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    Guidelines On The Choice & Planning of Appropriate Technolog

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    saikatdutta

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    oe indian Roads Congress Specie! Publication 24 GUIDELINES ON THE CHOICE AND PLANNING OF APPROPRIATE TECHNOLOGY IN ROAD CONSTRUCTION New Dalhi-t10 071 (Plus packing & | } (NEW DELHI 1984 Price Rs 24 | = First Published in June, 1984 (The Rights of Publication and Translation are reserved) Published by Ninan Koshi, Secretary, Incian Roads Congress, Jamnegar Shahjatan Road, Now Deli, Prine et PRINTAND, New Delh20 House, Shahjahan Road, New Delhi. FOREWORD The resources for the development of roads continue to be ‘d-and far short of the demand because of the phenomenal growth of trafic on our roads. Highway Engineers are thus Pressed to evolve the most economical design and construction Practices to match the specific technical requirements ‘compatible with the overall socio-economic needs. Though there have been Temarkable advancements in the use of equipment based technology in the field of rosd construction, such technology mnay not be see, able for use in entirety in our country in view of the large surplus Renpower available with us. Hence, there is need for going in for intermediate technology which perhaps is best suited to” ous country. The Highway Engineers have been quite conscious of this requirement and keeping this in view, the “Guidelines on we Choice and Planning of Appropriate Technology in Road Contre tion” ave been evolved by the Indian Roads Congress: through a Special Committee, These guidelines were approved by " the CKumeil in their 109th mesting held at Nagpur on the 8th January, (2k for being issued as a Special Publication of the Indian Rosas Congress. Thope that this publication will prove to be a very useful Buide to the Highway Engineers of our country. We would, how, ‘New Delhi KK. SARIN June, 1984 Director General (Road Development) & Addl. Secretary to the Govt. of India CONTENTS 1, Introduction 2, Scope 3. Site Planning 4. Considerations in the Choice of the Appropriate Construction Method 4.1. General 4.2, Technical Feasibility 4.3, Economic Viability 4.4, Social Desirability 4.5. Compatibility in Working 4.6, Overall Philosophy in the Choice of Appropriate Technology Guidelines on Planning and Organisation of Labour-Based Methods Sul. General 5.2, Labour 5.3. Site Clearance 5.4, Earthwork 5,5, Road Construction Aggregates 5.6. Compaction 5.1, Soil Stabilisation 5.8, Bituminous Works 5. 6. Guidelines on Planning and Organisation of Equipment-Intensive Methods 6.1. General 6.2, General Principles Governing the Selection of Machinery 6.3. Equipment Suitable for Earthwork Page "7 7 a 9 20 28 33 33 35 38 38 38 39 6.4, Output of Earthmoving Equipment 6.5. Other Road Construction Equipment 7. Cost Calculations 7A. General 7.2. Costing of Labour-based Methods 7.3. Costing of Equipment-intensive Methods 7.4. Comparison of Cost of Road Construction Jobs by different Methods LIST OF TABLES No. 1. Listing of Tasks and Available Construction Methods 2, Process of Choosing Optimum Construction Method 3, Break—Even Wage Rates for Selected Tasks 4, Productivity Data for Manual Excavation Using Hand Tools 5. Produetivity Data for Manual Loading or Unloading 6. Productivity Data for Manual Spreading in Earthworks 7 Productivity Data for Manual Haul and Unload Operations 8. Productivity Data for Manual Spreading of Pavement Materials 9. Productivity Data for Manual Production of Aggregates 10, Calculations for Number of Effective Days for Labour—An Example 11, Gang Balance Calculations for Earthwork by Headbasket 12, Gang Balance Calculations for Earthwork Using Flat-bed Truck for Haulage Page 41 49 34 54 55 7 13 4 15 15 16 16 a 19 29 30 1B 14. 15. 16, 7. 18. 19. 20. au. Characteristics and Output of 8/10T Three-whecled Roller Resource Calculations for 20 mm Thick Premix Carpet Work Using Mini Hot Mix Plant ‘Sample Calculations for Earthwork with Front End Loader and Dump Trucks ‘Sample Calculations for Working of Tractor- Drawn Water Tanker on Earthwork Job ‘Sample Calculations for Paving $0 mm Thick Bituminous Macadam. ‘Norms for Calculating Usage Charges of ‘Usage Charges for some Earthmoving Equipment Cost of Earthwork by Manual Methods Cost of Earthwork by Equipment: Method intensive LIST OF FIGURES Cost of Earthwork Task in Borrow-to-fill (Based on World Bank Study) Sequence of Borrow Excavation—-Short Hauls by Headbasket Method Sequence of Borrow Excavation—Haulage by Carts/Vebicles Balancing of Cut and Fill in Road Construction Productivity of Bulldozer Productivity of Towed Scraper Productivity of Motorised Seraper Productivity of Front End LoaderjExcavator Page 34 36 48 sl 3 58 60 u 23 2B 28 4B 45 47 " 18, 19. 