Steel Bridge Cost Manufacturing in Nepal Proposal subject to client approval Fe 415 Galvanized bridge to be constructed in Nepal . It is proposal from a manufacture.

1. Cost Analysis for
Fabrication and Erection of Steel Arch Bridges on
East West Highway (H01)

2. 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)

3. Plan and Elevation of Bridge

4. Total Weight of Bridges
S.No Bridge Name Span No of Span Width
max Height of
bridge
Steel Weight
KG
Nut Bolts
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

5. Maximum Sizes and Weights
S.No Bridge Name
Max Lifting
Weight
Max Length of single
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

6. Quantity of Plates in Different Thickness (E410)
Bridge Name
Plate Thickness
Total Qquantity
12mm 16mm 20mm 26mm 30mm 40mm
B 166718 183102 304235 162301 687233 3149 1506738
K 366740 417795 696074
326,304
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

7. Summary of Rate Analysis for 1MT of finished goods
(for 1000 kg weight/5% waste considered)
S. No Item Qty Unit
Unit
Rate
Amount
Assuming 6000
MT work)
Amount Assuming
12000 MT work)
1
Steel landed cost
1050 Kg 137.00 143,850.00 143,850.00
(78 IC CIF*1.6+7.5%+2.5 transport
Nepal)
2
Fabrication Consumables and
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
8
Depreciation of Equipments/Capital
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

8. Capital Investment Cost per KG
SN Items of Capital Investment
Cost/Kg for 6000
MT in total
Cost/Kg for 12000
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

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

10. General Approaches
to Carry Out the Project

11. Cutting
Method Tools/machine Explanation
Plasma Cutting
CNC Plasma Machine with 3.0m
x13.0m table up to 30mm Plate
cutting Capacity
Used for any shape of cutting,( linear and
curvilinear closed/open shape), specially for
curbed/cambered web plates, polygonal
gusset plates etc.
Oxyfuel Cutting
Pug Cutter with aluminium
Track,cutting Capacity up to 50 mm
thick plate
Generally used for Linear straight cutting
Hand cutting Tourch Used for rolled section cutting,
Shearing
Hydraulic Shearing machine up to
25mm and 2.5 m wide cutting
Used for rectangular shaped plates cutting,
e.g for splice plates, stiffner etc.
Band saw machine
Up to 300mm x300mm profile
cutting Used for rolled section cutting,

12. Drill Marking and Drilling
Method Tools/machine Explanation
CNC Marking
The same machine used for
cutting is used for centre mark of
hole position
Any pattern of hole positions
can be marked on plates
Core Drill
Magnet Drill machine with core
cutter bit , capacity from 14mm
dia. Hole to 42mm dia. hole and
up to 50 mm thick plate
Used for plate and other section
drilling at shop and site

13. Edge Preparation
Method Tools/machine Explanation
Machined edge
preparation
Edge preparation Machine
with beveling/camphering
tools
Used to prepare plate
edge for welding where
required as per
specification
Oxyfuel cutting for edge
preparation
Pug cutter with tilted cutting
head adjustment facility. The
same machine for plate cutting
can be is used.

14. Jiggs Assembly
Method Tools/machine Explanation
Different Components are
arranged on jig and fixture to
make single assembled unit at
shop by welding.
Jigs and fixture are
product dependent and
fabricated at shop
according to size and
shape of components to
be assembled
Jigs and fixtures are most
essential to place each
component at correct
location/position and to
control distortion due to
welding

15. Welding and Testing
Method Tools/machine Explanation
Arc Welding
Autometic Submerge arc welding
(track travelling type)
For Heavy and continuous welding
Manual Arc Welding
For tack welding, small piece
welding and for position where
ASW can not be used
MIG welding
Track travelling type MIG welding
machine For Heavy and contineous welding
Manual MIG welding Machine
For tack welding, small piece
welding and for position where
ASW can not be used
Welding Tests: NDT
X-ray, Altrasound welding testing
machine, Chemical Penetration
test
Depends on size and shape, lot
size, and specified on technical
specification
The defected welding is removed
by grinding and re-welded and
checked again .

16. SAW Pictures

17. Factory Assembly and Checking
Method Tools/machine Explanation
Partly or whole
bridge is assembled at shop
to ensure the correctness of
fabrication .
Lifting crane/Hydra
Temporary assembling bolts
are used for bolted joints

18. Corrosion Protection (Hot Dip Galvanizing)
Method Tools/machine Explanation
Pickling and rinsing Galvanizing plant with
12.5m long 1.5m wide
and 2.5m deep zinc bath
and other processing
tanks shall be at least
same capacity of zinc
bath
Pickling is to remove rust and other foreign material
sticked on steel surface with the help of acid bath
Fluxing is to make thin protection layer to prevent
rusting before hot dipping process.
Fluxing Hot dipping is to dip the well dried flux coated steel
parts on zinc bath for zinc coating on surface.
Hot dipping Quenching is to quench the hot steel immediate after
hot dipping process
Quenching
Coating Testing Coating Meter
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
piece is subjected to re galvanizing

19. Erection Works at Site
Method Tools/machine Explanation
False Works:
Metal False work is installed on
filled and compacted ground
below the true position of bridge
at site
Fabricated post ties and
bracing, lifting crane up to
50 MT capacity
The false work member shall be
designed to withstand the load of
steel bridge at construction
phase, these supports are
removed after fully tightening the
bolts and placing bridge at
bearing position
Erection of Main Structure:
Bottom member and floor beams
are first placed at position
maintaining required in place
camber. Then Top Chord
,suspender and top lateral ties are
installed
Lifting Cranes 50 Tonne,
Electrical Winches,
Bolt tightening Wrench,
Torque Wrench to ensure
the tightening torque.
The Bolt tightening torque value
and tightening method shall be
followed

20. Erection Photos

21. THANK YOU !!!