O&M Centre: Maintenance Manual Section 2 (A)

O&M CENTRE
Maintenance Manual
Section 2(A)
Highway Management System
L&T Interstate Road Corridor Limited

Gujarat & Rajasthan
DRAFT 1 March 08 AP MD MD
REV. DATE NAME SIGN. NAME SIGN. NAME SIGN.
AUTHOR CHECKED APPROVED
Document Title Location Project File Doc No Rev
MAINTENANCE MANUAL – SECTION 2(A) INDIA PRSG MANT 101 DRAFT

Maintenance Manual – Section 2(A) INDIA PRSG MANT ii/vii
1. CONFIDENTIALITY
The reader is reminded that neither this document, nor its contents, may be copied,
transcribed or replicated in part nor in full, without the written permission of L&T Interstate
Road Corridor Limited, Gujarat & Rajasthan. The permission, of which, shall be entirely at
the discretion of L&T.
Maintenance Manual – Section 2(A) Gujarat & Rajasthan

Maintenance Manual – Section 2(A) INDIA PRSG MANT iii/vii
2. REVISION GRID
Revision No. Revised or added page No’s Comments
00 Draft Issue

Maintenance Manual – Section 2(A) INDIA PRSG MANT iv/vii
3. IC’S COMMENT AND APPROVAL
Item No. Comments

Maintenance Manual – Section 2(A) INDIA PRSG MANT v/vii
4. TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION A (1-11)
CHAPTER 2 SAFETY B (1-12)
CHAPTER 3 CLEANING C (1-3)
CHAPTER 4 PAVEMENT D (1-53)
CHAPTER 5 DRAINAGE E (1-5)
CHAPTER 6 SHOULDERS, SLOPE F (1-3)

AND EARTHWORKS
CHAPTER 7 ROAD FURNITURE G (1-15)
CHAPTER 8 STRUCTURES H (1-18)
CHAPTER 9 BUILDINGS I (1-15)
CHAPTER 10 HORTICULTURE J (1-6)

Maintenance Manual – Section 2(A) INDIA PRSG MANT vi/vii
5. PURPOSE OF THIS DOCUMENT
This document serves to provide guidance on inspections of various elements of the

Highway during the period of Operations and Maintenance on the Interstate Road
Corridor Project.
The handbook covers the basic procedures for carrying out the inspections in an
organised and structured manner on the project road and structures. It deals with
interpretation of observations during inspections and then analyzing the causes of
defects and their appropriate remedial measures. It also lays a lot of emphasis on
documentation and referring to previous inspection reports. It describes the basic
planning for carrying out the maintenance activities in an organised way on the project
road and structures.
This document has been prepared with reference to the requirements of the
Concession Agreement, provisions of IRC, Indian and international standards, and
good engineering practices in civil engineering works.

Maintenance Manual – Section 2(A) INDIA PRSG MANT vii/vii
6. REFERENCE SHEET
The operations & maintenance manual has been prepared in two sections and four
volumes as follows:
Description Section Volume Functions Covered

Operations Manual Section I (A) Toll Operations
Operations Manual Section I (B) Route Operations
Maintenance Manual Section II (A) Maintenance Manual
Maintenance Manual Section II (B) Systems Maintenance
Concession Agreement
Specifications and Standards
1. IRC 35: 1997 Code of Practice for Road Marking

2. IRC 67: 2001 Code of Practice for Road Signs
3. IRC 79: 1981 Recommended Practice for Road Delineators
4. IRC 82: 1982 Code of Practices for Maintenance of Bituminous
Surfaces of Highways
5. IRC SP 18: 1996 Manual for Highway Bridge Maintenance Inspection
6. IRC SP 35:1990 Guidelines for Inspection and Maintenance of Bridges
7. IRC SP 42: 1994 Guidelines on Road Drainage
8. IRC SP 44: 1996 Highway Safety Code
9. IRC SP 55: 2001 Guidelines on Safety in Road Construction Zones
MoRTH Publications
1. Manual for Maintenance of Roads

2. Specifications for Road and Bridge Works

Chapter 1
INTRODUCTION
CONTENTS PAGE NO.
PROJECT DETAILS A-1
MAINTENANCE MANUAL A-2
INSPECTION SYSTEM A-3
VISUAL INSPECTIONS A-3
DETAILED INSPECTIONS A-4
THOROUGH INSPECTIONS A-5
ROUTE PATROL A-5
MAINTENANCE A-6
MAINTENANCE CALENDAR A-6
GROUPING OF DEFECTS A-7
MANPOWER A-9
Maintenance Manual – Section 2(A) INDIA PRSG MANT A - 1/11
CHAPTER 1
INTRODUCTION
Project Details
Highway
The project stretch that shall be maintained by

L&T Interstate Road Corridor Ltd. covers a length
of 76kms starting from chainage KM 264+000
(Rajasthan side) to KM 340+000 (Gujarat side) on
NH-14. The project stretch is a four lane dual
carriageway with a shoulder width of 1 – 2.5m
earthern shoulders on either side. The project
highway has easy gradients except two steep
gradients at the approaches of Balaram Bridge
(between km 331 and km 332). There are 97
intersections along the project highway, of
which 6 are major intersections. L&T IRCL is also
responsible for the maintenance of the
approach roads and underpasses and
overpasses up to 100m from the Project Section.
The available RoW varies from 20m to 56m.
Structures
There are 181 structures on the Project Stretch,

of which six are major bridges, 27 minor bridges,
1 flyover at Abu road at KM 296+100, 14
underpasses and 2 RoBs at KM 282+978 and KM
330+436. The remaining 131 structures are
culverts (56 box culverts and 75 pipe culverts).
Toll Plaza
There are two toll plazas located at KM 270+250

and KM 338+230 with 6 lanes; 3 lanes for each
direction. The plaza has a proper canopy I
structure and toll booths on islands which are
made of aluminium and glass. The plaza
N
building that houses the administration, T
operation and maintenance base camp is
located on one side of the toll plaza. R
Bus Bays
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The project stretch has 2 bus bays and 38 bus
shelters. U
Truck Lay byes
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A truck laybye is located at KM 304+625 with
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basic facilities like drinking water, public I
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telephone, rest area and toilets with proper

disposal system. Service roads are located at
KM 309+525 to KM 311+735 to cater for truck EQUIPMENT / TOOLS / MACHINERY
parking.
Lab Facility MAINTENANCE
Laboratory has been provided with basic testing

facilities having following equipments: 1. Wheel Barrows
2. Shovels
• Straight Edges
• Digital Thermometer 3. Pick Axe
• Glass Thermometer 4. Rakes
• Rapid Moisture Meter
• Weighing Balance 5. Wood Saw
6. Crow Bar
All other tests shall be carried out as and when
7. Spirit Level
required at Government recognized test
centers. 8. Rope (50m)
9. Extendable Ladder
MAINTENANCE MANUAL 10. Tripod Ladder

11. Hand Rammers with metal shoes
The manual covers areas of activity on the
12. Brooms (brush with long sticks)
highway where work is generally short term or
cyclic and necessary to keep the highway in 13. Wire Brushes
good working order. It also helps in identifying 14. Coir Brushes
what needs to be replaced or renewed on the
highway, which, over a longer term, becomes 15. Nylon Brushes
unserviceable because of general wear and 16. Watering Can for Bitumen /
tear, and would require structural maintenance
Emulsion
work. The inspection procedures will assist in
identifying the need for replacement or renewal 17. Metal Bucket
under planned programs of maintenance / 18. Straight Edge (2m)
rehabilitation.
19. Paint Brushes
The following elements are covered 20. Assorted Carpenter’s Tools
21. Assorted Electrician ‘s Tools
• Road
o Pavement 22. Pavement Cutter I
o
o
Drainage
Shoulders / Slopes / Earthworks
23. Bitumen Distributor – Small N
o Road Furniture 24. Bitumen Heating Arrangement T
• Structures R
• Buildings
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• Horticulture
U
Effective maintenance of highways is controlled
and implemented by a strong Maintenance
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Database. The Maintenance Database enables T
all inspection and other reports, complaints and
third party claims to be assessed in conjunction I
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with the inventory, previous maintenance

actions and other relevant data. EQUIPMENT / TOOLS / MACHINERY
An adequate inspection system is an essential
part of that requirement. MAINTENANCE
Inspection System 25. Trays for heating bitumen,

aggregates
The highway network is regularly inspected for
the purposes of safety of the road user and 26. Mechanical Mixer for emulsion and
identifying the need for routine maintenance aggregates
tasks to be carried out. Where a particular
27. Tar Sprinkler
interval is specified between inspections, this will
be adhered to as closely as possible, taking due 28. Tar Bucket
account of other activities on the network. 29. Tar Kettle
The inspections are divided into 3 types: visual, 30. GI Bucket
detailed and thorough. Besides these regular 31. Template for checking camber
inspections, specialist inspections are sometimes
32. Template for checking earthwork
required and are done at an appropriate time
for the purpose of determining the need for slopes
major repairs, rehabilitation, replacement or 33. Light Vehicle for transporting staff
enhancement requirements. Such inspections
identify activities that exclude routine and 34. Field Lighting Unit
periodic road maintenance. 35. LCV for transporting aggregates,
Before the commencement of any inspections, tools, etc.

it is necessary to mark the chainage on the road 36. Chemical Sprayer
on each carriageway. This marking shall be
37. Grass Cutter
done at 100m intervals, with 500m and kilometer
locations being marked differently for easy 38. Hedge Trimmer
identification. The text should be big enough so 39. Bush Cutter
that one can read the chainage while sitting in
a slow moving vehicle during inspection, and 40. Pruning Saw
should be legible in pictures. Wherever possible, 41. Air Temperature Meter
these chainage shall be marked on the
42. Bitumen Thermometer
guardrail, or bridge parapet / railing, otherwise
on pavement, close to the outer edge. 43. 20 litre cans for carrying diesel to
clean tools
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The formats will indicate check boxes for every
25m sections for each lane and for the shoulders 44. Walk behind roller N
as well. There will also be a legend on each 45. Pressure Washing Machine T
format in a very simple graphic form. The check
boxes shall be marked accordingly. R
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Visual Inspections D
The visual inspections may be carried out by a U
team not so technically competent such as
supervisors / technicians / foremen. They do not
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require many measuring instruments. Visual T
inspections are done at frequent intervals, and
are intended to determine any potential traffic I
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hazards to the road user or hampering the

aesthetics of the project stretch. These EQUIPMENT / TOOLS / MACHINERY
inspections also indicate any maintenance
needs which can be grouped with similar
activities in the maintenance calendar. These MAINTENANCE
inspections are carried out from slow moving
vehicles, with the occasional need to proceed
on foot. Based on the reports generated in 46. Compressor with pneumatic
these inspections the engineer can decide breaker
which areas require his inspection and how
47. Vacuum Cleaner
urgently. Besides carrying out these inspections
at predetermined intervals, sometimes these 48. Advance Warning Signs
need to be carried out in response to reports or a. Men at Work (500m)
complaints from Patrols, police or public, as a
result of major accidents, or extreme weather b. End of Restriction
conditions. c. Speed Limit 80kmph
d. Speed Limit 60kmph
Visual inspections are meant to identify defects
that constitute an imminent or immediate e. Restriction Ends
hazard to the public. Whenever such defects f. Lane Closed
are encountered, they will, if reasonably
practical, be corrected, made safe or otherwise g. Two Way Traffic
protected by the inspection personnel before h. Direction Traffic
being reported to the base office at the earliest
i. Direction Traffic –
opportunity with a request for immediate action.
Reverse
j. Closed Carriageway
Detailed Inspections
k. End of Road Works
The detailed inspections are done by a 49. Rechargeable Blinkers
technically competent team. These inspections
often require some measuring instruments, are 50. Traffic Safety Cones
done less frequently and are intended more 51. Reversible Stop (Red) / Go (Green)
towards determining performance and Signs
behaviour of various elements. These inspections
also indicate if there is any need for thorough 52. Flags (Red/ Green)
inspections. Detailed inspections are carried out
primarily to establish programs of periodic or
major maintenance tasks, and enhancement
requirements not requiring urgent execution. I
On all roads, including dual carriageway
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sections, detailed inspections will generally be T
carried out from the edge of the traffic lane. The
condition of the carriageway surface and road R
markings in all lanes should be observed from
these locations at certain frequencies.
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Additionally, gullies, kerbs and edge lines D
adjacent to the nearside verge and central
medians should be inspected from these U
locations at the appropriate frequencies. C
Detailed inspection data will be recorded using T
standard formats that include checklists setting
out the various defects to be noted. I
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Detailed inspection records include details of

the manner of inspection (e.g.: off-side lane
closure or nearside), the weather conditions and
any other unusual features of the inspection.
Thorough Inspections
Thorough inspections require even more

technical skills. These inspections will make use
of highly sophisticated instruments and may be
required to be undertaken once or twice in a
year. These inspections are aimed at finding the
cause and remedy of specific problems and at
specific locations.
Specialist inspections are required once in a

while or may not be required at all. The
technical skill level in such inspections is very
high and persons of renowned ability such as
from engineering colleges, manufacturers, or
professional bodies may be required. The
situations where a specialist’s inspection may be
necessary could be
• Structural failure of the pavement

• Design of overlays
• Geotechnical Investigations
• Structural surveys of pavement
• Structural investigations of bridges and
cross drainage works, etc.
Route Patrol
A route patrol is normally carried out daily

including weekends and public or national
holidays, by the route patrol team. The Route
Patrol will also report to the maintenance
department about any defects of hazardous I
nature requiring immediate action. These will be
corrected or made safe at the time of patrol by
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the route patrol team, if reasonably practical. T
The road user should be made safe from the
hazard by cordoning or fencing off the area R
and displaying warning notices. Whether to
correct or make safe the defect at the time of
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patrol is possible or not, the patrol team will send D
a daily report to the maintenance department.
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Examples of route patrol reporting to the
Maintenance Department:
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1. A street light pole fallen on the
carriageway. I
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2. A broken signboard protruding on the

carriageway or on to the shoulder.
3. Branch of a tree overgrown to hide a
signboard.
4. Vegetation overgrown to hide a Response Time
kilometer stone.
5. Clogged expansion joints, etc.
Routine Maintenance requirements will be
carried out within one week of being
observed / informed.
Maintenance
If it is not possible to rectify within one week,
Maintenance works are all required to be repairs of temporary nature will be carried
extremely procedure driven and out within a period of one week. Temporary
documentation oriented. All activities except repairs will be inspected regularly, and
hazardous defects will be done under a permanent repairs carried out within 3
planned program. A detailed record of activities months.
of maintenance will be kept in the form of
reports, tables, graphs, photographs and Periodic repairs will be carried out as
summaries. The manpower for maintenance planned at the beginning of the year.
activities will be organized under a Priorities will be considered keeping in mind
predetermined pattern and each member of the access requirements, other maintenance
works being undertaken, traffic levels and
the team will have clearly assigned role and
the need to minimize traffic management, in
responsibility. There will be an inspection system preparation of program of works.
and a safety procedure which shall be strictly
followed. Any further maintenance requirements
which might come out as a result of
All defects noticed after inspections or otherwise thorough or specialist surveys applying to
will be listed and will be grouped into various specific activities will also be built into the
categories. planned program of works.
Actions on defect removal will be taken within a All actions taken, including temporary
finite time frame as described later in this protective measures and repairs, will be
manual. promptly recorded and details retained for
future reference.
Maintenance Calendar
All the maintenance activities will be carried out

under a planned program which is named as
the Maintenance Calendar. This Maintenance
Calendar will take into consideration all defects I
and maintenance requirements which one can
foresee. All routine and periodic maintenance
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activities will be done in accordance with these T
provisions.
R
Maintenance requirements of immediate or
hazardous nature and those required as a result
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of thorough or specialist inspections will not be D
governed by the Maintenance Calendar.
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The Maintenance Calendar will be prepared
usually in the month of January for the next
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financial year. An annual maintenance budget T
will then be prepared based on this
maintenance calendar. I
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Grouping of Defects FREQUENCY OF INSPECTIONS
After Rainy
Before and
Defects which are identified as a result of Visual
Quarterly
Monthly
Season
Daily
Object
or Detailed Inspections, or any other reports and
complaints, will be put into three categories:
Pavement ♦ ∆ •
Immediate: Expansion Joints ♦ ∆ •
Kerb ♦ ∆ •
Those, which require urgent attention because
Shape ♦ ∆ •
they represent an immediate or imminent
hazard or because there is a risk of short-term Turfing ♦ •
structural deterioration. Reinforced Earth Wall ∆ •
Bearings ∆ •
Example: Retaining Wall ∆ •
Side Drain ♣ ∆
1. A street light pole fallen on the carriageway
Guidelines & Catchpits ♣ ∆
2. A signboard broken and protruding on the
carriageway or onto the shoulder Superstructure ∆ •
3. Branch of a tree overgrown to hide Substructure ∆ •
kilometer stone Protective Works ∆ •
4. Clogged expansion joints, etc.
Painting •
Hand Rail ∆ •
Routine: Culverts •
Safety Barrier ♣ ∆ •
These are routine maintenance works which Traffic Sign •
have to be taken up regularly as part of routine Road Marking ♣ ∆ ∆ •
maintenance.
Delineator ♣ ∆ ∆ •
Example: Lighting ♣ ∆
Vegetation / Toll Plaza
♣ ∆ •
/ Wayside / Amenities
1. Defects such as filling of potholes, repairing
Traffic Conditions ♣ • ∆
of cracks
Encroachments ♣ •
2. Cleaning of signboards
3. Trimming of vegetation, etc. Bearings ∆ •
♦ Visual Inspection
Periodic / Major ∆ Detailed Inspection
I
All other defects will be put under this group.
• Thorough Inspection N
♣
These defects are required to be done
Visual Inspection during
Rainy Season Only T
periodically every few years.
R
Example: O
1. Applying a seal or renewal coat D
2. Painting of buildings
3. Painting of signboards U
4.
5.
Bridge railings
Maintenance of earthworks
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6. Settlement of approaches to culverts / T
bridges
7. Pavement strengthening I
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8. Structural overlays
9. Any structural repairs, etc.
Defects requiring immediate action will be

corrected or made safe at the time of
inspection, if reasonably practicable. In this
context, making safe may constitute displaying
warning notices, cordoning off or fencing off to
protect the road user from the hazard.
If it is not possible to correct or make safe the

defect at the time of inspection, repairs of
temporary nature shall be carried out as soon as
possible and in any case within a period of 24
hours.
Temporary repairs will be inspected regularly as

part of visual inspections as well as route patrols,
and permanent repairs carried out within 28
days.
Emergency Situations
In the event of an emergency occurring on the

network it is essential for maintenance personnel
to respond as quickly as possible in order to
minimize any danger, disruption or delay.
An emergency is defined as a situation which

can be hazardous for a road user or for an asset.
Example:
1. A tree or a street light pole fallen across the

carriageway
2. An accident and consequently the vehicle
lying across the carriageway
3. Spillage of fuel on the road making it slippery
4. A rain cut extending into the shoulder or
beyond I
5. Bank erosion near a bridge during floods,
etc.
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Suitable plant, equipment and personnel will be
quickly mobilized for an effective response to R
the emergency. Staff will be committed to
attend to the site without delay, whenever an
O
emergency arises. D
Broken down vehicles, accident remnants, U
fallen trees or any other obstructions shall be
cleared immediately. A maximum of 30 minutes
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should be taken in clearing the site after T
noticing / clearance from the police (if
necessary). I
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MAN POWER CHART

The response time for attendance to an
emergency is the time taken from receipt of
notification of the emergency to the arrival of MAINTENANCE
personnel at the site of the incident. - IN - CHARGE
Response times should always be as short as

possible. INSPECTIONS
Manpower
The manpower for the maintenance section for PLANNING

all the activities including inspections, surveys
and maintenance as well as reporting and
documentation will be as follows:
BUDGETING
For Inspections Functions
The manpower for inspections will depend upon WORK

the type of inspections being taken up at a EXECUTION
particular time. The manpower described
hereunder is minimum. One can always have
more than what is shown here or, even more
DOCUMENTATION
qualified members in the inspection teams
depending upon the quantum of work to be
accomplished in the given time, or urgency of
the work. SUPERVISOR-I MAINTENANCE
Visual Inspections
SUPERVISOR-II
• Supervisor – 1, with ability to read simple
English on inspection formats, and tick or
cross on check boxes on the format.
Shall be an experienced technical ELECTRICIAN
person having knowledge about the
structures.
• Assistant – 1, an unskilled worker will be

enough. He will clear the path for
walking by clearing the vegetation. He I
will also clear hazardous situations, if any,
observed during visual inspections.
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T
Detailed Inspections
R
• Engineer – 1, technically qualified person
with ability to record accurately the type
O
of defects, to take measurements, and D
to record the observations at
appropriate places. He will have at least U
some basic idea of all the structures,
ability to read and interpret the
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drawings, and to analyze the cause of T
the defects, and put them in
appropriate categories for taking up the I
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maintenance work at an appropriate

time.
• Supervisor – 1, with ability to read simple

English on inspection formats, and tick or
cross on check boxes on the format.
• Assistants – 2, unskilled workers. They will

clear the path by cutting the vegetation.
They will also clear hazardous situations,
if any, observed during visual inspections.
• Assistants – 2, unskilled workers. They will

manage the traffic during detailed
inspections, when necessary.
Thorough Inspections
Manpower will be specific to the type of

inspection to be done, and will be decided on
case to case basis.
For Maintenance
The maintenance section will have a person

who will be over all in-charge at the project site.
Major functional activities of the maintenance
section can be broadly put into following
categories:
1. Inspections
2. Planning
3. Budgeting
4. Work Execution – Maintenance
5. Documentation
All these functions will be carried out by the

maintenance-in-charge. He in turn will be
suitably assisted by two supervisors for civil works I
and electricians for Heating, Ventilation & Air-
conditioning (HVAC) and electrical works.
N
T
The Maintenance-in-charge will also be guided
by the Project Manager at the project level and R
by the Senior Engineer (Civil) at the head office
at New Delhi.
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D
The manpower for maintenance will depend
upon the type of maintenance being taken up U
at a particular time of the year. This will vary
widely. However, some activities will go on
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regularly such as cleaning, pothole fixing, T
trimming and watering of plants, earthworks,
etc. Other works will be more technical in nature I
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and will be taken up at different times. Some of

this type of works could be overlays, welding,
etc.
The maintenance-in-charge in consultation with

the Project Manager will decide what works
would be taken up using labor on daily wages
and what to be sub-contracted.
However, both the supervisors shall be trained

for both – inspection works and the
maintenance works. However, each will be
assigned one responsibility at least for six months
at a time, and then by rotation the other
supervisor will handle the same work.
The supervisor for maintenance works need not

be a technically qualified person but must be
able to read and write simple English. He will
read the manual for maintenance activities and
will also record the activities done on day to
day basis.
Further, an unskilled worker shall be attached to

the Supervisor so that the work at two places
may be carried out simultaneously.
The contents of this manual will be subject to

continual review and revision and will be
developed through operational experience.
Revisions to the document will be re-issued as
required.
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SCHEDULES
L&T INTERSTATE ROAD CORRIDOR LIMITED.
Typical Inspection Schedule for a Month
NO. Description of Work MARCH ' 07
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
ROAD MAINTENANCE
Pavement
Riding Surface
Pavement
Kerb
Riding Quality Check
Drainage
Shoulder Drain
Shoulders, slopes, earthworks
Shape
Turfing
Pitching
Retaining Wall
ROAD FURNITURE
Guard Rails
Cat's Eye
Signages
Delineators
Road Marking
Boundary Stone
Kilometre Stone
Street Lights
STRUCTURES
Bridges
Superstructure
Substructure
Expansion Joints `
Bearings
Culverts
Box Culverts
Pipe Culverts
Flyover
Superstructure
Substructure
Expansion Joints
Bearings
Underpasses
BUILDINGS
Plaza Building
Booths
DG Room
HORTICULTURE
Plaza Building
ENCROACHMENTS
Visual Inspection Thorough Inspection
Close Inspection Holiday

