1 GATES AND HOISTS. GOVERNMENT OF Karnataka . WATER RESOURCES DEPARTMENT. SCHEDULE OF RATES . GATE / HOIST AND ALLIED WORKS. FOR THE YEAR : 2003-2004. CONTENTS PAGES. REFERENCE DATA 1 -- 2. NOTES ON BASIC RATES 3 -- 3. DATA FOR SCHEDULE OF RATES 4 -- 183. PREPARED BY SCHEDULE OF RATES COMMITTEE. JUNE, 2003. 0. GATES AND HOISTS. GATE / HOIST AND ALLIED WORKS -- REFERENCE DATA. FOR THE YEAR - 2003-2004. ITEMS : 1 - 31. COST OF MATERIALS : Acytelene gas per cum Rs: Alloy steel ( IS : 1570 ) Shafts per kg Rs: Alloy steel ( IS : 1570 ) Pins per kg Rs: Bolt / Nut / Washer ( hot dipped galvanized ) per kg Rs: Bolt / Nut / Washer ( mild steel ) per kg Rs: Bolt / Nut / Washer ( stainless steel ) per kg Rs: Bronze / Alluminium alloy ( IS : 305 ) Bearings / Bushes per kg Rs: Cast iron blocks per kg Rs: Cast steel Drums / Gears per kg Rs: Cast steel Pinions per kg Rs: Cast steel Wheels / Pulleys / Hubs / Rollers / retainers per kg Rs: Chequered plate per kg Rs: Coaltar epoxy paint per ltr Rs: Degreasing / derusting / phasphate coating chemical per ltr Rs: Forged steel Hooks / Shackles per kg Rs.
2 Gas cutting set ( 2 Nos 15 m hose and nozzle unit ) Rs: Grease per kg Rs: MS pipe 300 mm dia per kg Rs: MS pipe 32 mm dia per Rm Rs: Oxygen gas per cum Rs: Rails 45 kg / m per tonne Rs: Rubber seal ( flat type bottom seal ) IS : 11855 per Rm Rs: Rubber seal ( music note teflon claded corner seal ) IS : 11855 per Rm Rs: Rubber seal ( music note uncladed corner seal ) IS : 11855 per Rm Rs: Rubber seal ( music note teflon claded side seal ) IS : 11855 per Rm Rs: Rubber seal ( music note uncladed side seal ) IS : 11855 per Rm Rs: Rubber seal ( Z - type side seal ) IS : 11855 per Rm Rs: Stainless steel plate / flats per kg Rs: Steel wire rope 6x37 construction per kg Rs: Structural steel angle / channel / beam / bars per kg Rs: Structural steel plate / flats per kg Rs: Sundries ( Lump sum rate for unquantified inputs ) Rs: Synthetic enamel paint ( 1st quality ) per ltr Rs: Welding electrodes 4 mm x 450 mm ( radiographic ) per No.
3 Rs: Welding electrodes 4 mm x 450 mm ( radiographic low hydrogen ) per No. Rs: Welding electrodes 4 mm x 450 mm ( stainless steel ) per No. Rs: Welding holder set ( cable / holder / gloves / mask etc ) per set Rs: Wire brush per Each Rs: Zinc per kg Rs: Zinc rich ( zinc content : 85 % ) epoxy primer paint per ltr Rs: Zinc chromate red oxide primer per ltr Rs: Excise duty on cost of supplies % Insurance charges % LEAD, LOADING & UNLOADING CHARGES: 1 km lead Loading Unloading Steel per tonne Rs: 1. GATES AND HOISTS. HIRE CHARGES OF MACHINERY: Hire charge Fuel charge Crew charge Bending machine per hour Rs: Derric crane ( mobile ) per hour Rs: Derric crane ( stationary ) per hour Rs: --- Drilling machine for steel per hour Rs: Grinder per hour Rs: Planing machine per hour Rs: Plate shearing machine per hour Rs: Pug cutting machine per hour Rs: --- Tower crane 5 tonne per hour Rs: Welding transformer per hour Rs: --- WAGES OF WORKERS: Per day Electrician Rs: Foreman Rs: Gas cutter Rs: Helper fabrication / erection Rs: Khalasi Rs: Marker / Erector / Fabricator / Machanic Rs: Painter Class-II Rs: Welder ( General ) Rs: Welder ( X-ray quality ) Rs: 2.
4 GATES AND HOISTS. NOTES ON SCHEDULE OF RATES . GATE / HOIST AND ALLIED WORKS. FOR THE YEAR : 2003-2004. 1. All notes under ' General Notes on SCHEDULE of RATES ' are applicable to ' Gate / Hoist and Allied Works ' also to the extent they are relevant. 2. All materials / bought out components for embedded parts, gates, hoists and allied works shall conform to relevant Indian standards / technical specifications and approved drawings. 3. The basic RATES are inclusive of preparation of designs / drawings / material schedules etc., as per specifications and other technical data including revisions. 4. The basic RATES are inclusive of cost of all materials, machinery, labour, fabrication, erection, commissioning and testing of gates, hoists and other related components as per technical specifications.
