Cost Analysis for

Fabrication and Erection of Steel Arch Bridges on

East West Highway (H01)
Item of Work:
Steel Arch (Providing, Fabricating, assembling and erecting structural
steel components/elements including nut, bolt, gusset plate ,including
heavy zinc coat galvanization, facilities for inspection & test in gradual
assembling as per approved design, shop drawings, technical
specification and to the satisfaction of Engineer all complete)

Total Quantity:
12,555,255.00 KG (Two Packages)
Plan and Elevation of Bridge
Total Weight of Bridges

max Height of Steel Weight Nut Bolts

S.No Bridge Name Span No of Span Width bridge KG Weight KG
mtr mtr mtr
Pack-x
1 b 79.5 2 13.95 13.5 1,506,740.00 41,362.40
2 k 87.6 4 13.95 14.9 3,353,504.00 90,809.36
3 n 79.5 2 13.95 13.5 1,506,740.00 41,362.40
6,366,984.00 173,534.16
Pack-y
4 B 79.5 2 13.95 14.6 1,506,740.00 41,362.40
5 L 85.25 2 18.65 14.6 1,820,800.00 54,588.37
6 R 87.6 3 18.65 14.9 2,860,731.00 82,093.13
6,188,271.00 178,043.90
Total Weight 12,555,255.00 351,578.06
Maximum Sizes and Weights
Max Lifting Max Length of single
S.No Bridge Name Weight piece
MT m
Pack-x
1 b 14.6 11.6
2 k 15.5 12.4
3 n 14.6 11.6
Pack-y
4 B 14.6 11.6
5 L 15.3 11.8
6 R 15.6 12.4
Quantity of Plates in Different Thickness (E410)

Plate Thickness

Bridge Name 12mm 16mm 20mm 26mm 30mm 40mm Total Qquantity
B 166718 183102 304235 162301 687233 3149 1506738
326,304
K 366740 417795 696074 1539602 6990 3353505
N 166718 183102 304235 162301 687233 3149 1506738
B 166718 183102 304235 162301 687233 3149 1506738
L 232660 263298 351008 179947 790392 3495 1820800
R 359357 399288 539806 0 1557036 5243 2860730
Total MT 1458.911 1629.687 2499.593 993.154 5948.729 25.175 12555.249

Percentage by
thickness 11.6% 13.0% 19.9% 7.9% 47.4% 0.2% 100%
* Length Prefered 12.5m (minimum 12m) *Width prefered 2.0m to 3m
Summary of Rate Analysis for 1MT of finished goods
(for 1000 kg weight/5% waste considered)
Amount
Unit Assuming 6000 Amount Assuming
S. No Item Qty Unit Rate MT work) 12000 MT work)
Steel landed cost
(78 IC CIF*1.6+7.5%+2.5 transport
1 Nepal) 1050 Kg 137.00 143,850.00 143,850.00
Fabrication Consumables and
2 Electricity 7,500.00 7,500.00
3 Fabrication Labour 9,000.00 9,000.00
4 Erection labour 9,000.00 9,000.00
5 Erection Consumable and tools 5,000.00 5,000.00
6 Galvanization 17,970.00 17,970.00
7 Transportation to site 3,500.00 3,500.00
Depreciation of Equipments/Capital
8 Investment 29,683.33 18,266.67
225,503.33 214,086.67
OH Profit 7.50% 16,912.75 16,056.50
Rate/MT 242,416.08 230,143.17
Rate/Kg 242.42 230.14
Capital Investment Cost per KG

Cost/Kg for 6000 Cost/Kg for 12000

SN Items of Capital Investment MT in total MT in total

1 Fabrication Equipment 4.50 3.16

2 Erection Equipment 8.94 6.28

3 GI Structure and plant 7.42 4.41

4 Initial Zinc investment 8.82 4.41

Total 29.68 18.27

Sample Costing of Capital Investment (Fabrication Equipment)
Cost/Kg for Cost/Kg for
6000 MT in 12000 MT in
A Fabrication Equipment Qty Unit Unit Rate Amount total total

CNC cutting 2 Set 5,000,000.00 10,000,000.00

SAW 2 Set 2,000,000.00 4,000,000.00

Mig 10 Set 500,000.00 5,000,000.00

Crane 35 Mt 1 nos 17,500,000.00 17,500,000.00

Total 36,500,000.00

12% interest*2 years 24% 8,760,000.00

Recovery loses at the end of project 6000 MT Proj 50% 18,250,000.00

Recovery loses at the end of project 12000 MT Proj 80% 29,200,000.00

Total Effective Investment for 6000 MT Proj (intrest+rec. Loss) 27,010,000.00 4.50

