Annual Routine Maintenance Contract for Civil Works in Kochi Metro

Amount

(i) Strip Seal Joint – Providing and installing Single strip seal joint conforming to latest revisions of MORTH circulars incl. provision of edge beams at end edges of precast diaphragm segments and cast in situ unit and all related operations as required to complete the work as specified in specifications. Gap for expansion joint installation is 100mm & maximum variation in gap upto ± 50mm.

(ii) Omega (W) joint – Providing and installing omega joint conforming to IRC 83 - part II. The rate shall include casting of cast-in-situ plinth at edge of deck for fixing joint. Gap for expansion joint: 100mm.

Providing, bending to required curved profile and fixing single skin Hi-Rib Profiled sheeting 930-1020 mm cover width, 28-32 mm crests @ 186 - 333 mm c/c manufactured out of 0.45 mm BMT (Base Metal Thickness) Hi- Tensile Galvalume/zincalume steel. The sheets shall have wide pans with 2-3 nos. stiffening ribs for effective water shedding and special male/female ends with full return legs on side laps for purlins support and anti- capillary flute in side lap. The sheets shall have a hot- dip metallic Zinc - Aluminium alloy coating (150 gms/sq.m zinc(45%)/ alum (55%). Coating mass total on both sides. AZ-150 or equivalent as per AS 1397-1993), minimum 550 Mpa yield strength with SMP coating (min. silicone content 30% - 50%) or super polyster XRW quality paint coat of approved colour. The coating shall be as per AS/NZS- 2728 :1997 (category 3 ). The total coating thickness of 35 microns, comprising of 20 microns exterior coat of SMP or superpolyster XRW on top surface over 5 micron primer coats on both surfaces including side and End laps shall not be less than 225mm.(The sheets shall be fixed using polymer coated hot dip galvanised hex head self drilling fastners as per AS : 3566 class 3 on each crest of sheets for connection with purlins and polymer coated hot dip stitching fastners at 300 mm centres on all side and end laps and including providing and fixing corrugated cyclone assumbly "Corri-lok" or its equivalent in Zinculme K2-150 class 3 etc). The measurement shall be based on per unit of finished/laid area. Item to include curved sheets also wherever required. Approved Sealing tapes shall be used on side laps and end laps on sheets and closures to be provided at the last end of sheet. Contractor shall give minimum 20 year guarantee for the sheets against deterioration, disintegration, loss of lustre, variation in colours etc. and leakages across laps, fasteners etc. All type of steel sheets shall be load tested to safely carry 1.10 times the design wind loads and coating thickness to the satisfaction of Engineer- in -charge. Fasteners shall be load tested. The contractor is to submit design and shop drawings for approval on the sheet profile, design and details before installation.

Providing and fixing 300 mm long puddle flanges fabricated out of 6 mm thick M.S. plates along with flanges of suitable size propery fixed in walls and top slabs of underground and overhead tanks.

25 mm dia

32 mm dia

50 mm dia

65 mm dia

80 mm dia

100 mm dia

150 mm dia

200 mm dia

Making connection from existing water supply line including necessary excavation and making good the same including cutting, boring and taping the existing line by providing and installating ferrule and making good the same including cutting. Boring and taping the existing line by providing and installing ferrule connections with necessary fittings as required and making good the same. The rate for this items also includes complete services from the contractor for liasoning works such as filling necessary applications, submission of forms for approval to the municipal authorities depositing the fees and other amounts as required getting the premises installations, inspected and approved and all other formalities required till the water connection is obtained. All the expenses incurred in authorities following up this regard shall be borne by the contractor. Department charges if any will be reimbursed to the contractor on production of receipt of money deposited with the department.

Providing and fixing enclosed type water meter (bulk type) confirming to IS : 2373 and tested by appropriate authority with bolts, nuts, rubber insertions etc. (The tall pieces if required will be paid seperately)

Providing and fixing CI dirt box strainer for bulk type water metre with nuts, bolts, rubber insertion etc. complete confirming to IS: 2373

Providing and laying cement concrete 1:5:10 (1 cement : 5 fine : 10 graded stone aggregate 40 mm nominal size) up to haunches of RCC pipes including bed concrete as per specifications.

