Repair of Distressed Spans of Railway Over Bridge with Ultra High Performance Reinforced Fiber Concrete on ROB Deck Slab of Mumbra Kausa Bypass road MSH-04, Km 139.200 to 139.810 in Taluka and District Thane. 5054 Road and Bridge

Amount

Labour for traffic control / regulation during repairs to superstructure work.

Removal of existing asphaltic wearing coat comprising of 50 mm thick asphaltic concrete laid over 12 mm thick mastic asphalt including disposal with all lift and lead upto 100 m etc. complete.

Chipping of all loose and Spalling of concrete to bottom of slab, beams etc.(wherever required), cleaning of reinforcement, carrying out thorough sand blasting, application of anti- corrosive zinc rich epoxy primer to exposed reinforcement including cost of material, labour, equipment, tools, scaffolding etc. complete.

Dismantling the R.C.C. Work 1:2:4 and sorting out the materials such as steel etc. as directed and stacking them within the specified lead as directed etc. complete.

Dismantelling existing damaged Drainage Water Spout and providing 100mm diameter GI water spouts as per detailed drawings in RCC slab and wearing surface/kerb etc.complete

Replacement of existing damaged Expansion joints by providing and laying of Strip Seal Expansion Joint System, including removal of existing damaged expansion joints by dismantling of deck slab, wearing coat etc. and back filling of the recess up to final finish level with concrete of grade M-35, complete as per M.O.R. T&H specification.

Providing and cutting bending, hooking, laying in position and tying HCRM/ CRS for reinforcement as per detailed drawings for R.C.C. work.

Providing structural steel work in trusses, other similar trussed purlins and members with all bracing, gusset plates etc. as per detailed designs and drawings or as directed including cutting, fabricating, hoisting, erecting fixing in position, Making riveted/ bolted/ welded connection and one coat of anticorrosive paint and over it 2 coats of oil painting approved quality and shade etc. complete.

Providing and applying anticorrosive treatment with epoxy zinc rich primer to the exposed reinforcement after cleaning either with wire brush or sand blasting including all tools, tackels, machinery etc. complete.

Providing and laying in situ / ready mix M-40 controlled cement concrete of trap/ granite/ quartzite/ gneiss metal for RCC work in solid/ deck slab etc. including ramming, vibrating, curing, formwork, centering and finishing in cement plaster excluding reinforcement etc. complete. (with fully automatic micro processor based PLC with SCADA enabled concrete batch mix plant / pan mixer and fine agreegates of required specifications ( VSI sand finely washed etc )

Structural Repairs to damaged concrete surface with polymer concrete /mortar with AC- ACRYLATE-REPAIR and AC-BOND-AID as detailed in the method statement including material, labour, etc., all complete as directed by engineer. (Repairs to deck slab, piers, abutment, girders and other locations up to 40 mm thickness).

Carry out application of "Bi-polar migratory corrosion inhibitor" on concrete surface. This inhibitor has migratory kind of property which permits the material to migrate to a virtual extent of 100mm, through pores of concrete,inhibiting the corrosion etc complete.

STUDS FOR CONCRETE Drilling and installation of 10 mm dia. Stud Anchor Bar as shear connector using approved resin epoxy chemical by injection for installation of 10 mm diameter stud anchor, drilling hole of 12mm dia. in the concrete of RCC members to a depth of minimum 100 mm at 500 mm c/c or at suitable grid in zig-zag fashion using approved drilling machine and drill bit, cleaning the hole using wire brush and blow out pump for removing dirt and dust from the hole. After proper cleaning, inject approved resin epoxy chemical using approved chemical anchoring gun. Pull out strength should be min 8 KN per anchor. Insert the stud rod in the hole by slightly rotating the rod. Once the stud is inserted, allow it to set for min 30-45 min and final curing time 6-8 hours depending on ambient temperature etc. complete as per the directions of Engineer-In-Charge.

Providing and fixing Chemical Anchor fastners of 12mm dia. and 150mm length of HILTI or equivalent make including chemical grout, injecting gun etc. complete.

