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GATES AND HOISTS GOVERNMENT OF KARNATAKA WATER RESOURCES DEPARTMENT SCHEDULE OF RATES GATE / HOIST AND ALLIED WORKS FOR THE YEAR : 2003-2004 CONTENTS PAGES REFERENCE DATA 1 -- 2 NOTES ON BASIC RATES 3 -- 3 DATA FOR SCHEDULE OF RATES 4 -- 183 PREPARED BY SCHEDULE OF RATES COMMITTEE JUNE, 2003 0

SCHEDULE OF RATES and Hoists.pdfMS pipe 300 mm dia per kg Rs: 30.00 MS pipe 32 mm dia per Rm Rs: 80.00 Oxygen gas per cum Rs: 40.00 Rails 45 kg / m per tonne Rs: 24500.00 Rubber seal

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Page 1: SCHEDULE OF RATES and Hoists.pdfMS pipe 300 mm dia per kg Rs: 30.00 MS pipe 32 mm dia per Rm Rs: 80.00 Oxygen gas per cum Rs: 40.00 Rails 45 kg / m per tonne Rs: 24500.00 Rubber seal

GATES AND HOISTS

GOVERNMENT OF KARNATAKA

WATER RESOURCES DEPARTMENT

SCHEDULE OF RATES

GATE / HOIST AND ALLIED WORKS

FOR THE YEAR : 2003-2004

CONTENTS PAGES

REFERENCE DATA 1 -- 2

NOTES ON BASIC RATES 3 -- 3

DATA FOR SCHEDULE OF RATES 4 -- 183

PREPARED BY SCHEDULE OF RATES COMMITTEE

JUNE, 2003

0

Page 2: SCHEDULE OF RATES and Hoists.pdfMS pipe 300 mm dia per kg Rs: 30.00 MS pipe 32 mm dia per Rm Rs: 80.00 Oxygen gas per cum Rs: 40.00 Rails 45 kg / m per tonne Rs: 24500.00 Rubber seal

GATES AND HOISTS

GATE / HOIST AND ALLIED WORKS -- REFERENCE DATA FOR THE YEAR - 2003-2004 ITEMS : 1 - 31

COST OF MATERIALS :Acytelene gas per cum Rs: 185.00Alloy steel ( IS : 1570 ) Shafts per kg Rs: 145.00Alloy steel ( IS : 1570 ) Pins per kg Rs: 175.00Bolt / Nut / Washer ( hot dipped galvanized ) per kg Rs: 60.00Bolt / Nut / Washer ( mild steel ) per kg Rs: 45.00Bolt / Nut / Washer ( stainless steel ) per kg Rs: 100.00Bronze / Alluminium alloy ( IS : 305 ) Bearings / Bushes per kg Rs: 380.00Cast iron blocks per kg Rs: 18.00Cast steel Drums / Gears per kg Rs: 95.00Cast steel Pinions per kg Rs: 105.00Cast steel Wheels / Pulleys / Hubs / Rollers / retainers per kg Rs: 85.00Chequered plate per kg Rs: 25.20Coaltar epoxy paint per ltr Rs: 131.00Degreasing / derusting / phasphate coating chemical per ltr Rs: 175.00Forged steel Hooks / Shackles per kg Rs: 130.00Gas cutting set ( 2 Nos 15 m hose and nozzle unit ) Rs: 1125.00Grease per kg Rs: 90.00MS pipe 300 mm dia per kg Rs: 30.00MS pipe 32 mm dia per Rm Rs: 80.00Oxygen gas per cum Rs: 40.00Rails 45 kg / m per tonne Rs: 24500.00Rubber seal ( flat type bottom seal ) IS : 11855 per Rm Rs: 120.00Rubber seal ( music note teflon claded corner seal ) IS : 11855 per Rm Rs: 600.00Rubber seal ( music note uncladed corner seal ) IS : 11855 per Rm Rs: 240.00Rubber seal ( music note teflon claded side seal ) IS : 11855 per Rm Rs: 550.00Rubber seal ( music note uncladed side seal ) IS : 11855 per Rm Rs: 190.00Rubber seal ( Z - type side seal ) IS : 11855 per Rm Rs: 240.00Stainless steel plate / flats per kg Rs: 90.00Steel wire rope 6x37 construction per kg Rs: 75.00Structural steel angle / channel / beam / bars per kg Rs: 20.00Structural steel plate / flats per kg Rs: 24.00Sundries ( Lump sum rate for unquantified inputs ) Rs: 22.50Synthetic enamel paint ( 1st quality ) per ltr Rs: 140.00Welding electrodes 4 mm x 450 mm ( radiographic ) per No. Rs: 4.00Welding electrodes 4 mm x 450 mm ( radiographic low hydrogen ) per No. Rs: 6.00Welding electrodes 4 mm x 450 mm ( stainless steel ) per No. Rs: 35.00Welding holder set ( cable / holder / gloves / mask etc ) per set Rs: 3375.00Wire brush per Each Rs: 25.00Zinc per kg Rs: 100.00Zinc rich ( zinc content : 85 % ) epoxy primer paint per ltr Rs: 525.00Zinc chromate red oxide primer per ltr Rs: 140.00Excise duty on cost of supplies % 18.00Insurance charges % 1.00

LEAD, LOADING & UNLOADING CHARGES: 1 km lead Loading UnloadingSteel per tonne Rs: 25.90 27.70 27.70

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Page 3: SCHEDULE OF RATES and Hoists.pdfMS pipe 300 mm dia per kg Rs: 30.00 MS pipe 32 mm dia per Rm Rs: 80.00 Oxygen gas per cum Rs: 40.00 Rails 45 kg / m per tonne Rs: 24500.00 Rubber seal

GATES AND HOISTS

HIRE CHARGES OF MACHINERY: Hire charge Fuel charge Crew chargeBending machine per hour Rs: 31.00 61.00 26.70Derric crane ( mobile ) per hour Rs: 261.00 117.00 32.90Derric crane ( stationary ) per hour Rs: 50.00 5.00 ---Drilling machine for steel per hour Rs: 15.00 20.00 35.00Grinder per hour Rs: 15.00 20.00 35.00Planing machine per hour Rs: 66.00 61.00 42.75Plate shearing machine per hour Rs: 47.00 82.00 26.70Pug cutting machine per hour Rs: 13.00 2.00 ---Tower crane 5 tonne per hour Rs: 763.00 106.00 36.05Welding transformer per hour Rs: 9.00 49.00 ---

WAGES OF WORKERS: Per dayElectrician Rs: 82.65Foreman Rs: 108.65Gas cutter Rs: 93.70Helper fabrication / erection Rs: 81.60Khalasi Rs: 83.65Marker / Erector / Fabricator / Machanic Rs: 93.70Painter Class-II Rs: 81.60Welder ( General ) Rs: 93.70Welder ( X-ray quality ) Rs: 103.07

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Page 4: SCHEDULE OF RATES and Hoists.pdfMS pipe 300 mm dia per kg Rs: 30.00 MS pipe 32 mm dia per Rm Rs: 80.00 Oxygen gas per cum Rs: 40.00 Rails 45 kg / m per tonne Rs: 24500.00 Rubber seal

GATES AND HOISTS

NOTES ON SCHEDULE OF RATES GATE / HOIST AND ALLIED WORKS FOR THE YEAR : 2003-2004

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 worksshall 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 technicalspecifications.

5. The basic rates are inclusive of finishing, wastage of materials , incidental works, temperarysupports, scaffolding, all enabling works, profit, overheads, small tools / plants, hidden coston labour etc.

6. The basic rates are inclusive of taxes, duties, levies and all other incidental charges exceptsales tax on works contract. Separate provision shall be made in the estimate towards salestax on works contract at the rate prevailing at the time of preparation of estimate.

7. The basic rates are inclusive of all leads and lifts including rehandling.

8. Unless otherwise specified the basic rates are inclusive of standard finish required for all thefabricated and bought out gate and hoist components.

9. The basic rates are inclusive of preparatory works such as rectification of damages, repairingshop painting, cleaning, positioning and anchoring first stage embedments, cleaning surfacefor field painting etc.

10. The basic rates are exclusive of cost of river diversion arrangements, dewatering, desiltingetc., which form part of civil works.

11. 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 asper detailed designs / empirical formulae / similar works.

12. Dry film thickness for zinc rich epoxy primer and coal tar epoxy paints shall be 40 microns percoat and 100 microns per coat respectively.

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Page 5: SCHEDULE OF RATES and Hoists.pdfMS pipe 300 mm dia per kg Rs: 30.00 MS pipe 32 mm dia per Rm Rs: 80.00 Oxygen gas per cum Rs: 40.00 Rails 45 kg / m per tonne Rs: 24500.00 Rubber seal

GATES AND HOISTS

GATE / HOIST AND ALLIED WORKS - DATA RATES

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 1

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sillbeam, wall plates, anchors, anchor girders, yoke girders, tie flats, trunnion supports, rope andpulley supports etc., with all accessories for spillway radial gates including cost of all materials, machinery, labour, aligning, anchoring, welding, finishing, cleaning, applying onecoat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., completeas per specifications and approved drawings with all leads and 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 radialgate 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 for analysis.Details of material / Gas cutting / Welding considered for rate analysis are based on embeddedparts drawings for 15 m x 9 m spillway opening of Kodasalli dam.Size of gate for 15 x 9 m spillway opening at crest Length : 15 m Height : 9.75 mHead of water for sill level 0.6 m below crest : 9.60 mWeight of radial gate leaf in tonne with end shield and hood based on empirical formula : Weight of gate in tonnes = 0.0710 x ( L^2 x H x h )^0.673Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.Weight of embedded parts @ 25% = 0.0177 x ( L^2 x H x h )^0.673 = 0.0177 x ( 15 x 15 x 9.75 x 9.6 ) ^ 0.673 : 14.377The actual weight of embedded parts as per fabrication drawings : 14.334 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 1 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel angles / beams / channels / bars with 2.5 % wastage : 696 kgStructural steel plates / flats with 2.5 % wastage : 13690 kg

b. Alloy steel conforming to IS : 1570 :Stainless steel plates / flats : 195.00 kg

c. Bolt / Nut / Washer conforming to IS : 1363 :MS bolts / nuts with 2.5 % wastage : 112 kg

d. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 665 NosWelding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 66 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 5983 NosWelding electrodes ( SS ) for run welding at 90 % of total with 2.5 % wastage : 591 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides as per data sheet : 428 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 43 RmTotal length of cutting : 471 RmFor 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 mLength of steel to be cut by gas using pug cutting machine : 371 mLength of steel to be cut by using shearing machine : 40 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 30 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 124 hoursTime for cutting by shearing machine at av. 10 m / hour progress : 4 hoursAcetelyne gas @ 0.6 cum / hour ( 154 x 0.60 ) : 92 cumOxygen gas @ 1.8 cum / hour ( 154 x 1.80 ) : 276 cumUse of gas cutting torch with 50 min / hour working ( 30 x 60 / 50 ) : 36 hours

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Page 6: SCHEDULE OF RATES and Hoists.pdfMS pipe 300 mm dia per kg Rs: 30.00 MS pipe 32 mm dia per Rm Rs: 80.00 Oxygen gas per cum Rs: 40.00 Rails 45 kg / m per tonne Rs: 24500.00 Rubber seal

GATES AND HOISTS

Use of pug cutting machine with 50 min / hr working ( 124 x 60 / 50 ) : 149 hoursUse of shearing machine with 50 min / hour working ( 4 x 60 / 50 ) : 5 hours

3. Welding :Length of welding as per data sheet : 600 mFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 665 + 66 ) x 8 / 15 / 2 : 195 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 5983 + 591 ) x 8 / 15 / 6 : 585 hoursTotal : 780 hours

Deploy welding transformer for 780 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 195 x 0.25 + 585 x 0.75 ) : 488 hours4 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 RmLength of planing at a time for 4 m stroke planing machine 3 RmTime for planing 3 m length section with 50 min / hour working 8 hoursTime 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 : 143 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 143 sqm @ 9 sqm / ltr / coat : 16 ltr4 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 ltrAs 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 at 8 sqm / ltr : 18 ltr

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 16 hours use of drilling / grinding machine considered.For handling of parts during fabrication and erection use of mobile derric crane for 32 hours and stationery derric crane for 64 hours considered.

7 Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector /

Cutting sections 190 hours 12 24 24 48Drilling holes for anchors / supports 1 2 --- 2Fabricating by stitch welding 195 hours 12 24 --- 48Run welding 585 hours 7 --- 73 73Erection of Anchor / Yoke girders 13 26 --- 26Erection of tie flats 2 2 --- 4Erection of first stage anchors --- 10 --- 10Erection of Sill beam / Wall plates 3 3 --- 6Finishing / cleaning / checking 1 1 --- 2 Total : 51 92 97 219

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 10 helpers for 143 sqm.For painting 1 coat primer and 4 coats

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Page 7: SCHEDULE OF RATES and Hoists.pdfMS pipe 300 mm dia per kg Rs: 30.00 MS pipe 32 mm dia per Rm Rs: 80.00 Oxygen gas per cum Rs: 40.00 Rails 45 kg / m per tonne Rs: 24500.00 Rubber seal

GATES AND HOISTS

finishing paint at 15 sqm / day : 48 painter Cl-ll & 8 helper for 5 x 143 sqm.8 Excise duty on supply :

Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes / 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 14.334 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Str steel angle / beam / channel / bars kg 696.00 20.00 13920.002 Structural steel plate / flats kg 13690.00 24.00 328560.003 Stainless steel plate / flats kg 195.00 90.00 17550.004 MS bolts and nuts kg 112.00 45.00 5040.005 Oxygen gas cum 276.00 40.00 11040.006 Acetyline gas cum 92.00 185.00 17020.007 Welding electrodes Nos 665.00 4.00 2660.008 Welding electrodes ( LH ) Nos 5983.00 6.00 35898.009 Welding electrodes ( stainless steel ) Nos 657.00 35.00 22995.00

10 Zinc rich epoxy primer ltr 16.00 525.00 8400.0011 Coal tar epoxy paint ltr 96.00 131.00 12576.0012 Rust cleaner / inhibitor ltr 18.00 175.00 3150.0013 Use rate welding holder set Hour 780.00 3.38 2632.5014 Use rate gas cutting torch set Hour 36.00 1.88 67.5015 Wire brush Nos 2.00 25.00 50.0016 Sundries LS 100.00 22.50 2250.00

TOTAL Rs: 483809.00Add for small Tools and Plants @ 1% Rs: 4838.09Add for Contractor' Profit @ 10% Rs: 48380.90Add for Contrators' Overheads @ 5% Rs: 24190.45

Total cost of Materials Rs: 561218.44

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 780.00 9.00 7020.00

Fuel / Energy charges Hour 488.00 49.00 23912.002 Tower crane Hour 4.00 763.00 3052.00

Fuel / Energy charges Hour 4.00 106.00 424.003 Plate shearing machine Hour 5.00 47.00 235.00

Fuel / Energy charges Hour 5.00 82.00 410.004 Pug cutting machine Hour 149.00 13.00 1937.00

Fuel / Energy charges Hour 149.00 2.00 298.005 Mobile derric crane Hour 32.00 261.00 8352.00

Fuel / Energy charges Hour 32.00 117.00 3744.006 Stationery derric crane Hour 64.00 50.00 3200.00

Fuel / Energy charges Hour 64.00 5.00 320.00

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Page 8: SCHEDULE OF RATES and Hoists.pdfMS pipe 300 mm dia per kg Rs: 30.00 MS pipe 32 mm dia per Rm Rs: 80.00 Oxygen gas per cum Rs: 40.00 Rails 45 kg / m per tonne Rs: 24500.00 Rubber seal

GATES AND HOISTS

7 Grinding machine Hour 16.00 15.00 240.00Fuel / Energy charges Hour 16.00 20.00 320.00

8 Drilling machines Hour 16.00 15.00 240.00Fuel / Energy charges Hour 16.00 20.00 320.00

9 Planing machine Hour 150.00 66.00 9900.00Fuel / Energy charges Hour 150.00 61.00 9150.00

10 Sundries LS 100.00 22.50 2250.00TOTAL Rs: 75324.00

Add for small Tools and Plants @ 1% Rs: 753.24Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 4114.80Add for Contrators' Overheads @ 5% Rs: 3766.20 Total hire charges of Machinery Rs: 83958.24

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Tower crane Hour 4.00 36.05 144.202 Crew for Mobile crane Hour 32.00 32.90 1052.803 Crew for Shearing machine Hour 5.00 26.70 133.504 Crew for Planing machine Hour 150.00 42.75 6412.505 Crew for Drilling machine Hour 16.00 35.00 560.006 Crew for Grinding machine Hour 16.00 35.00 560.007 Foreman Day 51.00 108.65 5541.158 Marker / Fabricator / Erector Day 92.00 93.70 8620.409 Gas cutter Day 24.00 93.70 2248.80

10 Welder ( General ) Day 66.00 93.70 6184.2011 Welder ( X - ray ) Day 7.00 103.07 721.4912 Khalasi Day 50.00 83.65 4182.5013 Helper fabrication / erection Day 219.00 81.60 17870.4014 Helper for cleaning / painting Day 18.00 81.60 1468.8015 Painter Cl - II Day 48.00 81.60 3916.8016 Electrician Day 5.00 82.65 413.25

TOTAL Rs: 60030.79Add for small Tools and Plants @ 1% Rs: 600.31Add for Contractor' Profit @ 10% Rs: 6003.08Add for hidden cost on Labour @ 15% Rs: 9004.62Add for additional hidden cost on labour @ 15% Rs: 9004.62Add for Contrators' Overheads @ 5% Rs: 3001.54

Total cost of Labour Rs: 87644.95

ABSTRACT:A. Cost of Materials Rs: 561218.44B. Hire charges of Machinery Rs: 83958.24C. Cost of Labour Rs: 87644.95

Total Rs: 732821.63Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 23166.43Add for insurance charges @ 1.00% Rs: 7328.22Add for designs and drawings @ 2.5% Rs: 18320.54Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 18320.54Add for power supply arrangements @ 2.5% Rs: 18320.54Add for enabling works @ 2% Rs: 14656.43

Total Rs: 832934.34

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Page 9: SCHEDULE OF RATES and Hoists.pdfMS pipe 300 mm dia per kg Rs: 30.00 MS pipe 32 mm dia per Rm Rs: 80.00 Oxygen gas per cum Rs: 40.00 Rails 45 kg / m per tonne Rs: 24500.00 Rubber seal

GATES AND HOISTS

Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x14.334 tonnes @ Rs: 81.30 / tonne Rs: 2330.71Add for transportation upto work site @ 3% Rs: 24988.03 Total cost for 14.334 tonne Rs: 860253.07

Rate per tonne Rs: 60010.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 2

ITEM: Design, fabrication, supply, erection, testing and commissioning of radial gate consistingof skin plate, stiffeners, horizontal girders, sector arms, trunnion assemblies, tie beam, pulleysupports, bracings, rubber seals, clamps etc., with all accessories for spillway including 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 allleads 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 andare stiffened by vertical and diagonal stiffeners to form the main frame. Tee- sections are weldedto horizontal girders to make the frame regid and to support the skin plate. Skin plate is weldedto Tee-supports generally spaced vertically at about 40 cm apart.Consider radial gate for spillway opening of size 15 m x 9 m for analysis.Details of material / Gas cutting / Welding considered for rate analysis are based on radial gatedrawings for 15 m x 9 m spillway opening of Kodasalli dam with sill level 0.9 m below crest.Length : 15.00 m height : 9.75 m Head of water above sill : 9.60 mWeight of gate leaf in tonne with end shield and hood based on empirical formula : Weight of gate in tonnes = 0.0710 x ( L^2 x H x h )^0.673Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0710 x ( 15^2 x 9.75 x 9.6 )^0.673 : 57.669The actual weight of radial gate leaf as per fabrication drawings : 57.457 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 2 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel angles / beams / channels / bars with 2.5 % wastage 15806 kgStructural steel plates / flats with 2.5 % wastage : 38672 kg

b. Alloy steel components conforming to IS : 1570 :Stainless steel plates : 6 kgLifting 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 : 78 kgMS bolts / nuts / washers with 2.5 % wastage : 79 kg

f. Zinc at 70 kg / trunnion ( 2 x 70 ) : 140 kgg. Rubber seal conforming to IS : 11855 :

Bottom seal ( flat type )with wastage : 15.5 RmSide seals ( Z - type ) with wastage : 25 Rm

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Page 10: SCHEDULE OF RATES and Hoists.pdfMS pipe 300 mm dia per kg Rs: 30.00 MS pipe 32 mm dia per Rm Rs: 80.00 Oxygen gas per cum Rs: 40.00 Rails 45 kg / m per tonne Rs: 24500.00 Rubber seal

GATES AND HOISTS

h. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 2728 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 24554 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 928 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 93 Rm

Total : 1021 RmFor 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 mmthick use of shearing machine is assumed to the extent feasible.Length of steel to be cut by using gas manually : 350 mLength of steel to be cut by gas using pug cutting machine : 571 mLength of steel to be cut by using shearing machine : 100 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 175 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 190 hoursTime for cutting by shearing machine at av. 10 m / hr progress : 10 hoursAcetelyne gas @ 0.6 cum / hour ( 365 x 0.60 ) : 219 cumOxygen gas @ 1.8 cum / hour ( 365 x 1.80 ) : 657 cumUse of gas cutting torch with 50 min / hr working ( 175 x 60 / 50 ) : 210 hoursUse of pug cutting machine with 50 min / hr working ( 190 x 60 / 50 ) : 228 hoursUse of shearing machine with 50 min / hr working ( 10 x60 / 50 ) : 12 hours

3. Bending :Assuming 1.2 m wide plates, length of plate for bending ( 15 x 11 / 1.2 ) : 137.50 mLength of Tee sections @ 0.4 m spacing ( 15 x 11 / 0.4 ) : 412.50 mLength of side seal base and cover flats ( 11 x 2 x 2 ) : 44.00 m

Total ( say ) : 594.00 mAssuming 3 m bending / hour, time for bending 594 m ( 594 / 3 ) : 198 hoursWith 50 minutes / hour working deploy bending machine for : 238 hours

4. Welding :Length of welding : 2294 RmFor radial gates where field welding is more hourly progress is assumed at 12 electrodes / hour.For stich welding @ 2 hrs usage / shift & @ 12 electrodes / hr

( 2728 / 12 ) x 8 / 2 : 909 hoursFor run welding @ 6 hrs usage / shift & @ 12 electrodes / hr

( 24554 / 12 ) x 8 / 6 : 2728 hoursTotal : 3637 hours

Deploy welding transformer for 3637 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 909 x 0.25 + 2728 x 0.75 ) : 2273 hours

5. Surface cleaning and painting : Painting area for radial gate at 20 sqm / tonne : 1150 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 1150 sqm @ 9 sqm / ltr / coat : 128 ltr3 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 ltrAs 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 at 8 sqm / ltr : 144 ltr

6. Requirement of other machinery :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.

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Page 11: SCHEDULE OF RATES and Hoists.pdfMS pipe 300 mm dia per kg Rs: 30.00 MS pipe 32 mm dia per Rm Rs: 80.00 Oxygen gas per cum Rs: 40.00 Rails 45 kg / m per tonne Rs: 24500.00 Rubber seal

GATES AND HOISTS

For grinding and finishing weld joints in skin plate and other locations 50 hours use of grinding machine considered.For handling during fabrication and erection of gate parts mobile derric crane for 150 hours and stationery derric crane for 300 hours considered.

7. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 450 hours 28 56 56 112Drilling holes for seal fixing 3 6 --- 12Fabricating by stitch welding 909 hours 57 114 --- 456Run welding 2728 hours 34 --- 341 341Erection of trunnion and tie beam 4 8 --- 32Erection of Horizontal girders 3 3 --- 12Erection of sector arms 3 3 --- 12Erection of vertical stiffeners 5 10 --- 40Erection of skin plates 3 6 --- 24Erection of end sheilds and hood 4 8 --- 32Erection of bracings 6 6 --- 24Molten zinc filling for trunnion supports 2 2 --- 2Seal fixing 2 2 --- 4Finishing / cleaning / checking 1 2 --- 2 Total : 155 226 397 1105

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 77 helpers for 1150 sqmFor painting 1 coat primer and 3 coats finishing paint at 15 sqm / day : 306 painter Cl-ll & 77 helper for 4 x 1150 sqm

8. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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.

9. Use rate of materials :Cost of welding set @ Rs: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 57.457 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel :

Angles / beams / channels / bars kg 15806.00 20.00 316120.00Plates / flats kg 38672.00 24.00 928128.00

2 Cast steel components :Trunnion hubs / Guide rollers kg 1895.00 85.00 161075.00

3 Alloy steel components :Stainless steel plate kg 6.00 90.00 540.00Trunnion pins kg 1098.00 175.00 192150.00

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GATES AND HOISTS

4 Alluminium / Bronze alloy components :Bush for Trunnion / Guide roller kg 1155.00 380.00 438900.00

5 Bolt / Nut / Washer :GI bolts / nuts / washers kg 78.00 60.00 4680.00MS bolts / nuts / washers kg 79.00 45.00 3555.00

6 Zinc kg 140.00 100.00 14000.007 Rubber seals :

Bottom seal Rm 15.50 120.00 1860.00Side seals ( Z - type ) Rm 25.00 240.00 6000.00

8 Oxygen gas cum 657.00 40.00 26280.009 Acetyline gas cum 219.00 185.00 40515.00

10 Welding electrodes ( std ) Nos 2728.00 4.00 10912.0011 Welding electrodes ( LH ) Nos 24554.00 6.00 147324.0012 Zinc rich epoxy primer ltr 128.00 525.00 67200.0013 Coal tar epoxy paint ltr 575.00 131.00 75325.0014 Rust cleaner / inhibitor ltr 144.00 175.00 25200.0015 Use rate welding holder set Hour 3637.00 3.38 12274.8816 Use rate gas cutting torch set Hour 210.00 1.88 393.7517 Wire brush Nos 12.00 25.00 300.0018 Sundries LS 1000.00 22.50 22500.00

TOTAL Rs: 2495232.63Add for small Tools and Plants @ 1% Rs: 24952.33Add for Contractor' Profit @ 10% Rs: 249523.26Add for Contrators' Overheads @ 5% Rs: 124761.63

Total cost of Materials Rs: 2894469.85

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 3637.00 9.00 32733.00

Fuel / Energy charges Hour 2273.00 49.00 111377.002 Plate shearing machine Hour 12.00 47.00 564.00

Fuel / Energy charges Hour 12.00 82.00 984.003 Pug cutting machine Hour 228.00 13.00 2964.00

Fuel / Energy charges Hour 228.00 2.00 456.004 Bending machine Hour 238.00 31.00 7378.00

Fuel / Energy charges Hour 238.00 61.00 14518.005 Tower crane 5 t cpacity Hour 10.00 763.00 7630.00

Fuel / Energy charges Hour 10.00 106.00 1060.006 Mobile derric crane Hour 150.00 261.00 39150.00

Fuel / Energy charges Hour 150.00 117.00 17550.007 Stationery derric crane Hour 300.00 50.00 15000.00

Fuel / Energy charges Hour 300.00 5.00 1500.008 Grinding machine Hour 50.00 15.00 750.00

Fuel / Energy charges Hour 50.00 20.00 1000.009 Drilling machines Hour 50.00 15.00 750.00

Fuel / Energy charges Hour 50.00 20.00 1000.0010 Sundries LS 1000.00 22.50 22500.00

TOTAL Rs: 278864.00Add for small Tools and Plants @ 1% Rs: 2788.64Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 17194.50Add for Contrators' Overheads @ 5% Rs: 13943.20 Total hire charges of Machinery Rs: 312790.34

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GATES AND HOISTS

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 150.00 32.90 4935.002 Crew for Tower crane Hour 10.00 36.05 360.503 Crew for Bending machine Hour 238.00 26.70 6354.604 Crew for Drilling machine Hour 50.00 35.00 1750.005 Crew for Grinding machine Hour 50.00 35.00 1750.006 Foreman Day 155.00 108.65 16840.757 Marker / Fabricator / Erector Day 226.00 93.70 21176.208 Gas cutter Day 56.00 93.70 5247.209 Welder ( General ) Day 307.00 93.70 28765.90

10 Welder ( X - ray ) Day 34.00 103.07 3504.3811 Khalasi Day 250.00 83.65 20912.5012 Helper fabrication / erection Day 1105.00 81.60 90168.0013 Helper for cleaning / painting Day 154.00 81.60 12566.4014 Painter Cl - II Day 306.00 81.60 24969.6015 Electrician Day 30.00 82.65 2479.50

TOTAL Rs: 241780.53Add for small Tools and Plants @ 1% Rs: 2417.81Add for Contractor' Profit @ 10% Rs: 24178.05Add for hidden cost on Labour @ 15% Rs: 36267.08Add for additional hidden cost on labour @ 15% Rs: 36267.08Add for Contrators' Overheads @ 5% Rs: 12089.03

Total cost of Labour Rs: 352999.57

ABSTRACT:A. Cost of Materials Rs: 2894469.85B. Hire charges of Machinery Rs: 312790.34C. Cost of Labour Rs: 352999.57

Total Rs: 3560259.76Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 89881.64Add for insurance charges @ 1.00% Rs: 35602.60Add for designs and drawings @ 2.5% Rs: 89006.49Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 89006.49Add for power supply arrangements @ 2.5% Rs: 89006.49Add for enabling works @ 2% Rs: 71205.20

Total Rs: 4023968.67Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x57.457 tonnes @ Rs: 81.30 / tonne Rs: 9342.51Add for transportation upto work site @ 3% Rs: 120719.06 Total cost for 57.457 tonne Rs: 4154030.24

Rate per tonne Rs: 72300.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 3

ITEM: Design, fabrication, supply, erection, testing and commissioning of electrically operated ropedrum hoist of adequate capacity consisting of base frames, rope drums,connecting shaft, gearsystem, brake system, electric motor, wire ropes, gate position indicator, manual operationarrangement etc., with all accessories for spillway radial gate including cost of all materials,machinery, labour, aligning, anchoring, welding, finishing, cleaning, greasing, providing handrailing and approach staircase with gate to hoist platform, applying two coats of zinc chromatered oxide primer and three coats of approved synthetic enamel paint etc., complete as per

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GATES AND HOISTS

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 for analysis.Details of material / Gas cutting / Welding considered for rate analysis are based on rope drumhoist drawings for 15 m x 9 m spillway opening of Kodasalli dam.Weight of gate leaf in tonne for 15 m x 9 m spillway opening based on empirical formula : Size of gate for 15 x 9 m spillway opening: Length :15 m Height :9.75 mWeight of radial gate leaf in tonne for 9.6 m water head based on empirical formula : Weight of gate in tonnes = 0.0710 x ( L^2 x H x h )^0.673Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0710 x ( 15^2 x 9.75 x 9.6 )^0.673 : 57.669Hoist capacity including 25 % reserve capacity : 1.5 x Weight of gate in tonneCapacity of hoist required in tonnes : 1.5 x 57.669 : 86.504Hoist capacity shall be rounded off to next 10 tonne say : 90.00 tonnesActual capacity of hoist provided : 90.00 tonnesWeight of hoist with all accessories is assumed at 0.175 tonne per tonne capacity of hoist.Weight of hoist with all accessories ( 0.175 x 90 ) : 15.750 tonnesThe actual weight of spillway radial gate rope drum hoist as per data sheet : 15.440 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 3 of Annexer )a. Structural steel conforming to IS : 2062 :

Angles / Beams / Channels / Bars with 2.5 % wastage : 2571.00 kgPlates / Flats with 2.5 % wastage : 3632.00 kg

b. Cast steel components conforming to IS : 1030 :Rope drums 2 Nos / Gears 4 Nos : 3680.00 kgPinions : 218.00 kgPulleys 720 PCD 6 Nos : 1080.00 kgPlummer blocks / Hubs : 322.00 kg

c. Alloy steel components conforming to IS : 1570 :Shafts ( carbon steel ) : 557.00 kgPins ( 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 : 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 kg

g. Other components :Manual operation assembly : 1 No.Worm reducer : 1 NosElectric motor 20 hp : 1 No.Gate position indicator : 1 No.Ele-magnetic brake : 1 No.Wire rope sockets : 2 NosMS pipe 300 mm dia 13.32 Rm @ 75 kg / Rm : 1000 kgElectric cable / switch / control panel etc : 1 set

h. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 530 Nos

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GATES AND HOISTS

Welding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 4776 Nos 2. Cutting :

Length of cutting assuming cutting for 2 sides : 255 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 25 Rm

Total : 280 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 150 mLength of steel to be cut by gas using pug cutting machine : 130 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 75 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 44 hoursAcetelyne gas @ 0.6 cum / hour ( 119 x 0.60 ) : 71 cumOxygen gas @ 1.8 cum / hour ( 119 x 1.80 ) : 213 cumUse of gas cutting torch with 50 min / hr working ( 75 x 60 / 50 ) : 90 hoursUse of pug cutting machine with 50 min / hr working ( 44 x 60 / 50 ) : 53 hours

3. Welding :Length of welding : 447 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 530 / 15 ) x 8 / 2 : 141 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 4776 / 15 ) x 8 / 6 : 425 hoursTotal : 566 hours

Deploy welding transformer for 566 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 141 x 0.25 + 425 x 0.75 ) : 354 hours 4. Surface cleaning and painting :

Quantity of structural steel requiring cleaning for painting : 6.2 tonnesPainting area for hoist at 20 sqm / t of str steel ( 6.2 x 20 ) : 124 sqm2 coats of zinc chromate red oxide primer.Quantity of primer paint for 124 sqm @ 12 sqm / ltr / coat : 21 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 124 sqm @ 12 sqm / ltr / coat : 31 ltrAs 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 at 8 sqm / ltr : 16 ltr

5. Requirement of other machinery :For lifting and placing in position hoist drums, worm reducers, gears, floating shafts etc deploy tower crane for 4 hours.For handling and erection mobile derric crane for 50 hours considered.For drilling holes for bolts 16 hours use of drilling machine considered. For grinding and finishing weld joints 8 hours use of grinding machine considered

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 143 hours 9 18 18 36Drilling holes for pins / bolts fixing 1 2 --- 2Fabricating by stitch welding 141 hours 9 18 --- 36Run welding 425 hours 5 --- 53 53Erection of anchors 2 2 --- 4Erection of drums and gears 2 4 --- 16Erection of floating shaft / pulleys 1 2 --- 4Erection of worm reducers / brake / motor 1 2 --- 4Erection of other accessories 1 2 --- 2

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GATES AND HOISTS

Erection of control panel / cabling 1 1 --- 2Checking and trial running without ropes 1 2 --- 4Rope fixing and checking 1 2 --- 8Finishing / cleaning --- 1 --- 2Trial running for lifting / lowering gate 1 2 --- 2 Total : 35 58 71 175

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 8 helpers for 124 sqmFor painting 2 coats primer and 3 coats finishing paint at 20 sqm / day : 30 painter Cl-ll & 6 helpers for 5x124 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 15.440 tonne wtA. MATERIALS: 90.00 t capacity Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / beams / channels / bars kg 2571.00 20.00 51420.00Plates / flats kg 3632.00 24.00 87168.00

2 Cast steel components :Rope drums 2 Nos / Gears 4 Nos kg 3680.00 95.00 349600.00Pinions kg 218.00 105.00 22890.00Pulleys 720 PCD 6 Nos kg 1080.00 85.00 91800.00Plummer blocks / Hubs kg 322.00 85.00 27370.00

3 Alloy steel componentsShafts kg 557.00 145.00 80765.00Pins kg 546.00 175.00 95550.00

4 Bronze alloy components :Bronze bearings / bush kg 144.00 380.00 54720.00

5 Wire rope 36 mm dia 6/37 construction kg 448.00 75.00 33600.006 MS Bolt / Nut / Washer kg 85.00 45.00 3825.007 Worm reducers No. 1.00 45000.00 45000.008 Electric motor 20 hp No. 1.00 28125.00 28125.009 Floating shaft 300 mm dia kg 1000.00 30.00 30000.00

10 Manual operating system No. 1.00 8437.50 8437.5011 Gate position indicator No. 1.00 8437.50 8437.5012 Ele-magnetic brake No. 1.00 11250.00 11250.0013 Electric cable / switch / control panel etc LS 1.00 11250.00 11250.0014 Oxygen gas cum 213.00 40.00 8520.0015 Acetyline gas cum 71.00 185.00 13135.0016 Welding electrodes Nos 530.00 4.00 2120.0017 Welding electrodes ( LH ) Nos 4776.00 6.00 28656.00

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GATES AND HOISTS

18 Zinc chromate red oxide primer ltr 21.00 140.00 2940.0019 Synthetic enamel ( 1st quality ) paint ltr 31.00 140.00 4340.0020 Rust cleaner / inhibitor ltr 16.00 175.00 2800.0021 Grease kg 50.00 90.00 4500.0022 Use rate welding holder set Hour 566.00 3.38 1910.2523 Use rate gas cutting torch set Hour 90.00 1.88 168.7524 Wire brush Nos 3.00 25.00 75.0025 Sundries ( hand rail /staircase / gate etc ) LS 200.00 22.50 4500.00

TOTAL Rs: 1114873.00Add for small Tools and Plants @ 1% Rs: 11148.73Add for Contractor' Profit @ 10% Rs: 111487.30Add for Contrators' Overheads @ 5% Rs: 55743.65

Total cost of Materials Rs: 1293252.68

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 566.00 9.00 5094.00

Fuel / Energy charges Hour 353.00 49.00 17297.002 Tower crane 5 t capacity Hour 4.00 763.00 3052.00

Fuel / Energy charges Hour 4.00 106.00 424.003 Pug cutting machine Hour 53.00 13.00 689.00

Fuel / Energy charges Hour 53.00 2.00 106.004 Mobile derric crane Hour 50.00 261.00 13050.00

Fuel / Energy charges Hour 50.00 117.00 5850.005 Grinding machine Hour 8.00 15.00 120.00

Fuel / Energy charges Hour 8.00 20.00 160.006 Drilling machines Hour 16.00 15.00 240.00

Fuel / Energy charges Hour 16.00 20.00 320.007 Sundries LS 100.00 22.50 2250.00

TOTAL Rs: 48652.00Add for small Tools and Plants @ 1% Rs: 486.52Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 2640.70Add for Contrators' Overheads @ 5% Rs: 2432.60 Total hire charges of Machinery Rs: 54211.82

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 50.00 32.90 1645.002 Crew for Tower crane Hour 4.00 36.05 144.203 Crew for Drilling machine Hour 16.00 35.00 560.004 Crew for Grinding machine Hour 8.00 35.00 280.005 Foreman Day 35.00 108.65 3802.756 Marker / Fabricator / Erector / Mechanic Day 58.00 93.70 5434.607 Gas cutter Day 18.00 93.70 1686.608 Welder ( General ) Day 53.00 93.70 4966.109 Khalasi Day 20.00 83.65 1673.00

10 Helper fabrication / erection Day 175.00 81.60 14280.0011 Helper for cleaning / painting Day 14.00 81.60 1142.4012 Painter Cl - II Day 30.00 81.60 2448.0013 Electrician Day 3.00 82.65 247.95

TOTAL Rs: 38310.60Add for small Tools and Plants @ 1% Rs: 383.11

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GATES AND HOISTS

Add for Contractor' Profit @ 10% Rs: 3831.06Add for hidden cost on Labour @ 15% Rs: 5746.59Add for additional hidden cost on labour @ 15% Rs: 5746.59Add for Contrators' Overheads @ 5% Rs: 1915.53

Total cost of Labour Rs: 55933.48

ABSTRACT:A. Cost of Materials Rs: 1293252.68B. Hire charges of Machinery Rs: 54211.82C. Cost of Labour Rs: 55933.48

Total Rs: 1403397.98Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 14869.61Add for insurance charges @ 1.00% Rs: 14033.98Add for designs and drawings @ 2.5% Rs: 35084.95Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 35084.95Add for power supply arrangements @ 2.5% Rs: 35084.95Add for enabling works @ 2% Rs: 28067.96

Total Rs: 1565624.38Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x15.44 tonnes @ Rs: 81.30 / tonne Rs: 2510.54Add for transportation upto work site @ 3% Rs: 46968.73 Total cost for 15.440 tonne wt Rs: 1615103.65

90.000 t capacityRate per tonne wt Rs: 104610.00

Rate per tonne capacity of hoist Rs: 17950.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 4

ITEM: Design, fabrication, supply, erection and commissioning of 1 metre wide catwalk connectingspillway piers / abutments at trunnion platform level including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coatof zinc rich epoxy primer and two coats of cold applied coal tar epoxy paint etc., complete asper specifications and approved drawings with all leads and lifts.

DATA: Catwalk at trunnion level generally consists of 1 m wide structural steel bridge spanning acrosspiers / abutments for maintenance of gate parts at trunnion level.Consider catwalk for a clear span of 15 m and 3 m wide piers.Details of material / Gas cutting / Welding considered for rate analysis are based on foot bridgedrawings for 15 m x 9 m radial gate of Alamatti dam.Weight of catwalk for 18 m length ( C / C of piers ) @ 0.3 t / m : 5.400 tThe actual weight of catwalk ( foot bridge ) as per data sheet : 5.318 tConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 4 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel angles / beams / channels / bars with 2.5 % wastage : 4258 kgStructural steel plates / flats with 2.5 % wastage : 98 kgChequered plates with 2.5 % wastage : 856 kg

b. Bolts / Nuts / Washers conforming to IS : 1363 :MS bolts / nuts / washers with 2.5 % wastage : 8 kg

c. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 120 NosWelding electrodes for run welding at 90 % of total with 2.5 % wastage : 1075 Nos

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GATES AND HOISTS

2. Cutting :Length of cutting assuming cutting for 2 sides : 57 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 6 Rm

Total : 63 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 40 mLength of steel to be cut by gas using pug cutting machine : 23 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 20 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 8 hoursAcetelyne gas @ 0.6 cum / hour ( 28 x 0.60 ) : 17 cumOxygen gas @ 1.8 cum / hour ( 28 x 1.80 ) : 51 cumUse of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) : 24 hoursUse of pug cutting machine with 50 min / hr working ( 8 x 60 / 50 ) : 10 hours

3. Welding :Length of welding : 151 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 120 / 15 ) x 8 / 2 : 32 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 1075 / 15 ) x 8 / 6 : 96 hoursTotal : 128 hours

Deploy welding transformer for 128 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 32 x 0.25 + 96 x 0.75 ) : 80 hours

4. Surface cleaning and painting :Painting area for catwalk at 25 sqm / tonne : 132 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 132 sqm @ 9 sqm / ltr / coat : 15 ltr2 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 132 sqm @ 6 sqm / ltr / coat : 44 ltrAs 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 at 8 sqm / ltr : 16 ltr

5. Requirement of other machinery :For erection of fabricated catwalk 1 hour use of tower crane considered.For handling during fabrication mobile derric crane for 4 hours considered.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

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections / drilling holes 34 hours 2 4 4 8Fabricating by stitch welding 32 hours 2 4 --- 16Run welding 96 hours 1 --- 12 12Erection / anchoring / finishing / checking 1 2 --- 2 Total : 6 10 16 38

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 9 helpers for 132 sqmFor painting 1 coat primer and 2 coats finishing paint at 15 sqm / day : 26 painter Cl-ll & 7 helpers for 3 x 132 sqm

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GATES AND HOISTS

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 18.000 RmA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / beams / channels / bars kg 4258.00 20.00 85160.00Plates / flats kg 98.00 24.00 2352.00Chequered plates kg 856.00 25.20 21571.20

2 Bolt / Nut / WasherMS bolts / nuts / washers kg 8.00 45.00 360.00

3 Oxygen gas cum 51.00 40.00 2040.004 Acetyline gas cum 17.00 185.00 3145.005 Welding electrodes Nos 1195.00 4.00 4780.006 Zinc rich epoxy primer ltr 15.00 525.00 7875.007 Coal tar epoxy paint ltr 44.00 131.00 5764.008 Rust cleaner / inhibitor ltr 16.00 175.00 2800.009 Use rate welding holder set Hour 128.00 3.38 432.00

10 Use rate gas cutting torch set Hour 24.00 1.88 45.0011 Wire brush Nos 1.00 25.00 25.0012 Sundries LS 10.00 22.50 225.00

TOTAL Rs: 136574.20Add for small Tools and Plants @ 1% Rs: 1365.74Add for Contractor' Profit @ 10% Rs: 13657.42Add for Contrators' Overheads @ 5% Rs: 6828.71

Total cost of Materials Rs: 158426.07

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 128.00 9.00 1152.00

Fuel / Energy charges Hour 80.00 49.00 3920.002 Tower crane Hour 1.00 763.00 763.00

Fuel / Energy charges Hour 1.00 106.00 106.003 Pug cutting machine Hour 10.00 13.00 130.00

Fuel / Energy charges Hour 10.00 2.00 20.004 Mobile derric crane Hour 4.00 261.00 1044.00

Fuel / Energy charges Hour 4.00 117.00 468.005 Grinding machine Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.006 Drilling machines Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.007 Sundries LS 10.00 22.50 225.00

TOTAL Rs: 7968.00Add for small Tools and Plants @ 1% Rs: 79.68

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GATES AND HOISTS

Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 481.90Add for Contrators' Overheads @ 5% Rs: 398.40 Total hire charges of Machinery Rs: 8927.98

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 4.00 32.90 131.602 Crew for Tower crane Hour 1.00 36.05 36.053 Crew for Drilling machine Hour 2.00 35.00 70.004 Crew for Grinding machine Hour 2.00 35.00 70.005 Foreman Day 6.00 108.65 651.906 Marker / Fabricator / Erector Day 10.00 93.70 937.007 Gas cutter Day 4.00 93.70 374.808 Welder ( General ) Day 12.00 93.70 1124.409 Helper fabrication / erection Day 38.00 81.60 3100.80

10 Helper for cleaning / painting Day 16.00 81.60 1305.6011 Painter Cl - II Day 26.00 81.60 2121.6012 Electrician Day 1.00 82.65 82.65

TOTAL Rs: 10006.40Add for small Tools and Plants @ 1% Rs: 100.06Add for Contractor' Profit @ 10% Rs: 1000.64Add for hidden cost on Labour @ 15% Rs: 1500.96Add for additional hidden cost on labour @ 15% Rs: 1500.96Add for Contrators' Overheads @ 5% Rs: 500.32

Total cost of Labour Rs: 14609.34

ABSTRACT:A. Cost of Materials Rs: 158426.07B. Hire charges of Machinery Rs: 8927.98C. Cost of Labour Rs: 14609.34

Total Rs: 181963.40Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 3177.54Add for insurance charges @ 1.00% Rs: 1819.63Add for designs and drawings @ 2.5% Rs: 4549.08Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 4549.08Add for power supply arrangements @ 2.5% Rs: 4549.08Add for enabling works @ 2% Rs: 3639.27

Total Rs: 204247.09Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x5.318 tonnes @ Rs: 81.30 / tonne Rs: 864.71Add for transportation upto work site @ 3% Rs: 6127.41 Total cost for 18.000 Rm Rs: 211239.21

Rate per Rm Rs: 11740.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 5

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sill beam, slide tracks, seal seats, guide rails, dogging sets for storage of stoplog elementsetc., with all accessories for spillway stop log gate elements including cost of all materials,machinery, labour, cutting, welding, aligning, anchoring, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete asper specifications and approved drawings with all leads and lifts.

DATA: Spillway stoplog gate embedded parts consist of sill beam, slide tracks / seal tracks and gate

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GATES AND HOISTS

guides and dogging sets for storage of elements with accessories such as first stage anchors.Consider embedded parts for stoplog gate for spillway opening of size 15 m x 9 m for analysis.Details of material / Gas cutting / Welding considered for rate analysis are based on embeddedparts drawings for spillway stop log gate of Kodasalli dam with sill level 0.4 m below crest.Weight of stoplog gate elements in tonne for 15 m x 9 m opening based on empirical formula : Length of gate in m : Clear opening + 0.65 m : 15.00 + 0.65 : 15.65 mHeight of gate ( total height of gate elements ) in m : FRL - Sill level + 0.2 : 9.60 mHead of water in m : FRL - Sill level : 9.40 m Weight of all gate elements in tonnes = 0.0553 x ( L^2 x H x h )^0.716Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.Weight of embedded parts with dogging sets will be about 4 to 5 percent of stop log gate weight.Weight of embedded parts for stoplog gate = 0.0025 x ( L^2 x H x h )^0.716 = 0.0025 x ( 15.65^2 x 9.6 x 9.4 )^0.716: 3.225The actual weight of embedded parts as per data sheet : 3.179 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 5 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel angles / beams / channels / bars with 2.5 % wastage : 432 kgStructural steel plates / flats with 2.5 % wastage : 2301 kg

b. Alloy steel conforming to IS : 1570 :Stainless steel plates / flats : 411.00 kg

c. Bolt / Nut / Washer conforming to IS : 1363 :MS bolts and nuts with 2.5 % wastage : 115 kg

d. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 166 NosWelding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 103 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 1499 NosWelding electrodes ( SS ) for run welding at 90 % of total with 2.5 % wastage : 927 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides as per data sheet : 163 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 17 RmTotal length of cutting : 180 RmFor 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 mLength of steel to be cut by gas using pug cutting machine : 120 mLength of steel to be cut by using shearing machine : 30 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 15 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 40 hoursTime for cutting by shearing machine at av. 10 m / hr progress : 3 hoursAcetelyne gas @ 0.6 cum / hour ( 55 x 0.60 ) : 33 cumOxygen gas @ 1.8 cum / hour ( 55 x 1.80 ) : 99 cumUse of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hoursUse of pug cutting machine with 50 min / hr working ( 40 x 60 / 50 ) : 48 hoursUse of shearing machine with 50 min / hr working ( 3 x60 / 50 ) : 4 hours

3. Welding :Length of welding as per data sheet : 303 mFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 166 + 103 ) x 8 / 15 / 2 : 72 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 1499 + 927 ) x 8 / 15 / 6 : 216 hoursTotal : 288 hours

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GATES AND HOISTS

Deploy welding transformer for 288 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 72 x 0.25 + 216 x 0.75 ) : 180 hours 4. Planing SS plates for slide block / 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 50.4 RmLength of planing at a time for 4 m stroke planing machine 3 RmTime for planing 3 m length section with 50 min / hour working 8 hoursTime for planing 50.4 m SS plates ( 50.4 x 8 / 3 ) 135 hours

5. Surface cleaning and painting :Painting area for embedded parts at 7 sqm / tonne : 22 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 22 sqm @ 9 sqm / ltr / coat : 2.5 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 22 sqm @ 6 sqm / ltr / coat : 15 ltrAs 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 at 8 sqm / ltr : 3 ltr

6. Requirement of other machinery :For drilling holes for anchor bolts and for grinding surface / edges of parts requiring finishing 16 hours use of drilling / grinding machine considered.For handling and erection mobile derric crane for 4 hours and stationery derric crane for 8 hrsconsidered.

7. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 70 hours 4 8 8 16Drilling holes for anchors / supports 1 2 --- 2Fabricating by stitch welding 72 hours 4 9 --- 18Run welding 216 hours 3 --- 27 27Erection of anchors / dogging set --- 12 --- 12Erection of Sill beam / Tracks / Guide 3 3 --- 6Finishing / cleaning / checking 1 1 --- 2 Total : 16 35 35 83

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 2 helper for 20 sqmFor painting 1 coat primer and 4 coats finishing paint at 15 sqm / day : 7 painter Cl-ll & 1 helper for 5 x 20 sqm

8. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

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GATES AND HOISTS

RATE ANALYSIS UNIT : 3.179 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Str steel angle / beam / channel / bars kg 432.00 20.00 8640.002 Structural steel plate / flats kg 2301.00 24.00 55224.003 Stainless steel plate / flats kg 411.00 90.00 36990.004 MS bolts and nuts kg 115.00 45.00 5175.005 Oxygen gas cum 99.00 40.00 3960.006 Acetyline gas cum 33.00 185.00 6105.007 Welding electrodes Nos 166.00 4.00 664.008 Welding electrodes ( LH ) Nos 1499.00 6.00 8994.009 Welding electrodes ( stainless steel ) Nos 1030.00 35.00 36050.00

10 Zinc rich epoxy primer ltr 2.50 525.00 1312.5011 Coal tar epoxy paint ltr 15.00 131.00 1965.0012 Rust cleaner / inhibitor ltr 3.00 175.00 525.0013 Use rate welding holder set Hour 288.00 3.38 972.0014 Use rate gas cutting torch set Hour 18.00 1.88 33.7515 Wire brush Nos 1.00 25.00 25.0016 Sundries LS 20.00 22.50 450.00

TOTAL Rs: 167085.25Add for small Tools and Plants @ 1% Rs: 1670.85Add for Contractor' Profit @ 10% Rs: 16708.53Add for Contrators' Overheads @ 5% Rs: 8354.26

Total cost of Materials Rs: 193818.89

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 288.00 9.00 2592.00

Fuel / Energy charges Hour 180.00 49.00 8820.002 Plate shearing machine Hour 4.00 47.00 188.00

Fuel / Energy charges Hour 4.00 82.00 328.003 Pug cutting machine Hour 48.00 13.00 624.00

Fuel / Energy charges Hour 48.00 2.00 96.004 Planing machine Hour 135.00 66.00 8910.00

Fuel / Energy charges Hour 135.00 61.00 8235.005 Mobile derric crane Hour 4.00 261.00 1044.00

Fuel / Energy charges Hour 4.00 117.00 468.006 Stationery derric crane Hour 8.00 50.00 400.00

Fuel / Energy charges Hour 8.00 5.00 40.007 Grinding machine Hour 16.00 15.00 240.00

Fuel / Energy charges Hour 16.00 20.00 320.008 Drilling machines Hour 16.00 15.00 240.00

Fuel / Energy charges Hour 16.00 20.00 320.009 Sundries LS 20.00 22.50 450.00

TOTAL Rs: 33315.00Add for small Tools and Plants @ 1% Rs: 333.15Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 1907.70Add for Contrators' Overheads @ 5% Rs: 1665.75 Total hire charges of Machinery Rs: 37221.60

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GATES AND HOISTS

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 4.00 32.90 131.602 Crew for Planing machine Hour 135.00 42.75 5771.253 Crew for Drilling machine Hour 16.00 35.00 560.004 Crew for Grinding machine Hour 16.00 35.00 560.005 Foreman Day 16.00 108.65 1738.406 Marker / Fabricator / Erector Day 35.00 93.70 3279.507 Gas cutter Day 8.00 93.70 749.608 Welder ( General ) Day 24.00 93.70 2248.809 Welder ( X - ray ) Day 3.00 103.07 309.21

10 Helper fabrication / erection Day 83.00 81.60 6772.8011 Helper for cleaning / painting Day 3.00 81.60 244.8012 Painter Cl - II Day 7.00 81.60 571.2013 Electrician Day 2.00 82.65 165.30

TOTAL Rs: 23102.46Add for small Tools and Plants @ 1% Rs: 231.02Add for Contractor' Profit @ 10% Rs: 2310.25Add for hidden cost on Labour @ 15% Rs: 3465.37Add for additional hidden cost on labour @ 15% Rs: 3465.37Add for Contrators' Overheads @ 5% Rs: 1155.12

Total cost of Labour Rs: 33729.59

ABSTRACT:A. Cost of Materials Rs: 193818.89B. Hire charges of Machinery Rs: 37221.60C. Cost of Labour Rs: 33729.59

Total Rs: 264770.08Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 9578.41Add for insurance charges @ 1.00% Rs: 2647.70Add for designs and drawings @ 2.5% Rs: 6619.25Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 6619.25Add for power supply arrangements @ 2.5% Rs: 6619.25Add for enabling works @ 2% Rs: 5295.40

Total Rs: 302149.35Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x3.179 tonnes @ Rs: 81.30 / tonne Rs: 516.91Add for transportation upto work site @ 3% Rs: 9064.48 Total cost for 3.179 tonne Rs: 311730.74

Rate per tonne Rs: 98060.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 6

ITEM: Design, fabrication, supply, erection, testing and commissioning of vertical lift sliding type all interchangeable ( except bottom element ) stoplog gate elements consisting of skin plate, horizontal and vertical girders, stiffeners, lifting pins, bronze padded slide blocks, guide shoes, rubber seals, clamps etc., with all accessories for spillway including cost of all materials,machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coat of zincrich 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 stoplog gate consists of number of vertical lift slide gate elements. Each gate element consists of skin plate, horizontal girders, vertical end girders, stiffeners, slide blocks, gate guide shoes, lifting pins and seals with all accessories.

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GATES AND HOISTS

Consider spillway stoplog elements for 15 m x 9 m spillway opening for analysis.Details of material / Gas cutting / Welding considered for rate analysis are based on spillwaystop log gate drawings for 15 m x 9 m spillway opening of Kodasalli dam with sill level 0.4 mbelow the spillway crest.Weight of stoplog gate elements in tonne for 15 m x 9 m opening based on empirical formula : Length of gate in m : Clear opening + 0.65 m : 15.00 + 0.65 : 15.65 mHeight of gate ( total height of gate elements ) in m : FRL - Sill level + 0.2 : 9.60 mHead of water in m : FRL - Sill level : 9.40 m Weight of all gate elements in tonnes = 0.0553 x ( L^2 x H x h )^0.716Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0553 x ( 15.65 x 15.65 x 9.6 x 9.4 ) ^ 0.716 : 71.340The actual weight of spillway stoplog elements as per data sheet : 71.157 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 6 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel angles / beams / channels / bars with 2.5 % wastage : 473 kgStructural steel plates / flats with 2.5 % wastage : 71963 kg

b. Alloy steel components conforming to IS : 1570 :Lifting pins : 104 kg

c. Alluminium / Bronze alloy components conforming to IS : 305 :Bronze pads for slide blocks : 48 kg

d. Bolts / Nuts / Washers conforming to IS : 1363 :GI bolts / nuts / washers with 2.5 % wastage : 295 kgMS bolts / nuts / washers with 2.5 % wastage : 49 kg

e. Rubber seal conforming to IS : 11855 :Bottom seal : 123 RmSide seals ( music note type uncladed ) : 20 Rm

f. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 2765 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 24885 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 980 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 98 Rm

Total : 1078 RmFor cutting structural steel sections to required sizes gas cutting is assumed since most of thesections are above 10 mm thick.Length of steel to be cut by using gas manually : 50 mLength of steel to be cut by gas using pug cutting machine : 1028 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 25 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 343 hoursAcetelyne gas @ 0.6 cum / hour ( 368 x 0.60 ) : 221 cumOxygen gas @ 1.8 cum / hour ( 368 x 1.80 ) : 663 cumUse of gas cutting torch with 50 min / hr working ( 25 x 60 / 50 ) : 30 hoursUse of pug cutting machine with 50 min / hr working ( 343 x 60 / 50 ) : 412 hours

3. Welding :Length of welding : 3228 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 2765 / 15 ) x 8 / 2 : 737 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 24885 / 15 ) x 8 / 6 : 2212 hoursTotal : 2949 hours

Deploy welding transformer for 2949 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 737 x 0.25 + 2212 x 0.75 ) : 1843 hours

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GATES AND HOISTS

4. Surface cleaning and painting :Painting area for stoplog gate elements at 18 sqm / tonne : 1280 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 1280 sqm @ 9 sqm / ltr / coat : 142 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 1280 sqm @ 6 sqm / ltr / coat : 640 ltrAs 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 at 8 sqm / ltr : 160 ltr

5. Requirement of other machinery :For handling during fabrication mobile derric crane for 50 hours and stationery derric crane for 100 hours considered.For drilling holes in skin plate and seal clamps for seal fixing 100 hours use of drilling machine considered. For grinding and finishing weld joints in skin plate and other locations 50 hours use of grinding machine considered.

