supply :
Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all
taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.
9. Use rate of materials :
Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 4.50
Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00
Life of gas cutting set : 600 hours
Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50
RATE ANALYSIS UNIT : 3.179 tonne
A. MATERIALS:
Sl No Unit Amount
in Rs.
1 Structural steel
Angles / beams / channels / bars kg 432.00 37.95 16394.40
Plates / flats kg 2301.00 40.00 92040.00
2 Stainless steel plate / flats kg 411.00 120.00 49320.003 MS bolts and nuts kg 115.00 55.00 6325.00
4 Oxygen gas cum 99.00 48.00 4752.00
5 Acetyline gas cum 33.00 258.00 8514.00
6 Welding electrodes ( general purpose ) Nos 217.00 6.00 1302.00
7 Welding electrodes ( low hydrogen ) Nos 1953.00 12.00 23436.00
8 Welding electrodes ( stainless steel ) Nos 1150.00 43.00 49450.00
9 Zinc rich epoxy primer ltr 2.50 594.00 1485.00
10 Coal tar epoxy paint ltr 15.00 208.00 3120.00
11 Rust cleaner / inhibitor ltr 3.00 240.00 720.00
12 Use rate welding holder set Hour 355.00 4.50 1597.50
13 Use rate gas cutting torch set Hour 18.00 2.50 45.00
Contd
A. MATERIALS ( Contd ) :
Sl No Unit Amount
in Rs.
Contd
14 Wire brush Nos 3.00 30.00 90.00
15 Sundries LS 72.00 30.00 2160.00
Total Rs: 260750.90
Add for small Tools and Plants @ 1% Rs: 2607.51
Add for Contractor's Profit @ 10% Rs: 26075.09Add for Contractor's Overheads @ 5% Rs: 13037.55
Total cost of Materials : Rs: 302471.04
B. MACHINERY:
Sl No Unit Amount
in Rs.
1 Welding transformer Hour 355.00 12.00 4260.00
Fuel / Energy charges Hour 222.00 60.00 13320.00
Perticulars
Quantity
Quantity
in Rs.
Rate
in Rs.
in Rs.
Rate
Perticulars Quantity Rate
Description
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2 Plate shearing machine Hour 4.00 62.00 248.00
Fuel / Energy charges Hour 4.00 100.00 400.00
3 Pug cutting machine Hour 48.00 16.00 768.00
Fuel / Energy charges Hour 48.00 3.00 144.00
4 Planing machine Hour 135.00 88.00 11880.00
Fuel / Energy charges Hour 135.00 75.00 10125.00
5 Mobile crane 25 t Hour 4.00 3804.00 15216.00
Fuel / Energy charges Hour 4.00 1375.00 5500.00
6 Stationery derric crane Hour 50.00 66.00 3300.00
Fuel / Energy charges Hour 50.00 9.00 450.00
7 Grinding machine Hour 16.00 18.00 288.00
Fuel / Energy charges Hour 16.00 25.00 400.00
8 Drilling machines Hour 16.00 18.00 288.00
Fuel / Energy charges Hour 16.00 25.00 400.00
9 Sundries LS 64.00 30.00 1920.00
Total Rs: 68907.00
Add for small Tools and Plants @ 1% Rs: 689.07
Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 3265.90
Add for Contractor's Overheads @ 5% Rs: 3445.35
Total hire charges of Machinery : Rs: 76307.32
C. LABOUR:
Sl No Unit Amount
in Rs.
1 Crew for Mobile crane Hour 4.00 72.60 290.40
2 Crew for Shearing machine Hour 4.00 45.90 183.60
3 Crew for Planing machine Hour 135.00 73.40 9909.00
4 Crew for Drilling machine Hour 16.00 59.50 952.00
5 Crew for Grinding machine Hour 16.00 59.50 952.00
6 Foreman Day 25.00 177.00 4425.00
7 Marker / Fabricator / Erector Day 38.00 157.50 5985.00
8 Gas cutter Day 9.00 157.50 1417.50
Contd
C. LABOUR ( Contd ) :
Sl No Unit Amount
in Rs.
