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| Sl. No. | Item Description |
| 1 | Design, drawing, fabrication, transport and installation of canal/ river sluice shutter including skin plate with vertical stiffeners, horizontal girders, end verticals, rib plates, etc, suitable for canal/ river sluice gate of vent size 1520 x 1830mm as per IS 4622. The skin plate with vertical stiffeners, horizontal girders, end verticals, rib plates shall be made of structural steel confirming to IS 2062 : 2011.The side & top rubber seal shall be provided with ‘P’ type seal of size 100x44x14. The existing cast steel wheel assembly shall be serviced and reassembled to the new gate. The shutter shall be blast cleaned to SA 2 1/2 standard and the surface shall be with Aluminium wire metallising as per IS 6586 (1989) with adjuncts to IS 5905 : 1989 and a overcoat of epoxy zinc phosphate primer with 50µ shall be applied. The finish coat of coaltar epoxy for 250µ in two coats shall be applied. Each coat shall be given a drying time of minimum 24 hours. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, paint, primer, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like derrick, chain pulley block, power charges for generator, conveyance to site and clearing them after completion of work, including cost of trial operation, etc warranty for 5 years except rubber seals, protective coatings, etc., complete as directed by the departmental officers. |
| 2 | Design, drawing, fabrication, transport and installation of emergency shutter including skin plate with vertical stiffeners, horizontal girders, end verticals, rib plates, etc, suitable for emergency gate of size 3100x2740mm as per IS 4622.The wheels shall be made of cast steel of 400mm Ø adhering to IS 1030 and wheel pin of 100mm Ø made of 30 CR 13 grade adhering to IS 1570 . Rear side cover plate and seal base plates shall be provided with 20mm thick MS plate. Side rubber seals, Top seal & bottom seals shall be of “P” type of size 100x44x14mm. The involute spring and lifting valves shall be provided as per IS standards. The guide rollers with pins for side and upstream side shall be IS 210. All steel surfaces shall be blast cleaned as per SA 2 ½ standard and the surfaces shall be applied with epoxy primer to a thickness of 50µ. The finish coat shall be coal tar epoxy 250µ thick in two coats over the primer. 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. |
| 3 | 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, warranty for 5 years etc., complete as directed by the departmental officers. |
| 4 | Repair & Refurbishing of emergency shutter in River Sluice of size 3100x2740mm as per the following specification. Dismantling the shutter from hoist, removing all rollers, seals, water escape valves parts as directed by the department Officers. Dismantling all rollers, removing of bearings, seals, grease nipples, etc., cleaning of rollers and shafts and re assemble of rollers with new bearings, seals, grease nipples with full grease packed complete as directed by departmental Officers. Removing of water escape valve and overhauling of the valve seat, spring, spring seats and valves complete as directed by department Officers. Removing seals and CSK bolts and supply and fixing of musical note seal/P type seals and corner seals size of 100x44x14mm. Stainless steel 304 grade CSK bolts and nuts as per sample complete as directed by department Officers. Removal, cleaning and re fixing of water chamber plate with new gaskets and bolts complete as directed by Department Officers. The gate shall be blast cleaned with SA 2 ½ standard and the surface shall be applied one coat of zinc epoxy primer with 50µ. The finish coat shall be applied 250µ in two coats of coaltar epoxy. Labour charges including machining, drilling, welding, gas cutting, all materials and conveyance to this site, loading and unloading charges, grease packing, lubricating oil, all civil works and satisfactory trial run complete as directed by the Departmental Officers. Handing over of all old materials removed from this work and to be staked at dam site as directed by dam officials, etc., All materials and works should be as per technical specification. |
| 5 | Repair & Replacement of suspension channel in Amaravathi dam river sluice & canal sluice as per the following specification. New suspension channel shall be made of 125x65mm twin channels facing each other at a distance of 65mm with ISMC 125x65 welded between them as spacers. The spacers shall be provided at a vertical distance of 500mm c/c from each other. These twin channels shall withstand the designed loads. The existing screw rod of size 100mmØ & 3000mm length shall be connected to the new suspension channel with a system of bolt & nuts of size 6\\"x5/8\\". The suspension channel shall be of appropriate height as per site condition but should be fabricated in cut lengths of 3m since beyond that the suspension channel for screw rod cannot be removed from its position for maintenance. The suspension channels shall be connected to each other with a system of 10mm plate of size 200x250mm using bolts & nuts. The bottom of the suspension channel extends upto the top horizontal member of the shutter. Then it shall be assembled for efficient operation, as directed by the departmental officers. All members shall be given a coat of epoxy primer overwhich two coats of anticorrosive coaltar epoxy paint shall be applied. The cost includes cost of materials, labour charges, hirecharges for machinery like derrick, chainpulley block, gas cutting equipment, welding plant, erection, etc, cost of conveyance to & fro from site of work, risk allowance, trial operation, warranty for 5 years etc, complete. |
