Motor Grader Operators

Training Manual

Michigan's
Local Technical
Assistance Program
309 Dillman Hall Michigan Tech University Houghton, MI 49931 906-487-2102 www.michiganltap.org
 Motor Grader Training Manual
Table of Contents

Introduction ........................................................................................................ 1
Preface and Acknowledgements ......................................................................................... 1
County Engineers ................................................................................................................ 2

Parts of the Road ............................................................................................... 3

Parts of a Road ................................................................................................................... 3
Proper Cross-Section .......................................................................................................... 4
Roadway Cross-Section Elements ...................................................................................... 5
Typical Section for a Local Road (English) ......................................................................... 6
Typical Section for a Local Road (Metric) ........................................................................... 7
Gravel .................................................................................................................................. 8
Five Factors ......................................................................................................................... 9

Dust Control ..................................................................................................... 10

On the Road ...................................................................................................................... 10
Fighting Potholes and Dust ............................................................................................... 12
Calcium Chloride Environmental Concerns ................................................................... 14
Environmental Facts About Calcium Chloride .................................................................. 16
Dust Blading ...................................................................................................................... 19

Erosion Control................................................................................................ 20
Why Is Everyone So Concerned? ..................................................................................... 20
Six Major Principles ........................................................................................................... 21
Drainage ............................................................................................................................ 22
Culvert Maintenance ......................................................................................................... 23

Road Graders ................................................................................................... 24

Grader Types .................................................................................................................... 25
Grader Operation .............................................................................................................. 26
Tips for Better Grading ...................................................................................................... 28
Daily Inspection Check ...................................................................................................... 29
Pre-Start Walk-Around Inspection ..................................................................................... 30
Walk-Around Inspection (Diagram) ................................................................................... 34
Walk-Around Inspection (Checklist) .................................................................................. 35
Grader Preventive Maintenance ....................................................................................... 36
Preventive Maintenance Checklist .................................................................................... 38
Radiator-Cooling System .................................................................................................. 39
Tire Maintenance ............................................................................................................... 39

Safety Procedures ........................................................................................... 41

Comprehensive Checklist.................................................................................................. 41
Safety Tips and Safe Operation ........................................................................................ 43

Maintaining Gravel Roads ............................................................................... 44

Introduction ........................................................................................................................ 44
Two Common Mistakes ..................................................................................................... 46
Slope Meters ..................................................................................................................... 47
Tires................................................................................................................................... 48
Carbide Bit Blades ............................................................................................................. 49
Washboards ...................................................................................................................... 51
Eliminating Berm ............................................................................................................... 52
Figuring the Cost ............................................................................................. 53
How to Figure the Cost of Lost Gravel .............................................................................. 53
Two Closing Thoughts ....................................................................................................... 54

i
 Preface and Acknowledgements

This notebook was prepared for use in workshops being presented at various locations throughout
Michigan as part of a program developed by the Michigan Local Technical Assistance Program
(LTAP). Materials in this notebook have been adapted from material generously provided by the
Nebraska Technology Transfer Center, and the Maine Local Roads Center.

The workshops are intended for county, city, and township employees who are responsible for
maintaining gravel roads and require a working knowledge of gravel road characteristics, basic
maintenance procedures, and grader operator skills.

Workshop Instructor

Jeffrey Shook, Genesee CRC retired

Disclaimer

The contents of this notebook do not necessarily reflect any official views or policies, and use or
reference to specific products or equipment does not imply endorsement of these products by any
university, local, state, or federal agencies. This notebook does not constitute a standard,
specification, or regulation.

1
 Motor Grader Rated #1 Most Useful and Versatile

County Engineers

What do you call a county engineer with a motor grader? A highway department. This is an old joke, but its
true; the versatile motor grader was the number one choice among the 10 most important pieces of equipment
used by county highway departments, according to results of a survey conducted by Better Roads editors.

Nearly 88% of the surveyed county engineers and equipment operations managers called the grader their most
important piece of equipment. Trucks were not far behind.

The county highway department equipment top 10, as chosen by those who specify and buy the machines are:

1. Motor grader.
2. Dump truck.
3. Pickup truck.
4. A tie between mowers and surveying equipment.
5. A tie between snowplow and loader.
6. Spreader/salter.
7. Water truck.
8. A tie between excavators and portable barricades.
9. Bulldozer.
10. Pothole patcher.

Maintaining Roads

Bannock County, Idaho engineer Terry Bailey chose the motor grader as his top equipment pick, explaining, We
maintain 250-plus miles of gravel roads and do snow removal. This equipment does duty all seasons.

While often the motor grader is converted for winter road maintenance in more northerly areas, Gary Adkins,
county engineer in Lexington, South Carolina, also chose the motor grader, explaining, We grade over 800
miles of unpaved road. We grade daily, weather permitting, with the bulk of our road maintenance activity motor
grading.

Adkins says his department has 20 motor graders in its road fleet, with Caterpillar being the mainstay of the
department, although other manufacturers equipment John Deer, Champion, and Galion are also listed in his
inventory. Brian Faust in Fulton, Missouri, explains that motor graders are the only way to maintain the roads in
his county. We have 800 miles of gravel roads, Faust explains, and his stable of 10 graders a Cat 135H, 8
John Deere 670 Bs, and a Fiat F675 does the bulk of the work keeping roads in shape.

North Dakota engineer Jon Mill sys, Roadway maintenance is a large part of our assignment, and the motor
grader addresses many maintenance functions. It offers versatility, can blade gravel, lay patching mix, plow
snow, mix material, and do finish grade work.

Road construction was the main reason listed by Donald Brandon, Chambers County, Texas Highway
Department engineer, for his choice of motor grader as the number one piece of equipment. Construction and
maintenance of some 150 miles of gravel roads prompted Brandon to list compactor and dump truck as numbers
two and three, respectively, to go along with the grader to meet his construction needs.

Overall, 33% of those responding to the survey picked the motor grader as their first equipment choice.

County Engineers. Better Roads (July 1997) : 16.

2
 Parts of a Road

A road is composed of three major elements (see Figure 1):

The surface
The base and/or subbase layer(s)
The subgrade

The surface or wearing surface may be asphalt, concrete, gravel, or other material. It must provide
a good riding surface as well as wear resistance, skid resistance, and waterproofing.

The base and/or subbase layers provide the strength to carry heavy loads and support for the
pavement surface. This material consists of compacted gravel, sand, crushed rock, or a combination
of these. A minimum compacted thickness should be 18 inches for local roads.

The third element is the subgrade. This could be fill material if an embankment is being built to a
height more than 2 to 3 feet high, or it could be the existing natural soil in cut sections. It is the
subgrade which ultimately carries the traffic loads.

Before construction of a road, the top 12 to 24 inches of existing ground is usually prepared by
removing large boulders, stumps, bushes, and other objectionable materials.

The main function of the pavement surface and the subbase materials is to support a wheel load and
to spread and transfer that load to the subgrade. The ultimate load on the natural subgrade surface
should be small enough to be easily supported by the subgrade.

3
 Proper Cross-Section

To maintain good drainage, a road needs proper cross-section:

(Figure 1)

Without proper drainage, no roadway can survive. With proper drainage, you can maintain a stable
base and keep a proper cross-section. And with a proper cross-section, the roadway, shoulder,
inslope, ditch, and backslope will drain properly and your roads will be in better condition and easier
to maintain under all weather conditions. Practice good maintenance habits and your time will be well
spent.

Overall, this information will help you better understand your role as a gravel road maintainer and
sharpen your skills so that you can do the best job possible in maintaining your local gravel road
system!

4
 Roadway Cross-Section Elements

Other cross-section elements of a typical road are also illustrated in Figure 1. The road surface
should be crowned or sloped so that water will drain to the left and right towards the ditch. The slope
should be inch per foot of paved road width and to inch per foot of gravel road width.

Paved Gravel
per per
foot foot

Potholes in gravel surface roads can be directly related to road crown. Those roads with no
crown will experience the most severe pothole problems, and those with a cross slope of inch per
foot or more should have very few pothole maintenance problems.

