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PGPM 33 Material & Logistics Management

Rajkumar baghel 28-12-31-6399-2102

ASSIGNMENT
NICMAR / CODE OFFICE

1. 2.

Name Reg. No. Course Title

Rajkumar Baghel 28-12-31-6399-2102 PGPM 33 Material & logistics Management

3. Course No.
4.

PGPM 33 Material & Logistics Management

Rajkumar baghel 28-12-31-6399-2102

ASSIGNMENT Your company has been awarded a contract of developing and constructing a new International Airport 30km away from a city. You have been appointed as Planning Engineer (Materials and equipment). Project is to be implemented in phases. In phase I, one strip of landing of 100m width is to be constructed in 100 days. The scope of work for this assignment is only as follows a) Cutting and dozing of 100,000 cum of earth. Average height 0.75m b) Transportation of 20,000 cum of surplus earth from site to dumping place 3km away from site (including spreading). Filling of 80,000 cum in landing strip c) Bringing in 3000 cum of sand from 20km (including spreading and leveling ) at site

d) Procurement of 1,50,000 litres of bitumen. Duration of work 30 days from the 60th
day of starting of work. Bitumen to be obtained from refinery at Bongaigaon in Assam. Lead time up to site is 45 days. Storage facility available at site 50,000 litres tank. Estimate total cost of work and your plan of i. Equipment planning- Procurement & deployment

ii. Ordering and replenishing of Bitumen.

PGPM 33 Material & Logistics Management

Rajkumar baghel 28-12-31-6399-2102

SCOPE OF WORK a) Cutting and dozing of 100,000 cum of earth. Average height 0.75m b) Transportation of 20,000 cum of surplus earth from site to dumping place 3km away from site (including spreading). Filling of 80,000 cum in landing strip c) Bringing in 3000 cum of sand from 20km (including spreading and leveling ) at site

d) Procurement of 1,50,000 litres of bitumen. Duration of work 30 days from the 60th
day of starting of work. Bitumen to be obtained from refinery at Bongaigaon in Assam. Lead time up to site is 45 days. Storage facility available at site 50,000 litres tank.

PGPM 33 Material & Logistics Management

Rajkumar baghel 28-12-31-6399-2102

EQUIPMENT MANAGEMENT CONSISTS THE FOLLOWING: 1) Selection of equipment 2) Number and sizes of units 3) Matching capacities 4) Schedule of procurement 5) Arrangement of skilled staff for operation and maintenance 6) Establishment of services and repair facilities 7) Maintenance of spare parts inventory 8) Decision regarding number of shifts per operation

Thus a systematic approach in planning for equipment is necessary, incorporating all the factors detailed above. In addition an important factor to be considered is the necessary inter-disciplinary acceptance of the planning for equipment.

MATERIAL MANAGEMENT CONSISTS THE FOLLOWING: Materials management is very important for timely completion of the projects. A delay in providing the materials for construction will naturally put the project behind schedule from which

PGPM 33 Material & Logistics Management

Rajkumar baghel 28-12-31-6399-2102

it may never recover or the cost of bringing it back on schedule may never recover or the cost of bringing it back on schedule may be very high.

Some important functions are below: Identification and estimation of materials management Procurement Transportation Inventory control Storage Control and analysis of material information Disposal of surplus, materials, scrap, empties etc PROCUREMENT: The procurement of material can be done by two methods

Centralized procuring:- indicates that the entire purchases is done at on replace. Decentralized procuring:-indicates that materials are purchased at different places.

LEAD TIME: One of the factors to be considered in procurement of material is lead time. It is the period elapses between the point of time when the need for material is contemplated and the point of time the material actually available on the site of construction for use. It comprises time required for:

PGPM 33 Material & Logistics Management

Rajkumar baghel 28-12-31-6399-2102

o Users intimation to the materials management department regarding the time and quality of
material required.

o Materials management to decide that the materials purchased. o Selecting the source, fixing the price and ultimately placing the order. o To deliver material o Transportation and receiving the material including inspection and testing of material if
necessary.

