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| Sl. No. | Item Description |
| 1 | Slice IDrawing, fabrication, transport, Supply & installation of the new river sluice service gate as per the following specification for replacement of existing river sluice service gate. The existing service gate is totally corroded and hence leaking & not properly operable. Therefore, the platform around the river sluice service gate shall be dismantled from its position and safely stacked and re erection with new service gate.The new river sluice service gate shall be of size 2200x1980mm. The skin plate shall be of 16mm thick and vertical and horizontal stiffeners shall be provided ISMB 300. End verticals shall be provided with 20mm ms plate. The seal seat and cover shall be 10mm thick. The side & top rubber seal shall be provided with ‘P’ type seal of size 100x44x14. Fabrication and supply of cast steel roller assembly for service gates as per the following specification. cast roller wheels with stock allowance for machining shall be manufactured as per IS 2707 : grade 1 material. Roller wheels of size 355mm dia with bearing and retainers shall be machined as per approved drawing. The required tolerance shall be provided for wheel to fix the bearing & retainers. Spherical roller bearing of appropriate size and quality manufactured by reputed firm shall be used in the roller assembly. M10.5 drilling & M12 tapping shall be done in the wheel after machining. The retainer shall be drilled to M13.5 size for fastening to the wheel. The roller pin shall be made of a material conforming to IS 1570-30cr13 grade. The roller pin shall be machined as per the approved drawing. The bearing, retainer plates, pin and oil seals shall be assembled together with the roller . 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 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 , complete as directed by the departmental officers including warranty and maintenance for 5 years |
| 2 | 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 masonary 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 masonary 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, necessary scaffolding arrangements hire charges for machinery like derrick, chain pulley block, gas cutting equipment, welding plant, erection, etc, cost of conveyance to & fro from site of work, risk allowance, trial operation, complete. including maintenance for 5 years |
| 3 | Repair and Replacement of suspension channel in river 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 system of 10mm plate of size 200x250mm using bolts & nuts. 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, etc, complete . including maintenance for 5 years |
| 4 | Replacement of existing river sluice worm hoist bed & motor bed arrangements as per the following specification. The existing worm gear hoist assembly shall be dismantled from its position and safety stacked for reuse. The existing deeply corroded hoist bed shall be cut with gas cutting, removed and transferred to the scrap yard. A new hoist bed arrangements shall be provided with ISMC 300 channel placed back to back at a distance of 300mm from each other. Then 10mm MS plate shall be welded at the top & bottom of the appropriate length. This new hoist bed arrangements shall be welded to an appropriate location to accommodate the worm hoist and motor. Holes shall be drilled to match that of the ones in the worm gear & motor and fixed with MS bolts & nuts as directed by the departmental officers. 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 motor and accessories, spares, consumables such as oil, grease, paint, fasteners, etc., process charges like cutting, welding, machining, etc, labour charges for dismantling loading, lifting, unloading, scaffolding charges, hire charges for equipment like generator, welding & cutting set, etc, conveyance of men & machinery to & fro from site of work & back, risk allowance for working at a height of more than 3m, cost of trial operation, etc., complete. including maintenance for 5 years. |
| 5 | 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. including maintenance for 5 years. |
| 6 | Overhauling of existing hoisting arrangements for the shutter as per the following specification. The existing hoist covers shall be opened up and stored separately for reuse. The top cover of plummer blocks connecting the existing transmission shafts shall be opened and old grease shall be removed. 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 rope drum or the chain & chain sprocket mechanism in the hoisting system shall be manually cleaned of dried grease and dirt and appropriate lubricant shall be applied. The whole arrangements shall be tested & passed after a set of trial operation. The cost includes cost of inspection, spares, lubricants, transport charges, charges for dismantling & erection, including maintenance for 5 years etc, complete. |
| 7 | Repair, overhauling & refixing of the Double axis movement double grider crane in lower nirar tunnel entry as per the following specification. The crane has two parallel girders rigidly connected to the end carriages at a distance of 11300mm c/c and spanning the gantry of span 5600mm. The lifting unit is built on to a traversing crab overslung from the beams. The crab is of size 3200x3200mm. 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 totally dismantled & 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, including mainteance for 5 years etc., complete. |
| 8 | Repair & Realignment of existing grooves of spillway vertical gate and overhauling of existing spillway hoisting arrangements for the shutter of size 12450x7500mm as per the following specification. The existing hoist covers shall be opened up for inspection of hoisting components. The top cover of plummer blocks connecting the existing transmission shafts shall be opened and old grease shall be removed. 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 using a water jet machine. 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 rope drum or the chain & chain sprocket mechanism in the hoisting system shall be manually cleaned of dried grease and dirt and appropriate lubricant shall be applied. The existing grooves are misaligned preventing the smooth movement of shutter throughout 50’ height of shutter. Therefore, the existing grooves shall be realigned properly i.e to proper vertically and dimensions, so as the movement throughout the 50’ height is smooth & trouble free. In the process, concrete breaker shall be used for dismantling the masonary. Scaffolding shall be erected throughout the depth for safety & efficacy of the operation. A winch shall be employed to traverse the height of the grooves for inspection & execution. Proper safety equipment may be used to avoid accidents likely to occur at depth of 50’.The broken part of grooves of masonary shall be plastered to standards. A trial operation shall be conducted the shutter could be operated in the grooves. In case of obstruction, again the whole process shall be repeated until the operation is smooth & easy. The whole arrangements shall be tested & passed after a set of trial operation. The cost includes cost of lubricants like gear oil, lithium based grease, servo coats, hire charges for machinery like welding machine, grinding machine, gas cutting plant, corecut machine, hire charges for equipments like chain pulley charges for inspection, labour charges for dismantling erection, overhauling, loading, unloading etc., complete. including maintenance for 5 years |
