R2000 Operations Manual PARTIAL REHABILITATION F

F-1 SITE SUPPORT ARRANGEMENTS FOR PARTIAL

REHABILITATION WORKS
F-1.1 GENERAL APPROACH
Most of the unpaved roads have a substantial backlog of maintenance work. In
most cases the drainage system is not functioning and the road surface is
defective. Routine maintenance operations using labour and/or equipment can only
be effectively carried out if these roads are first brought to a maintainable
standard. This is achieved through a partial rehabilitation exercise.

The principal objective is therefore to partially rehabilitate

roads to a maintainable standard.

The following approach is used to set up maintenance:

On those roads which are in a reasonable condition and “maintainable”,

1) Routine Maintenance operations will be established and carried out by
small-scale labour-based routine maintenance contractors. Contractors will
be given annual maintenance contracts of a number of kilometres in
convenient packages (initially 10 to 50km)

For earth and gravel roads in a poor condition and which are not
2) maintainable, Partial Rehabilitation will be carried out to allow for the
establishment of effective routine maintenance. Partial rehabilitation means
clearing the road sides over the whole road length, opening up side drains
and culverts, reforming the camber, and replacing/establishing a minimum
of one culvert line per km if required. Labour-based rehabilitation
contractors will usually carry out these works. However, depending on the
local circumstances different work approaches are possible using a mix of
labour and equipment (see following paragraphs).

Roads that have been partially rehabilitated will be put under Routine
3) Maintenance using the same approach as under 1.

For roads where Spot Improvement is required, selected and limited spot
4) improvements on the network under maintenance will be carried out.
Depending on the funding situation, spot improvements may be carried out
in parallel with the partial rehabilitation activities or as a follow up
programme. These works are also usually contracted out to labour-based
contractors who have the technical and operational capacity to cope with a
wider range of construction and/or improvement activities.

This Module describes the Preparation (Partial Rehabilitation) of unpaved roads.

The actual partial rehabilitation operations can either be carried out by Labour only,
or by a combination of labour and equipment, or by equipment only with little
labour support.

F-1.2 PARTIAL REHABILITATION APPROACH OPTIONS

The following table highlights the three options while the Sections F.2 to F.4
describe them in detail.

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Table F.1 - Partial Rehabilitation Work Options

USING LABOUR ONLY

Gang 3 Gang 2 Gang 1

DRAINAGE WORK CAMBER FORMATION SETTING OUT + CLEARING

• 3rd labour gang • 2nd Labour Gang • 1st labour gang

• 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
maybe achieved by traffic or pedestrian rollers.
• The third labour gang opens mitre drains, cross water drains and places/replaces culvert
lines.

USING EQUIPMENT AND LABOUR

Gang 3 Gang 2 Gang 1

DRAINAGE WORK SHOULDER & CARRIAGEWAY SETTING OUT + CLEARING

• 2nd labour gang GRADING • 1st labour gang
• equipment grading gang

• 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.
USING MAINLY EQUIPMENT

Gang 3 Gang 2 Gang 1

OTHER DRAINAGE WORKS DITCH AND CAMBER GRADING SETTING OUT + CLEARING
• labour • !grader and compactor with • equipment with labour
labour support support

• 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.

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F-1.3 SITE SUPPORT REQUIREMENTS

A number of support activities are required for any of the three partial rehabilitation
options and spot improvement works. These activities are usually not covered by
separate items in the Bill of Quantity (BoQ) but are either covered by the item
“Mobilisation” as a lump sum amount or have to be included as overhead cost in
the price of every item. The following support activities have to be considered:

F-1.3.1 Site Camp Installation

The site camp installation is normally the first activity on a road rehabilitation
project. Labourers must be called to fence the compound, to excavate pit latrines
and to assist in erecting the field huts. It is usually better to have the camp fully
established before actual construction work starts. The following check list provides
an overview of the requirements for a site camp and includes all that is required for
a full rehabilitation or spot improvement site. For partial rehabilitation operations
using mainly labour, less facilities are required. Contractors may choose from this
list what they require for the particular job.

