Professional Documents
Culture Documents
Gates and Hoists
Gates and Hoists
GOVERNMENT OF KARNATAKA
SCHEDULE OF RATES
CONTENTS PAGES
REFERENCE DATA 1 -- 2
JUNE, 2003
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GATES AND HOISTS
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GATES AND HOISTS
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1. All notes under ' General Notes on Schedule of Rates ' are applicable to ' Gate / Hoist and
Allied Works ' also to the extent they are relevant.
2. All materials / bought out components for embedded parts, gates, hoists and allied works
shall conform to relevant Indian standards / technical specifications and approved drawings.
3. The basic rates are inclusive of preparation of designs / drawings / material schedules etc.,
as per specifications and other technical data including revisions.
4. The basic rates are inclusive of cost of all materials, machinery, labour, fabrication, erection,
commissioning and testing of gates, hoists and other related components as per technical
specifications.
5. The basic rates are inclusive of finishing, wastage of materials , incidental works, temperary
supports, scaffolding, all enabling works, profit, overheads, small tools / plants, hidden cost
on labour etc.
6. The basic rates are inclusive of taxes, duties, levies and all other incidental charges except
sales tax on works contract. Separate provision shall be made in the estimate towards sales
tax on works contract at the rate prevailing at the time of preparation of estimate.
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 the
fabricated and bought out gate and hoist components.
9. The basic rates are inclusive of preparatory works such as rectification of damages, repairing
shop painting, cleaning, positioning and anchoring first stage embedments, cleaning surface
for field painting etc.
10. The basic rates are exclusive of cost of river diversion arrangements, dewatering, desilting
etc., 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 as
per detailed designs / empirical formulae / similar works.
12. Dry film thickness for zinc rich epoxy primer and coal tar epoxy paints shall be 40 microns per
coat and 100 microns per coat respectively.
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GATES AND HOISTS
SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 1
ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sill
beam, wall plates, anchors, anchor girders, yoke girders, tie flats, trunnion supports, rope and
pulley supports etc., with all accessories for spillway radial gates including cost of all
materials, machinery, labour, aligning, anchoring, welding, finishing, cleaning, applying one
coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete
as per specifications and approved drawings with all 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 radial
gate will be generally at about 25 to 30 percent of weight of radial gate leaf.
Consider embedded parts for radial gate for spillway opening of size 15 m x 9 m for analysis.
Details of material / Gas cutting / Welding considered for rate analysis are based on embedded
parts 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 m
Head of water for sill level 0.6 m below crest : 9.60 m
Weight 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 )^0.673
Where ( 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 : 14.377
The actual weight of embedded parts as per fabrication drawings : 14.334 tonnes
Consider 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 kg
Structural 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 Nos
Welding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 66 Nos
Welding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 5983 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 43 Rm
Total length of cutting : 471 Rm
For cutting structural steel sections to required size gas cutting is assumed for cutting angles /
beams / channels / round bars. For plates / flats less than 12 mm in thickness plate shearing
machine and for the remaining sections pug cutting machine is considered.
Length of steel to be cut by using gas manually : 60 m
Length of steel to be cut by gas using pug cutting machine : 371 m
Length of steel to be cut by using shearing machine : 40 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 30 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 124 hours
Time for cutting by shearing machine at av. 10 m / hour progress : 4 hours
Acetelyne gas @ 0.6 cum / hour ( 154 x 0.60 ) : 92 cum
Oxygen gas @ 1.8 cum / hour ( 154 x 1.80 ) : 276 cum
Use of gas cutting torch with 50 min / hour working ( 30 x 60 / 50 ) : 36 hours
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Use of pug cutting machine with 50 min / hr working ( 124 x 60 / 50 ) : 149 hours
Use of shearing machine with 50 min / hour working ( 4 x 60 / 50 ) : 5 hours
3. Welding :
Length of welding as per data sheet : 600 m
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 665 + 66 ) x 8 / 15 / 2 : 195 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 5983 + 591 ) x 8 / 15 / 6 : 585 hours
Total : 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 hours
4 Planing SS plates for seal seats :
For surface finishing of stainless steel plates for seal seats planing machine is considered.
Length of SS plate for surface finishing by planing machine 56 Rm
Length of planing at a time for 4 m stroke planing machine 3 Rm
Time for planing 3 m length section with 50 min / hour working 8 hours
Time for planing 56 m SS plates ( 56 x 8 / 3 ) 150 hours
5 Surface cleaning and painting :
Painting area for embedded parts at 10 sqm / tonne : 143 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 143 sqm @ 9 sqm / ltr / coat : 16 ltr
4 coats of coal tar epoxy paint 100 micron dry film each coat.
Quantity of coal tar epoxy paint for 143 sqm @ 6 sqm / ltr / coat : 96 ltr
As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment
to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting
before applying primer painting.
Quantity of rust cleaner / inhibitor 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 / Welder
Erector /
Cutting sections 190 hours 12 24 24 48
Drilling holes for anchors / supports 1 2 --- 2
Fabricating by stitch welding 195 hours 12 24 --- 48
Run welding 585 hours 7 --- 73 73
Erection of Anchor / Yoke girders 13 26 --- 26
Erection of tie flats 2 2 --- 4
Erection of first stage anchors --- 10 --- 10
Erection of Sill beam / Wall plates 3 3 --- 6
Finishing / 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 cleaner
and wire brushing at 15 sqm / day : 10 helpers for 143 sqm.
For painting 1 coat primer and 4 coats
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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 all
taxes / duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.
9 Use rate of materials :
Cost of welding set @ Rs: 3375.00 / Each Rs: 3375.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 3.38
Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125
Life of gas cutting set : 600 hours
Use rate of gas cutting set per hr ( cost / life ) Rs: 1.88
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 23912.00
2 Tower crane Hour 4.00 763.00 3052.00
Fuel / Energy charges Hour 4.00 106.00 424.00
3 Plate shearing machine Hour 5.00 47.00 235.00
Fuel / Energy charges Hour 5.00 82.00 410.00
4 Pug cutting machine Hour 149.00 13.00 1937.00
Fuel / Energy charges Hour 149.00 2.00 298.00
5 Mobile derric crane Hour 32.00 261.00 8352.00
Fuel / Energy charges Hour 32.00 117.00 3744.00
6 Stationery derric crane Hour 64.00 50.00 3200.00
Fuel / Energy charges Hour 64.00 5.00 320.00
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C. LABOUR:
Sl No Description Unit Quantity Rate Amount
in Rs. in Rs.
1 Crew for Tower crane Hour 4.00 36.05 144.20
2 Crew for Mobile crane Hour 32.00 32.90 1052.80
3 Crew for Shearing machine Hour 5.00 26.70 133.50
4 Crew for Planing machine Hour 150.00 42.75 6412.50
5 Crew for Drilling machine Hour 16.00 35.00 560.00
6 Crew for Grinding machine Hour 16.00 35.00 560.00
7 Foreman Day 51.00 108.65 5541.15
8 Marker / Fabricator / Erector Day 92.00 93.70 8620.40
9 Gas cutter Day 24.00 93.70 2248.80
10 Welder ( General ) Day 66.00 93.70 6184.20
11 Welder ( X - ray ) Day 7.00 103.07 721.49
12 Khalasi Day 50.00 83.65 4182.50
13 Helper fabrication / erection Day 219.00 81.60 17870.40
14 Helper for cleaning / painting Day 18.00 81.60 1468.80
15 Painter Cl - II Day 48.00 81.60 3916.80
16 Electrician Day 5.00 82.65 413.25
TOTAL Rs: 60030.79
Add for small Tools and Plants @ 1% Rs: 600.31
Add for Contractor' Profit @ 10% Rs: 6003.08
Add for hidden cost on Labour @ 15% Rs: 9004.62
Add for additional hidden cost on labour @ 15% Rs: 9004.62
Add for Contrators' Overheads @ 5% Rs: 3001.54
Total cost of Labour Rs: 87644.95
ABSTRACT:
A. Cost of Materials Rs: 561218.44
B. Hire charges of Machinery Rs: 83958.24
C. Cost of Labour Rs: 87644.95
Total Rs: 732821.63
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 23166.43
Add for insurance charges @ 1.00% Rs: 7328.22
Add for designs and drawings @ 2.5% Rs: 18320.54
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 18320.54
Add for power supply arrangements @ 2.5% Rs: 18320.54
Add for enabling works @ 2% Rs: 14656.43
Total Rs: 832934.34
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SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 2
ITEM: Design, fabrication, supply, erection, testing and commissioning of radial gate consisting
of skin plate, stiffeners, horizontal girders, sector arms, trunnion assemblies, tie beam, pulley
supports, 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 all
leads and lifts.
DATA: Spillway radial gate consists of trunnions / sector arms / horizontal girders / Tee- supports /
skin plate / tie beam / bracings for horizontal girders and sector arms / pulley blocks / seals /
end shields etc., with all accessories.
Sector arms are connected to trunions by bolts and nuts with zinc padding in between.
Horizontal girders generally spaced at about 3 m apart are joined to sector arms by welding and
are stiffened by vertical and diagonal stiffeners to form the main frame. Tee- sections are welded
to horizontal girders to make the frame regid and to support the skin plate. Skin plate is welded
to Tee-supports generally spaced vertically at about 40 cm apart.
Consider radial gate for spillway opening of size 15 m x 9 m for analysis.
Details of material / Gas cutting / Welding considered for rate analysis are based on radial gate
drawings 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 m
Weight 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 )^0.673
Where ( 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 : 57.669
The actual weight of radial gate leaf as per fabrication drawings : 57.457 tonnes
Consider 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 kg
Structural steel plates / flats with 2.5 % wastage : 38672 kg
b. Alloy steel components conforming to IS : 1570 :
Stainless steel plates : 6 kg
Lifting pins : 1098 kg
c. Cast steel components conforming to IS : 1030 :
Trunnion hub / Guide roller : 1895 kg
d. Alluminium / Bronze alloy components conforming to IS : 305 :
Trunnion bush / Guide roller bush : 1155 kg
e. Bolts / Nuts / Washers conforming to IS : 1363 :
GI bolts / nuts / washers with 2.5 % wastage : 78 kg
MS bolts / nuts / washers with 2.5 % wastage : 79 kg
f. Zinc at 70 kg / trunnion ( 2 x 70 ) : 140 kg
g. Rubber seal conforming to IS : 11855 :
Bottom seal ( flat type )with wastage : 15.5 Rm
Side seals ( Z - type ) with wastage : 25 Rm
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h. Welding electrodes :
Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 2728 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 93 Rm
Total : 1021 Rm
For cutting structural steel sections to required sizes gas cutting is assumed for cutting angles/
beams / channels / round bars and for thick plates / flats. For plate / flats less than 12 mm
thick use of shearing machine is assumed to the extent feasible.
Length of steel to be cut by using gas manually : 350 m
Length of steel to be cut by gas using pug cutting machine : 571 m
Length of steel to be cut by using shearing machine : 100 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 175 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 190 hours
Time for cutting by shearing machine at av. 10 m / hr progress : 10 hours
Acetelyne gas @ 0.6 cum / hour ( 365 x 0.60 ) : 219 cum
Oxygen gas @ 1.8 cum / hour ( 365 x 1.80 ) : 657 cum
Use of gas cutting torch with 50 min / hr working ( 175 x 60 / 50 ) : 210 hours
Use of pug cutting machine with 50 min / hr working ( 190 x 60 / 50 ) : 228 hours
Use 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 m
Length of Tee sections @ 0.4 m spacing ( 15 x 11 / 0.4 ) : 412.50 m
Length of side seal base and cover flats ( 11 x 2 x 2 ) : 44.00 m
Total ( say ) : 594.00 m
Assuming 3 m bending / hour, time for bending 594 m ( 594 / 3 ) : 198 hours
With 50 minutes / hour working deploy bending machine for : 238 hours
4. Welding :
Length of welding : 2294 Rm
For 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 hours
For run welding @ 6 hrs usage / shift & @ 12 electrodes / hr
( 24554 / 12 ) x 8 / 6 : 2728 hours
Total : 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 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 1150 sqm @ 9 sqm / ltr / coat : 128 ltr
3 coats of coal tar epoxy paint 100 micron dry film each coat.
Quantity of coal tar epoxy paint for 1150 sqm @ 6 sqm / ltr / coat : 575 ltr
As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment
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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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 / Welder
Erector
Cutting sections 450 hours 28 56 56 112
Drilling holes for seal fixing 3 6 --- 12
Fabricating by stitch welding 909 hours 57 114 --- 456
Run welding 2728 hours 34 --- 341 341
Erection of trunnion and tie beam 4 8 --- 32
Erection of Horizontal girders 3 3 --- 12
Erection of sector arms 3 3 --- 12
Erection of vertical stiffeners 5 10 --- 40
Erection of skin plates 3 6 --- 24
Erection of end sheilds and hood 4 8 --- 32
Erection of bracings 6 6 --- 24
Molten zinc filling for trunnion supports 2 2 --- 2
Seal fixing 2 2 --- 4
Finishing / 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 cleaner
and wire brushing at 15 sqm / day : 77 helpers for 1150 sqm
For 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 all
taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % of machinery and labour components for erection ) is considered
for assessing excise duty.
9. Use rate of materials :
Cost of welding set @ Rs: 3375.00 / Each Rs: 3375.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 3.38
Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125
Life of gas cutting set : 600 hours
Use rate of gas cutting set per hr ( cost / life ) Rs: 1.88
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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 111377.00
2 Plate shearing machine Hour 12.00 47.00 564.00
Fuel / Energy charges Hour 12.00 82.00 984.00
3 Pug cutting machine Hour 228.00 13.00 2964.00
Fuel / Energy charges Hour 228.00 2.00 456.00
4 Bending machine Hour 238.00 31.00 7378.00
Fuel / Energy charges Hour 238.00 61.00 14518.00
5 Tower crane 5 t cpacity Hour 10.00 763.00 7630.00
Fuel / Energy charges Hour 10.00 106.00 1060.00
6 Mobile derric crane Hour 150.00 261.00 39150.00
Fuel / Energy charges Hour 150.00 117.00 17550.00
7 Stationery derric crane Hour 300.00 50.00 15000.00
Fuel / Energy charges Hour 300.00 5.00 1500.00
8 Grinding machine Hour 50.00 15.00 750.00
Fuel / Energy charges Hour 50.00 20.00 1000.00
9 Drilling machines Hour 50.00 15.00 750.00
Fuel / Energy charges Hour 50.00 20.00 1000.00
10 Sundries LS 1000.00 22.50 22500.00
TOTAL Rs: 278864.00
Add for small Tools and Plants @ 1% Rs: 2788.64
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 17194.50
Add for Contrators' Overheads @ 5% Rs: 13943.20
Total hire charges of Machinery Rs: 312790.34
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C. LABOUR:
Sl No Description Unit Quantity Rate Amount
in Rs. in Rs.
1 Crew for Mobile crane Hour 150.00 32.90 4935.00
2 Crew for Tower crane Hour 10.00 36.05 360.50
3 Crew for Bending machine Hour 238.00 26.70 6354.60
4 Crew for Drilling machine Hour 50.00 35.00 1750.00
5 Crew for Grinding machine Hour 50.00 35.00 1750.00
6 Foreman Day 155.00 108.65 16840.75
7 Marker / Fabricator / Erector Day 226.00 93.70 21176.20
8 Gas cutter Day 56.00 93.70 5247.20
9 Welder ( General ) Day 307.00 93.70 28765.90
10 Welder ( X - ray ) Day 34.00 103.07 3504.38
11 Khalasi Day 250.00 83.65 20912.50
12 Helper fabrication / erection Day 1105.00 81.60 90168.00
13 Helper for cleaning / painting Day 154.00 81.60 12566.40
14 Painter Cl - II Day 306.00 81.60 24969.60
15 Electrician Day 30.00 82.65 2479.50
TOTAL Rs: 241780.53
Add for small Tools and Plants @ 1% Rs: 2417.81
Add for Contractor' Profit @ 10% Rs: 24178.05
Add for hidden cost on Labour @ 15% Rs: 36267.08
Add for additional hidden cost on labour @ 15% Rs: 36267.08
Add for Contrators' Overheads @ 5% Rs: 12089.03
Total cost of Labour Rs: 352999.57
ABSTRACT:
A. Cost of Materials Rs: 2894469.85
B. Hire charges of Machinery Rs: 312790.34
C. Cost of Labour Rs: 352999.57
Total Rs: 3560259.76
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 89881.64
Add for insurance charges @ 1.00% Rs: 35602.60
Add for designs and drawings @ 2.5% Rs: 89006.49
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 89006.49
Add for power supply arrangements @ 2.5% Rs: 89006.49
Add for enabling works @ 2% Rs: 71205.20
Total Rs: 4023968.67
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x57.457 tonnes @ Rs: 81.30 / tonne Rs: 9342.51
Add 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 rope
drum hoist of adequate capacity consisting of base frames, rope drums,connecting shaft, gear
system, brake system, electric motor, wire ropes, gate position indicator, manual operation
arrangement etc., with all accessories for spillway radial gate including cost of all materials,
machinery, labour, aligning, anchoring, welding, finishing, cleaning, greasing, providing hand
railing and approach staircase with gate to hoist platform, applying two coats of zinc chromate
red oxide primer and three coats of approved synthetic enamel paint etc., complete as per
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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 drum
hoist 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 m
Weight 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 )^0.673
Where ( 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 : 57.669
Hoist capacity including 25 % reserve capacity : 1.5 x Weight of gate in tonne
Capacity of hoist required in tonnes : 1.5 x 57.669 : 86.504
Hoist capacity shall be rounded off to next 10 tonne say : 90.00 tonnes
Actual capacity of hoist provided : 90.00 tonnes
Weight 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 tonnes
The actual weight of spillway radial gate rope drum hoist as per data sheet : 15.440 tonnes
Consider 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 kg
Plates / 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 kg
Pinions : 218.00 kg
Pulleys 720 PCD 6 Nos : 1080.00 kg
Plummer blocks / Hubs : 322.00 kg
c. Alloy steel components conforming to IS : 1570 :
Shafts ( carbon steel ) : 557.00 kg
Pins ( stainless steel ) 546.00 kg
d. Alluminium/ Bronze alloy components conforming to IS : 305 :
Bearings / Bush : 144.00 kg
e. Bolt / Nut / Washers conforming to IS : 1363 :
MS Bolts / Nuts / Washers with 2.5 % wastage : 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 Nos
Electric motor 20 hp : 1 No.
