As Inspected by Mr. N.Dhamarajan Senior Pavement Specialist

CONSULTANCY SERVICES FOR OPERATION & MAINTENANCE OF 4-LANE DIVIDED CARRIAGEWAY OF
PANAGARH-PALSIT-DANKUNI SECTION FROM KM. 520.103 TO 649.072 (NEW CH.) OF NH-2 IN WEST BANGAL
(As Inspected by Mr. N.Dhamarajan Senior Pavement Specialist)

Subject:
Consultancy Services as Independent Engineer during Operation &

Maintenance of
4-lane divided carriageway facility constructed on BOT
(Annuity) of Panagarh-Palsit-Dankuni Section from km 520.103 to Km
649.072 of NH-2 in the state of West Bengal
Address the issues on Flexible Pavement

1. Certain deficiency on flexible Pavement-.
2. Mr. N.Dhamarajan, Senior Pavement Specialist deputed for from M/s Unihorn India Pvt. Ltd.,
3. Project Highway Site investigations and Detailed Report

Reference: Team Leader, M/s Unihorn India Pvt. Ltd., Burdwan, Letter No.
Unihorn/NHAI/NH-2/O&M/IC-5/2014/313, dated 10.08.2014.
Objective of the Visit:
Mr. N.Dharmarajan Senior Pavement Specialist from M/s Unihorn India Pvt. Ltd.
input was sought for on this project Panagarh-Palsit-Dankuni from Km 517.000
to Km 645.600 (Durgapur Expressway) (New Chainages from Km 520.103 to Km
649.072) a Total of 128.600 kms and a new length of 128.969 divided into 2
packages. The main purpose of the visit is to address some of the Pavement
issues arising or experienced during Operation & Maintenance Period.
Accordingly Mr. N.Dharmarajan, Senior Pavement Specialist visited the Project
Highway with effect from 25.08.2014 for about 17 days. Reported to the Team
Leader, M/s Unihorn India Pvt. Ltd., Independent Engineer for this project
presently on 25.08.2014 A.N. Had interactions with the Concessionaires
representatives and Independent Engineers representatives Team Leader,
Highway Engineer Mr. Durgesh and Assistant Highway Engineer Mr. Himadri at
Team Leaders chamber. The Project site was inspected along with
Concessionaires General Manager Mr. Teong Leong Ang, M/s Mapex
Infrastructure Pvt. Ltd., M/s Emas Expressway Pvt. Ltd. and M/s Gamuda-WcT
(India) Pvt. Ltd. and other site representatives along with Independent Engineers
representatives with effect from 26.08.2014 to 31.08.2014. The project site was
inspected from the starting point Palsit to end point Dankuni both LHS and RHS.
Core cutting and trial pit excavations were carried out on the Project Highway at
a few places where the cracks are pronounced.
Analyzed the material composition and thickness of pavement both LHS & RHS
of the Main Carriageway at places/locations where some surface cracks
observed due to pealing of fine particles from Bituminous surface (Bituminous
Concrete) leaving the surface scabby/or fungus due to Abrasion effect of wheel
pressure of loaded vehicles.
UNIHORN INDIA PVT. LTD.
PAVEMENT EVELUATION REPORT

PANAGARH-PALSIT-DANKUNI SECTION FROM CH/ KM. 520.103 TO CH/KM 649.072 (NEW CH.) OF NH-2 IN WEST BANGAL
Figure 1.1 Project Location Map

