Replacement of Service shutters of River sluice and canal sluice, Refurbishment of Spillway shutters and Fabrication of Inspection platforms and Emergency sluice shutter of Amaravathi Dam in Udumalpet Taluk of Tiruppur District.

Design, drawing, fabrication, transport and installation of canal/ river sluice shutter including skin plate with vertical stiffeners, horizontal girders, end verticals, rib plates, etc, suitable for canal/ river sluice gate of vent size 1520 x 1830mm as per IS 4622. The skin plate with vertical stiffeners, horizontal girders, end verticals, rib plates shall be made of structural steel confirming to IS 2062 : 2011.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, drawing, fabrication, transport and installation of emergency shutter including skin plate with vertical stiffeners, horizontal girders, end verticals, rib plates, etc, suitable for emergency gate of size 3100x2740mm as per IS 4622.The wheels shall be made of cast steel of 400mm Ø adhering to IS 1030 and wheel pin of 100mm Ø made of 30 CR 13 grade adhering to IS 1570 . Rear side cover plate and seal base plates shall be provided with 20mm thick MS plate. Side rubber seals, Top seal & bottom seals shall be of “P” type of size 100x44x14mm. The involute spring and lifting valves shall be provided as per IS standards. The guide rollers with pins for side and upstream side shall be IS 210. All steel surfaces shall be blast cleaned as per SA 2 ½ standard and the surfaces shall be applied with epoxy primer to a thickness of 50µ. The finish coat shall be coal tar epoxy 250µ thick in two coats over the primer. 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 shall be cleaned of dirt, grease, oil, welding spatter, 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 chainpulley 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, warranty for 5 years etc., complete as directed by the departmental officers.

Repair & Refurbishing of emergency shutter in River Sluice of size 3100x2740mm as per the following specification. Dismantling the shutter from hoist, removing all rollers, seals, water escape valves parts as directed by the department Officers. Dismantling all rollers, removing of bearings, seals, grease nipples, etc., cleaning of rollers and shafts and re assemble of rollers with new bearings, seals, grease nipples with full grease packed complete as directed by departmental Officers. Removing of water escape valve and overhauling of the valve seat, spring, spring seats and valves complete as directed by department Officers. Removing seals and CSK bolts and supply and fixing of musical note seal/P type seals and corner seals size of 100x44x14mm. Stainless steel 304 grade CSK bolts and nuts as per sample complete as directed by department Officers. Removal, cleaning and re fixing of water chamber plate with new gaskets and bolts complete as directed by Department Officers. The gate shall be blast cleaned with SA 2 ½ standard and the surface shall be applied one coat of zinc epoxy primer with 50µ. The finish coat shall be applied 250µ in two coats of coaltar epoxy. Labour charges including machining, drilling, welding, gas cutting, all materials and conveyance to this site, loading and unloading charges, grease packing, lubricating oil, all civil works and satisfactory trial run complete as directed by the Departmental Officers. Handing over of all old materials removed from this work and to be staked at dam site as directed by dam officials, etc., All materials and works should be as per technical specification.

Repair & Replacement of suspension channel in Amaravathi dam river sluice & canal sluice as per the following specification. New suspension channel shall be made of 125x65mm twin channels facing each other at a distance of 65mm with ISMC 125x65 welded between them as spacers. The spacers shall be provided at a vertical distance of 500mm c/c from each other. These twin channels shall withstand the designed loads. The existing screw rod of size 100mmØ & 3000mm length shall be connected to the new suspension channel with a system of bolt & nuts of size 6"x5/8". The suspension channel shall be of appropriate height as per site condition but should be fabricated in cut lengths of 3m since beyond that the suspension channel for screw rod cannot be removed from its position for maintenance. The suspension channels shall be connected to each other with a system of 10mm plate of size 200x250mm using bolts & nuts. The bottom of the suspension channel extends upto the top horizontal member of the shutter. Then it shall be assembled for efficient operation, as directed by the departmental officers. All members shall be given a coat of epoxy primer overwhich two coats of anticorrosive coaltar epoxy paint shall be applied. The cost includes cost of materials, labour charges, hirecharges for machinery like derrick, chainpulley block, gas cutting equipment, welding plant, erection, etc, cost of conveyance to & fro from site of work, risk allowance, trial operation, warranty for 5 years etc, complete.

Repair and Replacement of the suspension guide channel as per the following specification. The suspension guide channel is inside the sluice well to guide the suspension channel connecting the sluice shutter to the hoisting arrangements. The old corroded suspension guide channel shall be cut and removed from the masonry with concrete breaker machine & stacked at PWD stores as directed by the departmental officers. The new suspension guide channel shall be cut to the required size and given a coat of zinc rich primer over which two coats of coal tar epoxy shall be applied. The masonry on either ends of the channel shall be broken at appropriate places and then the channel shall be embedded with concrete at the appropriate place. The cost includes cost of materials, labour charges, hire charges for machinery like derrick, chain pulley block, gas cutting equipment, welding plant, erection, civil works wherever necessary etc, cost of conveyance to & fro from site of work, risk allowance, trial operation etc, complete.

Dismantling the existing corroded old ladder & replacement with new safety ladder arrangements to the sluice well as per the following specification. The main stiles at both ends shall be 410mm apart and made up of 50x8mm MS Flat. They shall be connected in between with treads of size 16mm dia MS rod. This tread shall be welded to the stiles on either side. The treads shall be spaced onebelow the other at a distance 300mm equidistant from each other. The bottom of the ladder shall be buried in concrete. The top of the ladder shall be welded to the operating head platform. All members shall be given a coat of redoxide and then two coats of aluminium oxide is given. The old unusable ladder shall be removed and stacked at stores for disposal as directed by the departmental officers. The cost includes cost of materials, labour, erection, transport, civil works wherever necessary etc, complete.

Replacement of bottom rubber seal of the spillway shutter as per the following specification. The old rubber seal shall be removed from the skin plate after removal of the rusted bolts & nuts by gascutting 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 100x10mm MS flat & the new 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. 18mm holes shall be punched accordingly in the rubber seal of size 100x12mm. The inside surface of the seal seat cover is given a coat of anticorrosive zinc rich primer over which two coats of coal tar epoxy shall be applied at an interval of 24 hours between each coat. 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 M16x75. 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 Z type rubber seal on either ends of the shutter with SS side seal seat as per the following specification. The seal seat shall be made of MS flat 70x16mm of length 7680mm and seal cover flat shall be made of MS flats 55x10mm of length 7680mm. They are tag welded together for matching and M10 holes shall be drilled with a centre to centre distance of 100mm. The seal seat shall be tap drilled size of M12. The seal cover flat shall be drilled M14 over the pilot drill. The seal seat shall be fitted with skin plate both ends and welded with skin plate. Now the ‘Z’ type seal of size 74x79x16mm shall be cut to the required size and matched with the seal seat cover and holes are punched in the rubber seal accordingly. Now the Z type seal shall be sandwitched between the skin plate & seal seat cover. SS bolts M12 shall be used to fasten them to the skin plate. SS flat of size 70x8m and of length 7700mm is used as side seal seat. The flat shall be cut to a length of 7700mm and fixed appropriately in the groove angle to act as side seal flat to reduce the friction during the sliding of rubber seal at the side. The cost includes cost all of materials, labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site, insurance etc., complete and as directed by departmental officers.

Providing dogging / latch beam arrangements including embeddment 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 warranty for 5 years. This includes scaffolding and civil works wherever necessary as directed by the departmental officers.