TENDER FOR REHABILITATION OF OIL JETTIES 26B (BD I) AND 27B (BD III) WITH ALLIED BUILDINGS AND PIPELINE TRESTLES IN BHARATHI DOCK AT CHENNAI PORT

1. Rehabilitation of the distressed RC structural elements of the various structures of the Oil Jetty 26B (BD-I)

1.01 Demolishing top Floor RCC Slab and existing micro concrete : Chipping carefully without causing vibrations to the existing Structures and removing the existing micro concrete/ cement concrete from the sides and top surfaces of RCC Mooring Dolphins, Breasting Dolphins, Jetty head, Catwalks between Mooring, Breasting Dolphins, etc., and wherever required above water level to receive new finish / micro concrete including chipping the concrete 100mm thick (approx.) or as directed, removing the spalled concrete, including cleaning the reinforcement all rust and scales, collecting and stocking the rubbish within a lead of 1km all as per relevant specifications and as directed including all machineries, labour, tools, plants, equipments, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note: The debris shall not be dumped into the Sea.

1.02. Surface Preparation : Preparation of sides and top surfaces of RCC Mooring Dolphins, Breasting Dolphins, Jetty head, Catwalks between Mooring, Breasting Dolphins and Jetty head etc., and wherever required above water level to receive new finish / micro concrete/M35 concrete including chipping the concrete upto 25mm thick (approx.) carefully without causing vibrations to the existing Structures or as directed behind the rebars, removing the spalled concrete and all loose particles, to achieve a laitance and contaminant free surface including cleaning the surface of reinforcement steel to remove all rust and scales, collecting and stocking the rubbish within a lead of 1km all as per relevant specifications and as directed including all machineries, labour, tools, plants, equipments, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note: The surface shall be prepared to receive new finish/coat as laid down in the manufacturer’s specification.

1.03 Surface preparation PMM : Preparation of RCC Surfaces, girders at BD-I and wherever required above water level to receive new finish of Polymer Modified Mortar (PMM) including removing the spalled concrete, loose particles, to achieve a laitance and contaminant free surface including checking the cleaned surfaces by conducting phenolphthalein test until reaching the good or uncontaminated concrete, collecting and stocking the rubbish within a lead of 1km all as per relevant specifications and as directed including all machineries, labour, tools, plants, equipments, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note: The surface shall be prepared to receive new finish/coat as laid down in the manufacturer’s specification.

1.04 Shear Connectors : Supplying and fixing shear connectors at 500mm c/c or as directed using 8mm dia 'L' shaped anchor rod High yield strength deformed (HYSD Fe 415/500 grade) TMT steel reinforcement bars on the surface of the RC structural elements of Mooring Dolphins, Breasting Dolphins, Jetty head, Catwalks between Mooring, Breasting Dolphins and Jetty head etc., and wherever required as directed including cutting, bending, fabricating the steel including drilling holes of 12mm dia and 75mm depth (maximum) using a hand held drilling machine, fixing the shear connectors in position in the drilled holes using polyster resin (Lok Fix S (or) P of Fosroc India Pvt. Ltd. or its equivalent) as per manufacturer’s specification and as directed to suit site requirement including all materials, Anchor rod, labour, machineries, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete.

1.05 Additional Reinforcement : Supplying fabricating and fixing 12 mm and 8mm dia High yield strength deformed bars (HYSD Fe415/500 grade), for providing Additional Reinforcement to the RC structural elements, in the sides and top surfaces of RCC Mooring Dolphins, Breasting Dolphins, Jetty head, Catwalks between Mooring, Breasting Dolphins and Jetty head etc., and wherever required, tie with shear connectors/anchor rod /fixing with anchor resin lok fix 'P' or 'S' including cost of materials, Steel, labour, tools, equipments, plants, scaffolding / working platform, cost of boat hiring, catamaran, Pontoon, fuel, transport etc. complete.

1.06 Anti-corrosive coating : Applying Protective coating to newly prepared exposed surfaces of old/new steel reinforcement bars with two coats of anti-corrosive rebar Coating Nitozinc Primer of Fosroc or equivalent including cleaning the rebars using the rust remover and making the rebars free of foreign materials and applying the anti-corrosive coating, at 45 microns/coat and total dry film thickness (DFT) 90 microns using suitable small brush all as per manufacturer’s specification and as directed including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring boat, catamaran, pontoon, transport, fuel, etc., complete.

1.07 Epoxy Jointing Compound : Applying epoxy resin bonding Compound Nitobond EP of Fosroc or equivalent in all repair areas of concrete surface using short haired brush and applied on the old concrete to receive PMM (polymer Modified Mortar) all as per manufacture's specifications and as directed to suit site requirement including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note : PMM/Concreting shall be done within 5 hrs (maximum) from the time of application of epoxy bonding compound or as per manufacturer's specification.

Note: 1. if an equivalent product is proposed, the bidder shall enclose the Third party test certificate alongwith the projects where the product has been used in marine environment and their performance in terms of current output density over the period of time through a monitoring system. 2.The above rate shall also include the installation of 10 monitoring boxes each connected to 15-20 anodes and establishing a current density of 0.2 to 2 mA/m2 as per EN ISO 12696 up to the Defect Liability Period. The elements to be monitored as well as the locations where the Monitoring boxes are to be installed shall be decided by the Engineer in charge. The monitoring shall be continued for a minimum period of 2 years at intervals of every month for the first 6 months and thereafter every 3 months for a further 6 months period and then half yearly. The current density data shall be submitted to the Port authorities. Galvanic Anode Performance (GAP) test certificate shall be provided.

1.09 Form work : Providing and fixing leak-proof shuttering for facilitating micro-concrete/concreting work in the side faces of Mooring Dolphin, Breasting Dolphin & Jetty Head and catwalk etc.,and wherever required to get a form finish concrete, using Marine plywood/ FRP sheets/steel with ribs, stiffeners, supporting frames, members, clamping arrangement, fixtures, bolts, nuts etc., including supplying, fabricating, conveying, fixing / erecting in position, sealing the edges with foam rubber sealing strips, de-shuttering, removing and taking away the materials (after completion of micro-concrete work/M35 concreting as recommended in manufacturer’s specification) all as directed including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring boat, catamaran, pontoon, transport, fuel, etc., complete. Note: 1) The contractor shall prepare and submit drawing for shuttering arrangement for approval before fabricating the same. 2) Payment will be made based on the actual area of repair work.

1.10 Micro - Concrete : Supplying, mixing and pouring / pumping ready to use non-shrink, cementitious micro concrete, Renderoc RG of Fosroc or equivalent 100mm average thickness to the side faces of Mooring Dolphins, Breasting Dolphins, Jetty head etc., and wherever required for repair of damaged concrete structures above water level mixed with aggregates of size and mix proportion (micro concrete and 12mm down graded chips in the ratio of 1:0.5 by weight) all as per manufacturer’s specifications, and as directed, including rectifying the surface defects if found on removal of form work by applying PMM, including conveying, pouring the micro-concrete using positive displacement pumps all as per the manufacturer’s specifications and as directed, including all material, labour, tools, equipments, transport, scaffolding / working platform, hiring boat, catamaran, pontoon, removing the formwork etc., complete.

1.11 Polymer Modified Mortar : Providing and applying Polymer Modified Mortar (PMM) of average thickness of 30mm (cement and sand mixed in the ratio o f 1:3 and 3 litres of Nitobond SBR of Fosroc Chemicals or equivalent per bag of cement) to the isolated repair of distressed RCC Surfaces, girders at BD-I and wherever required as per manufacturer’s specification and as directed to suit site requirement including Clean reinforcement by using Reebaklens RR of Fosroc or equivalent and make sure that there are no traces of rust on the surface of existing rebars, Check for the depth of carbonation using the phenolphthalein indicator and make sure that the contaminated concrete is removed completely, 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 and including all materials, labour, tools, equipments, plants,scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete.

1.12 Curing Compound : Providing and applying with membrane based curing compound Concure WB white of Fosroc or equivalent, on the surfaces of the newly laid micro concrete/ PMM, immediately after striping the form work or after completion of the repair works, including spraying of water on the surface and followed by application of curing compound diluted with water in the ratio of 1:1 as recommended in manufacturer’s specification and as directed including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring boat, catamaran, pontoon, transport, fuel, etc., complete.

