1.

Introduction
The Public Works Department, Government of Maharashtra has undertaken the
Project, Upgradation of Chandrapur-Ballarpur-Kothari-Gondpipari-Ashti Road
(PkgNo-PWD/2) to two lane with paved shoulder/Four lane configuration of NH-353B
from Ch 242+150 to 284+400. The proposed project stretch passes through
Chandrapur District and part of length in Gadchiroli District. The existing stretch
includes State Highways SH-267 and MSH 9.

The scope of work covered under this project includes Upgradation of the existing
road to two laned with paved shoulder. /Four lane configuration as per the details
mentioned in the Schedule B of the concessionaire Agreement. It includes Survey,
Investigation, Highway alignment Design, Pavement Design, Design of Structures,
Drainage Design, Design of Project Facilities. This report details the design of the
Rigid pavement and flexible pavement overlay in the project stretch.

2. Scope of Project
The project highway consists of existing intermediate/ two lane width with a flexible
pavement. The proposed width of the road to be constructed (with paved shoulders)
is 10.00 m concrete carriageway. The type of pavement proposed for the project is
Jointed Plain Cement Concrete Pavement (JPCP) with transverse and longitudinal
joints along with the dowel and tie bars as per the design requirement.
The total length of the project is 42.250 km. Out of this length, 15.310 km falls under
forest area which is proposed to be overlaid with bituminous layer without any
widening etc. For majority length of the project where the existing pavement is
available, it is proposed to dismantle the existing bituminous layers and construct the
rigid pavement from granular layers and above. For the widening portions, it is
proposed to provide the 500 mm compacted subgrade and the other layers (GSB,
DLC and PQC) which shall be provided as per the design requirement.

Table No. 3.2 Details of Existing Structures

Chandrapur-Ballarpur-Kothari-Gondpipari-Ashti section
Project Road Name
(Pkg No-PWD/2) in the state of Maharashtra
Total Road Length 42.500 km
Terrain Plain Terrain/Rolling
Existing Right of Way 24 m
Existing Road
Intermediate Lane with Earthen Shoulder
Configuration

Existing Pavement Type Flexible

Existing Service Road

Nil
length

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 S. No Type of structure No's
1 Major Bridges: 1
2 Railway Over Bridges 0
3 Grade Separators 0
4 Minor Bridges: 10
Vehicular and Non-Vehicular
5 0
Underpasses
6 HP Syphon 0
7 Pipe culvert: 48
8 Slab culvert: 2

Table No. 3.2 Existing Project Facilities

Truck Lay byes 0

Bus Bays 14
Toll Plaza 1

3. Review of Project Schedules

For the better understanding and the arriving best possible designs within the gamut
of the provisions in Concession Agreement is essential to have thorough study of the
schedules and specifications. The key elements used in preparation of project scope
documents will be studied at length by design team. Various documents and the
possible issues that would be resulting will be studied in detail during the project
planning and development of design stage.

These findings will be utilized while formulating the design philosophy of the
project. Salient Features of Proposals: (As mentioned in Schedule B and C)
Table No. 4.1 Existing Project Facilities
ROADS
Widening from intermediate lane to 2 lane 15.310 km
Nos. of Bypass Proposed Nil
Bypass Nil
Nos. of Realignment Nil

Realignment Nil
42.250km ( From Ch 242+150 to Ch
Total Length
284+400)
Service Road 0 Km
Major Junctions 03 Nos.
Minor Junctions 12 Nos.

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 Facilities
Toll plaza 1Nos
Bus Bays 14 Nos
Truck Lay-Byes Nil
Road Furniture As per Schedule C, Cl:3.(b)
Pedestrian Facilities As per Schedule C, Cl:3.(c)
Landscaping As per Schedule C, Cl:3.(d)
Highway Lighting As per Schedule C, Cl:3.(h)

STRUCTURES
Structures Retained Reconstruction New Total

Major Bridges - 1 - 1

Minor Bridges 5 6 11

Slab Culverts 0 0 0

Box Culverts - 11 11

Pipe Culverts 18 20 38

4. Overview of Proposed Design Standard

The project road passes through plain/rolling having villages/settlements with
restricted ROW and ribbon development at settlement areas along the road.
Considering the physical condition and cost effectiveness, the improvement proposals
are conceived and developed under following standards:

i. The desirable standards which could be adopted as a rule

ii. The minimum standards, which could be accepted for difficult stretches where
application of the desirable standards, would lead to exorbitant costs.

