Data Rates Gate Works 5

8/13/2019 Data Rates Gate Works 5

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GATE / HOIST AND ALLIED WORKS

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 : 9.088 tonne

A. MATERIALS:

Sl No Unit Amount

in Rs.

1 Structural steel

Angles / beams / channels / bars kg 1017.00 37.95 38595.15

Plates / flats kg 7617.00 40.00 304680.00

2 Stainless steel plate / flats kg 442.00 120.00 53040.00

3 MS bolts and nuts kg 240.00 55.00 13200.00

4 Oxygen gas cum 180.00 48.00 8640.00

5 Acetyline gas cum 60.00 258.00 15480.00

6 Welding electrodes ( general purpose ) Nos 578.00 6.00 3468.00

7 Welding electrodes ( low hydrogen ) Nos 5204.00 12.00 62448.00

8 Welding electrodes ( stainless steel ) Nos 790.00 43.00 33970.00

9 Zinc rich epoxy primer ltr 10.00 594.00 5940.00

10 Coal tar epoxy paint ltr 61.00 208.00 12688.00

11 Rust cleaner / inhibitor ltr 12.00 240.00 2880.0012 Use rate welding holder set Hour 701.00 4.50 3154.50

13 Use rate gas cutting torch set Hour 36.00 2.50 90.00

14 Wire brush Nos 2.00 30.00 60.00

15 Sundries LS 25.00 30.00 750.00

Total Rs: 559083.65

Add for small Tools and Plants @ 1% Rs: 5590.84

Add for Contractor's Profit @ 10% Rs: 55908.37

Add for Contractor's Overheads @ 5% Rs: 27954.18

Total cost of Materials : Rs: 648537.03

B. MACHINERY:

Sl No Unit Amount

in Rs.

1 Welding transformer Hour 701.00 12.00 8412.00

Fuel / Energy charges Hour 438.00 60.00 26280.00

2 Plate shearing machine Hour 7.00 62.00 434.00


Contd

B. MACHINERY ( Contd ) :

Sl No Unit Amount

in Rs.Contd

3 Pug cutting machine Hour 84.00 16.00 1344.00


4 Planing machine Hour 69.00 88.00 6072.00


5 Mobile crane 8 t Hour 4.00 362.00 1448.00


6 Stationery derric crane Hour 40.00 66.00 2640.00

Description

Perticulars

in Rs.

Quantity Rate

in Rs.

Quantity Rate

Description Quantity Rate

in Rs.

80


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7 Grinding machine Hour 25.00 18.00 450.00


8 Drilling machines Hour 50.00 18.00 900.00


9 Sundries LS 25.00 30.00 750.00

Total Rs: 59072.00


Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 3737.20


Total hire charges of Machinery : Rs: 66353.52

C. LABOUR:

Sl No Unit Amount

in Rs.

1 Crew for Mobile crane Hour 4.00 75.70 302.80

2 Crew for Shearing machine Hour 7.00 45.90 321.30

3 Crew for Planing machine Hour 69.00 73.40 5064.60

4 Crew for Drilling machine Hour 50.00 59.50 2975.00

5 Crew for Grinding machine Hour 25.00 59.50 1487.50

6 Foreman Day 42.00 177.00 7434.007 Marker / Fabricator / Erector Day 68.00 157.50 10710.00

8 Gas cutter Day 16.00 157.50 2520.00

9 Welder ( General ) Day 59.00 157.50 9292.50

10 Welder ( X - ray ) Day 7.00 173.25 1212.75

11 Helper fabrication / erection Day 186.00 141.50 26319.00

12 Helper for cleaning / painting Day 12.00 141.50 1698.00

13 Painter Cl - II Day 30.00 141.50 4245.00

14 Electrician Day 2.00 143.00 286.00

Total Rs: 73868.45



Add for hidden cost on Labour @ 15% Rs: 11080.27

Add for additional hidden cost on labour @ 15% Rs: 11080.27


Total cost of Labour : Rs: 107847.94

ABSTRACT:

A. Cost of Materials Rs: 648537.03

B. Hire charges of Machinery Rs: 66353.52

C. Cost of Labour Rs: 107847.94TOTAL Rs: 822738.49

Add for excise duty on 75 percent cost of

Machinery / Labour components @ 8.24% Rs: 10765.65

Add for insurance charges @ 1.00% Rs: 8227.38

Add for designs and drawings @ 2.50% Rs: 20568.46

Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 20568.46

Add for power supply arrangements @ 2.00% Rs: 16454.77

Add for enabling works @ 1.40% Rs: 11518.34

RateQuantity

in Rs.

