Expressway

J oint Seminar J oint Seminar
on
E G id li Expressway Guidelines
Expressways
The Next Leap
With 18,000 km Network
C.Kandasamy
M RT&H MoRT&H
Understanding &Dissemination Understanding & Dissemination
of
Guidelines for Expressways
for smooth implementation for smooth implementation
(under - PPP) (under PPP)
Background
1. By MoRTH in 2002 under R-69
Expressway Design Standards in India
2 By MoRTH Technical Committee in 2008-10 2. By MoRTH Technical Committee in 2008 10
Geometric Design Standards
M l Manual
[& further thro IRC Committees]
3. With J ICA Technical Co-operation
Detailed Guidelines [ Mr Tanaka with Detailed Guidelines [ Mr Tanaka with
Consultant Mr De - CES]
Training Component [Mr Dachiku] Training Component [Mr Dachiku]
What is newin Expressways What is new in Expressways
Alignment on Greenfield g
Fully Access Controlled
Logo &Route Marker Logo & Route Marker
Design Speed (kmph);120 (Ruling in Plain &
Rolling) and 60 (Min. in Mountainous) Rolling) and 60 (Min. in Mountainous)
Decision Sight Distance [for 120kmph, 265m
Stopping &360mSpeed/Path/Direction Change Stopping & 360m Speed/Path/Direction Change
Clothoid Transition Curve
ROW90 m(Plain &Rolling); 60 / 30 in ROW 90 m (Plain & Rolling); 60 / 30 in
Mountainous (Same / Split level)
What is newin Expressways (Cont) What is new in Expressways (Cont)
Lane Width 3.75 m / 3.5 m for Plain or Rolling /
Mountainous Mountainous
Climbing Lane of 3.5 m on the shoulder side
3 P d Sh ld t id f 3 m Paved Shoulder on outer side for
emergency usage [Median side PS of 1.75m for
Split level consideration] Split level consideration]
Min. 1.5 m verge on outer side
Ed St i 0 5 t id d 0 75 Edge Strip 0.5m on outer side and 0.75 on
median side
M di idth 12 ( ith t b i ) Mi 4 5 Median width 12 m (without barrier) ; Min. 4.5 m
with barrier
What is newin Expressways What is new in Expressways (Cont)
C di ti f H &V t li t Co-ordination of Hor. & Vert. alignment
Closed Tolling with Trumpet Interchange g p g
Service / System Interchanges
Wayside Facilities commercialization Wayside Facilities commercialization
Porous Asphalt for Wet Weather Skid
Resistance
Day / Night Visibility y g y
Min. 3.5 m high Embankment
1:4 or flatter emb. slope preferred without
safety barriers; else barriers for > 0.6m y ;
emb.
Irrespective of height or slope safety Irrespective of height or slope, safety
barriers on approaches to bridges on all 4
f 1 0 sides for minimum 150 m each; on outer
side of Hor Curves (in transition & Curve (
portion); close to hazardous location /
objects objects
Lateral Clearance at underpasses : Full
roadway width at approaches with min. y pp
10.5 m / 4m for Vehicular / Pedestrian
Vertical Clearance at underpasses : 5 0 m Vertical Clearance at underpasses : 5.0 m
/ 3.0 - 4.5 m for Vehicular / Pedestrian
Outline of Guidelines for Expressways
Under the J ICA Technical Cooperation
M TANAKA (J ICA E ) Mamoru TANAKA (J ICA Expert)

Overview of New JICA
The Worlds Largest Bilateral Aid Agency
J ICA merged with J BIC (J apan Bank for
International Cooperation) on 1 October 2008 International Cooperation) on 1 October, 2008.
New J ICA provides comprehensive assistance New J ICA provides comprehensive assistance
for developing countries by three major
assistance tools; technical cooperation ODA assistance tools; technical cooperation, ODA
loans and grant aid.
India is the largest recipient country of J apanese
ODA Loans since 2004 in terms of annual ODA Loans since 2004 in terms of annual
commitment. ($2.6 billion in FY2008)
JICA Technical Cooperation Project
1 P j t P
Capacity Development Project on Sustainable Development of Expressways
1. Project Purpose
Technical AssistancetoUnionMinistry of RoadTransport and
Highways for Expressway Development under National Highways for Expressway Development under National
HighwaysDevelopment Program(NHDP) PhaseVI .
2 Main Activities 2. Main Activities
Preparereferenceguidelinesfor expresswayengineers
Establishor improvetrainingcoursesonexpressways Establishor improvetrainingcoursesonexpressways
3. Project Period
35 (f J 2007 J 2011) 3.5years(fromJ une2007toJ anuary2011)
Dispatch of eight J apanese Experts in this field Dispatch of eight J apanese Experts in this field
Training in J apan participated by nine officials from MoRTH
JICA Expert Team
This document was produced with inputs and contribution from the following
teamof J ICA experts fromJ apan with assistance fromConsulting Engineering p p g g g
Services (India) Private Limited (CES), Consultant engaged by J ICA .
1) Mr Mamoru TANAKA (TeamLeader) 1) Mr. Mamoru TANAKA (TeamLeader)
: J ICA long-termExpert for Expressway Development
2) Mr. Kiyoshi DACHIKU
: J ICA long termExpert for Training Expressway Engineers : J ICA long-termExpert for Training Expressway Engineers
3) Mr. Takehiko TSUJ I : J ICA short-termExpert for Road Safety
4) Mr Takeshi MATSUSHITA J ICA short termE pert for Traffic Control 4) Mr. Takeshi MATSUSHITA : J ICA short-termExpert for Traffic Control
5) Mr. Mitsuyoshi FUSE : J ICA short-termExpert for Service Area Management
6) Mr. Takahiro YANO : J ICA short-termExpert for Toll Plaza Operation
7) Mr. J un TAKEUCHI : J ICA short-termExpert for Expressway Maintenance
8) Mr. Kiyoshi OGAWA : J ICA short-termExpert for Tunnel
9) Mr. D.C.DE : Consulting EngineeringServices (India) Pvt. Ltd. (CES)
Member of Technical Committee in MoRTH
as on 28th February 2010
1. Mr. Nirmal J it Singh, DG(RD)&SS
as o 8t eb ua y 0 0
g ( )
2. Mr. A.V.Sinha, ADG-I
3. Mr. S.K.Puri, ADG-II 3. Mr. S.K.Puri, ADG II
4. Mr. C.Kandasamy, CE(R)SR&T
5 Mr A N Dhodapkar CE(P&M) 5. Mr. A.N.Dhodapkar, CE(P&M)
6. Mr. A.K.Sharma, CE(B)SR&T
7 Mr S K Marwah CE(P 1) 7. Mr. S.K.Marwah, CE(P-1)
8. Mr. V.L.Patankar, Member (Tech) NHAI
C 9. Mr. Chaman Lal, Director, NITHE
10. Mr.S.K.Verma, SE(R)SR&T
11. Mr.Mamoru TANAKA, J ICA Expert
Government of India is proposing to develop a National Expressway
Why is this Guideline?
Government of India is proposing to develop a National Expressway
Network dedicated to provide a safe road infrastructure to world
standards, providing high-speed transportation facilities servicing
t j iti i d t i l/ i lt l t d j k t ports, major cities, industrial/agricultural centers and major markets
catalyising significant economic growth.
Construction of fully access controlled expressways for 1000 kmunder
National Highways Development Program(NHDP) Phase VI are about
to be launched.
In addition to the above, National Expressway Network Plan of about
18 000 kmfor completion upto the year 2022 has been accepted by the 18,000 kmfor completion upto the year 2022 has been accepted by the
Government.
Responsibility for providing safe reliable and convenient road network Responsibility for providing safe, reliable and convenient road network
primarily rests with the Government. It is, therefore, essential that
appropriate Guidelines are laid down for the development of
E i d i i ti f t f t Expressways covering good engineering practices, safety features
and amenities for the users.
Expressway Development in India
India (from NHAI Web) J apan (2008 d ( ) J p (
Expressways 200km 7,641km
(0.2% of NH) (14% of NH)
National Highways 70,548km 54,736km
State Highways and Major
Di t i t R d
599,662km 129,393km
District Roads
Rural and other Roads 2,650,000km 1,012,088km
Total 3,320,000km 1,203,858km
Progress of Expressway Development in India (1)
Completed Project
2002: Mumbai-Pune Expressway (93 km) was open
2003 Ah d b d V d d E (Ph 1 43 k ) 2003: Ahmedabad-Vadodara Expressway (Phase-1 : 43 km) was open
2004: Ahmedabad-Vadodara Expressway (Phase-2 : 50 km) was open p y ( ) p
A comprehensive Design
Standards for Expressways Standards for Expressways
became necessary
R-69 RESEARCH SCHEME MoRTH : Guidelines for Expressway
Design Standards was prepared in 2002 based on review of design
t d d i d l d d d l i t i lik USA UK standards in developed and developing countries like USA, UK,
Germany, J apan, Australia, Canada, Malaysia, and Indonesia
Progress of Expressway Development in India (2)
Ongoing Project
2003: KMP Expressway Project started
2003: Yamuna Expressway Project started
2007: Ganga Expressway Project started
2010: NHDP VI (1000kmExpressway) will start
Bangalore-Chennai (334km)
V d d M b i (400k ) Vadodara- Mumbai (400km)
Delhi-Meerut (66km)
Kolkata-Dhanbad (277km) Kolkata Dhanbad (277km)
Master Plan for National Expressway Network (1)
In 2009 the MoRTH had awarded a Consultancy Services for
Formulation of a Master Plan for the National Expressway Network in
the country. The Final Report submitted by the Consultants, duly
considering the views / observations received from the State
Governments and inter alia recommending total Expressway Network Governments and inter-alia recommending total Expressway Network
of 18,637 km for completion in prioritized manner in three phases
spanning upto the year 2022, has been accepted by the Government. spa g upto t e yea 0 , as bee accepted by t e Go e e t
(The detailed programme of implementation including funding
arrangements for the programme has not yet been finalized.)
These high-speed, access-controlled expressways will be of the four-
lane and six lane facilities with 3 530 km to come up in the next three lane and six-lane facilities with 3,530 km to come up in the next three
years (2009-2012)
For further information: http://morth.nic.in/index2.asp?langid=2&sublinkid=455
Master Plan for National Expressway Network (2)
Comprehensive, international standard
Guidelines for Expressways to assist the
designers with the requirements of the various g q
design elements for standardization of the
expressway network is required.
Contents of Guidelines
V l 1 Pl i Volume-1 : Planning
Volume-2 : Design
Volume-3 : Operations and Management
Volume-4 : Maintenance Volume 4 : Maintenance
VOLUME I: PLANNING
Chapter 1 - Survey, Investigations and Preparation of the project p y, g p p j
Chapter 2 - Route Planning
Chapter 3 - Economic and Financial Viability Analysis
Chapter 4 - Expressway Capacity Chapter 4 - Expressway Capacity
VOLUME II: Design
Chapter 1 - Geometric Design
Chapter 8 - Safety Barriers
g
Chapter 2 - Interchange Design
Chapter 3 - Embankment and
p y
Chapter 9 - Traffic Signs and
Pavement Markings
p
Cutting
Chapter 4 - Pavement Design
Pavement Markings
Chapter 10 - Toll Plaza Design
Chapter 11 - Service Areas
Chapter 5 - Design of Structures
Chapter 6 Tunnels
Chapter 12 - Pick-up Bus Stops
Chapter 13 Lighting
Chapter 6 - Tunnels
Chapter 7 - Drainage and Erosion
P t ti
Chapter 13 - Lighting
Chapter 14 - Noise Barriers
Protection
VOLUME III: OPERATIONS AND MANAGEMENT VOLUME III: OPERATIONS AND MANAGEMENT
Ch t 1 T ll Pl O ti Chapter 1 - Toll Plaza Operation
Chapter 2 - Traffic Management
Chapter 3 - Service Area Management
VOLUME IV: Maintenance
Chapter 1 General Chapter 1 - General
Chapter 2 - Maintenance Management
Chapter 3 - Inspection
Chapter 4 - Maintenance Works and Repair
Chapter 5 - Maintenance Operations
Chapter 6 - New Maintenance Practices Chapter 6 - New Maintenance Practices
Chapter 7 - Preventive Maintenance
Chapter 8 - Disaster Prevention
1 G Fi ld j t (N Ali t)
Key Features of Expressways in this Guidelines
1. Green Field project (New Alignment)
2 High Speed Design with safety measures (120km/h) 2. High Speed Design with safety measures (120km/h)
3 Fully Access control 3. Fully Access control
Entry/Exit only through interchanges
Only fast Vehicles are allowed Only fast Vehicles are allowed
(two & three wheelers may not be allowed)
High embankments to accommodate all cross traffic g e ba e ts to acco odate a c oss t a c
4. Closed System Toll Collection y
5. Service Area (Wayside Amenities)
6. Advanced Operation and Maintenance (including ETC/ITS)
New IRC Publication: Guidelines for Expressways
Mi i t f R d T t d Hi h h Ministry of Road Transport and Highways has
prepared Guidelines of Expressways through a
technical cooperation from Japan International
Cooperation Agency (JICA).
The Guidelines highlight appropriate design The Guidelines highlight appropriate design
principles for promoting safety conscious design
and will go a long way in guiding the highway
engineers and planners to make our expressway
more safe, comfortable and of international
standards.
Guidelines have been structured in four (4) volumes:
Volume I: Planning
Volume II: Design
V l III O ti d M t Volume III: Operations and Management
Volume IV: Maintenance
The intended users of this guideline will be the
transportation professionals / engineers that
participate in or are responsible for any phase in the
project preparation of the Expressway Project. This
includes all public or private practitioners (e.g.
managers, supervisors, engineers, planners, or
technicians) that are involved with any issue or technicians) that are involved with any issue or
decision (e.g. legislation, policy, program, funding,
operation & management and maintenance scenario)
that may directly or indirectly influence the
performance of an Expressway facility.
C i f h bli i b b i d f h S G l di d
The set of Guidelines is available from IRC as a
priced publication.
Copies of the publications may be obtained fromthe Secretary General, Indian Roads
Congress, J amnagar House, ShahjahanRoad, NewDelhi-110011against payment.
Phone: 011-23386724, 23387759E-mail:sale@irc.org.in, Fax:011-23391649.
Recent Development Recent Development
on Expressways in India on Expressways in India
New Training New Training
Governmenthasformulatedplansfordevelopmentofan Governmenthasformulatedplansfordevelopmentofan
extensiveexpresswaynetwork,whichwillspanalengthof extensiveexpresswaynetwork,whichwillspanalengthof
18,000kmby2022. 18,000kmby2022.
Programmes on Programmes on
Expressways Expressways
MinistryofRoadTransportandHighwayshasprepared MinistryofRoadTransportandHighwayshasprepared
GuidelinesforExpressways,whichhighlightappropriate GuidelinesforExpressways,whichhighlightappropriate
designprinciplesforpromotingsafetyconsciousdesign. designprinciplesforpromotingsafetyconsciousdesign.
p y p y
g p p p g y g g p p p g y g
TypesofTrainingProgrammes
RegularTrainingProgrammes
TrainingProgrammesInclude
E l ti ofGuidelines RegularTrainingProgrammes
CustomisedTrainingProgrammes
Dispatchexpertstoyourworkshop*
Organiseinternational trainings(Ex Japan*)
ExplanationofGuidelines
Backgroundinformation
LecturesonModernExpressway
Practices
National InstituteforTrainingofHighwayEngineers(NITHE)
Organiseinternationaltrainings(Ex.Japan*)
*NewProgrammes
Practices
NationalInstituteforTrainingofHighwayEngineers(NITHE)
(MinistryofRoadTransportandHighways)
A5,InstitutionalArea,Sector62,NH$Bypass,Noida201301(UP)
Tel:01202400085/86,2405006/7/8/9,Fax:2400087(95120fromDelhi)
Email:info@nithe.org/nithe@bol.net.inwww.nithe.org
Contact Point
MAMORU TANAKA
J ICA Expert for Expressway Development
(Deputation from Ministry of Land, Infrastructure,
Transport and Tourism, Government of J APAN)
E-mail: nmtanaka@gmail.com
Mobile:+91 98181 70708 Mobile:+91-98181-70708
KIYOSHI DACHIKU
J ICA Expert for Expressway Training
(Deputation from East Nippon Expressway Company)
E mail ki oshi dachik @ ahoo co jp E-mail: kiyoshi_dachiku@yahoo.co.jp
Mobile:+91-98103-50931
Ministry of Road Transport & Highways
Guidelines for Expressways p y
Volume-I : Planning
Volume-II : Design
February 2010 y
Indian Roads Congress
Published by:
On behalf of the Government of India,
New Delhi
Guidelines for Expressways p y
Volume-III : Operations and Management
Volume-IV : Maintenance
February 2010 y
Indian Roads Congress
Published by:
On behalf of the Government of India,
New Delhi

F O R E W O R D

Government of India is proposing to develop a National Expressway Network dedicated to provide a
safe road infrastructure to world standards, providing high-speed transportation facilities servicing
ports, major cities, industrial/agricultural centers and major markets catalyising significant economic
growth. Construction of fully access controlled expressways for 1000 km under National Highways
Development Program (NHDP) Phase VI are about to be launched.

Responsibility for providing safe, reliable and convenient road network primarily rests with the
Government. It is, therefore, essential that appropriate Guidelines are laid down for the development of
Expressways covering good engineering practices, safety features and amenities for the users.

Ministry took up the preparation of the Guidelines for Expressways through technical cooperation with
Japan International Cooperation Agency (JICA), and finalized it through a Technical Committee
comprising of the following Officers :

1 Shri Nirmal Jit Singh, Director General (Road Development) and Special
Secretary, MoRTH
- Chairman
2 Shri A.V.Sinha, Additional Director General I, MoRTH - Member
3 Shri S.K.Puri, Additional Director General II, MoRTH - Member
4 Shri C.Kandasamy, Chief Engineer (Roads) Standards, Research &
Technology, MoRTH
- Member
5 Shri A.N.Dhodapkar, Chief Engineer (Planning and Monitoring), MoRTH - Member
6 Shri A.K.Sharma, Chief Engineer (Bridges Standards, Research &
Technology), MoRTH
- Member
7 Shri S.K.Marwah, Chief Engineer (Project-I), MoRTH - Member
8 Shri V.L.Patankar Member (Technical), National Highways Authority of India - Member
9 Shri Chaman Lal, Director, National Institute for Training of Highway
Engineers
- Member
10 Shri S.K.Verma, Superintending Engineer (Roads) Standards, Research &
Technology, MoRTH
- Member
11 Shri Mamoru TANAKA, JICA Expert - Member

The Guidelines for Expressways as prepared highlights appropriate design principles for promoting
safe design and will go a long way in guiding the highway engineers and planners to make our
expressways safer, comfortable and to international standards.

