Refurbishment of 0.3 MGD Sewage Treatment Plant (Unit-1) at Kalpakkam Township

Amount

All kinds of soil upto 1.5 mtr depth

Providing and laying Cement Concrete 1:5:10 using 40mm and downgraded size hard granite broken stone in foundations, trenches etc., including necessary form work, ramming, compaction, levelling, mechanical mixing, curing, dewatering, if any and including dismantling the existing concrete, disposing the dismantled debris within 2 Km lead etc., all complete as per specifications and as directed by Engineer-in-charge.

Providing, erecting, placing in position and removing Formwork for all insitu concrete works at all lifts and all shapes such as circular works, chamfers, splays, etc., using Steel/Plywood shuttering including centering, scaffolding, strutting, propping with necessary bracing in all areas, fixing of EPs, cutting holes and fixing pipe sleeves, applying of approved from oil over surface in contact with concrete,de-shuttering after specified curing period, etc., all complete as per drawings and specifications. (Note: Measurement for the formwork shall be the area of forms in contact with concrete surfaces. Stop boards for construction joints will not be measured seperately for payment).

Providing, cutting, bending, placing and binding steel reinforcement using TMT bars of Fe-500 / Fe-500D grade in all reinforced cement concrete works including preparation of bar bending schedules, cutting, bending, fixing, tieing in position with 1.6 mm dia soft drawn annealed binding wire, cost of cover blocks in C.M 1:2, etc., complete as per specifications and drawings. Important Note: The required quantity of steel reinforcement as mentioned in the schedule should be procured by the contractor only of SAIL, Rashtriya Ispat Nigam Limited (VIZAG), TATA Steel & JINDAL from authorised dealers which shall conform to IS: 1786 (Latest Edition).

Providing and casting insitu Reinforced Cement Concrete 1:1.5:3 using machine crushed hard broken granite stone of nominal size 20mm including mechanical mixing, transporting, placing at all lifts, vibrating, consolidation, curing, finishing smooth all exposed faces, for all insitu concrete items, etc. as per drawings and specifications. (Note: The rate quoted shall be exclusive of reinforcement and formwork which will be paid for separately under relevant items)

Providing and laying Indian Patent Stone Flooring with cement concrete 1:2:4; 20mm thick using 10mm and below size hard broken stones by mixing with integral water proofing admixtures in recommended proportion of make Sika (Plastocrete-Plus) or FOSROC (Conplast-WL) or Ultratech (Cretepro) including cleaning the surface, applying cement slurry with water proofing admixture as above over the existing surface, finishing with IPS flooring, etc., all complete as per specification and as directed by the Engineer-in-charge. (Note: The leak test shall be conducted by stagnating water over the surface before and after the Indian Paten Stone flooring)

Providing and laying brick masonry in Cement Mortar 1:6 with well burnt chamber bricks/FALG Bricks of approved quality in all shapes and sizes including scaffolding, curing, raking out joints, etc., all complete as per specifications and as directed by Engineer -in - charge.

Plastering with Cement Morter 1:5; 12mm thick for brickwork/ Concrete on its Internal faces/External faces at all lifts including scaffolding, curing and forming grooves wherever necessary all complete as per specifications and as directed.

Chipping of unsound/weak reinforced cement concrete material from slabs, beams, walls, columns etc. with manual Chisel and/ or by standard power driven percussion type of approved make at all lifts including tapering of all edges, making square shoulders of cavities, cleaning the exposed concrete surface and reinforcement with wire brushes, disposal of debris within 2Km lead, etc., all complete as directed by Engineer-In-Charge.

