Pocketbook On Routine Maintenance

Outside
IMPROVEMENT OF QUALITY MANAGEMENT FOR

HIGHWAY AND BRIDGE CONSTRUCTION AND
MAINTENANCE, PHASE II
POCKETBOOK
ON
ROUTINE MAINTENANCE
2014
Department of Public Works and Highways
Inside
Improvement of Quality Management

for Highway and Bridge Construction
and Maintenance, Phase II
POCKETBOOK
ON
ROUTINE MAINTENANCE
SEPTEMBER 2014
Department of Public Works and Highways

Japan International Cooperation Agency
ACKNOWLEDGEMENT
iii
JICA Team Members

Hideo Nagao
-
Team Leader
Ryoichi Yamasaki
Co Team Leader
Nobuyuki Sagawa
Yoshinori Mikura
JICA Expert
(Pavement)
JICA Expert
(Slope/Drain)
Hiroyuki Matsuyama (Slope/Drain)
Yoriko Kawakami
Kensuke Matsushita
Feliciano P. Carpio
Rodrigo A. Yago
iv
JICA Expert
JICA Expert
(Bridge)
Project
Coordinator
Asst. Engr;
JICA TCP-II
Asst. Engr.
JICA TCP-II
ABBREVIATIONS
TABLE OF CONTENTS
Foreword . i-ii
Acknowledgment .. iii-iv
INTRODUCTION
Purpose . 1
Target Users.. 2
ROUTINE MAINTENANCE
Responsible Office and
Personnel 3
Materials and Equipment 4
Safety Management . 6
UNPAVED ROAD SURFACE
1-1 Manual Repair of Unpaved
Road Surfaces 8
1-2 Machine Grading Unpaved
Road Surfaces ... 10
BITUMINOUS PAVEMENT
2-1 Premix Patching Bituminous
Pavements ...
2-2 Penetration Patching
Bituminous Pavements
2-3 Sealing Bituminous
Pavements ...
2-4 Replacement of Bituminous
Pavements
vi
13
16
19
21
CONCRETE PAVEMENT
3-1 Patching Concrete
Pavements . 24
3-2 Crack and Joint Sealing of
Concrete Pavements . 27
3-3 Replacement of Concrete
Pavements . 29
UNPAVED SHOULDER
4-1 Manual Repair/Patching of
Unpaved Shoulders 32
4-2 Machine Grading of Unpaved
Shoulders . 35
DRAINAGE
5-1 Manual Ditch Cleaning 37
5-2 Manual Cleaning of Culvert
Inlet/Outlet and Culvert
Line/Barrel .. 39
5-3 Repair and/or Replacement of
Minor Drainage Structure ... 41
ROADSIDE FEATURES
6-1 Vegetation Control (Grass
Cutting/Tree Trimming) .. 43
6-2 Erosion Repair and Control on
Roadsides 45
6-3 Repair of Major Roadside
Structures 47
vii
TRAFFIC SERVICES
7-1 Sign Maintenance and Traffic
Services
7-2 Centerline and Lane
Repainting
7-3 Guardrail Maintenance
7-4 Sight Distance Mowing
and Cleaning
49
51
53
55
BRIDGES
8-1 Cleaning of Bridges .. 57
8-2 Patching Concrete Decks .. 59
8-3 Repair of Concrete Bridges
8-3-1 Crack Repair ... 63
8-3-2 Patching .. 65
8-4 Repair of Steel Bridges(Touchup Painting .... 68
8-5 Repair of Bridge Attributes ..... 70
8-6 Repair of Bridge Protection
Works ... 72
8-7 Cleaning Bridge Waterways .. .. 74
EMERGENCY WORKS
9-1 Initial Response to
Emergencies-Roads .. 76
9-2 Initial Response to
Emergencies-Bridges .... 78
Additional Information .. 80
viii
INTRODUCTION
PURPOSE
In road networks of 376,907 km in the
Philippines, half of these are in poor condition
that needs immediately repair, rehabilitation
and/or improvement In the current Mediumterm Road Development Program prepared by
the DPWH, priority is given to the
maintenance/management of national roads
and bridges.
This Pocketbook is being prepared to guide the
field engineers/supervisors/personnel involved
in the routine maintenance activities to improve
their technical capabilities in quality control and
keep constant level of service in the road
network in the Philippines.
It also serves as a tool and/or reference in the
on-site supervision and management for every
maintenance activity, as shown/ illustrated with
photos and
sketches.
Likewise,
this
Pocketbook must be carried on site for ready
reference.
TARGET USERS
Included in this Pocketbook are the commonly
used routine maintenance activities selected
from the list of "Activity Standards" of the
Revised Philippines Highway Maintenance
Management Manual (PHMMM) published by
the DPWH in 1985 and improved/updated by
the JICA-TCP II in 2014.Basic considerations
and guides are being introduced in every routine
maintenance activity by easy-to-understand
methods with the corresponding photographs
and sketches.
The target users of this Pocketbook are
engineers and personnel
of the District
Engineering Offices, particularly, those in the
District Maintenance Sections who are carrying
out the routine maintenance activities.
ROUTINE MAINTENANCE
RESPONSIBLE OFFICE AND
PERSONNEL
Organization for routine maintenance of
national roads is comprised of three levels:
Central Office (CO), Regional Office (ROs) and
District Engineering Offices (DEOs). Each
office has a division and a section, normally
named as Maintenance Division/Section,
responsible for the Road Maintenance.
(1) Central Office (CO)
The Central Office which is located in Manila is
mainly responsible for basic planning,
monitoring and development of standards for
the routine maintenance.
(2) Regional Offices (ROs)
DPWH is composed of 16 Regional Offices,
who supervise(s) the District Engineering
Offices(DEOs).
(3) District Engineering Offices (DEOs)
The District Maintenance Engineer, and his/her
subordinates which include Engineers or
Foreman/ Capataz, and responsible in the
maintenance and upkeeping of the national
roads within their jurisdiction. The engineers
and
Foreman/Capataz are also called
Maintenance Point Persons (MPPs),with
particular road sections assignment covering
approximately 35 to 50 km per point person.
3
Sample Organizational Structure of

Maintenance Section in First Class District
Engineering Office (DEO)
MATERIALS AND EQUIPMENT

Generally, basic tools/equipment/machines are
used for Routine Maintenance Activities and
small quantity of material.
The materials and equipment are necessary for
each work mentioned in the Activity List, but not
in detail on their specification. Some are
described in other documents, but most of them
are based on judgment through experiences of
engineer or foreman in charge.
Sometimes, materials and equipment available at
each site are limited, so personnel-in-charge have
to manage the situation.
4
Also, there is no need for actual detail

specification. Without proper equipment
and/or repair materials, life span of the
structure may become short.
Quality control affects the quality and
durability of the road facility. Therefore the
time span to the next repair becomes short,
which means frequency of repair increases if
this was not properly done during the
construction or improvement period.
Increase of frequency causes cost increase.