L&T INTERSTATE ROAD CORRIDOR LIMITED
TYPICAL MAINTENANCE CALENDAR FOR A MONTH
NO. Description of Work AUG SEP OCT NOV DEC JAN FEB MAR
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 1 2 3 4 5 6 7 8 9 10 11 12
ROAD MAINTENANCE
Pavement
1 Clearing ROW
2 Clearance of embankment etc.
3 Cleaning carriageways
4 Sealing cracks
a) Covered with 6-7 mm stone chipping @0.1 cum / 10 sqm
b) Covered with dry coarse sand surface dressing
5 Second coat of surface dressing
6 Repair to rutted portion and edge breaking
7 Sealing to closely spreaded cracks at scattered locations
8 Treatment to bleeding
9 Providing treatment and repair to pot-holes
a) Shallow potholes depth<75 mm.
b) Deep potholes depth>75 mm.
C) With Shelmac PR
10 Dense bituminous macadam
11 Bituminous macadam (profile corrective course)
12 Bituminous concrete
13 Single course semi-dense bituminous concrete
a) Using paying bitumen as per IS : 73
14 Patching of built up spray grout in layers
15 Slurry seal
16 Sealing the cracks using fog seal
17 Tack coat
a) With bituminous emulsion/cut back of specified grade
18 Pre-mix patching with stone chipping mixed with binder
Using straight run bitumen (3.5 to 4 )% compacted thickness
a)
upto 25 mm
b) Patch work using cationic bitumen emulsion rapid setting
19 Scarfying existing road surface
20 Scarifying existing stone metal layers
21 Mixing of distressed road pavement in depth
a) in variable depth up to 50 mm in single pass
b) for depth 50-100 mm in single pass
c) for depth 100-150 mm in single pass
22 Carriageway sweeping
23 Watch and ward on highway
24 Cleaning MBCB and median railings
a) Metal beam crash barrier
b) Anti glare median railing
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 1 2 3 4 5 6 7 8 9 10 11 12
Drainage
1 Cleaning road side unlined drains
2 Cleaningroad side lined drains
Shoulders, slopes, earthworks

1 Blading/grading shoulder & slopes
2 Reconstruction and regravelling of slopes / shoulders
3 Furnishing and laying turf
4 Stone pitching
5 Repair to stone pitching/ apron
a) Using boulders available as site
b) Using procured material
ROAD FURNITURE MANAGEMENT

1 Maintenance of road signs and deliniators
a) Road sign boards mounted on single post
b) Road sign boards mounted on double post
2 Repair to road signs
a) Road sign boards mounted on single post
b) Road sign boards mounted on double post
3 Replacing/installing delineators
4 Replacing/uninstalling delineators and all typesof road sign
5 Reflective stickers on MBCB crash barrier
6 Fixing of distance measurement stone
a) Hectometer Stones
b) Kilometer Stones
c) 5th kilometer Stones
d) Guard stone
7 Boundary stones
8 Painting two coats on old surface
a) Hecktometre Stones
b) Kilometre Stones
c) 5th kilometer Stones
d) Boundary Stones
9 Pavement marking
a) Ready-mixed road marking paint
b) Hot applied Thermoplastic compound
10 Painting kerb with synthetic enamel paint
11 Raised pavement markers (Cat-eyes)
12 Removal of encroachment of ROW
13 Removal of unauthorized approaches
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 1 2 3 4 5 6 7 8 9 10 11 12
STRUCTURES
1 Cleaning the upstream / downstream sides of C.D. Works
a) Bridges
b) Culverts
2 Replacing damaged/ broken railing
3
Cleaning gutters, vent holes, weep holes, drainage spouts, railing
4 Repair stone/ brick masonry
5 Pointing to existing pointing
6 Cement plaster / repair
7
Painting exposed concrete / masonry portion of bridges / CD works
a) Dry distemper of approved brand or lime
b) Water proofing cement paint of approved brand
c) Enamel paint of approved brand
8 Sealing of cracks by injection through nipples
a) Cement Grout
b) Epoxy Resin Grout
9 Providing guniting / shortcrete
a) 25 mm.
b) 40 mm.
c) 50 mm.
10 Repair to foundation
Applying epoxy mortar treatment over leached combed and pilled
11
concrete
12 Periodic maintenance of expansion joints
13 Dismantling / breaking of damaged cement concrete floor
14 Maintenance to all types of bearings
15 Providing and fixing weep holes 75 mm dia in walls
16 Providing and laying required dia. RCC hume pipe
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 1 2 3 4 5 6 7 8 9 10 11 12
BUILDINGS
1 15mm thick cement plaster 1:5
2 Edge gola
3 3 or more coats of oil bound distemper
4 External walls - waterproofing cement paint
5 Epoxy paint on steel work
6 Epoxy paint on concrete work
7 Carpenter
8 Painter
9 Welder
10 Plumber
11 Mason
12 Labourers
13 Materials for carpenter, painter, welder, plumber, mason, etc
Electrical works in the buildings
14 Replacement of luminaries
15 Replacement of switches, junction boxes, etc
16 Replacement of halogen lamps - filament only
17 Replacement halogen lamps - full set
18 Other miscellaneous repairs
HORTICULTURE
1 Maintenance of plants / shrubs
2 Plantation of shrubs/plants
RIVER TRAINING STRUCTURES (GUIDE BUNDS)

1 Stone pitching on slopes of guide bunds / road embankments
Repair stone pitching/apron/slopes of guide bunds, RTS, and
2
embankments
a) Using boulders available as site
b) Using procured material
3 Reconstruction damages to guide bunds
4 Turf forming grass
INCIDENT MANAGEMENT
Removing the dead animals & birdslying on the highway and
1
burying them
Removing vehicles which have met with accident from the
2
carriageway
Chapter 2
SAFETY
CONTENTS PAGE NO.
TRAFFIC MANAGEMENT DEVICES B-1
ROAD SIGNS B-1
GUIDING PRINCIPLES B-3
CONSTRUCTION ZONES B-4
SAFETY DURING MAINTENANCE AND REPAIRS B-6
LANE CLOSURE OF SIX LANE DIVIDED

B-7
CARRIAGEWAY
LANE CLOSURE DURING ACCIDENTS B-8
LANE CLOSURE DURING EMERGENCIES B-9
SAFETY OF WORKMEN AT SITE B-10
LEVELS OF SERVICE B-11

Maintenance Manual – Section 2(A) INDIA PRSG MANT B - 1/12
CHAPTER 2
SAFETY
This chapter covers the safety norms and
practices that need to be followed on the
project stretch during inspections, maintenance
or emergency situations. Whether the work is
short term or long duration, it is necessary to
keep the highway in good and safe working
order at all times. This safety is about that of the
road users, the maintenance workers, as well as
the project assets. It also ensures minimum
disruption to traffic in the event of accidents,
emergencies, or other incidents.
TRAFFIC MANAGEMENT DEVICES
Traffic management devices perform the task of

warning, informing and alerting the driver so
that he can ensure safety of his own, the
maintenance workers, as well as the assets on
the Project Highway.
These devices are cones, delineators, chevrons,

barricades, warning signs, pavement markings,
flashing lights, etc.
ROAD SIGNS
The road signs are essential for any

maintenance or repair works. They are meant
for providing advance information to the road
users to observe any caution, slow down or
otherwise.
Road signs fall into 3 categories:

S
Regulatory / Mandatory or Prohibitive Signs A
These are legal restrictions on the traffic and the
F
driver must read and comply with these
messages. Usually these are signs on a red
E
background with white messages and arrows or
white background with red border and black T
messages / arrows.
Y
The signs in this category are “Road Closed”,

“Speed Limit”, “Stop”, etc.
Warning / Cautionary Signs
The most common type of warning signs to alert

60
the drivers of the possible dangers ahead in
construction zones such as “Lane Closed”, “Two
Way Traffic”, etc.
Guide Signs
Guide signs in construction zones shall have

yellow background colour with black colour
messages and arrows on them. The common
guide signs are “Diversion”, “Road Ahead
Closed”, etc.
SPEED LIMIT SPEED LIMIT
60 80
13.5.1, IRC 67-2001
Diameter 600; Border 65 mm
RESTRICTION ENDS MEN AT WORK
500 m
13.6.1, IRC 67-2001
Diameter 600; Border 65, Band 130 mm 14.18, IRC 67-2001
Side 900; Border 70 mm
S
CLOSED CARRIAGEWAY DIRECTION TRAFFIC A
F
E
T
NOT IN IRC
INTERNATIONAL PRACTICE
NOT IN IRC
INTERNATIONAL PRACTICE
Y
Side 900; Border 70 mm Diameter 600; Border 65 mm
GUIDING PRINCIPLES
The guiding principles for safety measures are:
• Warning to the drivers must be given

unambiguously and sufficiently in
advance of the situation on the Highway
• Providing clear demarcation /

delineation for channelizing the traffic to
guide the drives along a safe path and
ensure smooth flow of traffic
• Providing devices to guide the drivers

through the construction zones, lane
closures, traffic diversions, etc.
• Providing protection to the maintenance

workers at the site
S
A
F
E
T
Y
CONSTRUCTION ZONES
To make the safety an integral part of the work
ADVANCED WARNING
by providing advance warning to the drivers for
safety, the maintenance/ repair areas are
divided into 4 categories:
sub-zone
1. Advance Warning Sub-Zone
300 m
Advance Warning Sub-Zone is meant to
prepare the driver for an alert behaviour
well in advance. A series of signboards
will indicate the distance, extent and the
type of hazard ahead so that he can
gradually reduce the speed.
TRANSITION
2. Transition Sub-Zone
sub-zone
100 m
This is the area where the traffic is
diverted into the diverted path. This is the
most crucial from the point of view of
safety. In this sub – zone safety cones are
provided.
VARIABLE WORK
Buffer
3. Work Sub-Zone
sub-zone
This is where maintenance activity is
taking place and safety of workers is the Work Area
main concern. Safety cones are
provided to ensure workers’ safety.
TERMINATION
4. Termination Sub-Zone
sub-zone
An information signboard is erected to
25 m
inform road users about the end of the
maintenance sub-zone, and they can
return to normal speed.
In special circumstances, traffic detours may

have to be provided by way of traffic diversion
roads. S
TYPICAL TRAFFIC
Temporary Diversion
CONTROL AREAS A
In the cases of major repairs or reconstruction of
Minimum Distance between
two Work Sub-Zones
F
cross drainage structures on a highway section,
damaged due to flood etc., the traffic may For Rural Areas: 5 km E
have to pass on a diversion, moving parallel to
the highway. Considering the intensively used
For Urban Areas: 2 km
T
urban section not more than two diversions shall
be there at anytime and there shall be
adequate distance between diversions so that
Y
there is no traffic hold up.
A temporary diversion road shall satisfy the

following requirements:
a. It shall have smooth horizontal and

vertical profile with smooth vertical and
horizontal curves;
b. It shall not get overtopped by flood or

drainage discharge under any
conditions;
c. It shall have adequate capacity to cater

for the diverted traffic;
d. It shall be dust free and shall ensure clear

visibility at all times of day and night;
e. It shall be provided with the required

safety standards ;
f. It shall be provided with suitable

barricades to prevent intrusion affecting
the movement of the traffic.
At the points where the traffic is to deviate from

its normal path, the channel for traffic shall be
clearly marked with the aid of pavement
markings or other similar device as directed by
the IC. At night the passage shall be delineated
with lamps or lanterns or any suitable light
source.
S
A
F
E
T
Y
100m
Safety during Maintenance and Repairs
The Project Highway, assets and facilities require

regular maintenance and upkeep at different
stages. In order to carry out these activities
without compromising safety of the road users,
the maintenance staff and workers, as well as
the assets it becomes necessary to close the
lanes, or part of the lane, or sometimes even the
entire carriageway.
Closure will be done only after appropriate

planning and implementation of correct
procedures. Measures for repair of a breach will
be taken within appropriate time depending
upon the magnitude of the repair work.
100m
On the approach of any type of closure, signs as GO
SLOW
described above will be installed for guidance
of road users. The signs shall be put up at
distances as detailed.
Any diversion or interruption of traffic will be 60
100m
remedied at the earliest. Temporary cones and
lights at night shall be used in unsafe conditions.
Removal of obstruction and debris shall be done
expeditiously.
100m
The warning for the maintenance ahead shall
be provided by the sign “Men at Work” about
500m before the maintenance work zone. In 80
addition, signs indicating Speed Restriction and
100m
“Lane Closed Ahead” shall be placed at 400m

and 300m respectively. It shall be followed by a
“Go Slow” at 100m and “Compulsory Turn
Right/Left Sign” at the beginning of the
Maintenance Zone. Hazard markers shall be 500 m
placed just where the railings for the cross
drainage structures on the diversion starts. A sign
showing the end of diversion shall be placed S
100m after the Maintenance Zone.
A
F
E
T
Y
Lane Closure of Six Lane Divided Carriageway
When the work is of small magnitude, to be

done in the middle of the carriageway, such as
minor repairs of potholes, cracks and patches,
then the traffic control measures shall mainly
consist of providing cautionary signs of “Men at 120m
Work”, about 500m before the work zone for the
approaching vehicle and other cautionary sign
of “Lane Closure”, shall be placed at 100m
ahead of work area. Regulatory sign of “Keep
Left/Right” shall be placed at the
commencement point of the work zone and
next to the barriers for the approaching
vehicles. Movable type of barriers shall also be
placed on both sides of the work area. Cones or
drums shall be placed at suitable interval to
demarcate the work area. The “Work Zone
Ends” sign shall be installed 120m beyond the 100m 60
work area. If the operation is to continue during
night time, necessary lighting arrangements with
flashing lights shall be provided.
GO
SLOW
200m
500 m
S
A
F
E
T
Y
Lane Closure during Accidents
Accidents are bound to happen in spite of all 500 m

the precautions. Our effort shall be to minimize
the accidents.
After any untoward incident, efforts shall be

made to restore the traffic at the earliest.
60
In case of accidents it may be necessary to
close one lane or the entire carriageway.
At points where the traffic has to deviate from its

normal path, the channel for traffic shall be GO
marked with the aid of pavement markings or SLOW
other similar device as directed by the

Independent Consultant. At night, the passage
shall be delineated with lamps, lanterns or any
suitable light source.
On the approach of any type of closure, signs as

described in this manual will be installed for
guidance of road users. The signs shall be put up
at distances as shown.
Any diversion or interruption of traffic will be

Removal of obstruction and debris shall be done
expeditiously.
GO
SLOW
60
S
100m
A
100m
F
80
E
T
100m
Y
500 m
Lane Closure during Emergencies
Emergency may arise when flood or heavy

rainfall washes out an entire section of the
embankment. In such a situation the entire
stretch may be required to be closed. Or, when
a culvert requires major repair or rehabilitation, it
may be necessary to close the entire highway.
In such situations, the traffic has to be diverted

onto a temporarily built road until it is restored
back on the highway.
Major breaches in the roadway of any type

endanger safety of traffic and cause
obstruction movement of vehicles. Whenever
any breaches in the roadway endangers the
safety of traffic and causes obstruction in the
movement of vehicles, these shall be repaired
urgently. The restoration of traffic shall be made
within 24 hours of its occurrence. The permanent
measures shall be completed within a period of
one week.
At points where traffic is to deviate from its

normal path, the channel for traffic shall be
marked with the aid of pavement markings or
other similar device. At night, the passage shall
be delineated with lamps, lanterns, or any
suitable light source.
On the approach of any type of closure, signs as

described in this manual will be installed for
guidance of road users. The signs shall be put up
at distances as shown
Any diversion or interruption of traffic will be

Removal of obstruction and debris shall be done S
expeditiously.
In Emergency arising on account of Force

A
Majeure due to nature or administrative reasons,
special safety measures may be called for the
F
traffic and / or the workmen at site.
E
T
Y
Safety of Workmen at Site
Safety of the project section workers at site

during duty hours is the responsibility of the
Concessionaire. It shall be ensured that safety
measures appropriate for the job a workman
performs shall be provided.
Safety measures against accidents of the worker

by the traffic using the highway and / or
diversions shall be taken. The worker shall be
provided with safety helmets and protective
chest vests to its workmen at site and made
compulsory for them to wear the same.
The Concessionaire shall insure all the project

section workers against accident.
In case of Emergency Situations, the

Concessionaire shall take action(s) for the safety
of the road users and the workers as required by
the site conditions immediately without waiting
for consultation with the IC and / or NHAI
because any delay will not absolve the
Concessionaire of its responsibilities under the
CA including its schedules.
S
A
F
E
T
Y
Levels of Service
1. Section XVIII Clause 18.8.1

Page 57
Safety, Vehicle Breakdown and
Accident
“In the case of unsafe conditions, vehicle breakdowns and

accidents, the Concessionaire shall follow the relevant
operating procedures, which shall include the setting up
of temporary traffic cones and lights as well as the
removal of obstruction and debris expeditiously. Such
procedures shall be in accordance with Applicable Laws,
Applicable Permits and provisions of this Agreement.”
2. Section XVIII Clause 18.8.3

Page 58
Safety, Vehicle Breakdown and
Accident
“The Concessionaire shall ensure that safety standards

specified in Schedule 'S' are strictly complied with in the
event of any lane closure or diversion of traffic.
Compliance with Schedule 'S' will be monitored by the
Independent Consultant and a breach by the
Concessionaire of its obligations in respect of this
Schedule identified by the Independent Consultant shall be
notified immediately and is required to be cured within 24
hours of its notification notwithstanding inspection,
reporting procedures outlined elsewhere in this
Agreement. In addition, each notified breach shall lead to
the award of a penalty point to the Concessionaire. A
total of five penalty points in any continuous period of
365 days shall constitute a Material Breach of this
Agreement.”
3. Section XVIII Clause 18.10

Page 58
Emergency De-commissioning
S
“The Concessionaire shall not close any lane of the A
F
Project Highway for undertaking maintenance or repair
works except with the prior written approval of the NHAI
which may delegate its authority to the Independent
Consultant. Such approval shall be sought by the
Concessionaire through a written request to be made at E
T
least 7 (seven) days before the proposed closure of lane
and shall be accompanied by particulars indicating the
nature 'and extent of repair works, the length and section
required to be closed and the period of closure. The
Concessionaire shall also furnish particulars indicating
Y
the minimum time required for completing such repair
works.”

Page 59
Emergency De-commissioning
“Within 5 (five) days of receiving such request, NHAI or

the Independent Consultant, as the case may be, shall
grant permission with such modifications as it may deem
necessary. Upon receiving such permission, the
Concessionaire shall be entitled to close the lane in
accordance with such permission and re-open it within the
period stipulated in such permission. For any delay in re-
opening such lane during the first Operations Year, the
Concessionaire shall pay Damages to NHAI calculated
at the rate of Rs.10,000 (Rs. Ten thousand), per day or
part thereof for every stretch of 100 (one hundred)
meters or part thereof in each lane until such time the
stretch has been re-opened for traffic. These damages of
Rs.10,000 (Rupees ten thousand) shall be applicable in
the first Operations year and shall be revised by WPI in
each subsequent Operations year. Provided, however,
that these provisions shall not apply to Emergency
decommissioning under Clause 18.9.”
S
A
F
E
T
Y
Chapter 3
CLEANING
CONTENTS PAGE NO.
INTRODUCTION C-1
CLEANING REQUIREMENT C-1
PAVEMENTS AND MEDIANS C-2
TOLL PLAZAS, BUS SHELTER AND TRUCK LAYBYE C-2
GUARD RAIL AND ROAD FURNITURE C-2
RIGHT OF WAY C-2
CULVERT DRAIN AND CHANNELS C-2

Maintenance Manual – Section 2(A) INDIA PRSG MANT C - 1/3
CHAPTER 3
CLEANING
INTRODUCTION
This section formalizes the procedure for

cleaning activities of the RoW, highway, road
furniture and other elements. It sets out the
cleaning operations, and their frequencies,
which are to be undertaken as routine
maintenance.
Cleaning Requirement
Cleaning requirement which are identified as a

result of inspections, route patrol, other reports
and complaints or are scheduled, will fall into
three categories:
Immediate / Urgent Cleaning
Those which require urgent attention because

they represent an immediate or imminent
hazard or because there is a risk of short term
structural deterioration e.g.: debris of the
accidents, dump / municipal waste on shoulder
/ carriageway, anything blocking the drains
(during the monsoon), pieces of tyre, stone,
droppings from the vehicle on the pavement,
dead animals on carriageway, etc. These will be
cleaned or at least pushed aside (cleaning the
carriageway) at the time of inspection if
reasonably practicable. If it is not possible to
clean such debris at the time of inspection, the
cleaning shall be done as soon as possible and
in any case within a period of 24 hrs.
Programmed Cleaning
Programmed Cleaning will be carried out in

C
accordance with the maintenance calendar. If
there is any cleaning required which cannot be
L
carried out with routine procedure and requires
specific equipment or agencies, they will be
E
organized and programmed to be carried out
within 3 months. The example of such activities
A
are cleaning of kerb drains, medians, open
channels, parking areas, road reserve,
N
guardrails, road signs, road furniture and so on.
I
N
G
Pavements and Medians
Litter and debris shall be cleaned on an

ongoing basis from the pavement and medians
including the service roads.
The frequencies shall be as follows:
Built up sections Once a week

Rural Sections Once a month
Toll Plazas, Bus Shelter and Truck Lay bye
Litter and debris shall be cleaned in and around

the Toll Plaza at least once every day, or more
frequently if required. The booths will be
thoroughly cleaned with dry cloth and broom
everyday. At least once a week wet cleaning
will be carried out. It will be necessary to make
sure the guardrail, lighting columns, traffic
islands, etc are thoroughly cleaned every day.
The pavement surface shall be swept every day
and any oil droppings shall be cleaned using
sawdust, lime, and soapy water as required at
least once a week.
Guard Rail and Road Furniture
All guard rails, delineators, bollards, culvert

parapets will be cleaned once a month with dry
cloth/coir brush. Wet cleaning using soapy
water will be done once in three months.
Right of Way
All the foreign articles including litter, branches,

stones larger than 75mm, rubble, tyres, striped
tyres, posters, illegal signs, and graffiti on
concrete structures will be cleaned from RoW.
This cleaning will be done twice a year.
C
L
Culvert Drain and Channels
E
All culverts, drains and channels shall be
cleaned. Necessary modern equipments (like A
drain sweeping equipment, etc.) shall be used
for cleaning of the drains. The inlet and outlet N
areas shall be thoroughly cleaned off all silt and
debris such that all structure surfaces are clearly I
visible and accessible. Silt and debris excavated
from the inlet & outlet areas shall be deposited N
G
and spread neatly in the close proximity of the

culvert where it can’t wash back. If necessary, it
will be loaded and transported to spoil and at
dumping areas. Such material shall not be
deposited against cut and fill slopes. For
drainage of underpasses, areas identified prone
to flooding shall be attended on occurrence
with Mobile Water Pumping System
arrangement. This cleaning shall be done once
every 3 months, before monsoon, or after dust
storms.
C
L
E
A
N
I
N
G
Chapter 4
PAVEMENT
CONTENTS PAGE NO.
INSPECTION D-1
VISUAL INSPECTION D-1
DETAILED INSPECTION D-1
SUMMARY OF PAVEMENT DISTRESS AND

D-4
MAINTENANCE MEASURES
FATTY SURFACE / BLEEDING D-5
STREAKING D-7
HUNGRY SURFACE D-8
CRACKS D-9
ALLIGATOR CRACKS D-10
LONGITUDINAL CRACKS D-11
EDGE CRACKS D-12
SHRINKAGE CRACKS D-13
REFLECTION CRACKS D-14
SLIPPAGE D-15
RUTTING D-16
DEPRESSIONS D-17
SETTLEMENTS D-18
STRIPPING D-19
POTHOLES D-20
EDGE BREAKING D-25
KERBS D-26
OTHER DEFECTS D-27
MAINTENANCE ACTIVITIES D-27
SURFACE DRESSING D-28
CONCEPT OF SURFACE DRESSING D-30
FOG SPRAY D-31
SLURRY SEAL D-33
CRACK FILLING D-35
PATCHING D-38
MAINTENANCE OF CEMENT CONCRETE

