GATE / HOIST AND ALLIED WORKS

Rate per tonne capacity Rate approved per tonne capacity SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

Rs: Rs:

44900.00 44900.00 ITEM No: 29

ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity manually operated rope drum hoist consisting of hoist platform, rope drum, gear system, brake system, wire rope, ladder etc., with all accessories for operating canal regulator radial gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying two coats of zinc chromate red oxide primer and three coats of approved synthetic enamel paint etc., complete with all leads and lifts. DATA: Rope drum hoist for radial gate consists of embedded parts for anchorage, hoist supporting structure, pulley supporting structures, pulleys, drive stool, rope drums, couplings, shafts, gears and pinions, plummer blocks, worm reducer, floating shaft, hand operation assembly, brake, wire rope, gate position indicator etc. with related accessories. Generally the capacity of rope drum hoist for small radial gate will be about 2 times the weight of radial gate and the weight of the hoist with all accessories is assumed at 0.30 tonne per tonne capacity of the rope drum hoist. Consider rope drum hoist for radial gate for canal regulator opening of size 3 m x 3.7 m. Size of radial gate : 3.00 m x 3.90 m Head of water : 3.70 m Weight of regulator radial gate leaf in tonne based on empirical formula : = 0.1690 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. = 0.1690 x ( 3 x 3 x 3.9 x 3.7 ) 0.673 : 4.470 Consider Capacity of hoist with 25% reserve capacity at 2 times the weight of gate : ( 2 x 4.470 ) : 8.940 tonnes Round off the capacity of hoist to next 5 tonne : 10 tonnes Consider weight of hoist @ 0.3 tonne per tonne capacity of hoist : ( 0.30 x 10 ) : 3.000 tonnes Less weight of drive unit ( electric motor / cover etc ) : 0.200 tonne Weight of manually operated hoist : 2.800 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 canal regulator radial gate rope drum hoist of same capacity provided for one of the canal work. Actual capacity of hoist as per data In Item :29 of Annexure-2 : 10 tonnes Actual weight of rope drum hoist as per data in Item : 29 of Annexure-2 : 2.804 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of rope drum hoist for canal regulator radial gate provided for one of the canal work for rate analysis ( for details refer Item : 29 of Annexure-2 ). 1. Requirement of materials: a. Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5 % wastage ( 1193x1.025 ) : 1223 kg

Plates / flats with 2.5 % wastage Chequered plate b. Cast steel components conforming to IS : 1030 : Rope drums 2 Nos / Gears Pinions Pulleys 6 Nos

( 442 x 1.025 ) ( 190 x 1.025 )

: 453 kg : 195 kg : 384 kg : 14 kg : 108 kg

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GATE / HOIST AND ALLIED WORKS

Plummer blocks / Hubs c. Alloy steel components conforming to IS : 1570 : Shafts Pins d. Alluminium/ Bronze alloy components conforming to IS : 305 : Bearings / Bush e. Bolt / Nut / Washers conforming to IS : 1363 : MS Bolts / Nuts / Washers with 2.5 % wastage ( 63 x 1.025 ) f. Steel wire rope conforming to IS : 2266 : 12 mm dia 6 / 36 construction 2 Nos 35 m each @ 0.6 kg / Rm g. Other components : Manual operating system Worm reducers Wire rope sockets MS pipe 32 mm dia h. Welding electrodes ( General purpose / Low hydrogen ) : GP / LH electrodes as per data sheet ( Item:29 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 755 x 0.1 ) Total requirement of GP / LH electrodes for stitch weld GP electrodes @t 10 % of total ( 830 x 0.10 ) for run welding LH electrodes @ 90 % of total ( 830 x 0.90 ) 2. Cutting : Length of cutting assuming cutting for 2 sides as per data sheet Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 %

: 47 kg : 75 kg : 24 kg : 11 kg : 65 kg : 42 kg : : : : : : : : : 1 No. 1 No. 2 Nos 10.5 Rm 755 Nos 75 Nos 830 Nos 83 Nos 747 Nos

Total For cutting structural steel sections to required sizes gas cutting is assumed. Length of steel to be cut by using gas manually : Length of steel to be cut by gas using pug cutting machine : Time for gas cutting manually at ( av ) 2 m cutting / hour : Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : Acetelyne gas @ 0.6 cum / hour ( 30 + 7 ) x 0.60 : Oxygen gas @ 1.8 cum / hour ( 30 + 7 ) x 1.80 : Use of gas cutting torch with 50 min / hr working ( 30 x 60 / 50 ) : Use of pug cutting machine with 50 min / hr working ( 7 x 60 / 50 ) : 3. Welding : Length of welding as per data sheet : For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 83 / 15 ) x 8 / 2 : For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 747 / 15 ) x 8 / 6 : Total : Deploy welding transformer for 88 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 22 x 0.25 + 66 x 0.75 ) :

: 73 Rm : 7 Rm : 80 Rm 60 Rm 20 Rm 30 hours 7 hours 22 cum 66 cum 36 hours 8 hours 113 Rm 22 hours 66 hours 88 hours

55 hours

4. Surface cleaning and painting : Painting area at 20 sqm / t of str steel ( 1.82 x 20 ) : 36 sqm 2 coats of zinc chromate red oxide primer. Quantity of primer paint for 36 sqm @ 12 sqm / ltr / coat : 6 ltr 3 coats of synthetic enamel paint. Quantity of synthetic enamel paint for 36 sqm @ 12 sqm / ltr / coat : 9 ltr As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment

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GATE / HOIST AND ALLIED WORKS

5.

6.

Note :

7.

8.

