DETAILED ENGINEERING DESIGNS

PAVEMENT DESIGN REPORT

92 – WATHUWATHTHEGAMA TO MUDIYANEGAMA VIA
UDADIULWEWA ROAD
(RIGID PAVEMENT DESIGN)
` FROM CH 04+500 TO 04+650 KM

EMPLOYER

PROJECT:
ADB FUNDED INTERAGRATED ROAD INVESTMENT CONSULTANT
PROGRAM REHABILITATION OF RURAL ROADS IN
KURUNEGALA DISTRICT, PACKAGE 4
WATHUWATHTHEGAMA TO MUDIYANEGAMA VIA
KUMBUKKADAWELA ROAD
FROM 00+000 TO 09+727 KM CONTRACTOR
CONTRACTOR

2016 DECEMBER
1. Introduction

KU4-92 Wathuwaththegama to Mudiyanegama via Kumbukkadawela Road is being

rehabilitated and improved by V.V. Karunarathne & Company Ltd under Package 4 of ADB
Funded project of rehabilitation/improvements of 97km of rural roads in Kurunegala district.

During the Site Inspection Walk on 2nd November 2016, road section from Ch 4+400 to Ch
4+650 is identified as an inundating section. Hence, it has been decided to propose a rigid
pavement for the particular section. This report contains the revised pavement design from Ch
4+500 to Ch 4+650. The existing road section consists with a macadam surface. Concrete
pavement with Dense Graded Aggregate Base over the existing macadam surface is proposed
considering site requirements and feasibility. Paved width is considered as 3.6m whereas the
soft shoulder width varies from 0.6n to 1.0m.

2. Pavement Investigation & Traffic Forecast

According to analysis done under the pavement design of KU4-92 Wathuwaththegama to
Mudiyanegama via Kumbukkadawela Road, subgrade CBR of carriageway and widening
sections are taken as 5% from Ch 4+500 to Ch 4+600. Design traffic for a 10 years’ design life
(2017 – 2026) is 0.0337 msa (million standard axels). For any further detail, refer Detailed
Engineering Designs Pavement Design Report - From Ch 0+000 To 09+727-2016 November-
KU4-92 Wathuwaththegama to Mudiyanegama via Kumbukkadawela Road.

3. Pavement Design
Design Calculation are based on Equations given in AASHTO Guide for Design of pavement
structures (1993). Design calculations are presented in Annex 1.
Concrete overlay with DGAB
Unreinforced Concrete slab on 125 mm dense graded aggregate base (DGAB) is proposed
considering traffic demand and subgrade strength. Introduced ABC layer will be act as sub base
layer as well as drainage layer. Design Unreinforced Concrete Slab thickness is 150mm.
Table 1– Design Layer thicknesses

Unreinforced Dense Graded

Traffic Design
Chainage Section Concrete Slab Aggregate Base
class CBR (%)
(mm) (CBR 80)

Carriageway T1 5% 150 125

Ch 4+500 to Ch 4+650
Widening T1 5% 150 125

Locations where highly deteriorated or damaged existing pavement, should be reconstructed

with given layers by scarifying the existing pavement and compacting formed subgrade to
achieve 95% MDD at modified Procter compaction.

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 Fig. 1–Typical Road Section of concrete Pavement with Dense graded aggregate Base

