ASSIGNMENT NICMAR/CODE OFFICE Name : Regn. No. : Course No.: Course Title: Assignment No.

: Date of Dispatch ; Last date of receipt of Assignment at CODE Office Scope of work: 100m width of Road construction for international airport 30 km away from city Cutting and dozing of 100,000 cum of earth. Average height 0.75 mtr Transportation of 20,000 cum of surplus earth from site to dumping place 3 km away from site. Filling of 80,000 cum in landing strip. Bringing of 3000 cum of sand from 20 km including spreading and leveling at site. Procurement of 150,000 litres of bitumen from refinery at Bongaigon in Assam.

NCP-24/25 Material And Equipment Management

Description of Equipments: Hauling equipments Tractor: Tractors have many uses as construction equipment. Use of this, primarily may be to pull or push goods, they are also used as mounts for many types of accessories such as front end shovel, rippers, bulldozers, sidebrooms, hoes, trenches and others. There are sizes and types to fit almost any job for which they are usable. Tractors may be divided into 2 major types crawlers and wheels. Dumpers Dumper is a heavy duty truck with a strongly built body which is hinged at back and is fitted with a hydraulic ram on the underside to lift the front of the body and tilt it backward into the dumping position. A tailgate may be fitted at the rear of the body or the body may have a chute like shape in the rear with inside corner rounded and sides tapered to facilitate dumping which is most popular now-a-days. Useful life of dumpers is generally 812 years i.e. 10,000 15,000 hours depending upon their capacity. The life is also expressed in terms of kilometers i.e. 200.000 kms. Earth moving machines These equipments are used to cut the earth or trees, rocks and then move them to a distance required. Equipments like bulldozers are also used for leveling of the ground, cleaning land of timber, stumps, spreading earth fill etc. These equipments are very common of all the earth moving machines, a bulldozer is most useful and most the project sites require its use in one form or the other. Bulldozers Bulldozers are basically a pushing unit consisting of a tractor either crawler mounted or wheeled to which a cutting blade is mounted at the direction perpendicular to the direction of travel. There is no difference between a bulldozer and anglodozer except that the cutting blade is set at an angle with the direction of travel. The size of the bulldozer is indicated by the length and height of the blade, its shape and capacity. The size of blade varies from 1.7mX 70 cm. (height) X0.7m3 (capacity of blade) to 3.38mX1.14mX3.7m3.

Working of dozer consists of lowering front blade to the ground. The moment dozer drives, it cuts and pushes earth collected in blade to a desirable distance. Compaction Equipment: Tandem Roller- there is also a smooth wheeled roller with to roller wheels of approximately the same width- one at the front and other at the rear. Compaction with this type is better. This roller is better for rolling finishing surfaces as it produces smooth and even surface. Bitumen Plant: Bitumen Boiler: This is used for heating bitumen from drums. Boiler is fitted with a fire box, fuel tube and chimney. Full asphalt drums are lifted to the top where the contents are emptied and heated by flame or combustion gasses. The boiler is mounted on the wheels and can be towed from one location to the other. Bitumen Spraying Equipment: Bitumen boiler is fitted with the pump with strainer in the suction pipe. The pump is operated either by hand or mechanically. On the delivery side there are flexible pipe spray bars and spray nozzle. The rate of application of bitumen can varied by adjusting the height of the spraying nozzle above the ground. Uniformity of spraying is control by the angle at which the spray bar is kept. Bitumen Tanker: When bulk bitumen is to be transported, tanker is used. It is mounted on a truck or a trailer. Capacity of the tanker may range from 5000 to 15000 liters. Oil fire burners are used to maintain the temperature of bitumen during transit. Bitumen Pressure Distributor: This equipment is used when a specified quantity of hot bitumen is to be sprayed uniformly for grouting or surface dressing. It is used with bulk bitumen supply.