Moreover, it is difficult to maintain huge
amount of asset within limited time and
resources.
Maintenance level becomes lower.
Wet aggregate for repair of asphalt pavement

is an improper material condition
5
SAFETY MANAGEMENT
The occurrence of accidents during operations
may cause suspension or delay of work and may
lead to casualty of workers. Safety measures
should be considered on site during routine
maintenance work not only for the workers but
also for the third party such as the motoring
public and nearby residents.
Safety gear
Proper use of safety gear depends on risk of the
work site.
Equipment and Materials
Check machines and tools before using.
Handle electric powered machines and
hazardous materials with care under
established operations procedure.
Operate vehicle-type construction
machines and mobile cranes only after
confirming safety of the surrounding areas.
Only licensed equipment/machine operator
is allowed to operate.
Stockpile materials properly at site to
prevent hazard to the motoring public.
Temporary Facilities
Install proper temporary facilities (e.g.
scaffolding) and regularly check firmness of
the facility.
Traffic Safety
Install proper traffic and site safety device
(e.g. Men at Work sign, Traffic restriction)
(Site base facilities)
6
1) Safety Gear
Hard Hat
Safety Belt
Safety Shoes
For maintenance of
vertical structures like
bridges/ buildings
For routine maintenance
2) Traffic safety
Install appropriate
warning signage
and site safety
devices.
1-1 MANUAL REPAIR OF UNPAVED

ROAD SURFACES
Related Activity Standard No. 101, 102
Purpose
To eliminate hazardous conditions, to provide
smooth and well-drained surfaces.
Procedure
Act. No.101 Repair without new materials
1. Reshape ditches.
2. Reclaim suitable materials from ditches and
sides. Unsuitable waste materials should be
disposed to designated areas.
3. Cut high areas.
4. Blend materials from high areas with
reclaimed materials.
5. Fill low areas and compact.
6. Reshape surrounding surface or dig outlet
channels through high areas of surface, if
needed, to allow water to drain.
Act. No.102 Patching with new materials
1. Restore shape of road surface.
2. Place material in layers to facilitate
compaction.
3. Compact each layer.
4. Shape surrounding surface or dig outlet
needed, to allow water to drain to the ditch.
5. Check cross-section, profile and drainage.
Rework if needed.
8
Checkpoint
For manual patching of potholes, surfacing
materials are taken from side ditches or high
spots of the road.
When there is water ponding, remove water
prior to filling of surface materials.
When Telford base is observed, remove
boulders or oversized aggregates and fill
surface with required materials.
Photographs
1) Filling pothole
Repair of pothole
using surfacing
material which is
taken from side
ditches.
2) Materials not to be used

Materials containing
tree and plant pieces
are inappropriate and
should be disposed
properly.
1-2 MACHINE PATCHING/GRADING

UNPAVED ROAD SURFACE
Purpose
Procedure
1. Restore shape of roadway surface.
compaction.
4. Shape surrounding surface or dig outlet
needed, to allow water to drain to the ditch.
Rework if needed.
Act. No.104 Grading without new materials
1. Scarify or cut surface to remove potholes,
erosion scars, corrugations, high areas, etc.
2. Clean and re-cut ditches and
outlets/turnouts Remove spoil material
from culvert inlets and outlets.
3. Reclaim suitable material from ditches
and sides.
4. Remove oversize or unsuitable material.
5. Blend reclaimed material with scarified surface
materials.
10
6. Spread, reshape and compact.

Rework if needed.
Checkpoint
For surface layer materials, use of
uniformly graded or oversized materials
should be avoided.
Work should start from shoulder to road
center.
During compaction, water content should be
kept at 15% to 20%. When material is dry,
water spraying is required.
Photographs
1) Reshaping with road grader
Work should start

from side ditch
and maintain
cross-fall of 3% to
5% for drainage.
2) Placing materials
Remove oversize
and unsuitable
materials.
11
3) Spreading with road grader

Uneven surface
should be scarified
in advance.
4) Compaction with road roller

When water
content is below
the optimum,
water spraying is
required.
5) Quality of aggregates
Aggregate
should be hard
and durable.
12
2-1 PREMIX PATCHING BITUMINOUS

PAVEMENTS
Related Activity Standard No. 111
Purpose
Procedure
1. Remove standing water and temporary
patching material from defect or area to be
levelled.
2. Shape defects so that: (a) depth provides for
sufficient strength; (b) sides are vertical; (c)
corners are square or slightly rounded; (d)
sides have no abrupt changes in line; and (e)
hole is up to stable base.
3. Add base material if needed.
4. Clean and tack defects or area to be levelled.
5. Place premix in layers and compact each
layer. Mix should be placed only within
limits of hole and area to be levelled.
6. Final layer should be flushed with
surrounding surface.
7. Dig channels through shoulders, if needed, to
allow water to drain.
8. Check cross section, profile and drainage.
Rework if needed.
Checkpoint
Materials to be used should be dense graded
asphalt mixture with maximum grain size
13
equal to or less than 19 mm.
Wet part should be blowered.

