Manual for Survey, Investigation and Preparation of Road Projects (Second Revision)

IRC SP 19 - Scope: Key Points & Specifications

Scope Overview:

• Covers improvement and new construction of highways.
• Includes road inventory, condition survey, soil investigations, environmental studies, and project preparation stages.
• Economic justification depends on existing road condition.
• Data collection includes riding quality, pavement width, vertical profile, horizontal curvature, subgrade strength, pavement thickness, and deflection (Benkelman Beam).

Key Specifications & Data Requirements:

• Road Inventory & Condition Survey (Clause 14):

  • Collect data on existing road condition, geometry, and pavement.
  • Use formats from Appendix-7 for road inventory.
  • Maintain data in computer-based road data bank (Appendix-8).
  • Essential parameters:
    • Riding quality
    • Pavement width
    • Vertical profile
    • Horizontal curvature
    • Subgrade soil strength
    • Pavement thickness and composition
    • Deflection characteristics (Benkelman Beam)

• Soil Investigations (Clause 13.3 & Table 1):

  • Laboratory tests per IS:2720.
  • Atterberg Limits: Liquid Limit (LL), Plastic Limit (PL), Plasticity Index (PI).
  • Sieve analysis for sand content.
  • Soil classification as per IS or IRC:36.
  • Density tests (Max dry density, OMC).
  • Avoid heterogeneous soils for embankment subgrade (top 500 mm).

Suggested Table Format for Soil Investigation Summary (Excerpt)

Deflection Measurement (Benkelman Beam):

• Record pavement temperature, soil type, moisture content.
• Dial readings: Initial, Intermediate, Final.
• Calculate rebound deflection to assess pavement strength.

flowchart TD
    A[Project Preparation] --> B[Road Inventory & Condition Survey]
    B --> C[Data Collection: Riding Quality,

IRC SP 19: Stages in Project Preparation

Though the code snippet lacks detailed clauses, typical project preparation stages per IRC SP 19 and standard practice include:

Key Stages in Project Preparation

1. Preliminary Investigation
   • Traffic surveys, reconnaissance, and feasibility studies.
2. Detailed Investigation
   • Topographical surveys, soil investigations, and environmental studies.
3. Preliminary Design
   • Alignment selection, cross-section design, and preliminary cost estimation.
4. Detailed Design
   • Final geometric design, structural design, and detailed drawings.
5. Cost Estimation and Sanction
   • Preparation of detailed cost estimates and obtaining administrative approval.
6. Tendering and Contract Award
   • Preparation of tender documents, bidding, and contract finalization.

Typical Table: Project Preparation Activities vs Deliverables

This structured approach ensures comprehensive project planning and sanctioning per IRC guidelines.

Preliminary Survey Key Points from IRC SP 19

• Traverse Survey:

  • Run traverse along probable final centerline.
  • Secondary traverse may be run in difficult terrain.
  • Use EDM/Total Station for distance measurement with accuracy ≥ 1:10,000.
  • Station intervals depend on terrain and alignment changes.
  • Mark and preserve transit stations.

• Offsets & Features:

  • Locate physical features (buildings, utilities, water crossings) by offsets from traverse.
  • Survey width covers entire right-of-way plus allowance for centerline shifts.

• Levelling:

  • Fly levels at 50 m intervals along traverse.
  • Cross-sections at 100-250 m (plain), 50 m (rolling), 20 m (hilly).
  • Benchmarks every 250-500 m connected to GTS datum.

• Map Scales:

• Additional Inputs:
  • Collect data on traffic, soil, drainage during survey.
  • Use aerial photography, photogrammetry, satellite imagery for large projects.
  • Ground reconnaissance with instruments like compass, Abney level, GPS/DGPS.

Summary Diagram of Preliminary Survey Process

flowchart TD
    A[Reconnaissance Survey] --> B[Preliminary Traverse Survey]
    B --> C[Feature Offsets & Levelling]
    C --> D[Map Preparation & Contour Drawing]
    D --> E[Final Alignment Selection]

This concise framework ensures accurate physical data collection for highway alignment decisions per IRC SP 19.

IRC SP 19: Guiding Principles of Route Selection and Alignment Improvement

Key Principle:

• Minimize overall transportation cost = Initial construction cost + Maintenance cost + Road user cost
• Simultaneously satisfy social and environmental requirements.