5 5. The basic RATES are inclusive of finishing, wastage of materials , incidental works, temperary supports, scaffolding, all enabling works, profit, overheads, small tools / plants, hidden cost on labour etc. 6. The basic RATES are inclusive of taxes, duties, levies and all other incidental charges except sales tax on works contract. Separate provision shall be made in the estimate towards sales tax on works contract at the rate prevailing at the time of preparation of estimate. 7. The basic RATES are inclusive of all leads and lifts including rehandling. 8. Unless otherwise specified the basic RATES are inclusive of standard finish required for all the fabricated and bought out gate and hoist components.
6 9. The basic RATES are inclusive of preparatory works such as rectification of damages, repairing shop painting, cleaning, positioning and anchoring first stage embedments, cleaning surface for field painting etc. 10. The basic RATES are exclusive of cost of river diversion arrangements, dewatering, desilting etc., which form part of civil works. 11. Unless otherwise specified the basic RATES for items are on per tonne basis. The rate per set or per number shall be worked out on the basis of rate per tonne and the tonnage computed as per detailed designs / empirical formulae / similar works. 12. Dry film thickness for zinc rich epoxy primer and coal tar epoxy paints shall be 40 microns per coat and 100 microns per coat respectively.
7 3. GATES AND HOISTS. GATE / HOIST AND ALLIED WORKS - DATA RATES . SECTION: GATE / HOIST & ALLIED WORKS. YEAR: 2003-2004 ITEM No: 1. ITEM: Design, fabrication, supply, erection and commissioning of embedded parts consisting of sill beam, wall plates, anchors, anchor girders, yoke girders, tie flats, trunnion supports, rope and pulley supports etc., with all accessories for spillway radial gates including cost of all materials, machinery, labour, aligning, anchoring, welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and four coats of cold applied coal tar epoxy paint etc., complete as per specifications and approved drawings with all leads and lifts. DATA: Embedded parts for radial gate consist of sill beam / wall plates / anchor girders / yoke girders /.
8 Tie flats / trunnion supports etc., with all accessories. The weight of embedded parts for radial gate will be generally at about 25 to 30 percent of weight of radial gate leaf. Consider embedded parts for radial gate for spillway opening of size 15 m x 9 m for analysis. Details of material / Gas cutting / Welding considered for rate analysis are based on embedded parts drawings for 15 m x 9 m spillway opening of Kodasalli dam. Size of gate for 15 x 9 m spillway opening at crest Length : 15 m Height : m Head of water for sill level m below crest : m Weight of radial gate leaf in tonne with end shield and hood based on empirical formula : Weight of gate in tonnes = x ( L^2 x H x h )^ Where ( L ) is length and ( H ) is height and ( h ) is head of water in metres.
9 Weight of embedded parts @ 25% = x ( L^2 x H x h )^ = x ( 15 x 15 x x ) ^ : The actual weight of embedded parts as per fabrication drawings : tonnes Consider actual weight for data rate analysis. 1. Requirement of materials : as per fabrication drawings ( for details refer Item : 1 of Annexer ). a. Structural steel conforming to IS : 2062 : Structural steel angles / beams / channels / bars with % wastage : 696 kg Structural steel plates / flats with % wastage : 13690 kg b. Alloy steel conforming to IS : 1570 : Stainless steel plates / flats : kg c. Bolt / Nut / Washer conforming to IS : 1363 : MS bolts / nuts with % wastage : 112 kg d. Welding electrodes : Welding electrodes for stitch welding at 10 % of total with % wastage : 665 Nos Welding electrodes (SS) for stitch welding at 10 % of total with % wastage : 66 Nos Welding electrodes ( LH ) for run welding at 90 % of total with % wastage : 5983 Nos Welding electrodes ( SS ) for run welding at 90 % of total with % wastage : 591 Nos 2.
10 Cutting : Length of cutting assuming cutting for 2 sides as per data sheet : 428 Rm Add for variations ( cutting for more than 2 sides / odd shapes etc ) at 10 % : 43 Rm Total length of cutting : 471 Rm For cutting structural steel sections to required size gas cutting is assumed for cutting angles /. beams / channels / round bars. For plates / flats less than 12 mm in thickness plate shearing machine and for the remaining sections pug cutting machine is considered. Length of steel to be cut by using gas manually : 60 m Length of steel to be cut by gas using pug cutting machine : 371 m Length of steel to be cut by using shearing machine : 40 m Time for gas cutting manually assuming average cutting progress of 2 m / hour : 30 hours Time for gas cutting by pug cutting machine at ( av ) 3 m / hour : 124 hours Time for cutting by shearing machine at av.