Data Rates Gate Works 4

8/13/2019 Data Rates Gate Works 4

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GATE / HOIST AND ALLIED WORKS

3 Acetyline gas cum 56.00 258.00 14448.00

4 Welding electrodes ( general purpose ) Nos 461.00 6.00 2766.00

Contd

A. MATERIALS ( Contd ) :

Sl No Unit Amount

in Rs.

Contd

5 Welding electrodes ( low hydrogen ) Nos 4152.00 12.00 49824.00

6 Zinc rich epoxy primer ltr 4.00 594.00 2376.00

7 Coal tar epoxy paint ltr 25.00 208.00 5200.00

8 Rust cleaner / inhibitor ltr 5.00 240.00 1200.00

9 Use rate welding holder set Hour 492.00 4.50 2214.00

10 Use rate gas cutting torch set Hour 18.00 2.50 45.00

11 Wire brush Nos 1.00 30.00 30.00

12 Sundries LS 5.00 30.00 150.00

Total Rs: 384837.00 Add for small Tools and Plants @ 1% Rs: 3848.37

Add for Contractor's Profit @ 10% Rs: 38483.70

Add for Contractor's Overheads @ 5% Rs: 19241.85

Total cost of Materials : Rs: 446410.92

B. MACHINERY:

Sl No Unit Amount

in Rs.

1 Welding transformer Hour 492.00 12.00 5904.00

Fuel / Energy charges Hour 308.00 60.00 18480.00

2 Pug cutting machine Hour 77.00 16.00 1232.00


3 Mobile crane 8 t Hour 4.00 362.00 1448.00


4 Stationery derric crane Hour 16.00 66.00 1056.00


5 Grinding machine Hour 12.00 18.00 216.00


6 Sundries LS 5.00 30.00 150.00

Total Rs: 31141.00

Add for small Tools and Plants @ 1% Rs: 311.41

Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 2128.50


Total hire charges of Machinery : Rs: 35137.96

C. LABOUR:

Sl No Unit Amountin Rs.

1 Crew for Mobile crane Hour 4.00 75.70 302.80

2 Crew for Grinding machine Hour 12.00 59.50 714.00

3 Foreman Day 20.00 177.00 3540.00

4 Marker / Fabricator / Erector Day 28.00 157.50 4410.00

5 Gas cutter Day 12.00 157.50 1890.00

6 Welder ( General ) Day 46.00 157.50 7245.00

7 Helper fabrication / erection Day 101.00 141.50 14291.50

Description Quantity

in Rs.

in Rs.

in Rs.

Perticulars Quantity Rate

Quantity

Rate

RateDescription

61




Head of water considered above sill of gate : 34 m

Weight of gate leaf in tonne for vertical lift roller gate 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 above sill in Rm.

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

: 9.229

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

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

one of the dam.

Actual weight of river sluice service gate as per data in Item : 13 of Annexure-2 : 9.202 tonnes

Consider actual weight for data rate analysis.

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

gate provided for one of the dam for rate analysis ( for details refer Item : 13 of Annexure-2 ).

1. Requirement of materials :

a. Structural steel conforming to IS : 2062 :

Plates / flats with 2.5 % wastage ( 4370 x 1.025 ) : 4479 kgb. Cast iron components conforming to IS : 210 :

Cast iron blocks for counter weight ( 4000 x 1.025 ) : 4100 kg

c. Alloy steel components conforming to IS : 1570 :

Wheel axles / Pins : 132 kg

d. Cast steel components conforming to IS : 1030 :

Wheels / guide rollers : 492 kg

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

Bearings / Bushes : 76 kg

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

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

GI bolts / nuts / washers with 2.5 % wastage ( 74 x 1.025 ) : 76 kg

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

g. Rubber seal conforming to IS : 11855 :

Bottom seal ( flat type ) ( 2.76 x 1.025 ) : 2.8 RmSide seals ( music note type teflon claded ) ( 5.71 x 1.025 ) : 5.85 Rm

