NICMAR SODE

PGP-CM-MODULE-01
ASSIGNMENT NO: 03
COURSE TITLE:

MATERIALS
AND EQUIPMENT
MANAGEMENT
COURSE CODE NCP 24/25
DATE OF DISPATCH: 25/11/2015
LAST DATE OF RECEIPT: 30/11/2015

PREPARED AND SUBMITTED BY:

NAME: MOHAMMED NOMAN
REG NO: 215-06-11-50423-2171
ASSIGNMENT

Your company has been awarded a contract of developing and

constructing a new International airport 30 K.M. away from the
city. You have been appointed as a Materials 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 the work for this
assignment is only as follows:
Cutting and dozing of 100,000 cum of earth. Average height
0.75m.
Transportation of 20,000 cum of surplus earth from site to
dumping place 3 K.m. away from site (including spreading).
Filling of 80,000 Kms in landing strip.
Bringing in 3000 cum of sand from 20K.m (including spreading
and levelling at site)
Procurement of 1,50,000 litres of bitumen. Duration of work 30
days from 60th day of starting of work. Bitumen to be obtained
from refinery at Bongaigon in Assam.Lead time upto site is 45
days. Storage facility available at site 50,000 litres tank.
Estimate total cost of work and your plan of:
i.
ii.

Equipment Planning Procurement & Deployment.

Ordering and replenishing of Bitumen.

INTRODUCTION
It is a common fact that we find a wide variety of construction
machines on every construction sites, which makes the
construction jobs easy, safe and quicker. Good project
management in construction must vigorously pursue the
efficient utilization of labour, material and equipment.
The use of new equipment and innovative methods has made
possible wholesale changes in construction technologies in
recent decades. The selection of the appropriate type and size
of construction equipment often affects the required amount of
time and effort and thus the job site productivity of a project.
These act as the backbone in the case of huge construction
projects. Proper use of the appropriate equipment contributes
to economy, quality, safety, speed and timely completion of a
project. Equipments are use for highway projects, irrigation,
buildings, power projects etc. Almost 15-30% of total project
cost has been accounted towards equipment and machinery.
It is therefore important for site managers and construction
planners to be familiar with the characteristics of the major
types of equipment most commonly used in construction.

Scope of work:
100m width of Road construction for international airport 30 Km
away from city.

Excavation of 100000 cum soil of 0.755 mt 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 +
levelling).
Total time 100 days
Strip width 100m.

Description of equipments considered:

Depending upon the application, construction machines are
classified into various categories.
1. Earth moving equipment.
2. Earth compacting equipment
3. Hauling equipment
4. Hoisting equipment
5. Conveying equipment
6. Aggregate production equipment
7. Equipments used in concrete construction
8. Pile driving 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.
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 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 the 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
Heat resistance
Reliability
Maintainability

Assumptions:
(a)
Type of equipment:
Excavator for excavation and cutting
Dozer for dozing
Grader for spreading of material
Dumper for shifting and hauling of material
Roller and water tanker for compaction.

(b)
Working hours: 10 hours per day and maximum of 60 per
week.
(c)
Maintenance: 10 hours per week per plant ( one day per
week)
(d)
Induction period: three working days (dismantling,
transport, reassembling and testing) for a lead of 100km.
(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 executed as per the mass diagram.
(i) Plant operators are experienced and are capable of achieving
the planned output.
(j) No disruptions have been considered for reasons of inclement
weather and other factors.
(k)
Plant / equipment as planned will be made available.

Cost analysis:
1 Excavation of 100000 cum soil.
Consider 3number of excavators 0.9 cum bucket capacity @ 60
cum per hour
Output 3 excavators = 1800 cum/day
Total duration required to excavate 100000 cum soil = 56 days
Assume cost of operation of excavator @ Rs 2200 per Hour
Total cost for excavation of 100000 cum soil = Rs 36.67 L
2 dozing of excavated material
Consider 3 numbers of dozer, 80HP @ 30cum per Hour
Output 3 dozers (10 Hrs working)

900 cum/day

Total duration required (consider 50000 cum soil) = 56 working

days
Assume cost of operation of dozer @ Rs 2500 per Hour
Total cost for dozing 50000 cum soil

= Rs 41.7 L

3 Shifting of 20000 cum soil 3Kms away

Consider 8 numbers of dumpers to execute this work
Capacity

10 cum/Trip

Cycle time for a single trip

Loading of material

15min

Forward journey with loaded material =

Unloading of material
Return journey

10min

5min

10min

Total duration required for a single trip

40min

Total number of trip in a day (10 Hr working)

Total output of 8 dumpers in a day

= 15 numbers

1200 cum

Total duration required to shift 20000 cum

17 working days

Assume cost of operation of material @ Rs 6 per Cum per Km

Total cost of hauling of 20000 cum soil for 3 Km lead
6*20000*3

= Rs 3.60 L
4 Shifting of 20000 cum sand from 20Km away
Consider 8 numbers of dumpers to execute this work
Capacity

