Construction Site Layout and Logistics PDF

 

Construction Site Layout and Logistics Construction Methods and Technology Technology Module 2

 

Tutorial 1: Logistic Planning Prepare a Construction Logistic Plan

 

Case: Site Key Plan

 

Case Case-- Log Logisti isticc Pla Planni nning ng •

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ABC construction company has been awarded a contract for the construction of a residential society located in Plot – G12, G12, sector 143, Noida, Uttar Pradesh. Prades h. Mr. Mr. Sanjay, Sanjay, project manager of ABC construction company needs to propose a logistic plan of the project in the Kick-off meeting for the approval, so that they can mobilise the resources to the site and can start the project on the scheduled date. Mr. Sanjay has successfully handed over 6 high rise residential projects for which he gives credit to efficient logistic planning of project. He have outlined below listed factors, that he always consider before starting logistic planning: Safety Site Challenges (Such as levelness, condition of soil, groundwater, etc.) Site Access • • • •

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Excavation and Hauling Hoisting. Movement of Manpower, material, mobile machinery and equipment. Concrete Conveyance and Placement Project Phasing Demobilisation

 

Project Details Site Pr Site Profi ofile le Plot Area: 10 Acres

Machinery/Equipment Required

Temporary Structure

2 Ba Batching Pl Plant-30 Cu Cum

Site Office

Back Side: Green Belt

100 mtr Co Concrete Pi Pipeli lin ne

Marketing Office

Right Side: Adjac Adjacent ent Empty Plot of size 5 acres (Available for Rent: Rs. 1000/M2)

100MT Weigh Bridge

Visitor View Gallery

4 Bar Bar Bendin Bending/Cuttin g/Cutting g Machines

Cement Storage – 5000 bags

Left Side: Side: 12 mtr wide road road

2 Transit Mixer

QA/QC Lab

Stories: 20 No. Basement: 2 No.

Tower Cr Crane

Labour Camps+ Toilets

DG set

Site General store

Club Cl ub:: 1 No.

2 Concrete Pump

Site Boundary

Ground water: At At 2.5 mtr from NGL

2 Ex Excavator+ 4 Dumpers

Labour Ca Canteen

Foundation Bottom: At At 8.5 mtr from Referenced Level

Dewatering Pumps

Frontt Side: Fron Side: 24 mtr mtr Expres Expresswa sway y

 

Constraint Related To Project Site •

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Expressway on front side of project, have time restriction over entry for all category Expressway heavy vehicl vehicle e i.e 10:30 10:30pm pm to 7am. 7am. Busy City Road on Left side of project, have time restriction over entry for all category heavy vehicl vehicle e i.e 9:00p 9:00pm m to 7am.

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Shall not use Groundwater for Construction. Sound emitting construction equipment shall not be used or operated during night time in this zone.

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Acoustic Barriers for controlling Noise in day time.

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Vehicles carrying goods such as steels bars, cement and other construction vehicles are not allowed on City road.

 

Site Logistic Planning Reading

 

Construction Site Lay Layout out Planning •

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Construction site layout involves involves identifying, identifying, sizing, and placing Temporary Facilities (TFs) within the boundaries of construction site. These temporary facilities range from simple laydo laydown wn areas to warehouses, fabrication shops, maintenance maintenance shops, batching plant, and housing facilities. Required temporary temporary facilities and their areas are depending in many factors including project type, type, scale, scale, design, location, and organization of construction work.

 

Objectives •

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The site must be designed designed to maximize efficiency of operations in order to promote worker productivity productivity,, to shorten project time time and to reduce cost. The final plan must create a project with with a good work environment environment in order to attract and retain the best personnel and thus contribute to better work quality and productivity Failure to plan the site layout in advance is a prime cause of operational inefficiency, inefficiency, and can increase the overall cost cost of a project substantially substantially.. Poor Site Layout Planning leads to •

Material stacks wrongly located

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Plant and equipment wrongly located Inadequate space allowed Site huts wrongly located in relation to their effective use

 

Elements of Site/ Layout Layout Planning •

Safety

Characteristics of Temporary Facilities

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Site Accessibility

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Information Signs

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Security Accommodation

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Offices

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Water Supply & Sanitation

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Material Handling

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Storage & Site Cleaning

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Craft Change-Houses

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Batch Plant & Fabrication Shops