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

Corner seal ( teflon claded ) : 2 Nos

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

GP / LH electrodes as per data sheet ( Item:13 Annexure-2 ) : 3265 Nos

Add for variations / wastage / misc welding @ 10 % ( 3265 x 0.1 ) : 326 Nos

Total requirement of GP / LH electrodes : 3591 Nos

for stitch weld GP electrodes @t 10 % of total ( 3591 x 0.10 ) : 359 Nos

for run welding LH electrodes @ 90 % of total ( 3591 x 0.90 ) : 3232 Nos

2. Cutting :

Length of cutting assuming cutting for 2 sides as per data sheet : 137 Rm

Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 14 Rm

Total : 151 RmFor 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 : 121 m

Time for gas cutting manually at ( av ) 2 m cutting / hour : 15 hours

Time for gas cutting by pug cutting machine at ( av ) 3 m cutting / hour : 40 hours

Acetelyne gas @ 0.6 cum / hour ( 15 + 40 ) x 0.60 : 33 cum

Oxygen gas @ 1.8 cum / hour ( 15 + 40 ) x 1.80 : 99 cum

63




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

Use of pug cutting machine with 50 min / hr working ( 40 x 60 / 50 ) : 48 hours

3. Welding :

Length of welding as per data sheet : 281 Rm

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

( 359 / 15 ) x 8 / 2 : 96 hours

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

( 3232 / 15 ) x 8 / 6 : 287 hours

Total : 383 hours

Deploy welding transformer for 383 hours.

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

( 96 x 0.25 + 287 x 0.75 ) : 239 hours

4. Surface cleaning and painting :

Painting area for river sluice gate at 10 sqm / tonne ( 9.202 x 10 ) : 92 sqm

1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 92 sqm @ 9 sqm / ltr / coat : 10 ltr

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

Quantity of coal tar epoxy paint for 92 sqm @ 6 sqm / ltr / coat : 46 ltr

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

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

before applying primer painting.

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

5. Requirement of other machinery :

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

For handling and erection 8 t mobile crane for 4 hours and stationery derric crane for 10 hours

considered.

For drilling holes in skin plate, counter weight blocks, horizontal girders and seal clamps use of

drilling machine for 8 hours considered.

For grinding and finishing weld joints in skin plate and other locations 8 hours use of grinding

machine considered.

6. Requirement of work force :

Work component Foreman Helper /

Painter Cl-II

Cutting sections 66 hours 4 8 8 16

Drilling holes for seal fixing 1 2 --- 2

Fabricating by stitch welding 96 hours 6 12 --- 24

Run welding 287 hours 3 --- 36 36

Fixing counter weight blocks --- 2 --- 4

Seal fixing 1 1 --- 2

Cleaning surface 92 sqm @ 15 sqm/day --- --- --- 6

Painting ( 4 x 92 ) sqm @ 15 sqm / day --- --- --- 30Guide roller fixing / Cleaning / Lowering 1 2 --- 2

Total : 16 27 44 122

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

considered for welder for stitch welding.

b. Workforce for painting 1 coat primer and 3 coats finishing paint consists of 25 Painters Cl-II

at 15 sqm / day and 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

Erector /

Marker /

Welder

Gas cutter /

Fabricator /

64




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

of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.

8. Use rate of materials :

Cost of welding set @ Rs: 4500.00 / Each Rs: 4500.00

Life of welding set : 1000 hours

Use rate of welding set per hour ( cost / life ) Rs: 4.50

Cost of gas cutting set @ Rs: 1500.00 / Each Rs: 1500.00

Life of gas cutting set : 600 hours

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

RATE ANALYSIS UNIT : 9.202 tonne

A. MATERIALS:

Sl No Unit Amount

in Rs.

