Design, Fabrication, Transport, Supply, Erection, Testing and Commissioning of Radial Gate Shutter and Hoisting arrangements for controlled spillway in Maduranthakam Tank in Maduranthakam Taluk of Chengalpattu District.

Amount

Spillway crest radial gate and its assembly

Design, Drawing, fabrication & supply of Trunnion girder, Trunnion hub, bracket and pin suitable for spillway crest radial gate of vent size 12100x4410mm as per IS 4623 : 2000. The trunnion girder made of IS 2062 : 2011 – E 250 grade mild steel. The turnion hub shall be made of steel casting as per IS 1030. The pin shall be made of SS 420 grade as per IS 1570. 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 a good welding equipment and a trained welder. All non – metallic substances shall be removed in the weld joints before commencement of welding. 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 loading, lifting, unloading, hire charges for equipments like chainpulley block, power charges for generator, including warranty for 5 years, etc., complete complying with standard specifications and as directed by the departmental officers.

Design, drawing, fabrication & supply of skin plate with vertical stiffeners, horizontal girders, etc., suitable for radial gate of vent size 12100 x 4410mm as per IS 4623 : 2000. The skin plate, vertical stiffeners, horizontal girders, arm, arm bracings, lifting assembly, side seal base plate, side seal cover, bottom seal cover, rear angles shall be made of structural steel confirming to IS 2062 : 2011. 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 a good welding equipment and a trained welder. All non – metallic substances shall be removed in the weld joints before commencement of welding. The cost includes cost of materials, cost of consumables like welding rods, grinding wheels, drill bits, oxygen & acetylene gas, oil & diesel for generator, process charges like gas cutting & welding, drilling, hire charges for machinery like gas cutting plant, welding equipment, magnetic drilling machine, generator, equipments like chain pulley block, derrick post, crane, labour charges for loading, lifting, unloading, etc., complete complying with standard specifications and as directed by the departmental officers. including warranty for 5 years.

Design, manufacture, supply and erection of bottom seal, side seal with fasteners for the spillway crest radial gate of vent size 12100x4410mm as per IS 11855 : 2004. The seals shall be made of a basic polymer that shall be natural rubber. Rubber seals shall be moulded to ensure homogeneous section. Natural rubber seal shall be used as it is elastic, deforms readily and regains its original shape on the removal of loads. The bottom seal shall be a flat seal of size 75x12mm. The side seals shall be of Z type seals of size 74x79x16mm. Holes shall be punched in the rubber seals with seal punchers to match with the holes in the skin plate and cover plate. SS 304 gr fasteners shall be used to fasten the rubber seal to the skin plate and cover plate as directed by the departmental officers. The cost includes cost of all materials, cost of consumables like grinding wheel, process charges like gas cutting, punching, labour charges for loading, lifting, unloading, hire charges for equipments power charges for generator, etc., complete complying with standard specifications and as directed by the departmental officers.

Erection / installation of Trunnion girder, Trunnion hub, bracket for spillway crest radial gate of vent size 12100x4410mm as per IS 4623 : 2000. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, charges for scaffolding, diesel & oil for generator, process charges like gas cutting, welding, labour charges for loading, lifting, unloading, erection, hire charges for equipments like chainpulley block, crane, power charges for generator, including warranty for 5 years, etc., complete complying with standard specifications and as directed by the departmental officers.

Erection, testing & commissioning of spillway crest radial gate of vent size 12100x4410 mm with structural steel skin plate, horizontal girders, vertical stiffeners, lifting brackets, etc., complete in all respects as per the technical specification and drawings as directed by the departmental officers. 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 a good welding equipment and a trained welder. All non – metallic substances shall be removed in the weld joints before commencement of welding. This also includes connection/assembly of hoists with gate for safe, proper and smooth functioning of gates 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 loading, lifting, unloading, charges for scoffolding, hire charges for equipments like chainpulley block, power charges for generator, including warranty for 5 years, etc., complete complying with standard specifications and as directed by the departmental officers.

Hoist bridge and operating assembly

Design, drawing, Fabrication & supply of hoist bridge for spillway crest radial gate of vent size 12100x4410 mm as per IS 800 : 2007. The hoist bridge frame made of IS 2062 : 2011 - E250 grade. 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 a good welding equipment and a trained welder. All non – metallic substances shall be removed in the weld joints before commencement of welding. 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 loading, lifting, unloading, hire charges for equipments like chainpulley block, power charges for generator, including warranty for 5 years, etc., complete complying with standard specifications and as directed by the departmental officers.