Construction of Concrete Slab

Construction of 150 mm thick concrete slab should be carried out as specified in section 900 of
the SSCM. Cube crushing strength of slab should be 30 N/mm2 at 28 days.
In the event any utility service lines, manholes etc. exist in the proposed rigid pavement area,
the utility lines should be shifted beyond the proposed rigid pavement.
Contraction joints should be formed across the road by saw cutting in a spacing of 5.5 m or
Immediately above existing joints to a depth of 1/4th of the thickness (30-40mm) of the slab
(refer fig 1). Cutting should not be delayed beyond 6 hours of laying concrete and carried out as
soon as the concrete is of sufficient strength to avoid raveling. Initially cut to about 3mm wide
and subsequently widened to accommodate the sealant of minimum width compatible with
properties of sealant. Smooth lubricated dowel bars shall be installed at mid depth in the slab &
parallel to the surface & centerline of the road using 20 mm diameter bar in a 300 mm center-
to-center spacing. (Refer fig. 4)
If the work must stop due to an emergency, machine breakdown or daily work segments,
construction joints should be placed. The smooth lubricated dowel bars shall be installed at mid
depth in the slab & parallel to the surface & centerline of the road using 20 mm diameter bar in
a 300 mm center to center spacing (Refer fig 5).
A camber of 2.0% should be maintained on the road surface for the straight sections. In case of
a bend, super elevation should be maintained which varies with the curvature of the center line
of the road.
Prior to laying of the concrete pavement the surface of the DGAB shall be cleaned of extraneous
material and over laid with a separating membrane using polythene sheets of 125 microns
thickness covering the DGAB layer and the vertical faces. Overlapping of the separation
membrane should be not less than 300mm.
Concrete should be prepared by a batch mix plant, laid and compacted using beam & poker
vibrator machinery and finished rough by means of brooms as per section 901 of the SSCM.

2
Curing of the laid concrete shall be carried out by spreading coir dust, etc., and regular wetting
for a period not less than 7 days.
This work should be carried out to the required levels, providing suitable drainage measures at
site.

Fig 4. - Transverse Contraction Joint

Fig 5. - Construction Joint

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4 Materials and Method of Construction
Material and method of construction has to be selected according to the references given in
Table 3.

Table 2- Reference for Materials and Method of Construction

Materials Reference

Standard Specification for Construction and Maintenance of

Embankment Type I
Road and Bridges (SSCM-2009) ,Cl:304 and Table 1708-1

Standard Specification for Construction and Maintenance of

Embankment Type II
Road and Bridges (SSCM-2009) ,Cl:304 and Table 1708

Standard Specification for Construction and Maintenance of

Sub Bases Road and Bridges (SSCM-2009) ,Cl:401.2 and Table
1708.2 ,1708.3

Standard Specification for Construction and Maintenance of

Dense Graded Aggregate Base
Road and Bridges (SSCM-2009) ,Cl:405 and Sub
(DGAB)
Cl:1701.3(Base course Aggregates) & Table 1701-5

Standard Specification for Construction and Maintenance of

Asphalt Concrete
Road and Bridges (SSCM-2009) ,Cl:506

5 Drainage
It is very essential to provide an efficient system of drainage throughout this road by way of
cross drainage structures; side drains lead-away drains etc.

6 References
Yang H. Huang - Pavement Analysis and Design, 2nd Edition
Transport & Road Research Laboratory, United Kingdom Road Note 31, 1977
RDA Pavement Design Guide, 1999
AASHTO Pavement Guide for Design of Pavement Structure, 1993
Standard Specification for Construction and Maintenance of Road and Bridges (SSCM-1989)
Standard Specification for Construction and Maintenance of Road and Bridges (SSCM-2009)

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Confirmation of Report Preparation

Prepared by,

…………………………………………………
Eng. D.M.H.M.A. Bandara

Checked by,

…..…………………………………………….
.
Eng. M.W.I.J. Kumara

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Annex
 ANNEX 1A
KU4-92 Wathuwaththegama to Mudiyanegama via Kumbukkadawela Road - Ch 4+500- Ch 4+650 Km - Rigid Pavement Section
Design Calculations - Overlay
Subgrade design CBR value for Carrigeway section = 5%
Estimated sub grade Resilient Modulus (MR) - (Refer eqn. 7.6*) = 1500 x CBR%
= 7500 psi
Sub base thickness = 125 mm
(125mm DGAB layer) = 4.92 inch
Sub base Elastic Modulus (ESB) - (Refer 3.2.1 **) = 25000 psi
Composite Modulus of subgrade Reaction (K) = 420 pci
(Fig 3.3**-Assume full contact of foundation support)

Effective Modulus of Subgrade Reaction corrected for Loss of Support = 140 psi
(Fig 3.6**-Assume Loss of Support to be 1.0)