1 Structural steel

Plates / flats kg 4479.00 40.00 179160.002 Cast iron components

CI blocks for counter wt kg 4100.00 32.00 131200.00

3 Alloy steel components

Wheel axles / Pins kg 132.00 215.00 28380.00

4 Cast steel components

Wheels / Guide rollers kg 492.00 125.00 61500.00

5 Alluminium / Bronze alloy components

Bearings / Bushes kg 76.00 635.00 48260.00

6 Bolt / Nut / Washer

SS bolts / nuts / washers kg 55.00 150.00 8250.00

GI bolts / nuts / washers kg 76.00 95.00 7220.00

MS bolts / nuts / washers kg 4.00 55.00 220.00

7 Rubber seals

Bottom seal ( flat uncladed ) Rm 2.80 147.00 411.60

Side seals ( bulb teflon claded ) Rm 5.85 675.00 3948.75

Top seal ( bulb teflon claded ) Rm 2.25 675.00 1518.75

Corner seals ( bulb teflon claded ) Nos 2.00 740.00 1480.00

8 Oxygen gas cum 99.00 48.00 4752.00









17 Wire brush Nos 1.00 30.00 30.0018 Sundries LS 5.00 30.00 150.00

Total Rs: 546089.60





QuantityPerticulars

in Rs.

Rate

65




B. MACHINERY:

Sl No Unit Amount

in Rs.





3 Tower crane Hour 1.00 994.00 994.00








7 Drilling machines Hour 12.00 18.00 216.00

Fuel / Energy charges Hour 12.00 25.00 300.008 Sundries LS 5.00 30.00 150.00

Total Rs: 26160.00





C. LABOUR:

Sl No Unit Amount

in Rs.


2 Crew for Tower crane Hour 1.00 62.00 62.00

3 Crew for Drilling machine Hour 12.00 59.50 714.00


5 Foreman Day 16.00 177.00 2832.00


7 Gas cutter Day 8.00 157.50 1260.00


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


11 Helper for cleaning / painting Day 11.00 141.50 1556.50

12 Painter Cl - II Day 25.00 141.50 3537.50

13 Electrician Day 2.00 143.00 286.00

Total Rs: 33181.30



Add for hidden cost on Labour @ 15% Rs: 4977.20 Add for additional hidden cost on labour @ 15% Rs: 4977.20


Total cost of Labour : Rs: 48444.70

Description


in Rs.

Quantity

in Rs.

Rate

Rate

66




ABSTRACT:

A. Cost of Materials Rs: 633463.94

B. Hire charges of Machinery Rs: 29463.00

C. Cost of Labour Rs: 48444.70

TOTAL Rs: 711371.63

Add for excise duty on 75 percent cost of

Machinery / Labour components @ 8.24% Rs: 4814.70

Add for insurance charges @ 1.00% Rs: 7113.72

Add for designs and drawings @ 2.50% Rs: 17784.29

Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 17784.29

Add for power supply arrangements @ 2.00% Rs: 14227.43

Add for enabling works @ 1.40% Rs: 9959.20

Total Rs: 783055.26

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

Fabricated parts 2x9.202 tonnes @ Rs: 129.10 / tonne Rs: 2375.96

Add for transportation upto work site @ 3.00% Rs: 23491.66

Total cost for 9.202 tonne Rs: 808922.88

Rate per tonne Rs: 87900.00Rate approved per tonne Rs: 87900.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 14

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

drum hoist consisting of hoist platform, rope drum, gear system, electric motor, electro-

magnetic brake system, hand operation assembly, control panel, wire rope, pulleys, ladder etc.,

with all accessories for operating river sluice / canal sluice service gate including cost of

all materials, machinery, labour, cutting, bending, aligning, anchoring, welding, finishing,

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

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

DATA:Rope drum hoist for river / canal sluice service gate consists of embedded parts for anchorage,

hoist supporting structure, pulley support, pulleys, drive stool, rope drums, shafts, couplings,

gears and pinions, plummer blocks, gear box, electric motor, hand operation assembly, brake,

wire rope, gate position indicator, switch box etc. with related accessories.

Generally the hoist capacity will be 2.5 times the weight of gate including weight of ballast.

Consider rope drum hoist for river / canal sluice service gate for vent of size 2.5 m x 3 m.

