Casting Bed

GAMMON INDIA LIMITED
GAMMON HOUSE, VEER SAWARKAR MARG,PRABHADEVI, MUMBAI-400 025

Phone: 91-22-61153000
E-Mail: gammon@gammonindia.com
Internet: http://www.gammonindia.com
OFFICE OF ORIGIN:
ENGINEERING DESIGN MANAGEMENT SECTION (HEAD OFFICE)
PROJECT:
FOUR LANING OF THE STRETCH OF THE NH-17B FROM VARUNPURI TO SADA JUNCTIO
EPC MODE
CLIENT:
PUBLIC WORK DEPARTMENT, GOA
TITLE:
DESIGN OF CASTING BED FOR PRETENSIONED I- GIRDER
( TROUGH TYPE)
9401/TS/DN-01
DESIGN CALCULATION NO.:
PAGES:
ANNEXURES, if any:
Date of
Issue
Revision
TO
27
NA
Revision to incorporate observations of client
Prepared By
vide their letter reference/minutes of meeting

as the case may be, and as refered below:
22/12/2015
R0
First submission
Name
AUD
APPROVED BY:
This design is the property of GAMMON INDIA LIMITED. It should not be used, copied
or reproduced without their written permission.
Page 1
BAI-400 025
CE)
UNPURI TO SADA JUNCTION ON
ENSIONED I- GIRDER
DATE: 22/12/2015
Checked By
Name
AUD
Sign
Name
RKM
Page 2
PROJECT: FOUR LANING OF THE STRETCH OF NH-17B FROM VARUNPU

JUNCTION ON EPC MODE
TITLE: DESIGN OF CASTING BED FOR PRE-TENSIONED BEAM
REV:
R0
DOC. NO: 9401/TS/DN-01
DSN:
AUD
CHK:
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DATE:
1.0 Preamble:
The following sheets present design of the casting bed to accommodate
4
nos.25
m long girder only.
It is proposed that there shall be one Casting bed for 4 Pre-tensioned girders.
2.0 Methodology:
There shall be two anchor girders, one at stressing end block and one at dead end block.
The girder at stressing end block shall be movable upto the extent of elongation in the
strands.The strands shall be threaded through the anchor girders and shall be anchored
by means of barrels. The movable anchor girder at stressing end block shall move ahead
head with the help of 2 no. hydraulic jacks. The movable anchor girder at Dead end block
shall be kept on rollers. The casting bed is design to take the reactions of the prestrssing
force
3.0 References:
Reference Codes:
IS 800:1984
Code of practice for general construction of

steel
Plain and Reinforced Concrete - Code of
Practice
Standard specification and Code of practice
for road bridges.
Uncoated stress relieved low relaxation seven
ply strand for prestressed concrete- Specific
ation
IS 456:2000
IRC 21-2000
IS 14268-1995
Reference Drg:
9401/TS/ 111/A9401/TS/112/A 9401/TS/113/A 9211/TS/114/A -
G.A. of Casting Bed

RCC details of casting bed- Trough, diaphragm & pedestals
RCC details of casting bed- Stressing/Dead end block
RCC details of Retaining wall at stressing/Dead end
4.0 Design Data:

For Beam at Midspan
No. of strands =
UTS of strand =
Assume
Pretensioning force (total) =
23
23
26.592 t
80 % of the UTL is applied for pretensioning.
x
=
say
For Beam at Support
Page 3
26.59
489.29 t
600
t
0.80
No. of strands =
UTS of strand =
Assume
Pretensioning force (total) =
23
23
26.592 t
80 % of the UTL is applied for pretensioning.
x
=
say
Page 4
26.59
489.29 t
600
t
0.80
NH-17B FROM VARUNPURI TO SADA
TENSIONED BEAM
22/12/2015
d end block.
e anchored
move ahead
ad end block
prestrssing
for general construction of
rced Concrete - Code of
cation and Code of practice
relieved low relaxation seven

stressed concrete- Specific
h, diaphragm & pedestals

sing/Dead end block
tressing/Dead end
Page 5
Page 6
PROJECT: FOUR LANING OF THE STRETCH OF NH-17B FROM VARUNPURI TO SADA

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To locate C.G of strand : (from bottom of beam )

For Beam at Mid Span
2
7
7
7
55
55
55
75
No of Strands =
Total no of strands =
Dia of strands =
U.T.S. of strands =
23
15.2
26.592
We will design the casting bed for

ie
0.80
23
nos
mm
ton
0.80
of U.T.S.
26.592
21.2736
=
say
Therefore, total force =
21.2736
23
Elongation in strands =
P
A
x
x
L
E
Span of girder (max)

No. of girders in single bed
Hence,
102.4
21.27
A=
140
Elongation in strands
m
ton
E=
mm2
778
489.29
600
25 m
4 nos
L=
P=
ton
2.00E+05
Mpa
IS 14268
mm
Page 7
ton
ton
per strand

