National Institute of Construction Management and Research, Pune School of Distance Education

ASSIGNMENT
COURSE TITLE: CONSTRUCTION MATERIAL & EQUIPMENT MANAGEMENT COURSE NO. : NCP 24/25 COURSE: PGPCM MODULE: 11 ASSIGNMENT NO.: 4 DATE OF DISPATCH: 25/04/2012 LAST DATE OF ASSIGNMENT AT CODE OFFICE: 15/05/2012

SUBMITTED BY:

PRAMOD PRABHAKAR JADYE

REG NO: 212-02-11-10418-2132

DEPARTMENT OF PGPCM NATIONAL INSTITUTE OF CONSTRUCTION MANAGEMENT AND RESEARCH SCOOL OF DISTANCE EDUCATION 25/1, BALEWADI, N.I.A. POST OFFICE, PUNE-411045

Assignment on Construction Material & Equipment Management NCP 24 - 25

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National Institute of Construction Management and Research, Pune School of Distance Education ASSIGNMENT 1. Your company has been awarded a contract of developing and construction a new International air port 30 KM from a city. You have been appointed as Planning Engineer. Project is to be implemented in phases. In phase I, one strip of landing 100 m width is to be constructed in 100 days. The scope of work is as follows: (a) Cutting and dozing of 1, 00,000 cum of earth. Average height is 0.75 m. (b) Transportation of 20,000 cum of surplus earth from site to dumping ground 3 KM away from site. Filling of 80,000cum of earth. (c) Bringing of 20,000 cum of sand from 20 KM (including of spreading and leveling). (d) Procurement of 1,50,000 liters of bitumen. Duration of work 30 days from the 60th day of starting work. Lead time for the procurement of bitumen is 45 days. Storage facility of 50,000 litres at site. 2. Estimate total cost of work and your plan of: (a) Equipment planning procurement and development. (b) Ordering and replenishing of Bitumen.

SCOPE OF WORK: 100m width of Road construction for international airport 30 km away from city Excavation of 100000 cum soil of 0.75mt height Shifting of 20000 cum of soil 3km away. Spreading of 80000 cum of soil in landing strip. Bringing 20000 cum of sand 20km away (spreading + leveling) Total time 100 days. Strip width 100mtr.

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National Institute of Construction Management and Research, Pune School of Distance Education

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. 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: 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. Choice should be restricted to standard equipment, special equipment should be selected if job justifies its selection. Topography conditions, type of soil, existing approaches and road working conditions etc, must be studied. Less variety of equipments should be used, more variety means more skilled workers, more spare parts requirements and more production cost.

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National Institute of Construction Management and Research, Pune School of Distance Education 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. 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. Obsolescence of the equipment should not be overlooked. Equipment should be capable of doing more than one job, but it should not be versatile. The technical and economic aspects should be analyzed to select the equipment.

Following aspects need detailed consideration at the selection stage: Suitability for the job with specific reference to climatic and other operating conditions. Size of the equipment Standardization and variety reduction Type of prime mover Degree of utilization Suitability of local condition Adaptability 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. Strength Vibration Stability Resistance to wear

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National Institute of Construction Management and Research, Pune School of Distance Education Heat Resistance Reliability Maintainability

Assumptions. (a) Type of equipment: Excavator: for cutting/ excavation Dozer for dozing Grader: for spreading of material Dumper: For shifting/ Hauling of material Roller and water tanker: for compaction 10 hours per day and max of 60 per week. 10 hours per week per plant (one day per week) Three working days, (for dismantling, transport, reassembly testing) for a lead of 100 km. (e) Break down period considered: Four days per equipment in a month. (f) Adequate spares and sub assemblies are available with trained maintenance staff. (g) Mass diagram of the area has been prepared and the plant operators are familiar with the task at hand. (h) Work is being executed as per the mass diagram. (i) Plant operators are experienced are capable of achieving the planned output. (j) No disruptions have been considered for reasons of inclement weather / other factors. (k) Plant / equipment as planned will be made available.

(b) Working Hours: (c) Maintenance: (d) Induction period:

COST ANALYSIS 1- Excavation of 100000 cum soil.