PAVEMENT EVELUTION REPORTS - Page -2

The surface Unevenness of Bituminous concrete surface is also experienced

especially on the LHS Main Carriageway though it is found to be within the
tolerance limits as per Bump Integrator Test results conducted in the recent past.
The outcome of the site inspections and observations are summarized as under.
From the site inspection, it is observed that the Concessionaire is putting all out
efforts to maintain the Project Highway during Operation and Maintenance period
to a desired and satisfactory level and there by fulfilling his Contractual
obligations in a class of its own.
On review of records, it is seen that the Road Roughness value measured twice
in a year by a properly calibrated Bump Integrator device before the monsoon
and soon after the monsoon (Conducted in the months April and November of
every year).
The Roughness value found to be well within the acceptable Tolerance limits
3000mm /km as per Concession Agreement.
The structural condition of the flexible Pavement of the Project Highway
assessed every year by conducting Benkelman Beam Deflection Test and
working out Characteristic deflections of homogeneous sections of the Project
Highway as per IRC: 81:1997.
It is found from the records that the same is conducted during March every year
before the monsoon. It is advisable to carry out the test preferably after the rains
during which period the Pavement will be at its worst condition.
Ensuring compliance to Technical Specifications and various stipulations as
contemplated in the Concession Agreement and a high standard of
professionalism, Quality Assurance during implementation and supervision of
O&M Works.
Project Stretches details and salient futures:Stretch I:1. Panagarh (Km 517.000) to Palsit Km 581.457) New Chainage from Km
520.103 to 584.929
2. Lengths in
: Kms 64.457
3. Concessionaire
: M/s Mapex Infrastructure Pvt. Ltd.,
4 Date of Commencement of services : 21/06/2002
5 Date of Commercial operation
: 09.06.2005.
6 Annuity Payments 30 installments
: at IRS 555 Million each on 21 st June
and 21st December of
each year
from 2005 to 2019
7 Concession Periods
: 17 Years & 6 Months
Stretch II:1. Palsit (Km 581.457) to Dankuni (Km 645.060) Durgapur Expressway (New
Chainage from Km 584.929 to
649.072
2. Lengths in
: Km 64.143
Page -3

3. Concessionaire
4 Date of Commencement of Services
5 Date of Commercial Operation
6 Annuity payments 30 installments
7 Concession Period
: M/s Emas Expressway Pvt. Ltd.

: 27/10/2002
: 20.06.2005
: at IRS 399.98 million each on 27th
August and 27th February of each year
from 2005-2020
: 17 years and 4 months (ending on
February 26, 2020)
3.0 Appointment of Independent Engineer (IE)

M/s Unihorn India Pvt. Ltd., have been appointed as Independent
Consultant vide NHAI letter on 03.09.2013 (NHAI/15019/1/2004/CGM
(Tech)/Vol-II/173/43204, dated 03.09.2013.
The Agreement was signed on 30.09.2013
The Contract Period is for 2 years initially
The Date of Commencement of Services 19.10.2013
4.0.
Operation & Maintenance requirements:

The O&M requirements are as set forth in schedule I of Concession
Agreement. The Concessionaire to ensure that during Concession Period
the project facilities are maintained as per standards and specifications
set out there in.
All materials used in the maintenance repair and maintenance of any kind
of the project facilities shall meet the design requirements, standards
prescribed in the DPR.
5.0
Maintenance Requirements:
All the road work and pavement contained in the project facilities during
operation period shall be maintained in traffic worthy condition as per
intervention levels 1 and 2 provided in the table 1-2 of Concession
Agreement for various maintenance activities.
The Concessionaire is fulfilling his contractual obligations in this regard
and ensures smooth and uninterrupted flow of traffic during normal
operating conditions for all 24 hours of a day by doing routine
maintenance works such as.
Routine Maintenance
In order to ensure smooth and uninterrupted flow of traffic during normal
operating conditions for all 24 hours of a day routine maintenance of the
Project facilities is being carried out by the Concessionaire such as.
Prompt repair of potholes and patch works,

Maintain shoulder to design and standards to the possible extent.
Still lot of improvements required.
Re-grading of Granular shoulders to design standards to avoid
any pool of rain water on the road surface there by damaging the
Pavement.
Page -4