D-40
PAVEMENT
LEVELS OF SERVICE D-43

Maintenance Manual – Section 2(A) INDIA PRSG MANT D - 1/53
CHAPTER 4
PAVEMENT
INSPECTION
The pavement inspections will cover the riding

surface, paved shoulders, paved lay-byes, kerbs,
junctions, lanes in the plaza area, etc.
Visual Inspection
Visual inspection of the pavement should record all

locations of cracks, settlements, potholes, bleeding,
rutting, edge damage, local aggregate loss, or any
other irregularities. However the exact location of
the defect needs to be noted. The stretch may be
divided into sections of 25 m and defects in this
portion shall be highlighted
The defects reported from visual inspections will

indicate the locations where detailed inspections
need to be done more carefully.
The requirements of visual inspections do not relate

to large scale works needed to strengthen the
carriageway or to work, which would be classed as,
or linked to, structural maintenance like
rehabilitation, overlay and strengthening. It is usual,
before carrying out surface dressing or resurfacing,
to ensure that the underlying road structure is
sound. This requires repairs to potholes, cracks,
bleeding, etc. The condition of kerbs will also be
recorded while carrying this inspection.
Detailed Inspection
Detailed inspections are intended to note those

types of defects which will require routine
maintenance, and not to establish general
structural condition of the pavement. Such P
inspections therefore do not often indicate need for
resurfacing, structural maintenance, rehabilitation, A
etc. They may indicate recurring problems.
V
Detailed inspection may also point to the need of
bringing forward a thorough inspection or a E
structural survey.
M
Together with the pavement surface, the condition
of kerbs also needs to be recorded. E
Maintenance Manual – Section 2(A) Gujarat & Rajasthan N
T
Detailed inspections should record exact locations

of defects such as cracks, settlements, potholes,
bleeding, rutting, edge damage, local aggregate
loss, or any other irregularities. Sometimes when the
defects are more complicated and difficult to
describe, they may also require to be plotted. The
measurements (such as crack width, settlements,
rut depths, etc) shall be recorded on the inspection
formats. The severity and extent of the problem will
also be recorded during such inspections.
Whenever any defects which are noticed but are

not visible easily (such as minor pavement
depressions, very thin cracks, etc) those areas shall
be marked on the field with a chalk, or white paint
(White Snowcem also works very well) such that
these remain easily identifiable when the
maintenance team comes to work.
Pavement defects can be classified into the

following groups, described below:
Surface Defects are on the surface of the

pavement such as fatty surface (bleeding),
streaking and hungry surface.
Cracks can be just on the surface or may be

deeper such as hair line cracks, alligator cracks,
longitudinal cracks, edge cracks, shrinkage cracks
and reflection cracks.
Deformation may also be in the top layer or in the

layers further down such as slippage, rutting,
corrugations, shoving, shallow depressions and
settlements.
Disintegration may be on the surface or in the

under layers also such as stripping, loss of
aggregate, ravelling, pot holes and edge breaking.
The guiding principle for writing this manual has

been that the expense on pavement maintenance
will reduce to a large extent by regular and
planned inspections, correct analysis, selection of P
appropriate method of repair, and timely
maintenance. A
The importance of ensuring quality even on small
maintenance jobs can never be over emphasized.
V
Proper quality procedures shall be followed in all
the maintenance works. Some small laboratory
E
equipment shall also be maintained even on small
jobs, especially for works which are more prone to
M
poor workmanship and which need regular testing
in the field laboratory. Expensive laboratory
E
T
equipments have been avoided and in case such

need arises, the services of established institutions
shall be taken.
Mechanization has been another area which has

been resorted to a large extent as practicable on
small works like this one. Mechanisation and
automation bring in quality and speed directly and
therefore economy indirectly on a maintenance
job.
The three most important rules of good highway

management are drainage, drainage and
drainage. Special emphasis has been laid on
drainage, and therefore whole chapter has been
dedicated for the same.
Possible pavements distress and possible

maintenance measure are described hereinafter in
summary form. Detailed procedures are described
thereafter
P
A
V
E
M
E
T
SUMMARY of Pavement Distress and Maintenance

Measures
Fatty surface (bleeding) Removal of bitumen, sand

blinding, hot dry
aggregates and rolling
Streaking Surface dressing, Removal

of streaked surface and
resurfacing
Hungry surface Fog spray, slurry seal
Alligator cracks If not wide spread, filling

emulsions
If wide spread,
reconstruction
Longitudinal cracks Fog spray if cracks are fine

and over large area,
Filling emulsion, light
sanding
Edge cracks Fog spray if crack is fine,

sanding
Shrinkage cracks Fog spray if cracks are fine,

sanding
Reflection cracks Removing surfacing layer

and resurfacing
Slippages Removing surfacing layer

and resurfacing with proper
tack or prime coat
Rutting Filling dense graded

patching materials, Re-
construction, Profile
correction course
Depression Filling dense graded

patching materials, Profile
correction
Settlements Reconstruction from the

level of affected layer,
Construction of under-
drains
Stripping Slurry seal, Surface dressing,

Replacement of affected
P
area
A
Pot holes – small
Pot holes – large

Shellmac filling
Filling, patching, partial

V
reconstruction
E
M
Edge breaking Brick paving, Re-
construction of edge
E
T
FATTY SURFACE OR BLEEDING
Description
A film, often soft in summer, and slippery in winter,

can be seen on the surface of a bituminous
pavement. It is also known as bleeding. Fatty
surface results due to the binder moving upwards
on the surface and forming a film on the surface.
When soft it may be picked up and spread by the
traffic. When slippery, it can cause accidents.
Bleeding can be isolated or extensive over a long
length of the road.
Cause
1. Over application of binder in surfacing due

to faulty design or construction
2. Loss of cover aggregates in surface dressing
3. Non-uniform spreading of cover aggregates

in surface dressing
4. Excessive application of binder in surface

dressing
5. Poor quality of aggregates leading to

fracture, breakdown and eventual loss
6. Cover aggregates with particles so small

that they are covered by the binder
7. Excessively heavy axle loads causing

compaction of surfacing, forcing the
bitumen to move to the top
Treatment P
Where bleeding is fairly uniform, not excessive and A
free binder is available on the surface, sand binding
shall be done. V
For small, localized areas (work in hot weather E
during middle of the day):
M
¾ Take sand in wheel barrows
¾ Scatter over affected area E
¾ Spread out with broom evenly
T
For large areas (work in hot weather during middle

of the day):
Response Time
¾ Take sand in a truck
¾ Scatter over affected area while driving Where bleeding occurs over
along the affected area significant length warning signs
¾ Spread out with broom evenly should be erected indicating slippery
conditions.
Maintenance of localized problems in

Where bleeding is excessive, it shall be removed potentially dangerous situations such
mechanically and sand / aggregate of 6 – 10 mm as at an intersection or at a sharp
size would be applied. The size of the stone would curve shall be taken up on an urgent
depend on the thickness of the free binder. basis.
Work shall be done in the middle of the day Other situations will be built into the
preferably during periods of hot weather. routine maintenance.
¾ Cut the excessive binder by pick-axe, chisel Note:

or a shovel, depending upon the extent
Preheating of the aggregate to
¾ Give a light application of pre-coated chips 1500C either in local asphalt plant or
¾ Roll well with a pneumatic roller and broom for small quantities in a half drum
off loose chips assists adhesion.
Crusher dust should not be used on

bleeding areas. It forms a slick
bitumen rich unstable skin on the
surface.
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STREAKING
Description
Appearance of alternate lean and heavy lines of

bitumen generally in longitudinal direction can be
seen. Sometimes streaking may be in transverse
direction also. Transverse streaking can lead to
corrugations on the pavement surface.
Cause
1. Non uniform application of bitumen
2. Mechanical faults
3. Poor adjustments and careless operation of

bitumen distributors
4. Applying bituminous binder at too low a

temperature and the bitumen is not fluid
enough to fan out properly from nozzles
Treatment
Treatment of streaking is not easy. An application of

surface dressing shall be an ideal solution for this
defect Response Time
However, if the defect reoccurs quickly, a thin layer Streaking in the initial stages is not
of overlay shall be done. harmful.
If longitudinal and transverse streaking appears on But, if neglected, the pavement

the pavement surface in area exceeding 5sqm, the surface can become more
same shall be treated by application of new permeable and potholes or
surface treatment or by a second treatment over deformation may occur.
the streak surface.
Generally this defect will be built into
a program of routine maintenance.
P
However, if it has become severe A
due to lack of maintenance or
neglect, it shall be attended to V
urgently.
E
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HUNGRY SURFACE
Description
The pavement surface can be seen due to

absence of sufficient binder and fines between the
aggregate particles, and sometimes due to loss of
aggregate. A hungry surface is also indicated very
fine cracks appearing on the pavement surface. A
hungry surface means that the surface is hungry for
bituminous binder.
Cause
1. Use of less bitumen in the surfacing
2. Use of absorptive aggregates in the

surfacing
3. Disintegration of bitumen due to UV rays

leading to loss of bitumen
Treatment
Normally a slurry seal should be resorted to for

treatment to a hungry surface.
Response Time
If however the situation is critical, fog spray shall be
applied as a temporary measure, and then the
A hungry surface does not create any
slurry seal shall be done as a part of routine
critical situation in the initial stages. It
maintenance.
will be built into a program of routine
maintenance.
When the defect has become severe and potholes
have formed, first the potholes shall be treated, and A hungry surface is prone to further
then surface dressing shall be done. deterioration. The aggregates can be
picked up by traffic which can lead to
If raveling of bituminous pavement exceeds 1sqm in formation of potholes. The treatment
area, slurry seal treatment shall be applied. shall start when the aggregates are P
found to be 20 % to 50 % exposed.
A
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CRACKS
Cracks are a very common defect in bituminous

surfaces.
Crack patterns in many cases indicate the cause of

the defect.
As soon as cracks are observed, the pattern must

be studied to arrive at the cause. Remedial action
should be taken as soon as possible because there
is a danger of ingress of water through the cracks
percolating to the under layers and further
damaging the pavement.
Cracks can hardly be observed from a moving

vehicle have inspection by foot is always desirable.
Very fine cracks can be easily observed when the

pavement surface is a little wet, immediately after
the rain.
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ALLIGATOR CRACKS
Description
Alligator cracks (also called crocodile cracks)

appear as interconnected cracks forming a series
of small blocks which resemble the skin of an
alligator.
Alligator cracking is an indication of serious

pavement failure to a point where reconstruction is
the only solution. It is an indication of the failure of
layers below and is usually due to inadequate
drainage.
Cause
1. Excessive deflection of the surface due to

weak under layers, particularly in the wheel
tracks
2. Unstable condition of the under layers due

to saturation
3. Excessive overload by heavy vehicles or

inadequate pavement thickness
4. Brittleness of binder either due to ageing or

initial overheating, when there is no
deflection of the surface
Response Time
Alligator cracking shall be treated first

temporarily which will be built into a
Treatment
program of routine maintenance, to
avoid further damage to the
Temporary treatment for alligator cracking if there pavement.
are no depressions shall be fog seal.
Further, this will undergo thorough
If there is depression with alligator cracking, first fog
seal will be done and then filling with dense graded
inspection. Based on the findings of
thorough inspection, re-construction
P
patching material. from the appropriate level of under
layer shall be taken up. A
Meanwhile thorough inspections will determine the
exact nature and level of emergency. The V
treatment will then be decided accordingly.
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LONGITUDINAL CRACKS
Description
These cracks appear more or less in a straight line,

longitudinally along the road. These may appear
either at the joint between the pavement and the
shoulder, or at the joint between two paving lanes.
These are generally on high fills or widened sections.
Failure to react quickly to longitudinal cracks can

lead to hazardous situations. For safety purpose it
may be necessary to close the shoulder, the lane or
whole carriageway.
If left unattended the crack can allow water to

ingress to the underlying layers and may damage
the pavement structure severely.
Cause
1. The cracking at the shoulder – pavement

joint may be due to alternate wetting and
drying beneath the shoulder surface
because of poor drainage or depressions in
the shoulder, allowing water ponding and
ingress downwards
2. Lane joint crack is caused by a weak joint

between adjoining spreads
3. When there is a noticeable vertical step

across the crack, the cause of crack is slope
failure in the embankment fill
4. Slope failure due to poor materials in the fill Response Time

sub-grade, steep side slope, or due to poor
compaction Longitudinal cracks shall be
5. Differential compaction between old and

handled as part of routine
maintenance.
P
new fill
If there is a severe problem in A
Treatment
some stretch, fog spray shall be
applied as a temporary measure. V
Subsequently, proper treatment
As a temporary measure fog spray shall be done if
shall be taken up as part of routine
maintenance.
E
cracks are fine and extend over large areas.
M
The crack shall be filled as part of routine
maintenance. E
T
EDGE CRACKS
Description
Edge cracks are formed parallel to the outer edge

of the pavement. Sometimes some transverse
cracks are seen to branch out towards the shoulder
from the edge cracks. Usually the cracks will be a
combination of arc shapes and there is a step
down towards the shoulder.
Cause
1. Slip failure in the embankment slope
2. Lack of support from the shoulder
3. Inadequate surface drainage
4. Inadequate pavement width, especially on

curves, forcing traffic too close to the edge
of the pavement, on to the shoulder
Treatment
As a temporary measure an application of fog

spray shall be done if cracks are fine and extend
over large areas. Response Time
The cracks shall be filled as part of routine The edge cracks can be
maintenance. dangerous, and if left unattended,
can lead to further severe damage
to the pavement.
In edge cracking, if the shoulders are not providing
adequate lateral support, the shoulder shall be An edge crack shall be cordoned
reconstructed with good quality material. off to keep the traffic away and to
avoid further deterioration to the
pavement.
The remedying of the edge cracks

P
shall be taken up on an urgent
basis. A
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SHRINKAGE CRACKS
Description
Shrinkage cracks appear in the transverse direction,

or as interconnected cracks forming a series of
large irregular blocks. The pavement itself does not
appear to have suffered any deterioration or
deformation, but the top surface looks old and
cracked.
Cause
1. Shrinkage of the bituminous layer with age
2. The bituminous binder becoming brittle due

to ageing
Treatment
The cracks shall be filled as part of routine

maintenance.
Response Time
Shrinkage cracks will be handled

as part of routine maintenance.
If there is a severe problem in

some stretch, fog spray shall be
done as a temporary measure.
Subsequently, proper treatment
shall be taken up as part of routine
maintenance.
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REFLECTION CRACKS
Description
The pattern of cracks can be longitudinal,

transverse, diagonal or blocks. These will occur
mostly in overlays if the cracks in the old pavement
have not been properly repaired prior to the
overlay. These cracks deteriorate quickly and the
riding quality of road is adversely affected. These
occur most frequently in overlay on cement
concrete pavements
Cause
1. Overlay without prior repair of cracks or

other defects in the pavement layer
underneath
Treatment
As a temporary measure fog spray shall be done if

cracks are fine and extend over large areas.
The cracks shall be filled as part of routine

maintenance.
Response Time
Reflection Cracks will be handled

as part of routine maintenance.
If the problem is severe, fog spray

shall be applied as a temporary
measure. P
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SLIPPAGE
Description
When crescent shaped crack – single or in groups –

are seen on the surface of the pavement, these are
slippages between the surface layer and the layer
beneath. These will point in the direction of the
thrust of the wheels on the pavement surface,
which may not be necessarily be in the direction of
movement of traffic. Usually they will point in the
direction opposite to that of the traffic.
Cause
1. Unusual thrust of wheels in a particular

direction
2. Omission or poor application of tack coat or

prime coat
3. Lack of bond between the surface and the

lower layers caused by presence of fine
dust, moisture, or both at the time of overlay
4. Failure of bond between two layers due to Response Time

excessive deflection of the pavement
Slippages shall be handled as part of
routine maintenance.
Treatment
Under a program of routine maintenance, the

slippages have to be rectified by removing the
surface layer around the area up to the point
where good bond between the new surface and
the layer underneath exists. After removing the
surface layer, apply tack coat and patch the
surface.
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RUTTING
Description
When the pavement surface shows longitudinal

depression or groove in the wheel tracks, these are
called the ruts.
Accumulation of water in the depressions can

cause skidding. Swerving from a rutted wheel path
at high speed can be dangerous. If rutting is
accompanied by adjacent bulging, it may be a
sign of sub-grade movement or a weak pavement.
Cause
1. Heavy channelised traffic
2. Inadequate compaction of mix at the

surface or in the under layers during
construction
3. Improper mix design
4. Weak pavement
5. Intrusion of sub-grade clay into the base

course
6. Aggregate of surface dressing being

pressed into the lower bituminous layer
Response Time
Treatment Rutting shall be handled as part of

Ruts shall be filled with dense graded patching
If there is a severe problem in some
material and compacting to the desired levels,
stretch, the area shall be cordoned
after applying tack coat.
Treatment of rutting consists of reconstruction of the

off and the repair shall be
undertaken on an urgent basis. P
affected areas. The reconstruction will be done with
specifications to match the existing layers. This shall
If the depth of the rut exceeds 10mm
with a length of 10m at a place in the A
wheel track of pavement surface, the
be determined after thorough inspection has been
carried out and the results have been analyzed to
same shall be repaired by full depth
patching.
V
find the cause of the problem and the method of
remedying has been decided.
E
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DEPRESSIONS
Description
Localized depressions can sometimes be seen on

pavement surface. These are shallow, up to 25 mm
in depth, where water will normally collect. These
can occur with or without cracking.
Cause
1. Pocket of inadequately compacted sub –

grade
2. Pocket of inadequately compacted under

layers
3. Excessive moisture content in sub – grade or

under layers
Response Time
4. Inadequate pavement thickness
Depressions shall be handled as part of
Treatment
If corrugations and shoving in the
Under a program routine maintenance, the pavement area exceeds 1sqm at a place
depressions shall be filled with dense graded and depth / height of corrugation / shoving
patching materials. If a problem recurs, thorough exceed 10 mm, the same shall be treated
by full depth patching.
inspection will be carried out and appropriate
remedial action will be taken up.
If upheaval or swell exceeds 0.5sqm in
area and its height is more than 10mm
such defects shall be treated.
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SETTLEMENTS
Description
Settlements are depressions on pavement surface

but deeper than 25 mm.
Here the possibility of water collecting and

deteriorating the pavement under layer is large,
especially when cracks are also there. These can
be hazardous to traffic.
Cause
1. Pocket of inadequately compacted sub-

grade
2. Pocket of inadequately compacted under

layers
Response Time
3. Excessive moisture content in sub-grade or
The settlements shall be taken up as part of
under layers
4. Inadequate pavement thickness If the settlement and grade depressions
exceed 1sqm in area and their depth is within
10mm, such defects shall be treated by skin /
full depth patching.
Treatment
The treatment consists of reconstruction of the

affected area. Sometimes the thorough inspections
will also indicate the need for construction of under
drains. Remedial works shall be taken up in
accordance with recommendations made after
thorough investigations.
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STRIPPING
Description
When there is a loss of material in larger areas from

the pavement surface, it is called stripping. This
indicates separation of bitumen adhering to the
surfaces of the aggregate particles, in the presence
of moisture, leading to loss of bond, and
subsequently to loss of strength.
Cause
1. Use of hydrophobic aggregates
2. Inadequate mix composition
3. Continuous contact of water with the

coated aggregate
4. Initial over-heating of the binder or the

aggregate or both
5. Presence of dust or moisture on aggregate
6. Occurrence of rain or dust storm

immediately after the construction
7. Opening road to fast traffic before the

binder has set
Treatment
If the problem is in the initial stages, that is when the Response Time
aggregates can still be seen on the pavement but
the binder has started stripping off, slurry seal shall Stripping shall be taken up as part of
be applied. When it has developed into a more routine maintenance.
severe state, surface dressing, or replacement of
the affected area shall be carried out. However, it should be taken up
P
during the initial stages of the defect.
A
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POTHOLES
Description
Potholes are bowl shaped, sometimes irregular

shaped holes of varying sizes in the pavement
surface, or extending in to the under layers when
not attended to timely. These usually appear after
the rains. The extent and severity can also be
varying.
Cause
1. Ingress of water into the pavement through

the surfacing course
2. Lack of proper camber
3. Not attending to cracks quickly
4. Lack of bond between bituminous surfacing

and the underlying WBM layer
Response Time
5. Insufficient bitumen content in localized
areas of the surface Potholes shall be repaired as soon
as they occur. If a pothole is left
6. Too thin bituminous surface untreated under heavy traffic for any
length of time, further widening and
deepening of the pothole is likely to
7. Too much or too less fines in the mix
occur. Potholes shall be treated
before the next wet season to avoid
damage to the pavement under
SMALL POTHOLES layers.
Pot Holes up to a diameter of 150 mm will be If the potholes cannot be repaired

treated as small pot holes. due to any reason, like monsoon or
wet season, they will be fixed
Treatment temporarily by filling and compacting
a suitable material like brick ballast,
¾ Mark the potholes to be filled with white /
yellow paint
stone ballast, emulsion, etc within a
period of two days. P
¾ Cut the pothole to a rectangular shape, For permanent repairs, the potholes A
will be classified into big and small
one edge parallel to the length of the
highway
sized potholes and treated
accordingly. Potholes up to 150mm
V
¾ The pothole should be cut to a depth where
diameter will be called small potholes
and others, big potholes.
E
the base is sound.
M
¾ Clean thoroughly with wire brush, nylon
brush and blower if required E
T
¾ Pour Shellmac-PR (ready to use material for

patching) into the pot hole, keeping about
20mm above the surrounding surface
¾ Use a hand rammer, with its head smaller

than the pot hole, to compact the material
filled into the pothole
¾ When the material gets compacted, pour

some Shellmac and re-compact
¾ Leave the compacted surface

approximately 10mm above the surrounding
surface, which may further get compacted
by the traffic Labour for fixing Big potholes
LARGER POTHOLES 1. Supervisor 1

2. Labour 4
Pot holes of diameter larger than 150 mm will be
treated as large pot holes.
Treatment
Temporary Fixing
Tools /Equipments for fixing Big
Whenever it is not possible to repair a pot hole potholes
properly due to wet season, they need to be fixed
temporarily to avoid hazardous situation for the
traffic. 1. Pick axes 2
2. Spades 2
3. Wire brush 2
¾ Remove the debris and any loose material
4. Block brush 1
out and clean the pot hole thoroughly using 5. Nylon Brush 1
a wire brush or a broom 6. Hand rammer 1
7. Rake 1
¾ It is not necessary to cut it to a rectangular 8. Measuring tape 1
shape 9. Wheel barrow (hot mix) 2
10. Thermometer 1
¾ However, the edges must be made vertical 11. Walk behind roller 1
12. Traffic management devices
¾ Put the brick ballast, or stone ballast, or both (as per Chapter 2 Safety)
into the pot hole. The size of the aggregate
will depend on the depth of the pothole P
¾ Use hand rammer to compact the A
aggregate into the hole
V
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Permanent Fixing
Material for Fixing Big potholes
¾ Mark the area around the pothole with 1. Hot mix for pothole filling
white / yellow paint in advance
2. Bitumen/emulsion for Tack coat
3. Solvent for cleaning tools and

equipment
4. Arrangement for re-heating the hot

mix
¾ Provide proper signages, flags and diversion

signs for traffic diversion
¾ Remove the area with the help of pickaxe,

forming a rectangular shape
¾ Cut the pothole to an appropriate depth till

a sound base, minimum 30mm
P
A
¾ Remove the debris and any loose material
out, and clean thoroughly by wire brush, V
broom and using a compressor
E
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¾ Apply prime / tack coat as the case may

be, using emulsion ensuring that the spread
is uniform with no area left uncoated
including the vertical edges
¾ After half an hour of applying the tack coat,

put hot mix into the pot hole
¾ Spread with a rake and compact with a

hand rammer
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¾ Pour more hot mix over 10mm higher than

the pavement surface
¾ Compact the hot mix using a walk behind

roller and make flush with the pavement
surface
¾ Open the lanes to the traffic after 4 hours
¾ Remove all the diversion signs, signages and

flags
If the bowl shaped pothole in the pavement

exceeds 0.5sqm in area and 10mm in depth
irrespective of the numbers existing on the
pavement shall be repaired by patching / pothole
filling.
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EDGE BREAKING
Description
The edge of the pavement gets broken in an

irregular way. If not remedied in time, the surfacing
will peel off in large chunks at the edges.
Cause
1. Ingress of water into the under layers which

softens the foundation causing the
pavement edges to break
2. Worn out shoulders resulting in insufficient

side support to the pavement
3. Inadequate strength at the edge of the

pavement due to improper compaction
Response Time
4. Lower layer of pavement not being wider
than the upper layer
The broken edges can be dangerous,
and if left unattended, can lead to
further, damage to the pavement. It
Treatment shall be taken up as part of routine
maintenance
The shoulder and pavement in the affected area
shall be reconstructed. The shoulder shall be built Brick paving can be done as temporary
up with thorough compaction. Pavement similar to measure if rain or wind do not permit
existing one shall also be constructed after the the regular work to be taken up.
shoulder is completed.
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KERBS
DESCRIPTION
Kerbs are provided in the centre medians and

sometimes on shoulders whenever there are
footways or cycle cracks. They must also be
provided sometimes in other locations. The kerbs
could be either cast in situ or pre-cast.
Although these items tend to be stable by their

nature and construction specification, hazardous
conditions can develop quickly when either
individual kerb, or short lengths, are damaged or
put out of alignment by heavy vehicles, or when
local subsidence occurs. The kerbs may also
develop cracks due to expansion joints not being
filled there or filled with debris and not allowing
expansion.
Due to repeated overlays the height of the kerbs

above the road surface becomes inadequate and
defeats the very purpose of kerbs.
Many times the kerb stones are removed by local

residents to make unauthorized access across the Response Time
medians, causing hazard to the traffic in the
opposite carriageway. These stones are then left For cracks or when the kerbs are too
scattered in the median or sometimes in the low no urgent action shall be taken.
carriageway itself. These faults shall be attended to
under programmed activities of
The damage to the kerbs will normally be isolated maintenance.
and rarely extensive (only in case of defective
manufacturing or faulty installation). The toppled kerb, especially when on
the carriage way shall be cleared as
soon as the fault is noticed.
Reinstatement shall be done
Maintenance
subsequently.
Kerbs, which have toppled, shall be restored with For kerbs which are misaligned shall
proper specification including bedding and be properly aligned before overlay.
backing. The expansion joint shall be provided in
the backing concrete also. The problem of too low kerbs shall
P
Cracked kerb shall be replaced. No repairs will be
also be attended to prior to overlay.
A
done to the cracks. Misalignment shall be taken
care of at the time of overlay. Too low kerbs also V
shall be set right at appropriate level prior to
overlay. E
If there is frequent damage by heavy vehicles, local M
re-alignment or reconstruction with more robust
specification shall be done. E
T
Where local residents make unauthorized cuts in

the medians repeatedly and damage the kerbs,
more robust kerbs or New Jersey barriers shall be
placed
Other Defects
Skid Hazards irrespective of size, shall be corrected

by improving the surface drainage and skid
resistance including cleaning the surface of
contamination, surface treatments or milling or
resurfacing
MAINTENANCE ACTIVITIES
Some activities of maintenance are exclusive to a

particular defect. They have been described under
the same defect such as pothole filling.
However, there are other maintenance activities

which are used for remedying several defects, such
as surface dressing, fog spray and so on. These
procedures have been described in following
pages.
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SURFACE DRESSING
Materials
Surface Dressing shall be carried out in dry weather. 1. Bitumen Emulsion

