Data Rates-Gate Works Part 1

8/13/2019 Data Rates-Gate Works Part 1

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GATE / HOIST AND ALLIED WORKS

FOR THE YEAR : 2010-11

CONTENTS PAGES

REFERENCE DATA 3 -- 5

NOTES ON BASIC RATES 6 -- 6

DATA FOR SCHEDULE OF RATES 7 -- 176

ANNEXURE-1 ( Data for Enabling works ) 177 -- 184

ANNEXURE-2 ( Details of Materials / Cutting / Welding ) 185 -- 257


WATER RESOURCES DEPARTMENT

SCHEDULE OF RATES

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COST OF MATERIALS :1 Acytelene gas per cum Rs: 258.00

2 Alloy steel ( Corbon steel : IS : 1570 ) Shafts per kg Rs: 175.00

3 Alloy steel ( Stainless steel : IS : 1570 ) Pins per kg Rs: 215.00

4 Bolt / Nut / Washer ( hot dipped galvanized ) per kg Rs: 95.00

5 Bolt / Nut / Washer ( mild steel ) per kg Rs: 55.00

6 Bolt / Nut / Washer ( stainless steel ) per kg Rs: 150.00

7 Bronze / Alluminium alloy ( IS : 305 ) Bearings / Bushes per kg Rs: 635.00

8 Cast iron blocks per kg Rs: 32.00

9 Cast steel Drums / Gears per kg Rs: 145.00

10 Cast steel Pinions per kg Rs: 150.00

11 Cast steel Wheels / Pulleys / Hubs / Rollers / retainers per kg Rs: 125.00

12 Chequered plate per kg Rs: 42.00

13 Coaltar epoxy paint per ltr Rs: 208.00

14 Degreasing / derusting / phasphate coating chemical per ltr Rs: 240.0015 Forged steel Hooks / Shackles per kg Rs: 165.00

16 Gas cutting set ( 2 Nos 15 m hose and nozzle unit ) Rs: 1500.00

17 Grease per kg Rs: 194.00

18 MS pipe 300 mm dia per kg Rs: 45.00

19 MS pipe 32 mm dia per Rm Rs: 127.00

20 Oxygen gas per cum Rs: 48.00

21 Rails 45 kg / m per tonne Rs: 42000.00

22 Rubber bottom seal ( flat type ) IS : 11855 per Rm Rs: 147.00

23 Rubber corner seal ( music note teflon claded ) IS : 11855 per Rm Rs: 740.00

24 Rubber corner seal ( music note uncladed ) IS : 11855 per Rm Rs: 295.00

25 Rubber side seal ( music note teflon claded ) IS : 11855 per Rm Rs: 675.00

26 Rubber side seal ( music note uncladed ) IS : 11855 per Rm Rs: 235.00

27 Rubber side seal ( Z - type ) IS : 11855 per Rm Rs: 295.0028 Stainless steel plate / flats per kg Rs: 120.00

29 Steel wire rope 6x37 construction per kg Rs: 105.00

30 Structural steel angle / channel / beam / bars per kg Rs: 37.95

31 Structural steel plate / flats per kg Rs: 40.00

32 Synthetic enamel paint ( 1st quality ) per ltr Rs: 176.00

33 Welding electrodes 4 mm x 450 mm ( general purpose ) per No. Rs: 6.00

34 Welding electrodes 4 mm x 450 mm ( low hydrogen ) / No. Rs: 12.00

35 Welding electrodes 4 mm x 450 mm ( stainless steel ) per No. Rs: 43.00

36 Welding holder set ( cable / holder / gloves / mask etc ) per set Rs: 4500.00

37 Wire brush per Each Rs: 30.00

38 Zinc per kg Rs: 140.00

39 Zinc rich ( zinc content : 85 % ) epoxy primer paint per ltr Rs: 594.00

40 Zinc chromate red oxide primer per ltr Rs: 140.00

LEAD, LOADING & UNLOADING CHARGES: Unloading

1 Steel per tonne Rs: 37.90 45.60 45.60

GATE / HOIST AND ALLIED WORKS -- REFERENCE DATA

1 km lead Loading

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HIRE CHARGES OF MACHINERY: Crew charge

1 Bending machine per hour Rs: 39.00 75.00 45.90

2 Diesel generating set 50 kVA per hour Rs: 94.00 660.00 45.10

3 Grinder per hour Rs: 18.00 25.00 59.50

4 Mobile crane 8 t ( pick & carry ) per hour Rs: 362.00 495.00 75.70

5 Mobile crane 25 t ( revolving ) per hour Rs: 3804.00 1375.00 72.60

6 Planing machine per hour Rs: 88.00 75.00 73.40

7 Plate shearing machine per hour Rs: 62.00 100.00 45.90

8 Pug cutting machine per hour Rs: 16.00 3.00 ---

9 Stationery Derric crane ( revolving ) per hour Rs: 66.00 9.00 ---

10 Tower crane 5 tonne per hour Rs: 994.00 130.00 62.00

11 Transformer 250 kVA per month Rs: 3523.00 --- ---

12 Upright / Hand drilling machine per hour Rs: 18.00 25.00 59.50

13 Welding transformer per hour Rs: 12.00 60.00 ---

WAGES OF WORKERS: Per day

1 Electrician Rs: 143.00

2 Foreman Rs: 177.00

3 Gas cutter Rs: 157.50

4 Heavy mazdoor Rs: 132.00

5 Helper fabrication / erection Rs: 141.50

6 Khalasi Rs: 145.50

7 Marker / Erector / Fabricator / Machanic Rs: 157.50

8 Painter Class-II Rs: 141.50

9 Welder ( General ) Rs: 157.50

10 Welder ( X-ray quality ) ( 10 % extra over Welder ) Rs: 173.25

ELECTRIC SUB-STATION MATERIALS:

1 Electric pole with fixtures per No. Rs: 4200.00

2 Flood light 500 W per Each Rs: 650.00

3 Flood light set per Each Rs: 1200.00

4 Fluoscent tube light 40 W per Each Rs: 50.00

5 Fluoscent tube light set per Each Rs: 190.00

6 HT / LT Circuit breaker with other accessories per set Rs: 30000.00

7 HT / LT Line conductor per 1000 Rm Rs: 27000.00

8 PVC Armoured cable 10 sqmm and below per Rm Rs: 48.00

9 PVC Armoured cable 16 sqmm per Rm Rs: 58.00

10 PVC Armoured cable 25 sqmm per Rm Rs: 100.0011 PVC Armoured cable 70 sqmm per Rm Rs: 250.00

Hire charge Fuel charge

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OTHER DATA :

1 Contractor's Overheads on Materials / Machinery / Labour % 5.00

2 Contractor's Profit on Materials / Fuel & Energy charges / Labour % 10.00

3 Demand charges per kVA / month Rs: 190.00

4 Electric power kWhr 5.60

5 Excise duty on cost of supplies % 8.24

6 Insurance charges on gate / hoist parts % on cost 1.00

7 Interest on average capital cost % / annum 11.00

8 Hidden cost on Labour % 15.00

Hidden cost on Labour ( additional for Gate / Hoist works ) % 15.00

9 Small Tools & Plant on Materials / Machinery / Labour % 1.00

10 Sundries ( Lump sum rate for unquantified inputs ) Rs: 30.00

11 Cost of Power supply arrangements ( Annexure-1.a ) % 2.00

12 Cost of Other enabling works ( Annexure-1.b ) % 1.40

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NOTES ON SCHEDULE OF RATES



1. All notes under ' General Notes on Schedule of Rates ' are applicable to ' Gate / Hoist and

Allied Works ' also to the extent they are relevant.

2. All materials / bought out components for embedded parts, gates, hoists and allied works

shall conform to relevant Indian standards / technical specifications and approved drawings.

3. The basic rates are inclusive of preparation of designs / drawings / material schedules etc.,

as per specifications and other technical data including revisions.

4. The basic rates are inclusive of cost of all materials, machinery, labour, fabrication, erection,

commissioning and testing of gates, hoists and other related components as per technical

specifications.

5. The basic rates are inclusive of taxes, duties, levies and all other incidental charges except

sales tax on works contract. Separate provision shall be made in the estimate towards sales

tax on works contract at the rate prevailing at the time of preparation of estimate.

6. The basic rates are inclusive of rehandling at fabrication and erection sites.

7. Unless otherwise specified the basic rates are inclusive of standard finish required for all the

fabricated and bought out gate and hoist components.

8. The basic rates are inclusive of preparatory works such as rectification of damages, repairing

shop painting, cleaning, positioning and anchoring first stage embedments, cleaning surface

for field painting etc.

9. The basic rates are exclusive of cost of river diversion arrangements, dewatering, desilting etc.

10. Unless otherwise specified the basic rates for items are on per tonne basis. The rate per set

or per number shall be worked out on the basis of rate per tonne and the tonnage computed

as per detailed designs / empirical formulae furnished in the ' Note ' under each item.

11. Minimum dry film thickness for zinc rich epoxy primer paint and coal tar epoxy paint shall be

40 microns per coat and 100 microns per coat respectively.

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SECTION: GATE / HOIST & ALLIED WORKS. YEAR : 2010-11 ITEM No: 1

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

beam, wall plates, anchors, anchor girders, yoke girders, tie flats, trunnion supports, rope and

pulley supports etc., with all accessories for spillway radial gates 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 leadsand lifts.

DATA:Embedded parts for radial gate consist of sill beam / wall plates / anchor girders / yoke girders /

tie flats / trunnion supports etc., with all accessories. The weight of embedded parts for radial

gate will be generally at about 25 to 30 percent of weight of radial gate leaf.

Consider embedded parts for radial gate for spillway opening of size 15 m x 9 m at crest.

Size of gate for 15 x 9 m opening at crest with gate sill on d /s 0.6 m below crest level.

Length of gate : 15 m Head of water at sill level : 9.60 m Height of gate : 9.75 m

Weight of radial gate leaf in tonne with end shield and hood based on empirical formula :

Weight of radial gate in tonnes = 0.0710 x ( L2

x H x h )0.673

Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.

Consider weight of embedded parts in tonnes @ 25% of weight of radial gate.