10 cum

Cycle time for a single trip

Loading of material

15 min

Forward journey with loaded material = 30 min

Unloading of material
Return journey

=
=

5min

30 min

Total duration required for a single trip = 90 min

Total number of trip in a day ( 10 hr working) = 7 nos

Total output of 8 dumpers per day

560 cum

Total duration required to shift 20000 cum

= 36 working days

Assume cost of operation of transportation of material @ Rs 6

per cum per km
Total cost of hauling of 20000 cum sand for 20km lead =
6x20000x20
= Rs
24.00 L
5 Spreading of 80000 cum soil and 20000 cum sand
Consider 2 numbers of motor grader 100cum per hour
Output of 2 graders ( 10hrs working)
day

2000 cum per

Total duration required

days

50 working

Assume cost of operation of grader @ Rs 1700 per Hour

Total cost for spreading 100000 cum material =

Rs 17.00 L

6 Compaction
Consider 2 nos. Vibratory road roller 8-10 tonnes capacity,
100cum per hour and 2 nos. Water tanker 6KL capacity.
Output of 2 rollers ( 10hrs working)
Total duration required

2000 cum per day

= 50 working days

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.n
o

Activity

Equipment
planned

Unit cost
of
operation

Total
estimated
cost

Excavation of 100000
cum soil

Excavator 0.90 Rs. 2200

cum bucket 3 per hour
nos.

Rs.36.67L

Dozing of 50000 cum

soil

Dozer, 80 hp
3 nos.

Rs.2500
per hour

Rs.41.67L

Shifting of 20000 cum

surplus soil 3kms
away

Dumper
8nos.

Rs 6 per
cum per
km

Rs. 3.60L

Shifting of 20000 cum

sand from 20kms
distance

Dumper
8nos.

Rs 6 per
cum per
km

Rs 24.00L

Spreading of 80000
cum soil and 20000
cum sand

Motor grader
2nos.

Rs. 1700
per hour

Rs. 17.00L

Compaction of 100000
cum material

a) Vibratory
roller, 810 T
capacity
b) Water
tanker 2
nos. 6KL
cap.

a) Rs.
1000
per
hour
b) Rs.
1700
per
day
Total
estimated
cost

Rs. 11.70L

Rs.
134.64L

 Equipment operating cost:

The cost of operating the equipment includes fuel costs, routine
maintenance costs, major repair cost, operators cost and
overhead costs.
Fuel cost:
Cost of fuel consumed in one hour = cost per litre x hourly fuel
consumption
Hourly fuel consumption = hourly fuel consumption at full load x
operating factor.
The fuel price per litre, delivered at the site is obtained from
local suppliers as 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 = 0.15litres 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
with 250HP, 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
= 26.25 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. 44
= Rs. 1155
Routine maintenance cost:
Maintenance costs include the cost of lubricating oil, grease,
filter, batteries, minor repairs and the labour involved in
performing maintenance.

The maintenance cost include 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

Hourly maintenance cost

Favourable
Average
Unfavourable

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 the 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, then 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 0.75
= 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 x 0.8 / 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:
The major factors that are required to be kept in mind when
planning logistics of procurement of bitumen are:
1. 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 45days 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.
Bitumen required from 60th day after work
commencement.
ii.
Lead time 45 days
iii. Total requirement 1,50,000 litres
iv. Storage capacity 50,000 litres
v.
No.of orders to be placed minimum three each of
50,000 litres bitumen
vi. first order to be placed on 15th day of work
vii. material reaches site on 60th day of work
viii. average rate of consumption of bitumen 5000 litres
per day. Second order to be placed on 25th day of
work.
ix. Similarly third order to be placed on the 35 th day of
work and order materialises on 80th day of work
x.
Work is completed on 90th day after commencement.

Day
from
beginni
ng
15
25
35
60
69
70
79
80
89

Openin
g stock

Order
placed

order

0
0
0
0
5000
0
5000
0
5000

50000
50000
50000
-

50000
50000
50000
-

Total

Consum Closing
ed
Stock

50000
5000
5000
5000
50000
5000
5000
5000
50000
5000
5000
5000
Work Complete

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. bitumen required from 60th day after work commencement
ii. lead time 45 days
iii. total requirement 1,50,000 litres
iv. storage capacity 50,000 litres
v. no.of orders being placed - four
vi. first order to be placed on 15th day of work for 50,000
litres

vii. material reaches site on 60th day of work

viii. average rate of consumption of bitumen 5000 litres per day
ix. second order for 40,000 litres to be placed on 23 rd day of
work
xi.Order materialises on 68th day of work. A safety stock of 10,000
litres is available to cater for delay in supply
xi. similarly third order of 40000 ltr to be placed on 31 st day of
work and order materialises on 76th day of work
xii.similarly fourth order is to be placed on the 39 th day of work
and order materialises on 84th day of work
xiii.work is completed on 90th day after commencement.
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 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.

Biblography / Readings:
As recommended in assignment and material from internet.