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    Expressway Manaul - 1 PDF

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    Vijay Kumar

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    © All Rights Reserved
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    IRC:SP:99.2013 MANUAL OF SPECIFICATIONS AND STANDARDS FOR EXPRESSWAYS Published by: INDIAN ROADS CONGRESS ‘Koma Kot Marg. ‘Sector 6, R.K. Puram, ‘New Deti-t10 022 November, 2013 Price :€ 1200 (Plus Packing & Postage) IRC'SP-99-2013, IRC-SP:99-2019, CONTENTS Fst Published November, 2013, Personnel ofthe General Specifications and Standards Commitee i Introduction 1 Seiion—1 General 3 ‘Seciion-2 Geometric Design and General Features 10 Section Grade Separators and interchanges 25 Section-4 Embankment and Cut Sections at Sodtion-5 Pavement Design 35 Soction-6 Design of Stuctures a Section-7 Tunnels 9 (At Rights Reserved. No port ofthis publication shal be reproduced, Section-8 Materials 0 translated or transmitedin any form or by any means without the permission of tha Indian Roads Congress) Section—9 Drainage a Section 10 Traffic Contol Devices, Road Safety Devicas and Road Side Furniture ™ Section—11 Trafic Management Systoms 105 Sedlion- 12 Toll Plazas 108 ‘Section 13 Project Facilities: Service Areas, Pick-Up Bus Stops, Stato Border Check Posts ne Sectior 14 Environmental and Social Aspects, Landscaping end Tree Planition| 135, Sectior —15 Lighting 138 Appenices 141 Annexure 146 Printed by India Offsot Press, Delhi 110064 1000 Copies 10. n 2 13. 4, 15 16. 18, 10, 20. a IRC-SP:99-2013, PERSONNEL OF THE GENERAL SPECIFICATIONS AND STANDARDS COMMITTEE (GSS) Kandasamy. © (Convener) Patankar Vi. (Co-Convenot) Kumar, Mano} (Member Seoretary) Dhodapkar, AN Das, SN Datta, PK: De, Dr. 0.G, Duhseka, Vania Jost, Lic Koaiyal, Ot LR, ‘Kumar, Ashok Kura, Dr Kishor Monde; PS. Narain, A.D, Pandy, LK. Patwardhan, $.%, Pun SK, Rajora, KB, Fao, PR, Redoy, K Siva Sell, Anand (As on 6" August, 2013) Director Goneral (RD) & Spl. Secreta Ministy of Road Transport & Highways. New Delhi ‘ud Diractor General, Ministry of Road Transport & Higheays, New Delhi Chit Engineer (R) (SR8T), Minky of Road Transport Highways, New Deli Members Chief Engineer (Rot), MORTH, New Di ‘Addl. Doctor General (Mech ), MORTH Now Det Director Corporate Development, Ws TransAsia Infrastructure Put Li, New Delhi Excoutive Director, Consulting Engineering Seivies (inci) Pvt Lie. New Dei Chiat Engineer, PWD Highways, Aizwal Former Seerotary, MORTH, New Det Chief Executive, LR. Kadiya & Associates, New Delhi Chie! Engineer (Reta), Ministry of Road Transport 4 Hiahways, New Deli Chit Scientist, Geotechnical Engg. On., CRRY, Naw Delhi Chit Engineer (NH), PWD Maharashira Dreeior General (RO) & AS (Ratd ), MORTH, Noida (Chief General Manager (Tech), National Highways. Author of India, Bhopal, Madhya Pradesh ‘Advisor, Madhacon Project, New Del Director General (RD) & Spl, Seoretary, MORTH (Reta), New Dethi Engineaein-Chief(Retd), Delhi PWO, New Deth Vice President, Soma Enterprises Lid, Gurgaon Engineer-in-Chlof (8), Adm, & National Highways, Hyderabad, Andhra Pradesh Former Enginesr-in-Chief, PWD Madhya Prados IRC:SP 99-2013 22. Sharma, 0.6. 23. Sharma, 0.0. 2A Sharma, Rama Shankar 25. Sharma, SC 28, Shrivastava, Palash 27. Singh, Nirmal Ji 28 Sinka, AV. 29. Sinha, NK. “Tamankar, Be MB. 31. Tandon, Prof. Mahesh 2 Vasava, $8 33. Voleyutham, v. 34, Vemma, Mal. VC. 36. Repof NRRDA, 30. The Dy. Diector General 37 The Ghiof Engineer (NH) 4 Kandasamy.¢ 2 Prasad, Vishnu Shankar ‘Sr Prncpal Sclontst and Head instrumentation Division, GRR’, Now Delhi CCheirman, Ms D28 Inrastructre Pvt Lid, New Delhi Chief Engineer (Ret), MORTH, New Delhi Director General (RO) & AS (Reta), MORTH, New Delhi Director, IDFC, New Det Directo General (RD) & Spl Secretary, MORTH (Rata), New Dat Director Gonora (RD) & Spl Secretary, MORTH (Rett), New Dat Direct General (RD) & Spl, Secreta, MORTH (Rata), New Delhi Director-Grado Scintst (SERC-G) (Rete), Navi Mumbad ‘Managing Director, Tandon Consuitants Pet, Li (Vico Prosidont, IRC) Chiet Engineer (P) & Addl ‘Secretary, R&B Depll. Ganchinagar, Gularat Director General (RD) & Spl. Secretary, MORTH (Ret). New Dath Exocutvo Director Markoting, Orintal Structure Engineers Pvt Lid, New Delhi (Paterya, Or XK) Director (Technical) NRRDA, NEC ‘Towar, Bika Cama Place, New Del (Cal, 88, Chief Engineer, OOG D&S Die, Seema Sadak Bhawan, Now Doth PWD Jaipur (Rajasthan) ExOfficlo Members Director Gonoral (Road Development) & Special Secretary, MORTH and Presidant, IRC, New Dati Socrotary Genera, nian Reads Congress, New Delhi IRe-sP:99-2013, INTRODUCTION