NATIONAL HIGHWAYS AUTHORITY OF INDIA

Consultancy Services for Preparation of Feasibility for

Six Laning of Selected Stretches of National Highways under
NHDP Phase-V (Lot-5)-Group B : Etawah - Chakeri (Kanpur)
(Package No. NHAI/NHDP-V/DK-II/BOT/FR/37)

FINAL FEASIBILITY REPORT :

EXECUTIVE SUMMARY
(REVISED)

MARCH 2011
C O N S U L T I N G
Engineers Group Ltd.
An ISO 9001 : 2000 Company
E-12, Moji Colony, Malviya Nagar, Jaipur – 302 017 (INDIA)
Phone: +91(141) 252 0899, 252 1899; Fax: +91(141) 252 1348
Email:ceg@cegindia.com
Feasibilty for 6 Laning of Etawah-Chakeri Section of
NH-2, Phase-V, Group B (NHAI/NHDP-V/DK-II/BOT/FR/37)

EXECUTIVE SUMMARY

CHAPTER 1: INTRODUCTION

1.1 Project Description

The 6-laning of existing 4-laned national highway sections is to be executed through public,
private partnership (PPP) on built, operate and transfer basis following design and built-
finance-operate (DBFO) pattern. The 6-laning of projects has essentially been conceived as a
retrofitting job on existing 4-laned national highways causing minimum possible
inconvenience to the traffic. It is taken up as a separate phase viz. NHDP Phase-V by
National Highways Authority of India.
Etawah- Chakeri (Kanpur) 160.212 km long section of NH-2 in Uttar Pradesh State, which
falls on the Delhi - Kolkata arm of Golden Quadrilateral, has been included for 6- laning
under NHDP-V. M/s. Consulting Engineers Group Ltd., having their registered office at E-
12, Moji Colony, Malviya Nagar, Jaipur, were selected for preparation of Feasibility Report.

The order to commence consultancy services was issued by NHAI on 30th December 2009.
As per clause 2.3 of the conditions of contract, read with Special Condition of contract, the
Consultants are required to commence their services at the end of 15 days of the letter of
January 2010 and an intimation to this effect has been communicated to NHAI vide
Consultant’s letter No. CEG/DL/87/2009/713 dated 15 January, 2010.

1.2 NHAI Overview

The NHAI was created through the promulgation of the National Highways Authority of
India Act, 1988. In February 1995, the Authority was formally made an autonomous body.
The vision of National Highways Authority of India is to meet the nation’s need for the
provision and maintenance of National Highways network to global standards and to meet
user’s expectations in the most time bound and cost effective manner, within the strategic
policy framework set by the Government of India and thus promote economic well being and
quality of life of the people.

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The NHAI has a Chairman, 5 full time Members, Chief General managers, General
Managers, Deputy General Managers, Managers and secretariat staff at head office and at
Project Implementation Units (PIU) spread all over country from technical, financial and
administration. NHAI is one of the agencies of the Ministry of Road Transport and
Highways and is responsible for development and maintenance of the National Highways
assigned to it.
NHAI is financing its projects by a host of financing mechanisms such as securitization of
cess on petrol and diesel given by central government, market borrowing, budgetary grants
from central government, loan form international funding bodies, toll on completed National
Highways, special purpose vehicles (SPVs) with other stake holders, and award of projects
on build operate and transfer basis (toll and Annuity)

CHAPTER 2: EXISTING FEATURES OF THE PROJECT HIGHWAY

The Project Highway is situated between km 323.475 (end of Etawah bypass) and
km 483.687 (end of Kanpur bypass (elevated) section) of Delhi- Kolkata section of NH-2,
with km 0.00 at Delhi. The total length of the Project Highway is 160.212 km.

Location Map of the Project Highway

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The construction of 4 Lane Highway was done in following three packages completed during
the period 2001- 2007.
1. Section I– C (km 323.475 to km 396.133) 72.660 km long.
2. Section II- A (km 396.133 to km 457.498) 61.365 km long.
3. Section III- B (km 457.498 to km 483.687) 26.290 km long.

