Carry out balance work of Restorative repair works for Berth No.8 KIOCL Berth at NMPT Retrofitting work of deck structure and RCC pile through risk and cost

SURFACE PREPARATION: The cover concrete shall be chipped and removed up to rear side of the steel bar shall be exposed using the electrically operated c hammer chipping machine and hand chiseling by using water jet for the removal of all loose particles, fungal and marine growth including the cost of all materials, hire charges of compressor, pneumatic tools, hire charges of barge, boat, water jet and all labour charges etc., complete.

ANCHORING SHEAR CONNECTORS: Providing and fixing the shear connectors (secondary reinforcement), 10 mm dia holes shall be drilled at the required locations as per the drawings. The pilot holes shall be drilled using 10mm dia hammer drill bit. The holes shall be widened using the appropriate drill bit size 16/18 mm dia. Drilling shall be carried out without much of vibration so as not to disturb adjacent concrete. The holes shall be roughened for better bonding. The holes shall be cleaned with good water. The base and hardener of Anchor grout shall be mixed and poured to 2/3 of the depth followed by insertion of the shear connecting rod of 12 mm dia gently in to the pre poured holes. The resin grout material utilized shall be tested in accordance with BS 4551, BS 5080 and BS 2782 respectively. Gaps if any shall be packed with mixed grout. Allow it to set for a minimum of 20 minutes without disturbing including the cost of all materials, hire charges of hammer drilling machine and all consumables cost of 12mm shear connecting rod and all labour charges etc., complete.

NEW REINFORCEMENT : Providing and fabricating T.M.T steel reinforcement including straightening, cutting, bending, hooking, placing in position, lapping and / or welding wherever required, tying with binding wire and anchoring to the adjoining members wherever necessary complete as per design (laps, hooks and wastage shall not be measured and paid) cost of materials, labour, HOM hire charges of barge, boat, complete as per specifications - TMT bars Fe 550

PROVISION OF ANTICORROSIVE TREATMENT TO THE OLD AND NEW REINFORCEMENT: Anticorrosive coating to the reinforcement: Consist of providing and Applying zinc Primer two coats for the Re bars, primer shall be an epoxy based, two component, zinc rich liquid packed and supplied ready to use confirming to IS14589:1999 (Reaffirmed 2004). An unbroken 40 microns dft/coat coating shall be capable of providing active galvanic protection and avoiding the generation of incipient anodes in the immediately adjacent locations. It shall be of suitable viscosity to enable the coating to penetrate into imperfections and pits within the surface of the structural steel, strictly following the manufacturers instruction. Cost of all materials, tools and labour cost etc., complete.

KSRRBM 2800-11: Epoxy bonding of new concrete to old concrete including cost of materials, labour, HOM complete as per specifications. MORTH Specification No. 2805

MICRO CONCRETE FOR 75 TO 100 MM THICK: Providing and laying Micro Concrete, polycrete - A or equivalent shall be stocked along with 12 mm downgraded chips at site to enable completion of pouring in a continuous operation. An approved grout concrete mixer of slow speed heavy duty drill shall be used for the mixing of the micro concrete. Exact quantity of water as directed by the department should be poured in to mixing vessel along with the polycrete or equivalent and 12 mm cleaned chips (in the ratio of 1:0.50 or 0.75) slowly. The mix shall be mixed thoroughly in forced action. The mixed material should be placed immediately in the formwork continuously without any gap through the PVC pipe fixed from the top of the deck. The cost inclusive of, providing and fabricating, fixing and removing Slurry tight formwork for facilitating micro-concreting work using water-proof plywood/ steel shuttering/ FRP sheets which should not deform or leak due to pressure of micro concrete shall be fabricated and erected in position. Provision shall be made for pouring micro concrete in to the form work, which shall be coated with mould release agent. Proper supporting arrangement shall be made for keeping the shutter in correct line and length Cost inclusive of sufficient Nos of Core cutting of minimum required diameter size of existing structure on the concrete surface for Pouring Micro concrete by trimmie method for the Slab areas. Cost inclusive of approved type and make pre-fabricated access and working platform, fabricated, as per site requirement for successful completion of work. The cost of all materials, cost of hire charges barges, pontoon, boat, all machineries diving equipment and all labour charges including divers etc., complete.

