Pocketbook On Routine Maintenance
Pocketbook On Routine Maintenance
POCKETBOOK
ON
ROUTINE MAINTENANCE
2014
Inside
SEPTEMBER 2014
ACKNOWLEDGEMENT
iii
Team Leader
Ryoichi Yamasaki
Co Team Leader
Nobuyuki Sagawa
Yoshinori Mikura
JICA Expert
(Pavement)
JICA Expert
(Slope/Drain)
Hiroyuki Matsuyama (Slope/Drain)
Yoriko Kawakami
Kensuke Matsushita
Feliciano P. Carpio
Rodrigo A. Yago
iv
JICA Expert
JICA Expert
(Bridge)
Project
Coordinator
Asst. Engr;
JICA TCP-II
Asst. Engr.
JICA TCP-II
ABBREVIATIONS
TABLE OF CONTENTS
Foreword . i-ii
Acknowledgment .. iii-iv
INTRODUCTION
Purpose . 1
Target Users.. 2
ROUTINE MAINTENANCE
Responsible Office and
Personnel 3
Materials and Equipment 4
Safety Management . 6
UNPAVED ROAD SURFACE
1-1 Manual Repair of Unpaved
Road Surfaces 8
1-2 Machine Grading Unpaved
Road Surfaces ... 10
BITUMINOUS PAVEMENT
2-1 Premix Patching Bituminous
Pavements ...
2-2 Penetration Patching
Bituminous Pavements
2-3 Sealing Bituminous
Pavements ...
2-4 Replacement of Bituminous
Pavements
vi
13
16
19
21
CONCRETE PAVEMENT
3-1 Patching Concrete
Pavements . 24
3-2 Crack and Joint Sealing of
Concrete Pavements . 27
3-3 Replacement of Concrete
Pavements . 29
UNPAVED SHOULDER
4-1 Manual Repair/Patching of
Unpaved Shoulders 32
4-2 Machine Grading of Unpaved
Shoulders . 35
DRAINAGE
5-1 Manual Ditch Cleaning 37
5-2 Manual Cleaning of Culvert
Inlet/Outlet and Culvert
Line/Barrel .. 39
5-3 Repair and/or Replacement of
Minor Drainage Structure ... 41
ROADSIDE FEATURES
6-1 Vegetation Control (Grass
Cutting/Tree Trimming) .. 43
6-2 Erosion Repair and Control on
Roadsides 45
6-3 Repair of Major Roadside
Structures 47
vii
TRAFFIC SERVICES
7-1 Sign Maintenance and Traffic
Services
7-2 Centerline and Lane
Repainting
7-3 Guardrail Maintenance
7-4 Sight Distance Mowing
and Cleaning
49
51
53
55
BRIDGES
8-1 Cleaning of Bridges .. 57
8-2 Patching Concrete Decks .. 59
8-3 Repair of Concrete Bridges
8-3-1 Crack Repair ... 63
8-3-2 Patching .. 65
8-4 Repair of Steel Bridges(Touchup Painting .... 68
8-5 Repair of Bridge Attributes ..... 70
8-6 Repair of Bridge Protection
Works ... 72
8-7 Cleaning Bridge Waterways .. .. 74
EMERGENCY WORKS
9-1 Initial Response to
Emergencies-Roads .. 76
9-2 Initial Response to
Emergencies-Bridges .... 78
Additional Information .. 80
viii
INTRODUCTION
PURPOSE
In road networks of 376,907 km in the
Philippines, half of these are in poor condition
that needs immediately repair, rehabilitation
and/or improvement In the current Mediumterm Road Development Program prepared by
the DPWH, priority is given to the
maintenance/management of national roads
and bridges.
This Pocketbook is being prepared to guide the
field engineers/supervisors/personnel involved
in the routine maintenance activities to improve
their technical capabilities in quality control and
keep constant level of service in the road
network in the Philippines.
It also serves as a tool and/or reference in the
on-site supervision and management for every
maintenance activity, as shown/ illustrated with
photos and
sketches.
Likewise,
this
Pocketbook must be carried on site for ready
reference.
TARGET USERS
Included in this Pocketbook are the commonly
used routine maintenance activities selected
from the list of "Activity Standards" of the
Revised Philippines Highway Maintenance
Management Manual (PHMMM) published by
the DPWH in 1985 and improved/updated by
the JICA-TCP II in 2014.Basic considerations
and guides are being introduced in every routine
maintenance activity by easy-to-understand
methods with the corresponding photographs
and sketches.
