SUROJ BUILDCON PVT LTD

CLIENT: DBG ESTATES PVT.LTD..

PROJECT NAME: – WELSPUN ONE LOGISTICS PARKS LIMITED

,BHIWANDI.

FLEXIBLE PAVEMENT DESIGN REPORT

AS PER
IRC-37-2018

Revision Date Subject Remark

R0 28.07.2020 Flexible Pavement

design

D61-FLX-PAVEMENT-DESIGN
 CUMULATIVE TRUCK COUNTS FOR VARIOUS ROADS CONSIDERED FOR DESIGN

NO OF
SR.NO ANALYSIS AS PER THE TRAFFIC DATA PROVIDED
TRUCK
NORTH ZONE
1 CVPD on 14 mts Spine road - Entry 762

1 CVPD on 10.5 mts Spine road - Exit 762

2 CVPD on 12 mts Internal road 401

3 CVPD on 9 mts Internal road 401

4 CVPD on 7.5 mts internal road 260

7 CVPD on 6.0 mts internal road 269

SOUTH ZONE
1 CVPD on 12 mts Spine road - Entry 316

3 CVPD on 9 mts Spine road - Exit 316

4 CVPD on 7.5 mts internal road 64

7 CVPD on 6.0 mts internal road 64

D61-FLX-PAVEMENT-DESIGN
 NORTH ZONE - SPINE ROAD -ENTRY
4.3.8 Design of 14 m Flexible Pavement

4.3.8.1 Design of New Flexible Pavement ( IRC-37)

1 Input Data:
Initial Traffic in each direction on counting year = 762 CV/day
Construction period since last traffic count = 3 Years
4.3.1 Design Life of pavement to be considered = 15 Years
Design CBR of subgrade soil to be employed = 10 %
4.2.2 Traffic growth rate = 5 %
4.4.6 Vehicle damage factor as per axle load survey = 3.9
4.5.1.5 Lane Distribution factor (Dual 2-lane carriage way) = 0.75
Directional Distribution = 0.50

2 Design Calculation:
Initial Traffic in each direction in the year of completion of construction
A=P(1+r)x
Where,
P= Numer of commercial vehicles as per last count
r= Annual growth rate of commercial vehicles
x=Constuction perod since last traffic count

A = 762 X 0.50 x (1+5/100)3= 441 CV/day

Cumulative number of standard axle to be carried during design life in msa

365 x [(1+r)n -1]
N= xA xDxF
r

Where, A= Initial traffic in the year of completion of construction

D= Lane distribution factor
F= Vehicle damage factor
n= Design life in years
r= Annual growth rate

N= 365*((1+5/100)^15-1)*441*0.75*3.9/(5/100)/1000000
N= 10.159676 msa = 10 Say 10 msa

Pavement thickness and composition (Refer IRC-37,2012, Fig.-12.1 and Plate-1)

Total Pavement thickness for Traffic 10 msa and CBR of 10 %= 530 mm

Thickness of the component layers proposed are :

Provisions made to the Layers & Thk.
BC= 0.030 m
DBM= 0.050 m
WMM 1st Layer= 0.125 m
WMM 2nd Layer= 0.125 m
GSB 1st Layer= 0.200 m
Total= 0.530 m

D61-FLX-PAVEMENT-DESIGN
 NORTH ZONE - SPINE ROAD -EXIT
4.6 Design of 10.5 m Flexible Pavement

Design of New Flexible Pavement ( IRC-37)

1 Input Data:
Initial Traffic in each direction on counting year = 762 CV/day
Construction period since last traffic count = 3 Years
4.3.1 Design Life of pavement to be considered = 15 Years
Design CBR of subgrade soil to be employed = 10 %
4.2.2 Traffic growth rate = 5 %
4.4.6 Vehicle damage factor as per axle load survey = 3.9
4.5.1.5 Lane Distribution factor (Dual 2-lane carriage way) = 0.75
Directional Distribution = 0.50

2 Design Calculation:
Initial Traffic in each direction in the year of completion of construction
A=P(1+r)x
Where,
P= Numer of commercial vehicles as per last count
r= Annual growth rate of commercial vehicles
x=Constuction perod since last traffic count

