DESIGN OF CEMENT CONCRETE ROAD

Ref: IRC - 58 - 2015

1 SLAB THICKNESS DESIGN
A cement concrete pavment is to be designed for 2lanes with single lane in each direction.
Design the pavment for a period of 30 years
Lane width 3.5m
So Max Lane width 12 m
Transverse joint spacing 5m

It is expected that the road will carry, in the year of 352.5 commercial vehicles per day in each direction.
completion of construction, about

Total traffic 2 x 352.5 705 CVPD

25% for Bottomup Craking 176.25 CVPD
Top down 50% of bottomup craking 88 CVPD
As per traffic survey
Breakup of Axle load shuld be
Front single (steering) axle 49 %
Rear single axle 27 %
Rear tandem axle 14 %
Rear tridem axle 10 %
The % of cvpd with spacing between the fornt axle and the
76 %
first rear axle less than 4.5m is
Considering the traffic count at night hour (6PM to 6AM)
60 %
Details of axle load spectrum of rear single, tandem and tridem axles are given in below Table.
Single Axle Loads Tandem Axle Loads Tandem Axle Loads
(% of
Axle Load Frequency (% Frequency (% of Axle Load tridem
Class kN of single axles) Axle Load Class kN tandem axles) Class kN axles)
185 - 195 18.15 380 - 400 14.5 530 - 560 5.23
175 - 185 17.43 360 - 380 10.5 500 - 530 4.85
165 - 175 18.27 340 - 360 3.63 470 - 500 3.44
155 - 165 12.98 320 - 340 2.5 440 - 470 7.12
145 - 155 2.98 300 - 320 2.69 410 - 440 10.11
135 - 145 1.62 280 - 300 1.26 380 - 410 12.01
125 - 135 2.62 260 - 280 3.9 350 - 380 15.57
115 - 125 2.65 240 - 260 5.19 320 - 350 13.28
105 - 115 2.65 220 - 240 6.3 290 - 320 4.55
095 - 105 3.25 200 - 220 6.4 260 - 290 3.16
085 - 095 3.25 180 - 200 8.9 230 - 260 3.1
<085 14.15 <180 34.23 <200 17.58
100 100 100

Min CBR Below subgrade (500mm depth) 8%

Effective CBR of compacted subgrade 8.00 %

Design of a concrete pavment with tied concrete shoulder with doweled transverse joints.

TYPICAL CROSS - SECTION OF CONCRETE PAVMENT

PQC Interface can be

bonded
(PAVMENT QUALITY CONCRETE)
DLC
(DRY LEAN CONCRETE)

GSB (DRAINAGE LAYER)

SUBGRADE
a) Selection of Modulus of subgrade reaction
i) Effective CBR of compacted subgrade = 8%
Modulus of subgrade reaction (k) 50.00 Mpa/m From Table 2
ii) Provide granular subbase (thick) 150 mm
iii) Provide DLC subbase with a minmum 7day compressive 200 mm
strength of 10MPa (thickness)
iv) Effective modulus of subgrade reaction of combined
foundation of subgrade + granular subbase and DLC 290 Mpa/m From Table 4
subbase.
v) Provide adebonding layer of polythene sheet of 125micron thickness between DLC and concrete slab.
b) Selection of Flexural Strength of Concrete
28 - day compressive strength of cement concrete =40MPa
c) Selection of Design Traffic for Fatigue Analysis.
i) Design period 30 years
ii) Annual growth rate of commercial traffic 0.05 Decimal form
iii) % of traffic in predominat direction 50% of 705 CVs = 352.5 CVs in each direction.
iv) Total two-way commercial vehicles during design period
C = 365 x 352.5{(1+0.05)^30 -1)} = 17,096,376 CVs
0.05
v) Average no of axles (steering/single/tandem/tridem)/CVs 2.35
vi) Total two-way axle load repetitions during the design period 40,176,484 Axels
vii) No of axles in predoniminat direction (50%) 20,088,242 Axels
viii) Design traffic after adjusting for lateral placement of axles
10,044,121 Axels
(25%)
ix) Night time (12-hour) design axle repetitions (60%) 6,026,473 Axels
x) Day time (12-hour) design axle repetitions (40%) 4,017,648 Axels
xi) Day time (6-hour) design axle repetitions 2,008,824 Axels
xii) Hence, design no of axel load repetitions for
Bottom-up cracking analysis 2,008,824 Axels
xiii) Night time 6-hour axel load repetitions 3,013,236
xiv) % of commercial vehicles having the spacing between 76 %
the from steering axle and the first axle of the rear axle unit
xv) Hence, the 6-hour nigth time design axel load repetitions for
Top-down cracking analysis (wheel base<4.5) 2,290,060 Axels