Gate position indicator : 1 No.
Ele-magnetic brake : 1 No.
Wire rope sockets : 2 Nos
MS pipe 300 mm dia 13.32 Rm @ 75 kg / Rm : 1000 kg
Electric cable / switch / control panel etc : 1 set
h. Welding electrodes :
Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 530 Nos
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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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 25 Rm
Total : 280 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas manually : 150 m
Length of steel to be cut by gas using pug cutting machine : 130 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 75 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 44 hours
Acetelyne gas @ 0.6 cum / hour ( 119 x 0.60 ) : 71 cum
Oxygen gas @ 1.8 cum / hour ( 119 x 1.80 ) : 213 cum
Use of gas cutting torch with 50 min / hr working ( 75 x 60 / 50 ) : 90 hours
Use of pug cutting machine with 50 min / hr working ( 44 x 60 / 50 ) : 53 hours
3. Welding :
Length of welding : 447 Rm
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 530 / 15 ) x 8 / 2 : 141 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 4776 / 15 ) x 8 / 6 : 425 hours
Total : 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 tonnes
Painting area for hoist at 20 sqm / t of str steel ( 6.2 x 20 ) : 124 sqm
2 coats of zinc chromate red oxide primer.
Quantity of primer paint for 124 sqm @ 12 sqm / ltr / coat : 21 ltr
3 coats of synthetic enamel paint.
Quantity of synthetic enamel paint for 124 sqm @ 12 sqm / ltr / coat : 31 ltr
As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment
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 / Welder
Erector
Cutting sections 143 hours 9 18 18 36
Drilling holes for pins / bolts fixing 1 2 --- 2
Fabricating by stitch welding 141 hours 9 18 --- 36
Run welding 425 hours 5 --- 53 53
Erection of anchors 2 2 --- 4
Erection of drums and gears 2 4 --- 16
Erection of floating shaft / pulleys 1 2 --- 4
Erection of worm reducers / brake / motor 1 2 --- 4
Erection of other accessories 1 2 --- 2
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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 17297.00
2 Tower crane 5 t capacity Hour 4.00 763.00 3052.00
Fuel / Energy charges Hour 4.00 106.00 424.00
3 Pug cutting machine Hour 53.00 13.00 689.00
Fuel / Energy charges Hour 53.00 2.00 106.00
4 Mobile derric crane Hour 50.00 261.00 13050.00
Fuel / Energy charges Hour 50.00 117.00 5850.00
5 Grinding machine Hour 8.00 15.00 120.00
Fuel / Energy charges Hour 8.00 20.00 160.00
6 Drilling machines Hour 16.00 15.00 240.00
Fuel / Energy charges Hour 16.00 20.00 320.00
7 Sundries LS 100.00 22.50 2250.00
TOTAL Rs: 48652.00
Add for small Tools and Plants @ 1% Rs: 486.52
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 2640.70
Add 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 1645.00
2 Crew for Tower crane Hour 4.00 36.05 144.20
3 Crew for Drilling machine Hour 16.00 35.00 560.00
4 Crew for Grinding machine Hour 8.00 35.00 280.00
5 Foreman Day 35.00 108.65 3802.75
6 Marker / Fabricator / Erector / Mechanic Day 58.00 93.70 5434.60
7 Gas cutter Day 18.00 93.70 1686.60
8 Welder ( General ) Day 53.00 93.70 4966.10
9 Khalasi Day 20.00 83.65 1673.00
10 Helper fabrication / erection Day 175.00 81.60 14280.00
11 Helper for cleaning / painting Day 14.00 81.60 1142.40
12 Painter Cl - II Day 30.00 81.60 2448.00
13 Electrician Day 3.00 82.65 247.95
TOTAL Rs: 38310.60
Add for small Tools and Plants @ 1% Rs: 383.11
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GATES AND HOISTS
ABSTRACT:
A. Cost of Materials Rs: 1293252.68
B. Hire charges of Machinery Rs: 54211.82
C. Cost of Labour Rs: 55933.48
Total Rs: 1403397.98
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 14869.61
Add for insurance charges @ 1.00% Rs: 14033.98
Add for designs and drawings @ 2.5% Rs: 35084.95
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 35084.95
Add for power supply arrangements @ 2.5% Rs: 35084.95
Add for enabling works @ 2% Rs: 28067.96
Total Rs: 1565624.38
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x15.44 tonnes @ Rs: 81.30 / tonne Rs: 2510.54
Add for transportation upto work site @ 3% Rs: 46968.73
Total cost for 15.440 tonne wt Rs: 1615103.65
90.000 t capacity
Rate 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 connecting
spillway piers / abutments at trunnion platform level including cost of all materials,
machinery, labour, cutting, aligning, anchoring, 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 approved drawings with all leads and lifts.
DATA: Catwalk at trunnion level generally consists of 1 m wide structural steel bridge spanning across
piers / 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 bridge
drawings 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 t
The actual weight of catwalk ( foot bridge ) as per data sheet : 5.318 t
Consider 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 kg
Structural steel plates / flats with 2.5 % wastage : 98 kg
Chequered 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 Nos
Welding electrodes for run welding at 90 % of total with 2.5 % wastage : 1075 Nos
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2. Cutting :
Length of cutting assuming cutting for 2 sides : 57 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 6 Rm
Total : 63 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas manually : 40 m
Length of steel to be cut by gas using pug cutting machine : 23 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 20 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 8 hours
Acetelyne gas @ 0.6 cum / hour ( 28 x 0.60 ) : 17 cum
Oxygen gas @ 1.8 cum / hour ( 28 x 1.80 ) : 51 cum
Use of gas cutting torch with 50 min / hr working ( 20 x 60 / 50 ) : 24 hours
Use of pug cutting machine with 50 min / hr working ( 8 x 60 / 50 ) : 10 hours
3. Welding :
Length of welding : 151 Rm
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 120 / 15 ) x 8 / 2 : 32 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 1075 / 15 ) x 8 / 6 : 96 hours
Total : 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 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 132 sqm @ 9 sqm / ltr / coat : 15 ltr
2 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 ltr
As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment
to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting
before applying primer painting.
Quantity of rust cleaner / inhibitor 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 / Welder
Erector
Cutting sections / drilling holes 34 hours 2 4 4 8
Fabricating by stitch welding 32 hours 2 4 --- 16
Run welding 96 hours 1 --- 12 12
Erection / 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 cleaner
and wire brushing at 15 sqm / day : 9 helpers for 132 sqm
For 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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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 3920.00
2 Tower crane Hour 1.00 763.00 763.00
Fuel / Energy charges Hour 1.00 106.00 106.00
3 Pug cutting machine Hour 10.00 13.00 130.00
Fuel / Energy charges Hour 10.00 2.00 20.00
4 Mobile derric crane Hour 4.00 261.00 1044.00
Fuel / Energy charges Hour 4.00 117.00 468.00
5 Grinding machine Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
6 Drilling machines Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
7 Sundries LS 10.00 22.50 225.00
TOTAL Rs: 7968.00
Add for small Tools and Plants @ 1% Rs: 79.68
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C. LABOUR:
Sl No Description Unit Quantity Rate Amount
in Rs. in Rs.
1 Crew for Mobile crane Hour 4.00 32.90 131.60
2 Crew for Tower crane Hour 1.00 36.05 36.05
3 Crew for Drilling machine Hour 2.00 35.00 70.00
4 Crew for Grinding machine Hour 2.00 35.00 70.00
5 Foreman Day 6.00 108.65 651.90
6 Marker / Fabricator / Erector Day 10.00 93.70 937.00
7 Gas cutter Day 4.00 93.70 374.80
8 Welder ( General ) Day 12.00 93.70 1124.40
9 Helper fabrication / erection Day 38.00 81.60 3100.80
10 Helper for cleaning / painting Day 16.00 81.60 1305.60
11 Painter Cl - II Day 26.00 81.60 2121.60
12 Electrician Day 1.00 82.65 82.65
TOTAL Rs: 10006.40
Add for small Tools and Plants @ 1% Rs: 100.06
Add for Contractor' Profit @ 10% Rs: 1000.64
Add for hidden cost on Labour @ 15% Rs: 1500.96
Add for additional hidden cost on labour @ 15% Rs: 1500.96
Add for Contrators' Overheads @ 5% Rs: 500.32
Total cost of Labour Rs: 14609.34
ABSTRACT:
A. Cost of Materials Rs: 158426.07
B. Hire charges of Machinery Rs: 8927.98
C. Cost of Labour Rs: 14609.34
Total Rs: 181963.40
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 3177.54
Add for insurance charges @ 1.00% Rs: 1819.63
Add for designs and drawings @ 2.5% Rs: 4549.08
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 4549.08
Add for power supply arrangements @ 2.5% Rs: 4549.08
Add for enabling works @ 2% Rs: 3639.27
Total Rs: 204247.09
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x5.318 tonnes @ Rs: 81.30 / tonne Rs: 864.71
Add 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 elements
etc., 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 as
per 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 embedded
parts 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 m
Height of gate ( total height of gate elements ) in m : FRL - Sill level + 0.2 : 9.60 m
Head 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 )^0.716
Where ( 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: 3.225
The actual weight of embedded parts as per data sheet : 3.179 tonnes
Consider 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 kg
Structural 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 Nos
Welding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 103 Nos
Welding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 1499 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 17 Rm
Total length of cutting : 180 Rm
For cutting structural steel sections to required size gas cutting is assumed for cutting angles /
beams / channels / round bars. For plates / flats less than 12 mm in thickness plate shearing
machine and for the remaining sections pug cutting machine is considered.
Length of steel to be cut by using gas manually : 30 m
Length of steel to be cut by gas using pug cutting machine : 120 m
Length of steel to be cut by using shearing machine : 30 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 15 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 40 hours
Time for cutting by shearing machine at av. 10 m / hr progress : 3 hours
Acetelyne gas @ 0.6 cum / hour ( 55 x 0.60 ) : 33 cum
Oxygen gas @ 1.8 cum / hour ( 55 x 1.80 ) : 99 cum
Use of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hours
Use of pug cutting machine with 50 min / hr working ( 40 x 60 / 50 ) : 48 hours
Use of shearing machine with 50 min / hr working ( 3 x60 / 50 ) : 4 hours
3. Welding :
Length of welding as per data sheet : 303 m
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 166 + 103 ) x 8 / 15 / 2 : 72 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 1499 + 927 ) x 8 / 15 / 6 : 216 hours
Total : 288 hours
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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 8820.00
2 Plate shearing machine Hour 4.00 47.00 188.00
Fuel / Energy charges Hour 4.00 82.00 328.00
3 Pug cutting machine Hour 48.00 13.00 624.00
Fuel / Energy charges Hour 48.00 2.00 96.00
4 Planing machine Hour 135.00 66.00 8910.00
Fuel / Energy charges Hour 135.00 61.00 8235.00
5 Mobile derric crane Hour 4.00 261.00 1044.00
Fuel / Energy charges Hour 4.00 117.00 468.00
6 Stationery derric crane Hour 8.00 50.00 400.00
Fuel / Energy charges Hour 8.00 5.00 40.00
7 Grinding machine Hour 16.00 15.00 240.00
Fuel / Energy charges Hour 16.00 20.00 320.00
8 Drilling machines Hour 16.00 15.00 240.00
Fuel / Energy charges Hour 16.00 20.00 320.00
9 Sundries LS 20.00 22.50 450.00
TOTAL Rs: 33315.00
Add for small Tools and Plants @ 1% Rs: 333.15
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 1907.70
Add for Contrators' Overheads @ 5% Rs: 1665.75
Total hire charges of Machinery Rs: 37221.60
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C. LABOUR:
Sl No Description Unit Quantity Rate Amount
in Rs. in Rs.
1 Crew for Mobile crane Hour 4.00 32.90 131.60
2 Crew for Planing machine Hour 135.00 42.75 5771.25
3 Crew for Drilling machine Hour 16.00 35.00 560.00
4 Crew for Grinding machine Hour 16.00 35.00 560.00
5 Foreman Day 16.00 108.65 1738.40
6 Marker / Fabricator / Erector Day 35.00 93.70 3279.50
7 Gas cutter Day 8.00 93.70 749.60
8 Welder ( General ) Day 24.00 93.70 2248.80
9 Welder ( X - ray ) Day 3.00 103.07 309.21
10 Helper fabrication / erection Day 83.00 81.60 6772.80
11 Helper for cleaning / painting Day 3.00 81.60 244.80
12 Painter Cl - II Day 7.00 81.60 571.20
13 Electrician Day 2.00 82.65 165.30
TOTAL Rs: 23102.46
Add for small Tools and Plants @ 1% Rs: 231.02
Add for Contractor' Profit @ 10% Rs: 2310.25
Add for hidden cost on Labour @ 15% Rs: 3465.37
Add for additional hidden cost on labour @ 15% Rs: 3465.37
Add for Contrators' Overheads @ 5% Rs: 1155.12
Total cost of Labour Rs: 33729.59
ABSTRACT:
A. Cost of Materials Rs: 193818.89
B. Hire charges of Machinery Rs: 37221.60
C. Cost of Labour Rs: 33729.59
Total Rs: 264770.08
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 9578.41
Add for insurance charges @ 1.00% Rs: 2647.70
Add for designs and drawings @ 2.5% Rs: 6619.25
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 6619.25
Add for power supply arrangements @ 2.5% Rs: 6619.25
Add for enabling works @ 2% Rs: 5295.40
Total Rs: 302149.35
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x3.179 tonnes @ Rs: 81.30 / tonne Rs: 516.91
Add 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 zinc
rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc.,
complete as per specifications and approved drawings with all leads and lifts.
DATA: Spillway 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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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 90307.00
2 Pug cutting machine Hour 412.00 13.00 5356.00
Fuel / Energy charges Hour 412.00 2.00 824.00
3 Mobile derric crane Hour 50.00 261.00 13050.00
Fuel / Energy charges Hour 50.00 117.00 5850.00
4 Stationery derric crane Hour 100.00 50.00 5000.00
Fuel / Energy charges Hour 100.00 5.00 500.00
5 Grinding machine Hour 50.00 15.00 750.00
Fuel / Energy charges Hour 50.00 20.00 1000.00
6 Drilling machines Hour 100.00 15.00 1500.00
Fuel / Energy charges Hour 100.00 20.00 2000.00
7 Sundries LS 100.00 22.50 2250.00
TOTAL Rs: 154928.00
Add for small Tools and Plants @ 1% Rs: 1549.28
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 10273.10
Add 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 277057.50
2 Crew for Drilling machine Hour 100.00 35.00 3500.00
3 Crew for Grinding machine Hour 50.00 35.00 1750.00
4 Foreman Day 115.00 108.65 12494.75
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ABSTRACT:
A. Cost of Materials Rs: 2598952.31
B. Hire charges of Machinery Rs: 174496.78
C. Cost of Labour Rs: 636482.17
Total Rs: 3409931.25
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 109482.16
Add for insurance charges @ 1.00% Rs: 34099.31
Add for designs and drawings @ 2.5% Rs: 85248.28
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 85248.28
Add for power supply arrangements @ 2.5% Rs: 85248.28
Add for enabling works @ 2% Rs: 68198.63
Total Rs: 3877456.19
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x71.157 tonnes @ Rs: 81.30 / tonne Rs: 11570.13
Add 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 elements
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 spillway stop log elements consists of fabricated beam with
lifting 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 spillway
stop 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 the
weight 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
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 5733.00
2 Pug cutting machine Hour 60.00 13.00 780.00
Fuel / Energy charges Hour 60.00 2.00 120.00
3 Mobile derric crane Hour 4.00 261.00 1044.00
Fuel / Energy charges Hour 4.00 117.00 468.00
4 Stationery derric crane Hour 8.00 50.00 400.00
Fuel / Energy charges Hour 8.00 5.00 40.00
5 Grinding machine Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
6 Drilling machines Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
7 Sundries LS 10.00 22.50 225.00
TOTAL Rs: 10633.00
Add for small Tools and Plants @ 1% Rs: 106.33
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 666.60
Add 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 32.90 131.60
2 Crew for Drilling machine Hour 2.00 35.00 70.00
3 Crew for Grinding machine Hour 2.00 35.00 70.00
4 Foreman Day 10.00 108.65 1086.50
5 Marker / Fabricator / Erector Day 18.00 93.70 1686.60
6 Gas cutter Day 10.00 93.70 937.00
7 Welder ( General ) Day 18.00 93.70 1686.60
8 Helper fabrication / erection Day 52.00 81.60 4243.20
9 Helper for cleaning / painting Day 5.00 81.60 408.00
10 Painter Cl - II Day 8.00 81.60 652.80
11 Electrician Day 1.00 82.65 82.65
TOTAL Rs: 11054.95
Add for small Tools and Plants @ 1% Rs: 110.55
Add for Contractor' Profit @ 10% Rs: 1105.50
Add for hidden cost on Labour @ 15% Rs: 1658.24
Add for additional hidden cost on labour @ 15% Rs: 1658.24
Add for Contrators' Overheads @ 5% Rs: 552.75
Total cost of Labour Rs: 16140.23
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ABSTRACT:
A. Cost of Materials Rs: 167717.01
B. Hire charges of Machinery Rs: 11937.58
C. Cost of Labour Rs: 16140.23
Total Rs: 195794.81
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 3790.50
Add for insurance charges @ 1.00% Rs: 1957.95
Add for designs and drawings @ 2.5% Rs: 4894.87
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 4894.87
Add for power supply arrangements @ 2.5% Rs: 4894.87
Add for enabling works @ 2% Rs: 3915.90
Total Rs: 220143.77
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x3.528 tonnes @ Rs: 81.30 / tonne Rs: 573.65
Add 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 drum
etc., with all accessories for operating spillway stop log gate elements and river sluice /
canal sluice emergency gates including cost of all materials, machinery, labour, cutting,
bending, aligning, anchoring, welding, finishing, cleaning, applying two coats of zinc chromate
red oxide primer and three coats of approved synthetic enamel paint etc., complete with all
leads and lifts.