Table F.2 - Checklist Site Camp Requirements

Location:
• To be within walking distance of all works. The distance from the camp to the
furthest working place should not exceed 4km. For roads longer than 8km, the
camp needs to be shifted. With Equipment option E4, the use of supervision
vehicles and labour transport will allow works to be organised at greater
distances.
• To be situated on a well-drained location and if possible not in a depression.
• To be close to a water source.
• To be large enough to contain stores, site office and if necessary staff
accommodation including latrines.
• Camps for major structural works (drifts, bridges) should be next to the site to
avoid hauling construction materials.
• Preferably to be located away from villages and markets centres but not so far
as to cause unnecessary problems with the purchase of food, etc.
• To be accessible to project vehicles.

Infrastructure:
• The size of the camp depends on the kind of work to be undertaken and on
how many people need to be housed on site. Movable field huts provide the
best comfort and security. On average the following huts are required:
• 1 hut for the site supervisor for accommodation,
• huts for the plant operators (mainly for the gravelling activities),
• 1 hut as site office,
• 1 site store for tools, small equipment, spare parts and cement,
• 1 site store for fuel, oil and lubricants,
• Latrine(s) and bathroom hut.
• Fence around the camp for security.

F-1.3.2 Site Camp Security

Security of the site camp(s) and store(s) is important at all times. Night watchmen
need to be employed for this purpose. A day watchman should be used for periods
when the site camp is not manned. A proper fence around the camp may also be

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required. The gate to the camp should be controlled as well as movements in and
out of the camp. It is also advisable to inform the local police of the camp location
and its purpose.

F-1.3.3 Water Supply

Clean drinking water must be supplied to the workers on site. This is drawn from
the nearest suitable water source by workers. Water for the site camp is supplied in
the same way and stored in drums or water tanks.

F-1.3.4 Setting Out and Measuring Aids

The surveying and setting out requirements for labour-based road construction vary
with the type of work to be executed. The construction of new roads requires a
complete survey by the Engineer to establish the alignment. The engineer provides
the contractor with the relevant reference points and levels. The module describes
simple methods for setting out on site after the Engineer has established the
alignment.
The site work setting out should be done using the simplest instruments and
methods possible.

Table F.3 - Simple Measuring Aids And Instruments For Site Works

Pegs:

1+250
Pegs are used for survey purposes and
for setting out all the activities. On
chainage peg
marking peg

labour-based sites usually wooden sticks

are used of approximately 50 cm length
and strings. On one end they are pointed
so that they can easily be hammered
into the ground. Survey pegs, for
example chainage pegs, are cut at the
edge so that a clear marking can be
made.

Tape Measure:
A great variety of tape measures exist.
The most common length of tape
measure used for setting out is 30
metres. The tapes are made of steel,
flexible plastic or linen. Although the 0 cm
former is stronger, the numbers/
marking on the tape often become
2
3
4
5
6
7
8
9

unreadable after a period of use.

Note: The location of the ‘zero point’
Metal Hook
may differ from tape measure to tape
measure

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Ranging Rods:

50 cm
Ranging rods are round poles usually 2
m long with a diameter of approximately Pointed Hard
2.5 cm. They are made of various Wood Lath
materials (metal, hard plastic, wood)

50 cm
and are usually provided with a pointed

200 cm
metal end. They are painted red and
white with black marking at the 1 meter

50 cm
point. The lengths of the red/white
sections are 50 cm.

As a cheaper alternative a hard wood

50 cm
lath (must be straight), which is pointed
at one, end can also be used as a
Metal Point
ranging rod. At the same time it can be
used as vertical part of the profile board
(see below).

80 cm
Boning Rods (also called Travellers):
Boning rods are T-shaped and of a 10 cm
uniform height. They can easily be
manufactured by nailing a wooden plank
of 80 cm length and 10 cm height on
another plank of 130 cm length and 10

130 cm
cm width so that the end result looks
like a ¨T¨. The horizontal plank should
be painted in clearly visible colours. 10 cm
Boning rods have to be used in a set of
three.