Accordingly, design standards for geometric elements have been proposed under
"desirable" and "minimum" categories. These proposed standards are consistent with
and fall within the parameters recommended in the related standards of the Indian
Roads congress.

Highway design is a 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 principal geometric features for fulfilment of these

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objectives are road classification, the horizontal alignment, vertical alignment and the
road cross-section.

As per IRC: SP:73-2015 “Manual of Specifications & Standards for Two laning of
Highways through public private partnership” clause 1.5 to 1.10, the Codes, Standards
and Technical Specifications applicable for the design and construction of project
components are:

 Indian Roads Congress (IRC) Codes and Standards shall invariably be followed.
 Specifications for Road and Bridge Works issued by the Ministry of Road
Transport &
 Highways (MORTH) hereinafter referred to as MORTH or Ministry’s
Specifications.
 Any other standards referred to in the manual and any supplement issued with the
bid document.
 Latest version of the codes, standards, specifications etc., notified/published at
least 60 days before the last date of Bid submission shall be considered
applicable.
 Section– 2: Geometric Design and General Features is to be followed to the
maximum extent.
 For aspects not covered by IRC and BIS, international standard practices, such
as, British and American Standards may be adopted.
For the design & construction of 2 Lane Highway sections the design team have
referred to the latest IRC publications and MORT&H circulars regarding design
standards for National Highways in India as well as the international American and
Canadian geometric design guidelines. The relevant Indian and international design
standards consulted include:
In this report, the engineering design is divided into two parts as under for explaining
the proposed design basis, standards and specifications.
 Road design
 Pavement Design

5. Road Designs
5.2 Design Controls
5.2.1 Terrain Classification
The project corridor of NH-353B from Bamni-Navegaon passes mainly through plain
and rolling terrain having cultivated, forested, barren lands and a few urban
settlements and industrial.

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 5.2.2 Design Speed
Ruling design speed will be the guiding criterion for correlating the various design
features as far as possible. However, minimum design speed will be adopted in
sections where site conditions, such as Right of Way / Relocation and Rehabilitation /
Social costs make it not feasible.
The design speed shall be 100kmph (desirable) and 80kmph (minimum) in plain and
rolling terrain and design speed shall be 60 kmph (desirable) and 40kmph (minimum)
in mountainous and hilly terrain.

As specified in the Schedule B, clause 2.2 of Concessionaire Agreement (CA) the

minimum design speed shall be the minimum design speed of 80 kmph ( in accordance
with section 2 of the manual) for plain terrain. For following stretches modified
provisions are mentioned in Annex-I of Schedule-D to provide the overlay over existing
road without any geometrical improvements in this section.
Table 2.1 Minimum Design Speed Stretches

Sr. No Location (Km) Remarks

Ch 244+220 to 245+900,
Ch 256+270 to 263+190,
1
Ch 263+830 to 268+890,
Ch 275+390 to 277+040
Overlay on existing
pavement shall be done as
per TCS-V given in
Schedule B and without any
geometric improvement in
these sections

5.2.3 Width of Carriage Way

The width of paved carriageway shall be as per CA Annex I (Schedule B) Cl- 1.2.1. for
open country, CL-1.2.2 for built up area and Cl-1.2.3 for four lane in built up area.
5.2.4 Width of Median
The width of Median shall be provided as per the width given in TCS of Schedule B
of Concessionaire Agreement (CA) for four lane urban section.

