Replacement of weak motors repair of spreader beam replacement of wire rope for gantry crane bottom side seal arrangement of stoplog gates repair renewal of stoney type roller frame surface coating with prime coal tar epoxy on stoplog gat

The repair and refurbishment of the twisted spreader beam shall be carried out as per the following specifications. The original layout drawing of the spreader beam shall be prepared for reference during the repair work. The existing lifting hook and shafts shall be dismantled and stored safely for reuse. The twisted main section of the spreader beam, made of ISMC 400 and measuring approximately 3300 mm, shall be marked and removed using gas-cutting equipment. A new ISMC 400 section of 3300 mm shall be cut, and the cutting edges shall be ground properly. The new channel shall be aligned and fitted to the existing frame as per the original measurements. The joint shall be welded, and a splicing plate shall be provided for additional strength, welded in accordance with standard procedures. The welding shall be done as per standard procedures and the burr and slag shall be removed by grinding the top of welds. A good weld is as strong as the base metal. A suitable electrode shall be chosen and welded with good welding equipment and a trained welder. All non - metallic substances shall be removed in the weld joints before commencement of welding. After welding, a thorough visual inspection shall be done for porosity, blowholes, unfused welds, unfilled craters, under cutting, burning & poor weld appearance, etc. Then all steel surfaces shall be cleaned of dirt, grease, oil, welding spatter, etc. After welding, the straightness of the beam shall be ensured, and if any deviation is found, necessary corrections shall be carried out. The steel surfaces shall be blast-cleaned as per SA 2.5 standards. A coat of epoxy primer (50 microns) shall be applied. Over the primer coat, a finish coat of coal tar epoxy shall be applied in two layers, each of 125 microns. Then the existing lifting hook and new guide rollers shall be fitted in the spreader beam. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like chainpulley block, welding machine, cutting set, grinding machine, power charges for generator, conveyance to site and clearing them after completion of work, etc., complete complying with standard specifications and as directed by the departmental officers

Renewal & refixing of wirerope of the following specification. The existing broken wirerope is unwound from the rope drum and removed from the rope locking plate & stacked as directed by the departmental officers. A new rope as per IS 2266 is provided in place of the old damaged rope. The rope is 6 strand with steel core bright or ungalvanised C flattened strand winding rope 6 x 36 with nominal diameter 24mm and wire strength 1770 N/mm2. The sheave groove is ensured that is is supporting the rope for 33% of its circumference as greater contact area between the rope & the pulley reduces abrasion & enhances service life. The spooling/anchorage of rope on drum should be proper as improper spooling induces torque in rope, reducing the rope life. The end of rope is fixed to the locking plate provided in the drum. The cost includes cost of rope, Labour charges, transport, erection, etc, complete complying with standard specifications and as directed by the departmental officers

Repair and modification of the stoplog gate lifting plate holes as per the following specifications. The shutter lifting center point and hole locations do not match the spreader beam lifting pin, preventing the shutter from being detached from the spreader beam underwater. To resolve this, the spreader beam lifting hook center and the shutter lifting hole center shall be verified and modified to align with the required tolerance. Additionally, the groove measurement is larger than the shutter end vertical measurement, exceeding the required tolerance. A new guide bush shall be provided in the end vertical beam side and rear portion to put off this issue. This guide bush will help control misalignment in the shutter movement within the groove portion. Once modifications are complete, the shutter shall be hooked to the spreader beam, and multiple trial operations shall be conducted to ensure smooth functioning between the shutter and the spreader beam. The cost includes cost of inspection, all materials, cost of consumables like welding rods, grinding wheels, oxygen & acetylene gas, diesel & oil for generator, lubricants, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, hire charges for equipments like chainpulley block, welding machine, cutting set, grinding machine, power charges for generator, conveyance to site and clearing them after completion of work, etc.,complete complying with standard specifications and as directed by the departmental officers

Repair & Replacement of weak motors and renewal of existing starters as per the following specifications. The existing worn-out motor shall be removed from its position, and the pinion wheel shall be detached from the motor shaft. The new motor base shall be matched to the existing hoist base frame and modified as required. The bore of the pinion gear wheel shall also be modified to fit the new motor’s output shaft. The new motor, rated at 400V, 3-phase, 10 HP, and 960 RPM, shall then be properly seated in the motor mount. The pin bush coupling shall be attached to the new motor's output shaft. The existing hand operation mechanism shall be integrated into the system, and the existing electrical connections and wiring shall be properly connected to the starter. The existing relay shall be replaced with new one in suitable to 10HP motor. The cost includes cost of materials, labour charges, transport, erection , testing, commissioning etc., complete complying with standard specifications and as directed by the departmental officers

