CONSTRUCTION MACHINERY

- Types, Procurement & Maintenance

P.MADANAIAH
Consultant.
09-12-2015 Centre for Good Governance
 CONSTRUCTION MACHINERY
for

Infrastructure Development

P.MADANAIAH
Consultant.
09-12-2015 Centre for Good Governance
 Evolution of Construction methods
• Manual Operation: From sickle, shovel, spade, trowel, pans, manual
bar bending/ cutting, etc.
- to hand-mixer, machine-mixer, vibratory rollers, excavators, bar
bending/cutting machines, sand washing machines, etc.
- to the modern day, concrete pavers, computerized concrete
mixing machines, rotary drillers etc. and still evolving
innovations.
• Construction industry - Employ the best possible technology and
machinery as applicable to local conditions to complete the job in
the minimum time and cost.
• Methods involved -Introduction of modern high-powered
earthmoving equipment, rock crushing plants, cranes , concrete
fixing machinery including concrete transport and placing
machinery, etc
• Construction Costs - Formulation of standards and work
specifications and prepare data on “scientific basis” using “The State
of Art technology” in vogue ,by deploying suitable machinery and
technology ,wherever possible and, reduce the component of
manual labour and construction costs with assured best quality
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construction machinery-necessity
• Increase in size of infrastructure development
projects- large quantities of material inputs
• Increase in complexity of projects involving high
grade materials
• Shortage of Skilled labour and lack of technology
up gradation
• To reduce period of construction- to pass on the
benefits to the user at the earliest
• To cut down construction costs drastically- with
modern machinery with least labour inputs
• External and internal funding agencies specify the
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use of sophisticated machinery
 Market Growth
• India -5th largest and fastest growing construction
equipment market in the world
• Construction Industry employs more than 18 million
people
• Construction equipment accounts -5 to 24% of
construction project costs
• Estimated Global market of construction equipment
- over $ 90 billions in 2013
- Indian sector - US $ 3 billion
• Growth rate in global industry- about 5% per
annum
- India’s growth is around 30%
• India-Total infrastructure expected 10 % of GDP
during the 12th Five Year Plan (2012–17),
compared to 7.6 per cent during the 11th plan
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(2007–12).
 India - Market Growth
As per ICEMA (Indian Construction Equipment manufacturers’ Association)

• Earthmoving and Construction Equipment Market

growth - 20-25%
• By 2020 sales reach 330,000 to 450,000 units,
from current levels of less than a lakh units
• 14 Major reputed manufacturing companies
- in collaboration with different oversees
manufacturers
- Adopting global technological
advancements suitable to country’s
construction sectors

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 India-Market Growth
• The Indian construction equipment sector -
broadly segments
Earthmoving equipment
Tunnelling & Drilling
Road construction equipment
Concrete equipment
Material handling equipment
Material Processing equipment

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India- usage of heavy machinery
percentage

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 ECM- India-Market Growth
 Earthmoving equipment and road construction
equipment account for about 70 per cent of India's
construction equipment market.
- Backhoe loaders, which comprise tractors, front
shovel/bucket backhoes and small backhoes, account for 65
per cent of the earthmoving equipment and road construction
segment.
 Concrete equipment is the second largest segment with a
market share of approximately 14 per cent. It comprises
asphalt finishers, transit mixers, concrete pumps and batching
plants.
 Material handling equipment -- 10 per cent
- Cranes are the largest category within the material handling
equipment
 material processing equipment account and 6 percent of the
market respectively. 12
Construction Planning and Machinery
Tips for Executive agencies
• Formulate detailed Plan of action and deliverables –priorities
and phases
• To adopt use of machinery wherever possible and reduce
manual labour component
• Select job specific requirements- inputs and machinery
• Prepare work data and use rate on scientific basis, using
“The State of Art technology” in vogue
• To employ the best possible technology and machinery
most suitable to local conditions at optimum costs.
• Deploy where needed the most modern, high powered
earthmoving equipment, rock crushing plants, cranes and
concrete fixing machinery
• Good construction equipment leads to reliable operation and
in turn offers productive and long lasting results in addition to
financial gains
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Construction machinery and equipment
Prime Categories
• Heavy Earth Moving Machinery: Its the largest segment
and includes products like, shovels/excavators,, backhoe,
loaders, Bulldozers, scrappers ,motor graders loaders,
dumpers etc

• General Construction Equipment: Tunnel boring

machines, Batching plants, concrete mixers, hot mix plant,
road making machine, concrete breakers, stone crushers etc.

