Standard Data Book for Analysis of Rates (Second Revision - 2019), Volume 2: For Hilly Terrain

Scope - MORTH Standard Data Book 2

The scope covers comprehensive standard data for highway construction and maintenance under MORTH, including:

• Materials handling: Loading/unloading for aggregates, cement, steel.
• Site clearance: Tree cutting, stump removal, clearing grass, dismantling structures and pavements.
• Earthwork & drainage: Excavation in soil, rock (manual & mechanical), disposal, erosion control.

Key Specifications & Units (from Preamble Table)

Important Notes:

• Lead distances (haulage) are measured one-way in kilometers.
• Cost data includes loading, unloading, and haulage separately.
• Earthwork includes manual and mechanical excavation with lead up to 1000 m.

Example: Lead Details Table Format

This scope ensures uniformity in estimating, costing, and execution for highway projects under MORTH standards.

flowchart TD
    A[Scope: MORTH Standard Data Book] --> B[Materials Handling]
    A --> C[Site Clearance]
    A --> D[Earthwork & Drainage]
    B --> B1[Loading/Unloading Aggregates]
    B --> B2[Handling Cement/Steel]
    C --> C1[Tree Cutting]
    C --> C2[Removing Stumps]
    C --> C3[Dismantling Structures]
    D --> D1[Excavation Soil/Rock]
    D --> D2[Disposal]
    D --> D3[Erosion Control]

This

Usage Rates of Plant and Machinery (MORTH Standard Data Book 2, Chapter 20)

1. Components of Hourly Cost

• Ownership Cost:

  • Interest on capital investment
  • Insurance cost
  • Depreciation cost
  • Taxes & duties (indicative)

• Operational Cost:

  • Fuel/energy and lubricants
  • Operation & maintenance crew charges
  • Repair charges
  • Miscellaneous supplies

2. Sample Usage Rates (₹ per Hour or per Tonne Km)

3. Important Notes

• Output considered is ~70% of rated capacity under ideal conditions (Clause 6.2).
• Rates vary by activity and terrain (e.g., tipper rates differ for surfaced vs. unsurfaced roads).
• Rates include all costs (ownership + operational).

4. Formula for Total Hourly Cost (Indicative)

[ \text{Total Hourly Cost} = \text{Ownership Cost} + \text{Operational Cost} ]

flowchart TD
    A[Capital Investment] --> B[Interest]
    A --> C[Depreciation]
    A --> D[Insurance]
    E[Operational Inputs] --> F[Fuel & Lubricants]
    E --> G[Maintenance & Repairs]
    E --> H[Crew Charges]
    B & C & D & F & G & H

Work in Urban Roads (MORTH Standard Data Book 2 - Clause 3.33)

Key Points:

• Higher cost in urban areas due to:

  • Mixed traffic causing 10-15% loss of working time.
  • Congestion from pedestrians, vendors, parking, encroachments reducing machine and manpower output.
  • Higher cost of living → increased wages.
  • Night work for traffic management → extra lighting and transport costs.

• Additional cost allowance: Authorities should consider 2-3% extra cost for urban work based on severity.

Equipment & Productivity (Example for Embankment with Flyash)

• Note: L1, L2 = lead distances (km) for water and material transport.

Cost Components

• Labour: Mate and Mazdoor days per 450 cum embankment.
• Machinery: Excavators, tippers, graders, rollers.
• Material: Water cost (5% additional moisture), compensation for earth from private land.
• Overhead & Profit: Applied on total (a+b+c).

Summary Table: Additional Cost Allowance for Urban Roads

Detailed content not available.

Detailed content not available.

Key Specifications & Formulas for Cement Concrete Pavements (MORTH Data Book)

1. Materials & Mix:

• Cement: Typically 400 kg/m³ (plain concrete pavement), 340 kg/m³ for thin white topping with fly ash (IRC SP-76).
• Coarse aggregate: Max size 25 mm, conforming to IS 383.
• Fine aggregate: As per IS 383.
• Water-cement ratio and admixtures per approved mix design.

2. Construction:

• Pavement type: Unreinforced, dowel-jointed, plain cement concrete.
• Joints: Contraction, expansion, longitudinal joints with fillers, sealants, dowel bars, tie rods, debonding strips.
• Curing: Use curing compound and water as per specification.
• Equipment: Fixed form or slip form paver, texturing machine, joint cutting machine.

