R2000 Operations Manual PARTIAL REHABILITATION F

F-4 EQUIPMENT PARTIAL REHABILITATION

WORKS

F-4.1 OPERATION OVERVIEW

This Module Section describes the Partial Rehabilitation Operations using
Equipment.
Although most of the operations are carried out 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.
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 in sequence. In this way a ¨train¨ of activities moves along the road
improving the carriageway and drainage in a controlled step-by-step manner.
A flexible approach to earth and gravel road rehabilitation is required as the works
necessarily differ from one road to another, and even from section to section along
a road. As funds for rehabilitation work are limited, only the essential
improvements can be carried out.
The principal approach, when mainly equipment is used is shown in Figure F.26
below. 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 DITCH AND CAMBER GRADING SETTING OUT + CLEARING
• labour • !grader and compactor with • equipment with labour
labour support support

The approach allows for a rapid improvement of the road network to a standard,
which allows Routine Maintenance to be effectively established.
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.

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The activities necessary for the equipment partial rehabilitation (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

For Details
Operation Activity
Refer to:
Site Support Work • Site Camp Installation Section F-1.3
• 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 • Setting out Horizontal Alignment Section F-4.2

• Setting out Horizontal Curves

Clearing • Bush Clearing Section F-4.3

• Stripping and Grubbing
• Tree and Stump Removal
• Boulder Removal

Rehabilitation Grading • Cleaning / Excavating Side Drains Section F-4.4

(heavy grading) • Cleaning / Excavating Mitre Drains
• Reforming The Camber

Compaction • Carriageway Compaction Section F-4.5

Other Drainage Works • Scour Checks Section F-4.6

• Relief Drainage Structures
• Culvert Cleaning
• Culvert Replacement or New
Installation

F-4.2 SETTING OUT

Roads 2000 partial rehabilitation work is normally carried out along the existing
established road alignment.
If a limited section of a road definitely requires a new alignment, then this section
has to be treated as spot improvement and needs to be assessed in detail.

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The horizontal alignment consists of a series of straight lines connected by curves.

The Roads 2000 partial rehabilitation works are carried out mainly on existing and
established earth and gravel roads, which in most cases were previously graded by
motor graders. Usually no specific alignment control was carried out during these
grading operations and very often the road cross section is frequently changing
along the route. However, for the Roads 2000 routine maintenance approaches it is
necessary to establish minimal technical standards as described in Module C of this
Manual.
The first site activity for the Contractor is therefore to re-establish the centre line;
a.) as close as possible to the relevant standard, and b.) to minimise earthworks as
much as possible.
The horizontal alignment, including curves, is set out in the same way as for the
labour-only partial rehabilitation operation. This is described in Section F-2 of this
Manual.

Setting out is achieved using ranging rods and tapes to establish the centre line
with wooden pegs every 10 metres along the alignment (see Figure F.27 - Job
Sheet ; Setting out a Straight Alignment).
Unlike full rehabilitation for partial rehabilitation work, it is sufficient to follow the
existing alignment of curves with minor corrections only.
Therefore the setting out procedure for curves is simple and straightforward. First,
the beginning and the end of the curve have to be located and a centre peg
established at these ends. Afterwards approximate centre pegs are set in-between
at intervals of 5 metres, the existing ditch or edge of camber can be used as a
guide to measure from. A string is then attached and laid along all these pegs. The
Site Supervisor has then to check by eye whether all curve segments look similar.
Where abnormal deviations can be found the nearest centre peg has to be re-set
until the entire curve looks uniform.
The Job Sheet, Figure F.28 explains the procedure in detail.

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Roads 2000

1. Establish the edges of the existing carriageway and measure the width.
2. Set the first centre peg at the middle of the established carriageway.
3. Repeat steps 1 and 2 after a maximum length of 100 metres or before the beginning of a
curve.
4. Place a ranging rod on each end of the established length of straight.
5. Move with the third ranging rod along the established line and place a centreline peg every
10 metres. Knock the centreline pegs firmly into the ground so that their tops are almost
flush with the existing ground.
6. After setting the centre line pegs over a 100 m section check again whether they are in a
straight line using the ranging rods. If necessary correct - then move to the next section.

Move this rod until all 3 rods are in one straight

line, then place pegs every 10 metres.

10m Intervals

• 1 Site Supervisor / or one • 3 Ranging Rods

trained Headman • Tape Measure, 30 m
• 1 Masons Hammer
• 2 Labourers • Wooden Pegs

approximately 2 km / day / gang

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Roads 2000

1. Establish the centre line pegs at each end of the curve (A and B).
2. Set intermediate pegs at 5 metre intervals along the approximate centre line.
3. Tie a string along all centre pegs.
4. Adjust pegs which do not appear to be on a smooth curved line until the entire curve
appears to be uniform.