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 442 hours 28 56 56 112Drilling holes for seal fixing 6 12 --- 12Fabricating by stitch welding 737 hours 46 92 --- 184Run welding 2212 hours 28 --- 277 277Seal fixing 8 elements @ 2 per day 4 4 --- 8Finishing / cleaning / guide shoe fixing 1 2 --- 4Trial operation and checking 2 2 --- 4 Total : 115 168 333 601

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 85 helpers for 1280 sqmFor painting 1 coat primer and 3 coats finishing paint at 15 sqm / day : 341 painter Cl-ll & 68 helpers for 4 x 1280 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 71.157 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / beams / channels / bars kg 473.00 20.00 9460.00Plates / flats kg 71963.00 24.00 1727112.00

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GATES AND HOISTS

2 Alloy steel componentsLifting pins kg 104.00 175.00 18200.00

3 Alluminium / Bronze alloy components Bronze pads kg 48.00 380.00 18240.00

4 Bolt / Nut / WasherGI bolts / nuts / washers kg 295.00 60.00 17700.00MS bolts / nuts / washers kg 49.00 45.00 2205.00

5 Rubber sealsBottom seal Rm 123.00 120.00 14760.00Side seals Rm 20.00 190.00 3800.00

6 Oxygen gas cum 663.00 40.00 26520.007 Acetyline gas cum 221.00 185.00 40885.008 Welding electrodes Nos 2765.00 4.00 11060.009 Welding electrodes ( LH ) Nos 24885.00 6.00 149310.00

10 Zinc rich epoxy primer ltr 142.00 525.00 74550.0011 Coal tar epoxy paint ltr 640.00 131.00 83840.0012 Rust cleaner / inhibitor ltr 160.00 175.00 28000.0013 Use rate welding holder set Hour 2949.00 3.38 9952.8814 Use rate gas cutting torch set Hour 30.00 1.88 56.2515 Wire brush Nos 13.00 25.00 325.0016 Sundries LS 200.00 22.50 4500.00

TOTAL Rs: 2240476.13Add for small Tools and Plants @ 1% Rs: 22404.76Add for Contractor' Profit @ 10% Rs: 224047.61Add for Contrators' Overheads @ 5% Rs: 112023.81

Total cost of Materials Rs: 2598952.31

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 2949.00 9.00 26541.00

Fuel / Energy charges Hour 1843.00 49.00 90307.002 Pug cutting machine Hour 412.00 13.00 5356.00

Fuel / Energy charges Hour 412.00 2.00 824.003 Mobile derric crane Hour 50.00 261.00 13050.00

Fuel / Energy charges Hour 50.00 117.00 5850.004 Stationery derric crane Hour 100.00 50.00 5000.00

Fuel / Energy charges Hour 100.00 5.00 500.005 Grinding machine Hour 50.00 15.00 750.00

Fuel / Energy charges Hour 50.00 20.00 1000.006 Drilling machines Hour 100.00 15.00 1500.00

Fuel / Energy charges Hour 100.00 20.00 2000.007 Sundries LS 100.00 22.50 2250.00

TOTAL Rs: 154928.00Add for small Tools and Plants @ 1% Rs: 1549.28Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 10273.10Add for Contrators' Overheads @ 5% Rs: 7746.40 Total hire charges of Machinery Rs: 174496.78

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 50.00 5541.15 277057.502 Crew for Drilling machine Hour 100.00 35.00 3500.003 Crew for Grinding machine Hour 50.00 35.00 1750.004 Foreman Day 115.00 108.65 12494.75

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GATES AND HOISTS

5 Marker / Fabricator / Erector Day 168.00 93.70 15741.606 Gas cutter Day 56.00 93.70 5247.207 Welder ( General ) Day 250.00 93.70 23425.008 Welder ( X - ray ) Day 27.00 103.07 2782.899 Khalasi Day 50.00 83.65 4182.50

10 Helper fabrication / erection Day 601.00 81.60 49041.6011 Helper cleaning / painting Day 153.00 81.60 12484.8012 Painter Cl - II Day 341.00 81.60 27825.6013 Electrician Day 5.00 82.65 413.25

TOTAL Rs: 435946.69Add for small Tools and Plants @ 1% Rs: 4359.47Add for Contractor' Profit @ 10% Rs: 43594.67Add for hidden cost on Labour @ 15% Rs: 65392.00Add for additional hidden cost on labour @ 15% Rs: 65392.00Add for Contrators' Overheads @ 5% Rs: 21797.33

Total cost of Labour Rs: 636482.17

ABSTRACT:A. Cost of Materials Rs: 2598952.31B. Hire charges of Machinery Rs: 174496.78C. Cost of Labour Rs: 636482.17

Total Rs: 3409931.25Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 109482.16Add for insurance charges @ 1.00% Rs: 34099.31Add for designs and drawings @ 2.5% Rs: 85248.28Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 85248.28Add for power supply arrangements @ 2.5% Rs: 85248.28Add for enabling works @ 2% Rs: 68198.63

Total Rs: 3877456.19Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x71.157 tonnes @ Rs: 81.30 / tonne Rs: 11570.13Add for transportation upto work site @ 3% Rs: 116323.69 Total cost for 71.157 tonne Rs: 4005350.01

Rate per tonne Rs: 56290.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 7

ITEM: Design, fabrication, supply, erection, testing and commissioning of automatic lifting beam with all accessories for handling, lowering and lifting of spillway stop log gate elementsincluding cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning,applying one coat of zinc rich epoxy primer and two coats of cold applied coal tar epoxy paint etc., complete as per specifications and drawings with all leads and lifts.

DATA: Automatic lifting beam for lifting spillway stop log elements consists of fabricated beam withlifting bracket and automatic engaging / dis-engaging type hooks for under water hooking / de-hooking of gate element. Lifting beam is an independent attachment to moving gantry crane.Consider spillway stoplog gate for spillway opening of size 15 m x 9 m for analysis.Details of material / Gas cutting / Welding considered for rate analysis are based on spillwaystop log gate lifting beam drawings for 15 m x 9 m spillway opening of Kodasalli dam.Generally the weight of lifting beam for spillway stoplog element will be about 40 percent of theweight of one stoplog element. Generally each stoplog element will be 1 to 1.2 m height.For 9.6 m height of stoplog gate the number of elements of 1.2 m each will be 8.

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GATES AND HOISTS

Weight of lifting beam in tonnes based on empirical formula : Weight of lifting beam in tonnes = 0.02212 x ( L^2 x H x h )^0.716 / nWhere ( L ) is length and ( H ) is total height and ( h ) is head of water in metres and ( n ) is the number of stoplog gate elements. = 0.02212 x ( 15.65 x 15.65 x 9.6 x 9.4 ) ^ 0.716 / 8 : 3.567The actual weight of stoplog element lifting beam as per data sheet : 3.528 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 7 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel angles / beams / channels / bars with 2.5 % wastage : 13 kgStructural steel plates / flats with 2.5 % wastage : 3389 kg

b. Alloy steel components conforming to IS : 1570 :Lifting pins : 101 kg

c. Alluminium / Bronze alloy components conforming to IS : 305 :Bronze Bush : 5 kg

d. Forged steel components conforming to IS : 2004 :Lifting hooks : 130 kg

e. Bolts / Nuts / Washers conforming to IS : 1363 :MS bolts / nuts / washers with 2.5 % wastage : 3 kgMS pipe 100 mm dia : 11 kg

f. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 175 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 1575 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 172 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 17 Rm

Total : 189 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 40 mLength of steel to be cut by gas using pug cutting machine : 149 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 20 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 50 hoursAcetelyne gas @ 0.6 cum / hour ( 70 x 0.60 ) : 42 cumOxygen gas @ 1.8 cum / hour ( 70 x 1.80 ) : 126 cumUse of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) : 24 hoursUse of pug cutting machine with 50 min / hr working ( 50 x 60 / 50 ) : 60 hours

3. Welding :Length of welding : 211 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 175 / 15 ) x 8 / 2 : 47 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 1575 / 15 ) x 8 / 6 : 140 hoursTotal : 187 hours

Deploy welding transformer for 187 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 47 x 0.25 + 140 x 0.75 ) : 117 hours

4. Surface cleaning and painting :Painting area for lifting beam at 12 sqm / tonne : 42 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 42 sqm @ 9 sqm / ltr / coat : 5 ltr2 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 42 sqm @ 6 sqm / ltr / coat : 14 ltrAs 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.

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GATES AND HOISTS

Quantity of rust cleaner / inhibitor at 8 sqm / ltr : 5 ltr 5. Requirement of other machinery :

For handling during fabrication mobile derric crane for 4 hours and stationery derric crane for 8 hours considered.For drilling holes for pins / guide shoes 2 hours use of drilling machine considered. For grinding and finishing weld joints 2 hours use of grinding machine considered.

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 84 hours 5 10 10 20Drilling holes for pins / bolts fixing 1 --- 1Fabricating by stitch welding 47 hours 3 6 --- 12Run welding 140 hours 2 --- 18 18Finishing / guide shoe fixing / checking 1 --- 1 Total : 10 18 28 52

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 3 helpers for 42 sqmFor painting 1 coats primer and 2 coats finishing paint at 15 sqm / day : 8 painter Cl-ll & 2 helpers for 3x42 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 3.528 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / beams / channels / bars kg 13.00 20.00 260.00Plates / flats kg 3389.00 24.00 81336.00

2 Alloy steel componentsLifting pins kg 101.00 175.00 17675.00

3 Bronze alloy components :Bronze bush kg 5.00 380.00 1900.00

4 Forged steel components :Lifting hooks kg 103.00 130.00 13390.00

5 MS pipe 100 mm dia kg 11.00 30.00 330.006 Bolt / Nut / Washer

MS bolts / nuts / washers kg 3.00 45.00 135.007 Oxygen gas cum 126.00 40.00 5040.008 Acetyline gas cum 42.00 185.00 7770.009 Welding electrodes Nos 175.00 4.00 700.00

10 Welding electrodes ( LH ) Nos 1575.00 6.00 9450.0011 Zinc rich epoxy primer ltr 5.00 525.00 2625.0012 Coal tar epoxy paint ltr 14.00 131.00 1834.00

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GATES AND HOISTS

13 Rust cleaner / inhibitor ltr 5.00 175.00 875.0014 Use rate welding holder set Hour 187.00 3.38 631.1315 Use rate gas cutting torch set Hour 24.00 1.88 45.0016 Wire brush Nos 1.00 25.00 25.0017 Sundries LS 25.00 22.50 562.50

TOTAL Rs: 144583.63Add for small Tools and Plants @ 1% Rs: 1445.84Add for Contractor' Profit @ 10% Rs: 14458.36Add for Contrators' Overheads @ 5% Rs: 7229.18

Total cost of Materials Rs: 167717.01

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 187.00 9.00 1683.00

Fuel / Energy charges Hour 117.00 49.00 5733.002 Pug cutting machine Hour 60.00 13.00 780.00

Fuel / Energy charges Hour 60.00 2.00 120.003 Mobile derric crane Hour 4.00 261.00 1044.00

Fuel / Energy charges Hour 4.00 117.00 468.004 Stationery derric crane Hour 8.00 50.00 400.00

Fuel / Energy charges Hour 8.00 5.00 40.005 Grinding machine Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.006 Drilling machines Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.007 Sundries LS 10.00 22.50 225.00

TOTAL Rs: 10633.00Add for small Tools and Plants @ 1% Rs: 106.33Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 666.60Add for Contrators' Overheads @ 5% Rs: 531.65 Total hire charges of Machinery Rs: 11937.58

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 4.00 32.90 131.602 Crew for Drilling machine Hour 2.00 35.00 70.003 Crew for Grinding machine Hour 2.00 35.00 70.004 Foreman Day 10.00 108.65 1086.505 Marker / Fabricator / Erector Day 18.00 93.70 1686.606 Gas cutter Day 10.00 93.70 937.007 Welder ( General ) Day 18.00 93.70 1686.608 Helper fabrication / erection Day 52.00 81.60 4243.209 Helper for cleaning / painting Day 5.00 81.60 408.00

10 Painter Cl - II Day 8.00 81.60 652.8011 Electrician Day 1.00 82.65 82.65

TOTAL Rs: 11054.95Add for small Tools and Plants @ 1% Rs: 110.55Add for Contractor' Profit @ 10% Rs: 1105.50Add for hidden cost on Labour @ 15% Rs: 1658.24Add for additional hidden cost on labour @ 15% Rs: 1658.24Add for Contrators' Overheads @ 5% Rs: 552.75

Total cost of Labour Rs: 16140.23

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GATES AND HOISTS

ABSTRACT:A. Cost of Materials Rs: 167717.01B. Hire charges of Machinery Rs: 11937.58C. Cost of Labour Rs: 16140.23

Total Rs: 195794.81Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 3790.50Add for insurance charges @ 1.00% Rs: 1957.95Add for designs and drawings @ 2.5% Rs: 4894.87Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 4894.87Add for power supply arrangements @ 2.5% Rs: 4894.87Add for enabling works @ 2% Rs: 3915.90

Total Rs: 220143.77Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x3.528 tonnes @ Rs: 81.30 / tonne Rs: 573.65Add for transportation upto work site @ 3% Rs: 6604.31 Total cost for 3.528 tonne Rs: 227321.74

Rate per tonne Rs: 64430.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 8

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, electro- magnetic brake system, cabin, control panel, wire rope, ladder, motorised cable reeling drumetc., 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 chromatered oxide primer and three coats of approved synthetic enamel paint etc., complete with allleads and lifts.

DATA: Moving gantry crane consists of rail mounted gantry frame with long travel arrangement, crosstravel trolley with track arrangement mounted on gantry frame top platform, rope drum hoistwith all accessories mounted on cross travel trolley for operating stoplog gate elements.Consider moving gantry crane for operating spillway stoplog gate element of 8.92 t weight.The same moving gantry crane can also be used for operating river sluice emergency gate.Therefore, the hoisting capacity of the gantry crane depends on the requirement of hoistingcapacity for spillway stoplog element or river sluice emergency gate whichever is higher.The capacity of moving gantry crane may be considered at 2.5 times wt of 1 stoplog element.Details of material / Gas cutting / Welding considered for rate analysis are based moving gantrycrane drawings for spillway of Alamatti dam.Total weight of stoplog elements as per item 6 : 71.34 tonnesNumber of elements : 8 NosCapacity 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 : 2.5 x ( 71.34 / 8 )( capacity to be rounded off to next 5 tonne ) : 24.97 tonnes

say : 25 tonneActual capacity of moving gantry crane as per data considered : 25 tonneWeight of moving gantry crane @ 1.25 t / tonne capacity ( 1.25 x 25 ) : 31.25 tThe actual weight of moving gantry crane as per data sheet : 30.856 tConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 8 of Annexer )a. Structural steel conforming to IS : 2062 :

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GATES AND HOISTS

Angles / Beams / Channels / Bars with 2.5 % wastage : 1743.00 kgPlates / Flats with 2.5 % wastage : 19700.00 kgChequered plate with 2.5 % wastage : 820 kg

b. Cast steel components conforming to IS : 1030 :Rope drums 2 Nos / Gears : 2336.00 kgPinions : 149.00 kgWheels and Pulleys : 2255.00 kgPlummer blocks / Couplings : 817.00 kg

c. Forged steel components conforming to IS : 2004 :Hook / Shackle : 127.00 kg

d. Alloy steel steel components conforming to IS: 1570 :Shafts : 556.00 kgPins 524.00 kg

e. Alluminium/ Bronze alloy components conforming to IS : 305 :Bearings / Bush : 181.00 kg

f. Bolt / Nut / Washers conforming to IS : 1363 :MS Bolts / Nuts / Washers with 2.5 % wastage : 63.00 kg

g. 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 : 4 NosElectric motor 17.5 hp : 1 No.Electric motor 5 hp : 2 NosElectric motor 3 hp : 1 No.Ele-magnetic / Thruster brakes : 4 No.MS pipe 32 mm dia : 50 RmElectric cable / switches / control panels etc : 3 sets

I. Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 1123 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 10110 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 761 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 76 Rm

Total : 837 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas cutting torch manually : 250 mLength of steel to be cut by gas using pug cutting machine : 587 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 125 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 196 hoursAcetelyne gas @ 0.6 cum / hour ( 321 x 0.60 ) : 193 cumOxygen gas @ 1.8 cum / hour ( 321 x 1.80 ) : 579 cumUse of gas cutting torch with 50 min / hr working ( 125 x 60 / 50 ) : 150 hoursUse of pug cutting machine with 50 min / hr working ( 196 x 60 / 50 ) : 235 hours

3. Welding :Length of welding : 1260 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 1123 / 15 ) x 8 / 2 : 300 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 10110 / 15 ) x 8 / 6 : 897 hoursTotal : 1197 hours

Deploy welding transformer for 1197 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 300 x 0.25 + 897 x 0.75 ) : 748 hours 4. Surface cleaning and painting :

Painting area for moving gantry crane at 25 sqm / t of str steel : 540 sqm2 coats of zinc chromate red oxide primer.

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GATES AND HOISTS

Quantity of primer paint for 540 sqm @ 12 sqm / ltr / coat : 90 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 540 sqm @ 12 sqm / ltr / coat : 135 ltrAs 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 at 8 sqm / ltr : 68 ltr

5. Requirement of other machinery :For lifting and placing in position hoist drums, worm reducers, gears, floating shafts etc deploy tower crane for 6 hours.For handling and erection of portals mobile derric crane for 100 hours 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.

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 385 hours 24 48 48 96Drilling holes for pins / bolts fixing 1 2 --- 2Fabricating by stitch welding 300 hours 19 38 --- 76Run welding 897 hours 11 --- 112 112Assembly/Erection of wheels/ base frame 2 4 --- 8Assembly/Erection of portals 2 4 --- 8Assembly/Erection of top frame 2 4 --- 8Assembly/Erection of CT trolley 2 4 --- 8Assembly/Erection of drums / drive units 2 4 --- 8Assembly/Erection of CT drive units 1 2 --- 4Assembly/Erection of LT drive units 1 2 --- 4Erection of cabin / railings etc 2 2 --- 4Erection of control panel / cabling 1 1 --- 2Checking and trial running without rope 2 4 --- 4Rope fixing and checking 1 2 --- 2Trial running by lifting / lowering gate 1 2 --- 2Finishing / cleaning --- 1 --- 2 Total : 74 124 160 350

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 36 helper for 540 sqmFor painting 2 coats primer and 3 coats finishing paint at 20 sqm / day : 135 painter Cl-ll & 27 helper for 5x540 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

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GATES AND HOISTS

RATE ANALYSIS UNIT : 30.856 tonneA. MATERIALS: 25 t capacity Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / beams / channels / bars kg 1743.00 20.00 34860.00Plates / flats kg 19700.00 24.00 472800.00Chequered plates kg 820.00 25.20 20664.00

2 Cast steel components :Rope drums 2 Nos kg 1320.00 95.00 125400.00Gears and pinions kg 1165.00 95.00 110675.00Wheels / Pulleys kg 2255.00 85.00 191675.00Plummer blocks / Couplings kg 817.00 85.00 69445.00

3 Forged steel componentsHook / Shackle kg 127.00 130.00 16510.00

4 Alloy steel componentsShafts kg 556.00 145.00 80620.00Pins kg 524.00 175.00 91700.00

5 Bronze alloy components :Bronze bearings / bush kg 181.00 380.00 68780.00

6 Wire rope 28 mm dia 6/37 construction kg 406.00 75.00 30450.007 MS Bolt / Nut / Washer kg 63.00 45.00 2835.008 MS pipe 32 mm dia for railing Rm 50.00 80.00 4000.009 Worm reducers Nos. 4.00 39375.00 157500.00

10 Electric motor 17.5 hp No. 1.00 28125.00 28125.00Electric motor 5 hp Nos. 2.00 11250.00 22500.00Electric motor 3 hp No. 1.00 6750.00 6750.00

11 Ele-magnetic / Thruster brakes Nos. 4.00 8437.50 33750.0012 Electric cable / switch / control panel etc LS 3.00 5625.00 16875.0013 Oxygen gas cum 579.00 40.00 23160.0014 Acetyline gas cum 193.00 185.00 35705.0015 Welding electrodes Nos 1123.00 4.00 4492.0016 Welding electrodes ( LH ) Nos 10110.00 6.00 60660.0017 Zinc chromate red oxide primer ltr 90.00 140.00 12600.0018 Synthetic enamel ( 1st quality ) paint ltr 135.00 140.00 18900.0019 Rust cleaner / inhibitor ltr 68.00 175.00 11900.0020 Grease kg 50.00 90.00 4500.0021 Use rate welding holder set Hour 1197.00 3.38 4039.8822 Use rate gas cutting torch set Hour 150.00 1.88 281.2523 Wire brush Nos 6.00 25.00 150.0024 Sundries LS 200.00 22.50 4500.00

TOTAL Rs: 1766802.13Add for small Tools and Plants @ 1% Rs: 17668.02Add for Contractor' Profit @ 10% Rs: 176680.21Add for Contrators' Overheads @ 5% Rs: 88340.11

Total cost of Materials Rs: 2049490.47

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 1197.00 9.00 10773.00

Fuel / Energy charges Hour 748.00 49.00 36652.002 Tower crane 5 t capacity Hour 6.00 763.00 4578.00

Fuel / Energy charges Hour 6.00 106.00 636.003 Pug cutting machine Hour 235.00 13.00 3055.00

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GATES AND HOISTS

Fuel / Energy charges Hour 235.00 2.00 470.004 Mobile derric crane Hour 100.00 261.00 26100.00

Fuel / Energy charges Hour 100.00 117.00 11700.005 Grinding machine Hour 32.00 15.00 480.00

Fuel / Energy charges Hour 32.00 20.00 640.006 Drilling machines Hour 16.00 15.00 240.00

Fuel / Energy charges Hour 16.00 20.00 320.007 Sundries LS 500.00 22.50 11250.00

TOTAL Rs: 106894.00Add for small Tools and Plants @ 1% Rs: 1068.94Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 6166.80Add for Contrators' Overheads @ 5% Rs: 5344.70 Total hire charges of Machinery Rs: 119474.44

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 100.00 32.90 3290.002 Crew for Tower crane Hour 6.00 36.05 216.303 Crew for Drilling machine Hour 16.00 35.00 560.004 Crew for Grinding machine Hour 32.00 35.00 1120.005 Foreman Day 74.00 108.65 8040.106 Marker / Fabricator / Erector Day 124.00 93.70 11618.807 Gas cutter Day 48.00 93.70 4497.608 Welder ( General ) Day 112.00 93.70 10494.409 Khalasi Day 20.00 83.65 1673.00

10 Helper fabrication / erection Day 350.00 81.60 28560.0011 Helper for cleaning / painting Day 63.00 81.60 5140.8012 Painter Cl - II Day 135.00 81.60 11016.0013 Electrician Day 10.00 82.65 826.50

TOTAL Rs: 87053.50Add for small Tools and Plants @ 1% Rs: 870.54Add for Contractor' Profit @ 10% Rs: 8705.35Add for hidden cost on Labour @ 15% Rs: 13058.03Add for additional hidden cost on labour @ 15% Rs: 13058.03Add for Contrators' Overheads @ 5% Rs: 4352.68

Total cost of Labour Rs: 127098.11

ABSTRACT:A. Cost of Materials Rs: 2049490.47B. Hire charges of Machinery Rs: 119474.44C. Cost of Labour Rs: 127098.11

Total Rs: 2296063.02Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 33287.29Add for insurance charges @ 1.00% Rs: 22960.63Add for designs and drawings @ 2.5% Rs: 57401.58Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 57401.58Add for power supply arrangements @ 2.5% Rs: 57401.58Add for enabling works @ 2% Rs: 45921.26

Total Rs: 2570436.93Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x30.856 tonnes @ Rs: 81.30 / tonne Rs: 5017.19

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GATES AND HOISTS

Add for transportation upto work site @ 3% Rs: 77113.11 Total cost for 30.856 tonne Rs: 2652567.22

25.000 t capacityRate per tonne Rs: 85970.00

Rate per tonne capacity Rs: 106100.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 9

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 spillwaystoplog gate elements / river sluice / canal sluice emergency gate including cost of all materials,machinery, labour, aligning, anchoring, welding, cleaning etc., complete as per specificationsand 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 therequirement of gantry long travel specifications.Consider track length of 200 m for rate analysis.Details of material / Gas cutting / Welding considered for rate analysis are based on 25 tonnecapacity moving gantry crane drawings for spillway of Alamatti dam.Weight of 45 kg / m rails ( 2 x 200 x 45 ) : 18000.00Add for anchors and fixtures @ 15 % including wastage : 2700.00

Total weight in tonnes : 20700.00Actual weight of materials as per data : 20.722 t

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 9 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel angles / beams / channels / bars with 2.5 % wastage : 1570 kgStructural steel plates / flats with 2.5 % wastage : 975 kg

b. Bolt / Nut / Washer conforming to IS : 1363 :MS bolts and nuts with 2.5 % wastage : 246 kg

c. Standard Rails 45 kg / m with 2.5 % wastage : 18450 kgd. Welding electrodes :

Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 180 NosWelding electrodes for run welding at 90 % of total with 2.5 % wastage : 1625 Nos

2. Cutting :Total length of cutting assuming cutting for 2 sides : 222 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas cutting torch manually : 222 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 111 hoursAcetelyne gas @ 0.6 cum / hour ( 111 x 0.60 ) : 67 cumOxygen gas @ 1.8 cum / hour ( 111 x 1.80 ) : 201 cumUse of gas cutting torch with 50 min / hr working ( 111 x 60 / 50 ) : 133 hours

3. Welding :Length of welding : 210 mFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 180 / 15 ) x 8 / 2 : 48 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 1625 / 15 ) x 8 / 6 : 145 hoursTotal : 193 hours

Deploy welding transformer for 193 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 48 x 0.25 + 145 x 0.75 ) : 121 hours 4. Surface cleaning and painting :

For painting buffers and supporting plates 0.5 ltr zinc rich epoxy primer and 1 ltr coal tar epoxypaint considered.

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GATES AND HOISTS

5. Requirement of other machinery :For drilling holes for anchor bolts 50 hours use of drilling machine considered.For grinding edges of parts requiring finishing 8 hours use of grinding machine considered.For handling and erection mobile derric crane for 4 hours considered.

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 133 hours --- 17 17 17Drilling holes for anchors / supports --- 6 --- 6Erection /stitch welding anchors 48 hours 3 6 --- 6Erection of rails & fixing clamps 2 2 --- 4Run welding 145 hours 2 --- 18 18Finishing / checking / cleaning 1 1 --- 1 Total : 8 32 35 52

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.1 Painter Cl- II for cleaning and painting.

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 200.000 RmA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Str steel angle / beam / channel / bars kg 1570.00 20.00 31400.002 Structural steel plate / flats kg 975.00 24.00 23400.003 Rails kg 18450.00 24.50 452025.004 MS bolts and nuts kg 246.00 45.00 11070.005 Oxygen gas cum 201.00 40.00 8040.006 Acetyline gas cum 67.00 185.00 12395.007 Welding electrodes Nos 1805.00 4.00 7220.008 Zinc rich epoxy primer ltr 0.50 525.00 262.509 Coal tar epoxy paint ltr 1.00 131.00 131.00

10 Use rate welding holder set Hour 193.00 3.38 651.3811 Use rate gas cutting torch set Hour 133.00 1.88 249.3812 Sundries LS 10.00 22.50 225.00

TOTAL Rs: 547069.25Add for small Tools and Plants @ 1% Rs: 5470.69Add for Contractor' Profit @ 10% Rs: 54706.93Add for Contrators' Overheads @ 5% Rs: 27353.46

Total cost of Materials Rs: 634600.33

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GATES AND HOISTS

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 193.00 9.00 1737.00

Fuel / Energy charges Hour 121.00 49.00 5929.002 Mobile derric crane Hour 4.00 261.00 1044.00

Fuel / Energy charges Hour 4.00 117.00 468.003 Grinding machine Hour 8.00 15.00 120.00

Fuel / Energy charges Hour 8.00 20.00 160.004 Drilling machines Hour 50.00 15.00 750.00

Fuel / Energy charges Hour 50.00 20.00 1000.005 Sundries LS 10.00 22.50 225.00

TOTAL Rs: 11433.00Add for small Tools and Plants @ 1% Rs: 114.33Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 778.20Add for Contrators' Overheads @ 5% Rs: 571.65 Total hire charges of Machinery Rs: 12897.18

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 4.00 32.90 131.602 Crew for Drilling machine Hour 50.00 35.00 1750.003 Crew for Grinding machine Hour 8.00 35.00 280.004 Foreman Day 8.00 108.65 869.205 Marker / Fabricator / Erector Day 32.00 93.70 2998.406 Gas cutter Day 17.00 93.70 1592.907 Welder ( General ) Day 18.00 93.70 1686.608 Helper fabrication / erection Day 52.00 81.60 4243.209 Painter Cl- II Day 1.00 81.60 81.60

10 Electrician Day 1.00 82.65 82.65TOTAL Rs: 13716.15

Add for small Tools and Plants @ 1% Rs: 137.16Add for Contractor' Profit @ 10% Rs: 1371.62Add for hidden cost on Labour @ 15% Rs: 2057.42Add for additional hidden cost on labour @ 10% Rs: 1371.62Add for Contrators' Overheads @ 5% Rs: 685.81

Total cost of Labour Rs: 19339.77

ABSTRACT:A. Cost of Materials Rs: 634600.33B. Hire charges of Machinery Rs: 12897.18C. Cost of Labour Rs: 19339.77

Total Rs: 666837.28Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 4351.99Add for insurance charges @ 1.00% Rs: 6668.37Add for designs and drawings @ 2.5% Rs: 16670.93Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 16670.93Add for power supply arrangements @ 2.5% Rs: 16670.93Add for enabling works @ 2% Rs: 13336.75

Total Rs: 741207.18Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x20.722 tonnes @ Rs: 81.30 / tonne Rs: 3369.40

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GATES AND HOISTS

Add for transportation upto work site @ 3% Rs: 22236.22 Total cost for 200.000 Rm Rs: 766812.80

Rate per Rm Rs: 3830.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 10

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( without grooveliner ) 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 sluiceservice 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 appliedcoal tar epoxy paint etc., complete as per specifications and approved drawings with all leadsand 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 / secondstage 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.Details of material / Gas cutting / Welding considered for rate analysis are based on embeddedparts drawings for river sluice service gate of Upper Tunga dam.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 mHead of water considered : 16 m Weight of embedded parts in tonnes = 0.0444 x ( L^2 x H x h )^0.659Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0444 x ( 2.2 x 2.2 x 3.3 x 16 ) ^ 0.659 : 1.714 tonnesWeight of breast wall lining about 7 sqm @ 250 kg / sqm 1.750 tonnes

Total : 3.464 tonnesThe actual weight of embedded parts as per data sheet 3.172 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 10 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel angles / beams / channels / bars with 2.5 % wastage 603 kgStructural steel plates / flats with 2.5 % wastage 2162 kg

b. Alloy steel components conforming to IS : 1570 :Stainless steel plates / flats 424.00 kg

c. Bolt / Nut / Washer conforming ti IS : 1363 :MS bolts and nuts with 2.5 % wastage 62.5 kg

d. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage 109 NosWelding electrodes ( SS ) for stitch welding at 10 % of total with 2.5 % wastage 39 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage 982 NosWelding electrodes ( SS ) for run welding at 90 % of total with 2.5 % wastage 348 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides as per data sheet : 152 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 15 RmTotal length of cutting : 167 RmFor 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.

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GATES AND HOISTS

Length of steel to be cut by using gas manually 30 mLength of steel to be cut by gas using pug cutting machine 107 mLength of steel to be cut by using shearing machine 30 mTime for gas cutting manually assuming average cutting progress of 2 m / hour 15 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour 36 hoursTime for cutting by shearing machine at av. 10 m / hr progress 3 hoursAcetelyne gas @ 0.6 cum / hour ( 51 x 0.60 ) 31 cumOxygen gas @ 1.8 cum / hour ( 51 x 1.80 ) 93 cumUse of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) 18 hoursUse of pug cutting machine with 50 min / hr working ( 36 x 60 / 50 ) 43 hoursUse of shearing machine with 50 min / hr working ( 3 x 60 / 50 ) 4 hours

3. Welding :Length of welding as per data sheet 191 mFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 109 + 39 ) x 8 / 15 / 2 40 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 982 + 348 ) x 8 / 15 / 6 118 hoursTotal : 158 hours

Deploy welding transformer for 158 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 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 30 RmLength of planing at a time for 4 m stroke planing machine 3 RmTime for planing 3 m length section with 50 min / hour working 8 hoursTime 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 32 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 32 sqm @ 9 sqm / ltr / coat 4 ltr4 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 ltrAs 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 at 8 sqm / ltr 4 ltr

6. Requirement of other machinery :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 parts during fabrication and erection use of mobile derric crane for 4 hours andstationery derric crane for 8 hours considered

7. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 65 hours 4 8 8 16Drilling holes for anchors / supports 1 1 2Fbricating by stitch welding 40 hours 2 5 10Run welding 118 hours 2 15 15Erection of first stage anchors 3 6 6Erection of Sill beam / Tracks / Guide 2 4 8

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GATES AND HOISTS

Erection of Breast wall 2 4 8Finishing / checking / cleaning 1 1 2 Total : 17 29 23 67

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 2 helper for 32 sqmFor painting 1 coat primer and 4 coats finishing paint at 15 sqm / day : 11 painter Cl-ll & 2 helper for 5 x 32 sqm

8. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 3.172 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Str steel angle / beam / channel / bars kg 603.00 20.00 12060.002 Structural steel plate / flats kg 2162.00 24.00 51888.003 Stainless steel plate / flats kg 424.00 90.00 38160.004 MS bolts and nuts kg 62.50 45.00 2812.505 Oxygen gas cum 93.00 40.00 3720.006 Acetyline gas cum 31.00 185.00 5735.007 Welding electrodes Nos 109.00 4.00 436.008 Welding electrodes ( LH ) Nos 982.00 6.00 5892.009 Welding electrodes ( stainless steel ) Nos 387.00 35.00 13545.00

10 Zinc rich epoxy primer ltr 4.00 525.00 2100.0011 Coal tar epoxy paint ltr 22.00 131.00 2882.0012 Rust cleaner / inhibitor ltr 4.00 175.00 700.0013 Use rate welding holder set Hour 158.00 3.38 533.2514 Use rate gas cutting torch set Hour 18.00 1.88 33.7515 Wire brush Nos 1.00 25.00 25.0016 Sundries LS 10.00 22.50 225.00

TOTAL Rs: 140747.50Add for small Tools and Plants @ 1% Rs: 1407.48Add for Contractor' Profit @ 10% Rs: 14074.75Add for Contrators' Overheads @ 5% Rs: 7037.38

Total cost of Materials Rs: 163267.10

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 158.00 9.00 1422.00

Fuel / Energy charges Hour 99.00 49.00 4851.002 Plate shearing machine Hour 4.00 47.00 188.00

Fuel / Energy charges Hour 4.00 82.00 328.00

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GATES AND HOISTS

3 Pug cutting machine Hour 43.00 13.00 559.00Fuel / Energy charges Hour 43.00 2.00 86.00

4 Planing machine Hour 80.00 66.00 5280.00Fuel / Energy charges Hour 80.00 61.00 4880.00

5 Mobile derric crane Hour 4.00 261.00 1044.00Fuel / Energy charges Hour 4.00 117.00 468.00

6 Stationery derric crane Hour 8.00 50.00 400.00Fuel / Energy charges Hour 8.00 5.00 40.00

7 Grinding machine Hour 8.00 15.00 120.00Fuel / Energy charges Hour 8.00 20.00 160.00

8 Drilling machines Hour 10.00 15.00 150.00Fuel / Energy charges Hour 10.00 20.00 200.00

9 Sundries LS 10.00 22.50 225.00TOTAL Rs: 20401.00

Add for small Tools and Plants @ 1% Rs: 204.01Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 1123.80Add for Contrators' Overheads @ 5% Rs: 1020.05 Total hire charges of Machinery Rs: 22748.86

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 4.00 32.90 131.602 Crew for Shearing machine Hour 4.00 26.70 106.803 Crew for Planing machine Hour 80.00 42.75 3420.004 Crew for Drilling machine Hour 10.00 35.00 350.005 Crew for Grinding machine Hour 8.00 35.00 280.006 Foreman Day 17.00 108.65 1847.057 Marker / Fabricator / Erector Day 29.00 93.70 2717.308 Gas cutter Day 8.00 93.70 749.609 Welder ( General ) Day 11.00 93.70 1030.70

10 Welder ( X - ray ) Day 4.00 103.07 412.2811 Helper fabrication / erection Day 67.00 81.60 5467.2012 Helper for cleaning / painting Day 4.00 81.60 326.4013 Painter Cl - II Day 11.00 81.60 897.6014 Electrician Day 2.00 82.65 165.30

TOTAL Rs: 17901.83Add for small Tools and Plants @ 1% Rs: 179.02Add for Contractor' Profit @ 10% Rs: 1790.18Add for hidden cost on Labour @ 15% Rs: 2685.27Add for additional hidden cost on labour @ 10% Rs: 1790.18Add for Contrators' Overheads @ 5% Rs: 895.09

Total cost of Labour Rs: 25241.58

ABSTRACT:A. Cost of Materials Rs: 163267.10B. Hire charges of Machinery Rs: 22748.86C. Cost of Labour Rs: 25241.58

Total Rs: 211257.54Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 6478.71Add for insurance charges @ 1.00% Rs: 2112.58Add for designs and drawings @ 2.5% Rs: 5281.44Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 5281.44

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GATES AND HOISTS

Add for power supply arrangements @ 2.5% Rs: 5281.44Add for enabling works @ 2% Rs: 4225.15

Total Rs: 239918.29Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x3.172 tonnes @ Rs: 81.30 / tonne Rs: 515.77Add for transportation upto work site @ 3% Rs: 7197.55 Total cost for 3.172 tonne Rs: 247631.61

Rate per tonne Rs: 78070.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 11

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( with grooveliner 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 accessoriesfor river / canal sluice service gate including cost of all materials, machinery, labour,aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primerand 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 service gate consist of sill beam, wheel / seal tracks, groovelining upto breast wall level, breast wall lining upto 1 vent plus 1 m above top of vent, gate guideetc., 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 about200 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. Details of material / Gas cutting / Welding considered for rate analysis are based on embeddedparts drawings including groove liner for river sluice service gate of Kodasalli dam.Weight of embedded parts in tonne for 2.5 m x 3 m opening based on empirical formula : Size of gate for 2.5 m x 3 m opening : Length : 3.2 m Height : 3.3 mHead of water considered : 34 m Weight of embedded parts in tonnes = 0.0444 x ( L^2 x H x h )^0.659Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0444 x ( 3.2 x 3.2 x 3.3 x 34 ) ^ 0.659 : 4.615 tonnesWeight of breast wall lining about 12 sqm @ 250 kg / sqm : 3.000 tonnesWeight of groove liner about 15 sqm @ 200 kg / sqm : 3.000 tonnes

: 10.615 tonnesThe actual weight of embedded parts as per data sheet : 10.657 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 11 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel angles / beams / channels / bars with 2.5 % wastage : 698 kgStructural steel plates / flats with 2.5 % wastage : 9195 kg

b. Alloy steel components conforming to IS : 1570 :Stainless steel plates / flats : 846 kg

c. Bolt / Nut / Washer conforming ti IS : 1363 :MS bolts and nuts with 2.5 % wastage : 185 kg

d. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 535 NosWelding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 64 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 4815 Nos

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GATES AND HOISTS

Welding electrodes ( SS ) for run welding at 90 % of total with 2.5 % wastage : 576 Nos 2. Cutting :

Length of cutting assuming cutting for 2 sides as per data sheet : 301 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 30 RmTotal length of cutting : 331 RmFor 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 mLength of steel to be cut by gas using pug cutting machine : 211 mLength of steel to be cut by using shearing machine : 60 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 30 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 70 hoursTime for cutting by shearing machine at av. 10 m / hr progress : 6 hoursAcetelyne gas @ 0.6 cum / hour ( 100 x 0.60 ) : 60 cumOxygen gas @ 1.8 cum / hour ( 100 x 1.80 ) : 180 cumUse of gas cutting torch with 50 min / hr working ( 30 x 60 / 50 ) 36 hoursUse of pug cutting machine with 50 min / hr working ( 70 x 60 / 50 ) 84 hoursUse of shearing machine with 50 min / hr working ( 6 x 60 / 50 ) 7 hours

3. Welding :Length of welding as per data sheet : 552 mFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 535 + 64 ) x 8 / 15 / 2 : 160 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 4815 + 576 ) x 8 / 15 / 6 : 479 hours

Total : 639 hoursDeploy welding transformer for 639 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 160 x 0.25 + 479 x 0.75 ) : 400 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 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime 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 : 107 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 107 sqm @ 9 sqm / ltr / coat : 12 ltr4 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 ltrAs 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 at 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 mobile derric crane for 20 hours and stationery derric crane for 40 hours considered.

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GATES AND HOISTS

7. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 127 hours 8 16 16 32Drilling holes for anchors / supports 3 6 --- 6Fbricating by stitch welding 160 hours 10 20 --- 40Run welding 479 hours 6 --- 60 60Erection of first stage anchors 5 10 --- 10Erection of Sill beam / Tracks / Guide 2 4 --- 8Erection of Breast wall liner 2 4 --- 8Erection of groove liners 3 6 --- 12Finishing / cleaning 1 2 --- 4 Total : 40 68 76 180

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 7 helper for 107 sqmFor painting 1 coat primer and 4 coats finishing paint at 15 sqm / day : 36 painter Cl-ll & 6 helper for 5 x 107 sqm

8. Excise duty on supply : Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 10.657 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Str steel angle / beam / channel / bars kg 698.00 20.00 13960.002 Structural steel plate / flats kg 9195.00 24.00 220680.003 Stainless steel plate / flats kg 846.00 90.00 76140.004 MS bolts and nuts kg 185.00 45.00 8325.005 Oxygen gas cum 180.00 40.00 7200.006 Acetyline gas cum 60.00 185.00 11100.007 Welding electrodes Nos 535.00 4.00 2140.008 Welding electrodes ( LH ) Nos 4815.00 6.00 28890.009 Welding electrodes ( stainless steel ) Nos 640.00 35.00 22400.00

10 Zinc rich epoxy primer ltr 12.00 525.00 6300.0011 Coal tar epoxy paint ltr 72.00 131.00 9432.0012 Rust cleaner / inhibitor ltr 14.00 175.00 2450.0013 Use rate welding holder set Hour 639.00 3.38 2156.6314 Use rate gas cutting torch set Hour 36.00 1.88 67.5015 Wire brush Nos 2.00 25.00 50.0016 Sundries LS 50.00 22.50 1125.00

TOTAL Rs: 412416.13Add for small Tools and Plants @ 1% Rs: 4124.16

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GATES AND HOISTS

Add for Contractor' Profit @ 10% Rs: 41241.61Add for Contrators' Overheads @ 5% Rs: 20620.81

Total cost of Materials Rs: 478402.71

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 639.00 9.00 5751.00

Fuel / Energy charges Hour 400.00 49.00 19600.002 Plate shearing machine Hour 7.00 47.00 329.00

Fuel / Energy charges Hour 7.00 82.00 574.003 Pug cutting machine Hour 84.00 13.00 1092.00

Fuel / Energy charges Hour 84.00 2.00 168.004 Planing machine Hour 80.00 66.00 5280.00

Fuel / Energy charges Hour 80.00 61.00 4880.005 Mobile derric crane Hour 20.00 261.00 5220.00

Fuel / Energy charges Hour 20.00 117.00 2340.006 Stationery derric crane Hour 40.00 50.00 2000.00

Fuel / Energy charges Hour 40.00 5.00 200.007 Grinding machine Hour 25.00 15.00 375.00

Fuel / Energy charges Hour 25.00 20.00 500.008 Drilling machines Hour 50.00 15.00 750.00

Fuel / Energy charges Hour 50.00 20.00 1000.009 Sundries LS 20.00 22.50 450.00

TOTAL Rs: 50509.00Add for small Tools and Plants @ 1% Rs: 505.09Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 2971.20Add for Contrators' Overheads @ 5% Rs: 2525.45 Total hire charges of Machinery Rs: 56510.74

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 20.00 32.90 658.002 Crew for Shearing machine Hour 7.00 26.70 186.903 Crew for Planing machine Hour 80.00 42.75 3420.004 Crew for Drilling machine Hour 50.00 35.00 1750.005 Crew for Grinding machine Hour 25.00 35.00 875.006 Foreman Day 40.00 108.65 4346.007 Marker / Fabricator / Erector Day 68.00 93.70 6371.608 Gas cutter Day 16.00 93.70 1499.209 Welder ( General ) Day 55.00 93.70 5153.50

10 Welder ( X - ray ) Day 5.00 103.07 515.3511 Helper fabrication / erection Day 180.00 81.60 14688.0012 Helper for cleaning / painting Day 13.00 81.60 1060.8013 Painter Cl - II Day 36.00 81.60 2937.6014 Electrician Day 5.00 82.65 413.25

TOTAL Rs: 43875.20Add for small Tools and Plants @ 1% Rs: 438.75Add for Contractor' Profit @ 10% Rs: 4387.52Add for hidden cost on Labour @ 15% Rs: 6581.28Add for additional hidden cost on labour @ 10% Rs: 4387.52Add for Contrators' Overheads @ 5% Rs: 2193.76

Total cost of Labour Rs: 61864.03

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GATES AND HOISTS

ABSTRACT:A. Cost of Materials Rs: 478402.71B. Hire charges of Machinery Rs: 56510.74C. Cost of Labour Rs: 61864.03

Total Rs: 596777.48Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 15980.59Add for insurance charges @ 1.00% Rs: 5967.77Add for designs and drawings @ 2.5% Rs: 14919.44Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 14919.44Add for power supply arrangements @ 2.5% Rs: 14919.44Add for enabling works @ 2% Rs: 11935.55

Total Rs: 675419.71Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x10.657 tonnes @ Rs: 81.30 / tonne Rs: 1732.83Add for transportation upto work site @ 3% Rs: 20262.59 Total cost for 10.657 tonne Rs: 697415.13

Rate per tonne Rs: 65440.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 12

ITEM: Design, fabrication, supply, erection and commissioning of vent liner using 20 mm thick plateswith stiffeners and anchors for river sluice / canal sluice vents including cost of all materials,machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat ofzinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete withall 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 anchorsare 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.Details of material / Gas cutting / Welding considered for rate analysis are based on vent liner drawings for river sluice vent of Kodasalli dam.Finished area of lining : ( 2 x 3 x 3.4 + 2 x 2.5 x 3.4 ) : 37.40 sqmWeight of 20 mm thick plate per sqm : 157.00 kgAdd 25 % for stiffeners / anchors / projections etc : 39.25 kgTotal requirement of steel for vent lining of sluice per sqm area : 196.25 kg

say : 200 kgQuantity of steel required for 37.40 sqm : 7.480 tonnesThe actual weight of liner for 37.4 sqm as per data sheet : 7.281 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 12 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel plates / flats with 2.5 % wastage : 7463 kgb. Welding electrodes :

Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 344 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 3100 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 203 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 20 Rm

Total : 223 RmFor cutting structural steel sections to required sizes gas cutting is assumed since most of thesections are above 10 mm thick.Length of steel to be cut by using gas manually : 30 m

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GATES AND HOISTS

Length of steel to be cut by gas using pug cutting machine : 193 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 15 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 64 hoursAcetelyne gas @ 0.6 cum / hour ( 79 x 0.60 ) : 48 cumOxygen gas @ 1.8 cum / hour ( 79 x 1.80 ) : 144 cumUse of gas cutting torch with 50 min / hr working : ( 15 x 60 / 50 ) : 18 hoursUse of pug cutting machine with 50 min / hr working :( 64 x 60 / 50 ) : 77 hours

3. Welding :Length of welding : 420 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 344 / 15 ) x 8 / 2 : 92 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 3100 / 15 ) x 8 / 6 : 275 hoursTotal : 367 hours

Deploy welding transformer for 367 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 92 x 0.25 + 275 x 0.75 ) : 229 hours 4. Surface cleaning and painting :

Painting area for liner : 37.4 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 37.4 sqm @ 9 sqm / ltr / coat : 4 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 37.4 sqm @ 6 sqm / ltr / coat : 25 ltrAs 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 at 8 sqm / ltr : 5 ltr

5. Requirement of other machinery :For handling during fabrication and erection mobile derric crane for 8 hours and stationery derric crane for 16 hours considered.For grinding and finishing weld joints in liner plates 8 hours use of grinding machine considered.

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 95 hours 6 12 12 24Fabricating by stitch welding 92 hours 6 12 --- 24Run welding 275 hours 3 --- 34 34Finishing / Cleaning 1 1 --- 1 Total : 16 25 46 83

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 2 helper for 37.4 sqmFor painting 1 coat primer and 4 coats finishing paint at 15 sqm / day : 12 painter Cl-ll & 2 helper for 5 x 37.4 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125

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GATES AND HOISTS

Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 37.400 sqmA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel plates / flats kg 7463.00 24.00 179112.002 Oxygen gas cum 144.00 40.00 5760.003 Acetyline gas cum 48.00 185.00 8880.004 Welding electrodes Nos 344.00 4.00 1376.005 Welding electrodes ( LH ) Nos 3100.00 6.00 18600.006 Zinc rich epoxy primer ltr 4.00 525.00 2100.007 Coal tar epoxy paint ltr 25.00 131.00 3275.008 Rust cleaner / inhibitor ltr 5.00 175.00 875.009 Use rate welding holder set Hour 367.00 3.38 1238.63

10 Use rate gas cutting torch set Hour 18.00 1.88 33.7511 Wire brush Nos 1.00 25.00 25.0012 Sundries LS 20.00 22.50 450.00

TOTAL Rs: 221725.38Add for small Tools and Plants @ 1% Rs: 2217.25Add for Contractor' Profit @ 10% Rs: 22172.54Add for Contrators' Overheads @ 5% Rs: 11086.27

Total cost of Materials Rs: 257201.44

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 367.00 9.00 3303.00

Fuel / Energy charges Hour 229.00 49.00 11221.002 Pug cutting machine Hour 77.00 13.00 1001.00

Fuel / Energy charges Hour 77.00 2.00 154.003 Mobile derric crane Hour 8.00 261.00 2088.00

Fuel / Energy charges Hour 8.00 117.00 936.004 Stationery derric crane Hour 16.00 50.00 800.00

Fuel / Energy charges Hour 16.00 5.00 80.005 Grinding machine Hour 8.00 15.00 120.00

Fuel / Energy charges Hour 8.00 20.00 160.006 Sundries LS 10.00 22.50 225.00

TOTAL Rs: 20088.00Add for small Tools and Plants @ 1% Rs: 200.88Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 1277.60Add for Contrators' Overheads @ 5% Rs: 1004.40 Total hire charges of Machinery Rs: 22570.88

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 8.00 32.90 263.202 Crew for Grinding machine Hour 16.00 35.00 560.003 Foreman Day 16.00 108.65 1738.404 Marker / Fabricator / Erector Day 25.00 93.70 2342.505 Gas cutter Day 12.00 93.70 1124.406 Welder ( General ) Day 34.00 93.70 3185.807 Helper fabrication / erection Day 83.00 81.60 6772.80

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GATES AND HOISTS

8 Helper for cleaning / painting Day 4.00 81.60 326.409 Painter Cl - II Day 12.00 81.60 979.20

10 Electrician Day 1.00 82.65 82.65TOTAL Rs: 17375.35

Add for small Tools and Plants @ 1% Rs: 173.75Add for Contractor' Profit @ 10% Rs: 1737.54Add for hidden cost on Labour @ 15% Rs: 2606.30Add for additional hidden cost on labour @ 10% Rs: 1737.54Add for Contrators' Overheads @ 5% Rs: 868.77

Total cost of Labour Rs: 24499.24

ABSTRACT:A. Cost of Materials Rs: 257201.44B. Hire charges of Machinery Rs: 22570.88C. Cost of Labour Rs: 24499.24

Total Rs: 304271.56Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 6354.47Add for insurance charges @ 1.00% Rs: 3042.72Add for designs and drawings @ 2.5% Rs: 7606.79Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 7606.79Add for power supply arrangements @ 2.5% Rs: 7606.79Add for enabling works @ 2% Rs: 6085.43

Total Rs: 342574.54Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x7.281 tonnes @ Rs: 81.30 / tonne Rs: 1183.89Add for transportation upto work site @ 3% Rs: 10277.24 Total cost for 37.400 sqm Rs: 354035.67

Rate per sqm Rs: 9470.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 13

ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type verticallift service gate consisting of skin plate, vertical and horizontal girders, wheels, stiffeners, liftingbrackets, guide rollers, ballast blocks, teflon claded rubber seals etc., with all accessories for river sluice / canal sluice vent including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and threecoats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with all leads and lifts.

DATA: Consider upstream seal vertical lift roller gate. The gate leaf consists of skin plate, horizontalgirders, vertical end girders, stiffeners, wheels, gate guide rollers, brackets for pulleys, seals etc., with all accessories.Consider river / canal sluice service gate for 2.5 m x 3 m sluice opening for analysis.Details of material / Gas cutting / Welding considered for rate analysis are based on river sluicegate drawings for 2.5 m x 3 m river sluice of Kodasalli dam.Weight of gate leaf in tonne for vertical lift gate based on empirical formula : Weight in tonnes = 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.For vent opening of 2.5 x 3.0 m the approximate size of gate leaf will be 3.2 x 3.3 m.Head of water above sill of gate : 34 m Weight in tonnes = 0.0888 ( 3.2 x 3.2 x 3.3 x 34 ) ^ 0.659 : 9.229The actual weight of river sluice service gate as per data sheet : 9.202 tonnesConsider actual weight for data rate analysis.

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GATES AND HOISTS

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 13 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel plates / flats with 2.5 % wastage : 4479 kgb. Cast iron components conforming to IS : 210 :

Cast iron blocks for counter weight : 4100 kgc. Alloy steel components conforming to IS : 1570 :

Wheel axles / Pins : 132 kgd. Cast steel components conforming to IS : 1030 :

Wheels / guide rollers : 492 kge. Alluminium / Bronze alloy components conforming to IS : 305 :

Bearings / Bushes : 76 kgf. Bolts / Nuts / Washers conforming to IS : 1363 :

SS bolts / nuts / washers with 2.5 % wastage : 55 kgGI bolts / nuts / washers with 2.5 % wastage : 76 kgMS bolts / nuts / washers with 2.5 % wastage : 4 kg

g. Rubber seal conforming to IS : 11855 :Bottom seal ( flat type ) : 2.8 RmSide seals ( music note type teflon claded ) : 5.85 RmTop seal ( music note type teflon claded ) : 2.25 RmCorner seal ( teflon claded ) : 2 Nos

h. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 282 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 2532 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 137 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 14 Rm

Total : 151 RmFor cutting structural steel sections to required sizes gas cutting is assumed since most of thesections are above 10 mm thick.Length of steel to be cut by using gas manually : 30 mLength of steel to be cut by gas using pug cutting machine : 121 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 15 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 40 hoursAcetelyne gas @ 0.6 cum / hour ( 55 x 0.60 ) : 33 cumOxygen gas @ 1.8 cum / hour ( 55 x 1.80 ) : 99 cumUse of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hoursUse of pug cutting machine with 50 min / hr working ( 40 x 60 / 50 ) : 48 hours

3. Welding :Length of welding : 281 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 282 / 15 ) x 8 / 2 : 75 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 2532 / 15 ) x 8 / 6 : 225 hoursTotal : 300 hours

Deploy welding transformer for 300 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 75 x 0.25 + 225 x 0.75 ) : 188 hours

4. Surface cleaning and painting :Painting area for river sluice gate at 10 sqm / tonne : 92 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 92 sqm @ 9 sqm / ltr / coat : 10 ltr3 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 ltrAs 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

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GATES AND HOISTS

before applying primer painting.Quantity of rust cleaner / inhibitor at 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 mobile derric crane for 10 hours and stationery derric crane for 20 hrsconsidered.For drilling holes in skin plate, counter weight blocks, horizontal girders and seal clamps use of drilling machine for 16 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 Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 66 hours 4 8 8 16Drilling holes for seal fixing 1 2 --- 2Fabricating by stitch welding 75 hours 5 10 --- 20Run welding 225 hours 3 --- 28 28Fixing counter weight blocks 1 2 --- 4Seal fixing 1 1 --- 2Guide roller fixing / Cleaning / Lowering 1 2 --- 2 Total : 16 25 36 74

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 6 helper for 92 sqmFor painting 1 coat primer and 3 coats finishing paint at 15 sqm / day : 25 painter Cl-ll & 5 helper for 4 x 92 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 9.202 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Plates / flats kg 4479.00 24.00 107496.002 Cast iron components

CI blocks for counter wt kg 4100.00 18.00 73800.003 Alloy steel components

Wheel axles / Pins kg 132.00 175.00 23100.004 Cast steel components

Wheels / Guide rollers kg 492.00 85.00 41820.005 Alluminium / Bronze alloy components

Bearings / Bushes kg 76.00 380.00 28880.00

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GATES AND HOISTS

6 Bolt / Nut / WasherSS bolts / nuts / washers kg 55.00 100.00 5500.00GI bolts / nuts / washers kg 76.00 60.00 4560.00MS bolts / nuts / washers kg 4.00 45.00 180.00

7 Rubber sealsBottom seal ( flat uncladed ) Rm 2.80 120.00 336.00Side seals ( bulb teflon claded ) Rm 5.85 550.00 3217.50Top seal ( bulb teflon claded ) Rm 2.25 550.00 1237.50Corner seals ( bulb teflon claded ) Nos 2.00 600.00 1200.00

8 Oxygen gas cum 99.00 40.00 3960.009 Acetyline gas cum 33.00 185.00 6105.00

10 Welding electrodes Nos 282.00 4.00 1128.0011 Welding electrodes ( LH ) Nos 2532.00 6.00 15192.0012 Zinc rich epoxy primer ltr 10.00 525.00 5250.0013 Coal tar epoxy paint ltr 46.00 131.00 6026.0014 Rust cleaner / inhibitor ltr 12.00 175.00 2100.0015 Use rate welding holder set Hour 300.00 3.38 1012.5016 Use rate gas cutting torch set Hour 18.00 1.88 33.7517 Wire brush Nos 1.00 25.00 25.0018 Sundries LS 50.00 22.50 1125.00

TOTAL Rs: 333284.25Add for small Tools and Plants @ 1% Rs: 3332.84Add for Contractor' Profit @ 10% Rs: 33328.43Add for Contrators' Overheads @ 5% Rs: 16664.21

Total cost of Materials Rs: 386609.73

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 300.00 9.00 2700.00

Fuel / Energy charges Hour 188.00 49.00 9212.002 Pug cutting machine Hour 48.00 13.00 624.00

Fuel / Energy charges Hour 48.00 2.00 96.003 Tower crane Hour 1.00 763.00 763.00

Fuel / Energy charges Hour 1.00 106.00 106.004 Mobile derric crane Hour 10.00 261.00 2610.00

Fuel / Energy charges Hour 10.00 117.00 1170.005 Stationery derric crane Hour 20.00 50.00 1000.00

Fuel / Energy charges Hour 20.00 5.00 100.006 Grinding machine Hour 8.00 15.00 120.00

Fuel / Energy charges Hour 8.00 20.00 160.007 Drilling machines Hour 16.00 15.00 240.00

Fuel / Energy charges Hour 16.00 20.00 320.008 Sundries LS 25.00 22.50 562.50

TOTAL Rs: 19783.50Add for small Tools and Plants @ 1% Rs: 197.84Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 1172.65Add for Contrators' Overheads @ 5% Rs: 989.18 Total hire charges of Machinery Rs: 22143.16

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 10.00 32.90 329.002 Crew for Tower crane Hour 1.00 36.05 36.05

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GATES AND HOISTS

3 Crew for Drilling machine Hour 16.00 35.00 560.004 Crew for Grinding machine Hour 8.00 35.00 280.005 Foreman Day 16.00 108.65 1738.406 Marker / Fabricator / Erector Day 25.00 93.70 2342.507 Gas cutter Day 8.00 93.70 749.608 Welder ( General ) Day 25.00 93.70 2342.509 Welder ( X - ray grade ) Day 3.00 103.07 309.21

10 Khalasi Day 10.00 83.65 836.5011 Helper fabrication / erection Day 74.00 81.60 6038.4012 Helper for cleaning / painting Day 11.00 81.60 897.6013 Painter Cl - II Day 25.00 81.60 2040.0014 Electrician Day 2.00 82.65 165.30

TOTAL Rs: 18665.06Add for small Tools and Plants @ 1% Rs: 186.65Add for Contractor' Profit @ 10% Rs: 1866.51Add for hidden cost on Labour @ 15% Rs: 2799.76Add for additional hidden cost on labour @ 10% Rs: 1866.51Add for Contrators' Overheads @ 5% Rs: 933.25

Total cost of Labour Rs: 26317.73

ABSTRACT:A. Cost of Materials Rs: 386609.73B. Hire charges of Machinery Rs: 22143.16C. Cost of Labour Rs: 26317.73

Total Rs: 435070.62Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 6542.22Add for insurance charges @ 1.00% Rs: 4350.71Add for designs and drawings @ 2.5% Rs: 10876.77Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 10876.77Add for power supply arrangements @ 2.5% Rs: 10876.77Add for enabling works @ 2% Rs: 8701.41

Total Rs: 487295.26Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x9.202 tonnes @ Rs: 81.30 / tonne Rs: 1496.25Add for transportation upto work site @ 3% Rs: 14618.86 Total cost for 9.202 tonne Rs: 503410.36

Rate per tonne Rs: 54710.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 14

ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity ropedrum 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 approvedsynthetic 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.Consider rope drum hoist for river / canal sluice service gate for vent of size 2.5 m x 3 m.Details of material / Gas cutting / Welding considered for rate analysis are based on river sluice

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GATES AND HOISTS

gate rope drum hoist drawings for 2.5 m x 3 m river sluice of Kodasalli dam.Capacity of hoist in tonnes :Weight of gate leaf in tonne for 2.5 m x 3 m sluice opening based on empirical formula : Size of gate for 2.5 x 3 m opening : 3.2 m x 3.3 mHead of water above sill level considered : 34 mGenerally the hoist capacity will be 2.5 times the weight of gate including weight of ballast.Weight of gate in tonnes ( including weight of ballast ) = 0.0888 x ( L^2 x H x h )^0.659Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0888 x ( 3.2^2 x 3.3 x 34 )^0.659 : 9.229Capacity of hoist in tonnes with 25% reserve capacity : 2.5 x wt of gate with ballast( Capacity of hoist to be rounded off to next 5 tonne ) : 2.50 x 9.229

: 23.073 tonnes say : 25.00 tonnes

Weight of hoist with all accessories is assumed at 0.25 tonne per tonne capacity of hoist.Weight of hoist with all accessories ( 0.25 x 25 ) : 6.25 tonnesThe actual weight of river sluice service gate rope drum hoist as per data sheet : 6.243 tConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 14 of Annexer )a. Structural steel conforming to IS : 2062 :

Angles / Beams / Channels / Bars with 2.5 % wastage : 1487.00 kgPlates / Flats with 2.5 % wastage : 402.00 kgChequered plates with 2.5 % wastage : 290.00 kg

b. Cast steel components conforming to IS : 1030 :Rope drums 2 Nos / Gears : 1926.00 kgPinions : 79.00 kgPulleys 3 Nos / Couplings 2 Nos : 306.00 kgPlummer blocks / Hubs : 72.00 kg

c. Alloy steel steel components conforming to IS : 1570 :Shafts : 346.00 kgPins 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 : 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 NoElectric 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 :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 80 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 720 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 57 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 6 Rm

Total : 63 RmFor 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 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 13 hours

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GATES AND HOISTS

Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 12 hoursAcetelyne gas @ 0.6 cum / hour ( 25 x 0.60 ) : 15 cumOxygen gas @ 1.8 cum / hour ( 25 x 1.80 ) : 45 cumUse of gas cutting torch with 50 min / hr working ( 13 x 60 / 50 ) : 16 hoursUse of pug cutting machine with 50 min / hr working ( 12 x 60 / 50 ) : 15 hours

3. Welding :Length of welding : 97 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 80 / 15 ) x 8 / 2 : 21 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 720 / 15 ) x 8 / 6 : 64 hoursTotal : 85 hours

Deploy welding transformer for 85 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 21 x 0.25 + 64 x 0.75 ) : 53 hours 4. Surface cleaning and painting :

Painting area for rope drum hoist at 20 sqm / tonne of str steel : 43 sqm2 coats of zinc chromate red oxide primer.Quantity of primer paint for 43 sqm @ 12 sqm / ltr / coat : 7 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 43 sqm @ 12 sqm / ltr /coat : 11 ltrAs 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 at 8 sqm / ltr : 5 ltr

5. Requirement of other machinery :For lifting and placing in position hoist drums, worm reducers, gears, floating shafts etc deploy tower crane for 2 hours.For handling during fabrication and erection mobile derric crane for 10 hours considered.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.

