Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

TABLE OF CONTENTS
1 PROJECT BACKGROUND..................................................................................................................2
1.1 INTRODUCTION.......................................................................................................................2
1.2 Project Location...........................................................................................................................2
1.3 SCOPE OF WORKS...................................................................................................................2
1.4 CONTENTS OF THE REPORT..................................................................................................2
2 INVESTIGATION OF EXISTING STRUCTURES..................................................................................2
2.1 General........................................................................................................................................2
2.2 Minor drainage structures............................................................................................................2
3 DESIGN OF NEW STRUCTURES........................................................................................................2
3.1 Introduction.................................................................................................................................2
3.2 Minor Drainage Structures Design...............................................................................................2
3.2.1 Slab Culverts........................................................................................................................2
3.2.2 Concrete Pipe Culverts........................................................................................................2
3.2.3 Components of Culverts.......................................................................................................2
3.2.4 Materials..............................................................................................................................2
3.2.5 Flow Control on Roadside Drainage....................................................................................2

List of Figures
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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

Figure 2-1 0+196 Slab culvert.....................................................................................................................7

Figure 2-2 Ford Structure at 0+392.............................................................................................................7
Figure 2-3 Masonry Crack at 0+553............................................................................................................7
Figure 2-4 Almost buried Slab Culvert at 0+553.........................................................................................7
Figure 2-5 Completely buried structure at 0+680........................................................................................8
Figure 2-6 Double cell Pipe culvert at 0+540 of Segment-II road with one pipe culvert is clogged and
doesn’t give fuction.....................................................................................................................................8

List of Tables

Table 1 Compressive strength of different Grade concrete...............................................................13

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

1 PROJECT BACKGROUND
1.1 INTRODUCTION

In accordance to overall road sector strategy, the Federal Democratic Republic of Ethiopia

represented by Ethiopian Roads Authority (ERA) has allocated sufficient budget to finance

payments for the design and construction works of Woldia Town section (Segment-I, II and III)

through the Design and Build contract delivery strategy.

The Ethiopian Roads Authority (ERA) of the Federal Democratic Republic of Ethiopia (the

Employer) signed an Agreement with Zeluel Yohannes General Contractor in JV with Bokra

Construction and Trading for design and construction works of Woldia Town section (Segment-I,

II and III) Design and Build Project.

The project involves designing and constructing of the road to DC-7 road standard with the

accompanying structures and protection works supplemented by with a compatible

Environmental Mitigation plan.

1.2 Project Location

The Project Road is located in the northern part of Ethiopia in Northern Wollo Zone of the

Amhara National Regional State in Woldia Town which is around 520km from Addis Ababa. The

project road Consists of three segments: Segment-I is a spur begins at the Roundabout near

Sheikh Mohammed Hussein Ali Al-Amoudi Stadium along the main trunk road of Addis Ababa-

Woldia and turn to left towards the Stadium and ends near the stadium Gate( about 1.27Km).

Segment –II Starts at segment – I road around 0+700 and Ends at T-Junction of Main Truck road

of Adiss ababa – Woldia road loacaly named Enchet Tera, with length of about 714m. Segment –

III begins from End of segment-I and Ends at the Gate of the Stadium.

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

1.3 SCOPE OF WORKS

The scope of services shall include:

 Investigating, surveying, Designing and constructing of the roadway and any necessary

structures

 Upgrading the existing road (where appropriate) as well as constructing new alignment

section of the route to DC5 and as modified herein, AC standard as per the final contract

agreement

 Designing and Constructing new Bridges and culverts

 Designing and constructing surface drains

 Designing and constructing under drains where appropriate

 Designing and Constructing Paved Roadways

 Designing and Constructing Retaining Walls, and other road protection works

 Pavement Markings and Erecting Traffic Signs

 Compatible traffic management during the construction stages of the project.

 Studying and applying applicable environmental mitigation measures at design stage so

that the impact of the construction of the road on the environment shall be prevented

initially

 Framing a sound Environmental Management plan to be followed at construction stage

so as to mitigate the negative impacts to the absolute minimum desirable

 And other necessary works to meet the Employer’s requirement

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

1.4 CONTENTS OF THE REPORT

This report discusses the structure design of road segment I, II and II. The report is divided in to

three chapters. This first chapter gives an introduction of the report and basic project

information. The second chapter comprises investigation of existing cross drainage structures.

The third chapter deals with new structures.

The report also include five appendix consisting

Appendix A: Culvert Schedule of all new minor cross drainage structures

Appendix B: Statical computation and design of slab culverts

Appendix C: Cross sectional design drawing of structures

Appendix D: Structure Standard Drawings

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

2 INVESTIGATION OF EXISTING STRUCTURES

2.1 General

Structures in road projects mainly consist of drainage structures and retaining walls for stability

of slopes. These are indispensable elements of road construction. The serviceability of a road is

highly influenced by the absence of proper drainage structures and lack of properly located

stabilizing structures. The structures mainly include culverts, bridges, energy dissipation

structures and retaining walls.