As you maintain your roads, you should be aware of what the towns standard dimensions are for
different types of roads. If a road does not meet the standard, you can gradually bring it back to
standard as you work on it. If it gets completely out of hand, an expensive re-grading or rebuilding
job might be necessary. Not only that, but there are potential legal problems that can develop if roads
standards are neglected and a serious accident results.

(Figure 2)

5
6
7
8
 Five Factors Which Affect a Roads Life

This can enter a road from surface cracks,

the underlying water table, and the
surrounding soil. The effects of water can
Moisture
be devastating, especially in Maine, when
water freezes and heaves the roads each
winter and spring.

Road damage depends on the number of

vehicles using the road, but even more on
the weight of vehicles. A few heavily
loaded wheels do far more damage than
Traffic many light ones. For example, it takes
500,000 axles carrying one ton each
(passenger car) to produce the same
damage as eleven axles carrying 16 tons
each.

Since the road depends on the natural

ground for support, the quality of the
Subgrade
surface can create large differences in
pavement performance.

Factors such as the moisture condition

during construction, the lack of proper soil
Construction
compaction, and the quality of paving
Quality
materials can seriously affect road
performance.

The life of a road depends on what, when,

Maintenance.
and how maintenance is performed.

9
 On the Road
The Newsletter for State Highway Superintendents Spring 1992

Liquid Calcium Chloride Keeps Roads in Houlton, Maine Golden

Ralph Cleale, public works superintendent for Houlton, Maine,

might never have tried liquid calcium chloride to control dust on
his towns unpaved roads had it not been for the Golden Road.

The town of Houlton sits on the border with New Brunswick,

Canada, close to Maines prime timber territory. Most everyone in
the state is familiar with the central logging truck artery called the
Golden Road, which links an impressive network of unpaved
roads built by local paper mills in the mid-1970s. With a great deal
of money invested in their roads, the paper companies tried new
methods and materials to build and maintain them, including liquid
calcium chloride.

Traffic on the roads is not limited just to trucks. Mr. Cleale

traveled some of them on trips to his hunting camp and noticed a
lack of dust and their overall good condition in spite of the heavy
truck traffic. Curiosity led him to investigate how the roads stayed
in such good shape. He learned that liquid calcium chloride was a
key part of the maintenance strategy. Since he had also heard
about the material through magazine articles and advertisements, he was eager to try it.

Complaints from Houlton residents about the dust from town roads in dry months were constant, says Mr.
Cleale. Wed found no reliable way to control the dust.

In 1988, he tested liquid calcium chloride on about one mile of a particularly rutted and dusty roadway, spreading
4,000 gallons. The results were as expected. The calcium chloride performed just as the advertisements said it
would, says Mr. Cleale. Over the next two years, we tripled the amount applied. It not only totally eliminated
the complaints and reduced the loss of fines, it also kept the roads compact. They stay together so well that
weve reduced grading by 70 percent.

With less grading, Mr. Cleale finds he is able to devote much less effort to maintaining the roads. He uses the
manpower that had been assigned to grading his formerly dusty roads in other important summer maintenance
tasks.

The towns road crew developed a regular procedure in laying the solution down. The roads are first lightly
graded to loosen their surfaces, with the crew occasionally adding gravel to fill in low areas.

Prepping the roads is a bit of a juggling act, says Mr. Cleale. We finish grading just before we order the spray
truck to apply the material. Weve learned to time this just right so traffic and rain wont compact the surfaces.

Loosening the surface allows liquid calcium chloride to penetrate better, improving the ability of the fines and
aggregates to bind together. This binding action stabilizes the unpaved road, keeping it dense and compact.

After the roads are prepared, W.H. Shurtleff, Inc., South Portland, Maine, is called in. Using a distributor truck
with a rear-mounted spray bar, a 35 percent liquid calcium chloride solution is applied. The truck makes two
eight-foot passes on the 18-to2-foot-wide roads, spraying approximately 2,800 gallons per mile. The liquid
calcium chloride is manufactured by General Chemical Corporation, Parsippany, New Jersey.

10
Mr. Cleale concentrates his annual treatment on high traffic areas and in front of houses, spreading a total of
12,000 gallons. To ensure that the calcium chloride solution is efficiently applied, he recommends using a
distance measuring device to accurately calculate the application rate.

Its important not only to control how much is applied, but to target where to apply it, Mr. Cleale explains.
Applicators dont know our roads, so we guide the truck driver to the correct spots. This way, were assured that
we have treated the intended sections and have obtained optimum coverage.

Through Mr. Cleales observation of the Golden Road, applying liquid calcium chloride to Houltons unpaved
roads is now the golden rule.

Liquid Calcium Chloride Keeps Roads in

Houlton, Maine Golden. On the Road
(Spring 1992)

11
 Fighting Pot Holes and Dust
By Jim L. Hennen, SD LTAP Western Satellite Coordinator

Many communities in South Dakota have a

number of gravel surfaced streets and are
fighting an ongoing battle against potholes and
dust. Faced with this problem on Canal Street
in the city of Custer, Street Supervisor, Corbin
Herman, contracted Alan Sarver of Z&S Dust
Control, Inc. of Rapid City for some help. The
two men decided to treat a five-block section
of Canal Street with a proprietary product from
Pennzoil being marketed under the brand
name PennzSuppress D.*

It was felt that this would provide a good

opportunity to evaluate the effectiveness of the
product as a soil stabilizer as well as a dust
suppressant. The treatment was applied in
mid-July of this year and the street condition
was observed approximately three and a half
months later.

The operation involved blading the entire

length of the section as well as a short section
coming onto Canal Street from the north. This
short section was to receive the same blading
and rolling passes as the longer five-block
section but without any of the product being
placed on it. This provided a good
comparison between a treated and untreated
section over which the same traffic volume
and traffic type would be passing.
The untreated section pictured at the top has
developed potholes. The treated section in the bottom
picture shows no sign of potholes and is in much
better condition.

After blading, the product was shot at a rate of one quarter gallon per square yard, using the same
distributor as normally used to apply magnesium chloride dust suppressant. Forty-five minutes later a
second application was shot. Following the forty-five minute waiting period for this second application
to absorb into the surface, a self-propelled rubber tire roller was used to compact the treated surface.
Corbin indicated that when they rolled the surfaces (treated and untreated), the treated surface
glazed up very nicely. When the product was first applied there were thousands of tiny bubbles rising
to the surface as the material penetrated the surface. With the second application the bubbles were
still evident but with less activity than with the first shot. Due to limited funds, Corbin elected not to
apply the recommended third application before rolling. The two applications, twenty-four feet wide
over the five blocks, cost approximately $1650 for the product alone.

The effectiveness of the product as a stabilizer for the gravel surfacing was very good and Corbin
indicated he was very pleased at how well the five blocks have remained very tight with no potholes

12
showing up in the entire length. The short, untreated section has numerous potholes. The difference
in the surface conditions between the sections can be seen in the accompanying photographs.

The effectiveness with respect to dust control was not what had been hoped for. Both Corbin and
Alan indicated that had the third application been given, as the manufacturer recommends, its
effectiveness as a dust suppressant would have received a more favorable evaluation.

Z&S Dust Control, Inc. did return to the job site some time later and shot an application of magnesium
chloride to mitigate the dust problem that the treatment did not adequately provide.

* The use of product brand names in this newsletter

article does not constitute any endorsement of
those products by the SD LTAP Center.

Hennen, Jim L.
Fighting Potholes and Dust.
The Connection p. 6.

13
 Calcium Chloride for Dust Control

Are There Environmental Concerns?

A popular method of controlling dust on many of Michigans gravel roads is by using calcium chloride.
It is available through several different suppliers in the state, in either flake, pellet, or liquid form.
Typically, a road will be treated one to three times per year to help keep the surface hard-packed and
dust-free under traffic.

