Equipment and their Maintenance

CONSTRUCTION EQUIPMENT Management

AND
THEIR MAINTENANCE MANAGEMENT • Major construction Equipment used in
Construction Industries
• Equipment utilization in the Department of
Er Satya Narayan
Er. R d
Roads
Shah • Fleet Management
B.Sc. Mechanical Engineering (India)
MS Manufacturing Engineering & Management (UK) • Maintenance & Operation System
• Source of Data
Institute of Engineering, Lalitpur
January, 2011

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Generally, we use the Equipment

when a job requires -
` Pneumatic/Hydraulic Tools
1. SPEED ◦ Air Compressors
◦ Rock Drill/Jack Hammer/Other Drills
◦ Concrete Breaker
2. QUALITY ◦ Asphalt Cutter
◦ Impact Wrenches/Nail Driver
◦ Grinder
3. ECONOMY ◦ Concrete Vibrator
◦ Back Fill Tamper
◦ Circular saw/ Chain Saw
4. EMERGENCY/DISASTER
◦ Road Broom
MANAGEMENT
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| Aggregate Producer ` Earth Moving Equipment

y Rock Crushers, Screen, and Conveyors ◦ Dozers (Track/Wheel)
y Central Mix Plant, (Batch Plant/Continuous
Mix Plant) ◦ Loader/Shovel (Track/Wheel)
y Bitumen Decanter,, Bitumen Heater ◦ Excavators (Track/Wheel)
( / )
y Bitumen Distributor ◦ Scrapers
y Portable Mix Plant
y Pavers
◦ Grader
y Rotary Sweeper ◦ Milling Machine
y Aggregate Spreader ◦ Hauler (Off highway haulers, Tipping
y Concrete Mixers/Concrete Batch Plant Trucks, Mini Dumpers)
y Concrete Vibrator

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 | Ancillary Equipment
` Compaction Equipment y Water Distributor
◦ Sheep Foot Rollers/Tamping y Rotary Tiller Mixer
Rollers y Portable Electric Generator
y Welding Generator
◦ Steel Wheel Static Roller
y Pile Driver
◦ Steel Wheel Vibrating Roller y Water Pump
◦ Pneumatic roller y Boring Rig
Crane/ Fork Lift
◦ Plate Compactor/Rammer y
y Flat Bed Truck
y Low Bed Transporter

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EQUIPMENT STATUS in DOR LIST OF MAJOR EQUIPMENT

Type of Equipment Total No Average Age
¾ ACTIVE EQUIPMENT: 487 Dozer Wheel 8 22
¾ AVERAGE AGE (approx): 16.4 YRS. Dozer Track 21 15.3
¾ MORE THAN 25 YEARS OLD: 79 (16.22 %) Excavator 12 6.8
¾ 21-25 YEARS OLD: 27(5.54%)
¾ 16-20 YEARS OLD: 149(30.60%) Motor Grader 21 19.2
¾ 11-15
11 15 YEARS OLD: 110(22 59%)
110(22.59%) Loader Wheel 41 15 2
15.2
¾ 6-10 YEARS OLD: 82(16.84%) Loader Backhoe 9 17.6
¾ Up to 5 YEARS OLD: 40 (8.21%) Roller 3 Wheel 52 19.9
¾ MORE THAN 15 YEARS OLD: 255 (52.36%) Roller Pneumatic 14 18.2
Economic service life is taken as 15 years Truck Tipper 95 20.2
¾RAINY SEASON DEPLOYMENT: 100 2- equipment owned by Baitadi-Darchula Road Project, 26 - equipment
(Equipment only) owned by Banepa-Sindhuli-Bardibas Project, 2 Tractors owned by Surkhet-
Jumla-Road Project and 8 equipment owned by MTC which are not used by
January 31, 2011 Er. Satya Narayan Shah 9 January 31,
DOR’s day2011
to day activities. Er. Satya Narayan Shah 10

% SHARE OF EQUIPMENT BY EQUIPMENT AGE

AGE 160 DISTRIBUTION
149
MORE THAN 25 YEARS OLD: 140
8.21 
16.22  120
110
21‐25 YEARS OLD:
100

79 82
16.84  5.54  80
16‐20
16 20 YEARS OLD:
YEARS OLD:
60

40
40
11‐15YEARS OLD: 27
20

22.59  30.60  6‐15 YEARS OLD: 0

MORE THAN 25 YEARS  21‐25 YEARS OLD: 16‐20 YEARS OLD: 11‐15YEARS OLD: 6‐15 YEARS OLD: Up to 5 YEARS OLD:
OLD:

