construction of national automotive test tracks - unique
TRANSCRIPT
9/15/2014
Construction of National Automotive Test Tracks
- Unique features and challenges faced
Dr. N. Karuppaiah
&
A. Prabhakar, Tejpal Mahajan, Manish Mishra, Vishalender Singh
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➢ To emerge as a Global Automotive Hub
➢ To invest in research and development to increase innovativebreakthroughs for vehicle design and in manufacturing technology
➢ To provide a world class infrastructure for Automotive R & D
➢ To achieve the mission plan, NATRIP (National Automotive Testingand R&D Infrastructure Project) is an important Initiative byGovernment of India
➢Unique partnership with joining hands by Union Government, StateGovernment and the Indian Automotive Industry.
AUTOMOTIVE MISSION PLAN 2006-16
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NATIONAL AUTOMOTIVE TESTING AND R&D INFRASTRUCTURE PROJECT
Project of Government of India with Investment of over Rs.3,700 Crores
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• ARAI - CHAKAN and VRDE-Ahmednagar inwestern hub, in Maharashtra.
• ICAT-Manesar, Haryana and GARC-Oragadam, Chennai, Tamil Nadu.
• A world-class Proving Ground on 3,000acres of land at NATRAX- Pithampur, nearIndore, Madhya Pradesh.
• Hill Area Driving Training Centre and In-UseVehicle Inspection & Maintenance Centre inNorth East at NIAIMT-Silchar, in Assam.
NATRIP CENTRES
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ICAT, Manesar
NATRAX, INDORE
VRDE, Ahmednagar
ARAI Chakan, Pune
NIAMIT, Silchar
GARC -Chennai
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TEST TRACKS AT NATRAX
Dynamic Platform Multi Friction Braking Track Gradient Track
Accelerated Fatigue Track Comfort Track Handling Track-2W
Dynamic Platform Braking Track Gradient Track
TEST TRACKS AT NATRAX
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Sustainability Track
Handling Track- 4W
Wet Skid Pad
Noise Track
TEST TRACKS AT NATRAX
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LAYOUT OF NATRAX – 2960 AcresLAYOUT OF NATRAX – 2,960 ACRES
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➢ Comprehensive Performance Validation / Evaluation :
❖ Performance - Max speed, Acceleration, Gradeability, Vibration / Ride Comfort etc.
❖ Safety – Brake efficiency, Steering effort, TCD, Handling & Stability, Noise etc.
❖ Durability - Accelerated Durability Testing
➢ To contain a variety of surfaces to simulate all sorts of terrain conditions
➢ Essential for product development at lower costs by auto industry
➢ Ability to innovate and offer new products for localized conditions
OBJECTIVE OF TEST TRACKS
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➢ Capable of producing Accurate, Repeatable, Reproducible results
➢ High precision surface finish; Evenness and Geometric tolerance
on levels ± 3mm
➢ Specific properties of surfaces (Noise / Braking track)
➢Variety of surfaces (Comfort / Fatigue track)
➢ Durable, Long lasting surfaces
➢ Open Air Laboratory
➢ Know how obtained from Global Consultant / Developed countries
UNIQUE FEATURES / REQUIREMENTS OF TEST TRACKS
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Volume of Work
Track
Excav- Soil Excav - Rock Embankment SubgradeDrainage
LayerGSB WMM DBM
BC-VG-30 & PMB
PCC/RCC
Volume in Cubic Metre
OTT 16,08,000 1,51,000 15,64,000 1,85,000 33,000 2,50,800 1,46,000 60,000 28,700 54,000
HST 15,46,000 8,84,000 9,31,000 47,500 62,900 93,500 75,400 38,350 25,900 61,000
Total 31,54,000 10,35,000 24,95,000 2,32,500 95,450 3,44,300 2,21,400 98,350 54,600 1,15,000
Earthwork : 65 Lakhs cum; Base / Sub Base work : 9 Lakhs cum; Bituminous/RCC work : 2.5 Lakhs cum
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CHALLENGES / DIFFERENCES IN CONSTRUCTION OF TEST TRACKS
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➢ Design of Pavement composition / Geometry
➢ Selection of Materials
➢ Grading of the Mix
➢ Laying methodology
➢ Rolling methodology
➢ Special Construction methodology
➢ Quality assurance and control procedure
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Geometry Parameters Specifications Parameters