A common concern around Michigan is whether this salt can create a significant environmental
hazard to groundwater, nearby wells, lakes, or vegetation. In one sentence, studies have found that
because the amount of calcium chloride required for dust control and stabilization is relatively small
and it is applied relatively infrequently, little potential for significant damage exists. This is unlike
sodium chloride (winter road salt) which is used in relatively large quantities for de-icing Michigan
roads.

The Center has two studies available which discuss this subject.

Here are the highlights from each study:

I. An Environmental Review of Calcium Chloride in Road Dust Control and Stabilization

Applications. Dow Chemical Company (June 1981).

The widespread use of calcium chloride for dust control and stabilization of unpaved roads
provides economic, personal safety and environmental benefits while presenting little
potential for harm to the environment. The evidence to support this conclusion can be
summarized as follows:

The amount of calcium chloride applied for dust control and stabilization is relatively
small.

Only a small percentage of the calcium chloride applied for dust control and stabilization
moves from the roadway to roadside areas.

Little potential exists for damage to roadside vegetation due to lack of calcium chloride
movement and the minor effect of calcium chloride on soils and vegetation.

The potential for damage to animal life is small due to the lack of movement from
application areas and the low toxicity of calcium chloride.

Because migration is limited, surface water contamination is unlikely.

Ground water contamination from leaching is unlikely, except in unusual cases.

II. School of Public Health. An Evaluation of Dust Suppressants: Calcium Chloride and
Liginsulfonates University of Minnesota (June, 1982).

Calcium is present in nearly all waters and is more abundant than any of the other alkaline-
earth metals. The addition of calcium for dust suppressant most likely would be insignificant
when compared to the amount already present in the environment.

14
The use of calcium chloride as a dust suppressant will elicit the same types of environmental
problems (chloride pollution of water systems) as it does when used as a road de-icer.
However, because these effects are directly related to the rate and method of application of
the salt, the environmental effects following its use as a dust suppressant should be
considerably less that those observed from its use as a road de-icer.

Due to its low systemic toxicity from oral administration, calcium chloride use as a dust
suppressant poses little internal hazard in animals and humans.

Toxicity to vegetation, especially in and around the area of application, should be expected
from the use of calcium chloride. This toxicity may be in the form of direct effects on the plant
life or they may arise indirectly via soil disturbances (alkalinity, low water availability, low
sodium availability, and poor aeration).

15
 Environmental

Facts
About Calcium Chloride

Growing concern for the environment means that we need to closely examine the materials used in de-icing and
other road maintenance. Calcium chloride works well not only for de-icing but also for dust control/base
stabilization and full depth reclamation, says Bill Massa of General Chemical Corporation. As its acceptance has
grown, so have questions about how this substance works and how it impacts water quality and vegetation. This
article answers questions road officials most frequently ask about calcium chloride.

How does calcium chloride work when mixed with aggregate?

Clays and other soft particles have a large negative surface charge. They act like magnets and repel each other.
When water coats the particles, Massa says, it insulates them and reduces the force pushing them apart. Water
also has a natural surface tension that acts to bind particles together.

A dry road is less cohesive than a wet one and loses fines more readily under the pounding of passing cars and
trucks. A commonly used rule of thumb is that one car traveling over a mile of untreated dirt road will throw off a
ton of gravel per year. Roads that retain water last longer. Calcium chloride helps keep water in roads in two
ways.

First, as calcium chloride penetrates a road surface, it reduces the negative charge on the particles. This
decreases the repelling force between particles and the thickness of the water coating. A thinner coating allows
particles to move closer together.

And second, the surface tension of a calcium chloride solution is far greater than that of plain water. The higher
surface tension and the thinner film coating the particles substantially increase the attraction between soil
particles. As the binding ability of the road fines increase, so does road stability. Calcium chloride in reclaimed
aggregate and base soils produces a material well suited for use as a road base or wearable surface for an
unpaved road.

Does calcium chloride migrate once it is added to soil?

Calcium chloride tends to stay where it is placed. Studies indicate that calcium chloride migration is minimal and
that total migration is low. Samples from a road in Maine found that the majority of calcium chloride per square
yard remained in the road base after 24 years. A recent study in Ontario, Canada, conducted by Trow
Geotechnical Ltd., indicated excellent migration of calcium chloride. Ninety-two percent of the material was
present 8 months after application.

What type of calcium chloride migration is most likely to occur?

Most migration occurs vertically in soil, depending upon rainfall, evaporation, temperature, and humidity. As rain
soaks into soil, it carries calcium chloride downward. Evaporation of water from the road surface has the
opposite effect due to capillary action. Although calcium chloride rises and falls with weather conditions, little is
lost from the road. Calcium chloride generally stays in place in road stabilization and dust control work.

One study showed that higher water tables carried calcium chloride from the road. With this in mind, calcium
chloride should not be placed in roads where drainage is poor.

How large a contribution are de-icers to water pollution?

A study on dust suppressants prepared for the Environment Ontario Waste Management Branch of the municipal
government of Toronto found no adverse effects on water or plants from the use of calcium chloride as a dust
suppressant, Massa says. The effect of salt on ground water is believed to be minimal, but difficult to assess
because of the many sources of chlorides.

More than 4 million tons of salt, both sodium chloride and calcium chloride, are carried in rain and snow each
year. Sewage treatment and industry also contribute to chloride levels.

16
What effect does calcium chloride have on a reservoir?

Studies in Maine and Wisconsin by the Highway Research Board in Washington, D.C., examined the effect of
de-icing chemicals on highways. These confirmed that chloride concentrations in rivers and streams are well
within acceptable limits, Massa says. The great water volume they contain dilutes chloride concentration to
acceptable levels. Many states have instituted reduced salt zones in the vicinity of reservoirs. Calcium chloride
is frequently used in these areas due to its performance and tendency not to migrate.

Water pollution from de-icers is primarily limited to shallow wells near roads and small ponds and streams that
get direct runoff from roadways. A study conducted in Maine found chloride concentration related directly to
distance from a road.

What about calcium chloride in drinking water?

The American Medical Association rate for sodium chloride in drinking water is 250 mg/liter. The limit for calcium
chloride is the same. It is interesting to note that the 250 mg level was set by the Public Health Service based on
the taste rather than health.

Is chloride harmful in drinking water?

Humans have drunk water containing as much as 2000 mg of chloride without adverse effects, Massa says.
People can taste sodium chloride and calcium chloride in concentration from 70 to 900 mg and 15 to 350 mg,
respectively.

How does calcium chloride affect vegetation?

As with water sources, the effect of salts on roadside vegetation is related to distance. Trees along highways de-
iced with salts are less vigorous than along unsalted highways. Salt injury is more apparent near the road and
on the side receiving salt-laden runoff.

Plant biologists are not exactly sure how salt injures plants. Nor do they know the amount and exposure needed
to harm them or what are the symptoms of salt-caused injury. Most blame plant damage on ion accumulation
that enters through the roots. Salt spray may also damage plant tissue.

Different trees are affected differently. A study of sugar maples showed that trees within 30 feet of highway were
moderately to severely affected. Those more than 30 feet away were almost always healthy. It was also found
that calcium was less toxic than sodium chloride to roadside vegetation, Massa reports.

Salt may be falsely blamed for plant injury from gasoline and diesel engine emissions. The Environmental
Health Service reports that gases such as ozone, nitrogen dioxide, ethylene, and chlorine account for the most
widespread injury to plant life, destroying plant chlorophyll, disrupting photosynthesis, and reducing the plants
food production.

What can I do?

Many factors determine how road salt affects plants. These include the amount of salt applied, how soon
plowing occurs after application, soil quality and drainage, slope, how much snow melt runs off before the ground
thaws, and the type of trees present. The type of salt also is important. Experiments show that sodium chloride
is at least five to ten times more toxic to elm and white pine than calcium chloride, Massa says.

Design plantings to minimize the effect of de-icing salts. Place the most salt-tolerant and persistent turf species
adjacent to the road and plant deciduous and evergreen trees as far from the roadway as possible. Plant trees
sensitive to salt, such as maples, hemlock, birch, and some pines 30 or more feet from a highway.

