road project

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NORTH DAKOTA STATE UNIVERSITY

COLLEGE OF ENGINEERING AND ARCHITECTURE

DEPARTMENT OF CONSTRUCTION MANAGEMENT &

ENGINEERING

CME 701: CONSTRUCTION TECHNOLOGY AND

EQUIPMENT

Final Course Project: Planning and estimating one mile

highway project

By Moh’d Jawad Albakri

Submitted to

Instructor: Joseph Memba

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Introduction:

This report describes the process for planning one mile interstate highway between

Fargo and Grand Forks in the State of North Dakota. The road has two lanes in each

direction with a median between them.

Process outline:

The first step is stripping material and cleaning the site along with determining

the equipment, time, quantity and cost for this step. Then we need to haul the

material and fill them on the road for building the sub grade course and

determine the equipment, cost, quantity and time for this step. Afterwards we

need to haul the material and fill them on the road for building the sub base

course and determine the equipment, cost, quantity and time for this step. The

fourth step is to haul the material and fill them on the road for building the base

course and determine the equipment, cost, quantity and time for this step. Then

we need to pave the asphalt on the road according to best practices to build the

pavement layer along with determining the equipment, cost, quantity and time for

this step

Stripping and clearing the site:

Stripping and clearing the site will be applied to the whole road including the

median and the shoulders. This will include removing the overburden material for

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the whole site and removing clay for the whole site except in the median. Clay

will be beneficial for median landscaping. The overburden materials and clay are

hauled to the plant that is 10 miles away from the site. The first step is to choose

the right truck for hauling the overburden and clay materials. We should put into

consideration that the project is relatively small, so it is wise when hauling the

clay and overburden material to the plant, to take into consideration filling up the

truck with filling materials for the subgrade, sub base, base layers on the way

back. For this purpose we need hauling equipment that can haul the filling and

cutting material. Another factor will be that the slope is 2% and the tractor will be

operating off road, but it is in very good condition. Taking into consideration

that the truck needs to travel, 10 miles, the materials going to be free flow

materials and clay, and we need high capacity then Rigid Frame trucks will be

most suitable for this. The ADT has low capacity and speed, and the bottom

dump is not efficient for clay so the Rigid Frame is the most suitable choice. The

trucks will be filled to reach its heaped capacity. Heaped capacity saves a lot

when hauling. The weight of the material should be calculated to assure that the

truck can carry the weight. The project has to be done in seven to eight months.

We will assume that the project has to be done within 220 days and keep the rest

as contingency.

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Along with the truck we will need an equipment to strip the land and load the

material to the truck. Scrapers are economical to distance up to 5,000 feet

according to table 3.2 from the text which is almost a mile. Dozers are efficient to

distance up to 300 feet. The third option is to use excavators for cutting the

materials and filling the trucks. We will compare the time for the scraper to cut

the materials and hauling them next to the truck and excavator + the time

needed for the excavator to move the materials to the truck to the time needed

for the excavators to cut the materials and moving them to the trucks.

Dozer:

First we will start with a dozer. The dozer will travel a maximum distance of 300

feet. It needs trucks and loaders to load the material to the truck. We will test the

efficiency of the dozer for the overburden materials and compare it to the scraper

with the loaders and trucks and loaders with trucks alone. The first step is to find

the production of one dozer based on the project conditions.

For the dozer we will use big dozer because of the large amount of hauling. We

will use D10 N as it has high capacity.

Dozers

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Ideal production 680 lcy/hr

Material weight correction 2800

Weight Constant 27

Soil density to loos cy 2240 lb/lcy

Standard weight 2300 lb/lcy

Weight correction 1.026786

Average skill operator 0.6

Material-type correction factor 1.2

Operating-technique correction factor 1

Visibility correction factor 1

Efficiency 0.75

Machine transmission 1

Blade adjustment factor 1

Grade correction 1

Product of correction factors 0.554464

Production 377.0357 bcy/hr

Convert to bcy 301.6286 bcy/hr

Weight in bank state

pcf

Swell 0.25

C.of mass distance 300 ft

Downhill grade 0.02

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O&O 95 $/hr

Operator Wage 15 $/hr

Operator Benefits Percentage 0.35

Total Operator Wage 20.25 $/hr

Cost Per Cubic Yard 0.382092 $ per cubic yard

Amount Required 18773.31 bcy

Work Shift 8 hrs per day

Hours needed to finish the job 62.23984 Hours

Days needed to finish the job 8 days

Total Operating Cost 7173.142 $

From the analysis above it takes 8 days to haul the overburden materials 300 feet

with operating cost of almost 7,000$. We need to take into consideration that

when moving the material 300 feet the truck and the loader have to move as well

which will increase the cost.