Diameter 300 m Longitudinal slope 0 %
Total length 1,800 m Evenness / Tolerance in levels ± 3 mm
Dynamic Platform (T-2)
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LIMIT HANDLING TESTS ON DYNAMIC PLATFORM
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ACCEPTANCE CRITERIA
S. No. Parameters Highway Test Tracks
Evenness Geometric Tolerance
1. Wearing Course ± 6 mm ± 2 mm ± 3 mm
2. Bituminous Base Course ± 6 mm ± 3 mm ± 4 mm
3. Non Bituminous Base Course ± 10 mm ± 4 mm ± 5 mm
4. Non Bituminous Sub-base course
± 10 mm ± 5 mm
5. Sub-Grade course ± 20 mm ± 10 mm
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Removal of BC Soil and replacement with Suitable soil
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Remedial Measures for Sub-Surface Water
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Selection of Materials
S. No. Typical Specifications – Highways Special Specifications – Test Tracks
1.0 Materials for GSB/DL shall be crushed gravel,crushed stone, crushed slag or their combination.
Only crushed stone is permitted.; CBR More than 30 %
2.0 Material for Sub-grade shall be good earth with 10% CBR
CBR 15% for good earth, if the Sub-grade bottom is 1.5m below from OGL than drainage layer of crushed stone of 30% CBR used in lieu of Sub-grade
3.0 Combined Flakiness & Elongation of coarseaggregate should be 35% (Max)
The limit of Combined Flakiness & Elongation of coarse aggregaterestricted to 25% (Max) to ensure the better quality of work.
4.0 VG-30 and the Minimum Stability (At 60⁰) of bituminous mix shall be 9.0 KN for VG Grade Bitumen
VG-30 with Polymer modified bitumen used (PMB-40) and The Minimum Stability (At 60⁰) of bituminous mix shall be 12.5 KN for VG Grade Bitumen
5.0 Bituminous mix prepared by using Indian Standardsieve.
Bituminous mix prepared by using British Standard sieve in line withInternational practice for proving grounds
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Asphalt laying with Wooden Batton Wooden Blocks for vertical edges
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Continuous supply through MTV
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Road unevenness measurement - Travelling Beam
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Sl. No. Type of Constructions Tests Frequency (min)
National Highways as per MORTH Technical specification Test Tracks
1. Embankment/Subgrade for Borrow Material
Plasticity Test Each soil type to be tested, Two Tests Four tests per 3000cum soil.
Density Test Each soil type to be tested, Two Tests Four tests per 2000cum soil.
Moisture Content Two tests Three tests for every 250cum of Soil.
CBR Test One CBR for closer as and when required by Engineer Two CBR test for every 3000cum or closer as when required by Engineer
2. Granular Sub base Gradation One test per 400 cum Two test per 200 cum
Atterberg limits One test per 400 cum Two test per 200 cum
Moisture content prior to compaction
One test per 400 cum Two test per 200 cum
Density of compacted layer One test per 1000 sqm Two test per 500 sqm
3. Wet Mix Macadam Aggregate Impact value One test per 1000 cum aggregate Two test per 200 cum of aggregate
Gradation of aggregate One test per 200 cum aggregate Two test per 100 cum of aggregate
Combined Flakiness and Elongation index
One test per 500 cum aggregate Two test per 200 cum of aggregate
Atterberg limits of portion of aggregate passing 425 micron sieve
One test per 200 cum aggregate Two test per 100 cum of aggregate
Density of compacted layer One test per 1000 sqm Two test per 500 sqm
Stringent Quality Assurance Procedure
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Sl. No. Type of Constructions Tests Frequency (min)
National Highways as per MORTH Technical specification
Test Tracks
4 Prime coat/Track coat Rate of spray of binder Three test per day Not less than 2 tests per day: Two test per 500 sqm
5. Dense Bituminous Macadam/Bituminous concrete
Aggregate Impact value
One test per 350 cum of aggregate for each source and whenever there is a change in the quality of aggregate.
