All about Smart Roads Constructions

A. Step by step guide for road construction 

Step No.	Activity	Details
1	Project Planning & Feasibility Study	Identify the road stretch, assess existing conditions, conduct traffic analysis, and perform soil investigation & topographical surveys.
2	Preparation of Detailed Project Report (DPR)	Includes road width, pavement type, utility plans, drainage, lighting, smart elements, and cost estimates.
3	Preparation of Detailed Drawings & Approvals	Obtain necessary approvals for road cross-sections, utility duct layouts, drainage plans, lighting, and landscape designs.
4	Shifting of Existing Utilities	Relocate underground water pipelines, electricity cables, telecom ducts, and sewage lines to prevent conflicts.
5	Site Clearance & Marking	Remove encroachments, debris, and existing damaged pavement. Mark road alignment and positions for smart elements.
6	Excavation & Preparation of Subgrade	Excavate to required depth and compact the subgrade. Lay geo-textile fabric (if needed) for soil stabilization.
7	Stormwater Drainage Construction	Construct side drains, culverts, and underground stormwater drainage channels to prevent waterlogging.
8	Laying of Utility Ducts	Install underground ducts for electricity, telecom, gas, fiber optic cables, and water supply with maintenance access points.
9	Base Layer Construction	Lay Granular Sub-Base (GSB) followed by Wet Mix Macadam (WMM) for road stability, ensuring proper compaction.
10	Pavement Construction	Based on road type: bituminous or concrete
11	Footpath & Pedestrian Infrastructure	Construct footpaths using interlocking tiles/concrete, install tactile paving for visually impaired, and develop pedestrian-friendly walkways.
12	Smart Elements Installation	Install smart poles, LED streetlights, CCTV cameras, traffic signals, smart parking sensors, EV charging stations, and integrate Wi-Fi & IoT-based monitoring.
13	Horticulture & Green Cover Development	Develop green belts, plant native trees, install tree guards, vertical gardens, and landscape the medians and footpaths.
14	Signage & Road Markings	Install traffic signboards, zebra crossings, lane markings, reflective studs, and digital traffic information systems for safety.
15	Final Inspection & Quality Check	Conduct a thorough quality audit, check pavement smoothness, utility ducts, smart installations, and ensure stormwater drainage efficiency.
16	Commissioning & Handover	Open the road for public use, conduct final inspections, rectify defects, integrate smart monitoring systems, and complete project documentation.

B. Drawings Required for Smart Road Construction

Drawing Name	Purpose	Details Included
Topographic Survey & Existing Utility Plan	To assess existing land conditions and identify existing utilities.	Road width, contours, slopes, existing utilities (water, electricity, telecom, sewer), trees, encroachments.
Alignment & Cross-Section Drawing	Defines road alignment and width, ensuring compliance with road design standards.	Road width, lanes, shoulders, footpath, cycle tracks, median, ROW (Right of Way).
Soil Investigation & Subgrade Preparation Plan	Helps in designing the base and sub-base layers of the road.	Soil type, bearing capacity, excavation depth, compaction details, stabilization layers (if required).
Stormwater Drainage Plan	Ensures proper water drainage to prevent flooding and waterlogging.	Location of stormwater drains, slopes, manholes, outfalls, rainwater harvesting pits.
Utility Duct Layout Plan	Ensures organized placement of underground utilities without conflicts.	Positions of ducts for electricity, water, sewage, telecom, fiber optics, and gas pipelines.
Pavement Layer Composition & Structural Design	Determines the road strength and durability.	Road base, sub-base, bituminous/concrete layer details, thickness, and material specifications.
Road Profile & Longitudinal Section	Shows elevation variations along the road length.	Gradient, elevation, slope details, and cut-and-fill requirements.
Bituminous/Concrete Pavement Design Details	Ensures proper material and layer design for road longevity.	Type of pavement, thickness of each layer, material composition, reinforcement details (for concrete roads).
Footpath & Pedestrian Infrastructure Plan	Ensures safe and accessible pedestrian movement.	Width of footpaths, material details, tactile paving for visually impaired, ramps, street furniture locations.
Smart Infrastructure & Electrical Plan	Placement of smart elements and electrical systems.	Streetlights, smart poles, CCTV locations, Wi-Fi hotspots, traffic signals, EV charging stations.
Horticulture & Landscaping Plan	Defines green spaces for aesthetics and environmental benefits.	Locations of trees, shrubs, planters, green medians, vertical gardens, and irrigation system.
Signage & Road Marking Plan	Enhances road safety and visibility for users.	Traffic signs, zebra crossings, lane markings, speed limits, direction boards, reflective studs.
Junction & Traffic Management Plan	Improves traffic flow and safety at intersections.	Roundabouts, signals, pedestrian crossings, traffic islands, lane bifurcations.
Final As-Built Drawings	Document actual execution and any modifications made.	Final layouts, changes made during construction, approved modifications, and location of all underground utilities.