DATA: Moving gantry crane consists of rail mounted gantry frame with long travel arrangement, cross
travel trolley with track arrangement mounted on gantry frame top platform, rope drum hoist
with all accessories mounted on cross travel trolley for operating stoplog gate elements.
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 hoisting
capacity 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 gantry
crane drawings for spillway of Alamatti dam.
Total weight of stoplog elements as per item 6 : 71.34 tonnes
Number of elements : 8 Nos
Capacity of moving gantry crane in tonnes with 25% reserve capacity : 2.5 x ( W / n )
Where ( W ) is weight of 1 set of stoplog elements and ( n ) is number of stoplog elements.
Capacity of moving gantry crane required : 2.5 x ( 71.34 / 8 )
( capacity to be rounded off to next 5 tonne ) : 24.97 tonnes
say : 25 tonne
Actual capacity of moving gantry crane as per data considered : 25 tonne
Weight of moving gantry crane @ 1.25 t / tonne capacity ( 1.25 x 25 ) : 31.25 t
The actual weight of moving gantry crane as per data sheet : 30.856 t
Consider 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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Quantity of primer paint for 540 sqm @ 12 sqm / ltr / coat : 90 ltr
3 coats of synthetic enamel paint.
Quantity of synthetic enamel paint for 540 sqm @ 12 sqm / ltr / coat : 135 ltr
As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment
to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting
before applying primer painting.
Quantity of rust cleaner / inhibitor 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 / Welder
Erector
Cutting sections 385 hours 24 48 48 96
Drilling holes for pins / bolts fixing 1 2 --- 2
Fabricating by stitch welding 300 hours 19 38 --- 76
Run welding 897 hours 11 --- 112 112
Assembly/Erection of wheels/ base frame 2 4 --- 8
Assembly/Erection of portals 2 4 --- 8
Assembly/Erection of top frame 2 4 --- 8
Assembly/Erection of CT trolley 2 4 --- 8
Assembly/Erection of drums / drive units 2 4 --- 8
Assembly/Erection of CT drive units 1 2 --- 4
Assembly/Erection of LT drive units 1 2 --- 4
Erection of cabin / railings etc 2 2 --- 4
Erection of control panel / cabling 1 1 --- 2
Checking and trial running without rope 2 4 --- 4
Rope fixing and checking 1 2 --- 2
Trial running by lifting / lowering gate 1 2 --- 2
Finishing / 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 cleaner
and wire brushing at 15 sqm / day : 36 helper for 540 sqm
For 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 all
taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.
8. Use rate of materials :
Cost of welding set @ Rs: 3375.00 / Each Rs: 3375.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 3.38
Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125
Life of gas cutting set : 600 hours
Use rate of gas cutting set per hr ( cost / life ) Rs: 1.88
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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 36652.00
2 Tower crane 5 t capacity Hour 6.00 763.00 4578.00
Fuel / Energy charges Hour 6.00 106.00 636.00
3 Pug cutting machine Hour 235.00 13.00 3055.00
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C. LABOUR:
Sl No Description Unit Quantity Rate Amount
in Rs. in Rs.
1 Crew for Mobile crane Hour 100.00 32.90 3290.00
2 Crew for Tower crane Hour 6.00 36.05 216.30
3 Crew for Drilling machine Hour 16.00 35.00 560.00
4 Crew for Grinding machine Hour 32.00 35.00 1120.00
5 Foreman Day 74.00 108.65 8040.10
6 Marker / Fabricator / Erector Day 124.00 93.70 11618.80
7 Gas cutter Day 48.00 93.70 4497.60
8 Welder ( General ) Day 112.00 93.70 10494.40
9 Khalasi Day 20.00 83.65 1673.00
10 Helper fabrication / erection Day 350.00 81.60 28560.00
11 Helper for cleaning / painting Day 63.00 81.60 5140.80
12 Painter Cl - II Day 135.00 81.60 11016.00
13 Electrician Day 10.00 82.65 826.50
TOTAL Rs: 87053.50
Add for small Tools and Plants @ 1% Rs: 870.54
Add for Contractor' Profit @ 10% Rs: 8705.35
Add for hidden cost on Labour @ 15% Rs: 13058.03
Add for additional hidden cost on labour @ 15% Rs: 13058.03
Add for Contrators' Overheads @ 5% Rs: 4352.68
Total cost of Labour Rs: 127098.11
ABSTRACT:
A. Cost of Materials Rs: 2049490.47
B. Hire charges of Machinery Rs: 119474.44
C. Cost of Labour Rs: 127098.11
Total Rs: 2296063.02
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 33287.29
Add for insurance charges @ 1.00% Rs: 22960.63
Add for designs and drawings @ 2.5% Rs: 57401.58
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 57401.58
Add for power supply arrangements @ 2.5% Rs: 57401.58
Add for enabling works @ 2% Rs: 45921.26
Total Rs: 2570436.93
Add 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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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 spillway
stoplog gate elements / river sluice / canal sluice emergency gate including cost of all materials,
machinery, labour, aligning, anchoring, welding, cleaning etc., complete as per specifications
and approved drawings with all leads and lifts.
DATA: Rail track for moving gantry crane consists of 45 kg / m standard rails fixed by welding and
bolting to anchors embedded in concrete at intervals. The width of track shall be as per the
requirement of gantry long travel specifications.
Consider track length of 200 m for rate analysis.
Details of material / Gas cutting / Welding considered for rate analysis are based on 25 tonne
capacity moving gantry crane drawings for spillway of Alamatti dam.
Weight of 45 kg / m rails ( 2 x 200 x 45 ) : 18000.00
Add for anchors and fixtures @ 15 % including wastage : 2700.00
Total weight in tonnes : 20700.00
Actual 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 kg
Structural 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 kg
d. Welding electrodes :
Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 180 Nos
Welding 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 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas cutting torch manually : 222 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 111 hours
Acetelyne gas @ 0.6 cum / hour ( 111 x 0.60 ) : 67 cum
Oxygen gas @ 1.8 cum / hour ( 111 x 1.80 ) : 201 cum
Use of gas cutting torch with 50 min / hr working ( 111 x 60 / 50 ) : 133 hours
3. Welding :
Length of welding : 210 m
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 180 / 15 ) x 8 / 2 : 48 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 1625 / 15 ) x 8 / 6 : 145 hours
Total : 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 epoxy
paint considered.
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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 5929.00
2 Mobile derric crane Hour 4.00 261.00 1044.00
Fuel / Energy charges Hour 4.00 117.00 468.00
3 Grinding machine Hour 8.00 15.00 120.00
Fuel / Energy charges Hour 8.00 20.00 160.00
4 Drilling machines Hour 50.00 15.00 750.00
Fuel / Energy charges Hour 50.00 20.00 1000.00
5 Sundries LS 10.00 22.50 225.00
TOTAL Rs: 11433.00
Add for small Tools and Plants @ 1% Rs: 114.33
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 778.20
Add 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 32.90 131.60
2 Crew for Drilling machine Hour 50.00 35.00 1750.00
3 Crew for Grinding machine Hour 8.00 35.00 280.00
4 Foreman Day 8.00 108.65 869.20
5 Marker / Fabricator / Erector Day 32.00 93.70 2998.40
6 Gas cutter Day 17.00 93.70 1592.90
7 Welder ( General ) Day 18.00 93.70 1686.60
8 Helper fabrication / erection Day 52.00 81.60 4243.20
9 Painter Cl- II Day 1.00 81.60 81.60
10 Electrician Day 1.00 82.65 82.65
TOTAL Rs: 13716.15
Add for small Tools and Plants @ 1% Rs: 137.16
Add for Contractor' Profit @ 10% Rs: 1371.62
Add for hidden cost on Labour @ 15% Rs: 2057.42
Add for additional hidden cost on labour @ 10% Rs: 1371.62
Add for Contrators' Overheads @ 5% Rs: 685.81
Total cost of Labour Rs: 19339.77
ABSTRACT:
A. Cost of Materials Rs: 634600.33
B. Hire charges of Machinery Rs: 12897.18
C. Cost of Labour Rs: 19339.77
Total Rs: 666837.28
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 4351.99
Add for insurance charges @ 1.00% Rs: 6668.37
Add for designs and drawings @ 2.5% Rs: 16670.93
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 16670.93
Add for power supply arrangements @ 2.5% Rs: 16670.93
Add for enabling works @ 2% Rs: 13336.75
Total Rs: 741207.18
Add 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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SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 10
ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( without groove
liner ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner ( upto one
vent height plus 1 m above the roof of vent ) etc., with all accessories for river / canal sluice
service gate including cost of all materials, machinery, labour, aligning, anchoring, welding,
finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied
coal tar epoxy paint etc., complete as per specifications and approved drawings with all leads
and lifts.
DATA: Embedded parts for river / canal sluice service gate without groove lining consist of sill beam,
wheel / seal tracks, breast wall lining and gate guide with accessories such as first / second
stage anchors.
The weight of embedded parts depends on the height of gate groove and height upto which
breast wall lining is to be provided. Weight of embedded parts will be about 50% of wt of gate.
Consider embedded parts for river sluice service gate for sluice opening of size 1.5 m x 3 m.
Weight of breast wall lining for 20 mm MS plate and 6 mm SS plate including stiffeners and
anchors will be about 250 kg per sqm area of breast wall.
Details of material / Gas cutting / Welding considered for rate analysis are based on embedded
parts 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 m
Head of water considered : 16 m
Weight of embedded parts in tonnes = 0.0444 x ( L^2 x H x h )^0.659
Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.
= 0.0444 x ( 2.2 x 2.2 x 3.3 x 16 ) ^ 0.659 : 1.714 tonnes
Weight of breast wall lining about 7 sqm @ 250 kg / sqm 1.750 tonnes
Total : 3.464 tonnes
The actual weight of embedded parts as per data sheet 3.172 tonnes
Consider 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 kg
Structural 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 Nos
Welding electrodes ( SS ) for stitch welding at 10 % of total with 2.5 % wastage 39 Nos
Welding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage 982 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 15 Rm
Total length of cutting : 167 Rm
For cutting structural steel sections to required size gas cutting is assumed for cutting angles /
beams / channels / round bars. For plates / flats less than 12 mm in thickness plate shearing
machine and for the remaining sections pug cutting machine is considered.
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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 4851.00
2 Plate shearing machine Hour 4.00 47.00 188.00
Fuel / Energy charges Hour 4.00 82.00 328.00
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C. LABOUR:
Sl No Description Unit Quantity Rate Amount
in Rs. in Rs.
1 Crew for Mobile crane Hour 4.00 32.90 131.60
2 Crew for Shearing machine Hour 4.00 26.70 106.80
3 Crew for Planing machine Hour 80.00 42.75 3420.00
4 Crew for Drilling machine Hour 10.00 35.00 350.00
5 Crew for Grinding machine Hour 8.00 35.00 280.00
6 Foreman Day 17.00 108.65 1847.05
7 Marker / Fabricator / Erector Day 29.00 93.70 2717.30
8 Gas cutter Day 8.00 93.70 749.60
9 Welder ( General ) Day 11.00 93.70 1030.70
10 Welder ( X - ray ) Day 4.00 103.07 412.28
11 Helper fabrication / erection Day 67.00 81.60 5467.20
12 Helper for cleaning / painting Day 4.00 81.60 326.40
13 Painter Cl - II Day 11.00 81.60 897.60
14 Electrician Day 2.00 82.65 165.30
TOTAL Rs: 17901.83
Add for small Tools and Plants @ 1% Rs: 179.02
Add for Contractor' Profit @ 10% Rs: 1790.18
Add for hidden cost on Labour @ 15% Rs: 2685.27
Add for additional hidden cost on labour @ 10% Rs: 1790.18
Add for Contrators' Overheads @ 5% Rs: 895.09
Total cost of Labour Rs: 25241.58
ABSTRACT:
A. Cost of Materials Rs: 163267.10
B. Hire charges of Machinery Rs: 22748.86
C. Cost of Labour Rs: 25241.58
Total Rs: 211257.54
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 6478.71
Add for insurance charges @ 1.00% Rs: 2112.58
Add for designs and drawings @ 2.5% Rs: 5281.44
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 5281.44
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SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 11
ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( with groove
liner upto breast wall level ) consisting of sill beam, wheel tracks, seal seats, guide rails,
breast wall liner ( upto one vent height plus 1 m above the roof of vent ) etc., with all accessories
for river / canal sluice service gate including cost of all materials, machinery, labour,
aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer
and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and
approved drawings with all leads and lifts.
DATA: Embedded parts for river sluice service gate consist of sill beam, wheel / seal tracks, groove
lining upto breast wall level, breast wall lining upto 1 vent plus 1 m above top of vent, gate guide
etc., with all accessories such as first stage anchors.
The wt of embedded parts depends on the height of gate groove and height upto which breast
wall lining is to be provided. Generally wt of embedded parts will be about 50% of wt of gate.
Weight of breast wall lining for 20 mm MS plate and 6 mm SS plate including stiffeners and
anchors will be about 250 kg per sqm area of breast wall.
Weight of groove liner for 20 mm MS plate including stiffeners and anchors will be about
200 kg / sqm area of groove liner.
Consider embedded parts for river sluice service gate for sluice opening of size 2.5 m x 3 m.
Details of material / Gas cutting / Welding considered for rate analysis are based on embedded
parts 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 m
Head of water considered : 34 m
Weight of embedded parts in tonnes = 0.0444 x ( L^2 x H x h )^0.659
Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.
= 0.0444 x ( 3.2 x 3.2 x 3.3 x 34 ) ^ 0.659 : 4.615 tonnes
Weight of breast wall lining about 12 sqm @ 250 kg / sqm : 3.000 tonnes
Weight of groove liner about 15 sqm @ 200 kg / sqm : 3.000 tonnes
: 10.615 tonnes
The actual weight of embedded parts as per data sheet : 10.657 tonnes
Consider 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 kg
Structural 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 Nos
Welding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 64 Nos
Welding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 4815 Nos
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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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 30 Rm
Total length of cutting : 331 Rm
For cutting structural steel sections to required size gas cutting is assumed for cutting angles /
beams / channels / round bars. For plates / flats less than 12 mm in thickness plate shearing
machine and for the remaining sections pug cutting machine is considered.
Length of steel to be cut by using gas manually : 60 m
Length of steel to be cut by gas using pug cutting machine : 211 m
Length of steel to be cut by using shearing machine : 60 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 30 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 70 hours
Time for cutting by shearing machine at av. 10 m / hr progress : 6 hours
Acetelyne gas @ 0.6 cum / hour ( 100 x 0.60 ) : 60 cum
Oxygen gas @ 1.8 cum / hour ( 100 x 1.80 ) : 180 cum
Use of gas cutting torch with 50 min / hr working ( 30 x 60 / 50 ) 36 hours
Use of pug cutting machine with 50 min / hr working ( 70 x 60 / 50 ) 84 hours
Use of shearing machine with 50 min / hr working ( 6 x 60 / 50 ) 7 hours
3. Welding :
Length of welding as per data sheet : 552 m
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 535 + 64 ) x 8 / 15 / 2 : 160 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 4815 + 576 ) x 8 / 15 / 6 : 479 hours
Total : 639 hours
Deploy 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 Rm
Length of planing at a time for 4 m stroke planing machine : 3 Rm
Time for planing 3 m length section with 50 min / hour working : 8 hours
Time for planing 30 m SS plates ( 30 x 8 / 3 ) : 80 hours
5. Surface cleaning and painting :
Painting area for embedded parts at 10 sqm / tonne : 107 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 107 sqm @ 9 sqm / ltr / coat : 12 ltr
4 coats of coal tar epoxy paint 100 micron dry film each coat.
Quantity of coal tar epoxy paint for 107 sqm @ 6 sqm / ltr / coat : 72 ltr
As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment
to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting
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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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 19600.00
2 Plate shearing machine Hour 7.00 47.00 329.00
Fuel / Energy charges Hour 7.00 82.00 574.00
3 Pug cutting machine Hour 84.00 13.00 1092.00
Fuel / Energy charges Hour 84.00 2.00 168.00
4 Planing machine Hour 80.00 66.00 5280.00
Fuel / Energy charges Hour 80.00 61.00 4880.00
5 Mobile derric crane Hour 20.00 261.00 5220.00
Fuel / Energy charges Hour 20.00 117.00 2340.00
6 Stationery derric crane Hour 40.00 50.00 2000.00
Fuel / Energy charges Hour 40.00 5.00 200.00
7 Grinding machine Hour 25.00 15.00 375.00
Fuel / Energy charges Hour 25.00 20.00 500.00
8 Drilling machines Hour 50.00 15.00 750.00
Fuel / Energy charges Hour 50.00 20.00 1000.00
9 Sundries LS 20.00 22.50 450.00
TOTAL Rs: 50509.00
Add for small Tools and Plants @ 1% Rs: 505.09
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 2971.20
Add 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 32.90 658.00
2 Crew for Shearing machine Hour 7.00 26.70 186.90
3 Crew for Planing machine Hour 80.00 42.75 3420.00
4 Crew for Drilling machine Hour 50.00 35.00 1750.00
5 Crew for Grinding machine Hour 25.00 35.00 875.00
6 Foreman Day 40.00 108.65 4346.00
7 Marker / Fabricator / Erector Day 68.00 93.70 6371.60
8 Gas cutter Day 16.00 93.70 1499.20
9 Welder ( General ) Day 55.00 93.70 5153.50
10 Welder ( X - ray ) Day 5.00 103.07 515.35
11 Helper fabrication / erection Day 180.00 81.60 14688.00
12 Helper for cleaning / painting Day 13.00 81.60 1060.80
13 Painter Cl - II Day 36.00 81.60 2937.60
14 Electrician Day 5.00 82.65 413.25
TOTAL Rs: 43875.20
Add for small Tools and Plants @ 1% Rs: 438.75
Add for Contractor' Profit @ 10% Rs: 4387.52
Add for hidden cost on Labour @ 15% Rs: 6581.28
Add for additional hidden cost on labour @ 10% Rs: 4387.52
Add for Contrators' Overheads @ 5% Rs: 2193.76
Total cost of Labour Rs: 61864.03
47
GATES AND HOISTS
ABSTRACT:
A. Cost of Materials Rs: 478402.71
B. Hire charges of Machinery Rs: 56510.74
C. Cost of Labour Rs: 61864.03
Total Rs: 596777.48
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 15980.59
Add for insurance charges @ 1.00% Rs: 5967.77
Add for designs and drawings @ 2.5% Rs: 14919.44
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 14919.44
Add for power supply arrangements @ 2.5% Rs: 14919.44
Add for enabling works @ 2% Rs: 11935.55
Total Rs: 675419.71
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x10.657 tonnes @ Rs: 81.30 / tonne Rs: 1732.83
Add 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 plates
with stiffeners and anchors for river sluice / canal sluice vents including cost of all materials,
machinery, labour, cutting, aligning, anchoring, welding, finishing, cleaning, applying one coat of
zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete with
all leads and lifts.