450 mm RCC Pipe

Providing an fixing on wall face M.S. Pipes rain water Pipes conforming to IS : 1239 / 3589 including jointing with seal ring leaving 10 mm gap for thermal connection.

110 mm dia

160 mm dia

300 mm dia

Providing and fixing SWR UPVC pipes as per IS : 4985 class-4 including all fittings e.g. bends junctions, cowls, offsets, clean out plugs etc. jointing with solvant cement including cutting holes in walls, floors excavation, refilling and disposal of surplus earth wherever required and making good.

75 mm dia

110 mm dia

Extra for Red/ Raw Silk/ Tan Brown/ Jet Black granite

Providing and installing counters of MS (with primer and 2 coats of enamel paint) carcass in TOM, EFO etc with 30mm polished & moulded Jet Black Granite top with all cutouts/ openings including providing and fixing over 19mm thick commercial board & 19 x 3 mm teak wood lipping all complete of approved quality as per specifications

Providing & Fixing Polished Granite Coping over prapet walls and cills of openings, bull-nosed on both edges over 20 mm thick cement mortar 1:4(1 cement: 4coarse sand) with joint treated with white cement mixed with matching pigment including Rubbing, Curing , Moulding & polishing to edge to give high gloss finish etc. complete.

30 mm thick Jet Black granite

Providing and laying 40mm polished Red/ Raw Silk/ Black/ Tan Brown granite slabs for trench cover with 25mm dia holes @ 100mm c/c spacing complete.

Providing and fixing access raised floor of light grade of minimum 15 KN/m2 UDL panels manufactured from pressed formed corrosion resistant galvanised steel with total overwrap of one piece top, sides and bottom flange encapsulating high performance cementatious board case stiched and with a panel to cater in the size 600 x 600 mm. The panel has to be placed on the pedestal made from all solid steel construction, galvanised plated consisting of stringers, an anti-vibrational head cap with cruciform upstands and four panels locating studs, positively clipped pedestal clipped to the steel base plate. The pedestal cap shall have an electrical conductor plate for discipation of static electricity. The steel base plate of the pedestal shall be fixed on the sub-floor with Epoxy pedestal adhesive and/or mechanical fixing with fasteners (8mm X 75mm). The Access floor should be able to take a point load of minimum 2.5 KN over 25 mm sq. and UDL of minimum 15 KN/sq. mtr. The panel shall be finished with high abrasion, anti static HPL of formica colour Y606 having fire rating as per BS 476 clause 5, 6 & 7 complete as per specifications

Upto 450 mm high cavity floor

Providing and laying 12mm (minimum) thick with 3mm (minimum) thick projection on surface yellow coloured directional porcelain tactile tile of Palican or equivalent (as per specifications) laid on floor with Laticrete 111 crete filler powder mixed with Laticrete 73 latex admix and applied to a minimum thickness of 4.5mm (The mixing ratio shall be as follows : 20kg bag Laticrete 111: 5.5 litre Laticrete 73. Spacer of 3mm shall be used between the tiles and joints filled using Laticrete Latapoxy SP-100 epoxy grout in Inca Gold colour. The joint depth shall be 6mm. Laticrete products shall be as maufactured by Laticrete India Pvt. Ltd. / Laticrete International Inc. over 20mm thick bed of cement mortar 1:4 (1 cement : 4 coarse sand) in levelling course laid to proper slopes over screed base including base preparation including movement joint in screed as per specifications with 10mm thick compressible filler to edge of screed with two parts polysulphide sealant to top edge as per approved drawings and directions of engineer -in-charge. Screed shall be measured and paid extra as per DSR 2018 item. 300 x 300 hazard warning and directional tactial tile as per specifications

Providing and laying yellow visibility vitrified tile as per control sample of size 200x100x8 mm thick at platform level over 20 mm thk bed of cement mortar 1:4 (1 cement : 4 coarse sand) in levelling course laid to proper slopes over screed base including base preparation including movement joint in screed as per specification with 10mm thick compressible filler to edge of screed with two parts polysulphide sealent to top edge as per approved drawing and directions of engineer-in-charge. Screed shall be measured, and paid extra as per DSR item no 4.1.8. - all complete as per relevant specifications

