Office of the Engineer-in-Chief (PR) Vijayawada Circular Memo No : AEE(T)/DEE(T)/ technical matters/ 2018 Dt: os /2. 2019 Sub: Roads- Design of crust for the roads having subgrade CBR less than 5% - detailed guidelines as per IRC SP 72-2015 & MORD 2014- Communicated- Reg. Ref: IRC SP 72-2015- Guidelines for Design and Construction of Flexible Pavements for Low Volume Roads, erst , During scrutiny of estimates it was observed that the provisions made in the most of the estimates received from the Superintending Engineers are not as per the guidelines contained by the IRC SP:72- 2015 for construction of Flexible pavements which causes much delay in sanctioning the estimates.. ‘Some of the SEs are proposing Insufficient crust based on the test reports furnished by Private engineering colleges which leads to premature failure of roads even during defect liability period. ‘The major causes of pre mature failure of pavements with in the design life are as follows. 1, Non assessment of correct strength of sub grade soils In terms of CBR. which plays vital role in the crust design. 2. Insufficient traffic data 3. Wrongly arriving the Crust thickness 4. Non availability of Soil classification data such as LL, PI and FSI in case of expansive soils. Defective Construction Practices Insufficient or weak sub grade Poor drainage or Shrinkage of Expansive soils Poor hot mix asphalt design exon 9.Traffic loading on the edge of the pavernent due to inadequate pavement width. Hence it is directed to test the soil samples in the University Engg colleges/Department QC labs/ISO certified labs and labs recognised by the V&E dept only with detailed soil classification analysis including FSI in case of BC soils since ‘subgrade CBR plays vital role in the design of crust. Further to adopt uniform provisions in the estimates through out the state the following crust design shall be adopted for the poor subgrade soils having CBR less than 5%. 1 ade soils with CBR : 3-4 %; 1.1 Conventional Crust design: Option 4: Based on the subgrade CBR and Traffic category modified soll /Improved subgrade having CBR >10% (Stone dust) has to be proposed to the total formation width over the Embankment soil , le 8 to 9 mts depending upon the height of the embankment . The Proposed subgrade has to be extended to the total formation width with required thickness as Per chart (subgrade as shown in the figure 100.1of MORD), and provide GSB and Base thicknesses as per Fig 4 of IRC SP 72-2015. :eavouewr Fig 100.1 Tors Used in the Speciation io Dascive Road Cross-Section Elements with o Flexiblo Pavement Stone dust provision should be made in the estimates which is having CBR >10% instead of Gravel in the form of Selected Earth sanctioned in the present estimares since the CBR of rormal gravel soils will be <10% only . Shoulders should be proposed with selector earth only, to the total depth of crust over subgrade and required width. The cross section of the Road with the above provisions will be as follows. ‘Qxtion 2: Provide Selected Earth (Gravel) having CBR >5% to a thickness of 300 mm to the {otal formation width (as shown in the Fig 100.1 of MORD) since top 300 mmm in thickness just Peneath the crust will act as Subgrade in the Embankment (Clause 4.1-1oF IRC oP 72-2015). Then design the remaining crust duly taking sul Of GSB and Base corresponding to the Traffic intensity. Shoulders should be Proposed with selected earth only to the total depth of crust over subgrade and required: width. The cross Section of ‘the “Road” “with the: above provisions willbe as Follows ibgracle CBR as 5% and arrive the thicknessOption 3 : Alternate Technology: Use of Geosynthetics: Main function: Reinforcing the soil (Clause 5.1 of IRC 113-2013) Woven Geotextiles ( as per Table 700. 