It is usually applied over the complete width of 2. Aggregate Chips
3. Solvent
lane.
4. Crayons
5. Corrugated Board
Single surface dressing will be done.
Method Statement
1. Arrange traffic management in

accordance with the chapter on safety.
2. Sweep the surface clean so that the binder

will stick to it
3. Mark the surface out by a string line to

ensure good alignment to the edge of the
surface dressing
4. Check temperature of the binder as per

manufacturer’s specification which is
approximately 180 0C for bitumen 80/100
grade
5. Check spray jets of the bitumen distributor

for operation
P
A
6. Put strips of strong paper to ensure clean
transverse joints V
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7. Keep clean round aggregate in wheel

barrow or in a truck, ready to be spread
8. Distribute the binder
9. Spread the aggregate from wheel barrows

or directly from the trucks driving backwards
(for large works)
10. Roll the surface using roller
11. Roll on the surface 10 -15 times if a walk

behind roller is used
12. For large works, keeping the two pneumatic

rollers at least 50m from the aggregate
truck, give 5 passes at speed of 5 to 8 km/hr
13. Open the traffic with speed restricted to 50

km/h after 2 hours
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CONCEPT OF SURFACE DRESSING Labour for surface dressing
1. Foreman 1
2. Supervisor 1
3. With aggregate truck 1
4. Bitumen Sprayer 1
5. Chip Spreaders 2
6. Traffic Controllers 2
1. The aggregate spread over the binder will

show approximately 50% void immediately
after spreading the aggregates.
2. When compaction is done by a roller , the Tools / Equipments Required

aggregates reorient and the void drops to
30%. 1. Wire Brushes 2
2. Pick Axes 2
3. Block Brushes 2
4. Nylon Brush 2
0.75ALD ALD 5. Wheel Barrows 2
6. Flower Cans 2
7. Thermometer
8. Cans 2
9. Compressor
3. Passage of traffic further compacts them 10. Pressure Bitumen Sprayer
and the void finally reduces to 20% 11. Light Commercial Vehicle
12. Walk behind Roller
13. Traffic Management Devices
Aggregate particles at final stage reorient
themselves such that they lie evenly on their flattest
side. The height of bitumen shall be so adjusted that
it occupies 3/4th of the height of average least
dimension of aggregates. If the height of binder is
more, it will cause bleeding. If it is less, it may cause
loss of aggregate.
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FOG SPRAY Labour for surfacing dressing
Fog spray is a very light application of low viscosity 1. Supervisor 1

bitumen emulsion for purposes of sealing cracks less 2. Worker 3
than 3mm wide, or to help reduce loosening of 3. Bitumen sprayer 1
chips by traffic on newly laid surface dressing, or 4. Traffic controller 2
when the pavement surface is hungry.
• Fog spray shall be done in dry weather
• Fog spray shall not be done on a wet surface
• Fog spray shall also not be done when the Tools/equipment for surface
weather is foggy, rainy, windy, or when dressing
there is a dust storm
1. Wire brushes 2
2. Block brushes 2
• It is also not to be done when the 3. Nylon brush 2
temperature in shade is less than 100 C 4. Wheel barrows 2
5. Pressure Bitumen sprayer
6. Thermometer
7. Compressor
8. Traffic management devices (as
per Chapter 2 Safety)
Material for surface dressing

1. Bitumen Emulsion SS1-h
2. Solvent
3. Corrugated Board
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Method Statement
1. Arrange the traffic management, as

provided for in the chapter on safety
2. Sweep the surface clean with wire brush,

and nylon brush and remove any dust or
loose material
3. Clean the cracks with compressed air by

means of a pressure air jet to completely
remove any dirt, dust, etc.
4. Protect road furniture, kerb, etc by use of a

self adhesive masking tape or other material
firmly secured against damage.
5. Take bitumen emulsion SS – 1h (or SS -1) or

equivalent
6. One part of emulsion shall be mixed with

one part of water
7. Apply the fog spray by using a bitumen P

pressure sprayer if the areas are large, at the
rate of 0.5 to 1 litre per square meter A
8. The traffic shall be opened after 24 hours. If V
the pickup occurs still after that, light
blinding of crusher dust shall be applied E
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SLURRY SEAL
Slurry seal is a mixture of fine aggregate, Portland

cement filler, bitumen emulsion and additional
water. When freshly mixed, they have a thick
consistency and can be spread to a thickness of 1.5
to 5 mm. They are used on top of a single coat of
surface dressing.
Method Statement
1. The optimum mixture design for the

aggregate, additive, water and bitumen
emulsion shall be determined well in
advance.
2. Slurry seal shall be done in dry weather
3. Slurry seal shall not be done on a wet

surface
4. Slurry seal shall not be done when the

weather is foggy, rainy, windy, or when
there is a dust storm.
5. It shall not be done when the temperature

in shade is less than 10 0C

provided for in the chapter on Safety.
P
7. Sweep the surface clean with wire brush, A
and nylon brush and remove any dust or
loose material. V
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8. Protect road furniture, kerb, etc by use of a

self adhesive masking tape or other material
firmly secured against damage.
9. Apply a tack coat to enhance bonding with

the existing pavement surface at a rate of
0.15 to 0.30 litres/sqm.
10. Carry out mixing preferably in a concrete

mixer: Emulsion, aggregate (passing 3mm
sieve), ordinary Portland cement @ 2% by
weight of dry aggregate. (For small areas
hand mixing may be used).
11. Remove the masking after the work is

finished.
12. Open to traffic after 24 hours.
13. Remove any loose aggregate over the next

48 hours after opening to traffic.
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Labour for filling cracks

CRACK FILLING
1. Supervisor 2
2. Labour 2
The treatment for most types of crack would
depend on whether the pavement is structurally
sound, or has become distorted or unsound.
If the pavement is sound then the cracks shall be

filled with a bituminous binder of low viscosity so
that it can be poured and worked into the cracks.
Emulsions shall be used for this kind of filling.
Tools/equipment for crack filling
If the width of the cracks is less than 3mm and
resulting into settlement of pavement up to 10mm in 1. Wire brushes 2
depth and exceeding more than 1sqm at a place, 2. Block brushes 2
such cracking shall be sealed by fog sealing. 3. Nylon Brush 2
4. Wheel Barrow 2
If the width of the cracks is more than 3mm and 5. Thermometer 1
causing settlement of the pavement up to 10mm
6. Squeegees 2
and the area of cracked surface exceeds 0.5sqm
7. Cans 2
at a place, such cracked surface shall be repaired
8. Compressor 1
by slurry sealing.
9. Traffic management devices(as
per Chapter 2 Safety)
If the cracked portion has settled more than 10mm
and its area exceeds 0.5sqm, such areas shall be
repaired by patching.
In case of alligator cracks, the permanent repair by

full depth patching, shall be carried out.
The slippage cracks shall be repaired by removing

the affected bituminous layer and replacing it with
surface patch.
P
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Material for filling cracks V
1. Bitumen Emulsion E
2. Solvent
3. Crayons M
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Method Statement
1. Arrange traffic management in

accordance with the chapter on Safety.
2. Clean the surface of the pavement with

wire brush and then with soft brush and
remove all loose materials from the surface
of the pavement
3. Clean the joints with air pressure jet from an

air compressor
4. Mix one part of emulsion with one part of

water, or as specified by the manufacturer P
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5. Pour the emulsion neatly into the crack with

a can
6. Use a hand sponge or wiper or brush to

assist the penetration of the emulsion into
the cracks
7. Spread a light coat of coarse sand to

prevent traffic picking up the emulsion
8. Clean the roads, remove the traffic

restrictions, and open the road to traffic
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PATCHING
Patching consists of laying a dense graded mixture

of aggregate, filler and bituminous binder on the
pavement by replacing the existing layer.
Method Statement

provided for in the chapter on Safety.
2. Mark out the area to be treated
3. Cut the affected area where patching is

required to be done
P
A
4. Clean the area using wire brush and nylon
V
brush, and remove any dust or loose
materials
E
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5. Use compressed air jets to further clean the
area E
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6. Apply tack coat RC – 3 or MC – 3 @ 0.75

kg/sqm for bitumen emulsion
7. Fill the hot mix into the prepared area,

taking care that filling is done in layers not
exceeding 40mm thickness
8. Compact each layer thoroughly either by

vibratory tampers (when the fill level is
below that of the surrounding pavement) or
by walk behind roller.
9. The compaction shall be completed before

the mix cools below 100 0C.
10. Compaction by traffic shall not be allowed
11. Clean the tools and plants, remove the

traffic management devices, and open the
road to traffic.
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MAINTENANCE OF CEMENT CONCRETE

PAVEMENT
Generally cement concrete roads need very little

maintenance. The main defect in this type of
pavement is the formation of cracks. Generally fine
cracks are not harmful to the pavement. If cracks
are wide enough to allow surface water to infiltrate
inside, then they should be attended to
immediately to avoid further damage to the
pavement.
Failure of cement concrete pavements are

attributed due to the following two factors:
a) Deficiency of materials used

b) Structural inadequacy of pavement system
a) Deficiency of materials
Following factors are grouped under this head of

deficiency of materials:
a. Use of soft aggregates

b. Poor workmanship in the construction of
joints
c. Use of poor joint filler and sealer materials
d. Poor surface finish
e. Inadequate curing
The above mentioned deficiencies give rise to the

following defects in the concrete pavement
I. Poor and soft aggregates cause crushing

and disintegration of the cement concrete
II. Development of cracks
III. Poor workmanship in joint construction
causes spalling of joints
IV. This will also result in poor riding surface
V. The poor surface finish may result in slippery
surface
VI. Inadequate curing may deteriorate the
strength of the concrete and also may
P
VII.
cause shrinkage cracks
Formation of cracks may allow the surface
A
water to seep in and may further
deteriorate the condition of pavement
V
b) Structural inadequacy of pavement system.
E
Under this head following factors are
classified: M
a. Inadequate thickness of pavement E
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b. Inadequate subgrade
c. Poor soil of subgrade
d. Incorrect spacing of joints
The above factors give rise to failure of the following

type:
I. Cracking of the slab at corners

II. Settlement of pavements
III. Widening of joints
IV. Mud pumping, etc.
Following failure are generally observed in rigid

pavements:
1. Sealing of cement concrete:
Sealing of cement concrete generally

occurs due to the presence of chemical
impurities in the mix or due to the poor mix
design. Further during construction period if
excessive vibration is given to the cement
concrete the mortar comes to the surface
which gets abraded during the long use of
the pavements leaving the aggregate
surface exposed. This makes the pavement
surface rough and unsightly in appearance.
2. Development of shrinkage cracks in

concrete:
During the curing period shrinkage cracks

generally develop in cement concrete
pavements in longitudinal as well as in
transverse directions. These cracks may
allow seeping water to enter inside the road
which may disintegrate the concrete.
3. Development of warping cracks:
If the joints are not well designed to

accommodate the warping of the slab at
edges, the slab will develop cracks due to
the development of excessive stresses in it. If P
longitudinal and transverse reinforcement is
provided at the joints, it will take care of all A
structural defects.
V
4. Structural cracks:
E
Structural cracks are developed due to the
inadequate thickness of the pavement. M
E
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5. Spalling of joints:
During construction of cement concrete

pavements, sometimes prepared filler
materials are used at joints. Sometimes these
fillers get disturbed and get filled. If
concreting is done on these fillers in this
position, an overhang layer of concrete
takes place on top of the filler later on and
this results in subsidence of soil under the
joint and excessive cracking takes place
near the joint.
6. Mud pumping:
If under the influence of wheel load the

cement concrete pavement moves
downward and gets cracked, the ejection
of soil slurry in such a condition is known as
mud pumping. Generally such
phenomenon occurs in pavements placed
on clayey soil subgrades. Due to the
repeated applications of loads, the
pavement gets vibration, due to which the
soil below concrete slab gets compacted
and some space is left underneath the
pavement slab. Water may seep through
joints and cracks into this space and may
form soil slurry.
7. The subsequent application of heavy wheel

loads defect the pavement slab at critical
location and force out some soil slurry each
time. This causes hollow underneath the
concrete slab and ultimately this results in
failure of the pavement.
Maintenance
The cracks should be cleaned of all dirt, sound or

any other loose particles by sharp tool and air
blowing by air blower to facilitate the bond
between the old surface and sealing material. The
cleaned surface is given a coat of kerosene oil. P
Then the cracks are filled with suitable grade of
bitumen in liquid form. The sealing material if A
provided 3mm extra than the required height and
then the treated surface is covered with sand. V
The spots at the construction joint are the weakest E
in the cement concrete road, it is essential that the
filler and sealing material are intact in the joints. M
Vertical edges of the joints are also very essential as
inclined faces get damaged seriously. E
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Levels of Service
1. Section VI Clause 6.3(b)

Page 26
Assured Availability
“Subject to the proviso to preceding sub-article(a), the

Carriageway or part thereof shall be deemed to be
unavailable if;
(i) the same is closed for traffic otherwise than in accordance
with the O & M Requirements as per Schedule' L',
(ii) irrespective of whether the same is closed for traffic or
not, if the Independent Consultant has determined that,
(a) the riding quality thereof has deteriorated to a level
which is below the acceptable level prescribed by the O & M
Requirements as per Schedule 'L'; and (b) the same is not, in
the opinion of the Independent Consultant, safe for
operations.”

Page 27
“(c) The Non-Availability shall be measured in terms of the

sum total of lane kilometer hours for which the Carriageway
or part thereof as the case may be was unavailable.
(d) The length of a lane that was unavailable for the use of the
traffic, shall be the actual length of the affected stretch of
that lane as determined by the Independent Consultant plus
1 km (500mtrs on either side of the affected stretch).”

Page 27
“(e) If in respect of any Annuity Payment Period, the

Independent Consultant has reported Non Availability or Non-
Availability has otherwise been established, the Annuity
payable for the immediately succeeding Annuity Payment
Period shall be adjusted for such Non Availability (the
Adjusted Annuity) as under and paid.
(f) Adjustment of Annuity on account of Non Availability in
accordance with this Article 6.3 shall be without prejudice to
P
any other right/remedy available to NHAI on account of
breach of its obligations by the Concessionaire and that NHAI
A
shall be entitled to treat frequent occurrences of Non-
Availability or continued Non-Availability (beyond a V
reasonable time having regard to Good Industry Practice) as
persistent breach of O&M Requirements within the meaning E
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of Article 18.16.”
E
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Page 57
Operation and Maintenance
“The Concessionaire shall be responsible for the maintenance

of the approach roads to and underpasses and overpasses up
to 100 mtrs from the Project Highway in accordance with
Good Industry Practice.”

Page 59
“In the event the Concessionaire does not maintain and / or

repair the Project Highway or a part thereof up to and in
accordance with the Specifications and Standards and / or in
accordance with the Maintenance Programme or the
Maintenance Manual, and shall have failed to commence
remedial works within 30 (thirty) days of receipt of notice in
this behalf from NHAI or the Independent Consultant, or the
O&M Inspection Report, as the case may be, NHAI shall,
without prejudice to its rights under this Agreement, including
Termination thereof, be entitled to undertake the repair and
maintenance of the Project Highway at the risk and cost of the
Concessionaire and to recover the same from the
Concessionaire.”

Page 60
“If the Concessionaire commences any works for curing any

defects or deficiencies in the Project Highway, it shall
complete such works expeditiously in accordance with Good
Industry Practice. If such works are carried out in a manner
that results in a delay of more than 30 (thirty) days as
compared to the time required in accordance with Good
Industry Practice, NHAI shall recover Damages from the
Concessionaire as if a default had occurred under Clause
18.13.”
7. Section XVIII Clause 18.15 P

Page 60
Operation and Maintenance A
“The Concessionaire shall not be considered in breach of its V
E
obligations under this Agreement if any part of the Project
Highway is not available to traffic after the COD on account
of any of the following for the duration thereof:
(i) an event of Force Majeure;
(ii) measures taken to ensure the safe use of the Project
M
Highway except when unsafe conditions on the road occurred
because of failure of the Concessionaire to perform its
E
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obligations under this Agreement; or

(iii) compliance with a request from NHAI or the directions
of any Governmental Agency the effect of which is to close all
or any part of the Project Highway.
Notwithstanding the above, the Concessionaire shall keep all
unaffected parts of the Project Highway open to traffic and
use provided they can be safely operated and kept open to
traffic.”
8. Section XIX Clause 19.1

Page 61
Monitoring and Supervision during
Operations
“The Concessionaire shall undertake periodic (at least once

every calendar month but once every week during
monsoons) inspection of the Project Highway to determine the
condition of the Project Highway including its compliance or
otherwise with the Maintenance Manual, the Maintenance
Programme, Specifications and Standards and the
maintenance required and shall submit reports of such
inspection ("Maintenance Reports") to NHAI and the
Independent Consultant.”

Page 61
Operations
“The Independent Consultant shall review the Maintenance

Reports and inspect the Project Highway at least once a
month during the Operations Period and make out an
Inspection Report of such inspection (the "O&M Inspection
Report"). The Independent Consultant shall send a copy of its
O&M Inspection Report to NHAI and the Concessionaire. The
Concessionaire shall within 30 (thirty) days of the receipt of
the O&M Inspection Report remedy the defects and
deficiencies, if any, set forth in such O&M Inspection Report
and submit its report in respect thereof to the Independent
Consultant and NHAI within the said 30 (thirty) days period.”
P
Page 60 A
Operations V
“Where the remedying of such defects or deficiencies is likely
to take more than 30 (thirty) days in accordance with Good
E
Industry Practice, the Concessionaire shall undertake the
works in accordance with such practice and submit progress
M
reports of such works every fortnight. The O&M Inspection
Report may also require the Concessionaire to undertake such E
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tests as may be specified by the Independent Consultant for

the purpose of determining that the Project Highway is at all
times in conformity with the Specifications and Standards. The
Concessionaire shall undertake such Tests without any delay
and furnish a copy of the results thereof to the Independent
Consultant and NHAI along with a written statement
specifying in reasonable detail the measures, if any, that it
proposes to undertake for curing the defaults or deficiencies
indicated in such results.”
11. Schedule L Clause 1

Page L-1
Operation and Maintenance Requirements
“The Concessionaire shall operate and maintain the Project

Highway such that from Commercial Operations Date (COD),
lane availability at the end of each year of the Concession will
be a minimum of 99% on a cumulative basis.”
12. Schedule L Clause 2.1.11(b)(i)

Page L-4
“Where the other road crosses an underpass, the

Concessionaire shall be responsible to maintain the crossing
structure, viz., culverts, bridges and their abutments and
related facilities, such as drainage, turfing, etc. The
Concessionaire shall not be responsible for maintenance of
the road surface, or the roadside drains of the other roads
that are 100 m beyond the RoW of Project Highway.”
13. Schedule L Clause 2.1.11(c)

Page L-4
“The Concessionaire shall operate and maintain all the street

lighting, traffic light system, structures, roadway surface and
the related facilities such as drainage, turfing, etc within the
interchanges, and such maintenance shall be extended until
the end of the flare and the deceleration and acceleration P
A
lanes of the interchanges.”
14. Schedule L Clause 2.1.11(d)

V
Page L-4
E
“The Concessionaire shall be responsible for maintaining all
M
cross roads indicated in Schedule B up to a length of 100
meters from the Right-of-Way of the Project Highways, and
E
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their flares to junctions at any interchange within the Project

Highway, whichever is more.”
15. Schedule L Clause 2.2.3.3

Page L-6
Traffic Management and Lane Closure
“The activity of renewal of pavement surface and / or

strengthening of the pavement structure shall not be taken up
in a continuous length of more than 2 kilometres at a time to
avoid long detour of the traffic.”

Page L-7
“The activity of renewal of pavement surface and/or

strengthening of the pavement structure shall be taken up in
one lane of the 2/3 lane carriageway so that at least one lane
of that carriageway is available to the traffic.”

Page L-7
“The activity of renewal or strengthening, shall not be carried

out in a continuous length of more than 2 km in rural
section and 1 km in urban section so that the closure of a
lane is not more than 2 days and 1 day in rural and urban
sections respectively.”

Page L-7
“Lane Closure in short lengths less than or equal to 500

metres for carrying out a routine maintenance activity defined
in item 4.2.1.1 of this Schedule shall not be for more than a
continuous period of 1 day.”
P
19. Schedule L Clause 2.6.1 A
Page L-9
Traffic Management and Lane Closure V
“Various important activities to be carried out during this E
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stage are:
a) Regular periodic maintenance activities:
i) Renewal of the wearing surface of the road pavement once
every 5 years;
ii) Strengthening course to be provided on 'as required'
E
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basis.
b) Maintenance activities arising out of the specific need(s) on
account of the site conditions are:
i. Strengthening course required on account of the
Benkelman Beam Deflection (B.B.D) values in excess of the
prescribed criteria obtained during regular testing as per the
Concession Agreement requirement;
ii. Wearing course required on account of the IRI values
higher than the prescribed criteria obtained during regular
testing as per the Concession Agreement requirement;
iii. Localized repairs in short lengths less than 500m on
account of pot holes, cracking, subsidence in isolated spots
or in scattered areas.”
20. Schedule L Clause 4.1.2

Page L-16
Maintenance
“The Concessionaire shall maintain the existing 2/3 lanes of

the Project Highway and already constructed 4/6 lanes of the
Project Highway during construction of new lanes in such a
manner that the unevenness index of the pavement does not
exceed 3000 mm per km, or the present roughness value of
the existing pavement, whichever is lesser and it is free of pot
holes.”

Page L-18
Pavement Riding Quality
“The riding quality of the pavement shall be ensured by

satisfying the minimum requirements given herein under.
i) Surface roughness of the Project Highway on completion of
construction shall be 2000 mm/km as measured by vehicle
mounted Bump Integrator.
ii) Surface roughness shall not exceed 3000 mm/km during

the service life of pavement at any time. A renewal coat of
bituminous concrete shall be laid every 5 years after initial
construction or where the roughness value reaches 3000
mm/km whichever is earlier to bring it to the initial value of
P
2000 mm/km.”

Page L-19
A
Structural Condition of the Pavement V
“The structural condition of the flexible pavement of the
Project Highway shall be assessed every year by taking
E
Benkelman Beam Deflections and working out characteristic
deflections of homogeneous sections of the Project Highway M
as per IRC-81-1997. Wherever the characteristic deflection
exceeds 1.2 mm a bituminous overlay shall be provided E
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appropriately designed according to IRC-81-1997 or its latest

versions or amendments to it.”

Page L-19
Structural Condition of the Pavement
“In the case of cement concrete pavement, joints shall be

thoroughly inspected every year and the loss of sealing
compounds made good.”

