Manual for Maintenance of Roads, 1983

MORTH 246 - Scope Overview

1. Scope Summary

• Objective: Maintain highways ensuring comfort, safety, preservation of investment, environmental compatibility, and operational economy.
• Maintenance Types:
  • Ordinary/Routine: Pavement upkeep, drains, bridges, signboards, arboriculture, rest houses.
  • Periodic: Renewals for serviceability (gravel, metalled, black-topped roads).
  • Special Repairs: Flood damage, major restorations.

2. Key Specifications & Norms

• Labour Output Norms (per person/day):
  • Dressing berms: 75 sqm
  • Jungle clearance: 100 sqm
  • Surface painting: 0.2 cum
  • Premix carpet: 0.75 cum
  • W.B.M patches: 0.30 cum
  • Edge covering: 60 m
• Gangmen Staffing (per 16-20 km beat):

• Tools for Gangmen: Spades, pans, pick axes, hand-carts, tar sprinklers, brushes, hammers, ropes, caution boards, goggles, etc.

3. Maintenance Priorities (Table 4.1)

MORTH 246: Basic Maintenance Objectives and Policies

Key Objectives (Clause 1.1)

• Safety & Convenience: Ensure safe, comfortable travel for the public within fiscal limits.
• Preservation of Investment: Maintain roads, bridges, and appurtenances in original or improved condition to protect public funds.
• Preventive Maintenance: Emphasize planned, preventive work rather than reactive repairs.
• Environmental Compatibility: Preserve/enhance roadside aesthetics and control erosion.
• Consistency: Equivalent maintenance care for similar roads based on regional needs.
• Economy & Improvement: Continuously improve maintenance efficiency through research, training, and communication.

Maintenance Classifications (Clause 1.2)

Planning & Financing (Clause 2)

• Road Inventory: Essential for planning; includes road classification, surface types, lane widths, traffic volume, and location of water crossings.
• Maps: Use district maps (1:50,000 scale) and strip maps for detailed planning.

Summary Table: Maintenance Objectives

flowchart TD
    A[Maintenance Objectives] --> B[Service to Public]
    A --> C[Preservation of Investment]
    A --> D[Preventive Maintenance]
    A --> E[Environmental Compatibility]
    A --> F[Consistency of Service]
    A --> G[Economy and Performance Improvement]

This framework ensures a systematic, efficient, and environmentally sensitive approach to highway maintenance per MORTH 246.

MORTH 246 - Key Definitions & Specifications (Clause 1.2)

Maintenance of highways is classified into three main categories:

1. Ordinary Repairs / Routine Maintenance

   • Upkeep of pavements and shoulders
   • Maintenance of roadside drains
   • Repair of culverts, bridges, retaining walls, parapets
   • Maintenance of sign boards, km stones, traffic aids
   • Roadside arboriculture (trees, vegetation)
   • Upkeep of rest houses, inspection bungalows, gang huts

2. Periodic Maintenance

   • Periodic renewal of carriageways (gravel, metalled, black-topped) to maintain serviceability

3. Special Repairs and Flood Damage Repairs

   • Repairs due to special circumstances or natural calamities

Basic Maintenance Objectives (Clause 1.1)

• Ensure comfort, convenience, and safety for users
• Preserve investment in infrastructure
• Maintain environmental compatibility and aesthetics
• Emphasize economy and efficiency in maintenance operations

Maintenance Priority (from Table 4.1)

Reference:

• Appendix 3: Condition survey format
• Appendix 6: Action for breached/blocked roads
• IRC:82 for renewal cycles based on traffic and rainfall

flowchart TD
    A[Maintenance of Highways]
    A --> B[Ordinary Repairs/Routine Maintenance]
    A --> C[Periodic Maintenance]
    A --> D[Special/Flood Damage Repairs]
    B --> B1[Pavements & Shoulders]
    B --> B2[Drainage]
    B --> B3[Culverts & Bridges]
    B --> B4

Planning and Financing as per MORTH 246 focuses on systematic maintenance of roads to ensure safety, preservation, and economy.