| 6 | Repair and Replacement of the suspension guide channel as per the following specification. The suspension guide channel is inside the sluice well to guide the suspension channel connecting the sluice shutter to the hoisting arrangements. The old corroded suspension guide channel shall be cut and removed from the masonry with concrete breaker machine & stacked at PWD stores as directed by the departmental officers. The new suspension guide channel shall be cut to the required size and given a coat of zinc rich primer over which two coats of coal tar epoxy shall be applied. The masonry on either ends of the channel shall be broken at appropriate places and then the channel shall be embedded with concrete at the appropriate place. The cost includes cost of materials, labour charges, hire charges for machinery like derrick, chain pulley block, gas cutting equipment, welding plant, erection, civil works wherever necessary etc, cost of conveyance to & fro from site of work, risk allowance, trial operation etc, complete. |
| 7 | Dismantling the existing corroded old ladder & replacement with new safety ladder arrangements to the sluice well as per the following specification. The main stiles at both ends shall be 410mm apart and made up of 50x8mm MS Flat. They shall be connected in between with treads of size 16mm dia MS rod. This tread shall be welded to the stiles on either side. The treads shall be spaced onebelow the other at a distance 300mm equidistant from each other. The bottom of the ladder shall be buried in concrete. The top of the ladder shall be welded to the operating head platform. All members shall be given a coat of redoxide and then two coats of aluminium oxide is given. The old unusable ladder shall be removed and stacked at stores for disposal as directed by the departmental officers. The cost includes cost of materials, labour, erection, transport, civil works wherever necessary etc, complete. |
| 8 | Replacement of bottom rubber seal of the spillway 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 and as directed by departmental officers. |
| 9 | Providing Z type rubber seal on either ends of the shutter with SS side seal seat as per the following specification. The seal seat shall be made of MS flat 70x16mm of length 7680mm and seal cover flat shall be made of MS flats 55x10mm of length 7680mm. They are tag welded together for matching and M10 holes shall be drilled with a centre to centre distance of 100mm. The seal seat shall be tap drilled size of M12. The seal cover flat shall be drilled M14 over the pilot drill. The seal seat shall be fitted with skin plate both ends and welded with skin plate. Now the ‘Z’ type seal of size 74x79x16mm shall be cut to the required size and matched with the seal seat cover and holes are punched in the rubber seal accordingly. Now the Z type seal shall be sandwitched between the skin plate & seal seat cover. SS bolts M12 shall be used to fasten them to the skin plate. SS flat of size 70x8m and of length 7700mm is used as side seal seat. The flat shall be cut to a length of 7700mm and fixed appropriately in the groove angle to act as side seal flat to reduce the friction during the sliding of rubber seal at the side. The cost includes cost all of materials, labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site, insurance etc., complete and as directed by departmental officers. |
| 10 | Providing dogging / latch beam arrangements including embeddment if any along with construction of niche of adequate size in existing masonry/concrete structure for holding the gate above the MWL for gate maintenance & also to facilitate maintenance /repair or replacement of gate wheels/wheel assembly, including warranty for 5 years. This includes scaffolding and civil works wherever necessary as directed by the departmental officers. |
| 11 | Repair & Replacement of old corroded steel stiffeners in the spillway shutters of size 11000x7700mm as per the following specification. The existing stiffeners shall be replaced with ISMC 125 welded back to back as in the original design. The shutters are lifted to a height of approximately 600mm for operational ease while carryingout the repairs. The existing channels shall be thoroughly investigated for corrosion and then they shall be clearly marked on the channels. They shall be cut & removed without damaging the skin plate & gusset plates. The corroded sections shall be transported & stacked at section stores. The new ISMC 125 channels shall be sheared to required sizes to fit the cut stiffeners and welded in the places of the old corroded channel. The butt welds between the channel joints shall be provided with 10mm thick splice plates on either side in the web of the channel. Welded joints shall be neatly ground to remove the welding spatter. The cost includes cost of all materials, process charges like gas cutting, welding, machining, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like chain pulley block, power charges from generator, conveyance to site and clearing them after completion of work including cost of trial operation, warranty for 5 years, etc., complete and as directed by the departmental officers. |
