Optimisation of the Optimisation of the Equipments for High Equipments for High
Rise structuresRise structures
Focus on Material Handling Horizontal
& Vertical
Rambabu Cheruvu CMAC
What is mechanization?
Practical examples from life
Wheel barrows to hoists Climbing steps to using
escalators So many more examples
which we can list from our daily life
Need for Mechanization
Increase in complexity and size of projects
Shortage of skilled manpower With FDIs coming in, they
also brought in new methodologies which are new to the existing practices. We are forced to adopt to international standards of construction
Quality consciousness and fast track construction is also contributing towards versatile construction equipment
Need for Mechanization
The complexities at a glance Hyderabad has witnessed sea
change in the last few years Hitec city has seen some new
& huge constructions From G+4 We have got
accustumed to G+14 upto G+30(Pune)
We have just got the clearances for G+25(Hyderabad) Lanco G+100
Mumbai is Poised at G + 30& still moving up
Need for Mechanization
Time factors Use of alternative
methods Vertical & horizontal
distances Size of development
is about 25 acres ~ up to 400 acres
What is Mechanization?
Mechanisation is one of the ways to get the consistency at the sites & also to speed up the work thus reducing the time & the construction costs.
Mechanisation is one of the ways to plan & reduce the wastages at the sites
Need for Bench Marking
Any segment has grown steeply after setting up the benchmark for themselves.
Maruti in the segment of small cars Deccan airways in terms of low cost
airlines Is there a need for infrastructure to bench
mark itself or is it poised to set a new set of rule by itself?
Stages of construction
As we all know the three stages Pre construction Structure Super structure & Interiors
So far not much attention was given on the post completion. With the changing profiles there is a need to address post completion as well.
Mechanisation: The Terminology
Commodities – Concreting / Batching equipments– Re-bar cutting & bending – Wheel barrows /trolleys / site trucks– Builders hoist
Project specifics– This has to be defined specifically w.r.t. the project &
its needs (Horizontal & Vertical Movements)
Mechanisation of what? (Stages)
So as to get to mechanisation we need to define what can be mechanised:– We need to define stages – Excavation (Pre construction)– Structure (P.C.C, Footings, columns & slabs)– Super structure (Brick walls, Plastering
internal & external, electrical, Plumbing etc..)– Interiors (Tiles, bathroom fittings, Kitchen otta
etc…
Mechanisation of What?(Stages)
Post completion Plumbing, Electrical
maintenance Cleaning & other services
for glass façades windows etc
Various issues of leakages, fillings & painting services etc….
Process & Mechanisation
Where ever there is a involvement of the skill & continuity could be defined as process Concreting can be defines as a process!
Form work & steel fitting Brick walls / partition walls Plastering Plumbing
Every thing else could be classified as Materialhandling.
Mechanisation of the Processes
Concreting (Batching units) Form work: Various methods are developed to simplify
the formwork staging. Steel fittings & re-bar shearing & bending Bricks (manufacturing & alternative methodologies for
partition walls) Plastering methods for externals are almost nearing to its
maturity. Alternative methods of approach are at a nascent stage. Plumbing consultants are exploring new avenues for
simplifying the erection detailing
Material Handling
Uniqueness of the infrastructure M.H is about the variety of the materials to be handled.
Semi- solids, steel, Wood, plastics ceramics etc…
Material Handling
Bulky to voluminous Horizontal, Vertical Vertical – horizontal
Material Handling
With whom should we bench mark ourselves or should we initiate to draw our own set of rules of the Game!!!
General movement of materials
Steel is shifted from ground to the surfaceConcrete is shifted from ground to the surfaceFormwork is shifted from floor to floorAll other material like
Bricks, doors & windows, Ceramics or for any other material for the super structure & the interiors move from ground to the particular place on the floor.
Analysing all the movements would help us get a good data input to offer various solutions.
