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2.

5 Details of Asphalt Institute Method of Design


of Flexible Pavements
Historical Development of AI Method
1956 1969 1st to 8th Editions Empirical Approach
1970 Revised 8th Edition - Empirical Approach

Thickness Design Full Depth Asphalt Pavement Structures for Highways and
Streets, The Asphalt Institute, Manual Series -1 (MS-1)
Other Versions
1981 9th Edition, M-E Approach
1991 Revised 9th Edition
1999 9th Edition, Reprint
2001 Revised 9th Edition
2008 Revised 9th Edition
Thickness Design Asphalt Pavement for Highways and Streets, The Asphalt
Institute, Manual Series -1 (MS-1)
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1970 and Earlier Editions

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1981 and Later Editions

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AI Method is used to design asphalt pavements composed of various


combinations of:
a) asphalt concrete surface and base;
b) Emulsified asphalt surface and base;
c) Untreated aggregate base and sub-base.
Emulsified asphalt is simply a suspension of small asphalt cement globules in water,
which is assisted by an emulsifying agent (such as soap). The emulsifying agent
assists by imparting an electrical charge to the surface of the asphalt cement globules
so that they do not combine (Roberts et al., 1996).

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Design Principles
Pavement is regarded as MULTI-LAYERED ELASTIC SYSTEM.
Design Procedure is based on Established Theory, Experience, Test Data and a
Computer Program DAMA were used to develop a comprehensive pavement
design procedure.
Materials in each layer are characterized by Modulus of Elasticity, E and Poissons
Ratio, .
Traffic is expressed in terms of Repetitions of 80 KN (18,000 lb) single axle load
applied to the pavement on two sets of dual tires i.e. ESAL Concept
Full Depth Asphalt Concrete Layer : 3- Layered System
Untreated Aggregates : 4- Layered System
Subgrade Layer (the lowest layer) Infinite in the Vertically Downward and
Horizontal Directions
Other Layers Finite Thickness Infinite in Horizontal Directions.
Full Continuity (Full Friction)
is Assumed at the boundaries between each of the
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layer.

Design Criteria
Horizontal Tensile Strain, t on the Underside of the Lowest Asphalt
Bound Layer should be within the Permissible Value. If the Strain is
Excessive Cracking of the Treated Layer Fatigue Failure Occurs
Vertical Compressive Strain, c at the Surface of the Subgrade Layer
should be such that Excessive Permanent Deformation (Rutting) should
not Take Place due to Overloading.

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Fatigue Criterion: Fatigue Cracking

The equation for fatigue criterion is:


Nf = 0.0796(t)-3.291(E)-0.854
Where,
Nf = allowable no. of repetitions of standard axle load to control fatigue cracking
t = horizontal tensile strain at the bottom of the asphalt layer.
E = dynamic modulus of the asphalt mixture

The equation for limiting the pavement deformation is:


Nd = 1.365 x 10-9 (c)-4.477
Where,
Nd= allowable no. of repetitions to limit rutting to 12.7 mm for the design traffic.
c = vertical compressive strain on the surface of the subgrade.
Resilient modulus of untreated granular material varies with stress conditions.
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Permanent Deformation
The equation for limiting the pavement deformation is:
Nd = 1.365 x 10-9 (c)-4.477
Where,
Nd= allowable no. of repetitions to limit rutting to 12.7 mm for the
design traffic.
c = vertical compressive strain on the surface of the subgrade.
Resilient modulus of untreated granular material varies with stress
conditions.

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Design Procedures
1. Input data:
Traffic loading, ESA
Sub-grade resilient modulus, MR
Surface and base type
2. Determine design thickness for the specific conditions described by
the input data.
3.

Prepare stage construction design

4.

Make economic analysis of various solutions.

5.