| 12 | Repair, overhaul & refixing of the rusted cast iron wheels of the existing shutters with gas cutting equipment and reconditioning with bushes / bearings and refixing to the original condition as per the site requirements. The wheel is of 400mm diameter & moves in the recessed groove of the vertical guide channel. The shutter shall be lifted to a workable height and the locking plate shall be removed by cutting the corroded bolts & nut with gas cutting equipments. The wheel pin shall also be removed.Then the wheel shall be transported to the workshop where the wheel shall be opened up and the old broken bearing & sleeves shall be removed after cleaning the wheel. Then the outer wheel surface shall be machined true to required size and so that it shall operate smoothly without vibration and without undergoing undue drift. The inside of the wheel shall also be machined to have a uniform surface. The existing bearing shall be cleaned and inspected for misalignment and breakage. Then shall be replaced as the case may be. The existing pin shall be machined and fitted snugly. Then the wheel shall be closed and fitted to the end vertical channel. Trial operation shall be conducted to ensure free movement & rotation of wheels. The cost includes cost of all materials, process charges like gas cutting, welding, machining, scaffolding charges, labour charges for dismantling, loading, lifting, unloading, transport, erection, labour charges for equipments like crane, chain pulley block, power charges for generator, risk allowance for working at a height of more than 3m, conveyance to site and clearing them after completion of work including cost of trial operation etc., complete and as directed by the departmental officers. |
| 13 | Supply and erection of inspection platform for the spillway vertical shutters of the following size & specification. The platform shall be provided in between the piers parallel to the skin plate of the shutter as well around the piers in the downstream side for effective inspection of shutters and its components. Also it serves for periodical maintenance operations such as oiling, greasing & painting. This easy & quick access enables to monitor any leakage from the shutter and enables carrying out emergency operations. The platform shall be of width 900mm and shall be supported by the main girder ISMB 400 on either ends of the platform. The platform in between pier shall be supported with “A” frame. The frame shall be anchored to piers with hybrid vinyl ester compound. ISA 50x50x6 shall be welded as intermediate stiffeners singularly between the main girders at distance of 450mm c/c from each other and cross stiffeners at a distance of 500 c/c from each other shall be provided throughout the length of the inspection platform. |
| 14 | A gusset plate made of 8mm thick MS plate and size 160 x 200mm shall be perpendicularly welded to the outer side of the main girder on either side to weld the vertical posts of height 1200 mm made of ISA 75x75x6mm. The handrail pipes of dia 25mm made of GI pipes shall be inserted into the holes drilled in the vertical post equidistant from each other as in the drawing. The platform top shall be finished with 6mm composite chequered plate from end to end throughout the platform for a width of 900mm. All joints in the frames shall be neatly welded and ground to give an excellent finish. The platform shall be blast cleaned with SA 2 1/2 standard and the surface shall be applied epoxy primer with 50µ, The finish coat shall be applied overthe primer coal tar epoxy with 250 µ in two coats. The foundation bolts of size 16mm with base plate of size 250x250x12mm shall be provided to anchor the platform to the existing pier. Necessary civil works like concreting & anchoring in existing masonry structure shall be included in the scope of this job. The Cost includes cost of materials, labour charges, transport, erection, crane hire charges, power charges from a generator at site, loading & unloading charges, conveyance of machinery to & fro from site of work, hire charges for machinery, painting, scaffolding charges , civil works wherever necessary risk allowance for working at a hazardous location at a height of 30m, warranty for 5 years etc., complete. |