DATA
Compressive Strength of Concrete (cube) fcu = 30 Mpa
Compressive Strength of Concrete (cylinder) fck = 0.8 x fcu
= 24 Mpa
f'ck = 3480.89 Psi
Concrete Elastic Modulus, (Ec) -(Refer 2.3.3**) = 57000x f'ck 0.5
= 3362946 Psi
= 23.2 Gpa
Mean Concrete Modulus of Rupture, (S’C) - (Refer eqn. 7.54*) = 10 x f'ck 0.5
= 590.0 Psi
= 4.1 Mpa
Load Transfer Coefficient, (J) -(with a Load transfer device & Soft shoulder) -
= 3.2
(Refer 2.4.2**)
Drainage Coefficient, (Cd) - (*Refer Table 12.20 ) = 1.0
Design Serviceability Loss, (∆PSI) -(Refer 2.2.1**) = 2.0
Estimated Total Equivalent Single Axle Load (w18 flexible refer cl 13.5.3*) = 0.0337 msa
(w18 Rigid) = 1.5 x (w18 flexible)
= 0.05055 msa
Hence,
Design Total Equivalent Single Axle Load = 0.3 msa
Overall Standard Deviation, (S0) -(Refer 2.1.3**) = 0.35
Reliability, (R %) -(Refer table 2.2**) = 50% - 80%
= 80%
ZR = -0.841
From Eqn 12.21*

Calculated Slab thickness (D) = 134.6 mm

Slab thickness is taken as 150 mm

Refference
* Refer Pavement Analysis and Design- Yang H. Huang
** Refer AASHTO pavement design guide
Fig. 3.3-Estimating Composite Modulus of subgrade Reaction (K)
Figure 3.6. Loss of Support Correcttion for Composite Modulus of Subgrade Reaction (K) Value
 ANNEX 1B
KU4-92 Wathuwaththegama to Mudiyanegama via Kumbukkadawela Road - Ch 4+500- Ch 4+650 Km - Rigid Pavement Section
Design Calculations -Widening

Subgrade design CBR value for Widening section = 5%

Estimated sub grade Resilient Modulus (MR) - (Refer eqn. 7.6*) = 1500 x CBR%
= 7500 psi

Sub base thickness = 125 mm

(125mm DGAB layer) = 4.92 inch

Sub base Elastic Modulus (ESB) - (Refer 3.2.1 **) = 25000 psi

Composite Modulus of subgrade Reaction (K) = 420 pci

(Fig 3.3**-Assume full contact of foundation support)

Effective Modulus of Subgrade Reaction corrected for Loss of Support = 140 psi
(Fig 3.6**-Assume Loss of Support to be 1.0)

DATA

Compressive Strength of Concrete (cube) fcu = 30 Mpa

Compressive Strength of Concrete (cylinder) fck = 0.8 x fcu
= 24 Mpa
f'ck = 3480.89 Psi

Concrete Elastic Modulus, (Ec) -(Refer 2.3.3**) = 57000x f'ck 0.5

= 3362946 Psi
= 23.2 Gpa
Mean Concrete Modulus of Rupture, (S’C) - (Refer eqn. 7.54*) = 10 x f'ck 0.5
= 590.0 Psi
= 4.1 Mpa
Load Transfer Coefficient, (J) -(with a Load transfer device & Soft shoulder) -
= 3.2
(Refer 2.4.2**)
Drainage Coefficient, (Cd) - (*Refer Table 12.20 ) = 1.0
Design Serviceability Loss, (∆PSI) -(Refer 2.2.1**) = 2.0
Estimated Total Equivalent Single Axle Load (w18 flexible refer cl 13.5.3*) = 0.0337 msa
(w18 Rigid) = 1.5 x (w18 flexible)
= 0.05055 msa
Hence,
Design Total Equivalent Single Axle Load = 0.3 msa
Overall Standard Deviation, (S0) -(Refer 2.1.3**) = 0.35
Reliability, (R %) -(Refer table 2.2**) = 50% - 80%
= 80%
ZR = -0.841
From Eqn 12.21*

Calculated Design Slab thickness (D) = 134.6 mm

Slab thickness is taken as 150 mm

Refference
* Refer Pavement Analysis and Design- Yang H. Huang
** Refer AASHTO pavement design guide
Fig. 3.3-Estimating Composite Modulus of subgrade Reaction (K)
Figure 3.6 Loss of Support Correcttion for Composite Modulus of Subgrade Reaction (K) Value