20. MEMBERS OF THE SPECIAL COMMITTEE ON MECHANISED ROAD CONSTRUCTION Maj, Gen. JM. Rai Director General Border Roads (Convenor) K. Arunachalam Deputy Secretary (Research), Indian Roads (Member-Secretary) Congress M.G. Dandavate The Associated Cement Cos. Ltd. GK. Deshpande Superintending Engineer, Maharashtra P.W.D. SK. Gupta Superintending Engineer (Mechanical) P.W.D. BAR, Haryana Ingman Singh Director (Techical, Continental Construction Ltd, New Delhi pe. (Chief Engineer & Addl. Seoy. (Retd.) Rajasthan P.W.D. MR. Malya 3, Panorama, 30, Pali Hill Road, Bombay PJ. Mehta Secy. to the Govt. of Gujarat, BRC Deptt, Gujarat R, Natarajan CChiet Engineer (Elect), C.P.W.D. V.B, Pandit (Chief Engineer (Mechanical, Irrigation Deptt, Maharashtra PAK. Rao ‘Superintending Engineer, National Highwas Circle, Orissa M.E. Madhusudan Addl. Industria) Adviser, Ditectorate General of, ‘Technical Development S.A, Salam Chief Engineer, Project Organisation, Jammu & Kashmir G. Viswanathan CChiet Engineer (Mechanical), Ministry of ‘Shipp- 1g & Transport (Roads Wing) LM. Verma Superintending Engincer (C), Directorate General Border Roads Director (P&M), Central Water Commission N. Sathyamurthy MN. Singh Manager (Project Management), Indian Road Construction Cerporation N. Vasudevan ‘Managing Director, Kerala State Construction Corporation K.K. Sarin Director General (Road Development) & Addl. Secretary to the Govt. of India -Ex- officio GUIDELINES ON THE CHOICE AND PLANNING OF APPROPRIATE TECHNOLOGY IN ROAD ‘CONSTRUCTION INTRODUCTION 1.1. The fundamental principle of alignment, design and construction of any road is to achieve the least overall cost of transportation having regard to the cost of initial construction of the facility, its periodic maintenance and vehicle operation, while ‘at the same time satisfying the social and environmental require- ments, Once a road project has been prepared on this principle, the prime objective of the Site Engineer will be to complete the construction to the stipulated requirements at the minimum cost, and within the time schedule. Fulfilment of this objective will involve several steps which will include, inter alia, the choice of the appropriate construction technology which is economically viable and technically suitable for the type of work and for which the necessary input resources are readily available or can be made is Once the construction method is chosen, whi ever method it may.be, the Site Engineer should arrange for the needed resources in time and take all measures for their efficient and economical working. 1.2. In the interest of better planning of works at site and ‘economical execution of highway projects, this publication provides guidelines for the choice of appropriate construction methods under different situations, and discusses the ways and means for improving the efficiency and productivity of these methods. A large number of worked out examples have been included for assisting the Site Engineers in this regard. 1.3. These guidelines were initially prepared by K. Aruna- chalam, Deputy Secretary (Research), Indian Roads Congress, These were considered and approved by the Special Committee for Mechanised Road Construction in their meeting held at New Delhi on the 2nd December, 1983. These were later approved by the Executive Committee by circulation and then by the Council —— 2 in their meeting held at Nagpur on the 8th January, 1984 for being issued as a Special Publication of the Indian Roads Congress. 