Planning, Scheduling, Cost Analysis and Risk Management of Industrial Machine Foundation

Planning, Scheduling, Cost Analysis and Risk Management of Industrial Machine Foundation

Mr. Viraj D. Bhosale (PG Student)

Department of Civil Engineering

Dr. D. Y. PATIL School of Engineering and Technology, Lohegaon, Pune 412 105, India

Mr. Ashish P. Waghmare (PG Co-ordinator)

Department of Civil Engineering

Dr. D. Y. PATIL School of Engineering and Technology, Lohegaon, Pune 412 105, India

Abstract The Industrial Machine foundations used to encounter such dynamic forces/vibrations caused by machines used is known as machine foundations. The dynamic forces are transmitted to the foundation supporting the machine. Generally, the moving, shaking components of the machines are balanced, yet there is always some unbalanced condition in actual practice which results the eccentricity of rotating parts. While Construction these types of foundation accuracy should be at higher side because the machines leg or foot should be at right place as per the machine drawing this become a challenging job, various type of risk is involved and their mitigation technique are mention.

Key Words: Planning, Scheduling, Risk Management of Industrial Machine Foundation, Use of Thermocol for pocket formwork

1. INTRODUCTION

   Machine Foundation is a structure used to receive and transfer to the ground the static load from a machine and the dynamic loads imposed during the operation of the machine as a result of imbalances in the moving parts.

   1. Problem Statement

      • Risk Involvement is more

      • Rate of Accuracy is Less

      • Due to Accuracy is Less, Cost is Increases

      • Time of construction More, goes beyond Deadline

   2. Objectives

      • Planning & Scheduling of Foundation

      • To Achieve More Accuracy by using Thermocol Formwork

      • Risk Management and Mitigation Technique.

      • Cost Analysis

2. METHODOLOGY Step 1: – Excavation

   Marking of excavation is done by adding 600mm on both-sides of original dismission of excavation.

   1. Excavation is done in: –

      • Soil or Murrum

      • Soft Rock

      • Hard Rock

      • Exist Concrete Flooring

   2. Equipment Used

   • JCB (Back How Front Bucket Machine)

   • Pork Clan Excavation Machine

     Note: – If Hard Strata is not available than Plump Concrete is done for 1Ft

     Step 2: – Disposal of Excavated Material

     1) Equipment Used

   • JCB (Back How Front Bucket Machine)

   • Tractor or Dumper (to dumper the excavated material in specific place)

     Step 3: – Ground Water Management

     If Ground water is present it is removed by using dewatering system.

     1) Equipment Used

   • Electrical Dewatering Pumps

     Step 4: – P.C.C

     P.C.C Bed is provided of M10 concrete at Thickness of 4 (100mm) or 6 (150mm).

     Step 5: – Water-proofing By Shahabad Tiles

     By Brunt Bricks

     Step 6: – Marking of Foundation

     Raft Reinforcement is marked for Installing of Formwork Marking of Pockets are done.

     Step 7: – Preparing of Raft

     1. Raft are construct to transfer load evenly. Raft are two types

   • Single Raft

   • Double Raft (Box Raft)

     1. Placing of Formwork for foundation reinforcement

     2. Preparation of Pockets

        This is the most popular method employed. Over-size holes are formed in the foundation concrete at the time of casting which have enough cross-section to permit a degree of lateral movement during the final positioning of bolts. When the bolts are positioned, the hole or pocket is filled with non- shrink engineering grout to ensure that the bolt is bonded to the foundation concrete thoroughly and reliably. The main advantages of pre-forming pockets are that less critical positioning tolerances are necessary compared with cast-in bolts and there is a choice of pocket size, shape and method of forming.

        Types of Pockets

   • Woods

   • Bricks

   • Thermocole

     Step 8: – Filling of Raft/ Side Pardi

     This Pardi is fill in levels e.g. If Pardi is 3m Depth it is filled in 1m intervals.

     Advantage in fill the pardi in levels are

   • Load on formwork is less.

   • Tamping can be done easily and efficiently.

   • Benefit for further Shuttering work.

   Step 9: – Water-Proofing for Side Pardi

   Water -Proofing is provided by Brick-work and Shahabad Tiles are place over it.

   Step 10: – Providing Curving Angles

   Curving Angles are provided to above edge of foundation to protects form Breaking.

   Step11: – Cleaning of Pockets

   Removal of Thermocol present in pockets by spraying petrol.

   Step12: – Miscellaneous Work Finalized the work, Final Touched ups.

