Ministry of Shipping & Traneport Rv) pec | Bu MANUAL FOR MAINTENANCE OF ROADS (Roads Wing) Ministry of Shipping, ‘end Transport (Rods Wing) Copies can be had by V.P-P. from the Secretary, Indian Roads Congress, Jamnagar House, Shakjakan Road. New Delhi-110 011 NEW DELHI 1989. Price Rs 48/- Plus packing & po:First published : December, 1983 Reprinted : September, 1989 Reprinted : February, 2000 (The Rights of Publication and Translation are Seserved) Printed at DEE KAY PRINTERS, New Delhi-110015 (500 copies) FOREWORD There are no two opinions about the importance of proper and timely maintenance in preserving the investments made on road facilities and in providing safe transportation at a satisfactory evel of service. This phase of operation has become all the more important in recent years in the wake of the phenomenal growth of traffic on the roads in the country accompanied by a steady increase in the axle loads of commercial vebicles. Maintenance of roads in the present day context can not there fore just be limited to isolated actions like filling up potholes, etc., but should follow a system approach involving a series of sequential operations. is the precise assessment and codifica- tion of the present fod condition, diagnosis of the problem encountered, and ‘selection of the most appropriate treatment. This would enable a clear understanding as to ‘when’, ‘what’ and show’ to treat, the determination of priorities more objectively and allotment of the available resources where they are most needed, and formulation of a rational road maintenance programme. Second is the effective improvement tn the quality of work and productivity. Third is the adoption of an‘easy and quick report- ing and recording system to check on the achievement of jobs assigned to gangs or units, equipment, etc., employed on mainte- nance in the field. Fourth is the observance of the duties and responsibilities assigned to inspecting staff such as the periodicity of inspection, a check list of items to be inspected, evaluation of productivity and solving of any field problems in this regard, Fifth is the training of all involved in the maintenance methodology and operations. In performing all these activities in the most efficient manner, the most important aspect is the human clement, iie., the personal involvement of all concerned with maintenance, right from the engineering supervisory staff down to gangmen. For providing guidance on all the above mentioned aspects with the objective of putting the road maintenance activities in thecountry.on a more rational footing with uniformity in approach, the ‘Ministry of Shipping & Transport (Roads Wing) have brought out this ‘Manual for Maintenance of Roads’. The initial draft for this document was prepared by Shri P.K. Lauria, .Chief Engineer and_ Shri MK. Saxena, Superintending Engineer, P.W.D. Rajasthan. This was reviewed, amplified and finalised in the Roads Standards Zone of the Ministry in consultation with a representative greup of State Chief Engineers dealing with roads, Tam sure this Manual will be useful to the Engineers in the field as well as to those in the office dealing with planning, pro- gramming and budgetting of maintenance activities. For more positive impact in the different parts of the country, it will be advantageous to translate the portions of this Manual dealing with field activities into local language. ‘As is the case with any technical document, this Manual may require improvementjrevision from time to time in light of the feed-back from the various road construction departments in the country. I do hope that this Ministry will get the necessary feed- back in order to improve this document in the years to come. K.K. Samin Director General (Road Development) and New Delhi ‘Additional Secretary to the Govt. of India December, 1983 CONTENTS Scope 1.1. Basic Maintenance Objectives and Policies 1.2. Definitions ‘Planning and Financing 21. Inventory of Road 2.2. Condition Survey 2.3. Programming and Planing 2.4, Annual Calendar of Road Maintenance Activities Inspection 3.1. Frequency 3.2. Duties 3.3, Identification of Defects Maintenance Criteria 4.1. Criteria for Renewal Execution of Maintenance Operations 5.1. Safety of Labour and Road User During Maintenance 5.2 