CMF - 2 Slide PDF Ciap May 2014

PURPOSE
This training/workshop is designed to provide a

basic understanding of key facility design
requirements and recommendations for
Customer Maintenance facilities located at
mine sites with large Off-
Off-Highway Trucks
Facility Planning For CMF

Page 1
Basic Knowledge
REASON
A sound understanding of the typical Customer

facility building modules and basic layout
concepts, will enable you to maximize
capabilities and capacities. The large OHT fleet
requires a unique facility size & site, and
building(s) layout and design. Years of proven
experience validate the course material.

Page 2
Basic Knowledge
COMPETENCY STANDARD
You will be competent in Customer mine site facility layout

if you can:
understand the different modules of a customer
facility and their adjacency requirements
understand the site requirements
use the questionnaires to identify the size/scope
apply knowledge and reference material to
customize specific needs, from concepts
understand the complexity of the entire facility
design to construct process, and the level
involvement/commitment required

Page 3
Basic Knowledge
LEARNING OUTCOMES
Upon completion of this training/workshop, participants

will be able to develop facility layout designs that are:
efficiently arranged for productivity
sized correctly to accommodate planned products,
services, and anticipated volumes
arranged to allow future expansion of key areas
without disrupting other areas
and,
know where to find the reference information, how
to use it, and how to engage with Caterpillar F.P.
provide valuable discussion and resources to their
architect to assist with improved project process

Page 4
Basic Knowledge
Facility Planning for CMFs Basic Knowledge
Overview of CMF Training

(Customer Maintenance Facilities)

Section CMF1-1
08/11 (1)
Basic Knowledge
Expected Course Results
Provide basic understanding of key facility design

requirements for customer facilities
Will learn basic principals for developing facility
layout designs, that are:
Efficiently arranged for productivity
Sized correctly to accommodate largest OHT model/
planned products / services / anticipated volumes
Arranged to allow future expansion of key areas, without
disrupting other areas

1-2
Basic Knowledge
Overview of Training
Why is CMF Planning Important

Planning Questionnaires
General Layout & Design Concepts
OHT & Equipment Repair Bays
Parts Warehouse
Main/Front Office
Utility Building
Equipment Wash Pad/Building
Sources for CMF Planning & Help
1-3
Basic Knowledge
Why is CMF Planning

Important ?

Section CMF-2-1
08/11 (1)
Basic Knowledge
Major Impact Factors For Customer Facilities
Are Major Capital Expenditures

Are Long-Term Investments (40 years or more), and
They have a major impact on:
Quality
Which
Productivity Equates More Profitability
To:
Efficiency

2-2
Basic Knowledge
As A Result Of These Major Impact Factors
The Facility Planning Process, must:

Be thorough
Be well thought out, and
Provide adequate time for investigation & planning
The number one goal should be to plan and
build a world-class facility for decades to come

2-3
Basic Knowledge
Customer Facilities Are Unique
The main building of a customer facility has 3 to 6

major building modules under one roof, that are
each totally different:
Parts warehouse
Front offices
Equipment shop
Shop offices / support complex
Component specialization shop
Small fleet vehicle service shop

2-4
Basic Knowledge
It is rare to have such diversity in construction,

layout, and function under a single roof
Many architects and builders do not have the
knowledge and experience with designing and
building such diverse facilities
(continue)

2-5
Basic Knowledge
(continued)
A world-class customer facility should meet various

Caterpillar initiatives that architects / builders are not
familiar with, such as:
Contamination Control
Service Tool Equipment Requirements
Infrastructure Requirements for Large OHTs and
Components
(continue)
Facility Planning For Dealers

2-6
Basic Knowledge

(continued)
Hiring a well-known, reputable architect does not

ensure an efficient, world-class facility
Customers need to be heavily involved in the
planning process
Facility Planning For Customers

2-7
Basic Knowledge
Facility Must Have Plans for Future Expansion
Facilities must be designed for future expansion of

each major building module, without disrupting:
The adjoining building modules
The existing interior layout of module being expanded
Daily business activities during construction
In addition, the site arrangement must provide
space for expansion without major alterations
Expansion must be planned to ensure growth
while maintaining facility efficiency

2-8
Basic Knowledge
The Time To Plan Is Prior To Construction
Once a facility is built:

Many features and much of the facility layout
can never be changed
It is difficult, if not impossible, to correct process-flow &
efficiency problems associated with poor
facility layout
There is no substitute for a thorough & detailed
facility plan

2-9
Basic Knowledge
Questions ?

2-10
Basic Knowledge
SUSTAINABILITY

Session 3
08-11 (1)
Basic Knowledge
Every Caterpillar customer worldwide can
participate and embrace Sustainable,
GreenBuilding, practices, operations, and
facility design, at some level.
From..
Improving the way a few things are done, or
Identifying & changing some key inefficiencies
To, seeking certification for their facility or
building through LEED, BREEAM, CASBEE, or
Green Star (Various local Global Assessment
Methodologies)

3-2
Basic Knowledge
BUILDING PRACTICES ARE CHANGING
Conventional building practices are not

sustainable
They use too much energy
Create too much waste
Sometimes undermine health & comfort of the
occupants (certainly not intentionally)
Building practices are changing
Today's sustainable innovations &
improvements will be the building
standards and benchmarks tomorrow
3-3
Basic Knowledge
DID YOU KNOW<<<
In the USA, Buildings Account for:
Potable Water Consumption 14%

Waste Output 30%
CO2 Emissions 38%
Raw Material Use 40%
Energy Use 24%-50%
Electricity Consumption 72%

3-4
Basic Knowledge
SUSTAINABLE PRACTICES POTENTIAL
Green Buildings Can Reduce:
Energy Consumption 24%-50%

CO2 Emissions 33%-39%
Water Use 40%
Solid Waste 70%

3-5
Basic Knowledge
SUSTAINABILITY METHODS BECOME THE NORM
Sustainable and GreenBuilding design and

construction are becoming the new
standard.
Architects, Contractors, and Suppliers are
shifting to GreenBuilding.
The Train has left the Station.

3-6
Basic Knowledge
GLOBAL ASSESSMENT METHODOLOGIES
LEED, Leadership in Energy and

Environmental Design (USA)
BREEAM, Building Research Establishment
Environmental Assessment Method ) (UK &
Europe)
CASBEE, Comprehensive Assessment System
for Building Environmental Efficiency (Japan)
GREEN STAR (Australia)

3-7
Basic Knowledge
SOME WAYS TO BE MORE SUSTAINABLE
So lets look at some key things that a

typical Caterpillar Customer can improve
or change to become more sustainable, or
possibly even seek LEED, BREEAM,
CASBEE, or GREEN STAR certification.

3-8
Basic Knowledge
ENERGY AND ATMOSPHERE
Reduce energy consumption

- Use efficient lighting, systems & appliances
- Use of controls, sensors, and monitoring
- Harvest natural light, reflective floors/walls
- Zone HVAC designs, Eco-corridor strategy
- Efficient design/construction walls, glazing,
insulation, doors
- Use of renewable, clean energy sources
Geothermal, solar, wind, hydroelectric

3-9
Basic Knowledge
WHERE IS THE ENERGY USED ?
A Typical Buildings Energy Use
Lighting 33%
Chiller 25%
Boiler 23%
Air Handling Units 7%
Other 12%

3-10
Basic Knowledge
SUSTAINABLE SITE DEVELOPMENT
Minimize use of undeveloped land

Enable, encourage, reward, smart
transportation choices
Minimize/reduce heat island effect
Minimize impact on ecosystems/waterways
Use regionally appropriate landscaping
Control storm water runoff, reduce erosion
Minimize light pollution
Reduce construction-related pollution

3-11
Basic Knowledge
WATER EFFICIENCY
- Encourage efficient/wiser use of water, both inside

& out
- More efficient fixtures, fittings, processes, &
appliances
Low-flow aerators, waterless urinals, low flush toilets
- Consider gray water treatment & re-use
- Harvest rain water
- Utilize water wise landscaping
- Re-cycle equipment wash water