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 36 sqm @ 8 sqm / ltr : 4.5 ltr Requirement of other machinery : For handling of parts during fabrication and erection use of 8 t mobile crane for 16 hours and stationery derric crane for 16 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 Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Painter Cl-II Fabricator / Welder Erector / Cutting sections 44 hours 2 5 6 10 Drilling holes for pins / bolts fixing --1 --1 Fabricating by stitch welding 22 hours 1 3 --6 Run welding 66 hours 1 --8 8 Erection of anchors 1 1 --1 Erection of drums and gears 1 2 --4 Erection of floating shaft / pulleys 1 1 --2 Erection of worm reducers / brake 1 2 --4 Erection of other accessories 1 1 --2 Checking and trial running without ropes 1 1 --2 Cleaning surface 36 sqm @ 15 sqm/day ------2 Painting ( 5 x 36 ) sqm @ 15 sqm / day ------11 Rope fixing and checking 1 1 --2 Finishing / cleaning --1 --1 Trial running for lifting / lowering gate 1 1 --2 Total : 12 20 14 58 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 9 Painters Cl-II at 15 sqm / day and 2 helpers to assist painters. Excise duty on supply : Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost of materials ( assuming 25 % erection cost ) is considered for assessing excise duty. Use rate of materials : Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00 Life of welding set : 1000 hours Use rate of welding set per hour ( cost / life ) Rs: 4.50 Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00 Life of gas cutting set : 600 hours Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50

RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars Unit Quantity

UNIT :

2.804 tonne 10.00 t capacity Rate Amount in Rs. in Rs. 37.95 40.00 42.00 46412.85 18120.00 8190.00

Structural steel Angles / beams / channels / bars Plates / flats Chequered plate

kg kg kg

1223.00 453.00 195.00

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GATE / HOIST AND ALLIED WORKS

4 5 6 7 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24

32 mm dia MS pipe Cast steel components : Rope drums 2 Nos / Gears Pinions Pulleys 6 Nos Plummer blocks / Couplings Alloy steel components Shafts Pins Bronze alloy components : Bronze bearings / bush Wire rope 12 mm dia 6/36 construction MS Bolt / Nut / Washer Worm reducers Manual operating system Brake Wire rope sockets Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen ) Zinc chromate red oxide primer Synthetic enamel ( 1st quality ) paint Rust cleaner / inhibitor Grease Use rate welding holder set Use rate gas cutting torch set Wire brush Sundries Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @

Rm kg kg kg kg kg kg kg kg kg No. No. No. No cum cum Nos Nos ltr ltr ltr kg Hour Hour Nos LS

10.50 384.00 14.00 108.00 47.00 75.00 24.00 11.00 42.00 65.00 1.00 1.00 1.00 2.00 66.00 22.00 83.00 747.00 6.00 9.00 4.50 10.00 88.00 36.00 1.00 100.00

127.00 145.00 150.00 125.00 125.00 175.00 215.00 635.00 105.00 55.00 45000.00 9000.00 6000.00 750.00 48.00 258.00 6.00 12.00 140.00 176.00 240.00 194.00 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

1333.50 55680.00 2100.00 13500.00 5875.00 13125.00 5160.00 6985.00 4410.00 3575.00 45000.00 9000.00 6000.00 1500.00 3168.00 5676.00 498.00 8964.00 840.00 1584.00 1080.00 1940.00 396.00 90.00 30.00 3000.00 273232.35 2732.32 27323.24 13661.62 316949.53

1% 10% 5% Total cost of Materials :

B. MACHINERY: Sl No 1

Description

Unit Hour Hour

Quantity 88.00 55.00

Welding transformer Fuel / Energy charges

Rate in Rs. 12.00 60.00 Contd

Amount in Rs. 1056.00 3300.00

B. MACHINERY ( Contd ) : Sl No Description

Unit

Quantity

2 3 4

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

Hour Hour Hour Hour Hour

8.00 8.00 8.00 8.00 16.00

Rate in Rs. Contd 16.00 3.00 362.00 495.00 66.00

Amount in Rs. 128.00 24.00 2896.00 3960.00 1056.00

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GATE / HOIST AND ALLIED WORKS

5 6 7

Fuel / Energy charges Grinding machine Fuel / Energy charges Drilling machines Fuel / Energy charges Sundries

Hour Hour Hour Hour Hour LS

16.00 8.00 8.00 8.00 8.00 50.00

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

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

144.00 144.00 200.00 144.00 200.00 1500.00 14752.00 147.52 932.80 737.60 16569.92

Description

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

Quantity 8.00 8.00 8.00 12.00 20.00 6.00 8.00 45.00 4.00 9.00 2.00

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

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

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

Amount in Rs. 605.60 476.00 476.00 2124.00 3150.00 945.00 1260.00 6367.50 566.00 1273.50 286.00 17529.60 175.30 1752.96 2629.44 2629.44 876.48 25593.22

ABSTRACT: A. Cost of Materials B. Hire charges of Machinery C. Cost of Labour Add for excise duty on 75 percent cost of Machinery / Labour components @

Rs: Rs: Rs: TOTAL Rs: 8.24% Rs:

316949.53 16569.92 25593.22 359112.66 2605.68

Add for insurance charges @ Add for designs and drawings @ Add for zigs / supports / winches / chain-pulley @ Add for power supply arrangements @ Add for enabling works @

1.00% 2.50% 2.50% 2.00% 1.40%

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

3591.13 8977.82 8977.82 7182.25 5027.58 395474.93 723.99 11864.25 408063.17

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 2.804 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 2.804 tonne weight

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GATE / HOIST AND ALLIED WORKS

10.000 tonne capacity Rate per tonne weight Rate per tonne capacity Rate approved per tonne capacity SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

Rs: Rs: Rs:

145530.00 40800.00 40800.00 ITEM No: 30

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( with top seal seat ) consisting of sill beam, wheel tracks, seal tracks, guide rails, groove lining upto top etc., with all accessories for vertical lift roller gate for canal escape / regulator 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., complets as per specifications and approved drawings with all leads and lifts. DATA: Embedded parts for canal escape / regulator gate consist of sill beam, wheel / seal tracks, groove lining upto top, gate guide with all accessories such as first stage anchors. Weight of embedded parts with groove lining for such small gates will be about 150 percent of gate weight. Consider embedded parts for canal escape / regulator gate for opening of size 2 m x 2 m. For 2 m x 2 m opening approximate size of gate : 2.5 m x 2.2 m Head of water above sill level : 3.7 m Weight of vertical lift roller gate in tonne for regulator / escape based on empirical formula : = 0.0888 x ( L 2 x H x h ) 0.659 Consider weight of embedded parts in tonnes @ 150 % of weight of gate : = 1.50 x 0.0888 x ( L 2 x H x h ) 0.659 Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.1332 x ( 2.5 x 2.5 x 2.2 x 3.7 ) 0.659 : 1.775 tonnes The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings of embedded parts for canal escape vertical lift roller gate of same size provided for one of the canal escape structure. Actual weight of embedded parts as per data in Item : 30 of Annexure-2 : 1.784 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of embedded parts for canal escape vertical lift roller gate provided for one of the canal escape structure for rate analysis ( for details refer Item : 30 of Annexure-2 ). 1. Requirement of materials: a. Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5% wastage ( 1189.5x1.025 ) : 1219 kg Plates / flats with 2.5 % wastage ( 514.5 x 1.025 ) : 527 kg

b. Alloy steel components conforming to IS : 1570 : Stainless steel plates / flats ( 79.5 x 1.025 ) c. Bolt / Nut / Washer conforming to IS : 1363 : MS bolts and nuts with 2.5 % wastage d. Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) : GP / LH electrodes as per data sheet ( Item:30 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 1182 x 0.1 ) Total requirement of GP / LH electrodes for stitch welding GP electrodes @t 10 % of total ( 1300 x 0.10 ) for run welding LH electrodes @ 90 % of total ( 1300 x 0.90 )

: 82.00 kg : 1 kg : : : : : 1182 Nos 118 Nos 1300 Nos 130 Nos 1170 Nos

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GATE / HOIST AND ALLIED WORKS

Stainless steel electrodes as per data sheet ( Item:30 Annexure-2 ) Add for variations / wastage @ 5 % ( 217 x 0.05 ) Total requirement of Stainless steel ( SS ) electrodes for stitch weld SS electrodes @t 10 % of total ( 228 x 0.10 ) for run weld SS electrodes @t 90 % of total ( 228 x 0.90 ) 2. Cutting : Total length of cutting assuming cutting for 2 sides as per data sheet Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 %

: : : : :

217 Nos 11 Nos 228 Nos 23 Nos 205 Nos

Total For cutting structural steel sections to required sizes gas cutting is assumed. Length of steel to be cut by using gas manually : 24 m Length of steel to be cut by gas using pug cutting machine : 20 m Time for gas cutting manually at ( av ) 2 m cutting / hour : 12 hours Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 7 hours Acetelyne gas @ 0.6 cum / hour ( 12 + 7 ) x 0.60 : 11 cum Oxygen gas @ 1.8 cum / hour ( 12 + 7 ) x 1.80 : 33 cum Use of gas cutting torch with 50 min / hr working ( 12 x 60 / 50 ) : 15 hours Use of pug cutting machine with 50 min / hr working ( 7 x 60 / 50 ) : 9 hours 3. Welding : Length of welding as per data sheet : 207 m For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 130 + 23 ) x 8 / 15 / 2 : 41 hours For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 1170 + 205 ) x 8 / 15 / 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. Planing SS plates for seal seats : For surface finishing of SS plates for wheel / seal tracks planing machine is considered. Length of SS plate for surface finishing by planing machine : 18.3 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 18.3 m SS plates ( 18.3 x 8 / 3 ) : 48 hours 5. Surface cleaning and painting : Painting area for embedded parts at 5 sqm / tonne ( 1.784 x 5 ) : 9 sqm 1 coats of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 15 sqm @ 9 sqm / ltr / coat : 1 ltr 4 coats of coal tar epoxy paint 100 micron dry film each coat. Quantity of coal tar epoxy paint for 15 sqm @ 6 sqm / ltr / coat : 6 ltr

: 40 Rm : 4 Rm : 44 Rm

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 9 sqm @ 8 sqm / ltr : 1 ltr 6. Requirement of other machinery : For handling during fabrication and erection use of 8 t mobile crane for 2 hours considered. For drilling holes for anchor bolts use of drilling machine for 1 hour considered. For finishing weld joints / edges 2 hours use of grinding machine considered. 7. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II

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GATE / HOIST AND ALLIED WORKS

Erector / Cutting sections / Drilling holes 24 hours 2 3 3 6 Fabricating by stitch welding 41 hours 2 5 --10 Run welding 122 hours 1 --15 15 Erection of first stage anchors --1 --2 Erection of Sill beam / Tracks / Guide 1 2 --4 Cleaning surface 9 sqm @ 15 sqm/day ------1 Painting ( 5 x 9 ) sqm @ 15 sqm / day ------4 Finishing / cleaning --1 --1 Total : 6 12 18 43 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 3 Painters Cl-II at 15 sqm / day and 1 helper 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 A. MATERIALS: Sl No 1 Perticulars Unit Quantity UNIT : 1.784 tonne Rate in Rs. 37.95 40.00 120.00 55.00 48.00 258.00 6.00 Contd Amount in Rs. 46261.05 21080.00 9840.00 55.00 1584.00 2838.00 780.00

2 3 4 5 6

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

kg kg kg kg cum cum Nos

1219.00 527.00 82.00 1.00 33.00 11.00 130.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

