By: Ravikant

Aaat. Engg.

Deptt. of Mechanical Bakhtiyarpur.

BSC-C&C “JV”

REPORT ON CONTRIBUTION OF MACHINERY IN CONSTRUTION

INTRODUCTIONThe old method to apply road construction

manually took hours of labour and also had poor durability due to manual errors. Now with automation in this field, application through machine is gaining wide spread popularity as its not only faster but also cheaper in long run as very less labour is required.

Modern road construction involves the removal of geographic obstacles, and the use of new construction materials that are far more improved and durable. Rock and earth is removed by explosion or digging. Embankments, tunnels, and bridges are constructed, and then vegetation is removed by deforestation, if necessary. Finally, the pavement material is laid by using a range of road construction equipment.

PROJECT OBJECTIVES: To evaluate performance of Mechanical

Department. Work Volume of Mech. Dept. must be

known to management. The Management as well as colleagues

should understand the importance of Dept. We are having a large scale of manpower

& machines involve for execution of Project.

ROLE AND RESPONSIBILITIES OF THE DEPARTMENT:

When we get the new project we plan for requirement of machine by considering the length of project & volume of work.

The objective of the Department is remain same as the objective given to Civil Dept. To construct the road.

Our role is very crucial for execution of project, Therefore we are known as provider, maintainer, operator, caretaker & evaluator.

Provider- we provide machine to site according to the plan as and when required by the site.

Maintainer- we maintain machines, as per given schedule and keep it ready for execution of project.

Operator- we provide an operation team of machine & to take care its optimum utilization.

Caretaker -we take care of all machines involved in project execution for better performance in minimum cost.

We maintain and operate more than thousands of equipment in Bihar Project every day. We are also having very big volume of manpower which involve for execution of a project, which is more than one thousands of manpower are working for the project on behalf of the Mechanical Dept. All these projects are being executed under the mechanised methodology. Hence not a single work is executed without help of Mechanical Dept. Therefore, Mech. Engineers are most important and responsible partner of Civil Engineers to execute any kind of project.

OPERATIONS WITH MACHINES

• Total Machine Population in Bihar Project is 1086

Performing Operations with the

Machines

• Manpower Population in Bihar Project for machine operations is 1500

Total Manpower

Diagnosis Analysis

Actual RepairAssembly Testing

Total No. of major Machines in Bihar Project are 1086

Total population of manpower in Bihar is 1500.

We worked more than lakhs kilometres with a machine and still using same machine with good efficiency.

The most of machine has lived its life for example: Tipper has cross 1, 85,000KM & Excavator is touching to the 12000Hrs mark. and most of the machine already reached.

CONTRIBUTION OF MACHINERY IN BIHAR PROJECT SO FAR

Cumulative Run of some Machines in Bihar project. These machine are taken for example.

S. NO. MACHINES NO. OF MACHINES

CUMULATIVE RUNHr./Year

TOTAL CUMULATIVE RUN OF M/C

1. MOTOR GRADER 41 40,836 3.26 lakh

2. DOZER 12 8,376 0.65 lakh

3. EXCAVATOR 20T 22 21,620.4 1.8 lakh

4. SOIL COMPACTOR 46 21,620.70 1,72 lakh

5. WHEEL LOADER 41 32,524.2 2.65 lakh

6. TIPPER 219 25,17,097.4 201 lakh

7. TRANSIT MIXER 43 36,066 2.8 lakh

8. WATER TANKER 47 2,03,147.16 16.25 lakh

9. JCB 14 16,234.44 1.32 lakh

10. TANDOM ROLLER 17 9,706 0.72 lakh

CUMULATIVE ACTUAL AVERAGE SPARES COST OF SOME MACHINES

S. NO. MACHINES TOTAL CUMULATIVE RUN OF M/C

AVG. SPARES COST/HR

1. MOTOR GRADER 3.26 lakh 336.70

2. DOZER 0.65 lakh 256.23

3. EXCAVATOR 20T 1.8 lakh 624.29

4. SOIL COMPACTOR 1,72 lakh 152.78

5. WHEEL LOADER 2.65 lakh 260.63

6. TIPPER 201 lakh 14.29

7. TRANSIT MIXER 2.8 lakh 66.31

8. WATER TANKER 16.25 lakh 11.31

9. JCB 1.32 lakh 94.43

10. TANDOM ROLLER 0.72 lakh 160.46

oThese machines are taken for example.

DIFFERENCES BETWEEN AVAILABILITY & UTILIZATION OF MACHINE AT OUR

DIFFERENT BIHAR SITS

0

10

20

30

40

50

60

70

80

90

100

Availability

Utilizations

oThese machines are taken for example.

COMPRATIVE STRUCTURE OF HIRE & OWN MACHINES

As we have calculated for the machines on sites and it’s working Hrs. during the project, difference between Hire & Own machines. And backhoe loader is taken for example. The total cost of expenditure on hire machine is Rs 687/Hr. and for

Own machine is 574/Hr.The difference between is Rs 113/Hr.Hence 113*15268(Cumulative run only for 4 backhoe loader) = Rs

17, 25,284 /Month

MACHINE TYPE OF COST TOTAL AMOUNT/Hr.     