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Satisfying environmental and safety regulations Availability of diverse solutions for the Availability same problem Relatively short life span of a specific Relatively s pecific location Reutilization with a minimum loss for the same or modified function at another location Easy of assembly assembly,, dismantling, and exploitation Standardization of design

 

Facility Identification and Siting •

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Identifying the required temporary facilities for a specific project and determining their areas are difficult decisions decisio ns that require require thorough thorough consideration of the project project conditio cond itions ns and local reg regulat ulations ions.. In order to develop the knowledge base for the facility identification and area detter de ermi mina nati tion on,, th the e kn kno owl wled edg ge wer ere e ac acqu quir ired ed an and d co comp mpil iled ed fr fro om di difffe fere rennt so sour urce cess, including •

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constructionn safety and health manual constructio manualss compan comp any y hand handbooks books published dissertations, techn technical ical articles, and interviews intervie ws with some experts in the construction construction industry

 

Example: Site Plan

 

A Typical Building Project

 

Details of equipment/mobilization/logistics •

3 Concrete Pumps to cater to 4 Pump Locations

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Batching Plant – 30 CuM/ Hr

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Pump Capacity – 30 CUM/ Hr

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Feeder Room Feeds the Cement to Batching Plant Boom Placer – 4 to 5 Lacs / Month  –  Rental

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Weigh Bridge – 100 MT

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Plant Machines & Vehicles Vehicles (PMV)

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Most of the Major Contractors were on Board on the day of Aw Award ard

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BIM was used for planning Monitoring of Cost – ERP / SAP (System Application Plan) Monthly Profitability is worked out by PM Any material which is procured at higher rate, owner owner has the option to supply at their rates Form Work Work is kept normally 1.5 times the generally erected Dry Cladding – Gap between wall and Cladding, Wet Cladding – cladding stone is stuck on the wall

 

ENTRY GATE

BATCHING PLANT

Truck Wash Area

30 cum. Per hr.

DG AREA

PMV QA OFFICE /QC

FEEDER CEMENT ROOM GODOWN SUBCONTRACTORS ‘

External Area Development

CONCRETE PUMP PIPELINES

BUILT-UP T-UP AREA : 3,84,587 sq. ft. BUIL South North ` Tower Crane 50 mtr. Tower Crane STEEL BENDING & CUTTING SPACE SPACE SHUTTERING YARD

SPACE General Stores Conference Hall Site Office

Site Logistics

 

Details of Equipment/Mobilization/Logistics •

HVAC •

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Chilled Water Loop Condensed water loop

Logistics for Finishing Items Logistics for Bought Out Items

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Safety Drills for New Workers every day

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Zero Accident Site

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First Aid Tr Training aining

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Fire Drill Prize / Award to Safety, Area wise, how and what was saved,

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Depending upon the lead time of

Nominated Sub Contractors by the Client

procurement for an item, Inventory is controlled. Generally •

Always have Plan A, and Plan B available,

 

Placement and Location of Tower Cranes South Tow ower er Crane

North Tow ower er Crane

 

Site Infrastructure

Type  – Pre-fabricated Capacity – 94 X 5 = 470 Facilities – 

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Toilet Water Supply Electricity Supply Crèche Medical Facilities

 

Key Project Team

Plant,

Quality

Safety

Services

Execution Planning Pla nning &

Machinery & Vehic Vehicle le

Monitoring

Project m anage anager  r 

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Lab Tests conducted on Site •

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Compressive Strength Test Slump-cone Test

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Field Density Test

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Aggregate Impact Test

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Silt Content Test

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Moisture Content Test

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Specific Gravity Test

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Initial Setting Time of Cement Final Setting Time of Cement

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Sieve Analysis

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Elongation Index

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Flakiness Index

 

Lab Tests conducted on Site

 

Internal Quality Inspection

Quality audits conducted quarterly

 

Public Safety •

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The site logistics team help create a coherent service to manage Fire Risk and First Aid. Occupational Health services benefit both the  Health of Work Force and Project Performance. Performance.  Managing risk associated associated with FIRE is one of of the most important part of the Site Logistics Team. Cause Caus e of Fire  –  disca discarded rded matchsticks matchsticks - smoki smoking, ng,  –

 short circuiting, loose electric connections, connections,  –

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Deliberate setting of Fire  Improper storage of flammable material, Gas cylinder, chemicals, packaging materials, waste  Improper Electrical Wiring in and around labour camp,

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Fire Safety Plan  –  one of the vital requirement require ment of constr construction uction site:  –

Government Regulations

Effective Fire Safety Measures, Fire  Safety Drills.