7 8 9 10 11 12 13 14

Welding electrodes ( low hydrogen ) Welding electrodes ( stainless steel ) Zinc rich epoxy primer Coal tar epoxy paint Rust cleaner / inhibitor Use rate welding holder set Use rate gas cutting torch set Wire brush

Nos Nos ltr ltr ltr Hour Hour Nos

1170.00 228.00 1.00 6.00 1.00 163.00 15.00 1.00

Rate in Rs. Contd 12.00 43.00 594.00 208.00 240.00 4.50 2.50 30.00

Amount in Rs. 14040.00 9804.00 594.00 1248.00 240.00 733.50 37.50 30.00

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GATE / HOIST AND ALLIED WORKS

15

Sundries Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @

LS

2.00

1% 10% 5% Total cost of Materials :

30.00 Total Rs: Rs: Rs: Rs: Rs:

60.00 109225.05 1092.25 10922.51 5461.25 126701.06

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

Description

Unit Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour LS

Quantity 163.00 102.00 2.00 2.00 9.00 9.00 48.00 48.00 2.00 2.00 1.00 1.00 3.00

Welding transformer Fuel / Energy charges Mobile crane 8 t Fuel / Energy charges Pug cutting machine Fuel / Energy charges Planing machine Fuel / Energy charges Grinding machine Fuel / Energy charges Drilling machines Fuel / Energy charges Sundries

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

Rate in Rs. 12.00 60.00 362.00 495.00 16.00 3.00 88.00 75.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 1956.00 6120.00 724.00 990.00 144.00 27.00 4224.00 3600.00 36.00 50.00 18.00 25.00 90.00 18004.00 180.04 1090.20 900.20 20174.44

Description

Unit Hour Hour Hour Hour Day

Quantity 48.00 1.00 2.00 2.00 6.00

Crew for Planing machine Crew for Drilling machine Crew for Grinding machine Crew for Mobile crane Foreman

Rate in Rs. 73.40 59.50 59.50 75.70 177.00 Contd

Amount in Rs. 3523.20 59.50 119.00 151.40 1062.00

C. LABOUR ( Contd ) : Sl No Description

Unit

Quantity

6 7 8 9 10 11 12 13

Marker / Fabricator / Erector Gas cutter Welder ( General ) Welder ( X - ray ) Helper fabrication / erection Helper for cleaning / painting Painter Cl - II Electrician

Day Day Day Day Day Day Day Day

12.00 3.00 13.00 2.00 38.00 2.00 3.00 1.00

Rate in Rs. Contd 157.50 157.50 157.50 173.25 141.50 141.50 141.50 143.00 Total Rs:

Amount in Rs. 1890.00 472.50 2047.50 346.50 5377.00 283.00 424.50 143.00 15899.10

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GATE / HOIST AND ALLIED WORKS

Add for small Tools and Plants @ Add for Contractor's Profit @ Add for hidden cost on Labour @ Add for additional hidden cost on labour @ Add for Contractor's Overheads @

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

Rs: Rs: Rs: Rs: Rs: Rs:

158.99 1589.91 2384.87 2384.87 794.96 23212.69

ABSTRACT: A. Cost of Materials B. Hire charges of Machinery C. Cost of Labour Add for excise duty on 75 percent cost of Machinery / Labour components @ Add for insurance charges @ Add for designs and drawings @ Add for zigs / supports / winches / chain-pulley @ Add for power supply arrangements @ Add for enabling works @

Rs: Rs: Rs: TOTAL Rs: 8.24% 1.00% 2.50% 2.50% 2.00% 1.40% Rs: Rs: Rs: Rs: Rs: Rs: Total Rs: Rs: Rs: Rs: Rs: Rs:

126701.06 20174.44 23212.69 170088.18 2681.32 1700.88 4252.20 4252.20 3401.76 2381.23 188757.80 460.63 5662.73 194881.16 109200.00 109200.00 ITEM No: 31

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 1.784 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 1.784 tonne Rate per tonne Rate approved per tonne SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type vertical lift gate ( with top seal ) consisting of skin plate, horizontal and vertical girders, wheels, guide rollers, rubber seals etc., with all accessories for canal escape / regulator 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 down stream sealing vertical lift roller gate. The gate leaf consists of skin plate,

horizontal girders, vertical end girders, stiffeners, wheels, gate guide rollers, brackets, pins, seals etc., with all accessories. Consider canal escape / regulator gate for 2 m x 2 m vent opening for analysis. For 2 m x 2 m opening approximate size of gate : 2.5 m x 2.2 m Head of water above sill level : 3.7 m Weight of vertical lift roller gate in tonne for regulator / escape based on empirical formula : = 0.0888 ( L 2 x H x h ) 0.659 Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water in metre. = 0.0888 ( 2.5 x 2.5 x 2.2 x 3.7 ) : 1.183 The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings of fixed wheel vertical lift roller gate of same size provided for one of the canal escape structurer. Actual weight of canal escape gate as per data in Item : 31 of Annexure-2 : 1.217 tonnes
0.659

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GATE / HOIST AND ALLIED WORKS

1. a.

b. c. d. e.

f.

g.

2.