Total Effective Investment for 12000 MT Proj (intrest+rec. Loss) 37,960,000.00 3.16
General Approaches
to Carry Out the Project
Cutting
Method Tools/machine Explanation
Used for any shape of cutting,( linear and
curvilinear closed/open shape), specially for
CNC Plasma Machine with 3.0m curbed/cambered web plates, polygonal
x13.0m table up to 30mm Plate gusset plates etc.
Plasma Cutting cutting Capacity

Pug Cutter with aluminium

Track,cutting Capacity up to 50 mm Generally used for Linear straight cutting
thick plate
Hand cutting Tourch Used for rolled section cutting,
Oxyfuel Cutting
Hydraulic Shearing machine up to Used for rectangular shaped plates cutting,
25mm and 2.5 m wide cutting e.g for splice plates, stiffner etc.
Shearing

Band saw machine Up to 300mm x300mm profile cutting Used for rolled section cutting,
Drill Marking and Drilling

Method Tools/machine Explanation

The same machine used for

CNC Marking cutting is used for centre mark of Any pattern of hole positions
hole position can be marked on plates

Magnet Drill machine with core

cutter bit , capacity from 14mm Used for plate and other section
Core Drill dia. Hole to 42mm dia. hole and up drilling at shop and site
to 50 mm thick plate
Edge Preparation
Method Tools/machine Explanation
Edge preparation Machine
Machined edge with beveling/camphering
preparation tools
Used to prepare plate
edge for welding where
Pug cutter with tilted cutting required as per
head adjustment facility. The specification
Oxyfuel cutting for edge same machine for plate cutting
preparation can be is used.
Jiggs Assembly
Method Tools/machine Explanation

Jigs and fixture are

product dependent and Jigs and fixtures are most
Different Components are fabricated at shop essential to place each
arranged on jig and fixture to according to size and component at correct
make single assembled unit at shape of components to location/position and to control
shop by welding. be assembled distortion due to welding
Welding and Testing
Method Tools/machine Explanation
Autometic Submerge arc welding For Heavy and continuous welding
(track travelling type)
Arc Welding For tack welding, small piece
Manual Arc Welding welding and for position where
ASW can not be used
Track travelling type MIG welding
machine For Heavy and contineous welding
MIG welding For tack welding, small piece
Manual MIG welding Machine welding and for position where
ASW can not be used
Depends on size and shape, lot
size, and specified on technical
X-ray, Altrasound welding testing specification
Welding Tests: NDT
machine, Chemical Penetration The defected welding is removed
test by grinding and re-welded and
checked again .
SAW Pictures
Factory Assembly and Checking

Method Tools/machine Explanation

Partly or whole
bridge is assembled at shop
to ensure the correctness of Temporary assembling bolts
fabrication . Lifting crane/Hydra are used for bolted joints
Corrosion Protection (Hot Dip
Galvanizing)
Method Tools/machine Explanation

Pickling is to remove rust and other foreign material

sticked on steel surface with the help of acid bath

Pickling and rinsing Galvanizing plant with Fluxing is to make thin protection layer to prevent
12.5m long 1.5m wide rusting before hot dipping process.
and 2.5m deep zinc bath
Fluxing and other processing Hot dipping is to dip the well dried flux coated steel
tanks shall be at least parts on zinc bath for zinc coating on surface.
same capacity of zinc
Hot dipping bath Quenching is to quench the hot steel immediate after
hot dipping process
Quenching
The Thickness of zinc coat on steel surface is
measured with the help of electronic coating meter to
ensure the required thickness of coating. If the
required thickness is less than specified the work
Coating Testing Coating Meter piece is subjected to re galvanizing
Erection Works at Site
Method Tools/machine Explanation

The false work member shall be

False Works: designed to withstand the load of
Metal False work is installed on Fabricated post ties and steel bridge at construction
filled and compacted ground bracing, lifting crane up to phase, these supports are
below the true position of bridge 50 MT capacity removed after fully tightening the
at site bolts and placing bridge at
bearing position

Erection of Main Structure:

Bottom member and floor beams Lifting Cranes 50 Tonne,
are first placed at position Electrical Winches,
maintaining required in place Bolt tightening Wrench, The Bolt tightening torque value
camber. Then Top Torque Wrench to ensure and tightening method shall be
Chord ,suspender and top lateral the tightening torque. followed
ties are installed
Erection Photos
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