The target users of this Pocketbook are
engineers and personnel
of the District
Engineering Offices, particularly, those in the
District Maintenance Sections who are carrying
out the routine maintenance activities.
ROUTINE MAINTENANCE
RESPONSIBLE OFFICE AND
PERSONNEL
Organization for routine maintenance of
national roads is comprised of three levels:
Central Office (CO), Regional Office (ROs) and
District Engineering Offices (DEOs). Each
office has a division and a section, normally
named as Maintenance Division/Section,
responsible for the Road Maintenance.
(1) Central Office (CO)
The Central Office which is located in Manila is
mainly responsible for basic planning,
monitoring and development of standards for
the routine maintenance.
(2) Regional Offices (ROs)
DPWH is composed of 16 Regional Offices,
who supervise(s) the District Engineering
Offices(DEOs).
(3) District Engineering Offices (DEOs)
The District Maintenance Engineer, and his/her
subordinates which include Engineers or
Foreman/ Capataz, and responsible in the
maintenance and upkeeping of the national
roads within their jurisdiction. The engineers
and
Foreman/Capataz are also called
Maintenance Point Persons (MPPs),with
particular road sections assignment covering
approximately 35 to 50 km per point person.
3
SAFETY MANAGEMENT
The occurrence of accidents during operations
may cause suspension or delay of work and may
lead to casualty of workers. Safety measures
should be considered on site during routine
maintenance work not only for the workers but
also for the third party such as the motoring
public and nearby residents.
Safety gear
Proper use of safety gear depends on risk of the
work site.
Equipment and Materials
Check machines and tools before using.
Handle electric powered machines and
hazardous materials with care under
established operations procedure.
Operate vehicle-type construction
machines and mobile cranes only after
confirming safety of the surrounding areas.
Only licensed equipment/machine operator
is allowed to operate.
Stockpile materials properly at site to
prevent hazard to the motoring public.
Temporary Facilities
Install proper temporary facilities (e.g.
scaffolding) and regularly check firmness of
the facility.
Traffic Safety
Install proper traffic and site safety device
(e.g. Men at Work sign, Traffic restriction)
(Site base facilities)
6
1) Safety Gear
Hard Hat
Safety Belt
Safety Shoes
For maintenance of
vertical structures like
bridges/ buildings
2) Traffic safety
Install appropriate
warning signage
and site safety
devices.
Checkpoint
For manual patching of potholes, surfacing
materials are taken from side ditches or high
spots of the road.
When there is water ponding, remove water
prior to filling of surface materials.
When Telford base is observed, remove
boulders or oversized aggregates and fill
surface with required materials.
Photographs
1) Filling pothole
Repair of pothole
using surfacing
material which is
taken from side
ditches.
2) Placing materials
Remove oversize
and unsuitable
materials.
11
5) Quality of aggregates
Aggregate
should be hard
and durable.
12
14
Photographs
1) Cutting and tack or prime coat
Cut damaged part
and surrounding area
by squaring with each
side vertical. Remove
dust and mud
completely.
2) Manual compaction
Manual compaction
with hand tamper.
Use manual plate
compactor for better
quality of work.
3) Machine compaction
Road roller is used in
compacting potholes.
However, it is
advisable to use manual
plate compactor on
corner and edge areas
that are difficult to
compact
15
Procedure
1. Remove stagnant water, if there is any, from the
defects.
2. Do proper squaring: (a) to the required depth;
(b) sides are vertical; (c) corners are square or
slightly rounded; (d) sides have no abrupt
changes in line; and (e) hole is cut up to stable
base.
3. Add base material if needed.
4. Place aggregate in layers and compact each
layer.
5. Spread final layer with asphalt per required rate
of application at 1.0-2.0 liters/sq.m. .
Avoid using too much asphalt.
6. Apply cover sand and compact. Final layer
should be flushed with surrounding surface.
7. Provide turnouts on shoulders, if needed, to
allow water to drain.
8. Check cross section, profile and drainage.
16
Checkpoint
Penetration macadam is suitable for
regions without asphalt plant.
Before placing and spreading macadam
aggregate, oversized and slender or flat
aggregate should be removed.
Bituminous material should be spread
uniformly so as to penetrate sufficiently
and cover aggregate.
The surface should be provided with seal
coat for water proofing.
Photographs
1) After cutting asphalt
When traces of
water is observed,
sealing of cracks
and joints should
be done to prevent
water intrusion to
the base.
2) Putting in aggregate
Mix macadam
smaller-sized
chippings to
minimize voids in
aggregates.
17
3) Finish
Use dry and clean
coarse sand.
18
Photographs
3) Seal coat
Seal coat is
applied to prevent
aging of asphalt
surface water
proofing and wear
resistance.
