SUBJECT: CONSTRUCTION METHODS AND TECHNOLOGY FACULTY: PROF. K.R.

RAMANA SUBJECT CODE: MCM 115 COURSE OBJECTIVE: Students in this subject will learn the emerging construction methods and technologies and their applications in construction activities. LESSON PLAN ( FOR 5 SESSIONS ):

STRUCTURAL STEEL FABRICATION, ERECTION METHODS AND PROCEDURES, LIGHT , MEDIUM AND HEAVY ERECTION. SITE AND PLANT LAYOUT MATERIAL HANDLING METHODS STATEMENT AND METHODS IMPROVEMENT PREFAB CONSTRUCTION AND SPACE STRUCTURES.

RECOMMENDED BOOKS FOR REFERENCE AND STUDY: 1) MANAGEMENT, MACHINES AND METHODS IN CIVIL ENGINEERING BY CHRISTIAN A. JOHN - REFERENCE 2) METHODS IMPROVEMENT FOR CONSTRUCTION MANAGERS HEWRY PARKER AND CLARKSON OGLESBY. 3) CONCRETE, MICROSTRUCTURE PROPERTIES AND MATERIALS. BY PK. MEHTA AND MONTEIRO PM PUBLISHERS : MCGRAW HILL, NEW YORK 2006 4) REINFORCED SOIL AND ITS ENGINEERING APPLICATION BY SWAMY SARAN PUBLISHERS I.K. INTERNATIONAL , NEW DELHI, 2005 5) SITE ENGINEERING MANUAL BY D.DORAN PUBLISHERS: WHITTLES PUBLISHING SCOTLAND 2006 6) PRINCIPLES OF FOUNDATION ENGINEERING Braja M.Das Publishers: Thompson India, 2007

Note: there will be 1 assignment and 1 class test in my portion.

STRUCTURAL STEEL FABRICATION ERECTION METHODS AND PROCEDURES HEAVY ERECTION by Prof. K.R.Ramana
ACM 25TH BATCH, SECTION A AND B

STRUCTURAL STEEL FABRICATION ERECTION METHODS AND PROCEDURES by K.R.Ramana, M.Tech

TOPICS BEING COVERED IN THE PRESENTATION: METHODS OF CONSTRUCTION RESOURCES REQUIRED FOR STEEL STRUCTURAL ERECTION

METHODS OF CONSTRUCTING STEEL STRUCTURES. Of the various methods of construction, erection of buildings power plants, petroleum refineries, petrochemical plants, huge hangers, ware houses are constructed out of steel structures. These can be constructed by 3 methods.

A) In situ construction
conventional methods: In this methods engineering is carried out separately by design team, the contractor assigned for fabricating and erecting the structures procures the material, moves them to the site, make the preparation at the site yard, erects the structures, places them together by a suitable methods which may involve, riveting, fabricating or bolting, finishes them by painting, cladding, glazing as the case may be. It is possible a single principle contractor may be involved on the job or a number of contractors may be involved on the job who is specialized in cladding the structural steel building or glazing the building as the case may be.

B) Pre fabricated Construction :

In this type One agency designs the structural steel building, the second one fabricates them in the workshop or factory, the fabricated steel in different section with raw material sections or plates are moved to the site, erection is carried out either by the same contractor or a separate erection contractor. In this the time required for the erection cycle on site is drastically reduced as the preparatory works are carried out in the work shop . The quality of the steel

structural is of superior as the fabrication is carried out in a controlled atmosphere. The planning and execution of works is of better order. C ) Pre-engineered Construction: In this type the engineering and fabrication is carried out at the factory or a huge workshop completely dedicated for the structural steel works. The factory may be designed with a good automation as well as good facitlity for preparing the material, fabricating the material, finishing the material. The fabricated material is also marked well with identification numbers inline with the engineering drawing. In this system dedicated contractors well versed in erection of the designed steel structures are engaged so that a professional work is carried out in the erection site. Since the entire building is preengineered this has advantage both from the quality and economy point of view. The only limitation in pre-engineering construction is the design once frozen must not be subject to change Any change after the design would involve heavy cost as the structures are designed specific to the location and usage. As in all constructions the main RESOURCES in steel structure construction are:

a) MATERIAL RESOURCE b) EQUIPMENT RESOURCE AND c) MAN POWER RESOURCE.

