GENERAL GUIDE LINES FOR PREPARATION OF SCHEDULE OF RATES

8/4/2019 GENERAL GUIDE LINES FOR PREPARATION OF SCHEDULE OF RATES

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GOVERNMENT OF KARANTAKA

WATER RESOURCES DEPARTMENT

GENERAL GUIDE LINES

FOR

PREPARATION OF SCHEDULE OF RATES

( FOR WATER RESOURCE PROJECTS )

PREPARED BY SCHEDULE OF RATES COMMITTEE

JUNE, 2003


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GENERAL GUIDE LINESFOR

PREPARATION OF SCHEDULE OF RATES( FOR WATER RESOURCE PROJECTS )

1. 0 PREAMBLE

1.1 River Valley Projects involve use of large quantities of materials, machinery, labour andother inputs for execution of various component works of the project. Preparation of estimatefor any work requires estimation of quantities and rates for individual items of work. While thequantities are mostly dependant on planning and design requirements, the estimated rates aredependant on the basic rates provided in the schedule of rates and other inputs which are notcovered in the basic rates. The basic rates in the schedule of rates, in turn, depend on thedata assessed / assumed in the data rate analysis for computing the quantities and rates ofvarious materials, machinery, labour and other ancillary / enabling works.

1.2 The rates quoted by the contractors is another important factor that ultimately determinesthe final cost of the work. The rates quoted by the contractors may be less or more comparedto the estimated rates. For the same item the quoted rates generally differ from one agency toanother agency due to each agency adopting his own system or method for computation ofrate for various items of work. Factors other than work inputs may also influence quoted ratesto some extent. A local contractor may quote less compared to a contractor who has tomobilize his machinery and work force from a for-off place. A contractor having surplus / idlemachinery and operating crew may prefer to quote comparatively less to get the work to utilisehis otherwise idle machinery and crew. Thus the rates quoted by the contractors may or maynot be representative of probable cost and as such need not always be considered as anyguiding factors for revising the rates provided in the schedule of rates. This aspect has alsobeen highlighted in the report of the committee on cost control of River Valley Projects

published by Central Water Commission ( CWC ). However, consistently low or high ratequoted by majority of the contractors for any particular item of work certainly suggests theneed for reviewing the standard data adopted for preparing the rate analysis.

1.3 CWC and Bureau of Indian Standards ( BIS) have published standard data for workingout the hire charges of machinery and rate analysis for major items of work used in theconstruction of River Valley Projects for guidance. These guide lines also include theprovisions to be considered judiciously towards the hidden costs on labour, wastage ofmaterials in handling, small T & P, profit and overheads of contractor etc., on percentagebasis. Appropriate percentage provisions for these shall be determined by the Schedule ofRates Committees duly considering the local conditions, nature of work, statutoryrequirements, provisions already included in the wage structure and other relevant features.

1.4 Standard data shall be formulated for each item of work included in the schedule of ratesto facilitate revision of rates each year on the basis of cost escalation or rise in the rates ofmaterials, machinery and labour compared to previous year. Though, no known method ofrate analysis can give exact cost under all operating conditions, a data rate preparedjudiciously duly accounting for all probable direct and in-direct work inputs is expectedto reflect the cost to a close approximation of the final cost.

1.5 Keeping in view the present trends in construction activities / practices being followed forexecution of works / wide disparity in estimated and tendered rates for many major items ofworks the Government of Karnataka set up a Committee under Notification No. ID 5 PAC2000 dated 24th March, 2000 for review of certain issues relating to Irrigation Works including

review and preparation of Data Rates on scientific basis. One of the Terms of Reference is toformulate General Guidelines for the preparation of Schedule of Rates.


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2.0 The following member partcipated in the deliberations of the Committee in meetingsscheduled on various dates.

1. Capt. S. Raja Rao Retd Secretary / GOK : Chairman2. Sri H. V. Eshwaraiah Retd Technical Director / KPCL : Member3. Sri V. H. Patil Retd Engineer-in-chief / GOK : Member4. Sri V. G. Kajagar Retd Chief Engineer / GOK : Member5. Sri R. Chandrashekhar Retd Engineer-in-chief / GOK : Member6. Sri G. A. Meti Retd Chief Engineer,BWSSB : Member7. Dr B. R. Srinivasa Murthy Professor IISc : Member8. Sri C. M. Shirol Controller of State Accounts : Member9. Sri K. K. Malpani Secretary Contractors Association : Member10. Superintending Engineer ( M & E )

WRDO : Member Secretary

2.1 The Committee co-opted Sri B. S. Mallapur, Retd Chief Engineer / KPCL as SpecialInvitee considering his experience in preparation of mechanized data rates for major worksand in addition he was also requested to computerise all the data rates in the form of aComputer Programme to facilitate quick revision of Schedule of Rates.

3.0 On going through the procedure adopted earlier for the preparation of data rates, thecommittee observed that extensive mechanisation and thorough review of Hidden cost onlabour are necessary to set right the deficiencies in the existing procedures for the

preparation of schedule of Rates.

4.0 The Committee during its deliberations on various issues referred for review, collectedand studied procedures / formats being suggested / followed in various agencies such asCWC / BIS/ KPCL / PWD / Other states.

4.1 The Committee also invited and consulted Experts from specialist organisations such asNIRM / School of Mines / Prof. Sastry of KREC, Surathkal / Equipment suppliers / Cementmanufacturers / Concrete admixture manufacturers / Geo-fabric and LDPE sheetmanufacturers / Gate and Hoist manufacturers / Shri Ramakrishnaiah, Design Consultant for

Gates and Hoists / Director Mines and Geology / Officers of State Labour Department onvarious issues related to points referred to the Committee.

5.0 The Committee, duly considering all the information collected on the issues referred to theCommittee and keeping in view the present trends in construction activities and procedures /practices / formats followed / suggested by various organisations / authorities, reviewed theSchedule of Rates for Water Resources Works thoroughly on scientific basis and formulatedthese procedures / guide-lines for preparation of Schedule of Rates for Water Resourcesworks.


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6.0 GENERAL :

6.1 The Schedule of Rates ( SR ) shall essentially consist of basic data such as generalnotes on SR, material rates, wages of workers, hire charges of machinery, lead charges, liftcharges, loading and unloading charges, royalty charges and item rates with supplimentaryinformation for various works. The item rates with supplimentary information for various worksshall be prepared making use of the rates in the basic data to finalise the schedule of ratesfor the year.

6.2 Material constants to be considered in the data rate analysis for any particular work itemcan be determined by computation or by trial studies or from design drawings or on the basisof data published in BIS / CWC / Departmental codes / Guide lines etc. However, in respectof machinery and labour there is scope, to some extent, for choice depending on the natureand extent of work and time within which the work is to be carried out. The data may beextensively labour oriented or machinery oriented or combination of both. In any case the datashall provide for optimum use of the machinery and workforce consisting of skilled, semi-skilled and un-skilled categories.

6.3 The preparation of schedule of rates broadly involves following steps:

a. Fixing unit rates for various construction materials.b. Fixing daily / hourly hire charges of machinery including Fuel ( DPOL ) / Energy

charges and operating crew charges.c. Fixing daily wages for various categories of workers duly ensuring compliance with

minimum wages and other requirements.d. Fixing extent of hidden costs on labour duly considering various statutory provisions.e. Fixing extent of provision for small T & P materials, loss on stock, de-watering, de-

silting, site clearance etc.f. Fixing extent of contractors profit and overheads.

g. Fixing rates for lead, lift, loading and un-loading of materials.h. Assessing quantities of materials per unit quantity of work item including extent of

wastage in handling and requirement for incidentals such as mortar layer, finishingetc., forming part of the item rate.

i. Assessing requirement of various construction plant and machinery in hours / days perunit quantity of work under each item.

j. Assessing extent of skilled / semi-skilled / un-skilled work force required per unitquantity of work under each item.

k. Assessing the extent of enabling works and making provision for these either on costbasis or on percentage basis in the rates.

l. Assessing extent of lump-sum provisions ( for minor work inputs not quantified ) andmaking suitable provisions for the same in the rate analysis in the form of sundries.

m. Preparing general / specific notes on use of rates and data based rate analysis forvarious items included in the Schedule of Rates.

7.0 SCOPE :

The object of these guidelines is to streamline the procedures, provisions, formats and otherrelated matters for the preparation of schedule of rates pertaining to irrigation project works.As the deployment of plant and equipments is becoming more and more common in thesedays even for small works emphasis has been laid on use of plant / equipment in data rateswherever possible. At present, no rates are available in the schedule of rates being used inthe department for gate and hoist works. Based on case studies, standard formats for rateanalysis for gate and hoist works are prepared for inclusion in the schedule of rates.


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8.0 GENERAL NOTES :

The schedule of rates shall include General Notes applicable to all sections in the SR to theextent they are relevant. These notes shall reflect the various provisions already included inthe basic rates and the additional provisions to be included to the basic rates while preparingthe work estimates. These notes shall include the following provisions in general:

1. These general notes are applicable to all sections of Schedule of Rates to the extentthey are relevant.

2. All materials to be used on work shall conform to relevant specifications of Bureau ofIndian Standards.

3. The basic rates, except otherwise specified, are inclusive of initial lead upto 50 m and alllifts. Additional lead, lift, loading and unloading charges, wherever applicable, shall beadded to basic rate as per the procedure stipulated under notes in each section andunder notes to lead, lift, loading and unloading charges. The quantities of materials forworking out lead, lift, loading and unloading charges shall be as per the statement ofrequirement of materials for various items of work included under relevant section.

