THE UNITED REPUBLIC OF TANZANIA

MINISTRY OF WORKS AND TRANSPORT

TANZANIA NATIONAL ROADS AGENCY

INTERNAL MEMORANDUM

TO: CE DATE: 09 August, 2021

UFS: DPL COPY:

FROM: CE/RDU

REF: JA

RE: PREMATURELY FAILED ROADS – CAUSES AND REMEDIAL MEASURES

Kindly make reference to the above heading.

We have prepared a list of roads which have developed distresses or failures well
before their typical lives have been attained.

The information provided covers the designed pavement structure, possible causes of
failures and recommendations on remedial measures.

Attached with this Memo, kindly find a summary of the above-mentioned information in
a tabular form.

I submit.

Enclosures: Table – … pages

Central Materials Laboratory – TANLAB, P.O. Box 9452, Dar Es Salaam Tel: + 255 22 2866122/2866088
Fax: + 255 22 2866088, E-mail: cml@tanroads.go.tz
 A LIST OF ROADS WHICH FAILED PREMATURELY

S/N SURFAC ROAD NAME AND PAVEMENT POSSIBLE CAUSE(S) OF FAILURE PROPOSED REMEDY
E TYPE DETAILS
ASPHALT CONCRETE (AC)
1. Ndundu – Somanga (56.4 km) Distresses: Cracks, potholes Holding measures (crack sealing and
 Wearing course: 50 mm Causes: overlay).
AC14 i. Poor asphalt properties in the Long term measures:
 Base course: 200 mm field (brittle asphalt, use of i. Remove the asphalt wearing course
CRS inappropriate mineral filler and to spoil
 Subbase: 200 mm CM marginal to poor grading) ii. Reprocess the existing base course
ii. Inadequate pavement design. to form new 200 mm cement
 Design TLC: TLC 10 iii. Inadequate insitu structural stabilised subbase class C1
strength of the pavement iii. Add new 150 mm CRR base course
 Current TLC: TLC 10
iv. Apply a 50 mm asphalt wearing
 Completed: Jan. 2011
course (SP 12.5 with PG 76-10
 Distress noted: 2016 binder)
 Investigation: (2016/CML)

2. Bagamoyo – Msata (60 km) Distresses: Wide longitudinal cracks i. Reconstruction with geo-grid
 Wearing course: 50 mm Causes: reinforcement method
AC20 i. Expansive soils of high degree ii. Crack filling and sealing
 Base course: 150 mm of expansivity
CRR ii. Inadequate storm water
 Subbase: 200 mm C1 management

3. Dodoma – Mayamaya (43.65 km) Distresses: Wide longitudinal cracks. Partial reconstruction:
 Wearing course: 50 mm Causes: i. Carry out pressure grouting to
AC20 i. Presence of Highly Expansive and properly fill the cracks.
 Base course: 150 mm Low Strength Soils ii. Remove the existing AC wearing
CRR ii. Improper treatment of the course to spoil.
 Subbase: 200 mm C1 expansive soils iii. Add suitable fines to the existing
iii. High Moisture Content in the CRR base, mix properly and
 Design TLC: TLC 10 Roadbed stabilise with suitable cement type to
 Current TLC: TLC 10 form new 150 mm C1 layer.
 Completed: 2013 iv. Provide suitable geogrid on top of
the subbase as per Figure 6.1.

Central Materials Laboratory – TANLAB, P.O. Box 9452, Dar Es Salaam Tel: + 255 22 2866122/2866088
Fax: + 255 22 2866088, E-mail: cml@tanroads.go.tz
S/N SURFAC ROAD NAME AND PAVEMENT POSSIBLE CAUSE(S) OF FAILURE PROPOSED REMEDY
E TYPE DETAILS
 Distress noted: 2013 v. Construct new 150 mm CRR base
 Investigation: (2017/CML) course on top of the geogrid.
vi. Construct new 50 mm asphalt
Full reconstruction:
i. Removal of the existing pavement
and fill layers
ii. Excavate 1.5 m expansive soils
beneath the entire road prism (with
side slopes of 1:2) and replace with
proper rock fill material, with voids
filled with granular material without
fines.
iii. Provide geotextile membrane on top
of rockfill to prevent infiltration of fill
material into the rockfill
iv. Construct a new embankment and
pavement layers.
ASPHALT CONCRETE (AC)

