Time-bound projects need reliable machines, and all equipment manufacturers are trying to innovate and adapt to the latest trends and are in the continuous process of improving productivity of the machine. Agith G Antony finds out product and technology trends in the motor grader segment.

Motor graders are fairly versatile machines used for a wide variety of applications. This sophisticated machine when stripped to its basics is a self-propelled mouldboard that can be angled right or left, tilted up or down, moved forward or backward, and also has various added features and a variety of tools. This simple machine is transformed to a multipurpose equipment that can be effectively used for grading, shaping, and moving earth and other materials. One can mix aggregates and other materials for a road project, remove materials from an existing road or bring it back for top dressing, make a rough or a finished grade, spread stone, cut or clean a ditch, and slope a bank, scarify hard ground, rip up asphalt, and doze construction materials.

If we consider some key parameters of performance, they would include the draw-bar pull, control on torque output (to prevent wheel slips) high reverse speed to improve productivity, high blade down force and ergonomically designed cab and cab controls. On the whole, a well-engineered motor grader combined with a trained and skilled operator is essential to ensure optimum productivity.

Applications
However, whether this piece of equipment is used to its full potential in India can be debated. Says Ajay Shankar, Country Manager, Caterpillar India, "There are many different applications a motor grader can complete, such as building and maintaining road networks, side slop construction, ditch (drain) building, cleaning and maintenance, ripping soil in Greenfield construction, scarifying of sealed and unsealed roads for rehabilitation. However, traditionally in developing markets, hydraulic excavators, bulldozers or wheel loaders are used to carry out work that is more suited to be effectively completed with a motor grader with the capability of better finished tolerances."

Are there any specific reasons for the limited applications of motor graders in India? According to Shankar, it is difficult to give any particular reason. He, however, lists some indications for limited motor grader use. His explanations runs so, "The limited use of motor graders can be due to regional finished road tolerance requirements, competitive conditions such as limited contracts in a bid to drive down the margins for contractors and reduce the opportunity to own and operate multiple plant types, and lack of awareness of motor graders' capabilities in completing road construction and other applications more effectively."

Rajendra Shah, Proprietor, RS Construction, a Mumbai-based hiring firm that has been hiring only motor graders for the last two decades, emphasises on the availability of spares and service as one of the deciding factors in the selection of motor graders. He says, "Major factors are availability of spare parts and service. Since the machines work in remote areas, it is important to ensure that the spare parts are available at the work site or near the site. Also important is the availability of qualified service engineers for maintenance service." He adds, "Motor graders are very expensive. The price range is between Rs 70 lakh and Rs 1.30 crore. The parts, especially the tyres, are very expensive. It is prone to torn and cuts in Indian work sites due to presence of rocky roads."

Amarnath Ramachandran, Vice President Product Engineering & Knowledge Management, LeeBoy India Construction Equipment, has a different perspective on this. He says, "The applications of motor graders are limited because till a few years ago mechanical pavers were used to do the job of a motor grader. Efficiency on Indian project sites is extremely low, which renders the grader idle for a long period of time. Hence speed of project completion is low as compared to foreign countries due to issues such as land acquisition, clearance, etc. So most project sites buy a few graders and hire when peak demand arises." According to him, if the new government sets a 50 to 75 per cent reduction in timeline for completing projects, the market for graders will rise to its true potential."

Unlike the National Highways Development Projects (NHDP) where the use of motor graders is well accepted, in the state highways and especially in the rural road projects, its use is still limited. Samir Bansal, General Manager, Off-Highway Research, India, explains, "Motor grader is an expensive machine and its use was made mandatory on national highways by the National Highways Authority of India (NHAI) at the time of conceiving NHDP. Many states adopted NHAI specifications subsequently, and the use of these machines started on state highways as well. However, in view of the small value of road building contracts for district and rural roads, use of motor graders is not mandatory, and is limited."

Ramachandran says, "There has been a major change in state highway specs and LeeBoy has sold many graders in the Mysore belt in Karnataka and also on internal roads in Rajasthan and Odisha where the grader is being quoted in state PWD specs. The major limitation in rural road projects is that as the existing road widths are very narrow?for widening and building 50 per cent at a time - a small grader is required with a blade width of 8 feet to enable traffic to pass by while the road repair is going on. This gap will shortly be filled by LeeBoy." He further adds, "There are states where NHAI has pulled out due to major land acquisition problems. In this case, the Kerala state government is going to execute the enhancement of highways with elevated structures and modern techniques through their existing PWD registered contractors."