20
Checkpoint
Considering mobility of machine, the width
to be replaced should not be less than one
lane of the road.
When the cause of damage is due to weak
base or sub-base, remove and replace the
base or sub-base prior to replacement of
bituminous pavement.
Disturbed base when removing damaged
bituminous pavement should be leveled and
compacted prior to laying of bituminous
21
pavement
Tack coat or prime coat should be applied
uniformly on bottom surface and vertical
side as well.
Laying of asphalt mixture should be approx.
0.5 to 1.0 cm. higher than the adjacent
surroundings to give allowance for
settlement.
Required Temperature:
- arrival at jobsite: above 160C
- during spreading and compaction above
135C
- before opening the pavement to traffic:
above 50C (max)
22
Photographs
1) Heat asphalt in kettle
Heat asphalt to
required temperature
and maintain the
temperature during
the activity
23
2) Penetration patching
Penetration patching
is applied to cracked
area similar to the
procedure under 2-2
25
26
Checkpoint
Heat asphalt to the required temperature
(180-200).
Clean or blow thoroughly dust and mud in
cracks and joints
27
28
Photographs
1) Road surface situation before replacement
It is of utmost
importance to verify
and address the cause
of damage prior to
replacement. In this
case, slope failure of
embankment is the
original cause.
3) Placing of concrete
Consolidate concrete
using vibrator
It is recommendable
to isolate old concrete
and new concrete to
minimize mutual
restraint stress
30
Photographs
31
33
3) Repair of shoulder
3.1. Levelling of
carriageway and
shoulder , and repair
of shoulder are
necessary to protect
the pavement
structure from
damage and for
traffic safety.
34
Procedure
1. Scarify or cut surface to remove
potholes, corrugations, erosion scars, high
areas, etc. Cut toward pavement.
2. Clean and re-cut ditches and
outlets/turnouts. Remove spoil
materials from culvert inlets and outlets.
3. Reclaim suitable material. Remove or
stockpile unsuitable material.
4. Remove oversize or unsuitable material.
5. Blend reclaimed suitable materials with
existing scarified materials.
6. Spread (away from pavement), reshape and
compact.
7. Check cross-section, profile and drainage.
Rework if needed.
Checkpoint
As for reclaiming work by grader,
scarification should be carried out in advance
for uneven shoulder surface.
35
Photographs
1) Reshaping shoulder with grader
Machine grading
works is very
effective on wide
shoulders without
obstructions.
Procedure
1. Start cleaning or digging from the
downstream side or from the discharge
point.
2. Remove debris from the ditches.
3. Reshape unlined ditch to an adequate flow
line and cross-section.
4. Final unlined ditch elevations should match
culvert inlet and outlet elevations.
5. Place ditch waste materials in a
safe location that does not obstruct
drainage (refer to item #3).
6. Always keep shoulder outlet channels open,
to allow water to drain, and report this
condition to Area - In Charge for
scheduling of needed corrective action
(refer to item #4).
Checkpoint
After natural phenomena, such as windstorm,
wind waves, heavy rainfall, and earthquake, it
is required to immediately inspect the drainage
structures.
37
Photographs
1) Immediate
removal/clearing of
mud/debris on drainage
facility is required to
maintain the flood
capacity of drainage
structure.
2) When cleaning, do
not leave earth and
sand on the
roadside or slope
but dispose off at
designated disposal
area.
3) Good example of
cleaning an open
lined canal.
38
Checkpoint
Regularly monitor condition of the drainage
inlet/outlet to ensure drainage facility functions
according to its flood capacity
Photographs
1) Mud/debris
accumulation
reduces the
discharge capacity
2)Remove accumulated
debris/mud
3) Good example of
cleaning drainage
outlet
40
Procedure
Work methods vary but includes:
a. Concrete repairs
b. Rip-rap repairs.
c. Placing culvert pieces.
d. Placing inlet grates.
e. Placing manhole covers.
Checkpoint
Focus the repair and maintenance on the
convergence/meeting of two ditches because
this part is prone to scouring.
41
Photographs
1) It is important to
ensure the
drainage capacity
in case of concrete
repairs.
42
Photographs
1. When cutting
vegetation, use
Personal
Protective
Equipment
2. Proper disposal
of cut vegetation
44
45
Photograph
Cleaning of ditch
to prevent
roadside erosion
46
Checkpoint
After natural phenomena, such as windstorm,
wind waves, heavy rain, and earthquake,
immediately inspect the face of slope and
structures.
