MECHANIZATON OF CONSTRUCTION

PRESENTATION BY:K.R.RAMANA, DY. DIRECTOR , NICMAR

Need for Building Roads

The Roads are the nerves carrying the men and materials to and from towns and cities. More and more reliance on road transport is imminent., especially for quick movement. The importance of road transport for quick movement has been recognized. The National High ways with peak densities of over 5000 vehicles per day, have reached a chocking point and alternate ways of augmenting this growing volume had to be devised. Infrastructure development is traditionally the preserve of Central Government in India and was handled by Public sector undertakings and corporations . This development calls for massive infusion of capital. Private and foreign participation was therefore encouraged and a package of incentives was offered . New Financing/ operating Models like the BOT, BOOT, BOLT etc were introduced for financing of Infrastructure projects ( Roads/ Highways) . Since the MNC were also involved in the competition for construction it pushed the Domestic construction companies to improve their productivity and efficiency by introducing Mechanization in Road construction works.

Construction of Roads in conventional method.

1) Involvement of huge man power 2) Time over run 3) Safety 4) Cost increase due to time over run 5) Dependability and administration 6) Quality of work.

Why Mechanization
High rise in Man power cost

Availability of skilled manpower

Restriction in manpower accomodation Statutory condition imposed by Acts/Laws Local administrative procedures and problems

- Constraints of space at site due to material Safety Quantum of work vs time

Advantages of Mechanization
Speedy in construction
Safety Time saving

Cost saving
Controlled Planning Less lead time for procuement.

Quality of work
Productivity

COST COMPARISIONMachinery Vs Manpower

We shall consider 2 activity which is commonly used in major construciton project works. They are Excavation / Grading works Concrete / Pre cast

Cost Comparison between Manual Work work & with Machinery

-------------------------------------------------------Sl.no Activity Cost Manual Machinery ------------------------------------------------------01 Excavation & Rs 75 Rs 25 grading works 02 Concreting Rs 180 Rs 35

Excavation/ Grading works

a) Productivity by Man power - One man can do maximum of 2 cubic meters in normal soils 1 cubic meters in hard soils 0.5 cubic meters in rocky soils b) Productivity by Machinery - An excavator in Normal soils- 500 M3/ day - A JCB excavator in normal soils- 125 M3/day - Depth of excavation can be greater than 4 meters

Excavation/ Grading Cost comparison

MANUAL EXCAVATION

-Daily production of 50 to 75 cubic meters with 40 to 50 labour for a maximum depth of 1.5 meters - Cost of excavation- 50 labour @ Rs 70 per labour= Rs 3500/Cost per cubic meters = Rs 3500/50 c.meters = Rs 70 per cubic meter Add for administrative and other charges Rs 5 per cubic meter
Total cost = Rs 75 per cubic meter

Excavation/Grading works
EXCAVATION BY MACHINERY

1 Cost of equipment ( excavator) = Rs 35,00,000 2 Considering depreciation for 5 yrs = Rs 3500000/5= 7,00,000 per yr. 3 There fore cost of equipment per month Rs 700000/ 12 Rs 58,333 4 Cost of equipment per day = Rs 2000 5 Considering interest at 15% per annum = Rs 1500/Therefore cost of equipment per day = Rs 2000 + 1500 = Rs 3500/6 Considering maintenance at 30% = Rs 1050 7 Considering cost of operator / Helper = Rs 500 8 Considering cost of fuel = Rs 7500 9 Total cost per day = Rs 12,550/10 Cost per hour = Rs 1050 CONSIDERING VOLUME OF EXCAVATION AS 500 CM/DAY
COST OF EXCAVATION PER CUBIC METER= 12550/500 Rs 25 perCM

De Watering

By Man power- un productive and time consuming either by use of Pump at Ground level or suitably designed pumps meant for de watering application . Note: At certain locations De watering can be carried out only by the use of equipment such as in deep excavations for docks, harbours, pump houses etc.
By Equipment - very efficient and productive. Mostly carried out

Concreting
A) MANUAL CONCRETING Considering a normal pour with 7 sets of 2 nos 10/7 concrete mixer, 1 no weigh batcher and 1no. Building hoist, man power required are approximately 40 labour for mixing and placing for a concrete of 240 cubic meter per day ( Similar to a Batching plant of avg. pouring capacity of 30 cu.mtrs/hr) Considering a normal mix and ground floor works only. Cost of 2 mixer (each of capacity 2 cu.mtrs/hr) = Rs 2,00,000 Cost of 1 weigh batcher = Rs 50,000 Cost of 1 builder hoist = Rs 1,00,000 Total cost of 1 set = Rs 3,50,000 Total no. of sets required are = 7 nos. Cost of Machinery = 7 x 3,50,000 = Rs 24,50,000/-