Laying of asphalt mixture should be
approx. 1 cm. higher than the adjacent
surroundings to give allowance for
settlement.
When depth of pothole is more than 7 cm,

compact mixture in two layers.
Required Temperature:
- arrival at jobsite: above 160C
- during spreading and compaction above
135C
- before opening the pavement to traffic:
above 50C (max)
14
Photographs
1) Cutting and tack or prime coat
Cut damaged part
and surrounding area
by squaring with each
side vertical. Remove
dust and mud
completely.
2) Manual compaction
Manual compaction
with hand tamper.
Use manual plate
compactor for better
quality of work.
3) Machine compaction
Road roller is used in
compacting potholes.
However, it is
advisable to use manual
plate compactor on
corner and edge areas
that are difficult to
compact
15
2-2 PENETRATION PATCHING

BITUMINOUS PAVEMENTS
Purpose
To provide smooth and well-drained surfaces.
This activity is not suitable for repairing
hazardous conditions, since lack of mobility
prevents quick response.
Procedure
1. Remove stagnant water, if there is any, from the
defects.
2. Do proper squaring: (a) to the required depth;
(b) sides are vertical; (c) corners are square or
slightly rounded; (d) sides have no abrupt
changes in line; and (e) hole is cut up to stable
base.
4. Place aggregate in layers and compact each
layer.
5. Spread final layer with asphalt per required rate
of application at 1.0-2.0 liters/sq.m. .
Avoid using too much asphalt.
6. Apply cover sand and compact. Final layer
should be flushed with surrounding surface.
7. Provide turnouts on shoulders, if needed, to
allow water to drain.
16
Checkpoint
Penetration macadam is suitable for
regions without asphalt plant.
Before placing and spreading macadam
aggregate, oversized and slender or flat
aggregate should be removed.
Bituminous material should be spread
uniformly so as to penetrate sufficiently
and cover aggregate.
The surface should be provided with seal
coat for water proofing.
Photographs
1) After cutting asphalt
When traces of
water is observed,
sealing of cracks
and joints should
be done to prevent
water intrusion to
the base.
2) Putting in aggregate
Mix macadam
smaller-sized
chippings to
minimize voids in
aggregates.
17
3) Finish
Use dry and clean
coarse sand.
4) Applying bituminous material

Bituminous
material should be
applied uniformly.
The rate of
application should
be strictly
observed.
5) Compaction with small road roller

After the spreading
of sand, compact
immediately using
road roller or plate
compactor to
prevent
segregation of
aggregates.
18
2-3 SEALING BITUMINOUS

PAVEMENTS
Purpose
To prevent further deterioration caused by
entry of water.
Procedure
1 Remove debris from cracks or clean raveled
surface.
2 (a) For individual cracks: fill cracks
completely with asphalt; use squeegee to
force asphalt into cracks and remove excess.
(b) For areas: apply asphalt, distribute with
broom and remove excess with squeegee.
3 Apply sand to cover.
Checkpoint
Sealing is generally applied to cracks of
more than 3 mm in width.
Loose damaged part around cracks should
be removed.
Fill cracks with bituminous material at a
temperature of 180 to 200 degrees
centigrade.
For deep crack, fill it twice with asphalt.
Sealing of wide area is effective for
preventive maintenance if it is carried out
regularly prior to rainy season.
Aggregate to be used should be clean, hard
and durable.
19
Photographs
1) Cleaning before filling

Remove dust and
mud in cracks
with broom, etc.
2) Applying bituminous material

Rain water trapped
on cracks intrudes
into lower layer,
which causes
premature
deterioration of
base and sub-base
course.
3) Seal coat
Seal coat is
applied to prevent
aging of asphalt
surface water
proofing and wear
resistance.
20
2-4 REPLACEMENT OF BITUMINOUS

PAVEMENTS
Procedure
1. Heat asphalt at proper temperature, if
penetration or hot asphalt is used.
2. Remove damaged pavements.
4. Clean surface to be covered.
5. Spray liquid asphalt at specified rate of
application for tack coat or prime coat.
6. Place pre-mix in layers and compact each
layer, or place aggregate in layers, compact
each layer, spread final layer with asphalt
and apply sand to cover .
Checkpoint
Considering mobility of machine, the width
to be replaced should not be less than one
lane of the road.
When the cause of damage is due to weak
base or sub-base, remove and replace the
base or sub-base prior to replacement of
bituminous pavement.
Disturbed base when removing damaged
bituminous pavement should be leveled and
compacted prior to laying of bituminous
21
pavement
Tack coat or prime coat should be applied
uniformly on bottom surface and vertical
side as well.
Laying of asphalt mixture should be approx.
0.5 to 1.0 cm. higher than the adjacent
surroundings to give allowance for
settlement.
Required Temperature:
- arrival at jobsite: above 160C
- during spreading and compaction above
135C
- before opening the pavement to traffic:
above 50C (max)
22
Photographs
1) Heat asphalt in kettle
Heat asphalt to
required temperature
and maintain the
temperature during
the activity
2) Removal of damaged asphalt concrete pavement

Disturbed base when
removing damaged
bituminous pavement
should be leveled and
compact prior to laying
of bituminous pavement.
3) Replacement of asphalt overlay on concrete

The damage of surface
layer is the result of
deterioration of sub-base
under old concrete
pavement. The major
cause is presumed to be
the decline of bearing
capacity due to rising
groundwater
23
3-1 PATCHING CONCRETE

PAVEMENTS
Related Activity Standard No. 121, 71X
Purpose
To eliminate hazardous condition, to provide
smooth and well-drained pavements.
Procedure
1. Remove stagnant water from defect or
area to be leveled.
2. Remove all broken pavement.
3. (a) For defects: shape defects, tack, place
pre-mix or penetration patch as in 2-1
and 2-2.
(b) For leveling: clean area, tack, place premix as in 2-1.
(c) For raveled areas: clean area, apply
asphalt and cover aggregate as in 2-3.
4. Provide turnouts on shoulders, to allow water
to drain.
Rework, if needed.
Checkpoint
Asphalt materials are widely used instead
of cement materials for patching due to its
easy application. Although cement
materials used on the existing PCCP is
desirable for patching, it is difficult to
cut/taper on the areas to be patched.
24
Likewise, curing takes time before the

road is opened to traffic.
Remove damaged part and expose sound
part by chipping off to clean the surface to
be patched.
Damaged joint and deep cracks should be
sealed prior to patching works to prevent
water intrusion into/from the lower layer of
road.
Photographs
1) Deep crack on concrete

pavement
Before patching,
treatment is
important to prevent
water intrusion.
2) Penetration patching
Penetration patching
is applied to cracked
area similar to the
procedure under 2-2
25
3) Patching with hot pre-mix

Repair work is the
same as asphalt
pavement of 2-1.
Keeping proper
temperature during
compaction is
important.
4) Patching for levelling

When gaps between
slabs are identified,
apply patching after
filling it with
sealing material.
5) Overlay with asphalt

