REHABILITATION AND IMPROVEMENT TO SHOLAYAR DAM AND UPPER NIRAR WEIR IN VALPARAI TALUK OF COIMBATORE DISTRICT UNDER DRIP PHASE II (Hydro Mechanical Works)

Amount

Slice 1: REHABILITATION AND IMPROVEMENT TO SHOLAYAR DAM OF WATER RESOURCES DEPARTMENT IN VALPARAI TALUK OF COIMBATORE DISTRICT UNDER DRIP PHASE II (Hydro Mechanical Works)

Repair & modification of shutter grooves as per the following specification. The existing groove and the shutter do not sink with each other. Hence the grooves shall be modified appropriately to accommodate the shutter to travel in the tunnel. The existing gantry crane is provided to service only one shutter. Hence the gantry crane shall be modified for cross travel to service the modified emergency shutter also. This would effectively assist in easy maintenance in the long run. In this process, the masonary of the tunnel also has to suitably modified to accommodate the new grooves. The cost includes cost of all materials,

cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like chain pulley block, welding machine, cutting set, grinding machine, power charges for generator, conveyance to site and clearing them after completion of work, including cost of trial operation, etc., complete as directed by the departmental officers.

Repair, overhaul & refixing of the rusted cast iron wheels of the existing shutters with gas cutting equipment and reconditioning with bearings and refixing to the original condition as per the site requirements. The wheel is of 355mm diameter & moves in the recessed groove of the vertical guide channel. The shutter shall be lifted to a workable height and the locking plate shall be removed by cutting the corroded bolts & nut with gas cutting equipments. The wheel pin shall also be removed. Then the wheel shall be transported to the workshop where the wheel shall be opened up and the old broken bearing shall be removed after cleaning the wheel. Then the outer wheel surface shall be machined true to required size and so that it shall operate smoothly without vibration and without undergoing undue drift. The inside of the wheel shall also be machined to have a uniform surface. The existing bearing shall be cleaned and inspected for misalignment and breakage. Then shall be replaced as the case may be. The existing pin shall be machined and fitted snugly. Then the wheel shall be closed and fitted to the end vertical channel. Trial operation shall be conducted to ensure free movement & rotation of wheels.

The cost includes cost of all materials, process charges like gas cutting, welding, machining, scaffolding charges, labour charges for dismantling, loading, lifting, unloading, transport, erection, labour charges for equipments like crane, chain pulley block, power charges for generator, risk allowance for working at a height of more than 3m, conveyance to site and clearing them after completion of work including cost of trial operation etc., complete and as directed by the departmental officers.

Replacement of Musical note rubber seal as per IS 11855:2004 at top, bottom & sides of the emergency shutter of size 3040x2770mm as per the following specification. The old seal cover plate shall be dismantled from the skin plate after removal of the rusted bolts & nuts by gascutting. The skin plate surface shall be neatly cleaned by grinding. Now, the existing seal seat cover made of 65x10mm MS flat shall be cleaned & painted. The rubber seal shall be now matched with the existing holes in the skin plate and then holes should be punched accordingly to align with that in the skin plate. The rubber seal of size 100mmx14mm, 44mm dia shall be placed on the skin plate over which the seal seat cover shall be placed and fastened with CSK SS bolts. The cost includes cost of materials, labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site etc., complete.

Repair & Replacement of the existing river sluice service gate as per the following specification & drawing. The existing service gate is totally corroded and hence leaking & not properly operable. Therefore, the platform around the river sluice service gate shall be dismantled and the suspension channel shall be removed from its position and safely stacked for re erection with new service gate. However care should be taken to paint the existing suspension channel before it is re erected with new service gate. The new river sluice service gate shall be of size 2200x1980mm. The skin plate shall be of 16mm thick and vertical and horizontal stiffeners shall be provided ISMB 300. End verticals shall be provided with ISMC 300. The seal seat and cover shall be 10mm thick. The side & top rubber seal shall be provided with ‘P’ type seal of size 100x44x14. The existing cast steel wheel assembly shall be serviced and reassembled to the new gate.The shutter shall be blast cleaned to SA 2 1/2 standard and the surface shall be with

Aluminium wire metallising as per IS 6586 (1989) with adjuncts to IS 5905 : 1989 and a overcoat of epoxy zinc phosphate primer with 50µ shall be applied. The finish coat of coaltar epoxy for 250µ in two coats shall be applied. Each coat shall be given a drying time of minimum 24 hours. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, paint, primer, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like derrick, chain pulley block, power charges for generator, conveyance to site and clearing them after completion of work, including cost of trial operation, etc warranty for 5 years except rubber seals, protective coatings, etc., complete as directed by the departmental officers.