| 15 | Supply and erection of approach staircase to the platform of the following size & specification. The staircase shall descend from the road bridge from an appropriate entry point to the inspection platform with adequate steps & hand rails. This is necessary to inspect vertical gate from the downstream side, Also it serves for periodical maintenance operations such as oiling, greasing & painting. This easy & quick access enables to monitor any leakage from the shutter and enables carrying out emergency operations. The staircase shall be of width 900mm and shall be supported by the main girder ISMC 200 on either ends of the staircase. The tread & the risers shall be of appropriate height & width. A gusset plate made of 8mm thick MS plate and size 160 x 200mm shall be perpendicularly welded to the outer side of the main girder on either side to weld the vertical posts of height 1200 mm made of ISA 75x75x6mm. The handrail pipes of dia 25mm made of GI pipes shall be inserted into the holes drilled in the vertical post equidistant from each other as in the drawing. The platform top shall be finished with 6mm composite chequered plate from end to end throughout the platform for a width of 900mm. All joints in the frames shall be neatly welded and ground to give an excellent finish. |
| 16 | The platform shall be blast cleaned with SA 2 1/2 standard and the surface shall be applied epoxy primer with 50µ, The finish coat shall be applied overthe primer coal tar epoxy with 250 µ in two coats. The foundation bolts of size 16mm with base plate of size 250x250x12mm shall be provided to anchor the platform to the existing pier. Necessary civil works like concreting & anchoring in existing masonry structure shall be included in the scope of this job. The cost includes cost of materials, labour charges, transport, erection, crane hire charges, power charges from a generator at site, loading & unloading charges, conveyance of machinery to & fro from site of work, hire charges for machinery, painting, scaffolding charges , civil works wherever necessary risk allowance for working at a hazardous location at a height of 30m, warranty for 5 years etc., complete. |
| 17 | Providing 6mm thick composite chequered plate in the operating platform in the following specification. The composite chequered plate shall be manufactured in vacuum infusion process. This process ensures freedom from all defects and thus increases the strength of the composite chequered plate. UV resistant polyester polymer and high grade reinforcement shall be used for manufacturing chequered plate. Excellent corrosion resistant gel coat shall be applied during the process. The composite material has high strength to weight ratio, durable, light weight and ease in handling. Then it shall be checked for flatness and lifted to the overhead platform and marked and cut to exact size. The composite plate has very good anti slippery property and ease in handling. Then the plate shall be laid in the panel screwed to the stiffeners below. Suitable holes shall be provided at appropriate places for drainage of rain water. Then the composite chequered plate, shall be loaded, transported to the site, unloaded & erected as directed by the departmental officers. The cost includes cost of mould, pattern and fixtures, cost of raw materials like UV stabilized infusion grade polymers, multi directional & flow media glass fiber reinforcements, core material hardeners, inhibitors, UV stabilized pigment & fumed silica powders, cost of consumables like vacuum film, peel fly, flow mesh, spiral hose, tacky tape, valves, connectors, clamps rollers, brushers, sanding sheets, acetone, buffing, grinding & cutting wheels, cost of tools like aluminium paddle rollers, squeegees, fibreglass scissors, measuring beakers, agitators,cost of release agent like, cleaner, sealer, releaser, wax, labour charges for pattern & mould work, hand layup, cutting, grinding, finishing, drilling, loading, unloading, transport, erection, hire charges for equipments like air compressors, pneumatic tools, gelcoat spray gun, vacuum infusion pump, catch pot, conveyance to site and clearing them after completion of work, including cost of trial operation, warranty for 5 years, etc., complete as directed by the departmental officers. |
| 18 | Providing an electromagnetic safety brake of 180mm dia to the hoisting arrangements of the spillway shutters as per the following specification. Electromagnetic brake is a mechanical device to keep or stop the gate at the desired position for safety reasons as well for proper operation of gates. The drive unit assembly cover shall be removed and motor starter shall be isolated. The coupling connecting motor & gearbox shall also be separated. The existing single end motor shall be modified into a double end motor. The brakedrum with the new 180mmØ brake assembly shall be fixed to the shaft. The arm fixing pin shall be fixed to the deck bridge with a supporting channel of size 75x40mm & of length 300mm. The motor wiring shall be connected to the electromagnetic brake. Now the gearbox & motor shall be reconnected with the existing coupling. The drive unit assembly cover shall be closed and motor starter shall be actuated. A trial operation shall be conducted as directed by the departmental officers. The cost includes cost of materials, labour charges for modification in the position of motor & worm reducer, assembly of EM brake and synchronising it to the existing system, cost of flexible couplings, rent charges for welding machine, cutting, drilling & grinding machines, generator etc, complete as directed by the departmental officers |