Providing and applying two coats of Unitile's Rodeo or Spectrum Perlina fine or Heritage Granula Surface Texture paint after applying corresponding roller coat as primer on pre-plastered surface as per approved sample in approved shade. The composition of the texture paint should consist of ACRYLIC copolymer resins combined with quartz, silica, mineral, aggregates, synthetic inorganic pigments, bactericide, fungicides and various other additives, giving the product water repellant properties. The first coat to be applied by brush or wool roller as a base coat, diluted with sufficient water and the final coat (Undiluted) to be applied by trowel and finished with acrylic trowel to maintain with or without groves, as per specifications. The thickness of both coats should be 1.0 to 1.5mm. the water repellency of the product shall be >= 86gm/m2 as per test method IS:5410-1969, complete as per manufacture’s specifications and instructions by Engineer in Charge at site. The rate shall include necessary scaffolding, labour and material complete

Providing and applying 3-4 layers of Unitile's Wax plaster or oikos Stucco/ Marmarino In approved shade on a smooth surface such as P.O.P or wall putty. The composition of the Wax plaster should consist of Acrylic Copolymer Resins combined with Quartz powder, hydrated mine, synthetic inorganic pigments, wax emulsions, silicone wax bactericides, fungicides and various other additives. The product shall be environment friendly, non toxic and free from any Volatile Organic Compound (V.O.C) the product shall be applied by stainless steel trowel in 3-4 layers as per the technical specifications of the manufacture with thickness between 1.0-1.5mm. The water repellency of the product should be >= 86gm/m2 as per test method IS: 5410-1969.

Providing and fixing Aluminum Composite panels in all coloures of Alucobond / Alpolic or any other approved equivalent for external / internal wall cladding at all heights and elevations including necessary aluminium composite panel consist of 3mm thermoplastic core of anti oxident LDPE sandwitched between two skin of 0.5 mm thick alloy sheet making a total sheet thickness of 4 mm. The surface shall be finished with PDVF base coating on the top side and service coating on the reverse side shall be with a polymer paint. Coating shall confirm to ECCA of AAMA. The system shall design to withstand wind pressure of 200 Kg/sqm and shall be fixed to the masonry/RCC walls with necessary clamps, bracket and anchor fasteners. All Clamps and brackets shall be hot dip galvanised minium 80 micron thick and confirmed to IS : 4759 - 1996. The extruded aluminium sections shall be anodised in approved colour with anodic coating minimum 20 microns.Extruded section shall be of 6063 T5 or T6 alloy confirming to ASTM B 221. (items include cost of aluminium frame, ACP Panels, Cramps 110mm size, weather sealent, gasket, foam, fixtures, scaffolding, all machineries and any other fastening streps, nuts, bolts, rivets, washers, etc complete).

Providing & fixing Toilet Cubicle (of following standard dimension which includes 600mm door size width) made of heat, bacteria, water, chemical, scratch, impact resistant 12mm thick solid compact laminate panels tested in approved laboratory. Finish of the compact laminate should be Suede, Raw silk model includes doors, pilasters & intermediate panels finished with approved texture/shade as per the specifications & as per IS 2046 (Indian Standard) and as per fire retardant BS-476/97 standard. This also includes providing and fixing in position necessary hardware made out of Stainless steel (Grade 304) as per manufacturer’s specifications & Architects instructions like (1) Door Knob, (2) Gravity Hinges, (3) Thumb turn lockset with Occupancy indicators, (4) Coat hooks with Door stopper (5) U- Channels, (6) Adjustable foot/pedestal, (7) Top rail (8) Rubber noise deafening tape, (9) Screws & wall Plugs. All screws will be of 304 Grade in stainless steel with satin finish. All pilasters are supported by stainless steel Bottom Cladding. The base of the stainless steel bottom cladding will be anchored to the floor with a clearance height upto 150mm. The top fitting should consist of SS top rail which will get fixed with pilasters. SS wall fixing is used only on the wall which will hold the ss top rail.