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National Institute of Construction Management and Research, Pune School of Distance Education Consider 3 no. of excavators 0.9 cum bucket capacity @ 60 cum per Hour Output 3 excavators (10 Hrs working) Total duration required to excavate 100000 cum soil Assume cost of operation of excavator @ Rs 2200 per Hour Total cost for excavation of 100000 cum soil = Rs 36.67 L = 1800 cum/ day = 56 days

2- Dozing of excavated material Consider 3 nos. of Dozer, 80HP @ 30 cum per Hour Output 3 Dozers (10 Hrs working) Total duration required (consider 50000 cum soil) Assume cost of operation of Dozer @ Rs 2500 per Hour Total cost for dozing 50000 cum soil = Rs 41.67 L = 900 cum/ day = 56 working days

3- Shifting of 20000 cum soil 3Kms away Consider 8 no. of dumpers to execute this work Capacity Cycle time for a single trip Loading of material Forward journey with loaded material Unloading of material Return journey Total duration required for single trip Total number of trip in a day (10 Hr working) Total Output of 8 dumpers per day Total duration required to shift 20000 cum = 15 min. = 10 min = 5 min. = 10 min. = 40 min = 15 nos. = 1200 cum = 17 working days = 10 cum/ Trip

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National Institute of Construction Management and Research, Pune School of Distance Education Assume cost of operation of transportation of material @ Rs 6 per Cum per Km Total cost of hauling of 20000 cum soil for 3 Km lead = 6 x 20000 x 3 = Rs 3.60 L

4- Shifting of 20000 cum sand from 20Km away Consider 8 no. of dumpers to execute this work Capacity Cycle time for a single trip Loading of material Forward journey with loaded material Unloading of material Return journey Total duration required for single trip Total number of trip in a day (10 Hr working) Total Output of 8 dumpers per day Total duration required to shift 20000 cum = 15 min. = 30 min = 5 min. = 30 min. = 90 min = 7 nos. = 560 cum = 36 working days = 10 cum

Assume cost of operation of transportation of material @ Rs 6 per Cum per Km Total cost of hauling of 20000 cum sand for 20 Km lead = 6 x 20000 x 20 = Rs 24.00 L

5- Spreading of 80000cum soil and 20000cum Sand Consider 2 nos. Motor Grader110 HP, 100 cum per Hour Output of 2 graders (10 Hrs working) Total duration required Assume cost of operation of grader @ Rs 1700 per Hour = 2000 cum per day = 50 working days

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National Institute of Construction Management and Research, Pune School of Distance Education Total cost for spreading 100000 cum material 6- Compaction Consider 2 nos. Vibratory road roller 8-10 tonne capacity, 100 cum per Hour and 2 nos. water tanker 6 KL capacity Output of 2 rollers (10 Hrs working) Total duration required = 2000 cum per day = 50 working days = Rs 17.00 L

Assume cost of operation of roller @ Rs 1000 per Hour and operational cost for water tanker @ Rs. 1700 per day Total cost for compacting 100000 cum material (Roller + Water tanker) = Rs 11.70 L SUMMARY OF EQUIPMENTS REQUIRED AND COST ESTIMATE Sl. No. 1 2 3 Activity Excavation of 100000 cum soil Dozing of 50000 cum soil Shifting of 20000 cum surplus soil 3Kms away 4 5 6 Shifting of 20000 cum sand from 20Kms distance Spreading of 80000 cum soil and 20000 cum sand Compaction of 100000 cum material Dumper- 8 nos. Motor Grader, 110 HP- 2 nos. a)Vibratory roller, 8-10 T capacity b) Water tanker2 nos., 6 KL cap. Rs 6 per Cum per Km Rs. 1700 per Hour a) Rs. 1000 per Hour b) Rs 1700 per day Total estimated cost Rs. 24.00 L Rs. 17.00 L Rs. 11.70 L Equipment planned Excavator 0.90 cum bucket- 3 nos. Dozer, 80HP- 3 nos. Dumper- 8 nos. Unit cost of Operation Rs. 2200 per Hour Rs. 2500 per Hour Rs 6 per Cum per Km Total estimated cost Rs. 36.67 L Rs. 41.67 L Rs. 3.60 L

Rs. 134.64 L

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National Institute of Construction Management and Research, Pune School of Distance Education 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 liter X hourly fuel consumption Hourly fuel consumption = Hourly fuel consumption at full load X operating factor. The fuel price liter, delivered at the site is obtained from the local suppliers at it varies from place to place. The rate of consumption depends 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 liters X rated HP X load factor Petrol engine fuel consumption per hour = 0.22 liters 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 liter., 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 liters = 26.25 liters Cost of hourly consumption = Diesel consumption X rate of diesel per liter = 26.25 liters X Rs. 44 = Rs. 1155 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.

