NH 342 Pavement Design 01.03.2024 (As Per DPR)

Rehabilitation and Upgradation of Existing
Two Lane Road to 4 Lane with Paved

Shoulders from 32/0 to 79/650 (Design Ch.
32+000 To Ch.78+760) of NN-342 of
Puttaparthi-Koduru Section in Sri Satyasai
District of Andhra Pradesh State Under EPC
for The Year 2022-23.
MENT DESIGN REPORT

UARY 2024
Rehabilitation and Upgradation of existing two-lane road to 4-lane with
Paved shoulders from km.32/0 to 79/650 (Design Ch.32+000 to
Ch.78+760) of NH-342 of Puttaparthi - Koduru Section in Sri Satyasai Pavemnent
district of Andhra Pradesh State under EPC for the year 2022-23. Design Report
LIST OF CONTENTS
1. PAVEMENT DESIGN .................................................................................................... 4
1.1 General ................................................................................................................. 4
1.2 Pavement Design ................................................................................................. 4
1.2.1 Design Life........................................................................................................... 4
1.2.2 Lane Distribution Factor ...................................................................................... 5
1.2.3 Design Traffic Volume ........................................................................................ 5
1.2.4 Traffic Growth Rates ........................................................................................... 5
1.2.5 Vehicle Damage Factor........................................................................................ 5
1.2.6 Computation of Design Traffic ............................................................................ 6
1.2.7 Adopted Pavement Design Loading .................................................................... 8
1.2.8 Design CBR Adopted .......................................................................................... 9
1.3 Pavement Crust .................................................................................................... 9
1.3.1 Pavement Design Check .................................................................................... 10
1.3.2 Proposed Pavement Composition ...................................................................... 12
KDMECPL 2
LIST OF TABLES
Table 1-1: Commercial Vehicle Traffic (AADT) Considered in Pavement Design ................. 5
Table 1-2: Vehicle Damage Factors adopted ............................................................................. 6
Table 1-3 :Estimation of CSA.................................................................................................... 7
Table 4-17 : Design Traffic Loading ......................................................................................... 9
Table 1-5 : Pavement Composition for Design Traffic ............................................................. 9
Table 1-6 :: Design Check Summary ....................................................................................... 12
Table 1-7 :: Proposed Pavement Composition......................................................................... 12
LIST OF FIGURES
Figure 1-1: IIT Pave Input ....................................................................................................... 11

Figure 1-2: IIT Pave Output ..................................................................................................... 11
KDMECPL 3
1. PAVEMENT DESIGN
1.1 General
This chapter describes the pavement design of pavement crust for widening of existing
road, new formation and overlay for existing road. Pavement designs for widening /
new construction of flexible pavement for main road are made in accordance with the
latest guidelines given in IRC: 37-2018.
The flexible pavements are usually referred as a layered structure comprising generally
bituminous surface like Bituminous Concrete (BC) and Dense Bituminous Macadam
(DBM), Wet Mix Macadam (WMM) base and Granular Sub-Base (GSB) course of
finite thickness, resting on sub-grade of minimum thickness of 500 mm.
The thickness design of these layers will principally depend on the sub-grade CBR and
the traffic loads that the pavement has to carry during its design life. Ideally, the flexible
pavement is built to such a depth that stresses on any given layer will not cause
unwarranted rutting, fatigue, shoving, or other differential movements which may result
in an uneven wearing surface. The chief function of the surfacing course is to provide
a smooth wearing surface, resistant to traffic. However, the wearing course can provide
some shearing resistance to the base structure and some added resistance to
deformation. Base courses are usually layers of aggregates that must possess high
resistance to deformation in order to withstand the higher pressures imposed by wheel
loads.
1.2 Pavement Design
Pavement designs for new construction of flexible pavement for main road are in
accordance with the latest guidelines given in IRC: 37-2018.
1.2.1 Design Life
Design life is defined in terms of the cumulative number of standard axles in msa that
can be carried before a major strengthening, rehabilitation or capacity augmentation of
the pavement is necessary.
IRC-37:2018 Clause 4.3.1 recommended the design life of 20 years for National
Highways and State Highways and Urban roads.
KDMECPL 4
Flexible pavement shall be designed for a minimum design period of 15 years, subject
to the condition that design traffic shall not be less than 20 msa. Stage construction shall
not be permitted as per clause 5.4.1 (ii) of IRC: SP: 84-2019.
As per Technical Schedules the Design life is considered 15 years. Sop design period
of 15 years is considered for pavement design.
1.2.2 Lane Distribution Factor
Lane distribution factor of 0.75 is considered for 4 lane dual carriageway in accordance
with the clause 4.5.1, (iv), IRC:37-2018 for commercial vehicles in each traffic
direction. Vehicle Damage Factor used is as estimated from axle load surveys (As per
DPR).
1.2.3 Design Traffic Volume
The Annual Average Daily Traffic (AADT) obtained from applying seasonal variation
factor is considered in computation of pavement traffic loading expressed in terms of
Million Standard Axles. AADT considered in estimation of CSA is given in Table 1.1.
Table 1-1: Commercial Vehicle Traffic (AADT) Considered in Pavement Design
At Km 60+200 @ Gummayagari palli