Demand-supply scenario
Demand for motor graders is closely linked to road building and construction activities being carried out in a country. Bansal throws light on the market trends. According to him, at the start of the new millennium, when road building activity was low, sales of motor graders stood at around 100 units. As infrastructure and construction projects gathered pace in the following years, demand increased significantly to peak at 553 units in 2008.

Bansal explains further, "Following the global economic crisis in 2008, the market dropped to 342 units in 2009, but recovered soon to 529 units in 2010 and remained at that level even in 2011. However, sales again dropped by 40 per cent in 2012 and a further 13 per cent in 2013 to finish at 276 units." He further adds, "The reason for this continued decline can be attributed to the slowdown in the award and execution of new projects due to pending policy decisions, government approvals and clearances, as well as project financing issues in the recent past. This in turn has led to a decline in road construction and mining activity in the country."

Categories
Motor graders are available in a wide range of sizes to suit different application requirements. In India, we can roughly divide it into three broad categories upto 150 hp, above 150 and upto 250 hp, and above 250 hp. According to Bansal, the less than 150 hp category is the most popular, and almost all machines of this size are used for standard road construction jobs. This segment accounts for over 60 per cent of the total motor graders sales in the country.

The mid-segment is from above 150 hp and upto 250 hp, and this category is deployed both for road construction projects by contractors wanting higher productivity, as well as for the maintenance of haul roads. The share of this segment has varied between 26-38 per cent during the last five years. Bansal adds, "The machines in the over 250 hp category are primarily sold to mining companies for the maintenance of haul roads in mines. These units are expensive and their utilisation is usually low owing to the intermittent nature of the work. Their replacement cycle is therefore long and so demand for this category has been small over the years. Although, there is a steady demand for these machines, but the segment's share has varied between 3-11 per cent of the total market during 2009-2013, depending on the rise and fall in road construction activities."

Ramachandran classifies graders used based on the type of mine where a grader is used. He says, "The selection of graders for haul road maintenance is based on the size of dumpers running on the projects. In large coal, iron ore and steel mines where we have 60, 100 and 120 and 400 tonne dump trucks running, the size of graders is enormous and the minimum size would be 22 tonne upwards (275 to 300 bhp). For road construction, limestone (cement) mines where dumper sizes are up to 60 tonne, the 15 to 16 tonne grader class will be optimal and where there are only 35 tonne dumpers, the 13 tonne class of graders will work well."

"For road projects and general construction, currently in India, the 13 tonner is the fastest selling model. For these, LeeBoy has a full range of graders including very small hydrostatic graders, which can be used for landscaping and development within medium to large housing projects," adds Ramachandran.

Selecting the right machine
As the customer has a wide variety and variants to choose from, selecting the right machine for the right application is becoming tougher. The performance of engine and hydraulic systems and components is very important. The machine must have a strong chassis and ample power to move through widely varying conditions. Weight of graders is another important factor as it should be able to cut through materials; and sufficient engine torque and horsepower to push the blade. The degree and type of curvature in the blade is another factor as it affects the rolling action; the fewer curve in the blade, the more it tends to carry material. There is more focus on visibility and comfort; and accessible service features are very important as there is growing awareness among the end-user segments on simple access to service and check points for the engine, transmission, and other systems.

According to Ramachandran, we need to look at the amount of material that needs to be moved. He says, "In India, as of today, a 13 tonne class grader typically runs only 2,000 hour a year. This is due to the fact that a stretch of 40-50 km takes 2.5 year to complete. If completion time is going to be reduced, then the class of grader automatically becomes larger. In Oman, for e.g., 5 km is completed in six months and hence they procure 18 tonne class of graders."

Ashok Srivastava, Vice President Soma Machinery Division, Soma Enterprise, puts it very simple. According to him, the machine should meet required specifications and proper utilisation. The road sector is expected to witness a boom. Will this boost the sale of motor grader? "The advanced technology on graders is more useful and suitable for road sector in green field areas, where more volume of work and vision from control points are clear. In most of road projects, existing 2 lane or 4 lane are developed/modified and converted to 4 lane or 6 lane respectively. In such cases these technologies are not viable in cost," says Srivastava.