Reflection cracks
will eventually
appear on the
existing cracks
and the weakened
plane joints after
thin layer (less
than approx. 5 cm)
of overlay is being
applied.
26
3-2 CRACK AND JOINT SEALING OF

CONCRETE PAVEMENTS
Purpose
To prevent entry of water, debris and other
incompressible materials into cracks and
joints and allow the free movement
(expansion or contraction) of the pavement.
Procedure
1. Heat asphalt to proper temperature, if hot
asphalt is used.
2. Remove incompressible materials from
cracks or joints, including old filler and blow
cracks or joint clean.
3. Pour asphalt in crack or joint to within
one-half cm of pavement surface. For large
cracks, fill with bituminous pre-mix/
aggregate and asphalt. Do not overfill.
4. Remove any excess asphalt by blotting using
fine sand then scrape.
5. Check to ensure that asphalt do not seep
underneath the pavement and that cracks
remained filled.
6. Apply sand to cover.
Checkpoint
Heat asphalt to the required temperature
(180-200).
Clean or blow thoroughly dust and mud in
cracks and joints
27
Further, remove damaged loose part of

surrounding areas.
Pour asphalt in cracks or joints kept in dry
conditions.
Causes of cracks should be identified and
corrected prior to sealing works.
Photographs
1) Heat asphalt in kettle
Heat asphalt to
required
temperature and
maintain the
temperature during
the activity
2) Clean cracks and joints
Air compressor
is more effective
for blowing dust
and mud. Wet
part should be
blown dried
3) Pour asphalt in cracks

and joints
Remove excess
asphalt.
28
3-3 REPLACEMENT OF CONCRETE

PAVEMENTS
Purpose
To provide smooth, well drained pavement
and prevent progressive deterioration of the
pavement.
Procedure
1. Remove damaged pavement.
2. Add base material, if needed.
3. Salvage waste material suitable for backfill.
Place excess materials in a proper location for
disposal.
4. Shape hole so that sides are vertical,
corners are square and sides have no
abrupt changes in line and hole is cut to
the required depth.
5. Mix and place concrete and finish to
match surrounding surface or place hot
mix in layers and compact each layer.
6. Cure concrete. Provide barricade and close
traffic for at least 14 days.
Checkpoint
Sub-grade or sub-base in poor conditions
should be replaced.
Damaged dowel bars of existing slab should
be replaced.
For contact surface with existing slab, joint
should be installed to separate old and new
concrete.
29
Photographs
1) Road surface situation before replacement
It is of utmost
importance to verify
and address the cause
of damage prior to
replacement. In this
case, slope failure of
embankment is the
original cause.
2) Removal of concrete slab with breaker

With chipping,
remove damaged part.
During the work, be
careful not to damage
dowel bars, etc.
3) Placing of concrete
Consolidate concrete
using vibrator
It is recommendable
to isolate old concrete
and new concrete to
minimize mutual
restraint stress
30
Photographs
31
4-1 MANUAL REPAIR/PATCHING OF

UNPAVED SHOULDERS
Purpose
To eliminate hazardous conditions and to
provide smooth, well-drained shoulders.
To provide functional ditches
Procedure
Act. No.131 Repair without new materials
1. Reshape ditches.
2. Reclaim suitable materials from ditches
and sides. Remove unsuitable material.
3. Cut high areas.
4. Blend material from high areas with
reclaimed suitable material.
5. Fill low areas and compact.
6. Reshape surrounding surface or provide
turnouts on shoulders, if needed, to allow
water to drain.
Rework if needed.
1. Restore shape of shoulder.
compaction.
4. Shape surrounding surface or dig channels
through high areas of surface, if needed,
to allow water to drain.
32

Rework if needed
Checkpoint
Water ponding will damage the sub-base and
sub-grade of carriageway, which easily
causes premature pavement failure.
Because scouring easily occurs in unpaved
with steep vertical alignment, installation of
turn-out ditch is recommendable.
Photographs
1) Shoulders are provided as rest areas for vehicles.
Shoulder must be stable to prevent depression
Rain water intrusion
into embankment is
ground for concern.
2) Installation of drainage in shoulder

Scouring in
shoulder is caused
by surface flow.
Turn-out ditch is
necessary to
reduce the flow
speed
33
3) Repair of shoulder
3.1. Levelling of
carriageway and
shoulder , and repair
of shoulder are
necessary to protect
the pavement
structure from
damage and for
traffic safety.
3.2. Repair shoulder

pothole using item
201/300
34
4-2 MACHINE GRADING UNPAVED

SHOULDERS
Purpose
To provide smooth, well-drained surfaces.
Reclaiming surface materials and ditching are
secondary purposes.
Procedure
1. Scarify or cut surface to remove
potholes, corrugations, erosion scars, high
areas, etc. Cut toward pavement.
2. Clean and re-cut ditches and
outlets/turnouts. Remove spoil
materials from culvert inlets and outlets.
3. Reclaim suitable material. Remove or
stockpile unsuitable material.
4. Remove oversize or unsuitable material.
5. Blend reclaimed suitable materials with
existing scarified materials.
6. Spread (away from pavement), reshape and
compact.
Rework if needed.
Checkpoint
As for reclaiming work by grader,
scarification should be carried out in advance
for uneven shoulder surface.
35
Particularly in urban area, consider not only

on ground/visible obstructions but also
underground facilities like water pipelines
and cable lines, etc.
Photographs
1) Reshaping shoulder with grader
Machine grading
works is very
effective on wide
shoulders without
obstructions.
2) Machine work in urban area

Caution must be
observed in order
not to damage
existing structures
including
underground
utilities like water
pipelines, cable
lines, etc.
3) Adding new material
When shoulder is
washed out, add
new material to
keep shoulder in
proper form to
provide efficient
drainage
36
5-1 MANUAL DITCH CLEANING