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Scrapers:

Type Auger Elevating Push Pull

Use For rocks and hard

materials

For small quantities For large

quantities

We will make calculations for each equipment to determine the best combination. For

this project we will use Push Pull scrapers. We will choose the Cat 657G scraper as it is a

push pull and has a high capacity. Scrapers are economical for distance up to 3,000 feet

but can reach till 5,000 for larger equipment. We will have trucks and loaders in the

middle and at the end of the site so the average hauling distance will be 2600 feet,

because it will take for the first trip 5200 but for the second it will be less and less till it

reaches next to the trucks and the loaders. Other trucks and loaders will be at the end of

the site. The rolling resistance for road will be estimated as 60 lb/ton as the it is in

excellent condition but not compacted which equal 60/20 = 3% . We will haul the

material in the slope that is going downward so the grade will be – 2% then the total

resistance will be 1%. According to the performance chart the speed will be at 35 mph

for 1% total resistance in both loaded and unloaded, this is taken from the Cat manual. It

is found that it takes 5.4 days to finish the whole work in comparison with the dozer that

requires 8 working days. This is big difference. Add to that, the trucks and the loaders

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don’t need to travel every three hundred feet to catch up with the dozer. The trucks and

the loaders should be at the end of the road and they will be loading the trucks which will

make the loading time a lot faster and more efficient.

Swell factor 0.75

Scraper type

Distance 5280 ft

Condition Normal

Avg haul speed 35 mph

Avg return speed 35 mph

Efficiency 0.83333333

Avg speed for acce. And deacce. 4 mph

Average distance 2600 ft

EVW 150761 lb

Load size 44 lcy

Load size 33 bcy

Unit weight 2800 lb/bcy

Load Weight 92400

Gross Weight 243161 lb

Loading time 1 min

Haul time 0.84415584 min

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Return time 0.84415584 min

Dump time 0.6 min

turn time fill 0.21 min

turn time cut 0.3 min


Total cycle time 3.79831169 min

Operator 11 $/hr

O&O 89 $/hr

Total Cost 100 $/hr

Production per hour 434.403529 bcy/hr

Total required quantity 18773.3146

Hours required to whole quantity 43.2163031 Hrs

Days 5.40203789 Days

Total Cost 4321.63031 For Job

Cost per cubic yard 0.23020071 $/bcy

Based on the above comparison we will use a scraper for this kind of job. We will now

analyze removing the clay from all areas except from the median. The rolling resistance

for clay is different than for topsoil. This step is when the top soil is already removed.

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Rolling Resistance 170 lb/ton

Rolling Resistance 8.5 %

Grade Resistance 2 %

Total Resistance Return 6.5 %

Total Resistance Haul 10.5 %

Material Clay

Swell factor 0.75

Scraper type 657G

Total Distance 5280 ft

Condition Normal

Avg haul speed 22 mph



Avg speed for acce. And deacce. 4 mph


EVW 150761 lb

Load size 44 lcy

Load size 33 bcy


Load Weight 89100

Gross Weight 239861 lb

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Loading time 1 min



Dump time 0.6 min





Operator 11 $/hr

O&O 89 $/hr

Total Cost 100 $/hr


Total required quantity 21902.2003

Hours required to whole quantity 68.9048946 Hrs




According to the above calculations it will take 15 days to remove the topsoil and clay.

All the materials will be hauled where loaders and trucks are there to move them to the

plant. Trucks should not come back empty, they should get filled with the materials that

are required for the different layers for the road construction.

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We will use two scrapers to remove the overburden materials and clay which equals 7

working days because we will divide the total days by two as two of them are working on

the same time.

Loaders:

First we need to choose the appropriate loader for the project. We will choose the loader

first to find the balanced number of trucks afterwards. All the needed information is

available to estimate the production. We need to check tipping and all other factors that

affect production, which is shown on the following table.

