Maximizing Construction Equipment Operator Potential for India

It is because the top car companies still believe that the person driving the machine needs to be the best to get the best out of the machine.

However, when it comes to India and especially the construction equipment segment the fact that “The man defines the machine” goes for a toss. We have seen numerous sites where people purchase high end imported machines only to be operated by personnel who barely have a legal driving license leave alone proper formal training and education to operate the machine.

Will such operators be able to get the maximum out of the machine? “NO”.

Will they be able to make more profits for the contractors? “NO”.

Will they be able to ensure uptime of the machine? “NO”.

Can this scenario be changed? “YES, definitely”.

So how do we bring about this change? Below are a few steps that contractors can effectively use to turn around this scenario.

TRAIN YOUR OPERATOR

Almost all construction equipment companies in India provide training for operators. Most of them financed by the company fully or at least partly financed. Contractors need to jut ask the company representatives and get their operators enrolled. The operators not only get trained and operate the machines to get more productivity, maintain the machine well and get higher uptime from the machine resulting in better profits but will also somewhere be grateful to the contractors to have them educated and invested in them. Operators feel a lot of pride in being respected by the contractors and this is one of the easiest and best ways to demonstrate the same. These trainings can be done in monsoon time when both the operator and machine are idle to ensure no productive time loss.

INCENTIVIZE OPERATORS BASED ON PERFORMANCE

Just like contactors get incentives for quick project completion, a similar mechanism can be put in place by contractors to get better productivity out of the operators and machines. If contractors can incentivize meeting daily work targets, zero breakdowns on monthly basis and meeting additional productivity targets, the operators will learn quicker, operate faster and maintain the machine better. An additional monthly expenditure of thousands can earn lakhs and even crores additionally for the contractor.

CARE FOR THE OPERATORS

Having a group Mediclaim for operators and their immediate family costing a few lakhs can ensure higher retention of operators and resulting in higher uptime. Otherwise in the time a couple of operators quit and their replacements start work, lakhs in machine idle days is anyways lost. Apart from this, getting insurances will also add brand trust for the contractors. This will especially go a long way in the current COVID scenario.

TRAINING FROM OEMs ON BUYING NEW MACHINE

Request your equipment manufacturer to get your operator and maintenance team trained if you induct a new product. Most manufacturers also look forward to such requests as trainings will ensure better machine usage and good feedback from user. From an operator standpoint this is important so that he gets the necessary confidence and learns quickly to use the machine effectively.

INCLUDE OPERATORS IN MORNING MEETINGS/DAILY BRIEFINGS

The operators crave for respect and their right place in the scheme of things mostly even more than money. When they are included in ground level meetings it helps to get them aligned to meeting the bigger project timelines. They also understand how important their role is and look forward to delivering. This also emphasizes the importance of their work to the operators and achieving the target gives them a strong sense of satisfaction.

ENSURE TIMEPLY SALARY PAYMENTS

Although managing cash flows is the construction line is not an easy thing but when we spoke to operators many of the good operators who were working with small and big contractors for years did so not because they were paid higher but because they were paid on time every month and respected for their work. Operators see timely salary payments as a big plus and this will go along way in operator retention. When salaries get delayed the operators see that as a sign of financial struggle and start looking out for other options as they feel the company/contractor is struggling. If not full salary payment on time, at least a part payment at the start of the month might ease the financial stress to a great extent for the operators on the personal front.

Listed above are simple steps which will ensure that operators are technically and emotionally poised to give their best resulting in higher productivity, profits, uptime and machine life for the contractors.

You can try these out and let us know your thoughts on the same. We also look forward to hearing from all of you on any other ideas that you may have in this context.

Five Profit-Draining Operator Errors and How to Spot Them

This is because it is only they who can avoid major accidents which can cause heavy damage to the equipment and people, by safely handling the equipment. That said, operator behaviour not only affects the machine health but also the profitability in the longer run. This makes formal heavy equipment operator training very important. However, many construction companies don’t look at this aspect and don’t hesitate in hiring a novice or inexperienced operator believing that their equipment is highly advanced and it might not need an experienced and skilled operator. Well, to tell you the truth, it is a wrong notion and this can result in various profit-draining errors operator errors. Here is a look at these errors and how to spot them as soon as possible.

1. Increased number of accidents at the jobsite

Accidents and mishaps are bound to happen at any construction site but they should be once in a while. If accidents increase at the jobsite considerably, then it should ring an alarm in the construction company’s or contractor’s ears. In fact, that time, companies or contractors should think about sending their operators for training. This is because untrained operators generally put themselves, those around them as well as the equipment at high risk. Hence, as soon as it is observed that there are increased accidents or near misses or there is a breakdown in general safety practices by the operator, it is time to act immediately and send the operator for training.

2. Equipment starts using too much fuel

Fuel is a huge cost associated with construction equipment and companies as well as contractors are always on the lookout to save the fuel cost. For that, efficient operation is the key. An experienced heavy equipment operator may generally know that if there is excessive amount of idling or equipment is always running at full RPMs, if not required, then the wasteful consumption of fuel can increase considerably. However, if he does not know then it is time to send your operator for acquiring training as he is not aware of the proper machine use and jobsite setup. For example, as per the experts, an unskilled operator can increase the idle time by 40-50 per cent of total running time and this can result in a gallon or more of wasted fuel every hour. However, on the other hand, by reducing the idle time, a skilled operator can reduce the fuel consumption by 10-12 per cent.

