Beruflich Dokumente
Kultur Dokumente
October 2017
NATIONAL HIGHWAYS AUTHORITY OF INDIA
(Ministry of Road Transport & Highways)
Table of Contents
Chapter 1 – Introduction............................................................................................................... 8
1.1. Introduction ............................................................................................................................ 8
1.2. Need of the Project ................................................................................................................. 8
1.3. The Project Highway ............................................................................................................... 9
1.4. Scope of Works for Design Report (Part 1: Road Works) ..................................................... 11
Chapter 2 – Design Standards ................................................................................................... 13
2.1. General .................................................................................................................................. 13
2.2. Geometric Design Standards ................................................................................................ 14
2.3. Terrain ................................................................................................................................... 15
2.4. Design Speed ......................................................................................................................... 15
2.5. Land Acquisition .................................................................................................................... 16
2.6. Traffic Lanes, Carriageway Width and Shoulders (Cross Section) ........................................ 17
2.7. Camber/Cross Fall ................................................................................................................. 18
2.8. Service Roads ........................................................................................................................ 18
2.9. Median Width ....................................................................................................................... 18
2.10. Horizontal Alignment ........................................................................................................ 19
2.11. Minimum Transition Length.............................................................................................. 19
2.12. Widening at Curves ........................................................................................................... 20
2.13. Sight Distance.................................................................................................................... 20
2.14. Setback Distance at Horizontal Curves ............................................................................. 20
2.15. Vertical Alignment............................................................................................................. 21
2.16. Lateral and Vertical Clearances ......................................................................................... 21
2.17. Standards for Interchange Elements ................................................................................ 22
2.18. Design of Project Highway Facility .................................................................................... 23
Chapter 3 – Pavement Design.................................................................................................... 31
3.1. General .................................................................................................................................. 31
3.2. Factors governing Design ...................................................................................................... 31
3.3. Axle load characteristics ....................................................................................................... 31
3.4. Wheel base characteristics ................................................................................................... 31
Revision Level: R0 October 2017 Page 4
Detailed Project Report for Two / Four laning with paved shoulder NH configuration
of "Dwarka - Khambhaliya - Devariya" & "Dhrol - Amran - Maliya" Road Sections in
Gujarat under Bharat Mala Project.
Final Detailed Project Report/Volume II (Part-1)/Table of Contents Highway Division
Document Ref: RITES/HW/RT300-00012/FDPR/Volume II (Part-1)/Table of Contents
List of Tables
Table 1-1: Start & End Location of Dwarka - Khambhaliya - Devariya Road Section ........................................... 10
Table 1-2: Start & End Location of Dhrol – Amran – Maliya Road Section ........................................................... 10
Table 2-1: Terrain Classification ........................................................................................................................... 15
Table 2-2: Guidelines for design Speed ............................................................................................................... 155
Table 2-3: Land Requirement for Different Cross-Section types ........................................................................... 16
Table 2-4: Cross-Sectional Elements ..................................................................................................................... 17
Table 2-5: Guidelines for camber .......................................................................................................................... 18
Table 2-6: Width of Median .................................................................................................................................. 18
Table 2-7: Design Parameters for Horizontal Curves ............................................................................................ 19
Table 2-8: Guidelines for Transition Length .......................................................................................................... 19
Table 2-9: Guidelines for Extra Widening at Curves (Two Lane Road).................................................................. 20
Table 2-10: Guidelines for Extra Widening at Curves (Four Lane Road) ............................................................... 20
Table 2-11: Guidelines for Safe Sight Distance ..................................................................................................... 20
Table 2-12: Guidelines on Gradients ..................................................................................................................... 21
Table 2-13: Minimum Length of Vertical Curves for Different Speeds .................................................................. 21
Table 2-14: Minimum Vertical Clearances ............................................................................................................ 22
TABLE 2-15: SPEED, HORIZONTAL CURVATURE AND SIGHT DISTANCE FOR RAMP DESIGN............................ 22
Table 3-1: Cumulative No. of Commercial Vehicle during Design Period ............................................................. 32
Table 3-2: Percentage Composition of Types of Axle ............................................................................................ 32
Table 3-3: Axle load spectrum for section I, section II and section III ................................................................... 33
Table 3-4: Axle load spectrum for section IV and section V .................................................................................. 33
Table 3-5: Average no of axles per commercial vehicle ........................................................................................ 34
Table 3-6: Cumulative Fatigue Damage value for Different Trial Thickness ......................................................... 34
Table 3-7: Pavement Layers .................................................................................................................................. 36
Table 3-8: Reinforcement Details ......................................................................................................................... 36
Table 3-9: Proposed Pavement Composition: Service Road.................................................................................. 37
Table 3-10: Cumulative No. of Commercial Vehicle (Section I: Kuranga to Limbdi)............................................ 37
Table 3-11: Cumulative No. of Commercial Vehicle (Section II: Limbdi to Khambhaliya) .................................... 38
Table 3-12: Cumulative No. of Commercial Vehicle (Section III: Khambhaliya to Devariya)................................ 39
Table 3-13: Cumulative No. of Commercial Vehicle (Section IV: Dhrol to Bhadra Patiya ) .................................. 40
Table 3-14: Cumulative No. of Commercial Vehicle (Section V: Bhadra Patiya to Pipaliya) ................................ 41
Chapter 1 – Introduction
Detailed Project Report for Two / Four laning with paved shoulder NH configuration
of "Dwarka - Khambhaliya - Devariya" & "Dhrol - Amran - Maliya" Road Sections in
Gujarat under Bharat Mala Project.