Loader

Model 990K

Material Overburden

Unit Weight 2240 lb/lcy

Swell Factor 0.8

Static weight table 9.8 150,000

Load weight 41070.4

Fill Factor 0.95


Bucket Capacity 19.3 lcyd

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Bucket Capacity for the material 18.335 lcyd

Cycle time 0.666666667 min

Cycle time 0.011111111 hour

Static check 33929.6 OK

Materials required to move 18773 bcy

Materials required to move 23466.25 lcy

Production 1375.125 lcyd/hr


Production 1540.14 ton/hr

Hours needed 17.06481229

Days needed 2.133101536 days

From the above, it takes just 17 hours to haul all the overburden materials to the trucks.

This also show that the loader can travel to materials that where hauled at 2300 feet and

at the end of the road by the scrapers. The loader needs to travel to six locations which

will add extra time so we will take that it takes 3 days to fill the trucks with all of the

overburden materials.

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Loader

Model 990K

Material Clay

Unit Weight 2000 lb/lcy

Swell Factor 0.75

Static weight table 9.8 150,000

Load weight 36670

Fill Factor 0.95


Bucket Capacity 19.3 lcyd

Bucket Capacity for the material 18.335 lcyd

Cycle time 0.666666667 min

Cycle time 0.011111111 hour

Static check 38330 OK

Materials required to move 21902 bcy

Materials required to move 29202.66667 lcy

Production 1375.125 lcyd/hr


Production 1375.125 ton/hr

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Hours needed 21.23637245

Days needed 2.654546556 days

Here it takes another 3 days (including traveling time between dumping locations) to fill

all the tractors. This shows that one loader is a good balance for two scrapers. The total

time that is estimated to fill all cut materials is 6 days. There will be one extra day that

makes a difference between loading all the trucks and the scraper work. This mean that

we can bring the loader one day after the scrapers start working if we are renting it to

save money. Here in the sketch it shows where are the dumping location should be

where scrapers can dump the materials and trucks can dump the materials that are hauled

from the plant that are needed for the road layers.

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Trucks:

The first and most important step is to balance the trucks numbers with the loader. We

need to do all the required calculations. We need to find the total cycle time which equals

dump, load, haul going and haul return for the truck. We need to take efficiency into

consideration. We will use the performance charts with the total resistance to determine

the speed. Though the truck can travel at maximum speed but 35 mph should be safe

enough. We then balance number of trucks to the loader to find the balanced number. All

the calculations were done on the following table for the overburden materials. We take

into consideration that the trucks will come back hauled with the filling materials, this

should save a lot of money. We can till from both calculations that the hourly production

for clay and overburden materials are almost the same, this should help us to determine

the quantity of material that the truck will have when coming back.

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Material Overburden Swell 0.8

Truck Model 770G Truck Capacity Heaped 32.9 lcy

Balanced number of buckets 2 Dump time 1 min

Load time 1.333333333 min

Load weight 73696 lb

EVW 73254 lb

GVW 146950 lb


Rolling Resistance 3 %

Total Resistance going 5 %

Total Resistance coming 1 %

Going speed 35 Mph

Coming speed 35 Mph

Hauling Distance 10 miles

Hauling Time going 17.14285714 Min

Haul Time coming 17.14285714 Min

Total cycle time 36.61904762 Min

Truck production 45.82041612 lcy/hr

Balanced number of trucks 27.46428571 Trucks

Number of trucks 28 Trucks

Trucks cost 55 $/hr

Total trucks cost 1540 $/hr

Material to be hauled 18773 Bcy

Material to be hauled 23466.25 Lcy

Hours needed 18.29054443 Hours

Total cost 28167.43843 $

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Material Clay Swell 0.75

Truck Model 770G Truck Capacity Heaped 32.9 Lcy

Balanced number of buckets 2 Dump time 1 Min

Load time 1.333333333 Min Load time (fill materials) at plant 1.333 Min

Load weight 65800 Lb

EVW 73254 Lb

GVW 139054 Lb



Total Resistance going 5 %

Total Resistance coming 1 %

Going speed 35 mph

Coming speed 35 mph

Hauling Distance 10 miles

Hauling Time going 17.14285714 min

Haul Time coming 17.14285714 min


Truck production 44.2110533 lcy/hr

Balanced number of trucks 28.46403571 Trucks

Number of trucks 28 Trucks

Trucks cost 55 $/hr

Total trucks cost 1540 $/hr

Material to be hauled 21902 bcy

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Material to be hauled 29202.66667 lcy

Hours needed 23.59030838 Hours

Total cost 36329.0749 $

At this point all the overburden materials and clay materials are removed and similar

quantity of filling materials are brought to the site. As it is specified in the specifications

the ACC is 6’’. The subgrade materials are from mixed rocks and soil with unit weight