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C.G. of strands =
AUD
CHK:
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7 X 75 +7 X 130 +7 X 185 +2 X 240

23
=
139.57
DATE:
22/12/2015
mm
(from soffit of beam)

2
7
7
7
55
55
55
75
No of Strands =
Dia of strands =
U.T.S. of strands =
23
15.2
26.592

ie
0.80
23
nos
mm
ton
0.80
of U.T.S.
26.592
21.2736
=
say
21.2736
23
P
A
x
x
L
E

=
=
25 m
4 nos
Page 8
ton
489.29
600
ton
ton
per strand

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DSN:
Hence,
L=
P=
102.4
21.27
A=
140
AUD
m
ton
RKM
DATE:
22/12/2015
E=
2.00E+05
mm2
C.G. of strands =
CHK:
Mpa
IS 14268
778
mm
7 X 75 +7 X 130 +7 X 185 +2 X 240

23
=
139.57
mm

325
250
325
1900
1.276
A
200
0.624
C
4500
To Locate C.G. of trough :

Area Mkd
(from bottom )
Area
A
B
C
m2
y
m
1.050
1.050
0.100
0.5525
0.5525
0.9
A =
y
A
Y=
0.580
0.580
0.09
Ay=
2.005
=
Ay
m3
1.250
2.005
0.624
1.250
m3
Geometric properties of trough :

Length of trough (L) =
102.4
Area =
Ixx =
2.01
1 X 1.93 X 0.325
m2
+
1.9 X 0.325 X 0.32642
X2
12
( 0.23 X 3.85 )
12
+ ( 3.85 X 0.2 X 0.5242 )
Page 9

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0.503
0.717
m4
1 X 0.3253 x 1.7
12
Iyy =
CHK:
RKM
DATE:
22/12/2015
0.214
0.33 X 1.70 X 2.08752
X2
mm
623.566
( 4.53 X 0.2 )
12
=
0.010
6.344
rmin =
1.519
0.562
m3
0.717
0.624
1.149
m3
6.344
2.819
m3
4.8152102
m4
0.717
2.01
0.60
0.717
Minimum section modulus :

Ixx
ZTxx =
yTmax
1.276
Ixx
yBmax
ZBxx =
Zyy =
Iyy
xmax
2.25
Force to be taken by strut action by trough =

=
Prestressing force
600
ton
To calculate the eccentricity of prestressing force :

Ht of pedestal
Ht of shuttering
Bottom slab thk.
C.G. of strands from soffit of beam =
unsupportted length to be considered
=
=
=
150 mm
139 mm
200 mm
139.57 mm
=
25
Therefore, eccentricity of prestressing force (ex)
=
=
628.57
4.999
Minimum eccentricity : ( as per IS:456 -2000,clause 25.4 )

About x - axis :
ex
unsupported length
500
lateral dimension
30
( subjected to minimum of
Page 10
20
mm)

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= 102400
500
= 204.8
=
268.1
AUD
CHK:
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DATE:
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1900
30
63.333
mm
About y - axis :
ey
unsupported length
500
= 102400
500
= 204.8
=
355
+
+
lateral dimension
30
20
4500
30
150
mm
We will design the trough as a compression member subjected to biaxial bending with,
ex =
268.1
mm
ey =
354.8
mm
Therefore, Axial force

Mx =
My =
=
213
161
600 ton
t-m
t-m
Material used :
M 35
Permissible stresses: (As per IS:456-2000)
cbc =
st =
11.5
275
N/mm2
N/mm2
m=
280
3cbc
&
Fe 500
cc =
sc=
280
34.5
9
190
8.115942
Using uncracked section theory

Direct stresses cc(cal) =
P
Ac
1.5m Asc
=
=
600
8.12
where,
P = Axial force
m = modular ratio
Asc = area of steel
Page 11
ton
N/mm2
N/mm2
mm)

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We will provide minimum steel (ie 0.8 % of c/s area of concrete)

Therefore, Asc =
Ac
0.8
= net area of concrete

=
2.01
=
1.99
Therefore, cc)cal
2.01
100
0.016 m2
0.016
m2
=
1988960
=
2.75
6000000
1.5
8.12
16040
N/mm2
Bending stresses ( about X-X axis)

Mxx
=
Zxx
3.79 N/mm2
cbcx =
=
2128800000
561540889.257921
Bending stresses ( about Y-Y axis)

Myy
cbcy =
1608800000
Zyy
=
2819416203.7037
0.571 N/mm2
Total bending stresses :

cbcx
=
=
=
+
+
N/mm2
3.79
4.36
cbcy
0.571
CHECK :
1)
Maximum stresses
(cc)cal
=
=
=
<
2)
Minimum stresses
ie
3.79
cbcy
+
+
0.571
N/mm2
N/mm2
Hence O.K.
cbcy
(cc)cal
+
3.79
+
0.571
1.61
N/mm2
0.75
x 7 days modulus of rupture of concrete
0.75
3.313004679
2.75
N/mm2
Hence O.K.
2.48
Resultant tension in concrete is not to be greater than 35% of resultant compression.

ie
4)
cbcx
+
+
cbcx
=
=
=
<
3)
2.75
7.109
11.5
(cc)cal
(cc)perm
2.75
9.00
35
100
+
+
cbcx
7.11
+
(cbc)perm
cbcy
2.49 N/mm2
>
1.61 N/mm2
<=
=
<
4.36
11.50
Page 12
Hence O.K.
1
0.68
1
Hence O.K.