Profile Board:
A profile board is designed in such a
way that it can be attached to a ranging
rod. It has a screw mechanism that
enables the profile board to slide up and Adjustable Adjustable
Profile Board
Profile Board
down on the ranging rod and be fixed at 40 x 10 cm 40 x 10 cm
any desired point simply by tightening
the screw. A long lasting profile board is
the one made from thin steel plate (40 Metal Clamp Wooden Clamp
cm x 10 cm) welded to a short length of with Wedge to Fix

metal tubing that can slide up and down

and can be clamped to the metal rod. Ranging Rod Hard Wood Lath

Alternatively wooden profile boards can

be attached to a hard wood rod and
fixed with a wedge pushed into the
wooden clamp.

Spirit Level:
Spirit levels are available in all different
sizes. For construction work robust and
long spirit levels are ideal. The longer
the spirit level the more exact the
measurement will be. Always ensure
that the spirit level is properly adjusted
/ adjustable before you buy it.

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Straight-Edge with Spirit Level:

If the spirit level is not long enough,
then a straightedge of 2.50 m to 3.50 m,
usually out of wood, can be used. Always
ensure that your straightedges on site
are actually straight on both sides.

Line Level:
A line level is a small spirit level of about
80 - 120 mm length. It has a hook on
each end of the level which is used for
hooking the level onto a smooth line.
The level is used together with a line, Check accuracy of line level:
ranging rods (or profile boards) and a • Place two ranging rods 20 m apart,
tape measure. The line level requires • Fix a line on the 1m-mark on one rod and
two people to operate. transfer the level to the other rod = mark
this level. The line should be kept tight and
The line level can be used to:
the bubble on the line level should be in the
• transfer levels
middle,
• check existing gradients
• Keep line in place, unhook the line level and
• set out gradients
turn it around
Always check: • Adjust the line again and make sure the
• that the line is smooth or of nylon bubble on the line level is in the middle.
• keep the line tight, Mark the new level on the rod and measure
• level is exactly in the middle between the difference between the two levels.
the two ranging rods,
• check the accuracy of the level
regularly.

Plumb Bob:
The plumb bob is usually used by
masons to check the vertical alignment
of walls, abutments, etc. On road sites
this is the case for structure work. The
distance plate is slightly wider than the
plumb bob itself and can be freely
moved along the string line. In this way
the plate can be held against the top of
the wall while the plumb bob hangs on
the lower end. If the plumb bob nearly
touches the wall, then the top and
bottom point of the wall are in a vertical
line. The alignment of the wall can then
be checked by sighting the string line
with the wall line. If they are parallel to
each other then the wall is straight
(vertical).

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Templates: are used to control certain shapes of the road. For example, to control the
correct shape for the slope and ditch, a template of the standard slope-ditch size can be
used by the labourers to continuously check whether the correct shape is being dug.
Templates are very useful control aids as any labourer can see the exact size and shape
of the work she/he is required to carry out. They are usually made of wood and tailor-
made for each particular project in accordance with the standard measurements (see
specifications).
Ditch/Slope h = height of ditch
h Template w = width of ditch
s s = slope
w

Ditch h = height of ditch Note:

h Template w = width of ditch Always use templates
together with spirit level
w

from shoulder to centre line (2,50 - 3,00 m)

Camberboard

camber gradient 8%

The partial rehabilitation method using labour requires the use of an Adjustable
Camber-Slope-Ditch Template (ACSDT).This template represents the finished profile of
half of the road. The template can be adjusted to the different cross-sections (carriageway
width), but has a standard slope of 1.20m and ditch of 0.60m. The template can be locally
fabricated (see Figure E.4 below for details).
PIN FOR 10 CM ST ATIONS

HINGE FOR FOLDING EXTENSION

TELESCOPE
SPIRIT LEVEL STATIONS
WITH 10 CM
8%
12
50
35

! 100
MATERIAL: SQUARE OR
ROUND PROFILE STEEL
PIPES

DITCH SLOPE 150

60 120
330 Max. Extension 150

180 300 Max

480 Max
(ALL DIMENSIONS IN CENTIMETRES) INTECH ASSOCIA TES 1/94

The template is used to establish the camber levels at 10 metre intervals along the road.
The levels are set by slots extending across the whole cross-section (from back of ditch to
back of ditch). The slots are constructed to generally balance the amount of cut and fill at
each 10 metre cross section. The slots will then guide the labour gangs on how much
material has to be excavated from the ditch and used as fill between the slots. In this way
the need to excavate to level is avoided which reduces the workday requirements
significantly.