3. Parts are replaced more than often

If you observe that your heavy equipment parts or components have to be replaced more than often despite the guarantee of long life offered by the manufacturers, then it is time to act upon quickly. That said, harsh jobsite conditions may also be the reason for the frequent need for equipment part replacement but that does not rule out operator’s lack of experience and training. In fact, on most occasions, it is the inexperienced operator that run the equipment improperly and this results in excessive wear or early-hour failure with high-cost items like tires etc., wearing out way ahead of schedule. This makes operator training a must.

4. Deadlines are missed most of the times

Project delays can harm the image of any construction company or contractor and can result in losses in the long run. Project delays can be caused by a variety of factors including untrained operator which can disrupt productivity and put the company behind schedule. This is because untrained operators are likely to make more errors that can cause rework or misuse of equipment in ways that can lead to unscheduled downtime. So, if the deadlines are flouted more than often, then the companies or contractors should think of sending their operators for training. This is because the trained operators know as to how to get the most out of their machine and perform the task quickly and accurately.

5. Machine technology is under-utilised

The present-day heavy equipment like motor graders or backhoe loaders are highly advanced and come with various built-in technologies to reduce fuel consumption and improve accuracy. However, if companies observe that the technology of the equipment is not completely utilised and the results are not quick, then it is the time to look at the operators behind the controls. In order to get the maximum ROI from the technologically-sound equipment, trained operators who can use the machine effectively should be employed by the companies and contractors.

Thus, above mentioned five profit-draining operator errors make it necessary for the companies to employ trained operators. Realising the growing need for operator training, various private heavy CE manufacturers in the country are coming up to bridge the skill gap by establishing their own training centres in various parts of the country in addition to introducing various certification courses for operator training. One such manufacturing giant in India is Mahindra Construction Equipment (MCE).

MCE’s initiative

MCE has six regional training centres across the country which imparts expertise and provides training on aspects such as equipment operation; daily, weekly and monthly equipment maintenance, and safety parameters. Apart from this, if you buy motor grader or backhoe loader from MCE, then as part of its post-sales services, the company offers few days’ dedicated training for the operators, in which they are personally trained on the various features of the machines by professional trainers.

In a nutshell

One small heavy equipment operator error can result into huge losses for the construction companies or contractors. So, it is necessary that heavy equipment operators are trained well as they can ensure maximum profit by utilising the equipment in the best possible manner.

Things You Should Not Do with Your Bachkoe Loader

Confused? Well, it simple means that precautions need to be exercised while operating the BHLs as otherwise they can cause major accidents at the site and prove costly in a variety of ways. That said, you can avoid any problems with your BHL by following simple safety tips during operation. Further, clearly knowing about things that you should not do with your BHL at the jobsite can also help. Here is a list of those things…

What you should not do with your BHL?

1. Never start the Backhoe Loader in gear as if there is any person either behind or in front of the tractor wheels, he/she could be run over before they can get out of the way.

2. Turning uphill on a steep slope should be avoided as they can cause overturns.

3. Turning too fast on a downhill slope may also cause an overturn, so that should be avoided too.

4. It should be remembered that swinging a bucket of dirt downhill changes the centre of gravity in a negative direction.

5. If the bucket is raised very high when loaded especially on an uneven ground and in turns, then the loader may overturn. Here, it should be noted that you should not raise the bucket too high as otherwise it can make the BHL more unstable.

6. Take care to not hit anything such as a ditch, stump or hole while moving, as the operator can fall and this can even cause overturn.

7. Never lift heavy weight with the front loader without ensuring that adequate counter weight is used at the back, otherwise the equipment may tip off.

8. There may be a slight bounce if the tires carry the weight of the machine and this can also transmit vibration to the operator and into the controls. This can also cause the machine to shake even more. Hence, care should be taken.

9. If the stabilizers are down, then you should not use the Backhoe Loader at all.

10. The hoe of the BHL should not be used without the stabilizers being down enough to support the weight of the machine.

11. The speed of the BHL should never be kept high when working on rough or uneven terrain and when there are people around.

Thus, it is mandatory that the BHL operators think about every single move they make with the equipment.

What can you do with your BHL?

Now you might be wondering if you should not do the above things with the BHL, then what should you do with the equipment to get maximum efficiency and productivity. Well, here is a look at those things as well…

1. The Backhoe Loader should be made stable as much possible when lifting heavy objects. The equipment should be kept in level with the front and rear tires raised clear of the ground by around six inches. The stabilizers should be spread as far apart as possible without letting any tires touch the ground. Proper lifting equipment should be used and the lifting should be done at low idle for maximum control.

2. The equipment should be levelled as much as possible by using the independent stabilizers and your front bucket when you are in operating position.

3. If the BHL has to be operated on the side of a hill and the BHL can’t be brought to a level, then operators should try as much as possible to swing uphill with the loaded bucket and downhill with the empty bucket.

4. In case of trenching while facing uphill, the hoe should be put into its tucked position, then the seat should be turned to the forward facing ready-to-drive position before raising the stabilizers.