Page L-20
Major Breaches in the Roadway
“Major breaches in the roadway of any type endanger safety

of traffic and cause obstruction in movement of vehicles.
These breaches shall be repaired urgently. Steps as mentioned
in O&M manual shall be followed by the Concessionaire for
repairing the breaches. The Concessionaire shall ensure
speedy restoration of traffic and take immediate action to
repair the damages as permanent measures for the Project
Highway. The restoration of traffic shall be made within 24
hours of its occurrence. The permanent measures shall be
completed within a period of one week.”

Page L-20
Minor Cuts, Rutting or Blockage
“Minor cuts, rutting and damages on Project Highway which

do not completely obstruct the traffic but endanger the safety
of traffic, shall be attended to on an urgent basis. For this
purpose any cut which is in width more than 1 m shall be
repaired within 24 hours. Any minor blockage, which
partially obstructs the traffic and endangers safety, shall be
removed by the Concessionaire immediately.”

Page L-23
Pavement / Cracking
P
“Cracking of bituminous pavements shall include all types of
cracks such as hairline, alligator, longitudinal, transverse, A
shrinkage, reflective and edge cracking, linear and slippage
etc. For any 50 m section of the pavement, the cracked area V
E
should not be more than 10% of the pavement surface of that
section and / or the cracked area shall not exceed 0.5 sq.m.
at a place. The treatment shall be completely done within 7
days after their detection.” M
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Page L-23
Pavement / Cracking
“If the width of the cracks is less than 3mm and resulting into
settlement of pavement up to 10 mm in depth and exceeding in
area more than 0.5 sq.m. at a place, such cracking shall be
sealed by fog sealing in accordance with the MORT&H
Specification 3004.”

Page L-23
Pavement / Cracking
“If the width of the cracks is more than 3mm and resulting
into settlement of pavement up to 10 mm in depth and
exceeding in area more than 0.5 sq.m. at a place, such
cracked surface shall be repaired by slurry sealing in
accordance with MORT &H Specification 516.”

Page L-23
Pavement / Cracking
“If the cracked portion has settled more than 10mm and its
area exceeds 0.5 sq.m., such areas shall be repaired by
patching as per MORT &H Specification 3004.”

Page L-23
Pavement / Cracking
“In case of alligator cracks, the permanent repair by full

depth patching shall be carried out. The slippage cracks shall
be repaired by removing the affected bituminous layer and
replacing it with surface patch. In edge cracking, if shoulders
are not providing adequate lateral support, the shoulder shall
be reconstructed with good quality materials.”

Page L-24
P
Pavement / Rutting
A
“For any 50 m section of the pavement, there shall not be ruts
deeper than 10 mm and / or the length of rutting should not V
be more than 5m. The treatment shall be completely done
within 15 days after their detection. The pavement surface E
M
shall be rectified / corrected as per directions laid out in IRC
82- I 982 and based on sound engineering practice at such
locations.”
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Page L-24
Pavement / Corrugations and Shoving
“If corrugations and shoving in the pavement area exceeds 1

sqm at any place and depth / height of corrugation / shoving
exceeds 10mm, the same shall be rectified / corrected within 2
days after its detection, as per directions laid out in IRC 82-
1982 and based on sound engineering practice.”

Page L-24
Pavement / Settlement or Grade
Depressions
“If the settlements and grade depressions exceed 1 sqm in

area and their depth is within 10mm, such defects shall be
treated within 3 days after detection as per directions laid out
in IRC 82 - 1982 and based on sound engineering practice.”

Page L-24
Pavement / Upheaval or Swell
“For any 50 m section of the pavement, there shall not be

upheaval or swell that exceeds 0.5 sqm in area; if its height is
more than 10mm, the same shall be treated within 7 days
after its detection as per as per directions laid out in IRC 82 -
1982 and based on sound engineering practice.”

Page L-24
Pavement / Ravelling
“For any 50 m section of the pavement, if the ravelling of

bituminous surface is not more than 3% of the pavement
surface of that section and/or the ravelled area does not
exceed 1 sqm at a place, the same shall be rectified within 7
days after their detection by slurry seal treatment in
accordance with the MORT&H Specification.”
P
Page L-24
A
Pavement / Potholes
V
“There shall not be any pothole on the pavement surface.
Irrespective of the size and depth, the potholes shall be E
M
repaired by patching / pothole filling in accordance with
MORT&H Specification 3004. The potholes shall be repaired
E
immediately if causing a threat to safety; other potholes shall
be repaired within 2 days after their detection.”

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Page L-25
Pavement / Skid Hazards
“The skid resistance of the pavement surface shall be

maintained in such a way that the skid number is a minimum
of 55 when tested as per BS-812 Part 114 ASTM - 274. Skid
hazards, irrespective of size, shall be corrected by improving
the surface drainage and skid resistance including cleaning
the surface of contamination, surface treatments or milling or
resurfacing.”

Page L-25
Pavement / Bleeding or Flushing
“For any 50 m section of the pavement, if the bleeding surface

area is more than 1% of the pavement surface of that section
and / or the bleeding surface area does not exceeds 0.25 sqm
at a place, the same shall be treated immediately within a day
after its detection in accordance with IRC:82-1982 or any
other relevant guidelines in consultation with the IC.”

Page L-25
Pavement / Edge Deformation or Breaking
“For any 100m section of the pavement, if the edge breaking

is more than 1m and / or the width of edge breaking is more
than 0.1m at a place, the same shall be treated immediately
within a day after its detection in accordance with IRC:82-
1982 or any other relevant guidelines in consultation with the
IC.”

Page L-25
Pavement / Loss of Cover of Aggregate
“If the loss of cover aggregate occurs in area exceeding 1

sqm of the pavement, treatment of seal coat shall be applied.”
P
Page L-25 A
Pavement / Longitudinal
Streaking
or Transverse
V
“If the longitudinal and transverse streaking appears on the E
M
pavement surface in area exceeding 5 sqm, the same shall be
treated by application of new surface treatment or by a second
E
treatment over the streak surface.”

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Page L-26
Pavement
“If any defects other than those mentioned above occur on the
pavement of the Project Highway, the same shall be rectified /
corrected by the Concessionaire as per directions laid out in
IRC 82 - 1982 and based on sound engineering practice.”
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INSPECTION
FORMATS
INSPECTION FORMAT - PAVEMENT
Date: NH No. Section:
Team: Start Time: Chainage:
1 Finish Time: From:
2 Pavement: Rigid/Flexible To:
3 Sections 25 metres each
SHOULDER / RoW OUTER LANE INNER LANE
GRY SURFACE
GRY SURFACE
NE MARKING
EDIAN DRAIN
CHAINAGE (Write
ETTLEMENT
ETTLEMENT
ETTLEMENT
DGE BREAK
DGE BREAK
DGE BREAK
SIDE DRAIN
CRACKING
CRACKING
CRACKING
DRAINAGE
DRAINAGE
DRAINAGE
POTHOLES
POTHOLES
POTHOLES
STRIPPING
STRIPPING
STRIPPING
BLEEDING
BLEEDING
BLEEDING
RUTTING
RUTTING
sections in 25m
SLOPE
KERB
increments, like 00-25,
25-50,.., etc.)
HUNG
HUNG
LAN
ED
ED
ED
B
B
D
D
C
C
S
S
P
P
SE
SE
SE
ME
COMMENTS
Note: Write comments from: T(1) Today, U(2) Urgent, W(3) Within a week, R(4) Routine
Mark Extent from: SINGLE MILD MORE EXCESSIVE
W i Severity
Write S i from:
f SMALL MEDIUM LARGE/BIG
For Median Drain: GRASS DEBRIS CRACKS

For Side Drain: GRASS DEBRIS CRACKS
SIGNATURE OF INSPECTING OFFICER
For details, attach a separate sheet.
Chapter 5
DRAINAGE
CONTENTS PAGE NO.
INTRODUCTION E-1
VISUAL INSPECTION E-1
DETAILED INSPECTION E-1
MAINTENANCE E-2
CAUSES OF DAMAGE E-3
TREATMENT E-3
LEVELS OF SERVICE E-4

Maintenance Manual – Section 2(A) INDIA PRSG MANT E - 1/5
CHAPTER 5
DRAINAGE
INTRODUCTION
This section discusses about the drainage of

pavement, junctions, kerb drains, shoulders,
embankments, slopes, chutes, side drains, RoW,
bridges, culverts, building tops, verandahs, toilets,
medians.
Visual Inspection
The requirements of visual inspections do not

relate to large scale works needed for structural
maintenance like rehabilitation, resizing and
strengthening of drainage system. It is usual to
carry out such inspections monthly. Such
inspections point out to the requirement of
cleaning of debris, removing obstructions,
clearing of vegetation, etc. The condition of
masonry / RCC if any will also be recorded while
carrying this inspection.
Also, the defects reported from visual inspections

will indicate the locations where detailed
inspections need to be done more carefully.
Drainage related inspections must also be

carried out during the rains. Visual inspection
should indicate the need for detailed inspections
during the rains. These inspections will indicate
wherever the water is overflowing, is not passing
through, crossing over the pavement, or ponding
on the pavement, shoulders, high vegetation on
shoulders, overgrown vegetation on slopes, earth
slipping, pitching settlement, etc.
Visual inspection of the drainage system should

record all locations of debris, silting, vegetation,
D
or any other irregularities in 25m sections of the
highway. Exact locations need not be recorded.
R
Detailed Inspection
A
The detailed inspections are always carried out
I
before and after the rainy season. These are
intended to note those types of defects which N
will require routine maintenance. Such
inspections, particularly post monsoon detailed A
inspections must indicate any
maintenance needs such as need for re-
major
G
Maintenance Manual – Section 2(A) Gujarat & Rajasthan E
plastering, structural maintenance, rehabilitation,

etc. They may also indicate any recurring
problems.
Detailed inspection may also point to the need

to bring forward a thorough inspection or
rehabilitation or an enhancement requirement
survey.
At the time of rainfall a detailed inspection must

also be carried out, even if not indicated in a
visual inspection survey report. These inspections
must record the need for action wherever the
water is overflowing, is not passing through,
crossing over the pavement surface or ponding
on the pavement, median, shoulders, reshaping
of shoulders, earth slipping, pitching settlement,
etc.
Detailed inspections shall record exact locations

of defects such as blockages, overflowing,
clogging, resizing requirements, additional
requirements, or any other irregularities.
Sometimes when the defects are more
complicated and difficult to describe, they may
also require to be plotted. The measurements
(such as crack width, settlement, rut depths, etc)
shall be recorded on the formats. The severity
and extent of the problem will also be recorded
during such inspections.
Whenever any defects are noticed but which

may not be visible or easy to find out after the
rains are over, will also be marked on the field
with a chalk, or white paint (White Snowcem also
works very well), or easily identifiable marker posts
so that these remain easily identifiable when the
Maintenance
Accumulation of water reduces the safety of

road users on the trafficked surfaces of the D
highway. The road pavement structure must be
adequately drained in order to reduce R
maintenance liabilities and realize the design life
of the road. A
The drainage system consists of kerb drains, side I
drains, median drains, manholes, chutes, culverts,
ditches and sub soil drains. The purpose of the N
system is to quickly collect the rain and ground
water away from the road. A
G
Water can cause widespread damage to the

road by weakening the pavement or
foundations and erosion.
Inadequate provision or operation of highway

drainage facilities or inadequacies in the non-
highway drainage system can damage the
highway.
Causes of damage
Vegetation growth, bushes, fallen trees, debris,

loose silt, loose rocks, too flat gradient can cause
blockages or narrowing down of the drains. Poor
construction, workmanship, soil settlement,
erosion of soil under the lining, poor alignment
can be other causes of damage to the drainage
system.
Backing up and flooding at the entry points to

the piped drainage system, dry outfalls, wet
areas on verges and the presence of lush
vegetation is an indication for further
investigation by thorough inspections.
Treatment
Response Time
Undesirable vegetation shall be regularly
removed either manually or through use of The damage to drainage system
herbicides. Any silting, loose rocks, debris shall shall be given immediate attention to
also be cleaned regularly. arrest progressive failure and more
serious damage to the pavement.
If the silting is a regular feature, which is due to However, before the onset of
monsoon it shall be ensured that all
too flat gradient, the drain must be designed
repairs are carried out and cleaning
again and construction done accordingly.
is completed.
Misalignments would also require redesigning
and reconstruction of the drains.
Erosion and settlement shall be handled carefully

by reconstruction and if need be, by
strengthening the existing system.
Gullies, catch-pits and interceptors will be D

emptied once per year, although a need for a
greater (or lesser) frequency may be established R
on the basis of routine maintenance.
A
Ditches, overgrown with vegetation, silted up,
blocked with debris, rubbish or bank erosion, will I
be cleaned out twice every year.
N
Any vegetation growth around culverts shall be
cleared. A
G
Whenever flooding over the pavement occurs,

thorough inspections will be carried out to
ascertain the cause of the flooding.
LEVELS OF SERVICE
1. Schedule L Clause 2.1.11(e)

Page L-4
“For setting out the limit of maintenance for the

Concessionaire, NHAI shall be responsible for negotiating
with the local authorities or where required, with other
relevant third parties. The Concessionaire shall maintain
all the drainage system within the RoW including the
culvert crossings and the drains. However, the
Concessionaire shall not be liable to maintain rivers and
the streams under the jurisdiction of Irrigation Department,
except when such maintenance is required as a result of
exceptional discharge.”

Page L-21
Drainage /Side Drains
“The Concessionaire must ensure that all drainage

elements and structures are without any obstructions, which
may reduce their normal cross section and impede the free
flow of water. They should not have silting more than 25%
of their size at any part of length.”

Page L-21
“All the Pipe and Box culverts shall have less than 10% D
deteriorated barrel and have more than 90% of the
diameter / size open. There should be no evidence of R
A
flooding with end protection intact and no dip on the road
over culvert indicating structural weakness.”
I
N
A
G

Page L-21
“If the side drains / median drains where provided, and

other drainage structures have been silted up in such a
manner that it is causing obstruction in flow of water, the
same shall be cleared off regularly within 7 days after
detection in order to keep the drains free from obstructions
all the time.”

Page L-21
“If the drainage system of Project Highway is covered and

damaged, it obstructs the flow of water causing damage to
the road pavement. Such damaged structures shall be
reconstructed to required shape, size and proper slope
within 21 days after detection or as instructed by IC.”
D
R
A
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INSPECTION
FORMATS
INSPECTION FORMAT - DRAINAGE
2 To:
LEFT SHOULDER + SIDE DRAIN PAVEMENT KERB DRAIN MEDIAN DRAIN RIGHT SHOULDER +SIDE DRAIN
DAMAGED CATCH PIT
DAMAGED CATCH PIT

DAMAGED CHUTES
DAMAGED CHUTES
FLOW TOO SLOW
FLOW TOO SLOW
FLOW TOO SLOW

CHAINAGE (Write
VEGETATION
VEGETATION
VEGETATION
OVERFLOW
OVERFLOW
OVERFLOW
DAMAGED
DAMAGED
PONDING
PONDING
PONDING
PONDING
PONDING
EROSION
EROSION
sections in 25m
SILTING
SILTING
DEBRIS
DEBRIS
DEBRIS
25-50,.., etc.)
COMMENTS

Chapter 6
SHOULDERS, SLOPE
AND EARTHWORKS
CONTENTS PAGE NO.
INTRODUCTION F-1
VISUAL INSPECTION F-1
DETAILED INSPECTION F-1
TREATMENT F-3
LEVELS OF SERVICE F-3

Maintenance Manual – Section 2(A) INDIA PRSG MANT F - 1/3
CHAPTER 6
SHOULDERS, SLOPE AND

EARTHWORKS
INTRODUCTION
The areas include shoulders (unpaved), median,

embankments, slopes, RoW, approaches to
bridges, culverts, but not the river training
structures.
Visual Inspection
The requirements of visual inspection do not

relate to large scale works needed for major
maintenance like rehabilitation, or strengthening
of earthworks. It is usual to carry out such
inspections monthly. Such inspections point out
the visual defects such as cleaning of debris,
clearing of vegetation, turfing, shoulders lower
than or higher than the pavement, etc. The
condition of pitching, masonry / RCC if any will
also be recorded while carrying this inspection.
Also, the defects reported from visual

inspections will indicate the location where
detailed inspections need to be done more
carefully.
Visual inspection of the earthworks should

record all locations of debris, slips, cuts,
vegetation, or any other irregularities in 25m
sections of the highway. Exact locations need
not be recorded.
Detailed Inspection
The detailed inspections are always carried out

before and after the rainy season. These are
intended to note those types of defects which
S
will require routine maintenance. Such
inspections, particularly post monsoon detailed
H
inspections must indicate
maintenance needs such as need for re-
any major O
shaping, re-pitching, rehabilitation, re-turfing, U
erosion control, slip repair, shoulders lower than,
or higher than the pavement, etc. They may L
also indicate any recurring problems.
D
to bring forward a thorough inspection or E
survey. R
S

of defects such as slips, cuts, erosion, damaged
pitching, settlements, turfing needs, additional
requirements, shoulder settlements, or any other
irregularities. Sometimes when the defects are
more complicated and difficult to describe,
they may also require to be plotted. The
measurements (such as settlement, etc) shall be
recorded on the formats. The severity and
extent of the problem will also be recorded

with a chalk, or white paint (white snowcem also
works very well), or easily identifiable marker
posts, or marker stones so that these remain
easily identifiable when the maintenance team
comes to work.
Shoulders include the side slopes and earth fill

when the highway is on higher elevations
compared to the surroundings. Side slopes are
not used by the traffic but its maintenance
contributes to the safety of traffic and the
stability of road.
Slopes at an early stage of instability can often

be recognized by bulging of the slope profile (at
the bottom of the potential slip), by
development of tension cracks (at the top of
NORMAL SHAPE OF SHOULDER
the potential slip) or by evidence of water
seepage. Presence of lush, greener or marsh
type vegetation will often serve to identify
seepage areas where water is not always visible
on the surface.
Embankments can have settlement or slippage

or rain cuts, etc. The embankment, or the
cutting, can become unstable due to any of SHAPE AFTER SLIP, TO BE RESTORED S
these damages. The slope which is too steep for
its height or if the water penetrates the slope H
from above or the ground water flow can cause
damage to the slopes in the form of earth slips. O
The damage to the embankment or cutting
U
slopes is usually extensive unless checked and
maintained at the very beginning of the
L
damage. D
E
R
S
Treatment
Depending upon the actual damage the

repairs may require reducing the slope angle,
clearing the slip material, surcharging the slope,
providing a toe wall, providing gabions, turfing, Response Time
etc. may be necessary. Control of grass, weeds,
bush and trees may be the other activity Any damage to the embankment or
necessary for repairs of the slope failure. slopes should be handled as soon
as they are noticed. Any place
The erosion caused by rainwater or by lack of which has frequent recurrence of
vegetation cover shall be repaired by filling any kind of damage would require
earth at required places, turfing, drainage thorough inspection for deeper
chutes, stone pitching, etc. investigations which should be
promptly organized.
LEVELS OF SERVICE

Page L-20
Shoulders
“The shoulder (Earthen/Hard) shall be maintained in

such a way that the shoulder drop off shall not be more
than 25 mm for a length of 10m in a section length of
100m and / or there shall not be any false ditch causing
the water to drain in reverse direction i.e. towards
pavement instead of away from pavement surface, the
same shall be rectified within 2 days.”

Page L-20
Shoulders
“If the shoulders are deformed or scoured and are lower

than 25mm from the adjacent carriageway, these shall be
corrected by excavation, filling, dressing and compacting
a material matching the existing material and it shall
conform to the relevant MORT&H Specifications. In case S
of earthen shoulder repairs shall be carried out as per
MORT &H Specifications 3003.” H
O
U
L
D
E
R
S
INSPECTION
FORMATS
INSPECTION FORMAT - SHOULDER & SLOPE EARTHWORKS
2 To:
LEFT BANK LEFT SHOULDER RIGHT BANK RIGHT SHOULDER
SLOPE BULGING
SLOPE BULGING
SLOPE CAVING
SLOPE CAVING
CHAINAGE (Write
RAIN CUTS
RAIN CUTS
RAIN CUTS
RAIN CUTS
TOO HIGH
TOO HIGH
PITCHING
PITCHING
TOO LOW
TOO LOW
PONDING
PONDING
TURFING
TURFING
TOE SLIP
TOE SLIP
sections in 25m
25-50,.., etc.)
COMMENTS

Chapter 7
ROAD FURNITURE
CONTENTS PAGE NO.
INTRODUCTION G-1
VISUAL INSPECTION G-1
DETAILED INSPECTION G-1
FENCES AND GUARDRAILS G-3
CAT’S EYE G-4
ROAD MARKING G-5
ROAD TRAFFIC SIGNS G-6
TRAFFIC SIGNALS G-7
DELINEATORS G-10
ROAD LIGHTING G-11
LEVELS OF SERVICE G-12

Maintenance Manual – Section 2(A) INDIA PRSG MANT G - 1/15
CHAPTER 7
ROAD FURNITURE
INTRODUCTION
The elements included here are guardrails,

fences, cat’s eyes, signage, delineators, road
marking, boundary stones, kilometer stones, any
other marker stones / posts, etc.
Visual Inspection

relate to large scale works needed for major
maintenance like rehabilitation, or
enhancements. The inspections for most of
these items are carried out daily. Such
inspections point out to the requirement of
cleaning, missing, damaged, condition of paint
– fading or peeling off, bill boards, vegetation
hiding signage, guard rail damage, worn
pavement markings, etc. The condition of
supporting structures which may be masonry,
RCC or steel, will also be recorded while
carrying out this inspection.

inspections will indicate the locations where
carefully.
Visual inspection of the road furniture should

record all locations of damage, dirt, peeling off,
missing, or any other irregularities in 25m sections
of the highway. Exact locations need not be
recorded.
R
O
Detailed Inspection A
D
The detailed inspections intended to note those
types of defects which will require routine
maintenance. Such inspections must also F
indicate any major maintenance needs such as U
need for re-painting, structural maintenance,
rehabilitation, etc. They may also indicate any R
enhancement requirements. N
I
Detailed inspection may also point to the need T
to bring forward a thorough inspection or
U
R
E

survey.

of defects such as broken, missing, or tilted
elements, repainting requirements, loose/broken
bolts, guard rail damage, worn pavement
markings, structural maintenance needs, or any
other irregularities.
R
O
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F
U
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FENCES AND GUARD RAILS
Description
Fences are provided on the carriageways to

prevent the cattle or pedestrians from crossing
and regulating or preventing access of animals,
vehicles or pedestrians. The guardrails are
provided to guide the vehicles and keep them
off the edges of the carriageway. They are
usually provided on the curves or whenever the
highway is elevated compared to the
surrounding ground level.
These items are usually damaged on account of

accidents. Sometimes, they are also broken by
local residents to provide unauthorized
openings. Occasionally the business community
will put hoardings or posters or paint
advertisements on the fences. If neglected for
long the metallic fences may get corroded.
The extent of damage could be isolated or

extensive depending on the cause of the
damage.
Treatment
Whenever an accident damages the fences or

the guardrail or the local residents break open
the same, it shall be repaired or replaced as
best as possible.
The hoardings or the posters shall be removed

within 24 hours. In case of repeated incidents Response Time
the matter shall be reported to the police. R
Painted advertisements shall be scraped and If the accident causes the fence or
the surface repainted within one week from the the guardrails to project on to the O
date of notice. Corroded areas shall be lanes the same shall be removed A
as soon as it comes to notice. If the
cleaned and repainted to match the existing
repair and reinstatement is likely to D
fences.
take a long time then temporary
arrangement shall be made for
Guardrails if they are painted shall be treated in protection. F
the same way as the fence described above.
Galvanized guardrails will not be painted.
U
Treatment to other areas shall be
However, in selected areas where they become inbuilt into routine maintenance. R
black due to vehicle exhaust or other reasons, N
they shall be cleaned with soapy water once in
6 months. If this cleaning is not adequate then I
the guardrails may be replaced. T
U
R
E
CAT’S EYES
Description
Cat’s eye / road studs (sometimes called retro-

reflective raised pavement markers – RRPM) are
required on the pavement surface to promote
adequate night time and wet weather roadway
delineation. These are extremely useful even in
foggy conditions when put all along the
carriage way in edge lines, centre-lines and
inner edge lines and provide a relaxed driving
environment.
The damage of these studs is caused by the

oncoming traffic and results in cracked, split or
otherwise damaged cat’s eyes. Sometimes
local people may take them out and leave the
pavement surface without any cat’s eyes. The
reflectivity of the cat’s eye may also get
adversely affected due to long use or due to
damage by accident.
Treatment
The damaged or missing cat’s eyes shall be

replaced as a part of routine maintenance.
Response Time
R
The damaged or missing cat’s O
eyes shall be replaced as a part of
routine maintenance. A
D
F
U
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N
I
T
U
R
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ROAD MARKING
Description
Road marking (sometimes called pavement

marking) is applied on the pavement surface for
easy delineation of the road and the curves. It is
provided in the form of solid lines on the edges
and broken lines in the centre. They are also
provided for arrows, pedestrian crossings
specifying the lane usage (e.g. bus lane) etc.
These markings are reflective thermoplastic road
markings and are applied hot on the pavement
surface.
Bleeding, honeycombing or other forms of

defects in the pavement surface can cause
damage to the road marking. Extremely heavy
traffic or extreme weather conditions can also
cause damage, besides the usual wear and
tear.
Treatment
Repairs of the road marking are not possible.