Consider actual weight for data rate analysis. Consider details of Material /Gas cutting / Welding based on fabrication drawings of fixed wheel vertical lift roller gate provided for one of the canal escape structure for rate analysis ( for details refer Item : 31 of Annexure-2 ). Requirement of materials: Structural steel conforming to IS : 2062 : Angles / beams / channels / bars with 2.5 % wastage ( 244x1.025 ) : 250 kg Plates / flats with 2.5 % wastage ( 877 x 1.025 ) : 899 kg Alloy steel components conforming to IS : 1570 : Wheel axles / Pins : 30 kg Cast steel components conforming to IS : 1030 : Wheels / guide rollers : 50 kg Alluminium / Bronze alloy components conforming to IS : 305 : Bearings / Bushes : 5 kg Bolts / Nuts / Washers conforming to IS : 1363 : GI bolts / nuts / washers with 2.5 % wastage ( 7.5 x 1.025 ) : 8 kg MS bolts / nuts / washers with 2.5 % wastage ( 3.5 x 1.025 ) : 4 kg Rubber seal conforming to IS : 11855 : Bottom seal ( uncladed ) ( 2.25 x 1.025 ) : 2.3 Rm Side seals ( uncladed ) ( 3.95 x 1.025 ) : 4.0 Rm Top seal ( uncladed ) ( 1.85 x 1.025 ) : 1.9 Rm Welding electrodes ( General purpose / Low hydrogen ) : GP / LH electrodes as per data sheet ( Item:31 Annexure-2 ) : 658 Nos Add for variations / wastage / misc welding @ 10 % ( 658 x 0.1 ) : 66 Nos Total requirement of GP / LH electrodes : 724 Nos for stitch weld GP electrodes @t 10 % of total ( 724 x 0.10 ) : 72 Nos for run welding LH electrodes @ 90 % of total ( 724 x 0.90 ) : 652 Nos Cutting : Total length of cutting assuming cutting for 2 sides as per data sheet : 45 Rm Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 5 Rm Total : 50 Rm For cutting structural steel sections to required sizes gas cutting is assumed. Length of steel to be cut by using gas manually : 20 m Length of steel to be cut by gas using pug cutting machine : 30 m Time for gas cutting manually at ( av ) 2 m cutting / hour : 10 hours Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 10 hours Acetelyne gas @ 0.6 cum / hour ( 10 + 10 ) x 0.60 : 12 cum

Oxygen gas @ 1.8 cum / hour ( 10 + 10 ) x 1.80 Use of gas cutting torch with 50 min / hr working ( 10 x 60 / 50 ) Use of pug cutting machine with 50 min / hr working ( 10 x 60 / 50 ) 3. Welding : Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 72 / 15 ) x 8 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 652 / 15 ) x 8 / 6 Total

: 36 cum : 12 hours : 12 hours

: 94 Rm : 19 hours : 58 hours : 77 hours

Deploy welding transformer for 77 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 19 x 0.25 + 58 x 0.75 ) : 48 hours

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4. Surface cleaning and painting : Painting area for canal escape gate at 18 sqm / tonne ( 1.217 x 18 ) : 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 3 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 : 11 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 22 sqm @ 8 sqm / ltr : 3 ltr 5. Requirement of other machinery : For handling of parts during fabrication and erection use of 8 t mobile crane for 2 hours and stationery derric crane for 2 hours considered. For drilling holes in skin plate, end girders and seal clamps use of drilling machine for 2 hours considered. For grinding and finishing weld joints in skin plate and other locations 2 hours use of grinding machine considered. 6. Requirement of work force : Work component

Foreman

Marker / Fabricator / Erector /

Gas cutter / Welder

Helper / Painter Cl-II

Cutting sections / Drilling holes 24 hours 1 3 3 6 Fabricating by stitch welding 19 hours 1 2 --4 Run welding 58 hours 1 --7 7 Wheel fixing / Seal fixing 1 1 --2 Cleaning surface 22 sqm @ 15 sqm/day ------1.5 Painting ( 4 x 22 ) sqm @ 15 sqm / day ------7.5 Guide roller fixing / Finishing / Erecting 1 1 --2 Total : 5 7 10 30 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 6 Painters Cl-II at 15 sqm / day and 1.5 helpers to assist painters.

7. Excise duty on supply : Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost of materials ( assuming 25 % erection cost ) is considered for assessing excise duty. 8. Use rate of materials : Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00 Life of welding set : 1000 hours Use rate of welding set per hour ( cost / life ) Rs: 4.50 Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00 Life of gas cutting set : 600 hours Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50 RATE ANALYSIS A. MATERIALS: Sl No Perticulars Unit Quantity UNIT : 1.217 tonne Rate Amount

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GATE / HOIST AND ALLIED WORKS

in Rs. 1 Structural steel Angles / Channels / Beams / Bars Plates / flats Alloy steel components Wheel axles / Pins Cast steel components Wheels / Guide rollers Alluminium / Bronze alloy components Bearings / Bushes Bolt / Nut / Washer GI bolts / nuts / washers MS bolts / nuts / washers Rubber seals Bottom seal ( uncladed ) Side seals ( uncladed ) Top seal ( uncladed ) Corner seal ( uncladed ) Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen ) Zinc rich epoxy primer Coal tar epoxy paint Rust cleaner / inhibitor Use rate welding holder set Use rate gas cutting torch set Wire brush Sundries Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @ kg kg kg kg kg kg kg Rm Rm Rm Nos cum cum Nos Nos ltr ltr ltr Hour Hour Nos LS 250.00 899.00 30.00 50.00 5.00 8.00 4.00 2.30 3.60 1.50 2.00 36.00 12.00 72.00 652.00 2.50 11.00 3.00 77.00 12.00 1.00 2.00 37.95 40.00 215.00 125.00 635.00 95.00 55.00 147.00 235.00 235.00 295.00 48.00 258.00 6.00 12.00 594.00 208.00 240.00 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

in Rs. 9487.50 35960.00 6450.00 6250.00 3175.00 760.00 220.00 338.10 846.00 352.50 590.00 1728.00 3096.00 432.00 7824.00 1485.00 2288.00 720.00 346.50 30.00 30.00 60.00 82468.60 824.69 8246.86 4123.43 95663.58

2 3 4 5

7 8 9 10 11 12 13 14 15 16 17

1% 10% 5% Total cost of Materials :

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

Description

Unit Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour LS

Quantity 77.00 48.00 12.00 12.00 2.00 2.00 2.00 2.00 2.00 2.00 1.00 1.00 2.00

Welding transformer Fuel / Energy charges Pug cutting machine Fuel / Energy charges Mobile crane 8 t Fuel / Energy charges Stationery derric crane Fuel / Energy charges Grinding machine Fuel / Energy charges Drilling machines Fuel / Energy charges Sundries

