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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
Final Detailed ProjectReport
EXECUTIVESUMMARY
E.1 INTRODUCTION
Aarvee associates were awarded the work of preparation of DPR for development of
Economic Corridors, Inter Corridors, Feeder Routes, Coastal Routes to improve the efficiency
of freight movement in India under Bharatmala Pariyojana (Lot – 4 Tamil Nadu - Package –
8) vide agreement signed on 21.02.2018. The details of stretches included in the said
package are given hereunder:
Table-E.1: List of Project Stretches
S.No Classification Corridor Name Stretch Name
Road Category Length(km)Old New
1 Feeder Route Chennai-Puduchery Mahabalipuram - Pondicherry
SH-49 NH-332A 99
2 Inter Corridor Melur-Thanjavur-Kumbakonam-Sirkazhi
Kumbakonam - Sirkazhi
SH-64 NH-136B 59
3 Inter Corridor Coimbatore – Trichy - Tanjavur
Karur - Trichy NH-81/67 NH-81/67 77
4 Inter Corridor Dindigal – Coimbatore-TN/Karnataka Border
Mettupalayam – Gudalur (NH-181)
NH-181 NH-181 98
5 Inter Corridor Melur - Thanjavur Tirupattur - Tanjavur
NH-36/226
NH-36/226 102
6 Inter Corridor Melur – Thanjavur (Branch to Karaikudi)
Kotampatti – Tirupattur - Karaikudi
SH-35 NH-383Ext.
52
7 Inter Corridor Melur - Thanjavur Melur - Tirupattur SH-191 NH-338 35
8 Feeder Route Chennai-Puduchery Chennai - Mahabalipuram
SH-49 NH-332A 50
9 Coastal Route Nagapatinam - Kanyakumari
Tuticorin – Kanyakumari
SH-176 - 115
Total Length in km 687
The alignment for the Inter Corridor branch to Karaikudi connecting the Melur to Thanjavur
section was finalized with a combination of greenfield and brownfield alignment as detailed
in the alignment report submitted vide letter No. AA/HW/NHAI/2145/2017-18/1889 dated
28.03.2018. The Draft Detailed Project Report for the project road was submitted vide letter
No. AA/HW/NHAI/2145/2018-19/2763 dated 25.07.2018.
This section is the Executive Summary for the Final Detailed Project Report for the project
corridor prepared based on the findings and up-gradation proposals submitted during the
Final Feasibility report submitted to the Authority.
AA/HD/2145 E – 1
E. EXECUTIVE SUMMARY
CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
Final Detailed ProjectReport
EXECUTIVESUMMARY
E.2 PROJECT OVERVIEW
The existing project corridor starts on SH-191(New NH-338) at the intersection with
National Highway – 45B at Melur in the district of Madurai and ends at the intersection with
SH-29 at Karaikudi in the district of Siva Gangai.
The proposed project highway which consists of Green and Brown field alignments starts
near Melur at Km 99.920 of NH-45B (Madurai-Trichy road) and ends at the intersection with
NH-210(new NH-536) near Karaikudi. The length of the proposed alignment is 45.855 Km.
The proposed project corridor passes through villages Vatakkuvalayapatty, Pillayarpatti,
Kundrakudi, Patharaikudi and Koviloor (Karaikudi).
Location map is shown in Figure 1.
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELUR TO KARAIKUDI UNDER BHARATMALAPARIYOJANA, PHASE I, ON EPC MODE IN THE STATE OF TAMIL NADU
Final Detailed Project Report
EXECUTIVE SUMMARY
Figure 1: Location Map
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
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2.1 KEY FEATURES OF ALONG EXISTING PROJECT ROAD
Table 1: Key features of Existing Project road
Attributes Details
SH/NH No.• Km 0.000 to Km 32.000 – SH 191 (NH-338)• Km 82.200 to Km 85.800 – SH 35 (NH-383 Extn.)• Km 0.000 to Km 14.000 – SH – 191A (NH-383 Extn.)
Origin - Destination
Melur (209639.00m E, 1110863.00m N) – Tirupattur(238507.18 m E,1118647.66 m N)
Tirupattur (237283.21m E,1118679.71 m N) – Pillayarpatti –Karaikudi (252624.65 m E,1114960.88 m N)
Via towns
Melur, Navinipatty, Keeliyur, Malampatti, Erumaipatti,S.S.Kottai, Kottaipatti, M.Krishnapuram, Karuppur,Thiruvudaiyarpatti, Tirupattur, Pillayarpatti, Kundrakudi,Patharaikudi and Karaikudi.
Existing Carraigeway The existing carriageway width varies from 7.0 m to 15.5m with mostly 2Lane and 4L in some urban locations.
Service lanes and slip roads Nil
Shoulder• Paved Shoulder of 0 – 1.5m width• Earthen Shoulder of 0 – 0.5m width
Condition of existing pavement
Good to Poor
Right of Way Varies in between 10m to 30m along the project stretch
Land use along project road
Predominant land use along the Melur – Tirupattur stretch isbarren land (56% on LHS, 50% on RHS), with rest being builtup (24% on LHS, 20% on RHS), agricultural (8% on LHS,11% on RHS), water bodies (3% on LHS, 2% on RHS),granite quarry(9% on LHS, 13% on RHS) and forest area (0%on LHS, 4% on RHS)
Predominant land use along the Tirupattur – Pillayarapatty –Karaikudi stretch is barren land (60% on LHS, 61% on RHS),with rest being built up (31% on LHS, 34% on RHS),agricultural (2% on LHS, 3% on RHS) and water bodies (7%on LHS, 2% on RHS)
Traffic on the stretch Predominatly passenger vehicles
Toll infrastructure There are no toll plaza in the current stretch
Terrain• Primarily plain(91%) and rolling(9%) terrain in Melur-
Tirupattur stretch.• 100% plain terrain in Tirupattur-Karaikudi stretch.
Structures along stretch 32 structures – 1 major bridge, 2 minor bridges, 1 VOP, 28 culverts
Key utilities in the existing ROW
3 HT towers and 1 HT crossing
Forest Stretches along existing ROW
Vettangudi Bird Sanctuary is situated adjacent to the existing road from Km 20.300 to Km 21.600 for a length of 1.300Kms.
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
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Attributes Details
Rail crossings along existing ROW
Nil
2.2 PROPOSED PROJECT ROAD
As already stated, mostly greenfield alignment is adopted for project corridor and
the details of the green field alignment are given in section 5.
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELUR TO KARAIKUDI UNDER BHARATMALAPARIYOJANA, PHASE I, ON EPC MODE IN THE STATE OF TAMIL NADU
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2.2 KEY PLAN OF EXISTING PROJECT STRETCH
Figure 2: Key Plan
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
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E 3. TRAFFIC DEMANDS ON PROJECT ROAD
3.1. TRAFFIC VOLUME SURVEYS
Based on the reconnaissance surveys, Mid block sections and major Intersections were
identified to capture the traffic flow pattern. Classified traffic volume count, Turning
movement survey, Origin & Destination surveys, Axle load surveys were conducted.