Where snowplow and vehicular splash is present, select the most spray-tolerant species. Also, do not plant salt-
sensitive trees and plants on slopes below the roadway. And, finally, place shallow diversion ditches between
the road and woody plantings.

17
 The Relative Salt-Tolerance of Trees and
What should I do to best use salt? Ornamentals

There are some ways to limit salt-

caused pollution or vegetation
damage. One is to use de-icers that
cause less environmental damage
than salt, or materials that reduce the
amount of salt used. For example,
calcium chloride melts more ice in less
time than sodium chloride, especially
at lower temperatures, according to
Massa. Also, it goes into solution
more rapidly than sodium chloride, so
less is wasted during plowing. Both of
these benefits mean that less salt is
needed to maintain bare pavement,
which minimizes salt-caused pollution
and damage to plants.

Another strategy is to pre-wet sodium

chloride with liquid calcium chloride,
which increases salt efficiency,
improves the application pattern, and
reduces salt loss and the frequency of
salt application.

Environmental Facts About Calcium Chloride.

Better Roads (June 1991) : 26+.

18
19
 Erosion Control

Why is everybody so concerned about it these days?

Simply put, soil erosion and

accelerated runoff can cause
serious problems, such as:

1. Clogged road ditches and culverts

that require more frequent
cleaning and digging out.

2. Eroded ditches and banks that

often reduce the life of recent road
improvements.

3. Pollution of water and land by

sediment.

4. Reduced private property values

and angry landowners.

5. Damage claims and lawsuits.

6. Government regulatory pressure.

Minnesota is a beautiful place to live. The relative rural nature of our state is appealing to
both native Minnesotans and out-of-staters. A pond, lake, or stream that is visibly polluted by
runoff laden with sediment seriously detracts from the beauty. The impact of erosion can
significantly impact swimming, fishing, and other recreational activities. Because this type of
pollution is becoming more of a problem, recently, more stringent erosion control laws have
been passed, and others are currently being developed to protect our fragile environment.

As a local road official or worker, you have the ability to reduce the amount of soil erosion
that takes place along your town roads. In doing so, you are helping yourself because you
may not have to clean out ditches or unplug culverts nearly as often as you do now.

20
 Erosion Control: Six Major Principles

Keep disturbed areas small.

o As you increase the amount of disturbed earth, you increase the likelihood of soil
erosion.
Stabilize disturbed areas.
o Several methods and various erosion control products are available to local
agencies. Contact the Michigan DEQ, Soil and Sedimentation Division at (517)_335-
3178 for more information.
Keep water velocities low.
o Slow it down! Removing grass, weeds, topsoil, etc. increases both the amount and
speed of runoff. Try to keep shallow slopes, short lengths of drainage runs, and
some vegetative cover to prevent the water from picking up speed.
Protect disturbed areas from storm water runoff.
o Use channel diversions, ditch checks, etc. to prevent water from entering and running
over disturbed areas.
Keep sediment within work boundaries.
o Retain sediment by: (1) filtering water as it flows, and (2) detaining dirty runoff for a
period so that the soil particles settle out.
Follow up and inspect recent work.
o This is vital to your efforts. At the end of the day, check that your erosion control
practices are working properly. Make sure that filter materials are not clogged or
washed out, sediment ponds arent filled, or channels have not formed under the
controls.

21
 Drainage

Waterways or ditches are intended to carry water away from its source. They are not meant to store
water. If you have standing water too near the roadway, there is a good chance it will work its way
under the road, damaging both the surface and the base.

Being aware of the following items will help you keep your roads Good drainage is the key
in good shape: to maintaining a good
driving surface and a
Inspect drainage areas. proper profile. Water has
Check culvert inlets and outlets for debris. to be kept AWAY from the
Check for piping (voids) around outside of culverts. roadway, not just off of it.
Document locations and inspection data.
Keep ditches free of vegetation.
If possible, keep ditch bottom at least one foot lower than the bottom of the road gravel base.
Maintain road profile at about inch of slope per foot of width measured from the centerline
to the shoulder.
Keep the shoulder smooth for good transmission of water from roadway to ditch.
Maintain proper road profile for better driving and reduced maintenance.
Eliminate double ditches or edge dams along shoulders.
Poor drainage can be the number one cause of base failures. Without proper drainage it is
very difficult to maintain a proper profile on your road.
Heavy traffic has a pumping action on roadway bases. This works water upward towards
surface of road and makes road soft and unmanageable.
Check profile of ditches regularly. A dirty, unmanaged drainage system is trouble!

22
 Culvert Maintenance

Any drainage system is doomed to failure if it is not properly maintained. These failures can range
from scoured stream banks or stream bottoms, to such large failures as road washouts and damaged
property adjacent to the stream.

Maintenance should include periodic inspection to see that:

The inside of the pipe is free from obstruction.

Both the inlet and outlet ends are as originally installed.
Embankment soils are free of erosion.
The endwalls or riprap are in place.
There is no misalignment or joint failure of the pipe.
The culvert materials are not corroded or deteriorated.
There are no pavement cracks or settling on the surface above the culvert.

Misalignment and joint failure can show up as soft spots in relatively shallow fills and piping on the
outside of the discharge end of the culvert pipe.

Remove large brush, weed growth, and any other materials from the upstream end of the culvert.
These materials prevent the reduction of flow by getting lodged in or blocking the pipe. Repair culvert
ends and correct erosion problems.

23
Road Graders

Preventive Maintenance
Inspections
Safety Procedures
Grader Operation

24
 Grader Types

Rigid Frame
It requires space for turning and requires maximum side-
shift to clean ditches unless the grader can get into the
ditch. It is best kept on a stable work platform. Use
caution near road edges. It is good for smooth
blading.

Articulated Frame
It can be turned and maneuvered in tighter spaces. The
frame allows offsetting the drive wheels away from edges
and ditches. Offsetting puts the most machine power
and mass directly behind the load on the moldboard while
keeping side-shift to a minimum to reduce strain on the
circle. When properly used it is a good choice for the
heaviest work and work near edges; use the
articulation or it is just a higher priced rigid frame
grader.

Single Rear-Axle Four-Wheel Drive

It is used for tighter areas or road alignments. It tends
to be too light for heavy mixing work. Its finish
grading capabilities are limited to low speeds even with
tires matched for circumference. All wheel drive gives
it good control in slick conditions.

Tandem Rear Drive

This places all the engine weight on the tandem
drivers for good traction. Medium to heavy
moldboard loadings can be handled in
reprocessing. It has good production capability for
quality finish grading when all the tires
circumferences are matched; otherwise, it may jump
and leave chatter marks.

Tandem Rear, on-Demand Front-Wheel Drive

In all-wheel drive it can handle heavier loads than
tandems alone. It has good control in slick
conditions. Finish quality grading is usually done
without front-wheel drive, so the same quality and
constraints apply.

25
 Grader Operation

Maintaining the surface of the road requires that the operator use a combination of skills, abilities,
knowledge, techniques and attitudes that are acquired over a period of time. All operators need to
constantly work at improving in all of these areas. Practice new methods and ideas that will sharpen
your skills and abilities. Learn all you can about your job, your equipment and what is expected of
your when you are out on the road. Finally, work on developing the kind of positive attitude that says
to the public, I care about what Im doing and Im doing the very best job I know how to do. You are
doing things differently now than you did the day you were hired. That means that you have learned
from the experiences of others as well as from your own efforts to find a better way of getting the job
done. Keep on learning.

Here are some pointers on the actual operation of your motor grader. Keep these things in mind as
you work on your roads and your work will be easier. Neither you nor your machine will show the
wear and tear at the end of the day if you follow these tips. Youll do a better job and the public will
notice it as their roads improve as a result of your work.

