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Design of Cement Concrete Pavements for Rural Roads

By Sri P. Ganeswara Rao, M. Tech.,(Structures)

Chief Engineer, PR, Vig & QC

Factors governing design


Wheel load
Legal axle load in India 102 KN. Hence, the design wheel load is 51 KN For link roads, wheel load 30 KN (Where only agriculture tractors and trailers and light commercial vehicles traffic only).

Tyre Pressure
0.7 Mpa for wheel load 51 KN 0.5 Mpa for wheel load 30 KN

Design Period: 20 years Characteristics of the Sub Grade


The strength of the sub grade strength is expressed in terms of modulus of sub grade reaction k which is determined by plate bearing test (k750 = 0.5k300 (1)) or from CBR values using the following table.

Approximate k value corresponding to CBR values


Soaked CBR % k value in 2 N/mm / -3 mmx10
Note:

10

15

20

50

21

28

35

42

48

62

69

140

k value may be taken 20% more than the k value of sub grade when proper sub base is provided

Sub-base: The provision of sub base below the concrete has the following advantages. It provides a uniform and reasonable firm support. It prevents mud pumping on sub grade of clays and silts. It acts as levelling course on distorted non uniform and undulating sub grade. It acts as a capillary cut off.

Sub base materials: The following materials may be used as sub base materials. W B M. Granular Sub base or gravel with CBR more than 20%. Soil cement or soil lime with CBR more than 20%. Minimum sub base thickness 150mm for wheel load of 51 KN 75mm for wheel load of 30 KN Note: i) Sub base surface shall be finished smooth. ii) A polythene sheet of 125 microns thickness shall be provided over the sub base to act as a separation layer between the sub base and concrete slab.

Concrete Strength:
The design is based on flexural strength of the concrete ft = 0.7 fc (2) where ft = Flexural Strength, N/mm2 fc = Characteristic compressive cube strength, N/mm2 Note: i) If the flexural strength observed from laboratory tests is higher than that given by the above formula, the same may be used. ii) The 90 day strength be used for design instead of the 28 day strength (the 90 day flexural strength may be taken as 1.2 times the 28 day flexural strength or as determined from laboratory tests). iii) Heavy traffic should not be allowed for 90 days. iv) For pavement construction, the characteristic 28 day compressive strength should be atleast 30 Mpa and the characteristic 28 day flexural strength shall be atleast 3.8 Mpa.

Design of Slab Thickness:


Critical Stress Condition
The slab is subjected to mainly two types of stresses. (1) Due to wheel load (2) Due to temperature maximum differential during day between top and bottom of the slab The total stress = stress due to wheel load + stress due to temperature differential The bottom edge of the slab is subject to maximum tensile stress due to wheel load and due to temperature differential. Hence, it is a critical section. The top corners of the slab are subject to maximum tensile stress due to wheel load. But due to temperature differential the stress is zero at corner. Hence the corners of slab are to be checked for stress due to wheel load.

Calculation of Stresses: The stresses at edges or at corners can be computed using formulae or charts as follows: Edge Stresses: (a) Due to Load: The load stress in the critical edge region may be obtained as per Westergaard analysis as modified by Teller and Sutherland from the following correlation (metric units). le = 0.529 P (1+0.54) (4log10 + log10 b 0.4048) (3) 2 h b where le = Load stress in the edge region, MPa P = Design Wheel load, N h = Pavement slab thickness, mm = Poissons ratio for concrete E = Modulus of elasticity for concrete, MPa k = Modulus of sub grade reaction of the pavement foundation, N/mm3x10-3 = radius of relative stiffness, mm = 4 Eh3 (4) 2)k 12(1- b = radius of equivalent distribution of pressure = a for a 1.724 h = (1.6a2 + h2) 0.675h for a < 1.724 (5) h and a = radius of load contact assumed circular, mm. = ( P p ) where p is tyre pressure

(b) Due to Temperature: The temperature stress at the critical edge region may be obtained as per Westergaards analysis, using Bradburys coefficient from the following correlation:
te = Et C (6)

where, te t

C
L W

2 = temperature stress in the edge region, MPa = maximum temperature differential during day between top and bottom of the slab, oC = coefficient of thermal expansion of concrete, /oC = Bradburys coefficient, which can be ascertained directly from Bradburys chart against values of L/ and W/ = slab length or spacing between consecutive contraction joints, m = slab width ,m = radius of relative stiffness, m

Corner Stresses: As per Westergaards analysis as modified by Kelley c = 3P ( 1 ( a2 )1.2 ) (7) h2 c = load stress in the corner region

Design Charts
CHART FOR DETERMINATION OF COEFFICIENT C

L/l or W/l 1 2 3 4 5 6

L/l or W/l

0 0.04 0.175 0.44 0.72 0.92

7 8 9 10 11 12 & above

1.03 1.077 1.08 1.075 1.05 1

Recommended Temperature Differentials for Concrete Slabs


Zone States Temperature Differential o C in Slabs of thickness 150mm I II III Punjab, U.P., Uttaranchal, Rajasthan, Haryana, Gujarat and North M.P., excluding hilly regions Bihar, Jharkand, West Bengal, Assam and Eastern Orissa excluding hilly regions and coastal areas. Maharashtra, Karnataka, South M.P., Chattisgarh, Andhra Pradesh, Western Orissa and North Tamil Nadu excluding hilly regions and coastal areas. Kerala and South Tamil Nadu excluding hilly regions and coastal areas. Coastal areas bounded by hills. Coastal areas unbounded by hills. 12.5 15.6 17.3 200mm 13.1 16.4 19 300mm 14.3 16.6 20.3