MASS DIAGRAM Earth moving is basically an operation where is removed from high spots and deposited in low spots with the making up of any deficit with borrow or the Wasting of Excess Cut Material. The mass diagram is an excellent method of analyzing linear earth moving operations. It is a graphical means of measuring haul distance in terms of earth work volume. On mass diagram graph, the horizontal dimension represents the stations of a project and the vertical dimension represents the cumulative sum of excavation and embankment from some point of beginning on the project profile. the diagram provides information covering 1. Quantities of materials 2. Average haul distances 3. Types of equipment that should be considered. When combined with a ground profile, the average slope of haul segments can be estimated. The mass diagram is one of the most effective tools for planning the movement of material on any project of linear extent. Using column 1 and column 12 of an earth work sheet, a mass diagram is plotted. In below mass diagram positive ordinate values are plotted above the zero datum line and negative values below.

PGPM 33 Material & Logistics Management

Rajkumar baghel 28-12-31-6399-2102

MASS DIAGRAM PROPERTIES: An excavation operation produces an ascending mass diagram curve; the excavation quantity exceeds the embankment quality requirements. Excavation is occurring between A and B and between Station D and E

USING MASS DIAGRAM: The Mass Diagram Is an Analysis Tool for Selecting the Appropriate equipment for excavating and hauling material. The analysis is accomplished using balance lines and calculating average hauls.

PGPM 33 Material & Logistics Management


Balance lines:

Rajkumar baghel 28-12-31-6399-2102

A Balance line is a horizontal line of specific length that intersects the mass diagram in two places. The balance line can be constructed so that its length is the maximum haul distance is the limiting economical haul distance for a particular type of equipment.

MACHINE TYPE Large dozers, pushing material Push-loaded scrapers Trucks Average grade % = change in elevation Average haul distance = - 18 mt x 100 => - 8.9% 203 mt The return trip will be an 8.9% grade.

ECONOMICAL HAUL DISTANCE up to 300 ft* 300 to 500ft* hauls greater than 5,000ft x 100

EQUIPMENTS CONSIDERED EARTH MOVING EQUIPMENTS

1. EXCAVATORS / DOZERS:
All excavators are designed to move large amounts of soil and earth in a minimal amount of time. Large excavators are useful for digging foundations and other huge projects, but many times you need a smaller excavator to handle more delicate jobs. These smaller excavators are also called compact excavators or mini excavators. Mini excavators bring many advantages to a wide range of construction job sites. Mini excavators are maneuverable and easy to operate. Most compact hydraulic excavators have three distinct assemblies: house, undercarriage and workgroup. The compact hydraulic excavator has many advantages over the traditional center-mount backhoe. Compact excavators offer many attachments to make any job easier. Remember, to optimize power and performance its important to match the

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attachments to type and size of compact excavators to prevent overloading. Excavators often have attachments, or you can purchase additional attachments to fit the machinery. Few of the attachments include jackhammers (breakers), shovels, grapples, augers, etc Grapples are similar to claws and are used to grasp objects (trees, stumps, etc). Hydraulic Mining Excavators often uses shovels. Finally, augers are similar to a drill bit, and are used to move materials. The role of excavators is to dig holes, trenches, and foundations. Excavators use large machinery with hinge metal buckets, which are often attached to hydraulic arms, while using the equipment to move heavy or bulky quantities of soil or earth. In addition, excavators are used in demolition, general landscaping, grading, heavy lifting, laying pipes, river dredging, mining, open-pit mining, brush cutting, etc. Brush cutting is possible when operators use hydraulic attachments.

2. SCRAPERS:
A wheel tractor-scraper is a piece of heavy equipment used for earthmoving. The rear part has a vertically moveable hopper with a sharp horizontal front edge. The hopper can be hydraulically lowered and raised. When the hopper is lowered, the front edge cuts into the soil like a cheese-cutter and fills the hopper. When the hopper is full (8 to 34 m3 (10 to 45 yd3) heaped, depending on type) it is raised, and closed with a vertical blade. The scraper can transport its load to the fill area where the blade is raised, the back panel of the hopper is hydraulically pushed forward and the soil load tumbles out. Then the empty scraper returns to the cut site and repeats the cycle. Scrapers can be very efficient on short hauls where the cut-and-fill areas are close together and have sufficient length to fill the hopper. The heavier scraper types have two engines ('tandem powered'), one driving the front wheels, one driving the rear wheels, with engines up to 400 kW (550 horsepower).