Repair & Renewal of stoney type cast iron rollers of size 145mm dia and 200 mm in length behind the shutter as per the following specification. The stoney type roller connected with a rope to the shutter shall be delinked. Now, the roller frame shall be retrieved from its position. The roller frame shall be of size 245mm x185mm x 3050mm. The outer member shall be made of solid MS plate of thickness 20mm and size 185x3050mm. Diapharam plates shall be connected by 12mm plate of size 200x130mm neatly placed equidistant from each other at 525mm equal intervals. 16 rollers are placed in between these partitions and roll on a pin as the pivot. One roller for tying the connecting rope is provided at the top end. The old corroded pins shall be replaced with EN8 steel and the old ones shall be stacked in the stores as directed by the departmental officers. All components of the roller frames shall be neatly cleaned with rust remover compounds and reassembled. Also, the old corroded ½” chain connecting the shutter & the roller frame shall be replaced with a new chain of same size. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like chainpulley block, welding machine, cutting set, grinding machine, power charges for generator, conveyance to site and clearing them after completion of work, including cost of trial operation, etc., complete complying with standard specifications and as directed by the departmental officers

Repairs and Replacement of bottom rubber seal of the shutter as per the following specification. The old rubber seal shall be removed from the skin plate after removal of the rusted bolts & nuts by gascutting equipments. The seal seat cover shall be removed along with the rubber seal. The skin plate & seal seat cover surface shall be neatly cleaned on either side by grinding. Now, the existing seal seat cover made of 100x10mm MS flat & the new rubber seal shall be now matched with the existing holes in the skin plate and then holes shall be drilled in the seal seat cover to align with that in the skin plate, if necessary. 18mm holes shall be punched accordingly in the rubber seal of size 100x12mm. The inside surface of the seal seat cover is given a coat of anticorrosive zinc rich primer over which two coats of coal tar epoxy shall be applied at an interval of 24 hours between each coat. Now the rubber seal shall be placed on the skin plate over which the seal seat cover shall be placed and fastened with SS bolts & nuts of size M16x75. The cost includes cost all of materials, labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site, etc., complete complying with standard specifications and as directed by the departmental officers

Replacement of Musical note rubber seal at side & top of the shutters as per the following specification. The old seal cover plate shall be dismantled from the skin plate after removal of the rusted bolts & nuts by gascutting. The skin plate surface shall be neatly cleaned by grinding. Now, the existing seal seat cover made of 65x10mm MS flat shall be cleaned & painted. The rubber seal shall be now matched with the existing holes in the skin plate and then holes should be punched accordingly to align with that in the skin plate. The rubber seal of size 100mmx44mmx14mmØ shall be placed on the skin plate over which the seal seat cover shall be placed and fastened with CSK SS bolts/hex bolt. The cost includes cost of materials, labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site etc., complete complying with standard specifications and as directed by the departmental officers

Providing abrasive blast cleaning using air blast cleaning with abrasive aluminium oxide/steel grits/sand as per the following specification. Moisture should not be present on the steel surface during blast cleaning. All, oil, paraffin, grease & dirt shall be removed from the surfaces to be painted primarily before blast cleaning. Then all weld spatter, slag, burrs, loose rust and mill scale and other foreign substances shall be removed by sandblasting. The average surface roughness after sand blasting shall not exceed 35 to 50 μ. Blast cleaning shall confirm to Swedish standard SA 2 1/2 (near white metal). Blast cleaned surfaces showing plate surface defects such as scabs or sharp gouges shall be repaired in an approved manner prior to painting. After blast cleaning, the surface shall be dusted off or blown off with compressed air free of detrimental oil and water. All surfaces to be painted shall be completely dry, clean and free from moisture just prior to and during painting. If rust forms or the surface becomes contaminated in the interval between cleaning and painting, recleaning to the same degree shall be required. All safety precautions like wearing helmets, respirators & grounding of blast hose to dissipate static charges should be adopted as directed by the departmental officers. The cost includes cost all materials, labour charges, hire charges for generator , compressor, hopper, accessories, conveyance of machinery to & fro from site of work, scaffolding charges, consumables like oil & diesel for generator, risk allowance,etc, complete complying with standard specifications and as directed by the departmental officers