Whenever the road marking peels off, or cracks
or loses reflectance it shall only be applied
again.
Response Time
The damaged road marking shall

be taken up as a routine R
maintenance activity. O
A
D
F
U
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I
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U
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ROAD TRAFFIC SIGNS
Description
Road traffic signs are provided on the

carriageway for easy identification of the routes
and places, for giving important messages to
the drivers, and to caution the drivers for any
typical road geometrics or hazards. They may
be provided on the shoulders in the medians as
stand alone boards or as overhead signs on the
gantries. This signage is mostly of reflective type.
The signage could get damaged due to

accident, corrosion, weathering effect, dust or
rainstorms, etc. The signage are also damaged
by unscrupulous population which may scratch
signboard faces. Several times people put
posters using adhesives and removal of these
posters damage the signage.
Treatment
Any damage to the signboard face as far as

possible shall be repaired. When repair is not
possible, they shall be replaced.
The supporting structure can have corrosion or

breakage. The damage shall be set right by
repainting or welding or replacement.
The sign board face shall be washed with water Response Time
and detergent and the bullet holes and other
minor dents shall be repaired with self adhesive Road signs shall be repaired or
reflective tapes. replaced within one week of them R
being damaged. O
A
D
F
U
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N
I
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U
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TRAFFIC SIGNALS
Monthly Routine Maintenance
• Inspect controller and cabinet for proper

operation.
• Check operation of the fan.
• Inspect all vehicular and pedestrian

signals for proper operation, alignment,
visibility and replace outages found.
• Check operations of all pedestrian

pushbuttons.
• Verify correct clock settings in the

controller, correct as needed.
• Visually check for wear and function of

controllers.
• Inspect illuminated street name signs for

proper operation, including lamps and
photocells.
• Test emergency/transit pre-emption.
• Check that intersection is adequately

serving traffic demands.
• Complete maintenance checklist, noting

any comments.
• Manually record inspection date and

time in controller cabinet, file checklist R
and send written confirmation of O
monthly inspection with
recommendations by intersection. A
D
3 – Month Routine Maintenance
F
(In addition to Monthly Routine Maintenance)
U
R
• Visually inspect roadway along loop
detectors for possible exposed wires,
N
cracks and pot holes. I
T
• Check manual operation of supplier.
U
R
E
• Check pull box covers.
• Check controller cabinet filter.
• Note vegetation preventing access to or

visibility of traffic controls.
• Check detector amplifiers and tune if

needed.
• Manually record inspection date and

time in controller cabinet and send
written confirmation of 3-month
inspection with recommendations by
inspector.
6 – Month Routine Maintenance

(In addition to Monthly Routine Maintenance and
3-Month Routine Maintenance)
• Check ground rod clamp and wire.
• Check wire schematics and records to

make sure they are in the cabinet.
• Check operation of ground fault

receptacle.
• Measure voltage at service inputs in

cabinet and record.
• Visually check integrity of splices.
• Verify controller signal timing plans

against the time sheet. Forward any
discrepancies to the
engineer/operations department.
R
• Test the battery back-up system.
O
• Manually record inspection date and A
time in controller cabinet and send D
written confirmation of 6-month
inspection with recommendations by
inspector. F
U
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N
I
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U
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Yearly Routine Maintenance

(In addition to Monthly Routine Maintenance,
3-Month and 6-Month Routine Maintenance)
• Clean and polish all lenses and

reflectors, as needed.
• Test the conflict monitor unit.
• Vacuum and clean controller cabinet

and contents.
• Replace cabinet filter.
• Check weatherproof gasket seal on

controller cabinets.
• Check for water accumulation and duct

sealant.
• Lubricate hinges and lock on controller

cabinets.
• Check indicator lamps.
• Check all connectors.
• Check detector extensions.
• Check load switches.
• Check relays.
• Verify flash rate.
• Spot check LED luminosity.

R
• Manually record inspection date and O
time in controller cabinet and send
written confirmation of yearly inspection
A
with recommendations by inspector. D
F
U
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N
I
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U
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DELINEATORS
Description
The delineators are there to assist the road user

identify the boundary of pavement – shoulder
edge or median kerb line. They are extremely
useful in the night time, during rain, and even in
a foggy weather.
The delineators also help drivers identify median

openings.
Treatment
Damaged delineators shall be repaired if

possible, or else replaced.
Dirty delineators shall be cleaned regularly.

When cleaning does not help, they shall be
washed or painted. Missing reflectors shall be
replaced.
Missing delineators shall be re-installed.
Response Time
The damaged, dirty, or missing

delineators shall be repaired,
cleaned, painted or replaced as a
routine maintenance activity.
R
O
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F
U
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ROAD LIGHTING
Description
Road lighting works include the wiring

(sometimes underground, sometimes
overhead), street light poles, brackets and the
bulbs. It also includes distribution boxes, and the
MCBs, etc.
The possible faults in the street lighting could be

fused bulbs, corrosion of street light poles,
peeling or cracking in the paint, snapped
cables, or broken glass covers. Several times
flying insects also get trapped inside the glass
cover and block the light coming onto the road.
The street light poles may get damaged due to

accidents and in such cases the bulbs, brackets
and the pole foundation also may get
damaged.
Treatment
Fused bulbs shall be replaced. Accident

damaged items shall be repaired, painted and
re-erected as far as possible. Whenever the
repairs are not possible they shall be replaced.
Whenever the flying insects enter the glass, the
sealing shall be removed and resealed after
cleaning.
R
Response Time O
A
Fused bulbs shall be replaced
within 24 hours. Accident D
damaged items shall be repaired /
replaced within 7 days. Other
faults such as deterioration in F
paint shall be treated in U
accordance with the routine
activities. R
N
I
T
U
R
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LEVELS OF SERVICE

Page L-26
Maintenance of Highway Lighting
System
“Maintenance of all lighting installations and related

appurtenances shall be as per relevant clauses of IS: 1944
(part I - V) 1981.”

Page L-26
System
“Lighting wherever provided shall be maintained by the

Concessionaire in a condition nearly similar to original
condition.”

Page L-26
System
“The faults shall be repaired instantly and lighting

restored. Missing and damaged items shall be replaced
instantly.”

Page L-26
Maintenance of Traffic Signals
“The traffic signals shall be maintained at all times as per

clause 18 of IRC: 93 -1985 and shall be periodically R
inspected, maintained and repaired so as to be in
satisfactory working condition all the time.”
O
A
D
Page L-26
Maintenance of Highway Lighting F
System U
“Cleaning shall be done at regular intervals to be R
mentioned in the Maintenance Manual to ensure that N
lighting is not below the specified standard.”
I
T
U
R
E

Page L-26
System
“All installations shall be safeguarded against weathering

and ageing effects by repainting and other preventive
measures.”

Page L-27
System
“The servicing of stand-by power generation units shall

be carried out in accordance with the manufacturer's
instructions.”

Page L-27
Maintenance of Highway Signs and
Pavement Markings
“All traffic signs and markings shall always be kept clean,

visible and in correct alignment and position.”

Page L-27
Pavement Markings
“Any damage to traffic signs, which reduces or threatens

to reduce full and clear visibility, shall be rectified within
twenty four (24) hours of its occurrence. If they are used
as base for posters, the posters shall be removed and the
signs cleaned within 24 hours. Signs shall be washed
using detergent solution followed by clean water to
maintain their visibility and reflectivity unimpaired due to
dust etc.”
R
O
A
Page L-27 D
Pavement Markings
F
“Any part of traffic signs damaged due to weathering, U
corrosion, vandalism or any other cause shall be replaced
by the Concessionaire within seven days.”
R
N
I
T
U
R
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Page L-27
Pavement Markings
“Any mandatory signs including those for traffic safety

and toll, 'damaged beyond repair' shall be replaced
within 2 days and all other signs with similar condition
shall be replaced within 3 days.”

Page L-27
Pavement Markings
“Appropriate devices for measuring the luminosity and

reflectivity shall be used to check visibility and reflectivity
of signs, delineators and markings. These shall be
replaced by similar material if the reduction in the level of
these two requirements falls below 50% of the original
level.”

Page L-27
Pavement Markings
“Pavement marking with thermo plastic paint shall be

carried out soon after any overlay / renewal coat is
provided.”

Page L-29
Maintenance of Road Furniture and
Facilities
“Maintenance of road furniture and facilities shall

include attending to repairs to various parts of the road R
furniture and connected services as and when necessary,
and replacement of irreparable items of work in
O
reasonable period.” A
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Page L-29 F
Maintenance of Road Furniture and
Facilities U
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“All the hectometre stones, Kilometre stones and 5th Km
stones shall be kept 100% clear of obstruction; and up to N
5% surface damage shall be rectified within 3 days after I
detection and shall bring it to its original state. If the
surface damage is more than 10%, the same shall be T
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removed and replaced with new ones meeting IRC

standards.”

Page L-32
Safety Management
“The Concessionaire shall repair all damaged fencing

that prevents access to animals and pedestrians to the
highway. In addition the Concessionaire shall recommend
to NHAI for installation of additional fencing where
necessary to prevent access to the Highway”
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INSPECTION
FORMATS
INSPECTION FORMAT - ROAD FURNITURE
2 To:
SHOULDER / RoW OUTER LANE INNER LANE
BOUNDARY POSTS
STREET LIGHTS
STREET LIGHTS
UTILITY POSTS
CHAINAGE (Write
DELINEATORS
DELINEATORS
SIGN BOARDS
SIGN BOARDS
GUARD RAIL
GUARD RAIL
KM STONES
CHEVRONS
CHEVRONS
CAT EYES
sections in 25m
FENCE
25-50,.., etc.)
COMMENTS

Inspection Report
Street Lights
Rectification
S.No Date Time Report by Location Pole / Feeder Piller Possible Fault
Date Time Actual Fault
Inspection Report
Gantry Lights
Rectification
S.No Date Time Report by Location Pole / Feeder Piller Possible Fault
Date Time Actual Fault
Chapter 8
STRUCTURES
CONTENTS PAGE NO.
INSPECTION H-1
VISUAL INSPECTION H-1
DETAILED INSPECTION H-2
THOROUGH INSPECTION H-2
SPECIALIST INSPECTION H-3
INSPECTION PROCEDURE H-3
APPROACHES H-4
FOUNDATION H-5
SUB-STRUCTURES H-5
BEARINGS H-6
SUPER-STRUCTURE H-7
EXPANSION JOINTS H-8
WEARING COAT H-8
CENTRAL VERGE H-9
DRAINAGE SPOUTS H-9
UTILITIES H-9
AESTHETICS H-9
MEANS OF ACCESS H-9

MAINTENANCE H-11
CULVERTS H-13
LEVELS OF SERVICE H-17

Maintenance Manual – Section 2(A) INDIA PRSG MANT H - 1/18
CHAPTER 8
STRUCTURES
INSPECTION
Structures shall include the major bridge,

flyovers, underpass, minor bridge, culverts and
the plaza canopy.
Bridge Inspection shall be undertaken to ensure

safety and serviceability to the road user.
The purpose of bridge inspection can be

identified as follows:
• To provide assurance that the bridge is

structurally safe and fit for its designed
use. This refers to the gradual
deterioration of the bridge with time or
due to an accidental occurrence such
as impact, flood or overloading.
• To identify actual and potential sources

of trouble at the earliest possible stage
and propose remedial and preventive
measures.
• To record systematically and periodically

the state of the structure. This would
provide necessary information on which
decision will be made for carrying out
maintenance repairs, strengthening or
replacement of the structure.
Visual Inspection

relate to large scale works needed for structural
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maintenance like rehabilitation. Some such
inspections are carried out daily, and some
T
need to be done monthly. Such inspections
point out to accumulation of dirt / debris on the
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deck, obstructions, vegetation, blocked
scuppers, stone / soil / dirt, etc in expansion
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joints and around bearings, vegetation, blocked C
weep holes, or in backfill drainage outlets, flood
debris under bridge, wind blown debris on or T
under the bridge, railing / parapet damaged
due to accidents, paint, reflectors, etc. The U
condition of masonry / RCC / steel if any will also
be recorded while conducting the visual R
inspection. These inspections shall also indicate
recurring problems.
E
Maintenance Manual – Section 2(A) Gujarat & Rajasthan S
Visual inspection aims at a general examination

of the structures at regular intervals and the spot
having outward physical defects are repaired
immediately. The defects reported from visual
carefully.
Visual inspections must also be carried out

before and after the rains. In order to check
deterioration, the data of pre-monsoon and
post-monsoon inspection should be compared.
Visual inspection should also indicate the need
for detailed inspections during rains.
Visual inspection of the structures should record

all locations of debris, or any other irregularities
such that the locations can be identified easily.
Detailed Inspection
Detailed inspections shall be conducted

monthly or sometimes quarterly. These are
intended to note those types of defects which
will require routine maintenance.

also be required to be plotted. The
measurements (such as crack width, settlement,
etc) shall be recorded. The severity and extent
of the problem will also be recorded during such
inspections.

with a chalk, or white paint (White Snowcem
also works very well), or easily identifiable marker S
posts so that these remain easily identifiable
when the maintenance team comes to work. T
to bring forward a thorough or specialist
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inspection. U
Thorough Inspection C
Thorough inspection must be done once a year T
or two years. This is an all-inclusive inspection
and will involve close examination of elements U
of the structure. In this case a comprehensive
check list related to material, condition and R
situation of the structure is used for inspecting
the structure closely with the aid of standard E
instruments. Detailed inspection of the

foundation should also be included and it may
involve underwater inspection wherever
appropriate.
The first thorough inspection shall be done

before the defect liability period of the contract
expires but not later than six months after
completion and opening of the bridge to traffic.
This shall be followed by subsequent inspections
at intervals of maximum three years. The
observations made in the first inspection shall
serve as a benchmark for subsequent inspection
observation. More frequent inspections shall be
essential if the routine inspection reveals any
distress in the bridge structure.
Specialist Inspection
Specialist inspections shall be undertaken in the

event of unusual occurrences such as strong
earth quake, accidents, unusual loads, floods,
major weaknesses noticed during
visual/thorough inspections, unusual settlements
of foundations and substantial changes of traffic
pattern. Such inspections may require a good
deal of supplementary testing and structural
analysis. It is started from the foundations and
carried out right up to the superstructure.
Inspection procedure
The inspecting engineer should familiarize

himself with the details of the structure and as to
how it is intended to function. The earlier
inspection report should be studied so that the
condition of the defect noticed earlier can be
checked. The activity schedule during the
inspection of the bridge should be planned in
detail including the sequence of inspection. S
Advantage should be taken of any situation
which will facilitate inspection such as erection T
of scaffolding for repair work, closure of traffic
lanes for road works, etc. where mobile bridge
R
inspection unit is decided to be used for
inspection, it should be carefully planned before
U
hand so as to minimize the period of use of such
equipment as the hourly cost is high and it
C
obstructs one lane of traffic on the bridge. A T
preliminary visit to the bridge site to locate the
position of bridge inspection unit is desirable. U
Effectiveness of an inspection depends on R
proper recording of the actual state of affairs.
Every point should be noted as soon as the E
observation is made. If any previous noted

defects have been rectified the same should be
noted and recorded. The inspection should
follow a predetermined pattern to ensure that
no component is overlooked.
A typical pattern of inspection may be on the

following basis:
• Foundations
• Abutments
• Wing Walls/Returns
• Piers
• Columns And Bearings
• Soffits Of The Deck Including Beams
• Details Under The Deck
• Condition Of Road Surface, Drainage,

Parapets
• Expansion Joints
• Condition Of Approaches
• Condition Of Protective Works
Approaches
The approaches in the vicinity of the bridge shall

be inspected for unevenness, settlements if any,
cracking of the pavement, camber, longitudinal
gradient, proper functioning, of the drainage
facility, damages to the guardrails, condition of S
approach slabs, erosion or damage to the
embankments, settlement or disturbances of the T
slopes, etc. The approach slabs shall also be
examined for any untoward cracking,
R
movement away from the dirt wall and to see
that no portion rests on the wing walls /
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cantilever returns. C
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Foundation
The foundations being usually below the ground

level shall be inspected during unusual
occurrences to ascertain adequacy of the
foundation compared with the design value
and suitable remedial measure shall be
suggested if the foundations are likely to be
endangered. The Engineer shall inspect the
general condition of the foundation to ascertain
aspects like cracking, disintegration, etc. Further
investigation of the defect can be made using
non destructive tests like ultrasonic testing
system, radiography, etc.
Sub-structures (piers, abutments and wing walls)
The Engineer shall inspect the sub-structures and

the repair procedure for structure shall be
ascertained by nature of defects.
The following are general guidelines for certain

defects occurring in the substructure. However,
suitable measures shall be taken up based on
actual conditions.
a. RCC piers, abutments and wing walls for

damages due to impact, cracks, spalling
or disintegration of concrete particularly
at construction joints and at top where
the superstructure rests. The spalled or
cracked section shall be checked to
ascertain upto what extent guniting or
reintegration by rich cement mortar or
epoxy mortar could be done to restore
the structure to a safe condition.
b. Exposed faces of abutment for presence

of any moisture indicating inadequate S
drainage of the backfill, proper
functioning of weep holes and filter T
media forming the backfill etc. In cases
of the backfill surcharged with moisture
R
examination shall be made to suggest
other suitable drainage methods to drain
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the accumulated water immediately. C
T
c. Check for verticality by plumb bob. Any
deviation indicates uneven settlement of U
foundations. The condition of the
pointing or plastering and the condition R
of the stone and bricks; any possible
bulging or movements, etc shall be E
noted. For monitoring the settlement in

foundation and deflection in deck,
permanent survey points shall be marked
in piers, top of the median/parapet. To
assess the deflection settlement level
shall be taken by precise levelling
instruments and compared with
previously recorded data.
d. The face of the dirt wall of the

abutments of any tilting, requisite
expansion gap for movement, etc.
Bearings
All bearings shall normally be inspected during

temperature extremes and heavy rains. They
should however, also be inspected for unusual
occurrences like earthquakes, passage of
excessive traffic loads, and battering on
account of the same. While inspecting different
types of bearings the following shall be kept in
mind:
Metallic Bearings:
The metallic bearings shall be inspected to

ascertain:
1. The general condition like cleanliness,

rusting, ceasing of plates, etc.
2. The proper functioning of bearings by

observing excessive movements if any,
jumping of the guides, etc.
3. The condition of the grease / oil, when

last greased and whether it needs to be S
replaced or not.
T
4. Whether any structural cracks in the
supporting members like abutment cap,
R
pier cap, pedestal, etc. U
5. Whether the anchor bolts are in position
and not loose.
C
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As regards the normal practice for changing
grease it should be done once every 3 years U
and only neutral grease conforming to IS: 1002
shall be used. R
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Superstructure
The Engineer shall inspect the superstructure

and report in respect of the following:
Reinforced Concrete Members
In cases of asphaltic wearing surface, the real

condition of deck may not be visible. In such
cases large cracks in the wearing surface are
often indication of deck damage. Efforts shall
be made to examine such areas by removing
the asphaltic wearing coat. Often the inside of
the deck also reveals the area of distress or
deterioration and thorough examination of the
same should be resorted to. Any evidence of
water passing through the cracks of the deck
shall be recorded. As a remedial measure it is
normal practice to repair cracks by grouting or
guniting with epoxy mortar.
Prestressed Concrete Members
The prestressed concrete members shall be

examined for loss of camber, excessive
deflection, distress due to buckling, cracking
and deterioration of concrete, cracking or
spalling in the area around the bearings and at
cast-in-situ diaphragms where creep and
humping of the girders may have an effect that
must be looked for. Where cracking is found,
location and size shall be noted and markers
installed to watch their future development. The
end anchorages shall be examined for water
tightness and corrosion of pre-stressing wires.
Structural Steel Members S

The structural steel members like trusses, girders, T
stringers, railings, etc. shall be checked for
corrosion, cracking, condition and looseness of
R
any holds, rivets and welds in connections, etc.
The flanges and webs of all sections shall be
U
checked for damage, misalignment and the
web stiffness for buckling. All joints shall be
C
checked for their worthiness. The bolted joints of T
new bridges shall be tightened after one year of
service. All components of the truss members U
must be checked in respect of alignment and
any kinks and bow in the members. Any R
eccentricity in the connecting details shall be
recorded. The bracing shall be examined for E
any traffic damage and whether they are

properly adjusted and functioning satisfactorily.
Any loss of camber in the main girders assessed
from comparative reading shall be recorded.
The condition of paint shall be examined and

the extent of corrosion if any recorded. The
paint shall never be allowed to deteriorate to
the extent that rusting occurs. Since the
connecting details are more susceptible to
corrosion more detailed examination of these
units shall be done specially looking for
deformation in reverted or bolted multiplate
section where moisture may have entered and
corroded the plates. Earth, leaves and any
debris at the member/joints shall be indicated
for removal, as these hasten the corrosive
action. Unusual vibrations if observed shall be
recorded.
Expansion Joints
Expansion Joints shall be inspected in respect of

the following:
1. Whether the joints are functioning

properly and the expansion gap is
adequate for thermal movement
2. Cracks if any in the deck in the

neighbourhood of the expansion joints
3. Condition of sealing material, secureness

of the joints, the condition of top sliding
plate and whether corroded or not
4. Debris in open type joints, resulting in

lack of expansion gaps
5. Rattling of joints S
T
Wearing Coat
R
1. The surface condition i.e., whether there
are any cracks, spalling of concrete,
U
disintegration, potholes, etc. C
2. Riding quality and the road worthiness T
with respect to slipperiness, bumps,
unevenness, etc. U
3. Evidence of wear by providing rings and R
checking the existing thickness of the
E
wearing coat against the designed

thickness.
Central Verge
The RCC crash barrier shall be inspected for

cracks, spalling, scaling, deterioration in the
concrete and any damage due to traffic.
Drainage Spouts
The Engineer shall inspect the entire drainage

system to ascertain its proper functioning and
whether some additional facilities have to be
provided. The drainage spouts shall be checked
for deterioration and damage. The projection of
the drainage spouts on the inside of structural
members shall also be checked to see that the
structural members are not damaged.
Utilities
Inspections shall report leakage of water and

sewage pipes, damage to telephone and
electric cables, the condition of lighting
facilities as well as any other damages to other
utilities.
Aesthetics
The inspecting officer shall report any visual

intrusion of bill-boards, paints on structural
members, etc.
Means of Access
Appropriate means of access are a prerequisite

for bridge inspection. For every means of
access, special emphasis shall be laid on safety,
ease and convenience. S
The possible means of access can be of T
following types
R
Semi mobile access U
a. Access ladders C
b. Manholes T
c. Hand-rails U
d. Catwalks R
e. Platforms E
f. Inspection kits
g. Provision for setting up planking,

scaffoldings etc.
h. Fixtures and provisions for

operation of semi-stationary
inspection equipments
Mobile equipment
a. Equipment operating under the

bridge (travelers) from the
ground.
b. Equipment operating from the

bridge deck (snoopers).
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MAINTENANCE
Maintenance of structures includes cleaning

debris on the deck, or other parts of the
structures, silting, and vegetation such that all
structural surfaces are clearly visible and
accessible at all times.
Maintenance of structures also includes Response Time

obstructions to the flow of water, expansion
joints on the bridges, scuppers, weep holes, Many of the tasks of maintenance of
railing / parapets, utilities crossing over the structures are fairly minor in themselves, but
bridge, etc. failure to carry them out may lead to
deterioration of the structure, and the need
Attending to any form of distress such as cracks, for more serious repair operations in the
spalling of any elements is also part of future.
maintenance of structures.
Maintenance requirements shall be built into
Erosion of the banks near bridges or culverts, program of routine maintenance, except
and of the river bed under the bridges shall also when the damaged element is protruding on
be maintained. to the pavement and is a hazard to the
traffic.
Cleaning / Clearing
Any damage of serious nature to a structure
may also require closure of the road and
Debris from over or under the structures shall be diversion of traffic through the RoW, or on to
cleaned such that the surface of concrete / the other carriageway.
steel is visible all the time.
Vegetation shall also be removed periodically

so that it does not cause any obstruction to the
flow of water.
Silt and debris removed from the inlet and outlet

areas shall be deposited and spread neatly in
the close proximity of the inlet and outlet areas
where it cannot wash back or, if necessary,
loaded and transported to spoil at dumping
areas.
S
Expansion Joints
T
Expansion joints on the bridges shall be kept
clean at all times. The debris shall be removed
R
regularly. Any rattling of the joints shall be an
indication for thorough inspection and
U
treatment according to the findings. C
Any missing sliding plates on the expansion joint T
on the walkways shall be reinstalled. Painting of
metallic elements which are prone to corrosion U
shall be painted periodically.
R
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Bearings
Bearings shall be replaced as and when it is

required.
Parapets / Railings
These will be cleaned periodically. Any cracks

will be filled up. Loose nuts or bolts will be
tightened. Distorted elements shall be repaired.
Missing items would be reinstalled. Corroded
elements shall be cleaned thoroughly and
painted. Broken or missing concrete / masonry
elements shall be repaired / reinstalled.
Drainage Spout
Prior to every monsoon, the drainage spout shall

be cleaned properly so that water logging on
the deck can be avoided. During the rainy
season, the drain spout shall be inspected every
week and if necessary cleaning of debris shall
be carried out. If water gets logged inside the
expansion joint, it shall be removed every
alternate day else there are chances of
deterioration.
Utilities
Many times one or more utilities cross over the

bridge. These could be water pipelines,
electrical cable, or telephone cables, etc.
Usually the cables shall also be in a pipe or
protected by other means, and may cross the
bridge along the walkway, or outside the
parapet / railing.
Any damage to these due to traffic or

accidents, or other reasons shall be set right. S
Any loose / broken supports shall be tightened /
reinstalled. T
Cracks / Spalling
R
Any cracks shall be repaired and will be under
U
observation. If they develop again or if they are
widening, thorough inspection will be arranged.
C
T
Any honey combing shall be repaired.
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CULVERTS
Culvert maintenance is undertaken to extend

the life of the structure and to ensure that it
functions as designed, thus ensuring public
safety. Culvert maintenance includes the
removal of accumulated material and debris
(e.g., logs, boulders, garbage) that prevents the
efficient passage of water through the structure.
Culvert maintenance may also include the
reinforcement of eroding inlets and outlets.
Poorly working culverts can cause flooding that

significantly damages roads and bridges. A
crushed or plugged culvert allows water to back
up in roadside ditches, even during normal wet
weather. This contributes to road deterioration
because standing water prevents drainage
from the road base and subgrade.
Culverts should be inspected regularly

especially before and after monsoon.
General Maintenance of the Culvert includes:
• Removing blockages
• Clean and flush the length of the

pipe
• Cut and remove trees and branches

that threaten to fall and block
upstream ditches
• Establish vegetation on bare slopes

at the pipe ends
• Add fill to cover pipe more S

thoroughly
T
CULVERT ENDS
R
U
1. Scouring or erosion at the inlet C
Cause T
• Ditch is too steeply graded. U
• Pipe is poorly located or aligned. R
• No headwalls. E
• Pipe is clogged.
Treatment
Line the inlet with stone. Realign the pipe.

