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32 Execution of Maintenance Operations. Gi “Narrow Road Ahead” should be at 100 m ahead of work area (li) “Keep leftight” sign to be placed at the commencement point of work and next to the barriers on either end of the work area arriers" should be placed on both sides ofthe work area ww) 453. Arrangements of signs for closure of one Jane Execution of Maintenance Operations 33 (9) Drums painted white and black should be placed at 10 m intervat for guiding the traffic. In the approaches these are to be kept in a tapered manner (vi) “Restriction Ends" sign should be installed 200m beyond the work area, Jn addition to the above, a watchman should be present at the barrier to control the traffic at all times. Police assistance may also be sought for in case of need. Necessary lighting arrangements may be made during night with flashing lights when required. The barricade should be protected with red warning lamps at night which should stay lit from sun set to sun rise. In addition, alternate black and white diagonal strips should be marked on these for effective advance warning, preferably with reflectorised paint. Signs, lights, barriers and other traffic control devices should be kept maintained in a satisfactory condition till such time that the traffic is restored and allowed to follow its normal path. S.1:4. Working in the centre of the carriageway : While working in the centre of the cartiageway, adequate attention has to be paid from the safety point of view, for example, marking/ painting of centreline. The positioning of the various cautionary and warning signs are illustrated in, Fig. 5.4. The sequence of installation of these signs are the same as explained in para 5.1.3. except in this case, the vehicles will Keep only to the left in each When the work is completed, it should be ensured that the signs are removed in the reverse order. 5.1.5. Diversions 5.1.5.1. In the interest of safety and convenience of traffic, appropriate measures must be taken whenever traffic on any section ofa National Highway is to be diverted to another route, or made to sever from its normal path into another. Basic principles to be kept in mind are (i) that the traffic must be guided properly where is required to follow an alternate facility and (ji) given a clear warning of any hazards that may be present ahead. 5.1.5.2. Arrangements when traffic is suspended on a sectionions 35 ‘Together with this, press and other mass media should be availed of to natify the public about road closure, and alternative routing for Execution of Maintenance Opera 34. Execution of Maintenance Operations (id Strong, 5 should’ be erected in the immediate vicinity of the damaged section on both sides so that traffic can have no chance of going through imprudently.. Besides, regulatory igns announcing that the road ahead is closed should be stalled on the approaches, one sigy at 10m from the barrier and the other 120m further away. These should be supplemented by a ‘road closed” sign affixed to the barrier ina prominent position. Word messages on the sign may be in. more than one language as dictated by needs of the road users; i) The barricades should be protected by red warning lamps at night ‘which should stay tit from sun set to sun rise. In addition, alternate black and white diagonal strips should be marked on these for effective advance warning. Preferably, reflectorised paint should be used for this purpose; jv) A watchman should be present at the barrier at all times. When- ever the barrier isto be temporarily opened for construction traffic jn connection with repairs 10 the damaged section, a responsible officer must be present at the site for supervising trafic arrangements and explaining the hazard ahead to adament rivers. The const- ruction trafic may be allowed through a small opening. (about 3m ide) at the extreme edge of the roadway, normally Kept blocked with a double row 6f painted tar drums which should be’ removed only for permitting the construction vehicles to pass each time and pt back in position immediately thereafter (©) Signs, lights, barriers and other traffic control devices should be kept ‘maintained in a satisfactory condition tll such time that the traffic is restored and allowed. follow its normal path; and centre of carriageway (vi) Typical arrangements according to the above plan are illustrated in of a National Highway because of flood breach or damage’ caused Fig. 5.5, due to certain other.reason SA53. Area ( It the duration of suspension is such as to necessitate diversion of trafic toxnother route, guidance about this should be provided atthe appropriate road intersection, on. either side of the damaged jements for traffic when repairs to an existing cross-drainage structure are to be carried out : The following instrve+ tions should be kept in mind when undertaking these works : () Traffic may be passed either over part width of the st section where it would be possible forthe through trafic to alter its : ‘course. This should be done with the help of suitable warning signs put up in'& pair, one just close to the intersection and the other 120 ‘metres away. In addition, a prominent ‘road closed” sign should be fixed on the far side ofthe intersection blocking half the width of the carriageway. Word message on the signs may be in more than fone language according to needs of the trafic. To regulate trafic at the poiats of re-routing, police help may also. be Fequisitioned. temporary diversion, depending on site conditions, volume of traffic, preferably on economic considerations and other related matters. The former method should be employed as far as possible, specially when the work could be conveniently carried. out in half width ata time and there are no undue problems in channel- ing the taffic through the available road width, Tn both cases, the36 Execution of Maintenance Operations fasten sues Eo deta ees Sheets are Ott id "gto etter eStad ko ene a 4 oe 4 AEA nor] iat cannot ane Pace ss | “CM WIDE Line TO on ‘iz | a a MM | (sizer 6 (Not to scale) Fig. 5. Arrangements for traf when a section of N.H. is to be closed due to breach or damage Execution of Maintenance Operations 37 Work should be so planned that repairs of the cross drainage facility is over in the shortest time possible following properly your eujpnysu01 “¢ syper9 soveaty oun suse “1 1989 Execution of Maintenance Operations 42 1898 Boy 10 [295 Sums soeyins Xu @ Jo uonnadsy rodeo xtuaud x0 Busso4p ‘0jns HP BuDRLNSa A soneBou83e aandiosqe 20 uouamng S89 28/1 ame adutay wo} 28 40 using Jo uoneandade wlosrun-uON ‘antssanx9 10 ‘owen s3pun sussoid ie J0 801 spe ou 10 save mi frounng jo sou AAvay pur ‘uep| STeWraqe Jo 2oUussaN bonnie bunt *y Aupyeang °¢, “Bieboitse jo Sagatod ‘sods sonjins yoowas *z save po.oye Jo f2souss spo ase Kava Syanssoxa Spud Jon03 Pye sol 00 ors 0 eas sous ‘fraud uf Sapa aareaoeg 2 Uo Z9puIg Jo wonDal0> soepins nea.