New Mangalore Port Trust Tender

SURFACE PREPARATION: The cover concrete shall be chipped and removed up to rear side of the steel bar shall be exposed using the electrically operated c hammer chipping machine and hand chiseling by using water jet for the removal of all loose particles, fungal and marine growth including the cost of all materials, hire charges of compressor, pneumatic tools, hire charges of barge, boat, waterjet and all labour charges etc., complete.

ANCHORING SHEAR CONNECTORS: Providing and fixing the shear connectors (secondary reinforcement), 10 mm dia holes shall be drilled at the required locations as per the drawings. The pilot holes shall be drilled using 10mm dia hammer drill bit. The holes shall be widened using the appropriate drill bit size 16/18 mm dia. Drilling shall be carried out without much of vibration so as not to disturb adjacent concrete. The holes shall be roughened for better bonding. The holes shall be cleaned with good water. The base and hardener of Anchor grout shall be mixed and poured to 2/3 of the depth followed by insertion of the shear connecting rod of 12 mm dia gently in to the prepoured holes. The resin grout material utilized shall be tested in accordance with BS 4551, BS 5080 and B S 2782 respectively. Gaps if any shall be packed with mixed grout. Allow it to set for a minimum of 20 minutes without disturbing including the cost of all materials, hire charges of hammer drilling machine and all consumables cost of 12mm shear connecting rod and all labour charges etc., complete.

New Reinforcement : Providing and fabricating T.M.T steel reinforcement including straightening, cutting, bending, hooking, placing in position, lapping and / or welding wherever required, tying with binding wire and anchoring to the adjoining members wherever necessary complete as per design (laps, hooks and wastage shall not be measured and paid) cost of materials, labour, HOM hire charges of barge, boat, complete as per specifications - TMT bars Fe 550

PROVISION OF SACRIFICIAL ANODE: Providing and fixing the sacrificial anode VProviding and fixing Sacrificial Anode for damaged RCC Member such as slab, beam, column etc Providing and fixing zinc alloy based galvanic disk type sacrificial anodes (50 mm dia, 18 mm thick) to the reinforcement and pass 500 hours salt spray test as per ASTM B 117, The anode shall be connected to the reinforcement steel by connectors provided with the anode. as per the manufacturer specification, before fixing, the location to be selected by using the Half Cell Potential meter test, checking the probability of corrosion, checking of conductivity of the rebars by using the multimeter, Tie up the sacrificial zinc anode at the prescribed spacing of 1.00 m C/c after marking the positions of each unit on the steel reinforcement, including cost of all materials, labours and machineries etc. complete.

PROVISION OF ANTICORROSIVE TREATMENT TO THE OLD AND NEW REINFORCEMENT: Anticorrosive coating to the reinforcement: Consist of providing and Applying zinc Primer two coats for the Re bars, primer shall be an epoxy based, two component, zinc rich liquid packed and supplied ready to use confirming to IS14589:1999 (Reaffirmed 2004). An unbroken 40 microns dft/coat coating shall be capable of providing active galvanic protection and avoiding the generation of incipient anodes in the immediately adjacent locations. It shall be of suitable viscosity to enable the coating to penetrate into imperfections and pits within the surface of the structural steel, strictly following the manufacturers instruction. Cost of all materials, tools and labour cost etc., complete.

KSRRBM 2800-11. Epoxy bonding of new concrete to old concrete including cost of materials, labour, HOM complete as per specifications. MORTH Specification No. 2805

