GATE / HOIST AND ALLIED WORKS

TOTAL Rs: 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:

318794.52 3143.52 3187.95 7969.86 7969.86 6375.89 4463.12 351904.72 910.93 10557.14 363372.80 103000.00 103000.00 ITEM No: 8

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 3.528 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 3.528 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 adequate capacity Class- II type moving gantry crane consisting of rail mounted gantry frame, top platform with hand railing, long / cross travel arrangements, rope drums, gear systems, electric motors, electromagnetic 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

40

GATE / HOIST AND ALLIED WORKS

1. a.

b.

c. d.

e. f. g.

gantry crane for operating spillway stoplog gate elements and river sluice emergency gate provided for one of the dam for rate analysis ( for details refer item : 8 of Annexure-2 ). Requirement of materials : Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5 % wastage ( 1700x1.025 ) : 1743.00 kg Plates / flats with 2.5 % wastage ( 19219 x 1.025 ) : 19700.00 kg Chequered plate with 2.5 % wastage ( 800 x 1.025 ) : 820 kg Cast steel components conforming to IS : 1030 : Rope drums 2 Nos / Gears : 2336.00 kg Pinions : 149.00 kg Wheels and Pulleys : 2255.00 kg Plummer blocks / Couplings : 817.00 kg Forged steel components conforming to IS : 2004 : Hook / Shackle : 127.00 kg Alloy steel steel components conforming to IS: 1570 : Shafts : 556.00 kg Pins : 524.00 kg Alluminium/ Bronze alloy components conforming to IS : 305 : Bearings / Bush : 181.00 kg Bolt / Nut / Washers conforming to IS : 1363 : MS Bolts / Nuts / Washers with 2.5 % wastage ( 61 x 1.025 ) : 63.00 kg Steel wire rope conforming to IS : 2266 : 28 mm dia 6 / 37 construction 150 Rm @ 2.71 kg / m : 406 .00 kg

h. Other components : Worm reducers Electric motor 17.5 hp Electric motor 5 hp Electric motor 3 hp Ele-magnetic / Thruster brakes MS pipe 32 mm dia Electric cable / switches / control panels etc i. Welding electrodes ( General purpose / Low hydrogen ) : GP / LH electrodes as per data sheet ( Item:8 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 16651 x 0.1 ) Total requirement of GP / LH electrodes for stitch weld GP electrodes @t 10 % of total ( 18316 x 0.10 ) for run welding LH electrodes @ 90 % of total ( 18316 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 % Total For cutting structural steel sections to required sizes gas cutting is assumed. Length of steel to be cut by using gas cutting torch 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 ( 125 + 196 ) x 0.60 Oxygen gas @ 1.8 cum / hour ( 125 + 196 ) x 1.80 Use of gas cutting torch with 50 min / hr working ( 125 x 60 / 50 ) Use of pug cutting machine with 50 min/hr working ( 196 x 60 / 50 ) 3. Welding :

: : : : : : : : : : : :

4 Nos 1 No. 2 Nos 1 No. 4 No. 50 Rm 3 sets 16651 Nos 1665 Nos 18316 Nos 1832 Nos 16484 Nos

: 761 Rm : 76 Rm : 837 Rm : : : : : : : : 250 m 587 m 125 hours 196 hours 193 cum 579 cum 150 hours 235 hours

41

GATE / HOIST AND ALLIED WORKS

Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 1832 / 15 ) x 8 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 16484 / 15 ) x 8 / 6 Total

: 1260 Rm : 489 hours : 1465 hours : 1954 hours

Deploy welding transformer for 1954 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 489 x 0.25 + 1465 x 0.75 ) : 1221 hours 4. Surface cleaning and painting : Painting area for crane at 25 sqm / t of str steel ( 21.443 x 25 ) say : 540 sqm 2 coats of zinc chromate red oxide primer. Quantity of primer paint for 540 sqm @ 12 sqm / ltr / coat : 90 ltr 3 coats of synthetic enamel paint. Quantity of synthetic enamel paint for 540 sqm @ 12 sqm / ltr / coat : 135 ltr As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting. Quantity of rust cleaner / inhibitor for 540 sqm @ 8 sqm / ltr : 68 ltr 5. Requirement of other machinery : For handling and erection of portals use of 25 t mobile crane for 16 hours with energy charges for 8 hours and 8 t momile crane for 40 hours considered

For drilling holes for bolts 16 hours use of drilling machine considered. For grinding and finishing weld joints 64 hours use of grinding machine considered. 6. Requirement of work force : Work component Foreman Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections 385 hours 24 48 48 96 Drilling holes for pins / bolts fixing 1 2 --2 Fabricating by stitch welding 489 hours 30 61 --122 Run welding 1465 hours 18 --183 183 Assembly/Erection of wheels/ base frame 4 8 --16 Assembly/Erection of portals 4 8 --16 Assembly/Erection of top frame 4 8 --16 Assembly/Erection of CT trolley 2 4 --8 Assembly/Erection of drums / drive units 2 4 --8 Assembly/Erection of CT drive units 1 2 --4 Assembly/Erection of LT drive units 1 2 --4 Erection of cabin / railings etc 2 2 --4 Erection of control panel / cabling 1 1 --2 Checking and trial running without rope 2 4 --4 Rope fixing and checking 1 2 --2 Cleaning surface 540 sqm @ 15 sqm/day ------36 Painting ( 5 x 540 ) sqm @ 15 sqm / day ------162 Trial running by lifting / lowering gate 1 2 --2 Finishing / cleaning --1 --2 Total : 98 159 231 689 Note : a. It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding. b. Workforce for painting 2 coat primer and 3 coats finishing paint consists of 135 Painters Cl-II