Select the final design

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Traffic Analysis
In pavement design, number of repetition of each axle load group during the
design period.
The initial daily traffic in two directions over all traffic lanes must be multiplied
by directional and lane distribution factors to obtain the initial traffic on design
lane.
The traffic loading for the AI method is the ESAL on the design lane
anticipated over the design life the pavement.
Load repetitions, expressed in terms of an 18-kip (80-kN) single-axle load, are
determined from traffic estimates by using AASHTO equivalent factors for a
structural number SN of 5 and a terminal serviceability index, pt of 2 .5

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Determination of Design ESAL


The procedure for determining the design ESAL can be summarized as
follows:
1. Estimate the number of vehicles of different types, such as
passenger cars, single-unit trucks (including buses), and multiple unit
trucks of various types, expected on the proposed facility.
2. Determine the number of each type of truck on the design lane
during the first year of traffic.
For two-lane highways, the design lane may be either lane of the
pavement facility. Under some conditions, more trucks may travel in one
direction than in the other . In many locations, heavily loaded trucks will
travel in one direction, but empty trucks in the other.
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3. Determine a truck factor for each vehicle type . Truck factor is


defined as the number of 18-kip (80-kN) axle load applications
contributed by one passage of a truck.
4. The equivalent 18-kip (80-kN) single-axle load applications can be
obtained directly by multiplying the total number of trucks with the
truck factor for all trucks. For the given design period, find a single
growth factor for all trucks or separate factors for each truck type, as
appropriate .
5. Multiply the number of trucks of each type by the truck factor and
the growth factor and sum the values determined to obtain the
design ESAL .
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Sub-grade Evaluation
CBR
Resilient Modulus

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Subgrade Strength Evaluation


The correlation considered reasonable for fine grained soils with a
soaked CBR of 10 or less is:
MR (MPa) = 10.3 x CBR (%) [AASHTO 93]

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esign Percentile for Various ESALs

Traffic Level (EAL)


Subgrade Value, %
104 or Less
60
Between 104 and 106
75
106 or More
87.5

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Design

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AI Design Charts
The AI design procedure is based on a series of charts that were produced
from computer programs for layered elastic systems.

Reasonable properties were assumed for the properties of the wearing layer
and of the base and subbase courses.

Thus, the design variables treated in the analysis of a given pavement type
are subgrade MR and traffic ESAL for 3 temperatures, MAAT (7, 15.5 and 24 0C)
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Minimum Thickness of HMA over Emulsified


Asphalt Bases
Traffic
Level ESAL

104
105
106
107
>107

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Thickness
for Type I
Mix
In.

Type II

Type III

mm

In.

1.0
1.5
2.0
2.0
2.0

50
50
75
100
130

2
2
3
4
5

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Minimum Thickness of Asphalt Concrete


over Untreated Aggregate Base
Traffic ESAL

104

Traffic Condition

Light traffic, parking


lots, driveways and
light traffic rural roads
104 but less
Medium truck traffic
than 106
106
Medium to heavy truck
traffic

Minimum
Thickness of
Asphalt
Concrete (mm)
75*

100
125

*For full depth asphalt concrete or emulsified asphalt pavements a


minimum thickness of 100 mm applies.

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Numerical Example - 1
A
pavement has to be designed for a certain length of existing single lane carriageway
road from the following considerations:
a)Current traffic of 80 kN equivalent single axle load = 0.26 x EAL/day
b)Design period = 10 years
c)Construction period = 18 months from the last traffic count
d)Traffic growth rate = 8%
e)87.5th CBR values of subgrade soil from seven samples collected = 5%
f) Elastic modulus of asphalt concrete for surface course, Eac = 2500 MPa
g)Elastic modulus of emulsified stabilized base, Eb = 1200 MPa
h)Elastic modulus of granular subbase (CBR 30%), E sb = 150 MPa
Draw the cross-section of final pavement layers considering the thickness of asphalt
concrete on the surface course is not less than 50 mm.
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Solution:
1)
Cumulative No. of Standard Axles to be Catered
N= xAxD

or,

N = x Px D

Here,
P = 0.26 x EAL/day
r = 8% = 0.08
n = 10 years
y = 18 months = 18/12 = 1.5 years
D = 1 (Since a Single lane carriageway road) (as per IRC: 37 2001)
Then, N = x 0.26x103 x 1
= 1.54 x EAL

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2)
87.5th CBR values of subgrade soil from seven
5%

samples collected =

Therefore, Design Resilient Modulus of Subgrade, Mr = 10.3 x CBR(%)


(in MPa)
= 10.3 x 5 = 51.5 MPa
3) For N = 1.54 x EAL and Mr = 51.5 MPa, from the given design chart,
Full Depth of Asphalt Concrete

= 250 mm

Now, adopt
AC Surface
Course
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= 50 mm

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4)
Now, Equivalent thickness of emulsified stabilized base course, tb
= x = x 200
= 255. 43 mm
Use 140 mm thick emulsified stabilized base course
The emulsified stabilized base course equivalent to granular subbase course,
tsb
= 255 140 = 115 mm