“ spp ons -y , € z t swveen 30 s9da 4804 sosmes atqego.d surordunks ssonspp Jo ad, SOMIDVENng SONINA.LIG NI S19114d 40 LNINLVERL GNY SERV "SHOLENAS “TS MOVE45 Execution of Maintenance Operations Execution of Maintenance Operations 44 -pringas pa. ‘0} vase porous 94) yim suorseaud 9 “Boe at 35K0 put ‘Foroedaios pur Burpeaids s2%00d paredatoo ‘Aprenbopeuy Jo s0usea3g 23 sonseduso> aie pue pata oq 200d “316 ‘res sxe Atteosn “s2}04 pedeus-jnog jo soueieaday soups oun 2341 plot or sapurg Jo aznie, suoniod owos u ayvBau80 430 Soy WIP BoR]ANS HERON amsou Jo souereud om uy oyesause {wos} wou Jo womeseds§ wuouaned Jo wopewiojap 2807 sttojsaidap -soUeMs pTEIOT senor Bupyeaiqs8pa '¢ 210-104 “y Aoyeara “¢ oreBai8Be Jo s807 Z saddens “1 wopestomsia a teavodn ue suouenes “9 Uorssexdap moneys “5 Bapous “> suoneBa0) (pmo) 9846 Execution of Maintenance Operations In this connection, duties of the following supervisory staff have been spelled out: (i) Duties and responsibilities Mate Appendix 7 @ » . Munshi Appendix 8 Gi) ” Mistry Appendix 9 5.3.2. Task norms of gangmen: The gangmen must fully know the tasks they are to carry out and the expected out-put, There should be regular checking whether the tasks assigned and output achieved are as per norms. The recommended tasks for labour are given in Appendix 10, 5.3.3. Gang beats : The gang should be made responsible for a particular section of the road depending upon the nature of works in that reach and the mobility of the labour. Normal beat ofa gang is from 15 to 20 km (see Appendix 11 for general norms). Storing materials, tools and plant should be at a central location for quick and proper access. 5.34. Mobile gangs; Mobile gangs may be made use of more conveniently, cheaply and efficiently where pick vans or trucks are available. The headquarters of one or more mobile ‘gangs should be fixed at @ convenient location on the read where the necessary store-sheds for tools, plant and construction materials would be available together with rest-shed. 5.3.5. Proper tools and plant: Proper tools and plant having multi-purpose use increase efficiency of the labour. Tractors trailers, dise-harrows, small mechanical rammers can do multi jobs. Use of tar-patcher, motorized equipment for preparing cut back by cutting with kerosene, folding wooden camber boards, etc. are small equipments which add to the efficiency of Iabour and quality of work. A list of tools to be kept with each gangman is given in Appendix 12. 5.3.6. Training : Right type of person should be employed for every type of work. Whereas female labour can be good tronsporters for small loads, only skilled male Inbour should Execution of Maintenance Operations . 47 ployed for work like bituminous construction. Regular ing regarding works to be carried out, use of tools, plant and materials, etc. should be imparted to these workers. 5.4, Material Procurement Material that is used for maintenance for bituminous paved surface is bitumen and aggregate. The procurement can be divided into different operations. 5.4.1. Control procurement of binders : The materials that are procured and stored centrally are bitumen, cut-backs and emulsions. These bituminous products should be procured and stored centrally in each section for use in the work. The quantity be calculated from the repairs programme approved which will also decide the time schedulings of procurement. 5.4.2. Aggregate : The aggregate for renewal work should be collected at site of work only when itis required to be used. ‘The best season is April—June and mid-Sept. to mid-November. Aggregate for patch work can be collected at the time of starting the work after calculating actual requirements and also can be procured before critical seasons (such as rains) and stored in every kilometre on a specially prepared platform by the side of ‘each kilometre stone. A judicious decision in this respect has to be taken by the engineer-in-charge depending upon likely work and availability of materials at short notice. 5.5. Mechanisation and Equipment Planning ‘The spectrum of technologies available for maintenance of roads ranges from labour based to equipment based, although the relative proportions can differ substantially. ‘The socio-economic requirements in India is basically for labour based maintenance to provide employment to a large number of people but it may be necessary to use special equipment to achieve a specified quality in the end product of certain activities, such as the use of (a) roller for compaction or (b) grit spreader and bitumen distributor for good surface dressing. Even the labour based methods use epuip- rent in the form of hand tools and equipment based approaches use labour in the form of operator. Work animals are also veryeye pes 48 Execution of Maintenance Operations Execution of Maintenance Operations 49 useful and cost effective in construction with labour and simple equipment such as carts and rollers. Tables 5.2 and 5.3 give an 2 3 : indication of the range of maintenance methéds potentially appro- : z(|2 é 3 oe priate for use in India. The adoption and modification of agricul- alg = oe 2g tural equipment like tractors and blades for grading of shoulders si be i a ee are the useful intermediate techniques. Agricultural ploughs drawn B|E & = & 3 a $2 8 ‘by animals or small tractors are useful for digging operation. ele eg 2 3 Po The loosened excess materials are then removed by hand of small ao |e Se ae 4 serapers. 