A = 762 X 0.50 x (1+5/100)3= 441 CV/day

Cumulative number of standard axle to be carried during design life in msa

365 x [(1+r)n -1]
N= xA xDxF
r

Where, A= Initial traffic in the year of completion of construction

D= Lane distribution factor
F= Vehicle damage factor
n= Design life in years
r= Annual growth rate

N= 365*((1+5/100)^15-1)*441*0.75*3.9/(5/100)/1000000
N= 10.159676 msa = 10 Say 10 msa

Pavement thickness and composition (Refer IRC-37,2012, Fig.-12.1 and Plate-1)

Total Pavement thickness for Traffic 10 msa and CBR of 10 %= 530 mm

Thickness of the component layers proposed are :

Provisions made to the Layers & Thk.
BC= 0.030 m
DBM= 0.050 m
WMM 1st Layer= 0.125 m
WMM 2nd Layer= 0.125 m
GSB 1st Layer= 0.200 m
Total= 0.530 m

D61-FLX-PAVEMENT-DESIGN
 NORTH ZONE - INTERNAL ROADS
4.3.8 Design of 12 m Flexible Pavement as Internal ways

4.3.8.1 Design of New Flexible Pavement ( IRC-37)

1 Input Data:
Initial Traffic in each direction on counting year = 260 CV/day
Construction period since last traffic count = 4 Years
4.3.1 Design Life of pavement to be considered = 15 Years
Design CBR of subgrade soil to be employed = 10 %
4.2.2 Traffic growth rate = 5 %
4.4.6 Vehicle damage factor as per axle load survey = 3.9
4.5.1.3 Lane Distribution factor(2-Lane 2-Way road) = 0.5
Directional Distribution = 0.50

2 Design Calculation:
Initial Traffic in each direction in the year of completion of construction
A=P(1+r)x
Where,
P= Numer of commercial vehicles as per last count
r= Annual growth rate of commercial vehicles
x=Constuction perod since last traffic count

A = 260 X 0.50 x (1+5/100)4= 158 CV/day

Cumulative number of standard axle to be carried during design life in msa

365 x [(1+r)n -1]
N= xA xDxF
r

Where, A= Initial traffic in the year of completion of construction

D= Lane distribution factor
F= Vehicle damage factor
n= Design life in years
r= Annual growth rate

N= 365*((1+5/100)^15-1)*158*0.5*3.9/(5/100)/1000000
N= 2.4266497 msa =2 Say 3 msa

Pavement thickness and composition (Refer IRC-37,2012, Fig.-12.1 and Plate-1)

Total Pavement thickness for Traffic 3 msa and CBR of 10 %= 475 mm

Thickness of the component layers proposed are :

Provisions made to the Layers & Thk.
BC= 0.025 m
DBM= 0.050 m
WMM 1st Layer= 0.125 m
WMM 2nd Layer= 0.125 m
GSB 1st Layer= 0.150 m
Total= 0.475 m

D61-FLX-PAVEMENT-DESIGN
 NORTH ZONE - INTERNAL ROADS
4.3.8 Design of 9 m Flexible Pavement as Internal ways

4.3.8.1 Design of New Flexible Pavement ( IRC-37)

1 Input Data:
Initial Traffic in each direction on counting year = 401 CV/day
Construction period since last traffic count = 3 Years
4.3.1 Design Life of pavement to be considered = 15 Years
Design CBR of subgrade soil to be employed = 10 %
4.2.2 Traffic growth rate = 5 %
4.4.6 Vehicle damage factor as per axle load survey = 3.9
4.5.1.3 Lane Distribution factor(2-Lane 2-Way road) = 0.5
Directional Distribution = 0.50

2 Design Calculation:
Initial Traffic in each direction in the year of completion of construction
A=P(1+r)x
Where,
P= Numer of commercial vehicles as per last count
r= Annual growth rate of commercial vehicles
x=Constuction perod since last traffic count

A = 401 X 0.50 x (1+5/100)3= 232 CV/day

Cumulative number of standard axle to be carried during design life in msa

365 x [(1+r)n -1]
N= xA xDxF
r

Where, A= Initial traffic in the year of completion of construction

D= Lane distribution factor
F= Vehicle damage factor
n= Design life in years
r= Annual growth rate

