Office of the Principal Jabalpur Engineering College, Jabalpur 482011 Jabalpur, Date [¢.12. 2021 No./CE/STR/RJ/2021/960 To, Manager (Civil) Food Corporation of India Regional Office Bhopal Sub : Design of Crust of Internal CC Road at FSD Balaghat Navegaon Ref: your letter No. Engg(CE)/4(932) 2019-20, Dated 12-10- 2020 With reference to the above cited subject, please find enclosed herewith the design of proposed CC Road at FSD Balaghat Navegaon. DESIGN OF CRUST OF INTERNAL CC Road at FSD Balaghat Navegaon As per IRC : SP:62-2014 Traffic Intensity intemal existing damaged WBM road. This road is at FSD Balaghat Navegaon The reported ‘The proposed CC roa traffic intensity of commercial Heavy vehicles is moderate. These roads will be designed for Traffic from 100 to 200 CVPD Wheel Load ‘The maximum legal load limit on single axle with dual wheels in India being 100 KN, the recommended design load on dual wheel is 50 KN having a spacing of the wheels as 310 mm centre-to-centre, ‘Tyre Pressure ‘The tyre pressure may be taken as 0.8 MPa for a truck carrying a dual wheel load of 50 KN while for a wheel of tractor trailer; the pressure may be taken as 0.5 MPa. The effect of tyre pressure on the wheel load stresses for practical thickness of pavement is not significant Design Period Concrete pavement designed will have a design life of 20 years. Design Traffic for Thickness Evaluation For traffic 100 to 200 CVPD, only wheel load stresses for a load of 50 KN on dual wheel need be considered for thickness estimation since there is a low probability of maximum wheel load and highest temperature differential between the top and the bottom of the rigid pavement occurring at the same time. of the Subgrade ium CBR of the subgrade shall be 2. Characteri ‘The miSub-Base ‘A good quality compacted foundation layer provided below a concrete pavement is commonly termed as subbase. It must be ‘of good quality so as not to undergo large settlement under repeated whee! load to prevent cracking of slabs, The provision of 1 sub-base below the concrete pavement has many advantages such as: i) Itprovides a uniform and reasonably firm support ii) It supports the construction traffic even if the subgrade is wet i) __Itprevents mud-pumping of subgrade of clays and silts iv) tacts as a levelling course on distorted, non-uniform and undulating subgrade ‘ ¥)- Ttacts as a capillary cut-off it is recommended that minimum 150 mm of borrowed material having CBR not <8% should be used as sub grade. Sub-base types Traffic from 150 to 450 CVPD 150 mm thick WBM I/WMM over 100 mm of granular subbase may also be used. Altemately, 100 mm of cementitious ‘granular layer with a minimum UCS of 3.0 MPa at 7 days with cement or at 28 days with lime or lime-flyash over 1 00 mm of cementious layer with naturally occurring material with a minimum UCS of 1.5 MPa at 7 days with cement or at 28 days with lime or lime-flyash, Cementitious marginal aggregates may be much cheaper than WBM/WMM in many regions having acute scarcity of aggregates. The granular subbase and WBM layers should meet the requirement of MORD Specifications, Section 400(34). Quality of subbases varies from region t region and past experience on performance of concrete pavements in different regions is tlie best guide for the selection of the most appropriate subbases. Concrete Strength Since concrete pavements fail due to bending stresses, it is necessary that their design is based on the flexural strength of ‘concrete. Where there are no facilities for determining the flexural strength, the mix design may be carried out using the ‘compressive strength values and the following relationship: te O.7V fx where, t = flexural strength, MPa Ja = characteristic