|
| 1 | Repair & Replacement of groove guide in the existing shutter as per the following specification. The existing Rope drum hoist vertical shutter of size 11650x4900mm shall be lifted to the highest position and locked with the dogging beam. The existing guide plate shall be remove stealthily by grinding without damaging the guide base. The end vertical guide assembly in the end vertical of shutter shall also be removed by grinding welded portions. A new guide plate with 32mm MS plate and of size 5000x65mm shall be neatly cut without any cutting notches and ground for smoothness. The guide plate shall be fitted to the existing base plate, verticality verified and then welded to the base plate. The end vertical guide assembly with 50mm plate machined suitably as well ISA 100 guide angles shall be appropriately fitted to the end vertical with M16 bolts & nuts as directed by the departmental officers. The shutter shall now be released and trial operation conducted. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like chainpulley block, welding machine, cutting set, grinding machine, power charges for generator, conveyance to site and clearing them after completion of work, including cost of trial operation, warranty for 5 years except protective coating etc ., complete as directed by the departmental officers. |
| 2 | Repair, overhaul & refixing of the rusted iron wheels from the vertical geared shutter of size 11650x4900mm with gas cutting equipment and reconditioning with phosphor bronze bushes & bearings and refixing to the original condition as per the site requirements. The wheel is of 300mm diameter & moves in the recessed groove of the vertical guide channel. The shutter shall be lifted to a workable height and the channel holding the wheels shall be cut 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 from 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 warranty for 5 years etc., complete and as directed by the departmental officers. |
| 3 | Overhauling of existing hoisting arrangements for the spillway shutter of size 11650 x 4900mm as per the following specification. The existing hoist covers shall be opened up and stored separately for reuse after neatly scrapping the surface and painting with a coat of aluminium paint on both the inside and outside surface. 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. The bearings, if found defective/ corroded, shall be replaced. The intermediate shafts shall also be provided with RH-block for stable, vibration free transmission. Fresh grease shall be applied to the plummer block and top cover and closed with requisite fasteners. The shaft shall be checked for its alignment and redone to ensure straightness of shaft. The existing gear wheels and pinions 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 rope and rope drum mechanism in the hoisting arrangements shall be cleaned of dried grease and dirt &appropriate lubricant shall be applied. The existing motor and gearbox outer surface shall be manually cleaned and a coat of metallic paint applied. The motor and EM brake shall be tested and aligned if need be. Suitable shim plates shall be added to ensure a zero level to eliminate vibration during operation and then installed. The whole arrangements shall be tested & passed after a set of trial operation. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, conveyance to site and clearing them after completion of work, including cost of trial operation, etc., complete as directed by the departmental officers. |
| 4 | Providing additional guide above the top of pier upto 4000mm height as per the following specification. The guide shall be made of 28x40mm MS bar and shall be fixed over ISMB 200 fixed contiguous with the existing groove guide in the groove portion. The joint between the new & existing guide plate shall be made of a bevel joint welded fully. Stiffeners shall be provided at the appropriate location for new extension of guide. The guide assembly shall be supported by providing an the existing support structure . All steel members shall be painted with a coat of anti corrosive primer overwhich aluminium paint is applied. 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. |
| 5 | Repair & service of existing electromagnetic brake of 150mm dia as per the following specification. The electromagnetic brake shall be dismantled from its position after removing the motor. The shoe and the solenoid brake coil shall be tested for its efficacy and if need be, replaced with a new one. The Electromagnetic brake shall be again be tested and then reinstalled along with the motor. A trial operation shall be conducted as directed by the departmental officers. The cost includes cost of materials, labour charges for modification in the position of motor & worm reducer, assembly & reassembly of EM brake and synchronising it to the existing system, cost of flexible couplings, rent charges for welding machine, cutting, drilling & grinding machines, generator etc, complete as directed by the departmental officers. |
| 6 | Repairs and Replacement of bottom rubber seal of the Barrage 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 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 M16x75. The cost includes cost all of materials, labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site, etc., complete and as directed by departmental officers |
| 7 | Replacement of Z type seal as per IS 11855:2004 at 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 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 departmental officers. |
| 8 | Repair & Overhauling of dialgauge as per the following specification. The chain & Chain sprocket shall be dismantled and all components shall be cleaned and verified for any defects. They shall be refixed / welded appropriately. Then the alignment shall be checked by conducting a few trial operation the cost includes cost of spares & consumables, hirecharges for tools & machinery, etc., complete as directed by the departmental officers. |
| 9 | 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 departmental officers. |
| 10 | 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 blast cleaning . The average surface roughness after blast cleaning 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, inspection charges, conveyance of machinery to & fro from site of work, transport charges, scaffolding charges, consumables like oil & diesel for generator, risk allowance, etc, complete as directed by the departmental officers. |
| 11 | 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 /metallising 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, IS : 2339-1963 and IS: 2932-1994. The cost includes cost of primer, thinner, paint, etc, labour charges for application of primer, hire charges for compressor, generator, airless spray, etc, cost of oil & diesel for generator, scaffolding charges, transport charges, conveyance of machinery & tools to and fro from site of work, testing & inspection charges, risk allowance, etc, complete as directed by the departmental officers.. |
| 12 | 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 100-125 µ per coat. The interval before over coating shall be 24 hours. All paint, when applied, shall provide a satisfactory film and a smooth and even surface. Paint shall be thoroughly stirred, strained, and kept at the uniform consistency during application. Paint shall not be applied when the temperature of the metal or surrounding air is below 10 degree Celsius and that of the metal is above 50 degrees Celsius, or when the humidity is above 90 percent, or when it threatens to rain before the painted coat gets dry. Each coat shall be protected during the initial curing period against the possibility of moisture condensation or contamination with foreign matter. All painting works shall be performed by airless spraying. When the coating material is applied by spraying, suitable means shall be provided to prevent segregation during the coating operation. Free oil and moisture shall be removed from the air supply lines of all spraying equipment. Each coat shall be uniform and free from runs, sags and other imperfections. The time between successive coats shall be not less than the minimum nor more than the maximum re-coating time specified by the paint manufacturer. The paint shall be applied so that the thickness at any point is not less than that stipulated in the approved painting specifications. Surface not required to be coated, but adjacent to surfaces which are to be cleaned and coated, shall be adequately protected during cleaning and coating. Repairs to damaged areas of the coating shall be carried out strictly in accordance with the approved painting specifications. Because of the flammable and toxic nature of the coating materials, precautions should be taken to eliminate any health or safety hazard that may arise during the application of the coating. Smoking and welding shall not be allowed within 10 meters of the place when painting is in progress. The painting to the gates, hoists and other parts shall be done as per IS specification No.14177-1994. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) – 1971, IS : 2339-1963 and IS: 2932-1994. The cost includes cost of coaltar epoxy paint, thinner, etc, labour charges for application, hire charges for compressor, generator, airless spray,etc, cost of oil & diesel for generator, scaffolding charges, transport charges, conveyance of machinery & tools to and fro from site of work, testing & inspection charges, risk allowance,etc, complete as directed by the departmental officers. |
| 13 | GST at 18% Please Enable Macros to View BoQ information |