Tie string along all centre pegs

m B
5

Adjust these two pegs to

the right until the curve
appears uniform

• 1 Site Supervisor / or one • 3 Ranging Rods

trained Headman • Tape Measure, 30 m
• 1 Masons Hammer
• 2 Labourers • Wooden Pegs
• Strings

approximately 2 km / day / gang

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F-4.3 CLEARING
Clearing consists of the following activities:
• Bush Clearing
• Stripping and Grubbing
• Tree and Stump Removal
• Boulder Removal

Very often the road reserves are overgrown. Bush and grass may even encroach on
the running surface. Before any excavation work can start, the road reserve and
running surface must be cleared. For Roads 2000 bush clearing and grubbing is
carried out as one activity. The width to be cleared is determined by the chosen
cross section. It consists of the running surface, including the slopes to the ditches
(inner side of ditch), plus 2 metres on either side. The table below provides
guidelines on how to choose the appropriate width for clearing.

ROAD CATEGORY RUNNING OVERALL WIDTH OVERALL WIDTH

SURFACE WIDTH TO FRONT OF FOR BUSH
DITCHES CLEARING

A/B/C Main +
6.0 m 8.4 m 12.4 m
Secondary

D/E Minor Roads 5.4 m 7.8 m 11.8 m

RAR Roads 4.5 m 6.5 m 10.5 m

Minor / RAR Roads
with insufficient
width 3.5 m 5.5 m 9.5 m
(temporary section)

Bush clearing includes the cutting of bushes, shrubs and small trees. Stripping and
grubbing includes the removal of all grass, upper grass roots and other vegetation
remaining after bush clearing (except bigger trees). All topsoil should also be
removed from the cleared width, as this must not be mixed into the road works.
The vegetation and topsoil should be discharged outside the cleared areas. If it is
necessary to burn the cuttings, this should be carried out after the clearing
operation, and in an area where the fire can be safely controlled.
It is important that all vegetation and topsoil is removed from the area to be
graded, otherwise the performance of the grader will be affected and the quality of
the work will be poor. It is also essential that all standing water be drained away
from the carriageway in advance of the grading operations by manually digging
drainage grips.
As these activities need to be carried out before the grading activities start, it is
important to balance the gang size in such a way that the clearing gang is always
well ahead of the grader gang. The activity can be carried out by labour, or using a
bulldozer or hydraulic excavator supported by labour.

The Job Sheet in Figure F.29 illustrates the detailed activity procedures.

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Roads 2000

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 and/or equipment. Give individual tasks for bush clearing,
and stripping and grubbing.

grass cutting and grubbing

A/B/C Main + Secondary Roads! = 12.4 m
D/E Minor Roads! = 11.8 m
RAR Roads! = 10.5 m
Reduced Section RAR/Minor Roads! = 9.5m
! 2m ! 2m
bush C bush
L
clearing clearing

edge pegs = chainage pegs

• 1 Headman • Tape Measure, 30 m

• 2 Labourers for setting out
• Labour Gang for Bush
Clearing and Stripping and
Grubbing,
• Plant Operator for clearing
equipment
• 1 Masons Hammer
• Wooden Pegs + Strings
• Pangas + Grass Slashers
• Axes + Rakes
• Jembes + Shovels
• Dozer, hydraulic Excavator
and/or Grader depending
on the nature of clearing

• Bush Clearing = 300 - 1000 m2 / day / labourer

• Stripping and Grubbing = 200 - 300 m2 / day / labourer

• Dozer / Grader; output depending on type and nature of work

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In normal circumstances these two activities will not be required as the Roads 2000
works are carried out along established roads. However, in certain cases where
roads have not been maintained for a prolonged period of time, this might be
required and these relatively costly activities have to be included in the estimates.
Bulldozer and/or hydraulic excavator may be required for this work.

F-4.4 REHABILITATION GRADING

Most of the roads to be taken over by Roads 2000 have an existing camber or a
running surface which is sufficiently stable. Heavy earthworks, as in the RARP or
MRP, are therefore usually not required and they are outside the scope of the
Roads 2000 partial rehabilitation operations. Where limited earthworks are required
they should normally be carried out under the follow up programme spot
improvements.
The partial rehabilitation activities should focus on re-building of the camber and
restoration of a functional drainage system. This is partially achieved by bringing
suitable material from the edge of the carriageway and the shoulder to rebuild the
camber.
The restoration of the camber and opening of the side / mitre drains is carried out
with graders and follows shortly after the clearing gang. It is important to schedule
the works in such a way that the clearing gang is always ahead of the grader team
by at least one working day. The Contractor should adjust the gang resources to
make the best use of the available equipment and do not interrupt their work.
Heavy grading is best scheduled to follow a period of rain, as the moisture in the
material will greatly help compaction. Before grading work can start any standing
water must be led away from the carriageway and drains.
The heavy grading operation includes;
1. Cleaning / Excavating Side Drains,
2. Cleaning / Excavating Mitre Drains, and
3. Reforming Camber

Most roads have in the past not been graded in accordance with any specified
standards. Earth and Gravel roads have very often no uniform cross-sections and
no clearly defined side ditches. However, for structured and controllable routine
maintenance activities and to provide a uniform carriageway standard to road
users, it is necessary to prepare the roads according to cross sectional standards.
Before the grading operation starts (after the initial setting out of the centre line
and bush clearing + grubbing) it is therefore important to clearly set out where the
graders have to cut.

