Week 6: Maintenance and Rehabilitation

What is Maintenance?

- Highway maintenance- Defined By AASHTO as “Maintenance is the preservation and keeping each type
of roadway, roadside, structures and facilities as nearby as possible to its original condition as constructed
or as subsequently improved the operation of highway facilities and services to provide satisfactory and
safe transportation. [4]

A day-to-day work that the goal is to preserve the infrastructure facilities to prolong the Lifespan of the
infrastructure. Improve thru.

a.) Routine Maintenance

b.) Preventive Maintenance
c.) Long Term Performance based on Maintenance

Routine Maintenance:

refers to maintenance activity regularly performed throughout the year and includes carriageway and
roadside maintenance.

For Routine Maintenance Activities:

Pothole patching

Sealing of cracks on pavement

 Manual cleaning and clearing of drainage and
culvert (inlet and outlet)

Roadside and feature maintenance; vegetation

control, road signs, guardrail cleaning,and
repainting; maintenance of other roadside
features and road markings maintenance

Bridge maintenance, cleaning of bridge decks,

shelves framework and drainage, spot repainting
and clearing of waterway flows.

Preventive Maintenance
-refers to works more extensive than routine maintenance and helps prevent:

Preventive Maintenance

(a) undue roadway deterioration

(b) increased routine maintenance requirement
(c) vehicular accidents.

For Preventive Maintenance Activities:

 Asphalt overlay

Concrete -Relocking

Long Term Performance based on Maintenance

Increase the efficiency and effectiveness of road maintenance operations.

A multiyear contract consists of two components:

a) Road and Bridge Performance Based Maintenance,

b) Preventive Maintenance.

Objective of Highway Maintenance

In order to keep up with the demand

Maintenance has its own role; in
for traffic, highway projects and
particular, paving rehabilitation after
activities are calculated by the
the construction has been completed
amount of spending for the building
is given priority to central, rural and
of new infrastructure and the
urban facilities.
rehabilitation of existing structures.

It requires grading and paving to

correct steep grades or sharp curves,
Maintenance was based on
re-surfacing and mulching, planting,
initiatives for change.
flood and erosion management for
short alignment adjustments
Maintenance Management System:

• Planning- it provides direct relationship between programmed work and budgeted costs
and bases for meaningful comparison of planned work with actual performance
• Scheduling- timely execution of maintenance activities it composed of the following
activities:
1. Identification of maintenance needs
2. preparation of quincenal schedule
3. Work assignment.
• Directing- actions necessary to produce acceptable work.
• Reporting- acts as the source of information and data upon which control of all
components system depends.
• Control- Ensuring the maintenance work done as nearly as possible to plans and
standards and that it is carried out with the financial constraints.
A. Relationship Between Design, Construction and Maintenance [1]

Poor very
insufficient poor mixture
preparation expensive
slab thickness ratio
of the base road repair

material expensive
Poor drainage
corrosion or clean-up
design
deposition operations.

expensive
sharp ditches steep slopes manual labor
maintenance.

Poor high
bad design construction maintenance
methods costs.
 Types of defects of roads and bridges and possible causes

Asphalt Pavement:

Surface Texture Deficiency

Description Possible Cause
Delamination- Loss of a Possible causes °
discrete and large area of Inadequate cleaning or
the wearing course layer. inadequate tack coat
Usually there is a clear before placement of
delineation of the upper layers ° Seepage
wearing course and the of water through
layer below (synonym - cracks to break bond
peeling) between surface and
lower layers °
Insufficient thickness
or stability of wearing
course ° Full damage
of surface layer °
Patching over failed
pavement
Polishing- Smooth and Inadequate resistance
rounding of the upper to polishing of surface
surface of the roadstone, aggregates,
usually occurs in the particularly in areas of
wheel tracks. Identified heavy traffic
partly by relative movements or where
appearance and feel of high stresses are
trafficked and nontraffic developed between
areas. Polished areas will surface and tyres
feel relatively smooth
and will sometimes be
noticeably shiny. The
quality of polishing
cannot be quantified by
observation
Ravelling- Progressive ° Separation of
disintegration of the bituminous film from
pavement surface by loss aggregates (stripping)
of both binder and due to water action,
aggregates chemicals (including
hydrocarbon oils) or
mechanical forces °
Disintegration of
aggregates ° Poor
construction
(segregation, faulty
mix design,

