TYPES OF CONSTRUCTION MACHINERY FOLLOWING ARE THE MAJOR

TYPES OF CONSTRUCTION MACHINERY

FOLLOWING ARE THE MAJOR TYPES OF EQUIPMENTS THAT IS BEING USED IN THE CONSTRUCTION INDUSTRY

STAGE TYPE OF WORK MACHINERIES PRELIMENARY SITE DEVELOPMENT FOUNDATION SUPER STRUCTURE WATERBODIES MANAGEMENT, FINISHING TUNNELINING CANALS TUNNELING CANALS ROAD MAKING, ASPHALTING EARTH MOVING EXCAVATING , GRABBING , CLEARANCE SHORT TRANSPORTATION OF SOIL LONG RANSPORTATION COMPACTING, EXCAVATING LOADING DIGGING DEWATERING ROCK BREAKING CONCREATING MATERIAL HANDLING PLASTERING STONE CUTTING DRILLING, DIGGING EARTH MOVING CONSTRUCTION OF PAVEMENT SURFACE FINISHING DOZERS TRACK OR WHEELED SCRAPPERS DUMPERS , TIPPERS HEAVY ROLERS SHEEP FOOT ROLLERS VIBRATING ROLLERS COMPACTING MACHINE PUMPS POWE HAMMERS COMPOSITE MACHINES PNEUMATIC TOOLS MIXERS, CONVAYOR BELTS, AGITATORS, VIBRATORS TOWER CRANES, MOBILE CRANES PLASTERING MACHINES POWER SAWS AIR COMPRESSORS, EXCAVATORS, BACK HOE, MOTER GRADERS, PAVERS HOT MIXER PLANT

DOZER TRACK

SCRAPER

DUMPER

TIPPER

HEAVY ROLLER SHEEP FOOT ROLLER VIBRATING ROLLER

POWER HAMMER

PNEUMATIC TOOLS

MIXER , CONVEYOR BELT

CONVEYOR BELT

PRIMARY EARTH EXCAVATING EQUIPMENT S ARE THE TRACTOR MOUNTED EXCAVATORS. IT OPERATES ON STATIONARY MOOD . THEY DUMP EXCAVATED MATERIALS ON THE SIDES OR DIRECTILY INTO THE WAITING TIPPERS /DUMP TRACK THEY GRADUALLY MOVE THE POSITION AS THE WORK PROGRESS

FACE SHAVELS IT OPERATES FROM A FLAT SURFACE, PRODUCING UPWORD DIGGING ACTION , EXCAVATING AND FILLING THE BUCKET AS IT CLIMBES. AFTER THE BUCKET FILLED ITS UPPER PART SWING S TO THE DUMPING POSITION WHER THE BUCKET EMPTIED IN A WAITING TRUCK. THERE AFTER IT RETURNS TO ITS ORIGINAL POSITION AND STARTS THE NEXT CYCLE OF EXCAVATION. BUCKET CAPACITY VARIES FROM 0. 3 M 3 TO 3. 25 M 3 AND ITS CUTTING LENGTH VARIES FROM 7 M TO 10. 5 M

FACE SHOVEL

BACK HOE OR EXCAVATORS IT IS PRIMARILY USED FOR EXCAVATING BELOW ITS TRACK LEVELS BACK HOE ARE GENERALLY TRACK MOUNTED BUT SMALL CAPACITY EQUIPMENT HAVE WHEEL MOUNTED TO ADD TO THEIR MOBILITY BUCKETS HAVING STRUCK CAPACITY 0. 38 M 3 TO 3. 25 M 3 CAPABILITY OF DIGGING DEPTH FROM 5 M TO 9. 5 M.

BACK HOE

EARTH EXCAVATING AND FITTING EQUIPMENT TYPE OF EQUIPMENT FEATURE BUCKET STRUCK CAPACITY BUCKET SIZE 0. 38 0. 57 0. 76 1. 14 1. 53 2. 30 ENGINE HP 50 75 100 130 160 200 1. FACE SHOVEL MAXIMUM 7. 0 7. 5 8. 5 10. CUTTING Ht(M) 60 90 120 180 220 300 IDEAL OUTPUT /Hr (LOOSE , EASY DIGGING) 2. BACK HOE OR MAXIMUM DIGGING 5. 0 6. 5 7. 5 8. 0 9. 0 EXCAVATER DEPTH (M) IDEAL OUTPUT / HR 48 72 96 144 176 240