MEMBRANE CURING AGENT: SELF CURING COMPOUND FOR CONCRETE SURFACE : (WATER/ WAX BASED) Providing & applying water based (WB) / wax based low viscosity wax emulsion curing compound membrane / layer applied in the form of spray over the concrete surface. The material consists of self-curing compound membrane satisfying ASTM C309-90 standard ensuring a non-penetrating continuous film on the concrete surface covering an area of 4.5 to 5 sqm per ltr of curing compound and shall be applied with a distance of 45 cms after 5 hours of concreting to get the best results.

High performance Anti carbonation protective coating Providing and applying primer and two coats of 100% acrylic breathable, water based, anti-carbonation coating. Coating to be applied at the rate 300 g/m2. Minimum OFT of coating to be 225 micron. The coating shall have at least a 4 year track record of use as an anti-carbonation coating and shall have the test reports evaluated from Ministry of New and renewable Resources supported laboratory demonstrating Solar Reflectance Index (ASTM E 1980-11, EN 673:2011, EN 410:2011) > 104. 1.Carbon dioxide diffusion equivalent air layer thickness (DIN EN 1062-6) >100m 2.Carbon dioxide diffusion resistance co-efficient (DIN EN 1062-6) > 7.50X105 3.Elongation of cured film shall be as per ASTM D 2310/98 > 400% 4.Chloride Ion Diffusion (ASTM C 1202) =Zero Penetration 5.Adhesion (ASTM D 4541) > 2 N/mm2

KSRRB M2800-10 Applying pre-packed cement based polymer mortar of strength 45 Mpa at 28 days for replacement of spalled concrete including cost of materials, labour, HOM complete as per specifications. MORTH Specification No. 2800

PRECAST DECK SLAB: Providing and laying cement concrete M40 using 20mm and down size granite coarse aggregates and fine aggregates of ready mixed concrete for RCC works laid in 15em thick layers and well compacted including vibrating curing etc., for all super structure works with all lead and lift, Including cost of Lifting and placing of slabs in position, cost of centering and shuttering, etc., complete. (excluding cost of steel and fabrication charges)

KSRRB M200-12.3 Dismantling of existing structures like culverts, bridges, retaining walls and other structure comprising of masonry, cement concrete, wood work, steel work, including T&P and scaffolding wherever necessary, sorting the dismantled material, disposal of unserviceable material and stacking the serviceable material with all lifts complete as per specifications. – Pre stressed I Reinforced cement concrete grade M-20 above. Deck Slabs

WEARING COURSE OVER BERTH SURFACE : Providing and laying cement concrete using 20mm and down size granite coarse aggregates and fine aggregates of ready mixed concrete for RCC works laid in 15 em thick layers and well compacted including vibrating curing etc., for all super structure works with all lead and lift etc., complete. (exculsive of cost of steel and fabrication charges) Note : The RMC should be obtained only from the plants certified by Quality Council of India as per CE, C&B letter, AE2, 2015-16, Dt. 12-09-2015 - Ready mixed Cement concrete M-35.

REMOVING OF PILE LINER: The pile liner shall be removed using the gas cutting equipment/ electrically operated cutting grinder to expose the concrete surface to continue the rehabilitation works. Including cost of stacking of removed pile liners at designalted place, cost of all materials, hire charges barge/ pontoon, boat, underwater cutting tool and all consumables and all labour charges etc., Complete.

SURFACE PREPARATION: The cover concrete shall be chipped and removed up to rear side of the steel bar shall be exposed using the electrically operated c hammer chipping machine and hand chiseling by using waterjet for the removal of all loose particles, fungal and marine growth including the cost of all materials, hire charges of compressor, pneumatic tools, hire charges of barge, boat, water jet and all labour charges etc., complete.