= 0.25 x 0.710 x ( L2

x H x h )0.673

= 0.0177 x ( 15 x 15 x 9.75 x 9.6 )0.673

: 14.377

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

actual weight as per embedded parts fabrication drawings for gate of same size provided for one

of the dam work.

Actual weight of embedded parts as per data in Item :1 of Annexure-2 : 14.334 tonnes

Consider actual weight of embedded parts for data rate analysis.

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

parts for radial gate provided for one of the dam having 15 m x 9 m spillway opening at crest forrate analysis ( for details refer Item :1 of Annexure-2 ).

1. Requirement of materials :

a. Structural steel conforming to IS : 2062 :

Angles / beams / channels / bars with 2.5 % wastage ( 679x1.025) : 696 kg

Plates / flats with 2.5 % wastage ( 13356 x 1.025 ) : 13690 kg

b. Alloy steel conforming to IS : 1570 :

Stainless steel plates / flats with 2.5 % wastage ( 190 x 1.025 ) : 195.00 kg

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

MS bolts / nuts with 2.5 % wastage ( 109 x 1.025 ) : 112 kg

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

GP / LH electrodes as per data sheet ( Item:1 Annexure-2 ) : 7539 Nos

Add for variations / wastage / misc welding @ 10 % ( 7539 x 0.1 ) : 754 Nos

Total requirement of GP / LH electrodes : 8293 Nos

for stitch welding GP electrodes @t 10 % of total ( 8293 x 0.10 ) : 829 Nos

for run welding LH electrodes @ 90 % of total ( 8293 x 0.90 ) : 7464 Nos

Stainless steel electrodes as per data sheet ( Item:1 Annexure-2 ) : 876 Nos

Add for variations / wastage @ 5 % ( 876 x 0.05 ) : 44 Nos

Total requirement of Stainless steel ( SS ) electrodes : 920 Nos

GATE / HOIST AND ALLIED WORKS - DATA RATES

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for stitch welding SS electrodes @t 10 % of total ( 920 x 0.10 ) : 92 Nos

for run welding SS electrodes @t 90 % of total ( 920 x 0.90 ) : 828 Nos

2. Cutting :

Length of cutting assuming cutting for 2 sides as per data sheet : 428 Rm

Add for variations ( cutting more than 2 sides / odd shape etc ) at 10 % : 43 Rm

Total : 471 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 : 371 m

Length of steel to be cut by using plate shearing machine : 40 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 : 124 hours

Time for cutting by shearing machine at ( av ) 10 m cutting / hour : 4 hours

Acetelyne gas @ 0.6 cum / hour ( 30 + 124 ) x 0.60 : 93 cum

Oxygen gas @ 1.8 cum / hour ( 30 + 124 ) x 1.80 : 279 cumUse of gas cutting torch with 50 min / hour working ( 30 x 60 / 50 ) : 36 hours

Use of pug cutting machine with 50 min/hr working ( 124 x 60 / 50 ) : 149 hours

Use of shearing machine with 50 min / hour working ( 4 x 60 / 50 ) : 5 hours

3. Welding :

Length of welding as per data sheet : 600 m

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

( 829 + 92 ) x 8 / 15 / 2 : 246 hours

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

( 7464 + 828 ) x 8 / 15 / 6 : 737 hours

Total : 983 hours

Deploy welding transformer for 983 hours.

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

( 246 x 0.25 + 737 x 0.75 ) : 614 hours

4. Planing SS plates for seal seats :

For surface finishing of stainless steel plates for seal seats planing machine is considered.

Length of SS plate for surface finishing by planing machine : 56 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 56 m SS plates ( 56 x 8 / 3 ) : 150 hours

5. Surface cleaning and painting :

Painting area for embedded parts at 10 sqm / tonne ( 14.33 x 10 ) : 143 sqm

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

Quantity of primer paint for 143 sqm @ 9 sqm / ltr / coat : 16 ltr

4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 143 sqm @ 6 sqm / ltr / coat : 96 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 143 sqm @ 8 sqm / ltr : 18 ltr

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6. Requirement of other machinery :

Hiring of tower crane for 4 hours considered for handling yoke / anchor girder parts from river

bed to pier / abutment at trunnion level.

For drilling holes for anchor bolts and for grinding surface / edges of parts requiring finishing

8 hours use of drilling machine and 24 hours grinding machine considered.

For handling of parts during fabrication and erection use of 8 t mobile crane for 32 hours and

stationery derric crane for 64 hours considered.

7. Requirement of work force :

Work component Foreman Helper /

Painter Cl-II

Cutting sections 190 hours 12 48

Drilling holes for anchors / supports 2 4

Fabricating by stitch welding 246 hours 15 62

Run welding 737 hours 9 92

Erection of Anchor / Yoke girders 13 52

Erection of tie flats( anchor bars ) 2 4

Erection of first stage anchors 5 20

Erection of Sill beam / Wall plates 3 12Cleaning surface 143 sqm @ 15 sqm/day --- 10

Painting ( 5 x 143 ) sqm @ 15 sqm / day --- 56

Finishing / cleaning / checking 5 10

Total : 66 370

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 48 Painters Cl-II

at 15 sqm / day and 8 helpers to assist painters.