Locations of the traffic surveys conducted are tabulated in Table 2.
Table 2: Location and schedule of the Traffic surveys
S.No
Type ofSurvey
LocationChainage
(km)Highway
Durationof Survey
Date ofSurvey
1
ClassifiedTrafficVolumeCounts
Malampatti 11.900 SH-191
3 Days
22.03.2018,23.03.2018
and26.03.2018Patharaikudi 11.100 SH-191A
Thuvakudi Toll Plaza(Tanjore – Trichy Road) 115.000 NH-67
1 Day
02.04.2018
Bothukudi Toll Plaza(Kotampatty – Trichy
Road)18.000 NH-45B 03.04.2018
2Turning
Movements
Kummankudi85.800/0.000
SH-35 / SH-191A
24 Hours
27.03.2018
Karaikudi 12.900SH-191A &
NH-21027.03.2018
3 OD Survey
Malampatti 11.900 SH-191
24 Hours
22.03.2018
Patharaikudi 11.100 SH-191A 26.03.2018
Thuvakudi Toll Plaza(Tanjore – Trichy Road) 115.000 NH-67
24 Hours
02.04.2018
Bothukudi Toll Plaza(Kotampatty – Trichy
Road)18.000 NH-45B 03.04.2018
4 Axle LoadSurvey Malampatti 11.900 SH-191
24 Hours22.03.2018
Patharaikudi 11.100 SH-191A 26.03.2018
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
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S.No
Type ofSurvey
LocationChainage
(km)Highway
Durationof Survey
Date ofSurvey
Thuvakudi Toll Plaza(Tanjore – Trichy Road) 115.000 NH-67
24 Hours
02.04.2018
Bothukudi Toll Plaza(Kotampatty – Trichy
Road)18.000 NH-45B 03.04.2018
5Number
plate Survey
Malampatti 11.900 SH-191
24 Hours
26.03.2018
Patharaikudi 11.100 SH-191A 26.03.2018
Automatic classified traffic volume count (ATCC) was done at four locations i.e., at Km
11.900 (Malampatti) on SH-191, at Km 11.100 (Patharaikudi) on SH-191A for 3 days and
additional TVC surveys were conducted at Km 115.000 (at Thuvakudi Toll Plaza) on NH-67 of
Tanjore – Trichy Section and at Km 18.000 (at Bothukudi Toll Plaza) on NH-45B of
Kotampatty – Trichy Section for 1 day by using pneumatic tubes and video graphic method.
The average daily traffic (ADT) was computed by using three day traffic data. By using
secondary data (fuel data), Seasonal correction factor was derived which can be used as
multiplication factor for converting average daily traffic (ADT) into Annual average daily
traffic (AADT). The annual average daily traffic (AADT) for each location is mentioned in the
Tables 3 & 4.
Table 3: AADTof the two Traffic survey locations along the project stretch
Vehicle Type
Melur – Karaikudi Section
Km. 11.900 (SH-191) Km. 11.100 (SH-191A)
Two Wheelers 2270 3267
Three Wheelers (Passenger) 42 119
Car 1888 1405
Tata Magic 2 4
RTC Bus 442 348
Private Bus 112 114
Mini Bus 78 56
School/ College Bus 34 46
Two Axle 160 97
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Vehicle Type
Melur – Karaikudi Section
Km. 11.900 (SH-191) Km. 11.100 (SH-191A)
Three Axle 29 43
Multi Axle 18 11
Heavy Earth Moving 1 2
Light Commercial Vehicle 169 61
Mini LCV 413 247
Tractor 0 8
Tractor with Trailer 3 8
Three Wheeler (Goods) 9 10
Bicycle 13 44
Cycle Rickshaw 1 1
Animal Drawn 1 0
Government Exempted 0 3
Vehicles
Motorised 5685 5848
Non Motorised 2 45
Total Traffic 5687 5893
Tollable Traffic 3348 2433
PCU
Motorised 6301 5649
Non Motorised 10 24
Total Traffic 6311 5673
Tollable Traffic 5094 3832
Table 4: AADT of the two additional Traffic survey locations
Vehicle Type
Madurai - Trichy Section Thanjavur - Trichy Section
Km. 18.000 (NH-45B) Km. 115.000 (NH-67)
Two Wheelers 5121 6039
Three Wheelers (Passenger) 49 158
Car 5006 7707
Tata Magic 2 7
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
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Vehicle Type
Madurai - Trichy Section Thanjavur - Trichy Section
Km. 18.000 (NH-45B) Km. 115.000 (NH-67)
RTC Bus 728 898
Private Bus 1006 471
Mini Bus 172 237
School/ College Bus 59 49
Two Axle 438 895
Three Axle 701 538
Multi Axle 512 329
Heavy Earth Moving 5 3
Light Commercial Vehicle 710 438
Mini LCV 674 948
Tractor 8 20
Tractor with Trailer 11 37
Three Wheeler (Goods) 3 36
Bicycle 60 42
Cycle Rickshaw 0 0
Animal Drawn 0 0
Government Exempted 5 1
Vehicles
Motorised 15211 18810
Non Motorised 60 42
Total Traffic 15271 18852
Tollable Traffic 10013 12520
PCU
Motorised 20814 23131
Non Motorised 31 21
Total Traffic 20845 23152
Tollable Traffic 18130 19719
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
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Additional traffic is added to the AADT for Homogeneous sections-I & II. The detail
description is given in Chapter-6 of Main Report. Final AADT of HS-I & II are mentioned in
Table-5.
Table 5: Final AADT adopted in Homogeneous Sections
Vehicle Type
HS-I HS-II
Km. 11.900 (SH-191) Km. 11.100 (SH-191A)
Two Wheelers 2270 3267
Three Wheelers (Passenger) 42 119
Car 3402 2359
Tata Magic 2 40
RTC Bus 442 348
Private Bus 651 140
Mini Bus 148 70
School/ College Bus 34 46
Two Axle 394 697
Three Axle 404 154
Multi Axle 217 34
Heavy Earth Moving 1 3
Light Commercial Vehicle 457 96
Mini LCV 745 412
Tractor 0 8
Tractor with Trailer 3 8
Three Wheeler (Goods) 9 10
Bicycle 13 44
Cycle Rickshaw 1 1
Animal Drawn 1 0
Government Exempted 0 3
Vehicles Motorised 9366 7813
Non Motorised 15 45
Total Traffic 9381 7858
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
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Vehicle Type
HS-I HS-II
Km. 11.900 (SH-191) Km. 11.100 (SH-191A)
Tollable Traffic 7042 4398
PCU
Motorised 13265 9191
Non Motorised 17 24
Total Traffic 13282 9215
Tollable Traffic 11958 7380
3.2. AXLE LOAD SURVEY
Axle load surveys were conducted at two locations i.e., at Km 11.900 (Malampatti) on SH-
191, at Km 11.100 (Patharaikudi) on SH-191A, along the project stretch to understand the
actual load spectrum of commercial vehicles plying on the project road. The results of the
load survey, were converted to Vehicle Damage Factor (VDF) using equivalency factors from
IRC 37-2012 for the purpose of MSA calculations.