4. The basic rates are inclusive of cost of all materials including wastage, machinery,labour, small tools and plants, loss on stock, contractors profit, contractors overheads,hidden cost on labour, cost of power supply arrangements, enabling works etc.

5. The basic rates are inclusive of royalty charges payable on materials. The royaltycharges, wherever applicable, shall be recovered as per the statement of royalty chargesunder each section.

6. The basic rates for concrete items are inclusive of standard finishing to surfaces such asrepairing honey-comb patches, uneven surfaces etc., and do not include regularplastering in cement mortar.

7. The cement content indicated for concrete items in the item description is based ontheoretical mix computations. The actual cement content may vary based on trial mixstudies . A suitable clause shall be included in the tender document for the work forregulating payment for any upward or downward variation in cement content.

8. The quantities of materials including wastage and requirement for incidentals for workingout additional lead, loading and unloading charges shall be as per the statement ofrequirement of materials under each section.

9. The basic rates are exclusive of Sales Tax on works contract. Separate provisionshall be made in the work estimate towards sales tax on works contract at the rateprevailing at the time of preparing estimate.

10. The basic rates are exclusive of site clearance, de-watering, de-silting, river diversionarrangements etc., wherever applicable.

11. When the market rates for cement / steel fluctuate from the rates provided in theschedule of rates, the difference in cost of these materials including contractors profitand overheads shall be added or deducted from the basic rate for finished item at thetime of preparing work estimate.

12. The rates as provided in the schedule of rates of other departments of the region may beadopted for the items not found in this schedule of rates.

If there are any other notes of general nature applicable to all sections the same may beadded to the above list of notes.


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9.0 RATES OF MATERIALS:

9.1 Prevailing market rates shall be the criteria for fixing the material rates for inclusion inschedule of rates. Prevailing material rates shall be obtained through quotations or throughlocal inquiries from major commercial centers near the project area. Average of the rates,ignoring freak rates, shall be reckoned as the prevailing market rate for inclusion in theschedule of rates for the year. For cement, steel and explosives the current price list shall beobtained from the leading suppliers and also from bulk consumers like Karnataka Land ArmyCorporation. Unless otherwise specified, all material rates shall be inclusive of all taxes,duties, levies, royalty, transportation and handling costs upto project area. For sand / coarseaggregate / stone the basic rates shall be at quarry and shall include royalty charges. Forearth / soil used for embankment works which is not included in the material list royaltycharges shall be added separately under material component in the data rate analysis. Forgate and hoist works, apart from structural steel, other materials such as alloy steel, bronzealloy, cast steel etc., are required for various component parts. For these materials basicmaterial rate shall be worked out including cost of casting and machining charges.

9.2 The list of materials in the Schedule of Rates shall include all the materials used in thedata rate for work items.

The rates for materials shall be furnished in the following format.

STATEMENT OF RATES OF MATERIALS

Sl No Description of material Unit Rate in Rs

1.2.

3.4.5.6.7.8.

Acetylene gasAsphalt 80 / 100 Grade

Binding wireBurnt stone slab 10 cm thickCement 43 GradeCoarse aggregate 10 4.75 mmCoarse aggregate 20 10 mmCoarse aggregate 40 20 mm. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .

CumKg

KgSqmKgCumCumCum. . . .. . . .. . . .

The following Notes shall be added under statement of rates for materials.

1. The rates provided for materials are inclusive of taxes, duties and other local levies.2. The rates provided for materials are inclusive of royalty charges wherever applicable.3. The rates provided for materials, except those for which lead charges are admissible as per

the statement of lead charges, are for all leads.4. The rates provided for useful rubble and stone chips from excavation are at the dump yard.

If there are any other notes specific to any materials the same shall added to the above list.


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10.0 WAGES OF WORKERS:

Wages of workers to be included in the schedule of rates shall be the prevailing daily rates inthe project area and shall not be less than the minimum wages fixed by the Governmentfrom time to time. Daily wages shall consist of Basic Wage and Living Allowance (variable dearness allowance ) and shall include the wages of 4 weekly holidays in amonth. The basic wages shall be reviewed generally when the minimum wages to be paidare revised by the Government. The living allowance shall be revised every year based onthe state average annual increase in the Consumer Price Index (CPI) for industrial workersover and above the base index notified by the Government at the time of revising theminimum wages. The workers shall be grouped into four categories namely ;

1. Skilled (2) Semi-skilled (3) Un-skilled (4) Other

The wages of workers shall be furnished in the following format in the schedule of rates.

STATEMENT OF WAGES FOR WORKERS

Sl No. Category of worker Basic wage/ day inRs.

Living allowance /day in Rs.

Total wage / dayin Rs.

Zone-I Zone-II Common toZone I & II

Zone-I Zone-II

I.

1.2.

II.

1.2.

III.

1.2.

IV.

1.2.

Skilled category:

Bar benderOperator Shovel

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

Semi-skilled category :

Mason Class IIHelper Shovel. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .

Un-skilled category :

Heavy mazdoorLight mazdoor. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .

Other category :

Graduate EngineerLiterate mazdoor


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The following Notes shall be added under the statement of wages for workers :

1. The wages under Zone-I are applicable to: Bangalore city agglomeration area andDistrict headquarters agglomeration area.

2. The wages under Zone-II are applicable to : All areas other than those listedunder Zone-I.

3. For categories of workers for which provision has not been made in the list, therates prevailing in the schedule of rates of other department may be adopted.

4. The wages of workmen of various categories are subject to revision duringcurrency of schedule of rates for any revision in the minimum wages and livingallowances by the Government of Karnataka.

11.0. HIRE CHARGES OF MACHINERY :

The hire charge of a machinery / equipment shall comprise of Basic Hire Charge, Fuel /energy charge and Operating Crew Charge. These components shall be worked outseparately and included in the schedule of rates.

11.1Basic hire charge:

The basic machinery hire charge shall include depreciation, interest on average capital costor profit, repair charges and miscellaneous charges. The practice in preparation of scheduleof rates is to consider interest on average capital cost. The capital cost of the machinery /

equipment shall be the current market price inclusive of all taxes, duties and freight charges.Guidelines published by CWC / BIS based on the report of committee on cost control of rivervalley projects shall be the basis for working out the machinery hire charges. The rate ofinterest for working out the interest on average capital cost shall be as fixed by the competentauthority. The salvage value shall be 10 percent of the capital cost. The life of machinery inyears / in hours and repair provisions shall be as per the guide lines published by CWC / BIS.The miscellaneous charges shall be at 10 percent of the repair charges. The hire chargesshall not include accessories like air line, water line, drill rods, drill bits etc. The use rate forthese accessories shall be worked out separately and the requirement of these shall beincluded under material component in the rate analysis. The hourly use rate of tyres includingtubes shall be worked out separately and added to hourly hire charges of machinerywherever applicable. The use rate is the ratio of cost of accessory to its working life.

11.2 Fuel ( DPOL ) / Energy charge:

The hourly consumption of diesel / petrol and electric energy shall be based on the guidelinespublished by CWC / BIS. The unit rates of diesel / petrol shall be the prevailing rates at theretail fuel outlets in the project area. Energy charges shall be as per the prevailing powersupply tariff applicable to HT-2B or other relevent category. Oil and lubricant charges shall betaken at 20 percent of energy charges for electrically operated machinery / equipment and at25 percent of diesel / petrol charges for diesel / petrol operated machinery / equipment.


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11.3 Crew charge:

Machinery / equipment operating crew charges shall be on hourly basis as per the guide-linesof CWC. The daily wages of operators and helpers provided in schedule of rates shall beconverted to yearly wages considering 26 working days in a month and then divided by yearlyusage of machinery in hours. Yearly usage of machinery in hours is the ratio of life ofmachinery in hours to life of machinery in years. The number of Operators and Helpers shallbe on the basis of type of equipment.

The hire charges of machinery and equipment shall be furnished in the schedule ofrates in the following format:

STATEMENT OF HIRE CHARGES OF MACHINERY AND EQUIPMENT

Sl

No.

Description of machineryHire charges

in Rs / HrDPOL /Energy

charges inRs / Hr

Crewcharges

in Rs / Hr

1234

Agitator carAir compressor 8.5 cmmBatching plant 2 x 1.5 cumBending machine. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .

The following notes shall be added under the statement of hire charges of machinery /equipment:

1. Hire charge includes depreciation, interest, repair charges, miscellaneous charges,insurance, road tax etc., wherever applicable.

2. Fuel charge includes cost of diesel / petrol / electric power as applicable and oil /lubricants and other miscellaneous charges.

3. Crew charge includes wages of operator and helper on hourly basis.4. Hire / Fuel / Crew charges are exclusive of provisions towards small tools and

plants, profit, overheads and hidden cost on operating crew.

Other notes if any relevant to any specific machinery may be added to the above list of notes.An example of working out hourly crew charges may also be furnished under note-3.

