PGPM 33

PGPM 33 Material & Logistics Management Rajkumar baghel 28-12-31-6399-2102

ASSIGNMENTNICMAR / CODE OFFICE

1. Name Rajkumar Baghel

2. Reg. No. 28-12-31-6399-2102

3. Course No. PGPM 33

4. Course Title Material & logistics Management

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ASSIGNMENT

Your company has been awarded a contract of developing and constructing a new International

Airport 30km away from a city. You have been appointed as Planning Engineer (Materials and

equipment). Project is to be implemented in phases. In phase I, one strip of landing of 100m width is to be

constructed in 100 days. The scope of work for this assignment is only as follows

a) Cutting and dozing of 100,000 cum of earth. Average height 0.75m

b) Transportation of 20,000 cum of surplus earth from site to dumping place 3km away

from site (including spreading). Filling of 80,000 cum in landing strip

c) Bringing in 3000 cum of sand from 20km (including spreading and leveling ) at site

d) Procurement of 1,50,000 litres of bitumen. Duration of work 30 days from the 60th

day of starting of work. Bitumen to be obtained from refinery at Bongaigaon in

Assam. Lead time up to site is 45 days. Storage facility available at site 50,000 litres

tank.

Estimate total cost of work and your plan of

i. Equipment planning- Procurement & deployment

ii. Ordering and replenishing of Bitumen.

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SCOPE OF WORK

a) Cutting and dozing of 100,000 cum of earth. Average height 0.75m

b) Transportation of 20,000 cum of surplus earth from site to dumping place 3km away

from site (including spreading). Filling of 80,000 cum in landing strip

c) Bringing in 3000 cum of sand from 20km (including spreading and leveling ) at site

d) Procurement of 1,50,000 litres of bitumen. Duration of work 30 days from the 60th

day of starting of work. Bitumen to be obtained from refinery at Bongaigaon in

Assam. Lead time up to site is 45 days. Storage facility available at site 50,000 litres

tank.

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EQUIPMENT MANAGEMENT CONSISTS THE FOLLOWING:

1) Selection of equipment

2) Number and sizes of units

3) Matching capacities

4) Schedule of procurement

5) Arrangement of skilled staff for operation and maintenance

6) Establishment of services and repair facilities

7) Maintenance of spare parts inventory

8) Decision regarding number of shifts per operation

Thus a systematic approach in planning for equipment is necessary, incorporating all the factors

detailed above. In addition an important factor to be considered is the necessary inter-disciplinary

acceptance of the planning for equipment.

MATERIAL MANAGEMENT CONSISTS THE FOLLOWING:

Materials management is very important for timely completion of the projects. A delay

in providing the materials for construction will naturally put the project behind schedule from which

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it may never recover or the cost of bringing it back on schedule may never recover or the cost of

bringing it back on schedule may be very high.

Some important functions are below:

Identification and estimation of materials management

Procurement

Transportation

Inventory control

Storage

Control and analysis of material information

Disposal of surplus, materials, scrap, empties etc

PROCUREMENT:

The procurement of material can be done by two methods

Centralized procuring:- indicates that the entire purchases is done at on replace.

Decentralized procuring:-indicates that materials are purchased at different places.

LEAD TIME:

One of the factors to be considered in procurement of material is lead time. It is the period elapses

between the point of time when the need for material is contemplated and the point of time the

material actually available on the site of construction for use.

It comprises time required for:

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o Users intimation to the materials management department regarding the time and quality of

material required.

o Materials management to decide that the materials purchased.

o Selecting the source, fixing the price and ultimately placing the order.

o To deliver material

o Transportation and receiving the material including inspection and testing of material if

necessary.

MASS DIAGRAM

Earth moving is basically an operation where is removed from high spots and deposited in low

spots with the “making up” of any deficit with borrow or the Wasting of Excess Cut Material. The mass

diagram is an excellent method of analyzing linear earth moving operations. It is a graphical means of

measuring haul distance in terms of earth work volume. On mass diagram graph, the horizontal dimension

represents the stations of a project and the vertical dimension represents the cumulative sum of excavation

and embankment from some point of beginning on the project profile. the diagram provides information

covering

1. Quantities of materials

2. Average haul distances

3. Types of equipment that should be considered.

When combined with a ground profile, the average slope of haul segments can be estimated. The mass

diagram is one of the most effective tools for planning the movement of material on any project of linear

extent.