Final Detailed Project Report / Volume II (Part-1)/ Chapter 1 - Introduction Highway Division
Document Ref: RITES/HW/RT300-00012/FDPR/Volume II (Part-1)/ Chapter 1
Chapter 1 – Introduction
1.1. Introduction
RITES Ltd. has been entrusted with Consultancy services for Detailed Project Report
for Two / Four laning with paved shoulder NH configuration of "Dwarka -
Khambhaliya - Devariya" & "Dhrol - Amran - Maliya" Road Sections in Gujarat
under Bharatmala Project vide NHAI Letter no. NHAI/BM/Proc./01/DPR/2015/
76292 dated 31.12.2015. The commencement date of the Consultancy Services is
21.01.2016. The present report is submitted in accordance with the Stage 3 (Clause
10.8) of Terms of Reference.
The start and end of the Road sections can be summarized as below:
TABLE 1-1: START & END LOCATION OF DWARKA - KHAMBHALIYA - DEVARIYA ROAD SECTION
Sl. Description Location Length
No. (km)
1. Start Km 203+500 of SH25 (Junction with NH-8E at Km 443+700) 73.5
2. End Km Stone 130 of SH25 (Start of 4 Lane Section: near Essar Green)
TABLE 1-2: START & END LOCATION OF DHROL – AMRAN – MALIYA ROAD SECTION
Sl. Description Location Length (km)
No.
1. Start Dhrol(Junction with Jamnagar – Rajkot Road 86.6
section SH-25 at Km. 50.9) (as per ToR)
2(a). End (Original) Maliya (Junction with Morbi – Samakhyali Road
Section of NH-8A at Km 268.5)
2(b). End (Revised) Km Stone 24 near Pipaliya 62.6@
(Revised length)
Note: Road Section between Maliya (Km 0 of CSH-6) to Pipaliya (Km 24 of CSH-6) delinked from
DPR vide NHAI Letter dated 09.08.2016.
@ Revised length of Road Section is 62.6 Km upon delink of Maliya-Pipaliya road section of
24.0Km.
FIGURE 1-1: ALIGNMENT ROUTE MAP APPROVED BY THE CLIENT NHAI AND STAKEHOLDERS
End of Project
Road
Start of
Project Road
The Present report “Volume II: Design Report (Part I Road Works)” is part of submissions
under Stage 3: Final Detailed Project Report (please refer Global Contents at start of the
report).
This is being submitted in accordance with Para 10.8 of Terms of Reference, Page 72 of
Contract Agreement. The Scope of Works for presenting details in Design Report, Part I:
Road Features and Pavement Composition is as under:
2. The detailed design for all features should be carried out as per the requirements of the
Design Standards for the project. However, there may be situations wherein it has not
been possible to strictly adhere to the design standards due to the existing site
conditions, restrictions and other considerations. The report should clearly bring out the
details of these aspect and the standards adopted.
2.1. General
Highway design is the process whereby the layout of the road in specific terrain is
designed to meet the needs of the road users, keeping in view the road function, type
and volume of traffic, potential traffic hazards and safety, capital cost, maintenance
costs, vehicle operating costs, environment impacts, aesthetics as well as convenience
of the road users.
The existing road mainly traverses through plain terrain to its entire section from
"Dwarka - Khambhaliya - Devariya" & "Dhrol -Amran - Maliya" Road Sections which
connects NH-8E at Kuranga Junction and with NH-8A at Maliya connecting
Khambhaliya, Jamnagar, Dhrol and Amran enroute.
The various design elements and factors, which govern the functions of any
highway, can be broadly grouped under the following:
• Cross-sectional layout;
• Land-use and access control;
• Geometric design, alignment and profile;
• Pavement design;
• Drainage;
• Bridges and structures;
• Interchanges and intersections;
• Traffic control and safety measures;
• Wayside facilities;
• Aesthetics;
• Socio environmental design and mitigation;
• Bypasses
• Service and side roads;
• Pedestrian facilities.
The objectives for upgrading and rehabilitation works of the project are:
would comply with the relevant IRC codes, as adopted in similar National / State
Highway projects and the same are being proposed for this particular project.
Design standards for the highways call for an in-depth study of available and
internationally adopted criteria for economy and safety. The consultants initiated
the study in this direction and the broad criteria emerging out of them, are proposed
for the project. The relevant standards consulted for the project includes the
following:
• IRC
IRC: 5-2015 Standard Specifications and Code of Practice for RoadBridges,
Section I – General Features of Design (EighthRevision)
IRC: 6-2017 Standard Specifications and Code of Practice for Road Bridges,
Section-II Loads and Stresses (Revised Edition)
IRC: 28-1967 Tentative Specifications for Construction of Stabilized Soil
Roads with Soft Aggregates in Areas of Moderate & High
Rainfall
IRC: 36-2010 Recommended Practice for Construction of Earth Embankments
and Subgrade for Road Works
IRC: 37-2012 Guidelines For The Design of Flexible Pavements
IRC: 38-1988 Guidelines for Design of Horizontal Curves for Highways and
Design Tables
IRC: 54-1974 Lateral and Vertical Clearances at Underpasses for Vehicular
Traffic
IRC: 62-1976 Guidelines for Control of Access on Highways
IRC: 64-1990 Guidelines for Capacity of Roads in Rural Areas
IRC: 65-1976 Recommended Practice for Traffic Rotaries
IRC: 66-1976 Recommended Practice for Sight Distance on Rural Highways
IRC: 67-2012 Code of Practice for Road Signs (Third Revision)
IRC: 73-1980 Geometric Design Standards for Rural (Non-Urban) Highways
IRC: 75-2015 Guidelines for the Design of High Embankments
IRC: 78-2014 Standard Specifications and Code of Practice for Road Bridges
Section : VII Foundations and Substructure (Revised Edition)
IRC: 81-1997 Guidelines for Strengthening of Flexible Road Pavements using
Benkelman Beam Deflection Technique
IRC: 83-2015 (Part II) Standard Specifications and Code of Practice for Road Bridges
Section : IX Bearings Part II : Elastomeric Bearings
IRC: 83-2002 (Part III) Standard Specifications and Code of Practice for Road Bridges
Section : IX Bearings Part III : POT, POT-Cum-PTFE, PIN and
Metallic Guide Bearings
IRC: 86-1983 Geometric Design Standards for Urban Roads in Plains
IRC: 92-1985 Guidelines for Design of Interchanges in Urban Areas
IRC: 102-1988 Traffic Studies for Planning Bypasses Around Towns
IRC: 104-1988 Guidelines for Environmental Impact Assessment of Highway
Projects
IRC: 108-2015 Guidelines for Traffic Forecast on Highways (First Revision)
IRC: 112-2011 Code of Practice for Concrete Road Bridges
IRC: SP: 13-2004 Guidelines for the Design of Small Bridges and Culverts
Revision Level: R0 October 2017 Page 14
Detailed Project Report for Two / Four laning with paved shoulder NH configuration
of "Dwarka - Khambhaliya - Devariya" & "Dhrol - Amran - Maliya" Road Sections in
Gujarat under Bharat Mala Project.