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5)
Then , Equivalent thickness of granular subbase course, (CBR
30%)
= x = x 115
=
AC Surface Course, Eac = 2500 MPa
50 mm
Emulsified Stabilized Base Course,
140 mm
Eb = 1200 MPa

260 mm, AC
Eac = 2500 MPa

Granular Subbase Course, (CBR 30%),


230 mm
Esb = 150 MPa

Subgrade, CBR = 5%
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Subgrade, CBR = 5%

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Numerical Example - 2
The results of eight tests produced the following subgrade resilient
modulus values: 42.8, 93.2, 60.7, 82.1, 53.8, 70.0, 65.6 and 69.0 MPa.
Design the flexible pavement using Asphalt Institute Method for a single
lane 2-way road to cater the traffic with the following considerations:
a) Base traffic of 80 kN equivalent single axle load = 8.2 x 104 ESAL/year
b) Design period = 10 years
c) Construction period = 15 months from the last traffic count
d) Traffic growth rate = 7%
e) Minimum depth of asphalt concrete wearing course with the modulus of
elasticity of 2500 MPa = 75 mm
f) Emulsified asphalt base course with the modulus of elasticity = 1250
MPa
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g) Granular
sub-base course
withKhadka,
the acem
modulus of elasticity = 150 MPa59

Solution Hints:
1. Put the test resilient modulus values in descending order:
Resilient
Resilient
Number equal
Number
to
equal
Percent
to equal
Percent
to
equal to
Modulus, MPa
Modulus,
or greater
MPa
than
or greater
or than
greater than
or greater than
93.2
82.1
78.0
69.0

93.2
82.1
78.0
69.0

1
2
3
4

( x 100) = 12.5

( x 100) = 25.0

( x 100) = 37.5

( x 100) = 50.0

65.6

65.6

( x 100) = 62.5

60.7

60.7

( x 100) = 75.0

53.8

53.8

( x 100) = 87.5

42.8

42.8

( x 100) = 100.0

From the above table, 87.5th percentile resilient modulus value for the design = 53.8 MPa
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2.
Cumulative No. of Standard Axles to be Catered
N= xAxD
or,

N = x Px D = ?

Here,
P = 8.2 x 104 ESAL/year
r = 7% = 0.07
n = 10 years
y = 15 months = 15/12 = 1.25 years
D = 1 (Since a Single lane carriageway road) (as per IRC: 37 2001)

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3. 87.5th percentile resilient modulus value for the design,


Mr = 53.8 MPa
4) For N = ? and Mr = 51.5 MPa, from the given Design Chart, Obtain
Full Depth of Asphalt Concrete
=?
Then, follow the steps as explained in Numerical Example 1.

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Numerical Example - 3
The results of eight tests produced the following subgrade resilient modulus values;
6200, 7800, 8800, 9500, 10000, 11300, 11900, and 13500 psi. Design the flexible
pavement using Asphalt Institute Method for a single lane 2-way road to cater the
traffic with the following considerations:
a) Base traffic of 80 kN equivalent single axle load = 0.22 x 10 3 ESAL/day
b) Design period = 15 years
c) Construction period = 18 months from the last traffic count
d) Traffic growth rate = 7.5%
e) Minimum depth of asphalt concrete wearing course with the modulus of
elasticity of 2600 MPa = 75 mm
f)

Emulsified asphalt base course with the modulus of elasticity = 1200 Mpa

g) Granular sub-base course with the modulus of elasticity = 150 Mpa


h) Use 90th percentile resilient modulus value for the design.
i)

Draw the cross-section of


final
pavement
layers
with
the design output.
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Pavement
Design Methods:
Prepared
by Rajesh

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Solution Hints:
1. Computation of Percentile Value

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2. Graphical determination of design subgrade


resilient modulus

7480

90

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From the above plot, 90th percentile design subgrade resilient


modulus value for the design
= 7480 x 103
psi
Since, 1 psi = 6.9 kPa; So, 7480 x 103psi = 6.9 x 7480 x 103 kPa = 51617 x
Flexible Pavement Design Methods: Prepared by Rajesh Khadka,
103 kPa = 51.617 Mpa
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Numerical Example - 4
A
pavement has to be designed for a specified stretch of existing two lane road
from the following considerations:
a) Current traffic of 80 kN equivalent single axle load = 1.08 x EAL/day
b) Design period = 10 yrs.
c) Construction period = 1 year fro the last traffic count
d) Traffic growth rate = 7%
e) Minimum CBR values in percent observed on six locations for that stretch of
the road are: 3.3, 5.0, 6.2, 4.1, 5.4 and 3.0 respectively for subgrade.
f)

Design resilient modulus of subgrade in MPa is to be taken as 87.5th


percentile value as is required fro the design. You are required to design the
pavement from Asphalt Institute Method.