Toilet Cubicle with standard dimension of 2000-2100mm Height x 1000mm Width x 1550mm Depth, which includes 600mm door size width).

Toilet Cubicle I-Shape (Front Partition) with standard dimension of 2000-2100mm Height x 1000mm Width which includes 600mm door size width).

Extra (over ceramic wall tiling item as in DSR BoQ) for decorative designer bands / border tiles of any size printed / embossed/mosaic etc.

Providing and fixing approved make GRC stone wall cladding tiles for external façade. The tiles in approved design, size 205mm x 60mm, texture, thickness, pattern and colour, the thickness of the tiles should be range b/w 12 to 18mm (depending on texture of tiles), allowing variance +/- 2mm in accordance with IS:1237-1980. The composition of tile should be 43 grade white portland cement, reinforced with alkali resistant glass fibre and homogeneous pigmentation should be done with exterior grade synthetic inorganic iron oxide the other additive should be fine washed graded quatz, super plasticizers and integrated water proofing agent. The compressive strength of tile should be M40 grade at 28 days and water absorption of tiles less than 8% by 2 hrs immersion.

PERFORATED METAL PANEL CEILING Providing and installing suspended ceiling system at all levels with interlocking grid of size 1200x600mm / 600x600mm ceiling module of size (1250x600) consisting of demountable infill units (size 1200x600x1.2mm) having 50mm gap at every 1200mm, gap covered with 82mm wide channel having flanges to hold ceiling panels. The panels and channels shall be made from 1.2mm thick GI sheet, punched and bent to shape. The panels shall have perforated area 30-40%. The ceiling shall be powder coated (PPC, 80micron) on exposed and unexposed surface with approved colour. The grid system shall include hangers and runners of size 50x50x3mm thick hot dip galvanised steel, fixed on soffit of slab with the help of stainless steel expansion fasteners of size 10x75mm (Tam Anchor), The ceiling system to include panels, hanging system including the cost of providing opening and electrical fittings/fixtures, secondary supporting system for opening and below cable tray and duct, access to maintenance, all complete as per requirement of Engineer-in Charge.

CALCIUM SILICATE BOARD CEILING Providing and installing suspended ceiling systems / vertical fascia as per controlled sample for concourse, 12mm thick Calcium Silicate Board panels with paint as per specification including supply of suspension system of galvanised steel as per manufacturer's recommendation, top fixing of SS expanding anchor bolts, rigid hangers, accessories inclusive of providing opening for electrical fixtures / fittings, fixed framing to support fixtures / fittings and providing secondary supporting system for cable tray and duct and all complete as per relevant drawings and the direction of Engineer-in-charge.

OPEN CELL GRID CEILING To supply, deliver and install at all levels open cell ceiling made out of pre-coated galvanised mild steel 0.3mm thick (no aluminium accepted). The assembled cell ceiling panels shall be made out of main blades and secondary blades in 9mm(W) x 40mm(H) x 1200mm(L) and 600mm (L) cross connected to form 75mm square cells, details as per drawing. The assembled cell ceiling panels are then dipped into U-profile carriers in Galvanised MS, pre-coated in black enameled finished at 1200mm c/c as per specifications. C-profile wire clips shall hold the cell ceiling panels into the carriers. Once the carriers are installed then primary angles made out of galvanised MS as per drawing are corss connected to the U-profile carriers for lateral bracing at 1200 c/c. The whole ceiling shall be suspended by threaded rods installed at 1200mm c/c as per design. All panels modules must be hingeable through wire clips. All cell ceiling main blades and secondary blades are pre-coated with polyester stove enameled finish in 18 microns paint thikness in matt finish. Colours must be as per directions of the EIC. Rates shall be inclusive of cell panels, horizontal and vertical suspension, grid elements, perimeter trims, carriers, wire clips and all other accessories etc. complete inclusive of providing opening for electrical fixtures/fittings, fixed framing to supports fixtures/fittings and providing secondary supportng system for cable tray/duct, scaffolding wherever required and all complete as per specifications. No separate payment shall be made for any other item. Payment shall be made on the basis of unit plan area measured.