ANCHORING SHEAR CONNECTORS: Providing and fixing the shear connectors (secondary reinforcement), 10 mm dia holes shall be drilled at the required locations as per the drawings. The pilot holes shall be drilled using 10mm dia hammer drill bit. The holes shall be widened using the appropriate drill bit size 16/18 mm dia. Drilling shall be carried out without much of vibration so as not to disturb adjacent concrete. The holes shall be roughened for better bonding. The holes shall be cleaned with good water. The base and hardener of Polyester resin Anchor grout shall be mixed and poured to 2/3 of the depth followed by insertion of the shear connecting rod of 12 mm dia gently in to the pre poured holes. The resin grout material utilized shall be tested in accordance with BS 4551, BS 5080 and BS 2782 respectively. Gaps if any shall be packed with mixed grout. Allow it to set for a minimum of 20 minutes without disturbing including the cost of all materials, hire charges of hammer drilling machine and all consumables and all labour charges etc., complete including cost of 12mm connecting rod

New Reinforcement: Providing and fabricating T.M.T steel reinforcement including straightening, cutting, bending, hooking, placing in position, lapping and / or welding wherever required, tying with binding wire and anchoring to the adjoining members wherever necessary complete as per design (laps, hooks and wastage shall not be measured and paid) cost of materials, labour, HOM hire charges of barge, boat, complete as per specifications - TMT bars Fe 550.

PROVISION EPOXY BONDING AGENT: KSRRBM 2800-11. Epoxy bonding of new concrete to old concrete including cost of materials, labour, HOM c

omplete as per specifications. MORTH Specification No. 2805

UNDER WATER MICRO CONCRETE: Providing and laying underwater micro concrete polycerate or equivalent and 12 mm downgraded chips shall be stocked at site to enable completion of pouring in a continuous operation. An approved grout concrete mixer of slow speed heavy duty drill shall be used for mixing. Exact quantity of water as directed by the department should be poured in to mixing vessel and polycerate or equivalent and cleaned chips shall be mixed slowly and thoroughly in forced action. The mixed material should be placed immediately to positioned form work continuously without any gap through the PVC pipe fixed from the top of the deck to the concrete location. The cost inclusive of providing, fabricating, fixing and removing Slurry tight formwork for facilitating micro-concreting work using water-proof plywood/ steel shuttering/ FRP sheets which should not deform or leak due to pressure of micro concrete shall be fabricated and erected in position. Provision shall be made for pouring micro concrete in to the form work, which shall be coated with mould release agent. Proper supporting arrangement shall be made for keeping the shutter in correct line and length. The cost of approved type and make pre-fabricated access and working platform, fabricated as per site requirement for successful completion of work. The cost of all materials, cost of hire charges barges, pontoon, boat, all machineries diving equipment and all labour charges including divers etc., complete.

MEMBRANE CURING AGENT: SELF CURING COMPOUND FOR CONCRETE SURFACE : (WATER/ WAX BASED) :Providing & applying water based (WB) / wax based low viscosity wax emulsion curing compound membrane / layer applied in the form of spray over the concrete surface. The material consists of self-curing compound membrane satisfying ASTM C309-90 standard ensuring a non-penetrating continuous film on the concrete surface covering an area of 4.5 to 5 sqm per ltr of curing compound and shall be applied with a distance of 45 cms after 5 hours of concreting to get the best results.

High performance Anti carbonation protective coating:- Providing and applying primer and two coats of 100% acrylic breathable, water based, anti-carbonation coating. Coating to be applied at the rate 300 g/m2. Minimum OFT of coating to be 225 micron. The coating shall have at least a 4 year track record of use as an anti-carbonation coating and shall have the test reports evaluated from Ministry of New and renewable Resources supported laboratory demonstrating Solar Reflectance Index (ASTM E 1980-11, EN 673:2011, EN 410:2011) > 104. 1. Carbon dioxide diffusion equivalent air layer thickness (DIN EN 1062-6) >100m 2. Carbon dioxide diffusion resistance co-efficient (DIN EN 1062-6) > 7.50X105 3. Elongation of cured film shall be as per ASTM D 2310/98 > 400% 4. Chloride Ion Diffusion (ASTM C 1202) =Zero Penetration 5. Adhesion (ASTM D 4541) > 2 N/mm2

CORE DRILLING: Core cutting of minimum required diameter size of existing structure on the concrete surface for Pouring Micro concrete by trimmie method for the Piles and Slab areas, the rate shall include cost of equipment, plants, materials, sand, instrumentation, etc. complete.