| 19 | Providing a dial gauge to read the movement of shutters from the deck bridge as per the following specification. The dial gauge is a safety instrument to read the position of the gate from the deck as well restrict the movement of the gate at predesignated heights. The dial gauge consists of dial with engraved scale, a pointer and a striker. A ultra reduction gearbox 1:20 as per site condition shall be assembled along with of chain & chain sprocket arrangement. The shaft for chain sprocket shall be made 25mm EN8 steel. The sprocket wheel shall be of 25 teeth with pinion of 12 teeth. The chain for sprocket shall be of length 2000mm. Necessary bushes & bearings of best quality shall be used. The whole assembly shall be housed in a composite dial gauge enclosure. The composite material shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties The cost includes cost of design cost of materials like ultra reduction gear box, chain, chain sprocket, composite head, hire charges for machinery like welding machine, grinding, corecut, consumables like welding rod, grinding wheel, core cut, drill bits, process charges like machinery, milling, mould charges, labour charges, charge for transport to & fro etc., complete |
| 20 | Providing safety limit switches as per the following specification. The safety limit switches shall be used to prevent the accidental impact of shutter to the sill beam. An ‘L’ clamp shall be provided to the gauge plate pipe at the top of the wormgear to fix the limit switch. The limit switch shall be provided appropriately for on/off operation of the shutter at designated heights. The wiring of the switches shall be done with 1.5sqmm x2 core copper flexible cable without joints. The cost includes cost of materials, labour charges, transport, erection, etc, complete |
| 21 | Replacement of gearwheel (G1) and pinion wheel & plummer block for chain sprocket shaft, realignment, and overhauling of existing hoists shall be carried out as per the following specifications. The shutter shall be seated in the sill. The hoist enclosure shall be opened, and the counter weight shall be dogged at deck bridge. The chain shall be disconnected from the shutter, and dismantling chain sprocket drive gear wheel and pinion wheel shall be dismantled. The new gear wheel size of OD -712mm and 48 teeth and 12 teeth pinion wheel -1 set shall be made of cast steel 28-52 grade. The gear box output shaft shall be made of EN8 material. The plummer block for chain sprocket shall be fabricated with En8 materials. The hoist assembly assembled and alignment shall be fine-tuned and the shutter shall be operated manually to check the alignment and smoothness of operation. This shall be repeated a few more times, moving up & down manually to ensure the smooth operation. Then the hoist shall be properly aligned after settling the issue Now, the hoist shall be operated using the coupled motor a couple of times and again checked for any misalignment, until smooth movement of hoist is ensured. Then, the top cover of plummer blocks connecting the existing transmission shafts shall be opened and old grease shall be removed. |
| 22 | Then, the existing bearings shall be cleaned with liquid cleaner and inspected for mis-alignment and breakage. Fresh grease shall be applied to the plummer block and top cover closed with requisite fasteners. The shaft shall be checked for its alignment and redone to ensure straightness of shaft. The existing gear wheels shall be cleaned of dried grease and dust manually. The reduction gearbox shall now be drained of old used lubricant thro the drain hole at the bottom. Now, the liquid cleaner shall be poured in the gearbox and the inside surface and gears are thoroughly cleaned and then the contaminated liquid cleaner shall be drained. The drain hole shall be plugged and fresh lubricant of appropriate grade shall be filled to the level as indicated by the department officers. The available chain hoist mechanism in the hoisting system shall be manually cleaned of dried grease and dirt and appropriate lubricant shall be applied. The whole arrangements of components of spillway gates including chain hoist, links of chains, beams, channels, counter weights, etc., shall be tested for strength and durability and to be replaced with new components whereever necessry & passed after a set of trial operation. 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, re-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 as directed by the departmental officers. |