3. Typical Quantities & Labor (per cum):

4. Cost Components:

• Material cost (cement, aggregates, curing compound, water).
• Labor and machinery cost.
• Overhead charges and contractor's profit (percentage on sum of above).

5. Rate Calculation:

[ \text{Rate per cum} = \frac{a + b + c + d + e}{\text{Quantity (e.g., 450 or 900 cum)}} ]

Where:

• a = Labor cost
• b = Machinery cost
• c = Material cost
• d = Overhead charges
• e = Contractor's profit

Summary Flow of

Key Specifications & Formulas for Maintenance of Roads (MORTH Standard Data Book 2 - Chapter 10)

1. Materials for Bituminous Concrete (40mm) & Premix Surfacing (20mm)

Alternative: Grading II (13mm Nominal) with adjusted percentages.

2. Labour & Machinery Productivity

3. Transportation Capacities & Rates

Key Formulas, Tables & Specifications for Foundations (MoRT&H Standard Data Book 2, Chapter 12)

1. Concrete Casting in Well Staining

• Lift height: 2 to 2.5 m
• Free fall of concrete: Restricted to 1.5 m
• Concreting layer thickness: 450 mm max

2. Excavation for Foundations

• Excavation depths:
  • Up to 3 m (manual/mechanical)
  • 3 m to 6 m and above 6 m with labor and machinery rates detailed
• Dewatering: Provided as per site; omitted if unnecessary
• Backfilling: Excavated earth reused except marshy soil
• Shoring & bracing included in excavation cost
• Rate analysis based on 10 cum output for earthwork

3. Concrete Mixes & Grades

• Bottom plug concrete: Min cement 330 kg/m³, slump ~150 mm (for tremie concreting)
• Well curb: RCC M25, steel reinforcement min 72 kg/m³
• Pile concrete: Min M35, cement content 400 kg/m³
• Leveling course below pile cap: M15 grade, thickness 100 mm (open foundation)
• Plain cement concrete in foundation: 1:3:6 mix with 40 mm aggregate, mechanically mixed and vibrated

4. Pile & Well Foundations

• Pile diameters covered: 300 mm to 1500 mm (bored & driven)
• Steel liners:
  • 10 mm thick for well curbs
  • 6 mm thick for staining above curb (max 3 m height)
• Pneumatic sinking max depth: 30 m below water level (IS: 4138 safety)
• Concrete stripping above pile top: 600 mm minimum

5. Excavation & Backfilling Rates (Sample)

Key Specifications for General Conditions & Overhead Charges in Bridge Works (MoRT&H Data Book)

Overhead Charges Components:

• Site accommodation, plant setup, access roads, utilities
• Office furniture, communication, site supervision, documentation
• Mobilization/demobilization, labor camps, transport
• Vehicles for supervision, lab equipment & quality control
• Minor tools & survey instruments, temporary diversion, watch & ward
• Traffic management, environment safeguarding, financing, insurance

Overhead & Contractor Profit Rates:

• Overhead charges are applied on the cost of materials and labor.
• Contractor's profit is added on top of the total cost including overheads.

Formula for Cost Estimation per Item:

[ \text{Total Cost} = a + b + c + d + e ]

Where:

• (a) = Base item cost
• (b) = Filter material cost
• (c) = 1% of (a + b) for miscellaneous items
• (d) = Overhead charges (25% or 30% on (a + b + c))
• (e) = Contractor's profit (10% on (a + b + c + d))

Notes:

• Rates for materials and labor must be updated by State/UT authorities.
• Equipment capacity and output are provided in Chapter 20 for rate analysis.
• Testing, traffic management, and temporary diversions are included in overheads.
• Bridge bearings and expansion joints are procured from approved manufacturers.

flowchart TD
    A[Base Cost (a)] --> C[Add Filter Material (b)]
    C --> D[Add Miscellaneous 1% (c)]
    D --> E[Calculate Overhead Charges (d = 25% or 30% of (a+b+c))]
    E --> F[Add Contractor Profit (e = 10% of (a+b+c+d))]
    F --> G[Total Cost = a+b+c+d+e]

This structured approach ensures comprehensive inclusion of all indirect costs and profit margins in bridge project estimations