25mm average thickness

Providing anti corrosive treatment to steel reinforcement by removing the rust from corroded reinforcement and applying anti-corrosive chemicals as details below including cleaning of reinforcement from rust to give it a total rust free steel surface by using alkaline chemical rust remover with paint brush, removing loose particles after 24 hours of its application with wire brush, thoroughly washing with water and allowing it to dry, applying anticorrosive coating, etc., all complete as per manufacturer specification and as directed by Engineer-In-Charge. a) Rust removal: - Removing the loose rusted particle thoroughly from the corroded reinforcement by light tapping, wire brushing and using emery paper. Applying rust converter of make Dominator plus or Bostik (Bostokleen) or FAB Chemical (Mixcoat RP). b) Anticorrosive coating: - Application of anticorrosive coating (corrosion inhibitor) of make MC Bauchemie (Zentrifix KMH) or FAB Chemical (Mixcoat ZR) or Bostik (Bostik ZRP) or Ultratech (Bindcrete). Mixing ratio of chemicals, consumption and application shall be as per manufacturer specifications.

Bars upto 12 mm diameter

Providing and fixing of 10mm dia shear connectors/ steel reinforcement in reinforced or plain cement concrete by drilling 12mm dia holes at 1mtr c/c or as specified with power driven drill machine to a minimum depth of 75mm and upto 200mm in RCC beams, lintels, columns and slabs to introduce steel bars/ shear connectors including drilling holes, fixing the steel bars in position using epoxy resin anchor grout of approved make, etc., all complete as directed by Engineer-In-Charge. (Note : The cost of steel reinforcement will be paid for seperately under relevant item)

Repairs to damaged RCC structural members at all locations and all lifts using SBR Polymer modified plain/ reinforced cement concrete for structural members having minimum characteristic compressive strength [with ordinary portland cement, coarse sand and graded stone aggregate of 10mm maximum size in proportion as per design criteria] with specified average thickness including preparing the dismantled concrete surface by hacking the surface for better adhesion, treating the exposed steel reinforcement using approved chemicals, providing additional reinforcement, if any required, applying bond coat, filling/plastering with polymer modified concrete repair mortar in layers using approved polymers, curing, cleaning of floor/windows thoroughly on completion of repair work etc., all complete as detailed below as per manufacturer specifications and as directed by the Engineer-in-Charge. (Note : Cost of additional reinforcement, shear keys, form work and anticorrosive treatment will be paid for separately under relevant item) a) Bond Coat: Applying SBR based bond coat of make MC Bauchemie (Naufufill-SBR) or FOSROC (Nitobond SBR) or FAB Chemical (Mixbond SBR) or Bostik (Boscocem 475) or Ultratech (Xtracrete). Mixing ratio of chemicals, consumption and application shall be as per manufacturer specifications. b) Application of repair concrete: Building up with polymer modified cement concrete repair concrete of ratio 1:1.5:3 (1 part of cement : 2.5 parts of sand : 3 parts of 6mm stone aggregates) and adding admixtures in recommended proportion of make MC Bauchemie (Naufufill-SBR) or FOSROC (Nitobond SBR) or FAB Chemical (Mixbond SBR) or Bostik (Boscocem 475) or Ultratech (Xtracrete). Mixing ratio of chemicals, consumption and application shall be as per manufacturer specifications (minimum 2% by wt. of cement shall be used). The mortar shall be applied in layers not exceeding 20 mm in a day.

20mm average thickness

Repairs to internal/ external plastering over brick work/ concrete at all locations and all lifts using Polymer modified cement repair mortar including preparing the surface by hacking the surface for better adhesion, providing glass fibre mesh or chicken reinforcement, if any required, applying bond coat, filling/plastering with polymer modified repair mortar in layers using approved polymers, curing, cleaning of floor/windows thoroughly on completion of repair work etc., all complete as detailed below as per manufacturer specifications and as directed by the Engineer-In-Charge. a) Surface Preparation: Preparing the wall surface by chipping of unsound/ weak /loose plaster surface mortar with manual Chisel and/ or by mechanical means at all lifts including cutting/trimming of edges to provide firm vertical faces, making square shoulders of cavities, cleaning the exposed surface to make surface dust free, disposal of debris within 2 Km lead. b) Bond Coat: Applying SBR based bond coat of make MC Bauchemie (Naufufill-SBR) or FOSROC (Nitobond SBR) or FAB Chemical (Mixbond SBR) or Bostik (Boscocem 475) or Ultratech (Xtracrete). Mixing ratio of SBR chemical shall be 2:1 (2 Cement : 1 SBR) application procedure shall be as per manufacturer specifications. c) Application of repair mortar: Building up with polymer modified cement concrete repair concrete of ratio 1:1.5:3 (1 part of cement: 2.5 parts of sand: 3 parts of 6mm stone aggregates) and adding admixtures in recommended proportion of make MC Bauchemie (Naufufill-SBR) or FOSROC (Nitobond SBR) or FAB Chemical (Mixbond SBR) or Bostik (Boscocem 475) or Ultratech (Xtracrete). Mixing ratio of chemicals, consumption and application shall be as per manufacturer specifications (minimum 2% by wt. of cement shall be used).