Final Detailed Project Report /Volume II (Part-1)/Chapter 2 – Design standards Highway Division
Document Ref: RITES/HW/RT300-00012/FDPR/Volume II (Part-1)/Chapter-2
IRC: SP: 19-2001 Manual for Survey, Investigation and Preparation of Road
Projects
IRC: SP: 23-1983 Vertical Curves for Highways
IRC: SP: 44-1996 Highway Safety Code
IRC: SP: 69-2011 Guidelines & Specifications for Expansion Joints (First Revision)
IRC: SP: 73-2015 Manual of Specifications & Standards for Two Laning of
Highways with Paved Shoulders (First Revision)
IRC: SP: 84-2014 Manual of Specifications & Standards for Four Laning of
Highways through Public Private Partnership (First Revision)
IRC: SP: 88-2010 Manual on Road Safety Audit
IRC: SP: 90-2010 Manual for Grate Separators and Elevated Structures
IRC: SP: 93-2011 Guidelines on Requirements for Environmental Clearance for
Road Projects
IRC: SP: 102-2014 Guidelines for Design and Construction of Reinforced Soil Walls
• AASHTO
Guide for Design of Pavement Structure, 1993.
A Policy on Geometric Design of Highways and Streets, 1990
• MoRT&H
Specifications for Road and Bridge Works (5th Revision, 2013)
Green Highways (Plantation, Transplantation, Beautification & Maintenance) Policy
• ICAO
International Standards and Recommended Practices.
• Ministry of Defense
Guidelines provided vide Letter no. Air HQ/36072/1/RWY (Pol)/W (P&C)
2.3. Terrain
The design speed is the guiding criteria for correlating features such as sight
distance, curvature and super elevation upon which the safe operation of the vehicle
depends. The design speeds for plain terrain have been proposed as follow:
Since, the project passes through the flat/plain terrain, hence a design speed of 100
km/hr. has been proposed.
Also, as suggested by NHAI ,vide Minutes of Meeting and letter no. NHAI/BM/
Proc./01/ DPR/2015/Pkg2/86714, dated 09.8.2016, the proposed ROW along
existing road shall be kept 45m and along bypass/realignment shall be 60m.
Accordingly the land acquisition activities have been taken up by the consultant
satisfying the advices of NHAI. In addition to the indicated ROW acquisition, then
consultant has also identified additional land requirement at Road user facilities;
Junction and Interchanges satisfying the codal provisions.
Based on the projected traffic along all road sections, the respective sections shall be
proposed to be developed as two/four lanes with paved shoulders. The consultants have
studied various alternatives proposals in similar projects and other design standards. The
typical cross-sectional elements and the minimum effective roadway width for the project
road have been presented in the following table:
Service roads if required will be proposed for the selected built-up sections for
effective segregation of traffic in addition to facilitate the local commuters and to
avoid the direct entry of the traffic on main carriageway if found essential. The
carriageway width of Service Road is proposed as 7.5m (includes kerb shyness of
0.5m) with a separator of 1.5m.
In open area, raised median of width 5.0 (including kerb shyness of 0.5m on either
side) is proposed. In built-up areas with 4-lane divided carriageway, the width of
median (distance between inside edges of carriageway) may be kept minimum 2.5 m
including kerb shyness of 0.50 m on either side, wherever found essential.
The width of median is the distance between inside edges of carriageway. The type
of median shall depend upon the availability of Right of Way. The minimum width
of median, subject to availability of Right of Way, for various locations is given
below:
TABLE 2-6: WIDTH OF MEDIAN
Type of Section Minimum Width of Median {m)
Plain and Rolling terrain Mountainous and
Steep terrain
Raised* Depressed Raised*
median
Open country with isolated built-up area 5.0 7.0 2.5
Revision Level: R0 October 2017 Page 18
Detailed Project Report for Two / Four laning with paved shoulder NH configuration
of "Dwarka - Khambhaliya - Devariya" & "Dhrol - Amran - Maliya" Road Sections in
Gujarat under Bharat Mala Project.
Final Detailed Project Report /Volume II (Part-1)/Chapter 2 – Design standards Highway Division
Document Ref: RITES/HW/RT300-00012/FDPR/Volume II (Part-1)/Chapter-2
The minimum transition length for a curve radius of 400m in flat/plain terrain
should be 130m & 60m for speeds of 100 km/hour & 80 km/hour respectively. In
case of curve radius of 250m, the minimum transition length should be 90 m for the
speed of 80 km/hour.
The minimum transition length for different speeds and curve radii shall be as
presented in the following table:
Broken-back curves will be avoided to the extent possible. Minimum curve length
would be 150m for a deflection angle of 5 degrees and this would be increased by 30
metres for each one-degree of decrease. No curve is required for deflection angle of
less than one degree.