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Design of Trough wall Reinforcement :Consider, Force in each strut =

Let the dimension be
300 t
1700
(d)
Stresses in axial compression =
=
300
(b)
3000000
1700 x
300 x
5.882 N/mm2
=
Area of the struts
Moment of Inertia Ixx
0.1228 m
Moment of Inertia Iyy
0.004 m
Radius of gyration
0.087 m
1 nos.
0.510 m2
4
Reinforcement in trough wall:

Minimum reinforcement =
0.8 % of the cross sectional area
=
4080 mm2
Provide,
20
bars of
16
dia.
+
Total area (Asc) =
4423.36 mm2
Ag =
=
=
Material used :
net area of concrete

510000
505577 mm2
M 35
4080 mm2
Hence ok
>
&
bars of
4423.36
Fe 500
Hence,
cc
8.1
N/mm2
sc
171
N/mm2
ccxAg + sc xAsc
Load capacity =
=
###
Page 13
>
300 t
Hence ok
16 dia.

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DATE:
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Reinforcement for Lateral Ties:Diametre - Minimum of

a) 5 mm
b) 4 mm
Spacing shall not exceed the least of following :
a)
300
mm
b)
256
mm
c)
240
mm
Provided
8 mm
@
125
mm c/c
Design of Trough Slab Reinforcement :For self wt + girder Load :Loading:

Depth of slab
Density of concrete
Dead load of slab
Dead load
=
=
=
=
200
2.6
0.52
0.1
mm
t/m3
t/m2
t/m2
Live load
Total Load
=
=
0.36
0.98
t/m2
t/m2
Weight of girder =
42 t
Length of the strip =
25 m
Provide
Area provided
3.85
25.0 m
96.25 m2
Load =
0.44 t/m2
Safe bearing capacity of soil =
Net upward pressure
20 t/m2
1.42 t/m2
(Assumed)
<
OK
20 t/m2
Calculation of depth of slab:

Grade of concrete =
Grade of steel =
cbc =
M 35
Fe 500
11.5 N/mm2
st =
275 N/mm2
Page 14
IS 456-2000

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Coefficient values,
m = 280/3cbc
k = 1/(1+(3st/280))
j = 1-k/3
Q = cbc.j.k/2
b
CHK:
8.1
0.25
0.92
1.33
1000
=
=
=
=
=
DATE:
22/12/2015
1.925
mm
Maximum bending moment
1.42
Maximum bending moment
2.62 t-m
Effective depth of the section required =

Use
12
Provide clear cover
RKM
d = (M/Q.b)
mm dia H.Y.S.D bars

=
30
mm
Over all depth
176.26
mm
We provide overall depth, D

Thus effective depth
=
=
200
164
mm
mm
Ast, required = M / st.j.d
635.56
mm2
Area of one bar

No. of bars required
ie.,
=
=
113.1
5.62
6.00
mm2
nos.
nos.
Total area of steel provided
678.6
mm2
Minimum reinforcement steel required:

Ast =
0.85
1000
500
=
Provide
Spacing of main bars
278.8 mm2
nos. of
12
1.925
2
140.26 mm
164
<
OK
678.6 mm2
mm dia. Bars.
200 mm
Say =
200 mm c/c
Distribution steel:
0.15
100
947.1 mm2
Minimum area of distribution steel

required =
=
Diameter of distribution bars provided
16
Page 15
3850
mm
164

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DSN:
Area of one bar
Provide
16
AUD
16
RKM
DATE:
22/12/2015
201.1 mm2
nos. of bars as distribution bars.
Total area of bars provided

Provide
CHK:
3216.99
=
nos. of
16
Spacing of distribution bars =
947.1 mm2
>
Ok
mm dia. Bars as a distribution bars.
256.67 mm
Say =
235 mm
Check for shear stress:

1925
200
1761
Effective depth, d
164
164
3850
mm
Critical section will be at a distance of 'd' from loading point.

ie.,
1761
mm from the edge of the footing.
Shear force at critical section, V
2.49
Nominal shear stress at critical section,tv =
Cross section of the footing
Percentage steel provided
V
bxd
mm
164000
100 x
Permissible shear stress in concrete
Here,
t
=
15.21
t/m2
0.152
N/mm2
678.6
164000
=
0.281 N/mm2
tv
tv =
0.152 N/mm2
tc =
0.281 N/mm2
tc
0.41 %
IS 456-2000, table 23
<
No shear reinforcement required
Page 16