42

GATE / HOIST AND ALLIED WORKS

at 15 sqm / day and 27 helpers to assist painters. 7. Excise duty on supply : Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of all taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost of materials ( assuming 25 % erection cost ) is considered for assessing excise duty. 8. Use rate of materials : Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00 Life of welding set : 1000 hours Use rate of welding set per hour ( cost / life ) Rs: 4.50 Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00 Life of gas cutting set : 600 hours Use rate of gas cutting set per hr ( cost / life ) Rs: 2.50 RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars Unit Quantity UNIT : 30.856 tonne 25 t capacity Rate Amount in Rs. in Rs. 37.95 40.00 Contd 66146.85 788000.00

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

kg kg

1743.00 19700.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

3 4

5 6 7 8 9 10

11 12 13 14 15 16

Chequered plates Cast steel components : Rope drums 2 Nos / Gears Pinions Wheels / Pulleys Plummer blocks / Couplings Forged steel components Hook / Shackle Alloy steel components Shafts Pins Bronze alloy components : Bronze bearings / bush Wire rope 28 mm dia 6 / 37 construction MS Bolt / Nut / Washer MS pipe 32 mm dia for railing Worm reducers Electric motor 17.5 hp Electric motor 5 hp Electric motor 3 hp Ele-magnetic / Thruster brakes Electric cable / switch / control panel etc Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen )

kg kg kg kg kg kg kg kg kg kg kg Rm Nos. No. Nos. No. Nos. LS cum cum Nos Nos

820.00 2336.00 149.00 2255.00 817.00 127.00 556.00 524.00 181.00 406.00 63.00 50.00 4.00 1.00 2.00 1.00 4.00 3.00 579.00 193.00 1832.00 16484.00

Rate in Rs. Contd 42.00 145.00 150.00 125.00 125.00 165.00 175.00 215.00 635.00 105.00 55.00 127.00 52500.00 37500.00 15000.00 9000.00 11250.00 7500.00 48.00 258.00 6.00 12.00

Amount in Rs. 34440.00 338720.00 22350.00 281875.00 102125.00 20955.00 97300.00 112660.00 114935.00 42630.00 3465.00 6350.00 210000.00 37500.00 30000.00 9000.00 45000.00 22500.00 27792.00 49794.00 10992.00 197808.00

43

GATE / HOIST AND ALLIED WORKS

17 18 19 20 21 22 23 24

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 ( scrap for counter wt etc ) Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @

ltr ltr ltr kg Hour Hour Nos LS

90.00 135.00 68.00 50.00 1954.00 150.00 6.00 200.00

1% 10% 5% Total cost of Materials :

140.00 176.00 240.00 194.00 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

12600.00 23760.00 16320.00 9700.00 8793.00 375.00 180.00 6000.00 2750065.85 27500.66 275006.59 137503.29 3190076.39

B. MACHINERY: Sl No 1

Description

Unit Hour Hour

Quantity 1954.00 1221.00

Welding transformer Fuel / Energy charges

Rate in Rs. 12.00 60.00 Contd

Amount in Rs. 23448.00 73260.00

B. MACHINERY ( Contd ) : Sl No Description

Unit

Quantity

2 3 4 5 6 7

Pug cutting machine Fuel / Energy charges Mobile crane 25 t Fuel / Energy charges Mobile crane 8 t Fuel / Energy charges Grinding machine Fuel / Energy charges Drilling machines Fuel / Energy charges Sundries

Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour LS

235.00 235.00 16.00 8.00 40.00 40.00 64.00 64.00 16.00 16.00 150.00

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

Rate in Rs. Contd 16.00 3.00 3804.00 1375.00 362.00 495.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 3760.00 705.00 60864.00 11000.00 14480.00 19800.00 1152.00 1600.00 288.00 400.00 4500.00 215257.00 2152.57 11126.50 10762.85 239298.92

Description

Unit Hour Hour Hour Hour Day Day Day

Quantity 16.00 40.00 16.00 64.00 98.00 159.00 48.00

Crew for Mobile crane 25 t Crew for Mobile crane 8 t Crew for Drilling machine Crew for Grinding machine Foreman Marker / Fabricator / Erector Gas cutter

Rate in Rs. 72.60 75.70 59.50 59.50 177.00 157.50 157.50

Amount in Rs. 1161.60 3028.00 952.00 3808.00 17346.00 25042.50 7560.00

44

GATE / HOIST AND ALLIED WORKS

8 9 10 11 12 13

Welder ( General ) Khalasi 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 @

Day Day Day Day Day Day

183.00 20.00 491.00 63.00 135.00 5.00

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

157.50 145.50 141.50 141.50 141.50 143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

28822.50 2910.00 69476.50 8914.50 19102.50 715.00 188839.10 1888.39 18883.91 28325.87 28325.87 9441.96 275705.09

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

Rs: Rs: Rs: TOTAL Rs:

3190076.39 239298.92 275705.09 3705080.39

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: Rs:

31827.25 37050.80 92627.01 92627.01 74101.61 51871.13 4085185.20 7967.02 122555.56 4215707.77 136630.00 168600.00 168600.00 ITEM No: 9

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2x30.856 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 30.856 tonne weight 25.000 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 rail track using 45 kg / m standard rails on spillway bridge for movement of gantry crane for handling and operating spillway stoplog gate elements / river sluice / canal sluice emergency gate including cost of all materials, machinery, labour, aligning, anchoring, welding, cleaning etc., complete as per specifications and approved drawings with all leads and lifts. DATA: Rail track for moving gantry crane consists of 45 kg / m standard rails fixed by welding and bolting to anchors embedded in concrete at intervals. The width of track shall be as per the requirement of gantry long travel specifications. Consider track length of 200 m for rate analysis. Weight of 45 kg / m rails in tonnes ( 2 x 200 x 45 ) / 1000 : 18.00 Add for anchors and fixtures @ 15 % including wastage : 2.70 Total weight in tonnes : 20.70

45

GATE / HOIST AND ALLIED WORKS

1. a.

b. c. d.