GFC (Good for Construction) Drawings are final approved drawings that contractors and engineers use for actual execution of the project. These drawings include detailed dimensions, materials, specifications, and construction techniques to be followed on-site. They are issued after all necessary approvals, ensuring that the design is practically feasible and executable. A detailed GFC drawing is made after topographic survey with detailing all elements. For executable, element wise GFC are made . 

C. Test needed in road construction work. 

Stage	Essential Test	Purpose	Conducted By
1. Soil/Subgrade Preparation	CBR Test (California Bearing Ratio)	Checks soil strength for load-bearing capacity.	Geotechnical Engineer / Third-Party Lab
	Soil Compaction Test (Field Dry Density Test)	Ensures proper soil compaction for stability.	Contractor QC Team / Site Engineer
2. Base & Sub-Base (GSB, WMM, etc.)	Aggregate Impact Value Test	Ensures aggregates are strong and durable.	Site Engineer / Third-Party Lab
	Gradation Test	Confirms correct particle size distribution for base layers.	Contractor QC Team
3. Bituminous Road Work	Bitumen Content Test	Ensures correct bitumen percentage in the mix.	Third-Party Lab / Asphalt Plant
	Marshall Stability Test	Checks strength and stability of bituminous mix.	Government / Private Testing Lab
	Core Cutting Test	Confirms the thickness of the laid bituminous layer.	Third-Party Lab
4. Concrete Road (If applicable)	Slump Test	Checks workability of concrete before laying.	Site Engineer / Contractor
	Cube Strength Test	Ensures concrete attains required strength.	Third-Party Testing Lab
5. Final Road Quality Check	Benkelman Beam Deflection Test	Measures the structural strength of the pavement.	Government / Third-Party Testing Agency
	Pavement Roughness Test (IRI – International Roughness Index)	Ensures smooth driving surface.	Specialized Survey Agency

C.1 Testing requirement for other smart road components 

Component	Test Name	Purpose	Stage of Testing
Drain Construction	Concrete Strength Test (Cube Test)	Ensures required strength of RCC drains.	After 7, 14, and 28 days of casting
	Water Permeability Test	Checks for water leakage or seepage.	After curing of concrete
	Gradient & Flow Test	Ensures proper drainage slope and water flow.	After construction, before road laying
Utility Ducts	Compaction Test for Backfilling	Ensures soil compaction around ducts.	After backfilling of trenches
	Air Pressure Test (for conduits)	Checks for air-tightness of electrical and telecom conduits.	Before cable installation
	Water Flow Test (for water lines)	Ensures proper water supply and pressure in pipes.	After pipe installation, before covering
Street Lights	Earth Resistance Test	Ensures proper earthing for safety.	Before energizing the system
	Illumination Level Test (Lux Test)	Checks if lighting meets required brightness levels.	After installation, during night testing
	Pole Load Test	Ensures pole can withstand wind and load conditions.	Before pole erection
Footpath & Pavement	Compressive Strength Test (for paver blocks)	Ensures durability of footpath paver blocks.	Before installation
	Skid Resistance Test	Ensures anti-slip properties of footpath surface.	After completion
Signages & Road Markings	Retro-Reflectivity Test	Ensures visibility of road signs and markings at night.	After application
Stormwater Management	Percolation Test (for rainwater harvesting pits)	Checks ground absorption capacity.	Before constructing pits

C.2 PDI and its need 

PDI (Pre-Dispatch Inspection) is a quality check conducted before materials or equipment are dispatched from the manufacturer or supplier to the project site. It ensures that items meet the required specifications, standards, and quality criteria before they are delivered.