8. Excise duty on supply :

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

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

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

9. Use rate of materials :

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

Life of welding set : 1000 hours

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

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

Life of gas cutting set : 600 hours

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

RATE ANALYSIS UNIT : 14.334 tonne

A. MATERIALS:

Sl No Unit Amount

in Rs.

1 Structural steel

Angles / beams / channels / bars kg 696.00 37.95 26413.20

Plates / flats kg 13690.00 40.00 547600.002 Stainless steel plate / flats kg 195.00 120.00 23400.00

3 MS bolts and nuts kg 112.00 55.00 6160.00

Contd

Perticulars

Erector /

Gas cutter /Marker /

4

---

Fabricator /

---

115

---

---

26

---

10 ---

10

116

---

Quantity Rate

in Rs.

Welder

---

24

31

92

24

---

---

6

4 ---

---

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A. MATERIALS ( Contd ) :

Sl No Unit Amount

in Rs.

Contd

4 Oxygen gas cum 279.00 48.00 13392.00

5 Acetyline gas cum 93.00 258.00 23994.00

6 Welding electrodes ( general purpose ) Nos 829.00 6.00 4974.00

7 Welding electrodes ( low hydrogen ) Nos 7464.00 12.00 89568.00

8 Welding electrodes ( stainless steel ) Nos 920.00 43.00 39560.00

9 Zinc rich epoxy primer ltr 16.00 594.00 9504.00

10 Coal tar epoxy paint ltr 96.00 208.00 19968.00

11 Rust cleaner / inhibitor ltr 18.00 240.00 4320.00

12 Use rate welding holder set Hour 983.00 4.50 4423.50

13 Use rate gas cutting torch set Hour 36.00 2.50 90.00

14 Wire brush Nos 2.00 30.00 60.00

15 Sundries LS 250.00 30.00 7500.00

Total Rs: 820926.70

Add for small Tools and Plants @ 1% Rs: 8209.27

Add for Contractor's Profit @ 10% Rs: 82092.67

Add for Contractor's Overheads @ 5% Rs: 41046.34Total cost of Materials : Rs: 952274.97

B. MACHINERY:

Sl No Unit Amount

in Rs.

1 Welding transformer Hour 983.00 12.00 11796.00

Fuel / Energy charges Hour 614.00 60.00 36840.00

2 Tower crane Hour 4.00 994.00 3976.00


3 Plate shearing machine Hour 5.00 62.00 310.00


4 Pug cutting machine Hour 149.00 5.00 745.00


5 Mobile crane 8 t Hour 32.00 362.00 11584.00


6 Stationery derric crane Hour 64.00 66.00 4224.00


7 Grinding machine Hour 24.00 18.00 432.00


8 Drilling machines Hour 8.00 18.00 144.00


9 Planing machine Hour 150.00 88.00 13200.00


10 Sundries LS 200.00 30.00 6000.00

Total Rs: 119184.00


Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 7277.30Add for Contractor's Overheads @ 5% Rs: 5959.20

Total hire charges of Machinery : Rs: 133612.34

Description

Perticulars

in Rs.

Quantity Rate

Quantity Rate

in Rs.

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C. LABOUR:

Sl No Unit Amount

in Rs.

1 Crew for Tower crane Hour 4.00 62.00 248.00

2 Crew for Mobile crane Hour 32.00 75.70 2422.40

3 Crew for Shearing machine Hour 5.00 45.90 229.50

4 Crew for Planing machine Hour 150.00 73.40 11010.00

5 Crew for Drilling machine Hour 8.00 59.50 476.00

6 Crew for Grinding machine Hour 24.00 59.50 1428.00

7 Foreman Day 66.00 177.00 11682.00

8 Marker / Fabricator / Erector Day 115.00 157.50 18112.50

9 Gas cutter Day 24.00 157.50 3780.00

10 Welder ( General ) Day 83.00 157.50 13072.50

11 Welder ( X - ray ) Day 9.00 173.25 1559.25

12 Khalasi Day 65.00 145.50 9457.50

13 Helper fabrication / erection Day 304.00 141.50 43016.00

14 Helper for cleaning / painting Day 18.00 141.50 2547.00

15 Painter Cl - II Day 48.00 141.50 6792.00

16 Electrician Day 5.00 143.00 715.00

Total Rs: 126547.65

Add for small Tools and Plants @ 1% Rs: 1265.48Add for Contractor's Profit @ 10% Rs: 12654.77

Add for hidden cost on Labour @ 15% Rs: 18982.15

Add for additional hidden cost on labour @ 15% Rs: 18982.15

Add for Contractor's Overheads @ 5% Rs: 6327.38

Total cost of Labour : Rs: 184759.57

ABSTRACT:

A. Cost of Materials Rs: 952274.97

B. Hire charges of Machinery Rs: 133612.34

C. Cost of Labour Rs: 184759.57

TOTAL Rs: 1270646.88

Add for excise duty on 75 percent cost of

Machinery / Labour components @ 8.24% Rs: 19675.38

Add for insurance charges @ 1.00% Rs: 12706.47

Add for designs and drawings @ 2.50% Rs: 31766.17

Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 31766.17

Add for stress relieving of anchor girders @ 1.50% Rs: 19059.70

Add for power supply arrangements @ 2.00% Rs: 25412.94

Add for enabling works @ 1.40% Rs: 17789.06

Total Rs: 1428822.78

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

Fabricated parts 2x14.334 tonnes @ Rs: 129.10 / tonne Rs: 3701.04

Add for transportation upto work site @ 3.00% Rs: 42864.68

Total cost for 14.334 tonne Rs: 1475388.50

Rate per tonne Rs: 102900.00

Rate approved per tonne Rs: 102900.00


Description

in Rs.