Design, Fabrication, supply & erection of trash rack arrangements to filter waste polybags, wooden logs, waterweed and garbage from entering the flood water diversion channel as per the following specification. The outer frame shall be made up of ISMC 250x80mm with overall size of 3200mmx3020mm. The panels in this arrangement shall be provided with 100x16mm flats welded at c/c distance of 100mm to form a louver arrangement. 4 horizontal members of ISMC 250x80mm shall be provided as shown in the drawing enclosed. The trash rack shall be fixed to the masonry with hold fasts made of 50x50x8mm MS angle at different points in the frame. All members shall be welded as per specifications and ground to have a neat finish. Providing abrasive blast cleaning using air blast cleaning with abrasive aluminium oxide/steel grits/sand as per the following specification. Moisture should not be present on the steel surface during blast cleaning. All, oil, paraffin, grease & dirt shall be removed from the surfaces to be painted primarily before blast cleaning. Then all weld spatter, slag, burrs, loose rust and mill scale and other foreign substances shall be removed by blast cleaning . The average surface roughness after blast cleaning shall not exceed 35 to 50 µ.Blast cleaning shall confirm to Swedish

standard SA 2 1/2 (near white metal). Blast cleaned surfaces showing plate surface defects such as scabs or sharp gouges shall be repaired in anapproved manner prior to painting. After blast cleaning, the surface shall be dusted off or blown off with compressed air free of detrimental oil and water. All surfaces to be painted shall be completely dry, clean and free from moisture just prior to and during painting. If rust forms or the surface becomes contaminated in the interval between cleaning and painting, recleaning to the same degree shall be required. All safety precautions like wearing helmets, respirators & grounding of blast hose to dissipate static charges should be adopted as directed by the departmental officers. Then metallizing using flame wire thermal spraying equipment as per the following specification. The metalizing should be applied within four hours of surface preparation of the component structure. Thermal spraying is a cold process and have proven that they provide long term corrosion protection and outperform all other methods. These thermal spray coating provide corrosion protection by excluding the environment and acting as a barrier coating and they also provide sacrificial anodic protection. The

temperatures during the process reach around 95°c. These coating are typically mechanically bonded to a grit blasted surface. Zinc wire with 85% and aluminium 15% composition as per IS 6586(1989) with adjuncts to this standard IS 5905 : 1989 shall be continuously melted in gas flame spray gun. Droplets of molten metal from the wire shall be deposited onto the steel forming the protective coating and this avoid corrosion for a long term. Now finally, a high performance primary coating to protect the steel structure from highly abrasive, erosive and corrosive environments. This being a industrial coating, enhances the life of the structure and reduces the strain of continuous maintenance. After metallizing of the structure, a primer coat with epoxy primer shall be applied as a sealer coat. The dry film thickness should be 40-60µ for primer coat. The colour is grey and minimum pot time should be 4 to 8 hours. 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. All painting works shall be performed by airless spraying. When the coating material is applied by spraying, suitable means shall be provided to prevent segregation during the coating operation. Free oil and moisture shall be removed from the air supply lines of all spraying equipment. Primer coat shall be uniform and free from runs, slag and other imperfections. The time between successive coats shall be not less than the minimum nor more than the maximum re-coating time specified by the paint manufacturer. 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. Smoking and welding shall not be allowed within 10 meters of the place when painting is in progress. The painting to the gates, hoists and other parts shall be done as per IS specification No.14177-1994. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) – 1971, IS : 2339-1963 and IS: 2932-1994. Application of coaltar epoxy over the primer shall be through airless spray method. The colour shall be black and the mixing ratio of base to accelerator should be by manufacturer standards. The dry film thickness should be between 100-125 µ per coat. The interval before over coating shall be 24 hours. 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. Each coat shall be protected during the initial curing period against the possibility of moisture condensation or contamination with foreign matter. All painting works shall be performed by airless spraying. When the coating material is applied by spraying, suitable means shall be provided to prevent segregation during the coating operation. Free oil and moisture shall be removed from the air supply lines of all spraying equipment. Each coat shall be uniform and free from runs, slag and other imperfections. The time between successive coats shall be not less than the minimum nor more than the maximum re-coating time specified by the paint manufacturer.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. Smoking and welding shall not be allowed within 10 meters of the place when painting is in progress.The painting to the gates, hoists and other parts shall be done as per IS specification No.14177-1994. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) – 1971, IS : 2339-1963 and IS: 2932-1994.

