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Ceylon Electricity Board Vestas Asia Pacific A/S Access Engineering PLC
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Pavement Design for Internal Roads of MWPP-ACCSS-
Date & Version: 12/05/2020, Rev.A
Accommodation Buildings’ Premises CIV-RPT-0025
Author: Access Engineering PLC
Version History
This version,
Main Document A4
Classification: Restricted
MANNAR WIND POWER PROJECT – PAVEMENT DESIGN FOR INTERNAL ROADS OF ACCOMMODATION
BUILDINGS’ PREMISES
TABLE OF CONTENTS
ENGINEERING PLC
MANNAR WIND POWER PROJECT – PAVEMENT DESIGN FOR INTERNAL ROADS OF ACCOMMODATION
BUILDINGS’ PREMISES
1.1 Introduction
Design and construction of Mannar Wind Power Project has been awarded to the
Vestas Wind System A/S and Access Engineering is the civil work design and built
subcontractor. Under the project, there are three main roads to be design and re-
construct and a main access road and ancillary roads to be newly design and
construct.
Field Work
ENGINEERING PLC 1
MANNAR WIND POWER PROJECT – PAVEMENT DESIGN FOR INTERNAL ROADS OF ACCOMMODATION
BUILDINGS’ PREMISES
Procedure
i. The sub grade CBR values for the DCP test locations are calculated based on the
method of weighted average using the formula1 given below. Soil within 1000 mm
depth was assumed in calculating the average CBR value.
Layer height of minimum 200mm is selected for average CBR selection.
The layer thickness less than 200mm added to the next layer and uses less CBR value
out of two layers.
3
h1CBR11 / 3 h2 CBR21 / 3 ......... hn CBRn1 / 3
CBRm
h1 h 2 ........ h n
Where,
CBRm = average CBR value of the location in question
CBR1,CBR2,…CBRn = CBR values of soil layers No. 1,2,…n
h1,h2,….hn = thickness of soil layers No. 1,2,…n
Note 1: In the case of vertical stratification of a subgrade with a thickness of one strata being under
20cm, a layer with its thickness being under 20cm should be included in the upper or lower
layer to calculate the average CBR value.
Note 2: The average CBR value is normally adopted for a subgrade of which the upper part has a
higher CBR value. It is not desirable to use the average CBR value in the presence of a weak
layer in the upper part of the subgrade, since the pavement structure can be directly affected
by the layer. In this case, the CBR value of the weak layer should be used, or the layer should
be stabilized or replaced with suitable materials.
ii. The values of DCP-CBR obtained by the above step (i), is given in Annex 02.
iii. Then the design CBR value is obtained by getting the 10 percentile value of corrected
CBR values as per section 3.2 of the TRL Overseas Road Note 31 – 1993, as
presented in figure 2.
1
Source “Manual for Asphalt Pavement” – 1989, Japan Road Association.
ENGINEERING PLC 2
MANNAR WIND POWER PROJECT – PAVEMENT DESIGN FOR INTERNAL ROADS OF ACCOMMODATION
BUILDINGS’ PREMISES
Following table shows the DCP CBR values obtained for the tests carried out. For detailed
calculation of DCP CBR values refer Annex 02.
Table 2.1: Test Pit CBR for the DCP Locations
DCP No DCP CBR %
P1 8
P2 8
P3 7
P4 10
P5 10
P6 5
P7 8
It was decided to design the pavement based on lowest 10% of DCP CBR values.
100
90
80
70
Cumulative CBR %
60
50
40
30
20
10
0
4 5 6 7 8 9 10 11
CBR Values
Sub grade CBR value was taken as 5 for the design of pavement layer thicknesses.
ENGINEERING PLC 3
MANNAR WIND POWER PROJECT – PAVEMENT DESIGN FOR INTERNAL ROADS OF ACCOMMODATION
BUILDINGS’ PREMISES
Table 2.2 shows the sub grade strength class and traffic class used for design of
pavement layer thicknesses of the proposed approach roads based on Overseas Road
Note 31,TRL , 1993 (Key To Structural Catalogue) attached in Annex 04.
Table 2.2: Subgrade Strength Class and the Traffic Class for Main Access Road
SUBGRADE TRAFFIC
STRENGTH CLASS CLASS
S3 T3
Pavement layer thicknesses were obtained from CHART 3: Granular Road Base / Semi
Structural Surface of “Overseas Road Note 31, TRL , 1993” attached in Annex 04.
Lowest Sub grade Strength Class of S3 and Traffic Class of T3 are taken to calculate the
theoretical layer thicknesses.
ENGINEERING PLC 4
MANNAR WIND POWER PROJECT – PAVEMENT DESIGN FOR INTERNAL ROADS OF ACCOMMODATION
BUILDINGS’ PREMISES
Proposed layer thicknesses vary with the theoretical layer thicknesses due to practical
reasons. Therefore, proposed layer thicknesses are calculated based on the structural
number. Table 3.1 shows the structural coefficients with the type of material.
