Road Design

Copyright © 2011 Gemcom Software International Inc.
(Gemcom)
All rights reserved. Gemcom publishes this documentation for the sole use of Gemcom licensees.
Without written permission, you may not sell, reproduce, store in a retrieval system, or transmit
any part of this documentation. For such permission, or to obtain extra copies please contact your
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This software and documentation is proprietary to Gemcom and, except where expressly provided
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any time without notice.
While every precaution has been taken in the preparation of this manual, neither the authors nor
Gemcom assumes responsibility for errors or omissions. Neither will be held liable for any damages
caused or alleged to be caused from the use of the information contained herein.
Gemcom Software International Inc., Gemcom, the Gemcom logo, combinations thereof, and
GEMS, Surpac, Minex, Whittle, Gemcom InSite, Gemcom Hub, and PCBC are trademarks of
Gemcom Software International Inc. or its wholly-owned subsidiaries.
Product
Surpac™ 6.2
Table of Contents
Introduction 4
Overview 4
Requirements 4
Workflow 4
Road design concepts 5
Inflection Point 5
Simple Curve 5
Spiral / Transition curve 6
Superelevation 6
Vertical curve 7
Setup for this tutorial 8
Task: Set the Work Directory (Windows XP) 8
Task: Set the Work Directory (Windows Vista) 8
Displaying the menubar 10
Task: Display the menus 10
Designing a road using string editing tools 11
Task: Design a road using CURVE END 11
Task: Design a road using CURVE TANGENT 20
Task: Design a road at a Constant Gradient Along Contours 25
Task: Create a variable width road outline 34
Using the road design module 38
Task: View the data 38
Task: Create horizontal curves 41
Task: Drape centreline over DTM 44
Task: Create longitudinal profile 47
Task: Create vertical inflection points 48
Task: Create vertical curves 49
Task: Apply longitudinal profile 50
Task: Create road outline 52
Calculating road design volumes 56
Task: Calculate road cut 56
Task: Calculate road cut volume 62
Task: Calculate road fill 65
Task: Calculate road fill volume 71
Introduction Overview
Introduction
Overview
To design a simple road with few horizontal and no vertical curves, you can use the string editing
tools available in the core module of Surpac. However, if you want to design a typical road that
contains many horizontal and some vertical curves, use the functionality available in the road design
module.
Requirements
Prior to proceeding with this tutorial, you will need:
l Surpac v6.1 installed, and
l The dataset accompanying this tutorial, and
l A basic knowledge of Surpac string files and editing tools as covered in the Introduction
to Surpac tutorial.
Workflow
Note: This workflow demonstrates the steps in this tutorial. There are other ways to achieve a
result.
Surpac™ 6.2 Page 4 of 77 Road Design

Road design concepts Workflow
Road design concepts

There are several concepts that you should understand before starting this tutorial.
Inflection Point
Most roads are designed from inflection points, which define a change, or inflection, in the horizontal
or vertical orientation of the road. The lines on either side of an inflection point define tangents to
the curve.
Simple Curve
A simple curve is a curve of constant radius from one tangent line to another. This curve type does
not allow for transitions from the straight to the maximum curvature, and should only be used in
situations where vehicle velocity is at a minimum.

Spiral / Transition curve

This is the most common form of curve creation in Road Design. A spiral (or transition) exists
between the tangent and the circular curve. This allows the vehicle to gradually increase its radius of
curvature as it travels around the corner until it reaches maximum curvature.
Superelevation
The effect of centrifugal force on a vehicle as it passes through a curve must be countered by raising
the outer edge. This process is known as superelevation. The outer edge is raised incrementally
through the transition curve until the beginning of the circular curve where it remains constant until
the exit transition curve where the outer edge is incrementally lowered.

Vertical curve
A vertical curve exists in a vertical plane. Vertical curves consist of a simple curve with or without
spiral / transition curves on either side.

Setup for this tutorial Task: Set the Work Directory (Windows XP)
Setup for this tutorial

Task: Set the Work Directory (Windows XP)
1. In the Navigator, right-click the road_design folder.
2. From the popup menu, select Set as work directory.
The name of the work directory is displayed in the title bar of the Surpac window.
Task: Set the Work Directory (Windows Vista)

1. In the Navigator, right-click the road_design folder.
2. From the popup menu, select Set as work directory.

Setup for this tutorial Task: Set the Work Directory (Windows Vista)
The name of the work directory is displayed in the title bar of the Surpac window.