Table 6: Vehicle Damage Factor
Type ofVehicle
VDF Near Malampatti @ Km 11.900(SH-191)
VDF Near Patharaikudi @ 11.1000 (SH-191A)
TowardsMelur
TowardsKaraikudi
Adopted TowardsKaraikudi
TowardsMelur
Adopted
2 Axle 1.92 2.13 2.13 2.58 2.40 2.58
3 Axle 1.34 5.07 5.07 3.21 1.50 3.21
M Axle 4.04 5.23 5.23 5.05 1.49 5.05
LCV 1.69 1.77 1.77 1.74 1.31 1.74
3.3. HOMOGENEOUS SECTIONS
Considering the various AADT values along the stretch, as observed in various traffic survey
locations, the total project road is divided into two homogeneous road sections for the
purpose of traffic analysis and forecast so as to examine the strategies for tolling and also
for pavement design purpose. Table below gives the details of the homogeneous sections
identified for the project road.
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
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Table 7: Homogeneous Sections along the project corridor
Section
Starting EndLength ofHS (km)Design
Chainage (Km)Location
DesignChainage (Km)
Location
HS-1 0.000 Melur 38.000 Pillayarpatty 38.000
HS-2 38.000 Pillayarpatty 45.855 Karaikudi 7.855
3.4. TRAFFIC VOLUME FORECAST
Traffic was projected by using estimated growth rates. A minimum growth rate of 5% has
been considered for capacity analysis. The growth rates adopted are given in the Table-8.
Table 8: Adopted traffic growth rate
Year 2w 3w Car (W) Bus Goods TractorTractor with
trailor
Upto 2020 10.0% 10.0% 10.0% 7.5% 6.5% 9.0% 6.0%
2021-2025 9.50% 9.50% 9.50% 7.00% 6.00% 8.50% 5.50%
2026-2030 9.00% 9.00% 9.00% 6.50% 5.50% 8.00% 5.00%
2031-2035 8.50% 8.50% 8.50% 6.00% 5.00% 7.50% 5.00%
2036-2040 8.00% 8.00% 8.00% 5.50% 5.00% 7.00% 5.00%
2040-2045 7.50% 7.50% 7.50% 5.00% 5.00% 6.50% 5.00%
Beyond 2045 7.00% 7.00% 7.00% 5.00% 5.00% 6.00% 5.00%
Traffic was projected by using growth rates represented in Table-8.
National and State Highways in rural areas are normally designed for LOS B as per IRC:64.
The maximum capacities per day for different types of carriageway for LOS B are:
• 15,000 PCUs for 2 lane carriageway with earthen shoulders
• 18,000 PCUs for 2 lane carriageway with paved shoulders
• 40,000 PCUs for 4 lane divided carriageway
• 60,000 PCUs for 6 lane divided carriageway
The recommended Design Service Volume per day for up-gradation of highway sections as
per Indian Highway Capacity Manual (Indo-HCM) are:
• 22,500 PCUs for conversion from four lane to six lane divided road
• 34,000 PCUs for conversion from six lane to eight lane divided road
Projected traffic for the project stretch is represented in Tables-9 & 10.
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
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Table-9: Projected Traffic for Homogeneous Section-I
YearVolume (In PCU)
Capacity CriteriaRecommended Lane
ConfigurationCapacity(PCU/day)
V/C Ratio LOS
2018 13282 36000 0.37 B 4 lane
2019 14225 36000 0.40 B 4 lane
2020 15364 36000 0.43 B 4 lane
2021 16520 36000 0.46 B 4 lane
2022 17768 36000 0.49 B 4 lane
2023 19113 80000 0.24 A 4 lane
2024 20565 80000 0.26 A 4 lane
2025 22131 80000 0.28 A 4 lane
2026 23711 80000 0.30 A 4 lane
2027 25410 80000 0.32 B 4 lane
2028 27235 80000 0.34 B 4 lane
2029 29198 80000 0.36 B 4 lane
2030 31310 80000 0.39 B 4 lane
2031 33424 80000 0.42 B 4 lane
2032 35689 80000 0.45 B 4 lane
2033 38116 80000 0.48 B 4 lane
2034 40717 120000 0.34 B 6 lane
2035 43504 120000 0.36 B 6 lane
2036 46338 120000 0.39 B 6 lane
2037 49364 120000 0.41 B 6 lane
2038 52598 120000 0.44 B 6 lane
2039 56053 120000 0.47 B 6 lane
2040 59745 120000 0.50 B 6 lane
2041 63473 120000 0.53 C -
2042 67443 120000 0.56 C -
2043 71671 120000 0.60 C -
2044 76175 120000 0.63 C -
2045 80973 120000 0.67 C -
2046 85873 120000 0.72 D -
2047 91077 120000 0.76 D -
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
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YearVolume (In PCU)
Capacity CriteriaRecommended Lane
ConfigurationCapacity(PCU/day)
V/C Ratio LOS
2048 96605 120000 0.81 D -
Table-10: Projected Traffic for Homogeneous Section II
Year Volume (In PCU)
Capacity CriteriaRecommended Lane
ConfigurationCapacity(PCU/day)
V/C Ratio LOS
2018 9219 36000 0.26 A 2 lane paved shoulder
2019 9966 36000 0.28 A 2 lane paved shoulder
2020 10776 36000 0.30 A 4 lane
2021 11616 36000 0.32 B 4 lane
2022 12513 36000 0.35 B 4 lane
2023 13482 36000 0.37 B 4 lane
2024 14530 36000 0.40 B 4 lane
2025 15663 36000 0.44 B 4 lane
2026 16827 36000 0.47 B 4 lane
2027 18082 80000 0.23 A 4 lane
2028 19435 80000 0.24 A 4 lane
2029 20894 80000 0.26 A 4 lane
2030 22468 80000 0.28 A 4 lane
2031 24053 80000 0.30 B 4 lane
2032 25745 80000 0.32 B 4 lane
2033 27563 80000 0.34 B 4 lane
2034 29515 80000 0.37 B 4 lane
2035 31614 80000 0.40 B 4 lane
2036 33768 80000 0.42 B 4 lane
2037 36074 80000 0.45 B 4 lane
2038 38546 80000 0.48 B 4 lane
2039 41193 120000 0.34 B 6 lane
2040 44030 120000 0.37 B 6 lane
2041 46904 120000 0.39 B 6 lane
2042 49972 120000 0.42 B 6 lane
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
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YearVolume (In PCU)
Capacity CriteriaRecommended Lane
ConfigurationCapacity(PCU/day)
V/C Ratio LOS
2043 53247 120000 0.44 B 6 lane
2044 56745 120000 0.47 B 6 lane
2045 60480 120000 0.50 C -
2046 64276 120000 0.54 C -
2047 68316 120000 0.57 C -
2048 72616 120000 0.61 C -
Ministry has recently revised the norms to take up 4 laning if traffic is more than 10,000
PCUs per day.