MATERIAL RESOURCE:
a) b) c) d)

How do you estimate the weight of structural steel Connections for structural steel Estimating the cost of steel structures. Items of cost in a structural steel estimate.

EQUIPMENT RESOURCE:
ii) iii) iv) Erection of structural steel Equipment required for erecting structural steel. Method of fabrication a) Bolting structural steel

b) Welding structural steel

MANPOWER RESOURCE:
i) ii) Labour for erecting structural steel Field painting of structural steel.

TYPES OF STEEL STRUCTURES:

Steel is used to erect such structures as Multistorey Buildings, Auditoriums, Gymnasiums, theatres, churches, Industrial Buildings, Roof trusses, Stadiums, Bridges, Towers etc. in addition to steel structures, steel members are frequently used for columns, beams, roof purlins, decking, joists, studs, lintels, and for others purposes. Due to its high strength, steel is ideal for long spans and tall structures. Steel consisting of standard shapes or fabricated plate girders is used for many multiple span bridges. Trusses made of steel can span large arenas for entertainment or educational facilities. Galvanized steel angles are fabricated into space-truss towers to support conductors and shield wires for electrical transmission structures. Transmission towers often are 120 to 200 ft ( 40 meters to 70 meters ) tall. Steel is also used to support water towers and other types of elevated storage units. Skyscrapers are typically constructed of steel.

MATERIAL RESOURCE:
MATERIALS USED IN STEEL STRUCTURES
Steel structures should be constructed with members fabricated from STANDARD SHAPES such as I Sections (W-wide flanged Beam section), C- channel section, T T section, L- angle section (equl or un equal angle , pipes, tubes, rods and plates. Members made from standard rolled shapes are usually more economical than the fabricated members. However if standards shapes are not available in sufficient sizes to supply the required strength, it is necessary to fabricate the members for several parts, such as adding plates to beam flanges or stiffners to beam webs. Large built-up plate girders can be fabricated by welding together steel in Pounds ( 1 kg = 2.205 pounds), hundred weight (cwt) , or in tons ( 1 ton 1000 kilogram). The Grade of structural steel denotes its yield strength, For example, a drawing may show a STEEL BEAM as W 18 x 55 Grade 50. The W represents a wide flange I Beam section, the 18 denotes the approximate depth in inches, the 55 represents the weight in Pounds per feet length, and the Grade 50 denotes 50,000 pounds ( psi)

a) ESTIMATING THE WEIGHT OF STRUCTURAL STEEL

In estimating the weight of structural steel for a Job, the total number of linear feet for each shape by size and weight must be determined from the drawings for a Project. Structural steel Hand Books give the nominal weights of all sections. However,

variations in weights amounting to 2 percent above or below the nominal weights are permissible and may occur. The purchaser is charged for
the actual weight furnished, provided that the weight does not fall outside the permissible variation. The weights of the details for connections should be estimated and priced separately if a detail estimate is desirable. In estimating the weight of a steel plate or irregular shape, the weight of the rectangular plate from which the shape is cut should be used. Steel weighs 490 pound per cubic foot or 7850 Kg per cubic meter.

b) CONNECTIONS FOR STRUCTURAL STEEL

In fabricating standard shapes to form the required members or in connecting the members into the structures, two types of connections are used: a) BOLTED CONNECTIONS b) WELDED CONNECTIONS There are advantages and dis-advantages in each type of connection.

c) ESTIMATING THE COST OF STEEL STRUCTURES.

In estimating the cost of structural steel for the job, a contractor will submit a set of plans and specifications for the structure to a commercial steel supplier for quotations. The steel supplier will make a quantity take off, including main members, detailed connections, and miscellaneous items. Then the supplier will add the fabrication costs for cutting, punching, drilling , welding, overhead, and profit as a basis for submitting a quotation to the general contractor. For some jobs , the steel supplier will paint the fabricated steel before delivery to the job. When the steel fabricator paints the steel, it is called SHOP PAINT. The cost of transporting the steel to the Project must be added to the cost of the finished products at the fabrication shop. General contractors who erect buildings and similar structures usually sub-contract the erection of the steel to the sub-contractors who specialize in this work. This practice is justified because the erection of steel is a highly specialized operation, which should be performed by a contractor with suitable equipment and a well trained erection crew. Because of these conditions, the general contractor can usually have the erection

performed more economically by a sub-contractor than with the general contractors equipment and employees. The charge for the erection is generally based on an agreed price per ton of steel in place, including bolting and welding connections. When estimating the cost of structural steel in place, a contractor will include in the estimate the cost of the steel delivered to the project, the cost of erection, and the cost of field welding and painting as required. To these costs the contractor will add

the contractors cost for job overhead, General overhead, and Profiit. ITEMS OF COST IN A STRUCTRUAL STEEL ESTIMATE:

The items of cost that should be considered in preparing a comprehensive detailed estimate for a steel structure include: 1) Cost of standard structural shapes delivered to the steel supplier.(A) 2) Cost of preparing drawings for use by the shop in fabricating the steel.(B) 3) Cost of fabricating the steel shapes into finished members.(C ) 4) Cost of transporting the steel to the Job site. (D) 5) Cost of erecting the steel, including equipmentl labor, bolts or welding(E) 6) Cost of field painting the steel structure.(F) 7) Cost of Job overhead, General overhead, Insurance, Taxes and Profit. (G) The base cost of steel is subject to change due to economic conditions. Therefore, the cost of any one or all of these items may vary considerably with respect to time. Consequently, the cost of each item must be estimated for each particular Project.
COST OF STANDARDS SHAPED STRUCTURAL STEEL:
Structural steel is hot rolled into standards shapes, sizes and lengths at steel mills. Steel suppliers purchase bulk quantities of structural steel from the Mills or from Govt owned steel manufacturers like vizag, salem steel in standards shapes and lengths, usually 40 feet long ( 12 meter long or in multiples of 6 meters). The cost of steel delivered by the mill to the steel suppliers fabrication shop depends on the shape, weight per foot or meter, grade and total quantity ordered, Large quantities of purchased steel generally are

priced lower than small quantities of steel. Typically, the construction contractor purchases the steel from local steel supplier ( distributors or agents) not the steel mill. The cost of purchase steel from steel supplier before it is fabricated is commonly called the BASE PRICE OF STEEL. Steel supplier have shops that specializes in fabricating standard shaped steel into members to meet the specifications required for each particular job. Before starting the fabrication process, the steel supplier prepares the shop drawings that are submitted for approval.

COST OF PREPARING SHOP DRAWINGS In preparing plans for a steel structure, the engineer or architect does not furnish drawings in sufficient detail to permit the shop to fabricate the members without additional information. The steel supplier must prepare shop drawings before steel can be fabricated. Reputed steel fabricators (suppliers) maintain engineering and drafting departments, which prepare shop drawings in sufficient detail to enable their shops to fabricate the members. These drawings show the actual cut-lengths of each member, precise location of drilled or punched holes, details of welded assemblies, and all other dimensions necessary to fabricate the steel. The sketch figure-1 shown below is an example of the fabrication details for a steel Beam with bolted connections. The W 16 X 40 Wide flange beam has a cut length of 18 feet 4-1/2 inch with three 3/8 inch thick siffner plates and 2 drilled holes at each end. Each member in a structrural steel project identified with unique designation, called Part number and detailed as illustrated in the figure. After all the members are detailed in the shop drawings, a Bill of Materials is prepared for the entire project. The bill of materials lists each piece of steel, its size, type , length and weight. The Bill of Material for the Beam in figure 2 is shown along with the Beam drawing.

Drawing showing the beam

1002 1001 18 ft 4.5 inch Bill of quantitites s.no 1) 2) Part no Description Dimension Specification Quantity 1001 stiffner 15.5X 4 IS: 2062 3 NOS 2002 Beam with W 16 X 40 1 NO. ends 18ft prepared 4.5inch for splicing with 1 inch hole at both ends

The shop drawings are usually prepared in A2 drawings sheet ( 24 inch x 36 inch), part drawings in A4 size (12 x 8.5 inch /295x210 mm) and small part in sheets of 6 inch x 4.2 inch . The number of shop drawings required depends upon the size and complexity of the Job. One job may require a few as one or two sheets of structural details, while another job may require 100 sheets. The costing is based on the drafting hours to produce. Since the total cost of drawings is charged to the steel that will be furnished for a job, the cost per unit weight of steel will vary with the total cost of the drawings and the quantity of steel. 7