1.13 Concreting : Providing and laying M35 grade cement concrete for the top surfaces of RCC Mooring Dolphins, Breasting Dolphins, Jetty head, Catwalks between Mooring, Breasting Dolphins and Jetty head etc., and wherever required to the required thickness to match with the adjoining surfaces as per the site condition and as directed wherever required using ready mixed or site batched design mix plain cement concrete (Minimum cement content 400kg/M3) using coarse aggregate and fine aggregate derived from natural sources, Portland Pozzolana / Ordinary Portland / Portland slag cement, admixtures in recommended proportions as per IS: 9103 to accelerate / retard setting of concrete, to improve durability and workability without impairing strength; excluding the cost of centering, shuttering, finishing and all as per relevant specifications and as directed including pumping of concrete upto the site, laying, vibrating, curing, carriage for all leads, all labour, material, tools, plants, equipment, transport, fuel, sampling, testing of concrete, cranes, etc., complete.

1.14 Floor Hardner with cutting and sealent : Providing and applying Dry shake Floor Hardner Nitoflor Hard Top of Fosroc or equivalent on the newly laid M35 concrete surfaces of RCC Mooring Dolphins, Breasting Dolphins, Jetty head, Catwalks between Mooring, Breasting Dolphins and Jetty head etc., and wherever required when the base concrete has stiffened to the point and when light foot traffic leaves an imprint of about 3mm all as per manufacturer's specifications and as directed to suit site requirement including application of dry shake on floor hardener, cutting the groove of width 6mm and depth 25mm (a panel of 6m x 6m) on the floor filling with PU sealant Colpor of Fosroc or equivalent including all materials, labour, tools, equipments, plants, transport, fuel etc., complete.

1.15 Protective coatings for Environmental face using Dekguard S of Fosroc : Providing and applying a single component High Build Elastomeric, crack-bridging, resistant to CO2 and chloride ion diffusion, UV resistant, breathable acrylic coating with elongation at break exceeding 200% using Dekguard S of Fosroc or equivalent material applied in two coats over the Primer (each top coat shall be 150 microns WFT). The primer coat is a single component Silane Siloxane primer and the Top coat is a single component pigmented and as per the recommendations of the manufacturers specification for the sides faces of RCC Mooring Dolphins, Breasting Dolphins, Jetty head, RCC Girders, Catwalks, Jetty head deck slab bottom etc., and wherever required all as per specifications and as directed including all cost of all materials, lahour, machineries, tools, equipments, plants, hiring boat, catamaran, pontoon, scaffolding / working platform transport, fuel, etc., complete

1.16 Debris Removing : Loading, transporting and taking away the dismantled debris outside the Chennai Port premises, all as directed including all labour, machineries, tools, transport, equipment, fuel etc., complete. Note: 1. The Contractor shall maintain trip sheets in triplicate in ChPA’s approved format at his own cost for the quantity of debris transported. 2. Interim Payment will be based on the lorry cubical content. No deduction of voids will be made for debris. 3. However, the final quantity will be restricted to actual quantity of dismantling / demolishing items.

2. Rehabilitation of the distressed RC structural elements of the various structures of the Oil Jetty 27B (BD-III)

2.01 Demolishing top Floor RCC Slab and existing micro concrete : Chipping carefully without causing vibrations to the existing Structures and removing the existing micro concrete/ cement concrete from the sides and top surfaces of RCC Mooring Dolphins, Breasting Dolphins, Jetty head, Catwalks between Mooring, Breasting Dolphins, RCC piles of Approach jetty, Jetty head building, Jetty head, cat walk and wherever required above water level to receive new finish / micro concrete including removing the steel casing, if necessary, chipping the concrete upto 100mm thick (approx.) or as directed, removing the spalled concrete, including cleaning the reinforement all rust and scale, collecting and stocking the rubbish within a lead of 1km or as directed all as per relevant specifications and as directed including all machineries, labour, tools, plants, equipments, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note: The debris shall not be dumped into the Sea.

2.02 Surface Preparation : Preparation of sides and top surfaces of RCC Mooring Dolphins, Breasting Dolphins, Jetty head, Catwalks between Mooring, Breasting Dolphins and Jetty head, RCC piles of Approach jetty, Jetty head building, Jetty head, cat walk and wherever required carefully without causing vibrations to the existing Structures above water level to receive new finish / micro concrete/M35 concrete including chipping the concrete upto 25mm thick (approx) or as directed behind the rebars, removing the spalled concrete and all loose particles, to achieve a laitance and contaminant free surface including cleaning the surface of reinforcement steel to remove all rust and scales including collecting and stocking the rubbish within a lead of 1km or as directed as per relevant specifications and as directed including all machineries, labour, tools, plant equipments, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note: The surface shall be prepared to receive new finish/coat as laid down in the manufacturer’s specification.

2.03 Surface Prepartion underwater : Preparation surfaces of Piles, Mooring Dolphins, Breasting Dolphins, Jetty head and wherever required carefully without causing vibrations to the existing Structures below water level to receive new finish micro concrete including removing the steel casing if necessary, chipping 25mm thick (approx) or as directed behind the rebars, removing the spalled concrete and all loose particles, to achieve a laitance and contaminant free surface including cleaning the surface of reinforcement steel to remove all rust and scales including collecting and stocking the rubbish within a lead of 1km or as directed as per relevant specifications and as directed including all machineries, labour, tools, plant equipments,scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note: The surface shall be prepared to receive new finish/coat as laid down in the manufacturer’s specification.

2.04 Surface Prepartion DSRM: Surface Preparation of RCC Pile muff of approach Jetty and Jetty head building, Jetty head and Deck slab, catwalk and other RC structures such as RCC beams, bottom of deck slab etc., and wherever required for applying Dry Spray Repair Mortar (DSRM) including removing the spalled concrete, loose particles, to achieve a laitance and contaminant free surface including checking the cleaned surfaces by conducting phenolphthalein test until reaching the good or uncontaminated concrete collecting and stocking the rubbish within a lead of 1km all as per relevant specifications and as directed including all machineries, labour, tools, plants, equipments, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note: The surface shall be prepared to receive new finish/coat as laid down in the manufacturer’s specification.

2.05 Additional Reinforcement : Supplying, fabricating and fixing 12mm and 8mm dia High yield strength deformed (HYSD Fe415/500 grade), for providing Additional Reinforcement to the structural elements such as RCC beams, RCC piles of Approach Jetty and Jetty head building, Jetty head, cat walk and wherever required, sides and top surfaces of RCC Mooring Dolphins, Breasting Dolphins, Jetty head, Catwalks between Mooring, Breasting Dolphins and Jetty head etc., and wherever required, tie with shear connectors / anchor rods/ fixing with anchor resin lok Fix 'P' or 'S' including cost of materials, steel, binding wire, labour, tools, equipments, plants, scaffolding / working platform, cost of boat hiring, catamaram, Pontoon, fuel, transport etc. complete.

2.06 Additional Reinforcement underwater : Supplying fabricating and fixing 12 mm and 8mm dia High yield strength deformed (HYSD Fe415/500 grade), for providing Additional Reinforcement for Piles of RCC Mooring Dolphins, Breasting Dolphins, Jetty head and wherever required below water level etc., tie with shear connectors / anchor rods/ fixing with anchor resin lok Fix 'P' or 'S' including cost of materials, steel, binding wire, labour, tools, equipments, plants, scaffolding / working platform, cost of boat hiring, catamaram, Pontoon, fuel, transport etc. complete.