The Project Highway passes through plain terrain in its entire length. There are a number of
settlements along the Project Highway. The section has habitation and encroachment in
some stretches. The existing Right of Way varies from 23 m to 80 m and is generally
between 40 m to 60 m. The carriageway width is 7.0 m with 1.5 m wide paved and 2.0 m
wide earthen shoulders for either side traffic. The existing road has both the flexible and rigid
pavement. The height of embankment varies from at ground level to about 10 m near
approaches to structures and other places. The 85.958 km long service road, with width
varying from 4 m to 7 m, has been provided on both sides, though not continuous. The width
of raised median varies from 1.5 m to 5.0 m in different stretches.

There are three major bridges, 17 minor bridges and 279 box/ slab/ pipe/ culverts on the
Project Highway. Since one carriageway of the Etawah- Chakeri Section is new, the
structures are in good condition. However, in the old carriageway, the structures need some
rehabilitation measures/ reconstruction. Two railway line crossings exist at km 465.890 and
km 478.540. Both ROBs have two lane carriageways for Main Highway and two lane
carriageways for service road on both sides. A number of grade separators in the form of
pedestrian/ cattle crossings and vehicular underpasses as per details given below, exist along
the Project Highways.

SI Km 323.475- Km 460.475-
Item Total
No. km 460.475 km 483.687
Vehicular
1 2 21 23
Underpasses
Cattle/ Pedestrian
2 2 7 9
underpasses

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There are a number of major and minor at grade junctions. Utilities like telephone cables,
OFC lines, water pipe lines and electric lines run along the Project Highway.
There is mixed traffic on the Project Highway comprising of trucks, buses, cars, two-
wheelers, non-motorized vehicles etc. The Consultant had carried out the traffic surveys at
km 353.500, km 399.550, km 466.000 (elevated), km 466.000 (service road) in March 2010
and the second set at km 352.500, km 438.000 and km 466.000 (service road and elevated
portion) in June 2010. The total vehicles at these locations in June 2010 are under.

Total Traffic (AADT) June 2010

Number of
Location (km) Vehicles PCUs
352.500 16189 27715
438.500 21793 40287
466.00 (Elevated) 7883 17620
466.00 (Service Road) 20461 33466

CHAPTER 3: ENGINEERING SURVEYS AND INVESTIGATIONS

The needed data was collected from the office records and through additional surveys, such
as topographic surveys, digital still photography, physical surveys, and traffic surveys
conducted by the Consultant. Two sets of traffic volume counts were carried out for 7 days,
both for up and down directions, at four locations viz. km 353.500, km 399.550 and km
466.000 (elevated) and km 466.000 (service road) in the months of March 2010 and then at
km 352.500, km 438.000 and km 466.000 (both on elevated section and service road) in June
2010. Details of traffic surveys are presented in Chapter 4 of the Feasibility Report.

Pavement Condition Survey and Roughness Measurement

The pavement condition and road inventory surveys , roughness measurement and the
structural evaluation of the pavement, both by Benkelman Beam deflection and test pits,
were carried out in February – March 2010. Details of pavement evaluation studies are given
in Chapter 5.

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Material and Geo-technical Investigations

A number of borrow areas of aggregates and soils, having adequate quantity and appropriate
quality of materials for 6 laning work, are available. The samples collected from the borrow
areas were subjected to detailed laboratory studies. It is seen that good quality soil and
aggregates are available within reasonable leads for the widening work.
Inventory and Condition Survey of Bridges and Culverts
The needed surveys for all the structures on the Project Highway were conducted in
January – February 2010. Based on visual inspection, deficiencies in the structures were
identified. The details of the structures are given in Chapter 6.
Public Consultation Meetings
The Public Consultation meetings were held at three places, viz (i) Bakewar (ii) Auraiya and
(iii) Rania during October and November, 2010. The meetings were held with the general
public, elected representatives of Gram Panchayat, Zila Parishad and other key personnel of
the area. The NHAI officials also participated in the meetings. The participants were
explained of the proposals planned in 6 laning work. The suggestions received from them
generally in the form of safety considerations have duly been taken in the report.