6. Horizontal Alignment
General principles followed for designing the horizontal alignment are:
i) Alignment shall be fluent and blend well with the surrounding topography.
ii) All horizontal curves requiring super elevation shall consist of circular portion
flanked by spiral transitions at both ends.
iii) Reverse curves may be needed in difficult terrain. Sufficient length between two
curves shall be provided for introduction of requisite transition curves, and
required super elevation.
iv) The curves in the same direction separated by short tangents known as broken
back curves shall be avoided.
v) Radius of Horizontal Curves:

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 The radius of horizontal curves shall not be less than ruling minimum values
as given in IRC 73: 2015 for the specified design speed. Wherever possible
higher radii shall be adopted.
vi) Transition Curves:
Length of transition curves shall be as per IRC 73: 2015 for the specified
design speed.
vii) The horizontal alignment of Service Roads near grade separator openings
should be designed in such a way that the minimum required Sight Distance is
achieved.
6.1 Cross Slope
Camber
Camber/Unidirectional cross fall shall be provided for each carriageway including
paved shoulders in accordance with IRC 73: 2015. The cross-fall for earthen shoulder
shall be minimum 0.5% steeper than that of the carriageway. The camber details as
per TCS drawings given under Scheduled B of Concession Agreement are shown in
the below Table-
Table 7.1 Camber Details

S.No Type of Shoulder Camber

Carriageway including 2% for Rigid Pavement &
1
paved shoulder 2.5% for Flexible Pavement
2 Earthen shoulder 3.50%

Superelevation

Super Elevation shall be provided on curves in accordance with IRC 73: 2015. It should
be noted that the super elevation should be given up to a certain radius as presented
in Table 15 of IRC 73: 2015. On super elevated sections, the earthen portion of the
shoulder on the outer side of the curve would be provided with reverse cross fall of
0.5%.
Table 7.2 Radius beyond which super elevation not required

Camber
Radius (m) Speed (km/hr)
(%)
2.5 1800 100
2.5 1200 80

6.2 Sight Distance

The design shall be provided for values of stopping sight distance in accordance with
IRC 73: 1980 corresponding to design speed adopted unless there are site constraints,
where a minimum safe stopping sight distance shall be applied. Stopping Sight
Distance is the clear distance ahead needed by a driver to bring his vehicle to a stop

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before meeting a stationary object in his path. These are based on the perception and
brake reaction time and distance as shown in the below.
Table 2.4 Stopping Sight Distance as per Design Speed

Perception and Safe Stopping Sight

Speed Braking
brake reaction Distance (m)
Rounde
Distance(m Coefficient Distance(m Calculate d off
V(km/hr Time, ) of ) d Values Values
) t(sec) Longitudina
for
l friction (f)
d1 = 0.278Vt d2=V2/254f d1+d2 Design
100 2.5 70 0.35 112 182 180
40 2.5 28 0.35 18 45 45

For Valley curves, the design is governed by night visibility which is considered in
terms of Headlight Sight Distance. It is the distance ahead of the vehicle illuminated
by the head light which is within the view of the driver. The headlight sight distance
shall be at least equal to the safe stopping sight distance.
6.3 Vertical Alignment
General principles followed for designing the vertical alignment are:
i) The vertical alignment shall be designed as per IRC SP 23: 1993.
ii) Gradients up to the value corresponding to ruling gradient shall be provided in
accordance with IRC 73: 1980 as specified in CA.
iii) Grade changes shall not be too frequent as to cause kinks and visual
discontinuities in the profile. Desirably, there should be no change in grade
within a distance of 150m in case of new carriageway and bypass.
iv) The aspect of efficient drainage shall be taken into consideration while
designing vertical profile and cross sections of the highway in accordance with
IRC SP 42: 1994 and IRC SP 50: 1999.
v) The minimum gradient of 0.3% shall be provided in sections with kerbed edges
like urban sections/structures applicable for bypass/realignment sections.
vi) There shall be coordination between horizontal alignment and vertical profile of
the project highway and guidelines in accordance with IRC 73: 1980.
vii) The Vertical clearance should be provided from the proposed top level of main
carriageway.
viii)The level of minor bridge/box culvert shall be worked out with respect to High
Flood level and the proposed soffit level shall be cross verified with existing
soffit level.
ix) If the cushion over the pipe culvert at any point across the road is arrived to be
less than 0.6m, the particular section of the pipe culvert shall be encased with
concrete.