TABLE 2-9: GUIDELINES FOR EXTRA WIDENING AT CURVES (TWO LANE ROAD)
Radius of Curve (m) Up to 40 41 to 60 61 to 100 101 to 300 Above 300
Extra Width (m) – 1.5 1.2 0.9 0.6 Nil
Two lane road
TABLE 2-10: GUIDELINES FOR EXTRA WIDENING AT CURVES (FOUR LANE ROAD)
Radius of Curve (m) 75 – 100m 101-300m
Extra Width (m) – Four Lane road 0.9m 0.6m
The safe stopping sight distance and desirable minimum sight distance are given in
the following table:
The minimum setback distance from the centre line of the carriage way to the object
obstructing the line of sight will be as under:
Parameters Setback distance
a) V = 100 km/hr.
S = 180 m 13 m
R = 360 m
b) V = 80 km/hr.
S = 120 m 9m
R = 230 m
Where horizontal and summit vertical curves overlap, the design should provide for
the required sight distance both in vertical directions along the pavement and in
horizontal direction on the inside of the curve.
There are two major elements in vertical geometry of an alignment i.e. longitudinal
gradient and vertical curve. The following gradients for different terrain conditions
are given below.
The vertical curve would be provided at all grade changes exceeding those indicated
in the following table.
Lateral and vertical clearances for the roads at the locations of underpass and grade-
separators are proposed as per Indian Roads Congress Standards IRC: 54-1974, IRC:
73-1980, IRC: 5-2015, IRC:SP:73-2015 and IRC:SP:84-2014.
(i) Full roadway width of the cross road shall be carried through the
Vehicular Underpass. The lateral clearance shall not be less than 12 m
(7 m carriageway+ 2 x 2.5 m shoulder width on either side)
(ii) For Light Vehicular Underpass the lateral clearance shall not be less
than 10.5 m including 1.5 m wide raised footpath on either side
(iii) For pedestrian and Cattle underpasses the lateral clearance shall not
be less than 7 m
(iv) Guard rails/crash barriers shall be provided for protection of vehicles
from colliding with the abutments and piers and the deck of the
structures
The design standards of the interchange elements viz. direct ramps, loops; speed
change lanes are given hereunder:
The design standards of the interchange elements viz. direct ramps, loops; speed
change lanes shall be as per Indian Roads Congress Standards IRC: 92-1985. Design
speed of ramp corresponding to the highway design speeds of 80 Km/hr and 100
Km/hr is given in the following table:
TABLE 2-15: SPEED, HORIZONTAL CURVATURE AND SIGHT DISTANCE FOR RAMP DESIGN
Particulars Design values for Major Highway For Loop ramps
Design Speed of
80 Km/hr 100 Km/hr
Min. Desirable Min. Desirable Min. Desirable
Ramp design speed (Km/hr) 40 50 50 65 30 40
Radius of Curvature (m) 60 90 90 155 30 60
Stopping Sight Distance (m) 45 60 60 90 25 45
The desirable values are normally meant for Direct Ramps and diagonal connections,
whereas the minimum values are for loops.
Both summit and valley curves would be designed as per stopping sight distance
subject to a minimum length equal to 0.6 V, where V = Design Speed in km/h.
The primary factors considered for suitability of any stretch to be utilized as runway
are length of straight segment, cleared zone available on the sides and gradient etc.
The other factors that govern the execution of operations from these locations and
would depend on the distance from the IB / nearest IAF base, distance from
populated areas etc.
The following factors need to be considered while identifying such linear highway
stretches:
(a) Length: Availability of a linear stretch of road 3000-4000m long on a highway or
feasibility of creating such a stretch on planned highways.
(b) Width: The minimum width required is 35-45m (absolute minimum 23m).
(c) Strength: The highway has to be able to bear the load of high speed landing /
takeoff and operations of aircraft. The surface should be capable of supporting
operations of aircraft with weight upto 40 Tonnes.
(d) Gradient: Vertical gradient along the stretch should be less than 3.5% and
transverse slope from centre line to either side should be 1-1.5%.
(e) Medians: The medians in such stretches could be movable concrete blocks.
(f) Orientation: The orientation of the landing strip needs to cater for the surface
wind conditions. Wind direction for the greater part of the year should be within
±30 degree of the orientation of the road.
(g) Obstructions:
(i) These stretches are to be free from obstructions like medians, signboards,
trees, fencing, sidewalls, high tension cables, poles or any other
construction.
(ii) Approach and take-off funnel should also be devoid of obstructions.
(iii) Preferably the stretches are not to have any underpasses, overpasses,
culverts or bridges which do not confirm to load bearing strength.
(iv) There has to be fencing, catering for dog / cattle intrusion on either side,
which should be collapsible outwards when crashed into (in case of any
aircraft emergency), from the highway side.
Design Considerations
The following design specifications have been finalised by SWAC, IAF for the
proposed Project Highway Facility:
The Detailed Engineering Report for the indicated road section between Dwarka – Maliya
was submitted and designed during April 2017. While carrying out the Detailed Design of
project road, RITES have taken account of past rainfall details, its intensity and precipitation
to assess the hydraulics which are directly influenced with the design of cross drainages
such as Culverts, Minor Bridges along with due consideration to road formation assessment
to avoid any inundation/submergence possibilities.
However, in recent days (July 2017), heavy to extremely heavy rains battered entire
Saurashtra and Kutch region of Gujarat leading to massive flooding in Project Influence
Area and in Rajkot, Jamnagar, Limbdi, Morbi etc. The rainfall recorded has not only
surpassed the highest spell of rains recorded in last 10 years in the period of 24 hours but
also surpassed the monthly average rainfall, which is rarer natural incident. The recent rain
has caused great loss to infrastructure and severe damage to connectivity including various
National and State Highways.
Accordingly, the consultant, as an exceptional case and with due respect to good
engineering practice, has taken serious notes on the devastating flood like situation which
also affects the proposed improvement proposal of Project Road and immediately deployed
a team of experts to assess the condition. Based on findings, the consultant has modified
proposed improvement proposal so that the project road will be designed in more effective
manner to function in such scenario and serve the nation in all-weather condition.
