Repair to vertical lift gate shutters in old existing spillway vent 1,2,3 with hoisting arrangements in Manimukthanadhi Dam in Sankarapuram Taluk of Kallakurichi District.

Amount

Repair and replacement of second stage embedded parts like roller track plate, side seal track and sill seat for spillway gate of vent size 12140x4500 mm as per the following specification. The existing corroded MS roller track plate is in two layers. The bottom layer is made of 100x16mm MS flat securely welded to the roller track embedded in concrete. The top layer is made of 100x16mm MS flat and is welded to the bottom layer. This layer shall be removed by grinding and gas cutting operations from the bottom layer. Then a SS track plate of size 120x16mm shall be welded to the existing bottom MS track plate appropriately to enable the rollers move vertically on the SS track plate. The side seal track plate shall be of size 80x8mm made of SS 304 grade. It shall be appropriately welded to the existing angle ISA 100 welded in the upstream side upto 6.50m from sill level. The sill seat shall be made of 80x8mm SS flat of 304 grade. This shall be provided on top of the existing sill beam which is embedded in concrete. The existing corroded guide base and guide angle shall be removed. The guide base of size 200x100x32mm shall be fabricated and the edges shall be finished by grinding. 22mm dia holes shall be drilled at a pitch of 110mm in the guide base. Guide plate of size 25x100x8000mm shall be fabricated and the edges finished by grinding.The groove guide shall be fixed in position by marking a center mark in vertical position on the existing guide portion. The holes shall be marked for a pitch of 110mm in vertical intervals of 500mm c/c. The groove guide portion in masonry shall be drilled for 24mm dia and 250mm depth to accommodate the guide base. Anchor rod of 20mm dia and 300mm length shall be fixed using vinyl ester hybrid motor chemical . The guide base plate shall be connected to the anchor bolt at vertical intervals of 500mm. Guide plate of 25mm shall be welded to the center of base plate in vertical position. The straightness shall be ensured using plump level. The cost includes cost of materials, labour charges for dismantling and erection at site, hire charges for machinery like grinding machine, gas cutting equipment, drilling machine, welding plant & generator, rental charges for erection equipments like chain block & crane, cost of consumables such as oil, diesel & lubricants for generator, welding rod, grinding wheel, core cutter bits, oxygen & LPG, incidental charges like conveyance to &fro from site of work, loading & unloading, risk allowance, etc., complete, including maintenance & warranty for 5 years.

Repairing and Reconditioning of the cast steel Roller Assembly for the spillway gates of size 12140x4500mm as per the following specification. The gates shall be made to rest on the sill portion. The counterweight shall be locked to the deck bridge through pin connecting both sides. Lifting chains shall be released from the shutter by removing the pin from the chains. Then the shutter shall be lifted and placed on the dogging beam for repair. The wheel is 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 & sleeves 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, deducting the cost of old scrab materials and 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.

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 sandblasting. The average surface roughness after sand blasting 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, scaffolding charges, consumables like oil & diesel for generator, risk allowance, replacing the above parts with new one if it most necessary,etc, complete. including maintenance & warranty for 5 years.

Application of 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 a primer coat with Mastic primer shall be applied. The surface to be applied should be dry & abrasive blast cleaned up to Sa2 1/2. The dry film thickness should be 40 - 60 u for primer coat . The colour is grey and minimum plot time should be 12 hours. The mixing ratio of base to accelerator by volume should be according to the manufactures standard. All paint, when applied , shall provide a satisfactory film and as smooth and even surface . Paint shall be thoroughly stirred, strained and kept at the uniform consistency during application . Paint shall no be applied when the temperature of the metal or surrounding air is below 10 degree celcius and that of the metal is above 50 degree celcius, 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 during the initial curing period against the possibility of moisture condensation or contamination with foreign matter. All painting works shall be performed by spraying, when the coating material is applied by spraying, suitable means shall be removed from the air supply lines of all spraying equipment. primer coat shall be uniform and free from runs ,sags and other imperfections. The time between successive coats shall be not less then the minimum nor more then the maximum re-coating time specified bye 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 surface 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 and any health or safety hazard that may arise during the applications of the coating. Smoking and welding shall not be allowed within 10 meters of the place when painting in progress. The painting to the gates, hoists and other parts shall be done as per IS specification No.14177-1994.GuidIines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477(Part) 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 replacing the above parts with new one if it most necessary.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 u 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 degree 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 work 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 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 recoating 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 surface 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: 14177-1994.Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477(Part 1)- AND IS.•293-1994.The cost includes cost of coal tar 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.