Recegnizing tho need for expeditious development of Access Controlled Fecilties simultaneously ensuring safe and high speed travel which interalia improves the productivity ‘of road tensport system, twas decided by the Ministry of Road Transport & Highways and tho Planning Commission through a series of meetings during December 2012 and January 2013 that a standard Manual of Spectications and Standards for Expressways should be brought ‘out by the Indian Roads Cangress (IRC). Accordingly, the IRC formulatad the proposal and the task forthe same was entrusted to IRC by the Ministry of Road Transport & Highways on ‘1 February, 2013. An Export Group comprising of following experts wes constiluted by IRC {or the preparation of the Manual:- 4. Shri8.C. Sharma ‘Team Leader 2. ShiDP, Gupta Member 3, ShiS. Sharma Member 4. DLR. Kadlyal Member 5. Shri Kiyoshi Dactuku Member 6. Ms Neha Vyas Member ‘The Vinistry of Road Transport & Highways constituted a Peer Review Group under the ‘Chaimanship of Director General (Road Development) & Special Secretary having members ropresenting al catogories of stakeholders, ‘The Expert Group prepared a Technical Note on Critical Issues which was dlscussod during the Workshop organized by the MORTH on 22” February, 2013 and also in Planning Commission on 6 March, 2013. Tho Crtical Issues ware deliberated, discussed and frozen ‘curing these two meetings, which enavied the Expert Group to move forward I was deoldad that the Manual should be structured on the lines of the existing Manual of ‘Spectfcetions and Standards for Four-laning of Highways published by IRC. The expressways heed to be planned as fully access controlled highways where entry and oxit points ara proviied at pre-determined locations. The Maral is intended mainly for newigreen eld exprossuays projacts. This Manual is nol applicable for design of expressways in uiban reas andin hilly terrain, Due consideration has beon given to conservation of material and environmental aspects as well, As a deparure from the existing guidelines, the Manual professes near ground level expressways in the plain terrain and with moderate cutting and filings in te roling torain ‘The design considerations require that this type of expressways Is constructed winare flood, rairage or water table do nol pose any problem and due care is taken from drainage point of view while keeping the expressway lavel close lo the existing ground level “The side approach roads should invariably cross over the expressway faclty to maintain tha sancity of access controled features, IRO'SP:99-2013, ‘The Draft Version 1 of the Manual prepared by the Expert Group was discussed by the Peer Review Group during is socond meeting held on 26" May, 2013. The comments of the Peet Review Group wore suitably incorporated by the Expert Group in Draft Version 2, which was placed before the H-7 Committee and the G-1 Committee of IRC. The H-7 Committee lst of the members appended) approved the draft in is 4” meeting and the comments ofthe same ‘were also incorporated by the Expert Group and placed the modified version before G-1 ‘Commitee. The G-1 Committee constituted @ Sub-Group under the Chairmanship of Shri ‘Ashok Kumer with the following membors: 1. Shri, Bhasin 2. SiviR.K, Pandey 3. Sh Kishore Kumar 4. Sil Jacob George 5. ivi Varun Aggarwal ‘The G-1 Gomamitee (Ist of the members appended) fray approved the Draft Manual on 27° uy, 2013. The GSS Commitoo during its meeting held on 6 August, 2013 approved the raft Manual. The final version of Manual was considered, dolberated ard approved by IRC Councit during its 200" Council Meeting held at Now Delhi on 11°& 12"August, 2013 after ‘aking on board the comments offorod by the Members. IRCSP-99-2013, SECTION-1 GENERAL, 14 Application ‘This Manual is applicable for the construction of Expressways (four lanes, six lanes or cight lanes) through Public Private Partnership (PPP) made. The scope of work shal be as defined in the Concession Agrooment This Manusl shall be read harmoniously with the intont of the Concession Agreement, ‘This Nanual is intended mainly for Expressways planned as groan fold projects. For this purpose, the Expressway is defined as an arterial highway for motorised traffic, with divided Carriageways for high speed travel, with ful control of accass and provided with grads ‘Separators at location of intersections. Generally, only fast moving vehicles are allowed ‘cress on Expressways. They are intercity Expressways located in open country outside: the buit-up area, The allgnment may, however, pass through isolated small stretches of bull- lupatres as long 2s the character