Related Activity Standard No.141
Purpose
To provide functional ditches.
Procedure
1. Start cleaning or digging from the
downstream side or from the discharge
point.
2. Remove debris from the ditches.
3. Reshape unlined ditch to an adequate flow
line and cross-section.
4. Final unlined ditch elevations should match
culvert inlet and outlet elevations.
5. Place ditch waste materials in a
safe location that does not obstruct
drainage (refer to item #3).
6. Always keep shoulder outlet channels open,
to allow water to drain, and report this
condition to Area - In Charge for
scheduling of needed corrective action
(refer to item #4).
Checkpoint
After natural phenomena, such as windstorm,
wind waves, heavy rainfall, and earthquake, it
is required to immediately inspect the drainage
structures.
37
Photographs
1) Immediate
removal/clearing of
mud/debris on drainage
facility is required to
maintain the flood
capacity of drainage
structure.
2) When cleaning, do
not leave earth and
sand on the
roadside or slope
but dispose off at
designated disposal
area.
3) Good example of
cleaning an open
lined canal.
38
5-2 MANUAL CLEANING OF

CULVERT INLET/OUTLET AND
CULVERT LINE/BARREL
Related Activity Standard No.142, 143
Purpose
To provide functional drainage structures.
Procedure
Act. No. 142 MANUAL CLEANING OF
CULVERT INLET/OUTLET
1. Remove debris from inlets and outlets.
2. Remove obstructions that do not normally
wash out.
3. Place waste material in a safe location that
does not obstruct drainage of waste on site
(refer item 2).
4. Report structural failures and eroded areas to
Area- In Charge (refer item 3).
Act. No. 143 CULVERT LINE / BARREL
CLEANING
1. Place safety devices
2. Clean culvert barrel using hand tools.
3. Place waste material in location where it will
not obstruct drainage or where it will not be
carried or deposited back in the culvert line.
Report structure defects (refer item 2).
4. Remove safety devices
39
Checkpoint
Regularly monitor condition of the drainage
inlet/outlet to ensure drainage facility functions
according to its flood capacity
Photographs
1) Mud/debris
accumulation
reduces the
discharge capacity
2)Remove accumulated
debris/mud
3) Good example of
cleaning drainage
outlet
40
5-3 REPAIRING AND/OR REPLACING

MINOR DRAINAGE STRUCTURES
Related Activity Standard No.144
Purpose
To provide properly aligned, functional and
structurally sound drainage structures.
Procedure
Work methods vary but includes:
a. Concrete repairs
b. Rip-rap repairs.
c. Placing culvert pieces.
d. Placing inlet grates.
e. Placing manhole covers.
Checkpoint
Focus the repair and maintenance on the
convergence/meeting of two ditches because
this part is prone to scouring.
41
Photographs
1) It is important to
ensure the
drainage capacity
in case of concrete
repairs.
2) After the repair

work, earth and
sand on the
roadside must be
immediately
hauled/disposed.
42
6-1 Vegetation Control

(Grass Cutting / Tree Trimming)
Purpose
The primary purpose is beautification
Procedure
1. Split crew, as needed, by placing some on
each side of the road
according to the width of the area to be
mowed.
2. Use Grass cutter, if available, to make the
work faster and easier
3. Cut vegetation to a height of (7-12cm) within
mowing limits:
- 2m from edge of pavement or traveled way
or top edge of embankment slope,
whichever is less on fill sections.
- 1m beyond ditch flow line in cut sections.
- Taper from cut to fill sections.
- If vegetation control in urban areas is
needed, cut up to right- of-way limits.
4. Observe proper disposal of cut vegetation
Checkpoint
Small to medium-sized shrubs should be
trimmed to clear sight distance.
When using the grass cutter, the operator must
face the flow of traffic to avoid accident to
both the operator and approaching vehicle
43
Photographs
1. When cutting
vegetation, use
Personal
Protective
Equipment
2. Proper disposal
of cut vegetation
44
6-2 EROSION REPAIR AND

CONTROL ON ROADSIDES
Purpose
To correct and prevent conditions that
threaten the structure of the roadway.
Procedure
1., If possible shape defect.
2. Place material.
3. Compact, if possible, or mortar.
4. Clean or dig interceptor ditches, if needed,
when length is less than 25 meters.
Checkpoint
After natural phenomena, such as heavy
rainfall, immediately inspect the structure
and establish appropriate measures against
breakage and defects.
45
Photograph
Cleaning of ditch
to prevent
roadside erosion
46
6-3 REPAIR TO MAJOR ROADSIDE

STRUCTURE
Purpose
To preserve the structure of the roadway and
to prevent further deterioration.
Procedure
Work methods vary, but may include:
a) Concrete patching
b) Repairing rip-rap or grouted rip-rap
c) Modifying structures to improve roadway
drainage
d) Replacing backfill
e) Rebuilding tops of walls
f) Crack sealing
Checkpoint
After natural phenomena, such as windstorm,
wind waves, heavy rain, and earthquake,
immediately inspect the face of slope and
structures.
47
Photographs
1. Loose deposit of soil on
the back slope can be a
major cause a debris
flow resulting to a great
disaster; hence the need
to provide appropriate
countermeasure to such
kind of slope.
2. Maintenance of
drainage structure is
water from seeping into
the retaining wall.
3. Clean clogged
weepholes and replace
the damaged ones.
48
7-1 SIGN MAINTENANCE AND

TRAFFIC SERVICES
Purpose
To preserve and restore the signs in its
functional condition, in order to maintain its
clarity, conspicuity, comprehensibility,
credibility/ consistency and to prolong their useful
life. Include activity for routine traffic services
not described by, or incidental to major activities.
Procedure
1. Perform maintenance in accordance
with current traffic control devices standards.
Work includes:
- washing and cleaning,
- replacing sign boards, such as traffic
signs, delineator, hazard marker, drainage
marker, km. post and ROW markers.
- Trimming vegetation to improve sign
visibility is also included.
Checkpoint
Use soft materials in cleaning and
washing of signage to prevent damage of
the surface
49
Installation/re-installation of road signs

with its pole, embedment length or
sound should be in accordance to
Standard Specifications of Road Signs
and Pavement Markings Manual.
Photographs
1) Washing and
cleaning the
signage prior to
re-installation
Wash signage
using water
2) Set up the signage

with the pole prior
to pouring of
concrete.
50
7-2 CENTERLINE AND LANE

REPAINTING
Purpose
To adequately guide the traveling public.
Procedure
1. Clean area to be repainted.
2. Lay out markings in accordance with
Road Safety standards.
3. Place paint and glass beads in
accordance with Standard
Specification.
4. Place traffic cones along newly repainted
lines until paint is dry.
Checkpoint
Materials to be used should be selected
on its effectiveness, durability and
workability.
New markings should fit in well with
existing markings.
Application of pavement markings
should be done when pavement is dry;
wet condition is not applicable.
51
Photographs
1) After repainting
Cure it properly
until it dries
(approx. 30
min.).
2) Equipment for
painting .
Lane marking is
repainted using
hand cart by melt
method
3) Repainting
centerline
Manual repainting
of centerline lane
markings.
52
7-3 GUARDRAIL MAINTENANCE