Contd
9 Welder ( General ) Day 30.00 157.50 4725.00
10 Welder ( X - ray ) Day 3.00 173.25 519.75
11 Helper fabrication / erection Day 95.00 141.50 13442.50
12 Helper for cleaning / painting Day 3.00 141.50 424.50
13 Painter Cl - II Day 7.00 141.50 990.50
14 Electrician Day 2.00 143.00 286.00Total Rs: 44502.75
Add for small Tools and Plants @ 1% Rs: 445.03
Add for Contractor's Profit @ 10% Rs: 4450.28
Add for hidden cost on Labour @ 15% Rs: 6675.41
Add for additional hidden cost on labour @ 15% Rs: 6675.41
Add for Contractor's Overheads @ 5% Rs: 2225.14
Total cost of Labour : Rs: 64974.02
Description Quantity
Description
in Rs.
Rate
in Rs.
Rate
Quantity
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ABSTRACT:
A. Cost of Materials Rs: 302471.04
B. Hire charges of Machinery Rs: 76307.32
C. Cost of Labour Rs: 64974.02
TOTAL Rs: 443752.38
Add for excise duty on 75 percent cost of
Machinery / Labour components @ 8.24% Rs: 8731.19
Add for insurance charges @ 1.00% Rs: 4437.52
Add for designs and drawings @ 2.50% Rs: 11093.81
Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 11093.81
Add for power supply arrangements @ 2.00% Rs: 8875.05
Add for enabling works @ 1.40% Rs: 6212.53
Total Rs: 494196.29
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2 x 3.179 tonnes @ Rs: 129.10 / tonne Rs: 820.82
Add for transportation upto work site @ 3.00% Rs: 14825.89
Total cost for 3.179 tonne Rs: 509843.00
Rate per tonne Rs: 160400.00
Rate approved per tonne Rs: 160400.00
SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 6
ITEM: Design, fabrication, supply, erection, testing and commissioning of vertical lift sliding type all
interchangeable ( except bottom element ) stoplog gate elements consisting of skin plate,
horizontal and vertical girders, stiffeners, lifting pins, bronze padded slide blocks, guide shoes,
rubber seals, clamps etc., with all accessories for spillway including cost of all materials,
machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coat of zinc
rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc.,
complete as per specifications and approved drawings with allleads and lifts.
DATA:Spillway stoplog gate consists of number of vertical lift slide gate elements. Each gate element
consists of skin plate, horizontal girders, vertical end girders, stiffeners, slide blocks, gate guide
shoes, lifting pins and seals with all accessories.
Consider spillway stoplog elements for 15 m x 9 m spillway opening for analysis.
Size of stoplog gate for 15 x 9 m opening at crest with gate sill 0.4 m below crest level :
Length of gate in m : Clear opening + 0.65 m : 15.00 + 0.65 : 15.65 m
Height of gate ( total height of gate elements ) in m : FRL - Sill level + 0.2 : 9.60 m
Head of water in m : FRL - Sill level : 9.40 m
Generally, the height of each stoplog element will be in the range of 1.00 to 1.20 m.
For 9.60 m total height consider 8 stoplog elements of 1.20 m height each.
Weight of stoplog gate elements in tonne for 15 m x 9 m opening based on empirical formula :
= 0.0553 x ( L2
x H x h )0.716
Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.
= 0.0553 x ( 15.65 x 15.65 x 9.6 x 9.4 )0.716
: 71.340
The weight computed as above based on empirical formula is further checked by computing the
actual weight as per fabrication drawings for stoplog gate of same size provided for one of dam.
Actual weight of spillway stoplog elements as per data in Item :6 of Annexure-2 : 71.157 tonnes
Consider actual weight for data rate analysis.
Consider details of Material / Gas cutting / Welding based on fabrication drawings of spillway
stoplog gate elements provided for one of the dam for rate analysis ( for details refer Item : 6
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of Annexure-2 ).