| 9 | Drawing, fabrication, transport, Supply & installation of emergency shutter of size 2495x2020mm as per the following specification. The skin plate shall be made of 16mm thick MS plate, horizontal girder and vertical stiffeners shall be made with ISMC 400. The end verticals shall be made of ISMC 400. The wheels shall be made of cast steel of 335mm 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 12mm 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. 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 & maintenance for 5 years etc., complete as directed by the departmental officers. |
| 10 | Drawing, fabrication, transport, supply and installation of new Tunnel entry service shutter of shutter size 3710x3860mm for the Lower Nirar tunnel entry to replace the existing old corroded shutter as per drawing confirming to IS 4622. The skin plate shall be made of 20mm thick confirming to IS 2062. The end vertical shall be made of 20mm Ms plates and horizontal girders shall be made of ISMB 300 with confirming to IS 2062. The existing cast steel wheels assembly shall be serviced and reassembled to the new gate. The side & top rubber seal shall be provided with P type seal of size 100x44x14. Blast cleaning to SA 2 1/2 standard over which epoxy primer to a thickness of 50 µ and final coat of coal tar epoxy of 250µ shall be applied as per IS 14177-1994. The cost includes cost of materials, cost of consumables like welding rods, grinding wheels, oxygen & acetylene gas, oil & diesel for generator,paint, primer, process charges like gas cutting & welding, drilling, hire charges for machinery like gas cutting plant, welding equipment, magnetic drilling machine, generator, grinding machine, compressor, airless spray machine, hoisting equipments like chain pulley block, derrick post, labour charges for loading, lifting, unloading, transport erection, scaffolding, conveyance to site and clearing them after completion of work, warranty & maintenance for 5 years except protective coatings and rubber seals, etc., complete and as directed by the departmental officers. |
| 11 | Modification of existing gantry crane for lateral movement /cross travel movement in the tunnel entry emergency shutter of size 3710x3860mm. The tunnel entry in the Lower nirar tunnel , 2 vents is one adjacent to the other. The emergency shutters to be operated in the tunnel entry is at a depth of 50’ from ground level. They have to be operated by lateral / cross in case of repair /maintenance. However, the gantry crane, at present, has to be moved manually to reach different shutters. This strenuous manual effort is not safe during emergency and urgently procuring scarce manpower for lateral movement / cross movement is difficult. Therefore, the lateral movement / cross travel movement shall be made possible by motorising & modification by introducting a gear system in the existing gantry crane as per the following specification. The drive shaft is of dia 50mm and appropriate length presently. This drive shaft shall be cut into two at the centre to accommodate a pair of spur gears made as per IS 1030. The gears shall be made of cast steel Gr 27-54/EN9. Suitable plummer block with bearing and sleeve shall be introduced on either side of the spur gear. The spur gear shall be connected with a existing shaft of dia 50mm to a worm reducer UD 500 with ratio 100:1. This worm reducer, in turn shall be connected through a flexible coupling to a 3 HP motor squirrel cage induction motor with 960RPM Class E insulation, 400-440V, as per IS 325. The motor shall be of double end type totally enclosed & fan cooled and the other end of the motor shall be connected to a EM brake of 150mm dia with a maximum braking torque 5.6kgm. The EM brake in turn shall be connected to a manual operating chain wheel through dog clutch & plummer blocks. A pendent switch arrangements shall be provided to operate the crane effortlessly. Necessary dust proof cover arrangements shall be provided for these equipments. The new motor shall be provided with suitable electrical connection. The equipments shall be mounted on the existing frame work and they may be modified as per the load & movement. All these equipments shall be procured from the market, transported to site, necessary modification in the supporting structural framework made and then shall be assembled at site. All new steel support structure shall be painted as directed by the departmental officers. The gantry crane shall be conducted with a trial operation. The cost includes cost of motor and accessories, spares, consumables such as oil, grease, paint, fasteners, etc., process charges like cutting, welding, casting, grooving, machining, etc, labour charges for dismantling loading, lifting, unloading, scaffolding, charges, hire charges for equipment like generator, welding & cutting set, etc, conveyance of men & machinery to & fro from site of work & back, risk allowance for working at a height of more than 3m, cost of trial operation, warranty & maintenance for 5 years etc., complete. |
| 12 | 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 compoiste 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 & maintenance for 5 years, etc., complete as directed by the departmental officers. |
| 13 | Repair & Replacing the existing electromagnetic brake of 200mm Ø in the gantry crane as per the following specification. The existing electrical wiring shall be disconnected. The motor shall be removed from its bed after dismantling the flexible coupling and if necessary the rear side shaft shall be extended for EM brake fixing. Then installed in the bed channel taking care of the alignment with the EM brake. The flexible coupling in the existing shaft shall be fitted up again. The electrical wiring shall then be connected & energised. Testing shall be done at no load and then shall be gradually loaded to ascertain the capacity & efficiency. The 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 Electromagnetic device has a central shaft which also has a drum with brake lining in the inner side the central shafts on either side, beyond the brake, ending in a flexible coupling on both ends. The other side of the flexible coupling is connected to a worm reducer on one end and to a motor on the other end. The cost includes cost of materials, consumables, assembly of EM brake and synchronising it to the existing system, cost of flexible couplings, rent charges for welding machine, cutting, drilling & grinding machine, generator, hoist & pulley etc, complete as directed by the departmental officers. including maintenance for 5 years |