Estimating and requirement of the equipment: Equipment on roadwork (or on any work) has either to be purchased, obtained on hire or transferred from some other project. In either of the cases a fairly accurate estimate of the requirement of equipment has to be done so as to ensure that expenditure on equipment is not wasted. This needs planning well an advance. Factors to be considered are: 1. What is most desirable sequence of operations involved in the work? 2. Which are the operations are to be performed by the machinery? 3. In case some or all equipment is to be transferred from other projects how the programmes of both project to be arranged so that there is no undue to and from movement of the equipment and at the same time the work is completed in optimum time. Data required: 1. Quantities of items of work: Road project is sub divided in operations like (A) Earthwork (B) Aggregate production (C) Transporting Aggregate to road (D) Compaction (E) Wearing surface- Concrete/ Bituminous surface etc. Quantities of items are worked out. 2. Period of completion of the project. Normally road work has to be completed in a stipulated period particularly when the work is to be completed on contract. In such cases the duration of the constituent operation have to be adjusted taking in to consideration the activity interrelation and overall period of completion. While fixing of activity duration due allowance must be made for bad weather, monsoon, loss of time due to shifting of equipment, break down, repairs and maintenance of equipment. 3. Normally no work is possible for 3 to 4 months in a year due to monsoon. Further considering weekly holidays normally 25 days could be considered to be available for working. Though a working day is considered to comprise 8 hours, a part is spent in

4.

inevitable operations like shifting, waiting etc. thus in about 200 days available, working hours could be about 1200-1500. From above a fair estimate of requirement of equipment can be done. Over the above this suitable provision ( to the extant of 10%) is done as stand by to take care of break down or unforeseen circumstances.

Determine the output of a bulldozer from the following operating conditions: Material: Sand Swell = 20% Haul Distance = 40m Rated mold board capacity = 3 cubic metre (loose volume) Operating factor 45 minutes/ hour Solution: Probable round trip time Pushing 40 m @ 2,5 kmph Returning 40m @5kmph Loading shifting gear Time per Trip Trip per Hour Net mold board capacity Output per hour output per day

= 0.96 minute = 0.48 minute = 0.30 minute = 1.74 minutes = 1.74 minute = 34.5 Trips = 3/1.2 = 2.5 =2.5x34.5 = 86.25 m3 = 86.25x8 (hours) = 690 m3

cutting and dozing of 100,000cum of earth = 100,000/690 =145 days Equipment operating cost: The cost of operating the equipment includes fuel costs, routine maintenance costs, major repair cost, operators cost, tyre replacement cost, and overhead costs. Fuel costs: cost of fuel consumed in one hour = cost per litre X hourly fuel consumption Hourly fiel consumption = Hourly fuel consumption at full load X operating factor. The fuel price litre, delivered at the site is obtained from the local suppliers at it varies from place to place. The rate of consumption depend upon the type of engine (diesel or petrol), the state of the engine and the working conditions. Diesel engine fuel consumption per hour = 0.15 litres X rated HP X load factor Petrol engine fuel consumption per hour = 0.22 litres X rated HP X load factor. For example: the hourly fuel consumption of a crawler tractor rated with 250 HP, operating under average conditions (load factor 70 %) and diesel costing Rs. 35 per litre., can be worked out as under: Diesel consumption per hour = 0.15 X Rated flywheel HP X load factor = 0.15 X 250 X 0.7 litres = 26.25 litres Cost of hourly consumption = Diesel consumption X rate of diesel per litre

= 26.25 litres X Rs. 35 = Rs. 918.75 Routine maintenance costs: Maintenance costs include the cost of lubricating oil, grease, filter batteries, minor repairs, and the labour involved in performing maintenance. The maintenance cost including service, labour cost and minor repairs vary with the type of equipment involved and the project environment, and these can be approximately calculated as proportion of hourly fuel cost as follows. Operating conditions Favourable Average Unfavourable Hourly maintenance cost 1/4 fuel cost 1/3 Fuel cost 1/2 Fuel cost