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections/ drilling holes 31 hours 2 4 4 8Fabricating by stitch welding 21 hours 1 3 --- 6Run welding 64 hours 1 --- 8 8Erection of anchors 1 1 --- 2Erection of hoist frame 1 1 --- 2Erection of drums / gears / shafts 1 2 --- 4Erection of pulleys / plummer blocks 1 1 --- 2Erection of worm reducers / brake / motor 1 1 --- 2Erection of other accessories 1 1 --- 2Erection of control panel / cabling 1 1 --- 1Checking and running without rope 1 1 --- 2Rope fixing and checking 1 1 --- 2Trial running by lowering / lifting gate 1 1 --- 2Final checking / Finishing / cleaning 1 1 --- 1 Total : 15 19 12 44

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 3 helpers for 43 sqmFor painting 2 coats primer and 3 coats

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GATES AND HOISTS

finishing paint at 20 sqm / day : 11 painter Cl-ll & 2 helpers for 5 x 43 sqm 7. Excise duty on supply :

Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 6.243 tonne wtA. MATERIALS: 25 t capacity Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / beams / channels / bars kg 1487.00 20.00 29740.00Plates / flats kg 402.00 24.00 9648.00Chequered plate kg 290.00 25.20 7308.00

2 Cast steel components :Rope drums 2 Nos / Gears kg 1926.00 95.00 182970.00Pinions kg 79.00 105.00 8295.00Pulleys 3 Nos / Couplings 2 Nos kg 306.00 85.00 26010.00Plummer blocks / Hubs kg 72.00 85.00 6120.00

3 Alloy steel componentsShafts kg 346.00 145.00 50170.00Pins kg 73.00 175.00 12775.00

4 Bronze alloy components :Bronze bearings / bush kg 57.00 380.00 21660.00

5 Wire rope 28 mm dia 6/37 construction kg 325.00 75.00 24375.006 MS Bolt / Nut / Washer kg 32.00 45.00 1440.007 Worm reducers No. 1.00 39375.00 39375.008 Electric motor 5 hp No. 1.00 11250.00 11250.009 Manual operating system No. 1.00 8437.50 8437.50

10 Gate position indicator No. 1.00 8437.50 8437.5011 Ele-magnetic brake No. 1.00 8437.50 8437.5012 Electric cable / switch / control panel etc LS 1.00 5625.00 5625.0013 Oxygen gas cum 45.00 40.00 1800.0014 Acetyline gas cum 15.00 185.00 2775.0015 Welding electrodes Nos 80.00 4.00 320.0016 Welding electrodes ( LH ) Nos 720.00 6.00 4320.0017 Zinc chromate red oxide primer ltr 7.00 140.00 980.0018 Synthetic enamel ( 1st quality ) paint ltr 11.00 140.00 1540.0019 Rust cleaner / inhibitor ltr 5.00 175.00 875.0020 Grease kg 50.00 90.00 4500.0021 Use rate welding holder set Hour 85.00 3.38 286.8822 Use rate gas cutting torch set Hour 16.00 1.88 30.0023 Wire brush Nos 1.00 25.00 25.0024 Sundries LS 25.00 22.50 562.50

TOTAL Rs: 480087.88Add for small Tools and Plants @ 1% Rs: 4800.88

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GATES AND HOISTS

Add for Contractor' Profit @ 10% Rs: 48008.79Add for Contrators' Overheads @ 5% Rs: 24004.39

Total cost of Materials Rs: 556901.94

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 85.00 9.00 765.00

Fuel / Energy charges Hour 53.00 49.00 2597.002 Tower crane 5 t capacity Hour 2.00 763.00 1526.00

Fuel / Energy charges Hour 2.00 106.00 212.003 Pug cutting machine Hour 15.00 13.00 195.00

Fuel / Energy charges Hour 15.00 2.00 30.004 Mobile derric crane Hour 10.00 261.00 2610.00

Fuel / Energy charges Hour 10.00 117.00 1170.005 Grinding machine Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.006 Drilling machines Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.007 Sundries LS 25.00 22.50 562.50

TOTAL Rs: 9807.50Add for small Tools and Plants @ 1% Rs: 98.08Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 465.15Add for Contrators' Overheads @ 5% Rs: 490.38 Total hire charges of Machinery Rs: 10861.10

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 10.00 32.90 329.002 Crew for Tower crane Hour 2.00 36.05 72.103 Crew for Drilling machine Hour 2.00 35.00 70.004 Crew for Grinding machine Hour 2.00 35.00 70.005 Foreman Day 15.00 108.65 1629.756 Marker / Fabricator / Erector Day 19.00 93.70 1780.307 Gas cutter Day 4.00 93.70 374.808 Welder ( General ) Day 8.00 93.70 749.609 Khalasi Day 4.00 83.65 334.60

10 Helper fabrication / erection Day 44.00 81.60 3590.4011 Helper for cleaning / painting Day 5.00 81.60 408.0012 Painter Cl - II Day 11.00 81.60 897.6013 Electrician Day 2.00 82.65 165.30

TOTAL Rs: 10471.45Add for small Tools and Plants @ 1% Rs: 104.71Add for Contractor' Profit @ 10% Rs: 1047.15Add for hidden cost on Labour @ 15% Rs: 1570.72Add for additional hidden cost on labour @ 10% Rs: 1047.15Add for Contrators' Overheads @ 5% Rs: 523.57

Total cost of Labour Rs: 14764.74

ABSTRACT:A. Cost of Materials Rs: 556901.94B. Hire charges of Machinery Rs: 10861.10C. Cost of Labour Rs: 14764.74

Total Rs: 582527.78

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GATES AND HOISTS

Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 3459.49Add for insurance charges @ 1.00% Rs: 5825.28Add for designs and drawings @ 2.5% Rs: 14563.19Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 14563.19Add for power supply arrangements @ 2.5% Rs: 14563.19Add for enabling works @ 2% Rs: 11650.56

Total Rs: 647152.69Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x6.243 tonnes @ Rs: 81.30 / tonne Rs: 1015.11Add for transportation upto work site @ 3% Rs: 19414.58 Total cost for 6.243 tonne wt Rs: 667582.38

25.000 t capacityRate per tonne wt Rs: 106930.00

Rate per tonne capacity of hoist Rs: 26700.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 15

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( without grooveliners ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner upto1m height above the roof of vent etc., with all accessories for river / canal sluice emergencygate 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 appliedcoal tar epoxy paint etc., complete as per specifications and approved drawings with all leadsand lifts.

DATA: Embedded parts for river sluice emergency gate consist of sill beam, wheel / seal tracks, breastwall 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, height upto which breastwall lining is to be provided.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. Details of material / Gas cutting / Welding considered for rate analysis are based on embedded parts drawings for emergency gate for river sluice vent of Upper Tunga dam.Generally wt of embedded parts for sluice gate will be 50% of wt of gate including ballast.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 mHead of water considered above sill level : 16 m Weight of embedded parts in tonnes = 0.0444 x ( L^2 x H x h )^0.659Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0444 x ( 2.2 x 2.2 x 3.3 x 16 ) ^ 0.659 : 1.714 tonnesWeight of breast wall lining about 2 sqm @ 250 kg / sqm : 0.500 tonnes

: 2.214 tonnesThe actual weight of embedded parts as per data sheet : 2.180 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 15 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel angles / beams / channels / bars with 2.5 % wastage : 608 kgStructural steel plates / flats with 2.5 % wastage : 1337 kg

b. Alloy steel components conforming to IS : 1570 :Stainless steel plates / flats : 225.00 kg

c. Bolt / Nut / Washer conforming ti IS : 1363 :MS bolts and nuts with 2.5 % wastage : 66 kg

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GATES AND HOISTS

d. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 77 NosWelding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 34 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 697 NosWelding electrodes ( SS ) for run welding at 90 % of total with 2.5 % wastage : 305 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides as per data sheet : 135 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 14 RmTotal length of cutting : 149 RmFor 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 mLength of steel to be cut by gas using pug cutting machine : 89 mLength of steel to be cut by using shearing machine : 30 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 15 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 30 hoursTime for cutting by shearing machine at av. 10 m / hr progress : 3 hoursAcetelyne gas @ 0.6 cum / hour ( 45 x 0.60 ) : 27 cumOxygen gas @ 1.8 cum / hour ( 45 x 1.80 ) : 81 cumUse of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hoursUse of pug cutting machine with 50 min / hr working ( 30 x 60 / 50 ) : 36 hoursUse of shearing machine with 50 min / hr working ( 3 x 60 / 50 ) : 4 hours

3. Welding :Length of welding as per data sheet : 143 mFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 77 + 34 ) x 8 / 15 / 2 : 30 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 697 + 305 ) x 8 / 15 / 6 : 89 hoursTotal : 119 hours

Deploy welding transformer for 119 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 30 x 0.25 + 89 x 0.75 ) : : 75 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 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 26 m SS plates ( 26 x 8 / 3 ) : 72 hours

5. Surface cleaning and painting :Painting area for embedded parts at 12 sqm / tonne : 26 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 26 sqm @ 9 sqm / ltr / coat : 3 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 26 sqm @ 6 sqm / ltr / coat : 18 ltrAs 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 at 8 sqm / ltr : 4 ltr

6. Requirement of other machinery :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 mobile derric crane for 2 hours and stationery derric crane for 4 hours considered.

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GATES AND HOISTS

7. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 58 hours 3 7 7 14Drilling holes for anchors / supports 1 1 1Fbricating by stitch welding 30 hours 2 4 8Run welding 89 hours 1 11 11Erection of first stage anchors 2 4 8Erection of Sill beam / Tracks / Guide 2 4 8Erection of Breast wall 1 2 4Finishing / cleaning 1 1 2 Total : 13 23 18 56

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 2 helper for 26 sqmFor painting 1 coat primer and 4 coats finishing paint at 15 sqm / day : 9 painter Cl-ll & 1 helper for 5 x 26 sqm

8. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 2.180 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Str steel angle / beam / channel / bars kg 608.00 20.00 12160.002 Structural steel plate / flats kg 1337.00 24.00 32088.003 Stainless steel plate / flats kg 225.00 90.00 20250.004 MS bolts and nuts kg 66.00 45.00 2970.005 Oxygen gas cum 81.00 40.00 3240.006 Acetyline gas cum 27.00 185.00 4995.007 Welding electrodes Nos 77.00 4.00 308.008 Welding electrodes ( LH ) Nos 697.00 6.00 4182.009 Welding electrodes ( stainless steel ) Nos 339.00 35.00 11865.00

10 Zinc rich epoxy primer ltr 3.00 525.00 1575.0011 Coal tar epoxy paint ltr 18.00 131.00 2358.0012 Rust cleaner / inhibitor ltr 4.00 175.00 700.0013 Use rate welding holder set Hour 119.00 3.38 401.6314 Use rate gas cutting torch set Hour 18.00 1.88 33.7515 Wire brush Nos 1.00 25.00 25.0016 Sundries LS 10.00 22.50 225.00

TOTAL Rs: 97376.38Add for small Tools and Plants @ 1% Rs: 973.76

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GATES AND HOISTS

Add for Contractor' Profit @ 10% Rs: 9737.64Add for Contrators' Overheads @ 5% Rs: 4868.82

Total cost of Materials Rs: 112956.60

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 119.00 9.00 1071.00

Fuel / Energy charges Hour 75.00 49.00 3675.002 Plate shearing machine Hour 4.00 47.00 188.00

Fuel / Energy charges Hour 4.00 82.00 328.003 Pug cutting machine Hour 36.00 13.00 468.00

Fuel / Energy charges Hour 36.00 2.00 72.004 Planing machine Hour 72.00 66.00 4752.00

Fuel / Energy charges Hour 72.00 61.00 4392.005 Mobile derric crane Hour 2.00 261.00 522.00

Fuel / Energy charges Hour 2.00 117.00 234.006 Stationery derric crane Hour 4.00 50.00 200.00

Fuel / Energy charges Hour 4.00 5.00 20.007 Grinding machine Hour 8.00 15.00 120.00

Fuel / Energy charges Hour 8.00 20.00 160.008 Drilling machines Hour 10.00 15.00 150.00

Fuel / Energy charges Hour 10.00 20.00 200.009 Sundries LS 10.00 22.50 225.00

TOTAL Rs: 16777.00Add for small Tools and Plants @ 1% Rs: 167.77Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 930.60Add for Contrators' Overheads @ 5% Rs: 838.85 Total hire charges of Machinery Rs: 18714.22

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 2.00 32.90 65.802 Crew for Planing machine Hour 72.00 42.75 3078.003 Crew for Drilling machine Hour 10.00 35.00 350.004 Crew for Grinding machine Hour 8.00 35.00 280.005 Foreman Day 13.00 108.65 1412.456 Marker / Fabricator / Erector Day 23.00 93.70 2155.107 Gas cutter Day 7.00 93.70 655.908 Welder ( General ) Day 8.00 93.70 749.609 Welder ( X - ray ) Day 3.00 103.07 309.21

10 Helper fabrication / erection Day 56.00 81.60 4569.6011 Helper for cleaning / painting Day 3.00 81.60 244.8012 Painter Cl - II Day 9.00 81.60 734.4013 Electrician Day 1.00 82.65 82.65

TOTAL Rs: 14687.51Add for small Tools and Plants @ 1% Rs: 146.88Add for Contractor' Profit @ 10% Rs: 1468.75Add for hidden cost on Labour @ 15% Rs: 2203.13Add for additional hidden cost on labour @ 10% Rs: 1468.75Add for Contrators' Overheads @ 5% Rs: 734.38

Total cost of Labour Rs: 20709.39

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GATES AND HOISTS

ABSTRACT:A. Cost of Materials Rs: 112956.60B. Hire charges of Machinery Rs: 18714.22C. Cost of Labour Rs: 20709.39

Total Rs: 152380.20Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 5322.19Add for insurance charges @ 1.00% Rs: 1523.80Add for designs and drawings @ 2.5% Rs: 3809.51Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 3809.51Add for power supply arrangements @ 2.5% Rs: 3809.51Add for enabling works @ 2% Rs: 3047.60

Total Rs: 173702.31Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x2.180 tonnes @ Rs: 81.30 / tonne Rs: 354.47Add for transportation upto work site @ 3% Rs: 5211.07 Total cost for 2.180 tonne Rs: 179267.85

Rate per tonne Rs: 82230.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 16

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( with grooveliner ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner ( upto1 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 primerand 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, groovelining upto breast wall level, breast wall lining upto 1 m above top of vent, gate guide etc., withall 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 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. Details of material / Gas cutting / Welding considered for rate analysis are based on embeddedparts drawings including groove liner for river sluice service gate of Kodasalli dam.Weight of embedded parts for emergency gate will be about 65 to 70 % of gate wt with ballast.Weight of embedded parts in tonne for 2.5 m x 3 m opening based on empirical formula : Size of gate for 2.5 m x 3 m opening : Length : 3.2 m Height : 3.3 mHead of water considered above sill level : 34 m Weight of embedded parts in tonnes = 0.0600 x ( L^2 x H x h )^0.659Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0600 x ( 3.2 x 3.2 x 3.3 x 34 ) ^ 0.659 : 6.236 tonnesWeight of breast wall lining about 3.5 sqm @ 250 kg / sqm : 0.875 tonnesWeight of groove liner about 10 sqm @ 200 kg / sqm : 2.000 tonnes

: 9.111 tonnesThe actual weight of embedded parts as per data sheet : 9.088 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 16 of Annexer )a. Structural steel conforming to IS : 2062 :

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GATES AND HOISTS

Structural steel angles / beams / channels / bars with 2.5 % wastage : 1017 kgStructural steel plates / flats with 2.5 % wastage : 7617 kg

b. Alloy steel components conforming to IS : 1570 :Stainless steel plates / flats : 442 kg

c. Bolt / Nut / Washer conforming ti IS : 1363 :MS bolts and nuts with 2.5 % wastage : 240 kg

d. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 416 NosWelding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 59 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 3746 NosWelding electrodes ( SS ) for run welding at 90 % of total with 2.5 % wastage : 529 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides as per data sheet : 301 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 30 RmTotal length of cutting : 331 RmFor 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 mLength of steel to be cut by gas using pug cutting machine : 211 mLength of steel to be cut by using shearing machine : 60 mTime for gas cutting manually assuming average cutting progress of 2 m / hour 30 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 70 hoursTime for cutting by shearing machine at av. 10 m / hr progress : 6 hoursAcetelyne gas @ 0.6 cum / hour ( 100 x 0.60 ) : 60 cumOxygen gas @ 1.8 cum / hour ( 100 x 1.80 ) : 180 cumUse of gas cutting torch with 50 min / hr working ( 30 x 60 / 50 ) 36 hoursUse of pug cutting machine with 50 min / hr working ( 70 x 60 / 50 ) 84 hoursUse of shearing machine with 50 min / hr working ( 6 x 60 / 50 ) 7 hours

3. Welding :Length of welding as per data sheet : 560 mFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 416 + 59 ) x 8 / 15 / 2 : 127 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 3746 + 529 ) x 8 / 15 / 6 : 380 hours

Total : 507 hoursDeploy welding transformer for 507 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 127 x 0.25 + 380 x 0.75 ) : 317 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 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 26 m SS plates ( 26 x 8 / 3 ) : 69 hours

5. Surface cleaning and painting :Painting area for embedded parts at 10 sqm / tonne : 91 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 91 sqm @ 9 sqm / ltr / coat : 10 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 91 sqm @ 6 sqm / ltr / coat : 61 ltrAs 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 at 8 sqm / ltr : 12 ltr

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GATES AND HOISTS

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 mobile derric crane for 20 hours and stationery derric crane for 40 hours considered.

7. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 127 hours 8 16 16 32Drilling holes for anchors / supports 3 6 --- 6Fbricating by stitch welding 127 hours 8 16 --- 32Run welding 380 hours 5 --- 48 48Erection of first stage anchors 5 10 --- 10Erection of Sill beam / Tracks / Guide 2 4 --- 8Erection of Breast wall liner 1 2 --- 4Erection of groove liners 3 6 --- 12Finishing / cleaning 1 2 --- 4 Total : 36 62 64 156

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 6 helper for 91 sqmFor painting 1 coat primer and 4 coats finishing paint at 15 sqm / day : 30 painter Cl-ll & 6 helper for 5 x 91 sqm

8. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 9.088 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Str steel angle / beam / channel / bars kg 1017.00 20.00 20340.002 Structural steel plate / flats kg 7617.00 24.00 182808.003 Stainless steel plate / flats kg 442.00 90.00 39780.004 MS bolts and nuts kg 240.00 45.00 10800.005 Oxygen gas cum 180.00 40.00 7200.006 Acetyline gas cum 60.00 185.00 11100.007 Welding electrodes Nos 416.00 4.00 1664.008 Welding electrodes ( LH ) Nos 3746.00 6.00 22476.009 Welding electrodes ( stainless steel ) Nos 588.00 35.00 20580.00

10 Zinc rich epoxy primer ltr 10.00 525.00 5250.0011 Coal tar epoxy paint ltr 61.00 131.00 7991.0012 Rust cleaner / inhibitor ltr 12.00 175.00 2100.0013 Use rate welding holder set Hour 507.00 3.38 1711.13

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14 Use rate gas cutting torch set Hour 36.00 1.88 67.5015 Wire brush Nos 2.00 25.00 50.0016 Sundries LS 20.00 22.50 450.00

TOTAL Rs: 334367.63Add for small Tools and Plants @ 1% Rs: 3343.68Add for Contractor' Profit @ 10% Rs: 33436.76Add for Contrators' Overheads @ 5% Rs: 16718.38

Total cost of Materials Rs: 387866.45

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 507.00 9.00 4563.00

Fuel / Energy charges Hour 317.00 49.00 15533.002 Plate shearing machine Hour 7.00 47.00 329.00

Fuel / Energy charges Hour 7.00 82.00 574.003 Pug cutting machine Hour 84.00 13.00 1092.00

Fuel / Energy charges Hour 84.00 2.00 168.004 Planing machine Hour 69.00 66.00 4554.00

Fuel / Energy charges Hour 69.00 61.00 4209.005 Mobile derric crane Hour 20.00 261.00 5220.00

Fuel / Energy charges Hour 20.00 117.00 2340.006 Stationery derric crane Hour 40.00 50.00 2000.00

Fuel / Energy charges Hour 40.00 5.00 200.007 Grinding machine Hour 25.00 15.00 375.00

Fuel / Energy charges Hour 25.00 20.00 500.008 Drilling machines Hour 50.00 15.00 750.00

Fuel / Energy charges Hour 50.00 20.00 1000.009 Sundries LS 20.00 22.50 450.00

TOTAL Rs: 43857.00Add for small Tools and Plants @ 1% Rs: 438.57Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 2497.40Add for Contrators' Overheads @ 5% Rs: 2192.85 Total hire charges of Machinery Rs: 48985.82

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 20.00 32.90 658.002 Crew for Shearing machine Hour 7.00 26.70 186.903 Crew for Planing machine Hour 69.00 42.75 2949.754 Crew for Drilling machine Hour 50.00 35.00 1750.005 Crew for Grinding machine Hour 25.00 35.00 875.006 Foreman Day 36.00 108.65 3911.407 Marker / Fabricator / Erector Day 62.00 93.70 5809.408 Gas cutter Day 16.00 93.70 1499.209 Welder ( General ) Day 42.00 93.70 3935.40

10 Welder ( X - ray ) Day 6.00 103.07 618.4211 Helper fabrication / erection Day 156.00 81.60 12729.6012 Helper for cleaning / painting Day 12.00 81.60 979.2013 Painter Cl - II Day 30.00 81.60 2448.0014 Electrician Day 2.00 82.65 165.30

TOTAL Rs: 38515.57Add for small Tools and Plants @ 1% Rs: 385.16Add for Contractor' Profit @ 10% Rs: 3851.56

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GATES AND HOISTS

Add for hidden cost on Labour @ 15% Rs: 5777.34Add for additional hidden cost on labour @ 10% Rs: 3851.56Add for Contrators' Overheads @ 5% Rs: 1925.78

Total cost of Labour Rs: 54306.95

ABSTRACT:A. Cost of Materials Rs: 387866.45B. Hire charges of Machinery Rs: 48985.82C. Cost of Labour Rs: 54306.95

Total Rs: 491159.22Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 13944.52Add for insurance charges @ 1.00% Rs: 4911.59Add for designs and drawings @ 2.5% Rs: 12278.98Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 12278.98Add for power supply arrangements @ 2.5% Rs: 12278.98Add for enabling works @ 2% Rs: 9823.18

Total Rs: 556675.46Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x9.088 tonnes @ Rs: 81.30 / tonne Rs: 1477.71Add for transportation upto work site @ 3% Rs: 16700.26 Total cost for 9.088 tonne Rs: 574853.43

Rate per tonne Rs: 63250.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 17

ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type vertical liftemergency gate consisting of skin plate, horizontal and vertical girders, wheels, stiffeners,lifting brackets, guide rollers, ballast blocks, teflon claded rubber seals etc., with all accessories for river sluice / canal sluice vent including cost of all materials, machinery, labour, cutting,aligning, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and threecoats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with all leads and lifts.

DATA: Consider upstream seal vertical lift roller gate. The gate leaf consists of skin plate, horizontalgirders, vertical end girders, stiffeners, wheels, gate guide rollers, brackets for hooks, seals etc., with all accessories.Consider river / canal sluice emergency gate for 2.5 m x 3 m sluice opening for analysis.Details of material / Gas cutting / Welding considered for rate analysis are based on emergency gate drawings for river sluice vent of Kodasalli dam.Weight of gate leaf in tonne for vertical lift gate based on empirical formula : Weight in tonnes ( including weight of ballast ) = 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.For vent opening of 2.5 x 3.0 m the approximate size of gate leaf will be : 3.2 m x 3.3 mHead of water above sill level considered : 34 m Weight in tonnes = 0.0888 ( 3.2 x 3.2 x 3.3 x 34 ) ^ 0.659 : 9.229The actual weight of river sluice emergency gate as per data sheet : 9.215 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 17 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel plates / flats with 2.5 % wastage : 4409 kgb. Cast iron components conforming to IS : 210 :

Cast iron blocks for counter weight : 4100 kgc. Alloy steel components conforming to IS : 1570 :

Wheel axles / Pins : 144 kg

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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 : 55 kgGI bolts / nuts / washers with 2.5 % wastage : 148 kgMS bolts / nuts / washers with 2.5 % wastage : 4 kg

g. Rubber seal conforming to IS : 11855 :Bottom seal ( flat uncladed ) : 2.8 RmTop seal ( bulb type teflon claded ) : 2.25 RmSide seals ( bulb type teflon claded ) : 5.85 RmCorner seal ( bulb teflon claded ) : 2 Nos

h. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 256 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 2308 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 134 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 14 Rm

Total : 148 RmFor cutting structural steel sections to required sizes gas cutting is assumed since most of thesections are above 10 mm thick.Length of steel to be cut by using gas manually : 30 mLength of steel to be cut by gas using pug cutting machine : 118 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 15 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 39 hoursAcetelyne gas @ 0.6 cum / hour ( 54 x 0.60 ) : 32 cumOxygen gas @ 1.8 cum / hour ( 54 x 1.80 ) : 96 cumUse of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hoursUse of pug cutting machine with 50 min / hr working ( 39 x 60 / 50 ) : 47 hours

3. Welding :Length of welding : 271 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 256 / 15 ) x 8 / 2 : 68 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 2308 / 15 ) x 8 / 6 : 205 hoursTotal : 273 hours

Deploy welding transformer for 273 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 68 x 0.25 + 205 x 0.75 ) : 171 hours 4. Surface cleaning and painting :

Painting area for river sluice gate at 10 sqm / tonne : 92 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 92 sqm @ 9 sqm / ltr / coat : 10 ltr3 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 ltrAs 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 at 8 sqm / ltr : 12 ltr

5. Requirement of other machinery :For lowering gate leaf from hoist chamber use of tower crane for 1 hour considered.For handling of gate parts during fabrication and erection mobile derric crane for 10 hours and stationery derric crane for 20 hours considered.For drilling holes in skin plate, counter weight blocks, horizontal girders and seal clamps use of

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GATES AND HOISTS

drilling machine for 16 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 Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 65 hours 4 8 8 16Drilling holes for seal fixing 1 2 --- 2Fabricating by stitch welding 68 hours 5 9 --- 18Run welding 205 hours 3 --- 26 26Fixing counter weight blocks 1 1 --- 2Seal fixing 1 1 --- 2Guide roller fixing / Cleaning / Lowering 1 2 --- 2 Total : 16 23 34 68

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 6 helper for 92 sqmFor painting 1 coat primer and 3 coats finishing paint at 15 sqm / day : 25 painter Cl-ll & 5 helper for 4 x 92 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 9.215 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Plates / flats kg 4409.00 24.00 105816.002 Cast iron components

CI blocks for counter wt kg 4100.00 18.00 73800.003 Alloy steel components

Wheel axles / Pins kg 144.00 175.00 25200.004 Cast steel components

Wheels / Guide rollers kg 492.00 85.00 41820.005 Alluminium / Bronze alloy components

Bearings / Bushes kg 76.00 380.00 28880.006 Bolt / Nut / Washer

SS bolts / nuts / washers kg 55.00 100.00 5500.00GI bolts / nuts / washers kg 148.00 60.00 8880.00MS bolts / nuts / washers kg 4.00 45.00 180.00

7 Rubber sealsBottom seal ( flat uncladed ) Rm 2.80 120.00 336.00Side seals ( bulb teflon claded ) Rm 5.85 550.00 3217.50Top seal ( bulb teflon claded ) Rm 2.25 550.00 1237.50

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GATES AND HOISTS

Corner seals ( bulb teflon claded ) Nos 2.00 600.00 1200.008 Oxygen gas cum 96.00 40.00 3840.009 Acetyline gas cum 32.00 185.00 5920.00

10 Welding electrodes Nos 256.00 4.00 1024.0011 Welding electrodes ( LH ) Nos 2308.00 6.00 13848.0012 Zinc rich epoxy primer ltr 10.00 525.00 5250.0013 Coal tar epoxy paint ltr 46.00 131.00 6026.0014 Rust cleaner / inhibitor ltr 12.00 175.00 2100.0015 Use rate welding holder set Hour 273.00 3.38 921.3816 Use rate gas cutting torch set Hour 18.00 1.88 33.7517 Wire brush Nos 1.00 25.00 25.0018 Sundries LS 50.00 22.50 1125.00

TOTAL Rs: 336180.13Add for small Tools and Plants @ 1% Rs: 3361.80Add for Contractor' Profit @ 10% Rs: 33618.01Add for Contrators' Overheads @ 5% Rs: 16809.01

Total cost of Materials Rs: 389968.95

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 273.00 9.00 2457.00

Fuel / Energy charges Hour 171.00 49.00 8379.002 Pug cutting machine Hour 47.00 13.00 611.00

Fuel / Energy charges Hour 47.00 2.00 94.003 Tower crane Hour 1.00 763.00 763.00

Fuel / Energy charges Hour 1.00 106.00 106.004 Mobile derric crane Hour 10.00 261.00 2610.00

Fuel / Energy charges Hour 10.00 117.00 1170.005 Stationery derric crane Hour 20.00 50.00 1000.00

Fuel / Energy charges Hour 20.00 5.00 100.006 Grinding machine Hour 8.00 15.00 120.00

Fuel / Energy charges Hour 8.00 20.00 160.007 Drilling machines Hour 16.00 15.00 240.00

Fuel / Energy charges Hour 16.00 20.00 320.008 Sundries LS 25.00 22.50 562.50

TOTAL Rs: 18692.50Add for small Tools and Plants @ 1% Rs: 186.93Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 1089.15Add for Contrators' Overheads @ 5% Rs: 934.63 Total hire charges of Machinery Rs: 20903.20

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 10.00 32.90 329.002 Crew for Tower crane Hour 1.00 36.05 36.053 Crew for Drilling machine Hour 16.00 35.00 560.004 Crew for Grinding machine Hour 8.00 35.00 280.005 Foreman Day 16.00 108.65 1738.406 Marker / Fabricator / Erector Day 23.00 93.70 2155.107 Gas cutter Day 8.00 93.70 749.608 Welder ( General ) Day 23.00 93.70 2155.109 Welder ( X - ray grade ) Day 3.00 103.07 309.21

10 Khalasi Day 10.00 83.65 836.50

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GATES AND HOISTS

11 Helper fabrication / erection Day 68.00 81.60 5548.8012 Helper for cleaning / painting Day 11.00 81.60 897.6013 Painter Cl - II Day 25.00 81.60 2040.0014 Electrician Day 2.00 82.65 165.30

TOTAL Rs: 17800.66Add for small Tools and Plants @ 1% Rs: 178.01Add for Contractor' Profit @ 10% Rs: 1780.07Add for hidden cost on Labour @ 15% Rs: 2670.10Add for additional hidden cost on labour @ 10% Rs: 1780.07Add for Contrators' Overheads @ 5% Rs: 890.03

Total cost of Labour Rs: 25098.93

ABSTRACT:A. Cost of Materials Rs: 389968.95B. Hire charges of Machinery Rs: 20903.20C. Cost of Labour Rs: 25098.93

Total Rs: 435971.08Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 6210.29Add for insurance charges @ 1.00% Rs: 4359.71Add for designs and drawings @ 2.5% Rs: 10899.28Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 10899.28Add for power supply arrangements @ 2.5% Rs: 10899.28Add for enabling works @ 2% Rs: 8719.42

Total Rs: 487958.33Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x9.215 tonnes @ Rs: 81.30 / tonne Rs: 1498.36Add for transportation upto work site @ 3% Rs: 14638.75 Total cost for 9.215 tonne Rs: 504095.43

Rate per tonne Rs: 54700.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 18

ITEM: Design, fabrication, supply, erection, testing and commissioning of automatic lifting beam with all accessories for handling, lowering and lifting of river sluice / canal sluice emergencygate including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and two coats of cold applied coal tar epoxy paint etc., complete as per specifications and drawings with all leads and lifts.

DATA: Automatic lifting beam for lifting river sluice emergency gate consists of fabricated beam withlifting bracket and automatic engaging / dis-engaging type hooks for under water hooking / de-hooking of gate leaf. Lifting beam is an independent attachment to moving gantry crane.Generally the weight of lifting beam for river sluice emergency gate will be about 10 percent of the weight of gate leaf with ballast.Consider river sluice emergency gate for sluice opening of size 2.5 m x 3 m for analysis.Details of material/ Gas cutting / Welding considered for rate analysis are based on lifting beamdrawings for river sluice emergency gate of Kodasalli dam.Weight of lifting beam for emergency gate for 2.5 m x 3 m sluice as per empirical formula :Weight of lifting beam in tonnes = 0.0090 ( 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.For vent opening of 2.5 x 3.0 m the approximate size of gate leaf will be : 3.2 m x 3.3 mHead of water above sill level considered : 34 m Weight lifting beam in tonnes = 0.0090 ( 3.2 x 3.2 x 3.3 x 33 ) ^ 0.659 : 0.917 tonneThe actual weight of lifting beam as per data sheet : 0.922 tonne

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GATES AND HOISTS

Consider actual weight for data rate analysis. 1. Requirement of materials : as per fabrication drawings ( for details refer Item : 18 of Annexer )

Structural steel :Structural steel angles / beams / channels / bars with 2.5 % wastage : 234 kgStructural steel plates / flats with 2.5 % wastage : 488 kgAlloy steel components :Pins : 71 kgBronze alloy components :Bush : 4 kgForged steel components :Hooks : 130 kgBolts / Nuts / Washers :MS bolts / nuts / washers with 2.5 % wastage : 2 kgMS pipe 100 mm dia : 11 kgWelding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 43 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 387 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 43 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 4 Rm

Total : 47 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 10 mLength of steel to be cut by gas using pug cutting machine : 37 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 5 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 12 hoursAcetelyne gas @ 0.6 cum / hour ( 17 x 0.60 ) : 10 cumOxygen gas @ 1.8 cum / hour ( 17 x 1.80 ) : 30 cumUse of gas cutting torch with 50 min / hr working ( 5 x 60 / 50 ) : 6 hoursUse of pug cutting machine with 50 min / hr working ( 12 x 60 / 50 ) : 15 hours

3. Welding :Length of welding : 49 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 43 / 15 ) x 8 / 2 : 12 hoursFor run welding @ 6 hrs usage / shift & @ 12 electrodes / hr

( 387 / 15 ) x 8 / 6 : 35 hoursTotal : 47 hours

Deploy welding transformer for 47 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 12 x 0.25 + 35 x 0.75 ) : : 29 hours 4. Surface cleaning and painting :

Painting area for lifting beam at 12 sqm / tonne : 11 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 11 sqm @ 9 sqm / ltr / coat : 1.25 ltr2 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 11 sqm @ 6 sqm / ltr / coat : 4 ltrAs 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 at 8 sqm / ltr : 1.5 ltr

5. Requirement of other machinery :For drilling holes for pins / guide shoes 2 hours use of drilling machine considered. For grinding and finishing weld joints 1 hour use of grinding machine considered.

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GATES AND HOISTS

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 17 hours 1 2 2 4Drilling holes for pins / bolts fixing --- 1 1Fabricating by stitch welding 12 hours 1 1 --- 2Run welding 35 hours --- --- 4 4Finishing / guide shoe fixing / checking --- 1 --- 1 Total : 2 5 6 12

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 1 helper for 11 sqmFor painting 1 coat primer and 2 coats finishing paint at 15 sqm / day : 2 painter Cl-ll & 1 helper for 3x11 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 0.922 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / beams / channels / bars kg 234.00 20.00 4680.00Plates / flats kg 488.00 24.00 11712.00

2 Alloy steel componentsLifting pins kg 71.00 175.00 12425.00

3 Bronze alloy components :Bronze bush kg 4.00 380.00 1520.00

4 Forged steel components :Lifting hooks kg 130.00 130.00 16900.00

5 MS pipe 100 mm dia kg 11.00 30.00 330.006 Bolt / Nut / Washer

MS bolts / nuts / washers kg 2.00 45.00 90.007 Oxygen gas cum 30.00 40.00 1200.008 Acetyline gas cum 10.00 185.00 1850.009 Welding electrodes Nos 43.00 4.00 172.00

10 Welding electrodes ( LH ) Nos 387.00 6.00 2322.0011 Zinc rich epoxy primer ltr 1.25 525.00 656.2512 Coal tar epoxy paint ltr 4.00 131.00 524.0013 Rust cleaner / inhibitor ltr 1.50 175.00 262.5014 Use rate welding holder set Hour 47.00 3.38 158.6315 Use rate gas cutting torch set Hour 6.00 1.88 11.25

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GATES AND HOISTS

16 Wire brush Nos 1.00 25.00 25.0017 Sundries LS 5.00 22.50 112.50

TOTAL Rs: 54951.13Add for small Tools and Plants @ 1% Rs: 549.51Add for Contractor' Profit @ 10% Rs: 5495.11Add for Contrators' Overheads @ 5% Rs: 2747.56

Total cost of Materials Rs: 63743.31

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 47.00 9.00 423.00

Fuel / Energy charges Hour 29.00 49.00 1421.002 Pug cutting machine Hour 15.00 13.00 195.00

Fuel / Energy charges Hour 15.00 2.00 30.003 Grinding machine Hour 1.00 15.00 15.00

Fuel / Energy charges Hour 1.00 20.00 20.004 Drilling machines Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.005 Sundries LS 5.00 22.50 112.50

TOTAL Rs: 2286.50Add for small Tools and Plants @ 1% Rs: 22.87Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 162.35Add for Contrators' Overheads @ 5% Rs: 114.33 Total hire charges of Machinery Rs: 2586.04

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Drilling machine Hour 2.00 35.00 70.002 Crew for Grinding machine Hour 1.00 35.00 35.003 Foreman Day 2.00 108.65 217.304 Marker / Fabricator / Erector Day 5.00 93.70 468.505 Gas cutter Day 2.00 93.70 187.406 Welder ( General ) Day 4.00 93.70 374.807 Helper fabrication / erection Day 12.00 81.60 979.208 Helper for cleaning / painting Day 2.00 81.60 163.209 Painter Cl - II Day 2.00 81.60 163.20

10 Electrician Day 1.00 82.65 82.65TOTAL Rs: 2741.25

Add for small Tools and Plants @ 1% Rs: 27.41Add for Contractor' Profit @ 10% Rs: 274.13Add for hidden cost on Labour @ 15% Rs: 411.19Add for additional hidden cost on labour @ 10% Rs: 274.13Add for Contrators' Overheads @ 5% Rs: 137.06

Total cost of Labour Rs: 3865.16

ABSTRACT:A. Cost of Materials Rs: 63743.31B. Hire charges of Machinery Rs: 2586.04C. Cost of Labour Rs: 3865.16

Total Rs: 70194.51Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 870.91Add for insurance charges @ 1.00% Rs: 701.95

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GATES AND HOISTS

Add for designs and drawings @ 2.5% Rs: 1754.86Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 1754.86Add for power supply arrangements @ 2.5% Rs: 1754.86Add for enabling works @ 2% Rs: 1403.89

Total Rs: 78435.84Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x0.922 tonnes @ Rs: 81.30 / tonne Rs: 149.92Add for transportation upto work site @ 3% Rs: 2353.08 Total cost for 0.922 tonne Rs: 80938.84

Rate per tonne Rs: 87790.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 19

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sill beam, wheel tracks, seal seats / tracks, guide rails, etc., with all accessories for verticallift barrage gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of coldapplied coal tar epoxy paint, etc., complete as per specifications and aproved drawings withall leads and lifts.

DATA: Barrage gate embedded parts consist of sill beam, wheel tracks / seal tracks and gate guides with accessories such as first / second stage anchors.Weight of embedded parts for barrage gate will be about 15 to 20 percent of gate weight.Consider embedded parts for vertical lift gate for barrage opening of size 13.7 m x 8.26 m.Details of material / Gas cutting / Welding considered for rate analysis are based on embeddedparts drawings for barrage gates of Hipparagi Barrage.Weight of embedded parts in tonne for vertical lift gate based on empirical formula : Weight in tonnes = 0.0055 ( L^2 x H x h )^0.716 Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm.For vent opening of 13.72 x 8.26 m the approximate size of gate leaf will be 14.7 x 8.6 m.Head of water above sill level considered : 8.26 m Weight of embedded parts in tonnes = 0.0055 ( 14.7 x 14.7 x 8.6 x 8.26 ) ^ 0.716

: 5.465 tonnesThe actual weight of embedded parts as per data sheet : 5.193 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 19 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel angles / beams / channels / bars with 2.5 % wastage : 603 kgStructural steel plates / flats with 2.5 % wastage : 3777 kg

b. Alloy steel components conforming to IS : 1570 :Stainless steel plates / flats : 772.00 kg

c. Bolt / Nut / Washer conforming ti IS : 1363 :MS bolts and nuts with 2.5 % wastage : 171 kg

d. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 665 NosWelding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 117 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 5983 NosWelding electrodes ( SS ) for run welding at 90 % of total with 2.5 % wastage : 1055 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides as per data sheet : 210 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 21 RmTotal length of cutting : 231 RmFor cutting structural steel sections to required size gas cutting and use of plate shearingmachine is considered.Length of steel to be cut by using gas manually : 50 m

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GATES AND HOISTS

Length of steel to be cut by gas using pug cutting machine : 151 mLength of steel to be cut by using shearing machine : 30 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 25 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 50 hoursTime for cutting by shearing machine at av. 10 m / hr progress : 3 hoursAcetelyne gas @ 0.6 cum / hour ( 75 x 0.60 ) : 45 cumOxygen gas @ 1.8 cum / hour ( 75 x 1.80 ) : 135 cumUse of gas cutting torch with 50 min / hr working ( 25 x 60 / 50 ) : 30 hoursUse of pug cutting machine with 50 min / hr working ( 50 x 60 / 50 ) : 60 hoursUse of shearing machine with 50 min / hr working ( 3 x60 / 50) : 4 hours

3. Welding :Length of welding as per data sheet : 252 mFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 665 + 117 ) x 8 / 15 / 2 : 209 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 5983 + 1055 ) x 8 / 15 / 6 : : 626 hours

Total : 835 hoursDeploy welding transformer for 835 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 209 x 0.25 + 626 x 0.75 ) : 522 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 : 32.5 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 32.5 m SS plates ( 32.5 x 8 / 3 ) : 88 hours

5. Surface cleaning and painting :Painting area for embedded parts at 10 sqm / tonne : 52 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 52 sqm @ 9 sqm / ltr / coat : 6 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 52 sqm @ 6 sqm / ltr / coat : 35 ltrAs 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 at 8 sqm / ltr : 6.5 ltr

6. Requirement of other machinery :For drilling holes for anchor bolts use of drilling machine for 16 hours considered.For grinding weld joints and edges requiring finishing use of grinding machine for 8 hours considered.For handling during fabrication and erection mobile derric crane for 5 hours considered.

7. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 94 hours 6 12 12 24Drilling holes for anchors / supports 1 2 --- 4Fabricating by stitch welding 209 hours 13 26 --- 52Run welding 626 hours 8 --- 78 78Erection of first stage anchors 5 10 --- 10Erection of Sill beam / Tracks / Guide 2 4 --- 8Finishing / cleaning 2 2 --- 4 Total : 37 56 90 180

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

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GATES AND HOISTS

For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 4 helper for 52 sqmFor painting 1 coat primer and 4 coats finishing paint at 15 sqm / day : 17 painter Cl-ll & 3 helper for 5 x 52 sqm

8. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 5.193 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Str steel angle / beam / channel / bars kg 603.00 20.00 12060.002 Structural steel plate / flats kg 3777.00 24.00 90648.003 Stainless steel plate / flats kg 772.00 90.00 69480.004 MS bolts and nuts kg 171.00 45.00 7695.005 Oxygen gas cum 135.00 40.00 5400.006 Acetyline gas cum 45.00 185.00 8325.007 Welding electrodes Nos 665.00 4.00 2660.008 Welding electrodes ( LH ) Nos 5983.00 6.00 35898.009 Welding electrodes ( stainless steel ) Nos 1172.00 35.00 41020.00

10 Zinc rich epoxy primer ltr 6.00 525.00 3150.0011 Coal tar epoxy paint ltr 35.00 131.00 4585.0012 Rust cleaner / inhibitor ltr 6.50 175.00 1137.5013 Use rate welding holder set Hour 835.00 3.38 2818.1314 Use rate gas cutting torch set Hour 30.00 1.88 56.2515 Wire brush Nos 2.00 25.00 50.0016 Sundries LS 25.00 22.50 562.50

TOTAL Rs: 285545.38Add for small Tools and Plants @ 1% Rs: 2855.45Add for Contractor' Profit @ 10% Rs: 28554.54Add for Contrators' Overheads @ 5% Rs: 14277.27

Total cost of Materials Rs: 331232.64

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 835.00 9.00 7515.00

Fuel / Energy charges Hour 522.00 49.00 25578.002 Plate shearing machine Hour 4.00 47.00 188.00

Fuel / Energy charges Hour 4.00 82.00 328.003 Pug cutting machine Hour 60.00 13.00 780.00

Fuel / Energy charges Hour 60.00 2.00 120.004 Planing machine Hour 88.00 66.00 5808.00

Fuel / Energy charges Hour 88.00 61.00 5368.005 Mobile derric crane Hour 5.00 261.00 1305.00

Fuel / Energy charges Hour 5.00 117.00 585.00

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GATES AND HOISTS

6 Grinding machine Hour 8.00 15.00 120.00Fuel / Energy charges Hour 8.00 20.00 160.00

7 Drilling machines Hour 16.00 15.00 240.00Fuel / Energy charges Hour 16.00 20.00 320.00

8 Sundries LS 20.00 22.50 450.00TOTAL Rs: 48865.00

Add for small Tools and Plants @ 1% Rs: 488.65Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 3290.90Add for Contrators' Overheads @ 5% Rs: 2443.25 Total hire charges of Machinery Rs: 55087.80

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 5.00 32.90 164.502 Crew for Plate shearing machine Hour 4.00 26.70 106.803 Crew for Planing machine Hour 88.00 42.75 3762.004 Crew for Drilling machine Hour 16.00 35.00 560.005 Crew for Grinding machine Hour 8.00 35.00 280.006 Foreman Day 37.00 108.65 4020.057 Marker / Fabricator / Erector Day 56.00 93.70 5247.208 Gas cutter Day 12.00 93.70 1124.409 Welder ( General ) Day 70.00 93.70 6559.00

10 Welder ( X - ray ) Day 8.00 103.07 824.5611 Helper fabrication / erection Day 180.00 81.60 14688.0012 Helper for cleaning / painting Day 7.00 81.60 571.2013 Painter Cl - II Day 17.00 81.60 1387.2014 Electrician Day 2.00 82.65 165.30

TOTAL Rs: 39460.21Add for small Tools and Plants @ 1% Rs: 394.60Add for Contractor' Profit @ 10% Rs: 3946.02Add for hidden cost on Labour @ 15% Rs: 5919.03Add for additional hidden cost on labour @ 10% Rs: 3946.02Add for Contrators' Overheads @ 5% Rs: 1973.01

Total cost of Labour Rs: 55638.90

ABSTRACT:A. Cost of Materials Rs: 331232.64B. Hire charges of Machinery Rs: 55087.80C. Cost of Labour Rs: 55638.90

Total Rs: 441959.33Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 14948.10Add for insurance charges @ 1% Rs: 4419.59Add for designs and drawings @ 2.5% Rs: 11048.98Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 11048.98Add for power supply arrangements @ 2.5% Rs: 11048.98Add for enabling works @ 2% Rs: 8839.19

Total Rs: 503313.16Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x5.193 tonnes @ Rs: 81.30 / tonne Rs: 844.38Add for transportation upto work site @ 3% Rs: 15099.39 Total cost for 5.193 tonne Rs: 519256.94

Rate per tonne Rs: 99990.00

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GATES AND HOISTS

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 20

ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type verticallift gate consisting of skin plate, vertical and horizontal girders, wheels, stiffeners, liftingbrackets, guide shoes, rubber seals etc., with all accessories for barrage including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coatof zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc.,complete as per specifications and approved drawings with all leads and lifts.

DATA: Consider upstream seal vertical lift roller gate. The gate leaf consists of skin plate, horizontalgirders, vertical end girders, stiffeners, wheels, gate guide shoes, brackets for pulleys, seals etc., with all accessories.Consider vertical lift roller gate for 13.72 m x 8.26 m opening for analysis.Details of material / Gas cutting / Welding considered for rate analysis are based on vertical liftroller gate drawings of Hipparagi Barrage.Weight of gate leaf in tonne for vertical lift gate based on empirical formula : Weight in tonnes = 0.0335 ( L^2 x H x h )^0.716 Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm.For vent opening of 13.72 x 8.26 m the approximate size of gate leaf will be 14.7 x 8.6 m.Head of water above sill level considered : 8.26 m Weight in tonnes = 0.0335 ( 14.7 x 14.7 x 8.6 x 8.26 ) ^ 0.716 : 33.289The actual weight of vertical lift barrage gate as per data sheet : 33.025 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials : as per fabrication drawings ( for details refer Item : 20 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel angles / beams / channels with 2.5 % wastage : 3382 kgStructural steel plates / flats with 2.5 % wastage : 29372 kg

b. Alloy steel components conforming to IS : 1570 :Wheel axles / Pins : 176 kg

c. Cast steel components conforming to IS : 1030 :Wheels : 656 kg

d. Alluminium / Bronze alloy components conforming to IS : 305 :Bearings / Bushes : 80 kg

e. Bolts / Nuts / Washers conforming to IS : 1363 :GI bolts / nuts / washers with 2.5 % wastage : 93 kgMS bolts / nuts / washers with 2.5 % wastage : 70 kg

f. Rubber seal conforming to IS : 11855 :Bottom seal ( flat uncladed ) : 14.5 RmSide seals ( bulb uncladed ) : 18 Rm

g. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 1574 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 14161 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 695 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 70 Rm

Total : 765 RmFor cutting structural steel sections to required sizes gas cutting and plate shearing machinefor plates less than 12 mm thick are considered.Length of steel to be cut by using gas manually : 200 mLength of steel to be cut by gas using pug cutting machine : 465 mLength of steel to be cut by gas using plate shearing machine : 100 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 100 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 155 hoursTime for cutting by plate shearing machine at ( av ) 10 m / hour : 10 hoursAcetelyne gas @ 0.6 cum / hour ( 255 x 0.60 ) : 153 cum

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GATES AND HOISTS

Oxygen gas @ 1.8 cum / hour ( 255 x 1.80 ) : 459 cumUse of gas cutting torch with 50 min / hr working ( 100 x 60 / 50 ) : 120 hoursUse of pug cutting machine with 50 min / hr working ( 155 x 60 / 50 ) : 186 hoursUse of plate shearing machine with 50 min / hr working ( 10 x 60 / 50 ) : 12 hours

3. Welding :Length of welding : 1837 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 1574 / 15 ) x 8 / 2 : 420 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 14161 / 15 ) x 8 / 6 : 1259 hoursTotal : 1679 hours

Deploy welding transformer for 1679 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 420 x 0.25 + 1259 x 0.75 ) : 1049 hours

4. Surface cleaning and painting :Painting area for barrage gate at 18 sqm / tonne : 595 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 595 sqm @ 9 sqm / ltr / coat : 66 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 595 sqm @ 6 sqm / ltr / coat : 298 ltrAs 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 at 8 sqm / ltr : 75 ltr

5. Requirement of other machinery :For lowering gate leaf use of tower crane for 4 hours considered.For handling of gate parts during fabrication and erection mobile derric crane for 50 hours and stationery derric crane for 100 hours considered.For drilling holes in skin plate and seal base / clamps use of drilling machine for 50 hoursconsidered. For grinding and finishing weld joints in skin plate and other locations 50 hours use of grinding machine considered.

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 318 hours 20 40 40 80Drilling holes for seal fixing 3 6 --- 6Fabricating by stitch welding 420 hours 26 52 --- 104Run welding 1259 hours 16 --- 158 158Joining units & wheel fixing 4 8 32Seal fixing & guide shoe fixing 1 2 4Aligning and lowering in position 1 2 4Cleaning / checking 1 2 --- 2 Total : 72 112 198 390

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 40 helper for 595 sqmFor painting 1 coat primer and 3 coats finishing paint at 15 sqm / day : 158 painter Cl-ll & 30 helper for 4 x 595 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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.

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GATES AND HOISTS

8. Use rate of materials :Cost of welding set @ Rs: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 33.025 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angle / beam / channel kg 3382.00 20.00 67640.00Plates / flats kg 29372.00 24.00 704928.00

3 Alloy steel componentsWheel axles / Pins kg 176.00 175.00 30800.00

4 Cast steel componentsWheels kg 656.00 85.00 55760.00

5 Alluminium / Bronze alloy componentsBearings / Bushes kg 80.00 380.00 30400.00

6 Bolt / Nut / WasherGI bolts / nuts / washers kg 93.00 60.00 5580.00MS bolts / nuts / washers kg 70.00 45.00 3150.00

7 Rubber sealsBottom seal ( flat uncladed ) Rm 14.50 120.00 1740.00Side seals ( bulb uncladed ) Rm 18.00 190.00 3420.00

8 Oxygen gas cum 459.00 40.00 18360.009 Acetyline gas cum 153.00 185.00 28305.00

10 Welding electrodes Nos 1574.00 4.00 6296.0011 Welding electrodes ( LH ) Nos 14161.00 6.00 84966.0012 Zinc rich epoxy primer ltr 66.00 525.00 34650.0013 Coal tar epoxy paint ltr 298.00 131.00 39038.0014 Rust cleaner / inhibitor ltr 75.00 175.00 13125.0015 Use rate welding holder set Hour 1679.00 3.38 5666.6316 Use rate gas cutting torch set Hour 120.00 1.88 225.0017 Wire brush Nos 10.00 25.00 250.0018 Sundries LS 100.00 22.50 2250.00

TOTAL Rs: 1136549.63Add for small Tools and Plants @ 1% Rs: 11365.50Add for Contractor' Profit @ 10% Rs: 113654.96Add for Contrators' Overheads @ 5% Rs: 56827.48

Total cost of Materials Rs: 1318397.57

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 1679.00 9.00 15111.00

Fuel / Energy charges Hour 1049.00 49.00 51401.002 Pug cutting machine Hour 186.00 13.00 2418.00

Fuel / Energy charges Hour 186.00 2.00 372.003 Plate shearing machine Hour 12.00 47.00 564.00

Fuel / Energy charges Hour 12.00 82.00 984.004 Tower crane Hour 4.00 763.00 3052.00

Fuel / Energy charges Hour 4.00 106.00 424.00

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GATES AND HOISTS

5 Mobile derric crane Hour 50.00 261.00 13050.00Fuel / Energy charges Hour 50.00 117.00 5850.00

6 Stationery derric crane Hour 100.00 50.00 5000.00Fuel / Energy charges Hour 100.00 5.00 500.00

7 Grinding machine Hour 50.00 15.00 750.00Fuel / Energy charges Hour 50.00 20.00 1000.00

8 Drilling machines Hour 50.00 15.00 750.00Fuel / Energy charges Hour 50.00 20.00 1000.00

9 Sundries LS 100.00 22.50 2250.00TOTAL Rs: 104476.00

Add for small Tools and Plants @ 1% Rs: 1044.76Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 6378.10Add for Contrators' Overheads @ 5% Rs: 5223.80 Total hire charges of Machinery Rs: 117122.66

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 50.00 32.90 1645.002 Crew for Tower crane Hour 4.00 36.05 144.203 Crew for Plate shearing machine Hour 12.00 26.70 320.404 Crew for Drilling machine Hour 50.00 35.00 1750.005 Crew for Grinding machine Hour 50.00 35.00 1750.006 Foreman Day 72.00 108.65 7822.807 Marker / Fabricator / Erector Day 112.00 93.70 10494.408 Gas cutter Day 40.00 93.70 3748.009 Welder ( General ) Day 142.00 93.70 13305.40

10 Welder ( X - ray grade ) Day 16.00 103.07 1649.1211 Khalasi Day 50.00 83.65 4182.5012 Helper fabrication / erection Day 390.00 81.60 31824.0013 Helper for cleaning / painting Day 70.00 81.60 5712.0014 Painter Cl - II Day 158.00 81.60 12892.8015 Electrician Day 20.00 82.65 1653.00

TOTAL Rs: 98893.62Add for small Tools and Plants @ 1% Rs: 988.94Add for Contractor' Profit @ 10% Rs: 9889.36Add for hidden cost on Labour @ 15% Rs: 14834.04Add for additional hidden cost on labour @ 10% Rs: 9889.36Add for Contrators' Overheads @ 5% Rs: 4944.68

Total cost of Labour Rs: 139440.00

ABSTRACT:A. Cost of Materials Rs: 1318397.57B. Hire charges of Machinery Rs: 117122.66C. Cost of Labour Rs: 139440.00

Total Rs: 1574960.23Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 34635.96Add for insurance charges @ 1.00% Rs: 15749.60Add for designs and drawings @ 2.5% Rs: 39374.01Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 39374.01Add for power supply arrangements @ 2.5% Rs: 39374.01Add for enabling works @ 2% Rs: 31499.20

Total Rs: 1774967.01

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GATES AND HOISTS

Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x33.025 tonnes @ Rs: 81.30 / tonne Rs: 5369.87Add for transportation upto work site @ 3% Rs: 53249.01 Total cost for 33.025 tonne Rs: 1833585.89

Rate per tonne Rs: 55520.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 21

ITEM: Design, fabrication, supply, erection and commissioning of structural steel hoist bridge consisting of columns, beams, bracings, stiffeners, ties, chequered plate covering, hand railing,ladder etc., with all accessories for supporting rope drum hoist for operating barrage gates including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying two coats of zinc chromate red oxide primer and three coats of synthetic enamel paint etc., complete with all leads and lifts.