The Guidelines have been structured in four (4) volumes:
Volume I: Planning
Volume II: Design
Volume III: Operations and Management
Volume IV: Maintenance

The intended users of this Guideline will be the highway engineers who participate in or are
responsible for any phase of the Expressway, be it Planning, Design, Operations and Management, or
Maintenance. Both public and private practitioners (e.g. managers, supervisors, engineers, planners,
or technicians) addressing any issue or involved with any decision (e.g. legislation, policy, program,
funding, operation & management and maintenance scenario) directly or indirectly influencing the
performance of the Expressway facility, will be benefited by this Guideline.

In the Planning, Design, Operations and Management, or Maintenance, of the Expressways, the
Highway Engineer strives to develop and improve within the limits of the given constraints while
adapting to the changing expectations of the users / developments in technology, to ensure a high
level of safety, efficiency and travelling comfort to the users of the facility. Therefore, the intent of this
Guidelines is to remain dynamic in nature, and the users based on their experience, are encouraged
to give their feedback so as to impove the Guidelines from time to time.

(Nirmal Jit Singh)
Director General (Road Development) and Special Secretary
Ministry of Road Transport and Highways
Dated February, 2010

A C K N O W L E D G E M E N T

The Guidelines for Expressways was prepared under Japan International Cooperation Agency (JICA)
Technical Cooperation Project for Capacity Development on Sustainable Development of Expressways.
for the Ministry of Road Transport & Highways (MoRTH). This document was produced with inputs and
contribution from the following team of JICA experts from Japan with assistance from Consulting
Engineering Services (India) Private Limited (CES), Consultant engaged by JICA.

Mr. Mamoru TANAKA (Team Leader) : JICA long-term Expert for Expressway Development
Mr. Kiyoshi DACHIKU : JICA long-term Expert for Training Expressway Engineers
Mr. Takehiko TSUJI : JICA short-term Expert for Road Safety
Mr. Takeshi MATSUSHITA : JICA short-term Expert for Traffic Control
Mr. Mitsuyoshi FUSE : JICA short-term Expert for Service Area Management
Mr. Takahiro YANO : JICA short-term Expert for Toll Plaza Operation
Mr. Jun TAKEUCHI : JICA short-term Expert for Expressway Maintenance
Mr. Kiyoshi OGAWA : JICA short-term Expert for Tunnel
Mr. D.C.DE : Consulting Engineering Services (India) Pvt. Ltd. (CES)

MoRTH expresses its gratitude to the JICA team, the Members of the Technical Committee indicated in
the Foreword, Mr. Kishor Chandwani, Mr Richhpal Singh and other Officers of the MoRTH who took
great pains and contributed immensely with their suggestions for the preparation of this Guideline.

The contributions of Mr D P Gupta, Director General (Retired), MoRTH, in editing the Guidelines
and Mr R. P. Indoria, Secretary General, IRC, and his team of Officers in IRC for bringing out this
publication is gratefully appreciated and acknowledged.

(Nirmal Jit Singh)
Director General (Road Development) and Special Secretary
Ministry of Road Transport and Highways
Dated February, 2010

VOLUME I
PLANNING
Sheet 1 of 2
VOLUME I : PLANNING

EXECUTIVE SUMMARY

INTRODUCTION

The Document Volume-I: Planning, is complementary to other guideline volumes.
The objective of this document is to assist the expressway professionals/engineers with the basic
requirements in project preparation for the identified sections of National Expressway Network.

IRC: SP: 19-2001 Manual for Survey, Investigations and Preparation of Road Project may be
treated as a base document along with its limitations for use under the present context. This
Volume-I: Planning document intends to provide comprehensive information on project preparation
under commercial format (PPP BOT, BOOT, DBFO etc.)

The contents of this document are necessarily a compilation on illustrative requirements which are
generally not covered comprehensively by the available documents/practices.

This document has been structured into 4 (four) chapters as follows:

Chapter 1 : Survey, Investigation and Preparation of the Project
Chapter 2 : Route Planning
Chapter 3 : Economic and Financial Viability Analysis
Chapter 4 : Expressway Capacity

Chapter 1 : Survey, Investigations and Preparation of the Project

This chapter provides broad stages in project preparation involving basic data assembly, socio
economic profile, environmental impact study and resettlement & rehabilitation action plan and soil
material investigations.

Stages in project preparation inter-alia include knowledge of legislative policies and various
requirements such as PPPAC for implementation under Public Private Partnership (PPP). For
details the user may refer to www.pppindia.com and www.infrastructure.gov.in. Demographics,
current transportation scenario along with regional development have been broadly discussed in
socio economic section.

The requirements on basic data assembly inter-alia provide (a) information on use of satellite
imageries for alignment identification; (b) Global Positioning System (GPS); and (c) Geographic
Information System (GIS).

Environmental impact study and resettlement & rehabilitation action plan is based on current
practices and are subject to modification conforming to future developments.

Soil material investigation section covers broadly the aspect on collection of data on material
availability, geotechnical & sub-soil exploration and the hydraulic & hydrological studies.

Sheet 2 of 2

This chapter documents expressway alignment selection process considering engineering,
economic, social, ecology and aesthetics aspects.

Evaluation of alternative alignments has been based on (i) social economic and environmental
criteria; and (ii) engineering (operational) aspects including costs. Individual ranking matrices has
been developed for evaluation. A simultaneous use, appreciation and considerations of the
ranking developed in the above matrices will help in deciding selection of final alignment. This may
not be least cost one.


For implementation under BOT DBFO format, financial analysis is of prime consideration. Toll
rates play a significant role. The toll rates and link wise estimation of traffic as available from
National Expressway Network study will form the basis. However, for individual project segments,
it would be prudent to consider toll elasticity analysis, diversion-ratio curve analysis and possible
business development at road side facilities for possible traffic - toll rate estimation. The aspect
of business development at road side has been included in Volume-III: Operations and
Management.

The current practice on financial analysis has been explained along with considerations for
sensitivity analysis. Apart from financial analysis, it is desirable to undertake economic analysis of
the Expressway projects as these will contribute to overall growth of the influence area and the
economy of the region as well as the country.


On this aspect Highway Capacity Manual (HCM) 2000 is the document considered to be
authentic. However, highway capacity analysis is a complex procedure involving generation of
diverse data requirements for individual project segments.

The capacity analysis is primarily required for (a) expressway segment between interchanges
and; (b) at entry and exit ramps junctions. In absence of any Indian data, as an interim measure,
the following have been presented for planning purposes.

For capacity analysis of expressway segments between interchanges, a user friendly method has
been illustrated considering the default values given in HCM-2000 and subjective adoption of the
necessary parameters. With the foregoing preamble, a Table has been generated for use by the
designer and deals with 2x2 lane and 2x3 lane configuration using the cross-sectional elements
and geometric criterion presented in Volume-II: Design.

For capacity analysis at the junction of entry and exit ramps, the HCM procedure appears to be too
complex and require a lot of subjective data adoption. The simplified procedure as developed and
practiced in Japan has been adopted and included in this chapter.

CONTENTS

CHAPTER 1: SURVEY, INVESTIGATIONS AND PREPARATION OF THE PROJECT

1.1 Introduction
1.2 Stages in Project Preparation

1.2.1 Context of IRC: SP:19-2001 for BOT/DBFOT projects
1.2.2 Legislative Policies
1.2.3 Considerations for Public Private Partnership (PPP)
1.2.3.1 Viability Gap Funding (VGF) Scheme
1.2.3.2 PPPAC Requirements
1.3 Socio-Economic Profile

1.3.1 General
1.3.2 Demographics
1.3.3 Current Transport Conditions
1.3.4 Other Important Considerations
1.4 Basic Data Assembly

1.4.1 Introduction
1.4.2 Methods for Reconnaissance Survey
1.4.3 Survey of India (SOI) Maps
1.4.4 Aerial Photography
1.4.5 Photogrammetry Support
1.4.6 Satellite Remote Sensing and Allied Activities
1.4.7 Small Format Aerial Photography (SFAP)
1.4.8 Geographic Information System (GIS)
1.4.9 Global Positioning System (GPS)

1.5 Environmental Impact Study and Resettlement & Rehabilitation Action Plan

1.5.1 General
1.5.2 Environmental & Social Analysis
1.5.3 Environmental Design
1.5.4 Environmental Management Action Plan
1.5.5 Resettlement and Rehabilitation Action Plan (RAP)

1.6 Soil and Material Investigation

1.6.1 Study of Available Information
1.6.2 Soil Investigations for Embankments
1.6.3 Soil and Material Investigation
1.6.4 Geotechnical Investigations and Sub-Soil Exploration
1.6.5 Hydraulic and Hydrological Investigations

CHAPTER 2: ROUTE PLANNING

2.1 Routing of Expressway
2.2 Considerations in Expressway Alignment Selection
2.3 Selection of Alternative Alignments
2.3.1 Evaluation of Alternative Alignments

CHAPTER 3: ECONOMIC AND FINANCIAL VIABILITY ANALYSIS

A. FINANCIAL ANALYSIS
3.1 Introduction
3.1.1 Contextual Appraisal
3.1.2 Link to Overall Economy
3.1.3 Quality of Work Required
3.1.4 Importance of Traffic Forecasts

3.2 Appraisal Methodology
3.2.1 Assumptions
3.2.2 Overview of the Financial Analysis Process

B. ECONOMIC ANALYSIS
3.3 Introduction
3.3.1 Overall Context Appraisal
3.3.2 Traffic Demand Analysis and Forecasting

3.4 Methodology for Economic Analysis
3.4.1 Inputs for Economic Appraisal
3.4.2 Identification, Quantification and Valuation of Key Economic
Costs and Benefits
3.4.3 Determining Economic Costs
3.4.4 Determining Economic Benefits
3.4.5 Economic Viability: Procedures for Evaluation
3.4.6 Environmental Impact in Economic Analysis
3.4.7 Identification of Non-Quantifiable Benefits or Secondary Benefits
3.5 Stepwise Approach for Economic Appraisal

CHAPTER 4: EXPRESSWAY CAPACITY

4.1 Introduction

4.2 Capacity Analysis

4.2.1 Indian Scenario
4.2.2 Expressway Capacity Terminology
4.2.3 Flow Characteristics
4.2.4 Factors Affecting Free Flow Speed (FFS)
4.2.5 Expressway Capacity Calculation
4.2.6 Level of Service of the Expressway
4.2.7 Example: Assessment of Service Volume for Basic Expressway
Segment (Illustrative only)

