5

ROAD REHABILITATION WORKS

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8

Introduction Using Labour Only Using Labour Plus Intermediate Equipment Using Mainly Equipment Spot Improvement Small Structure Works Reconstruction of Gravel Shoulders on Bitumen Roads Quality Control

52 53 5 13

5 33 5 41 5 41 5 - 44

5 ROAD REHABILITATION WORKS

5 23

Improvement Works

5 ROAD REHABILITATION WORKS

5 ROAD REHABILITATION WORKS

5.1 INTRODUCTION

Under Roads 2000 strategy the existing classified road network needs to be first partially rehabilitated before maintenance can be effectively established. Spot improvement activities are carried out after the initial rehabilitation works have been carried out. Depending on certain circumstances, there are three rehabilitation methods that can be applied:

Using Labour Only: This approach is appropriate for roads with a low traffic level and where sufficient local labour is available. The first labour gang establishes the centre line, sets out the road formation and reserve width, and clears the road reserve area of bush and grass. The second labour gang excavates the side drains and forms the camber. Compaction may be achieved by traffic or pedestrian rollers. The third labour gang opens mitre drains, cross water drains and places/replaces culvert lines. ! See details of this method in Section 5.2 (pages 5-3 to 5-12) Using Equipment and Labour: This approach is appropriate for roads with a higher traffic level and where sufficient local labour is available. The first labour gang establishes the centre line, sets out the road formation and reserve width, and clears the road reserve area of bush and grass. The second gang consists of motor or towed grader(s) and forms the camber. The grader DOES NOT cut drains. Compaction is achieved using towed or self-propelled rollers. The third labour gang opens all drains, cross water drains and places/replaces culvert lines. ! See details of this method in Section 5.3 (pages 5-13 to 5-22) Using Mainly Equipment: This approach is appropriate for roads where there is insufficient labour available, e.g. semi arid and arid areas. The first working gang establishes the centre line, sets out the road formation and reserve width, and clears the road reserve area of bush and grass. Most of the clearing work is done using equipment, such as dozer and grader, and supported by labour for minor works. The second gang consists of motor or towed grader(s) to excavate/clean the side and mitre drains and to form the camber. The last gang, mainly labour, deals with other drainage works. This includes scour-check installation, cleaning of culverts and repair or installation of new culverts. ! See details of this method in Section 5.4 (pages 5-23 to 5-32)

5-2

Improvement Works

5 ROAD REHABILITATION WORKS

5.2

USING LABOUR ONLY

In order to achieve satisfactory workmanship and simplify supervision, the road rehabilitation process is broken down into a series of simple activities. They are carried out by separate groups of labourers, in a sequence. In this way a train of activities moves along the road improving the carriageway and drainage in a controlled step-by-step manner. The work is subdivided into three main operations, each carried out by a separate labour gang that follow each other in sequence:

Gang 3

Gang 2

Gang 1

DRAINAGE WORK 3rd labour gang

CAMBER FORMATION 2nd Labour Gang

SETTING OUT + CLEARING 1st labour gang

The activities necessary for the labour only partial rehabilitation approach should be selected from the following schedule and carried out in the sequence shown:
SEQUENCE OF PARTIAL REHABILITATION ACTIVITIES FOR EARTH AND GRAVEL ROADS USING LABOUR ONLY Operation Site Support Work Activity Site Camp Installation Site Camp Security Water Supply Setting Out and Measuring Aids Tools and Tool Repair / Maintenance Equipment Stores Control Equipment Control and Maintenance Employment of Casual Labour Setting out Horizontal Alignment Setting out Horizontal Curves Bush Clearing Stripping and Grubbing Tree and Stump Removal Boulder Removal Establishment of Levels (Slotting) Ditch Excavation and sloping Camber Formation Carriageway Compaction Mitre Drains Scour Checks Culvert Cleaning Culvert Replacement or New Installation For Details Refer to: Sections 3, 4, 13 and 15

Setting Out Clearing

Sections 3 and 4 Job Sheet: PR(L)03

Vertical Alignment Side Drains / Formation Compaction Other Drainage Culvert Rehabilitation

(usually not required for R2000 rehab.) Job Sheet: PR(L)04 Job Sheet: PR(L)05
Job Sheet: PR(L)06 Job Sheets: PR(L)07 and PR(L)08 Job Sheet: PR(L)09

5-3

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF PUBLIC WORKS & HOUSING

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (LABOUR ONLY)

Code:

BUSH CLEARING + STRIPPING AND GRUBBING

PR(L) 03

Standard: (See Contract Specifications) Work Method: 1. Set out pegs for bush clearing, and stripping and grubbing at 10m intervals. Use the centre pegs as reference. Use the edge pegs as chainage pegs and mark them accordingly. Do not remove these pegs after bush clearing has been completed. 2. Tie strings along the bush clearing reference pegs. 3. Estimate the area to be cleared. 4. Allocate tasks to the labourers. Give individual tasks for bush clearing, and stripping and grubbing.

grass cutting and grubbing

A/B/C Main + Secondary Roads! D/E Minor Roads! RAR Roads! Reduced Section RAR/Minor Roads!
! 2m bush clearing

= 12.4 m = 11.8 m = 10.5 m = 9.5m

! 2m bush clearing

C L

edge pegs = chainage pegs

Manpower: 1 Headman 2 Labourers for setting out Labour Gang for Bush Clearing Labour Gang for Stripping and Grubbing

Tools + Equipment: Tape Measure, 30 m 1 Masons Hammer Wooden Pegs + Strings Pangas Grass Slashers Axes Rakes Jembes Shovels

Material:

Quality Control: Check the cleared width and ensure that the area is free of trees, bushes, shrubs, grass and roots. Productivity: Bush Clearing Stripping and Grubbing = 300 - 1000 m2 / day / labourer = 200 - 300 m2 / day / labourer
Intech 1.94/05

5-4

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (LABOUR ONLY)

Code:

VERTICAL ALIGNMENT

PR(L) 04

Standard: (See Contract Specifications) Work Method: A. SET-OUT SLOTS: 1. At every 10 metre station set out in plan a slot 0.5 metres wide and length from back to back of ditch (standard lengths see figure below) using pegs and strings. 2. Set a peg immediately on either side of the centre line peg and at right angles to the centre line (across the road). The two pegs should be fixed approx. 20 cm above the existing road level. The tops of the pegs should be on the same level (check with a spirit level).

setting out slots = from back of ditch to back of ditch A/B/C Main + Secondary Roads! D/E Minor Roads! RAR Roads! Reduced Section RAR/Minor Roads! = = = = 9.6 m 9.0 m 7.3 m 5.5 m

back of ditch

back of ditch

C L
20

spirit level sisal twine to set out slot 50cm wide

B. CHECK VERTICAL ALIGNMENT: 3. Set out the vertical alignment of the road adjusting the twin pegs at each slot position as necessary using the boning rods. The difference in alignment between any 3 consecutive slots (20 metres) should not be more than 10 cm.

max. 10cm
10m 10m

C L

Slots

5-5

Improvement Works

5 ROAD REHABILITATION WORKS

Work Method (Cont.): C. EXCAVATE / FILL SLOTS: 4. Fix the length of the adjustable-camber-slope-ditch-template (ACSDT) according to the relevant cross-section (use the dimension back of ditch to back of ditch and divide by 2 to get the correct measurement = see diagram below). Place the ACSDT on the twin pegs to get an idea of the extent and amount of excavation required to allow the template to sit level. 5. Cut and fill within the limits of the slot area, checking with the template and spirit level from time to time. Material may be used on either side of the centreline. If there is insufficient material to support the template throughout in the level position then lower the twin pegs a few cm. Conversely if there is surplus material raise the pegs a little. Include any back sloping material in the slot. Compact the filled material using hand rammers.