2.07 Anchoring the Main Reinforcement : Drilling of 16mm dia holes to a depth of 75mm in RC Deck slab/ RC Piles/ beams and wherever required in the marked places for anchoring rebars using rotary hammer drilling machine of reputed make, Cleaning the holes neatly and wash the same with jet of water, including filling the holes with the polyester resin (Lok Fix S (or) P of Fosroc India Pvt. Ltd. or its equivalent) pushing the same in to the holes with a proper tool so that the bottom most point of the hole receives the polyster resin material for a minimum portion of 1/3rd of the hole depth and inserting the rebar which need to be anchored for the provision of main reinforcement, gently and finish the surface of the around the rebar area using the same polyster resin material all as per manufacturer’s specification and as directed to suit site requirement including all materials, labour, machineries, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel, etc., complete. Note : Steel reinforcement shall be measured and paid separately under relevant item of this schedule

2.08 Shear Connectors : Supplying and fixing shear connectors at 500mm c/c or as directed using 8mm dia L shaped anchor rods High yield strength deformed (HYSD Fe 415/500 grade) TMT steel reinforcement bars on the surface of the Piles, RCC beams, slabs etc.,and other RC structural elements wherever required, all as directed including cutting, bending, fabricating the steel including drilling holes of 12mm dia and 75mm depth (maximum) using a hand held drilling machine, fixing the shear connectors in position in the drilled holes using polyster resin (Lok Fix S (or) P of Fosroc India Pvt. Ltd. or its equivalent) as per manufacturer’s specification and as directed to suit site requirement including all materials, steel reinforcement, labour, machineries, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel, etc., complete.

Note: 1. if an equivalent product is proposed, the bidder shall enclose the Third party test certificate alongwith the projects where the product has been used in marine environment and their performance in terms of current output density over the period of time through a monitoring system. 2.The above rate shall also include the installation of 10 monitoring boxes each connected to 15-20 anodes and establishing a current density of 0.2 to 2 mA/m2 as per EN ISO 12696 up to the Defect Liability Period. The elements to be monitored as well as the locations where the Monitoring boxes are to be installed shall be decided by the Engineer in charge. The monitoring shall be continued for a minimum period of 2 years at intervals of every month for the first 6 months and thereafter every 3 months for a further 6 months period and then half yearly. The current density data shall be submitted to the Port authorities. Galvanic Anode Performance (GAP) test certificate shall be provided.

2.10 Core Cutting: Core Cutting of the RCC beam and RCC slab to facilitate for the pouring of micro concrete for the repair works with an electrically operated core drilling machine fitted with diamond tool of dia not less than 69mm including marking the core holes along the RC beams at an intervel of 1m and in RC deck slab at an intervel of 1 sqm all as per specification and as directed including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring boat, catamaran, pontoon, transport, fuel, etc., complete. Note: Care to be taken to avoid the cutting of the reinforcement steel.

2.11 Anti-corrosive Coating: Applying Protective coating to newly prepared exposed surfaces of old/new steel reinforcement bars with two coats of anti-corrosive rebar Coating Nitozinc Primer of Fosroc or equivalent including cleaning the rebars using the rust remover and making the rebars free of foreign materials, applying the anti-corrosive coating at 45 microns/coat and total dry film thickness (DFT) 90 microns using suitable small brush all as per manufacturer’s specification and as directed including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring boat, catamaran, pontoon, transport, fuel, etc., complete.

2.12 Epoxy Jointing Compound : Applying epoxy resin bonding Compound Nitobond EP of Fosroc or equivalent in all repair areas of concrete surface using short haired brush to receive DSRM all as per manufacture's specifications and as directed to suit site requirement including all materials, labour, tools, equipments, plants, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note : Concreting/PMM shall be done within 5 hrs (maximum) from the time of application of epoxy bonding compound or as per manufacturer's specification.

2.13 Form Work: Providing and fixing leak-proof shuttering for facilitating micro-concrete / M35 concrete work and wherever required to get a form finish concrete, using Marine plywood/ FRP sheets/steel with ribs, stiffeners, supporting frames, members, clamping arrangement, fixtures, bolts, nuts etc., including supplying, fabricating, conveying, fixing / erecting in position, sealing the edges with foam rubber sealing strips, de-shuttering, removing and taking away the materials (after completion of micro-concrete work/M35 concreting as recommended in manufacturer’s specification) and as directed including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring boat, catamaran, pontoon, transport, fuel, etc., complete. Note: 1) The contractor shall prepare and submit drawing for shuttering arrangement for approval before fabricating the same. 2) Payment will be made based on the actual area of repair work.

2.14 Form Work under water: Providing and fixing leak-proof shuttering for facilitating micro-concrete work and wherever required below water level to get a form finish concrete, using Marine plywood/ FRP sheets/steel with ribs, stiffeners, supporting frames, members, clamping arrangement, fixtures, bolts, nuts etc., including supplying, fabricating, conveying, fixing / erecting in position, sealing the edges with foam rubber sealing strips, de-shuttering, removing and taking away the materials (after completion of micro-concrete work as recommended in manufacturer’s specification) and as directed including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring boat, catamaran, pontoon, transport, fuel, etc., complete. Note: 1) The contractor shall prepare and submit drawing for shuttering arrangement for approval before fabricating the same. 2) Payment will be made based on the actual area of repair work.

2.15 Micro Concrete: Supplying, mixing and pouring / pumping ready to use non-shrink, cementitious micro concrete, Renderoc RG of Fosroc or equivalent 100mm average thickness to the side faces of Mooring Dolphins, Breasting Dolphins, Jetty head and RC piles of Jetty head, approach Jetty, Jetty Head Building, catwalk etc., and wherever required for repair of damaged concrete structures above water level mixed with aggregates of size and mix proportion (micro concrete and 12mm down graded chips in the ratio of 1:0.5 by weight) all as per manufacturer’s specifications, and as directed, rectifying the surface defects if found during removal of form work by applying PMM including conveying, pouring the micro-concrete using positive displacement pumps all as per the manufacturer’s specifications and as directed, including all material, labour, tools, equipments, transport, scaffolding / working platform, hiring boat, catamaran, pontoon, removing the formwork etc., complete.

2.16 Micro Concrete underwater: Supplying, mixing and pouring / pumping ready to use non-shrink, cementitious micro concrete,Renderoc UW of Fosroc or equivalent 80mm average thick to the RCC piles of Mooring Dolphins, Breasting Dolphins, Jetty head and wherever required for repair of damaged concrete structures and wherever required below water level mixed with aggregates of size and mix proportion (micro concrete and 12mm down graded chips in the ratio of 1:0.5 by weight) all as per manufacturer’s specifications, including rectifying the surface defects if found during removal of form work by applying PMM, and as directed, including conveying, pouring the micro-concrete using positive displacement pumps all as per the manufacturer’s specifications and as directed, including all material, labour, tools, equipments, transport, scaffolding / working platform, hiring boat, catamaran, pontoon, removing the formwork etc., complete.

2.17 M35 concrete : Providing and laying M35 grade cement concrete for the top surfaces of RCC Mooring Dolphins, Breasting Dolphins, Jetty head, Catwalks between Mooring, Breasting Dolphins and Jetty head etc., to the required thickness to match with the adjoining surface as per the site condition and wherever required, as directed using ready mixed or site batched design mix plain cement concrete (Minimum cement content 400kg/M3) using coarse aggregate and fine aggregate derived from natural sources, Portland Pozzolana / Ordinary Portland / Portland slag cement, admixtures in recommended proportions as per IS: 9103 to accelerate / retard setting of concrete, to improve durability and workability without impairing strength; excluding the cost of centering, shuttering, finishing and all as per relevant specification and as directed including pumping of concrete upto the site, laying, vibrating, curing, carriage for all leads, all labour, material, tools, plants, equipment, transport, fuel, sampling, testing of concrete, cranes, etc., complete.

2.18 Floor Hardner: Providing and applying Dry shake Floor Hardner Nitoflor Hard Top of Fosroc or equivalent of newly laid M35 concrete surfaces of RCC Mooring Dolphins, Breasting Dolphins, Jetty head, Catwalks between Mooring, Breasting Dolphins and Jetty head etc., and wherever required, when the base concrete has stiffened to the point and when light foot traffic leaves an imprint of about 3mm all as per manufacturer's specifications and as directed to suit site requirement including application of dry shake on floor hardener, cutting the groove of width 6mm and depth 25mm (a panel of 6m x 6m) on the floor filling with PU sealant Colpor of Fosroc or equivalent including all materials, labour, tools, equipments, plants, transport, fuel etc., complete.