Table 3.1: Table of Structural Layer Coefficients
No. Type of Material Structural
Coefficient
1 Single surface dressing 0.10
2 Sand seal, hot bitumen application 0.05 -0.10(*)
3 Double surface dressing 0.20
4 Asphalt concrete (high stability) 0.40
5 Hot rolled asphalt (surfacing) 0.35 – 0.40
6 Flexible bituminous surfacing 0.30
7 Bitumen macadam road base 0.30
8 Bitumen bound base, Asphalt treated base 0.30
9 Penetration macadam 0.20(*)
10 Dense graded crushed stone base (CBR 110) 0.14
11 Water bound and dry bound macadam 0.14
12 Single sized aggregate base 0.125(*)
13 Granular base, Dense graded crushed stone base (CBR 80) 0.12
14 Cement or Lime stabilized base (3.0-6.0 MPa) 0.18 – 0.27
15 Cement or Lime stabilized base (1.5-3.0 MPa) 0.13 – 0.18
16 Cement or Lime stabilized base (CBR 80) 0.12(*)
17 Cement or Lime stabilized base (0.75-1.5 MPa) 0.11
18 Granular sub-base (CBR 30) 0.11
19 Granular sub-base (CBR 20) 0.095
20 Capping layer (CBR 15) 0.09
21 Granular sub-base/ Capping layer (CBR 8) 0.07
ENGINEERING PLC 5
MANNAR WIND POWER PROJECT – PAVEMENT DESIGN FOR INTERNAL ROADS OF ACCOMMODATION
BUILDINGS’ PREMISES
Table 3.2: Structural Number of theoretical layers
Theoretical
Structural Structural Number
Layer Type Layer Thickness
Coefficient for layers
(mm)
Flexible Bituminous Surface 0.3 50 15
DGAB 0.12 175 21
Granular Sub‐base (CBR‐30+) 0.11 225 24.75
Total Structural Number 60.75
Hence, Layer thickness appropriate for proposed sub base are as follows.
Table 3.3: Structural Number of proposed layers
Structural Proposed Layer Structural Number
Layer Type
Coefficient Thickness (mm) for layers
50 mm Asphalt concrete
50 mm
surfacing (wearing course)
100 mm Granular base (ABC)
275 mm Granular Subbase (CBR 30+)
Height
Granular Subbase (CBR 8+)
Varies
Capping Layer (correction layer)
ENGINEERING PLC 6
MANNAR WIND POWER PROJECT – PAVEMENT DESIGN FOR INTERNAL ROADS OF ACCOMMODATION
BUILDINGS’ PREMISES
Removal of unsuitable top soil with vegetation shall be carried out (probably 200mm)
and disposed from the site. Any local spots having unsuitable material in the
formation level of the subgrade ground shall be excavated and replaced with suitable
well compacted material.
The suitable excavation depth for subgrade shall be decided at the site (probably
300mm) and below this level subgrade shall be compacted to improve the properties
of the soil. Any excavated good material that is not contaminated shall be piled-up to
be re-used. Levels and cross fall of the subgrade has to be maintained to
accommodate the Soil Sub-base as given in pavement design above.
The sub grade layer shall be compacted to not less than 95% of the maximum dry
density determined by BS 1377: Test 13(Modified Proctor) by approved number of
passes of an 8 to 10 Ton steel wheeled roller or by any other approved roller after
ensuring that the surface is watered.
At the time of construction, the engineer after inspection shall decide the exact extent
to be improved.
Construct the sub base to a compacted thickness as given in the Figure 3 above with
materials having a 4 day soaked CBR not less than 20%, LL not greater than 40%, PI
not greater than 15% compacted to not less than 98% of the MDD at OMC as
determined by BS 1377: Test B (Modified Proctor) or AASHTO T-180. Construction
shall be carried out as per section 401 of the SSCM.
The sub-base should be compacted with 4-6 passes of an 8-10 tonne steel wheeled
roller or by an approved number of passes of any other roller after ensuring that the
surface is watered. The degree of compaction shall be checked by field density
measurements (BS 1377 test 15).
ENGINEERING PLC 7
MANNAR WIND POWER PROJECT – PAVEMENT DESIGN FOR INTERNAL ROADS OF ACCOMMODATION
BUILDINGS’ PREMISES
Construct the DGAB layer as specified in section 405 of the SSCM. The requirements
for DGAB material as specified in the SSCM are as follows.
(i) Aggregate Impact Value (AIV) should not be greater than 30%
(ii) Flakiness Index (FI) should not be greater than 35%
(iii) The grading of aggregate for DGAB should conform to the specification given
below in Table 4.1.