Hire Backhoe Loader

Hiring cost 375

  Fuel cost 312    Total cost =687     

Own Backhoe Loader

Running cost 94

  Depreciation cost 87  Operator cost 50  Fuel cost 312   Lubrication cost 31

Total cost = 574

ORGANIZATION CHART OF MECHANICAL DEPARTMENT FOR BIHAR PROJECT

CHARECTRISTIC OF EQUIPMENT

We are having these categories of Equipment's:-

1. Earthmoving Equipment2. Transport Equipment3. Laying Equipment4. Lifting Equipment5. Plants

Earthmoving Machines

Excavator Dozer Motor Grader

Wheel Loader Roller Backhoe

LoaderSoil

Compactor

At present most of the equipment's are ECM control therefore it’s difficult to repair & maintain without help of service engg. Because at present these machines have to be calibrated & rectified by Electronic technician (ET).

We don’t have rights to take Electronic Technician(ET) in our account because its works on exclusive password and copy rights to their dealer only . Therefore, we are dependent on their service. However, we are developing & try to repair, these components ourselves, where it can be done.

Some of the equipment having electronic control engine, which is equipped with electronically operated injector, In such engine we were facing a problem of injectors failure due to inferior filters & deteriorated fuel.

Fuel testing system in our company exists on density test but density test can’t give results of deterioration level because kerosene & diesel has no much difference in density. Resulting it is hard to recognise percentage of kerosene into the diesel.

We can see the problem of deteriorated fuel in given table.The deteriorated fuel is how harmful for machine that because, the value of Kinematic viscosity changes.

DETERIORATION RATIO

FUEL DENSITY

KINEMATIC VISCOSITY

85:15 0.8400 2.3375:25 0.8390 2.1665:35 0.8321 1.8950:50 0.8304 1.8325:75 0.8234 1.5

FUEL QUALITY

Poor quality of filter doesn’t mean that it is only low efficiency filter but these filters may have a problem of sealing, proper fitting, and rate of proper flow of fuel.

Now if filter is highly efficient, it may also create a problem for pump & engine, because high efficiency of filter will not allow proper flow rate of fuel and resulting starvation may happen in fuel injection pump & injector. This could also be a reason of failure.

OEM designed filter by considering all these parameters according to the nature of engine.

FILTER QUALITY

Life of the injector recorded after fitment of OEM filter:-

Under carriageMajor problem of chain operated machine is due to excessive traveling of machine from one point to another point of project - location where the existing road condition is not sufficient to carry or shift through trailer resulting required to travel itself up to 7-8KM continuously, therefore our undercarriage component’s wear & tear is very high & it is highly expensive, Hence we can minimize this traveling to save the life of this component by doing proper planning itself.

S. No. INJECTOR CHANGING READING

CURRENT READING

TOTAL RUNNING TIME (Hrs.)

1. 937 1472.2 535.22. 11588.3 11771.5 183.23. 13629 14698 10694. 9547 9667 1205. 10477 10630 155

AVG. RUNNING TIME IS 412.48

Tipper, Water Tanker, Bitumen tank are some example of transport machine.

In transport we are having huge quantity of transport equipment & it is performing at the site in a worst working environmental condition.

The common failure is being observed in Engine, Gear box & Turbocharge failure.

Engine (Reason of failure). o Neglecting on the miner leakage, such as leakage of oil

pressure line.o Leakage in turbocharger lubrication line. o Problem with timing covers oil seal.o Poor predict maintenance o Failure of turbocharger.

Transport Machines

Tipper Water Tanker Bitumen Tank

Gear Box (Our vehicles work on very high load and worst road conditions).

There are two major reasons for gear box failure.o Rough driving: The driver while carrying heavy load and

passes through high gradient, and changes the gear in between, it results in failure between pinion and housing.

o Rear engine mounting failure is also cause of gear box failure.

• Oil leakage of gear box.• Double clutching, while changing the gears.Turbocharger (Reason of failure).o Unskilled driving is a major reason of failure. o Due to chocked air filter.

It is highly important & sophisticated machine, and its performance is up to mark but there are some common failure in these machine.

The common failure in these machines is electronic failure, it happens due to wire connector, because the moisture enters into the connector and it sparks in between, and it fails electronic component. There fore its cleaning must be done on regular interval.

Laying Machine

Kerb Laying Machine Paver Finisher

These are highly important & costly machine which we have. Generally we observe that maximum failure is occurs due to high traveling of these cranes, to solve this problem, we have started the fabrication of such trailers which can shift these cranes easily to our projects and its break down may be reduced.