Setup for this tutorial Task: Display the menus
Displaying the menubar

Task: Display the menus
1. Right-click in the area to the right of the menus.
2. Choose Menus > Surface design.

Designing a road using string editing tools Task: Design a road using CURVE END
Designing a road using string editing tools

In this section, you will learn how to create a road design by using simple string editing tools available
in the Core Module.
Task: Design a road using CURVE END
In this task, you will learn how to use the function CURVE END to create a road design containing a
simple horizontal curve with transition curves on either side.
1. Click the Reset graphics icon .

2. Open pit&dump.str
3. Open pit_dump_road_centreline.str.
4. Use the mouse (scroll wheel, right button, middle button/both buttons, etc.) to zoom
into the view as shown.
5. In the Layers pane, double-click main graphics layer to set it as the default layer.
6. Click the design string button on the status bar.

7. Enter the information as shown, and click Apply.
The design string number 4 will be used for the road centreline.

8. Choose Create > Points > By angle.

9. Click Point 1 and then Point 2, as shown.
This creates the start point for the new road, which is at the same coordinates as the
point near the second point selected. Note that the point is created using the design
string number of 4.

11. Click the same two points (Point 1 and then Point 2) again.
This creates the second point of the road centreline, as shown.
13. Press ESC.

14. Choose Create > Curve at segment end.

15. Click Point 1 and then Point 2, as shown.
16. Enter the information as shown, and click Calculate.

17. After the transition lengths are calculated (as shown), click Apply.
18. Press ESC.

19. Use the mouse (scroll wheel, right button, middle button/both buttons, etc.) to zoom

20. Choose Display > Point > Markers.

Note: Points have been created every 30 metres of arc length to approximate the
curve.

22. Choose Display > Point > Attributes.

Note: The points where the transition curve ends, and the simple curve begins have
the description "End transition curve".

24. Choose Inquire > Bearing and distance between 2 points.

25. Click Point 1 and then click Point 2, as shown.
26. Press ESC.

The bearing from Point 1 to Point 2 is displayed in the message window, as shown. (DMS
= Degrees Minutes Seconds).
Next, the road centreline will be extended at this bearing.

27. Choose Create > Points > By bearing.
28. Click the end of the curve (Point 2 in the preceding image).
30. Press ESC.

The road centreline is extended horizontally 200 metres at the bearing of 331 degrees, 49
minutes, 10 seconds, as shown.
The centreline design is complete. The next step is to create the road outline.

The design string number of 9 will be used for the road outline.
33. Choose Design > Underground tools > Room & pillar from centrelines.

Designing a road using string editing tools Task: Design a road using CURVE TANGENT
The road outline is created, as shown.
Note: The function MAKE PILLARS is used to create the road outline in this example.
35. Click .
Note: To see all the steps performed in this section, run 1a_curve_end.tcl. You will need to click
Apply on any forms presented.
Task: Design a road using CURVE TANGENT
In this task, you will learn how to use the function CURVE TANGENT to create a road design from a
centreline string that contains an inflection point.


2. Open pit&dump.str
3. Open pit_dump_road_centreline.str.
Use the mouse (scroll wheel, right button, middle button/both buttons, etc.) to zoom
4. Choose Display > Point > Numbers.


The point numbers are displayed, as shown.
Note: It is not necessary to display the point numbers. This is done in this example to
identify the points to select.
6. From the mode selector, choose Insert point mode.
Note: The insert mode will result in points inserted within the centreline string when
the curve is created.
7. Choose Create > Curve from tangents.
8. Click Point 1 and then Point 2.
Note: The line connecting points 1 and 2 define the first tangent.

9. Click Point 2 (again) and then Point 3.

Note: The line connecting points 2 and 3 define the second tangent.
Note: In this example, a simple curve is created by not selecting Use transition curve.
11. Press ESC.
12. Choose Display > Hide point > Attributes.
You should now see the curve as shown, created between the two tangents.


The road outline is created, as shown.
Note: The function MAKE PILLARS is used to create the road outline in this example, as
the function is a part of the Core Module.

Designing a road using string editing tools Task: Design a road at a Constant Gradient Along Contours
18. Click .
Note: To see all the steps performed in this section, run 1b_curve_tangent.tcl. You will need to
click Apply on any forms presented.
Task: Design a road at a Constant Gradient Along Contours
In this task, you will create an access road with a maximum gradient of 5%. The road design will be
based on a string file of topography contours.