The weight computed as above based on percentage provision for fixtures is further checked by computing the actual weight as per fabrication drawings for gantry track provided for one of dam. Actual weight of materials as per data in Item : 9 of Annexure-2 : 20.722 t Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on fabrication drawings of gantry track provided for one of the dam for rate analysis ( for details refer Item : 9 of Annexure-2 ). Requirement of materials : Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5 % wastage ( 1531x1.025 ) : 1570 kg Plates / flats with 2.5 % wastage ( 951 x 1.025 ) : 975 kg Bolt / Nut / Washer conforming to IS : 1363 : MS bolts and nuts with 2.5 % wastage ( 240 x 1.025 ) : 246 kg Standard Rails 45 kg / m with 2.5 % wastage ( 18000 x 1.025 ) : 18450 kg Welding electrodes ( General purpose ) : GP electrodes as per data sheet ( Item:9 Annexure-2 ) : 1710 Nos Add for variations / wastage / misc welding @ 10 % ( 1710 x 0.1 ) : 171 Nos Total requirement of GP electrodes : 1881 Nos

for stitch weld GP electrodes @t 10 % of total ( 1881 x 0.10 ) for run welding GP electrodes @ 90 % of total ( 1881 x 0.90 ) 2. Cutting : Total length of cutting assuming cutting for 2 sides as per data sheet For cutting structural steel sections to required sizes gas cutting is assumed. Length of steel to be cut by using gas cutting torch manually Time for gas cutting manually at average cutting progress of 2 m / hour Acetelyne gas @ 0.6 cum / hour ( 111 x 0.60 ) Oxygen gas @ 1.8 cum / hour ( 111 x 1.80 ) Use of gas cutting torch with 50 min / hr working ( 111 x 60 / 50 ) 3. Welding : Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 188 / 15 ) x 8 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 1693 / 15 ) x 8 / 6 Total

: 188 Nos : 1693 Nos : 222 Rm : : : : : 222 m 111 hours 67 cum 201 cum 133 hours

: 210 m : 50 hours : 150 hours : 200 hours

Deploy welding transformer for 200 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 50 x 0.25 + 150 x 0.75 ) : 125 hours 4. Surface cleaning and painting : For painting buffers and supporting plates 0.5 ltr zinc rich epoxy primer and 1 ltr coal tar epoxy paint considered. 5. Requirement of other machinery : For drilling holes for anchor bolts 24 hours use of drilling machine considered. For grinding edges of parts requiring finishing 8 hours use of grinding machine considered. For handling and erection use of 8 t mobile crane for 2 hours considered. 6. Requirement of work force : Work component

Foreman

Marker / Fabricator /

Gas cutter / Welder

Helper / Painter Cl-II

46

GATE / HOIST AND ALLIED WORKS

Erector / Cutting sections 133 hours --17 17 17 Drilling holes for anchors / supports --6 --6 Erection /stitch welding anchors 50 hours 3 6 --6 Erection of rails & fixing clamps 2 2 --4 Run welding 150 hours 2 --19 19 Cleaning surface 3 sqm @ 15 sqm/day --------Painting ( 3 x 3 ) sqm @ 15 sqm / day ------1 Finishing / checking / cleaning 1 1 --1 Total : 8 32 36 54 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. 1 Painter Cl- II considered or cleaning and painting. 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 @ 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:

4500.00 / Each ( cost / life ) 1500.00 / Each ( cost / life ) UNIT : Unit Quantity

Rs:

Rs: 4500.00 : 1000 hours Rs: 4.50 Rs: 1500.00 : 600 hours Rs: 2.50 200.000 Rm Rate in Rs. 37.95 40.00 42.00 55.00 48.00 258.00 6.00 594.00 208.00 4.50 2.50 30.00 Total Rs: Rs: Rs: Rs: Rs: Amount in Rs. 59581.50 39000.00 774900.00 13530.00 9648.00 17286.00 11286.00 297.00 208.00 900.00 332.50 300.00 927269.00 9272.69 92726.90 46363.45 1075632.04

RATE ANALYSIS A. MATERIALS: Sl No 1 Perticulars

2 3 4 5 6 7 8 9 10 11

Structural steel Angles / channels / beams / bars Plates / flats Rails MS bolts and nuts Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Zinc rich epoxy primer Coal tar epoxy paint Use rate welding holder set Use rate gas cutting torch set Sundries Add for small Tools and Plants @ Add for Contractor's Profit @ Add for Contractor's Overheads @

kg kg kg kg cum cum Nos ltr ltr Hour Hour LS

1570.00 975.00 18450.00 246.00 201.00 67.00 1881.00 0.50 1.00 200.00 133.00 10.00

1% 10% 5% Total cost of Materials :

B. MACHINERY: Sl No

Description

Unit

Quantity

Rate in Rs.