The cost includes cost of all materials, cost of consumables like welding rods,grinding wheel, oxygen & acetylene gas, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like chainpulley block, welding machine, cutting set, grinding machine, metallizing wire and its equipments, primer, thinner, paint, etc, labour charges for application of primers paint, hire charges for compressor, generator, airless spray,etc, cost of oil & diesel for generator, scaffolding charges, transport charges, conveyance of machinery & tools to and fro from site of work, testing & inspection charges, risk allowance, etc, complete.

Repair and modification of operating platform with composite chequered plate as per the following specification. The existing corroded steel chequered plate shall be removed by using gas cutting. Then the required additional steel stiffeners 40x40x6 angle shall be provided in existing deck bridge. Providing 6mm thick composite chequered plate in the operating platform in the following specification. The composite chequered plate shall be manufactured in vacuum infusion process. This process ensures freedom from all defects and thus increases the strength of the composite chequered plate. UV resistant polyester polymer and high grade reinforcement shall be used for manufacturing composite shutter. Excellent corrosion resistant gel coat shall be applied during the process. The composite material has high strength to weight ratio, durable, light weight and ease in handling. Then it shall be checked for flatness and lifted to the overhead platform and marked and cut to exact size. The composite plate has very good anti slippery property and ease in handling. Then the plate shall be laid in the panel screwed to the stiffeners below. Suitable holes shall be provided at appropriate places for drainage of rain water. Then the shutter, shall be loaded,

transported to the site, unloaded & erected as directed by the departmental officers. The cost includes cost of all materials, Cost of raw material like UV stabilized infusion grade polymers, multi directional glass fibre reinforcements, hardners, pigment, cost of pattern and mould process charges for infusion, cost of consumables such as vacuum film, peel ply, flow mesh, spiral hose, tacky tape and equipment charges like vacuum infusion pump, catch pot, pneumatic tools, Air compressor, labour charges for loading, lifting, unloading, transport, erection, power charges for generator, conveyance to site, including cost of trial operation, warranty for 5 years, etc., complete as directed by the departmental officers.

Design, drawing, fabrication, transport & installation of an inspection platform for the spillway vertical shutters of the following size & specification. The platform shall be provided in between the piers parallel to the skin plate of the shutter as well around the piers in the downstream side for effective inspection of shutters and its components. Also it serves for periodical maintenance operations such as oiling, greasing & painting. This easy & quick access enables to monitor any leakage from the shutter and enables carrying out emergency operations. The platform shall be of width 900mm and shall be supported by the main girder ISMB 400 on either ends of the platform. The platform in between pier shall be supported with “A” frame. The frame shall be anchored to piers with hybrid vinyl ester compound. ISA 50x50x6 shall be welded as intermediate stiffeners singularly between the main girders at distance of 450mm c/c from each other and cross stiffeners at a distance of 500 c/c from each other shall be provided throughout the length

of the inspection platform. A gusset plate made of 8mm thick MS plate and size 160 x 200mm shall be perpendicularly welded to the outer side of the main girder on either side to weld the vertical posts of height 1200 mm made of ISA 75x75x6mm. The handrail pipes of dia 25mm made of GI pipes shall be inserted into the holes drilled in the vertical post equidistant from each other as in the drawing. The platform top shall be finished with 6mm composite chequered plate from end to end throughout the platform for a width of 900mm. All joints in the frames shall be neatly welded and ground to give an excellent finish. The platform shall be blast cleaned with SA 2 1/2 standard and the surface shall be applied epoxy primer with 50µ, The finish coat shall be applied overthe primer coal tar