Draw the cross-section of final pavement layers considering the thickness of


asphalt concrete on surface
course is not less than 50 mm.
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Solution Hints:
1) To determine the Design Subgrade Resilient Modulus, M r.
For this, tabulate the CBR results, determine the correct value for the traffic
percentile and then convert the Design CBR value to the Design Subgrade
Resilient Modulus using the expression,

Mr = 10.3 x CBR (%) (in MPa)


Put
CBR
(%)
6.2
5.4

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the
test
values
in descending
order.
Number
CBRCBR
equal
Number
to
Percent
equal
toequal
Percent
to
equal to
or greater
(%)
than
or greater
or greater
than
than
or greater than
6.2
5.4

1
2

( x 100) = 16.7

( x 100) = 33.3

5.0

5.0 3

( x 100) = 50.0

4.1

4.1 4

( x 100) = 66.7

3.3

3.3 5

( x 100) = 83.3

3.0

3.0 6

Flexible Pavement Design Methods: Prepared by


6Rajesh Khadka, acem ( x 100) =

100

67

From the interpolation or from the plot between percent equal to or greater than vs CBR (%), the 87.5th
percentile Design Subgrade CBR Value = 3.2%.
Therefore the Design Subgrade Resilient Modulus,

Mr = 10.3 x 3.2 33 Mpa


2) Cumulative No. of Standard Axles to be Catered
N= xAxD
or,

N = x Px D = ?

Here,
P = 1.08 x EAL/day
r = 7% = 0.07
n = 10 years
y = 1 yr.
D = 0.75 (Since two lane carriageway road) (as per IRC: 37 2001)
3) For N = ? and Mr = 33 MPa, from the given Design Chart, Obtain Full Depth of Asphalt Concrete
=?
Then, follow the steps as explained in Previous Examples.
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Numerical Example - 5
Calculate the accumulated equivalent single axle load for a proposed 2lane rural highway. The first year AADT will be 3000, the annual growth
rate = 5% and the design period = 20 years. The projected vehicle mix
S.
Vehicle
Types
Truck
% of
for that highway during
the
first
year of operation
is
given in the table
N
Factor, Vehicles
below.
TF

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1)

Single Unit Trucks

a)

2-Axle, 4-Tire

0.02

18

b)

2-Axle, 6-Tire

0.21

c)

3-Axle or More

0.73

2)

Tractor Semitrailers and


Combination

a)

3-Axle

0.47

b)

4-Axle

0.83

3)

Passenger Cars
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Solution:
1)
Calculation of Growth Factor
GF = = = 33.06
S
.
N

Vehicle Types

No. of Vehicles
for 1st Year of
Operation

Truck
Factor,
TF

GF

ESAL

(1)

(2)

(3)

(1) X (2)
x (3)

1 Single Unit
) Trucks

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a
)

2-Axle, 4-Tire

98,550

0.02

33.0
6

65,161

b
)

2-Axle, 6-Tire

43,800

0.21

33.0
6

3,04,686

c
)

3-Axle or More

21,900

0.73

33.0
6

5,28,530

2 Tractor
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) Semitrailers and

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Sample Calculation: Values Under Column No.1