Amount in Rs.

47

GATE / HOIST AND ALLIED WORKS

1 2 3 4 5

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

Hour Hour Hour Hour Hour Hour Hour Hour LS

200.00 125.00 2.00 2.00 8.00 8.00 24.00 24.00 10.00

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 :

12.00 60.00 362.00 495.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

2400.00 7500.00 724.00 990.00 144.00 200.00 432.00 600.00 300.00 13290.00 132.90 959.00 664.50 15046.40

C. LABOUR: Sl No 1 2 3 4 5 6 7 8 9 10

Description

Unit Hour Hour Hour Day Day Day Day Day Day Day

Quantity 2.00 24.00 8.00 8.00 32.00 17.00 19.00 53.00 1.00 1.00

Crew for Mobile crane Crew for Drilling machine Crew for Grinding machine Foreman Marker / Fabricator / Erector Gas cutter Welder ( General ) Helper fabrication / erection 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 59.50 177.00 157.50 157.50 157.50 141.50 141.50 143.00 Total Rs: Rs: Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 151.40 1428.00 476.00 1416.00 5040.00 2677.50 2992.50 7499.50 141.50 143.00 21965.40 219.65 2196.54 3294.81 3294.81 1098.27 32069.48

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:

1075632.04 15046.40 32069.48 1122747.92 2911.76 11227.48 28068.70 28068.70 22454.96 15718.47 1231197.99

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

48

GATE / HOIST AND ALLIED WORKS

Fabricated parts 2x20.722 tonnes @ Rs: Add for transportation upto work site @ Total cost for

129.10 / tonne 3.00% 200.000 Rm Rate per Rm Rate approved per Rm YEAR : 2010-11

Rs: Rs: Rs: Rs: Rs:

5350.42 36935.94 1273484.35 6400.00 6400.00 ITEM No: 10

SECTION: GATE / HOIST & ALLIED WORKS.

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( without groove liner ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner ( upto one vent height plus 1 m above the roof of vent ) etc., with all accessories for river / canal sluice service gate including cost of all materials, machinery, labour, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with all leads and lifts.

DATA: Embedded parts for river / canal sluice service gate without groove lining consist of sill beam, wheel / seal tracks, breast wall lining and gate guide with accessories such as first / second stage anchors. The weight of embedded parts depends on the height of gate groove and height upto which breast wall lining is to be provided. Weight of embedded parts will be about 50% of wt of gate. Consider embedded parts for river sluice service gate for sluice opening of size 1.5 m x 3 m. Weight of breast wall lining for 20 mm MS plate and 6 mm SS plate including stiffeners and anchors will be about 250 kg per sqm area of breast wall. Size of gate for 1.5 m x 3 m opening : Length : 2.2 m Height : 3.3 m Head of water above sill level considered : 16 m Weight of vertical lift roller gate in tonne for 1.5 m x 3 m opening based on empirical formula : = 0.0888 x ( L x H x h ) Consider weight of embedded parts in tonnes @ 50 % of weight of gate leaf : = 0.50 x 0.0888 x ( L x H x h ) Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. : 1.714 tonnes : 1.750 tonnes Total : 3.464 tonnes The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings of embedded parts for river sluice service gate of same size provided for one of the dam. Actual weight of embedded parts as per data in Item :10 of Annexure-2 : 3.172 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on embedded parts drawings for river sluice service gate provided for one of the dam for rate analysis ( for details refer Item : 10 of Annexure - 2 ). Requirement of materials : Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5 % wastage ( 588x1.025 ) : 603 kg Plates / flats with 2.5 % wastage ( 2109 x 1.025 ) : 2162 kg Alloy steel components conforming to IS : 1570 : Stainless steel plates / flats ( 414 x 1.025 ) : 424.00 kg Bolt / Nut / Washer conforming ti IS : 1363 : MS bolts and nuts with 2.5 % wastage ( 61 x 1.025 ) : 62.5 kg Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) : = 0.0444 x ( 2.2 x 2.2 x 3.3 x 16 ) Weight of breast wall lining about 7 sqm @ 250 kg / sqm
0.659 2 0.659 2 0.659

1. a.

b. c. d.

49

GATE / HOIST AND ALLIED WORKS

GP / LH electrodes as per data sheet ( Item:10 Annexure-2 ) Add for variations / wastage / misc welding @ 10 % ( 1359 x 0.1 ) Total requirement of GP / LH electrodes for stitch welding GP electrodes @t 10 % of total ( 1495 x 0.10 ) for run welding LH electrodes @ 90 % of total ( 1495 x 0.90 ) Stainless steel electrodes as per data sheet ( Item:10 Annexure-2 ) Add for variations / wastage @ 5 % ( 417 x 0.05 ) Total requirement of Stainless steel ( SS ) electrodes for stitch weld SS electrodes @t 10 % of total ( 438 x 0.10 ) for run weld SS electrodes @t 90 % of total ( 438 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 % Total length of cutting

: : : : : : : : : :