1. Requirement of materials :
a. Structural steel conforming to IS : 2062 :
Angles/ beams/ channels/ bars with 2.5 % wastage ( 461x1.025 ) : 473 kg
Plates / flats with 2.5 % wastage ( 70208 x 1.025 ) : 71963 kg
b. Alloy steel components conforming to IS : 1570 :
Lifting pins : 104 kg
c. Alluminium / Bronze alloy components conforming to IS : 305 :
Bronze pads for slide blocks : 48 kg
d. Bolts / Nuts / Washers conforming to IS : 1363 :
GI bolts / nuts / washers with 2.5 % wastage ( 288 x 1.025 ) : 295 kg
MS bolts / nuts / washers with 2.5 % wastage ( 48 x 1.025 ) : 49 kg
e. Rubber seal conforming to IS : 11855 :
Bottom seal ( 120 x 1.025 ) : 123 Rm
Side seals ( music note type uncladed ) ( 19.2 x 1.025 ) : 20 Rm
f. Welding electrodes ( General purpose / Low hydrogen ) :
GP / LH electrodes as per data sheet ( Item:6 Annexure-2 ) : 33626 Nos
Add for variations / wastage / misc welding @ 10 % ( 33626 x 0.1 ) : 3363 Nos
Total requirement of GP / LH electrodes : 36989 Nos
for stitch weld GP electrodes @t 10 % of total ( 36989 x 0.10 ) : 3699 Nos
for run welding LH electrodes @ 90 % of total ( 36989 x 0.90 ) : 33290 Nos 2. Cutting :
Length of cutting assuming cutting for 2 sides as per data sheet : 980 Rm
Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 98 Rm
Total : 1078 Rm
For cutting structural steel sections to required sizes gas cutting is assumed since most of the
sections are above 10 mm thick.
Length of steel to be cut by using gas manually : 50 m
Length of steel to be cut by gas using pug cutting machine : 1028 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 : 343 hours
Acetelyne gas @ 0.6 cum / hour ( 25 +343 ) x 0.60 : 221 cum
Oxygen gas @ 1.8 cum / hour ( 25 + 343 ) x 1.80 : 663 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 ( 343 x 60 / 50 ) : 412 hours
3. Welding :
Length of welding as per data sheet : 3228 Rm
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 3699 / 15 ) x 8 / 2 : 986 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 33290 / 15 ) x 8 / 6 : 2959 hours
Total : 3945 hours
Deploy welding transformer for 3945 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.
( 986 x 0.25 + 2959 x 0.75 ) : 2466 hours
4. Surface cleaning and painting :
Painting area for stoplog elements at 18 sqm / tonne ( 71.157x18 ) : 1280 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 1280 sqm @ 9 sqm / ltr / coat : 142 ltr
3 coats of coal tar epoxy paint 100 micron dry film each coat.
Quantity of coal tar epoxy paint for 1280 sqm @ 6 sqm / ltr / coat : 640 ltr
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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 1280 sqm at 8 sqm / ltr : 160 ltr
5. Requirement of other machinery :
For handling during fabrication 25 t mobile crane for 100 hours and stationery derric crane for
100 hours considered.
For drilling holes in skin plate and seal clamps for seal fixing 100 hours use of drilling machine
considered.
For grinding and finishing weld joints in skin plate and other locations 200 hours use of grinding
machine considered.
6. Requirement of work force :
Work component Foreman Helper /
Painter Cl-II
Cutting sections 442 hours 28 56 56 112
Drilling holes for seal fixing 6 12 --- 12
Fabricating by stitch welding 986 hours 62 124 --- 248
Run welding 2959 hours 37 --- 370 370
Seal fixing 8 elements @ 2 per day 8 8 --- 16
Cleaning surface1280 sqm @15 sqm/day --- --- --- 85Painting ( 4x1280 ) sqm @ 15 sqm / day --- --- --- 409
Finishing / cleaning / guide shoe fixing 1 2 --- 4
Trial operation and checking 2 2 --- 4
Total : 144 204 426 1260
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 341 Painters Cl-II
at 15 sqm / day and 68 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 : 71.157 tonne
A. MATERIALS: Sl No Unit Amount
in Rs.
1 Structural steel
Angles / beams / channels / bars kg 473.00 37.95 17950.35
Plates / flats kg 71963.00 40.00 2878520.00
2 Alloy steel components
Lifting pins kg 104.00 215.00 22360.00
3 Alluminium / Bronze alloy components
Perticulars
Fabricator /
Marker /
Erector /
Welder
Gas cutter /
Quantity Rate
in Rs.