Major Repair cost: Repair cost = Depreciation cost X Repair cost Repair cost during nth year = n X Value to be depreciated / Digit sum of equipment life in years For example: If the total value of depreciation of a wheel equipment (repair factor = 0.75) works out as Rs. 375,000 and its life is 5 years, than the repair cost during each year of operation (working 1500 hours per year) can be estimated as under: Total repair cost = Total depreciation X Repair factor = 375000 X .75 = Rs. 281250 Tyre cost for wheel equipment: The tyre manufactures provide indication of tyre life but these should be taken as guidelines. Hourly tyre replacement cost = 115 X tyre price X no. of tyres / Tyre life in hours Example : If the four tyres of an equipment each costing Rs. 2500, are replaced after 800 hours and the tyre can be recapped locally, then the hourly tyre cost calculated as follows: = 115 X 4 X Rs. 2500 X0.8 / 800 = Rs. 115/hr Manpower cost: An equipment requires operators, drivers and helpers for its operations. The number of persons working on an equipment varies with type of equipment. A dumper may have only one driver-cum-operator whereas a bulldozer will need one operator and a helper. Depending upon the persons require per machine, the prevalent wage rates and the facilities provided by the company, the hourly manpower costs can be calculated. Selection of Construction Equipment: Proper selection of equipment increases the speed of construction and makes project most economical. Some general consideration may be made for selections of construction equipment are: 4. As far as possible only equipment available with ease should be selected. Unless and until it is ascertained that new equipment will earn more than its cost or cab used in future also, it should not be purchased. Economics should be worked out. 5. Choice should be restricted to standard equipment, special equipment should be selected if job justifies its selection. 6. Topography conditions, type of soil, existing approaches and road working conditions etc., must be studied. 7. Less variety of equipments should be used, more variety means more skilled workers, more spare parts requirements and more production cost. 8. It is always better to purchase equipment manufactured in our own country. This will decrease the cost of repairs and down-time cost. It will be beneficial to the nation also. As far as possible equipment of same make should be purchased.

9.

Size of equipment should be made according to the amount of work. It is better to use more than one equipment of small size than using of one of large size. 10. Obsolescence of the equipment should not be overlooked. 11. Equipment should be capable of doing more than one job, but it should not be versatile. 12. The technical and economic aspects should be analyzed to select the equipment. Following aspects need detailed consideration at the selection stage: 1. Suitability for the job with specific reference to climatic and other operating conditions. 2. Size of the equipment 3. Standardization and variety reduction 4. Type of prime mover 5. Degree of utilization 6. Suitability of local condition 7. Adaptability 8. Technical considerations. The choice of size of the equipment is indicated as either a minimum number of large size machines or several units of medium/small size machines. Technical consideration for selection should include the following points. 1. Strength 2. Vibration Stability 3. Resistance to wear 4. Heat Resistance 5. Reliability 6. Maintainability Equipment can be classified as: 1. Standard equipment 2. special equipment It depends on extent of its use, availability and cost. One equipment standard for one may be special to other, for example a concrete mixer of specific capacity is a standard equipment for all most all the contactor whether class A or class D but cranes or concrete mixer of very large capacity are special to one whilst standard for other. One definition for standard equipment is that which is easily available in the market. It is easy to repair, spare parts are easily available and can be disposed off easily. Whilst special equipment manufactured on order and can not be disposed off easily and cannot be repaired by all. In general special equipment can be defined as an equipment manufactured for a single construction project or for a specific job. Material Management : The management of materials in project is different from that in an ongoing situation. Most of the materials in projects are bulky and heavy. The lead time for procurement of materials in most cases is usually much more. The principle of EOQ has very limited applicability in project situations. Usually sequential arrival of material is desired. The demand of material in project is by and large highly deterministic. Sufficient care has the be taken in the selection of vendors has significant impact on the project performance. The demand of materials in a project situation is highly deterministic. The gross requirement of various material is worked out during the detailed project report stage. The primary concern in material planning for project is that the cost of not meeting a demand is very high. As it may lead to delay in proper completion. Hence the right time is the key word in material planning for projects. The capital requirements are to be planned in such a way that these are available at the site just before the erection/ installation of these. The demand of construction is known as soon as the resource requirement for the project is finalized. These material are normally required before the construction can start and are to be planned for availability prior to the construction phase of the project.