Capacity of hoist in tonnes :

Size of gate for 2.5 x 3 m opening : 3.2 m x 3.3 m

Head of water above sill level considered : 34 m

Weight of gate leaf in tonne including weight of ballast 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 ( 3.2 x 3.2 x x 3.3 x 34 )0.659

: 9.229

Capacity of hoist in tonnes with 25% reserve capacity at 2.5 times wt of gate with ballast.( 2.50 x 9.229 ) : 23.073 tonnes

Round off the capacity of hoist to next 5 tonne say : 25.00 tonnes

Weight of hoist with all accessories is considered at 0.25 tonne per tonne capacity of hoist.

Weight of hoist with all accessories ( 0.25 x 25 ) : 6.250 tonnes

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

67




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

sluice gate rope drum hoist of same capacity provided for one of the dam.

Actual capacity of hoist as per data sheet : 25.00 tonnes

Actual weight of rope drum hoist as per data in Item :14 of Annexure-2 : 6.243 tonnes


Consider details of Material / Gas cutting / Welding based on fabrication drawings of 25 tonne

capacity rope drum hoist provided for river sluice service gate for one of the dam work for rate

analysis ( for details refer Item : 14 of Annexure- 2 ).



Angles/ beams/ channels/ bars with 2.5 % wastage ( 1451x1.025 ) : 1487.00 kg

Plates / flats with 2.5 % wastage ( 392 x 1.025 ) : 402.00 kg

Chequered plates with 2.5 % wastage ( 283 x 1.025 ) : 290.00 kg

b. Cast steel components conforming to IS : 1030 :

Rope drums 2 Nos / Gears ( 1420 +506 ) : 1926.00 kg

Pinions : 79.00 kg

Pulleys 3 Nos / Couplings 2 Nos : 306.00 kg

Plummer blocks / Hubs : 72.00 kg

c. Alloy steel steel components conforming to IS : 1570 :Shafts : 346.00 kg

Pins : 73.00 kg

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

Bearings / Bush : 57.00 kg

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

MS Bolts / Nuts / Washers with 2.5 % wastage ( 31 x 1.025 ) : 32.00 kg

f. Steel wire rope conforming ti IS 2266 :

28 mm dia 6 / 37 construction 1 No 120 Rm @ 2.71 kg / m : 325 kg

g. Other components :

Manual operating system : 1 No.

Worm reducer : 1 No

Electric motor 5 hp : 1 No.

Gate position indicator : 1 No.

Ele-magnetic brake : 1 No.

Electric cable / switch / control panel etc : 1 set

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




for stitch weld GP electrodes @t 10 % of total ( 1105 x 0.10 ) : 110 Nos


2. Cutting :



Total : 63 Rm

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

Length of steel to be cut by using gas manually : 26 mLength of steel to be cut by gas using pug cutting machine : 37 m




68







3. Welding :

Length of welding as per data sheet : 97 Rm


( 110 / 15 ) x 8 / 2 : 29 hours


( 995 / 15 ) x 8 / 6 : 88 hours

Total : 117 hours



( 29 x 0.25 + 88 x 0.75 ) : 73 hours


Painting area at 20 sqm / tonne of str steel (1487+402+290 ) x 20 : 43 sqm

2 coats of zinc chromate red oxide primer.

Quantity of primer paint for 43 sqm @ 12 sqm / ltr / coat : 7 ltr

3 coats of synthetic enamel paint.

Quantity of synthetic enamel paint for 43 sqm @ 12 sqm / ltr /coat : 11 ltr

As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatmentto remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting




For handling during fabrication and erection 8 t mobile crane considered for 2 hours.

For drilling holes for bolts 2 hours use of drilling machine considered.

