PROJECT OFFICE ADDRESS: _ AFCONS INFRASTRUCTURE LTD. AFCONS 9, Shiv Park, Ishwar Nagar Society, Maninagar, Ahmedabad ~ 380008, Gujarat AECONS wrRastRucTURe unareo | SHOPOOYs Pallongi Email: afcons2291@afcons.com Ref : AFC/AMD-UG1/2291/GEC-MEGA/0528 Date : 19-08-2017 To, The Engineer, General Engineering Consultant (MEGA) ‘SYSTRA-RITES-OCG-AECOM (Consortium) Block No.1, Third Floor, Karmayogi Bhavan, Behind Nirman Bhavan, Sector - 108 Gandhinagar ~ 382010, Gujarat, India. Project: “Design and Construction Underground Stations and Tunnel including Finishes and excluding PHE, Electrical and HVAC from Chainage 14328.88m to Chainage 11882.88m for Ahmedabad Metro Rail Project Phase-1”. ubmission of Revised Design Manual for Cut & Cover Structures for UG1 Ref: 1. Contract Agreement No. MEGA/EW/UGSAT/PKG1/Civil dated 09.03.2017 2. Your letter GEC-102-UG1-1713097-A dated 05.06.2017. 3. Our letter AFC/AMD-UG1/2291/GEC-MEGA/0400 dated 07.07.2017 4. Several discussions held with GEC-MEGA, Dear Sir, Please find enclosed herewith Subr Structures for your review & approval. n of Revised Design Manual for Cut & Cover S.No. Document no. Description Revision | Status 1 | USEDETORS- CEN ian Manual na > Thanking you and assuring our best services at all times. AFCONS INFRASTRUCTURES LIMITED, jard copies/2 CDs (soft copies) Copy to: Additional GM (UG), MEGA {1 Hard copy/ 1 CD (soft copy)} ns Regd, Office: cons House. 16, Shah Indust Estate. Veera Desai Road, Azad Nagar PO, Box No, 11978, Andheri (Wh Mumbai - 400 053 Tek 191-67191000 /2673 Fax: +91-22-2673 0047/2673 0026 wow-afeons. com (CIN Nor U4S200ME1976PL.COI9335NER MEGA-GEC Ahmedabad Metro Phase-1 Contract: UG1 Transmittal Form CONTRACTOR GENERAL CONSULTANT Nan: [Tranemitl Ref No; AFCIANOUGH INANE: IMR. Suresh Seetaram Hegde 28 e.STEFAN W HOFSAESS [CONTRACT Ne: IDATE OF SUBMISSION IMEcwewucsaripKcucivuuzo16 {19.08.17 [SIGNATURE: We submit: ; Stage of submission: FPlans Ti specications Sdperatey a on TiWork plan & methodology [8.0.0 F itemattespecity Tvesign citric, studies ‘7 Report © Breation Ticaleutation Ti Prints F other speci: Otess TP Drewings F Samples cag [Submission of Revised Design Manual for Cut & Cover Structures for UG1 Date of document | No. of Copies Document reference Revision 6 UG1-D-ET043-GEN-003 Bt T Foryourinformation REMARKS First Submission for Notice of No Objection ‘These are transmitted as checked below : Fy Resubmission with corrections fr Notice of No Objection TF onerto speci) ISSUING ENTITY : [Ths document (6 hereby aubrited have Boon prope reviewed cording to ou" QA yetemo cov the complotaness sceuecy nd valty Sionature Pate 15 8] 19 copy To: AFC-MEGA UGLf TCPL-GCJV SS 17, LINK ROAD, JANGPURA EXTN. NEW DELHI- 110014, Phone: 24317684, 24310508, 24319288 FAX: 24316057 This Dated: 18.08.2017 DESIGN CERTIFICATE ign Certificate refers to Submission No. ET-043/DC/069 which comprises of Definitive Design Note in respect of: DESIGN MANUAL LEAD DESIGNER'S STATEMENT We certify that: (a) The outline designs, design briefs and performance specifications of those elements of the Permanent Works, as illustrated and described in the documents scheduled in attached transmittal, complies with the design basis criteria and other contract provisions. (b) An in-house check has been undertaken and completed to confirm the completeness. ‘Adequacy and validity of the design of the Permanent Works as illustrated and described in the documents scheduled in attached transmittal. (ce) Allnecessary and required approvals relating to the design of the Permanent Works, as illustrated and described in the documents scheduled in attached transmittal, have been obtained. (@)_Alll effects of the design comprising the submission on the design of adjacent or other parts of the Works have been fully taken into account in the design of those parts: Signed by “Authorized Representative” (For Designer) Reamerel Name Praveen Kumar Sharma Position/Designation Design Team Leader Date 18.08.2017 TANDON CONSULTANTS PVT LTD GEOCONSULT India Pvt.Ltd i STRUCTURAL ENGHEERNG SrECMLSTS Gi Sonera my, Bk imamgestSonwesane asta 180 908-2015 Certified 180 9001-2015 CertifiedLEAD DESIGN CHECKER’S CERTIFICATION We certify the work described in section A of this certificate has been checked by us, and meets the requirement of the contract. Name Position Date ‘Signature Reviewed By | TARUN GOEL _| Lead Design Checker — Structure gieln Ky Verified By |DKSHARMA | Lead Design Checker |i, hey ‘Dit he fyhasr- Date: This certifies that all design has been performed utilizing the skill and care to be expected of a professionally qualified and competent designer, experienced in work of similar nature and scope. ‘This further certifies that all relating to the preparation, review, checking and certification of design has been verified by us and the design proposed by the designer has been accepted by us vide sub clause 4.1 of GCC. ‘Signed by “Authorized Representative” Name Position/Designation Project Mi horized Signatory Date Section | SY & | Design note No. Description Revision | Status A ee eee Design Manual RI D Section Il_ § | Drawing. | Description Rev StatusMETRO LINK EXPRESS FOR GANDHINAGAR (a |" AND nana) cone LIMITED L = GEC CONTRACT: UG | Contract : Package UGOI - Design and Construction of Underground Stations and Tunnel including Finishes and Excluding PHE, Electrical And HVAC from East End of East Ramp to East End of Launching Shaft Near Kalupur Metro Station from Chainage 14328.88m to Chainage 11882.88m, Which Comprises of East Ramp, Twin Bored Underground Tunnel Between East Ramp and Kalupur Metro Station all Cut and Cover Portion including Two ‘Underground Station Kankaria East and Kalupur Metro Station including a Portion of NATM and Launching and Receiving chambers of TBM for Ahmedabad Metro Rail Project, Phase-1 EMPLOYER : METRO LINK EXPRESS FOR GANDHINAGAR AND AHMEDABAD COMPANY LIMITED (MEGA). GENERAL CONSULTANT : CONSORTIUM OF SYSTRA-RITES-OCG-AECOM (MEGA-GEQ) DETAILED DESIGN CONSULTANT : TCPL-&C JV LEAD DESIGN CHECKER : ILF-SCPL JV CONTRACTOR + AFCONS INFRASTRUCTURE LIMITED. DOCUMENT STATUS DESIGN MANUAL Preliminary Design a Definitive Design uw Construction Reference Design — | C) UGI-D-ET043-GEN-003-R1 ‘This certifies that the report has been checked and approved in accordance with the approved Preliminary ‘Quality Assurance Plan Document No UGI-P-E7043-GEN-001. Office of Origin | * Tandon Consultants Pvt. Lid Designer || vk fh i rant Chaudhary (VC) Vijcont= Checker _|:| Ashish