1359 Nos 136 Nos 1495 Nos 150 Nos 1345 Nos 417 Nos 21 Nos 438 Nos 44 Nos 394 Nos

Total

: 152 Rm : 15 Rm : 167 Rm

For cutting structural steel sections to required size gas cutting is assumed for cutting angles / beams / channels / round bars. For plates / flats less than 12 mm in thickness plate shearing machine and for the remaining sections pug cutting machine is considered. Length of steel to be cut by using gas manually : 30 m Length of steel to be cut by gas using pug cutting machine : 107 m Length of steel to be cut by using shearing machine : 30 m Time for 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 : 36 hours Time for cutting by shearing machine at ( av ) 10 m cutting / hour : 3 hours Acetelyne gas @ 0.6 cum / hour ( 15 + 36 ) x 0.60 : 31 cum Oxygen gas @ 1.8 cum / hour ( 15 + 36 ) x 1.80 : 93 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 ( 36 x 60 / 50 ) : 43 hours Use of shearing machine with 50 min / hr working ( 3 x 60 / 50 ) : 4 hours 3. Welding : Length of welding as per data sheet For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 150 + 44 ) x 8 / 15 / 2 For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 1345 + 394 ) x 8 / 15 / 6 Total

: 191 m : 52 hours : 154 hours : 206 hours

Deploy welding transformer for 206 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 52 x 0.25 + 154 x 0.75 ) : 129 hours 4. Planing SS plates for wheel / seal tracks : For surface finishing of SS plates for wheel / seal tracks planing machine is considered. Length of SS plate for surface finishing by planing machine : 30 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 30 m SS plates ( 30 x 8 / 3 ) : 80 hours 5. Surface cleaning and painting : Painting area for embedded parts at 10 sqm / tonne ( 3.172 x 10 ) 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 32 sqm @ 9 sqm / ltr / coat

: 32 sqm : 4 ltr

50

GATE / HOIST AND ALLIED WORKS

4 coats of coal tar epoxy paint 100 micron dry film each coat. Quantity of coal tar epoxy paint for 32 sqm @ 6 sqm / ltr / coat : 22 ltr 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 @ 8 sqm / ltr : 4 ltr 6. Requirement of other machinery : For drilling holes for anchor bolts use of drilling machine for 8 hours considered. For grinding weld joints and edges requiring finishing use of grinding machine for 8 hours considered. For handling parts during fabrication and erection use of 8 t mobile crane for 4 hours and stationery derric crane for 8 hours considered

7. Requirement of work force : Work component

Foreman

Marker / Fabricator / Erector /

Gas cutter / Welder

Helper / Painter Cl-II

Cutting sections 65 hours 4 8 8 16 Drilling holes for anchors / supports 1 1 --2 Fbricating by stitch welding 52 hours 3 6 --12 Run welding 154 hours 2 --19 19 Erection of first stage anchors 3 6 --6 Erection of Sill beam / Tracks / Guide 2 4 --8 Erection of Breast wall 2 4 --8 Cleaning surface 32 sqm @ 15 sqm/day ------2 Painting ( 5 x 32 ) sqm @ 15 sqm / day ------13 Finishing / checking / cleaning 1 1 --2 Total : 18 30 27 88 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 11 Painters Cl-II at 15 sqm / day and 2 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 A. MATERIALS: Sl No 1 Perticulars Unit Quantity UNIT : 3.172 tonne Rate in Rs. 37.95 40.00 Amount in Rs. 22883.85 86480.00

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

kg kg

603.00 2162.00

51

GATE / HOIST AND ALLIED WORKS

2 3 4 5 6 7 8 9 10 11 12

Stainless steel plate / flats MS bolts and nuts Oxygen gas Acetyline gas Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen ) Welding electrodes ( stainless steel ) Zinc rich epoxy primer Coal tar epoxy paint Rust cleaner / inhibitor Use rate welding holder set

kg kg cum cum Nos Nos Nos ltr ltr ltr Hour

424.00 62.50 93.00 31.00 150.00 1345.00 438.00 4.00 22.00 4.00 206.00

120.00 55.00 48.00 258.00 6.00 12.00 43.00 594.00 208.00 240.00 4.50 Contd

50880.00 3437.50 4464.00 7998.00 900.00 16140.00 18834.00 2376.00 4576.00 960.00 927.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

13 14 15

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 @

Hour Nos LS

18.00 1.00 20.00

1% 10% 5% Total cost of Materials :

Rate in Rs. Contd 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 45.00 30.00 600.00 221531.35 2215.31 22153.14 11076.57 256976.37

B. MACHINERY: Sl No 1 2 3 4 5 6 7 8 9

Description

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

Quantity 206.00 129.00 4.00 4.00 43.00 43.00 80.00 80.00 4.00 4.00 8.00 8.00 8.00 8.00 8.00 8.00 10.00

Welding transformer Fuel / Energy charges Plate shearing machine Fuel / Energy charges Pug cutting machine Fuel / Energy charges Planing 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

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 :

Rate in Rs. 12.00 60.00 62.00 100.00 16.00 3.00 88.00 75.00 362.00 495.00 66.00 9.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 2472.00 7740.00 248.00 400.00 688.00 129.00 7040.00 6000.00 1448.00 1980.00 528.00 72.00 144.00 200.00 144.00 200.00 300.00 29733.00 297.33 1702.10 1486.65 33219.08

52

GATE / HOIST AND ALLIED WORKS

C. LABOUR: Sl No 1 2 3 4 5 6

Description

Unit Hour Hour Hour Hour Hour Day

Quantity 4.00 4.00 80.00 8.00 8.00 18.00

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

Rate in Rs. 75.70 45.90 73.40 59.50 59.50 177.00 Contd

Amount in Rs. 302.80 183.60 5872.00 476.00 476.00 3186.00

C. LABOUR ( Contd ) : Sl No Description

Unit

Quantity

7 8 9 10 11 12 13 14

Marker / Fabricator / Erector Gas cutter Welder ( General ) Welder ( X - ray ) 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 @

Day Day Day Day Day Day Day Day

30.00 8.00 17.00 2.00 73.00 4.00 11.00 2.00

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

Rate in Rs. Contd 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. 4725.00 1260.00 2677.50 346.50 10329.50 566.00 1556.50 286.00 32243.40 322.43 3224.34 4836.51 4836.51 1612.17 47075.36

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:

256976.37 33219.08 47075.36 337270.81 4962.20 3372.71 8431.77 8431.77 6745.42 4721.79 373936.46 819.01 11218.09 385973.57 121700.00 121700.00

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2 x 3.172 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 3.172 tonne Rate per tonne Rate approved per tonne

53

GATE / HOIST AND ALLIED WORKS

SECTION: GATE / HOIST & ALLIED WORKS.