Shankar of Caterpillar says, "From the perspective of Caterpillar and its dealers, it is important to understand the customer's needs. The factors that impact a customer's buying decision and the selection of the right machine include net horsepower, operating weight, blade length, operator interface and controls, ergonomics, visibility to drawbar, circle, moldboard, front axle and rear tandems."

Tech trends
Equipment uptime is one of the major factors that customer considers while deciding on the machine. Time-bound projects need reliable machines, and considering this fact, all equipment manufacturers are trying to innovate and adapt the latest trends and are in continuous process of improving the productivity of the machine.

The Cat range of motor graders is equipped with Cat? C7 engine that uses ACERT? Technology that helps provide electronic control, precision fuel delivery and refined air management, resulting in outstanding performance and lower emissions. For instance, the 120K2 is certified to Bharat Stage III and offers increased horsepower in the lower gears (1-3) as compared to the previous 120K model. This enhancement provides improved performance for tough applications such as ripping and heavy blading, as well as the ability to carry more material for improved productivity. Customised torque curves increase peak torque for improved lugging performance and responsiveness. The Electronic Throttle Control (ETC) provides easier, more precise and consistent throttle operation. Says Shankar, "Caterpillar motor graders are designed with direct drive power shift transmission that provides for an efficient transfer of power to the lower drivetrain with a reduction in parasitic loss providing for a more efficient fuel usage versus alternative drive train systems (eg, hydrostatic and torque convertor). The direct drive powertrain provides operator with better feel (feedback) of underfoot conditions to assist in effective processing of material."

He adds, "Caterpillar motor graders feature full on-the-go power shifting capabilities without harmful shock loading to the drivetrain. For operator safety and engine drivetrain protection, the transmission includes a downshift inhibitor to prevent over speed of the engine and transmission."

The B series motor graders launched by CASE are fitted with FPT 6.7 litre engine equipped with common rail diesel (CRD) injection system and electronic diesel control (EDC) systems. These engines are equipped with internal exhaust gas recirculation system (IEGR) to minimise emissions such as nitrogen oxides and hydro carbons. Moreover, the high pressure diesel injection system helps complete burning of fuel and produces low emissions and particulate matters.

Says Abhijit Gupta, Managing Director, CASE New Holland Construction Equipment, "The recently launched B Series motor graders are offered with a state-of-the-art NEF engine with variable horsepower. The engine horsepower varies depending on the load exerted on the machine. The grader is offered with an automatic ZF transmission. The machine has a multi-curvature mouldboard, which reduces the resistance coming on the engine and hence reduces the fuel consumption. The cabin of the grader is spacious and provides excellent mouldboard visibility."

The Volvo G series motor graders include three highly efficient and versatile tandem-drive models? G930, G940 and G960?as well as the G946 machine with the industry-leading Volvo All Wheel Drive (AWD) and the original ?creep mode' front-wheel-only hydrostatic drive. The result is a selection of graders with outstanding power, torque and fuel efficiency for the widest range of grader applications.

Says AM Muralidharan, President, Volvo Construction Equipment, "We deliver fuel efficiency across all elements of our machines via engines, systems, operator behaviour and future technologies, while increasing the productivity for our customers." Volvo engines are renowned for high torque at low RPMs, producing responsive, fuel-efficient performance under all operating conditions. The new generation of D7E engines with Volvo Advanced Combustion Technology (V-ACT) is tailored for grader applications, designed to run cleanly and efficiently without the extra service requirements of additional equipment or after-treatment of exhaust gases.

LiuGong's CLG 414 BSIII motor grader is equipped with water-cooled BS III Cummins engines rated at 112 kW. Power from the engine is transferred to a Hang Zhou 6YD13 transmission with six forward and three rear gears. The mouldboard is supported and rotated by a unique sealed ball bearing roller circle that provides much more accurate blade control than the conventional open gear type. The machine muscles its way through the toughest surfaces and conditions", says Rohit Punjabi, Asst Director (Strategy & Marketing), LiuGong India.

The CLG 414BSIII motor grader offers high reliability load sensing hydraulic system that increases the ease of precision operations using less fuel. Punjabi adds, "The machine is turbo charged, which means you have adequate torque and power in higher altitudes. The fuel consumption of the machine is 15-20 per cent lesser than our competitor's machine. Lower owning and operating costs and high resale value have always been attribute of Liugong motor graders, providing further protection for your motor grader investment."