ofthe Expressway as a whole does not change. The Menual is not ciety applicable tothe design of Fxpressways in urban areas and in hil torain 1.2 Concessionaire’s Responsibility ‘The Project Expressway and the project facilis shall conferm tothe requirements of design ‘and specifications set out in this Manual, which are the minimum prescribed. The project report and other information provided by the Authority’ shell be used by the Concessionaira only for his own reference and fr carrying out further investigations. The Concessionaire shall be solely responsible for undertaking all the necessary surveys, investigations and dtaled designs in accordance with good industry practice and due dligenca, and shail have no claim agains the Authority for any loss, damage, risks, costs, labliies or obligations arising out of or in reafion to the projectreport and other information provided ay the Authority, 1.3 Quality Assurance Requirements At leas: wo weeks prior to commencement ofthe work, the Concesstonsire shall draw up 2 Quelty Assurance Manual (QAM) covering the Quality System (QS), Quality Assurance Pan (GAP) and documentation for all aspects ofthe bridge and road works and send three ‘copies each to the independent Engineer (IE) for raviow. The class of quality assurance shall be Extra High QA (0-4) for al aspects of the project covering project proparation, dsign and drawings, procurement, materials and workmanship (Refer IRC:SP:47 and IRCSE:57) *AuthortyiGovernmenuCtient IRC:SP:99-2013, 14 Acceptable Codes, Standards, Guidelines and Technical Specifications ‘The Codes, Standards and Technical Spectications applicable forthe design and construction (of project components are |) "Guidelines for expressways" issued by the MORTH and published by the Indian Roads Congress (IRC), ii) Indian Roads Congress (IRC) Codes and Standards (Refer Appendix-1). ii) Specications for Road and Bridge Works issued by the Ministry of Road Transport & Highways (MORTH) herainafter referred to as MORTH or Ministry's Speciications, (iv) Any other standards referred to in the Manual and any supplement issued withthe bid document. 1.5 Latest Version’Amendments Latest version of the Codes, Standards, Specifications and Amendments thereio notified! Published at least 60 days before the last dato of bid submission shall be considered applicable, 16 Terins Relating to Ministry of Road Transport and Highways ‘The terms ‘Ministry of Surface Transport, ‘Ministy of Shipping, Road Transport & Highways’ ‘and Ministry of Road Transport and Highways’ or any successor 1 or substitute thereof shal bbe considered as synonymous, 17 Terms Denoting Independent Engineer ‘The torms ‘Inspector’ and ‘Engineer’ used in MORTH Spectcations shall be deemed to be Substituted by the tem “Independent Engineer, tothe extent itis consistent with he provisions ‘of the Concession Agreement and this Manual. The role of the Independent Enghhoer shall be 88 definad in the Concession Agreement, 18 Conflict or Inconsistancy in the Codes, Standards, Guidelines and Specifications In case of any conflict oF inconsistency in the provisions of the applicable IRC Codes, Standards or MORTH Specifications, the provisions contained inthis Manual shall apply. 19 Building Works Al items of building works shall conform to Central Public Works Department (CPWD) Specifications for Class 1 building works? and standards given in the National Building Code (NBC). For the Project Expressway through the stato entily, to the extent specific provisions The State Goveinmentmay presebe concemed Sats PWD Specticatns, itso desied 4 IRC:SP:90-2013 {or bulding works are mac in IRC/MORTH Specifications, the same shall prevail over the GPWDINBC provisions. For this purpose, bulling works shall be deemed to include toll laze complex, road fumiture, roadside faciltes,landscano elements andlor any other works Incidental to the building works. 1.40 Alternative Standards and Specifications The requirements stated in the Manual are the minimum, The Concessioneire may, however, ‘don international practices, allemative specications, materials and standards to bring it innovation in the design and construction provided they are better or comparable with the Standards prescrited in the Manual. The proposed alternative specifications and techniques, including those which are not included in the MORTH/IR Specifications shall be supported with authentic standards and specifications mentioned below: 8) American Association of State Highway and Transpotaion Officials (aasHTo) +b) American Sociaty for Testing of Materiats (ASTI) ©) Eure Codes: 8) National Standards of any of the folowing