compressive cube strength, MPa As per IRC:SP:62-2014, for Low volume roads, itis suggested that the 90 day strength may be used for design since concrete keeps on gaining strength with time. The 90 day flexural strength may be taken as 1.10 times the 28 day flexural strength. For pavement construction for rural roads, it is recommended that the characteristic 28 day compressive strength should be at least 30 MPa and corresponding flexural strength (third point loading) shall not be less than 3.8 MPa. ‘Modulus of Elasticity and Poisson's Ratio ‘The Modulus of Elasticity, E, of concrete and the Poisson's ratio may be taken as 30,000 MPa and 0.15 respectively. Coefficient of Thermal Expansion ‘The coefficient of thermal expansion of concrete, ct, may be taken as: = 10x 10° per °C CBR of Soil below Subgrade is found 8 % to 8.8% 1 anEffective CBR of Subgrade The road having earthen surface with CBR of 5-6%, will be proposed to provide earthwork of CBR equal to >8% of appropriate thickness, so that effective CBR should be > 8% . here itis required to make formation level at shoulder region if necessary. k value over granular sub base for effective CBR 8% = 59 MPa/m (150 t0 250 mm thick) (100 mm thick) Edge stresses Load stresses at edge © = [0.803 Ph] x [4log (Va) - 0.034) Where Ge = load stress in the edge region, MPa P= Single wheel Load, N ‘= pavement slab thickness, mm Ht = Poisson's ratio for concrete E= Modulus of elasticity for concrete, MPa k= Modulus of subgrade reaction of the pavement foundation, MPa/m. (= radius of relative stiffness, mm, a= radius of the equivalent circular area in mm 028 Where 7 = (enna -p) Kj a = (P/np)”* for single wheel load = { (0.8521Pa/pr)+(Sy/m)(Py/0.5227p)°5}°> for Dual wheel load Pavement Thickness for Traffic Greater than 150 CVPD For traffic greater than 150 CPD, fatigue also is to be considered and the thicknesses are shown in Table 4.3 of the code for M30 concrete for a traffic of 250 CVPD having a subgrade CBR of 8 percent. It has a cementitious base with a total thickness ‘0f 200 mm. Fatigue cracking of pavement slab is considered because of heavy traffic. Thicknesses forall six zones are given. s the highest thickness because of higher curling stresses, Zone 3 has highest temperature differential and hence it Note : Design thickness values are based on the 90 day flexural strength are computed in next sheets,Calculation Sheet for Crust Design Design of a Cement Concrete Pavement for Internal Road of Jabalpur ‘AS per IRC-SP-62 2014 Design Consideration : [ Design period 20 | years Design thickness for Traffic of CVPD 150 to 400 | cvPD. Design wheel load = P 50000 [ N Load of One wheel of Dual Wheel Set = Pd 25000 [ N Tyre Pressure of dual wheel = 0.8 | Mpa Tyre Pressure for single wheel of agricultural tractor 0.5 | Mpa CBR 8] % Poisson’ Ratio of Concrete (4) 0.15 Length of Joint spacing (L) = 4000 | mm Temperature Difference °C for 150 mm trial thickness 17.31% Temperature Difference °C for 180 mm trial thickness 18.32 | °c ‘Temperature Difference °C for 200 mm trial thickness 19 | ‘Temperature Difference °C for 250 mm trial thickness 203 | °c Coefficient of thermal Expansion a = 70"-5 Modulus of Elasticity of Concrete E = 3E+04 | Mpa K value for 100mm granular sub base Corresponding to CBR 42 | Mpa/m Spacing between the centre of dual wheel (S,) = ai an Effective k over 150mm/200mm granular subbase 50 | Mpa Effective k over 150mm/200mm Cementitious base 84 | Mpa 28 Day flexural strength of 30 MPa (Fy = 3.834 | Mpa 90 Day flexural strength = 4.22 | Mpa Trial thickness of slab (h) 150 | mm Radius of relative stiffness (I) = (Eh*/12(1-u™)k)*0.25 644.59 | mm Total stresses resulting from wheel load of 50 KN and temperature differential ul 6.21 Bradbury Coefficient for (L/I) From table C 0.94 Radius of the equivalent circular area for dual wheel in mm (a) = { (0.8521P4/pr}+(Sa/n)(Pe/0.5227p)*1/2}"(1/2) 180.6 mm Load stress at edge (Z.)