Description

81


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Total Rs: 910841.56

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

Fabricated parts 2 x 9.088 tonnes @ Rs: 129.10 / tonne Rs: 2346.52

Add for transportation upto work site @ 3.00% Rs: 27325.25

Total cost for 9.088 tonne Rs: 940513.33

Rate per tonne Rs: 103500.00

Rate approved per tonne Rs: 103500.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 17

ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type vertical lift

emergency gateconsisting of skin plate, horizontal and vertical girders, wheels, stiffeners,

lifting brackets, guide rollers, ballast blocks, teflon claded rubber seals etc., with all accessories

for river sluice / canal sluice vent including cost of all materials, machinery, labour, cutting,

aligning, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and three

coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications

and approved drawings with all leads and lifts.

DATA:Consider upstream seal vertical lift roller gate. The gate leaf consists of skin plate, horizontal

girders, vertical end girders, stiffeners, wheels, gate guide rollers, brackets for hooks, seals

etc., with all accessories.Consider river / canal sluice emergency gate for 2.5 m x 3 m sluice opening for analysis.

For vent opening of 2.5 x 3.0 m approximate size of gate leaf will be : 3.2 m x 3.3 m

Head of water above sill level considered : 34 m

Weight of vertical lift roller gate in tonnes including ballast based on empirical formula :

= 0.0888 ( L2

x H x h )0.659

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

= 0.0888 ( 3.2 x 3.2 x 3.3 x 34 )0.659

: 9.229

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

actual weight as per fabrication drawings for river sluice emergency gate of same size provided

for one of the dam.

Actual wt of river sluice emergency gate as per data in Item :17 of Annexure-2 : 9.215 tonnes

Consider actual weight for data rate analysis.

Consider details of Material / Gas cutting / Welding based on fabrication drawings of river sluicegate provided for one of the dam for rate analysis ( for details refer Item:17 of Annexure-2 ).

1. Requirement of materials :

a. Structural steel conforming to IS : 2062 :

Plates / flats with 2.5 % wastage ( 4301 x 1.025 ) : 4409 kg

b. Cast iron components conforming to IS : 210 :

Cast iron blocks for counter weight ( 4000 x 1.025 ) : 4100 kgc. Alloy steel components conforming to IS : 1570 :

Wheel axles / Pins : 144 kg

d. Cast steel components conforming to IS : 1030 :

Wheels / guide rollers : 492 kg

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

Bearings / Bushes : 76 kg

f. Bolts / Nuts / Washers conforming to IS : 1363 :

SS bolts / nuts / washers with 2.5 % wastage ( 54 x 1.025 ) : 55 kg

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GI bolts / nuts / washers with 2.5 % wastage ( 144 x 1.025 ) : 148 kg

MS bolts / nuts / washers with 2.5 % wastage ( 4 x 1.025 ) : 4 kg

g. Rubber seal conforming to IS : 11855 :

Bottom seal ( flat uncladed ) ( 2.76 x 1.025 ) : 2.8 Rm

Top seal ( bulb type teflon claded ) ( 2.2 x 1.025 ) : 2.25 Rm

Side seals ( bulb type teflon claded ) ( 5.71 x 1.025 ) : 5.85 Rm

Corner seal ( bulb teflon claded ) : 2 Nos

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

GP / LH electrodes as per data sheet ( Item:17 Annexure-2 ) : 3017 Nos

Add for variations / wastage / misc welding @ 10 % ( 3017 x 0.1 ) : 302 Nos

Total requirement of GP / LH electrodes : 3319 Nos

for stitch weld GP electrodes @t 10 % of total ( 3319 x 0.10 ) : 332 Nos

for run welding LH electrodes @ 90 % of total ( 3319 x 0.90 ) : 2987 Nos

2. Cutting :

Length of cutting assuming cutting for 2 sides as per data sheet : 134 Rm

Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 13 Rm

Total : 147 Rm

For cutting structural steel sections to required sizes gas cutting is assumed since most of the

sections are above 10 mm thick.

