SPECIAL REPAIR TO DECK SLAB AND BEAMS OF SOUTH JETTY AT NSRY KOCHI

Amount

M&L for Surface Preparation: Labour charges for chipping/cutting the spalled/distressed and old concrete of the RC Structural elements viz., RC Deck Slab, RC Deck Beams, RC column etc., with out damaging the existing rebar and rear side of rebar shall be exposed using mechanical arrangements/ by hand chiselling. Check for the phenolphthalein test and if there is no change in color, chip the same further down until, reaching the good or uncontaminated concrete. Clean the surface and make sure that surface is clean and free from loose particle. Water jet may be used for removal of all loose particles and corrosion stains complete all as specified and as directed. Note:- The quoted rate shall include the cost of all the materials and operations

M&L for Anchoring Reinforcement into RC Elements: Mark the position of holes to be drilled for anchoring the rebar into the RC Deck slab/ RC Deck Beams or other RC elements. Drill 16mm dia holes in the marked places using rotary hammer drilling machine of reputed make to a depth of 75mm into the RC Deck Beams or other RC elements, perpendicular to the surface, in staggered manner. Clean the holes neatly and wash the same with jet of water. Allow it do dry and make sure that no fine dust particles are present in the holes. Mix the base and hardener of the epoxy resin LokfixE77 and apply using a gun to the holes with a proper tool so that the bottom most point of the hole receives the material (Lokfix S manufactured by M/S FOSROC Chemicals(I) Pvt Ltd or Eqiuvalent). The filling is to be done for a minimum portion of 1/3rd of the hole depth. Now insert the rebar (dia of bar 12mm and length 150 mm or as directed by Eng in charge) which need to be anchored for the provision of main reinforcement, gently and finish the surface around the rebar area using the same material which comes out of the hole excessively complete all as specified and as directed. Note:- The rate shall include cost of equipment, plants, materials, sand, instrumentation, hiring of boat, catamaran, pontoon, labour and survey, fuel etc. complete.

M&L for Additional Reinforcement: Check the diameter of the existing rebars and if the rebars have undergone 30% loss in original diameter, provides additional reinforcement. Cut the required bars of same dia of existing main reinforcement to the required length with proper development length. Tie or weld it properly with binding wire(annealed) of dia not less than 0.9 mm to the prefixed shear connectors so that the additional rebar acts monolithically with the existing ones and core concrete. In the case of the shear reinforcement also, if the diameter of the rebars are reduced to the extend as gived above, provide stirrups of same dia of existing stirrups in the form of 2 "U" shaped bars. Tie or weld them properly so that it has a tight contact with the main bars. The rate shall include cost of equipment, plants, materials, instrumentation, hiring of boat, catamaran, pontoon, labour and survey, fuel etc. complete.

M&L for Shear Connectors: Drilling 12mm dia holes up to a depth of 75mm maximumin to the members from the surface (perpendicular to the surface)with out damaging the existing steel reinforcement in the structural element and fixing 10mm dia L shaped anchor rods as shear connectors at every 750mm c/c on the surfaces of the Deck slab or any other structural member as the case may be. Clean the holes using water jet or jet of compressed air and make sure that there are no fine particles present in the hole. Mix the base and hardner of the epoxy resin Lokfix E77. Fill the drilled and cleaned holes to a minimum depth of 1/3rd of the hole with the epoxy resin Lokfix E77. Make sure that the resin has reached till the end of the hole. At this stage push the shear connector gently in to the hole and finish the excess resin which comes out of the hole and allow the shear connectors not to be disturbed for minimum 20 minutes - complete (total length of shear connector minimum 150mm or as directed by Eng in Charge). The rate shall include cost of equipment, plants, materials, instrumentation, hiring of boat, catamaran, pontoon, labour and survey, fuel etc. complete.

M&L for Anti-corrosive Coating: Clean the rebars using the rust remover if there exists any rust, otherwise clean the rebar free of foreign material. Mix the base and hardener of the anti-corrosive coating like Nitozinc Primer of Fosroc or equivalent mechanically using a slow speed heavy duty drilling machine fitted with mixing paddle. Apply the mixed materials to the cleaned rebar at 45 microns/coat and total dry film thickness (DFT ) 90 microns in 2 coats and allow it to dry complete. Note: The rate shall include cost of equipment, plants, materials, sand, instrumentation, hiring of boat, catamaran, pontoon, labour and survey, fuel etc. complete.

M&L for Epoxy Jointing Compound: Clean the concrete surface, remove the loose particle, if any. Make sure that the form work is ready for positioning. Mix the base and hardener of the epoxy resin jointing compound and apply the same to the prepared surface. Care shall be taken and new concrete or mortar to be applied within 5 hours maximum from the time of application of epoxy jointing compound Nitobond EP of Fosroc or equivalent. Note:The rate shall include cost of equipment, plants, materials, sand, instrumentation, hiring of boat, catamaran, pontoon, labour and survey, fuel etc. complete.