Symptoms, Causes and Treatment of Surface Defects . Output of Labour Material Procurement ‘Mechanisation and Equipment Planning Maintenance of Drains, Shoulders, Slopes and CD Works Page 29 40 4 4 47 485.7. Maintenance of Road Furniture Organising Maintenapce Operations in Field 6.1. Preliminary Steps 6.2. Execution of Work 6.3. Work Report Monitoring ‘Training in Maintenance Operations and ‘Management Problems of Special Areas 9.1. Maintenance of Roads in Desert Areas 9.2. Special Problems and Techniques for Maintenance of Roads in Hilly Terrain in Heavy Rainfall Areas 9.3. Special Problems and Techniques for Maintenance of Roads in High Altitude Areas APPENDICES - Surface History of Road Check List of Items reouired to be Inspected during Lnspection for Maintenance of Roads |. Routine Inspection Card (Recording Format) . Annual Calendar of Road Maintenance Acti . Field Procedure for Inspection and Planning Maintenance Works Action to be taken in case the Road is Breached or Blocked s . Duties and Responsibilities of Mate 8. Duties and Responsibilities of Store MunshijMunshi 9. 10. Duties and Responsibilities of Mistry/SR Mistry Recommended Norms for Task for Road Gangs Page 55 39 61 6 63 65 69 B 78 18 8 85 86 88 89 90 92 95 56 7 | | nM 12, 13, 4 15. Norms for work charged Staff Engaged on ‘Maintenance of Roads Tools for Gangmen Work Sheet ‘Work Report Maintenance of Roads—Format of Performance for Annual Maintenance in the Division Page 100 tor 102 103ScopeSCOPF. 1.1, Basle Maintenance Objectives and Policies ‘The basic objectives of maintenance function are to. maintain and operate the highway system ina manner such that (@) Confort, convenience and safety are afforded to public (©) The investment inroads, ridges and appurtenances is preserved (© The aesthetics and compactly of the highway system with the environment is preserved () The necessary expenditure of resuurces is accomplished with cont ‘ving emphasis on econoriy. 11.1, “Service to traveling public : The road system should bbe maintained adequately at all times within the fiscal constraints to enture safe and convenient travel considering the density and nature of traffic being served. . 1.1.2. Employees on call: Emergent conditions may deve- lop from time to time adversly affecting safe and convenient travel. Persons dealing with maintenance of traffic are on call at all times and should be ready to be of service in effective use of the roads. 1.1.3, Preservation of investment : Its the objective, as far as possible, to maintain all roads, bridges and appurtenances in originally constructed or subsequently improved condition, perfor- ming work of such conclusive and restorative nature to ensure that the investment of public funds in each road is preserved. 1.1.4, Preventive maintenance: Maintenance of a clearly preventive nature (as opposed to waiting until correction is re- quired) shail be performed by operating units. Planned work of restorative nature (maintenance, replacements or reconstruction) which will be done in a reasonable length of time, shall be the only reason Yor deferring rovtine maintenance provided funds are available. Environmental considerations : Maintenance opera~ tions should be performed in such a manner as to preserve or enhance the compatibility of the road system with environment,4 Scope The maintenance of roadside shall be directed towards the preservation or enhancement of the natural beauty of the road land. Special emphasis shall be directed towards the control of roadside erosion, 1.1.6. Consistency of maintenance service : All roads pro- Viding similar service should require equivalent maintenance care based on needs and requirements of particular region and road, 1.1.7. Economy of operation and performance improvement : It is the objective to constantly devote efforts towards impraving the performance of the maintenance organisation through a process ‘of methods of research and analysis, management improvement and training, the investigative research in the field of maintenance, equip- ment, materials and technology and regular communication with operating personnel to incorporate improvement as developed. 1.2. Definitions ‘The maintenance of highways can be broadly-classified ander the following three sub-heads. 