Process:

• Conduct detailed investigations before finalizing the route.
• Consider multiple factors (see Appendix-1 & Fig. 4.1 in IRC SP 19):
  • Topography and geology
  • Environmental impact
  • Land acquisition and resettlement
  • Traffic patterns and future growth
  • Construction and maintenance feasibility
  • Social and cultural impacts

Engineer-in-charge Role:

• Apply judgment to balance conflicting factors.
• Achieve an optimum compromise aligned with minimum transportation cost.

Typical Cost Components Formula:

[ \text{Total Cost} = C_c + C_m + C_u ]

Where:

• (C_c) = Initial Construction Cost
• (C_m) = Maintenance Cost (over design life)
• (C_u) = Road User Cost (vehicle operating + travel time costs)

flowchart TD
    A[Start: Preliminary Survey] --> B[Consider Factors: Topography, Environment, Social]
    B --> C[Estimate Costs: Construction, Maintenance, User]
    C --> D[Evaluate Alternatives]
    D --> E[Select Optimum Route]
    E --> F[Detailed Investigation]
    F --> G[Final Alignment & Approval]

Summary: Route selection balances cost, environment, and social factors, aiming for the lowest life-cycle transportation cost.

IRC SP 19: Preliminary Survey Procedures — Key Points

1. Traverse Survey:

• Run traverse close to the probable final center line.
• Use primary and secondary traverses if needed.
• In hilly areas, make a trace cut 1.0–1.2 m wide if required (see IRC:52 for hill roads).

2. Distance Measurement:

• Use EDM or total station.
• Accuracy: 1 in 10,000 minimum.

3. Transit Stations:

• Spacing depends on alignment changes, terrain, visibility.
• Mark stations with stakes, number sequentially, and protect till final survey.

4. Feature Location:

• Offset measurements for buildings, monuments, pipelines, roads, rivers, etc.
• Survey width covers entire right-of-way plus allowance for center line shifts.

5. Levelling:

• Fly levels at 50 m intervals on traverse line and breaks.
• Cross-sections at:
  • 100–250 m (plain terrain)
  • up to 50 m (rolling terrain)
  • up to 20 m (hilly terrain)
• Benchmarks every 250–500 m, connected to GTS datum.

6. Map Scales:

7. Additional:

• Collect traffic, soil, drainage data during traverse.
• Prepare plans and longitudinal sections with contours (1–3 m interval) at critical points.

flowchart TD
    A[Start Preliminary Survey] --> B[Run Traverse along Route]
    B --> C[Measure Distances with EDM/Total Station]
    C --> D[Mark Transit Stations]
    D --> E[Record Offsets of Physical Features]
    E --> F[Fly Leveling at 50m Intervals]
    F --> G[Take Cross-sections (Spacing by Terrain)]
    G --> H[Prepare Maps & Sections (with Contours)]
    H --> I[Collect Additional Data (Traffic, Soil, Drainage)]
    I --> J[Complete Preliminary Survey]

This concise summary aligns with IRC SP 19 clauses 8.2

IRC SP 19: Bench Marks and Staking Final Centre Line

1. Staking Final Centre Line (Clause 12.2)

• Run a traverse along the selected route, close to the probable final centre line.
• Use EDM or total station for distance measurement with accuracy of 1 in 10,000.
• Transit stations (stakes) should be spaced based on alignment curvature, terrain, and visibility.
• Mark and number stakes sequentially; protect until final location survey.
• Offsets to physical features (buildings, streams, roads) must be recorded from the traverse line.
• For hilly terrain, include grades, ridges, valleys, and vertical curves in survey data.

2. Bench Marks (Clause 12.3)

• Establish temporary or permanent bench marks every 250 to 500 m.
• Bench marks must be connected to the GTS datum for vertical control.
• Bench marks assist in levelling during surveys and construction.

3. Survey and Levelling Specifications (from Clause 8.2)

4. Map Scales for Final Drawings (Clause 8.3.2)

Summary Diagram: Staking Final Centre Line Workflow

flowchart TD
    A[Preliminary Survey] --> B[Traverse along Probable Centre Line]
    B --> C[Mark Transit Stations (Stakes)]
    C --> D[Measure Distances with EDM/Total Station]
    D --> E[Record Offsets to Physical Features]
    E --> F[Establish Bench Marks (250-500m)]

Soil and Material Surveys — IRC SP 19 Key Points

1. Soil Investigation Summary (Table 1 Proforma)

2. Soil Selection Guidelines

• Use homogeneous soils for embankment.
• Reserve best soil for top 500 mm subgrade layer.
• Avoid heterogeneous or variable soils.
• Follow IRC:36 for classification and norms.