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The partial rehabilitation method using grader for forming the camber requires the
use of an Adjustable Crossfall Template (ACT). This template allows the crossfall of any
width of carriageway from the crown to the edge to be measured. The ACT can be locally
manufactured. The Figure below shows the ACT details including a table of crossfall
percentage for easy use in the field.

USE SPIRIT LEVEL

200cm
100cm
CL
I J H G F E D C B A

10 cm Pin Pin
10cm
intervals
max. 5 cm
20cm intervals

Note:! to check whether the camber is uniform turn the

! template around and use it as a straight edge

TABLE OF CROSSFALL PERCENTAGE (%)

H A (200) B (210) C (220) D (230) E (240) F (250) G (260) H (270) I (280) J (290) K (300)
V
1 (10) 5.00 4.76 5.54 4.35 4.17 4.00 3.84 3.7 3.57 3.45 3.33

2 (15)

acceptable
7.50 7.14 6.82 6.52 6.24 6.00 5.77 5.56 5.36 5.17 5.00

crossfall
3 (20) 10.00 9.52 9.09 8.70 8.33 8.00 7.69 7.41 7.14 6.90 6.63
4 (25) 12.50 11.90 11.36 10.87 10.42 10.00 9.62 9.26 8.93 8.62 8.33
5 (30) 15.00 14.29 13.64 13.04 12.50 12.00 11.54 11.11 10.71 10.34 10.00

ACCEPTABLE CROSSFALL:
• un-compacted crossfall minimum 10%
• compacted crossfall between 5% to 8% INTECH ASSOCIATES 1.94

F-1.3.5 Tools and Tool Repair / Maintenance

Tools have to be regularly maintained and repaired. Broken handles and worn out
tools need to be replaced. It is also of advantage to employ locally a casual
blacksmith who sharpens pickaxes and other tools which need to be heated. The
blacksmith may provide his own tools and charcoal but is adequately compensated
for this.

It is the right of every labourer to have the correct tools in

good quality for the job to be carried out and it is the
responsibility of the employer to provide and maintain them!

The following Table E.4 is a guideline for the tools to be made available for a) a
labour only partial rehabilitation site, and b) for an equipment and labour partial
rehabilitation site. It is assumed that for labour only site about 80 labourers will be
employed and for the equipment and labour site about 50 labourers.

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Table F.4 - Hand Tool Requirements per Site

Equipment with
Items Labour Only Site
Labour Site
Jembe (Hoe) 70 40
Fork Jembe /Hoe 30 10
Shovel, round nose 60 40
Mattock 30 15
Pick Axe 30 10
Panga (18¨) (Bush Knife) 20 15
Slasher, Grass 20 10
Spreader 20 5
Garden Rake, 14 Prong 20 5
Axe 2 2
Sledge Hammer 2 2
Masons Hammer 5 5
Earth Rammer 10 5
Flat File 12" Second Cut 10 5
Wheelbarrow 10 2
Claw Hammer 2 1
Crow Bar, Chisel and Point 2 2
Abney Level - -
Line Level 2 2
Spirit Level (50 cm) 5 3
Tape Measure 30M 4 4
Ranging Rod 9 9
Boning Rod (Set) 2 1
Electric Torch 2 2
Water Bucket 8 5
Bushman Saw 2 2
2 Man Crosscut Saw - -
Masons Trowel 3 3
Great Coat 2 2
Police Whistle 2 2
Ditch-Slope Template (w. Scour Ch.) 2 2
Adjust. Camber-Slope-Ditch Template 2 -
Adjustable Crossfall Template - 2
Ditch Template (with back slope) - 4
60cm Dia. Culvert Excav. Template 1 1
Rope 1 1
Knotted Ropes - -
Grinding Wheel 1 1
Anvil 1 1
Pair of Bellows 1 1
Sisal Twine (1kg balls) 5 5
First Aid Kit 1 1
Water Drum (200 litre.) 5 1
Long Handled Trowels 2 2
Long Handled Shovels 2 2
The tools required for a spot improvement site will vary depending on the activities
involved. The above list may be used as a checklist.