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Design of Diaphragm Reinforcement (Part-I) :-
Force in Axial = 2.5% of total load

250
(d)
Stresses in axial compression
15
x
250
(b)
1 nos.
150000
250 x
250 x
2.400 N/mm2
Permissible stresses in the struts:

Area of the struts
0.063 m2
0.00032552 m4
=
=
=
0.00032552 m4
0.072 m
4500 mm
Radius of gyration
Length
Reinforcement in diphragm:
Minimum reinforcement =
Provide
12
Area of one bar
Total area (Asc)

Ag =
=
0.8
=
mm dia
113.14 mm2
678.86 mm2

62500
-
% of the cross sectional area

500 mm2
6 nos
>
500 mm2
&
Fe 500
Hence ok
678.86
61821.14 mm2
Material used :
M 35

cc
N/mm2
sc
190
N/mm2
ccxAg + sc xAsc
Hence, Load capacity =

=
68.54 t
>
Page 17
15 t
Hence ok

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DATE:
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Reinforcement for Lateral Ties:Diametre - Minimum

a) 5 mm
b) 3 mm
a)
250
mm
b)
192
mm
c)
240
mm
Provided
12 mm
@
250
mm c/c
Design of Diaphragm Reinforcement (Part-II) :-
Force in Axial = 2.5% of total load =

600
(d)
Stresses in axial compression
15 t
x
250
(b)
=
600 x
=
1 nos.
150000
250 x
1.000 N/mm2
Permissible stresses in the struts:

Area of the struts
0.150 m2
0.0045 m4
=
=
=
Radius of gyration
Length
0.00078125 m4
0.072 m
4500 mm
Reinforcement in diphragm:
Minimum reinforcement
0.8
=
Provide,
Total area (Asc) =

Ag
=
=
bars of
1306.90 mm2

150000
-
=
Material used :
% of the cross sectional area
1200 mm2
12
dia.
>
1200 mm
&
Fe 500
1306.90
148693 mm2
M 35
Page 18
bars of
Hence ok
16
dia.

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DATE:
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cc =
9
N/mm2
sc=
Hence,
190
N/mm2
ccxAg + sc xAsc
Load capacity =
=
158.65 t
>
Reinforcement for Lateral Ties:Diametre - Minimum

a) 5 mm
b) 4 mm
a)
250
mm
b)
256
mm
c)
240
mm
Provided
12 mm
@
250
mm c/c
Page 19
15 t
Hence ok

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DATE:
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Design of Stressing End Block :Loading on Beam-I :

300 t
150
1.35 m
Maximum B.M.
Maximum shear
=
=
101
150
150 t
t-m
t
Please input the following data :

Design bending moment M =
Assume width of beam ' b '
=
Material used :
Concrete M
Steel
Fe
Steel
Fe
=
=
=
101 t-m
1500 mm
cbc
st
sc
35
500
500
Perm. Stresses in bending

=
11.5 N/mm2
=
275 N/mm2 tension
2
=
N/mm
190
compression
Design constants :
1
27
280
3 cbc
=
=
8.115942
k
k
0.253394
j
j
=
=
1 - (k / 3)
0.915535
Q
Q
=
=
1/2 * cbc * k * j
Q b d2
dc
1
1 + ( 3 st / 280 )
b=
D=
750
dt
1.333948
d req. =
711.34864 mm
using
25
dia. Bars.
Taking clear cover
=
Overall depth ' D '
=
Provide overall depth ' D '
1500
40
mm
763.84864 mm
=
750 mm
Page 20

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Therefore effective depth ' d '

=
697.5 mm
2
Mbal =
Qxbxd
Hence,
97.34607 t-m
=
Doubly Reinforced section is reqd.
Effective
Effective
cover cover
'
dc ' =
' dt ' =
40 mm
40 mm
=
=
(To tension reinforcement)

(To compression reinforcement)
Moment to be resisted by compression steel :

M1 =
4 t-m
Calculation of tension steel :
Ast1
=
Mbal
M1
st jd
Provide,
Ast provd
st(d - dc)
5759.185 mm2
6
=
bars of
25
5890.486 mm2
dia.
Hence ok
bars of
25
Calculation of compression steel :

Taking moment of equivalent area of tension & comp steel about N.A.
Asc
M1
=
(1.5 m -1) *cbc*(1- dc / (k*d))*(d-dc)
Asc
Provide,
Asc provd =
=
5
597.2283 mm2
bars of
16
1005.31 mm2
Check for shear :

Design shear ' V '
=
Percentage of steel ' Pt ' =
Therefore ' Pt ' =

Permissible shear stresses c perm.
Actual shear stresses c act.
dia.
Hence ok
t
150
100 Ast
bd
0.563009 %
=
0.3251223 N/mm2
=
=
V
bd
1.433692 N/mm2
Page 21
Shear reinforcement reqd.
dia.