Up to 5 YEARS OLD:

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 DEPARTMENT OF ROADS DoR Organization (Mechanical)
Organization
DIRECTOR
GENERAL

PD DDG DDG DDG DDG

ADB Directorate Planing &Design Maintenance Foreign
g Mechanical
Cooperation

Bi-lateral Equipment
PMEU GENERAL
Maintenance

Multi
Lateral
BRIDGE Procurement
DEVELOPMENT and
DRU Training
GEU

CONTRACT
RSSDU MANAGEMENT

CENTRAL Administration Accounts

January 31, 2011
L AB Er. Satya Narayan Shah 13 14

ORGANISATION MECHANICAL
ƒ Mechanical Branch:
Equipment Maintenance and Management Section
Equipment Procurement and Training Section

ƒ Heavy Equipment Division (HED) : 
ƒ 6 Locations
Itahari, Hetauda, Kathmandu, Butwal, Nepalgunj, Godawari

ƒ Mechanical Office (MO) : 9 Locations
Birtamod, Lahan, Janakpur, Bharatpur, Kathmandu, Pokhara, 
Dang, Surkhet, Budar
(2 MOs at Phidim and Butwal not opened)

ƒ Mechanical Training Centre (MTC), Lalitpur
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MECHANICAL BRANCH & ITS ANCILLARIES
MANPOWER
Sanctioned Posts: 1038 Posts
y To provide support services to the 
Engineers (Diff. Level) 47
construction and maintenance of 
Mechanics (Diff. Level) 477
Highways and other constructions.
Operators (Diff. Level) 228
y DOR
Drivers (Diff. Level) 89
Administrative Staff 90
y Other Government Agencies
(Diff Level) y Contractors
Peon 50 y During Emergency 
Guard & Sweeper 57
y Disaster Management
Total 1038

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MAIN RESPONSIBILITY Activities of Mechanical Branch
y EQUIPMENT MANAGEMENT
Major activities of Mechanical Branch are as follows:
y REPAIR & MAINTENANCE OF EQUIPMENT. y Monitoring of Heavy Equipment Divisions, 
y SUPPORT DIVISION ROAD OFFICES AND PROJECTS  Mechanical Offices and Mechanical Training 
FOR OPERATION OF EQUIPMENT Centre.
y PROCUREMENT OF EQUIPMENT y Budgeting and Program formulation.
y GOVERNMENT FUND
y PROJECT REQUEST
y Equipment procurement.
y SUPPORT DOR & OTHER  y Spare parts procurement from the manufacturer.
CONSTRUCTION INDUSTRIES  y Monitoring of auction of equipment & vehicles.
THROUGH y Advise equipment and vehicle allocation.
y PROVIDING TRAININGS TO THE MANPOWER y Support DOR in policy formulation process.
y RENTING EQUIPMENT
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Activities of Heavy Equipment Divisions and  Activities of Heavy Equipment Divisions and 
Mechanical Offices Mechanical Offices‐ contd…….
y Maintain and report necessary records of financial expenditure 
Major activities of HEDs and MOs are as follows: as per the financial regulation.
y Repair and maintain equipment owned by the HEDs/MOs.
y Maintain and report repair, maintenance and operation records 
y Repair and maintain vehicles owned by the Civil Divisions. of equipments and vehicles as per the directives of the 
y Avail equipment to the Civil Divisions as per the directions of  Mechanical Branch.
g
the Regional Directorate. y Advise Regional Directorate, Division Road Offices and Road 
y Support and monitor Mechanical Offices (not applicable to  Projects related to equipment and vehicles.
MO)  y Plan necessary spare parts requirements and send requisition 
y Support DoR projects. to department for procurement of spare parts from the 
y Give equipment on hire without affecting the departmental  manufacturer, if necessary.
work and administer Revolving Fund from the hire revenue.  y Auction economically not repairable, obsolete and scrap asset.
y Keep store inventory record of asset owned by the HEDs/MOs