5. Precautions should be taken while transporting materials. You should try to carry materials in a level or racked-back position.

To sum up…

Well, if the above-mentioned precautions are kept in mind, then accidents with BHLs can be reduced drastically and BHLs can prove to be the best equipment at the jobsite. These small but important tips can help to increase the productivity as well as efficiency of the equipment to a very large extent. Here it should be noted that if the BHL is from Mahindra Construction Equipment (MCE), then the operators can do much more with the equipment as MCE offers best-in-class equipment with best of safety features.

Useful Techniques for an Experienced Motor Grader Operator

Given that motor graders are a very expensive equipment, it is imperative that they are used wisely by the operator every time to give the best result. In fact, motor grader operators need to always adopt best of the techniques to bring about an improvement in equipment’s performance that can positively impact the productivity at the jobsite.

We list here some of the techniques and tips that can be an eye opener for a novice but also definitely useful for an experienced motor grader operator. In fact, it is these techniques and tips that if practiced, can differentiate an experienced motor grader operator from a novice.

Top tips for the motor grader operators

In order to operate and maintain the motor grader effectively at all times, here are some useful tips and techniques for the motor grader operators…

1. Motor graders can face wear and tear due to harsh or rocky terrain. Thus, operators need to safely handle the equipment at any such site and prevent any unnecessary damage to the equipment. Only required amount of downward pressure should be applied by the operators as excessive pressure on hard and dry surface can cause rapid cutting-edge wear and will require more horsepower and fuel, thereby, reducing productivity.

2. Correct positioning of the moldboard is important. So, experienced operators need to always keep it straight up as rolling the grader blade forward makes the edge blunt.

3. In order to keep the motor grader blade sharp, experienced operators need to keep top of the blade just slightly forward of the cutting edge, so as to pitch the blade forward only when its necessary to make a cut.

4. Operators should change the blade angle periodically. If the moldboard is kept forward, it might result in wear just along the front of the cutting edge. Hence, periodically tilting it back like in case of carrying, mixing, spreading or combing material can even out the wear across the edge, thus, keeping the blade even and sharp.

5. For light and free-flowing material, moldboard angles of 10 to 30 degrees should be used and when processing of wet and sticky material, mixing large windrows and ditching is required, higher moldboard angles of 30 to 50 degrees should be used by operators.

6. While grading along gutters and curbs, operators need to pay extra attention to the task as any slight error can result in the machine running up against the curb and the edge being chipped as well as the moldboard being highly affected.

7. When sacrificing or ripping across a slope, operators need to keep the moldboard parallel with the front axle, centred to the frame and lowered close to the ground to provide protection against rolling over.

8. When using the ripper, operators need to lower the teeth into the ground with the grader in motion. If the rear wheels lose traction, operators need to raise the ripper until the wheels regain traction. For especially hard surfaces, operators should reduce the number of teeth. To break old pavement, teeth under the pavement should be lowered and the ripper should be raised. The ripper should not be used when turning. This reduces wear on the equipment.

9. Operating speed of the motor grader highly affects the quality of work. So, while ditching or blading, there should be no hurry. Higher speed can sometimes cause the motor grader to bounce and gauge the surface rather than smoothen it. Sometimes, in extreme cases, bouncing can cause the operator to lose control of the grader, producing a potential accident situation. So, operators should keep the machine travel speed low enough to prevent machine bounce (generally 3 to 5 mph).

In a nutshell

Above mentioned are some of the many useful techniques that can come handy even for the experienced motor graders. These techniques if followed by the motor grader operators can ensure that the equipment gives maximum productivity at the jobsite. Well, here it is to be noted that if you buy motor grader from Mahindra Construction equipment (MCE), then it can also help in training your motor grader operator. This is because as part of its post-sales services, MCE offers few days’ dedicated training for the operators, in which they are personally trained on various features of the machines by professional trainers. Thus, this can increase the skills of the operators and teach them the necessary techniques and methods which can make them an experienced motor grader operator in the longer run.

Building a Great Gravel Road: 10 Basic Principles

Hence, it becomes imperative to ensure that the gravel roads that connect most of the rural areas of the country are properly built.

However, building a gravel road is not an easy task. It involves meticulous planning, preparation and usage of specialised equipment. This is to ensure that the road is smooth, has uniform surface which can handle all types of loads and does not break easily in extreme weather conditions.

So, whether you aim to build a short stretch or a complete network of gravel roads covering a large area, it is imperative that you understand the basics of building a gravel road. Thus, in order to get a detailed insight about how to build a great gravel road, read on the pointers below…

1. Determine the road usage

Which type of vehicles would be using the gravel road will define various things in the gravel road construction process. In fact, if you have this information, then you can easily determine the ideal path and width of the road as well as the required depth of the base material.

Take an example, in case of a gravel road that is intended to support heavy-duty vehicle, the road has to be kept rather straight with less curves and switchbacks to accommodate the limited manoeuverability of the heavy vehicles. Further, it would be much stronger than the gravel road which is intended for light vehicles and low traffic volume.

2. Get the right machinery and operator to work:

A lot depends on the road construction equipment that is used. Like in the case of any other type of road construction project, gravel roads also need the right machinery which can build quality road and extend its service life.