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Design shear ' Vs '

Using
12
Asv
sv
CHK:
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DATE:
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115.9841 t
mm dia
legged stirrups
678.584 mm2
275 N/mm2
Spacing of stirrups 's'
=
s =
sv * Asv * d
Vs
112.2231 mm
Spacing of stirrups shall be lesser of following :

i)
ii)
iii)
iiii)
112.2231 mm
491.9734 mm
450 mm
523.125 mm
Therefore the spacing of stirrups ' s ' =

Provide
12 mm dia
6
112.2231 mm
legged stirrups
125
mm c/c
Loading on Beam-II :
150.0 t
150 t
3m
150 t
4.5 m
Maximum B.M.
Maximum shear
=
=
113
150
150 t
t-m
t

Design bending moment M
113 t-m
750 mm
Material used :
Concrete
Steel
M
Fe
35
Perm. Stresses
in bending
cbc
=
11.5 N/mm2
500
st
275 N/mm2
Page 22

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Design constants :
m
=
CHK:
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DATE:
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dc
280
3 cbc
0.25
j
j
=
=
1 - (k / 3)
0.92
1/2 * cbc * k * j
b=
750
8.115942
1
1 + ( 3 st / 280 )
D=
1250
dt
1.3339476
Q b d2
d req.
=
1060.4159 mm
using
25
dia. Bars.
Taking clear cover
=
40
mm
Overall depth ' D '
=
1112.9159 mm
Provide overall depth ' D ' =
1250
mm
Thus, effective depth (d)
1197.5
mm
Singly reinforced section is adeqate.
Calculation of Ast :
M
st x Ast x j x d
Therefore Ast req

Provide
12
bars of
Therefore Ast prov. =
3731.3771 mm2
25
dia.
5890.4862 mm2
Check for shear :

Design shear ' V ' =
Percentage of steel ' Pt '
Therefore ' Pt '
150.0
=
t
100 Ast
bd
0.6558649
Page 23
Hence ok

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CHK:
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Permissible shear stresses c perm. =
DATE:
0.3598768 N/mm2
Actual shear stresses c act. =
V
bd
= 1.6701461 N/mm2
Design shear ' Vs ' =

Using
sv
117.67857 t
12
Asv
22/12/2015
mm dia
legged stirrups.
678.58401 mm2
275 N/mm2
=
=
sv * Asv * d
Vs
189.89541 mm

i)
ii)
iii)
iv)
189.89541 mm
983.9468 mm
450 mm
898.125 mm

Provide
12
189.89541 mm
mm dia
legged stirrups.
Since the overall depth is greater than 750 mm, provide side face reinf.
Side face reinforcement on both face =
Provide
10
bars of
Therefore Ast prov.
0.1 percent of bxD

937.5 mm2
12
dia.
1130.9734 mm
Page 24
Hence ok
150
mm c/c

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DATE:
22/12/2015
Design of Dead End Block :Loading on Beam :

150.0 t
150.0 t
3m
150
4.5 m
Maximum B.M.
Maximum shear
=
=
113
150
150 t
t-m
t

Design bending moment M
=
=
113 t-m
890 mm
Material used :
Perm. Stresses
in bending
Concrete
M 35
Steel
11.5 N/mm2
Fe 500
1
275 N/mm2
27
Design constants :
m
k
j
j
=
=
=
Q
Q
=
=
1
1 + ( 3 st / 280 )
0.25
1 - (k / 3)
0.92
1/2 * cbc * k * j
1.3339476
Q b d2
d req.
using
280
3 cbc
8.115942
973.44603 mm
25
dia. Bars.
Page 25

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CHK:
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mm
mm
1250
DATE:
22/12/2015
Taking clear cover

=
Overall depth ' D '
=
Provide overall depth ' D '
40
1025.946
=
Thus, effective depth (d)
=
1197.5
mm
Singly reinforced section is adeqate.
mm
Calculation of Ast
M
Therefore Ast req

Provide
12
Therefore Ast prov.
st x Ast x j x d
=
bars of
3731.3771 mm2
25
dia.
5890.4862 mm2
Hence ok
Check for shear :

Design shear ' V '
Percentage of steel ' Pt '
=
=
Therefore ' Pt '
=
Permissible shear stresses c perm.
Actual shear stresses c act.
150.0
100 Ast
bd
0.5526951
=
=
=
Design shear ' Vs '

Using
Asv =
sv =
12
mm dia
0.358 N/mm2
V
bd
1.4074265 N/mm2
111.845255 t
legged stirrups.
sv * Asv * d
Vs
199.79944 mm
678.58401 mm2
275 N/mm2
=
i)
ii)
iii)
iv)
199.79944 mm
829.1687 mm
450 mm
898.125 mm
Page 26