4.3 Interchange Capacity Analysis

4.3.1 Design Capacity of Rampway
4.3.2 Ramp J unction Capacity

GUIDELINES FOR EXPRESSWAYS
PRESENTATION BY
D C DE
Consulting Engineering Services (India) Private Limited
(Consultant engaged by JICA) ( g g y )
Contributors to Guidelines
The following team of JICA experts with assistance from The following team of JICA experts with assistance from
CES (I) Pvt. Ltd., Consultant engaged by JICA.
Mr. Mamoru TANAKA (Team Leader)
JICA long-term Expert for Expressway Development
Mr. Kiyoshi DACHIKU
JICA long-term Expert for Training Expressway Engineers g p g p y g
Mr. Takehiko TSUJI
JICA short-term Expert for Road Safety
Mr. Takeshi MATSUSHITA Mr. Takeshi MATSUSHITA
JICA short-term Expert for Traffic Control
Mr. Mitsuyoshi FUSE
JICA short-term Expert for Service Area Management JICA short term Expert for Service Area Management
Mr. Takahiro YANO
JICA short-term Expert for Toll Plaza Operation
Mr Jun TAKEUCHI Mr. Jun TAKEUCHI
JICA short-term Expert for Expressway Maintenance
Mr. Kiyoshi OGAWA
JICA short term Expert for Tunnel JICA short-term Expert for Tunnel
Mr. D C DE
Consulting Engineering Services (India) Pvt. Ltd.
R 69 RESEARCH SCHEME MoRTH : Guidelines for Expressway R-69 RESEARCH SCHEME MoRTH : Guidelines for Expressway
Design Standards was prepared in 2002
Based on review of design standards in developed and developing
countries like USA, UK, Germany, Japan, Australia, Canada,
Malaysia, and Indonesia a six volume INTERIM REPORT
presenting the salient practices was prepared.
Final Reports (Four Volumes) contained Expressway Planning;
Design; Facilities Provision and Environmental issues; g ; ;
Expressway Operation, Management and Maintenance.
This document was mainly based on the information available till This document was mainly based on the information available till
1998 in various published literatures.
For the present the document required updating.
WHY IS THIS GUIDELINE
The Government of India has drawn up a target to lay 18,637 km network
of new expressways by 2022 These high-speed access-controlled of new expressways by 2022. These high speed, access controlled
expressways will be of the four-lane and six-lane facilities with 3,530 km
to come up in the next three years (2009-2012).
These Expressways Network will be developed as Greenfield projects
d d i bl b b ilt hi h b k t t d t ll and are desirably be built on high embankments to accommodate all
cross traffic.
Appreciating the need for development of Expressways Network (since
road transport would remain the mainstay for sustaining the economic y g
momentumof the country) the MoRTH prepared a master plan.
Contd
WHY IS THIS GUIDELINE
The Master Plan document (2009) has also phased the expressway
development programme for 2012 2017 and 2022 and this has been development programme for 2012, 2017 and 2022 and this has been
done on the basis of financial viability, relative traffic intensity along
various corridor segments, network comprehensiveness, connectivity
t d l ti i t ti l warrants and relative economic potential.
This set target required the development of a comprehensive, g q p p ,
international standard Guidelines for Expressways to assist the
designers with the requirements of the various design elements for
standardization of the NETWORK standardization of the NETWORK.
GUIDELINES FOR EXPRESSWAYS GUIDELINES FOR EXPRESSWAYS
CONTENTS CONTENTS
VOLUME I: PLANNING
Chapter 1 - Survey, Investigations and Preparation of the project
VOLUME I: PLANNING
p y, g p p j
Chapter 2 - Route Planning
Chapter 3 - Economic and Financial Viability Analysis
Chapter 4 - Expressway Capacity Chapter 4 - Expressway Capacity
These four volumes of Guidelines for Expressways will be
published by the Indian Roads Congress (IRC) on behalf of the published by the Indian Roads Congress (IRC) on behalf of the
Ministry of Road Transport and Highways (MoRTH) in two parts.
One part will contain
Volume-1 : Planning o u e a g
Volume-2 : Design
Other part will contain
Volume-3 : Operations and Management g
Volume-4 : Maintenance
Volume-I : Planning
Volume-I : Planning
Volume I : Planning
Volume-II : Design
Volume I : Planning
1
Volume-I : Planningg
Volume-I: Planning, is complementary to other volumes of the
guideline. The objective of this document is to assist the
expressway professionals/engineers with the basic requirements in
j t ti f th id tifi d ti f N ti l project preparation for the identified sections of National
Expressway Network .
IRC: SP: 19-2001 Manual for Survey, Investigations and
Preparation of Road Project along with guideline issued by the j g g y
various authorities shall be treated as a base document along with
due regard to limitations for use in National Expressway Network
j t Thi d t i t d t id h i projects. This document intends to provide comprehensive
information on project preparation under commercial format (PPP
BOT BOOT DBFO DBFOT etc ) BOT, BOOT, DBFO, DBFOT, etc.)
2 April 2010
This chapter provides broad stages in project preparation involving
basic data assembly socio economic profile environmental impact basic data assembly, socio economic profile, environmental impact
study and resettlement & rehabilitation action plan and soil material
investigations. Stages in project preparation inter-alia include
knowledge of legislative policies and various requirements such as
PPPAC for implementation under Public Private Partnership (PPP).
For details the user may refer to www.pppindia.com and For details the user may refer to www.pppindia.com and
www.infrastructure.gov.in.
D hi t t t ti i l ith i l Demographics, current transportation scenario along with regional
development have been broadly discussed in socio economic
section. sect o
3 April 2010 Contd
The requirements on basic data assembly comprise (a) information
on use of satellite imageries for alignment identification; (b) Global
Positioning System (GPS); and (c) Geographic Information System
(GIS).
Environmental impact study and resettlement & rehabilitation
action plan shall be based on current practices and are subject to
difi ti f i t f t di ti modifications conforming to future directions.
Soil material investigation section covers broadly the aspect on Soil material investigation section covers broadly the aspect on
collection of data on material availability, geotechnical & sub-soil
exploration and the hydraulic & hydrological studies.
4 April 2010
This chapter documents expressway alignment selection process
considering engineering, economic, social, ecology and aesthetics considering engineering, economic, social, ecology and aesthetics
aspects.
Evaluation of alternative alignments has been based on (i) social
economic and environmental criteria; and (ii) engineering
(operational) aspects including costs Individual ranking matrices (operational) aspects including costs. Individual ranking matrices
has been developed for evaluation. A simultaneous use,
appreciation and considerations of the ranking developed in the appreciation and considerations of the ranking developed in the
above matrices will help in deciding selection of final alignment.
This may not be least cost one .
5 April 2010 Contd
Factors Affecting Road Alignment Selection
Factors Affecting Road Alignment Selection
6 April 2010 Contd
Evaluation of Alternative Alignments
Evaluation of Alternative Alignments
The selection and recommendation of alternatives shall meet;
(a) the satisfaction of set goals; (b) preliminary geometric / safety ( ) g ; ( ) p y g y
analysis; and (c) documentation with reasons for elimination of
less feasible alternatives. The evaluation of alternatives may be
based on: based on:
Social, Economic and Environmental Criteria
Engineering Considerations
To make the evaluation more objective (i.e. less subjective) the
approach for evaluation shall preferably be based on (i) approach for evaluation shall preferably be based on (i)
Transportation related criteria, (ii) Economic criteria, (iii) Social
criteria, (iv) Regional planning criteria, and (v) Aesthetic design
7 April 2010
criteria. Rating based evaluation is suggested.
Contd
Typical Social, Economic and Environmental Ratings (Example)
yp g ( p )
Sl.
No.
Factors Relative Weight
No.
1. Transportation Related Criteria 45
2. Economic Criteria 15
3 Social Criteria 15 3. Social Criteria 15
4. Regional Planning Criteria 15
5. Aesthetic Design Criteria 10
8 April 2010 Contd
6. Total Evaluation Rating 100
yp g ( p )
Sl.
No.
Factors
Relative
Weight
1. Transportation Related Criteria 45
a. Fast, Safe and Efficient Transportation 15
b.
Engineering. Right-of-Way and Construction
Costs
10
c Maintenance and Operating Costs 10 c. Maintenance and Operating Costs 10
d. National Defence 10
e Fire Protection 2 e. Fire Protection 2
f. Public Utilities 2
Operation and use of existing facilities during and
4
9 April 2010 Contd
g.
Operation and use of existing facilities during and
after construction
4
Sl.
No.
Factors
Relative
Weight
2 Economic Criteria 15 2. Economic Criteria 15
a. Economic Activity 5
b E l t 5 b. Employment 5
c. Property Values 5
10 April 2010 Contd
Sl.
No.
Factors
Relative
Weight No. Weight
3. Social Criteria 15
a Displacement of Families and Business 4 a. Displacement of Families and Business 4
b. Residential and Neighbourhood Character 2
c Religious Institutions and Practices 1 c. Religious Institutions and Practices 1
d. Rights and Freedoms of Individuals 2
e. Natural and historical Landmarks 1
f. Replacement Housing 3
11 April 2010 Contd
g. Education 2
Sl.
No.
Factors
Relative
Weight
4 R i l Pl i C it i 15 4. Regional Planning Criteria 15
a. Open Spaces 4
b. Recreation and Parks 4
c. Conduct and Financing of Government 5
d. Multiple Use of Space 2
12 April 2010 Contd
Sl R l ti Sl.
No.
Factors
Relative
Weight
5 Aesthetic Design Criteria 10 5. Aesthetic Design Criteria 10
a. Aesthetics 2
b Public Health and Safety 3 b. Public Health and Safety 3
c. Noise, Air and Water Pollution 3
d. Conservation 2
13 April 2010 Contd
Operational Considerations
p
Subsection
Length
Principal Alternatives
A B C
Length
A B C
VERTICAL ALIGNMENT (Maximum grade
and length)
HORIZONTAL ALIGNMENT (Maximum
degree of curve No. & % length)
EARTHWORK Cut / fill
RUNNING TIMES (Minutes) * ( )
AVERAGE RUNNING SPEED (kmph) *
14 April 2010 Contd
* These are subjective assessments based on length of gradients.
Volume-I : Planning Volume I : Planning
Route Comparisons on Significant Aspects
Significant Aspects Unit A B C
Route Length Km g
Intrusion in City Km
Waterway Lm Waterway Lm
Grade Separators Lm
Vi d t L Viaducts Lm
Tunnel Lm
Total Structures Lm
Weighting
15 April 2010 Contd
Preference
Broad Costs of Section (Comparison only)
Unit A B C
Earthwork & Pavement Rs Million
Structures Rs Million
Tunnels Rs Million
Miscellaneous Rs Million
Construction Rs Million
POL & Contingent Costs Rs Million
Land & Building Acquisition Costs Rs Million
Total Cost
Weighting Overall Costs
16 April 2010 Contd
Preference
Final Selection Process: Based on A simultaneous use,
appreciation and considerations of the matrices developed
Typical Social Economic and Environmental Ratings
as follows will decide the final alignment.
Typical Social, Economic and Environmental Ratings
Operational Considerations
Route Comparisons on Significant Aspects
Broad Costs of Section (Comparison only) Broad Costs of Section (Comparison only)
This may not be the least cost one.
17 April 2010
y
For implementation under BOT DBFO format, financial analysis is
of prime consideration. Toll rates play a significant role. The toll
rates and link wise estimation of traffic as available from National rates and link wise estimation of traffic as available from National
Expressway Network study will form the basis. However, for
individual project segments, it would be prudent to consider toll individual project segments, it would be prudent to consider toll
elasticity analysis, diversion-ratio curve analysis and possible
business development at road side facilities for possible traffic -
toll rate estimation. The aspect of business development at road
side has been included in Volume-III: Operations and Management.
Al ith fi i l l i it i d i bl t d t k i Along with financial analysis it is desirable to undertake economic
analysis for appreciation of overall growth of the influence area and
the economic of the region as well as the country. the economic of the region as well as the country.
18 April 2010 Contd
APPRAISAL METHODOLOGY APPRAISAL METHODOLOGY
The Financial Analysis includes the following steps to establish and
understand a reasonable likelihood of being financially viable: g y
Step 1 - Define the project scope;
Step 2 - Assess the veracity of the traffic forecasts;
Step 3 - Set up the financial model for use in analysis of the project or Step 3 - Set up the financial model for use in analysis of the project or
prepare;
Step 4 - Determine the annual toll revenues and all other relevant revenues;
Step 5 Determine the project capital costs and other associated cost; Step 5 - Determine the project capital costs and other associated cost;
Step 6 - Determine the project operating and maintenance costs based
assumptions for analysis
St 7 C l l t k fi i l ti Step 7 - Calculate key financial ratios;
Step 8 - Perform risk and sensitivity analysis;
Step 9 - Conclude on financial viability of the project considering VGF,
19 April 2010 Contd
Annuity and other subsidies.
The economic appraisal of projects req ires certain acti ities to be The economic appraisal of projects requires certain activities to be
carried out in sequence. The following presents the key activities
and their requirements. q
Step 1:Project Definition
Identify the project and define the scope of work clearly Identify the project and define the scope of work clearly
Step 2:Collection of Base Economic Data
GDP and state specific growth rates
Key economic sectors and their growth rates, such as
agriculture, industry, services, etc.
Population growth rates Population growth rates
Motor vehicle registration growth rates
Labour force characteristics and employment profile, Per
20 April 2010 Contd
capita income
Step 3: Traffic Assessment Step 3: Traffic Assessment
For road tolling, conduct tolling preference surveys (willingness
to pay surveys) to determine level of acceptance at specified p y y ) p p
toll rates, and toll diversion surveys to determine the level
of traffic which would not materialize if tolls were applied.
Step 4: Selection of Key Project Assumptions
road life (usually 20 30 years) road life (usually 20 - 30 years)
construction period and % expenditure/year
maintenance and operation costs, including savings derived p , g g
discount rate (12% is commonly used in India)
road salvage factor
21 April 2010 Contd
Step 5: Developing Traffic Forecasts Step 5: Developing Traffic Forecasts
Determine historical growth rates for traffic; GDP. Population;
Determine extent and potential for diverted traffic from: other roads
and other transport networks (if applicable) including rail and other and other transport networks (if applicable) including rail and other
roads;
Estimate level of diverted traffic (as % of normal traffic);
E i l l f d ffi ( % f l ffi ) Estimate level of generated traffic (as a % of normal traffic);
Conduct toll diversion analysis;
Determine elasticity of demand;
Determine applicable growth rate (simple deduction would be to use
state GDP plus elasticity of demand) for five yearly intervals;
Estimate average annual traffic in vehicles/annum, and convert if g ,
necessary to PCUs. Apply PCU standard conversion factor as
indicated in Table 7 IRC: SP 30
Prepare forecast for the project life under two scenarios: do
22 April 2010 Contd
Prepare forecast for the project life under two scenarios: do
minimum and with project .
Step 6:Identification of Financial Costs Step 6:Identification of Financial Costs
physical works costs from engineering estimates
land acquisition costs from engineering and revenue land acquisition costs from engineering and revenue
department estimates
relocation and resettlement from social assessment relocation and resettlement from social assessment
environmental mitigation from environmental assessment
operations and maintenance from engineering estimates p g g
Step 7:Conversion of Financial Costs to Economic Costs
deduct all taxes, duties and subsidies from above noted
costs, OR
use a standard conversion factor, generally 0.85
23 April 2010 Contd
Step 8:Identification of Socio-Economic Benefits Step 8:Identification of Socio-Economic Benefits
what is a socio-economic benefit
key economic benefits
key social benefits
Step 9: Methodology for Quantification and Valuation of Benefits
vehicle operating cost savings vehicle operating cost savings
time savings
accident savings
h h ll i l d l others such as overall regional development etc.
Step 10: Economic Distribution of Benefits
fiscal: budgetary savings; increased tax fiscal: budgetary savings; increased tax
social: increased land value
social: HIV Costs
t l t
24 April 2010 Contd
poverty: employment
S 11 Ch i C B fi P Step 11: Choosing Cost-Benefit Parameters
project life and construction period
conversion factor (financial to economic) conversion factor (financial to economic)
discount rate and salvage value
Step 12: Modeling Cost-Benefit Analysis
hi h l d f HDM 4 high volume roads - use of HDM 4
Step 13: Undertaking Sensitivity Analyses
cost increase/benefit decrease
construction delay/deferment of commencement
traffic decrease
advanced heavy maintenance advanced heavy maintenance
switching values
Step 14: Conclusion Appraisal Report
25 April 2010 Contd
Formal for Economic Appraisal
Economic Appraisals Format Economic Appraisals Format
Title Description of Activity
Methodology Assumptions and Parameters, Models Used
Economic Costs Identification of all costs, Conversion of Financial Costs to Economic
Costs
Economic Identification of all Benefits, Assumptions for quantification and
Benefits
, p q
valuation of key benefits
Cost-Benefit
Analysis
Results in terms of EIRR, NPV and B/C Ratio at specified
rate of discount
Sensitivity
Analysis
Results of Analysis in terms of cost increase/benefit
decrease, switching values, construction delays, traffic not
generated
Sustainability and
Project Risks
Analysis of capability for sustaining asset Identification of critical
project risks and mitigation measures
Performance Identification of key performance indicators Identification of Targets
26 April 2010 Contd
Indicators
y g
and milestone dates
Summary of sensitivity analysis (As Example only) Base case 21.5% y y y ( p y)
Risk Variation Highly likely Probable Highly unlike
Construction cost + 20% 18.6%
- 20% 23.2%
Construction timing + 1 year 19.3%
- 6 months 22.0%
Traffic in base year + 20% 23.7%
- 20% 17.6%
Traffic growth rates + 20% 22.9%
20% 18 0% - 20% 18.0%
O&M costs + 20% 21.0%
- 20% 21 9%
27 April 2010
20% 21.9%
Note: This is a sample only and subject to change
On this aspect Highway Capacity Manual (HCM) 2000 is the
document considered to be authentic. However, highway capacity
analysis is a complex procedure involving generation of diverse
data requirements for individual project segments.
Realizing the necessity of capacity analysis for situation in India,
the MORTH have taken up a research study to develop HCM- p y p
India . The capacity analysis is primarily required for (a)
expressway segment between interchanges and; (b) at entry and
exit ramps junctions. In absence of the conclusions from the above
mentioned research study, as an interim measure, the following
have been presented for planning purposes have been presented for planning purposes.
28 April 2010 Contd
For capacity analysis of expressway segments between
interchanges, a user friendly method has been illustrated
considering the default values given in HCM-2000 and subjective
adoption of the necessary parameters. With the foregoing
preamble, a Table has been generated for use by the designer and
deals with 2x2 lane and 2x3 lane configuration using the cross-
sectional elements and geometric criterion presented in
Volume-II: Design.
29 April 2010 Contd
S i V l f B i E S t ( hi l h ) Service Volumes of Basic Expressway Segment (vehicle per hour)
For 2 x 2 Lane Expressway
PT (Percent of Trucks) (%) 70 60 50 40 30 25 Level of Service
Peak Cap for PHF = 0 88
428 477 643 725 1020 1075 A
673 750 1010 1139 1602 1690 B
Peak Cap. for PHF = 0.88
673 750 1010 1139 1602 1690 B
918 1022 1378 1553 2185 2304 C
448 499 672 758 1066 1124 A
Peak Cap. for PHF = 0.92 704 784 1056 1191 1675 1767 B
960 1069 1440 1624 2285 2409 C
463 515 694 782 1101 1161 A
463 515 694 782 1101 1161 A
727 809 1091 1229 1730 1824 B
992 1103 1487 1676 2359 2487 C
30 April 2010 Contd
Note: For Service volumes at Level of Service A, B & C the peak capacity values have been
multiplied by 0.35, 0.55 and 0.75 respectively.
S i V l f B i E S t ( hi l h ) Service Volumes of Basic Expressway Segment (vehicle per hour)
For 2 x 3 Lane Expressway
PT (P t f T k1) (%) 70 60 50 40 30 25 L l f S i PT (Percent of Truck1) (%) 70 60 50 40 30 25 Level of Service
643 715 964 1087 1530 1613 A
1010 1124 1515 1708 2404 2534 B
1378 1533 2066 2330 3278 3456 C
Peak Cap for PHF = 0 92
672 748 1008 1136 1599 1686 A
1056 1175 1584 1786 2512 2649 B Peak Cap. for PHF = 0.92 1056 1175 1584 1786 2512 2649 B
1440 1603 2160 2435 3426 3613 C
694 772 1041 1174 1651 1741 A
1091 1213 1636 1844 2594 2736 B
1487 1655 2231 2515 3538 3731 C
31 April 2010 Contd
Note: For Service volumes at Level of Service A, B & C the peak capacity values have been
multiplied by 0.35, 0.55 and 0.75 respectively.
Interchange Capacity Analysis
f For capacity analysis at the junction of entry and exit ramps, the
HCM procedure appears to be too complex and require a lot of
subjective data adoption. The simplified procedure as developed
and practiced in Japan has been adopted and are presented as
follows:
32 April 2010 Contd
1 L R t 3 L C i
1 L ff R f 3 L C i
1-Lane on-Ramp to 3-Lane Carriageway
1-Lane off-Ramp from 3-Lane Carriageway
Note: Vf = Traffic Volume on Through Lane Vehicles Per Hour (VPH)
Vr = Traffic Volume at Ramp Function Vehicles Per Hour (VPH)
33 April 2010 Contd
VD = Design Traffic Capacity of Through Lane (VPH)
2 L R t 3 L C i
2 L ff R f 3 L C i
2-Lane on-Ramp to 3-Lane Carriageway
2-Lane off-Ramp from 3-Lane Carriageway
Note: Vf = Traffic Volume on Through Lane Vehicles Per Hour (VPH)
34 April 2010
VD = Design Traffic Capacity of Through Lane (VPH)
VOLUME II
DESIGN
1 of 3
VOLUME II: DESIGN

EXECUTIVE SUMMARY

The objective of the document Volume-II: Design is to assist the design engineer in project preparation for
the identified sections of Expressway Design. These design standards deal with geometric design of inter-
city expressways located in open country outside the built-up area. The alignment may, however, pass
through isolated small stretches of built-up area as long as the basic character of the expressway as a whole
does not change. The standard is not directly applicable to the design of urban expressways.

IRC documents have limitations for use under the present context. This Volume intended to assist
expressway planners/designers with the basic information on project preparation. The contents of this
document are necessarily illustrative. This document does not intend to replace text books or other
published commercially available documents.

This document has been structured into 14 (fourteen) chapters as follows:

Chapter 1 : Geometric Design
Chapter 2 : Interchange Design
Chapter 3 : Embankment and Cutting
Chapter 4 : Pavement Design
Chapter 5 : Design of Structures
Chapter 6 : Tunnels
Chapter 7 : Drainage and Erosion Protection
Chapter 8 : Safety Barriers
Chapter 9 : Traffic Signs and Pavement Markings
Chapter 10 : Toll Plaza Design
Chapter 11 : Service Areas
Chapter 12 : Pick-up Bus Stops
Chapter 13 : Lighting
Chapter 14 : Noise Barriers

Chapter 1: Geometric Design

This section describes primarily the salient aspects considered in alignment design with specific importance
for the high density, high speed access controlled expressways. The considerations involve Terrain
Classification, Design speeds, Cross Sectional elements, Safety barriers, Sight distance, Horizontal and
Vertical alignment, Climbing lane, Coordination of Horizontal and Vertical alignment, Lateral and Vertical
clearances at underpasses safety barriers, signages and associated features.

Decision sight distance for avoidance manoeuvres has been considered. The critical locations
where it is desirable to provide Decision Sight Distance are (i) Interchange and intersection locations
and (ii) Wherever changes in cross-sections occur such as toll plazas and lane drops areas
demanding concentration due to competing sources of information.
Radius beyond which no super elevation is required has been adopted based on normal crossfall
and friction value of 0.035.
Length of Horizontal Curve
The horizontal curve length at the centerline of the carriageway should not be less than two times
the transition curve where intersecting angle is not less than 7 degree.
The Clothoid type transition curves have been considered for smooth manoeuvring of a vehicle at
high speed.

Chapter 2: Interchange Design

The considerations involve Location planning, Spacing, Types and forms, Capacity, Geometric design, Lane
balance, Weaving sections, Exit and entrance terminals, Speed changes lanes and Traffic dispersal
Schemes.

2 of 3
For closed tolling system, trumpet type interchanges integrated with toll plazas are desirable and have been
deliberated.

As a general guide the following may be useful for preliminary design consideration of interchanges spacing.

- Between Cities a spacing of 20 - 30 km would be desirable
- City outskirt areas a spacing of 15 - 25 km would be desirable
- Urban areas In areas of concentrated urban development where the habitation and development is
considerable: a spacing of 5 - 10 km would be desirable

Chapter 3: Embankment and Cutting

Structural design of embankment and cutting shall be as per relevant IRC documents. Expressways are to
be built in embankment or cutting or on long elevated structures. Desirably, a minimum height of 3.5 m shall
be considered to accommodate animals, pedestrians, agricultural vehicles etc requiring a minimum vertical
clearance of 3.0 m. The Finished Road Levels (FRL) shall be finalized with this minimum value as datum.

Chapter 4: Pavement Design

Structural design of pavements shall be as per relevant IRC documents. The three main characteristics
expected of an expressway pavement surface from the
-
user's point of view are i) Good riding quality (low
roughness value); ii) Skid-resistance i.e. good pavement tyre friction during wet weather situation; and
iii) Absence or limitation of rutting on wheel tracks. These have been deliberated in the chapter.

Chapter 5: Design of Structures

Structural design of structures shall be as per relevant IRC documents. An expressway alignment would
meet various hazards in the form of cross roads, railways, the rivers/waterways, canals, and topographical
features such as dips, gorges, valleys, lakes and water bodies and other physical barriers.

Chapter 6: Tunnels

The classifications of tunnels have been adopted from NEXCO practices in Japan and are based on traffic
volume and length of tunnel. The standards for installation of the emergency facilities according to this
classification have also been adopted from the same source. Tunnel emergency facilities are designed for
mitigating damage in the event of fire or accident which may occur in the tunnel.