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FLEET MANAGEMENT
Activities of Mechanical Training Centre Fleet management is the function that
y Develop and provide trainings in operation of the  oversees, coordinates and facilitates various
construction equipment to DoR employees. Equipment related activities
y Develop and provide trainings in repair and  • TOTAL FLEET REQUIREMENT- COMPOSITION
maintenance of the construction equipment to DoR  • TOTAL FLEET AVAILABLE
employees. • ASSET MANAGEMENT
y Develop and provide modular trainings and custom  • REPORTS/INFORMATION GENERATION
made trainings to other agencies and individuals and  • EQUIPMENT DEPLOYMENT
administer Revolving Fund from the training fees. • EQUIPMENT RENTING
• EQUIPMENT MAINTENANCE
y Keep store inventory record of asset owned by the MTC. 
• DISPOSAL
y Maintain and report necessary records of financial  • REPLACEMENT
expenditure as per the financial regulation. • INSURANCE
• HEALTH, SAFETY & SECURITY Er. Satya Narayan Shah
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 BENEFITS OF FLEET BENEFITS OF FLEET
MANAGEMENT MANAGEMENT
Optimize the Fleet Operations Optimize the Use, Size & Maintenance
•Improve equipment efficiency of Fleet
•Fact-based decision making •Reduce capital expenditures
•Increase availability and productivity •Reduce
Reduce costs for maintenance
maintenance, repair and
•Improve return on your assets operations
•Secure extra revenue by billing correctly •Lower total cost of ownership
and preventing under billing •Extend asset life cycles and warranties
•Proof adherence to agreed Service Level
Agreements
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BENEFITS OF FLEET
Er. Satya Narayan Shah January 31, 2011

EQUIPMENT OPERATIONAL & MAINTENANCE

MANAGEMENT SYSTEM
• TO ENSURE THAT THE OPERATIONAL FLEET
Increase Safety & Security REQUIREMENT IS OPERABLE AND MAINTAINABLE
•Provide access control to the fleet WITHIN THE ALLOCATED BUDGET
•Detect safety violations ´ IDENTIFICATION OF EQUIPMENT
•Reconstruct incidents and audit safety ´ EQUIPMENT MOVEMENT MONITORING
practices ´ OPERATION RECORD KEEPING
•Formulate safety norms/standards and ´ MONITOR STATUS OF EQUIPMENT
guidelines • TO PROVIDE ALL INFORMATION AND ADVICE TO TOP
•Insurance policy MANAGEMENT FOR THE PROCESS OF DECISION
MAKING
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Er. Satya Narayan Shah January 31, 2011

CLASSIFYING EQUIPMENT Life of Equipment

• Service Life; which indicates the amount of time a
´ Similar Design unit is capable of operating and rendering service.
« Heavy Equipment – Graders, Trucks, Loaders The service life often permits the use of equipment
« Light Equipment – Vans, Sedans, Pickups well beyond its economic life
´ Similar Use • Technological Life; which represents the relative
« 12000 Kg K operating
i wt excavator vs. 20000 productivity decline of a unit in comparison to
Kg operating wt excavator newer models. The difference is represented by
obsolesce factor in hire rate calculation.
« Single cab pickup vs. Double cab pickup
• Economic Life; which is critical as it refers to both
´ Regular vs. Limited Use
time and costs and generally refers to the time
« Pile driver, mini duper, tipper trucks, inspection when maintenance costs exceed the units ability to
vehicles generate revenue, i.e. the unit is no longer cost
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 Departmental Equipment Coding System Of Construction Equipment
Identification ASPHALT PLANT 001
• It is necessary to have a system to identify ASPHALT PLANT 001
each equipment as the Department ASPHALT PAVER 002
operates the largest fleet of equipment in ASPHALT, MIXER 003
the country. BROOM ROAD, TOWED 009
BORING RIG 011
• The DoR has developed and introduced a
AIR COMPRESSOR 017
system to allot RD No to all the CRANE MOBILE 021
Construction Equipment and Inspection CRANE MOBILE 021
Vehicles. CRUSHER STONE 022
• RD No. consists of Departmental Code (for CUTTER CONCRETE 024
each type of equipment) and Equipment No. DOZER WHEEL 030

(allotted to every individual equipment) e.g.. DOZER, TRACK 031

001-017
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Maintenance of Equipment Maintenance is: -

• Replacing oils, which become contaminated with
Objectives of Maintenance particles and break down into constituents, one of which
Effective fleet management aims at reducing is acid.
and minimizing overall costs through maximum • Replacing filters, which become blocked with particles
cost effective utilization of resources such as reducing flow or allowing fluids directly into precision
components by being by-passed.
vehicles, fuel, spare parts, etc.
• Greasing,
Greasing which either gets squeezed out or looses its
• To reduce down time lubricating properties resulting in abnormal component
• To lower overall maintenance costs wear.
• To improve plant efficiency and performance • Adjusting for normal wears in order to ensure maintain
standard performance.
• To assure residual value
• Adjusting, calibrating and setting in order to ensure
• To improve safety levels economic operation.
• To reduce the demand for skilled maintenance staff. • Enabling worn or damaged components to be replaced
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before serious and costly breakdown occur.

