Highway Maintenance

Highways are lifelines of a nation, it is crucial to keep these in good working condition. Markolines provides a suite of maintenance services to address diverse road conditions. Weather, traffic volume and geographical conditions often impact the roads and it is important to take these factors into consideration while arriving at the right treatment. Our team of experts is experienced to handle repairs, replacements and maintenance projects, and is guided by the tenets of health, safety, security and environment (HSSE). We are updated with knowledge on the latest trends and technologies, and implement the same on our site to deliver an improved solution.

MAJOR MAINTENANCE (BITUMINOUS) RIGID PAVEMENT MAINTENANCE PREVENTIVE MAINTENANCE

We undertake major maintenance and repairs of highways which covers rehabilitation, renewal or resurfacing of the assets. The complex nature of these projects involves temporary road closures and diversion during the works. Such maintenance project requires accurate planning of resources, adequate safety arrangements, advanced machinery,proper coordination, faster turnaround time and seamless traffic management. Under Major Maintenance our team designs tailor-made plans for each project and follows stringent timelines to minimise disruption time.

We undertake major maintenance and repairs of highways which covers Preventive, rehabilitation, renewal or resurfacing of the assets. The complex nature of these projects involves temporary road closures and diversion during the works. Such maintenance project requires accurate planning of resources, adequate safety arrangements, advanced machinery,proper coordination, faster turnaround time and seamless traffic management. Under Major Maintenance our team designs tailor-made plans for each project and follows stringent timelines to minimise disruption time.

Our Major Maintenance activities involve:

Repair and Rehabilitation

Pavement Milling & Filling
Bituminous Overlay/ Resurfacing with HiMA/ PG 76-10/ CRMB-65 produced at site etc.
Rehabilitation with Glass grid
Hot in Plant RAP30 % & upto 40% -60%
Cold in Place Recycling

The rigid pavement is basically the plain concrete, or reinforced concrete slabs laid directly over the Dry Lean Concrete or a stabilized base course. The cement concrete slab has a very high modulus of elasticity; therefore, the deflection of the slab is very little under the vehicular load, hence they are very suitable for carrying high traffic loads. While rigid pavements have a higher initial construction cost about 1.5 times that of flexible pavements, they offer a longer service life and lower maintenance costs. However, factors like geological movements, faulty design, inaccurate traffic volume predictions, subpar workmanship etc., can significantly impact the overall performance and reduce their expected lifespan. Hence to address these challenges and extend the life of rigid pavements, timely and effective maintenance is very crucial.

Given the vast scope for maintenance and the lack of organized players in this field, we have established a exclusive team dedicated to rigid pavement maintenance and rehabilitation. The Division specializes in the rehabilitation and maintenance of concrete pavements, ensuring long-lasting and durable solutions. With a focus on quality and innovation, we employ advanced techniques and adequate materials to repair and rehabilitate rigid pavements, extending their lifespan and improving the performance.

Our team of experts with extensive experience in technical due diligence and investigation is dedicated to delivering cost-effective and sustainable rehabilitation services, tailored to meet the specific needs of Customers. We pride ourselves on our commitment to excellence, timely execution, and customer satisfaction, making us a trusted partner in the industry.

Rigid Pavement failures are broadly categorized into two categories where we as MARKOLINES offer our services:

Structural Distresses

These affect the pavement's load-bearing capacity and are typically caused by excessive loading, improper joint spacing, and material issues.

Structural Cracks: These can compromise the pavement's integrity. Partial or complete panel replacement is the solution offered.
Damage to DLP/GSB/Subgrade: Depending on the extent of the damage, full or partial depth replacement is adopted to mitigate the issue.

Functional Distresses

These affect the riding quality and safety but do not significantly impact load-bearing capacity.

Plastic Shrinkage Cracks, Edge Cracks, Corner Cracks, Punchouts, Pop-Outs, Transverse, Longitudinal, and Diagonal Cracks are developed affecting the riding quality. To cater to this we use stitching or stapling, depending on severity.
Raveling and Roughness: Treated with partial depth repairs using speciality chemicals.
Separation at Joints and Sealant Failure: Micro concrete or speciality chemicals are used for partial depth rehabilitation, depending on damage severity.