Formwork: Centering and shuttering including strutting, propping, etc., as per the required line and length at all different elevations level as per the standard specification-complete. Form work should be rigid to prevent loss of grout or mortar concrete from concrete at all stages & appropriate to the methods of placing & compacting as per standard specification. It should be made of suitable material i.e., timber, plywood, plastic, Steel depending upon the type of finish specified. Note: The rate shall include cost of equipment, plants, materials, instrumentation, hiring of boat, catamaran, pontoon, labour and survey, fuel ,scaffolding or alternate way of carrying work with proper safety required at site etc. complete.

M&L for Micro- Concrete: Stock sufficient quantity of micro concrete (Rendroc RG or equivalent) and washed surface dry condition 12mm downgraded chips on site to enable the completion of the pouring in a continuous operation. An approved concrete mixer or a slow speed heavy duty drilling machine fitted with mixing paddle shall be used for mixing. Mix the micro concrete and the 12mm down grade chips in the ratio of 1: 0.5 by weight using water cement ratio as per manufacturer's specification and place the same to the prefixed formwork using proper hopper arrangement in such a way that no air is entrapped in the concrete . Micro concrete should have minimum characteristic compressive strength of 45 MPa at 28 days. Remove the formwork after 24 hours in the case of columns and after a period of 72 hours in the case of deck slab and deck beam and check for any surface defects and if so apply the polymer modified mortar to rectify such defects- complete. The rate shall include the cost of all the operations and etc complete. Note (i):The rate shall include cost of equipment, plants, materials, instrumentation, hiring of boat, catamaran, pontoon, labour and survey, fuel etc. complete. (ii) Micro concreting to soffit of slab by provide 50mm dia core cutting at 1 meter c/c distance on top of slab in staggered manner without disturbing the reinforcement

M&L for Concreting for Wearing Coat: Cut and remove isolated patches in the cracked/damaged concrete portion in the top of RC deck slab, prepare the surface suitably using epoxy based bond coat like Nitobond EP or equivalent as per manufacturer's instruction. Providing & laying of cement concrete M25 grade using washed surface dry condition 12mm downsize aggregate as per mix design including necessary centering, shuttering, compacting, curing & finishing to required line and length all as directed by the Engineer In Charge. Providing, laying concrete of M25 Grade including cost of cement, aggregate, etc., and including the concrete admixture conforming to IS: 9103 to improve workability as per mix design without affecting the strength and durability as directed by the Engineer-in-charge. Membrane curing with curing compound Concure WB of Fosroc or equivalent shall be used for curing the finished surface. The rate shall include cost of equipment, plants, materials, instrumentation, hiring of boat, catamaran, pontoon, labour and survey, fuel etc. complete. Note :-Bond coat and curing compound will be measured and paid seperately under relevant items of BOQ.

M&L for Polymer Modified Mortar: Chip off the corrosion damaged areas on the deck beam/ column/ deck slab or any other structural members. Clean reinforcement using Reebaklens RR of Fosroc or equivalent and make sure that there are no traces of rust on the surface of existing rebars and apply anti corrosive coating like Nitozinc primer of Fosroc or equivalent . Check for the depth of carbonation using the phenolphthalein indicator and make sure that the contaminated concrete is removed completely and prepare the surface suitably using epoxy based bond coat like Nitobond EP or equivalent as per manufacturer's instruction. Wet the surface with potable water and make sure that the surface is kept moist so that the water cement ratio in the polymer modified mortar is maintained. Cement and sand (sieved) shall be mixed in the ratio of 1:3 with 3 litres of Nitobond SBR per each bag of cement and applied to primed surface and finished neatly to required line and length. Soon after the finishing is over, apply the curing compound Concure WB of Fosroc or equivalent complete. The rate shall include cost of all the operations and etc., complete include cost of equipment, plants, materials, instrumentation, hiring of boat, catamaran, pontoon, labour and survey, fuel etc. complete. Note :-Bond coat , curing compound and anti corrosive coating shall be measured and paid seperately under relevant items of BOQ.

M&L for Drilling and fixing of NRV ports Drill 13mm diameter holes into the concrete surface to a depth of 50 mm and spacing of the holes should not be more than 500 mm center to center in grid pattern. Clean the holes and wash the same followed by air blower. Provide metal based non return nipple (NRV port) and fix it using Polyester resin Lokfix S or equivalent

M & L for injection of Low Viscous Epoxy Resin in dry conditions; Make “v’ groove along length of crack, remove all dust and loose particles and place injection ports at spacing of 200 to 500mm centre to centre spacing depending on porosity of substrate, seal the cracks with epoxy putty followed by pressure grouting using electrically operated pressure grouting machine (pressure not to exceed 4-5 kg/cm2) with Conbextra EP10 low viscous solvent free two component epoxy resin having density of 1050kg/m3. The epoxy injecting materials shall have viscosity< 0.6 poise as per ASTM D1200, compressive strength> 80 MPa as per ASTM D695 and bond strength >4 MPa as per ASTM C882, etc complete. Product used shall have CE(CE-29842) marking and compliance according to Construction Products Directive 89/106/EEC(CPD). Continue pressure grouting until the injection port refuses the grout or the grout comes out of the nearby port. In case the grout comes out of the adjacent port, the same may be closed and those ports need not be grouted again. Continue the operation until all the ports are grouted. Cut the ports and finish the surface to match the nearby surface.