Not only having the right equipment is important but it is equally necessary to hire an experienced equipment operator. Take an example, if you are using a motor grader, then the operating speed of the equipment along with the angle and tilt of the moldboard can either make or break the road. Here, it is worth the mention that only an experienced motor grader operator will know these tactics and principles well. So, the importance of hiring an experienced equipment operator cannot be undermined.

3. Use the right materials

Just like using the right equipment and operator is important, making use of the right material as per the need is also equally necessary. Like if you wish to have a dry and stable base, then soils with high clay content or moisture should not be used at all. Typically, in order to build a smooth and firm top surface of the road, best quality of gravel consisting of a combination of fractured stone, sand and fine particles with a binding characteristic should be used.

4. Compact the soil properly

Like grading, soil compaction is also one of the most important processes in gravel road construction. Soil compaction helps in reducing the volume of water and air in the soil. This helps in creating a harder, denser and more durable surface that can resist heavy traffic and extreme weather conditions easily.

5. Build a base that is solid:

It goes without saying that on a stabilised base, a good gravel road is built. In order to obtain a stable foundation, binding agents such as cement, calcium chloride, salt or lime should be mixed into the soil using a stabilising machine. Then the soil compaction process should be carried out to get a firm foundation.

6. Construct the gravel road in layers

Gravel roads should always be constructed upwards in layers from a stable base. Before applying the final surface layer, the base layer should be allowed to harden and settle. If the base is poor, then the quality of the road would not be good and then no amount of top grading can save that road.

7. Design the road to sustain extreme conditions

The gravel roads should be designed and built in such a way that they sustain heavy vehicles, high traffic volumes as well as worst weather conditions. In cases where the road would be used by large trucks, make it a point to never use gradients more than 10 per cent. You also need to ensure that the road is wide enough to accommodate all types of vehicles travelling in both directions.

8. Ensure proper drainage

It is a known fact that those gravel road last longer and require less maintenance that have proper drainage. If crowns and shoulders are properly shaped and there are appropriate ditches, culverts and drains, then water can be easily channelled away from the gravel road surface.

9. Apply surface strengthening solutions

Bituminous surface treatment should be done when you want to make the gravel road smooth and free of cracks, ruts and potholes. This also makes the surface hard, all-weather and water-resistant.

10. Maintain the road regularly

Regular grading of gravel roads is necessary to keep them in good condition. Common maintenance tasks may include reshaping the road, clearing the drainage system of foliage and rubble and removing any excess material.

Thus, by following the above mentioned points, a great gravel road can be constructed. In addition, construction equipment like motor graders can also help in doing so. Particularly, Mahindra Construction Equipment’s Mahindra RoadMaster G75 which is made in India for the Indian roads deserves a special mention here. It can serve as an ideal grading machine for spreading and grading of earthwork in different types of roadwork including the gravel roads across the nation.

How Motor Grader Can be Used for Cutting Ditches?

Among all, one of the most important earth-moving jobs that is performed by motor graders is cutting ditches. In order to carry out this task well, it is imperative that the motor grader operator is experienced enough to use well all the features of the motor grader. In addition, he should know about creating proper crowns and slopes.

Typically, ditch slopes differ on the grounds of soil type, the gravel used, ditch depth and width, expected rainfall in the region and so on. While the ditch slope types may differ, certain standard best practices remain the same for cutting all the ditches. The general rule is that wherever possible, the ditch slopes should be flatter than 2:1 or 50 per cent.

Various types of ditches and things to be kept in mind

In case of Vee-ditches, they should be at least 2-feet lower than the road wear surface but their depth can vary depending on road and soil type and available right of way. On the other hand, a flat-bottomed ditch can handle large amounts of rain or snowfall and cutting flat-bottomed ditches can supply extra material if it is needed to elevate the road. In regions subject to extreme precipitation, it is required to raise the travel surface high enough to prevent water from seeping under the road.

The basics for cutting ditches

1. To begin with, a line marked with visible stakes should be laid out. This can help you to cut straight. Then you need to move the blade at a sharp angle, so that its leading edge or toe is pulled tight behind the front wheel and its heel is raised. To simplify, the steps to establish a marking cut includes:

a) The moldboard should be high enough off the surface to allow unrestricted movement.

b) The blade should be pitched halfway.

c) You need to shift towards the centre until the left lift heel is straight up and down.

d) The moldboard should be rotated so that the toe is just behind the outside edge of the right front wheel.

e) If necessary, then you need to side shift the blade so as to extend the edge of the moldboard to the outside edge of the right front wheel.

f) The left lift cylinder should be raised all the way.

g) The front wheels should be leaned towards the left. The grader is then in the ditching position.

2. After following this step, it is easy to do the marker pass. Now, you have to drive along the line that is set, cutting out about two to four centimetres. Here, it is to be noted that if you cut away too much at this point, a steering trouble may arise.

3. Keeping the setting same, the front wheel should now be included in the marker cut, with a bit of load on the machine to do the next pass. This pass should be performed in the first gear only.

4. As the next step, in order to deliver the material on the outside of the wheels, on both the ends, the blade should be tighten. The windrow should be straddled so that it can be shifted from the bank of the ditch.

5. In case of deeper ditches, you will have to repeat these steps barring the marker pass one. In order to maintain a straight ditch, make it a point to have the front wheels lean up the slope.