Srivastava (AS) FL Approver | :) Praveen Kumar (PK) Ramanand. ir] TANDON CONSULTANTS PVT LTD GEOCONSULT India Pvt.Ltd Einaaa memes es AUSTS saan te Rawhide tee ate eee Saar ‘GhLnengiesem WEBSITE wwe 180 9004-2018: Certified| NE METRO LINK EXPRESS FOR GANDHINAGAR | AND AHMEDABAD COMPANY LIMITED (MEGA) MEGH-GEC ——coutmnet vcs Stee Praveen Kumar Consultant Representative Contractor Représeihative ISSUE CONTROL SHEET J TCPL-GCaV | Approved By | Rev | Date Reason For Issue "Prepared | Checked | Approved | pyc | | by by By | RO First Submission | Ri 11.08.17 | Comments incorporated. kw] & | | | Signed / Initials - ve AS PK) DKS. Note: This page is a record of all issues of this document. All previous issues are hereby superseded and are to be destroyed. TANDON CONSULTANTS PVT TLID Gwe GEOCONSULT India Pvt.Ltd | STRUCTURAL ENGINEERING SPECIALISTS fae term cereimee ARTE Mae harmon eee len 180 9004-2015 : Certified 180 8001-208 :CortiedPhase |AFCONS| comme 6) cons EAST UTD tea nto oy DESIGN MANUAL CUT & COVER AND STATION STRUCTURES, TABLE OF CONTENTS 1. INTRODUCTION........ 2. CUT & COVER STRUCTURES. 2.1 General Principles 2.2 Design Principles 23 Excavation support 24 Design Life and Serviceability 24.1 General e 2.42 Civil Engineering Structures. 2.43 Road Pavements. c 2.44 Serviceability of Civil and Building Works.. 2.5 Material Parameters. QSA Cement ornare 2.52 Conerete.. 2.53. Reinforcement. 2.54 Structural Steel 2.6 Durability Crier 2.6.1 Concrete Grade. 2.62. Fire Design Requirements : 2.6.3 Flexure Cracking. 2.64 Barly Age Thermal and Shrinkage Cracking. 2.7 LOADS & REQUIREMENTS. A 272 273 2.7.4 Railway Loads... 2.1.5. Coefficient of Dynamic Augment 2.1.6 Derailment & Collision Loads 2.7.7 Fatigue UGI-D-BT043-GEN-003-RI.docx 1y) Phase- TED fo (AFcons) 278 Winton 2.7.9 Temperature. 2.7.10 Seismic Loads. 2.7.11 Construction/Erection Loads 2.7.12 Shrinkage and Creep.. 2.7.13 Movement and Distortion 2.7.14 Earth Pressure. 2.7.15 Surcharge... 2.7.16 Groundwater 2.7.17 Accidental 2.7.18 Differential Movement between In-line Structures . 2.7.19 Loading Combinations. 2.8.1 Vertical Deflection Limits 29.2. Flotation. s nas 2.10 Civil Design Work. 2.10.1 Excavation Base Stability... 2.10.2 Excavation Toe Stability 2.10.3 Waterproofing... 2.10.4 Water Control in Excavations.. 2.10.5 Underpinning of Existing Building Structures (EBS)... 2.11 Temporary Works.. 2H. General Prineiples...00n 2.11.2 Design of Temporary Excavation Support. 2.11.3 Ground Movements... 2.11.4 Construction Dewatering. 2.11.5 Ground Improvement 2.12 Connection Details. 2.12.1 Comers. 2.12.2 Construction Joins. 2.123 Slab to Wall Connections 2.12.4 Connections between Bored and Cut-and-Cover Structures. UGI-D-ET043-GEN-003-RI.docx 2FEN =... ‘AFcons| AFCO FRATRUCTRE TED ‘Sep al ry omgy 2.13 Instrumentation 2 3. LIST OF DESIGN CODES AND STANDARDS. Appendix A: 120 years’ Service Life Appendix B: Racking Analysis UGI-D-BT043-GEN-003-RI.docx 3Have: AFCONS| c ual AECONS INFRASTAUCTURE LINED Se a ey oy 1. INTRODUCTION ‘The contract UG-1 of the Metro-link Express for Gandhinagar & Ahmedabad (MEGA) consists of two underground stations and connecting tunnels and ramp viz. Kalupur and Kankaria East. This Design Manual summarises the proposed design criteria and other related parameters for the project related to structural aspects. This design Manual shall bbe read in conjunction with ‘outline design specifications’, (Part 2 — Section VI, Division G2 of tender document). It may be noted that, the basis for developing design & construction drawings shall be the tender document. This note intends to highlight the broad overview of design process for permanent works, temporary works for earth retaining structures and associated sequence of construction. Please refer construction ‘methods, construction sequence and other dimensional drawings for relevant details of various stations and asscociated structures included in the package. In addition to design data and criteria particularly specified in tender documents, key design data extracted from reference design standards, approach towards design of various elements, a summary of design methods, assumptions, software used have been provided in this document. ‘The report gives the basis for calculations including the applicable codes and standards, the material properties, the design method, the loading to be taken into account and the considered load combinations. The present document will be used as reference for the future calculation/design notes and structural drawings for the project. This report should be read in conjunction with the Geotechnical Interpretative Report (GIR) specific for each Underground structure. The GIR document will be submitted separately based on the factual geotechnical investigation report provided. | This volume is for structural aspects. Separate volumes should be referred for Architectural | and Geotechnical aspects. UGI-D-ET043-GEN-003-RI docx 4UGI-D-ET043-GEN-003-RI docx 5 2. 2A AFCONS) pea ep cy CUT & COVER STRUCTURES General Principles . Cut-and-Cover structures include all stations, station entrances/exits, vent shafts, pedestrian subways, utilities, services, ducts, Cut & Cover ramp structure (where applicable) and the like, other than bored/NATM tunnels, that are required to be constructed below ground surface including parts of above ground under this Contract. However, the provisions/stipulations in these specifications shall also be applied to all other works (including Bored and NATM tunnels) under the Contract, wherever considered applicable and relevant, ‘The cut-and-cover structure is proposed to be a rigid box section with permanent walls as external wall support system and beam-slab & column forming the internal structural framing. The roof slab shall support the soil and vehicular surcharge while the passenger and plant/services/structural loads are carried by the concourse slab/intermediate. The track and platform (including passenger and plant/services/structural) loads shall be supported by the base slab. The permanent walls shall resist the lateral earth and hydrostatic pressures in addition to the surcharge and services/structural loads. ‘The completed stations, station entrances, vent shafts and passenger subways shall comply with Contract water-tightness criteria (as per clause 2.1(3) of the Part 2, Sec. VI, ODS, Div. G2 — Cut & Cover structure). |. Where temporary walls are intended as part of the Permanent Works, the feasibility and suitability of such structure shall be justified. The following shall be considered in the design of his cut-and cover structures. 