Length of steel to be cut by using gas manually : 29 m

Length of steel to be cut by gas using pug cutting machine : 118 mTime for gas cutting manually at ( av ) 2 m cutting / hour : 15 hours

Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 39 hours

Acetelyne gas @ 0.6 cum / hour ( 15 + 39 ) x 0.60 : 32 cum

Oxygen gas @ 1.8 cum / hour ( 15 + 39 ) x 1.80 : 96 cum

Use of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hours

Use of pug cutting machine with 50 min / hr working ( 39 x 60 / 50 ) : 47 hours

3. Welding :

Length of welding as per data sheet : 271 Rm

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

( 332 / 15 ) x 8 / 2 : 89 hours

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

( 2987 / 15 ) x 8 / 6 : 265 hours

Total : 354 hours

Deploy welding transformer for 354 hours.

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

( 89 x 0.25 + 265 x 0.75 ) : 221 hours

4. Surface cleaning and painting :

Painting area for river sluice gate at 10 sqm / tonne ( 9.215 x 10 ) : 92 sqm

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

Quantity of primer paint for 92 sqm @ 9 sqm / ltr / coat : 10 ltr

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

Quantity of coal tar epoxy paint for 92 sqm @ 6 sqm / ltr / coat : 46 ltr As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment

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

before applying primer painting.

Quantity of rust cleaner / inhibitor for 92 sqm @ 8 sqm / ltr : 12 ltr

5. Requirement of other machinery :

For lowering gate leaf from hoist chamber use of tower crane for 1 hour considered.

For handling of gate parts during fabrication and erection 8 t mobile crane for 4 hours and

stationery derric crane for 10 hours considered.

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SS bolts / nuts / washers kg 55.00 150.00 8250.00

GI bolts / nuts / washers kg 148.00 95.00 14060.00

MS bolts / nuts / washers kg 4.00 55.00 220.00

7 Rubber seals

Bottom seal ( flat uncladed ) Rm 2.80 147.00 411.60

Side seals ( bulb teflon claded ) Rm 5.85 675.00 3948.75

Top seal ( bulb teflon claded ) Rm 2.25 675.00 1518.75

Corner seals ( bulb teflon claded ) Nos 2.00 740.00 1480.00

8 Oxygen gas cum 96.00 48.00 4608.00






14 Rust cleaner / inhibitor ltr 12.00 240.00 2880.00

15 Use rate welding holder set Hour 354.00 4.50 1593.00


17 Wire brush Nos 1.00 30.00 30.00

18 Sundries LS 5.00 30.00 150.00

Total Rs: 549075.10

Add for small Tools and Plants @ 1% Rs: 5490.75Add for Contractor's Profit @ 10% Rs: 54907.51



B. MACHINERY:

Sl No Unit Amount

in Rs.





3 Tower crane Hour 1.00 994.00 994.00


Contd


Sl No Unit Amount

in Rs.

Contd




Fuel / Energy charges Hour 10.00 9.00 90.006 Grinding machine Hour 8.00 18.00 144.00




8 Sundries LS 5.00 30.00 150.00

Total Rs: 24541.00



Description Quantity


Rate

in Rs.

in Rs.

85


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C. LABOUR:

Sl No Unit Amount

in Rs.

1 Crew for Mobile crane Hour 4.00 75.70 302.80

2 Crew for Tower crane Hour 1.00 62.00 62.00



5 Foreman Day 17.00 177.00 3009.00

6 Marker / Fabricator / Erector Day 25.00 157.50 3937.50

7 Gas cutter Day 8.00 157.50 1260.00


9 Welder ( X - ray grade ) Day 4.00 173.25 693.00

10 Khalasi Day 4.00 145.50 582.00



13 Painter Cl - II Day 25.00 141.50 3537.50

14 Electrician Day 2.00 143.00 286.00

Total Rs: 31924.30Add for small Tools and Plants @ 1% Rs: 319.24






ABSTRACT:



C. Cost of Labour Rs: 46609.48

TOTAL Rs: 711165.15








Total Rs: 782602.59

Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2 x 9.215 tonnes @ Rs: 129.10 / tonne Rs: 2379.31






Rate

in Rs.