countries: United States of America (USA), Canada, Untied Kingdom (UK), France, ‘Germany, Sweden, Denmark, Norway. the Nethorlands, Spain, Australia, ‘New Zealand, Japan and South Afric, (©) IRC rovised codes or new codes or amendments to existing codes, which become applicabla after the deadline specified in para 1.6 ‘Such 3 proposal shall be submitted by the Concessionalre to the Independent Engineer In case the Independent Engineer is of the opinion that the proposal submitted by the Goncesslonaire is notin conformity with any ofthe international standarcs or cades, then he ill record his reasons and convey the same to the Concessionaire for complance. Arecard shall be Kept by the Independent Engineer ofthe non-compliance by the Concossionaire of the minimum Specifications and Standards specified in the Manual, Adverse consequences, it any, arising from any such non-compliance, shell be treated 25 “Concossionaire Detauit ‘and shall be dealt in accordance withthe provisions af the Concession Agreement, 11 Guidelines for Preparing Schedules of the Concession Agroemont Certair paras (full or part) in Sections 1 to 19 of this Manual refer to the Schedules of tho Concession Agreement. While finaizing the feasibiliyroject roport for the Project Expressway, andthe scope ofthe projec, each of these pares should be carefully oxaruned ‘and addressed by the Authority witha viow to making appropriate provisions in the Schedules fof the Concession Agreement. (A list of the paras that refer to such Schedules has been Provided at Appendix-2 for ready reference) IRC:SP:99.2013 412 General cons Jerations for Planning, Design and Construction The Project Expressway shall be planned as a "ully access controlled highway’ where entry ‘io and exit from the Expressuay shall be provided only at pre-determined locations through properly designed entry/exit amps andlor from interchanges. In doing ¢0, the Concessionaire shall take measures to avercoma the physical and operational constraints and plan, design and construct the Project Expressway using appropriate methods, management techniques ‘and technologios, General considerations shall, without being limited to, be as follows: 1) Carriageway provision and future widening ‘The numbor of lanes to be provided for the Project Expressway shall be specified in Schedule-B of tho Concession Agroement It shall be developed in accordance withthe typical cross-sections given in Para 2.16 of Section-2. ‘Whore only four lane (2x2) or six lane (2x3) carriageway is specified initial With deprassed median, placement of the divided carriageway shall be as shown in the typical coss-secions (Fig. 2.1(a) and Fig. 2.4(b)). In this situation, the width of median shall be increased by multiple of 3.75 m for ‘each additional lane fo allow widaning of the cariageway on the right sida Of the inside lane to achieve the ultimate eight lane carriageway (with 15 m ‘wide deprossad median) as and when required in future. In the ease of lush median, future widening shall be done on outer side, Safety of design ‘The Project Expressway shall be designed to provide for high level of safety ‘and operational efficiency for the movement of large volumes of traffic athigh ‘speed. Alignment design, geometrics, cross-sectional features, structures, road signage, markings, advance information system, and other traffic safely and management featuros and tolling systom shall bo designed to conform to the best standards and intemational practices fo achieve a consistent, safe and efficient design to caler for highest safety to the user and meet the intended functions of the Project Expressway. Interchangas, exits and fenirances should be tested for ease of operation and for route continuity ‘rom a driver's point of view. ‘All designs shal be structurally safe to ensure that the Project Expressway fr arly part thereof (for example embankment. pavement, interchanges, felaning stuctures, bridges, culverts, otc.) does not collapse (gobal stability) nor ts servicsabilityipertermance (for example settlement, riding ‘ually, undulations, deflections, et.) deteriorates below acceplable level 25 prescribed in Schedule-K of tho Concession Agrooment tm) Durabinity “The Project Expressway shall not only be safe bul also durable. This would ‘mean thal the deteriorating effects of climate and environment (for example IRe-$P:99.2013, \etting and drying, freezing and thawing, rainfall, temperature differences, aggressive environment leading to corrosion, etc) in addition to the traffic shall be duly considered in design and construction to make the Project Expressway durable. ‘v)_ Mitigating disruptive effects of