DATA: Structural steel hoist bridge for supporting rope drum hoist for operating barrage gates consistsof steel columns and beams with cross beams, ties, bracings, stiffeners, hand railing, ladder,chequered plate covering, anchorages etc., with all accessories.Consider hoist bridge for supporting 50 t rope drum hoist.Consider 15 m span and 10 m over all height for bridge.Details of material / Gas cutting / Welding considered for rate analysis are based on structuralsteel bridge drawings for barrage gates of Hipparagi Barrage.Assessment of weight of structural steel for bridge:Columns with bracings, anchors, stiffeners etc @ 400 kg / m for 9 m ht : 3600.00 kgBeams with cross beams, stiffeners etc @ 400 kg / m for 15 m span : 6000.00 kg

Total : 9600.00 kgOther accessories such as railing, chequered plate, ladder etc @ 10 % 960.00 kg

Total : 10560.00 kgThe actual weight of hoist supporting bridge as per data sheet : 10239.00 kgConsider actual weight for data rate analysis.

1. Requirement of materials: as per fabrication drawings ( for details refer Item : 21 of Annexer )a. Structural steel conforming to IS : 2062 :

Structural steel angles / beams / channels with 2.5 % wastage : 4564 kgStructural steel plates / flats with 2.5 % wastage : 5567 kgChequered plate with 2.5 % wastage : 136 kg

b. MS pipes 32 mm dia : 32 RmMS pipes 25 mm dia : 64 Rm

c. Bolt / Nut / WasherMS bolt / Nut / Washers with 2.5 % wastage : 18.5 kg

d. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 388 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 3495 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 290 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 29 Rm

Total : 319 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 100 mLength of steel to be cut by gas using pug cutting machine : 219 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 50 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 73 hoursAcetelyne gas @ 0.6 cum / hour ( 123 x 0.60 ) : 74 cumOxygen gas @ 1.8 cum / hour ( 123 x 1.80 ) : 222 cumUse of gas cutting torch with 50 min / hr working ( 50 x 60 / 50 ) : 60 hoursUse of pug cutting machine with 50 min / hr working ( 73 x 60 / 50 ) : 88 hours

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3. Welding :Length of welding : 473 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 388 / 15 ) x 8 / 2 : 104 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 3495 / 15 ) x 8 / 6 : 311 hoursTotal : 415 hours

Deploy welding transformer for 415 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 104 x 0.25 + 311 x 0.75 ) : 259 hours 4. Surface cleaning and painting :

Painting area for hoist bridge @ 20 sqm per tonne : 205 sqm2 coats of zinc chromate red oxide primer .Quantity of primer paint for 205 sqm @ 12 sqm / ltr / coat : 35 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 205 sqm @ 12 sqm / ltr / coat : 51 ltrAs 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 at 8 sqm / ltr : 26 ltr

5. Requirement of other machinery :For handling of parts during fabrication and erection mobile derric crane for 20 hours and stationery derric crane for 40 hours considered.For drilling holes in plates 8 hours use of drilling machine considered.For grinding and finishing weld joints in liner plates 8 hours use of grinding machine considered.

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 148 hours 9 18 18 36Fabricating by stitch welding 104 hours 6 13 --- 26Run welding 311 hours 4 --- 39 39For erection of columns & bracings 2 4 --- 8For erection of beams / cross beams 4 8 --- 16For erection of railing / covering etc 1 2 --- 4Finishing / Cleaning 1 1 --- 1 Total : 27 46 57 130

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 14 helper for 205 sqmFor painting 2 coats primer and 3 coats finishing paint at 20 sqm / day : 51 painter Cl-ll & 10 helper for 5 x 205 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

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RATE ANALYSIS UNIT : 10.239 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel angles/ beams / channels kg 4564.00 20.00 91280.00

Structural steel plates / flats kg 5567.00 24.00 133608.00Chequered plate kg 136.00 25.20 3427.20

2 MS pipe 32 mm dia Rm 32.00 80.00 2560.00MS pipe 25 mm dia Rm 64.00 60.00 3840.00

3 Bolt / Nut / Washers kg 18.50 45.00 832.504 Oxygen gas cum 222.00 40.00 8880.005 Acetyline gas cum 74.00 185.00 13690.006 Welding electrodes Nos 388.00 4.00 1552.007 Welding electrodes ( LH ) Nos 3495.00 6.00 20970.008 Zinc chromate red oxide primer ltr 35.00 140.00 4900.009 Synthetic enamel paint ( 1st quality ) ltr 51.00 140.00 7140.00

10 Rust cleaner / inhibitor ltr 26.00 175.00 4550.0011 Use rate welding holder set Hour 415.00 3.38 1400.6312 Use rate gas cutting torch set Hour 60.00 1.88 112.5013 Wire brush Nos 5.00 25.00 125.0014 Sundries LS 50.00 22.50 1125.00

TOTAL Rs: 299992.83Add for small Tools and Plants @ 1% Rs: 2999.93Add for Contractor' Profit @ 10% Rs: 29999.28Add for Contrators' Overheads @ 5% Rs: 14999.64

Total cost of Materials Rs: 347991.68

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 415.00 9.00 3735.00

Fuel / Energy charges Hour 259.00 49.00 12691.002 Pug cutting machine Hour 88.00 13.00 1144.00

Fuel / Energy charges Hour 88.00 2.00 176.003 Mobile derric crane Hour 20.00 261.00 5220.00

Fuel / Energy charges Hour 20.00 117.00 2340.004 Stationery derric crane Hour 40.00 50.00 2000.00

Fuel / Energy charges Hour 40.00 5.00 200.005 Drilling machine Hour 8.00 15.00 120.00

Fuel / Energy charges Hour 8.00 20.00 160.006 Grinding machine Hour 8.00 15.00 120.00

Fuel / Energy charges Hour 8.00 20.00 160.007 Sundries LS 50.00 22.50 1125.00

TOTAL Rs: 29191.00Add for small Tools and Plants @ 1% Rs: 291.91Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 1685.20Add for Contrators' Overheads @ 5% Rs: 1459.55 Total hire charges of Machinery Rs: 32627.66

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 20.00 32.90 658.002 Crew for Drilling machine Hour 8.00 35.00 280.003 Crew for Grinding machine Hour 8.00 35.00 280.00

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4 Foreman Day 27.00 108.65 2933.555 Marker / Fabricator / Erector Day 46.00 93.70 4310.206 Gas cutter Day 18.00 93.70 1686.607 Welder ( General ) Day 39.00 93.70 3654.308 Helper fabrication / erection Day 130.00 81.60 10608.009 Helper for cleaning / painting Day 24.00 81.60 1958.40

10 Painter Cl - II Day 51.00 81.60 4161.6011 Electrician Day 5.00 82.65 413.25

TOTAL Rs: 30943.90Add for small Tools and Plants @ 1% Rs: 309.44Add for Contractor' Profit @ 10% Rs: 3094.39Add for hidden cost on Labour @ 15% Rs: 4641.59Add for additional hidden cost on labour @ 10% Rs: 3094.39Add for Contrators' Overheads @ 5% Rs: 1547.20

Total cost of Labour Rs: 43630.90

ABSTRACT:A. Cost of Materials Rs: 347991.68B. Hire charges of Machinery Rs: 32627.66C. Cost of Labour Rs: 43630.90

Total Rs: 424250.24Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 10294.91Add for insurance charges @ 1.00% Rs: 4242.50Add for designs and drawings @ 2.5% Rs: 10606.26Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 10606.26Add for power supply arrangements @ 2.5% Rs: 10606.26Add for enabling works @ 2% Rs: 8485.00

Total Rs: 479091.42Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x10.239 tonnes @ Rs: 81.30 / tonne Rs: 1664.86Add for transportation upto work site @ 3% Rs: 14372.74 Total cost for 10.239 tonne Rs: 495129.02

Rate per tonne Rs: 48360.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 22

ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity ropedrum hoist consisting of hoist platform, rope drum, pulleys, gear system, electri c motor, electro-magnetic brake system, manual operation assembly, position indicator, control panel, wire rope etc., with all accessories for operating vertical lift roller gates for barrageincluding 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 vertical lift barrage gate consists of hoist supporting frames, pulleysupports, pulleys, drive stool, rope drums, shafts, couplings, gears and pinions, plummerblocks, gear box, electric motor, hand operation assembly, brake, wire rope, gate positionindicator, switch box etc. with related accessories.Consider rope drum hoist for operating barrage gate for clear opening of 13.72 m x 8.26 m.Details of material / Gas cutting / Welding considered for rate analysis are based on rope drumhoist drawings for barrage gate of Hipparagi Barrage.Generally the capacity of hoist required for barrage gate will be 1.5 times the weight of gate.Weight of gate leaf in tonnes based on empirical formula : Weight in tonnes = 0.0335 ( L^2 x H x h )^0.716

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Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water above sill in Rm.For vent opening of 13.72 x 8.26 m the approximate size of gate leaf will be 14.7 x 8.6 m.Head of water above sill level considered : 8.26 m Weight in tonnes = 0.0335 ( 14.7 x 14.7 x 8.6 x 8.26 ) ^ 0.716 : 33.289Capacity of hoist with 25% reserve capacity : 1.5 x Weight of barrage gate( Capacity of hoist to be rounded off to next 10 tonne ) : 1.5 x 33.289

: 49.933 tonnes say : 50.00 tonnes

Weight of hoist with all accessories is assumed at 0.1 tonne per tonne capacity of hoist as thehoist is supported on steel bridge and no anchorages and base frames are required.Weight of hoist with all accessories ( 0.1 x 50 ) : 5.00 tonnesThe actual weight of barrage gate rope drum hoist as per data sheet : 5.069 tConsider actual weight for data rate analysis.

1. Requirement of materials: as per fabrication drawings ( for details refer Item : 22 of Annexer )a. Structural steel conforming to IS : 2062 :

Angles / Beams / Channels / Bars with 2.5 % wastage : 420.00 kgPlates / Flats with 2.5 % wastage : 225.00 kg

b. Cast steel components conforming to IS : 1030 :Rope drums 2 Nos / Gears : 1290.00 kgPinions : 98.00 kgPulleys 3 Nos / Couplings 2 Nos : 650.00 kgPlummer blocks / Hubs : 250.00 kg

c. Alloy steel steel components conforming to IS : 1570 :Shafts / Keys : 350.00 kgPins 96.00 kg

d. Alluminium/ Bronze alloy components conforming to IS : 305 :Bearings / Bush : 100.00 kg

e. Bolt / Nut / Washers conforming to IS : 1363 :MS Bolts / Nuts / Washers with 2.5 % wastage : 26.00 kg

f. Steel wire rope conforming ti IS 2266 :28 mm dia 6 / 37 construction 1 No 120 Rm @ 2.71 kg / m : 435.00 kg

g. Other components :Manual operation assembly : 1 No.Worm reducer ( size 800 ) : 1 NoElectric motor 12.5 hp : 1 No.Gate position indicator : 1 No.Ele-magnetic brake : 1 No.Electric cable / switch / control panel etc : 1 set

h. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 44 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 392 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 37 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 4 Rm

Total : 41 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 20 mLength of steel to be cut by gas using pug cutting machine : 21 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 10 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 7 hoursAcetelyne gas @ 0.6 cum / hour ( 17 x 0.60 ) : 10 cumOxygen gas @ 1.8 cum / hour ( 17 x 1.80 ) : 30 cumUse of gas cutting torch with 50 min / hr working ( 10 x 60 / 50 ) : 12 hours

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GATES AND HOISTS

Use of pug cutting machine with 50 min / hr working ( 7 x 60 / 50 ) : 9 hours 3. Welding :

Length of welding : 53 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 44 / 15 ) x 8 / 2 : 12 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 392 / 15 ) x 8 / 6 : 35 hoursTotal : 47 hours

Deploy welding transformer for 47 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 12 x 0.25 + 35 x 0.75 ) : 30 hours 4. Surface cleaning and painting :

Painting area for rope drum hoist at 20 sqm / tonne of str steel : 13 sqm2 coats of zinc chromate red oxide primer.Quantity of primer paint for 13 sqm @ 12 sqm / ltr / coat : 2 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 13 sqm @ 12 sqm / ltr /coat : 3.5 ltrAs 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 at 8 sqm / ltr : 1.5 ltr

5. Requirement of other machinery :For lifting and placing in position hoist drums, worm reducers, gears, floating shafts etc deploy tower crane or other suitable lifting device for 2 hours.For handling during fabrication and erection mobile derric crane for 10 hours considered.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

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections/ drilling holes 23 hours 1 3 3 6Fabricating by stitch welding 12 hours 1 2 --- 3Run welding 35 hours 1 --- 5 5Erection of hoist frame 1 1 --- 2Erection of drums / gears / shafts 1 2 --- 4Erection of pulleys / plummer blocks 1 2 --- 4Erection of worm reducers / brake / motor 1 1 --- 2Erection of other accessories 1 1 --- 2Erection of control panel / cabling 1 1 --- 1Checking and running without rope 1 1 --- 2Rope fixing and checking 1 1 --- 2Trial running by lowering / lifting gate 1 1 --- 2Final checking / Finishing / cleaning 1 1 --- 1 Total : 13 17 8 36

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 1 helpers for 13 sqmFor painting 2 coats primer and 3 coats finishing paint at 20 sqm / day : 3 painter Cl-ll & 1 helper for 5 x 13 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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.

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GATES AND HOISTS

8. Use rate of materials :Cost of welding set @ Rs: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 5.069 tonne wtA. MATERIALS: 50.00 t capacity Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / beams / channels / bars kg 420.00 20.00 8400.00Plates / flats kg 225.00 24.00 5400.00

2 Cast steel components :Rope drums 2 Nos / Gears kg 1290.00 95.00 122550.00Pinions kg 98.00 105.00 10290.00Pulleys 3 Nos / Couplings 2 Nos kg 650.00 85.00 55250.00Plummer blocks / Hubs kg 250.00 85.00 21250.00

3 Alloy steel componentsShafts / Keys kg 350.00 145.00 50750.00Pins kg 96.00 175.00 16800.00

4 Bronze alloy components :Bronze bearings / bush kg 100.00 380.00 38000.00

5 Wire rope 28 mm dia 6/37 construction kg 435.00 75.00 32625.006 MS Bolt / Nut / Washer kg 26.00 45.00 1170.007 Worm reducers No. 1.00 45000.00 45000.008 Electric motor 12.5 hp No. 1.00 16875.00 16875.009 Manual operating system No. 1.00 8437.50 8437.50

10 Gate position indicator No. 1.00 8437.50 8437.5011 Ele-magnetic brake No. 1.00 8437.50 8437.5012 Electric cable / switch / control panel etc LS 1.00 9000.00 9000.0013 Oxygen gas cum 30.00 40.00 1200.0014 Acetyline gas cum 10.00 185.00 1850.0015 Welding electrodes Nos 44.00 4.00 176.0016 Welding electrodes ( LH ) Nos 392.00 6.00 2352.0017 Zinc chromate red oxide primer ltr 2.00 140.00 280.0018 Synthetic enamel ( 1st quality ) paint ltr 3.50 140.00 490.0019 Rust cleaner / inhibitor ltr 1.50 175.00 262.5020 Grease kg 50.00 90.00 4500.0021 Use rate welding holder set Hour 47.00 3.38 158.6322 Use rate gas cutting torch set Hour 12.00 1.88 22.5023 Wire brush Nos 1.00 25.00 25.0024 Sundries LS 25.00 22.50 562.50

TOTAL Rs: 470551.63Add for small Tools and Plants @ 1% Rs: 4705.52Add for Contractor' Profit @ 10% Rs: 47055.16Add for Contrators' Overheads @ 5% Rs: 23527.58

Total cost of Materials Rs: 545839.89

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GATES AND HOISTS

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 47.00 9.00 423.00

Fuel / Energy charges Hour 47.00 49.00 2303.002 Tower crane 5 t capacity Hour 2.00 763.00 1526.00

Fuel / Energy charges Hour 2.00 106.00 212.003 Pug cutting machine Hour 9.00 13.00 117.00

Fuel / Energy charges Hour 9.00 2.00 18.004 Mobile derric crane Hour 10.00 261.00 2610.00

Fuel / Energy charges Hour 10.00 117.00 1170.005 Grinding machine Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.006 Drilling machines Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.007 Sundries LS 25.00 22.50 562.50

TOTAL Rs: 9081.50Add for small Tools and Plants @ 1% Rs: 90.82Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 434.55Add for Contrators' Overheads @ 5% Rs: 454.08 Total hire charges of Machinery Rs: 10060.94

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 10.00 32.90 329.002 Crew for Tower crane Hour 2.00 36.05 72.103 Crew for Drilling machine Hour 2.00 35.00 70.004 Crew for Grinding machine Hour 2.00 35.00 70.005 Foreman Day 13.00 108.65 1412.456 Marker / Fabricator / Erector Day 17.00 93.70 1592.907 Gas cutter Day 3.00 93.70 281.108 Welder ( General ) Day 5.00 93.70 468.509 Khalasi Day 4.00 83.65 334.60

10 Helper fabrication / erection Day 36.00 81.60 2937.6011 Helper for cleaning / painting Day 2.00 81.60 163.2012 Painter Cl - II Day 3.00 81.60 244.8013 Electrician Day 2.00 82.65 165.30

TOTAL Rs: 8141.55Add for small Tools and Plants @ 1% Rs: 81.42Add for Contractor' Profit @ 10% Rs: 814.16Add for hidden cost on Labour @ 15% Rs: 1221.23Add for additional hidden cost on labour @ 10% Rs: 814.16Add for Contrators' Overheads @ 5% Rs: 407.08

Total cost of Labour Rs: 11479.59

ABSTRACT:A. Cost of Materials Rs: 545839.89B. Hire charges of Machinery Rs: 10060.94C. Cost of Labour Rs: 11479.59

Total Rs: 567380.41Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 2907.97Add for insurance charges @ 1.00% Rs: 5673.80Add for designs and drawings @ 2.5% Rs: 14184.51

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GATES AND HOISTS

Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 14184.51Add for power supply arrangements @ 2.5% Rs: 14184.51Add for enabling works @ 2% Rs: 11347.61

Total Rs: 629863.32Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x5.069 tonnes @ Rs: 81.30 / tonne Rs: 824.22Add for transportation upto work site @ 3% Rs: 18895.90 Total cost for 5.069 tonne wt Rs: 649583.44

50.000 t capacityRate per tonne wt Rs: 128150.00

Rate per tonne capacity of hoist Rs: 12990.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 23

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sillbeam, wall plates, first stage anchors, anchor girders, anchor bars, trunnion supports etc., with all accessories for canal regulator radial gates including cost of all materials, labour, machinery, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zincrich 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 radial gate consist of sill beam / wall plates / anchor girders / anchor bars /trunnion supports etc., with all accessories. The weight of embedded parts for small radial gate will be generally at about 50 to 60 percent of weight of radial gate leaf.Consider embedded parts for radial gate for canal cross regulator opening of size 3 m x 3.7 m.Details of material / Gas cutting / Welding considered for rate analysis are based on embeddedparts drawings for radial gate of UKP - ALBC Cross regulator.Weight of embedded parts in tonne for canal regulator opening based on empirical formula : Weight of embedded parts in tonnes = 0.092 x ( L^2 x H x h )^0.673Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.092 x ( 3 x 3 x 3.9 x 3.7 ) ^ 0.673 : 2.433The actual weight of embedded parts as per data sheet : 2.404 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials: as per fabrication drawings ( for details refer Item : 23 of Annexer )a. Structural steel conforming ti IS : 2062 :

Structural steel angles / beams / channels / bars with 2.5 % wastage : 832 kgStructural steel plates / flats with 2.5 % wastage : 1512 kg

b. Alloy steel conforming to IS : 1570 :Stainless steel plates / flats : 53.00 kg

c. Bolt / Nut / Washer conforming to IS : 1363 :MS bolts and nuts with 2.5 % wastage : 67 kg

d. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 120 NosWelding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 16 NosWelding electrodes ( LH ) for run welding at 90 % of tota with 2.5 % wastage : 920 NosWelding electrodes ( SS ) for run welding at 90 % of tota with 2.5 % wastage : 144 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 97.00 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 10.00 Rm

Total : 107.00 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 40 mLength of steel to be cut by gas using pug cutting machine : 67 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 20 hours

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GATES AND HOISTS

Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 22 hoursAcetelyne gas @ 0.6 cum / hour ( 42 x 0.60 ) : 25 cumOxygen gas @ 1.8 cum / hour ( 42 x 1.80 ) : 75 cumUse of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) : 24 hoursUse of pug cutting machine with 50 min / hr working ( 22 x 60 / 50 ) : 26 hours

3. Welding :Length of welding : 142 mFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 120 + 16 ) x 8 / 15 / 2 : 36 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 920 + 144 ) x 8 / 15 / 6 : 95 hoursTotal : 131 hours

Deploy welding transformer for 131 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 36 x 0.25 + 95 x 0.75 ) : : 80 hours 4. Planing SS plates for seal seats :

For surface finishing of SS plates for wheel / seal tracks planing machine is considered.Length of SS plate for surface finishing by planing machine : 13.3 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 13.3 m SS plates ( 13.3 x 8 / 3 ) : 36 hours

5. Surface cleaning and painting :Painting area for embedded parts at 5 sqm / tonne : 12 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 12 sqm @ 9 sqm / ltr / coat : 1.5 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 12 sqm @ 6 sqm / ltr / coat : 8 ltrAs 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 at 8 sqm / ltr : 1.5 ltr

6. Requirement of other machinery :For drilling holes for anchor bolts 8 hours use of drilling machine considered.For finishing weld joints / edges 8 hours use of grinding machine considered.For handling of parts during fabrication and erection use of mobile derric crane for 4 hours and stationery derric crane for 8 hours considered.

7. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 50 hours 3 6 6 12Drilling holes for anchors / supports --- 1 --- 1Fabricating by stitch welding 36 hours 2 4 --- 8Run welding 95 hours 1 --- 12 12Erection of Anchor girders / anchor bars 2 4 --- 8Erection of first stage anchors --- 2 --- 2Erection of Sill beam / Wall plates 1 1 --- 2Finishing / Checking 1 1 --- 1 Total : 10 19 18 46

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 1 helper for 12 sqm.For painting 1 coat primer and 4 coats finishing paint at 15 sqm / day : 4 painter Cl-ll & 1 helper for 5 x 12 sqm.

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GATES AND HOISTS

For surface finishing of stainless steel plates for seal seats planing machine is considered. 8. Excise duty on supply :

Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 2.404 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Str steel angle / beam / channel / bars kg 832.00 20.00 16640.002 Structural steel plate / flats kg 1512.00 24.00 36288.003 Stainless steel plate / flats kg 53.00 90.00 4770.004 MS bolts and nuts kg 67.00 45.00 3015.005 Oxygen gas cum 75.00 40.00 3000.006 Acetyline gas cum 25.00 185.00 4625.007 Welding electrodes Nos 120.00 4.00 480.008 Welding electrodes ( LH ) Nos 920.00 6.00 5520.009 Welding electrodes ( stainless steel ) Nos 160.00 35.00 5600.00

10 Zinc rich epoxy primer ltr 1.50 525.00 787.5011 Coal tar epoxy paint ltr 8.00 131.00 1048.0012 Rust cleaner / inhibitor ltr 1.50 175.00 262.5013 Use rate welding holder set Hour 131.00 3.38 442.1314 Use rate gas cutting torch set Hour 24.00 1.88 45.0015 Wire brush Nos 1.00 25.00 25.0016 Sundries LS 10.00 22.50 225.00

TOTAL Rs: 82773.13Add for small Tools and Plants @ 1% Rs: 827.73Add for Contractor' Profit @ 10% Rs: 8277.31Add for Contrators' Overheads @ 5% Rs: 4138.66

Total cost of Materials Rs: 96016.83

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 131.00 9.00 1179.00

Fuel / Energy charges Hour 80.00 49.00 3920.002 Pug cutting machine Hour 26.00 13.00 338.00

Fuel / Energy charges Hour 26.00 2.00 52.003 Planing machine Hour 36.00 66.00 2376.00

Fuel / Energy charges Hour 36.00 61.00 2196.004 Mobile derric crane Hour 4.00 261.00 1044.00

Fuel / Energy charges Hour 4.00 117.00 468.005 Stationery derric crane Hour 8.00 50.00 400.00

Fuel / Energy charges Hour 8.00 5.00 40.006 Grinding machine Hour 8.00 15.00 120.00

Fuel / Energy charges Hour 8.00 20.00 160.00

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7 Drilling machines Hour 8.00 15.00 120.00Fuel / Energy charges Hour 8.00 20.00 160.00

8 Sundries LS 10.00 22.50 225.00TOTAL Rs: 12798.00

Add for small Tools and Plants @ 1% Rs: 127.98Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 722.10Add for Contrators' Overheads @ 5% Rs: 639.90 Total hire charges of Machinery Rs: 14287.98

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 4.00 32.90 131.602 Crew for Planing machine Hour 36.00 42.75 1539.003 Crew for Drilling machine Hour 8.00 35.00 280.004 Crew for Grinding machine Hour 8.00 35.00 280.005 Foreman Day 10.00 108.65 1086.506 Marker / Fabricator / Erector Day 19.00 93.70 1780.307 Gas cutter Day 6.00 93.70 562.208 Welder ( General ) Day 10.00 93.70 937.009 Welder ( X - ray ) Day 2.00 103.07 206.14

10 Helper fabrication / erection Day 46.00 81.60 3753.6011 Helper for cleaning / painting Day 2.00 81.60 163.2012 Painter Cl - II Day 4.00 81.60 326.4013 Electrician Day 1.00 82.65 82.65

TOTAL Rs: 11128.59Add for small Tools and Plants @ 1% Rs: 111.29Add for Contractor' Profit @ 10% Rs: 1112.86Add for hidden cost on Labour @ 15% Rs: 1669.29Add for additional hidden cost on labour @ 10% Rs: 1112.86Add for Contrators' Overheads @ 5% Rs: 556.43

Total cost of Labour Rs: 15691.31

ABSTRACT:A. Cost of Materials Rs: 96016.83B. Hire charges of Machinery Rs: 14287.98C. Cost of Labour Rs: 15691.31

Total Rs: 125996.12Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 4047.20Add for insurance charges @ 1.00% Rs: 1259.96Add for designs and drawings @ 2.5% Rs: 3149.90Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 3149.90Add for power supply arrangements @ 2.5% Rs: 3149.90Add for enabling works @ 2% Rs: 2519.92

Total Rs: 143272.91Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x2.404 tonnes @ Rs: 81.30 / tonne Rs: 390.89Add for transportation upto work site @ 3% Rs: 4298.19 Total cost for 2.404 tonne Rs: 147961.99

Rate per tonne Rs: 61550.00

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SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 24

ITEM: Design, fabrication, supply, erection, testing and commissioning of radial gate consistingof skin plate, stiffeners, horizontal girders, sector arms, trunnion assemblies, tie beam, pulleysupports, bracings, rubber seals, seal clamps etc., with all accessories for canal regulator including 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: Regulator radial gate consists of trunnions / sector arms / horizontal girders / Tee- supports / skin plate / tie beam / bracings for horizontal girders and sector arms / pulley blocks / sealswith all accessories.Sector arms are connected to trunions by bolts and nuts.Horizontal girders generally spaced at about 3 m apart are joined to sector arms by welding andare stiffened by vertical and diagonal stiffeners to form the main frame. Tee- sections are weldedto horizontal girders to make the frame regid and to support the skin plate. Skin plate is weldedto Tee-supports generally spaced vertically at about 40 cm apart.Consider radial gate for canal cross regulator opening of size 3 m x 3.7 m for analysis.Details of material / Gas cutting / Welding considered for rate analysis are based on radial gatedrawings of UKP - ALBC Cross regulator.Weight of gate leaf in tonne for 3 m x 3.7 m opening based on empirical formula : Weight of gate in tonnes = 0.1685 x ( L^2 x H x h )^0.673Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.1685 x ( 3^2 x 3.9 x 3.7 )^0.673 : 4.456The actual weight of radial gate leaf as per data sheet : 4.455 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials: as per fabrication drawings ( for details refer Item : 24 of Annexer )Structural steel :Structural steel angles / beams / channels / bars with 2.5 % wastage : 2215 kgStructural steel plates / flats with 2.5 % wastage : 2093 kgAlloy steel components :Pins : 41 kgCast steel components :Trunnion hub / Guide roller : 122 kgAlluminium / Bronze alloy components :Trunnion / Guide roller bush : 19 kgBolts / Nuts / Washers :GI bolts / nuts / washers with 2.5 % wastage : 16.5 kgMS bolts / nuts / washers with 2.5 % wastage : 55 kgZinc at 20 kg / trunnion ( 2 x 20 ) : 40 kgRubber seal :Bottom seal ( flat type ) : 3.1 RmSide seals ( Z - type ) : 10.2 RmWelding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 168 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 1515 Nos

2. Cutting :Total length of cutting assuming cutting for 2 sides : 108 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 11 Rm

Total : 119 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 60 mLength of steel to be cut by gas using pug cutting machine : 59 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 30 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 20 hours

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Acetelyne gas @ 0.6 cum / hour ( 50 x 0.60 ) : 30 cumOxygen gas @ 1.8 cum / hour ( 50 x 1.80 ) : 90 cumUse of gas cutting torch with 50 min / hr working ( 30 x 60 / 50 ) : 36 hoursUse of pug cutting machine with 50 min / hr working ( 20 x 60 / 50 ) : 24 hours

3. Bending machine:Assuming 1.5 m wide plates, length of plate for bending ( 3 x 5 / 1.5 ) : 10.00 mLength of Tee sections : 30.00 mLength of side seal cover angles ( 5 x 2 ) : 10.00 m

Total : 50.00 mAssuming 3 m bending / hour, time for bending 50 m ( 50 / 3 ) : 17 hoursWith 50 minutes / hour working deploy bending machine for : 20 hours

4. Welding :Length of welding : 196 RmFor stich welding @ 2 hrs usage / shift & @ 12 electrodes / hr

( 168 / 12 ) x 8 / 2 : 56 hoursFor run welding @ 6 hrs usage / shift & @ 12 electrodes / hr

( 1515 / 12 ) x 8 / 6 : 168 hoursTotal : 224 hours

Deploy welding transformer for 224 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding. ( 56 x 0.25 + 168 x 0.75 ) : 140 hours

5. Surface cleaning and painting : Painting area for radial gate at 20 sqm / tonne : 89 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 89 sqm @ 9 sqm / ltr / coat : 10 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 89 sqm @ 6 sqm / ltr / coat : 45 ltrAs 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 at 8 sqm / ltr : 11 ltr

6. Requirement of other machinery :For drilling holes in skin plate and seal clamps for seal fixing 16 hours use of drilling machine considered. For grinding and finishing weld joints in skin plate and other locations 8 hours use of grinding machine considered.For handling of parts during fabrication and erection use of mobile derric crane for 10 hours and stationery derric crane 20 hours considered.

7. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 60 hours 4 8 8 16Bending sections 20 hours 1 2 --- 4Drilling holes for seal fixing 1 2 --- 2Fabricating by stitch welding 56 hours 3 7 --- 14Run welding 168 hours 2 --- 21 21Erection of trunnion and tie beam 1 2 --- 4Erection of H -girders / Sector arms 1 2 --- 4Erection of vertical stiffeners 1 2 --- 4Erection of skin plates 1 2 --- 4Erection of bracings / Zinc filling 1 2 --- 4Seal fixing 1 2 --- 2Finishing / checking / cleaning 1 1 --- 1 Total : 18 32 29 80

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Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 6 helper for 89 sqmFor painting 1 coat primer and 3 coats finishing paint at 15 sqm / day : 24 painter Cl-ll & 6 helper for 4x89 sqm

8. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 4.455 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / beams / channels / bars kg 2215.00 20.00 44300.00Plates / flats kg 2093.00 24.00 50232.00

2 Cast steel componentsTrunnion hubs / Guide rollers kg 122.00 85.00 10370.00

3 Alloy steel componentsTrunnion pins kg 41.00 175.00 7175.00

4 Alluminium / Bronze alloy componentsBush for Trunnion / Guide roller kg 19.00 380.00 7220.00

5 Bolt / Nut / WasherGI bolts / nuts / washers kg 16.50 60.00 990.00MS bolts / nuts / washers kg 55.00 45.00 2475.00

6 Zinc for trunnion seating kg 40.00 100.00 4000.007 Rubber seals

Bottom seal Rm 3.10 120.00 372.00Side seals Rm 10.20 240.00 2448.00

8 Oxygen gas cum 90.00 40.00 3600.009 Acetyline gas cum 30.00 185.00 5550.00

10 Welding electrodes Nos 168.00 4.00 672.0011 Welding electrodes ( LH ) Nos 1515.00 6.00 9090.0012 Zinc rich epoxy primer ltr 10.00 525.00 5250.0013 Coal tar epoxy paint ltr 45.00 131.00 5895.0014 Rust cleaner / inhibitor ltr 11.00 175.00 1925.0015 Use rate welding holder set Hour 224.00 3.38 756.0016 Use rate gas cutting torch set Hour 36.00 1.88 67.5017 Wire brush Nos 2.00 25.00 50.0018 Sundries LS 25.00 22.50 562.50

TOTAL Rs: 163000.00Add for small Tools and Plants @ 1% Rs: 1630.00Add for Contractor' Profit @ 10% Rs: 16300.00Add for Contrators' Overheads @ 5% Rs: 8150.00

Total cost of Materials Rs: 189080.00

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GATES AND HOISTS

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 224.00 9.00 2016.00

Fuel / Energy charges Hour 140.00 49.00 6860.002 Pug cutting machine Hour 24.00 13.00 312.00

Fuel / Energy charges Hour 24.00 2.00 48.003 Bending machine Hour 20.00 31.00 620.00

Fuel / Energy charges Hour 20.00 61.00 1220.004 Mobile derric crane Hour 10.00 261.00 2610.00

Fuel / Energy charges Hour 10.00 117.00 1170.005 Stationery derric crane Hour 20.00 50.00 1000.00

Fuel / Energy charges Hour 20.00 5.00 100.006 Grinding machine Hour 8.00 15.00 120.00

Fuel / Energy charges Hour 8.00 20.00 160.007 Drilling machines Hour 16.00 15.00 240.00

Fuel / Energy charges Hour 16.00 20.00 320.008 Sundries LS 25.00 22.50 562.50

TOTAL Rs: 17358.50Add for small Tools and Plants @ 1% Rs: 173.59Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 1044.05Add for Contrators' Overheads @ 5% Rs: 867.93 Total hire charges of Machinery Rs: 19444.06

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 10.00 32.90 329.002 Crew for Bending machine Hour 20.00 26.70 534.003 Crew for Drilling machine Hour 16.00 35.00 560.004 Crew for Grinding machine Hour 8.00 35.00 280.005 Foreman Day 18.00 108.65 1955.706 Marker / Fabricator / Erector Day 32.00 93.70 2998.407 Gas cutter Day 8.00 93.70 749.608 Welder ( General ) Day 19.00 93.70 1780.309 Welder ( X - ray ) Day 2.00 103.07 206.14

10 Helper fabrication / erection Day 80.00 81.60 6528.0011 Helper for cleaning / painting Day 12.00 81.60 979.2012 Painter Cl - II Day 24.00 81.60 1958.4013 Electrician Day 3.00 82.65 247.95

TOTAL Rs: 19106.69Add for small Tools and Plants @ 1% Rs: 191.07Add for Contractor' Profit @ 10% Rs: 1910.67Add for hidden cost on Labour @ 15% Rs: 2866.00Add for additional hidden cost on labour @ 10% Rs: 1910.67Add for Contrators' Overheads @ 5% Rs: 955.33

Total cost of Labour Rs: 26940.43

ABSTRACT:A. Cost of Materials Rs: 189080.00B. Hire charges of Machinery Rs: 19444.06C. Cost of Labour Rs: 26940.43

Total Rs: 235464.49Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 6261.91

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Add for insurance charges @ 1.00% Rs: 2354.64Add for designs and drawings @ 2.5% Rs: 5886.61Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 5886.61Add for power supply arrangements @ 2.5% Rs: 5886.61Add for enabling works @ 2% Rs: 4709.29

Total Rs: 266450.17Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x4.455 tonnes @ Rs: 81.30 / tonne Rs: 724.38Add for transportation upto work site @ 3% Rs: 7993.51 Total cost for 4.455 tonne Rs: 275168.06

Rate per tonne Rs: 61770.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 25

ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacityelectrically operated rope drum hoist consisting of hoist platform, rope drum, gear system, electric motor, electro- magnetic brake system, control panel, wire rope, ladder etc., with all accessories for operating canal regulator radial 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 enamelpaint etc., complete with all leads and lifts.

DATA: Rope drum hoist for radial gate consists of embedded parts for anchorage, hoist supporting structure, pulley supporting structures, pulleys, drive stool, rope drums, couplings, shafts,gears and pinions, plummer blocks, worm reducer, floating shaft, 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 canal regulator opening of size 3 m x 3.7 m.Details of material / Gas cutting / Welding considered for rate analysis are based on rope drumhoist drawings for radial gate of UKP - ALBC Cross regulator.Generally the capacity of rope drum hoist for small radial gate will be about 2 times the weightof radial gate.Weight of gate leaf in tonne for 3 m x 3.7 m spillway opening based on empirical formula : Weight of gate in tonnes = 0.1685 x ( L^2 x H x h )^0.673Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.1685 x ( 3^2 x 3.9 x 3.7 )^0.673 : 4.456Capacity of hoist required in tonnes with 25% reserve capacity : 2 x Wt of gate( Capacity of hoist to be rounded off to next 5 tonne ) ( 2 x 4.456 ) : 8.912 tonnes

say : 10 tonnesActual capacity of hoist as per data : 10 tonnesWeight of hoist with all accessories is assumed at 0.3 tonne per tonne capacity of hoist.Weight of hoist with all accessories ( 0.30 x 10 ) : 3.000 tonnesThe actual weight of regulator radial gate rope drum hoist as per data sheet : 3.002 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials: as per fabrication drawings ( for details refer Item : 25 of Annexer )a. Structural steel conforming to IS : 2062 :

Angles / Beams / Channels / Bars with 2.5 % wastage : 1269 kgPlates / Flats with 2.5 % wastage : 544 kgChequered plate 195 kg

b. Cast steel components conforming to IS : 1030 :Rope drums 2 Nos / Gears : 384 kgPinions : 14 kgPulleys 6 Nos : 108 kgPlummer blocks / Hubs : 47 kg

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c. Alloy steel components conforming to IS : 1570 :Shafts : 75 kgPins 24 kg

d. Alluminium/ Bronze alloy components conforming to IS : 305 :Bearings / Bush : 11 kg

e. Bolt / Nut / Washers conforming to IS : 1363 :MS Bolts / Nuts / Washers with 2.5 % wastage : 68 kg

f. Steel wire rope conforming to IS : 2266 :12 mm dia 6 / 36 construction 2 Nos 35 m each @ 0.6 kg / Rm : 42 kg

g. Other components :Manual operating system : 1 No.Worm reducers : 1 No.Electric motor 2 hp : 1 No.Ele-magnetic brake : 1 No.Wire rope sockets : 2 NosMS pipe 32 mm dia : 10.5 RmElectric cable / switch / control panel etc : 1 set

h. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 79 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 712 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 86 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 9 Rm

Total : 95 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 78 RmLength of steel to be cut by gas using pug cutting machine : 17 RmTime for gas cutting manually assuming average cutting progress of 2 m / hour : 39 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 6 hoursAcetelyne gas @ 0.6 cum / hour ( 45 x 0.60 ) : 27 cumOxygen gas @ 1.8 cum / hour ( 45 x 1.80 ) : 81 cumUse of gas cutting torch with 50 min / hr working ( 39 x 60 / 50 ) : 47 hoursUse of pug cutting machine with 50 min / hr working ( 6 x 60 / 50 ) : 7 hours

3. Welding :Length of welding : 130 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 79 / 15 ) x 8 / 2 : 21 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 712 / 15 ) x 8 / 6 : 63 hoursTotal : 84 hours

Deploy welding transformer for 84 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 21 x 0.25 + 63 x 0.75 ) : 53 hours 4. Surface cleaning and painting :

Painting area at 20 sqm / t of str steel ( 1.96x20 ) : 39 sqm2 coats of zinc chromate red oxide primer.Quantity of primer paint for 39 sqm @ 12 sqm / ltr / coat : 6.5 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 39 sqm @ 12 sqm / ltr / coat : 10 ltrAs 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 at 8 sqm / ltr : 5 ltr

5. Requirement of other machinery :For handling of parts during fabrication and erection use of mobile derric crane for 4 hours and

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GATES AND HOISTS

stationery derric crane for 8 hours considered.For drilling holes for bolts 16 hours use of drilling machine considered. For grinding and finishing weld joints 8 hours use of grinding machine considered

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 54 hours 3 7 7 14Drilling holes for pins / bolts fixing 1 1 --- 1Fabricating by stitch welding 21 hours 2 3 --- 6Run welding 63 hours 1 --- 8 8Erection of anchors 1 1 --- 1Erection of drums and gears 1 2 --- 4Erection of floating shaft / pulleys 1 1 --- 2Erection of worm reducers / brake / motor 1 2 --- 4Erection of other accessories / cabling 1 1 --- 2Checking and trial running without ropes 1 1 --- 2Rope fixing and checking 1 1 --- 2Finishing / cleaning --- 1 --- 1Trial running for lifting / lowering gate 1 1 --- 2 Total : 15 22 15 49

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 3 helpers for 39 sqmFor painting 2 coats primer and 3 coats finishing paint at 20 sqm / day : 10 painter Cl-ll & 2 helpers for 5 x 39 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 3.002 tonneA. MATERIALS: 10.00 t capacity Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / beams / channels / bars kg 1269.00 20.00 25380.00Plates / flats kg 544.00 24.00 13056.00Chequered plate kg 195.00 25.20 4914.00

2 Cast steel components :Rope drums 2 Nos / Gears kg 384.00 95.00 36480.00Pinions kg 14.00 105.00 1470.00Pulleys 6 Nos kg 108.00 85.00 9180.00Plummer blocks / Couplings kg 47.00 85.00 3995.00

3 Alloy steel componentsShafts kg 75.00 145.00 10875.00Pins kg 24.00 175.00 4200.00

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4 Bronze alloy components :Bronze bearings / bush kg 11.00 380.00 4180.00

5 Wire rope 12 mm dia 6/36 construction kg 42.00 75.00 3150.006 MS Bolt / Nut / Washer kg 68.00 45.00 3060.007 Worm reducers No. 1.00 39375.00 39375.008 Electric motor 2 hp No. 1.00 11250.00 11250.009 Manual operating system No. 1.00 8437.50 8437.50

10 Ele-magnetic brake No. 1.00 8437.50 8437.5011 Wire rope sockets No 2.00 562.50 1125.0012 Electric cable / switch / control panel etc LS 1.00 5625.00 5625.0013 Oxygen gas cum 81.00 40.00 3240.0014 Acetyline gas cum 27.00 185.00 4995.0015 Welding electrodes Nos 79.00 4.00 316.0016 Welding electrodes ( LH ) Nos 712.00 6.00 4272.0017 Zinc chromate red oxide primer ltr 6.50 140.00 910.0018 Synthetic enamel ( 1st quality ) paint ltr 10.00 140.00 1400.0019 Rust cleaner / inhibitor ltr 5.00 175.00 875.0020 Grease kg 10.00 90.00 900.0021 Use rate welding holder set Hour 84.00 3.38 283.5022 Use rate gas cutting torch set Hour 47.00 1.88 88.1323 Wire brush Nos 1.00 25.00 25.0024 Sundries LS 50.00 22.50 1125.00

TOTAL Rs: 212619.63Add for small Tools and Plants @ 1% Rs: 2126.20Add for Contractor' Profit @ 10% Rs: 21261.96Add for Contrators' Overheads @ 5% Rs: 10630.98

Total cost of Materials Rs: 246638.77

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 84.00 9.00 756.00

Fuel / Energy charges Hour 53.00 49.00 2597.002 Pug cutting machine Hour 7.00 13.00 91.00

Fuel / Energy charges Hour 7.00 2.00 14.003 Mobile derric crane Hour 4.00 261.00 1044.00

Fuel / Energy charges Hour 4.00 117.00 468.004 Stationery derric crane Hour 8.00 50.00 400.00

Fuel / Energy charges Hour 8.00 5.00 40.005 Grinding machine Hour 8.00 15.00 120.00

Fuel / Energy charges Hour 8.00 20.00 160.006 Drilling machines Hour 16.00 15.00 240.00

Fuel / Energy charges Hour 16.00 20.00 320.007 Sundries LS 25.00 22.50 562.50

TOTAL Rs: 6812.50Add for small Tools and Plants @ 1% Rs: 68.13Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 416.15Add for Contrators' Overheads @ 5% Rs: 340.63 Total hire charges of Machinery Rs: 7637.40

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 4.00 32.90 131.602 Crew for Drilling machine Hour 16.00 35.00 560.00

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3 Crew for Grinding machine Hour 8.00 35.00 280.004 Foreman Day 15.00 108.65 1629.755 Marker / Fabricator / Erector Day 22.00 93.70 2061.406 Gas cutter Day 7.00 93.70 655.907 Welder ( General ) Day 8.00 93.70 749.608 Helper fabrication / erection Day 49.00 81.60 3998.409 Helper for cleaning / painting Day 5.00 81.60 408.00

10 Painter Cl - II Day 10.00 81.60 816.0011 Electrician Day 2.00 82.65 165.30

TOTAL Rs: 11455.95Add for small Tools and Plants @ 1% Rs: 114.56Add for Contractor' Profit @ 10% Rs: 1145.60Add for hidden cost on Labour @ 15% Rs: 1718.39Add for additional hidden cost on labour @ 10% Rs: 1145.60Add for Contrators' Overheads @ 5% Rs: 572.80

Total cost of Labour Rs: 16152.89

ABSTRACT:A. Cost of Materials Rs: 246638.77B. Hire charges of Machinery Rs: 7637.40C. Cost of Labour Rs: 16152.89

Total Rs: 270429.05Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 3211.69Add for insurance charges @ 1.00% Rs: 2704.29Add for designs and drawings @ 2.5% Rs: 6760.73Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 6760.73Add for power supply arrangements @ 2.5% Rs: 6760.73Add for enabling works @ 2% Rs: 5408.58

Total Rs: 302035.79Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x3.002 tonnes @ Rs: 81.30 / tonne Rs: 488.13Add for transportation upto work site @ 3% Rs: 9061.07 Total cost for 3.002 tonne Rs: 311584.99

10.000 t capacityRate per tonne Rs: 103790.00

Rate per tonne capacity of hoist Rs: 31160.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 26

ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacitymanually operated rope drum hoist consisting of hoist platform, rope drum, gear system,brake system, wire rope, ladder etc., with all accessories for operating canal regulatorradial gate including cost of all materials, machinery, labour, cutting, aligning, anchoring,welding, finishing, cleaning, applying two coats of zinc chromate red oxide primer and threecoats of approved synthetic enamel paint etc., complete with all leads and lifts.

DATA: Rope drum hoist for radial gate consists of embedded parts for anchorage, hoist supporting structure, pulley supporting structures, pulleys, drive stool, rope drums, couplings, shafts,gears and pinions, plummer blocks, worm reducer, floating shaft, hand operation assembly,brake, wire rope, gate position indicator etc. with related accessories.Consider rope drum hoist for radial gate for canal regulator opening of size 3 m x 3.7 m.Details of material / Gas cutting / Welding considered for rate analysis are based on rope drumhoist drawings for radial gate of UKP - ALBC Cross regulator without considering drive unit.

Generally the capacity of rope drum hoist for small radial gate will be about 2 times the weight

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of radial gate.Weight of gate leaf in tonne for 3 m x 3.7 m spillway opening based on empirical formula : Weight of gate in tonnes = 0.1685 x ( L^2 x H x h )^0.673Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.1685 x ( 3^2 x 3.9 x 3.7 )^0.673 : 4.456Capacity of hoist required in tonnes with 25% reserve capacity : 2 x Wt of gate( Capacity of hoist to be rounded off to next 5 tonne ) ( 2 x 4.456 ) : 8.912 tonnes

say : 10 tonnesWeight of hoist with all accessories is assumed at 0.3 tonne per tonne capacity of hoist. Weight of hoist with all accessories ( 0.3 x 10 ) : 3.000 tonnesLess weight of drive unit ( electric motor / cover etc ) 0.200 tonneWeight of manually operated hoist 2.800 tonnesThe actual weight of regulator radial gate rope drum hoist as per data sheet : 2.804 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials: as per fabrication drawings ( for details refer Item : 26 of Annexer )a. Structural steel conforming to IS : 2062 :

Angles / Beams / Channels / Bars with 2.5 % wastage : 1229 kgPlates / Flats with 2.5 % wastage : 453 kgChequered plate 195 kg

b. Cast steel components conforming to IS : 1030 :Rope drums 2 Nos / Gears : 384 kgPinions : 14 kgPulleys 6 Nos : 108 kgPlummer blocks / Hubs : 47 kg

c. Alloy steel components conforming to IS : 1570 :Shafts : 75 kgPins 24 kg

d. Alluminium/ Bronze alloy components conforming to IS : 305 :Bearings / Bush : 11 kg

e. Bolt / Nut / Washers conforming to IS : 1363 :MS Bolts / Nuts / Washers with 2.5 % wastage : 64 kg

f. Steel wire rope conforming to IS : 2266 :12 mm dia 6 / 36 construction 2 Nos 35 m each @ 0.6 kg / Rm : 42 kg

g. Other components :Manual operating system : 1 No.Worm reducers : 1 No.Wire rope sockets : 2 NosMS pipe 32 mm dia : 10.5 Rm

h. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 69 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 622 Nos

2. Cutting :Length of cutting assuming cutting for 2 sides : 73 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 7 Rm

Total : 80 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 70 RmLength of steel to be cut by gas using pug cutting machine : 20 RmTime for gas cutting manually assuming average cutting progress of 2 m / hour : 35 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 7 hoursAcetelyne gas @ 0.6 cum / hour ( 42 x 0.60 ) : 25 cumOxygen gas @ 1.8 cum / hour ( 42 x 1.80 ) : 75 cumUse of gas cutting torch with 50 min / hr working ( 35 x 60 / 50 ) : 42 hours

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Use of pug cutting machine with 50 min / hr working ( 7 x 60 / 50 ) : 8 hours 3. Welding :

Length of welding : 113 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 69 / 15 ) x 8 / 2 : 18 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 622 / 15 ) x 8 / 6 : 55 hoursTotal : 73 hours

Deploy welding transformer for 73 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 18 x 0.25 + 55 x 0.75 ) : 46 hours 4. Surface cleaning and painting :

Painting area at 20 sqm / t of str steel ( 1.82 x 20 ) : 36 sqm2 coats of zinc chromate red oxide primer.Quantity of primer paint for 36 sqm @ 12 sqm / ltr / coat : 6 ltr3 coats of synthetic enamel paint.Quantity of synthetic enamel paint for 36 sqm @ 12 sqm / ltr / coat : 9 ltrAs 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 at 8 sqm / ltr : 4.5 ltr

5. Requirement of other machinery :For handling of parts during fabrication and erection use of mobile derric crane for 4 hours andstationery derric crane for 8 hours considered.For drilling holes for bolts 16 hours use of drilling machine considered. For grinding and finishing weld joints 8 hours use of grinding machine considered

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 50 hours 3 6 6 12Drilling holes for pins / bolts fixing 1 1 --- 1Fabricating by stitch welding 18 hours 1 2 --- 4Run welding 55 hours 1 --- 7 7Erection of anchors 1 1 --- 1Erection of drums and gears 1 2 --- 4Erection of floating shaft / pulleys 1 1 --- 2Erection of worm reducers / brake 1 2 --- 4Erection of other accessories 1 1 --- 2Checking and trial running without ropes 1 1 --- 2Rope fixing and checking 1 1 --- 2Finishing / cleaning --- 1 --- 1Trial running for lifting / lowering gate 1 1 --- 2 Total : 14 20 13 44

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 2 helpers for 36 sqmFor painting 2 coats primer and 3 coats finishing paint at 20 sqm / day : 9 painter Cl-ll & 2 helpers for 5 x 36 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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.

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8. Use rate of materials :Cost of welding set @ Rs: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 2.804 tonneA. MATERIALS: 10.00 t capacity Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / beams / channels / bars kg 1229.00 20.00 24580.00Plates / flats kg 453.00 24.00 10872.00Chequered plate kg 195.00 25.20 4914.00

2 Cast steel components :Rope drums 2 Nos / Gears kg 384.00 95.00 36480.00Pinions kg 14.00 105.00 1470.00Pulleys 6 Nos kg 108.00 85.00 9180.00Plummer blocks / Couplings kg 47.00 85.00 3995.00

3 Alloy steel componentsShafts kg 75.00 145.00 10875.00Pins kg 24.00 175.00 4200.00

4 Bronze alloy components :Bronze bearings / bush kg 11.00 380.00 4180.00

5 Wire rope 12 mm dia 6/36 construction kg 42.00 75.00 3150.006 MS Bolt / Nut / Washer kg 64.00 45.00 2880.007 Worm reducers No. 1.00 39375.00 39375.009 Manual operating system No. 1.00 8437.50 8437.50

10 Brake No. 1.00 2250.00 2250.0011 Wire rope sockets No 2.00 562.50 1125.0013 Oxygen gas cum 75.00 40.00 3000.0014 Acetyline gas cum 25.00 185.00 4625.0015 Welding electrodes Nos 69.00 4.00 276.0016 Welding electrodes ( LH ) Nos 622.00 6.00 3732.0017 Zinc chromate red oxide primer ltr 6.00 140.00 840.0018 Synthetic enamel ( 1st quality ) paint ltr 9.00 140.00 1260.0019 Rust cleaner / inhibitor ltr 4.50 175.00 787.5020 Grease kg 10.00 90.00 900.0021 Use rate welding holder set Hour 73.00 3.38 246.3822 Use rate gas cutting torch set Hour 42.00 1.88 78.7523 Wire brush Nos 1.00 25.00 25.0024 Sundries LS 25.00 22.50 562.50

TOTAL Rs: 184296.63Add for small Tools and Plants @ 1% Rs: 1842.97Add for Contractor' Profit @ 10% Rs: 18429.66Add for Contrators' Overheads @ 5% Rs: 9214.83

Total cost of Materials Rs: 213784.09

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 73.00 9.00 657.00

Fuel / Energy charges Hour 46.00 49.00 2254.00

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2 Pug cutting machine Hour 8.00 13.00 104.00Fuel / Energy charges Hour 8.00 2.00 16.00

3 Mobile derric crane Hour 4.00 261.00 1044.00Fuel / Energy charges Hour 4.00 117.00 468.00

4 Stationery derric crane Hour 8.00 50.00 400.00Fuel / Energy charges Hour 8.00 5.00 40.00

5 Grinding machine Hour 8.00 15.00 120.00Fuel / Energy charges Hour 8.00 20.00 160.00

6 Drilling machines Hour 16.00 15.00 240.00Fuel / Energy charges Hour 16.00 20.00 320.00

7 Sundries LS 25.00 22.50 562.50TOTAL Rs: 6385.50

Add for small Tools and Plants @ 1% Rs: 63.86Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 382.05Add for Contrators' Overheads @ 5% Rs: 319.28 Total hire charges of Machinery Rs: 7150.68

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 4.00 32.90 131.602 Crew for Drilling machine Hour 16.00 35.00 560.003 Crew for Grinding machine Hour 8.00 35.00 280.004 Foreman Day 14.00 108.65 1521.105 Marker / Fabricator / Erector Day 20.00 93.70 1874.006 Gas cutter Day 6.00 93.70 562.207 Welder ( General ) Day 7.00 93.70 655.908 Helper fabrication / erection Day 44.00 81.60 3590.409 Helper for cleaning / painting Day 4.00 81.60 326.40

10 Painter Cl - II Day 9.00 81.60 734.4011 Electrician Day 2.00 82.65 165.30

TOTAL Rs: 10401.30Add for small Tools and Plants @ 1% Rs: 104.01Add for Contractor' Profit @ 10% Rs: 1040.13Add for hidden cost on Labour @ 15% Rs: 1560.20Add for additional hidden cost on labour @ 10% Rs: 1040.13Add for Contrators' Overheads @ 5% Rs: 520.07

Total cost of Labour Rs: 14665.83

ABSTRACT:A. Cost of Materials Rs: 213784.09B. Hire charges of Machinery Rs: 7150.68C. Cost of Labour Rs: 14665.83

Total Rs: 235600.60Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 2945.23Add for insurance charges @ 1.00% Rs: 2356.01Add for designs and drawings @ 2.5% Rs: 5890.01Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 5890.01Add for power supply arrangements @ 2.5% Rs: 5890.01Add for enabling works @ 2% Rs: 4712.01

Total Rs: 263283.89Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x2.804 tonnes @ Rs: 81.30 / tonne Rs: 455.93

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GATES AND HOISTS

Add for transportation upto work site @ 3% Rs: 7898.52 Total cost for 2.804 tonne Rs: 271638.34

10.000 t capacityRate per tonne Rs: 96880.00

Rate per tonne capacity of hoist Rs: 27160.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 27

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( with top seal seat ) consisting of sill beam, wheel tracks, seal tracks, guide rails, groove lining upto top etc.,with all accessories for vertical lift roller gate for canal escape / regulator including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paintetc., complets as per specifications and approved drawings with all leads and lifts.