5.1.
5.2.
Making good the deficiency of material on the shoulders and

redressing as advised or as pointed out.
Carrying out repairs to Pavement by crack sealing/repairs when
and as required
Maintaining the approach roads to under passes, over passes and
drainages within the Project in accordance with good Industry
practice. However, adequate care shall be exercised.
Keeping the project site/project facilities in a clean, tidy and
orderly condition.
Taking all practical measures to prevent damages to the
Pavement.
Undertake maintenance work in accordance with the O&M Plan
and O&M Manual.
For routine maintenance works, the Concessionaire generally
follow the operational and performance criteria specified in the
respective IRC/MORT&H Standards and Specifications for each
of the performance indicator covered under Pavement Condition
Survey, Roughness and BBD deflections.
The Concessionaire regularly carryout the necessary preventive
maintenance activities for the project facilities to ensure
adherence he the design requirements/construction requirements
throughout the Concession Period to avoid any damage to the
Pavement.
An effective surface and sub surface drainage system of
Pavement Structure is designed and adopted as stipulated in
IRC:SP: 42:1994 and is well maintained during Operation &
Maintenance period to avoid any damages to the Pavement.
Periodic Maintenance:
Periodic Maintenance to be carried out during 5 thYear,10th Year and
15th Year from COD in respect of Panagarh-Palsit Section and
Palsit-Dankuni Section as per the Concession Agreement.
Accordingly, the specified over lay thickness on Panagarh- Palsit
section would be 40mm on both sides.
Similarly, the Specified overlay on Palsit to Dankuni section would
be 5omm on both sides.
It is Concessionaires contractual obligation to fulfill the above
requirements at his own cost and risk.
Strengthening/Rehabilitation:
It is Concessionaires responsibility to fulfill the Contractual
obligations as per Concession Agreement.
5.3
Work Plan
Page -5

Total work Plan comprising detailed work Programme, Methodology, Job

Mix Formulae for 10th Year renewal course is already submitted by the
Concessionaire for both the section of NH-2.
5.4
The Tests
The Concessionaire has carried out traffic Count and Axle Load Test for
Panagarh-Palsit and Palsit- Dankuni section. Report submitted. Slide
presentation conducted regarding Pavement Evaluation on 07.03.2014.
5.5
Right of Way
The Right of Way ROW generally varies from 45meters and 60 meters
and is in the order of 90 meters in respect of Palsit-Dankuni section and
Palsit- Panagarh section.
5.6
Raising of Height of Median Kerb

The Median Kerb are raised to the required level by laying Concrete in
order to accommodate the Over Lay.
5.7
Design of Pavement Composition & thickness and Trial pit

excavation details on Panagarh to Palsit Section.
Pavement Composition
Actual Trial Pit

Excavation
Thickness
LHS
RHS
Thickness
Adopted
(LHS)
Thickness
Adopted
(RHS)
50+40mm
50+40mm
240
240
Dense Bituminous Macadam (DBM)

Wet Mix Macadam (WMM)
Granular Sub. Base (GSB)
Dnainage Layer
150mm
250mm
200mm
150mm
150mm
250mm
200mm
150mm
255
195
150
245
200
155
Total
840mm
840mm
840
840
Bituminous Concrete
Designed for 100 Kms Speed/Hour

Designed for Maximum Standard Axle Load (MSA) :Design Life Period
100 msa
20 Years for Flexible Pavement
30 Years for Concrete Pavement/
Rigid Pavement.
As such the Composition and Thickness adopted is in compliance with the

proposed thickness in the Design.
No structural deficiency is noticed except the surface peal of at places all along
the Project Corridor with 3mm to 5mm and more at places with wide cracks to a
depth of 3 to 4mm. At places, it is more just like elephant foot prints, crocodile
type and alligator type especially on the LHS of the Project Highway
.
This is pronounced throughout the Project Corridor from Panagarh to Dankuni.
Page -6