YEAR : 2010-11

ITEM No: 11

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( with groove liner upto breast wall level ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner ( upto one vent height plus 1 m above the roof of vent ) etc., with all accessories for river / canal sluice service gate including cost of all materials, machinery, labour, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with all leads and lifts.

DATA: Embedded parts for river sluice service gate consist of sill beam, wheel / seal tracks, groove lining upto breast wall level, breast wall lining upto 1 vent plus 1 m above top of vent, gate guide etc., with all accessories such as first stage anchors. The wt of embedded parts depends on the height of gate groove and height upto which breast wall lining is to be provided. Generally wt of embedded parts will be about 50% of wt of gate. Weight of breast wall lining for 20 mm MS plate and 6 mm SS plate including stiffeners and anchors will be about 250 kg per sqm area of breast wall. Weight of groove liner for 20 mm MS plate including stiffeners and anchors will be about 200 kg / sqm area of groove liner. Consider embedded parts for river sluice service gate for sluice opening of size 2.5 m x 3 m. Size of gate for 2.5 m x 3 m opening : Length : 3.2 m Height : 3.3 m Head of water above sill level considered : 34 m Weight of vertical lift roller in tonne for 2.5 m x 3 m opening based on empirical formula : = 0.0888 x ( L x H x h ) Consider weight of embedded parts in tonnes @ 50 % of weight of gate leaf : = 0.50 x 0.0888 x ( L x H x h ) Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. : 4.615 tonnes : 3.000 tonnes : 3.000 tonnes Total : 10.615 tonnes The weight computed as above based on empirical formula is further checked by computing the actual weight as per fabrication drawings of embedded parts with groove liners for river sluice service gate of same size provided for one of the dam. Actual weight of embedded parts as per data in Item : 11 of Annexure-2 : : 10.657 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on embedded parts and gate groove liner drawings for river sluice service gate provided for one of the dam work for rate analysis ( for details refer Item : 11 of Annexure - 2 ). Requirement of materials : Structural steel conforming to IS : 2062 : Angles/ beams/ channels/ bars with 2.5 % wastage ( 681x1.025 ) : 698 kg Plates / flats with 2.5 % wastage ( 8971 x 1.025 ) : 9195 kg Alloy steel components conforming to IS : 1570 : Stainless steel plates / flats ( 825 x 1.025 ) : 846 kg Bolt / Nut / Washer conforming ti IS : 1363 : MS bolts and nuts with 2.5 % wastage ( 180 x 1.025 ) : 185 kg Welding electrodes ( General purpose / Low hydrogen / Stainless steel ) : GP / LH electrodes as per data sheet ( Item:11 Annexure-2 ) : 5569 Nos Add for variations / wastage / misc welding @ 10 % ( 5569 x 0.1 ) : 557 Nos = 0.0444 x ( 3.2 x 3.2 x 3.3 x 34 ) Weight of breast wall lining about 12 sqm @ 250 kg / sqm Weight of groove liner about 15 sqm @ 200 kg / sqm
0.659 2 0.659 2 0.659

1. a.

b. c. d.

54

GATE / HOIST AND ALLIED WORKS

Total requirement of GP / LH electrodes for stitch welding GP electrodes @t 10 % of total ( 6126 x 0.10 ) for run welding LH electrodes @ 90 % of total ( 6126 x 0.90 ) Stainless steel electrodes as per data sheet ( Item:11 Annexure-2 ) Add for variations / wastage @ 5 % ( 457 x 0.05 ) Total requirement of Stainless steel ( SS ) electrodes for stitch weld SS electrodes @t 10 % of total ( 480 x 0.10 ) for run weld SS electrodes @t 90 % of total ( 480 x 0.90 )

: : : : : : : :