7 of MORT&H) shall be placed over 75 to 100 mm stone dust layer (which act as a friction layer) to the total formation width after compacting the original embankment. Then design the crust duly taking the sub grade CBR as 5%. Shoulders should be proposed with selected earth only to the total depth of the crust and required width.The cross section of the Road with the above provisions will be as follows. Embankment (omr— ote 42) Typical Pavement Gross Components wih GEO Toxtl Rote: Weven Seo Textiles should satiery nitration, Drainage TT. CBR equals to 2 and less than 2% : Expansive soils /Black cotton soils may have a soaked CBR 2or less than 2%. These soils ‘are subject to volumetric changes associated with seasonal moisture variations have led to pavement heave during wet season and shrinkage during dry season . ‘These cyclic movement cause considerable damage in form of longitudinal cracks as shown In the following Fig 3.Design of Crust: Option 1: Conventional approach: For Embankment construction normally the estimates are sanctioned with side earth and carting earth with 1000 m lead in BC/ Expansive soils even though the soils are unsuitable for fil. Clays having LL exceeding 70 and PI exceeding 45 and FSI exceeding 50 percent are unsuitable fill material in the Embankment, Hence provide 0.6 mts thick non expansive soil to the entire formation width and design the pavement with CBR of Imp subgrde. Alternatively blanket course or /medium sand or lime treated black cotton soil sub base can be provided (Clause 4.2.2 of IRC SP 72-2015) Option 2: Alternate Technology: Use of Geosynthetics: Main function: Reinforcing the soil(Clause 5.1 of IRC 113-2013) Non woven Geotextile ( as per Table 700.1 of MORT&H )should be placed over the consolidated embankment to the total formation width in between embankment and subgrade. 150 mm thick stone dust / Coarse sand should be laid over Non woven geo textile and Woven Geotextiles ( as per Table 700.7 of MORT&H) shall be placed over stone dust layer to the total formation width .Then design the crust duly taking the sub grade CBR as 5%, ‘Shoulders should be proposed with selected earth only to the total depth of the crust and required Width. The cross section of the Road with the above provisions will be as follows. 1 as Reinforcement 700.7 of MORT & Non-Woven Geo Textiles as Drainage: aN Layer as per Table 700.1 of MORT & | a Embankment (CBR =28<2%) Typical Pavement Gross Section Consists of Different Components with GEO Textiles for Supgrade having CER 2 & < 2% III, Alternate Technology : For Reconstruction of Roads : using Non woven geotextile barrier : ~ Excavate a trench on both sides of existing road as shown in fig with 0.45 m X 0.75 mts ~ Non woven geotextile should be placed all-round the trench inside and refill with excavated soil with proper compaction, - Cover the top portion also with Non Woven Geotexttile, which will act as a barrier to prevent sliding which is often experienced in BC soils all along the canal portions. ~ Fill the remaining shoulders with selected earth having MDD not less than 18,5 kN/cum. ‘The cross section of the Road with the above provisions will be as follows,Non-Woven Geo Textiles barrier filled with Exeavated earth or Subgrade Embankment (CR =28 3t04% ) Typical Pavement Cross Section for Reconstruction of roads ‘Consists of Different Components with Non- Woven GEO. Textiles filled with excavated earth to act as barrier to prevent Soil erosion/siiding. Note: Non-Woven Geo Textiles barrier with 0.45 mts X 0.75 mts nolo. stabil Re Cement and Stabil Road is mixed with different proportions as per design mix in the in-situ soil and mixed with required quantity of water, compacting, rolling and watering. After curing BT can be laid directly on the stabilized base duly ascertaining the UCS of base as 4.50 to 7 Mpa for 7/28 days (Clause 7.3.2 of IRC : 37-2012). This may be suitable for roads where existing BT/WBM damaged badly which requires Reconstruction and in-situ soil stabilization without adding any foreign material. Further the Superintending Engineers are also directed to adopt other alternate technologies which are economical when compared to conventional crust design with the prior Permission of the higher authorities in poor subgrade soils. Hence all the Superintending Engineers are requested to adopt the above provisions in the estimates of Flexible pavements in future without any deviation for the soils having sub grade CBR <5%. Sd/ R Venkateswara Rao Engineer-in-Chief(PR) Vijayawada, AP. To All the Superintending Engineers in the State with a request to see that the instructions should reach to all the section officers without fail Copy to all Chief Engineers (PR) for necessary action with a request to communicate to all scrutinizing staff under their control Copy to all Chief Engi \eers (PR) table. : Copy to all Executive Engineers in the state including ENC’s office for taking necessary action, /[Authenticated// 2, bp oe Gb na Aes