OUTPUT PLANNING DATA PLANNED OUTPUT = IDEAL OUTPUT * CORRECTION FACTOR * PERFORMANCE FACTOR IDEAL OUTPUT = BUCKET OUTPUT/CYCLE* NO OF CYCLES/HR BUCKET OUTPUT /CYCLE = BUCKET STRUCK CAPACITY NO OF CYCLES = 60/EACH CYCLE TIME IN MIN

CORRECTION FACTOR OUTPUT ADJUSTMENT FACTOR FOR SECONDARY TASK EQUIPMENT NATURE OF SECONDARY TASK n SHOVEL MOVEMENT FROM EXCAVATING PLACE TO MALVADING PLACE TASK n 1. WITHIN VICINITY 1. 0 2. LITTLE MOVEMENT 0. 6 TO 0. 9 3. APPRECIABLE MOVEMENT BACK HOE 0. 4 TO 0. 6 TRENCHING 1. EQUAL TO BUCKET WIDTH 1. 0 2. MORE THAN BUCKET 0. 7 TO 0. 9

CORRECTION FACTOR EQUIPMENT FACTOR MULTIPLIES FACE SHOVEL 1. 00 BACK HOE 0. 80 SOIL DIGGING FACTOR DIGGING FACTOR EFFORT MULTIPLIES EASY DIGGING 1. 00 MEDIUM DIGGING 0. 85

SWING FACTOR ANGLE OF SWING 45 60 75 90 120 150 180 FACTOR VALUE 1. 2 1. 0 0. 88 0. 79 0. 71 1. 16 1. 07 LOAD CASTING FACTOR METHOD OF CASTING FACTOR MULTIPLIES OPEN AREA RESTRICTED AREA SIDE CASTING 1. 0 0. 8 LOADING IN VEHICLE 0. 6 0. 8

EXAMPLE ESTIMATE THE HOURLY PRODUCTION IN BULK VOL (CCM) OF A BACK HOE WITH BUCKET CAPACITY OF 0. 96 cum EMPLOYED ON EXCAVATION OF A FOUNDATIN FOUR METRES DEEP IN HARD DIGGING SOIL. THE EXCAVATED EARTH IS TO BE LOADED IN WAILING DUMP TRACKS PLACED AT A SWING ANGLE OF 75. THE EXPECTED PERFORMANCE IS 83% IDEAL OUTPUT ASSUMED – 150 CUBIC M/HR BACKHOE OUTPUT USING EQUIPMT CONVERSION = A* 0. 8

CORRECTION FACTOR SOIL FACTOR FOR HARD DIGGING - 0. 67 FOOD FACTOR FOR LOADING INTO VEHICLE - 0. 87 SWING FACTOR FOR 75 - 1. 05 CORRECTION FACTOR = 0. 67*0. 87*1. 05 = 0. 56 PERFORMANCY n = 0. 83 HENCE EXPECTED OUTPUT = IDEAL OUTPUT * CORRECTION FACTOR * PERFORMANCE n = 150*0. 8*0. 56*0. 83 = 56 cubm/hr

HAULING EQUIPMENT REAR DUMPER TIPPER AND REAR DUMPER TRICULOR AS HIGH WAY HAULING GENERALLY FRONT END LOADERS AND EXCAVATORS ARE USED TO LOAD TIPPERS AND DUMPERS THE NO OF HAULAGE VEHICLE REQUIRED = 1 + CYCLE TIME / TRIP OF VEHICLE/LOAD FILLING TIME OF VEHICLE

HAULING EQUIPMENT

PROBLEM CONSTRUCTION OF A MILITARY HELIPAD AT AN ATTITUDE OF 2400 m INVOLVES 80, 000 CUBM (LOOSE) OF AREA EXCAVATION OF SOFT SOIL. THE TASK IS TO BE COMPLETED IN 200 WORKING HRS. THE COMPANY ENTRUSTED WITH THE EXECUTION OF THE TASK HAS TOO DOZER EACH WITH AN OUTPUT OF 220 CUBM/HR UNDER JOB CONDITION. IT ALSO HOLDS WHEELAND 22 CUBM DUMP TRUCKS ONE LOADER CAN LOAD IN TRUCKS BOUT 120 CUBM OF EXCAVATED SOIL/Hr THE DUMP TRUCK CYCLE TIME FOR DISPOSED OF EXCAVATED MATERIALS IN 35 MINUTES. THIS INCLUDES 7 MINUTES OF LOADING TIME BY A LOADER TEAM CONSISTING OF 2 LOADERS

ESTIMATE THE OUTPUT OF FRONT END LOADER FOR LOADING EXCAVATED SOIL HEAP INTO DUMP TRUCKS AND DETERMINE APPROXIMATELY THE NO OF DOZERS , LOADERS AND DUMPERS REQUIRED TO COMPLTE THE TASK ON TIME