epoxy with 250 µ in two coats. The foundation bolts of size 16mm with base plate of size 250x250x12mm shall be provided to anchor the platform to the existing pier. Necessary civil works like concreting & anchoring in existing masonry structure shall be included in the scope of this job. The Cost includes cost of materials, labour charges, transport, erection, crane hire charges, power charges from a generator at site, loading & unloading charges, conveyance of machinery to & fro from site of work, hire charges for machinery, painting, scaffolding charges , risk allowance for working at a hazardous location at a height of 30m, warranty for 5 years except protective coating, etc., complete.

Design, drawing, fabrication, transport & installation of a approach staircase to the platform of the following size & specification. The staircase shall descend from the road bridge from an appropriate entry point to the inspection platform with adequate steps & hand rails. This is necessary to inspect vertical gate from the downstream side, Also it serves for periodical maintenance operations such as oiling, greasing & painting. This easy & quick access enables to monitor any leakage from the shutter and enables carrying out emergency operations. The staircase shall be of width 900mm and shall be supported by the main girder ISMB 400 on either ends of the staircase. The tread & the risers shall be of appropriate height & width. A gusset plate made of 8mm thick MS plate and size 160 x 200mm shall be perpendicularly welded to the outer side of the main girder on either side to weld the vertical posts of height 1200 mm made of ISA 75x75x6mm. The handrail pipes of dia 25mm made of GI pipes shall be inserted into the holes drilled in the vertical post equidistant from each other as in the drawing. The platform top shall be finished with 6mm composite chequered plate from end to end throughout the platform for a width of

900mm. All joints in the frames shall be neatly welded and ground to give an excellent finish. The platform shall be blast cleaned with SA 2 1/2 standard and the surface shall be applied epoxy primer with 50µ, The finish coat shall be applied overthe primer coal tar epoxy with 250 µ in two coats. The foundation bolts of size 16mm with base plate of size 250x250x12mm shall be provided to anchor the platform to the existing pier. Necessary civil works like concreting & anchoring in existing masonry structure shall be included in the scope of this job. The Cost includes cost of materials, labour charges, transport, erection, crane hire charges, power charges from a generator at site, loading & unloading charges, conveyance of machinery to & fro from site of work, hire charges for machinery, painting, scaffolding charges , risk allowance for working at a hazardous location at a height of 30m, warranty for 5 years except protective coating, etc., complete.

Providing a portable winch for access to the upstream and downstream of the masonary dam from the dam top to the dead storage level and entire width of the masonary dam. The winch should be able to accommodate 3 people and electrically operated with safety gear. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like chain pulley block, welding machine, cutting set, grinding machine, power charges for generator, conveyance to site and clearing them after completion of work, including cost of trial operation, etc., complete as directed by the departmental officers.

Providing mobile tower extendable ladder of 13' height and extended by 7' making it to reach a height of 20'. The ladder shall be made of aluminium alloy mounted on a MS Trolley which has four wheels to make it mobile. A platform with handrail shall be provided at the top for safe working of personnel. The ladder could be used in open spaces for maintenance of high rise structures and electrical installations. The cost includes cost of materials, labour charges, transport, erection, etc, complete.

Repair & replacement of stiffener channels in the rear side of the spillway shutter as per the following specification. The rear stiffener channels shall be inspected for corrosion & damaged portions to be replaced shall be marked and cut to required lengths.Then new twin channels fabricated out of ISMC 200x75mm as per original design and shall be welded to the rear stiffeners.The edges of skin plate and corners of channels shall be neatly ground to get rid of corrosive particles and then welding shall be done. 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 shall be as strong as the base metal.A

suitable electrode should be chosen and welded with a good welding equipment and a trained welder. All non - metallic substances are 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. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like derrick, chain pulley block, power charges for generator, conveyance to site and clearing them after completion of work, including cost of trial operation, etc., complete as directed by the departmental officers.