3 eee ee esa : Ae ore 8 = 62s 5.5.1. Mobile gang system: Mobile system of gangs ia the af 2 place of the conventional labour gangs, who are practically ma FREE BE EEE immobile and have little or no equipments will go along way in e132 ess. 3 =" g streamlining the routine maintenance work. In this system, the E|@ oy bo ge 3 labourers instead of ‘moving individually on foot move about , Fak Hie = 2g BE 3 collectively in groups of 10 or more in a truck equipped with 8) 2 258 § ies. necessary base tools for routine maintenance work. In addition gy i? é og to the required equipments, the truck may carry premixed stock cia tof Bie Bye 58 piled patching material. Such groups, because of their mobility - e|= agi 3 Zne een ee are capable of looking after sections of road from 30 to 50 km i E52 22335235 with much greater ease and efficiency than the dispersed gang et a labourers as now. Despite its initial cost, it is advantageous in the gle rd Jong run. The headquarters of one or more mobile gangs should é z a Oe be fixed at a convenient location on the road side where the g|2 #3 gy is necessary store sheds for tools/plant and construction mate 2/3 ioe 28 32 ‘could be available together with rest shed. ela : tH His ziulet fees ee 5.5.2. A list of equipment that is needed for various types 6 | 2 |2.az S35 23, Es of bituminous works is given in IRC-72: “Recommended practice 2/2 | 2735 gu gu for use and upkeep of equipment tools, and appliances for bitu- - a es aed zee fee minous construction”. ol eese sek a 5.6. Maintenanance of Drains, Shoulders, Slopes and CD 2 ae eeatet el i want : oe FY), |SRSnETET ES sas zi 3 : else oe 5.6.1, Drainage else ee 5.6.1.1. Objective: To ensure that drainage elements 2) es ge 42 ay qi remain free of obstruction and retain their intended cross sections . a3 ae $f BS 83 and grades, = eS + 46 ope saveraee “Good “Excellent50 ‘Tame 5.3. Haulage Method Execution of Maintenance Operations Aureananive Mettions Haul Distance Constraints (m) 1. Head baskets 5430 A traditional method: Better results ‘can be obtained with a litle super- vision. Route conditions and steep- ress not critical. 2. Sacks Tnefficient, particularly loading but usefulforlong distance haulage hilly ferrain and for fine granular material ‘Two man bamboo IneGlcient but useful for hot _mate- stretchers rials, 4. Hand.carts, [Need good haul route, 5. Wheel barrows 25-125 Very competitive if. well organised, with ball bearings Haul route condition and critical, this can be improved by using steep. 6 Donkeys 50-125 Reasonably independent of ‘haul route condition and steepness. Gang toalance fairly critical for good results, 7. Ponies 50-125 Mules Sonus 9. Camebearts 100-600 Can be used in sandy soil with baloon tyres. 10. Bullock-carts 100-600 Require average route conditions. M1, Tractorfteaiter 250-500 Good organisation critical fot econo- ‘ical result 12, Trucks flatbed or $004 ‘Cost dependent on organisation 10 tipping ‘maximise trips. Execution of Maintenance Operations 51 They must function properly so that surface water, and ground water can drain freely gnd quickly away from the road or under the road. © © oy @ ) ) Water is the worst enemy of any road, it can. —Frode soils Weaken pavements ‘Destroy shoulders and slopes —Wash out culverts, and even bridges. 5.6.1.2. ROUTINE ACTIVITIES -—Reshape}regrade/deepen —Clearing and cleaning Erosion repair PERIODIC ACTIVITIES Provision of lateral ditches (turn outs) 5.6.1.3. Culverts ROUTINE ACTIVITIES Clearing and cleaning Erosion repair to cracks —Repairs to protection works PERIODICAL ACTIVITIES Reps of invert 5.6.1.4, Causeways ROUTINE ACTIVITIES —Minor surface repair Replacing guide posts Repairing flood gauges —Repairing protection works 1,5. Inspection : Inspection of drainage system is an year round task.” Structures must be examined in dry season when little52 Execution of Maintenance Operations or no water is flowing so that structural damage cracks, settlement, erosion can be better seen and identified and waterway cleared of debris. The functioning of drainage system during the rainy season should also be inspected. The drainage structures usually require examination on foot. ‘The Junior Engineer, Assistant Engineer must check them on foot and look for signs of damage and distress. If surface and ground water drains freely as intended the system can be deemed satisfactory. However, if water does‘ not flow as intended, there is something wrong and needs to be repaired. For example It a culvert outlet discharge i small when the inlet is at full head or submerged the culvert is not functioning’ Where the carriageway does not have an adequate camber or cross fall, the surface water will pond on the surface and accelerate the formation of rus, pot holes and unintended ditches Where drains have litle or no scope or inadequate turn outs, sitting will occur and cause ponding of water and weakening of pavement. 5.6.1.6. Inspection check list (a) DRAINS Drain cross section destroyed —Ponding in drain silting Erosion, (®) CAUSEWAYS —Pothbles in paved surface =Cracks in paved surface —Guide posts missing —Flood gauge missingjtited (© CULVERTS —Silting, sanding, blockage of debris =Erosion at inlet and outlet Settlement cracks Execution of Maintenance Operations 53 5.6.1.7. Defects, causes and remedies DRAINS (@ DEFECT—PONDING CAUSE—Cross sect ‘The shoulder material be- comes soft and can easily erode. ‘The pavement can also be flooded and thus weakened. ACTIVITY—Deepen drain + (&) DEFECT—SILTING CAUSE—Invert slope is too flat, the water can not flow at suili= cient velocity. If neglected the drain will get blocked. ACTIVITY—Deepen. drains (desing) and/or provide lateral drains (turn outs). (©) DEFECT—Uneven drain iavert varying crosss section, CAUSE—Blockade by debris, and vegetation, if neglected cross section is reduced and water cannot flow asfatended ACTIVITY—Cleening, clearing, repairing. (@) DEFECT—avert and sides of drains are eroded. + CAUSE—Invert slope is too steep, If neglected, water flows at 100 high a. velocity and starts carrying away the soi ‘The drain becomes deeper (ravine). ‘The sides then cave ia, the shoulder can even part of carriageway can ‘be washed away. ACTIVITY Reinforce drain slopes aud invert —Regrading/realigning dai —Provision of drain checks, 5.6.1.8, Causeways : ‘The surface of causeways is endangered by vashouts and slash movement caused by water current. Routine maintenance in this case can only be regarded as temporary measure. The activities include ‘masonary repair, placing of stone crates; and erosion protection ‘of causeway. openings. DEFECT—Cracks in paved sucface. CAUSE—Settlement of siab. I neglected, the cracks in concrete slab spread and widen especially during the following flood season. ACTIVITY—Minor surface repaic sealing cracks). DEFECT—Guide posts/ood gauges are missing or damaged.Execution of Maintenance Operations Accident, vandals, food dhinge, 1 melee, CAUSE ‘Men he pavement becomes submerged during. food the edge of pavement cia aot Be sen, eile teckel drive lato deep ae ACTIVITY—Replacing guide poss, 54. 