4, Method of construction, including temporary works and construction sequence. b, Groundistructure interaction, including the effects of temporary works. ©. Ground pressure, shear force and bending moment distribution during ‘construction and in the long-term. 4, Short-and long-term ground and groundwater response.Cons-Uot AFCONS 1a el oe nner . Other static loads changes such as; excavation, surcharge, traffic loadings and the like. f. Long-term surface water level changes. g. Dynamic (such as seismic or vibratory plant) loads and displacements. 6. For the purposes of assessing ground and groundwater pressures during service stage, the cut-and cover structures shall be considered to be effectively impermeable rigid box structures subject to "at rest" (Ke) earth pressure and earth pressure due to seismic force. 7. Structures shall be designed to minimize the effects (such as movement, distortion of the ground and the like) on all Existing Building Structure (EBS) that may be affected by the works and shall comply with all the requirements/provisions of the contract in this respect. Where necessary additional support for these EBS shall be provided. 8. Temporary ground support shall be designed in accordance with the requirements of the codes for live load surcharge and all other loads including seismic loads, 2.2 Design Principles 1, The design of all cut-and-cover structures shall take into account, but not be limited to the following: a) The variation in ground conditions along the alignment. b) The geological/hydro geological features and their variations including rock joint orientation and spacing etc. ©) The variation in engineering properties of soil or rock within the influence of the proposed works. @ All dewatering and groundwater cut-off systems required to maintain dry and stable’ conditions within all excavations required for these Works. ©) Any ground treatment before, during or after construction of the Works (e.g. groundwater recharge) which is required to st ize the ground and EBS in order to minimize adjacent ground and EBS movement and distortion.can AFCONS Contract - UGI 1) Methods by which the completed structure shall be secured against flotation. Any temporary dewatering system shall not be turned off unless and until provisions have been made to satisfy that the structure ‘will not be subject to leakage or flotation when the ground water returns to the design levels. 2) Differential groundwater pressures. 1h) Methods of waterproofing the completed structure. i) The magnitude of ground and EBS movements and distortions, and changes in loading conditions on these EBS that might be expected as a result of the works and how these will be mitigated so as to comply with any imposed constraints or so as to minimize disturbance to these EBS. i) Any difficulties that the Contractors intended plan might meet with in respect of access, clearances, working space and obstruction to excavation. K) Maintenance of traffic flows along roads including access to adjoining properties and roads. 1) Noise/vibration levels produced during construction and subsequent operation of the railway. m) Control-of heave, swell, piping and instability of the excavations. n) The effects of earthquake, vibration and vibration induced movements. 2, The following methods of construction shall be used cither individually or in ‘combination depending upon the particular requirements of the location, size and type of structure. a) Diaphragm Walls - Particular attention shall be paid to the wall and panel alignment, the stability of excavation, the mix and condition of the slurry, placement of the reinforcement cage, methods for forming and locating box-outs, ‘waterproofing of the vertical panel joints, placement of concrete, and the overall integrity and water-tightness of the formed wall including nominal cover to rebar. b) Secant Piles/Sheet Piles/Soldier Piles and Horizontal lagging - Particular attention shall be paid to the construction/installation of the piles and ground support systems to ensure their integrity and water-tightness and to provide adequate support to the ground during excavation, UGLD-ET043-GEN.003-R1 docs 7 SIComet -UOt AFCONS| UGI-D-ET043-GEN-003-RI.docr 8 Diaphragm walling is the preferred support method for the proposed deep stations, vent shafis/TBM Shafis/ other shafts and other deep excavations close to sensitive structures, Cut & Cover Box tunnel excavations at large to medium depths close to existing structures. Soldier Pile wall/ Bored Pile wall methods of support may be used for other medium excavations such as Cut & Cover tunnel, entrances/exits, utilities and services ducts etc., where site conditions/contraints so permit. Soldier pile with wodden lagging is not permitted. Only diaphragm wall and secant pile wall can be allowed to form part of the permanent works. Where the excavation involves soft ground in upper portion and hard ground (rock) in lower portion, the diaphragm/secant piles wall may be permitted to be terminated into hard ground at a level that provides adequate rock socketing and the required water-tightness, depending upon the geological and hydrological conditions. In such situations, particular attention shall be paid for design and detailing of the required shear-pin connection between the diaphragm/secant piles wall and the supporting hard ground below and also to the ground treatment (e.g. grouting ete.) to seal the junction between the wall and the ground and its surroundings to ensure their integrity and water-tightness. In’ the hard ground portion an adequately designed Reinforced concrete (RCC) permanent lining wall shall be provided. Particular attention shall be paid for design and detailing of the connection of this RCC lining wall to the various slabs (including base slab) as applicable and to the diaphragm/secant piles wall, depending upon the location/shapelsize/available space etc., to ensure integrity and ‘water-tightness of the so formed structural configuration. 2.3. Excavation support 1. General Detailed Design Report including calculations schedules and drawings for each proposed excavation support wall construction, prior to the commencement of any such works shall be prepared and submitted to the Engineer for his notice. This Design Report shall take into account but not be limited to the following: a) Earth pressure. b) Hydrostatic pressure. ©) Deck loadPee AFCONS) Contract - UGI Sipe na ae ony 4d) Surcharge loads. ©) Seismic and/or vibratory loads 4) Support types and arrangement. 