Preventive maintenanceis performed in response to triggers of deteriorating road condition that requires action before the problem gets out of hand(e.g. Microsurfacing, crack sealing, pothole patching, Rut Filling etc). Our team is well- equipped and trained to perform the various Preventive or specialised activities such as microsurfacing

Roads are among the most important public assets involving massive investment. We help keep the roads to the extent possible in its original condition, thus preserving the investments made on road assets

Services managed under Preventive Maintenance:

Crack Sealing
Fog Sealing
Slurry Sealing
Rut Filling
Surface dressing / Chip Seal
Cape Seal

Specialized Maintenance Services

Micro Surfacing
Cold In Place Recycling (CIPR)/Cold Centr al Plant Recycling (CCPR) with Cement and Foam Bitumen/ Emulsion as per IRC 120:2015
Rehabilitation with Glass Grid.
Hot in Plant RAP
- Cold RAP upto 30%
- Hot and cold RAP upto 40% - 60%

MICROSURFACING

Microsurfacing is a cost-effective surface treatment for preservation and extension of life of roads. With ample technical knowledge, Markolines has ventured into Microsurfacing to execute turn-key jobs and ensure smooth journeys across India specialized due to specified emulsifiers and is a chemical break.

Advantages

Quick Application with minimum traffic hold up and traffic opening in maximum 2 hrs., causes minimum traffic disruption. Night placement is possible.
Cost effective as compared to Hot Mix (BC) and extends life span of the road.
Rectifies surface defects and Ruts including minor cracks, hungry surface due to ageing & surface oxidation.
Environment friendly - Nonpolluting for environment since no heating or hot paving required.

We have introduced the next generation known as Microsurfacing with Suspended Fiber Technology (MS - SFT) for the first time in India.

Moreover, as a step ahead Markolines has set up an exclusive Technology Centre to offer latest techniques in Microsurfacing. The Technology Centre supports the field staff for the precise technical needs of a project considering the vital aspects like condition of road, resources available & environment and delivers solutions tailor-made for it – making us the #1 in Microsurfacing in India.

Our expertise in Microsurfacing: Services managed under Preventive Maintenance:

Own fleet of Microsurfacing Pavers
Adherence to World-class Standards of Quality
Captive Technology Centre for QA/QC
Tie-up with international organisations such as Bergkamp Inc. USA, Ingevity and Owens Corning for technical back-up

Services managed under Preventive Maintenance:

Crack Sealing
Fog Sealing
Slurry Sealing
Microsurfacing + Rut Filling
Surface dressing / Chip Seal
Cape Seal (Chip Seal + Microsurfacing

Downloads

Introduction to Microsurfacing Download
MORTH Approval for Microsurfacing Download
IRC Code for Microsurfacing Download
MORTH specification for Microsurfacing Download

COLD-IN-PLACE RECYCLING

CIPR involves removing and reusing the existing asphalt surface. It involves grinding off the top layer (up to 200mm) of the existing asphalt surface and mixing the crushed asphalt with foamed bitumen/ Emulsion and placing it back down with a recycler and allied machinery. Our team of experts can undertake this complex and specialized activity.

As described in the ARRA (Asphalt Recycling and reclaiming Association) Basic Asphalt Recycling Manual, CIR “consists of recycling asphalt pavement without the application of heat during the recycling process to produce a rehabilitated pavement.

The cold-in-place process is typically performed using a “train” of equipment, which includes a water tanker, bitumen tanker, recycler, graders and rollers. We own the complete set of machinery used in the Cold-in-Place Recycling (CIPR) process.

CIPR can correct deep asphalt defects such as rutting, fatigue (alligator) cracking, and utility cuts that cannot be addressed by a surface treatment or an overlay, and allows minor corrections to the proﬁle of a road surface, reduces reﬂective cracking, and results in a minor inconvenience to trafﬁc.