QuantityDescription

86


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ITEM: Design, fabrication, supply, erection, testing and commissioning of automatic lifting beam

with all accessories for handling, lowering and lifting of river sluice / canal sluice emergency

gate including cost of all materials, machinery, labour, cutting, aligning, welding, finishing,

cleaning, applying one coat of zinc rich epoxy primer and two coats of cold applied coal tar

epoxy paint etc., complete as per specifications and drawings with all leads and lifts.

DATA:Automatic lifting beam for lifting river sluice emergency gate consists of fabricated beam with

lifting bracket and automatic engaging / dis-engaging type hooks for under water hooking /

de-hooking of gate leaf. Lifting beam is an independent attachment to moving gantry crane.

Generally the weight of lifting beam for river sluice emergency gate will be about 10 percent of

the weight of gate leaf with ballast.

Consider river sluice emergency gate for sluice opening of size 2.5 m x 3 m for analysis.

For vent opening of 2.5 x 3.0 m approximate size of gate leaf will be : 3.2 m x 3.3 m

Head of water above sill level considered : 34 m

Weight of vertical lift roller gate in tonnes including weight of ballast as per empirical formula :

= 0.0888 ( L2x H x h )

0.659


Consider weight of lifting beam @ 10 % of weight of gate including ballast:

= 0.10 x 0.0888 ( L2x H x h )

0.659

= 0.0089 ( 3.2 x 3.2 x 3.3 x 34 )0.659

: 0.925 tonneThe weight computed as above based on empirical formula is further checked by computing the

actual weight as per fabrication drawings of lifting beam for river sluice emergency gate of same

size provided for one of the dam.

Actual weight of lifting beam as per data in Item : 18 of Annexure-2 : 0.922 tonne


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

beam for river sluice emergency gate provided for one of the dam for rate analysis ( for details

refer Item : 18 of Annexure-2 ).


a. Structural steel :

Angles/ beams/ channels/ bars with 2.5 % wastage ( 228x1.025 ) : 234 kg


b. Alloy steel components :

Pins : 71 kg

c. Bronze alloy components :

Bush : 4 kg

d. Forged steel components :

Hooks : 130 kg

e. Bolts / Nuts / Washers :

MS bolts / nuts / washers with 2.5 % wastage ( 2 x 1.025 ) : 2 kg

f. MS pipe 100 mm dia : 11 kg

g. Welding electrodes ( General purpose / Low hydrogen ) :GP / LH electrodes as per data sheet ( Item:18 Annexure-2 ) : 508 Nos





2. Cutting :



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Total : 47 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 : 37 m

Time for gas cutting manually at ( av ) 2 m cutting / hour : 5 hours






3. Welding :



( 56 / 15 ) x 8 / 2 : 15 hours


( 503 / 15 ) x 8 / 6 : 45 hours

Total : 60 hours



( 15 x 0.25 + 45 x 0.75 ) : 38 hours

4. Surface cleaning and painting :Painting area for lifting beam at 12 sqm / tonne ( 0.922 x 12 ) : 11 sqm


Quantity of primer paint for 11 sqm @ 9 sqm / ltr / coat : 1.25 ltr


Quantity of coal tar epoxy paint for 11 sqm @ 6 sqm / ltr / coat : 4 ltr

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



Quantity of rust cleaner / inhibitor for 11 sqm @ 8 sqm / ltr : 1.5 ltr


For drilling holes for pins / guide shoes 2 hours use of drilling machine considered.

For grinding and finishing weld joints 2 hour use of grinding machine considered.