4. Kilwa road (10 km) Distresses: Rutting, cracks and Milling off the existing Asphalt Concrete
 Wearing course: 70 mm potholes (AC) wearing course. Scarifying the
AC14 Causes: existing base and stabilizing with
 Base course: 200 mm i. Under estimation of design traffic cement to obtain material class C2,
CRS loading recompacting properly to the required
 Subbase: 260 mm C1 ii. inadequate asphalt mix stability, densities and laying to form 200mm
low voids in the mix, segregated recycled base course. Laying a new
mix and use of inappropriate 70mm high stability AC wearing course.
bitumen grade A surface dressing on top of the AC
iii. Inferior quality of base course should be considered in order to reduce
material rate of binder ageing taking place at the
surface, causing surface cracks that
progress into the AC layer over time.
5. Chalinze – Kitumbi (125 km) Distresses: Cracks and rutting Full reconstruction from the subgrade
 Wearing course: 35-65 mm Causes:
SP12.5 i. Inadequate rehabilitation design
 Binder course: 35-100 mm ii. Inadequate asphalt mix design

Central Materials Laboratory – TANLAB, P.O. Box 9452, Dar Es Salaam Tel: + 255 22 2866122/2866088
Fax: + 255 22 2866088, E-mail: cml@tanroads.go.tz
S/N SURFAC ROAD NAME AND PAVEMENT POSSIBLE CAUSE(S) OF FAILURE PROPOSED REMEDY
E TYPE DETAILS
AC20
 Base course: 200 mm CRR
 Subbase: 200 mm C1

 Design TLC: TLC 10

 Current TLC: TLC 10
 Completed: Jan. 2011
 Distress noted: 2008
 Investigation: (2015/CML)

6. Kasinde – Mpanda (105.389 km) Distresses: Longitudinal cracks Partial reconstruction

 Wearing course: 50 mm Causes:
SP12.5 i. Inadequate storm water
 Base course: 150 mm management
CRR ii. Inadequate compaction of the
 Subbase: 200 mm C1 earthworks
ASPHALT CONCRETE (AC)

7. Korogwe-Mkumbara-Same (Lot 1, 76 Distresses: Rutting (in AC), bleeding Replace the unstable asphalt mix with
km) Causes: properly designed asphalt layer.
 Wearing course: 50 mm Poor asphalt mix design process:
AC20 i. excess binder in the mix
 Base course: 150 mm ii. questionable grading in the field.
CRR iii. lack of voids / VMA
 Subbase: 200 mm C1

 Design TLC: TLC 10

 Current TLC: TLC 10
 Completed: Sept. 2014
 Distress noted: 2017
 Investigation: (2017/CML)

8. Iringa – Mafinga (Ifunda section) Distresses: Cracking, rutting, potholes  Partial reconstruction from the
(68.9 km) Causes: subbase

Central Materials Laboratory – TANLAB, P.O. Box 9452, Dar Es Salaam Tel: + 255 22 2866122/2866088
Fax: + 255 22 2866088, E-mail: cml@tanroads.go.tz
S/N SURFAC ROAD NAME AND PAVEMENT POSSIBLE CAUSE(S) OF FAILURE PROPOSED REMEDY
E TYPE DETAILS
 Wearing course: 50 mm Poor workmanship leading to:  Extensive patchworks
SP12.5 i. Weak subbase
 Base course: 150 mm ii. Low compaction
CRR
 Subbase: 180 mm C1
9. Screening Lanes at Dakawa Distresses: Severe deformation in the Partial reconstruction (replacement of
Weighbridge (1 km) form of rutting and shoving the existing asphalt with rut-resistant
 Wearing course: 100 mm Causes: asphalt or replacement of both the
AC20 Design issues asphalt and CRR base with cement
 Base course: 150 mm CRR i. Use of inappropriate binder in concrete pavement).
 Subbase: 150 mm C2 + the asphalt mix
150 mm C1 ii. Poor workmanship resulting in:
iii. Marginally poor asphalt mix
properties in the field leading to
Instability, possibly an indication
of initiation of the rutting.
iv. Deficiencies in the mix design
process for the asphalt layer (AC
20)
v. Marginal aggregate grading for
the asphalt layers in the field
10. Mafinga – Nyigo (74.1 km) Distresses: On SP 19 binder course:  Repair of the localized failures
 Wearing course: 40 mm Localised wide deformations (ruts), soft  It was recommended that the
SP12.5+50mm SP19 spots, high permeability, segregation asphalt works be suspended until
 Base course: 150 mm Causes: assessment by expert is done.
CRR Poor workmanship leading to:  Areas which had not shown signs of
 Subbase: 150 mm C2 i. Low thickness of the asphalt distress be monitored until verified
+ 150 mm C1 layer. otherwise by the expert.
ii. High exposure to moisture
iii. Use of segregated mix
iv. Improper gradation of
aggregates used (e.g. from
production at crusher).