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 x) The vertical alignment of the widening carriageway, bypass and realignment
locations shall be designed as per IRC SP 73: 2015.
xi) Minimum k-value adopted for summit curves are 135 & 73.6 for new
carriageway and existing pavement respectively. Minimum k-value adopted for
valley curves is 41.5 for both new and existing carriageway.
xii) At proposed structure locations of minor bridges the vertical alignment is
designed for the SSD to maintain the approach length minimum to avoid the
following of toe outside of EROW.
6.4 Intersections
The intersection designs will be done as per the guidelines given in Ministry of Surface
Transport (MoRT&H) Type Designs for Intersections on National Highways, 1992 and
on the basis of IRC SP 41: 1994, ‘Guidelines for the Design of At-grade Intersections
in Rural and Urban Areas’. The lateral and vertical clearances for underpasses will be
set according to IRC 54: 1974. Summing up, the intersections will be designed based
upon the following parameters.
 Number of approach roads and their category
 Width of approach roads
 Angle of approach with main highway
 Surface type
 Site conditions / constraints
 Local importance and demand
IRC 92: 1985, which gives guidelines for the design of interchanges, IRC 62: 1976,
Guidelines for Control of Access on Highways shall be followed for the design.
6.5 Surface Drainage
An effective drainage system shall be planned for the drainage of roadway including
medians, toll plazas, wayside amenities such as rest areas, truck parking areas and
bus stops. The following types of drains will be provided for surface drainage of
roadway within ROW.
 Longitudinal lined/ unlined drains near the toe with outlets at cross-drainage
structures in rural sections.
 The drain size and shape will be adequately designed to take design run off, and
prevent soil erosion;
 Longitudinal covered drains beneath the footpath beside service road or slip road,
whichever is applicable;
 Median drains in super elevated sections following in urban area location and
 Combination of longitudinal drains and chute drains in high embankment stretches
of height 3m and above.
6.6 Bus Bays
The lay out for bus bays will be in accordance with Manual of Specifications and
Standards on Two-Laning of Highways through Public Private Partnership by the

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Indian Roads Congress and IRC 80: 1981. Minor modifications will be made in the
layout plan to take care of ROW constraints, if any.
6.7 Truck Lay Byes
The truck lay-byes shall be designed as per the guidelines of MoRT&H. Minor
modifications will be made to suit site requirements. The minimum length of truck lay
bye will be fixed at 100m.
6.8 Toll Plaza
The Manual of Specifications and Standards on Two-Laning of Highways through
Public Private Partnership by the Indian Roads Congress shall be followed for the
planning and design of toll plazas. An open system of toll collection shall be followed
on the Project Corridor. The number of service lanes shall be as per the above
guidelines. There shall be a separate lane for traffic not required to pay fees. A
minimum gradient shall be followed at the approaches and toll plaza area for drainage
requirement. The vertical clearance shall be kept at 5.5m in normal lanes.
7.9 Way side Amenities
All building works, water storage systems, sanitary sewer and sewage disposal
system, electrical systems shall be as per relevant sections and clauses of NBC. All
steel works shall conform to Section 6, Part VI of the NBC and Section 1900 of
MoRT&H specifications.

7. Road Embankment
Reconstruction and up-gradation of the existing road embankment/cuttings
and construction of new road embankment. cuttings shall conform to the
Specifications and Standards given in section 4 of the Manual and the specified cross-
sectional details. Deficiencies in the plan and profile of the existing road shall be
corrected.
Table No. 8.1 Raising of the Existing Road

Design Chainages Design

Sr. Length Remark
No. From To (km)

1 242+150 242+310 1
2 242+860 243+090 6
2
3 244+000 244+220 0
3
2
4 246+610 247+200 0
2
5
5 247+800 247+990 0
9
1
6 253+180 253+250 07
9
7 253+590 254+510 0
90
8 255+510 255+570 26
9 278+750 278+890 0
10
4
0

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Note: The chainages given in above table are indicative and stretches may increase
or decrease depending upon profile designed by contractor, the raising for
Reconstruction/ New Construction in approaches of Major/Minor Bridges shall be
carried out by contractor as per Schedule D and in consultation with the Authority’s
Engineer and as per availability of land, however, this shall not be treated as change
of scope.