Purpose
To maintain guardrails in as-constructed
condition.
Procedure
1. Perform maintenance in accordance
with current traffic control devices
guidelines.
Checkpoint
For guardrail replacement or installation of
metal beam rails, overlapping must go with
the direction of the flow of traffic.
Before painting, check the guardrails

whether cleaned and well dried. If they are
dirty with dust or wet, the paint life may
become short.
Proper Lapping of Guardrails
53
Photographs
1) Replace
damage metal
beam rail
2) Clean guardrail
using soft
material then
paint
3) Remove
grasses around
around and
under the rail
54
7-4 SIGHT DISTANCE MOWING AND

CLEARING
Purpose
To eliminate or prevent hazardous conditions
due to inadequate sight distance. Improving
traffic sign and guardrail visibility is included.
Procedure
1. Cut vegetation in designated areas to a
height of 7 - 12 centimeters.
2. Trim tree branches.
Checkpoint
If it is necessary for safety of road
users, traffic regulation measures should be
taken. It depends on traffic volume or
original sight distance of the section.
It is more difficult at the right shoulder of the
right curve to secure a sight distance.
Downhill should be most considered on the
sight visibility because it is much difficult to
stop for traffic.
Trimmed/cut branch or grass should be
disposed properly so that it does not become
an obstacle to road users or land owners.
55
Photographs
1) Trim trees
obstructing the
road signs
2) Cut tree
branches
obstructing
the sight
distance
3) Cut trees, vines,

creepers,
obstructing road
signs and sight
distance.
Bolo, a tool to
cut grasses
Scythe, a tool to
trim branches
56
8-1 CLEANING BRIDGES

Purpose
To prevent deterioration due to: abrasion,
corrosion, rutting, inadequate
expansion and vegetation at decks or
girders, as well as to provide safety to
the travelling public
Procedure
1. Place scaffolding if needed
2.Perform required cleaning using high pressure
water blasting or manual
shovelling/sweeping.
3.Remove scaffolding after its use.
Checkpoint
All foreign materials shall be completely
removed manually prior to cleaning with highpressure water.
Points of cleaning
Bridge sidewalks, bridge decks, top of curbs
beam flanges, gusset plates abutment bridge
seats, top of pier truss joints, deck drain
systems
Water should be clean and free of
chemicals and salt. River water can be used.
The high pressure water shall be sufficient to
clean without damaging the bridge.
Minimum water flow rate: 10 liters/min.
Maximum water pressure: approx. 8000 kPa
57
The removed materials shall be collected and

disposed to an approved area in accordance
with governing local regulations.
Photographs
1) Removal of foreign materials
All foreign materials

such as dirt, dust, and
vegetation shall be
removed.
2) Cleaning around bearing

Cleaning around
bearing on the pier is
damage of bridge
structure.
3) Cleaning deck drains
All deck drains and its
accessories shall be
flushed with
high-pressure water.
4) Procedure in cleaning bridge girder
All toxic substance
of completely
removed by washing
from top to bottom
and from end to the
center of girder
58
8-2 PATCHING CONCRETE DECK

Purpose
To restore small areas of concrete deck where
sound concrete is damaged by spalling, scaling and
impact. The patch thickness is limited to a
maximum of 100 mm depth of hollow surface.
Type A
Type B
(Routine Maintenance)
(Major Maintenance)
Defects without exposed

rebar. Defective widths
of up to 300 mm and
depths of up to 50 mm
Defects with exposed

from 300 mm to 600 mm,
and up to 100 mm depths
Procedure
1. Removal of defective concrete
Remove all defective concrete and prepare
the edges for the patch area.
Remove additional area of concrete in case
of adding rebar because of its section loss.
59
2. Cleaning of concrete and rebar

Remove loose
particles and dust of
concrete.
Remove the rust of
rebar.
3. Bonding coat to concrete and rebar

Apply epoxy
bonding coats to dry
and clean concrete
surfaces.
Apply the epoxy
bonding coat to steel
bars.
4. Placing mortar
The mortar should
be placed in layers
of about 20 mm
thick.
Compact each layer
thoroughly over the
entire surface.
5. Curing
All types of cement repairs need thorough and
continuous curing to develop strength, and to
minimize drying shrinkage while bond strength
is developing.
60
Checkpoint
Material requirement
The materials for repair shall conform to the
required specification.
TYPE-A
Portland cement
Epoxy bonding coat
TYPE-B
Polymer cement
Epoxy bonding coat
Zinc-rich primer
Removal of damaged concrete
Remove concrete within marked out areas and
confirm the sound of concrete substrate.
Concrete surface preparation
All concrete surfaces to be patched with
mortar shall be prepared by mechanical
scrubbing to remove any substance without
causing delamination of adjacent concrete by
vibration.
Additional concrete chipping
If the exposed reinforcement is further
corroded or the surrounding concrete is not
sound, the Area-In-Charge shall determine
enlarged area to be removed and repaired.
The chipping off of concrete shall not extend
to more than 20 mm from the main
reinforcement.
61
Additional or rebar replacement

Any rebar with 10% or more section loss by
corrosion shall be reported to the Area-InCharge and additional or replacement rebar
shall be provided.
It shall be fixed along its length at suitable
intervals to prevent sagging.
The corroded rebars shall be cleaned and
apply zinc-rich primer to prevent further
corrosion.
Method of mortar placing
Mortar liquid shall be added to the dry
components and thoroughly mixed to
achieve a uniform consistency.
Apply mortar to the bonding agent.
The finished surface of the final mortar layer
shall match with the existing surface.
62
8-3-1 REPAIR OF CONCRETE