DATA: Embedded parts for canal escape / regulator gate consist of sill beam, wheel / seal tracks, groove lining upto top, gate guide with all accessories such as first stage anchors.Weight of embedded parts with groove lining for such small gates will be about 150 percent of gate weight.Consider embedded parts for canal escape / regulator gate for opening of size 2 m x 2 m. Details of material / Gas cutting / Welding considered for rate analysis are based on embeddedparts drawings for vertical lift roller gate of UKP - ALBC Canal escape.Weight of gate leaf in tonne for 2 m x 2 m opening based on empirical formula : Size of gate : 2.5 m x 2.2 m Head of water above sill : 3.7 m Weight of embedded parts in tonnes = 0.1332 x ( L^2 x H x h )^0.659Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.1332 x ( 2.5 x 2.5 x 2.2 x 3.7 ) ^ 0.659 : 1.775 tonnesThe actual weight of embedded parts as per data sheet : 1.784 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials: as per fabrication drawings ( for details refer Item : 27 of Annexer )Structural steel conforming to IS : 2062 :Structural steel angles / beams / channels / bars with 2.5 % wastage : 1219 kgStructural steel plates / flats with 2.5 % wastage : 527 kgAlloy steel components conforming to IS : 1570 :Stainless steel plates / flats : 82.00 kgBolt / Nut / Washer conforming to IS : 1363 :MS bolts and nuts with 2.5 % wastage : 1 kgWelding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 121 NosWelding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 23 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 1094 NosWelding electrodes ( SS ) for run welding at 90 % of total with 2.5 % wastage : 210 Nos

2. Cutting :Total length of cutting assuming cutting for 2 sides : 40 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 4 Rm

Total : 44 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 24 mLength of steel to be cut by gas using pug cutting machine : 20 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 12 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 7 hoursAcetelyne gas @ 0.6 cum / hour ( 19 x 0.60 ) : 11 cumOxygen gas @ 1.8 cum / hour ( 19 x 1.80 ) : 33 cumUse of gas cutting torch with 50 min / hr working ( 12 x 60 / 50 ) : 15 hours

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Use of pug cutting machine with 50 min / hr working ( 7 x 60 / 50 ) : 9 hours 3. Welding :

Length of welding : 207 mFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 121 + 23 ) x 8 / 15 / 2 : 38 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr ( 1094 + 210 ) x 8 / 15 / 6 : 116 hours

Total : 154 hoursDeploy welding transformer for 154 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 38 x 0.25 + 116 x 0.75 ) : 97 hours 4. Planing SS plates for seal seats :

For surface finishing of SS plates for wheel / seal tracks planing machine is considered.Length of SS plate for surface finishing by planing machine : 18.3 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 18.3 m SS plates ( 18.3 x 8 / 3 ) : 48 hours

5. Surface cleaning and painting :Painting area for embedded parts at 5 sqm / tonne : 9 sqm1 coats of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 15 sqm @ 9 sqm / ltr / coat : 1 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 15 sqm @ 6 sqm / ltr / coat : 6 ltrAs 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 at 8 sqm / ltr : 1 ltr

6. Requirement of other machinery :For drilling holes for anchor bolts use of drilling machine for 1 hour considered.For finishing weld joints / edges 2 hours use of grinding machine considered.

7. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections / Drilling holes 25 hours 1.5 3 3 6Fabricating by stitch welding 38 hours 2 5 --- 10Run welding 116 hours 1.5 --- 15 15Erection of first stage anchors --- 1 --- 2Erection of Sill beam / Tracks / Guide 1 2 --- 4Finishing / cleaning --- 1 --- 1 Total : 6 12 18 38

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 1 helper for 9 sqmFor painting 1 coat primer and 4 coats finishing paint at 15 sqm / day : 3 painter Cl-ll & 1 helper for 5 x 9 sqm

8. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38

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Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 1.784 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Str steel angle / beam / channel / bars kg 1219.00 20.00 24380.002 Structural steel plate / flats kg 527.00 24.00 12648.003 Stainless steel plate / flats kg 82.00 90.00 7380.004 MS bolts and nuts kg 1.00 45.00 45.005 Oxygen gas cum 33.00 40.00 1320.006 Acetyline gas cum 11.00 185.00 2035.007 Welding electrodes Nos 121.00 4.00 484.008 Welding electrodes ( LH ) Nos 1094.00 6.00 6564.009 Welding electrodes ( stainless steel ) Nos 233.00 35.00 8155.00

10 Zinc rich epoxy primer ltr 1.00 525.00 525.0011 Coal tar epoxy paint ltr 6.00 131.00 786.0012 Rust cleaner / inhibitor ltr 1.00 175.00 175.0013 Use rate welding holder set Hour 154.00 3.38 519.7514 Use rate gas cutting torch set Hour 15.00 1.88 28.1315 Wire brush Nos 0.50 25.00 12.5016 Sundries LS 5.00 22.50 112.50

TOTAL Rs: 65169.88Add for small Tools and Plants @ 1% Rs: 651.70Add for Contractor' Profit @ 10% Rs: 6516.99Add for Contrators' Overheads @ 5% Rs: 3258.49

Total cost of Materials Rs: 75597.06

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 154.00 9.00 1386.00

Fuel / Energy charges Hour 97.00 49.00 4753.002 Pug cutting machine Hour 9.00 13.00 117.00

Fuel / Energy charges Hour 9.00 2.00 18.003 Planing machine Hour 48.00 66.00 3168.00

Fuel / Energy charges Hour 48.00 61.00 2928.004 Grinding machine Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.005 Drilling machines Hour 1.00 15.00 15.00

Fuel / Energy charges Hour 1.00 20.00 20.006 Sundries LS 2.00 22.50 45.00

TOTAL Rs: 12520.00Add for small Tools and Plants @ 1% Rs: 125.20Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 780.40Add for Contrators' Overheads @ 5% Rs: 626.00 Total hire charges of Machinery Rs: 14051.60

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Planing machine Hour 48.00 42.75 2052.002 Crew for Drilling machine Hour 1.00 35.00 35.00

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GATES AND HOISTS

3 Crew for Grinding machine Hour 2.00 35.00 70.004 Foreman Day 6.00 108.65 651.905 Marker / Fabricator / Erector Day 12.00 93.70 1124.406 Gas cutter Day 3.00 93.70 281.107 Welder ( General ) Day 13.00 93.70 1218.108 Welder ( X - ray ) Day 2.00 103.07 206.149 Helper fabrication / erection Day 38.00 81.60 3100.80

10 Helper for cleaning / painting Day 2.00 81.60 163.2011 Painter Cl - II Day 3.00 81.60 244.8012 Electrician Day 1.00 82.65 82.65

TOTAL Rs: 9230.09Add for small Tools and Plants @ 1% Rs: 92.30Add for Contractor' Profit @ 10% Rs: 923.01Add for hidden cost on Labour @ 15% Rs: 1384.51Add for additional hidden cost on labour @ 10% Rs: 923.01Add for Contrators' Overheads @ 5% Rs: 461.50

Total cost of Labour Rs: 13014.43

ABSTRACT:A. Cost of Materials Rs: 75597.06B. Hire charges of Machinery Rs: 14051.60C. Cost of Labour Rs: 13014.43

Total Rs: 102663.08Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 3653.91Add for insurance charges @ 1.00% Rs: 1026.63Add for designs and drawings @ 2.5% Rs: 2566.58Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 2566.58Add for power supply arrangements @ 2.5% Rs: 2566.58Add for enabling works @ 2% Rs: 2053.26

Total Rs: 117096.62Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x1.784 tonnes @ Rs: 81.30 / tonne Rs: 290.08Add for transportation upto work site @ 3% Rs: 3512.90 Total cost for 1.784 tonne Rs: 120899.60

Rate per tonne Rs: 67770.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 28

ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type vertical lift gate ( with top seal ) consisting of skin plate, horizontal and vertical girders, wheels, guide rollers, rubber seals etc., with all accessories for canal escape / regulator ventincluding cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning,applying one coat of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with all leads and lifts.

DATA: Consider down stream sealing vertical lift roller gate. The gate leaf consists of skin plate, horizontal girders, vertical end girders, stiffeners, wheels, gate guide rollers, brackets, pins, seals etc., with all accessories.Consider canal escape / regulator gate for 2 m x 2 m vent opening for analysis.Details of material / Gas cutting / Welding considered for rate analysis are based on vertical liftroller gate drawings for UKP - ALBC escape.Weight of gate leaf in tonne for vertical lift gate based on empirical formula : Weight in tonnes = 0.0888 ( L^2 x H x h )^0.659 Where ( L ) is length and ( H ) is height of gate and ( h ) is head of water in metre.

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GATES AND HOISTS

For vent opening of 2 x 2 m the approximate size of gate leaf will be 2.5 x 2.2 m.Head of water above sill level : 3.7 m Weight in tonnes = 0.0888 ( 2.5 x 2.5 x 2.2 x 3.7 ) ^ 0.659 : 1.183The actual weight of canal escape gate as per data sheet : 1.217 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials: as per fabrication drawings ( for details refer Item : 28 of Annexer )a. Structural steel conforming to IS : 2062 :

Angles / Channels / Beams / Bars with 2.5 % wastage : 250 kgPlates / flats with 2.5 % wastage : 899 kg

b. Alloy steel components conforming to IS : 1570 :Wheel axles / Pins : 30 kg

c. Cast steel components conforming to IS : 1030 :Wheels / guide rollers : 50 kg

d. Alluminium / Bronze alloy components conforming to IS : 305 :Bearings / Bushes : 5 kg

e. Bolts / Nuts / Washers conforming to IS : 1363 :GI bolts / nuts / washers with 2.5 % wastage : 8 kgMS bolts / nuts / washers with 2.5 % wastage : 4 kg

f. Rubber seal conforming to IS : 11855 :Bottom seal ( uncladed ) : 2.3 RmSide seals ( uncladed ) : 4.0 RmTop seal ( uncladed ) : 1.9 Rm

g. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 67 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 605 Nos

2. Cutting :Total length of cutting assuming cutting for 2 sides : 45 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 5 Rm

Total : 50 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 20 mLength of steel to be cut by gas using pug cutting machine : 30 mTime for gas cutting manually assuming average cutting progress of 2 m / hour 10 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 10 hoursAcetelyne gas @ 0.6 cum / hour ( 20 x 0.60 ) : 12 cumOxygen gas @ 1.8 cum / hour ( 20 x 1.80 ) : 36 cumUse of gas cutting torch with 50 min / hr working ( 10 x 60 / 50 ) : 12 hoursUse of pug cutting machine with 50 min / hr working ( 10 x 60 / 50 ) : 12 hours

3. Welding :Length of welding : 94 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 67 / 15 ) x 8 / 2 : 18 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 605 / 15 ) x 8 / 6 : 54 hoursTotal : 72 hours

Deploy welding transformer for 72 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 18 x 0.25 + 54 x 0.75 ) : : 45 hours 4. Surface cleaning and painting :

Painting area for canal escape gate at 18 sqm / tonne : 22 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 22 sqm @ 9 sqm / ltr / coat : 2.5 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 22 sqm @ 6 sqm / ltr / coat : 11 ltrAs surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment

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GATES AND HOISTS

to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting before applying primer painting.Quantity of rust cleaner / inhibitor at 8 sqm / ltr : 3 ltr

5. Requirement of other machinery :For handling of parts during fabrication and erection use of mobile derric crane for 2 hours andstationery derric crane for 4 hours considered.For drilling holes in skin plate, end girders and seal clamps use of drilling machine for 2 hours considered. For grinding and finishing weld joints in skin plate and other locations 2 hours use of grinding machine considered.

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections / Drilling holes 26 hours 1 3 3 6Fabricating by stitch welding 18 hours 1 2 --- 4Run welding 54 hours 1 --- 7 7Wheel fixing / Seal fixing 1 1 --- 2Guide roller fixing / Finishing / Erecting 1 1 --- 2 Total : 5 7 10 21

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 1.5 helper for 22 sqmFor painting 1 coat primer and 3 coats finishing paint at 15 sqm / day : 6 painter Cl-ll & 1.5 helper for 4 x 22 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 1.217 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / Channels / Beams / Bars kg 250.00 20.00 5000.00Plates / flats kg 899.00 24.00 21576.00

2 Alloy steel componentsWheel axles / Pins kg 30.00 175.00 5250.00

3 Cast steel componentsWheels / Guide rollers kg 50.00 85.00 4250.00

4 Alluminium / Bronze alloy componentsBearings / Bushes kg 5.00 380.00 1900.00

5 Bolt / Nut / WasherGI bolts / nuts / washers kg 8.00 60.00 480.00MS bolts / nuts / washers kg 4.00 45.00 180.00

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GATES AND HOISTS

6 Rubber sealsBottom seal ( uncladed ) Rm 2.30 120.00 276.00Side seals ( uncladed ) Rm 3.60 190.00 684.00Top seal ( uncladed ) Rm 1.50 190.00 285.00Corner seal ( uncladed ) Nos 2.00 240.00 480.00

7 Oxygen gas cum 36.00 40.00 1440.008 Acetyline gas cum 12.00 185.00 2220.009 Welding electrodes Nos 67.00 4.00 268.00

10 Welding electrodes ( LH ) Nos 605.00 6.00 3630.0011 Zinc rich epoxy primer ltr 2.50 525.00 1312.5012 Coal tar epoxy paint ltr 11.00 131.00 1441.0013 Rust cleaner / inhibitor ltr 3.00 175.00 525.0014 Use rate welding holder set Hour 72.00 3.38 243.0015 Use rate gas cutting torch set Hour 12.00 1.88 22.5016 Wire brush Nos 0.50 25.00 12.5017 Sundries LS 10.00 22.50 225.00

TOTAL Rs: 51700.50Add for small Tools and Plants @ 1% Rs: 517.01Add for Contractor' Profit @ 10% Rs: 5170.05Add for Contrators' Overheads @ 5% Rs: 2585.03

Total cost of Materials Rs: 59972.58

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 72.00 9.00 648.00

Fuel / Energy charges Hour 45.00 49.00 2205.002 Pug cutting machine Hour 12.00 13.00 156.00

Fuel / Energy charges Hour 12.00 2.00 24.003 Mobile derric crane Hour 2.00 261.00 522.00

Fuel / Energy charges Hour 2.00 117.00 234.004 Stationery derric crane Hour 4.00 50.00 200.00

Fuel / Energy charges Hour 4.00 5.00 20.005 Grinding machine Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.006 Drilling machines Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.007 Sundries LS 5.00 22.50 112.50

TOTAL Rs: 4261.50Add for small Tools and Plants @ 1% Rs: 42.62Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 267.55Add for Contrators' Overheads @ 5% Rs: 213.08 Total hire charges of Machinery Rs: 4784.74

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 2.00 32.90 65.802 Crew for Drilling machine Hour 2.00 35.00 70.003 Crew for Grinding machine Hour 2.00 35.00 70.004 Foreman Day 5.00 108.65 543.255 Marker / Fabricator / Erector Day 7.00 93.70 655.906 Gas cutter Day 3.00 93.70 281.107 Welder ( General ) Day 6.00 93.70 562.208 Welder ( X - ray grade ) Day 1.00 103.07 103.07

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GATES AND HOISTS

9 Helper fabrication / erection Day 21.00 81.60 1713.6010 Helper for cleaning / painting Day 3.00 81.60 244.8011 Painter Cl - II Day 6.00 81.60 489.6012 Electrician Day 1.00 82.65 82.65

TOTAL Rs: 4881.97Add for small Tools and Plants @ 1% Rs: 48.82Add for Contractor' Profit @ 10% Rs: 488.20Add for hidden cost on Labour @ 15% Rs: 732.30Add for additional hidden cost on labour @ 10% Rs: 488.20Add for Contrators' Overheads @ 5% Rs: 244.10

Total cost of Labour Rs: 6883.58

ABSTRACT:A. Cost of Materials Rs: 59972.58B. Hire charges of Machinery Rs: 4784.74C. Cost of Labour Rs: 6883.58

Total Rs: 71640.90Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 1575.22Add for insurance charges @ 1.00% Rs: 716.41Add for designs and drawings @ 2.5% Rs: 1791.02Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 1791.02Add for power supply arrangements @ 2.5% Rs: 1791.02Add for enabling works @ 2% Rs: 1432.82

Total Rs: 80738.41Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x1.217 tonnes @ Rs: 81.30 / tonne Rs: 197.88Add for transportation upto work site @ 3% Rs: 2422.15 Total cost for 1.217 tonne Rs: 83358.45

Rate per tonne Rs: 68500.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 29

ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity screwtype hoist consisting of supporting structure, platform, ladder etc., with all accessories foroperating canal escape / regulator gate including cost of all materials, machinery, labour,cutting, aligning, anchoring, welding, finishing, cleaning, applying two coats of zinc chromate red oxide primer and three coats of approved synthetic enamel paint etc., complete with all leads and lifts.

DATA: Screw type hoist for operating gate consists of supporting structure, hoist body, hoist stem, thrust bearings, operating wheel / handle with related accessories.The capacity of screw hoist for canal gate may be considered at 2.5 times the weight of gate.Consider screw type hoist for canal escape / regulator gate for vent opening of size 2 m x 2 m. Details of material / Gas cutting / Welding considered for rate analysis are based on screw typehoist drawings for UKP - ALBC escape.Weight of gate leaf in tonne for 2 m x 2 m vent opening based on empirical formula : Size of gate : 2.5 m x 2.2 m Head of water above sill : 3.7 m. Weight of gate in tonnes = 0.0888 x ( L^2 x H x h )^0.659Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres. = 0.0888 x ( 2.5^2 x 2.2 x 3.7 )^0.659 : 1.183Capacity of hoist with 25 % reserve capacity : 2.5 x Weight of gate( Capacity of hoist to be rounded off to next 1 tonne ) : 2.5 x 1.183

: 2.957 tonnes

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GATES AND HOISTS

say : 3.00 tonnesActual capacity of hoist as per data : 3.00 tonnesWeight of hoist with all accessories is assumed at 0.3 tonne per tonne capacity of hoist.Weight of hoist with all accessories ( 0.3 x 3 ) : 0.900 tonneThe actual weight of screw hoist as per data sheet : 0.871 tonneConsider actual weight for data rate analysis.

1. Requirement of materials: as per fabrication drawings ( for details refer Item : 29 of Annexer )a. Structural steel conforming to IS : 2062 :

Angles / Beams / Channels / Bars with 2.5 % wastage : 402.00 kgPlates / Flats with 2.5 % wastage : 145.00 kgChequered plates with 2.5 % wastage : 176.00 kg

b. Cast iron components conforming to IS : 210 :Hoist body / Lock nut / Main nut : 55.00 kg

c. Alloy steel components conforming to IS : 1570 :Hoist stem : 75.00 kg

d. Alluminium/ Bronze alloy components conforming to IS : 305 :Bearings / Bush : 4.00 kg

e. Bolt / Nut / Washers conforming to IS : 1363 :MS Bolts / Nuts / Washers with 2.5 % wastage : 8.00 kgMS pipe 32 mm dia : 8.8 Rm

f. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 7 NosWelding electrodes for run welding at 90 % of total with 2.5 % wastage : 66 Nos

2. Cutting :Total length of cutting assuming cutting for 2 sides : 18 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 2 Rm

Total : 20 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Time for gas cutting manually assuming average cutting progress of 2 m / hour : 10 hoursAcetelyne gas @ 0.6 cum / hour ( 10 x 0.60 ) : 6 cumOxygen gas @ 1.8 cum / hour ( 10 x 1.80 ) : 18 cumUse of gas cutting torch with 50 min / hr working ( 10 x 60 / 50 ) : 12 hours

3. Welding :Length of welding : 10 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 7 / 15 ) x 8 / 2 : 2 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 66 / 15 ) x 8 / 6 : 6 hoursTotal : 8 hours

Deploy welding transformer for 8 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 2 x 0.25 + 6 x 0.75 ) : 5 hours 4. Surface cleaning and painting :

Painting area for screw hoist at 20 sqm / tonne of str steel : 18 sqm2 coats of zinc chromate red oxide primer.Quantity of primer paint for 18 sqm @ 12 sqm / ltr / coat : 3 ltr3 coats of synthetic enamel paint.Quantity of coal tar epoxy paint for 18 sqm @ 12 sqm / ltr / coat : 4.5 ltrAs 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 at 8 sqm / ltr : 2 ltr

5. Requirement of other machinery :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

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GATES AND HOISTS

6. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections / Drilling holes 14 hours 1 2 2 4Fabricating / welding 8 hours 1 1 1 2Erection of hoist frame / body 1 1 --- 2Trial operation and final adjustments 1 1 --- 1 Total : 4 5 3 9

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 1 helpers for 18 sqmFor painting 2 coats primer and 3 coats finishing paint at 20 sqm / day : 4 painter Cl-ll & 1 helpers for 5 x 18 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 0.871 tonneA. MATERIALS: 3.000 t capacity Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / beams / channels / bars kg 402.00 20.00 8040.00Plates / flats kg 145.00 24.00 3480.00Chequered plate kg 176.00 25.20 4435.20

2 Cast iron components :Hoist body / Lock nut / Main nut kg 55.00 95.00 5225.00

3 Alloy steel componentsHoist stem kg 75.00 145.00 10875.00

4 Bronze alloy components :Thrust bearings kg 4.00 380.00 1520.00

5 MS Bolt / Nut / Washer kg 8.00 45.00 360.006 Oxygen gas cum 18.00 40.00 720.007 Acetyline gas cum 6.00 185.00 1110.008 Welding electrodes Nos 7.00 4.00 28.009 Welding electrodes ( LH ) Nos 66.00 6.00 396.00

10 Zinc chromate red oxide primer ltr 3.00 140.00 420.0011 Synthetic enamel ( 1st quality ) paint ltr 4.50 140.00 630.0012 Rust cleaner / inhibitor ltr 2.00 175.00 350.0013 Grease kg 2.00 90.00 180.0014 Use rate welding holder set Hour 8.00 3.38 27.0015 Use rate gas cutting torch set Hour 11.00 1.88 20.6316 Wire brush Nos 0.50 25.00 12.5017 Sundries LS 2.00 22.50 45.00

TOTAL Rs: 37874.33

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GATES AND HOISTS

Add for small Tools and Plants @ 1% Rs: 378.74Add for Contractor' Profit @ 10% Rs: 3787.43Add for Contrators' Overheads @ 5% Rs: 1893.72

Total cost of Materials Rs: 43934.22

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 8.00 9.00 72.00

Fuel / Energy charges Hour 5.00 49.00 245.002 Grinding machine Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.003 Drilling machines Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.004 Sundries LS 2.00 22.50 45.00

TOTAL Rs: 502.00Add for small Tools and Plants @ 1% Rs: 5.02Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 37.00Add for Contrators' Overheads @ 5% Rs: 25.10 Total hire charges of Machinery Rs: 569.12

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Drilling machine Hour 2.00 35.00 70.002 Crew for Grinding machine Hour 2.00 35.00 70.003 Foreman Day 4.00 108.65 434.604 Marker / Fabricator / Erector Day 5.00 93.70 468.505 Gas cutter Day 2.00 93.70 187.406 Welder ( General ) Day 1.00 93.70 93.707 Helper fabrication / erection Day 9.00 81.60 734.408 Helper for cleaning / painting Day 2.00 81.60 163.209 Painter Cl - II Day 4.00 81.60 326.40

10 Electrician Day 0.50 82.65 41.33TOTAL Rs: 2589.53

Add for small Tools and Plants @ 1% Rs: 25.90Add for Contractor' Profit @ 10% Rs: 258.95Add for hidden cost on Labour @ 15% Rs: 388.43Add for additional hidden cost on labour @ 10% Rs: 258.95Add for Contrators' Overheads @ 5% Rs: 129.48

Total cost of Labour Rs: 3651.23

ABSTRACT:A. Cost of Materials Rs: 43934.22B. Hire charges of Machinery Rs: 569.12C. Cost of Labour Rs: 3651.23

Total Rs: 48154.57Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 569.75Add for insurance charges @ 1.00% Rs: 481.55Add for designs and drawings @ 2.5% Rs: 1203.86Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 1203.86Add for power supply arrangements @ 2.5% Rs: 1203.86Add for enabling works @ 2% Rs: 963.09

Total Rs: 53780.54

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GATES AND HOISTS

Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x0.871 tonnes @ Rs: 81.30 / tonne Rs: 141.62Add for transportation upto work site @ 3% Rs: 1613.42 Total cost for 0.871 tonne Rs: 55535.59

3.000 t capacityRate per tonne Rs: 63760.00

Rate per tonne capacity Rs: 18510.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 30

ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sillbeam, wheel tracks, seal tracks, guide rails, gate groove liners etc., with all accessories forcanal escape / regulator stoplog gate including cost of all materials, machinery, labour, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with all leads and lifts.

DATA: Embedded parts for canal escape / regulator stop log gate consist of sill beam, wheel / sealtracks, groove lining upto top, gate guide with all accessories such as first stage anchors. Weight of embedded parts for such small gates will be in the range of 65 to 70 % of gate weight.Consider embedded parts for canal escape / regulator stoplog gate for 2 m x 2 m vent opening. Details of material / Gas cutting / Welding considered for rate analysis are based on embeddedparts drawings for stop log gate of UKP - ALBC escape.Weight of embedded parts in tonne for 2 m wide opening based on empirical formula : Length of gate element : 2.50 m Total height of elements : 4.00 mHead of water above sill level : 3.70 m Weight of embedded parts in tonnes = 0.0665 x ( L^2 x H x h )^0.716Where ( L ) is length and ( H ) is total height and ( h ) is head of water in metres. = 0.0665 x ( 2.5 x 2.5 x 4 x 3.7 ) ^ 0.716 : 1.701The actual weight of embedded parts as per data sheet : 1.685 tonnesConsider actual weight for data rate analysis.

1. Requirement of materials: as per fabrication drawings ( for details refer Item : 30 of Annexer )Structural steel conforming to IS : 2062 :Structural steel angles / beams / channels / bars with 2.5 % wastage : 1134 kgStructural steel plates / flats with 2.5 % wastage : 523 kgAlloy steel components conforming to IS : 1570 :Stainless steel plates / flats : 68.00 kgBolt / Nut / Washer conforming to IS : 1363 :MS bolts and nuts with 2.5 % wastage : 1 kgWelding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 116 NosWelding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 21 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 1042 NosWelding electrodes ( SS ) for run welding at 90 % of total with 2.5 % wastage : 190 Nos

2. Cutting :Total length of cutting assuming cutting for 2 sides : 37 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 4 Rm

Total : 41 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 20 mLength of steel to be cut by gas using pug cutting machine : 21 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 10 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 7 hours

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GATES AND HOISTS

Acetelyne gas @ 0.6 cum / hour ( 17 x 0.60 ) : 10 cumOxygen gas @ 1.8 cum / hour ( 17 x 1.80 ) : 30 cumUse of gas cutting torch with 50 min / hr working ( 10 x 60 / 50 ) : 12 hoursUse of pug cutting machine with 50 min / hr working ( 7 x 60 / 50 ) : 8 hours

3. Welding :Length of welding : 195 mFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 116 + 21 ) x 8 / 15 / 2 : 37 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 1042 + 190 ) x 8 / 15 / 6 : 109 hoursTotal : 146 hours

Deploy welding transformer for 146 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 37 x 0.25 + 109 x 0.75 ) : 91 hours 4. Planing SS plates for seal seats :

For surface finishing of SS plates for wheel / seal tracks planing machine is considered.Length of SS plate for surface finishing by planing machine : 16.3 RmLength of planing at a time for 4 m stroke planing machine : 3 RmTime for planing 3 m length section with 50 min / hour working : 8 hoursTime for planing 16.3 m SS plates ( 16.3 x 8 / 3 ) : 44 hours

5. Surface cleaning and painting :Painting area for embedded parts at 5 sqm / tonne : 8 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 8 sqm @ 9 sqm / ltr / coat : 1 ltr4 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 8 sqm @ 6 sqm / ltr / coat : 5.5 ltrAs 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 at 8 sqm / ltr : 1 ltr

6. Requirement of other machinery :For finishing weld joints / edges 2 hours use of grinding machine considered.

7. Requirement of work force :Work component Foreman Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 20 hours 1 2 2 5Fabricating by stitch welding 37 hours 2 5 --- 10Run welding 109 hours 2 --- 14 14Erection of Sill beam / Tracks / Guide 1 2 --- 4Finishing / cleaning --- 1 --- 1 Total : 6 10 16 34

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 0.5 helper for 8 sqmFor painting 1 coat primer and 4 coats finishing paint at 15 sqm / day : 3 painter Cl-ll & 0.5 helper for 5 x 8 sqm

8. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hours

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GATES AND HOISTS

Use rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 1.685 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Str steel angle / beam / channel / bars kg 1134.00 20.00 22680.002 Structural steel plate / flats kg 523.00 24.00 12552.003 Stainless steel plate / flats kg 68.00 90.00 6120.00

Bolt / Nut / Washer ( MS ) kg 1.00 45.00 45.005 Oxygen gas cum 30.00 40.00 1200.006 Acetyline gas cum 10.00 185.00 1850.007 Welding electrodes Nos 116.00 4.00 464.008 Welding electrodes ( LH ) Nos 1042.00 6.00 6252.009 Welding electrodes ( stainless steel ) Nos 211.00 35.00 7385.00

10 Zinc rich epoxy primer ltr 1.00 525.00 525.0011 Coal tar epoxy paint ltr 5.50 131.00 720.5012 Rust cleaner / inhibitor ltr 1.00 175.00 175.0013 Use rate welding holder set Hour 146.00 3.38 492.7514 Use rate gas cutting torch set Hour 12.00 1.88 22.5015 Wire brush Nos 0.50 25.00 12.5016 Sundries LS 5.00 22.50 112.50

TOTAL Rs: 60608.75Add for small Tools and Plants @ 1% Rs: 606.09Add for Contractor' Profit @ 10% Rs: 6060.88Add for Contrators' Overheads @ 5% Rs: 3030.44

Total cost of Materials Rs: 70306.15

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 146.00 9.00 1314.00

Fuel / Energy charges Hour 91.00 49.00 4459.002 Pug cutting machine Hour 8.00 13.00 104.00

Fuel / Energy charges Hour 8.00 2.00 16.003 Planing machine Hour 44.00 66.00 2904.00

Fuel / Energy charges Hour 44.00 61.00 2684.004 Grinding machine Hour 2.00 15.00 30.00

Fuel / Energy charges Hour 2.00 20.00 40.005 Sundries LS 2.00 22.50 45.00

TOTAL Rs: 11596.00Add for small Tools and Plants @ 1% Rs: 115.96Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 724.40Add for Contrators' Overheads @ 5% Rs: 579.80 Total hire charges of Machinery Rs: 13016.16

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Planing machine Hour 44.00 42.75 1881.002 Crew for Grinding machine Hour 2.00 35.00 70.003 Foreman Day 6.00 108.65 651.90

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4 Marker / Fabricator / Erector Day 10.00 93.70 937.005 Gas cutter Day 2.00 93.70 187.406 Welder ( General ) Day 12.00 93.70 1124.407 Welder ( X - ray ) Day 2.00 103.07 206.148 Helper fabrication / erection Day 34.00 81.60 2774.409 Helper for cleaning / painting Day 1.00 81.60 81.60

10 Painter Cl - II Day 3.00 81.60 244.8011 Electrician Day 1.00 82.65 82.65

TOTAL Rs: 8241.29Add for small Tools and Plants @ 1% Rs: 82.41Add for Contractor' Profit @ 10% Rs: 824.13Add for hidden cost on Labour @ 15% Rs: 1236.19Add for additional hidden cost on labour @ 10% Rs: 824.13Add for Contrators' Overheads @ 5% Rs: 412.06

Total cost of Labour Rs: 11620.22

ABSTRACT:A. Cost of Materials Rs: 70306.15B. Hire charges of Machinery Rs: 13016.16C. Cost of Labour Rs: 11620.22

Total Rs: 94942.53Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 3325.91Add for insurance charges @ 1.00% Rs: 949.43Add for designs and drawings @ 2.5% Rs: 2373.56Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 2373.56Add for power supply arrangements @ 2.5% Rs: 2373.56Add for enabling works @ 2% Rs: 1898.85

Total Rs: 108237.41Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x1.685 tonnes @ Rs: 81.30 / tonne Rs: 273.98Add for transportation upto work site @ 3% Rs: 3247.12 Total cost for 1.685 tonne Rs: 111758.51

Rate per tonne Rs: 66330.00

SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 31

ITEM: Design, fabrication, supply, erection, testing and commissioning of sliding type stoplog gateelements consisting of skin plate, horizontal and vertical girders, slide blocks, stiffeners, guide shoes, rubber seals etc., with all accessories for canal regulator vent including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coats of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc., complete as per specifications and approved drawings with all leads and lifts.

DATA: Consider down stream sealing vertical lift slide gate. The stoplog gate consists of number of inter-changeable elements having height of each element in the range of 0.9 to 1.2 m. Eachelement consists of skin plate, horizontal girders, vertical end girders, stiffeners, slide blocks, gate guide shoes, brackets, lifting pins,seals etc., with all accessories.Consider canal escape / regulator gate for 2 m vent opening and 3.7 m depth of water.Details of material / Gas cutting / Welding considered for rate analysis are based on stop logelements drawings for stop log gate of UKP - ALBC escape.Weight of 1 set of stoplog gate in tonne based on empirical formula : Weight of 1 set of elements in tonnes = 0.0995 ( L^2 x H x h )^0.716Where ( L ) is length and ( H ) is total height of gate and ( h ) is head of water in metres. Weight in tonnes = 0.0995 ( 2.5 x 2.5 x 4.0 x 3.7 ) ^ 0.716 : 2.544The actual weight of 1 set ( 4 elements ) of stoplog elements as per data sheet: 2.534 tonnes

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GATES AND HOISTS

Consider actual weight for data rate analysis. 1. Requirement of materials: as per fabrication drawings ( for details refer Item : 31 of Annexer )

a. Structural steel conforming to IS : 2062 :Angles / Channels / Beams / Bars with 2.5 % wastage : 1195 kgPlates / flats with 2.5 % wastage : 1376 kg

b. Alluminium/ Bronze alloy components conforming to IS : 305 :Bronze pads : 16.00 kg

c. Bolts / Nuts / Washers conforming to IS : 1363 :GI bolts / nuts / washers with 2.5 % wastage : 20.5 kgMS bolts / nuts / washers with 2.5 % wastage : 6 kg

d. Rubber seal conforming to IS : 11855 :Bottom seal ( uncladed ) : 8.2 RmSide seals ( uncladed ) : 8.25 Rm

e. Welding electrodes :Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 160 NosWelding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 1443 Nos

2. Cutting :Total length of cutting assuming cutting for 2 sides : 70 RmAdd for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 7 Rm

Total : 77 RmFor cutting structural steel sections to required sizes gas cutting is assumed.Length of steel to be cut by using gas manually : 40 mLength of steel to be cut by gas using pug cutting machine : 37 mTime for gas cutting manually assuming average cutting progress of 2 m / hour : 20 hoursTime for gas cutting by pug cutting machine at ( av ) 3 m / hour : 12 hoursAcetelyne gas @ 0.6 cum / hour ( 32 x 0.60 ) : 19 cumOxygen gas @ 1.8 cum / hour ( 32 x 1.80 ) : 57 cumUse of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) : 24 hoursUse of pug cutting machine with 50 min / hr working ( 12 x 60 / 50 ) : 14 hours

3. Welding :Length of welding : 216 RmFor stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr

( 160 / 15 ) x 8 / 2 : 43 hoursFor run welding @ 6 hrs usage / shift & @ 15 electrodes / hr

( 1443 / 15 ) x 8 / 6 : 128 hoursTotal : 171 hours

Deploy welding transformer for 171 hours.Fuel / Energy charges @ 25 % hrs for stitch welding & @ 75 % hrs for run welding.

( 43 x 0.25 + 128 x 0.75 ) : 107 hours 4. Surface cleaning and painting :

Painting area for reulator stoplog gate at 18 sqm / tonne : 45 sqm1 coat of zinc rich epoxy primer 40 micron dry film each coat.Quantity of primer paint for 45 sqm @ 9 sqm / ltr / coat : 5 ltr3 coats of coal tar epoxy paint 100 micron dry film each coat.Quantity of coal tar epoxy paint for 45 sqm @ 6 sqm / ltr / coat : 23 ltrAs 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 at 8 sqm / ltr : 6 ltr

5. Requirement of other machinery :For handling of parts during fabrication and erection use of mobile derric crane for 2 hours andstationery derric crane for 4 hours considered.For drilling holes in skin plate, end girders and seal clamps use of drilling machine for 8 hours considered.

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GATES AND HOISTS

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 Marker / Gas cutter / Helper

Fabricator / WelderErector

Cutting sections 38 hours 2 5 5 10Drilling holes 8 hours 1 1 --- 1Fabricating by stitch welding 43 hours 3 5 --- 10Run welding 128 hours 2 --- 16 16Slide blocks fixing / Seal fixing 1 2 --- 2Guide shoe fixing / Finishing / Erecting 1 1 --- 2 Total : 10 14 21 41

Note : It is assumed that all stitch welding will be done by fabricator. Hence, no separate provision is considered for welder for stitch welding.For surface cleaning by chemical cleanerand wire brushing at 15 sqm / day : 3 helper for 45 sqmFor painting 1 coat primer and 3 coats finishing paint at 15 sqm / day : 12 painter Cl-ll & 3 helper for 4 x 45 sqm

7. Excise duty on supply :Excise duty is applicable on supply of fabricated parts. The cost of materials is inclusive of alltaxes/ 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: 3375.00 / Each Rs: 3375.00Life of welding set : 1000 hoursUse rate of welding set per hour ( cost / life ) Rs: 3.38Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125Life of gas cutting set : 600 hoursUse rate of gas cutting set per hr ( cost / life ) Rs: 1.88

RATE ANALYSIS UNIT : 2.534 tonneA. MATERIALS: Sl No Perticulars Unit Quantity Rate Amount

in Rs. in Rs.1 Structural steel

Angles / Channels / Beams / Bars kg 1195.00 20.00 23900.00Plates / flats kg 1376.00 24.00 33024.00

2 Alluminium / Bronze alloy componentsBronze pads kg 16.00 380.00 6080.00

3 Bolt / Nut / WasherGI bolts / nuts / washers kg 20.50 60.00 1230.00MS bolts / nuts / washers kg 6.00 45.00 270.00

4 Rubber sealsBottom seal ( uncladed ) Rm 8.20 120.00 984.00Side seals ( uncladed ) Rm 8.25 190.00 1567.50

5 Oxygen gas cum 57.00 40.00 2280.006 Acetyline gas cum 19.00 185.00 3515.007 Welding electrodes Nos 160.00 4.00 640.008 Welding electrodes ( LH ) Nos 1443.00 6.00 8658.009 Zinc rich epoxy primer ltr 5.00 525.00 2625.00

10 Coal tar epoxy paint ltr 23.00 131.00 3013.0011 Rust cleaner / inhibitor ltr 6.00 175.00 1050.0012 Use rate welding holder set Hour 171.00 3.38 577.13

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GATES AND HOISTS

13 Use rate gas cutting torch set Hour 24.00 1.88 45.0014 Wire brush Nos 1.00 25.00 25.0015 Sundries LS 20.00 22.50 450.00

TOTAL Rs: 89933.63Add for small Tools and Plants @ 1% Rs: 899.34Add for Contractor' Profit @ 10% Rs: 8993.36Add for Contrators' Overheads @ 5% Rs: 4496.68

Total cost of Materials Rs: 104323.01

B. MACHINERY: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer Hour 171.00 9.00 1539.00

Fuel / Energy charges Hour 107.00 49.00 5243.002 Pug cutting machine Hour 14.00 13.00 182.00

Fuel / Energy charges Hour 14.00 2.00 28.003 Mobile derric crane Hour 2.00 261.00 522.00

Fuel / Energy charges Hour 2.00 117.00 234.004 Stationery derric crane Hour 4.00 50.00 200.00

Fuel / Energy charges Hour 4.00 5.00 20.005 Grinding machine Hour 8.00 15.00 120.00

Fuel / Energy charges Hour 8.00 20.00 160.006 Drilling machines Hour 8.00 15.00 120.00

Fuel / Energy charges Hour 8.00 20.00 160.007 Sundries LS 10.00 22.50 225.00

TOTAL Rs: 8753.00Add for small Tools and Plants @ 1% Rs: 87.53Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 607.00Add for Contrators' Overheads @ 5% Rs: 437.65 Total hire charges of Machinery Rs: 9885.18

C. LABOUR: Sl No Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 2.00 32.90 65.802 Crew for Drilling machine Hour 8.00 35.00 280.003 Crew for Grinding machine Hour 8.00 35.00 280.004 Foreman Day 10.00 108.65 1086.505 Marker / Fabricator / Erector Day 14.00 93.70 1311.806 Gas cutter Day 5.00 93.70 468.507 Welder ( General ) Day 14.00 93.70 1311.808 Welder ( X - ray grade ) Day 2.00 103.07 206.149 Helper fabrication / erection Day 41.00 81.60 3345.60

10 Helper for cleaning / painting Day 6.00 81.60 489.6011 Painter Cl - II Day 12.00 81.60 979.2012 Electrician Day 1.00 82.65 82.65

TOTAL Rs: 9907.59Add for small Tools and Plants @ 1% Rs: 99.08Add for Contractor' Profit @ 10% Rs: 990.76Add for hidden cost on Labour @ 15% Rs: 1486.14Add for additional hidden cost on labour @ 10% Rs: 990.76Add for Contrators' Overheads @ 5% Rs: 495.38

Total cost of Labour Rs: 13969.70

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GATES AND HOISTS

ABSTRACT:A. Cost of Materials Rs: 104323.01B. Hire charges of Machinery Rs: 9885.18C. Cost of Labour Rs: 13969.70

Total Rs: 128177.89Add for excise duty on 75 percent cost excluding cost of materials @ 18.00% Rs: 3220.41Add for insurance charges @ 1.00% Rs: 1281.78Add for designs and drawings @ 2.5% Rs: 3204.45Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 3204.45Add for power supply arrangements @ 2.5% Rs: 3204.45Add for enabling works @ 2% Rs: 2563.56

Total Rs: 144856.97Add for 2 rehandling leads for 1 km including loading and unloading :Fabricated parts 2x2.534 tonnes @ Rs: 81.30 / tonne Rs: 412.03Add for transportation upto work site @ 3% Rs: 4345.71 Total cost for 2.534 tonne Rs: 149614.71

Rate per tonne Rs: 59040.00

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GATES AND HOISTS

ANNEXER TO

GATES AND HOISTS

DETAILS OF MATERIALS / CUTTING / WELDING

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GATES AND HOISTS

GATES AND HOISTS : REQUIREMENT OF MATERIALS -

1. Embedded parts for spillway radial gates:Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on embedded parts drawings for 15 m x 9 m radial gate of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Sill beam / wall plates:1 Flats 100x100x10 mm 152 Nos 120.00 15.2 1.5 122 Flats 100x250x10 mm 26 Nos 43.00 9.1 0.3 33 Anchor rods 12 dia 350 mm 152 Nos 48.00 1.8 5.3 434 Anchor rods 12 dia 350 mm 52 Nos 16.00 0.6 1.8 155 Sill beam ISMB 300 half 2820 mm 2 Nos 130.00 5.6 0.5 86 Sill beam ISMB 300 half 2400 mm 4 Nos 221.00 9.6 1.5 247 Anchor plate 80x200x10 mm 26 Nos 33.00 2.1 4.2 348 Anchor bolts 16 dia 180 mm 52 Nos 15.00 --- 2.6 219 Stiffeners 60x135x10 mm 12 Nos 8.00 3.6 6.5 52

10 Stiffeners 60x135x10 mm 12 Nos 8.00 3.6 6.5 5211 Stiffeners 125x125x10 mm 2 Nos 3.00 0.8 1.2 1012 Stiffeners 125x125x10 mm 2 Nos 3.00 0.8 1.2 1013 Anchor bolts 16 dia 190 mm 108 Nos 32.00 --- 5.4 4414 Anchor bolts 16 dia 430 mm 36 Nos 24.00 --- 1.8 1515 Seal base 190x200x10 mm 2 Nos 6.00 0.8 ( SV ) 0.8 1216 Seal base 130x200x10 mm 2 Nos 4.00 0.7 ( SV ) 1.1 1717 Seal seat SS 80x420x6 mm 2 Nos 3.00 1.0 2.0 1618 Seal seat SS 100x2640x6 mm 2 Nos 25.00 5.5 10.8 8719 Seal seat SS 100x2400x6 mm 4 Nos 45.00 10.0 19.6 15720 Seal seat SS 100x1232x6 mm 16 Nos 93.00 21.3 41.0 32821 Seal seat SS 100x1208x6 mm 2 Nos 11.00 2.6 5.0 4022 Seal seat SS 100x350x6 mm 2 Nos 3.00 0.9 1.6 1323 Cleats ISA 75x75x8 mm 80 mm 108 Nos 77.00 16.2 17.3 13924 Wall plate base 360x1232x12 mm 16 Nos 668.00 25.5 ( SV ) 5.8 12225 Wall plate base 360x1365x12 mm 2 Nos 93.00 3.5 ( SV ) 0.8 1526 Stiffener 80x126x8 mm 16 Nos 99.00 1.3 40.5 32427 Stiffener 80x1202x8 mm 16 Nos 97.00 1.3 39.8 31928 Stiffener 80x1173x8 mm 2 Nos 12.00 0.2 4.9 4029 Stiffener 80x1308x8 mm 2 Nos 13.00 0.2 5.4 4430 Stiffener 70x222x8 mm 52 Nos 51.00 3.6 37.7 30231 Stiffener 80x315x8 mm 2 Nos 3.00 0.2 1.9 1632 Wall plate 350x360x12 mm 2 Nos 24.00 1.4 ( SV ) 0.7 1533 Splice plate 120x320x6 mm 10 Nos 18.00 4.4 3.2 2634 Nuts / Washers 16 dia 392 Nos each 17.00 --- --- ---35 Bolts / Nuts / Washers 16 dia 55 mm 40 6.00 --- --- ---

Anchors / Anchor girders / Yoke girders :36 Anchor bars 275x8900x40 mm 8 Nos 6148.00 73.4 ( F16 )33.8 216337 Anchor girder web 950xx2760x20 mm 2 823.00 7.4 --- ---38 Flange U / S 200x2760x20 mm 2 Nos 173.00 9.4 ( F8 ) 11.0 16539 Flange D / S 350x2760x25 mm 2 Nos 379.00 9.7 ( F8 ) 11.0 16540 Yoke girder web 1160x2440x20 mm 2 Nos 889.00 7.2 --- ---41 Flange U / S 1000x2440x28 mm 2 Nos 1073.00 10.3 ( F 8 ) 9.8 14742 Flange D / S 250x2440x20 mm 2 Nos 192.00 8.8 ( F 8 ) 9.8 14743 Stiffeners 150x950x12 mm 20 Nos 268.00 32.0 48.0 384

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GATES AND HOISTS

44 Stiffeners 150x200x10 mm 48 Nos 113.00 21.6 33.6 26945 Stiffeners 475x1160x16 mm 8 Nos 554.00 18.7 28.2 22646 Stiffeners 475x450x12 mm 24 Nos 483.00 29.4 44.4 35647 Stiffeners 105x150x10 mm 8 Nos 10.00 3.2 1.9 1648 Stiffeners 100x1160x12 mm 8 Nos 87.00 0.8 21.8 17549 Stiffeners 425x1160x12 mm 4 Nos 186.00 8.3 13.7 11050 Pad plates 380x430x20 mm 4 Nos 103.00 3.2 6.5 5251 Bolts / Nuts 24 dia 16 Nos 9.00 --- --- ---

Trunnion supports :52 Thrust plates 700x731x20 mm 2 Nos 166.00 2.9 --- ---53 Stiffeners 110x288x12 mm 8 Nos 24.00 3.2 6.4 5254 Stiffeners 120x700x12 mm 6 Nos 47.00 4.9 8.4 6855 Cleats ISA 75x75x8 mm 80 mm 8 Nos 6.00 1.2 1.4 1256 Base plate 650x940x20 mm 2 Nos 192.00 3.2 --- ---57 SS sliding plates 60x570x6 mm 6 Nos 10.00 0.4 7.6 6158 Stiffeners 140x538x12 mm 6 Nos 43.00 4.1 8.1 6559 Stiffeners 150x940x12 mm 4 Nos 53.00 4.4 7.5 6060 Align plate 120x800x12 mm 4 Nos 36.00 3.6 6.4 5261 Align rod 16 dia 180 mm 8 Nos 2.00 0.4 0.4 462 Nuts / Washers 16 dia 16 Nos each 2.00 --- --- ---63 Align plate 100x100x12 mm 8 Nos 8.00 1.6 --- ---64 Align rod 45 dia 1778 mm 8 Nos 178.00 1.0 --- ---65 Nuts / Washers 45 dia 24 Nos / 8 Nos 2.00 --- --- ---66 Align rod 12 dia 360 mm 8 Nos 3.00 0.5 0.3 3

Total : 14334.00 428.1 600.0 7127 kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angles / Beams / Channels / Bars : 679.00 kgStructural steel Plates / Flats : 13356.00 kg

2. Alloy steel components : IS : 1570Stainless steel plates / flats : 190.00 kg

3. Bolt / Nut / Washer : IS : 1363MS Bolts / Nuts / Washers : 109.00 kg

4. Other details :Length of cutting : 428.10 RmLength of welding : 600.00 RmNumber of electrodes ( str steel ) : 6486 NosNumber of electrodes ( stainless steel ) 641 Nos

2. Spillway radial gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on drawings for 15 m x 9 m radial gate of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Trunnion assembly :1 Side plate(FS) 1177x1437x25 mm 2 Nos 664.00 6.2 ( F16 ) 2.0 842 Side plate(NS) 1177x1272x25 mm 2 Nos 588.00 5.9 ( F16 ) 2.0 843 Web plate 490x1119x14 mm 4 Nos 241.00 9.0 23.8 1904 Web plate 490x969x12 mm 2 Nos 90.00 4.9 10.7 865 Hub 590 / 390 / 340 dia 680 mm 2 Nos 1865.00 --- --- ---6 Stiffener 170x200x16 mm 6 Nos 26.00 2.3 4.5 367 Con. Plate 397x720x 25 mm 4 Nos 224.00 5.0 --- ---

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8 Con. Plate 260x720x 20 mm 2 Nos 59.00 2.0 --- ---9 Stiffener 100x200x10 mm 4 Nos 6.00 1.2 2.4 20

10 Stiffener 170x250x 10 mm 4 Nos 13.00 1.7 3.4 2811 Stiffener 400x250x10 mm 2 Nos 16.00 1.3 3.6 2912 Back strip 25x1119x6 mm 4 Nos 5.00 0.1 4.5 3613 Back strip 25x962x6 mm 4 Nos 5.00 0.1 3.9 3214 Back strip 25x432x6 mm 4 Nos 2.00 0.1 1.8 1515 Back strip 25x460x6 mm 4 Nos 2.00 0.1 1.9 1516 Bracket pl 725x745x36 mm 4 Nos 610.00 11.8 ( F16 ) 12.0 76817 Plate 775x850x25 mm 2 Nos 259.00 3.3 --- ---18 Plate 610x850x20 mm 2 Nos 163.00 3.0 --- ---19 R / F plate 620 dia x 10 mm 2 Nos 47.00 6.0 4.0 3220 Stiffener 160x716x12 mm 4 Nos 43.00 3.5 8.3 6721 Stiffener 90x716x16 mm 6 Nos 49.00 0.6 10.8 8722 Stiffener 60x200x16 mm 4 Nos 6.00 0.3 2.1 1723 SS plate 40x555x6 mm 6 Nos 6.00 0.3 6.7 5424 Bush 330/390/620 dia 2 Nos 1128.00 --- --- ---25 Pin 330 dia x 815 mm 2 Nos 1094.00 --- --- ---26 Brass washers 590 dia x5 mm 2 Nos 21.00 --- --- ---27 Keeper pl 120x530x20 mm 2 Nos 20.00 0.3 --- ---28 Hex screws 24 dia x50 mm 4 Nos 1.00 --- --- ---29 Plate washer 100x100x25 mm 8 Nos 16.00 1.6 --- ---30 Tie holder 390x500x32 mm 2 Nos 98.00 2.6 ( F16 ) 4.0 25631 Stiffener 230x515x16 mm 2 Nos 60.00 3.0 7.8 6332 Stiffener 165x515x16 mm 2 Nos 21.00 1.5 5.5 4433 Stiffener 130x515x16 mm 2 Nos 17.00 1.3 5.2 4234 R/F plate 650 dia 10 mm 2 Nos 6.00 6.0 4.0 32

Trunnion tie beam :35 ISMC-300 : 6652 mm 2 Nos 483.00 1.2 --- ---36 ISMC-300 : 8652 mm 2 Nos 628.00 1.2 2.4 4037 Plate 160x6302x10 mm 2 Nos 158.00 12.9 25.5 20438 Plate 160x8302x10 mm 2 Nos 196.00 16.9 33.6 26939 Plate 240x300x8 mm 4 Nos 18.00 2.2 4.3 3540 Plate 160x700x12 mm 4 Nos 42.00 6.7 6.2 5041 Plate 55x300x12 mm 4 Nos 6.00 1.5 2.9 2442 Plate 240x370x12 mm 4 Nos 33.00 2.5 4.9 4043 Bolts 22 dia x 100 mm 40 Nos 20.00 --- --- ---

Sector arms and bracings :44 Web plate 500x9716x12 mm 2 Nos 915.00 20.5 --- ---45 Web plate 500x9766x10 mm 2 Mos 767.00 20.5 --- ---46 Web plate 516x10286x10 mm 2 Nos 833.00 21.6 --- ---47 Flange plate 360x9556x20 mm 2 Nos 1080.00 19.9 ( F10 ) 39.7 91348 Flange plate 340x9606x20 mm 2 Nos 1026.00 19.9 ( F10 ) 39.7 91349 Flange plate 180x10126x12 mm 2 Nos 344.00 20.6 41.3 33150 Flange plate 360x9723x20 mm 2 Nos 1099.00 20.2 ( F10 ) 40.4 92951 Flange plate 340x9773x20 mm 2 Nos 1043.00 20.3 40.5 93052 Flange plate 180x10293x12 mm 2 Nos 349.00 21.0 41.9 33653 Pad plate 360x760x25 mm 2 Nos 107.00 2.3 ( F10 ) 5.0 11554 Pad plate 340x760x25 mm 2 Nos 101.00 2.2 ( F10 ) 5.0 11555 Pad plate 210x750x20 mm 2 Nos 49.00 2.0 ( F10 ) 5.0 11556 Pad plate 370x690x25 mm 2 Nos 100.00 2.2 ( F10 ) 4.8 11157 Pad plate 350x690x25 mm 2 Nos 95.00 2.1 4.8 11158 Pad plate 220x690x20 mm 2 Nos 48.00 1.8 4.8 11159 Stiffener 150x250x10 mm 8 Nos 24.00 3.2 6.4 5260 Stiffener 90x200x10 mm 4 Nos 6.00 1.2 2.3 1961 Stiffener 80x150x10 mm 6 Nos 6.00 1.4 2.8 23

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GATES AND HOISTS

62 Stiffener 128x150x10 mm 6 Nos 9.00 1.7 2.8 2363 Bracing L 100x100x6 - 3530 mm 4 Nos 130.00 0.8 4.0 3264 Bracing L 100x100x6 - 3776 mm 4 Nos 139.00 0.8 4.0 3265 Bracing L 75x75x6 - 2642 mm 4 Nos 72.00 0.6 3.5 2866 Bracing L 75x75x6 - 2995 mm 4 Nos 81.00 0.6 3.5 2867 Bracing L 75x75x6 - 1714 mm 4 Nos 47.00 0.6 3.5 2868 Bracing L 75x75x6 - 2161 mm 4 Nos 59.00 0.6 3.5 2869 Bracing L 75x75x6 - 786 mm 4 Nos 21.00 0.6 3.5 2870 Bracing L 100x100x6 - 2762 mm 4 Nos 102.00 0.8 4.0 3271 Bracing L 100x100x6 - 3175 mm 4 Nos 117.00 0.8 4.0 3272 Bracing L 75x75x6 - 2010 mm 4 Nos 55.00 0.6 3.5 2873 Bracing L 75x75x6 - 2534 mm 4 Nos 69.00 0.6 3.5 2874 Bracing L 75x75x6 - 1258 mm 4 Nos 34.00 0.6 3.5 2875 Bracing L 75x75x6 - 1810 mm 4 Nos 49.00 0.6 3.5 2876 Bracing L 75x75x6 - 496 mm 4 Nos 13.00 0.6 3.5 2877 Gusset pl 160x220x8 mm 8 Nos 18.00 4.3 3.5 2878 Gusset pl 160x280x8 mm 4 Nos 11.00 1.8 2.3 1979 Gusset pl 160x300x8 mm 4 Nos 12.00 10.9 2.4 2080 Gusset pl 160x360x8 mm 4 Nos 14.00 2.1 2.9 2481 Gusset pl 170x410x8 mm 4 Nos 18.00 2.4 3.3 2782 Gusset pl 170x430x8 mm 4 Nos 18.00 2.4 3.4 2883 Gusset pl 170x520x8 mm 4 Nos 22.00 2.8 4.1 3384 Gusset pl 170x500x8 mm 4 Nos 21.00 2.7 4.0 3285 Gusset pl 160x200x8 mm 8 Nos 16.00 2.9 3.2 2686 Gusset pl 160x160x8 mm 8 Nos 13.00 2.6 2.5 2887 Gusset pl 160x270x8 mm 8 Nos 22.00 1.8 4.3 3588 Gusset pl 170x350x8 mm 4 Nos 15.00 2.1 2.8 2389 Gusset pl 170x430x8 mm 4 Nos 18.00 2.4 3.4 2890 Gusset pl 170x540x8 mm 4 Nos 23.00 2.9 4.3 3591 Stiffener 40x450x8 mm 118 Nos 133.00 4.7 35.4 28492 Bolts 22 dia x 75 mm Nos 7.00 --- --- ---93 Bolts 22 dia x 80 mm 17.00 --- --- ---94 Bolts 27 dia x 100 mm 18.00 --- --- ---95 Bolts 24 dia x 90 mm 12.00 --- --- ---

Horizontal girders and bracings :96 Web plate 1200x14840x10 mm 1 No. 1398.00 4.0 --- ---97 Flange plate 450x14840x20 mm 1 No. 1048.00 15.3 ( F10 ) 29.7 68398 Flange plate 340x14938x20 mm 1 No. 797.00 15.3 ( F10 ) 29.9 68899 Flange plate 370x2750x10 mm 2 Nos 159.00 6.3 12.4 100

100 Bracket 700x1085x20 mm 2 Nos 238.00 5.0 ( F10 ) 6.0 138101 Bracket 700x1200x20 mm 2 Nos 264.00 5.4 6.0 138102 Stiffener 200x900x12 mm 4 Nos 68.00 4.4 8.8 71103 Stiffener 428x1300x10 mm 2 Nos 87.00 3.5 2.6 21104 Stiffener 125x1200x10 mm 6 Nos 70.00 8.0 17.4 140105 Stiffener 155x1260x20 mm 8 Nos 245.00 11.3 25.1 201106 Stiffener 150x300x10 mm 12 Nos 42.00 5.4 10.8 87107 Web plate 1200x14840x10 mm 1 No. 1398.00 4.0 --- ---108 Flange plate 380x14840x20 mm 1 No 885.00 15.2 ( F10 ) 29.7 683109 Flange plate 320x13122x20 mm 1 No. 659.00 13.5 ( F10 ) 26.3 605110 Flange plate 320x1000x20 mm 2 Nos 100.00 2.7 ( F10 ) 4.7 108111 Flange plate 350x2752x10 mm 2 Nos 151.00 6.2 12.4 100112 Stiffener 145x1200x10 mm 6 Nos 82.00 8.1 17.9 144113 Stiffener 145x1260x20 mm 8 Nos 229.00 11.3 24.8 199114 Stiffener 100x700x10 mm 4 Nos 22.00 3.2 7.2 58115 Stiffener 100x950x10 mm 4 Nos 30.00 4.2 9.2 74116 Web plate 800x14840x10 mm 1 No. 932.00 4.0 --- ---