Using column 1 and column 12 of an earth work sheet, a mass diagram is plotted. In below mass diagram

positive ordinate values are plotted above the zero datum line and negative values below.

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MASS DIAGRAM PROPERTIES:

An excavation operation produces an ascending mass diagram curve; the excavation quantity exceeds the

embankment quality requirements. Excavation is occurring between A and B and between Station D and

E

USING MASS DIAGRAM:

The Mass Diagram Is an Analysis Tool for Selecting the Appropriate equipment for

excavating and hauling material. The analysis is accomplished using balance lines and calculating

average hauls.

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Balance lines:

A Balance line is a horizontal line of specific length that intersects the mass diagram in two

places. The balance line can be constructed so that its length is the maximum haul distance is the limiting

economical haul distance for a particular type of equipment.

MACHINE TYPE ECONOMICAL HAUL DISTANCE

Large dozers, pushing material up to 300 ft*

Push-loaded scrapers 300 to 500ft*

Trucks hauls greater than 5,000ft

Average grade % = change in elevation x 100

Average haul distance

= - 18 mt x 100 => - 8.9%

203 mt

The return trip will be an 8.9% grade.

EQUIPMENTS CONSIDERED

EARTH MOVING EQUIPMENTS

1. EXCAVATORS / DOZERS:

All excavators are designed to move large amounts of soil and earth in a minimal amount of time.

Large excavators are useful for digging foundations and other huge projects, but many times you need a

smaller excavator to handle more delicate jobs. These smaller excavators are also called compact

excavators or mini excavators. Mini excavators bring many advantages to a wide range of construction

job sites. Mini excavators are maneuverable and easy to operate. Most compact hydraulic excavators have

three distinct assemblies: house, undercarriage and workgroup. The compact hydraulic excavator has

many advantages over the traditional center-mount backhoe. Compact excavators offer many attachments

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to make any job easier. Remember, to optimize power and performance it’s important to match the

attachments to type and size of compact excavators to prevent overloading. Excavators often have

attachments, or you can purchase additional attachments to fit the machinery. Few of the attachments

include jackhammers (breakers), shovels, grapples, augers, etc… Grapples are similar to claws and are

used to grasp objects (trees, stumps, etc…). Hydraulic Mining Excavators often uses shovels. Finally,

augers are similar to a drill bit, and are used to move materials. The role of excavators is to dig holes,

trenches, and foundations. Excavators use large machinery with hinge metal buckets, which are often

attached to hydraulic arms, while using the equipment to move heavy or bulky quantities of soil or earth.

In addition, excavators are used in demolition, general landscaping, grading, heavy lifting, laying pipes,

river dredging, mining, open-pit mining, brush cutting, etc. Brush cutting is possible when operators use

hydraulic attachments.

2. SCRAPERS:

A wheel tractor-scraper is a piece of heavy equipment used for earthmoving. The rear part has a

vertically moveable hopper with a sharp horizontal front edge. The hopper can be hydraulically lowered

and raised. When the hopper is lowered, the front edge cuts into the soil like a cheese-cutter and fills the

hopper. When the hopper is full (8 to 34 m3 (10 to 45 yd3) heaped, depending on type) it is raised, and

closed with a vertical blade. The scraper can transport its load to the fill area where the blade is raised, the

back panel of the hopper is hydraulically pushed forward and the soil load tumbles out. Then the empty

scraper returns to the cut site and repeats the cycle.

Scrapers can be very efficient on short hauls where the cut-and-fill areas are close together and

have sufficient length to fill the hopper. The heavier scraper types have two engines ('tandem powered'),

one driving the front wheels, one driving the rear wheels, with engines up to 400 kW (550 horsepower).