CHAPTER 4: TRAFFIC STUDIES AND ANALYSIS

Traffic studies were undertaken for determination of the travel characteristics, and for future
traffic projections. The following surveys were conducted in the field:

• Classified traffic volume count survey for 7-days at four locations, twice
• Origin-Destination survey for 24 hours at 2 locations, once
• Turning movement survey for 12 hours at four locations, once.
• Speed and delay survey on the project corridor, once.
• Axel load survey for 1-day at two locations, once.

From the various surveys, the analysis for ADT, seasonal variation, AADT, average journey
and running speed, speed and delay and traffic forecasting was undertaken. Two times traffic
volume counts were conducted in March 2010 and June 2010. The second survey has shown

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an increase of about 30 to 50 percent in toll able traffic over the first count. The vehicles
damage factors at locations km 353.000 and km 400.00 vary between 2.63 and 6.44 for the
two directions of traffic. The axle repetitions for various sections of the corridor calculated
for the 20 year design period are estimated to be in the range of 69- 100 msa. The average
travel speeds for different sections are found in the range of 69 and 77 km per hour.

The traffic growth rates were worked out by applying various techniques. The future traffic
projections have also been done by assuming a uniform growth rate of 5 percent for all
categories of vehicles.

CHAPTER 5: PAVEMENT EVALUATION AND PRELIMINARY DESIGN

Pavement evaluation was done to assess the functional and structural condition of the Project
Highway. It has been 4-laned recently. Except for rutting in some stretches, no major
distress was observed. Roughness measurement for each lane and each direction of the road
were undertaken with duly calibrated Fifth Wheel Bump Integrator. The riding quality is
generally very good with roughness levels varying between 1300-2500 mm per km.
However, at a few locations, riding quality is not good with roughness levels varying
between 2500-3000 mm per km. From km 400 onwards the roughness levels are higher in
the Etawah- Chakeri carriageway (LHS).

The structural capacity was evaluated with Benkelman Beam. The Project Highway was
divided into homogeneous sections based on the condition survey and deflections were
measured in one km stretch of each homogeneous section of about 10 km length. The data
was analysed for working out the overlay requirement on different stretches. Further, 30 test
pits were excavated in both the carriageways, with a view to examine the thickness and
composition of constituent layers of existing pavement and to evaluate the sub-grade
conditions. The pavement thickness varies from 790-975 mm for the flexible pavement and
560-700 mm of the rigid pavement for the main carriageway and 730- 1060 mm for the
service road. The test pits were excavated at pavement shoulder interface. The sub-grade
compaction is in the range of 70 to 97 per cent of the laboratory density for main carriageway

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and 86 to 94 percent at sub grade level. The soil is generally good, yielding 4 days soaked
CBR of 4 to 13 percent at 97 percent density.

Preliminary Pavement Design

(i) Main Carriageway
Based on the traffic for the 20 years life, the pavement composition has been worked out for
different stretches. Since the traffic with 6-laning gets distributed further over the
carriageway width, the existing thickness provided is adequate. It is proposed that additional
lane shall be provided with flexible/ rigid pavement, with paved shoulders, having similar
specifications as that of the existing carriageway. The following composition is
recommended for sub-grade of CBR 8 percent to match with the existing crust.
a) Flexible Pavement
50 BC + 160 DBM + 250 WMM + 370 GSB
b) Rigid Pavement
320 PQC + 150 DLC + 150 Drainage Layer
Further, an overlay of 50 BC is required by the year 2010 over the existing carriageway.
(ii) Service Road
The crust of the service road has been designed for 10 MSA traffic. The widening of service
road/ new construction shall be done with sub-grade of CBR 8 percent and provided the crust
as under:
40 BC + 60 DBM + 250 WMM + 200 GSB.
Further, an overlay of 40 BC is proposed on existing service road to match with the
bituminous requirement for 10 MSA traffic.