3. Borrow Area Charting

• Prepare charts showing strata depth, fill quantities, and borrow locations.
• Quantify earth required for subgrade and embankment body separately.
• Mark source locations with estimated quantities.

Formula: Sand Content Calculation

[ \text{Sand Content (%)} = % \text{Passing 4-7 mm sieve} - % \text{Passing 75 micron sieve} ]

Reference: IRC:36 Soil Classification (Summary)

• Soils classified based on grain size distribution and Atterberg limits.
• Important for embankment stability and compaction behavior.

flowchart TD
    A[Soil Sampling] --> B[Laboratory Tests]
    B --> C[Sieve Analysis]
    B --> D[Atterberg Limits]
    B --> E[Density & Moisture Content]
    C --> F[Calculate Sand Content]
    D --> G[Classify Soil (IRC:36)]
    F --> H[Select Homogeneous Soil]
    G --> H
    H --> I[Prepare Borrow Area Chart]
    I --> J[Design Embank

IRC SP 19: Road Inventory and Condition Survey – Key Points

1. Purpose

• Assess existing roads for improvements (strengthening, widening, bypasses).
• Economic justification depends on current road condition.

2. Essential Data for Inventory & Condition Survey

• Riding quality
• Pavement width
• Vertical profile
• Horizontal curvature
• For strengthening: Subgrade soil strength, pavement thickness/composition, deflection data (Benkelman Beam).

3. Typical Road Inventory Format

Refer to Appendix-7 of IRC SP 19 for detailed formats.

4. Pavement Deflection Measurement (Benkelman Beam)

5. Notes

• Use temperature and seasonal corrections for deflection data.
• Maintain data in computer-based road data banks (Appendix-8).
• Use existing Road and Bridge Registers if available.

Example: Deflection Data Table Format (Benkelman Beam)

This structured approach ensures comprehensive road condition assessment aligned with IRC SP 19 guidelines.

IRC SP 19: Drainage Studies - Key Points & Specifications

Objectives of Drainage Studies (Clause 15.1.2)

• Fixing grade line of road
• Pavement design
• Surface/sub-surface drainage design

Data to Collect (Clause 15.1.3)

• High Flood Level (HFL)
• Ponded water level
• Depth of water table (high and low)
• Range of tidal levels
• Surface runoff quantity
• Special seepage/sub-terranean flow studies in cut/hilly sections

High Flood Level (HFL) (Clause 15.2)

• Governs road grade line
• Based on return period (importance-dependent)
• Use irrigation dept. data, local inspection (marks on trees/structures)
• Account for afflux due to embankments; provide adequate openings

Depth of Water Table (Clause 15.3)

• Measure at wells/test holes every ~1 km, preferably post-monsoon
• Record spring flow if any
• Reference to common datum
• Measure lowest water table in driest month to understand fluctuations
• Not needed if water table >1 m below ground in arid areas

Ponded Water Level (Clause 15.4)

• Consider in stagnant water-prone areas (e.g., irrigated fields)
• Use alongside HFL and water table data in design

Special Investigations for Cut Sections (Clause 15.5)

• Identify seepage from high water table, sub-terranean channels, irrigation
• Measures:
  • Deep side drains (open/French drains)
  • Buried transverse drains (cut longitudinal flows)
  • Blanket course/sub-drains under pavement
• Investigate soil profile, hydraulic gradient via standpipes in observation holes

Typical Drainage Study Workflow

flowchart TD
    A[Preliminary Survey] --> B[Site Inspection & Local Enquiry]
    B --> C[Data Collection: HFL, Water Table, Ponded Water]
    C --> D[Special Investigations in Cut Sections]
    D --> E[Design Drainage System]
    E --> F[Finalize Road Grade & Pavement Design]

Summary Table: Key Parameters for Drainage Design

Key Specifications & Formulas for Cross-Drainage Structures (IRC SP 19)

1. Catchment Area & Cross-Section Survey

• For catchments < 1.25 sq.km, conduct chain and compass traverse.
• For flat areas, contour survey needed before watershed identification.
• Cross-section distances upstream/downstream (Table 5):

2. Design Steps (Clause 16.4.1)

• Estimate design discharge (Q)
• Choose structure type (culvert, bridge, etc.)
• Determine waterway & vent height
• Structural design of foundation, sub-structure & super-structure

3. Velocity & Flood Level

• Observe velocity during actual floods; adjust if flood < max flood.
• Determine Maximum High Flood Level (HFL) via local observation & enquiry.
• Velocity check:
  [ V_{adjusted} = V_{observed} \times \frac{Q_{max}}{Q_{observed}} ]

4. Trial Pits / Bores

• Dig trial pits to rock or twice max scour depth.
• Plot soil profile on cross-section.
• Use trial bores if pits not feasible.