Repair and Overhauling of existing Hoist assembly by dismantling all the parts of drive unit consisting of drums, gears, motors, pinion wheels & Plumber Blocks replacing the above parts with new one if it most necessary. And drain the old oil from motor and removing the old grease and dirts from the above parts and refix the assembly filled with new oil and grease such lubricants for smooth operation with correct alignment. the cost includes cost of materials, cost of consumables like welding rods, grinding wheels, drill bits, oxygen & acetylene gas, oil & diesel for generator, process charges like gas cutting and welding, drilling, abrasive blast cleaning, application of zinc rich primer & coal tar epoxy, hire charges for machinery like gas cutting plant, welding equipment, magnetic drilling machine generator, grinding machine, compressor, airless spray machine, hoisting equipment like chain pulley block, derrick post, crane, labour charges for loading, lifting, unloading, transport erection, scaffolding, conveyance to site and clearing them after completion of work, inclusive of all taxes etc., complete and as directed by the departmental officers.

Fabrication supply and installation of chain enclosure for hoist assembly by using composite panels of thickness 3mm made as single unit as per the drawing. The composite cover shall be spaced in such a way to resist bending with inherent stiffeners provided . A liftyhandie in steel composite material shall also be incorporated. UV resistant polyester polymer and high grade reinforcement shall be used for fabricating composite rope drum enclosure the composite material made of glass fiber reinforced polymer shall be of high strength of 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 ,Hardners, pigments, Aerosil powder cost of consumables like ,Rotters, brushes, labour charges for handly up, grinding, finishing, loading, transport , erection hire charges for equipments like air compressor, 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.

Fabrication supply and installation of center hoist enclosure for hoist assembly by using composite panels of thickness 3mm made as single unit as per the drawing. The composite cover shall be spaced in such a way to resist bending with inherent stiffeners provided . A liftyhandie in steel composite material shall also be incorporated. UV resistant polyester polymer and high grade reinforcement shall be used for fabricating composite rope drum enclosure the composite material made of glass fiber reinforced polymer shall be of high strength of 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 ,Hardners, pigments, Aerosil powder cost of consumables like, Rotters, brushes, labour charges for handly up, grinding, finishing, loading, transport , erection hire charges for equipments like air compressor, 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 & modification of operating platform by removing the old chequered plate from the existing platform arrangements and providing the new 6mm chequered plate over the existing steel structure and providing new ms angles and channels in the structure wherever necessary. The steel members shall be coated with a coat of zinc rich primer over which coal tar epoxy shall be applied. 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 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, warranty for 5 years, etc., complete as directed by the departmental officers.

Repair and Replacing the damaged portion of lifting chain and repairing the counter weight arrangements in the hoisting arrangements of vertical lift gate of size 12140 X 4500 mm including removing the chain from the counter weight arrangement to avoid accidental movement. And Conveyed to work shop and delink the damaged portion of the chain. The new roller chain of 5" pitch made up of steel links and short cylindrical rollers are linked with the existing chain arrangements and conveyed to the work site and lifted to the platform by using cranes and chain pulley and fixed to the existing chain on one side with connecting shackle by means scaffolding arrangement of and other side fitted to the counter weight arrangement with required eye bolts. The cost includes cost of all materials, process charges like gas cutting, welding, machining, Milling, Shaping, scaffolding charges, labour charges for dismantling, loading, lifting, unloading, transport, erection, labour charges for equipments like crane, derrick, chain pulley block, power charges from 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.

GST 18% IN FIGURES

Rali Engineering Works (BID ID -1089655)