Investigating on some of the new road making machines and technologies that are hitting the Indian market  India is on course to becoming a global manufacturing hub with the PM’s ‘Make in India’ initiative. Infrastructure being an integral part of the initiative directly provides a boost to the construction equipment manufacturing industry. The total investment requirements for power, roads, ports and civil aviation during the 12th Plan period is projected at USD 1 trillion, nearly half of which is expected to come from the private sector.
India having 48.65 lakh km of road network is the second largest in the world.  At present, national highway network of about 92,851 km comprises only 1.9 per cent of the total length of roads, but carries over 40 per cent of the total traffic across the length and breadth of the country.
“As per the market analysts, the value of total roads and bridges infrastructure in India will grow at a CAGR of 17.4 per cent over FY12-17. Further, it is believed that factors such as national highway expansion program of 4-lane to 6-lane by NHAI, state highways development programs, rural roads development programs etc., will open new arenas for the road construction machinery market. Thus, obviously the road construction machinery manufactures in India need to gear up well to cater to this growing demand,” says Vijay Kalantri, Chairman & MD, Dighi Port Ltd.
Need for advanced machinesWith the country ambitiously planning to lay increasing number of new roads and retouch the old ones to match the projected economic growth, new doors of opportunity have opened for road construction machinery manufacturers. However, the questions that gains ground here is that is the nation equipped technologically to take up so many road projects?
Market analysts sound positive in response to this question and claim that India is already manufacturing a variety of road construction equipment (indigenous as well as in collaboration with global manufacturers). However, they feel that there is still the need to invest in advanced machines to build world-class roads. Indian road construction equipment manufacturers need to adopt new technologies so as to give better results in terms of accuracy, quality and cost of construction.
Clients encouragement on use of new technology and construction methodology have given opportunities for construction equipment manufacturer to benchmark and introduce equipment’s being used in developed countries.
“We at G R Infraprojects Ltd (GRIL) have acquired world’s best-in-class equipment and having best technologies. We are among the first Indian companies introducing use of new construction technology and construction methodologies which have brought in value in terms of quality, cost, faster execution, reuse of reclaimed material at site which has resulted in save of environment,” says Ratan Lal Kashyap, Sr. Vice President – Procurement, G R Infraprojects Ltd.
Construction equipment industry is gearing up to remodel the industry that will help materialise these ambitious plans of a world-class road network across the country. Keeping with the emerging trends, the industry has started looking at some of the new generation equipment.
1. Tracked paver
To support the Government of India’s ambitious road building program, Volvo CE has developed the new P5320B ABG tracked paver, bringing 50 years of experience in the road construction industry into a single machine. With the government having announced its ‘Make in India’, this newest product will have even greater appeal for customers in India having been designed and built at the company’s Bengaluru factory. It is ideal for medium and large-scale paving projects where widths range from 2.5 m up to 7 m.
“The P5320B ABG’s environment friendly engine delivers best-in-class 88 kW (118 hp) performance capable of pushing 25-tonne trucks, along with quiet, fuel efficient operation. Performance efficiency is further enhanced by the paver’s load sensing hydraulic system, powered by a variable displacement axial piston pump. Here, hydraulics is perfectly matched to all components from hopper to screed, ensuring less maintenance, a longer lifespan and higher traction performance. An automatic hydraulic track tensioner also maintains accurate track tension for smooth operation, while simultaneously reducing wears and minimising downtime,” says Dimitrov Krishnan, Vice President & Head, Volvo CE in India.The paver’s material handling system is designed to incorporate hard and extra thick, wear-resistant components, resisting wear and tear from abrasive lay down material. This, together with the multi-level protection design incorporated into every bearing of the material handling system; ensure repair costs over the long term are kept to a minimum.
The P5320B ABG’s ability to pave widths up to 7 m comes courtesy of Volvo’s Omni V screed. This maximum paving width is achieved through the simple installation of optional extensions which attach to the unit’s standard 3 m track plates. The heavy-duty screed features powerful tamping bars and vibration systems that deliver a high pre-compaction density. An adjustable mechanical crown enables the screed plate to flex at (±) 3 degrees as well. The screed’s electronically ignited gas heating system, designed with flame failure protection, quickly and efficiently heats the screed plate, while an LPG blower burner system provides uniform heat for a high quality consistent mat finish.
Operators benefit from the safe and comfortable dual seating position in the paver’s cab, with ergonomically-positioned controls and sliding control panel which enables excellent visibility to the hopper, material deliver truck, auger area, material flow, screed and final mat. There is an ergonomically-designed control panel that includes a colour TFT display that relays information on the paving cycle, as well as details on diagnostics and service data. An all-weather sunshade attached to the cab also reduces fatigue for increased safety and productivity, without sacrificing operator visibility. Handrails and all-weather grip walk areas permit further safe movement around all machine platforms for extra operational safety.
To improve material transfer and flow, the P5320B ABG’s auger allows operators to adjust its height. Its reversal feature improves material control and reduces hand labour, contributing to additional productivity. For industry-wide compatibility, the electrical system fitted on the P5320B ABG is designed to accommodate standard global levelling systems.