Item	Why is PDI Required?	When to Conduct PDI?	Who Conducts It?
Street Light Poles & Fixtures	Ensures proper fabrication, height, alignment, and wiring.	Before dispatch from manufacturer.	Vendor + Project QC Team
LED Street Lights	Checks wattage, lumens, material quality, and IP rating.	Before dispatch.	Vendor + Electrical Engineer
Utility Duct Pipes (HDPE/PVC/GI)	Ensures correct diameter, material thickness, and strength.	Before dispatch.	Vendor + Site Engineer
Precast RCC Drain Covers	Verifies dimensions, strength, and load-bearing capacity.	Before dispatch.	Vendor + Structural Engineer
Paver Blocks for Footpath	Checks compressive strength, uniformity, and anti-skid properties.	Before dispatch.	Vendor + Quality Inspector
Signboards & Road Markings Paint	Ensures retro-reflectivity, durability, and compliance with IRC standards.	Before dispatch.	Vendor + Traffic Engineer
Smart Road Furniture (Benches, Bollards, Railings)	Ensures correct material, finish, and durability.	Before dispatch.

D. Layers in a Road 

Layer	Purpose	Material Used	Applicable to
1. Subgrade	Acts as the foundation of the road, bearing the load of traffic.	Compacted natural soil, sand, geotextiles (if needed for stabilization).	All roads (bituminous & concrete)
2. Granular Sub-Base (GSB)	Provides drainage and distributes load evenly.	Crushed stone, gravel, sand, fly ash (in some cases).	All roads
3. Base Course (WMM/WBM)	Provides structural strength to the road.	- WMM (Wet Mix Macadam): Crushed aggregates, stone dust, water. - WBM (Water Bound Macadam): Aggregates bound with water and compacted.	All roads
4. Binder Course (For Bituminous Roads)	Intermediate layer to bind base and surface course.	- Bituminous Macadam (BM): Coarse aggregates mixed with bitumen. - Dense Bituminous Macadam (DBM): Stronger bituminous mix.	Bituminous roads only
5. Surface Course (Wearing Layer)	Provides a smooth, durable surface for vehicles.	- Bituminous Roads: Bituminous Concrete (BC), Mastic Asphalt. - Concrete Roads: Pavement Quality Concrete (PQC) with reinforcement.

E. Construction steps for utility ducts, drain, road and electric street poles 

E.1 Utility ducts 

Step	Activity	Description	Tentative Time
1. Marking & Excavation	Mark trench alignment & dig as per depth	Done as per design considering future utilities.	3-5 days
2. Base Preparation	Leveling and compacting base	Ensures stability and prevents settlement.	1-2 days
3. Duct Installation	Laying RCC/PVC pipes or pre-cast ducts	Placing conduits for electrical, telecom, water, etc.	5-7 days
4. Manhole & Chamber Construction	Creating access points at intervals	Manholes allow maintenance & future expansion.	4-5 days
5. Covering & Backfilling	Concrete encasement & refilling trench	Protects ducts and restores surface.	3-4 days
6. Surface Restoration	Rebuilding footpath or road surface	Final finishing depending on surface type.	4-6 days