The consumables are used throughout the project duration and the total requirements are known. However the consumption rate at different period is different but deterministic. As the total number of consumable materials may run in to hundreds, the analysis of aggregate demand pattern may be restricted to high consumption value materials only. Procurement is of special significance in a project situation. The net effect of delay in delivery and supply of inferior quality of material is delay in the completion of the project. Economic procurement is also very important as it is determinant for the viability of the project. Because of these considerations vendor selection plays an important role. The consumables are standard materials and are usually available from many sources. Occasionally there is a scarcity of some of these materials. The gross demand as well as the demand profile of these materials for the entire project duration are known, and it is desirable to enter into contracts with the suppliers. Apart from these discussion on the technical details and price the negotiation can centre around the following issues: Ordering Schedule : To match with the project network. The suppliers network for manufacture ca also be discussed. Payment terms Liquidated damages Quality specifications and procedures for checking quality Inspection at different stages of manufacture at the suppliers premises. Incorporation of design changes while the manufacturing is in progress. Performance guarantee etc. The inventory replenishment model shows the number of cycles of replenishment during the usage period. The initial inventory of materials at the start of the work consists of working stock (Q) and safety stock (S). Economic order Quantity: Two important decision to be take while repetitive materials inventory are how much to order at one time and when to order this quantity, or in other words, to decide the reorder the quantity level and the reorder time cycle so as to effect economy in cost of purchasing and holding inventory. This economic order quantity (EOQ) and the numbers of orders are determined mathematically as under: Inventory cost C = Ordering cost + Inventory carrying cost C = Co . N + Ci . A/2N For cost to be minimum : dC/dN = Co Ci . A/ 2 . N2 = 0 N2 = Ci . A/2 . Co And Therefore Least Inventory cost = square root of 2CoCiA Safety Stock: It is the floating stock held to cater for changes in rate of consumption, delays in delivery of materials from the agreed dates and under unforeseen causes, so as to prevent stock-outs resulting in production hold-ups. The safety stock for a given situation can be determined using statistical techniques. Generally, a minimum safety stock can be taken as equal to consumption quantity in lead time period. C = CoN + Ci A/2N = 1/2N (2CoN2 + Ci A) = 2Ci A/2N

Lead Time: It is defined as the total time required for replenishment of an item of material from the time and indent is submitted to the purchased department, to the time that ready for use materials are received at the project stock-yard for storage or delivered at the site of work. Reorder level: It is the level at which the stock is ordered. This is determined by adding assessed consumption during the lead time period to the minimum stock level. Conclusion: As can be seen the management of materials in a project is very much different that in an on-going organization. It calls for decisions which are very much related to the specific project situation and improper attention to this function in projects may lead to undesirable cost and time overrun. (a) Procurement of 1,50,000 litres of bitumen. Duration of work 30 days from the 60 th day of starting work. Lead time for the procurement of bitumen is 45 days. Storage facility of 50,000 litres at site.

Estimate total cost of work and your plan of: (b) (c) Equipment planning procurement and development. Ordering and replenishing of Bitumen.

SCOPE OF WORK 1. The scope of Work in Phase I, comprises of construction of one strip of landing 100 m width is to be constructed in 100 days. The scope of work is as follows: (a) (b) Cutting and dozing of 1,00,000 cum of earth. Average height is 0.75 m. Transportation of 20,000 cum of surplus earth from site to dumping ground 3 KM

away from site. Filling 80,000cum of earth. (c) (d) Bringing of 20,000 cum of sand from 20 KM (including of spreading and levelling). Procurement of 1,50,000 litres of bitumen. Duration of work 30 days from the 60 th

day of starting work. Lead time for the procurement of bitumen is 45 days. Storage facility for bitumen is 50,000 litres at site.

DESCRIPTION OF EQUIPMENT CONSIDERED

2. The work can be divided into various sub tasks, for each of the sub tasks different type of earth moving plant should be used as mentioned against each in the table given below:

S No (a) (b)

Activity Area Clearance and Cutting of earth. Filling / disposal of earth.

Equipment Recommended Dozer D 80 A 12 Tippers / Dumpers

Remarks

(c) (d)

Levelling. Spreading of sand and Compaction.

Motor Graders Motor Grader, Rollers

3. Description of the Equipment. (a) Dozers. There are basically two types of dozers they are tracked and wheeled, both these

equipment are manufactured. manufactured by BEML India, as the type of terrain has not been mentioned, tracked type of dozer has been considered as it has better traction and rolling resistance as compared to the wheeled dozer. D 80 A 12 has been considered for the said task it has the following salient characteristics: (i) (ii) (iii) (iv) Blade capacity Output 4.8 cum

- 50 cum/hour

Diesel consumption - 18 litres/ hour Blade can move up and down and can be tilted side wards to give an angle cut.