6. Requirement of work force :

Work component Foreman Helper /

Painter Cl-II

Cutting sections 21 hours 1 3 3 6

Drilling holes for pins / bolts fixing --- 1 --- 1

Fabricating by stitch welding 15 hours 1 2 --- 4

Run welding 45 hours 1 --- 6 6

Cleaning surface 11 sqm @ 15 sqm/day --- --- --- 1

Painting ( 3 x 11 ) sqm @ 15 sqm / day --- --- --- 3Finishing / guide shoe fixing / checking --- 1 --- 1

Total : 3 7 9 22

Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision

is considered for welder for stitch welding.

b. Workforce for painting 1 coat primer and 2 coats finishing paint consists of 2 Painters Cl-II

at 15 sqm / day and 1 helper to assist painters.

7. Excise duty on supply :

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

Gas cutter /Marker /

Erector /

Fabricator / Welder

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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





A. MATERIALS:

Sl No Unit Amount

in Rs.

1 Structural steel


Plates / flats kg 488.00 40.00 19520.00

2 Alloy steel components

Lifting pins kg 71.00 215.00 15265.00

3 Bronze alloy components :

Bronze bush kg 4.00 635.00 2540.004 Forged steel components :

Lifting hooks kg 130.00 165.00 21450.00

5 MS pipe 100 mm dia kg 11.00 45.00 495.00

6 Bolt / Nut / Washer


7 Oxygen gas cum 30.00 48.00 1440.00




Contd

A. MATERIALS ( Contd ) :

Sl No Unit Amount

in Rs.

Contd






16 Wire brush Nos 1.00 30.00 30.00

17 Sundries LS 5.00 30.00 150.00

Total Rs: 81051.80Add for small Tools and Plants @ 1% Rs: 810.52




B. MACHINERY:

Sl No Unit Amount

in Rs.

Rate

QuantityPerticulars Rate

in Rs.

Perticulars Quantity Rate

Description

in Rs.

in Rs.

Quantity

89


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5 Sundries LS 3.00 30.00 90.00

Total Rs: 3547.00





C. LABOUR:

Sl No Unit Amount

in Rs.



3 Foreman Day 3.00 177.00 531.004 Marker / Fabricator / Erector Day 7.00 157.50 1102.50

5 Gas cutter Day 3.00 157.50 472.50




9 Painter Cl - II Day 2.00 141.50 283.00

10 Electrician Day 1.00 143.00 143.00

Total Rs: 6545.00

Contd

C. LABOUR ( Contd ) :

Sl No Unit Amount

in Rs.

Contd







ABSTRACT:

A. Cost of Materials Rs: 94020.09B. Hire charges of Machinery Rs: 4011.32


TOTAL Rs: 107587.11







in Rs.

in Rs.

Description RateQuantity

90


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Total Rs: 118538.74








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

sill beam, wheel tracks, seal seats / tracks, guide rails, etc., with all accessories for vertical

lift barrage gate including cost of all materials, machinery, labour, cutting, aligning, anchoring,

welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold

applied coal tar epoxy paint, etc., complete as per specifications and aproved drawings with

all leads and lifts.

DATA:Barrage gate embedded parts consist of sill beam, wheel tracks / seal tracks and gate guides

with accessories such as first / second stage anchors.Weight of embedded parts for barrage gate will be about 15 to 20 percent of gate weight.

Consider embedded parts for vertical lift gate for barrage opening of size 13.7 m x 8.26 m.

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

Head of water above sill level considered : 8.26 m

Weight of vertical lift barrage gate in tonnes based on empirical formula :

= 0.0335 ( L2x H x h )

0.716


Consider weight of embedded parts @ 17.5 % of weight of gate leaf :

= 0.175 x 0.0335 ( L2x H x h )

0.716

= 0.0058 ( 14.7 x 14.7 x 8.6 x 8.26 )0.716

: 5.763 tonnes


actual weight as per fabrication drawings of embedded parts for vertical lift barrage gate of same

size provided for one of the barrage.

Actual weight of embedded parts as per data in Item :19 of Annexure-2 : 5.193 tonnes


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

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

refer Item : 19 of Annexure-2 ).