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F-1.3.6 Equipment Requirements

Equipment is required for those activities that cannot be carried out by labour, e.g.
compaction and haulage, either because the required quality cannot be achieved or
there is insufficient labour available.

The typical requirements for labour only partial rehabilitation works are:
• 1 Pick-up for tool and camp transport, supervision by the contractor
• 1 tractor with a towed 2t dead-weight roller, or 2 pedestrian vibrating rollers
• 1 or 2 bicycles for the Site Supervisors

The requirements for equipment with labour partial rehabilitation works are:
• 1 Pick-up for tool and camp transport, fuel transport and supervision by the
contractor
• 2 to 3 100HP tractors with 2 towed 5t graders, or 1 motor grader
• 1 towed 2t dead-weight roller, or 1 self propelled roller/compactor, or 2 to 3
pedestrian vibrating rollers
• 1 Water bowser
• 1 Fuel bowser or sufficient drums for diesel
• 1 or 2 bicycles for the Site Supervisors
Note: The graders are deployed for reforming the camber while the labour force
opens reinstates/opens the drainage system.
For the ‘Mainly Equipment’ option the contractor may use a bulldozer or hydraulic
excavator for clearing and drainage work. However arrangements must be made to
transport these items to and from site, with the contractor’s own or hired vehicles.

For spot improvement, haulage equipment is usually required, e.g. tractors with
trailers or tipper trucks for gravel hauling or material transport for structural works
or other road surface types.

F-1.3.7 Stores Control

The Site Supervisor is responsible for the safekeeping of the hand tools and
materials issued to the site. He/she may appoint a trustworthy labourer to assist
with the daily issue and collection of tools and material. It is important that store
records are maintained to be able to control issue, collection and maintenance of
tools. A store record may be a simple stock control card and a daily issue/receipt
form (see sample form in the Annex I to this Module).

F-1.3.8 Equipment Control and Maintenance

The Site Supervisor is also responsible for the safekeeping of the site equipment,
its effective utilisation and maintenance. The equipment operators themselves with
the support of a site mechanic may carry out small repairs and daily services.
Equipment movements, fuel and lubricant consumption and repair/maintenance
activities have to be carefully recorded on a daily basis. Simple logbooks should be

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kept and maintained for each piece of equipment (see sample forms and guidelines
for equipment control and maintenance in the Annex II to this Module).

F-1.3.9 Employment of Casual Labour

General:
One of the objectives of Roads 2000 is to involve the local people in the
improvement and maintenance works as much as possible.
The labourers will therefore be recruited from the location of the road. They will
walk to the worksite from their home each day. In this way local communities gain
the benefits of the improvement and maintenance activities. Using mainly labour-
based methods means that a big percentage of the money used for road works
remains in the local economy and therefore is one of the measures to contribute to
poverty alleviation. This employment policy has been established in order to spread
the temporary employment opportunities to as many people as possible.
When the preparation of the road, or section of road, is completed the site will
move to another location and the casual labour force will be discharged. Casual
labourers should not be employed for a continuous period of more than three
months.
Women will be offered equal opportunity to men for employment and the
recruitment process must clearly demonstrate this. Opportunities for employment
should also be offered for disabled people. Special activities that they can carry out
have to be identified and allocated to them.
The recruitment of the casual labour force for each site will be carried out at a
Baraza, or public meeting, a week or two before the start of the actual site works.
The recruitment will be carried out by the Contractor accompanied by an
employment clerk of the DRE and will be achieved with the assistance of the local
administration (preferably the Chief).
When a Recruitment Baraza fails to obtain the required number of labourers, it is
usually because insufficient effort has been made to ensure as many people as
possible know about the recruitment. Often it is women rather than men who are
not advised about employment opportunities in time. Therefore the following
procedures are necessary to ensure good dissemination of information about
recruitment.