Central Materials Laboratory – TANLAB, P.O. Box 9452, Dar Es Salaam Tel: + 255 22 2866122/2866088
Fax: + 255 22 2866088, E-mail: cml@tanroads.go.tz
S/N SURFAC ROAD NAME AND PAVEMENT POSSIBLE CAUSE(S) OF FAILURE PROPOSED REMEDY
E TYPE DETAILS

DOUBLE SURFACE DRESSING (DBST)

11. Msoga – Msolwa road (10 km) Distresses: Large Potholes, rutting and i. overlay with 50 mm SP 12.5 asphalt
 Wearing course: DSD cracks (after extensive patchworks) OR
 Base course: 150 mm Causes: ii. partial reconstruction: Reprocess
CRR i. Inappropriate type of subbase with the existing CRR base course and
 Subbase: 200 mm respect to the base course. part of the subbase by milling to a
G45 ii. Low thickness of the main load depth of 200 mm and stabilise to
bearing layer (base course) form 200 mm C1 subbase.
iii. Low structural integrity of the Introduce new 150 mm CRR base.
pavement
iv. Underestimation of traffic loading
leading to inadequate pavement
structure.
v. Marginal quality of the subbase
material (low CBR).
12. Kyamyorwa – Buzirayombo Distresses: Potholes and rutting Partial reconstruction involving
(Kiziramuyaga-Muganza Section: 41 Causes: reprocessing of the existing base course
km) i. Inadequate pavement design to 1150 mm CM subbase, adding new
 Wearing course: DSD (the adopted pavement was for 150 mm CRS base, followed by a
 Base course: 200 mm TLC 1 instead of TLC 3). Double surface dressing.
G80 natural gravel material ii. Inferior quality of pavement
 Subbase: 200 mm materials
G45 natural gravel material iii. Poor workmanship (inadequate
compaction)

Central Materials Laboratory – TANLAB, P.O. Box 9452, Dar Es Salaam Tel: + 255 22 2866122/2866088
Fax: + 255 22 2866088, E-mail: cml@tanroads.go.tz
S/N SURFAC ROAD NAME AND PAVEMENT POSSIBLE CAUSE(S) OF FAILURE PROPOSED REMEDY
E TYPE DETAILS

DOUBLE SURFACE DRESSING (DBST)

13. Mwigumbi – Maswa (50.3 km) Distresses: Potholes, rutting, cracks: Different options were recommended on
 Wearing course: DSD Causes: different sections of the road based on
 Base course: 150 mm i. Poor workmanship leading to the condition. Remedial measures
CRR localized inadequate thickness of varied from:
 Subbase: 200 mm C1 CRR base layer, weak C1 i. Monitoring the performance,
subbase, low field compaction and ii. Patchworks and re-seal
excessive moisture in the iii. Partial reconstruction (replace C1,
earthworks. CRR and SD)
ii. Inferior/marginal quality of the iv. Full reconstruction (from G3 to SD)
material in the earthworks layer
iii. Inadequate in situ structural
strength of the pavement
14. Mbeya – Lwanjilo (36 km) Distresses: Cracks, potholes and Partial reconstruction to reinstate the
 Wearing course: DSD rutting designed pavement
 Base course: 150 mm Causes:
CRS i. Poor workmanship:
 Subbase: 200 mm CM ii. Low compaction
iii. High moisture
 Design TLC: TLC 3 iv. Inferior quality materials (base
 Current TLC: TLC 3 and subbase)
 Completed: Jan. 2011
 Distress noted: 2018
 Investigation: (2018/CML)