Quantity Rate

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ITEM: Design, fabrication, supply, erection, testing and commissioning of radial gateconsisting

of skin plate, stiffeners, horizontal girders, sector arms, trunnion assemblies, tie beam, pulley

supports, bracings, rubber seals, clamps etc., with all accessories for spillwayincluding cost

of all materials, machinery, labour, cutting, bending, aligning, anchoring, 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:Spillway radial gate consists of trunnions / sector arms / horizontal girders / Tee- supports /

skin plate / tie beam / bracings for horizontal girders and sector arms / pulley blocks / seals /

end shields etc., with all accessories.

Sector arms are connected to trunions by bolts and nuts with zinc padding in between.

Horizontal girders generally spaced at about 3 m apart are joined to sector arms by welding and

are stiffened by vertical and diagonal stiffeners to form the main frame. Tee- sections are welded

to horizontal girders to make the frame regid and to support the skin plate. Skin plate is welded

to Tee-supports generally spaced vertically at about 40 cm apart.

Consider radial gate for spillway opening of size 15 m x 9 m at crest.

Size of gate for 15 x 9 m opening at crest with gate sill on d /s 0.6 m below crest level :


Weight of gate leaf in tonne with end shield and hood based on empirical formula := 0.0710 x ( L

2x H x h )

0.673


= 0.0710 x ( 152x 9.75 x 9.6 )

0.673 : 57.669

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

actual weight as per fabrication drawings for gate of same size provided for one of the dam work.

Actual weight as per data in Item : 2 of Annexure-2 : 57.457 tonnes

Consider actual weight for data rate analysis.

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

provided for one of the dam having spillway opening of 15 m x 9 m at crest for rate analysis ( for

details refer Item : 2 of Annexure-2 ).



Angles/ beams/ channels/ bars with 2.5% wastage ( 15421x1.025 ) : 15806 kgPlates / flats with 2.5 % wastage ( 37729 x 1.025 ) : 38672 kg

b. Alloy steel components conforming to IS : 1570 :

Stainless steel plates : 6 kg

Lifting pins : 1098 kg

c. Cast steel components conforming to IS : 1030 :

Trunnion hub / Guide roller : 1895 kg

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

Trunnion bush / Guide roller bush : 1155 kg

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

GI bolts / nuts / washers with 2.5 % wastage ( 76 x 1.025 ) : 78 kg

MS bolts / nuts / washers with 2.5 % wastage ( 77 x 1.025 ) : 79 kg

f. Zinc at 70 kg / trunnion ( 2 x 70 ) : 140 kg

g. Rubber seal conforming to IS : 11855 :Bottom seal ( flat type ) with wastage ( 15 x 1.025 ) : 15.5 Rm

Side seals ( Z - type ) with wastage ( 24.2 x 1.025 ) : 25 Rm

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

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2. Cutting :



Total : 1067 Rm

For cutting structural steel sections to required sizes gas cutting is assumed for cutting angles/

beams / channels / round bars and for thick plates / flats. For plate / flats less than 12 mm

thick use of shearing machine is assumed to the extent feasible.



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



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


Oxygen gas @ 1.8 cum / hour ( 198 + 190 ) x 1.80 : 699 cum

Use of gas cutting torch with 50 min / hr working ( 198 x 60 / 50 ) : 238 hoursUse of pug cutting machine with 50min/ hr working ( 190 x 60 / 50 ) : 228 hours

Use of shearing machine with 50 min / hr working ( 10 x60 / 50 ) : 12 hours

3. Bending :

Curved length of plates / tee for bending for 9.75 m height gate : 11.00 m

For 1.2 m wide plates, length of plate for bending ( 15 x 11/ 1.2 ) : 137.50 m

Length of Tee sections @ 0.4 m spacing ( 15 x 11 / 0.4 ) : 412.50 m

Length of side seal base and cover flats ( 11 x 2 x 2 ) : 44.00 m

Total : 594.00 m

Assuming 3 m bending / hour, time for bending 594 m ( 594 / 3 ) : 198 hours

With 50 min / hr working use bending machine for ( 198 x 60 / 50 ) : 238 hours

4. Welding :

Length of welding as per data sheet : 2294 Rm

For radial gates where field welding is more hourly progress is assumed at 12 electrodes / hour.


( 3414 / 12 ) x 8 / 2 : 1138 hours


( 30728 / 12 ) x 8 / 6 : 3414 hours

Total : 4552 hours



( 1138 x 0.25 + 3414 x 0.75 ) : 2845 hours


Painting area for radial gate at 20 sqm / tonne ( 57.457 x 20 ) : 1150 sqm

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


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

Quantity of coal tar epoxy paint for 1150 sqm @ 6 sqm / ltr / coat : 575 ltr As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment



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Quantity of rust cleaner / inhibitor for 1150 sqm at 8 sqm / ltr : 144 ltr


For lifting and placing in position sector arms / horizontal girders / tie beam 10 hours use of

tower crane considered.