Un authorized parking of such heavy vehicles may also cause damages to the
Pavement and hard shoulders due to Lack of adequate parking area.
Significant distress/or Fatigue stress is not seen on the surface but it looks like
surface fungus or scabby and gradually getting deteriorated.
Also, it is notable that the entire Project Highway is passing through
predominantly Agricultural (Durgapur Expressway) Paddy field with irrigation
canals on either side of the Highway.
Proper camber shall be provided to the earthen shoulders as per cross section.
May be 3%
Proper open Drainage is cut on either side of the Project Highway and is well
maintained. The Earthen shoulders are not dressed properly to the required
camber and cross fall of 3% and compacted properly. Reverse slope is seen at
many places resulting in Pool of rain water on the Bituminous surface damaging
the Pavements.
Any lapses, deficiency and defects noticed shall be rectified forthwith by
the Concessionaire at his own cost and risks as per the Concession
Agreement.
The thickness of periodic over lay in Palsit to Dankuni Section is 50 mm
thick and in Panagarh- Palsit section it will be 40 mm on both sides.
This periodic overlay shall be maintained and executed at the end of
5th,10th and 15th year from the date of completion COD as per the original
Pavement Design.
However, THE Concessionaire is requested to do the Benkelman Beam
Deflection test after the monsoon preferably to identify the worst condition
of the Pavement.
All Quality control testing as required shall be conducted as per section
900 of MORT&H Specifications and in compliance with Concession
Agreement.
Stability Voids and Density shall be checked for compliance. Bitumen
Content must be optimized while carrying out the overlay.
5.8
Maintenance Requirements
Road Works:A. Maintenance Standards.

The Concessionaire ensure that the 4 lane divided Carriageway is
maintained in traffic worthy conditions as per the Intervention levels 1 and
2 provided in table 1-2 of Schedule-H of Concession Agreement during
the Operation period like
Roughness by Bump Integrator once before monsoon (in March to June)
and once after the rains (in November) every Year.
Pothole/ Patch repairs
Percent cracking
Rut depth not exceeding 10mm
Page -7

5.9
Drainage including shoulders on Main Line and Service Roads.

Drainage including shoulders to avoid visible pool with in the Project
Highway.
Characteristic deflection as per IRC: 81:1997. The structural condition of
the flexible Pavement of the Project Highway assessed every year by
taking Benkelman Beam Deflections and the characteristic deflections of
homogeneous sections of the Project Highway as per IRC ; 81 : 1997.
Also, in case of cement concrete Pavement, joints being thoroughly
checked/inspected every year and the loss of sealing compounds made
good.
In this connection the Pavement evaluation Report submitted by Solo
Consultancy on the 7th March 2014 for Operation and Maintenance of
Panagarh to Palsit (PP) Section of NH-2 is taken for study and
review/comments (before the rains). Preferably after the rains would be
better.
The observations are as under
The Concessionaires commercial operation date(COD) is 9 th June 2005
Concessionaires operation period is from 9 th June 2005 to 20th December
2019
3 Stage Design approach is adopted with an overlay of bituminous
concrete of 40mm and 50mm for the Panagarh-Palsit and Palsit- Dankuni
section respectively.
Pavement was designed for a period of 10 years with further over lays
after 5th, 10th and 15th year of COD proposed to serve the facility for 20
years.
Stage construction as per IRC: 37: 2001 Clause 3.3.3.3 and the Pavement is
designed for a life period of 20 years.
Periodic Maintenance with an overlay of 40mm Bituminous Concrete

during the completion of 5th, 10th and 15th Year of COD as per Concession
Agreement
Accordingly existing crust thickness from Trial Pits is determined.
Average daily traffic is computed(ADT)
VDF(Vehicle Damage Factor) determined from Axle Load Survey 7 days
24 Hours count and one day 24 hours count
The Characteristic deflection by Benkelman Beam(BBD) is determined
Road Roughness Value evaluated by Bump Integrator
Compared the structural(SN) number of each layer(composition) of the
Pavement against the (SN) Structural Number derived from MSA.
A) Trial Pit Details for Panagarh to Palsit (Taken on 9th & 10th January 2014)
SI.
Pavement
As per as built
As per as
As per Trial
Actual at