Two test per 50 cum of aggregate
Flakiness and Elongation index
One test per 350 cum of aggregate for each source and whenever there is a change in the quality of aggregate.
Two test per 50 cum of aggregate
Density compacted layer
One test per 700 sqm area. Two test per 250 sqm area ; 10% of total shall be taken from edges
6 Bituminous Macadam Aggregate Impact value
One test per 350 cum of aggregate for each source and whenever there is a change in the quality of aggregate.
Two test per 50 cum of aggregate
Flakiness and Elongation index
One test per 350 cum of aggregate for each source and whenever there is a change in the quality of aggregate.
Two test per 50 cum of aggregate
Density compacted layer
One test per 700 sqm area. Two test per 250 sqm area ; 10% of total shall be taken from edges.
Stringent Quality Assurance Procedure
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Friction coefficient : 0.15 – 0.9
Surfaces : Ceramic / Basalt Tiles / Polished Concrete / High Friction Asphalt
Multi Friction Braking Track (T-3)
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Laid over RCC pavement base;Selection of special type of mortar and grouting materialsSelection of adhesive materials based on pull out tests.Maintenance of suitable gap and levels
Basalt Tiles Surface Ceramic Tiles Surface
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BASALT TILES FIXING
Placing ofreference tiles
Premixedmortar overprimed surface
Fixing ofBasalt Tilesover mortar
Basalt Tiles aftergrouting
CERAMIC TILES FIXING
Fixing oftiles
Leveling oftiles bytemplate
Adjustment of gap(3 mm)between tiles
CeramicTiles aftergrouting
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S. No.
Parameter Basalt Tiles Ceramic Tiles
1. Dimension 200mm x 200mm x 40mm (thick)200mm x 200mm x 40mm (thick)-At Edges only
98.0 X 98.0 X 11.0 mm (Thick)148.0 X 98.0 X 11.0 mm (Thick)- at Edges only
2. Dimensional Tolerances ± 2 mm ± 0.5%
3. Water absorption 0% 0.08% < E < 1%
4. Modulus of Rupture ( N/mm2)
Not applicable Avg.50 (Min),Individual Min.47.0
5 Bending strength Min. 45 MPa Not applicable
6 Compression strength Min. 300 - 450 MPa Not applicable
7 Minimum Flexion Strength ( Break)
Not Applicable 47 N/mm2
8 Breaking strength ( in N)
Not Applicable >= 7.5 mm thickness, Min 2100
9 Mohs hardness 8.0 ( Mohs scale) 7.0 ( Mohs scale)
10 Abrasion Resistance Max. loss 110 mm3 (ČSN EN ISO 10545-6) Min(III),For commercial operation as per IS
11 BPN 25-35 (on BPN Scale) 10-15 (on BPN Scale)
Important Parameter of Basalt & Ceramic Tiles for Low mu Surfaces
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Road Friction measurement
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British Pendulum Tester -
Skid Resistance m/mTyre Traction Trailer -
Peak Braking Coefficient m/m
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ISO-10844-2014
ISO-10844-1994
External Noise Track T-13
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Surface properties of the drive lane
The surface of the drive lane shall
a) exhibit a sound absorption equal to or less than 8 % in any one third octave band between 315 Hz and 1600Hz
a) have a mean profile depth (MPD) shall be 0.5 mm +/- 0.2mm.