Lifting Machine

Crane Overhead Crane

Concrete Mix Plant is completely PLC control & high quality performing plant and its very low failure is recorded.

o It is having very good pollution control arrangement it provides high quality of concrete mix.

o These machine having a minimum failure with compare to its output. o And we are using concrete transporting machine i.e. Transit mixer for

the transport of concrete to the sites. o We are having very good quality of concrete machine & its

performance is very well or up to the marks & not such failure is recorded.

Plants

Concrete Mix Plant Hot Mix Plant Wet Mix

Macadam Plant

Hot Mix(HM) Plant is also PLC control and having high quality performing plant .

o Its dryer drum gear box failure is a common failure in HM plant. The reason of failure is due to the wear & tear of plunks inside the drum and resulting unseen vibration, therefore its gear box pinion gets damage..

o Its regular inspection and maintenance to be ensured. Wet Mix Macadam Plant is continuous base plant and

they are performing according to needs. WMM Plant production provides higher productivity with close control on quality of mix and production costs.

TRAINING PROGRAMWe have taken this training program as a mission, to enhance

the knowledge of our employees because the day by day technology is getting advanced into the machine, therefore it is necessary to keep them updated.

Now we have decided to appoint a training officer who will coordinate with the different training institution as well as OEM in India.

Mean while, we are organising a training program of Ashok Leyland form 11th Sept. 2015 to 22nd Sept. 2015. Its schedule is already prepared and will be circulated to all sites. It is requested to all Project Manager to get maximum attendance for maximum benefit of it.

The topic of this training is: 1. Road Safety 2. Driving Skills 3. Maintenance and 4. Fuel ConservationAfter this training program we are in a process to conduct a

next training of caterpillar in coming months.

SAFETY FACTOR Vehicle accident is the number one cause for death of people from

the age of 3 to 34 years. An estimated 39 000 – 46 000 people are killed in vehicle accident every year. More than 2.2 million recorded injuries from accident in 2008 alone. More than 1.6 million accident are caused by cell phone use, and texting while driving each year

Some safety factor which reduce accident happening with the machines:

o Drivers obeying the safety ruleso The routes used safe and properly maintained.o The effectiveness of the breaking system, bearing in mind the slopes

it is expected to work on.o The standard of vehicles used at mines should be as good as vehicles

used on public roads. Regular inspections and maintenance should be done to ensure a safe workplace.

o We should not allow drivers to use cell phone while driving.

You can avoid accidents and health risks by strictly following good practices.

Make sure that all machinery is properly maintained and repaired.

Wearing of suitable clothing and footwear, namely safety boots.

Read and understand the instructions manual of any machine, for which you are going to use.

Put on a seat belt - this is a legal requirement.Make sure the machine’s handbrake is applied.Remove loose tools and other pieces of equipment from

inside cabs.Keep machinery clean and mud-free.

DRIVING & OPERATION SKILLSDriver distraction is the leading factor to fatal

and serious accidents.Driving Distractions Reasons: o Cell phone distractions while driving.o Distraction of visuals on the road and

potential hazards.o Driver hands not on steering wheel.o Driver’s focus not on the road.

The Health and Safety Skills at Work Establish a carefully prepared action plan on

health and safety that’s specific to your site.Organise your workers through

communication, co-operation, competence and control.

Plan and set standards to be sure that your health and safety practices work.

Check how you’re doing through regular inspections and monitoring, and by acting on any problems should they occur.

FUTURE PLAN Maintenance of Machine & Vehicles. Regular maintenance extends the life

of your machinery and keeps up its appearance. It also prevents the wear and tear of original components, due to less use of spares, the expenditure will be minimised. Therefore, we have taken a preventive maintenance very serious objective and massage given to all project mechanical Incharge to maintain preventive maintenance schedule properly and should not fail in any circumstances.

Machine technical specification card: We have given a dead line of three months to ourselves to complete this project. In which there will be a card of each & every individual machine which will have all its technical parameters other then make & model like bore, stroke, BHP, Torque ratio etc.

Given a time bound schedule to all mechanical Incharge to repair all breakdown machines available in their workshop. To achieve such schedule, we would required financial help from management to achieve the goal.

FUTURE PLAN OF CENTRAL WORKSHOPWe have established central workshop & central store with

a great intension to start the major repairs of equipment which are shifted from the sites after completion of project & some how we are succeeded, now lots of improvement in workshop is to be done for quality repair.

Central store is playing a major role in consuming a dead stocks available at different sites and its results are very positive & effective.

The central workshop is going to be divided in three sections.

1. Earth Moving Section 2. Engine Section 3. Vehicles & Generator Section

Distribution of central workshopCENTRAL

WORKSHOP

Engines/Transmission Section

CENTRAL WORKSHOP

Earth Moving Section

Crane Excavator

Wheel Loader Soil Compactor Motor Grader

Dozer Tandem Roller

Baby Tandem Roller PTR

PAVER BACHKHOE LOADER

Rock Drill

Tipper Transit Mixer

Trailer LMV

Generator Light Sources

Bitumen Bowser Air Compactor

Small Other Equipment

FIP Test Bench

Hydraulic Hose Crimping

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