adjusted length of ACSDT A/B/C Main + Secondary Roads D/E Minor Roads! RAR Roads! Reduced RAR/Minor Roads!
spirit level

back of ditch

= = = =

4.8 m 4.5 m 3.65m 2.75m

back of ditch

FILL

C L

CUT

6. Recheck the vertical alignment and make any adjustments necessary to the pegs. Exchange material between adjacent slots to accommodate this adjustment in template level. The slot profile is now that of the finished compacted road camber. 7. Mark the ditch and slope positions with pegs to the correct level using the templates, and fix string lines, which enable the excavation quantities to be calculated and tasks to be set. Manpower: 1 Site Supervisor (to set the levels and check the alignment) 1 trained Headman 3 Labourers Tools + Equipment: Tape Measure, 30 m 1 Template (ACSDT) 1 Set Boning Rods 1 Spirit Level 1 Mason Hammer Wooden Pegs Strings 2 Jembes 2 Shovels 1 Pick Axe 1 Hand Rammer Material:

Quality Control: Check that the vertical difference from slot to slot is less than 10cm (measure over three slots) Productivity: 10 to 20 slots / day / gang (if more slots are required then a second gang needs to be engaged)
Intech 1.94/05

5-6

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (LABOUR ONLY)

Code:

SIDE DRAINS AND FORMATION

PR(L) 05

Standard: (See Contract Specifications) Work Method: 1. Calculate earthworks between slots and allocate task rates. 2. Set out pegs and strings for slopes and ditches. 3. Excavate and fill according to the established slots. Provide enough fill to allow for compaction. 4. Check ditch and slope with a wooden template. 5. Check formation with a straight edge and the ACSDT- Template and correct where necessary. 6. After compaction fill any depressions and compact again.

check levels of ditch, slope edge and crown with boning rods, use slots as reference points pegs and strings to set out ditch, slope and if necessary backslope

C L
check finished formation with the ACSD-Template and a spirit level

Manpower: 1 to 2 Headpersons Labour gangs according to task rates

Tools + Equipment: 1 Mason Hammer Wooden Pegs and Strings ACSD-Template, Spirit Level Ditch-Slope Template Straight Edge Pick Axes or Mattocks Rakes or Spreaders Jembes or Forked Jembes Shovels Wheelbarrows

Material:

Quality Control: Check with standard ditch/slope or ACSD template the size of the ditch and camber Ditch to be able to drain (normally minimum 2% gradient, in flat section minimum 1%9 Ditch bottom to be of uniform gradient. Use boning rods to check. Productivity: 3 - 4 m3 / day / labourer
Intech 1.94/05

5-7

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (LABOUR ONLY)

Code:

COMPACTION

PR(L) 06

Standard: (See Contract Specifications) Work Method: 1. Mark the exact length and width of the carriageway to be compacted after the camber has been formed. 2. Establish the number of passes (depending on the thickness of the layer, the chosen type of compaction device and the natural moisture content). 3. Compact if possible on the same day as the camber was formed. Arrange for the gang to work in the afternoon if necessary. 4. Check with the straight edge where depressions on the running surface appear. 5. Fill depressions on the same day and repeat compaction on these spots (material to be borrowed from the back slope or if necessary widen the ditch). 6. Where compaction cannot be achieved on the same day, make sure it is organised as early as possible on the next day.

Compact layers of not more than allowed thickness Depending on the equipment 4 to 12 passes are required at each point of the carriageway Passes should overlap each other Start rolling from the edge and work towards the centre-line, then repeat on the other side

C L

overlap of passes

Manpower: Site Supervisor to control passes and check quality Plant Operator 1 to 2 Labourers to assist (cleaning roller cylinder, filling depressions, etc.)

Tools + Equipment: Compaction Equipment Water Bowser Straight edge, Camber Board Jembes, Shovels, Rakes

Material: Water for Compaction

Quality Control: Count passes and ensure uniform rolling as indicated above (this does not replace compaction tests). Ensure rolling only at optimum moisture content. Productivity: depending on equipment used. Check Section 3.4, Equipment
Intech 1.94/05

5-8

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (LABOUR ONLY)

Code:

MITRE DRAINS

PR(L) 07

Standard: (See Contract Specifications)

Work Method: 1. Set out mitre drains at minimum 20 metre intervals where possible. 2. Set out mitre drains with an angle of 30-60 to the side drain and with the same width as the side drain, but minimum 60 cm. 3. Make sure the mitre drain is leading to an open outlet, preferably between shamba boundaries. 4. Establish gradient of mitre drain = same gradient as ditch but not less than 3%. Use boning rods to transfer ditch gradient and line-level to establish a new gradient. 5. Excavate the ditch and make sure the gradient is uniform. The sides should be backsloped. Dump material on the lower side of the drain. 6. Provide a block in the ditch on the downhill side of the mitre drain.

road centr e line

side drain blocked with material from mitre drain backslope

side drain

side drain

ang le 3 0 t o

1:1

60cm

1:1

60

e itr m n ai dr

CROSS SECTION MITRE DRAIN

Manpower: 1 Headperson to set out and control mitre drains Labour gang

Tools + Equipment: Strings and pegs Tape measure Set of boning rods, 3 ranging rods and line level Jembes, mattocks, shovels

Material:

Quality Control: - Check size cross-section of drain at regular intervals - Check gradient of mitre drain (not less than ditch) - Check that block at mitre-drain entrance is properly filled and compacted 3 to 4 m3 / day / labourer
Intech 1.94/05

Productivity:

5-9

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (LABOUR ONLY)

Code:

SCOUR CHECKS (using wooden pegs)

PR(L) 08a

Standard: (See Contract Specifications) Work Method: 1. Identify road sections where ditch gradient is more than 4% using a line-level = construct scour checks. 2. Identify exact ditch gradient and space scour checks according to gradient (see drawing). 3. Cut pegs (min 50 cm long) and prepare stones for apron 4. Construct scour check with the correct profile. Use the scour check template for control. 5. Construct stone apron below scour check of min 40cm length. Dig stones into the ground.

template flush with slope edge

spirit level place 1st peg at the edge of the ditch hammer the peg into the ground until the spirit level on the template ledge is horizontal

Gradient of Road 4% or less 5% 8% 10%

Scour Check Spacing not required 20 m 10 m 5m edge pegs

1st peg

build scour check flush to the template provide 1 or 2 edge pegs at the outer side of the ditch construct an apron of stones below the scour check of approx. 40cm length

flush with template

1st peg

Manpower: 1 labour gang

Tools + Equipment: Template + Spirit level Sledge Hammer Mason Hammer Panga and Shovel

Material: Pegs of min. 40cm length for scour check Stones for apron

Quality Control: Check spacing of the scour checks using tape measure. Maximum tolerance of + / - 0.5m. Confirm sizes of the stakes/pegs. Check the shape of the scour check using the scour check template. Productivity: 3 - 4 No / day / labourer (including preparation of pegs and collection of stones)
Intech 1.94/05

5 - 10

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (LABOUR ONLY)

Code:

SCOUR CHECKS (using stones)

PR(L) 08b

Standard: (See Contract Specifications) Work Method: 1. Identify road sections where ditch gradient is more than 4% using a line-level = construct scour checks. 2. Identify exact ditch gradient and space scour checks according to gradient (see drawing). 3. Select and prepare stones (cut to shape if necessary, length minimum 35cm) 4. Construct scour check with the correct profile. Use the scour check template for control. 5. Construct stone apron below scour check of min 40cm length. Dig stones into the ground.
template flush with slope edge spirit level place 1st stone at the edge of the ditch bury the stone into the ground until the spirit level on the template ledge is horizontal

1st stone

Spacing
Gradient 4% or less 5% 6% 7% Spacing not req. 20m 15m 10m Gradient 8% 9% 10% > 10% Spacing 7.5m 6m 5m 4m

edge stone

build scour check flush to the template provide 1 or 2 edge stones at the outer side of the ditch construct an apron of stones below the scour check of approx. 40cm length

flush with template

1st stone

Manpower: 1 labour gang

Tools + Equipment: Template + Spirit level Sledge and Mason Hammer Shovel Wheelbarrow

Material: Stones of min. 35cm length for scour check Stones for apron

Quality Control: Check spacing of the scour checks using tape measure. Maximum tolerance of + / - 0.5m. Confirm sizes of the stones. Check the shape of the scour check using the scour check template. Productivity: 3- 4 No / day / labourer (including collection of stones)
Intech 1.94/05

5 - 11

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (LABOUR ONLY)

