Renewal of Spillway Vertical Shutters, River sluice shutters and Canal Sluice Shutter of Palar Porundalar Dam in Balasamuthiram Village of Palani Taluk in Dindigul District

Amount

Repair and service to Porundalar Spillway vertical shutter of size 9.75m x 6.70 m - Repairs and Services to 4.00 Nos of roller guide channel of size ISMC 400 x 100 x 6700 mm, 12.00 Nos of brazing channel of size ISMC 125 x 75 x 6700 mm, 8.00 Nos of skin plate channel of size ISMC 125 x 75 x 9750 mm. Repairs and service to Hoisting drum, Gear box service, Gear box oil replacing, oil seal changing and brake repairs. Repairs and Services to the alignment of gear wheel, crank shaft, operating platform and Electric motor unit. Radicon arm pinion joint oil changing. Repairs and services to chain end connection at shutter end and chain drum end. Repair and services to shutter supporting structures such as stiffeners, beams, channels, bracings and angles etc., Replacement of bottom flat rubber seal with new flat rubber seal of size 100 x 12 mm and vertical pipe seals with new pipe seal of size 2 3/4 “ dia including new bolts and nuts with suitable washer, existing counter weight shall be replaced with new counter weights. Repair and replacing the damaged portions of ladder with new ladders and services of electrical wiring and flood warning siren. Repairs, Patch works, corroded sheets and angles replacing with GI sheet to dust proof cover of chain and gear box assembly, motor and chain guards. Platform lifting chequered plates should be welded.

Existing drain holes should be cleaned and new Drain holes (12 to 25mm dia) to be provided in platform chequered plate and in shutter and members to avoid water stagnation as per the instructions of departmental engineers. The welding shall be done as per standard procedures and the burr and slag shall be removed by grinding the top of welds. A good weld is as strong as the base metal. A suitable electrode shall be chosen and welded with good welding equipment with trained welder. All non - metallic substances shall be removed in the weld joints before commencement of welding. After welding, a thorough visual inspection shall be done for porosity, blowholes, unfused welds, unfilled craters, under cutting, burning & poor weld appearance, etc. ., Including scrubbing of old paint and application of a primary coat to protect the steel structure from highly abrasive, erosive and corrosive environments. After surface preparation, a primer coat with epoxy primer shall be applied. The mixing ratio of base to accelerator by volume should be according to the manufacturers standard. All paint, when applied, shall provide a satisfactory film and a smooth and even surface. Paint shall be thoroughly stirred, strained, and kept at the uniform consistency during application. Paint shall not be applied when the temperature of the metal or surrounding air is below 10 degree Celsius

and that of the metal is above 50 degrees Celsius, or when the humidity is above 90 percent, or when it threatens to rain before the painted coat gets dry. Primer coat shall be protected during the initial curing period against the possibility of moisture condensation or contamination with foreign matter. The paint shall be applied so that the thickness at any point is not less than that stipulated in the approved painting specifications. Surface not required to be coated, but adjacent to surfaces which are to be cleaned and coated, shall be adequately protected during cleaning and coating. Repairs to damaged areas of the coating shall be carried out strictly in accordance with the approved painting specifications. Because of the flammable and toxic nature of the coating materials, precautions should be taken to eliminate any health or safety hazard that may arise during the application of the coating. Conducting the following minimum quality tests as per approved QAP at various stages of work to ensure raw materials and its fabrication are free from defects as per industry standards and maintenance of records at all stages for assurance of quality. The manufacturer test certificate shall be furnished for with rubber seals tested with physical properties such as Hardness, Elongation, Tensile strength, Tensile test after ageing.

Test as per IS 11855 : 2004 and IS 15466 : 2004. All raw materials are 100% dimensional checked and verified in accordance with manufacturer test certificate. The temporary scaffolding for repair and welding work shall be erected and dismantled after completion of work.After completion of above work a satisfactor 2/7 trial run should be shown to the departmental Engineers. All materials and works should be as per IS specification. The cost includes cost all materials, labour charges, hire charges for generator, compressor, hopper, accessories, conveyance of machinery to & fro from site of work, inspection charges, loading and unloading charges, scaffolding charges, lathing, drilling, welding, gas cutting, grease packing, lubricating oil, all civil works, and consumables like oil & diesel for generator, risk allowance, etc, handing over of all old materials removed from this work to dam officials, complete as directed by the departmental officers.