Providing and laying in situ / ready mix M30 RCC of trap/ granite/ quartzite/ gneiss metal for RCC work of ballast walls, kerbs and box returns including scaffolding, compaction, formwork finishing and curing etc. complete. (excluding reinforcement, with fully automatic micro processor based PLC with SCADA enabled concrete batch mix plant / pan mixer with fine agreegates of required specifications ( VSI sand finely washed etc )

Providing and applying Kelox R 101 (Resin) + Kelox H 404 (Hardner) water misible epoxy of approved make for bonding old concrete to new moratr after mixing slowely in predefined ratio and applying by brush on the surface, when it is tacky then apply the moratr complete as per specification and as directed by engineer-in-charge. Work shall be executed by certified applicator only and work shall be guaranteed for 5 years and guarantee shall be provided on Rs. 500 /- stamp paper

Providing & Supplying corrosion inhibiting admixture in concrete to protect steel bars for all concrete in every part Polyalk CP 293 of approved make & approved by Engineer in charge migrating, non-nitrite based corrosion inhibiting admixture shall be added at a dose of 3 Kilograms per cum of concrete. The admixture should protect both cathodic and anodic sites and have been accredited by Indian Roads Congress, recommended for use by Ministry of Road Transport & Highways and should have a 4 year track record of use in both the Gulf Region and India. Admixture should have evaluated test reports demonstrating a corrosion rate of zero coulombs after 9 test cycles as per ASTM G 109 when tested from a research institution NBA accredited Grade A and internationally ranked among top 5 research institutions in the world in Annual Survey conducted by Georgia Institute of Technology ranking of research institutions. PH of admixture should be alkaline in nature, specific gravity of 0.99 – 1.1, colour : brownish. The contractor must intimate the engineer in charge prior to addition in concrete for recording. If the admixture is put in the concrete mix at the batching plant, a written record of the amount of admixture used shall be supplied to the engineer. The engineer must ensure that the specified dosage of admixture is added in the concrete mix. (Material Cost Analysis only)

ULTRA HIGH-PERFORMANCE FIBER REINFORCED CONCRETE (UHPFRC) Providing and laying in situ Ultra High-Performance Fiber Reinforced Concrete Mix of high strength of 70 Mpa to 140 Mpa, formulated by combining Portland Cement, Supplementary Cementitious Materials, Reactive Powder, Lime Stone and or Quartz Flour, Micro-Silica, Silica Fumes, Fly-Ash, Granulated Slag, Admixtures, for High Early Gain compressive Strength of 20 Mpa to 28 MPa at 3 to 12 hours, Chemical Admixtures, Super Plasticizers, optimally graded aggregates, Fine Sand, High-Range Water Reducers, Metal or Organic Fibers (High Carbon Steel, Polypropylene, PVA, Glass, Carbon or a combination of these types) having High Flow Characteristic to make it self-Compacting. UHPFRC matrix shall be very dense with a minimal disconnected pare structure resulting in low permeability, low shrinkage, low creep, high resistivity with compressive strength minimum 70 Mpa to 140 MPa, Flexural strength minimum 25 MPa and Modulus of Elasticity more than 40GPa, including ramming, vibrating, curing, form work, centering and finishing excluding reinforcement etc. complete. (with fully automatic microprocessor-based PLC with SCADA enabled concrete batch mix plant / pan mixer and fine aggregates of required specifications (Natural Sand / VSI Sand finely washed etc.) etc. complete as per directions of Engineer-In-Charge. Conforming to IRC:SP:70:2005, High Early Compressive Strength as per ASTM C 39 (AASHTO T 22), High Early Flexural Strength as per ASTM C 78 (AASHTO T 97), Abrasion Resistance as per ASTM C 944, Low Permeability as per ASTM C 1202 (AASHTO T 277), Chloride Penetration as per AASHTO T 259 & T 260, High Resistivity as per ASTM G 59, Low Absorption as per ASTM C 642, Low Diffusion Coefficient as per ASTM, Resistance to Chemical Attack, Resistance to Sulfate Attack as per ASTM C 1012, High Modulus of Elasticity as per ASTM C 469, High Resistance to Deicer Scaling as per ASTM C 672, Low shrinkage as per ASTM C 157, Low Creep as per ASTM C 512 and any other Codes, Standards applicable. For Deck Slab