CHAPTER 6: CONDITION SURVEY AND ANALYSIS OF STRUCTURES

Relevant GADs as per DPR, GFC and As-built drawings were collected from NHAI and
supervision consultant and reviewed. There are a number of river and drainage crossings in
the Project Highway and all of them have been bridged. There are 3 major bridges, 17 minor
bridges and 279 numbers of culverts in the existing Project Highway.

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Major Bridges
The existing major bridges at km 421.700 and 450.587 have 2 lanes on both sides and are in
good condition. These bridges have well foundation.
The third major bridge is at km 467.400 and is on pile foundation. Service road bridges exist
at this location for each direction of traffic. This bridge is a part of Kanpur bypass (elevated)
section.
Minor Bridge
There are 17 minor bridges existing on the entire project road. Out of these, 5 minor bridges
are in poor condition and are proposed for reconstruction. Remaining 12 minor bridges which
are in fair/good condition are proposed to be retained after rehabilitation. Out of these 12
bridges proposed to be retained, 3 bridges along with both side service road bridge from km
467.728 to km 472.970 are part of Kanpur bypass (elevated) section
Culverts

There are 279 existing culverts in the entire project road. Out of 279, 255 culverts exist
between km 323.475 to km 460.467 and remaining 24 culverts exist on Kanpur bypass
elevated section. Out of 255 existing culverts in section from km 323.475 to km 460.467, 96
are RCC box type, 20 are slab type and 139 are pipe type. Out of remaining 24 culverts in
Kanpur bypass (elevated) section, 23 are RCC box culvert and 1 is pipe culvert. All culverts
are in fair/ good condition.

Grade Separators (Vehicular Underpasses)

There are 23 existing grade separators (vehicular underpasses). Out of which 21 are part of
Kanpur bypass (elevated) section. All have been constructed between years 2004 to 2007. All
grade separators (vehicular underpasses) are in fairly good condition.
Pedestrian Underpasses / Cattle Passes

There are 9 existing Pedestrian Underpasses / Cattle Passes. Out of which 7 are part of
Kanpur Bypass elevated section. All are constructed between years 2004 to 2007. All
Pedestrian Underpasses / Cattle Passes are in fairly good condition.
Rail Over Bridge (ROBs)
There are 2 ROBs at km 465.890 and at km 478.540 on main carriageway along with service
road bridges on both sides. These are part of Kanpur bypass (elevated) section whose
approaches are of RE wall. All ROBs are in fairly good condition.

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CHAPTER 7: PROJECT FACILITIES

Two toll plazas exist on the Project Highway at km 353.900, and km 399.500. The new
proposed locations for toll plazas are km 353.000 and km 437.000. These shall be provided
as per provisions of the 6-laning manual.

A total of 88 bus bays and shelters are proposed in both the directions. There are 4 truck lay
byes planned at km 377.600 (LHS), km 378.000 (RHS), km 438.500 (RHS) and km 439.500
(LHS). A provision of Advance Traffic Management System (ATMS) shall be made to
monitor the movement of traffic and for giving requisite information to the users.

CHAPTER 8: DESIGN STANDARDS

The widening to 6 lanes standards from a present 4 lane road is to be done as per provisions
of the IRC: SP: 87-2010 ‘Manual of Specifications and Standards for Six Laning of National
Highways through Public Private Partnership’ and the NHAI Guidelines on BOT (Toll)
projects. However, some deviations have been made keeping in view the site conditions.