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Bronze pads kg 48.00 635.00 30480.00
4 Bolt / Nut / Washer
GI bolts / nuts / washers kg 295.00 95.00 28025.00
MS bolts / nuts / washers kg 49.00 55.00 2695.00
5 Rubber seals
Bottom seal Rm 123.00 147.00 18081.00
Side seals ( uncladed ) Rm 20.00 235.00 4700.00
6 Oxygen gas cum 663.00 48.00 31824.00
7 Acetyline gas cum 221.00 258.00 57018.00
8 Welding electrodes ( general purpose ) Nos 3699.00 6.00 22194.00
9 Welding electrodes ( low hydrogen ) Nos 33290.00 12.00 399480.00
10 Zinc rich epoxy primer ltr 142.00 594.00 84348.00
11 Coal tar epoxy paint ltr 640.00 208.00 133120.00
12 Rust cleaner / inhibitor ltr 160.00 240.00 38400.00
13 Use rate welding holder set Hour 3945.00 4.50 17752.50
14 Use rate gas cutting torch set Hour 30.00 2.50 75.00
15 Wire brush Nos 13.00 30.00 390.00
16 Sundries LS 150.00 30.00 4500.00
Total Rs: 3791912.85
Add for small Tools and Plants @ 1% Rs: 37919.13
Add for Contractor's Profit @ 10% Rs: 379191.29Add for Contractor's Overheads @ 5% Rs: 189595.64
Total cost of Materials : Rs: 4398618.91
B. MACHINERY:
Sl No Unit Amount
in Rs.
1 Welding transformer Hour 3945.00 12.00 47340.00
Fuel / Energy charges Hour 2466.00 60.00 147960.00
Contd
B. MACHINERY ( Contd ) :
Sl No Unit Amount
in Rs.
Contd
2 Pug cutting machine Hour 412.00 16.00 6592.00
Fuel / Energy charges Hour 412.00 3.00 1236.00
3 Mobile crane 25 t Hour 100.00 3804.00 380400.00
Fuel / Energy charges Hour 100.00 1375.00 137500.00
4 Stationery derric crane Hour 100.00 66.00 6600.00
Fuel / Energy charges Hour 100.00 9.00 900.00
5 Grinding machine Hour 200.00 18.00 3600.00
Fuel / Energy charges Hour 200.00 25.00 5000.00
6 Drilling machines Hour 100.00 18.00 1800.00Fuel / Energy charges Hour 100.00 25.00 2500.00
7 Sundries LS 150.00 30.00 4500.00
Total Rs: 745928.00
Add for small Tools and Plants @ 1% Rs: 7459.28
Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 29959.60
Add for Contractor's Overheads @ 5% Rs: 37296.40
Total hire charges of Machinery : Rs: 820643.28
Description Quantity
in Rs.
Rate
Description Quantity Rate
in Rs.
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C. LABOUR:
Sl No Unit Amount
in Rs.