Towards Towards
Vehcile Puttaparthi Koduru Total, no Total, PCU
Standard Bus 218 235 453 1359
2 Axle Trucks 172 169 341 1023
3 Axle Trucks 185 192 377 1131
4-6 Axle Trucks 170 175 345 1553
LCV 149 161 310 465
Total 894 932 1826
1.2.4 Traffic Growth Rates
The growths are assuming as 5% as per IRC.
1.2.5 Vehicle Damage Factor
The vehicle damage factor is a multiplier for converting the number of commercial
vehicles of different axle loads to the number of standard axle load repetitions. Design
of new pavement is based upon the cumulative number of 8.16 tonne equivalent
standard axles (ESA) that will pass over during the design period.
KDMECPL 5
The VDF values are considered (As per DPR) as given below.
Table 1-2: Vehicle Damage Factors adopted
VDF Location DIRECTION BUS LCV 2-Axle 3-Axle M-Axle

Trucks Trucks Trucks
Towards 0.79 1.49 2.86 4.10 4.96

PUTTAPARTHI
Km. 60+200
Towards 0.88 1.87 2.19 3.98 5.00
KODURUU
Max 0.88 1.87 2.86 4.10 5.00
1.2.6 Computation of Design Traffic
The design traffic is considered in terms of cumulative number of standard axles to be

carried during the design life of the road. Its computations involves estimates of the
initial volume of commercial vehicles per day, lateral distribution of traffic, the growth
rate, the design life in years and the vehicle damage factor to convert commercial
vehicles to standard axles.
The following equation is used to compute the design traffic in terms of the cumulative
number of standard axles.
N = 365 × {(1 + r )n− 1}x A × LD × VDF

r
Where,
N = Cumulative number of standard axles for the design life in msa
r = Annual growth rate of commercial vehicles
n = Design life in years
A = Initial traffic in terms of number of commercial vehicles per day
LD = Lane Distribution factor
VDF = Vehicle Damage Factor
The cumulative standard axles (CSA) estimation is prepared in Excel spreadsheet year
wise. Computation of CSA is given in Table 1.3.
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Table 1-3 :Estimation of CSA
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1.2.7 Adopted Pavement Design Loading
The design considerations for pavement design are governed by applicable clauses of
IRC: SP: 84-2019 and IRC-37-2018. Accordingly, following considerations are made
in choosing pavement design loading in estimation of pavement crust for the project
road.
Pavement design loading for the project road are computed and the summary of
pavement loading adopted is given in Table 1.4.
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Table 1-4 : Design Traffic Loading
Million Standard Axles for Design Life
Homogeneous Sections Directions 5 10 15 20 25 30
Years Years Years Years Years Years
Towards
Puttaparthi 6 12 20 29 38 48
At Km 60+200 @
Gummayagari palli Towards 6 12 20 29 39 48
Koduru
Note:
➢ As per calculations indicate the current 15-year msa is 20 msa of traffic, So we are
considering here the design traffic is 20 MSA.
1.2.8 Design CBR Adopted
CBR is assumed 10 % effective CBR for pavement design.

1.3 Pavement Crust
Pavement composition for effective subgrade CBR of 10% is considered and the
abstract of pavement composition for the project road stertch is given below.
Table 1-5 : Pavement Composition for Design Traffic
Pavement Compositions (Conventional)
Towards Puttaparthi Towards Koduruu