Announcement:
The announcement of the Recruitment Baraza in the relevant sub-location / location
should be made if possible, about two weeks in advance of the event.
A standard Notice of Recruitment (see sample in the Annex III to this Module)
should be filled and handed to the following individuals:
• Chief and Assistant Chief,
• Local Political Leaders, e.g. Councillors, MPs, etc.
• Women's Group Leader,
• Other Group Leaders, e.g. Churches, etc.
The notices should be posted at churches, schools, markets and other places near
the site where they will be seen by a large number of people.
In addition barazas may be called at sub-location level to inform local households of
the proposed recruitment.
At all times it should be stressed that:
• both men and women are equally eligible for recruitment,
• employment opportunities are also provided to certain handicapped people,

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• I.D. cards must be brought to the recruitment place.

The place for recruitment should be as close as possible to the road site.

Recruitment:
At the Recruitment Baraza the Contractor will explain the following, with the
assistance of the local administration official for the translation into the vernacular
if necessary:
• function and organisation of the programme,
• type of work which the job seekers will be expected to carry out ,
• employment duration,
• numbers of labourers to be recruited,
• terms of employment (detailed on the recruitment form),
• pay rates, timing and arrangements for payment including first payment
date,
• need for Identity Card for recruitment and payment,
• women and men are equally eligible and welcome to seek employment,
• employment opportunities may also exist for handicapped people,
• if there are more job seekers than vacancies then a secret ballot will be
made to select the labour force.
After the above introduction the job seekers will be invited to step forward and
form an orderly queue. The number of applicants will be counted.
If more people than are required come forward for employment, then selection will
be carried out by a secret ballot system. This is important to avoid possible
accusations of corruption or favouritism.
The recruits will sign the completed Casual Labour Employment Form in
triplicate; original to Employee, one copy to the Contractor and one copy to DRE
(see form in Annex IV to this Module).
Enough people should be recruited to cover the requirements of labourers,
headpersons, store person, water carriers, watchmen and tool repairer. The recruits
should be advised on which days they will report for work as not all will be required
on the first day.
Where possible a register of reserve applicants should be made in case further
recruits are required due to absentees or desertions as site work progresses. It is
recommended that a further 25% more names are selected by the lottery system
and put on a Waiting List.
The Contractor will only be permitted to employ people with signed casual
employment forms or from the waiting list.
The Contractor will also maintain a Musterroll where all labourers and their
achieved work task are recorded on a daily basis. The labourers will be paid against
this record and it is therefore an accountable document. A copy of the Musterroll
may be required by the client to ensure the correctness of payments, as an
accounting evidence and as a standard report on labour statistics.

• For examples of store and equipment control forms,

recruitment notice, casual employment forms and
musterroll, refer to the Annexes III, IV, and V in this
Module
• For monthly, weekly and daily work management forms
refer to Module I. Site Management

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F-1.4.3 Task Rates for Gravelling Work Activities

Table F.6 – Task Rates for Gravelling Works

TASK RATES FOR PREPARATION ACTIVITIES
Activity Task Rate
Reshaping road 20 - 50 m/WD
Clearing bush 200 - 1000 m2/WD
Excavating overburden + loading onto 2 - 4 m3/WD
wheelbarrow if necessary
Hauling by wheelbarrow See table above

TASK RATES FOR GRAVELLING ACTIVITIES

Activity Task Rate/ Person

Excavating Gravel 1.6 - 2.4 m3/WD (insitu)

2 - 3 m3/WD (loose)
Loading Gravel onto Trailer 8 - 10 m3/WD (loose)
Loading Gravel onto Trucks 5 – 7.5 m3/WD (loose)

Off Loading and Spreading 12 - 16 m3/WD (loose)

The labourers assigned to each activity can be determined using the total quantities
to be hauled and the productivity ranges shown in the table above.