PGPM 33 Material & Logistics Management 11 3. ROAD ROLLER:

Rajkumar baghel 28-12-31-6399-2102

A Road roller (sometimes called a roller-compactor, or just roller) is an engineering vehicle used to compact soil, gravel, concrete, or asphalt in the construction of roads and foundations. In many parts of the world, road rollers are still known colloquially as steam rollers, regardless of their method of propulsion. This typically only applies to the largest examples (used for road-making). This article concentrates on non- steam-powered rollers. Road rollers work by using the weight of the vehicle to compress the surface being rolled. Initial compaction of the substrate is done using a pneumatic-tyred roller, where instead of the single- or double-drum is replaced by two rows (front and back) of pneumatically filled tyres. The flexibility of the tyres, with a certain amount of vertical movement of the wheels, enables the roller to operate effectively on uneven ground. The finish is done using metal-drum rollers to ensure a smooth, even result. Rollers are also used in landfill compaction. Such compactors typically have knobby ('sheeps-pad') wheels and do not attempt to achieve a smooth surface, merely a squashed one.

CALCULATIONS Dimensions of the landing Average height of filling of earth Volume of the earth refilled Width of the landing Length of the landing Volume of sand filling Height of sand filling = 0.75m = 80,000cum = 100m = 80,000/(100*0.75) = 1066.7m =1.067km = 3000cum = 3000/ (1066.7*100) = 0.028m

Total quantity of asphalt required for the work = 1,50,000 litres

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BITUMEN ORDERING SCHEDULE Economic Order quantity (EOQ):

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The quantity of order corresponding to the frequency is known as economic order quantity.

The curve AMB indicates the graph of inventory cost for various frequencies of ordering OMG shows the ordering costs corresponding to various frequencies. AMB+OMG= PQR (TOTAL INVENT COST).Q is the least c and hence intercepts OS shows most desirable frequency of order of which the total inventory cost is minimum. Lead time for bitumen to arrive at site = 45 days Day in which bitumen is Day in which bitumen is Order no. Order quantity (in litres)

AVAILABLE AT SITE from ORDERED commencement of project 60th day 70th day 80th day commencement of project 15th day 25th day 35th day

from

I II III

50,000 50,000 50,000

DIRECT TUBE HEATING:

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Rajkumar baghel 28-12-31-6399-2102

Direct tube heating is the most efficient and economical method available in asphalt tank heating. The ONE-PLUS-ONE direct heating system offers both precise temperature control and even heating distribution characteristics without flame impingement, hot spots or product degradation. Direct Fire Tanks Each unit has an oversized refractory lined submerged fire tube the length of the tank with dual jacketed exhaust venting system, thus increasing heat transfer and reducing energy loss. All of the tanks are also wrapped with a high-density insulation covered by a stucko embossed aluminum jacket skin that traps precious energy inside providing the ability to produce high performance asphalt at enormous cost savings.

Hot Oil Heated Tanks o All the hot oil heated tanks are constructed with a multiple pass serpentine coil design,

which provides over 1200 feet of heat exchange area. As a result, we can heat asphalt more consistently and at hotter temperatures without coking issues.

MONITORING Someone must be present to visually monitor asphalt that is loaded and unloaded. That person must be able to shut off product transfer before an overfill occurs. On a monthly basis, a visual inspection is required. This inspection must include a walk through of the site to identify crack. Visual examination of the exterior surfaces of tanks, piping, valves, pumps, and other equipment for cracks, corrosion, releases, and maintenance deficiencies must take place. The monthly inspection must also identify poor maintenance, operating practices, or malfunctioning equipment.

ASPHALT HAUL TRUCKS

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Various types of trucks are used to deliver hot mix to the paver. The most common type is the 5-ton end-dump truck but other trucks have been used and can be used to deliver mix.