2.19 Dry Spray Repair Mortar: Providing and applying Dry Spray Repair Mortar (DSRM) of Renderoc DS40 of Fosroc or equivalent, ready to use blend of dry powers which is formulated for application using the dry spray process, to the RCC Pile muff of approach Jetty and Jetty head building, Jetty head and Deck slab, catwalk and other RC structures such as RCC beams, bottom of deck slab etc., and wherever required including cleaning the reinforcements using Reebaklens RR of Fosroc or equivalent and making sure that there is no traces of rust on the surface of the rebars applying the mortar on the prepared surfaces as per manufacturer’s specification and as directed to suit site requirement including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete.

2.20 Curing compound: Providing and applying with membrane based curing compound Concure WB white of Fosroc or equivalent, on the surfaces of the newly laid micro concrete / DSRM, immediately after striping the form work or after completion of the repair works, including spraying of water on the surface and followed by application of curing compound diluted with water in the ratio of 1:1 as recommended in manufacturer’s specification and as directed including all materials, labour, tools, equipments ,scaffolding / working platform, plants, hiring of boat, catamaran, pontoon, transport, fuel, etc., complete.

2.21 Protective coating for Environmental face using Deckguard: Providing and applying a single component High Build Elastomeric, crack-bridging, resistant to CO2 and chloride ion diffusion, UV resistant, breathable acrylic coating with elongation at break exceeding 200% using Dekguard S of Fosroc or equivalent material applied in two coats over the Primer (each top coat shall be 150 microns WFT). The primer coat is a single component Silane Siloxane primer and the Top coat is a single component pigmented and as per the recommendations of the manufacturer to the repaired areas and RCC pile muff, bottom of jetty head & Catwalk etc., and other structural elemnets wherever required as per specifications and as directed including alll abour, materials, machineries, tools, equipments, plants, hiring boat, catamaran, pontoon, scaffolding / working platform, transport, fuel, etc., complete

2.22 Debris Removal: Loading, transporting and taking away the dismantled debris outside the Chennai Port premises, all as directed including all labour, machineries, tools, transport, equipment, fuel etc., complete. Note: 1. The Contractor shall maintain trip sheets in triplicate in ChPA’s approved format at his own cost for the quantity of debris transported. 2. Interim Payment will be based on the lorry cubical content. No deduction of voids will be made for debris. 3. However, the final quantity will be restricted to actual quantity of dismantling / demolishing items.

3. RC structural elements of the various buildings at Oil jetty

3.01 Surface Preparation: Chipping the spalled and old concrete of the column, beam/slab, other elements and wherever required including checking the phenolphthalein test and if there is no change in color, chip the same further down until, reaching the good or uncontaminated concrete, Cleaning the surface and make sure that surface is clean and free from loose particles including collecting and stocking the rubbish within a lead of 1km all as per relevant specifications and as directed including all machineries, labour, tools, plants, equipments, scaffolding, transport, fuel, etc., complete. Note: The debris shall not be dumped into the Sea.

3.02 Surface Preparation for Wall Cracks: Mark 75/150 mm on either side of the crack. Cut the same using hand held cutting machine fitted with a diamond abrasive wing. Chip off the plaster and expose the brickwork. Make groove at every 150-mm c/c in the brick wall perpendicular to the direction of crack. Provide 20 mm dia nozzle for the grouting. Provide 8 mm dia reinforcement perpendicular to the direction of the cracks. Prepare AR mortar in the ratio of 1:3. Add 1 litres of Nitobond AR per bag of cement or any equivalent to the above mortar mix and apply to the primed concrete surface using a trowel. The dosage of AR shall be 1 lit per bag of cement and all as directed including all machineries, labour, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.03 Anchoring Main Reinforcement into RC Structural elements: Mark the position of holes to be drilled for anchoring the rebar into the floor/roof, column and beam. Drill diameter of rebars + 4 mm holes in the marked places using rotary hammer drilling machine of reputed make to a depth of 75mm into the floor/slab, column and beam and wherever required Clean the holes neatly and wash the same with jet of water. Allow it to dry and make sure that no fine dust particles are present in the holes. Mix the base and hardener of the polyester resin using a spatula and push the same in to the holes with a proper tool so that the bottom most point of the hole receives the material. The filling is to be done for a minimum portion of 1/3rd of the hole depth. Now insert the rebar 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 and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete. Note : Steel reinforcement shall be measured and paid separately under relevant item of this schedule

3.04 Anchoring the beam Main Reinforcement into Column: Mark the position of holes to be drilled for anchoring the rebar into the column Drill diameter of rebars + 4 mm holes in the marked places using rotary hammer drilling machine of reputed make to a depth of 75mm into the Beam/slab, Clean the holes neatly and wash the same with jet of water. Allow it to dry and make sure that no fine dust particles are present in the holes. Mix the base and hardener of the polyester resin using a spatula and push the same in to the holes with a proper tool so that the bottom most point of the hole receives the material. The filling is to be done for a minimum portion of 1/3rd of the hole depth. Now insert the rebar 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 and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete. Note : Steel reinforcement shall be measured and paid separately under relevant item of this schedule

3.05 Additional Reinforcement: Check the diameter of the existing rebars and if the diameter is less than 30% of the original diameter, provide additional reinforcement. Cut the required bars as main reinforcement to the required length with proper development length. Tie them 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, provide 8mm dia stirrups in the form of 2 "U" shaped bars. Tie them properly so that it has a tight contact with the main bars and all as directed including all machineries, labour, materials, shear reinforcement, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.06 Shear Connectors: Drilling 12mm dia holes up to a depth of 75mm maximum and fixing 8mm dia 'L' shaped anchor rods as shear connectors at every 300mm c/c on the surfaces of the columns/beams or any other structural member as the case may be. Clean the same using water and make sure that there are no fine particles present in the hole. Mix the base and hardener of the polyester resin with the spatula thoroughly. Fill the drilled and cleaned holes to a minimum depth of 1/3rd of the hole with the prepared polyester resin. 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 and all as directed including all machineries, labour, materials, anchor rods, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

Note: 1. if an equivalent product is proposed, the bidder shall enclose the Third party test certificate alongwith the projects where the product has been used in marine environment and their performance in terms of current output density over the period of time through a monitoring system. 2.The above rate shall also include the installation of 10 monitoring boxes each connected to 15-20 anodes and establishing a current density of 0.2 to 2 mA/m2 as per EN ISO 12696 up to the Defect Liability Period. The elements to be monitored as well as the locations where the Monitoring boxes are to be installed shall be decided by the Engineer in charge. The monitoring shall be continued for a minimum period of 2 years at intervals of every month for the first 6 months and thereafter every 3 months for a further 6 months period and then half yearly. The current density data shall be submitted to the Port authorities. Galvanic Anode Performance (GAP) test certificate shall be provided.

3.08 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 and allow it to dry and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.09 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 should be taken that the micro concrete need to be done within 5 hours maximum from the time of application of epoxy jointing compound Nitobond EP of Fosroc or equivalent. The rate shall include the cost of all the operations and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.10 Formwork: Centering and shuttering including strutting, propping, etc, as per the required line and length at all different floor levels and wherever required all as per standard specification etc., 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 depending upon the type of finish specified and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.11 Micro- Concrete: Stock sufficient quantity of micro concrete and 12mm downgraded chips on site to enable the completion of the pouring in a continuous operation and wherever required for an average thickness of 80mm. An approved concrete mixer or a slow speed heavy duty drilling machine fitted with mixing paddle shall be used. Mix the micro concrete and the 12mm down grade chips in the ratio of 1: 0.5 by weight with required quantity of water as per the data sheet and place the same to the prefixed formwork well before the epoxy jointing compound dries up. Remove the formwork after 24 hours in the case of columns and after a period of 72 hours in the case of slab and beam and check for any surface defects and if so apply the polymer modified mortar and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.12 Polymer Modified Mortar 30mm average thickness : Chip off the corrosion damaged areas on the beam/ column/ slab/wall 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. Check for the depth of carbonation using the phenolphthalein indicator and make sure that the contaminated concrete is removed completely. 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. Supply and application of Nitobond SBR or equivalent soon after the finishing is over, apply the curing compound and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.13 Curing Compound: Immediately after striking the form work or after completion of the repair works, the surface should be sprayed with 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 and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.14 Debris Removal: Loading, transporting and taking away the dismantled debris outside the Chennai Port premises, all as directed including all labour, machineries, tools, transport, equipment, fuel etc., complete. Note: 1. The Contractor shall maintain trip sheets in triplicate in ChPA’s approved format at his own cost for the quantity of debris transported. 2. Interim Payment will be based on the lorry cubical content. No deduction of voids will be made for debris. 3. However, the final quantity will be restricted to actual quantity of dismantling / demolishing items.