Install headwalls. Clean and flush the pipe.
2. Scouring or erosion at the outlet
Cause
• Pipe is sloped too much
• No endwalls or aprons
• Outlet velocity is too high
Treatment
Build a stone splash pad. Install endwalls or

aprons. Check design and replace pipe.
3. “Ponded” water
Cause
• Inlet is too high
• Ditch grade is too flat
Treatment
Match the inlet to the channel bottom. Reset

the pipe and/or raise the channel.
Re-grade the ditch to maintain correct flow.
4. Dented or crushed ends S

Cause T
• Vehicles are hitting the ends
R
Treatment
U
Fix, mark, and protect the pipe ends.
C
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5. Heavy Corrosion
Cause
• Water flowing through the pipe is acidic
Treatment
Install a sleeve of PVC in the pipe, or replace

with a PVC or concrete pipe.
6. Piping around outlet
Cause
• Pipe is incorrectly installed, causing

water to flow along the outside surface
of pipe
Treatment
Reinstall the pipe on suitable, properly

compacted bedding. Install a headwall or
entrance device.
INSIDE CULVERTS
1. Sediment Buildup
Cause
• Pipe carrying sediment inefficiently

Objects blocking the pipe to the culvert
Treatment S
Determine sediment source and install erosion T
prevention measure to reduce sediment.
Redesign and install pipe to carry sediments
R
through it. Debris is traveling from the ditch.
Remove the blockage. Install check dams
U
upstream of the culvert. C
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2. Sagging Bottom
Cause
• Foundation material has settled or has

low bearing capacity
Treatment
Reinstall the pipe on suitable, properly

compacted bedding.
3. Crushed Top
Cause
Cover is inadequate. Soil around pipe isn’t

compacted sufficiently and/or traffic load is too
great
Treatment
Add cover. Reinstall the pipe more deeply, and

use suitable, properly compacted bedding and
backfill. Install multiple small pipes or a pipe with
a different shape. Replace pipe with a stronger
one.
4. Heavy Corrosion
Cause
Water flowing through the pipe is acidic
Treatment S
Install a sleeve of PVC in the pipe, or replace T
with a PVC or concrete pipe.
R
Plaza Canopy U
Plaza Canopy will require periodical
C
maintenance such as tightening of nuts,
welding, painting and sometimes setting right
T
distortions. U
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LEVELS OF SERVICE
1. Schedule L Clause 2.1.11 (b) (ii)

Page L-4
“For the road that crosses an overhead bridge, and the

bridge is not a part of an interchange, the Concessionaire
shall be responsible for maintenance of the surface of the
bridge, joints repairs, drainage linked to the bridge and
its abutments.”

Page L-22
Cross Drainage Structure and Other Works
“The scouring of piers and abutments of bridges and

culverts shall be observed carefully particularly before
and after rainy season and suitable remedial measures as
deemed fit looking to site conditions shall be taken in
consultation with IC.”

Page L-22
“The bridge deck must be clean and have minimal spalls,

cracks or scaling. The drains / scuppers on the deck must
be clean and functional always.”

Page L-22
Cross Drainage Structure and Other Works S
T
“The Super-structure should not have any cracks or loss
of section. There should be no spalling and have proper
R
vertical clearance and opening height. Paint on the super
structure must be in good shape.”
U
C
Page L-22
T
Cross Drainage Structure and Other Works U
“The sub-structure should not have spalls, cracks and
R
scaling. The bearing assembly should be functional and E
lubricated periodically. Abutment / pier seats should be

clean and sound.”

Page L-22
“The joints on the structures shall not be loose and should

be sealed always.”

Page L-22
“Retaining walls should not have spalling or cracks and

its weep holes must be open always. There should be no
indication of settlement or rotation.”

Page L-22
“If any settlement cracks are appearing in substructure

and superstructure of the CD works beyond permissible
limits, the same shall be carefully observed and suitable
remedial measures as per sound engineering practice
taken.”

Page L-22
“The treatment for the damaged culverts / bridges shall be S

assessed at site after ascertaining the damaged portion as
per site exigencies. The repair shall be carried out T
expeditiously in consultation with IC.”
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INSPECTION
FORMATS
INSPECTION FORMAT BRIDGE – VISUAL
(From IRC SP 18: Manual for Highway Bridge Maintenance Inspection)
1. General
1.1 Name of bridge/No. of the bridge,
name of the river
1.2 Name, No. of Highway, Bridge
location
2. Type of Bridge
3. Last Date of Inspection
4. Approaches
4.3 Erosion of embankment by rain cuts
or any other damage to
embankment.
4.4 Approach slab (report settlement,
cracks, movement, etc.)
6 Waterway
6.1 Presence of obstruction,
undergrowth, etc.
6.3 Any abnormal change in flow
pattern
6.4 Maximum flood level observed
during the year and mark the same
on the pier/abutment both on the
U/S and D/S
8 Piers, abutments and wing walls

8.1 Efficiency of drainage of the backfill
behind abutments (check
functioning of weep holes, evidence
of moisture on abutment faces, etc.)
8.2 Cracking, disintegration, decay, etc.
10 Superstructure
10.1 Reinforced concrete and
prestressed concrete members
10.1.1 Report spalling, disintegration or
honey combing etc.
10.1.2 Report cracking (pattern, location,
explain preferably by plotting on
sketch)
10.1.3 Report corrosion of reinforcements
if any
10.1.4 Report damages if any due to
moving vehicles
11 Expansion joints
11.1 Functioning (report cracks in deck in
the existing gap and approximate
temp.
11.2 Report condition of sealing material
(for neoprene sealing material,
check for splitting, oxidation, creep,
flattering, bulging and for bitumen
filler, check for hardening, cracking
etc.)
11.3 Report secureness of the joints
11.4 Top sliding plate (report corrosion,
damage to welds, etc.)
11.5 Locking of joints (report locking of
joints especially for finger type
expansion joints)
11.6 Check for debris in open joints
11.7 Report rattling, if any
12 Wearing Coat (concrete/bitumen)

12.1 Report surface condition (cracks,
spalling, disintegration, pot – holes,
etc.)
12.2 Report evidence of wear (tell- tale
rings, check for thickness, report
date of last inspection)
13 Drainage spouts
13.1 Check clogging, deterioration and
damage, if any
14 Handrails
14.1 Report general condition (check
expansion gaps, missing parts, if
any, etc.)
14.2 Report damage due to collision
14.3 Check alignment (report any
abruptness in profile)
15 Utilities
15.1 Report leakage of water and
sewage pipes
15.2 Report any damage by telephone
and electric cables
15.3 Report condition of lighting facilities
15.4 Report damages due to any other
utilities
16 Bridge Number
16.1 Report condition of painting
17 Aesthetics
17.1 Report any visual intrusion (Bill-
boards, paints on structural
members, etc)
Date: Signature
Designation of the
Inspecting officer.
Note: The numbering above is not in sequence because same order as on the detailed inspection format has been
retained for the purpose of easy of matching data/information.
PROFORMA FOR BRIDGE INSPECTION - DETAILED
(From IRC SP 18 : Manual for Highway Bridge Maintenance Inspection)
1. General
1.1 Name of bridge/No. of the bridge,
name of the river
1.2 Name, No. of Highway, Bridge
location
2. Type of Bridge
4. Approaches
4.1 Condition of Pavement surface
(Report unevenness settlement,
cracking, pot-holes, etc.)
4.2 Side slopes (report pitched or
unpitched, condition of
pitching/turfing any sign of slope
failure, etc.)
embankment.
4.5 Approach geometric (report whether
it satisfies the standards as in force)
5. Protective works
5.1 Type (mention whether guide bund
or protection around abutments or
spurs)
5.2 Damage of the layout, cross section
profile (check whether the layout
and the cross – sections are in
order)
5.3 Condition of slope pitching, apron
and toe walls indicating the nature
of damage if any (check for proper
slope, thickness of pitching in the
slopes, width and thickness of
apron, erosion of toe walls, etc.)
5.4 Condition of floor protection works,
indicate nature of damage if any,
(condition of impervious floor,
flexible apron, curtain walls etc.)
5.5 Extent of scour (report any
abnormal scour)
6 Waterway
undergrowth, etc.
6.2 Maximum observed scour and
location and compare with the
design values
pattern
U/S and D/S
6.5 Abnormal afflux if any
6.6 Adequacy of waterway
7 Foundations
7.1 Settlement if any
7.2 Cracking, disintegration, decay,
erosion, cavitation, etc.
7.3 Damage due to impact of floating
bodies, boulders, etc
7.4 For sub – ways report seepage if
any, damage to the foundations,
etc.
8 Piers, abutments and wing walls

8.1 Efficiency of drainage of the backfill
behind abutments (check
functioning of weep holes, evidence
of moisture on abutment faces, etc.)
8.2 Cracking, disintegration, decay, etc.
8.3 For subways, report condition of
side retaining walls like cracking,
disintegration, etc, seepage, if any
9 Bearings
9.1 Type of bearings
9.1.1 Report general condition (check
rusting, cleanliness, ceasing of
plates)
9.1.2 Functioning (report excessive
movement, tilting, jumping off
guides)
9.1.3 Greasing / oil bath (report date of
last greasing/ oil bath and weather t
be redone or not)
9.1.4 Report cracks in supporting
member (abutment cap, pier cap,
pedestals)
9.1.5 Report effectiveness of anchor bolts
(check whether they are in position
and tight)
9.2 Concrete bearing
9.2.1 Report any signs of distress
(cracking, spalling, disintegrating)
9.2.2 Report any excessive tilting
10 Superstructure
10.1 Reinforced concrete and
prestressed concrete members
honey combing etc.
sketch)
if any
moving vehicles
10.1.6 Report perceptible vibrations if any
10.1.7 Report excessive deflections or loss
of camber if any (measure at same
point each time)
10.1.8 Report cracks in end anchorage
zone (for prestressed concrete
members)
10.1.9 Report deflection at central hinge,
tip of cantilever bridges
11 Expansion joints
11.1 Functioning (report cracks in deck in
the existing gap and approximate
temp.
11.2 Report condition of sealing material
(for neoprene sealing material,
check for splitting, oxidation, creep,
flattering, bulging and for bitumen
filler, check for hardening, cracking
etc.)
11.3 Report secureness of the joints
11.4 Top sliding plate (report corrosion,
damage to welds, etc.)
11.5 Locking of joints (report locking of
joints especially for finger type
expansion joints)
11.6 Check for debris in open joints
11.7 Report rattling, if any
12 Wearing Coat (concrete/bitumen)

12.1 Report surface condition (cracks,
spalling, disintegration, pot – holes,
etc.)
12.2 Report evidence of wear (tell- tale
rings, check for thickness, report
date of last inspection)
13 Drainage spouts
damage, if any
13.2 Check the projection of the spout on
the underside (see whether
structural members are being
affected)
13.3 Report adequacy, thereof
13.4 For sub-ways report about
adequacy of pumping
arrangements, etc
14 Handrails
any, etc.)
15 Utilities
sewage pipes
and electric cables
utilities
16 Bridge Number
17 Aesthetics
members, etc)
18 Report whether maintenance

recommended during last inspection
has been done or not (give details)
19 Maintenance and improvement

recommendations
20 Certificate to be accorded by the

inspecting official.
Certified that I have personally

inspected this bridge.
Date: Signature
Designation of the
Inspecting officer.
INSPECTION FORMAT CULVERT - VISUAL
(Based on IRC SP 18: Manual for Highway Bridge Maintenance Inspection)
1. General
1.1 Name of culvert/No. of culvert
1.2 Name, No. of Highway, Culvert location
2. Type of Culvert
4. Approaches
4.1 Condition of Pavement surface (Report unevenness
settlement, cracking, pot-holes, etc.)
4.2 Side slopes (report pitched or unpitched, condition of
pitching/turfing any sign of slope failure, etc.)
4.3 Erosion of embankment by rain cuts or any other
damage to embankment.
4.4 Approach slab (report settlement, cracks, movement,
etc.)
5 Superstructure
5.1 Parapets
5.1.1 Report cracks, damage, etc.
5.1.2 Report condition of painting
6 Culvert Number
7 Aesthetics
7.1 Report any visual intrusion (Bill-boards, paints on
structural members, etc)
8 Drainage spouts
8.1 Check clogging, deterioration and damage, if any
8.2 Check the projection of the spout on the underside
(see whether structural members are being affected)

8.4 For sub-ways report about adequacy of pumping
arrangements, etc.
9 Report whether maintenance recommended during
last inspection has been done or not (give details)
10 Maintenance and improvement recommendations
11 Certificate to be accorded by the inspecting official.
Certified that I have personally inspected this bridge.
Date: Signature:
Designation of the Inspecting Officer:
INSPECTION FORMAT CULVERT - DETAILED
(From IRC SP 18 : Manual for Highway Bridge Maintenance Inspection)
1. General
1.1 Name of culvert/No. of culvert
1.2 Name, No. of Highway, Culvert
location
2. Type of Culvert
4. Approaches
4.1 Condition of Pavement surface
(Report unevenness settlement,
cracking, pot-holes, etc.)
4.2 Side slopes (report pitched or
unpitched, condition of
pitching/turfing any sign of slope
failure, etc.)
embankment.
4.5 Approach geometric (report whether
it satisfies the standards as in force)
5. Protective works
5.1 Type (mention whether wing walls)
5.2 Damage of the layout, cross section
profile (check whether the layout
and the cross – sections are in
order)
5.3 Condition of slope pitching, apron
and toe walls indicating the nature
of damage if any (check for proper
slope, thickness of pitching in the
slopes, width and thickness of
apron, erosion of toe walls, etc.)
5.4 Condition of floor protection works,
indicate nature of damage if any,
(condition of impervious floor,
flexible apron, curtain walls etc.)
5.5 Extent of scour (report any
abnormal scour)
6 Waterway
undergrowth, etc.
6.2 Maximum observed scour and
location and compare with the
design values
pattern
U/S and D/S
6.5 Abnormal afflux if any
6.6 Adequacy of waterway
7 Foundations
7.1 Settlement if any
7.2 Cracking, disintegration, decay,
erosion, cavitation, etc.
7.3 Damage due to impact of floating
bodies, boulders, etc
7.4 For sub – ways report seepage if
any, damage to the foundations,
etc.
8 Superstructure
8.1 Reinforced concrete members
honey combing etc.
sketch)
if any
moving vehicles
9 Handrails/parapets
any, etc.)
10 Drainage Spouts
damage, if any
10.2 Check the projection of the spout on
the underside (see whether
structural members are being
affected)
10.4 For sub-ways report about
adequacy of pumping
arrangements, etc.
11 Utilities
sewage pipes
and electric cables
utilities
12 Bridge Number
13 Aesthetics
members, etc)
14 Report whether maintenance
recommended during last inspection
has been done or not (give details)
15 Maintenance and improvement
recommendations
16 Certificate to be accorded by the
inspecting official.
Certified that I have personally
inspected this Culvert.
Date: Signature
Designation of the
Inspecting officer.
Chapter 9
BUILDINGS
CONTENTS PAGE NO.
INTRODUCTION I-1
VISUAL INSPECTION I-1
DETAILED INSPECTION I-2
TOLL PLAZA AND PLAZA BUILDING I-4
TOLL BOOTHS I-5
BUS BAYS AND SHELTERS I-6
TRUCK LAY BYE I-6
FIXTURES, FURNITURE AND FITTINGS I-7
ELECTRICAL SYSTEMS I-8
AIR CONDITIONING SYSTEM I-9
LIGHTING I-9
WATER SUPPLY SYSTEMS I-10
STORM WATER DRAINAGE SYSTEM I-11
SEWERAGE AND WASTE WATER DISPOSAL I-12
ACCESS ROADS AND PARKING AREAS I-13
LEVELS OF SERVICE I-14

Maintenance Manual – Section 2(A) INDIA PRSG MANT I - 1/15
CHAPTER 9
BUILDINGS
INTRODUCTION
The section includes the toll plaza, plaza

building, toll booths, bus bays and shelters and
truck lay bye. Each building besides the civil
works also includes the electrical, HVAC, fire
and smoke, security, drainage, water supply,
sewerage and waste disposal systems. The plaza
also includes the approaches, the islands, the
lanes, the kerbs, lighting, drainage, etc. Litter
and debris shall be cleaned in and around the
Bus Bay and Shelter at least once every day, or
more frequently if required. The pavement
surface will be swept everyday and any oil spill
shall be cleaned using sawdust, lime and soapy
water as required at least once a week.
Visual Inspection

relate to large scale works, which would be
classed as, or linked to, structural maintenance
like rehabilitation. These will be carried out
weekly except for the booths which will be
inspected on a daily basis. Such inspections
point out to cracks, loose plaster, fading or
peeling off of paint or polish, improper fitting or
creaking of doors and windows, improper
working of locking devices, broken glass panes,
missing items, etc.
These inspections will also point out to the

malfunctioning of any control devices in various
equipment or services in the buildings. B
Also, the defects reported from visual U
detailed inspections need to be done more I
carefully.
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Visual inspection of the buildings should record
all locations of cracks, settlements, loose plaster,
or any other irregularities. However exact
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Detailed Inspection
The detailed inspections are intended to note

those types of defects which will require routine
maintenance, and not to establish general
structural condition of the building. These will be
carried out quarterly except in case of toll
booths which will have detailed inspections
done monthly. They may indicate recurring
problems.

to bring forward a thorough inspection which
done once a year will be sufficient.
Detailed inspections should record exact

locations of defects such as cracks, settlements.
also require to be plotted, such as development
of cracks, or bulging of walls, or settlement of
floors, etc. The measurements (such as crack
width, settlement, rut depths, etc) shall be
recorded on the formats. The severity and
extent of the problem will also be recorded
Whenever any defects which are noticed but

are not visible easily (such as very thin cracks,
floor settlements, etc) will be marked on the
field with a chalk, or white paint (white
snowcem also works very well) such that these
remain easily identifiable when the
In buildings the work is generally short term or

periodic to maintain buildings and other facilities
in good working order. It also includes
replacement or renewal of those elements of
the facilities which, over a longer term,
becomes unserviceable due to general wear
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and tear. U
The following elements are included in the
buildings:
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• Toll Plaza and Plaza Building
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• Toll Booths
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• Bus Bays and Shelters
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• Truck Lay bye
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• Electrical System including external

lighting
• HVAC
Response Time
• Fire and Smoke
In the event of an emergency occurring in
• Water Supply System any of the buildings or facilities it is essential
for maintenance personnel to respond as
• Drainage System quickly as possible in order to minimize any
danger to occupants or users or further
• Sewerage and Waste Disposal deterioration.
• Access Roads and Parking Areas To achieve response times and levels of
service, sufficient suitable labour, plant and
equipment will be utilized to enable prompt
• Fixtures, Furniture and Fittings
response to emergencies.
• Security
The maintenance guidelines may not be

appropriate to all circumstances and there
might be instances where they will have to be
modified to take account of specific conditions.
Variations will be implemented where the need
for such a variation is clearly justified.
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TOLL PLAZA AND PLAZA BUILDING

the Toll Plaza at least once every day, or more
frequently if required. It will be necessary to
make sure the traffic islands, etc are thoroughly
cleaned everyday. The pavement surface will
be broomed everyday and any oil spill shall be
cleaned using sawdust, lime and soapy water as
required at least once a week. Any damage to
the plaster would be repaired and repainted to
match the existing finish. Cracks would be filled
up and watched for re-development if any.
Paint and polish peeling off or fading in
localized areas will be attended to. Periodic
painting shall be done.
Operational elements such as doors, locks, door

closers, etc will be attended to periodically. Any
doors which are loose or when locks do not work
properly will be quickly repaired. Broken glass
panes will be replaced immediately.
Stair railings must be secure at all times.
Presence of vermin if any will be treated in

according to specific case and depending on
extent and severity.
Any settlements in the floors call for major repair.