DATA: Vent lining consists of forming river / canal sluice of specified size using 20 mm thick structural
steel plates for the specified length. The liner plates are stiffened on the back side and anchors
are provided for embedment in concrete.
Consider vent lining for river / canal sluice of size 2.5 m x 3 m for analysis.
Consider vent lining for 3.40 m length of vent.
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 sqm
Weight of 20 mm thick plate per sqm : 157.00 kg
Add 25 % for stiffeners / anchors / projections etc : 39.25 kg
Total requirement of steel for vent lining of sluice per sqm area : 196.25 kg
say : 200 kg
Quantity of steel required for 37.40 sqm : 7.480 tonnes
The actual weight of liner for 37.4 sqm as per data sheet : 7.281 tonnes
Consider 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 kg
b. Welding electrodes :
Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 344 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 20 Rm
Total : 223 Rm
For cutting structural steel sections to required sizes gas cutting is assumed since most of the
sections are above 10 mm thick.
Length of steel to be cut by using gas manually : 30 m
48
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49
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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 11221.00
2 Pug cutting machine Hour 77.00 13.00 1001.00
Fuel / Energy charges Hour 77.00 2.00 154.00
3 Mobile derric crane Hour 8.00 261.00 2088.00
Fuel / Energy charges Hour 8.00 117.00 936.00
4 Stationery derric crane Hour 16.00 50.00 800.00
Fuel / Energy charges Hour 16.00 5.00 80.00
5 Grinding machine Hour 8.00 15.00 120.00
Fuel / Energy charges Hour 8.00 20.00 160.00
6 Sundries LS 10.00 22.50 225.00
TOTAL Rs: 20088.00
Add for small Tools and Plants @ 1% Rs: 200.88
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 1277.60
Add 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 32.90 263.20
2 Crew for Grinding machine Hour 16.00 35.00 560.00
3 Foreman Day 16.00 108.65 1738.40
4 Marker / Fabricator / Erector Day 25.00 93.70 2342.50
5 Gas cutter Day 12.00 93.70 1124.40
6 Welder ( General ) Day 34.00 93.70 3185.80
7 Helper fabrication / erection Day 83.00 81.60 6772.80
50
GATES AND HOISTS
ABSTRACT:
A. Cost of Materials Rs: 257201.44
B. Hire charges of Machinery Rs: 22570.88
C. Cost of Labour Rs: 24499.24
Total Rs: 304271.56
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 6354.47
Add for insurance charges @ 1.00% Rs: 3042.72
Add for designs and drawings @ 2.5% Rs: 7606.79
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 7606.79
Add for power supply arrangements @ 2.5% Rs: 7606.79
Add for enabling works @ 2% Rs: 6085.43
Total Rs: 342574.54
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x7.281 tonnes @ Rs: 81.30 / tonne Rs: 1183.89
Add 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 vertical
lift service gate consisting of skin plate, vertical and horizontal 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 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, horizontal
girders, 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 sluice
gate 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 : 9.229
The actual weight of river sluice service gate as per data sheet : 9.202 tonnes
Consider actual weight for data rate analysis.
51
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 kg
b. Cast iron components conforming to IS : 210 :
Cast iron blocks for counter weight : 4100 kg
c. Alloy steel components conforming to IS : 1570 :
Wheel axles / Pins : 132 kg
d. Cast steel components conforming to IS : 1030 :
Wheels / guide rollers : 492 kg
e. Alluminium / Bronze alloy components conforming to IS : 305 :
Bearings / Bushes : 76 kg
f. Bolts / Nuts / Washers conforming to IS : 1363 :
SS bolts / nuts / washers with 2.5 % wastage : 55 kg
GI bolts / nuts / washers with 2.5 % wastage : 76 kg
MS bolts / nuts / washers with 2.5 % wastage : 4 kg
g. Rubber seal conforming to IS : 11855 :
Bottom seal ( flat type ) : 2.8 Rm
Side seals ( music note type teflon claded ) : 5.85 Rm
Top seal ( music note type teflon claded ) : 2.25 Rm
Corner seal ( teflon claded ) : 2 Nos
h. Welding electrodes :
Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 282 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 14 Rm
Total : 151 Rm
For cutting structural steel sections to required sizes gas cutting is assumed since most of the
sections are above 10 mm thick.
Length of steel to be cut by using gas manually : 30 m
Length of steel to be cut by gas using pug cutting machine : 121 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 15 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 40 hours
Acetelyne gas @ 0.6 cum / hour ( 55 x 0.60 ) : 33 cum
Oxygen gas @ 1.8 cum / hour ( 55 x 1.80 ) : 99 cum
Use of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hours
Use of pug cutting machine with 50 min / hr working ( 40 x 60 / 50 ) : 48 hours
3. Welding :
Length of welding : 281 Rm
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 282 / 15 ) x 8 / 2 : 75 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 2532 / 15 ) x 8 / 6 : 225 hours
Total : 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 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 92 sqm @ 9 sqm / ltr / coat : 10 ltr
3 coats of coal tar epoxy paint 100 micron dry film each coat.
Quantity of coal tar epoxy paint for 92 sqm @ 6 sqm / ltr / coat : 46 ltr
As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment
to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting
52
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53
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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 9212.00
2 Pug cutting machine Hour 48.00 13.00 624.00
Fuel / Energy charges Hour 48.00 2.00 96.00
3 Tower crane Hour 1.00 763.00 763.00
Fuel / Energy charges Hour 1.00 106.00 106.00
4 Mobile derric crane Hour 10.00 261.00 2610.00
Fuel / Energy charges Hour 10.00 117.00 1170.00
5 Stationery derric crane Hour 20.00 50.00 1000.00
Fuel / Energy charges Hour 20.00 5.00 100.00
6 Grinding machine Hour 8.00 15.00 120.00
Fuel / Energy charges Hour 8.00 20.00 160.00
7 Drilling machines Hour 16.00 15.00 240.00
Fuel / Energy charges Hour 16.00 20.00 320.00
8 Sundries LS 25.00 22.50 562.50
TOTAL Rs: 19783.50
Add for small Tools and Plants @ 1% Rs: 197.84
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 1172.65
Add 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 32.90 329.00
2 Crew for Tower crane Hour 1.00 36.05 36.05
54
GATES AND HOISTS
ABSTRACT:
A. Cost of Materials Rs: 386609.73
B. Hire charges of Machinery Rs: 22143.16
C. Cost of Labour Rs: 26317.73
Total Rs: 435070.62
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 6542.22
Add for insurance charges @ 1.00% Rs: 4350.71
Add for designs and drawings @ 2.5% Rs: 10876.77
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 10876.77
Add for power supply arrangements @ 2.5% Rs: 10876.77
Add for enabling works @ 2% Rs: 8701.41
Total Rs: 487295.26
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x9.202 tonnes @ Rs: 81.30 / tonne Rs: 1496.25
Add 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 rope
drum hoist consisting of hoist platform, rope drum, gear system, electric motor, electro-
magnetic brake system, hand operation assembly, control panel, wire rope, pulleys, ladder etc.,
with all accessories for operating river sluice / canal sluice service gate including cost of
all materials, machinery, labour, cutting, bending, aligning, anchoring, welding, finishing,
cleaning, applying two coats of zinc chromate red oxide primer and three coats of approved
synthetic enamel paint etc., complete with all leads and lifts.
DATA: Rope drum hoist for river / canal sluice service gate consists of embedded parts for anchorage,
hoist supporting structure, pulley support, pulleys, drive stool, rope drums, shafts, couplings,
gears and pinions, plummer blocks, gear box, electric motor, hand operation assembly, brake,
wire rope, gate position indicator, switch box etc. with related accessories.
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
55
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 m
Head of water above sill level considered : 34 m
Generally 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 )^0.659
Where ( 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 : 9.229
Capacity 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 tonnes
The actual weight of river sluice service gate rope drum hoist as per data sheet : 6.243 t
Consider 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 kg
Plates / Flats with 2.5 % wastage : 402.00 kg
Chequered plates with 2.5 % wastage : 290.00 kg
b. Cast steel components conforming to IS : 1030 :
Rope drums 2 Nos / Gears : 1926.00 kg
Pinions : 79.00 kg
Pulleys 3 Nos / Couplings 2 Nos : 306.00 kg
Plummer blocks / Hubs : 72.00 kg
c. Alloy steel steel components conforming to IS : 1570 :
Shafts : 346.00 kg
Pins 73.00 kg
d. Alluminium/ Bronze alloy components conforming to IS : 305 :
Bearings / Bush : 57.00 kg
e. Bolt / Nut / Washers conforming to IS : 1363 :
MS Bolts / Nuts / Washers with 2.5 % wastage : 32.00 kg
f. Steel wire rope conforming ti IS 2266 :
28 mm dia 6 / 37 construction 1 No 120 Rm @ 2.71 kg / m : 325 kg
g. Other components :
Manual operating system : 1 No.
Worm reducer : 1 No
Electric motor 5 hp : 1 No.
Gate position indicator : 1 No.
Ele-magnetic brake : 1 No.
Electric cable / switch / control panel etc : 1 set
h. Welding electrodes :
Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 80 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 6 Rm
Total : 63 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas manually : 26 m
Length of steel to be cut by gas using pug cutting machine : 37 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 13 hours
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57
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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 all
taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.
8. Use rate of materials :
Cost of welding set @ Rs: 3375.00 / Each Rs: 3375.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 3.38
Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125
Life of gas cutting set : 600 hours
Use rate of gas cutting set per hr ( cost / life ) Rs: 1.88
58
GATES AND HOISTS
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 2597.00
2 Tower crane 5 t capacity Hour 2.00 763.00 1526.00
Fuel / Energy charges Hour 2.00 106.00 212.00
3 Pug cutting machine Hour 15.00 13.00 195.00
Fuel / Energy charges Hour 15.00 2.00 30.00
4 Mobile derric crane Hour 10.00 261.00 2610.00
Fuel / Energy charges Hour 10.00 117.00 1170.00
5 Grinding machine Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
6 Drilling machines Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
7 Sundries LS 25.00 22.50 562.50
TOTAL Rs: 9807.50
Add for small Tools and Plants @ 1% Rs: 98.08
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 465.15
Add 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 32.90 329.00
2 Crew for Tower crane Hour 2.00 36.05 72.10
3 Crew for Drilling machine Hour 2.00 35.00 70.00
4 Crew for Grinding machine Hour 2.00 35.00 70.00
5 Foreman Day 15.00 108.65 1629.75
6 Marker / Fabricator / Erector Day 19.00 93.70 1780.30
7 Gas cutter Day 4.00 93.70 374.80
8 Welder ( General ) Day 8.00 93.70 749.60
9 Khalasi Day 4.00 83.65 334.60
10 Helper fabrication / erection Day 44.00 81.60 3590.40
11 Helper for cleaning / painting Day 5.00 81.60 408.00
12 Painter Cl - II Day 11.00 81.60 897.60
13 Electrician Day 2.00 82.65 165.30
TOTAL Rs: 10471.45
Add for small Tools and Plants @ 1% Rs: 104.71
Add for Contractor' Profit @ 10% Rs: 1047.15
Add for hidden cost on Labour @ 15% Rs: 1570.72
Add for additional hidden cost on labour @ 10% Rs: 1047.15
Add for Contrators' Overheads @ 5% Rs: 523.57
Total cost of Labour Rs: 14764.74
ABSTRACT:
A. Cost of Materials Rs: 556901.94
B. Hire charges of Machinery Rs: 10861.10
C. Cost of Labour Rs: 14764.74
Total Rs: 582527.78
59
GATES AND HOISTS
SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 15
ITEM: Design, fabrication, supply, erection and commissioning of embedded parts ( without groove
liners ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner upto
1m height above the roof of vent etc., with all accessories for river / canal sluice emergency
gate including cost of all materials, machinery, labour, cutting, aligning, anchoring, welding,
finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied
coal tar epoxy paint etc., complete as per specifications and approved drawings with all leads
and lifts.
DATA: Embedded parts for river sluice emergency gate consist of sill beam, wheel / seal tracks, breast
wall lining upto 1 m height above vent top, gate guide etc., with all accessories such as f irst
stage anchors.
The weight of embedded parts depends on the height of gate groove, 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.
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 m
Head of water considered above sill level : 16 m
Weight of embedded parts in tonnes = 0.0444 x ( L^2 x H x h )^0.659
Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.
= 0.0444 x ( 2.2 x 2.2 x 3.3 x 16 ) ^ 0.659 : 1.714 tonnes
Weight of breast wall lining about 2 sqm @ 250 kg / sqm : 0.500 tonnes
: 2.214 tonnes
The actual weight of embedded parts as per data sheet : 2.180 tonnes
Consider 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 kg
Structural 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 Nos
Welding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 34 Nos
Welding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 697 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 14 Rm
Total length of cutting : 149 Rm
For cutting structural steel sections to required size gas cutting is assumed for cutting angles /
beams / channels / round bars. For plates / flats less than 12 mm in thickness plate shearing
machine and for the remaining sections pug cutting machine is considered.
Length of steel to be cut by using gas manually : 30 m
Length of steel to be cut by gas using pug cutting machine : 89 m
Length of steel to be cut by using shearing machine : 30 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 15 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 30 hours
Time for cutting by shearing machine at av. 10 m / hr progress : 3 hours
Acetelyne gas @ 0.6 cum / hour ( 45 x 0.60 ) : 27 cum
Oxygen gas @ 1.8 cum / hour ( 45 x 1.80 ) : 81 cum
Use of gas cutting torch with 50 min / hr working ( 15 x 60 / 50 ) : 18 hours
Use of pug cutting machine with 50 min / hr working ( 30 x 60 / 50 ) : 36 hours
Use of shearing machine with 50 min / hr working ( 3 x 60 / 50 ) : 4 hours
3. Welding :
Length of welding as per data sheet : 143 m
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 77 + 34 ) x 8 / 15 / 2 : 30 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 697 + 305 ) x 8 / 15 / 6 : 89 hours
Total : 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 Rm
Length of planing at a time for 4 m stroke planing machine : 3 Rm
Time for planing 3 m length section with 50 min / hour working : 8 hours
Time for planing 26 m SS plates ( 26 x 8 / 3 ) : 72 hours
5. Surface cleaning and painting :
Painting area for embedded parts at 12 sqm / tonne : 26 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 26 sqm @ 9 sqm / ltr / coat : 3 ltr
4 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 ltr
As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment
to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting
before applying primer painting.
Quantity of rust cleaner / inhibitor 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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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 3675.00
2 Plate shearing machine Hour 4.00 47.00 188.00
Fuel / Energy charges Hour 4.00 82.00 328.00
3 Pug cutting machine Hour 36.00 13.00 468.00
Fuel / Energy charges Hour 36.00 2.00 72.00
4 Planing machine Hour 72.00 66.00 4752.00
Fuel / Energy charges Hour 72.00 61.00 4392.00
5 Mobile derric crane Hour 2.00 261.00 522.00
Fuel / Energy charges Hour 2.00 117.00 234.00
6 Stationery derric crane Hour 4.00 50.00 200.00
Fuel / Energy charges Hour 4.00 5.00 20.00
7 Grinding machine Hour 8.00 15.00 120.00
Fuel / Energy charges Hour 8.00 20.00 160.00
8 Drilling machines Hour 10.00 15.00 150.00
Fuel / Energy charges Hour 10.00 20.00 200.00
9 Sundries LS 10.00 22.50 225.00
TOTAL Rs: 16777.00
Add for small Tools and Plants @ 1% Rs: 167.77
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 930.60
Add 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 65.80
2 Crew for Planing machine Hour 72.00 42.75 3078.00
3 Crew for Drilling machine Hour 10.00 35.00 350.00
4 Crew for Grinding machine Hour 8.00 35.00 280.00
5 Foreman Day 13.00 108.65 1412.45
6 Marker / Fabricator / Erector Day 23.00 93.70 2155.10
7 Gas cutter Day 7.00 93.70 655.90
8 Welder ( General ) Day 8.00 93.70 749.60
9 Welder ( X - ray ) Day 3.00 103.07 309.21
10 Helper fabrication / erection Day 56.00 81.60 4569.60
11 Helper for cleaning / painting Day 3.00 81.60 244.80
12 Painter Cl - II Day 9.00 81.60 734.40
13 Electrician Day 1.00 82.65 82.65
TOTAL Rs: 14687.51
Add for small Tools and Plants @ 1% Rs: 146.88
Add for Contractor' Profit @ 10% Rs: 1468.75
Add for hidden cost on Labour @ 15% Rs: 2203.13
Add for additional hidden cost on labour @ 10% Rs: 1468.75
Add for Contrators' Overheads @ 5% Rs: 734.38
Total cost of Labour Rs: 20709.39
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ABSTRACT:
A. Cost of Materials Rs: 112956.60
B. Hire charges of Machinery Rs: 18714.22
C. Cost of Labour Rs: 20709.39
Total Rs: 152380.20
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 5322.19
Add for insurance charges @ 1.00% Rs: 1523.80
Add for designs and drawings @ 2.5% Rs: 3809.51
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 3809.51
Add for power supply arrangements @ 2.5% Rs: 3809.51
Add for enabling works @ 2% Rs: 3047.60
Total Rs: 173702.31
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x2.180 tonnes @ Rs: 81.30 / tonne Rs: 354.47
Add 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 groove
liner ) consisting of sill beam, wheel tracks, seal seats, guide rails, breast wall liner ( upto
1 m above the roof of vent ), groove liner upto breast wall level etc., with all accessories for
river / canal sluice emergency gate including cost of all materials, machinery, labour,
aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer
and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and
approved drawings with all leads and lifts.