What to be done for a back slope?

For a back slope, the following steps should be taken…

1. One set of wheels should be on the outer edge of the ditch and the other should be at the bottom of the ditch.

2. Always keep the leading edge down enough to cut the slope and the heel down. It should be angled in such a position to give the needed windrow.

You need to keep both the leading edge and heel of the blade inside the wheels and almost parallel with the machine so as to clean the windrow from the ditch thoroughly. When you are driving, one wheel should be in the bottom of the ditch and the other should be on the first slope. In order to avoid cutting too deep, both the ends of the blade should be set tight.

Finally, keep the blade set at the usual sharp angle and take the material up the slope for removal so as to clean the bottom of the ditch.

What to do in case of a flat-bottomed ditch?

The same procedure is used for creating a flat-bottomed ditch. However, one thing should be remembered that the blade level should be kept at a position so as to avoid material leaking into the bottom of the ditch. Do keep in mind that the angle of the blade determines the width of the slope.

Other things to be kept in mind

1. Ditches should be at least 2 feet lower than the road travel surface.

2. More forward tip is required for proper cutting-edge-to-material contact when you want to cut high bank slopes or deep ditches.

3. In case of soft shoulders, you can cut the ditches without rutting them by following few steps. This includes articulating toward the moldboard toe or the leading end far enough that the toe-side front wheel can be driven into the bottom of the ditch and the heavy tandems up on the road-wearing surface can be left behind. The link bar should be left in a centre position. Then the mouldboard should be circled to an angle which promotes smooth material flow up out of the ditch and side shift for the desired reach into the ditch.

4. The moldboard’s tailing end should always be raised to match the ditch slope. The top of the moldboard should be tipped about two inches in front of the cutting edge.

Thus, by keeping the above mentioned points in mind, an experienced motor grader operator can easily cut ditches and obtain the desired results.

How to Grade a Road with a Motor Grader?

Thus, it can be clearly stated that it surely takes time and patience to master the road grading job. Even the operators who are pro with motor graders have to keep on evolving themselves to produce better results.

What makes operation of motor graders a bit difficult is that this single equipment is highly versatile and can perform multiple tasks from mixing asphalt to grading shoulders. And each task generally requires different tricks and practices to get the best result. However, the general motor grader operating tips remain the same.

General operating tips

1. The materials should not be moved regularly as this can cause damage.

2. If there is good compaction, trimming becomes much easier. To make the blade steady, some weight can be put over it. This is better than being overly concerned with having material on the blade while trimming.

3. It is better to get familiar with all the blade movements which is made possible by the hydraulic controls, as they are suited to different tasks. Some cases may require a combination of some or even all of the blade movements. You should be fully aware of the settings and even the angles and heights.

4. A loose blade can be chosen for spreading loose material or spreading and a tight blade can be chosen for reshaping an area by cutting down into it. Most of the times, you will be needing these two options at different stages.

5. You should know that the moldboard can be lifted from both the sides so the blade is at a level height (for levelling an area etc), or you can have just one side raised, if your surface needs to be sloped.

Grading the road with the motor grader

The starting process

To begin with, in order to dress the road, some moisture is needed. Recent rains can do this task or the road should be made wet using water from a water tank. It should be ensured that there is good drainage. Another thing to be kept in mind is that the curves should have super elevation and road crown should be in straight sections.

Straights, slopes and bends

The wear surface should rise at about a three percent slope from the shoulder to the road centre in case of the straight road. Here, the gravel type and area’s rainfall should be taken into consideration. Curved roads need to be flat but with an incline that has a six per cent slope down to the inside of the corner.

The cutting edges should be trimmed with a torch so as to keep them absolutely straight. You need to check for any blade wear as then it would be needed to replace it so as to avoid any wear on the bottom of the moldboard.

The road crown should be shaped properly. If still there is moisture on the ground, you can cut lightly in the spring.

Ditches and surfaces

In case of hard and dry road surface, the cutting edge should be dragged along the surface, however, it should be set about 90 degrees to the surface.

In case of ditches, the soil and road type as well as the right of way should be considered. Generally, the rule is that they should be about five centimetres or two inches lower than the road wear surface.

The road surface should be elevated considerably in areas with high rainfall so as to avoid water running beneath the road. This can also cause potholes.

The right speed and modlboard angle should be chosen before starting the grading process. When the work is delicate, you need to be slow and when you have to remove rocks from a road surface, then you need to move fast. By making use of the various moldboard angles (between 10 to 45 degrees), you can make a smooth motion as against just bulldozing your way forward.

In the link bar, there are several holes or positions that allow the operator to choose as to how far offset the circle from the frames centre line. Generally, first and second holes should be used for cleaning shallow ditches and moving large windrows and combined with articulation to build narrow and flat-bottom ditches.

Potholes

You should cut straight to the depth of a large pothole. Here, it is to be noted that loose material should not be filled in the pothole if you don’t want the pothole to form again. When you are performing road maintenance, then it’s best to have the centre-shift lock pin centred with the drawbar and circle also centred beneath the mainframe.

If you want the equipment to be stable, then the mainframe should either be straight or articulated only a little. By keeping the mainframe articulated towards the mouldboard’s toe at about 1 to 1.5 times the tyre width, the machine can be prevented from bouncing. When cutting washboard from a road’s surface, this really helps.