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Provide
12
mm dia
DATE:
22/12/2015
199.79944 mm
6
legged stirrups.
Since the overall depth is greater than 750 mm, provide side face reinf.
Side face reinforcement on both face =
0.1 percent of bxD

=
Provide
10
Therefore Ast prov. =
bars of
12
1112.5 mm2
dia.
1130.9734 mm
Page 27
Hence ok
150
mm c/c

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DATE:
22/12/2015
Design of Casting Bed Pedestal-I :i) Check For Slender Ratio of Pedestal
(As per IRC:21-2000,Cl.306.1, page 58)
Ht. of Column =
0.15
Leff
0.3
r min.
0.6
m2
Ixx
0.0180
m4
0.0500
m4
0.173
(As per Table-13of IRC:21)
0.6
Iyy
2xL
Imin
A
Area
rmin
Slenderness Ratio =
1.0
Leff
rmin
1.73
<
12
IT IS A PEDESTAL COLUMN
ii) Check For Allowable pressure on Loaded Area

cc
co A1
A2
(As per IRC:21-2000,Cl.307.1, page 65)

Grade of Concrete = M 35
here;
co
Permissible direct compressive stress in concrete at the bearing area of base

N/mm2
=
9
(As per IRC:21-2000,Table-9, page 18)
A1
Dispersed concentric area which is geometrically similar to the loaded area

that can be contain in the plane of A1 (maxm. Width of dispersion beyond the
loaded area face shall be limited to twice the height)
m2
=
1.170
A2
=
=
=
A1
A2
Loaded area
1
x
m2
0.6
=
Allowable Bearing Pressure

cc
=
27
0.6
1.1700
0.6000
1.396
1.396424
Page 28
<
12.57
2 Hence ok
N/mm2

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Developed Bearing Pressure

P
=
4
A
=
0.6
Pressure (P/A) =
0.07
CHK:
RKM
DATE:
22/12/2015
<
12.57
N/mm2
tons
m2
N/mm2
iii) Longitudinal Reinforcement for Pedestal
Hence ok
(As per IRC:21-2000,Cl.306.2, page 58)
Area of Long. Reinforcement = 0.15 % of gross c/s area

2
=
900 mm
Provide
Area of one bar
Total area
12
=
mm dia bar
113.14 mm2
1131.43 mm2
10 nos
900 mm2
>
iv) Transverse Reinforcement for Pedestal
Hence ok
(As per IRC:21-2000,Cl.306.3, page 60)
Diametre - Minimum
a) 8 mm
b) 3 mm
Pitch of Transverse reinforcement shall not exceed
=
OR
Lesser of the following two dimensions;
a) The least lateral dimensionsof the column
=
b) 12 times the diameter of the smallest long. Reinforcement in the column
=
Provided
12 mm
@
100
mm c/c
300
600
mm
144
mm
Design of Casting Bed Pedestal-II :i) Check For Slender Ratio of Pedestal
Ht. of Column =
Leff
=
0.3
r min.
(As per IRC:21-2000,Cl.306.1, page 58)

0.15 m
2xL
(As per Table-13of IRC:21)
Imin
A
0.35
Area
0.35
m2
Ixx
0.0036
m4
Iyy
0.0292
m4
1.0
Page 29
mm

REV:
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DSN:
rmin
0.101
AUD
CHK:
RKM
DATE:
22/12/2015
m
Leff
Slenderness Ratio =
rmin
=
2.97
<
12
IT IS A PEDESTAL COLUMN
ii) Check For Allowable pressure on Loaded Area

cc
here;
co
co A1
A2
(As per IRC:21-2000,Cl.307.1, page 65)

Grade of Concrete = M 35
Permissible direct compressive stress in concrete at the bearing area of base

N/mm2
9
(As per IRC:21-2000,Table-9, page 18)
A1 = dispersed concentric area which is geometrically similar to the loaded area

that can be contain in the plane of A1 (maxm. Width of ispersion beyond the
loaded area face shall be limited to twice the height)
m2
=
0.845
A2 = Loaded area
=
1
0.35
x
m2
=
0.35
A1
A2
0.8450
0.3500
Allowable Bearing Pressure

cc
=
Developed Bearing Pressure

P=
2
tons
A=
0.35
m2
Pressure (P/A) =
0.06
1.554 =
1.554
<
13.98
N/mm2
<
13.98
N/mm2
iii) Longitudinal Reinforcement for Pedestal
Hence ok
N/mm2
Hence ok
(As per IRC:21-2000,Cl.306.2, page 58)
Area of Long. Reinforcement = 0.15 % of gross c/s area

2
=
525 mm
Provide
12
mm dia bar
Area of one bar
113.14 mm2
Total area
1131.43 mm2
10 nos
>
Page 30
525 mm2
Hence ok