Blade Pitch and Angle

1. It is very important to use the proper blade and pitch settings.

2. Improper blade angle can create a big loss of aggregate from toe of the moldboard. (See
Chapter 10, How to Figure the Cost of Lost Gravel).
3. Improper blade angle and pitch will:
a. Overwork machine and cause it to burn excessive amounts of fuel.
b. Thrust the machine sideways.
c. Cause unnecessary wear on both the machine and the operator.
4. For maintenance work, the top of the moldboard should be pitched forward. Pitch varies with
types of material, moisture content, etc.
5. The pitch and angle will vary for different operations
performed during the day.
6. With proper pitch and angle, material will roll and
have a packing action.
7. With improper pitch and angle, material will ball up
and cause both the machine and operator to work
harder than necessary.

26
Articulation

1. Use articulation when possible.

2. Harden shoulders by running front wheels on the shoulder and rear wheels towards the
center of road. This packs the shoulder.
3. Articulate machine for maneuvering.
4. While winging back snow, machine can be held from sliding sideways. Ditching and sloping
is made easier with articulation.
5. Articulate machine when cleaning wet ditches.
6. Check your operators manual for tips on various maneuvers you can make with the machine
by articulating.

Grader Speed

1. The slower you go, the smother the road.

2. Going faster than 3 mph causes the grader to bounce and the blade to move up and down.
This eventually leads to a washboard gravel surface.

Blade Types

1. Standard Straight Edge or Carbide Tooth

2. Proper pitch for carbide tooth blade.
3. Proper angle for carbide tooth blade.

27
 Tip for Better Grading

Shape and smooth so that water runs off and away from the road.
Slow down!
Take your time.
Use the correct pitch and angle of the blade for different operations.
Undercut potholes dont just fill them in.
Treat grading as a rainy day job a light rain or moist road softens the material. Too much
rain, though, can create a mucky mess.
Maintain your machine daily.
Practice all the time.
Consider using some form of dust and erosion control.

28
 Motor Grader

Daily Inspection Check

Vehicle # _________ Date ___________ PM Location ____________________

# Hours ___________ Type of Service _____________________________________

Service OK Repair Follow Up

Complete Visual Inspection
Check Engine Oil
Check Transmission and Hydraulic Level
Check Coolant Level
Check Hydraulic Fluid Level
Check Tension and Wear All Belts
Check Gear Box for Leaks
Check All Instruments and Gauges
Check Brake Fluid
Check Operation of Lights, Brakes, Back Up
Alarms, and Accessories
Check Engine Air Filter Pre-Cleaner
Drain Water and Sediment from Fuel Filter and
Sump
Inspect Battery Cables and Terminals
Lube All Grease Fittings
Check Tires for Wear and Damage
Record Tire Pressure
Check Cutting Edge and Bolts for Wear

Performed by _________________________________

29
January/March 1995 The Bridge Fact Sheet Page 1

Pre-start, Walk-Around Inspection for Motor Graders

The following pages present a walk-around inspection for

Special considerations for winter operations:
motor graders adapted from Nebraskas Motor Grader Check engine block heaters and pre-
Operator Workshop. Special thanks go out to Nebraskas heaters before cold weather sets in.
T2 staff, Al Hauser, Bill Bowmaster, and Don Neary for Know what type of engine you are
making this project possible. running before using starting fluids.
Never use starting fluid on engines with
glow plugs.
One of the most important aspects of motor grader Review cold-weather starting procedures
operation is the pre-start inspection. Insuring that your in the operators manual.
grader is in proper operating condition not only preserves Understand the proper way to jump the
a financial investment made by your agency but also batteries in the event that this is necessary.
prevents against costly breakdowns out on the road and
keeps you, the operator, in a safe work environment.

When servicing the air filter, check the gasket and the Do NOT bang the air filter against a tire or other object.
inner filter. If the gasket is damaged, unfiltered air can Doing so will distort the shape of the filter, degrading the
make its way through the system and into the engine. seal to the intake. If the filter is dirty, replace it!

Check for leaks around the fuel filter, and all fittings At the air compressor, check for leaks in the air system.
and fuel lines leading to the engine. An accumulation Examine the compressor unit and all fittings and air
of moist dirt is an indication of a leak. lines. An accumulation of moist dirt is an indication of a
leak.

30
Keep the cover of the circle turn gear clean. This will Check clearance of the drawbar ball and socket. Look
allow the breather to function properly. for excessive free-play. Adjust if necessary.

Hoses should be checked daily. Hydraulic hose failure Check for hoses that touch other hoses. Hose contact
is a major cause of motor grader breakdown. causes abrasion that will eventually lead to failure.

Loose hoses are a breakdown waiting to happen. Hoses that have been replaced must be the proper
Hydraulic hoses that have been added to the length and secured in the same way as the originals.
machine must be of the proper pressure rating and
secured to the frame with clamps or brackets.

31
Mismatched tires cause internal wear on the drive Check all lug nuts. Because of the vibration
chains and differential. Using mismatched tires experienced during grading operations, lug nuts
does not save money. can become loose.

Check the condition of the tires. A sliced tire that Check the spindles for excessive wear and play.
fails while out on the road incurs downtime that
neither you not your agency can afford.

Check the condition of the blade slide. Keep the Accumulated debris will cause excessive wear on the
shims adjusted according to the manufacturers shims. Keep the blade slide area clean.
specifications.

32
Keep the articulation area free of dirt, ice, and snow. Be sure to replace the safety guard if you remove it to
Accumulated debris can knock off the water pump grease the drive shaft. The guard is there to protect you
elbow, or damage the hood, cowling, or hoses when the and your co-workers from injury.
machine is articulated.

Battery cables that are in poor condition cannot carry the Keep the top of the batteries clean. Accumulated dirt
current needed to start the engine and are an electrical attracts moisture, and this mixture can drain the
hazard. Replace immediately. batterys charge.

Keep the areas around all vent caps clean. Prevent dirt from accumulating around the control
valves. Valves in the condition shown above cannot
operate properly. A clean machine reflects operator
pride!

Pre-Start, Walk-Around Inspection for Motor Graders.

The Bridge Fact Sheet (January/March 1995) 1-4.

33
 Walk-Around Inspection

For maintenance and operator personnel safety, and maximum service life of the machine, make a
thorough walk-around inspection when performing lubrication and maintenance work. Inspect under
and around the machine for such items as loose or missing bolts, trash build-up, cut or gouged tires,
oil, fuel, or coolant leaks, and condition of blade.

34
Records should be kept in a convenient place for recording and verification. The location of records
varies with the use of equipment and owners policies. Records may be kept with the machine or in
the service area.

Pre-service

The key to preventive maintenance is a pre-service walk-around inspection or check that should be
performed each day before a machine is used. This inspection will identify potential problems that
can cause a breakdown. For example, a machine that is low on oil may develop engine damage if
the problem is not detected and corrected before putting the machine is service.

All operators should also inspect their machines at the end of the day and should be alert for
problems that might develop during operations.

Walk-Around Inspection

1. Start at same location every time so that you dont miss anything.

2. Check all hoses for wear, loose connections, leaks and loose mounting brackets.

3. Check windows, doors, wipers, lights, and direction signals where applicable.

4. Check rear tandems for poor alignment and leaks.

5. Check all fluid levels as recommended by manufacturer.

6. Inspect frame for cracks.

7. Check steering system.

8. Check brakes.

9. Make sure all warning devices are in place and that flasher lights are clean and working.

10. Clean out machine and wash windows. Take pride in your equipment.

11. After machine has been thoroughly checked, start engine and let warm up for at least 2
minutes in warm weather and 5 minutes or longer in cold weather.

35
 Grader Preventive Maintenance

Equipment supervisors and operators want their equipment to work properly all day, every day. Of
course, this is not possible because machines will break down unexpectedly. However, breakdowns
can be minimized by initiating a preventive maintenance program.

Increased use of specialized equipment with the addition of new components increases the possibility
of breakdowns. These machines have increased horsepower, greater load capacity, and are
subjected to more stress and shock than ever before. Now components such as torque converters,
power shift transmissions, power brakes, power steering, air conditioning, and greater speed and
capacity have increased the maintenance workload on supervisors and maintenance personnel.

Failure of any of the components may cause an expensive shutdown. A machine that is down for
repair is costly not only in parts and labor, but also in loss of production time. It seems as if
breakdowns usually occur when the workload is the greatest and work time is limited.