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 Provision of Adequate Fire Extinguishers

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Evacuation Plans Fire Tenders, Fire Marshals and Fire Wardens.

 Periodic Fire Safety Audit Audit

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Effective First Aid, and training for Dealing with Emergencies.

 Provision of Occupational Health  

Fire Safety Training

 

Health Safety Training Programme

 

First Aid Training

 

Safety Practices Rope

Safety Net

 

Prize Distribution

 

Medical Check up of Workers

 

Security •

A vital part of Project Construction: •

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Deploy Security Team with logistics of managing and mitigating security risks Deployment of CISF or other Security Agencies for managing access to site Provision of CCTV at strategic locations for 24x7 monitoring Crime Prevention Police Station

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Security Drill

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Night Security

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Alarms

 

Construction Industry — Traditional Traditional Approach to Logistics

 

Logistics Functions and Their Integration TRANSPORTATION • Mo Move veme ment nt of Go Good ods: s: Ai Airr, ra rail il,, ro road ad,, wat ater er,, pi pipe peli line ne

WAREHOUSING

• Activities related to receiving, storing and shipping materials to and from production or distribution

locations

3RD & 4TH PARTY LOGISTICS • Per erffor orm m or ma mana nag ge on one e or mo more re lo logi gist stic icss se servi rvice cess (3rd party – outsourcing) • Lo Logi gist stic icss sp spec ecia iali list stss pl pla ay th the e rol ole e of gen ener eral al co cont ntra ract ctor or,, by ta taki king ng ov over er th the e en enti tire re lo logi gist stic icss fu func ncti tion on (4th Party)

REVERS REV ERSEE LOG LOGIST ISTICS ICS • To ha hand ndle le th the e re retu turn rn,, re reus use e, re recy cycl clin ing g or di disp spos osal al of pr prod oduc ucts ts

 

Traditional position of Logistics •

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Traditionally very little attention is paid to Supply Chain Management (SCM) or Traditionally Logistics. It recognizes the final leg of delivery of material as important ignoring the earlier part. Has a tendency to outsource / pass on risks leading to Fragmented Fragmented Supply Chain Each trade contractor is increasingly responsible for procurement of their own material, thereby thereb y leading to Unsatisfactory Unsat isfactory situation, whereb whereby y no one has overall control of a project. This risks other stakeholders being adversely adversely affected, and project performance being diminished. Factors Influenced by Construction Logistics: •

Work Force Motivation, Speed of Construction, Security Se curity,, Emergency Response, Project Cost, Congestion Level, Use of Offsite Fabrication, Air Pollution Level, Task Time Reliability, Reliability, Industry Image, Competitiveness of a Tender, Supply Chain Performance, Project Time Reliability, Level of Innovation, Noise Pollution Level, Health and Safety, Client Image, Waste Waste Production, Community Impact, Contactors Image

 

Factors Influenced by Construction Logistics  — Tendency Tendency to Ignore •

Work Force Motivation

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Congestion Level

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Health & Safety

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Use of Offsite Fabrication

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Client Image

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Air Pollution Level

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Waste Production Community Impact

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Task Time Reliability Industry Image

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Community Image

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Competitiveness of Tender

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Speed of Construction

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Supply Chain Performance

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Security

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Project Time Reliability

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Emergency Response

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Level of Innovation

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Project Cost

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Noise Pollution Level

 