N= 365*((1+5/100)^15-1)*232*0.5*3.9/(5/100)/1000000
N= 3.5631819 msa =4 Say 4 msa

Pavement thickness and composition (Refer IRC-37,2012, Fig.-12.1 and Plate-1)

Total Pavement thickness for Traffic 4 msa and CBR of 10 %= 475 mm

Thickness of the component layers proposed are :

Provisions made to the Layers & Thk.
BC= 0.025 m
DBM= 0.050 m
WMM 1st Layer= 0.125 m
WMM 2nd Layer= 0.125 m
GSB 1st Layer= 0.150 m
Total= 0.475 m

D61-FLX-PAVEMENT-DESIGN
 NORTH ZONE - INTERNAL ROADS
4.3.8 Design of 7.5 m Flexible Pavement as public way

4.3.8.1 Design of New Flexible Pavement ( IRC-37)

1 Input Data:
Initial Traffic in each direction on counting year = 260 CV/day
Construction period since last traffic count = 3 Years
4.3.1 Design Life of pavement to be considered = 15 Years
Design CBR of subgrade soil to be employed = 10 %
4.2.2 Traffic growth rate = 5 %
4.4.6 Vehicle damage factor as per axle load survey = 3.9
4.5.1.3 Lane Distribution factor(2-Lane 2-Way road) = 0.5
Directional Distribution = 0.50

2 Design Calculation:
Initial Traffic in each direction in the year of completion of construction
A=P(1+r)x
Where,
P= Numer of commercial vehicles as per last count
r= Annual growth rate of commercial vehicles
x=Constuction perod since last traffic count

A = 260 X 0.50 x (1+5/100)3= 150.5 CV/day

Cumulative number of standard axle to be carried during design life in msa

365 x [(1+r)n -1]
N= xA xDxF
r

Where, A= Initial traffic in the year of completion of construction

D= Lane distribution factor
F= Vehicle damage factor
n= Design life in years
r= Annual growth rate

N= 365*((1+5/100)^15-1)*150.5*0.5*3.9/(5/100)/1000000
N= 2.3114607 msa =3 Say 3 msa

Pavement thickness and composition (Refer IRC-37,2012, Fig.-12.1 and Plate-1)

Total Pavement thickness for Traffic 3 msa and CBR of 10 %= 475 mm

Thickness of the component layers proposed are :

Provisions made to the Layers & Thk.
BC= 0.025 m
DBM= 0.050 m
WMM 1st Layer= 0.125 m
WMM 2nd Layer= 0.125 m
GSB 1st Layer= 0.150 m
Total= 0.475 m

D61-FLX-PAVEMENT-DESIGN
 NORTH ZONE - INTERNAL ROADS
4.3.8 Design of 6 m Flexible Pavement as drive way

4.3.8.1 Design of New Flexible Pavement ( IRC-37)

1 Input Data:
Initial Traffic in each direction on counting year = 269 CV/day
Construction period since last traffic count = 3 Years
4.3.1 Design Life of pavement to be considered = 15 Years
Design CBR of subgrade soil to be employed = 10 %
4.2.2 Traffic growth rate = 5 %
4.4.6 Vehicle damage factor as per axle load survey = 3.9
4.5.1.2 Lane Distribution factor( Intermidiate lane load) = 0.75
Directional Distribution = 0.50

2 Design Calculation:
Initial Traffic in each direction in the year of completion of construction
A=P(1+r)x
Where,
P= Numer of commercial vehicles as per last count
r= Annual growth rate of commercial vehicles
x=Constuction perod since last traffic count

A = 269 X 0.50 x (1+5/100)3= 155.5 CV/day

Cumulative number of standard axle to be carried during design life in msa

365 x [(1+r)n -1]
N= xA xDxF
r

Where, A= Initial traffic in the year of completion of construction

D= Lane distribution factor
F= Vehicle damage factor
n= Design life in years
r= Annual growth rate

N= 365*((1+5/100)^15-1)*155.5*0.75*3.9/(5/100)/1000000
N= 3.5823801 msa =4 Say 4 msa