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http://en.wikipedia.org/wiki/Heavy_equipment

http://en.wikipedia.org/wiki/Horsepower

http://en.wikipedia.org/wiki/Kilowatt

http://en.wikipedia.org/wiki/Fill

http://en.wikipedia.org/wiki/Cheese

http://en.wikipedia.org/wiki/Soil

http://en.wikipedia.org/wiki/Hydraulics

http://en.wikipedia.org/wiki/Hopper

http://en.wikipedia.org/wiki/Earthworks_(engineering)


3. ROAD ROLLER:

A Road roller (sometimes called a roller-compactor, or just roller) is an engineering vehicle used

to compact soil, gravel, concrete, or asphalt in the construction of roads and foundations. In many parts of

the world, road rollers are still known colloquially as steam rollers, regardless of their method of

propulsion. This typically only applies to the largest examples (used for road-making). This article

concentrates on non- steam-powered rollers. Road rollers work by using the weight of the vehicle to

compress the surface being rolled. Initial compaction of the substrate is done using a pneumatic-tyred

roller, where instead of the single- or double-drum is replaced by two rows (front and back) of

pneumatically filled tyres. The flexibility of the tyres, with a certain amount of vertical movement of the

wheels, enables the roller to operate effectively on uneven ground. The finish is done using metal-drum

rollers to ensure a smooth, even result. Rollers are also used in landfill compaction. Such compactors

typically have knobby ('sheep’s-pad') wheels and do not attempt to achieve a smooth surface, merely a

squashed one.

CALCULATIONS

Dimensions of the landing

Average height of filling of earth = 0.75m

Volume of the earth refilled = 80,000cum

Width of the landing = 100m

Length of the landing = 80,000/(100*0.75) = 1066.7m =1.067km

Volume of sand filling = 3000cum

Height of sand filling = 3000/ (1066.7*100) = 0.028m

Total quantity of asphalt required for the work = 1,50,000 litres

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http://en.wikipedia.org/wiki/Steamroller

http://en.wikipedia.org/wiki/Engineering_vehicle


BITUMEN ORDERING SCHEDULE

Economic Order quantity (EOQ):

The quantity of order corresponding to the frequency is known as economic order quantity.

The curve AMB indicates the graph of inventory cost for various frequencies of ordering OMG shows the

ordering costs corresponding to various frequencies. AMB+OMG= PQR (TOTAL INVENT COST).Q is

the least c and hence intercepts OS shows most desirable frequency of order of which the total inventory

cost is minimum.

Lead time for bitumen to arrive at site = 45 days

Day in which bitumen is

AVAILABLE AT SITE from

commencement of project

Day in which bitumen is

ORDERED from

commencement of project

Order no. Order quantity (in

litres)

60th day 15th day I 50,000

70th day 25th day II 50,000

80th day 35th day III 50,000

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DIRECT TUBE HEATING:

Direct tube heating is the most efficient and economical method available in asphalt tank heating.

The ONE-PLUS-ONE direct heating system offers both precise temperature control and even heating

distribution characteristics without flame impingement, hot spots or product degradation.

Direct Fire Tanks

Each unit has an oversized refractory lined submerged fire tube the length of the tank with dual

jacketed exhaust venting system, thus increasing heat transfer and reducing energy loss. All of the tanks

are also wrapped with a high-density insulation covered by a stucko embossed aluminum jacket skin that

traps precious energy inside providing the ability to produce high performance asphalt at enormous cost

savings.

Hot Oil Heated Tanks

o All the hot oil heated tanks are constructed with a multiple pass serpentine coil design, which

provides over 1200 feet of heat exchange area. As a result, we can heat asphalt more

consistently and at hotter temperatures without coking issues.

MONITORING

Someone must be present to visually monitor asphalt that is loaded and unloaded. That person

must be able to shut off product transfer before an overfill occurs. On a monthly basis, a visual inspection

is required. This inspection must include a walk through of the site to identify crack. Visual examination

of the exterior surfaces of tanks, piping, valves, pumps, and other equipment for cracks, corrosion,

releases, and maintenance deficiencies must take place. The monthly inspection must also identify poor

maintenance, operating practices, or malfunctioning equipment.

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ASPHALT HAUL TRUCKS

Various types of trucks are used to deliver hot mix to the paver. The most common type is the 5-ton

end-dump truck but other trucks have been used and can be used to deliver mix.

Truck Condition

Trucks must have metal beds, and the beds must be clean, smooth, and free of holes. All trucks

must meet minimum safety criteria. Each truck must be clearly numbered for easy identification and

must be equipped with a tarpaulin. Before being loaded, the truck bed must be cleaned of foreign

material and hardened asphalt and then lightly coated with a release agent (lubricant) that assists

in preventing fresh hot-mix asphalt from sticking to the surfaces of the bed. After the bed is coated,

any excess release agent must be drained from the bed. Before loading, the truck must also be weighed to

establish its unloaded weight. This weight is later subtracted from the loaded weight of the truck to

determine the weight of the hot mix that the truck is hauling.