• Material Handling Equipment: mobile cranes, forklifts, truck

mounted cranes, tower cranes, conveyors, winches etc.

• Transport Vehicles: dumpers, trippers, tankers, trailers

Lorries etc. 14
 Construction Machinery &Equipment
Heavy earth moving machinery:
• Tunnel boring machines (Special purpose M/c)
• Bulldozers- Track/wheel mounted

• Shovels/ excavators- Track/wheel mounted

• Loaders
• Graders
• Scrapers – with/without pushers
• Draglines - Track/wheel mounted
• Dumpers – side, rear, universal
• Dredgers – Under water operations
• Trimmers- to trim to size and shape
• Dredgers , etc.
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Construction Machinery &Equipment
Construction machinery equipment:
 Air Compressors- Mobile, Stationery
 Cable ways
 Tower cranes,
 Batching plants- for mass production,
- Storage bins for aggregate and sand
- Cement/fly ash storage Silos
- weighing conveyor system
- water admix storage tanks
- Mixing and discharge chambers
- control station
 Transit mixers/Agitating Cars –for concrete
 Heavy duty drilling machines
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 Canal lining machines- size and capacity
 Construction Machinery &Equipment
• Road laying equipment- pavers, asphalt mix
plant , sprayers
• C.C. Mixers- Electrical/Mechanical/Hand driven,
• Concrete Pumps
• Road rollers/Compactors- tandem, Vibratory
compactors, Sheep foot, etc.
• Vibrators- Pin (25/40/60 mm), Disc type (dia of
disc)
• Jack drills and hammers- Pneumatic, power
drive
• wagon drilling equipment
• Pump sets- Diesel or petrol engines/electric
motor drive
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• Welding transformers/Generators, etc;
 Construction Machinery &Equipment
Material handling equipment
• Mobile cranes- track mounted ,wheel mounted, EOT,
Gantry ,jib etc.
• Pipe line laying & special purpose Cranes
• Winches, pulley blocks and lifting machines
Transport machinery
Trucks
Tippers
Tractor-trailers
Trolleys
Jeeps, cars, Ambulances, etc

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 Construction Machinery &Equipment