Code:

CULVERT CLEANING

PR(L) 09

Standard: Clean culverts of specified size including pipe barrels, the outlet/inlet structures, and the outlet drains, keeping them free of all debris, weed, silt and any obstruction to ensure free passage of water at all times. Deposit debris in approved spoil dumps directed by the Engineer. Maintain correct widths and slopes of the outlet drains. The gradient of the outlet to be checked to ensure it is greater than 2 % using boning rods and line and level. All broken culvert barrels to be reported to the Engineer. Work Method: 1. Check culvert inlets, barrel and outlets for silt, sand and debris (use torch to check barrel). 2. Remove material from the inlet, barrel and outlet, and dispose of material well clear of the drainage system preferably on the lower side of the road or as instructed by the Engineer. 3. Check outlet gradient and ensure a minimum gradient of 2% using line-level and boning rod set. Ensure that the drain bottom has a uniform gradient. Set out outlet width and length using pegs and strings. 4. When the culvert is cleaned out check for cracks in the barrels (use torch if necessary). In case of damages report to the Engineer.
repair inlet and outlet aprons including head and wingwalls if necessary C L

gradient 2 to 5%

clean silt and debris from outlet, culvert and inlet maintain same gradient as the culvert excavate outlet with a minimum width of 60cm

use long handled shovel or trowel for cleaning

culvert blocked with silt and debris

Special Considerations: If the culvert is severely blocked use long handled tools, like shovel and rode (iron bar 10 to 12mm, 12m long) or scoop with a bucket tied to a rope. Tools and Equipment: Material: Safety Signs and Devices Tape Measure, 30 m Pegs Safety Vest Strings Set of boning rods Shovel, Jembe, Pick Axe, Panga Long handled shovel + trowel Quality Control: Visual inspection to check that the culvert, inlet and outlet are cleaned out and maintained to the correct standard dimensions. Check longitudinal profile of outlet using boning rods and string and line-level. Suggested Productivity Range: Cleaning = 1/4 to 4 culvert lines / day / labourer (depending on
blockage level and length of culvert) Intech 05

5 - 12

Improvement Works

5 ROAD REHABILITATION WORKS

5.3

USING LABOUR AND INTERMEDIATE EQUIPMENT

The activities for this method are carried out by separate groups of labourers and/or equipment, in a sequence. In this way a train of activities moves along the road improving the carriageway and drainage in a controlled step-by-step manner. The work is subdivided into three main operations, each carried out by a separate work gang that follow each other in sequence:

Gang 3

Gang 2

Gang 1

DRAINAGE WORK 2nd labour gang

SHOULDER & CARRIAGEWAY GRADING equipment grading gang

SETTING OUT + CLEARING 1st labour gang

For grading either tractor towed heavy graders or motor graders can be used. The 5-tonne towed grader has to be pulled by a 100HP tractor to be able to manage rehabilitation grading. Compaction is achieved with either a towed dead weight or a self propelled roller. The activities necessary for the labour and equipment partial rehabilitation approach should be selected from the following schedule and carried out in the sequence shown:
SEQUENCE OF PARTIAL REHABILITATION ACTIVITIES FOR EARTH AND GRAVEL ROADS USING LABOUR AND EQUIPMENT Operation Site Support Work Activity Site Camp Installation Site Camp Security Water Supply Setting Out and Measuring Aids Tools and Tool Repair / Maintenance Equipment selection, control and maint. Stores Control Employment of Casual Labour Setting out Horizontal Alignment Setting out Horizontal Curves Bush Clearing Stripping and Grubbing Tree and Stump Removal Boulder Removal Ditch and Slope Grading Camber Grading Carriageway Compaction Ditch Excavation Mitre Drains Scour Checks Culvert Cleaning Culvert Replacement or New Installation For Details Refer to: Sections 3, 4, 13 and 15

Setting Out Clearing

Sections 3 and 4 Job Sheet: PR(E+L)03

Shoulder Grading Camber Formation Compaction Side Drains Other Drainage Culvert Rehabilitation

(usually not required for R2000 rehab.) Job Sheet: PR(E+L)04 Job Sheet: PR(E+L)05 Job Sheet: PR(E+L)06 Job Sheet: PR(E+L)07 Job Sheets: PR(E+L)08 and 09 Job Sheet: PR(E+L)10

5 - 13

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF PUBLIC WORKS & HOUSING

Roads 2000
Activity:

JOB SHEET

PART. REHAB. (EQUIPMENT AND LABOUR)

Code:

BUSH CLEARING + STRIPPING AND GRUBBING

PR(E+L) 03

Standard: (See Contract Specifications) Work Method: 1. Set out pegs for bush clearing, and stripping and grubbing at 10m intervals. Use the centre pegs as reference. Use the edge pegs as chainage pegs and mark them accordingly. Do not remove these pegs after bush clearing has been completed. 2. Tie strings along the bush clearing reference pegs. 3. Estimate the area to be cleared. 4. Allocate tasks to the labourers. Give individual tasks for bush clearing, and stripping and grubbing.

grass cutting and grubbing

A/B/C Main + Secondary Roads! D/E Minor Roads! RAR Roads! Reduced Section RAR/Minor Roads!
! 2m bush clearing

= 12.4 m = 11.8 m = 10.5 m = 9.5m

! 2m bush clearing

C L

edge pegs = chainage pegs

Manpower: 1 Headman 2 Labourers for setting out Labour Gang for Bush Clearing Labour Gang for Stripping and Grubbing

Tools + Equipment: Tape Measure, 30 m 1 Masons Hammer Wooden Pegs + Strings Pangas Grass Slashers Axes Rakes Jembes Shovels

Material:

Quality Control: Check the cleared width and ensure that the area is free of trees, bushes, shrubs, grass and roots. Productivity: Bush Clearing Stripping and Grubbing = 300 - 1000 m2 / day / labourer = 200 - 300 m2 / day / labourer
Intech 1.94/05

5 - 14

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PART. REHAB. (EQUIPMENT AND LABOUR)

Code:

SHOULDER GRADING

PR(E+L) 04

Standard: (See Contract Specifications)

Work Method:
1. Set out the guide pegs for the towed grader to follow in 20 metre intervals along straight sections and 10 metre intervals in curves. Measure the relevant width from the centre line as shown in the table below.

outer side ditch peg

C L

centre peg chainage peg chainage peg

centre line to back of ditch centre line to back of ditch A/B/C Main + Secondary Roads! = 5.40 m D/E Minor Roads! = 5.10 m RAR Roads! = 4.05m Reduced RAR/Minor Roads! = 3.55m 2. Cut a V ditch with the grader in 1 or 4 passes and grade the shoulder. The edge of the grader blade follows the established line of outer ditch pegs. Check the crossfall from time to time with the AC or ACSDT -Template so that the amount of material required to form the camber can be estimated. 3. 2 to 3 labourers accompany the grader to remove large stones, roots and to support manually wherever necessary.

grader blade

C L

V-ditch along line of pegs

Manpower: 1 Site Supervisor 1 to 2 Grader Operators 1 Headperson + 1 labourer for setting out 2 to 3 labourers per grader to support

Tools + Equipment: Material: 2 heavy towed graders + 100 HP tractors or motor grader Tape Measure, 30 m 1 Mason Hammer Wooden Pegs AC- or ACSDT -Template with Spirit Level

Quality Control: Check camber at regular intervals using AC or ACSDT template Productivity: Together with activity Camber Formation approximately 1km / day / towed grader or 1.5 to 2km per motor grader, depending on the existing condition.
Intech 8.94/05

5 - 15

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS AND PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PART. REHAB. (EQUIPMENT AND LABOUR)

Code:

CAMBER FORMATION

PR(E+L) 05

Standard: (See Contract Specifications)

Work Method:
1. Grade carriageway from edge towards centre, then from centre towards edge, with 4 to 6 passes to obtain the correct crossfall. 2. Check the achieved crossfall with the AC or ACSDT-Template and correct where necessary. Additional material can be added if necessary by labour during the follow up drainage works. Also check the uniformity of the fill with a straight edge. 3. Assign 2 to 3 labourers to accompany the grader to remove large stones, roots and to support manually wherever necessary.