Preventive maintenance of equipment is essential and not difficult. The leading cause of premature
equipment failure is putting things off. Certain steps should be taken on a regular basis to prevent
expensive failures later on. Good preventive maintenance practices should become a habit and
should be performed on a regular basis.

Benefits of a Good Maintenance Program

A good preventive maintenance program not only reduces the possibility of a machine
breakdown, but also:

1. Saves money on costs of repairs (labor and parts).

2. Saves time (loss of production).
3. Reduces inconvenience to the traveling public.
4. Reduces loss of power (machines in need of maintenance may be sluggish).
5. Increases operators safety.

36
One of the primary reasons for properly
Equipment that needs
maintaining equipment is safety. Operator safety
and the safety of others is dependent on properly maintenance is inefficient. A
maintained equipment. A good preventive vehicle needing a tune-up may
maintenance program will enable you to operate use 10 gallons more fuel per day
your equipment efficiently and safely. than one that is in good
condition. Ten gallons of fuel,
Setting up the Preventive Maintenance Program per day, per machine, can cost
Every owner or operator of machinery should an agency far more than the
establish a good preventive maintenance program. cost of routine maintenance.
Certain components on most machines need to be
inspected, lubricated, and/or replaced at specific
time intervals.

Instructions for preventive maintenance are usually in the operators manual of each machine.

Time intervals are determined by hours of operation or by mileage. If a machine has a large
percentage of idling time and/or stop-and-go driving, preventive maintenance is usually based on
hours. An hour meter can be attached to a machine if it does not already have one. This
automatically records the hours of operation. Machines may also be inspected daily, weekly,
monthly, or annually. Examples of time intervals are 5 hours (twice daily), 10 hours (daily), 50 hours
(weekly), 100 hour, 250 hours, 500 hours, etc. The time intervals for most machines have been
established by the Society of Automotive Engineers (SAE) and adopted by most machine
manufacturers.

Each time an inspection is made, all preceding inspections should also be completed. Machines
removed from service for the 500 hour inspection should also receive the 250 hour, 100 hour, and 50
hour inspection. Time must be allowed for each inspection and service in order for a preventive
maintenance program to be effective.

An important procedure that can help reduce the possibility of costly breakdowns is to establish an oil
sampling program. Some equipment manufacturers and/or dealers, and some oil suppliers have oil
analysis programs available. If your town is not presently using such a service it might be
worthwhile to look into. Oil analysis involves taking samples of oil from the engine, transmission,
and gear boxes, and sending them to a laboratory for analysis. This is a very worthwhile service to
have when you consider the cost of major component repairs. An oil sampling program can be
established when a new machine is purchased or when an older machine is overhauled. One should
even consider including an analysis service when writing the specifications for new machines.

Preventive Maintenance Records

Accurate, up-to-date, preventive maintenance records are essential. It is recommended that there be
a chart for each machine that describes each inspection or service that is to be done, and the
corresponding time intervals. The chart should also have a record of the date each inspection or
service was actually completed.

37
 Motor Grader
Preventive Maintenance Check List

Vehicle # ______ Date _______ PM Location _____________ # Hours _____

150 Hour Service (90 Days) OK Repair Follow Up

Change Engine Oil and Filter
Check Air Filter Elements (replace if necessary)
Check Exhaust System
Check Air Inlet System for Leaks
Check Wiring for Chafing, Loose Connections, etc.
Check Battery Electrolyte Level
Check Front End
Check and Tighten Wheel Studs
Check Drive Axle Oil
Check Oil Level in Tandem Drives
Check Parking Brake Adjustment
Check Oil Level In Circle Drive Gear Box
300 Hour Service OK Repair Follow Up
Change Fuel Filter
Change Hydraulic Filter and Clean Magnets
Change Transmission Filter
Visually Inspect Engine Mounts
Take Oil Sample
Check and Adjust Brake Pedal Linkage
Steam Clean Radiator
1000 Hour Service OK Repair Follow Up
Steam Clean Engine
Check and Adjust Engine Speeds
Check and Adjust Valve Clearance
Clean and Repack Front Wheel Bearings
Clean Hydraulic Tank Breather Filter
Check Pivot Pins and Bushings
Road Test Prior to Releasing to Using Agency

Performed by ____________________________

38
 Radiator-Cooling System

1. Check radiator daily for damage, leaks, loose mounting.

2. Keep fluid at recommended level determined by equipment manufacturer.
3. Check fluid level when cold. Consult instruction manual for removal when engine is hot. Use
extreme caution!
4. Blow dust and debris out with compressed air daily. Keep clean.
5. Clean and flush every fall prior to adding new anti-freeze.
6. Never run anti-freeze longer than recommended by its manufacturer and be sure to use the
proper type.
7. 50 percent anti-freeze and 50 percent water is a good mix. Too much anti-freeze will raise,
and not lower, the freezing point of the mix. When adding fluid, use 50-50 mix.
8. Replace hoses as recommended by manufacturer. Normally, hoses will not last over four
year.
9. Tighten all loose hoses.
10. Check water pump daily.
11. Check fan belts for wear and proper tension daily.
12. Check head gasket for seep and leaks.
13. Check heater core for leaks.
14. Use additives only when recommended by manufacturer of machine.

Tire Maintenance

1. Check tire pressure regularly, at least weekly.

2. Maintain the pressure recommended by manufacturer.
3. Always check and inflate tires when they are cold.
4. Never bleed air pressure from warm or hot tires.
5. If tire becomes low while operating, increase pressure to match the other tires.
6. Always use liquid tire gauge when checking pressure in tires with liquid ballast.
7. Inspect tires for abnormal wear, cuts, tears, nails, broken belts, separations, etc.
8. Match and pair tires. Keep tire diameters within 3/8 inch of each other if possible.
Mismatched tires (different sizes) will affect work performance and can cause serious
damage to equipment.
9. Buy tires with proper load capacity and lug design.
10. Tire pressure may be increased when a wing plow, sloper, v-plow one-way plow, snow
blower, rotary mower, ripper, or other heavy accessories are mounted on the side, front, or

39
 rear of the machine. Important: Dont use excessive pressure or under-inflate tires.
Consult tire dealer for proper pressure.
11. Use proper rim width. Consult manual.
12. Avoid sharp objects.
13. Buy good quality tires that are round.
14. Always put tire in safety cage when inflating. If tire is on machine, stand to side of tire while
adding air.
15. Inspect locking ring.
16. Always have tire running in right direction. Non-pulling tires normally run in opposite direction
as pulling tires.

Tire Wear

Uneven tire wear is usually caused by a mechanical problem such as improper balancing of wheels,
front-end misalignment, broken springs, etc. Tire problems that are mechanically caused can only be
cured by correcting the mechanical problem. The list of causes and effects on tire life is very long.
Tires that are well maintained will give long, hard service.

40
 Safety Procedures

The safety of the equipment operator is of prime concern to everyone. This unit includes helpful
guidelines for the operator.

It is the operators responsibility to know all specific requirements, precautions, and work area
hazards connected with his/her job. An understanding should be reached between the operator and
supervisor to ensure safe operating performance.

Remember that on any job the operator is the key to safety. Good safety practices not only protect
the operator, but also the other workers. Practice safe operation. Be alert to possible hazards before
they cause trouble. Perform the following procedures:

Be Prepared

1. Know the safety rules for the job.

2. Check with the supervisor if appropriate, for specific instructions and safety equipment
requirements.
3. Be aware of the many safety and warning devices that exist. They indicate possible hazards
to expect.
4. Learn the traffic rules at each work site. Know the hand signals and who will be responsible
for giving them.
5. Know the equipment. Read the manual to learn its operating characteristics, capabilities, and
limitations. Be familiar with control and safety devices.
6. Know the work area. Check weight limitations, types of surfaces, and clearances.

Check Equipment Regularly

1. Inspect the machine according to the operators manual.

2. Clean windshields and windows.
3. Remove oil and grease from the equipments walkways.
4. Remove or fasten any loose item.