Design, Drawing, manufacture & supply of the hoist assembly of rope drum, drum gearwheel, pinion wheels worm reducer, electromagnetic brake, 3ph motor and base frames. The gear wheels and rope drum shall be made by cast steel material as per IS 1030. The casted materials shall be machined as per approved drawings. The motor shall be provide with 3ph squirrel cage, S3 duty as per IS 12615:2011. The worm reducer and electromagnetic brake shall be provided with IS standards. The base frame shall be fabricated with for rope drum hoist and drive unit mild steel as per structurals IS 2062. 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. 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 loading, lifting, unloading, hire charges for equipments power charges for generator, including warranty for 5 years, etc., complete complying with standard specifications and as directed by the departmental officers.

Erection / installation of Hoist bridge for spillway radial gate as per standards. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, charges for scaffolding, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for loading, lifting, unloading, erection, hire charges for equipments like chainpulley block, power charges for generator, including warranty for 5 years, etc., complete complying with standard specifications and as directed by the departmental officers.

Erection / Installation of rope drum and drive unit hoist arrangements as per the following specification. The rope drum and gear wheels shall be assembled over the base frame. The centre hoist drive unit assembly fitted with hand operating arrangements over entire hoist base frame. The hoisting arrangements shall be erected at top of the hoist bridge. The rope drum hoist assembly and drive units shall be connected through intermediate shaft and bearings with hoisting blocks used for straight running. The shutter hoist shall be connected through wire ropes as per IS.2266. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, charges for scaffolding , oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for loading, lifting, unloading, hire charges for equipments power charges for generator, including warranty for 5 years, etc., complete complying with standard specifications and as directed by the departmental officers.

Design, drawing, fabrication, transport & installation of an inspection platform for the Madhurantagam tank spillway crest radial shutters at the following size & specification. The total length of the platform shall be 15080mm and necessary to inspect the shutter trunnion and arms from the downstream side, Also it serves for periodical maintenance operations such as oiling, greasing & painting. This easy & quick access enables to monitor any leakage from the shutter and enables carrying out emergency operations. The platform shall be of width 900mm and shall be supported by the main girder ISMB 400 on either ends of the platform. ISA 50x50x6 shall be welded as intermediate stiffeners singularly between the main girders at distance of 450mm c/c from each other and cross stiffeners at a distance of 500 c/c from each other shall be provided throughout the length of the inspection platform. A gusset plate made of 8mm thick MS plate and size 160 x 200mm shall be perpendicularly welded to the outer side of the main girder on either side to weld the vertical posts of height 1200 mm made of ISA 75x75x6mm. The handrail pipes of dia 25mm made of GI pipes shall be inserted into the holes drilled in the vertical post equidistant from each other as in the drawing. The platform top shall be finished with 6mm composite chequered plate from end to end throughout the platform for a width of 900mm. All joints in the frames shall be neatly welded and ground to give an excellent finish. The foundation bolts of size 16mm with base plate of size 250x250x12mm shall be provided to anchor the platform to the existing pier. Necessary civil works like concreting & anchoring in existing masonry structure shall be included in the scope of this job. The Cost includes cost of materials, labour charges, transport, erection, crane hire charges, power charges from a generator at site, loading & unloading charges, conveyance of machinery to & fro from site of work, hire charges for machinery, scaffolding charges , risk allowance for working at a hazardous location at a height of 15m, warranty for 5 years, etc., complete complying with standard specifications and as directed by the departmental officers.

Conducting the following minimum quality tests as per approved QAP at various stages of work to ensure raw materials and its fabrication are free from defects as per industry standards and maintenance of records at all stages for assurance of quality. Raw materials such as hot rolled plates and sectional structures are tested for physical & chemical properties - one random sample for minimum of 40 tonnes of plate/structural weight. Stainless steel seal seat, wheel track plate shall be tested for physical & chemical properties – one sample (Random) for entire lot of any size. Steel casting materials shall be checked with ultrasonic testing and magnetic particle inspection on finished surfaces in outer diameter and inner diameter, wherever applicable on wheels, gears, pinion, drum. Rubber seals are tested in house for physical properties such as Hardness, Elongation, Tensile strength, Tensile test after ageing, water absorption test as per IS 11885 : 2004. All raw materials are 20% dimensional checked and verified in accordance with manufacturer test certificate. In shop welding process, quality of fillet welds are checked visually and using 100% magnetic particle inspection. In site welding, quality of fillet weld is inspected either by 100% dye penetrant or magnetic particle inspection. For butt welds, 100% ultrasonic inspection is done for skin plate joints. Root weld is inspected by 100% dye penetrant test in butt welds. In site welding, internal inspection report shall be furnished at all stages of fabrication. Surface protective treatment such as blast cleaning, zinc primer and coal tar epoxy coating shall be done as per standard norms. Quality of blast cleaning is ensured by cleanliness to SA 2 ½ finish and profile measured using calibrated surface profile gauge. Adhesion of coating is done with cross hatch / X cut test as per ASTM D 3359. Thickness of primer and coal tar epoxy coatings are ensured by coating thickness gauge at random points. Finally to ensure the quality of coating system to be free from pinholes and cracks through holiday detector at random points. All reports and tests shall be furnished to the appropriate authority as directed by the departmental officers.

