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6-Lane Expressway (per km, Bharatmala / NHAI)

Access-controlled 6-lane expressway per IRC SP-87 (Expressway Manual) + IRC SP-84 + MoRTH 5th Rev. Configuration: 2 × 10.5 m main carriageway (3 lanes × 3.5 m each direction) + 4.5-5.0 m raised RCC median + 3.0 m paved shoulder both outer sides + earthen berm + service road (one each side) + lined drainage. Heaviest standard pavement: GSB 300 + WMM 300 + DBM 130 + BC 50 mm OR rigid PQC 350 + DLC 150 + GSB 200 mm. Design traffic 80,000-150,000 PCU/day at 100-120 km/h. Rates: CPWD DSR Vol 1 + Vol 2 (2023).

Visual confirmation
Plan · 1 km · 6-lane expressway + service roads
SERVICE ROAD (5.5 m)SERVICE ROAD (5.5 m)3 LANES (DIR-1)MEDIAN 5 m3 LANES (DIR-2)1 km
Long section · 1 km · flexible pavement · ~1.2 m embankment
NGL0.00 km0.25 km0.50 km0.75 km1.00 kmBC + DBM + WMM + GSB · 30 m+ paved width
Cross-section · flexible BC · 2×10.5m + 5m median + 2×3m PS · pavement 780mm
BC 50DBM 130WMM 300GSB 30010.5m5m med10.5m
Bill of Quantities15 items · CPWD DSR Vol 1 + Vol 2 (2023)
#CodeDescriptionUnitQtyRate (₹)Amount (₹)
12.6.1Earthwork EmbankmentEarth work in excavation by mechanical means (Hydraulic excavator)/ manual means over areas (exceeding 30 cm in depth, 1.5 m in width as well as 10 sqm on plan) including getting out and disposal of excavated earth lead upto 50 m and for all lift, as directed by Engineer-in-charge. — All kinds of soilCum55,200.00177.5097,98,000.00
216.78.1Gsb Grade I[item not found: 16.78.1]11,970.000.000.00
SOR item dsr_vol2_2023:16.78.1 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
316.4Wmm BaseLaying, spreading and compacting stone aggregate of specified sizes to WBM specifications in uniform thickness, hand picking, rolling with 3 wheeled road/vibratory roller 8-10 tonne capacity in stages to proper grade and camber, applying and brooming requisite type of screening / binding material to fill up interstices of coarse aggregate, watering and compacting to the required density .Cum11,400.001,046.951,19,35,230.00
416.39Prime Coat[item not found: 16.39]38,000.000.000.00
SOR item dsr_vol2_2023:16.39 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
516.54.1Dbm Binder[item not found: 16.54.1]4,940.000.000.00
SOR item dsr_vol2_2023:16.54.1 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
616.40Tack Coat[item not found: 16.40]38,000.000.000.00
SOR item dsr_vol2_2023:16.40 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
716.57.1Bc WearingProviding and laying Bituminous concrete using crushed stone aggregates of specified grading, premixed with bituminous binder and filler, transporting the hot mix to work site by tippers, laying with paver finisher equiped with electronic sensor to the required grade, level and alignment and rolling with smooth wheeled, vibratory and tandem rollers to achieve the desired compaction and density as per specification, complete and as per directions of Engineer-in-Charge. — 40/50 mm compacted thickness with bitumen of grade VG-30 @ 5.5% (percentage by weight of total mix) and lime filler @ 3% (percentage by weight of Aggregate) prepared in Batch Type Hot Mix Plant of 100-120 TPH capacity.Cum1,900.0012,126.202,30,39,780.00
85.3Median RccReinforced cement concrete work in beams, suspended floors, roofs having slope up to 15° landings, balconies, shelves, chajjas, lintels, bands, plain window sills, staircases and spiral stair cases above plinth level up to floor five level, excluding the cost of centering, shuttering, finishing and reinforcement with 1:1.5:3 (1 cement : 1.5 coarse sand(zone-III) derived from natural sources : 3 graded stone aggregate 20 mm nominal size derived from natural sources).Cum1,000.0011,505.501,15,05,500.00
95.22.6Median SteelSteel reinforcement for R.C.C. work including straightening, cutting, bending, placing in position and binding all complete upto plinth level. — Thermo-Mechanically Treated bars of grade Fe-500D or more.Kg60,000.00107.8564,71,000.00
102.8.1Drain ExcavEarth work in excavation by mechanical means (Hydraulic excavator) / manual means in foundation trenches or drains (not exceeding 1.5 m in width or 10 sqm on plan), including dressing of sides and ramming of bottoms, for all lift, including getting out the excavated soil and disposal of surplus excavated soil as directed, within a lead of 50 m. — All kinds of soil.Cum2,000.00260.305,20,600.00