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



Painter Cl-II

Cutting sections/ drilling holes 31 hours 2 4 4 8

Fabricating by stitch welding 29 hours 2 4 --- 8


Erection of anchors 1 1 --- 2

Erection of hoist frame 1 1 --- 4

Erection of drums / gears / shafts 1 2 --- 4

Erection of pulleys / plummer blocks 1 1 --- 2

Erection of worm reducers / brake / motor 1 2 --- 4

Erection of other accessories --- 1 --- 2

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

Checking and running without rope 1 1 --- 2

Rope fixing and checking 1 1 --- 2


Painting ( 5 x 43 ) sqm @ 15 sqm / day --- --- --- 13

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

Final checking / Finishing / cleaning 1 1 --- 1 Total : 14 21 15 71


is considered for welder for stitch welding.

Erector /

Marker /

Fabricator / Welder

Gas cutter /

69




b. Workforce for painting 2 coats primer and 3 coats finishing paint consists of 11 Painters Cl-II

at 15 sqm / day and 2 helpers to assist painters.












RATE ANALYSIS UNIT : 6.243 tonne wt

A. MATERIALS: 25 t capacity

Sl No Unit Amount

in Rs.

1 Structural steel

Angles / beams / channels / bars kg 1487.00 37.95 56431.65

Plates / flats kg 402.00 40.00 16080.00Chequered plate kg 290.00 42.00 12180.00

2 Cast steel components :

Rope drums 2 Nos / Gears kg 1926.00 145.00 279270.00

Pinions kg 79.00 150.00 11850.00

Pulleys 3 Nos / Couplings 2 Nos kg 306.00 125.00 38250.00

Plummer blocks / Hubs kg 72.00 125.00 9000.00

3 Alloy steel components

Shafts kg 346.00 175.00 60550.00

Pins kg 73.00 215.00 15695.00

4 Bronze alloy components :

Bronze bearings / bush kg 57.00 635.00 36195.00

5 Wire rope 28 mm dia 6/37 construction kg 325.00 105.00 34125.00

6 MS Bolt / Nut / Washer kg 32.00 55.00 1760.00

7 Worm reducers No. 1.00 52500.00 52500.00

8 Electric motor 5 hp No. 1.00 12000.00 12000.00

9 Manual operating system No. 1.00 11250.00 11250.00

10 Gate position indicator No. 1.00 11250.00 11250.00

11 Ele-magnetic brake No. 1.00 11250.00 11250.00

12 Electric cable / switch / control panel etc LS 1.00 7500.00 7500.00

13 Oxygen gas cum 45.00 48.00 2160.00




17 Zinc chromate red oxide primer ltr 7.00 140.00 980.00

18 Synthetic enamel ( 1st quality ) paint ltr 11.00 176.00 1936.00


20 Grease kg 25.00 194.00 4850.0021 Use rate welding holder set Hour 117.00 4.50 526.50

Contd

A. MATERIALS ( Contd ) :

QuantityPerticulars Rate

in Rs.

70




Sl No Unit Amount

in Rs.

Contd


23 Wire brush Nos 1.00 30.00 30.00

24 Sundries LS 5.00 30.00 150.00

Total Rs: 705479.15





B. MACHINERY:

Sl No Unit Amount

in Rs.






Fuel / Energy charges Hour 2.00 495.00 990.004 Grinding machine Hour 2.00 18.00 36.00




6 Sundries LS 5.00 30.00 150.00

Total Rs: 8105.00





C. LABOUR:

Sl No Unit Amount

in Rs.

1 Crew for Mobile crane 8 t Hour 2.00 75.70 151.40



4 Foreman Day 14.00 177.00 2478.00


6 Gas cutter Day 4.00 157.50 630.00




10 Painter Cl - II Day 11.00 141.50 1556.50

11 Electrician Day 2.00 143.00 286.00

Total Rs: 18869.90

Add for small Tools and Plants @ 1% Rs: 188.70Contd

C. LABOUR ( Contd ) :

Sl No Unit Amount

Description


Quantity

Perticulars

Description

Rate

RateQuantity

RateQuantity

in Rs.

Rate

in Rs.

in Rs.

71




in Rs.