8) Any other incidental load. h) Construction / deconstruction sequence. i) Calculated ground and adjacent EBS movements and distortions. 4) Calculated fluctuations in groundwater levels both within and outside of the excavation and support walls. 1k) Calculated changes in EBS loading conditions. 1) Construction plant and machinery movement and their maximum loads on structure 2. Method statement a) The method statement shall give full details of materials, plant, and operations involved in the construction of excavation support walls, The method statement shall be incorporated into the design report submission and shall include but mot be limited to the following details: i, Formation of the joints between panels and installation of water stops; ii, _ Method of producing the durable concrete; ii, Methods of handling within the excavations and disposing of groundwater outside the excavations; iv. Sequence of excavation and concreting of panels; ¥. Methods of instrumentation, monitoring and reporting of the performance of all adjacent EBS that may be affected by the works; vi. Methods of instrumenting, monitoring and reporting on the performance of the excavation support walls and their lateral support systems; vii, Type and construction of permanent lining wall; viii, Contingency and emergency procedures to be implemented in the event that monitoring indicates tolerances assosciated with the excavation support wall may be exceeded; b) Where temporary ground support is provided using polymer slurry, the following additional information shall be provided in the method statement 1% reinforcement |180 [Blockwork Wall Thickness 150 [Staircase (waists) 170 UGI-D-ET043-GEN-003-RI.docx 16 te aae Cc AFCONS) Spent ne ei ey Alll above ground ancillary structural elements shall be designed for a minimum fire resistance period of 2 hours. The minimum element thicknesses for this fire resistance shall be as follows: [Element [Minimum Sizes for 2-hour FRP (mm) |RC Slab Thickness 125 |RC Beam Width 200 IRC Column Sizes 300 IRC Wall Thickness 160 IBlockwork Wall Thickness 100 2.6.3 Flexure Cracking Formulae for Flexural crack width shall be as mentioned as per IRS CBC. Permissible crack width criterion for UG Station shall as per Table below: [Maximum [Nominal Cover] [Exposure Minimum [Element [Location ICrack Width] for Crack Width] \Condition (Cover (mm) (um) Icheck (mm) [Soil Face Severe 02 B 50 | Diaphragm Wall [Excavated Face | Moderate | 0.25 5 5 Soil Face Severe 02 50 5 [Roof Slab lExcavated Face |Moderate | 0.25 50 40 [Concourse Slab Moderate| 0.25 50 40 Soil Face severe 02 5 30 Base Slab [Excavated Face |Moderate| 0.25 50 40 [Retaining Wall |Soil Face severe 02 50 45 [Excavated Face |Moderate | 0.25 50 40 [Columns Moderate | 0.25 50 40 Water Tank Severe [0.2 50 45 (Contact with| [Beams Top Face] Severe | 0.2 50 45 oi UGI-D-ET043-GEN-003-RI docx nSeay ree! AFCONS| oc OX WERASTRUCTRE UTED Stet le ony [No Contact] Moderate] 0.25 50 40 |with Soil [Simply 70 40 ‘Beams Bottom Moderate] 0.25 |Supported & Side Face — (Continuous [Moderate | 0,25 50 40 Notes: Wrapping Mesh required in cover zone (of a mnimum size of A252 to BS:4483) for 4 hrs fire resistance protection requirements, 1. Ground slab/beam is protected by waterproof membrane and a minimum of 50- millimetre-thick blinding, the concrete surface is fully protected from the effects of Griving rain, and aggressive water. Therefore, the exposure class shall be considered to bbe moderate. 2. Nominal cover is measured to the outermost main reinforcement. 3. Nominal cover does not include any allowance for construction tolerance. 4, External surfaces are fully protected by Architectural rendering and cladding and hence shall be considered to be having moderate exposure condition. 5. For underground structures, minimum diameter of main reinforcement bar all be 12mm and for distribution it shall be 10mm, for underground structures. 6. Minimum reinforcement as per IRS: CBC. For underground section in contact with NALLAH/Sewer water with or within the influence zone, minimum required cover must be increased by a minimum if 15mm. Early Age Thermal and Shrinkage Cracking 1. Suitable reinforcement shall be designed & provided to prevent early age thermal and shrinkage cracking for walls and slabs more than 250 millimetres thick and subjected to internal and external restraints during construction. The thermal and shrinkage strains due to early age temperature differences and shrinkage shall be accounted for in the design of reinforcement for cracking. 2, Generally, bundling of the bars and more than one layer of bards is not preferred. ‘Smaller diameter bars in any direction are placed at closer intervals to prevent carly age thermal and shrinkage cracks. The limits specified in table of Cl. 2.4aes AFcons) tne Pa ep one above shall be imposed. Guidance can be sought from CIRIA C660 on Early Age ‘Thermal Control of concrete. 3. Anti-crack reinforcement shall be provided in all wall & slabs more than 250mm thick to distribute cracking arising from shrinkage, early thermal and temperature effects. Recommendations given in C1 3.9.4.19 of part 1 of BS 8110 shall be followed with the modification for Minimum reinforcement as listed below: * For grade 500 and above — 0.125% of the concrete cross-sectional area. * For grade 250 — 0.15% of the concrete cross-sectional area. In addition, C/e distance spacing between the bars should not be greater than 160mm. 2.7 LOADS & REQUIREMENTS 2.7.1 General Unless specified otherwise, the principles of structural design for concrete and steel elements shall comply with codes given in tis contract and precedence of codes shall be followed respectively. For design life and durability considerations, the Sub-Sections 2.4 and 2.6 shall be referred to. 2.7.2 Nominal Loads For the purpose of computing stresses and dformations, the following minimum load types and consequential effects shall be taken into account as applicable. [Dead loads (including notional loads) DL imposed (Live) loads LL {Superimposed Dead loads SIDL [Earth Pressure EP [Railway loads RL Surcharge SR (Centrifugal CF | Hydrostatic we: find Loads WL |Accidental AC (Temperature loads TE [Buoyancy force BF [Seismic Loads EQ [Braking/Traction BR (TR) [Construction / Erection ER |Collision load cL (Dynamic DY — |Derailment load DR Fatigue FG [Shrinkage UGI-D-ET043-GEN-003-RI docx 19eile Phase-1 Contract - UGI AFCONS! eee ee any (Creep CP [Movement and Distortion ~ MD ‘| 2.7.3 Design Loads Design shall include all of the following loads: 2.7.3.1 Dead Loads Self-weight of the materials shall be calculated in accordance with IS 875:1987 Part 1 2.7.3.2 Superimposed Dead Loads and Imposed (Live) Load ‘The minimum distributed and concentrated loads shall be in accordance with Table below and contract specifications Superimposed Dead Loads (SIDL) & Imposed (Live) Loads (all loads are unfactored) ‘Superimposed Dead Load Imposed Load Description | Fimishes | Partitions | Ceiling & UDL. Concentrated (kN/m*) | (Nim?) | Services (KNim’) Load (KN) (vim?) (Note2 & 3) Station Concourse 24 10 10 60 a Area (Note 5) | qnote 6) | (Note 6) (Note 1) Platform 24 10 : 60 isa Area (Note 5) | (Note 6) (Note 1) Track (Note 11) Refer Section 3.3.3 Stairs and 1a 1.0 60 ra Landings (Note 4) . (Note 6) (Note 1) 2 General Plant | 2.4 10 100 a Rooms, Pump | (Note 5) - (Note 6) (Note 7) ° General 24 10 1.0 FA ag Office (Note 5) | (Note 6) | (Note 6) Staff Rooms | 24 : Ee 60 75 E (Note 5) (Note 6) Toilets, 24 10 10 6.0 15 Change Note 5) | (Notes) | (Note 6) Store ae) = fd 10.0 150 (Note 5) (Note6) UGI-D-ET043-GEN-003-RI.docx 20ree AFCOnS| Saeet neem omnr Water Tank, 24 20.0/ (Water Ht Fire Tank (Notes) ° - +0.3m) : Chiller 24 . 10 | 100 | 15.0 ote Rooms (Note 5) (Note 6) (Note 7) D Transformer, 24 10 20.0 20.0 (Note Sub station | (Note 5) 7 (Note 6) (Note 7) n ‘Switch Gear 24 a 1.0 15 100 | Plant Room | (Note 5) (Note6) | (Note 7) Root Shab) 24 . 10 Soil Load + 20 7 (ote 5) (Note 6) Wote 8 & 9) Notes: 1, Stairs and landings to be designed for the same load as the floors to which they give access with a minimum of 5 kN/m? and a maximum of 10 kN/m?, 2. Concentrated loads act on a square of 300 mm each side, 3. As specified or wall loads in accordance with layout in architectural plan, whichever is greater. 4. All loads are unfactored. 5. Minimum of 100 mm thick screed on top, unit weight of 24 KN/m’. 6. As specified above or the imposed load from services fixed to the underside of floor whichever is greater. 7. The design loads shall be actual plantlequipment loads or the ones specified above, whichever is maximum. For seismic design plate/machinery loading shall be considered as Super Imposed Dead Load. 8, Backfill / Barth Load Shall be calculated for the available soil depth for a unit weight of soil of 20 kN/m?. 9. Live Load surcharge of 20 kN/m’ shall be considered for slabs subjected to traffic surcharge. 10. The Construction Load on concourse Level shall be minimum 10 KN/m? 11. The Track loads due to: a) Track work- UIC rails and other fittings and accessories. b) Track bed - RCC blocks or concrete pour or precast slabs in RCC with inserts and fittings in case of unballasted track (450 to 600 mm thick) or PSC sleepers over 250/300 mm of ballast for ballasted track.fay AFCcOns| iconmact UG! con merce we ©) Other loads - as per Indian Railway Standards (IRS) and Bureau of Indian Standards GIs). 2.7.4 Railway Loads Each component of the structure shall be designed/checked for all possible combonations of these loads and forces. They shall resist the effect of the worst combinations. 1, Vertical Train Live Load The Train live Load will have the following axle configuration Axle loads = 16 tons ‘Maximum number of successive cars: 6 where, L=22600mm a= (balance) b= 2200mm to 2400mm (Length of a rigid wheel base for single bogie) b + c= 14800mm + 250mm (Distance between bogie centres) ‘Maximum number of axles shall be loaded on the station to arrive at maximum longitudinal force, max shear and max BM. Since both the tracks shall be supported by single slab, hence superstructure and substructure shall be checked for one track loaded condition as well as both tracks loaded condition Maximum number of axles shall be loaded on the structure to arrive at maximum Jongitudinal force, maximum shear and maximum bending moments. The structure shall be checked for one-track load condition as well as (both) 2-tracks load condition, 2. Lurching Lurching forces are caused by the temporary transfer of part of live loading from one rail to another, In accordance with BS5400: Part 2 — Specification for Loads — Clause 8.2.7, 56% of track load shall be considered acting on one rail concurrently eee A ieCar eat AFCONS| (See ae Coon ny with 44% of the track load on the other rail (See Figure below). This redistribution of load need only be taken into account on one track where members support two tracks. Lurching may be ignored in the case of elements that support load from more than two tracks, + ¥ 3. Nosing ‘An allowance shall be made for lateral loads applied by trains to the track. In accordance with BS5400 : Part 2 — Specification for Loads — Clause 8.2.8, nosing force shall be taken as a single nominal load of 100KN, acting horizontally in either irection at right angles to the track at rail level and at such a point as to produce the ‘maximum effect in the element under consideration. It shall be applied on both the straight and curved track. For element supporting more than one track a single load as specified shall be taken. This force shall always be combined with the vertical train load. However, it shall be neglected in combination with scismic loading. 4. Horizontal Train Live Load Braking and Traction + Braking load is taken as 18% of the unfactored vertical loads. * Traction load is taken as 20% of the unfactored vertical loads. ‘+ Where the structure carries two tracks, both tracks shall be considered to be occupied simultaneously. Traction forces shall be considered as acting ‘on one track and braking forces acting on the other, with both forces acting in the same direction simultaneously to produce the worst loading condition, in the rails and supporting elements. ‘* Provision shall be made in supporting elements for the effects of horizontal and longitudinal forces transferred to rails, especially in ballast less deck. ‘© Additional stresses while considering this contingency may be proposed by the Contractor for Notice by the Engineer. Forces shall then be UGI-D-ET043-GEN.003-RI.docx B te cSConst UG \AFCONS| itp te ay nme calculated for the case of interaction between continuous welded rails and a concrete structural support resulting from temperature differentials of the rail and concrete base. ‘© Longitudinal forces shall consider the effects on stability and safety of the applied axle-loading arising from a broken rail on a ballastless track. ‘* As per RDSO guidelines on seismic Design of Railway Bridges-January 2015, in transverse/ longitudinal seismic condition, only 50% of gross tractive effort/braking force shall be considered ‘* Forces due to temperature variation in long welded stee! rail. 5. Centrifugal Force - Centrifugal Force shall be considered as per IRS Bridge Rules. 