3.15 Drilling & fixing of Nozzle - wall cracks: Identify the point to be grouted and care to be taken to drill at the horizontal and vertical joint along the other weak points. Drill holes of 20mm dia holes to depth of about 75mm. Fix the pvc nipple using rapid setting compound like Rendroc Plug of Fosroc or equivalent. Allow it to set and all as directed including all machineries, labour, tools, materials, plants, equipments, scaffolding, transport, fuel etc., complete.

3.16 Cement Grouting: Prepare the cement grout by adding the cement with water. Grout the same using cement grout mixed with copolymer (SBR) of 1 lit per bag of cement. Inject the same using a positive displacement pump until the nipple refuses the grout or the grout comes out in the near by points. Cut the nipple and finish the same using polymer modified mortar and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.17 Removal of brick jelly from terrace & Suken portion : Remove the existing tiles, brick jelly and bed mortar and expose up to the parent concrete slab. Check for cracks, if any, and if so pressure grout the same and close the crack using polymer modified mortar. Acid wash and water wash the surface and allow the surface to dry and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.18 Drilling & fixing of Nozzle - Terrace & sunken portion: Identify the point to be grouted and care to be taken to drill at the horizontal and vertical joint along the other weak points. Drill holes of 20mm dia holes to depth of about 75mm. Fix the pvc nipple using rapid setting compound like Rendroc Plug of Fosroc or equivalent. Allow it to set and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.19 Injection of Microfine cement: Prepare the micro fine cement slurry by adding the micro fine cement with water with minimum of 0.5 water cement ratio. Mixing to be done mechanically and expandable grout additive like Cebex 100 of Fosroc or equivalent at 225 gms per bag of cement need to be added to compensate the shrinkage. Inject the same using a positive displacement pump until the nipple refuses the grout or the grout comes out in the near by points. Cut the nipple and finish the same using polymer modified mortar and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.20 Water Proofing Toilets: All the surfaces which are to receive the waterproofing coating like Brushbond of Fosroc or equivalent, must be free from dirt or any other form of foreign matter which might affect adhesion. Acid wash and water wash the surface and allow it to surface dry condition. Mix the part A and part B of the polymer modified cementitious coating mechanically using an electrical operated drilling machine fitted with mix paddle. Apply the same in two coats over the prepared surface one after the other dries up with a minimum interval of 4 hours between the coats. Providing pressure grouting in all the vertical and horizontal joint including the suspected areas and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.21 Relaying of Tiles: Prepare bed mortar with CM 1:6 added with waterproofing liquid like Conplast X 421 IC or equivalent at 150ml per bag of cement. Prepare cement slurry and pour the same on the surface as cement punning. Place the vitrified tiles of approved make and size followed by release of entrapped air. Fill the tile joint with polymer based tile filling compound and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.22 Water Proofing Terrace: All the surfaces which are to receive the waterproofing coating like Brushbond of Fosroc or equivalent, must be free from dirt or any other form of foreign matter which might affect adhesion. Acid wash and water wash the surface and allow it to surface dry condition. Mix the part A and part B of the polymer modified cementitious coating mechanically using an electrical operated drilling machine fitted with mix paddle. Apply the same in two coats over the prepared surface one after the other dries up with a minimum interval of 4 hours between the coats. Providing pressure grouting in all the vertical and horizontal joint including the suspected areas and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

3.23 Supplying & applying of Heat resitant tiles : Providing the primer and heatproofing & climate control plaster by mixing silicon PP with cement with required water powder ratio and apply the same over the water proffing area in the terrace complete.Lay the new good quality heat resistant tiles as per manufacture specifications to the required line and levels and all as directed including all machineries, labour, materials, tools, plants, equipments, scaffolding, transport, fuel etc., complete.

4. Rehabilitation of the distressed RC structural elements in the New Pipeline Trestle of Oil Jetty

4.01 Surface preparation for Micro Concreting: Preparing the surfaces of RC piles, structural elements etc., and wherever required to receive new finish / micro concrete including removing the steel casing / liners if necessary, chipping the concrete upto 25mm thick (approx.) behind the rebars or as directed, removing the spalled concrete and all loose particles, to achieve a laitance and contaminant free surface including cleaning the surface of reinforcement steel to remove all rust and scales including collecting and stocking the rubbish within a lead of 1km or as directed as per relevant specifications and as directed including all machineries, labour, tools, plant equipments, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note: The surface shall be prepared to receive new finish/coat as laid down in the manufacturer’s specification.

4.02 Surface preparation for Dry Spray Repair Mortar: Surface Preparation of RCC pile muff, Main beam, secondary beams etc and wherever required for applying Dry Spray Repair Mortar (DSRM) including removing the spalled concrete, loose particles, to achieve a laitance and contaminant free surface including checking the cleaned surfaces by conducting phenolphthalein test until reaching the good or uncontaminated concrete collecting and stocking the rubbish within a lead of 1km all as per relevant specifications and as directed including all machineries, labour, tools, plants, equipments, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note: The surface shall be prepared to receive new finish/coat as laid down in the manufacturer’s specification.

4.03 Anchoring Main Reinforcement: Drilling of 16mm dia holes to a depth of 75mm in the RC Pile / Muff / Beams and wherever required in the marked places for anchoring rebars using rotary hammer drilling machine of reputed make and Cleaning the holes neatly and wash the same with jet of water, including filling the holes with the polyester resin (Lok Fix S (or) P of Fosroc India Pvt. Ltd. or its equivalent) pushing the same in to the holes with a proper tool so that the bottom most point of the hole receives the polyster resin material for a minimum portion of 1/3rd of the hole depth and inserting the rebar which need to be anchored for the provision of main reinforcement, gently and finish the surface of the around the rebar area using the same polyster resin material all as per manufacturer’s specification and as directed to suit site requirement including all materials, labour, machineries, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel, etc., complete. Note : Steel reinforcement shall be measured and paid separately under relevant item of this schedule

4.04 Additional reinforcement: Supplying, fabricating and fixing 12mm and 8mm dia High yield strength deformed (HYSD Fe415/500 grade), for providing Additional Reinforcement to the RC structural elements such as RCC beams, RCC piles etc., of pipe line trestle and wherever required tie with shear connectors / anchor rods / anchor resin Lokfix 'P' including cost of materials, labour, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaram, Pontoon, fuel, transport etc. complete.

4.05. Shear Connectors: Supplying and fixing shear connectors at 500mm c/c or as directed using 8mm dia 'L' shaped High yield strength deformed (HYSD Fe 415/500 grade) TMT steel reinforcement bars on the surface of the RC pile, beam etc., wherever required all as directed including cutting, bending, fabricating the steel including drilling holes of 12mm dia and 75mm depth using a hand held drilling machine, fixing the shear connectors in position in the drill holes using polyster resin (Lok Fix S (or) P of Fosroc India Pvt. Ltd. or its equivalent) as per manufacturer’s specification and as directed to suit site requirement including all materials, steel reinforcement, labour, machineries, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete.

4.06 Provision of Galvanic Anode: Supplying and fixing of self-sacrificial Galavanic Anode of Galvashield XPI manufactured by M/s Vector Technologies or equivalent units, at locations positioned around/along the repair boundary including checking the continuity of the steel reinforcement and providing additional electrical connections or restoration of continuity by effective means, preparing the substrate and thoroughly pre-soaking the self-sacrificial Galavanic Anode in clean water for a minimum of 10 minutes and a maximum of 20 minutes, prior to the application of the repair mortar, Tightening the tie wires using Galvashield Fixing Tool so that no free movement is possible and ensuring good electrical continuity including testing the electrical continuity between tie wires and reinforcement bar, using electrical multi meter all as per manufacture's specifications and as directed to suit site requirement including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete.