Reference: Policy matters – Quality Assurance
(Decision taken on File No NHAI/CGM/QA/DPRs/2017, in January 2017.)
As per the traffic survey data, there is an immediate requirement for 4 lane configuration.
3.5. TURNING MOVEMENT SURVEYS
Classified direction wise turning movement count surveys were conducted at two major
intersections i.e., Kummankudi Intersection and Karaikudi Intersection to determine the
need for re-design and addition of structure at the intersection.
Table-11: Turning movement survey results
S.No. Ex.Chainage
LocationTotal
Volume(PCU)
PeakHour
Volume(PCU)
PeakHour
Intersection type
Gradeseparatorproposed
1 85.800 (SH-35)
Kummankudi 15841 1109 06:45 –07:45
3 arm No
212.900
(SH-191A)Karaikudi 15246 901
17:00 –18:00
4 arm No
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E 4. PAVEMENT AND CORRIDOR SURVEYS
4.1. PAVEMENT CONDITION AND DISTRESS SEEN
The overall pavement condition varies from good to poor with high percentage of alligator
cracking and significant presence of potholes and raveling.
Table-12: Condition survey of existing pavement
Type of distress
Percentage of Severity (%)
Melur - TirupatturTirupattur – Pillayarpatti -
Karaikudi
Raveling(%) 24.30 22.58
Pot holes (%) 11.35 8.16
Edge Fretting(m) 10.00 0.00
Rut Depth(mm) 0.00 0.00
Block
cracking (%)
Wide >
3 mm0.000 0.000
Narrow <
3 mm0.00 0.00
Alligator
cracking (%)
Wide > 3
mm15.91 1.236
Narrow <
3 mm8.75 0.090
Transverse
cracking (%)
Wide > 3
mm0.000 0.000
Narrow <
3 mm0.000 0.000
Longitudinal
cracking (%)
Wide > 3
mm8.312 0.000
Narrow <
3 mm0.625 0.028
4.2. PAVEMENT COMPOSITION
The existing pavement structure is a flexible pavement consisting of sub-grade, sub-base,
granular base and bituminous top. The summary of pavement composition seen is as follows
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Table-13: Composition of existing pavement
S. No. Chainage(Km)
SideBitumen
(BC+DBM)Granular
BaseGranularSub-base
Total
Melur to Pillayarpatty
01 Km 27.000 RHS 150 420 180 750
02 Km 27.500 LHS 130 410 160 700
03 Km 28.000 LHS 120 390 110 620
04 Km 28.500 RHS 140 380 130 650
05 Km 29.000 RHS 120 390 200 710
06 Km 29.500 LHS 120 370 210 700
Pillayarpatty to Karaikudi
01 0.00 RHS 110 130 200 440
02 0.500 RHS 120 140 210 470
03 1.000 LHS 160 140 330 630
04 1.500 LHS 150 130 310 590
05 3.000 RHS 90 160 310 560
06 3.500 RHS 100 150 320 570
07 4.000 LHS 130 200 180 510
08 4.500 LHS 140 180 210 530
09 5.000 RHS 130 100 230 460
10 5.500 RHS 150 120 240 510
11 6.000 LHS 140 230 190 560
12 6.500 LHS 150 220 180 550
13 7.000 LHS 160 240 200 600
14 7.500 RHS 190 320 290 800
4.3. PAVEMENT STRENGTH
FWD was carried out to test strength of the existing pavement, and the 15th percentile of
moduli of subgrade, granular and bituminous layers have been calculated for project road to
enable design of overlay for the road.
AA/HD/2145 E – 18
CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
Final Detailed ProjectReport
EXECUTIVESUMMARY
Table-14: 15th Percentile Back calculated Modulus Values
Section & Side 15th Percentile of Moduli for the design
Bituminous (Mpa) Granular (Mpa) Subgrade (Mpa)
Melur to Karaikudi (Km 5.000 to Km 12.500) LHS
2333 228 77
Melur to Karaikudi (Km 5.000 to Km 12.500) RHS
4307 199 77
4.4. SUB-GRADE SOIL SURVEY
Extensive review of available soil information and testing was done to understand the sub-
grade characteristics. Summary of soil investigation surveys is as follows:
Table-15: Soil Investigation Survey results
Table-16: Soil types observed
Soil Type % of length Plasticity Index Comments
Clayey Sand (SC) 80% 8 to 63 -
Silty Sand (SM) 20% Non-plastic -
AA/HD/2145 E – 19
S.no Chainage & side
Grain Size Analysis
IS Cla
ssific
ation
Atterberg Limits
FSI(%
)
Core cutter
FDD
(g/cc
)
NMC (
%)
SECTION : km. 0+000 (Melur) to km. 37+500 (Pillaiyarpatti)1 km. 27+000, RHS 7.0 6.1 26.0 27.6 33.3 SC 63 17 46 82 1.80 12.21 52 km. 28+000, LHS 15.4 13.4 22.4 20.3 28.5 SC 70 18 52 90 1.71 19.54 43 km. 29+000, RHS 10.1 10.7 26.4 16.8 36.0 SC 80 17 63 60 1.78 15.96 6
SECTION : km. 0+000 (Pillaiyarpatt) to km. 7+750 (Koviloor)1 km. 0+000, RHS 5.8 6.1 22.2 41.8 24.1 SM NP NP NP 0 1.88 3.11 72 km. 1+000, LHS 14.8 13.7 25.8 29.4 16.3 SM NP NP NP 0 1.90 3.58 93 km. 3+000, RHS 16.8 20.5 15.9 18.3 28.5 SC 32 15 17 10 1.69 10.86 64 km. 4+000, LHS 16.2 9.6 19.0 31.7 23.5 SC 21 12 09 0 1.78 3.97 95 km. 5+000, RHS 6.5 5.9 24.1 41.0 22.5 SC 19 13 06 0 1.71 2.62 76 km. 6+000, LHS 29.5 9.5 14.6 19.7 26.7 SC 33 14 19 10 1.73 10.17 87 km. 7+700, RHS 7.0 6.1 22.4 39.4 25.1 SC 19 11 08 0 1.81 3.60 10
Soak
ed CB
R at
FD
D (%
)
Gravel%
Coarse Sand
%
Medium Sand
%
Fine Sand
%
Fines%
Liquid Limit
%
Plastic Limit
%
Plasticity Index
%
CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
Final Detailed ProjectReport
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E.5 IMPROVEMENT PROPOSALS
5.1 PROPOSED ALIGNMENTThe proposed Project Highway starts with design chainage Km 0.000 near Melur, at the
intersection with NH-45B (Madurai - Trichy road) and ends at design chainage Km 45.855 at
the intersection with NH-210 (new NH-536) near Karaikudi. The project stretch passes through the districts of Madurai and Siva-Gangai in the state of
Tamil Nadu.