Raising of scaffolding to reach the entire surface area of bridge. upto10 m height above ground level, made with MS tube, horizontal and vertical tub joint with cup and lock system with MS tubes, challies, MS clamp and maintaing it in a serveciable condition for execution work of cleaning and/ or pointing and or/applying protection coating and/ inspection of work at required locations and removing it there after etc complete. (Item includes making of temporary support for scaffolding, cost of scaffolding, labour, material, safety devices,etc.,all complete)

Erecting supports for placing the jacks, props and necessary steel structure. Placing of the jacks below bearings. (as per the design of lifting scheme). The lifting scheme shall be put up to the approval of consultants after approval of the work shall be done by competent authority. Cost of the bearings, design of erection system, jacks, platforms, safety devices, etc., complete including releasing of bridge span on the new bearings.

Dismantling of concrete pedestal up to required height including cutting reinforcement by using of concrete saw, complete including all fixing arrangements of the machines, water for cooling, diamond saw, other accessories, safety of workers and removal and disposal of debris as per instruction of site in- charge etc complete.

Provision of cranes 12 T during deck slab centering arrangements for concreting.

Supplying, fitting and fixing in position true to line and level POT- PTFE bearing consisting of a metal piston supported by a disc or unreinforced elastomer confined within a metal cylinder, sealing rings, dust seals, PTFE surface sliding against stainless steel mating surface, complete assembly to be of cast steel / fabricated structural steel, metal and elastomer elements to be as per IRC: 83 part I and II respectively and other parts conforming to BS:5400, section 9.1 and 9.2 and clause 2006 of MoRTH specifications as per drawing and approved technical specifications etc. complete.

Providing and injecting epoxy grout including structuring of crack in the body of slab girder by sand blasting, fixing inlet tube arrangement including cost of materials, machinery required for the work and labour charges etc. complete.

Crack Groove Cutting: Groove shall be cut using hand held electrically operated concrete cutting machine of size of 30 mm wide and 20 mm deep on each side of the crack to form as "V" groove all along the crack to fill the polyester resin/ Epoxy putty (horizontal and vertical cracks). After the groove cutting, the concrete shall be removed from the groove using the pneumatic concrete chipping machine to form "V" groove. The item includes the cost of hire charges for all machineries, tools and barges and all labour charges etc., complete.

CARBON FIBER WRAP 900 GSM IN TWO LAYERS adhesion of a lightweight sheet with the concrete, by dry/wet layup system including Surface Preparation by Grinding/ molding concrete substrate, cleaning it with wire brush, removing oil, laitance if present, rounding sharp edges to min 25 mm radius etc. complete and Profiling by applying two-component low viscous epoxy based compatible primer on prepared substrate, Filling the holes and uneven surface with thixotropic putty etc. complete and Wrapping the first layer of carbon fiber sheet to structural element at desired orientation using tamping roller to avoid any air voids etc. and repeat the same procedure for the second layer with the interval of 8 hrs., applying second coat of saturant after min. 12 hrs, rectifying air voids, if any, pasting river sand on it to make surface rough to take any further finishes etc. complete.

VERMICULITE FIRE RESISTANCE PLASTER Providing and applying Vermiculite Fire resistance plaster at soffit of Bridge deck slab for the deck bottom surface that is treated with carbon fiber polymer, including all necessary materials, labour, machinery, transportation etc. complete.

ANTI CARBONATION PAINT Providing and applying two coats of Anti Carbonation Paint to meet the requirements of anti-carbonation and elastomeric waterproofing with durable protection to concrete or concrete structures to form a flexible membrane, which prevents chloride, ion ingress. It shall have UV & weather resistance properties. It shall provide good mechanical and abrasion resistance to the exterior. The surface should be made, clean and free from oil, grease, loose particles, dust etc. It should be applied by Roller, Brush or Spray. For cleaning / Thinning water to be used. Thinner (Volume) Should be 5-10 %. It shall include one coat of Acrylic Primer (W.B.), one coat of penetrating primer sealer, two coats of Anti Carbonation paint and two coats of shield exterior filler. Its dry film thickness (DFT) should be 100-150 microns per coat. Its drying time shall be touch dry in 20-30 minutes, hard dry in 24 Hours etc. complete as per directions of Engineer-In-Charge.