Advantages of Cold-In-Place Recycling:

CIPR overlay lasts 10-15 years as compared to 5-8 years of traditional overlay (Subject to trafﬁc and overloading)
Shorter construction period, due to high production capacity of recycling machines
Cost effective due to reuse as well as on site execution.
Conserves raw materials and natural Resources.
Conserves energy
Reduces greenhouse gas emissions
Work is performed with minimal trafﬁc disruption

Download Introduction to our Specialized Offerings

Specialized Construction Services

Base and Subbase Stabilization
Full Depth Reclamation (FDR) as per IRC 120:2015 and IRC SP 89:2018
Tunnelling

SOIL STABILIZATION

Soil Stabilization converts ground of insufficient bearing capacity into soil that is highly suitable for construction of roads, airports, ports, and factories. This improves the bearing capacity, Volume stability and the Resistance to water of the existing ground, which later forms the backbone of the new base strengthening the road pavements.

Lime Treatment reduces the soil moisture content (drying). It reduces the plasticity of soil by aiding the compaction (modification) and Increasing early strength (Modification). It also increases the long-term strength of soil by reducing its swell potential (Stabilization).

The permeability of cement-stabilized material is greatly reduced. The result is a moisture-resistant material that is highly durable and resistant to leaching over the long term. Cement-soil Stabilization is another technique, where Portland cement can be used to stabilize and strengthen certain type of soils.

Advantages of Soil Stabilization:

Higher resistance (R) values
Reduction in plasticity
Lower permeability
Reduction of pavement thickness
Elimination of excavation, exporting unsuitable material and importing new materials aids compaction

FULL DEPTH RECLAMATION (FDR)

Full depth reclamation is a process in which all of the asphalt pavement section and a predetermined amount of underlying materials are treated with recycling agents to produce a stabilized base course. Asphalt emulsions and/or chemical agents like fly ash or Portland cement are added as recycling agents.

The main steps include pulverization, introduction of additive, shaping of the mixed material, compaction, and application of wearing or surface course. This method of recycling is normally performed to a depth of 100 to 300 mm (4 to 12 in)

Full depth reclamation has been recommended for pavements with deep rutting, load-associated cracks, non-load associated thermal cracks, reflection cracks, and pavements with maintenance patches such as spray, skin, pothole, and deep hot mix. It is particularly recommended for pavements having a base or subgrade problem.

The major advantages and benefits of full depth reclamation are as follows:

The structure of the pavement can be improved significantly without changing the geometry of the pavement and shoulder reconstruction.
It can restore old pavement to the desired profile, eliminate existing wheel ruts, restore crown and slope, and eliminate potholes, irregularities, and rough areas. Pavement widening operations can also be accommodated in the process. A uniform pavement structure is obtained by this process.
It can eliminate alligator, transverse, longitudinal, and reflection cracking. Ride quality can be improved.
Frost susceptibility may be improved.
The production cost is low, and only a thin overlay or chip seal surfacing is required on most projects.
Engineering costs are low
Materials and energy are conserved, and air quality problems resulting from dust, fumes, and smoke are eliminated. The process is environmentally desirable, since disposal problem is avoided.

TUNNELING

Tunnel is an artificial passage, especially one built through a hill, Mountain or under the ground or water to provide ease of operations in terms of convenience, distance and Logistic Speed.

Due to the vast expanse and variety of terrain across India, there is a huge scope and potential for building tunnels in various infrastructure Industries like roads, railways, and pipelines etc.

Various degrees of complexity depending on function and safety needs or the code requirements at the time of construction, tunneling requires a special skill & set of machinery. It also need some very basic operations/process to be followed in sequence.

The steps Involved are:

Soil Investigation
Profile Marking
Face Drilling
Charging & Blasting
De-Fuming
Mucking
Scaling & Chipping
Geological Mapping
Face Sealing Shotcrete (primary support)
Arrangement to prevent ingress of water
Lattice Girder Erection (secondary support)
Fore Poling
3D Monitoring Targets
Shotcreting
Rock Bolting & Grouting
Final Lining

SERVICES

MARKOLINES SERVICES

Highway Maintenance