Traditional Approach Approac h to Logistics •

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UNCONTROLLED

  INCONSIDERATE   

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DISRUPTIVE  WASTEFUL

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The uncontrolled, fragmented nature of supply chain permits delivery vehicle to arrive on site underutilized. This form of waste is inconsiderate as it causes disruption to local traffic flow and adds to congestion.   Limited control is exerted by site to regulate delivery vehicle parking / offload. a result may park /disruption. offload inconsiderately on the public highway As causing considerable The uncontrolled flow of delivery vehicles to site causes a security threat to the site and inconsiderate to its neighbors. The Principal contractor has no authority or  control to stipulate offsite

traffic management, permitting delivery arrive at thedisruption site via any route. This is inconsiderate and oftenvehicles causes to considerable Lack of control permits the use of poorly maintained vehicle, which produces high level of pollution, po llution, showing little consideration to the environment (Being Inconsiderate). uncontrolled The which materials are handled causesby a threat to health and safety and stored is inconsiderate as itmethod

 

Traditional Approach Approac h to Logistics

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The construction industry produces high volume of waste. Involving skilled operatives any logistics actively is wasteful and disruptive

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UNCONTROLLED

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  INCONSIDERATE  •

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DISRUPTIVE  •

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WASTEFUL •

  Waste is increased as a result of poor waste management at site.

Inadequate / inappropriate material storage facilities on site causes damage to material leading to waste and disrupts the progress at site. Late deliveries cause disruption and waste at site as the project is not able to progress as planned Lack of control permits the use of poorly maintained vehicle, vehicle, which produces high level of pollution, po llution, showing little consideration to the environment. The uncontrolled method by which materials are handled and stored is inconsiderate as it causes a threat to health and safety

 

Barriers in Improving Construction Logistics •

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Lack of Incentive to Change Construction Projects seen as a one – off and therefore difficult to optimize logistics for long term benefit like Retail Sector.

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Fragmented nature of Construction Industry and lack of direct employment.

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Inadequate advance planning of projects and short lead times.

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Lack of Cost Transparency in construction process hinders the identification of potential savings from Improved Logistics.

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Inadequate Information Flow

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Lack of Understanding, Trust, Confidence in Supply Chain.

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Clients (and others) believe that project cost already include for appropriate logistics resources to be committed to project.

 

Resistance to Change •

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Many Practices are outdated and are overdue for Reform. The organizational Structure of the Project Team, Team, that is temporary coalition of small firms to complete a Building Project provides very little incentive to research and develop new, improved method of working. Need to change in this highly competitive market, consumer demand for greater value and lower lower price clubbed clubbed with regulatory norms is a necessity . The concept that “INNOV “INNOVATI ATION ON IS INSEPERABLE FROM F ROM PROGRESS” is particularly par ticularly true tr ue

of Construction, with many projects delivered behind time with cost overrun

 

Concept Concept of a Consolidation Centre

 

Concept of a Consolidation Centre Tr Trade ade contractor orders orders goods from supplier and books the delivery in to the consolidation center

G O O

Supplier delivers into the consolidation center

D

I N

S Goods are offloaded and checked Consolidation center informs the trade contractor that the delivery has been received and updates its stock records Materials are placed into storage

G O O O U

When materials are required on site, the trade contractor ’calls ’calls off’ the materials from consolidation center

D T S

Consolidation centers delivers materials to an agreed location onsite  

Logistics Strategies •

Substituting Information for Inventory

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Improve communications with suppliers / clients

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Collaborate / Talk Talk regularly with suppliers

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Tr Track inventory precisely Bar Code & Radio Radio Frequency Identification - RFI and GPS) toack track exact location of (Use Material

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Keep inventory in transit as far as possible

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Use postponement centers to avoid clogging of materials or warehousing

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Mix shipments to match customer needs Don’t wait wait in line at customs (let ( let this be a parallel activity - obtai obtainn custom custom clear clearances ances

while the material is in air / sea)

 

The Reverse Reverse Logistics Hierarchy Hi erarchy Reduce

Reuse

Recycle

• Reducing resource use is considered to be the most responsible “green” strategy strategy

• Design products for reuse of materials and components and with easy upgrades to extend life • Similar to reuse; product materials reprocessed into products or components components..

Recover Energy

• Disposal of product but recov recover er energy in the process; eg.,”Trash to energy” plants

Dispose To Responsible

• Last resort: Send unusable, unrecyclable materials and