Pocketbook for Road Construction Equipment

Scope of MoRTH 245: Pocket Book for Road Construction Equipment

This code serves as a comprehensive reference for equipment used in road and bridge construction, covering:

• Classification and specifications of batching plants, mixers, vibrators, pavers, and more (Tables 20-31).
• Equipment selection and application guidelines for activities like earthworks, compaction, and tunneling (Tables 1-19, 30, 32).
• Recommended constructions for Bailey bridges with different deck types and transom configurations (Tables 40-47).
• Emission norms and environmental compliance for diesel gensets and construction vehicles (Tables 48-49).
• Testing equipment and consumables for soil, aggregate, cement, bitumen, and concrete (Tables 36-39, 20).
• Equipment for disaster management and restoration works (Section 21).
• Calibration procedures and relevant IRC/BIS codes (Appendices IV and III).

Key Tables Summary (Page No. in brackets):

Example: Recommended Bailey Bridge Construction (Wooden Deck, 2 Transoms)

This pocket book is essential for selecting, specifying, and managing road construction equipment per MoRTH standards.

Key Specifications & Equipment for Prestressing (MORTH 245, Clause 6.6)

1. Tensioning Apparatus:

• Use hydraulic or mechanical jacks (mono-strand or multi-strand) for tensioning.
• Multi-strand jacks must tension all strands simultaneously.
• Apparatus must allow force measurement (dynamometers/pressure gauges) and linear extension measurement (nearest mm).
• Independent support to avoid secondary stresses.

2. Types of Jacks:

3. Gripping Devices:

• Wedges, yokes, double cones, etc.
• Must ensure wire breaks before grip fails.

4. Releasing Device:

• Maintains tension positively during transfer.
• Allows gradual transfer to avoid uneven tension or sudden stress.

5. Anchorage Device Requirements:

• Strength ≥ breaking strength of tendon.
• Even force transfer to concrete without local stresses.
• Safe under static, dynamic, and impact loads.
• Provision for protective medium (e.g., cement grout).

Important Notes:

• Calibration of jacks and gauges is essential.
• Safety devices must protect pressure gauges from sudden pressure release.
• Linear and slip measurements must be accurate.

flowchart LR
    A[Tensioning Apparatus] --> B{Jack Type}
    B --> C(Mono-Strand Jack)
    B --> D(Multi-Strand Jack)
    B --> E(Bar Jack)
    A --> F[Force Measurement Devices]
    A --> G[Linear Extension Measurement]
    H[Gripping Device] --> I[Wedges/Yokes/Double Cones]
    J[Releasing Device] --> K[Maintains Tension Gradually]
    L[Anchorage Device] --> M[Strength ≥ Breaking Load]
    L --> N[Even Force Transfer]
    L --> O[Safety & Protection]

This summary covers the essentials for prestressing equipment per MORTH 245 Clause 6.6.

Concrete Pumps Classification (MORTH 245, Clause 6.2.2 & Table 31)

Concrete pumps are classified based on:

1. Type of Pumping Unit:

   • Piston: Hydraulic driven, Mechanical driven, Single or Multi Piston
   • Rotary: Vacuum, Elastic

2. Mode/Frequency of Transportation:

   • Self-propelled mobile (Truck mounted)
   • Non self-propelled mobile (Trailer mounted)
   • Stationary (Skid mounted/fixed)

3. Form of Conveying:

   • With integral distribution boom (Boom Pump)
   • With separate distribution boom (Articulating arm, Tower mounted)
   • With connected conveying line (Line Pump)

4. Concrete Mix Delivery Assistance:

   • With pressurized air (Shotcreting)

Key Specifications for Selection (Clause 6.2.8)

• Maximum volumetric output (Q): in m³/hr
• Peak pumping pressure (P): depends on:
  • Total lead (horizontal + vertical distance)
  • Pipeline diameter & bends
  • Concrete consistency
  • Desired output rate

Pumping Pressure Estimation (Conceptual)

[ P = P_{friction} + P_{static} + P_{losses} ]

Where:

• (P_{friction}) = friction loss in pipe (depends on length, diameter, roughness)
• (P_{static}) = static head due to vertical height
• (P_{losses}) = losses due to bends, fittings, valves

Simplified Selection Flow

flowchart TD
    A[Determine Output (m³/hr)] --> B[Calculate Total Lead (m)]
    B --> C[Estimate Pumping Pressure (kPa)]
    C --> D[Select Pump Type & Size]
    D --> E[Check Transportation Mode]
    E --> F[Choose Conveying Form]
    F --> G[Finalize Pump Specification]

This classification and selection approach ensures efficient concrete delivery tailored to site conditions.