2950 lb/cy with 0.7 swell factor and 13.5 $ per ton. The subbase also from the rocks and

soil mixture that are obtained from the plant. Base course will be from course and fine

aggregate. We need first to determine the quantity that is needed for the subgrade layer

and subbase layer. For this we need to find the thickness. According to North Dakota

Asphalt conference for the subbase it is 16’’ and the subgrade it is 5’’ inches and 9’’

inches for the base course. The pavement is 6 inches from the project information. This

total is 36 inches which equal to the materials that have been removed from the site. The

total volume of materials to be hauled from the plant is 24640 cyd which means there are

no need for additional trips just to bring filling material and their cost and time are

included in hauling the cut materials.

We need now to spread the materials using the scrapers and rolling them to get the

subgrade, subbase and base courses then we can pave the highway with Asphalt. The

scrapers will load the materials. As all the materials are similar we will treat them as one

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kind for saving time, as this project was supposed to be group project and it is done by

one student. With two scrapers it will take almost 6 days to spread all the materials on

the road.

Rolling Resistance 170 lb/ton



Total Resistance Return 1 %

Total Resistance Haul 5 %

Material Fill materials

Swell factor 0.7 Scraper type 657G

Total Distance 5280 ft

Condition Normal Avg haul speed 35 mph


Efficiency 0.83333333 Avg speed for acce. And deacce. 4 mph


EVW 150761 lb

Load size 44 lcy

Load size 30.8 bcy


Load Weight 90860 Gross Weight 241621 lb

Loading time 1 min



Dump time 0.6 min



Efficiency 0.83333333 Total cycle time 5.53857143 min

Operator 11 $/hr

O&O 89 $/hr

Total Cost 100 $/hr


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Total required quantity 24640 Hours required to whole quantity 88.6171429 Hrs




Number of scrapers 2

We need rollers to compact the layers behind the scrapers. As the production of the two

scrapers are not very high because of the traveling one roller would be enough roll all the

layers. From bellow even one roller can be enough for both scrapers. Roller is not on the

critical path so the time needed to finish the job is not critical. We will need the roller for

6 days to roll after both of the scrapers with daily operating cost of 400$ and then 2800$

for the six days.

Number of rollers

Compacted Width of Roller Pass 7 feet Speed 3 mph Compacted lift thickness 36 inches Number of passes req 16

Constant 16.3 Effecincy 0.833333 Compacted cubic yard per hr 641.8125 ccy/hr

1 bc = ccy 0.7 Bank cubic yard per hr for roller 916.875 Fill Rate in bank 278 cy/hr

Fraction 0.303204

Number of rollers 1

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The final step is to pave the asphalt. First we need to apply a prime coat using an asphalt

distributer.

Asphalt distributer

residual application 0.035 gal/sy Length 5280 ft Width 56 ft Constant 9

emulsion rate 0.7 Amount of water 2

Liquid asphalt cement 1149.867 gal

Total gallons of emulsion 1642.667 gal Total gallons of diluted emulsion 1888848 gal Application rate of diluted emulsion 0.1 gal/sy

Paver

Model Ap600D Paving Width 24 feet

Paving speed 65 ft/min Road length 5280 ft Required time 1.353846 hrs Return speed 10 mph Number of lanes 4

Total hours 5.415385 hrs

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It takes 5.4 hours to pave the four lanes. The roller has to be driving after it as required in

the specifications.

Rent VS Buying

It is appropriate some times to rent instead of putting a lot of investment in projects that

don’t come often or when the company is just starting. Quotes were taken from a dealer

in North Dakota, Butler Machinery Company, though Oscar knew that it was a

university project but still provided me with renting rates. Here is an example from the

rates:

D9T with U dozer and rear ripper = $18,400/4 weeks with $96/hr. for excess hours

657G = $50,150/4 weeks with $214/hr. for excess hours

988K = $25,250/4 weeks with $108/hr. for excess hours

770G = $16,650/4 weeks with $71/hr. for excess hours

Based upon 160 hours of use per 4 weeks.

From the above rates it is practical to rent an equipment that we need for few days such

the paver instead of spending a lot of money on buying one. This is a one mile project so

most likely the company is fresh and would not want to invest a lot in machines. More in

depth analysis can be done but for time limitations this is what has be done for the one

mile project planning.

road project

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