SECOND PENANG BRIDGE LAND EXPRESSWAY PACKAGE 2A : PROPOSED UPGRADING WORKS OF BAYAN LEPAS EXPRESSWAY FROM BATU MAUNG TO THE PENANG BRIDGE DESIGN CALCULATION FOR T-BEAM & PRECAST SEGMENTAL CROSSHEAD BASE MOULDS Report No. : PKG2A/UEM/KKSB/REPORT_100 Issue No. 1 Issue Date July 2013 Prepared for : KEN KEONG SDN. BHD. No. 39-2, Jalan PJU 5/11, Dataran Sunway, Kote Damansara, 47810 Petaling Jaya, Selangor Tel : +603-6141 6398, Fax : +603-6141 6362DDESIGN CALCULATION SHEET Made By: _MK/OKB Date: July 2013 SUBJECT: T-Beam and Precast Segmental Crosshead Mould Base Page z Introdu: This calculation outlines the design calculation for the T-Beam Base Mould and Precast Segmental Crosshead Base Mould. The base mould will be supported by plywood, RHS and timber for the T-Beam. At both edges of T-beam, the weight of T-Beam will be supported by plywood, RHS and concrete slab. Concrete slab is used to spread the load to bigger area once the beam is stressed and hogged. ‘The calculation for T-Beam is appended in Appendix A. For the precast segmental crosshead, the weight of segmental crosshead will be supported on falsework which is not included in this report. The falsework is placed on concrete slab and this report outline the bearing pressure calculation and reinforcement needed for the slab. The calculation for concrete slab for precast segmental crosshead is appended in Appendix B Contractor had carried out numbers of Makintosh Probe in the T-Beam and precast segmental crosshead casting yard to verify the allowable bearing pressure. The Makintosh Probe test result for T-Beam casting yard are appended in Appendix C while result for segmental crosshead storage are appended in Appendix D. ‘This report excludes calculation for storage of segmental crosshead.DESIGN CALCULATION SHEET [Job No 10005) Made By: MK/OKB Date July 2013, Page 2 SUBJECT: T-Beam and Precast Segmental Crosshead Mould Base APPENDIX A : T-BEAM BASE MOULD DESIGN‘DESIGN CALCULATION SHEET [fob No T0005, SUBJECT: _T-Beam Mould Base a) ¢ A) Intermediate Section of T-Beam Mould Base ‘T-Beam Weight Calculati 1800 <—___—_, 200 300 Area of T-Beam leon = (1.8 x0.2) + (0.66 x0.2) + 0.5 x (0.3 +0.66) x0.16 + 160 | (1.8-0.2-0.2-0.16)x0.3 200} = 0.941 m' 660 Say Area of T-Beam = 10m'/m Width of T-Beam Base = 60mm UDL on Plywood 1/0.66 25 kN/m? 38 kN/m? b) Arrangement of Mould Base Plywood Design Check i Senin 660 J 1m long 50x75x3mm RHb @ 750mm spacing =) -——— 3"x6" timber runner ‘50mm Sand Bedding JIRNYTRWY RWS Well Compacted Groun« Bending Check Maximum Bending Moment = wl’ / 10 = 38x0.2"/10 = 0.152 kNm/m Section Modulus, Z = bd’ /6 = 1000x12°/6 = 24,000 mm?DESIGN CALCULATION SHEET T0005 [Made By: __MK/OKB. Date Tuly 2013 Page BJECT: _1-Beam Mould Base Bending Stress, o = M/Z 0.152 x 10° / 24000 =6.3.N/mm? Allowable Working Stress for Bending for 12mm thk. Plywood ~ Parallel to face grain 11.07 N/mm? ~ Perpendicular to face grain = 7.57 N/mm* Bending stresses < allowable working stress for bending OK! ii) Shear Check Max Shear stress = 1.5 x0.6 wl / (bd) 1.5 x 0.6 x 38 x 0.2 x 