Soil Stabilization Equipment - Key Specifications (MORTH 245)

1. Equipment Selection Criterion

For cohesive soils, use the factor:

[ \text{Factor} = \text{Plasticity Index (PI)} \times % \text{Fraction finer than 425 micron} ]

2. Equipment Types & Processing Depth (Table 14)

3. Notes:

• Mobile soil stabilizer is preferred for Mix-in-Place stabilization.
• Tractor-driven rotavators/disc harrows are suitable for small-scale works.
• Depth capability depends on soil plasticity and equipment power.

flowchart LR
    A[Soil Sample] --> B{Calculate Factor}
    B -->|PI × % Finer < 1000| C[Disc Harrow]
    B -->|1000 ≤ Factor < 2000| D[Light Duty Rotavator]
    B -->|2000 ≤ Factor < 3500| E[Heavy Duty Rotavator]
    C --> F[Depth 120-150 mm]
    D --> G[Depth 150 mm]
    E --> H[Depth 200-300 mm]

This ensures efficient pulverization and mixing for soil stabilization.

Key Formulas, Tables & Specifications for Bridge Construction Equipment (MoRTH 245)

1. Essential Tables for Bridge Equipment Construction

2. Recommended Construction of Bailey Bridges

• Tables 40-47 provide detailed specifications for Standard & Extra Wide Bailey Bridges with wooden or steel decks and varying transom spacing.
• Example:
  • Table 43: Extra Wide Bailey Bridge (Wooden Deck) with 4 Transoms per Bay (p.279)
  • Table 44: Standard Width Bailey Bridge (Steel Deck) with 2 Transoms per Bay (p.280)

3. Important Equipment Specifications

• Concrete Batching & Mixing Plants (Tables 20-23): Classification, mixing times, capacities.
• Concrete Pumps (Table 31): Classification and performance.
• Vibrators & Vibrating Tables (Tables 25-28): Power ratings and sizes.
• Emission Norms for Diesel Gensets & Equipment Vehicles (Tables 48-49).

4. Typical Formula for Concrete Pumping Capacity

[ Q = A \times V ]

Where:

• ( Q ) = Discharge rate (m³/hr)
• ( A ) = Cross-sectional area of the pump pipe (m²)
• ( V ) = Velocity of concrete flow (m/s)

5. Mermaid Diagram: Bridge Equipment Workflow

graph TD
    A[Site Preparation] --> B[Foundation Works]
    B --> C[Piling Equipment

Key Equipment & Specifications for Tunnel Works (MORTH 245)

1. Essential Equipment for Tunnelling (Table 32)

2. Common Tunnelling Methods

• Cut and Cover
• Shield Tunnelling
• Bored Tunnelling
• Tunnel Jacking
• Immersed Tube
• Drill and Blast
• Conventional Excavation (Road Header/Hand Tools)
• Rock Splitting
• Sequential Excavation Method (SEM)

3. Basic Operating Parameters for Platform Type MBIU (Clause 8.5)

• Max Load on cage/platform (including equipment)
• Max Lowering Depth
• Max Horizontal Outreach
• Angle of Rotation
• Cage/platform Dimensions

Summary Diagram: Equipment Flow for Tunnel Excavation

flowchart LR
    A[Excavation] --> B

Tunnel Ventilation Systems (TVS) - Key Points from MoRTH 245

Modes of Operation

• Normal Mode: Dilutes vehicular pollutants.
• Emergency Mode: Removes smoke and heat during fire.