2. Open pit&dump.str.
3. Open access_start&end.str.
4. Choose Display > Point > Attributes.

In this example, the goal is to create the shortest, straightest road possible between
these two points, while ensuring that the maximum gradient is not more than 5%.
6. In the Layers pane, double-click main graphics layer to set it as the default layer.

The design string number 2 will be used for the road centreline.

9. Click the design grade button on the status bar.

Note: In this example, you will not use the actual design gradient value (set to zero in
the previous form) to create points. You will digitise points, and will want to see the
gradient between any two points expressed as a percentage. By setting the units to
"percentage", the gradient between the digitised points will be displayed as a value in
percent in the status bar.
11. Choose Create > Digitise > New point by selection.
12. Click the Access road start point as shown:
13. From the snap mode selector, select Line.


15. Move the cursor along the contour as shown.
Note: As you move the cursor along the contour line, the gradient (expressed as a
percentage in the status bar) will change. Remember that the goal is to create a road
whose centreline is at a maximum gradient of 5%. Since we are designing from the
uppermost point down, the gradient will be -5%.
16. Click on the contour line near Point 2 when the percentage value displayed in the status
bar is approximately -5%, as shown:

Note: There will be two or more locations along a contour where the gradient will be
the same. In this example, the points are selected based on the desire to create a road
that is as straight as possible.
17. Click on the contour line near Point 3, when the gradient is approximately -5%, as shown:
18. Click on the next contour line near Point 4, when the gradient is approximately -5%, as
shown:

19. Click on the next contour line near Point 5, when the gradient is approximately -5% as
shown:

shown:

shown:

22. Click the Access road end point, as shown:
23. Press ESC.


Designing a road using string editing tools Task: Create a variable width road outline
The road outline is created, as shown:
28. Click .
Note: To see all the steps performed in this section, run 1c_access_road.tcl. You will need to click
Task: Create a variable width road outline
In this task, you will learn how to create a road outline of variable width from several centreline
strings.

2. Open pit&dump.str.
3. Open all_centrelines.str.

4. In the Layers pane, click the "eye" icon to hide pit&dump.str.
5. Choose Display > Strings > With string numbers.

The road centreline strings are displayed.

7. Choose File tools > String maths.

Note: The D1 field is set to the desired road width for each string or string range.
9. If prompted, click Apply to overwrite the file.
10. Open all_centrelines.str.

Note: The output of the STR MATHS function is written to the file on disk. In order to
have the information available for MAKE PILLARS, it must be re-opened in graphics.

The design string number 9 will be used for the road outline.

14. Enter the information as shown, and then click Apply.
The road outline for all centrelines is created at the width specified in the D1 field.
15. Click .
Note: To see all the steps performed in this section, run 1d_variable_width_outline.tcl. You will
need to click Apply on any forms presented.

Using the road design module Task: View the data
Using the road design module

In this section, you will learn how to create a road design by using the Road Design Module. The
workflow for this module is:
Note: This workflow demonstrates the steps in this tutorial. There are other ways to achieve a
result.
Task: View the data

2. Open inflection_points.str.
3. Choose Display > Point > Numbers.

In this example, you will create a road design between points 1 and 8, with horizontal
curves at each inflection point (2, 3, 4, 5, 6, and 7).
5. Open topo.dtm.
The DTM representing the surface topography is displayed.

6. Choose View > Surface view options > Lighting options, or click the icon.
Notice how the Gourad rendering smooths the surface.

Using the road design module Task: Create horizontal curves
8. Choose Display > Surface or solid with colour banding.

Notice how the lower elevations are coloured blue and green, and the higher elevations
are magenta and white.
Note: To see all the steps performed in this section, run 2a_view_data.tcl. You will need to click
Task: Create horizontal curves
In this task, you will learn how to create horizontal curves from a string representing the start and
end point of a road design, and one inflection point per horizontal curve. In this example, the

inflection points, maximum vehicle velocity, and the radius for each curve are given. In practice, you
would determine these values.

2. Open inflection_points.str.
In this example, you will design horizontal curves at each of the inflection points in this
string.
3. Choose Road design > Design horizontal alignment.

4. Click the string.
5. Enter the information as shown, and click Calculate.

A new string will be created in the current layer with the output string number of 2.
The name is optional and can be left blank. You may choose to enter a name if you want
to create a map with this information.
"Chainage" values are the cumulative two-dimensional distances at each point along the
design, and will begin with the "Initial Chainage" value.
Points will be created at the start and end of each simple and transition curve, and at the
chainage interval of 25 meters along the curves.
The vehicle velocity is in kilometers per hour.
The radius of each curve is in meters.
When you have clicked the Calculate button, transition lengths and superelevation
values are calculated for each curve which is not nominated as "Fixed". In this example, all
curves will contain a transition curve.
6. Click Apply when the transition and superelevation values have been calculated.