DATA: Embedded parts for river sluice emergency gate consist of sill beam, wheel /seal tracks, groove
lining upto breast wall level, breast wall lining upto 1 m above top of vent, gate guide etc., with
all accessories such as first stage anchors.
The weight of embedded parts depends on the height of gate groove and height upto which
breast wall lining is to be provided.
Weight of 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 embedded
parts 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 m
Head of water considered above sill level : 34 m
Weight of embedded parts in tonnes = 0.0600 x ( L^2 x H x h )^0.659
Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.
= 0.0600 x ( 3.2 x 3.2 x 3.3 x 34 ) ^ 0.659 : 6.236 tonnes
Weight of breast wall lining about 3.5 sqm @ 250 kg / sqm : 0.875 tonnes
Weight of groove liner about 10 sqm @ 200 kg / sqm : 2.000 tonnes
: 9.111 tonnes
The actual weight of embedded parts as per data sheet : 9.088 tonnes
Consider 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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Structural steel angles / beams / channels / bars with 2.5 % wastage : 1017 kg
Structural 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 Nos
Welding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 59 Nos
Welding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 3746 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 30 Rm
Total length of cutting : 331 Rm
For cutting structural steel sections to required size gas cutting is assumed for cutting angles /
beams / channels / round bars. For plates / flats less than 12 mm in thickness plate shearing
machine and for the remaining sections pug cutting machine is considered.
Length of steel to be cut by using gas manually : 60 m
Length of steel to be cut by gas using pug cutting machine : 211 m
Length of steel to be cut by using shearing machine : 60 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour 30 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 70 hours
Time for cutting by shearing machine at av. 10 m / hr progress : 6 hours
Acetelyne gas @ 0.6 cum / hour ( 100 x 0.60 ) : 60 cum
Oxygen gas @ 1.8 cum / hour ( 100 x 1.80 ) : 180 cum
Use of gas cutting torch with 50 min / hr working ( 30 x 60 / 50 ) 36 hours
Use of pug cutting machine with 50 min / hr working ( 70 x 60 / 50 ) 84 hours
Use of shearing machine with 50 min / hr working ( 6 x 60 / 50 ) 7 hours
3. Welding :
Length of welding as per data sheet : 560 m
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 416 + 59 ) x 8 / 15 / 2 : 127 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 3746 + 529 ) x 8 / 15 / 6 : 380 hours
Total : 507 hours
Deploy 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 Rm
Length of planing at a time for 4 m stroke planing machine : 3 Rm
Time for planing 3 m length section with 50 min / hour working : 8 hours
Time for planing 26 m SS plates ( 26 x 8 / 3 ) : 69 hours
5. Surface cleaning and painting :
Painting area for embedded parts at 10 sqm / tonne : 91 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 91 sqm @ 9 sqm / ltr / coat : 10 ltr
4 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 ltr
As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment
to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting
before applying primer painting.
Quantity of rust cleaner / inhibitor at 8 sqm / ltr : 12 ltr
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14 Use rate gas cutting torch set Hour 36.00 1.88 67.50
15 Wire brush Nos 2.00 25.00 50.00
16 Sundries LS 20.00 22.50 450.00
TOTAL Rs: 334367.63
Add for small Tools and Plants @ 1% Rs: 3343.68
Add for Contractor' Profit @ 10% Rs: 33436.76
Add 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 15533.00
2 Plate shearing machine Hour 7.00 47.00 329.00
Fuel / Energy charges Hour 7.00 82.00 574.00
3 Pug cutting machine Hour 84.00 13.00 1092.00
Fuel / Energy charges Hour 84.00 2.00 168.00
4 Planing machine Hour 69.00 66.00 4554.00
Fuel / Energy charges Hour 69.00 61.00 4209.00
5 Mobile derric crane Hour 20.00 261.00 5220.00
Fuel / Energy charges Hour 20.00 117.00 2340.00
6 Stationery derric crane Hour 40.00 50.00 2000.00
Fuel / Energy charges Hour 40.00 5.00 200.00
7 Grinding machine Hour 25.00 15.00 375.00
Fuel / Energy charges Hour 25.00 20.00 500.00
8 Drilling machines Hour 50.00 15.00 750.00
Fuel / Energy charges Hour 50.00 20.00 1000.00
9 Sundries LS 20.00 22.50 450.00
TOTAL Rs: 43857.00
Add for small Tools and Plants @ 1% Rs: 438.57
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 2497.40
Add 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 32.90 658.00
2 Crew for Shearing machine Hour 7.00 26.70 186.90
3 Crew for Planing machine Hour 69.00 42.75 2949.75
4 Crew for Drilling machine Hour 50.00 35.00 1750.00
5 Crew for Grinding machine Hour 25.00 35.00 875.00
6 Foreman Day 36.00 108.65 3911.40
7 Marker / Fabricator / Erector Day 62.00 93.70 5809.40
8 Gas cutter Day 16.00 93.70 1499.20
9 Welder ( General ) Day 42.00 93.70 3935.40
10 Welder ( X - ray ) Day 6.00 103.07 618.42
11 Helper fabrication / erection Day 156.00 81.60 12729.60
12 Helper for cleaning / painting Day 12.00 81.60 979.20
13 Painter Cl - II Day 30.00 81.60 2448.00
14 Electrician Day 2.00 82.65 165.30
TOTAL Rs: 38515.57
Add for small Tools and Plants @ 1% Rs: 385.16
Add for Contractor' Profit @ 10% Rs: 3851.56
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ABSTRACT:
A. Cost of Materials Rs: 387866.45
B. Hire charges of Machinery Rs: 48985.82
C. Cost of Labour Rs: 54306.95
Total Rs: 491159.22
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 13944.52
Add for insurance charges @ 1.00% Rs: 4911.59
Add for designs and drawings @ 2.5% Rs: 12278.98
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 12278.98
Add for power supply arrangements @ 2.5% Rs: 12278.98
Add for enabling works @ 2% Rs: 9823.18
Total Rs: 556675.46
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x9.088 tonnes @ Rs: 81.30 / tonne Rs: 1477.71
Add 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 lift
emergency 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 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, horizontal
girders, 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 m
Head 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 : 9.229
The actual weight of river sluice emergency gate as per data sheet : 9.215 tonnes
Consider 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 kg
b. Cast iron components conforming to IS : 210 :
Cast iron blocks for counter weight : 4100 kg
c. Alloy steel components conforming to IS : 1570 :
Wheel axles / Pins : 144 kg
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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 8379.00
2 Pug cutting machine Hour 47.00 13.00 611.00
Fuel / Energy charges Hour 47.00 2.00 94.00
3 Tower crane Hour 1.00 763.00 763.00
Fuel / Energy charges Hour 1.00 106.00 106.00
4 Mobile derric crane Hour 10.00 261.00 2610.00
Fuel / Energy charges Hour 10.00 117.00 1170.00
5 Stationery derric crane Hour 20.00 50.00 1000.00
Fuel / Energy charges Hour 20.00 5.00 100.00
6 Grinding machine Hour 8.00 15.00 120.00
Fuel / Energy charges Hour 8.00 20.00 160.00
7 Drilling machines Hour 16.00 15.00 240.00
Fuel / Energy charges Hour 16.00 20.00 320.00
8 Sundries LS 25.00 22.50 562.50
TOTAL Rs: 18692.50
Add for small Tools and Plants @ 1% Rs: 186.93
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 1089.15
Add 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 32.90 329.00
2 Crew for Tower crane Hour 1.00 36.05 36.05
3 Crew for Drilling machine Hour 16.00 35.00 560.00
4 Crew for Grinding machine Hour 8.00 35.00 280.00
5 Foreman Day 16.00 108.65 1738.40
6 Marker / Fabricator / Erector Day 23.00 93.70 2155.10
7 Gas cutter Day 8.00 93.70 749.60
8 Welder ( General ) Day 23.00 93.70 2155.10
9 Welder ( X - ray grade ) Day 3.00 103.07 309.21
10 Khalasi Day 10.00 83.65 836.50
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ABSTRACT:
A. Cost of Materials Rs: 389968.95
B. Hire charges of Machinery Rs: 20903.20
C. Cost of Labour Rs: 25098.93
Total Rs: 435971.08
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 6210.29
Add for insurance charges @ 1.00% Rs: 4359.71
Add for designs and drawings @ 2.5% Rs: 10899.28
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 10899.28
Add for power supply arrangements @ 2.5% Rs: 10899.28
Add for enabling works @ 2% Rs: 8719.42
Total Rs: 487958.33
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x9.215 tonnes @ Rs: 81.30 / tonne Rs: 1498.36
Add 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 emergency
gate 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 with
lifting 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 beam
drawings 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 m
Head 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 tonne
The actual weight of lifting beam as per data sheet : 0.922 tonne
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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 1421.00
2 Pug cutting machine Hour 15.00 13.00 195.00
Fuel / Energy charges Hour 15.00 2.00 30.00
3 Grinding machine Hour 1.00 15.00 15.00
Fuel / Energy charges Hour 1.00 20.00 20.00
4 Drilling machines Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
5 Sundries LS 5.00 22.50 112.50
TOTAL Rs: 2286.50
Add for small Tools and Plants @ 1% Rs: 22.87
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 162.35
Add 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 70.00
2 Crew for Grinding machine Hour 1.00 35.00 35.00
3 Foreman Day 2.00 108.65 217.30
4 Marker / Fabricator / Erector Day 5.00 93.70 468.50
5 Gas cutter Day 2.00 93.70 187.40
6 Welder ( General ) Day 4.00 93.70 374.80
7 Helper fabrication / erection Day 12.00 81.60 979.20
8 Helper for cleaning / painting Day 2.00 81.60 163.20
9 Painter Cl - II Day 2.00 81.60 163.20
10 Electrician Day 1.00 82.65 82.65
TOTAL Rs: 2741.25
Add for small Tools and Plants @ 1% Rs: 27.41
Add for Contractor' Profit @ 10% Rs: 274.13
Add for hidden cost on Labour @ 15% Rs: 411.19
Add for additional hidden cost on labour @ 10% Rs: 274.13
Add for Contrators' Overheads @ 5% Rs: 137.06
Total cost of Labour Rs: 3865.16
ABSTRACT:
A. Cost of Materials Rs: 63743.31
B. Hire charges of Machinery Rs: 2586.04
C. Cost of Labour Rs: 3865.16
Total Rs: 70194.51
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 870.91
Add for insurance charges @ 1.00% Rs: 701.95
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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 vertical
lift 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 cold
applied coal tar epoxy paint, etc., complete as per specifications and aproved drawings with
all 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 embedded
parts 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 tonnes
The actual weight of embedded parts as per data sheet : 5.193 tonnes
Consider 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 kg
Structural 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 Nos
Welding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 117 Nos
Welding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 5983 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 21 Rm
Total length of cutting : 231 Rm
For cutting structural steel sections to required size gas cutting and use of plate shearing
machine is considered.
Length of steel to be cut by using gas manually : 50 m
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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 25578.00
2 Plate shearing machine Hour 4.00 47.00 188.00
Fuel / Energy charges Hour 4.00 82.00 328.00
3 Pug cutting machine Hour 60.00 13.00 780.00
Fuel / Energy charges Hour 60.00 2.00 120.00
4 Planing machine Hour 88.00 66.00 5808.00
Fuel / Energy charges Hour 88.00 61.00 5368.00
5 Mobile derric crane Hour 5.00 261.00 1305.00
Fuel / Energy charges Hour 5.00 117.00 585.00
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C. LABOUR:
Sl No Description Unit Quantity Rate Amount
in Rs. in Rs.
1 Crew for Mobile crane Hour 5.00 32.90 164.50
2 Crew for Plate shearing machine Hour 4.00 26.70 106.80
3 Crew for Planing machine Hour 88.00 42.75 3762.00
4 Crew for Drilling machine Hour 16.00 35.00 560.00
5 Crew for Grinding machine Hour 8.00 35.00 280.00
6 Foreman Day 37.00 108.65 4020.05
7 Marker / Fabricator / Erector Day 56.00 93.70 5247.20
8 Gas cutter Day 12.00 93.70 1124.40
9 Welder ( General ) Day 70.00 93.70 6559.00
10 Welder ( X - ray ) Day 8.00 103.07 824.56
11 Helper fabrication / erection Day 180.00 81.60 14688.00
12 Helper for cleaning / painting Day 7.00 81.60 571.20
13 Painter Cl - II Day 17.00 81.60 1387.20
14 Electrician Day 2.00 82.65 165.30
TOTAL Rs: 39460.21
Add for small Tools and Plants @ 1% Rs: 394.60
Add for Contractor' Profit @ 10% Rs: 3946.02
Add for hidden cost on Labour @ 15% Rs: 5919.03
Add for additional hidden cost on labour @ 10% Rs: 3946.02
Add for Contrators' Overheads @ 5% Rs: 1973.01
Total cost of Labour Rs: 55638.90
ABSTRACT:
A. Cost of Materials Rs: 331232.64
B. Hire charges of Machinery Rs: 55087.80
C. Cost of Labour Rs: 55638.90
Total Rs: 441959.33
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 14948.10
Add for insurance charges @ 1% Rs: 4419.59
Add for designs and drawings @ 2.5% Rs: 11048.98
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 11048.98
Add for power supply arrangements @ 2.5% Rs: 11048.98
Add for enabling works @ 2% Rs: 8839.19
Total Rs: 503313.16
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x5.193 tonnes @ Rs: 81.30 / tonne Rs: 844.38
Add 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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SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 20
ITEM: Design, fabrication, supply, erection, testing and commissioning of fixed wheel type vertical
lift gate consisting of skin plate, vertical and horizontal girders, wheels, stiffeners, lifting
brackets, guide shoes, rubber seals etc., with all accessories for barrage including cost of all
materials, machinery, labour, cutting, aligning, welding, finishing, cleaning, applying one coat
of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint, seal fixing etc.,
complete as per specifications and approved drawings with all leads and lifts.
DATA: Consider upstream seal vertical lift roller gate. The gate leaf consists of skin plate, horizontal
girders, 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 lift
roller 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 : 33.289
The actual weight of vertical lift barrage gate as per data sheet : 33.025 tonnes
Consider 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 kg
Structural 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 kg
MS bolts / nuts / washers with 2.5 % wastage : 70 kg
f. Rubber seal conforming to IS : 11855 :
Bottom seal ( flat uncladed ) : 14.5 Rm
Side seals ( bulb uncladed ) : 18 Rm
g. Welding electrodes :
Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 1574 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 70 Rm
Total : 765 Rm
For cutting structural steel sections to required sizes gas cutting and plate shearing machine
for plates less than 12 mm thick are considered.
Length of steel to be cut by using gas manually : 200 m
Length of steel to be cut by gas using pug cutting machine : 465 m
Length of steel to be cut by gas using plate shearing machine : 100 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 100 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 155 hours
Time for cutting by plate shearing machine at ( av ) 10 m / hour : 10 hours
Acetelyne gas @ 0.6 cum / hour ( 255 x 0.60 ) : 153 cum
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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 51401.00
2 Pug cutting machine Hour 186.00 13.00 2418.00
Fuel / Energy charges Hour 186.00 2.00 372.00
3 Plate shearing machine Hour 12.00 47.00 564.00
Fuel / Energy charges Hour 12.00 82.00 984.00
4 Tower crane Hour 4.00 763.00 3052.00
Fuel / Energy charges Hour 4.00 106.00 424.00
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C. LABOUR:
Sl No Description Unit Quantity Rate Amount
in Rs. in Rs.
1 Crew for Mobile crane Hour 50.00 32.90 1645.00
2 Crew for Tower crane Hour 4.00 36.05 144.20
3 Crew for Plate shearing machine Hour 12.00 26.70 320.40
4 Crew for Drilling machine Hour 50.00 35.00 1750.00
5 Crew for Grinding machine Hour 50.00 35.00 1750.00
6 Foreman Day 72.00 108.65 7822.80
7 Marker / Fabricator / Erector Day 112.00 93.70 10494.40
8 Gas cutter Day 40.00 93.70 3748.00
9 Welder ( General ) Day 142.00 93.70 13305.40
10 Welder ( X - ray grade ) Day 16.00 103.07 1649.12
11 Khalasi Day 50.00 83.65 4182.50
12 Helper fabrication / erection Day 390.00 81.60 31824.00
13 Helper for cleaning / painting Day 70.00 81.60 5712.00
14 Painter Cl - II Day 158.00 81.60 12892.80
15 Electrician Day 20.00 82.65 1653.00
TOTAL Rs: 98893.62
Add for small Tools and Plants @ 1% Rs: 988.94
Add for Contractor' Profit @ 10% Rs: 9889.36
Add for hidden cost on Labour @ 15% Rs: 14834.04
Add for additional hidden cost on labour @ 10% Rs: 9889.36
Add for Contrators' Overheads @ 5% Rs: 4944.68
Total cost of Labour Rs: 139440.00
ABSTRACT:
A. Cost of Materials Rs: 1318397.57
B. Hire charges of Machinery Rs: 117122.66
C. Cost of Labour Rs: 139440.00
Total Rs: 1574960.23
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 34635.96
Add for insurance charges @ 1.00% Rs: 15749.60
Add for designs and drawings @ 2.5% Rs: 39374.01
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 39374.01
Add for power supply arrangements @ 2.5% Rs: 39374.01
Add for enabling works @ 2% Rs: 31499.20
Total Rs: 1774967.01
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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 consists
of 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 structural
steel 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 kg
Beams with cross beams, stiffeners etc @ 400 kg / m for 15 m span : 6000.00 kg
Total : 9600.00 kg
Other accessories such as railing, chequered plate, ladder etc @ 10 % 960.00 kg
Total : 10560.00 kg
The actual weight of hoist supporting bridge as per data sheet : 10239.00 kg
Consider 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 kg
Structural steel plates / flats with 2.5 % wastage : 5567 kg
Chequered plate with 2.5 % wastage : 136 kg
b. MS pipes 32 mm dia : 32 Rm
MS pipes 25 mm dia : 64 Rm
c. Bolt / Nut / Washer
MS 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 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 29 Rm
Total : 319 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas manually : 100 m
Length of steel to be cut by gas using pug cutting machine : 219 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 50 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 73 hours
Acetelyne gas @ 0.6 cum / hour ( 123 x 0.60 ) : 74 cum
Oxygen gas @ 1.8 cum / hour ( 123 x 1.80 ) : 222 cum
Use of gas cutting torch with 50 min / hr working ( 50 x 60 / 50 ) : 60 hours
Use 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 Rm
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 388 / 15 ) x 8 / 2 : 104 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 3495 / 15 ) x 8 / 6 : 311 hours
Total : 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 sqm
2 coats of zinc chromate red oxide primer .