Truck Condition Trucks must have metal beds, and the beds must be clean, smooth, and free of holes. All trucks must meet minimum safety criteria. Each truck must be clearly numbered for easy identification and must be equipped with a tarpaulin. Before being loaded, the truck bed must be cleaned of foreign material and hardened asphalt and then lightly coated with a release agent (lubricant) that assists in preventing fresh hot-mix asphalt from sticking to the surfaces of the bed. After the bed is coated, any excess release agent must be drained from the bed. Before loading, the truck must also be weighed to establish its unloaded weight. This weight is later subtracted from the loaded weight of the truck to determine the weight of the hot mix that the truck is hauling. Determination of the no. of trucks required The number of trucks required on the project is determined by many factors: the mix production rate at the plant, the length of the haul, the type of traffic en- countered The expected time needed for unloading.

Types of Trucks Each type of truck used for hot-mix delivery must have certain physical features that are required to haul properly and to discharge the mix properly into the paver. Below are listed a few guidelines for the two most common types of trucks.

END-DUMP TRUCKS

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An end-dump truck must first be inspected to be certain the rear of the bed overhangs the rear wheels enough to discharge mix into the paver hopper. If it does not, an apron with side plates must be added to increase the overhang and prevent spillage of the mix in front of the paver. The bed must also be of a size that will fit into the hopper without pressing down on the paver. Leaking trucks should not be used. Tarpaulins should be pulled over the mixture during hauling in cool weather or on long hauls to protect the mixture from excessive cooling. A cool mix forms lumps and a crust over its surface. When a tarpaulin is used, care must be taken to be sure it is securely fastened to the top of the truck bed so that cold air cannot funnel under it.

BOTTOM-DUMP TRUCKS Bottom-dump trucks can be used when a grader is spreading the mix or when a pickup device is used to feed the windrow left by the truck into the paver hopper. Two common methods for unloading bottomdump trucks are in use. The first method involves the use of a spreader box, designed to be operated under the gates of the truck. The amount of material, placed in the windrow, is governed by the width of the spreader box opening. The disadvantage of this method is that the spreader box can restrict the amount of material to less than the required amount. The second method, which is used more often than the first, is to use chains to control the dump gate opening.

Truck Hitches The purpose of a truck hitch on the front of the paver hopper is to keep the truck dumping hot mix into the hopper in contact with the paver. If, during dumping, the truck and the paver separate and hot mix spill, it must be cleaned up before the paver passes over it. Two types of truck hitches are in common use. One type uses an extension that reaches under the truck and hooks onto the rear axle of the truck. The other type of hitch has retractable rollers that are attached to the truck push bar and grip the outer side of the rear wheels of the truck. The rollers revolve with the wheels while the truck dumps its load into the hopper.

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Pivoted Truck Push Rollers The pivoted push roller is a device, mounted on the front of the paver that adjusts when alignment between the truck and paver is uneven. This device reduces the uneven force exerted on the paver by the misaligned truck, minimizing interference in the steering of both vehicles.

ASPHALT FINISHERS (PAVERS) Even though the finishers may operate differently, their primary jobs are all the same: receiving asphalt and spreading it in a predetermined, uniform length, width, thickness, and shape. The finisher also provides initial compaction of the mat (layer of mixture in place.) Because asphalt finishers are different, you must always read the operators manual for the unit you are operating. It is also good to have a practice sand letdown before actually using a hot mix. This is to familiarize yourself and others with the machine and also ensure that the machine is working properly. Figure 16-39 shows a practice letdown, using just the aggregate mix without the asphalt

Tractor Unit (Power Unit) The tractor unit provides moving power for the paver wheels or tracks and for all powered machinery on the paver. The tractor unit includes the receiving hopper, feed conveyor, flow control gates, distributing augers (or spreading screws), power plant (engine), transmissions, dual controls, and operators seat. The tractor unit power plant (engine) propels the paver, pulls the screed (leveling) unit, and provides power to the other components through transmissions. Hot mix is deposited in the hopper and is then carried by the feed conveyor through the flow control gates to the distributing augers (spreading screws). The augers distribute the mix evenly across the full width of the paver, thus providing uniform placement of the mix onto the roadway surface. These operations are controlled by the paver operator by means of dual controls within easy reach of the operators seat. To ensure the paver functions

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properly, you should inspect the paver before commencement of paving. Below are some of the comments you should check.