Thus, the Road section 1: Dwarka – Khambhaliya – Devariya section of SH-25 has been
provided with additional cross drainage structures for smooth functioning and
Road section 2: Dhrol - Amran - Maliya section of SH-25 : It is noticed that majority of road
sections remains inundated and damaged. Most of the cross drainage structures experienced
overtopping. In order to address such issues, the consultant have carried out “Redesign of
Road profile” and “Structure” (Major & Minor Bridges) and cross drainage Culverts.
Based on the findings, the design of road and cross drainage structures are dealt in details in
“Chapter 07- Improvement Proposal of Main Report.”
Revision Level: R0 October 2017 Page 25
Detailed Project Report for Two / Four laning with paved shoulder NH configuration of "Dwarka - Khambhaliya - Devariya" & "Dhrol - Amran
- Maliya" Road Sections in Gujarat under Bharat Mala Project.
Final Detailed Project Report /Volume II (Part-1)/Chapter 2 – Design standards Highway Division
Document Ref: RITES/HW/RT300-00012/FDPR/Volume II (Part-1)/Chapter-2
3.1. General
Based on the field studies and analysis of data, the improvement, rehabilitation and
upgrading requirements for Pavement of Project Road have been identified. The general
design procedure is to be based on the prevalent practices in the country. The pavement
design is based on and is carried out in accordance with IRC: 58 -2015 “Guidelines for the
Design of Plain Jointed Rigid Pavements for Highways”.
The main factors governing design of concrete pavements are given below:
• Design Period
• Design Commercial Traffic Volume
• Composition of Commercial Traffic in terms of Single, Tandem and Tridem
• Axle Load Spectrum
• Tyre Pressure
• Lateral Placement characteristics
• Directional Distribution
• Strength of Foundation
• Climatic Consideration
Though the legal axle load limits in India are 10.2 tonnes (100kN), 19.0 tonnes (186kN) and
24.0 tonnes (235kN) for single, tandem and tridem axle respectively, a large number of axle
operating on National Highways carry much heavier loads than the legal limits. The
vehicles are surveyed on randomly basis to avoid bias and classified into following intervals
of axle load groups for fatigue damage analysis.
Single Axle 10Kn
Tandem Axle 20kn
Tridem Axle 30kn
Wheel base of trucks of different models generally ranges from 3.6m to more than 5.0m
whereas the commonly used spacing of transverse joint is 4.5m. Thus, axle with spacing of
more than the 4.5m will not contribute to top down cracking.
Revision Level: R0 October 2017 Page 31
Detailed Project Report for Two / Four laning with paved shoulder NH configuration
of "Dwarka - Khambhaliya - Devariya" & "Dhrol - Amran - Maliya" Road Sections in
Gujarat under Bharat Mala Project.
Final Detailed Project Report /Volume II (Part-1)/Chapter 3 – Pavement Design Highway Division
Document Ref: RITES/HW/RT300-00012/FDPR/Volume II (Part-1)/Chapter-3
It has been recommended that pavements for National Highways should be designed for a
minimum life of 30 years or more.
In view of above, Design life of 30 years is proposed and adopted for project road
sections.
Lane width of 3.5m is proposed and adopted for project road sections.
Design Commercial Traffic volume (year 2050) as per traffic survey as below:
TABLE 3-1: CUMULATIVE NO. OF COMMERCIAL VEHICLE DURING DESIGN PERIOD
Section Cumulative No. of Commercial Vehicle during Design Period
I 28163765
II 62031750
III 82900990
IV 15229625
V 74712215
Axle Load Spectrum for different road section as per axle load survey as follows:
TABLE 3-3: AXLE LOAD SPECTRUM FOR SECTION I, SECTION II AND SECTION III
Single Axle Tandem Axle Tridem Axle
Axle Load No Frequency Axle Load No of Frequency Axle No of Frequency
Class KN of (% of Single Class KN axles (% of Load axles (% of
axle Axles) Tandem Class Tridem
s Axles) KN Axles)
Tyre Pressure of 0.8 MPa is adopted for designing of proposed concrete pavement.
Proportion of traffic in predominant direction is 50% for four lane Highway. Directional
Distribution for commercial traffic: traffic counts indicates the 40 % of the commercial
vehicle travels during night hours (6 PM to 6AM) Average no of axles per commercial
vehicle is as follow:
TABLE 3-5: AVERAGE NO OF AXLES PER COMMERCIAL VEHICLE
Section Average no of axles per commercial vehicle
I 2.27
II 2.27
III 2.27
IV 2.57
V 2.57
Adopted maximum temperature differentials for Gujarat state for a slab thickness of 250mm
is 14.3o c as per table 1 of IRC: 58-2015.
For a given slab thickness and other design parameter, the pavement shall be checked for
cumulative bottom up cracking (BUC) and top down cracking (TDC).
If CFD (BUC) +CFD (TDC) ≤1, the pavement is safe from large scale cracking.
Based on previous inputs for a cement concrete slab (3.5mx4.5m) different trial thickness
have been tested for calculating cumulative fatigue damages for bottom up cracking analysis
and top down cracking analysis and results are summarized for different section as follow:
TABLE 3-6: CUMULATIVE FATIGUE DAMAGE VALUE FOR DIFFERENT TRIAL THICKNESS
Section I
CFD for BUC Case CFD for BUC Case
Due to Due to Due to Sum of
Slab Due to Due to
Rear Rear Rear Total BUC and Remarks
Thickness,m Tendem Total CFD Tendem
Single Single Tridem CFD TDC CFD
Axle Axle
Axle Axle Axle
200 2.335 1.076 3.411 0.196 1.008 0.001 1.205 4.616 Unsafe
210 0.674 0.274 0.948 0.074 0.368 0.000 0.442 1.390 Unsafe
220 0.218 0.077 0.294 0.027 0.145 0.000 0.171 0.465 Safe
Section II
CFD for BUC Case CFD for BUC Case
Due to Due to Due to Sum of
Slab Due to Due to
Rear Rear Rear Total BUC and Remarks
Thickness,m Tendem Total CFD Tendem
Single Single Tridem CFD TDC CFD
Axle Axle
Axle Axle Axle
Revision Level: R0 October 2017 Page 34
Detailed Project Report for Two / Four laning with paved shoulder NH configuration
of "Dwarka - Khambhaliya - Devariya" & "Dhrol - Amran - Maliya" Road Sections in
Gujarat under Bharat Mala Project.