“Road construction contractors looking to minimise recurring variable costs throughout the life cycle of the paver will find reassurance in Volvo CE’s end-to-end service network. With an extensive infrastructure of technicians, workshops and dealers spread across India, a Volvo CE expert is able to respond quickly to any operational emergency,” adds Krishnan.
2. Advanced cold milling machines
At Wirtgen, no less than eight models are available to customers in the compact class, with standard working widths between 1.0 and 1.5 m and depths up to 330 mm. Combined with the flexible cutter system, working widths from 8 cm to 1.5 m even are possible. The entire line of machines including W 100 CF/ W 100 CFi, W 120 CF/ W 120 CFi, W 130 CF/ W 130 CFi and W 150 CF/ W 150 CFi offer high output and cost-efficiency.
“Fields of application range from classical small milling machine operations, such as partial road repairs, all the way to the removal of entire roadways, a job usually reserved for the large milling machines. In other words, Wirtgen’s compact milling machines are extremely flexible. By combining the advantages of the small and large machine classes, implementing a uniform operating concept and in particular incorporating pioneering control technologies, Wirtgen’s compact class is now one thing above all: The next step in the development of cold milling,” says Ramesh Palagiri, MD & CEO, Wirtgen India Pvt Ltd.
Like the new generation of small milling machines, Wirtgen also equipped its compact class with numerous added and automated functions, integrated in both the uniform operating concept and various control functions. The result: Simple machine operation, fast and precise milling and levelling processes.
The side plate, for example, now has an active floating position, meaning it is lifted at specific intervals to keep it from sinking into the surface when the machine is at work on loose ground material, such as gravel. The scraper on the rear rotor plate also has new features, such as a sensor that prevents it from catching on any edges. The scraper is raised automatically in the process. An ultrasonic sensor determines the distance between the scraper and the milled material during partial transfer, in order to regulate how wide the scraper ideally should be opened. In this way, the material is optimally deposited behind the milling drum unit, increasing output and simultaneously reducing wear on the unit, the drum itself and the cutting tools.“The modern control technology in Wirtgen’s compact milling machines displays its advantages in terms of steering. In the 1 m milling machine W 100 CF / W 100 CFi, for instance, the right rear support wheel can be folded in automatically, without lowering the milling drum or manually loosening a bolt. In addition to the ‘basic position’, the right rear crawler track also has the new positions ‘outside’ and ‘folded in’. In the ‘outside’ position, the crawler track is located within the cutting diameter of the drum, enabling the machine to easily be positioned along the right-hand milled cut. In addition to the steering wheel, the operator also has access to an extremely sensitive, fingertip steering function in the multifunctional armrest,” explains Palagiri.
Optimally coordinated processes save time and money, and that applies not least to transferring the milled material. Wirtgen has practical solutions here as well. The conveyor’s extremely wide slewing angle of 60 degree in each direction makes it possible to transfer material even on difficult job sites, such as traffic circles or intersections. For high-precision material transfer, the machine operator can move the conveyor at two different speeds and due to the most advanced control technology, the conveyor speed is held constant even if engine speed fluctuates.
“With 261 KW, the W 130 CF is the second most powerful cold milling machine in the compact class. This front-loader is the ideal machine for large construction sites with confined space, such as in downtown areas. In these places, in particular, the advanced visibility concept, combined with the camera systems, provide critical assistance to the operator when he is maneuvering the machine,” states Palagiri.
For maximum traction of the crawler tracks, Wirtgen has adopted the central cutting drum design from its large milling machines. With an operating weight of 20.2 tonne, the W 130 CF can be transported without a special heavy transport permit, and that is another major advantage for completing milling jobs flexibly and quickly.
3. Hot Mix Plant
Introduction of new technology on hot mix plant which comes at a low cost of operation compared to conventional plants manufactured in India and this new plants has helped GRIL use of RAP very efficiently upto 35 per cent saving the environment and reuse of reclaimed material from the roads. Warm mix technology feature available with this plant helps produce bituminous concrete at low temperature and lay at lower temperature resulting to very less carbon emission while production and also during laying of pavement at low temperature.
“Equipment manufacturers from worldwide are aggressive in promoting mix technology which is increasingly finding acceptance by the construction industry. Few among them have already set up the manufacturing plants in India following government’s campaign on ‘Make in India’ which has made them cost effective and assurance to customers for better after market supports,” says Kashyap.
4. Soil Stabiliser
Another gradual shift is new road stabilisation technology and is visible due to availability of this technology and soil stabilisation machines.
“OEM supplies have played in a big role in promoting road stabilisation technology initially focusing on customer education and technical sales to client and concessionaire. Stabilising of existing soil on the road to the required CBR as per technical requirement helps regulate excavation of cultivable soil from the borrow areas. Introduction of cold recycling technology is being promoted by the OEMs for use in the industry,” concludes Kashyap.
————————Road construction contractors looking to minimise recurring variable costs throughout the life cycle of the paver will find reassurance in Volvo CE’s end-to-end service network.Dimitrov Krishnan, Vice President & Head, Volvo CE in India.