POCKET BOOK FOR ROAD CONSTRUCTION EQUIPMENT Published by: INDIAN ROADS CONgRESS 2018 Price : ` 1200/- (Plus Packing & Postage) Pocket Book for Road Construction Equipment First Published : November, 2018 (All Rights Reserved. No part of this publication shall be reproduced, translated or transmitted in any form or by any means without the permission of the Indian Roads Congress) Printed by India Offset Press, Delhi-110 064 500 Copies FOREwORD It gives me great pleasure to present the first edition of the Pocket Book for Road Construction Equipment. The highway sector in India is poised for rapid growth and mechanisation plays an important role in achieving economy, speed and quality in highway construction and maintenance. Currently, there exists no single document covering all major equipment involved in road construction. Therefore, an initiative has been taken to come out with a compilation of construction equipment for road, bridge and tunnel works. The Pocket Book for Road Construction Equipment is meant to act as a single-stop platform for acquainting the practising Highway Engineers and stakeholders with the mechanisation aspect involved in each activity of road making. References to Ministry’s Specifications for Road & Bridge Works have been drawn for each construction activity. Critical equipment for road and bridge works as well as tunnel works has been discussed. A summary of various quality control tests along with requisite apparatus and reference IS Codes has also been included for easy reference. This book has been compiled based upon extensive study of the IRC Publications and IS Codes and review of literature and current practices. The Pocket Book for Road Construction Equipment is the result of the untiring efforts of the officers of the Roads Wing and other professionals who contributed to the drafting of this document. I wish to express my appreciation for the efforts put in by Shri K.C. Sharma, Shri Ananyabrata Maulik, Shri N.K. Nayak and Dr. Sanjay Wakchaure in preparing this document and GSS Committee for reviewing the document. Pocket Book for Road Construction Equipment I hope this Pocket Book, in its present form, will prove to be very useful for day to day reference for all the engineers in highway profession. However, the compilation of this kind of Pocket Book will need to be updated periodically with changes in technology and environment. The Indian Roads Congress would, therefore, welcome suggestions and feedback from users so that any further amplification/ modification/ updating may be attempted in due course. New Delhi (S.K. Nirmal) 9th November, 2018 Secretary General, IRC Pocket Book for Road Construction Equipment CONTENTS Sl. Description Page No. No. Personnel of the General Specifications and Standards Committee (i) 1. Introduction 1 2. Scope 1 PART A : EQUIPMENT FOR ROAD wORKS 3. Activity Wise Equipment for Road Works 5 4. Description of Essential Equipment For Road Works 30 4.1 Dozer 30 4.2 Hydraulic Excavator 33 4.3 Motor Grader 37 4.4 Scraper 39 4.5 Front End Loader 41 4.6 Backhoe Loader 45 4.7 Crusher 45 4.8 Tipper Truck 57 4.9 Wheel Barrow 60 4.10 Wet Mix Plant 61 4.11 Soil Stabilisation Equipment 63 4.12 Tractor-Rotavator and Disc Harrow 66 4.13 Road Sweeper 68 4.14 Bitumen Distributor 70 4.15 Hot Mix Plant 77 4.16 Paver Finisher 81 4.17 Roller 84 4.18 Aggregate Chip Spreader 88 4.19 Concrete Batching and Mixing Plant 91 4.20 Transit Mixer 95 4.21 Concrete Placer/Spreader 97 4.22 Concrete Paver 98 4.23 Concrete Vibrator 104 4.24 Floater/ Trowel 112 Pocket Book for Road Construction Equipment Sl. Description Page No. No. 4.25 Scabbler 114 4.26 Texturing Equipment 115 4.27 Curing Compound Sprayer 117 4.28 Diamond Cutter/ Saw 118 4.29 Joint Sealing Machine 119 4.30 Kerb Casting Machine 121 4.31 Road Marking Machine 122 4.32 Hot In Place Recycling (HIPR) Equipment 124 4.33 Cold In Place Recycling (CIR) Equipment 125 4.34 Cold Milling Machine 129 4.35 Pneumatic Breaker 133 4.36 Hydraulic Breaker 135 4.37 Mobile Slurry Seal Equipment 137 4.38 Mastic Cooker 139 4.39 Snow Blower 140 4.40 Cold Bituminous Mixing Plant 142 PART B : EQUIPMENT FOR BRIDgE wORKS 5. Activity Wise Equipment for Bridge Works 145 6. Description of Essential Equipment For Bridge Works 157 6.1 Concrete Placement Equipment 157 6.2 Concrete Pump 159 6.3 Pneumatic Sinking Equipment 164 6.4 Pile Driver 166 6.5 Pile Boring Equipment 176 6.6 Prestressing Equipment 184 6.7 Grouting Equipment 187 6.8 Shotcreting Equipment 191 6.9 Drill 196 7. Mobile Elevating Work Platform (MEWP) 202 8. Mobile Bridge Inspection Unit (MBIU) 205 Pocket Book for Road Construction Equipment Sl. Description Page No. No. PART C : EQUIPMENT FOR TUNNEL wORKS 9. Essential Equipment for Tunnelling Works 213 10. Tunnelling Methods 215 10.1 Cut and Cover Method 216 10.2 Shield Tunnelling Method 216 10.3 Bored Tunnelling Method 217 10.4 Tunnel Jacking Method 218 10.5 Immersed Tube Method 218 10.6 Drill and Blast Method 219 10.7 Conventional Excavation by Road Header or Hand 220 Tools 10.8 Rock Splitting Techniques 222 10.9 Sequential Excavation Method (SEM) 223 11. Tunnel Boring Machine (TBM) 223 12. Tunnel Ventilation System (TVS) 232 13. Other Tunnel Systems 239 PART D : EQUIPMENT FOR QUALITY CONTROL 14. Tests for Soils 243 15. Tests for Aggregates 252 16. Tests for Bitumen 256 17. Tests for Cement and Concrete 259 18. Essential Equipment for Central Laboratory 261 18.1 Soil Testing Equipment 261 18.2 Aggregate Testing Equipment 262 18.3 Cement and Cement Concrete Testing Equipment 263 18.4 Bitumen Testing Equipment 264 18.5 Sub- Soil Testing Equipment 265 19. Essential Equipment for Plant/Site Laboratory 265 19.1 Wet Mix Plant 265 19.2 Hot Mix Plant 266 19.3 Concrete Batching Plant 267 Pocket Book for Road Construction Equipment Sl. Description Page No. No. 20. Inventory of Consumables for Laboratory 268 20.1 Soil Testing 268 20.2 Aggregate Testing 268 20.3 Cement Testing 268 20.4 Bitumen Testing 268 20.5 Concrete Testing 268 20.6 Sub-Soil Testing 268 PART E : EQUIPMENT FOR DISASTER MANAgEMENT 21. Essential Equipment for Restoration Works in Landslide 271 Management 21.1 Heavy Equipment 271 21.2 Power Tools 271 21.3 Lighting Equipment 272 21.4 Hand Tools 272 21.5 Miscellaneous Utility Items 272 21.6 Individual Kit 272 21.7 Personal Protection Gear 273 21.8 Radio and Communication Equipment 273 21.9 Lightweight Temporary Bridges 273 21.10 Skilled Human Resources 273 22. Bailey Bridge 274 Appendix–I: Emission and Noise Limits for Diesel Gensets 288 (upto 800 KW) Appendix–II: Emission Norms for Construction Equipment 289 Vehicles Appendix–III: IRC/BIS Codes for Road and Bridge Construction 290 Equipment Appendix–IV: Equipment Calibration 292 References 293