Renewal of spillway Radial shutters, River sluice Shutters and sluice shutter of Kuthiraiyar Dam in Andipatti Village of Palani Taluk in Dindigul District

Amount

Repair and Service to the Spillway Radial shutter of size 10.00 x 4.50 m Repair and services to, all connection joints and bolts of anchoring joints, end arms, bracings, trunnion pin, radial arm, girders, hoist drums, plummer blocks, open drive gears, hand operating chains, motor shaft, damaged wire rope shall be replaced with new wire rope and applying carlium components to the ropes, stop logs, including all electrical works, flood warning siren, replacing breaking shoe arrangements, and the corroded vertical stiffeners shall be replaced with new vertical stiffeners of required length, ensuring ease of operation on both manual and electrical and providing remote to operate the shutters, lubricating threads, repairs to ladders and damaged ladders shall be replaced with the new ladders etc., Change of flat rubber seal of size 100 x 12mm for bottom, change of MS flat, all MS bolt-nuts-washers for bottom rubber seal. After removal of old MS flats for rubber seal arrangements, surfaces of the new MS flat, skin plate contact surface with bottom seal, to be cleaned using grinding and buffing machines, painted with zinc rich primer (85% ±5% zinc content) of 2 coats and epoxy coal tar paint of two coats before fixing with new rubber seals. Renewal of vertical side musical node rubber seal with new musical node rubber seal of size 105 x 40x 20 mm on both sides.

Servicing and repairs to hoisting arrangement - gear box service, change of gear box oil, oil seal changing and break repairs. Service and repairs to manual operation. Checking and correcting alignment of motor, gear box, gear wheel, shaft, pinion wheels, chain sprocket wheels and chain assembly. Repairs to broken teeth's in gear wheels and pinion wheels by drilling taping screw inserting, welding and facing to shape. 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 and 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 the River Sluice shutter of size 1.20 x 1.80 m. Repairs and Services - all embedded parts, change of rubber seal, corner seal, 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. Service and repairs to gantry girders, side rollers of the emergency shutter with necessary dismantling works, by removing side GI plate, guide rail, all the roller pins, rollers, Changing the bearings, changing the oil seals, bearing repairs, facing of pins and washer plates, roller adjustment lever repairs, reassembling the roller with grease packing, etc.. During repair and trial run smooth rotation of all the rollers should be verified.

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. 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.

Replacing and servicing the Left and Right Main Canal sluice shutters of vent size 0.90 x 1.50 m including all embeded parts, replacing the RMC worm box and servicing the LMC worm box, Rubber seal, bolts, nuts and joints, grooves, I-Beam, Head set, screw rod of 90mm dia, stiffeners, 2Nos of suspension channel ISMC 125x65x2750, 2Nos of guide channel ISMC 150x75x2750, operating platform, ensuring ease operation on manual. 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, cleaning of drain holes and provide new drain holes of 12mm to 25mm dia as per the instructions of departmental engineers. 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, 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.