1000/ (1000 x 12) = 0.57 N/mm? Allowable Working Stress for rolling shear for 12mm thk. Plywood - Parallel to face grain = 0.91 N/mm? ~ Perpendicular to face grain = 0.63 N/mm? Shear stresses < allowable wor ig stress for Shear ==> OK! ili) Deflection Second Moment of inertia, |, = 143 x 10° mm* Elastic Constant, E (Parallel to face grain) = 8.45 kN/mm? Deflection, 8 = wi*/145E1 = 38x 200°/ (145 x 8.45 x 143 x 10°) =0.35mm ——_ OK! Bending stress < Permissible Bending Stress ii) Shear Check Max Shear force = 1.5 x wl =15x84x0.75 x05 = A7N Shear Capacity = p,x(0.6A) = 275x0.6x2x2.4x75/ 1000 = 59.4 kN Low ShearDESIGN CALCULATION SHEET [SUBJECT: T-Beam Mould Base ili) Deflection Elastic Constant, E =195 kN/mm? Second Moment of Inertia, , = bd? / 12 = 0.3746 x10° mm* Deflection, 5 = Sw I*/ 384E1 =5x8.4x 750° / (384 x 195 x 0.3746 x 10°) =0.47mm ——_ OK! ii) Shear Check Max Shear Force =1.5xP 15x63 = 9.5kN Shear Capacity = p,x (0.6A) = 275x0.6x2x3x 75/1000 =74kN > Low ShearDESIGN CALCULATION SHEET [lob No [Made By: MK/OKB Date July 2013, SUBJECT: T-Beam Mould Base Page: 7 iil) Deflection Elastic Constant, E = 195 kN/mm* Second Moment of Inertia, |, 57.75 x 10° Deflection, 5 = 23 PI*/ 648 El 3 x6.3 x 610° / (648 x 195 x 0.5578 x 10°) =0.28mm < least of 3mm or 0.003L = 1.8mm f) 3%x6" Timber Runner - Ground Bearing Pressure 3.2KN G3KN 6.3KN 3.2kN 610mm Bearing Pressure Total Load (6.3 +3.2)x2 =19KkN 50 x2 x 500 (6" in horizontal) = 150000 mm? Ground Bearing Pressure = 19 x 1000 / 150000 = 127 kN/m?DESIGN CALCULATION SHEET [ob No Made By Date SUBJECT: T-Beam Mould Base B) End Section of T-Beam Mould Base a) T-Beam Weight Calculation 660 1600 Area of T-Beam = 0.6616 = 1.06m?/m Width of T-Beam Base = = 660mm UDL on Plywood 1.06 / 0.66 x 25 kN/m? = 40.2 kN/m? b) Arrangement of Mould Base 40.2 N/m? 650 <—_a 12mm Plywood 38x75x2.4mm thk. RHS }<—— 2.0m x 2.0m x 0.25m thi 50mm Sand Bedding TTR TRV TRY 7X wecompactes cro ) Plywood Design Check i) Bending Check Maximum Bending Moment = wi? / 10 =40.2x0.27/10 = 0.161 kNm/m Section Modulus, Z = bd” /6 = 1000 x 12°/6 = 24,000 mm? Page rc. slabDESIGN CALCULATION SHEET [Job No 10005 [Made By: MK/OKB Date: July 2013, Page 9 SUBJECT T-Beam Mould Base Bending Stress, o = M/Z = 0.161 x 10°/ 24000 = 6.7 N/mm* Allowable Working Stress for Bending for 12mm thk. Plywood ~ Parallel to face grain 11.07 N/mm? 57 N/mm? = Perpendicular to face grain Bending stresses < allowable working stress for bending ii) Shear Check Max Shear stress = 1.5 x 0.6 wl / (bd) = 15 0.6 x 40.2 x 0.2 x 1000/ (1000 x 12) = 0.60 N/mm? Allowable Working Stress for rolling shear for 12mm thk. Plywood - Parallel to face grain = 0.91 N/mm? Perpendicular to face grain = 0.63 N/mm? Shear stresses < allowable working stress for Shear iil) Deflection Second Moment of inertia, |, = 143 x 10° mm* Elastic Constant, E (Parallel to face grain) = 8.45 kN/mm* Deflection, 8 = wI*/ 14561 = 40.2 x 200° / (145 x 8.45 x 143 x 10°) =0.37mm —— OK! Shear Check Max Shear force = 1.5 x wl =15x8.4x075x05 4.7 kN Shear Capacity = p, x (0.6A) = 275 x0.6x2x2.4x75 / 1000 = 59.4kN ==> Low Shear Made By: _MK/OKB Date: July 2013, Page 10DESIGN CALCULATION SHEET SUBJECT: T-Beam Mould Base iii) Deflection Elastic Constant, £ =195 kN/mm? Second Moment of Inertia, |, = bd? / 12 = 0.3746 x10° mm* Deflection, 8 = Sw I*/ 38461 5.x8.4 x 750° / (384 x 195 x 0.3746 x 10°) =0.47mm ——_< least of 3mm or 0.003L = 25mm, e) 2.0m x 2.0m x 0.25m thk. B.C. Slab 610mm 2.2kN E Atothitetatetatetet 200mm, 3 4kN | 2.2kN i) Bearing Pressure After tedon of T-Beam is stressed, the beam will hog and weight of T-Beam will be concentrated on the both edge of support. Consider the loac Total T-Beam Load 1.0.x 25x 38.6 965 kN Consider the load will spread in 1:1 to the concrete soffit. Ground Bearing Pressure = 965 /2 / {{0.7 + (0.25 x 2)] x [2.0 + (0.25 x 2)]} = 160 kN/m* Allowable bearing pressure will be calculated in later section. [rob No 10005 Made By: MK/OKB duly 2013,DESIGN CALCULATION SHEET SUBJECT: T-Beam Mould Base [lob No Date Page ii) Moment Check Moment (ULS) @ A = 160 x 1.5 x ([2 -0.61]/2)' /2 A =58kNm/m (Moment at edge of cantile\ tttt | TT z=d [0.5 + (0.25 -k/0.9)"7] 95d Aoreg= M / 0.87 f,2. = 58x 10°/ (0.87 x 460 x0.95 x 210) = 727 mm*/m A, min= 0.15 / 100 x 1000 x 210 = 315mm?/m Provide T12- 150 (Bot) (565 mm’/m) - Both ways Provide T12 - 250 (Top) (452 mm?/m) - Both ways ver) 10005 MKJOKB Tuly 2013 2,DESIGN CALCULATION SHEET [Job No 10005, Made By: MK/OKB: Date July 2013 T-Beam Mould Base Page: 3, SUBJECT [ TA a (220mm CENTRE TO CENTRE) a f sree mNBER (6° THK, CRUSHER RUN EXISTING GROUND EBEAM BASE MOULD. (AT INTERMEDIATE SECTION’ See 12m THK, PLYWOO! CENTRE SScentae) 2.0m x 2.0m x0.26m —~ Ax \ THR CONCRETE SLAB : STAR CRUSHER RUN exisTING GROUND T.BEAM BASE MOULD. (AT EDGE SECTION) FOR 2m LENGTHDESIGN CALCULATION SHEET SUBJECT: T-Beam Mould Base Allowable Bearing Pressure at Site (T-Beam Casting Yard) ~ Contractor has carried out numbers of Makintosh Probe Test at the T-Beam casting yard. ~ In the casting yard planning, there will be 7 nos. of casting area = 40 nos. of Makintosh Probe test has been carried out to verify the allowable bearing pressure for design purpose. ~ Casting yard layout with Makintosh Probe test position and test result are appended in Appendix. = Job No 10005, GAPACITY ALCUWABLE BEAKINL 0 10 Macimutosa vatue (Bows) CHART A: ALLOWABLE BEARING CAPACITY vs. MACKINTOSH m0 From Chart A above, the values are summarised in table format. ‘Mackintosh Probe ‘Allowable Bearing Capacity Value (blow/ft) in Design (kN/m’) VALUE,(DESIGN CALCULATION SHEET ob No 10005 Made By: MK/OKB: July 2013 [SUBJECT: T-Beam Mould Base - From the Makintosh Probe result, they are summarised as below with T-Beam Casting Yard 1 to 7 in related allowable bearing pressure in different ground depth. Table 1: Allowable Bearing Pressure in T-Beam Casting/Storage Yard Depth of Taeam Storage Ares Ground z 3 1 3 ‘Allowable Bearing Pressure (ar 03 Teo] 130 25 730 06 ‘400 | 00 | 160 | 250 09 ‘$00 | 400 70 360 12 300 | 200 1s 160 | 400. 