7.1 Structural features and design of embankment

i) Embankment shall be designed to ensure the stability of the roadway and shall
incorporate only those materials, which are suitable for embankment
construction.
ii) Side slopes shall not be steeper than 2H: 1V and where necessary, the
embankment shall be retained by a retaining structure.
iii) Where the embankment is to be supported on a weak stratum, it shall be
necessary to specially design the embankment and also to provide appropriate
remedial/ground improvement measures.
iv) High embankments (height 6m or above) in all soils shall be designed from
stability considerations. Design of high embankments shall be carried out in
accordance with IRC 75: 1979 and MORTH – Guidelines for Design of High
Embankments.
v) The side slopes shall be protected against erosion by providing
turfing/vegetative cover, stone/cement concrete block pitching, geo-synthetics,
gabion walls or any other measures depending on the height of the
embankment, type of soil involved and susceptibility of soil to erosion in
accordance with IRC 56: 1974. Pitching on the slopes shall be done in
accordance with MORTH Specifications.
7.2 Earth retaining structures
Reinforced earth retaining structures shall be provided as per BS 8006-1995.
7.3 Road Side Furniture’s
Road side furniture shall be provided in accordance with Section 9 of IRC SP: 73-
2015.
The road signs shall be provided in accordance with IRC 67: 2012. Traffic signs include
roadside signs, overhead signs, and route marker signs and curb mounted signs along
the entire Project Highway and shall be designed as per IRC 67: 2012.

Pavement markings on the project highway shall be in accordance with IRC 35: 1997.
These markings shall be applied to road centre, edge line, continuity line, stop line,
give way lines, diagonal/chevron markings, and zebra crossing and at parking areas.
ROW Boundary stones shall be provided at an interval of 50m on both sides Km
stones, 5th Km stone and Hectometre stones for the project shall be provided in
accordance with IRC 8: 1980 and IRC 26: 1967. The foundation details, text size,

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height and locations shall be in accordance with the IRC codes stated above. Road
Delineators on either side of carriageway are in accordance with IRC 79: 1981.

Traffic Blinker Signal (L.E.D) shall be provided at intersections and median opening
locations as per Cl: 9.11 of IRC SP 73: 2015.
7.4 Slope Protection

Embankments less than 3m shall be turfed and the embankments with height more
than 3m will be evaluated and provided with adequate acceptable erosion control
measures.
7.5 Landscaping & Tree Plantation
Landscaping shall be in accordance with IRC SP 21: 1979 and Set back distance of
trees in different situations shall be as per IRC 66: 1976. Landscaping shall be done
in Median, grade separated intersections, at grade islands of intersection locations
and at Toll Plaza area.

8. Summary of Design Standards

The design standards for various Road design and Project Facilities are presented in
the Error! Reference source not found. 9.1

Table No 9.1 Summary of Design Standards

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S.No Items Standards

Design Speed

1 I) Ruling 100 kmph

II) Minimum 80 kmph

2 Proposed ROW 24m-96m

3 Carriageway

I) Width per lane 3.5 m

II) Rate of taper 1 in 20

4 Median width (including shyness)

I) Built up area 1.5 m

II) Median opening 1.5 m

III) Rate of taper 1 in 20

5 Paved shoulder

I) Rural area 1.5 m

II) Urban area 2.5 m

III) Approached to bridges 1.5m

6 Earthen Shoulder

I) Rural area 1.0 m

II) Approached to bridges 1.0 m

7 Utility Corridor

Rural area 2.0 m

2.0 m-1.0m
Urban area
(min)