Replacement of bottom rubber seal flat type as per IS 11855:2004 for the spillway shutter of size 13500x7700 mm as per the following specification. The old rubber seal shall be removed from the skin plate after removal of the rusted bolts & nuts by gas cutting equipments. The seal seat cover shall be removed along with the rubber seal. The skin plate & seal seat cover surface shall be neatly cleaned on either side by grinding. Now, the existing seal seat cover made of 100 x 10mm MS flat & rubber seal shall be now matched with the existing holes in the skin plate and then holes shall be drilled in the seal seat cover to align with that in the skin plate, if necessary. Holes shall be punched accordingly in the rubber seal of size 100x12mm.

Now the rubber seal shall be placed on the skin plate over which the seal seat cover shall be placed and fastened with SS bolts & nuts of size M18x75. The cost includes cost all of materials, labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site, etc., complete and as directed by departmental officers.

Providing dogging arrangement for spillway gate embedment if any along with construction of niche of adequate size in existing masonry/concrete structure for holding the gate above the MWL for gate maintenance & also to facilitate maintenance /repair or replacement of gate wheels/wheel assembly, including maintenance. The includes scaffolding and incidental petty civil works as directed by the departmental officers.

Providing abrasive blast cleaning using air blast cleaning with abrasive aluminium oxide/steel grits/sand as per the following specification. Moisture should not be present on the steel surface during blast cleaning. All, oil, paraffin, grease & dirt shall be removed from the surfaces to be painted primarily before blast cleaning. Then all weld spatter, slag, burrs, loose rust and mill scale and other foreign substances shall be removed by blast cleaning . The average surface roughness after blast cleaning shall not exceed 35 to 50 µ. Blast cleaning shall confirm to Swedish standard SA 2 1/2 (near white metal). Blast cleaned surfaces showing plate surface defects such as scabs or sharp gouges shall be repaired in an approved manner prior to painting. After blast cleaning, the surface shall be dusted

off or blown off with compressed air free of detrimental oil and water. All surfaces to be painted shall be completely dry, clean and free from moisture just prior to and during painting. If rust forms or the surface becomes contaminated in the interval between cleaning and painting, recleaning to the same degree shall be required. All safety precautions like wearing helmets, respirators & grounding of blast hose to dissipate static charges should be adopted as directed by the departmental officers. 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, conveyance of machinery to & fro from site of work, transport charges, scaffolding charges, consumables like oil & diesel for generator, risk allowance, etc, complete

Application of a high performance primary coating to protect the steel structure from highly abrasive, erosive and corrosive environments. This being a industrial coating, enhances the life of the structure and reduces the strain of continuous maintenance. After surface preparation of the structure, a primer coat with epoxy primer shall be applied. The dry film thickness should be 40-60µ for primer coat. The colour is grey and minimum pot time should be 4 to 8 hours. 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. All painting works shall be performed by airless

spraying. When the coating material is applied by spraying, suitable means shall be provided to prevent segregation during the coating operation. Free oil and moisture shall be removed from the air supply lines of all spraying equipment. Primer coat shall be uniform and free from runs, slag and other imperfections. The time between successive coats shall be not less than the minimum nor more than the maximum re-coating time specified by the paint manufacturer. 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. Smoking and welding shall not be allowed within 10 meters of the place when painting is in progress.

The painting to the gates, hoists and other parts shall be done as per IS specification No.14177-1994. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) – 1971, IS : 2339-1963 and IS: 2932-1994. The cost includes cost of primer, thinner, paint, etc, labour charges for application of primer, hire charges for compressor, generator, airless spray, etc, cost of oil & diesel for generator, scaffolding charges, transport charges, conveyance of machinery & tools to and fro from site of work, testing & inspection charges, risk allowance, etc, complete.

Application of coal tar epoxy over the primer shall be through airless spray method. The colour shall be black and the mixing ratio of base to accelerator should be by manufacturer standards. The dry film thickness should be between 100-125 µ per coat. The interval before over coating shall be 24 hours. 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. Each coat shall be protected during the initial curing period against the possibility of moisture condensation or contamination with foreign matter. All painting works shall be performed by airless spraying. When the coating material is applied by spraying, suitable means shall be provided to prevent segregation during the coating operation. Free oil and moisture shall be removed from the air supply lines of all spraying equipment. Each coat shall be uniform and free from runs, sags and other imperfections.