3-12
Basic Knowledge
MATERIALS AND RESOURCES
Reduce any waste in general

Salvage, re-build, use Cat Reman
Re-cycle & re-use within the facility or outside
Use sustainably grown, harvested, produced &
transported, products and materials
Use materials and products that have been
manufactured with, or contain re-cycled content
Use local materials and suppliers to reduce
transportation & all associated costs/negatives
Share sustainable, greenbuilding objectives with
suppliers, and encourage participation

3-13
Basic Knowledge
MATERIALS AND RESOURCES
Materials and Resources include:

Caterpillar equipment and components
Furniture, Office Supplies
Office Partitions/Panels/Walls
Glass/Doors/Hardware/Millwork
Ceiling Systems
Carpet/ Hard Surface/Resilient Flooring
Building Structure Components
- Steel Framing, Concrete, Roofing, Paving, Walls

3-14
Basic Knowledge
INDOOR ENVIRONMENTAL QUALITY
Maximize access to natural daylight/outside views

Strategies to improve indoor air, exchange/control
- CO2 sensors in densely occupied spaces
Biophilic Elements (elements of nature)
- Images of nature, water feature, long-views to outdoors
Light variability, some personal control
Use of Low Volatile Organic Compound (VOC)
materials and construction processes
- Adhesives, paints/coatings, furnishings, wood composites,
agrifiber products, flooring, fabrics

3-15
Basic Knowledge
COSTS AND BENEFITS
Typically adds 0%-7% to construction cost

Should consider the holistic perspective, entire
life cycle costs and not just the initial capital or
construction costs
Greenbuild vs. not, might be compared to
building per minimum code requirements, vs.
upgrading some building features

3-16
Basic Knowledge
COSTS AND BENEFITS
On average, green buildings perform better &

the average energy per unit of floor space is
24% lower than typical buildings
- 13% lower maintenance costs

- 26% lower energy usage
- 27% higher levels of occupant satisfaction
- 33% lower CO2 emissions

3-17
Basic Knowledge
KEY ELEMENTS FOR SUCCESS
Commitment from Customer Leadership

Recognition that conventional design and
construction will be modified
Have a holistic view, consider the entire Life
Cycle
Must be integrative/collaborative team effort
of the owner, architect, and contractor from
concept to occupancy

3-18
Basic Knowledge
KEY TAKEAWAY<<<<<<.
There are many, many ways to be more

sustainable and make our world a better place
for future generations. Even the seemingly
insignificant smaller efforts add up.
EVERYBODY can do something, in some way,
to be more sustainable.
Caterpillar supports and commends all of our
Customer and Dealer sustainable efforts.

3-19
Basic Knowledge
DEALER EXAMPLE
Reference Cashman Equipment
CSS, Service Operations, has Developed a

Dealer Best Practice for Sustainable
Development Around Cashmans New Facility
in Henderson, Nevada
https://dealerbestpractices.cat.com/cda/layout?m=148161&x=7

3-20
Basic Knowledge
Questions ?

3-21
Basic Knowledge
GENERAL DESIGN
CONCEPTS

Section CMF-4-1
08/11 (1)
Basic Knowledge
COMMITTED TO CUSTOMER SUCCESS
Helping Our Mining Customers With Facilities:

Consultation, Information, and Recommendations
Assist With Planning and Development
Providing Layout Concepts and Examples
Ensure the Facility Matches Their Needs
Maximize Operational Efficiency
Offering Cat In-Depth Knowledge and Experience
Questionnaires to Gather Requirements

4-2
Basic Knowledge
What is a Customer Maintenance Facility? - CMF
Customer Maintenance Facility :

On or Adjacent to Mine Site
Ownership Typically is the Customer
Base for Mine Operations and Support
Direct Access to Mine
Key Requirement: Accommodate & Support the
Largest Off-Highway Trucks in Fleet Now, & Future
Employee Mix Varies
Usually majority of employees on site are customer employees
Dealer employees involved with warranty and MARC contracts
Venders may be contracted for specific operations/activities
(continue)

4-3
Basic Knowledge
CMF Site Layout Includes Several Buildings

Main Building Typically Includes:
Office
Parts warehouse
Equipment repair bays
Component specialization repair area
Small fleet vehicle repair area
Support services
Machine Wash Area
Building or pad
Single or two-stage
(continue)

4-4
Basic Knowledge
Utility Building Typically Includes

Weld and fabrication
Undercarriage and track shop
Grit/sand blasting
Painting
Tire repair
Machine Shop
Preventive Maintenance and Inspection Bays
Stand-alone building or within main building
(continue)

4-5
Basic Knowledge
The Facility & Site Layout are Customer and Mine

Specific
Largest OHT Model On-Site Determine:
Building, bay, & door dimensions
Dimensions between buildings and recommended aprons
- safe equipment maneuverability
Crane capacities
Wash bay or pad dimensions
Building expansion - space requirements
(continue)

4-6
Basic Knowledge
Operations Determine Need For:
Specialized component repair area
Machine shop
Fleet repair shop
Support services
Repair strategy & required infrastructure
Storage for other non-Cat parts
Fleet Size (current/future) Impact:
Number of repair bays
Number of PM bays
Specialized PM bays
Support services (for employee totals) (continue)

4-7
Basic Knowledge
Employee Support Requirements:

Parking
Wash, rest-rooms, and lockers
Cafeteria, kitchen, or lunch room
Training, briefing, & conference rooms
Report writing or library room
Office space
Field service assembly area and parking area
Equipment operator assembly area
Tool cribs

4-8
Basic Knowledge
A great deal of Contamination Control (CC) success is
directly related to operations, procedures, and good
employee habits. However, facility site-plans, building
layouts, and facility infrastructure also impact the ability
to improve and maintain good CC practices.
The CMF recommendations and layouts support
Caterpillars CCs initiatives by providing facility layouts
that will enable the customer to maximize good CC
practices and operations.
That said, infrastructure alone is no guarantee for a top
CC rating.
(continue)

4-9
Basic Knowledge
Some Facility Planning, CC related areas :
Equipment wash pad/building
Concrete aprons & drives
Doors
HVAC & building pressurization
General lube & utility information, filtering
Space requirements, organization, workflow
Floor drains, oil/water separators
Concrete Specifications
Long lasting proper soil analysis, quality contractor
Specifications, sealers, hard surface toppings

4-10
Basic Knowledge
Site Arrangement General Overview
Typically 3 or 4 Large Buildings
Maneuverability & Staging Require Safe, Site Spacing
Consider and maintain safe, operational traffic flow
Fleet & Operation Size is Key Factor
Future Expansion Must be Considered
PM Strategy & Location of Operation Vary
Within main building or in a separate building
Machine Wash Operations Vary
Utility Building Operations Vary
Fuel Island
(continue)

4-11
Basic Knowledge

This Example Shows a Separate Building for PMs, a
Large U.B., and a Significant Component Repair
Shop in the Main Building.

4-12
Basic Knowledge
Typical Traffic Flow pattern

4-13
Basic Knowledge

This Example Shows the PM Bay Within the Main
Building, and a Smaller U.B.

4-14
Basic Knowledge
Typical Traffic Flow pattern

4-15
Basic Knowledge
There Must Be Sufficient Space Between

Buildings to Permit Safe OHT Maneuverability
The Largest OHT Should Be Able to Easily Maneuver
Between Buildings or Service Operations
For Safety, it is Recommended OHT Maneuvering
Require No Backing Up, or Minimal Backing
The Only Exception Should Be to Back Out of the
Service Bays
Reference the Caterpillar Performance Handbook for
the Machine Clearance Turning Circle
Circle Dimensions Should be Used During Site and
Facility Layout Planning
4-16
Basic Knowledge
Machine Clearance Turning Circle for OHTs

4-17
Basic Knowledge
Questions ?