Tunnel Cross Sections are designed based on safety considerations and cost considerations. An efficient and
effective water proofing and drainage system is required in all road tunnels for removal of water from rainfall,
seepage, tunnel washing operations, vehicle drippings/spillage or fire-fighting operations. Ventilation in tunnels
is to provide fresh air so as to reduce the effect of contaminants within permissible limits during operation of
expressway facility

Chapter 7: Drainage and Erosion Protection
Structural design of drainage and erosion protection shall be as per relevant IRC documents. The
considerations involve Road side drains, Median drains, Culver and cross drainage, Subsurface drainage,
Subgrade drainage, Edge drain collector, Erosion control measures, Existing drain and Rainwater harvesting
and conservations.

Chapter 8: Safety Barriers

Barrier Acceptance Standards are generally in accordance with NCHRP Report 350.
For Expressway, the barriers shall be provided for the entire length. However, a crashworthy end treatment
is considered essential near the Toll plaza and at Gore areas. In addition this may also be required to
protect bridge piers, utility poles and foundation of overhead sign boards.

Chapter 9: Traffic Signs and Pavement Markings

To provide adequate level of safety to high speed users of expressways long distance visibility; large
lettering and symbols; and short legends for quick comprehension are the basic necessity.

Interchange exit numbering provides valuable information for the users of Expressway. Interchange exit
shall be guided in the consistent manner by traffic signs such as advance Guide sign, Exit direction sign
and Gore sign.
3 of 3
The other considerations involve Rest area and general service, Toll plaza, Route Markers, Distance marker,
Regulatory signs, Cautionary Warning signs, Design, Pavement marking, and Colour and material.

Chapter 10: Toll Plaza Design

This chapter deals with Toll System based on Closed system with ticketing payment mode. The
considerations involve Toll plaza elements such as lane width at toll booth, toll plaza lane length and Utility
Bridge/Tunnel, number of toll lanes, ETC systems, Management and Operation facilities and Audit systems.

Chapter 11: Service Areas

For the expressway, the service areas shall be planned to be provided at intervals of 30 minutes to one hour
drive, which corresponds to around 50 100 km spacing. The facility previsions have been adopted from
AASHTO Guide for Development of Service Areas on Major Arterials and Freeways third edition and
NEXCO practices in Japan.

From security considerations, it is of prime consideration that service areas will be provided near
interchanges and at intermediate locations where the distance between successive interchanges is more
than 100 km.

Consideration for Physically challenged persons is mandatory for the facilities provided on expressways.

Chapter 12: Pick-up Bus Stops

The expressway bus stops shall be located in the service area adjacent to local bus routes. For a closed toll
system of expressway the basic philosophy of design is to provide layout convenient for both local and
expressway bus services and do not involve passing through toll plaza.

Chapter 13: Lighting

The primary purpose of warrants is to assist designers in evaluating locations or lighting needs and selecting
locations for installing. AASHTO - Warrants for expressway lighting categories as (i) Continuous Expressway
Lighting; (ii) Interchange Lighting Complete and Partial; (iii) Bridge Structures and Underpasses; and (iv)
Special situations.

Lighting Standards has been adopted from CIE 180:2007 Road Transport Lighting for Developing Countries.
Tunnel Lighting has been adopted from CIE 88:2004 Guide for the Lighting of Road Tunnels and Underpasses.

Guidance facilities during night time comprise of interior/exterior illuminated signs, blinker lights and
delineators.

Glare reduction devices are required for reducing the headlight glare of opposing traffic at night which may
distract from driving tasks.

Chapter 14: Noise Barriers

Noise Barrier shall be provided to protect sensitive land uses from expressway noise. The considerations
involve Placement, reduction effect, Design and Types of barriers.

CONTENTS

CHAPTER 1: GEOMETRIC DESIGN

1.1 Definition and Scope

1.2 Terrain Classification

1.3 Design Speeds

1.4 Cross Sectional Elements

1.4.1 Right of Way, Building Lines and Control Lines
1.4.2 Lane Width
1.4.3 Edge Strip Width
1.4.4 Shoulder Width
1.4.5 Median Width
1.4.6 Crossfall /Camber
1.4.7 Embankment
1.4.7.1 General
1.4.7.2 Structural Features and Design of Embankment
1.4.7.3 Embankment Slope
1.4.7.4 Cut Slope
1.4.7.5 Retaining Structures
1.4.7.6 Use of Fly Ash for Embankment Construction

1.5 Safety Barriers

1.5.1 Outside Barriers
1.5.2 Median Barriers

1.6 Sight Distance

1.6.1 Stopping Sight Distance
1.6.2 Decision Sight Distance

1.7 Horizontal Alignment

1.7.1 General
1.7.2 Horizontal Curves
1.7.2.1 Radii of Horizontal curves
1.7.2.2 Radius beyond which no superelevation is required
1.7.2.3 Length of Horizontal Curve
1.7.2.4 Setback distance at Horizontal Curves

1.7.3 Superelevation
1.7.3.1 Design values
1.7.3.2 Attaining superelevation
1.7.4 Transition Curves
1.7.4.1 Radii beyond which no transition is required

1.8 Vertical Alignment

1.8.1 General
1.8.2 Gradients
1.8.3 Vertical Curves

1.9 Climbing Lane

1.10 Coordination of Horizontal and Vertical Alignment

1.11 Three Dimensional Alignment

1.11.1 Design Approach
1.11.2 Horizontal Design Elements
1.11.3 Vertical Design Elements

1.12 Lateral and Vertical Clearance at Underpasses

1.12.1 Vehicular underpasses
1.12.2 Facilities for pedestrian and cyclist
1.12.3 Cattle Crossing
1.12.4 Lateral clearance
1.12.5 Vertical clearance

CHAPTER 2 : INTERCHANGE DESIGN

2.1 Introduction

2.1.1 Justification for Interchanges

2.2 Location Planning

2.3 Interchange Spacing

2.3.1 General
2.3.2 Route Continuity

2.4 Types and Forms of Interchanges

2.4.1 Types of Interchanges
2.4.2 Forms of Interchanges
2.4.2.1 Service Interchanges
2.4.2.2 System Interchanges
2.4.2.3 Typical Interchanges
2.5 Capacity Considerations

2.6 Design Considerations

2.6.1 Ramp Types
2.6.2 Design Speed
2.6.3 Width and Cross-section

2.7 Geometric Design Considerations

2.7.1 Sight Distance
2.7.2 Superelevation and Side Friction Factor

2.8 Lane Balance

2.8.1 Exit from Expressway
2.8.2 Entry to Expressway

2.9 Weaving Sections

2.10 Exit and Entrance Terminals

2.11 Acceleration / Deceleration Lanes

2.12 Traffic Dispersal Schemes

2.12.1 Introduction
2.12.2 General Considerations

CHAPTER- 3 : EMBANKMENT AND CUTTING

3.1 General Considerations

3.2 Expressway on Embankment

3.2.1 General
3.2.2 Relevant Indian Roads Congress Publications
3.2.3 Relevant Bureau of Indian Standards Publications

3.3 Salient Structural Features on Embankment Design

3.3.1 Stability Analysis
3.3.2 Settlement Analysis
3.3.3 Fill Slopes
3.3.4 Cut Slopes
3.3.5 Ground Improvement
3.3.5.1 Requirements and Investigations
3.3.5.2 Methods of Ground Improvement
3.3.6 Use of Fly Ash for Embankment Construction
CHAPTER 4 : PAVEMENT DESIGN

4.1 General Considerations

4.2 Riding Quality

4.2.1 Measurement of Riding Quality

4.3 Skid Resistance

4.3.1 Measurement of Pavement Skid Resistance
4.3.2 Practice in Various Countries
4.3.3 Anti Skid Measures

4.4 Rut Depth

4.5 Recommendation for Pavement Surface Characteristics

CHAPTER 5 : DESIGN OF STRUCTURES

5.1 Introduction

5.2 Overpass Versus Underpass: Considerations

5.2.1 General Design Considerations
5.2.2 Additional Design Considerations for Underpass

5.3 Types of Structures

5.3.1 Location of Bridge
5.3.2 Structural Integrity
5.3.3 Loading and Hydraulic Considerations
5.3.4 Bridge Type
5.3.5 Cross Section (Basic Geometry)
5.3.6 Transverse Width of Bridge
5.3.7 Safety Barriers on Structures

5.4 Clubbing of Grade Separation Facilities

5.4.1 Considerations for Merger of Cross Roads

5.5 Aesthetics

5.6 Durability and Maintenance

5.7 Inspection Facilities for Maintenance

CHAPTER 6: TUNNELS

6.1 Expressway In Tunnels

6.2 Classification of Tunnels

6.3 Designing a Tunnel

6.4 Emergency Facilities

6.4.1 General
6.4.2 Types of Details of Emergency Facilities

6.5 Tunnel Cross Sections

6.6 Tunnel Waterproofing and Drainage

6.6.1 Lining
6.6.2 Tunnel Drainage

6.7 Tunnel Ventilation

6.7.1 Vehicle Emissions, Exhaust Emissions and Emission Rates
6.7.2 Tunnel Ventilation Systems

6.8 Fire Resistance of Tunnel Structure and Appurtenances

6.8.1 Tunnel Structures
6.8.2 Tunnel Appurtenances

6.9 Portals

CHAPTER 7: DRAINAGE AND EROSION PROTECTION

7.1 Introduction

7.2 Road Side and Median Drains

7.2.1 Road Side Drains - Rural Expressways
7.2.2 Kerbs and Channels (for Wayside Amenities and Other Areas)
7.2.3 Chutes and Flumes
7.2.4 Median Drainage

7.3 Design of Drainage

7.3.1 Hydraulics of Storm Sewers
7.3.2 Runoff
7.3.3 The Rational Method
7.3.4 Watershed Area
7.3.5 Runoff Coefficient
7.3.6 Time of Concentration
7.3.7 Rainfall Frequency and Intensity
7.3.8 Road Geometrics

7.4 Culverts and Cross Drainage Structures

7.4.1 Culvert Location, Plan and Type
7.4.2 Cross Drainage Structures
7.4.3 Catch Water Drain
7.4.4 Rainwater Harvesting and Conservation

7.5 Sub-Surface Drainage

7.5.1 Horizontal Drains

7.6 Pipe Underdrains

7.7 Subgrade Drainage Systems

7.8 Edge Drain Collector Systems

7.9 Erosion Control Measures

7.9.1 Vegetative Cover
7.9.2 Permanent Non-Vegetative Cover
7.9.3 Slope Modification
7.9.4 Temporary Runoff Control
7.9.5 Temporary Check Dams

7.10 Existing Drain, Canals and Minor Waterways

APPENDIX

Appendix-7 : Rainwater Harvesting and Conservation

CHAPTER 8 : SAFETY BARRIERS

8.1 Introduction
8.2 Barrier Acceptance Standards

8.2.1 Selection Criteria
8.2.2 Barrier Warrants
8.2.3 Types of Safety Barriers
8.2.4 Verge/Edge Barrier Selection
8.2.4.1 Cost Considerations for use of Concrete Barrier on Roadside
8.2.5 Median Barrier Selection

8.3 Verge Side/Edge Barrier: Placement and End Treatments

8.3.1 Placement Considerations
8.3.2 End Treatments

8.4 Median Barriers: Placement and End Treatments

8.4.1 Placement Recommendations

8.5 Barriers on Bridges

8.6 Other Barriers

8.6.1 Barriers to Shield Hazards
8.6.2 Fences against Falling Objects

8.7 Crash Cushions

8.7.1 Application of Crash Cushions

CHAPTER 9 : TRAFFIC SIGNS AND ROAD MARKINGS

9.1 General

9.1.1 Introduction
9.1.2 Expressway Signing Principles and Classes
9.1.3 Siting of Signs with Respect to the Carriageway
9.1.4 Mounting Height and Clearance
9.1.5 Visibility of Signs

9.2 Expressway Terminals and Interchanges: Sign and
Lane Marking Layouts

9.2.1 Interchange Exit Numbering
9.2.2 Interchange Guide Signs
9.2.2.1 Advance Guide Signs
9.2.2.2 Exit Direction Signs
9.2.2.3 Exit Gore signs
9.2.3 Next Exit Supplemental Signs
9.2.4 Expressway Symbol Sign
9.2.5 End of Expressway
9.2.6 Characteristics of Rural Signing
9.2.7 Post Interchange Signs
9.2.8 Distance Sign
9.2.9 Signing by Class of Interchange
9.2.10 Entry to Service Interchange
9.2.11 Direction Sign at System Interchange
9.2.12 Lane Drop Exit Type
9.2.13 Wrong way Traffic Control at Interchange Ramps
9.2.14 Keep Adequate Headways
9.2.15 Miscellaneous Guide Signs

9.3 Rest Area and General Service Sign

9.4 Toll Plaza

9.5 Route Markers

9.6 Distance Marker (Kilometre and 100 m Marking)

9.7 Regulatory (Mandatory) Signs

9.7.1 Speed Limit Sign
9.7.2 Movement Series
9.7.3 Parking Series
9.8 Cautionary Warning Signs

9.8.1 Turn and Curve Sign
9.8.2 Large Arrow Sign
9.8.3 Chevron Alignment Signs
9.8.4 Merge Sign
9.8.5 Hill Sign
9.8.6 Slippery When Wet Sign
9.8.7 Warning for Animal Crossing
9.8.8 Slow Traffic Keep Left Sign
9.8.9 Climbing Lane/Overtaking Lane Sign

9.9 Design

9.9.1 Letter Size, Letter Series, Legend Limits and Sign Size
9.9.2 Establishment
9.9.3 Material
9.9.4 Variable Message Signs

9.10 Pavement Markings and Raised Pavement Markers

9.10.1 Visibility of Road Markings
9.10.2 Classes of Markings

9.11 Colour and Material

CHAPTER 10: TOLL PLAZA DESIGN

10.1 Introduction

10.2 Toll System

10.2.1 Closed Ticket System
10.2.2 Closed-Cash System
10.2.3 Open System

10.3 Payment Type .2

10.4 Toll Plaza Elements .4

10.4.1 Lane Width at Toll Booth
10.4.2 Transition Zone
10.4.3 Removable Barrier
10.4.4 Traffic Signs
10.4.5 Road Markings
10.4.6 Toll Booth
10.4.7 Office Building
10.4.8 Barrier Gate
10.4.9 Toll Plaza Lane Length
10.4.10 Utility Tunnel / Overbridge
10.4.11 Turn Around Provisions

10.5 Number of Toll Lanes 11

10.5.1 Recommendation in the Manual of 4/6-laning by MORTH
10.5.2 Japanese Method

10.6 ETC (Electronic Toll Collection) System 12

10.6.1 General
10.6.2 Available Technologies
10.6.3 ETC Facilities
10.6.3.1 System configuration
10.6.3.2 Toll Layout
10.6.4 Signages and Markings

10.7 Operations and Maintenance Center 19

10.7.1 Operation Center
10.7.1.1 General Administration and Functional Areas
10.7.1.2 Common Areas
10.7.1.3 Equipment Areas
10.7.1.4 Other Areas which Include
10.7.2 Maintenance Office
10.7.2.1 Administration and Functional Areas
10.7.2.2 Common Areas
10.7.2.3 Other Areas
10.7.2.4 Garage Related Areas
10.7.3 Toll Office

10.8 Other Facilities .22

10.8.1 Vehicle Weighing System and Associated Storage Space
10.8.2 Electrical
10.8.3 Interior Lighting
10.8.3.1 Canopy Lighting
10.8.4 Exterior Lighting
10.8.4.1 High Mast Lighting
10.8.4.2 Highway Lighting
10.8.5 Water Supply
10.8.6 Drainage
10.8.7 Fire Fighting System
10.8.7 Air Conditioning

10.9 Audit System 24

CHAPTER 11 : SERVICE AREAS
11.1 Introduction .1

11.2 Service Areas

11.2.1 Locations

11.3 Size

11.4 Amenities/Service Facilities

11.5 Development Control

11.6 Conceptual Layout

11.7 Design Considerations for the Service Areas and Amenities

11.7.1 Capacity of Facilities
11.7.2 Toilet and Washing Facilities
11.7.2.1 Planning
11.7.3 Restaurants and Fast Food Centres
11.7.3.1 Planning
11.7.3.2 Area Requirements
11.7.4 Dormitories and Cubicles
11.7.5 Filling Station
11.7.6 Mechanical Repairing Service
11.7.7 Sewerage Facility
11.7.8 Waste and Recycling Receptacles
11.7.9 Other Facilities
11.7.10 Internal Circulation and Distribution of Sites for Parking
11.7.11 Entry and Exit
11.7.12 Lighting
11.7.13 Electrical Systems
11.7.14 Road Markings, Signs and Safety
11.7.15 Water Supply and Sanitary Systems
11.7.16 Landscaping
11.7.17 Pick-up Bus Stops
11.7.18 External Parking

APPENDIX

Appendix-11 : Provisions for Persons with Disabilities (PwD)

CHAPTER 12 : PICK-UP BUS STOPS

12.1 Introduction

12.2 Pick-up Bus Stops

CHAPTER 13 : LIGHTING

13.1 General

13.2 Warrants For Expressway Lighting
13.2.1 Continuous Expressway Lighting
13.2.2 Interchange Lighting
13.2.3 Bridge Structures and Underpasses
13.2.4 Special situations

13.3 Transition Lighting

13.4 Lighting Standards

13.5 Tunnel Lighting

13.5.1 General
13.5.1.1 Long and Short Tunnels: Defined
13.5.1.2 Tunnel related zones

13.6 Daytime Lighting For Long Tunnels

13.6.1 General
13.6.2 Length of the threshold zone
13.6.3 Luminance in the Transition Zone
13.6.4 Daytime luminance in the interior zone
13.6.5 Luminance in the exit zone
13.6.6 Parting zone lighting
13.6.7 Lighting of the walls and the ceiling in all zones
13.6.8 Uniformity of Luminance
13.6.9 Daylight variation and lighting control
13.6.10 Glare Restriction
13.6.11 Restriction of the flicker effect
13.6.12 Night-Time Lighting
13.6.13 Emergency Lighting
13.6.14 Lighting in Other Places

13.7 Guidance Facilities During Night Time

13.7.1 Interior/Exterior Illuminated Signs
13.7.2 Blinker Lights
13.7.3 Delineators

13.8 Glare Reduction

CHAPTER 14 : NOISE BARRIERS

14.1 Noise Barrier

14.1.1 General
14.1.2 Noise Barriers for Expressways
14.1.3 Noise Barrier Placement and Reduction Effect
14.1.4 Type of Noise Barriers