1.2.1. Ordinary repairs/routine maintenance : ‘The ordinary repairs include the following nature of works : ( Upkeep of road pavements and side shoulders Ail) Upkeep of roadside drain system (it) Upkeep of culverts and bridges, and earth retaining structures and parapets (Gv) Keeping the sign boards, km stones and other trafic aids and furni- ture in good shape and condition (©) Maintenance of réadside arboriculture (vi) Upkeep and maintenance of rest houses, inspection bungalows and ‘sag buts, 1.2.2, Periodic maintenance : It covers periodic renewalé to the carriageway whether it is gravelled road, metalled road or black topped road to ensure that adequate level of services maintained, 1.2.3, Special repairs and flood damage repairs Planning and Financing § 2 Planning and Financing2. PLANNING AND FINANCING 2.1. Inventory of Road The first step to planning of maintenance operation is the evaluation of the existing road in terms of its physical condition, structural capacity and surface profile (roughness) etc. For this purpose, basic road inventory containing all details of the existing highway should be available. The following data are required to have a coniplete inventory. 2.1, District map (Fig. 2.1.) : District map on the scale of 1000 shoilld be available with the following details : (a) Classifcationjcategory width of roads (b) Location of streams and C.D. works (© Type of surfaces (@ Lane width of road (@) Traffic intensity and volume (©) Urban limits. 2.1.2. Strip maps (Fig. 2.2.): Strip map of particular section of the road must have the following details: (a) Kilometerags, road geometries vs. road width, steep aradints, i ‘ny, colverth with Bre particular, crossings et, (availability of materials and location st quarries (© Availability of T & P, existence of stores and. department workshops, gang huts (8) Any other features suchas sections which require special attention cr substandard geometric, eq. inadequate tight distance, forizonal or vertical alisnment, arrow width, inadequate super. elevation, weak bridges (© Broad soil types 2.1.3. Surface history : Surface history of the road should be compiled in format given in Appendix I. It will contain the summary of information available in the road register maintained on ‘the lines prescribed by M.O.S. & T. The information should be as accurate as possible and collected from the available records.Planning and Financing Planning and Financing 9 Rees, | | | | ade omavecun | Wee ee Fig 2.1, Dist map Fig.2.2,, Road inventory chart,10 Planning and Financing 2.2, Condition Survey When all the inventory data of the road are available, condition survey can be carried out : (@) By visual inspection (©) By mechanical evaulation Condition surveys by visual inspection/assessment of the pavement, cover the type, magnitude and location of the deficiency or distress. Necessary information about the routine maintenance ‘can be had by simply going along the rond-both past and_ present and the likely causes of distress. Pavement surface evaulation based on surface condition (cracking, patching) riding quality (j.e. road roughness) and skid resistance would form basis for taking periodic maintenance decisions. Condition surveys at fixed frequency are necessary for determining periodic renewal requirements and long term main= tenance strategy. For that purpose, the condition surveys should be conducted for each stretch of the road as per frequency prescribed in para 3.1. Generally, the condition’ surveys are. cirtied out from a Vehicle travelling at slow speed supplemented by inspection of more critical spots on foot. The data collected should be recorded methodically kilometre-wise. It is desirable that these condition surveys be carried out by the Junior Engineer/Assistant Engineer. While carrying out inspections, the check list of items given in Appendix 2 should be kept in mind. The findings of condition survey should be recorded in format given in Appendix 3. 