Contd


Add for hidden cost on Labour @ 15% Rs: 2830.49

Add for additional hidden cost on labour @ 15% Rs: 2830.49



ABSTRACT:




TOTAL Rs: 855063.67








Total Rs: 937708.20 Add for 2 rehandling leads for 1 km including loading and unloading :

Fabricated parts 2 x 6.243 tonnes @ Rs: 129.10 / tonne Rs: 1611.94


Total cost for 6.243 tonne weight Rs: 967451.39

25.000 tonne capacity

Rate per tonne weight Rs: 154970.00

Rate per tonne capacity Rs: 38700.00

Rate approved per tonne capacity Rs: 38700.00


ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( without groove

liners ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner upto

1m height above the roof of vent etc., with all accessories for river / canal sluice emergency

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

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

coal tar epoxy paint etc., complete as per specifications and approved drawings with all leads

and lifts.

DATA:Embedded parts for river sluice emergency gate consist of sill beam, wheel / seal tracks, breast

wall lining upto 1 m height above vent top, gate guide etc., with all accessories such as f irst

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.

Generally wt of embedded parts for sluice gate will be 50% of wt of gate including ballast.

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.

Consider embedded parts for river sluice emergency gate for sluice opening of size 1.5 m x 3 m.

Weight of embedded parts in tonne for 1.5 m x 3 m opening based on empirical formula :

Size of gate for 1.5 m x 3 m opening : Length : 2.2 m Height : 3.3 m

Head of water considered above sill level : 16 m

in Rs.

72




Weight of gate with ballast in tonnes = 0.0888 x ( L 2

x H x h )0.659

Consider weight of embedded parts at 50 % of weight of gate including ballast:

Weight of embedded parts in tonnes = 0.50 x 0.0888 x ( L 2

x H x h )0.659


= 0.0444 x ( 2.2 x 2.2 x 3.3 x 16 )0.659

: 1.714 tonnes

Weight of breast wall lining about 2 sqm @ 250 kg / sqm : 0.500 tonnesTotal : 2.214 tonnes


actual weight as per fabrication drawings of embedded parts for river sluice emergency gate of

same size provided for one of the dam.

Actual weight of embedded parts as per data in Item : 15 of Annexure-2 : 2.180 tonnes


Consider details of Material / Gas cutting / Welding based on embedded parts drawings for river

sluice emergency gate provided for one of the dam for rate analysis ( for details refer Item 15 of

Annexure - 2 ).



Angles/ beams/ channels/ bars with 2.5 % wastage ( 593x1.025 ) : 608 kg

Plates / flats with 2.5 % wastage ( 1304 x 1.025 ) : 1337 kg

b. Alloy steel components conforming to IS : 1570 :Stainless steel plates / flats ( 219 x 1.025 ) : 225.00 kg

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

MS bolts and nuts with 2.5 % wastage ( 64 x 1.025 ) : 66 kg

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




for stitch welding GP electrodes @t 10 % of total ( 1026 x 0.10 ) : 103 Nos


Stainless steel electrodes as per data sheet ( Item:15 Annexure-2 ) : 430 Nos

Add for variations / wastage @ 5 % ( 430 x 0.05 ) : 22 Nos

Total requirement of Stainless steel ( SS ) electrodes : 452 Nos

for stitch weld SS electrodes @t 10 % of total ( 452 x 0.10 ) : 45 Nos

for run weld SS electrodes @t 90 % of total ( 452 x 0.90 ) : 407 Nos

2. Cutting :



Total length of cutting Total : 149 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 shearing machine : 30 m



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




73





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

3. Welding :

Length of welding as per data sheet : 143 m


( 103 + 45 ) x 8 / 15 / 2 : 40 hours


( 923 + 407 ) x 8 / 15 / 6 : 118 hours

Total : 158 hours



( 40 x 0.25 + 118 x 0.75 ) : 99 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 : 26 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 26 m SS plates ( 26 x 8 / 3 ) : 72 hours


Painting area for embedded parts at 12 sqm / tonne ( 2.18 x 12 ) : 26 sqm

1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 26 sqm @ 9 sqm / ltr / coat : 3 ltr








For drilling holes for anchor bolts use of drilling machine for 10 hours considered.