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GATES AND HOISTS

117 Flange plate 300x14840x16 mm 1 No. 559.00 15.2 ( F10 ) 29.7 683118 Flange plate 240x12888x16 mm 1 No. 389.00 13.2 ( F10 ) 25.8 594119 Flange plate 240x1000x16 mm 2 Nos 60.00 2.5 ( F10 ) 4.5 104120 Flange plate 280x2280x10 mm 2 Nos 100.00 5.1 10.3 83121 Stiffener 115x800x10 mm 6 Nos 43.00 5.5 12.4 100122 Stiffener 115x840x16 mm 8 Nos 97.00 7.7 17.1 137123 Stiffener 120x895x10 mm 2 Nos 17.00 2.1 4.6 37124 Stiffener 120x1020x10 mm 2 Nos 19.00 2.3 5.0 40125 Stiffener 100x600x10 mm 4 Nos 19.00 2.8 6.4 52126 Stiffener 300x300x10 mm 4 Nos 28.00 2.4 4.8 39127 Bracing L 110x110x8 - 4560 mm 2 Nos 122.00 0.5 1.4 12128 Bracing L 110x110x8 - 2360 mm 2 Nos 63.00 0.5 1.4 12129 Bracing L 110x110x8 - 2041 mm 2 Nos 54.00 0.5 1.4 12130 Bracing L 110x110x8 - 3879 mm 2 Nos 104.00 0.5 1.4 12131 Bracing L 110x110x8 - 1968 mm 2 Nos 53.00 0.5 1.4 12132 Bracing L 110x110x8 - 1608 mm 2 Nos 43.00 0.5 1.4 12133 Bracing L 130x130x8 - 5575 mm 2 Nos 177.00 0.5 1.8 15134 Bracing L 130x130x8 - 2798 mm 2 Nos 88.00 0.5 1.8 15135 Bracing L 130x130x8 - 2638 mm 2 Nos 83.00 0.5 1.8 15136 Bracing L 130x130x8 - 4968 mm 2 Nos 158.00 0.5 1.8 15137 Bracing L 130x130x8 - 2395 mm 2 Nos 76.00 0.5 1.8 15138 Bracing L 130x130x8 - 2255 mm 2 Nos 72.00 0.5 1.8 15139 Bracing L 110x110x8 - 3210 mm 5 Nos 215.00 1.2 3.5 28140 Bracing L 110x110x8 - 3970 mm 5 Nos 266.00 1.2 3.5 28141 Bracing L 75x75x8 - 1200 mm 5 Nos 53.00 0.8 2.5 20142 Bracing L 75x75x8 - 1986 mm 10 Nos 177.00 1.5 5.0 40143 Bracing L 75x75x8 - 1100 mm 5 Nos 49.00 0.8 2.5 20144 Bracing L 75x75x8 - 2390 mm 10 Nos 213.00 1.5 5.0 40145 Gusset pl 180x500x10 mm 5 Nos 35.00 3.4 2.5 38146 Gusset pl 180x440x10 mm 5 Nos 31.00 3.1 2.2 35147 Gusset pl 180x570x10 mm 2 Nos 16.00 1.5 1.2 18148 Gusset pl 200x700x10 mm 1 No. 11.00 0.9 0.7 11149 Gusset pl 210x700x10 mm 2 Nos 23.00 1.8 1.4 23150 Gusset pl 180x730x10 mm 2 Nos 21.00 1.9 1.5 24151 Gusset pl 230x420x10 mm 2 Nos 15.00 1.3 0.9 14152 Gusset pl 230x400x10 mm 2 Nos 15.00 1.3 0.9 14153 Gusset pl 230x330x10 mm 2 Nos 12.00 1.2 0.7 11154 Gusset pl 230x460x10 mm 2 Nos 17.00 1.5 0.9 14155 Gusset pl 240x460x10 mm 2 Nos 17.00 1.6 0.9 14156 Gusset pl 200x500x10 mm 4 Nos 31.00 3.0 2.4 39157 Gusset pl 220x580x10 mm 4 Nos 40.00 3.4 2.8 45

Skin plate and stiffeners :158 Skin plate 2980x1800x12 mm 2 Nos 1011.00 6.0 8.9 204159 Skin plate 2100x1600x12 mm 2 Nos 633.00 4.2 6.8 156160 Skin plate 2400x1800x12 mm 2 Nos 814.00 4.8 7.7 177161 Skin plate 2980x8415x10 mm 2 Nos 3937.00 6.0 19.6 313162 Skin plate 2100x9076x10 mm 2 Nos 2992.00 4.2 18.9 302163 Skin plate 2400x8876x10 mm 2 Nos 3345.00 4.8 19.1 306164 Stiffener 1/2 ISMB 350-10155 mm 14 Nos 3725.00 71.0 284.0 2272165 Stiffener 1/2 ISMB 350-10646 mm 22 Nos 6136.00 117.0 468.4 3748166 Web plate 158x10215x10 mm 2 Nos 253.00 20.8 40.9 327167 Flange 100x10015x12 mm 2 Nos 189.00 0.2 20.0 160168 Seal base 25x2980x16 mm 2 Nos 19.00 0.1 11.9 248169 Seal base 25x2100x16 mm 2 Nos 13.00 0.1 8.4 177170 Seal base 25x2400x16 mm 2 Nos 15.00 0.1 9.6 202171 Back strip 40x10215x6 mm 5 Nos 96.00 0.2 102.0 816

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GATES AND HOISTS

172 Stiffener 60x160x8 mm 204 Nos 123.00 12.3 114.2 914173 Stiffener 80x158x8 mm 6 Nos 5.00 0.5 3.8 31174 Diaphragm 170x391x10 mm 6 Nos 31.00 3.4 8.8 71

End shields :175 Skin plate 2200x3010x10 mm 2 Nos 1040.00 5.0 6.0 96176 Stiffener L 150x75x8 - 2400 mm 16 Nos 525.00 3.6 6.4 51177 Shield plate 150 / 715x2300x8mm 2 Nos 125.00 6.9 11.8 130178 Stiffener L 65x65x6 - 1350 mm 6 Nos 470.00 0.8 16.2 130179 Stiffener L 65x65x6 - 3450 mm 2 Nos 400.00 0.3 1.6 13

Guide rollers 4 Nos180 Plates for guide roller assembly 48.00 5.2 2.9 24181 Guide roller 4 Nos 30.00 --- --- ---182 Bronze bush 4 Nos 6.00 --- --- ---183 Pins 4 Nos 4.00 --- --- ---184 Bolt/Nut/Washer 2.00 --- --- ---

Seal assembly :185 Bottom seal 100x15000x20 mm 1 No. --- --- --- ---186 Side seal 12110x20 mm 2 Nos --- --- --- ---187 Seal clamp 75x1984x16 mm 2 Nos 37.00 0.2 --- ---188 Seal clamp 75x1998x16 mm 4 Nos 75.00 0.3 --- ---189 Seal clamp 75x1398x16 mm 2 Nos 26.00 0.2 --- ---190 Seal clamp 60x1969x16 mm 2 Nos 30.00 0.1 --- ---191 Seal clamp 60x1998x16 mm 10 Nos 151.00 0.6 --- ---192 Lock plate 30x120x27 mm 24 Nos 18.00 3.6 --- ---193 GI Bolts 16 dia x 70 mm 388 Nos 67.00 --- --- ---194 GI Washers 16 dia 388 Nos 9.00 --- --- ---

Total : 57457.00 927.5 2293.9 26617kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angles / Beams / Channels / Bars : 15421.00 kgPlates / Flats : 37729.00 kg

2. Cast steel components : IS : 1030Trunnion hub / Guide roller : 1895.00 kg

3. Alloy steel components : IS : 1570SS plates / Flats : 6.00 kgPins : 1098.00 kg

4. Alluminium / Bronze alloy components : IS : 305Trunnion & Guide roller bush : 1155.00 kg

5. Bolt / Nut / Washer IS :1363GI Bolts / Nuts / Washers : 76.00 kgMS Bolts / Nuts / Washers / Screws : 77.00 kg

6. Rubber seals : IS : 11855Bottom seal : 15.00 RmSide seals : 24.22 Rm

7. Other details :Length of cutting : 927.50 RmLength of welding : 2293.90 RmNumber of electrodes : 26617 Nos

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GATES AND HOISTS

3. Rope drum hoist for spillway radial gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on 70 t rope drum hoist drawings for 15 m x 9 m radial gate of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Embedments :1 Anchor bars 25 dia x 1670 mm 24 Nos 154.00 0.6 --- ---2 Template 180x1290x12 mm 4 Nos 44.00 5.9 --- ---3 Anchor plate 180x220x20 mm 4 Nos 25.00 1.6 1.2 594 Anchor plate 100x180x20 mm 4 Nos 11.00 0.7 0.6 295 Anchor bars 20 dia x 490 mm 4 Nos 5.00 0.1 --- ---6 Washers & Nuts for anchor bars 8.00 --- --- ---7 Bolts / Washers / Nuts 20 dia 4 Nos 1.00 --- --- ---8 Pack plate 180x180x6 mm 1 No. 2.00 --- --- ---

Hoist supporting structure :9 Girder ISMB-450 x 2950 mm 4 Nos 854.00 3.0 --- ---

10 Girder ISMB-300 x 1670 mm 4 Nos 295.00 2.4 --- ---11 Girder ISMB-300 x 1230 mm 2 Nos 109.00 1.2 --- ---12 Bracing L 75x75x8 - 1780 mm 2 Nos 32.00 0.3 0.6 513 Bracing L 75x75x8 - 1650 mm 6 Nos 88.00 0.9 2.7 2214 Bracing L 90x90x8 - 2130 mm 2 Nos 46.00 0.4 1.2 1015 Bracing L 90x90x8 - 1020 mm 2 Nos 22.00 0.4 1.2 1016 Bracing L 90x90x8 - 970 mm 2 Nos 21.00 0.4 1.2 1017 Cleats L 75x75x10 - 220 mm 24 Nos 58.00 3.6 17.8 14318 Stiffener 60x280x10 mm 4 Nos 5.00 0.3 3.2 2619 Stiffener 65x424x12 mm 48 Nos 125.00 23.5 53.2 42620 Stiffener 65x137x12 mm 8 Nos 7.00 1.6 4.3 3521 R / F plate 180x300x16 mm 4 Nos 26.00 1.9 ( F10 ) 3.5 8122 R / F plate 250x250x16 mm 4 Nos 31.00 2.0 ( F10 ) 4.0 9223 Gusset plate 170x430x10 mm 2 Nos 12.00 2.0 1.0 2324 Gusset plate 150x230x8 mm 8 Nos 17.00 3.0 4.3 64

Pulley supporting structure :25 Girder ISMB-500 - 2040 mm 4 Nos 709.00 4.0 --- ---26 Flange 500x750x20 mm 4 Nos 236.00 4.8 7.8 18027 Diaphragm 590x488x12 mm 2 Nos 54.00 2.2 6.3 5128 Stiffener 80x476x12 mm 18 Nos 65.00 1.5 25.0 20029 Stiffener 120x510x12 mm 18 Nos 104.00 11.4 27.0 21630 Diaphragm 545x590x36 mm 2 Nos 182.00 2.3 ( F10 ) 6.4 41031 Diaphragm 590x769x20 mm 2 Nos 141.00 2.7 ( F10 ) 6.4 14832 R / F plate 200 dia x 16 mm 4 Nos 20.00 2.5 ( F10 ) 2.5 5833 Pin 190 dia x 800 mm 2 Nos 356.00 --- --- ---34 Nuts 130 dia 4 Nos 1.00 --- --- ---35 Washers 250/132 dia x 10 mm 2 Nos 6.00 2.4 --- ---36 Washers 250/120 dia x 10 mm 2 Nos 4.00 2.6 --- ---37 Pin 170 dia x 534 mm 2 Nos 190.00 --- --- ---38 Keeper pl 60x250x16 mm 4 Nos 8.00 0.3 --- ---39 Washer 280/172 dia x16 mm 2 Nos 10.00 2.9 --- ---40 Washer 250/172 dia x 2 mm 2 Nos 2.00 2.6 --- ---41 Washer 280/172 dia x 2 mm 4 Nos 5.00 2.9 --- ---42 Plate 200x750x16 mm 2 Nos 38.00 1.9 1.8 1543 Plate 380x750x16 mm 2 Nos 72.00 2.3 1.8 1544 Plate 425x1220x10 mm 4 Nos 163.00 6.6 6.6 52

Drive stool :

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GATES AND HOISTS

45 Pad plate 340x340x12 mm 1 No. 11.00 0.7 1.4 1246 Pad plate 220x620x12 mm 1 No. 13.00 0.8 0.9 847 Pad plate 430x620x12 mm 1 No. 25.00 1.1 2.5 2048 Pad plate 260x400x12 mm 1 No. 16.00 0.7 1.0 849 Web plate 259x1890x8 mm 2 Nos 60.00 2.5 --- ---50 Flange 90 x 1890x12 mm 2 Nos 31.00 4.0 7.6 6151 Stiffener 60x251x8 mm 2 Nos 2.00 0.1 1.5 1252 Stiffener 192x251x8 mm 1 No. 3.00 0.5 1.3 1153 Stiffener 177x200x8 mm 2 Nos 8.00 0.8 1.8 1554 Stiffener 177x192x8 mm 1 No. 4.00 0.4 1.1 955 Stiffener 100x259x8 mm 4 Nos 7.00 1.4 3.4 2856 Stiffener 192x259x8 mm 2 Nos 6.00 0.9 2.9 2457 Stiffener 50x136x8 mm 4 Nos 2.00 0.2 1.9 1658 Stiffener 136x192x8 mm 2 Nos 3.00 0.7 1.9 1659 Shim plates 340x340x2/2/1 mm 1 each 5.00 --- --- ---60 Shim plate 220x620x2/2/1 mm 1 each 5.00 --- --- ---61 Shim plate 430x620x2/2/1 mm 1 each 10.00 --- --- ---62 Bolts / Washers / Nuts 6.00 --- --- ---

Gear box :63 Web plate 532x2358x10 mm 2 Nos 196.00 5.8 9.5 7664 Web plate 532x410x10 mm 2 Nos 34.00 1.9 1.6 1365 Web plate 532x1178x10 mm 2 Nos 98.00 3.5 4.7 3866 Web plate 532x1230x10 mm 2 Nos 102.00 3.5 4.9 4067 Web plate 532x1300x10 mm 2 Nos 108.00 3.7 5.2 4268 Web plate 532x1230x10 mm 2 Nos 102.00 3.5 4.7 3869 Flange pl 140x2358x16 mm 2 Nos 82.00 5.0 9.4 7670 Flange pl 140x416x16 mm 2 Nos 14.00 1.1 1.6 1371 Flange pl 140x1178x16 mm 2 Nos 42.00 2.6 4.7 3872 Flange pl 140x670x16 mm 2 Nos 24.00 1.6 2.7 2273 Flange pl 140x1300x16 mm 2 Nos 46.00 2.9 5.2 4274 Flange pl 100x1230x16 mm 2 Nos 44.00 2.5 4.9 4075 Flange pl 150x2238x12 mm 2 Nos 66.00 4.8 9.3 7576 Flange pl 150x370x12 mm 2 Nos 10.00 0.8 1.5 1277 Flange pl 150x1058x12 mm 2 Nos 30.00 2.4 4.3 3578 Flange pl 150x1280x12 mm 2 Nos 36.00 2.9 5.2 4279 Flange pl 150x1190x12 mm 2 Nos 68.00 5.4 10.0 8080 Drum support 400x570x20 mm 4 Nos 144.00 4.5 ( F10 ) 4.0 23081 Pad plate 100x380x45 mm 4 Nos 56.00 0.4 ( F16 ) 3.9 24682 Pad plate 120x430x10 mm 4 Nos 16.00 2.2 4.4 3683 Stiffener 140x240x10 mm 8 Nos 22.00 3.0 8.3 6784 Stiffener 140x532x10 mm 8 Nos 40.00 5.4 13.0 10485 Stiffener 100x532x10 mm 24 Nos 100.00 2.4 35.2 28286 Stiffener 200x200x8 mm 12 Nos 30.00 4.8 14.4 11687 Flange pl 100x180x12 mm 2 Nos 4.00 0.2 0.7 688 Flange pl 100x600x10 mm 2 Nos 1.00 0.2 2.4 2089 Bolts / Nuts / Washers 10.00 --- --- ---

Floating shaft :90 Pipe 300 dia x 6671 mm 2 Nos 983.00 --- --- ---91 Flange pl 440/325 dia x 25 mm 4 Nos 54.00 9.6 ( F16 ) 4.0 25292 Plate 440 dia x 14 mm 1 No. 17.00 1.4 --- ---93 Stiffeners 55x100x10 mm 24 Nos 10.00 3.8 3.8 3194 Plate 300 dia x 8 mm 2 Nos 9.00 2.0 2.0 1695 Bolts / Nuts / Washers 13.00 --- --- ---

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GATES AND HOISTS

Gear box coupling :96 Plate 440/153 dia x 25 mm 2 Nos 54.00 3.7 ( F10 ) 1.9 4497 Hub 150 dia x 83 mm 2 Nos 20.00 --- --- ---98 Stiffener 60x140x10 mm 12 Nos 8.00 0.7 4.8 39

Other components :99 Plummer blocks for drums 4 Nos 192.00 --- --- ---

100 Bronze bush for plummers 4 Nos 32.00 --- --- ---101 Bolts / Nuts / Washers 12.00 --- --- ---102 Plummer blocks for gears 4 Nos 110.00 --- --- ---103 Bronze bush for plummers 4 Nos 28.00 --- --- ---104 Bolts / Nuts / Washers 7.00 --- --- ---105 Pulleys 720 PCD 6 Nos 1080.00 --- --- ---106 Bush for pulleys 6 Nos 84.00 --- --- ---107 Roap drums 290 dia x 1170 mm 2 Nos 2370.00 --- --- ---108 Shafts for drums / pinions 557.00 --- --- ---109 Gears 1310.00 --- --- ---110 Pinions 218.00

Covers for gear and drive units :111 ISA 45x45x5 mm 100.00 4.0 4.0 32112 Plates / Flats 250.00 16.0 20.0 80113 Round bars 15.00 0.1 0.5 4114 Bolt/Nut/Washers 10.00 --- --- ---

Other components :115 Manual operation assembly 124.00 10.0 10.0 230116 Gate position indicator 25.00 --- --- ---117 Wire rope 36 mm dia 448.00 --- --- ---118 Elecon gear units 1000.00 --- --- ---119 Electric motor 20 hp 1 No. 150.00 --- --- ---120 Ele-magnetic brake 29.00 --- --- ---121 Bolts / Nuts / Washers for above 15.00 --- --- ---

Total : 15440.00 254.6 447.2 5177kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angles / Beams / Channels / Bars : 2508.00 kgPlates / Flats : 3543.00 kg

2. Cast steel components : IS : 1030Rope drums 2 Nos / Gears 4 Nos : 3680.00 kgPinions : 218.00 kgPulleys 720 PCD 6 Nos : 1080.00 kgPlummer blocks / Hubs : 322.00 kg

3. Alloy steel steel components : IS : 1570Shafts : 557.00 kgPins 546.00 kg

4. Alluminium/ Bronze alloy components : IS : 305Bearings / Bush : 144.00 kgBolt / Nut / Washers IS : 1363MS Bolts / Nuts / Washers : 83.00 kg

5. Wire rope : IS : 226636 mm dia 6 / 37 construction 2 Nos : 100 Rm

6. Other components :Manual operating system : 1 No.Elecon gears : 2 NosElectric motor 20 hp : 1 No.Gate position indicator : 1 No.Ele-magnetic brake : 1 No.

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GATES AND HOISTS

MS pipe 300 mm dia : 13.32 Rm 7. Other details :

Length of cutting : 254.60 RmLength of welding : 447.20 RmNumber of electrodes : 5177 Nos

4. Foot bridge ( catwalk ) at spillway trunnion level : Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on 15 m clear span and 1 m wide catwalk drawings of Alamatti dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

1 ISMB 500 x 17900 mm 2 Nos 3111.00 5.2 2.0 162 ISMB 200 x 990 mm 15 Nos 377.00 10.0 6.0 483 ISA 75x75x8 x 150 mm 60 Nos 80.00 9.0 36.0 2884 ISA 75x75x8 x 17900 mm 2 Nos 319.00 1.0 72.0 5765 ISA 75x75x8 x 1000 mm 30 Nos 267.00 4.5 4.5 366 Chequered pl 990 x 17900 mm 1 No. 835.00 20.0 ( F3 ) 20.0 1207 32 dia pipe 17900 mm 4 Nos 225.00 --- --- ---8 Plate 300x300x12 mm 8 Nos 68.00 5.0 5.0 409 Plate 250x400x12 mm 4 Nos 28.00 2.5 5.2 42

10 Bolt/Nut/Washer 20 dia x 60 mm 16 Nos 8.00 --- --- --- Total : 5318.00 57.2 130.7 1166

kg Rm Rm NosABSTRACT :Structural steel : IS : 2062Angles / Beams / Channels / Bars : 4154.00 kgStructural steel plates / flats : 96.00 kgChequered plates : 835.00 kgBolts / Nuts / Washers : IS : 1363MS Bolts / Nuts / Washers : 8.00 kgOther components :MS pipes 32 mm dia : 71.60 RmOther details :Length of cutting : 57.2 RmLength of welding : 150.7 RmNumber of electrodes for 6 mm fillet weld : 1166 Nos

5. Embedded parts for spillway stoplog gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on 15 m span spillway stoplog gate embedded parts drawings of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

First stage anchors :1 Anchor plate 80x280x10 mm 36 Nos 63.00 2.9 --- ---2 Anchor bars dia 12 x 360 mm 72 Nos 26.00 0.9 2.7 223 Anchor plate 80x220x10 mm 70 Nos 97.00 5.6 --- ---4 Anchor bars dia 12 x 360 mm 140 Nos 50.00 1.7 5.3 435 Anchor plate 250x250x12 mm 3 Nos 18.00 1.5 --- ---6 Anchor bars dia 12 x 360 mm 6 Nos 2.00 0.1 0.2 2

Embedded parts :

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GATES AND HOISTS

7 SS plate 100x2400x6 mm 4 Nos 45.00 0.4 ( F4 ) 19.6 988 SS plate 100x2900x6 mm 2 Nos 27.00 0.2 ( F4 ) 11.8 599 SS plate 100x2300x6 mm 2 Nos 22.00 0.2 ( F4 ) 9.4 47

10 SS plate 120x2400x12 mm 4 Nos 108.00 10.1 ( F8 ) 19.7 29611 SS plate 120x2900x12 mm 2 Nos 66.00 6.0 ( F8 ) 11.8 17712 SS plate 120x2700x12 mm 2 Nos 61.00 5.6 ( F8 ) 11.1 16713 Track plate 180x2400x32 mm 4 Nos 434.00 10.3 ( DV ) 0.8 5314 Track plate 180x2900x28 mm 2 Nos 230.00 6.2 ( DV ) 0.4 2115 Track plate 180x2800x28 mm 2 Nos 222.00 6.0 ( DV ) 0.4 2116 Tr Angle 150x75x8 x 2400 mm 4 Nos 132.00 0.9 20.1 16117 Tr Angle 150x75x8 x 2900 mm 2 Nos 79.00 0.5 12.1 9718 Tr Angle 150x75x8 x 2400 mm 2 Nos 66.00 0.5 10.0 8019 Stiffener 70x120x8 mm 36 Nos 19.00 2.5 18.7 15020 Stiffener 85x312x8 mm 24 Nos 40.00 9.5 18.6 14921 Cleat ISA 75x75x8 x 100 mm 72 Nos 64.00 10.8 14.4 11622 SS plate 100x2160x6 mm 2 Nos 20.00 0.2 ( F4 ) 8.9 4523 SS plate 100x2650x6 mm 4 Nos 50.00 0.4 ( F4 ) 22.0 11024 Sill beam flange 130x2600x12 mm 2 Nos 64.00 5.5 ( DV ) 0.5 725 Sill beam flange 130x2650x12 mm 4 Nos 130.00 11.1 ( DV ) 1.0 1426 Sill beam web 150x2600x10 mm 2 Nos 61.00 5.5 11.0 8827 Sill beam web 150x2650x10 mm 4 Nos 125.00 11.2 22.4 18028 Stiffener 60x150x8 mm 12 Nos 7.00 0.7 5.1 4129 Stiffener 60x180x8 mm 12 Nos 8.00 0.7 5.1 4130 Anchor plate 80x200x10 mm 30 Nos 38.00 3.0 6.0 4831 SS plate 112x175x6 mm 2 Nos 2.00 0.6 ( F4 ) 1.2 632 Guide plate 140x2625x16 mm 6 Nos 277.00 16.6 ( DV ) 1.7 3333 Anchor plate 100x220x12 mm 42 Nos 87.00 4.2 8.4 6834 Anchor bolt dia 16 x 200 mm 144 Nos 46.00 2.3 7.3 5935 Anchor bolt dia 16 x 185 mm 144 Nos 42.00 2.3 7.3 5936 Nuts / Washers dia 16 mm 576 each 24.00 --- --- ---37 Anchor plate 40x250x6 mm 24 Nos 11.00 2.4 3.6 2938 Guide plate 140x3225x16 mm 2 Nos 113.00 6.7 ( DV ) 0.5 9

Dogging set :39 Bearing pl 150x200x25 mm 2 Nos 12.00 0.7 --- ---40 Anchors 60x250x10 mm 4 Nos 5.00 0.3 0.5 441 Diaphragm pl 596x790x12 mm 2 Nos 89.00 2.8 1.2 1042 Beam 150x750x36 mm 2 Nos 64.00 0.9 --- ---43 R / F plates 130x290x16 mm 4 Nos 19.00 1.7 1.0 844 Guide plate 140x220x25 mm 2 Nos 12.00 0.7 ( SV ) 0.5 945 Handle / stopper 2.00 --- 0.2 2

Total : 3179.00 162.9 302.5 2629kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angles / Beams / Channels / Bars : 421.00 kgPlates / Flats : 2245.00 kg

2. Alloy steel components : IS : 1570SS plates for wheel track 235.00 kgSS plates for seal seat : 166.00 kg

3. Bolts / Nuts / Washers : IS : 1363MS Bolts / Nuts / Washers : 112.00 kg

4. Other details :Length of cutting : 163.00 RmLength of welding : 303.00 RmNumber of electrodes ( for str steel ) : 1624 NosNumber of electrodes ( stainless steel ) : 1005 Nos

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GATES AND HOISTS

6. Spillway stoplog gate elements :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on stoplog elements drawings of 15 m spillway opening of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.Data for 1 element ( size 15 m x 1.2 m ) : 8 elements considered.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Gate leaf :1 Skin plate 1200x15620x16 mm 1 No. 2354.00 2.4 ( DV ) 2.4 462 Stiffener 80x790x10 mm 36 Nos 179.00 2.9 68.4 5483 Web plate 1400x15488x10 mm 2 Nos 3404.00 21.6 123.9 9924 Stiffener 120x1320x10 mm 20 Nos 249.00 28.8 62.4 5005 Flange 345x15816x20 mm 2 Nos 1713.00 33.0 --- ---6 Bracing ISA 65x65x6 x 730 mm 4 Nos 17.00 0.5 3.0 247 Bracing ISA 65x65x6 x 1339 mm 4 Nos 31.00 0.5 2.5 208 Plate 550x1200x16 mm 2 Nos 166.00 3.5 8.0 649 Slide block 40x1200x40 mm 2 Nos 30.00 0.1 ( F8 ) 4.8 53

10 Bronze padding for slide blocks 6.00 --- --- ---11 Seal base 45x1105x12 mm 2 Nos 9.00 2.3 4.4 3612 Seal support 25x14955x16 mm 1 Nos 47.00 --- 30.0 24013 Plate 140x140x12 mm 4 Nos 7.00 1.1 2.3 1914 Pin support 300x523x16 mm 4 Nos 79.00 3.4 6.0 4815 Pin 80 dia x 160 mm 2 Nos 13.00 --- --- ---16 Stiffener 340x528x10 mm 2 Nos 28.00 1.8 4.3 3517 Stiffener 340x740x10 mm 2 Nos 40.00 2.2 5.1 4118 Cleat ISA 65x65x6 x 150 mm 6 Nos 5.00 0.8 2.2 1819 Plate 150x150x10 mm 6 Nos 11.00 1.8 2.7 2220 Stiffener 50x550x12 mm 4 Nos 10.00 0.2 5.2 4221 Plate 100x14965x10 mm 1 No 117.00 0.2 30.0 24022 Stiffener 80x150x8 mm 40 Nos 30.00 3.2 18.4 14823 Plate 120x1004x10 mm 8 Nos 76.00 9.0 19.9 160

Guide Shoe :24 Plate 200x220x12 mm 4 Nos 17.00 1.7 --- ---25 Plate 97x220x12 mm 8 Nos 16.00 0.8 1.8 1526 Plate 28x220x12 mm 4 Nos 2.00 0.6 ( SV ) 1.8 3627 Plate 92x70x10 mm 8 Nos 4.00 --- 2.9 2428 Shims 7.00 --- --- ---29 Bolt/Nut/Washer 20 dia x60 mm 16 Nos 6.00 --- --- ---

Seal assembly :30 Bottom seal 100x15000x16 mm 1 No --- --- --- ---31 Side seals 100x1200x12 mm 2 Nos --- --- --- ---32 Seal clamp 90x1566x16 mm 2 Nos 35.00 --- --- ---33 Seal clamp 90x1598x16 mm 6 Nos 108.00 --- --- ---34 Seal clamp 90x1108x16 mm 2 Nos 25.00 --- --- ---35 Seal clamp 45x1190x16 mm 2 Nos 13.00 --- --- ---36 GI Bolts / Nuts 16 dia x 80 mm 24 Nos 5.00 --- --- ---37 GI Bolt / Nuts 16 dia x 75 mm 152 Nos 29.00 --- --- ---38 Washers 16 dia 176 Nos 2.00 --- --- ---

Total for 1 element 8890.00 122.4 403.4 3371Total for 8 elements 71120.00 979.2 3227.2 26968Additional supports for bottom element :

46 ISA 65x65x6 x 1000 mm 3 Nos 37.00 0.4 1.0 8 Total : 71157.00 979.6 3228.2 26976

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GATES AND HOISTS

kg Rm Rm NosABSTRACT :( For 8 Elements )

1. Structural steel : IS : 2062Angles / Beams / Channels : 461.00 kgPlates / Flats : 70208.00 kg

2. Alloy steel components : IS : 1570Pin : 104.00 kg

3. Alluminium / Bronze alloy components : IS : 305Bronze pads : 48.00 kg

4. Bolt / Nut / Washer : IS : 1363GI Bolts / Nuts / Washers : 288.00 kgMS Bolts / Nuts / Washers : 48.00 kg

5. Rubber seal : IS : 11855Bottom seal ( uncladed ) : 120.00 RmSide seal ( uncladed ) : 19.20 Rm

6. Other details :Length of cutting : 979.60 RmLength of welding : 3228.20 RmNumber of electrodes : 26976 Nos

7. Lifting beam for spillway stoplog gate elements :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on lifting beam drawings for spillway stoplog elements of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

1 Web plate 540x15476x8 mm 2 Nos 1050.00 33.0 ---2 Flange plate 150x15476x16 mm 4 Nos 1166.00 62.8 123.8 9913 Stiffener 100x400x10 mm 28 Nos 88.00 2.8 8.7 704 End plate 560x1120x12 mm 2 Nos 118.00 3.4 2.3 195 Stiffener 250x525x10 mm 4 Nos 41.00 3.1 6.2 506 Hook plate 350x625x20 mm 4 Nos 137.00 3.9 4.6 377 Stiffener 120x540x10 mm 20 Nos 102.00 13.2 31.2 2508 Plate 120x125x10 mm 8 Nos 9.00 2.0 3.9 329 Plate 200x200x16 mm 4 Nos 20.00 1.6 3.2 26

10 Plate 160x1130x10 mm 4 Nos 57.00 9.5 --- ---11 Plate 122x165x20 mm 2 Nos 6.00 0.6 0.5 412 Plate 60x162x10 mm 4 Nos 3.00 0.9 1.0 813 Plate 140x140x20 mm 10 Nos 31.00 2.8 --- ---14 Plate 200x2071x20 mm 48 Nos 260.00 17.0 --- ---15 Plate 427x604x25 mm 2 Nos 101.00 3.0 --- ---16 Hook 315x815x60 mm 2 Nos 100.00 --- --- ---17 Plate 100x160x20 mm 2 Nos 5.00 0.2 0.5 418 Bush dia 105 / 85 x 120 mm 2 Nos 5.00 --- --- ---19 Pin dia 85 x 268 mm 2 Nos 24.00 --- --- ---20 Keeper pl 40x140x10 mm 4 Nos 2.00 --- --- ---21 Pin dia 90 x 285 mm 2 Nos 29.00 --- --- ---22 Pin dia 120 x 252 mm 1 Nos 22.00 --- --- ---23 Pin dia 85 x 300 mm 2 Nos 26.00 --- --- ---24 Guide shoe pl 150x150x12 mm 4 Nos 8.00 1.2 --- ---25 Guide shoe pl 103x150x12 mm 8 Nos 12.00 2.0 1.2 1026 Plate 26x150x12 mm 4 Nos 2.00 0.7 ( SV ) 1.2 2427 Stiffener 40x93x8 mm 8 Nos 2.00 0.5 2.1 1728 Stiffener 140x120x10 mm 4 Nos 5.00 1.0 1.0 8

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GATES AND HOISTS

29 Stiffener 120x250x10 mm 2 Nos 5.00 0.8 1.0 830 Rod dia 60 x 300 mm 2 Nos 13.00 0.2 0.7 631 Stopper pl 60x210x20 mm 2 Nos 4.00 0.2 0.5 432 Plate 40x150x12 mm 1 No. 1.00 --- --- ---33 Bolt/Nut/Washer dia 24 x150 mm 2 Nos 1.00 --- --- ---34 Bolt/Nut/Washer dia 16 x35 mm 16 Nos 2.00 --- --- ---35 Plate 210x540x10 mm 8 Nos 71.00 6.0 17.3 139

Total : 3528.00 172.4 210.9 1707kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angle / Channel / Beam / Bar : 13.00 kgPlates / Flats : 3306.00 kg

2. Alloy steel components : IS : 1570Pin : 101.00 kg

3. Forged steel components : IS : 2004Hook : 103.00 kg

4. Alluminium / Bronze alloy components : IS : 305Bush : 5.00 kg

5. Bolts / Nuts / Washers IS : 1363MS Bolts / Nuts / Washers : 3.00 kg

6. Other details :Length of cutting : 172.40 RmLength of welding : 210.90 RmNumber of electrodes : 1707 Nos

8. Spillway gantry crane :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on 25 t spillway gantry crane drawings for Alamatti dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Portal :1 Plate 850/450x2650x10 mm 4 Nos 544.00 16.0 --- ---2 Plate 1500/850x2800x10 mm 4 Nos 858.00 20.0 ( DV ) 6.8 613 Plate 850/650x2700x10 mm 4 Nos 638.00 17.0 ( DV ) 2.6 254 Plate 1500/650x2650x10 mm 4 Nos 651.00 18.0 --- ---5 Plate 320x10700x20 mm 2 Nos 1076.00 22.0 86.0 6886 Plate 320x2589x20 mm 2 Nos 260.00 5.8 22.0 1767 Plate 320x1300x20 mm 2 Nos 131.00 3.3 10.4 848 Plate 320x1050x20 mm 2 Nos 106.00 2.8 9.7 789 Plate 320x2757x20 mm 2 Nos 277.00 6.2 23.4 188

10 Plate 320x1050x20 mm 2 Nos 106.00 2.8 9.7 7811 Plate 320x282x20 mm 8 Nos 114.00 4.8 ( DV ) 19.3 56012 Plate 320x728x20 mm 2 Nos 73.00 2.1 6.8 5513 Plate 320x450x16 mm 4 Nos 73.00 3.1 9.8 7914 Plate 320x650x16 mm 4 Nos 105.00 3.9 13.0 10415 Plate 320x500x10 mm 4 Nos 50.00 3.3 6.5 5216 Plate 280x489x8 mm 2 Nos 17.00 1.5 5.0 4017 Plate 280x584x8 mm 2 Nos 21.00 1.8 5.8 4718 Plate 280x725x8 mm 2 Nos 25.00 2.0 6.9 5619 Plate 280x850x8 mm 6 Nos 90.00 6.8 23.8 19120 Plate 280x839x8 mm 2 Nos 29.00 2.3 7.8 6321 Stiffener 280x774x8 mm 2 Nos 27.00 2.1 7.3 59

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GATES AND HOISTS

22 Stiffener 280x768x8 mm 2 Nos 27.00 2.1 7.3 5923 Stiffener 280x650x8 mm 2 Nos 23.00 1.9 6.3 5124 Stiffener 280x635x8 mm 2 Nos 22.00 1.8 6.2 5025 Stiffener 150x892x10 mm 2 Nos 21.00 2.1 4.8 3926 Plate 320x4231x16 mm 8 Nos 1361.00 36.4 --- ---27 Plate 500/380x4230x10 mm 8 Nos 1328.00 40.0 135.4 108428 Plate 240x240x10 mm 8 Nos 36.00 3.9 7.7 6229 Washer dia 160x10 mm 4 Nos 8.00 2.0 2.0 1630 Stiffener 280x500x8 mm 4 Nos 35.00 3.1 10.2 8231 Plate 280x468x8 mm 4 Nos 33.00 3.0 9.7 7832 Plate 280x431x8 mm 4 Nos 30.00 2.9 9.1 7333 Plate 280x393x8 mm 4 Nos 28.00 2.7 8.5 6834 Plate 280x380x8 mm 4 Nos 27.00 2.6 8.3 6735 Flange pl 380x7176x8 mm 2 Nos 342.00 15.1 --- ---36 Web plate 250x7176x8 mm 2 Nos 225.00 14.9 ( SV ) 28.7 25937 Stiffener 220x380x8 mm 8 Nos 42.00 4.8 16.2 13038 Flange pl 412x7176x10 mm 2 Nos 464.00 15.2 --- ---39 Stiffener 396x450x10 mm 2 Nos 28.00 1.7 3.4 2840 Web plate 450x7176x8 mm 2 Nos 406.00 15.3 ( SV ) 28.7 25941 Stiffener 396x450x8 mm 8 Nos 89.00 6.8 20.7 16642 Web plate 320x7176x10 mm 2 Nos 361.00 15.0 57.4 46043 Flange pl 510x7176x8 mm 2 Nos 460.00 15.4 --- ---44 End plate 430x630x12 mm 2 Nos 51.00 2.2 3.4 2845 Stiffener 284x510x8 mm 2 Nos 18.00 1.6 20.9 16846 Plate 400x7140x14 mm 2 Nos 628.00 15.0 --- ---47 Plate 1000x7140x10 mm 2 Nos 1121.00 16.3 ( SV ) 28.6 42948 Plate 360x1000x8 mm 10 Nos 226.00 13.6 47.2 37849 Plate 350x460x10 mm 4 Nos 51.00 3.3 6.5 5250 Pin dia 80 x 520 mm 2 Nos 41.00 --- --- ---51 Keeper pl 40x130x10 mm 4 Nos 2.00 0.2 --- ---52 Screw dia 12 x 50 mm 8 Nos 2.00 --- --- ---53 Plate 255x320x12 mm 16 Nos 123.00 9.2 --- ---54 Plate 180x450x8 mm 16 Nos 81.00 10.0 --- ---55 Bolt/Nut/Washer dia 10x40 mm 160 Nos 6.00 --- --- ---56 Bolt/Nut/Washer dia 16x80 mm 192 Nos 26.00 --- --- ---57 Plate 350x450x12 mm 4 Nos 60.00 3.2 6.4 5258 Plate 400x540x16 mm 4 Nos 108.00 3.8 ( F10 ) 7.5 16559 Plate 270x500x12 mm 4 Nos 52.00 3.1 6.2 50

Long travel wheel bogie :60 Plate 520x1400x16 mm 4 Nos 366.00 7.7 --- ---61 Plate 520x1556x16 mm 4 Nos 407.00 8.3 --- ---62 Plate 500x562x16 mm 4 Nos 141.00 4.3 4.5 3663 Plate 350x430x16 mm 6 Nos 113.00 4.1 7.3 5964 Plate 325x606x16 mm 2 Nos 50.00 1.9 3.0 2465 Plate 176x386x10 mm 6 Nos 32.00 3.4 13.5 10866 Plate 395x386x10 mm 6 Nos 72.00 4.7 9.5 7667 Plate 386x520x10 mm 2 Nos 31.00 1.8 2.8 2368 Plate 100x386x10 mm 4 Nos 12.00 0.4 0.1 169 Plate 75x370x10 mm 4 Nos 9.00 0.3 0.8 770 Plate 100x370x10 mm 12 Nos 35.00 1.2 13.7 11071 Plate 85x125x10 mm 24 Nos 20.00 5.0 10.1 8172 Plate 240x240x10 mm 16 Nos 72.00 7.7 15.4 12473 Plate 400x515x20 mm 4 Nos 129.00 3.7 ( F8 ) 7.3 11074 Plate 314x350x20 mm 8 Nos 138.00 5.3 5.6 4575 Plate 120x120x10 mm 8 Nos 9.00 2.0 3.9 3276 Plate 125x475x10 mm 8 Nos 37.00 4.8 11.6 93

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GATES AND HOISTS

77 ISMC100 x 845 mm 2 Nos 16.00 0.4 1.5 1278 ISMC100 x 845 mm 3 Nos 23.00 0.6 1.0 879 ISA 75x75x6 x 560 mm 4 Nos 15.00 0.6 0.6 580 Plate 230x440x10 mm 1 No 8.00 0.7 2.0 1681 Plate 130x360x10 mm 1 No 4.00 0.5 1.0 882 Plate 230x270x10 mm 1 No 5.00 0.5 0.8 783 Keeper pl 60x200x12 mm 8 Nos 9.00 0.5 --- ---84 Pin dia 100x515 mm 4 Nos 127.00 --- --- ---

Long travel wheel / gear / pinion / shafts :85 LT wheel 500 mm dia 8 Nos 1600.00 --- --- ---86 Wheel pin dia 120 x 442 mm 8 Nos 314.00 --- --- ---87 Sleeve for pin 150/115 dia x 340 mm 8 No 156.00 --- --- ---88 Wheel retainer 16 Nos 32.00 --- --- ---89 Gear 320 PCD x 75 mm 2 Nos 90.00 --- --- ---90 Sleeve for gear 2 Nos 3.00 --- --- ---91 Gear shaft 75/60 dia x 440 mm 2 Nos 30.00 --- --- ---92 Gear retainer 4 Nos 6.00 --- --- ---93 Rim gear 400 PCD x 80 mm 4 Nos 280.00 --- --- ---94 Pinion 136 PCD x 80 mm 2 Nos 16.00 --- --- ---95 Pinion retainer 2 Nos 2.00 --- --- ---96 Keeper pl 60x190x12 mm 16 Nos 17.00 --- --- ---97 Plate 50x180x12 mm 16 Nos 14.00 0.8 --- ---98 Plate 40x130x10 mm 2 Nos 1.00 0.1 --- ---99 Plate 40x120x10 mm 2 Nos 1.00 0.1 --- ---

100 Bolt/Nut/Washer dia 20x160 mm 48 Nos 22.00 --- --- ---101 Wheel bearing 16 Nos 80.00 --- --- ---102 Gear bearing 4 Nos 16.00 --- --- ---

Long travel drive assembly :103 Motor 5 hp 2 Nos 75.00 --- --- ---104 Solenoid operated brake 2 Nos 25.00 --- --- ---105 Worm reducer 2 Nos 500.00 --- --- ---

Trolley structure :106 ISMB 400 x 1990 mm 2 Nos 246.00 3.0 6.0 48107 ISMC 300 x 1990 mm 2 Nos 143.00 1.0 4.5 36108 ISMC 150 x 1980 mm 2 Nos 65.00 0.6 2.4 20109 ISMC 150 x 1685 mm 4 Nos 111.00 1.2 2.4 20110 ISMC 150 x 1230 mm 2 Nos 41.00 0.6 2.4 20111 ISMC 150 x 990 mm 2 Nos 32.00 0.6 2.4 20112 ISMC 250 x 1265 mm 2 Nos 77.00 0.8 2.8 23113 ISA 100x100x6 x 1265 mm 8 Nos 94.00 1.6 3.2 26114 Plate 430x590x10 mm 1 No. 20.00 1.0 1.2 10115 Plate 360x360x10 mm 1 No. 10.00 0.7 1.1 9116 Plate 300x500x12 mm 2 Nos 28.00 1.6 2.0 16117 Web plate 800x7800x10 mm 2 Nos 980.00 17.2 --- ---118 Flange pl 240x7800x20 mm 2 Nos 588.00 16.1 31.2 250119 Flange pl 240x6708x20 mm 2 Nos 506.00 13.9 26.9 216120 Plate 240x457x20 mm 4 Nos 69.00 2.8 4.6 37121 Plate 240x325x20 mm 4 Nos 49.00 2.3 3.6 29122 Plate 110x400x10 mm 24 Nos 83.00 12.3 29.8 239123 Plate 110x800x10 mm 12 Nos 83.00 10.9 24.5 196124 Plate 110x394x10 mm 10 Nos 14.00 2.0 4.9 40125 ISA 75x75x6 x 200 mm 4 Nos 6.00 0.6 1.4 12126 Web plate 400x3550x10 mm 4 Nos 446.00 15.8 --- ---127 Flange pl 70x3550x16 mm 4 Nos 125.00 14.5 28.4 228128 Flange pl 70x2778x16 mm 4 Nos 98.00 11.4 22.2 178129 Flange pl 70x295x16 mm 8 Nos 21.00 3.0 5.3 43

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GATES AND HOISTS

130 Flange pl 70x370x16 mm 8 Nos 26.00 3.5 6.5 52131 Plate 100x160x16 mm 16 Nos 32.00 4.2 6.4 52132 Plate 300x160x16 mm 4 Nos 24.00 1.9 3.7 30133 End plate 200x320x16 mm 4 Nos 32.00 2.1 4.2 34134 Stiffener 220x400x8 mm 10 Nos 55.00 6.2 8.0 64135 Stiffener 90x220x10 mm 4 Nos 6.00 1.3 3.2 26136 Plate 280x280x20 mm 4 Nos 49.00 2.3 3.4 28137 Plate 230x380x8 mm 2 Nos 11.00 1.2 2.4 20138 ISA 100x100x6 x 770 mm 4 Nos 28.00 0.8 1.6 13139 ISA 100x100x6 x 425 mm 4 Nos 16.00 0.8 1.6 13140 ISA 100x100x6 x 440 mm 4 Nos 16.00 0.8 1.6 13141 ISA 100x100x8 x 800 mm 2 Nos 19.00 0.4 3.5 28142 Plate 85x90x8 mm 4 Nos 2.00 0.7 2.1 17143 ISA 75x75x6 x 475 mm 2 Nos 7.00 0.3 0.6 5144 ISMC 150 x 440 mm 2 Nos 15.00 0.6 1.2 10145 Plate 200x250x10 mm 1 No. 4.00 0.5 0.6 5

End gear box base frame :146 ISMC 300 x 1750 mm 2 Nos 126.00 1.0 4.8 39147 ISMC 300 x 1425 mm 2 Nos 103.00 1.0 --- ---148 ISMC 300 x 1020 mm 2 Nos 74.00 1.0 4.8 39149 ISMC 300 x 1072 mm 2 Nos 77.00 1.0 4.8 39150 ISMC 300 x 830 mm 2 Nos 60.00 1.0 4.8 39151 ISMC 300 x 345 mm 2 Nos 25.00 1.0 4.8 39152 Plate 110x1750x12 mm 2 Nos 36.00 3.7 1.8 15153 Plate 110x730x12 mm 2 Nos 15.00 1.7 0.8 7154 Plate 60x1020x12 mm 2 Nos 12.00 0.2 1.4 12155 Plate 305x500x20 mm 3 Nos 72.00 2.4 2.7 22156 Plate 110x325x10 mm 4 Nos 11.00 1.8 2.5 20157 Plate 180x285x10 mm 12 Nos 48.00 5.6 13.3 107158 Plate 130x285x10 mm 6 Nos 18.00 2.5 6.1 49159 Plate 70x160x10 mm 8 Nos 7.00 1.9 3.7 30160 Plate 70x120x10 mm 4 Nos 3.00 0.8 1.5 12161 Plate 100x350x10 mm 2 Nos 6.00 0.9 0.8 7162 Plate 110x1750x20 mm 2 Nos 61.00 3.7 7.0 56163 Plate 110x1020x20 mm 2 Nos 35.00 2.3 4.1 33164 Plate 110x830x20 mm 2 Nos 29.00 1.9 3.3 27

Cross travel assembly :165 Cross travel wheels 450 mm dia 4 Nos 320.00 --- --- ---166 CT wheel gear 498 PCD x 80 mm 2 Nos 150.00 --- --- ---167 Pinion and shaft dia 60 x 535 mm 2 Nos 30.00 --- --- ---168 Driving wheel shaft 435 mm long 2 Nos 48.00 --- --- ---169 Floating shaft 60 dia x 2536 mm 2 Nos 116.00 --- --- ---170 Bearing journals 8 Nos 344.00 --- --- ---171 Idle wheel shaft 270 long mm 2 Nos 32.00 --- --- ---172 Wheel gear shaft 485 mm long 2 Nos 30.00 --- --- ---173 Outer retainer dia 220/92x6 mm 8 Nos 16.00 --- --- ---174 Inner retainer dia 220/117x6 mm 8 Nos 12.00 --- --- ---175 Pillow block with bronze bush 4 Nos 60.00 --- --- ---176 Collars dia 115x32 mm 2 Nos 5.00 --- --- ---177 Flexible coupling 2 Nos 25.00 --- --- ---178 Flanged coupling 2 Nos 30.00 --- --- ---179 Flanged coupling 2 Nos 70.00 --- --- ---

Drum and gear assembly :180 Rope drum 600 PCD x 1095 mm 2 Nos 1320.00 --- --- ---181 Drum hub bush 2 Nos 10.00 --- --- ---182 Drum gear 876 PCD x 1351 mm 2 Nos 330.00 --- --- ---

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GATES AND HOISTS

183 Second gear 570 PCD x 60 mm 2 Nos 160.00 --- --- ---184 Bearing bush 2 Nos 4.00 --- --- ---185 Pinion 1st reduction 216 PCD 2 Nos 64.00 --- --- ---186 Pinion 2nd reduction 190 PCD 2 Nos 26.00 --- --- ---187 Drum shaft 2 Nos 146.00 --- --- ---188 Pinion shaft 2 Nos 76.00 --- --- ---189 Third shaft 2 Nos 48.00 --- --- ---190 Plummer blocks 8 Nos 120.00191 Flexible coupling 2 Nos 25.00 --- --- ---192 Drum spacers 4 Nos 28.00 --- --- ---193 Clamp 100x150x25 mm 4 Nos 12.00 0.4 --- ---194 Bolt / Nut dia 20 x 100 mm 12 Nos 3.00 --- --- ---195 Bolt / Nut dia 20 x 80 mm 8 Nos 2.00 --- --- ---198 Keys ( various size ) 8 Nos 3.00 --- --- ---199 Keeper pl 50x295x12 mm 4 Nos 6.00 0.2 --- ---

Sheave assembly :200 Plate 760x1680x12 mm 2 Nos 200.00 6.0 --- ---201 Plate dia 300 x 8 mm 4 Nos 18.00 3.8 3.8 31202 Plate 50x210x10 mm 1 No. 1.00 --- --- ---203 ISA 75x75x6 x 75 mm 2 Nos 1.00 0.3 0.6 5204 Plate 232/126x 950x3 mm 2 Nos 10.00 2.0 2.0 16205 Main sheave 500 mm dia 2 Nos 200.00 --- --- ---206 Balancing sheave 320 mm dia 1 No. 75.00 --- --- ---207 Sheave bearing bush 6 Nos 50.00 --- --- ---208 Main sheave pin 2 Nos 57.00 --- --- ---209 Balancing sheave pin 1 No. 26.00 --- --- ---210 Hook cross piece 1 No. 10.00 --- --- ---211 Shanh hook 1 No. 100.00 --- --- ---212 Hook nut 1 No. 17.00 --- --- ---213 Hook lock pl 1 No. 20.00 --- --- ---214 Keeper plates 8 Nos 5.00 0.4 --- ---215 Plate 230x230x8 mm 2 Nos 7.00 1.8 1.8 15216 Thruster bearing for hook 1 No. 5.00 --- --- ---217 Wire rope 28 mm dia 6/37 con 150 m 406.00 --- --- ---

Trolley drive :218 Motor 3 hp for cross travel drive 1 No. 25.00 --- --- ---219 Motor 17.5 hp for load 1 No. 75.00 --- --- ---220 Worm reducer 2 Nos 800.00 --- --- ---221 Thruster brake 1 No. 25.00 --- --- ---222 Solenoid operated brake 1 No. 25.00 --- --- ---223 Brake for CT 1 No. 25.00 --- --- ---

Platform / Ladder :224 Chequered pl 6 mm th 16 sqm 800.00 18.0 2.0 16225 ISA 60x60x6 mm Hand railing 12 Rm 64.00 1.5 2.5 20226 Pipe 32 mm dia for railing/ ladder 50 Rm 150.00 --- --- ---227 Angles for cabin / ladder / covers etc 200.00 1.0 2.0 16

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GATES AND HOISTS

228 Plates for cabin / covers 270.00 17.5 12.6 10130856.00 760.6 1260.0 10960

kg Rm Rm NosABSTRACT :

1. Structural steel : IS : 2062Angle / Channel / Beam / Bars : 1700.00 kgPlates / Flats : 19219.00 kgChequered plate for platform covering : 800.00 kg

2. Cast steel components : IS : 1030Rope drums : 1320.00 kgGears : 1016.00 kgWheels with retainers : 1980.00 kgPinions : 149.00 kgPulley / sheave : 275.00 kgPlummer blocks / Bearing journals : 508.00 kgCouplings / Sleeves : 309.00 kg

3. Alloy steel components : IS : 1570Pins : 524.00 kgShafts : 556.00 kg

4. Forged steel components : IS : 2004Hook : 127.00 kg

5. Alluminium / Bronze alloy components : IS : 305Bearings / Bushes : 181.00 kg

6. Wire rope : IS : 226628 mm dia 6/37 construction : 150 Rm

7. Bolts / Nuts / Washers : IS : 1363MS Bolts / Nuts / Washers : 61.00 kg

8. Other components :Electric motor 3 hp : 1 No.Electric motor 5 hp : 2 Nos.Electric motor 17.5 hp : 1 No.Worm reducer : 4 NosBrakes 4 Nos : 4 NosPipe 32 mm dia for railing / ladder : 50 Rm

9. Other details :Length of cutting : 760.60 RmLength of welding : 1260.00 RmNumber of electrodes : 10960 Nos

9. Rail track for Spillway gantry crane : Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on 200 m length spillway gantry crane rail track drawings of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

1 Track rail 45 kg / m 2 x 200 m 18000.00 --- --- ---2 Anchor rod dia 16 x 430 mm 1068 Nos. 726.00 17.0 53.6 4293 Cleat ISA 65x65x6 x 260 mm 534 Nos. 805.00 69.5 ---4 Packing plate 50x50x10 mm 1068 Nos 210.00 53.4 53.4 4275 Clamp 50x90x8 mm 1068 Nos 302.00 53.4 53.4 4276 Bolt 60 mm / Nut / Washer 16 dia 1068 240.00 --- --- ---7 Plate 180x1200x12 mm 20 Nos 407.00 27.6 48.0 384

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GATES AND HOISTS

8 Buffers 150x190x36 mm 4 Nos 32.00 1.4 ( F16 ) 1.5 95 Total : 20722.00 222.3 209.9 1762.00

kg Rm Rm NosABSTRACT :

1. Structural steel : IS : 2062Angles / Beams / Channels / Bars : 1531.00 kgPlates / Flats : 951.00 kg

2. Bolts / Nuts / Washers : IS : 1363MS Bolts / Nuts / Washers : 240.00 kg

3. Other components :Rails 45 kg / m : 18000.00 kg

4. Other details :Length of cutting : 222.30 RmLength of welding : 209.90 RmNumber of electrodes : 1762 Nos

10. Embedded parts without groove lining for river / canal sluice service gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on emedded parts drawings for river sluice service gate of Upper Tunga dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

First stage anchors :1 Anchor plate 100x210x10 mm 28 Nos 46.00 8.7 5.6 452 Anchor bar 12 dia x 350 mm 56 Nos 18.00 0.7 1.0 173 Anchor plate 100x180x10 mm 24 Nos 34.00 6.7 4.8 384 Anchor bar 12 dia x 350 mm 48 Nos 15.00 0.6 1.8 155 Anchor plate 80x515x8 mm 10 Nos 26.00 6.0 3.6 296 Anchor bar 12 dia x 350 mm 20 Nos 6.00 0.3 0.8 67 Anchor plate 80x150x10 mm 20 Nos 19.00 1.6 --- ---8 Anchor bar 12 dia x 350 mm 40 Nos 13.00 0.5 1.5 129 Anchor plate 80x150x10 mm 24 Nos 23.00 1.9 --- ---

10 Anchor bar 12 dia x 350 mm 48 Nos 15.00 0.6 1.8 1411 Anchor plate 100x210x10 mm 20 Nos 33.00 2.0 --- ---12 Anchor bar 12 dia x 350 mm 40 Nos 13.00 0.5 1.5 12

Embedded parts :13 Anchor bolt 16 dia x 285 mm 48 Nos 22.00 0.8 2.4 1914 Anchor bolt 16 dia x 200 mm 8 Nos 2.00 0.1 0.4 315 Anchor bolt 16 dia x 185 mm 20 Nos 6.00 0.3 1.0 816 Anchor bolt 16 dia x 500 mm 24 Nos 18.00 0.4 1.2 1017 Alignment plate 100x210x10 mm 28 Nos 46.00 2.8 --- ---18 Alignment plate 100x180x10 mm 24 Nos 34.00 2.4 --- ---19 Alignment plate 80x515x8 mm 10 Nos 26.00 0.8 --- ---20 Split anchor plate 60x400x6 mm 20 Nos 23.00 10.4 3.6 2921 Nut / Washer for anchor bolts 200 Nos 10.00 --- --- ---22 SS track 115x6750x10 mm 2 Nos 122.00 13.7 27.5 22023 Track base 130x7100x12 mm 2 Nos 174.00 14.5 28.4 22724 Track base ISMB 200x7100 mm 2 Nos 360.00 0.6 --- ---25 Sill beam ISMB 200x2300 mm 1 No. 58.00 0.3 --- ---26 SS seal seat 115x2300x6 mm 1 No. 12.00 2.4 ( F4 ) 4.6 2327 SS seal seat 80x3035x5 mm 2 Nos. 19.00 6.3 ( F4 ) 12.2 6128 Seal base ISA100x100x8 x3020 mm 2 No 73.00 0.4 --- ---29 SS seal seat 1680x1985x5 mm 1 No. 131.00 3.7 ( F4 ) 7.4 3730 SS seal seat 1680x1975xx5 mm 1 No. 130.00 3.7 ( F4 ) 7.3 37

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GATES AND HOISTS

31 Seal base 1700x2000x20 mm 2 Nos 1068.00 7.4 --- ---32 Guide 120x2200x20 mm 2 Nos 82.00 4.7 --- ---33 Guide 120x2400x20 mm 4 Nos 180.00 10.1 --- ---34 Stiffener 130x1700x20 mm 1 No. 35.00 2.0 3.4 2735 Stiffener 120x390x8 mm 8 Nos 24.00 4.1 10.1 8136 Stiffener 130x1700x10 mm 3 Nos 52.00 5.5 10.2 8237 Stiffener 120x1960x10 mm 10 Nos 184.00 20.8 44.0 35238 Cleat ISA75x75x8 x 80 mm 24 Nos 17.00 3.6 4.8 3839 Spacer pipe/ washer 20 dia x 20 mm 1.00 --- --- ---40 Bolt / Nut / Washer 16 dia x 60 mm 8 No 2.00 --- --- ---

Total : 3172.00 151.9 190.9 1442.0kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angle / Channel / Beam / Bars : 588.00 kgPlates / Flats : 2109.00 kg