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

considered.

For grinding and finishing weld joints in skin plate and other locations 200 hours use of grinding

machine considered.

For handling during fabrication and erection of gate parts 25 t mobile crane for 75 hours and

8 t mobile crane for 100 hours and stationery derric for 200 hours considered.



Painter Cl-II

Cutting sections 478 hours 30 60 60 120

Drilling holes for seal fixing 3 6 --- 12

Fabricating by stitch welding 1138 hours 71 142 --- 568

Run welding 3414 hours 43 --- 427 427

Erection of trunnion and tie beam 4 15 --- 60

Erection of Horizontal girders 3 10 --- 20

Erection of sector arms 3 10 --- 20Erection of vertical stiffeners 5 20 --- 40

Erection of skin plates 3 15 --- 30

Erection of end sheilds and hood 4 20 --- 40

Erection of bracings 6 10 --- 20

Molten zinc filling for trunnion supports 2 2 --- 2

Seal fixing 2 5 --- 10

Cleaning surface1150 sqm @15 sqm/day --- --- --- 77

Painting ( 4x1150 ) sqm @ 15 sqm / day --- --- --- 383

Finishing / cleaning / checking 1 5 --- 5

Total : 180 320 487 1834



b. Workforce for painting 1 coat primer and 3 coats finishing paint consists of 306 Painters Cl-II




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

of materials ( assuming 25 % of machinery and labour components for erection ) is considered

for assessing excise duty.


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






RATE ANALYSIS UNIT : 57.457 tonne

A. MATERIALS:

Sl No Unit AmountQuantityPerticulars

Fabricator /

Marker / Gas cutter /

Welder

Rate

Erector /

14


15/20


in Rs.

1 Structural steel :


Plates / flats kg 38672.00 40.00 1546880.00

2 Cast steel components :

Trunnion hubs / Guide rollers kg 1895.00 125.00 236875.00

3 Alloy steel components :

Stainless steel plate kg 6.00 120.00 720.00

Trunnion pins kg 1098.00 215.00 236070.00

4 Alluminium / Bronze alloy components:

Bush for Trunnion / Guide roller kg 1155.00 635.00 733425.00

5 Bolt / Nut / Washer :

GI bolts / nuts / washers kg 78.00 95.00 7410.00

MS bolts / nuts / washers kg 79.00 55.00 4345.00

6 Zinc kg 140.00 140.00 19600.00

7 Rubber seals :

Bottom seal Rm 15.50 147.00 2278.50

Side seals ( Z - type ) Rm 25.00 295.00 7375.00

8 Oxygen gas cum 699.00 48.00 33552.00


10 Welding electrodes ( general purpose ) Nos 3414.00 6.00 20484.0011 Welding electrodes ( low hydrogen ) Nos 30728.00 12.00 368736.00

12 Zinc rich epoxy primer ltr 128.00 594.00 76032.00

13 Coal tar epoxy paint ltr 575.00 208.00 119600.00

14 Rust cleaner / inhibitor ltr 144.00 240.00 34560.00

15 Use rate welding holder set Hour 4552.00 4.50 20484.00

16 Use rate gas cutting torch set Hour 238.00 2.50 595.00

17 Wire brush Nos 20.00 30.00 600.00

18 Sundries LS 300.00 30.00 9000.00

Total Rs: 4138573.20




Total cost of Materials : Rs: 4800744.91

B. MACHINERY:

Sl No Unit Amount

in Rs.

1 Welding transformer Hour 4552.00 12.00 54624.00


2 Plate shearing machine Hour 12.00 62.00 744.00


3 Pug cutting machine Hour 228.00 16.00 3648.00


4 Bending machine Hour 238.00 39.00 9282.00


Contd

B. MACHINERY ( Contd ) :

Sl No Unit Amount

in Rs.

Contd

Description

Description Quantity

Quantity

in Rs.

Rate

in Rs.

in Rs.

Rate

15


16/20


5 Tower crane 5 t cpacity Hour 10.00 994.00 9940.00


6 Mobile crane ( pick & carry ) 8 t Hour 100.00 362.00 36200.00


7 Mobile crane ( revolving ) 25 t Hour 75.00 3804.00 285300.00


8 Stationery derric crane Hour 200.00 66.00 13200.00


9 Grinding machine Hour 200.00 18.00 3600.00


10 Drilling machines Hour 50.00 18.00 900.00


11 Sundries LS 400.00 30.00 12000.00

Total Rs: 781847.00


Add for Contractor's Profit on DPOL / Energy @ 10% Rs: 36440.90


Total hire charges of Machinery : Rs: 865198.72

C. LABOUR:

Sl No Unit Amountin Rs.