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8 Horizontal Radius of curvature
Radius beyond which no super elevation is
a) required (100/80 kmph) in Plain and Rolling 1800m/1200m
terrain
Radius beyond which no super elevation is
b) required (60/40kmph) in Mountainous and Hilly 750m/280m
terrain
c) Desirable minimum radius (100/80 kmph) 400m/250m

d) Desirable minimum radius (60/40 kmph) 150m/75m

9 Camber/Cross fall

Bituminous concrete surfacing including paved

a) 2.50%
shoulder

b) Cement concrete surfacing 2.00%

c) Earthen shoulder 3.50%

Reverse cross slope of outer side earthen

d) 0.50%
shoulders on super elevation (min)

10 Super elevation

For radius of curvature 400m/250m and above for

a) 5%
100kmph/80kmph
For radius of curvature less than 400m/250m for
b) 7%
100kmph/80kmph

11 Stopping Sight Distance

a) Desirable (100/80kmph) 360m/240m

b) Minimum (100/80kmph) 180m/120m

c) Desirable (60/40kmph) 180m/90m

d) Minimum (60/40kmph) 90m/45m

12 Vertical Alignment

Desirable distance between change in grade

a) 150m
(tangent points)

b) Minimum length of vertical curve(100/60kmph) 60m/40m

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c) Minimum k -value

i) Summit Curve (100/80 kmph)

1) New carriageway/Bypass/Realignments 135/60

2) Existing Carriageway 73.6/32.6

ii) Valley Curve (100/80 kmph) 41.5/25.3

i) Summit Curve (60/40 kmph)

1) New carriageway/Bypass/Realignments 26.7/8.4

2) Existing Carriageway 14.5/4.6

ii) Valley Curve (60/40 kmph) 15/6.6

Maximum grade change not requiring vertical

d) ≤0.5%
curve

13 Gradient

a) Maximum 3.30%

b) Minimum 0.30%

c) For approaches to structures Max 2.5%

14 Median Opening

a) Length of Median Opening Min 20m

b) Taper Length Min 1 in 20

18 Embankment

Side Slope 2H:1V

19 Safety barriers
Recommended barrier will be provided based on
site requirement and as specified in
Concessionaire Agreement

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 20 Toll Plaza

a) Width of lane at toll plaza 3.2m

b) Width of lane for oversized vehicles 4.5m

c) Width of Traffic islands 1.8m

d) Minimum Length of the Traffic islands 25m

e) Rate of taper 1 in 10

Minimum vertical clearance of canopy over

f) 5.5 m
standard lane

21 Bus bay

a) Min. length of bus bay 15 m

b) Min. Width of bus bay 5.0 m

23 Landscaping
Landscaping and road side plantation shall be
provided in accordance with the manual of
specifications and standards as referred in
a) Schedule B and D. Contractor shall be responsible
for implementation of Environment management
plan on the project (EMP). The Cost of the EMP
Shall be borne by Contractor.

9. Details of Crossection Elements

Typical cross
Proposed Cross Section Type
section
Four lane Urban section (Concentric Widening)
TCS-04

TCS-02 Two lane Rural section (Concentric Widening)

TCS-03 Two lane Village section (Concentric Widening)

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TCS-02 Two lane Rural section (Concentric Widening)

TCS-05 Forest Section

TCS-02 Two lane Rural section (Concentric Widening)

TCS-01 Two lane New section (Concentric Widening)

TCS-02 Two lane Rural section (Concentric Widening)

TCS-03 Two lane Village section (Concentric Widening)

TCS-02 Two lane Rural section (Concentric Widening)

TCS-01 Two lane New section (Concentric Widening)

TCS-02 Two lane Rural section (Concentric Widening)

TCS-03 Two lane Village section (Concentric Widening)

TCS-02 Two lane Rural section (Concentric Widening)

Two lane Village section (Concentric Widening)

TCS-03

TCS-02 Two lane Rural section (Concentric Widening)

TCS-01 Two lane New section (Concentric Widening)

TCS-02 Two lane Rural section (Concentric Widening)

TCS-03 Two lane Village section (Concentric Widening)

TCS-02 Two lane Rural section (Concentric Widening)

TCS-01 Two lane New section (Concentric Widening)

TCS-02 Two lane Rural section (Concentric Widening)