2.3. Programming and Planning Based on the condition evaulation, the causes for the various defects observed should be examined in detail and a decision taken whether to initiate a particular maintenance activity, or to go in for more detailed investigations to determine the maintenance/rebabi- Imation needs precisely. Whenever distress on the pavement has reached the stage which affects the smooth operation of traffic, it should be rectified straightaway. For other defects like cracking, ravelling etc., the optimal strategy should be determined having regard to the various factors involved and a decision taken whether Planning and Financing " to go in for measures like seal/renewal coat or to strengthen/recon- struct the pavement. If the latter appears necessary, further investigations about structural deficiencies must be takea up. In other words, the planning of the various maintenance operations should be correlated and looked upon as a total system rather than each activity being considered in isolation. The criteria. for maintenance priorities/rebabilitation needs would be as per Chapter 4. ‘Once the overall maintenance plan has been drawn up, attention should be-given to the proper organisation and manage- ment of the whole programme including deployment of various resources ie, men, materials and equipment, in an efficient manner. For each maintenance activity, the work at site should be carefully controlled so that the optimum out-put and quality are achieved. 2.4, Annual Calender of Road Maintenance Acti The planning and programming of various maintenance acti= vities throughout the year should be done in advance keeping in view the climatic condition and periods available for carrying out different activities, A suggested programme with regard to various activities involved in respect of maintenance is given.in Appendix 4.Inspection 3 InspectionINSPECTION 1. Frequency ‘The minimum frequency of inspections for condition is suggested in Table 3.1. ‘Tame 3 Section |e. road pee est | ee a (oe | L NH Twisein Before Once in Before Oncea Every &.ayear and and month week SH (Aphl& after after {Oaober) ‘mon- mon twice during ‘The inspection should_ be carried out not only to check the conditions of works but also for planning future strategies. Senior officers should make it a point to note and communicate the instructions to the subordinates. While on inspection, the senior officer should go through the notes of Junior colleagues and make suitable suggestions so that inspections are meaningful. 3.2. Dates ‘The duties of supervisory staffisuch as mates-and civil mis- tries nave been defined elsewhere under the sub-head “Out-put of labour”. The duties of Engineering subordinates, Assistant Engineers and Executive Engineers are as follows : 3.2.1. Duties of engineering subordinates {i Inspection and supervision of works as per prescribed norms Gi) Reporting observations to higher authorities16 Inspection fer conducting condition surveys of Gi) Preparing estimates for repair road Reporting about closure of roadjobstructions due to any of the following reasons : (2) Over toppingybreach (®) Landslides (© Earthquake (a) Accident (©) Any other reason (specify) () Arranging for removal of obstructions, dead animals and other debris wing on road (wi Enumeratine ssrery measures and restoration works in case of flood damages and erehches and reports on opening of tafe/completion restoration 3.2.2. Duties of Assistant Engineers 44) Inspection and supervision of workk a8 per norms i) Reporting observations with suggestion for ren authorities ) Getting estimates: prepared and’ checked after conducting surveys and site investigations Gv) Reporting about heavy rainfalls in the area and consequent rain damage (¥) Enumerating action oa the report of engineering subordinates regarding obstructions, accidents etc (vi) Boumerating safety measures and restoration of (both temporary and permanent) works in case of flood damages and brea il action to higher 3.2.3, Duties of Executive Engineers (@ Inspection and recording of observations as per prescribed-norms i) Planning and finalisation of nature of maintenance activity eg. ‘surface cemoval, repair to CD works ete. (Gi) Arranging men, materiats and machinery in advance s per require- jing action on reports of Assistant Engineers and also on safety ‘measures, diversion in case of breaches and flood damages (9) Coordination with various ageticies like trafic police, local adminis tration, publicity mediaretc., in case of emergent repairs interruption to traffic by road blockage, ete. (vi) Tnitiate steps for finalising