| 14 | 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 3/4\\" pitch. The chain for sprocket shall be of 3/4\\" pitch with required length. 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 & from , etc.complete. |
| 15 | Providing counterweight arrangements as per the following specification & size. The counterweight shall be made with MS heavy plates of size 32mm for base plate, 25mm for side walls and 25mm for inside stiffeners. The top cover plate shall be 16mm thick. The plates shall be welded in sequence appropriately with skilled welders. 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 a good welding equipment and a trained welder. All non – metallic substances shall be removed in the weld joints before commencement of welding. The box is volumetrically divided into 5 compartments with 32mm inside cross stiffeners. The inner surface of the counter weight, which would be inaccessible on erection, shall be applied with metallising to a thickness of 150µ. The space 360x140x1000mm – 4 nos on each side at both ends of the counterweight shall filled up with concrete. To avoid corrosion, concrete blocks of approximate size 280x150x150mm shall be neatly stacked inside the counterweight in the middle portion. The concrete blocks are stacked one over the other in 6 rows. Lifting plates of size 32x300x1310mm are welded in the inside of the box from the bottom, on both corners of the box. 45mm dia holes are drilled in the plates for locking of chain & locking of counterweight while carrying out repairs in the shutter. A Groove guide shall be welded to either sides of the box, one at top & one at bottom. This serves as guides to the counterweight arrangement while moving up & down. Steel scaffolding is done upto a height of 15m to install the counterweight arrangements. Mobile crane shall be used to handle the box during installation of the counterweight arrangements. The cost includes cost of materials, labour charges for fabrication and erection, hire charges for hydra crane, Telescopic crane , winch, chain block, generator, paint , primer machinery & tools, consumables such as oil, diesel & lubricants, scaffolding/temporary platforms, risk allowance, transport, etc, complete, with warranty and maintenance for 5 years. |
| 16 | Design, drawing, fabrication, transport supply & installation of an 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. 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 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,paint,primer, 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, scaffolding charges , risk allowance for working at a hazardous location at a height of 30m, warranty & maintenance for 5 years etc., complete. |
| 17 | Design, drawing, fabrication, transport supply & installation of a 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. 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, scaffolding charges , risk allowance for working at a hazardous location at a height of 30m, warranty & maintenance for 5 years etc., complete. |
| 18 | Repair & Renewal of the existing deckbridge as per the following specification. The existing deck bridge is heavily rusted and needs strengthening to extend its life and also safe movement of personnel & equipments. MS plates / structurals are cut to required size and welded to appropriate location which have to be strengthened. 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 a good welding equipment and a trained welder. All non – metallic substances shall be removed in the weld joints before commencement of welding. The beam & channels is bottom of deckbridge shall be inspected and the joints shall be cleaned with wire brush to eliminate rust & dust and then welded wherever necessary. 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, complete as directed by the departmental officers. |
| 19 | Repair 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 M16. 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. |
| 20 | Replacement of existing pipe seal at the sides with rubber seals in both the sides of the vertical lift geared shutter of size 12450x7560mm as per following specification. The existing pipe seals in the upstream face of the pier is affected by metal to metal contact, (i.e) G.I pipe & MS angle. Since all GI pipes used as side seals are rusted and worn-out the pipe seal shall be removed from the sides of skin plate after removal of the clamps by gascutting equipment. The skin plate surface shall be neatly cleaned on either side by grinding. Side seal base shall be made of 80x10mm Ms flat and seal seat cover shall be made of MS flats 50x10mm. They are tag welded together for matching and 12mm holes shall be drilled with a centre to centre distance of 100mm. The inside surface of the seal base and seal seat cover shall be given a coat of anticorrosive zinc rich primer overwhich two coats of industrial black paint shall be applied before welding to the skin plate. Then they shall be parted from each other after matching. Now, side seal base shall be run welded to the sides of the skin plate at appropriate place throughout the height of the 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 seal base flat & seal seal cover. SS bolts 80x12mm shall be used to fasten them to the seal base flat.SS flat 75x8mm fixed over groove channel to act as side seal flat to reduce the friction is 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, etc., complete and as directed by departmental officers. |
| 21 | Replacement of Musical note rubber seal as per IS 11855:2004 at top & bottom and sides 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 seal seat 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. |