Note: 1. if an equivalent product is proposed, the bidder shall enclose the Third party test certificate alongwith the projects where the product has been used in marine environment and their performance in terms of current output density over the period of time through a monitoring system. 2.The above rate shall also include the installation of 10 monitoring boxes each connected to 15-20 anodes and establishing a current density of 0.2 to 2 mA/m2 as per EN ISO 12696 up to the Defect Liability Period. The elements to be monitored as well as the locations where the Monitoring boxes are to be installed shall be decided by the Engineer in charge. The monitoring shall be continued for a minimum period of 2 years at intervals of every month for the first 6 months and thereafter every 3 months for a further 6 months period and then half yearly. The current density data shall be submitted to the Port authorities. Galvanic Anode Performance (GAP) test certificate shall be provided.

4.07 Anti-corrosive Coating : Applying Protective coating to newly prepared exposed surfaces of old/new steel reinforcement bars with two coats of anti-corrosive rebar Coating Nitozinc Primer of Fosroc or equivalent including cleaning the rebars using the rust remover and making the rebars free of foreign materials, applying the anti-corrosive coating using suitable small brush, at 45 microns/coat and total dry film thickness (DFT) 90 microns all as per manufacturer’s specification and as directed including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring boat, catamaran, pontoon, transport, fuel, etc., complete.

4.08 Epoxy Jointing Compound : Applying epoxy resin bonding Compound Nitobond EP of Fosroc or equivalent in all repair areas of concrete surface using short haired brush to receive DSRM all as per manufacture's specifications and as directed to suit site requirement including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note : Concreting shall be done within 5 hrs (maximum) from the time of application of epoxy bonding compound or as per manufacturer's specification.

4.09 Form Work: Providing and fixing leak-proof shuttering for facilitating micro-concrete works for RCC piles and wherever required to get a form finish concrete, using Marine plywood/ FRP sheets/steel with ribs, stiffeners, supporting frames, members, clamping arrangement, fixtures, bolts, nuts etc., including supplying, fabricating, conveying, fixing / erecting in position, sealing the edges with foam rubber sealing strips, de-shuttering, removing and taking away the materials (after completion of micro-concrete works as recommended in manufacturer’s specification) and as directed including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel, etc., complete. Note: 1) The contractors shall prepare and submit drawing for shuttering arrangement for approval before fabricating the same. 2) Payment will be made based on the actual area of repair work.

4.10 Micro concrete: Supplying, mixing and pouring / pumping ready to use non-shrink, cementitious micro concrete, Renderoc RG of Fosroc or equivalent 80mm average thickness for RCC piles and wherever required for repair of damaged concrete structures above water level with mix proportion (micro concrete and 12mm down graded chips in the ratio of 1: 0.5 by weight) all as per manufacturer’s specifications, and as directed, including rectifying the surface defects if found during removal of form work by applying PMM, including conveying, pouring the micro-concrete using positive displacement pumps all as per the manufacturer’s specifications and as directed, including all material, labour, tools, equipments, transport, scaffolding / working platform, hiring boat, catamaran, pontoon, removing the formwork etc., complete.

4.11 Micro concrete - Underwater: Supplying, mixing and pouring / pumping ready to use non-shrink, cementitious micro concrete,Renderoc UW of Fosroc or equivalent 80mm average thick to the RCC piles and wherever required for repair of damaged concrete structures below water level with mix proportion (micro concrete and 12mm down graded chips in the ratio of 1: 0.5 by weight) all as per manufacturer’s specifications, and as directed, including rectifying the surface defects if found during removal of form work by applying PMM, including conveying, pouring the micro-concrete using positive displacement pumps all as per the manufacturer’s specifications and as directed, including all material, labour, tools, equipments, transport, scaffolding / working platform, hiring boat, catamaran, pontoon, removing the formwork etc., complete.

4.12 Dry Spray Repair Mortar: Providing and applying Dry Spray Repair Mortar (DSRM) of Renderoc DS40 of Fosroc or equivalent, ready to use blend of dry powers which is formulated for application using the dry spray process, to the isolated repair of the distressed RCC Muff, Main and Secondary beams etc., and wherever required including cleaning the reinforcements using Reebaklens RR of Fosroc or equivalent and making sure that there is no traces of rust on the surface of the rebars applying the mortar on the prepared surfaces as per manufacturer’s specification and as directed to suit site requirement including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete.

4.13 Curing compound : Providing and applying with membrane based curing compound Concure WB white of Fosroc or equivalent, on the surfaces of the newly laid Micro concrete / DSRM, immediately after striping the form work or after completion of the repair works, including spraying of water on the surface and followed by application of curing compound diluted with water in the ratio of 1:1 as recommended in manufacturer’s specification and as directed including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring boat, catamaran, pontoon, transport, fuel, etc., complete.

4.14 Protective coating for Environmental face using Dekguard S of Fosroc: Providing and applying a single component High Build Elastomeric, crack-bridging, resistant to CO2 and chloride ion diffusion, UV resistant, breathable acrylic coating with elongation at break exceeding 200% using Dekguard S of Fosroc or equivalent material applied in two coats over the Primer (each top coat shall be 150 microns WFT). The primer coat is a single component Silane Siloxane primer and the Top coat is a single component pigmented and as per the recommendations of the manufacturer for the repaired areas, RC Pile muff, beams etc., and whereever required all as per specifications and as directed including all labour, materials, machineries, tools, equipments, plants, hiring boat, catamaran, pontoon, transport, fuel, etc., complete

4.15 Debris Removal: Loading, transporting and taking away the dismantled debris outside the Chennai Port premises, all as directed including all labour, machineries, tools, transport, equipment, fuel etc., complete. Note: 1. The tenderer shall maintain trip sheets in triplicate in ChPA’s approved format at his own cost for the quantity of debris transported. 2. Interim Payment will be based on the lorry cubical content. No deduction of voids will be made for debris. 3. However, the final quantity will be restricted to actual quantity of dismantling / demolishing items.

5. Rehabilitation of the distressed RC structural elements in the old Pipeline Trestle of Oil Jetty

5.01 Dismatling the existing Micro Concreting: Chipping carefully without causing vibrations to the existing Structures and removing the existing micro concrete / cement concrete from the sides and surfaces of RCC piles, RCC beams etc.,and wherever required above water level to receive new finish / micro concrete upto 100mm thick (approx.) all as directed, including chipping the concrete, removing the spalled concrete, all rust and scales including collecting and stocking the rubbish within a lead of 1km all as per relevant specifications and as directed including all machineries, labour, tools, plants, equipments, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note: The debris shall not be dumped into the Sea.

5.02 Surface preparation for Micro Concreting: preparing the surfaces of RC piles, Pile Muff, beams, other structural elements etc., and wherever required to receive new finish / micro concrete including removing the steel casing / liners if necessary, chipping the concrete upto 25mm thick (approx.) behind the rebars or as directed, removing the spalled concrete and all loose particles, to achieve a laitance and contaminant free surface including cleaning the surface of reinforcement steel to remove all rust and scales including collecting and stocking the rubbish within a lead of 1km or as directed as per relevant specifications and as directed including all machineries, labour, tools, plant equipments, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note: The surface shall be prepared to receive new finish/coat as laid down in the manufacturer’s specification.

5.03 Surface preparation for PMM: Preparation of surfaces of deck slab of the pipe line Tresle and wherever required above water level to receive new finish of Polymer Modified Mortar (PMM) including removing the spalled concrete, loose particles, to achieve a laitance and contaminant free surface including checking the cleaned surfaces by conducting phenolphthalein test until reaching the good or uncontaminated concrete, collecting and stocking the rubbish within a lead of 1km all as per relevant specifications and as directed including all machineries, labour, tools, plants, equipments, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note: The surface shall be prepared to receive new finish/coat as laid down in the manufacturer’s specification.

5.04 Additional reinforcement: Supplying, fabricating and fixing 12mm and 8mm dia High yield strength deformed (HYSD Fe415/500 grade), for providing Additional Reinforcement to the RC structural elements such as RCC piles, Pile muffs etc., of pipe line trestle and wherever required tie with shear connectors / anchor rods / anchor resin Lokfix 'P' including cost of materials, labour, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaram, Pontoon, fuel, transport etc. complete.