5.6.19. Calverts DEFECT—Siking, sanding, blockage by debris CCAUSE=Invet slope to fat. Culvert conseucted 100 low, 40 that materi sueam bed gts deposited inthe culvert Vegetation and Nooding debris cacied by water ave become lodged inthe eulvert. Hf neglected, the aten- ed wacrwey opening wil be 9 reduced that Hood water cangot ow. itil back up or podd onthe Ustream side-of culvert and may eventual overflow the road enbankwient, "The road is in danger of beiag wathed away. isa problem, VITY-Clsaing and clarng. If footing debris es the provision of debris rack should be considered. from Teast econ Sees nen eaeed ae eer ere ae ee Seen rn ee Se eceatanne a Stee mere rn Sr ce ar core tend eee eae eee ACTIVETY—Cracking repair for minor damage. Execution of Maintenance Operations 55 5.6.2. Shoulders: Shoulders. (Berms) provide lateral Support to the pavement. They are used for parking vehicles in case of single lane roads, provide room for passing vehicles where carriageway width is insufficient and also comes in handy for the parking of disabled vehicles. These are at times serve as a track for slow moving vehicies. The properly maintained shoulders also helps the drainage of surface water quickly to the side drains. Improper maintenance of side shoulders will cause. drainage along the edge of the pavements resulting in caving and there by pene- tration of moisture to the subgrade. In order to perform satisfactorily the functions stated above, it is necessary that the surface of the shoulders are hard enough to resist the abrasive action of vehicles and likewise the disrupting influences of the elements of nature, The shoulder surface should always slope uniformly from the edge of the pavement so that any water falling on the road surface or shoulders, is speedly drained off. If funds are available, itis better to have the shoulders paved or have hard shoulders with BT. surfacing. The work of maintenance consists of periodically replacing earth or moorum carried away from the shoulders, to reniove ruts, and restore the slope to the designed level. This work is generally heavy during and after the rains. 5.7. Maintenance of Road Furniture 5.7.1. Traffic signs : Traffic signs are the principal means of conveying information about the road to drivers and, as the road network becomes more extensive, the number of traffic signs increases, As traffic flow increase, an increasing effort on theit maintenance is needed. Signs which are clean and in good repair can be easily seen and'tinderstood and inspire confidence that their message .is accurate and reliable. Damaged or missing signs should, for the same reasons, be replaced promptly, as should temporary signs upon completion of the maintenance works to which they are related. The provision and care of signs is very cheap and coit effective,56 Execution of Maintenance Operations Signs should be inspected and cleaned at least twice a yeur. Wherever repairs can not be cartied out at site, the signs can be taken to the workshop and got done as decided by the Engineer-in- charge. It is worthwhile keeping records of traftic signs: they should be included in an inventory and transferred to. a signs register in which inspections, repairs and replacements are recorded. It is useful if their location is recorded in strip map. 5.7.2, Rails and kilometre stones: Guard-rails and parapet rails are provided to protect roads users: guard-rails to prevent vehicles from running over high embankments and parapet rails on bridges to safeguard pedestrains and vehicles. They should be repaired promptly if damaged and kept clean and repainted regu- larly so as to maintain their visibility. Kilometre stones provide both drivers and the maintenance organisation with the basic reference for the position. of any point on the road. ‘Kilometre stones should be kept clean and repainted regularly, and vegetation around these should be cleared so that they can easily be read from a’ moving. vebicle. Similar requirements apply to bridge and culvert marker stones, It istecommended that each bridge and culvert is pro- vided with a market stone (or stones), serially numbered within the kilometre in which it is located thus: 80/2 is the second culvert co bridge in km 80, These numbers should be used as references in the culvert and bridge registers. Delineators are usually provided -only on high bank or on bends. They should be kept clean and colour washed/painted regularly, reflectors may also be fitted. Vegetation, around the Gelinators should:be cleared so that they can be easily seen at a distance. Execution of Maintenance Operations 87 5.7.3, Requirement of equipments: The team required: to carry out these works require the following equipments : 1 Pick—axe 1 Spade or shovel 1 Hand rammer Dry mixed concrete 4 small ladder Water Paints Brushes Solveat for brush cleaning ‘Safety equipment.Organising Maintenance 69 Operations in Fi 6 Organising Maintenance Operations in Field6. ORGANISING MAINTENANCE OPERATIONS IN FIELD The section incharge may follow the following steps suggested for efficient working : 6.1, Preliminary Steps 6.1.1. Examine the section to be repaired: Tlie section of road to be repaired must be examined along its whole length in order to determine : The types of defects —The extent of defects 6.1.2. Look at work sheets: These sheets give the dates on which work on the road section concered is to be carried out as well as information on the materials to be used, The format of work- sheet is given in Appendix 13. 6.1.3. Check required resources Please check All necessary personnel are available All items of tools and plant available All trafic signs available =Required quantity of bitumen and other required materials avs lable 6.1. This ‘Temporary sign posting is to ensure the safety of Road users Personnel working on site Vehicles and equipment employed. 6.2, Execution of Work 6.2.1. Treating bleeding {Coarse sandjchipping over 6 mm size scattered over effected surface preferably during sunny hot afternoon or after preheating. sand{chipp- ing to °C.62 Organising Maintenance Operations in Field Coarse sandjehipping is spread by a broom so that surface is evenly covered. 