Scope
Identify the repetitive processes Define the construction process Define the movements of each material Identify the human dependability and control in
terms of time and quality Identify the critical processes & the bottlenecks In all the above safety should be the key note
Applicability(Case study T.S)
7 structures Each structure
12000sft Time frames
24months No critical
conditions at
the site
Applicability(Case study T.S)
Suggested to go with one tower crane & 4 passenger & material hoists
Internal movements to be handled by site truck or loaders
Yet to conclude on the site mix concrete for PCC & columns
Case Study Sun city
Location near Delhi G+17 each floor
6000Sft 23 independent
towers Covered car parking
& other facilities Well laid out leisure
facilities
Quantities (thumb rules)558 Sqmts (block)
Steel
45 Kgs /SqM
Concrete
0.4 CuM/ SqM
Bricks (normal)
90000/floor
Tiles
4000 tiles
Bathrooms
Per flat 3
Internal plastering 20mm
Plumbing
Pvc & steel acc.
Electrical
Regular acc..
External lastering 20mm
Kitchen otta & sinks
Door frames & doors(wood)
Windows
Allum../UPVC
Concreting / steel
228 CuM of concreting per floor
15 ~ 18% column concreting
15 days considered per slab
Total wt of concreting is 558 tonnes per floor
Off which columns concreting 16%(90 tons)
45 kgs of steel / sqM Per floor 25 tonnes Columns 8 tons
Centring Nearly 1.8 times the
floor area @64 kgs /sqm
Total centering @36 tonnes per floor
BBM/ Plastering & tiles
90000 bricks /floor 2.5 kg / brick Plastering (internal)
– Sand Cement & water– 50 units of sand – 15 units of cement – Approximately 80
tonnes of sand & cement
Tiles & other materials
Tiles for 558 SqMt will weigh say 15 tons
24 door frames & doors
20 windows per floor Plumbing /electricals /
ottas sinks/ wc’s etc…
Recommendation for Sun city
This is a typical site Each tower 6K sft No linkage with other
buildings The tower crane if
installed will work only at 20 % efficiency because of the lay out & the dimensions of the structure.
Here the concrete is being handled by the pumps for all purposes
The T.C. is reduced to carrying steel alone
Hence we suggest the usage of the P& M Hoist for all the vertical motions with a steel rebar attachments
Case Study Chennai
Case Study Chennai
Suggestions at Chennai
The project is a mall with a multiplex & a hotel
Size 140 mts /135 mts Mall & Multiplex
G+5 & the hotel G+15
Sheer dimension very huge & massive
Massive dimensions dictates its own logic
Here we went ahead with one tower crane & two P&M Hoists
Couple of winches & builder hoists
Horizontal movements are derived by Tractor loaders & site trucks
Applicability
Applicability of the equipments / machines should be determined by various factors viz;
Capability of the equipments
Site or the project conditions
Volume of the project Limitation at the sites Time limits for the project
completion
Applicability
Capabilities of the Crane: (5013) Jib Radius 50Mts Tip loads @1.3 tones
Can carry loads from 6 tonnes up to a radius of 30mts.
Will place any equipment within the given radius
Mainly used to carry Steel, Centering equipments, Concrete through buckets
Applicability
Advantages: Can carry literally anything to the top of the surface
Picks up & places anything anywhere within the given radius Very dependable
Exhaustively used during the structure of the project
Applicability
For example lets take a site say 25 mts by 50 mts with the total height of the structure being Cellar + Ground + 14 floors.
RCC & column concreting would be done by Concrete pumps & the boom placers
Applicability
In this case the tower crane is merely reduced to carry steel bars & the centering materials from one floor to the other. In these cases if we can get an alternative ways of looking at the vertical movement of the steel then we could avoid the investment of the Crane.
Selection of equipment
Properties and operating of equipment and the choice of equipment systems.
Estimate and control of equipment costs structure, properties and production rates
of various types of equipment. principles of location on the construction
site
Value
The Value that mechanisation can add to the construction process:
Speed: How fast are we going to handle the material & the project?
Safety: Is the safety factor addressed or not!
Value
Savings: Technology is the only way to reduce the costs. Does the selected equipment gives the value for money? Is it quantifiable? Are there factors, which cannot be quantified? If so what can be the key factor.
Strength: In this context we should call it as Quality inputs.
Conclusions
Organised approach Integrated approach Equipment know how Change management
Change management
Most important to get the new environment into the sites
Addressing the additional responsibilities of the project in-charge
Induction of new departments– Planning – Work & time study– Maintenance– Spares & stores
Thank you
We at CMAC want to get the value of mechanisation to the project sites.
Please feel to call us up or mail for any information or any assistance please Reach
us at [email protected] call me at
09348211464 / 04031001464