CONTENTS
Chapter 1 - Geometric Design
VOLUME II: DESIGN
Chapter 8 - Safety Barriers
p g
Chapter 2 - Interchange Design
Chapter 3 Embankment and
Chapter 8 Safety Barriers
Chapter 9 - Traffic Signs and
P M ki
Chapter 3 - Embankment and
Cutting
Pavement Markings
Chapter 10 - Toll Plaza Design
Chapter 5 - Design of Structures
Chapter 12 - Pick-up Bus Stops
Chapter 6 - Tunnels
p p p
Chapter 13 - Lighting
Chapter 14 Noise Barriers
Protection
Chapter 14 - Noise Barriers
1
Volume-II : Design g
The objective of the document Volume-II: Design is to assist the
design engineer in project preparation for the identified sections of design engineer in project preparation for the identified sections of
Expressway Design . These design standards deal with geometric
design of intercity expressways located in open country outside the
built-up area. The alignment may, however, pass through isolated
small stretches of built-up area as long as the basic character of
the Greenfield Expressway as a whole does not change The the Greenfield Expressway as a whole does not change. The
standard is not directly applicable to the design of urban
expressways.
This Volume intended to assist expressway planners/designers with
the basic information on design aspects. The contents of this the basic information on design aspects. The contents of this
document are necessarily illustrative. This document does not
intend to replace text books or other published commercially
il bl d t available documents.
April 2010 2
Volume-II : Design
g
This chapter describes primarily the salient aspects considered in
alignment design with specific importance for the high density,
high speed access controlled expressways The considerations high speed access controlled expressways. The considerations
involve Terrain Classification, Design speeds, Cross Sectional
elements, Safety barriers, Sight distance, Horizontal and Vertical
alignment, Climbing lane, Coordination of Horizontal and Vertical
alignment, Lateral and Vertical clearances at underpasses safety
barriers signage and associated features barriers, signage and associated features.
IRC documents with their limitations for use under the present
f context will be the guiding documents for design with due
considerations for the requirement of Expressway features.
April 2010 Contd 3
Volume-II : Design
For Expressways the following aspects need special considerations:
g
p y g p p
Decision sight distance for avoidance manoeuvres has been
considered The critical locations for provision are (i) considered. The critical locations for provision are (i)
interchange, (ii) wherever changes in cross-sections occur
such as toll plazas, and (iii) lane drop areas at entry / exit
locations.
Radius beyond which no super elevation is required is based on
normal cross fall and lateral tyre-pavement friction value of normal cross fall and lateral tyre-pavement friction value of
0.035.
The horizontal curve length at the centerline of the carriageway
should not be less than two times the transition curve for
intersecting angle is not less than 7 degree.
The Clothoid type transition curves have been considered for The Clothoid type transition curves have been considered for
smooth manoeuvring of a vehicle at high speed.
4 April 2010 Contd
Volume-II : Design
Cross Sectional Elements
g
Right of Way, Building Lines and Control Lines
Minimum Right of Way for different terrains indicated below:
S N T i Ri ht f W ( )* S. No. Terrain Right of Way (m)*
1. Plain 90
2 R lli 90 2. Rolling 90
3. Mountainous
Same level 60 Same level 60
Split level 30
* This ROW width will contain 2 m wide corridor for placement of utility inside
5 April 2010 Contd
This ROW width will contain 2 m wide corridor for placement of utility inside
boundary fencing.
Volume-II : Design
Cross Sectional Elements
g
Recommended standards for building and control lines
Terrain Open areas Built up areas
Overall width Overall Width Distance between Building Overall. width
between
Building Lines
Overall Width
between
Control Lines
Distance between Building
line and right of way
boundary (set back) (m)
(m) (m)
Plain 110 130 5
Rolling 110 130 5
Mountainous 70 80 5
6 April 2010 Contd
* The terminologies are same as IRC standards.
Volume-II : Design
g
Typical cross section for 2 x 3 lane expressways in plain & rolling terrain
7 April 2010 Contd
* All dimensions are in millimeters
Volume-II : Design
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Typical cross section for 2 x 3 lane expressways in mountainous terrain
8 April 2010 Contd
Volume-II : Design
C f
g
Coordination of Horizontal
and Vertical Alignment: The
overall appearance and safety overall appearance and safety
aspects can be enhanced
considerably by judicious
bi ti f th h i t l combination of the horizontal
and vertical alignments. IRC
standard provides some p
considerations on this
aspects and this guideline
includes the three includes the three
dimensional aspects as an
added tool for designers .
9 April 2010
Volume-II : Design
S
g
The considerations involve Location planning, Spacing, Types and
forms, Capacity, Geometric design, Lane balance, Weaving
sections, Exit and entrance terminals, Speed changes lanes and sections, Exit and entrance terminals, Speed changes lanes and
Traffic dispersal Schemes.
Cl d T lli d d f E N t k d Closed Tolling are recommended for Expressways Network and
trumpet type interchanges integrated with toll plazas are desirable.
The desirable interchange spacing for preliminary design are:
Between Cities a spacing of 20 - 30 km would be desirable
City outskirt areas a spacing of 15 25 km would be desirable City outskirt areas a spacing of 15 - 25 km would be desirable
Urban areas In areas of concentrated urban development
where the habitation and development is considerable: a
10 April 2010 Contd
spacing of 5 10 km would be desirable
Volume-II : Design
g
Types and Forms of Interchanges: Service and System interchanges
Service Interchanges Expressways vs. Ordinary Road Service Interchanges Expressways vs. Ordinary Road
11 April 2010 Contd
Volume-II : Design
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Types and Forms of Interchanges: Service and System interchanges
System Interchanges Expressways vs. Expressways y g p y p y
12 April 2010 Contd
Volume-II : Design
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Ramps in a Trumpet Interchanges
13 April 2010 Contd
Volume-II : Design
g
VMS
Typical Trumpet Interchanges: (Thematic Layout)
Expressway
200m
1
0
0
VMS
EXPRESSWAY
VMS
V
M
S
1
0
0
m
200m
VMS
TOLL GATE
TOLL GATE
V
N
a
t
i
o
n
a
l

H
i
g
h
w
a
y
1
0
0
m
14 April 2010 Contd
V
M
S
Volume-II : Design
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Traffic Dispersal Schemes :
This is a complex planning
process involving various
States and concerned
authorities.
Thematic Traffic Dispersal Arrangement
15 April 2010
Volume-II : Design
Chapter 3 : Embankment and Cutting
g
Structural and stability design of embankment and cutting
shall be as per relevant IRC standard.
Expressways are to be built in embankment or cutting or on
long elevated structures long elevated structures.
Desirably, a minimum height of 3.5 m shall be considered for
animals, pedestrians, agricultural vehicles crossings etc.
requiring a minimum vertical clearance of 3.0 m.
The Finished Road Levels (FRL) shall be finalized considering
these minimum values
16 April 2010
these minimum values.
Volume-II : Design
g
Pavement Design shall consider the structural and the functional
requirements.
Structural design of pavements shall be as per relevant IRC
documents.
For Functional requirement, three main characteristics are
expected of pavement surface from the-user's point of view are: p p p
(i) Good riding quality (low roughness value);
(ii) Skid resistance i e good pavement tyre friction during wet (ii) Skid-resistance i.e. good pavement tyre friction during wet
weather situation; and
(iii) Absence or limitation of rutting on wheel tracks. These have
17 April 2010 Contd
( ) g
been deliberated in the chapter.
Volume-II : Design
g
Recommendation for Pavement Surface Characteristics
The new Flexible Pavement surface on completion shall satisfy the The new Flexible Pavement surface on completion shall satisfy the
following standards.
(a) Roughness: In each lane measured by Bump Integrator (BI)
Not more than 2000 mm/km for each lane in a km length
(b) Rutting: In wheel path measured By 3 m Straight Edge
No rutting
(c) Cracking No cracking (c) Cracking No cracking
(d) Characteristics Deflection not more than 0.5 mm (IRC:81)
18 April 2010 Contd
Volume-II : Design
g
The new rigid pavement surface on completion shall satisfy the
following standards:
(a) Roughness: In each lane measured by Bump Integrator (BI)
Not more than 2000 mm/km for each lane in a km length
(b) Cracking No cracks other than shrinkage cracks
(c) Other distresses such as Scaling raveling, spalling at edges -
Nil
19 April 2010 Contd
Volume-II : Design
R d ti f P t S f Ch t i ti
g
To ensure sufficient macro-texture for safe driving and day-night To ensure sufficient macro texture for safe driving and day night
visibility the desirable texture depth (determined by sand patching
method) are:
(a) For satisfactory skid resistance
- 1.00 mm for bituminous surfacing
0 50 f t f i - 0.50 mm for concrete surfacing
(b) For Day and Night Visibility ( ) y g y
- General requirement is a pronounced macro texture depth of
1.0 to 1.5 mm, along with use of angular chippings, use of
impervious materials and 'avoidance of smooth or polished
20 April 2010
impervious materials and avoidance of smooth or polished
areas of surface
Volume-II : Design
Structural design shall be as per relevant IRC standard. An expressway
g
Structural design shall be as per relevant IRC standard. An expressway
alignment would meet various obstacles in the form of cross roads,
railways, rivers/waterways, canals, topographical features such as dips,
gorges valleys lakes and water bodies and other physical barriers gorges, valleys, lakes and water bodies and other physical barriers.
These obstacles are generally grouped as follows:
Group 1 : Rivers, streams, rivulets, canals and water bodies
Group 2 : Cross Roads Major and important roads based on
service provided and community requirements service provided and community requirements
Group 3 : Crossing facilities required for agricultural activities,
pedestrian, animals movement
Group 4 : Depressions & short valley between two elevated Group 4 : Depressions & short valley between two elevated
plateau
Group 5 : Railway crossings
21 April 2010 Contd
Group 6 : Interchange locations (both service and system)
Volume-II : Design
All the si gro ps need grade separated str ct res and shall
g
All the six groups need grade separated structures and shall
generally meet the followings:
(i) The structure shall be designed to be durable to withstand the
deteriorating effects of climate and environment.
(ii) All bridges shall have independent superstructure for each (ii) All bridges shall have independent superstructure for each
direction of travel. Culverts may have single or independent
structure. Width of median on approaches shall be
maintained.
(iii) For median open to sky adequate safety measures and
protection of spilling fill materials shall be considered protection of spilling fill materials shall be considered.
(iv) All bridges width shall desirably be provided to carry the
roadway width before and after the bridge.
22 April 2010 Contd
(v) Utility service, if any, shall be taken on the structures.
Volume-II : Design
g
Inspection Facilities for Maintenance
For preventive maintenance visual inspection of the bridging For preventive maintenance, visual inspection of the bridging
structure is an important component. Visual inspection is effective
when it is carried from close quarters. For long span structure, q g p ,
moving inspection platform suspended from the underside of the
bridge are employed. However, most of the bridges for the
expressway will be related with grade separator for the cross traffic expressway will be related with grade separator for the cross traffic
where these suspended moving platforms are not suitable as these
are likely to foul with the vertical clearances available. Moreover, as
the length for these grade separating structures will generally be
less than 50 m, the conventional system with access ladder and
stairs may be both economical and practical
23 April 2010
stairs may be both economical and practical.
Volume-II : Design
Chapter 6 : Tunnels
Expressway in Tunnels
g
p y
Expressways may require sections to be constructed in tunnels
either to carry the alignment under or through a natural obstacle either to carry the alignment under or through a natural obstacle
or to minimize the impact on the community. The general
conditions under which tunnel construction may be warranted
are:
Long, narrow mountainous terrain where a cut section may be
expensive or leads to environmental consequences expensive or leads to environmental consequences.
Narrow right-of-way, where all the surface area must be
retained for road purpose
Railroad yard, airport and runways, or similar facilities
Parks or other land uses, existing or planned
Right-of-way acquisition costs exceed cost of tunnel
24 April 2010 Contd
Right of way acquisition costs exceed cost of tunnel
construction and operation
Volume-II : Design
Chapter 6 : Tunnels
g
Tunnel Cross Sections
Th b t t f t l ti b d There can be two types of tunnel cross sections based on
construction practices:
(i) Tunnels constructed by mining method;
(ii) Tunnels constructed by cut-and-cover method.
Road tunnel cross sections contain in breadth a certain number
f l t hi h d id ti d i ti i ti of elements which need considerations during an optimization
study of the geometric characteristics of the profile.
25 April 2010 Contd
Volume-II : Design
Chapter 6 : Tunnels
Tunnel Cross Sections (Typical Mining Method)
g
Tunnel Cross Sections (Typical Mining Method)
26 April 2010 Contd
Volume-II : Design
Chapter 6 : Tunnels
g
Two unidirectional tunnels (tubes) are spaced at minimum three
times the dimension of the tunnel at carriageway level (D).
27 April 2010 Contd
Volume-II : Design
Chapter 6 : Tunnels
Tunnel Cross Sections (Typical Cut and Cover Method)
g
Tunnel Cross Sections (Typical Cut and Cover Method)
28 April 2010 Contd
Volume-II : Design
Chapter 6 : Tunnels
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Classification of Tunnels
Th l ifi ti f The classification of
tunnels, based on Traffic
volume and length of volume and length of
tunnel is given below and
the standards for
installation of the
emergency facilities
di t thi according to this
classification are given in
tabular form
29 April 2010 Contd
tabular form.
Volume-II : Design
Chapter 6 : Tunnels
E F iliti
g
Emergency Facilities
30 April 2010 Contd
Volume-II : Design
Chapter 6 : Tunnels
Fi R i t f T l St t
g
Fire Resistance of Tunnel Structure
The objectives for fire resistance of tunnel structures are: j
To make evacuation or protection of tunnel users possible
To make rescue and firefighting operations possible and ensure
their safety
To limit damage to tunnel structure and equipment, and to
surrounding buildings surrounding buildings
It is generally acceptable that repairs are necessary after a large
fire, but not that whole tunnel is lost.
Unreinforced concrete lining of 300 450 mm is used as main
31 April 2010 Contd
Unreinforced concrete lining of 300 450 mm is used as main
structure of the tunnel.
Volume-II : Design
Chapter 6 : Tunnels
g
Tunnel Ventilation Systems: The objective of ventilation is to reduce
the harmful substances in vehicle emissions for good visibility and
reduce adverse effects on users and maintenance personnel reduce adverse effects on users and maintenance personnel.
Natural ventilation system depends on traffic ventilation power and
mechanical ventilation system uses machines.
32 April 2010 Contd
Volume-II : Design
Chapter 6 : Tunnels
g
Portals : Functionally, the
portal is regarded as a
sort of retaining wall to
protect at entrance and
exit. Its purpose is to
reduce the luminance of
facing walls.
33 April 2010
Volume-II : Design
g
Design of drainage and erosion protection measures shall be as
per relevant IRC standards. The considerations involve Road side
drains, Median drains, Culver and cross drainage, Subsurface
drainage, Subgrade drainage, Edge drain collector, Erosion control
measures, Existing drain and Rainwater harvesting and
conservations. All these elements are well covered in IRC
standards. The typical arrangement of edge drain collector and
rain harvesting are presented here.
34 April 2010 Contd
Volume-II : Design
g
Edge Drain Collector
Systems
An adequate collector and
outlet system must be used outlet system must be used
with a permeable drainage
layer under the pavement.
Typical Pavement Edge Drain
35 April 2010 Contd
Typical Pavement Edge Drain
Volume-II : Design
T i l R i W t
g
Typical Rain Water
Harvesting Arrangement
(IRC SP 50) (IRC:SP:50)
36 April 2010
Volume-II : Design
Barrier Acceptance Standards are generally in accordance with NCHRP Report 350.
g
Test Level Vehicle mass
(kg)
Speed
(km/h)
Impact Angle
(degrees)
TL 5 820 (small car) 100 20 TL - 5 820 (small car) 100 20
36000 (tanker type semi trailer) 80 15
TL 4 820 (small car) 100 20
8000 (rigid chassis truck) 80 15
TL 3 820 (small car) 100 20
2000 (utility) 100 25 2000 (utility) 100 25
TL 2 820 (small car) 70 20
2000 (utility) 70 25
TL 1 820 (small car) 50 20
2000 (utility) 50 25
TL 0 820 (small car) 50 20
37 April 2010 Contd
0 820 (small car) 50 20
1600 (small car) 50 25
Volume-II : Design
For Expressway desirably the barriers shall be provided for the
g
For Expressway, desirably, the barriers shall be provided for the
entire length. However, a crashworthy end treatment is considered
essential near the Toll plaza and at Gore areas. In addition this may
l b i d b id i ili l d also be required to protect bridge piers, utility poles and
foundation of overhead sign boards.
Barrier Type Placement.
TL-3 On mainline expressway.
TL 4
and
On stretches with significant percentage of trucks;
Where third party injury risk is high;
Likely places affecting other railway, important highway and
TL 5 important utility lines and places;
Adjacent to water bodies of importance.
For all other places such as interchange ramps, connection to local roads,
38 April 2010 Contd
TL 2
For all other places such as interchange ramps, connection to local roads,
protection of bridge piers on median and roadside etc.
Volume-II : Design
Typical Metal Beam Barriers
g
2
4
(
2
0
) Wood or
Plastic Block
Thrie-Beam
Thrie-Beam Back-up Plate
(at posts where Thrie-Beam
splice does not occur)
3
2
W150 x 13.5 Post
Typical Metal Beam Barriers
7
0
6
(
7
0
0
) (
3
3
0
)
2
5
6
1
4
92
5
1
8
0
4
3
0
splice does not occur)
1
8
3
0
(
1
8
0
0
)
4
0
150
2
8
9
0
6
0
8
7
0
0
6
0
4
0
150
W360 x 33 spacer
tt i l
(
2
0
6
W150 x 13.5
Post
2
0
p
except terminal
1
1
7
0
39 April 2010 Contd
Blocked out W-beam Modified Thrie beam
Modified Thrie beam (Median)
Volume-II : Design
Typical Concrete Barriers
g
Typical Concrete Barriers
300mm 80mm
60mm
Tall wall NJ - Shape F - Shape
50mm
0
7
0
m
m
8
1
5
m
m
8
180
m
8 m
m
180mm
m
m
1
0
Top of Pavement
5
8
4
180mm
m
m
8
1
0
m
m
5
8
4
125mm
m
8
1
0
m
5
m
m
2
5
5
2%
820mm
5
5
7
5
m
m
2
5
5
m
5
5
5
m
m 1
8
0
m
40 April 2010 Contd
7
5
820mm
Asphaltic Concrete
7
7
5
Volume-II : Design
C h C hi t G A
g
Crash Cushion at Gore Area
Main Carriageway
Cushion Drum
GuideSign
Blinker Lighting
Crash Barrier
Off Ramp
Guide Sign
41 April 2010 Contd
Volume-II : Design
End Treatment at Bridge and Tunnel
g
End Treatment at Bridge and Tunnel
42 April 2010 Contd
End Treatment at Bridge End Treatment at Tunnel
Volume-II : Design
Other locations of Barriers
g
Other locations of Barriers
WATER BALASTED WATER BALASTED
REMOVABLE BARRIER
(Flexibility and ease in
placement)
Protection at Road Lighting Post
placement)
43 April 2010
Volume-II : Design
g
To provide adequate level of safety to high speed users of
expressways long distance visibility; large lettering and symbols;
and short legends for quick comprehension are the basic and short legends for quick comprehension are the basic
necessity.
I t h it b i id l bl i f ti f th Interchange exit numbering provides valuable information for the
users of Expressway. Interchange exit shall be guided in the
consistent manner by traffic signs such as advance Guide sign, consistent manner by traffic signs such as advance Guide sign,
Exit direction sign and Gore sign.
Th th id ti i l R t d l i The other considerations involve Rest area and general service,
Toll plaza, Route Markers, Distance marker, Regulatory signs,
Cautionary Warning signs, Design, Pavement marking, and Colour
44 April 2010 Contd
y g g , g , g,
and material.
Volume-II : Design
g
Expressway Start and End Signs
45 April 2010 Contd
Start of Expressway End of Expressway
Volume-II : Design
g
Exit (km) Numbering Sign
46 April 2010 Contd
Volume-II : Design
g
Exit Direction Sign
Exit Direction Sign Exit Sign at Gore Area
47 April 2010 Contd
Volume-II : Design
g
48 April 2010 Contd
Typical Layout for Trumpet Interchange
Volume-II : Design
g
Signing for Service Area
49 April 2010 Contd
Volume-II : Design
g
100 m Markers on Expressway
Detail A
50 April 2010 Contd
Volume-II : Design
g
Typical Overhead Mounted Structure Typical Exit Gore Sign
51 April 2010
Typical Overhead Mounted Structure. Typical Exit Gore Sign
Volume-II : Design
This chapter deals with Toll System based on Closed system with
g
This chapter deals with Toll System based on Closed system with
ticketing payment mode . The considerations involve Toll plaza
elements such as lane width at toll booth, toll plaza lane length
and Utility Bridge/Tunnel, number of toll lanes, ETC systems,
Management and Operation facilities and Audit systems.
Toll System: A closed-ticket toll system has an entrance and exit
booth for the toll system and capture all users. The closed-barrier
toll system provides the following benefits:
To capture toll from all facility users; To capture toll from all facility users;
To provide better enforcement for toll collection; and
To ensure users pay tolls that are directly related to the
di ll d h
52 April 2010 Contd
distance travelled on the system
Volume-II : Design
Payment Type
g
Payment Type
(a) Semi Automatic Toll Collection
In these lanes users can provide the toll in cash.
(b) Smart Card (b) Smart Card
A smart card is a plastic card with information on vehicle
details and the balance cash amounts. This is also known
as Touch & Go System.
(C) Electronic Toll Collection (ETC) (C) Electronic Toll Collection (ETC)
ETC consist of an On Board Unit (OBU) fitted on a vehicle
and a roadside antenna for necessary transaction.
53 April 2010 Contd
Volume-II : Design
Toll Plaza Elements
g
Toll Plaza Elements
The toll plaza consists of the following components:
(i) Lane width at toll booth; (ii) Transition zone; (iii) Removable (i) Lane width at toll booth; (ii) Transition zone; (iii) Removable
barrier; (iv) Traffic signs; (v) Road markings; (vi) Toll booth facility;
(vii) Office building; (viii) Barrier gate; (ix) Toll Plaza lanes;
(x) Utility Tunnel or over bridge for utility services and safe
movement of cash collections; and (xi) Turn around vehicular
underpass underpass
Lane Width at Toll Booth
Cash and Touch & Go may have lane width of 3.2 m and ETC
lane shall be of 3.5 m wide and a lane for 4.5 m wide for over
dimensional vehicles. It is desirable to keep provisions so that all
54 April 2010 Contd
dimensional vehicles. It is desirable to keep provisions so that all
lanes are upgradeable to ETC.
Volume-II : Design
g
Schematic Arrangement : Service Facilities at Toll Plaza
55 April 2010 Contd
Volume-II : Design
ETC T h l i DSRC S t Cl
g
ETC Technologies: DSRC System Classes
56 April 2010 Contd
Volume-II : Design
g
Comparison of ETC Technologies
Aspects
Infrared Radiation
with Active OBU
DSRC with Passive
OBU
DSRC with
Active OBU
p
with Active OBU OBU Active OBU
System
Performance
Satisfactory except
during heavy rain
Satisfactory Satisfactory
System Economy
Satisfactory except
monopoly nature
on the supply side
Satisfactory Satisfactory
System Expansion
& Upgrade for ITS
Limited Limited Abundant
European
Adopted areas
Malaysia, India
(Noida)
European
Countries, India
(Gurgaon)
Japan, USA,
Korea, China
M f t EFKON (A t i ) M M
57 April 2010 Contd
Manufacturers EFKON (Austria) Many Many
Volume-II : Design
g
Signages and Markings
Toll Plaza Sign
Toll Rate Sign at Exit Ramp
58 April 2010 Contd
(Assumed : Sign Placed at Jaipur)
Volume-II : Design
g
ETC Signages and Markings
Advance Gantry Sign Advance Gantry Sign
C
59 April 2010
Guide sign on Toll Lane Portal ETC Lane Marking
Volume-II : Design
g
For the expressway, the service areas shall be planned to be
provided at intervals of 30 minutes to one hour drive, which
corresponds to around 50 100 km spacing. The facility corresponds to around 50 100 km spacing. The facility
previsions have been adopted from AASHTO Guide for
Development of Service Areas on Major Arterials and Freeways
thi d diti d NEXCO ti i J third edition and NEXCO practices in Japan.
From security considerations, it is of prime consideration that o secu ty co s de at o s, t s o p e co s de at o t at
service areas will be provided near interchanges and at
intermediate locations where the distance between successive
interchanges is more than 100 km interchanges is more than 100 km.
Consideration for Physically challenged persons is mandatory for
60 April 2010 Contd
y y g p y
the facilities provided on expressways.
Volume-II : Design
C t l L t f I t h S i A B St
g
Conceptual Layout of Interchange cum Service Areas cum Bus Stop
61 April 2010 Contd
Volume-II : Design
g
TATSUNO-NISHI IC, AKAGI IC,
62 April 2010 Contd
SANYO Expressway KANETSU Expressway
Volume-II : Design
g
NADACHI TANIHAMA IC,
63 April 2010 Contd
HOKURIKU Expressway
Volume-II : Design
Si f S i A
g
Signages for Service Areas
Si f S i A
Distance Assurance Sign for Service Area
64 April 2010 Contd
Sign for Service Area
Volume-II : Design
P i i f P ith Di biliti (P D)
g
Provisions for Persons with Disabilities (PwD)
65 April 2010 Contd
Volume-II : Design
P i i f P ith Di biliti (P D)
g
Provisions for Persons with Disabilities (PwD)
66 April 2010
Volume-II : Design
Th b t h ll b l t d i th i
g
The expressway bus stops shall be located in the service area
adjacent to local bus routes. For a closed toll system of
expressway the basic philosophy of design is to provide layout p y p p y g p y
convenient for both local and expressway bus services and do not
involve passing through toll plaza.
67 April 2010 Contd
Volume-II : Design
T i l Pi k B St i J
g
Typical Pick-up Bus Stop in Japan
Expressways
Local Roads
Expressways
68 April 2010
Volume-II : Design
Th i f t i t i t d i i
g
The primary purpose of warrants is to assist designers in
evaluating locations or lighting needs and selecting locations for
installing AASHTO Warrants for expressway lighting categories installing. AASHTO - Warrants for expressway lighting categories
as (i) Continuous Expressway Lighting; (ii) Interchange Lighting
Complete and Partial; (iii) Bridge Structures and Underpasses; and Complete and Partial; (iii) Bridge Structures and Underpasses; and
(iv) Special situations.
Lighting Standards has been adopted from CIE 180:2007 Road
Transport Lighting for Developing Countries. p g g p g
Tunnel Lighting has been adopted from CIE 88:2004 Guide for the
69 April 2010 Contd
Lighting of Road Tunnels and Underpasses.
Volume-II : Design
G id F iliti D i Ni ht Ti
g
Guidance Facilities During Night Time
Guidance facilities during night time comprise of interior/exterior Guidance facilities during night time comprise of interior/exterior
illuminated signs, blinker lights and delineators.
Gl d ti d i i d f d i th h dli ht Glare reduction devices are required for reducing the headlight
glare of opposing traffic at night which may distract from driving
tasks.
70 April 2010
Blinker Lights Delineators Visual Barrier
Volume-II : Design
Chapter 14 : Noise Barriers
Noise Barrier shall be provided to protect sensitive land uses from
g
Noise Barrier shall be provided to protect sensitive land uses from
expressway noise. The considerations involve Placement,
reduction effect, Design and Types of barriers. Transparent type
i b i f d th h th i f t noise barriers are preferred even though these require frequent
maintenance (cleaning).
71 April 2010
Full height transparent acrylic panel
Combination of acrylic and metal panel
VOLUME III
OPERATIONS AND
MANAGEMENT
Sheet 1 of 2
VOLUME III : OPERATIONS AND MANAGEMENT