Key Specifications:

• Inventory of Road (Clause 2.1):
  Essential data includes:

  • Road classification, width, surface type
  • Location of streams, cross drainage (CD) works
  • Traffic volume and intensity
  • Urban limits
  • Use district maps (1:50,000 scale) and strip maps for detailed layout.

• Condition Survey (Clause 2.2):
  Regular surveys to assess physical and structural condition, surface roughness, and defects.

• Programming and Planning (Clause 2.3):
  Develop annual maintenance calendar based on condition survey and inventory.

Objectives of Maintenance (Clause 1.1):

• Ensure comfort, safety, and convenience for users.
• Preserve investment in infrastructure.
• Maintain environmental compatibility.
• Emphasize preventive maintenance to reduce costly repairs.

Sample Road Inventory Data Table (Simplified):

Maintenance Planning Flow (Mermaid.js):

flowchart TD
    A[Road Inventory] --> B[Condition Survey]
    B --> C[Defect Identification]
    C --> D[Prioritization of Works]
    D --> E[Annual Maintenance Calendar]
    E --> F[Execution & Monitoring]

This structured approach ensures efficient allocation of resources and timely maintenance interventions.

Inventory of Road (MORTH 246 - Clause 2.1)

The inventory is the foundation for planning road maintenance, capturing physical, structural, and operational data:

Key Data for Road Inventory:

• District Map (Scale 1:50,000) with:

  • Road classification/category & width
  • Location of streams and cross drainage (CD) works
  • Surface type (gravel, metalled, black-topped)
  • Lane width
  • Traffic intensity & volume
  • Urban limits

• Strip Maps showing detailed linear features and road elements (not fully listed in context but typically include chainage, landmarks, and condition).

Purpose:

• Evaluate physical condition, structural capacity, surface profile (roughness)
• Assist in maintenance programming and budgeting

Maintenance Classifications (Related):

• Routine Maintenance: Pavement, drains, culverts, road furniture
• Periodic Maintenance: Surface renewals to maintain serviceability
• Special Repairs: Flood damage, major restoration

Example Table: Basic Road Inventory Elements

flowchart LR
    A[Start: Road Inventory] --> B[District Map]
    B --> C[Surface Type & Width]
    B --> D[Traffic Volume]
    B --> E[Location of CD Works]
    A --> F[Strip Maps]
    F --> G[Detailed Road Features]
    G --> H[Condition Assessment]
    H --> I[Maintenance Planning]

This structured inventory enables effective maintenance planning preserving investment, ensuring safety, and optimizing expenditure per MORTH guidelines.

Condition Survey - Key Points from MORTH 246

1. Condition Survey (Clause 2.2 & 4.1)

• Conduct inspection and record findings as per Appendix 3.
• Assign maintenance priorities based on:
  • Safety and unobstructed traffic flow.
  • Preservation of roadway assets.
  • Preventive maintenance to avoid further deterioration.

2. Maintenance Priorities (Table 4.1)

3. Renewal Cycle (Clause 4.2)

• Depends on traffic density, rainfall, lane width.
• Refer IRC:82 for detailed renewal guidelines.

Summary Diagram of Priority Assignment

flowchart TD
    A[Condition Survey] --> B[Record Findings]
    B --> C[Assess Urgency]
    C --> D{Safety Concern?}
    D -->|Yes| E[Urgent Action]
    D -->|No| F{Extent of Damage}
    F -->|Minor| G[Routine Maintenance]
    F -->|Major| H[Special Attention]
    E --> I[Immediate Repair]
    G --> J[Local Sealing]
    H --> K[Sealing + Chippings]

Use this framework to prioritize maintenance effectively and ensure road safety and longevity.

MORTH 246: Programming and Planning (Clause 2.3)

Though Clause 2.3 lacks direct formulas, key specifications and planning essentials from MORTH 246 for road maintenance programming are:

Key Steps in Programming and Planning:

• Inventory of Road Assets: Complete data on road classification, surface type, width, traffic volume, and condition.
• Condition Survey: Assess surface distress, structural capacity, and roughness.
• Prioritization: Rank maintenance works based on urgency, traffic importance, and budget.
• Annual Calendar: Schedule routine and periodic maintenance activities.
• Resource Allocation: Assign labor, materials, and equipment based on norms (see Clause 5.3, 5.4, 5.5).
• Monitoring & Reporting: Use inspection cards and work reports to track progress.

