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b Zonsultancy Services for Feasibility study and Detailed Project Report
or 416 Laning of Karur=Madurai section of NH.7 from Km 30518 to 42616
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January 2005
TABLE OF CONTENTS
CHAPTER -I
S. No Description Page No.
I
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LlST OF FIGURES
Project road and & location of various quarries and borrow areas
Soil Classification
Plasticity lndex
MDD of Borrow Area Samples
CBR of Borrow Area Samples
Soil Classification
Plasticity lndex
FDD & MDD
FMC & OMC
Soaked CBR at 97% MDD
LlST OF TABLES
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Final Detailed Project Report Table of Contents ii
A Contract Package: - NS 82 (TN)
Volume Ill: Material Report
A
Chapter 1 :Material Investigations
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1.0 REPORT ON MATERIAL INVESTIGATIONS
II INTRODUCTION
The Ministry of Road Transport and Highways (MoRT&H), Govt. of lndia has taken up the
development of various National Highway Corridors where the traffic intensity has increased
significantly thereby necessitating capacity augmentation for safe and efficient movement of
traffic. This Project is a part of North - South corridor connecting Srinagar in J&K State to
Kanyakumari in Tamil Nadu. National Highways Authority of lndia (NHAI) has been entrusted to
implement the development projects for these corridors. The work of conducting Feasibility
Studies and Preparation of Detailed Project Report for Four I Six laning from Karur (Km
305.800) to Madurai (Km. 426.660), a section of NH 7 has been entrusted to the Joint Venture
of BCEOM - Aarvee Associates.
For the convenience in construction, the present project corridor has been divided into three
packages. They are:
Package NS-80 (TN): Km 305.800 to Km 345.000
Package NS-81 (TN): Km 345.000 to Km 381.ZOO
Package NS-82 (TN): Km 381.ZOO to Km 426.660
In this chapter, the data pertaining to the Construction package: NS-82 (TN) is presented.
The road section from Km 381.200 to Km 426.660 of NH-7 (Package NS82 (TN)) is taken up
for conducting detailed engineering studies for rehabilitation and up-gradation of existing 2 lane
to 4 lane divided carriage way highway with improved traffic capacity. Suitable construction
materials (such as embankment material, sub-grade material, Granular sub base material,
metal quarries and Aggregate crushers) investigations form an essential part of studies
conducted for identification of potential sources with minimum lead and easy approach to the
construction site. The study involves assessing the requisite quantity available in respect of
estimated quantity.
The investigation entails carrying out the visual locations of Borrow areas, locations of quarries
etc. with approachable minimum lead, collection of samples, laboratory testing for assessing
their quality, and suitability, and assessment of their quantity available for construction
purposes.
The investigation and testing of materials is carried out in accordance with the provisions of
TOR clause 4.1 1.5. A mass haul diagram is also prepared and enclosed indicating locations of
selected Borrow areas, quarries etc. haulage routs with minimum lead approximate quantity
available against the requirement and the ownership of the Borrow areaslquarries etc. The
following sections discuss about the details of samples collection, laboratory tests carried out
and their results and suitability of materials.
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4 /6 Laning of Kamr- MaduraiSection of NH-7
Consultancy Services for Feasibility study and Preparation of DPR :
1.3 OBJECTIVE OF MATERIAL INVESTIGATIONS
Suitable sources have been identified along the project stretch by local enquiry. However,
consultants have carried out tests on selected sources to find their suitability for use. Sufficient
number of quarries has been identified to verify availability of materials within economical leads.
The information on the materials sources was summarized with the following objectives:
ldentification of source locations indicating places and the status of quarries whether in
operation or new sources.
Identificationof requirements for road pavements, shoulder works, cross drainage and other
works.
Material specification and characteristics.
Testing and evaluation of materials for use in works.
Consultants have identified a number of quarries for stone, sand, gravel and borrow areas for
earth. More borrow areas are available along the roadside. The samples were tested in the
laboratory to evaluate their suitability for road construction. A sketch showing the project road
and location of various quarries and borrow areas along with the leads is given in Figure 1.I.