EXECUTIVE SUMMARY

The Document Volume-III: Operations and Management is complementary to other guideline
volumes. The objective of this document is to assist the design engineer in project preparation for
the identified sections of National Expressway Network.

The contents of this document are necessarily a compilation on requirements illustrative which are
generally not covered by the available documents/practices. The intended users of this document
will be the Expressway professionals/engineers.

This document has been structured into 3 (three) chapters as follows:

Chapter 1 : Toll Plaza Operation
Chapter 2 : Traffic Management
Chapter 3 : Service Area Management


This chapter provides relevant aspects of toll plaza operations in a holistic manner. The toll plaza
at various interchange location have different toll lane requirements involving various methods of
collection viz. Manual, Smart Card and ETC.

For a closed toll system the collection methodology deliberates ticketing systems, toll collection
methods and toll gate operations. Operations in toll plaza cover the aspects and activities at entry
and exit; control of over loaded/over sized vehicles along with regulatory authorities for imposing
necessary legal/penal measures. Activities for alleviating traffic congestion including measures
such as flexible gate opening, capacity enhancement, organizations, and responsibilities along
with occasions for surprise checking have been covered.

Traffic safety measures include signage, road markings, safety cushions at gore areas, ETC
related safety measures and toll area safety including provisions for utility and turn around
provisions for emergency vehicles.

Additional safety measures dealt features (not mandatory but desirable) to enhance safety of toll
operators, toll lane inspectors. This include adequate information to drivers/users, push button /
alarm switch inside toll booth, wide signage over toll booth along with flashing spindle, safety
ropes and safety bars between toll lanes and provision of air conditioning facilities inside booth.
Security at toll plaza mainly deliberates on overall safety of the plaza area.

Audit section describes the general procedures and the frequently met aspects of monitoring toll
collection data and associated counter measures.

Counter measures for toll evasion covers on measures for control on ticket exchange and
preventing / minimizing passing through toll gate without paying (Tailgating).

Sheet 2 of 2

This chapter has been presented under two broad heads viz. Traffic Control and Incident
Management.

Traffic Control section deliberates on (i) Information collection includes emergency communication
system; mobile communication system, meteorological data system, automatic traffic counters
cum classifiers system, closed circuit television, transmission system and vehicles for route patrol.
(ii) Control center which comprises of traffic management center, facility control center and
disaster control center which inter-alia include natural disasters. (iii) Information dissemination
deliberates on types of information and the medium such as variable message signs, portable
VMS on vehicles, highway advisory radio, internet or mobile services, and Vehicle Information
and Communication System (VICS).

Incident Management section covers with aspects of (i) traffic accident, (ii) bad weather,
(iii) current practices, methods, strategies and technologies.


The conventional development of road side amenities and rest areas is no longer being
considered as free facilities for the toll roads. The current global trend is to commercialize these
facilities, and service areas. New developments in this regard are as follows:

- Administration for service area covers on organisation and risk sharing between the
expressway authority and the concessionaires. This has been discussed using current
J apan scenario for developing under Indian scenario.

- Customer services include provision for high quality services and facilities to the
expressway users. This includes traffic information, local tourist information, facilities for
Persons with Disability (PwD), and services available for comfortable and enjoyable stay.

- Use of Eco friendly energies such as solar and wind power, recycling of waste water, heat
sealed pavement, water retaining pedestrian blocks, garbage recycling including reduction,
and rainwater harvesting have been covered.

- Facility planning for profitable service area includes merchandising plans explained based
on case study for Connecticut, USA; J apan, and Indian scenario.

As an added tool, Parking Management has been described along with pictorial layout of similar
facilities in J apan.

CONTENTS

CHAPTER 1: TOLL PLAZA OPERATION

1.1 Toll Collection Methodology

1.1.1 Outline of Ticketing Systems
1.1.2 Types of Toll Collection Methods
1.1.3 Toll Gate Activities

1.2 Operation in Toll Plaza

1.2.1 Broad Operations
1.2.2 Control of Overloaded/Oversize Vehicles
1.2.2.1 Daily Checking
1.2.2.2 Special Checking with Police
1.2.3 Traffic Congestion Measures
1.2.3.1 Flexible Gate Opening
1.2.3.2 Capacity Enhancement
1.2.4 Organization and Responsibilities
1.2.5 Surprise Checking

1.3 Traffic Safety at Toll Plaza

1.3.1 Safety Measures at Toll Plaza
1.3.1.1 Signages
1.3.1.2 Road Markings
1.3.1.3 Safety Cushions
1.3.1.4 ETC related Safety Measures
1.3.1.5 For Toll Area Safety

1.4 Additional Safety Measures at Toll Plaza

1.4.1 Additional Safety Features

1.5 Security at Toll Plaza

1.6 Audit

1.6.1 General Procedure
1.6.2 Monitoring Toll Collectors Data and Counter Measures

1.7 User Service at Exit Booth

1.7.1 Drivers Enquiry
1.7.2 Traffic Information on Incident
1.7.3 Advertisement
1.7.4 Trouble shooting
1.7.4.1 Machine Trouble
1.7.4.2 Lost Ticket
1.7.4.3 ETC Error

1.8 Toll Evasion Counter Measures

1.8.1 Ticket Exchange
1.8.2 Pass through Toll Gate without Paying
1.8.2.1 Tailgating

CHAPTER 2: TRAFFIC MANAGEMENT

2.1 Traffic Control

2.1.1 Information Collection
2.1.1.1 Emergency Communication System
2.1.1.2 Mobile Communication System
2.1.1.3 Meteorological Data System
2.1.1.4 Automatic Traffic Counters cum Classifier System (ATCC)
2.1.1.5 Closed Circuit Television (CCTV)
2.1.1.6 Transmission System
2.1.1.7 Patrol Vehicle: Route Patrol

2.1.2 Control Center
2.1.2.1 Traffic Management Center
2.1.2.2 Facility Control Center
2.1.2.3 Disaster Prevention Center

2.1.3 Information Dissemination
2.1.3.1 Variable Message Signs
2.1.3.2 Portable VMS on Vehicles
2.1.3.3 Highway Advisory Radio
2.1.3.4 Internet or Mobile Services
2.1.3.5 Vehicle Information and Communication System (VICS)

2.2 Incident Management

2.2.1 Traffic Accident
2.2.1.1 Information Collection
2.2.1.2 Information Provisions
2.2.1.3 On Site Action

2.2.2 Inclement Weather
2.2.2.1 Information Collection
2.2.2.2 Information Provisions
2.2.2.3 On Site Action
CHAPTER 3: SERVICE AREA MANAGEMENT

3.1 Administration for Service Area

3.1.1 Organisation
3.1.2 Expressway Authority and Business Tenants :
Risk Sharing

3.2 Customer Services

3.2.1 Traffic Information
3.2.2 Local Tourist Information
3.2.3 Facilities for Persons with Disabilities (PwD)
3.2.4 Facilities for Comfortable and Enjoyable Services

3.3 Environmental Consideration

3.3.1 Solar and Wind Power
3.3.2 Recycling of Waste Water
3.3.3 Heat Sealed Pavement and Water Retaining
Pedestrian Blocks
3.3.4 Garbage Recycle and Reduction
3.3.5 Rainwater Harvesting