construction The planning, design and construction of the Project Expressway shall be such that its construction does not have adverse impact on the environment, ‘ecology and does not disrupt the lives and business aciviles of the people living close to the Project Expressway. Appropriate measures shall be taken ‘as spoeified in Section-14 ofthis Manual 1.43 Safety during Construction and Operation & Maintenance 1.43.1 The Concessionaire shall develop, implement and administer a survellance and safely programme for proving a safe environment on or about the Project Expressiay, and shall comply wth te safety requirements et forth in tho Concession Agreement 4.132 Before taking up any constuction or maintenance eparatlonwork, the Conoessionaire hall prepare a Trafic Management Plan foreach work zone andfumish tt the IndopendontEnginaer for coriments duly incorporating the folowing: |) Designate a Site Safety Team hoadod by a quaiiod Safety Oftoar |) Traffic safoty dovieos as por IRC:SPS. 1) Sprinking of water for dust conial at work Zones, haul roads and planticamp sie, I) Nolee/Potuton suppression measures at work zones, haul roads and planticamp sites, ¥) Mechanical, electrical and fire safety practices Wi) Salty measures ike PPE (Personal Protection Equipment for workers engaged Vi) Fist Ald and Emergency Response Anangements |@. First Ald Box, Ambulance, paramodical staf, alarms, ce. vit) Safety vaininglawarcness programmes. x) Formas to maintsin the accident records/emergency response provided during ‘accidents 1.14 Field Laboratory ‘The Concessionaie shall setup feld laboratory for testing of materials and finished products asstipulatedin Clause 120 of MORTH Specifications. He shall makenecessary arrangemonts for adsitionalconfimatory testing of any matorials/products at a government accroditod laboratory for which facies at site laboratory are not avaiable, IRC:SP:99-2013 118 Environment Mitigation Measures The Concessioncire shall carry out teste!mon\tor various parameters impacting the environment of the Project Expressway keeping in view the guidalins of the Ministry of Environment and Forests and submit proposals for miigation of adverse environment impact Including provision of noise barriers, etc for review and comments of the IE, and undertake Implementation ofthe proposals in consultation with the IF 116 Utilities “The details ofthe neve ulti which are to be constructed or provided for along or across the Project Expressway shall be as specified in Schedulo-B of the Concossion Agreement. No uiilty should be situated under any part ofthe roadway, except where the utlly crosses the Expressway. Such ules shall cross through a culvert. 1.47 Review and Comments by the Independent Engineer In cases where the Conoessionaie is required fo send any drawings or documents to the Independent Engineer for reviaw and comments, and in the event such comments are receivad by the Concessionaire, it shall duly consider such comments in aceordarice with tho Concession Agreemant and Good Industry Practica for taking appropriate action thereon. “The correspondence betiveen the Conoessionaire and the Independant Engineer shall be ‘doomed valid only fa copy thereof Is endorsed to and received by the Authonly, 1.18 Definitions and Interpretation 4484 Unless specitied ottemiso in this Manual, the definitions contained in the Concession Agreement shall apply. 1.18.2 Grade separated structures i) Tho structures through which the trafic flows at diferent levels are called rade separatod structures, ji) Agrade seperated stricture which is provided for crossing of vehicles under the Project Expressway is called as Vehleular Underpass (VUP}, ii) Acgrade separates structure which Is provided for crossing of vehicles over the Project Expressway is called as Vehicular Overpass (VOP), iy) A structure provided below the Project Expressway for crossing of the pedestians ls called Pedastian Underpass (PUP). V)__Astructure provided below the Project Expressway for crossing of the catlla is called Calle Undexpass (CUP), vi) A padestvianicatle underpass through which light vehicles of height up to ‘3 mean also pass is calles Light Vehicular Underpass (LVUP). vi) Flyover is synonymous to VUP/VOP. a IRC:SP:99-2013, Vill) structure provided above the Project Expressway for crossing of pedestrians i) x” is called Foot Over Bridge(FOR) A structure provided over the ralway lines to carry tho Projact Expressway is called Road Ovor Bridge (ROB). A structure providad below the ralWvay lines to carry the Project Expressway is called Road Under Bridge (RUB) a EE S-':'

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