ATTITUDE AT HEIGHT OF 2400 cm THE SOIL REQUIRED FOR HELIPAD IS 80888 CUBcm TIME PERIOD OF COMPLETION – 200 HRS MACHINERIES USED DOZERS - 2 NOS OUTPUT OF EACH DOZER IS 220 CUBM/HR ALSO WHEEL LOADER MACHINE IS USED CAPACITY OF EACH BUCKET IS 22 CUBM WHEEL LOADER OUTPUT/HR – 120 CUBM/HR EACH CYCLE TIME OF DUMP TRUCK – 35 MIN TIME OF FRONT END LOADER ? NO OF DOERS , LOADERS , DUMPER?

NOW OUTPUT/HR OF EACH DOZER 220 CUBM/HR TOTAL WORKING HR OF EACH DOZER – 200 OUTPUT = 220 * 200 = 44000 CUBM EXCAVATION QUANTITY = 80000 CUBM NO OF DOZERS = 80000/44000 = 1. 8 i. e 2 DOZER

LOADERS REQUIRED = EXCAVATION /HR BY DOZERS/ LOADER OUTPUT /HR = NO OF DOZERS*DOZEROUTPUT/HR LOADER OUTPUT /HR = 2*220/120 = 4 LOADERS 1 DOZER = 2 LOADER (1 TEAM) 2 TEAMS

DUMPERS REQUIRED FOR EACH LOAD OF TEAM = 1 + DUMPER CYCLE TIME LOADING TIME = 1+ 35/7 = 1+5 = 6 TOTAL DUMPERS REQUIRED = 6*2 = 12

LOADER FRONT END WHEEL LOADER ARE GENERALLY AVAILABLE AND THEY ARE EQUIPPED WITH A FRONT MOUNTED GENERAL PURPOSE BUCKET EACH TRANSPORTER FOR SHORT DISTANCE IT IS AVAILABLE AS WHEEL MOUNTED AND TRACK MOUNTED IT CAN SPREAD AND COMPACT THE FILLING MATERIAL

OUTPUT DATA THE OUTPUT DEPENDS UPON THE SIZE OF BUCKET AND HP OF ENGINE BUCKET CAPACITY ARE SPECIFIED BY THE MANUFACTURER EITHER IN TERMS OF HEAPED CAPACITY OR STRUCK CAPACITY PLANNING IN MODE ON LOOSE SOIL STRUCK CAPACITY OF THE BUCKET HEAPED CAPACITY IS CONVERTED TO STRUCK CAPACITY BUCKET CAPACITY = BUCKET HEAPED CAPACITY * FILL FACTOR

FILL FACTOR NATURE OF SOIL BUCKET FILL FACTOR COMMON EARTH 0. 95 SAND GRAVEL 0. 95 HARD CLAY 0. 80 BLASTED ROCK 0. 70

BULL DOZER IT IS ONE OF THE HEAVY EARTH MOVING MACHINERY USED FOR , IT COME UNDER EARTH CUTTING AND HAULING EQUIP. 1. DITCHING 2. GRUBBING 3. STUMPING 4. PIONEERING 5. STRIPPING 6. MOVING AND LEVELLING

BULL DOZER IT IS TO CUT AND SHIFT EARTH FROM ONE PLACE TO OTHER. THEY ARE AVAILABLE WITH DIFFERENT TYPES OF BLADES IT IS A VERSATILE MACHINE BULL DOZER IS USED TO MOVE EARTH UPTO 100 m EXCAVATING TO A SHALLOW DEPTH OF 200 m AT A TIME OTHER TYPES OF EARTH CUTTING AND HAULING EQUIP 1. FRONT END LOADER 2. TOWED SCRAPER 3. MOTORISED SCRAPER

BULL DOZER

IT COMES UNDER DIFFERENT TYPES OF BLADES(4 NO) “S” BLADE STRAIGHT USED FORWARD PUSHING OF EARTH “U” BLADE IT HAS LARGE CAPACITY AND IS USED FOR PUSHING LOOSE MATERIAL ANGLE “A” BLADE FOR PUSHING SOIL TO ONE SIDE , IT IS REQUIRED IN HILL ROAD FORMATION CUTTING “P” BLADE FOR PUSH LOADING A SCRAPPER