| 22 | Providing new safety ladder arrangements from the floor level to the gantry crane operating platform as per the following specification. The ladder shall be of appropriate height the floor level to the top of gantry crane operating platform. The main stiles at both ends shall be 600mm apart and made up of 100x50mm MS channels. They shall be connected in between with treads of size 600x230mm. The tread outer frame shall be made of 35x35x5mm MS angles and composite chequered plate of 6mm thickness shall be fastened to the top of the tread frame. This tread shall be welded to the stiles on either side. The treads shall be spaced onebelow the other at a distance 250mm from each other. Handrails shall be provided with 1\\" GI Pipe. Verticals for handrails shall be made of 75x75x6mm Ms angle fixed to the 100x50mm Ms Channel and spaced at 1000mm apart. 1\\" holes shall be drilled at two appropriate places in the vertical to accomdate 1\\" GI pipe for Handrail. The whole ladder shall be supported from the rear with 75x40MS Channel from the concrete columns. The bottom of the ladder shall be buried in ground. The top of the ladder shall be welded to the operating platform. All members shall be given a coat of mastic primer over which two coats of polyurethane aluminium paint shall be given. The cost includes cost of all materials, paint, primer process charges like gas cutting, welding, machining, scaffolding charges, labour charges for dismantling, loading, lifting, unloading, transport, erection, labour charges for equipments like winch arrangements, power charges from generator, risk allowance for working at a depth of more than 3m, conveyance to site and clearing them after completion of work, etc., complete and as directed by the departmental officers. |
| 23 | Fabrication, supply and installation of Chain hoist cover by using composite panels of thickness 3mm made as a single unit as per the drawing. The composite cover shall be spaced in such a way to resist bending with inherent stiffeners provided. A lifting handle in steel material shall also be incorporated. UV resistant polyester polymer and high grade reinforcement shall be used for fabricating composite rope drum enclosure. The composite material made of glass fibre reinforced polymer shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties. The cost includes cost of mould, pattern and fixtures, cost of raw material like UV stabilized polymers, multi directional glass fiber reinforcements, hardeners, UV stabilized pigment & fumed silica powders, cost of consumables like rollers, brushes, gloves, sanding sheet, 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, conveyance to site and clearing them after completion of work, including cost of trial operation, including warranty for 5 years, etc., complete as directed by the departmental officers. |
| 24 | Fabrication, supply and installation for centre hoist cover by using composite panels of thickness 3mm made as a single unit as per the drawing. The composite cover shall be spaced in such a way to resist bending with inherent stiffeners provided. A lifting handle in steel/composite material shall also be incorporated. UV resistant polyester polymer and high grade reinforcement shall be used for fabricating composite rope drum enclosure. The composite material made of glass fibre reinforced polymer shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties. The cost includes cost of mould, pattern and fixtures, cost of raw material like UV stabilized polymers, multi directional glass fiber reinforcements, hardeners, UV stabilized pigment & fumed silica powders, cost of consumables like rollers, brushes, gloves, sanding sheet, 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, conveyance to site and clearing them after completion of work, including cost of trial operation, including warranty for 5 years, etc., complete as directed by the departmental officers. |
| 25 | 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 appropriate 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. |
| 26 | 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. |
| 27 | 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 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. |
| 28 | 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 airsupply 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, |
| 29 | Repair & realignment of existing grooves for the emergency shutter of size 3545x2990mm as per the following specification. The existing grooves are misaligned preventing the smooth movement of shutter throughout 40ft’ height of shutter. Therefore, the existing grooves shall be realigned properly i.e to proper verticality and dimensions, so as the movement throughout the 40ft height is smooth & trouble free. In the process, concrete breaker shall be used for dismantling the masonary. Scaffolding shall be erected throughout the depth for safety & efficacy of the operation. A winch shall be employed to traverse the height of the groove for inspection & execution. Proper safety equipment may be used to avoid accidents likely to occur at depth of 40ft. The broken part of grooves of masonary shall be plastered to standards. The roller track and side seal tracks shall be inspected of vertically and sizes. Incase of deviation or any defect, the track plates shall be replaced with suitable size. A trial operation shall be conducted in the groove. In case of obstruction, again the whole process shall be repeated until the operation is smooth & easy. 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., complete as directed by the departmental officers. |
| 30 | Drawing, fabrication,Transport, supply & erection of emergency shutter of size 3545x2990mm as per the following specification. The skin plate shall be made of 16mm thick MS plate, horizontal girder and vertical stiffeners shall be made with ISMC 300. The end verticals shall be made of ISMC 300. The wheels shall be made of cast steel of 335mm 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 12mm thick MS plate. Side rubber seals, Top seal & bottom seals shall be of “P” type of size 100x44x14mm. 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. 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. |
| 31 | Repair and Reconditioning of damaged of the rope drum assembly as per the following specifications. The complete rope drum hoist assembly shall be dismantled. The spreader beam, rope in rope drum, gear wheel, and pinion wheel shall be dismantled properly, using by the A frame, arrangement of 5T capacity shall be used to lift the rope drum form the assembly. The transmission shaft and locking plates in the drum shall be removed. The rope drum shall be dismantled and removed form the hoist bed using heavy cranes. Then the Plummer block and bearings shall be opened and check the alignment of the bearings. If any misalignment or damage found, It shall be replaced. The rope drum, gear wheels inner diameter, alignment shall be checked, If found ovality it shall be conveyed to machine shop and it’s shall be machined as per the standard tolerance and provide the new bushes as required size with made of non ferrous material as per the standard. The weak motor shall be replaced with 15 HP, 960RPM squirrel gauge motor. Then all hoist equipment shall be re-erected. The trial operation shall be carried out with spreader beam connection. The cost includes cost of non-ferrous bush, labour charges, hire charges for machinery like A frame assembly, crane, hydraulic press, machining charges, charges for dismantling, assembly and trial operation, etc, complete as directed by the departmental officers. |