BRIDGES (CRACK REPAIR)
Purpose
To repair minor cracks (W<=0.3mm, 1
direction) on concrete bridges by epoxy
coating.
Epoxy coating is suitable for fine pattern cracks,
but is not effective on active cracks and those
subject to movement due to applied loads and
temperature changes.
Procedure
1. Preparation of concrete surface
Concrete surfaces adjacent to the crack shall be
cleaned, and free from laitance and
contaminants such as grease and oil.
2. Application of epoxy sealant
Apply approximately 50 mm width strips of
epoxy sealant coating to concrete surfaces
along the crack, as recommended by the
manufacturer.
3. 3. Curing
Cure until the epoxy coating hardens after
application.
4. Monitoring of crack width
The cracks coated with sealant shall be
monitored by the area in charge.
Checkpoint
The epoxy material shall conform with
required specifications.
63
Apply epoxy after the concrete surface is

completely cleaned.
Photographs
1) Preparation of concrete surface
Prepare concrete
surface adjacent to
the crack by
cleaning and free
from laitance and
contaminants.
2) Application of epoxy sealant

Apply
approximately
50mm width strips
of epoxy sealant
coating by hand
tool to concrete
surfaces along the
crack.
3) Curing
After application,
perform curing until
the epoxy coating
hardens.
64
8-3-2 REPAIR OF CONCRETE

BRIDGES (PATCHING)
Purpose
To restore small areas where sound concrete is
damaged by spalling, scaling and impact.
Type A
(Routine Maintenance)
Type B
(Major Maintenance)
Defects without exposed

of up to 300 mm and
depths of up to 50 mm
Defects with exposed rebar.

Defective widths from 300
mm to 600 mm, and up to
100 mm depths
Procedure
1. Removal of loose debris
Remove all defective concrete at corner edges
of area to be repaired. Remove loose debris.
2. Furnishing formwork
If necessary, provide formwork around the
damaged concrete to straighten the edges of
the damaged section.
65
3. Coating bonding agent or setting nail

Apply bonding agent
to the damaged area
or set concrete
nails/bids to reinforce the repair.
If rebar is exposed,
anticorrosion agent
coating on the bar
surface should be
applied prior to
patching.
4. Placing cement mortar
Prepare the mortar
mix and spread
fresh mortar over
the area.
Smoothen and
level the mortar
with a trowel.
5. Curing
Cure repaired
concrete to
develop
strength and
impermeability
66
Checkpoint
Material requirement
The materials for repair shall conform
to the required specification.
Method of mortar placing

The repair mortar shall be built up to
the original surface profile in layers not
exceeding 20 mm with the final layer not
exceeding 15mm, unless otherwise
recommended by the manufacturer and
approved by the Area-In-Charge.
Refer to section of Patching concrete
deck.
Concrete surface preparation, removal of

damaged concrete, curing
Refer to section of 8-2 Patching
concrete deck.
67
8-4 REPAIR OF STEEL BRIDGES

(TOUCH-UP PAINTING)
Purpose
To repair small areas of less than 30% of the
total area of a member to prevent occurrence of
series of corrosion.
Procedure
1. Scaffolding
Install the scaffolding at the side of the
structure prior to touch-up painting work.
2. Preparation of steel surface and
touch-up painting
Remove old coating film and rust with tools
such as disc grinder, scraper and wire brush.
Apply special anti-corrosion paint or
aluminum paint. The special anti-corrosion
paint can be applied on heavily corroded
steel portion.
The special anti-corrosion paint can be
applied on remaining rust. However, it is
advisable to totally remove the rust.
Checkpoint
The materials for repair shall conform to the
required specification.
Sharp ridges and deep narrow grooves or pits
shall be removed from the steel surface using
power grinder.
Sufficient thickness of anti-corrosion paint is
needed for durability of touch-up paint.
68
Aluminum paint shall be in accordance

with DPWH Standard Specifications Item411 Paint
The paint shall be applied preferably
within 4 hours after surface preparation.
Photographs
The paint shall be
applied in uniform
smooth coat without
runs, wrinkles, or
other defects.
2) Condition level of corrosion
69
8-5 REPAIR OF BRIDGE ATTRIBUTES

Purpose
To maintain the functionality of the bridge
attributes such as expansion joint
(sealant joint), bridge bearing and bridge railing,
thus, preventing deterioration of the bridge
structures.
Procedure
1. Expansion joint
Clean and reseal of sealant joint between the
bridge deck and abutment and at gaps on
intermediate supports in case of
multiple spans.
2. Bridge bearing
Remove debris, sand and other deposited
materials around bearing on abutment and
pier and then clean.
3. Bridge railing
Concrete railing shall be regularly painted to
prevent deterioration.
Checkpoint
Refer to section of 8-1 Cleaning Bridges
and 3-2 Crack and Joint Sealing of Concrete
Pavements) for expansion joint repair.
Refer to section of 8-1 Cleaning Bridges
for bridge bearing repair.
Refer to DPWH Standard Specification Item
411-Paint for painting of Bridge railing.
70
Photographs
1) Expansion Joint (Sealant Joint)
Sealant joints are
usually unprotected,
thus
they
might
deteriorate and peeloff when the edge of
the deck is damaged.
2) Bridge
Deposited materials
around bearing can
contribute
to
the
damage of bridge
structure by restricting
movement of bearing.
3) Bridge Railing
Concrete railing shall
be painted regularly.
71
8-6 REPAIR OF BRIDGE

PROTECTION WORKS
Purpose
To repair protection works of bridge pier or
abutment listed as follows.
Stone Masonry
Gabion Wire Mesh
It is important to repair the broken gabion and
slope protection in the early stage of
routine maintenance; otherwise it will become
more difficult to repair the damages, increasing
the risk of failure.
Procedure
Partial replacement of Stone Masonry
1. All unsound, imperfect or loose stones and
mortar joint, panel, etc. shall be removed.
2. The foundation base shall be properly
compacted prior to placing of boulders .
3. The slope line shall be carefully prepared at
the same level as shown in the drawings.
4. Stones shall be laid in full bed of mortar,
with joints completely filled with mortar
and shove into place.
Partial replacement of Gabion Wire Mesh
1. Replace damaged area by installing new
gabion wire mesh in accordance to DPWH
Standard Specification Item 511- Gabions
and Mattresses.
72
Checkpoint
Stones and mortar joints must be placed
as directed by the Area-In-Charge.
Stones shall be laid and anchorage shall
be installed in accordance with the
drawings.
Photographs
1) Damage on Stone Masonry
Stones are
lost from
stone
masonry due
to strong
river flow.
2) Damage on Gabion wire mesh