6mm average thickness

20mm average thickness - 2 layers -plain plaster

Providing and laying Polymer modified self compacting micro concrete jacket for the structural members e.g. columns, pillars, piers, beams etc at all locations and all lifts using self compacting micro concrete of make Ultratech (Microcrete) or FAB Chemicals (Mixbuild MC) or BASF (MasterEmacoS346) having minimum characteristic compressive strength including preparing the dismantled concrete surface by hacking the surface for better adhesion, treating the exposed steel reinforcement using approved chemicals, providing additional reinforcement, if any required, applying bond coat, providing form work, preparation of micro concrete, adding coarse aggregate if required, filling with self compacting micro concrete in layers, curing, etc., all complete as detailed below as per manufacturer specifications and as directed by the Engineer-in-Charge. Note : 1) Cost of additional reinforcement, shear keys, form work and anticorrosive treatment will be paid for separately under relevant item. 2) Payment will be made for actual consumption of dry micro concrete.

Providing Painting over all exposed surfaces at all heights over rough cast plaster / plain plaster with Two Coat of premium exterior emulsion paint of make Asian (APEX - Dust proof exterior emulsion) / Berger (Anti dust weather coat) or other approved equivalent make of approved shade over a coat of exterior wall primer of make Asian / Berger or other approved equivalent make including preparation of surfaces by scrubbing / cleaning the fungus / stains, cleaning with water, filling the cracks with approved crack filler and including cost of all materials, labour, tools and plants, curing, scaffolding at all lifts, etc., all complete as per specifications and as directed by Engineer-In-Charge

Painting over Plain Plaster at all lifts.

Painting all internal faces of walls / plastered surfaces with One coat of Interior Emulsion paint of make Asian (Tractor) / Berger (Bison) or other approved equivalent make of approved shade over a coat of primer of make Asian (Professional) / Berger (BP Primer) or other approved equivalent make including preparation of surfaces by scrapping the existing white wash / colour wash using scrapping / sanding machine with dust free vacuum collection system, cleaning the existing white wash/colour wash area, roughening the surface, washing the area thoroughly with lime and soda mix or other approved chemical using high pressure washer, preparing the surface dust free for applying the primer coat, applying approved make wall care putty to make surface smooth without porous by using putty knife and sand papers, the dust accumulated during scraping shall be collected in appropriate dust bin collector/ equipment and disposed with in 2Kms lead, etc., all complete as per specification and as directed by Engineer-in-charge. (Note: The sample shall be got approved by the EIC before making bulk order)

Providing a system for dewatering and drainage of Sewage water/Effulent water/water from chamber/liftwell to main drain/other places so as to retain the surface dry for the duration required for repair works including all equipments, consumables, site protection, etc., all complete as per specifications and as directed by Engineer -in - charge.

Collection and conveying of suspended solids from aerator tank and clarifier tank of Sewage treatment plant (UNIT-1) having capacity 0.3MGD after the dewatering process, which includes picking, loading, conveying, unloading and levelling at the places as shown at site within 1km lead etc., all complete as directed by Engineer. Note: 1) The rate in respect of this item are applicable for the corresponding stack / truck measurements. 2) The earth shall be dumped well inside the dumping yard and not over approach pathway road. 3) Cost of Dewatering will be paid separately under relevant item.