Rate in Rs. 12.00 60.00 16.00 3.00 362.00 495.00 66.00 9.00 18.00 25.00 18.00 25.00 30.00

Amount in Rs. 924.00 2880.00 192.00 36.00 724.00 990.00 132.00 18.00 36.00 50.00 18.00 25.00 60.00

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GATE / HOIST AND ALLIED WORKS

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

Total Rs: Rs: Rs: Rs: Rs:

6085.00 60.85 405.90 304.25 6856.00

Description

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

Quantity 2.00 1.00 2.00 5.00 7.00 3.00 6.00 1.00 21.00 3.00 6.00 1.00

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

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

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

Amount in Rs. 151.40 59.50 119.00 885.00 1102.50 472.50 945.00 173.25 2971.50 424.50 849.00 143.00 8296.15 82.96 829.62 1244.42 1244.42 414.81 12112.38

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

Rs: Rs: Rs: TOTAL Rs:

95663.58 6856.00 12112.38 114631.96

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

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

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

1172.25 1146.32 2865.80 2865.80 2292.64 1604.85 126579.60 314.23 3797.39 130691.22 107400.00 107400.00 ITEM No: 32

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 1.217 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 1.217 tonne Rate per tonne Rate approved per tonne SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

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GATE / HOIST AND ALLIED WORKS

ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity screw type hoist consisting of supporting structure, platform, ladder etc., with all accessories for operating canal escape / regulator gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying two coats of zinc chromate red oxide primer and three coats of approved synthetic enamel paint etc., complete with all leads and lifts. DATA: Screw type hoist for operating gate consists of supporting structure, hoist body, hoist stem, thrust bearings, operating wheel / handle with related accessories. The capacity of screw hoist for canal gate may be considered at 2.5 times the weight of gate. Consider screw type hoist for canal escape / regulator gate for vent opening of size 2 m x 2 m. For 2 m x 2 m opening approximate size of gate : 2.5 m x 2.2 m Head of water above sill level : 3.7 m Weight of vertical lift gate in tonnes for regulator / escape based on empirical formula : = 0.0888 x ( L 2 x H x h ) 0.659 Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0888 x ( 2.5 x 2.5 x 2.2 x 3.7 ) : 1.183 Consider capacity of screw hoist with 25 % reserve capacity @ 2.5 times the weight of gate : ( 2.5 x 1.183) : 2.957 tonnes Round off the capacity of hoist to next 1 tonne : 3.00 tonnes Consider weight of hoist with all accessories at 0.3 tonne per tonne capacity of hoist : ( 0.3 x 3 ) : 0.900 tonne 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 screw type hoist of same capacity for vertical lift roller gate provided for one of the canal escape. Actual capacity of hoist as per data : 3.00 tonnes Actual weight of screw hoist as per data in Item : 32 of Annexure-2 : 0.871 tonne Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of screw type hoist for canal escape vertical lift roller gate provided for one of the canal escape structure ( for details refer Item : 32 of Annexure-2 ).
0.659

1. Requirement of materials: a. Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5% wastage ( 392.5x1.025 ) Plates / flats with 2.5 % wastage ( 141.5 x 1.025 ) Chequered plates with 2.5 % wastage ( 172 x 1.025 ) b. Cast iron components conforming to IS : 210 : Hoist body / Lock nut / Main nut c. Alloy steel components conforming to IS : 1570 : Hoist stem d. Alluminium/ Bronze alloy components conforming to IS : 305 : Bearings / Bush e. Bolt / Nut / Washers conforming to IS : 1363 : MS Bolts / Nuts / Washers with 2.5 % wastage ( 8 x 1.025 ) MS pipe 32 mm dia f. Welding electrodes ( General purpose ) : GP / LH electrodes as per data sheet ( Item:32 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 71 x 0.1 )

: 402.00 kg : 145.00 kg : 176.00 kg : 55.00 kg : 75.00 kg : 4.00 kg : 8.00 kg : 8.8 Rm : 71 Nos : 7 Nos

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GATE / HOIST AND ALLIED WORKS

2.

3.

4.

5.

Total requirement of GP / LH electrodes : 78 Nos for stitch weld GP electrodes @t 10 % of total ( 78 x 0.10 ) : 8 Nos for run welding GP electrodes @ 90 % of total ( 78 x 0.90 ) : 70 Nos Cutting : Total length of cutting assuming cutting for 2 sides as per data sheet : 18 Rm Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 2 Rm For cutting structural steel sections to required sizes gas cutting is assumed. Time for gas cutting manually at average cutting progress of 2 m / hour : 10 hours Acetelyne gas @ 0.6 cum / hour ( 10 x 0.60 ) : 6 cum Oxygen gas @ 1.8 cum / hour ( 10 x 1.80 ) : 18 cum Use of gas cutting torch with 50 min / hr working ( 10 x 60 / 50 ) : 12 hours Welding : Length of welding as per data sheet : 10 Rm For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 8 / 15 ) x 8 / 2 : 2 hours For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 70 / 15 ) x 8 / 6 : 6 hours Total : 8 hours Deploy welding transformer for 8 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 2 x 0.25 + 6 x 0.75 ) : 5 hours Surface cleaning and painting : Painting area for hoist at 20 sqm / tonne of str steel ( 0.723 x 20 ) : 15 sqm 2 coats of zinc chromate red oxide primer. Quantity of primer paint for 15 sqm @ 12 sqm / ltr / coat : 3 ltr 3 coats of synthetic enamel paint. Quantity of coal tar epoxy paint for 15 sqm @ 12 sqm / ltr / coat : 4 ltr As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting. Quantity of rust cleaner / inhibitor for 15 sqm @ 8 sqm / ltr : 2 ltr Requirement of other machinery : For handling of parts during fabrication / erection use of 8 t mobile crane for 1 hour considered.