Repair and service to Palar Spillway vertical shutter of size 8.53m x 6.70 m - Repairs and Services to 4.00 Nos of roller guide channel of size ISMC 400 x 100 x 6700 mm, 12.00 Nos of brazing channel of size ISMC 125 x 75 x 6700 mm, 8.00 Nos of skin plate channel of size ISMC 125 x 75 x 8530 mm. Repairs and service to Hoisting drum, Gear box service, Gear box oil replacing, oil seal changing and brake repairs. Repairs and Services to the alignment of gear wheel, crank shaft, operating platform and Electric motor unit. Radicon arm pinion joint oil changing. Repairs and services to chain end connection at shutter end and chain drum end. Repair and services to shutter supporting structures such as ISMB 250, ISMC 150, roller guided channel and backside bottom stiffeners of 12mm plate, vertical stiffeners on roller side channels if size of ISMC 300 and bracings of size ISA 75 x 75 x 8 mm including all stiffeners, beams, channels, bracings and angles etc., Replacement of bottom flat rubber seal with new flat rubber seal of size 100 x 12 mm and vertical pipe seals with new pipe seal of size 2 3/4 “ dia including new bolts and nuts with suitable washer, existing counter weight shall be replaced with new counter weights. Repair and replacing the damaged portions of ladder with new ladders and services of electrical wiring and flood warning siren

Repairs, Patch works, corroded sheets and angles replacing with GI sheet to dust proof cover of chain and gear box assembly, motor and chain guards. Platform lifting chequered plates should be welded. Existing drain holes should be cleaned and new Drain holes (12 to 25mm dia) to be provided in platform chequered plate and in shutter and members to avoid water stagnation as per the instructions of departmental engineers. The welding shall be done as per standard procedures and the burr and slag shall be removed by grinding the top of welds. A good weld is as strong as the base metal. A suitable electrode shall be chosen and welded with good welding equipment with a trained welder. All non - metallic substances shall be removed in the weld joints before commencement of welding. After welding, a thorough visual inspection shall be done for porosity, blowholes, unfused welds, unfilled craters, under cutting, burning & poor weld appearance, etc. ., Including scrubbing of old paint and application of a primary coat to protect the steel structure from highly abrasive, erosive and corrosive environments. After surface preparation, a primer coat with epoxy primer shall be applied. The mixing ratio of base to accelerator by volume should be according to the manufacturers standard. All paint, when applied, shall provide a satisfactory film and a smooth and even surface.

Paint shall be thoroughly stirred, strained, and kept at the uniform consistency during application. Paint shall not be applied when the temperature of the metal or surrounding air is below 10 degree Celsius and that of the metal is above 50 degrees Celsius, or when the humidity is above 90 percent, or when it threatens to rain before the painted coat gets dry. Primer coat shall be protected during the initial curing period against the possibility of moisture condensation or contamination with foreign matter. The paint shall be applied so that the thickness at any point is not less than that stipulated in the approved painting specifications. Surface not required to be coated, but adjacent to surfaces which are to be cleaned and coated, shall be adequately protected during cleaning and coating. Repairs to damaged areas of the coating shall be carried out strictly in accordance with the approved painting specifications. Because of the flammable and toxic nature of the coating materials, precautions should be taken to eliminate any health or safety hazard that may arise during the application of the coating. Conducting the following minimum quality tests as per approved QAP at various stages of work to ensure raw materials and its fabrication are free from defects as per industry standards and maintenance of records at all stages for assurance of quality.

The manufacturer test certificate shall be furnished for with rubber seals tested with physical properties such as Hardness, Elongation, Tensile strength, Tensile test after ageing. Test as per IS 11855 : 2004 and IS 15466 : 2004. All raw materials are 100% dimensional checked and verified in accordance with manufacturer test certificate. The temporary scaffolding for repair and welding work shall be erected and dismantled after completion of work.After completion of above work a satisfactor 2/7 trial run should be shown to the departmental Engineers. All materials and works should be as per IS specification. The cost includes cost all materials, labour charges, hire charges for generator, compressor, hopper, accessories, conveyance of machinery to & fro from site of work, inspection charges, loading and unloading charges, scaffolding charges, lathing, drilling, welding, gas cutting, grease packing, lubricating oil, all civil works, and consumables like oil & diesel for generator, risk allowance, etc, handing over of all old materials removed from this work to dam officials, complete as directed by the departmental officers.