Quantity of primer paint for 205 sqm @ 12 sqm / ltr / coat : 35 ltr
3 coats of synthetic enamel paint.
Quantity of synthetic enamel paint for 205 sqm @ 12 sqm / ltr / coat : 51 ltr
As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment
to remove grease, rust, scaling etc., and to form phasphate coating to prevent further rusting
before applying primer painting.
Quantity of rust cleaner / inhibitor 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 / Welder
Erector
Cutting sections 148 hours 9 18 18 36
Fabricating by stitch welding 104 hours 6 13 --- 26
Run welding 311 hours 4 --- 39 39
For erection of columns & bracings 2 4 --- 8
For erection of beams / cross beams 4 8 --- 16
For erection of railing / covering etc 1 2 --- 4
Finishing / 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 cleaner
and wire brushing at 15 sqm / day : 14 helper for 205 sqm
For 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 all
taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.
8. Use rate of materials :
Cost of welding set @ Rs: 3375.00 / Each Rs: 3375.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 3.38
Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125
Life of gas cutting set : 600 hours
Use rate of gas cutting set per hr ( cost / life ) Rs: 1.88
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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 12691.00
2 Pug cutting machine Hour 88.00 13.00 1144.00
Fuel / Energy charges Hour 88.00 2.00 176.00
3 Mobile derric crane Hour 20.00 261.00 5220.00
Fuel / Energy charges Hour 20.00 117.00 2340.00
4 Stationery derric crane Hour 40.00 50.00 2000.00
Fuel / Energy charges Hour 40.00 5.00 200.00
5 Drilling machine Hour 8.00 15.00 120.00
Fuel / Energy charges Hour 8.00 20.00 160.00
6 Grinding machine Hour 8.00 15.00 120.00
Fuel / Energy charges Hour 8.00 20.00 160.00
7 Sundries LS 50.00 22.50 1125.00
TOTAL Rs: 29191.00
Add for small Tools and Plants @ 1% Rs: 291.91
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 1685.20
Add 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 32.90 658.00
2 Crew for Drilling machine Hour 8.00 35.00 280.00
3 Crew for Grinding machine Hour 8.00 35.00 280.00
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ABSTRACT:
A. Cost of Materials Rs: 347991.68
B. Hire charges of Machinery Rs: 32627.66
C. Cost of Labour Rs: 43630.90
Total Rs: 424250.24
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 10294.91
Add for insurance charges @ 1.00% Rs: 4242.50
Add for designs and drawings @ 2.5% Rs: 10606.26
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 10606.26
Add for power supply arrangements @ 2.5% Rs: 10606.26
Add for enabling works @ 2% Rs: 8485.00
Total Rs: 479091.42
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x10.239 tonnes @ Rs: 81.30 / tonne Rs: 1664.86
Add 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 rope
drum 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 barrage
including cost of all materials, machinery, labour, cutting, bending, aligning, anchoring, welding,
finishing, cleaning, applying two coats of zinc chromate red oxide primer and three coats of
approved synthetic enamel paint etc., complete with all leads and lifts.
DATA: Rope drum hoist for vertical lift barrage gate consists of hoist supporting frames, pulley
supports, 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 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 drum
hoist 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 : 33.289
Capacity 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 the
hoist 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 tonnes
The actual weight of barrage gate rope drum hoist as per data sheet : 5.069 t
Consider 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 kg
Plates / Flats with 2.5 % wastage : 225.00 kg
b. Cast steel components conforming to IS : 1030 :
Rope drums 2 Nos / Gears : 1290.00 kg
Pinions : 98.00 kg
Pulleys 3 Nos / Couplings 2 Nos : 650.00 kg
Plummer blocks / Hubs : 250.00 kg
c. Alloy steel steel components conforming to IS : 1570 :
Shafts / Keys : 350.00 kg
Pins 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 No
Electric 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 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 4 Rm
Total : 41 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas manually : 20 m
Length of steel to be cut by gas using pug cutting machine : 21 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 10 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 7 hours
Acetelyne gas @ 0.6 cum / hour ( 17 x 0.60 ) : 10 cum
Oxygen gas @ 1.8 cum / hour ( 17 x 1.80 ) : 30 cum
Use of gas cutting torch with 50 min / hr working ( 10 x 60 / 50 ) : 12 hours
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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 2303.00
2 Tower crane 5 t capacity Hour 2.00 763.00 1526.00
Fuel / Energy charges Hour 2.00 106.00 212.00
3 Pug cutting machine Hour 9.00 13.00 117.00
Fuel / Energy charges Hour 9.00 2.00 18.00
4 Mobile derric crane Hour 10.00 261.00 2610.00
Fuel / Energy charges Hour 10.00 117.00 1170.00
5 Grinding machine Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
6 Drilling machines Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
7 Sundries LS 25.00 22.50 562.50
TOTAL Rs: 9081.50
Add for small Tools and Plants @ 1% Rs: 90.82
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 434.55
Add 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 32.90 329.00
2 Crew for Tower crane Hour 2.00 36.05 72.10
3 Crew for Drilling machine Hour 2.00 35.00 70.00
4 Crew for Grinding machine Hour 2.00 35.00 70.00
5 Foreman Day 13.00 108.65 1412.45
6 Marker / Fabricator / Erector Day 17.00 93.70 1592.90
7 Gas cutter Day 3.00 93.70 281.10
8 Welder ( General ) Day 5.00 93.70 468.50
9 Khalasi Day 4.00 83.65 334.60
10 Helper fabrication / erection Day 36.00 81.60 2937.60
11 Helper for cleaning / painting Day 2.00 81.60 163.20
12 Painter Cl - II Day 3.00 81.60 244.80
13 Electrician Day 2.00 82.65 165.30
TOTAL Rs: 8141.55
Add for small Tools and Plants @ 1% Rs: 81.42
Add for Contractor' Profit @ 10% Rs: 814.16
Add for hidden cost on Labour @ 15% Rs: 1221.23
Add for additional hidden cost on labour @ 10% Rs: 814.16
Add for Contrators' Overheads @ 5% Rs: 407.08
Total cost of Labour Rs: 11479.59
ABSTRACT:
A. Cost of Materials Rs: 545839.89
B. Hire charges of Machinery Rs: 10060.94
C. Cost of Labour Rs: 11479.59
Total Rs: 567380.41
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 2907.97
Add for insurance charges @ 1.00% Rs: 5673.80
Add for designs and drawings @ 2.5% Rs: 14184.51
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SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 23
ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sill
beam, 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 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 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 embedded
parts 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 )^0.673
Where ( 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 : 2.433
The actual weight of embedded parts as per data sheet : 2.404 tonnes
Consider 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 kg
Structural 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 Nos
Welding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 16 Nos
Welding electrodes ( LH ) for run welding at 90 % of tota with 2.5 % wastage : 920 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 10.00 Rm
Total : 107.00 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas manually : 40 m
Length of steel to be cut by gas using pug cutting machine : 67 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 20 hours
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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 all
taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.
9. Use rate of materials :
Cost of welding set @ Rs: 3375.00 / Each Rs: 3375.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 3.38
Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125
Life of gas cutting set : 600 hours
Use rate of gas cutting set per hr ( cost / life ) Rs: 1.88
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 3920.00
2 Pug cutting machine Hour 26.00 13.00 338.00
Fuel / Energy charges Hour 26.00 2.00 52.00
3 Planing machine Hour 36.00 66.00 2376.00
Fuel / Energy charges Hour 36.00 61.00 2196.00
4 Mobile derric crane Hour 4.00 261.00 1044.00
Fuel / Energy charges Hour 4.00 117.00 468.00
5 Stationery derric crane Hour 8.00 50.00 400.00
Fuel / Energy charges Hour 8.00 5.00 40.00
6 Grinding machine Hour 8.00 15.00 120.00
Fuel / Energy charges Hour 8.00 20.00 160.00
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C. LABOUR:
Sl No Description Unit Quantity Rate Amount
in Rs. in Rs.
1 Crew for Mobile crane Hour 4.00 32.90 131.60
2 Crew for Planing machine Hour 36.00 42.75 1539.00
3 Crew for Drilling machine Hour 8.00 35.00 280.00
4 Crew for Grinding machine Hour 8.00 35.00 280.00
5 Foreman Day 10.00 108.65 1086.50
6 Marker / Fabricator / Erector Day 19.00 93.70 1780.30
7 Gas cutter Day 6.00 93.70 562.20
8 Welder ( General ) Day 10.00 93.70 937.00
9 Welder ( X - ray ) Day 2.00 103.07 206.14
10 Helper fabrication / erection Day 46.00 81.60 3753.60
11 Helper for cleaning / painting Day 2.00 81.60 163.20
12 Painter Cl - II Day 4.00 81.60 326.40
13 Electrician Day 1.00 82.65 82.65
TOTAL Rs: 11128.59
Add for small Tools and Plants @ 1% Rs: 111.29
Add for Contractor' Profit @ 10% Rs: 1112.86
Add for hidden cost on Labour @ 15% Rs: 1669.29
Add for additional hidden cost on labour @ 10% Rs: 1112.86
Add for Contrators' Overheads @ 5% Rs: 556.43
Total cost of Labour Rs: 15691.31
ABSTRACT:
A. Cost of Materials Rs: 96016.83
B. Hire charges of Machinery Rs: 14287.98
C. Cost of Labour Rs: 15691.31
Total Rs: 125996.12
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 4047.20
Add for insurance charges @ 1.00% Rs: 1259.96
Add for designs and drawings @ 2.5% Rs: 3149.90
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 3149.90
Add for power supply arrangements @ 2.5% Rs: 3149.90
Add for enabling works @ 2% Rs: 2519.92
Total Rs: 143272.91
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x2.404 tonnes @ Rs: 81.30 / tonne Rs: 390.89
Add 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 consisting
of skin plate, stiffeners, horizontal girders, sector arms, trunnion assemblies, tie beam, pulley
supports, 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 / seals
with 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 and
are stiffened by vertical and diagonal stiffeners to form the main frame. Tee- sections are welded
to horizontal girders to make the frame regid and to support the skin plate. Skin plate is welded
to Tee-supports generally spaced vertically at about 40 cm apart.
Consider radial gate for 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 gate
drawings 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 )^0.673
Where ( 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 : 4.456
The actual weight of radial gate leaf as per data sheet : 4.455 tonnes
Consider 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 kg
Structural steel plates / flats with 2.5 % wastage : 2093 kg
Alloy steel components :
Pins : 41 kg
Cast steel components :
Trunnion hub / Guide roller : 122 kg
Alluminium / Bronze alloy components :
Trunnion / Guide roller bush : 19 kg
Bolts / Nuts / Washers :
GI bolts / nuts / washers with 2.5 % wastage : 16.5 kg
MS bolts / nuts / washers with 2.5 % wastage : 55 kg
Zinc at 20 kg / trunnion ( 2 x 20 ) : 40 kg
Rubber seal :
Bottom seal ( flat type ) : 3.1 Rm
Side seals ( Z - type ) : 10.2 Rm
Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 168 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 11 Rm
Total : 119 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas manually : 60 m
Length of steel to be cut by gas using pug cutting machine : 59 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 30 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 20 hours
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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 cleaner
and wire brushing at 15 sqm / day : 6 helper for 89 sqm
For 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 all
taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.
9. Use rate of materials :
Cost of welding set @ Rs: 3375.00 / Each Rs: 3375.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 3.38
Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125
Life of gas cutting set : 600 hours
Use rate of gas cutting set per hr ( cost / life ) Rs: 1.88
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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 6860.00
2 Pug cutting machine Hour 24.00 13.00 312.00
Fuel / Energy charges Hour 24.00 2.00 48.00
3 Bending machine Hour 20.00 31.00 620.00
Fuel / Energy charges Hour 20.00 61.00 1220.00
4 Mobile derric crane Hour 10.00 261.00 2610.00
Fuel / Energy charges Hour 10.00 117.00 1170.00
5 Stationery derric crane Hour 20.00 50.00 1000.00
Fuel / Energy charges Hour 20.00 5.00 100.00
6 Grinding machine Hour 8.00 15.00 120.00
Fuel / Energy charges Hour 8.00 20.00 160.00
7 Drilling machines Hour 16.00 15.00 240.00
Fuel / Energy charges Hour 16.00 20.00 320.00
8 Sundries LS 25.00 22.50 562.50
TOTAL Rs: 17358.50
Add for small Tools and Plants @ 1% Rs: 173.59
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 1044.05
Add 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 32.90 329.00
2 Crew for Bending machine Hour 20.00 26.70 534.00
3 Crew for Drilling machine Hour 16.00 35.00 560.00
4 Crew for Grinding machine Hour 8.00 35.00 280.00
5 Foreman Day 18.00 108.65 1955.70
6 Marker / Fabricator / Erector Day 32.00 93.70 2998.40
7 Gas cutter Day 8.00 93.70 749.60
8 Welder ( General ) Day 19.00 93.70 1780.30
9 Welder ( X - ray ) Day 2.00 103.07 206.14
10 Helper fabrication / erection Day 80.00 81.60 6528.00
11 Helper for cleaning / painting Day 12.00 81.60 979.20
12 Painter Cl - II Day 24.00 81.60 1958.40
13 Electrician Day 3.00 82.65 247.95
TOTAL Rs: 19106.69
Add for small Tools and Plants @ 1% Rs: 191.07
Add for Contractor' Profit @ 10% Rs: 1910.67
Add for hidden cost on Labour @ 15% Rs: 2866.00
Add for additional hidden cost on labour @ 10% Rs: 1910.67
Add for Contrators' Overheads @ 5% Rs: 955.33
Total cost of Labour Rs: 26940.43
ABSTRACT:
A. Cost of Materials Rs: 189080.00
B. Hire charges of Machinery Rs: 19444.06
C. Cost of Labour Rs: 26940.43
Total Rs: 235464.49
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 6261.91
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SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 25
ITEM: Design, fabrication, supply, erection, testing and commissioning of adequate capacity
electrically 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 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, 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 drum
hoist 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 weight
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 )^0.673
Where ( 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 : 4.456
Capacity 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 tonnes
Actual capacity of hoist as per data : 10 tonnes
Weight 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 tonnes
The actual weight of regulator radial gate rope drum hoist as per data sheet : 3.002 tonnes
Consider 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 kg
Plates / Flats with 2.5 % wastage : 544 kg
Chequered plate 195 kg
b. Cast steel components conforming to IS : 1030 :
Rope drums 2 Nos / Gears : 384 kg
Pinions : 14 kg
Pulleys 6 Nos : 108 kg
Plummer blocks / Hubs : 47 kg
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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 2597.00
2 Pug cutting machine Hour 7.00 13.00 91.00
Fuel / Energy charges Hour 7.00 2.00 14.00
3 Mobile derric crane Hour 4.00 261.00 1044.00
Fuel / Energy charges Hour 4.00 117.00 468.00
4 Stationery derric crane Hour 8.00 50.00 400.00
Fuel / Energy charges Hour 8.00 5.00 40.00
5 Grinding machine Hour 8.00 15.00 120.00
Fuel / Energy charges Hour 8.00 20.00 160.00
6 Drilling machines Hour 16.00 15.00 240.00
Fuel / Energy charges Hour 16.00 20.00 320.00
7 Sundries LS 25.00 22.50 562.50
TOTAL Rs: 6812.50
Add for small Tools and Plants @ 1% Rs: 68.13
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 416.15
Add 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 32.90 131.60
2 Crew for Drilling machine Hour 16.00 35.00 560.00
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ABSTRACT:
A. Cost of Materials Rs: 246638.77
B. Hire charges of Machinery Rs: 7637.40
C. Cost of Labour Rs: 16152.89
Total Rs: 270429.05
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 3211.69
Add for insurance charges @ 1.00% Rs: 2704.29
Add for designs and drawings @ 2.5% Rs: 6760.73
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 6760.73
Add for power supply arrangements @ 2.5% Rs: 6760.73
Add for enabling works @ 2% Rs: 5408.58
Total Rs: 302035.79
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x3.002 tonnes @ Rs: 81.30 / tonne Rs: 488.13
Add for transportation upto work site @ 3% Rs: 9061.07
Total cost for 3.002 tonne Rs: 311584.99
10.000 t capacity
Rate 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 capacity
manually operated rope drum hoist consisting of hoist platform, rope drum, gear system,
brake system, wire rope, ladder etc., with all accessories for operating canal regulator
radial gate including cost of all materials, machinery, labour, cutting, aligning, anchoring,
welding, finishing, cleaning, applying two coats of zinc chromate red oxide primer and three
coats of approved synthetic enamel paint etc., complete with all leads and lifts.
DATA: Rope drum hoist for radial gate consists of embedded parts for anchorage, hoist supporting
structure, pulley supporting structures, pulleys, drive stool, rope drums, couplings, shafts,
gears and pinions, plummer blocks, worm reducer, floating shaft, hand operation assembly,
brake, wire rope, gate position indicator etc. with related accessories.
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 drum
hoist 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 )^0.673
Where ( 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 : 4.456
Capacity 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 tonnes
Weight 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 tonnes
Less weight of drive unit ( electric motor / cover etc ) 0.200 tonne
Weight of manually operated hoist 2.800 tonnes
The actual weight of regulator radial gate rope drum hoist as per data sheet : 2.804 tonnes
Consider 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 kg
Plates / Flats with 2.5 % wastage : 453 kg
Chequered plate 195 kg
b. Cast steel components conforming to IS : 1030 :
Rope drums 2 Nos / Gears : 384 kg
Pinions : 14 kg
Pulleys 6 Nos : 108 kg
Plummer blocks / Hubs : 47 kg
c. Alloy steel components conforming to IS : 1570 :
Shafts : 75 kg
Pins 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 Nos
MS pipe 32 mm dia : 10.5 Rm
h. Welding electrodes :
Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 69 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 7 Rm
Total : 80 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas manually : 70 Rm
Length of steel to be cut by gas using pug cutting machine : 20 Rm
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 35 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 7 hours
Acetelyne gas @ 0.6 cum / hour ( 42 x 0.60 ) : 25 cum
Oxygen gas @ 1.8 cum / hour ( 42 x 1.80 ) : 75 cum
Use of gas cutting torch with 50 min / hr working ( 35 x 60 / 50 ) : 42 hours
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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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C. LABOUR:
Sl No Description Unit Quantity Rate Amount
in Rs. in Rs.
