Renewal of lift gate of vent in Sithamalli Reservoir in Kargudy village of Udayarpalayam Taluk in Ariyalur District

Amount

Repairing the Lift Gate of Sithamalli reservoir(vent size 11.00m X 4.75 m) by cutting the eroded shutter parts at the bottom portion up to 1.90m height including eroded skin plate and two bottom trusses by using gas cutting equipments . The process carefully done without cause any damage to the skin plate and roller box arrangements. After the cutting, the cutting materials conveyed to the section store by lorries including stacking carefully at the section store. The cutting edges of the skin plate cleaned with hand grinders and wire brushes for free from rust and dirts. The gate rollers dismantled from the end verticals carefully by using gas cutting equipments. The damaged bottom portion of the end verticals on both sides dismantled for 1.70m height and providing new end verticals made up of ISMB 500 two numbers on both sides provided with holes for roller pin and strengthened with diaphram plate made of 12mm thick MS plate and welded to the existing end verticals firmly by using proper electrodes with welding machine powered by Power Generators. The dismantled rollers repaired by remove the roller pin with proper equipments and then the roller box opened up and body cleaned with cleaner liquid and with wire brushes and the damaged roller bearings removed from the roller and new two numbers of NU 220 bearings and new chromium coated 100mm dia roller pin for each roller to be fixed in proper alignment . After completion of the process the four gate rollers fixed to the end vertical with roller pin with proper scaffolding arrangement and hoisting equipments . The shutter repair work process done with new skin plates for bottom portion made up of 12mm thick mild steel plate cutting into required size match to the existing joints for 1.90m height and welded to the existing shutter skin plate with same alignment with welding machine powered with power generators. The bottom trusses fabricated with outer frame made with 200 X 75 mm mild steel two numbers welded back to back for full width in inner and outer side of the truss. The vertical stiffeners for the truss six numbers made up of 50 X 50 X 10 mm mild steel angles welded back to back welded to the inner and outer channel frame firmly to the correct alignment and position .And the trusses diagonally stiffened both sides at six joint made up of two numbers of 65 X 65 X 10 mm mild steel angles welded back to back and welded to the channel frames to the correct alignment and position . All the six joints and the corners of the shutter supported with gusset plate made up of 12 mm thick mild steel plates for required size. The fabricated truss welded to the skin plate in correct position by using necessary support frames and with hoisting equipments for holding the truss at required height and welding the truss properly to the skin plate and welding the diagonal stiffeners in all the six joint two numbers welded with bottom truss to the upper truss made up of 65 X 65 X 10 mm mild steel angles and then the Vertical additional stiffeners 12 nos made up of 75 X 75 X 10 mm mild steel angles welded to the inner side of the outer frame to the full height. Then skin plate vertically stiffened with 10 nos of mild channel of 250 X 75 mm size welded firmly to the skin plate with welding equipments .The rate including supply of new structural members, cut to shape, connecting bolts and nuts, gazette plates, etc. drilling, machining, welding, grinding, facing, power generating and scaffolding charges and including cost of conveyance of materials to site, to and from charges of manual labours and equipments to site . etc., complete complying with standard specification and as directed by the departmental officers.

Renewal of operating platform including renewal of damaged operating platform of size 13.00m x 3.00m by dismantling the existing eroded chequered plate by using gas cutting equipments without cause any damage to the structural supports and removing the cutting pieces from the regulator and conveying and stacking at the section store. Cleaning and grinding the structural members such as RSJ beams , channels and angles by using wire brushes and hand grinding machine operated by power generator for removal of rust. After the cleaning process painting the structural members with two coat of anti corrosive black paint over on coat of zinc chromate primer at an interval of 24 hrs. Providing new surface of operating platform made up of 5mm thick mild steel chequered plate laying and fixing plates properly over the structural members by cutting the plates for required sizes by using cutting equipments and welding the plates with welding machine operated by power generator with recommended welding rods and grinding the edges smoothly for with hand grinders . After welding cleaning the welded portion with wire brushes to remove the welding flags and dusks. Then painting the platform with two coat of anti corrosive black paint over one coat of zinc rich primer on both sides of the plates as per IS standards . The cost includes cost of materials charges for grinding. finishing, loading, lifting, unloading, transport, erection, hire charges for equipments like welding machine , cutting equipments, pneumatic tools, conveyance of equipments to site and clearing them after completion of work, including warranty for 5 years, etc. complete as directed by the departmental officers

Overhauling of existing hoisting arrangements for the Regulator shutter of size 11000 x 4750 mm as per the following specification. The existing hoist covers shall be opened up and conveyed to the section store. 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. The bearings, if found defective/ corroded, shall be replaced. Fresh grease shall be applied to the Plummer block and top cover and closed with requisite fasteners. The shaft shall be checked for its alignment and redone to ensure straightness of shaft. The existing gear wheels and pinions shall be cleaned of dried grease and dust manually. The reduction gearbox shall now be drained of old used lubricant thro 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 chain and chain sprocket mechanism in the hoisting arrangements shall be cleaned of dried grease and dirt &appropriate lubricant shall be applied. The existing motor and 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 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, conveyance to site and clearing them after completion of work, including cost of trial operation, etc., complete as directed by the departmental officers.

Fabrication, supply and installation of centre hoist cover by using composite panels of thickness 3mm made as a single unit as per the drawing The composite cover shall be spaced in such a way to resist bending with inherent stiffeners provided A lifting handle 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 fibre reinforced polymer shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties. The cost includes cost of mould & pattern, deducting the cost of old scrab materials and charges for 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, 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

Fabrication, supply and installation of chain enclosure for hoist assembly by using thickness 3mm made as a single unit as per the drawing The composite cover shall be spaced in such a way to resist bending with inherent stiffeners provided. A lifting handle 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 fibre reinforced polymer shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties. The cost includes cost of mould & pattern, deducting the cost of old scrab materials and charges for 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 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

Providing abrasive blast cleaning using air blast cleaning with abrasive aluminum oxide/steel grits/sand a per the following specification. Moisture should not be present on the steel surface during blast cleaning. All, oil, paraffin, grease & din 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 substance 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, clam 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, reclining 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 changes for generator, compressor, hopper, accessories. conveyance of machinery to & fro from site of work, inspection charges,transport charges, scaffolding charges, consumables like oil & diesel for generator, risk allowance , etc, complete.as directed by the departmental officers

Providing metalizing 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 costing provide corrosion protection by excluding the environment and acting as a barrier coasting and they also provide sacrificial anodic protection. The temperatures during the process reach around 95oc. These coating are typically mechanically bonded to a gift 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. The cost includes cost of materials, labour charges, transport, erection, hire charges for machinery incidental charges like conveyance to & fro from site, risk allowance etc., complete as directed by the departmental officers

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 Mastic primer shall be applied. The surface to be applied should be dry & abrasive blast cleaned up to Sa21/2. The dry film thickness should be 40-60µ For prime: 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 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 min 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 he 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 cont 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 specification. Surface not required to be coated, but adjacent to surfaces which an: 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.14 177-1994. 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:2339-1994. 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 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-l25 h 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 min 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.14l77-l994. 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. .

GST at 18%

Rali Engineering Works (BID ID -1152717)