General Allied Equipment

Power generators
petrol or diesel/kerosene driven …
Electrical equipment
• Power Distribution Station
• Transmission lines
• Transformers (step down)
• D.P/Four Pole structures,
• Sub-Distribution systems,
• Power cables and allied equipment
• Motors
• Illumination,.
Safety Equipment
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 Construction Machinery &Equipment
Technical aspects for selection
• Based on drive
- Mechanical
- Electrical
- Pneumatic
- Hydraulic
- Manual
• Capacity of Machine- bucket volume/tons/HP/ Area of
operation/ swing etc, depending on type of machine.
-- Operation Area/ distance/ Height
-- Angle of Swing
-- BHP
-- Fuel efficiency
• Mounting
-- Wheel mounted
-- Track mounted
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 Construction Machinery &Equipment
Key factors
• Suitability for the job-quantity and time
• Operating conditions and weather
• Standardization and variety reduction
• Type of Prime mover
• Type of Mounting
• Degree of utilisation
• Equipment transportation- route and safety
• Suitability for local conditions
• Technical considerations
• Maintenance and repair facility
• Insurance 21
Construction Machinery &Equipment
Selection Criteria
• Efficiency- machine and Expertise level of
operator
• Fuel Economy
• Life of tyres / track
• Spares-availability
• Maintenance & Repair workshops /Machinery
– Locations of workshops or as per Contract
terms with equipment suppliers
• Working conditions and area of operation
• Operation Field - Forest/desert/Disturbed or
sensitive areas
• Safety aspects-
• Proven records of machinery 22
 Construction Machinery &Equipment
Selection Criteria
• Efficiency &Economy
– Deploy right machine to right job (Specified
usage)
– Life and working condition of machinery (engine
and other
components)
- Balance Life of Machinery
– Regular servicing as per norms
– Battery and prime mover condition
– Overloading/under loading
– Lubrication
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 Construction Machinery &Equipment
Selection Criteria
• Efficiency &Economy
– Lubrication
– Fuel quality
– Fuel pump calibration
– Tyres- Condition and inflation
– Track-condition and abrasion of grip plates
– Operator-efficiency
– Avoiding unplanned idle running
– Supervision
– Data storage
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 Contractors & Field Engineers -tips
• User awareness of machinery
• Check up deploy right machine for right job
• Check - Life of Machinery-consideration
• Optimum usage of machine capacity-overload/
under utilization
• Check Operators- capability
• Check up Statutory licenses and documents
• Establish Safety in operation
• Ensure Facilities of maintenance
• To avoid damage to other works and premises
• Check up log books and output
• Keep ready for emergencies 25
26
 TBM- General Specifications
General Usages
• Water passage
• Laying underground cables.
• Tunneling for the purpose of laying tracks
for underground transportation-rails,Roads
• mining.
• For laying huge pipes for various
purposes/penstocks etc.

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 TBM- General Specifications
• Boring Diameter
• Cutter head
Installed power
RPM
Thrust
• Cutters
Numbers,
Tip width,
Diameter ,
Max load/cutter
• Boring Stroke
• Max. turning radius
• Weight
• Other- job specific
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TBM-Rotary cutters

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 Bulldozer
• Horse power
• Mounting type
• Blade size.
• Cutting blade section
• Effective lift for material say,1 meter.
• Reach of ground 0.8 meter
• Attachments (specify)

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Bulldozer (Dozer)

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 Bulldozer
bulldozer blades-shapes &usage
• A Straight Blade ("S-Blade") -short and
has no lateral curve, no side wings, and
can be used for fine grading.
• A Universal Blade ("U-Blade") -tall and
very curved, and has large side wings to
carry more material.
• A "S-U“ -used for pushing piles of large
rocks

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Ripper

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 Excavators
Excavators –usage
• Digging of trenches, holes, foundations
• Demolition
• General grading/landscaping
• Heavy lift, e.g. lifting and placing of pipes
• River dredging
• Mining- opencast mining,
• Loading, etc

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 Hydraulic excavator
Example
• Engine Rated Power--
400 HP
• Operating Weight : 45t

• Backhoe Bucket - 2.7

m3

• Heaped : 1.00 - 2.50

m3

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DRAG LINE EXCAVATOR

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WHEEL – LOADER

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 loading shovel

example:

HP of prime Mover - 400

Bucket capacity -
upto12 cum
Mounting - track mounted
Weight -150 tons

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loading shovel

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Front end loader-Tyre mounted

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 DUMPER TRUCKS -Types

 Crawler/Tyre mounted Dumper

 Super/Heavy duty dumper

 Side dumper

 Bottom Dumpers

 Rear dumper

 Articulated dumper

 Transfer dumper
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 CONSTRUCTION MACHINERY

DUMPERS
Specifications
(example)
-- Rated Power - 400 HP
-- Maximum Gross
weight - 45 Tons
-- Payload with Standard
Equipment -30 tons
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Rear Dumper

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backhoe-attachment

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 Back hoe for excavation
• Loading height
• Digging Depth
• Maximum reach
• Bucket working angle --170 deg.
• Boom Swing ---165 deg.
• King Post Travel ---2.5 ft.
• Bucket out side width- 1 ft /2 ft.

