This paper presents indigenous solution for real problem statement faced at toll-ways. National Highways Authority of India (NHAI) is facing problems to classify the different kinds of vehicles under the same class having dissimilar height, length and shape. The system consists of an equipment which is deployed across the road on toll-ways emitting and receiving driven pulse through IR LED's and IR receivers. The system consist paired transmitter and receiver sensor array that is mounted horizontally and vertically on toll-ways. Vehicle side profile is obtained on receiver side when IR LED pulse is transmitted sequentially at counter time and captured at receiver sensor to generate a sensor array pattern. Vehicle classification is accomplished by comparing a vehicle profile with build database. Results elevated are presented and discussed. © 2015 IEEE.