If only one member is fabricated, the cost per member will be high, on the contrary if many members are fabricated, the cost per member will be much lower. After the shop drawings are prepared, they are provided to the contractor, who submits them to the designer for approval. The cost of preparing the shop drawings is approximately 5 to 10 % of the BASE PRICE OF STEEL. COST OF FABRICATING STRUCTURAL STEEL: Cost of fabricating structural steel varies with Operations performed Sizes of members Duplicability of similar members Fabrications operations a) Bolted connections: cutting , punching, milling , planning, marking each member b) Welded connection: cutting , some punching for temporary hole connection, milling , beveling , planning and shop welding. Note: It is economical, easier to perform & control welding in the shop rather than in field Cost per ton of light weight roof trusses is higher than that of large size beams fabricated from rolled sections. The cost per pound is significantly higher to fabricate angles and plates for space truss tower compared to beams and columns of Buildings or plate girders for bridges. 1000s of members are required in space trusses , each cut to a precise length and holes punched in each end of a member so that it can be bolted to other members in the completed structure. 8

Cost per ton or per hundred weight is based on weight of finished members including details ie cutting, punching , drilling , welding etc. The time reqd to set up fabricating eqpt is fairly constant regardless of the no. of operations performed. Hence when identical opn can be performed on many members , the cost per lb will substantially lowered compared to a shop operation on only a few members. Specification for struct steel frequently require the fabricator to apply a coat of paint after the fabrication is completed. Spray guns are used to apply paints using which 1 to 2 T/ hr can be painted.( a gallon of paint should cover about 400 sq ft of surface) . The cost of painting structural steel is about 8 to 12 % of BASE PRICE. Total cost of fabricating steel can range from 50 to 100% of the Base Price. COST OF TRANSPORTING STEEL TO THE JOB SITE Usually the steel supplier delivers the fabricated steel to the job. However if the contractor is providing the deliver y of the steel the estimator should determine the freight or truck cost per ton or per cwt for the particular project to include the correct amount in the estimate. The cost of transporting structural steel from the fabrication shop to the job will vary with the quantity of steel, method of transporting it, and the distamnce, from the shop to the job. A truck can haul about 20 tonnes per load. THE COST OF FABRICATED STRUCTURAL STEEL DELIVERED TO A PROJECT A complete list of material by size, shape and length must be 9

prepared to estimate the cost of fabricated steel. Example given below illustrates the breakdown of costs for fabricating and delivering steel to a project. Example : Structural steel, consisting of beams, columns, angles, and plates is used for framed buildings. All members are to be fabricated at a shop for high strength bolted connections. Wide flange beams will be used for beam and column members. A list of members and details are given in the accompanying table. The small size beams are used for short spans and larger size beams will be used for the longer spans. The larger column size will be used for lower floors whereas the smaller column size is used for upper floors. Angles are used as seats and clips for beam to column connections for joining together the structural members. Steel plates are used for column base plates and splicing of column members. Based on current economic conditions, the base price of steel quoted from the supplier is 24.96 $ per cwt for beams and columns, 28.43$ per cwt for plates and 22.17$ per cwt for angles and clips. The steel will be delivered by 20 ton trucks from the steel supplier a distance of 134 miles to the job at the rate of 2.75$ per mile. An illustrative breakdown of the base, fabrication, delivery cost of the steel is given in the example. For computation purposes the following percentage have been considered: a) Fabrication cost of - Main members of beams and columns: 85% of Base Price - For plates and angle section 98% of Base price

10 b) shop painting: 7.5% of Base price c) Shop drawing: 10% of Base Price. Number Description of pieces Length each Weight in lb/ Total linear ft. weight (Lbs)

EQUIPMENT RESOURCE
The following is the list of Major equipment used for construction of a ware house constructed of structural steel Value of the Project : 100 million Indian Rupees Sl.no 1 2 3 4 5 6 5 6 7 8 9 10 Equipment description Hydraulic excavator 90 CK Back hoe (JCB) or equivalent Dozer Air compressors Mobile crane - Hydra 20 Tons Pick and move crane Dumpers Concrete mixer 10/7 and 14/10 Vibrators Pumps Welding sets Gas cutting set Quantity 1 no 2 nos 1 no 2 nos 1 no 1 no. 12 nos 6 nos As required 4 nos 6 nos 2 nos

11 12 13 14 15

Surveying instrument Lab . equipment Tool set Fork lift truck 1, 2 Ton capacity Lifting tools and tackles D-shackle-0.5,1 ton capacity u-bolt Bull dog clip Steel wire rope slings Manila ropes Tie rods Chain pulley block 05.1`.2.5.10 T Turfer 1, 2, 5 ton capacity ERECTING STRUCTURAL STEEL:

1 set 1 set 6 sets. 2 nos (Diesel opn.) As required As required As required As required As required As required As required As required

Most general contractors subcontract the erection of structural steel for their projects . The sub contracts may be assigned to a company that specializes in steel erection or it may be sub contracted to the steel supplier. Many steel suppliers have the crew and equipment and are capable of erecting the steel that they fabricate and deliver to the Project. When a structural steel building is erected, the columns are erected first on the previously prepared concrete foundations, with anchor bolts already in place. The ends of the anchor bolts are usually threaded to allow installation of the column base plates, which have holes drilled to match the pattern of the anchor bolts. Nuts are installed in each threaded anchor bolt, one above and one below the common base plate, to adjust and plumb the column After the columns are erected, the beams are installed for the first tier of floors, usually two floors. The connections between the columns and beams are temporarily bolted thro holes, by using 2 or more bolts per connection. Horizontal bracing is necessary to stabilize the structural members during the erection process. After the tier of columns and beams is in place, it is necessary to plumb the structures before installing the permanent bolts. The operation is repeated for subsequent tiers until the erection of the structure is completed. EQUIPMENTS FOR ERECTING STRUCTURAL STEEL:

The equipments used for erecting structural steel depends on

a) b) c) d) the type of structure, the size of structure and the Height of structure. Its location in relation to the adjoining structures or buildings.

Roof trusses are usually delivered to the job partly or completely assembled and hoisted directly from the delivery trucks into place by TRUCK MOUNTED CRANES. Several types of truck mounted cranes are available. A hydraulic truck crane has a self contained boom, which enables the unit to travel on public high ways between projects under its own power without set up delay. A hydraulic truck crane ideal for short duration jobs, less than several days, For taller steel structures, a lattice boom truck crane is some times used. . The lattice boom is cable suspended, and there fore acts as a compression member and not a bending member like the telescoping hydraulic boom. . However mobilisaiton and de- mobilization of the lattice boom crane require time. Some times a second crane is required to assemble and disassemble the lattice boom . The scanned sketch shows two truck mounded crane erecting steel roof trusses. Multistoreyed steel frame buildings can be erected with truck- mounted cranes if the height is not excessive, usually about 4 stories. . If a building is so tall that a truck mounted crane cannot be used , the steel members may be placed with a Tower crane. These cranes provide high lifting height with a good working radius and require limited spaced. Several types are available. Some units have a fixed vertical tower with a rotating horizontal boom truss. The climbing frame type crane is supported by the floors of the building that it is being used to construct. Because cranes are used to hoist and move loads , from one location to another, it is necessary to know the lifting capacity and working range of a crane selected to perform a given service. The lifting capacity of cranes for erecting steel structures typically varies from 20 T to 100T. However lifting capacity upto 500 tons are available. Individual manufacturers of equipment furnish specifications and information that describes the lifting capabilities and tipping loads of their equipment. Steel erection contractors typically own the lifting equipment. However , for special jobs that may require an unusually heavy or high lift, the crane may be rented. The crane can be rented per day, week or Month . BOLTING STRUCTURAL STEEL: When bolting structural steel, one worker will be required at each end of the member to install atleast enough bolts to secure the member to the supporting structure. One or two other workers may be required on the ground level to assist in attachement of slings and rigging the next structural member to be erected. As structural members are erected, adequate lateral bracing is necessary to ensure adequate rigidity and stability of the entire steel framing system.