Important Tables and Formats:

Norms Example (from Appendix 10):

Summary Flow for Planning:

flowchart TD
    A[Road Inventory] --> B[Condition Survey]
    B --> C[Prioritization of Works]
    C --> D[Resource Allocation]
    D --> E[Annual Maintenance Calendar]
    E --> F[Execution & Monitoring]

This structured approach ensures economy, safety, and preservation of road assets per MORTH 246 guidelines.

Annual Calendar of Road Maintenance Activities (MoRTH 246 - Clause 2.4 & Appendix 4)

The Annual Calendar is a planned schedule to ensure timely and systematic maintenance of roads, covering:

• Routine Maintenance: Regular upkeep like patch repairs, cleaning drains, shoulder maintenance.
• Periodic Maintenance: Renewal of carriageway surfaces to maintain serviceability.
• Special Repairs: Flood damage, structural repairs, or emergency works.

Key Specifications & Norms

Labour Norms for Maintenance Gangs (per Beat)

Maintenance Objectives

• Preserve investment by maintaining roads in original or improved condition.
• Ensure safety, comfort, and convenience for users.
• Emphasize preventive maintenance over corrective.
• Maintain environmental compatibility and

Inspection Key Points from MORTH 246

1. Inspection Frequency & Duties (Clause 3.1 & 3.2)

• Regular inspections ensure safety, asset preservation, and preventive maintenance.
• Inspectors: Assistant Engineers, Junior/Sub Engineers.

2. Maintenance Priorities (Table 4.1)

3. Inspection Checklist

• Safety: Blockades, deep cuts, damaged culverts, tree branches, power line clearances (per IRC:32).
• Carriageway: potholes, edges, undulations, crust failures.
• Berms: width, cross slope (3-5%), side slopes.
• Drainage: cross-sectional area, blockages.
• Road fixtures: km stones, traffic signs, markings.
• Protection works: retaining walls, parapets.
• Roadside trees: numbering, disposal, register.
• Geometrics: curves, sight distances (IRC standards).

4. Routine Inspection Format

• Record defects and actions at each km mark.
• Example columns: Side drain condition, carriageway patches, encroachments, road furniture.

Summary Diagram: Inspection Priority Flow

flowchart TD
    A[Inspection Findings] --> B{Safety Risk?}
    B -- Yes --> C[Urgent Action: Repair/Blockade Removal]
    B -- No --> D{Cracking >25%?}
    D -- Yes --> E[Special Attention: Sealing + Chippings]
    D -- No --> F[Routine Maintenance: Local Sealing]
    C --> G[Record & Monitor]
    E --> G
    F --> G

MORTH 246: Frequency of Road Maintenance Inspections

Though the provided context lacks explicit formulas or tables on Frequency (Clause 3.1), typical guidelines based on standard road maintenance practice are:

Frequency of Inspections

• Routine Inspection: Monthly or quarterly for low-traffic roads.
• Condition Survey: Annually or bi-annually, more frequent for high-traffic or critical roads.
• Special Inspection: After extreme weather events or accidents.

Key Points

• Frequency depends on traffic volume, climatic conditions, and road type.
• Urgent defects (e.g., major breaches) require immediate inspection and repair.
• Preventive maintenance scheduling is based on inspection findings (Clause 4.1).

Suggested Inspection Frequency Table (Typical)

Maintenance Priority Flow (from Clause 4.1)

flowchart TD
    A[Inspection Conducted] --> B{Defect Severity}
    B -->|Major Breach| C[Urgent Action - Immediate Repair]
    B -->|Minor Cuts/Ruts| D[Urgent - Remove Blockades & Repair]
    B -->|Cracking < 25%| E[Routine - Local Sealing]
    B -->|Cracking > 25%| F[Special - Surfacing Repairs]
    B -->|Stripping < 25%| E
    B -->|Stripping > 25%| F

Summary:

• Schedule inspections based on traffic and climate.
• Use inspection data to prioritize maintenance (urgent, special, recurrent, routine).
• Refer to Appendix 3 for condition survey format and Appendix 6 for emergency steps.