Assessment of condition of existing structures is essential task to decide for the structure

whether it can function the intended purpose for the design life of the new design standard with

rehabilitation or shall be replaced, depending on the severity of the existing condition.

In addition to the desk top study, number of site visits has been undertaken to the site with key

professionals as a team to investigate the road project on the respective expertise.

Accordingly, there are a total of 5 existing cross drainage structures in the Road segments of the

project road. Two existing slab culverts, one pipe culvert and one ford structure are found on

Segment-I. One existing RC pipe culvert is identified on Road Segment-II and there is no

existing cross drainage structure on Segment-III. There is no Major cross drainage structure in

this project.

2.2 Minor drainage structures

There are total of 5 existing minor drainage structures along the segment. Among this there are

two existing reinforced concrete slab culverts, two Pipe culverts and one Ford Structure. The

defects on the existing minor drainage structures are summarized as follows:

Partially and Completely Clogged Pipe Culverts

Lack of proper erosion Protection structures, damp of waste material has also disturbed

the channel flow

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

Substandard pipe culverts

Slab culverts has no edge beam

Crack on the masonry

In addition to this, disposal of waste material on the stream channels and lack of channelization

are the potential challenge for the structures to use the structures for the intended purpose.

Some of these structure are shown pictorially as follows

Figure 2-1 0+196 Slab culvert Figure 2-2 Ford Structure at 0+392

Figure 2-3 Masonry Crack at 0+553 Figure 2-4 Almost buried Slab Culvert at 0+553

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

Figure 2-5 Completely buried structure at 0+680 Figure 2-6 Double cell Pipe culvert at 0+540 of Segment-II
road with one pipe culvert is clogged and doesn’t give
fuction

Figure 2-8 Waste material disposal on the channel at

Figure 2-7 Waste material disposal on the channel at 0+553
0+392
However as clearly stated in the employer’s requirement all minor drainages culverts in
the project are replaced with new structures.

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

3 DESIGN OF NEW STRUCTURES

3.1 Introduction

As it is clearly stipulated on the employer’s requirement, all the minor culverts are to be

demolished and replaced with new structure. Besides, additional new structure is provided

where required. Hence all the minor culverts are designed as new, pertinent to the hydrologist

recommendations.

3.2 Minor Drainage Structures Design

3.2.1 Slab Culverts

Based on the visual assessment and geotechnical recommendation slab culverts are to be

provided with replacement of unsuitable material with good quality material as summarized in

the table below.

Recommendation
No Station Footing Depth Note/Remark
B.C. (kPa)
(m)

SEGMENT-I

Replace 2.0m of the natural soil below

1 0+195 2 300
bottom of abutment seats

Replace 2.0m of the natural soil below

2 0+390 2 290
bottom of abutment seats

Replace 1.5m of the natural soil below

3 0+550 2 350
bottom of abutment seats
Replace 1.5m of the natural soil below
4 0+680 2 350
bottom of abutment seats
SEGMENT-II
Replace 1.5m of the natural soil below
5 0+540 2 350
bottom of abutment seats

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

Accordingly all slab culvert super structures and substructure are designed specific to the

recommendation of hydrologist and geotechnical investigation. Superstructure and substructure

analysis and design of each slab culvert are submitted along with this report on Appendix-B

Substructures of slab culverts are designed to be Class “B” cement mortared stone masonry

walls. Wing walls with flare angle of 30° are used to retain the roadway embankment.

Skewness angle of culvert is recommended not to exceed 45 degrees as measured from a line

perpendicular to the roadway centerline.

In this section of the road there are five slab culverts. Cross section design drawing and schedule

of these slab culverts is submitted along with this report.

3.2.2 Concrete Pipe Culverts

The reinforced concrete pipe culverts shall be prefabricated

 C-35 reinforced concrete, compressive cube strength of 35MPa, and

 Reinforcement bars of φ6 and φ8 with a tensile strength of 300Mpa.

Joints between the pipes shall be sealed with reinforced concrete capping to prevent infiltration

of water and fine soils. Selection of pipe bedding is made in accordance to ERA’s 2013 standard

drawing, ERA’s Drainage Design Manual and ERA’s Standard Specification requirements.

Accordingly, depending on the foundation material different types of pipe bedding have been

designed to provide uniform support for the entire length of pipe.

Class “A” bedding type is recommended for culverts located on rock, shale or other hard

material sections.

Class “B” bedding type is recommended when soft or other objectionable founding

material is encountered. Pipe culverts located in unsuitable stretch, the material

underneath the bedding should be replaced with suitable compactable granular

materials.

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

To prevent scouring at the inlet and outlet level masonry paved water way and cut-off walls is

provided.

Absolute minimum sizes of 1220 millimeters for cross culverts are used to avoid maintenance

problems and clogging.