C L

AC or ACSDT -Template

C L
Straight Edge

7-10%

Manpower: 1 Site Supervisor 1 to 2 Grader Operator 2 to 3 labourers per grader to support

Tools + Equipment: 2 heavy towed graders + 100 HP tractors AC or ACSDT-Template with Spirit Level Straight Edge

Material:

Quality Control: Check camber at regular intervals using AC or ACSDT template Productivity: Together with activity Shoulder Grading approximately 1km / day / towed grader
Intech 8.94/05

5 - 16

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PART. REHAB. (EQUIPMENT AND LABOUR)

Code:

COMPACTION

PR(E+L) 06

Standard: (See Contract Specifications) Work Method: 1. Mark the exact length and width of the carriageway to be compacted after the camber has been formed. 2. Establish the number of passes (depending on the thickness of the layer, the chosen type of compaction device and the natural moisture content). 3. Compact if possible on the same day as the camber was formed. Arrange for the gang to work in the afternoon if necessary. 4. Check with the straight edge where depressions on the running surface appear. 5. Fill depressions on the same day and repeat compaction on these spots (material to be borrowed from the back slope or if necessary widen the ditch). 6. Where compaction cannot be achieved on the same day, make sure it is organised as early as possible on the next day.

Compact layers of not more than allowed thickness Depending on the equipment 4 to 12 passes are required at each point of the carriageway Passes should overlap each other Start rolling from the edge and work towards the centre-line, then repeat on the other side

C L

overlap of passes

Manpower: Site Supervisor to control passes and check quality Plant Operator 1 to 2 Labourers to assist (cleaning roller cylinder, filling depressions, etc.)

Tools + Equipment: Compaction Equipment Water Bowser Straight edge, Camber Board Jembes, Shovels, Rakes

Material: Water for Compaction

Quality Control: Count passes and ensure uniform rolling as indicated above (this does not replace compaction tests). Ensure rolling only at optimum moisture content. Productivity: depending on equipment used. Check Section 3.4, Equipment
Intech 1.94/05

5 - 17

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity: SIDE DRAINS

JOB SHEET

PART. REHAB. (EQUIPMENT AND LABOUR)

Code:

PR(E+L) 07

Standard: (See Contract Specifications)

Work Method:
1. Establish inner and outer ditch lines using pegs and strings. Set pegs at 10m intervals. Use centre pegs or chainage pegs as reference points. 2. Excavate ditch slots every 5 to 10m. Use template to check size and shape. Slots can be used to calculate the volume of excavation and to issue task rates. 3. Excavate/ widen the ditch according to the slots (the ditch becomes rectangular). Use material to raise camber or to fill depressions on the carriageway if required. Otherwise cast material well clear of the ditch, so that it will not wash back. 4. Check finished ditch using the ditch template and if necessary correct.

pegs in 10m intervals along inner ditch line slots every 5 to 10 metres

ditch template

C L

centre line to front of ditch A/B/C Main + Secondary Roads! D/E Minor Roads! RAR Roads! Reduced RAR/Minor Roads! = = = = 4.2 m 3.9 m 3.25m 2.75m

Manpower: 1 Site Supervisor and one trained Headman Labour Gang

Tools + Equipment: 3 Ranging Rods Tape Measure, 30 m 1 Mason Hammer Wooden Pegs and Strings Ditch or ACSDT-Template + Spirit Level Straight Edge Jembes and Shovels Mattocks Rakes or Spreaders

Material:

Quality Control: Check every slot using template and spirit level. Check drain after reconstruction again. Productivity: 20 to 50 metres / day / labourer (or equivalent to 3 to 4 m3 )
Intech 8.94705

5 - 18

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (LABOUR ONLY)

Code:

MITRE DRAINS

PR(E+L) 08

Standard: (See Contract Specifications) Work Method: 1. Set out mitre drains at minimum 20 metre intervals where possible. 2. Set out mitre drains with an angle of 30-60 to the side drain and with the same width as the side drain, but minimum 60 cm. 3. Make sure the mitre drain is leading to an open outlet, preferably between shamba boundaries. 4. Establish gradient of mitre drain = same gradient as ditch but not less than 3%. Use boning rods to transfer ditch gradient and line-level to establish a new gradient. 5. Excavate the ditch and make sure the gradient is uniform. The sides should be backsloped. Dump material on the lower side of the drain. 6. Provide a block in the ditch on the downhill side of the mitre drain.

road centr e line

side drain blocked with material from mitre drain backslope

side drain

side drain

ang le 3 0 t o

1:1

60cm

1:1

60

e itr m n ai dr

CROSS SECTION MITRE DRAIN

Manpower: 1 Headperson to set out and control mitre drains Labour gang

Tools + Equipment: Strings and pegs Tape measure Set of boning rods, 3 ranging rods and line level Jembes, mattocks, shovels

Material:

Quality Control: - Check size cross-section of drain at regular intervals - Check gradient of mitre drain (not less than ditch) - Check that block at mitre-drain entrance is properly filled and compacted 3 to 4 m3 / day / labourer
Intech 1.94/05

Productivity:

5 - 19

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PART. REHAB. (EQUIPMENT AND LABOUR)

Code:

SCOUR CHECKS (using wooden pegs)

PR(E+L) 09a

Standard: (See Contract Specifications) Work Method: 1. Identify road sections where ditch gradient is more than 4% using a line-level = construct scour checks. 2. Identify exact ditch gradient and space scour checks according to gradient (see drawing). 3. Cut pegs (min 50 cm long) and prepare stones for apron 4. Construct scour check with the correct profile. Use the scour check template for control. 5. Construct stone apron below scour check of min 40cm length. Dig stones into the ground.

template flush with slope edge

spirit level place 1st peg at the edge of the ditch hammer the peg into the ground until the spirit level on the template ledge is horizontal

Gradient of Road 4% or less 5% 8% 10%

Scour Check Spacing not required 20 m 10 m 5m edge pegs

1st peg

build scour check flush to the template provide 1 or 2 edge pegs at the outer side of the ditch construct an apron of stones below the scour check of approx. 40cm length

flush with template

1st peg

Manpower: 1 labour gang

Tools + Equipment: Template + Spirit level Sledge Hammer Mason Hammer Panga and Shovel

Material: Pegs of min. 40cm length for scour check Stones for apron

Quality Control: Check spacing of the scour checks using tape measure. Maximum tolerance of + / - 0.5m. Confirm sizes of the stakes/pegs. Check the shape of the scour check using the scour check template. Productivity: 3 - 4 No / day / labourer (including preparation of pegs and collection of stones)
Intech 1.94/05

5 - 20

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PART. REHAB. (EQUIPMENT AND LABOUR)

Code:

SCOUR CHECKS (using stones)

PR(E+L) 09b

Standard: (See Contract Specifications) Work Method: 1. Identify road sections where ditch gradient is more than 4% using a line-level = construct scour checks. 2. Identify exact ditch gradient and space scour checks according to gradient (see drawing). 3. Select and prepare stones (cut to shape if necessary, length minimum 35cm) 4. Construct scour check with the correct profile. Use the scour check template for control. 5. Construct stone apron below scour check of min 40cm length. Dig stones into the ground.
template flush with slope edge spirit level place 1st stone at the edge of the ditch bury the stone into the ground until the spirit level on the template ledge is horizontal

1st stone

Spacing
Gradient 4% or less 5% 6% 7% Spacing not req. 20m 15m 10m Gradient 8% 9% 10% > 10% Spacing 7.5m 6m 5m 4m

edge stone

build scour check flush to the template provide 1 or 2 edge stones at the outer side of the ditch construct an apron of stones below the scour check of approx. 40cm length

flush with template

1st stone

Manpower: 1 labour gang

Tools + Equipment: Template + Spirit level Sledge and Mason Hammer Shovel Wheelbarrow

Material: Stones of min. 35cm length for scour check Stones for apron

Quality Control: Check spacing of the scour checks using tape measure. Maximum tolerance of + / - 0.5m. Confirm sizes of the stones. Check the shape of the scour check using the scour check template. Productivity: 3- 4 No / day / labourer (including collection of stones)
Intech 1.94/05