Final Detailed Project Report /Volume II (Part-1)/Chapter 3 – Pavement Design Highway Division
Document Ref: RITES/HW/RT300-00012/FDPR/Volume II (Part-1)/Chapter-3
200 5.143 2.370 7.513 0.431 2.221 0.002 2.654 10.167 Unsafe
210 1.484 0.605 2.089 0.163 0.810 0.000 0.973 3.062 Unsafe
220 0.479 0.169 0.648 0.059 0.318 0.000 0.377 1.025 Unsafe
230 0.158 0.043 0.201 0.019 0.129 0.000 0.148 0.349 Safe
Section III
CFD for BUC Case CFD for BUC Case
Due to Due to Due to Sum of
Slab Due to Due to
Rear Rear Rear Total BUC and Remarks
Thickness,m Tendem Total CFD Tendem
Single Single Tridem CFD TDC CFD
Axle Axle
Axle Axle Axle
200 6.874 3.168 10.042 0.576 2.968 0.003 3.547 13.589 Unsafe
210 1.983 0.808 2.791 0.218 1.083 0.000 1.301 4.092 Unsafe
220 0.640 0.225 0.865 0.079 0.426 0.000 0.505 1.370 Unsafe
230 0.211 0.057 0.268 0.025 0.172 0.000 0.197 0.465 Safe
Section IV
CFD for BUC Case CFD for BUC Case
Due to Due to Due to Sum of
Slab Due to Due to
Rear Rear Rear Total BUC and Remarks
Thickness,m Tendem Total CFD Tendem
Single Single Tridem CFD TDC CFD
Axle Axle
Axle Axle Axle
180 82.906 12.893 95.799 1.198 3.965 0.015 5.178 100.977 Unsafe
190 11.697 1.947 13.644 0.338 1.013 0.005 1.356 15.000 Unsafe
200 2.250 0.385 2.635 0.113 0.321 0.002 0.436 3.071 Unsafe
210 0.552 0.091 0.643 0.041 0.115 0.000 0.156 0.799 Safe
Section V
CFD for BUC Case CFD for BUC Case
Due to Due to Due to Sum of
Slab Due to Due to
Rear Rear Rear Total BUC and Remarks
Thickness,mm Tendem Total CFD Tendem
Single Single Tridem CFD TDC CFD
Axle Axle
Axle Axle Axle
200 11.040 1.887 12.927 0.554 1.576 0.008 2.138 15.065 Unsafe
210 2.706 0.448 3.154 0.199 0.562 0.002 0.763 3.917 Unsafe
220 0.780 0.119 0.899 0.073 0.212 0.000 0.285 1.184 Unsafe
230 0.244 0.034 0.278 0.027 0.081 0.000 0.108 0.386 Safe
Adopted pavement layers thickness for plain jointed cement concrete slab with tied concrete
shoulder with dowel bar across transverse joint (i.e. lane width of 3.5m and transverse joint
spacing 4.5m) are as follow:
As per IRC: 58-2015, the details of reinforcement at construction joint and longitudinal joints
for a slab thickness of 250mm are given below.
TABLE 3-8: REINFORCEMENT DETAILS
Detail of Dowel Bar
Diameter Length Spacing
32mm 450mm 300mm
Detail of Tie Bar (Deformed)
Diameter Length Spacing
12mm 640mm 720mm
The existing section of the project road has intermediate / two lane configuration. Four lane
with / without Service Road facility have been proposed to cater the future traffic and to
reduce the congestion.
The design traffic for a Service Road is 10msa as per IRC:SP:84-2014 and the same has been
consider to design composition of Pavement Layers in case of Service Road stretches.
The bases and sub-bases have been designed for the full design life of 15-years while the
surfacing course has been designed for a life of 10 years.