End walls or wing walls are used to retain the roadway embankment to avoid a projecting

culvert barrel. They are also used where the side slopes of the channel are unstable, and where

the culvert is skewed to the normal channel flow.

The selection of end structure for pipe culverts is generally dependent on factors such as the

condition of the approaching channel, slope and stability of the outlet channel. The culvert inlet

type is selected from standard details from the Standard drawing prepared based on ERA’s

Standard Detail Drawings for type A, Drop inlet and Type B end wall structures. In addition to

this end wall type C structure is also provided specific to the project. End wall structure types

may need to be modified in site with approval of the engineer based on the actual site situation.

Since the existing minor culvert drainages of the road project are all to be replaced all the

culverts are designed as new. There are two RC pipe culverts on the road segments.

The Schedule of Minor drainage structures is found on Appendix A of this report, though it have

been already submitted along with plan profile drawings.

3.2.3 Components of Culverts

A) Headwalls: For prefabricated reinforced concrete pipe culverts, Class B stone masonry

headwalls& wing wall shall be provided. These retain and protect the embankment at

the ends of the culvert and help to counteract the dislocation of concrete pipes due to

lateral earth fill forces at base of embankment.

B) Inlet and Out let Structure:

Culverts’ inlet and outlet type and configuration has been selected based on

 Invert level of pipe (to determine type of end wall and inlet)

 The longitudinal ditch slope and level (type of inlet)

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

 Steepness of ground cross sectional slope (necessity of energy dissipater)

 Type of culvert (pipe or slab)

To prevent scouring at the inlet and outlet proper measures have been taken. For inlets paved

water way and cut-off walls have been provided. Whereas for outlets two cases of outlet

conditions are encountered during determination of type of structure. The first case is where

there is no significant elevation difference between the outlet level of the pipe and the

surrounding ground. In this case normal outlet paved waterway was provided. Moreover, the

outlet velocity was controlled by adopting mild slope for the culvert. The second case is where

there is marked difference between the outlet level of the pipe and the surrounding ground. In

this case energy dissipating structures including cascades, retaining walls in conjunction with

paved waterway have been used. Details of these structures and their respective locations are

indicated on the drawing section of the design.

C) Erosion Protection:-Scour control measures at culvert inlet and outlet shall be designed which

includes, outlet channeling & Stone pitching at the inlet and outlet with cut-off walls of each

pipe culvert as shown on the typical drawings.

D) Culvert Skewness:-In accordance with the ERA DDM angle of skew limits, skew culvert shall be

provided for culverts with the reference of Centre line of the culvert and roadway profile.

The selection shall be based on:

 Proper catchment of the flow

 Standard requirement,

 Past experience and appropriate engineering judgment.

3.2.4 Materials

Accordingly, all super structural elements are to be of Reinforced Concrete, while the sub-

structures are to be made using stone masonry of class B, with or without RC Pad depending on

the foundation material. Designs would be based on the material properties cited herein.

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

Concrete

The classes of concrete recommended for the different component of minor and major

structures are taken in accordance to ERA’s 2014 Standard Technical specification requirement.

The recommended grades of concrete and specified strengths are given in the table below:-

Table 1 Compressive strength of different Grade concrete

28 day Compressive
Grade of Components of bridge to be designed using
Strength (15cm
Concrete specified type of concrete
Cylinder) MPa
Box culvert, Superstructure of Bridge and slab
C30/20 24
culvert
Bridge Substructures (RC Footing of Abutment,
C30/40 24
Wingwall and Pier)
C15/20 12 Lean Concrete under footings
RC footing pad of Slab culvert and retaining
C20/40 16
wall, Plain Concrete footing and lined drains
C35/20 28 Production of Pipe Culverts

Stone Masonry

Stone Masonry consists of stones shaped, dressed, and laid broken-coursed in cement mortar in

accordance with certain specified requirements. Class B is used for minor structures such as pipe

headwall, slab culvert and retaining walls. Sand cement ratio of 3:1 for minor drainage

structures.

Reinforcement

The yield strength for deformed reinforcing steel bar would be grade 420 for main bars with

diameters greater than or equal to 20mm and grade 300 for secondary bars with diameters less

than 20mm and ties with diameters less than 12mm. The minimum yield strength of grade 400

reinforcement steel is 420Mpa, while that of grade 300 is 300Mpa.

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

3.2.5 Flow Control on Roadside Drainage

To minimize erosion on roadside watercourse channels, stone masonry check dams will be

provided at required locations.

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

APPENDIX A

CULVERT SCHEDULE OF ALL NEW MINOR CROSS

DRAINAGE STRUCTURES

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

APPENDIX B

STATICAL COMPUTATION AND DESIGN OF

SLAB CULVERTS

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

APPENDIX C

CROSS SECTIONAL DESIGN DRAWING OF

STRUCTURES

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Woldia Town Segment- I, II,and III Design-Build Road Project Draft Structural report

APPENDIX D

STRUCTURE STANDARD DRAWINGS

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