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BACKHOE- Excavator with Loader

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BACKHOE LOADER

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EXCAVATION&TRIMMING

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SCRAPER

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Scraper with Pusher

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Grader

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Road Roller/Roller Compactor

Specifications

-Capacity : say 8-10 tons

- Rolling Width say 1.8 mts
- Rollers Dimensions: Dia-Width
- Overlap of Rolls 100 mm.
- Line Pressure - Front Rolls/ Rear
Rolls
Minimum
Maximum
-Type : Diesel Engine (DRR)
-Wheel Base
-Turning Radius
- Speeds – 4/3 speed

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 Vibratory Compactors
Specifications (Common)
– Operating weight:
– Drum width
– Drum Diameter
– BHP
– TYRE Size
– Vibratory Frequency - Standard 31/34 Hz (
Say 1000 vpm)
and other features as in Road rollers

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Vibratory compactors

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Batching Plant

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 Batching plant specifications
Technical Data Model

Capacity (M3 / Hour) 20

Geometrical Volume (M3) 2.25
Nominal Capacity (M3) 0.666
% of filling 35%
Batches / Hour 40
Capacity / Day (8 HRS.) 120
Power Consumption 20 [KW/HP]

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TRANSIT MIXURES

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 Transit mixers
Technical Specifications
NOMINAL CAPACITY
TOTAL GEOMETRIC VOLUME
FILLING RATIO

ENGINE

POWER
DRUM SPEED
WATER TANK
WATER PUMP
LENGTH OF MIXER
WIDTH OF MIXER
HEIGHT OF MIXER (W/o. Truck)
WEIGHT OF MIXER ONLY

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CC Mixer

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 CC MixersSPECIFICATIONS

SPECIFICATIONS- CC Mixer
10/7 (drum 7/5
cap)unmixed/mixe
d
Capacity (unmixed) 300 Ltrs. 200 Ltrs

Capacity (mixed) 200 Ltrs. 150 Ltrs

Drum Speed (Rev./mm) 20-22 RPM 20-22 RPM

Power Electric Motor 3 HP 3 Ph 2 HP 3 Ph

Power Diesel Engine 6.5 HP 5 HP

Production Rate 6.8 m3/hr.

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cable ropeway

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concrete placing boom

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TOWER CRANE

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CANAL LINING MACHINE

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Mobile Hot Mix Plant

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Telescopic (Boom) mobile crane

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Wheel Mounted Cranes

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EOT Cranes

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Jib cranes

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FORKLIFTS

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Piling Rig

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Piling Rig

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Hydraulic Pile driver

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Heavy pile Rig

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Hydraulic Pile driver

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Pile Hammer

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Diaphragm wall machine

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Sheet piling

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 Sheet piling
• Sheet piling is a form of driven piling
- Thin interlocking sheets of steel used,to
obtain a continuous barrier in the ground.
• Main application of sheet piles
- Temporary supportive wall/ Retaining walls
and coffer dams.
• General Machinery:
- vibrating hammer,
- crane
- crawler drill 85
Sheet piling

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Tracked Paver

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 Bitumen Sprayer
TECHNICAL DATA (An example)

• Bitumen tank
• Model : ABS - 4000 / ABS - 6000 - ABS - 8000 / ABS – 10000
• Capacity :4000 / 6000 / 8000 / 10000 Litres
• Tank Shape :Oval
• Insulation :50 mm thick glass wool
• Temperature gauge :0-300° C
• Mounting :Tank mounted on any truck chassis of wheel base 176”/166”
• Spray bar Length :2.4 Mtr. Length with extension :4.20 Mtr.
• Fully circulating of pre-heated bitumen- Bitumen spraying pressure :0-4 Kg./
cm2
• Bitumen pump2" x 2" size positive displacement gear pump with output of
400 Ltrs. / Min
• Air compressor: Standard make 2 Cyl. air compressor
• Burner Fuel consumption : 20 Ltr. / Hr.
• Fuel tank- 50 Ltrs. capacity
• Fuel tank 100 Ltrs. Capacity
• Engine Standard make, Air cooled diesel engine,.
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Bitumen Sprayer

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 Tracked pavers
• Maximum paving width --11.0 - 13.0
meters
• Paving speed 20 meters/min
• Propulsion --Tracked
• Dead weight