Dismantling of existing surface aerator setups (except civil structures) in Unit 1 of the Sewage Treatment Plant, having a capacity of 0.3 MGD, includes dismantling the steel structure (including steel beams) from the civil structure, dismantling of gear box and motors, dismantling the joints within the steel structures, segregating the material, cutting the steel structures into pieces of each size less than 3 mtrs and also not more than 50 kg of weight, transporting the material to the scarp yard (which is inside IGCAR), stacking the material at the specified location, etc., all complete as per specifications and as directed by the engineer-in-charge.

Supply, installation, testing, and commissioning of an electrically driven surface aerator (complete setup) with a suitable gearbox of reduction ratio 30/1 for an aeration tank having diameters of 8 m to 9 m. The mixing provided shall be sufficient to ensure that the MLSS concentration shall not vary more than +/- 10% of the average value from top to bottom at any point in the basin. The oxygen transfer efficiency of aerator shall be 1.88kg/BKw/Hour when aerating clean tap water. The aerator impeller blade shall include a rotating conical, vaned impeller, pipe shaft, and flanged adaptor. The impeller shall be an inverted cone with equally spaced blades extending to the periphery. The entire surface aerator setup (gear box, motor, common base plate, aerator blade, etc.) should be mounted in the middle of diametrically running two I beams of size 450mm x 150mm x 9.4mm (as per IS 808). The two I beams should be suitably placed apart to provide the minimum walkway of 1000 mm to approach the surface aerator setup. The walkway platform should be made up of chequered plate with a minimum thickness of 5 mm. A suitable handrail should be provided on the sides of the walkway as per OSHA standards. A motor used for running the gear box should be TEFC, foot mount, IP 55, 3-phase, 415V, with a minimum of 7.5 HP, 1450 rpm, and an IE3 energy efficiency level. The gear box should be made by an ISO 9001-certified company, foot mount, worm & worm wheel type gear box. The motor and gear box shall be coupled by a tyre coupling. A common base plate should be made up of a 20-mm-thick MS plate and shall be mounted in such a way that it is adjusted in a vertical direction to adjust the immersion depth of the aerator blade. The gear box and motor shall be covered with a guard made of 1.6-mm-thick MS sheet with proper provision for air circulation. Note: For detailed specifications, refer to the technical specification attached to the tender document.

Supply, installation, testing, and commissioning of a centrally driven secondary clarifier mechanism suitable for a 10 m dia (inner) circular cross-section RCC tank having 3 to 3.5 m depth. The fixed bridge having span one half of the above tank shall be supported at one end on the outer wall of the clarifier and another end to be the central RCC column. The walkway of the bridge shall be at least 1000 mm wide and shall be made up of a chequered plate of 5 mm thickness. The center assembly will be bolted to the top of the RCC centre column with anchor bolts and levelled and grouted. The turn table at the top of the RCC Centre column shall have precision large bearing assemblies (rolling contact bearings). The rake arms shall be driven by a set of gear mechanisms running in the center of the tank and driven at a constant speed. A suitable-size feed well shall be provided, made up of 3mm FRP material. A motor used for running the gear box should be TEFC, foot/flange mount, IP 55, 3-phase, 415V, with a minimum of 2 HP, 1450 rpm, and an IE3 energy efficiency level. The gear box should be made by an ISO 9001-certified company. The motor and gear box shall be coupled by a suitable chain drive. Note: For detailed specifications, refer to the technical specification attached to the tender document.