12.0 LEAD, LIFT, LOADING & UNLOADING CHARGES :

12.1 The estimated cost of the work shall be inclusive of cost of conveyance of materials fromsource of supply upto work site and cost of further rehandling,if any, at work site. The basicrates for materials considered in preparation of schedule of rates may be inclusive of cost ofconveyance upto site or may be at the source of their supply depending on the prevailingpractice for their supply. It is the general practice to provide for the material rates in theschedule of rates inclusive of cost of conveyance and handling upto work site for all materialsexcept for Earth / Sand / Gravel / Murum / Lime / Surki / Wood / Stones of all types /

Coarse aggregate / Stone and Concrete slabs / Cement / Steel / Pipes / AC sheets / GIsheets / RCC poles. The material rates provided in the schedule of rates for sand / gravel /


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murum / stones / aggregatesshall be at quarry. For steel, cement, AC sheets, GI sheets,hume pipes, wood and stone slabsthe rates provided shall be the rate prevailing at the

major commercial centre near project area or the departmental stores in case if thesematerials are to be supplied departmentally. In certain cases it may be necessary to transportwater also to work site. The basic item rates provided in the schedule of rates do not includeconveyance and handling charges from source of supply to work site for these materials.Conveyance of materials can be by head load or by mechanical means. In case ofconveyance by mechanical means loading and unloading of materials also shall beconsidered separately if the same is not covered by the working cycle of the machinerydeployed.

12.2 Generally conveyance by head load shall be considered for total lead upto 150 m and bymechanical means for total lead exceeding 150 m. The basic item rates provided in the

schedule of rates include 50 m or 1 km as initial lead and no lead charges shall be allowedwhere the source of material is within the initial lead specified in item rate. Additional leadcharges shall be allowed for the lead exceeding initial lead specified in the item rate.

12.3 The lead charges per unit quantity for conveyance of these materials shall be worked outand included in the schedule of rates in increament of 50 m for head load and in increament of1 km for mechanical mode. The rates for lead charges by head load and upto 5 km by anymode shall be cumulative and inclusive of lead charges for preceding lead. For lead beyond 5km the lead charges shall be worked out on per km basis.

12.4 Conveyance by head load:

12.4.1 Lead charges for conveyance of materials by head load shall be allowed upto 150 m.The lead charges by head load per unit quantity shall be worked out and included in theschedule of rates in increament of 50 m. The rates for lead charges by head load shall becumulative and inclusive of lead charges for preceding lead. The rates shall be inclusive ofprovisions for contractors profit, overheads, hidden cost on labour etc.

12.4.2 For the purpose of working out lead charges by head load the materials shall begrouped into three categories as under based on type of material, unit for measurement,

mode of handling etc.

Category I : Earth / Sand / Gravel / Murum / Lime / Surki / Stones / Aggregates.Category II : Cement / Steel.Category III : Stone slabs / PCC slabs / Laterite blocks / Wood

12.4.3 For earth / sand / gravel / murum / lime / surki / size stone / cut stone /rubble /coarse aggregatesthe lead charges by head load shall be worked out on per cum basisforloose volume. For cement / steel / pipes / AC sheets / GI sheets / RCC poles the leadcharges shall be worked out on per tonne basis. For shahabad slabs / PCC slabs / BSslabs / CC blocks / Laterite blocks / Wood the lead charges shall be worked out on percum basis for stacked volume.


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12.4.4 Data rates shall be prepared for each category of material and rate per unit quantityshall be included in the schedule of rates in the following format.

CONVEYANCE CHARGES FOR MATERIALS BY HEAD LOAD

SlNo.

Total distance( Total lead includes initial lead )

Earth / sand /Gravel / Murum /Lime / Surki /Rubble /Cut stone / SizeStone / CoarseAggregate

Cement /ReinforcementSteel / StrSteel

Shahabad/PCC slab/BS slab /CC block/LateriteBlocks /Wood

Rs / cum Rs / tonne Rs / cum

1

2

3

Total lead upto 50 m



Initial lead Initial lead Initial lead

The following notes shall be added under the statement of conveyance charges by head load

1. For total lead upto 150 m ( including initial lead ) lead charges by head load onlyshall be adopted irrespective of mode of conveyance.

2. For total lead exceeding 150 m conveyance by mechanical means only shall beadopted irrespective of mode of conveyance.

3. Loading and unloading charges are not payable for conveyance by head load.4. Unless otherwise specified lead charges for Earth / Sand / Gravel / Aggregates and

stones are for loose volume and not for compacted or in-situ volume.5. The rates for lead charges by head load and upto 5 km by any mode are cumulative

and inclusive of lead charges for preceding lead.

12.5 Conveyance by any mode :

12.5.1 Lead charges for conveyance of materials by any mode shall be allowed for total leadexceeding 150 m. The lead charges per unit quantity shall be worked out and included in theschedule of rates in increament of 1 km. The rates for lead charges by any mode upto 5 kmshall be cumulative and inclusive of lead charges for preceding lead . The rates shall beinclusive of provisions for contractors profit, overheads, hidden cost on crew etc.

12.5.2 For the purpose of working out lead charges by any mode the materials shall beclassified into five categories as under based on type of material, unit for measurement, modeof handling etc.

Category I : Earth / Sand / Murum / Gravel / Lime / Surki .Category II : Rubble / Size stones / Cut stones / Coarse aggregates.Category III : Cement / Steel / Pipes / AC sheets / GI sheets / RCC poles.


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Category IV : Shahabad slab / PCC slab / BS slab / CC block / Laterite block / Wood.Category V : Water.

12.5.3 For earth / sand / gravel / murum / lime / surki / size stone / cut stone / rubble /coarse aggregates the lead charges shall be worked out per cum on the basis of loosevolume. For cement / steel / pipes / AC sheets / GI sheets / RCC poles the lead chargesshall be worked out on per tonne basis. For shahabad slabs / PCC slabs / BS slabs / CCblocks / Laterite blocks the lead charges shall be worked out on per cum basis forStacked volume. For water the lead charges shall be worked out per 1000 ltr basis. Incase of conveyance by mechanical means idle hire charges shall be considered for waitingperiod ( loading and unloading time ) and full hire charges including fuel charges shall beconsidered for running time. The rates shall be inclusive of provisions for contractors profit,overheads, hidden cost on crew etc. The rates for conveyance charges and loading /unloading shall be furnished separately. Wherever, tipper is considered for conveyance,unloading of material can be by mechanical tipping. For water unloading can be by gravityflow.

12.5.4 Data rates shall be prepared for each category of material and rate per unit quantityshall be included in the schedule of rates in the following formats.

CONVEYANCE CHARGES FOR MATERIALS BY ANY MODE

SlNo.

Distance from source of supplyto work site

Earth /Sand /Murum/Gravel /Lime /Surki

Rubble/Sizestone /Cutstone /CoarseAggreg

ate

Cement/ Steel /Pipes/AC / GIsheet /Poles

Shahbad/ PCC /BS slab /CC block/ LateriteBlocks /Wood

Water

Rs /cum

Rs/cum

Rs / t Rs / cum Rs / kl

1234567

Lead upto 1 kmLead more than 1 km upto 2 kmLead more than 2 km upto 3 kmLead more than 3 km upto 4 kmLead more than 4 km upto 5 kmEvery km beyond 5 km upto 30 kmEvery km beyond 30 km

The following Notes shall be added under statement for conveyance charges by any mode :

1. For total lead exceeding 150 m conveyance by mechanical means only shall beadopted irrespective of mode of conveyance.

2. Unless otherwise specified lead charges for Earth / Sand / Gravel / Aggregates andstones are for loose volume and not for compacted or in-situ volume.

3. The rates for lead charges upto 5 km by any mode are cumulative and inclusive oflead charges for preceding lead.


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LOADING AND UNLOADING CHARGES FOR MATERIALS

SlNo.

Distance Earth / Sand /Murum/Gravel/Lime /Surki /

Rubble/Sizestone/Cutstone/CoarseAggregate

Cement/Steel/Pipes/AC / GIsheet/Poles

Shahbad/ PCC /BS slab /CC block/ Wood

Water

Rs/ cum Rs / cum Rs / tonne Rs / cum Rs / kl

1

2

Loading

Unloading

The following Notes shall be added under the statement of rates for loading and unloading:

1. Loading and unloading charges are not payable for conveyance by head load.2. Loading charges are not payable for conveyance by mechanical means for disposal

of excavated material beyond initial lead of 50 m wherever specified.3. Loading and unloading charges are not payable for conveyance by mechanical

means for disposal of excavated material beyond initial lead of 1 km wherever

specified.4. The rates for unloading of materials except earth, sand, gravel, coarse aggregate,

rubble, size stone and cut stone are inclusive of stacking wherever applicable.

12.6 Lift charges :

12.6.1 Lift charges for materials shall be allowed wherever the total lift exceeds the initial liftspecified in the item descriptoin. Lift charges shall be worked out in increament of 1.5 m lift.Where the conveyance / lifting of material is by mechanical means lift charges shall not beconsidered as the cycle time of operation of the machine includes lift involved.

12.6.2 For the purpose of working out lift charges by head load the materials shall be groupedinto three categories as under based on type of material, unit for measurement, mode ofhandling etc.

Category I : Earth / Sand / Gravel / Murum / Lime / Surki / Stones / Aggregates.Category II : Cement / Steel.Category III : Stone slabs / PCC slabs / Laterite blocks / Wood.

