S.

No Description Heavy Fabrication Medium Fabrication Light Fabrication

Roof
Box Girders & Built-up
1 Steel structures Girders,Columns,Trusses Purlins & Bracings
sections
& Ductings
2 Mandays per Tonne 16 -18 13-15 08--10

3 Consumables

Oxygen m 3 / t 6 4.5 3

DA m 3 / t 2 1.5 1

Electrode kg / t 16 12 8

Metal Deposit- Metal Deposit

S.No Electrode Size
E 6013-gm/Electrode E 7018 - gm / Electrode
1 2.5 dia 12 14
2 3.15 dia 23 26
3 4 dia 38 42
S.No Classification of Work Mandays / tonne
1 Boiler MainStructure & Sp Structures 8
2 Boiler auxiliary structure 10
3 Platforms, Ladders ,Gratings & Handrails 12
4 Ductings and Coal Bunkers 12
5 Steam Drum 4
6 Furnace Walls 20
7 SuperHeaters 25
8 Preheater 25
9 Economiser 20
10 Buckstay 10
11 Downcomers & Aux. Piping 35
12 Mainstream, Hotcold reheat,Boiler Feed etc.. 30
13 Coal Mill 8
14 Fans & Blowers 12
15 Fuel Feeders,Pumps 15
16 Air Preheater 10
17 Blowdown / Flashtank 6
18 Soot Blowers 10
19 Boiler Casings 20
20 Windbox,Fuel burner,Sampling rack etc.. 15
21 ESP Housing, Hopper & Electordes 10
22 Service / Instrument Air System equipments 12
23 Fuel Piping 12
24 Boiler Controls, Instrument panels etc.. 12
25 Service / Instrument Air Piping 100
26 Lifting tackles 15
27 Headers 15
Average for Boiler / Excluding ESP 15
 Consumables per Metric Tonne
S.No Description of Work
Electrode Oxygen DA
kg m3 m3
Boiler Main Structure, Bunker,ESP
1 3 1.8 0.6
Structure
2 Boiler Auxiliary Structure 5 3 1

3 Platforms, Ladder 5 3 1

4 Ductings, Coal Bunkers 9 3.6 1.2

5 Boiler Casings 10 3.6 1.2

6 Housing & Hopper 9 3.6 1.2

7 Supports of Pressure Part 1 4.5 1.5

1 Oxygen 30"dia / m 3
2 DA 90"dia /m 3
3 Carbon Steel FillerWire 120"dia / kg
4 SS Filler Wire 80"dia / kg
5 Cut-off wheel -1/8" x 7" 50" dia / disc
6
7
Tungsten rod 3 /32"
Grinding Wheel-3/16"x7"
120" / rod
100" / disc
1 Welding Gloves 15 Mandays / glove
2
8 Hand Wire brush CS 120" dia / brush 2 Painting 8 m / l or 3 l / t
9 Hand Wire brush SS 80" dia / brush
10 Welding Helmet 80 Welderday / No. Structural 10 t / fabricator
11 Leather hand Gloves 15 Welderday / No. 3
12 Electrode Holder 30Wlederday / No. Fabrication /month
13 Hacksaw blade-1/2" x 12" 120"dia / blade
14 Hacksaw blade 1" x 12" 500"dia / blade 10 t / Welder /month
15 Ceramic Nozzle 200" dia / No.
16 Grinder's Goggles 15 Grinderday / No.
17 Gas Cutter Goggles 12 Grinderday /No.
18 Welders dark glass 20Welder day/No.
19 Welders white glass 10 times the Darkglass
20 Argon Gas 16" dia / m 3
 Static Equipments upto 20 tonnes - 12 to 14 mandays per tonne
above 20 tonnes - 8 mandays per tonne

•Average of 3 to 4 meters on 6 mm fillet weld [two runs] per day - 8 hrs shift

•One welder deposits 3 to 3.5 kg of Electrode or burns 50-60 electrodes.

•CO2 Welding 3 times productivity when compared to manual welding

•SAW deposit rate of 20 to 25 kg per shift

Concreting footings 0.13 m3 / manday

Concreting major raft 0.16 m3/manday
Concreting superstructure 0.09 m3 / manday
PCC - 8 m3 / manday
Brickwork 1 m3 / masonday or 4 to 5 m2
Plaster 10-12 m2/masonday
Painting 30 m2 / painterday
Excavation Soft Soil 3 m3 / manday
Excavation Hard Soil 2 m3 / manday
Earth filling 3m3/ manday
• Welding Machine - 16 to 20 kW
• Mixer Machine 3 to 4 kW
• Concrete vibrator - 2.5 kW
• 5 ton Winch - 11 kW
• 10 ton Winch - 25 kW

• Water required for 1m3 of concrete - 200 litres

• Water required for curing - 50 litres / m3
• Potable & service water - 10000 litres / day
• Water for Labour Colony - 20litres / person / day

• Refractory of castables / bricks - 20 manday /m3

• Hot Insulation 2.5 m2 / manday
• Cold Insulation 1.5 m2 / manday
• Cryogenic insulation 1 m2 / manday
• HT Switch gear - 12 mandays / panel • Instrumentation Supports - 1 metre / manday

• 10 MVA transformer - 60 mandays / no. • JB & instruments one / manday.

• Smaller Size - 40 mandays / no. • Trays - 4 meter / manday.

• Panels - 8 to 10 mandays / panel • Impulse lines - two meter / manday

• Lighting transformers - 6 mandays • Air Lines - 2 meter / manday

• JB and Push button - 3 mandays / no. • Laying Multitubes - 5 meter / manday.

• Cable tray erection - 25 to 30 manday / tonne • Multi-cables - 8 m / manday

• HT cable laying - 2 m / manday • Copper tubes - 16 m / manday

• LT cable laying - 15 m/ manday • Local controller - installation - 2 mandays

• Conduit laying 4 m/ manday • Hydro /Pneumatic testing - 15 m/ manday

• Light fixtures - 2 manday / no. • Loop Checking 0.75 loop / manday.

• HT termination - 6 mandays • Inter-connection - 20 connections / manday

• LT termination - 3mandays
• Light poles - 2 nos. /manday