Supply, installation, testing & commissioning of Solid handling Non-clog Pump (bare shaft pump). Erecting the pumps in position, proper aligning, providing and fixing suitable standard size and number of MS bolts, nuts and washers, 3mm thick ply rubber insertion, testing the joints to 10kg/sq.cm. hydrostatic pressure and making good all defects and leakages in inclusive of cost of all jointing materials, labour etc., all complete and as directed by Engineer-In-Charge. Pump Specification: Liquid Handled: - Activated Sludge in Waste Water Treatment Plant. Temperature of Liquid: - Ambient Temperature. Specific Gravity of Liquid: - 1.1. Capable of Solid to be Handled: - solid size of minimum 25mm. Pump Capacity: - 60m3/Hour at 11m Head in 1450RPM (Revolution Per minute). Pump Suction and Delivery Size: - 65mm (2 1/2”) × 50mm (2”). Number of stages: - Single stage. Direction of Rotation: - Clockwise viewed from drive end. Type of Pump: - Back Pullout Type. Type of casing: - End suction top centerline delivery. Type of shaft: - Stuffing box area is protected by a shaft sleeve. Type of Impeller: - Symmetrical and Dynamically Balanced Three vanes semi open impeller Type of Stuffing Box: - Gland packing with grease sealing (without cooling). Type of Bearing: - Deep Groove Ball bearings at DE/NDE adequately protected from moisture and dust. Type of lubrication: - Grease Lubrication. Type of Flange: - Flanges are to be drilled as per IS 1538 Standard. Material of Construction: Casing and casing cover - Cast Iron, Bearing Bracket - Cast Iron, Shaft - Stainless Steel, Impeller - Stainless Steel, Shaft Sleeve and Locknut - Stainless Steel, Lantern ring: Stainless Steel, Gland (Split type) - Cast iron

Providing and fixing in position of following specification Non-Return Valve in the branches of pump delivery and pipe header, erecting the valves in position, proper aligning, providing and fixing suitable standard size and number of MS bolts, nuts and washers, 3mm thick ply rubber insertion, testing the joints to 10kgs/sq.cm. hydrostatic pressure and making good all defects and leakages in inclusive of cost of all jointing materials, labour etc., all complete and as directed by Engineer-In-Charge. Non-Return valve as per IS 5312 of following specifications: Suitable for handling Clear cold water of Nominal Pressure: - 1.6 MPa, Size of the valve: - 80mm (3”). Operating position of the valve: Horizontal. Flanges are drilled to be in the standard of IS 1538, Flange to flange dimension: - 241mm, without any bypass arrangement valve. Metal to Metal contact of seat rings when preventing back flow. Material of Construction: - Body, cover door, bearing holder – Grey Cast Iron (FG 200), Hinge pin, door pin and door suspension pin: - Stainless steel (12Cr12), Body seat rings: - Leaded tin bronze (LTB2), Door face ring: - Leaded tin bronze (LTB2), Bearing bushes/bearing block: - Leaded tin bronze (LTB2), Bolts & Nuts: - Carbon Steel, Hinges: -Grey cast iron.

Providing and fixing in position of following specification Knife Gate valve. erecting the valves in position, proper aligning, providing and fixing suitable standard size and number of MS bolts, nuts and washers, 3mm thick ply rubber insertion if required, testing the joints to 10kg/sq.cm. hydrostatic pressure and making good all defects and leakages in inclusive of cost of all jointing materials, labour etc., all complete and as directed by Engineer-In-Charge. Valve specification: Mode of operation: Hand Wheel, Pressure rating: PN 10, Valve Type: Rising Spindle type (Bonnetless), Unidirectional, End connection: Lugged end to suit between flanges drilled to IS 1538 Table 4 and 6, Fluid Handled: Sewage Water, Min. & Max. Temperature (°C): 10 - 65 Degree Celcius. Material of construction: Body, Gland: Ductile iron, Gate, Stem: Stainless steel (SS304), Yoke: Carbon steel, Gland packing: PTFE Impregnated, Seat: EPDM, Secondary seal: EPDM & PTFE, Fasteners: High tensile steel, Hand wheel - SG Iron.

80mm Dia. Valve

100mm Dia. Valve

Supplying, laying and fixing in position the following sizes of ductile iron pipes in standard length of K-7 class conforming to IS: 8329/2000, suitable for rubber gasket (SPR) push on joints, pipes shall be bearing with ISI marks and cement mortar lining inside barrel conforming to ISO:4179 including lowering them into the excavated trenches and laying, fixing in position to proper grade and alignment all as per IS: 12288 and standard specifications including cutting the pipes to the required length, cost of labour, pipes and other materials, tools and plants for laying and installing the pipe lines and testing the lines to the required hydrostatic pressure of 10kgs./sq.cm. at the specified intervals but excluding cost of Ductile iron specails/fittings and joints which will be paid under relevant items. (The effective length of the DI fittings/specials, valves, double flanged pipes, etc., will be deducted from the overall measurement of the pipe line for making payment against this item).