| 32 | 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 appropriate diameter as per per existing 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. |
| 33 | Slice IIDismantling of existing old corroded vertical gates from its respective groove portion by the following process. The gates shall be made to rest on the sill portion. The counter weight shall be locked to the deck bridge through pin connecting both sides. Lifting chains shall be released from the shutter by removing the pin from the chains. The shutter shall be cut out into pieces with gas cutting equipment. Then the cut pieces shall be carried from vent portion using a crane and then transported to the department store through trucks and stacked as directed by the departmental officers. The counter weight also shall be removed from the vent portion using a suitable lifting mechanism. The damaged concrete counter weight shall be suspended through a winch after releasing the lock from the deck bridge. The counter weight shall then be lowered to the rest portion. After that both ends of the counter weight in groove portion shall be broken using a heavy duty breaker, the balance centre piece of the counter weight shall be lowered to the sill using a winch . Finally the counter weight balance piece shall be disposed in the upstream side. The cost includes cost of consumables like oxygen gas & LPG, grinding wheels, oil, diesel & lubricants for generator, labour charges for dismantling, lifting, loading, unloading & stacking, hire charges for crane, lorry, machinery like cutting equipment, grinding machine & generator, etc., complete as directed by the Engineer in charge of work. |
| 34 | Replacement of second stage embedded parts like roller track plate, side seal track and sill seat as per the following specification. The roller track is made of 100x15mm MS flat securely welded to the roller track embedded in concrete. This existing roller track shall be removed by grinding and gas cutting operations from the track. Then a SS track plate of size 100x16mm shall be welded with existing roller track appropriately to enable the rollers move vertically on the SS track plate. This would reduce friction to a large extent. The side seal track plate shall be of size 80x8mm made of SS 304 grade. It shall be appropriately welded to the existing angle welded in the upstream side upto 5000mm from sill level. This would facilitate the smooth movement of side seal without friction, while the gate moves up & down. The sill seat shall be made of 80x8mm SS flat of 304 grade. This shall be provided on top of the existing Ms sill beam which is embedded in concrete. This provides an even surface for the bottom seal to land, preventing water from leakage. The existing corroded guide angle shall be removed. The guide base of size 200x100x32 shall be fabricated and the edges shall be finished by grinding. 22mm dia holes shall be drilled at a pitch of 110mm in the guide base. Guide plate of size 25mm thick plate shall be provided in appropriate size. The groove guide shall be fixed in position by marking a center mark in vertical position on the existing guide portion. The holes shall be marked for a pitch of 110mm in vertical intervals of 500mm c/c. The groove guide portion in masonry shall be drilled for 24mm dia and 250mm depth to accommodate the guide base. Anchor rod 20mm dia 300mm length shall be fixed using vinyal ester hybrid mortar chemical. The guide base plate shall be connected to the anchor bolt at the vertical intervals of 500mm. The guide plate of 25mm shall be welded to the center of base plate in vertical position. The straightness shall be ensured using plump level. The cost includes cost of materials, labour charges for dismantling and erection at site, hire charges for machinery like grinding machine, gas cutting equipment, drilling machine, welding plant & generator, rental charges for erection equipments like chain block & crane, cost of consumables such as oil, diesel & lubricants for generator, welding rod, grinding wheel, core cutter bits, oxygen & LPG, incidental charges like conveyance to & fro from site of work, loading & unloading, risk allowance, etc., complete, including warranty and maintenance for 5 years. |
| 35 | Design, drawing, fabrication, supply, erection, testing and commissioning of vertical shutter including skin plate with vertical stiffeners, horizontal fabricated girders, end verticals, rear angle, connecting plates, rib plates, etc, suitable for spillway gate of vent size 7900x3840mm as per IS 4622 . The skin plate, end verticals, vertical stiffeners, horizontal girders, lifting assembly, side seal base plate, side seal cover, bottom seal cover, rear angles shall be made of structural steel confirming to IS 2062 : 2011. The connecting fasteners shall be made of MS confirming to IS 2062. This also includes connection/assembly of lifting arrangements with gate for safe, proper and smooth functioning of gates. All steels structures shall be welded appropriately with skilled workmen. 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 a good welding equipment and a trained welder. All non – metallic substances shall be removed in the weld joints before commencement of welding. The inaccessible areas such us the inside of the end vertical and diaphragm plate shall be applied with metallising to a thickness of 150µ. On fabrication of all components of the shutter, a trial assembly shall be done at the shopfloor to ensure the dimensional accuracy and integration of all sub components. Also, the layout shall be clearly marked & serially numbered by punching. Match drilling in different components and cleats provided wherever necessary to assure minimum tolerance levels. The cost includes cost of MS materials, cost of consumables like welding rods, grinding wheels, drill bits, cut off wheels, oxygen & LPG gas, oil, diesel & lubricant for generator, process charges like gas cutting, welding and drilling, hire charges for machinery like gas cutting plant, welding equipment, corecut machine, generator, electric ovens, grinding machine equipments like chain pulley block, hydra crane, Telescopic crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers including warranty and maintenance for 5 years. |