1 Crew for Mobile crane Hour 100.00 75.70 7570.00
2 Crew for Drilling machine Hour 100.00 59.50 5950.00
3 Crew for Grinding machine Hour 200.00 59.50 11900.00
4 Foreman Day 144.00 177.00 25488.00
5 Marker / Fabricator / Erector Day 204.00 157.50 32130.00
6 Gas cutter Day 56.00 157.50 8820.00
7 Welder ( General ) Day 333.00 157.50 52447.50
8 Welder ( X - ray ) Day 37.00 173.25 6410.25
9 Khalasi Day 150.00 145.50 21825.00
10 Helper fabrication / erection Day 766.00 141.50 108389.00
11 Helper cleaning / painting Day 153.00 141.50 21649.50
12 Painter Cl - II Day 341.00 141.50 48251.50
13 Electrician Day 5.00 143.00 715.00
Total Rs: 351545.75
Add for small Tools and Plants @ 1% Rs: 3515.46
Add for Contractor's Profit @ 10% Rs: 35154.58
Add for hidden cost on Labour @ 15% Rs: 52731.86
Add for additional hidden cost on labour @ 15% Rs: 52731.86Add for Contractor's Overheads @ 5% Rs: 17577.29
Total cost of Labour : Rs: 513256.80
ABSTRACT:
A. Cost of Materials Rs: 4398618.91
B. Hire charges of Machinery Rs: 820643.28
C. Cost of Labour Rs: 513256.80
TOTAL Rs: 5732518.98
Add for excise duty on 75 percent cost of
Machinery / Labour components @ 8.24% Rs: 82435.02
Add for insurance charges @ 1.00% Rs: 57325.19
Add for designs and drawings @ 2.50% Rs: 143312.97
Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 143312.97
Add for power supply arrangements @ 2.00% Rs: 114650.38
Add for enabling works @ 1.40% Rs: 80255.27
Total Rs: 6353810.79
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x71.157 tonnes @ Rs: 129.10 / tonne Rs: 18372.74
Add for transportation upto work site @ 3.00% Rs: 190614.32
Total cost for 71.157 tonne Rs: 6562797.85
Rate per tonne Rs: 92200.00
Rate approved per tonne Rs: 92200.00
SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 7
ITEM: Design, fabrication, supply, erection, testing and commissioning of automatic lifting beam
with all accessories for handling, lowering and lifting of spillway stop log gate elements
including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning,
applying one coat of zinc rich epoxy primer and two coats of cold applied coal tar epoxy paint
etc., complete as per specifications and drawings withallleads and lifts.
in Rs.
RateDescription Quantity
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DATA:Automatic lifting beam for lifting spillway stop log elements consists of fabricated beam with
lifting bracket and automatic engaging / dis-engaging type hooks for under water hooking /
de-hooking of gate element. Lifting beam is an independent attachment to moving gantry crane.
Consider lifting beam for stoplog element for spillway opening of size 15 m x 9 m for analysis.
Spillway stoplog gate consists of number of elements of convenient height. Generally the height
of each stoplog element will be in the range of 1.00 to 1.20 m.
For 9.60 m height of stoplog gate the number of elements of 1.2 m each will be 8.
Generally the weight of lifting beam for spillway stoplog element will be about 40 percent of the
weight of one stoplog element.
Size of stoplog gate for 15 x 9 m opening at crest with gate sill 0.4 m below crest level :
Length of gate in m : Clear opening + 0.65 m : 15.00 + 0.65 : 15.65 m
Height of gate ( total height of gate elements ) in m : FRL - Sill level + 0.2 : 9.60 m
Head of water in m : FRL - Sill level : 9.40 m
Weight of stoplog gate elements in tonne for 15 m x 9 m opening based on empirical formula :
= 0.0553 x ( L2x H x h )
0.716
Consider weight of lifting beam in tonnes @ 40 % of weight of one stoplog element:
= 0.40 x 0.0553 x ( L2
x H x h )0.716
/ n
Where ( L ) is length and ( H ) is total height and ( h ) is head of water in metres and ( n ) is the
number of stoplog gate elements. = 0.0221 x ( 15.65 x 15.65 x 9.6 x 9.4 )
0.716/ 8 : 3.567
The weight computed as above based on empirical formula is further checked by computing the
actual weight as per fabrication drawings for lifting beam for stoplog gate of same size provided
for one of the dam.
Actual weight of stoplog gate lifting beam as per data in Item : 7 of Annexure-2 : 3.528 tonnes
Consider actual weight for data rate analysis.
Consider details of Material / Gas cutting / Welding based on fabrication drawings of lifting
beam for spillway stoplog elements provided for one of the dam for rate analysis ( for details
refer Item : 7 of Annexure-2 ).