E.2 Drain 

Step	Activity	Description	Tentative Time
1. Marking & Excavation	Layout alignment & digging	As per design & required depth.	3-5 days
2. Base Preparation	Leveling & compacting base	Ensures proper gradient for water flow.	2-3 days
3. Formwork & Reinforcement	Placing steel reinforcement (if RCC drain)	Required for concrete drains to enhance durability.	4-6 days
4. Drain Casting (RCC/Masonry)	Concrete pouring or brick masonry	Constructing the drain walls & base.	5-7 days
5. Curing & Strength Gain	Allow concrete to gain strength	Essential for durability & crack prevention.	7-10 days
6. Cover Slab/Grating Fixing	Placing RCC or iron grates	Protects drain & allows easy cleaning.	3-4 days
7. Surface Restoration	Rebuilding footpath/road if required	Final finishing work.	3-5 days

E.3 Roads 

Step	Activity	Description	Tentative Time
1. Site Preparation & Excavation	Clearing, marking, and excavation	Removal of obstructions, grading, and preparation of the site.	5-7 days
2. Subgrade Preparation	Compaction of natural soil	Stabilizing the soil base to prevent settlement.	3-5 days
3. Sub-Base Layer (GSB - Granular Sub-Base)	Laying crushed aggregates and compacting	Ensures load distribution and drainage.	4-6 days
4. Base Layer (WMM/WBM)	Laying Wet Mix Macadam (WMM) or Water Bound Macadam (WBM)	Provides structural strength.	5-7 days
5. Binder Course (For Bituminous Roads)	Applying Bituminous Macadam (BM) or Dense Bituminous Macadam (DBM)	Acts as an intermediate layer to bind the base and surface.	4-6 days
6. Surface Course (Wearing Layer)	Laying Bituminous Concrete (BC) or Pavement Quality Concrete (PQC)	Final smooth surface for vehicles.	4-6 days
7. Curing (For Concrete Roads Only)	Allowing concrete to gain strength	Essential for durability and preventing cracks.	7-14 days (if PQC)
8. Road Marking & Signage Installation	Painting lane markings, placing road signs	Enhances safety and traffic management.	2-4 days
9. Final Inspection & Opening to Traffic	Checking quality and final approvals	Ensuring proper construction before opening.	1-2 days

E.4 Street Light 

Step	Activity	Description	Tentative Time
1. Site Survey & Design Planning	Identifying pole locations and preparing the layout	Ensures optimal light coverage and alignment with road design.	2-3 days
2. Excavation for Pole Foundation	Digging pits for pole installation	Depth depends on pole height and wind load.	2-4 days
3. Foundation Construction	Laying concrete foundation for stability	Ensures pole strength and durability.	4-6 days
4. Pole Erection & Alignment	Installing poles and aligning them properly	Ensures uniform height and positioning.	3-5 days
5. Cable Laying & Ducting	Placing underground cables for power supply	Done through pre-installed ducts or new trenches.	5-7 days
6. Fixing Electrical Components	Installing junction boxes, control panels, and switches	Ensures power regulation and control.	3-5 days
7. Light Fixture Installation	Fixing LED lights, brackets, and fittings	Mounting the lighting system on poles.	2-4 days
8. Connection & Testing	Connecting to the power supply and checking functionality	Ensures proper illumination and safety compliance.	3-5 days
9. Final Inspection & Commissioning	Checking alignment, brightness, and system efficiency	Ensures smooth operation before handover.	2-3 days

F. PERT chart preparation ( assume 2 km smart road ) 

Task Name	Duration (Days)	Dependency (Must be Completed Before Starting)
Survey & Design	15	None
Utility Shifting Planning	10	Survey & Design
Excavation for Ducts (Electric, Water, Telecom)	20	Utility Shifting Planning
Laying Electrical & Water Pipelines	25	Excavation for Ducts
Telecom & OFC Laying	15	Excavation for Ducts
Backfilling & Surface Restoration	20	Laying Electrical & Water Pipelines, Telecom & OFC Laying
Road Widening & Sub-base Preparation	25	Backfilling & Surface Restoration
Drainage & Footpath Construction	20	Road Widening & Sub-base Preparation
Asphalt/Paver Road Surfacing	15	Drainage & Footpath Construction
Smart Features Installation (Lights, Signage)	10	Asphalt/Paver Road Surfacing
Final Road Markings & Testing	7	Smart Features Installation
Project Handover	5	Final Road Markings & Testing