3. CASE STUDY

1. Location: – Bharat Forge Limited, Pune Cantonment, Mundhwa at 5000 Ton Shop.

1. Name of Machine: – Roller Conveyor Shot Blast Machine.

   Construction Blaster Type X roller conveyors differentiate themselves from the Type G and Type HD roller conveyors by the shot blast wheels being installed at an angle to the direction of movement through the machine. The angled positioning of the shot blast wheels ensures that the blasting operation is perfect, especially on parts such as welded constructions, flame cut parts or other complex formed prefabricated parts with base ends.

2. Application of Machine: – Cleaning, Corrosion Removal, Cosmetic Finishing, Deburring, Deflating, Internal Cleaning, Paint Stripping, Preparation for Painting, Bonding and Plating, Rust and Heat Scale Removal, Shot Peening, Surface Texturing

3. Foundation Type for this Machine: – R.C.C Wall Type Machine Foundation. This type of machine foundation consists of a pair of walls with a slab resting on top. This type of foundation is constructed of homogeneous materials. It is used for small machines and the machine is rested on the top slab.

4. Planning and Scheduling of Roller Conveyor Shot Blast

   Machine Foundation

   TABLE I. Planning and Scheduling of Roller Conveyor Shot Blast Machine Foundation

5. Risk Management for Roller Conveyor Shot Blast Machine Foundation

   1. Scaffolding was very difficult to install for water-proofing to pardi.

      Sol: – Foundation Pardi was built in level of 1m brick work is done and after that the Shahabad tiles were placed.

      Advantage: –

      • Scaffolding is not needed i.e. Cost Effective.

      • Extra excavation for installing scaffolding is eliminated.

      • Only inner side the Formwork were used, by using only at one side formwork cost as well as time is saved

      • By concreting in levels load on formwork is sustainable.

      • After completing this level murrum is filled and that level is finished the job is 10% completed.

   2. Making Pockets.

      Sr. No.	DESCRIPTION OF ITEMS	QTY	UT.	RATE	AMOUNT	SAC
      1	Excavation in Concrete J.C.B Breaker	12.88	M3	1250.0 0	16100.00	9954 33
      2	Excavation in Soft Rock	6.22	M3	450.00	2799.00	9954 33
      3	Disposal of Excavation Material	28.65	M3	250.00	7162.50	9954 33
      4	Murrum Filling Around Foundation	51.42	M3	250.00	12855.00	9954 33
      5	P/L Plum Ready Mix Concrete M10	4.61	M3	3450.0 0	15904.50	9954 54
      6	P/L Ready Mix Concrete M60	4.80	M3	9250.0 0	44400.00	9954 54
      7	P/L Ready Mix Concrete M25	25.16	M3	6550.0 0	164798.00	9954 54
      8	P/C B.B Masonry	5.56	M3	6125.0 0	34055.00	9954 56
      9	P/F Waterproofing Box Type Shabad Tiles	21.83	M2	800.00	17464.00	9954 28
      10	P/L Shuttering	53.60	M2	352.00	18867.20	9954 52
      11	P/F Pockets (0.20 x 0.30 x 0.35)	16.00	Nos	450.00	7200.00	9954 28
      12	P/F Pockets (0.32 x 0.0.42 x 0.35)	8.00	Nos	500.00	4000.00	9954 28
      13	P/F Pockets (0.35 x 0.40 x 0.35)	8.00	Nos	550.00	4400.00	9954 28
      14	P/L GP2 Concrete	1.05	M3	45000. 00	47250.00	9954 54
      15	P/A Plastering	4.78	M2	338.00	1615.64	9954 72
      16	Misc. Work	1.00	Nos	6500.0 0	6500.00	9954 33
      17	Charges for Reinforcements of Steel	452.6 5	Kgs.	8.00	3621.20	9954 28
      		Rate of Taxes		Sub Total	408992.04
      Amount In Words		CGST 9%			36809.28
      		SGST 9%			36809.28
      Four Lakh Eight-Two Thousand Six Hundred Ten & Paise Sixty-One Only.				Total Amt.	482610.61

      Pockets is an important aspect for this foundation because the machines legs will be rest on these pockets. The challenge was to keep the demission of these pockets undisturbed.

      Sol: – Thermocole Box are used i.e. Thermocole box are made as per the accurate Dimension and that box are placed in the place of these pockets.

      Advantage of using Thermocole

      • Dimension remains undisturbed.

      • Removal of thermocole is easy after the concrete is set.