Er. Satya Narayan Shah January 31, 2011 Er. Satya Narayan Shah January 31, 2011

MAINTENANCE PLANNING
MAINTENANCE SCHEDULING
´ Manufacturer’s maintenance schedules ´ Cycle scheduling- which is the
´ Staff and skill level determination of work required on
´ Spare parts stock level and lead times equipment through unit inspections. This
´ Consumable stock level and local sources method is used to identify work tasks
´ Status and level of workshop tools/ capacity which might be necessary in addition to
´ Work priority the standard periodic servicing tasks.
´ Field maintenance capability ´ Calendar scheduling- which is the logging
´ Availability of fund/budget of required activities on a calendar or
planning chart.
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 Er. Satya Narayan Shah January 31, 2011 Er. Satya Narayan Shah January 31, 2011

MAINTENANCE CATEGORIES
Preventive Maintenance/ Minor Maintenance
´ Unscheduled maintenance- resulting from
accidents, breakdown caused by unforeseen
component or component failure, abuse of ´ Replacement of oils, filters, greases etc.
equipment, operator negligence etc. ´ Specified intervals
´ Planned maintenance- refers to all the
´ Prevents the need of repairs – reduces
p
planningg of all maintenance works; reduces
the need of unscheduled maintenance. breakdowns.
b kd
« Preventive Maintenance/ Minor Activities are-
Maintenance « Walkaround check, operator’s report
« Major Repair « Scheduled periodic servicing
« Overhaul « Scheduled periodic inspection
« Reconditioning/Rehabilitation
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Er. Satya Narayan Shah January 31, 2011 Er. Satya Narayan Shah January 31, 2011

Major Repair Reconditioning/Rehabilitation

´ Defects identified before complete failure of ´ Total overhauling of the equipment
the equipment ´ Rebuilding to economic operational condition.
´ Repair against failure of a component/unit ´ Returning the equipment as good as new
´ Only the broken down parts are replaced equipment.
Overhaul
O h l ´ It undertakes
d t k allll the
th components t off the
th
• Returning a unit to an economic operational equipment
condition ´ Proper testing and calibration is required after

• Limited to broken-down component only rehabilitation.

´ Special tools and workshop facilities are
required.
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LIFE EXTENSION THROUGH FACTORS TO BE EVALUATED FOR OVERHAUL

OVERHAUL/RECONDITION CONSIDERATION
´ This option can be applied to two ´ Replacement cost of comparable unit
situations when the economic life span ´ Availability of spare parts
has been exceeded; ´ Workshop p facilities
«the equipment is required due to lack of
´ The Benefits- Reliability, Maintenance
fund for replacement. Cost, Performance against Replacement.
«the equipment has specialized function
´ Cost Estimation Vs. Budget
and low utilization.

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 Er. Satya Narayan Shah January 31, 2011 Er. Satya Narayan Shah January 31, 2011

WORKSHOP DOCUMENTATION
REPORTS/INFORMATION

´ Repair Requisition form ´ Inventory of Spare Parts

´ Job Record Card ´ Annual Report on Equipment Utilization

´ Cost estimate form q p

´ Annual Equipment Status
´ Spare parts stock situation ´ Annual Report on Activities of HEDs &

´ Spare part order form MOs

´ External repair form ´ Recovery on Equipment

´ Profit Loss Analysis

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EQUIPMENT OPERATION SOURCE OF DATA

SYSTEM • Goods Requisition Forms
• Operational Control System • Contract Document/Purchase Order
– Monthly Status Report • Invoice
– Annual equipment Inventory • Letter of Credit
– Movement Control • Custom Documents
– Equipment Operation Log Sheet • Store Entry Voucher
– Monthly Utilization Report • Repair Order
– Monthly Hire Report • Job Card
– Theoretical Hire Report • Operation Logbook
– Vehicle log Sheet • Equipment Hire Bill
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January 31, 2011 Er. Satya Narayan Shah 57 January 31, 2011 Er. Satya Narayan Shah 58

Questions THANK YOU ALL

Please
?
Contact:  er.snshah@gmail.com
? ? snshah@dor.gov.np

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