ADO CONMAT INDIA

PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 1

5.3 Design of Skin plate and vertical stiffener above Girder ‘B’ :
Head to the center of the panel : 6.2 – (0.42 + 1.03 + 0.55 / 2) = 4.475M
ie., p = 0.448kg/cm2

s16y
b = 40

s18x

37.5
s16x
s18y
55

s17x

17.5
s17y
15

a =35 a = 35

b/a = 40 / 35 = 1.143 ‘K’ value for b/a = 1.143 is

 16X =  19.46  16Y =  11.95

 17X =  9.17  17Y =  30.57

 18X =  32.13  18Y =  9.64

Bending stress in skin plate :

b = [(K / 100) X ((p X a2) / s2)] = [(K / 100) X (0.448 X 352) / 1.452] = 2.610K kg/cm2

 16X =  51kg/cm2 < 1020kg/cm2  16Y =  31kg/cm2 < 1020kg/cm2

 17X =  24kg/cm2 < 1020kg/cm2  17Y =  80kg/cm2 < 1020kg/cm2

 18X =  84kg/cm2 < 1020kg/cm2  18Y =  25kg/cm2 < 1020kg/cm2

Check for combined stress : Max. on D/S of skin plate.

x = 634 + 25 = 659kg/cm2 < 1020kg/cm25
y = - 84kg/cm2 < 1020kg/cm2
c =  6592 + 842 + 659 X 84 = 705kg/cm2 < 1275kg/cm2
 ADO CONMAT INDIA
PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 2

Design of vertical stiffeners :

Head to the centre of the panel = 0.448kg/cm2 w5 w6
W5 = 2 X ½ X 17.52 X 0.448 = 307kg

17.5
W6 = 2 X 37.5 X 17.5 X 0.448 = 588kg
D
RD = 895kg 17.5 37.5

Point of application 55

= (½ X 17.53 X ⅔ + 37.5 X 17.5 X 36.25) / [(17.52 / 2) + (37.5 X 17.5)] = 31.599cm

BM = 895 X 31.599 – [307 (31.599 – 17.5 X ⅔) + (588 / 37.5) X (14.0992 / 2)]
= 20603kgcm

The co-acting width of skin plate :

L = 55 B = 17.5
L/B = 3.142 V = 0.432
2VB = 2 X 0.432 X 17.5 = 15.12cm ≈ 15cm

It is proposed 200 X 10mm plate as stiffeners.

Area = 41.75cm2 15
1.45
5.86

IXX = 1869cm4
20
15.59

1.0
Z1 = 319cm3

Z2 = 120cm3

Bending stress in compression = 20603 / 319 = - 65kg/cm2 < 1020kg/cm2

Bending stress in tension = 20603 / 120 = 172kg/cm2 < 1020kg/cm2

Check for combined stress :

x = - 25 - 65 = - 90kg/cm2 < 1020kg/cm2
y = + 84kg/cm2 < 1020kg/cm2
C =  902 + 842 + 90 X 84 = 151kg/cm2 < 1275kg/cm2

Note : There is no need to check 2nd element for bending moment in skin plate and short
stiffeners since the head is less than bottom element. How ever it is proposed to
provided stiffeners similar to that of bottom element.
 ADO CONMAT INDIA
PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 3

6.0 Design of embedded parts :

Max. roller load = 50000kg

6.1. Design of Thickness of roller track plate : (When track with line contact)
t = 6 X 0.786 X 1.55  (P / l X r / E)
Where l = tread width in mm = 130
P = Wheel load in N = 490500N
r = radius of the wheel = 225mm
E = Modulus of elasticity = 200810.7N/mm2

t = 6 X 0.786 X 1.55  (490500 / 130) X (225 / 200810.7) = 15.03mm

As per technical specification minimum thickness of track plate is 20mm.

Proposed 200 X 20mm thick as track plate after machining.