Damage on
wire mesh
might lead
to failure of
gabion.
73
8-7 CLEARING BRIDGE WATERWAYS

Purpose
To maintain bridge opening for full flood
capacity.
Procedure
1. Remove the debris or sand and gravel
sedimentation out of river bed.
2. Remove driftwoods and debris lodged on the
piers.
3. Use excavated sand or gravel to fill low
portion downstream or remove and replace
where it will not cause sedimentation again.
Checkpoint
Clean bridge waterways at an early stage
wherein the volume of debris to be removed
measured at small amount, hence decreasing
the risk of bridge or slope failure.
Driftwoods and debris shall be removed and
properly disposed to a designated disposal
area.
Burning of driftwoods or debris is not allowed.
It must be stockpiled for drying at the
disposal area.
If the materials taken out from the riverbed
pass the specification for road surfacing,
some may be stockpiled at designated area
for maintenance use.
74
Photographs
1) Piled driftwood and debris around pier
Immediately
remove the
driftwoods and
debris lodged on
the piers.
2) Removing driftwoods and debris around pier
Inspection
vehicle with
scaffolding
device can be
utilized in
accessing area
difficult to
reach.
75
9-1 INITIAL RESPONSE TO

EMERGENCIES - - - ROADS
Purpose
To immediately remove road slips to make
the road clear and passable.
Procedure and Required Equipment/Tools
1. Perform initial work such as re-routing traffic
and/or detouring.
2. Cleaning of roadslips with the use of payloaders
and dump trucks.
3. Install appropriate warning signs, barricades
and informative signs.
4. Provide safe pedestrian passage if the road is
closed to traffic and detour road is not available.
Checkpoint
In case a road is impassable, install
warning/informative signs.
Reconnaissance of possible re-routing is of top
priority.
Confirm safety of the structure before opening
the road to traffic.
Materials must be ready and schedule of needed
equipment/tools readily prepared for emergency
response.
Check drains during heavy rain.
76
Photographs Example of emergency response
Because of heavy rain, a lot of water has come out

from gap of damaged drain. The water washed the
embankment.
As an initial response, tarpaulins and sand bags are
applied to cover and reinforce the damaged part.
(1) Shoulder of the embankment
Before
After
(2) Drain at the shoulder of the embankment

Before
After
(3) Toe of the embankment

Before
After
77
9-2 INITIAL RESPONSE TO

EMERGENCIES - - - BRIDGES
Purpose
To remove hazardous elements and debris
immediately that endanger the bridge, thus
making it clear, safe and passable.
Procedure
1. Install appropriate warning signs, barricades
and informative signs.
2. Adopt re-routing traffic scheme or find
detour route.
3. Perform initial work to make the bridge safe
and passable to vehicular traffic based on the
actual needs or to suit actual conditions.
4. Provide or construct a safe pedestrian
passage if detour route is not available and
bridge is closed to traffic.
5. Remove debris and hazardous elements and
clear the area.
Checkpoint
Check for possible detour route.
Ensure the safety of the bridge structures
before opening it to vehicular traffic
Materials must be ready and schedule of
needed equipment/tools readily prepared for
emergency response.
Check network in case of emergencies.
Rapid assessment of the damaged structures is
recommended.
78
Photographs
1) Closing and detouring traffic
Install appropriate
warning signs and
barricades
2) Provision of materials for initial response

Stock materials
for emergency
response.
3) Initial response for keeping bridge safety

Immediate
repair of bridge
damage portion
to keep safety
measures.
79
Additional Information
In an emergency due to unusual weather,
responsible MPPs and his team need to rush to
the site as soon as possible but beforehand, site
instructions from his supervisors must already be
carried out for his team to take appropriate action
bringing with them the necessary belongings
before leaving such as the following tools and
equipment:
Work Glove
80
Additional Information
In a disaster, several emergency materials and
tools are needed depending on the size of the
disaster. For quick action, therefore, sources of
materials, arrangement of needed equipment, and
arrangement of emergency hotlines must be
readily available, such as the following:
Handheld Radio
81

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IMPROVEMENT OF QUALITY MANAGEMENT FOR

Department of Public Works and Highways

Improvement of Quality Management

Department of Public Works and Highways

JICA Team Members

Sample Organizational Structure of

MATERIALS AND EQUIPMENT

Also, there is no need for actual detail

Increase of frequency causes cost increase.

Wet aggregate for repair of asphalt pavement

For routine maintenance

1-1 MANUAL REPAIR OF UNPAVED

2) Materials not to be used

1-2 MACHINE PATCHING/GRADING

6. Spread, reshape and compact.

Work should start

3) Spreading with road grader

4) Compaction with road roller

2-1 PREMIX PATCHING BITUMINOUS

equal to or less than 19 mm.

Wet part should be blowered.

When depth of pothole is more than 7 cm,

2-2 PENETRATION PATCHING

4) Applying bituminous material

5) Compaction with small road roller

2-3 SEALING BITUMINOUS

1) Cleaning before filling

2) Applying bituminous material

2-4 REPLACEMENT OF BITUMINOUS

2) Removal of damaged asphalt concrete pavement

3) Replacement of asphalt overlay on concrete

3-1 PATCHING CONCRETE

Likewise, curing takes time before the

1) Deep crack on concrete

3) Patching with hot pre-mix

4) Patching for levelling

5) Overlay with asphalt

3-2 CRACK AND JOINT SEALING OF

Further, remove damaged loose part of

3) Pour asphalt in cracks

3-3 REPLACEMENT OF CONCRETE

2) Removal of concrete slab with breaker

4-1 MANUAL REPAIR/PATCHING OF

5. Check cross-section, profile and drainage.

2) Installation of drainage in shoulder

3.2. Repair shoulder

4-2 MACHINE GRADING UNPAVED

Particularly in urban area, consider not only

2) Machine work in urban area

5-1 MANUAL DITCH CLEANING

5-2 MANUAL CLEANING OF

5-3 REPAIRING AND/OR REPLACING

2) After the repair

6-1 Vegetation Control

6-2 EROSION REPAIR AND

6-3 REPAIR TO MAJOR ROADSIDE

7-1 SIGN MAINTENANCE AND

Installation/re-installation of road signs

2) Set up the signage

7-2 CENTERLINE AND LANE

7-3 GUARDRAIL MAINTENANCE