1 Crew for Mobile crane 8 t Hour 100.00 75.70 7570.00

2 Crew for Mobile crane 25 t Hour 75.00 72.60 5445.00

3 Crew for Tower crane Hour 10.00 62.00 620.00

4 Crew for Bending machine Hour 238.00 45.90 10924.20

5 Crew for Drilling machine Hour 50.00 59.50 2975.00

6 Crew for Grinding machine Hour 200.00 59.50 11900.00

7 Foreman Day 180.00 177.00 31860.00

8 Marker / Fabricator / Erector Day 320.00 157.50 50400.00

9 Gas cutter Day 60.00 157.50 9450.00

10 Welder ( General ) Day 384.00 157.50 60480.00

11 Welder ( X - ray ) Day 43.00 173.25 7449.75

12 Khalasi Day 200.00 145.50 29100.00

13 Helper fabrication / erection Day 1374.00 141.50 194421.00

14 Helper for cleaning / painting Day 154.00 141.50 21791.00

15 Painter Cl - II Day 306.00 141.50 43299.00

16 Electrician Day 30.00 143.00 4290.00

Total Rs: 491974.95



Add for hidden cost on Labour @ 15% Rs: 73796.24

Add for additional hidden cost on labour @ 15% Rs: 73796.24


Total cost of Labour : Rs: 718283.43

ABSTRACT:

A. Cost of Materials Rs: 4800744.91

B. Hire charges of Machinery Rs: 865198.72

C. Cost of Labour Rs: 718283.43

TOTAL Rs: 6384227.06

Description Quantity Ratein Rs.

16


17/20


Add for excise duty on 75 percent cost of

Machinery / Labour components @ 8.24% Rs: 97859.20

Add for insurance charges @ 1.00% Rs: 63842.27

Add for designs and drawings @ 2.50% Rs: 159605.68

Add for zigs / supports / winches / chain-pulley @ 2.50% Rs: 159605.68

Add for power supply arrangements @ 2.00% Rs: 127684.54

Add for enabling works @ 1.40% Rs: 89379.18

Total Rs: 7082203.60

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

Fabricated parts 2x57.457 tonnes @ Rs: 129.10 / tonne Rs: 14835.40

Add for transportation upto work site @ 3.00% Rs: 212466.11

Total cost for 57.457 tonne Rs: 7309505.10

Rate per tonne Rs: 127200.00

Rate approved per tonne Rs: 127200.00


ITEM: Design, fabrication, supply, erection, testing and commissioning of electrically operatedrope

drum hoistof adequate capacity consisting of base frames, rope drums,connecting shaft, gear

system, brake system, electric motor, wire ropes, gate position indicator, manual operation

arrangement etc., with all accessories for spillway radial gateincluding cost of all materials,machinery, labour, aligning, anchoring, welding, finishing, cleaning, greasing, providing hand

railing and approach staircase with gate to hoist platform, applying two coats of zinc chromate

red oxide primer and three coats of approved synthetic enamel paint etc., complete as per

specifications and approved drawings with all leads and lifts.

DATA:Rope drum hoist for radial gate consists of embedded parts for anchorages, hoist supporting

structure, pulley supporting structures, pulleys, drive stool, rope drums, couplings, shafts,

gears and pinions, plummer blocks, worm reducer, floating shaft, electric motor, hand operation

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

Consider rope drum hoist for radial gate for spillway opening of size 15 m x 9 m at crest.

Generally the rope drum hoist capacity in tonnes with 25 % reserve will be about 1.50 times the

weight of radial gate in tonnes.

Size of gate for 15 x 9 m opening at crest with gate sill on d /s 0.6 m below crest level :


Weight of radial gate leaf in tonne for 9.6 m water head based on empirical formula :

= 0.0710 x ( L2

x H x h )0.673


= 0.0710 x ( 152x 9.75 x 9.6 )

0.673 : 57.669

Consider capacity of hoist including 25 % reserve capacity @ 1.5 times the weight of gate :

( 1.50 x 57.669 ) : 86.504 tonnes

Round off the rope drum hoist capacity to next 10 tonne : 90.00 tonnes

Consider weight of hoist with all accessories @ 0.175 tonne per tonne capacity of hoist :

( 0.175 x 90 ) : 15.750 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

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

Actual capacity of hoist provided : 90.00 tonnes

Actual weight of rope drum hoist as per data in Item : 3 of Annexure-2 : 15.440 tonnes

Consider actual capacity and weight for data rate analysis.

17


18/20


Consider details of Material / Gas cutting / Welding based on fabrication drawings of 90 tonne

capacity rope drum hoist provided for spillway radial gate for one of the dam for rate analysis

( for details refer Item : 3 of Annexure- 2 ).



Angles/ beams/ channels/ bars with 2.5 % wastage ( 2508x1.025 ) : 2571.00 kg

Plates / flats with 2.5 % wastage ( 3543 x 1.025 ) : 3632.00 kg

b. Cast steel components conforming to IS : 1030 :

Rope drums 2 Nos / Gears 4 Nos : 3680.00 kg

Pinions : 218.00 kg

Pulleys 720 PCD 6 Nos : 1080.00 kg

Plummer blocks / Hubs : 322.00 kg

c. Alloy steel components conforming to IS : 1570 :

Shafts ( carbon steel ) : 557.00 kg

Pins ( stainless steel ) : 546.00 kg

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

Bearings / Bush : 144.00 kg

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

MS Bolts / Nuts / Washers with 2.5 % wastage ( 83 x 1.025 ) : 85.00 kg

f. Steel wire rope conforming to IS : 2266 :

36 mm dia 6 / 37 construction 2 Nos 50 m each @ 4.48 kg / Rm : 448 kgg. Other components :

Manual operation assembly : 1 No.