Concreting ( contd.)
Considering depreciation of 5 yrs = Rs 4,90,000 Cost per year 24,50,000/5 = Rs 4,90,000 Cost per day = Rs 1342/( out put of 2 mixer 2 x 2 x 8=32 x 7 = 224 m3 / day) There for cost per cubic meter Rs 1342/224 = 5.9 say 6 M3/day--(a) Cost of labour for concrete per cubic meter - Rs 150 ..... (b) Man power for operation ( 28 operators at Rs 125 per operator) - Rs 125 x 28 = Rs 3500 Operation cost per cubic meter = 3500/224 = 15.6 say Rs 16...(c) Maintenance cost of eqpt @ 25% of eqpt cost for the period of 5 yrs. = Rs 8 per cubic meter..(d) There for Total cost of Manual concrete /Cu.meter = Rs 180/ CM

Concreting
B) CONCRETING USING MACHINERY - Considering 30 cu.mtrs/hr batching plant - Cost of Batchng plant = Rs 30,00,000 - Cost of 2 nos Transit Mixers = Rs 40,00,000 - Total = Rs 70,00,000 Considering economic life at 10 Yrs Depreciatin over period of 10 Yrs Rs 70,00,000/10= Rs 7,00,000 Cost of equipment per day = Rs 7,00,000/ 12 x 30 = Rs 2000/Considering a concrete pump, cost of pump = Rs 30,00,000 Considering other pump accessories (6 to 7 %) Rs 2,00,000 Total = Rs 32,00,000 Considering depreciation over a period of 7 yrs Cost of equipment per day Rs 32,00,000/ 7 x 12 x 30= Rs 1270/ day.

Concreting (contd.)
There for Total cost of Machinery= Rs 2000+ 1270= 3270/ day The batching plant of 30 M3/Hr will deliver an avg. quantity of 20 CM3/Hr concrete a) Operation cost ( Man power) 2 Operators, 2 Drivers, 2 Helpers 4 x Rs 150/day + 2 x 80 / 240 cu.meters = Rs 4 / M3 ..... (a) Volume of concrete for a 12 hours shift 12 hr x 20 M3 = 240 M3 Therefore cost of concrete per cubic meter= 3270 / 240 = Rs 14/ M3...(b) Adding interest @ 15% on investment = Rs 13 / M3....(c) Total ( a + b + c ) = Rs 31 per cubic meter. Man power charges for machinery concrete considering 10 labour @ Rs 80 perlabour = Rs 800/Therefore cost of labour / cubic meter = Rs 800 / 240 M3= Rs 4/M3 Therefore total cost of Concrete by Machinery= Rs 31 + 4= Rs 35/M3

Reference to Construction Equipment in Specs of Roads and Bridge works by Indian Road Congress.
( Ministry of Road Transport and High ways)

The following conditions regarding use of equipment in works shall be satisfied. 1) Contractor must give trail run of equipment for establishing their capability, to achieve the laid down specification and tolerances to the satisfaction of the Engineer before commencement of work. 2) All equipments provided shall be of proven efficiency and shall be operated and maintained at all times in a manner acceptable t o Engineer. 3) All Plant and Equipment shall be got approved from Engineer for ensuring their fitness and efficiency before commencment of work. 4) Any material or Equipment not meeting the approval of the Engineer shall be removed from the site. 5) No equipment will be removed from site without permission of the Engineer.

Equipment used in Road way construction

Equipment for carrying out the various operation s are available in a variety of sizes and with different attachments to perform specific tasks. Selection of the Equipment to be used, size and attachements should therefore be carefully made. A) SCRAPPERS- these are used for earth moving - loading, hauling and discharging. They can be crawler or wheel tractor pulled, single or Twin engne B) EXCAVATORS: are used for excavating earth and include.Power shovels, Back hoes, Drag lines- Crawler, wheel or truck mounted, Clam shells, Trenching Machine. Or wheel mounted belt loaders. C) BULL DOZERS are available depending upon mounting ( crawler or wheel) method of raising and lowering blade and control ( cable or hydraulic). These are used for clearingland, opening pilot roads, moving earth, spreading earth, back filling, clearing and levelling.

D) COMPACTION EQUIPENT Compaction of soil in road making is attained by applying energy to loose soil by one or more of the following methods. Kneading action Static weight Vibration Impact A variety of equipment is available including the following: Tamping rollers, smooth wheel rollers, Vibrating rollers, Manually operated compactors, vibrating compactors for deep sand. Besides the above a number of other Plant and Machinery are used such as Concrete Mixer/ Batching plant, Bituminous plant comprisign of Boiler, sprayer spreader and pavers, Hauling vehicles like tippers or dumpers, Metal crushing plant etc.

END OF THE SHOW part-I