Flushing- Immersion,
partially or completely, of
the aggregate into the
bituminous binder
resulting in a black and
brilliant aspect (synonym
- bleeding)
Stripping- The loss of
bond between
aggregates and asphalt
binder that typically
begins at the bottom of
the HMA layer and
progresses upward.
When stripping begins at
the surface and
progresses downward it
is usually called raveling
Depression- Localized
area with elevations
lower than the
surrounding area
Corrugations- Transverse
undulations, closely and
regularly spaced
(synonym - ripples)
overheating of mix,
bad compaction,
inadequate coating of
aggregates or
aggregates Badly
embedded)
Excessive binder
content of wearing
course and associated
low voids °
Penetration of
aggregate into base
(low strength base)
Poor aggregate
surface chemistry •
Water in the HMA
causing moisture
damage • Overlays
over an existing open-
graded surface course.
Based on experience,
these overlays will
tend to strip
Deformation
Loss of sub-base
support ° Settlement
of service trenches °
Consolidation of
isolated areas of soft
or poorly compacted
subgrade or
embankment
materials ° Vehicle
damage
Low in service stability
of bituminous mix °
Low air voids ° Road
locations under high
tangential traffic
stresses (steep
gradients with
considerable heavy
traffic – braking
zones).
Rutting- Longitudinal Inadequate strength
deformation in a wheel in surfacing or base °
path (synonym - Poor bond between
channeling) pavement layers °
Stop and start of
vehicles at
intersections °
Pressure exerted by a
cement concrete
pavement at
transition point with
bituminous pavement
° Low void content in
surfacing or other
layers
Cracks
Alligator cracks-it Possible causes °
resembles the alligator’s Saturated base or
skin or chicken wire. a subgrade ° Rupture of
crack that is caused by surface course due to
excessive deflection of traffic load, fatigue,
surface over unstable ageing and brittleness
subgrade of the binder °
Inadequate pavement
thickness ° Developing
from a surface
showing block
cracking
Shrinkage Crack- a large Hardening and
series of cracks,usually shrinkage of
with sharp corners or bituminous mixture °
angles. It caused by Fatigue cracking in
change in volume of fine embrittled bituminous
aggregates that have a wearing course
high content of low
penetration asphalt

Corrective measure- fill it with asphalt emulsion

slurry followed by putting slurry seal over the
entire surface.
Slippage crack-Caused by Inadequate bond of
braking or turning of the wearing course with
wheels due to lack of underlying layer or
good band between the insufficient thickness
surface layer and the of wearing course.
course beneath Inadequate bond may
be due to dust, dirt,
oil or the absence of a
tack coat ° Slippage of
wearing course at
road locations with
high shearing stresses
Corrective measure-
Remove the affected
surface layer from
around the crack to
the point where you
find a good bond
between the layers.
Then patch the area
with plant-mixed
asphalt.

Concrete Pavement:

Surface Texture Deficiency

Faulting- A
difference in the
levels of abutting
concrete slabs at a
transverse joint.

Rocking- Vertical ° Lack of support from sub-

movement at joint base ° Lack of or ineffective
(or crack) when load transfer dowel or tie
vehicles pass over - bars at joint
Plate 15,
sometimes the
vertical movement
cause water of
slurry to be ejected
up through the
joints or cracks
leading to loss of
support which may
be referred to as
pumping
Sagging- a ° Weakness of subgrade °
downward curve or Excessive weight or pressure
bulge in a structure
or concrete slab
Depression- Loss of sub-base support °
Localised area with Settlement of service
elevations lower trenches ° Consolidation of
than the isolated areas of soft or
surrounding area poorly compacted subgrade
or embankment materials °
Vehicle damage

Scaling- is the • poor quality of

disintegration or concrete
loose of concrete • Improper finishing
from the surface of technique
the pavement

Spalling- Break Infiltration of stones, silt or

down or other fine material into the
disintegration of joint groove/crack ° Weak
slab surface at concrete lacking in durability
edges, joints, or compaction ° Mechanical
corners or cracks damage caused by removal
of formwork etc. ° Dowel
restraint ° Corrosion of
dowels
Cracks
Block Crack- Insufficient slab thickness °
Interconnected Settlement of sub-base or
cracks forming a subgrade ° Advanced stage in
series of blocks pavement life cycle
approximately
rectangular in
shape, commonly
distributed over
the full pavement
Longitudinal crack- Poor longitudinal joint
crack running construction
longitudinally along Differential movement in the
the pavement. Can case of pavement widening
occur singly or as a
series of almost
parallel cracks.
Some limited
branching may
occur.
 Transverse crack - Shrinkage of slab during
Crack or break curing, associated with
running contraction joints being sawn
transversely across too late or excessive slab
the pavement/slab length ° Dowel bar restraint
at joints ° Sub-base restraint
(lack of separation layer or
excessive irregularity

Corner crack: Crack Lack of load transfer joints °

linking a transverse Dowel bar restraint near
joint to the slab edge of slab ° Ingress of
edge or a solids into joint at edge of
longitudinal joint. slab ° Acute angles in non-
rectangular slabs ° Loss of
sub-base support

Routine Maintenance Activity:

Reference (DPWH)

BITUMINOUS PAVEMENTS

➢ PREMIX PATCHING BITUMINOUS PAVEMENTS (Related Activity Standard No. 111)

Purpose: To eliminate hazardous conditions and to provide smooth, well-drained surfaces.