| 36 | Design, drawing, fabrication and supply of cast steel roller assembly for Spillway gates of size 7900 x 3840 mm as per the following specification. Cast roller wheels with stock allowance for machining shall be manufactured as per IS 2707 : grade 1 material. Roller wheels of size 350mm dia with bearing and retainers shall be machined as per approved drawing. The required tolerance shall be provided for wheel to fix the bearing & retainers. Spherical roller bearing of appropriate size and quality manufactured by a reputed firm shall be used in the roller assembly. M10.5 drilling & M12 tapping shall be done in the wheel after machining. The retainer shall be drilled to M13.5 size for fastening to the wheel. The roller pin shall be made of a corrosion resistant material conforming to IS 1570-30cr13 grade. The roller pin shall be machined as per the approved drawing. The bearing, retainer plates, pin and oil seals shall be assembled together with the roller as directed by the departmental officers. The cost includes cost of materials like steel, fasteners, grease nipple, bearing, retainer plate, roller and pin, process charges like Pattern, Pattern mounting, steel casting, machining, cylindrical grinding, drilling, tapping, case hardening, assembly, cost of oil, diesel & lubricants for generator, conveyance charges, loading & unloading, etc, complete, including warranty and maintenance for 5 years. |
| 37 | Providing bottom rubber seal of the shutter as per the following specification. The skin plate & seal seat cover surface shall be neatly cleaned on either side by grinding. Now, the existing seal seat cover made of 75x10mm 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 75x12mm. 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 M16. 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 as directed by the Engineer in charge of work. |
| 38 | Providing Z type seal as per IS 11855:2004 at sides of the shutters as per the following specification. 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 74x79x16mmshall be placed on the skin plate over which the seal seat cover shall be placed and fastened with 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 as directed by the Engineer in charge of work. |
| 39 | Conducting the following minimum quality tests as per approved QAP at various stages of work to ensure raw materials and its fabrication are free from defects as per industry standards and maintenance of records at all stages for assurance of quality. Raw materials such as hot rolled plates and sectional structures are tested for physical & chemical properties - one random sample for minimum of 40 tonnes of plate/structural weight. Stainless steel seal seat, wheel track plate shall be tested for physical & chemical properties – one sample (Random) for entire lot of any size. Cast rollers are tested to be free from defects by ultrasonic flaw detector 100% in house as per acceptable standard ASME section VIII witnessed by authorized third party agency. Rubber seals are tested in house for physical properties such as Hardness, Elongation, Tensile strength, Tensile test after ageing, water absorption test as per IS 11855 : 2004. All raw materials are 100% dimensional checked and verified in accordance with manufacturer test certificate. In shop welding process, quality of fillet welds are checked visually and using 100% magnetic particle inspection. In site welding , quality of fillet weld is inspected either by 10% dye penetrant or magnetic particle inspection. For butt welds, 100% ultrasonic inspection is done for skin plate joints. Root weld is inspected by 100% dye penetrant test in butt welds. Internal inspection report shall be furnished at all stages of fabrication. Surface protective treatment such as blast cleaning, epoxy primer and coal tar epoxy coating shall be done as per standard norms. Quality of blast cleaning is ensured by cleanliness to SA 2 ½ finish and profile measured using calibrated surface profile gauge before commencement of blast cleaning & coatings. Adhesion of coating is done with cross hatch & X cut test as per ASTM D 3359. Thickness of primer and coal tar epoxy coatings are ensured by coating thickness gauge at random points. All reports and tests shall be furnished to the appropriate authority etc., complete as directed by the Engineer in charge of work. |
| 40 | Drawing, fabricating, supplying and erecting of River sluice and Canal Sluice service gates as per the following specification & drawing. The existing service gate is totally corroded and hence leaking & not properly operable. Therefore, the platform around the service gates shall be dismantled and the suspension channel shall be removed from its position and safely stacked for re erection with new service gate. However care should be taken to paint the existing suspension channel before it is re erected with new service gate. The new service gates shall be of size 2200x1980mm. The skin plate shall be of 16mm thick and vertical and horizontal stiffeners shall be provided ISMB 300. End verticals shall be provided with 20mm ms plate. The seal seat and cover shall be 10mm thick. The side & top rubber seal shall be provided with ‘P’ type seal of size 100x44x14. Fabrication and supply of cast steel roller assembly for service gates as per the following specification. cast roller wheels with stock allowance for machining shall be manufactured as per IS 2707 : grade 1 material. Roller wheels of size 355mm dia with bearing and retainers shall be machined as per approved drawing. The required tolerance shall be provided for wheel to fix the bearing & retainers. Spherical roller bearing of appropriate size and quality manufactured by reputed firm shall be used in the roller assembly. M10.5 drilling & M12 tapping shall be done in the wheel after machining. The retainer shall be drilled to M13.5 size for fastening to the wheel. The roller pin shall be made of a material conforming to IS 1570-30cr13 grade. The roller pin shall be machined as per the approved drawing. The bearing, retainer plates, pin and oil seals shall be assembled together with the roller . 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 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 , complete as directed by the departmental officers including warranty and maintenance for 5 years. |
| 41 | Design,fabricating, supply & erection of hydraulic hoist for lifting of vertical gates. The hydraulic hoists consists of a cylinder with upper and lower cylinder head, piston and stem passing through a packing in the lower cylinder head. The hoists are operated by a motor and oil pump arrangement with the directional control by valves which are actuated by electric contacts from any desired position. Manual operating arrangements shall also be provided along with the hydraulic system. The cost includes cost of materials, labour charges transport, scaffolding, installation and maintenance & warranty for 5 years. |