Worm reducer : 1 Nos

Electric motor 20 hp : 1 No.

Gate position indicator : 1 No.

Ele-magnetic brake : 1 No.

Wire rope sockets : 2 Nos

MS pipe 300 mm dia 13.32 Rm @ 75 kg / Rm : 1000 kg

Electric cable / switch / control panel etc : 1 set

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






2. Cutting :



Total : 280 Rm

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






Oxygen gas @ 1.8 cum / hour ( 75 + 44 ) x 1.80 : 216 cum

Use of gas cutting torch with 50 min / hr working ( 75 x 60 / 50 ) : 90 hours

Use of pug cutting machine with 50 min / hr working ( 44 x 60 / 50 ) : 53 hours

3. Welding :

Length of welding as per data sheet : 447 Rm

18


19/20



( 584 / 15 ) x 8 / 2 : 156 hours


( 5250 / 15 ) x 8 / 6 : 467 hours

Total : 623 hours



( 156 x 0.25 + 467 x 0.75 ) : 390 hours


Quantity of structural steel requiring cleaning for painting : 6.2 tonnes

Painting area for hoist at 20 sqm / t of str steel ( 6.2 x 20 ) : 124 sqm

2 coats of zinc chromate red oxide primer.


3 coats of synthetic enamel paint.

Quantity of synthetic enamel paint for 124 sqm @ 12 sqm / ltr / coat : 31 ltr

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



Quantity of rust cleaner / inhibitor for 124 sqm at 8 sqm / ltr : 16 ltr


For lifting and placing in position hoist drums, worm reducers, gears, floating shafts etc use oftower crane for 4 hours considered.

For handling and erection 25 t mobile crane for 48 hrs with energy charges for 24 hrs considered.

For drilling holes for bolts 16 hours use of drilling machine considered.

For grinding and finishing weld joints 32 hours use of grinding machine considered



Painter Cl-II

Cutting sections 143 hours 9 18 18 36

Drilling holes for pins / bolts fixing 1 2 --- 4

Fabricating by stitch welding 156 hours 10 20 --- 40

Run welding 467 hours 6 --- 58 58

Erection of anchors 2 4 --- 8

Erection of drums and gears 2 4 --- 16

Erection of floating shaft / pulleys 1 2 --- 4

Erection of worm reducers / brake / motor 1 4 --- 8

Erection of other accessories 1 2 --- 2

Erection of control panel / cabling 1 1 --- 2

Checking and trial running without ropes 1 2 --- 4

Rope fixing and checking 1 4 --- 8

Cleaning surface 124 sqm @ 15 sqm/day --- --- --- 8

Contd

6. Requirement of work force ( Contd ) :


Painter Cl-II

Contd

Painting ( 5 x 124 ) sqm @ 15 sqm / day --- --- --- 36

Finishing / cleaning --- 2 --- 2

Trial running for lifting / lowering gate 1 2 --- 4

Erector /

Erector /

Marker /

Marker /

Fabricator / Welder

Fabricator /

Gas cutter /

Welder

Gas cutter /

19


20/20


Total : 37 67 76 240



b. Workforce for painting 2 coats primer and 3 coats finishing paint consists of 30 Painters Cl-II




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.


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






RATE ANALYSIS UNIT : 15.440 tonne wt

A. MATERIALS: 90.00 t capacity

Sl No Unit Amount

in Rs.1 Structural steel


Plates / flats kg 3632.00 40.00 145280.00

2 Cast steel components :

Rope drums 2 Nos / Gears 4 Nos kg 3680.00 145.00 533600.00

Pinions kg 218.00 150.00 32700.00

Pulleys 720 PCD 6 Nos kg 1080.00 125.00 135000.00

Plummer blocks / Hubs kg 322.00 125.00 40250.00

3 Alloy steel components

Shafts kg 557.00 175.00 97475.00

Pins kg 546.00 215.00 117390.00

4 Bronze alloy components :

Bronze bearings / bush kg 144.00 635.00 91440.00

5 Wire rope 36 mm dia 6/37 construction kg 448.00 105.00 47040.00

6 MS Bolt / Nut / Washer kg 85.00 55.00 4675.00

7 Worm reducer No. 1.00 120000.00

8 Electric motor 20 hp No. 1.00 60000.00 60000.00

9 Floating shaft 300 mm dia kg 1000.00 45.00 45000.00

10 Manual operating system No. 1.00 22500.00 22500.00

Contd

A. MATERIALS ( Contd ) : Sl No Unit Amount

in Rs.

Contd

11 Gate position indicator No. 1.00 9000.00 9000.00

12 Ele-magnetic brake No. 1.00 15000.00 15000.00

13 Electric cable /switch /control panel etc LS 1.00 18000.00 18000.00

14 Oxygen gas cum 216.00 48.00 10368.00


Perticulars Quantity

in Rs.

120000.00

in Rs.

Rate

Perticulars Quantity Rate

Data Rates-Gate Works Part 1

Documents

Transcript of Data Rates-Gate Works Part 1