Determination of the no. of trucks required

The number of trucks required on the project is determined by many factors:

the mix production rate at the plant,

the length of the haul,

the type of traffic en- countered

The expected time needed for unloading.

Types of Trucks

Each type of truck used for hot-mix delivery must have certain physical features that are required to haul

properly and to discharge the mix properly into the paver. Below are listed a few guidelines for the two

most common types of trucks.

END-DUMP TRUCKS

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An end-dump truck must first be inspected to be certain the rear of the bed overhangs the rear wheels

enough to discharge mix into the paver hopper. If it does not, an apron with side plates must be added to

increase the overhang and prevent spillage of the mix in front of the paver. The bed must also be of a size

that will fit into the hopper without pressing down on the paver. Leaking trucks should not be used.

Tarpaulins should be pulled over the mixture during hauling in cool weather or on long hauls to protect

the mixture from excessive cooling. A cool mix forms lumps and a crust over its surface. When a

tarpaulin is used, care must be taken to be sure it is securely fastened to the top of the truck bed so that

cold air cannot funnel under it.

BOTTOM-DUMP TRUCKS

Bottom-dump trucks can be used when a grader is spreading the mix or when a pickup device is used to

feed the windrow left by the truck into the paver hopper. Two common methods for unloading bottom-

dump trucks are in use. The first method involves the use of a spreader box, designed to be operated

under the gates of the truck. The amount of material, placed in the windrow, is governed by the width of

the spreader box opening. The disadvantage of this method is that the spreader box can restrict the

amount of material to less than the required amount. The second method, which is used more often than

the first, is to use chains to control the dump gate opening.

Truck Hitches

The purpose of a truck hitch on the front of the paver hopper is to keep the truck dumping hot mix into

the hopper in contact with the paver. If, during dumping, the truck and the paver separate and hot mix

spill, it must be cleaned up before the paver passes over it. Two types of truck hitches are in common use.

One type uses an extension that reaches under the truck and hooks onto the rear axle of the truck. The

other type of hitch has retractable rollers that are attached to the truck push bar and grip the outer side of

the rear wheels of the truck. The rollers revolve with the wheels while the truck dumps its load into the

hopper.

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Pivoted Truck Push Rollers

The pivoted push roller is a device, mounted on the front of the paver that adjusts when alignment

between the truck and paver is uneven. This device reduces the uneven force exerted on the paver by the

misaligned truck, minimizing interference in the steering of both vehicles.

ASPHALT FINISHERS (PAVERS)

Even though the finishers may operate differently, their primary jobs are all the same: receiving

asphalt and spreading it in a predetermined, uniform length, width, thickness, and shape. The finisher also

provides initial compaction of the mat (layer of mixture in place.) Because asphalt finishers are different,

you must always read the operator’s manual for the unit you are operating. It is also good to have a

practice sand letdown before actually using a hot mix. This is to familiarize yourself and others with the

machine and also ensure that the machine is working properly. Figure 16-39 shows a practice letdown,

using just the aggregate mix without the asphalt

Tractor Unit (Power Unit)

The tractor unit provides moving power for the paver wheels or tracks and for all powered machinery on

the paver. The tractor unit includes the receiving hopper, feed conveyor, flow control gates,

distributing augers (or spreading screws), power plant (engine), transmissions, dual controls, and

operator’s seat. The tractor unit power plant (engine) propels the paver, pulls the screed (leveling) unit,

and provides power to the other components through transmissions. Hot mix is deposited in the hopper

and is then carried by the feed conveyor through the flow control gates to the distributing augers

(spreading screws). The augers distribute the mix evenly across the full width of the paver, thus providing

uniform placement of the mix onto the roadway surface. These operations are controlled by the paver

operator by means of dual controls within easy reach of the operator’s seat. To ensure the paver functions

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properly, you should inspect the paver before commencement of paving. Below are some of the

comments you should check.