4-18
Basic Knowledge
MAIN BUILDING

Section CMF5-1
08/11 (1)
Basic Knowledge
Main Building
The Main Building Typically Consist of 3 Major

Operations, With Different Building Structures, That
Are All Connected
Office
Parts Warehouse
Truck/Equipment Service Repair Shop
Future Expansion Must Always be Considered

During Building and Site Layout
(continue)

5-2
Basic Knowledge
Main Building 3 Major Operations
All 3 Major Operations
Adjacent to Each Other
Providing Easy Access For
Support & Interaction
Provides Operational
Separation for:
Sound
Functionality
Contaminants
Security
Shop Main Center Aisle Aligns
With Parts Warehouse Aisle
Future Expansion Will Cause
Minimal Disruption to Daily
Operations (continue)

5-3
Basic Knowledge
Main Building Other Operations
Additional Operations/Options Sometimes Located

in the Main Building
Small vehicle fleet repair

Preventive maintenance & inspection bays
Component repair specialization shops
(continue)

5-4
Basic Knowledge
Fleet Repair Could be Located

Here but Must be Relocated if
Parts Warehouse Expands
PM & Inspection Bays

Locate Between Repair
Bays and Office/PW
Inspection Bay Can be
Used for Minor Repairs
When Needed
May Also Be Located in a
Separate Building
Repair Shop Expansion Will
Not Disrupt PM Operation
(continue)

5-5
Basic Knowledge
Component Specialization
Rebuild Area
Customer/Site Specific
Size/Operations Vary
Should be Located
Between Repair Bays and
Office/PW
Shop Support Functions
Locate Between Repair
Bays and Office/PW
Includes: Wash/Lockers,
Tool Crib, Compressor,
Janitorial, Shop Supv.,
Library, Off-Shift Tools, etc.
(continue)

5-6
Basic Knowledge
Questions ?

5-7
Training Course 101
Equipment Repair
Bays for CMFs

Section CMF 6-1
08/11 (1)
Basic Knowledge
Repair Bays for OHTs
(continued)
Used For OHTs as Well as All Other Mine Support

Equipment Brought to Shop
Must Design For Largest, Anticipated OHT
Truck Model Determines Bay Specifications
Bay Dimensions
Crane Capacity
Door Sizes
When Not Being Used For OHTs, Bays Will
Accommodate Multiple Equipment Repairs (continue)

6-2
Basic Knowledge
Equipment Service Shop

6-3
Basic Knowledge
Repair Bay Arrangements
There are two types of repair bay arrangements:

Opposed Bay Arrangement
In-Line Bay Arrangement

6-4
Basic Knowledge
Repair Bay Arrangements Opposed Bay
Arranged in pairs, with a 4.0m (13) center aisle

separating them
Uses least amount of
floor area space
Shortest aisle length from
PW & support functions
to end of shop

6-5
Basic Knowledge
Repair Bay Arrangements In
In--line Bay
Arranged in a single row on one

side of the main shop aisle
Has a greater floor space area
in the shop aisle
(continue)

6-6
Basic Knowledge
Repair Bay Arrangements In

In--line Bay
(continued)
Used primarily for

smaller facilities:
Where property size dictates a
compact facility
Usually 2 to 4 repair
bays, maximum

6-7
Basic Knowledge
Super Bays - General Overview
Design uses 18.0m x 18.0m (60 x 60) up to 21.0m x

20.0m (70 x 66) repair bays, called Super Bays
Most efficient use of floor space, with only 15% of
shop floor area not covered by crane hook

6-8
Basic Knowledge
Provides floor space flexibility

Each Repair bay can
accommodates one
OHT, or a several of
support machines
Number of machines
per bay, can vary
depending on product
mix for any given
day / week
End bays/doors provide
option and more room
for tire handling
6-9
Basic Knowledge
All layout & design features apply to both Opposed

Bay & In-Line Bay arrangements, except:
Width of main or center shop aisle
Total width of equipment shop
Crane column spacing

6-10
Basic Knowledge
Super Bays Main or Center Shop Aisle
Primary functions:
For delivery of parts to
repair bays
Personnel movement
For pickup & delivery of
major components
Provides exit access for
smaller machines or tire
handler
Smaller machines turn
onto aisle & exit shop
through end door

6-11
Basic Knowledge
Super Bays Main Shop Aisle & Shop Width
Aisle width for Opposed Bays is 4.0m (13)

Total shop width for
Opposed Bay Shop
Varies per truck
model
40m to 46m wide
(130 to 151 wide)

6-12
Basic Knowledge
Super Bays Main Shop Aisle & Shop Width
Aisle width for In-Line Bays is 5.0m (16.5)

Increased width to allow for
turning machines near the wall
along the aisle
Total shop depth for
In-Line Bay Shop
Varies per truck
model
23m to 26m deep
(75 to 85 deep)

6-13
Basic Knowledge
Super Bays Crane Orientation
Overhead cranes should run perpendicular to

shop aisle
Advantages:
Provides needed crane hook
coverage above shop aisle,
needed during engine R&I
Allows major components to be
lifted to/from center aisle for
delivery & pickup by lift truck
Provides crane hook coverage
immediately next to center aisle
for all repair bays
6-14
Basic Knowledge
Some architects & builders want to layout cranes

to run parallel with the shop aisle
Not Recommended

6-15
Basic Knowledge
Disadvantages (Opposed Bay) cranes parallel

with center aisle
Half the bays (one side), do not have crane access to the
center aisle, difficult engine R&I
Half the bays (other
side), have crane
dead space in
center aisle
Possibility of
trapping a crane
(larger shops)
(continue)

6-16
Basic Knowledge
Disadvantages (Opposed Bay) cranes parallel with

center aisle (continued)
Few locations for lube, air, electrical, & water outlets
For half the bays (one side), the center column line for locating
utilities is on opposite side
of shop aisle
Hoses & cords must
be stretched across
shop aisle
interrupting
aisle traffic
(continue)

6-17
Basic Knowledge
Disadvantages (Opposed Bay) cranes parallel with

center aisle
Few locations for lube, air, electrical, & water outlets (contd)
Both outside walls primarily contain doorways with little
space for utilities

6-18
Basic Knowledge
Disadvantages (In-Line Bay) -

cranes parallel with shop aisle
Few locations for lube, air,
electrical, & water outlets
Avoid locating utilities along shop
aisle wall, since hoses & cords
stretched across shop aisle will
interrupt aisle traffic
Outside wall primarily contains
doorways with little space
for utilities

6-19
Basic Knowledge
Super Bay Bay & Crane Specifications
Bay and Crane specifications will vary per largest

OHT model in fleet
Bay concept drawing
& specification chart is
on web site
Getting Started module
O
777 797 OHT models

6-20
Basic Knowledge
Bay concept drawing and spec chart provide:

Drawing with notes &
Machine footprints
Repair & PM Bay size
Door size
Crane capacities
Hook heights

6-21
Basic Knowledge
Building eave height:

Varies depending on type of crane & building construction
Typically, 2.4m (8) to 3.0m (10) above crane hook height
Could be more than 3.0m (10)

6-22
Basic Knowledge
Super Bay Crane Quantity
For Opposed Bays:

Recommend two cranes per crane span, to accommodate:
Crane burden (one crane
for each bay)
Ability to bring two cranes
together for splitting a machine
If only one crane is initially
installed for cost reduction,
design crane support
structure to support two
cranes in the future

6-23
Basic Knowledge
Super Bay Crane Column Spacing
For Opposed & In-Line Bays

Distance between column rows is 18.0m (60) center-to-
center for 777 793 OHT models
For 797 OHT model, increases to 20.0 m (66)
(continue)

6-24
Basic Knowledge

(continued)
Column spacing within column rows Opposed Bay:

The dimensions vary per OHT model
Drawing specific to OHT model available from Cat F.P.
(continue)

6-25
Basic Knowledge
(continued)
Column spacing within column rows Opposed Bay:

Center column span also varies per OHT model
Keeps columns away from center aisle to avoid interference with
tire handlers or smaller machines maneuvering on aisle
(continue)

6-26
Basic Knowledge
Column spacing within column rows In-Line Bay:

Three equally spaced column spans
Dimensions shown for 777
Dimension varies with
model & bay depth
777 is 7.6 x 3 = 23m
(25 4 x 3 = 76)
785 is 8.3 x 3 = 25m
(27 4 x 3 = 82)
789-797 is 8.6 x 3 = 26m
(28 4 x 3 = 85)

6-27
Basic Knowledge
Super Bay Service Bay Doors
Each bay has a service door sized for the largest

OHT model in the fleet
Review concept dwg.
and spec chart on web
site for specific OHT
model door dimensions
Either overhead
or rollup type
(continue)