6.2.2. Local seiling —Sweep the area, The surface must be clean and try. —Mark the area to be repaired by a brick piece or chalk. —Spread bitumen (cut-backjemulsion) using watering ether atthe rate of. 1.5 kgym* of bitumen emulsion or 1 kgrm? of cut-back bitumen —Distrbute agsregate ‘Chipping (6-10 mm size) when dealing with local surface repairs. ‘Chippings should be compacted, 6.2.3. Crack sealing using slarry © 6.2.3.1. Closely spread cracks —Sweep the area clean and dry Mark the area to be repaired —Slorry is prepared by mt:iog bitumen emulsion with sand in a wheel ‘barrow —Sand—20 it femolsion—6 It —Material may be spread approximately 5mm thick over the whole of ‘marked out area and not in a thin layer. 6.24. Treatment of isolated cracke } Filling cracks with hot bitumen/cut back bitumen, Sweep the area! —Diatribute bitumen to follow line of crack . Distribute sand using a shovel. 6.2.5. Filling in depressions : To deal with subsidence, and surface irregularities due to shoving —Sweep the aren clean anid dey ack thie area to be rated Apply tack coat at a ae of shout 0.5 kg/m Pini the deprenion Mic peed hn mate ue lg ft dein an fhicknet of about one hid of the: depth of depres. to allow for compaction Compaction of material by either durmats or Wibrating simmer. Organising Maintenance Operations in Field 63 6.2.6, Patching 6.2.6.1. Patching is used to repair Mesh cracking Ruts and depressions Edge, subsidence and rutting Pot holes Edge surface failures —Shoving 6.2.6.2. Four steps are involved Marking of area to be repaired —Excavation of area to be repaired ‘These steps are necessary to (@) remove all material from the marked out area (©) increase the depth of hole until firm material is found then dress the walls ofthe hole so that they are vertical (©) dress the bottom of hole such that it is fat! and horizontal ‘and thea compact it —Back filing the hole with selected well graded material which ‘may consist of a material of base layer to be repaired. The material is placed in the hole and compacted in one or more layers of regular thickness depending on the depth involved. The last layer, prior to compaction, must have an excess thickness of about one fifth the depth of excavation, in order to allow for settlement on compaction. Compaction is continued depending on the size of excavation, using durmats or vibrating rammer until the surface is level. -~Completion and removal of temporary signs (a) Remove all excavated material ©) Swoep all aggregate from edges of repairs, apyy sand to all areas where 100 much binder has been appliee (© Signs should be removed, removing the MEN AT WORK sign in the last 6.3. Work Report Report on work accomplished during the week should be filled in the form of work report given in Appendix 14:Monitoring 7 Monitoring7. MONITORING 7.1. In order to ensure the desired progress in terms of physical and financial targets, it is essential to keep a close watch by monitoring through returns. The required returns for monitoring at field level have been explained elsewhere. For monitoring at circle level, a proforma at Appendix 15 has been suggested. This return of the physical and financial performance should be submitted by the Executive Engineer to the Superintending Engineer after finalis- ing the yearly accounts, in no case later than the 15th of June every year. The shortfalls, if any, should be discussed for better perfor- ‘mance next year. 112 Detailed procedure and time schedule for the State Government's to forward proposals for maintenance and repairs of National Highways has been laid down by the Ministry of Transport vide letter No. NH III/Misc/139/77 dated 5th December, 1977.. The ime schedule is as under : (@), Proposal for ordinary repairsrenewals Ist Jon, of maintenance of urban links and major each year bridges (b) Continuing S/R and flood damage repair 30th April works. (©) S/R (New) works Ist June of each year (@ FDR. (New) works 18th Oa. of ‘each year (© Reappropriation of funds 28th February Itis also to be ensured that all the special repair works and Flood Damage repair works are completed within two years.Training in Maintenance 69 Operations and Training in Maintenance Operations and Management8.1. Training of all the personnel involved in maintenance is an integral part of the maintenance function. Such training, as may be required by the operating and maintenance personnel to achieve better performance can be classified as below : (a) ‘Training of Engineering subordinates/section officer. (©) Training of gangmen/mate, 8.1.1. Training of section officers : The section officers are cither ‘diploma holders or fresh degree holders. Either way they are expected to perform all the necessary management taske ometime without any formal management orientation or training, The typical section officer learns about maintenance managemen, While he is on the job. This can be effective but most of the time bad pratctices are learnt with the good ones. Frequently the new {ection officer handles’ the job in the same manner as the person before him. Techhiques which may or may not have worked twenty years ago are tried again today. Section officers nad Potential section officers must be provided with the opportunity to attend maintenance ‘management and operations training. The areas to be covered during the training should be (D) entifcation of defects @) Planning maintenance operations eectively (©) Crew scheduling and control to achieve higher productivity at low ott consiatent with quality (8) Problems of crew supervsion-—commusicating and coord (©) Preparing road iaveatory (© Management by objectives ©) Repair methods 8.2.1. Training of gangmen/mates : The training of mainte- ‘nance gangmen in two areas is very essential, (2) Safety aspects (©) xepair methods72 Training in Maintenance Operations and Management ‘The training in safety aspects will include : @ training of fag-men (i) use and lay out of temporary trafic signs for repsir works (Gi) safety oriented handling and parking of machinery aid ‘equipment. ‘The training in repair methods will include : () proper patching methods i) proper grading of shoulders (iit) maintenance of drainage structure (iv) crack sealing (painting and maintenance of the traffic