Material was collected from the borrow areas and tests were conducted to determine the
following parameters:
Grain size analysis
Atterberg's limits
Compaction characteristics
Strength characteristics
Table 1.1 presents details of location of borrow areas for embankment and subgrade. The
analysis brings out the following
Soils are predominantly GC (29%) and SC(71%)
Plasticity index ranges from 15% to 18%
Maximum dry density is ranges from 1.98 gmlcc to 2.17 gmlcc
CBR was found to be ranging between 15% to 35%
Figure 1.2 to Figure 1.5 shows the location wise variation of Plasticity Index, Maximum dry
density and CBR respectively. The summary of test results of borrow area samples furnished in
Table 1.1 and Gravel samples in Table 1.2. The details of quarry and borrow locations are
given in Table 1.5.
It can be inferred from above that all borrow soils are suitable for Embankment an
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4 /6 Laning of Karur - Madumi Section of NH-7
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Plasticity index
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Location of B o r n h a
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LocatJon of Bomm Area
Samples have been collected from the existing quarries and crushers to find their suitability for
use in the cement concrete, sub base, base and wearing courses.
1.3.4 Sand
Sand has been collected from three quarries and all the quarries satisfy requiremen
II sand, which is ideal for reinforced concrete. But, there is a recent order that san
only through PWD
Cement conforming to BIS specifications can be procured directly form factories or can be
purchased from dealers of the factories in all the major towns along the project road. The
reinforcement steel both CRS and ordinary Tor steel of different grades conforming to BIS
specifications is available. Hence there is no difficulty in respect of its availability in this project.
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Final Project Report
Contract Package - NS82 (TN)
Chapter - I:Material lnve 6of 11
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G4 Somkkapatti
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39412 R 8.5 100 100 96 89 73 48 40 34 29 25 35 15 20 GC 2.10 10.3 30 12.6
roadofy0-810km
In Behneen to
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41012 L 0.2 100 BB 94 90 76 46 40 37 25 27 37 18 19 GC 2.092 8 29 10.5
Andipatly village of Kodal mad
MI NH-7
Table 1.3 Test Results of *qgmgah Samples
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DESCRIPTIONOF
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Value(%)
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394n 37916 R 14.5.20.5 19.8 2.818 0.15 I.M 1&20
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Location Details
2.1 INTRODUCTION
The Ministry of Road Transport and Highways (MoRT&H), Govt. of lndia has taken up the
development of various National Highway Corridors where the traffic intensity has increased
significantly thereby necessitating capacity augmentation for safe and efficient movement of
traffic. This Project is a part of North - South corridor connecting Srinagar in J8K State to
Kanyakumari in Tamil Nadu. National Highways Authority of lndia (NHAI) has been entrusted to
implement the development projects for these corridors. The work of conducting Feasibility
Studies and Preparation of Detailed Project Report for Four I Six laning from Karur (Km
305.800) to Madurai (Km. 426.660), a section of NH 7 has been entrusted to the Joint Venture
of BCEOM - Aarvee Associates.
For the convenience in construction, the present project conidor has been divided into three
packages. They are:
Package NS-80 (TN): Km 305.800 to Km 345.000
Package NS-81 (TN): Km 345.000 to Km 381.200
Package NS-82 (TN): Km 381.200 to Km 426.660
In this chapter, the data pertaining to the Construction package: NS-82 (TN) is presented.
The road section from Km 381.200 to Km 426.660 of NH-7 Package NS-82 (TN) is taken up for
conducting detailed engineering studies for rehabilitation and up-gradation of existing 2 lane to
4 lane divided carriage way highway with improved traffic capacity. Soils and material
investigation for a road project is an essential requirement to assess real scenario for design
and construction. During design stage, the road pavement, embankment, and other structures,
the existing soils and materials inventory is needed for their characteristics, availability in right
quality and quantity for constructions at reasonable cost. The investigations covered all relevant
aspects.
All relevant information such as geological maps data published by various authorities
regarding soil profile, ground water quality etc., have been studied to the extent possible.
Subgrade investigations along the alignment of the project was essentially directed towards
collecting all the data about the existing pavement, subgrade etc., necessary for strengthening
the existing pavement for widening and paved shoulders and for new bypass alignments.