15. Singida – Shelui (110 km) Distresses: i. Section with combined base and
 Wearing course: DSD Localized longitudinal depressions subbase failure:
 Base course: 150 mm (rutting) along the outer wheel paths. Partial reconstruction from
CRR Causes: subbase
 Subbase: 200 mm C1 Poor workmanship: ii. Sections with base course
i. Inadequate thickness of base failure:
 Design TLC: TLC 10 course Partial reconstruction from base
 Current TLC: TLC 10 ii. Inadequate compaction of base course
 Completed: 2008 course
iii. Weak subbase constructed from
Central Materials Laboratory – TANLAB, P.O. Box 9452, Dar Es Salaam Tel: + 255 22 2866122/2866088
Fax: + 255 22 2866088, E-mail: cml@tanroads.go.tz
S/N SURFAC ROAD NAME AND PAVEMENT POSSIBLE CAUSE(S) OF FAILURE PROPOSED REMEDY
E TYPE DETAILS
 Distress noted: 2016 G7 material (soil).
 Investigation: (2016/CML)

16. Iringa – Dodoma (260 km). Dominant Distresses: Potholes, cracks, rutting i. Partial reconstruction
failures occurred on the following Design issues: ii. Overlay (on AC surfaced sections)
pavement structure: Underestimation of design traffic loading
 Wearing course: DSD resulting in inadequate pavement
 Base course: 150 mm C1 structure to withstand the prevailing
 Subbase: 200 mm traffic loading.
G45 Construction issues:
i. Inadequate insitu structural
 Design TLC: TLC 3 strength of the pavement:
 Current TLC: TLC 20 ii. Water ingress through cracks,
 Completed: 2014 which normally accelerates
propagation of distresses and
 Distress noted: 2018
failures.
 Investigation: (2018/CML)

17. Dumila – Rudewa (45 km) Distresses: Partial reconstruction

 Wearing course: DSD Localized longitudinal cracks.
 Base course: 150 mm Causes:
CRR i. Inadequate design of embankment
 Subbase: 200 mm C1 and construction on expansive
soils
ii. Excessive field moisture content as
a result of water ponding
iii. Inadequate drainage structures
leading to water damming during
rains and exacerbates the
situation.
18. Nyanguge – Musoma Distresses: Wide longitudinal cracks: i. Reconstruction with geo-grid
 Wearing course: DSD Causes: reinforcement method
 Base course: 150 mm i. Expansive soils of high degree ii. Crack filling and sealing
CRR of expansivity

Central Materials Laboratory – TANLAB, P.O. Box 9452, Dar Es Salaam Tel: + 255 22 2866122/2866088
Fax: + 255 22 2866088, E-mail: cml@tanroads.go.tz
S/N SURFAC ROAD NAME AND PAVEMENT POSSIBLE CAUSE(S) OF FAILURE PROPOSED REMEDY
E TYPE DETAILS

DOUBLE SURFACE DRESSING (DBST)

 Subbase: 200 mm C1 ii. Inadequate storm water
management

19. Peramiho Junction - Mbinga (Lot 2, Distresses: Reconstruction of the cracked sections
78 km) Wide longitudinal parallel cracks. Monitor sections which were still intact
 Wearing course: DSD Causes:
 Base course: 150 mm i. The construction of fills on
CRR slopes that obstructed the
 Subbase: 200 mm C1 natural channel for runoff of
water during intense rainfall with
structural deficiencies for
drainage management.
ii. Construction of fills on steep
slopes, prone to instability with
excessive moisture.
iii. Construction on a roadbed that
in some sections required that
Central Materials Laboratory – TANLAB, P.O. Box 9452, Dar Es Salaam Tel: + 255 22 2866122/2866088
Fax: + 255 22 2866088, E-mail: cml@tanroads.go.tz
S/N SURFAC ROAD NAME AND PAVEMENT POSSIBLE CAUSE(S) OF FAILURE PROPOSED REMEDY
E TYPE DETAILS
further testing, other than
indicator tests, be carried out to
adequately characterise the
material.
iv. Initial translational failure,
settlement with horizontal
component of movement,
occurred as the mode of
instability and exacerbated by
excessive moisture.
DOUBLE SURFACE DRESSING (DBST)