Repairs and Services to Palar & Porundalar River Sluice shutter of size 1.52 m X 1.83 m - Repairs to all embedded parts, rubber seal ,bed channel, replacing 3 level suspension channel 4.5m long 2 Nos. per each level, repairs to guide angles, repair and replacing the damaged portions of ladder with new ladder, and change of all MS flats, bolts, MS bolt-nuts-washer. After removal of old MS flats for rubber seal arrangements, surfaces of the flats and skin plate contact surface with bottom seal to be cleaned using buffing machine, painted with zinc rich primer (85% ±5% zinc content) 2 coats and epoxy coal tar paint two coats before re-fixing the same with new rubber seals. Repairs and service of gear box, screw rod, hoist bed arrangement, electric motor,

Rubber seal, bolts, nuts and joints and electrical wiring arrangements, motor shaft, grooves, operating platform, platform chequerred plate, ensuring ease operation on both manual and electrical. Strengthening of shutter frames by providing additional MS plate stiffeners in corroded members by welding and facing etc... Servicing the manual operation system, worm box, gear arrangement, repairs, welding and surface facing by buffing and grinding machines to embedded groove frames, sill beam top, seal track and roller track.Repairs to the joints connecting to shutter and screw rod assembly. Repairs to the platforms inside the sluice well and ensuring ease of operation on both manual and electrical and providing remote to operate the shutters, cleaning of drain holes and provide new drain holes of 12mm to 25mm dia as per the instructions of departmental engineers.

The rate is inclusive of dismantling the existing completely removing by gas cutting the bolts and Nuts lifting the Gate assembly. Including scrubbing of old paint of shutter, groove frames etc., should be painted with zinc rich primer (85% ±5% zinc content) of 2 coats and epoxy coal tar paint of two coats after thorough cleaning by hand tools and power tools (buffing machine, etc.). Repairs to groove open covering chequered plates. Labour charges including lathing, drilling. welding, gas cutting, musical node rubber seal, flat rubber seal, corner seals and also inclusive of all bolt and nuts, all material conveyance to this site, loading and unloading charges, grease packing, lubricating oil, all civil works and trial run satisfactorily, handing over of all old materials removed from this work to dam officials, etc., complete as directed by the Departmental Officers. All materials and works should be as per IS specification.

Renewal, Repairs and Services to Tadakulam Canal Sluice shutter of size 1.52m X 1.83 m of thickness 16 mm - Renewal for Skin plate, bed channel, 2 Nos of level 3 suspension channel of length 4.5m each. Renewal of existing angles, channels, vertical stiffeners, horizontal stiffeners and providing flate rubber seal at bottom and musical rubber seal in vertical sides. Repairs and services to 2.00 Nos of 2.50 m long bed channels of size ISMC 150 x 75 mm and 2.00 Nos of suspension channels of size ISMC 125 x 65 mm. Repairs to guide angles, repair and replacing the damaged portions of ladder with new ladder, repairs and services to worm box, screw rod, hoist bed arrangement, electric motor, Rubber seal, bolts, nuts and joints and electrical wiring arrangements, motor shaft, grooves, operating platform, platform chequerred plate, ensuring ease operation on both manual and electrical. And Including scrubbing of old paint of shutter, groove frames etc., should be painted with zinc rich primer (85% ±5% zinc content) of 2 coats and epoxy coal tar paint of two coats after thorough cleaning by hand tools and

power tools (buffing machine, etc.). Labour charges including lathing, drilling. welding, gas cutting, musical node rubber seal, flat rubber seal, corner seals and also inclusive of all bolt and nuts, all material conveyance to this site, loading and unloading charges, grease packing, lubricating oil, all civil works and trial run satisfactorily, handing over of all old materials removed from this work to dam officials, etc., complete as directed by the Departmental Officers. All materials and works should be as per IS specification.

Repairs and Services to Left Main Canal Sluice shutter of size 1.52 m X 1.83 m - Repairs to bed channel, replacing 3 level suspension channel 4.5m long 2 Nos. per each level, repairs to guide angles, repair and replacing the damaged portions of ladder with new ladder. Repairs and service of gear box, screw rod, hoist bed arrangement, electric motor, Rubber seal, bolts, nuts and joints and electrical wiring arrangements, motor shaft, grooves, operating platform, platform chequerred plate, ensuring ease operation on both manual and electrical. And Including scrubbing of old paint of shutter, groove frames etc., should be painted with zinc rich primer (85% ±5% zinc content) of 2 coats and epoxy coal tar paint of two coats after thorough cleaning by hand tools and power tools (buffing machine, etc.). Labour charges including lathing, drilling. welding, gas cutting, musical node rubber seal, flat rubber seal, corner seals and also inclusive of all bolt and nuts, all material conveyance to this site, loading and unloading charges, grease packing, lubricating oil, all civil works and trial run satisfactorily, handing over of all old materials removed from this work to dam officials, etc., complete as directed by the Departmental Officers. All materials and works should be as per IS specification.l

MMM CONSTRUCTIONS (BID ID -1171191)