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5 June 2017

Subject: Use readymade, idiotproof, permanent pothole patching mix


throughout the year (Watch my Lecture Video)

Dear Highway Colleagues:

Monsoon is around the corner. Soon, like every year, we will see the menace of
potholes on our roads and streets across India. This would result in innumerable,
avoidable injuries and fatalities.

We have successfully brainwashed the common public to believe that potholes are a
natural phenomenon which occurs during monsoon. As usual, our engineers in State
PWDs and City Governments are going to use the 19th century technology of repairing
potholes: dump soil and stone. This is despite the fact that a readymade, idiotproof,
permanent pothole patching mix, which can be used around the year (including
monsoon and cold winter), is available. This mix was approved in 2014 by the Indian
Roads Congress (IRC) as IRC Standard IRC:116, Specifications for Readymade
Pothole Patching Mix Using Cut-Back Bitumen.

Our engineers are either ignorant of this novel pothole patching mix or do not have
the WILL to implement new, proven technology. I have been reminding you almost
every year about this technology since 2010 when the Jaipur Development Authority
(JDA) started to use it on a large scale. Now, I have prepared a 25-minute video clip
of my lecture on it to convince you about its unbelievable field performance. Please
watch it at the following link:

https://youtu.be/85yKlkxGsPU

Our engineers in State PWDs, CPWD, MES, BRO, and City Governments have to
take the following simple actions immediately:

Include the items of supplying and applying this mix in potholes in their Basic
Schedule of Rates (BSR) to facilitating the tendering process. Necessary
nomenclature and rate analyses for inclusion in the BSR are given in attached
Annexure A, B, and C. [I am offering you everything on a plate; you just have
to eat it.]
Estimate the quantities of the readymade mix required by you and issue
tenders today. Keep in mind, this mix has a shelf life of over 6 months and can
be used throughout the year. Your local contractors can make it using locally
available materials.

I realize many of you are not directly responsible for pothole repairs. However, as a
responsible citizen of India it is your moral duty to make the concerned engineers in
your state and city governments aware of this IRC approved amazing technology.
This way, you will make a positive contribution towards preventing unnecessary
injuries and fatalities resulting from potholes. This is far better than just criticizing the
Government for not repairing potholes properly.

Sincerely,

Prof. Prithvi Singh Kandhal


Jaipur, Rajasthan
pkandhal@gmail.com
Home page: www.eng.auburn.edu/users/kandhps

American roads are not good because America is rich, but America is rich
because American roads are good. - John F. Kennedy

Those who resist change will become irrelevant in the 21st Century.
Narendra Modi

ANNEXURE A

Basic Schedule of Rates (BSR)


(Revised 6 April 2017)

Include the following 3 items in your agencys BSR right now to facilitate the
production and use of the readymade cold pothole patching mix.

1. Supply of readymade cold bituminous pothole patching mix in accordance


with IRC:116-2014 Specifications in 50-kg plastic lined sturdy bags with 10-
km average lead. Mix shall contain at least 5.6% MC-800 Cut-back Bitumen
and suitable anti-stripping agent. Mix shall be workable and usable for at least
6 months. All 50-kg bags shall be transported to a storage facility designated
by the Engineer. Since the mix contains volatile kerosene, sealed bags shall
not be stored in a closed building or warehouse. No open flame or smoking
shall be permitted near the stored mix. Cost Rs. 370 per 50-kg bag

2. Placing and compacting readymade cold bituminous pothole patching mix in


potholes in accordance with IRC:116-2014 Specifications from 50-kg plastic
lined sturdy bags with 20-km average lead. Cost Rs. 23 per 50-kg

3. Supply, placing and compacting readymade cold bituminous pothole patching


mix in accordance with IRC:116-2014 Specifications in 50-kg plastic lined
sturdy bags with 10-km average lead for supply and 20-km average lead for
placement. Mix shall contain at least 5.6% MC-800 Cut-back Bitumen and
suitable anti-stripping agent. Mix shall be workable and usable for at least 6
months. All 50-kg bags shall be transported to a storage facility designated by
the Engineer. Since the mix contains volatile kerosene, sealed bags shall not be
stored in a closed building or warehouse. No open flame or smoking shall be
permitted near the stored mix. Cost Rs. 393 per 50-kg bag

ANNEXURE B

Cost Analysis of Supplying Readymade Bituminous Pothole Patching Mix (IRC:


116-2014) to Department Godown
(Revised 6 April 2017)

Assume one ton (1000 kg) of the mix is to be made and filled in 20 bags of 50 kg
each, which will be supplied to Department Godown for use later.

A. Cost of Materials

1. Aggregate of specified gradation


Aggregate 940 kg @ Rs. 525 per ton.... 493.50

2. Bitumen MC-800 Cutback supplied in drums:


60 kg @ Rs. 57,000 per ton. 3420.00

3. Anti Stripping Agent @ 0.3 % by weight of MC-800


1.8 kg @ Rs. 140 per kg. 252.00

Total for A 4165.50

B. Production Cost

1. Portable Mini Hot Mix Plant with capacity of 8 tons/day


Rent for one day = Rs. 3500. Rent to produce one ton will be
one-eighth of Rs. 3500, that is, Rs. 437.50 437.50

2. Fuel costs: 24 liters per day; 3 liters per hour


3 liters @ Rs. 60 per liter 180.00

3. Labour: 8 labourers needed per day to produce 8 tons


1 labourer needed per ton @ Rs. 400 per day. 400.00

Total for B 1017.50

C. Packing, Handling and Transport to Department Godown


1. Cost of 50-kg empty bags
20 bags @ Rs. 12 per bag.. 240.00

2. Labour for filling, weighing and sealing bags;


3 labourers can fill 160 bags in one day (20 bags in one hour)
Cost of labourers for one day = 3 times Rs. 400 = Rs. 1200
Cost of filling 20 bags in one hour = 1200/8.. 150.00

3. Transport of bags from plant to department godown


(average 10 km lead) 1 ton@ Rs. 300 per ton . 300.00

Total for C 690.00

D. Total of A + B + C. 5,873.00

Contractors overhead @ 10% of D........................................................... 587.30

Royalties, sales tax, income tax etc. @ 4.5% of D....................................... 264.28

Total 6724.58
Add 10% contractors margin 672.46

Total Cost per ton (20 bags of 50 kg each)..Rs. 7397.04

Cost per kg..Rs. 7.40

Cost per 50-kg bag..Rs. 370.00

ANNEXURE C

Cost Analysis of Laying Readymade Bituminous Pothole Patching Mix (IRC:116-


2014)
(Revised 6 April 2017)

Assume Eight (8) tons of the readymade mix will be laid


in potholes in one day. Costs for one day operation are as follows:

1. 4 Labourers @ Rs. 400 each 1,600.00

2. Transportation of bags from Department Godown to


laying site (average one-way lead of 20 km)
(a) Rent of tractor = Rs. 800
(b) Cost of diesel = Rs. 480 (tractor will consume one liter
per 5 km; 8 liters for 40 km @ Rs. 60 per liter = Rs. 480
Total transportation cost = 800 + 480 = 1280 1,280.00

3. Sand bags for sprinkling sand on patches to avoid pickup:

2 sand bags @ Rs. 12 per bag24.00

Total 2,904.00

Add 10% contractor overhead... 290.40

Add 4.5% for royalty, sales tax, income tax, etc.. 130.68

Total 3325.08

Add 10% contractor margin.. 332.51

Total 3657.59

This is the cost for 8 tons.

Cost per ton = Rs. 457.20


Cost per kg = Rs. 0.46
Cost per 50-kg bag = Rs. 23.00

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