Providing and fixing P.V.C. Rain water pipes of 110 mm outer diameter and having wall thickness of 2.2 to 2.7 mm confirming to I.S. 13592-1992 including proper rainwater receiving recess with P.V.C. plug, bend, necessary fittings, such as, offsets, shoes, inluding fixing the pipe on wall using approved wooden cleats projecting 25mm to 40mm from face of wall a fixing with clips of approved quality and number ,filing the joint using rubber gasket with solvent cement and properly resting the shoe of pipes on C.C. or masonry blocks, including necessary scaffolding and maintenance for 3 yrs for any leakages or dislocations of pipes. All the P.V.C. fittings and additional 2 piece socket clips shall be got approved from engineer in charge etc. complete. (The contractor shall give 3 yrs guarantee bond for payment)

Providing structural steel work in single stanchions composed of R.S.J. Channel etc. with caps, bases, mild steel plated, angle brackets, cleats, gusset plates, anchor bolts etc. as per detailed designs and drawings or as directed including cutting, fabrication, hoisting, erecting fixing in position, making riveted/ bolted/ welded connection and one coat of anticorrosive paint and over it two. coats of oil painting approved quality and shade etc. complete.

Providing and applying two coats of lead/zinc base oil paint/ bituminious paint of approved colour to new structural steel work and iron work in buildings including scaffolding if necessary, cleaning and preparing the surface etc. complete. (excluding primer coat)

Dismantling of cement concrete pavement by mechanical means using pneumatic tools, breaking to pieces not exceeding 0.02 cum in volume and stock piling at designated locations and disposal of dismantled materials up to a lead of 1000 metres, stacking serviceable and unserviceable materials separately etc. complete.

Construction of dry lean cement concrete Sub-base over a prepared sub-grade with coarse and fine aggregate (VSI grade finely washed crushed sand) conforming to IS:383, the size of coarse aggregate not exceeding 25 mm,, cement content not to be less than 150 Kilogram/cum, optimum moisture content to be determined during trial length construction, concrete strength not to be less than 10 Mpa at 7 days, mixed in a batching plant/ Weigh batch mixer, transported to site with all leads and lifts, laid with a paver with electronic sensor / by suitable means as approved by Engineer-in-charge, compacting with vibratory roller, finishing, curing and including preparation of sub-grade surface if required etc. complete.

Providing and laying 125 micron Low Density Polyethylene (LDPE) sheet confirming to IS 3395 : 1997 below concrete pavement including all materials and labour complete.

Providing and fixing in position TMT FE 500, 32 mm dia dowel bars precoated with anticorrosive epoxy paint of required Dia. 60 cms. Long and at 30.00 cm. C/C and wherever directed including handling, straightening, necessary cutting supported by TMT FE 500, chairs with proper alignment by using properly designed assembly of Bulkheads lubricating half length with bituminous paint as directed etc. complete.

Providing and fixing in position TMT FE 500, tie bars precoated with anticorrosive epoxy paint of 12 mm dia. 70 cms. long and at 30.00 cm. C/C and wherever directed including handling, straightening wrapping with paper of approved quality for half length, necessary cutting, handling, straightening, supported by assembly of TMT FE 500, chairs with proper alignment etc. complete.

Providing and laying in-situ M40 Grade unreinforced plain cement concrete pavement over a prepared sub base with 43 grade cement , coarse and fine aggregate conforming to IS 383, using fine and coarse aggregates combined gradation as per Table 600-3 of MORTH Specification 2013, mixed in a batching and mixing plant/ non tilting mixer and Weigh batcher as per approved mix design, admixtures, transporting to site, spreading, laying compacting and finished in a continuous operation, finishing to lines and grades as directed by Engineer-in-charge and curing by curing compound /by providing cement vata in cement Mortar 1:8 @0.6m X 0.6m centre to centre, admeasuring 80 mm at bottom and 40 mm at top with depth of 75mm and maintaining the same throughout curing period by any other method approved by Engineer-in-charge. with adding admixture for early gain strengthby mixing polypropylene fibers 300 e3 Multi-Dimensional graded Fibillated 100% Vergin as per ASTM C 1116 III Type 4.1.3 Std. at the rate o 125 gms per bag of 50 Kgs. of cement etc.