(b)

Excavator (E JCB 3 DX). This equipment is manufactured by Tata Engineering, India and

has the following salient characteristics: (i) (ii) (iii) (iv) Bucket capacity Output 1.5 cum

40cum/hour

Diesel consumption 07 litres/ hour The equipment is versatile and has many attachments and can perform many

functions such as digging, dozing, hauling, loading etc. (c) Motor Grader. This equipment is manufactured by BEML Engineering, India and has the

following salient characteristics:

(i)

The equipment is predominantly used for levelling shaping, grading etc It has a scarifier that

loosens the earth before the blade levels the area. The motor grader has a capacity of 100 cum per hour.

(d)

Compaction Equipment. After the area is levelled out the soil has to be compacted so as to

prepare it for the laying of the wearing course this is achieved by the use of compaction equipment. There are various types of compaction equipment in the market they are: (i) Smooth Wheel Rollers. The equipment comprises of one heavy roller that leading in front of

the equipment and two smaller rollers that by virtue of its weight compact the loose earth. (ii) Tandem Rollers. The equipment is similar to the smooth wheel roller except that the there

are only two wheels of the same width that by virtue of its weight compact the loose earth. (iii) Vibratory Roller. The roller in addition toits self weight generates vibrations in static and

dynamic mode that results in better compaction. The roller that is being considered is of 10 ton capacity. (iv) Sheep Foot Roller. The surface of the roller has projections that help in exerting point

pressure on the earth surface thereby enabling better compaction.

(e)

Tippers. The excavated earth has to be disposed off / transported to the filling sites in

case it is beyond the economic haulage distance. This is done by the help of tippers. The loaded material can be unloaded from the vehicle either by tilting the body if the vehicle backwards or to the sides, in certain tippers the material is discharged from the base of the tipper. This equipment can be utilised for the transportation of construction material.

CALCULATION OF WORK PER DAY

4. Assumptions. The following are assumed.

(a) (b) (c) (d)

Type of equipment. As considered in the paragraphs above. Working Hours. 10 hours per day and max of 60 per week. Maintenance. 10 hours per week per plant (one day per week) Induction period. Three working days, (for dismantling, transport,reassembly testing). For

a lead of 100 km. (e) (f) (g) Break Down Period Considered. Four days per equipment. Adequate spares and sub assemblies are available with trained maintenance staff. Mass diagram of the area has been prepared and the plant operators are familiar with the

task at hand. (h) (i) (j) (k) Work is being executed as per the mass diagram. Plant operators are experienced are capable of achieving the planned out put. No disruptions have been considered for reasons of inclement weather / other factors. Plant / equipment as planned will be made available.

5. Cost of Equipment Operation per Hour. The cost has been calculated based on the equipment cost (including interest, depreciation,, maintenance charges, operator charges and fuel and lubricants)

S No (a) (b) (c) (d) (e) (f)

Equipment Name D 80 A 12 E JCB Wheel Dozer Motor Grader Dumper Roller

Cost of Operation Rs / hour 2,200.00 800.00 1,300.00 1,500.00 400.00 800.00

6. Cost of each Item of Work. (a) Cutting and Dozing. (i) Total earth cutting 1,00,000 cum

(ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x)

Out put of dozer Out put per day -

- 50 cum/ hour; 10 hrs per day 500 cum in one day

Out put of Excavator - 40 cum / hour Out put per day - 400 cum in one day

Team of two dozers and Excavators 1800 cum No of days required - 55 days. Cost of Dozers =2* 55*10*2,200= Rs 24,20,000.00 Cost of Excavator =2*55*10* 800= Rs 8,80,000.00 Additional requirement of plant due to days lost for maintenance 10; (Rs 4,40,000

for Dozer and Rs 1,60,000) (xi) Total for excavation Rs 38,80,000.00 (b) Transportation and Spreading of Earth. (i) (ii) (iii) Volume of earth to be shifted from site 20,000cum Capacity of Dumper 5 cum No of trips per day (aa) Dumping site total distance 6 Km (ab) Travelling time 20min (ac) Loading / Unloading time 10 min (ad) Trips per day 2* 10= 20 trips (ae) Volume of earth shifted per day 100 cum (af) Volume to be shifted in a day 364 cum (ag) Number of dumpers required 4 (ah) Cost of Dumpers 4*400*55 = Rs 88,000

(iv)

Cost of levelling. (aa) Motor graders used two.

(ab) No of Days -55 (ac) Cost 2*55*1500 = Rs 1,65,000.00