signs and warniogs (vi) equipment maistenance. Problems of Special 73 Areas 9 Problems of Special Areas9, PROBLEMS OF SPECIAL AREAS Roads in special areas like desert areas, hilly and heavy rain- fall areas und high altitude areas pose problems of maintenance Which need-greuter attention. Even though the planning, imple~ mentation and monitoring of maintenance activities will be, by and large, as detailed so far, still there are specific points which need special treatment and these are detailed below : 9:1, Maintenance of Roads in Desert Areas T problems (a) Removal of drifting sand dune which cover tne road during the summer months. (b) Weak shoulders and age works. road maintenance of desert areas has two unique n cut erosions on shoulders and cross. drain- ‘The problem of drifting sand dunes can be remedied by : (@) Choosing correct alignment during construction of the road. The tlighment should be a far as possible run parallel to the sand dunes ind the sand dunes should be erossed without disturbing the existing prodile of sand dunes, and (©) Plantation of shelter bolts using ight species of plants such as Acacia Tortis and. Prosipius Juliora. Shelter belis should be planted uring early July jmmediately after the first rain. Along with it, ‘Moonj: grass or locally available grass can be grown behind the “shelter belt over the entire sand dune as ground cover to stabilize the ‘The sohition to rain cut gullies lies in shoulder packing, check. walls, pitching and lined chutes. These works are to be executed as and when need arises. 9.2, Special Problems and Techniques for Maintenance of ‘Poads in HillviTerrain in Heavy Rainfall Areas In heavy rainfall areas in hilly terrain, the major problems faced in maintaining the roads are landslides,76 Problems of Special Areas drainage and soil erosion, apart from frequent damages to road pavement. The remedial measures to be adopted are discussed below. 9.2.2. Landslides problem : Landslides constitute by far the most serious problem in maintenance of roads in hilly terrain subjected to heavy rainfall. The remedial measures for controlling! minimising landslides will be = ( The side slopes of the hill should be maintained to proper angle s0 ‘that they are stable. ii) Minimum deforestation should be allowed on the hill face above the road as this causes disturbances to the stability of hillslope. ii) AM potential lanslide/disturbed slopes should be identified and suitable treatment should be provided eg. terraced bally afforesta- tion, turfingiplantation of shrubs/bushes, along with asphalt mulch ‘treatment, of jutejcoir netting etc. (iv) Terraced paddy cultivation, Jhoom cui the road constitute potential factors for de this should be discouraged. (0) Indiscriminate blasting io hil slopes causes destabilisation and this should be avoided as far as possibl (i) Apart from the treatment of disturbed hill slopes, protective struc- tures in the form of check wallsjlow Breast walls/toe walls help i stabilising hillslopes and contain the landslides and should be pro- perly maintained. 0 in hillslopes above ilising hill slopes and 9.2.3. Drainage problem : Most of the maintenance problems in hill roads of heavy rainfall areas starts from improper drainage. Itis, therefore, very essential to provide adequate system for ensur- ing easy and prompt drainage of rain water flowing to the road from the upper catchment areas. Following steps should be taken to ensure effective drainage : (@) Surface/subsurface water should be Jed to natural water courses below road through cross drainage structurés, In particular, inter~ cepting or catch water drains provided above the cut slopes for speedy and safe disposal of rainwater should be kept in good repair fand cleared of obstructions. Side drains should be maintained to their capscity for enturing effective drainage even when partially Problems of Special Areas ad blocked/choked due to debris, growth of plants, etc. The drains Should have gentle. gradients aud side slopes to enable carrying the flow without erosion. Drains should be linedjeement pointed where Grosion iz anticipated due to poor or weak soil and in subsidence (by Where the side drains are likely to be choked with sliding materials, they should be covered temporarily during rainy season with closely plaved wooden ballies where feasible, in order to ensure unint rupted drainage. (© At the upstream side of the culvert the catchpt provided should be kept clean. (a) Drains, catchpits, ete. should be cleared of all debris and repaired where necessary before the onset of the rainy season. (©) Im order to avoid rain water lowing across the road surface, when tide drains. are_ blocked in part length due to landslides/erosion of Hill slopes, false drains with guide bunds should be provided by the Fide of the chocked. drain in. order to channelise water to the un- Affected portion of road side drain. (0) Weep holes of retaining was and breast walls should be cleared and all vegitative growthichokage should be removed. before onset of 9.2.4, Soil erosion problems : Measures should be taken to censure that erosion of soil from hillslopes both above and below the road formation is kept to the minimum, as this eventually leads to landslides/chokage of drains and natural water courses, Some ‘of the erosion control measures are indicuted below (@) It should be ensured thatthe cross ‘drainage structures discharging Vater on the valleyside do not eause erosion even when flowing for a Tong period. Necessary channel training and erosion control works like pavingipitching of the channel and outfall points, drop walls, lanron, ete. below the outlet of cross drainage structures should be properly maintained. (©) Vegetative cover should be established on cu/fil slopes through any of the techniques described in TRC: 56 “Recommended practice for treatment. of embankment slopes for eroxion control”. The activity of establishing végetation on barren slopes ahould be treated ‘as part of the regular maintenance activities on ronds. 