6-28
Basic Knowledge
Shop End Door
Overhead or Rollup type

Permits exit for tire handler and smaller
machines to avoid being trapped
(continue)

6-29
Basic Knowledge
Shop End Door
(continued)
Opposed Bay:
6.0m (20 wide x 6.0m (20) high service door for 797 OHT
5.0m (16 6) wide x 6.0m (20) high service door for other
OHT models
(continue)

6-30
Basic Knowledge
Shop End Door

(continued)
In-Line Bay:
5.5m (18) wide by 6.0 (20) high service door

6-31
Basic Knowledge
Pedestrian Aisles
(continued)
Always locate outside the repair bay area to avoid:

Decreasing size of repair bay, thus reducing bay space
flexibility & utilization, and
Having hoses & cords stretched across aisle creating
safety hazards and difficulty in walking

6-32
Basic Knowledge
Bay Features - Optional Convenience Stations
Consists of toilet &

urinal in a room, with
wash basin & water
fountain outside
Locate near outside
wall, in column line
between repair bays
Highly recommend to
reduce technicians
time out of the area

6-33
Basic Knowledge
Bay Features - Utilities Outlet Locations
Typical location
pattern for utility
outlets (lube, air,
electrical, & water)
Utility outlets
along column
lines between
bays, are shared
by both adjacent
bays

6-34
Basic Knowledge
Bay Features - Optional Floor Drain Troughs
Located along the

bay service doors just
inside the bay
Heavy-duty grid cover
to support machine
weights
(continue)

6-35
Basic Knowledge
Bay Features - Optional Floor Drain Troughs
(continued)
Recommended for:
Cold weather climates
to avoid water freezing
under bay doors
Local environmental
regulations that
require containment of
spills within building
(avoiding
outside runoff)

6-36
Basic Knowledge
Bay Features - Floor Slope
Slope bay floor 0.5% from shop main aisle to either

floor drain troughs or outside service doors
Helps with cleaning & draining of spills
Main shop aisle is level (flat)

6-37
Basic Knowledge
Concrete Floor
Concrete specifications:
Steel reinforced
31,000 to 35,000 kPa (4,500 to 5,000 psi)
compressive strength
Designed to support heaviest machines and
anticipated floor loading practices
Minimum of 25.4cm (10) thick
Actual floor thickness based on a thorough soil
analysis & determined by qualified architect or
engineer

6-38
Basic Knowledge
Concrete Floor
To prevent wear from machine grousers, there are

three options:
Apply a 70,000 kPa (10,000 psi) compressive strength
hard surface topping on concrete floor
Use trap rock aggregate in concrete
Install inverted railroad tees flush with floor surface

6-39
Basic Knowledge
Combination Bay Arrangements
Super bays arranged in

both opposed & in-line
Can be used for building
arrangements to align the
various building modules,
such as facilities having:
Larger warehouses
Component rebuild shops

6-40
Basic Knowledge
Combination Bay Arrangements
Super bays in opposed

arrangement with a
partial size in-line bay
Can be used for building
arrangements to align
building modules
The partial in-line bay
could also be for
hydraulic cylinder repair
in smaller facilities

6-41
Basic Knowledge
Future Shop Expansion Opposed Bay
Overall facility site

layout must allow for
future equipment
shop expansion
Expansion should be
to the rear as shown
Avoid installing lube
oil tanks along rear
shop wall
End wall should
be removable

6-42
Basic Knowledge
Future Shop Expansion In

In--Line Bay
Overall facility site layout

must allow for future
equipment shop expansion
Expansion should be to the
rear as shown
Avoid installing lube oil tanks
along rear shop wall
End wall should be removable

6-43
Basic Knowledge
Tire Handling For OHTs Impact on Bay Space
Tire R&I requires significant space

Tires must be removed in shop repair bays to
permit subsequent component R&I and repair
Tire R&I requires significant maneuvering space
for the tire handler at the side of the OHT
Rear tires can be removed with the OH crane, but
is difficult and requires the body to be removed
Front tires always need tire handler for R&I due to
cab platform and fenders

6-44
Basic Knowledge
Tire Handling For OHTs Options
Remove body, for rear tire R&I only with OH crane

Leave adjacent bay(s) empty to enable
maneuvering space for tire handler (challenging)
Design repair bays wide enough to accommodate
a tire handler in between two adjacent repair bays
containing OHTs (costly)
Utilize end bays and doors on the end of the shop
to position OHT parallel to the center aisle
Only 2 end bays
Difficult to schedule or predict for tire R&I
6-45
Basic Knowledge
Options--Bigger Bays
Both depth & width

OH cranes run parallel to
center aisle
No columns between bays
Maneuverability room
between OHTs for tire
handlers
Deeper bays for engine
R&I under OH crane
Tire R&I in all bays

6-46
Basic Knowledge

Options--End Doors
Doors provide multiple

options
Position OHT parallel
to center aisle
No interference with
building columns
Crane direction and
aisle provide room for
engine R&I
Smaller fleets

6-47
Basic Knowledge
Tire Handling For OHTs Decision
Determine a strategy that fits your operations
Considerations
Safety
Tire handling equipment, methods, and
maneuvering space required
Cost of bigger bays and added space
Efficiency
Leaving bays empty
Fleet size
Dont overlook tire R&I requirements
6-48
Basic Knowledge
Establishing Required Number of Repair Bays

(continued)
Questionnaire asks for fleet size & availability target

projected 5 years in future
To avoid being undersized once facility is completed (in 2 to
3 years)
That data provides simplistic calculation formula
90% availability for 40 OHTs = 4 in shop, need 4 bays
Cat Global Mining can also provide an alternate, data
intensive method of estimating number of bays
required.
Always plan for expansion
(continue)

6-49
Basic Knowledge
Questions ?

6-50
Training Course 101
GENERAL DESIGN
CONCEPTS
(Parts Warehouse)

Section CMF 7-1
08/11 (1)
Basic Knowledge
Parts Warehouse

7-2
Basic Knowledge
Establishing Required Size
This section provides common warehouse layouts

& concepts recommended to Cat dealers
A parts warehouse at a customer mine site
supports and stores many non-Cat parts and
operations that are unique & unknown to Cat
Facility Planning
The exact size of the parts warehouse must be
determined by the customer after consideration of
the following Cat recommendations along with the
customers unique mine operation specifics
Basic requirements & operations are the same (continue)

7-3
Basic Knowledge
The Customer Equipment Maintenance Facility

Planning Questionnaire contains a Parts Warehouse
section that identifies the major
factors that should be considered
Cat parts
Non-Cat parts
Major/large components
Outside parts storage
Tires
Docks
Ceiling clearance (continue)

7-4
Basic Knowledge

(continued)
When estimating warehouse size, the standard

recommendation used for Caterpillar Dealers is:
0.11 sq m (1.2 sq ft) per number of Parts Line Items (five
years in future). This space calculation figure:
Includes floor space for aisles and shipping/receiving work area
Provides for 20% additional future storage space
This factor was developed for non-mining Cat

dealers
Mining operations, a larger (size) mix of parts, and
storage of non-Cat parts, may be different
(continue)

7-5
Basic Knowledge
(continued)
To also consider using as a reference:

The Parts Warehouse section within the Dealer Facility
Planning Questionnaire
Provides many common warehouse related operations,
area dimensions, and related activities that may be
overlooked such as:
Hydraulic Hose Assembly
Warehouse Office
Restrooms
Janitorial Room
Tool Room
Battery Storage (continue)

7-6
Basic Knowledge
Determining the Footprint
Two key items establish footprint of warehouse

1st Key Item The dimensions:
Length and width dimensions must be in multiples
of 6.0m (20)
Provides most efficient pallet-racking layout between interior
column rows
Maximizes floor space
Overall dimensions are center-to-center of outside columns, plus
0.6m (2) from center of column to outside edge of outside walls
(continue)

7-7
Basic Knowledge
(continued)
2nd Key Item The shape:

Most efficient shape is a square
To maintain length and width in
multiples of 6.0m (20) may,
however, dictate a
rectangular shape
For Example Projected size
of 1250 sq. m. (14,200 sq. ft.)
requires actual dimensions
of 36.6m x 36.6m (122 x 122)
or 1296 sq. m. (14,884 sq. ft.)
(continue)

7-8
Basic Knowledge
2nd Key Item The shape: (continued)

If a square is not feasible due to area size, go
to a rectangle
A rectangle should be as close to square as possible,
while maintaining dimensions in multiples of 6.0m (20)
For Example Projected size
of 1560 sq. m. (16,600 sq. ft.)
requires actual dimensions
of 36.6m x 42.6m (122 x 142),
or 1559 sq. m. (17,324 sq. ft.)
(continue)

7-9
Basic Knowledge

Avoid long, narrow rectangular warehouses
Creates inefficiencies in flow and operation
Harder to manage
Reduces parts storage floor space
(continue)

7-10
Basic Knowledge

Avoid irregular-shaped warehouses (jogs and notches)
Reduces amount of useable parts storage floor space

7-11
Basic Knowledge
Irregular-shaped warehouse illustrates reduction in

usable floor space (Not recommended)

7-12
Basic Knowledge
Warehouse Placement
Locate adjacent to:

Front Offices
Parts Offices
Lobby
Service Shop

7-13
Basic Knowledge
Main Parts Delivery Aisle
Runs parallel to adjacent front offices

Extends from front
to rear of warehouse
Provides access
directly into shop
center aisle

7-14
Basic Knowledge
Main Parts Delivery Aisle
Locate aisle 6.0m (20) to 6.5m (22) from office wall

7-15
Basic Knowledge
Area For Support Functions
Space between main parts

delivery aisle and front offices
used for support functions,
such as:
Parts Staging Storage
Warehouse Office
Hydraulic Hose Assembly Area
Restrooms
Janitorial Room

7-16
Basic Knowledge
Area For Support Functions
Locating support functions in

this area:
Allows remaining warehouse
to be used primarily for
parts storage
Avoids inefficient use of floor
space with irregular jogs
Maximizes useable floor space

7-17
Basic Knowledge
Hydraulic Hose Assembly Area
(continued)
Hydraulic area can be in

an enclosed room or an
open area
An enclosed room
minimizes contamination
and reduces odor from
hose cut-off saw
(continue)

7-18
Basic Knowledge
Restrooms and Janitorial Room (if desired)
Locate these rooms:

Between main parts
delivery aisle and
front office
Near rear of warehouse

7-19
Basic Knowledge
Parts Storage Area
Floor space for parts line items storage

Other storage
requirements for this
space include:
Major Components
Bulk Fluids
Other Mine Equipment
Parts

7-20
Basic Knowledge
Direction Of Warehouse Expansion
Overall facility layout must allow for future

warehouse expansion
Expansion should
be to the side

7-21
Basic Knowledge
Parts Dock Placement
Located at front of warehouse
(continue)

7-22
Basic Knowledge

(continued)
Location at front of warehouse provides a number of

key advantages:
1. Warehouse can
expand without
expensive
dock relocation
(continue)

7-23
Basic Knowledge
(continued)

key advantages:
2. Future expansion
will not disrupt
dock activities
(continue)

7-24
Basic Knowledge

(continued)

key advantages:
3. Future expansion
will not change
existing storage
parts bin and
shelving arrangement
(continue)

7-25
Basic Knowledge
(continued)

key advantages:
5. Conveniently located for truck traffic
Consolidated in one area
Away from other facility areas
Allows evening parts operations when rest of facility is
fenced and locked
(continue)

7-26
Basic Knowledge

(continued)

key advantages:
6. One dock area
reduces staff
7. One dock area
simplifies supervision

7-27
Basic Knowledge
Parts Dock Design and Layout
Dock arrangement varies, depending on number

and type of trucks

7-28
Basic Knowledge
Typically, docks are designed to handle two to three

different types of vehicles:
Pickup trucks
Straight-body
style trucks
Tractor-trailer
trucks

7-29
Basic Knowledge
Pickup truck approach stalls:

Typically, same grade level as dock floor because pickup
trucks vary in bed height

7-30
Basic Knowledge
Straight-body and tractor-trailer truck stalls:

Recessed to dock face (via down ramp)
Dock face is equipped with a dock leveler

7-31
Basic Knowledge
Tractor-trailer truck stalls can also serve straight-

body trucks in low volume situations

7-32
Basic Knowledge
Optional flush dock arrangement for

tractor-trailer trucks
Warehouse wall is dock face
Dock area is inside warehouse
Located adjacent
to outside
parts dock
Provides protection
from outside
weather elements
and contaminants

7-33
Basic Knowledge
Optional sideways tractor-trailer arrangement

Stall(s) rotated 90, running parallel to front of warehouse
(continue)

7-34
Basic Knowledge
Parts Dock Design Layout
Optional sideways tractor-trailer arrangement (contd)

Used primarily for smaller warehouses
Creates a more compact site arrangement
Reduces truck maneuvering area in front of warehouse
(continue)

7-35
Basic Knowledge
Parts Dock Design Layout

Used for warehouse operations that only require one or
two tractor-trailer stalls
A single tractor-trailer stall is illustrated here
(continue)

7-36
Basic Knowledge

A decorative screen wall is placed along the length of
tractor-trailer stall

7-37
Basic Knowledge
Optional lift truck access area

Allows occasional loading and unloading of trucks away
from the dock area
Can be used with any parts dock configuration

7-38
Basic Knowledge
Dock width should be 6.0m (20)

7-39
Basic Knowledge
Dock should extend past last truck stall at least 1.0m

to 3.5m (3 to 12) for maneuvering lift truck

7-40
Basic Knowledge
Dock should be canopy-covered

Canopy should extend approximately 1.5m (5)
beyond edge of dock

7-41
Basic Knowledge
Outside Parts Storage If Desired
Locate along side of warehouse, where future

expansion will occur
Fenced concrete
area
FUTURE EXPANSION

7-42
Basic Knowledge
Outside Parts Storage If Desired
For storage of parts, such as:

Ground-engaging tools
Track components

7-43
Basic Knowledge
Interior Column Spacing
Keep number of
columns in middle of
warehouse to a
minimum
Design for largest
practical center-to-
center spacing using a
multiple of 6.0m (20)
Typical interior column
spacing is 12.0m (40) in
in both directions
7-44
Basic Knowledge
Interior Column Spacing
Depending on overall warehouse dimensions,

there may be:
One interior column row
spaced at 6.0m (20) in one
or both directions
With all other column rows
spaced at 12.0m (40)

7-45
Basic Knowledge
Interior Ceiling Clearance
Provide approximately 8.0m (26) from floor to

underside of roof trusses
This height allows for:
6.0m (20) high pallet racks, and
Possible future mezzanine installation

7-46
Basic Knowledge
Use Of Mezzanines
Not recommended as part of a new warehouse

Operational inefficiencies with second-level storage
Should only be considered as a last resort, after:
Future ground floor expansion has occurred, and
No more ground level expansion space is available

7-47
Basic Knowledge
Questions ?

