Repair and Rehabilitation of Hanuman Setu Flyover Delhi. (SH Repair of Spalled and Honeycomb Concrete, Replacement of Expansion joints and Bearing)

Amount

Item No. 1: Demolishing R.C.C. work manually/ by mechanical means including stacking of steel bars and disposal of unserviceable material within 50 metres lead as per direction of Engineer - in- charge.

Item No. 2: Disposal of malba/building rubbish/malba/similar unserviceable, dismentled or waste materials by mechanical means, including loading, transporting unloading to approved municipal dumping ground or as approved by Engineer-in-charge, beyond 50m initial lead, for all leads including all lifts involved.

Item No. 3: Chipping of unsound/weak concrete material from slabs, beams, columns etc. with manual Chisel and/ or by standard power driven percussion type or of approved make including tapering of all edges, making square shoulders of cavities including cleaning the exposed concrete surface and reinforcement with wire brushes etc. and disposal of debris for all lead and lifts all complete as per direction of Engineer-In-Charge Average Thickness =50 mm

Item No. 4: Cleaning of reinforcement from rust from the reinforcing bars to give it a total rust free steel surface by using alkaline chemical rust remover of approved make with paint brush and removing loose particles after 24 hours of its application with wire brush and thoroughly washing with water and allowing it to dry, all complete as per direction of Engineer-In-Charge

(a) Bars up to 12 mm diameter

(b) Bars above 12 mm diameter

Item No. 5: Providing, mixing and applying bonding coat of approved adhesive on chipped portion of RCC as per specifications and direction of Engineer-In-charge complete in all respect.

(a) Epoxy bonding adhesive having coverage 2.20 sqm/kg of approved make

Item No. 6: Providing and inserting 12mm dia galvanized iron / PVC injection nipple in honey comb area and along crack line including drilling of holes of required diametre (12mm to 30mm) up to depth from 30mm to 80mm at required spacing and making the hole & crack dust free by blowing compressed air, sealing the distance between injection nipple with adhesive chemical of approved make and allow it to cure complete as per direction of Engineer-In-Charge.

Item No.7:Providing and injecting approved grout in proportion recommended by the manufacturer into cracks/honey-comb area of concrete/ masonry by suitable gun/pump at required pressure including cutting of nipples after curing etc. complete as per directions of Engineer in-Charge. (The payment shall be made on the basis of actual weight of approved grout injected.)

Epoxy injection grout in concrete/RCC work of approved make

Item No. 8: Dismantling the existing strip seal expansion joint i/c structural steel edge beam anchor plate etc. of the existing damaged expansion joint by cutting with gas cutter and breaking of concrete by mechanical means i/c disposal of rubbish & malba etc. complete as per the direction of the Engineer-in-Charge.

Item No. 9:Providing and fixing in position single strip seal expansion joints catering to horizontal movement upto 80 mm. The expansion joints shall contain single cell assembly comprising of edge beams, poly chloroprene seal, anchorage elements, support and control system, all steel sections protected against corrosion, welded with suitable anchoring arrangement as per MORTH/manufacturer’s specifications and approved design and drawing. Poly chloroprene seal shall be a preformed/extruded single strip of such a shape as to promote self- removal of foreign material during normal joint operation. All complete as per direction of Engineer-in-Charge. Note: (i) cost of design and drawing shall also be borne by the contractor for expansion joints and temporary arrangement for covering gap of expansion joint. (ii) The item includes the cost of providing and welding additional reinforcement steel where required and cost of shuttering, thermocol etc. (iii) Dismantling of existing damaged joints and concreting shall be paid separately. (iv) Expansion joint shall be provided with a warranty of trouble free maintenance of 15 years.

Item No.10: Providing and placing high strength, non shrink, pre-packed, free flow micro concrete having compressive strength of 60 MPa at 28 days (compressive strength of one day should not be less than 25 MPa). The micro concrete mix shall be prepared by mixing high strength, non shrink, pre-packed, free flow micro concrete powder with well graded cleaned crushed aggregates of 10mm & down size (Aggregates should be less than 10mm but retained on 3.36mm) in proportion of 2:1 (Two part pre-packed micro concrete powder : one part stone aggregates) by weight for repairing excessively damaged area of structural elements/Jacketing work/expansion joint repair etc. excluding reinforcement but including centering and shuttering as required, scaffolding, curing as per manufacturer's specifications inclusive of all labours, materials, equipments etc. all complete as per directions of Engineer-in-Charge. (Note:-High strength, Non shrink, prepacked, free flow micro concrete powder content considered in this item is 1450 kg/cum).