6126 Nos 613 Nos 5513 Nos 457 Nos 23 Nos 480 Nos 48 Nos 432 Nos

2. Cutting : Length of cutting assuming cutting for 2 sides as per data sheet : 301 Rm Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 30 Rm Total length of cutting Total : 331 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 : 60 m Length of steel to be cut by gas using pug cutting machine : 211 m Length of steel to be cut by using shearing machine : 60 m Time for gas cutting manually at ( av ) 2 m cutting / hour : 30 hours Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 70 hours Time for cutting by shearing machine at ( av ) 10 m cutting / hour : 6 hours Acetelyne gas @ 0.6 cum / hour ( 30 + 70 ) x 0.60 : 60 cum Oxygen gas @ 1.8 cum / hour ( 30 + 70 ) x 1.80 : 180 cum Use of gas cutting torch with 50 min / hr working ( 30 x 60 / 50 ) : 36 hours Use of pug cutting machine with 50 min / hr working ( 70 x 60 / 50 ) : 84 hours Use of shearing machine with 50 min / hr working ( 6 x 60 / 50 ) : 7 hours 3. Welding : Length of welding as per data sheet : 552 m For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 613 + 48 ) x 8 / 15 / 2 : 176 hours For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 5513 + 432 ) x 8 / 15 / 6 : 528 hours Total : 704 hours Deploy welding transformer for 704 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 176 x 0.25 + 528 x 0.75 ) : 440 hours 4. Planing SS plates for wheel / seal tracks : For surface finishing of SS plates for wheel / seal tracks planing machine is considered. Length of SS plate for surface finishing by planing machine : 30 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 30 m SS plates ( 30 x 8 / 3 ) : 80 hours 5. Surface cleaning and painting : Painting area for embedded parts at 10 sqm / tonne ( 10.657 x 10 ) : 107 sqm 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 107 sqm @ 9 sqm / ltr / coat : 12 ltr 4 coats of coal tar epoxy paint 100 micron dry film each coat. Quantity of coal tar epoxy paint for 107 sqm @ 6 sqm / ltr / coat : 72 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

55

GATE / HOIST AND ALLIED WORKS

before applying primer painting. Quantity of rust cleaner / inhibitor for 107 sqm @ 8 sqm / ltr : 14 ltr 6. Requirement of other machinery : For drilling holes for anchor bolts use of drilling machine for 50 hours considered. For grinding weld joints and edges requiring finishing use of grinding machine for 25 hours considered. For handling of parts during fabrication and erection 8 t mobile crane for 10 hours and stationery derric crane for 40 hours considered.

Marker / Gas cutter / Helper / Fabricator / Welder Painter Cl-II Erector / Cutting sections 127 hours 8 16 16 32 Drilling holes for anchors / supports 3 6 --6 Fbricating by stitch welding 176 hours 11 22 --44 Run welding 528 hours 7 --66 66 Erection of first stage anchors 5 10 --10 Erection of Sill beam / Tracks / Guide 2 4 --8 Erection of Breast wall liner 2 4 --8 Erection of groove liners 3 6 --12 Cleaning surface 107 sqm @ 15 sqm/day ------7 Painting ( 5 x 107 ) sqm @ 15 sqm / day ------42 Finishing / cleaning 1 2 --4 Total : 42 70 82 239 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 36 Painters Cl-II at 15 sqm / day and 6 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 A. MATERIALS: Sl No 1 Perticulars Unit Quantity UNIT : 10.657 tonne Rate in Rs. 37.95 40.00 120.00 55.00 48.00 258.00 Amount in Rs. 26489.10 367800.00 101520.00 10175.00 8640.00 15480.00

7. Requirement of work force : Work component

Foreman

2 3 4 5

Structural steel Angles / beams / channels / bars Plates / flats Stainless steel plate / flats MS bolts and nuts Oxygen gas Acetyline gas

kg kg kg kg cum cum

698.00 9195.00 846.00 185.00 180.00 60.00

56

GATE / HOIST AND ALLIED WORKS

6 7 8 9 10 11

Welding electrodes ( general purpose ) Welding electrodes ( low hydrogen ) Welding electrodes ( stainless steel ) Zinc rich epoxy primer Coal tar epoxy paint Rust cleaner / inhibitor

Nos Nos Nos ltr ltr ltr

613.00 5513.00 480.00 12.00 72.00 14.00

6.00 12.00 43.00 594.00 208.00 240.00 Contd

3678.00 66156.00 20640.00 7128.00 14976.00 3360.00

A. MATERIALS ( Contd ) : Sl No Perticulars

Unit

Quantity

12 13 14 15

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 @

Hour Hour Nos LS

704.00 36.00 2.00 40.00

1% 10% 5% Total cost of Materials :

Rate in Rs. Contd 4.50 2.50 30.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 3168.00 90.00 60.00 1200.00 650560.10 6505.60 65056.01 32528.01 754649.72

B. MACHINERY: Sl No 1 2 3 4 5 6 7 8 9

Description

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

Quantity 704.00 440.00 7.00 7.00 84.00 84.00 80.00 80.00 10.00 10.00 40.00 40.00 25.00 25.00 50.00 50.00 40.00

Welding transformer Fuel / Energy charges Plate shearing machine Fuel / Energy charges Pug cutting machine Fuel / Energy charges Planing 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

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

Rate in Rs. 12.00 60.00 62.00 100.00 16.00 3.00 88.00 75.00 362.00 495.00 66.00 9.00 18.00 25.00 18.00 25.00 30.00 Total Rs: Rs: Rs: Rs: Rs:

Amount in Rs. 8448.00 26400.00 434.00 700.00 1344.00 252.00 7040.00 6000.00 3620.00 4950.00 2640.00 360.00 450.00 625.00 900.00 1250.00 1200.00 66613.00 666.13 4173.70 3330.65 74783.48

Description

Unit Hour

Quantity 10.00

Crew for Mobile crane

Rate in Rs. 75.70

Amount in Rs. 757.00

57

GATE / HOIST AND ALLIED WORKS

2 3 4 5 6

Crew for Shearing machine Crew for Planing machine Crew for Drilling machine Crew for Grinding machine Foreman

Hour Hour Hour Hour Day

7.00 80.00 50.00 25.00 42.00

45.90 73.40 59.50 59.50 177.00 Contd

321.30 5872.00 2975.00 1487.50 7434.00

C. LABOUR ( Contd ) : Sl No Description

Unit

Quantity

7 8 9 10 11 12 13 14

Marker / Fabricator / Erector Gas cutter Welder ( General ) Welder ( X - ray ) 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 @