5.05 Anchoring Main Reinforcement: Drilling of 16mm dia holes to a depth of 75mm in the RC Piles and wherever required in the marked places for anchoring rebars using rotary hammer drilling machine of reputed make and Cleaning the holes neatly and wash the same with jet of water, including filling the holes with the polyester resin (Lok Fix S (or) P of Fosroc India Pvt. Ltd. or its equivalent) pushing the same in to the holes with a proper tool so that the bottom most point of the hole receives the polyster resin material for a minimum portion of 1/3rd of the hole depth and inserting the rebar which need to be anchored for the provision of main reinforcement, gently and finish the surface of the around the rebar area using the same polyster resin material all as per manufacturer’s specification and as directed to suit site requirement including all materials, labour, machineries, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel, etc., complete. Note : Steel reinforcement shall be measured and paid separately under relevant item of this schedule

5.06 Shear Connectors: Supplying and fixing shear connectors at 500mm c/c or as directed using 8mm dia 'L' shaped High yield strength deformed (HYSD Fe 415/500 grade) TMT steel reinforcement bars on the surface of the RC pile, muff, beam etc., wherever required all as directed including cutting, bending, fabricating the steel including drilling holes of 12mm dia and 75mm depth using a hand held drilling machine, fixing the shear connectors in position in the drill holes using polyster resin (Lok Fix S (or) P of Fosroc India Pvt. Ltd. or its equivalent) as per manufacturer’s specification and as directed to suit site requirement including all materials, steel reinforcement, labour, machineries, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete

5.07 Provision of Galvanic Anode: Supplying and fixing of self-sacrificial Galavanic Anode of Galvashield XPI manufactured by M/s Vector Technologies or equivalent units, at locations positioned around/along the repair boundary including checking the continuity of the steel reinforcement and providing additional electrical connections or restoration of continuity by effective means, preparing the substrate and thoroughly pre-soaking the self-sacrificial Galavanic Anode in clean water for a minimum of 10 minutes and a maximum of 20 minutes, prior to the application of the repair mortar, Tightening the tie wires using Galvashield Fixing Tool so that no free movement is possible and ensuring good electrical continuity including testing the electrical continuity between tie wires and reinforcement bar, using electrical multi meter all as per manufacture's specifications and as directed to suit site requirement including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete.

Note: 1. if an equivalent product is proposed, the bidder shall enclose the Third party test certificate alongwith the projects where the product has been used in marine environment and their performance in terms of current output density over the period of time through a monitoring system. 2.The above rate shall also include the installation of 10 monitoring boxes each connected to 15-20 anodes and establishing a current density of 0.2 to 2 mA/m2 as per EN ISO 12696 up to the Defect Liability Period. The elements to be monitored as well as the locations where the Monitoring boxes are to be installed shall be decided by the Engineer in charge. The monitoring shall be continued for a minimum period of 2 years at intervals of every month for the first 6 months and thereafter every 3 months for a further 6 months period and then half yearly. The current density data shall be submitted to the Port authorities. Galvanic Anode Performance (GAP) test certificate shall be provided.

5.08 Anti-corrosive Coating : Applying Protective coating to newly prepared exposed surfaces of old/new steel reinforcement bars with two coats of anti-corrosive rebar Coating Nitozinc Primer of Fosroc or equivalent including cleaning the rebars using the rust remover and making the rebars free of foreign materials, applying the anti-corrosive coating using suitable small brush, at 45 microns/coat and total dry film thickness (DFT) 90 microns all as per manufacturer’s specification and as directed including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring boat, catamaran, pontoon, transport, fuel, etc., complete.

5.09 Epoxy Jointing Compound : Applying epoxy resin bonding Compound Nitobond EP of Fosroc or equivalent in all repair areas of concrete surface using short haired brush to receive PMM all as per manufacture's specifications and as directed to suit site requirement including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete. Note : Concreting shall be done within 5 hrs (maximum) from the time of application of epoxy bonding compound or as per manufacturer's specification.

5.10 Form Work: Providing and fixing leak-proof shuttering for facilitating micro-concrete work for RCC piles, Muffs, Main and secondary beams etc.,to get a form finish concrete, using Marine plywood/ FRP sheets/steel with ribs, stiffeners, supporting frames, members, clamping arrangement, fixtures, bolts, nuts etc.,and wherever required including supplying, fabricating, conveying, fixing / erecting in position, sealing the edges with foam rubber sealing strips, de-shuttering, removing and taking away the materials (after completion of micro-concrete work as recommended in manufacturer’s specification) and as directed including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring boat, catamaran, pontoon, transport, fuel, etc., complete. Note: 1) The contractors shall prepare and submit drawing for shuttering arrangement for approval before fabricating the same. 2) Payment will be made based on the actual area of repair work.

5.11 Micro concrete: Supplying, mixing and pouring / pumping ready to use non-shrink, cementitious micro concrete, Renderoc RG of Fosroc or equivalent 80mm average thickness for RCC piles, Muff, beams and wherever required for repair of damaged concrete structures above water level with mix proportion (micro concrete and 12mm down graded chips in the ratio of 1: 0.5 by weight) all as per manufacturer’s specifications, and as directed, including conveying, pouring the micro-concrete using positive displacement pumps all as per the manufacturer’s specifications and as directed, including all material, labour, tools, equipments, transport, scaffolding / working platform, hiring boat, catamaran, pontoon, removing the formwork etc., complete.

5.12 Micro concrete underwater: Supplying, mixing and pouring / pumping ready to use non-shrink, cementitious micro concrete,Renderoc UW of Fosroc or equivalent 80mm average thick to the RCC piles and wherever required for repair of damaged concrete structures below water level with mix proportion (micro concrete and 12mm down graded chips in the ratio of 1: 0.5 by weight) all as per manufacturer’s specifications, and as directed, including rectifying the surface defects if found during removal of form work by applying PMM, including conveying, pouring the micro-concrete using positive displacement pumps all as per the manufacturer’s specifications and as directed, including all material, labour, tools, equipments, transport, scaffolding / working platform, hiring boat, catamaran, pontoon, removing the formwork etc., complete.

5.13 Polymer Modified Mortar: Providing and applying Polymer Modified Mortar of average thickness of 30mm (cement and sand mixed in the ratio of 1:3 and 3 litres of Nitobond SBR of Fosroc Chemicals or equivalent per bag of cement) to the deck slab and applying the same on the prepared surfaces as per manufacturer’s specification and as directed to suit site requirement including Cleaning the reinforcement using Reebaklens RR of Fosroc or equivalent and make sure that there are no traces of rust on the surface of existing rebars, Check for the depth of carbonation using the phenolphthalein indicator and make sure that the contaminated concrete is removed completely, 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 and including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring of boat, catamaran, pontoon, transport, fuel etc., complete.

5.14 Curing compound: Providing and applying with membrane based curing compound Concure WB white of Fosroc or equivalent, on the surfaces of the newly laid micro concrete/ PMM, immediately after striping the form work or after completion of the repair works, including spraying of water on the surface and followed by application of curing compound diluted with water in the ratio of 1:1 as recommended in manufacturer’s specification and as directed including all materials, labour, tools, equipments, plants, scaffolding / working platform, hiring boat, catamaran, pontoon, transport, fuel, etc., complete.

5.15 Protective coating for Environmental face using Dekguard S of Fosroc: Providing and applying a single component High Build Elastomeric, crack-bridging, resistant to CO2 and chloride ion diffusion, UV resistant, breathable acrylic coating with elongation at break exceeding 200% using Dekguard S of Fosroc or equivalent material applied in two coats over the Primer (each top coat shall be 150 microns WFT). The primer coat is a single component Silane Siloxane primer and the Top coat is a single component pigmented and as per the recommendations of the manufacturer to the repaird areas, RCC pile, Pile Muf, beams, botom portion of old trestle etc., and wherever required all as per specifications and as directed including all labour, materials, machineries, tools, equipments, plants, hiring boat, catamaran, pontoon, transport, fuel, etc., complete

5.16 Debris Removal: Loading, transporting and taking away the dismantled debris outside the Chennai Port premises, all as directed including all labour, machineries, tools, transport, equipment, fuel etc., complete. Note: 1. The tenderer shall maintain trip sheets in triplicate in ChPA’s approved format at his own cost for the quantity of debris transported. 2. Interim Payment will be based on the lorry cubical content. No deduction of voids will be made for debris. 3. However, the final quantity will be restricted to actual quantity of dismantling / demolishing items

5.17 Dismantling of Parapet wall: Demolishing the brick parapet wall in C.M as existing at site manually / by mechanical means without damaging the nearby structures and including collecting and stacking within a lead of 50m(for transportation and disposal) all as per relevant specifications and as directed including all labour, tools, tackles, equipment, plants, fuel etc., complete.