Table 4.1:‐Grading of Dense Graded Aggregate Base Course
The compacted DGAB should be primed with CSS-1 at the rate of 1 litre per Sq.m.
Prior to the construction of the surfacing, the surface should be cleaned and a tack
coat using emulsion at a rate of 0.3 lit./sq.m. Should be applied if found necessary as
per section 501 of the SSCM. The Asphalt Concrete layer should be constructed to a
thickness of 50, using 60 - 70 penetration grade bitumen.
The specification requirements for the binder and wearing course material are given in
Table 4.2 below.
ENGINEERING PLC 8
MANNAR WIND POWER PROJECT – PAVEMENT DESIGN FOR INTERNAL ROADS OF ACCOMMODATION
BUILDINGS’ PREMISES
Table 4.2:‐ Specification requirement for the Binder and Wearing Course
Sieve size Percentage passing sieve size
mm m
Binder Course Wearing Course /Type-3
28 100 100
20 90 – 100 93 – 100
14 - -
10 56 - 82 59 – 94
5 36 – 58 38– 69
2.36 21 – 38 25 – 48
1.18 15 – 32 20 - 40
600 10 – 26 15 - 32
300 6 – 20 10 – 23
150 3 – 13 4 - 15
75 1–7 3 - 12
Los Angeles Abrasion Value (LAAV) of aggregate should not be more than 40%
Aggregate Impact Value (AIV) of aggregate should not be more than 30%
The density of compacted asphaltic concrete layer shall not be less than 97% of the
Marshall density obtained on specimens compacted using 75 blows on either side. The
other construction requirements are given in section 506 of the SSCM.
ENGINEERING PLC 9
ANNEX 01
DCP Test Pit Location Map
ANNEX 02
Corected
Start End Thickness Corrected Calculated DESIGN
Test No Layer CBR % Subgrade
(mm) (mm) / [mm] Thickness CBR CBR
CBR
Layer 1 240 335 95 7.8
284 8
Layer 2 335 524 189 22.2
Layer 3 524 710 186 18.1
386 11
P1 Layer 4 710 910 200 11.4 12 8
Layer 5 910 925 15 35.9
482 13
Layer 6 925 1392 467 13.1
Layer 7 1392 1712 320 17 320 17
Layer 1 210 391 181 8.2
391 8
Layer 2 391 601 210 16
Layer 3 601 711 110 9.1
245 9
P2 Layer 4 711 846 135 11.2 12 8
Layer 5 846 1059 213 14.4 213 14
Layer 6 1059 1579 520 15.3 520 15
Layer 7 1579 1674 95 25 95 25
Layer 1 180 355 175 7
405 7
Layer 2 355 585 230 9.8
Layer 3 585 745 160 9.4
P3 405 8 7 7
Layer 4 745 990 245 8.1
Layer 5 990 1210 220 6.7 220 7
Layer 7 1210 1695 485 7.7 485 8
Layer 1 220 345 125 10.1
445 10
Layer 2 345 665 320 18.7
Layer 3 665 875 210 19.9 210 20
Layer 4 875 1145 270 24.4 270 24
P4 16 10
Layer 5 1145 1350 205 24.4 205 24
Layer 6 1350 1545 195 27.2
305 14
Layer 7 1545 1655 110 14
Layer 8 1655 1725 70 18.6 70 19
Layer 1 170 409 239 15 239 15
Layer 2 409 600 191 12
371 8
Layer 3 600 780 180 8.3
P5 10 10
Layer 4 780 940 160 7.7
350 8
Layer 5 940 1130 190 12
Layer 6 1130 1705 575 11.4 575 11
Layer 1 220 380 160 4.5
390 5
Layer 2 380 610 230 7.5
Layer 3 610 705 95 7.8
458 11
Layer 4 705 1068 363 11.1
P6 9 5
Layer 5 1068 1162 94 13.6
Layer 6 1162 1243 81 12.6 495 14
Layer 7 1243 1563 320 6.9
Layer 8 1563 1708 145 8.6 145 9
Layer 1 190 283 93 8
288 8
Layer 2 283 478 195 20.1
Layer 3 478 573 95 16.3
860 16
P7 Layer 4 573 1338 765 16.9 13 8
Layer 5 1338 1433 95 10.6
254 11
Layer 6 1433 1592 159 14.5
Layer 7 1592 1658 66 11.5 66 12
Pavement Design for Internal Roads of Accomodation buildings premises'
Calculation of Design CBR from DCP values for RHS
NO OF TEST CUMILATIVE
CBR % OF CBR
PIT POINT CBR %
5 1 14 14
7 1 14 29
8 3 43 71
10 2 29 100
7 100
100
90
80
70
Cumulative CBR %
60
50
40
30
20
10
0
4 5 6 7 8 9 10 11
CBR Values
Hence lowest 10% CBR can be considered as 5
ANNEX 03
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300
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500 ^
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1 500
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1 /00
1 800
1 900
2000
Remarks:-
Signature Y,J -
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No. I Point 0l urface Material stib