Description
Project Name NH-342
Design Loading, MSA 20
Pavement Composition, mm
BC 40
Dense Bituminous Macadam 80
Wet Mix Macadam 250
Granular Subbase 200
Subgrade 500
Total 1120
Effective Subgrade CBR, % 10%
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1.3.1 Pavement Design Check
Pavement design check is carried out using the stress analysis software IITPAVE for
the computation of stresses and strains in the flexible pavements. Tensile strain at the
bottom of the bituminous layers and the vertical compressive strain on the top of the
sub-grade are conventionally considered as critical parameters for pavement design to
limit cracking and rutting in the bituminous layers.
Pavement compositions for the project road for widening / new construction of
pavement for main road are given in Table 1.5 As per the IRC: 37-2018, selected
pavement composition should be checked for stress and strains at critical locations
below the pavement. Pavement is checked for the following conditions:
• Maximum tensile strain at the bottom of the bituminous layer as per equation
3.4 of IRC:37-2018 (at 90% reliability level as per Cl. 3.7) is as follows.
Where,
Nf = Fatigue life in number of standard axles
= Maximum tensile strain at the bottom of the bituminous layer

MR = Resilient modulus of the bituminous layer =3000Mpa
C = Factor introduced in fatigue models to take into account the
effect of air voids (Va) and volume of bitumen (Vb) , which is
given by the following relationships
Where,
Va (air voids) = 3.5%
Vb (volume of the bitumen) = 11.5%.
By substituting above values in equation, maximum tensile strain at bottom of

bituminous layer is determined.
• Maximum vertical strain at top of sub-grade as per equation 3.2 of IRC: 37-
2018 (at 90% reliability level), which is given by.
Where,
N = Number of cumulative standard axles.
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= Vertical strain in the sub-grade
By substituting above values in equation, maximum vertical strain on top of sub-grade

layer is determined.
The strains at critical layers in pavement for both the options for design traffic are
computed using IITPave software. The inputs and corresponding outputs for both the
options are generated from the software are given from Figure 1.1 to Figure 1.2.
Figure 1-1: IIT Pave Input
Figure 1-2: IIT Pave Output

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The computed values of critical stress and strains are compared with allowable values
and the summary is given in Table 1.6.
Table 1-6 :: Design Check Summary
Allowable Computed
S.No Critical Stress / Strain Limits Value Remarks
(Microstrain) (Microstrain)
Horizontal tensile
1 strain in bituminous 225.4 207.6 SAFE
layer
Vertical compressive
2 454.4 317.2 SAFE
strain on sub-grade
1.3.2 Proposed Pavement Composition
The pavement crust proposed as per the design traffic loading is found safe as per the
design check. Considering the possibility of delay in start of implementation of the
project, the thickness of pavement layers are slightly increased. The proposed pavement
composition for the project road is given in Table 1.7
Table 1-7 :: Proposed Pavement Composition
Description New construction

Towards Towards
Direction
Puttaparthi Koduru
Design Loading, MSA 20 20
Pavement Composition, mm
BC 40 40
Dense Bituminous
80 80
Macadam
Wet Mix Macadam 250 250
Granular Subbase 250 250
Total 620 620
Effective Subgrade CBR, % 10% 10%
KDMECPL 12

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Rehabilitation and Upgradation of Existing

Two Lane Road to 4 Lane with Paved

MENT DESIGN REPORT

Figure 1-1: IIT Pave Input ....................................................................................................... 11

1.2 Pavement Design

1.2.1 Design Life

1.2.2 Lane Distribution Factor

1.2.3 Design Traffic Volume

Table 1-1: Commercial Vehicle Traffic (AADT) Considered in Pavement Design

At Km 60+200 @ Gummayagari palli

1.2.4 Traffic Growth Rates

The growths are assuming as 5% as per IRC.

1.2.5 Vehicle Damage Factor

VDF Location DIRECTION BUS LCV 2-Axle 3-Axle M-Axle

Towards 0.79 1.49 2.86 4.10 4.96

Max 0.88 1.87 2.86 4.10 5.00

1.2.6 Computation of Design Traffic

The design traffic is considered in terms of cumulative number of standard axles to be

N = 365 × {(1 + r )n− 1}x A × LD × VDF

1.2.7 Adopted Pavement Design Loading

1.2.8 Design CBR Adopted

CBR is assumed 10 % effective CBR for pavement design.

Table 1-5 : Pavement Composition for Design Traffic

Pavement Compositions (Conventional)

Towards Puttaparthi Towards Koduruu

= Maximum tensile strain at the bottom of the bituminous layer

By substituting above values in equation, maximum tensile strain at bottom of

By substituting above values in equation, maximum vertical strain on top of sub-grade

Figure 1-1: IIT Pave Input

Figure 1-2: IIT Pave Output

Table 1-6 :: Design Check Summary

1.3.2 Proposed Pavement Composition

Table 1-7 :: Proposed Pavement Composition

Description New construction

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