12.6.3 For earth / sand / gravel / murum / lime / surki / size stone / cut stone / rubble /coarse aggregatesthe lift charges by head load shall be worked out on per cum basis forloose volume. For cement / steel / pipes / AC sheets / GI sheets / RCC poles the liftcharges shall be worked out on per tonne basis. For shahabad slabs / PCC slabs / BS

slabs / CC blocks / Laterite blocks the lift charges shall be worked out on per cum basisfor stacked volume.


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12.6.4 Data rates shall be prepared for each category of material and rate per unit quantityshall be included in the schedule of rates in the following format.

LIFT CHARGES FOR MATERIALS

SlNo.

Total lift( Total lift includes initial lift )

Earth / sand /Gravel / Murum /Lime / Surki /Rubble /Cut stone / SizeStone / Coarse

Aggregate

Cement /ReinforcementSteel / StrSteel

Shahabad/PCC slab/BS slab /CC block/LateriteBlocks /

Wood

Rs / cum Rs / tonne Rs / cum

1

2

3

4

5

Total lift upto 1.50 m( covered by item rate )Total lift upto 3.00 m

Total lift upto 4.50 m



Initial lift Initial lift Initial lift

The following Notes shall be added under the statement of rates for lift charges:

1. The rates for lift charges are cumulative and inclusive of rates for preceding lift.2. Lift charges are not payable where conveyance / lifting of materials is by

mechanical means to final placing point.

12.7Royalty charges:

Government of Karnataka has levied royalty charges on certain construction materials.

Therefore, the item rates provided in the schedule of rates shall be inclusive of royaltycharges payable to Government of Karnataka. The schedule of rates book shall includeextract of latest copy of Government notification on royalty charges for reference.

12.7.1 The following notes shall be added under the notification on royalty charges:

1. The royalty charges on materials, wherever applicable, shall be recovered as per thefollowing guide-lines:

a. Where the land, from where the materials are extracted by the contractor for use ondepartmental work, belongs to the department / corporation the royalty chargesincluded in the rates for materials extracted from such land shall be recovered from the

contractor as per the statement of royalty charges included in each section of schedule


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of rates and the amount shall be credited to the specified revenue head of account ofthe department / corporation.

b. Where the land, from where the materials are extracted by the contractor for use on

work, belongs to other department and is taken on lease by the department /corporation the royalty charges included in the rates for the materials extracted fromsuch land shall be recovered from the contractor as per the statement of royaltycharges included in each section of schedule of rates and the amount shall be creditedto the specified revenue head of account of the other department.

c. Where the land, from where the materials are extracted by the contractor for use onwork, is neither owned nor taken on lease by department / corporation then the paymentof royalty charges on materials, extracted from such land, shall be the responsibility ofthe contractor or his sub-contractor. The contractor shall give an undertaking to theeffect that the royalty charges are being paid by him / his sub-contractor / supplierdirectly to the concerned department and no deductions shall be made from his workbills towards royalty charges.

2. Royalty charges as applicable to murum shall be made applicable to earth / soil also.3. Royalty charges as applicable to ordinary building stones shall be made applicable to

coarse aggregate also.4. Royalty charges as applicable to ordinary sand shall be made applicable to fine

aggregate.5. Royalty charges as applicable to Shahabad stone slabs shall be made applicable to

similar slabs from other sources also.

13.0 RATE SCHEDULE FOR WORK ITEMS :

13.1 The rate schedule for work items in the schedule of rates shall be furnished separatelyfor Dam & Allied Works, Canal & Allied Works, Canal, CD works, Tunnel & AlliedWorks, Gates/Hoists & Allied works and Preliminary & Maintenance works. Each sectionshall include :

- Notes on rates for the work ;- Statement of requirement of materials for unit quantity of work under each item;- Statement of royalty charges included in each item rate; and- Item rate schedule.

13.2 The item rate schedule shall include item number, brief description of item, unit and rateper unit quantity. The rate per unit quantity shall be based on the data rate analysis for the

item. The data rate analysis for any item of work shall consist of the following three majorcomponents.

1. Brief description of item of work.2. Data for assessing the quantities of various in-puts.3. Rate analysis.

13.2.1 Brief description of item of work :

The description of the item of work in the schedule of rates shall be short but cover allimportant aspects of the work included in the basic rate. On reading the item description oneshould be in a position to assess the various cost components involved in the work.

Typical item description in SR for concrete item:


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Providing and laying in-situ vibrated M-20 ( 28 days cube compressive strength notless than 20 N / sq mm ) grade cement concrete using 20 mm down size approved,clean, hard, graded aggregates including cost of all materials including royaltycharges, machinery, labour, form-work, centering, scaffolding, cleaning, batching,mixing, placing in position, levelling, vibrating, finishing, curing etc., complete for RCCworks of spillway bridge, block-outs for embedded parts and such other similarlocations with conjected reinforcement with initial lead upto 1 km and all lifts. (Cementcontent: 330 kg / cum for use of super plasticiser )

Typical item description in SR for radial gate item:

Design,fabrication, supply, erection, testing and commissioning of radial gateconsisting of skin plate, stiffeners, horizontal girders, sector arms, trunnionassemblies,tie beam, pulley supports, bracings, rubber seals, clamps etc., with all accessories forspillway including cost of all materials, machinery, labour, cutting, bending, aligning,welding, finishing, cleaning, applying one coat of zinc rich epoxy primer and three

coats of cold applied coal tar epoxy paint, seal fixing etc., complete as perspecifications and approved drawings with all leads and lifts.

13.2.2 Data for assessing quantities :

13.2.2.1 The data shall reflect the various assessments / assumptions made in arriving at thequantities of materials, machinery, labour and other in-puts. In case of plants and equipmentthe output of main plant shall be worked out and the requirement of all other in-puts shall beassessed to match the output of the main plant. Cycle time of operations shall be the criteriafor assessing the output of equipment. Generally the equipment manufacturers furnish theoutput of machinery under ideal conditions of working. Suitable job and managementefficiency factors shall be considered while working out the average output of machinery

under field conditions. In case of combination of machinery and manpower the assessment ofmanpower shall match the output of machinery.

13.2.2.2 Though cycle time of operations is the criteria for hourly / daily out-put of machinery /work-force the actual progress of work depends on several other factors such as powerinterruptions, minor break-downs, time for meals and other needs of work-force, stray rainsetc. Therefore, it is the general practice to consider 50 minutes as the actual working time perhour for workingout the hourly / daily out-put of machinery / work-force. Further, where thework is to be carried out in more than one shift, there will be further reduction in dailyproduction hours due to time required for change in shift for work-force and for dailymaintenance of plant / machinery such as cleaning, oiling, greasing, minor repairs etc.Considering all these aspects CWC / BIS guide-lines stipulate the following actual working

hours for the purpose of equipment planning and utilisation.

No. of shifts Total available time Actual available time

One shift 8.00 hours 7.00 hoursTwo shifts 16.00 hours 12.50 hoursThree shifts 24.00 hours 16.50 hours

The daily out-put shall be computed duly considering the actual available working time.

13.2.2.3 For gate and hoist works it is the general practice to specify the quantity of work interms of number of sets of embedded parts / gates. In such cases, naturally, the estimated

rates shall be per set for embedded parts and per gate / hoist for gates and hoists. However,as the rate per set or per number depends on the tonnage per set / number and varies from


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work to work depending on the size of gate and other design considerations, it not practicableto workout the unit rate on per set / number basis. Therefore, the basic rates for gate / hoistworks to be included in the SR shall be on per tonne basis for each item. The rate per set /number for the purpose of estimation shall be computed based on the rate per tonne providedin the SR and the estimated weight per set / number of the embedded part / gate / hoist. Forrate analysis the data to be considered shall be for one set of embedded parts or one numberof gate / hoist. The material requirement shall be based on either emperical rules or based onactual fabrication details for the typical gate / hoist / embedded parts. The requirement ofmachinery and work-force for cutting, bending, fabrication, erection, painting etc., shall beassessed commensurate with the task involved.

13.2.2.4 Typical example of data for rate analysis of concrete item:

Concrete item M-20 using 20 mm down Coarse aggregate ( CA ) :

Quantity of materials for 1 cum concrete:Cement :- 330 kg. Coarse aggregate ( CA ):- 0.80 cum. Fine aggregate ( FA ):- 0.44 cum

Blending ratio for CA :- 65 : 35. Wastage :- 1 % for cement and 2 % for CA and FA.Daily output of concrete mixer:Consider 300/ 200 litre capacity ordinary concrete mixer.Output for 1 bag ( 50 kg cement ) mix : 50 / 330 = 0.1515 cum.Cycle time for batching / mixing one load :Batching 20-10 mm coarse aggregate : 3.00 minutesBatching 10-4.75 mm coarse aggregate : Parallel activityBatching fine aggregate : Parallel activityBatching cement : Parallel activityLoading mixer drum / adding water / admixture etc : 1.50 minutesMixing and unloading concrete : Parallel to batchingTotal cycle time per mix : 4.50 minutes

Daily out-put considering 50 min / hour working say : 14 cum( 0.15`5 x 8 x 50 / 4.50 )

Deploy 300/ 200 litre mixer for 8 hrs and consider 14 cum daily output for rate analysis.Deploy needle vibrator for 8 hrs for compacting concrete and 5 hp pump for 1 hr for waterrequirement of concrete including curing.Requirement of work force per mixer per day considering equivalent volume batching:Cleaning / washing / curing : 1 light mazdoorBatching 20-10 mm coarse aggregate : 3 heavy mazdoorsBatching 10 4.75 mm coarse aggregate : 3 heavy mazdoorsBatching fine aggregate : 3 heavy mazdoorsBatching cement : 2 heavy mazdoorsRe-mixing and loading mortar pans : 4 heavy mazdoors

Conveying from mixer to placing point : 14 light mazdoorsPlacing and vibrating : 1 Mason & 3 MazdoorsOperating crew for mixer : 8 hoursOperating crew for vibrator : 8 hoursOperating crew for pump : 1 hourFormwork / shuttering : @ 2.50 sqm / cum of concrete.Scaffolding materials : @ 100 % of shuttering.