115.3Drain Rcc LiningReinforced cement concrete work in beams, suspended floors, roofs having slope up to 15° landings, balconies, shelves, chajjas, lintels, bands, plain window sills, staircases and spiral stair cases above plinth level up to floor five level, excluding the cost of centering, shuttering, finishing and reinforcement with 1:1.5:3 (1 cement : 1.5 coarse sand(zone-III) derived from natural sources : 3 graded stone aggregate 20 mm nominal size derived from natural sources).Cum800.0011,505.5092,04,400.00
1216.71W Beam Crash Barrier[item not found: 16.71]4,000.000.000.00
SOR item dsr_vol2_2023:16.71 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
1316.62Thermoplastic Marking[item not found: 16.62]14,000.000.000.00
SOR item dsr_vol2_2023:16.62 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
1416.59Road Signs[item not found: 16.59]18.000.000.00
SOR item dsr_vol2_2023:16.59 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
1516.65Reflective Road Studs[item not found: 16.65]1,600.000.000.00
SOR item dsr_vol2_2023:16.65 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
Your inputsRoad length 1 km · Main carriageway each direction 10.5 m · RCC median width 5.0 m · Paved shoulder each outer side 3.0 m · Service road both sides · Pavement type Flexible (GSB + WMM + DBM + BC) — common · GSB thk 300 mm · WMM thk 300 mm · DBM thk 130 mm · BC wearing course 50 mm · DLC thk 150 mm · PQC thk 350 mmTOTAL₹7,24,74,510
12.6.1₹97,98,000
Earthwork Embankment
Earth work in excavation by mechanical means (Hydraulic excavator)/ manual means over areas (exceeding 30 cm in depth, 1.5 m in width as well as 10 sqm on plan) including getting out and disposal of excavated earth lead upto 50 m and for all lift, as directed by Engineer-in-charge. — All kinds of soil
55,200.00 Cum× ₹177.50
216.78.1₹0
Gsb Grade I
[item not found: 16.78.1]
11,970.00 × ₹0.00
SOR item dsr_vol2_2023:16.78.1 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
316.4₹1,19,35,230
Wmm Base
Laying, spreading and compacting stone aggregate of specified sizes to WBM specifications in uniform thickness, hand picking, rolling with 3 wheeled road/vibratory roller 8-10 tonne capacity in stages to proper grade and camber, applying and brooming requisite type of screening / binding material to fill up interstices of coarse aggregate, watering and compacting to the required density .
11,400.00 Cum× ₹1,046.95
416.39₹0
Prime Coat
[item not found: 16.39]
38,000.00 × ₹0.00
SOR item dsr_vol2_2023:16.39 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
516.54.1₹0
Dbm Binder
[item not found: 16.54.1]
4,940.00 × ₹0.00
SOR item dsr_vol2_2023:16.54.1 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
616.40₹0
Tack Coat
[item not found: 16.40]
38,000.00 × ₹0.00
SOR item dsr_vol2_2023:16.40 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
716.57.1₹2,30,39,780
Bc Wearing
Providing and laying Bituminous concrete using crushed stone aggregates of specified grading, premixed with bituminous binder and filler, transporting the hot mix to work site by tippers, laying with paver finisher equiped with electronic sensor to the required grade, level and alignment and rolling with smooth wheeled, vibratory and tandem rollers to achieve the desired compaction and density as per specification, complete and as per directions of Engineer-in-Charge. — 40/50 mm compacted thickness with bitumen of grade VG-30 @ 5.5% (percentage by weight of total mix) and lime filler @ 3% (percentage by weight of Aggregate) prepared in Batch Type Hot Mix Plant of 100-120 TPH capacity.
1,900.00 Cum× ₹12,126.20
85.3₹1,15,05,500
Median Rcc
Reinforced cement concrete work in beams, suspended floors, roofs having slope up to 15° landings, balconies, shelves, chajjas, lintels, bands, plain window sills, staircases and spiral stair cases above plinth level up to floor five level, excluding the cost of centering, shuttering, finishing and reinforcement with 1:1.5:3 (1 cement : 1.5 coarse sand(zone-III) derived from natural sources : 3 graded stone aggregate 20 mm nominal size derived from natural sources).
1,000.00 Cum× ₹11,505.50
95.22.6₹64,71,000
Median Steel
Steel reinforcement for R.C.C. work including straightening, cutting, bending, placing in position and binding all complete upto plinth level. — Thermo-Mechanically Treated bars of grade Fe-500D or more.
60,000.00 Kg× ₹107.85