The investigation and testing of materials is carried out in accordance with the provisions of
TOR clause 4.1 1.3.3.
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Subgrade investigations along the alignment of the project was essentially directed towards
collecting all the data about the existing pavement, subgrade etc., necessary for strengthening
the existing pavement for widening and paved shoulders and for new bypass alignments.
2.3.1 Methodology
All relevant information such as geological maps data published by various authorities
regarding soil profile, ground water quality etc and data available with PWD (NH) have been
studied to the extent possible. In addition fresh investigations were carried out by cutting trial
pits in the following manner.
-
Large test pits (1.0m x 1.0m) were excavated at the pavement shoulder interface to a
depth of 1 m, Minimum three pits were dug for each homogeneous road segment or change
of soil as per TOR and staggered IeWright for carrying out the following activities.
9 Measuring and logging the thickness of various pavement layers.
9 Conducting field (in-situ) density test using sand replacement method as per 18:2720 part-28
> Field moisture content
9 Conducting DCP Test (TRL Method) down to a depth of 1.5m below subgrade level.
9 Collecting samples of subgrade (approx. 50Kg) for following laboratory tests
s Atterberg limits As per 18:2720
3 Grain size analysis As per 18:2720
3 Maximum laboratory As per 18:2720
Dry density (heavy compaction)
s Optimum Moisture content As per 18:2720
3 CBR (4 days soaked) at AASHTO TI93
three energy levels
3 Free swell index As per lS:2720
9 Collecting Auger samples at different depths for Laboratory tests for soil classification
Small pits (0.7m x 0.7m) were dug upto the subgrade level at the pavement - shoulder
interface staggered left/right in between the large pits at every I k m interval. The following
activities were carried out
> Measuring and logging the thickness of various pavement layers
9 Collecting samples of subgrade for following laboratory tests
3 Atterberg limits,
3 Grain size analysis
3 Natural moisture content
The results of field and laboratory investigations have been compiled in the form of tables and
are given in the Appendix, at the end of this chapter.
Table 2.1 Test results at Subgrade level at every 1km interval from small pits
Table 2.3 Test results at Subgrade and below sub-grade level from large pits
The existing sub-grade soils have been investigated for moisture content, density, DCP-CBR
etc. The test was done staggered at the junction of shoulder and carriageway through test pit
dug up to the formation level as per standard procedure.
Dynamic Cone Penetration test according to TRL method was conducted to assess the in-situ
CBR at and below subgrade level. The test was conducted at large pits along the existing
pavement edge (300 mm from the edge of the carriageway) of the road. TRRL's DCP
apparatus consists of a hardened steel cone (60°cone) 20 mm in diameter, which is driven by a
weight of 8 Kg with a drop height of 575 mm. The CBR value was calculated for different soil
layers encountered from the graph of penetration versus number of blows. Slope changes of
penetration versus number of blows graph indicates interface of two soil layers. From this
graph, layer thickness and respective slopes (penetration 1 blow) have been calculated.
DCP-CBR value have been calculated using the following formula (TRL overseas
using 60" cone)
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Contract package- ~ ~ (TN) 8 2
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Part - 2: Re~orton Subarade lnvestiaations \L of 12
The above DCP-CBR value was converted to an overall equivalent DCP - CBR value using the
following Japanese formula.
-
Overall CBR = [@(Layer thickness) x (DCP CBR)'") I(Z(Layer thickness)13
Table 2.2 of Appendix gives the data on the overall CBR. Maximum, minimum and average
values of DCP-CBR value have been found to be 71.8, 30.9 and 48.6 respectively.
Laboratory test results obtained from small pits have been grouped along with results of large
pits and analyzed. The soil samples have been primarily classified on the basis of Bureau of
Indian Standards (BIS) which is based on the unified soil classification System (UCS). Density-
moisture relation, CBR (soaked) swell at
10, 30 and 65 blows, were determined. Soil Classification
Comprehensive results of laboratory tests
on subgrade samples of the existing SM
pavement are summarized in Table 2.1 & 27
2.3 in Appendix. The subgrade soil is
mostly sand, sandy clay and some gravel
C
material, with low plasticity. The soil is 73%
mostly classified as SM or SC group
according to the UCS System. Soil
profiles along the alignment have been Fig 2.1 Soil Classification
given in Figure 2.6, Appendix.