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Bituminous Sprayer

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 Dredging
• Dredging is the removal of sediments and debris
from the bottom of lakes, rivers, harbors, and
other water bodies.
• A cutter-suction dredger's (CSD) suction tube
has a cutting mechanism at the suction inlet.
• The cutting mechanism loosens the bed material
and transports it to the suction mouth.
• The dredged material is usually sucked up by a
wear-resistant centrifugal pump and discharged
either through a pipe line or to a barge.
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Dredger

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final phase of buddha statue installation

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Use Rate /Hire Charges of machinery

• BIS Standards for working out unit rate cost of the

Construction equipment (IS: 11590 /19950)
including fuel consumption.
- CAPACITY ---Per hour/day/cycle
- BHP of the drive
- LIFE- Years and Hours ,
- Repair Provision
- Operation Factors C1- Type/category factor,
C2 -- Duty factor
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 Canals- Excavation in all kinds of soils

Example-1 : combination of Machinery

All kinds of soils
Initial lead=1 km
lifts --- all
• Ideal combination of machinery-to
handle 800 cum per day
– Shovel 1.5 Cum capacity 1No
– Tippers 5 cum capacity 6 Nos

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 Hire charges of construction machinery
PART-A
• Capital cost of machinery / equipment --C

• Salvage value of machinery / equipment ( as percentage of capital cost ) - s

• Rate of interest per annum ---- -- I

• Life of machinery / equipment in years -n

• Life of machinery / equipment in hours --h

• Average capital cost C x ( n + 1 ) / 2 n – - C’

• Repair charges ( as percentage of capital cost ) -r
• ( for value of ' r ' refer standard data table )
• Depreciation charges = ( 1 - s / 100 ) x Capital cost / life in hours
• Interest charges = 'Av. Capital cost x Rate of interest x life in years/life in
hours/100
• Repair charges- = Repair provision x Capital cost / life in hours / 100
• Miscellaneous charges= ( as percentage of repair charges ) 10% 98
 Hire charges of construction machinery
Part-B
Fuel consumption
• Electric motor powered machinery :
Energy consumption( in kwhr/hr) --- 0.746 x BHP x c1 x c2

• Diesel engine powered machinery :

--Diesel consumption ( in ltr / hr ) : 0.220 x FHP x c1 x c2
-- c1 and c2 are type and duty factors
( refer standard data table for values of c1 and c2 ).

• Provision for Oil & Lubricants :

Electric motor operated machinery : 20 percent of energy charges
Diesel engine operated machinery : 25 percent of fuel charges
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 Hire charges of construction machinery
Part-C

Yearly wages of Operator compressor = ( 26 x 12 x Daily wages )

Yearly wages of Helper compressor = ( 26 x 12 x Daily wages)

Total yearly operating crew charges for Air compressor ( diesel )

Hourly operating crew charges= ( yearly crew charges / yearly

usage of machinery)

Total Hire charges/ Hour= Part (A+B+C)

100
 working Use rate of machinery and SR for Canal works
Excavation in soft rock without blasting including boulders above 0.30 m upto 0.6 m dia. for
canals, seating of embankment, filter drain / catch water drains etc., including dressing of
bed and sides to required level and profile, cost of all materials, machinery, labour, placing the
excavated soft rock neatly in dump area or for formation of service road as directed etc.,
complete with lead upto 1 km and all lifts.