| 23 | Overhauling of the existing worm hoisting arrangements for the deep sluice gate shall be carried out as per the following specifications. The worm hoist consists of a worm wheel, worm shaft, screw rod, thrust bearing, and bushes. The screw rod shall be cleaned with liquid cleaner and inspected for misalignment and breakage. The worm gearbox shall then be drained of the old lubricant. The gearbox shall be opened, and the worm wheel and worm shaft shall be thoroughly cleaned using liquid cleaner and inspected for proper gear teeth alignment. The bearings and bushes shall also be cleaned with liquid cleaner and inspected for misalignment and breakage. The worm wheel and shaft shall then be assembled with proper alignment, and fresh grease shall be applied to the bearings and bushes.The joint sealing shall be replaced, ensuring that there are no leakages. Fresh lubricant oil shall be filled in the required quantity into the gearbox. The worm gearbox shall then be reinstalled in its existing position. The hoist shall be tested through trial operation until free movement is achieved. The cost shall include all materials and process charges such as gas cutting, welding, machining, scaffolding, and labour charges for dismantling, loading, lifting, unloading, transport, erection, and equipment usage (such as cranes, chain pulley blocks, and power charges for generators). It shall also include risk allowance for working at heights of more than 3 metres, conveyance to site, and site clearance after completion of work, including the cost of trial operation. All works shall be carried out completely and as directed by the departmental officers. |
| 24 | Repair, overhauling & refixing of the Double axis movement double grider crane in Amaravathi dam as per the following specification. The crane has two parallel girders rigidly connected to the end carriages at a distance of 7300mm c/c and spanning the gantry of span 6000mm. The lifting unit is built on to a traversing crab overslung from the beams. The crab is of size 3000x3500mm. The wheels run directly over the crane grider. Due to ageing prolonged use and minimal maintenance the health of all the systems has deteriorated and unusable. Therefore, all the existing system shall be overhauled & repaired wherever necessary & refixed as directed by the departmental officers. The hoisting machinery consists of motor, gearbox, rope drum, rope guide. The gearing is of hardened helical type and motors are of squirrel cage motors. The rope drum is large and the rope pulleys ensure that the rope shall be retained in the pulley. All safety features as existing shall be repaired to ensure safety of operations, increased productivity & optimal maintenance planning. This existing machinery as described above shall be tested for best performance & repairs attended, wherever necessary. All lubricants shall be drained & cleaned & re topped. The cost includes cost of all required necessary spares, lubricants, labour charges, charges for dismantling & erection, hire charges for machinery & equipment used during repair, provision of pendant control switches, etc., complete. |
| 25 | Repair, overhauling & refixing of the single axis movement double grider crane in Amaravathi dam as per the following specification. The crane has two parallel girders rigidly connected to the end carriages at a distance of 7200mm c/c and spanning the gantry of span 3500mm. The lifting unit is built on to a traversing crab overslung from the beams. The crab is of size 3500x3000mm. The wheels run directly over the crane grider. Due to ageing prolonged use and minimal maintenance the health of all the systems has deteriorated and unusable. Therefore, all the existing system shall be overhauled & repaired wherever necessary & refixed as directed by the departmental officers. The hoisting machinery consists of motor, gearbox, rope drum, rope guide. The gearing is of hardened helical type. The rope drum is large and the rope pulleys ensure that the rope shall be retained in the pulley. All safety features as existing shall be repaired to ensure safety of operations, increased productivity & optimal maintenance planning. This existing machinery as described above shall be tested for best performance & repairs attended, wherever necessary. All lubricants shall be drained & cleaned & re topped. The cost includes cost of all required necessary spares, lubricants, labour charges, charges for dismantling & erection, hire charges for machinery & equipment used during repair, provision of pendant control switches, etc., complete. |
| 26 | Renewal & refixing of wirerope of the following specification. The existing wornout 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 C flattened strand winding rope 6 x 36 with nominal diameter 22mm and wire strength 1770 N/mm2. The sheave groove is ensured that 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. |
| 27 | Replacement of old damaged starter box for the following specification. The starter to motor old cable shall be replaced with 4 core x 4 sqmm copper flexible unarmoured cable for cable leading from starter to motor. Necessary gland & lugs shall be used as required. Starter to motor cable shall be protected with 1” Ms pipe. A new DOL starter with forward & reverse shall be provided inside the old panel box after removing the old existing damaged starter. The starter box enclosure made of hybrid composite super structure panels. This process ensures freedom from all defects and this increases the strength of the composite box. UV resistant polyester polymer, fire retardant and high grade reinforcement shall be used for manufacture of composite enclosures. Excellent corrosion resistant gel coat shall be applied during the process. The composite material has high strength to weight ratio, durable, excellent corrosion resistant and very good insulator. The starter shall be housed in 20A contactor – 2nos, 12 to 18 amps relay – 1 no, single phase preventer – 1 no, pushbutton for forward, reverse & off, indicators lamps -3 nos, 32A 4 pole MCB -1 no & terminal -1 no shall be welded after removing the existing cover. The cost includes cost of composite enclosure box & accessories cable from starter to motor, labour charges, painting , transport charges, erection at site etc., complete. |
