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

The MoRTH Standard Data Book 2 specifies equipment usage rates for paving and surface dressing adapted to hilly areas in Chapter 20. For paving, machines such as the Paver Finisher Hydrostatic with sensor controls (240 HP and 170 HP) are used for layers like DBM, BM, BC, and Premix, with rates ranging approximately from Rs. 4,362 to Rs. 26,922 per hour depending on power. Surface dressing employs equipment like the Hydraulic Chip Spreader (200 HP) charged at Rs. 2,217 per hour, along with bitumen pressure distributors and oil-fired bitumen boilers for tack coat applications. Additional hill-specific machinery includes hydraulic mechanical brooms for surface cleaning, motor graders with blade widths from 3.35 to 4.3 meters for tasks such as clearing and scarifying (hourly rates between Rs. 4,796 and Rs. 5,991), and water tankers used for moisture control during compaction. These rates incorporate both ownership and operating costs, and equipment selection depends on terrain challenges and project scale, with smaller capacity, sensor-controlled pavers preferred for precision in mountainous settings.

According to the MoRTH Standard Data Book 2, granular sub-base construction involves using close-graded material conforming to Grading-I specifications, typically composed of 30% aggregates sized 45-22.4 mm, 40% sized 22.4-2.36 mm, and 30% fines between 2.36 mm and 75 microns. The process includes proper spreading with motor graders, moisture conditioning at optimal moisture content, and compaction using vibratory rollers. Cement concrete pavements are constructed with a dry lean cement concrete sub-base and a cement-treated crushed stone base prepared by plant mix methods with about 4% cement by weight. The pavement itself is unreinforced, dowel-jointed plain cement concrete with appropriate jointing, curing, and finishing equipment such as slip form pavers and joint cutting machines. This methodology ensures a well-graded, compacted sub-base foundation for durable and quality cement concrete pavement layers.

The MoRTH Standard Data Book 2 defines overhead and contractor profit rates as follows: For road projects, overhead charges reduce with increasing project size—10% for large projects (above Rs. 500 crore), 12% for medium projects (Rs. 200 to 500 crore), and 15% for small projects (up to Rs. 200 crore). Contractor profit is uniformly applied at 10% across all sizes. Bridge works have a fixed overhead charge of 25% with a 10% contractor profit margin, while bridge rehabilitation projects have a 30% overhead with the same profit percentage. Tunnel works also incur a 25% overhead and 10% profit. The overhead is calculated on the base civil work cost excluding GST, and the profit is computed after the addition of overheads, ensuring complete coverage of indirect costs and fair contractor remuneration.

Material quantities and labor productivity in the MoRTH Standard Data Book 2 are differentiated based on project scale: Large, Medium, and Small. Equipment capacities correspond accordingly, with large and medium projects typically using 14 cubic meter capacity vehicles and small projects using 10 cubic meter ones. Transportation quantities are expressed in tonne-kilometers and depend on the lead distance. Loading and unloading durations vary with vehicle size and project classification. Labor output is quantified in terms of days or hours per defined quantity of work, for example, in lime-treated soil embankment, a large project might require 0.638 mate days, 2.66 skilled mazdoor days, and 13.3 mazdoor days per 300 cubic meters. Material consumption figures such as bitumen, aggregates, and water are standardized but adjusted for reclaimed materials or mix designs. Overhead and contractor profit are applied as percentages on the combined costs of labor, machinery, and materials, ensuring accurate cost estimation across different project magnitudes.

The MoRTH Standard Data Book 2 stipulates several provisions for road maintenance and traffic management during construction. Traffic arrangements conform to Clause 112 of MoRTH Specifications and include installing traffic signs, portable barricades, and safety devices following IRC guidelines (IRC:SP:55 and IRC:67). Warning signs cover situations like diversions, road closures, work zones, lane changes, speed restrictions, and no stopping areas. Signs must be positioned safely outside the carriageway edges at specified heights. Safety devices include steel barricades, traffic cones, pylons, drum delineators, high mast lighting, overhead message boards, and communication systems such as telephones and wireless sets. Road maintenance activities during construction encompass repairing rain cuts, pothole filling with premix or bituminous concrete, crack sealing, shoulder upkeep, drain and landslide clearance, and replacement of crash barriers. Additional facilities include toll plaza safety features and emergency aid posts, ensuring safety and smooth traffic flow throughout construction phases.