For drilling holes for bolts 1 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 Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections / Drilling holes 14 hours 1 2 2 4 Fabricating / welding 8 hours --1 1 2 Erection of hoist frame / body 1 1 --2 Cleaning surface 15 sqm @ 15 sqm/day ------1 Painting ( 5 x 15 ) sqm @ 15 sqm / day ------6 Trial operation and final adjustments 1 1 --1 Total : 3 5 3 16 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 5 Painters Cl-II at 15 sqm / day and 1 helper to assist painters. 7. Excise duty on supply :

155

GATE / HOIST AND ALLIED WORKS

Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost of materials ( assuming 25 % erection cost ) is considered for assessing excise duty. 8. Use rate of materials : Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00 Life of welding set : 1000 hours Use rate of welding set per hour ( cost / life ) Rs: 4.50 Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00 Life of gas cutting set : 600 hours Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50 RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars Unit Quantity UNIT : 0.871 tonne 3.000 t capacity Rate Amount in Rs. in Rs. 37.95 40.00 42.00 127.00 125.00 175.00 635.00 55.00 48.00 258.00 6.00 12.00 Contd 15255.90 5800.00 7392.00 1117.60 6875.00 13125.00 2540.00 440.00 864.00 1548.00 48.00 840.00

2 3 4 5 6 7 8 9 10

Structural steel Angles / beams / channels / bars Plates / flats Chequered plate 32 mm dia MS pipe Cast iron components : Hoist body / Lock nut / Main nut Alloy steel components Hoist stem Bronze alloy components : Thrust bearings MS Bolt / Nut / Washer Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen )

kg kg kg Rm kg kg kg kg cum cum Nos Nos

402.00 145.00 176.00 8.80 55.00 75.00 4.00 8.00 18.00 6.00 8.00 70.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

11 12 13 14 15 16 17 18

Zinc chromate red oxide primer Synthetic enamel ( 1st quality ) paint Rust cleaner / inhibitor Grease Use rate welding holder set Use rate gas cutting torch set Wire brush Sundries Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @

ltr ltr ltr kg Hour Hour Nos LS

3.00 4.50 2.00 2.00 8.00 12.00 0.50 1.00

1% 10% 5% Total cost of Materials :

Rate in Rs. Contd 140.00 176.00 240.00 194.00 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 420.00 792.00 480.00 388.00 36.00 30.00 15.00 30.00 58036.50 580.37 5803.65 2901.83 67322.34

B. MACHINERY:

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GATE / HOIST AND ALLIED WORKS

Sl No 1 2 3 4 5

Description Welding transformer Fuel / Energy charges Mobile crane 8 t Fuel / Energy charges Grinding machine Fuel / Energy charges Drilling machines Fuel / Energy charges Sundries

Unit Hour Hour Hour Hour Hour Hour Hour Hour LS

Quantity 8.00 5.00 1.00 1.00 2.00 2.00 1.00 1.00 1.00

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

Rate in Rs. 12.00 60.00 362.00 495.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 96.00 300.00 362.00 495.00 36.00 50.00 18.00 25.00 30.00 1412.00 14.12 40.50 70.60 1537.22

Description

Unit Hour Hour Hour Day Day Day Day Day Day

Quantity 1.00 2.00 1.00 3.00 5.00 2.00 1.00 9.00 2.00

Crew for Drilling machine Crew for Grinding machine Crew for Mobile crane Foreman Marker / Fabricator / Erector Gas cutter Welder ( General ) Helper fabrication / erection Helper for cleaning / painting

Rate in Rs. 59.50 59.50 75.70 177.00 157.50 157.50 157.50 141.50 141.50 Contd

Amount in Rs. 59.50 119.00 75.70 531.00 787.50 315.00 157.50 1273.50 283.00

C. LABOUR ( Contd ) : Sl No Description

Unit

Quantity

10 11

Painter Cl - II Electrician Add for small Tools and Plants @ Add for Contractor's Profit @ Add for hidden cost on Labour @ Add for additional hidden cost on labour @ Add for Contractor's Overheads @

Day Day

4.00 0.50

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

Rate in Rs. Contd 141.50 143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 566.00 71.50 4239.20 42.39 423.92 635.88 635.88 211.96 6189.23

ABSTRACT: A. Cost of Materials B. Hire charges of Machinery C. Cost of Labour Add for excise duty on 75 percent cost of

Rs: Rs: Rs: TOTAL Rs:

67322.34 1537.22 6189.23 75048.79

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Machinery / Labour components @ Add for insurance charges @ Add for designs and drawings @ Add for zigs / supports / winches / chain-pulley @ Add for power supply arrangements @ Add for enabling works @

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

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

477.49 750.49 1876.22 1876.22 1500.98 1050.68 82580.87 224.89 2477.43 85283.19 97910.00 28400.00 28400.00 ITEM No: 33

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 0.871 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 0.871 tonne weight 3.000 tonne capacity Rate per tonne weight Rate per tonne capacity Rate approved per tonne capacity SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sill beam, wheel tracks, seal tracks, guide rails, gate groove liners etc., with all accessories for canal escape / regulator stoplog gate including cost of all materials, machinery, labour, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with all leads and lifts. DATA: Embedded parts for canal escape / regulator stop log gate consist of sill beam, wheel / seal tracks, groove lining upto top, gate guide with all accessories such as first stage anchors. Weight of embedded parts for such small gates will be in the range of 65 to 70 % of gate weight. Consider embedded parts for canal escape / regulator stoplog gate for 2 m wide vent opening.