5 - 21

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PART. REHAB. (EQUIPMENT AND LABOUR)

Code:

CULVERT CLEANING

PR(E+L) 10

Standard: Clean culverts of specified size including pipe barrels, the outlet/inlet structures, and the outlet drains, keeping them free of all debris, weed, silt and any obstruction to ensure free passage of water at all times. Deposit debris in approved spoil dumps directed by the Engineer. Maintain correct widths and slopes of the outlet drains. The gradient of the outlet to be checked to ensure it is greater than 2 % using boning rods and line and level. All broken culvert barrels to be reported to the Engineer. Work Method: 1. Check culvert inlets, barrel and outlets for silt, sand and debris (use torch to check barrel). 2. Remove material from the inlet, barrel and outlet, and dispose of material well clear of the drainage system preferably on the lower side of the road or as instructed by the Engineer. 3. Check outlet gradient and ensure a minimum gradient of 20% using line-level and boning rod set. Ensure that the drain bottom has a uniform gradient. Set out outlet width and length using pegs and strings. 4. When the culvert is cleaned out check for cracks in the barrels (use torch if necessary). In case of damages report to the Engineer.
repair inlet and outlet aprons including head and wingwalls if necessary C L

gradient 2 to 5%

clean silt and debris from outlet, culvert and inlet maintain same gradient as the culvert excavate outlet with a minimum width of 60cm

use long handled shovel or trowel for cleaning

culvert blocked with silt and debris

Special Considerations: If the culvert is severely blocked use long handled tools, like shovel and rode (iron bar 10 to 12mm, 12m long) or scoop with a bucket tied to a rope. Tools and Equipment: Material: Safety Signs and Devices Tape Measure, 30 m Pegs Safety Vest Strings Set of boning rods Shovel, Jembe, Pick Axe, Panga Long handled shovel + trowel Quality Control: Visual inspection to check that the culvert, inlet and outlet are cleaned out and maintained to the correct standard dimensions. Check longitudinal profile of outlet using boning rods and string and line-level. Suggested Productivity Range: Cleaning = 1/4 to 4 culvert lines / day / labourer (depending on
blockage level and length of culvert) Intech 05

5 - 22

Improvement Works

5 ROAD REHABILITATION WORKS

5.4

USING MAINLY EQUIPMENT

The activities for this method are carried out mainly using equipment. Some labour input is required for those activities that cannot be carried out by equipment, such as scour check construction, culvert repair or installation, support work, etc. The work process is broken down into a series of simple activities. The work is subdivided into three main operations, each carried out by a separate work gang that follow each other in sequence:

Gang 3

Gang 2

Gang 1

OTHER DRAINAGE WORKS labour

DITCH AND CAMBER GRADING ! grader and compactor with labour support

SETTING OUT + CLEARING equipment with labour support

For grading either tractor towed heavy graders or self-propelled motor graders can be used. The 5 tonne towed grader will have to be pulled by a 100 HP tractor to be able to manage rehabilitation grading. Compaction is achieved with either a towed dead weight roller or a self propelled roller. The activities necessary for the equipment partial rehabilitation approach should be selected from the following schedule and carried out in the sequence shown:
SEQUENCE OF PARTIAL REHABILITATION ACTIVITIES FOR EARTH AND GRAVEL ROADS USING LABOUR AND EQUIPMENT Operation Site Support Work Activity For Details Refer to: Site Camp Installation Sections 3, 4, 13 and Site Camp Security 15 Water Supply Setting Out and Measuring Aids Tools and Tool Repair / Maintenance Equipment selection, control and maint. Stores Control Employment of Casual Labour Setting out Horizontal Alignment Sections 3 and 4 Setting out Horizontal Curves Bush Clearing Job Sheet: PR(E)03 Stripping and Grubbing Tree and Stump Removal (usually not required Boulder Removal for R2000 rehab.) Cleaning / Excavating Side Drains Job Sheets: PR(E)04 Cleaning / Excavating Mitre Drains and PR(E)05 Reforming The Camber Carriageway Compaction Job Sheet: PR(E)06 Scour Checks Job Sheets: PR(E)09 Relief Drainage Structures and PR(E)10 Culvert Cleaning Culvert Replacement or New Installation

Setting Out Clearing

Rehabilitation Grading (heavy grading) Compaction Other Drainage Works

5 - 23

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (EQUIPMENT)

Code:

BUSH CLEARING + STRIPPING AND GRUBBING

PR(E+L) 03

Standard: (See Contract Specifications) Work Method: 1. Set out pegs for bush clearing, and stripping and grubbing at 10m intervals. Use the centre pegs as reference. Use the edge pegs as chainage pegs and mark them accordingly. Do not remove these pegs after bush clearing has been completed. 2. Tie strings along the bush clearing reference pegs. 3. Estimate the area to be cleared. 4. Allocate tasks to the labourers. Give individual tasks for bush clearing, and stripping and grubbing.

grass cutting and grubbing

A/B/C Main + Secondary Roads! D/E Minor Roads! RAR Roads! Reduced Section RAR/Minor Roads!
! 2m bush clearing

= 12.4 m = 11.8 m = 10.5 m = 9.5m

! 2m bush clearing

C L

edge pegs = chainage pegs

Manpower: 1 Headman 2 Labourers for setting out Labour Gang for Bush Clearing Labour Gang for Stripping and Grubbing Tools + Equipment: Tape Measure, 30 m 1 Masons Hammer Wooden Pegs + Strings Pangas Grass Slashers Axes Rakes Jembes Shovels Material:

Quality Control: Check the cleared width and ensure that the area is free of trees, bushes, shrubs, grass and roots. Productivity: Bush Clearing Stripping and Grubbing = 300 - 1000 m2 / day / labourer = 200 - 300 m2 / day / labourer
Intech 1.94/05

5 - 24

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (EQUIPMENT)

Code:

CLEANING/EXCAVATING SIDE AND MITRE DRAINS

PR(E) 04

Standard: (See Contract Specifications)

Work Method:
1. Set out the guide pegs for the towed or motor grader to follow in 20 metre intervals along straight sections and 10 metre intervals in curves. Measure the relevant width from the centre line as shown in the table below. 2. Define where mitre drains have to be excavated, mark with pegs and discuss/agree with landowners.

outer side ditch peg

C L

centre peg chainage peg chainage peg

centre line to back of ditch centre line to back of ditch A/B/C Main + Secondary Roads! D/E Minor Roads! RAR Roads! Reduced RAR/Minor Roads! = = = = 5.40 m 5.10 m 4.05m 3.55m

3. Drain away any standing water from carriageway and drains. 4. Cut a V ditch with the grader in 1 or 4 passes and grade the drain and shoulder. (See detailed operation on back of Job Sheet). 5. Cut V-shape mitre drains at the pre-defined locations. 6. 2 to 3 labourers accompany the grader to remove large stones, roots and to support manually wherever necessary. Manpower: 1 Site Supervisor 1 to 2 Grader Operators 1 Headperson + 1 labourer for setting out 2 to 3 labourers per grader to support Tools + Equipment: Material: 2 heavy towed graders + 100 HP tractors or self-propelled grader Tape Measure, 30 m 1 Mason Hammer Wooden Pegs AC- or ACSDT -Template with Spirit Level

Quality Control: Check drain gradient using boning rods. Ensure uniform profile of V ditch. Productivity: Together with activity Camber Formation approximately 1km / day / towed grader or 1.5 to 2km per self-propelled grader, depending on the existing condition.
Intech 8.94/05

5 - 25

Improvement Works

5 ROAD REHABILITATION WORKS

Narrow flat-bottomed ditches are not well suited to maintenance by grader. These should be cleaned out by hand.

Graders should be used to maintain V-shaped ditches and wide flat-bottomed ditches.

If unsuitable, material from the ditch should not normally be graded onto the running surface. In certain circumstances the engineer may instruct the recovery and mixing of ditch material, where the running surface lacks suitable fines present in the ditch The first grading pass cleans the side slope near the road and windrows the material to the bottom of the ditch.

The second grading pass cleans the ditch back slope and removes the material to the top of the ditch.