After members are erected and plumbed, two iron workers should be able to complete the permanent bolting, including application of the proper tightening torque. For safety, fall protection must be provided for ironworkers (fitter) when they are working at high elevation. When a tower crane is used to hoist the members and place them into position, it is common practice to install enough bolts in the connections to permit the structure to be plumbed and braced as it is erected. . If this procedure is followed, the rest of the permanent bolts will be installed later. Callibrated Torque wrenches, selected to produce the desired tension in the bolts, can be used in tightening the nuts on the Bolts. The crew size required for installing the bolts will vary with the number of bolts needed and the ease or difficulty in getting at the Bolts. WELDING STRUCTURAL STEEL: In general , welded connections provide more rigidity than bolted connections. For welded steel structures, Gasoline or kerosene operated welding machines are used. Otherwise the general procedure and erection equipment are essentially the same as for a bolted structure. Welders who are certified by laboratory tests, are used in producing high quality welding of steel structures. The cost of field welding can be substantially reduced if the structure is designed for a minimum over head welding. Various types of structural welds are used in structural erection If a structure is designed for welded connections, it is possible to reduce the total weight of steel by as much as 5 %, as compared to bolted connections. It is not necessary to punch bolt holes in members at points of critical stress for connection purposes. Where a few holes are required for temporarily bolting members in place, the holes can be punched at non critical points, thus permitting the use of the full strength of a member at joints rather than a reduced net section through the member. Since the welded joints can be made as strong as the full sections of the members, it is possible to design beams as continuous members over several supports, thus reducing the critical bending moment stresses. As a result of these conditions, ligher beams can be used in a structure, which will reduce the total weight of steel required. Also smaller and less expensive foundation costs should result from reduction in dead weight of the structures. After a member of the structure is plumbed or broght to the correct position, welding of the connections is started. To eliminate undesirable distortion of a structure, resulting from unequal heating at the connections, a definite pattern for welding should be established and rigidly followed. If beams are to be welded to opposite flanges of a column, the two welds should be performed simultaneously to eliminate unequl expansion of the two sides of the column would result from welding the beam separately. If welding girders to columns or Beams to columns and girders, the top flanges should be welded first and allowed to cool to the atmospheric temperature prior to welding the bottom flanges. As the weld for the bottom flanges cool, the bottom flanges at the ends of the beams will be subjected to tension. Since the stress is opposite the stress to which the beams will be subjected under loaded conditions, the effect of welding is to reduce the

ultimate bending stresses in the beams. The correct procedure of welding beam to column is depicted in the pictures.

MANPOWER RESOURCE
Construction laborers who erect structural steel are called Iron workers or Structural steel workers. The cost of labour erecting structural steel will vary with the type of structures, the type of equipment used, size of members, climatic conditions, and the prevailing wage rates of the workers. A common size of steel erection crew consists of four iron workers, a crane operator, and foreman. However, crews for erecting steel may vary from two to eight iron workers, depending upon the size of the structural members that must be handled and the height of the structure. For example a High rise multistoreyed building may use a crew consisting of 8 iron workers, several welders, crane operator, hoist operator and two foremen. The data in the table gives the approximate number of crew hours per 1000 linear feet of members for erecting steel for various sizes and shapes of structural steel members that have been fabricated and delivered to the job. Wide flange beams with deeper depths can span longer distances than shallower depth beams. However, the time to set a 25 feet long beam is about the same as the time to set a 22 feet long beam. Therefore the crew hours per foot are less for erecting large size beams compared to smaller size beams. If fabrication is required at the job site, the costs of fabricating and erecting the steel is substantially higher than when using shop fabricated steel. However, some times smaller members, such as angles, channels or junior beams, are field fabricated. Table given below gives the approximate crew hours for a field fabricating and erecting small size steel members. The crew for performing this type of work consists of only one Iron worker, one welder and one foreman. TABLE- 1: approx crew hours per 1000 linear feet for erecting various sizes and shapes of shop fabricated steel members.

Type of work
1-Erecting steel beam bolted connections: Crew 4 iron worker, 1 crane operator, 1 foreman, equipment: 1 crane. W section 8 in deep W section 10 in. deep W section 12 in. deep W section 14 in. deep W section 16 in. deep

Crew hours per 1000 linear feet.

15.6-17.3 hours 15.2-16.8 hours 12.6-13.8 hours 11.0-12.1 hours 10.5-11.6 hours

2-Erecting steel beam welded connections: Crew 5 iron woker, 1 crane operator, 1 foreman,1 welder Eqpt: 1 crane, 1 welding machine. W section 18 in deep W section 21 in. deep W section 24 in. deep W section 30 in. deep W section 36 in. deep 10.3-11.4 hours 9.3-10.2 hours 8.9-9.7 hours 8.6-9.4 hours 8.5-9.3 hours

3- Erecting steel columns Crew 4 iron workers, 1 crane operator, 1 foreman, Eqpt: 1 crane W section 8 in deep W section 10 in. deep W section 12 in. deep W section 14 in. deep 8.6-9.6 hours 8.9-9.9 hours 9.1-10 hours 9.3-10.3 hours

TABLE-2: approx crew hours per 1000 linear feet for field fabricating and erecting of small members. Type of work
Field fabricating small members Crew: 1 iron worker, 1 welder, 1 foreman Eqpt: 1 welding machine Angle to 1 inch Angle 2 to 3 inch Channel 2 inch to 5 inch deep Channel 6 to 8 inch deep Junior I Beam 3 to 5 inch deep Junior I Beam 6 to 8 inch deep

Crew hours per 1000 linear feet.