Day Day Day Day Day Day Day Day

70.00 16.00 59.00 7.00 190.00 13.00 36.00 5.00

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

Rate in Rs. Contd 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. 11025.00 2520.00 9292.50 1212.75 26885.00 1839.50 5094.00 715.00 77430.55 774.31 7743.06 11614.58 11614.58 3871.53 113048.60

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:

754649.72 74783.48 113048.60 942481.80 11608.02 9424.82 23562.04 23562.04 18849.64 13194.75 1042683.11 2751.64 31280.49 1076715.24 101000.00 101000.00 ITEM No: 12

Add for 2 rehandling leads for 1 km including loading and unloading : Fabricated parts 2x10.657 tonnes @ Rs: 129.10 / tonne Add for transportation upto work site @ 3.00% Total cost for 10.657 tonne Rate per tonne Rate approved per tonne SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11

ITEM: Design, fabrication, supply, erection and commissioning of vent liner using 20 mm thick MS plates with stiffeners and anchors for river sluice / canal sluice vents including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying

58

GATE / HOIST AND ALLIED WORKS

one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete with all leads and lifts. DATA: Vent lining consists of forming river / canal sluice of specified size using 20 mm thick structural steel plates for the specified length. The liner plates are stiffened on the back side and anchors

1. a. b.

2.

3.

are provided for embedment in concrete. Consider vent lining for river / canal sluice of size 2.5 m x 3 m for analysis. Consider vent lining for 3.40 m length of vent. Finished area of lining : ( 2 x 3 x 3.4 + 2 x 2.5 x 3.4 ) : 37.40 sqm Weight of 20 mm thick MS plate per sqm : 157.00 kg Add 25 % for stiffeners / anchors / projections etc : 39.25 kg Total requirement of steel for vent lining of sluice per sqm area Total : 196.25 kg say : 196 kg Quantity of steel required for 37.40 sqm ( 37.40 x 0.196 ) : 7.330 tonnes The weight computed as above on percentage basis for stiffeners / anchors is further checked by computing the actual weight as per fabrication drawings of vent liner for river sluice service gate vent of same size provided for one of the dam. Actual weight of liner for 37.4 sqm as per data in Item : 12 of Annexure-2 : 7.281 tonnes Consider actual weight for data rate analysis. Consider details of Material / Gas cutting / Welding based on vent liner drawings for river sluice service gate vent provided for one of the dam for rate analysis ( for details refer Item : 12 of Annexure - 2 ). Requirement of materials : Structural steel conforming to IS : 2062 : Plates / flats with 2.5 % wastage ( 7281 x 1.025 ) : 7463 kg Welding electrodes ( General purpose / Low hydrogen ) : GP / LH electrodes as per data sheet ( Item:12 Annexure-2 ) : 4194 Nos Add for variations / wastage / misc welding @ 10 % ( 4194 x 0.1 ) : 419 Nos Total requirement of GP / LH electrodes : 4613 Nos for stitch weld GP electrodes @ 10 % of total ( 4613 x 0.10 ) : 461 Nos for run welding LH electrodes @ 90 % of total ( 4613 x 0.90 ) : 4152 Nos Cutting : Length of cutting assuming cutting for 2 sides : 203 Rm Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 20 Rm Total : 223 Rm For cutting structural steel sections to required sizes gas cutting is assumed since most of the sections are above 10 mm thick. Length of steel to be cut by using gas manually : 30 m Length of steel to be cut by gas using pug cutting machine : 193 m 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 : 64 hours Acetelyne gas @ 0.6 cum / hour ( 15 + 64 ) x 0.60 : 47 cum Oxygen gas @ 1.8 cum / hour ( 15 + 64 ) x 1.80 : 141 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 ( 64 x 60 /:50 ) : 77 hours Welding : Length of welding : 420 Rm For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr ( 461 / 15 ) x 8 / 2 : 123 hours For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 4152 / 15 ) x 8 / 6 : 369 hours

59

GATE / HOIST AND ALLIED WORKS

Total : 492 hours Deploy welding transformer for 492 hours. Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 123 x 0.25 + 369 x 0.75 ) : 308 hours

4. Surface cleaning and painting : Painting area for liner : 37.5 sqm 1 coat of zinc rich epoxy primer 40 micron dry film each coat. Quantity of primer paint for 37.5 sqm @ 9 sqm / ltr / coat : 4 ltr 4 coats of coal tar epoxy paint 100 micron dry film each coat. Quantity of coal tar epoxy paint for 37.5 sqm @ 6 sqm / ltr / coat : 25 ltr 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 37.5 sqm @ 8 sqm / ltr : 5 ltr 5. Requirement of other machinery : For handling during fabrication and erection 8 t mobile crane for 4 hours and stationery derric crane for 16 hours considered. For grinding and finishing weld joints in liner plates 12 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 95 hours 6 12 12 24 Fabricating by stitch welding 123 hours 8 15 --30 Run welding 369 hours 5 --46 46 Cleaning surface 37.4 sqm @15 sqm/day ------2 Painting ( 5x37.4 ) sqm @ 15 sqm / day ------14 Finishing / Cleaning 1 1 --1 Total : 20 28 58 117 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 12 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 A. MATERIALS: Sl No 1 2 Perticulars Unit kg cum Quantity 7463.00 168.00 UNIT : 37.400 sqm Rate in Rs. 40.00 48.00 Amount in Rs. 298520.00 8064.00

Structural steel plates / flats Oxygen gas

60