Cutting and moldboard position

Generally and as a rule of thumb, the moldboard top should be about five centimetres ahead of the cutting edge. This position can be adjusted according to the material and other variables. It should be clearly remembered that the depth of cut across the entire moldboard can be changed by tipping the moldboard forwards or backwards.

If we talk about the wheel position, then the top of the front wheels are generally leaned in the same direction that material comes off the moldboard. In cases, where the windrow becomes heavy, then the front wheels should be leaned in the direction of the windrow.

The front wheel should be kept in a vertical position when you are working on side slopes or ditches. The wheels should be leaned down the slope so as to ensure that the front-axle doesn’t reach its oscillating limit when you’re using articulation to work across a slope.

Learning about wheel leans is important as they can also help an operator make steering adjustments without taking his hands off the hydraulic controls.

You should be always careful when using the full rear tip as otherwise you can run into penetration problems. If cutting edges are worn, doing so could also damage the moldboard bottom or pivot area.

In a nutshell

Grading a road with the motor grader is not at all an easy task. Also, the style of every motor grader operator differs from the other. The general principle is that you start slow, keep your calm, understand the need of the job and then perform the task of road maintenance.

If as a contractor or constructor, you are assigned the task of grading roads and you are looking to buy a motor grader, then you should surely consider Mahindra Construction Equipment’s RoadMaster G75 and RoadMaster G90 motor graders that offer an affordable, un-compromised and mechanised grading solution.

How Motor Graders Improve Performance, Lower Costs and Advance Safe Operation?

Given the above fact and the present scenario where the Indian government is aiming at massive infrastructure development projects including huge urban as well as rural road building and maintenance programs, the demand for motor graders is definitely expected to rise. Further, the coal mining activity in the country is also picking up and this is also leading to the growth in demand for motor graders which are used to make haul roads at such sites. That said, there are no reasons for the motor graders demand to not go up as they highly increase productivity and efficiency at any jobsite.

There is also no doubt about the fact that motor graders improve performance, lower costs and advance safe operation. How? Then read the pointers below that prove the statement above.

1. Performs many tasks: Motor graders can be used to set the native soil foundation pads, move unearthed soil and debris or raw building materials, completely remove a layer of soil and then spread a new layer at that particular point to produce even surfaces, grade land surfaces, level soil and mix materials. They can be even used to perform other tasks like trenching, digging shallow holes, ditching and laying pipes.

2. Cuts on labour cost: By performing the tasks as mentioned above, motor graders highly reduce the need for labour and thus, decrease the labour cost as well.

3. Helps in keeping up with the project deadlines: Since the present-day highly advanced and technologically-sound motor graders are not at all affected by any weather or extreme operating conditions, they can very well complete the projects on time and even help contractors to take up more and more projects.

4. Reduces rework and increases accuracy, reliability and productivity: Equipped with advanced technologies, motor graders can reach the final grade much faster with more accuracy, thus, saving time and cost associated with rework tasks. This also increases the productivity at the construction site.

5. Increase profitability: Increased productivity and the reliability of motor graders ultimately translate into higher profitability.

6. Enhances jobsite safety: With advanced technology, telematics, machine control and integrated technology, motor graders greatly help in improving jobsite safety by not causing harm to the men and material.

Apart from the above, motor graders also ensure that the compactor is effectively used with minimum load on it. Thus, it is very advantageous to have motor graders at the jobsite.

If the discussion is about how motor graders can improve performance, lower costs and advance safe operations, then here Mahindra Construction Equipment’s (MCE) RoadMaster G75 motor grader do deserve a special mention. The RoadMaster G75 is manufactured at MCE’s state-of-the-art facility at Chakan, Pune. Extensive consumer insights and feedback has been taken to develop this equipment which is built to withstand Indias rough terrain and heavy usage. In addition, the product offers all the relevant features using the latest vehicle systems and technologies at competitive prices.

How RoadMaster G75 improves performance?

1. RoadMaster G75 is equipped with powerful and proven Mahindra 79.95 hp DITEC engine which brings fuel efficiency down to an incredible 4.5 litres per hour and results in 10 per cent more savings. The equipment possesses compact 4 cylinder, 3532cc engine and is BS III pollution compliant.

2. RoadMaster G75 includes the latest technologies to protect the machine from potential operating or maintenance issues.

3. The equipment is optimised to deliver zero compromise grading at 33 per cent as compared to conventional motor graders.

4. Its mouldboard is designed to suit required productivity and durability.

5. The equipment offers full blade visibility from operator station for superior grade finish.

6. It possesses hydraulic multi-function capability with two independent hydraulic pumps.

7. It has torque converter type clutch and power shuttle transmission.

8. It comes with GPRS-based remote monitoring system dogosense that keeps a track of the machine with the touch of a finger.

Apart from the above, motor graders RoadMaster G75 comes with the option of having additional fitments i.e., the ripper and dozer for added versatility.

How RoadMaster G75 lowers cost?