The Axle load category-wise design axle load repetitions for bottom-up and top-down fatigue analysis given in the following table
Category wise axle repetitions Category wise axle
Proportion of the axle
Axle category repetitions for top-down
category for Bottom-up cracking analysis
cracking analysis
Front (steering) single 0.49 984324 1122129
Rear single 0.27 542383 618316
Tandem 0.14 281235 320608
Tridem 0.1 200882 229006

d) Cumulative Fatigue Damage (CFD) analysis for Bottom-up Cracking (BUC) and Top-down Cracking (TDC) and Selection
of Slab Thickness.
i) Effective modulus of subgrade reaction of foundation k = 290.00 Mpa/m
ii) Elastic Modulus of concrete, E = 30000 Mpa
iii) Poission's ratio of concrete, µ = 0.15
3
iv) Unit weight of concrete, ‫= ץ‬ 24 kNm
v) Design flexural strength of concrete = 4.14 Mpa
0
vi) Max- day-time Temprature Differential in slab (for bottom-up cracking) for Odisha = 16.8 C
0
vii) Night-time Temparature Differential in Slab (for top-down cracking)= day-time diff/2 + 5 = 13.4 C
Trial thickness of slab, h = 0.25 m
Trial thickness of slab, h = 0.275 m
Radius of relative stiffness, I = (Eh3/12k(1-µ2))0.25 = 0.654 m
Beta' factor in the stress equations will be 0.66 for undoweled transverse joints for carring out TDC analysis
 Cumulative Fatigue Damage Analysis for Bottom-up Cracking
Bottom-up Cracking Fatigue Analysis for Day-Time (6-hour) traffic and positive Temperature
Differential
Rear Single Axles

Axle Load kN Expected Flex Stress Mpa Stress ratio (SR) Allowable Fatigue
Repetition (ni) repetition (Ni) Damage
Tonne (ni/Ni)
0 1 2 3 (2/4.9) 28days 4 5 (1/4)
30 185 - 195 98442 2.51 0.51 485184 0.20
28 175 - 185 94537 2.4 0.49 1286914 0.07
26 165 - 175 99093 2.29 0.47 5202474 0.02
24 155 - 165 70401 2.18 0.44 infinite 0.00
22 145 - 155 16163 2.07 0.42 infinite 0.00
20 135 - 145 8787 1.97 0.4 infinite 0.00
18 125 - 135 14210 1.86 0.38 infinite 0.00
16 115 - 125 14373 1.75 0.36 infinite 0.00
14 105 - 115 14373 1.64 0.33 infinite 0.00
12 095 - 105 17627 1.53 0.31 infinite 0.00
10 085 - 095 17627 1.42 0.29 infinite 0.00
8 <085 76747 1.32 0.27 infinite 0.00
542383 0.30

Bottom-up Cracking Fatigue Analysis for Day-Time (6-hour) traffic and positive Temperature
Rear Tandem Axles
Axle Load kN Expected Flex Stress Mpa Stress ratio (SR) Allowable Fatigue
Repetition (ni) repetition (Ni) Damage
(ni/Ni)
0 1 2 3 (2/4.9) 28days 4 5 (1/4)
380 - 400 40779 2.2 0.45 62790761 0.00
360 - 380 21093 2.11 0.43 infinite 0.00
340 - 360 10209 2.02 0.41 infinite 0.00
320 - 340 7031 1.93 0.39 infinite 0.00
300 - 320 7565 1.84 0.38 infinite 0.00
280 - 300 3544 1.75 0.36 infinite 0.00
260 - 280 10968 1.66 0.34 infinite 0.00
240 - 260 14596 1.57 0.32 infinite 0.00
220 - 240 17718 1.48 0.3 infinite 0.00
200 - 220 17999 1.39 0.28 infinite 0.00
180 - 200 25030 1.3 0.27 infinite 0.00
<180 96267 1.25 0.26 infinite 0.00
272799 0.00