2.75 Coefficient of Dynamic Augmentation Impact factor for longitudinal analysis shall be 1.2 while for transverse analysis the same shall be 1.67. 2.7.6 Derailment & Collision Loads A) Derailment Loads shall be in accordance with Clause 8.5.2 of BS 5400, Part 2 with the exception that condition (¢) shall not apply to underground structures. B) The Structural elements within 10m of the center line of track, which are at risk from collision by railway vehicles, shall be designed for the following collision loading. Collision loads shall be considered at ultimate limit state only: i. For Station platform edges a nominal load of 1000KN acting horizontally and normal to the platform slab edge over a length of 2.2m, shall be considered. ii. For all structural elements other than platform edges a nominal point load of 1250KN acting horizontally in any direction at the top of the element level, or 1.2m. above the adjacent rail level, whichever is less, shall be considered. Where the soffit of the structural element occurs between 1.2m and 4.0m above adjacent rail level, the load shall be applied at soffit level. The above-mentioned loads are indicative only. In case the relevant Authority specifies a different loading for Derailment and/or Collision, the Contractor shall adopt the same. iv. The adjacent structures are to be protected by direct means (e-g., strengthening) or, indirect means (¢.g., repositioning rail alignments or providing barriers) to ens UGL-D-ETOA-GEN-O05-81 docx m4 SG(7AUE CAN Contec -vc AFCONS) these structures are still functional after an impact occurs. It is required to mitigate impact effects on elements that may be adversely affected without enhancements. 2.7.7 Fatigue 2.79 UGI-D-ET043-GEN-003-RI.doct 25 The nominal loading for the design of members in accordance with fatigue requirements shall comprise trains with six individual cars each having four axles, the axle loads and vehicle lengths as specified in 2.7.4 Fatigue load histories shall be evaluated to provide valid and representative design spectra, with stress histories analysed by the rainflow or equivalent method, both in conjunction with the projected annual tonnages of rail traffic per track. The provisions ‘of BS 5400 Part 10 Clause 9.3.3 or other relevant methods may be used as a rigorous, ‘method of evaluation of compliance with fatigue criteria, ‘Wind load Wind loading may affect the surface elements of inderground structures such as vent- shafts, entry structrues, cooling towers and ancillary structures. The effects on the temporary structures shall also be considered. For ebove ground structures, the wind loads will be taken as per IS: 875 Part 3, Wind effect from venting in below-ground areas shall be designed appropriately Temperature Forces may arise from a thermal gradient within a structural element; this may be from. external sources or, in the case of fresh concrete, from the intemal heat of hydration during curing. ‘These forces shall be considered in combination with those from other types of loads to determine the worst loading condition. ‘Locked-in’ forces from temperature effects (exg., from curing of concrete) shall be considered as a permanent load and due allowance made in the design for such. ‘Temporary works with structural steel bracing elements or similar may also suffer adverse effects from thermal strains. These thermal strains shall be suitably accounted for and suitable measures shall be taken to avoid losses in preloading and subsequent excessive deformations in structural members.Pee! AFCONS| Contract - UGI cos uRASTUCTURE UTED 2.7.10 Seismic Loads General Seismic effects shall be considered on all structures, including underground structures. Evaluation of seismic loads shall conform to RDSO guidelines on seismic design of Railway Bridges, the relevant Indian Standards or to other relevant seismic standards or references where the Indian Standards are either not applicable or do not provide sufficient guidance or formulaes. The zonal demarcations for levels of seismicity shall be evaluated as per IS 1893- 2002. Where two or more zones are deemed to act on a structure, the more onerous level of compliance shall be used in the design when a static lateral force analysis approach is used. Alternatively, the structural loads can be directly evaluated using a dynamic lateral force (response-spectra) approach. The structure is required to be evaluated as an ‘important service and community building’ for the purpose of “functional use’ as stated in IS 1893. Seismic design using a response-spectra approach requires adopting the more onerous loading from strong- ‘motion data from recent seismic events in the region or from earthquake events ‘that have occurred in the similar ground conditions and suitably factored accounting for intensity in the region. The effects of load changes and deformation as a result of soil behaviour (eg, liquefaction) shall be allowed for in the assessment and design. Seismic design for above-ground structures Earthquake design shall follow RDSO guidelines on seismic Design of Railway Bridges — January 2015 and IS 1893 for Seismic requirements and the ductile detailing of reinforced concrete structure shall comply with IS 13920 & IS 4326. The design base shear shall be calculated based on recommendation given in RDSO guidelines on seismic Design of Railway Bridges — January 2015 and IS: 1893. The total design lateral force or design seismic base shear (VB) along any principal direction shall be determined by the following expression: VB = AW Where Ah = Design horizontal acceleration spectrum value, using the fundamental natural period Ta calculated according to clause 7.6 of IS 1893-2002 (Part 1) in the considered direction of vibration, and; W-= Seismic weight of the building calculated according to cl. 7.4.2 of IS1893- 2002 Part 1 UGI-D-ET043-GEN-003-RI.docx 6Phase { er AFCONS)| 2.741 2742 The design horizontal seismic coefficient A, for a structure shall be determined by the following expression : An= (ZT Sa)/(2 Rg) Provided that for any structure with T < 0.1 s, the value of Ah will not be taken less than Z/2 whatever be the value of IR Where, Z=Zone factor. The project site falls within Zone Ill. Zone factor (Z) of 0.16 shall bbe taken as per IS 1893-2002 (Part 1). 