Liugong offers two model variants ? CLG 414BSIII with an operating weight of 12,400 kg with 3,660 mm blade width and CLG418 with an operating weight of 15,500 kg with 3,960 mm blade width. LeeBoy India entered the fray with the launch of 785i motor grader, a 12.4 tonner, with 150 hp equipped with advanced automatic power shift with an electronic transmission control unit, which continuously compares converter impeller speed, turbine speed and operator demand to gear selection for optimal fuel efficiency. "The fully automatic power transmission, which is a standard feature in the 785i, also offers the best heavy-duty, tandem power drive system and 6-speed automatic power-shift transmission, lock up clutch and stator freewheel. The automatic transmission optimises the fuel consumption," says Ramachandran.

Recently LeeBoy introduced 985i, a 15.5-tonner that boasts of high torque, performance and reliability. The 985i is powered by the Cummins 6BTAA 5.9 litre, 150 hp, BSIII engine, and is equipped with an automatic power-shift transmission, and a direct drive from ZF. The tandem power drive system, and 6-speed automatic power-shift transmission features six forward and three reverse speeds, lock up clutch and stator freewheel as a standard feature. The press button toggle, facilitates manual and auto manual power shift transmission. The machine is also fitted with an intelligent transmission control unit, which possesses various interlocks to prevent transmission damage and facilitates easy diagnostics. The 985i comes equipped with an advanced electronic gauge display, which contains a single, electronic LCD display, mounted in front of the steering column. The multiple screens allow for unobstructed visibility. It displays critical gauges on the default screen in day and night modes.

A significant trend in the current scenario is the shift from post breakdown maintenance of machines to a preventive diagnostic to monitor the health of the machine. This is apparent in the replacement of mechanical displays by all electronic displays, which are increasingly becoming a part of the machine's standard features for monitoring and service reminders. Some other indications are increasing electronic controls of the motor grader to make operation more effortless. Also, the ideal driveline would have step-less control of torque and speed. This is possible with a continuously variable transmission. Awareness of the environmental challenges in today's world is also shifting focus around fuel consumption and emission norms. This is another area where more and more manufacturers are ramping up their features to make it more eco-friendly, says Ramachandran.

Cab front or rear?
Has the location of the cab any bearing on the performance of a motor grader? Response for this was a mixed bag. According to Shankar, Cat? K series motor grader cab is mounted on the front frame forward of the articulation joint. He says, "Mounting the cabin on the front frame provides the operator with enhanced visibility to the drawbar, circle and moldboard positions through to the front steering axle. The operator's position is kept relative for drawbar, circle and moldboard positioning when mounted to the same front frame."

Says Ramachandran, "Theoretically, if the cabin is on the rear frame, one can save on the articulation sensor, which indicates if the vehicle is straight or twisted on the electronic display. Here, the operator will instantly see the boom which is skewed. However, the service accessibility on these is compromised as the transmission comes directly beneath the cab." He adds, "LeeBoy grader has a boom mounted cab, and the revolutionary design wherein the transmission is at the rear has very good service access as compared to others. By removing a total of six bolts for the canopy and eight bolts for the fuel and hydraulic tanks, the entire and driveline can be accessed for service."

Growth potential
Despite the muted demand for motor graders due to stalled NHAI projects, and sheer lack of new projects, coupled with the de-growth in mining sector, motor grader segment is expected to register good growth once the new government remove the bottlenecks of the road sector and come out with bankable projects. Lack of awareness on the versatility of this unique piece of equipment, and therefore its limited use, has adversely impacted the growth of the motor grader segment. However, there is increased use of GPS guidance and laser control technologies for better grading. Bansal sums up on a positive note, "Sales of motor graders follow very closely the trends of expenditure on the construction and maintenance of roads, so demand for machines will largely depend on the speed at which existing and future road projects are executed. The backlog of pending road construction work in the country as well as the government's ambitious infrastructure development plans offers enormous potential for growth in the market. Off-Highway Research estimates that the motor grader market is likely to grow to 300 units in 2014 and to 750 units by 2018.

APPLICATIONS

• Making rough of finished grade
• Moving earth and other materials
• Grading and shaping
• Building and maintaining road networks
• Mixing aggregates and other materials
• Cleaning and maintenance
• Side slop construction
• Scarifying hard ground and ripping up asphalt
• Dozing construction materials