ASPHALT DISTRIBUTOR The asphalt distributor is a unit consisting of an insulated storage and heating tank, an open flame heating system, an asphalt pump, a low-pressure air blower, and a circulating and spraying system. Power to operate the components is PTO driven. Heating System The air blower provides low-pressure air to atomize fuel for the burners. The burners heat the tubes, located in the tank. An asphalt covering must be maintained over the fire tubes to prevent them from overheating and causing a fire or explosion. Because the distributor is mobile, care must be taken to ensure that heating is performed in a level area that is well-ventilated and that the distributor truck is not moving at all and is at a COMPLETE HALT. Whenever you are heating cutbacks, the asphalt must be circulating at all times. This is a must to prevent any chance of volatile liquids overheating around the flues, which can be very dangerous Spray System The spray system consists of necessary piping, a series of hand-operated valves to control the flow of bitumen, and an adjustable length spray bar, capable of providing coverage from 4 to 14 feet wide. The spray bar may be equipped with either 1/8-inch nozzles or 3/8-inch nozzles; the 1/8-inch nozzles are used for most applications. The application rate is controlled by the length of the spray bar, the pump output, and the forward speed of the distributor truck. Spray Bar Adjustments For normal use, the spray bar of the distributor should be adjusted, so the vertical axes of the nozzles are perpendicular to the roadway. Also, each nozzle on the spray bar should be set at the same angle. The angle set for each should be between 15 degrees to 30 degrees of the horizontal axis of the spray bar (fig. 16-34) or according to manufacturers specifications. This action prevents the fan-shaped spray patterns

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of the nozzles from interfering with each other. Another adjustment that is essential for uniform prime or tack coat coverage is the adjustment of the height of the spray bar.

NO OF EQUIPMENTS CONSIDERED AND REQUIRED COST: a) Cutting and Dozing of earth Scope of work = 100000 cum of earth of avg height = 0.75m w.k.t Phase I, one strip of landing of 100m width Therefore =100000 / 0.75 = 133,333 sqm. For executing 100000 cum let us consider excavator with grader. As per the productivity norms = 1000 m3 Total Days required = 100000 / 1000 = 100 Days Let us consider two excavators with grader can be deployed in our project = 100 / 2 = 50 Days Market Hire rate for excavator with grader including operator including taxes = 1,80,000 Rs As per the terms and condition the excavator with grader should work 10 hrs / day , 260 cumulative hrs in a month. Diesel Cost involved = 34 x (10 x 11 x 26) = 97,240 Rs Total cost for one excavator with grader = 1,80,000 + 97,420 = 2,77,240 Rs. Therefore total cost involved for completing the 100000 cum of earth = 2 x 277240 = 5, 54,480 Rs (Consumption norms = 10 12 lit / hr)

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b) Transportation of surplus earth & filling of earth Scopes of work are as follows

Rajkumar baghel 28-12-31-6399-2102

i) Transportation of 20,000 cum of surplus earth from site to 3 km away from site ii) Filling of 80,000 cum in landing strip For executing the above scope of work let us consider the tippers As per the productivity norms = 10 m3 / trip i) Transportation of 20,000 cum of earth to 3 km away per site Let us consider 10 trips can be done in a day Therefore the out per tipper = 10 m3 / trip x 10 trips = 100 m3 Total Days required for executing 20,000 cum of earth disposal = 20000 / 100 = 200 Days Let us consider 20 tippers are to be deployed for completing the 20,000 cum of earth disposal with a lead of 3 km away from site = 200 / 40

= 5 Days ii) Filling of 80,000 cum in landing strip Let us consider 10 trips can be done in a day Therefore the out per tipper = 10 m3 / trip x 10 trips = 100 m3

Total Days required for executing 80,000 cum of earth disposal = 80000 / 100 = 800 Days Let us consider 40 tippers are to be deployed for completing the 80,000 cum of earth filling on landing strip = 800 / 40 = 20 Days will be requires to complete the work