TCS-05 Forest Section

TCS-02 Two lane Rural section (Concentric Widening)

TCS-03 Two lane Village section (Concentric Widening)

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 TCS-05 Forest Section

Typical Cross
Proposed Cross Section Type
Section

TCS-02 Two lane Rural section (Concentric Widening)

TCS-03 Two lane Village section (Concentric Widening)

TCS-02 Two lane Rural section (Concentric Widening)

TCS-01 Two lane New section (Concentric Widening)
TCS-02 Two lane Rural section (Concentric Widening)
TCS-01 Two lane New section (Concentric Widening)
TCS-02 Two lane Rural section (Concentric Widening)
TCS-05 Forest Section
TCS-02 Two lane Rural section (Concentric Widening)

TCS-04 Four lane Urban section (Concentric Widening)

TCS-02 Two lane Rural section (Concentric Widening)
TCS-01 Two lane New section (Concentric Widening)
TCS-02 Two lane Rural section (Concentric Widening)

TCS-03 Two lane Village section (Concentric Widening)

TCS-02 Two lane Rural section (Concentric Widening)

TCS-03 Two lane Village section (Concentric Widening)

Total Length 42.25 km

10. Pavement Design

10.2 General
The design of Flexible pavement for main carriageway shall be in accordance with
IRC 37: 2012 and rigid pavement design shall be in accordance with IRC 58:2015 for
design traffic estimated from traffic surveys. The total length of the project is 42.250

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km. Out of this length, 15.310 km falls under forest area which is proposed to be
overlaid with bituminous layer without any widening etc. For majority length of the
project where the existing pavement is available, it is proposed to dismantle the
existing bituminous layers and construct the rigid pavement from granular layers and
above. For the widening portions, it is proposed to provide the 500 mm compacted
subgrade and the other layers (GSB, DLC and PQC) which shall be provided as per
the design requirement. The granular subbase which also acts as a drainage layer
shall be provided throughout the entire formation width of the pavement to facilitate
the proper subsurface drainage of the pavement. The details of the pavement design
standards as adopted are given in Table below.
10.3 Overlay design
This design will apply for strengthening the existing two lane road. The following
guidelines have been followed for overlay design.

IRC 115: 2014 "Guidelines for Structural Evaluation and Strengthening of Flexible
Road Pavements Using Falling Weight Deflectometer Technique.
10.4 Design CBR
For new pavement in widening portion, the sub grade will be arranged from the borrow
area. The design CBR will be finalised on the basis of the CBR values obtained from
the laboratory test for the collected samples from the borrow area location.

Table 11.1 Design Standards of Pavement

S. No Item Standards

Main Carriageway Flexible Pavement Design

New Flexible Pavement design as per IRC: 37-

2012.
1 Design Methodology
Overlay thickness design as per IRC 115-2014

Design life shall be 15 years for the flexible

2 Design Life
pavement and 30 years for rigid pavement

50 Number of Million Standard Axle repetitions for

3 Design Traffic
design life of the pavement

4 Subgrade 4-day soaked laboratory CBR

Same thickness and composition as main
5 Paved Shoulder
carriageway
Toll Plaza Rigid Pavement Design

1 Design Methodology IRC 58: 2015

Grade for Pavement
2 M 40
Quality Concrete

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 Grade for Dry Lean
3 M 10
Concrete
4 Subbase Granular Material

5 Subgrade 4-day soaked laboratory CBR

Modulus of Subgrade
6 55 MPa/m
Reaction
7 Transverse Joint Spacing 4.5 m

8 Lane Width 2.5 m

A. Transverse Joints

Dowel bars shall be mild steel rounds conforming to

IS: 432, IS: 1786 and Grade IS: 240.

1. Transverse Expansion Joints

Width of Joint - 20 mm

2. Transverse Contraction Joints

9 Joint Details
Width of Joint - 10-12 mm

3. Transverse Construction Joints

Width of Joint - 10-12 mm

B. Longitudinal Joints

Tie bars in longitudinal joints shall be plain mild steel

bars conforming to IS: 432 or deformed steel bars
complying with IS: 1786.

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