Application of a high performance primary coating to protect the steel structure from highly abrasive, erosive and corrosive environments. This being a industrial coating, enhances the life of the structure and reduces the strain of continuous maintenance. After surface preparation of the structure, a primer coat with epoxy primer shall be applied. The dry film thickness should be 40-60μ for primer coat. The colour is grey and minimum pot time should be 4 to 8 hours. The mixing ratio of base to accelerator by volume should be according to the manufacturers standard. All paint, when applied, shall provide a satisfactory film and a smooth and even surface. Paint shall be thoroughly stirred, strained, and kept at the uniform consistency during application. Paint shall not be applied when the temperature of the metal or surrounding air is below 10 degree Celsius and that of the metal is above 50 degrees Celsius, or when the humidity is above 90 percent, or when it threatens to rain before the painted coat gets dry. Primer coat shall be protected during the initial curing period against the possibility of moisture condensation or contamination with foreign matter. All painting works shall be performed by airless spraying. When the coating material is applied by spraying, suitable means shall be provided to prevent segregation during the coating operation. Free oil and moisture shall be removed from the air supply lines of all spraying equipment. Primer coat shall be uniform and free from runs, slag and other imperfections. The time between successive coats shall be not less than the minimum nor more than the maximum re-coating time specified by the paint manufacturer. The paint shall be applied so that the thickness at any point is not less than that stipulated in the approved painting specifications. Surface not required to be coated, but adjacent to surfaces which are to be cleaned and coated, shall be adequately protected during cleaning and coating. Repairs to damaged areas of the coating shall be carried out strictly in accordance with the approved painting specifications. Because of the flammable and toxic nature of the coating materials, precautions should be taken to eliminate any health or safety hazard that may arise during the application of the coating. Smoking and welding shall not be allowed within 10 meters of the place when painting is in progress. The painting to the gates, hoists and other parts shall be done as per IS specification No.14177-1994. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) -1971. The cost includes cost of primer & thinner, labour charges for application of primer, hire charges for compressor, generator & airless spray gun with its accessories, cost of oil, diesel & lubricant for generator, scaffolding charges, conveyance of machinery & tools to and fro from site of work, risk allowance, etc, complete complying with standard specifications and as directed by the departmental officers

Application of coaltar epoxy over the primer shall be through airless spray method. The colour shall be black and the mixing ratio of base to accelerator should be by manufacturer standards. The dry film thickness should be between 125-150 μ per coat. The interval before over coating shall be 24 hours. All paint, when applied, shall provide a satisfactory film and a smooth and even surface. Paint shall be thoroughly stirred, strained, and kept at the uniform consistency during application. Paint shall not be applied when the temperature of the metal or surrounding air is below 10 degree Celsius and that of the metal is above 50 degrees Celsius, or when the humidity is above 90 percent, or when it threatens to rain before the painted coat gets dry. Each coat shall be protected during the initial curing period against the possibility of moisture condensation or contamination with foreign matter. All painting works shall be performed by airless spraying. When the coating material is applied by spraying, suitable means shall be provided to prevent segregation during the coating operation. Free oil and moisture shall be removed from the air supply lines of all spraying equipment. Each coat shall be uniform and free from runs, sags and other imperfections. The time between successive coats shall be not less than the minimum nor more than the maximum re-coating time specified by the paint manufacturer. The paint shall be applied so that the thickness at any point is not less than that stipulated in the approved painting specifications. Surface not required to be coated, but adjacent to surfaces which are to be cleaned and coated, shall be adequately protected during cleaning and coating. Repairs to damaged areas of the coating shall be carried out strictly in accordance with the approved painting specifications. Because of the flammable and toxic nature of the coating materials, precautions should be taken to eliminate any health or safety hazard that may arise during the application of the coating. Smoking and welding shall not be allowed within 10 meters of the place when painting is in progress. The painting to the gates, hoists and other parts shall be done as per IS specification No.14177- 1994. The colour of the paint coat when applied is generally black but turns into brown over a period time. However, the properties of the paint remain intact assuring the performance. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) – 1971. The cost includes cost of coaltar epoxy paint, thinner, etc, labour charges for its application, hire charges for compressor, generator, airless spray machine with its accessories , cost of oil, diesel & lubricant for generator, scaffolding charges, conveyance of machinery & tools to and fro from site of work, risk allowance, etc, complete complying with standard specifications and as directed by the departmental officers