Clear the Area

1. Walk around the machine to make sure there is no one near the equipment.
2. Warn all people nearby that the equipment is to be started.

Practice Start-up Safety

1. Check to ensure all controls are in neutral.

2. Start equipment only from operators seat.
3. Be certain brake is set.

41
Test Machine Before Operating

1. Test brakes for proper operation.

2. Check transmission through all gear ranges.
3. Operate all equipment controls through a complete cycle.

Work Safely

1. Do not carry riders.

2. Do not let anyone ride in a pivot area.
3. Look, then look again, before backing up.
4. Move vehicle slowly in congested areas.
5. Give loaded vehicles the right-of-way.
6. Stay away from edges.
7. Use care on slopes.
8. Keep equipment under control at all times.
9. Watch for overhead dangers.
10. Report defective equipment.
11. Keep your mind on your job and stay alert.
12. Use lights after dark.
13. Select a safe parking area.
14. Shut equipment down according to the operators manual.
15. Be sure equipment is safe to leave.

Perform Maintenance with Care

1. Keep area clean.

2. Tag controls when servicing.
3. Remove pressure caps carefully.
4. Watch out for hot fluids.
5. Watch for exhaust gases.
6. Keep hands clear of moving parts.

Wear Appropriate Safety Equipment

1. Reflective vest.
2. Proper footwear.
3. Hardhat.
4. Keep loose clothing away from moving parts.

42
 Safety Tips and Safe Operation

Seat Belts
Seat belts are required by law. Heavy equipment operators sometimes have a false sense of security
and neglect to use the safety belts. We need to let go of the illusion of well being, and recognize the
possible danger when we neglect to follow safety procedures.

Clean Windows
Many times, the insides of windows are overlooked; this can create mirror reflection and blind spots.

Slow Moving Vehicle Signs

These are required by law; you can be ticketed for using faded or otherwise illegible signs.

Three-Point Stance (Entering and Exiting Grader)

Most injuries occur when operator exits forward and doesnt keep a three-point stance.

Although government agencies arent required to have daily inspection sheets, the same standard for
police checks exist. Keep all checklist items safe!

Flags on moldboards, strobe lights, and strobe light color are a matter of local policy.

Always remember You, as the operator of any given piece of equipment, are
responsible, and may be held legally liable, for unsafe use or maintenance of the
equipment.

43
 Maintaining Gravel Roads

Introduction

Anyone who is responsible for the proper maintenance of a gravel road has two main objectives:

1. To maintain roads and ditches in the proper shape and surface condition in order to insure a
good driving surface, good drainage, and low maintenance costs.
and
2. To take care of the grading equipment in a way that makes the most efficient and economical
use of its capabilities.

Your job is a very important one. Generally, the highway maintenance budget is a large share of
the towns budget. Operators can either make or break a maintenance program. With proper
application of your skills as a grader operator you can make your road system one everyone can be
proud of. When the taxpayers are happy with your roads, they are more likely to support the
operation of the highway department. You are road commissioners or town officials, and the public
will appreciate your efforts.

For those of you who are the managers, administrators, or overseers of an operator or two, or a
private contractor, this program will alert you to the fundamental concepts of proper gravel road
maintenance. Knowledge of these concepts allows you to be aware of the desired end-product, and
to experience the good feeling that comes from knowing that the town got its moneys worth.

For those of you who already have grader operating experience, it is not the purpose of this
training program to completely change the way you operate your machine. However, many operators
taught themselves how to run a grader and learned the hard way, by doing the actual work. If this is
the case, here is your chance to improve on the skills you have developed by getting a little
professional advice and some really useful operating tips. This guidance should help make you even
more valuable as a top-notch grader operator.

For those trainees who are relatively new to running a grader, this training program offers you a
one-in-a-million chance to get some sound, professional instruction. We will help you learn the basic
skills needed in order to develop into a knowledgeable, qualified operator. A grader is a complex
machine and good professional instruction is necessary if you hope to be able to use your own talents
to their fullest.

For all road maintenance people, the experienced and inexperienced, this program is designed
both to refresh your memory and provide some new information about gravel roads themselves. We
will stress the importance of good drainage and emphasize the need for well-crowned gravel roads
and shoulders, clear ditches, and properly installed culverts. In addition, we want to help you improve
the techniques for achieving these goals through better grader operation.

Remember, you need to know your equipment, your roads, proper operating procedures, the law, and
the policies of your agency. To be a good operator, you must expend a lot of time and effort. No
matter how much you know today, youll need to know more in the future. So keep an open mind and
be willing to try new ideas that come along.

44
We realize that what is discussed in this course can be achieved by many different methods and
procedures. However, the end product should be the same having a road with the proper cross-
section, a good riding surface, a good base, and good drainage. This will produce an excellent
roadway one that shows the traveling public that the roads are being maintained by knowledgeable,
skilled personnel.

The three most important

elements In maintaining a
good road are:

Drainage
Drainage
Drainage

45
 Two Common Mistakes Cause Most
Grading Problems

1. Trying to get too much done in too short a time. Often the operator runs his blade too straight
across, goes too fast, and tries to move too much material in one pass.
2. Tilting the moldboard in the wrong direction. For maintenance work, the moldboard needs to
be tilted forward so that the material rolls and packs. If the moldboard is tilted back instead of
forward, the blade will cut rather than scrape.

Conclusion

You, the grader operator, are the key to good roads in your local agency.

You have the roads, the equipment, and the knowledge, to understand the importance of good gravel
road shape and dimensions; you have the operating tips and techniques with which to further develop
your skills and abilities.

How good your roads are is almost entirely up to you.

How well you do your job is entirely up to you!

46
 Slope Meters

Slope Meters are a very inexpensive add-on to the motor grader that allow operators to see exactly
what they are doing at all times. I include information on two available meters of which I am aware.
As a matter of FACT, the most widely used is the Slope Meter Company model. It has been around
longer, and durability and accuracy are well proven.

When the Slope Meter is used on a daily maintenance basis, it is usually mounted in the cab, but
sometimes it is mounted on the main beam. For fine grade work, it is typically mounted on the
moldboard for true readings of the blade.

Factors that will change readings are tire lean, articulation, and change in tire pressure.

Slope Meter Inc.

1317 Rice Creek Rd. Slope-Meter No. 2 NS . . . . . . . . (Call for price)
Minneapolis, Minn. 55432 Slope-Meter No. 2 NS has a larger Indicator tube
and larger numerical scale for easier reading with
a quick glance. It is desirable for applications
where the Slope-Meter is mounted at some
distance from the operator. It is largely used for
the same purposes and on the same type of
equipment as Slope-Meter No. 2.

R & B Manufacturing
4948 NW High Dr.
Riverside, MO 64150 OEM and Quantity Discounts Available!
Model #15 Degree Indicator
Standard Model (#15a)

47
 Tires

The latest in tire innovation are tires that many grader operators look at initially and say something
like You must be kidding. This is because of the old idea that heavy equipment tires have to have
big, grabbing treads.

The new tires I am referring to are all designated as some sort of SNOW name. Bridgestone,
Michelin, and Goodyear all have variations of these tires on the market, and all are equally as good.

The tread pattern is unlike any you have seen, unless youve already seen these. They look very
much like all weather tread tires for your car or pickup. Many agencies in the winter areas are
extremely happy with the traction and less need for tire chains. Many agencies say they only use
chains approximately 20% as often as in the past.

Other advantages are that tread life reports range from 40% up to 200% longer than standard tires. It
is easy to understand this because with these tires, you have much more rubber on the road at all
times. Many operators also say the ride is much better, which again is reasonable, since consistent
tread is on the road surface to create a smoother ride.

Contact your local tire dealers for more info. Always remember, many companies selling products will
give a pretty good allowance toward existing tires if you want to try newer styles.

Models by brand name:

Bridgestone (G2 VSW)

Michelin (XSNOPLUS M or S)
Goodyear (AS-3A, G-3T)

New style heavy equipment tires that resemble all

season radials.