If possible, a third grading pass is used to push the material away from the edge of the ditch, to prevent it washing back.

Mitre Drains can also be constructed with a grader. They lead the water away from the edge of the road and follow closely the natural contours of the ground. Mitre Drains should be spaced more closely as gradients become steeper. The discharge of water should be little and often to minimise erosion in the drains and adjoining land.

5 - 26

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS AND PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (EQUIPMENT)

Code:

CAMBER FORMATION

PR(E) 05

Standard: (See Contract Specifications)

Work Method:
1. Grade carriageway from edge towards centre, then from centre towards edge, with 4 to 6 passes to obtain the correct crossfall. 2. Check the achieved crossfall with the AC or ACSDT-Template and correct where necessary. Additional material can be added if necessary by labour during the follow up drainage works. Also check the uniformity of the fill with a straight edge. 3. Assign 2 to 3 labourers to accompany the grader to remove large stones, roots and to support manually wherever necessary.

C L

AC or ACSDT -Template

C L
Straight Edge

7-10%

Manpower: 1 Site Supervisor 1 to 2 Grader Operator 2 to 3 labourers per grader to support

Tools + Equipment: 2 heavy towed graders + 100 HP tractors AC or ACSDT-Template with Spirit Level Straight Edge

Material:

Quality Control: Check camber at regular intervals using AC or ACSDT template Productivity: Together with activity Shoulder Grading approximately 1km / day / towed grader
Intech 8.94/05

5 - 27

Improvement Works

5 ROAD REHABILITATION WORKS

Heavy Grading to Restore the Camber:

L C

Heavy grading requires additional passes to achieve the required camber. Work should be completed on one side of the road at a time. Start grading from road shoulder and work your way towards the centre line.

L C

An even number of passes should be used to avoid a flat finished crown (centre of road).

L C

Normally initial cutting passes are required to bring the material in from the edges of the road towards the centre.

L C

Spreading passes are required to redistribute the material away from the crown towards the shoulder.

L C

Source: PIARC, International Road Maintenance Handbook

5 - 28

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF PUBLIC WORKS & HOUSING

Roads 2000
Activity: COMPACTION

JOB SHEET

PARTIAL REHABILITATION (EQUIPMENT)

Code:

PR(E) 06

Standard: (See Contract Specifications) Work Method: 1. Mark the exact length and width of the carriageway to be compacted after the camber has been formed. 2. Establish the number of passes (depending on the thickness of the layer, the chosen type of compaction device and the natural moisture content). 3. Compact if possible on the same day as the camber was formed. Arrange for the gang to work in the afternoon if necessary. 4. Check with the straight edge where depressions on the running surface appear. 5. Fill depressions on the same day and repeat compaction on these spots (material to be borrowed from the back slope or if necessary widen the ditch). 6. Where compaction cannot be achieved on the same day, make sure it is organised as early as possible on the next day.

Compact layers of not more than allowed thickness Depending on the equipment 4 to 12 passes are required at each point of the carriageway Passes should overlap each other Start rolling from the edge and work towards the centre-line, then repeat on the other side

C L

overlap of passes

Manpower: Site Supervisor to control passes and check quality Plant Operator 1 to 2 Labourers to assist (cleaning roller cylinder, filling depressions, etc.)

Tools + Equipment: Compaction Equipment Water Bowser Straight edge, Camber Board Jembes, Shovels, Rakes

Material: Water for Compaction

Quality Control: Count passes and ensure uniform rolling as indicated above (this does not replace compaction tests). Ensure rolling only at optimum moisture content.

Productivity:

depending on equipment used. Check Section 3.4, Equipment

Intech 1.94/05

5 - 29

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (EQUIPMENT)

Code:

SCOUR CHECKS (using wooden pegs)

PR(E) 09a

Standard: (See Contract Specifications) Work Method: 1. Identify road sections where ditch gradient is more than 4% using a line-level = construct scour checks. 2. Identify exact ditch gradient and space scour checks according to gradient (see drawing). 3. Cut pegs (min 50 cm long) and prepare stones for apron 4. Construct scour check with the correct profile. Use the scour check template for control. 5. Construct stone apron below scour check of min 40cm length. Dig stones into the ground.

template flush with slope edge

spirit level place 1st peg at the edge of the ditch hammer the peg into the ground until the spirit level on the template ledge is horizontal

Gradient of Road 4% or less 5% 8% 10%

Scour Check Spacing not required 20 m 10 m 5m edge pegs

1st peg

build scour check flush to the template provide 1 or 2 edge pegs at the outer side of the ditch construct an apron of stones below the scour check of approx. 40cm length

flush with template

1st peg

Manpower: 1 labour gang

Tools + Equipment: Template + Spirit level Sledge Hammer Mason Hammer Panga and Shovel

Material: Pegs of min. 40cm length for scour check Stones for apron

Quality Control: Check spacing of the scour checks using tape measure. Maximum tolerance of + / - 0.5m. Confirm sizes of the stakes/pegs. Check the shape of the scour check using the scour check template. Productivity: 3 - 4 No / day / labourer (including preparation of pegs and collection of stones)
Intech 1.94/05

5 - 30

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (EQUIPMENT)

Code:

SCOUR CHECKS (using stones)

PR(E) 09b

Standard: (See Contract Specifications) Work Method: 1. Identify road sections where ditch gradient is more than 4% using a line-level = construct scour checks. 2. Identify exact ditch gradient and space scour checks according to gradient (see drawing). 3. Select and prepare stones (cut to shape if necessary, length minimum 35cm) 4. Construct scour check with the correct profile. Use the scour check template for control. 5. Construct stone apron below scour check of min 40cm length. Dig stones into the ground.

template flush with slope edge

spirit level place 1st stone at the edge of the ditch bury the stone into the ground until the spirit level on the template ledge is horizontal

1st stone

Spacing
Gradient 4% or less 5% 6% 7% Spacing not req. 20m 15m 10m Gradient 8% 9% 10% > 10% Spacing 7.5m 6m 5m 4m

edge stone

build scour check flush to the template provide 1 or 2 edge stones at the outer side of the ditch construct an apron of stones below the scour check of approx. 40cm length

flush with template

1st stone

Manpower: 1 labour gang

Tools + Equipment: Template + Spirit level Sledge and Mason Hammer Shovel Wheelbarrow

Material: Stones of min. 35cm length for scour check Stones for apron

Quality Control: Check spacing of the scour checks using tape measure. Maximum tolerance of + / - 0.5m. Confirm sizes of the stones. Check the shape of the scour check using the scour check template. Productivity: 3- 4 No / day / labourer (including collection of stones)
Intech 1.94/05

5 - 31

Improvement Works

5 ROAD REHABILITATION WORKS

MINISTRY OF ROADS & PUBLIC WORKS

Roads 2000
Activity:

JOB SHEET

PARTIAL REHABILITATION (EQUIPMENT)

Code:

CULVERT CLEANING

PR(E) 10

Standard: Clean culverts of specified size including pipe barrels, the outlet/inlet structures, and the outlet drains, keeping them free of all debris, weed, silt and any obstruction to ensure free passage of water at all times. Deposit debris in approved spoil dumps directed by the Engineer. Maintain correct widths and slopes of the outlet drains. The gradient of the outlet to be checked to ensure it is greater than 2 % using boning rods and line and level. All broken culvert barrels to be reported to the Engineer. Work Method: 1. Check culvert inlets, barrel and outlets for silt, sand and debris (use torch to check barrel). 2. Remove material from the inlet, barrel and outlet, and dispose of material well clear of the drainage system preferably on the lower side of the road or as instructed by the Engineer. 3. Check outlet gradient and ensure a minimum gradient of 20% using line-level and boning rod set. Ensure that the drain bottom has a uniform gradient. Set out outlet width and length using pegs and strings. 4. When the culvert is cleaned out check for cracks in the barrels (use torch if necessary). In case of damages report to the Engineer.
repair inlet and outlet aprons including head and wingwalls if necessary C L

gradient 2 to 5%

clean silt and debris from outlet, culvert and inlet maintain same gradient as the culvert excavate outlet with a minimum width of 60cm

use long handled shovel or trowel for cleaning

culvert blocked with silt and debris

Special Considerations: If the culvert is severely blocked use long handled tools, like shovel and rode (iron bar 10 to 12mm, 12m long) or scoop with a bucket tied to a rope. Tools and Equipment: Material: Safety Signs and Devices Tape Measure, 30 m Pegs Safety Vest Strings Set of boning rods Shovel, Jembe, Pick Axe, Panga Long handled shovel + trowel Quality Control: Visual inspection to check that the culvert, inlet and outlet are cleaned out and maintained to the correct standard dimensions. Check longitudinal profile of outlet using boning rods and string and line-level. Suggested Productivity Range: Cleaning = 1/4 to 4 culvert lines / day / labourer (depending on
blockage level and length of culvert) Intech 05