For grinding weld joints and edges requiring finishing use of grinding machine for 8 hours

considered.

For handling of parts during fabrication and erection use of mobile crane for 2 hours and

stationery derric crane for 4 hours considered.



Painter Cl-II


Drilling holes for anchors / supports 1 1 --- 1

Fbricating by stitch welding 40 hours 2 5 --- 10


Erection of first stage anchors 2 4 --- 8

Erection of Sill beam / Tracks / Guide 2 4 --- 8

Erection of Breast wall liners 1 2 --- 4

Contd

Requirement of work force ( Contd ) :


Painter Cl-II


Marker /

Erector /

Gas cutter /

Fabricator / Welder

Marker / Gas cutter /

Fabricator /

Erector /

Welder

74





Finishing / cleaning 1 1 --- 2

Total : 15 24 21 73




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













A. MATERIALS: Sl No Unit Amount

in Rs.

1 Structural steel


Plates / flats kg 1337.00 40.00 53480.00

2 Stainless steel plate / flats kg 225.00 120.00 27000.00

3 MS bolts and nuts kg 66.00 55.00 3630.00

4 Oxygen gas cum 81.00 48.00 3888.00




8 Welding electrodes ( stainless steel ) Nos 452.00 43.00 19436.00






14 Wire brush Nos 1.00 30.00 30.00

15 Sundries LS 5.00 30.00 150.00

Total Rs: 156589.60





B. MACHINERY:

Sl No Unit Amount

in Rs.



2 Plate shearing machine Hour 4.00 62.00 248.00

Description Rate

in Rs.

RatePerticulars

in Rs.

Quantity

Quantity

75







4 Planing machine Hour 72.00 88.00 6336.00










9 Sundries LS 10.00 30.00 300.00

Total Rs: 24078.00





C. LABOUR: Sl No Unit Amount

in Rs.


2 Crew for Shearing machine Hour 4.00 45.90 183.60

3 Crew for Planing machine Hour 72.00 73.40 5284.80



6 Foreman Day 15.00 177.00 2655.00


8 Gas cutter Day 7.00 157.50 1102.50


10 Welder ( X - ray ) Day 2.00 173.25 346.50



13 Painter Cl - II Day 9.00 141.50 1273.50

14 Electrician Day 1.00 143.00 143.00

Total Rs: 27056.30



Add for hidden cost on Labour @ 15% Rs: 4058.45

Add for additional hidden cost on labour @ 15% Rs: 4058.45



ABSTRACT:




TOTAL Rs: 248036.21



Quantity Rate

in Rs.

Description

76









Total Rs: 275454.66

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

Fabricated parts 2 x 2.180 tonnes @ Rs: 129.10 / tonne Rs: 562.88


Total cost for 2.180 tonne Rs: 284281.18

Rate per tonne Rs: 130400.00

Rate approved per tonne Rs: 130400.00


ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( with groove

liner ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner ( upto

1 m above the roof of vent ), groove liner upto breast wall level etc., with all accessories for

river / canal sluice emergency 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 andapproved drawings with all leads and lifts.

DATA:Embedded parts for river sluice emergency gate consist of sill beam, wheel /seal tracks, groove

lining upto breast wall level, breast wall lining upto 1 m above top of vent, gate guide etc., with

all accessories such as first 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 for emergency gate will be about 65 to 70 % of gate wt with ballast.

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 emergency 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 considered above sill level : 34 m

Weight of embedded parts in tonne including weight of ballast based on empirical formula :

= 0.0888 x ( L 2

x H x h )0.659

Consider weight of embedded parts at 67.5 % og weight of gate including ballast:

= 0.675 x 0.0888 x ( L 2

x H x h )0.659


= 0.0600 x ( 3.2 x 3.2 x 3.3 x 34 )0.659

: 6.236 tonnes

Weight of breast wall lining about 3.5 sqm @ 250 kg / sqm : 0.875 tonnes

Weight of groove liner about 10 sqm @ 200 kg / sqm : 2.000 tonnes

Total : 9.111 tonnes


actual weight as per fabrication drawings of embedded parts and groove liner for river sluice

emergency gate of same size provided for one of the dam.

