Strengthening and retrofitting of RCC support structure of Head-end of NP-1 Gantry on west side of Suphala Silo at Rashtriya Chemicals and Fertilizers Limited, Trombay factory at Chembur, Mumbai 400074

Jacketting the existing column of size as per drawing prepared at site by contractor by removing the concrete cover to reinforcement, by chipping or other suitable means to expose the reinforcement of existing column in order to make available the same for binding the extra reinforcement as shown in the drawing and also removing corrosion of steel reinforcement by mechanical means like wire brushing, chipping to remove loose rust and then applying rust removal solution by using brush application, leaving the surface for at least 15 to 30 minutes, then removing loose materials by scrubbing or with brush. After detachment of loose scales reddish rusted surface is still left exposed, this has to be retreated or as per approved manufacturers specifications. Application of Corrosion Inhibitor: Providing & applying One coat of Concrete Penetrating Corrosion Inhibitor (Surface applied) which works on Bipolar Inhibition Mechanism on entire concrete surface to be repaired by using brush or spray at 250 ml per Sq.Mt./Coat or as per manufacturer’s specification and prior to application of first coat of anti corrosive coating to reinforcement and exposed concrete. Also provide and apply approved make of epoxy resin to get proper bond with newly laid M30 grade SELF COMPACTING CONCRETE (SCC) concrete. The aforesaid concrete shall be laid by the sides of the existing column with thickness up to 100 mm or as specified, for jacketing purposes thereby increasing the sectional dimensions as specified (excluding finishing) at any height with requisite shuttering, centring, proping, champhering the edges, repairing the existing surface as specified and also removal of debris, curing etc. complete as per design and drawing etc. directed. (NOTE :- Reinforcement will be paid separately under respective item of schedule ). Concreting to be done while epoxy bond coat is still sticky and in adhesive condition by quick shuttering and pouring of concrete. The rate includes providing and laying in any position, without usage of vibrator design mix Self Compacting Cement Concrete (SCC) of M30 grade ( Cement OPC, Bagged sand and aggregates as specified in the mix design) for Form Finished reinforced cement concrete work in super structure at all floor including admixtures as per designed proportions to accelerate, retard setting of concrete, improve workability without impairing strength and durability as per mix design. The Mix design as per particular specfications shall be got approved by Engineer-in-Charge before execution of the item. The rate excludes scaffolding but includes shuttering and centering up to a height of 4.5 mtr. from ground.

Extra for providing two stage centering for height more than 4.5m and upto 9m height in terms of floor beams including finishing, etc

Extra for providing two stage centering for height more than 9m and upto 13m height in terms of floor beams including finishing, etc

Extra for providing two stage centering for height more than 13m and upto 20m height in terms of floor beams including finishing, etc

Extra for providing two stage centering for height more than 4.5m and upto 9m height in terms of columns including finishing, etc

Extra for providing two stage centering for height more than 9m and upto 13m height in terms of columns including finishing, etc

Extra for providing two stage centering for height more than 13m and upto 20m height in terms of columns including finishing, etc

Additional Reinforcement: Cutting, bending and fixing in position steel reinforcement of specified/required sizes and shapes in the form or main rebars, stirrups & rings, distribution rebars etc., and tying them to shear connectors using GI binding wire. The additional rebars should be coated with TWO coats of Anti Corrosive protective coating & dry sand sprinkled on second coat. Rate includes fixing shear connectors/welding with old rebars to the existing concrete. Thermo-Mechanically Treated steel bars. (Fe 500 D) of SAIL, TATA TISCON, JINDAL, RINL make only

Dismantling R.C.C. slab, R.C.C. wall of any thickness, R.C.C. beams, joists, R.C.C. columns, piles, pile caps etc., ( Excluding dismantling covered under Item No. 1) in any thickness and size manually/ by mechanical means including stacking of steel bars and disposal of unserviceable material within RCF Premises & up to 20 mtr. height as per direction of Engineer - in- charge.

Dismantling brick work in lime or cement mortar including plaster, paint, etc. manually/ by mechanical means including stacking of serviceable material and disposal of unserviceable material within RCF Premises & up to 20 mtr. height as per direction of Engineer-in-charge.

Brick work with common burnt clay F.P.S. (non modular) bricks of class designation 3.5 and above in superstructure above plinth level upto any height in all shapes and sizes in : Cement mortar 1:4 (1 cement : 4 coarse sand)

Providing and applying 12 mm thick internal plaster and external by using ready-mix mortar as per manufacturers recommendations at all heights and locations for masonry (except stone masonry) and concrete surfaces including racking out joints, hacking of concrete surface, finishing, curing etc. complete.

Repair with Polymer Modified Mortar (PMM): Chipping /removing loose concrete upto reinforcement bars, without damaging the reinforcement, removing all the loose materials and to make all the exposed surfaces free from oil, dust and all impurities etc complete. Removing corrosion of steel reinforcement by mechanical means like wire brushing, chipping to remove loose rust and then applying rust removal solution by using brush application, leaving the surface for at least 15 to 30 minutes, then removing loose materials by scrubbing or with brush. After detachment of loose scales reddish rusted surface is still left exposed, this has to be retreated or as per approved manufacturers specifications. Application of Corrosion Inhibitor: Providing & applying One coat of Concrete Penetrating Corrosion Inhibitor (Surface applied) which works on Bipolar Inhibition Mechanism on entire concrete surface to be repaired by using brush or spray at 250 ml per Sq.Mt./Coat or as per manufacturer’s specification and prior to application of first coat of anti corrosive coating to reinforcement. Repairs to the deteriorated / damaged areas of RCC elements in the structure shall be carried out by using powder Polymer Modified repair mortar. The polymer modified mortar is applied when the epoxy bonding coat is still tacky. In one application 25 mm average thickness shall be built to match the level of surrounding. The polymer modified repair mortar shall be mixed in proportion of 1:5:15 ( 1 Part of approved polymer chemical : 5 part of Cement : 15 part of Kharshaliya sand) by weight , applied and cured as per technical.