Figure 3: Map showing proposed alignment of project road
5.2 GREENFIELD ALIGNMENTS
Considering built up locations along the existing road, granite quarry near Keelayur,
Vettangudi Bird Sanctuary and poor geometry, a Greenfield Alignment is proposed from
Melur to Pillayarpatty.
Table 17: Greenfield Alignment
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Final Detailed ProjectReport
EXECUTIVESUMMARY
GreenField AlignmentDesign Chainage (Km) Design Length
(Km)From To
Melur to Tirupattur 0.000 27.100 27.100
Tirupattur to Pillayarpatty 29.700 37.970 8.270
5.3 ROAD GEOMETRY
The project road has been designed to accommodate speeds of 100kmph, adopted as per
IRC SP: 84-2014.
5.4 WIDENING SCHEME
80% of the proposed alignment is passing through greenfield. Four lane configuration is
proposed throughout the project stretch.
Based on availability of ROW and the land acquisition constraints, greenfield alignment is
proposed and summary of widening scheme is given in below table.
Table 18: Summary of widening type proposed
S.No Type of widening Length (Km)
1 Concentric 1.185
2 Eccentric, Left 1.170
3 Eccentric, Right 2.440
4 Greenfield 23.650
5 VUP/LVUP/FO Approaches 16.750
5.5 PAVEMENT DESIGN
5.5.1 Design period, loading and pavement type
Using the projected traffic, VDF values, lane and directional distribution factors, the design
traffic loading used for the project is 20 MSA.
Through preliminary design and life cycle comparisons, the flexible type of pavement was
chosen for construction with a design life of 15 years as per IRC: 37-2012 has been
considered for design.
5.5.2 Design sub-grade strength
Considering the soil investigations conducted in the project road area and the availability of
suitable soil in the region, the following sub-grade strength has been assumed to vary from
5% to 10% for various sections of the highway.
AA/HD/2145 E – 21
CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
Final Detailed ProjectReport
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5.5.3 PAVEMENT COMPOSITION FOR NEW CARRIAGEWAY
5.5.3.1 Flexible Pavement
The proposed pavement composition for the project corridor according to IRC:37-2012 is as
given below:
Table 19: Proposed pavement composition
SectionDesign Chainage Design MSA
(15 yrs)CBR(%)
Crust Composition in mm
Start End BC DBM WBM GSB Total1 0.000 38.000 20.0 10 40 80 250 200 570
2 38.000 45.855 20.0 10 40 80 250 200 570
5.5.3.2 Rigid Pavement
Rigid pavement for entire project corridor including toll plaza is designed in accordance with
IRC:58-2015.
Table 20: Rigid Pavement Crust Composition
S.No ItemRigid pavement with Tied concrete shoulders
HS-1 HS-2
1 PQC of M40 grade, mm 260 280
2 DLC of M10 grade, mm 150 150
3 GSB, mm 150 150
4 Dia. of Dowel bar, mm 40 40
5 Length of Dowel bar, mm 500 500
6 Spacing of Dowel bar, mm 300 300
7 Dia. of Tie bar, mm (Plain bars)
12 12
8 Length of tie bar, mm 580 580
9 Spacing of tie bar, mm 465 400
5.5.4 Strengthening of existing pavement
The strengthening requirements for the existing pavement have been estimated by Falling
Weight Deflectometer survey. The design overlay proposed is as below:
Table 21: Overlay thickness required
AA/HD/2145 E – 22
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Section & SideLife of Pavement after Overlay Proposed Overlay
thicknessFatigue Rutting
Melur to Karaikudi (Km. 5.000to Km. 12.500) LHS
49.53 msa 272.09 msa 50 mm
Melur to Karaikudi (Km. 5.000to Km. 12.500) RHS
85.90 msa 397.37 msa 50 mm
5.5.5 Pavement design for service lanes
Pavement for service lanes is designed for MSA of 10 with a design CBR of 10%. The
composition for the flexible service lane pavement along the project corridor is as follows:
Table-22: Pavement Composition for Service Road
S.No Pavement composition Design thickness(mm)
Total thickness(mm)
1 Bituminous Concrete (BC) 40
5402 Dense Bituminous Macadam (DBM) 50
3 Wet Mix Macadam (WMM) 250
4 Granular Sub-Base (GSB) 200
5.6 DESIGN OF STRUCTURES
Along the project stretch, there are several bridges, culverts, under/overpasses and
flyovers. A summary of the total number and proposed additions is given in the table below
Table-23: Proposed improvement to structures along project road
S.No.