Actual weight of embedded parts as per data in Item :16 of Annexure-2 : 9.088 tonnes


77




Consider details of Material / Gas cutting / Welding based on embedded parts and groove liner

drawings for river sluice emergency gate provided for one of the dam work for rate analysis ( for

details refer Item : 16 of Annexure - 2 ).



Angles/ beams/ channels/ bars with 2.5 % wastage ( 992x1.025 ) : 1017 kg

Plates / flats with 2.5 % wastage ( 7431 x 1.025 ) : 7617 kg

b. Alloy steel components conforming to IS : 1570 :

Stainless steel plates / flats ( 431 x 1.025 ) : 442 kg

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

MS bolts and nuts with 2.5 % wastage ( 234 x 1.025 ) : 240 kg

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




for stitch welding GP electrodes @t 10 % of total ( 5782 x 0.10 ) : 578 Nos


Stainless steel electrodes as per data sheet ( Item:16 Annexure-2 ) : 752 Nos

Add for variations / wastage @ 5 % ( 752 x 0.05 ) : 38 Nos

Total requirement of Stainless steel ( SS ) electrodes : 790 Nos

for stitch weld SS electrodes @t 10 % of total ( 790 x 0.10 ) : 79 Nos for run weld SS electrodes @t 90 % of total ( 790 x 0.90 ) : 711 Nos

2. Cutting :



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 shearing machine : 60 m



Time for cutting by shearing machine at ( av ) 10 m cutting / hour : 6 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 : 560 m


( 578 + 79 ) x 8 / 15 / 2 : 175 hours


( 5204 + 711 ) x 8 / 15 / 6 : 526 hours

Total : 701 hours



78




( 175 x 0.25 + 526 x 0.75 ) : 438 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 : 26 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 26 m SS plates ( 26 x 8 / 3 ) : 69 hours


Painting area for embedded parts at 10 sqm / tonne ( 9.088 x 10 ) : 91 sqm

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

Quantity of primer paint for 91 sqm @ 9 sqm / ltr / coat : 10 ltr








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 4 hours and stationery

derric crane for 40 hours considered.



Painter Cl-II


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

Fbricating by stitch welding 175 hours 12 22 --- 44


Erection of first stage anchors 5 10 --- 10

Erection of Sill beam / Tracks / Guide 2 4 --- 8

Erection of Breast wall liner 1 2 --- 4

Erection of groove liners 3 6 --- 12



Finishing / cleaning 1 2 --- 4

Total : 42 68 82 228




at 15 sqm / day and 6 helpers to assist painters. 8. Excise duty on supply :








Erector /

Fabricator /

Marker / Gas cutter /

Welder

79








A. MATERIALS:

Sl No Unit Amount

in Rs.

1 Structural steel


Plates / flats kg 7617.00 40.00 304680.00

2 Stainless steel plate / flats kg 442.00 120.00 53040.00

3 MS bolts and nuts kg 240.00 55.00 13200.00

4 Oxygen gas cum 180.00 48.00 8640.00




8 Welding electrodes ( stainless steel ) Nos 790.00 43.00 33970.00



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


14 Wire brush Nos 2.00 30.00 60.00

15 Sundries LS 25.00 30.00 750.00

Total Rs: 559083.65





B. MACHINERY:

Sl No Unit Amount

in Rs.



2 Plate shearing machine Hour 7.00 62.00 434.00


Contd

B. MACHINERY ( Contd ) :

Sl No Unit Amount

in Rs.Contd



4 Planing machine Hour 69.00 88.00 6072.00





Description

Perticulars

in Rs.

Quantity Rate

in Rs.

Quantity Rate

Description Quantity Rate

in Rs.

Data Rates Gate Works 4

Documents

Transcript of Data Rates Gate Works 4