5.18 Parapet wall work: Providing common burnt clay F.P.S. (non modular) bricks of class designation 7.5 in Cement Morter 1:4 (1 cement : 4 CS sand) for pile line trestle and as per relevant specification, drawing and as directed including curing, all labour, material, tools, plants, equipment, transport, fuel etc.,complete

5.19 Parapet wall plastering work: Preparing the exposed surfaces of brick work and wherever required and providing plastering in C.M 1:4,(1 cement : 4 Fine CS sand) with addition of super plasticiser at the rate of 100ml per bag of cement all as per Manufacturers specification for better bonding and achieving the required strength of plaster12mm thick to the required finish, including providing plastiziser all as per relevant pecifications and as directed including curing, all labour, materials, scaffolding, tools, equipment, transport and fuel etc., complete.

6. Safety measures

6.01 SSS- Shift Safety Supervisors : Deploying 2 Nos of Shift Safety Supervisors (SSS) per shift to monitor the safety aspects during execution of the rehabilitation works all as directed. Note: 1. Shift Safety Supervisors shall be qualified from any reputed fire engineering college with minimum 1 - 2 years of experience in fire & safety in reputed industries 2.In case of absence of Shift Safety Supervisors deductions will be made on pro-rata basis.

6.02 CCTV Network : Providing “Portable CCTV Units” with standalone recording facility or wireless facility including providing “Body- Cameras” to all safety personnel and making the recordings for review and monitoring (Cameras shall be provided with IR facility for night monitoring) including providing the CCTV units with stand and shelter arrangement with necessary protection from wind, rain etc., all as per technical specification and as directed including all labour, materials, machineries, tools, plants, equipments, fuel, transport etc., complete. Note: Deductions will be made on pro-rata basis in case of non-availability/non-functioning of the above facility.

6.03 3D Model both in Physical & soft Forms : Providing 3D Model both in Physical &Soft Forms of size 4 ft x 3 ft x 2 ft height as per the industrial standards in control room for deciding site specific conditions to be implemented, viz., Fire screen dimensions, List of Portable Fire Fighting Arrangements, Positioning of Gas Monitors, CC Camera Locations, hand Operated Siren location, Wind Socks etc., as detailed during Job Safety Analysis (JSA)/Target Response Times (TRT). Soft 3D Model shall be as per industrial standards along with TV screen and computer for discussion in control room at site. The 3D model shall be designed suitably such that any updation on completion of work is also frequently incorporated as the work progresses. Modelling in terms of graphical model shall be made available in video format for use by engineers in their mobiles on weekly basis all as directed including all labour, materials, machineries, tools, plants, equipments, fuel, transport etc., complete. Note: 1. Accommodation for establishing Control room to equip the 3D model, gas monitoring system, CCTV will be provided by the Port. 2. Deductions will be made in case of short falls of the above facility.

6.04 Gas Monitoring Arrangements Fixed/Mobile/Portable-Network Monitoring : Providing Network of Mobile Gas Monitors (meeting the safety standards) around the work spots (minimum of 6 nos for each jetty) where work is happening. The gas monitors shall have suitable communication system with wireless network system and battery + memory for recording gas levels. These units shall be monitored from control room including providing suitable set up for managing through software. The gas monitoring units shal be Drager or equivalent with AEX approval. Sufficient numbers to be available at any given point of time calibrated certified and working meeting specification. Note: Deductions will be made on pro-rata basis in case of non-availability/non-functioning of the above facility.

6.05 Divers Team at site : Providing trained divers team consisting of 2 divers at site to attend any emergency and for safety management of the workers/personnels engaged during the execution of work. (Mechanized boat shall be made available for divers team) Note: Deductions will be made on pro-rata basis in case of non-availability/non-functioning of the above facility.

6.06 VHF/UHF Communication Sets : Providing 25 sets of VHF/UHF units at each jetty with intrincically safe (IS) and with separate channel frequency for communication at site as per safety requirements till completion of work all as per specifications and as directed including all labour, materials, machineries, tools, plants, equipments, fuel, transport etc., complete. Note: Technical specification VHF/UHF units shall be as per Annexure 23 of Tender document issued under Amendment No.3

6.07 Portable/First Aid Fire Fighting system/PPE Safety Gears : Providing First Aid/ Fire Fighting facilities viz., Stretchers of reputed make, life jackets - 20 nos., Long range - Heavy Duty Torch Lights, Reflective jackets etc., for people working at site for immediate use in case of any emergency till completion of the project. Note: Technical specification of Inherent Fire Retardant (IFR) Suits for Workers and PPEs shall be as per Annexure 25 of Tender document issued under Amendment No.3

6.08 Fire Screen Portable : Contractors shall make suitable arrangements for having Fire Screen provided for every hot work location irrespective of the position and suitable minoring which shall be suitably provided around the work spots. During the JSA / TRT by use of 3D models and boards sufficient discussion and detailing shall be made for identifying the need for fire screen. The necessity for fire screen shall be viewed in the back ground where in the contractor workers working should not be blocked from viewing and also facilitate dilution of concentration of vapors.

6.09 Drone Services : Providing Two drones for Drone Services during the execution of the work whenever the need for close supervision in terms of inspection of works and monitoring is required suitable drone services shall be made available. The drones as perin perfectly working condition suitable for flying at wind speeds above sea /coastal area with all necessary licenses should be available permanently at site with qualified /licensed / certified / trained drone operators for use at any given point of time. The streaming of the videos (real time) basis as the drone services will be used for monitoring safety during works as and when required and for inspection of the work being executed. Such recordings shall be the property of port only and no permission for the contractor or anyone to use such views/ clippings etc.

The permission to fly the drones will be only with suitable work permit (separate work permit) as this will help to monitor multiple aspects. The Drones shall be capable of having minimum focused illumination and audio recording facility. Port or any other statutory agency will have the right to refuse a particular drone (example make in China etc) and contractor must accept / agree to such conditions unrestrictedly. All the footages should be stored in an orderly manner for easy retrieval or recall purpose and logged with port and safety manager of the project. Use of Drones when ships are at jetties are under loading operation of class A products will be avoided. The working area is handling the petroleum products, special care in ensuring the best quality drones with maximum safety features including control to block flying (no-fly zone area) of a particular geo fence area including Suitable accessories for this facility / features shall also be made available along with laptop for live viewing at site. Note : 1. The drones shall be always good in working condition. 2. Payment will be made in 4 equal instalments and last instalment will be paid during final bill and or as directed. 3. Technical specification of drone shall be as per Annexure 24 of Tender document issued under Amendment No.3

6.10 Water Pumps - For Fighting - Submersible - with Generator : Providing Three Submersible pumps of suitable capacity with floating arrangement of fixed frame on edge of jetty with water intake facility from Sea with Foot valve and hose for immersion with all necessary safety requirements to facilitate the supply of water for Fire Tenders directly to get topped and or for filling water tanker of 10000 lits capacity to shuttle / transport water from the tanker to fire tender for meeting any exigency. One pump at BD1 and one at BD3 to be kept in working condition and third one will be spare portable for use as and when required. The submersible pump capacity and type shall be to fill 12000 lits within a time frame of 10 minutes onto the top of the truck and pumping head of at least 15 meters all as directed including all labour, materials, machineries, tools, plants, equipments, fuel, transport etc., complete.

6.11 Vehicle: : Providing 1No of Mahindra Xylo / Bolero / Bolero neo vehicle for inspection/monitoring the rehabilitation works by the ChPA/PMC/saftey officials and shall be fitted with spark arrestors and not to be taken out of port premises including supply, maintenance, operations, road tax, permit charges, diesel, driver salary, insurance, parking charges, all taxes and other statuory charges etc., as applicable excluding GST for the vehicle service. Note: 1. Total Hours of operation - 24 hrs. 2. The vehicle shall be provided on all days in a month.

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