MICRO CONCRETE FOR 75 TO 100 MM THICK: Providing and laying Micro Concrete, polycrete - A or equivalent shall be stocked along with 12 mm downgraded chips at site to enable completion of pouring in a continuous operation. An approved grout concrete mixer of slow speed heavy duty drill shall be used for the mixing of the micro concrete. Exact quantity of water as directed by the department should be poured in to mixing vessel along with the polycrete or equivalent and 12 mm cleaned chips (in the ratio of 1:0.50 or 0.75) slowly. The mix shall be mixed thoroughly in forced action. The mixed material should be placed immediately in the formwork continuously without any gap through the PVC pipe fixed from the top of the deck. The cost inclusive of, providing and fabricating, fixing and removing Slurry tight formwork for facilitating micro-concreting work using water-proof plywood/ steel shuttering/ FRP sheets which should not deform or leak due to pressure of micro concrete shall be fabricated and erected in position. Provision shall be made for pouring micro concrete in to the form work, which shall be coated with mould release agent. Proper supporting arrangement shall be made for keeping the shutter in correct line and length Cost inclusive of sufficient Nos of Core cutting of minimum required diameter size of existing structure on the concrete surface for Pouring Micro concrete by trimmie method for the Slab areas. Cost inclusive of approved type and make pre-fabricated access and working platform, fabricated, as per site requirement for successfull completion of work. The cost of all materials, cost of hire charges barges, pontoon, boat, all machineries diving equipment and all labour charges including divers etc., complete.

MEMBRANE CURING AGENT: SELF CURING COMPOUND FOR CONCRETE SURFACE : (WATER/ WAX BASED) Providing & applying water based (WB) / wax based low viscosity wax emulsion curing compound membrane / layer applied in the form of spray over the concrete surface. The material consists of self curing compound membrane satisfying ASTM C309-90 standard ensuring a non penetrating continuous film on the concrete surface covering an area of 4.5 to 5 sqm per ltr of curing compound and shall be applied with a distance of 45 cms after 5 hours of concreting to get the best results.

High performance Anti carbonation protective coating Providing and applying primer and two coats of 100% acrylic breathable, water based, anti-carbonation coating. Coating to be applied at the rate 300 g/m2. Minimum OFT of coating to be 225 micron. The coating shall have atleast a 4 year track record of use as an anti-carbonation coating and shall have the test reports evaluated from Ministry of New and renewable Resources supported laboratory demonstrating Solar Reflectance Index (ASTM E 1980-11, EN 673:2011, EN 410:2011) 104.1. Carbon dioxide diffusion equivalent air layer thickness (DIN EN 1062-6) 100m 2. Carbon dioxide diffusion resistance co-efficient (DIN EN 1062-6) 7.50X105 3. Elongation of cured film shall be as per ASTM D 2310/98 400% 4. Chloride Ion Diffusion(ASTM C 1202) =Zero Penetration 5. Adhesion (ASTM D 4541) 2 N/mm2

KSRRB M2800-1 0. Applying pre-packed cement based polymer mortar of strength 45 Mpa at 28 days for replacement of spalled concrete including cost of materials, labour, HOM complete as per specifications. MORTH Specification No. 2800

CORROSION MONITORING BOX: Supplying and fixing of monitor box as per specification to monitor corrosion in selected members of the structure in desired locations, and as directed including cost of all equipment, plants, cost of materials, instrumentation, cost of boat hiring, catamaran, Pontoon, labour, transport and fuel, etc. Complete and as direct by the Engineer-in-charge.

PRECAST DECK SLAB: Providing and laying cement concrete M40 using 20mm and down size granite coarse aggregates and fine aggregates of ready mixed concrete for RCC works laid in 15 em thick layers and well compacted including vibrating curing etc., for all super structure works with all lead and lift, Including cost of Lfting and placing of slabs in position, cost of centring and suttering, etc., complete. (excluing cost of steel and fabrication charges)

KSRRB M2800-1. Removal of existing cement concrete wearing coat including its disposal complete as per Technical Specification without causing any detrimental effect to any part of the bridge structure and removal of dismantled material with all lifts and lead including cost of materials, labour, HOM complete as per specifications. MORTH Specification No.2809

KSRRB M200-12.3. Dismantling of existing structures like culverts, bridges, retaining walls and other structure comprising of masonry, cement concrete, wood work, steel work, including T&P and scaffolding wherever necessary, sorting the dismantled material, disposal of unserviceable material and stacking the serviceable material with all lifts complete as per specifications. - Prestressed I Reinforced cement concrete grade M-20 above. Deck Slabs