3.4 Facility Planning for Profitable Service Area

3.4.1 Merchandising Planning
3.4.2 Parking Management
3.4.3 Safety and Maintenance of Service Areas

GUIDELINES FOR EXPRESSWAYS GUIDELINES FOR EXPRESSWAYS
CONTENTS CONTENTS
VOLUME III: OPERATIONS AND MANAGEMENT
Ch t 1 T ll Pl O ti
VOLUME III: OPERATIONS AND MANAGEMENT
Chapter 1 - Toll Plaza Operation
Chapter 2 - Traffic Management
Chapter 3 - Service Area Management
Volume-III: Operations and Management
Volume-IV: Maintenance
Volume III: Operations and Management
Volume-IV: Maintenance
Volume-III : Operations and Management p g
The Document Volume-III: Operations and Management is p g
complementary to other guideline volumes. The contents of this
document are necessarily a compilation on requirements and docu e t a e ecessa y a co p at o o equ e e ts a d
illustrative which are generally not covered by the available
documents / practices comprehensively. documents / practices comprehensively.
1 April 2010
p g
This chapter provides relevant aspects of toll plaza operations in a
holistic manner. The toll plaza at various interchange location have
different toll lane requirements involving various methods of
collection viz. Manual / Cash, Smart Card and ETC.
2 April 2010 Contd
Two piece OBU with an IC Card Touch & Go Smart Card
p g
For a Closed Toll System the collection operations comprise
ticketing systems, toll collection methods and toll gate operations. g y , g p
Operations in toll plaza cover the aspects and activities at entry and
exit; control of over loaded/over sized vehicles along with
regulatory authorities for imposing necessary legal/penal
measures.
Activities for alleviating traffic congestion such as flexible gate
opening, capacity enhancement, safety and surprise checking
i i provisions.
3 April 2010 Contd
p g
Traffic safety measures include signage, road markings, safety
cushions at gore areas, ETC related safety measures and toll area
safety including provisions for utility and turn around provisions
for emergency vehicles.
Additional safety measures dealt features (not mandatory but
desirable) to enhance safety of toll operators and toll lane
inspectors. This include adequate information to drivers/users,
push button /alarm switch inside toll booth, wide signage over toll
booth along with flashing spindle safety ropes and safety bars booth along with flashing spindle, safety ropes and safety bars
between toll lanes and provision of air conditioning facilities inside
booth. Security at toll plaza mainly deliberates on overall safety of y p y y
the plaza area.
4 April 2010 Contd
p g
Toll Area Provisions
Typical View inside Toll Booth Typical Turn Around
5 April 2010 Contd
Typical View inside Toll Booth Typical Turn Around
p g
Additional Safety Measures
Large size Open/closed signal along
Signal
with spin light at the toll plaza gantries
should be provided. This will facilitate
th t l t th i t l It the user to select the appropriate lane. It
shall be operable from the toll booth as
well as from the operation office (toll
Spin light
well as from the operation office (toll
office).
Signal and Spin Light
6 April 2010 Contd
g p g
p g
Safety rope and barrier may reduce the danger of accident with
casualties for lane supervisor.
7 April 2010 Contd
Typical Safety Rope and Bar
p g
Blocking sunlight, especially in the
morning and in the afternoon with
provision of a shield to eliminate provision of a shield to eliminate
reflection of light which improves
the visibility of the display panel of
th l f t ll ll t d the console for toll collectors and
of the toll indicator for users.
The roof of the toll gate at both
ends shall be designed
accordingly
Typical Sunray Shield at Toll Booth
accordingly.
8 April 2010
p g
This chapter has been presented under two broad heads viz. Traffic
Control and Incident Management.
Traffic Control section deliberates on (i) Information collection
includes emergency communication system; mobile communication
system, meteorological data system, automatic traffic counters cum
classifiers system, closed circuit television, transmission system and
vehicles for route patrol (ii) Control center which comprises of traffic vehicles for route patrol. (ii) Control center which comprises of traffic
management center, facility control center and disaster control center
which inter-alia include natural disasters. (iii) Information
dissemination deliberates on t pes of information and the medi m dissemination deliberates on types of information and the medium
such as variable message signs, portable VMS on vehicles, highway
advisory radio, internet or mobile services, and Vehicle Information
and Communication System (VICS).
9 April 2010 Contd
p g
Information Collection
View transmitted to TMC Typical CCTV
10 April 2010 Contd
View transmitted to TMC Typical CCTV
p g
Control Center
Traffic Management Center
Close View of Monitoring Screen
11 April 2010 Contd
p g
Information Dissemination : VMS at Interchanges
Expressway
200m
VMS
VMS
V
M
S
1
0
0
m
200m
VMS
M
S
TOLL GATE
V
M
N
a
t
i
o
n
a
l

H
i
g
h
w
a
y
1
0
0
m
12 April 2010 Contd
V
M
S
p g
Typical Pictorial Presentations on VMS
13 April 2010 Contd
p g
Portable VMS in Work Zone
14 April 2010 Contd
p g
Incident Management comprises:
15 April 2010 Contd
Incident Management - 1
16 April 2010 Contd
I id t M t 2 Incident Management - 2
Incident Management - 3
17 April 2010 Contd
p g
Incident Management - This section covers:
Traffic Accident
Information Collection from (i) Field units at the incident site; Information Collection from (i) Field units at the incident site;
(ii) Closed circuit TV images; (iii) Information service providers;
and (iv) Combing and fusing information from multiple cellular
calls.
Information Provisions using (i) Commercial radio and Information Provisions using (i) Commercial radio and
television; (ii) Variable message signs; (iii) Highway advisory
radio; (iv) In-vehicle and personal information system; and
( ) I t t/ li i ( bil ) (v) Internet/on-line services (mobile)
18 April 2010 Contd
p g
Traffic Accident (Contd)
On site action The prime requirement would be:
- To send ambulance at the incident site
- Traffic regulation / control / management g g
- Removal of vehicle or cargo involved in the incident
Vehicle fire extinguish - Vehicle fire extinguish
- Removal of vehicles damaged in the accident
19 April 2010 Contd
Incident Management This section covers:
Inclement Weather (not conducive to comfortable driving)
Information Collection from the metrological information facilities.
Item Meteorological Observation Instrument Item Meteorological Observation Instrument
Air temperature Thermometer
Rainfall Rain/snow gauge, precipitation sensor a a a /s o gauge, p ec p tat o se so
Snowfall Rain/snow gauge, CCTV, transmissivity meter, or B S type visibility meter
Mist CCTV, transmissivity meter or B S type visibility meter
Wind Anemoscope/anemometer (wind vane type)
Earthquake Seismograph
20 April 2010 Contd
Road icing Road surface temperature gauge (underground thermometer)
Inclement Weather (not conducive to comfortable driving) (Contd)
I f ti i i Th l d i f ti hi h Information provisions : The analyzed information which are
non-conducive to comfortable driving shall be communicated to
drivers using (i) Commercial radio and television; (ii) Variable g ( ) ; ( )
message signs; (iii) Highway advisory radio; (iv) In-vehicle and
personal information system; and (v) Internet / on-line services
(mobile) (mobile)
On site action:
Cl d id d i i l di h t - Clean road side drains including chutes
- Enhance surfacing to prevent hydroplaning
M h i d l d di d i i h i l
21 April 2010
- Mechanized snow removal and spreading de-icing chemicals
Contrary to conventional development of service and rest areas,
the current global trend is to commercialize these facilities.
New developments in this regard are as follows:
- Administration for service area covers on organization and risk
sharing between the expressway authority and the
i i concessionaires.
- Customer services include high quality services and facilities Customer services include high quality services and facilities
to the expressway users. This includes traffic information, local
tourist information, facilities for Persons with Disability (PwD)
d i il bl f f t bl d j bl t
22 April 2010 Contd
and services available for comfortable and enjoyable stay.
View of a typical PASAR
23 April 2010 Contd
Typical Customer Services Layout
24 April 2010 Contd
Integrated Arrangement : Service Area with Amusement Parks
25 April 2010 Contd
Facilities for Persons with Disability (PwD)
Exclusive Parking
Eli i t diff i l l
Exclusive Parking
Eliminate difference in level
26 April 2010 Contd
Installation of handrail
Multipurpose toilet Special toilet
Environmental Consideration
Use of Solar and Wind Power
27 April 2010 Contd
Solar Power
Hybrid (Solar & Wind Power)
Water Retaining Pedestrian Blocks and
Heat Sealed Pavement
Walkways are provided with porous water
retaining/holding blocks to reduce g g
accumulation of rainwater on the surface
in addition to adequately designed
drainage provisions and cross slopes drainage provisions and cross slopes.
For the adjoining areas, the restaurants,
h t hi ld t f heat shield pavement surfaces are
provided to reduce the ambient
temperatures to a lower level, giving the
28 April 2010
p , g g
visitors more comfort.
VOLUME IV
MAINTENANCE
Sheet 1 of 2
VOLUME IV: MAINTENANCE

EXECUTIVE SUMMARY

The document Volume-IV: Maintenance shall be read along with the other volumes of the
Guidelines to appreciate the various considerations on design, operations and management
aspects for the expressways along with all the appurtenances. The expressway maintenance
requires a systematic approach to preserve, repair and restore its elements to its design or
accepted configurations. Its system elements include carriageway surfaces, shoulders, road
verges and slopes, drainage facilities, bridges, tunnels, signs, markings, lightings, fixtures, toll
plaza, service areas etc.

Maintenance shall also take care to offset the effect of weather, environments, growth of
vegetation, deterioration, traffic wear and damages on asset due to vandalism. Deterioration
would include effects of ageing, material failures and fatigues, design and construction faults.

Maintenance and repair of building, stock piles and equipments are essential to preserve the
expressway asset.

This document intends to provide basic information for maintenance engineers to formulate
appropriate maintenance, inspection and reporting system, which will in turn enable better
expressway management in terms of planning, manpower and budgeting.

Document has been structured into 8 (eight) chapters as follows:

Chapter 1 : General
Chapter 2 : Maintenance Management
Chapter 3 : Inspection
Chapter 4 : Maintenance Works and Repair
Chapter 5 : Maintenance Operations
Chapter 6 : New Maintenance Practices
Chapter 7 : Preventive Maintenance
Chapter 8 : Disaster Prevention

The first and second chapter deliberates on general requirement and maintenance management,
which inter-alia covers base data collection and relationship between inspection & maintenance.

Chapter-3 deliberates on the essential requirements of maintenance Inspection. This
comprehensively presents the type, frequency and inspection targets. The inspection work also
covers Inspection Program & Operation, Assessment and Inspection Reports. Typical ranking of
inspection for maintenance dealing with various item of maintenance and its assessment for
ranking (AA, A, B, C, OK, E) has been presented in tabular forms to aid maintenance engineers in
formulations of work programs.

Maintenance Works and Repair as provided in Chapter-4, deliberates on the various items broadly
in two sections (i) maintenance works, and (ii) maintenance repair. Each section covers brief
description of the various items associated with maintenance to retain functional and structural
integrity of the expressway asset.

Sheet 2 of 2
Chapter-5 : Maintenance Operations has been provided with the essential considerations for
carrying out the maintenance activities such as work zone safety, environmental protection,
inspection and assessment, defect treatments along with consideration and options. This chapter
also highlights the mechanization and equipment necessary to provide due diligence to the
maintenance operations on high volume, high speed expressways.

Chapter-6 : New Maintenance Practices, deliberates on the current scenario as followed in other
countries for similar services. This chapter comprehensively deals with equipment for data
collection for roadways; bridge and structures; service areas and other appurtenances. For
functional improvement of road surfaces in wet weathers, use of porous asphalt and micro
surfacing along with improvement in drainage has been briefly mentioned. The other aspects
considered are (i) rigid pavement milling and overlaying, (ii) waterproofing and repair of structures,
(iii) protection against corrosion and salt damage, and (iv) special road marking for night visibility.
This chapter also indicates on formation of Maintenance Company for leasing of maintenance
vehicles.

Preventive Maintenance as briefly mentioned in Chapter-7, includes (i) necessity for applying the
right treatment to the right pavement at the right time, and (ii) necessity of preventive
maintenance has been broadly linked to inspection assessment.

Damages occurring due to natural calamities like heavy floods, sand storms, cyclones,
earthquakes to any element or system of the expressway shall be rectified and restored. All such
activities require exhaustive deliberation. However, this Chapter-8 presents a cursory glance to
essential aspects. This chapter broadly covers (i) pre-event preparedness measures, (ii) policy
and organization for repair, (iii) emergency measures, (iv) classifications of works, (v) slope
protections against disaster, and (vi) protection against earthquake disaster. A disaster restoration
work flow and typical damages suffered by the various components have been presented in
pictorial form with short illustrations.

CONTENTS

CHAPTER 1: GENERAL

1.1 Introduction

1.2 Basic Maintenance Objectives and Policies

1.2.1 Basic Objectives
1.2.2 Policies for Maintenance Implementation

CHAPTER 2: MAINTENANCE MANAGEMENT

2.1 Introduction

2.2 Base Data Collection

2.3 Relationship Between Inspection and Maintenance

CHAPTER 3: INSPECTION

3.1 Inspection

3.1.1 General
3.1.2 Types of Inspection
3.1.3 Frequency of Inspection
3.1.4 Inspection Targets

3.2 Inspection Works

3.2.1 Inspection Programme and Operation
3.2.2. Assessment
3.2.3 Inspection Report
3.2.3.1 Daily Inspection Report
3.2.3.2 Monthly Summary Report
3.2.3.3 Periodic or Special Inspection Report
3.2.3.4 Annual Summary Report

CHAPTER 4: MAINTENANCE WORKS AND REPAIR

4.1 Introduction

4.2 Maintenance Works

4.2.1 Cleaning Works
4.2.2 Horticultural
4.2.2.1 Type of planting work
4.2.2.2 Pruning
4.2.2.3 Plant fertilization
4.2.2.4 Insecticide spray on trees
4.2.2.5 Weed-vine clearing
4.2.2.6 Irrigation
4.2.2.7 Renovation of props and supports
4.2.2.8 Removal of propos
4.2.2.9 Removal of decayed or damaged trees
4.2.2.10 Weed Cutting
4.2.2.11 Felling
4.2.2.12 Lawn mowing
4.2.2.13 Fertilizing turfs
4.2.2.14 Manual weeding
4.2.2.15 Chemical spray
4.2.2.16 Insecticide spray on turfs
4.2.2.17 Top dressing
4.2.2.18 Grass cutting
4.2.2.19 Slope fertilization
4.2.3 Traffic Accidents Recovery Works
4.2.3.1 Replacement of crash barriers
4.2.3.2 Replacement of boundary fences
4.2.3.3 Replacement of anti-glare screens
4.2.3.4 Replacement of delineators
4.2.3.5 Replacement of kilometer posts
4.2.3.6 Replacement of traffic signs

4.3 Maintenance Repair

4.3.1 Replacement of Bridge Bearings and Expansion J oints

4.3.1.1 Bridge Bearings
4.3.1.2 Expansion Joints
4.3.1.3 Replacement of Elastomeric Joint
4.3.2 Replacement of steel finger joint
4.3.3 Replacement of elastomer with buried joint

4.3.4 Waterproofing of steel finger joint
4.3.5 Minor renovation of pavements
4.3.5.1 Pot holes
4.3.5.2 Crack Seal
4.3.6 Local replacement of pavements
4.3.7 Correction of difference in grade
4.3.8 Road Marking
4.3.9 Partial replacement of bridge decks

CHAPTER 5: MAINTENANCE OPERATIONS

5.1 Operational Considerations

5.1.1 General
5.1.2 Work Zone Safety
5.1.3 Environmental Protection
5.1.4 Inspection and Assessment
5.1.5 Defect Treatments considerations and selection
5.1.6 Defect Treatment Options
5.1.7 Mechanisation and Equipment
5.1.7.1 Introduction
5.1.7.2 Equipment for Maintenance

CHAPTER 6: NEW MAINTENANCE PRACTICES

6.1 Equipment for Data Collection

6.1.1 Introduction
6.1.2 Data Collection
6.1.3 Types of Pavement Evaluations
6.1.4 Pavement Data Collection Equipment
6.1.5 Bridge Evaluations
6.1.6 Bridge Inspections and Data Collection Equipment
6.1.7 Use of Data Collection Equipment
6.1.7.1 Data Collection for Road Surface Conditions
6.1.7.2 Data Collection for Structures and Road Appurtenances
6.2 Bituminous Pavement Mill and Overlay (including recycling)

6.3 Porous Asphalt Pavement

6.3.1 Introduction
6.3.2 Drainage

6.4 Micro Surfacing Special Treatment

6.5 Rigid Pavement Milling and Overlaying

6.5.1 Pavement Milling
6.7.2 Concrete Pavement Overlaying

6.6 Waterproofing Bridge Decks

6.7 Repair of Structures with Epoxy Resin

6.8 Protection against Spalling of Concrete

6.8.1 Spray Coating
6.8.2 Installation of Steel Plate

6.9 Protection against Corrosion and Salt Damage

6.10 Special Road Marking for Improved Day/Night Visibility

6.10.1 Introduction
6.10.2 Materials
6.10.3 Applications

6.11 Tunnel Maintenance

6.11.1 Inspection
6.11.2 Maintenance/ Improvement Work
6.11.3 Tunnel Water Leakage

6.12 Leasing of Maintenance Vehicles (Maintenance Company)

6.12.1 Introduction
6.12.2 Possible Scope of Business outline
6.12.3 Essential Equipment for Maintenance of Expressways
6.12.4 Conclusion

CHAPTER 7: PREVENTIVE MAINTENANCE

7.1 Introduction

7.2 Necessity of Preventive Maintenance

7.3 Benefits of Preventive Maintenance

7.4 Conclusions

CHAPTER 8: DISASTER PREVENTION

8.1 General

8.2 Pre-Event Preparedness Measures

8.3 Policy and Organisation for Repair

8.4 Emergency Measures

8.5 Classification of Works

8.6 Protection of Slopes against Disaster

8.6.1 Concrete block frame
8.6.2 Concrete (mortar) spray
8.6.3 Concrete Sprayed Frame
8.6.4 Installation of Gabion Mat
8.6.5 Installation of rockfall protection net
8.6.6 Treatment of Boulders
8.6.7 Concrete block masonry
8.6.8 Earth reinforcement