Structure Dismantle &Reconstruction
Retain &Widen
NewConstruction
Total
1 Major Bridge - - 9 9
2 Minor Bridge - 1 18 19
3 Box Culvert 11 6 55 72
4 Trumpet - - 1 1
5 Flyover - - 1 1
6 Vehicle overpass - - 1 1
7 Vehicle underpass - - 9 9
8 Vehicle underpass (SVUP) - - 12 12
9 Vehicle underpass (LVUP) - - 1 1
AA/HD/2145 E – 23
CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
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5.7 INTERSECTIONS AND GRADE SEPARATORS
The details of major junctions and grade separated structures are represented in below
tables:
Table-24: List of Major Junctions
S.NoExisting
Chainage(Km)
DesignChainage
(Km)
Type ofIntersection
Leads to Village
Left Right
1 - 29.816 +Tirupattur,Pudukkottai
Panayampatti
2 12.900 45.855 + Trichy Madurai
Table-25: List of Grade separated structures
S. NoDesign Chainage
(Km)Span (m)
Type ofStructure
Name of IntersectingRoad
1 0.433 2 X 30 X 5.5 Trumpet NH 38 (old NH 45B)
2 0.760 1 X 20 X 5.5 VUP -
3 2.157 1 x 7 x 4.0 SVUP Filed Track
4 4.598 1 x 15 x 5.5 VUP Keeliyur toThaniyamangalam
5 7.115 1 x 7 x 4.0 SVUPKeeliyur to
Thaniyamangalam Road
6 8.978 1 x 7 x 4.0 SVUP Kongampatti to AriyurpattiRoad
7 10.331 1 x 20 x 5.5 VUPKongampatti to
Jeyankondanilai Road
8 11.622 1 X 7 X 4.0 SVUP E.Malampatti tojeyankondanilai Road
9 14.325 1 x 7 x 4.0 SVUPErumaipatti to Nainappatti
Road
10 15.700 1 x 7 x 4.0 SVUP Mampatti Road
11 16.080 1 x 7 x 4.0 SVUPErumaipatti to Mampatti
Road
12 17.063 1 x 7 x 4.0 SVUP Erumaipatti to MampattiRoad
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
Final Detailed ProjectReport
EXECUTIVESUMMARY
S. NoDesign Chainage
(Km) Span (m)Type of
StructureName of Intersecting
Road
13 19.160 1 x 7 x 4.0 SVUP Sevalpatti to MampattiRoad
14 19.914 1 x 7 x 4.0 SVUPSevalpatti to Mampatti
Road
15 20.540 1 x 7 x 4.0 SVUP Kundenthalpatti toTirukostiyur Road
16 26.110 2 x 30 x 5.5 FOThirupattur to Tirukostiyur
Road
17 27.508 1 x 7 x 4.0 SVUP RanasingapuramKattambur Road
18 29.816 1 x 30 x 5.5 VUPThirupattur to
Themmapatti Road
19 33.744 2 x 30 x 5.5 VOP Thirupattur to ThalakavurRoad
20 36.900 1 x 12 x 4.0 LVUPPillayarpatty Kilamadam
Road
21 40.582 1 X 15 X 5.5 VUP Kundrakudi Road
22 44.400 1 X 15 X 5.5 VUP Patharaikudi Road
5.8 TOLL PLAZAS
Based on the traffic surveys, O-D surveys and layout of project road, One toll plaza has
been proposed along the project road. and the same mentioned in the table
Table 26: Location of Toll Plaza
Location
Location of Toll Plaza Minimum number of Toll lanes
Existingchainage (Km)
Designchainage (Km)
Entry Exit
Brahmanapatti - 22.000 7+1 7+1
5.9 WAYSIDE AMENITIES PROPOSED
A summary of the improvements proposed is given below.
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CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
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Table 27: Proposed user amenities along project stretch
S.No Amenity type Proposed
1 Rest Areas 1
2 Truck lay-byes 4
3 Bus bays 2
4 Bus shelters 16
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Final Detailed ProjectReport
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E.6 ENVIRONMENTAL IMPACT ASSESSMENT
6.1 IMPACT AND CLEARANCES NEEDED
An environmental impact study was undertaken during the process of creating the detailed
project report to understand impact of the project road on the surrounding ecology and
environment. The proposed project stretch neither falls under Category-A nor Category-B.
Hence, Environmental Clearance is not required for this project.
A summary of the environmental impact and clearances required is provided below
Table 28: Environmental impact and clearances required
S.No Impact Type Description
1Environmental Clearances
Not required as project stretch neither falls under Category-A nor Category-B.
2 Wildlife Clearances
As per the MoEF vide its OM No.Z-11012/5/2012-IA.II (T)
dated 02.07.2012 has clarified that project falling in Eco-
sensitive zones around National Parks and Wildlife Sanctuaries,
which are not covered under EIA Notification, 2006 and which
do not require environmental clearance, would also not require
prior approval of the Standing Committee of National Board of
Wildlife. Hence, Wild Life clearance is not required for this
project.
6.2 COST OF ENVIRONMENTAL MITIGATION
The design and construction of the project involves a number of items such as erosion
prevention, rehabilitation of borrow areas, safety signage, etc., which are included in the
contract cost. Only those items that are not covered under the budget for construction are
shown in the EMP implementation budget. The Budget for Environmental Management Plan for
Items to be covered in BoQs works out to Rs. 46.78 Crores.
AA/HD/2145 E – 27
CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
Final Detailed ProjectReport
EXECUTIVESUMMARY
E.7 SOCIAL IMPACT ASSESSMENT AND LAND ACQUISITION
The proposed project highway consists of Green and Brown field alignments. As most of the
alignment is of greenfield, there is requirement for land acquisition.
Preliminary interactions have been held with locals to understand their issues and concerns
and help communicate the project plan and its impact on them.
Table 29: Village wise Project Impact & Requirement of Land in Hectares
Sl.No.
Village Taluk DistrictLand to beacquired inHectares
Percentage(%)
Mellur-Pillayarpatti Section
1 Navinipatti Melur Madurai 19.983 8.018
2 Sathamangalam Melur Madurai 1.837 0.737
3 Thaniyamangalam Melur Madurai 0.581 0.233
4 Suruguvalaiyapatti Melur Madurai 8.990 3.607
5 Keelaiyur Melur Madurai 14.174 5.687
6 Keelavalavu Melur Madurai 15.025 6.028
7 Melur Melur Madurai 1.305 0.524
8 E.Mallampatti Melur Madurai 20.753 8.327
9 Mampatti North Singampunari Sivaganga 22.437 9.002
10 Mampatti South Singampunari Sivaganga 1.884 0.756
11 Nainapatti Singampunari Sivaganga 9.221 3.700
12 Vaniyankadu Melur Madurai 12.811 5.140
13 Sirukudalpatti Tirupattur Sivaganga 19.348 7.763
14 Tenkarai Tirupattur Sivaganga 13.237 5.311
15 Thenmapattu Tirupattur Sivaganga 6.281 2.520
16 Brahmanapatti Tirupattur Sivaganga 22.248 8.927
17 Kattambur Tirupattur Sivaganga 4.993 2.003
18 Pattakurichi Tirupattur Sivaganga 7.183 2.882
19 Tevarambur Tirupattur Sivaganga 8.495 3.408
20 Thanipatti Tirupattur Sivaganga 2.4877 0.998
Pillayarpatti- Karaikudi Section
21 Managirisukkanendal Karaikudi Madurai 6.627 2.659
22 Kunnakuddi Tirupattur Sivaganga 19.521 7.832
23 Siravayal Tirupattur Sivaganga 9.697 3.891
24 Thattati Tirupattur Sivaganga 0.118 0.047
Total Land in Hectares 249.237 100.000
AA/HD/2145 E – 28
CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
Final Detailed ProjectReport
EXECUTIVESUMMARY
E.8 PROJECT COST ESTIMATES
The cost estimates for the project have been prepared based on detail designs, bill of
quantities and the schedule of rates for Tamil Nadu state for the year 2018-19.