M&L for Curing Compound: Immediately after striking the form work or after completion of the repair works, the surface should be sprayed water once and followed by application of membrane based curing compound like Concure WB of Fosroc or equivalent diluted with water in the ratio of 1: 1 as a curing membrane - Complete. The rate shall include cost of equipment’s, plants, materials, instrumentation, hiring of boat, catamaran, pontoon, labour and survey, fuel etc. complete.

Demolition of cement Concrete of any description and in any position using manual chipping only in proper geometric pattern and edge to be cut using cutter without disturbing main deckslab, including disposal of debris/waste material away from MD Land complete all as specified.

Dismantling of floor hearth or wall tilling tiles including CM bedding and disposing the rubbish/ debrisesaway from Defence land all as directed

M & L for Chequered cement concrete coloured tiles 30cm x 30cm x 25mm thick, set, jointed and pointed in neat cement slurry in floors over 15 mm thick screed bed of CM 1:4 complete all as specified and as directed .

Dismantling wrought iron or mild steel work of any description not otherwise provided for all as specified.

Dismantling wrought iron or mild steel work for cable holder from cable trench and transport to store of GE(NS) complete all as specified and as directed .

S&F of Rolled mild steel section conforming to FE 410-W(Gde- E- 250)quality-A for framed work as in doors or gates of angle or other section with gusset plates, rails, braces, etc., complete, drilled for fixing of steel sheeting or other covering. Doors, etc. to be prepared for hanging or sliding with and including either hooks and hinges or steel hanging door fittings (exclusive of steel sheeting or other covering, running rails and guides) and hanging; also fastening and fixing complete all as specified.

S&Fof Rolled mild steel section conforming to FE 410-W(Gde- E- 250)quality-A for Stairs case railing (framed) including stringers, treades, landing, balusters, hand rails etc. including cleats, brackets, etc. complete all as specified and as directed .

S&F Framed work such as grills, gratings, etc.. with ends of bars shouldered and/or riveted, or forged into spikes; framed guard bars; barred iron doors; ladders; framed balusters; walk ways; railings; framework of water tanks and similar work conforming to Fe.290.Gde-E-165

S&F Mild steel plate , Plain or chequered 8 mm thick or over in thickness complete all as specified and as directed .

M&L for preparation of old painted steel surfaces of any description, over 10cm in width or girth,not otherwise described and applying a coat of synthetic enamel paint all as specified and directed .

M&L for preparation of new steel surfaces of any description, over 10cm in width or girth,not otherwise described and applying two coat of synthetic enamel paint over a coat of primer all as specified and directed .

M&L for preparation of new steel surfaces of any description, not exc. 10cm in width or girth,not otherwise described and applying two coat of synthetic enamel paint over a coat of primer all as specified and directed .

Dismantling timber scantlings 40 sq. cm and over in section, in any position all as specified and as directed.

M&L first class HW baulk (wrought) fixed as in cope timber cross section 300 mm x 200 mm, including provision of necessary bolts all as specified and as directed .

M&L for preparation of new wood surfaces of any description not otherwise described over 10 cm width or girth and applying two coat of synthetic enamel paint over a coat of pink primer omplete all as specified. General Notes :- (a)The tenderers are advised to visit the site before bidding and make themself thoroughly acquainted with the working conditions , approaches/ accessibility to the site and nature and scope of work. (b) The work is to be carried out on jetty structure where different types of marine vessels are berthed. The work may get disturbed due to activities of berthed vessels, movement of ship support vehicles and machineries etc and restricted/limited working hours due to tidal conditions. No compensation for same will be allowed. (c) The work is to be carried out at various locations of the jetty structure, which may include service ducts under the deck slab, bottom side of deck etc . The contractor may require to hire boat/ catamaran /floating pontoon etc and erect scafolding / working platform etc above water level , to facilitate inspection/survey or to carry out the work at different locations of the jetty structure. Nothing extra shall be allowed for the same. (d) The contractor shall observe all necessary precautions and safety measures for the safety of his work force and other employees at site. (e) The contractor shall provide necessary equipments to measure DFT of various coatings provided under the work.

General Notes continued :- (f) The work shall be executed by authorized expertised agencies of the manufactures approved by GE (g) Any Damage done to the existing structure/Machineries such as firefighting pumps,water pipelines,electric panels etc /cable/fittings etc during the execution of work shall be made good by the contractor at his own cost. (h) Adequate lighting arrangement should be done during execution (i) dewatering should be done whenever required at no extra cost (j) The waste materials/debris obtained during the repair work shall not be disposed off into the water body. All the debries shall be dispossed off outside the MD land in consonace with the regulations of local body.Nothing extra will be paid on this account (k) :- Cleaning of cable trench/duct in respect of any foreign material, wood, cloth, dry bushes etc debris should be removed from cable trench and deposited away from defence land. (l) The work to be executed as per detailed methodology as per clause No.10 of particular specifications.

JKM CONSTRUCTIONS