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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