2. Alloy steel components : IS : 1570Stainless steel plates : 414.00 kg

3. Bolt / Nut / Washer : IS : 1363MS Bolt / Nut / Washer : 61.00 kg

4. Other details :Length of cutting : 152.00 RmLength of welding : 191 RmNumber of electrodes ( str steel ) : 1064 NosNumber of electrodes ( stainless steel ) : 378 Nos

11. Embedded parts with groove lining for river / canal sluice service gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on emedded parts drawings for river sluice service gate of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

First stage anchors :1 Plate 80x210x10 mm 162 Nos 214.00 13.0 --- ---2 Anchor bar 12 dia x 350 mm 324 Nos 100.00 3.9 12.2 983 Plate 80x80x10 mm 82 Nos 41.00 6.6 --- ---4 Anchor bar 12 dia x 350 mm 82 Nos 25.00 1.0 3.1 25

Embedded parts :5 SS seal seat 100x2800x6 mm 1 No. 13.00 0.1 ( F4 ) 5.8 297 Liner plate 666x3550x20 mm 1 No. 371.00 4.2 --- ---

10 Stiffener 220x3520x10 mm 1 Nos 61.00 3.8 7.0 5611 Stiffener 120x3520x10 mm 1 Nos 33.00 3.7 7.0 5613 Stiffener 155x420x8 mm 3 Nos 12.00 1.7 4.4 3615 Cleat ISA 75x75x8 x 80 mm 44 Nos 31.00 6.6 8.3 6716 SS B/W seat 1300x2720x6 mm 1 No. 167.00 4.0 ( F4 ) 8.0 4017 SS B/W seat 1976x2720x6 mm 1 No. 253.00 4.7 ( F4 ) 9.4 4718 Base plate 2000x2750x20 mm 1 No. 864.00 4.8 ( DV ) 2.8 8719 base plate 2000x3640x20 mm 1 No. 1143.00 5.7 --- ---20 Bottom liner Gr 484x2600x20 mm 1 No. 198.00 3.1 5.2 4221 Stiffener 180x1898x10 mm 7 Nos 188.00 14.5 26.6 21322 Stiffener 180x1960x10 mm 7 Nos 194.00 15.0 27.4 22023 Stiffener 100x2570x10 mm 1 No. 20.00 0.1 5.2 4224 Stiffener 100x410x10 mm 30 Nos 97.00 3.0 36.6 29325 SS track plate 150x3000x20 mm 2 Nos 141.00 6.3 ( F8 ) 12.3 185

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GATES AND HOISTS

26 Track base pl 200x3000x40 mm 2 Nos 377.00 6.4 ( DV ) 0.4 5627 Web plate 320x3000x20 mm 2 Nos 301.00 6.7 12.7 10228 Track ISMB 150 x 4200 mm 8 Nos 504.00 2.4 ( DV ) 2.4 3629 Anchor plate 80x200x10 mm 66 Nos 83.00 5.3 10.5 8430 Anchor plate 80x200x12 mm 80 Nos 121.00 6.4 12.8 10331 Guide 110x2050x16 mm 20 Nos 566.00 43.2 ( Dv ) 2.2 8632 Anchor bolt 16 dia x 300 mm 12 Nos 6.00 0.2 0.6 533 Anchor bolt 16 dia x 185 mm 180 Nos 53.00 2.9 9.0 7234 Anchor bolt 16 dia x 135 mm 112 Nos 24.00 0.4 5.6 4535 Anchor bolt 16 dia x 380 mm 32 Nos 20.00 0.5 1.6 1336 Nut / Washer for 16 dia bolt 672 Nos 29.00 --- --- ---37 Cover plate 270x290x10 mm 4 Nos 25.00 2.3 --- ---38 Back strip 40x2610x6 mm 2 Nos 10.00 0.1 5.2 4239 Split anchor 80x400x8 mm 25 Nos 50.00 4.0 5.5 4440 Bolt/Nut/Washer 25 diax65 mm 24 Nos 7.00 --- --- ---41 Track base pl 220x4767x40 mm 2 Nos 659.00 10.0 --- ---42 Track web pl 320x4767x20 mm 2 Nos 479.00 10.2 ( Dv ) 19.0 58943 SS track plate 170x4150x20 mm 2 Nos 222.00 8.7 ( F8 ) 17.3 26044 Side plate 210x3917x20 mm 2 Nos 258.00 8.3 15.7 12645 Side plate 115x3029x20 mm 2 Nos 109.00 6.3 12.1 9747 Stiffener 260x295x8 mm 8 Nos 39.00 4.5 8.9 7248 Stiffener 210x260x8 mm 4 Nos 14.00 1.9 3.8 3149 Stiffener 210x260x10 mm 2 Nos 9.00 1.5 2.6 2150 Anchor plate 80x200x10 mm 16 Nos 20.00 1.3 2.6 2151 Groove lining 560x3915x20 mm 2 Nos 688.00 9.0 17.9 14452 Guide 40x3878x16 mm 2 Nos 39.00 0.1 15.5 12453 Stiffener 100x3915x10 mm 2 Nos 61.00 0.2 16.0 12854 Stiffener 100x3841x10 mm 2 Nos 60.00 0.2 15.8 12755 Stiffener 120x3878x10 mm 2 Nos 73.00 8.0 15.5 12456 Stiffener 110x265x8 mm 16 Nos 29.00 6.0 12.0 9657 Cleat ISA 75x75x6 x 80 mm 28 Nos 15.00 4.0 7.5 6058 SS seal seat 100x3052x6 mm 2 Nos 29.00 0.2 ( F4 ) 12.6 6359 Liner plate 570x3029x20 mm 2 Nos 542.00 7.2 ( SV ) 1.2 6061 Stiffener 120x3024x10 mm 2 Nos 57.00 6.3 12.5 10062 Stiffener 330x220x10 mm 6 Nos 34.00 3.3 7.9 6464 Stiffener 460x820x10 mm 3 Nos 89.00 3.9 7.3 5966 Stiffener 80x975x10 mm 8 Nos 49.00 0.7 16.9 13668 Stiffener 80x988x10 mm 4 Nos 25.00 0.3 8.8 7169 B/W liner 800x2780x20 mm 1 No. 349.00 3.6 7.2 5870 B/W liner 484x2780x20 mm 1 No. 211.00 3.3 6.5 5271 Stiffener 100x2740x10 mm 1 No. 43.00 0.2 5.5 4472 Stiffener 100x1245x10 mm 2 Nos 10.00 0.1 5.8 4773 Anchor bolt 16 dia x 185 mm 32 Nos 9.00 0.5 1.6 1374 Anchor bolt 16 dia x 355 mm 28 Nos 16.00 0.5 1.4 1275 Anchor bolt 16 dia x 450 mm 12 Nos 9.00 0.2 0.6 576 Nut / Washer for 16 dia bolt 144 Nos 7.00 --- --- ---78 Back strip 40x3027x8 mm 6 Nos 46.00 0.3 18.2 14679 Cleat ISA 75x75x6 x 80 mm 12 Nos 6.00 1.8 1.9 1680 Stiffener 110x195x10 mm 6 Nos 10.00 1.8 3.7 30

Total : 10657.00 301.0 551.6 5220.0kg Rm Rm Nos

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GATES AND HOISTS

ABSTRACT : 1. Structural steel : IS : 2062

Angle / Channel / Beam / Bars : 681.00 kgPlates / Flats : 8971.00 kg

2. Alloy steel components : IS : 1570Stainless steel plates : 825.00 kg

3. Bolt / Nut / Washer : IS : 1363MS Bolt / Nut / Washer : 180.00 kg

4. Other details :Length of cutting : 301.00 RmLength of welding : 552 RmNumber of electrodes ( str steel ) : 4596 NosNumber of electrodes ( stainless steel ) : 624 Nos

12. Vent lining for river / canal sluice vents.Details of materials / Gas cutting / Welding for rate analysis :( For 38.50 sqm finished lining area )

Note : 1. Data based on groove / vent lining drawings for 2 m x 3 m river sluice vents of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Vent liner parts :1 Liner plate 454x2610x20 mm 1 No. 186.00 3.1 5.2 422 Liner plate 429x2610x20 mm 1 No. 176.00 3.1 5.2 423 Stiffener 110x2580x10 mm 4 Nos 89.00 10.8 20.6 1654 Stiffener 139x294x8 mm 3 Nos 8.00 1.3 3.4 285 Stiffener 139x299x8 mm 3 Nos 8.00 1.3 3.5 286 Side plate 225x3062x20 mm 2 Nos 216.00 6.6 12.3 997 Liner plate 250x3064x20 mm 2 Nos 240.00 6.7 25.0 2008 Stiffener 70x80x8 mm 48 Nos 17.00 3.9 14.4 1169 Side liner 230x1020x20 mm 8 Nos 295.00 10.0 20.0 160

10 Plate 230x1018x20 mm 4 Nos 147.00 5.0 10.0 8011 Side lining D/S 2525x3358x20 mm 2 Nos 2662.00 11.8 33.6 26912 Top/bottom liner 2547x2580x20 mm 2 No. 2063.00 10.3 10.3 8313 Stiffener 120x2780x10 mm 12 Nos 314.00 34.8 66.7 53414 Stiffener 120x3066x10 mm 12 Nos 347.00 38.3 73.6 58915 Stiffener 160x455x8 mm 60 Nos 274.00 36.9 93.0 74416 Split anchor 80x400x8 mm 119 Nos 239.00 19.0 22.6 181

Total : 7281.00 202.9 419.4 3360.0kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Plates / Flats : 7281.00 kg 2. Other details :

Length of cutting : 203 RmLength of welding : 420 RmNumber of electrodes ( str steel ) : 3360 Nos

13. River / canal sluice service gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on river sluice service gate drawings 2 m x 3 m sluice opening of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

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GATES AND HOISTS

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Gate leaf :1 Skin plate 3220x3372x18 mm 1 No. 1534.00 6.6 --- ---2 Ver stiffener 140x688x10 mm 28 Nos 212.00 23.2 54.2 4343 Web plate 350x688x10 mm 6 Nos 114.00 6.2 16.7 1344 Web plate 350x688x10 mm 2 Nos 38.00 2.0 5.8 475 Girder web 350x2788x12 mm 4 Nos 368.00 12.5 50.2 4026 Girder web 390x2788x12 mm 1 No 102.00 3.2 7.1 577 Flange plate 320x2788x20 mm 4 Nos 560.00 12.5 ( SV ) 2.6 1308 Flange plate 250x2788x20 mm 1 No. 109.00 3.0 ( SV ) 3.3 1659 End plate 370x3251x12 mm 4 Nos 453.00 14.5 26.0 208

10 Flange plate 150x380x12 mm 6 Nos 32.00 3.2 6.4 5211 Flange plate 150x152x12 mm 2 Nos 4.00 0.6 1.2 1012 Flange plate 80x380x18 mm 6 Nos 26.00 0.5 ( SV ) 3.2 10013 Flange plate 80x152x18 mm 2 Nos 4.00 0.2 ( SV ) 1.0 3114 End ver plate 80x3170x18 mm 2 Nos 72.00 0.2 SV ) 6.4 19915 Diaphragm plate 188x360x12 mm 10 Nos 64.00 5.5 18.2 14616 End stiffener 50x352x12 mm 24 Nos 40.00 1.2 21.7 17417 Pad plate 250x300x16 mm 8 Nos 75.00 4.4 8.8 7118 Stiffener 80x130x10 mm 8 Nos 7.00 0.7 3.4 2819 Support plate 20x2540x16 mm 1 No. 6.00 2.6 5.1 4120 Seal support 65x2905x12 mm 2 Nos 36.00 5.9 --- ---21 Support plate 20x3105x12 mm 2 Nos. 12.00 6.3 12.5 10022 Sealing frame 65x2795x12 mm 1 No. 17.00 2.8 --- ---23 Sealing frame 20x2755x12 mm 1 No. 5.00 2.8 5.5 4424 Seal support 65x1965x12 mm 1 No. 12.00 2.0 --- ---25 Seal support 65x375x12 mm 2 Nos 5.00 0.9 --- ---26 Stopper 20x2540x12 mm 1 No. 5.00 2.5 5.1 4127 Plate 50x70x12 mm 2 Nos 1.00 0.1 0.2 228 Bracket plate 400x570x16 mm 4 Nos 115.00 3.9 3.2 2629 Bracket plate 180x785x6 mm 2 Nos 13.00 2.0 1.0 830 Stiffener 172x350x12 mm 4 Nos 23.00 2.0 5.5 4431 Stiffener 56x250x12 mm 4 Nos 5.00 1.2 4.4 3632 Counter weight ( CI blocks ) 4000.00 --- --- ---33 GI Bolt/Nut/Washer 24 diax280 mm 60 No 72.00 --- --- ---34 Plates for guide roller 4 sets 72.00 1.4 1.8 1535 Guide roller 4 Nos 8.00 --- --- ---

Wheel assembly : --- ---36 Wheels 484.00 --- --- ---37 Bearings 76.00 --- --- ---38 Bearing retainer plate 80.00 --- --- ---39 Cover plate 8.00 --- --- ---40 Spacer plates 16.00 --- --- ---41 Stainless steel pin 132.00 --- --- ---42 Keeper plate 8.00 0.1 --- ---43 GI Bolt / Nut / Screw / Washer 2.00 --- --- ---44 MS Bolt / Nut / Screw / Washer 4.00 --- --- ---

Seal assembly :45 Flat bottom seal 2755 mm 1 No. --- --- --- ---46 Music note side seal 2855 mm 2 Nos --- --- --- ---47 Double flange top seal 2199 mm 1 No. --- --- --- ---48 Corner seal 2 Nos --- --- --- ---49 seal clamp 90x2545x20 mm 1 No. 36.00 0.1 --- ---50 Seal clamp 45x1495x20 mm 2 Nos 21.00 0.1 --- ---51 Seal clamp 45x1628x20 mm 2 Nos 23.00 0.1 --- ---

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GATES AND HOISTS

52 Seal clamp 45x2545x20 mm 1 No. 18.00 --- --- ---53 Seal clamp 45x2660x20 mm 1 No. 19.00 0.1 --- ---54 SS Bolt / Nut / Washer 20 dia x 80 mm 10.00 --- --- ---55 SS Bolt / Nut / Washer 20 dia x 100 mm 44.00 --- --- ---

Total : 9202.00 137.1 280.5 2745kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Plates / Flats : 4370.00 kg 2. Cast steel components : IS : 1030

Wheels / Guide roller : 492.00 kg 3. Alluminium / Bronze alloy components : IS : 305

Bearings / Bushes : 76.00 kg 4. Alloy steel components : IS : 1570

Wheel axle / lifting pin : 132.00 kg 5. Rubber seals : IS : 11855

Bottom rubber seal ( uncladed ) : 2.76 RmSide rubber seal ( teflon claded ) : 5.71 RmTop rubber seal ( teflon claded ) 2.20 RmCorner seal 2 Nos

6. Bolt / Nut / Washer IS : 1363SS Bolt / Nut / Washer : 54.00 kgGI Bolt / Nut / Washer 80.00 kg

7. Other components :CI counter weight : 4000.00 kg

8. Other details :Length of cutting : 137.10 RmLength of welding : 280.50 RmNumber of electrodes : 2745 Nos

14. Rope drum hoist for river / canal sluice service gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on 25 t rope drum hoist drawings for river sluice service gate of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Hoist frame :1 ISMC 400 x 3900 mm 4 Nos 782.00 2.4 --- ---2 ISMC 250 x 935 mm 3 Nos 80.00 1.2 --- ---3 ISMC 250 x 1236 mm 2 Nos 76.00 0.8 --- ---4 ISMC 200 x 1330 mm 8 Nos 237.00 2.8 --- ---5 ISMC 200 x 440 mm 2 Nos 20.00 0.7 --- ---6 ISMC 150 x 1330 mm 6 Nos 134.00 1.8 --- ---7 Bracket plate 300x560x16 mm 4 Nos 84.00 2.4 4.8 398 Stiffener 95x160x10 mm 8 Nos 10.00 2.0 4.1 339 Stiffener 85x378x10 mm 24 Nos 61.00 11.1 26.3 211

10 Base plate 145x370x30 mm 2 Nos 25.00 1.0 1.1 911 Stiffener 120x399x10 mm 2 Nos 8.00 1.1 2.1 1712 Base plate 110x430x10 mm 2 Nos 8.00 1.0 1.2 1013 ISMC 400 x 110 mm 2 Nos 14.00 1.2 0.5 414 Base plate 336x340x10 mm 1 No. 9.00 0.7 0.5 415 Base plate 160x390x10 mm 1 No. 5.00 0.6 0.5 416 Base plate 210x300x10 mm 1 No. 5.00 0.5 0.5 417 Cleat ISA 50x50x6 x 150 mm 36 Nos 22.00 3.6 18.0 144

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GATES AND HOISTS

18 Cleat ISA 65x65x6 x 180 mm 20 Nos 21.00 2.6 12.4 10119 Cleat ISA 50x50x6 x 100 mm 24 Nos 11.00 2.4 9.6 7720 Cleat ISA 50x50x6 x 121 mm 2 Nos 1.00 0.2 0.9 821 Cleat ISA 50x50x6 x 116 mm 2 Nos 1.00 0.2 0.9 822 Base plate 200x250x20 mm 8 Nos 63.00 3.6 --- ---23 Bracket plate 300x500x12 mm 2 Nos 28.00 1.6 1.4 1224 Stiffener 260 dia x 12 mm 2 Nos 13.00 1.6 1.6 1325 Anchor bolt 20 dia x 350 mm 16 Nos 14.00 0.3 1.0 826 Nut / Washer 20 dia 16 Nos 1.00 --- --- ---27 Anchor plate 60x60x12 mm 16 Nos 5.00 1.0 --- ---28 Bolt/Nut/Washer dia 22 x 85 mm 4 Nos 2.00 --- --- ---29 Bolt/Nut/Washer dia 10 x 65 mm 4 Nos 1.00 --- --- ---30 Bolt/Nut/Washer dia 14 x 65 mm 4 Nos 1.00 --- --- ---31 Bolt/Nut/Washer dia 16 x 65 mm 4 Nos 1.00 --- --- ---32 Bolt/Nut/Washer dia 24 x 110 mm 4 Nos 3.00 --- --- ---33 ISMC 150 x 935 mm 2 Nos 31.00 0.6 --- ---34 ISMC 200 x 935 mm 1 No. 21.00 0.4 --- ---35 Plate 80x2250x10 mm 2 Nos 28.00 0.2 9.3 7536 Chequered plate 6 mm th 6 sqm 283.00 6.0 --- ---

Plummer blocks :37 Plummer body 2 Nos 72.00 --- --- ---38 Bronze bush 2 Nos 13.00 --- --- ---39 Shims 2 Nos 2.00 --- --- ---40 Bolt/Nut/Washer 4 Nos 1.00 --- --- ---

Shafts :41 Drum shaft 110 dia x 1381 mm 2 Nos 206.00 --- --- ---42 1st pinion shaft 70 dia x 650 mm 1 No. 20.00 --- --- ---43 2nd pinion shaft 120 dia x 1350 mm 1 No. 120.00 --- --- ---

Drum assembly :44 Drum 560 PCD 2 Nos 1420.00 --- --- ---45 Bronze bush 140/110 diax140 mm 2 Nos 12.00 --- --- ---46 Bronze bush 140/110 diax100 mm 2 Nos 10.00 --- --- ---47 Spacers 240/112 x 10 mm 2 Nos 6.00 --- --- ---48 Spacers 240/112 x 6 mm 2 Nos 4.00 --- --- ---49 Clamping plate 100x150x32 mm 4 Nos 16.00 0.4 --- ---50 Lock plate 50x210x12 mm 4 Nos 4.00 0.2 --- ---51 Bolt/Nut/Washer 12 Nos 5.00 --- --- ---

Gears and pinions :52 Drum gear 980 PCD 2 Nos 350.00 --- --- ---53 Gear 800 PCD 1 No. 156.00 --- --- ---54 1st reduction pinion 1 No. 19.00 --- --- ---55 2nd reduction pinion 2 No. 60.00 --- --- ---

Pulleys and sheaves :56 Pulley 672 PCD 2 Nos 180.00 --- --- ---57 Pin 120 dia x 262 mm 2 Nos 46.00 --- --- ---58 Bronze bush 145/120 dia x 160 mm 2 14.00 --- --- ---59 Spacer 170/123 dia 2.00 --- --- ---60 Lock plate 50x190x12 mm 4 Nos 4.00 0.2 --- ---61 Pulley 350 PCD 1 No. 76.00 --- --- ---62 Pin 130 dia x 258 mm 1 No. 27.00 --- --- ---63 Bronze bush 1 No. 8.00 --- --- ---64 Brass Washer 180/132x8 mm 2 Nos 2.00 --- --- ---65 Keeper plate 50x190x12 mm 2 Nos 2.00 0.1 --- ---

Hoist drive :66 Electric motor 5 hp 1 No. 50.00 --- --- ---67 Worm reducer 1 No. 500.00 --- --- ---

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GATES AND HOISTS

68 Flexible coupling 2 Nos 50.00 --- --- ---69 Wire rope 28 dia 6x37 constn 120 m 500.00 --- --- ---70 Manual operation assembly 1 No. 120.00 --- --- ---71 Position indicator 1 No. 32.00 --- --- ---72 EM brake 1 No. 25.00 --- --- ---

Total : 6243.00 56.5 96.7 781.0kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angle / Channel / Beam / Bars : 1451.00 kgPlates / Flats : 392.00 kgChequered plate for platform covering : 283.00 kg

2. Cast steel components : IS : 1030Rope drums 2 Nos : 1420.00 kgGears 3 Nos : 506.00 kgPinions : 79.00 kgPulleys 3 Nos / Couplings 2 Nos : 306.00 kgPlummer blocks : 72.00 kg

3. Alloy steel components : IS : 1570Shafts : 346.00 kgPins : 73.00 kg

4. Alluminium / Bronze alloy components : IS : 305Bearings / Bushes : 57.00 kg

5. Wire rope : IS : 226628 mm dia 6/37 construction rope : 120 Rm

6. Bolts / Nuts / Washers : IS : 1363Bolts / Nuts / Washers ( various size ) : 31.00 kg

7. Other components :Electric motor 5 hp Standard : 1 No.Worm reducer Standard : 1 NoElectro-megnatic brake Standard : 1 NoManual operation assembly : 1 No.Position indicator : 1 No.

8. Other details :Length of cutting : 56.50 RmLength of welding : 96.70 RmNumber of electrodes : 781 Nos

15. Embedded parts without groove lining for river / canal sluice emergency gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on emedded parts drawings for river sluice service gate of Upper Tunga dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

First stage anchors :1 Anchor plate 100x210x10 mm 28 Nos 46.00 8.7 5.6 452 Anchor bar 12 dia x 350 mm 56 Nos 18.00 0.7 1.0 173 Anchor plate 100x180x10 mm 40 Nos 56.00 11.1 8.0 644 Anchor bar 12 dia x 350 mm 48 Nos 15.00 0.6 1.8 155 Anchor plate 80x515x8 mm 10 Nos 26.00 6.0 3.6 296 Anchor bar 12 dia x 350 mm 36 Nos 11.00 0.5 1.4 117 Anchor plate 80x150x10 mm 20 Nos 19.00 1.6 --- ---8 Anchor bar 12 dia x 350 mm 40 Nos 13.00 0.5 1.5 129 Anchor plate 80x150x10 mm 24 Nos 23.00 1.9 --- ---

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GATES AND HOISTS

10 Anchor bar 12 dia x 350 mm 48 Nos 15.00 0.6 1.8 1411 Anchor plate 100x210x10 mm 20 Nos 33.00 2.0 --- ---12 Anchor bar 12 dia x 350 mm 40 Nos 13.00 0.5 1.5 12

Embedded parts :13 Anchor bolt 16 dia x 285 mm 48 Nos 22.00 0.8 2.4 1914 Anchor bolt 16 dia x 200 mm 8 Nos 2.00 0.1 0.4 315 Anchor bolt 16 dia x 185 mm 36 Nos 11.00 0.5 1.8 1416 Anchor bolt 16 dia x 500 mm 24 Nos 18.00 0.4 1.2 1017 Alignment plate 100x210x10 mm 28 Nos 46.00 2.8 --- ---18 Alignment plate 100x180x10 mm 24 Nos 34.00 2.4 --- ---19 Alignment plate 80x515x8 mm 10 Nos 26.00 0.8 --- ---20 Split anchor plate 60x400x6 mm 20 Nos 23.00 10.4 3.6 2921 Nut / Washer for anchor bolts 200 Nos 10.00 --- --- ---22 SS track 115x6750x10 mm 2 Nos 122.00 13.7 27.5 22023 Track base 130x7100x12 mm 2 Nos 174.00 14.5 28.4 22724 Track base ISMB 200x7100 mm 2 Nos 360.00 0.6 --- ---25 Sill beam ISMB 200x2300 mm 1 No. 58.00 0.3 --- ---26 SS seal seat 115x2300x6 mm 1 No. 12.00 2.4 ( F4 ) 4.6 2327 SS seal seat 80x3035x5 mm 2 Nos. 19.00 6.3 ( F4 ) 12.2 6128 Seal base ISA100x100x8 x3020 mm 2 No 73.00 0.4 --- ---29 SS seal seat 1680x990x5 mm 1 No. 66.00 1.8 ( F4 ) 5.4 2730 Seal base 1700x1000x20 mm 1 Nos 267.00 2.7 --- ---31 Guide 120x2200x20 mm 6 Nos 246.00 14.1 --- ---32 Guide 120x2400x20 mm 4 Nos 180.00 10.1 --- ---33 Stiffener 130x1700x20 mm 1 No. 35.00 2.0 3.4 2734 Stiffener 120x390x8 mm 8 Nos 24.00 4.1 10.1 8135 Stiffener 120x980x10 mm 5 Nos 46.00 5.2 11.0 8836 Cleat ISA75x75x8 x 80 mm 24 Nos 17.00 3.6 4.8 3837 Spacer pipe/ washer 20 dia x 20 mm 1.00 --- --- ---

Total : 2180.00 134.7 143.0 1086kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angle / Channel / Beam / Bars : 593.00 kgPlates / Flats : 1304.00 kg

2. Alloy steel components : IS : 1570Stainless steel plates : 219.00 kg

3. Bolt / Nut / Washer : IS : 1363MS Bolt / Nut / Washer : 64.00 kg

4. Other details :Length of cutting : 135 RmLength of welding : 143 RmNumber of electrodes ( str steel ) : 755 NosNumber of electrodes ( stainless steel ) : 331 Nos

16. Embedded parts with groove lining for river / canal sluice emergency gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on embedded parts drawings for river sluice emergency gate of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

First stage anchors :1 Plate 80x210x10 mm 234 Nos 309.00 18.7 --- ---2 Anchor bar 12 dia x 350 mm 468 Nos 145.00 5.6 17.6 141

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GATES AND HOISTS

3 Plate 80x80x10 mm 58 Nos 29.00 4.7 --- ---4 Anchor bar 12 dia x 350 mm 58 Nos 18.00 0.7 2.2 18

Embedded parts :5 SS seal seat 100x2800x6 mm 1 No. 13.00 0.1 ( F4 ) 5.8 296 Liner plate 666x3550x20 mm 1 No. 371.00 4.2 --- ---7 Stiffener 220x3520x10 mm 1 Nos 61.00 3.8 7.0 568 Stiffener 120x3520x10 mm 1 Nos 33.00 3.7 7.0 569 Stiffener 155x420x8 mm 3 Nos 12.00 1.7 4.4 36

10 Cleat ISA 75x75x8 x 80 mm 20 Nos 14.00 3.0 3.8 3111 SS seal seat 180x2720x6 mm 1 No. 23.00 2.9 ( F4 ) 5.8 2912 Liner plate 814x3640x20 mm 1 No. 465.00 4.5 --- ---13 Liner plate 484x2600x20 mm 1 No. 198.00 3.1 5.2 4214 Stiffener 120x814x12 mm 7 Nos 64.00 6.5 17.8 14315 SS track plate 150x3000x20 mm 2 Nos 141.00 6.3 ( F8 ) 12.6 18916 Track base 200x3000x40 mm 2 Nos 377.00 6.4 --- ---17 Track web pl 320x3000x20 mm 2 Nos 301.00 6.6 24.0 19218 Anchor plate 80x200x10 mm 98 Nos 123.00 7.8 15.7 12619 Track ISMB 150 x 4200 mm 12 Nos 751.00 3.6 6.0 4820 Track ISMB 150 x 1200 mm 2 Nos 36.00 0.6 1.0 821 Guide 110x2000x16 mm 30 Nos 829.00 63.3 126.6 101322 Guide anchor pl 80x200x12 mm 120 Nos 181.00 9.6 --- ---23 Anchor bolt 16 dia x 185 mm 436 Nos 127.00 7.0 21.9 17624 Anchor bolt 16 dia x 300 mm 12 Nos 6.00 0.2 0.6 525 Anchor bolt 16 dia x 380 mm 8 Nos 5.00 0.1 0.4 426 Nut / Washer for 16 dia bolts 912 Nos 38.00 --- --- ---27 Anchor plate 80x400x8 mm 7 Nos 14.00 0.6 1.6 1328 Stiffener 120x2600x10 mm 2 Nos 49.00 5.5 10.4 8429 Cover plate 270x290x10 mm 4 Nos 25.00 2.3 --- ---30 Back strip 40x2580x6 mm 2 Nos 10.00 0.1 2.0 1631 Bolt/Nut/Washer 20 diax65 mm 24 Nos 8.00 --- --- ---32 Track base pl 220x4767x40 mm 2 Nos 659.00 10.0 --- ---33 Track web pl 320x4767x20 mm 2 Nos 479.00 10.2 19.0 15234 SS track plate 170x4217x20 mm 2 Nos 225.00 8.8 ( F8 ) 17.6 26435 Side plate 210x3917x20 mm 2 Nos 258.00 8.3 16.5 13236 Side plate 115x3026x20 mm 2 Nos 109.00 6.3 12.6 10137 Stiffener 260x295x8 mm 8 Nos 39.00 4.5 8.9 7238 Stiffener 210x260x8 mm 4 Nos 14.00 1.9 3.8 3139 Stiffener 210x260x10 mm 2 Nos 9.00 1.0 1.9 1640 Anchor plate 80x200x10 mm 16 Nos 20.00 1.3 2.6 2141 Groove lining 560x3915x20 mm 2 Nos 688.00 9.0 --- ---42 Guide 40x3878x16 mm 2 Nos 39.00 0.1 7.8 6343 Stiffener 100x3915x10 mm 2 Nos 61.00 0.2 16.0 12844 Stiffener 100x3841x10 mm 2 Nos 60.00 0.2 15.8 12745 Stiffener 120x3878x10 mm 2 Nos 73.00 8.0 16.0 12846 Stiffener 110x265x8 mm 16 Nos 29.00 6.0 12.0 9647 Cleat ISA 75x75x6 x 80 mm 40 Nos 22.00 6.0 8.0 6448 SS seal seat 100x3050x6 mm 2 Nos 29.00 0.2 ( F4 ) 12.6 6349 Liner plate 570x3026x20 mm 2 Nos 542.00 7.2 --- ---50 Stiffener 120x3024x10 mm 2 Nos 57.00 6.3 12.1 9751 Stiffener 330x220x10 mm 6 Nos 34.00 4.5 6.6 5352 Stiffener 760x350x10 mm 3 Nos 69.00 4.0 8.2 6653 Stiffener 80x975x10 mm 8 Nos 49.00 0.7 15.6 12554 Stiffener 80x988x10 mm 4 Nos 25.00 0.3 7.9 6455 B/W liner 800x2780x20 mm 1 No. 349.00 3.6 5.5 4456 B/W liner 484x2780x20 mm 1 No. 211.00 3.3 5.6 4557 Stiffener 100x2740x10 mm 2 No. 43.00 0.2 11.0 88

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GATES AND HOISTS

58 Stiffener 100x1245x10 mm 2 Nos 20.00 0.2 5.8 4759 Anchor bolt 16 dia x 185 mm 32 Nos 10.00 0.5 1.6 1360 Anchor bolt 16 dia x 355 mm 28 Nos 16.00 0.5 1.4 1261 Anchor bolt 16 dia x 450 mm 12 Nos 9.00 0.2 0.6 562 Nut / Washer for 16 dia bolt 144 Nos 7.00 --- --- ---63 Back strip 40x3027x6 mm 6 Nos 34.00 0.3 2.0 1664 Cleat ISA 75x75x6 x 80 mm 12 Nos 6.00 1.8 1.9 1665 Bolt/Nut/Washer 20 diax65 mm 28 Nos 8.00 --- --- ---66 Stiffener 110x195x10 mm 6 Nos 10.00 1.8 3.7 30

Total : 9088.00 300.6 560.0 4634.0kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angle / Channel / Beam / Bars : 992.00 kgPlates / Flats : 7431.00 kg

2. Alloy steel components : IS : 1570Stainless steel plates : 431.00 kg

3. Bolt / Nut / Washer : IS : 1363MS Bolt / Nut / Washer : 234.00 kg

4. Other details :Length of cutting : 301 RmLength of welding : 560 RmNumber of electrodes ( str steel ) : 4060 NosNumber of electrodes ( stainless steel ) : 574 Nos

17. River / canal sluice emergency gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based river sluice emergency gate drawings for 2m x 3 m sluice vent of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Gate leaf :1 Skin plate 3220x3372x18 mm 1 No. 1534.00 6.6 --- ---2 Ver stiffener 140x688x10 mm 28 Nos 212.00 23.2 54.2 4343 Web plate 350x688x10 mm 6 Nos 114.00 6.2 16.7 1344 Web plate 350x688x10 mm 2 Nos 38.00 2.0 5.8 475 Girder web 350x2788x12 mm 4 Nos 368.00 12.5 50.2 4026 Girder web 390x2788x12 mm 1 No 102.00 3.2 7.1 577 Flange plate 320x2788x20 mm 4 Nos 560.00 12.5 ( SV ) 2.6 1308 Flange plate 250x2788x20 mm 1 No. 109.00 3.0 ( SV ) 3.3 1659 End plate 370x3251x12 mm 4 Nos 453.00 14.5 26.0 208

10 Flange plate 150x380x12 mm 6 Nos 32.00 3.2 6.4 5211 Flange plate 150x152x12 mm 2 Nos 4.00 0.6 1.2 1012 Flange plate 80x380x18 mm 6 Nos 26.00 0.5 ( SV ) 3.2 10013 Flange plate 80x152x18 mm 2 Nos 4.00 0.2 1.0 814 End ver plate 80x3170x18 mm 2 Nos 72.00 0.2 6.4 5215 Diaphragm plate 188x360x12 mm 10 Nos 64.00 5.5 18.2 14616 End stiffener 50x352x12 mm 16 Nos 27.00 0.8 14.5 11617 Pad plate 250x300x16 mm 8 Nos 75.00 4.4 8.8 7118 Stiffener 80x130x10 mm 8 Nos 7.00 0.7 3.4 2819 Support plate 20x2540x16 mm 1 No. 6.00 2.6 5.1 4120 Seal support 65x2905x12 mm 2 Nos 36.00 5.9 --- ---21 Support plate 20x3105x12 mm 2 Nos. 12.00 6.3 12.5 10022 Sealing frame 65x2795x12 mm 1 No. 17.00 2.8 --- ---

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GATES AND HOISTS

23 Sealing frame 20x2755x12 mm 1 No. 5.00 2.8 5.5 4424 Seal support 65x1965x12 mm 1 No. 12.00 2.0 --- ---25 Seal support 65x375x12 mm 2 Nos 5.00 0.9 --- ---26 Stopper 20x2540x12 mm 1 No. 5.00 2.6 5.1 4127 Plate 50x70x12 mm 2 Nos 1.00 0.1 0.3 328 Bracket plate 300x500x16 mm 4 Nos 75.00 3.2 2.4 2029 GI Bolt/Nut/Washer 24 diax280 mm 118 142.00 --- --- ---30 Stiffener 148x300x12 mm 4 Nos 17.00 1.8 4.9 4031 Stiffener 90x250x12 mm 4 Nos 8.00 1.4 4.7 3832 Counter weight ( CI blocks ) 4000.00 --- --- ---33 Pin 80 dia x 150 mm 2 Nos 12.00 --- --- ---34 Plates for guide roller 4 sets 72.00 1.4 1.8 1535 Guide roller 4 Nos 8.00 --- --- ---

Wheel assembly :36 Wheels 484.00 --- --- ---37 Bearings 76.00 --- --- ---38 Bearing retainer plate 80.00 --- --- ---39 Cover plate 8.00 --- --- ---40 Spacer plates 16.00 --- --- ---41 Stainless steel pin 132.00 --- --- ---42 Keeper plate 8.00 0.1 --- ---43 GI Bolt / Nut / Screw / Washer 2.00 --- --- ---44 MS Bolt / Nut / Screw / Washer 4.00 --- --- ---

Seal assembly :45 Flat bottom seal 2755 mm 1 No. --- --- --- ---46 Music note side seal 2855 mm 2 Nos --- --- --- ---47 Double flange top seal 2199 mm 1 No. --- --- --- ---48 Corner seal 2 Nos --- --- --- ---49 seal clamp 90x2545x20 mm 1 No. 36.00 0.1 --- ---50 Seal clamp 45x1495x20 mm 2 Nos 21.00 0.1 --- ---51 Seal clamp 45x1628x20 mm 2 Nos 23.00 0.1 --- ---52 Seal clamp 45x2545x20 mm 1 No. 18.00 --- --- ---53 Seal clamp 45x2660x20 mm 1 No. 19.00 0.1 --- ---54 SS Bolt / Nut / Washer 20 dia x 80 mm 10.00 --- --- ---55 SS Bolt / Nut / Washer 20 dia x 100 mm 44.00 --- --- ---

Total : 9215.00 134.1 271.3 2502.0kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Plates / Flats : 4301.00 kg 2. Cast steel components : IS : 1030

Wheels / Guide roller : 492.00 kg 3. Alluminium / Bronze alloy components : IS : 305

Bearings / Bushes : 76.00 kg 4. Alloy steel components : IS : 1570

Wheel axle / lifting pin : 144.00 kg

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GATES AND HOISTS

5 Rubber seals : IS : 11855Bottom rubber seal ( uncladed ) : 2.76 RmSide rubber seal ( teflon claded ) : 5.71 RmTop rubber seal ( teflon claded ) 2.20 RmCorner seal 2 Nos

6. Bolt / Nut / Washer IS : 1363SS Bolt / Nut / Washer : 54.00 kgGI Bolt / Nut / Washer 144.00 kgMS Bolt / Nut / Washer : 4.00 kg

7. Other components :CI counter weight : 4000.00 kg

8. Other details :Length of cutting : 134.10 RmLength of welding : 271.30 RmNumber of electrodes : 2502 Nos

18. Lifting beam for river / canal sluice emergency gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on lifting beam drawings for river sluice emergency gate of Kodasalli dam.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

1 ISMC 300 x 3186 mm 2 Nos 228.00 1.2 3.8 312 Plate 250x450x20 mm 4 Nos 71.00 2.8 4.0 323 Plate 190x300x10 mm 7 Nos 31.00 3.5 8.4 684 Stiffener 75x278x10 mm 14 Nos 23.00 5.0 12.3 995 Stiffener 80x100x10 mm 8 Nos 5.00 0.8 2.9 246 Stiffener 80x330x10 mm 10 Nos 21.00 0.8 4.4 367 Stiffener 140x330x10 mm 2 Nos 7.00 1.0 1.2 108 Pipe 100 dia x 540 mm 2 Nos 11.00 --- 0.6 59 Plate 400x720x12 mm 2 Nos 54.00 2.3 --- ---

10 Plate 200x390x10 mm 4 Nos 24.00 2.0 4.7 3811 Plate 50x190x20 mm 2 Nos 3.00 0.3 0.6 512 Hook 2 Nos 130.00 --- --- ---13 Plate 80x150x20 mm 2 Nos 4.00 0.2 0.3 314 Bronze bush 110/90/70 dia x 100 mm 2 4.00 --- --- ---15 SS pin 70 dia x 250 mm 2 Nos 15.00 --- --- ---16 Plate 120x700x10 mm 4 Nos 26.00 6.0 --- ---17 Plate 104x145x20 mm 2 Nos 5.00 0.5 0.3 318 Plate 120x120x25 mm 8 Nos 23.00 1.9 --- ---19 Plate 180x766x20 mm 4 Nos 87.00 7.5 --- ---20 Plate 331x462x25 mm 2 Nos 60.00 2.0 --- ---21 SS pin 85 dia x 65 mm 4 Nos 11.00 --- --- ---22 SS pin 110 dia x 231 mm 1 No. 17.00 --- --- ---23 SS pin 90 dia x 280 mm 2 Nos 28.00 --- --- ---24 Plate 150x190x12 mm 4 Nos 11.00 1.4 --- ---25 Plate 83x150x12 mm 8 Nos 9.00 1.9 2.4 2026 Plate 26x150x16 mm 4 Nos 2.00 0.7 ( SV ) 1.2 2827 Plate 40x73x8 mm 4 Nos 1.00 0.5 0.9 828 Shims 4.00 --- --- ---29 Keeper plate 40x140x12 mm 1 No. 1.00 --- --- ---30 Keeper plate 40x140x10 mm 4 Nos 2.00 0.2 --- ---31 Plate 73x80x8 mm 4 Nos 2.00 0.6 1.2 1032 Bolt/Nut/Washer 20 dia x 150 mm 2 Nos 1.00 --- --- ---

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GATES AND HOISTS

33 Bolt/Nut/Washer 16 dia x 35 mm 16 Nos 1.00 --- --- --- Total : 922.00 43.1 49.2 420

kg Rm Rm NosABSTRACT :

1. Structural steel : IS : 2062Angle / Channel / Beam / Bars : 228.00 kgPlates / Flats : 476.00 kg

2. Forged steel components IS : 2004Lifting hooks : 130.00 kg

3. Alluminium / Bronze alloy components : IS : 305Bearings / Bushes : 4.00 kg

4. Alloy steel components : IS : 1570Stainless steel pins : 71.00 kg

5. Bolt / Nut / Washer IS : 1363Bolt / Nut / Washer : 2.00 kg

6. Other components :Pipe 100 mm dia : 1.08 Rm

7. Other details :Length of cutting : 43.10 RmLength of welding : 49.20 RmNumber of electrodes : 420 Nos

19. Embedded parts for Barrage gates :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on embedded parts drawings for vertical lift roller gate of Hipparagi barrage.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

1 SS track plate 130x8100x20 mm 2 Nos. 331.00 16.5 33.0 3962 SS track plate 130x7090x20 mm 2 Nos. 289.00 14.5 29.4 3523 Track base 220x8500x25 mm 2 Nos. 734.00 17.5 --- ---4 Track base 220x7190x25 mm 2 Nos. 621.00 15.0 --- ---5 Track web 360x8500x16 mm 2 Nos. 769.00 17.8 34.0 2726 Track web 360x7190x16 mm 2 Nos. 650.00 15.1 28.8 2307 Sill beam ISMB 200 x 3750 mm 2 Nos 191.00 0.8 --- ---8 Sill beam ISMB 200 x 3600 mm 2 Nos 183.00 0.8 --- ---9 SS seal seat 80x3750x6.5 mm 2 Nos 31.00 7.7 15.2 91

10 SS seal seat 80x3600x6.5 mm 2 Nos 29.00 7.4 14.6 8811 SS seal seat 20x140x6.5 mm 2 Nos 1.00 0.3 0.4 212 SS seal seat 80x4200x6.5 mm 2 Nos 34.00 8.6 17.0 10213 SS seal seat 80x4600x6.5 mm 2 Nos 38.00 9.4 18.6 11214 Seal base ISA100x100x8x4200 mm 2 No 102.00 0.2 --- ---15 Seal base ISA100x100x8x4630 mm 2 No 112.00 0.2 --- ---16 Seal base 75x515x8 mm 30 Nos. 73.00 17.7 8.3 6617 Guide 110x3000x20 mm 8 Nos. 414.00 24.9 --- ---18 Guide 110x3690x20 mm 2 Nos. 127.00 7.6 --- ---19 Anchor pl 100x220x10 mm 76 Nos. 131.00 7.6 15.2 12220 Anchor pl 100x200x12 mm 52 Nos. 98.00 5.0 10.4 8321 Anchor bolt 16 dia x 200 mm 52 Nos. 16.00 0.8 2.6 2122 Anchor bolt 16 dia x 290 mm 74 Nos. 34.00 1.2 3.7 3023 Anchor bolt 16 dia x 185 mm 60 Nos. 18.00 1.0 3.0 2424 Anchor bolt 16 dia x 295 mm 104 Nos. 48.00 1.7 5.2 4225 Nuts & Washer 16 dia 580 Nos 33.00 --- --- ---26 Stiffener 90x210x8 mm 20 Nos. 24.00 6.0 12.0 96

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GATES AND HOISTS

27 Splice pl 210x320x12 mm 4 Nos. 22.00 2.2 --- ---28 Splice pl 150x260x12 mm 6 Nos. 22.00 2.5 --- ---29 Bolt/Nut/Washer 16 dia x 60 mm 36 Nos 8.00 --- --- ---30 Bolt/Nut/Washer 20 dia x 70 mm 24 Nos 10.00 --- --- ---

Total : 5193.00 210.0 251.4 2129kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angles / Beams / Channels / Bars : 588.00 kgStructural steel Plates / Flats : 3685.00 kg

2. Alloy steel components : IS : 1570Stainless steel plates / flats for track : 620.00 kgStainless steel plates / flats for seal seat 133.00 kg

3. Bolt / Nut / Washer : IS : 1363MS Bolts / Nuts / Washers : 167.00 kg

4. Other details :Length of cutting : 210.00 RmLength of welding : 251.40 RmNumber of electrodes ( str steel ) : 6486 NosNumber of electrodes ( SS for wheel track ) 748 NosNumber of electrodes ( SS for seal seat ) 395 Nos

20. Vertical lift roller gate for barrageDetails of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on vertical lift roller gate drawings of Hipparagi barrage.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Gate leaf bottom unit :1 Skin plate 2420x14700x16 mm 1 No. 4468.00 17.4 24.2 1942 Stiffener ISA100x75x8x295 mm 35 Nos. 108.00 6.1 32.9 2643 Stiffener ISA100x75x8x1730 mm 35 Nos. 634.00 6.1 145.6 11654 Stiffener ISA100x75x8x265 mm 33 Nos. 92.00 5.8 24.0 1925 Web plate 1320x12820x10 mm 1 No. 1223.00 14.2 52.6 4216 Web plate 1335x12820x10 mm 1 No. 1237.00 14.3 52.7 4227 Web plate 650x718x10 mm 4 No. 293.00 9.0 20.6 1658 Flange 300x8820x32 mm 2 Nos. 1329.00 18.5 --- ---9 Flange 300x2852x32 mm 2 Nos. 430.00 6.3 1.2 18

10 Flange 300x2584x32 mm 2 Nos. 389.00 6.2 1.2 1811 Flange 268x300x32 mm 2 Nos. 40.00 1.1 0.6 912 Flange 250x8000x12 mm 1 Nos. 188.00 8.5 16.5 13213 Flange 270x8000x12 mm 1 Nos. 203.00 8.6 16.6 13314 End girder 532x2410x12 mm 4 Nos. 483.00 11.8 19.3 15515 Diaphragm 140x532x20 mm 6 Nos. 70.00 4.0 16.1 19316 Flange 60x2320x16 mm 2 Nos. 35.00 5.6 9.3 7517 Flange 60x235x16 mm 2 Nos. 4.00 0.6 1.2 1018 Flange 60x1255x16 mm 2 Nos. 19.00 2.7 2.8 2319 Flange 60x220x16 mm 2 Nos. 3.00 2.5 1.0 820 Pad plate 230x230x16 mm 8 Nos. 53.00 6.7 7.4 6021 Stiffener 365x1210x10 mm 2 Nos. 69.00 3.2 7.8 6322 Stiffener 150x980x10 mm 2 Nos. 23.00 2.3 5.1 4123 Stiffener 150x1225x10 mm 2 Nos. 29.00 2.8 6.1 4924 Stiffener 100x1320x10 mm 18 Nos. 186.00 1.8 54.7 438

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GATES AND HOISTS

25 Gusset pl 210x250x10 mm 3 Nos. 12.00 1.5 2.8 2326 Bracing ISA90x90x8x1520 mm 3 Nos 49.00 0.6 2.3 1927 Bracing ISA90x90x8x1904 mm 1 Nos 21.00 0.2 0.7 628 Bracing ISA90x90x8x1830 mm 2 Nos 40.00 0.4 1.4 1129 Seal guard 20x2345x12 mm 2 Nos. 9.00 --- 9.4 7530 Seal guard 20x13770x20 mm 1 No. 43.00 --- 27.5 22031 Seal base 65x2345x10 mm 2 Nos. 24.00 4.8 9.4 7532 Stiffener 500x1220x10 mm 4 Nos. 191.00 6.9 14.6 11733 Stiffener 150x200x10 mm 6 Nos. 14.00 2.1 3.6 2934 Stiffener 150x1090x10 mm 1 Nos. 13.00 1.2 2.5 2035 Stiffener 50x506x10 mm 6 Nos. 12.00 0.3 7.2 5836 Splice pl 120x6879x8 mm 4 Nos. 207.00 28.0 --- ---

Gate leaf top unit : ---37 Skin plate 3203x3810x10 mm 2 Nos. 1915.00 14.0 --- ---38 Skin plate 2435x8295x10 mm 1 No. 1586.00 10.7 13.2 10639 Skin plate 3705x8295x10 mm 1 No. 2412.00 12.0 7.4 5940 Skin plate 2330x3203x10 mm 2 Nos. 1171.00 11.1 6.4 5141 Stiffener ISA 75x75x8x1990 mm 35 Nos. 731.00 6.1 163.8 131042 Stiffener ISA 75x75x8x2590 mm 33 Nos. 893.00 5.8 194.0 155243 Stiffener ISA 75x75x8x1095 mm 35 Nos. 402.00 6.1 88.9 71144 Stiffener 100x1130x10 mm 24 Nos. 213.00 2.4 63.8 51145 Stiffener 100x970x10 mm 5 Nos. 38.00 0.5 11.7 9446 Stiffener 150x995x10 mm 2 Nos. 23.00 2.3 5.2 4247 Stiffener 150x833x10 mm 8 Nos. 78.00 7.9 18.1 14548 Stiffener 150x755x10 mm 1 No. 9.00 0.9 2.1 1749 Stiffener 100x880x10 mm 13 Nos. 90.00 1.3 28.0 22450 Diaphragm 1062/848x2590x8 mm 2 Nos. 310.00 7.4 28.4 22751 Web plate 1150x8295x10 mm 2 Nos. 1498.00 9.5 8.5 6852 Web plate 1150/566x2981x10 mm 4 Nos. 663.00 14.2 28.4 22753 Web plate 900x8295x10 mm 1 No. 586.00 9.2 18.4 14754 Web plate 900/512x2981x10 mm 2 Nos. 330.00 7.0 14.0 11255 Flange pl 300x8820x32 mm 2 Nos. 1329.00 18.3 36.5 54856 Flange pl 300x2803x32 mm 4 Nos. 845.00 12.4 24.8 37257 Flange pl 250x8820x20 mm 1 Nos. 346.00 9.5 18.6 22358 Flange pl 250x2750x20 mm 2 Nos. 216.00 6.0 13.0 15659 Flange pl 270x8000x12 mm 2 Nos. 406.00 16.5 34.2 27460 Flange pl 150x2336x12 mm 2 Nos. 66.00 5.0 10.5 8461 Stiffener 100x882x10 mm 4 Nos. 28.00 3.9 8.6 6962 End girder 532x6140x12 mm 4 Nos. 1231.00 26.7 --- ---63 Diaphragm 140x532x10 mm 10 Nos. 58.00 6.7 26.7 21464 Pad plate 230x230x16 mm 8 Nos. 53.00 5.7 7.4 5965 Seal base 65x6140x10 mm 2 Nos. 63.00 12.4 24.8 19866 Seal base 20x6140x12 mm 2 Nos. 23.00 12.3 24.6 19767 Cover plate 120x8175x8 mm 1 No. 62.00 8.3 16.4 13168 Cover plate 120x6040x8 mm 2 Nos. 91.00 13.4 24.6 19769 Cover plate 120x310x8 mm 2 No. 5.00 0.9 1.8 1570 Cover plate 120x1960x8 mm 2 No. 30.00 4.2 8.4 6771 Cover plate 120x2560x8 mm 2 No. 39.00 5.4 10.7 8672 Cover plate 120x1090x8 mm 2 No. 16.00 2.5 5.0 4073 Splice pl 120x1100x8 mm 8 Nos. 66.00 9.8 19.5 15674 Splice pl 120x850x8 mm 8 Nos. 51.00 7.8 15.5 12475 Splice pl 120x1022x10 mm 2 Nos 19.00 2.3 4.6 3776 Stiffener 425x1062x10 mm 2 Nos. 71.00 3.0 5.9 4777 Stiffener 120x8145x12 mm 1 No. 92.00 8.5 16.5 13278 Flange plate 60x6140x16 mm 2 Nos. 93.00 12.4 24.6 19779 Flange plate 60x985x16 mm 2 Nos. 15.00 2.1 4.0 32

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GATES AND HOISTS

80 Flange plate 60x2325x16 mm 2 Nos. 35.00 4.8 9.3 7581 Flange plate 60x1700x16 mm 2 Nos. 26.00 3.5 6.8 5582 Flange plate 60x280x16 mm 2 Nos. 4.00 0.7 1.4 1183 Stiffener 50x506x10 mm 20 Nos. 40.00 11.1 24.2 19484 Bracing ISA90x90x8x1960 mm 3 Nos. 64.00 0.6 2.0 1685 Bracing ISA90x90x8x2047 mm 1 Nos. 22.00 0.2 0.7 686 Bracing ISA90x90x8x2572 mm 2 Nos. 55.00 0.4 1.4 1187 Stiffener ISA100x75x8x325 mm 35 Nos. 119.00 6.1 9.6 7788 Gusset pl 125x265x10 mm 1 No. 3.00 0.4 0.8 789 Gusset pl 125x210x10 mm 1 No. 2.00 0.3 0.7 690 Gusset pl 135x250x10 mm 3 Nos. 8.00 1.2 2.3 1991 Gusset pl 140x200x10 mm 3 No. 7.00 1.0 2.0 1692 Gusset pl 130x270x12 mm 2 No. 7.00 0.8 1.6 1393 Gusset ISA100x100x6x895 mm 4 Nos. 33.00 0.8 2.8 2294 Pack plate 60x13760x6 mm 1 No. 26.00 13.9 --- ---95 Diaphragm 140x532x12 mm 4 Nos. 28.00 2.7 10.8 8696 Lifting lug 400x400x20 mm 4 Nos. 100.00 3.5 1.6 1397 Lifting pl 670x1040x16 mm 4 Nos. 250.00 6.9 --- ---98 Stiffener 146x1005x10 mm 4 Nos. 46.00 4.6 16.0 12899 R / F plate 220/80 dia x 12 mm 4 Nos. 12.00 3.8 2.8 22

100 Stiffener 250x300x10 mm 4 Nos. 24.00 2.2 6.4 51101 Stiffener 250x250x10 mm 4 Nos. 20.00 2.0 5.2 42102 Stiffener 120x879x10 mm 2 Nos. 14.00 2.0 4.5 36103 Stiffener 120x819x10 mm 2 Nos. 13.00 1.9 4.2 34104 Bracing ISA75x75x8x2004 mm 2 Nos. 36.00 0.3 1.1 9105 Bolts 16 diax 60 mm 4.00 --- --- ---106 Bolts 16 dia x 35 mm 4.00 --- --- ---107 Bolts 16 dia x 50 mm 40 Nos 7.00 --- --- ---108 Bolts 16 dia x 75 mm 276 Nos 53.00 --- --- ---109 Flange 190x600x10 mm 4 Nos. 36.00 3.2 6.3 50110 Web plate 518x566x12 mm 4 Nos. 110.00 4.4 8.8 70111 Stiffener 120x703x10 mm 4 Nos. 22.00 3.3 7.5 60

Seal assembly : ---112 Bottom seal 14.00 Rm --- --- --- ---113 Side seal 17.20 Rm --- --- --- ---114 Seal clamp 70x3503x12 mm 2 Nos. 46.00 7.0 --- ---115 Seal clamp 70x3389x12 mm 2 Nos. 45.00 6.8 --- ---116 Seal clamp 45x3068x12 mm 4 Nos. 52.00 12.3 --- ---117 Seal clamp 45x2414x12 mm 2 Nos. 20.00 4.8 --- ---118 GI Bolt/Nut/Washer 12 diax65 mm 310 62.00 --- --- ---

Wheel assembly : ---119 Wheels 410 mm dia x 200 mm 8 Nos. 528.00 --- --- ---120 Bearings 8 Nos 80.00 --- --- ---121 SS Pins 125/110/95 dia 8 Nos 176.00 --- --- ---122 Bearing retainers 16 Nos. 128.00 --- --- ---123 Spacers 8 Nos 8.00 2.0 --- ---124 Spacers 8 Nos 8.00 2.0 --- ---125 Cover 16 Nos 32.00 7.5 --- ---126 GI Screws 15.00 --- --- ---127 Keeper pl 60x210x10 mm 8 Nos. 8.00 2.2 --- ---128 GI bolts 16 dia x 80 mm 16 Nos 4.00 --- --- ---129 GI washers 4.00 --- --- ---

Guide shoe : ---130 Base pl 220x220x20 mm 4 Nos. 32.00 1.8 --- ---131 Guide pl 103x220x16 mm 8 Nos 24.00 2.6 3.5 28132 Guide pl 32x220x20 mm 4 Nos 4.00 1.0 1.8 14

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GATES AND HOISTS

133 Stiffener 70x95x10 mm 8 Nos 4.00 1.4 2.6 21134 Pack plate 4 Nos 4.00 --- --- ---135 GI Bolts 20 dia x 65 mm 16 Nos 6.00 --- --- ---

Total : 33025.00 694.5 1837.1 15351kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angle / Channel / Beam / Bars : 3299.00 kgPlates / Flats : 28655.00 kg

2. Cast steel components : IS : 1030Wheels / Guide roller : 656.00 kg

3. Alluminium / Bronze alloy components : IS : 305Bearings / Bushes : 80.00 kg

4. Alloy steel components : IS : 1570Wheel axle / lifting pin : 176.00 kg

5. Rubber seals : IS : 11855Bottom rubber seal ( uncladed ) : 14.00 RmSide rubber seal ( uncladed ) : 17.20 Rm

6. Bolt / Nut / Washer IS : 1363GI Bolt / Nut / Washer : 91.00 kgMS Bolt / Nut / Washer : 68.00 kg

7. Other details :Length of cutting : 694.50 RmLength of welding : 1837.10 RmNumber of electrodes : 15351 Nos

21. Hoist supporting bridge for barrage gates .Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on 10 m ht & 15 m span hoist supporting bridge drawings of Hipparagi barrage.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Columns :1 ISMB350 x 9918 mm 4 Nos. 2079.00 2.6 16.0 1282 Base pl 340x550x20 mm 4 Nos. 179.00 3.6 5.0 403 Stiffener 100x550x20 mm 6 Nos. 52.00 3.9 6.6 534 Stiffener 300x530x12 mm 6 Nos. 90.00 5.0 6.4 515 Stiffener 90x300x12 mm 20 Nos. 51.00 7.8 15.6 1256 Stiffener 100x326x20 mm 2 Nos. 10.00 0.9 2.1 177 Stiffener 100x100x20 mm 4 Nos. 6.00 1.2 2.4 198 Stiffener 78x300x12 mm 12 Nos. 26.00 4.5 9.1 739 Stiffener 210x430x12 mm 4 Nos. 34.00 2.6 2.7 22