18 20 400) 2a 20) - For 40m span T-Beam, the weight of T-Beam will be approximately 1000kN - After tendon is stressed, T-Beam will hog and the selfweight will concentrate at the both edge of T-Beam. = With the Concrete slab (thickness of 250mm), size of 2m (W) x 2.2m (L) the spread area in different soil depth - The spread in concrete is in 1:1 spread while in soil, 2(v) : 1(h) is used in spread of loads. Contact Area ? 0.7m x 2.0m old Concrete Slab \. Tovah : \ 03m 4 1.5mx2.8m 0.6m 1.8m x3.1m 09 mh 2am x34. 1.2m - A 2.4mx3.7m - From the bearing pressure calculated and talbe 1, T-Beam Storage Area No. 4 hhas ground bearing issues in layer of 0.3m (45 KN/m*). CONCLUSION AND RECOMMENDATION - Itis recommended that 300mm soil in T-Beam Storage Area No. 4 where MP result is less than 50 blow/ft to be replaced by well compacted crusher run. - Other areas do not have ground bearing Bering Pressure 167 kN/m? 120 kN/m? 90 kN/m? 70 kN/m? 56 kN/m?DESIGN CALCULATION SHEET [lob No 10005 MK/OKB, Date: July 2013, SUBJECT: T-Beam and Precast Segmental Crosshead Mould Base Page 16 ‘APPENDIX B : PRECAST SEGMENTAL CROSSHEAD BASE MOULD DESIGNT0005 DESIGN CALCULATION SHEET Taly 2013, SUBJECT: Precast Cosshead Mould Foundation A) Crosshead Mould Foundation a) Precast Crosshead Weight Calculation 10500 YH esbrse- 11 en 00000 500 5 -Seaneev2 sang 0500 5000) Total volume of concrete = (2.72 x 18.5) + (0.5 x (4.5 +7.5) x0.5x 1.5) = 54.82 m?* 54,82 x 25 kN/m? = 1370 kN Total Weight of Segmental Crosshea Say total weight including mould will be 1500 kN.DESIGN CALCULATION SHEET [obNo 710005 Made By MK / OKB Date July 2013 |sua1ect: Precast Cosshead Mould Foundation Page 718 b) Arrangement of Mould Base Foundation S4kN/m? DDAW <_ 300mm thk. R.C. Slab IX WIKWIRNT RX \ Well Compacted Ground 25m 1500 kN Punching Shear is OK Provide T12 - 200 (565 mm?/m) Acmin= 0.15 / 100 x 1000 x 270 = 405mm?/m10005 DESIGN CALCULATION SHEET July 2013 Er} Precast Cosshead Mould Foundation susiecT- INOW GVAHSSONO WLNAWDAS LSVOIud Os LYOddNS SV V1S ALAYONOD - NVId SuVEsY SAVM HLO8 WOLLOE 8 dOL SV 002-211 HLIM 8V1S ALBSYONOO “HUY WED X LUD, X WZ o00sz ~ | AVAHSSOND WLNANS3S ——— sO LNAWS9V1dDESIGN CALCULATION SHEET [Job No. 710005) Made By: YKC/OKB Date July 2013 SUBJECT: Precast Cosshead Mould Foundation Page: 20 Allowable bearing pressure for segmental crosshead mould base From the Makintosh probe result in Appendix D and segmental crosshead casting layout, the ground condition is far better than T-Beam casting yard. Basically the numbers of blow/ft fi? and from Table 1 in Appenx B, the allowable bearing pressure is more than 200 kN/m’, Thre is no issue with the ground in segmental crosshead mould base slab.DESIGN CALCULATION SHEET 10005 MK/OKB) July 2013 SUBJECT: T-Beam and Precast Segmental Crosshead Mould Base ‘APPENDIX C : MAKINTOSH PROBE TEST RESULTS FOR T-BEAM CASTING YARD AND T-BEAM CASTING YARD LAYOUTDESIGN CALCULATION SHEET 10005) MK/OKB Date: duly 2013 Page 22 SUBJECT: T-Beam and Precast Segmental Crosshead Mould Base APPENDIX D : MAKINTOSH PROBE TEST RESULTS FOR PRECAST SEGMENTAL CROSSHEAD CASTING YARD AND SEGMENTAL CROSSHEAD CASTING YARD LAYOUT