Gang tasks should be used for gravelling operations wherever

possible

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F-1.4.4 Productivity Rates for Hauling Equipment

Principle:
The haul distance, type of equipment used and condition of the haul route
determine the quantity of gravel that can be hauled in a day by each operational
piece of haulage equipment. An estimation of expected haulage productivity is best
achieved by analysing separately the time requirements for each of the sub-
activities involved as follows:
• Loading of gravel in quarry
• Haulage of full tractor/trailer or truck from quarry to dumping site
• Off-loading of gravel at dumping site
• Return of empty tractor/trailer or truck from dumping site to quarry
Choice of Haulage Equipment:
• The maximum economic hauling distance of gravel by the tractor/trailer
combination is usually about 2 - 4 km.
• Trucks may be economic for any distance up to about 20 km.
• The number of pieces of haulage equipment to be used is determined after
establishing the quantity of stockpiled gravel that is ready for hauling, the
haul distance, and the number of labourers available.
Table F.6 – Gravelling Cycle Times:
CYCLE TIME IN MINUTES
Tractor / Trailer 7 Ton Truck
Haul 45 – 55 HP 56 – 75 HP Flat Bed Tipper
Distance Poor Good Poor Good Poor Good Poor Good
0–1 26 22 24 21 44 42 38 36
1–2 41 29 36 28 51 45 45 39
2–3 56 37 47 34 57 47 51 41
3–4 71 45 59 40 63 50 57 44
4–5 87 52 71 47 70 52 64 46
5–6 102 60 82 53 76 55 70 49
6–7 117 68 94 59 83 57 77 51
7–8 132 75 106 66 89 60 83 54
8 – 10 156 87 123 75 99 64 93 58
10 – 12 186 102 146 88 111 69 105 63
12 – 14 216 117 170 100 124 74 118 68
14 – 16 247 132 193 113 137 79 131 73
16 – 20 292 155 228 132 156 86 150 80
20 – 24 353 186 275 157 182 96 176 90
24 – 30 429 224 333 189 214 109 208 103
Assumptions LOADING AND OFF-LOADING IN MINUTES
Tractor / Trailer 7 Ton Truck
45 – 55 HP 56 – 75 HP Flat Bed Tipper
Loading 6 6 25 30
Off-loading 12 12 16 5
TRAVEL SPEED IN KM/HOUR
Tractor / Trailer 7 Ton Truck
45 – 55 HP 56 – 75 HP Flat Bed Tipper
Poor Good Poor Good Poor Good Poor Good
Full 7 14 9 18 15 40 15 40
Empty 9 18 12 20 25 60 25 60

May 05 F - 16
R2000 Operations Manual PARTIAL REHABILITATION F

Table F.6 – Gravelling Haul Targets:

GRAVELLING DAILY LOAD TARGETS: GOOD & POOR HAUL ROUTES

Tractor / Trailer 7 Ton Truck
Haul 45 – 55 HP 56 – 75 HP Flat Bed Tipper
Distance Poor Good Poor Good Poor Good Poor Good
0–1 16 19 18 20 10 10 11 12
1–2 10 14 12 15 8 9 9 11
2–3 7 11 9 12 7 9 8 10
3–4 6 9 7 10 7 8 7 10
4–5 5 8 6 9 6 8 7 9
5–6 4 7 5 8 6 8 6 9
6–7 4 6 4 7 5 7 5 8
7–8 3 6 4 6 5 7 5 8
8 – 10 3 5 3 6 4 7 5 7
10 – 12 2 4 3 5 4 6 4 7
12 – 14 2 4 2 4 3 6 4 6
14 – 16 2 3 2 4 3 5 3 6
16 – 20 1 3 2 3 3 5 3 5
20 – 24 1 2 2 3 2 4 2 5
24 – 30 1 2 1 2 2 4 2 4
Assumptions: Daily working hours for tractors/trailers and trucks = total working hours (8) minus service hour (1) =
actual time on hauling job = 7 hours per day

May 05 F - 17