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 support@cmac.co.in call me at

09348211464 / 04031001464