Providing and fixing door with shutter fabricated from18 gauge thick galvanised steel sheets press formed to provide a 46mm thick fully flushed double skin door with lock seam joints at stile edge and infill insulation kraft core. Door frames 57x120 mm approx. to be single rebated made of 16 gauge galvanised steel. Door shutter and frame to be primered in stoving grade epoxy zincphosphate primer and finished in aliphatic grade u.v. resistance polyurethane paint. Door shutter and frames to have all hardware preparations, prepunctured at the factory. all complete with and including filling of door frames with P.C.C. 1:5:10 (1 cement : 5 aggregate : 10 coarse sand).

Single leaf door shutter

Double leaf door shutter

Extra for 250 x 150 mm vision panel with 6mm thick clear toughened glass.

Extra for provision of air transfer grille appx. 400x400 mm

Heavy Duty Door Closer

Concealed SS finish tower bolts (300mm)

Magnum or equivalent make SS 4 Ball Bearing hinges

SS handles as per specifications for double leaf door

Installation Charges

Supplying, fabricating, MATTE FINISH, erection of required height (900 to 1100 mm) SS handrailing as per design comprising of 50mm OD Stainless steel Grade 304 , 3.15mm thick, 25mm dia jointing pin, SS Spider fittings, SS base plate, pipe adjuster M16X200mm SS fastners for fixing railing in floor/staircase by cutting hole of required dia covering with SS cover plate complete in all respect with 1 No. 12mm thick toughened glass and fixed with SS brackets and hinges and making good the flooring as per Specifications.

Supplying, fabricating, MATTE FINISH, errection of 900 to 1100mm high SS handrailing as per design comprising of 50mm dia, 3.15mm thick, Stainless steel Grade 304 with balustrades as per drawing, SS base plate, pipe adjuster M16X200mm SS fasteners for fixing railing in floor by cutting hole of required dia in floors/ landing/staircase complete in all respect and making good the floors as per Specifications.

Supplying, fabricating, matt finished, erection of wall mounted handrail as per design comprising of 50mm dia Stainless steel Grade 304 including threading on both sides to receive grub screw on one side and rail holding barrel on the other side, 25mm dia rod upright threaded to receive 50mm dia handrail, 80mm OD 6mm thick SS plate, 50mm OD-3.15mm thick pipe fixing the same by cutting 49mm dia hole in granite/vitrified tile wall cladding in required position including angular assembly at every bend and fixing handrail in concrete/block with SS fastners complete in all respect and making good the wall as per Specifications .

Providing and fixing M.S. tube of approved size by welding etc. for substructure for panels, screens etc. including applying a priming coat of approved steel primer fixed with dash fastener complete.

Fire check doors supply of approved make 2hrs fire rated door fabricated and successfully tested at CBRI Roorkee in both direction -satisfying two criteria (Stability and Integrity) confirming to BS:476 Part II, IS:3614 Part II as per schedule of requirement.

Clear Vision Panel of 200mm x 300mm

Heavy Duty Door Closer

Eurofile Mortice lock -240 with double pin cylinder having master arrangement and ss handles

Concealed SS finish tower bolts (300mm)

Magnum or equivalent make SS 4 Ball Bearing hinges

SS handles for double leaf door

Panic Bar for Double leaf door

Installation Charges

Providing and fixing 6mm clear toughened float glass in aluminium door, window, ventilator shutters and partitions etc. with PVC / neoprene gasket etc. complete as per the architectural drawings and the directions of engineer-in-charge. (Cost of aluminium snap beading shall be paid in basic item.)

Providing and fixing of toughened laminated glass door in EFO (6mm + 1.52mm + 6mm) including stainless steel door handles, deadlock and Floorspring complete necessary cutting in granite flooring for housing of floor spring as per specifications

Providing and installing fixed glazed security wall assembly of stainless steel to ticket offices, Station Control Room, shop fronts etc. with specified fixings and finish using 2 sheets of 6mm thick toughened glass with nominal gap silicone sealant joints. Glass shall be clear, toughened and laminated with 1.52mm thick polyvinyl butyral layer- all complete as per specification with cut out & holes.