9.2.5 Repairs of damages of pavement : Repairs to damages to pavement like potholes and depression from another important maintenance task. Such repairs should be done to regular80 Problems of Special Areas motor graders and special rotary cutter type snow clearance ‘machine ‘Clearing of roadside drains promptly. i) If reitscted width of road has been opened due to comptlsion of providing prompt road’ communication by clearing snow, then cross 44. Spirit level with straight edge and camber 1 No. templates with graduated wedge ‘5. One metre square light-weight portable frame 1 No, 6 Printed inspection forms 1No. 11. Clip board and ball point pen 8. Coloured pencilisketch pencil 9. Warning signs 2 Nos. 10. Maps of the area 11, Maintenance Manual Appendices a 1.2. Methods of assessment 1.21, Visual assesgments—Most of the assessments should be done with careful observations. However instruments are to be used for purposes of accuracy. 1.22. Side drains and turn ouls—Side drains should be maintained at least one! mietce below the formation level. The depth and cross section ‘should be checked and measured at least 200 mts. intervals. 1.23, Corrugations—They can be measured with a straight edge and ‘measuring wedge at 200 mts, intervals along the’ roads. The mean of the reading at each 200 mats s to be recorded. The readings are to be at closer intervals, any 50 metre, where by visual inspection itis noted that the surface is highly corrugated. 1.24. Rutiing—The depth of rut is to be measured by keeping the straight ‘edge piacing transversely across the wheel tracks and using graduated measuring ‘wedge. The mean value for the wheel tracks to be worked out 1.25. Potholes—The area covering majority of pot holes should ‘be measured along with number in every 200 metreage. The percentage area is to bbe worked out 1.2.6, Camber and cross fall—It should be checked with a camber templates ‘on bothsde of the centre line, 1.2.7. Los of materials—The thickness of the W.B.M. layer should be ‘checked at 15 mts. intervals to assess the loss. of material. The measurements should be done at least at three places across the road. 1.28, Cracking~The light weight portable frame of im x tm size should be planned -and type and extent of cracking should be assessed visually ‘at 200 mts, intervals or the places of defects whichever is less.92 Appendices Appendix 6 ACTION TO BE TAKEN IN CASE THE ROAD IS BREACHED OR BLOCKED ‘Action tobe taken by the mate ‘The following actions will be taken by the mate (2) Immediate report of the road breach/blockade will be made to Subj Junior Engineer and Assistant Engineer. The following points will be included in the reports ‘Name of the road i) Location of the breachyblockade (Gl) Length and nature of the breach blockade (uv) Date and time of occurrence (9) Assessment of the assistance in the form of men and material required. (by Road closed” boards and “Diversion” boards shall be fixed on both sides at 120m distance in advance of the hazard in case of NH. & SH. (Jn case of MDRS & ODRS this distance will be 90m sand 60 m respectively). (©) Arrangements for red lights to be done in ease of darkness (@ Beldars will be deployed to guide the trafic to prevent any accident {©) Construction of diversion, if possible, Action to be taken by Engineering subordinate ‘The Engineering subordinate in charge of the road. will take following actions at once : (@) He will at once vist the site of the hazard and shall ensure that (@ Road has been closed by means of barricading with empty drums ‘or kachha wall or by any other means available atthe site. (Gi) That caution and diversion boards have been fixed ‘on’ both the sides (Gil) Arrangementé made 0 guide the trafic by posting & gangmen ‘having red flags. (Gv) Arrangements made for red light and chowkidar, ote. (©) Steps to stop farther damages to the road are taken as per site requirements (vip Possibilities of construction of diversion to be explored. If possible the diversion should be constructed. with available resources. Appendices 93 (b) He will immediately report to the Assistant Engineer, Executive Engineer and Superitending Engineer telegraphically regarding the road breach, duration of blockade of the traffic followed by a detailed report contani (@ Name‘of the road Gi) Location of the breach/blockade iil) Length and average depth of the breach (Gv) Duration of suspension of the trafic (¥) Date and time of occurrence (i) Requirement of man and material for restoration of traffic and road and the approximate cost (©) Allout arrangements and efforts shall be made for restoration of Acafic 3. Actions to he taken by the Assistant Engineer ‘The Assistant Engineer will take the following action in case of an emergency of road breach, etc (@) He will at once inspect the site of the hazard (&) He will inspect all safety measures taken by the engineering sub- ordinate (© He will ensure thatthe restoration of traffic is done atthe earliest (@) He will send a detailed report regarding the breach/blockade enume- ‘ating all the points given under 2. (b) In addition to these he will also include the following points (i) The causes ofthe breachblockade (ii) Forecast estimate for restoration of trafie and road (iy Remedial measures to avoid any future occurrence with forecast estimates (iv) Any other information which he wants to include 4, Action to be taken by the Executive Engineer : ‘The Executive Engineer will take the follow ing action in case of an emergency of a road breach of similar blockade (@ He will at once visit the site of breach. In case of more than one ‘occurrences, he will inspect them in order of priority and importasice (@) He will ensure speedy restoration of trate (©) He will cond a detailed report about the road damage indicating (i Nature and cause of damage with locations.94 Appendices ) Proposals for remedial measures with financial implication ii) Nature and course of consequential damages to public properties, ete (iv) Action taken for restoration of traffic and restoration of damages with financial implications. (2) He will be fully responsible forall the actions taken for the protection and safety of traffic and road. Appendices 95 uM. 2 1B. 14 1s. 6. Appendix 7 DUTIES AND RESPONSIBILITIES OF MATE ‘To report to MistryJunior Engineer/Sub Engineer. ‘To make daily attendance of labour working under him. ‘To help in the layout, dagbeling, marking, checking up the quality and ‘quantity of work done by the labour and get the work executed as per instructions, ‘To assist the Mistry/Junior/Sub Engineer in taking out the measuremgat for daily work done by labour. ‘To display necessary caution boards from safety point of view as per standard layout ‘To report to his senior about any