1. Requirement of materials :
a. Structural steel conforming to IS : 2062 :
Angles / beams / channels / bars with 2.5 % wastage ( 13 x 1.025 ) : 13 kg
Plates / flats with 2.5 % wastage ( 3306 x 1.025 ) : 3389 kg
b. Alloy steel components conforming to IS : 1570 :
Lifting pins : 101 kg
c. Alluminium / Bronze alloy components conforming to IS : 305 :
Bronze Bush : 5 kg
d. Forged steel components conforming to IS : 2004 :
Lifting hooks : 130 kg
e. Bolts / Nuts / Washers conforming to IS : 1363 :
MS bolts / nuts / washers with 2.5 % wastage : 3 kg
MS pipe 100 mm dia : 11 kgf. Welding electrodes ( General purpose / Low hydrogen ) :
GP / LH electrodes as per data sheet ( Item:7 Annexure-2 ) : 2121 Nos
Add for variations / wastage / misc welding @ 10 % ( 2121 x 0.1 ) : 212 Nos
Total requirement of GP / LH electrodes : 2333 Nos
for stitch weld GP electrodes @t 10 % of total ( 2333 x 0.10 ) : 233 Nos
for run welding LH electrodes @ 90 % of total ( 2333 x 0.90 ) : 2100 Nos
2. Cutting :
Length of cutting assuming cutting for 2 sides as per data sheet : 172 Rm
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Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 17 Rm
Total : 189 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas manually : 40 m
Length of steel to be cut by gas using pug cutting machine : 149 m
Time for gas cutting manually at ( av ) 2 m cutting / hour : 20 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 50 hours
Acetelyne gas @ 0.6 cum / hour ( 20 + 50 ) x 0.60 : 42 cum
Oxygen gas @ 1.8 cum / hour ( 20 + 50 ) x 1.80 : 126 cum
Use of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) : 24 hours
Use of pug cutting machine with 50 min / hr working ( 50 x 60 / 50 ) : 60 hours
3. Welding :
Length of welding as per data sheet : 211 Rm
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 233 / 15 ) x 8 / 2 : 62 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 2100 / 15 ) x 8 / 6 : 187 hours
Total : 249 hours
Deploy welding transformer for 249 hours.
Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.
( 62 x 0.25 + 187 x 0.75 ) : 156 hours 4. Surface cleaning and painting :
Painting area for lifting beam at 12 sqm / tonne ( 3.528 x 12 ) : 42 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 42 sqm @ 9 sqm / ltr / coat : 5 ltr
2 coats of coal tar epoxy paint 100 micron dry film each coat.
Quantity of coal tar epoxy paint for 42 sqm @ 6 sqm / ltr / coat : 14 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 42 sqm @ 8 sqm / ltr : 5 ltr
5. Requirement of other machinery :
For handling during fabrication 8 t mobile crane for 2 hours and stationery derric crane for
4 hours considered.
For drilling holes for pins / guide shoes 2 hours use of drilling machine considered.
For grinding and finishing weld joints 2 hours use of grinding machine considered.
6. Requirement of work force :
Work component Foreman Helper /
Painter Cl-II
Cutting sections 84 hours 6 11 11 22
Drilling holes for pins / bolts fixing --- 1 --- 1Fabricating by stitch welding 62 hours 4 8 --- 16
Run welding 187 hours 2 --- 24 24
Cleaning surface 42 sqm @ 15 sqm/day --- --- --- 3
Painting ( 3 x 42 ) sqm @ 15 sqm / day --- --- --- 10
Finishing / guide shoe fixing / checking --- 1 --- 1
Total : 12 21 35 77
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.
Gas cutter /
Fabricator /
Erector /
Marker /
Welder
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b. Workforce for painting 1 coat primer and 2 coats finishing paint consists of 8 Painters Cl-II
at 15 sqm / day and 2 helpers to assist painters.
7. Excise duty on supply :
Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all
taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.
8. Use rate of materials :
Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 4.50
Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00
Life of gas cutting set : 600 hours
Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50
RATE ANALYSIS UNIT : 3.528 tonne
A. MATERIALS:
Sl No Unit Amount
in Rs.
1 Structural steel
Angles / beams / channels / bars kg 13.00 37.95 493.35Plates / flats kg 3389.00 40.00 135560.00
2 Alloy steel components
Lifting pins kg 101.00 215.00 21715.00
Contd
A. MATERIALS ( Contd ) :
Sl No Unit Amount
in Rs.