Requirement of labour for conveying from mixer to placing point depends on the distance tobe covered and the lift along the ramp-way.Alternatively, combination of plant / equipment can also be deployed for batching, conveyingand placing concrete as under:Conveyor system for conveying materials from stock piles to batching bins;Batching plant for weighing, batching and mixing;


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Combination of tippers / locos and tower cranes / cable-way for conveying and placing;

13.2.2.5 Typical example of data for rate analysis of gate item:

Consider radial gate for spillway opening of size 15 m x 9 m for analysis.

Spillway radial gate consists of trunnions, sector arms, horizontal girders, Tee-supports, skinplate, tie beam, bracings for horizontal girders and sector arms, pulley blocks, seals etc., withall accessories.Sector arms are connected to trunnions with zinc padding in between. Horizontal girdersgenerally spaced at about 3 m apart are joined to sector arms by welding and are stiffened byvertical and diagonal stiffeners to form the main frame. Tee sections are welded to horizontalgirders to make the frame rigid and to support the skin plate. Skin plate is welded to Teesupports generally spaced vertically at about 40 cm apart.

Weight of gate leaf in tonnes as per fabrication drawings :57.457 tonnes

1. Requirement of materials as per fabrication drawings:a. Structural steel conforming to IS : 2062 :

Angles / channels / beams / bars with 2.5 % wastage :15806.00 kgPlates / flats with 2.5 % wastage :38672.00 kg

b. Alloy steel components conforming to IS : 1570 :Stainless steel plate :6.00 kgPins :1098.00 kg

c. Cast steel components conforming to IS : 1030 :Trunnion hub / guide roller :1895.00 kg

d. Alluminium bronze alloy components conforming to IS : 305 :

Trunnion bush / guide rollor bush :1155.00 kge. Bolt / Nut / Washers :

GI bolt / nut / washers with 2.5 % wastage :78.00 kgBlack bolt / nut / washers with 2.5 % wastage :79.00 kg

f. Zinc for padding trunnion and trunnion support :140.00 kgg. Rubber seal conforming to IS : 11855 :

Bottom seal :15.50 RmSide seals :25.00 Rm

h. Welding electrodes :For stitch welding at 10 % of total with 2.5 % wastage :2728 NosFor run welding ( LH ) at 90 % of total with 2.5 % wastage :24554 Nos

2. Cutting sections for fabrication:Length of cutting as per fabrication drawings assuming cutting for 2 sides :928 RmAdd for additional cutting for odd shapes and final trimming etc at 10 % : 93 RmTotal length of cutting involved :1021 Rm

For cutting structural steel sections to required size combination of use of manual gas cuttingtorch, pug cutting machine and plate shearing machine is assumed depending on the shape,size and thickness of sections to cut for fabrication.Length of steel to be cut by using gas cutting torch manually :350 RmLength of steel to cut using pug cutting machine :571 RmLength of steel to be cut using plate shearing machine :100 RmTime for gas cutting manually assuming av. Progress of 2 m / hr :175 hoursTime for gas cutting using pug cutting machine at av. 3 m / hr :190 hoursTime for cutting by shearing machine at av. 10 m / hr :10 hours


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Acetelyne gas @ 0.6 cum / hr ( 365 x 0.6 ) :219 cumOxygen gas @ 1.8 cum / hr ( 365 x 1.8 ) :657 cumUse of gas cutting torch with 50 min / hr working ( 175 x 60 / 50 ) :210 hoursUse of pug cutting machine with 50 min / hr working ( 190 x 60 / 50 ) :228 hoursUse of plate shearing machine with 50 min / hr working ( 10 x 60 / 50 ) :12 hours

3. Bending :Assuming 1.2 m wide plates, length of plates for bending ( 15 x 11 / 1.2 ) :137.5 RmLength of Tee sections @ 0.4 m spacing ( 15 x 11 / 0.4 ) :412.5 RmLength of seal base / cover flats ( 11 x 2 x 2 ) : 44.0 RmTotal length of bending involved :594.0 RmTime for bending 594 m at av. 3 m / hr ( 594 / 3 ) :198 hoursWith 50 min / hr working deploy bending machine for ( 198 x 60 / 50 ) :238 hours

4. Welding :Length of welding as per fabrication drawings :2294 RmFor radial gates where field welding is more progress is assumed at 12 electrodes / hour.

Time for stitch welding @ 2 hrs / shift ( 2728 / 12 ) x 8 / 2 :909 hrsTime for run welding @ 6 hrs / shift ( 24554 / 12 ) x 8 / 6 :2728 hrsTotal time for welding :3637 hrsDeploy welding transformer for 3637 hours.Fuel / Energy charges @ 25 % hrs for stitch welding and 75 % hrs forRun welding ( 909 x 0.25 + 2728 x 0.75 ) :2273 hrs

5. Surface cleaning and painting:As surface cleaning by sand blasting is hazarous, the alternative method of cleaningto remove rust / scaling / grease etc and to form phasphate coating is assumed.Area of painting for radial gate @ 20 sqm / tonne ( 57.61 x 20 ) say :1150 sqmQuantity of rust cleaner @ 8 sqm / ltr ( 1150 / 8 ) :144 ltr

Quantity of zinc rich epoxy primer 1 coat 40 micron @ 9 sqm / ltr :128 ltrQuantity of coal tar epoxy paint 3 coats 100 micron each @ 6 sqm / ltr :575 ltr

6. Requirement of other machinery:For drilling holes in skin plate, seal cover flats, trunnion supports etc., 50 hours use of drillingmachine considered.For grinding weld joints, edges etc., 50 hours use of grinding machine considered.For handling during fabrication and erection 150 hours use of mobile derric crane and 300hours use of stationery derric crane considered.For lifting and placing in position sector arms / horizontal girders etc., 10 hours use of Towercrane considered.

7. Requirement of work-force :Work component Foreman Marker / Welder/ Painter Helper

Fabricator/ Gas cutter Cl IIErector /

Cutting sections 403 hrs 28 56 56 -- 112Drilling holes 3 6 -- -- 12Fab / Stitch welding 909 hrs 57 114 -- -- 456Run welding 2728 hrs 34 -- 341 -- 341Erection of trunnion / tie beam 4 8 -- -- 32Erection of H girders 3 3 -- -- 12Erection of sector arms 3 3 -- -- 12Erection of vertical stiffeners 5 10 -- -- 40Erection of skin plates 3 6 -- -- 24Erection of end sheild / hood 4 8 -- -- 32


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Erection of bracings 6 6 -- -- 24Zinc filling for trunnion support 2 2 -- -- 2Cleaning / primer painting -- -- -- -- 77Finishing paint 3 coats -- -- -- 306 77Seal fixing 2 2 -- -- 4Finishing / checking / cleaning 1 2 -- -- 2

8. Excise duty is applicable on fabricated parts. The cost of materials is inclusive of all taxes /duties. Therefore, for purpose of rate analysis 75 percent of the total cost excluding cost ofmaterials ( assuming 25 percent of Machinery and Labour components for erection ) isconsidered for assessing excise duty.

9. Use rate of materials:Cost of welding holder set @ Rs: / Each Rs:Life of welding holder set : 1000 hoursUse rate of welding set ( Cost / life ) Rs:Cost of gas cutting torch set @ Rs: / Each Rs:

Life of gas cutting torch set : 600 hoursUse rate of gas cutting torch ( Cost / life ) Rs:

14.0 RATE ANALYSIS :

14.1 Rate analysis shall be prepared as for as possible considering the output of main plant orgroup of work force and shall consist of three major cost components namely;

A.Material B. Machinery C. Labour

14.2 The above components shall include profit, overheads, small T & Pand hidden costson labour. In case of major works, in addition to material, machinery and labour components

there will be other ancillary components such as work shop / stores / parking sheds,transportation / erection / dismantling of plant & machinery, electric sub-station &distribution lines, air lines, water supply arrangements, ventilation arrangements,portable magazine etc. For these ancillary or enabling works of common utility for executionof several items of work provision shall be generally made in the data rate either by workingout the details or on appropriate percentage basis.

14.2.1 Material component:

Material component shall include description of material, quantity, unit rate and cost for eachmaterial. The quantities shall be for the quantity of work considered for analysis and shallinclude wastage and requirements for incidentals such as finishing, mortar layer at lift joints

etc. For minor materials, not quantified but generally required for the work, appropriate lump-sum provision shall be made in the form of sundries. The material component shall includeprovisions for small T & P materials, contractors profit, overheads on percentage basis. Theprofit on materials shall be excluding cost of any materials supplied departmentally. Thematerial component shall also include royalty charges if the same is not included in the basicrate of materials.