The time between successive coats shall be not less than the minimum nor more than the maximum re-coating time specified by the paint manufacturer. 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. Smoking and welding shall not be allowed within 10 meters of the place when painting is in progress. The painting to the gates, hoists and other parts shall be done as per IS specification No.14177-1994. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) – 1971, IS : 2339-1963 and IS: 2932-1994. The cost includes cost of coaltar epoxy paint, thinner, etc, labour charges for application, hire charges for compressor, generator,airless spray,etc,

cost of oil & diesel for generator, scaffolding charges, transport charges, conveyance of machinery & tools to and fro from site of work, testing & inspection charges, risk allowance,etc, complete.

Overhauling of existing hoisting arrangements for the shutter as per the following specification. The existing hoist covers shall be opened up and stored separately for reuse after neatly scrapping the surface and painting with a coat of aluminium paint. The top cover of plummer blocks connecting the existing transmission shafts shall be opened and old grease shall be removed. Then, the existing bearings shall be cleaned with liquid cleaner and inspected for mis-alignment and breakage. Fresh grease shall be applied to the plummer block and top cover closed with requisite fasteners. The shaft shall be checked for its alignment and redone to ensure straightness of shaft. The existing gear wheels shall be cleaned of dried grease and dust manually. The reduction gearbox shall now be drained of old used lubricant through the drain hole at the bottom. Now, the liquid cleaner shall be poured in the gearbox and the inside surface and gears are thoroughly cleaned and then the contaminated liquid cleaner shall be drained. The drain hole shall be plugged and fresh lubricant of appropriate grade shall be filled to the level as indicated by the department officers. The available chain & chain sprocket mechanism in the hoisting system shall be manually cleaned of dried grease and dirt and appropriate lubricant

shall be applied The existing motor &gearbox outer surface shall be manually cleaned and a coat of metallic paint applied. The whole arrangements shall be tested & passed after a set of trial operation. The cost includes cost of inspection, spares, lubricants, transport charges, charges for dismantling & Erection,etc,complete

Providing openable protection arrangements and arch welcome board for the tourist to the sholayar dam entrance of the following specification. The frames shall be made of 2” sq tube as per standard specification. The arch board shall be made of 2” MS pipe and cross stiffener with the same section. 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. Then all steel surfaces are cleaned of dirt, grease, oil, welding spatter, etc and then a coat of anticorrosive primer shall be given. After a curing period of 24 hours a coat of synthetic Enamel shall be given over which another coat shall be applied at an interval of 24 hours. Then the production arrangements shall be loaded, transported to the site, unloaded & erected as directed by the departmental officers.

The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like chain pulley block, welding machine, cutting set, grinding machine, power charges for generator, conveyance to site and clearing them after completion of work, including cost of trial operation, , etc., complete as directed by the departmental officers.

Supplying, fabricating and erection of Colour galvanium sheet roof of 0.47 mm thick and Steel Tubular box section of 100 X 50 X 3mm of 1m interval etc., including one coat red oxide primer and finishing with two coats of enamel paint. With necessary screws, including cost of labour and materials etc., complete complying with standard specification as directed by the departmental officers.

Slice 2: REHABILITATION AND IMPROVEMENTS TO UPPER NIRAR WEIR AND ASSOCIATED APPURTENANCES IN VALPARAI TALUK OF COIMBATORE DISTRICT UNDER DRIP PHASE II (Hydro Mechanical Works)

Design, drawing, fabrication, transport, supply and installation of new shutter of size 4030x5420mm for the Upper Nirar tunnel entry to replace the existing old corroded shutter as per drawing confirming to IS 4622 for vertical fixed wheels gates. Blast cleaning to SA 2 1/2 standard over which epoxy primer to a thickness of 40 to 60 μ and final coat of coal tar epoxy of 250μ shall be applied as per IS 14177-1994. The cost includes cost of materials, cost of consumables like welding rods, grinding wheels, oxygen & acetylene gas, oil & diesel for generator, process charges like gas cutting & welding, drilling, hire charges for machinery like gas cutting plant, welding equipment, magnetic drilling machine, generator, grinding machine, compressor, airless spray machine, hoisting equipments like chain pulley block, derrick post, labour charges for loading, lifting, unloading, transport erection, scaffolding, conveyance to site and clearing them after completion of work, warranty for 5 years except protective coatings, etc., complete and as directed by the departmental officers.