CHAPTER 9: PROPOSALS FOR WIDENING AND RETROFITTING

Major Bridges

The existing major bridges at km 421.700 and 450.587 have 2 lanes of carriageway for each
direction of traffic and are in fair condition. They are proposed to be retained after
rehabilitation. These bridges have well foundation, which cannot be widened so new bridges
with footpath are proposed on outer side of existing bridge either on one side or both sides as
per requirement of manual and considering site constraints.

The third major bridge is at km 467.400 has 2 lanes of carriageway for each direction of
traffic in main carriageway along with service road bridges on both sides. The bridge is not
proposed to be widened as it is on pile foundation and a part of existing elevated section in
Kanpur whose approach is of RE wall.

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Minor Bridges

There are 17 existing minor bridges on the project highway. All the bridges have 2 lanes of
carriageway for each direction of traffic. The bridges in fair/ good condition are proposed to
retained after rehabilitation. Existing bridges are with well/pile foundation or T-beam type
superstructure which cannot be widened so new bridges with footpath are proposed on outer
side of existing bridge either on one side or both sides as per requirement of manual and site
constraints. There are 5 bridges on LHS, in poor condition, and are proposed for
reconstruction, and 3 bridges on Kanpur bypass (elevated) not proposed for widening since
their approaches are on RE wall.

There are 3 minor bridges presently existing on service road at 3 locations for each direction
of traffic. All the bridges are in fair/ good condition and are proposed to be retained after
rehabilitation. Additional minor bridges for service road are proposed at 5 locations for
one/both direction of traffic. One new bridge on proposed Umarhat Pump Canal is provided
at km 393.315 as per Irrigation Deptt, U.P

Culverts

There are 279 existing culverts in the entire project road, out of which, 255 culverts exist
between km 323.475 to km 460.467 and the remaining 24 culverts exist on Kanpur bypass
(elevated) section. All the 255 culverts between km 323.475 to km 460.467 are proposed to
be widened, to match roadway width, after rehabilitation. Remaining 23 RCC box and 1 pipe
culvert in Kanpur bypass (elevated) section are not proposed to be widened as proposed
roadway are kept same as existing. All the culverts on Kanpur bypass (elevated) section are
to be retained after rehabilitation.

Grade Separators (Vehicular Underpasses)

There are 23 existing grade separators (vehicular underpasses). All are proposed to be
retained after rehabilitation since the approaches are of RE wall and cannot be widened.
Additional 18 grade separators (vehicular underpasses) of 3 lane carriageway have been
proposed on the project road.

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Pedestrian Underpasses / Cattle Passes

There are 9 existing Pedestrian Underpasses / Cattle Passes. Out of these 8 are proposed to
be retained without widening after rehabilitation since the approaches are of RE wall. The
PUP at km 413.453 is proposed for widening on RHS with 3 lane carriageway with paved
shoulder and at km 437.570 existing PUP is widened on both sides. Additional 25 Pedestrian
Underpasses / Cattle Passes of 3 lane carriageway both sides have been proposed on the
project road.

Rail Over Bridges (ROBs)

There are 2 ROBs at km 465.890 and at km 478.540 on main carriageway and service road
on both sides. The ROBs are not proposed to be widened as these are part of Kanpur bypass
elevated section whose approaches are of RE wall.

Foot Over Bridges

Four new Foot Over Bridges (FOBs) have been proposed at locations km 324.600,
km 384.900, km 425.400 and km 444.200

Exit/ Entry Ramps and Junction Improvement

Naubasta crossing is located at km 471.600 of Kanpur bypass (elevated portion). The

following provisions shall be made at this location.

1. Entry and exit ramps to and from the elevated portion.

2. The existing service road at ground level shall be widened accommodate the ramps.
3. The cross roads at ground level shall be provided with properly designed signalized
intersection.

Service Road

Service road of 223.464 km length and 7.0 m width is proposed on both sides. It comprises
of new road, and strengthening/ widening of the existing road.