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For drain grading the outer sides of the ditches have to be defined and clearly
marked using pegs every 20 m on straight sections and every 10 m in curves (see
Figure F.31).
The pegs should be long enough (approx. 40 cm) so that the plant operator can
easily see them. The outer edge of the grader blade has to follow this line during
the first pass by cutting a “V” ditch. To re-instate the drain and inner slope to the
shoulder, 2 - 4 passes are normally required on each side of the road.
A trained Headperson and a labourer can carry out the setting out by measuring
2m from the established chainage/bush clearing pegs towards the centre line. The
table in Figure F.31 (Job Sheet ¨Cleaning / Excavating Side And Mitre Drains¨)
specifies this measurement.
Also where mitre drains will have to be cut should be established and marked with
pegs. Special attention should be given to finding the correct location and gradient
for mitre drains to ensure effective drainage and avoiding erosion of the adjacent
land. The location of mitre drains should also be discussed and agreed upon with
the landowners prior of the actual grading activity. Where necessary erosion
protection measures have to be made.

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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

CL

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
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.

• 1 Site Supervisor • 2 heavy towed graders + 100

• 1 to 2 Grader Operators HP tractors or self-propelled
• 1 Headperson + 1 labourer for grader
setting out • Tape Measure, 30 m
• 2 to 3 labourers per grader to • 1 Mason Hammer
support • Wooden Pegs
• AC- or ACSDT -Template with
Spirit Level

Together with activity ¨Camber Formation¨ approximately 1km / day / towed

grader or 1.5 to 2km per self-propelled grader, depending on the existing condition.

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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.

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Usually 4 to 6 passes will be sufficient to bring the camber back to the acceptable
shape. It is important that the Site Supervisor frequently checks the achieved
camber crossfall using the AC or ACSDT-Template. The uncompacted crossfall
should be between 7 to 10%, which will allow for a compacted crossfall between 5
to 8%.

USE SPIRIT LEVEL

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

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

!
!

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)
2 (15)

acceptable
crossfall
3 (20)
4 (25)
5 (30)

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

In some cases there will not be sufficient material to form the recommended
crossfall. The Site Supervisor has then to plan to bring in additional material from
the ditches. However, this operation is carried out by labour after the grading has
been finished. The camber may be reshaped and compacted in a follow up routine
maintenance re-grading operation.
It is preferable for the partial rehabilitation operation to work with 2 graders at the
same time. This is necessary to ease supervision and to concentrate support
activities.

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Figure F.34 (Job Sheet ¨Camber Formation¨) illustrates the detailed activity
procedures.

Roads 2000

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.

• 1 Site Supervisor • 2 heavy towed graders + 100

• 1 to 2 Grader Operator HP tractors OR self-propelled
• 2 to 3 labourers per grader to grader(s)
support • AC or ACSDT-Template with
Spirit Level
• Straight Edge

Together with activity ¨Shoulder Grading¨ approximately 1km / day / towed

grader OR 1.5 to 2km when using a self-propelled grader.

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Figure F.35 provides details on heavy grading operations for camber

restoration:

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F-4.6 OTHER DRAINAGE WORKS

After the ditch and surface grading activities have been completed, some cleaning
out and finishing work has to be carried our by labour.
The activities consist of installation of:
• scour checks,
• cleaning out of existing culverts, and
• replacement and/or installation of additional new culverts.

The additional drainage works are carried out in the same way as for the labour-
only partial rehabilitation operation.

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Roads 2000

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
below).
3. Cut pegs (min 50 cm long) and/or prepare stones.
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 spirit level

with slope edge
• place 1st peg at the
edge of the ditch

• hammer the peg

into the ground
1st peg until the spirit level
Gradient of Road Scour Check
on the template
Spacing
ledge is horizontal
4% or less not required
5% 20 m
8% 10 m
10% 5m

edge pegs • build scour check

flush to the
template

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

• 1 labour gang • Template + Spirit level • Pegs of min. 40cm

• Sledge Hammer length
• Mason Hammer • Stones for apron, and/or
• Panga and Shovel for scour check

4 No / day / labourer (including collection of stones and /or preparation of

pegs)

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