Table 29: Summary of project cost
BILLNo
BILL NAMETotal cost in
crores % of
total cost
Civil Construction cost
1 SITE CLEARANCE AND DISMANTLING 3.25 0.43%
2 EARTH WORKS 151.47 20.18%
3 BASE COURSES 124.03 16.53%
4 PAVING COURSES 102.86 13.71%
5a REPAIR AND REHABILATION OF STRUCTURES 0.21 0.03%
5b BRIDGES 134.20 17.88%
5c CULVERTS 27.91 3.72%
5d VUP AND PUP 23.87 3.18%
5eROB, RUB, FLYOVER, VIADUCT AND OVERPASS, INTERCHANGE
18.90 2.52%
5f DRAINAGE, PROTECTIVE WORKS AND OTHER SERVICES
45.85 6.11%
5g REINFORCED EARTH AND TOE WALLS 65.34 8.71%
6 JUNCTIONS AND INTERCHANGES 0.52 0.07%
7 TOLL PLAZA 7.96 1.06%
8 USER AMENITIES 3.87 0.52%
9 TRAFFIC SIGNS, MARKINGS AND APPURTENANCES 10.82 1.44%
10 MISCELLANEOUS 29.20 3.89%
11 MAINTENANCE OF ROAD DURING CONSTRUCTION 0.27 0.04%
A Total Civil Cost 750.52
12 Add contingencies @ 2.8% on civil construction cost 21.01
B Estimated project cost 771.54
13Construction supervision @ 1% on civil construction cost
7.51
AA/HD/2145 E – 29
CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELURTO KARAIKUDI UNDER BHARATMALA PARIYOJANA, PHASE I, ON EPCMODE IN THE STATE OF TAMIL NADU
Final Detailed ProjectReport
EXECUTIVESUMMARY
BILLNo
BILL NAMETotal cost in
crores % of
total cost
14 Agency charges @ 2% on civil construction cost 15.01
15 Quality control changes @ 1% on civil construction cost
7.51
16Road safety cell audit charges @ 0.5% on civil construction cost
3.75
17 Maintenance costs @ 5% on civil construction cost 37.53
18 Escalation @ 5% per annum for 2 years i.e., 10% on civil construction cost
75.05
C Total Project Cost 917.89
19 Environment Cost 46.78
20 Cost of shifting utilities 16
21 LA compensation cost 200
D Total capital cost 1180.67
AA/HD/2145 E – 30
CONSTRUCTION OF FOUR LANE DIVIDED HIGHWAY FROM MELUR TO KARAIKUDI UNDER BHARATMALAPARIYOJANA, PHASE I, ON EPC MODE IN THE STATE OF TAMIL NADU
Final Detailed Project Report
EXECUTIVE SUMMARY
E.9 MATERIAL INVESTIGATION
Material investigations were carried out to explore the availability and identify sources of suitable material for the construction of the road.
10.1 BORROW PITS FOR SOIL
Total six borrow areas in Melur-Pillayarpatty section and two in Pillayarapatty-Karaikudi section were identified in the vicinity of the project road
and representative samples have been collected and tested in the laboratory.
Along the corridor, most of the soils fall under the category of Clayey sand and clayey gravel. For these soils, MDD ranges from 1.93 g/cc to 2.27
g/cc, soaked CBR value ranges from 5.0% to 25.0%. These soils are good for embankment fill as well as for sub-grade construction.
Table-30: Test results of Borrow Area
S.N
o.
Ch
ain
ag
e
Sid
e
Grain Size Analysis
IS C
lass
ific
ati
on Atterberg Limits
FS
I (%
)
Proctor test
So
aked
CB
R (
%)
Gra
vel
Co
ars
e S
an
d
Med
ium
San
d
Fin
e s
an
d
Fin
es
LL %
PL %
PI
%
MD
D (
g/c
c)
OM
C (
%)
Km 0.000(Melur) to Km 37.500 (Pillayarapatty)
1 0+000 RHS 0.7 2.6 28.1 46.7 21.9 SC 20 14 6 0 2.10 7.50 15 2 8+700 LHS 4.4 8.7 18.6 23.3 45.0 SC 37 18 19 30 1.96 12.10 13
3 15+800 RHS 52.3 10.2 11.7 15.7 10.1 GW-GM NP NP NP 0 2.27 5.40 25
4 20+000 RHS 10.3 16.0 43.6 14.7 15.4 SC 43 21 22 60 2.08 8.45 85 27+000 RHS 8.6 9.0 20.2 28.1 34.1 SC 42 15 27 80 2.04 10.15 5
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Final Detailed Project Report
EXECUTIVE SUMMARYS
.No.
Ch
ain
ag
e
Sid
e
Grain Size Analysis
IS C
lass
ific
ati
on Atterberg Limits
FS
I (%
)
Proctor test
So
aked
CB
R (
%)
Gra
vel
Co
ars
e S
an
d
Med
ium
San
d
Fin
e s
an
d
Fin
es
LL %
PL %
PI
%
MD
D (
g/c
c)
OM
C (
%)
6 33+500 LHS 0.0 0.6 27.9 39.8 31.7 SC 31 14 17 10 2.03 9.20 13Km 0.000 (Pillayarapatty) to Km 7.750 (Koviloor)
1 1+000 RHS 9.6 21.3 30.1 7.7 31.3 SC 48 24 24 20 1.94 12.35 12 2 6+500 RHS 4.6 7.0 21.3 23.4 43.7 SC 36 19 17 0 1.93 11.50 12
10.2 FLYASH
One flyash sample was identified in the vicinity of the project road and representative samples have been collected and tested in the laboratory.
Test results of the flyash sample is represented in the below table.
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Final Detailed Project Report
EXECUTIVE SUMMARY
Table-31: Test results of Flyash sample
S.N
o.
Ch
ain
ag
e
Sid
e
Grain Size Analysis Atterberg Limits
FS
I (%
)
Proctor test
So
aked
CB
R (
%)
Gra
vel
Co
ars
e S
an
d
Med
ium
San
d
Fin
e s
an
d
Fin
es
LL %
PL %
PI
%
MD
D (
g/c
c)
OM
C (
%)
Km 0.000(Melur) to Km 37.500 (Pillayarapatty)
1 0+000 RHS 0.00 0.30 14.22 57.80 27.70 NP NP NP 0 1.21 26.00 4Km 0.000 (Pillayarapatty) to Km 7.750 (Koviloor)
2 7+750 RHS 0.00 0.30 14.22 57.80 27.70 NP NP NP 0 1.21 26.00 4
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10.3 GRAVEL
Two sources for coarse aggregate materials were identified in the vicinity of the project road.
Summary of test results of aggregates is represented in the below table.