= 0.803P/h[4Log((/a)+0.666(a/1)-0.034] 4.22 | wpa Temperature stresses at edge (Be) = [Eat/2xc = ee Total Stress (Ze+ite) = 6.66 | Mpa Design is Safe if total Stress <90 Day flexural strength 4.22 | Mpa UNSAFE Trial thickness of slab (h) = 180 | mm Radius of relative stiffness (I) = (Eh'/12(1-1)k)°0.25 739.04 | mm Total stresses resulting from wheel load of 50 kN and ¢2—234 temperature differential ul 5.41 Bradbury Coefficient for (Wl) From table C= = 08 Load stress at edge (£,)= 0.803P/h" [4Logii/a}+0.666(a/1)-0.034) 3.19 | Mpa Temperature stresses at edge (B,) = [Eai/axc > 2.20| Mpa Total Stress (Ze+3te) = i 5.39 | Mpa Design is Safe if total Stress <90 Day flexural svength 4.22 | Mpa UNSAFE Trial thickness of slab (h) = 200 mm for ‘Branular base 200 | mm. Radius of relative stiffness (I) = (Eh*/12(1-w")}Kj90.25, soant | aan Total stresses resulting from wheel load of SOkN and. temperature differential ul 5.00 Bradbury Coefficient for (L/I) From table C= 0.72 Load stress at edge (Z.) = 0.803P/h ‘{4Log(|/a)+0.666(a/1)-0.034) 2.71 | Mpa Temperature stresses at edge (&,.) = [Eat/2hxc = 2.05 | Mpa Total Stress (HevEte) = 4.76 | Mpa Design is Safe if total Stress < 90 Day flexural strength 4.22 | Mpa UNSAFE Trial thickness of slab (h) = 200 mm for cementitious base 200 | mm Radius of relative stiffness (I) = (Eh'/12(1-4")"0,25 702.52 | mm Total stresses resulting from wheel load of 50 KN and temperature differential vl 5.69 Bradbury Coefficient for (L/I) From table C= 0.858 Load stress at edge (Z.) = 0.803P/h’{4Log(l/a)+0.666(a/1)-0.034) 2.51 | Mpa Temperature stresses at edge (E.) = [Eat/2C = 2.45 | Mpa Total Stress (Ze+Ste) = 4.95 | Mpa Design is Safe if total Stress < 90 Day flexural strength 4.22 | Mpa UNSAFE Trial thickness of (h) = 250 mm for cementitious base 250 | mm Radius of relative stiffness (I) = (Eh'/12(1-4")K)"0.25, 830.50 | mm Total stresses resulting from wheel load of 50 KN and temperature differential VI 4.82 Bradbury Coefficient for (L/I) From table C= 0.67 Load stress at edge (£,) = 0.803P/h"[4Log(I/a)+0.666(a/1)-0.034] 1.68 | Mpa Temperature stresses at edge (Bu) = [Eat/2xC = 2.04 | Mpa Total Stress (Se+Ete) = 4.72 | Mpa Design is Safe if total Stress < 90 Day flexural strength 4.22 | Mpa UNSAFE Trial thickness of (h) = 300 mm for cementitious base 300 | mm[Radius of relative stiffness (i)= (eh 7iz(ay 1ky0.25 904.18 | mm | Total stresses resulting from wheel load of SO KN and : temperature differential fw 4.42 [ Bradbury Coefficient for ((/l) From table Cz 0.557 I Load stress at edge (2_) = 0.803P/h’ [aLog(i/a}+0.666(a/)-0.034) 1.42 | Mpa [Temperature stresses at edge (&.) = [Eai/apc > 1.70 | Mpa [Total Stress (Ze+Ete) = 3.11 | Mpa | Design is Safe if total Stress < 90 Day flexural strength 4.22 | Mpa l Hence SAFE Recommended Pavement Crust Thickness for Traffe 150 to 200 cvpp. ~ 1. PQC eS ‘M30 grade 2. Width of concrete Road fe . 9.00 m 3. Longitudinal joint at (Tie Bar are Provided ) - 4.50 m 4. Width of concrete panel = 4.50 m 5. Thickness of PQC over Cementitious base - 300 mm 6. Thickness of Cementitious Base over GSB - 100mm 7. Thickness of GSB Grading IIt a 200 mm 8. Thickness of subgrade with selected soil CBR equal’> 8% - 150 mm as for 9. Joint spacing - 4.00 m max 10, Dowel bar 36 mm dia of 450 mm long, @ 300 mm c/c at 32,0 m intervals Jabalpur Engineering College Jabalpur Oe \ 4 Principal (OD) pee ae Civil Engineering Jabalpur Engineering Cite Jabalpur Engineering College Jabalpur area Jabalpur Engineering College Jabalpur (M.P.)