102.8.1₹5,20,600
Drain Excav
Earth work in excavation by mechanical means (Hydraulic excavator) / manual means in foundation trenches or drains (not exceeding 1.5 m in width or 10 sqm on plan), including dressing of sides and ramming of bottoms, for all lift, including getting out the excavated soil and disposal of surplus excavated soil as directed, within a lead of 50 m. — All kinds of soil.
2,000.00 Cum× ₹260.30
115.3₹92,04,400
Drain Rcc Lining
Reinforced cement concrete work in beams, suspended floors, roofs having slope up to 15° landings, balconies, shelves, chajjas, lintels, bands, plain window sills, staircases and spiral stair cases above plinth level up to floor five level, excluding the cost of centering, shuttering, finishing and reinforcement with 1:1.5:3 (1 cement : 1.5 coarse sand(zone-III) derived from natural sources : 3 graded stone aggregate 20 mm nominal size derived from natural sources).
800.00 Cum× ₹11,505.50
1216.71₹0
W Beam Crash Barrier
[item not found: 16.71]
4,000.00 × ₹0.00
SOR item dsr_vol2_2023:16.71 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
1316.62₹0
Thermoplastic Marking
[item not found: 16.62]
14,000.00 × ₹0.00
SOR item dsr_vol2_2023:16.62 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
1416.59₹0
Road Signs
[item not found: 16.59]
18.00 × ₹0.00
SOR item dsr_vol2_2023:16.59 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
1516.65₹0
Reflective Road Studs
[item not found: 16.65]
1,600.00 × ₹0.00
SOR item dsr_vol2_2023:16.65 not in private subset — regenerate via scripts/boq-import-sor-subset.mjs
Road length 1 km · Main carriageway each direction 10.5 m · RCC median width 5.0 m · Paved shoulder each outer side 3.0 m · Service road both sides · Pavement type Flexible (GSB + WMM + DBM + BC) — common · GSB thk 300 mm · WMM thk 300 mm · DBM thk 130 mm · BC wearing course 50 mm · DLC thk 150 mm · PQC thk 350 mm
Estimated total
₹7,24,74,510
Notes & assumptions
  • **6-Lane Expressway** = 2 × 3-lane carriageway separated by wide RCC median + 3 m paved shoulders + service roads + grade-separated intersections only. Per IRC SP-87 (Expressway Manual) — distinct from 6-lane NH (which can have at-grade intersections + mixed traffic).
  • **Cross-section default** (with service roads): 5.5 (service) + 1.5 (separator) + 3.0 (paved shoulder) + 10.5 (carriageway) + 5.0 (median) + 10.5 (carriageway) + 3.0 (paved shoulder) + 1.5 (separator) + 5.5 (service) = 46 m formation. ROW typically 60-100 m depending on terrain + future-proofing.
  • **Service roads** parallel the main carriageway on both sides, give access to roadside properties + slow vehicles + local traffic. 5.5 m wide (2-lane intermediate per IRC), pavement spec lighter (GSB 250 + WMM 200 + DBM 50 + BC 25 — equivalent to a 2-lane SH). Toggle off if no service-road provision (e.g. on bypass routes).
  • **Pavement choice**: **Flexible** (GSB + WMM + DBM 130 + BC 50, ~780 mm total) is the conventional choice — cheaper upfront, 15-20 year life. **Rigid** (GSB 300 + DLC 150 + PQC 350, ~800 mm total) is preferred for: very heavy traffic > 30,000 cv/day, toll plaza approaches, waterlogged subgrades, long-life infra. Rigid is ~35-50 % more upfront BUT 60-70 % cheaper over 25-year lifecycle.
  • **Median 4.5-5.0 m** is the IRC SP-87 standard — provides space for: (a) future widening to 8-lane; (b) lighting + signage poles; (c) emergency vehicle u-turns. Depressed turfed median (12 m) is reserved for premium expressways (Bundelkhand Expressway, Mumbai-Nagpur Samruddhi).
  • **Crash barrier on all 4 edges** (outer × 2 + median × 2 sides) — mandatory per IRC SP-44 + NHAI expressway specs.
  • **Cost target** for default 6-lane × 1 km with service road + flexible pavement + full drainage + barriers + markings: approximately **₹8-15 crore / km** per CPWD DSR 2023. NHAI expressway tender awards: ₹10-18 Cr/km in plain, ₹20-35 Cr/km in hill / cutting, ₹50-100 Cr/km in tunneled / elevated.
  • **Excludes**: bridges + flyovers + ROBs / RUBs (separate, often 30-50 % of total project cost on expressways); interchanges (cloverleaf, trumpet, partial — 5-15 Cr each); toll plazas (₹15-30 Cr each); ATMS / VMS / CCTV / variable message signs (₹50L-1.5 Cr/km); high-mast lighting (₹3-8L per Rmt); ducting for OFC / utilities (₹15-30L/km); slope protection (hill sections); land acquisition + R&R (Right of Way 60-100 m wide, can dominate budget).