54 to 66 hours 104 to 127 hours 97 to 119 hours 170 to 208 hours 99 to121 hours 126 to 154 hours

FIELD PAINTING STRUCTURAL STEEL Although structural steel is usually shop painted by the fabricator, it is some times necessary to perform limited field painting. The cost of applying coats of paint in the field to structural steel will vary with the type of structures, size of member to be painted, and access to steel members. The cost of painting a ton of steel for a roof truss will be considerably higher than for a steel frame building because of the greater area of steel per ton for the truss and also because of the difficulty of moving along the truss with the painting equipment. Paint is applied with a spray gun, operated by an air comprssor. One gallon of paint should cover about 400 square feet. Two field coats are usually applied. Table gives the approximate rates of applying a field coat of paint, by using a spray gun, to structural steel for various types of members and structures. The costs are based on painting 400 square feet/ gallon. A painter should be able to field paint to 1-1/2 Ton/ Hr, depending upon the structure.

Rate of applying field coat of paint on steel structure using spraygun. Member / structure Beams Girders Columns Roof trusses Bridge structure. SQFT/ TON 200 - 250 125 - 200 200 - 250 275 - 350 200 - 250

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TUTORIALS: Estimate the cost for erecting the following 5-storey structural steel building shown in the accompanying drawing. A column schedule is given for the Building. All beams will be W 14 X 125 with 20 feet span length. a) Estimate the cost of erecting the beams and columns using average rates. Note: The type of connections used will be Bolted for Light Beams less than W 18 and Welded connection for Heavy Beams more than W 18. ( All connections between columns to columns, beam to beam, beam to columns will be bolted)) DATA PROVIDED: A ) Column schedule: Floor-1: Floor 2 : Floor 3: Floor 4: Floor 5: W 10 x 112 W 10 x 89 W 10 x 72 W 10 x 60 W 10 x 60

Unit Labour rates. Iron worker/ Fitter: USD 20.97/ Hr b) Crane operator: USD 21.67/Hr c) Foreman: USD 28.5 /Hr.
a)

Equipment used: A 40 ton Jib Crane is used for the erection Unit Hourly rate of the equipment is USD 125.5/Hr.

PLAN: 20ft

20ft 20ft

20 ft

20 ft

20 ft

20 ft

20ft

SIDE ELEVATION

60 FT

Total height 12 feet x 5floors = 60 feet.

Solution; Since the beam are of light schedule bolted connections will be used as connection type No of columns= 24 in each floor ( 1 to 5) 1) 24 nos of w 10 x 112 x 20 ft = 480 Lft ---- FF 2) 24 nos of w 10 x 89 x 20 ft = 480 Lft ---- SF 3) 24 nos of w 10 x 72 x 20 ft = 480 Lft ---- THF 4) 24 nos of w 10 x 60 x 20 ft = 480 Lft ---- FF 5) 24 nos of w 10 x 60 x 20 ft = 480 Lft ---- FIFFL Total = 2400 Lft. (x) Beams all are of uniform length of 20 feet. All beams are of schedule W 14 x 125 Each floor has 4 rows of W 14 x125 of 20 feet span x 5 spans Ie. 20 ft x 5 x 4 = 400 Lft. Each floor has 6 columns of w 14 x 125 of 20 ft span 3 spans Ie . 20 ftx 3 x 6 = 360 Lft. Total = 400 + 360 = 760 Lft. For 5 floor Beam length = 760 x 5 = 3800 Lft. .(Y)