14.2.2 Wastage and incidentals:

CWC guidelines provide for wastage of 5 percent for cement and 2.5 percent forreinforcement and structural steel. The wastage of 5 percent considered for cement in theCWC guidelines includes requirement for incidental works like finishing and other minorassociated jobs forming part of the item. As cement for incidental works is not a regularrequirement, it is proposed to make provision for wastage of cement at 1 percent for all items


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involving use of cement. For incidentals such as finishing, mortar layer for lift joints etc.,wherever required, specific provisions may be considered for additional cement for such itemsin the rate analysis. For steel wastage at 2.5 percent as per CWC guidelines may beconsidered. For other construction materials like stone, rubble, coarse and fine aggregatesetc., wastage upto 2 percent may be considered in the data rates.

14.2.3 Quantity of Materials:

14.2.3.1 The quantities of materials to be considered in the rate analysis shall becommensurate with the quantity of finished work considered for working out rate and shallinclude wastage and requirement for incidentals if any.

14.2.3.2 The material constants for concrete items shall be based on theoretical mixcomputations for average conditions of placement. For structural concrete durabilityrequirements shall also be considered while fixing the cement content of particular grade ofconcrete. Minimum cement content and maximum water to cement ratio to be considered for

the concrete mix from durability requirements are furnished in IS: 456-2000 both for plain andreinforced concrete. The gradation of coarse aggregate for concrete shall be average of therange furnished in IS:383. For the purpose of preparing data rate for concrete items thefollowing grading limits shall be adopted for working out the quantity of coarse aggregate indifferent size ranges:

80 mm and down size: 80 to 40 mm size range : 40 %40 to 20 mm size range : 30 %20 to 10 mm size range : 20 %10 to 4.75 mm size range : 10 %

40 mm and down size: 40 to 20 mm size range : 50 %

20 to 10 mm size range : 30 %10 to 4.75 mm size range : 20 %

20 mm and down size: 20 to 10 mm size range : 65 %10 to 4.75 mm size range : 35 %

14.2.3.3 All concrete mix proportions shall be on weight basis. Equivalent volume batchingmay be permitted for batching of fine and coarse aggregates. Batching of cement shall be onweight basis only. Nominal concrete mixes on volumetric basis such as 1:2:4 / 1:1.5:3 etc.,are not recommended for inclusion in SR as fixed cement content for these mixes results inun-economical use of cement where maximum size of coarse aggregate is more than 20 mm.

14.2.3.4 The gradation of coarse aggregate for filter shall satisfy the filter criteria. For thepurpose of determining quantities of filter aggregates for rate analysis following gradationlimits satisfying the filter criteria shall be adopted:

80 mm down filter aggregate:80 to 40 mm : 90 %40 to 20 mm : 10 %

40 mm down filter aggregate:40 to 20 mm : 85 %20 to 10 mm : 15 %

20 mm down filter aggregate:20 to 10 mm : 75 %


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Below 10 mm : 25 %

14.2.3.5 Material constants for masonry items shall be computed based on type of masonryand mortar content. Suitable provision shall be made for stone chips as percentage ofquantity of stone for wedging and packing. For other items material constants shall becomputed as per the requirement.

14.2.3.6 A statement showing the requirement of materials per unit quantity includingwastage and requirements for incidentals based on the data rates shall be included in theschedule of rates for reference for computing the lead charges.

14.3 Material rates:

14.3.1 The rates for materials included in the rate analysis shall be as per the unit rateprovided under the statement of rates for materials.Certain materials such as air hose, water hose, gas cutting torch, welding accessories,drilling

accessories, formwork / centering / scaffolding materials etc., which contribute to the cost ofwork are used for several unit quantities of work till they become scrap or absolute. The rateto be considered for such materials under the material component shall be the use rate whichis the ratio of cost to life. The life for such material may be in hours / years / Rm / number ofuses etc., depending on the type of material.

14.3.2 Royalty charges:

The item rates provided in the schedule of rates shall be inclusive of royalty charges payableto Government of Karnataka. The schedule of rates book shall include a statement of royaltycharges included in the basic rate for various items of work under each section to facilitaterecovery of royalty charges accordingly. The recovery of royalty charges, wherever

applicable, per unit quantity of work shall be as per the provisions under this statement.

14.4 Machinery component:

14.4.1 Machinery component shall include description of machinery, hours of usage, hirecharges per hour, fuel charges per hour to work out the cost. The crew charges shall beconsidered under labour component. The machinery component shall include all plant andmachinery considered in the data and the number of hours of usage shall be commensuratewith quantity of work considered for rate analysis. For any unforeseen or minor machineryrequirements suitable lump-sum provision shall be made in the form of Sundries.

14.4.2 Hours of machinery usage:

The provision for machinery in data rates shall be for actual hours of usage of machinery. Thehourly out-put of any particular machine depends on the capacity, task to be performed, cycletime of operation, efficiency of working etc., and may vary depending on the nature of work.Out-put of machinery shall be computed considering 50 minutes working per hour. Forworking out the data rates out-put of major plant shall be taken as the task.

14.4.3 Hire charges :

The hire charges of plant and machinery to be considered in the rate analysis shall be as perthe statement of hire charges included in the schedule of rates. Basic hire charge and fuelcharge shall be furnished for each machinery separately to facilitate computation of profit onlyon fuel charges.


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14.4.4 Labour component:

Labour component shall consist of number of workers of various category and operating crewas per data and wages per day or per hour to work out the cost. Requirement of number ofworkers of various category for particular type of work shall be commensurate with the taskconsidered for data rate and daily / hourly output of worker / group of workers. In addition tooperating crew provision may be made for other category of skilled / semi-skilled workers suchas foreman, mechanic, welder, electrician, etc., wherever required for routine dailymaintenance of plant and machinery. Suitable provision shall be included in the data rate forthese maintenance staff apportioning the requirement to various major items of workdepending on the number of plant / machinery considered in the item.

14.4.5 Requirement of work force:

The labour constants to be considered in the data rate for any particular item of work dependon the type of work force, site conditions, nature of work, cycle time of operations and job /management efficiency in organizing the work-force. The requirement of work-force shall be

assessed duly considering the various work requirements and standard published data /experience on out-put of particular type of labour. Provision may be made for Maistry / WorkInspector, wherever required, for organising and supervising the activities of work-force. Therequirement of work-force shall be commensurate with the quantity of work considered for rateanalysis.

14.4.6 Daily / Hourly wages:

The wages to be considered in the data rate for plant / machinery operating crew shall be onhourly basis and at the rate as provided under statement of hire charges of machinery. Forother work-force the wages to be considered shall be on daily basis and at the rate asprovided under statement of wages of workers.

15.0 USE OF ADMIXTURES AND CURING COMPOUNDS:

Concrete admixtures such as Air-Entraining Agent ( AEA ) / Water reducing agent can beused advantageously for better quality concrete. Dosing of such chemical admixtures forconcrete shall be as recommended by the suppliers or as specified by the project QualityControl unit on the basis of trial studies. Similarly, Curing compound can be used for curing ofcanal concrete lining works where there is scarcity of water in the work area. Suitableprovision shall be made in the SR data rates under material component towards the cost ofadmixtures / curing compounds. A Note on Chemical Admixtures for Concrete is given inAnnexure-I.

16. OTHER PROVISIONS :

16.1 Other provisions to be considered in the data rate analysis are :1. Small tools and plants:2. Contractors profit and overheads.3. Hidden cost on labour.4. Enabling works.5. Excise duty on supplies ( for gate works )6. Rehandling lead.

16.2. Small tools and plants:


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Small tools and plants are necessary for routine maintenance of plant / equipment and forwork force in day today work. For machinery / Equipment the repair charges as per Clause :2.2.6 of IS: 11590 include cost of spare parts and wages for all major repairs but do notinclude normal / routine maintenance. It is difficult to quantify and make provision in the rateanalysis for all small tools and plants required in the execution of work. Therefore, it is thegeneral practice to make provision towards small T & P materials on percentage basis in therate analysis. In the CWC guide lines for preparation of project estimates a provision of 1percent of cost of works is suggested for small tools and plants. In the proforma for estimationof unit rates published by BIS for various work items small tools and plants is included as datarate component. Based on CWC guidelines a provision of 1 percent of basic cost of materials,machinery and labour components is proposed in the data rates towards small T & P and losson stocks etc.

16.3 Contractors profit and overheads:

In the CWC guidelines 20 percent of the cost of materials, machinery and labour is proposedtowards contractors profit and overheads together. It is also indicated in the guidelines that for

large jobs a lesser percentage of profit may be adequate. Considering the above provisions inthe CWC guidelines and also the present practice being followed for preparation of scheduleof rates, it is proposed to retain the provision towards the contractors profit at 10percent of cost of materials (excluding departmental supplies), machinery (excludingmachinery hire charges in view of inclusion of interest on average capital cost ) and labour inthe data rate. In addition to profit, overhead costs at 5 percent of the cost of material(including departmental supplies), machinery ( including hire charges) and labourcomponents is proposed in the data rates under dam, canal, tunnel, gates and canalcross drainage works. No overheads are considered necessary in the data rates for itemsrelated to investigation and maintenance works.