TABLE 3-11: CUMULATIVE NO. OF COMMERCIAL VEHICLE (SECTION II: LIMBDI TO KHAMBHALIYA)
Bus LCV Truck All Vehicle in Cumulative
No. of
Year
Mini Full 2Axle 3Axle Artic Nos PCU Commercial
Vehicle
2016 75 199 424 98 264 461 5,412 7,500
Growth Rate (%) 5.85% 5.85% 6.50% 6.50% 6.50% 6.50%
2017 79 211 452 104 281 491 5,859 8,065
2018 84 223 481 111 299 523 6,344 8,674
2019 89 236 512 118 318 557 6,869 9,329
2020 94 250 545 126 339 593 7,440 10,039 7,10,655
2021 99 265 580 134 361 632 8,059 10,805 7,55,915
Growth Rate (%) 6.30% 6.30% 7.00% 7.00% 7.00% 7.00%
2022 105 282 621 143 386 676 8,783 11,693 8,07,745
2023 112 300 664 153 413 723 9,574 12,657 8,63,225
2024 119 319 710 164 442 774 10,439 13,708 9,22,720
2025 126 339 760 175 473 828 11,383 14,845 9,85,865
2026 134 360 813 187 506 886 12,414 16,079 10,53,390
Growth Rate (%) 5.40% 5.40% 6.00% 6.00% 6.00% 6.00%
2027 141 379 862 198 536 939 13,380 17,228 11,15,075
2028 149 399 914 210 568 995 14,424 18,463 11,80,775
2029 157 421 969 223 602 1055 15,553 19,797 12,50,855
2030 165 444 1027 236 638 1118 16,771 21,225 13,24,220
2031 174 468 1089 250 676 1185 18,087 22,761 14,02,330
2032 183 493 1154 265 717 1256 19,508 24,412 14,84,820
2033 193 520 1223 281 760 1331 21,045 26,190 15,72,420
2034 203 548 1296 298 806 1411 22,705 28,102 16,65,130
2035 214 578 1374 316 854 1496 24,500 30,162 17,63,680
2036 226 609 1456 335 905 1586 26,440 32,376 18,67,705
2037 238 642 1543 355 959 1681 28,535 34,755 19,77,570
2038 251 677 1636 376 1017 1782 30,803 37,323 20,94,735
2039 265 714 1734 399 1078 1889 33,255 40,087 22,18,835
2040 279 753 1838 423 1143 2002 35,905 43,061 23,49,870
2041 294 794 1948 448 1212 2122 38,770 46,262 24,88,570
2042 310 837 2065 475 1285 2249 41,870 49,712 26,35,665
2043 327 882 2189 504 1362 2384 45,223 53,429 27,91,520
2044 345 930 2320 534 1444 2527 48,850 57,434 29,56,500
2045 364 980 2459 566 1531 2679 52,774 61,751 31,31,335
2046 384 1033 2607 600 1623 2840 57,021 66,406 33,16,755
2047 405 1089 2763 636 1720 3010 61,614 71,419 35,12,395
2048 427 1148 2929 674 1823 3191 66,586 76,828 37,20,080
2049 450 1210 3105 714 1932 3382 71,965 82,655 39,39,445
2050 474 1275 3291 757 2048 3585 77,789 88,944 41,71,950
Total 6,20,31,750
TABLE 3-12: CUMULATIVE NO. OF COMMERCIAL VEHICLE (SECTION III: KHAMBHALIYA TO DEVARIYA)
Cumulative
Bus LCV Truck All Vehicle in
No. of
Year
Commercial
Mini Full 2Axle 3Axle Artic Nos PCU
Vehicle
2016 180 344 146 227 395 757 15,684 16,531
Growth Rate (%) 5.85% 5.85% 6.50% 6.50% 6.50% 6.50%
2017 191 364 155 242 421 806 17,016 17,850
2018 202 385 165 258 448 858 18,462 19,274
2019 214 408 176 275 477 914 20,036 20,824
2020 227 432 187 293 508 973 21,745 22,497 9,56,300
2021 240 457 199 312 541 1036 23,601 24,308 10,16,525
Growth Rate (%) 6.30% 6.30% 7.00% 7.00% 7.00% 7.00%
2022 255 486 213 334 579 1109 25,776 26,427 10,86,240
2023 271 517 228 357 620 1187 28,155 28,736 11,60,700
2024 288 550 244 382 663 1270 30,756 31,250 12,39,905
2025 306 585 261 409 709 1359 33,601 33,992 13,24,585
2026 325 622 279 438 759 1454 36,715 36,984 14,15,105
Growth Rate (%) 5.40% 5.40% 6.00% 6.00% 6.00% 6.00%
2027 343 656 296 464 805 1541 39,636 39,782 14,98,325
2028 362 691 314 492 853 1633 42,792 42,794 15,85,925
2029 382 728 333 522 904 1731 46,204 46,045 16,79,000
2030 403 767 353 553 958 1835 49,890 49,548 17,77,185
2031 425 808 374 586 1015 1945 53,875 53,324 18,80,845
2032 448 852 396 621 1076 2062 58,184 57,402 19,91,075
2033 472 898 420 658 1141 2186 62,844 61,802 21,07,875
2034 497 946 445 697 1209 2317 67,880 66,541 22,30,515
2035 524 997 472 739 1282 2456 73,330 71,665 23,61,550
2036 552 1051 500 783 1359 2603 79,221 77,189 24,99,520
2037 582 1108 530 830 1441 2759 85,595 83,157 26,46,250
2038 613 1168 562 880 1527 2925 92,488 89,599 28,01,375
2039 646 1231 596 933 1619 3101 99,947 96,558 29,65,990
2040 681 1297 632 989 1716 3287 1,08,014 1,04,068 31,39,730
2041 718 1367 670 1048 1819 3484 1,16,742 1,12,178 33,23,690
2042 757 1441 710 1111 1928 3693 1,26,186 1,20,941 35,18,600
2043 798 1519 753 1178 2044 3915 1,36,407 1,30,413 37,25,555
2044 841 1601 798 1249 2167 4150 1,47,465 1,40,643 39,44,190
2045 886 1687 846 1324 2297 4399 1,59,431 1,51,694 41,75,235
2046 934 1778 897 1403 2435 4663 1,72,382 1,63,639 44,20,150
2047 984 1874 951 1487 2581 4943 1,86,400 1,76,550 46,79,300
2048 1037 1975 1008 1576 2736 5240 2,01,574 1,90,508 49,53,780