These will be attended to according to specific
cases.
Waterproofing will require special attention. Any

water leak or moisture ingress through roof,
walls, floors, or through window jambs shall be
repaired. B
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TOLL BOOTHS
The booths will be thoroughly cleaned with dry

cloth and broom everyday. Any damage to the
plaster would be repaired and repainted to
match the existing finish. Cracks would be filled
up and watched for re-development if any.
Paint and polish peeling off or fading in
localized areas will be attended to. Periodic
painting shall be done.
Operational elements such as doors, locks, door

closers, etc will be attended to periodically. Any
doors which are loose or when locks do not work
properly will be quickly repaired. Broken glass
panes will be replaced immediately.
Waterproofing will require special attention. Any

water leak or moisture ingress through roof,
walls, floors, or through window jambs shall be
repaired.
Visibility of approach through the window of the

booth shall always be maintained. Any
obstruction on the islands which inhibits line of
visibility shall be removed / repaired without
delay.
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BUS BAYS AND SHELTERS

the Bus Bay and Shelter at least once every day,
or more frequently if required. The pavement
TRUCK LAY BYE

the Truck Lay bye at least once every day, or
more frequently if required. The pavement
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FIXTURES, FURNITURE AND FITTINGS
This section relates to all fixtures, furniture and

loose fittings in all types of buildings within the
toll plaza and plaza building area in respect of
the condition of the items and their functionality.
A record of all fixtures, furniture and loose fittings

in all the buildings, is kept in the database
inventory.
Inspection of fixtures, furniture and loose fittings

will be conducted annually. They should be
coordinated as far as possible with the periodic
Inspection of other items of building inspection.
Periodic Inspections shall include but not be
limited to inspections for correct operation;
broken items; missing loose items and cleanliness
and serviceability of items. Defects to items
requiring repair or replacement, and the action
taken will be recorded.
Additional inspections may be necessary

following user or occupier complaints.
All fixtures, furniture and loose fittings in all

buildings in respect of the condition of the items
and their functionality shall be maintained in top
class.
Maintenance of specialized items shall be in

accordance with the manufacturer’s
recommendations for each item.
Depending upon the needs a carpenter,

polisher or other tradesmen will be called from
the open market and the maintenance shall be
done. Record of all such activities shall be B
maintained.
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ELECTRICAL SYSTEMS
This section deals with the maintenance of

systems for provision and distribution of power
supplies to buildings and facilities in respect of
the condition of the items and their functionality.
The power supply to all building installation is

supplied by the State Electricity Board. In the
event of mains power failures, generators are
provided for back up power supply.
A record of all power distribution installation

including stand by generators, electrical wiring,
installations and equipment will be maintained.
The record, preferably in the form of schematic
and layout plans, will supplement information
held on the inventory by providing details of all
associated installations. The record will be
reviewed annually and amendments made as
required.
Periodic Inspections of the main control and

sub-distribution panels will be carried out every 6
months. Periodic Inspections shall include but
not be limited to inspections of general wiring,
fuses and switches for deterioration; ingress of
water; corrosion; signs of arcing; loose
connections and cleanliness and serviceability
of items. In addition, the cabinets containing
sub distribution panels will be checked at
intervals of 1 week for security and
weatherproofing. Inspections of generators will
be in accordance with the manufacturer’s
recommendations. Additional inspections may
be necessary following severe weather or
seismic activity.
Maintenance of generators and other B

specialized electrical equipment will be in
accordance with the manufacturer’s U
recommendations.
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Maintenance record data sheets will be
maintained for regular upkeep. L
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AIR CONDITIONING SYSTEM
Inspections of the air conditioning units will be

carried out annually. Periodic Inspections shall
include but not be limited to inspections for
correct operation, broken or missing parts,
cleanliness of filters and presence of insect
screens.
Additional inspections may be necessary

following high winds or sand storms where wind
blown debris may block filters or damage
screens.
Inspection of air conditioning units will be in

accordance with the manufacturer’s
recommendations.
LIGHTING
Inspections of external lighting will be carried

out at intervals of 3 month in respect of
operation (outages) and safety of fittings.
Additional inspections will be carried out at

intervals of 1 year in respect of structural
condition. These will include but not be limited
to condition and paint finish of posts and
lanterns; post foundations and fastenings;
brackets or other fixings and condition of
electrical equipment.
Additional inspections of post foundations may

be necessary after severe winds or heavy rain.
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WATER SUPPLY SYSTEMS
This section relates to the maintenance of water

supply systems, including extraction, storage
and distribution. It does not relate to pipe work
and fittings or other installations within buildings
or other facilities.
Daily visual checks of the extraction, storage

and filtration unit will be made for water clarity
and water levels. The water supply system,
including extraction, purification, distribution
and storage facilities will be inspected annually.
Daily observations for possible leakage shall
generally be user led. Electrical installations
associated with water supply system will be
inspected every year by a qualified electrician.
Periodic Inspections are designed to note not
only those types of defects likely to require
routine maintenance but also to establish
general structural condition.
Additional inspection may be necessary

following severe weather or seismic activity.
A record of all water supply installations

including tube wells and both underground and
surface mounted pipes will be maintained. The
record, preferably in the form of schematic and
layout plans, will supplement information held
on the inventory by providing details of water
supply installations. The record will be reviewed
annually and amendments made as required.
Storage tanks will be cleaned every 6 months. In

addition, at the same interval, electric pumps
will be maintained in accordance with
manufacturer’s documentation. B
All the taps and fittings will be checked and
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repaired/replaced periodically and will be
maintained in proper operational condition all
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the time. Storage tanks will be cleaned every 6
months.
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In addition, at the same interval, electric pumps
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will be maintained in accordance with
manufacturer’s documentation.
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A record of all installations, both underground
and surface mounted, will be maintained. The G
record will be reviewed annually and

amendments made as required.
Depending upon the needs a plumber or other

tradesmen will be called from the open market
and the maintenance shall be done
periodically. Record of all such activities shall be
maintained.
STORM WATER DRAINAGE SYSTEM
Inspections of storm water drainage will be

carried out every 6 months. Periodic Inspections
shall include but not be limited to inspections of
damage to brickwork or concrete; loose bricks;
silt or other debris.
Additional inspections may be necessary after

severe weather or heavy rain.
The part of a system that habitually gives

problem is known and may need to be
inspected more frequently than normal.
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SEWERAGE AND WASTE WATER DISPOSAL
This section relate to the maintenance of

sewerage and waste disposal from buildings
and facilities in respect of the condition of the
items and their functionality.
Condition of all the installations of sewerage

and waste disposal from buildings and facilities
and their functionality will be maintained at all
the times.
A record of all sewer and drainage pipes,

manholes and chambers and other installations
will be maintained. The record in the form of
layout plans, will supplement information held
on the inventory by providing details of
sewerage installations. The record will be
reviewed annually and amendments made as
required.
Inspections of manholes and inspection

chambers will be carried out every 6 months.
Periodic Inspections shall include but not be
limited to inspections of damage to brickwork or
concrete; missing covers and accessibility for
emptying.
In addition, the tanks should be checked

monthly to ensure they can be emptied before
they reach capacity.
The septic tanks will be emptied on an as needs

basis dependant on occupation and usage of
the facilities. The frequency will be determined
by monthly inspections.
Blockages shall be cleared by rodding or B

otherwise, as necessary.
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Depending upon the needs a plumber or other
tradesmen will be called from the open market I
and the maintenance shall be done. Record of
all such activities shall be maintained. L
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ACCESS ROADS AND PARKING AREAS
This section relates to the paved access roads

and parking areas within the buildings and
facilities in respect of the condition of the items
and their functionality. Access roads to the
facilities are generally constructed of
herringbone brick on edge. Footpaths and
other paved areas may be constructed of brick,
concrete or pre cast flags.
A record of all paved access roads and parking

areas will be held on the inventory. Inspections
of paved access roads and parking areas will
be carried out every 6 months. Periodic
Inspections shall include but not be limited to
inspections of damage by vehicular traffic and
loose or spalling bricks.
Additional inspections may be necessary after

Paved access roads and parking areas to

buildings and facilities in respect of the
condition of the items and their functionality will
be maintained periodically.
Litter and debris shall be cleaned on an

ongoing basis.
A record of all paved access roads and parking

areas will be held on the inventory
Special care shall be taken during and after

Parking areas shall be clearly demarcated by

white lines or by other means. B
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LEVELS OF SERVICE

Page L-27
Maintenance of Pickup Bus Stops
“Maintenance of pickup bus stops shall include attending

to repairs to the bus-bay pavement and also to various
parts of the passenger shelter and connected facilities as
and when necessary. Replacement of irreparable items
shall be done within 2 days.”

Page L-28
Maintenance of Control Centre
“There shall be periodic inspection and maintenance of

the Control Centres. This shall include attending to
repairs and maintenance (both regular and periodic) to
various parts of the building and connected services and
facilities as and when necessary, and replacement of
irreparable items of work. Cleaning & disinfecting of the
water supply systems, inspection and maintenance of
drainage / sanitation systems and electrical installations
shall be as per relevant clauses of National Building Code
(NBC).”

Page L-28
Maintenance of Buildings
“Maintenance of buildings shall include routine

maintenance and attending to repairs to various parts of
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the building and connected services as and when
necessary, and replacement of irreparable items of work,
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cleaning & disinfection of the water supply systems,
inspection and maintenance of drainage / sanitation I
systems and electrical installations shall be as per
relevant clauses of NBC.” L
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Page L-33
Road Asset Management
“The Concessionaire shall maintain the buildings, plaza

facilities in a manner that projects a well managed
professional image to the motoring public.”

Page L-33
Road Asset Management
“Keep the plaza neat and litter free at all times.

Maintain the vegetation, lawns and shrubs etc
Maintain the parking areas and approaches neat and
litter free. Maintain all the toll plaza such that the walls
remain freshly painted, the woodwork neat, and all
structural defects immediately attended to. The
Concessionaire shall ensure that any visual defects of the
buildings, occasioned by accident or wear and tear are
rectified within one week.”
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INSPECTION
FORMATS
2-
1-
Date:
Team:
LOCATION
FUNCTIOINIG
HANDLES
PAINT/POLISH
GLASS
BOLTS / LOCKS
DOOR CLOSER
DOOR STOPPER
DOOR / WINDOWS
WINDOW STOPPER
PAINT – INT / EXT
PLASTER – IN / EX
FLOOR
CIVIL
Building:
Start Time:
LIGHTS
Finish Time:
SWITCHES
FAN / EXHAUST
AC
SOCKETS
ELECTRICAL
INSPECTION FORMAT – BUILDINGS
LEAK / WETNESS
TAPS / SHOWER
FLUSH
URINAL
MIRROR
Project:
TOWEL RAIL
SOAP TRAY
T. PAPER HOLEER
NAHANI JALI
PLUMBING / DRAINAGE
ROOF WAT TANKS
RAINWATER PIPE
KHURRA
2-
1-
Date:
Team:
BOOTH NO.
LANE SWEEP
LANE NOT OILY
ISLAND CLEAN
WALLS CLEAN
PIPES CLEAN
TARIFF BOARD
BOOTH GLASS
BOOTH ROOF
EXTERNALLY
TRAFFIC SIGNAL
PAINT POLISH
OHLS RED
OHLS GREEN
Start Time:
GLASS
Finish Time:
CHAIR
DESK
DOOR FINCTION
BOOTHS
LOCKS/BOLTS
INSPECTION FORMAT – BOOTHS
PLAZA LIGHTS
PLAZA SWITCHES
BOOTH LIGHTS
BOOTH SWITCHES
FAN / EXHAUST
Project:
ELECTRICAL
SOCKETS
GENERALLY
TAP LEAKS
LANE DRAINAGE
PROBLEM IN RAIN
OTHERS
SIGNATURE OF INSPECTING OFFICER:

INSPECTION REPORT OF DOORS & WINDOWS DATE:
DOORS WINDOWS
STOPPER
SAGGING
HANDLE
CLOSER
HINGE'S
SLIDING
TRACK
LOCKS
LOCKS
SPEED
S.NO LOCATION REMARKS
LOCATION
Tap
Soap Pot
Bottle Trap
Stop Cock
BUILDING CHECK LIST - PLUMBING
Towel Rail
Odonil Pot
Mirror
Jali
Cistern
Paper Holder
Rainwater pipe
Terrace Khurra
Water Leak
DATE:
REMARK
Present
Clean outside
Cover not broken

Cover & Frame
Cover no rust
Present
Pipe no rust
Mud, dirt
Wheel tight
Valve
Water not leaking
Valve operation
SR
NO
LOCATION
AC UNIT
INSIDE
POWER POINT
UPS POINT
FIRE
BUILDING CHECK LIST - ELECTRICAL
EXTINGUISHE
R
TUBE LIGHT
TL GLASS
BULB
FIRE ALARM
PANEL
HAND BREAK
GLASS
DATE:
REMARK
RED
UPS NO DG NO
DG
GREEN
UPS
TIME TIME
TIME
LANE 01 OVERLOAD
LITRES
DIESEL
LANE 02 VOLTAGE HIGH
OVERHEAD LANE SIGNS

M
LANE 03 VOLTAGE LOW

MOBIL OIL
LANE 04 OVER CHARGE
RADIATOR
LANE 05 BATTERY LOW
WATER
BATTERY SP. GR.

LANE 06 LOAD ON UPS 1220 <1220A
>1220W
INSPECTION FORMAT DG UPS OHLS GANTRY
BATTERY
LANE 07 LOAD ON BYPASS
VOLTAGE
24-28V
F
LANE 08
CHARGER
POSITION
B
LANE 09
LANE 10 Indication Lamps
LANE 11
LANE 12 Hooters
GENERATED
VOLTAGE
440 V
MAX TEMP
RUNNING
950C
DATE:
LOW LUBE OIL

PRESsure
0.4 - 7
RPM
1540
(MAX)
TRIP LOAD
SIGNATURE INSPECTION OFFICER
Chapter 10
HORTICULTURE
CONTENTS PAGE NO.
INTRODUCTION J-1
VISUAL INSPECTION J-1
DETAILED INSPECTION J-1
SCHEDULE OF OPERATIONS J-2
ROUTINE AND PERIODIC MAINTENANCE

J-3
FREQUENCIES
GRASSED AREAS J-3
PLANTS AND TREES J-3
LEVELS OF SERVICE J-5

Maintenance Manual – Section 2(A) INDIA PRSG MANT J - 1/6
CHAPTER 10
HORTICULTURE
INTRODUCTION
The section deals with the horticulture in the

medians, plaza buildings, islands at junctions,
RoW, etc on the entire project stretch.
Visual Inspection
The requirements of visual inspections relate to

general health, missing, sick or dead plants, over
growth, etc. Any growth which inhibits visibility of
any traffic control devices shall also be
recorded. The infestation of insects/pests if any
will also be recorded while carrying this
inspection. It is sufficient to carry out such
inspections once a week.

carefully.
Exact locations need not be recorded.

Recording each 25m sections would be
sufficient.
Detailed Inspection
The detailed inspections are intended to note

the problems such as needs for manure, insect
or fungus treatment, and critically ill plants.
The severity and extent of the problem will also

be recorded during such inspections. H
O
Whenever any defects which are noticed but
are not visible easily (such as minor pavement R
depressions, shoulder settlements, very thin T
cracks, etc) will also be marked on the field with
a chalk, or white paint (white snowcem also I
works very well) such that these remain easily C
identifiable when the maintenance team
comes to work. U
L
Horticulture works shall include all the grassing,
bushes, plants, trees or shrubs. These may be in T
the median, plaza buildings, at junctions, RoW, U
or on embankment slopes.
R
It will cover the re-plantation of the dead or

plantation of the new trees and shrubs, which
have become dead / damaged because of
accidents or for other reasons.
All the horticulture works will be maintained

under routine and periodic maintenance to
ensure that they are in good shape and health
at all the time.
Grass cutting including the cutting of planted or

natural grasses by means of mechanical
mowers or by hand shall be done periodically.
Hoeing around trees and shrubs shall be done
taking care not to damage or disturb the roots
of these trees and shrubs during hoeing or grass
cutting. Light hoeing shall be done around
designated newly planted and young trees and
shrubs to protect them from being smothered by
weeds.
Schedule of Operations
The schedule of operations including watering is

mentioned below. This schedule will remain
valid until any component is replaced or
modified, or a particular need develops. Any
need for revision shall be incorporated and
revised Maintenance Manual will be issued.
• Making basin for each plant to hold

sufficient water, cleaning by cutting and
removal of grass and weeds, and
disposal of muck, cut grass, weeds
polythene pieces, polythene bags, cloth
pieces, stones, leaves and prunes
• Trimming and pruning of plants to

required shape, size and spread H
• Watering of plants as required
O
R
• Applying manure (well decayed) @ ½
cu. ft in each plant at a time
T
I
• Application of fertilizer as required C
• Application of pesticides and fungicides U
@ 5 ml at a time in each plant, or as per L
recommendations of manufacturer
T
• Replacement of causalities U
• Cutting grass and disposal of cut grass R
• Cleaning of ground in median and

disposal of muck.
Routine and Periodic Maintenance
Sl.No. Operation Frequency
• Removal of weeds by digging,
Making of plant
uprooting, etc and disposal thereof 1 basin for holding 3 Months
water
• Control of monsoon growth by digging, Cleaning of Plant
cutting and their disposal 2 basin for holding 1 Month
water
• Dressing and levelling of median ground Hoeing and
3 1 Month
weeding
• Sprinkling water on grass to keep the Training, trimming
ground/grass moist/green 4 and pruning of 3 Months
plants
5 Watering of plants 2 days
Routine and Periodic Maintenance Frequencies 6 months
Application of
6 (February and
manure
The frequencies of maintenance operations August)
shall be as described. The specified intervals Application of 6 Months
may have to be varied to suit seasonal and 7 fertilizer (March and
weather changes from time to time. (Urea/NKP/DAP) September)
Application of 6 months(April
8
fertilizers(organic) and October)
Grassed Areas
Application of
9 pesticides and As required
Grass on medians, shoulders, embankment fungicides
slopes, and river training structures shall be Replacement of As early as
maintained. Grassed areas on the Highway will 10
causalities possible
be shown on the strip maps. These maps will 11 Cutting of grass As required
supplement the information held in the Cleaning of
inventory. The information of areas to be 12 1 Week
Medians
maintained will be reviewed every year. Control of
13 After monsoon
monsoon growth
Visibility at junctions, median openings, accesses Dressing and
and bends should not be obstructed by 14 levelling median After monsoon
vegetation. Cutting or clearance should ground
therefore be undertaken within sight lines.
Grass cutting and other clearance may also be

necessary where growth obstructs signs. In the H
special case of the visibility of kilometer /
hectometer stones, a swathe cut is of little use
O
on its own, and where this is a problem it will be R
more effective to use a total herbicide around
the base of the post once a year.
T
I
Plants and Trees
C
Trees are the most important feature, which U
should be preserved. If they are allowed to
decay or become unstable, they can be a
L
serious hazard to road users and possibly T
adjoining land users.
U
R
The inventory of all the plants and trees will be

maintained which will be updated following
each Detailed Inspection.
Cutting or clearance to safeguard visibility at

junctions, bends and accesses and of signs will
be carried out as needed and at a time which
gives maximum effect, but care will be taken to
avoid permanent damage to the hedge or tree.
Hedges and trees overhanging carriageways

will be trimmed to provide a minimum of 5.5 m
headroom.
Median plants shall be cut to a height of 1.2

meters above the median. Whenever they
reach 1.5 meter, they shall be cut again. Growth
of plants more than 1.5 meters shall not be
allowed because that will restrict visibility of sign
boards.
Tree removal if necessary will be carried out as

determined by a qualified arborist as a result of
detailed or safety inspections. Tree felling
should be undertaken wherever possible outside
the bird-nesting season to minimize the risk of
damaging habitats.
Thinning of foliage and un-seasonal loss of

leaves, dying back of branches, peeling bark,
moisture issuing from trunk, water staining, signs
of bacterial disease; growth fungi shall be
noted. Once reported, expert advice should be
sought on the health and potential life of the
tree and any remedial action that needs to be
taken by preservative action, tree surgery or
felling to maintain safe conditions.
H
O
R
T
I
C
U
L
T
U
R
LEVELS OF SERVICE

Page no. L-20
Branches of Trees
“The branches of the roadside trees if hanging closer

than 5.5m over the road level of the Project Highway
shall be cut, trimmed or lopped within 24 hours.”

Page no. L-29
Maintenance of Highway Landscape
“Maintenance of Highway Landscape shall include

attending to repairs to elements of the landscape
connected services as and when necessary, and
replacement of irreparable items of work.”

Page no. L-29
“Trees shall be maintained as per the guidelines in IRC:

SP: 21-1979 and no indiscriminate felling of trees shall be
resorted to while upgrading, widening and improving the
highway. The felling of trees shall be undertaken in
consultation with the IC and after obtaining due
permission of the Forest Department, as applicable.”

Page no. L-29 H
O
R
“While borrowing earth from roadside land for routine
maintenance it shall be ensured that no earth is removed T
around root of trees. All borrowing operations shall be as
per IRC: 10-1961.”
I
C
U
L
T
U
R

Page no. L-30
“Maintenance operations include numbering and

maintaining a register of all road side trees within the
RoW.”

Page no. L-30
“The routine maintenance such as trimming and shaping

shall also cover those hedges and trees within the RoW,
which affect the performance of the Project Highway.”

Page no. L-30
“Cutting or clearance to safeguard visibility at

intersections, road bends, accesses and signs shall be
carried out in such a way as to avoid permanent damage
to hedges and trees. Hedges and trees overhanging
carriageways shall be trimmed to provide a minimum
headroom of 5.5 metres at all times.”

Page no. L-30
“Turfing within the RoW shall be mown as to achieve a

visual pattern in harmony with adjacent areas. Mowing
shall be done when the height of cut reaches 150 mm.” H
O
Page no. L-30
R
Maintenance of Highway Landscape T
I
“The grass / turf within RoW shall be maintained in such C
away that the roadway is free of obstruction and the
availability of sight distance is ensured at intersections, U
passing zones, curves, etc. The grass / turf around crash L
barrier, headwalls, paved ditches etc. shall be maintained
neatly.” T
U
R
INSPECTION
FORMATS
PROFORMA FOR HORTICULTURE INSPECTION
Team: Start Time: Carriageway:
1- Finish Time: From:
2- To:
3- Sections 25 metres each
MEDIAN SHOULDER/RoW
PLANTS GRASS TREES PLANTS GRASS TREES REMARKS
HIDING KM STONE
HIDING SIGNAGES
HIDING SIGNAGES
EXCEES HEIGHT1
EXCEES HEIGHT1
OVERHANGING 2
OVERHANGING2
OVERGROWN
OVERGROWN
OVERGROWN
OVERGROWN
CHAINAGE
UPROOTED
UPROOTED
UPROOTED
UPROOTED
DISEASED
DISEASED
DISEASED
DISEASED
MISSING
MISSING
MISSING
MISSING
BASINS
WEEDS
WEEDS
DEAD
DEAD
DRY
DRY
SIGNATURE OF INSPECTING OFFICER:
1
The height of the plant should be a maximum of 1.2m.
2
Branches of trees should not overhang on the carriageway below 5.5m headroom.

O&M Centre: Maintenance Manual Section 2 (A)

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O&M CENTRE

Highway Management System

L&T Interstate Road Corridor Limited

REV. DATE NAME SIGN. NAME SIGN. NAME SIGN.

AUTHOR CHECKED APPROVED

Document Title Location Project File Doc No Rev

MAINTENANCE MANUAL – SECTION 2(A) INDIA PRSG MANT 101 DRAFT

Maintenance Manual – Section 2(A) Gujarat & Rajasthan

Revision No. Revised or added page No’s Comments

Maintenance Manual – Section 2(A) Gujarat & Rajasthan

3. IC’S COMMENT AND APPROVAL

Item No. Comments

Maintenance Manual – Section 2(A) Gujarat & Rajasthan

CHAPTER 1 INTRODUCTION A (1-11)

CHAPTER 2 SAFETY B (1-12)

CHAPTER 3 CLEANING C (1-3)

CHAPTER 4 PAVEMENT D (1-53)

CHAPTER 5 DRAINAGE E (1-5)

CHAPTER 6 SHOULDERS, SLOPE F (1-3)

CHAPTER 7 ROAD FURNITURE G (1-15)

CHAPTER 8 STRUCTURES H (1-18)

CHAPTER 9 BUILDINGS I (1-15)

CHAPTER 10 HORTICULTURE J (1-6)

Maintenance Manual – Section 2(A) Gujarat & Rajasthan

5. PURPOSE OF THIS DOCUMENT

This document serves to provide guidance on inspections of various elements of the

Maintenance Manual – Section 2(A) Gujarat & Rajasthan

Description Section Volume Functions Covered

Specifications and Standards

1. IRC 35: 1997 Code of Practice for Road Marking

1. Manual for Maintenance of Roads

Maintenance Manual – Section 2(A) Gujarat & Rajasthan

CONTENTS PAGE NO.

PROJECT DETAILS A-1

MAINTENANCE MANUAL A-2

INSPECTION SYSTEM A-3

VISUAL INSPECTIONS A-3

DETAILED INSPECTIONS A-4

THOROUGH INSPECTIONS A-5

ROUTE PATROL A-5

MAINTENANCE CALENDAR A-6

GROUPING OF DEFECTS A-7

The project stretch that shall be maintained by

There are 181 structures on the Project Stretch,

There are two toll plazas located at KM 270+250

telephone, rest area and toilets with proper

Lab Facility MAINTENANCE

Laboratory has been provided with basic testing

MAINTENANCE MANUAL 10. Tripod Ladder

with the inventory, previous maintenance

Inspection System 25. Trays for heating bitumen,

Before the commencement of any inspections, tools, etc.

hazards to the road user or hampering the

Detailed inspection records include details of

Thorough inspections require even more

Specialist inspections are required once in a

• Structural failure of the pavement

A route patrol is normally carried out daily

2. A broken signboard protruding on the

All the maintenance activities will be carried out

Grouping of Defects FREQUENCY OF INSPECTIONS

Defects requiring immediate action will be