Design, Fabrication, supply and installation of rope drum Cover for Drive unit assembly by using composite panels of thickness 2.5mm made as a single unit as per the drawing. A lifting handle in composite material shall also be incorporated. All surfaces shall be applied with two coats of anticorrosive and UV resistant grade polymer coating. The composite material shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties. The cost include cost of materials, labour charges for fabrication, painting, loading & unloading, transport, etc., complete.

Fabrication, supply and installation of hoist motor cover for Hoisting arrangements by using composite panels of thickness 2.5mm made as a single unit as per the drawing. A lifting handle in composite material shall also be incorporated. All surfaces shall be applied with two coats of inherent anticorrosive and UV resistant grade polymer coating. The composite material shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties. The cost includes cost of mould and pattern, cost of raw materials like UV grade polymers, multi directional glass fibers, Hardeners, pigments, Aerosil powder, cost of consumables like Rollers, brushes, labour charges for handlay up, grinding, finishing, machining charges, loading,lifting, unloading, transport, erection, hire charges for equipments like Air compressors, pneumatic tools, conveyance to site and clearing them after completion of work, including cost of trial operation, warranty for 5 years, etc., complete as directed by the departmental officers.

Repair & Replacement of sill beam flat in river sluice shutter in Uppar nirar. The vertical tunnel entry shutter shall be closed so as to stop water from flowing to the river sluice shutter. Then, the river sluice shutter shall be lifted to a height of 1500mm. The leakage water shall be diverted conveniently with sandbags for execution of the work. New SS sill beam flat of size 75x12x 2200mm shall be cut to size. The stainless steel flat shall be tested and of 316 quality. The existing beam ISMB 200x100 shall be inspected for corrosion & mechanical cleaning done. Then the SS flat shall be welded with MS beam with appropriate welding rods of special quality. Then all steel surfaces shall be coated with zinc rich primer overwhich two coats coaltar epoxy shall be given. Then, the shutter shall be operated & verified for the effectiveness of the sill beam flat. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for dismantling,loading, lifting, unloading, transport, erection, hire charges for equipments like chain pulley block, welding machine, cutting set,grinding machine, power charges for generator, conveyance to site and

clearing them after completion of work, risk allowance for working in a tunnel at a depth of 130’ including cost of trial operation, warranty for 5 years except protective coating, etc.,complete as directed by the departmental officers

Repair & Replacement of the existing river sluice service gate as per the following specification & drawing. The existing service gate is totally corroded and hence leaking & not properly operable. Therefore, the platform around the river sluice service gate shall be dismantled and the suspension channel shall be removed from its position and safely stacked for re erection with new service gate. However care should be taken to paint the existing suspension channel before it is re erected with new service gate. The new river sluice service gate shall be of size 2200x1980mm. The skin plate shall be of 16mm thick and vertical and horizontal stiffeners shall be provided ISMB 300. End verticals shall be provided with ISMC 300. The seal seat and cover shall be 10mm thick. The side & top rubber seal shall be provided with ‘P’ type seal of size 100x44x14. The existing cast steel wheel assembly shall be serviced and assembled to the new gate. The shutter shall be blast cleaned to SA 2 1/2 standard and the surface shall be with Aluminium wire metallising as per IS 6586 (1989) with adjuncts to IS 5905 : 1989 and a overcoat of epoxy zinc phosphate primer with 50μ shall be applied. The finish coat of coaltar epoxy for 250μ in two coats shall be applied. Each coat shall be given a drying time of minimum 24 hours.,

The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, paint, primer, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like derrick, chain pulley block, power charges for generator, conveyance to site and clearing them after completion of work, including cost of trial operation, etc warranty for 5 years except rubber seals, protective coatings, etc., complete as directed by the departmental officers.

Sub Total

GST @ 12% of SubTotal

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