Page -8

No.
Composition
Drawing
thickness on
LHS mm
built Drawing
thickness on
RHS mm
Pit at KM
570+467 (LHS)
mm
Trial Pit
at Km
524+950
(RHS)
existing
(Old
Road)
mm
1.
Bituminous Concrete (BC)

using 60/70 Grade Bitumen
90mm
(50+40)
mm (A)
90mm
(40+40)
mm (A)
240 mm
(A+B)
(50+40)
240 mm
(A) + (B)
(40+40)
Dense
Bituminous
Macadem (DBM)
Wet Mix Macadem (WMM)
Granular Sub-Base (GSB)
Granular Sub-Base (GSB)
Drainage layer (Graded
Aggregate)
150mm
(B)
250mm
200mm
150mm
150mm
(B)
250mm
200mm
150mm
255mm
195mm
150mm
255mm
200mm
155mm
Brickbats
2.
3.
4.
5.
Total
Subgrade CBR >7%
6
840mm
840mm
840mm
840mm
500mm
Selected
soil from approved
borrow area with
soaked CBR > 7%
500mm Selected
soil
from
approved borrow
area with soaked
CBR > 7%
500 mm using 80%

FlyAsh +20% sand
or sand 100%
500
mm
Brick Bats +
sand
mixed.
Remarks: The Concessionaire has complied with the Design requirements.

B. Trial Pit Details for Palsit-Dankuni Section of NH-2
SI.
No.
1
1.
2.
3.
4.
5.
Pavement Composition
As per as built
Drawing
thickness on
RHS mm
As per as built
Drawing Actual
Thickness on
LHS mm
As per as buil
Drawing
thickness on
RHS mm
Bituminous
Concrete
(BC) using 60/70 Grade
Bitumen
Dense
Bituminous
Macadem (DBM)
Wet
Mix
Macadem
(WMM)
Granular
Sub-Base
(GSB)
Granular
Sub-Base
(GSB)
Drainage layer (Graded
Aggregate)
100mm
(50+50)
mm (A)
150mm
(50+50)
(100mm)
(50+50)
100mm
(50+50)
100mm
150mm
150mm
150mm
250mm
250mm
250mm
250mm
200mm
200mm
200mm
200mm
150mm
150mm
150mm
150mm
Total
6.
As per as built
Drawing
thickness on
LHS mm
Subgrade sand & FlyAsh

CBR 80%+20% CBR
>7%
850mm
850mm
850mm
850mm
500mm
Selected
soil
from approved
borrow area or
sand
500 mm 80%
Flyash+20%
sand
500 mm sand
500 mm sand
Note: - LHS Graded Aggregates is used as GSB Drainage layer

RHS Brick Bats used as Drainage Layer
Trial pit Excavation taken at KM 612.400

Page -9

6.6. Based on ADT of commercial Vehicles obtained/day and Axle Load survey
carried out at KM 578 Truck Lay By. The Axle Load configurations identified and
noted for different categories of commercial Vehicles.
The Vehicles weighed (each type) on Axle Load Pad for Front and Rear Axles
and compared with Standard Load.
The Maximum permissible Weight for a particular Vehicle Configuration is carried
out and found to be 16.2 Tones as per standards where as the actual weight of
the same vehicle in loaded condition presently found to be 26.98 Tones.
Accordingly, the total damaging weight of the vehicle or vehicle Damage factor is
thus derived at is 32.386(sample of 6 vehicles at random sampling basis) Tones.
Based on the above, the Vehicle Damage Factor VDF calculated for all types of
vehicle is found out.
The VDF thus arrived at is used as a multiplier to convert the number of
commercial vehicles of different Axle Loads and Axle configurations in to number
of repetitions of Standard Axle Load of magnitude 80 KN.
It is defined as ESA (Equivalent Standard Axles) per commercial Vehicle
The VDF varies with Axle configuration and Axle Loading.
Accordingly, the VDF & Axle Load calculation for a 2 Axle Truck was found to be
37.900/6 Nos.
Average of 6.317
For various types of vehicles like LCV, 2 Axle Truck, 3 Axle Truck and Multi Axle
vehicle checked. It was calculated and found to be much higher than the VDF
adopted at the time of Pavement Design
Consequently, the projected MSA (Maximum Standard Axle Load) based on the
present VDF& ADT on the (LHS) and (RHS) is worked out to be higher
respectively on completion of the Concession period from the date of COD.
Accordingly, the projected Design MSA arrived at with the present data for the
Year ending is as follows with a Growth Factor of 0.05
Year
MSA
Cu MSA
Design MSA
LHS
2014
22.75
22.75
22.75
2019
29.04
154.75
132.00
2024
37.06
323.21
168.46
It is on the higher side than the Axle Load survey conducted at the time of
Design of Pavement before during the preparation of Detailed Project Report.
Similarly for the right hand side (RHS)
Year
MSA
Cu MSA
2014
12.50
12.50
Design MSA
12.50
LHS