IV V VI

15 14.6 15.5

16.4 15.8 17

17.6 16.2 19

CONCRETE PAVEMENT THICKNESS FOR RURAL ROADS


28-Day Concrete Strength (Compressive) (MPa)
Pavement Thickness (mm)
Low Traffic (Wheel load-30 kN) Heavy Traffic (Wheel load-51 kN)

ZoneI

Zone-II, IV, V, VI
o

ZoneIII
o

Zone -I

Zone-II, IV, V, VI
0 o

ZoneIII
o

Temperature differential, C

0 15.0

15.1 to o 17.0
160 150

17.1 to o 20.0
170 160

<15. o 0
190 180

15.1 to o 17.0
190 180

17.1 to o 20.0
200 190

30 35

150 150

40

150

150

150

170

180

180

Design Procedure
1. Select design wheel load, concrete flexural strength, modulus of sub grade reaction, modulus of elasticity of concrete, Poissons ratio, coefficient of thermal expansion of concrete. 2. Decide Joint Spacing and lane width. 3. Select tentative design thickness of slab, based on defined design load, k value/CBR and flexural strength of concrete. 4. Ascertain maximum temperature stress for the critical edge region from Equation (6). 5. Calculate the residual available strength of concrete for supporting traffic loads. 6. Ascertain edge load stress from Equation (3) or Fig. 2 or Fig.4 as relevant and calculate the factor of safety. 7. In case the available factor of safety is less than or far in excess of 1, adjust the tentative slab thickness and repeat steps 3 to 6 till the factor of safety is 1 or slightly more. 8. Check the adequacy of thickness in the corner region by ascertaining corner load stress from Equation (7) or fig. 3 or Fig. 5 as relevant and readjust the thickness if inadequate.

Example: A cement concrete pavement is to be designed for a rural road in A.P. having a traffic volume of 150 vehicles per day consisting vehicles like agricultural tractors/trailers, light good vehicles, heavy trucks, buses, animal drawn vehicles, motorized two wheels and cycles. Design the pavement. The soil has a soaked CBR value of 4. Design: Wheel load = 51 KN k value corresponding to CBR value of 4 is 35x10-3 N/mm2/mm (from table). Sub base Provide 150mm granular sub base Effective k value = 1.2x35x10-3 = 42x10-3 N/mm2/mm (since required sub base is provided)

Concrete Strength: Adopt M30 i.e., 28 day compressive strength of 30 MPa. Flexural strength = 0.7 fc = 0.7 30 Therefore, 28 day Flexural Strength=3.834 MPa Thickness Try a thickness of 150mm Edge load stress From Fig. 4, for k= 42x10-3 N/mm3 and thickness 150mmm Edge load stress = 4.5 MPa

Temperature Stress: From the table, the temperature differential for AP for a slab thickness of 150mm is 17.3 0C. Assuming a contraction joint spacing of 3.75m and 3.75m width, the radius of relative stiffness is as under. L = 3750mm B = 3750mm = radius of relative stiffness 4 = Eh3 12(1-2)k E = 3x104 N/mm2 h = 150mm = 0.15 k = 42x10-3 N/mm3 4 3x104x1503x103 = 12 (1- 0.152)x42 = 673.3 mm L/ = 3750/673.3 = 5.57 W/ = 3750/673.3 = 5.57 Both values are same. For L/ = 5.57 from table, Bradburys coefficient C = 0.834 Using chart at Fig. 1, for C = 0.834 & temp. differential 17.30C, the temp. stress te = 2.1 MPa Total Stress = Edge load stress +Temperature stress = 4.5 + 2.1 = 6.6 MPa This is greater than the allowable flexural strength of 4.6MPa. So thickness of 150mm assumed is inadequate. Try a thickness of 190mm.

Edge load stress From Fig.4, k= 42x10-3 N/mm3 and thickness = 200mm, the edge load stress=2.9 MPa. Temperature stress: From Table, the temperature differential for AP for a slab thickness of 190mm is 18.70C. Radius of relative stiffness = 4 Eh3 12(1-2)k
= 4 3x104x1903x103 12 (1- 0.152)x42 = 804 mm L/ = 3750/804 = 4.66 W/ = 3750/8045 = 4.66 Both values are same. For L/ = 4.66 from tables Bradburys coefficient C = 0.625 Using chart at Fig.1, for C=0.625 and temperature difference 18.70C, temperature stress te = 1.6MPa The total stress is less than 4.6MPa, hence, the assumed thickness of 190mm is OK. Corner Stress: From Fig. 5, Corner load stress for wheel load of 51kN, K=42x10-3 N/mm2 and slab thickness of 190mm, Corner Stress c = 3.4 MPa The corner stress is less than 4.6 MPa, hence, the thickness of 190mm assumed is safe.

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