16.4 Hidden cost on labour:

Labour component shall also include certain indirect expenses on labour such as providentfund, workmen compensation, wages for leave period / paid holidays, retrenchmentcompensation, gratuity, travelling expenses, providing housing / medical / canteen / dresses /gum-boots facilities etc., to comply with the various statutory and other local requirements.CWC guide-lines provide for hidden costs on labour as percentage of labour cost. Theprovisions vary upto 80 percent for skilled category and upto 55 percent for semi-skilled andun-skilled category and are subject to modification depending on the local conditions ofworking, availability of local work-force, duration of work, geographical location of work etc.From the break-up of various provisions listed out in the CWC guide-lines it can be observedthat the major contributing factors to hidden costs are housing, idle wages during mansoonperiod and provident fund. Generally, the minimum wages fixed by the Government include

some of the amenities to be provided to the work force. Hidden cost on labour shall be forsuch amenities that are not covered / included in the wages. During non-working mansoonperiod most of the operating crew will be deployed for over-hauling of plant and machineryand the wages are covered under repair charges. Further, as the hourly wages of operatingcrew are worked out on the basis of annual pay and yearly working hours of machinery, thereis no need to consider hidden cost on operating crew for non-working mansoon period.Considering all such cases where the hidden cost is already covered in the wagestructure, the provisions suggested in the CWC guide-lines are reviewed and finally itis proposed to fix the provision for hidden cost at 15 percent of the labour cost for allworks.

16.5 Additional hidden cost on labour:


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For dam, tunnel and gate works where certain risks / hazards such as working during nighttime, working under partial reservoir condition, gas cutting and welding hazards, dusty andhumid conditions etc., are unavoidable additional hidden cost at 5 percent for Dam &Allied Works and 10 percent for Tunnel & Allied Works and 15% for Gate/Hoists andAllied Works on the cost of labour component may be considered.

The details of provisions to be considered towards hidden costs and additional hidden costsare furnished in Annexure-II.

16.6 Enabling works:

16.6.1 Construction of major project works involves transportation, erection anddismantling of plant / equipment, construction of fuel depots / stores / sheds / haulroads / water tanks / trestle structures / minor protective works, establishing electricsub-station / portable explosive magazines, laying water / power supply lines etc.Suitable provision for these enabling works either by assessing the probable costs or onpercentage basis shall be included in the rate analysis of work items. Monthly demand

charges per KVA of sanctioned power is also a major cost input and needs to be consideredas part of establishing electric sub-station.

16.6.2 In the CWC guide-lines transportation / erection / commissioningcost is includedin the capital cost of equipment. In this system the cost of transportation / erection /dismantling gets distributed to entire working life of equipment. However, in practice, use ofequipment is only for few years in a project. When the equipment is transferred to anotherproject the cost of transportation / erection / dismantling is again involved. Therefore,considering this cost separately for each work is more rational.Provisions made in the CWC rate analysis data are as under:Construction and maintenance of haul roads 5 %Electricity 2 %

Lump-sum provisions are made for electrity / work shop / track charges / compressed air /small tools etc., for concrete items.

In the proforma for estimation of unit rate published by BIS for various work items provision forenabling works including carriage and freight of machinery is included under field set-up andfield charges.

In case of gate and hoist works the item rates are inclusive cost of designs and drawings andalso cost of transportation of component parts from place of fabrication to work site. The basicrates to be included in the SR shall include suitable provision for these enabling works.

16.6.3 Based on the data prepared for enabling works the following provisions may be

included in the data rates as percentage of total cost of material, machinery and labourcomponents.

1.Dam and allied works:

a. Electric sub-station & demand charges ( for concrete items ) 2.50 %b. Trestle bridge for moving tower cranes( for concrete items ) 4.00 %c. Aggregate conveyor system( for concrete items only ) 3.00 %d. General enabling works ( for all items ) 2.00 %

2.Canal and allied works:

a. General enabling works ( for all items ) 1.00 %b. Shifting of batching plant ( for CC lining by paver ) 2.00 %


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c. Ledge cutting / paver track laying ( for lining by paver ) 1.00 %

3.Canal cross drainage works:

a. General enabling works . ( for all items ) 1.00 %

4.Tunnel and allied works:

a. Electric sub-station & demand charges ( all items ) 5.00 %b. Lighting inside tunnel ( all items ) 1.50 %c. Air and water lines( all items ) 1.00 %d. Ventilation arrangements ( only for excavation items ) 5.00 %

e. General enabling works ( for all items ) 2.00 %

5. Gate / Hoist and allied works:

a. Designs and drawings 2.50 %b. Zigs / supports / winches / chain & pulley etc 2.50 %c. Power supply arrangements 2.50 %d. Insurance charges 1.00 %e. General enabling works 2.00 %f. Transportation upto work site 3.00 %

6. Preliminary and Maintenance works:

a. General enabling works( only for drilling & embankment breached section works ) 1.00 %

General enabling works include ancillary works such as stores / work shop / guarage / fueldepot / machinery sheds / storage water tanks / air & water supply lines / haul roads /transportation, erection & dismantling of machinery etc., which are common to all items ofwork.

16.7 Excise duty on supplies :

In respect of gates, hoists and allied works excise duty is applicable on the value of fabricatedcomponents supplied to site. Suitable provision shall be made in the rate analysis towardsexcise duty on the supply value of gate and hoist parts. Excise duty is not applicable onerection charges. Further, the excise duty shall not be considered in the rate analysis on

material component as basic material rates are inclusive of excise duty. Therefore, exciseduty to be considered in the rate analysis shall be only on machinery and labour componentsrequired for fabrication of gates and hoists at the central fabrication yard. It is difficult todetermine the machinery and labour components separately for fabrication and erection. Forthe purpose of computation of excise duty to be included in the rate analysis the machineryand labour components may aportioned at 75 % for central fabrication yard and 25 % for fielderection and commissioning. Therefore, 75 % of the machinery and labour components maybe considered for assessing the extent of excise duty to be added in the rate analysis.

16.8 Rehandling lead charges:

In case of major works requirement of cement and steel will be large and generally thesematerials will be purchased in bulk quantities. Cement will be stored in site stores and steel


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will be stored in fabrication yard. These materials will be conveyed to batching plant / workarea subsequently to the extent required at a time. Therefore, conveyance of cement andsteel from source of supply to work spot involves re-handling from site store / fabrication yard.As site stores / fabrication yards will be generally located beyond 150 m from work spotrehandling lead of 1 km including loading and unloading shall be considered for cement andsteel for major works. While working out addditional lead charges for cement and steel the 1km rehandling lead shall be deducted from total lead.

In respect of gate and hoist works rehandling is involved both at fabrication site and aterection site. At the fabrication site materials are rehandled from stores to fabrication site forcutting, bending and fabrication of parts. At the work site the fabricated parts are rehandledfrom site yard to erection spots for assembly and erection. Therefore, for gate and hoists tworehandling charges shall be considered in the rate analysis.

17.0 FORMAT FOR RATE ANALYSIS:

17.1 The data rate analysis for items to be included in the schedule of rates shall be furnishedin suitable format duly making appropriate provisions for all the requirements as explained inthe above paragraphs. Cost of materials shall include royalty charges wherever applicable. Anabstract of cost of materials, machinery and labour components shall be prepared at the endand other provisions such as power supply arrangements, ventilation arrangements,transportion / erection / dismantling costs, enabling works, excise duty on supplies,rehandling charges etc., to the extent they are relevent for perticular item shall be added tothe total cost on cost / percentage basis as the case may be to finalise the unit rate to beincluded in the schedule of rates.

17.2 The final unit rate may be rounded off suitably as under :

Rate less than Rs:10 : to be rounded off to nearest Rs:0.05Rate more than Rs:10 upto Rs:100 : to be rounded off to nearest Rs:0.10Rate more than Rs:100 upto Rs:1000 : to be rounded off to nearest Rs:0.50Rate more than Rs:1000 upto Rs: 10000 : to be rounded off to nearest Rs:1.00Rate more than Rs: 10000 : to be rounded off to nearest Rs: 5.00

17.3 The rates worked out on the basis of approved standard data and rounded off to nearestvalue as suggested above for inclusion in the Schedule of Rates shall not be increased ordecreased further for any reason.

17.4Typical rate analysis format: ( For concrete item illustrated in para 9 )

RATE ANALYSIS UNIT:14.00 CumA. MATERIALS:

Sl No Particulars Unit Quantity Rate AmountIn Rs. in Rs.

1 Cement for incidentals @ 3 kg/ cum Kg 4666.002 Coarse aggregate 20-10 mm kg 42.00

Coarse aggregate 10 mm below cum 7.403 Fine aggregate cum 4.004 Super plasticiser cum 6.305 Use rate of shuttering ltr 14.00

6 Scaffolding @ 100 % of shuttering sqm 35.00


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ABSTRACT:A. Cost of Materials including royalty charges Rs:B. Hire charges of Machinery Rs:C. Cost of Labour Rs:

Total Rs:Add for enabling works @ 2% Rs:

Total Rs:Add for 1 km re-handling / initial lead & loading /unloading:

Cement 4708 kg @ Rs: / tonne Rs:Coarse aggregates 11.4 cum @ Rs: / cum Rs:Fine aggregates 6.3 cum @ Rs: / cum Rs:

Total cost for 14.00 CumRs:

Rate per Cum Rs:

17.5 Typical rate analysis format :( For gate item illustrated in para 9 )

A. MATERIALS: UNIT : 57.457 tonnes

SlNo

Particulars Unit Quantity Rate Amount

in Rs. in Rs.