Factors Affecting Fresh Air Quantity

• Traffic volume, density, composition
• Elevation and gradient effects
• Vehicle speed
• Meteorological conditions

Types of Tunnel Ventilation Systems (Table 33)

Basic Formula for Fresh Air Quantity (Q):

[ Q = \frac{N \times E}{C} ]

Where:

• (N) = Number of vehicles per hour
• (E) = Emission rate per vehicle (pollutants)
• (C) = Permissible concentration limit of pollutant

Diagram: Longitudinal Ventilation Concept

flowchart LR
    A[Fresh Air Intake] -->|Fans push air| B(Tunnel Bore)
    B --> C[Exhaust Portal]
    subgraph Tunnel
    B
    end
    D[Vehicles] -->|Piston Effect| B

Summary:
For tunnels <500 m with low traffic, natural ventilation suffices. For longer or congested tunnels, mechanical (longitudinal or semi-transverse) ventilation is essential, with fan placement and direction tailored to traffic flow and tunnel length.

Key Tests for Soils as per IS: 2720 Series (Referenced in MORTH 245)

Important Formulae

• Unconfined Compressive Strength (qu):

[ q_u = \frac{P}{A} ]

Where:
(P) = Failure load (N)
(A) = Cross-sectional area of specimen (mm²)

• Relative Density (Dr):

[ D_r = \frac{e_{max} - e}{e_{max} - e_{min}} \times 100% ]

Where:
(e) = Void ratio of soil sample
(e_{max}), (e_{min}) = Maximum and minimum void ratios

• **

Key Tests for Aggregates as per MoRTH 245 & IS Codes

Important Notes:

• IS Sieves: Use IS 460 sieves with specified sizes (e.g., 20 mm, 12.5 mm, 2.36 mm).
• Sample Preparation: Oven dry aggregates before testing.
• Test Conditions: Follow specified loading rates and number

Key Tests for Bitumen as per MORTH 245 & Relevant IS Codes

Example: Penetration Test Formula

Penetration (mm) = Distance (in 0.1 mm) needle penetrates bitumen under standard conditions (100g load, 5 sec, 25°C).

Summary Diagram of Bitumen Testing Process

flowchart TD
    A[Sample Preparation] --> B[Specific Gravity Test]
    B --> C[Penetration Test]
    C --> D[Softening Point Test]
    D --> E[Viscosity Tests]
    E --> F[Ductility Test]
    F --> G[Flash & Fire Point]
    G --> H[Water Content & Loss on Heating]
    H --> I[Distillation & Solubility]
    I --> J[Bitumen Content & Miscibility]

Note: Use the specified apparatus and follow the detailed procedures in each IS code for accurate results. This ensures quality

Key Tests for Cement and Concrete (MORTH 245 & IS Codes)

Cement Testing (Clause 20.3)

• Fineness Test: Using 90 μm IS sieve or Blaine air permeability method.
• Consistency: Normal consistency of cement paste.
• Setting Time: Initial and final setting times (IS 4031).
• Soundness: Le Chatelier method for volume stability.
• Compressive Strength: 3-day and 7-day strength on 70.7 mm cubes (IS 4031).

Concrete Testing

• Slump Test: Measures workability (IS 1199).
• Compressive Strength: 150 mm cubes tested at 7, 14, 28 days (IS 516).
• Water-Cement Ratio: Critical for strength and durability.
• Density and Air Content: For lightweight and air-entrained concrete.

Common Formulas

• Water-Cement Ratio (w/c):
  [ w/c = \frac{\text{Weight of water}}{\text{Weight of cement}} ]

• Compressive Strength, ( f_c ):
  [ f_c = \frac{P}{A} ]
  where ( P ) = load at failure, ( A ) = cross-sectional area.

Typical Testing Equipment

• Compression testing machine, slump cone, Vicat apparatus, Le Chatelier apparatus.

flowchart LR
    Cement -->|Fineness, Consistency| CementTests
    CementTests -->|Strength, Setting Time| QualityControl
    Concrete -->|Slump, Strength| ConcreteTests
    ConcreteTests -->|Durability| QualityControl

For detailed values and procedures, refer to IS 4031 (Cement) and IS 516/1199 (Concrete).