Page -10

2019
2024
15.96
20.37
85.04
177.63
72.54
92.59
Based on the above findings, the VDF is found to be much on higher side.
Correspondingly, the Projected MSA is on the higher side due to higher
VDF.
Atmospheric temperature variation from 10 0 C to 400 C, may be polluted
with salt or sulphur content causing Bitumen losing its binding property.
Also, moisture in Air, due to rain and ingress and egress of water from
bottom and sides of Embankment and percolation effect from top surface
may also cause such damages to the Road surface.
The Benkelman Beam Deflection tests reveal varied deflection of
0.50 mm to 0.80 mm
Axle Load survey reveals MSA is > 100msa.
IRC : 81 : 1997 is applicable for overlay design up to 0.50 mm deflection
only (Overlay of 40mm with BC (Bituminous Concrete) with MSA<
100MSA where as in this case the deflection is > 0.50mm and varies up to
0.85mm MSA > 100MSA.
If tested after the rainy season, it may be much more.
6.0
Interpretation
Based on the above, AASHTO-1993 method of overlay may not be
adequate as the Bituminous Concrete surface is not withstanding the
Abrasive effect of Wheel Loads of various type of heavy vehicles with
multi axles plying on this Project Highway and hence (Resistance to
Abrasion Effect of Wheels) wear and tear is more resulting in
damages/cracks or failure of the Bituminous Concrete surface. The
structural condition of the flexible Pavement of the Project Highway is
getting deteriorated further and further.
However, the scope of the Project is limited to the specified periodic
overlay of 40mm on Panagarh- Palsit section and 50mm on PalsitDankuni section respectively.
6.1
Recommendations
In such eventuality, the Concessionaire is advised to carry out Pavement
condition survey, Benkelman Beam Deflection Test for evaluation of
existing structural conditions and its residual strength soon after the
monsoon to identify and make up the structural deficiency if any as per
IRC: 81:1997.
6.2
Suggestions

Page -11

Bitumen and Aggregates shall be got tested through Third party

Accredited Laboratory (Government Approved) for Physical and
mechanical properties.
Crack sealing shall be pressure grouted.
Surface shall be cleaned properly before pressure grouting.
All testing of materials shall be complied with as per section 900 of
MORT&H Specifications.
Manufacturers Test certificate shall be produced before commencement
of any works on the Project Highway/ or incorporating the materials on the
Highway.
6.3 Conclusion
This may be treated as a preventive and proactive action please.
The Concessionaire is responsible for Quality, soundness, durability,
Safety and the overall Project requirements, Operate & Maintain the
Project facilities as per the terms and conditions of the Concession
Agreement.
The defects, deficiencies and lapses if any noticed have got to be rectified
by the Concessionaire at its own cost and expenses and make good the
riding Quality of the surface with a crack proof layer.
An early action in this regard would be highly appreciated.
6.4
Enclosures:
Photographs showing typical damages of the BC overlay surface at
various location of the Project Highway on LHS and RHS of PanagarhPalsit-Dankuni section of NH-2 during Operation and Maintenance period.
N.Dhamarajan
(Senior Pavement Specialist)
Unihorn India Pvt. Ltd.
Burdwan, West Bengal

Page -12


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CONSULTANCY SERVICES FOR OPERATION & MAINTENANCE OF 4-LANE DIVIDED CARRIAGEWAY OF