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iv) Transverse Reinforcement for Pedestal
CHK:
RKM
DATE:
22/12/2015
(As per IRC:21-2000,Cl.306.3, page 60)
Diametre - Minimum
a) 8 mm
b) 3 mm
Pitch of Transverse reinforcement shall not exceed
=
OR
Lesser of the following two dimensions;
a) The least lateral dimensionsof the column
=
350
b) 12 times the diameter of the smallest long. Reinforcement in the column
=
144
Provided
12 mm
@
100
mm c/c
Page 31
300
mm
mm
mm

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DATE:
22/12/2015

2
7
7
7
55
55
55
75
No of Strands =
Dia of strands =
U.T.S. of strands =
23
15.2
26.592

ie
0.80
23
nos
mm
ton
0.80
of U.T.S.
26.592
21.2736
=
say
21.2736
23
P
A
x
x
L
E

Hence,
102.4
21.27
A=
140
C.G. of strands =
m
ton
E=
2.00E+05
mm2
778
489.29
600
per strand
ton
ton
25 m
4 nos
L=
P=
ton
Mpa
IS 14268
mm
7 X 75 +7 X 130 +7 X 185 +2 X 240

23
=
139.57
mm

2
7
7
7
55
55
55
75
No of Strands =
Dia of strands =
U.T.S. of strands =
23
15.2
26.592

ie
0.80
23
nos
mm
ton
0.80
of U.T.S.
26.592
21.2736
=
say
21.2736
23
P
A
x
x
L
E

=
=
Hence,
L=
P=
102.4
21.27
A=
140
C.G. of strands =
ton
489.29
600
per strand
ton
ton
25 m
4 nos
m
ton
E=
2.00E+05
mm2
Mpa
IS 14268
778
mm
7 X 75 +7 X 130 +7 X 185 +2 X 240

23
=
139.57
mm
325
250
325
1900
1.276
A
200
0.624
C
4500
To Locate C.G. of trough :

Area Mkd
(from bottom )
Area
A
B
C
m2
y
m
1.050
1.050
0.100
0.5525
0.5525
0.9
A =
y
A
Y=
Ay
m3
0.580
0.580
0.09
Ay=
2.005
=
1.250
2.005
0.624
1.250
m3
Geometric properties of trough :

Length of trough (L) =
102.4
Area =
2.01
Ixx =
1 X 1.93 X 0.325
m2
+
1.9 X 0.325 X 0.32642
X2
12
( 0.23 X 3.85 )
12
0.503
0.717
m4
1 X 0.3253 x 1.7
12
Iyy =
+ ( 3.85 X 0.2 X 0.5242 )
0.214
X2
0.33 X 1.70 X 2.08752

( 4.53 X 0.2 )
12
rmin =
0.010
6.344
0.717
2.01
4.8152102
1.519
0.562
m3
1.149
m3
m4
=
0.60
0.717
Minimum section modulus :

ZTxx =
Ixx
yTmax
ZBxx =
Ixx
yBmax
1.276
=
0.717
0.624
Zyy =
Iyy
6.344
xmax
2.819
m3
2.25
Force to be taken by strut action by trough =

=
Prestressing force
600
ton
To calculate the eccentricity of prestressing force :

Ht of pedestal
Ht of shuttering
Bottom slab thk.
C.G. of strands from soffit of beam =
unsupportted length to be considered
=
=
=
150 mm
139 mm
200 mm
139.57 mm
=
25
Therefore, eccentricity of prestressing force (e x)
=
=
628.57
4.999
mm
623.566
Minimum eccentricity : ( as per IS:456 -2000,clause 25.4 )

About x - axis :
ex
unsupported length
500
= 102400
500
= 204.8
=
268.1
+
+
lateral dimension
30
20
mm)
lateral dimension
30
20
mm)
1900
30
63.333
mm
About y - axis :
ey
unsupported length
500
= 102400
500
= 204.8
=
355
+
+
4500
30
150
mm
We will design the trough as a compression member subjected to biaxial bending with,
ex =
268.1
mm
ey =
354.8
mm
Therefore, Axial force

Mx =
My =
=
213
161
slenderness ration of the section =
600 ton
t-m
t-m
Effective length
min Lateral dim.
= 0.65 x L
b OR D
=
66.56
OR
1.7
= 39.152941
OR
66.56
4.5
14.79111111
From Clause B-3.3 of IS 456-2000

Max permissible stresses are to be reduced by the Reduction coefficient Cr
>
12
Section is Slender
Cr
1.25
leff
48b
b
=
=
Least lateral dimension

1.7
Cr
0.4343137
Material used :
M 35
cbc =
st =
&
cc =
sc=
4.9946078 N/mm2
119.43627 N/mm2
m=
280
3cbc
Fe 500
280
14.983824
3.908823529 N/mm2
82.51960784 N/mm2
18.686819
Using uncracked section theory