CHAPTER 10: ENVIRONMENTAL AND SOCIAL IMPACT ASSESSMENT

The Project Highway passes, primarily through agricultural area. The water quality is good
and the noise levels are low. The noise may be an irritant in city areas mainly Rania during

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the construction phase. There is no ecologically sensitive area and forest falling along the
highway. Some of the recently planted trees within the corridor of impact area are likely to
be affected, which shall be taken care by transplanting of younger plants and compensatory
afforestation. Some religious places/ other structures which are located near main
carriageway/ service road and shall be affected during 6 laning.

CHAPTER 11: PRELIMINARY COST ESTIMATE

Cost estimate has been prepared for widening the existing 4 lane Project Highway to 6 lane
divided dual carriageway. The unit rates have been taken from the Schedule of Rates
published by the Uttar Pradesh PWD for the year 2010. For some of items, the prevailing
market rates have also been taken for estimation purpose. The cost of civil works for the
project is Rs. 1205.91 crores, as per details below.
Abstract of Cost Estimate

S. Amount
No. Items Unit Quantity Rate (lakhs) (lakhs)
A ROAD WORKS
TCS ( TYPE-1) km 17.083 748.87 12,792.89
TCS ( TYPE-2) km 38.602 673.27 25,989.41
TCS ( TYPE-3) km 8.875 512.97 4,552.58
TCS ( TYPE-4) km 17.403 352.67 6,137.49
TCS ( TYPE-5) km 4.3 512.97 2,205.76
TCS ( TYPE-2- RIGID) km 22.841 562.12 12,839.48
TCS ( TYPE-3- RIGID) km 1.677 401.83 673.86
1 TCS ( TYPE-4- RIGID) km 17.654 241.53 4,263.92
TCS ( TYPE-5- RIGID) km 2.8 401.83 1,125.11
TCS - 8 (Rania) km 1.99 385.51 767.17

TCS-7 (overlay of kanpur bypass) km 22.214 134.37 2,984.88

TCS - 6 (Overlay cost of existing

underpasses & service road widening on km 2.43 307.18 746.44
Both sides)

TCS - 6A (Overlay cost of existing

underpasses & service road widening on km 0.82 379.62 311.28
LHS and New service road on RHS)

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S. Amount
No. Items Unit Quantity Rate (lakhs) (lakhs)
TCS - 6B (Overlay cost of existing
underpasses & service road shifting on km 0.52 452.86 235.48
outer sides)

B BRIDGES AND STRUCTURES

2 MAJOR BRIDGES m 261 8.18 2,136.1
3 MINOR BRIDGES m 665 6.86 4,561.6
4 VEHICULAR UNDERPASSES*** m 396 28.82 11,414.0
5 PEDISTRIAN/ CATTLE UNDERPASS*** m 254 31.95 8,109.4
6 CULVERTS (pipe/slab/box) No. 255 1,511.6
7 FOB No. 4 220.00 880.0
Exit/Entry Ramps and improvement of
junction at Naubasta crossing(Kanpur
No.
bypass)& main carriageway overlay
8 (TCS-9) 4 4,556.6
9 Repair and Rehabilitation LS 1,000.0
OTHER ROAD
APPURTENENCE/MISCELLENEOUS
C ITEMS
10 JUNCTIONS
11 MAJOR No. 15 60 900
12 MINOR No. 230 6.00 1,380
13 TOLL PLAZA No. 2 750 1,500
14 BUS BAYS No. 88 10 880
15 TRUCK LAY BYES No. 4 80 320
16 Road Marking and signages km 160.212 15 2,403
17 Advanced Traffic Management system No. 160.212 6 961

19 Street Lighting m 46300 0.04 1,852.0

OTHER MISCELLENEOUS ITEMS (sign

boards, Aboriculture, medical/traffic aid
20 post, ambulances, cranes etc) LS 600
TOTAL AMOUNT (lakhs) 120,591.6
Cost per km(Length 160.212)in crores 7.53
RE walls/RCC Walls cost have been included
*** in the structure cost

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