WEARING COURSE OVER BERTH SURFACE : Providing and laying cement concrete using 20mm and down size granite coarse aggregates and fine aggregates of ready mixed concrete for RCC works laid in 15 em thick layers and well compacted including vibrating curing etc., for all super structure works with all lead and lift etc., complete. (exculsive of cost of steel and fabrication charges) Note : The RMC should be obtained only from the plants certified by Quality Council of India as per CE, C&B letter, AE2, 2015-16, Dt. 12-09-2015 - Ready mixed Cement concrete M-35

Part B RCC Pile

REMOVING OF PILE LINER: The pile liner shall be removed using the gas cutting equipment/ electrically operated cutting grinder to expose the concrete surface to continue the rehabilitation works. including cost of stacking of removed pile liners at designalted place, cost of all materials, hire charges barge/ pontoon, boat, underwater cutting tool and all consumables and all labour charges etc., Complete.

PRESURVEY: Carrying out pre- survey by taking Half Cell & UPV potential meter reading, in selected piles (at least 4Nos in each selected structural component) in 5 sequence all as per the relevant specifications. The rate including instrumentation, hiring of cost of boat, survey, equipment, labour and, etc. complete and as directed by the Eingineer-in-Charge.

POST SURVEY: Carrying out Post- survey by taking Half Cell & UPV potential meter reading, in selected piles (at least 4Nos in each selected structural component) in 5 sequence all as per the relevant specifications. The rate including instrumentation, hiring of cost of boat, survey, equipment, labour and, etc. complete and as directed by the Eingineer-in-Charge.

SURFACE PREPARATION: The cover concrete shall be chipped and removed up to rear side of the steel bar shall be exposed using the electrically operated c hammer chipping machine and hand chiseling by using water jet for the removal of all loose particles, fungal and marine growth including the cost of all materials, hire charges of compressor, pneumatic tools, hire charges of barge, boat, waterjet and all labour charges etc., complete.

ANCHORING SHEAR CONNECTORS: Providing and fixing the shear connectors (secondary reinforcement), 10 mm dia holes shall be drilled at the required locations as per the drawings. The pilot holes shall be drilled using 10mm dia hammer drill bit. The holes shall be widened using the appropriate drill bit size 16/18 mm dia. Drilling shall be carried out without much of vibration so as not to disturb adjacent concrete. The holes shall be roughened for better bonding. The holes shall be cleaned with good water. The base and hardener of Polyester resin Anchor grout shall be mixed and poured to 2/3 of the depth followed by insertion of the shear connecting rod of 12 mm dia gently in to the prepoured holes. The resin grout material utilized shall be tested in accordance with BS 4551, BS 5080 and BS 2782 respectively. Gaps if any shall be packed with mixed grout. Allow it to set for a minimum of 20 minutes without disturbing including the cost of all materials, hire charges of hammer drilling machine and all consumables and all labour charges etc., complete including cost of 12mm connecting rod

New Reinforcement : Providing and fabricating T.M.T steel reinforcement including straightening, cutting, bending, hooking, placing in position, lapping and / or welding wherever required, tying with binding wire and anchoring to the adjoining members wherever necessary complete as per design (laps, hooks and wastage shall not be measured and paid) cost of materials, labour, HOM hire charges of barge, boat, complete as per specifications - TMT bars Fe 550

PROVISION OF SACRIFICIAL ANODE: Providing and fixing the sacrificial anode VProviding and fixing Sacrificial Anode for damaged RCC Member such as slab, beam, column etc Providing and fixing zinc alloy based galvanic disk type sacrificial anodes (50 mm dia, 18 mm thick) to the reinforcement and pass 500 hours salt spray test as per ASTM B 117, The anode shall be connected to the reinforcement steel by connectors provided with the anode. as per the manufacturer specification, before fixing, the location to be selected by using the Half Cell Potential meter test, checking the probability of corrosion, checking of conductivity of the rebars by using the multimeter, Tie up the sacrificial zinc anode at the prescribed spacing of 1.00 m C/c after marking the positions of each unit on the steel reinforcement, including cost of all materials, labours and machineries etc. complete.