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Market Hire rate for tipper including operator including taxes = 25,000 Rs As per the terms and condition the excavator with grader should work 12 hrs / day, 336 cumulative hrs in a month. Diesel Cost involved = 34 x (30 x 26) = 26,520 Rs Total cost for one excavator with grader = 25,000 + 26,520 = 51,520 Rs. Therefore total cost involved for completing the 100000 cum of earth = 40 x 51520 = 20,60,800 Rs (Consumption norms = 2-3 km / lit)

c) Bringing 3000 cum of sand from 20 km (including spreading & leveling at site) Total Qty of sand to be procured = 3000 cum Let us plan 6 trips per day of 10cum capacity of tipper Total Days required = 3000 / 60 = 50 days so we are telling to the subcontractor to supply the material by 5 tippers, so that = 50/5 = 10 Days Cost of the Sand including the transportation and taxes = 7 Rs / Cft Cost of sand including the transportation and taxes = 7x 35.31 = 247.17 Rs / Cum Total sand to be procured = 3000 x 247.17 =7, 41,510 Rs

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For doing the spreading and leveling and rolling works we need

Rajkumar baghel 28-12-31-6399-2102

a) Road Rollers (Vibratory Rollers)


b) Water Tanker c) JCB

a) Road Rollers (Vibratory Rollers) :


As per the Productivity norms = 750 800 Sqm /Day Total scope of work = 100000 / 0.75 = 133333 m2 Therefore No of days requires = 133333 / 6 = 178 Days Let us consider 7 Road rollers are to be deployed = 178 / 7 = 26 Days Hire charges for the road roller with operator including taxes = 120000 Rs Diesel cost to be involved = 34 x 26 x 10 x 10 = 88,400 Rs Total cost involved for one Road Roller = 1,20,00 + 88,400 = 2,08,400 Rs Total cost to be involved for 7 rollers hired = 7 x 113040 = 14,58,800 Rs (Consumption norms = 8 10 lit / hr)

b) Water Tanker :
The cost of water tanker of (10,000 lit capacity) = 1500 Rs / trip Water are generally used for compacting the soil to attain its Maximum Dry Density Therefore total cost of water tanker = 1500 x 26 days = 39,000 Rs c) JCB As per the Productivity norms = 1000 Cum /Day We are going to hire 5 JCB for spreading and leveling works Initially 5 JCB will be involved in loading of sand in tippers

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Total No of Days = 20000 cum / 1000 cum /Day = 20 Days If 5 Jcbs are involved for loading = 20 / 5 = 4 Days Later on the jcb are to be mobilized in the spreading work Total No of Days = 80000 cum / 2000 cum /Day = 40 Days If 5 jcbs are to be put in the job = 40/ 5 = 8 Days Hire charges for the road roller with operator including taxes = 60000 Rs Diesel cost to be involved = 34 x 26 x 10 x 6 = 53,040 Rs Total cost involved for one Road Roller = 60000 + 53040 = 1,13,040 Rs Total cost to be involved for 5 rollers hired = 5 x 113040 = 5,65,200 Rs (Consumption norms = 5 6 lit / hr)

BITUMEN CHARGES: Procurement of Bitumen = 1,50,000 lit (1lit = 0.93 kg) The rate of Bitumen 60 / 70 as on dated 25.04.2008 = Rs. 33000/ Mt (including taxes) Therefore the rate for 1,50,000 lts of Bitumen =(1,50,000*0.93) = 139.5 Mt. = 139.5 Mt * 33000/ Mt. = 46, 03,500 Rs/-

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ABSTRACT COST OF THE WHOLE WORK:

Sl.No 1 2 3 4 5

DESCRIPTION Cutting and Dozing works Transportation of surplus earth (20,000 + 80,000) Procurement of Sand Spreading and leveling works Bitumen Charges

Unit Cum Cum Cum Cum Lit

Qty 100,000 100,000 3000 100,000 1,50,000 Total

AMOUNT 5,54,480 20,60,800 7,41,510 20,63,000 46,03,500 1,00,23,290 15,03,494 10,02,329 1,25,29,113

Sub contractor super vision charges 15% = Sub contractor Profit charges 10% = Grand Total

ASSUMPTIONS & REFERENCES: 1. Schedule of rates 2. Prices from the suppliers.

BIBLIOGRAPHY Knowledge gained from working experience.

1. Details from the Internet.

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