Cumulative Fatigue Damage Analysis for Top-down Cracking

Top-down Cracking Fatigue Analysis for Night-Time (6-hour) traffic and negative Temperature
Rear Single Axles
Axle Load kN Expected Flex Stress Mpa Stress ratio (SR) Allowable Fatigue
Repetition (ni) repetition (Ni) Damage
(ni/Ni)
0 1 2 3 (2/4.9) 28days 4 5 (1/4)
185 - 195 112224 2.44 0.5 762043 0.15
175 - 185 107772 2.38 0.49 1286914 0.08
165 - 175 112966 2.32 0.47 5202474 0.02
155 - 165 80257 2.27 0.46 14335236 0.01
145 - 155 18426 2.21 0.45 62790761 0.00
135 - 145 10017 2.15 0.44 infinite 0.00
125 - 135 16200 2.09 0.43 infinite 0.00
115 - 125 16385 2.04 0.42 infinite 0.00
105 - 115 16385 1.98 0.4 infinite 0.00
095 - 105 20095 1.92 0.39 infinite 0.00
085 - 095 20095 1.86 0.38 infinite 0.00
<085 87492 1.83 0.37 infinite 0.00
618316 0.26
Top-down Cracking Fatigue Analysis for Day-Time (6-hour) traffic and positive Temperature Differential
Rear Tandem Axles
Axle Load kN Expected Flex Stress Mpa Stress ratio (SR) Allowable Fatigue
Repetition (ni) repetition (Ni) Damage
(ni/Ni)
0 1 2 3 (2/4.9) 28days 4 5 (1/4)
380 - 400 46488 2.47 0.5 762043 0.06
360 - 380 33664 2.41 0.49 1286914 0.03
340 - 360 11638 2.35 0.48 2402754 0.00
320 - 340 8015 2.29 0.47 5202474 0.00
300 - 320 8624 2.24 0.46 14335236 0.00
280 - 300 4040 2.18 0.44 infinite 0.00
260 - 280 12504 2.12 0.43 infinite 0.00
240 - 260 16640 2.06 0.42 infinite 0.00
220 - 240 20198 2.01 0.41 infinite 0.00
200 - 220 20519 1.95 0.4 infinite 0.00
180 - 200 28534 1.89 0.39 infinite 0.00
<180 109744 1.86 0.38 infinite 0.00
320608 0.09

Top-down Cracking Fatigue Analysis for Day-Time (6-hour) traffic and positive Temperature Differential
Rear Tridem Axles
Axle Load kN Expected Flex Stress Mpa Stress ratio (SR) Allowable Fatigue
Repetition (ni) repetition (Ni) Damage
(ni/Ni)
0 1 2 3 (2/4.9) 28days 4 5 (1/4)
530 - 560 11977 2.35 0.48 2402754 0.00
500 - 530 11107 2.30 0.47 6222971 0.00
470 - 500 7878 2.24 0.46 infinite 0.00
440 - 470 16305 2.18 0.44 infinite 0.00
410 - 440 23153 1.90 0.39 infinite 0.00
380 - 410 27504 1.62 0.33 infinite 0.00
350 - 380 35656 1.48 0.3 infinite 0.00
320 - 350 30412 1.41 0.29 infinite 0.00
290 - 320 10420 1.34 0.27 infinite 0.00
260 - 290 7237 1.17 0.24 infinite 0.00
230 - 260 7099 1.20 0.24 infinite 0.00
<200 40259 1 0.2 infinite 0.00
229007 0.01

From the above table Total CFD for BUC case 0.30
And Total CFD for TDC case 0.36
0.65 <1, Hence Safe
Hence design is Adequate for trial slab thickness 0.250 m

From Table 5 Recommended Dimension of Dowel Bar for 0.25m thick slab is as
Diametere = 36mm
Length = 450mm
Spacing = 300mm
From Table 6 Recommended Dimension of Deformed Tie Bar for 0.25m thick slab is as
Diametere = 12mm
Length = 600mm
Spacing = 640mm