(obtained from the first year AADT and the design lane factor)
For 2-lane highway, design lane factor, fd = 50% = 0.5
For Example: For 2-Axle, 6-Tire Single Unit Trucks, the No. of Vehicles
during first year of operation (i.e at the end of the construction) = AADT
x 365 x % of Vehicles x fd
= 3000 x 365 x 0.08 x 0.5 = 43,800 and so on.
Note: Passenger cars are not considered in the calculations since their
Flexible Pavement Design Methods: Prepared by Rajesh
contribution
to the ESAL is negligible.
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Numerical Example - 6
Results of seven tests produced the following subgrade resilient modulus
test values 44.8, 67.3, 68.3, 58.6, 68.3, 106.9 and 80.0 MPa. The traffic
classification at the end of construction is projected as below:
No. of
Truck
Vehicles (both Factor
directions)
4000
0.003
2050
0.280
1000
1.060
1100
0.620
1200
1.050
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Design the flexible pavement using Asphalt Institute Method for two lane two way road to
cater the above traffic with the following details:
a) Minimum depth of Asphalt Concrete wearing course with modulus of elasticity 2500
MPa = 50 mm
b) Emulsified asphalt base course with modulus of elasticity = 1250 MPa
c) Granular sub-base course with modulus of elasticity = 150 MPa
d) Annual growth rate of traffic = 6.5%
e) Design period = 12 yrs.
f) Use 87.5th percentile resilient modulus value for the design
Draw the cross-section of the pavement layers with your design output.

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Solution Hints:

1. Growth factor = = = 17.37


2. Calculation of ESAL
No. of Vehicles
(both directions)

Truck
Factor

Growth
Factor

ESAL
(1) X (2) x (3)

(1)

(2)

(3)

(4)

4000

0.003

17.37

208.44

2050

0.280

17.37

9970.38

1000

1.060

17.37

18412.2

1100

0.620

17.37

11846.34

1200

1.050

17.37

21886.2

Total (N)
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62323.56 =
x 104
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3. Calculation of 87.5th Percentile Design Subgrade Resilient Modulus, M r


Put the test resilient modulus values in descending order:

Resilient
Resilient
Number equal
Number
to
equal
Percent
to equal
Percent
to
equal to
Modulus, MPa
Modulus,
or greater
MPa
than
or greater
or than
greater than
or greater than
106.9
80.0
68.3
68.3

106.9
80.0
68.3
68.3

1
2
3
4

( x 100) = 14.28

( x 100) = 28.57

( x 100) = 42.85

( x 100) = 57.14

67.3

67.3

( x 100) = 71.42

58.6

58.6

( x 100) = 85.71

44.8

44.8

( x 100) = 100

Plot between Percent equal to or greater than vs Mr to get 87.5th Percentile Design Subgrade Resilient Modulus.
For N and Mr from the given Design Chart, Obtain Full Depth of Asphalt Concrete. Then, follow the steps as explained in Previous
Examples.
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Numerical Example - 7
Calculate the accumulated equivalent single axle load for a proposed 8-lane
highway. Traffic volume forecasts indicate that the average annual daily
traffic (AADT) in both directions during the first year of operation will be
12,000 with the following vehicle mix and axle loads.
Vehicle Types

Load
Equivalency
Factors

% of Vehicles

Passenger Cars (4.45 kN/axle)

0.00002

50

2-Axle Single Unit Trucks (22.25


kN/axle)

0.00500

33

2-Axle Single Unit Trucks (31.15


kN/axle)

0.01960

17

Vehicle mix is expected to remain the same throughout the design life of the
pavement. If the expected annual traffic growth rate = 4% for all the vehicles
and the design period = 20 years.
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Solution:
1)
Calculation of Growth Factor, GF:

GF = = = 29.78

2) Percentage Truck Volume on Design Lane, fd = 45 (Assume) [Range = 25 48 for No. of


Lanes
3) No. of Equivalent Accumulated Axle Loads in the Design Lane
= AADT x GF x % of Vehicles x 365 x N x F Ex fd
a)

Passenger Cars = 12000 x 29.78 x 0.5 x 365 x 2 x 0.00002 x 0.45 = 0.001 x 106

b) 2-Axle Single unit Trucks = 12000 x 29.78 x 0.33 x 365 x 2 x 0.00500 x 0.45 = 0.1937 x 106
c) 3-Axle Single unit Trucks = 12000 x 29.78 x 0.17 x 365 x 3 x 0.01960 x 0.45 = 0.5867 x 106
Total ESAL = 0.781 x 10 6
Note: It can be seen that the contribution of passenger cars to the ESAL is negligible so, the
passenger cars can be omitted when calculating ESAL values.
2/12/16

Flexible Pavement Design Methods: Prepared by Rajesh


Khadka, acem

77

2/12/16

Flexible Pavement Design Methods: Prepared by


Rajesh Khadka, acem

78

2/12/16

Flexible Pavement Design Methods: Prepared by Rajesh Khadka,


acem

79

2/12/16

Flexible Pavement Design Methods: Prepared by Rajesh


Khadka, acem

80

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