100 mm nominal bore DI pipe

Providing and fixing rubber gasket (SPR-Synthetic propylene rubber) push on joints to the following size of DI pipes including insertion of rubber gasket into the centering rings of the socket of the pipes and pushing the spigot end into socket and making the joint intact to withstand the joint hydrostatic pressure of 10 Kgs./sq.cm. including cost of all materials, rubber gasket, tools and plants, etc., complete conforming to IS:5382/1985 and IS:12288/1987.

100mm nominal bore DI pipe

Supplying, laying and fixing in position the following sizes of Double Flanged ductile iron pipes in standard length of K-9 class conforming to IS: 8329/2000 and PN10 rating flanges, making flanged joints with MS bolts, nuts and washers and inserting 3mm thick ply rubber gasket, pipes, shall be bearing with ISI marks and cement morter lining inside barrel conforming to ISO: 4179 including lowering them into the excavated trenches and laying, fixing in position to proper grade and alignment all as per IS standard specifications including cutting the pipes to the required length, welding the flanges wherever required as per site condition, cost of labour, pipes and other materials, tools and plants for laying and installing the pipe lines and testing the lines to the required hydrostatic pressure of 10kgs./sq.cm at the specified intervals but excluding the cost of Ductile iron specials/fittings and joints which will be paid under relevant items. (Note: The effective length of DI fittings/specials, valves, etc., will be deducted from the overall measurement of the pipe line for making payment against this item).

80mm dia.K9 DI pipes (Upto 1mtrs length)

100mm dia.K9 DI pipes (Upto 1mtrs length)

100mm dia.K9 DI pipes (Beyond 1mtr. and upto 2mtr. Length)

100mm dia.K9 DI pipes (Beyond 2mtr. and upto 3mtr. Length)

Supplying and fixing tested heavy quality DI specials/fittings K-12 class socket, spigot and flanged specials such as bends, collars, tapers, tees, duckfoot bend, flanged socket and flanged spigot tail pieces, blank flanges, etc. and conforming to IS:9523/2000 and IS:8329/2000 drilling holes to the flanged fittings shall be PN classification and socket specials / fittings shall be suitable for rubber gasket (SPR) push on joints, etc., complete all as per standard specification and as directed by the Engineer-in-charge. ( Note : joints will be paid for separately under relevant items). Upto 300 mm dia.

Making flanged joints of the following DI pipes, specials and valves, providing and fixing suitable standard size and numbers of MS bolts, nuts and washers, 3mm thick ply rubber insertion and testing the joints to 10 kgs./sq.cm hydrostatic pressure and making good all defects and leakages inclusive of cost of all jointing materials, bolts and nuts, labour etc. all as per standard specifications and as per IS: 8329/2000 and IS: 9523/2000.

80mm dia. NB DI pipes/Specials/Valves

100mm dia. NB DI pipes/Specials/Valves

Dismantling Reinforced cement concrete at all lifts including clearing and depositing the same with a distance of 2Km as directed by Engineer-in-charge.

Dismantling Brick work in cement mortar at all lifts including clearing and depositing the same with a distance of 2Km all as directed by Engineer-in-charge.

Disposal of surplus excavated earth / Debris by collecting, loading, transporting by mechanical means and unloading them at places as shown by the Department within a lead specified below and levelling, etc., all complete as per specifications and as directed by the Engineer-in-Charge. Note: 1) The rates in respect of this item are applicable for the NET Quantities arrived at after making deductions for voids @ 20% in respect of soil and @ 50% in respect of rock from the corresponding stack / truck measurements. 2) The earth shall be dumped well inside the dumping yard and not over approach pathway road.

Exceeding 1 Km but not exceeding 2 Kms

VA EXERGY TECHNOLOGIES INDIA PVT LTD (BID ID -3125037)

Water Systems India Pvt ltd (BID ID -3133108)

Bidder Name

PURE GREEN ENGINEERING PVT LTD

Water Systems India Pvt ltd

VA EXERGY TECHNOLOGIES INDIA PVT LTD