Direct stresses cc(cal) =
P
Ac
1.5m Asc
=
=
600
18.69
where,
P = Axial force
m = modular ratio
Asc = area of steel
ton
We will provide minimum steel (ie 0.8 % of c/s area of concrete)

Therefore, Asc =
Ac
0.8
= net area of concrete

=
2.01
=
1.99
Therefore, cc)cal
2.01
100
0.016 m2
0.016
m2
=
1988960
=
2.46
6000000
1.5
18.69
N/mm2
Bending stresses ( about X-X axis)

cbcx =
=
Mxx
=
Zxx
3.79 N/mm2
2128800000
561540889.257921
Bending stresses ( about Y-Y axis)

Myy
cbcy =
Zyy
=
1608800000
2819416203.7037
0.571 N/mm2
Total bending stresses :

=
=
=
cbcx
3.79
4.36
+
+
N/mm2
cbcy
0.571
CHECK :
1)
Maximum stresses
(cc)cal
=
2.46
6.822
=
> 4.9946078
+
+
cbcx
3.79
N/mm2
N/mm2
+
+
cbcy
0.571
Not Safe.
16040
2)
Minimum stresses
cbcx
=
=
=
<
ie
3)
0.75
3.313004679
2.46
N/mm2
Hence O.K.
2.48
Resultant tension in concrete is not to be greater than 35% of resultant compression.

ie
4)
cbcy
(cc)cal
+
+
3.79
0.571
N/mm2
1.90
0.75
x 7 days modulus of rupture of concrete
(cc)cal
(cc)perm
2.46
3.91
35
100
+
+
6.82
cbcx
4.36
4.99
+
(cbc)perm
cbcy
2.39 N/mm2
>
1.90 N/mm2
<=
=
>
Hence O.K.
1
1.50
1
Not Safe.

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GAMMON INDIA LIMITED

GAMMON HOUSE, VEER SAWARKAR MARG,PRABHADEVI, MUMBAI-400 025

DESIGN CALCULATION NO.:

Revision to incorporate observations of client

vide their letter reference/minutes of meeting

UNPURI TO SADA JUNCTION ON

PROJECT: FOUR LANING OF THE STRETCH OF NH-17B FROM VARUNPU

Code of practice for general construction of

G.A. of Casting Bed

4.0 Design Data:

For Beam at Support

NH-17B FROM VARUNPURI TO SADA

for general construction of

rced Concrete - Code of

cation and Code of practice

relieved low relaxation seven

h, diaphragm & pedestals

PROJECT: FOUR LANING OF THE STRETCH OF NH-17B FROM VARUNPURI TO SADA

To locate C.G of strand : (from bottom of beam )

We will design the casting bed for

Therefore, total force =

Span of girder (max)

PROJECT: FOUR LANING OF THE STRETCH OF NH-17B FROM VARUNPURI TO SADA

7 X 75 +7 X 130 +7 X 185 +2 X 240

(from soffit of beam)

To locate C.G of strand : (from bottom of beam )

We will design the casting bed for

Therefore, total force =

Span of girder (max)

PROJECT: FOUR LANING OF THE STRETCH OF NH-17B FROM VARUNPURI TO SADA

7 X 75 +7 X 130 +7 X 185 +2 X 240

(from soffit of beam)

To Locate C.G. of trough :

Geometric properties of trough :

1.9 X 0.325 X 0.32642

+ ( 3.85 X 0.2 X 0.5242 )

PROJECT: FOUR LANING OF THE STRETCH OF NH-17B FROM VARUNPURI TO SADA

0.33 X 1.70 X 2.08752

Minimum section modulus :

Force to be taken by strut action by trough =

To calculate the eccentricity of prestressing force :

Therefore, eccentricity of prestressing force (ex)

Minimum eccentricity : ( as per IS:456 -2000,clause 25.4 )

PROJECT: FOUR LANING OF THE STRETCH OF NH-17B FROM VARUNPURI TO SADA

Therefore, Axial force

Using uncracked section theory

PROJECT: FOUR LANING OF THE STRETCH OF NH-17B FROM VARUNPURI TO SADA

We will provide minimum steel (ie 0.8 % of c/s area of concrete)

= net area of concrete

Bending stresses ( about X-X axis)

Bending stresses ( about Y-Y axis)

Total bending stresses :

Resultant tension in concrete is not to be greater than 35% of resultant compression.

PROJECT: FOUR LANING OF THE STRETCH OF NH-17B FROM VARUNPURI TO SADA

Design of Trough wall Reinforcement :Consider, Force in each strut =

Moment of Inertia Ixx

Moment of Inertia Iyy

Reinforcement in trough wall:

net area of concrete

Permissible stresses: (As per IS:456-2000)

PROJECT: FOUR LANING OF THE STRETCH OF NH-17B FROM VARUNPURI TO SADA

Reinforcement for Lateral Ties:Diametre - Minimum of

Design of Trough Slab Reinforcement :For self wt + girder Load :Loading:

Length of the strip =