7-48
Training Course 101
GENERAL DESIGN
CONCEPTS
(Front Offices)

Section CMF 8-1 Basic Knowledge
08/11 (1)
This section provides common office layouts &

concepts recommended to Cat dealers
The office operations and requirements at a
customer mine site have some differences from a
Cat dealer & unknown to Cat Facility Planning
The exact size and layout of the office must be
determined by the customer to satisfy the needs of
the specific mining and operational requirements
Since basic office requirements & office operations
are similar, this information should provide a good
foundation for a CMF office (continue)

8-2
Basic Knowledge

(continued)

The Office section within the Dealer Facility Planning
Questionnaire
Provides many common office related operations, area
dimensions, and related activities that may be
overlooked such as:
IS/DP Areas, Communication Rooms
Meeting/Conference Rooms
Restrooms, Janitorial Rooms
Mechanical Rooms,
Library, Storage/Files
Kitchen, Lunch Area, Cafeteria (continue)

8-3
Basic Knowledge
Front Offices

8-4
Basic Knowledge
Establishing Required Footprint Size
Size based on dealer-entered information in Facility

Planning Questionnaire
The offices, rooms, and areas selected will be in two
or three different sections of the questionnaire
Admin-GO-Sales-Parts Offices section
Service Offices section (if located in front office module)
Offices Support section
(continue)

8-5
Basic Knowledge
(continued)
A summary sheet allows these sections to be

consolidated into one list for calculating Front Office
area size

8-6
Basic Knowledge
It is common for the front office module to be

irregularly shaped
The outside wall many times can have one or two jogs
Done to obtain front offices depth close to warehouse
depth, while avoiding a long, narrow module

8-7
Basic Knowledge
Parts Offices Area
The parts & warehouse

office operations should be
located adjacent to the parts
warehouse with direct access LOBBY AREA AND
OTHER MINE
into it. OFFICE OPERATIONS
(Illustration may contain certain

office operations or areas that
will not be required for a CMF)

8-8
Basic Knowledge
Main Lobby/Office Entrance
Recommend a vestibule to
help reduce temperature
variations due to extreme OFFICE
outside temperatures
(hot or cold)


8-9
Basic Knowledge
Main Office Aisle / Hall
Main aisle should be in-line with

main entrance and extend from
lobby straight back to the service
shop
Provides easy access for
employees, and vendors/visitors
to the service department ACTUAL OFFICE
LAYOUT WILL
VARY PER MINE
& CUSTOMER
OPERATIONS


8-10
Knowledge
Office Restrooms
Should be centrally located along

a main aisle
Convenient to the lobby area for
vendors, customers, & visitors
Convenient for employees
Do not make it difficult to find
Should have privacy entrance
design to prevent view of
restroom area from main aisle


8-11
Basic Knowledge
Office Janitorial Room
Highly recommended to have,

even if cleaning is performed
by an outside vendor
Used to store
cleaning equipment and
supplies
Has a floor level sink
Should be located near
restrooms to centralize
plumbing


8-12
Basic Knowledge
Service Offices For Smaller Facilities
For smaller facilities, service

offices may be located in the
front offices module
If so, they should be located at
the rear of the offices adjacent
to the service shop
Should be along the main aisle
from the lobby for easy vendor
& employee access


8-13
Basic Knowledge
Multiple--Level Offices
Multiple
May be desirable for:

Smaller property size
Future office expansion
Building ascetics
Roof valley construction associated with tying into
surrounding higher warehouse and shop roof eaves

8-14
Basic Knowledge
Multiple--Level Offices - Stairways

Multiple
Requires at least two

stairways for emergencies
One stairway should be
located at or near main
lobby entrance
For easy employee access,
and
For direct outside egress
for emergencies
will not be required for a CMF) (continue)

8-15
Basic Knowledge
Multiple--Level Offices - Stairways
Multiple
(continued)
The second stairway should be located at rear

outside corner of office, adjacent to service shop
Location provides shop
personnel easy access to
upper level for training,
lunch, locker rooms, etc.
Local codes typically require
this stairway to:
Be enclosed due to potential
shop hazards, and
Have direct outside egress
for emergencies

8-16
Basic Knowledge
Multiple Level Offices - Elevators
Local codes may

require an elevator for
handicap accessibility


8-17
Basic Knowledge
Multiple Level Offices Upper Floor Areas
Should contain those areas that have little or no

customer, vendor, or visitor contact:
Accounting
Information Technology (IT)
Credit records
Printing
Training
Conference rooms
Lunch / break rooms

8-18
Basic Knowledge
Multiple Level Offices Each Floor
Should contain restrooms and a janitorial storage

room for convenience

8-19
Basic Knowledge
Questions ?

8-20
Training Course 101
Facility Planning for CMF Basic Knowledge
GENERAL DESIGN
CONCEPTS
(Utility Building)

Section CMF 9-1
08/11 (1)
Basic Knowledge
Utility Building Operational Functions
Contains all major dirty, noisy, and more hazardous-

type service operations, which can include:
Undercarriage rebuild (track / rollers / idlers)
Welding & Fabrication
Machine Shop
Machine Painting
Machine Blasting
Machine Wash
(continue)

9-2
Basic Knowledge
Utility Building Operational Functions

(continued)
Advantages for locating these operations in a

separate building:
Controls contamination
Typically, results in lower insurance rate for main building
Work environment in main equipment shop is improved
due to absence of dirt, noise, smoke, fumes, & weld flash

9-3
Basic Knowledge
Utility Building Placement
Location of U.B. should always consider:

Sufficient room
for safe, OHT
maneuvering
Sufficient room
for future expansion
Location that will
minimize traffic
congestion
(continue)

9-4
Basic Knowledge
Utility Building Footprint
Exact size of the U.B. is building based on total

number of U.B. functions to be performed
Varies with each customer and mine operation
Some bay sizes may have to be increased to
accommodate the largest OHT and components

9-5
Basic Knowledge
(continued)

The Utility Building section within the Full Product Line,
Facility Planning Questionnaire
Provides many common U.B. related operations, area
dimensions, and related activities such as:
Paint Bays
Sand/Grit Blasting
Track and Undercarriage
Machine Shop
Tires, Filter Cleaning
Office, Storage, and Support Areas
Fleet Vehicle Repair (continue)

9-6
Basic Knowledge
Standard required width (depth) of

building is 18m (60) wide, unless:
There will be a track shop with track
press to handle D10 / D11 track
Any of the bays will be required to
accommodate a fully assembled
OHT
Any of the bays will be required to
accommodate a truck body/bed

9-7
Basic Knowledge
Track bay depth for D10 / D11 size

tracks, should be minimum of
24m (80)
Three options available for building
width to accommodate D10 / D11
track repair:
Option A Increase entire building
width (depth) to minimum of 24m (80)
Some dealers elect to have building
30m (100) wide, when there will be
a complete undercarriage shop
(continue)

9-8
Basic Knowledge

(continued)
Option B Increase only track

bay depth to 24m (80) and leave
rest of building at 18m (60) wide
(deep)
(continue)

9-9
Basic Knowledge
(continued)
Option C Increase depth

of track bay and one or
more adjoining areas to
24m (80), leaving rest of
building at 18m (60) wide

9-10
Basic Knowledge
The length of the entire building

is simply a total of the individual
bay widths of the various
selected building functions

9-11
Basic Knowledge
Building Interior Layout
No recommended order for building functions. Place

function most likely to expand at expansion end
Various building support functions should be grouped
together in a single support complex
Building office
Rest rooms / locker rooms
Paint Supplies storage room
Welding supplies storage room
Mechanical equipment room
Electrical & communications rooms

9-12
Basic Knowledge
Building Interior Layout
Building support complex should be located as

central as possible for employee convenience
Many times located between paint & fabrication due to
welding supplies & paint supplies rooms

9-13
Basic Knowledge
Undercarriage Track Repair Bay
To control contamination of internal track

components, track bay must be in a walled-off room
Can have optional 5-ton overhead crane for lifting
complete chain assemblies off conveyor

9-14
Basic Knowledge
Undercarriage Roller & Idler Rebuild
Roller & idler disassembly & assembly must be

performed in a clean room to control contamination
Outside service door 3.6m x 3.6m (12 x 12)
Welding idler shells must be performed in a
separate area / room from D&A clean room to
control contamination
ENCLOSED
DOOR

9-15
Basic Knowledge
Undercarriage Roller / Idler & Track Rebuild
This illustrates a total undercarriage

shop arrangement
Parts washing area in roller / idler room, also for track parts
using baskets on carts

9-16
Basic Knowledge
Weld & Fabrication Bay(s) Overhead Crane
Typically, bay depth is 18m (60)

Bay size & door(s) will vary
depending upon OHT size,
and whether the truck or
body will be serviced inside
BAY & DOOR
For 18m (60) wide ARE SIZED

FOR
SPECIFIC
bays, that are also USE
18m (60) deep,

overhead crane can:
Either, run perpendicular
to the outside bay doors (continue)

9-17
Basic Knowledge
(continued)
- Or, run parallel to the

outside bay doors
also,
For Non-OHT bays, bay
doors may be smaller

9-18
Basic Knowledge
For bays that are 24m (80) or more in depth the

crane should run perpendicular to the outside
bay doors
For crane spans
of more than
23m (75), the
cost of crane goes
up dramatically