For detailed frequency tables, consult IRC: 82 and MORTH guidelines.

Key Formulas, Tables & Specifications for Duties (MORTH 246)

1. Output Norms for Labour (Clause 1.75)

Note: Quantities refer to grit and ballast used for patch repairs.

2. Labour Deployment Norms for Road Maintenance (Work Charged Staff)

3. Essential Tools for Gangmen (One gang: 5 gangmen + 1 mate)

• Spades (3 Nos.), Pan (3 Nos.), Pick axes (2 Nos.), Axe (1 No.)
• Hand-cart with solid rubber tyres (1 No.)
• Wooden & Iron weights (1 No. each)
• Wire, Coir, Hair brushes (5 Nos. each)
• Tar sprinklers, buckets, kettle (optional with Section Incharge)
• Cross slope template (camber 3%), Tar thermometer, Spring balance
• Measuring wooden boxes (2 Nos.), G.I. bucket, Straight edge
• Caution boards

Identification of Defects (MORTH 246 - Clause 3.3 & 4.1 Highlights)

Inspection & Recording

• Divide road into 5 km sections, each subdivided into 200 m stretches.
• Inspect before/after rains and routinely.
• Record defects in Appendix 3 format with measurements:
  • Length to nearest 1 m
  • Width to nearest 0.1 m
• Use instruments like steel tapes (3m, 15m, 30m), spirit level, camber templates, 1m² frame, and inspection forms.

Defect Severity & Priority (Table 4.1 Summary)

Measurement Methods

• Corrugations: Straight edge + wedge every 200 m; closer if severe.
• Rutting: Measure depth transversely with straight edge + wedge.
• Potholes: Count & measure area per 200 m; compute % area.
• Camber/Crossfall: Use camber templates.
• Material loss: Check WBM thickness every 15 m at 3 points across road.
• Cracking: Assess visually with 1m² frame every 200 m or defect location.

Emergency Action for Road Breach/Blockade

• Mate: Immediate report, fix warning signs (distance: NH/SH=120m, MDR=90m, ODR=60m), deploy guides.
• Engineering Subordinate: Barricade, caution/diversion boards, guide traffic, report

MORTH 246: Maintenance Criteria Summary

1. Maintenance Priorities (Table 4.1)

2. Renewal Criteria (Table 4.2)

Renewal depends on traffic, rainfall, and lane width:

Notes:

• SD = Single coat surface dressing (3½ cu.ft chips + 25 lb bitumen)
• PC = 20 mm premix chipping carpet (IRC:14)
• MS = Mix seal surfacing (Ministry specs)
• Periodicity is a guideline for budgeting, not absolute life expectancy.

Key Formulas for Local Sealing:

• Bitumen emulsion: **1.5 kg

Criteria for Renewal – Key Points from MoRTH 246 Clause 4.2 & Table 4.2

Renewal cycle of bituminous surfacing depends on:

• Traffic density (commercial vehicles per day)
• Rainfall intensity
• Lane width

Notes:

• SD: Single coat surface dressing with 3½ cu.ft. chips + 25 lb bitumen.
• PC: 20 mm premix chipping carpet (IRC:14).
• MS: Mix seal surfacing as per MoRTH clause 508.
• Renewal periodicity is a guideline for budgeting, not a fixed lifespan.
• Closer renewal intervals needed in snowfall/hilly/heavy rainfall areas.

Maintenance Priorities (from Table 4.1)

• Urgent: Major breaches, safety hazards.
• Special: Significant cracking, pot holes, edge subsidence.
• Recurrent: Reflection cracks, edge rutting.
• Routine: Minor cracks, silting, shoulder maintenance.

flowchart TD
    A[Inspection & Condition Survey] --> B[Record Findings (Appendix 3)]
    B --> C[Assign Priorities]
    C -->|Urgent| D[Immediate Repair]
    C -->|Special| E[Schedule

Detailed content not available.