Table-32: Summary of Test results of Aggregates
S.No. Chainage SideSpecificgravity
WaterAbsorption
(%)AIV (%) Suitability
Km 0.000(Melur) to Km 37.500 (Pillayarapatty)
137+500(MQ 1)
LHS 2.85 0.20 30.46 Suitable only for GSB
237+500(MQ 2)
LHS 2.85 0.11 23.84Suitable for all
bituminous non-bituminous works
Km 0.000 (Pillayarapatty) to Km 7.750 (Koviloor)
1 0+000(MQ 1)
LHS 2.85 0.20 30.46 Suitable only for GSB
20+000(MQ 2) LHS 2.85 0.11 23.84
Suitable for allbituminous non-bituminous works
From the test results in can be concluded that the crushed aggregates obatined from MQ 1 is
suitable only for GSB where as that from MQ 2 satisfy the limits specified in MORT&H for all
bituminous, non-bituminous works such as BM, BC, WMM, GSB and Structural Concrete.
10.4 SAND
Two sand sources were identified in the vicinity of the project road. These sources are located
on the riverside and satisfies the requirement of zone-II & III. Summary of test results of
aggregates is represented in the below table.
Table-33: Summary of Test results of Sand
S.No Chainage Side ZoneFinenessModulus
SpecificGravity
WaterAbsorption
(%)
Km 0.000(Melur) to Km 37.500 (Pillayarapatty)
1 0+000 (SQ 1) RHS II 3.16 2.62 0.29
Km 0.000 (Pillayarapatty) to Km 7.750 (Koviloor)
1 0+000 (SQ 1) LHS III 2.07 2.61 0.32
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EXECUTIVESUMMARY
10.5 LOCATION OF MATERIAL SOURCES
Figure 4: Masshaul diagram for Melur-Pillayarpatty section
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EXECUTIVESUMMARY
Figure 5: Masshaul diagram for Pillayarpatty-Koviloor (Karaikudi) section
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EXECUTIVESUMMARY
E.10 ECONOMIC AND FINANCIAL ANALYSIS
11.1 ECONOMIC ANALYSIS OF THE PROJECT
The EIRR and NPV of the project has been carried out using discounted cash flow
technique under multiple scenarios.
The various sensitivity scenarios considered were as follows:
Case-I Base Cost and Base Benefits
Case-II Base Cost plus 15 % and Base Benefits
Case-III Base Cost and Base Benefits minus 15%
Case-IV Base cost plus 15% and Base Benefits minus 15%
Summary for the Sensitivity analysis for the three sections are given below:
Table-34: Sensitivity Analysis (20 years)
Case HS-1 HS-2 Total Package
Case-I 20.5 17.2 20.0
Case-II 17.6 15.3 18.3
Case-III 17.2 15.1 18.0
Case-IV 14.4 13.3 16.6
The results for the improvement scheme are presented below:
Table-35: EIRR & NPV
Total PackageEIRR (%) NPV (Cr.)
20 Year 30 Years 20 Year 30 Years
HS-1 20.5 21.6 411.5 632.6
HS-2 17.2 18.7 49.1 86.4
Total Package 20.0 21.2 461.9 720.4
From the results of the Economic Analysis, it can be seen that the improvement scheme, the
EIRR is getting higher than minimum threshold value of 12%.
So it can be concluded that the project of four lane with paved shoulder option is economically
viable and recommended for implementation.
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11.2 FINANCIAL ANALYSIS
11.2.1 Potential for toll revenue
The classified traffic volume count data collected has been analyzed to assess the traffic
intensity at the proposed toll plaza location. The summary of Annual Average Daily Traffic
(AADT in number of vehicles) at the proposed toll plaza location is given below.
Table-36:Tollable Traffic at Toll plaza location
At Toll PlazaLocation
Tollable Traffic
Cars M. Bus Bus LCV 2 AT 3 AT M AT M. LCV Total
Design chainage Km 22.000
2619 102 673 235 307 82 79 536 4635
11.2.2 Results of Financial analysis
Table-37:Financial Analysis results
Tolling Lengths(km) Grant
(%)Concession
PeriodCivil Cost in
Cr. Year 2018Project FIRR
(%)Equity
FIRR (%)From To Length
0.000 45.855 45.855 40 20 750.52 0.46% -
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E.11 EXECUTION PLAN
In consultation with NHAI, it is proposed to complete the proposed project road in a period of
24 months. Planning for the project packaging, bidding process and construction was
conducted as a part of this project.
12.1 PACKAGING
Given the length of the project, the entire project is planned to be bid out in single package.
12.2 BIDDING MODE AND TIMELINES
The authority has proposed to initiate bidding of the project under EPC mode. The tentative
timelines for this are
• Submission of bid documents to authority Submitted
• Review and finalization of documents Completed
• Launch of tender Tenders were called
• Tender close date Not Known
• Tentative date for award of project December, 2018
12.3 CONSTRUCTION TIME AND PLANNING
Upon reviewing the improvements planned and in consultation with NHAI, the design and
construction period for this project has been arrived at 24 months from the date of
appointment of the contractor/concessionaire. To enable this construction schedule, a detailed
construction plan and timeline has been included in the detailed project report. This also
includes a traffic management and lane closure plan for the period of construction.
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E.12 CONCLUSIONS AND RECOMMENDATIONS
Construction of Four Lane Divided Highway From Melur To Karaikudi Under Bharatmala
Pariyojana, Phase I, in The State of Tamil Nadu is recommended for implementation on EPC
Mode as the project is likely to provide enhanced connectivity and reduce the travel time
between Madurai-Thanjavur and Madurai-Karaikudi with improved level of service.
A minimum return on equity of around 15% could be considered satisfying the requirement of
prospective concessionaire. The project is not yielding any return on equity even with 40%
grant and 20 years concession period. In view of this, it can be concluded that the option with
BOT (Toll) is not viable for taking up the project on BOT -Toll basis.
In view of the above it is recommended to taken up the project on one EPC Mode.
Table 38: Salient features and key financial aspects of the project road
Project road lengthProject road length 45.855 Km
Connecting Melur – Karaikudi
on National Highway• NH-338 (0.000 to 37.970) • NH-383 Extn. (37.970 to 45.855)
Project Features Current road Proposed roadLanes 2 4
Realignments proposed - 4
Major junctions 1 2
Minor junctions 3 6
Trumpets - 1
Flyovers - 1
Major bridges 1 9
Minor bridges 2 19
ROBs - -
Culverts 28 72
Vehicle Underpasses including LVUP &SVUP
- 19
Vehicle overpasses 1 1
Service roads(Kms) - 6.180
Slip roads(Kms) - 21.440
Toll plazas(No.) - 1
Bus bays(No.) - 2
Bus shelters(No.) - 16
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Truck lay-byes(No.) - 4
Rest Areas(No.) - 1
Financial Implications INR cr.Total capital cost 1180.67
Total project cost 917.89
Civil construction cost (Incl. Contingency) 771.54
Pre-construction expensesLand Acquisition 200
Utilities shifting 16
Environment Cost 46.78
Implementation mode proposed EPC
Total project cost 917.89
Concession period 20
Authority Support(Grant/Premium) -
Estimated NPV 461.9
Project IRR 0.46%
Equity IRR -
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