9-19
Basic Knowledge
Weld & Fabrication Bay(s) Bay & Crane Specs
Bay and Crane specifications may vary per largest

OHT model in fleet
Truck body/bed repair
strategy within bays will
impact crane specs
Bay concept drawing
& specification chart is
on web site
Getting Started module O
777 797 OHT models
9-20
Basic Knowledge
Bay concept drawing and spec chart provide:

Drawing with notes &
Machine footprints
Repair & PM Bay size
Door size
Crane capacities
Hook heights

9-21
Basic Knowledge
Building eave height:

Varies depending on type of crane & building construction
Typically, 2.4m (8) to 3.0m (10) above crane hook height
Could be more than 3.0m (10)

9-22
Basic Knowledge
Weld & Fabrication Bay(s) Crane Quantity
Recommend two cranes to accommodate:

Crane burden, productivity
Ability to bring two cranes
together for heavy lifts
Ability to use two cranes
for body/bed rotation
If only one crane is initially
installed for cost reduction,
design crane support
structure to support two
cranes in the future

9-23
Basic Knowledge
Weld & Fabrication Bay(s) Service Doors
All bay service doors are:

Will depend upon largest OHT model (see chart)
Either overhead
or rollup type
Varies with climate

9-24
Basic Knowledge
Paint Bay
Typically, contains a pre-fabricated commercial

paint booth
To meet local environmental & safety codes
Size will be determined by fleet and painting strategies
Many local codes
require an emergency
exit aisle on both sides
of the paint insert

9-25
Basic Knowledge
Paint Bay Service Door
Bay service door should be:

Will depend upon largest OHT model (see chart)
Rollup, with opener
explosion proof

9-26
Basic Knowledge
Concrete Floor
Concrete floor in bays having machine traffic should

have same concrete specifications as the equipment
shop floor
Fabrication bay floor should be level, not sloped, due
to fabrication work

9-27
Basic Knowledge
Questions ?

9-28
Training Course 101
GENERAL DESIGN
CONCEPTS
(Equipment Wash & Loading / Unloading Area)

Section CMF 10-1
08/11 (1)
Basic Knowledge
Wash Pad Site Location
Location should consider safety, maneuverability, traffic flow,
and operation strategy

10-2
Basic Knowledge
Purpose Of Equipment Wash Facility
For facility & equipment contamination control:

All machines coming in for service must be externally high
pressure washed, prior to entering equipment shop or
Preventive Maintenance bays
All track assemblies, rollers, & idlers must be externally
high pressure washed, prior to entering undercarriage
rebuild shop
For final washing prior to painting

10-3
Basic Knowledge
Single or Two Stage Wash Bays
Some customers prefer a two-stage equipment wash

operation to minimize the most complex water re-
cycling volumes and associated costs:
The 1st stage uses high volume water cannons to blast
mud and debris from the equipment. Simple, low-tech
mud-settling basins separate out dirt, mud, & debris
The 2nd stage uses hot, high pressure focused cleaning
which removes mainly oils and greases. This requires
much less volumes of water, but more sophisticated re-
cycling methods and equipment
Separating the two stages simplifies re-cycling and
reduces the water re-cycling costs
10-4
Basic Knowledge
Two Stage Wash Facility

10-5
Basic Knowledge
Major Components Of Equipment Wash Facility
Wash Pad 1st Stage Mud Settling

Where equipment and
undercarriage components
are washed
Has a 3% slope for water
& mud runoff into a
collection basin
Sized to accommodate
largest OHT in fleet
Standard concept drawings
are available for all OHTs

10-6
Basic Knowledge
Wash Pad 1st Stage Mud Settling

Must handle largest machine, with adequate working
space to avoid being drenched
by mud & water splash back
OHTs require blasting
from water cannons mounted
on elevated platforms
For stores with track repair,
need adequate space to
roll-out track for cleaning,
without interfering with
machine cleaning

10-7
Basic Knowledge
Elevated Platforms
OHTs require blasting
from water cannons mounted
on elevated platforms
Also require ground level, manual
operated hose water blasting

10-8
Basic Knowledge
Mud Settling Basin

Water & mud from wash pad flow
into the mud basin
Mud settles to the bottom of the
basin, while water at the top
drains off into buckets/compartments
Basin has a tapered ramp to allow
easy periodic mud removal with
a loader
Inside width of basin can range from
3.6m to 4.8m (10 to 16), depending
on volume
10-9
Basic Knowledge
Mud Settling Basin

Basin has a tapered
ramp to allow easy
periodic mud removal
with a loader
Inside width of basin
can range from 3.6m
to 4.8m (10 to 16),
depending on volume

10-10
Basic Knowledge
Silt bucket compartment

Water from surface of mud basin
flows into the bucket compartment
Compartment contains 3 large
fabricated buckets for filtering silt
from the water
Water cascades/flows through
each bucket into the next, with the
silt settling to the bottom of each
bucket
Particulates settle out through
out this simple process (continue)

10-11
Basic Knowledge
Silt bucket compartment

Buckets periodically removed with
a loader for silt removal
Compartment has a removable
cover for safety

10-12
Basic Knowledge
Oil skimmer compartment & pad

From silt bucket compartment, water
flows into oil skimmer compartment
An oil skimmer mounted on an
adjacent pad, skims oil from top of
water and deposits waste oil into a
container for disposal
Water is then stored in pond or tank
to be recycled and used again
Skimmer compartment should have
a removable cover for safety

10-13
Basic Knowledge
Mechanical equipment Mechanical

Equipment
room Room
Used to house water

pump equipment
Used to store supplies
and equipment related
to washing operations
For larger operations
this room could be
expanded to contain a
small office

10-14
Basic Knowledge
Mud drying room/area Mechanical

Equipment
Allows mud removed from Room
settling basin to dry before

hauling it away
Area should be covered in
wet climates
Mud Drying
Room

10-15
Basic Knowledge
2nd Stage Wash High Tech Water Re
Re--
Cycling
Wash Pad 2nd Stage Re-Cycling
The 2nd stage uses hot, high
pressure which removes mainly oils
and greases. This requires much Specialized filtering
and re-
re-cycling equipment
less volumes of water, but more

Mud Settling
sophisticated re-cycling methods
and equipment
Required in some locations
More efficient and cost effective
when performed after the initial
wash due treating much less water Hot, High Pressure
Low Volume
Wash

10-16
Basic Knowledge
2nd Stage Wash Re-

Re-Cycling Equipment
Water is processed, filtered,

and treated chemically
This process is used to remove
particles and contaminants that
are not removed through the
mud-settling and oil skimming
process
This may be an optional step
and operation for some sites

10-17
Basic Knowledge
Standard Drawings Available for Mud-
Mud-Settling
Detailed construction drawings available on Facility

Planning Sections web site for download
Drawings illustrate
details for mud
basin, bucket
compartment,
oil skimmer
Configuration of
basin &
compartments is
slightly different in
the drawings, but
details are still applicable
10-18
Basic Knowledge
Types Of Equipment Wash Installations
Open outdoor wash facility

Canopy-covered wash facility
to prevent having to process the rain water through the
mud-settling basin and re-cycling equipment
Totally-enclosed in a building
Local weather climate may dictate having an enclosed
building

10-19
Basic Knowledge
Stand--Alone Equipment Wash Building
Stand
Enclosed with both 1st & 2nd stage wash bays

Buckets
Re-
Re-Cycling Equipment
Ramp Settling Basin Storage Tanks
Mechanical Settling Ramp

Equipment Basin
Drive Through
Supplies or
Office

10-20
Basic Knowledge
Equipment Wash Placement Considerations
Be positioned to allow drive-thru on the wash pad

Very important to provide drive-thru capability for washing
dead machines being towed
Safer and easier maneuverability for the OHTs

10-21
Basic Knowledge
If facility has track repair, consideration should be

given to providing a separate wash facility for track
and undercarriage
A single wash pad could be overburdened and
inconvenient to the track shop location
Must be located in-line with track bay in utility
building
For easy maneuvering of track assemblies from wash pad
onto the track press
Do not locate wash pad against side of utility building
at undercarriage shop, due to contamination control
10-22
Basic Knowledge
Example Separate wash building for smaller

machines, track, and undercarriage. Must be
located in-line with track bay in utility building
For easy maneuvering Door
For
of track assembly Track