1. The equipment highly reduces maintenance cost as it lowers lubricant refilling requirement with the extended service intervals.

a) Hydraulic Oil: 50 litres with 2000 hours change interval

b) Rear Axle Oil (Differential): 14.5 litres with 1500 hours change interval

c) Engine Oil:13.5 litres with 500 hours change interval

d) Transmission Oil: 16 litres with 1000 hours change interval

2. RoadMaster G75 provides a superior finish and saves 50 per cent on the time required to get the job done and it saves at least 40 per cent of the costs.

3. RoadMaster G75 is 180 per cent faster and can single-handedly do the work of 30 labourers.

4. The optimal productivity allows on-time project completion leading to higher revenues.

How RoadMaster G75 advances safe operations?

1. It comes with ROPS/FOPS Canopy inline with international standards for operator safety.

2. Its advanced joystick controls boost safety, efficiency and productivity at all times.

3. DiGiSense also help in safe operations at the jobsite.

These above mentioned points clearly prove that the MCE’s motor graders are high in performance, save considerable costs and ensure jobsite safety, all of which are crucial to success of any project.

Looking at the above positives of motor graders, you might want to buy them but may be worried about operator training. Fret not! In order to improve productivity and safety, MCE offers heavy equipment operator training services i.e., if you buy the motor grader from MCE, then as part of its post-sales services, the company offers few days’ dedicated training for the operators, in which they are personally trained on various features of the machines by professional trainers. So, you can definitely look to have the RoadMaster G75 in your fleet.

Conclusion

To sum up, overall, motor graders are one of the best equipment for road construction and maintenance and they offer multiple advantages including improving productivity, safety and optimising costs. If you looking to buy one, then MCE’s offering should be on the top of your list.

Learning from Experience: Motor grader Operators Get Hands-on Training

Although today construction equipment like motor graders have become highly advanced and come equipped with intelligent features and smart machine controls so as to help the operators operate the equipment very efficiently and reduce their difficulties, yet these features cannot decrease the importance of an experienced motor grader operator. No matter, how advanced is the machine, if the motor grader is not that experienced or trained, you may not get the best results even from a machine that is highly advanced.

Agreed that to some extent, with such advanced machines, even less-experienced operators can work easily and achieve grade characteristics similar to those with more field experience, however, such operators cannot give best results and compete with those who have very good experience gained through hands-on training. Thus, it always makes sense to have an operator that is well-trained and has years of experience to bank upon. Simply put, merely having theoretical knowledge or having awareness about the equipment is not enough, operators need to have practical or hand-on training so as to excel in the field and give their best results.

Why it is important for motor graders operators to get hands-on training?

1. To operate the machine independently, safely and responsibly.

2. To make the best of the equipment and give best results.

3. To know about various functions and use of the equipment and its various attachments.

4. To know about maintaining, troubleshooting and storing the equipment.

5. To know about the workplace safety requirements and procedures very well.

6. To ensure safety of the equipment as well as others at the jobsite.

7. To understand the work ethics clearly.

8. To develop good communication skills that can help them in communicating and directing their co-workers to perform the relevant tasks.

9. To know about the new technologies and trends. At a time, when new technologies are continuously coming up and introduced in the heavy machinery like motor graders, generally, the operators who have experience and hands-on training are abreast about such innovations and up-gradations in the field.

Thus, it is very necessary for motor graders operators to learn through experience and get hands-on training.

Experienced motor graders demand in India

It is estimated that the demand of motor graders will increase by 15-20 per cent in the next 4-5 years. With the increase in demand for motor graders, the need for experienced motor graders is also slated to increase in the country. This is because of the reason that motor grades are very different from other construction equipment and also, they are one of the most difficult vehicles to operate. In fact, they are bit different from the others in terms of setting the controls such as the angle and height of the blade which requires certain skills, especially when setting them to obtain fine degree of result. Thus, experienced motor graders will be in great demand in the country.

However, there are not many institutes in the country that provide practical training to operators of heavy equipment like motor graders. Even if there are few government-backed institutes, then the training that the students get at these institutes is inadequate to meet the standards of work and efficiency that the industry demands. Also, in these institutes, only theoretical training is given and practical training is lacking.

MCE’s initiative for providing heavy equipment operating training to budding operators

While the demand for construction equipment including motor graders is continuously growing in the country, there are not many experienced motor graders to operate the equipment. In fact, the country is facing major skills gap and it’s becoming harder for the contractors and construction companies to find skilled operators to operate their motor graders. Realising this growing need for experienced operators of heavy equipment like motor graders who have the required hands-on training, various private heavy construction equipment manufacturers in the country are establishing their own training centres in various parts of the country in addition to introducing various certification courses for operator training. One such manufacturing giant in India is Mahindra Construction Equipment (MCE).

With its 6 regional training centres across the country, MCE imparts expertise and provides training on the below mentioned aspects to the budding heavy equipment operators…

1. Equipment operation

2. Daily, weekly and monthly equipment maintenance

3. Safety parameters

Further, the curriculum is usually updated on a regular basis to stay relevant. Also, adequate practical training is provided by MCE to the students. Apart from this, if you buy motor grader from MCE, then as part of its post-sales services, the company offers few days’ dedicated training for the operators, in which they are personally trained on various features of the machines by professional trainers.