b) Longitudinal and Transverse irregularity shall be less than or equal to 2 mm and 3 mm respectively
Surface properties of the propagation area
a) The average of the values of the sound absorption in each one-third-octave band between 315 Hz and 1600 Hz central frequency shall be less than or equal to 10%
Homogeneity of surface properties
The properties of drive lane and propagation area shall be homogenous with respect to acoustic absorption, surface texture and geometrical compliance
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Testing properties of Noise Track Surface
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Splash road
Wash board CobblestonesPot HolesBelgium Pave Track
Resonance Track Rough RoadTwist Track
Low Severity High Severity
Fatigue Track (T-5)
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Twist Track
• CNC Shuttering Concrete Pouring
Concrete finishing & texturing
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Manual Finishing of Rough ConcreteFixing of Back Up rods for Levels
Rough Road
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Cobble Stones & Potholes
Fixing of Cobble Stones Finishing of potholes
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Construction Method – Pave Track
Finished Surface
Fixing of granite stones as per given Data
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Use of Poly Fiber in Concrete Works
M45 Concrete Steelfiber
Polymer fiber
Cement (Kg) 385 385
W/C Ratio 0.38 0.37
Fiber (Kg) 35 4.05
90 min Slump 55 40
Comp. Strength @ 28 days
59.3 59.7
Comfort Track (T-8)
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Wash Board-1Speed Braker-1
Rough Bitumen
Rough Concerte-2
Big step @ h = 20mm Scratch Road patchesCleat Set @ h-10mm
U shape @ D = 35mm Rough Concerte-1
Wash Board-2
Step Input Sinusoidal input Random input
Comfort Track @ NATRAX
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PSD Plots of Road Profiles
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Gradient Track (T-4)
6 % / 8 % 12 % 18 % 20 % 24 % 30 %
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Hillock converted to Gradient Track
Handling Track (T-7)
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Parameters Typical Specifications -Highways
Special Specifications –High Friction Asphalt (HFA)
Special Specifications – Noise Test Track
Special Specifications –Handling Track/Aquaplaning Track
Chipping size of aggregates
13.2 mm down – 90 to 100 %
12.5-7.5mm - 45-50% , 11.2mm-8mm - 4% 7.5-4.5mm - 21%
13.2 – 4.75 mm - 40 % 7.5-4.75mm - 28-30%, 8mm-5.6mm - 12% 5.6mm- 4mm -18%
4.75-2.5mm - 25%
4.75 mm down – 60 % 4.75mm down - 20% 4.0mm down is 66% 2.5mm down - 54%
Difference in Mix Design - Bituminous roads on Highways and Test Tracks
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Safety Features
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Sustainability Track (T-10)
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Wet Skid Pad (T-11)
Parabolic Sensor Paver
High Speed Track (T-1)
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Super-elevation Vs. Width Cross Profile Vs. Width
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Trapezoidal and U Drain
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Kerb Drain & Other Drains
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COST EFFECTIVE SOLUTIONS
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➢ Gravel in lieu of Argex Clay balls
➢ Local ceramic tiles in lieu of imported tiles
➢ Use of natural slopes on L section for Fatigue Track
➢ Use of existing hillock for gradient track
➢ Kerb drain in lieu of U drains in fatigue track
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IDIADA, SPAIN
ATP, GERMANY JARI, JAPAN MIRA, UK
GM, USANATRAX, INDIA
BENCHMARKING OF NATRAX WITH INTERNATIONAL PROVING GROUNDS
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CONCLUSION
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➢World Class Automobile Test Tracks created
➢ Being utilized by Industry
➢ Indigenous capability enhanced
➢ Experience can be carried forward
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ACKNOWLEDGEMENT
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➢ Department of Heavy Industries, MoHIPE, Govt of India
➢ Government of Madhya Pradesh
➢ IDIADA, Spain; RITES, Gurgaon; SGSITS, Indore; IIT Roorkee
➢ Mr. Nitin Gokarn, Ms. Neeti Sarkar - CEO & PD, NATRiP
➢ Mr. VP Singh, Mr. Pradeep Agrawal – Director (C&I)
➢ Management/Team from NATRAX / NATRIP; RITES & L&T
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Thank You
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TYPICAL PAVEMENT SECTION