1 =Importance factor shall be taken as 1.5. R=Response reduction factor shall be as per Table 7 of IS 1893, Sa/g = Average response acceleration coefficient for soft soil or medium soft soil as, given by RDSO guidelines based on appropriate natural periods (Ta) and damping of the structure, These curves represent free field ground motion, Damping for the concrete structure shall be assumed as 5%. For N>100 soil shall be considered as stiff soil or soft soil. Rock shall be defined by RQD criteria only. [PGA for DBE should be 0.12g is considered for design purposes. The limportance factor of 1.5 is already built in these values. For UG Station box, sesismic effects will be calculated using Free Field Deformation ignoring the soil-structure interaction. For details refer Appendix-B. Construetion/Erection Loads ‘The weight of all permanent and temporary materials together with all other forces and effects which can operate on any part of structure during construction shall be taken into account. For construction stage only ‘ULS design checks’ shall be made keeping. partial safety factors for imposed loads as 1.3 as specified in ‘outline design specifications’, (Part 2 ~ Section VI, Division G2 of tender document). Allowances shall be made in the permanent design for “locked-in” stresses caused in any member during construction. Shrinkage and Creep Provisions shall be made for the effects of shrinkage and creep within concrete structures. This includes interface shear transfer mechanisms as a result of differential UGI-D-ET093-GEN-003-RI.doct n iF cspeel AFCONS!| conan OG cons austere wud Sept lr ony 2.113 2.714 2.7.15 creep and residual shrinkage effects from staged casting of concrete elements. The shrinkage and creep strains shall be included in calculation of long term deflection of all structural elements in accordance with Annexure C of IS 456-2000 and the limits specified in IS 456 and IS 800 shall be applied. Movement and Distortion Consideration of the forces resulting from differential movement (distortion) of foundation elements shall be checked as appropriate. All movements and distortions ‘must not be greater than the least of the following limits: = adhered to in the Relevant Codes = as acceptable to the Relevant Authority ~ as specified in the Contract. These may be architectural, structural, rail performance or other types of limitations currently in force. Earth Pressure Underground vertical elements that are in direct contact with the ground shall be designed as permanent retaining walls to resist the lateral ‘At Rest’ earth pressure. The dynamic increment or seismic force on soil as per RDSO guidelines shall also be be considered. The earth pressure coefficients shall be deduced based on Geotechnical Interpretative Report separately. Surcharge 1) For existing buildings and other existing structure occupying areas around the excavation, detailed assessments based on building and foundation type, and loading are to be carried out to determine the applied loads and other impacts of such building loads on the proposed underground structure. For future buildings or planned infrastructure, the appropriate Authorities and Employer/Enginecr shall be consulted for obtaining the details for taking into account the surcharge to be considered for the design of underground structures. 2) Where provision for a specific fature structure is not made, a minimum uniformly distributed surcharge of SOkPa at the design finished ground level shall be assumed. In case, the actual building load surcharge exceeds SOKPa, the actual value shall be considered. UGI-D-ET043-GEN-003-RI.docx 2B te csSAN Cer AFCONS) 3) Footpath live load shall be adopted as SkPa, 4) A vehicular live load surcharge of 20KPa shall be adopted for the design of all underground structures, 5) A general loading due to construction plants and equipment (during construction stage) shall be taken to be a minimum of 10kPa. For heavy plants and equipment, the actual loading shall be determined individually and considered in the design. 2.7.16 Groundwater 1) Loads due to water pressure shall be calculated using a unit weight of 10 kN/m? for fresh water and a unit weight of 10.3 KN/m* for sea-water. 2) Should liquefaction of soils be a potential risk then the design water table level for permanent structures shall include layers affected by liquefaction if this is above the design groundwater levels 3) The effects of temporary drawdown, seepage and base heave effects shall be considered in design of the temporary works, and catered for in the permanent works if there is a ‘locked-in’ effect from carry-over forces. The extent of the temporary walls shall be sufficient to mitigate the effects of such loads during construction. 4) The full uplift force due to groundwater shall be considered in the design both in the temporary and permanent design stages of structures. The effects of flotation loads shall be allowed for in the design both in the temporary and permanent design stages. 5) The proposed structures (primarily the stations) may act as obstructions to groundwater movement. The Contractor shall design and subsequently construct for unobstructed movement of the groundwater through and around these structures so that these structures do not result in changes to the phreatic surface that exceed normal expected diurnal fluctuations. Accidental The design shall allow for impact loading of 50 KN acting at any position & any direction on temporary works or on partially completed permanent works. UGI-D-ET043.GEN-003-RI.doct 29ee 2.7.18 Differential Movement between In-line Structures AFCONS)| ‘Sper rl nip omro Differential movement between adjacent in-line structures arising from static and/or dynamic loading shall be evaluated. Due allowance for such shall be incorporated into the size of the structures and detailing of joints to ensure that the total and differential movements, including distortion and relative rotation, between in-line structures shall not exceed the serviceability limits of the structures for the design life of the structures, 2.7.19 Loading Combinations Each component of the structure shall be designed and checked for all possible combinations of applied loads and forces. The