The **6-Lane Expressway** is India's highest standard road category — access-controlled, grade-separated, designed for 100-120 km/h speeds. Built under **Bharatmala (2017-) + state expressway authorities** (UPEIDA, MPEIDA, MMRDA), India's expressway network has grown from ~200 km (2014) to ~5,000 km (2026, operational + under construction). Per **IRC SP-87 (Expressway Manual) + IRC SP-84 + MoRTH 5th Revision**, the standard cross-section is 2 × 10.5 m main carriageway (3 lanes × 3.5 m each direction) + 4.5-5.0 m RCC median + 3.0 m paved shoulders + service road on both sides + lined drainage. Heaviest standard pavement: GSB 300 + WMM 300 + DBM 130 + BC 50 mm (flexible) OR GSB 300 + DLC 150 + PQC 350 mm (rigid for long-life). Design traffic 80,000-150,000 PCU/day, 30-year design life. Cost ~₹8-15 Cr/km civil works per CPWD DSR 2023; NHAI awards ₹10-18 Cr/km plain terrain.

Expressway vs 6-Lane NH — what's different

**6-Lane NH** (under NHDP / NHAI standard 4L → 6L upgrade): same number of lanes but **at-grade intersections allowed** (signalised or non-signalised), mixed traffic permitted (slow vehicles, tractors, 2-wheelers), median 1.5-3 m standard, design speed 80-100 km/h, smaller paved shoulder (2.5 m). **6-Lane Expressway** (under Bharatmala expressway programme / state expressway authorities): **grade-separated intersections ONLY** (cloverleaf / trumpet / interchange), restricted access (slow vehicles + 2-wheelers banned in many states), wider median (4.5-5+ m), wider paved shoulder (3-3.5 m), service roads on both sides for local + slow traffic, design speed 100-120 km/h. **Cost difference**: ~30-50 % more per km than 6-lane NH due to wider cross-section + grade-separation infrastructure + more elaborate drainage + ATMS. Use this template for true expressways; for 6-lane NH (with at-grade allowed) the 4-lane template scaled up gives a closer approximation.

Flexible vs Rigid pavement for expressway

**Flexible (default)** — GSB 300 + WMM 300 + DBM 130 + BC 50 mm. Cheaper upfront (~₹8-12 Cr/km civil); 15-20 year design life; re-surfacing every 8-10 years (₹50-80L/km). Most Bharatmala expressways are flexible. **Rigid (PQC)** — GSB 300 + DLC 150 + PQC 350 mm. 35-50 % more upfront (~₹12-18 Cr/km civil); 30-40 year design life; minimal maintenance for 25 years; recommended for: very heavy traffic > 30k cv/day, toll plaza approaches, waterlogged subgrade, urban expressways with stop-start (toll fences, exits). **Hybrid** — flexible on main carriageway + rigid (PQC) at toll plazas + interchanges is common practice. **Lifecycle cost** crossover is typically 12-15 years — rigid wins for 25+ year horizon, flexible wins for short horizons or where surfacing technology improves rapidly.

Frequently asked questions
**Civil works only (CPWD DSR 2023)**: ₹8-15 Cr/km plain terrain default config. **NHAI Bharatmala expressway awards**: ₹10-18 Cr/km plain, ₹20-35 Cr/km hill, ₹50-100 Cr/km elevated / tunneled. **Total project cost** (civil + bridges + interchanges + toll + ATMS + land + R&R): typically 2-3x the civil number. **For 100-km expressway project**: expect ₹1,500-3,000 Cr total in plain terrain, much higher in challenging terrain. Mumbai-Nagpur Samruddhi (701 km, 6+6L) cost ₹55,000 Cr ≈ ₹78 Cr/km total; Delhi-Mumbai (1,386 km, 8L+) ~₹95,000 Cr ≈ ₹68 Cr/km.
Disclaimer: Rates sourced from CPWD DSR Vol 1 + Vol 2 (2023). Indicative for estimation only — actual tender quotations are governed by market forces, locality factors and current input prices. Quantities follow IS 1200 measurement. Always verify with a local quote before finalising. © InfraLens — infralens.in