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 ( 620 + 133 ) x 1.025 : 772.00 kg

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

MS bolts and nuts with 2.5 % wastage ( 167 x 1.025 ) : 171 kg

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


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for stitch welding GP electrodes @t 10 % of total ( 1907 x 0.10 ) : 191 Nos


Stainless steel electrodes as per data sheet ( Item:19 Annexure-2 ) : 1282 Nos

Add for variations / wastage @ 5 % ( 1282 x 0.05 ) : 64 Nos

Total requirement of Stainless steel ( SS ) electrodes : 1346 Nos

for stitch weld SS electrodes @t 10 % of total ( 1346 x 0.10 ) : 135 Nos

for run weld SS electrodes @t 90 % of total ( 1346 x 0.90 ) : 1211 Nos

2. Cutting :



Total length of cutting Total : 231 Rm

For cutting structural steel sections to required size gas cutting and use of plate shearing

machine is considered.



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



Time for cutting by shearing machine at ( av ) 10 m cutting / hour : 3 hoursAcetelyne gas @ 0.6 cum / hour ( 25 + 50 ) x 0.60 : 45 cum




Use of shearing machine with 50 min / hr working ( 3 x 60 / 50) : 4 hours

3. Welding :

Length of welding as per data sheet : 252 m


( 191 + 135 ) x 8 / 15 / 2 : 87 hours


( 1716 + 1211 ) x 8 / 15 / 6 : 260 hours

Total : 347 hours



( 87 x 0.25 + 260 x 0.75 ) : 217 hours

4. Planing SS plates for wheel / seal tracks :

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

Length of SS plate for surface finishing by planing machine : 63.00 Rm

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

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

Time for planing 63 m SS plates ( 63 x 8 / 3 ) : 168 hours 5. Surface cleaning and painting :

Painting area for embedded parts at 10 sqm / tonne ( 5.193 x 10 ) : 52 sqm




Quantity of coal tar epoxy paint for 52 sqm @ 6 sqm / ltr / coat : 35 ltr



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Quantity of rust cleaner / inhibitor for 52 sqm @ 8 sqm / ltr : 6.5 ltr


For drilling holes for anchor bolts use of drilling machine for 24 hours considered.

For grinding weld joints and edges requiring finishing use of grinding machine for 16 hours

considered.

For handling during fabrication and erection 25 t mobile crane for 24 hours with energy charges

for 12 hours and stationery derric crane for 75 hours considered.



Painter Cl-II


Drilling holes for anchors / supports 3 6 --- 12



Erection of first stage anchors 10 20 --- 40

Erection of Sill beam / Tracks / Guide 10 10 --- 20


Painting ( 5 x 52 ) sqm @ 15 sqm / day --- --- --- 20

Finishing / cleaning 1 4 --- 4 Total : 40 63 44 177


is considered for welder for stitch welding.


at 15 sqm / day and 3 helpers to assist painters.













A. MATERIALS:

Sl No Unit Amount

in Rs.

1 Structural steelAngles / beams / channels / bars kg 603.00 37.95 22883.85

Plates / flats kg 3777.00 40.00 151080.00

2 Stainless steel plate / flats kg 772.00 120.00 92640.00

3 MS bolts and nuts kg 171.00 55.00 9405.00

4 Oxygen gas cum 135.00 48.00 6480.00




Perticulars

Marker /

Erector /

Fabricator /

Quantity Rate

Gas cutter /

Welder

in Rs.

93


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8 Welding electrodes ( stainless steel ) Nos 1346.00 43.00 57878.00






14 Wire brush Nos 4.00 30.00 120.00

15 Sundries LS 70.00 30.00 2100.00

Total Rs: 389975.35





B. MACHINERY:

Sl No Unit Amount

in Rs.




Fuel / Energy charges Hour 4.00 100.00 400.003 Pug cutting machine Hour 60.00 16.00 960.00


4 Planing machine Hour 168.00 88.00 14784.00


Contd


Sl No Unit Amount

in Rs.

Contd









9 Sundries LS 70.00 30.00 2100.00

Total Rs: 163941.00


Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 4667.50Add for Contractor's Overheads @ 5% Rs: 8197.05


C. LABOUR:

Sl No Unit Amount

in Rs.

1 Crew for Mobile crane 25 t Hour 24.00 75.70 1816.80

2 Crew for Plate shearing machine Hour 4.00 45.90 183.60

Description

Description

Description

Quantity

in Rs.