permanent restoration work. Inspection 7 3.3, Wentification of Defects : Itis important to identify and locate the defects of surface, shoulders, side drains and cross drainage during the inspection of the road by various officers. Reference should be made to IRC : 82 “Code of Practice for Maintenance of Bituminous Surfaces of hways” to help in identifying the various surface defects such as bleeding, streaking, cracking, ravelling, edge subsidence, edge fretting, rutting, shoving, pot holes ete. Common defects and deficiencies of shoulder draining and cross drainage works have been indicated in para 5.6, A brie note'on field procedure for inspection and planning maintenance works is given in Appendix 5.He The / 82 Maintenance Criteria 19 4 Maintenance Criteria4. MAINTENANCE CRITERIA 4.1. Once the inspection of road for condition survey has been carried out and its findings recorded in the prescribed format given in Appendix 3 in accordance with the instructions ‘contajned in para 2.2, the priorities for the required maintenance operations are required to be fixed. These priorities are to be assigned judiciously looking to. the urgency of the -work. The urgency is governed by factors like (a) safe and unobstructed flow of traffic (b) preservation of the assets in the form of roadway and its appurtenances and (c) preventive maintenance to avoid any further deterioration. Guidance regarding assignment of priorities is given. in table 4.1 which indicates the priorities for various operations as (a) urgent for jobs requiring top priority (b) spe for jobs which are in next order of priority (c) recurrent-for jobs which occur recurrently and are next to special in order of prioriij=and (d) routine—for jobs which are to be attended to in-a routine manner. In case road is breached or blocked, urgent action sbull be taken. by Mate/Scction Officer/Assistant Engineer and others as per steps indicated in Appendix 6. 4.2. Criteria for Renewal Generally, the renewal cycle of bituminous surfacing would be dependent on the traffic density, rainfall and lane width. Table 4.2. gives the guidelines recommended in IRC : 82 “Code of Practice for Maintenance of Bituminous Surfaces of Highways” for National and State Highways.aryoy 29quuv9 sndoud 0} Banas 2 a -susad 1301109 PUE AP3K) ape Kay sppinous at syedos pure 98p2 peo! Ysted, apo Ay ue souspisqns 38pq 1-4. day 28 syp819 UONDDyU sou ed {eur810 50 330 10 Soryot repods Zoo war 9g wre TC § sunnoy ee 3 reads 8 uno sopetd om e § é 2 £ s ory e129 sumneoa 7 ® ‘eaze e101 a4 Jo 039 Jo 52 5 sunnow tuyeas roo} dary" Buypasoua sease reo0r ST) sodas ca = eats fei0) 24) é sonmanerepads ue repute oe 4J9 iso saz Butpaox 8 soiimieriapegng et. ene ae Suh (@) & Some ot e ay 2 J0.sw/84 STB pa (@). —_twI69 amp Jo 3429 20d sz & ne trot 20.01 ens s eupnow 24940 Buty 20 Boyes 201 seate eso] a ButyaEs (8) = suoppeos ys pus Keastouie “g Soupnos 2380 13g sou0 Jat weg oe set uuonwone reeds 4J0 19p10 oF 39 U9 pury cay We Soon yo MME EV ours 29 Koyo satupe> an asytdat in om 1089 onasgo Aspfduios Yow wuslin pee pasouiarsaperoo(a 2D Op Hotum s9peyaO!a 10 ND owen 39 ou ot coponsnge snes sapuadde pie awe Jo 49 Konpsor matin upon secomm ag ot saaig Stam ed jose May aM ULSAUERIG IONE IV agen Jo Gpyes uta pourss009 sammeeg “y suo wopoy a | amivaa a a {YRURLEND ONYNELNIVI “TP SEV,Maintenance Criteria fal attention Special attention Special attention Special attention ‘Special attention Routine ‘Special attention ‘Special attention ‘Special attention Routine ‘Action Bo texraveing Fill and compact and tring its | Rovtine Eirtecsto deur camber™ Clean out he drains \ Reconsrt to adequate Bape and see Repair by filing Repair epalaReplce Fak mw one rectly Repair Clean and repair replace Investigate the cause and ‘Any extent Any extent Any extent ‘Any exteat | z é ‘Any extent Any extent ‘Any Any extedt Any ‘in paved (o) Erosion at aletfoutlet ) Guide posts/ood ? ange musing Feature D2 Culverts surface (© Settlement cracks E. Othe Works 7 ‘shoulder C2 Sing of side drains G3 Damage or scour Cees @) Pot 8 ‘anlng diy or corroded ‘Sr dammed ning 2 Mining road signs B oaba at inesy ‘unpaved road C. Shoulders—side dralas BS Undulations ‘B-10 Loss of materia frous C1 Deformation or scour D. CD. Works DI ca EAL Road farnitare and Maintenance