Grain size analysis: In the entire section soil, the 75 micron passing material is 33%
(average value) which ranges from 3.4% to 59.9%.
Atterberg's Limits: The mean Liquid limit and Plastic limit values are found to be 30% and
15% respectively. The average value of plasticity index of the soil is found to be 15%.
About 9% of soil samples have a PI value in the range of 0-10%, 51% of soil samples have
PI in the range of 10-20%, about 13% of
Plasticity lndex
samples have PI in the range of 20-30%
and 27% of samples are non-plastic in NP 0-10
nature, and is given in the figure 2.2.
.1&20
Moisture content vs. Dry Density
20
relationship (Heavy compaction), is given 13% 51%
in the figure 2.4
Soil samples obtained from trial pits have
Fia 2.2 Plasticitv lndex
been compacted in the laboratory at
various moisture contents to derive a dry density versus moisture content relationship. The
method of heavy compaction in accordance with IS: 2720 (P
given in figure 2.3.
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FMC 8 OMC
compaction.
The field dry density and moisture content of the subgrade soil has been measured at every
large pit and the results are
CBR (%)
illustrated in Table C8 of Appendix-
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C. It shows a range of FDD from
25 -
18.0kNl m3 having an average
value of 20.0kNI m3. The field sm-
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abutting the existing carriageway and along proposed alignment of bypasses was done through
test pit and auger samples collected for Laboratory tests. Comprehensive results of laboratory
tests are presented in Table 2.4 of Appendix.
Grain size analysis : Results of Grain size indicates an average value of 75 micron down
material is 33% (Range 3.4 % to 59.9%)
Atterberg's Limits: The mean Liquid limit and Plastic limit values are found to be 30% and 15%
respectively. The average value of plasticity index of the soil is found to be 15% (Range 8% to
25%)
Moisture content vs. Dry Density relationship (Heavy compaction)
a Average Maximum dry density (MDD) of the natural ground is 2.0glcc (Range: 1.8glcc to 2.
2gmlcc). The optimum moisture content (OMC) varies from 9.5% to 16.5% &owing an
average of 12.2%.
CBR Test: Laboratory CBR on the test pit sample from natural ground at MDD has been found
to be 18.4% (average value) with a range of 9.6% to 27.7%.
Auger Samples: Auger samples were collected at three depth 50cm, Im, 1.5m for natural
moisture content. The soil samples from different depths were collected at each site and
representative test samples were prepared for analysis.
2.3.3.4 Interpretation of Test Results
Majority of the alignment soil is mostly sand, sandy clay and some gravel material, with low
plasticity. The soil is mostly classified as SM or SC group according to UCS system.
Existing Subgrade
In-situ average DCP-CBR value is 48.6% with large variation (Range: 30.9% to 71.8%) which is
more than Laboratory CBR 18.4% (Range: 9.6% to 27.7%). This indicates the densification of
sub-grade has occurred over a period of time.
Average Optimum Moisture Content (OMC) is 12.2% where as Natural Moisture Content (NMC)
is about 6.3%. Therefore the mean NMC is 50% less than OMC.
Majority of the natural soil abutting existing alignment is predominantly sandy claylsandy silt
(SCISM group) and average Laboratory CBR 13.47% (Range 5% to 23%) which is less than
existing subgrade CBR at MDD (20.23%). Average Optimum Moisture Content (OMC) is 12%
where as Natural Moisture Content (NMC) at a depth of 0.50m, I m and 2m below ground level
was collected and presented in Table 2.4, Appendix.
2.4 RECOMMENDATIONS
Basic input for the design of pavements is the soaked CBR value compacted at 97% MDD.
Considering this parameter, and the type of existing soils available, a soaked CBR value of
10% has been adopted uniformly for the design of existing and new pavement.
In order to evaluate the stability of high embankments in the approaches to bridge and other
structures, two bore holes were drilled in each of the approaches as well as the strength
properties of fill soils were evaluated. The sub-soils in the stretch are materials having high
shear strength as also the fill materials. The high embankments are safe with 1:2 side slopes.
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