5. Reference Codes

• IRC 13: Design of Small Bridges and Culverts
• IRC 78: Foundation and Sub-structure for Minor Bridges

flowchart TD
    A[Estimate Design Discharge] --> B[Choose Structure Type]
    B --> C[Determine Waterway & Vent Height]
    C --> D[Structural Design]
    D --> E[Construction & Inspection]

Summary:
For cross-drainage structures, accurate catchment and cross-section data are essential, with design based on maximum flood discharge and velocity. Trial pits inform foundation design. Follow IRC 13 and IRC 78 for detailed structural guidelines.

IRC SP 19: Preparation & Presentation of Detailed Project Report (DPR)

Key Specifications & Structure of DPR (Clause 17)

The DPR should be comprehensive, systematic, and clear for technical, administrative, and financial approval. It is divided into three parts, with the Project Report as the core document.

Project Report Contents (Clause 17.2)

• Executive Summary: Concise overview for decision-makers.
• Introduction & Socio-economic Profile
• Traffic Surveys & Forecasts
• Engineering Surveys & Investigations
• Pavement Studies
• Design Standards & Specifications
• Drainage & Cross-drainage Structures
• Environmental & Social Considerations
• Materials, Labour & Equipment
• Rates & Cost Estimates
• Economic & Financial Analysis
• Construction Constraints & Programme
• Conclusions & Recommendations

Important Notes

• Attach design calculations and relevant data.
• Use checklists (Appendices 4,5,6) to ensure completeness.
• Present data in tabular form for clarity, especially for existing structures and improvements (Clause 16.5).

Example Table Format for Existing Drainage Structures (Clause 16.5.1)

Flow of DPR Preparation

flowchart TD
    A[Survey & Investigations] --> B[Data Collection]
    B --> C[Analysis & Design]
    C --> D[Preparation of DPR]
    D --> E[Submission for Approval]

Summary: DPR preparation per IRC SP 19 involves a structured, detailed report covering all technical, economic, and social aspects, supported by data, calculations, and clear presentation to

IRC SP 19: Guiding Principles for Route Selection and Highway Location

Key Principle:

• Minimize overall transportation cost, including:
  • Initial construction cost
  • Maintenance cost
  • Road user cost
• While satisfying social and environmental requirements.

Process:

• Conduct detailed investigations before finalizing location.
• Consider multiple factors (see Appendix-1 & Fig. 4.1 in IRC SP 19):
  • Topography
  • Geology
  • Environmental impact
  • Social factors (resettlement, land acquisition)
  • Traffic projections
  • Economic feasibility

Engineer's Role:

• Exercise judgment to balance competing factors.
• Aim for an optimum compromise minimizing total cost and impact.

Typical Cost Components Formula:

[ \text{Total Cost} = C_{\text{construction}} + C_{\text{maintenance}} + C_{\text{user}} ]

Where:

• ( C_{\text{user}} = \sum (\text{Vehicle Operating Cost} + \text{Travel Time Cost}) \times \text{Traffic Volume} \times \text{Distance} )

Conceptual Route Selection Flowchart:

flowchart TD
    A[Start: Identify Project Need] --> B[Preliminary Surveys]
    B --> C[Consider Topography & Environment]
    C --> D[Estimate Construction & Maintenance Costs]
    D --> E[Estimate Road User Costs]
    E --> F{Evaluate Social & Environmental Impact}
    F -->|Acceptable| G[Select Optimal Route]
    F -->|Not Acceptable| B
    G --> H[Finalize Route & Design]

Summary: Route selection in IRC SP 19 prioritizes minimizing total transportation cost while balancing environmental and social factors, requiring detailed study and engineering judgment.