20. Laela – Sumbawanga (95.31 km) Distresses: Reconstruction of the cracked sections
 Wearing course: DSD Wide longitudinal parallel cracks. Monitor sections which were still intact
 Base course: 150 mm Causes:
CRR i. Inferior quality of earthworks
 Subbase: 200 mm C1 ii. Inadequate storm water
management
21. Kagoma – Lusahunga Distresses: i. Reconstruction to subgrade level
 Wearing course: DSD Rutting, cracks, potholes, Unstable side ii. Reconstruction to base course
 Base course: 150 mm C2 slopes on cut sections level
 Subbase: 200 mm Causes: iii. Catch-water drains to be provided
G45 Poor workmanship on localised areas to prevent erosion of the slope
leading to: iv. Construct benches in the cut
 Design TLC: TLC 10 i. Low compaction slope.
 Current TLC: TLC 10 ii. Low thickness of subbase v. Construct retaining walls (e.g.
 Completed: Jan. 2011 iii. Low strength of stabilised base stone masonry), if it is not practical
iv. Steep side slopes on cut slopes to attain the required slope.
 Distress noted: 2013
 Investigation: (2014/CML)

22. Nangurukuru – Mbwemkuru Road Distresses: Long term measure:

Project (95km)-2008 Alligator cracks, multiple wide  Full reconstruction
 Wearing course: DSD longitudinal cracks, ruts, patches,  Partial reconstruction
 Base course: 150 mm surface ageing and localised heaves Short term measures
Central Materials Laboratory – TANLAB, P.O. Box 9452, Dar Es Salaam Tel: + 255 22 2866122/2866088
Fax: + 255 22 2866088, E-mail: cml@tanroads.go.tz
S/N SURFAC ROAD NAME AND PAVEMENT POSSIBLE CAUSE(S) OF FAILURE PROPOSED REMEDY
E TYPE DETAILS
CRR Causes:  Overlay
 Subbase: 200 mm C1 i. Presence of Expansive and Low  Resealing
Strength Soils with high field
 Design TLC: TLC 10 moisture
 Current TLC: TLC 50 ii. Inadequate treatment of the
 Completed: Jan. 2008 expansive soils
 Distress noted: 2016 iii. High Moisture Content in the
 Investigation: (2017/CML) Roadbed
iv. Inadequate insitu structural strength
of the pavement
v. Water ingress through cracks
DOUBLE SURFACE DRESSING (DBST)

23. Dareda – Babati – Minjingu (84.6 km) Distresses: Cracking i. Crack sealing
 Wearing course: DSD Causes: ii. Improve drainage
 Base course: 150 mm i. Consolidation of the soil bed iii. Repair the section of the road
CRR beneath the fill sections from around km 153+450 to km
 Subbase: 200 mm C1 ii. Instability of the fill resulting in local 154+100, including the culvert
shear failure
iii. Consolidation within the fill due to
inadequacy of subgrade to the newly
placed material as a result of road
widening
iv. Moisture migration in pavement due
to inadequate drainage system
v. Stabilisation process, including type
of cement, shrinkage due to over
exposure to high temperature.
24. Arusha – Namanga (105 km) Distresses: Cracking  Full reconstruction
 Wearing course: DSD Causes:  Partial reconstruction
 Base course: 150 mm C2 Poor workmanship leading to:
 Subbase: 125 mm i. poor materials for C2, C1 and
C1+125 mm CM CM
ii. Low compaction

Central Materials Laboratory – TANLAB, P.O. Box 9452, Dar Es Salaam Tel: + 255 22 2866122/2866088
Fax: + 255 22 2866088, E-mail: cml@tanroads.go.tz
S/N SURFAC ROAD NAME AND PAVEMENT POSSIBLE CAUSE(S) OF FAILURE PROPOSED REMEDY
E TYPE DETAILS
25. Mara bridge approach roads Distresses: Potholes  Reconstruction to achieve the

SURFACE
DRESSING DOUBLE  Wearing course: DSD Causes: designed pavement structure.
 Base course: 150 mm i. The constructed pavement was  Improve the drainage system.
CRS inferior to the designed
 Subbase: 200 mm pavement.
G45 ii. Inferior quality of the base
material.
iii. Inadequate drainage structure.

Central Materials Laboratory – TANLAB, P.O. Box 9452, Dar Es Salaam Tel: + 255 22 2866122/2866088
Fax: + 255 22 2866088, E-mail: cml@tanroads.go.tz
SUMMARY OF THE ROAD PROJECTS BASED ON THE TYPE OF FAILURE

Central Materials Laboratory – TANLAB, P.O. Box 9452, Dar Es Salaam Tel: + 255 22 2866122/2866088
Fax: + 255 22 2866088, E-mail: cml@tanroads.go.tz