Pavement thickness and composition (Refer IRC-37,2012, Fig.-12.1 and Plate-1)

Total Pavement thickness for Traffic 4 msa and CBR of 10 %= 475 mm

Thickness of the component layers proposed are :

Provisions made to the Layers & Thk.
BC= 0.025 m
DBM= 0.050 m
WMM 1st Layer= 0.125 m
WMM 2nd Layer= 0.125 m
GSB 1st Layer= 0.150 m
Total= 0.475 m

D61-FLX-PAVEMENT-DESIGN
 SOUTH ZONE - SPINE ROAD -ENTRY
4.3.8 Design of 12 m Flexible Pavement

4.3.8.1 Design of New Flexible Pavement ( IRC-37)

1 Input Data:
Initial Traffic in each direction on counting year = 316 CV/day
Construction period since last traffic count = 3 Years
4.3.1 Design Life of pavement to be considered = 15 Years
Design CBR of subgrade soil to be employed = 10 %
4.2.2 Traffic growth rate = 5 %
4.4.6 Vehicle damage factor as per axle load survey = 3.9
4.5.1.5 Lane Distribution factor (Dual 2-lane carriage way) = 0.5
Directional Distribution = 0.50

2 Design Calculation:
Initial Traffic in each direction in the year of completion of construction
A=P(1+r)x
Where,
P= Numer of commercial vehicles as per last count
r= Annual growth rate of commercial vehicles
x=Constuction perod since last traffic count

A = 316 X 0.50 x (1+5/100)3= 183 CV/day

Cumulative number of standard axle to be carried during design life in msa

365 x [(1+r)n -1]
N= xA xDxF
r

Where, A= Initial traffic in the year of completion of construction

D= Lane distribution factor
F= Vehicle damage factor
n= Design life in years
r= Annual growth rate

N= 365*((1+5/100)^15-1)*183*0.5*3.9/(5/100)/1000000
N= 2.8106133 msa =3 Say 3 msa

Pavement thickness and composition (Refer IRC-37,2012, Fig.-12.1 and Plate-1)

Total Pavement thickness for Traffic 3 msa and CBR of 10 %= 475 mm

Thickness of the component layers proposed are :

Provisions made to the Layers & Thk.
BC= 0.025 m
DBM= 0.050 m
WMM 1st Layer= 0.125 m
WMM 2nd Layer= 0.125 m
GSB 1st Layer= 0.150 m
Total= 0.475 m

D61-FLX-PAVEMENT-DESIGN
 SOUTH ZONE - SPINE ROAD -EXIT
4.6 Design of 10.5 m Flexible Pavement

Design of New Flexible Pavement ( IRC-37)

1 Input Data:
Initial Traffic in each direction on counting year = 316 CV/day
Construction period since last traffic count = 3 Years
4.3.1 Design Life of pavement to be considered = 15 Years
Design CBR of subgrade soil to be employed = 10 %
4.2.2 Traffic growth rate = 5 %
4.4.6 Vehicle damage factor as per axle load survey = 3.9
4.5.1.5 Lane Distribution factor (Dual 2-lane carriage way) = 0.5
Directional Distribution = 0.50

2 Design Calculation:
Initial Traffic in each direction in the year of completion of construction
A=P(1+r)x
Where,
P= Numer of commercial vehicles as per last count
r= Annual growth rate of commercial vehicles
x=Constuction perod since last traffic count

A = 316 X 0.50 x (1+5/100)3= 183 CV/day

Cumulative number of standard axle to be carried during design life in msa

365 x [(1+r)n -1]
N= xA xDxF
r

Where, A= Initial traffic in the year of completion of construction

D= Lane distribution factor
F= Vehicle damage factor
n= Design life in years
r= Annual growth rate

N= 365*((1+5/100)^15-1)*183*0.5*3.9/(5/100)/1000000
N= 2.8106133 msa =3 Say 3 msa

Pavement thickness and composition (Refer IRC-37,2012, Fig.-12.1 and Plate-1)

Total Pavement thickness for Traffic 3 msa and CBR of 10 %= 475 mm

Thickness of the component layers proposed are :