10-23
Basic Knowledge
Equipment Wash Placement
Wash facilities that are not in utility building

Are located on far side of
the utility building (side
opposite main building)
Open and
canopy-covered wash
facilities should be Track
Shop
positioned 18m (60)
from the utility building

10-24
Basic Knowledge
Wash facilities that are not in utility building

Stand-alone wash building
should be positioned
24m (80) from the
utility building
Track
Shop

10-25
Basic Knowledge
Wash facilities that are within the utility building,

should be located:
At the non-expansion
end of the utility building
Typically a wash pad in
UB is not for OHTs due
to maneuverability

10-26
Basic Knowledge
Path Between Wash Facility & Service Shop
A concrete, claycrete, crushed stone/gravel, apron

or drive must connect wash area to service shop
apron area
To provide a clean path
for washed machines to
the service shop
Prevents getting
clean machines
dirty
Controls
contamination

10-27
Basic Knowledge
Equipment Loading / Unloading Area
Consists of machine dock, either:

Single level dock, or
Two-level dock
Open area for folding & Two-Level Dock
detachable gooseneck
low-boy trailer
Typically, most machine
delivery & pickup is with
gooseneck low-boy trailers
Both of these should be
located beside each other Detachable Gooseneck

10-28
Basic Knowledge
Equipment Loading / Unloading Area Placement
Should be in-line with equipment wash pad, and

Be 18m to 24m (60 to 80) from wash pad
Want minimal distance
to wash pad for controlling
contamination
Distance between
wash & loading area
prevents interference
with machines being
picked-up

10-29
Basic Knowledge
Equipment Loading / Unloading Area Placement
If machine delivery & pickup truck entrance is located

at rear of property:
Loading / unloading is
then located on backside
of wash pad

10-30
Basic Knowledge
Loading / Unloading Truck Maneuvering Space
Ample space must be

provided in the loading /
unloading area for
maneuvering trucks
For the machine dock,
space must be provided for
trucks to turn around and
back up to dock face
For gooseneck low-boy
trailer area, space must be
provided for trucks to turn
around when leaving

10-31
Basic Knowledge
Loading / Unloading Truck Maneuvering Space
How trucks are going to

maneuver on the property
must be planned and
designed for
For ease in backing a
truck into a 90 turn, the
turning needs to be on the
drivers side

10-32
Basic Knowledge
Questions ?

10-33
Training Course 101
Facility Planning for Customers Basic Knowledge
PREVENTIVE
MAINTENANCE BAYS

Section CMF 11-1
08/11 (1)
Basic Knowledge
PREVENTIVE MAINTENANCE & INSPECTION BAYS
Used to Perform the Equipments Scheduled

Maintenance Operations
May Be Located in the Main Building (Typically for
Smaller Fleets, Lower Volumes)
OrP.Could Be Separate Stand-Alone PM Buildings
for Larger Fleets and Higher Volumes
Specialized Bays
Typically Smaller Bays (see OHT bay sizes chart)
No Overhead Crane
Complete, Convenient Lube/Fluid Drain & Fill Capabilities
(continue)

11-2
Basic Knowledge
PM BAYS IN MAIN BUILDING
PM & Inspection Bays Should Be
Located on the Non-Expandable End MAIN BUILDING
of the Shop
Separation From Repair Bays With EQUIPMENT
REPAIR BAYS
Partial Walls Helps Promote Better

Contamination Control Practices LUBE ISLAND
Drive Through Capability is PM

BAY
Recommended INSPECTION BAY
Narrower Bays, No Overhead Crane OFFICE

PARTS
WAREHOUSE
Equipped For Efficient Through-Put

Overflow Bays For Minor Repair Work

11-3
Basic Knowledge
Separate PM Building
Larger Fleets
Less Congested Site

Traffic Flow
Task Specific Building
Improved Efficiency &

Productivity
One-Way, Drive
Through

11-4
Basic Knowledge
793 Pit Stop Servicing Trakindo, Batu Hijau
CONCEPT - DEDICATED PLATFORMS TO PERFORM PM SERVICING .

11-5
Basic Knowledge
Top View
Objective Reduce Service Time

11-6
Basic Knowledge
Pit Stop Platforms
Right & Left Hand Platforms are Movable for Positioning

11-7
Basic Knowledge
Service Platform

11-8
Basic Knowledge
Service Platform

11-9
Basic Knowledge
Center Platform

11-10
Basic Knowledge
Truck in Position

11-11
Basic Knowledge
Right Platform

11-12
Basic Knowledge
Best Practice from Cat Global Mining Web Site
https://mining.cat.com/cda/files/520708/7/BP_PM+Bay.pdf

11-13
Basic Knowledge
Facility Planning for Customers Basic Knowledge
SOURCES FOR FACILITY

PLANNING HELP

Section CMF 12-1
08/11 (1)
Basic Knowledge
Sources For Help Self
Self--Help Sources
Cat Facility Planning Web Site (via Cat Dealer)
Customer Facility Planning Questionnaire

Available from Facility Planning Web Site
Customer Basic Knowledge Training Slides

Available from Facility Planning Web Site

12-2
Basic Knowledge
Sources For Help Cat Consultation Assistance
Facility Planning Consultation available free of

charge. Consists of:
Guide customers to all available facility planning resources
and information
Provide example drawings & photos
Review of completed questionnaire for completeness
Recommendation on how to proceed after questionnaire
On-site & phone consulting with customers and their
architect concerning facility layout

12-3
Basic Knowledge
Sources For Help Cat Consultation Assistance
To obtain Cat Facility Planning Consultation

Assistance:
1st Discuss project plans and support needs with local
Caterpillar Global Mining (CGM) representative. Request
should come through CGM to ensure awareness.
2nd - Once discussed, contact Cat Facility Planning
Consultant for Support
Email: rabe_mike_w@cat.com
Email: riggs_dan_a@cat.com
Phone: Mike @ 309-675-8067 or Dan @ 309-636-5105

12-4
Basic Knowledge

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PURPOSE

This training/workshop is designed to provide a

Facility Planning For CMF

A sound understanding of the typical Customer

Facility Planning For CMF

You will be competent in Customer mine site facility layout

Facility Planning For CMF

Upon completion of this training/workshop, participants

Facility Planning For CMF

Overview of CMF Training

Facility Planning For CMF

Expected Course Results

Provide basic understanding of key facility design

Facility Planning For CMF

Why is CMF Planning Important

Facility Planning for CMFs Basic Knowledge

Why is CMF Planning

Facility Planning For CMF

Are Major Capital Expenditures

Facility Planning For CMF

As A Result Of These Major Impact Factors

The Facility Planning Process, must:

Facility Planning For CMF

The main building of a customer facility has 3 to 6

Facility Planning For CMF

Customer Facilities Are Unique

It is rare to have such diversity in construction,

Facility Planning For CMF

A world-class customer facility should meet various

Facility Planning For Dealers

Customer Facilities Are Unique

Hiring a well-known, reputable architect does not

Facility Planning For Customers

Facilities must be designed for future expansion of

Facility Planning For Customers

The Time To Plan Is Prior To Construction

Once a facility is built:

Facility Planning For Customers

Facility Planning For Customers

Facility Planning for CMFs Basic Knowledge

Facility Planning For CMF

Facility Planning For CMF

BUILDING PRACTICES ARE CHANGING

Conventional building practices are not

In the USA, Buildings Account for:

Potable Water Consumption 14%

Facility Planning For CMF

SUSTAINABLE PRACTICES POTENTIAL

Green Buildings Can Reduce:

Energy Consumption 24%-50%

Facility Planning For CMF

Sustainable and GreenBuilding design and

Facility Planning For CMF

GLOBAL ASSESSMENT METHODOLOGIES

LEED, Leadership in Energy and

Facility Planning For CMF

So lets look at some key things that a

Facility Planning For CMF

ENERGY AND ATMOSPHERE

Reduce energy consumption

Facility Planning For CMF

A Typical Buildings Energy Use

Facility Planning For CMF