Computation of weight of beams: W 14 x 125 has 125 lbs / ft. Total wt of beam = 125 x 3800 = 4,75,000Lbs. (a) Computation of weight of columns: a) 480 x 112 = 53760 Lbs b) 480 x 89 = 42720 Lbs c) 480 x 72 = 34560 Lbs d) 480 x 60 = 28800 Lbs e) 480 x 60 = 28800 Lbs Total = 188640 Lbs..(b) Total wt of Beams and columns: (a) + (b) = 663640 Lbs Total wt in tons of Beams and columns = 663640/2000=331.82T Assume Unit Market rate of steel as USD 1500/ Ton Base Price of steel= 331.82 x 1500 = USD 497730/( From the crew charts, the crew required for Bolted connection extracted from data base provided is CREW: 4 Iron worker/ fitter 1 crane operator 1 fore man 1 40 ton jib crane (equipment resource) (From the crew output chart for bolted connection for Beams of W 14 Beam, 14 in ch deep output is 12 crew hours/ 1000 lft W10 Beam, 10 inch deep , output is 16 crew hours/ 1000 lft

CREW HOURS FOR ERECTING STRUCTURAL STEEL. Beams = 3800 x 12 / 1000 = 45.6 crew hours Columns = 2400 x 16 /1000= 38.4 crew hours Total crew hours for the job = 84 crew hours. Cost of erecting beams and columns. Iron worker: 84 x @ 20.97 USD/ HR = 1761.48 USD Crane operator: 84 x 21.67 = 1820.28 USD Foreman: 84 x 28.5 = 2394 USD Eqpt Jib crane 84 x 125.5 = 10542 USD TOTAL COST IN USD = 16523.76

COST PER TON FOR THE STRUCTURAL FABRICATION AND ERECTION JOB: 16523.76 / 331.28 = USD 49.87/ Ton COST PER TON BASED ON BASIC STEEL PRICE AND FABRICATON+ ERECTION: ( (331.28 X 1500) + ( 16523.76) ) / 331.28 = 1549.88 usd/ton

QUESTION BANK: 1- What are the various methods of constructing steel structures. ? Explain them briefly? Under what conditions a pre-engineered steel structural erection is preferred over the Pre-fabricated structural erection. 2- What are the various methods of joining steel structural members? List the relative advantages and dis-advantages ? 3- What are the main resources required for steel structural erection ? 4- What are the items of cost in a steel structure estimate.?

CONSTRUCTION METHODS AND TECHNOLOGY MCM 115 ACM 23RD 1a) What are the various methods of constructing steel structures. ? Explain them briefly? Under what conditions a pre-engineered steel structural erection is preferred over the Pre-fabricated structural erection. b) Estimate the cost in Rupees per Ton of steel structural works whose break up is given below: Weight of standard structural shapes delivered to the steel supplier involved in fabrication , erection and commissioning a) For Beam and column section W18 ..20 Tons b) For trusses of assorted steel sections weighing5 tons c) Cost of preparing shop drawings7% of Base price of steel d) Cost of fabricating the steel shapes into finished members.........15% of Base price of steel. e) Cost of transporting the steel to the Job site. 1.5 % of Base price of steel. f) Cost of erecting the steel, including equipment labor, bolting and or welding6% of Base price of steel. g) Cost of field painting the steel structure12% of Base price of steel. h) Cost of Job overhead, General overhead, including taxes and profits. 10% ( Note: 1) Assume the average cost of steel per ton is Rs 30,000 2) Assume the wastage in fabrication to be 2% by weight.

2) a)Define Plant Location, Plant Layout and Facility Layout.? What are the factors to be considered for plant location? b)Asian construction company adopts the Rating plan method of locating plant production . locations. for their Aggregate They are seriously considering three

They have identified the five important

factors for Aggregate production plant which are listed in order of priority with respective rating points. ----------------------------------------------------------------------------------------------------------Factor Max.possible points Site-A 1 2 3 4 5 Nearness to Raw Material Nearness to Market Labour supply Transportation Water supply 400 300 275 200 125 150 150 150 125 100 200 225 150 125 Location Site-B 250 250 175 140 100 Site-C 300

Identify the suitable plant location considering the above inputs under the Rating plan method. Indicate the choice of location in order of priority.
3)

a) Define Material Handling ? What are the Objectives of good Material handling ? b) Suggest suitable Material handling device for the following: a) Transfering oil from 200 litre drum to 5 litre cans b) Dismantling engine of commercial vehicle in workshop with out any over head cranes.

c) Pouring concrete for casting roof slabs at 20 meters height. ( Tall Buildings) d) Shifting and placing building cladding material comprising of Aluminium and glass cladding sheets. e) Replacing street lights on lamp posts 4) Write short notes on any 2 in about 25 to 30 lines: a) Methods statement b) Method improvement techniques. c) Resources for structural steel constructions. d) Benefits of a good site layout