ASPHALT DISTRIBUTOR

The asphalt distributor is a unit consisting of an insulated storage and heating tank, an open

flame heating system, an asphalt pump, a low-pressure air blower, and a circulating and spraying

system. Power to operate the components is PTO driven.

Heating System

The air blower provides low-pressure air to atomize fuel for the burners. The burners heat the tubes,

located in the tank. An asphalt covering must be maintained over the fire tubes to prevent them from

overheating and causing a fire or explosion. Because the distributor is mobile, care must be taken to

ensure that heating is performed in a level area that is well-ventilated and that the distributor truck is not

moving at all and is at a COMPLETE HALT. Whenever you are heating cutbacks, the asphalt must be

circulating at all times. This is a must to prevent any chance of volatile liquids overheating around the

flues, which can be very dangerous

Spray System

The spray system consists of necessary piping, a series of hand-operated valves to control the flow of

bitumen, and an adjustable length spray bar, capable of providing coverage from 4 to 14 feet wide. The

spray bar may be equipped with either 1/8-inch nozzles or 3/8-inch nozzles; the 1/8-inch nozzles are used

for most applications. The application rate is controlled by the length of the spray bar, the pump output,

and the forward speed of the distributor truck.

Spray Bar Adjustments

For normal use, the spray bar of the distributor should be adjusted, so the vertical axes of the nozzles are

perpendicular to the roadway. Also, each nozzle on the spray bar should be set at the same angle. The

angle set for each should be between 15 degrees to 30 degrees of the horizontal axis of the spray bar (fig.

16-34) or according to manufacturer’s specifications. This action prevents the fan-shaped spray patterns

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of the nozzles from interfering with each other. Another adjustment that is essential for uniform prime or

tack coat coverage is the adjustment of the height of the spray bar.

NO OF EQUIPMENTS CONSIDERED AND REQUIRED COST:

a) Cutting and Dozing of earth

Scope of work = 100000 cum of earth of avg height = 0.75m

w.k.t Phase I, one strip of landing of 100m width

Therefore =100000 / 0.75

= 133,333 sqm.

For executing 100000 cum let us consider excavator with grader.

As per the productivity norms = 1000 m3

Total Days required = 100000 / 1000

= 100 Days

Let us consider two excavators with grader can be deployed in our project

= 100 / 2 = 50 Days

Market Hire rate for excavator with grader including operator including taxes = 1,80,000 Rs

As per the terms and condition the excavator with grader should work 10 hrs / day , 260 cumulative hrs in

a month.

Diesel Cost involved = 34 x (10 x 11 x 26) (Consumption norms = 10 – 12 lit / hr)

= 97,240 Rs

Total cost for one excavator with grader = 1,80,000 + 97,420

= 2,77,240 Rs.

Therefore total cost involved for completing the 100000 cum of earth = 2 x 277240

= 5, 54,480 Rs

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b) Transportation of surplus earth & filling of earth

Scopes of work are as follows

i) Transportation of 20,000 cum of surplus earth from site to 3 km away from site

ii) Filling of 80,000 cum in landing strip

For executing the above scope of work let us consider the tippers

As per the productivity norms = 10 m3 / trip

i) Transportation of 20,000 cum of earth to 3 km away per site

Let us consider 10 trips can be done in a day

Therefore the out per tipper = 10 m3 / trip x 10 trips

= 100 m3

Total Days required for executing 20,000 cum of earth disposal = 20000 / 100

= 200 Days

Let us consider 20 tippers are to be deployed for completing the 20,000 cum of earth disposal with a

lead of 3 km away from site = 200 / 40

= 5 Days

ii) Filling of 80,000 cum in landing strip

Let us consider 10 trips can be done in a day

Therefore the out per tipper = 10 m3 / trip x 10 trips

= 100 m3

Total Days required for executing 80,000 cum of earth disposal = 80000 / 100

= 800 Days

Let us consider 40 tippers are to be deployed for completing the 80,000 cum of earth filling on landing

strip = 800 / 40

= 20 Days will be requires to complete the work

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Market Hire rate for tipper including operator including taxes = 25,000 Rs

As per the terms and condition the excavator with grader should work 12 hrs / day, 336 cumulative hrs in

a month.

Diesel Cost involved = 34 x (30 x 26) (Consumption norms = 2-3 km / lit)

= 26,520 Rs

Total cost for one excavator with grader = 25,000 + 26,520

= 51,520 Rs.