      • While removing of thermocole the accurate demission is maintained.

      • Thermocole and concrete does not have any type of bond in between them, so thermocole plays the role of separator.

   Fig 1. Use of Thermocole box as pockets formwork

   Fig 2. Thermocole box are aligned as per pockets of Machine

6. Cost Analysis for Roller Conveyor Shot Blast Machine Foundation

Table II. Cost Analysis for Roller Conveyor Shot Blast Machine Foundation

IV CONCLUSIONS

1. Achieve More Accuracy: –

   Accuracy is achieved by using Thermocole Box as pocket formwork. The accurate demission is maintained.

2. Risk Management: –

   Foundation Pardi was built in level of 1m brick work is done and after that the Shahabad tiles were placed.

   Pockets is an important aspect for this foundation because the machines legs will be rest on these pockets. The challenge was to keep the demission of these pockets undisturbed.

3. Cost Effective: –

   Foundation Pardi was built in level of 1m brick work is done and after that the Shahabad tiles were placed. That Scaffolding is not needed, cost of Scaffolding is eliminated.

   Hence it Cost Effective.

4. Outcomes: –

   The project details literature provided explains concept of Machine Foundation is a structure used to receive and transfer to the ground the static load from a machine and the dynamic loads imposed during the operation of the machine as a result of imbalances in the moving parts.

   To Sustain these type of load, foundation is designed, While Execution many Risk are involved to mitigate these Risk is challenging job. While mitigating these Risk the cost should be in economy side.

5. Recommendation: –

• While Excavation extra dimension should be considering i.e. by adding 600mm on both-sides of original dismission of excavation.

• Thermocole should be use Mandatory in these types of structure to achieve accuracy

REFERENCES

1. Azam S., Al-Homound and Omar N. Al-Maatiah.(1996)., An experimental investigation of vertical vibration of model footings on sand, Jou. of Soil dynamics and Earthquake Engg., , Vol. 15, 431-445.Baidya D.K. and A.Sridharan.(2002)., Foundation Vibration on Layered Soil System, Indian Geotech. Jou, 2002,Vol.32 (2), .236-257.

2. Baidya, D.K. and Muralikrishna, G. (2001)., Investigation of resonant frequency and amplitude of vibrating footing resting on a layered soil system, Jou. Of American Society for testing and Materials, 409-417.

3. E. Sriprasert., N. Dawood., Multi-constraint information management and visualization for collaborative planning and control in construction, J. Inf. Technol. Constr. 8 (2003) 341366 (special issue eWork and eBusiness).New York, 17(5), 200-201, a translation of Osnovaniya, Fundamenty i Mekhanika Gruntov in Russian.

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5. Richart, F.E., Hall, J.R. and Woods, R.D. (1970). Vibrations of soils and foundations,Prentice-Hall, Inc., Englewood Cliffs, NJ.

6. Roesset, J.M. (1980). "The use of simple models in soil-structure interaction." CivilEngineering and Nuclear Power,ASCE, No. 1/3, 1-25.

7. Savinov, O.A. (1979). Modern construction of machine foundations and their calculations.Second Edition, Stroiizdat, Leningrad (in Rissian)cheglov, V.F. (1960). Soil vibrations from forge hammers with various degree of vibration isolation. Forge-Punching Production, Mashinostroenie, 8 (in Russian).

8. Svinkin, M.R. (1980). Determination of dynamic loads transmitted to a hammer foundation. Soil Mechanics and Foundation Engineering, Publishing Corporation,

9. Svinkin, M.R. (1982). Determining the vibration amplitude of foundations supporting crankshaft presses. Soil Mechanics and Foundation Engineering, Publishing

10. Semenov, A. Anton Anichkin, S.Morozov, O. Tarlapan, V. Zolotov, Effective project schedulin under workspace congestion and workflow disturbance factors, Australia. J. Constr. Econ. Build. Conf. Ser. 2 (1) (2014) 3550.

11. W.Y. Thabet, Y.J. Beliveau, Modeling work space to schedule repetitive floors inmultistory buildings, J. Constr. Eng. Manag. 120 (1) (1994) 96116.

12. X. Su, H. Cai, Life cycle approach to construction workspace modeling and planning, J. Constr. Eng. Manag. 7 (7) (2014) 04014019.

13. BOOKS: – Construction Management and Design of Industrial

Concrete and Steel Structures

WEBOGRAPHY: –

http://machinefoundation.com/ http://machinefoundation.com/ https://uk.rosler.com/uk-en/products/shot-blasting/

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