Length of stoplog element for 2 m wide opening : 2.50 m Head of water above sill level : 3.70 m Total height of stoplog gate considering 4 elements of 1 m height each : 4.00 m Weight of embedded parts for stoplog gate in tonnes based on empirical formula : = 0.0995 x ( L 2 x H x h ) 0.716 Where ( L ) is length and ( H ) is total height and ( h ) is head of water in metres. Consider weight of embedded parts @ 67.5 % of weight of stoplog gate : = 0.675 x 0.0995 x ( L x H x h )
2 0.716

= 0.0671 x ( 2.5 x 2.5 x 4 x 3.7 ) 0.716 : 1.716 The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings of embedded parts for canal escape/ regulator stoplog gate of same size provided for one of the canal escape / regulator structure. Actual weight of embedded parts as per data in Item :33 of Annexure-2 : 1.685 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of embedded parts for canal escape / regulator stoplog gate provided for one of the canal escape / regulator structure ( for details refer Item : 33 of Annexure-2 ). 1. Requirement of materials: a. Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5% wastage ( 1106.5x1.025 ) : 1134 kg

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GATE / HOIST AND ALLIED WORKS

Plates / flats with 2.5 % wastage ( 510 x 1.025 ) b. Alloy steel components conforming to IS : 1570 : Stainless steel plates / flats ( 68 x 1.025 ) c. Bolt / Nut / Washer conforming to IS : 1363 : MS bolts and nuts with 2.5 % wastage d. Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) : GP / LH electrodes as per data sheet ( Item:33 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 1131 x 0.1 ) Total requirement of GP / LH electrodes for stitch welding GP electrodes @t 10 % of total ( 1244 x 0.10 ) for run welding LH electrodes @ 90 % of total ( 1244 x 0.90 ) Stainless steel electrodes as per data sheet ( Item:30 Annexure-2 ) Add for variations / wastage @ 5 % ( 199 x 0.05 ) Total requirement of Stainless steel ( SS ) electrodes for stitch weld SS electrodes @t 10 % of total ( 209 x 0.10 ) for run weld SS electrodes @t 90 % of total ( 209 x 0.90 ) 2. Cutting : Total length of cutting assuming cutting for 2 sides as per data sheet Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % Total For cutting structural steel sections to required sizes gas cutting is assumed. Length of steel to be cut by using gas manually Length of steel to be cut by gas using pug cutting machine Time for gas cutting manually at ( av ) 2 m cutting / hour Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour Acetelyne gas @ 0.6 cum / hour ( 10 + 7 ) x 0.60 Oxygen gas @ 1.8 cum / hour ( 10 + 7 ) x 1.80 Use of gas cutting torch with 50 min / hr working ( 10 x 60 / 50 ) Use of pug cutting machine with 50 min / hr working ( 7 x 60 / 50 )

: 523 kg : 70.00 kg : 1 kg : : : : : : : : : : 1131 Nos 113 Nos 1244 Nos 124 Nos 1120 Nos 199 Nos 10 Nos 209 Nos 21 Nos 188 Nos

: 37 Rm : 4 Rm : 41 Rm : : : : : : : : 20 m 21 m 10 hours 7 hours 10 cum 30 cum 12 hours 8 hours

3. Welding : Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 124 + 21 ) x 8 / 15 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 1120 + 188 ) x 8 / 15 / 6 Total

: 195 m : 39 hours : 116 hours : 155 hours

Deploy welding transformer for 155 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 39 x 0.25 + 116 x 0.75 ) : 97 hours 4. Planing SS plates for seal seats : For surface finishing of SS plates for wheel / seal tracks planing machine is considered. Length of SS plate for surface finishing by planing machine : 16.3 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 16.3 m SS plates ( 16.3 x 8 / 3 ) : 44 hours 5. Surface cleaning and painting : Painting area for embedded parts at 5 sqm / tonne ( 1.685 x 5 ) : 8 sqm 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 8 sqm @ 9 sqm / ltr / coat : 1 ltr 4 coats of coal tar epoxy paint 100 micron dry film each coat.

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GATE / HOIST AND ALLIED WORKS

6. 7.

Note :

8.

9.

Quantity of coal tar epoxy paint for 8 sqm @ 6 sqm / ltr / coat : 5.5 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 8 sqm @ 8 sqm / ltr : 1 ltr Requirement of other machinery : For finishing weld joints / edges 2 hours use of grinding machine considered. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections 20 hours 1 2 2 5 Fabricating by stitch welding 39 hours 2 5 --10 Run welding 116 hours 2 --15 15 Erection of Sill beam / Tracks / Guide 1 2 --4 Cleaning surface 8 sqm @ 15 sqm/day ------0.5 Painting ( 5 x 8 ) sqm @ 15 sqm / day ------3.5 Finishing / cleaning --1 --1 Total : 6 10 17 39 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 3 Painters Cl-II at 15 sqm / day and 0.5 helper to assist painters. Excise duty on supply : Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost of materials ( assuming 25 % erection cost ) is considered for assessing excise duty. Use rate of materials : Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00

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

Rs:

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

: 1000 hours Rs: 4.50 Rs: 1500.00 : 600 hours Rs: 2.50 1.685 tonne Rate in Rs. 37.95 40.00 120.00 55.00 48.00 258.00 6.00 12.00 43.00 594.00 208.00 Amount in Rs. 43035.30 20920.00 8400.00 55.00 1440.00 2580.00 744.00 13440.00 8987.00 594.00 1144.00

RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars

2 3 4 5 6 7 8 9 10

Structural steel Angles / beams / channels / bars Plates / flats Stainless steel plate / flats Bolt / Nut / Washer ( MS ) Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen ) Welding electrodes ( stainless steel ) Zinc rich epoxy primer Coal tar epoxy paint

kg kg kg kg cum cum Nos Nos Nos ltr ltr

1134.00 523.00 70.00 1.00 30.00 10.00 124.00 1120.00 209.00 1.00 5.50

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