Procedure:

1. Remove standing water and temporary

patching material from defect or area to
be leveled.

2. Shape defects so that: (a) depth provides

for sufficient strength; (b) sides are
vertical; (c) corners are square or slightly
rounded; (d) sides have no abrupt
changes in line; and (e) hole is cut back
into sound pavement. Add base material
if needed.

3. Clean and tack defects or area to be

leveled
4. Place premix in layers and compact each
layer. Mix should be placed only within
limits of hole and area to be leveled.
 Manual Compaction
5. Final layer should be flushed with
surrounding surface.

Machine Compaction

6. Dig channels through shoulders, if

needed, to allow water to drain.

7. Check cross section, profile and drainage. Rework if needed.

Checkpoint

• Materials to be used should be dense graded asphalt mixture with maximum grain size equal to or
less than 19 mm.
• Wet part should be heated to be dried with burner
• Laying of asphalt mixture should be approx.1 cm. higher than the adjacent surroundings to give
allowance for settlement during compaction.
• When depth of pothole is more than 7 cm, compact mixture in two layers.

➢ PENETRATION PATCHING BITUMINOUS PAVEMENTS

Purpose - To provide smooth, well-drained surfaces. This activity is not suitable for repairing hazardous
conditions, since lack of mobility prevents quick response.

Procedure:

1. Remove standing water and temporary When traces of water is observed, sealing of
patching material from defect or area to cracks and joints should be done to prevent
be leveled. water intrusion to the base.
2. Shape defects so that: (a) depth provides
for sufficient strength; (b) sides are
vertical; (c) corners are square or slightly
rounded; (d) sides have no abrupt
changes in line; and (e) hole is cut back
into sound pavement. Add base material
if needed.

3. Clean and tack defects or area to be

leveled
4. Place aggregate in layers and compact
each layer.

Mix macadam aggregates and smaller

sized chippings to minimize void among
aggregates.

5. Penetrate final layer with asphalt. Avoid

using too much asphalt.
 6. Apply cover sand and compact. Final Bituminous material should be applied uniformly.
layer should be flushed with surrounding The rate of application should be strictly
surface observed.
Use dry and clean coarse sand.

After the spreading of sand, compact

immediately using road roller or plate compactor
to prevent segregation of aggregates.

7. Dig channels through shoulders, if

needed, to allow water to drain.
8. Check cross section, profile and drainage. Rework if needed.

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 to keep water tightness.
 ➢ SEALING BITUMINOUS PAVEMENTS

Purpose- To prevent further deterioration caused by entry of water.

Procedure:

1. Remove debris from cracks or clean

raveled surface.

Remove dust and mud in cracks with broom, etc.

2. (a) For individual cracks: fill cracks

completely with asphalt; use
squeegee to force asphalt into cracks
and remove excess. (b) For areas:
apply asphalt, distribute with broom
and remove excess with squeegee.

Seal coat is applied to prevent aging of asphalt

surface and wear resistance. to improve water
proofness and wear resistance.
3. Apply cover sand.
Checkpoint

• Sealing is generally applied to cracks of more than 3 mm in width.

• Loose damaged part around cracks should be removed.
• Fill cracks with bituminous material at a temperature of 180 to 200 degrees centigrade.
• For deep crack, fill it twice with asphalt.
• Sealing for wide area is effective for preventive maintenance if it is carried out regularly prior to rainy
season.
• Aggregate to be used should be clean, hard and durable.

➢ REPLACEMENT OF BITUMINOUS PAVEMENTS

Purpose - To provide smooth, well-drained pavements.

Procedure:
1. Heat asphalt at proper
temperature, if penetration or
hot asphalt is used.

Heat asphalt to proper temperature and

keep it constantly during the activity.

2. Remove damaged pavements.

Disturbed base or subbase should be

levelled and re-compacted prior to laying
bituminous pavement .
3. Add base material if needed.
4. Clean surface to be covered

5. Spray liquid asphalt at specified

rate as tack coat or prime coat.
6. Place pre-mix in layers and
compact each layer, or place
 aggregate in layers, compact each
layer, penetrate final layer with
asphalt and apply cover sand.
7. Final layer should be flushed with
surrounding surface

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 pavement.
• Tack coat or prime coat should be applied uniformly on bottom surface and vertical side
as well.
• Laying of asphalt mixture should be approximately 0.5 to 1.0 cm higher than the
adjacent surroundings to give allowance for settlement.