Cutting transverse contraction joints 3 to 4 mm wide and depth 60 mm in concrete slab using concrete cutting machine with diamond studded saw within 48 hours of casting of bay / slab etc. complete including subsequent widening of the groove 8 to 10 mm. wide at top having depth of 15 mm. as directed by Engineer incharge.

Providing to contraction joints polysuphide sealent (Pouring grade) confirming to BS : 5212 - 1989 into sawed groove widened at top for sealent reservoir of specified size and shape as per detailed drawing including fixing Polyethylene foam backer rod of required diameter (appraox. 25% larger than the initial 3 mm.to 4 mm. joint) overlaid with bond breaking tape as per detailed drawing. Item includes cleaning the joints with water jet / air compressor and allowing joint to become thoroughly dry before sealent is applied and applying primer. (A) Contraction and longitudinal joints (15 mm. deep x 8 mm.wide)

Road Marking with Hot Applied Thermoplastic Compound with Reflectorizing Glass Beads on Bituminous Surface- Providing and laying of hot applied thermoplastic compound 2.5 mm thick including reflectorizing glass beads @ 250 gms per sqm area, thickness of 2.5 mm is exclusive of surface applied glass beads as per IRC:35 .The finished surface to be level, uniform and free from streaks and holes.complete.

Providing and erecting Overhead signs made out of 2mm aluminum sheet bonded with white retro reflective sheeting of Class B ( Type IV High intensity micro-prismatic grade sheeting-HIP) having pressure sensitive/heat activated adhesive retoreflective specified back ground, border and back side retoreflctive symbols, letters, numerals, arrow as per IRC:67-2012, with designed back support frame of mild steel angle with vertical and lateral clearance given in clause 801 and 802, duly painted on back side with two coats of grey stove enamel paint and installed as per clause 802.6 over a designed support system of structural steel work trestles and trusses of sections and type as per structural design requirements and approved plans including painting with one coat of epoxy primer and two coats of epoxy finish paint.The nut bolts of board with angle iron post/supporting structure after fixing at site has to be electrically welded. Class B ( Type IV High intensity micro-prismatic grade sheeting-HIP) sheeting shall have 7 years written warranty from the manufacturer and authorised distributor/convertor issued for field performance including the screen printed areas and cut-out sheeting and cut-out durable transparent overlay film and this warranty certificate in original should be submitted to the Engineer in charge by the contractor/supplier.This item does not include the cost of structural steel work required for support system. 2mm aluminum sheet of Class B

Providing and fixing sign boards of size 90cm having shape of an equilateral triangle made out of 14 gauge sheet with retro reflective sheeting of Engineering Grade as per M.O.T. specification No. 801-3(1993) white reflective back ground, lettering symbol bordering of black non reflective paint including M. S. angle iron back frame of size 35 mm X 35 mm X 5 mm & M.S.angle one post of 50mm x 50mm x 5mm size 3.45 metre long duly painted with white and black bands including fixing M.S. angle of the boards with galvanised nuts and bolts and washers. The Board shall be as per IRC-67-1977 including conveying fixing in ground with C.C. 1:4:8 block of size 0.60 x 0.60 x 0.75 m, with 7 year guarantee for the sheeting etc. complete. Mild Steel Board with Engineering Grade

Providing and fixing Mandatory / Regulatory sign board of circular shape of size 60 cm. dia. prepared on 16 gauge M.S. sheet including painting with zinc chromate stoving primer and two coats each of white back ground,red border and backside gray stove enamelled, bonded with cut out of Retro reflective sheet Engineering grade, symbol / letters / numerals / border, coated with non pealable crystal clear protective transparent coat retaining 100% relection including one number of M.S. Angle iron post of size 50 x 50 x 5 mm of 3.45 m. long inflated at bottom drilled on top in one piece without joint painted with white and black bands of 30 cm. fixing board and post with 2 Nos. high strength G.I. bolts and nuts of size 10 mm dia. and 20 mm long including all taxes, conveying, fixing in ground with cement concrete 1:4:8 block of 60 cm x 60 cm x 75 cm size etc. complete. circular shape of size 60 cm. dia. M.S. sheet with Retro reflective sheet Engineering grade