8.7 Protection against Seismic Disasters

8.7.1 Edge expansion and girder linkage
8.7.2 Reinforcement of piers

8.8 Disaster Restoration
CONTENTS
Chapter 1 General
VOLUME IV: MAINTENANCE
Chapter 1 - General
Chapter 2 - Maintenance Management
Chapter 3 - Inspection
Chapter 4 - Maintenance Works and Repair
Chapter 5 - Maintenance Operations
Chapter 6 - New Maintenance Practices Chapter 6 - New Maintenance Practices
Chapter 7 - Preventive Maintenance
Chapter 8 - Disaster Prevention
Volume-IV: Maintenance shall be read along with the other volumes
of the
Guidelines to appreciate the various considerations on design,
f operations and management aspects for the expressways along
with all the appurtenances.
The expressway maintenance require a systematic approach to
preserve repair and restore its elements to its designed or preserve, repair and restore its elements to its designed or
accepted configurations. Asset elements include carriageway
surfaces shoulders road verges & slopes drainage facilities surfaces, shoulders, road verges & slopes, drainage facilities,
bridges & culverts, underpasses, tunnels, signs, markings,
lightings, toll plaza, service areas etc. g g , p ,
1 April 2010 Contd
Maintenance shall also take care to offset the effect of weather,
environments, growth of vegetation, traffic wear and damages on
asset due to vandalism. Deterioration would include effects of
f f ageing, material failures and fatigues, design and construction
faults.
This document intends to provide basic information for
i t i t f l t i t i t maintenance engineers to formulate appropriate maintenance,
inspection and reporting system along with planning, manpower
and budgeting.
2 April 2010
Chapter 1: General & Chapter 2: Maintenance Management
The first and second chapter deliberates on general requirement
and maintenance management, which inter-alia covers base data
collection and relationship between inspection & maintenance collection and relationship between inspection & maintenance.
3 April 2010 Contd
Types of Maintenance Activities
Inspection Inspection
Planning Planning
Inspection Inspection
Maintenance Maintenance
Work Work
The Typical Maintenance Cycle
Evaluation Evaluation and and
Judgment Judgment
Maintenance Maintenance
Planning Planning
4 April 2010 Contd
Maintenance Flow
5 April 2010 Contd
Maintenance Flow : Inspection
Inspection from vehicle
Embankment inspection
6 April 2010 Contd
Maintenance Flow : Inspection
Bridge inspection
Tunnel inspection
7 April 2010 Contd
Maintenance Flow : Maintenance / Improvement
Pavement repair
Safety barrier repair
8 April 2010 Contd
Maintenance Flow : Maintenance / Improvement
Embankment repair
Bridge pier jacketing
9 April 2010 Contd
Maintenance Flow : Emergency Repair
Implementing traffic
t i ti i t
Implementation of
10 April 2010
restrictions on main route
emergency repair work
Chapter 3: Inspection
Frequency of Inspection and Reporting
Type of
Inspection
Description Reporting
R ti i ti t l t d d Routine inspection to evaluate road and
traffic condition. Coarse Visual
Inspection (CVI) to assess overall
Daily
Routine
inspection
health of the asset as a whole. Any
defect noticed shall be highlighted
identifying locations.
Daily
y g
Road user facilities and amenities
including Service Areas, Rest Areas,
Toll Plazas Truck Parking Areas etc
Weekly
11 April 2010 Contd
Toll Plazas, Truck Parking Areas, etc.
T f D i ti R ti Type of
Inspection
Detailed Visual Inspection (DVI)
M thl
eta ed sua spect o ( )
periodically especially identified in CVI,
structures, slope protection or
embankment, safety measures, etc. with
Monthly,
commencing from
the date of
t ti
Periodic
inspection
embankment, safety measures, etc. with
diagnostic and prescriptive content.
construction
Pavement Condition Assessment
functional and structural
Yearly (Preferably
after monsoon) functional and structural. after monsoon)
Mechanical and Electrical (Toll, emergency
telephone, street light, traffic signage)
Quarterly
12 April 2010 Contd
Type of
Inspection
S i l
Unusual emergency cases impeding
the service facility, due to storm,
rain, landslide, earthquakes and
Immediately on
occurrence and on
Special
inspection
rain, landslide, earthquakes and
similar natural avalanches.
M j id t ill f li id
occurrence and on
compliance with
necessary
ti iti Major accidents, spillage of liquids
requiring lane closure.
activities
13 April 2010 Contd
Process of Inspection,
Assessment, and Assessment, and
Repairs
14 April 2010 Contd
R ki T i l C diti Ranking Typical Condition
AA Has severe damage/deformation. Requires immediate repair to recover its
functionality
A Has damage/deformation and functional deterioration Requires repair but not
Functional
A Has damage/deformation and functional deterioration. Requires repair but not
immediately
A1* Does not require immediate repair, but has functional deterioration which is
expected to worsen rapidly. Estimated to require repair within 2 years.
deterioration
(including
visual
structural
A2* Does not require immediate repair, but has functional deterioration which is
expected to worsen gradually. Estimated to require repair within 5 years.
A3* Has functional deterioration but the speed of deterioration is slow. Requires
it i ti l ft 5 ti d d t i i th ti i f
distresses)
monitoring continuously or after 5 years time, and determining the timing of
repair accordingly.
B No sign of functional deterioration albeit damage/ deformation. Requires
continuous monitoring of damage/deformation g g
C Requires investigation in order to assess its functionality
OK No or only slight sign of damage/deformation
Affect Traffic E Has risk of affecting the safe traffic condition Requires immediate attention
15 April 2010 Contd
Affect Traffic
Safety
E Has risk of affecting the safe traffic condition. Requires immediate attention.
R ki T i l C diti Ranking Typical Condition
AA Has severe damage/deformation. Requires immediate repair to
recover its functionalityy
A Has damage/deformation and functional deterioration. Requires
repair but not immediately
A1* Does not require immediate repair, but has functional
deterioration which is expected to worsen rapidly. Estimated to
require repair within 2 years.
A2* Does not require immediate repair, but has functional
deterioration which is expected to worsen gradually. Estimated to
require repair within 5 years. require repair within 5 years.
A3* Has functional deterioration but the speed of deterioration is
slow. Requires monitoring continuously or after 5 years time,
and determining the timing of repair accordingly
16 April 2010 Contd
and determining the timing of repair accordingly.
Ranking Typical Condition
B
No sign of functional deterioration albeit damage/
d f ti R i ti it i f B deformation. Requires continuous monitoring of
damage/deformation
C Requires investigation in order to assess its functionality
OK No or only slight sign of damage/deformation OK No or only slight sign of damage/deformation
E
Has risk of affecting the safe traffic condition. Requires
immediate attention. immediate attention.
For ranking AA and E shall be considered for maintenance activities.
For ranking A, B and C shall be noted and informed to the following
i ti f i t ti
17 April 2010 Contd
inspection group for appropriate actions.
I ti It d R ki
Sl.
N
Item Assessment
Inspection Items and Ranking
No.
AA A (A1, A2, A3) B
1. Pothole, patching,
scaling
Over 20 mm in depth and
over 20 cm in diameter
Less than 20 mm in depth or
less than 20 cm in diameter
2. Faulting Over 20 mm 10 mm to 20 mm
3. Rutting Over25mm 15 mm to 25mm
4. Cracking Over 20% of Cracking Ratio 10% to 20% of Cracking Ratio
5. Stagnant water stagnant water observed
whenever it rains
6. Joint breakage Joint break
7. Damage to kerb Extreme breakage or lifting Appreciable breakage or lifting
of precast kerb
Minor breakage
or lifting of
18 April 2010
p
Losing drainage function
g
precast kerb
Chapter 4: Maintenance Works and Repair
Maintenance Works and Repair as provided in Chapter-4,
deliberates on the various items broadly in two sections (i) deliberates on the various items broadly in two sections (i)
maintenance works, and (ii) maintenance repair. Each section
covers brief description of the various items associated with covers brief description of the various items associated with
maintenance to retain functional and structural integrity of the
expressway asset expressway asset.
19 April 2010 Contd
Cleaning Works
Classification
Sub-
Working method Coverage Classification
classification
Working method Coverage
Type A
cleaning
Cleaning by sweeper
Main line and ramp way
shoulders and their
cleaning
peripheries
Type B
cleaning
Washing by sprinkler
truck
Main line and ramp way
shoulders beyond reach of
Surface
cleaning
cleaning truck
sweeper
Type C
cleaning
Manual cleaning to
supplement type A or B Mostly, road surfaces
cleaning
cleaning
Type D
cleaning
Manual cleaning of
roads not covered by Road surfaces
20 April 2010 Contd
cleaning
y
type-A or B cleaning
Cleaning Works
S b Working
Classification
Sub-
classification
Working
method
Coverage
Type A Manual Service and parking areas (road
Interchange
and area
cleaning
cleaning cleaning portions)
Type B
cleaning
Manual
cleaning
Service and parking areas
(garden portions)
cleaning
g g (g p )
Type C
cleaning
Manual
cleaning
Interchanges (garden portions)
Associated Lavatories Manual Lavatories in service/parking Associated
facilities
cleaning
Lavatories Manual
cleaning
Lavatories in service/parking
areas and bus stops (windows,
floors, washrooms, stools and
bowls etc )
21 April 2010 Contd
bowls, etc.)
Cleaning Works
Classification
Sub-
classification
Working
method
Coverage
classification method
Crash
b i
A
Manual
cleaning
Guardrails
Cleaning of
barriers
B
Manual
cleaning
Handrails
A
Manual Delineators, distance markers,
g
road
appurtenances,
etc.
T ffi i
A
cleaning emergency telephone signs
B
Manual
cleaning
Overhead traffic signs
Traffic signs
C
Manual
cleaning
Signs on the shoulder
Manual Traffic control warning and other
22 April 2010 Contd
D
Manual
cleaning
Traffic control, warning and other
signs installed on the shoulder
Cleaning Works
Classification
Sub-
classification
classification
A
Mechanical
cleaning
Underground drain pipes (150-300 mm
dia)
Cl i f d
Drain pipes B
Mechanical
cleaning
Underground drain pipes (350-1200
mm dia)
Mechanical
Cleaning of road
appurtenances,
etc.
C
Mechanical
cleaning
Circular waterways
A
Manual
cleaning
Rolled gutters
Gutters
cleaning
B
Manual
cleaning
Uncovered gutters
Manual
23 April 2010 Contd
C
Manual
cleaning
Covered gutters
Cleaning Works
Classification
Sub- Working method Coverage
Classification
classification
Median strips
(inlets)
Manual cleaning Median strip (inlets)
Cleaning of road
( )
Catch basins
A Manual cleaning Catch basins
Cleaning of road
appurtenances,
etc.
Catch basins
B
Mechanical
cleaning
Catch basins
Mechanical Joints on the two-lane (each way)
Joints
A
Mechanical
cleaning
Joints on the two-lane (each way)
highway
B
Mechanical
cleaning
Joints on the three-lane (each way)
highway
24 April 2010 Contd
cleaning highway
Cleaning Works
Classification
Sub-
l ifi ti
C ass cat o
classification
Catch basins
A
Manual or
mechanical
l i
Catch basins on bridges and viaducts
Cleaning of
road
or highway
bridges
cleaning
B
Mechanical
cleaning
Cleaning of catch basins and drain pipes of
bridges and viaducts to assure smooth flow
road
appurtenances,
etc.
Tunnel side
A
Mechanical
cleaning
Cleaning of tunnel side walls (interior boards,
etc.) with tunnel washer and sprinkler truck
Mechanical
Cleaning of tunnels side walls (interior
Tunnel side
walls
B
Mechanical
cleaning
boards, etc) with multi-purpose wet cleaner
and sprinkler trucks
C
Mechanical Cleaning of tunnels side walls (interior
25 April 2010 Contd
C
cleaning boards, etc) with multi-purpose dry washer
Surface Cleaning
(i) Type-A Cleaning (i) Type-A Cleaning
This involves road surface cleaning by
sweeper, removing, sand and litter using
brush or vacuum type sweeper.
Type A cleaning (surface)
(ii) Type-B Cleaning
I thi ti i kl t k d t In this operation, sprinkler trucks are used to
blow off soil, sand, etc. with the pressure of
water flushed through the sprinkler nozzle. water flushed through the sprinkler nozzle.
26 April 2010 Contd
Type B cleaning (surface)
Surface Cleaning
(i) Type-C Cleaning (i) Type-C Cleaning
In this cleaning, litters, and other scattered
obstacles such as spilled cargoes and waste
slipped off from running vehicles are
removed manually by workers
Type C cleaning (surface)
removed manually by workers.
(ii) Type-D Cleaning
This involves manual cleaning of roads not
covered by type A and B cleaning. covered by type A and B cleaning.
27 April 2010 Contd
Type D cleaning (surface)
Pruning
Pruning (mechanical): Mechanical trimming,
cutting off and thinning of limbs and twigs of
trees.
Pruning (Mechanical)
Pruning (with multi-purpose vehicle): This
involves pruning with a special vehicle
attached with trimmer.
Pruning with multi-purpose
28 April 2010
Pruning with multi purpose
vehicle
Chapter 5: Maintenance Operations
Maintenance Operations has been provided with the essential
considerations for carrying out the maintenance activities such as
work zone safety, environmental protection, inspection and
assessment, defect treatments along with consideration and
options This chapter also highlights the mechanization and options. This chapter also highlights the mechanization and
equipment necessary to provide due diligence to the maintenance
operations on high volume, high speed expressways. p g , g p p y
Salient areas which require proper understanding and planning for
maintenance (i) Work Zone Safety; (ii) Environmental Protection;
(iii) Inspection and Assessment; (iv) Defect Treatment; and (v)
Proper equipment Proper equipment.
29 April 2010 Contd
30 April 2010 Contd
Work Zone Safety
Defect Treatment Options (Partial)
01. Bituminous Pavement
Defect Summary inspections Treatment Options Defect Summary inspections Treatment Options
Isolated
Depressions
and Bumps
Isolated depressions and bump which
causes noticeable riding discomfort
Ponding of water hazardous to traffic
Surface Correction
Pavement Repairs
Thin Bituminous Overlay and Bumps Ponding of water hazardous to traffic
may occur.
Thin Bituminous Overlay
Profile Correction
Ruts Maximum depth of depression
measured vertically using straight
Surface Correction
Slurry Seal y g g
edge and wedge, placed laterally
Ponding of water may cause hydro-
planing and hazardous to traffic.
y
Scarify and reshape
Thin Bituminous Overlay
Shoving Depth of depression measured vertically
using straight edge and wedge, placed
laterally
Pavement Repairs
31 April 2010
may occur.
Chapter 6: New Maintenance Practices
New Maintenance Practices, deliberates on the current scenario as
followed in other countries for similar services. This chapter
comprehensively deals with equipment for data collection for comprehensively deals with equipment for data collection for
roadways; bridge and structures; service areas and other
appurtenances. For functional improvement of road surfaces in wet
weathers, use of porous asphalt and micro surfacing along with
improvement in drainage has been briefly mentioned. The other
aspects considered are (i) rigid pavement milling and overlaying (ii) aspects considered are (i) rigid pavement milling and overlaying, (ii)
waterproofing and repair of structures, (iii) protection against
corrosion and salt damage, and (iv) special road marking for night
i ibilit visibility.
This chapter also indicates on formation of Maintenance Company This chapter also indicates on formation of Maintenance Company
for leasing of maintenance vehicles.
32 April 2010 Contd
Data Collection for Road Surface Conditions
Skid Resistance Test Vehicles Rut and crack survey vehicles)
33 April 2010 Contd
34 April 2010 Contd
ARRB Vehicle
ARAN Capabilities:
ARAN Capabilities:
Photo-log: Single or Multiple Cameras.
Geometry and Spatial: Curve start and
end, radius, grade, cross slope,
centerline centerline.
Pavement: Roughness, texture,
r tting cracking rutting, cracking.
Assets: Type, location, offset, height
d idth i d diti and width, sign code, condition.
35 April 2010 Contd
ARAN Vehicles
Porous Asphalt Pavement
Porous asphalt or open-
graded asphalt is the result
of advanced technology in
pavement design. It is
used in the top layers,
usually has an air void
Conventional
Pavement
Porous asphalt
Pavement
content of 20% or greater.
Pavement Pavement
36 April 2010 Contd
Special Road Marking for Improved Day/Night Visibility
The thermoplastic materials The thermoplastic materials
with high visibility is applied
using screed technique using using screed technique using
a special mechanism which
h t l h tt t t has a control shutter to create
the distinctive rib pattern of
th ki the marking.
37 April 2010 Contd
Special Road Marking for Improved Day/Night Visibility
38 April 2010 Contd
Tunnel Maintenance
For expressway tunnels, to maintain speed and safety mechanized
l i d i t i it cleaning and maintenance is a necessity.
Remote Controlled Tunnel Mechanized and Manual Tunnel
39 April 2010 Contd
Remote Controlled Tunnel
Wall Cleaning
Mechanized and Manual Tunnel
Wall Cleaning
Leasing of Maintenance Vehicles (Maintenance Company)
Possible Scope of Business outline Possible Scope of Business outline
40 April 2010 Contd
41 April 2010 Contd
Leasing of Maintenance Vehicles (Maintenance Company) Leasing of Maintenance Vehicles (Maintenance Company)
1* Road patrol car 11 Milling machine
2* Fleet of Trucks for Maintenance 12 Recycling machine 2 Fleet of Trucks for Maintenance 12 Recycling machine
3 Portable Lift on Truck 13* Patching & pothole repair machine
4 Mountable signboard arrows, etc. 14* Bituminous and concrete plant
5* Towing vehicle 15* Aggregate crusher and accessories
6 Road Sweeper 16* Dozer and rippers
7 Self propelled cleaning machine for 17* Tipper Trucks 7 Self propelled cleaning machine for
drainage
17 Tipper Trucks
8 Watering machine for horticulture 18* Transportation truck
9 Jet water cleaner 19 Road marking equipment
10 Tunnel wall cleaning machine 20 Cranes
The * marked equipment are expected to be available with the BOT concessionaire whereas
42 April 2010 Contd
q p p
the other equipment shall be available on lease basis from the Maintenance Company.
Equipment List for Inspection (Coarse & Detailed)
1 Bridge inspection vehicles
2 Road surface survey vehicle
3 FWD Benkelman Beam Skid 3 FWD, Benkelman Beam, Skid
4 Tunnel wall survey machine (Laser type)
43 April 2010 Contd
Conclusion
Formation of Maintenance Company will have the following explicit
benefits for expressway concessionaires to deal with high speed
vehicle and high volume of traffic. Such organization with
appropriate and adequate number of equipment and trained appropriate and adequate number of equipment and trained
manpower will also ensure:
A i t i ti Appropriate inspection
Expeditious maintenance
Appropriate traffic regulation Appropriate traffic regulation
Increasing traffic safety level
A fleet of appropriate machines
Ad t b f l f d d i ht
44 April 2010
Adequate number of employees for day and night
operations
Chapter 7: Preventive Maintenance
Preventative Maintenance takes a proactive approach in
maintenance of the expressway network reducing time-consuming
rehabilitation and reconstruction and the associated traffic rehabilitation and reconstruction and the associated traffic
disruptions. Timely preservation can ensure improved mobility,
reduced congestion and safer, smoother, long lasting expressway
network.
Conventional Pavement Treatment
Preventive Treatment
with Preventive Maintenance Treatment
Preventive Treatment
Trigger
e
n
t

C
o
n
d
i
t
i
o
n
Rehabilitation
Trigger
P
a
v
e
m
e
Optimal Timing
45 April 2010 Contd
Time / Traffic
Conceptual
Chapter 7: Preventive Maintenance
Thematic Relations Maintenance Level and Users Satisfaction
Maintenance
Level
Thematic Relations
Maintenance level
Comfortability
Scenery
Level
High
Service
Scenery
Drivability
Environmental
Performance
Low
Maintenance
Preservation of infrastructure
Safety
Maintenance Corrective intervention Inspection assessment ranking AA
P ti i t ti I ti t ki A B C
46 April 2010
Preventive intervention Inspection assessment ranking A, B, C
Chapter 8: Disaster Prevention
Damages occurring due to natural calamities like heavy floods, sand
storms cyclones earthquakes to any element or system of the storms, cyclones, earthquakes to any element or system of the
expressway shall be rectified and restored. All such activities require
exhaustive deliberation However this Chapter-8 presents a cursory exhaustive deliberation. However, this Chapter-8 presents a cursory
glance to essential aspects. This chapter broadly covers (i) pre-event
preparedness measures, (ii) policy and organization for repair, (iii) preparedness measures, (ii) policy and organization for repair, (iii)
emergency measures, (iv) classifications of works, (v) slope protections
against disaster, and (vi) protection against earthquake disaster. A g , ( ) p g q
disaster restoration work flow and typical damages suffered by the
various components have been presented in pictorial form with short
47 April 2010
illustrations.

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