| 28 | Repair & Replacement of existing damaged river sluice/canal sluice emergency shutter gantry hoist starter, gantry lateral movement starter and cross travel starter. providing new DOL starter and pendant switch with required cable. The existing damaged starter box shall be removed and replaced with new DOL forward reverse starter. The three starters shall be housed in single enclosures. The starter box enclosure shall be made of hybrid composite super structure panels. This process ensures freedom from all defects and this increases the strength of the composite box. UV resistant polyester polymer, fire retardant and high grade reinforcement shall be used for manufacture of composite enclosures. Excellent corrosion resistant gel coat shall be applied during the process. The composite material has high strength to weight ratio, durable, excellent corrosion resistance and very good insulator. The starter shall be housed with 32A contactor – 2nos, 16A contactor – 4 nos , 18 to 25 amps over load thermal relay – 2nos, 5-8amps over load thermal relay – 4 nos , single phase preventer – 3 nos, pushbutton for forward, reverse & off – 7 nos, indicators lamps -3 nos, 32A 4 pole MCB -1 no 16A MCB – 2 nos, FN 63A main switch -1 no & terminal block -3 nos . The new pendent switch shall be provided for hoist motor forward & reverse, lateral movement motor forward & reverse and cross travel motor forward & reverse operation. The Pendant switch shall be housed with forward, reverse push button 3 sets & 1 no for stop bush button with “NO” & “NC” switches. The 10 core x 1sqmm cable shall be connected with starters. The cost includes cost of materials like cables, pendant switch, starter box, terminal box and, labour charges for laying, transport, etc., complete. |
| 29 | Repair and Replacement of Screw gearing steel shutters of size above 1.00 m and upto 2.00m width consist of skin plate made out of 8mm thick mild steel plate and horizontally stiffened with 100x50mm mild steel channel at an interval not more than 0.50m and vertical stiffeners made out of same section at an interval not more than 0.60m and provided with 8mm thick mild steel gusset plate of required size on both sides fastened with rust free bolts and nuts etc. Conveying the fabricated shutter by using lorries including loading, unloading and leading the shutter to the vent. Dismantling the eroded shutter and shuttering arrangements by using necessary gas cutting equipment. Erecting the new shutter and the shuttering arrangements in the vent in proper position by using necessary hoisting equipment. The shutter shall be painted with two coats of Anticorrosive black paint over one coat of Red Oxide Primer. The rate including cost of materials consumables, labours power charges, conveyance charges for all equipment required conveying the dismantled materials to the section stores, cost of petty civil works, trial operation of shutter and warranty for 5 years etc.,complete. |
| 30 | Modification of CI headset with wormnut hoist comprising of a screw rod made of 75mm Ø MS Rod of length 3500mm. The threaded portion shall be 3000mm with 12mm pitch. The screw rod shall be connected to the shutter. Wormnut hoist to suit 75mm screw rod shall be provided. The worm wheel shall be made of phosphor bronze with 175mm OD with 25 teeth x 25mm circular pitch. Thrust ball bearings should be provided on either side of the worm wheel. Oil seal of size 110x135x13 shall be provided on either side of the worm wheel. A cast iron cover shall be provided over the whole arrangement. MS Worm 75mm ID & 25mm, pitch double thread shall be provided. Thrust ball bearing O 12 shall be provided on either side of worm. A wormnut stand of height 740mm & 380mm at the top & 590mm at the bottom shall be provided with 10mm MS plate. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheels, 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, civil works wherever necessary etc., warranty for 5 years, complete as directed by the departmental officers. |