Criteria 26 awe 4.2, | Lane | Trafic commercial | Type of renewal and periodicity width | vehicles per day)” | ‘ofthe renewal treatment for Class of road | tow | atedium | sigh | rainfall | rainfall" rainfall 150.300 | above | Se | 150m | cm per | 300 cm I per year | year | pee year National ‘Singk = Lessthan 450 SD SSD Highways 4 4 7 and State (430-1500 ep Highways + a 3 iy More than 1300 PC PCB 6 3 i Mos as 3 iu . Double) Lessthan 450, SD SDS 3 4 cs (i) 430-1500 sD sD SD 4 3 ‘S Gi) Morethan 1500 PEPE 6 3 ‘ ashes 5 TO & Notes (1) SD = Single coat of uric desig with 3 ct, of chips and 25 1 of ‘itnee PC = 20 mm premix chipping carpet as per IRC : 14 MS ~ Mix sal surfacing at pet Minitry of Shiping and “Transport ‘Goads Wing Speciation for Roads & Bridge Works cause 508 (2) The denomfaator retro the perodicy of renewal io year G) For areas subject to snowfall and hilly areas with steep side slopes and heavy rainfall the priodiey of renewal maybe at ose teva (© Theperiodbty of he renewal indicated in the table above should only bétaken asa general guideline forthe purpose of Budgeting and’ deer mining the extent of renewal programme. It does not india ether the ‘xpected life ofthe parteular typeof treatment or the imperative need for ‘enewals after the period india. :Execution of 27 Maintenance Operations Execution of Maintenance Operations5. EXECUTION OF MAINTENANCE OPERATIONS 5.1. Safety of Labour and Road User During Maintenance S.1.1. Principles : In the implementation of maintenance ‘operations, the road user and personnel involved in the work should not be exposed to hazards. Besides, delay and inconve- rience to the traffic should be reduced to the minimum. Road user, even when fully aware that maintenance is for his ultimate good and safety, does not take it kindly if it is not done in a proper manner. Traffic hazards and inconvenience can be minimised by use of temporary road signs and controlling/guiding of the traffic, while keeping in mind the positioning of road signs as follows: The standard signs in good and clear condition should be displayed in a proper and standard layout, so as to give the drivers sufficient time to ‘understand and react to the information on the sign.’ The signs to be used should be as per IRC: 67 “Code of Practice for Road Signs”, some of which are shown in Fig. 5.1. Maintenance operations should at a time be confined to small lengths, say 30 m in half the pavement width, leaving the other half for use by traffic. However, some times this may not be possible and in such a case, maintenance work can be divided in the following four categories from the point of view of safety and traffic control : (@ Repairing the edges of the carriageway, shoulders, cleaning out rains, cutting grass ec, where carriageway is not affected Repairing. the carriageway restricting to one lane while trafic can be allowed on the other lane (ii) White working on the centre line such as centre line marking! painting necessitating the trafic to se restricted width on ether side Total closure ofthe road necessitating use of diversion due to ‘widening[reconstruction ofan existing CD work or construction of a new structure or ue to breach or damage 10: works. The detailed instru Follows: «30 Execution of Maintenance Operations eines af RESTRICTION ENOS MEN AT WORK ary ‘40 4 Pope ne t00 NARROW ROAD AHEAD SPEED LIMIT Hiook Fig 5.1 5.1.2. Works on edges and shoulders : The positioning of the cautionary signs for this category are illustrated in Fig. 5.2 Before starting the work, all warning signs should be installed in the following manner. “Men at Work” should be placed 200 m before approaching the work area and “Restriction Ends” sign should be displyed 200-m béyond the work area. When the work is completed, these'signs should be removed in the reverse order. Execution of Maintenance Operations 31 Fig. 5.2. Arrangements of signs for work on edges and shoulders 5.1.3, Restricting the traffic to one lane: At times, the trafic is to be restricted to one lane only due to repairs being carried out in the other lane such as major patch repairs, etc. The position of various cautionary and warning signs are illustrated in Fig. 5.3, which are to be installed before start of the work in the following sequence : () “Men at Work work