In a nutshell

The skills level of an operator, coupled with proper maintenance practice can go a long way in optimising performance and enhancing the life of a motor grader. Typically, a motor grader operator has to perform various tasks like…

1. Driving and controlling the equipment safely and as per schedule

2. Maintaining the equipment

3. Identifying defects and malfunctioning of the equipment

So, given the technicalities involved in all the above mentioned tasks, employing an operator that is well-qualified, experienced and have hand-on experience is extremely important. Such a motor grader operator is surely a boon at the jobsite.

Thus, simply put, an advanced equipment like the MCE’s RoadMaster G75 with intelligent features operated by an experienced motor grader can boost the productivity, accuracy, reduce downtime and increase life of the equipment without any doubt. However, to employ such operators, operator training in India need to be promoted well. For that, a massive-scale joint effort by the government and private players is required. There is no doubt that gradually, developments are taking place in that direction and efforts are being taken to provide more and more hands-on training to the motor grader operators.

Key Motor Grader Safety Tips for Peace of Mind

If you are a contractor or a construction company owner, then you might agree that adherence to the safety and maintenance tips not only keep the equipment in the good condition but give you a peace of mind too that your equipment will not show signs of depreciation too early and can be used efficiently for years together.

Now, you may wonder as to what are these safety tips. Well, here are the key motor grader safety tips…

Motor grader safety tips before operation and at the time of starting the equipment

1. Read the operators’ manual to get familiar with the controls of the equipment.

2. Pay heed to the warning labels and stickers as well as maintenance information, specification charts and other important information posted around the machine.

3. Visually inspect controls, engine, compartment, cooling system, gear boxes, hydraulic parts and other parts.

4. Listen for unusual noises and vibrations before starting.

5. Walk around the equipment and check loose bolts, trash build-up, oil or coolant leaks and damaged tires.

6. See and ensure that there is no one next to, under or on the machine.

7. Check all the signals, lights and flags on mouldboard and cab.

8. Check all the attachments of the motor grader if they are in proper place.

9. Check and ensure that all the safety equipment are working and clean.

10. All the brakes, steering and accelerator should be tested before starting the equipment.

11. Before opening the fuel cap and refuelling the vehicle, loosen radiator cap slightly, pause to relieve pressure slowly and then remove the cap.

12. Understand that the controls should always be in the neutral position.

13. The electric starter should not be operated for more than 30 seconds. If you do so, then you should give two minutes for cooling before starting again. This is because an overheated starter could cause a fire.

Motor grader safety tips during operation

1. Look behind the machine before moving and while backing up, even when the backup alarm is engaged.

2. Make it a point to know and understand the width of the machine in order to maintain proper clearances from surrounding obstacles and obstructions.

3. Always wear the hardhat and seatbelt.

4. Wear safety gloves and appropriate safety gear.

5. Be aware of overhangs, electric wires, slide areas or other dangerous conditions.

6. Watch for overhead dangers.

7. Get full information about your work area i.e., make it a point to check weight limitations, types of surfaces and clearances.

8. Match speed with job conditions.

9. Drive at a slow speed in congested areas or on a rough terrain.

10. Stay in proper gear when travelling downhill. Never coast in neutral and use engine RPM to help maintain control.

11. Be very careful when working on slopes and never turn on the slopes as the motor grader is least stable in such a situation.

12. Make sure that the machine is not left on a slope with the engine running as this may put the machine into motion.

13. While working on top of a slope or a side hill, keep away from the outer edge. Make it a point to extend the blade out to the side to move material near the edge.

14. In case of carrying or working the blade at a sharp angle, always be careful when articulating to avoid puncturing the tire.

15. Use proper hitch equipment and technique when towing the grader.

16. Communicate with the traffic effectively while operating the motor grader. This includes, using flashing safety lights when blading and keeping headlights on whenever operating.

17. Report defective equipment immediately.

18. When you stop the equipment, lower all the raised equipment parts.

Motor grader safety tips after operation

1. Choose the right parking place. In fact, choose a level ground.

2. Set park brake.

3. Shift blade to centre and lock it when parking.

4. Allow engine to cool gradually.

5. Keep the transmission neutral.

6. Always lower the blade or any other attachment to the ground before leaving the motor grader.

7. When leaving the grader, remove the ignition key.

8. Secure the machine to prevent unauthorised starting and movement.

9. Be aware that boarding and exiting grader may put you in danger of slipping, tripping or falling. Thus, make it a point to use a three-point (two feet and one hand or one foot and two hands) approach when entering or exiting the cab.

10. If the grader is disabled and cannot be moved from the roadway, then put out flags and flares (flares are mandatory at night and during periods of poor visibility).

11. Have the grader removed from the roadway as soon as possible.

Hence, if you wish to increase the lifespan of your motor grader and prevent dangerous injuries to men and machine, then you must follow the above mentioned safety tips. These small but important tips can help to increase productivity as well as efficiency of the machine to a very large extent. Also, it is to be noted that regardless of the amount of experience an operator may have, one small mistake can result in an injury or worse. Hence, these before, during and after operating a motor grader safety should be always kept in mind and followed religiously by every motor grader operator or owner.

Last but not the least, it is to be noted that apart from following the given safety tips, it is extremely essential to stay alert at all times as even a brief distraction can be very harmful. In a nutshell, an alert mind and adherence of all the safety tips can help the contractors or construction companies as well as the motor grader operators to live peacefully.