| 42 | Repairs and Replacement of suspension channel in canal sluice/ River 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. 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, etc, complete. Including maintenance for 5 years |
| 43 | 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 masonary 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 masonary 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, necessary scaffolding arrangements hire charges for machinery like derrick, chain pulley block, gas cutting equipment, welding plant, erection, etc, cost of conveyance to & fro from site of work, risk allowance, trial operation, complete. Including maintenance for 5 years. |
| 44 | 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. Including maintenance for 5 years. |
| 45 | Repair & modification of the existing river sluice worm hoist bed as per the following specifications. The existing worm gear hoist assembly shall be dismantled from its position and safety stacked for reuse. The existing deeply corroded hoist bed shall be cut with gas cutting, removed and transferred to the scrap yard. A new hoist bed arrangements shall be provided with ISMC 300 channel placed back to back at a distance of 300mm from each other. Then 10mm MS plate shall be welded at the top & bottom of the appropriate length. This new hoist bed arrangements shall be welded to an appropriate location to accommodate the worm hoist and motor. Holes shall be drilled to match that of the ones in the worm gear & motor and fixed with MS bolts & nuts. The main member shall be provided with ISMB 300 over the river sluice well top with proper anchorage. The worm hoist bed shall be mount overthe ISMB 300. The platform shall be provided in appropriate size around the worm hoist. 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 motor and accessories, spares, consumables such as oil, grease, paint, fasteners, etc., process charges like cutting, welding, machining, etc, labour charges for dismantling loading, lifting, unloading, scaffolding charges, hire charges for equipment like generator, welding & cutting set, etc, conveyance of men & machinery to & fro from site of work & back, risk allowance for working at a height of more than 3m, cost of trial operation, etc., complete. |
| 46 | Refurbishing of existing emergency shutter as per the following specification. The shutter shall be dismantled from the position from the spreader beam manually and loaded with a crane to a vehicle and shall be transported to factory for repair & service. Repair & overhauling of components of emergency shutter are taken up in the factory as follows. The corroded lifting plate rod shall be cut & replaced with new one for extended life. The spring & valves in the lifting assembly shall be overhauled & directed by the departmental officers. The existing rollers shall be removed and then overhauled. The existing pins & bearing inside the rollers shall be removed & operationalised. The whole shutter shall be given a coat of anticorrosive primer overwhich 2 coats of coaltar epoxy. Then the emergency shutter shall be loaded into a vehicle & transported back to the site as directed by the departmental officers. It shall always be stored flat on the platform to avoid stagnation of rain water in the emergency shutter. 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 as directed by the departmental officers. |
| 47 | Providing new safety ladder arrangements for accessing from spillway vertical gate D/S sill as per the following specification. The main stiles at both ends shall be 450mm 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 welded to shutter bottom flange. The top of the ladder shall be welded to the top of shutter flange. 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, etc, complete as directed by the Engineer in charge of work. |
| 48 | Design, procurement, fabrication & supply, erection/ installation of dogging/latch beam 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 incidental petty civil works etc, complete as directed by the Engineer in charge of work. |
| 49 | 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 & maintenance for 5 years, etc., complete as directed by the departmental officers. |
| 50 | Replacing the existing electromagnetic brake of 200mm Ø in the gantry crane as per the following specification. The existing electrical wiring shall be disconnected. The motor shall be removed from its bed after dismantling the flexible coupling and if necessary the rear side shaft shall be extended for EM brake fixing. Then installed in the bed channel taking care of the alignment with the EM brake. The flexible coupling in the existing shaft shall be fitted up again. The electrical wiring shall then be connected & energised. Testing shall be done at no load and then shall be gradually loaded to ascertain the capacity & efficiency. The 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 Electromagnetic device has a central shaft which also has a drum with brake lining in the inner side the central shafts on either side, beyond the brake, ending in a flexible coupling on both ends. The other side of the flexible coupling is connected to a worm reducer on one end and to a motor on the other end. The cost includes cost of materials, consumables, assembly of EM brake and synchronising it to the existing system, cost of flexible couplings, rent charges for welding machine, cutting, drilling & grinding machine, generator, hoist & pulley etc, complete as directed by the departmental officers. including maintenance for 5 years |
| 51 | Fabrication, supply and installation of motor cover for Hoisting arrangements by using composite panels of thickness 2.5mm made as a single unit as per the drawing. A lifting handle in composite material shall also be incorporated. All surfaces shall be applied with two coats of anticorrosive and UV resistant grade polymer coating. The composite material shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties. The cost include cost of materials, labour charges for fabrication, painting, loading & unloading, transport, etc, complete as directed by the Engineer in charge of work. |
| 52 | Replacement of old damaged starter box for the following specification. The starter to motor old cable shall be replaced with 4 core x 6 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 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 – 2nos, 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 as directed by the Engineer in charge of work. |