PROVISION OF ANTICORROSIVE TREATMENT TO THE OLD AND NEW REINFORCEMENT: Anticorrosive coating to the reinforcement: Consist of providing and Applying zinc Primer two coats to the Re bars, primer shall be an epoxy based, two component, liquid packed and supplied ready to use. An unbroken 40 microns dft/coat coating shall be capable of providing active galvanic protection and avoiding the generation of incipient anodes in the immediately adjacent locations. It shall be of suitable viscosity to enable the coating to penetrate into imperfections and pits within the surface of the structural steel, strictly following the manufacturers instruction. Cost of all materials, tools and labour cost etc., complete.

PROVISION EPOXY BONDING AGENT: KSRRBM 2800-11. Epoxy bonding of new concrete to old concrete including cost of materials, labour, HOM complete as per specifications. MORTH Specification No. 2805

UNDER WATER MICRO CONCRETE: Providing and laying underwater micro concrete polycrete or equivalent and 12 mm downgraded chips shall be stocked at site to enable completion of pouring in a continuous operation. An approved grout concrete mixer of slow speed heavy duty drill shall be used for mixing. Exact quantity of water as directed by the department should be poured in to mixing vessel andpolycrete or equivalent and cleaned chips shall be mixed slowly and thoroughly in forced action. The mixed material should be placed immediately to positioned form work continuously without any gap through the PVC pipe fixed from the top of the deck to the concrete location. The cost inclusive of providing, fabricating, fixing and removing Slurry tight formwork for facilitating micro-concreting work using water-proof plywood/ steel shuttering/ FRP sheets which should not deform or leak due to pressure of micro concrete shall be fabricated and erected in position. Provision shall be made for pouring micro concrete in to the form work, which shall be coated with mould release agent. Proper supporting arrangement shall be made for keeping the shutter in correct line and length. The cost of approved type and make pre-fabricated access and working platform, fabricated as per site requirement for successful completion of work. The cost of all materials, cost of hire charges barges, pontoon, boat, all machineries diving equipment and all labour charges including divers etc., complete.

MEMBRANE CURING AGENT: SELF CURING COMPOUND FOR CONCRETE SURFACE : (WATER/ WAX BASED) Providing & applying water based (WB) / wax based low viscosity wax emulsion curing compound membrane / layer applied in the form of spray over the concrete surface. The material consists of self curing compound membrane satisfying ASTM C309-90 standard ensuring a non penetrating continuous film on the concrete surface covering an area of 4.5 to 5 sqm per ltr of curing compound and shall be applied with a distance of 45 cms after 5 hours of concreting to get the best results.

High performance Anti carbonation protective coating Providing and applying primer and two coats of 100% acrylic breathable, water based, anti-carbonation coating. Coating to be applied at the rate 300 g/m2. Minimum OFT of coating to be 225 micron. The coating shall have atleast a 4 year track record of use as an anti-carbonation coating and shall have the test reports evaluated from Ministry of New and renewable Resources supported laboratory demonstrating Solar Reflectance Index (ASTM E 1980-11, EN 673:2011, EN 410:2011) 104. 1. Carbon dioxide diffusion equivalent air layer thickness (DIN EN 1062-6) 100m 2. Carbon dioxide diffusion resistance co-efficient (DIN EN 1062-6) 7.50X105 3. Elongation of cured film shall be as per ASTM D 2310/98 400% 4. Chloride Ion Diffusion(ASTM C 1202) =Zero Penetration 5. Adhesion (ASTM D 4541) 2 N/mm2

CORROSION MONITORING BOX: Supplying and fixing of monitor box as per specification to monitor corrosion in selected members of the structure in desired locations, and as directed including cost of all equipment, plants, cost of materials, instrumentation, cost of boat hiring, catamaran, Pontoon, labour, transport and fuel, etc. Complete and as direct by the Engineer-in-charge.

CORE DRILLING: Core cutting of minimum required diameter size of existing structure on the concrete surface for Pouring Micro concrete by trimmie method for the Piles and Slab areas, the rate shall include cost of equipment, plants, materials, sand, instrumentation, etc. complete.

Credit for taking away dismantled items (amount shall be deducted from contractor's bill)

Credit for taking away removed MS linner, rate incusive of loading, wighment, transporation, disposal of debris, cost of labour, hire charges of machineries etc. complete