48
 Carbide Bit Blades

Carbide bit blades are one of the most effective and efficient add-ons available to grader operators at
this time. With this blade, you have a system that will give you the best results with the least work,
less wear and tear on your machine, and lower fuel consumption.

After scraping for a short period of time, standard flat blades get what is referred to as banana curve.
The carbide bit blade eliminates this problem because the cutting edge of this blade is not a flat
surface, but rather a series of teeth that cut, break and mix the roadbed material. Your road is
maintained much more consistently and has a better surface to bond back to after scraping.

Another major advantage to this system is that with a flat blade, you create a quarter round profile
on your road. This blade eliminates that because you always have a flat cutting surface working the
roadbed. You also have a better balance of fines and aggregates, due to the cutting and mixing
action of these blades.

In many instances, you will have to make fewer passes to get your roads in better shape than you
typically would with a standard flat blade. The dynamics of this blade create less resistance while
scraping, and therefore allow you to go a bit faster and also save fuel.

The cutting and breaking abilities of these blades in extremely hard conditions or rocky areas also
lessens wear and tear on equipment. While cutting and breaking larger stones that are embedded in
your roadbed, you will also be making aggregate and fines to help keep your road stable and bound
together better.

Initial cost of these systems is high, but as will be shown, the long-term payoff far outweighs the initial
investment. Savings come in fuel, less wear and tear, less labor, and changing blades less often.
The most significant advantage is years and years of use of one set of carbide bit blades, versus
many, many changes of standard blades.

Over 90% of the agencies at which Ive instructed, that use this typed of blade, use either the Pacal or
Sandvik blades. From my own experience and that of others, it is because of the quality and
durability of these blades. I present this information from my own personal experience, only to
suggest that these are the most widely accepted and most widely used blades.

(As you will notice, information on Caterpillar blades is not included here, by their own choice.)

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 Comparison of Carbide Bit Grader Blade Systems
Pacal Sandvik Kennametal Caterpillar Deere
Stinger
Rotating Bits Yes Yes Yes No Yes
Full
Moldboard Yes Yes Yes No Yes
Cast Angle
Moldboard
Back Angle 70 70 90 90 90
Warranty Yes Yes Limited Yes Limited
Back Drag
Capabilities Yes Yes Poor Poor Poor
Heat Treated
Adapters Yes Yes No Yes No
# Bits Per Foot
(Std) 8 8 6 5 6
Adapter
Construction
1-Pc. 1-Pc. Welded Bit Single Piece Welded Bit
(Std) Extruded Extruded Holders Casting Holders

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 Washboards

Washboards, also known as corrugations, are closely spaced ridges and valleys (ripples) at fairly
regular intervals. The ridges are perpendicular to the traffic direction. This type of distress is usually
caused by traffic volume/speed and loose aggregate. These ridges usually form on hills, on curves,
in areas of acceleration or deceleration, or in areas where the road is soft or potholed. Removal of
the washboard corrugations and relaying the gravel material can only be effectively accomplished
during the spring and fall when soil moisture conditions are adequate. Without proper moisture
conditions, washboarding will rapidly reappear, increasing the cost of maintenance. Washboard
corrugations can be a serious problem, both during the summer and winter months.

It is extremely important not to break

the surface crust when removing the
washboards. The most effective
means of removing the washboard
corrugations and loose material is to
use a normal straight cutting edge
on a motor grader and to sweep the
loose aggregate off with the blade.
The use of carbide tip points on the
blade tends to break up the
aggregate and leaves loose material.
The removal of the loose material is
important. If it is not removed, the
road surface crust may break loose
and the washboard corrugations will
reform. Loose material on the road
will enhance the dust problem and
the binder material is lost.

The removal of the washboard

corrugations and loose aggregate is
effective as long as the surface
material has at least 7% fines (minus
200 sieve). The fines work as a
binder for the crust and facilitate a
smooth road surface. Past
experience has demonstrated that
hard vehicle braking on the road
where the washboards have been removed has resulted in black tire skid marks on the road surface.

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 Eliminating Berm

The most important thing to remember about berm is this: IF YOU DONT CREATE THEM, YOU
WONT HAVE A BIG PROBLEM LATER!

There are a few ways to deal with berm, depending on the circumstances. If you are dealing with
average, or reasonable berm, sometimes you can cut it all into the road, break it up and mix it in at
one time, if the material is not too full of debris or dirt and sand. If you have some of these problems,
the best bet is to work a little in each time you scrape, and let it mix in gradually so as not to
contaminate your existing material.

If you have large berm, it is going to take time, unless you are able to cut, load, and haul away, or
have an area to cut it to behind the ditch line. Cutting a little each time you go out will help in many
ways. Berm that hasnt been touched for a long time has a hard surface that doesnt let water soak
into it, which keeps your road wet longer. A wet road is not good, so by cutting a little away, you open
that area for water to begin soaking off the road. Work at it a bit at a time, and eventually it will be
worked into the existing roadbed.

Turnpiking is an old method that is not recommended at all. This consists of using your blade and
cutting a trench in the roadbed, then cutting the berm material into it. After cutting the berm into the
trench, the material cut up from the road is rolled back over it to cover it. This is a huge problem,
because you have now put vegetation under there that will rot and hold moisture and keep your road
soft.

In the case of large berm, many operators think it necessary to cut them down to the level of the
existing road, but if you start cutting from the top down, the berm will blend in with the rest easier,
without having to go as deep as you may think.

To break up the sods and materials youve brought into the road, place your blade at half the depth of
the material. If the clumps are 10 inches high, set your blade 5 inches off the ground, with the blade
set at 45 degrees, moldboard rolled all the way back, going as fast as you can safely. The blade cuts
into the material, flings it back into the blade, breaking it some, then curls it back onto the roadbed
and breaks it more. This may be repeated a few times depending on the type of material and
wetness of your material.

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 How to Figure the Cost of Lost Gravel
Or
Grab Your Coffee Can

Question: How would you like to save over $6,000 per motor grader operator per year?

Answer: Train your operators to properly pick up windrows of gravel.

Some do-it-yourself coffee-can research by the Nebraska Technology Transfer Centers Ed Wootton
led to this conclusion.

As he watched motor grader operators at work, Ed wondered about the cost of the gravel lost off the
toe of moldboards, as windrows were picked up.

So he measured one foot in the ditch and put all the spilled gravel he found in that area in a coffee
can. When he weighed the can he found he had two pounds of gravel (which he says is a very
minimal loss often it is much more).

At that rate, the gravel loss is 21,120 pounds in one mile (includes both sides). If an operator grades
3 miles in a day, he loses about 32 tons (which is about 18 cubic yards). At $7.00 per cubic yard, the
dollar loss is $126 per day.

If the operator works 53 days per season (grading 40 miles of gravel road four times per season), the
total dollar amount of lost gravel is about $6,700, nearly five months of salary for an average town
grader operator.

The main cause of this loss, Ed says, is improper blade angle.

We know there are other factors in the loss, such as wind, water loss, and heavy traffic, says Ed,
but the chief cause is improper procedure.

The spilled gravel is partially retrievable by pulling up the slopes, but that is time-consuming and
costly, and you dont get it all.

Here is Eds formula, if you want to measure your own losses:

1. Weigh gravel collected from one foot of ditch = 2 pounds per foot.
2. Multiply x 5,280 (feet per mile) x two sides = _____ pounds per mile.
3. Multiply x number of miles, per day, per machine = _____ pounds per day.
4. Multiply x number of days worked per year = _____ pounds per year.
5. Divide by 3,500 pounds per cubic yard (to get number of cubic yards) = _____ cubic yards
per year.
6. Multiply number of cubic yards per year x cost per cubic yard of gravel = ________dollars per
year for LOST GRAVEL.

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 Two Closing Thoughts

1. Theres an old saying that goes like this:

If youre not part of the solution, youre part of the problem!!

Which do you choose to be?

2. An old-timer who taught me a lot always reminded me that the

most important thing at the end of each day was to answer this
simple question:

If someone else did a job like that in front of YOUR home,

would you be happy with it?

Thank You!

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