Quantity

in Rs.

Rate

Rate

Rate

in Rs.

Quantity

94


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3 Crew for Planing machine Hour 168.00 73.40 12331.20



6 Foreman Day 40.00 177.00 7080.00


8 Gas cutter Day 12.00 157.50 1890.00


10 Welder ( X - ray ) Day 3.00 173.25 519.75



13 Painter Cl - II Day 17.00 141.50 2405.50

14 Electrician Day 2.00 143.00 286.00

Total Rs: 66498.85







ABSTRACT:A. Cost of Materials Rs: 452371.41



TOTAL Rs: 727904.69








Total Rs: 813355.68








ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type vertical

lift gateconsisting of skin plate, vertical and horizontal girders, wheels, stiffeners, lifting

brackets, guide shoes, rubber seals etc., with all accessories for barrageincluding cost of all

materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coat

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

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

DATA:Consider upstream seal vertical lift roller gate. The gate leaf consists of skin plate, horizontal

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girders, vertical end girders, stiffeners, wheels, gate guide shoes, brackets for pulleys, seals

etc., with all accessories.

Consider vertical lift roller gate for 13.72 m x 8.26 m opening for analysis.



Weight of gate leaf in tonne for vertical lift roller gate based on empirical formula :

= 0.0335 ( L

2

x H x h )

0.716


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

: 33.289


actual weight as per fabrication drawings of vertical lift barrage gate of same size provided for

one of the barrage.

Actual weight of vertical lift barrage gate as per data in Item : 20 of Annexure-2 : 33.025 tonnes


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

gate provided for one of the barrage for rate analysis ( for details refer Item : 20 of Annexure-2 ).


a. Structural steel conforming to IS : 2062 :

Angles/ beams/ channels with 2.5 % wastage ( 3299x1.025 ) : 3382 kg


b. Alloy steel components conforming to IS : 1570 :

Wheel axles / Pins : 176 kg

c. Cast steel components conforming to IS : 1030 :

Wheels : 656 kg

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

Bearings / Bushes : 80 kg

e. Bolts / Nuts / Washers conforming to IS : 1363 :

GI bolts / nuts / washers with 2.5 % wastage ( 91 x 1.025 ) : 93 kgMS bolts / nuts / washers with 2.5 % wastage ( 68 x 1.025 ) : 70 kg

f. Rubber seal conforming to IS : 11855 :

Bottom seal ( flat uncladed ) ( 14 x 1.025 ) : 14.5 Rm

Side seals ( bulb uncladed ) ( 17.2 x 1.025 ) : 18 Rm

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






2. Cutting :



Total : 765 RmFor cutting structural steel sections to required sizes gas cutting and plate shearing machine

for plates less than 12 mm thick are considered.



Length of steel to be cut by gas using plate shearing machine : 100 m



96


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




Use of pug cutting machine with 50 min/hr working ( 155 x 60 / 50 ) : 186 hours

Use of plate shearing machine with 50 min/hr work ( 10 x 60 / 50 ) : 12 hours

3. Welding :



( 2024 / 15 ) x 8 / 2 : 540 hours


( 18216 / 15 ) x 8 / 6 : 1620 hours

Total : 2160 hours



( 540 x 0.25 + 1620 x 0.75 ) : 1350 hours

4. Surface cleaning and painting :

Painting area for barrage gate at 18 sqm / tonne ( 33.025 x 18 ) : 595 sqm



3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 595 sqm @ 6 sqm / ltr / coat : 298 ltr




Quantity of rust cleaner / inhibitor for 595 sqm @ 8 sqm / ltr : 75 ltr


For handling of gate parts during fabrication and erection 25 t mobile crane for 20 hours with

energy charges for 10 hours and 8 t mobile crane for 40 hours and stationery derric crane for

150 hours considered.

For drilling holes in skin plate and seal base / clamps use of drilling machine for 50 hours

considered.

For grinding and finishing weld joints in skin plate and other locations 50 hours use of grinding

machine considered.