Using the road design module Task: Drape centreline over DTM
The horizontal curves are created in string 2, as displayed.
7. Click .
Note: To see all the steps performed in this section, run 2b_horizontal_design.tcl. You will need to
Task: Drape centreline over DTM

2. Open topo.dtm.

3. Open design_centreline.str.
The string and DTM are displayed.
4. In the Layers pane, right-click topo.dtm.
5. Click Visible to hide the DTM.

6. Choose Road design > Drape segment over DTM.

9. Choose Edit > String > Renumber.

12. Press ESC.

13. In the Layers pane, right-click topo.dtm and click Visible to display the DTM.
Note: Rotate the graphics to view the string draped over the DTM.
14. Click .
Note: To see all the steps performed in this section, run 2c_design_centreline_draped.tcl. You will

Using the road design module Task: Create longitudinal profile
Task: Create longitudinal profile

2. Open design_centreline_draped.str.
The draped string is displayed.
3. Choose Road design > Create longitudinal profile.


Using the road design module Task: Create vertical inflection points
The longitudinal profile is displayed in the lower viewport.
Note: You will need to keep string 5 displayed in the graphics window to perform the
next task.
6. Click .
Note: To see all the steps performed in this section, run 2d_create_longitudinal_profile.tcl. You
will need to click Apply on any forms presented.
Note: You will need to keep the data displayed in the graphics window to perform the next task.
Task: Create vertical inflection points
Note: You will need the data displayed as per the previous task.
1. Click the lower viewport.

2. Click the button below the graphics window.

5. Click the string at Point 1.
The numbered string is displayed.

Using the road design module Task: Create vertical curves
6. Choose Create > Digitise > New point at mouse location.

7. Click the string at Points 2 to 5.
9. Click the string at Point 6.
10. Press ESC.
next task.
11. Click .
Note: To see all the steps performed in this section, run 2e_create_vertical_inflection_points.tcl.
You will need to click Apply on any forms presented.
Task: Create vertical curves

2. Choose Road design > Design vertical alignment.
3. Click string 5.

Using the road design module Task: Apply longitudinal profile
The vertical curves are displayed.
next task.
5. Click .
Note: To see all the steps performed in this section, run 2f_create_vertical_curves.tcl. You will
Task: Apply longitudinal profile

Using the road design module Task: Apply longitudinal profile
1. Choose Road design > Apply longitudinal profile.

3. Press F1 to suspend the function.
4. Zoom in on a curve.
5. Press ESC to continue.
6. Click string 6.
7. Click in the upper viewport.
8. Click string 3.
10. Choose Edit > Segment > Renumber.

11. Click string 3.
13. Click .

Using the road design module Task: Create road outline
Note: To see all the steps performed in this section, run 2g_apply_longitudinal_outline.tcl. You
will need to click Apply on any forms presented.
Task: Create road outline

2. Open final_centreline_design.str.
3. Choose Road design > Create road outline.

The road outline is displayed.
6. Choose Edit > String > Clean.




13. Enter the information as shown, and click Apply


15. Click .
Note: To see all the steps performed in this section, run 2h_create_road_outline.tcl. You will need
to click Apply on any forms presented.

Calculating road design volumes Task: Calculate road cut
Calculating road design volumes

Task: Calculate road cut

2. Open final_road_outline.str.
The road outline string is displayed.
3. Click the button below the graphics window.

5. Choose Pit design > Set slope gradient.

7. Choose Edit > Segment > Expand/Contract.

8. Click the road outline in the graphics window.

The expanded string is displayed.
10. Press ESC.


The road outline with string 8 and string 10 displayed.


15. Click string 10.




22. Click .

24. Choose Surfaces > DTM File functions > Create DTM from string file.
The road cut log report is displayed.

Calculating road design volumes Task: Calculate road cut volume

27. Open road_cut.dtm.
28. Open topo.dtm.
The DTM is displayed.
Note: To see all the steps performed in this section, run 3a_road_cut_dtm.tcl. You will need to
Task: Calculate road cut volume

2. Open road_cut.dtm.
3. Open topo.dtm.
4. Choose Surfaces > DTM File functions > Line of intersection between 2 DTMs.

6. If prompted, click Yes to overwrite the file.

7. Choose Surfaces > Volumes > Net volume between DTMs.


Calculating road design volumes Task: Calculate road fill
The road cut volume report is displayed.
Note: To see all the steps performed in this section, run 3b_road_cut_volume.tcl. You will need to
Task: Calculate road fill

2. Open final_road_outline.str.

5. Choose Pit design > Set slope gradient.

7. Choose Edit > Segment > Expand/Contract.

The expanded string is displayed.
10. Click ESC.