Providing & fixing 8mm thick toughened glass on wall with stainless steel spider fitting and on glass back side Translucent film of approved shade the vinyl should be 2-mil thick with or without adhesive: 3 to 4 mils (0.08 to 0.1 mm), long-term cast vinyl films with a synthetic layflat liner that is not affected by water or humidity. The film should be plottercutted as per the approved design. Warranty to be given by vinyl company for 5 years.

Providing and fixing toilet mirror in 6 mm thick clear float glass with bevelled and polished at edge, fixed on wall with 6mm thick hard board backing fixed to wooden cleats with 8mm dia 38mm long stainless steel stud complete.

Designing, Providing, erecting and fixing structural glazing unitized using specially designed aluminium grade 63400 WP IS: 733 and ID: 1285 electro colour anodised 25 micron or pure polyester powder coated 65 microns in approved shade and colour through adequately designed MS galvanised / aluminium anchor brackets. The structural glazing design to be based on rain screen and pressure equalised drainage system. The complete drainage system to be incorporated in the design which drain water at every transom in the unlikely event that water penetrate the pressure seal. This include structural grade and weathering grade silicon sealant ''Dow Corning'' or ''GE Silicon'' or equivalent as per the design requirement. This includes structural designing, shop drawing complete. structural calculations and water penetration test as per (Structural Test ( Wind load serviceability) - ASTM E 330, Water Penetration Test - AAMA 501.2).The specified test is to be carried out only for location where executed qty will be more than 50sqm in one go.The structure glazing shall be double glazed 23mm thick (6mm thick toughened blue/smoke grey on outer side, 12 mm air gap and 5 mm thick clear float glass on inner side). no members to visible from outside complete as per specifications and direction of engineer in charge. including required aluminium sub-frame Silicon filling all height ie double height for straight / curve and scaffolding complete.

Proma seal acrylic intumescent sealant 2 hours fire rated in accordance with BS 476-Part 20, IS 1530 Part 4 to seal gap & joint in fire rated walls and floors and around service penetration for 25 mm gap and 12 mm depth.

Core cutting in RCC having depth up to 300mm deep.

50mm dia

100mm dia

DEAD LOCK WITH - CYLINDER of IS specification Supply and fixing of dead lock with cylinder for metal doors. Work includes removal of the existing damaged locks,disposal etc. complete at various stations and Muttom depot.

D handle set with SS plate of IS specification Supply and fixing of D-Handle set with SS plate for metal doors. Work includes removal of the exisiting damaged locks,disposal etc complete at various stations and Muttom Depot.

Motise lock set of IS specification Supply and fixing of Motise lock set for metal doors.The work includes removal of the damaged locks, disposal etc complete at various stations and Muttom Depot

Liver handle set of IS specification Supply and fixing of Liver handle set for metal doors.The work includes removal of the damaged handle, disposal etc complete at various stations and depot

Door closer (heavy Duty) Supply and fixing of Door closer (Heavy Duty) for metal doors.The work includes removal of the damaged door closer, disposal etc complete at various stations and depot .

Metal door hinges (heavy duty)Supply and fixing metal door hinges (One set).The work includes removal of the damaged hinges, disposal etc complete at various stations and depot .

Fire rated glass with beading Supply and fixing of 4 Hour fire rated German glass of 220*320mm size and 5mm thickness and beading etc complete at various stations and Muttom Depot

Labour Charge for rectifying the jammed metal door. Works includes breaking the lock, removing the hinges, grinding, welding etc complete at various stations and Muttom Depot

Hire of Manlifter having a woking boom length upto 20 meters with operator. the rate includes the operator expence, operator BATA, fuel, water charges maintenance of the machinery. NOTE: The work has to be carried out in both day and night times

Hire of Diesel Generator 7.5 KVA

Welding Set Electronic 200 A (Inverter)

Hire of wheel mounted excavator/back hoe/JCB or equivalent machine, the rate includes the operator expence, operator BATA, fuel, water charges maintenance of the machinery. NOTE: The work has to be carried out in both day and night times

Description of Work / Item(s)

SCHEDULE A - Any DSR 2018 item