Providing abrasive blast cleaning using air blast cleaning with abrasive aluminium oxide/steel grits/sand as per the following specification. Moisture should not be present on the steel surface during blast cleaning. All, oil, paraffin, grease & dirt 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 substances 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, clean 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, recleaning 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 charges for generator , compressor, hopper, accessories, conveyance of machinery to & fro from site of work, scaffolding charges, consumables like oil & diesel for generator, risk allowance,etc, complete complying with standard specifications and as directed by the departmental officers. including warranty for 5 years.

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 epoxy primer shall be applied. The dry film thickness should be 40-60µ for primer coat. The colour is grey and minimum pot time should be 4 to 8 hours. The mixing ratio of base to accelerator by volume should be according to the manufacturers 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 rain 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 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. Primer coat shall be uniform and free from runs, slag 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.14177-1994. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) -1971. The cost includes cost of primer & thinner, labour charges for application of primer, hire charges for compressor, generator & airless spray gun with its accessories, cost of oil, diesel & lubricant for generator, scaffolding charges, conveyance of machinery & tools to and fro from site of work, risk allowance, etc, complete complying with standard specifications and as directed by the departmental officers, including warranty for 5 years.

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 125-150 µ 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 rain 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.14177-1994. The colour of the paint coat when applied is generally black but turns into brown over a period time. However, the properties of the paint remain intact assuring the performance. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) – 1971. The cost includes cost of coaltar epoxy paint, thinner, etc, labour charges for its application, hire charges for compressor, generator, airless spray machine with its accessories , cost of oil, diesel & lubricant for generator, scaffolding charges, conveyance of machinery & tools to and fro from site of work, risk allowance, etc, complete complying with standard specifications and as directed by the departmental officers, including warranty for 5 years.

Fabrication, supply and installation for 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 and fixtures, cost of raw material like UV stabilized polymers, multi directional glass fiber reinforcements, hardeners, UV stabilized pigment & fumed silica powders, cost of consumables like rollers, brushes, gloves, sanding sheet, acetone, buffing, grinding & cutting wheels, cost of tools like aluminium paddle rollers, squeegees, fibreglass scissors, measuring beakers, agitators, cost of release agent like, cleaner, sealer, releaser, wax, labour charges for pattern & mould work, hand layup, cutting, grinding, finishing, drilling, loading, unloading, transport, erection, hire charges for equipments like air compressors, pneumatic tools, gelcoat spray gun, conveyance to site and clearing them after completion of work, including cost of trial operation, including warranty for 5 years, etc., complete as directed by the departmental officers.

Fabrication, supply and installation of rope drum enclosure for hoist assembly 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 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 and fixtures, cost of raw material like UV stabilized polymers, multi directional glass fiber reinforcements, hardeners, UV stabilized pigment & fumed silica powders, cost of consumables like rollers, brushes, gloves, sanding sheet, acetone, buffing, grinding & cutting wheels, cost of tools like aluminium paddle rollers, squeegees, fibreglass scissors, measuring beakers, agitators, cost of release agent like, cleaner, sealer, releaser, wax, labour charges for pattern & mould work, hand layup, cutting, grinding, finishing, drilling, loading, unloading, transport, erection, hire charges for equipments like air compressors, pneumatic tools, gelcoat spray gun, conveyance to site and clearing them after completion of work, including cost of trial operation, including warranty for 5 years, etc., complete complying with standard specifications and as directed by the departmental officers.

Providing a dial gauge to read the movement of shutters from the deck bridge as per the following specification. The dial gauge is a safety instrument to read the position of the gate from the deck as well restrict the movement of the gate at predesignated heights. The dial gauge consists of dial with engraved scale, a pointer and a striker. A ultra reduction gearbox 1:20 as per site condition shall be assembled along with of chain & chain sprocket arrangement. The shaft for chain sprocket shall be made 25mm EN8 steel. The sprocket wheel shall be of 25 teeth with pinion of 12 teeth. The chain for sprocket shall be of length 2000mm. Necessary bushes & bearings of best quality shall be used. The whole assembly shall be housed in a composite dial gauge enclosure. The composite material shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties The cost includes cost of design cost of materials like ultra reduction gear box, chain, chain sprocket, composite head, hire charges for machinery like welding machine, grinding, corecut, consumables like welding rod, grinding wheel, core cut, drill bits, process charges like machinery, milling, mould charges, labour charges, charge for transport to & fro etc., complete complying with standard specifications and as directed by the departmental officers.

GST 18 % in Figures

Super Fabricators