IRC SP 19 Appendix-4 provides a comprehensive Check List of Major Operations Involved in Survey and Investigation for a Road Project. Key points include:

Major Operations Checklist:

• Study of Available Information: Collect existing maps, soil data, traffic, and environmental studies.
• Soil Investigations:
  • Low embankments
  • High embankments (special investigations)
  • Cut sections
  • Landslide-prone areas
• Pavement Design Investigations:
  • Flexible pavement detailed study
  • Rigid pavement detailed study
• Material Investigations:
  • Naturally occurring aggregates
  • Manufactured aggregates (brick aggregates)
  • Water quality for construction
• Road Inventory and Condition Survey
• Drainage Studies:
  • Flood levels, water table, ponded water, surface runoff
• Cross-Drainage Structures Survey
• Preparation of Project Documents:
  • Detailed Project Report (DPR)
  • Estimates and drawings
  • Checklists for quality control

Reference Table (Excerpt):

This checklist ensures all critical survey and investigation aspects are covered for a robust road project planning phase.

flowchart TD
    A[Start: Study Available Info] --> B[Soil Investigations]
    B --> C{Type of Embankment}
    C -->|Low| D[Low Embankment Soil Tests]
    C -->|High| E[High Embankment Special Tests]
    B --> F[Cut Section Soil Tests]
    B --> G[Landslide Area Tests]
    A --> H[Pavement Design Investigations]
    H --> I[Flexible Pavement]
    H --> J[Rigid Pavement]
    A --> K[Material & Water Quality Tests]
    A --> L[Road Inventory & Condition Survey]
    A --> M[Drainage Studies]
    M --> N[High Flood

Typical Road Inventory Format (IRC SP 19 - Clause 14)

Road inventory is essential for assessing existing roads before improvement. Key components include:

Key Data Items:

• Riding Quality
• Pavement Width
• Vertical Profile
• Horizontal Curvature
• Subgrade Soil Strength
• Pavement Thickness & Composition
• Deflection Characteristics (e.g., Benkelman Beam readings)

Pavement Deflection Data (Benkelman Beam as per IRC:81-1997):

Notes:

• Soil plasticity parameters (LL, PL, PI) tested as per IS:2720 Part XVI.
• Use computer-based road data banks for efficient data management (Appendix-8).
• Refer to Appendix-7 for suggested detailed formats.

flowchart TD
    A[Start Road Inventory] --> B[Collect Road Geometry Data]
    B --> C{Existing Data Available?}
    C -->|Yes| D[Use Existing Road & Bridge Registers]
    C -->|No| E[Conduct Fresh Road Inventory]
    E --> F[Measure Riding Quality, Pavement Width, Profiles]
    F --> G[Assess Soil & Pavement Properties]
    G --> H[Perform Deflection Tests (Benkelman Beam)]
    H --> I[Compile Data into Road Data Bank]
    D --> I
    I --> J[Use Data for Economic & Design Analysis]

This format ensures comprehensive data collection for effective road improvement planning.

Key Laboratory Tests for Highway Embankments (IRC SP 19)

Based on IRC SP 19 and related IRC codes (IRC:36, IRC:37):

1. General Soil Tests for Embankment Material

• Sieve Analysis: Percent passing 4.75 mm, 2 mm, 425 micron, 75 micron sieves.
• Sand Content: Calculated as % passing 4.75 mm sieve minus % passing 75 micron sieve.
• Atterberg Limits: Liquid Limit (LL), Plastic Limit (PL), Plasticity Index (PI).
• Density Tests: Maximum dry density and Optimum Moisture Content (OMC) by Proctor test (Normal/Heavy compaction).
• Field Density & Moisture Content: For compaction control.
• Soil Classification: According to IS system or IRC:36 guidelines.
• Deleterious Constituents: Presence of salts, organic matter, etc.

2. Special Tests for Pavement Design

• California Bearing Ratio (CBR): For remoulded soil samples, soaked and unsoaked.
• Water Table Depth: Below subgrade under worst conditions.

3. Suggested Proforma for Data Presentation

4. Notes:

• Homogeneous soils preferred for subgrade (top 500 mm).
• Avoid heterogeneous soils.
• For high embankments, refer to IRC Special Reports 13 & 14.
• For landslide-prone areas, special geological investigations are required.
• For flexible pavement design, follow IRC:37 guidelines.

Formula for Sand Content:

[ \text{Sand Content (%)} = % \text{passing 4.75 mm sieve} - % \text{passing 75 micron sieve