| 31 | Providing a shed to accommodate labour during rain and shine in spillway deck bridge as per the following specification. The deck bridge is of total length more than 125 m and hence during operation & maintenance a protected shed arrangements are needed to safeguard the workers from being drenched. The main stanchions shall be 3 in number and spaced at 2500 mm equidistant from each other made 2 1/2” dia MS pipe with a height of 1300 mm in upstream side and 1000 mm in downstream side. A Gusset plate made of 8 mm MS plate and size 200x160 mm shall be provided at the bottom end for connecting the vertical stanchions to the deck bridge channel by means of bolts and nuts. The rafters shall be made of 100x50 mm rectangle tube of length 3600 mm along the width of the deck bridge. The ends shall be bolted connections with vertical stanchions. The Purlin shall be with 75x40 mm rectangle tubes of length 5000mm. They shall be 4 in nos at a equidistant from each other. The ends of Purlin shall be closed. Cleat angles shall be fabricated and appropriate holes shall be drilled in the cleat angle and matching holes in rafter for bolted joints. Colour coated corrugate colour profile sheets shall be provided for roofing . All MS surfaces shall be manually cleaned and applied with 2 coats of enamel paint over a coat of anticorrosive primer as directed by the departmental officers. The cost includes cost of all materials, process charges like gas cutting, welding, machining, scaffolding charges, labour charges for dismantling, loading, lifting, unloading, transport, erection, labour charges for equipments like crane, chain pulley block, power charges from generator, conveyance to site and clearing them after completion of work including cost of trial operation, etc., complete and as directed by the departmental officers. |
| 32 | Application of 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. |
| 33 | 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. |
| 34 | 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, |
| 35 | 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. |
| 36 | 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 |
| 37 | Repair and replacement of existing corroded top seal seat, side seal seat & roller track per the following specification. The suspension channel of the service shutter shall be removed. The service shutter shall then be lifted through a chain block and rested in the landing portion of the sluice wall. The existing corroded MS top seal seat shall be ground to get rid of corroded particles. The welded surface shall then be cleaned with grinding machine. New stainless steel plate as required shall be cut to appropriate size and welded after edge preparation suitably. The top edge shall be taperground for smooth operation. Then, it shall be welded & ground to a neat finish. The existing corroded side seal seat shall be removed. Then, the surface shall be ground to give a smooth finish. Now, new SS side seal – 2 nos shall be cut and edge preparation shall be done. Top edge of the SS side seal shall also be taperground. Then, shall be fitted with existing roller girder and welded with suitable electrodes. The existing corroded roller track shall be removed. Then, the surface shall be ground to give a smooth finish. Now, new SS roller track flat – 2 nos shall be cut and edge preparation shall be done. Top edge of the SS roller track flat shall also be taperground. Then, shall be welded with suitable electrodes. The cost includes cost of materials, labour charges, hire charges for machinery like derrick, chain pulley block, gas cutting equipment, welding plant, erection, civil works wherever necessary etc, cost of conveyance to & fro from site of work, risk allowance, trial operation, warranty for 5 years etc, complete. |
| 38 | Drawing, fabrication, transport and installation of lifting beam for a shutter of size 3100x2740 mm as per approved drawing and specifications as follows. ISMB 300 of length 3100 mm shall be placed parallel to each other but facing away from each other at a distance of 200 mm from each other. 20 mm MS plate of size 380*880 mm shall be welded appropriately to the ISMC 300. 90*90*10 mm MS angle of lengh 380 mm shall be welded connecting the pulley plate and ISMC 300. Rib plate 12 mm thick and of size 300*90 mm shall be welded to improve the strength of the channel ISMC 300. 12 mm MS plate of size 380*500 mm shall be welded at the center . The hook plate of size 900*250 mm shall be made out of 45 mm Ms plate. The hook pin shall be made of 75mm dia with 300mm length confirming to IS 1570. The 12mm thick washer plate shall be provided with ISMC 300 web portion for strengthen at lifting hook pin holes. A Rib plate with 10 mm MS plate of size 300*80 mm shall be provided to avoid deflection of hook pin. Rope pulley of 600 mm ø shall be fabricated along with the pin of 75 mm ø and length 300 mm. Guide rollers shall be 452mm & with a pin of 75mm and 530 mm length. The end plate of the roller pin shall be of 380*500 mm size and 12 mm thick. All steel components are welded as per standard specifications. A trial run shall be conducted as directed by the departmental officers. |
| 39 | All steel members shall be blast cleaned with SA 2 ½ standard and surface shall be applied zinc epoxy primer with 50µ, the finish coat shall be applied over the primer coal tar epoxy with 250 and zinc rich primer and coal tar epoxy shall be applied as per site condition. 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. 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, warranty for 5 years except protective coating, etc., complete as directed by the departmental officers. |
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