of Test 04.03.2020 re Roncl Zero Reading (mm) 195
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No. AC/MWPP/DCP,'ACM/t -l 03 Surfacc Nlaterial Dcs sub
of Test 04.03.2020 Structure DCP Zero Reading (mm) 160
No Dcpth from EGL 180
1 400
-/M^
1 500
1 600
" e1l^4r":'
1 700
1 800
1 900
2000
Remarks:-
tlhcckccl by(Access)
Signature \/J'
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I 14 565 585 I I
1 15 595 61s I
I 16 6)i 64511 I
1 17 650 670 I I I
1 18 615 695 I
I l9 700 720 I
1 20 125 '7
45 I
I 21 765 785 I
I 22 800 82ol I I
1 )3 830 8sol I I
l 24 855 87.5 I
eool
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I 25 880 I I
1 26 9t0 eioII I
I 27 940 e6ol I
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1 29 1 004 1074 I I
I 30 I 040 1060 I I
I il I 075 loes I I I I
32 1l 15 1135 I I I I
I I 154 t1t4 I I I I
I 34 l 190 l2r0 I I
1 35 l 230 1 250 I I
I 36 I 26-5 r 285 I I
Remarks:-
Signature v-1-
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CCO METER TE
Test No. A('M/04 Location/C Point 0,1 Surface N{aterial sub
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D METER TEST
Test No. AC/MWPPiDCUACM/05 Locatio n/C ha in age Point 05 Surface Material Dcsccription sub gracle
Date of 'l'est 04.03.2020 Structure Road DCP Zero Reading (mm) 150
Point No 0.0 Depth from EGL 110
CBR Refatiorship Log u (CBR) = 2.18 ..1.057 Log 11, (nun/ blo|)
Remarks:-
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D METER TEST
Test No. AC/M WPPiDCP/A(' N,I/05 05 Surlhce Material sub
Date of Test 04.03.2020 Structure Road DCP Zero Rcading (mm) 150
I 2 1lJ9 2(rq I
l l9 I 030 ro5o I I
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1 40 1 052 to72 I I
1 ,1 ti 95 915 I I
I 34 92.0 910 I I
I 35 949 969 I I
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Rcmarks:-
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Test No, AC]/MWPP/D(' P,/A (' MiO6 Poinl l-)6 Material sub
Date of Test 04 0.1.2020 Structure Road Zero (--) 160
500
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1 800
1 300
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Remarks:-
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I 28 9EI.i ro48 I I I
I 29 1008 to68 I I I I
I 30 I02u ro8r{ I I I
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Cumulative No of Blows
0 10 20 30 40 50 60 70 80 90
0
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100
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400 ."qr/U/WWkm
500 w4,m,*
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,
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1 400
v/t
1 500
1 600
F{
1700
1 800
'1
900
2000
Remarks:-
Signature
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Name ,';'t." ry'2'* ,Q rT,tuut*-n
Desipnation oF
Date A/1.^1- P?O .th,,.t 1.'2*t Ls
SEMI DISPATCHABLE
WIND FARM IN MANNAR ISLAND
Client : Ceylon Electricity Board Main Contractor : Vestas Sub Contractor : Access
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TER TEST
Test No. ACMWPP,DCPIACMIOT 07 Surfacc Material sub
Date of 'I'est 04.03.2020 Structurc DCP Zero Reading (mm) t72
Offset 0.0 from EGL 190
'l-otal
No Total Reading DepthI I No Reading Depthl. I No fotal I{eading Depth
Blows Blrws mm mm I I nlo*. Blows mm mm I I sto*. BIows mm mm
0 0 112 leo I I r 37 150 168 I I I l4 I itO I ) )a
I I 2t5 233 I I r l8 165 183I I r 15 I 340 I 158
1 2 245 26il I r 39 780 7e8l I I 76 I 375 I 39i
1 J 265 2831 I r 40 790 8o8l I I 71 I 395 1.111
1 19 165 r8i I
1 56 1 030 ro48 I I
1 20 il89 iu7 I
I 57 I 045 106.1
I
I
2t
22
5(X)
520
sur
538
I I r 58
59
I
l
060
080
ro78
1oe8 I
I I
Remarks:-
Signature ba -/-
Name ,', a vQ*---^ -4. <1 <vr^M
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Desisnation zr C
Date r1j. -;2 . nn n ,.L ,1'? .. ?..i1 h
ANNEX 04
52
CHART 3 GRANULAR ROADBASE / SEMI-STRUCTURAL SURFACE
55