5 - 32

Improvement Works

5 ROAD REHABILITATION WORKS

5.5

SPOT IMPROVEMENT

Spot improvement operations can be very varied as the defect situations also vary greatly. However, very common defects are short sections of roads that have been flooded or structures that are damaged and impassable. In terms of work implementation, spot improvement operations are technically and managerially challenging. Wherever possible spot improvement work is carried out using principally labour-based methods. Equipment will be mainly required for the haulage of material, such as gravel, stones, chipping, etc., and for compaction. The nature of spot improvement work changes from case to case and requires careful planning and monitoring by the District Engineer or hired Consultant. The Contractor may be confronted with a number of different possible operations as described in the following list: 5.5.1 Reconstruction of a Road Section Roads are occasionally impassable due to short sections, which have completely failed. In most cases such sections have been swept away by floods or the effect of heavy rains and the road section requires full reconstruction.

The construction methods for Rural Access and Minor Roads are described in detail in the Technical Manual, Volume I, Minor Roads Programme.

A contractor carrying out full labour-based reconstruction of short road sections requires the following main resources on site: One or two fully trained and qualified Site Supervisors Number of competent (on-the-job trained) Headmen/women Handtool set for approximately 50 to 80 labourers Two to three tractors with trailers or two tipper trucks (exact number depends on hauling distance) One 3 to 5 tonne dead weight roller or two pedestrian vibrating rollers One towed water bowser One pick-up for supervision and transport of smaller items Site camp facilities (stores, office, accommodation for staff) 5.5.2 Regravelling of a Road Section: The main defect on the classified unpaved road network is the missing or insufficient gravel layer. This are usually steep sections or sections with weak sub-grades, like black cotton soil. The contract document specifies the detailed standards to be achieved for gravelling works of a particular contract and road. If labour-based methods are used, the work execution is the same as for the Rural Access and Minor Roads Programme.

The labour-based gravelling methods for Rural Access and Minor Roads are described in detail in the Technical Manual, Volume I, Minor Roads Programme.

A contractor carrying out regravelling of short road sections using labour-based methods requires the following main resources on site: 5 - 33

Improvement Works

5 ROAD REHABILITATION WORKS

One or two fully trained and qualified Site Supervisors Number of competent (on-the-job trained) Headmen/women Handtool set for approximately 50 labourers Two to three tractors with trailers or two tipper trucks (exact number depends on hauling distance) One 3 to 5 tonne dead weight roller or two pedestrian vibrating rollers One towed water bowser One pick-up for supervision and transport of smaller items Site camp facilities (stores, office, accommodation for staff)

! If the road section is longer than 2km, additional hauling equipment is required. In cases where the gravelling work is carried out using mainly equipment the following resources are required: One fully trained and qualified Site Supervisors One or two competent (on-the-job trained) Headmen/women Handtool set for approximately 10 labourers One dozer and one front end loader for gravel excavation and loading Three to four tractors with trailers or three to four tipper trucks (exact number depends on hauling distance) One 3 to 5 tonne dead weight roller or one self-propelled vibrating roller One water bowser with spraying bar One pick-up for supervision and transport of smaller items Site camp facilities (stores, office, accommodation for staff) ! If the road section is longer than 2km, additional hauling equipment is required.

Note: using equipment for short sections of regravelling may only be economical if local labour is not available.

5.5.3 Rehabilitation of a Single Barrel Culvert: Non-functional culverts are a very common problem on existing roads and often need to repaired or replaces There are three basic culvert installation situations and they each require separate arrangements depending on the outfall gradient: A - Flat Outfall (<5%) B Intermediate Outfall (5 10% approx.) C Steep Outfall (>10% approx.)

5 - 34

Improvement Works

5 ROAD REHABILITATION WORKS

Culvert Type A; Flat Outfall This should be used in flat areas and watercourses with shallow gradients. In these circumstances a culvert set tool low would simply silt up. A culvert set too high would cause silting upstream and possibly erosion problems in the outfall. The road has to be built up over the culvert using a ramp/embankment. The vertical alignment must be adjusted.

5 - 35

Improvement Works

5 ROAD REHABILITATION WORKS

Culvert Type B; Intermediate Outfall This arrangement should be used when the outfall gradients are between 5% and 10% approximately. The culvert may be excavated slightly into the existing ground and the outfall ditch will be of reasonable length. However, the road will still require to be built up over the culvert barrel with gentle ramps of less than 5% extending at least 20 metres either side of the culvert.

5 - 36

Improvement Works

5 ROAD REHABILITATION WORKS

Culvert Type C; Steep Outfall On steep sidelong ground (above 10%) the culvert can be installed without adjusting the vertical alignment of the road. The culvert barrel may be buried and adequate cover achieved with an outfall ditch or reasonable length. A suitable drop pit will need to be constructed at the culvert inlet. It should be large enough to allow later access for maintenance of the culvert barrel. At the outlet, particular attention should be given to preventing erosion, particularly on steep slopes and easily erodible soils.

5 - 37

Improvement Works

5 ROAD REHABILITATION WORKS

Culvert Installation:
The exact site of the culvert should be determined at each low point in the vertical alignment and at each location where a relief or crossover culvert is required. These locations have to be determined by the Engineer and the Contractor to be instructed accordingly. The next step is to determine the type of installation arrangement required: A, B or C, so that the culvert may be correctly set out. The following provides guidance on this procedure taking a 5.40m wide road (carriageway width) as an example: PROCEDURE FOR SETTING OUT 60 CM ! CULVERT If the culvert site is flat check the watercourse gradient for 20 metres downstream form the location of the culvert outlet. Use boning rods and Abney Level, or line level, for this purpose. If the gradient is less than 5% (1m fall in 20m), then construct the culvert in arrangement Type A with the culvert inverts as close to the existing ground/water course level as possible, use guidelines of Figure G.1. Also construct arrangement Type A, if the height of the embankment fill (measured to edge of running surface) at the culvert is at least 1.1m. Otherwise proceed with the following steps to install arrangements Type B or C.

5 - 38

Improvement Works

5 ROAD REHABILITATION WORKS

Culvert Bedding:
The culvert must be bedded on stable material. Firm clay or sandy material is suitable. We, soft or organic material should be excavated and replaced with fine murram (gravel). Large stones could damage the culvert rings under loading and must not be allowed in contact with the rings. They should be removed, or covered with suitable material. If necessary murram (gravel) containing stones up to 20mm, or concrete, may be used to bed the culvert rings. The culvert bed should be excavated to give continuous support over the lower third of the barrel. The shape of the bed should be controlled with a culvert template (see following Figure). The gradient should be controlled using boning rods and the established excavation pegs. 5 - 39

Improvement Works

5 ROAD REHABILITATION WORKS

PROCEDURE FOR CONSTRUCTION AND CONTROLLING CULVERT BED

Backfilling should be carried out in layers of about 15cm compacted with hand rammers. Material must be particularly compacted against the culvert rings to avoid later settlement. Care must be taken that stones larger than 20mm are not placed in contact with the rings. The backfill cover requirements as detailed in the contract specifications (3/4 of barrel diameter minimum) must be ensured. Where the road has to be kept open to traffic, the culvert may be constructed in two halves. Care must be taken to protect the culvert works, and the traffic both during and after working hours. Suitable warning signs and barricades should be placed.