CONCRETE PAVEMENTS
➢ PATCHING CONCRETE PAVEMENTS
Purpose -To eliminate hazardous condition and to provide smooth, well-drained pavements.

Procedure:
1. Remove standing water from defect or
area to be levelled and remove all broken
pavement.
2. For defects: a.) shape defects, tack, place
pre-mix or penetration patch as in 2-1
and 2- 2. (b) For leveling: clean area, tack,
place pre-mix as in 2-1. (c) For ravelled
areas: clean area, apply asphalt and cover
aggregate as in 2-3.

Before Patching treatment.

Penetration patching is applied to cracked area

 Patching with hot pre-mix
3. Dig channels through high shoulders to
allow water to drain to ditch.
4. Check cross section, profile and drainage. Rework, if needed.

Checkpoint

• Asphalt materials are widely used instead of cement materials for patching due to its easy
application. Although cement materials used on the existing PCCP is desirable for patching, it is
difficult to cut/taper on the areas to be patched. Likewise, it takes time to be cured before the
road will be opened to traffic. Remove damaged part and expose sound part by chipping off to
clean the surface to be patched.
• Damaged joint and deep cracks should be sealed prior to patching works to prevent water
intrusion into/from the lower layer of road.

➢ CRACK AND JOINT SEALING OF CONCRETE PAVEMENTS (Related Activity Standard No. 122)

Purpose - To prevent entry of water, debris and other incompressible materials into cracks and joints
and allow the free movement (expansion or contraction) of the pavement.

Procedure:

1. Heat asphalt at proper

temperature, if penetration or
hot asphalt is used.

Heat asphalt to proper temperature and

keep it constantly during the activity.
 2. Remove incompressible materials
from cracks or joints, including
old filler and blow cracks or joint
clean.

3. Pour asphalt in crack or joint to

within onehalf cm of pavement
surface. For large cracks, fill with
bituminous pre-mix/ aggregate
and asphalt. Do not overfill.
4. Remove any excess asphalt by
squeegeeing.
5. Check to be sure asphalt do not
seep underneath the pavement
and that cracks remained filled.
Apply cover sand.

Checkpoint

• Heat asphalt to adequate temperature (180- 200℃). • Clean or blow thoroughly dust and mud
in cracks and joints.
• Further, remove damaged loose part of surrounding areas.
• Pour asphalt in cracks or joints kept in dry conditions.
• Causes of cracks should be identified and corrected prior to sealing works.

➢ REPLACEMENT OF CONCRETE PAVEMENTS (Related Activity Standard No. 123)

Purpose- To provide smooth, well-drained pavements and prevent progressive deterioration of the
pavement.

1. Remove damaged pavement.

2. Add base material, if needed.
3. Salvage waste material suitable for
backfill. Place remainder in a safe
location for removal

Removal of concrete slab with breaker

4. Shape hole so that sides are vertical,
corners are square and sides have no
 abrupt changes in line and hole is cut
back into sound pavement.
5. Mix and place concrete and finish to
match surrounding surface or place hot
mix in layers and compact each layer.

6. Cure concrete. Barricade from traffic for

at least 14 days.

Checkpoint

• Sub-grade or sub-base in poor conditions should be replaced.

• Damaged dowel bars of existing slab should be replaced.
• For contact surface with existing slab, joint should be installed to separate old and new
concrete. In addition, underlay paper is used on the sub-base surface to reduce friction with
concrete slab.

Pavement rehabilitation – is an operation that mainly provides good riding and skid resistance
or enhances the pavement's structural performance.

The FHWA defined rehabilitation as:

“Resurfacing, restoration and rehabilitation work, restoring to the original safe useable
condition without addition to the original capacity”
• A. According to AASHTO, the primary objective of pavement rehabilitations is to
Improve:

Skid resistance
of the road
Construction
the sections
pavement life.
with poor
foundations

The primary
Smoothness of objective of Drainage
the road pavement
rehabilitations Facilities.
surface
is to Improve:

B. The efficiency of the highway system could be rated by:

1. Sufficiency ratings
2. Accident data
3. skid test
4. maintenance report
 5. Public comments and suggestion

• Resurfacing – is the extension of the pavement layer to provide additional capacity over the
new roadway or bridge deck surface. The thickness of the added re-surface pavement should
not be less than 20mm.

C Restoration and Rehabilitation

• Restoration and rehabilitation work include: Replacing

faulty
Removing joints.
Spalled
and
joints
replacing
reparations
deteriorate
.
d materials.

Restoration
Major
Improveme and
pavement
nt shoulder Rehabilitation work
Work

Under Reinforcem
drains are ent of the
added Recycling of sub-base
existing
materials to
improve their
integrity in the
structure.