2049 1093 2082 1068 1671 2900 5554 2,18,000 2,05,598 52,44,320
2050 1152 2194 1132 1771 3074 5887 2,35,782 2,21,912 55,51,650
Total 8,29,00,990
TABLE 3-13: CUMULATIVE NO. OF COMMERCIAL VEHICLE (SECTION IV: DHROL TO BHADRA PATIYA )
Bus LCV Truck All Vehicle in Cumulative
No. of
Year
Mini Full 2Axle 3Axle Artic Nos PCU Commercial
Vehicle
2016 16 77 126 82 34 42 3,768 3,278
Growth Rate (%) 5.85% 5.85% 6.50% 6.50% 6.50% 6.50%
2017 17 82 134 87 36 45 4,087 3,547
2018 18 87 143 93 38 48 4,434 3,840
2019 19 92 152 99 40 51 4,809 4,152
2020 20 97 162 105 43 54 5,217 4,492 1,75,565
2021 21 103 173 112 46 58 5,662 4,867 1,87,245
Growth Rate (%) 6.30% 6.30% 7.00% 7.00% 7.00% 7.00%
2022 22 109 185 120 49 62 6,180 5,298 1,99,655
2023 23 116 198 128 52 66 6,746 5,767 2,12,795
2024 24 123 212 137 56 71 7,366 6,285 2,27,395
2025 26 131 227 147 60 76 8,045 6,852 2,43,455
2026 28 139 243 157 64 81 8,786 7,465 2,59,880
Growth Rate (%) 5.40% 5.40% 6.00% 6.00% 6.00% 6.00%
2027 30 147 258 166 68 86 9,482 8,045 2,75,575
2028 32 155 273 176 72 91 10,232 8,666 2,91,635
2029 34 163 289 187 76 96 11,041 9,335 3,08,425
2030 36 172 306 198 81 102 11,917 10,062 3,26,675
2031 38 181 324 210 86 108 12,863 10,845 3,45,655
2032 40 191 343 223 91 114 13,885 11,689 3,65,730
2033 42 201 364 236 96 121 14,988 12,600 3,86,900
2034 44 212 386 250 102 128 16,181 13,585 4,09,530
2035 46 223 409 265 108 136 17,470 14,650 4,33,255
2036 48 235 434 281 114 144 18,863 15,799 4,58,440
2037 51 248 460 298 121 153 20,370 17,046 4,85,815
2038 54 261 488 316 128 162 21,998 18,388 5,14,285
2039 57 275 517 335 136 172 23,759 19,843 5,44,580
2040 60 290 548 355 144 182 25,661 21,410 5,76,335
2041 63 306 581 376 153 193 27,719 23,109 6,10,280
2042 66 323 616 399 162 205 29,944 24,947 6,46,415
2043 70 340 653 423 172 217 32,349 26,929 6,84,375
2044 74 358 692 448 182 230 34,949 29,071 7,24,160
2045 78 377 734 475 193 244 37,761 31,391 7,66,865
2046 82 397 778 504 205 259 40,803 33,903 8,12,125
2047 86 418 825 534 217 275 44,091 36,615 8,59,575
2048 91 441 875 566 230 292 47,650 39,554 9,10,675
2049 96 465 928 600 244 310 51,499 42,734 9,64,695
2050 101 490 984 636 259 329 55,663 46,173 10,21,635
Total 1,52,29,625
TABLE 3-14: CUMULATIVE NO. OF COMMERCIAL VEHICLE (SECTION V: BHADRA PATIYA TO PIPALIYA)
Bus LCV Truck All Vehicle in Cumulative No.
Year of Commercial
Mini Full 2Axle 3Axle Artic Nos PCU
Vehicle
2016 14 49 159 107 323 1145 2,926 7,704
Growth Rate (%) 5.85% 5.85% 6.50% 6.50% 6.50% 6.50%
2017 15 52 169 114 344 1219 3,144 8,226
2018 16 55 180 121 366 1298 3,377 8,781
2019 17 58 192 129 390 1382 3,629 9,378
2020 18 61 204 137 415 1472 3,899 10,013 8,42,055
2021 19 65 217 146 442 1568 4,192 10,699 8,96,805
Growth Rate (%) 6.30% 6.30% 7.00% 7.00% 7.00% 7.00%
2022 20 69 232 156 473 1678 4,531 11,485 9,59,220
2023 21 73 248 167 506 1795 4,897 12,327 10,25,650
2024 22 78 265 179 541 1921 5,295 13,237 10,97,190
2025 23 83 284 192 579 2055 5,727 14,214 11,73,840
2026 24 88 304 205 620 2199 6,195 15,265 12,55,600
Growth Rate (%) 5.40% 5.40% 6.00% 6.00% 6.00% 6.00%
2027 25 93 322 217 657 2331 6,629 16,233 13,30,425
2028 26 98 341 230 696 2471 7,094 17,262 14,09,630
2029 27 103 361 244 738 2619 7,594 18,359 14,93,580
2030 28 109 383 259 782 2776 8,131 19,530 15,83,005
2031 30 115 406 275 829 2943 8,708 20,780 16,78,270
2032 32 121 430 292 879 3120 9,328 22,112 17,79,010
2033 34 128 456 310 932 3307 9,994 23,531 18,85,955
2034 36 135 483 329 988 3505 10,706 25,038 19,98,740
2035 38 142 512 349 1047 3715 11,471 26,643 21,18,095
2036 40 150 543 370 1110 3938 12,293 28,358 22,45,115
2037 42 158 576 392 1177 4174 13,176 30,183 23,79,435
2038 44 167 611 416 1248 4424 14,125 32,131 25,22,150
2039 46 176 648 441 1323 4689 15,143 34,204 26,72,895
2040 48 186 687 467 1402 4970 16,237 36,413 28,32,400
2041 51 196 728 495 1486 5268 17,413 38,771 30,01,760
2042 54 207 772 525 1575 5584 18,679 41,290 31,81,705
2043 57 218 818 557 1670 5919 20,039 43,976 33,72,235
2044 60 230 867 590 1770 6274 21,500 46,837 35,73,715
2045 63 242 919 625 1876 6650 23,070 49,887 37,86,875
2046 66 255 974 663 1989 7049 24760 53,148 40,13,540
2047 70 269 1032 703 2108 7472 26579 56,628 42,53,710
2048 74 284 1094 745 2234 7920 28535 60,340 45,08,115
2049 78 299 1160 790 2368 8395 30640 64,303 47,77,850
2050 82 315 1230 837 2510 8899 32905 68,535 50,63,645
Total 7,47,12,215