1 Crew for Mobile crane Hour 4.00 32.90 131.60
2 Crew for Drilling machine Hour 16.00 35.00 560.00
3 Crew for Grinding machine Hour 8.00 35.00 280.00
4 Foreman Day 14.00 108.65 1521.10
5 Marker / Fabricator / Erector Day 20.00 93.70 1874.00
6 Gas cutter Day 6.00 93.70 562.20
7 Welder ( General ) Day 7.00 93.70 655.90
8 Helper fabrication / erection Day 44.00 81.60 3590.40
9 Helper for cleaning / painting Day 4.00 81.60 326.40
10 Painter Cl - II Day 9.00 81.60 734.40
11 Electrician Day 2.00 82.65 165.30
TOTAL Rs: 10401.30
Add for small Tools and Plants @ 1% Rs: 104.01
Add for Contractor' Profit @ 10% Rs: 1040.13
Add for hidden cost on Labour @ 15% Rs: 1560.20
Add for additional hidden cost on labour @ 10% Rs: 1040.13
Add for Contrators' Overheads @ 5% Rs: 520.07
Total cost of Labour Rs: 14665.83
ABSTRACT:
A. Cost of Materials Rs: 213784.09
B. Hire charges of Machinery Rs: 7150.68
C. Cost of Labour Rs: 14665.83
Total Rs: 235600.60
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 2945.23
Add for insurance charges @ 1.00% Rs: 2356.01
Add for designs and drawings @ 2.5% Rs: 5890.01
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 5890.01
Add for power supply arrangements @ 2.5% Rs: 5890.01
Add for enabling works @ 2% Rs: 4712.01
Total Rs: 263283.89
Add 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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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 paint
etc., complets as per specifications and approved drawings with all leads and lifts.
DATA: Embedded parts for canal escape / regulator gate consist of sill beam, wheel / seal tracks,
groove lining upto top, gate guide with all accessories such as first stage anchors.
Weight of embedded parts with groove lining for such small gates will be about 150 percent of
gate weight.
Consider embedded parts for canal escape / regulator gate for opening of size 2 m x 2 m.
Details of material / Gas cutting / Welding considered for rate analysis are based on embedded
parts 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 )^0.659
Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.
= 0.1332 x ( 2.5 x 2.5 x 2.2 x 3.7 ) ^ 0.659 : 1.775 tonnes
The actual weight of embedded parts as per data sheet : 1.784 tonnes
Consider 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 kg
Structural steel plates / flats with 2.5 % wastage : 527 kg
Alloy steel components conforming to IS : 1570 :
Stainless steel plates / flats : 82.00 kg
Bolt / Nut / Washer conforming to IS : 1363 :
MS bolts and nuts with 2.5 % wastage : 1 kg
Welding electrodes :
Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 121 Nos
Welding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 23 Nos
Welding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 1094 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 4 Rm
Total : 44 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas manually : 24 m
Length of steel to be cut by gas using pug cutting machine : 20 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 12 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 7 hours
Acetelyne gas @ 0.6 cum / hour ( 19 x 0.60 ) : 11 cum
Oxygen gas @ 1.8 cum / hour ( 19 x 1.80 ) : 33 cum
Use of gas cutting torch with 50 min / hr working ( 12 x 60 / 50 ) : 15 hours
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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 4753.00
2 Pug cutting machine Hour 9.00 13.00 117.00
Fuel / Energy charges Hour 9.00 2.00 18.00
3 Planing machine Hour 48.00 66.00 3168.00
Fuel / Energy charges Hour 48.00 61.00 2928.00
4 Grinding machine Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
5 Drilling machines Hour 1.00 15.00 15.00
Fuel / Energy charges Hour 1.00 20.00 20.00
6 Sundries LS 2.00 22.50 45.00
TOTAL Rs: 12520.00
Add for small Tools and Plants @ 1% Rs: 125.20
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 780.40
Add 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 2052.00
2 Crew for Drilling machine Hour 1.00 35.00 35.00
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ABSTRACT:
A. Cost of Materials Rs: 75597.06
B. Hire charges of Machinery Rs: 14051.60
C. Cost of Labour Rs: 13014.43
Total Rs: 102663.08
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 3653.91
Add for insurance charges @ 1.00% Rs: 1026.63
Add for designs and drawings @ 2.5% Rs: 2566.58
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 2566.58
Add for power supply arrangements @ 2.5% Rs: 2566.58
Add for enabling works @ 2% Rs: 2053.26
Total Rs: 117096.62
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x1.784 tonnes @ Rs: 81.30 / tonne Rs: 290.08
Add 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 vent
including cost of all materials, machinery, labour, cutting, aligning, welding, finishing, cleaning,
applying one coat of zinc rich epoxy primer and three coats of cold applied coal tar epoxy paint,
seal fixing etc., complete as per specifications and approved drawings with all leads and lifts.
DATA: Consider down stream sealing vertical lift roller gate. The gate leaf consists of skin plate,
horizontal girders, vertical end girders, stiffeners, wheels, gate guide rollers, brackets, pins,
seals etc., with all accessories.
Consider canal escape / regulator gate for 2 m x 2 m vent opening for analysis.
Details of material / Gas cutting / Welding considered for rate analysis are based on vertical lift
roller 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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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 : 1.183
The actual weight of canal escape gate as per data sheet : 1.217 tonnes
Consider 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 kg
Plates / 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 kg
MS bolts / nuts / washers with 2.5 % wastage : 4 kg
f. Rubber seal conforming to IS : 11855 :
Bottom seal ( uncladed ) : 2.3 Rm
Side seals ( uncladed ) : 4.0 Rm
Top seal ( uncladed ) : 1.9 Rm
g. Welding electrodes :
Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 67 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 5 Rm
Total : 50 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas manually : 20 m
Length of steel to be cut by gas using pug cutting machine : 30 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour 10 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 10 hours
Acetelyne gas @ 0.6 cum / hour ( 20 x 0.60 ) : 12 cum
Oxygen gas @ 1.8 cum / hour ( 20 x 1.80 ) : 36 cum
Use of gas cutting torch with 50 min / hr working ( 10 x 60 / 50 ) : 12 hours
Use of pug cutting machine with 50 min / hr working ( 10 x 60 / 50 ) : 12 hours
3. Welding :
Length of welding : 94 Rm
For stich welding @ 2 hrs usage / shift & @ 15 electrodes / hr
( 67 / 15 ) x 8 / 2 : 18 hours
For run welding @ 6 hrs usage / shift & @ 15 electrodes / hr
( 605 / 15 ) x 8 / 6 : 54 hours
Total : 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 sqm
1 coat of zinc rich epoxy primer 40 micron dry film each coat.
Quantity of primer paint for 22 sqm @ 9 sqm / ltr / coat : 2.5 ltr
3 coats of coal tar epoxy paint 100 micron dry film each coat.
Quantity of coal tar epoxy paint for 22 sqm @ 6 sqm / ltr / coat : 11 ltr
As surface cleaning by sand blasting is hazardous, it is proposed to adopt chemical treatment
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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 and
stationery 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 / Welder
Erector
Cutting sections / Drilling holes 26 hours 1 3 3 6
Fabricating by stitch welding 18 hours 1 2 --- 4
Run welding 54 hours 1 --- 7 7
Wheel fixing / Seal fixing 1 1 --- 2
Guide 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 cleaner
and wire brushing at 15 sqm / day : 1.5 helper for 22 sqm
For 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 all
taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.
8. Use rate of materials :
Cost of welding set @ Rs: 3375.00 / Each Rs: 3375.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 3.38
Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125
Life of gas cutting set : 600 hours
Use rate of gas cutting set per hr ( cost / life ) Rs: 1.88
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6 Rubber seals
Bottom seal ( uncladed ) Rm 2.30 120.00 276.00
Side seals ( uncladed ) Rm 3.60 190.00 684.00
Top seal ( uncladed ) Rm 1.50 190.00 285.00
Corner seal ( uncladed ) Nos 2.00 240.00 480.00
7 Oxygen gas cum 36.00 40.00 1440.00
8 Acetyline gas cum 12.00 185.00 2220.00
9 Welding electrodes Nos 67.00 4.00 268.00
10 Welding electrodes ( LH ) Nos 605.00 6.00 3630.00
11 Zinc rich epoxy primer ltr 2.50 525.00 1312.50
12 Coal tar epoxy paint ltr 11.00 131.00 1441.00
13 Rust cleaner / inhibitor ltr 3.00 175.00 525.00
14 Use rate welding holder set Hour 72.00 3.38 243.00
15 Use rate gas cutting torch set Hour 12.00 1.88 22.50
16 Wire brush Nos 0.50 25.00 12.50
17 Sundries LS 10.00 22.50 225.00
TOTAL Rs: 51700.50
Add for small Tools and Plants @ 1% Rs: 517.01
Add for Contractor' Profit @ 10% Rs: 5170.05
Add 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 2205.00
2 Pug cutting machine Hour 12.00 13.00 156.00
Fuel / Energy charges Hour 12.00 2.00 24.00
3 Mobile derric crane Hour 2.00 261.00 522.00
Fuel / Energy charges Hour 2.00 117.00 234.00
4 Stationery derric crane Hour 4.00 50.00 200.00
Fuel / Energy charges Hour 4.00 5.00 20.00
5 Grinding machine Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
6 Drilling machines Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
7 Sundries LS 5.00 22.50 112.50
TOTAL Rs: 4261.50
Add for small Tools and Plants @ 1% Rs: 42.62
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 267.55
Add 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 65.80
2 Crew for Drilling machine Hour 2.00 35.00 70.00
3 Crew for Grinding machine Hour 2.00 35.00 70.00
4 Foreman Day 5.00 108.65 543.25
5 Marker / Fabricator / Erector Day 7.00 93.70 655.90
6 Gas cutter Day 3.00 93.70 281.10
7 Welder ( General ) Day 6.00 93.70 562.20
8 Welder ( X - ray grade ) Day 1.00 103.07 103.07
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ABSTRACT:
A. Cost of Materials Rs: 59972.58
B. Hire charges of Machinery Rs: 4784.74
C. Cost of Labour Rs: 6883.58
Total Rs: 71640.90
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 1575.22
Add for insurance charges @ 1.00% Rs: 716.41
Add for designs and drawings @ 2.5% Rs: 1791.02
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 1791.02
Add for power supply arrangements @ 2.5% Rs: 1791.02
Add for enabling works @ 2% Rs: 1432.82
Total Rs: 80738.41
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x1.217 tonnes @ Rs: 81.30 / tonne Rs: 197.88
Add 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 screw
type hoist consisting of supporting structure, platform, ladder etc., with all accessories for
operating canal escape / regulator gate including cost of all materials, machinery, labour,
cutting, aligning, anchoring, welding, finishing, cleaning, applying two coats of zinc chromate
red oxide primer and three coats of approved synthetic enamel paint etc., complete with all
leads and lifts.
DATA: Screw type hoist for operating gate consists of supporting structure, hoist body, hoist stem,
thrust bearings, operating wheel / handle with related accessories.
The capacity of screw hoist for canal gate may be considered at 2.5 times the weight of gate.
Consider screw type hoist for canal escape / regulator gate for vent opening of size 2 m x 2 m.
Details of material / Gas cutting / Welding considered for rate analysis are based on screw type
hoist 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 )^0.659
Where ( 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 : 1.183
Capacity 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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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 49.00 245.00
2 Grinding machine Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
3 Drilling machines Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
4 Sundries LS 2.00 22.50 45.00
TOTAL Rs: 502.00
Add for small Tools and Plants @ 1% Rs: 5.02
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 37.00
Add 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 70.00
2 Crew for Grinding machine Hour 2.00 35.00 70.00
3 Foreman Day 4.00 108.65 434.60
4 Marker / Fabricator / Erector Day 5.00 93.70 468.50
5 Gas cutter Day 2.00 93.70 187.40
6 Welder ( General ) Day 1.00 93.70 93.70
7 Helper fabrication / erection Day 9.00 81.60 734.40
8 Helper for cleaning / painting Day 2.00 81.60 163.20
9 Painter Cl - II Day 4.00 81.60 326.40
10 Electrician Day 0.50 82.65 41.33
TOTAL Rs: 2589.53
Add for small Tools and Plants @ 1% Rs: 25.90
Add for Contractor' Profit @ 10% Rs: 258.95
Add for hidden cost on Labour @ 15% Rs: 388.43
Add for additional hidden cost on labour @ 10% Rs: 258.95
Add for Contrators' Overheads @ 5% Rs: 129.48
Total cost of Labour Rs: 3651.23
ABSTRACT:
A. Cost of Materials Rs: 43934.22
B. Hire charges of Machinery Rs: 569.12
C. Cost of Labour Rs: 3651.23
Total Rs: 48154.57
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 569.75
Add for insurance charges @ 1.00% Rs: 481.55
Add for designs and drawings @ 2.5% Rs: 1203.86
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 1203.86
Add for power supply arrangements @ 2.5% Rs: 1203.86
Add for enabling works @ 2% Rs: 963.09
Total Rs: 53780.54
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SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 30
ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sill
beam, wheel tracks, seal tracks, guide rails, gate groove liners etc., with all accessories for
canal escape / regulator stoplog gate including cost of all materials, machinery, labour,
aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer
and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and
approved drawings with all leads and lifts.
DATA: Embedded parts for canal escape / regulator stop log gate consist of sill beam, wheel / seal
tracks, groove lining upto top, gate guide with all accessories such as first stage anchors.
Weight of embedded parts for such small gates will be in the range of 65 to 70 % of gate weight.
Consider embedded parts for canal escape / regulator stoplog gate for 2 m x 2 m vent opening.
Details of material / Gas cutting / Welding considered for rate analysis are based on embedded
parts 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 m
Head of water above sill level : 3.70 m
Weight of embedded parts in tonnes = 0.0665 x ( L^2 x H x h )^0.716
Where ( L ) is length and ( H ) is total height and ( h ) is head of water in metres.
= 0.0665 x ( 2.5 x 2.5 x 4 x 3.7 ) ^ 0.716 : 1.701
The actual weight of embedded parts as per data sheet : 1.685 tonnes
Consider 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 kg
Structural steel plates / flats with 2.5 % wastage : 523 kg
Alloy steel components conforming to IS : 1570 :
Stainless steel plates / flats : 68.00 kg
Bolt / Nut / Washer conforming to IS : 1363 :
MS bolts and nuts with 2.5 % wastage : 1 kg
Welding electrodes :
Welding electrodes for stitch welding at 10 % of total with 2.5 % wastage : 116 Nos
Welding electrodes (SS) for stitch welding at 10 % of total with 2.5 % wastage : 21 Nos
Welding electrodes ( LH ) for run welding at 90 % of total with 2.5 % wastage : 1042 Nos
Welding 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 Rm
Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 4 Rm
Total : 41 Rm
For cutting structural steel sections to required sizes gas cutting is assumed.
Length of steel to be cut by using gas manually : 20 m
Length of steel to be cut by gas using pug cutting machine : 21 m
Time for gas cutting manually assuming average cutting progress of 2 m / hour : 10 hours
Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 7 hours
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Use rate of welding set per hour ( cost / life ) Rs: 3.38
Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125
Life of gas cutting set : 600 hours
Use rate of gas cutting set per hr ( cost / life ) Rs: 1.88
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 4459.00
2 Pug cutting machine Hour 8.00 13.00 104.00
Fuel / Energy charges Hour 8.00 2.00 16.00
3 Planing machine Hour 44.00 66.00 2904.00
Fuel / Energy charges Hour 44.00 61.00 2684.00
4 Grinding machine Hour 2.00 15.00 30.00
Fuel / Energy charges Hour 2.00 20.00 40.00
5 Sundries LS 2.00 22.50 45.00
TOTAL Rs: 11596.00
Add for small Tools and Plants @ 1% Rs: 115.96
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 724.40
Add 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 1881.00
2 Crew for Grinding machine Hour 2.00 35.00 70.00
3 Foreman Day 6.00 108.65 651.90
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ABSTRACT:
A. Cost of Materials Rs: 70306.15
B. Hire charges of Machinery Rs: 13016.16
C. Cost of Labour Rs: 11620.22
Total Rs: 94942.53
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 3325.91
Add for insurance charges @ 1.00% Rs: 949.43
Add for designs and drawings @ 2.5% Rs: 2373.56
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 2373.56
Add for power supply arrangements @ 2.5% Rs: 2373.56
Add for enabling works @ 2% Rs: 1898.85
Total Rs: 108237.41
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x1.685 tonnes @ Rs: 81.30 / tonne Rs: 273.98
Add 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 gate
elements 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. Each
element 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 log
elements 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 )^0.716
Where ( 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 : 2.544
The actual weight of 1 set ( 4 elements ) of stoplog elements as per data sheet: 2.534 tonnes
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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 / Welder
Erector
Cutting sections 38 hours 2 5 5 10
Drilling holes 8 hours 1 1 --- 1
Fabricating by stitch welding 43 hours 3 5 --- 10
Run welding 128 hours 2 --- 16 16
Slide blocks fixing / Seal fixing 1 2 --- 2
Guide 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 cleaner
and wire brushing at 15 sqm / day : 3 helper for 45 sqm
For 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 all
taxes/ duties. Therefore, for purpose of rate analysis 75 percent of total cost excluding the cost
of materials ( assuming 25 % erection cost ) is considered for assessing excise duty.