BULL DOZER OUTPUT DOZER OPTIMUM OUTPUT = DOZER IDEAL OUTPUT * CORRECTION FACTOR DOZER PLANNING DATA DOZER OPTIMUM = OUTPUT * PERFORMANCE FACTORS NOW CORRECTION FACTORS DEPENDS ON THE FOLLOWING FACTORS 1 . BLADE FACTOR S 1. 00 A 0. 75 U 1. 25 2. TRANSMISSION FACTOR - 80% OF IDEAL OUTPUT

3. GRADE FACTOR - AS PER SLOPE FOR PLANNING PURPOSE IT CAN BE TAKEN AS DOWN HILL +2. 5 * GRADE % UP HILL -2 * GRADE % 4. SOIL FACTOR DIGGING EFFORT NATURE OF SOIL FACTOR EASY DIG SAND, GRAVEL 1. 0 MEDIUM DIG COMMON 0. 85 EARTH IN NATURAL STATE HARD DIG HARD STUFF CLAY , SOFT ROCK 0. 67

5. SWING FACTOR IN PLACE (OR BANK) VOLUME = BULK VOL SWELL FACTOR FLY WHEEL HP ONE WAY HAUL DISTANCE IN METRES 15 M 30 M 45 M 60 M 60 -75 220 115 78 73 75 - 125 375 195 132 123 125 - 200 514 266 180 169 200 275 705 350 246 229

EXAMPLE DETERMINE THE OUTPUT OF A BULL DOZER HAVING 215 HP ENGINE FILLED WITH A GRADE RATEDCAPACITY 4. 40 CUBM THE DOZER IS EMPLOYED FOR EXCAVATING A HARD CLAYED AREA WITH AVERAGE HAULAGE OF 50 M ON A GROUND WITH DOWN SLOPE OF 10%. IT HAS A DIRECT DRIVE TRANSMISSION AND ITS EXPECTED PERFORMANCE IN 50 MIN/HR SOLUTION OUTPUT/HR = IDEAL OUTPUT/HR*CORRECTION FACTOR * PERFORMANCE FACTOR

1. IDEAL OUTPUT/HR FOR 50 M HAULAGE OF 215 HP DOZER WITH “S” BLADE OF CAPACITY 4. 4 CUBM = 200 CUBM/HR 2. CORRECTION FACTOR APPLICABLE SOIL FACTOR FOR HARD DIGGING= 0. 67 BLADE FACTOR FOR “A”BLADE = 0. 65 GRADE FACTOR FOR 10% DOWN GRADE ASSISTANCE = 1+ 2. 5 * 10% = 1. 25 TRANSMISSION FACTOR FOR DIRECT DRIVE – 0. 8 SWELLING FACTOR OF CLAYED SOIL – 1. 3 LOOSE VOL BANK VOL = 1/1. 3 CORRECTION FACTOR = 0. 67*0. 65*1. 25*0. 8*0. 4355*1/1. 3= 0. 335 PERFORMANCE FACTOR FOR 50 MIN/HR = 0. 83 OUTPUT = 200 *0. 83*0. 335 = 55. 61 CUBM/HR

COMPACTING EQUIPMENT TYPES OF COMPACTING EQUIPMENT – SMOOTH DRUM VIBRATION , PADDED , DUAL DRUM ASPHALT NOW PRODUCTION OF SPREADING EQUIPMENT TIME FOR COMPLETING JOB: NO OF PASSES *DISTANCE IN Km AVG SPEED IN Km/Hr * n FACTOR

COMPACTING EQUIPMENT

EQUIPMENT PRODUCTION DEPENDS ON THE COMPACTED THICKNESS OF MATERIAL AVERAGE SPEED FLY WHEEL POWER WEIGHT OF OPERATING FREQUENCY OF VIBRATION

COMPACTED SOIL /SUB BASE /ASPHALTICCONCRETE IM CUBM/HR = W*S*L*0. 83 P W= EFFECTIVE ROLLING WITH WIDTH OF COMPACTION (M) S= AVERAGE SPEED OF COMPACTION (M/HR) L = COMPACTED THICKNESS OF THE MATERIAL P= NO OF PASSES REQD TO ACHIEVE DESIRED COMPACTION ( DEPENDS UPON WEIGHT AND TYPE OF COMPACTIONAND THE REQD DENSITY TO ACHIEVE) WHILE SELECTING THE ROLLER OR WIDTH IN RELATION TO WIDTH OF THE LAYDOWN LANE TO BE TAKEN INTO CONSIDERATION NO OF PASSES DEPEND UPON WEIGHT AND TYPE OF THE COMPACTER AND THE REQUIREMENT OF DENSITY TO BE ACHEIVED