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National Institute of Construction Management and Research, Pune School of Distance Education Operating conditions Favorable Average Unfavorable Hourly maintenance cost 25% of fuel cost 33% of fuel cost 50% of 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: 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. PROCUREMENT OF BITUMEN:

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National Institute of Construction Management and Research, Pune School of Distance Education The major factors that are required to be kept in mind when planning logistics of procurement of bitumen are: (a) Lead Time: The time taken for a supply to materialise from the time the requirement is felt is called lead time. Consider the case of bitumen, from the time the order is placed, it takes 45 days for the material to reach the site, and this is taken to be the lead time. Hence, the order for the material is to be placed a minimum of 45 days before the requirement for use actually comes up. We will consider the case in detail: i. ii. iii. iv. v. vi. vii. viii. Bitumen required from 60th day after work commencement. Lead time 45 days. Total Requirement 1, 50,000 liters. Storage capacity 50,000 liters. No of orders to be placed minimum three each of 50,000 liters bitumen. First order to be placed on 15th day of work. Material reaches site on 60th day of work. Average rate of consumption of bitumen 5000 ltrs per day. Second order to be placed on 25th day of work. ix. x. Order materialises on 70th day of work. Similarly third order to be placed on 35th day of work and order materialises on 80th day of work. xi. Work is completed on 90th day after commencement.

Day

from Opening

Order

Order

Total

Consumed

Closing

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National Institute of Construction Management and Research, Pune School of Distance Education beginning 15 25 35 60 69 70 79 80 89 stock 0 0 0 0 5000 0 5000 0 5000 placed 50000 50000 50000 50000 50000 5000 50000 50000 5000 50000 50000 5000 Work complete 5000 5000 5000 5000 5000 5000 stock 45000 45000 45000 -

(b) Safety Level: The above case was planned considering ideal conditions where there were no delays anticipated. However in case of any delays in the supply chain, the work would suffer, hence certain safety levels are maintained to cater for emergencies. In the above case a safety level can be incorporated by decreasing the order quantity and increasing the number of orders. Consider the above case with changed order levels; i. ii. iii. iv. v. vi. vii. viii. ix. x. Bitumen required from 60th day after work commencement. Lead time 45 days. Total Requirement 1, 50,000 liters. Storage capacity 50,000 liters. No of orders being placed Four. First order to be placed on 15th day of work for 50,000 liters. Material reaches site on 60th day of work. Average rate of consumption of bitumen 5000 ltrs per day. Second order for 40,000 liters to be placed on 23rd day of work. Order materialises on 68th day of work. A safety stock of 10,000 liters is available to cater for delay in supply. xi. Similarly third order of 40000 ltr to be placed on 31st day of work and order materialises on 76th day of work.

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National Institute of Construction Management and Research, Pune School of Distance Education xii. Similarly fourth order is to be placed on 39th day of work and order materialises on 84rd day of work. xiii. Work is completed on 90th day after commencement.

In the above case at every stage a safety stock of 10,000 litres of bitumen is present. Day from beginning 15 23 31 39 60 67 68 75 76 83 84 89 Opening stock 0 0 0 0 0 15000 10000 15000 10000 15000 10000 5000 Order placed 50000 40000 40000 20000 Order Total Consumed 5000 5000 5000 5000 5000 5000 5000 5000 45000 10000 45000 10000 45000 10000 25000 Closing stock

50000 50000 15000 40000 50000 15000 40000 50000 15000 20000 30000 5000 Work complete

RECOMMENDATIONS The work is time bound with no cushion provided to cater for delays. The work has to be planned and executed with this fact kept in mind. The following recommendations are made: Adequate serviceable equipment catered for. Skilled staff to be employed. Dedicated staff to be placed for the monitoring of works. Regular reviews to be carried out and corrective actions to be taken in case of delays. Well equipped and dedicated maintenance team to be placed at site. Maintenance schedule of equipment to be adhered to. Close watch to be kept on the placing of orders of various material required for the work, with due consideration given to lead time.

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National Institute of Construction Management and Research, Pune School of Distance Education BIBLOGRAPHY/ READINGS As recommended in assignment and material from internet.

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