Required Resources:
A contractor carrying out culvert rehabilitation works requires the following main resources on site: One fully trained and qualified Site Supervisors Handtool set for approximately 5 to 8 labourers One tractor with trailer or one flat-bed/tipper truck (depends on hauling distance) for transporting culvert rings or material to cast culverts on site. One small concrete mixer for cases where culverts have to be haunched. One pick-up for supervision and transport of smaller items

5 - 40

Improvement Works

5 ROAD REHABILITATION WORKS

5.6

SMALL STRUCTURE WORKS

Missing or defective structures are often the cause for impassable roads and are therefore the critical spots in the road network. It is advisable to construct wherever possible multiple culvert lines, drifts or simple structures instead of bridges. These have three main advantages: - they are cheaper, - they can be built using locally available resources, and - they can be easier maintained. A contractor carrying out structure works requires the following main resources on site: One fully trained and qualified Site Supervisors Handtool set for up to 20 labourers Form work material for concrete structure elements One tractor with trailer or one flat-bed/tipper truck (depends on hauling distance) for transporting culvert rings or material to cast culverts on site. One concrete mixer (size depending on the amount of concrete to be mixed) One concrete vibrator with one 40mm and one 60mm needle. One pick-up for supervision and transport of smaller items Site camp facilities (stores, office, accommodation for staff)

!
5.7

For technical and operational information on concrete and masonry works refer to Sections 7 and 8 of this Handbook.

RECONSTRUCTION OF GRAVEL SHOULDERS ON BITUMEN ROADS

Most shoulders along the bitumen roads of Kenya are unpaved. Gravel shoulders are subject to constant wear and tear by vehicle and animal traffic and to softening and erosion by surface water. Edge repair and shoulder regravelling are usually dealt with in one operation. Where edge repair is not necessary and only shoulder regravelling needs to be carried out, the work procedure is the same as detailed in method 1 of the work description presented below: Work Description (Method 1) Define the depth of the shoulder erosion and check whether the base or even the sub-base is affected.
Surfacing
Base

Shoulder

Sub-base

SHOULDER TO STANDARD

If base and sub-base are not affected, regravel the shoulder and then repair the edge (see method 1).
SURFACE EDGE BROKEN AND SHOULDER ERODED

5 - 41

Improvement Works

5 ROAD REHABILITATION WORKS

If the base and sub-base are affected, first repair the entire shoulder including the base and sub-base and then the road edge (see method 2).
SURFACE EDGE BROKEN, SHOULDER ERODED, BASE AND SUB-BASE DEFECTIVE

Dig and remove all unstable material (surface and shoulder) to the depth of the base. Brush out and clean the area. Loosen the existing shoulder gravel to allow a key for the added material. Add new gravel in layers of not more than 10 cm to shoulder, add water if necessary and compact with hand rammer or hand roller. Allow for some surplus material (level of shoulder to be slightly higher than surface) for later settlement. Make sure the crossfall of the shoulder is the same as for the carriageway. Remove excess material for further use and clear the section of debris. Mark out the line along the road edge to be cut. Cut a trench of about 8 cm width and 8 cm depth into the base. Make sure the sides are vertical. Brush out and clean the excavation area.

Apply a prime coat to the surface of the excavated area. Make sure edges of patch are well coated. Place premix carefully in the edge trench and rake the material to the correct level. Compact the premix thoroughly. The surface of the new edge should stand approximately 5 mm above the existing road surface after compaction. The surface of the patch must be dusted or sanded just before the final compaction pass to prevent pick-up by vehicles. After 3 days or more the patch must be sealed by applying bitumen emulsion and a single layer of 6 mm chippings. The chippings must be well rolled. 5 - 42

Improvement Works

5 ROAD REHABILITATION WORKS

Work Description (Method 2) Dig and remove all unstable material until you find firm material. Level the area. Brush out and clean the area.

Rebuilt the base and sub-base using the same material. Compact thoroughly.

Rebuilt the shoulder as described in method 1.

Repair the surface edge as described in method 1.

Required Resources:
A contractor carrying out shoulder and bitumen edge rehabilitation works requires the following main resources on site: One fully trained and qualified Site Supervisors Handtool set for 10 to 10 labourers. If labour is used for excavation, loading and spreading of gravel up to 50 labourers require tools. Two to three tractors with trailer or two to three tipper trucks (depending on hauling distance) for transporting gravel for shoulder repair. Dozer and Loader for gravel excavation and loading if equipment is used. One grader for spreading shoulder gravel, if equipment is used. One bitumen emulsion hand sprayer One pedestrian vibrating roller One pick-up for supervision and transport of smaller items For larger sites camp facilities (stores, office, accommodation for staff) Depending on the existing surface and base composition, additional material will be required to carry out the repair work. In most places the following material will be used: lime (for stabilisation of base) tack coat (for spaying the prime coat) bituminous premix (for the edge repair) bitumen emulsion (for patch seal) chippings, 6 mm (for patch seal) 5 - 43

Improvement Works

5 ROAD REHABILITATION WORKS

5.8

QUALITY CONTROL

For Contractors it is advisable to maintain an own quality control system that ensures constant checking through all working steps. It is in the interest of the Contractor to detect any shortcomings as early as possible so that rectifications can be carried out at low cost. The following tables provide practical quality control measures for the most important work items for labour-based road works.
ROAD DIMENSION TESTS Type of tests: Simple checks on the dimensional accuracy of the construction works. (ii) Methods used: Tapes and/or templates are used to measure the completed works. Test Width of carriage way sub-base terrace (excavation to level) Width and depth of side drains Method tape template Location field field Test Interval (every ..) 100m 10m Tolerance +/- 50mm +/- 20mm (i)

ROAD PROFILE TESTS (i) (ii) Type of tests: Checks on the camber and longitudinal profile of the carriageway. Methods used: Camber boards, boning rods and/or levelling instrument are used to measure the completed base and surface layer. Test Camber Longitudinal profile Method template boning rods Location field field Test Interval (every ..) 20m 20m Tolerance +/- 10mm +/- 50mm

GRAVEL SOURCE TESTS (FOR BASE LAYER) (i) Type of tests: Check on the suitability of a gravel source for surface layer. Unlike most other tests, the client can only carry out these tests in the laboratory before construction commences. However, if you are doubtful about the quality of the material you may use a simple field test to identify the suitability of the chosen gravel. If the test described below shows doubtful results, then the client should be consulted for further instructions. Methods used: - Bottle test to identify the grading. - Moulding and drying test to identify plasticity and strength Test Grading Plasticity Strength Method bottle moulding drying Location field field field When? when in doubt of quality when in doubt of quality when in doubt of quality Tolerance NA NA NA

(ii)

5 - 44

Improvement Works

5 ROAD REHABILITATION WORKS

GRAVEL LAYER TESTS (FOR BASE OR SURFACE LAYER) (i) Type of tests: Tests on the thickness and degree of compaction of the finished base layer. (ii) Methods used: - Tapes are used to measure the gravel thickness. - Special laboratory tests are used by the client to measure the degree of compaction. A simple way of ensuring the compaction is achieved is by ensuring that the required minimum number of compaction passes, at optimum moisture content, are actually made. This method does not provide the contractor with the actual result but ensures that the desired compaction is achieved in most cases. Test Thickness of gravel layer Method tape Location field Test Interval (every ..) 50 m (in centre and towards edge) always Tolerance +/- 10 mm

Degree of compaction

counting compaction passes

field

Field Density Test For Gravel Layers To control whether the required compaction has been achieved density tests have to be regularly taken during the construction period. This is part of the measurement procedure of the client or his representative. However, as a contractor you are also interested to find out yourself: whether the density specified in the contract has been achieved before the client measures, and what the minimum compaction operation is to achieve this required density so that you do not carry out more work and spend more money then what is actually required.
For large-scale contracts the contractors are required to establish a site laboratory where both the client and the contractor can carry out the tests. For small-scale contracts, where mainly labour is used, such laboratories are usually not set up. However, tests can still be carried out, for example by using the laboratory facilities of Road Departments or Material Departments.

Several methods are used for determining the achieved field density. These are explained in Section 6 of this Hand Book. Quality control checks for concrete works and mortar are provided in Sections 7 and 8 respectively.

5 - 45