Painter Cl-II


Drilling holes for seal fixing 3 6 --- 6



Joining units & wheel fixing 4 8 --- 32Seal fixing & guide shoe fixing 1 2 --- 4


Painting ( 4 x 595 ) sqm @ 15 sqm / day --- --- --- 188

Aligning and lowering in position 2 4 --- 16

Cleaning / checking 1 2 --- 2

Total : 85 130 243 707


considered for welder for stitch welding.

Erector /

Marker / Gas cutter /

Fabricator / Welder

97


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at 15 sqm / day and 30 helpers to assist painters.













A. MATERIALS:

Sl No Unit Amount

in Rs.

1 Structural steel


Plates / flats kg 29372.00 40.00 1174880.002 Alloy steel components

Wheel axles / Pins kg 176.00 215.00 37840.00

Contd

A. MATERIALS ( Contd ) :

Sl No Unit Amount

in Rs.

Contd

3 Cast steel components

Wheels kg 656.00 125.00 82000.00

4 Alluminium / Bronze alloy components

Bearings / Bushes kg 80.00 635.00 50800.00

5 Bolt / Nut / Washer

GI bolts / nuts / washers kg 93.00 95.00 8835.00


6 Rubber seals

Bottom seal ( flat uncladed ) Rm 14.50 147.00 2131.50

Side seals ( bulb uncladed ) Rm 18.00 235.00 4230.00

7 Oxygen gas cum 459.00 48.00 22032.00




11 Zinc rich epoxy primer ltr 66.00 594.00 39204.0012 Coal tar epoxy paint ltr 298.00 208.00 61984.00




16 Wire brush Nos 10.00 30.00 300.00

17 Sundries LS 100.00 30.00 3000.00

Total Rs: 1917663.40


in Rs.

Perticulars

Perticulars

Rate

Rate

in Rs.

Quantity

Quantity

98


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B. MACHINERY:

Sl No Unit Amount

in Rs.














Fuel / Energy charges Hour 100.00 25.00 2500.00Contd


Sl No Unit Amount

in Rs.

Contd



9 Sundries LS 75.00 30.00 2250.00

Total Rs: 256458.00





C. LABOUR:

Sl No Unit Amount

in Rs.



3 Crew for Plate shearing machine Hour 12.00 45.90 550.80

4 Crew for Drilling machine Hour 50.00 59.50 2975.005 Crew for Grinding machine Hour 100.00 59.50 5950.00

6 Foreman Day 85.00 177.00 15045.00


8 Gas cutter Day 40.00 157.50 6300.00


10 Welder ( X - ray grade ) Day 20.00 173.25 3465.00

11 Khalasi Day 100.00 145.50 14550.00


in Rs.

Description

Description

Description

Quantity

Rate

Rate

in Rs.

Quantity

RateQuantity

in Rs.

99


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14 Painter Cl - II Day 158.00 141.50 22357.00

15 Electrician Day 10.00 143.00 1430.00

Total Rs: 204083.80







ABSTRACT:




TOTAL Rs: 2806663.17








Total Rs: 3106467.84


Fabricated parts 2x33.025 tonnes @ Rs: 129.10 / tonne Rs: 8527.06






ITEM: Design, fabrication, supply, erection and commissioning of structural steel hoist bridge

consisting of columns, beams, bracings, stiffeners, ties, chequered plate covering, hand railing,

ladder etc., with all accessories for supporting rope drum hoist for operating barrage

gatesincluding cost of all materials, machinery, labour, cutting, aligning, anchoring, welding,

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

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

DATA:Structural steel hoist bridge for supporting rope drum hoist for operating barrage gates consists

of steel columns and beams with cross beams, ties, bracings, stiffeners, hand railing, ladder,chequered plate covering, anchorages etc., with all accessories.

The size of the steel hoist bridge depends on the size of the gate and hoist capacity required to

operate the gate. Generally the hoist capacity will be 1.5 times the weight of the gate and the

weight of hoist bridge will be about 400 kg per metre height of column or per metre span of beam.

Consider vertical lift roller gate for 13.72 m x 8.26 m opening for analysis.



Weight of gate leaf in tonne for vertical lift roller gate based on empirical formula :

Documents

Data Rates Gate Works 5