Contd
3 Bronze alloy components :
Bronze bush kg 5.00 635.00 3175.00
4 Forged steel components :
Lifting hooks kg 103.00 165.00 16995.00
5 MS pipe 100 mm dia kg 11.00 45.00 495.00
6 Bolt / Nut / Washer
MS bolts / nuts / washers kg 3.00 55.00 165.00
7 Oxygen gas cum 126.00 48.00 6048.00
8 Acetyline gas cum 42.00 258.00 10836.00
9 Welding electrodes ( general purpose ) Nos 233.00 6.00 1398.00
10 Welding electrodes ( low hydrogen ) Nos 2100.00 12.00 25200.00
11 Zinc rich epoxy primer ltr 5.00 594.00 2970.00
12 Coal tar epoxy paint ltr 14.00 208.00 2912.0013 Rust cleaner / inhibitor ltr 5.00 240.00 1200.00
14 Use rate welding holder set Hour 249.00 4.50 1120.50
15 Use rate gas cutting torch set Hour 24.00 2.50 60.00
16 Wire brush Nos 1.00 30.00 30.00
17 Sundries LS 20.00 30.00 600.00
Total Rs: 230972.85
Add for small Tools and Plants @ 1% Rs: 2309.73
Add for Contractor's Profit @ 10% Rs: 23097.29
Quantity Rate
in Rs.
in Rs.
Perticulars Quantity Rate
Perticulars
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Add for Contractor's Overheads @ 5% Rs: 11548.64
Total cost of Materials : Rs: 267928.51
B. MACHINERY:
Sl No Unit Amount
in Rs.
1 Welding transformer Hour 249.00 12.00 2988.00
Fuel / Energy charges Hour 156.00 60.00 9360.00
2 Pug cutting machine Hour 60.00 16.00 960.00
Fuel / Energy charges Hour 60.00 3.00 180.00
3 Mobile crane 8 t Hour 2.00 362.00 724.00
Fuel / Energy charges Hour 2.00 495.00 990.00
4 Stationery derric crane Hour 4.00 66.00 264.00
Fuel / Energy charges Hour 4.00 9.00 36.00
5 Grinding machine Hour 2.00 18.00 36.00
Fuel / Energy charges Hour 2.00 25.00 50.00
6 Drilling machines Hour 2.00 18.00 36.00
Fuel / Energy charges Hour 2.00 25.00 50.00
7 Sundries LS 15.00 30.00 450.00
Total Rs: 16124.00
Add for small Tools and Plants @ 1% Rs: 161.24Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 1111.60
Add for Contractor's Overheads @ 5% Rs: 806.20
Total hire charges of Machinery : Rs: 18203.04
C. LABOUR:
Sl No Unit Amount
in Rs.
1 Crew for Mobile crane Hour 2.00 75.70 151.40
2 Crew for Drilling machine Hour 2.00 59.50 119.00
3 Crew for Grinding machine Hour 2.00 59.50 119.00
4 Foreman Day 12.00 177.00 2124.00
5 Marker / Fabricator / Erector Day 21.00 157.50 3307.50
6 Gas cutter Day 11.00 157.50 1732.50
7 Welder ( General ) Day 24.00 157.50 3780.00
8 Helper fabrication / erection Day 64.00 141.50 9056.00
9 Helper for cleaning / painting Day 5.00 141.50 707.50
10 Painter Cl - II Day 8.00 141.50 1132.00
11 Electrician Day 1.00 143.00 143.00
Total Rs: 22371.90
Add for small Tools and Plants @ 1% Rs: 223.72
Add for Contractor's Profit @ 10% Rs: 2237.19
Add for hidden cost on Labour @ 15% Rs: 3355.79Add for additional hidden cost on labour @ 15% Rs: 3355.79
Add for Contractor's Overheads @ 5% Rs: 1118.60
Total cost of Labour : Rs: 32662.97
ABSTRACT:
A. Cost of Materials Rs: 267928.51
B. Hire charges of Machinery Rs: 18203.04
C. Cost of Labour Rs: 32662.97
QuantityDescription
in Rs.
Rate
in Rs.
Rate
QuantityDescription
39
8/13/2019 Data Rates Gate Works 2
21/21
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