casualty, accident, encroachment to Government property or any type of serious damage to the Government ‘property within his beat ‘To maintain T&P and sign boards under his charge. ‘To carry out jobs of semi-skilled nature connected with his trade along with his gang. General supervision o¥er unskilled labour. “To get the lime/cement/eomposite mortar prepared in his presence as per instructions of Junior Sub Engincer/Mistry incharge. ‘To report about damages to structures, kilometre stone etc. and keeping them in position: ‘To comply with any instruction given by his immediate superior. Daily labour report, D.LR. ‘To ensure quantum of work being done by gang, conform to norms. ‘To keep account of permanent articles, for example direction boards, tees, drums, etc. in his beat ‘To ensure providing and propér upkeep of diversions.96 Appendices Appendii 8 DUTIES AND RESPONSIBILISIES OF STORE MUNSHI/MUNSHI 1. To report to Sub Engineer/Supervisor/Junior Engineer. 2, To maintain proper receipt and despatch register, wherever necessary. 3. To maintain proper work-wise files and records as maintained in other ‘offices with the guidance and instructions of Junior EngincerjSub Enginecr/ Tncharge of works. 4. Hewill work like a LDC under the Assistantunior/Sub Engineer or where he will be posted from time to time to maintain all records including ‘those of labour establishment of the Section. 5, To maintain TAP and its register, issue and recsipt of T&P as per order of Junior/Sub Engineer/Incharge of Section. 6. To assist the Junior/Sub Engineer in correspondence connected with labour ‘engagement and payment and other matters. 7. To maintain requisite register for ropairs/maintenance for buildings/roads ‘and put up to Junior/Sub Engineer every day for seeking his orders. 8, To maintain the register for occupancyjvacation for Govt. bungalow and quarters. 9. To prepare timely pay bills/medical billsjarrears:billsjadvance Joan bills, ete. for the work-charge establishment working under Junior/Sub Engineer. 10, To maintain casual leave/?. leave records for staff working in the section. 11, To work in Section/Store of Sub-Dn.|Dn. Office as per instruction: 12, He will do the typing work where facilities are available and will make ‘copies of estimates and letters as directed by Junior Sub Engineer 13, To comply with the instructions given to him by his immediate superior. Appendices 10. nL 2 1B. “4 15, 16. 1. 18. 97 Aprendic 9 DUTIES AND RESPONSIBILITIES OF MISTRY/SR MISTRY ‘To report to Sub Engineer Junior Engin ‘To maintain daly dary of the work done by him and put up tothe setion incharge. “To maintain daily receipt/ity consumption of meeral used in original repair works. “To prepare estimates for minor works and rer section incharge. ‘To help a giving ayout of bili per approved drawings. ‘To ensure execution of work according to specications and drawings. To take round-of various buildings, bridges and roads under his charge {rom time fo time and report to section incharge about repairs to be done Hr shall also assist to plan out a programme for such repairs in advance and ensure their exeeution through the denartiental tsbour within the seciied period. ‘To asist Junior Engineer/Sub Esgineer in taking out measuremenis and Aistibuting work to labour daly and checking their attendance. To estimate and indicate rough quantities of mat To take measurement of daily work done. ‘To mtintain material at ste account, and account of tafe signs. ‘To report about unauthorised encroachment, addi Govt. premites. ‘To comply with the instructions given to him by his immediate officer To lodge FR. with police for encroachments and damages to Govt propery, rond, building, arboriculture. ‘To ensure submission of daily report. To see that log books are fled daly for machinery and riaebinery are parked propery with lights, ete. “To matatan details of land width on road and check encronchments ‘To ensure proper maintenance of speed humps including panting and ‘aution boards vy with the And bridges and alignment of roauls as for sue and alteration in98 Appendix 10 RECOMMENDED NORMS FOR TASK FOR ROAD GANGS. 1, Earth work such as in berms, desing of drains, etc, (@) Ordinary soil 25 Cum/personiday (b) Hard soit 1.75 Cum/person/day 2. Dressing of berms 15 Sqmjpertonjday 3, Jungle clearance 100 Sqm/person/day 4, Patches by (a), Surface paintiog 02 Cum/pertonjday (b) Premix carpet 0.75 Cumjperson{day 5. W.BM. patches 0.30 Cumjperson/day 6, Blinding of WBM surface 150 Sqm/person/day 1. Bdge covering 60 Metres/perton{day 8, Other items as per norms worked cout from BSR of that area. ‘Note + “The quantity ‘mentioned is that of grit and ballast used for patch repairs Appendice: 90 Appendix 11 NORMS FOR WORK CHARGED STAFF ENGAGED ON MAINTENANCE OF ROADS. ‘The norms for engaging work charged staff on maintenance of roads will ‘be as follows: National Highways (Beat 16 Km) (@) Single lane 1 5 6 (b) Double lane 1 4 s State Highways & M Roads (Beat 20 Km) (@) Single tane 1 4 5 6 (©) Double lane 1 3 4 3100 Appendices Appendix 12 ‘TOOLS FOR GANGMEN (One gang for 20 km beat having 5 gangmen and one mate) ea on with cot gang) | Sectlon Tncharse 1. Spades 3 Nos. 2, Pan (parat) 3Nos. 3. Pick axes 2Nos. Axe 1 No. 5, Hand-eart with solid rubber tyres 1No. (@) Wooden—$ kg to 10 kg weight 1 No. (b) Iron—10 to 15 kg weight 1 No, 6, Tar sprinklers (Uharas) 1 No. 7. Tar buckets 1No. 4. Tar kettle or tar boile (mini) 1 No. 9. Brashes (@) Wire brushes Sox. (b) Coir brushes Sos. (©) Hair brushes Sos, Hammer 1 No. Rope 12 mu 1 No. 6mm 1 No. 12, Cross slope wemplate for berms. ‘with original level (camber 3 per cent) 1 No. 13, Tar thermometer 4Nos. 14. Spring balance 1No. 15. Tape 15m 1 No. 16, Measuring wooden boxes (a5 emx25 om>40 om) 2Nos. 17. GA. bucket 1No. 18 Straight edge INo. 19, Caution board 2Nos 20. Gogales for dust protection (Bor desert areas) 10Nos. ——_—— oO wa Se? Appendices 101 Appendix 13 WORK SHEET WEEK ROAD NO... ‘Type of repair Road surface Others 1. Correct depressions [Resurface shoulders cracks (Clean drains fil, Patch repairs EMULSION. OTHER103 Appendices Appendices 102 St puady Appendix: 4 WORK REPORT WORK SHEET NO. WEEK FROM. tmox [anoaet| #2900 Suypopypucce/iemsuTy, exmyptodrg supedoy pedg, sourosrureW sunny, NOISIAIG HL NI JONVNAINIV ‘TVANNV WOU FONVAUOATA AO LYWUOI-SAVOU 40 TONVNALNIVW i il 8 I SECTION... (Quantity & Type of Work Done