2. SCoPE 21. The choice of the appropriate construction method for & work or task is governed by several factors such as terrain, climate, available resources, technical feasibility for the nature of operations and relative economy. While for some operations, there can be more than one method that could be feasible and the choice will mostly be dictated by the availability of the needed resources, for some other technical requirements or the time factor will dic- tate the adoption of only one type of method. For example, compaction of aggregates for WBM can be done only by a power roller even in cases where the aggregates are broken and hauled to site of work by purely manual me:hods. Similarly, even though the manual methods might be the most economical alternative for ‘earthworks within short leads, equipment-intensive methods might have to be resorted to in cases where time of completion is the crucial factor. : 2.2. This document gives guidelines for helping the Site Engineer in choosing the appropriate methods for the various. tasks involved in road construction under different situations and dis- cusses the ways and means of improving the efficiency and productivity of these methods. It should be understood that these guidelines are neither absolute nor static and would need changes, from time to time depending on the relative cost of materials, equipment and services involved. It is, therefore, suggested that road construction departments should collect, compile and analyse the productivity data along with the governing parameters at least for major road construction projects so that the guidelines could bbe up-dated in the years to come. 2.3, The construction methods are generally classified into three categories, namely @ Labour-intensive methods which depend mostly on unskilled. labour who may use nothing more than simple hand tools, (ii) Intermediate methods which employ certain simple equipment or ‘non-human resources for aiding the manual operations, such as pack of animals, wheeled earts, small mixing machines, ec, 3 ii), Equipment—intensive methods in which the operations are executed by a single oF series of machines and where no unskilled labour is employed except in purely ancillary capacity. Thus for any task, a broad spectrum of methods is available with the labour-intensive and equipment-intensive methods falling at either extreme and the intermediate methods falling in-between. In actual practice, however, for certain ranges of site parameters, it will be inevitable even for the labour-intensive methods to use some simple equipment or devices. For exemple, haulage for a distance of over 100 m for which pack animals, cart and the like will necessarily have to be inducted though use of unskilled labour will be predominant. Such cases almost merge with the inter~ mediate methods because of physical inevitability. From this consideration, as also to avoid any confusion in the classification of the different methods, both the labour-intensive and the inter~ mediate methods which are practiced extensively in the country will be dealt with together in these guidelines under the broad heading ‘Labour-based methods’. 3. SITE PLANNING Site planning forms the forerunner to the starting of any construction operation. It is at this stage that the site engineer decides om the appropriate construction method for the various tasks to be accomplished, plans the needed resources and takes measures for improving the productivity at task/activity level for ‘economical working, All this involves a step by step procedure which will include the following (i) Listing out all the required tasks along with the quantities split ‘according to critical site parameters (e. g. hardness of soll to be excavated, haulage distance, etc.) and the possible construction methods. "A typical lst is shown ia Table I for illustration. i) Selecting the most appropriste method of working for each task from angles of technical feasibility, economic viability and soci esirabilty. This will require a good’ understanding and relevant information relating to the specification requirements and the capabilities of the different methods in achieving these, the product tivity and cost of operation with these, the advantage and disadvan- tage of adopting method peculiar to particular site ete. This ‘exercise will involve the listing out ofall the possible methods, and choosing the most approriste one through a process of ational and pret puey soyugcreaed ae[d xuIop “tox jeopreypour 49}!0q 78], popess-uado, soystuystoaed “uetd su20H - popestosuq — radieo uowmig “g ‘ajoejans/areq sbII01 29m0d 224101 ToMog husuiyoequi Bomou oya2:330 my Surpsoqan ons danp—19p207 apr0 [meH Supney BupeoT “9 sos pa soot ued Ban Baypeoy jenuour yun sued Bolym9 oygow ‘ouweH oyeBo1332 2003s Jo voponposd ayets830 10 s310p 1039p t19) ‘2401 10 20H Hos Sujpeaias “p soya spyue1 Jee poydord jog S978 ump roe /LEUTBY, Boyer “¢ yen

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