load factors and load combinations for ultimate and serviceability limit states are specified in the following table. ‘Ultimate Limit State Load Combinations Load Dead Load (DL) | Imposed Lond (iL) | Grounsan’ Water | Wind | Seismic Combination ood a ‘Adverse | Benefecial | Adverse | Benefecial | Adverse | Benefecial | (WL) | (EQ) 1.DL+ | SIDL+ TL a) ¢ 1s - [3s o ; _ 2.DL+ ] SIDLYEQ ag 09 S - | - - 1s | 1s 3.DLt SIDL#IL + 12 - 12 S 12 S 12 | 12 EQ | 4.Construction Stage(**) 1s - 13 - 1s - - : 5.Collision / Accidental i 1.0 1s - 1s 10 - - Notes: 1. Load combination 4 will be used in checking temporary works proposals and checking the structure during temporary construction stages. The imposed load is the construction imposed load. 2. For checking structures at the Extreme water levels, the partial factors of safety for water loads shall be reduced as per table ECO7 of the ODS. 3. Structural steel design load combinations and partial factors of safety for the design of ‘structural steelwork are to be in accordance with IS 800 - Code of Practice for the Structural ‘Use of Steel Work. UGI-D-ET043-GEN-003-RI docx on Is)PAE 23.01 (AFCONS| ‘Sipecg ne mp Conny 4, Earthquake loads are reversible. 5. 50% imposed load is to be used in line with the building mass calculated for seismic loads in load case 2 & 3. 6. Creep, shrinkage, temperature and differential settlement are not considered in combination with the lateral loads at ultimate limit state. Creep and shrinkage effects will usually be ‘minor for building type structures, no specific calculation will be necessary for Ultimate limit state. 7. Wind load combinations are applicable for above-ground structures and shall be considered in addition to the other combinations. 8. Wind and earthquake load will not be considered to be acting simultaneously. 9. (#*) For those structural members which are load bearing during the construction stage and subsequently form part of the Permanent Works, the Serviceability Limit State(SLS) checks shall be carried out both for” Construction” and “Service/Operation” stages. 10, Also for factor SIDL loads reference shall be made to BS5400 Part 4 and BD/37(including, for ULS and SLS). State load Combinations tancominin | Dnt | ym Crm | win ent 1. DL+SIDL+L 10 10 1.0 - - 3. DL+SIDLHL+EQ 1.0 1.0 10 10 10 2.7.20 Design Conditions ‘© Structure shall be designed for the following four main conditions a) “Construction” - during and immediately after construction of the Works. b) “Service/Operation” - during general operation of the completed facility. ©) “Accidental” - during “Construction and/or “Service/Operation” when unusual incidents, such as collision/derailment etc. occur, which may alter loading conditions. UGE D ETS GENE 4 te SesToy AFCONS| Contract - UG cons nastmCTUR UTD 4) “Extreme” - during “Construction and/or “Service/Operation” when ‘groundwater may rise to unusually high level. ‘* The assumed partial load factors and overall design factors of safety for the four main conditions shall be included with the calculations to determine and design for the most critical cases as provided in his design submissions ‘¢ For ground loads on cut-and-cover structures, the worst combination (minimum and maximum) of lateral loading shall be considered for the Construction and Service/Operation condition. 2.8 Deflection Criteria The deflection limitations imposed in 1S 456 and IS 800 shall be followed for Concrete and Structural Steel elements used in permanent works respectively. 2.8.1 Vertical Deflection Limits The deflection of structure or part thereof shall not adversely affect the appearance or efficiency of the structure or finishes or partitions. The deflection shall be limited to the following. 2.8.1.1 Diaphragm wall ‘The vertical and horizontal deflections of the D-wall are to be limited only in the cases, ‘where there is an existing building in the close vicinity of D-wall. The traditional methods shall be used to estimate the settlement at ground level (volume loss) due to deflected shape of Diaphragm wall. The settlement analysis shall be carried out along the alignment and the existing buildings shall be checked after review of information available in the building assessment and risk assessment report. 2.8.1.2 Concrete structures ‘© The final deflection due to all loads including the effects of temperature, creep and shrinkage and measured from the as-cast level of the, supports of floors, roofs and all other horizontal members, should not exceed span/250. © The deflection including the effects of temperature, creep and shrinkage occurring after erection of partitions and the application of finishes should not normally exceed span/350 or 20 mm whichever is less. UGI-D-E1043-GEN-003-RI docx 2Pay ee ot AFCONS| ons RAST MED hme ro ep enna ‘The settlement analysis shall be carried out along the alignment and the existing buildings shall be checked after review of information available in the building assessment and risk assessment report, 2.8.1.3 Steel structures Designs shall comply with the limits defined in IS 800:2007. a) Plunge-in steel column Plunge in steel column shall be designed considering stress limit as per IS 800:2007. The final section for service stage shall be RCC structure only. 2.9. Design Groundwater Levels 291 General ‘The groundwater levels to be assumed in design for various stages or conditions shall be as follows: “Construction” — groundwater level at measured maximum elevation + 1.5m. “Service/Operation” ~ Maximum HFL as per last 50 yrs data + 1.0m, “Accidental” ~ groundwater level at ground level. “Extreme” — Maximum HFL as per last 50 yrs data + 2.0m 2.9.2. Flotation + A-minimum soil cover over the underground structures shall be 2.0m or depth to the underside of major utilities which ever is greater. + Structure shall be checked against flotation during service stage for groundwater level at ‘Ground’ as well as actual groundwater level for construction stage. * For protection against flotation in the fully dry internal condition, the following shall apply. a) A load factor of 0.9 shall be applied to the self-weight of the structure, including the first stage only of the track concrete. The minimum selfweight of proposed Over Site Development structures (including structural weight and any backfill proposed on the over site structure) may be included in the flotation assessment. b) A load factor of 0.9 shall be applied to the weight of backfill material over JE fhe structure. Fe(ononn)a) = ee /