Essential Equipment for Central Laboratory as per MORTH 245

• Direct Shear Apparatus: Proving rings with capacities of 2 kN and 2.5 kN for shear strength tests.
• Weigh Balances:
  • 5 kg capacity, electronic, accuracy ±0.5 g
  • 500 g capacity, electronic, accuracy ±0.01 g
• Oven: Electrically operated, thermostatically controlled, stainless steel interior, temperature range 0°C to 220°C.
• Sieves: As per IS:460, 200 mm internal diameter, brass frame with steel/brass wire cloth mesh. Complete sets with lids and pans.
• Liquid Limit Device: With ASTM grooving tools as per IS:2720 (Part 5).
• Sampling Pipettes: 10 ml capacity, fitted with pressure and suction inlets.
• Sampling Tins: Diameter 100 mm, height 75 mm, capacity 500 gm, with lids.
• Miscellaneous: Moisture tins with lids (50 gm capacity).

These ensure accurate soil and material testing for highway construction quality control.

flowchart TD
    A[Central Laboratory] --> B[Direct Shear Apparatus]
    A --> C[Weigh Balances]
    A --> D[Oven]
    A --> E[Sieves]
    A --> F[Liquid Limit Device]
    A --> G[Sampling Pipettes]
    A --> H[Sampling Tins]
    A --> I[Miscellaneous Items]

Essential Equipment for Plant/Site Laboratory (MORTH 245 & IS: 2720 series)

Key equipment required includes:

• Direct Shear Test (IS: 2720 Part XIII):

  • Shear Box, Loading Frame, Weights
  • Proving Rings (2 kN & 2.5 kN capacity)
  • Micrometer Dial Gauges, Sample Trimmer/Core Cutter
  • Stop Clock, Balance, Spatula, Straight Edge

• Weighing Balances:

  • 5 kg capacity electronic balance (±0.5 gm accuracy)
  • 500 gm capacity electronic balance (±0.01 gm accuracy)

• Oven:

  • Electrically operated, thermostatically controlled (0ºC to 220ºC)
  • Stainless steel interior with thermometer

• Sieves:

  • As per IS:460, 200 mm internal diameter, brass frame, steel/brass wire mesh

• Liquid Limit Device:

  • With ASTM grooving tools as per IS:2720 (Part 5)

• Sampling Tools:

  • Sampling pipettes (10 ml capacity with pressure/suction inlets)
  • Sampling tins (100 mm dia × 75 mm height, 500 gm capacity)
  • Moisture tins with lids (50 gm capacity)

Summary Table for Soil Tests & Equipment (IS: 2720)

Key Equipment for Quality Control (MORTH 245, Part D)

The equipment specified aligns with IS: 2720 series for soil testing and other standards for materials testing:

Soil Testing Equipment (IS: 2720 Series)

Additional Equipment Highlights:

• Balances for weighing samples.
• Ovens for moisture content determination.
• Sieves (4.75 mm size and others) for particle size analysis.
• Timers and stop clocks for test duration control.

Example: Unconfined Compressive Strength Test Formula

[ q_u = \frac{P}{A} ]

• (q_u): Unconfined compressive strength (kPa)
• (P): Load at failure (N)
• (A): Cross-sectional area of specimen (mm²)

Summary Diagram of Soil Testing Equipment Setup

graph TD
A[Soil Sample Preparation] --> B[Specimen Moulding]
B --> C{Test Type}
C -->|Unconfined Compression| D

Inventory of Consumables for Laboratory (MORTH 245)

From the Pocket Book for Road Construction Equipment (Page 268), key consumables and apparatus for various tests are:

Cement Testing Consumables:

• Cement Motor Moulds: 70.6 mm × 70.6 mm × 70.6 mm cubes
• Vicat Needle Apparatus: As per IS:269 for setting time
• Soundness Testing Apparatus: Le Chatelier method
• Weigh Balances:
  • 5–20 kg capacity, accuracy 1 gm
  • 500 gm capacity, accuracy 0.01 gm
  • 5 kg capacity, accuracy 0.5 gm
  • 50 kg capacity, accuracy 2 gm

Concrete Testing Consumables:

• Cylinders: 150 mm diameter × 300 mm height with capping set
• Cubes: 150 mm and 100 mm sizes
• Slump Test Apparatus
• Vibrating Table: 1 m × 1 m, variable frequency and amplitude
• Compression & Flexural Strength Testing Machine: 200 ton capacity with dial flexural testing

Summary Table:

This inventory ensures precise and standardized testing of construction materials as per MORTH guidelines.