The road outline with string 8 and string 10 displayed.






22. Click Save .

24. Choose Surfaces > DTM File functions > Create DTM from string file.
The road fill log report is displayed.

Calculating road design volumes Task: Calculate road fill volume
Note: To see all the steps performed in this section, run 3c_road_fill_dtm.tcl. You will need to click
Task: Calculate road fill volume

2. Open road_fill.dtm.
3. Open topo4fill.dtm.
4. Choose Surfaces > DTM File functions > Line of intersection between 2 DTMs.
6. Choose View > Surface view options > Hide triangle faces to hide the face attributes.
7. Drag road_fill_boundary.str into Graphics to refresh the data.



10. Click String 1.


13. Click String 1.

16. Click string 1.

17. Choose View > Surface view options > Hide triangle faces to display the face attributes.
The DTM is displayed.
18. Click Save .

20. Choose Surfaces > Volumes > Net volume between DTMs.

23. Enter the information as shown, and then click Apply.

The road fill volume report is displayed.
Note: To see all the steps performed in this section, run 3d_road_fill_volume.tcl. You will need to

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Copyright © 2011 Gemcom Software International Inc.

l Surpac v6.1 installed, and

l The dataset accompanying this tutorial, and

Surpac™ 6.2 Page 4 of 77 Road Design

Road design concepts

Surpac™ 6.2 Page 5 of 77 Road Design

Spiral / Transition curve

Surpac™ 6.2 Page 6 of 77 Road Design

Surpac™ 6.2 Page 7 of 77 Road Design

Setup for this tutorial

Task: Set the Work Directory (Windows Vista)

Surpac™ 6.2 Page 8 of 77 Road Design

Surpac™ 6.2 Page 9 of 77 Road Design

Displaying the menubar

Surpac™ 6.2 Page 10 of 77 Road Design

Designing a road using string editing tools

1. Click the Reset graphics icon .

6. Click the design string button on the status bar.

Surpac™ 6.2 Page 11 of 77 Road Design

8. Choose Create > Points > By angle.

10. Enter the information as shown, and click Apply.

Surpac™ 6.2 Page 12 of 77 Road Design

This creates the second point of the road centreline, as shown.

13. Press ESC.

Surpac™ 6.2 Page 13 of 77 Road Design

14. Choose Create > Curve at segment end.

16. Enter the information as shown, and click Calculate.

Surpac™ 6.2 Page 14 of 77 Road Design

18. Press ESC.

Surpac™ 6.2 Page 15 of 77 Road Design

20. Choose Display > Point > Markers.

Surpac™ 6.2 Page 16 of 77 Road Design

22. Choose Display > Point > Attributes.

Surpac™ 6.2 Page 17 of 77 Road Design

24. Choose Inquire > Bearing and distance between 2 points.

26. Press ESC.

Next, the road centreline will be extended at this bearing.

30. Press ESC.

Surpac™ 6.2 Page 18 of 77 Road Design

31. Click the design string button on the status bar.

Surpac™ 6.2 Page 19 of 77 Road Design

The road outline is created, as shown.

Surpac™ 6.2 Page 20 of 77 Road Design

1. Click the Reset graphics icon .

4. Choose Display > Point > Numbers.

Surpac™ 6.2 Page 21 of 77 Road Design

The point numbers are displayed, as shown.

Surpac™ 6.2 Page 22 of 77 Road Design

9. Click Point 2 (again) and then Point 3.

Surpac™ 6.2 Page 23 of 77 Road Design

14. Click the design string button on the status bar.

The road outline is created, as shown.

Surpac™ 6.2 Page 24 of 77 Road Design

1. Click the Reset graphics icon .

Surpac™ 6.2 Page 25 of 77 Road Design

7. Click the design string button on the status bar.

Surpac™ 6.2 Page 26 of 77 Road Design

9. Click the design grade button on the status bar.

13. From the snap mode selector, select Line.

Surpac™ 6.2 Page 27 of 77 Road Design