Item No. 11: Providing and applying of anticorrosive treatment to exposed structural reinforcement by two coats of IPNET RB or equivalent application with time interval of minimum 8 -10 hours between each coat after application of two coats of alkaline rust converting primer confirming to ASTM-B-117. The application shall be done by brush or spray after cleaning existing reinforcement with wire/ rotary wire brush to make the surfaces free from loose material, dirt etc. inclusive of all labour, materials, equipment etc. complete as per specifications and instructions of Engineer in Charge. (Surface area of member shall be measured for payment purpose).

Item No.12: Credit for cost of scrap/salvage value of dismantled mild steel materials (Bearings, Expansion Joints etc.) received from site, which will be the property of the contractor.

Item No. 13: Providing and painting with approved quality two or more coats of anti-carbonation paint, single component, flexible, elastomeric coating based on acrylic co-polymer coating and compatible primer coat as per manufacturer’s specifications and the direction of Engineer-in-Charge over un-plastered concrete surface of piers and superstructures after cleaning and removing dirt, dust, oil, grease, efflorescence to obtain an even surface and applying paint @0.44 kg per sqm and primer @ 0.22 kg per sqm, total dry film thickness (DFT) of the coating shall not be less than 150 microns including all scaffolding, testing of materials etc necessary tools, plants, machinery with all leads, lifts and depths and all related operations as required to complete the work as per drawings, specifications and directions of Engineer- in-Charge. Note:- The work shall be carried out only through approved applicator of manufacturer. The manufacturer/ applicator shall provide a guarantee of satisfactory performance of anti carbonation coating for 5 years through contractor.

Item No. 14: Lifting of superstructure span by deploying appropriate Lifting System for all span length with centralised power jack to facilitate for removing of existing bearing without damaging the girders, cleaning and removing the damaged bearings including its stacking. After completion of restoration of bearings at supports, lowering of deck shall be carried out to its original position without causing any damage to the deck and girder as per approved method statement and standard practice. The item includes all labour, materials equipments etc. complete as per specification and instructions of Engineer in Charge including MORT&H specification (5th Revision) clause 2810.

Item No.15: Providing , fitting and fixing in position true in line and level elastomeric bearings (conforming to IRC: 83 (Part-II) section IX and clause 2005 of MORTH specifications) on pedestals from pier cap / abutment cap for vertical loads, complete in all respect with all components including grouting with non-shrink cementatious grout as per specification. Item includes preparation of design and drawing and its approval from the Engineer-in-charge, manufacturing, testing, transportation to site, storage with all handling, lead, lift etc. and placing the permanent bearings in position. Cost of providing temporary bearings / supports as required and other incidental expenses (if any) shall also be included. Bearings shall be provided with a warranty of trouble free maintenance of 15 years.

Item No.16: Supplying, fitting and fixing in position true to line and level cast steel rocker bearing conforming to IRC: 83(Pt.-1) section IX and clause 2003 of MoRTH specifications complete including all accessories as per drawing and Technical Specifications. Bearings shall be provided with a warranty of trouble free maintenance of 25 years.

450 t vertical & 18 t horizontal load capacity / bearing

Item No. 17:Drainage spout having corrosion resistant structural steel, HDPE Pipe 160 mm dia 6 meter long including fixing of to 160 mm dia HDPE runner and down take pipes with reducer, fixed using G.I. Bolts, Galvanised M.S. Flat Clamaps including fabrication fixing in position as per drawing & technical specification. (Cost is inclusive of T&P, Material, Labour and required centering shuttering etc.)

Drainage spouts with Stainless steel plate fixed with pipe outlet for dispersion of water and HDPE pipe of 160mm dia runner and down take pipe all complete i/c 160mm dia water spout with IG grating

Item No. 18: Patching of damaged concrete surface with polymer concrete and curing compounds, initiator and promoter, available in present formulations, to be applied as per instructions of manufacturer and as approved by the Engineer for replacement of spalled concrete in the locations where spalling occurs with & without exposed reinforcement in components of superstructure, substructure, foundation (well cap), approach road/ramp and honeycombing etc.

D P Associates

SSA TECHNO CONSTRUCTION PRIVATE LIMITED

SANFIELD INDIA LIMITED

Hercules Structural Systems Pvt. Ltd.