10 Bracings ISA65x65x6x2127 mm 16 Nos. 197.00 2.1 8.5 6811 Bracings ISA65x65x6x1120 mm 20 Nos. 130.00 2.6 10.6 8512 Bracings ISA65x65x6x1781 mm 4 Nos. 41.00 0.6 2.1 1713 Lacing ISA40x40x5x450 mm 30 Nos. 41.00 2.7 9.0 7214 Tie beam ISMB300 x 2026 mm 6 Nos. 537.00 3.5 --- ---15 Column cap 280x410x16 mm 4 Nos. 58.00 2.8 5.0 4016 Gusset pl 170x330x12 mm 12 Nos. 63.00 6.0 13.9 11117 Gusset pl 200x280x10 mm 20 Nos. 88.00 12.0 19.2 15418 Stiffener 60x328x10 mm 40 Nos. 62.00 2.4 35.8 28619 Anchor bolt 25 dia x 1200 mm 24 Nos 111.00 0.6 --- ---20 Nuts 24 dia 48 Nos 4.00 --- --- ---21 Plate washer 70x70x16 mm 24 Nos. 15.00 3.4 --- ---

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GATES AND HOISTS

22 Bolt/Washer 20 dia x 70 mm 24 Nos 8.00 --- --- ---23 Bolt/Washer 20 dia x 60 mm 16 Nos 4.00 --- --- ---24 Stiffener 300x326x12 mm 2 Nos 19.00 1.3 3.7 3025 Stiffener 60x159x10 mm 16 Nos. 12.00 3.5 8.9 7126 Gusset pl 125x330x10 mm 8 Nos. 26.00 3.7 7.3 58

Beams and hoist supports :27 Web plate 1000x15430x8 mm 1 No. 969.00 17.5 --- ---28 Web plate 1008x15430x8 mm 1 No. 977.00 17.6 --- ---29 Flange 150x15430x16 mm 2 Nos. 581.00 15.7 31.5 25230 Flange 250x15430x20 mm 2 Nos. 1211.00 16.0 31.8 25531 Bearing pl 250x380x16 mm 4 Nos. 48.00 2.6 2.0 1632 Stiffener 180x1000x10 mm 4 Nos. 57.00 4.7 10.0 8033 Stiffener 180x1008x10 mm 4 Nos. 60.00 4.8 10.1 8134 Stiffener 130x1000x10 mm 11 Nos. 155.00 12.5 25.3 20235 Stiffener 130x1008x10 mm 11 Nos. 113.00 13.0 25.5 20436 Cross beam ISMC150x2392 mm 6 Nos 235.00 1.8 3.6 2937 Cross beam ISMC200x2392 mm 2 Nos 106.00 0.8 3.2 2638 Cross beam ISMC300x2392 mm 6 Nos 515.00 3.6 14.4 11539 Cross beam ISMC200x1418 mm 4 Nos 126.00 1.6 6.4 5140 Bracket 240x685x12 mm 4 Nos. 62.00 3.7 3.4 2741 Bracket 240x555x12 mm 4 Nos. 50.00 3.2 3.4 2742 R / F plate 220 dia x 12 mm 8 Nos. 29.00 5.5 5.5 4443 Bracing ISA65x65x6x1437 mm 4 Nos. 33.00 0.5 2.1 1744 Stiffener 75x808x10 mm 2 Nos. 10.00 1.8 3.8 3145 Stiffener 100x800x10 mm 2 Nos. 13.00 1.8 4.0 3246 Stiffener 75x708x10 mm 4 Nos. 17.00 3.1 6.9 5547 Stiffener 100x700x10 mm 4 Nos. 22.00 3.2 7.2 5848 Stiffener 75x858x10 mm 4 Nos. 20.00 3.7 7.3 5849 Stiffener 100x850x10 mm 4 Nos. 27.00 3.8 8.4 6750 Railing post ISA50x50x6x1160 mm 26 136.00 2.6 5.2 4251 Railing plate 75x15430x6 mm 2 Nos. 109.00 31.0 2.6 2152 Railing pipe 32 dia x15430 mm 2 Nos 80.00 --- 0.5 453 Railing pipe 25 dia x15430 mm 4 Nos 124.00 --- --- ---54 Plate 70x2000x8 mm 4 Nos. 35.00 8.3 16.6 13355 Splice plate 120x900x8 mm 4 Nos. 27.00 4.1 8.2 6656 Splice plate 120x300x8 mm 2 Nos. 5.00 0.8 1.7 1457 Splice plate 220x300x8 mm 2 Nos. 10.00 1.0 2.1 1758 Splice plate 45x300x8 mm 4 Nos. 3.00 1.4 2.8 2259 Splice plate 90x300x10 mm 4 Nos. 8.00 1.6 3.1 2560 Chequered plate 25 sqm 133.00 10.0 5.0 4061 Stiffener 65x184x8 mm 8 Nos. 6.00 2.0 5.0 4062 Stiffener 75x278x10 mm 4 Nos. 7.00 1.4 3.4 2763 Batten 100x300x10 mm 4 Nos. 9.00 1.6 0.8 764 Cross beam ISMC200x2392 mm 2 Nos 106.00 0.8 3.2 2665 Cross beam ISMC200x600 mm 3 Nos 40.00 1.2 4.8 3866 Cross beam ISMC150x600 mm 2 Nos 20.00 0.6 2.4 1967 Bolts 26 & 16 dia 2.00 --- --- ---

Total : 10239.00 290.2 473.1 3788kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angles / Beams / Channels / Bars : 4453.00 kgStructural steel Plates / Flats : 5431.00 kgChequered plate 133.00 kg

2 Bolt / Nut / Washer : IS : 1363

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GATES AND HOISTS

MS Bolts / Nuts / Washers : 18.00 kgMS pipes :32 mm dia pipe 30.86 Rm25 mm dia pipe 61.72 Rm

3 Other details :Length of cutting : 290.20 RmLength of welding : 473.10 RmNumber of electrodes ( str steel ) : 3788 Nos

22. Rope drum hoist for barrage gates .Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on rope drum hoist drawings for vertical lift roller gate of Hipparagi barrage.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Gear box :1 Frame ISMC250x1800 mm 2 No. 104.00 1.0 --- ---2 Frame ISMC250x1094 mm 2 No. 66.00 1.0 --- ---3 Frame ISMC250x1432 mm 4 No. 174.00 2.0 8.0 644 Frame ISMC250x780 mm 2 No. 44.00 1.0 2.0 165 Frame ISMC250x330 mm 2 No. 22.00 1.0 4.0 326 Drum support 260x550x16 mm 4 Nos. 72.00 3.2 2.8 237 Stiffener 70x305x10 mm 8 Nos. 14.00 3.0 6.0 488 Stiffener 65x228x10 mm 12 Nos. 14.00 3.6 8.6 699 Stiffener 110x350x10 mm 4 Nos. 12.00 1.8 3.6 29

10 Stiffener 110x320x16 mm 4 Nos. 10.00 1.8 2.8 2311 Bolts / Screws 3.00 --- --- ---

Rope drums :1 Drum ( 632/566 dia )x1310 mm 2 Nos 680.00 --- --- ---2 Bronze bush 125/100 diax130 mm 2 Nos 10.00 --- --- ---3 Bronze bush 125/100 diax100 mm 2 Nos 8.00 --- --- ---4 Spacers 4.00 --- --- ---5 Clamping pl 33x150x100 4 Nos 16.00 --- --- ---6 Bolts 24 dia x 90 mm 8 Nos 5.00 --- --- ---7 Bolts 24 dia x 80 mm 12 Nos 8.00 --- --- ---

Gears and pinions :Drum gear 2 Nos. 480.00 --- --- ---1st gear 2 Nos 130.00 --- --- ---1st pinion 2 Nos 76.00 --- --- ---2nd pinion 2 Nos 22.00 --- --- ---Shafts :Drum shaft 100 diax1480 mm 2 Nos 182.00 --- --- ---2nd pinion shaft 110 diax695 mm 1 Nos 52.00 --- --- ---2nd pinion shaft 110 diax595 mm 1 Nos 44.00 --- --- ---1st pinion shaft 75 diax763 mm 2 Nos 53.00 --- --- ---Keys 28x150x16 mm 2 Nos. 1.00 --- --- ---Keys 28x130x16 mm 2 Nos. 1.00 --- --- ---Keys 20x115x12 mm 2 Nos. 1.00 --- --- ---Pipe shaft :MS pipe 200 dia x 4601 mm 2 Nos 391.00 --- --- ---Flange 355/200 dia x12 mm 4 Nos 25.00 7.0 2.5 20Flange 355/140 dia x12 mm 4 Nos 20.00 6.2 2.5 20Hub 140/68 dia x 85 mm 2 Nos 16.00 --- 0.9 7Stiffener 62x65x6 mm 16 Nos 3.00 2.0 4.0 32

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GATES AND HOISTS

Stiffener 68x100x6 mm 16 Nos 5.00 2.7 5.4 43Bolt/Nut/Washer 20 dia x50 mm 24 Nos 7.00 --- --- ---Pulleys :Pulley 622 mm dia 6 Nos 480.00 --- --- ---Pulley 400 mm dia 2 Nos 120.00 --- --- ---Bronze bush 115/90 mm dia 6 Nos 24.00 --- --- ---Bronze bush 115/90 mm dia 2 Nos 8.00 --- --- ---Pin 90 dia x 244 mm 6 Nos 72.00 --- --- ---Pin 90 dia x 244 mm 2 Nos 24.00 --- --- ---Spacers 16 Nos 16.00 --- --- ---Keeper pl 40x140x10 mm 16 Nos 8.00 --- --- ---Screws 2.00 --- --- ---Other components :Worm reducer 60 :1 ( size 800 ) 1 No. 500.00 --- --- ---Electric motor 12.5 hp 1000 rpm 1 No. 60.00 --- --- ---Electro-megnatic brake 1 No. 25.00 --- --- ---Manual operation unit 1 No. 120.00 --- --- ---Plummer block body 10 Nos 250.00 --- --- ---Bronze bush 10 Nos 50.00 --- --- ---Fexible couplings 2 Nos 50.00 --- --- ---Position indicator unit 1 No. 50.00 --- --- ---Wire rope 6/36 construction 160 Rm 435.00 --- --- --- Total : 5069.00 37.3 53.1 426.0

kg Rm Rm NosABSTRACT :

1. Structural steel : IS : 2062Angle / Channel / Beam / Bars : 410.00 kgPlates / Flats : 219.00 kg

2. Cast steel components : IS : 1030Rope drums 2 Nos / Gears : 1290.00 kgPinions 98.00 kgPulleys 8 Nos / Couplings 2 Nos : 650.00 kgPlummer blocks : 250.00 kg

3. Alloy steel components : IS : 1570Shafts / Keys : 350.00 kgPins 96.00 kg

4. Alluminium / Bronze alloy components : IS : 305Bearings / Bushes : 100.00 kg

5. Wire rope : IS : 226628 mm dia 6/36 construction rope : 160 Rm

6. Bolts / Nuts / Washers : IS : 1363Bolts / Nuts / Washers ( various size ) : 25.00 kg

7. Other components :Electric motor 12.5 hp Standard : 1 No.Worm reducer 60 :1 ( size 800 ) 1 No. Standard : 1 NoElectro-megnatic brake Standard : 1 NoManual operation assembly : 1 No.Position indicator : 1 No.

8. Other details :Length of cutting : 37.30 RmLength of welding : 53.10 RmNumber of electrodes : 426 Nos

23. Embedded parts for Cross regulator radial gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on embedded parts drawings for cross regulator radial gate of Alamatti LBC.

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GATES AND HOISTS

2. Unless otherwise specified 5 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

First stage anchors :1 Anchor plate 300x100x10 mm 7 Nos 16.00 0.7 --- ---2 Anchor rod 20 dia x 615 mm 7 Nos 11.00 0.1 0.9 53 Anchor plate 300x100x10 mm 34 Nos 94.00 3.4 --- ---4 Anchor rod 20 dia x 740 mm 34 Nos 63.00 0.7 4.3 26

Sill beam :5 ISMB 200 x 3500 mm 1 No. 89.00 0.4 --- ---6 SS plate 80x6x3100 mm 1 No. 12.00 0.1 6.3 387 Stiffener 200x190x10 mm 14 Nos 42.00 5.5 10.9 658 Plate 150x3500x10 mm 2 Nos 83.00 7.3 ( SV ) 7.0 1059 Plate 300x100x10 mm 7 Nos 17.00 0.7 1.4 8

10 Anchor bolts 20 dia x 300 mm 14 Nos 10.00 --- 0.9 511 SS plate 120x100x6 mm 2 Nos. 2.00 0.2 0.2 1

Wall plates :12 Plate 500x350x10 mm 2 Nos 27.00 1.7 ( SV ) 0.7 1013 Plate 1500x350x10 mm 10 Nos 412.00 18.5 ( SV ) 3.5 5214 Plate 600x350x10 mm 2 Nos 33.00 1.9 ( SV ) 0.7 1015 SS plate 80x5000x6 mm 2 Nos 38.00 0.2 20.0 12016 ISA 75x75x8 mm x 100 mm 68 Nos 60.00 10.2 13.6 8117 Anchor bolts 20 dia x 190 mm 68 Nos 32.00 --- 4.4 26

Anchor girders : ( All welds 6 mm fillet )18 Plate 450x2226x12 mm 2 Nos 189.00 5.4 --- ---19 Plate 276x2226x12 mm 2 Nos 116.00 4.9 13.6 10920 Stiffener 138x276x12 mm 6 Nos 22.00 2.5 6.6 5321 Stiffener 144x276x12 mm 12 Nos 45.00 5.0 13.5 10822 End plate 450x300x12 mm 2 Nos 25.00 1.5 2.4 1923 Stiffener 138x200x12 mm 6 Nos 16.00 2.0 4.0 3224 Stiffener 144x200x12 mm 12 Nos 33.00 4.1 8.2 6625 Bolt/Nut/Washer 24 diax60 mm 16 Nos 8.00 --- --- ---

Anchor bar and chairs : ( All welds 8 mm fillet )26 Anchor bars 40 dia x 4500 mm 12 Nos 533.00 0.5 --- ---27 Anchor plate 200x200x20 mm 24 Nos 151.00 9.6 6.0 7228 Anchor bars 25 dia x 1200 mm 12 Nos 56.00 0.3 --- ---29 Anchor plate 80x80x16 mm 12 Nos 10.00 2.0 1.9 2330 Plate 250x325x20 mm 4 Nos 52.00 2.3 --- ---31 Plate 130x250x20 mm 2 Nos 11.00 0.8 2.0 2432 Plate 250x325x20 mm 2 Nos 25.00 1.2 2.0 2433 Stiffener 195x325x20 mm 2 Nos 20.00 1.0 3.4 4134 Plate 250x340x20 mm 2 Nos 27.00 1.2 2.0 2435 Stiffener 90x325x20 mm 2 Nos 9.00 0.8 1.9 23

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GATES AND HOISTS

36 Nuts / Washers for anchor bars 15.00 --- --- --- Total : 2404.00 96.7 142.3 1170

kg Rm Rm NosABSTRACT :

1. Structural steel : IS :2062Angle / Channel / Beam / Bars : 812.00 kgPlates / Flats : 1475.00 kg

2. Alloy steel components : IS : 1570Stainless steel plates : 52.00 kg

3. Bolt / Nut / Washer : IS :1363MS Bolt / Nut / Washer : 65.00 kg

4. Other details :Length of cutting : 96.70 RmLength of welding : 142.30 RmNumber of electrodes 4x450 mm : 1170 Nos

24. Radial gate for Cross regulator :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on radial gate drawings for cross regulator radial gate of Alamatti LBC.2. Unless otherwise specified 6 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Trunnions / Brackets / Tie beam :1 Tie beam ISMB 250 x 2200 mm 1 No. 82.00 0.5 1.6 72 Plate 250x400x12 mm 4 Nos 38.00 4.2 2.6 213 Pin 90 dia x 370 mm 2 Nos 37.00 --- --- ---4 Trunnion hub 180/110x250 mm 2 Nos 92.00 --- --- ---5 Trunnion bush 110/90 x 260 mm 2 Nos 13.00 --- --- ---6 Plate 350x450x20 mm 4 Nos 99.00 6.2 2.3 287 Stiffener 220x450x20 mm 4 Nos 62.00 2.7 9.0 728 Plate 300x160x20 mm 4 Nos 30.00 1.9 2.9 239 Bolt/Nut/Washer 20 dia x 100 mm 24 Nos 16.00 --- --- ---

10 Bracket base pl 450x400x20 mm 2 Nos 57.00 1.7 --- ---11 Bracket pl 350x350x20 mm 4 Nos 77.00 4.5 2.8 2312 Stiffener 280x80x20 mm 6 Nos 21.00 0.5 5.3 4313 Stiffener 130x80x20 mm 4 Nos 7.00 0.3 2.3 1814 Keeper pl 140x60x20 mm 4 Nos 3.00 0.3 --- ---15 Screws 16 dia x 30 mm 8 Nos 1.00 --- --- ---16 Bolt/Nut/Washer 20 dia x 100 mm 16 Nos 10.00 --- --- ---

Sector arms and Horizontal girders :17 Sector arm ISMB 250 x 5150 mm 4 Nos 768.00 2.0 --- ---18 Bracing ISMB 250 x 2200 mm 2 Nos 164.00 1.0 4.0 3219 ISA 75x75x8 x 1900 mm 4 Nos 68.00 0.6 1.8 1420 ISA 75x75x8 x 1400 mm 4 Nos 50.00 0.6 1.8 1421 ISA 75x75x8 x 1900 mm 4 Nos 68.00 0.6 1.8 1422 ISA 75x75x8 x 550 mm 4 Nos 20.00 0.6 1.8 1423 Gusset pl 250x150x10 mm 4 Nos 12.00 1.6 1.6 1324 Gusset pl 200x150x10 mm 4 Nos 10.00 1.4 1.4 1125 Gusset pl 250x200x10 mm 4 Nos 16.00 1.8 1.8 1426 Gusset pl 200x200x10 mm 4 Nos 13.00 1.6 1.6 1327 Gusset pl 250x200x10 mm 4 Nos 16.00 1.8 1.8 1428 Plate 280x160x20 mm 4 Nos 28.00 1.8 4.0 3229 Plate 300x160x20 mm 4 Nos 30.00 1.8 4.0 3230 Bolt/Nut/Washer 20 dia x 70 mm 24 Nos 12.00 --- --- ---

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GATES AND HOISTS

31 H-Girder ISMB 300 x 2900 mm 2 Nos 256.00 1.8 --- ---32 Stiffener 70x320x20 mm 16 Nos 56.00 6.3 14.7 11833 Plate 300x160x20 mm 4 Nos 30.00 1.8 3.7 3034 Bolt/Nut/Washer 20 dia x 100 mm 24 Nos 15.00 --- --- ---35 ISA 75x75x8 x 1994 mm 3 Nos 53.00 0.5 1.3 1036 ISA 75x75x8 x 2150 mm 2 Nos 38.00 0.3 0.9 737 Gusset pl 200x200x10 mm 3 Nos 9.00 1.2 1.2 938 Gusset pl 240x200x10 mm 2 Nos 8.00 0.9 0.8 639 Gusset pl 300x200x10 mm 1 Nos 5.00 0.5 0.5 4

Skin plate assembly :40 Skin plate 2880x4950x10 mm 1 No. 1119.00 12.8 5.0 11541 Tee ISMB 250/2 x 4950 mm 6 Nos 554.00 14.9 59.4 47542 Top plate 150x2880x10 mm 1 Nos 34.00 3.0 6.0 4843 Stiffener 120x120x10 mm 14 Nos 16.00 3.4 6.7 5444 Bottom pl 150x2880x10 mm 1 No. 34.00 3.0 3.8 3145 Seal support 10x10x2880 1 No. 2.00 --- 5.8 4646 Side clamp ISA 45x45x6x5000 mm 2 Nos 40.00 0.2 --- ---47 Bottom clamp 70x2880x10 mm 1 No 16.00 3.0 --- ---48 Z - seal 5000 mm 2 Nos --- --- --- ---49 Flat seal 3000 mm 1 No. --- --- --- ---50 Back plate 60x5000x10 mm 1 No. 24.00 --- 10.0 8051 GI Bolt/Nut/Washer 12 dia x 50 mm 140 14.00 --- --- ---

Guide roller assembly :52 Plates 48.00 5.2 2.9 2453 Guide roller 4 Nos 30.00 --- --- ---54 Bronze bush 4 Nos 6.00 --- --- ---55 Pins 4 Nos 4.00 --- --- ---56 GI Bolt/Nut/Washer 12 dia x 50 mm 16 2.00 --- --- ---

Pulley supports in gate :57 Bracket pl 300x350x20 mm 4 Nos 66.00 2.7 5.2 4258 Plate 160x400x6 mm 2 Nos 6.00 1.1 3.2 2659 Plate 300x360x20 mm 2 Nos 34.00 1.3 1.9 1560 Stiffener 70x150x10 mm 8 Nos 7.00 2.0 3.5 2861 Stiffener 123x220x10 mm 4 Nos 9.00 1.4 2.8 22

4455.00 107.3 195.5 1642 Total : kg Rm Rm NosABSTRACT :

1. Structural steel : IS : 2062Angles / Beams / Channels / Bars : 2161.00 kgPlates / Flats : 2042.00 kg

2. Cast steel components : IS : 1030Trunnion hub / Guide roller : 122.00 kg

3. Alloy steel components : IS : 1570Pins : 41.00 kg

4. Alluminium / Bronze alloy components : IS : 305Trunnion & Guide roller bush : 19.00 kg

5. Bolt / Nut / Washer IS :1363GI Bolts / Nuts / Washers : 16.00 kgMS Bolts / Nuts / Washers / Screws : 54.00 kg

6. Rubber seals : IS : 11855Bottom seal : 3.00 RmSide seals : 10.00 Rm

7. Other details :Length of cutting : 107.30 Rm

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GATES AND HOISTS

Length of welding : 195.50 RmNumber of electrodes : 1642 Nos

25. Rope drum hoist for regulator radial gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on rope drum hoist drawings for cross regulator radial gate of Alamatti LBC.2. Unless otherwise specified 5 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Embedments :1 Anchor bolts 20 dia x 750 mm 16 Nos 30.00 0.4 1.0 62 Bolt / Nut / Washers 2.00 --- --- ---3 Plate 220x280x20 mm 8 Nos 77.00 4.0 --- ---

Hoist supporting structure :4 Girder ISMB-250 x 3600 mm 2 Nos 269.00 1.0 --- ---5 Rib plate 225x250x10 mm 8 Nos 35.00 3.8 1.8 116 ISMC- 150 x 500 mm 2 Nos 17.00 0.6 2.4 147 ISMC- 150 x 1990 mm 2 Nos 61.00 0.6 2.4 148 ISMC- 250 x 790 mm 2 Nos 54.00 0.8 4.0 249 ISMC- 250 x 1990 mm 4 Nos 272.00 1.6 8.0 48

10 ISMC- 250 x 570 mm 4 Nos 78.00 1.7 8.0 4811 MS pipe 32 dia x 5250 mm 2 Nos 42.00 --- 0.5 312 Flat 50x3100x8 mm 2 Nos 20.00 0.1 0.8 513 ISA 65x65x6 mm x 1130 mm 6 Nos 39.00 0.8 --- ---14 ISA 65x65x6 mm x 3600 mm 2 Nos 42.00 0.3 14.4 8615 Bolt/Nut/Washer 12 diax50 mm 12 Nos 2.00 --- --- ---16 Rib plate 200x250x10 mm 6 Nos 14.00 2.7 4.6 2817 Chequered pl 400x687x6 mm 2 Nos 29.00 2.2 2.2 1318 Chequered pl 525x1935x6 mm 2 Nos 109.00 4.9 4.9 2919 Chequered pl 247x560x6 mm 1 No. 7.00 0.8 0.8 520 Chequered pl 587x630x6 mm 2 Nos 40.00 2.4 2.4 1421 Chequered pl 162x560x6 mm 1 No. 5.00 0.8 0.8 522 Plate 250x350x16 mm 4 Nos 44.00 2.4 3.2 1923 R/F plate 120/62 dia x 8 mm 4 Nos 1.00 2.3 1.5 924 Plate 120x470x20 mm 2 Nos 18.00 1.2 0.8 525 Plate 80x80x10 mm 4 Nos 2.00 0.6 1.3 8

Pulleys and accessories :26 CI Pulley 300 dia 2 Nos 36.00 --- --- ---27 Pin 60 dia x 200 mm 2 Nos 16.00 --- --- ---28 Bronz bush 80/60 dia x 50 mm 2 Nos 2.00 --- --- ---29 Plate 40x90x8 mm 4 Nos 2.00 0.5 --- ---30 Bolt/Nut/Washer 12 diax30 mm 16 Nos 2.00 --- --- ---31 Pulley pin 50 dia x 250 mm 2 Nos 8.00 --- --- ---32 Lock plate 50x90x10 mm 8 Nos 8.00 --- --- ---33 Spacer 130/60 dia x 25 mm 2 Nos 6.00 --- --- ---34 Spacer 130/60 dia x 8 mm 4 Nos 2.50 --- --- ---35 CI Pulley 276 dia 4 Nos 72.00 --- --- ---36 Bronz bush 80/60 dia x 60 mm 4 Nos 4.50 --- --- ---

Gear box :37 ISMC 250 x 880 mm 2 Nos. 60.00 1.0 --- ---38 ISMC 250 x 570 mm 2 Nos. 39.00 1.0 0.8 539 ISMC 250 x 660 mm 2 Nos. 45.00 1.0 0.8 540 ISMC 250 x 450 mm 2 Nos. 31.00 1.0 0.8 541 ISMC 250 x 260 mm 2 Nos. 14.00 1.0 0.8 5

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GATES AND HOISTS

42 ISMC 250 x 400 mm 2 Nos. 27.00 1.0 1.6 1043 Plate 60x880x10 mm 2 Nos 8.00 0.2 1.8 1144 Plate 60x220x10 mm 2 Nos 2.00 0.2 0.7 445 Stiffener 75x90x10 mm 12 Nos 4.00 2.0 3.9 2346 Plate 250x400x20 mm 4 Nos 63.00 2.6 4.0 2447 Plate 75x240x10 mm 2 Nos 3.00 0.6 1.6 1048 Plate 130x240x10 mm 8 Nos 20.00 3.0 6.4 3849 Plate 80x290x20 mm 4 Nos 15.00 1.5 3.0 18

Drive stool :50 ISMC 150 x 1525 mm 2 Nos 51.00 0.6 --- ---51 ISMC 150 x 500 mm 3 Nos 25.00 0.9 3.0 1852 ISA 75x75x8 mm x 500 mm 4 Nos 14.00 0.6 2.4 1453 Plate 230x280x8 mm 1 No 4.00 0.6 0.5 354 Plate 312x330x8 mm 1 No 7.00 0.7 0.7 455 ISA 75x75x8 mm x 500 mm 2 Nos 7.00 0.3 0.2 156 Plate 65x100x8 mm 3 Nos 1.00 --- --- ---57 Bolt/Nut/Washer 16 dia x 60 mm 10 Nos 3.50 --- --- ---58 Bolt/Nut/Washer 20 dia x 100 mm 4 Nos 2.00 --- --- ---59 Bolt/Nut/Washer 10 dia x 50 mm 4 Nos 0.50 --- --- ---60 Bolt/Nut/Washer 12 dia x 50 mm 4 Nos 0.50 --- --- ---61 Bolt/Nut/Washer 12 dia x 50 mm 12 Nos 1.50 --- --- ---

Drums / Gears / Pinions / Shafts62 Rope drum 300 dia x 470 mm 2 Nos 240.00 --- --- ---63 Drum gear 2 Nos 144.00 --- --- ---64 Drum shaft 60 dia x 610 mm 2 Nos 31.00 --- --- ---65 First pinion 2 Nos 14.00 --- --- ---66 Pinion shaft 60 dia x 540 mm 2 Nos 28.00 --- --- ---67 Bearings 4 Nos 4.00 --- --- ---68 Plummer blocks for pinions 4 Nos 20.00 --- --- ---69 Line shaft 50 dia x 431 mm 2 Nos 16.00 --- --- ---70 Flexible coupling 50 dia 4 Nos 20.00 --- --- ---71 Lock plate 180x50x8 mm 4 Nos 3.00 0.2 --- ---72 Bolt/Nut/Washer 16 diax30 mm 8 Nos 1.00 --- --- ---73 Bolt/Nut/Washer 16 diax75 mm 24 Nos 6.00 --- --- ---74 Bolt/Nut/Washer 10 diax40 mm 100 Nos 10.00 --- --- ---75 Bolt/Nut/Washer 16 diax100 mm 8 Nos 2.00 --- --- ---76 Spacer pl 150/62 dia x 8 mm 4 Nos 2.00 2.6 1.9 11

Gear box cover :77 Plate 50x416x5 mm 2 Nos 2.00 0.1 0.9 578 IAS 45x45x5 mm x1920 mm 2 Nos 17.00 0.2 0.2 179 IAS 45x45x5 mm x1900 mm 4 Nos 35.00 0.4 0.4 280 Plate 50x600x5 mm 2 Nos 2.00 0.1 1.3 881 Plate 340x1600x3 mm 2 Nos 27.00 3.9 2.0 1282 Plate 420x850x3 mm 2 Nos 18.00 3.8 2.0 1283 Plate 420x850x3 mm 2 Nos 18.00 4.0 2.0 1284 Plate 50x1600x5 mm 2 Nos 7.00 0.1 1.5 985 Plate 50x1200x5 mm 2 Nos 5.00 0.1 1.0 686 Inspection cover 200x200x3 mm 2 Nos 2.00 0.8 --- ---87 Handle 16 dia 250 mm 6 Nos 3.00 0.1 0.6 4

Drive unit cover :88 IAS 45x45x5 mm x590 mm 2 Nos 4.00 0.2 0.2 189 IAS 45x45x5 mm x247 mm 2 Nos 2.00 0.2 0.2 190 IAS 45x45x5 mm x1037 mm 2 Nos 7.00 0.2 0.2 191 IAS 45x45x5 mm x940 mm 2 Nos 6.00 0.2 0.2 192 IAS 45x45x5 mm x1570 mm 2 Nos 11.00 0.2 0.2 1

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GATES AND HOISTS

93 IAS 45x45x5 mm x520 mm 2 Nos 4.00 0.2 0.2 194 Plate 550x580x3 mm 1 No. 8.00 1.1 1.1 695 Plate 930x1495x3 mm 2 Nos 34.00 4.9 4.5 2796 Plate 550x930x3 mm 1 No 13.00 1.5 1.5 997 Plate 50x715x3 mm 2 Nos 2.00 0.1 1.5 998 Plate 620x1600x3 mm 1 No 25.00 2.3 2.0 1299 Plate 200x200x3 mm 1 No 1.00 0.4 --- ---

100 Plate 250x400x3 mm 1 No 2.00 0.7 1.0 6101 Plate 100x100x3 mm 1 No 0.50 0.2 0.4 2102 Flat 50x350x5 mm 2 Nos 1.00 0.10 1.4 8103 Flat 50x100x5 mm 2 Nos 1.00 0.10 0.4 2104 Flat 50x350x5 mm 2 Nos 1.00 0.10 0.7 4105 Handle 16 dia x 450 mm 4 Nos 3.00 0.10 0.8 5106 Handle 16 dia x 350 mm 2 Nos 1.00 --- 0.4 2107 Bolt/Nut/Washer 20 dia x 30 mm 30 Nos 2.00 --- --- ---108 Bolt/Nut/Washer 12 diax40 mm 12 Nos 1.00 --- --- ---

Other components :109 Steel wire rope 12 dia 6x36 - 2 x 35 m 40.00 --- --- ---110 Rope socket with pin 2 Nos 14.00 --- --- ---111 Elecon gear unit 1 No 102.00 --- --- ---112 Electric motor 2 hp 1 No. 44.00 --- --- ---113 Ele-magnetic brake 18.00 --- --- ---114 Brake drum coupling 150 dia 7.00 --- --- ---

Total : 2947.50 85.5 129.5 772kg Rm Rm Nos

Manual operation assembly :115 IAS 50x50x5 mm x 775 mm 4 Nos 14.00 0.4 0.6 4116 Plummer blocks - sprocket shafts 3 Nos 6.00 --- --- ---117 Handle 1.50 --- --- ---118 Round 32 dia x 500 m / c 3.00 --- --- ---119 ISA 50x50x6 mm x 300 mm 2 Nos 3.00 0.2 0.4 2120 ISA 75x75x8 mm x 210 mm 1 No 2.00 0.2 0.6 4121 Round 32 dia x 361 m / c 2.00 --- --- ---122 Dog clutch 45 dia and lever 15.00 --- --- ---123 Sprocket 30 theeth 4.50 --- --- ---124 Sprocket 15 theeth 1.00 --- --- ---125 Sprocket chain 2.50 --- --- ---126 Bolt/Nut/Washer 10 dia x 40 mm 6 Nos 0.50 --- --- ---

55.00ABSTRACT :

1. Structural steel : IS : 2062Angles / Beams / Channels / Bars : 1238.00 kgPlates / Flats : 531.00 kgChequered plate 190.00 kg

2. Cast steel components : IS : 1030Rope drums 2 Nos Gears 2 Nos : 384.00 kgPinions : 14.00 kgPulleys 6 Nos : 108.00 kgPlummer blocks 6 Nos / couplings : 47.00 kg

3. Alloy steel components : IS : 1570Shafts : 75.00 kgPins 24.00 kg

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GATES AND HOISTS

4. Alluminium/ Bronze alloy components : IS : 305Bearings / Bush : 10.50 kgBolt / Nut / Washers IS : 1363MS Bolts / Nuts / Washers : 66.00 kg

5. Wire rope : IS : 226612 mm dia 6 / 36 construction 2 x 35 Rm : 40.00 kg

6. Other components :Manual operating system : 1 No.Worm reducer : 1 NosElectric motor 2 hp : 1 No.Ele-magnetic brake : 1 No.Rope socket with pin 2 NosMS pipe 32 mm dia : 10.50 Rm

7. Other details :Length of cutting : 85.50 RmLength of welding : 129.50 RmNumber of electrodes : 772 Nos

26. Manually operated Rope drum hoist for regulator radial gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on rope drum hoist drawings for cross regulator radial gate of Alamatti LBC without considering drive unit. 2. Unless otherwise specified 5 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Embedments :1 Anchor bolts 20 dia x 750 mm 16 Nos 30.00 0.4 1.0 62 Bolt / Nut / Washers 2.00 --- --- ---3 Plate 220x280x20 mm 8 Nos 77.00 4.0 --- ---

Hoist supporting structure :4 Girder ISMB-250 x 3600 mm 2 Nos 269.00 1.0 --- ---5 Rib plate 225x250x10 mm 8 Nos 35.00 3.8 1.8 116 ISMC- 150 x 500 mm 2 Nos 17.00 0.6 2.4 147 ISMC- 150 x 1990 mm 2 Nos 61.00 0.6 2.4 148 ISMC- 250 x 790 mm 2 Nos 54.00 0.8 4.0 249 ISMC- 250 x 1990 mm 4 Nos 272.00 1.6 8.0 48

10 ISMC- 250 x 570 mm 4 Nos 78.00 1.7 8.0 4811 MS pipe 32 dia x 5250 mm 2 Nos 42.00 --- 0.5 312 Flat 50x3100x8 mm 2 Nos 20.00 0.1 0.8 513 ISA 65x65x6 mm x 1130 mm 6 Nos 39.00 0.8 --- ---14 ISA 65x65x6 mm x 3600 mm 2 Nos 42.00 0.3 14.4 8615 Bolt/Nut/Washer 12 diax50 mm 12 Nos 2.00 --- --- ---16 Rib plate 200x250x10 mm 6 Nos 14.00 2.7 4.6 2817 Chequered pl 400x687x6 mm 2 Nos 29.00 2.2 2.2 1318 Chequered pl 525x1935x6 mm 2 Nos 109.00 4.9 4.9 2919 Chequered pl 247x560x6 mm 1 No. 7.00 0.8 0.8 520 Chequered pl 587x630x6 mm 2 Nos 40.00 2.4 2.4 1421 Chequered pl 162x560x6 mm 1 No. 5.00 0.8 0.8 522 Plate 250x350x16 mm 4 Nos 44.00 2.4 3.2 1923 R/F plate 120/62 dia x 8 mm 4 Nos 1.00 2.3 1.5 924 Plate 120x470x20 mm 2 Nos 18.00 1.2 0.8 525 Plate 80x80x10 mm 4 Nos 2.00 0.6 1.3 8

Pulleys and accessories :26 CI Pulley 300 dia 2 Nos 36.00 --- --- ---

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GATES AND HOISTS

27 Pin 60 dia x 200 mm 2 Nos 16.00 --- --- ---28 Bronz bush 80/60 dia x 50 mm 2 Nos 2.00 --- --- ---29 Plate 40x90x8 mm 4 Nos 2.00 0.5 --- ---30 Bolt/Nut/Washer 12 diax30 mm 16 Nos 2.00 --- --- ---31 Pulley pin 50 dia x 250 mm 2 Nos 8.00 --- --- ---32 Lock plate 50x90x10 mm 8 Nos 8.00 --- --- ---33 Spacer 130/60 dia x 25 mm 2 Nos 6.00 --- --- ---34 Spacer 130/60 dia x 8 mm 4 Nos 2.50 --- --- ---35 CI Pulley 276 dia 4 Nos 72.00 --- --- ---36 Bronz bush 80/60 dia x 60 mm 4 Nos 4.50 --- --- ---

Gear box :37 ISMC 250 x 880 mm 2 Nos. 60.00 1.0 --- ---38 ISMC 250 x 570 mm 2 Nos. 39.00 1.0 0.8 539 ISMC 250 x 660 mm 2 Nos. 45.00 1.0 0.8 540 ISMC 250 x 450 mm 2 Nos. 31.00 1.0 0.8 541 ISMC 250 x 260 mm 2 Nos. 14.00 1.0 0.8 542 ISMC 250 x 400 mm 2 Nos. 27.00 1.0 1.6 1043 Plate 60x880x10 mm 2 Nos 8.00 0.2 1.8 1144 Plate 60x220x10 mm 2 Nos 2.00 0.2 0.7 445 Stiffener 75x90x10 mm 12 Nos 4.00 2.0 3.9 2346 Plate 250x400x20 mm 4 Nos 63.00 2.6 4.0 2447 Plate 75x240x10 mm 2 Nos 3.00 0.6 1.6 1048 Plate 130x240x10 mm 8 Nos 20.00 3.0 6.4 3849 Plate 80x290x20 mm 4 Nos 15.00 1.5 3.0 18

Drive stool :50 ISMC 150 x 1525 mm 2 Nos 51.00 0.6 --- ---51 ISMC 150 x 500 mm 3 Nos 25.00 0.9 3.0 1852 ISA 75x75x8 mm x 500 mm 4 Nos 14.00 0.6 2.4 1453 Plate 230x280x8 mm 1 No 4.00 0.6 0.5 354 Plate 312x330x8 mm 1 No 7.00 0.7 0.7 455 ISA 75x75x8 mm x 500 mm 2 Nos 7.00 0.3 0.2 156 Plate 65x100x8 mm 3 Nos 1.00 --- --- ---57 Bolt/Nut/Washer 16 dia x 60 mm 10 Nos 3.50 --- --- ---58 Bolt/Nut/Washer 20 dia x 100 mm 4 Nos 2.00 --- --- ---59 Bolt/Nut/Washer 10 dia x 50 mm 4 Nos 0.50 --- --- ---60 Bolt/Nut/Washer 12 dia x 50 mm 4 Nos 0.50 --- --- ---61 Bolt/Nut/Washer 12 dia x 50 mm 12 Nos 1.50 --- --- ---

Drums / Gears / Pinions / Shafts62 Rope drum 300 dia x 470 mm 2 Nos 240.00 --- --- ---63 Drum gear 2 Nos 144.00 --- --- ---64 Drum shaft 60 dia x 610 mm 2 Nos 31.00 --- --- ---65 First pinion 2 Nos 14.00 --- --- ---66 Pinion shaft 60 dia x 540 mm 2 Nos 28.00 --- --- ---67 Bearings 4 Nos 4.00 --- --- ---68 Plummer blocks for pinions 4 Nos 20.00 --- --- ---69 Line shaft 50 dia x 431 mm 2 Nos 16.00 --- --- ---70 Flexible coupling 50 dia 4 Nos 20.00 --- --- ---71 Lock plate 180x50x8 mm 4 Nos 3.00 0.2 --- ---72 Bolt/Nut/Washer 16 diax30 mm 8 Nos 1.00 --- --- ---73 Bolt/Nut/Washer 16 diax75 mm 24 Nos 6.00 --- --- ---74 Bolt/Nut/Washer 10 diax40 mm 100 Nos 10.00 --- --- ---75 Bolt/Nut/Washer 16 diax100 mm 8 Nos 2.00 --- --- ---76 Spacer pl 150/62 dia x 8 mm 4 Nos 2.00 2.6 1.9 11

Gear box cover :77 Plate 50x416x5 mm 2 Nos 2.00 0.1 0.9 5

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GATES AND HOISTS

78 IAS 45x45x5 mm x1920 mm 2 Nos 17.00 0.2 0.2 179 IAS 45x45x5 mm x1900 mm 4 Nos 35.00 0.4 0.4 280 Plate 50x600x5 mm 2 Nos 2.00 0.1 1.3 881 Plate 340x1600x3 mm 2 Nos 27.00 3.9 2.0 1282 Plate 420x850x3 mm 2 Nos 18.00 3.8 2.0 1283 Plate 420x850x3 mm 2 Nos 18.00 4.0 2.0 1284 Plate 50x1600x5 mm 2 Nos 7.00 0.1 1.5 985 Plate 50x1200x5 mm 2 Nos 5.00 0.1 1.0 686 Inspection cover 200x200x3 mm 2 Nos 2.00 0.8 --- ---87 Handle 16 dia 250 mm 6 Nos 3.00 0.1 0.6 4

Other components :88 Steel wire rope 12 dia 6x36 - 2 x 35 m 40.00 --- --- ---89 Rope socket with pin 2 Nos 14.00 --- --- ---90 Elecon gear unit 1 No 102.00 --- --- ---

Total : 2749.00 72.7 112.6 674kg Rm Rm Nos

Manual operation assembly :91 IAS 50x50x5 mm x 775 mm 4 Nos 14.00 0.4 0.6 492 Plummer blocks - sprocket shafts 3 Nos 6.00 --- --- ---93 Handle 1.50 --- --- ---94 Round 32 dia x 500 m / c 3.00 --- --- ---95 ISA 50x50x6 mm x 300 mm 2 Nos 3.00 0.2 0.4 296 ISA 75x75x8 mm x 210 mm 1 No 2.00 0.2 0.6 497 Round 32 dia x 361 m / c 2.00 --- --- ---98 Dog clutch 45 dia and lever 15.00 --- --- ---99 Sprocket 30 theeth 4.50 --- --- ---

100 Sprocket 15 theeth 1.00 --- --- ---101 Sprocket chain 2.50 --- --- ---102 Bolt/Nut/Washer 10 dia x 40 mm 6 Nos 0.50 --- --- ---

55.00ABSTRACT :

1. Structural steel : IS : 2062Angles / Beams / Channels / Bars : 1193.00 kgPlates / Flats : 442.00 kgChequered plate 190.00 kg

2. Cast steel components : IS : 1030Rope drums 2 Nos Gears 2 Nos : 384.00 kgPinions : 14.00 kgPulleys 6 Nos : 108.00 kgPlummer blocks 6 Nos / couplings : 47.00 kg

3. Alloy steel components : IS : 1570Shafts : 75.00 kgPins 24.00 kg

4. Alluminium/ Bronze alloy components : IS : 305Bearings / Bush : 10.50 kgBolt / Nut / Washers IS : 1363MS Bolts / Nuts / Washers : 63.00 kg

5. Wire rope : IS : 226612 mm dia 6 / 36 construction 2 x 35 Rm : 40.00 kg

6. Other components :Manual operating system : 1 No.Worm reducer : 1 NosRope socket with pin 2 NosMS pipe 32 mm dia : 10.50 Rm

7. Other details :

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GATES AND HOISTS

Length of cutting : 73 RmLength of welding : 113 RmNumber of electrodes : 674 Nos

27. Embedded parts for vertical lift Regulator / Escape gate :( With top seal seat arrangement )Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on embedded parts drawings for vertical lift roller gate of Alamatti LBC escape.2. Unless otherwise specified 5 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Sill beam :1 SS seal seat 60x2200x6 mm 1 No. 6.50 0.1 ( F4 ) 4.5 232 Plate 400x2600x10 mm 1 No. 82.00 3.0 --- ---3 ISA 75x75x8 x 2600 mm 2 Nos 46.50 0.3 10.4 734 Anchor rod 16 dia x 300 mm 10 Nos 5.00 0.2 0.5 4

Roller track :5 SS track plate 80x4800x8 mm 2 Nos 48.50 0.2 ( F5 ) 19.5 1366 ISMC 300 x 4800 mm 2 Nos 349.00 1.0 1.6 127 Half ISMB 250 x 4800 mm 2 Nos 180.00 5.3 19.2 1358 Stiffener 110x120x10 mm 20 Nos 19.00 4.6 13.4 949 Stiffener 110x170x10 mm 20 Nos 32.00 5.6 15.4 108

10 Anchor rod 16 dia x 300 mm 40 Nos 19.00 0.6 2.0 14Side seal track :

11 SS seal seat 60x2250x6 mm 2 Nos 13.00 0.1 ( F4 ) 9.2 4612 ISMC 300 x 4800 mm 2 Nos 349.00 1.0 1.6 1113 ISA 75x75x8 x 300 mm 20 Nos 53.50 3.0 18.0 12614 Anchor rod 16 dia x 300 mm 40 Nos 19.00 0.6 2.0 14

Guide :15 Plate 400x4800x10 mm 2 Nos 301.50 10.4 39.2 27516 ISA 75x75x8 x 4800 mm 2 Nos 85.50 0.3 19.2 13417 Plate 40x4800x25 mm 2 Nos 75.50 0.1 19.2 134

Top seal track :18 SS seal seat 120x2040x6 mm 1 No. 11.50 2.1 ( F4 ) 4.3 2219 ISMC 300 x 2000 mm 1 No. 73.00 0.5 1.2 920 Plate 90x300x10 mm 2 Nos 4.50 0.2 1.9 1321 ISA 75x75x8 x 300 mm 4 Nos 6.00 0.6 3.8 2722 Anchor rod 16 dia x 300 mm 8 Nos 4.00 0.1 0.4 323 Bolt/Nut/Washer 20 dia x 80 mm 4 Nos 0.50 --- --- ---

Total : 1784.00 39.9 206.5 1413kg Rm Rm Nos

ABSTRACT : 1. Structural steel : IS : 2062

Angle / Channel / Beam / Bars : 1189.50 kgPlates / Flats : 514.50 kg

2. Alloy steel components : IS : 1570Stainless steel plates : 79.50 kg

3. Bolt / Nut / Washer : IS : 1363MS Bolt / Nut / Washer : 0.50 kg

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GATES AND HOISTS

4. Other details :Length of cutting : 39.90 RmLength of welding : 206.50 RmNumber of electrodes ( structural steel ) : 1186 NosNumber of electrodes ( stainless steel ) : 227 Nos

28. Vertical lift roller gate for Regulator / Escape :( With top seal arrangement )Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on embedded parts drawings for cross regulator radial gate of Alamatti LBC.2. Unless otherwise specified 5 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

1 Skin plate 2200x2480x10 mm 1 No. 428.00 4.7 --- ---2 End girder pl 230x2200x10 mm 4 Nos 159.00 9.8 17.6 1233 H-girder half ISMB 450 x 2260 mm 2 Nos 163.50 2.6 10.2 724 Stiffener ISA 75x75x8 x 2260 mm 1 No. 20.00 0.2 5.1 365 Ver stiffener half ISMB450 x 340 mm 1 12.00 0.5 2.2 156 Ver stiffener half ISMB450 x 1340 mm 1 48.50 2.0 4.0 287 Stiffener 340x150x10 mm 4 Nos 16.00 2.0 5.1 368 Stiffener 150x1340x10 mm 4 Nos 63.00 6.9 13.1 929 Stiffener 150x490x10 mm 4 Nos 23.00 2.6 5.1 36

10 Stiffener 150x200x10 mm 2 Nos 5.00 0.8 1.6 1111 Stiffener 150x250x10 mm 2 Nos 6.00 0.8 1.6 1112 Plate 230x500x10 mm 2 Nos 18.00 1.5 3.5 2413 Stiffener 80x230x10 mm 6 Nos 5.00 0.5 5.5 3814 Cover plate 160x160x10 mm 8 Nos 16.00 3.8 --- ---15 Cover plate 80x160x10 mm 4 Nos 4.00 0.6 --- ---16 Cover plate 160 dia x 10 mm 4 Nos 6.50 2.0 --- ---17 Seal base pl 40x2130x10 mm 2 Nos 13.50 0.1 8.7 6118 Clamp plate 40x2175x10 mm 2 Nos 13.50 0.1 --- ---19 Side seal 30 diax90 x 1975 mm 2 Nos --- --- ---20 Clamp plate 70x2060x10 mm 1 No 11.50 0.1 --- ---21 Seal support 12x2060x12 mm 1 No. 2.50 2.1 4.1 2922 Bottom seal 76x2250x10 mm 1 No. --- --- ---23 Top seal 30 diax90 x 1850 mm 1 No. --- --- ---24 Clamp plate 40x2160x10 mm 1 No. 7.00 --- --- ---25 Seal base pl 40x2250x10 mm 1 No. 7.00 --- 4.5 3126 Plate for guide rollers 72.00 1.4 1.8 1327 Guide roller 4 Nos 8.0028 Wheel bush 4 Nos 5.00 --- --- ---29 Lifting pin 90 dia x150 mm 1 No. 9.00 --- --- ---30 Keeper plate 50x110x10 mm 1 No. 0.50 --- --- ---31 Bolt/Nut/Washer 12 dia x 20 mm 28 Nos 2.00 --- --- ---32 Corner seal 200x200 mm 2 Nos --- --- ---33 Bolt/Nut/Washer 12 dia x 20 mm 16 Nos 0.50 --- --- ---34 Bolt/Nut/Washer 12 dia x 40 mm 16 Nos 1.00 --- --- ---35 Wheel 200/80 dia x 50 mm 4 Nos 41.50 --- --- ---36 Wheel axle 60 dia x 176 mm 4 Nos 21.00 --- --- ---

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GATES AND HOISTS

37 Seal bolts/nuts 12 dia x 40 mm 110 Nos 7.50 --- --- --- Total : 1216.50 45.1 93.7 656

kg Rm Rm NosABSTRACT :

1. Structural steel : IS : 2062Angle / Channel / Beam / Bars : 244.00 kgPlates / Flats : 877.00 kg

2. Cast steel components : IS : 1030Wheels / Guide roller : 49.50 kg

3. Alluminium / Bronze alloy components : IS : 305Bearings / Bushes : 5.00 kg

4. Alloy steel components : IS : 1570Wheel axle / lifting pin : 30.00 kg

5. Rubber seals : IS : 11855Bottom rubber seal ( uncladed ) : 2.25 RmSide rubber seal ( uncladed ) : 3.95 RmTop rubber seal ( uncladed ) 1.85 Rm

6. Bolt / Nut / Washer IS : 1363GI Bolt / Nut / Washer : 7.50 kgMS Bolt / Nut / Washer : 3.50 kg

7. Other details :Length of cutting : 45.10 RmLength of welding : 93.70 RmNumber of electrodes : 656 Nos

29. 3 t capacity screw hoist for vertical lift roller gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on embedded parts drawings for cross regulator radial gate of Alamatti LBC.2. Unless otherwise specified 5 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Hoist platform :1 ISMB 250 x 2600 mm 2 Nos 194.00 1.0 --- ---2 ISMC 200 x 2125 mm 2 Nos 95.00 0.7 --- ---3 Chequered plate 1000x1900x5 mm 2 Nos 172.00 3.8 --- ---4 ISA 65x65x6 x 1990 mm 2 Nos 23.00 0.3 0.4 35 ISA 50x50x6 x 2600 mm 2 Nos 23.50 0.2 0.4 36 ISA 50x50x6 x 1255 mm 6 Nos 34.00 0.6 --- ---7 Plate 50x2000x5 mm 2 Nos 8.00 0.1 0.2 28 Plate 135x250x10 mm 8 Nos 21.00 3.1 6.0 429 Plate 300x300x16 mm 8 Nos 90.50 4.8 --- ---

10 Plate 200x205x10 mm 6 Nos 19.00 2.4 3.0 2111 Pipe 32 dia x 4400 mm 2 Nos 23.00 --- --- ---12 Anchor rod 20 dia x 500 mm 16 Nos 23.00 0.3 --- ---13 Bolt/Nut/Washer 8.00 --- --- ---

Hoist parts :14 Hoist body 1 No. 36.00 --- --- ---15 Hoist stem 60 dia x 3400 mm 1 No. 75.50 --- --- ---16 Lock nut 1 No. 3.00 --- --- ---17 Main nut 1 No. 16.00 --- --- ---18 Thrust bearing 2 Nos 4.00 --- --- ---19 Plate 120x150x10 mm 2 Nos 2.50 0.5 --- ---

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GATES AND HOISTS

20 Plate 40x40x10 mm 4 Nos 0.50 0.2 --- --- Total : 871.50 18.0 10.0 71.0

kg Rm Rm NosABSTRACT :

1. Structural steel : IS : 2062Angle / Channel / Beam / Bars : 392.50 kgPlates / Flats : 141.50 kgChequered plate : 172.00 kg

2. Cast iron components : IS : 1030Hoist body / Lock nut / Main nut : 55.00 kg

3. Alluminium / Bronze alloy components : IS : 305Bearings / Bushes : 4.00 kg

4. Alloy steel components : IS : 1570Hoist stem : 75.50 kg

5. Bolt / Nut / Washer : IS : 1363MS Bolt / Nut / Washer : 8.00 kg

6. Other components :Pipe 32 mm dia : 8.80 Rm

7. Other details :Length of cutting : 18.00 RmLength of weld : 10.00 RmNumber of electrodes : 71 Nos

30. Embedded parts for Regulator / Escape stoplog gate :Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on embedded parts drawings for cross regulator radial gate of Alamatti LBC.2. Unless otherwise specified 5 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

Sill beam :1 SS seal seat 60x2200x6 mm 1 No. 6.50 0.1 ( F4 ) 4.5 232 Plate 400x2600x10 mm 1 No. 82.00 3.0 --- ---3 ISA 75x75x8 x 2600 mm 2 Nos 46.50 0.3 10.4 734 Anchor rod 16 dia x 300 mm 10 Nos 5.00 0.2 0.5 4

Roller track :5 SS track plate 80x4800x8 mm 2 Nos 48.50 0.2 ( F5 ) 19.5 1366 ISMC 300 x 4800 mm 2 Nos 349.00 1.0 1.6 117 Half ISMB 250 x 4800 mm 2 Nos 180.00 5.3 19.2 1348 Stiffener 110x120x10 mm 20 Nos 19.00 4.6 13.4 949 Stiffener 110x170x10 mm 20 Nos 32.00 5.6 15.4 108

10 Anchor rod 16 dia x 300 mm 40 Nos 19.00 0.6 2.0 14Side seal track :

11 SS seal seat 60x2250x6 mm 2 Nos 13.00 0.1 ( F4 ) 9.3 4712 ISMC 300 x 4800 mm 2 Nos 349.00 1.0 1.6 1113 ISA 75x75x8 x 300 mm 20 Nos 53.50 3.0 18.0 12614 Anchor rod 16 dia x 300 mm 40 Nos 19.00 0.6 2.0 14

Guide :15 Plate 400x4800x10 mm 2 Nos 301.50 10.4 39.2 27416 ISA 75x75x8 x 4800 mm 2 Nos 85.50 0.3 19.2 13417 Plate 40x4800x25 mm 2 Nos 75.50 0.1 19.2 134

Total : 1684.50 36.4 195.0 1337kg Rm Rm Nos

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GATES AND HOISTS

ABSTRACT : 1. Structural steel : IS : 2062

Angle / Channel / Beam / Bars : 1106.50 kgPlates / Flats : 510.00 kg

2. Alloy steel components : IS : 1570Stainless steel plates : 68.00 kg

3. Other details :Length of cutting : 36.40 RmLength of welding : 195.00 RmNumber of electrodes ( str steel ) : 1131 NosNumber of electrodes ( stainless steel ) 206 Nos

31. Stoplog gate for Regulator :( Data for one element )Details of materials / Gas cutting / Welding for rate analysis :

Note : 1. Data based on embedded parts drawings for cross regulator radial gate of Alamatti LBC.2. Unless otherwise specified 5 mm fillet weld considered for computation of requirement of welding electrodes.3. Plate cutting considered for 2 sides assuming other 2 sides free face.

Sl No. DESCRIPTION OF MATERIALS Weight Gas cutting Weld length Number of in kg length in m in m electrodes

1 Skin plate 990x2450x10 mm 1 No. 190.00 3.4 --- ---2 ISMB 250 x 2293 mm 2 Nos 171.00 1.0 9.6 673 ISMB 250 x 980 mm 2 Nos 73.00 1.0 4.4 314 Plate 150x250x10 mm 2 Nos 4.00 0.7 0.4 35 ISMB 250 x 237 mm 2 Nos 18.00 1.0 1.4 106 ISMB 250 x 493 mm 1 No. 18.50 0.5 1.2 87 Plate 150x493x10 mm 2 Nos 11.50 1.3 2.0 148 Plate 150x237x10 mm 4 Nos 11.50 1.6 4.3 309 Plate 200x237x10 mm 4 Nos 15.00 1.8 5.1 36

10 Plate 200x493x10 mm 2 Nos 15.50 1.4 3.6 2511 Plate 100x260x10 mm 5 Nos 10.00 0.5 --- ---12 Plate 50x1000x10 mm 2 Nos 8.00 0.1 4.0 2813 Slide blocks 50x25x20 mm 4 Nos 1.00 0.1 0.6 414 Plate 50x2200x10 mm 1 Nos 8.50 --- 4.4 3115 Plate 70x250x10 mm 2 Nos 3.00 0.2 2.3 1616 Plate 150x300x10 mm 4 Nos 14.00 1.8 1.2 917 Plate 110x250x10 mm 2 Nos 4.50 0.7 1.5 1018 Pin 50 dia x 100 mm 2 Nos 3.00 --- --- ---19 Seal base 50x980x10 mm 2 Nos 9.50 0.1 4.0 2820 ISA 45x45x6 x 1000 mm 2 Nos 8.00 0.1 --- ---21 Side seal 1005 mm 2 Nos --- --- ---22 Plate 10x1860x10 mm 1 No. 1.50 --- 3.9 2823 Seal clamp 70x1860x10 mm 1 No. 10.00 0.1 --- ---24 Bottom seal 76x2000 mm 1 No. --- --- ---25 Plates for 4 Guide shoe assembly 18.00 1.3 1.8 1326 Bolt/Nut/Washer 12 dia x 65 mm 16 Nos 1.50 --- --- ---27 GI Bolt/Nut/Washer 12 dia x 50 mm 28 2.50 --- --- ---28 GI Bolt/Nut/Washer 12 dia x 60 mm 30 2.50 --- --- ---

Total for 1 element : 633.50 18.7 55.7 391 Total for 4 elements : 2534.00 74.8 222.8 1564

kg Rm Rm Nos

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GATES AND HOISTS

ABSTRACT : 1. Structural steel : IS :2062

Angle / Channel / Beam / Bars : 1154.00 kgPlates / Flats : 1342.00 kg

2. Alloy steel components : IS : 1570Hook pins : 12.00 kg

3. Rubber seal : IS : 11855Bottom rubber seal ( uncladded ) : 8.00 RmSide rubber seal ( uncladded ) : 8.04 Rm

4. Bolt / Nut / Washer : IS :1363GI Bolt / Nut / Washer : 20.00 kgMS Bolt / Nut / Washer : 6.00 kg

5. Other details :Length of cutting : 69.60 RmLength of welding : 215.60 RmNumber of electrodes 4x450 mm : 1564 Nos

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