Provisions made to the Layers & Thk.
BC= 0.025 m
DBM= 0.050 m
WMM 1st Layer= 0.125 m
WMM 2nd Layer= 0.125 m
GSB 1st Layer= 0.150 m
Total= 0.475 m

D61-FLX-PAVEMENT-DESIGN
 SOUTH ZONE - INTERNAL ROADS
4.3.8 Design of 7.5 m Flexible Pavement as public way

4.3.8.1 Design of New Flexible Pavement ( IRC-37)

1 Input Data:
Initial Traffic in each direction on counting year = 64 CV/day
Construction period since last traffic count = 3 Years
4.3.1 Design Life of pavement to be considered = 15 Years
Design CBR of subgrade soil to be employed = 10 %
4.2.2 Traffic growth rate = 5 %
4.4.6 Vehicle damage factor as per axle load survey = 3.9
4.5.1.3 Lane Distribution factor(2-Lane 2-Way road) = 0.5
Directional Distribution = 0.50

2 Design Calculation:
Initial Traffic in each direction in the year of completion of construction
A=P(1+r)x
Where,
P= Numer of commercial vehicles as per last count
r= Annual growth rate of commercial vehicles
x=Constuction perod since last traffic count

A = 64 X 0.50 x (1+5/100)3= 37 CV/day

Cumulative number of standard axle to be carried during design life in msa

365 x [(1+r)n -1]
N= xA xDxF
r

Where, A= Initial traffic in the year of completion of construction

D= Lane distribution factor
F= Vehicle damage factor
n= Design life in years
r= Annual growth rate

N= 365*((1+5/100)^15-1)*37*0.5*3.9/(5/100)/1000000
N= 0.5682661 msa =1 Say 3 msa

Pavement thickness and composition (Refer IRC-37,2012, Fig.-12.1 and Plate-1)

Total Pavement thickness for Traffic 3 msa and CBR of 10 %= 475 mm

Thickness of the component layers proposed are :

Provisions made to the Layers & Thk.
BC= 0.025 m
DBM= 0.050 m
WMM 1st Layer= 0.125 m
WMM 2nd Layer= 0.125 m
GSB 1st Layer= 0.150 m
Total= 0.475 m

D61-FLX-PAVEMENT-DESIGN
 SOUTH ZONE - INTERNAL ROADS
4.3.8 Design of 6 m Flexible Pavement as drive way

4.3.8.1 Design of New Flexible Pavement ( IRC-37)

1 Input Data:
Initial Traffic in each direction on counting year = 64 CV/day
Construction period since last traffic count = 3 Years
4.3.1 Design Life of pavement to be considered = 15 Years
Design CBR of subgrade soil to be employed = 10 %
4.2.2 Traffic growth rate = 5 %
4.4.6 Vehicle damage factor as per axle load survey = 3.9
4.5.1.2 Lane Distribution factor( Intermidiate lane load) = 0.75
Directional Distribution = 0.50

2 Design Calculation:
Initial Traffic in each direction in the year of completion of construction
A=P(1+r)x
Where,
P= Numer of commercial vehicles as per last count
r= Annual growth rate of commercial vehicles
x=Constuction perod since last traffic count

A = 64 X 0.50 x (1+5/100)3= 37 CV/day

Cumulative number of standard axle to be carried during design life in msa

365 x [(1+r)n -1]
N= xA xDxF
r

Where, A= Initial traffic in the year of completion of construction

D= Lane distribution factor
F= Vehicle damage factor
n= Design life in years
r= Annual growth rate

N= 365*((1+5/100)^15-1)*37*0.75*3.9/(5/100)/1000000
N= 0.8523991 msa =1 Say 3 msa

Pavement thickness and composition (Refer IRC-37,2012, Fig.-12.1 and Plate-1)

Total Pavement thickness for Traffic 3 msa and CBR of 10 %= 475 mm

Thickness of the component layers proposed are :

Provisions made to the Layers & Thk.
BC= 0.025 m
DBM= 0.050 m
WMM 1st Layer= 0.125 m
WMM 2nd Layer= 0.125 m
GSB 1st Layer= 0.150 m
Total= 0.475 m

D61-FLX-PAVEMENT-DESIGN