F.1 How do I speed up the work 

Category	Optimized Strategy	Expected Time Savings
1. Parallel Execution of Tasks	Start utility shifting and excavation simultaneously instead of sequentially.	Saves 5-7 days
	Lay telecom and electrical ducts together instead of separately.	Saves 5-6 days
	Begin road widening on completed sections while utilities are being laid in other areas.	Saves 7-10 days
	Start footpath and drainage work while sub-base preparation is ongoing.	Saves 5-6 days
2. Use of Advanced Construction Methods	Use precast concrete ducts for utilities instead of traditional RCC work.	Saves 7-10 days
	Deploy Ready-Mix Concrete (RMC) for road surfacing to speed up paving.	Saves 4-6 days
	Use mechanized excavation and backfilling instead of manual work.	Saves 7-10 days
3. Improved Resource Allocation	Increase night shifts for critical work like asphalt laying and surfacing.	Saves 7-10 days
	Deploy multiple work teams for different sections simultaneously.	Saves 5-7 days
4. Efficient Material & Logistics Planning	Procure all key materials in advance to avoid site delays.	Saves 5-7 days
	Arrange backup machinery and workforce to avoid idle time.	Saves 3-5

G. Manpower requirement in the project ( assuming above one )

Category	Role	Key Responsibilities	Approx. No. Required
Planning & Supervision	Project Manager	Overall coordination, approvals, timeline management	1
	Road Design Engineer	Designing road alignment, widening plan, and cross-sections	1
	Structural Engineer	Ensuring stability of underground utilities, footpaths, and road	1
	Surveyor	Conducting site surveys, marking, and leveling	2
	Site Engineers	On-site supervision, quality control, coordination with contractors	2-3
	Safety Officer	Ensuring worker safety, enforcing safety protocols	1
Excavation & Earthworks	Excavator Operators	Digging trenches for utility ducts and road widening	4-5
	Dump Truck Drivers	Transporting excavated soil and materials	3-4
Utility Installation	Electricians	Laying and connecting electrical cables and streetlights	5-6
	Plumbers	Installing water pipelines and drainage systems	3-4
	OFC Technicians	Laying fiber optic cables and telecom ducts	3-4
Civil & Structural Works	Masons	Concrete work for footpaths, drains, and ducts	8-10
	Road Workers	Asphalt laying, compacting, leveling	10-12
	Concrete Finishers	Finishing curbs, footpaths, drainage structures	4-5
Machinery Operators	Road Roller Operators	Compacting asphalt and sub-base layers	2
	Paver Machine Operators	Operating bitumen/asphalt laying machines	2
Smart Infrastructure	IT Technicians	Installing smart poles, traffic sensors, and CCTVs	3-4
Miscellaneous Workers	Welders	Fabrication and installation of railings, signboards	2-3
	Painters	Road marking, signage painting	3-4
	Helpers & General Laborers	Assisting in all tasks, material handling, miscellaneous work	30-40

*Urban mobility planner ( for planning )

H. Important Aspects in Road Construction Beyond Basic Layers

Category	Key Aspects
1. Roadside Safety Features	Crash barriers, bollards, pedestrian railings for accident prevention
2. Road Markings & Signages	Thermoplastic markings, reflective signboards, wayfinding signage
3. Utility Coordination & Planning	Common utility ducts, coordination with utility agencies
4. Smart Road Infrastructure	Smart poles, EV charging stations, underground waste bins
5. Water Management & Flood Prevention	Permeable pavements, stormwater drains, rainwater harvesting
6. Landscaping & Aesthetic Enhancements	Green verges, vertical gardens, tree guards
7. Road Longevity & Maintenance	Pavement monitoring, pothole repair strategy, material choice
8. Smart Road Safety Measures	AI-based traffic sensors, rumble strips, CCTV surveillance
9. Construction Quality & Environmental Compliance	Dust suppression, noise barriers, use of recycled materials
10. Emergency & Disaster Preparedness	Emergency parking bays, flood-resistant design, fire hydrants