Therefore total cost involved for completing the 100000 cum of earth = 40 x 51520

= 20,60,800 Rs

c) Bringing 3000 cum of sand from 20 km (including spreading & leveling at site)

Total Qty of sand to be procured = 3000 cum

Let us plan 6 trips per day of 10cum capacity of tipper

Total Days required = 3000 / 60

= 50 days

so we are telling to the subcontractor to supply the material by 5 tippers,

so that = 50/5 = 10 Days

Cost of the Sand including the transportation and taxes = 7 Rs / Cft

Cost of sand including the transportation and taxes = 7x 35.31

= 247.17 Rs / Cum

Total sand to be procured = 3000 x 247.17

=7, 41,510 Rs

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For doing the spreading and leveling and rolling works we need

a) Road Rollers (Vibratory Rollers)

b) Water Tanker

c) JCB

a) Road Rollers (Vibratory Rollers) :

As per the Productivity norms = 750 – 800 Sqm /Day

Total scope of work = 100000 / 0.75 = 133333 m2

Therefore No of days requires = 133333 / 6 = 178 Days

Let us consider 7 Road rollers are to be deployed = 178 / 7 = 26 Days

Hire charges for the road roller with operator including taxes = 120000 Rs

Diesel cost to be involved = 34 x 26 x 10 x 10 (Consumption norms = 8 – 10 lit / hr)

= 88,400 Rs

Total cost involved for one Road Roller = 1,20,00 + 88,400

= 2,08,400 Rs

Total cost to be involved for 7 rollers hired = 7 x 113040

= 14,58,800 Rs

b) Water Tanker :

The cost of water tanker of (10,000 lit capacity) = 1500 Rs / trip

Water are generally used for compacting the soil to attain its Maximum Dry Density

Therefore total cost of water tanker = 1500 x 26 days

= 39,000 Rs

c) JCB

As per the Productivity norms = 1000 Cum /Day

We are going to hire 5 JCB for spreading and leveling works

Initially 5 JCB will be involved in loading of sand in tipper’s

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Total No of Days = 20000 cum / 1000 cum /Day

= 20 Days

If 5 Jcb’s are involved for loading = 20 / 5 = 4 Days

Later on the jcb are to be mobilized in the spreading work

Total No of Days = 80000 cum / 2000 cum /Day

= 40 Days

If 5 jcb’s are to be put in the job = 40/ 5 = 8 Days

Hire charges for the road roller with operator including taxes = 60000 Rs

Diesel cost to be involved = 34 x 26 x 10 x 6 (Consumption norms = 5 – 6 lit / hr)

= 53,040 Rs

Total cost involved for one Road Roller = 60000 + 53040

= 1,13,040 Rs

Total cost to be involved for 5 rollers hired = 5 x 113040

= 5,65,200 Rs

BITUMEN CHARGES:

Procurement of Bitumen = 1,50,000 lit

(1lit = 0.93 kg)

The rate of Bitumen 60 / 70 as on dated 25.04.2008 = Rs. 33000/ Mt (including taxes)

Therefore the rate for 1,50,000 lts of Bitumen =(1,50,000*0.93) = 139.5 Mt.

= 139.5 Mt * 33000/ Mt.

= 46, 03,500 Rs/-

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ABSTRACT COST OF THE WHOLE WORK:

Sl.No DESCRIPTION Unit Qty AMOUNT

1 Cutting and Dozing works Cum 100,000 5,54,480

2 Transportation of surplus earth

(20,000 + 80,000)

Cum 100,000 20,60,800

3 Procurement of Sand Cum 3000 7,41,510

4 Spreading and leveling works Cum 100,000 20,63,000

5 Bitumen Charges Lit 1,50,000 46,03,500

Total 1,00,23,290

Sub contractor super vision charges 15% = 15,03,494

Sub contractor Profit charges 10% = 10,02,329

Grand Total 1,25,29,113

ASSUMPTIONS & REFERENCES:

1. Schedule of rates

2. Prices from the suppliers.

BIBLIOGRAPHY

1. Knowledge gained from working experience.

2. Details from the Internet.

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PGPM 33

Documents

direct tube

dumping place

flow control

total cost

spreader box

spray bar

average height

mass diagram