Providing and fixing of retro- reflectorised informatory sign board rectangular/Square in shape having area less than 0.9 square meter made out of 2 mm aluminum sheet bonded with white retro reflective sheeting of Class B ( Type IV High intensity micro-prismatic grade sheeting-HIP) having pressure sensitive/heat activated adhesive retoreflective specified back ground, border and back side retoreflctive symbols, letters, numerals, arrow as per IRC:67-2012 Table No 8.3, supported with back support frame 25mm x 25mm x 3mm, duly painted on back side with two coats of grey stove enamel paint and supported on one no. mild steel angle iron post 75 mm x 75 mm x 6 mm, 3.5 mt long firmly fixed to the ground by means of properly designed foundation with M25 grade cement concrete 45 cm x 45 cm x 60 cm, 60 cm below ground level as per approved drawing The angle iron post shall be duly painted with one coat of epoxy primer and two coats of epoxy finish paints having alternate black and white bands of 25 cm width including GI fixures and transportation etc.complete.The nut bolts of board with angle iron post/supporting structure after fixing at site has to be electrically welded. Class B ( Type IV High intensity micro-prismatic grade sheeting-HIP) sheeting shall have 7 years written warranty from the manufacturer and authorised distributor/convertor issued for field performance including the screen printed areas and cut-out sheeting and cut-out durable transparent overlay film and this warranty certificate in original should be submitted to the Engineer in charge by the contractor/supplier. a) 2mm aluminum sheet Class B

Supplying and Fixing of Molded Shank Raised Pavement Markers / Cat's Eye made of polycarbonate and ABS moulded body and reflective panels with micro prismatic lens capable of providing total internal reflection of the light entering the lens face and shall support a load of 16000 kg tested in accordance to ASTM D 4280 Type H and complying to Specifications of Category A of MORTH Circular No RW/NH/33023/10-97 DO III Dt 11.06. 1997. The height, width and length shall not exceed 50 mm, 100 mm and 102 +/- 2 mm and with minimum reflective area of 13 Sqcm on each side and the slope to the base shall be 35 +/- 5 degree. The strength of detachment of the integrated cylindrical shanks, (of diameter not less than 19 +/- 2 mm and height not less than 30+/- 2 mm) from the body is to be a minimum value of 500 Kg. Fixing will be by drilling holes on the road for the shanks to go inside, without nails and using epoxy resin based adhesive as per manufacturer's recommendation and complete as directed by the engineer.The contractor shall submit a two year warranty for satisfactory field performance including stipulated retro-reflectance of the reflecting panel, to the Engineer.Supplying & Fixing of Molded Shank Raised Pavement Markers / Cat's Eye made of polycarbonate and ABS moulded body and reflective panels with micro prismatic lens capable of providing total internal reflection of the light entering the lens face and shall support a load of 16000 kg tested in accordance to ASTM D 4280 Type H and complying to Specifications of Category A of MORTH Circular No RW/NH/33023/10-97 ? DO III Dt 11.06. 1997. The height, width and length shall not exceed 50 mm, 100 mm and 102 +/- 2 mm and with minimum reflective area of 13 Sqcm on each side and the slope to the base shall be 35 +/- 5 degree. The strength of detachment of the integrated cylindrical shanks, (of diameter not less than 19 +/- 2 mm and height not less than 30+/- 2 mm) from the body is to be a minimum value of 500 Kgf. Fixing will be by drilling holes on the road for the shanks to go inside, without nails and using epoxy resin based adhesive as per manufacturer?s recommendation and complete as directed by the engineer.

Removing any kind if debris including loading in truck and conveying day to day basis to approved dumping point loading and spreading etc. complete with all leads and lifts.

Supplying of Truck Trailor of 30 tonne capacity for load test after completion of work.