CRANES AND HOISTS CRANES ARE HOISTING DEVICES AND THEY ARE USED FOR LIFTING MATERIAL/ EQUIPMENTS MACHINERY BASICALLY THEY ARE OF TWO TYPES OF CRANES 1. MOBILE CRANES 2. TOWER CRANES

MOBILE CRANES ARE THE BEST MEANS FOR LIFTING AND SHIFTING OF SMALL TO HEAVY LOADS. THEY ARE OF THREE TYPES 1. GRAWLER MOUNTED CRANES 2. SELF PROPELLED RUBBER TYRED WHEELS CRANE 3. TRUCK MOUNTED TOWER CRANES 1. STATIONARY CRANES 2. TRAVELLING CRANES 3. CLIMBING CRANES

MOBILE CRANE TOWER

ESTIMATING CRANE OUTPUT CAPACITY TO HANDLE LOAD = GRA=OVE OUTPUT/HR= LOAD/CYCLE* CYCLES/HR TO REFER MACHINERY MANUAL FOR LOAD/CYCLE AND CYCLES/HR

ACTIVITY HOOKING LOAD AT g. l 1. 0 MIN RAISING LOAD FROM g. l TO A HT OR 30 m AT 60 m/min 0. 5 MIN Slewing through 120 deg at 60 deg/min 2. 0 MIN TRAVELLING ON RAILS FOR 45 m AT 30 m/min 1. 5 MIN MOVING TROLLEY AT JIP LEVEL FOR UNLOADING AND 1. 0 MIN POSITIONING BY 15 m AT 15 m /min UNHOOKING LOAD 1. 0 MIN LOWERING LOAD BY 5 M at 60 TO 100 m/min and resting at THE PROPER PLACE 1. 0 MIN RAISING HOOK BY 5 METRES (OVERTAPPING) 0. 0 MIN SLEWING ORIGINAL LOADING POSITION 1. 0 MIN MOVING TROLLEY AT JIB LEVEL TO OADING POSTN 0. 5 MIN TRAVELLING ON RAIL TO ORIGINAL LOADING POSTN 1. 5 MIN LOWERING HOOK 0. 5 MIN TOTAL CYCLE/TIME 11. 0 MIN

TOTAL CYCLE / TIME : . n = 44 min/hr AND SHIFTING AT 5 TONS LOAD IN EACH CYCLE 5 TON LOADS * CYCLES IN ONE HOUR (OF 44 MIN) 44 * 5 11 = 20 TON/HR

METHOD OF COMPUTING OWNING AND OPERATING COST OF AN EQUIPMENT TO GET COST OF EQUP/HR , TO UNDERSTAND OWNING AND OPERATING COST EQPT – LOADER : - FLYWHEEL POWER 112 HP PAYLOAD = 2722 kg (A) COST AT SITE FOR 1. 53 CUBM (FOR EARTH) Rs 1500000. 00 LESS TYRE REPLACEMENT COST Rs. 40000 . 00 LANDED PRICE LESS COST OF TYRES Rs. 1460000. 00 LESS : RESALE VALUE : Rs. 150 000. 00

(B) NET VALUE FOR DEPRECIATION : Rs 1310000. 00 (C) OWNING COST 1. DEPRECIATION : NET DEPRECIATION VALUE LIFE IN HRS = 1310000. 00 = Rs 81. 88 HR 16000 ASSUMING ANNUAL USE IN HRS = 16000 HRS ®INTEREST @ 12% AND INSURANCE @ 1% LANDED PRICE * % INVESTMENT = TOTAL ANNUAL RATE ANNUAL USE IN HRS = RS. 67, 03/HR

REPAIR COST TYRES: REPLACEMENT COST = 40000 ESTIMATED LIFE 3200 = Rs 12. 50 NORMAL REPAIR = 90% OF LANDED COST – TYRE COST TOTAL HOUR = 0. 9 * 1500000 – 40000 = Rs 81. 88/hr 16000

SERVICE COST FUEL – 11 Kg /HR * Rs 4 = Rs 44. 00/HR (a ) Lubricant greace etc - Rs 10. 00/HR (b ) Total service cost = 44 + 10 = 54. 00/HR OPERATION SALARY – 80. 00 = Rs. 10. 00/HR 8 TOTAL OWNING AND OPERATING COST PER HOUR = DEPREATION + INTEREST @ 12% AND INSURANCE @ 1% + TYRE REPAIR COST + NORMAL REPAIR COST + TOTAL SERVICE COST + OPERATOR SALARY = 81. 88+ 67. 03+12. 03+81. 88+ 54. 00 + 10. 00 = Rs 307. 29/HR

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