Safety of Labour and Road User During Maintenance (MORTH 246 - Clause 5.1)

Though the provided context lacks explicit formulas or detailed safety specs, key safety practices from standard road maintenance guidelines include:

Key Safety Specifications:

• Advance Warning Signs: Place warning signs at adequate distances (minimum 150-300 m on highways) before maintenance zones.
• Traffic Diversion: Use cones, barricades, and flagmen to guide traffic safely around work zones.
• Labour Protection: Provide personal protective equipment (PPE) like helmets, reflective jackets, gloves, and safety boots.
• Lighting: Ensure adequate lighting for night work.
• Speed Control: Implement temporary speed limits in maintenance zones.
• Emergency Access: Maintain clear access for emergency vehicles.

Typical Safety Setup (schematic):

flowchart LR
    A[Advance Warning Sign] --> B[Traffic Cones & Barricades]
    B --> C[Flagmen/Traffic Controllers]
    C --> D[Work Zone with Labour PPE]
    D --> E[Safe Traffic Diversion]

Reference Table: Minimum Distances for Warning Signs on Highways

Note: Follow MORTH guidelines and local traffic authority rules for detailed safety protocols during maintenance.

For detailed procedures, refer to MORTH 246 Clause 5.1 and related IRC codes on road safety during maintenance.

MORTH 246: Mechanisation and Equipment Planning - Key Points

1. Planning Principles

• Mechanisation aims to improve efficiency, safety, and economy in maintenance.
• Equipment selection depends on:
  • Road category & traffic volume
  • Type of maintenance work (routine, periodic, special)
  • Availability of skilled operators and maintenance support
• Balance between manual labour and mechanisation is essential.

2. Equipment Norms & Labour Output

• Labour output norms (e.g., 1.75 Cum/person/day for earthwork).
• Gang composition varies by road type & traffic volume (see table below).

3. Essential Tools for Gangmen (per gang of 5 + 1 mate)

• Spades (3 nos.), Pick axes (2 nos.), Axes (1 no.)
• Hand-cart with solid rubber tyres (1 no.)
• Tar sprinklers, buckets, mini tar kettle (optional)
• Brushes (wire, coir, hair), Hammer, Rope, Cross slope template
• Tar thermometer, Spring balance, Measuring boxes, Caution boards

4. Equipment Planning Checklist

• Assess work type: patching, resurfacing, drain cleaning, shoulder maintenance.
• Match equipment capacity with work volume and labour norms.
• Plan for maintenance and storage of equipment.
• Train operators for safe and efficient use.

Summary Diagram: Mechanisation Planning Process

flowchart TD
    A[Assess Road Inventory & Condition] --> B[Determine Maintenance Work Type]
    B --> C[Estimate Labour Output & Equipment Needs]
    C --> D[Select Appropriate Equipment & Tools]
    D --> E[Plan Equipment Allocation & Maintenance]
    E --> F[Train Operators & Implement Work]

References:

• Clause 5.5 Mechanisation and Equipment Planning, MORTH 246
• Labour output norms and

Maintenance of Drains, Shoulders, Slopes, and CD Works (MORTH 246 - Clause 5.6)

Objectives

• Ensure drainage elements remain free of obstruction, retaining cross sections and grades.
• Prevent water damage to pavements, shoulders, slopes, culverts, and bridges.

Key Routine Activities

• Drains: Reshape, regrade, deepen, clear, clean, and repair erosion.
• Shoulders and Slopes: Regular grading using labour or mechanized equipment.
• Culverts: Clear debris, repair erosion and cracks.

Maintenance Methods (Table 5.2 Summary)

Haulage Recommended Distances (Table 5.3)

• Head baskets: 5-30 m
• Wheelbarrows: 25-125 m
• Bullock carts: 100-600 m
• Trucks: 500+ m

Equipment & Labour Efficiency Codes

• Excellent = *
• Good = **
• Average = ***
• Poor = ****

Best Practices

• Use mobile gang systems for efficient maintenance over 30-50 km stretches.
• Maintain side drains to prevent waterlogging and erosion.
• Repair culverts promptly to avoid washouts.
• Employ agricultural tractors/blades for shoulder grading.
• Prioritize preventive maintenance to preserve road investment.

flowchart TD
    A[Drainage Maintenance]