Injection Grouting of approved super low Viscosity Epoxy Grout System: Pressure grouting Super low viscosity epoxy resin using injector till nozzles refused to accept the grout under pressure of 3-4 Kg/cm2. Grout the material through pre-fixed nozzles in the structural elements and subsequently cutting /removal of nozzles and sealing of holes with putty Monitor the leakages through other nozzles while grouting and seal them as per the specifications.

Providing & applying a bond coat of structural grade epoxy (resin+hardner) as per manufacturer's specifications to RCC columns, beams, walls, silo shell, diaphragms, slabs etc. including cleaning the surfaces thoroughly so as to remove deposited salts, oil, grease, tar, moisture etc. from the surface, preparing the surface, applying putty consisting of epoxy base paint and steolite powder, to render the concrete surfaces smooth by covering small irregularities and applying one coat of epoxy primer and two coats of epoxy paints conforming to ASTM-C-882-87 to the prepared concrete surface to the repaired / strengthened. The coverage shall be 1.30 Sqm/kg of mix or as per manufacturer including scaffolding etc. complete as specified and directed.(2 coats epoxy + primer) Epoxy material specification/brand: Asian Paints PPG, Shalimar, Berger, SIKA, BASF or equivalent

Providing, detailing, supplying, erecting structure consist of Pre-fabricated members like column, beam, angle, bracings, supports, purlins, runners and similar structural steel pre-fabricated members using hot rolled steel sections as per approved fabrication drawings ( which are prepared by contractor and approved by Engineer-in Charge), for retrofitting work around column, beams and slab soffit, including transportation of the same to site, cleats, stiffeners, plate, toe plate and all necessary operations like preheating welding burr and MS Plates of grade Fe 250 as per specifications and straightening, bending, cutting, drilling, grinding, machining if specified, welding, grinding and removing the welding burr and preparing surface for painting by de-rusting copper slag blasting confirming to SA 2.5, providing and applying four coats of epoxy paint after fabrication as per the specifications mentioned below including scaffolding etc. complete as per drawings and direction of RCF Ltd. One coat of Sunepoxy Prime and three coats of Sunanda SUNPU Guard as per manufacturer's specifications etc complete as directed by Engineer In Charge. Painting also includes touching up after erection etc. complete as directed by Engineer In Charge. All material is in Contractor's Scope including Only TATA/ SAIL/JSW/VIZAG make Structural steel shall be used. The scope also includes providing and supplying connection nut bolts of EN-8- MS Black / High Strength Bolts, nuts, washers etc. shall be as per IS 800, IS-1363 and IS-1367. Connection of structural members shall be done with bolts and welded both. (The qty. for this item shall be measured for gusset plates, base plates, bolts in M.T.)

Providing and fixing the Chemical Anchor Fasteners as specified below of Hilti Make or equivalent confirming to IS 1367 (Part 3) at required locations and level including drilling the hole, cleaning with blow pump and anchoring the bolt with chemical as per manufacturers specifications etc. complete as directed by Engineer In Charge. M16 x 125 foil capsule (HVU) & M16 x 190 Rod

Providing and erecting two legged metal tubular scaffolding (cup lock type) of width 1200 to 1500mm largely free standing using H frames of tubular pipes of minimum 40mm diameter, with base plates fixed or adjustable with necessary clamps, coulders, brackets for projections, joint pins, pulleys and other accessories including steel angle or tubular pipe bracings at adequate intervals, access platforms of metal or timber planks of span not exceeding 1.5 metre centre to centre, horizontal & vertical tubes joint with cup & lock system with M.S. Tubes, M.S. tube challis, M.S. clamps and staircase system in the scaffolding for working platform etc. and maintaining it in a serviceable condition for execution of work including provision of rubber inserts to pipe ends at point of contact with structure to avoid damage, including access ladders with intermidiate platforms. the scaffolding to be suitably braced and anchored to to the building using support systems created temporarily at the opening in walls using vertical and horizontal adjustable props on the exterior side of building structure, upto 25 metre height, above ground level .

Providing and fixing 2.50 mm thick UPVC sheet of trapezoidal profile for cladding and roof at any height, including providing and fixing with stainless steel Self tapping screw of 6x50 mm with SS hex cap and 3 mm thick EPDM seal complete. Sheets shall have uniform pigmentation and thickness without air pockets. The sheets shall be opaque or translucent, clear or pigmented, textured or smooth. UPVC should be plain white at one face and of approved color at the other face. Net area colvered by sheeting will be measured. Laps will not be paid separately.complete and as directed. (Net Area covered by sheeting will be measured. Laps will not be paid separately)

Fabricating ,fixing and removing at desired location using hot rolled sections and MS Plates of grade Fe 250 , transporting to site and erecting structural steel members for all heights & at all levels including provision of necessary erection bolts, fixing bolts, nuts, washers, cleats, stiffeners, gussets, base plate, and all necessary fixtures and operations like preheating as per specifications, straightening, bending, cutting, drilling, grinding, machining if specified, welding, grinding for providing temporary structural support for members to be repaired complete as directed by Engineer In Charge.(The qty. of gusset plates, base plates, bolts shall be measured in M.T for this item.) Structural steel shall be provided by RCF on non-chargeable basis at its store. Rs.3600.00 will be reduced by for removal work If not removed from its place after completion of work as directed then applyicable rate for this item is Rs.10703.00