47
Photographs
1. Loose deposit of soil on
the back slope can be a
major cause a debris
flow resulting to a great
disaster; hence the need
to provide appropriate
countermeasure to such
kind of slope.
2. Maintenance of
drainage structure is
important to prevent
water from seeping into
the retaining wall.
3. Clean clogged
weepholes and replace
the damaged ones.
48
49
Photographs
1) Washing and
cleaning the
signage prior to
re-installation
Wash signage
using water
50
51
Photographs
1) After repainting
Cure it properly
until it dries
(approx. 30
min.).
2) Equipment for
painting .
Lane marking is
repainted using
hand cart by melt
method
3) Repainting
centerline
Manual repainting
of centerline lane
markings.
52
53
Photographs
1) Replace
damage metal
beam rail
2) Clean guardrail
using soft
material then
paint
3) Remove
grasses around
around and
under the rail
54
Checkpoint
If it is necessary for safety of road
users, traffic regulation measures should be
taken. It depends on traffic volume or
original sight distance of the section.
It is more difficult at the right shoulder of the
right curve to secure a sight distance.
Downhill should be most considered on the
sight visibility because it is much difficult to
stop for traffic.
Trimmed/cut branch or grass should be
disposed properly so that it does not become
an obstacle to road users or land owners.
55
Photographs
1) Trim trees
obstructing the
road signs
2) Cut tree
branches
obstructing
the sight
distance
Bolo, a tool to
cut grasses
Scythe, a tool to
trim branches
56
Procedure
1. Removal of defective concrete
Remove all defective concrete and prepare
the edges for the patch area.
Remove additional area of concrete in case
of adding rebar because of its section loss.
59
5. Curing
All types of cement repairs need thorough and
continuous curing to develop strength, and to
minimize drying shrinkage while bond strength
is developing.
60
Checkpoint
Material requirement
The materials for repair shall conform to the
required specification.
TYPE-A
Portland cement
Epoxy bonding coat
TYPE-B
Polymer cement
Epoxy bonding coat
Zinc-rich primer
Removal of damaged concrete
Remove concrete within marked out areas and
confirm the sound of concrete substrate.
Concrete surface preparation
All concrete surfaces to be patched with
mortar shall be prepared by mechanical
scrubbing to remove any substance without
causing delamination of adjacent concrete by
vibration.
Additional concrete chipping
If the exposed reinforcement is further
corroded or the surrounding concrete is not
sound, the Area-In-Charge shall determine
enlarged area to be removed and repaired.
The chipping off of concrete shall not extend
to more than 20 mm from the main
reinforcement.
61
62
3) Curing
After application,
perform curing until
the epoxy coating
hardens.
64
Type B
(Major Maintenance)
Procedure
1. Removal of loose debris
Remove all defective concrete at corner edges
of area to be repaired. Remove loose debris.
2. Furnishing formwork
If necessary, provide formwork around the
damaged concrete to straighten the edges of
the damaged section.
65
5. Curing
Cure repaired
concrete to
develop
strength and
impermeability
66
Checkpoint
Material requirement
The materials for repair shall conform
to the required specification.
67
69
Photographs
1) Expansion Joint (Sealant Joint)
Sealant joints are
usually unprotected,
thus
they
might
deteriorate and peeloff when the edge of
the deck is damaged.
2) Bridge
Deposited materials
around bearing can
contribute
to
the
damage of bridge
structure by restricting
movement of bearing.
3) Bridge Railing
Concrete railing shall
be painted regularly.
71
Checkpoint
Stones and mortar joints must be placed
as directed by the Area-In-Charge.
Stones shall be laid and anchorage shall
be installed in accordance with the
drawings.
Photographs
1) Damage on Stone Masonry
Stones are
lost from
stone
masonry due
to strong
river flow.
73
Photographs
Immediately
remove the
driftwoods and
debris lodged on
the piers.
Inspection
vehicle with
scaffolding
device can be
utilized in
accessing area
difficult to
reach.
75
76
After
After
77
Photographs
1) Closing and detouring traffic
Install appropriate
warning signs and
barricades
79
Additional Information
In an emergency due to unusual weather,
responsible MPPs and his team need to rush to
the site as soon as possible but beforehand, site
instructions from his supervisors must already be
carried out for his team to take appropriate action
bringing with them the necessary belongings
before leaving such as the following tools and
equipment:
Work Glove
80
Additional Information
In a disaster, several emergency materials and
tools are needed depending on the size of the
disaster. For quick action, therefore, sources of
materials, arrangement of needed equipment, and
arrangement of emergency hotlines must be
readily available, such as the following:
Handheld Radio
81