| 53 | Replacement of damaged 3.5 core 70s.qmm UG aluminium cable as per the following specification. The old punctured cable shall be removed from its position and new cable from main line to genset room. Necessary clamp & stiffeners shall be provided . Suitable cable lug and glands shall be provided as required at site as directed by the departmental officers. The cost includes cost of materials confirming to IS specifications, labour charges for laying, transport, etc, complete as directed by the Engineer in charge of work. |
| 54 | Replacement of damaged 3.5 core 50s.qmm UG aluminium cable as per the following specification. The old punctured cable shall be removed from its position and new cable from genset room to spillway deck bridge. Necessary clamp & stiffeners shall be provided. Suitable cable lug and glands shall be provided as required at site as directed by the departmental officers. The cost includes cost of materials confirming to IS specifications, labour charges for laying, transport, etc, complete as directed by the Engineer in charge of work. |
| 55 | Replacement of existing punctured incoming cable from busbar panel box and main switch to Gantry starter, providing new DOL starter and pendant switch with required cable. The old punctured cable shall be removed and new 4 core x 25 sqmm armoured aluminium cable shall be provided up to terminal box and 4x6sqmm copper flexible cable shall be provided from terminal box to starter box. The copper flexible cable shall be tagged with real and GI wire. This cable arrangements would enable the cable to move along with gantry crane trolley forward & Reverse movement. The existing damaged starter box shall be removed and replaced with new DOL forward reverse starter. 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, 18 to 25 amps over load thermal relay – 1no, single phase preventer – 1 no, pushbutton for forward, reverse & off, indicators lamps -3 nos, 32A 4 pole MCB -1 no & terminal block -1 no . 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 as directed by the Engineer in charge of work. |
| 56 | 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 appropriate diameter as per per existing 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 as directed by the Engineer in charge of work. |
| 57 | Modification of existing gantry crane for lateral movement movement in the emergency gates of River sluice and canal sluice. The River sluice & canal sluice in the Thirumoorthy dam, 2/3 vents is one adjacent to the other. The emergency shutters to be operated in the River sluice /canal sluice is at a depth of 50’ from ground level. They have to be operated by parallel to the vent for maintenance. However, the gantry crane, at present, has to be moved manually to reach different shutters. This strenuous manual effort is not safe during emergency and urgently procuring scarce manpower for lateral movement shall be difficult. Therefore, the lateral movement shall be made possible by motorising & modification by introducting a gear system in the existing gantry crane as per the following specification. The drive shaft is of dia 50mm and appropriate length presently. This drive shaft shall be cut into two at the centre to accommodate a pair of spur gears made as per IS 1030. The gears shall be made of cast steel Gr 27-54/EN9. Suitable plummer block with bearing and sleeve shall be introduced on either side of the spur gear. The spur gear shall be connected with a existing shaft of dia 50mm to a worm reducer UD 500 with ratio 100:1. This worm reducer, in turn shall be connected through a flexible coupling to a 3 HP motor squirrel cage induction motor with 960RPM Class E insulation, 400-440V, as per IS 325. The motor shall be of double end type totally enclosed & fan cooled and the other end of the motor shall be connected to a EM brake of 150mm dia with a maximum braking torque 5.6kgm. The EM brake in turn shall be connected to a manual operating chain wheel through dog clutch & plummer blocks. A pendent switch arrangements shall be provided to operate the crane effortlessly. Necessary dust proof cover arrangements shall be provided for these equipments. The new motor shall be provided with suitable electrical connection. The equipments shall be mounted on the existing frame work and they may be modified as per the load & movement. All these equipments shall be procured from the market, transported to site, necessary modification in the supporting structural framework made and then shall be assembled at site. All new steel support structure shall be painted as directed by the departmental officers. The gantry crane shall be conducted with a trial operation. The cost includes cost of motor and accessories, spares, consumables such as oil, grease, paint, fasteners, etc., process charges like cutting, welding, casting, grooving, machining, etc, labour charges for dismantling loading, lifting, unloading, scaffolding, charges, hire charges for equipment like generator, welding & cutting set, etc, conveyance of men & machinery to & fro from site of work & back, risk allowance for working at a height of more than 3m, cost of trial operation, warranty for 5 years etc, complete as directed by the Engineer in charge of work. |
| 58 | Repair, overhauling & refixing of the double axis movement double grider crane in river sluice / canal sluice at Thirumoorthy dam as per the following specification. The crane has two parallel girders rigidly connected to the end carriages at a distance of 9870 mm and spanning the gantry of span 7920mm. The crane traverses in the second axis on the floor of the dam over rails for lifiting of emergency shutter. The lifting unit is built on to a traversing crab overslung from the beams. The crab is of size 2600x2300mm. 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 & renewed wherever necessary & refixed as directed by the departmental officers. The hoisting machinery consists of motor, gearbox, rope drum, rope guide and rollers for long travel trolley and crab. The gearing shall be of hardened helical type and motors are of squirrel cage motors. The rope drum shall be 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 are drained & cleaned & retopped. The cost includes cost of all required necessary spares, lubricants, labour charges, charges for dismantling & erection, hire charges for machinery & equipment used during repair warranty for 5 years etc, complete as directed by the Engineer in charge of work. |
| 59 | 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 as directed by the Engineer in charge of work. |
| 60 | 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 as directed by the Engineer in charge of work. |
| 61 | 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 etc, complete as directed by the Engineer in charge of work. |
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