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

Various machines with impact or shock loads are used for production processes at plants and in industrial buildings. Forge and drop hammers are most powerful machines producing impact loads. Forge hammer production is usually accompanied with high vibration levels of ground vibrations because substantial dynamic loads are transmitted on hammer foundations, and these vibrations may detrimentally affect adjacent and remote structures. 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.

● Lack of Planning & Scheduling ● Low rate of Accuracy ● Due to Less Accuracy, Cost of Structure get increased ● Time of construction More, goes beyond Deadline

● Planning & Scheduling of Foundation ● To Achieve More Accuracy by using Thermocol Formwork ● Cost Analysis ● Risk Management and Mitigation Techniques

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

• 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) 2) Placing of Formwork for foundation reinforcement 3) Preparation of Pockets 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.

• 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.

Bharat Forge Limited, Pune Cantonment, Mundhwa at New Fab Line Shop.

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.

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

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.

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.

2. Making Pockets. Pockets is an important aspect for this foundation because the machine‘s 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.

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

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 machine‘s legs will be rest on these pockets. The challenge was to keep the demission of these pockets undisturbed.

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.

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 this Risk the cost should be in economy side.

● 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

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, pp. 431-445. Baidya D.K. and A.Sridharan.(2002). ―Foundation Vibration on Layered Soil System‖, Indian Geotech. Jou, 2002, Vol.32 (2), pp. 236-257. 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, pp. 409-417. E. Sriprasert., N. Dawood (2003). Multi-constraint information management and visualization for collaborative planning and control in construction, J. Inf. Technol. Constr. 8, pp. 341–366 (special issue e-Work and e-Business).New York, 17(5), pp. 200-201, a translation of Osnovaniya, Fundamenty i Mekhanika Gruntov in Russian. and temporal exposure to safety hazards in construction, J. Constr. Eng. Manag. 135 (8) pp. 726–736. Richart, F.E., Hall, J.R. and Woods, R.D. (1970). Vibrations of soils and foundations,Prentice-Hall, Inc., Englewood Cliffs, NJ. Roesset, J.M. (1980). "The use of simple models in soil-structure interaction." CivilEngineering and Nuclear Power, ASCE, No. 1/3, pp. 1-25. 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). Svinkin, M.R. (1980). ―Determination of dynamic loads transmitted to a hammer foundation.‖ Soil Mechanics and Foundation Engineering, Publishing Corporation, Svinkin, M.R. (1982). ―Determining the vibration amplitude of foundations supporting crankshaft presses.‖ Soil Mechanics and Foundation Engineering, Publishing V. Semenov, A. Anton Anichkin, S. Morozov, O. Tarlapan, V. Zolotov (2014). Effective project scheduling under workspace congestion and workflow disturbance factors, Australia. J. Constr. Econ. Build. Conf. Ser. 2 (1) pp. 35–50. W.Y. Thabet, Y.J. Beliveau (1994). Modeling work space to schedule repetitive floors inmultistory buildings, J. Constr. Eng. Manag. 120 (1) pp. 96–116. X. Su, H. Cai (2014). Life cycle approach to construction workspace modeling and planning, J. Constr. Eng. Manag. 7 (7) pp. 0401-4019. Books: - Construction Management and Design of Industrial Concrete and Steel Structures Handbook of Machine Foundations

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(PG Student) Department of Civil Engineering, Dr. D. Y. PATIL School of Engineering and Technology, Lohegaon, Pune – 412 105, India