1 Structural steel :Angles / beams / channels / barsPlates / flats

KgKg

15806.0038672.00

2 Cast steel components :Trunnion hubs / guide rollers Kg 1895.00

3 Alloy steel components :Stainless steel plateTrunnion pins

KgKg

6.001098.00

4 Bronze alloy components :Bush for trunnion / guide rollers Kg 1155.00

5

67

89

10111213

141516

Bolts / Nuts / Washers :G I bolts / nuts / washersM S bolts / nuts / washersZinc for paddingRubber seals :Bottom sealsSide sealsOxygen gasAcetyline gasWelding electrodes ( ordinary )Welding electrodes ( LH )Zinc rich epoxy primer paintCoal tar epoxy paint

Rust cleaner / inhibitorUse rate of welding holder setUse rate of gas cutting torch set

KgKgKg

RmRmCumCumNosNosLtrLtr

LtrHourHour

78.0079.00

140.00

15.5025.00

657.00219.00

2728.0024554.00

128.00575.00

144.003637.00210.00


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17 Wire brush Nos 12.0018 Sundries LS 1000.00

TOTAL Rs:Add for small Tools and Plants @ 1% Rs:

Add for Contractor' Profit @ 10% Rs:Add for Contractors' Overheads @ 5% Rs:

Total cost of Materials Rs:

B. MACHINERY:

SlNo

Particulars Unit Quantity Rate Amount

in Rs. in Rs.1 Welding transformer

Fuel / Energy chargesHourHour

3637.002273.00

2 Plate shearing machineFuel / Energy charges

HourHour

12.0012.00

3

4

5

6

7

8

9

Pug cutting machineFuel / Energy chargesBending machineFuel / Energy chargesTower crane 5 t capacityFuel / Energy chargesMobile derric craneFuel / Energy chargesStationery derric craneFuel / Energy chargesGrinding machineFuel / Energy chargesDrilling machineFuel / Energy charges

HourHourHourHourHourHourHourHourHourHourHourHourHourHour

228.00228.00238.00238.0010.0010.00

150.00150.00300.00300.0050.0050.0050.0050.00

10 Sundries LS 1000.00

TOTAL Rs:Add for small Tools and Plants @ 1% Rs:

Add for Contractor' Profit on DPOL/Energy @ 10% Rs:Add for Contractors' Overheads @ 5% Rs:

Total hire charges of machinery Rs:

C. LABOUR:

SlNo

Description Unit Quantity Rate Amount

in Rs. in Rs.1 Crew for Mobile crane Hour 150.00


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23456789

101112131415

Crew for Tower craneCrew for Bending machineCrew for Drilling machineCrew for Grinding machineForemanMarker / Fabricator / ErectorGas cutterWelder ( General )Welder ( X ray grade )KhalasiHelper fabrication / erectionHelper for cleaning / paintingPainter Class IIElectrician

HourHourHourHourDayDayDayDayDayDayDayDayDayDay

10.00238.0050.0050.00

155.00226.0056.00

307.0034.00

250.001105.00

154.00306.0030.00

TOTAL Rs:Add for small Tools and Plants @ 1% Rs:Add for Contractor' Profit @ 10% Rs:

Add for hidden cost on Labour @ 15% Rs:Add for additional hidden cost on labour @ 15% Rs:Add for Contractors' Overheads @ 5% Rs:

Total cost of Labour Rs:

ABSTRACT :A. Cost of Materials Rs:B. Hire charges of Machinery Rs:C. Cost of Labour Rs:

Total Rs:Add for excise duty on 75 % of totalcost excluding cost of materials

Add for insurance charges @Add for designs and drawings @Add for zigs/ supports/ winches @Add for power supply arrangements @Add for enabling works @

18%

1.0%2.5%2.5%2.5%

2%

Rs:

Rs:Rs:Rs:Rs:Rs:

Total Rs:

Add for 2 rehandling leads for 1 km & loading / unloading:

Fabricated parts 2 x 57.457 t @Add for transportion upto site @:

Rs: / tonne3 %

Rs:Rs:

Total cost for 57.457 Tonnes Rs:Rate per Tonne Rs:

18.0 ADDITIONAL LEAD, LOADING & UNLOADING CHARGES:

18.1 The conveyance of materials from source of supply to final placement may be in singlestage or in multi stage depending on the nature of work. The conveyance of materials withinthe site area is reckoned as initial lead and is generally included in the basic rate provided inthe schedule of rates. The lead upto site is reckoned as additional lead and is added to thebasic rate at the stage of preparation of estimate for the work. The quantities of materials tobe considered for the purpose of working out additional lead charges shall be computed and a

statement to this effect shall be included in the schedule of rates under each section. Therates provided in the schedule of rates for lead, loading and un-loading costs shall be based


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on the standard data. Lead charges upto 5 km shall be on cumulative basis in increment of 1km and beyond 5 km the lead charges shall be for each additional km. The rate shall includehire charges of transport equipment and crew charges on round trip cycle time basis with thefuel charges only for the running time of transport vehicle. Un-loading shall include stackingwherever required. The basic rates in the schedule of rates for work items shall be with initiallead of 1 km for mechanical conveyance or 50 m for manual conveyance depending upon thetype and location of work. For work items involving use of materials not listed in the statementof lead charges the basic rates in the schedule of rates shall be with all leads.

18.2 For certain works such as dam / canal / tunnel where it may not be possible / feasible tostack steel and cement within 50 m distance ( initial lead by head load ) from the work areathe initial lead shall be 1 km and shall be considered as re-handling lead. In such cases theadditional lead charges for lead exceeding 1 km shall be computed by deducting the initiallead of 1 km from the total lead.

Example:

Total lead for cement 100 km.Initial lead considered in basic rate 1 km.Additional lead involved 99 km.Additional lead charges : Lead charges for 99 km + loading and unloading.

18.3 Additional lead charges shall be computed for 99 km including loading and un-loading asit involves transportation and re-handling of cement from store yard to work area.For sand, coarse aggregate and stone required for concrete / masonry works the materials tothe extent of daily requirement can be stacked near the work place and as such re-handlinglead can be avoided. Additional lead charges for these materials shall be computed asdeference of total lead charges and initial 1 km lead charges included in basic rate. No loading

and unloading charges shall be allowed.

Example:

Total lead for sand 25 kmInitial lead considered in basic rate 1 km

18.4 Additional lead charges : Lead charges for 25 km Lead charges for initial 1 km.For earth / rock-fill works of dam and canal generally borrow areas will not be permitted closeto embankment. Therefore, the initial lead for embankment items shall be 1 km. For theseworks where the actual lead exceeds initial lead of 1 km additional lead charges shall becomputed as deference of total lead charges and 1 km initial lead charges included in basic

rate. No loading and un-loading charges shall be added to the basic rate as soil / rock isconveyed directly from borrow area / quarry to embankment area without re-handling inbetween.

Example:

Total lead for soil----------------------------------- 3 km.Initial lead considered in basic rate------------ 1 km.Additional lead involved--------------------------- 2 km.Additional lead charges : Lead charges for 3 km : Lead charges for initial 1 km.

18.5 Where the basic rates (other than excavation items) provided in the schedule of ratesinclude initial lead of 50 m the additional lead charges for mechanical conveyance shall becomputed for the total lead involved and both loading and un-loading charges shall be added.


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18.6 For excavation items, where the basic rates provided in the schedule of rates includeinitial lead of 50 m, the additional lead charges by mechanical conveyance shall be for thetotal lead and only un-loading charges shall be added.

18.7 The quantity for the purpose of lead by mechanical means, loading and un-loadingcharges shall be the bulk volume without deduction for voids. The allowance for bulkage toaccount for voids / increase in voids in the excavated materials shall be as under:

All kinds of soil 20 percent.All kinds of soft rock 30 percent.Hard rock 40 percent.

18.8 The quantities of materials required for each item for working out the additional leadcharges shall be computed and a statement to this effect shall be included in each section ofschedule of rates.

18.9 Additional lift charges:

Lifting of materials to point of final placement can be by deploying manual labour or bymechanical means. In case of use of machinery the cycle time for round trip operationincludes lifting of the materials vertically or along the specified gradient in case of haulage. Incase of manual labour also generally material storage and handling is managed by creatingworking platforms at convenient elevations along the valley slopes to minimise the liftingefforts. Such arrangement also ensures better progress of work. The cycle time considered inworking out the daily output of labour includes conveying materials along such ramp ways.Therefore the basic rates to be included in the schedule of rates for dam / canal / tunnel andallied works shall be for all lifts.

19.0 DEWATERING & DESILTING:

19.1 De-watering and de-silting are need based requirements and as such the rates providedin the schedule of rates for individual items shall be exclusive de-watering and de-silting.Provision for de-watering may be made under separate item in the estimate / contract or byincluding the cost of de-watering in various items of work on percentage basis while preparingestimates / tenders. Though provision of separate item for de-watering is more rational as itallows payment for actual quantity of water pumped out, the monitoring is difficult particularlyfor dams / canals and allied works in view of de-watering at various places and use of dieselpumps also. There are also some other lacunae in this system leading to possible dis-proportionate increase in de-watering costs for dams / canal works. However, for tunnelworks, where diesel operated pumps are not allowed, better monitoring is possible by

arranging separate power supply line with metering arrangement for de-watering and as such

GENERAL GUIDE LINES FOR PREPARATION OF SCHEDULE OF RATES

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