Capacity of shovel bucket : 0.85 cum

Capacity of shovel bucket under heaped condition : 1.00 cum
Capacity of tipper : 5.00 cum
Lead for disposal of excavated soft rock :Upto 1 km
Speed for loaded tipper under canal excavation condition : 15 km / hr
Speed for empty tipper under canal excavation condition : 15 km / hr
Turning and unloading time : 2.00 min
Shovel digging and loading cycle per bucket : 30 sec
In-situ qty / bucket for 30 % bulkage on unloading ( 1 / 1.30 ) : 0.77 cum
In-situ quantity / load for 5 cum of soft rock ( 5 / 1.3 ) : 3.85 cum
Number of buckets per load ( 3.85 / 0.77 ) say : 5 buckets
Ideal cycle time for loading 5 buckets ( 5 x 30 / 60 ) : 2.50 min
The ideal cycle time for shovel requires spotting of a tipper within 2.50 minutes near the shovel.
However, in practice for dam or canal excavation the space available may not permit positioning
of tippers on either side of the shovel. Generally one tipper has to move after loading to position
the next tipper for loading. Assuming extra time of 20 seconds the corrected cycle time for the
shovel will be 2.83 minutes.
Round trip cycle time for tipper:
Ideal cycle time of shovel for digging & loading : 2.50 min
Time for ( av ) 0.75km haulage under load ( 0.75 x 60 / 15 ) : 3.00 min
Time for turning and un-loading : 2.00 min
Time for average 0.75 km return trip ( 0.75 x 60 / 15 ) : 3.00 min
Extra time for spotting : 0.33 101
min
Total : 10.83 min
working Use rate of machinery and SR-Canal

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working Use rate of machinery and SR-Canal

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working Use rate of machinery and SR--Canal

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Procurement of Construction Machinery
Pre requisites
• Type of job/work
• Quantity
• Scheduled program of work
• Group of machinery- for optimum out turn
• Approach to work place
• Transportation/Conveyance constraints
• Availability of Electric Power
• Economy- Life and efficiency of machine
• Availability of machinery
- with executive agency
- Market and downtime
- For Hire
- alternates
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 Procurement-Process
 Role or Area of Construction of the Company or
contractor--Roads, Bridges, Buildings,Dams, Canals,
Industries ,Special Civil Constructions jobs etc.
 Work Schedule - Committed dates of
commencement and completion
 Financial capacity and sources of funding
 Contract specific/Work specific requirements,
quantity, scheduled time
 Machinery requirement
 Equipment on hand- make, model, balance estimated
life
 Condition of Existing equipment- Good, Fair or
Poor condition
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 Balance machinery required
 Procurement or Hiring of Machinery
 Renting has a strong potential in India,
particularly for smaller equipment
 Hiring of Machinery avoids large capital
expenditure
 Saves on maintenance and storage cost
 Provides access to broad selection of
equipments.
 Enable to adopt for the job/ work the best
equipment
 Take decision to buy/hire only on working out
economics
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 Procurement-Tips
 Detailed specifications
 Grouping of machinery for optimum out puts
 Select Standard manufacturers with Proven record in the market for
the similar machines
 Preferable to procure the machinery of same make/manufacturer
already in use, to reduce O&M costs, inventory and down time costs
 Check for Warranties & Guarantees
 O&M aspects- role of company and facilities
 Thoroughly examine the conditions of supply agreements and
conditions
 Payment conditions
 Training to operational & maintenance staff
 Company’s record of litigations and Legal issues
 Do not just jump to the lowest offered rate, unless the above
requirements are met with
 Economy - considerations

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Maintenance Aspects

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 Types of Maintenance
• Planned Maintenance
– Ensure maintenance charts for each machine
– plans / preparedness to meet emergency repairs and
replacements
• Types of Maintenance
 Preventive Maintenance
• Daily Checks
• Weekly checks on week holidays
• Scheduled maintenance by manufacturer or technicians -
Monthly/half yearly/yearly or on using specified or fixed
hours of running, or both
• Special Maintenance
– Corrective maintenance
– Predictive maintenance
 Reactive maintenance – Non plan - On failure only
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 Maintenance-plans
• Ensure supply of updated maintenance charts – Display
in field offices /workshops
• Indicate clearly the back logs of maintenance
• Check and display warranty and guarantees of
Suppliers
• Standby/ spare machinery availability
• Field maintenance facility for day to date maintenance
• Maintenance staff - stationed in the field
• Maintenance contract with manufacturer /dealer
• Manufacturer maintenance schedule at site workshops
• Location of dealer workshops and types of jobs
• Fuel efficiency: As per manufacturer
- present fuel efficiency
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- Adopt best practices
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