8. Use rate of materials :
Cost of welding set @ Rs: 3375.00 / Each Rs: 3375.00
Life of welding set : 1000 hours
Use rate of welding set per hour ( cost / life ) Rs: 3.38
Cost of gas cutting set @ Rs: 1125.00 / Each Rs: 1125
Life of gas cutting set : 600 hours
Use rate of gas cutting set per hr ( cost / life ) Rs: 1.88
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13 Use rate gas cutting torch set Hour 24.00 1.88 45.00
14 Wire brush Nos 1.00 25.00 25.00
15 Sundries LS 20.00 22.50 450.00
TOTAL Rs: 89933.63
Add for small Tools and Plants @ 1% Rs: 899.34
Add for Contractor' Profit @ 10% Rs: 8993.36
Add 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 5243.00
2 Pug cutting machine Hour 14.00 13.00 182.00
Fuel / Energy charges Hour 14.00 2.00 28.00
3 Mobile derric crane Hour 2.00 261.00 522.00
Fuel / Energy charges Hour 2.00 117.00 234.00
4 Stationery derric crane Hour 4.00 50.00 200.00
Fuel / Energy charges Hour 4.00 5.00 20.00
5 Grinding machine Hour 8.00 15.00 120.00
Fuel / Energy charges Hour 8.00 20.00 160.00
6 Drilling machines Hour 8.00 15.00 120.00
Fuel / Energy charges Hour 8.00 20.00 160.00
7 Sundries LS 10.00 22.50 225.00
TOTAL Rs: 8753.00
Add for small Tools and Plants @ 1% Rs: 87.53
Add for Contractor' Profit on DPOL / Energy @ 10% Rs: 607.00
Add 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 65.80
2 Crew for Drilling machine Hour 8.00 35.00 280.00
3 Crew for Grinding machine Hour 8.00 35.00 280.00
4 Foreman Day 10.00 108.65 1086.50
5 Marker / Fabricator / Erector Day 14.00 93.70 1311.80
6 Gas cutter Day 5.00 93.70 468.50
7 Welder ( General ) Day 14.00 93.70 1311.80
8 Welder ( X - ray grade ) Day 2.00 103.07 206.14
9 Helper fabrication / erection Day 41.00 81.60 3345.60
10 Helper for cleaning / painting Day 6.00 81.60 489.60
11 Painter Cl - II Day 12.00 81.60 979.20
12 Electrician Day 1.00 82.65 82.65
TOTAL Rs: 9907.59
Add for small Tools and Plants @ 1% Rs: 99.08
Add for Contractor' Profit @ 10% Rs: 990.76
Add for hidden cost on Labour @ 15% Rs: 1486.14
Add for additional hidden cost on labour @ 10% Rs: 990.76
Add for Contrators' Overheads @ 5% Rs: 495.38
Total cost of Labour Rs: 13969.70
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ABSTRACT:
A. Cost of Materials Rs: 104323.01
B. Hire charges of Machinery Rs: 9885.18
C. Cost of Labour Rs: 13969.70
Total Rs: 128177.89
Add for excise duty on 75 percent cost
excluding cost of materials @ 18.00% Rs: 3220.41
Add for insurance charges @ 1.00% Rs: 1281.78
Add for designs and drawings @ 2.5% Rs: 3204.45
Add for zigs / supports / winches / chain-pulley @ 2.5% Rs: 3204.45
Add for power supply arrangements @ 2.5% Rs: 3204.45
Add for enabling works @ 2% Rs: 2563.56
Total Rs: 144856.97
Add for 2 rehandling leads for 1 km including loading and unloading :
Fabricated parts 2x2.534 tonnes @ Rs: 81.30 / tonne Rs: 412.03
Add 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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ANNEXER
TO
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117 Flange plate 300x14840x16 mm 1 No. 559.00 15.2 ( F10 ) 29.7 683
118 Flange plate 240x12888x16 mm 1 No. 389.00 13.2 ( F10 ) 25.8 594
119 Flange plate 240x1000x16 mm 2 Nos 60.00 2.5 ( F10 ) 4.5 104
120 Flange plate 280x2280x10 mm 2 Nos 100.00 5.1 10.3 83
121 Stiffener 115x800x10 mm 6 Nos 43.00 5.5 12.4 100
122 Stiffener 115x840x16 mm 8 Nos 97.00 7.7 17.1 137
123 Stiffener 120x895x10 mm 2 Nos 17.00 2.1 4.6 37
124 Stiffener 120x1020x10 mm 2 Nos 19.00 2.3 5.0 40
125 Stiffener 100x600x10 mm 4 Nos 19.00 2.8 6.4 52
126 Stiffener 300x300x10 mm 4 Nos 28.00 2.4 4.8 39
127 Bracing L 110x110x8 - 4560 mm 2 Nos 122.00 0.5 1.4 12
128 Bracing L 110x110x8 - 2360 mm 2 Nos 63.00 0.5 1.4 12
129 Bracing L 110x110x8 - 2041 mm 2 Nos 54.00 0.5 1.4 12
130 Bracing L 110x110x8 - 3879 mm 2 Nos 104.00 0.5 1.4 12
131 Bracing L 110x110x8 - 1968 mm 2 Nos 53.00 0.5 1.4 12
132 Bracing L 110x110x8 - 1608 mm 2 Nos 43.00 0.5 1.4 12
133 Bracing L 130x130x8 - 5575 mm 2 Nos 177.00 0.5 1.8 15
134 Bracing L 130x130x8 - 2798 mm 2 Nos 88.00 0.5 1.8 15
135 Bracing L 130x130x8 - 2638 mm 2 Nos 83.00 0.5 1.8 15
136 Bracing L 130x130x8 - 4968 mm 2 Nos 158.00 0.5 1.8 15
137 Bracing L 130x130x8 - 2395 mm 2 Nos 76.00 0.5 1.8 15
138 Bracing L 130x130x8 - 2255 mm 2 Nos 72.00 0.5 1.8 15
139 Bracing L 110x110x8 - 3210 mm 5 Nos 215.00 1.2 3.5 28
140 Bracing L 110x110x8 - 3970 mm 5 Nos 266.00 1.2 3.5 28
141 Bracing L 75x75x8 - 1200 mm 5 Nos 53.00 0.8 2.5 20
142 Bracing L 75x75x8 - 1986 mm 10 Nos 177.00 1.5 5.0 40
143 Bracing L 75x75x8 - 1100 mm 5 Nos 49.00 0.8 2.5 20
144 Bracing L 75x75x8 - 2390 mm 10 Nos 213.00 1.5 5.0 40
145 Gusset pl 180x500x10 mm 5 Nos 35.00 3.4 2.5 38
146 Gusset pl 180x440x10 mm 5 Nos 31.00 3.1 2.2 35
147 Gusset pl 180x570x10 mm 2 Nos 16.00 1.5 1.2 18
148 Gusset pl 200x700x10 mm 1 No. 11.00 0.9 0.7 11
149 Gusset pl 210x700x10 mm 2 Nos 23.00 1.8 1.4 23
150 Gusset pl 180x730x10 mm 2 Nos 21.00 1.9 1.5 24
151 Gusset pl 230x420x10 mm 2 Nos 15.00 1.3 0.9 14
152 Gusset pl 230x400x10 mm 2 Nos 15.00 1.3 0.9 14
153 Gusset pl 230x330x10 mm 2 Nos 12.00 1.2 0.7 11
154 Gusset pl 230x460x10 mm 2 Nos 17.00 1.5 0.9 14
155 Gusset pl 240x460x10 mm 2 Nos 17.00 1.6 0.9 14
156 Gusset pl 200x500x10 mm 4 Nos 31.00 3.0 2.4 39
157 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 8.9 204
159 Skin plate 2100x1600x12 mm 2 Nos 633.00 4.2 6.8 156
160 Skin plate 2400x1800x12 mm 2 Nos 814.00 4.8 7.7 177
161 Skin plate 2980x8415x10 mm 2 Nos 3937.00 6.0 19.6 313
162 Skin plate 2100x9076x10 mm 2 Nos 2992.00 4.2 18.9 302
163 Skin plate 2400x8876x10 mm 2 Nos 3345.00 4.8 19.1 306
164 Stiffener 1/2 ISMB 350-10155 mm 14 Nos 3725.00 71.0 284.0 2272
165 Stiffener 1/2 ISMB 350-10646 mm 22 Nos 6136.00 117.0 468.4 3748
166 Web plate 158x10215x10 mm 2 Nos 253.00 20.8 40.9 327
167 Flange 100x10015x12 mm 2 Nos 189.00 0.2 20.0 160
168 Seal base 25x2980x16 mm 2 Nos 19.00 0.1 11.9 248
169 Seal base 25x2100x16 mm 2 Nos 13.00 0.1 8.4 177
170 Seal base 25x2400x16 mm 2 Nos 15.00 0.1 9.6 202
171 Back strip 40x10215x6 mm 5 Nos 96.00 0.2 102.0 816
133
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137
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138
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139
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kg Rm Rm Nos
ABSTRACT :( For 8 Elements )
1. Structural steel : IS : 2062
Angles / Beams / Channels : 461.00 kg
Plates / Flats : 70208.00 kg
2. Alloy steel components : IS : 1570
Pin : 104.00 kg
3. Alluminium / Bronze alloy components : IS : 305
Bronze pads : 48.00 kg
4. Bolt / Nut / Washer : IS : 1363
GI Bolts / Nuts / Washers : 288.00 kg
MS Bolts / Nuts / Washers : 48.00 kg
5. Rubber seal : IS : 11855
Bottom seal ( uncladed ) : 120.00 Rm
Side seal ( uncladed ) : 19.20 Rm
6. Other details :
Length of cutting : 979.60 Rm
Length of welding : 3228.20 Rm
Number of electrodes : 26976 Nos
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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 120.00
191 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 31
202 Plate 50x210x10 mm 1 No. 1.00 --- --- ---
203 ISA 75x75x6 x 75 mm 2 Nos 1.00 0.3 0.6 5
204 Plate 232/126x 950x3 mm 2 Nos 10.00 2.0 2.0 16
205 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 15
216 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 16
225 ISA 60x60x6 mm Hand railing 12 Rm 64.00 1.5 2.5 20
226 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
146
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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 45
2 Anchor bar 12 dia x 350 mm 56 Nos 18.00 0.7 1.0 17
3 Anchor plate 100x180x10 mm 24 Nos 34.00 6.7 4.8 38
4 Anchor bar 12 dia x 350 mm 48 Nos 15.00 0.6 1.8 15
5 Anchor plate 80x515x8 mm 10 Nos 26.00 6.0 3.6 29
6 Anchor bar 12 dia x 350 mm 20 Nos 6.00 0.3 0.8 6
7 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 12
9 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 14
11 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 19
14 Anchor bolt 16 dia x 200 mm 8 Nos 2.00 0.1 0.4 3
15 Anchor bolt 16 dia x 185 mm 20 Nos 6.00 0.3 1.0 8
16 Anchor bolt 16 dia x 500 mm 24 Nos 18.00 0.4 1.2 10
17 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 29
21 Nut / Washer for anchor bolts 200 Nos 10.00 --- --- ---
22 SS track 115x6750x10 mm 2 Nos 122.00 13.7 27.5 220
23 Track base 130x7100x12 mm 2 Nos 174.00 14.5 28.4 227
24 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 23
27 SS seal seat 80x3035x5 mm 2 Nos. 19.00 6.3 ( F4 ) 12.2 61
28 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 37
30 SS seal seat 1680x1975xx5 mm 1 No. 130.00 3.7 ( F4 ) 7.3 37
148
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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 98
3 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 29
7 Liner plate 666x3550x20 mm 1 No. 371.00 4.2 --- ---
10 Stiffener 220x3520x10 mm 1 Nos 61.00 3.8 7.0 56
11 Stiffener 120x3520x10 mm 1 Nos 33.00 3.7 7.0 56
13 Stiffener 155x420x8 mm 3 Nos 12.00 1.7 4.4 36
15 Cleat ISA 75x75x8 x 80 mm 44 Nos 31.00 6.6 8.3 67
16 SS B/W seat 1300x2720x6 mm 1 No. 167.00 4.0 ( F4 ) 8.0 40
17 SS B/W seat 1976x2720x6 mm 1 No. 253.00 4.7 ( F4 ) 9.4 47
18 Base plate 2000x2750x20 mm 1 No. 864.00 4.8 ( DV ) 2.8 87
19 base plate 2000x3640x20 mm 1 No. 1143.00 5.7 --- ---
20 Bottom liner Gr 484x2600x20 mm 1 No. 198.00 3.1 5.2 42
21 Stiffener 180x1898x10 mm 7 Nos 188.00 14.5 26.6 213
22 Stiffener 180x1960x10 mm 7 Nos 194.00 15.0 27.4 220
23 Stiffener 100x2570x10 mm 1 No. 20.00 0.1 5.2 42
24 Stiffener 100x410x10 mm 30 Nos 97.00 3.0 36.6 293
25 SS track plate 150x3000x20 mm 2 Nos 141.00 6.3 ( F8 ) 12.3 185
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150
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ABSTRACT :
1. Structural steel : IS : 2062
Angle / Channel / Beam / Bars : 681.00 kg
Plates / Flats : 8971.00 kg
2. Alloy steel components : IS : 1570
Stainless steel plates : 825.00 kg
3. Bolt / Nut / Washer : IS : 1363
MS Bolt / Nut / Washer : 180.00 kg
4. Other details :
Length of cutting : 301.00 Rm
Length of welding : 552 Rm
Number of electrodes ( str steel ) : 4596 Nos
Number of electrodes ( stainless steel ) : 624 Nos
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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 39
8 Stiffener 95x160x10 mm 8 Nos 10.00 2.0 4.1 33
9 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 9
11 Stiffener 120x399x10 mm 2 Nos 8.00 1.1 2.1 17
12 Base plate 110x430x10 mm 2 Nos 8.00 1.0 1.2 10
13 ISMC 400 x 110 mm 2 Nos 14.00 1.2 0.5 4
14 Base plate 336x340x10 mm 1 No. 9.00 0.7 0.5 4
15 Base plate 160x390x10 mm 1 No. 5.00 0.6 0.5 4
16 Base plate 210x300x10 mm 1 No. 5.00 0.5 0.5 4
17 Cleat ISA 50x50x6 x 150 mm 36 Nos 22.00 3.6 18.0 144
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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 45
2 Anchor bar 12 dia x 350 mm 56 Nos 18.00 0.7 1.0 17
3 Anchor plate 100x180x10 mm 40 Nos 56.00 11.1 8.0 64
4 Anchor bar 12 dia x 350 mm 48 Nos 15.00 0.6 1.8 15
5 Anchor plate 80x515x8 mm 10 Nos 26.00 6.0 3.6 29
6 Anchor bar 12 dia x 350 mm 36 Nos 11.00 0.5 1.4 11
7 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 12
9 Anchor plate 80x150x10 mm 24 Nos 23.00 1.9 --- ---
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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
156
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157
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158
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159
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160
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161
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ABSTRACT :
1. Structural steel : IS : 2062
Angles / Beams / Channels / Bars : 588.00 kg
Structural steel Plates / Flats : 3685.00 kg
2. Alloy steel components : IS : 1570
Stainless steel plates / flats for track : 620.00 kg
Stainless steel plates / flats for seal seat 133.00 kg
3. Bolt / Nut / Washer : IS : 1363
MS Bolts / Nuts / Washers : 167.00 kg
4. Other details :
Length of cutting : 210.00 Rm
Length of welding : 251.40 Rm
Number of electrodes ( str steel ) : 6486 Nos
Number of electrodes ( SS for wheel track ) 748 Nos
Number of electrodes ( SS for seal seat ) 395 Nos
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164
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165
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ABSTRACT :
1. Structural steel : IS : 2062
Angles / Beams / Channels / Bars : 4453.00 kg
Structural steel Plates / Flats : 5431.00 kg
Chequered plate 133.00 kg
2 Bolt / Nut / Washer : IS : 1363
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169
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172
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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 6
2 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 11
6 ISMC- 150 x 500 mm 2 Nos 17.00 0.6 2.4 14
7 ISMC- 150 x 1990 mm 2 Nos 61.00 0.6 2.4 14
8 ISMC- 250 x 790 mm 2 Nos 54.00 0.8 4.0 24
9 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 48
11 MS pipe 32 dia x 5250 mm 2 Nos 42.00 --- 0.5 3
12 Flat 50x3100x8 mm 2 Nos 20.00 0.1 0.8 5
13 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 86
15 Bolt/Nut/Washer 12 diax50 mm 12 Nos 2.00 --- --- ---
16 Rib plate 200x250x10 mm 6 Nos 14.00 2.7 4.6 28
17 Chequered pl 400x687x6 mm 2 Nos 29.00 2.2 2.2 13
18 Chequered pl 525x1935x6 mm 2 Nos 109.00 4.9 4.9 29
19 Chequered pl 247x560x6 mm 1 No. 7.00 0.8 0.8 5
20 Chequered pl 587x630x6 mm 2 Nos 40.00 2.4 2.4 14
21 Chequered pl 162x560x6 mm 1 No. 5.00 0.8 0.8 5
22 Plate 250x350x16 mm 4 Nos 44.00 2.4 3.2 19
23 R/F plate 120/62 dia x 8 mm 4 Nos 1.00 2.3 1.5 9
24 Plate 120x470x20 mm 2 Nos 18.00 1.2 0.8 5
25 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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Length of cutting : 73 Rm
Length of welding : 113 Rm
Number of electrodes : 674 Nos
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4. Other details :
Length of cutting : 39.90 Rm
Length of welding : 206.50 Rm
Number of electrodes ( structural steel ) : 1186 Nos
Number of electrodes ( stainless steel ) : 227 Nos
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180
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181
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ABSTRACT :
1. Structural steel : IS : 2062
Angle / Channel / Beam / Bars : 1106.50 kg
Plates / Flats : 510.00 kg
2. Alloy steel components : IS : 1570
Stainless steel plates : 68.00 kg
3. Other details :
Length of cutting : 36.40 Rm
Length of welding : 195.00 Rm
Number of electrodes ( str steel ) : 1131 Nos
Number of electrodes ( stainless steel ) 206 Nos
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ABSTRACT :
1. Structural steel : IS :2062
Angle / Channel / Beam / Bars : 1154.00 kg
Plates / Flats : 1342.00 kg
2. Alloy steel components : IS : 1570
Hook pins : 12.00 kg
3. Rubber seal : IS : 11855
Bottom rubber seal ( uncladded ) : 8.00 Rm
Side rubber seal ( uncladded ) : 8.04 Rm
4. Bolt / Nut / Washer : IS :1363
GI Bolt / Nut / Washer : 20.00 kg
MS Bolt / Nut / Washer : 6.00 kg
5. Other details :
Length of cutting : 69.60 Rm
Length of welding : 215.60 Rm
Number of electrodes 4x450 mm : 1564 Nos
183