Material 20 Cr 13 IS 1570 Part V Hardness 200 to 220BHN

6.3 Design of Roller Track :

The section proposed is as follows 20

2.0
17.48

3.2
Area = 282cm2

IXX = 68991cm4
35

3.2
24.72

Z1 = 3946cm3
2.0

Z2 = 2791cm3
25

6.2.1 Checking the Bearing stress in concrete :

b = 0.2813 X P[EC / (ES X I X w2)] 1/3
P =Roller load = 50000kg
EC = Young’s modulus of concrete (M200)
ES = Young’s modulus of steel (Ec / Es = 1/8.98)
I = Moment of Inertia = 68991cm 4
w = width of plate contact with concrete = 25cm

b = 0.2813 X 50000 [(1/8.98) X (1 / 68991) X (1 / 252)] 1/3 = 19.297kg/cm2 < 52kg/cm2

 ADO CONMAT INDIA
PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 4

6.2.2 Check for Bending stress :

b = 0.5 X (50000 / 2791) [8.98 X 68991 / 25]1/3 = 261kg/cm2 < 979kg/cm2

6.2.3 Check for Shear stress in web :

Shear stress in web = 50000 / (2 X 35 X 3.2) = 223kg/cm2 < 893 kg/cm2

6.2.4 Check for Web Compression :

50000kg
wheel load = 50000kg
Web thickness = 32mm

3.2 2.0
Under 45 dispersion of load

45°
Web Compressive Stress = 50000 / (10.4 X 3.2)
10.4cm
= 1502kg/cm2 < 1958kg/cm2

6.2.5 Check for Pressure distribution under track :

Length of influence of pressure under track L = 3/2 X P / pw
= (3 / 2) X 50000 / (17.07 X 25) = 175cm
The rollers are spaced at 74cm apart hence the pressure distribution under track will
even overlap.
Max. Stress = 17.07 X 2 = 34.14kg/cm2 < 62kg/cm2

35 12.5
6.2.6 Check for Shear stress in concrete :
Roller load = 50000kg
.9
10
X

Bearing stress in concrete 17.07kg/cm 2

√2

Length of shear =  2 X (10.9 + 47.5) = 82.59cm 3.2

Shear stress = Bearing stress in concrete X width of track

2 X Length of Shear 25

= (17.07 X 25) / (2 X 82.59)

= 2.6kg/cm2 < 5.0kg/cm2
Permissible punching shear as per IS800 clause
.5
47
X
√2
 ADO CONMAT INDIA
PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 5

6.2.7 Design of welds in roller track :

Max. shear force = 25000kg
IXX of section = 23454cm4
a. Weld between track plate and U/S flange :
F1 = SAy / 2I = (25000 X 20 X 2 X 16.48) / (2 X 68991) = 119kg/cm length
Proposed 6mm fillet weld having strength of 308kg/cm length

b. Weld between U/S flange and web :

F2 = SAy / 2I = [25000 (20 X 2 + 25 X 3.2) 15.4 / (2 X 68991)] = 335kg/cm length
Proposed 8mm fillet weld having strength of 896kg/cm length

c. Weld between web and D/S flange :

F3 = SAy / 2I = (25000 X 25 X 2.0 X 23.72) / (2 X 68991) = 215kg/cm length
Proposed 6mm fillet weld having strength of 411kg/cm length
 ADO CONMAT INDIA
PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 6

7.0 Check for Earthquake effect :

Due to horizontal acceleration, there will be an instantaneous hydro dynamic pressure
exerted on the gate in addition to hydro static pressure. The direction of the hydro dynamic
force is opposite to the direction that of earthquake acceleration. Based on the assumption
that water is incompressible, the hydrodynamic pressure at depth y below the reservoir
surface shall be determined as follows. (Cl. 7.2 of IS : 1893 – 1984).

P = CSnWh
Where P = Hydrodynamic pressure in kg/cm2 at a depth y.
n = Design horizontal seismic co-efficient = Io – (cl. 3.4.2.3 –a of IS 1893)
= 1 X 3 X 0.02 = 0.06
CS = Co-efficient which varies with shape and depth.
= (Cm / 2) {(y / h) (2 – y / h) +  (y / h) (2 – y / h)}
Cm = 0.73 from table – 10 of IS 1893, y = 3.8M, h = 3.8M
= (0.73 / 2) {1 X (2 – 1) +  1 (2 – 1)} = 0.73
W = Unit weight of water = 1000kg/m3
h = Depth of reservoir = 6.5M.

P = 0.73 X 0.06 X 1000 X 6.5 = 284.7kg/cm = 0.2847t/M2

Hence percentage of increase in pressure = (0.2847 / 6.5) X 100 = 4.42%

Permissible increase in stresses = 33.33% > 4.42%

As earthquake forces are not critical and do not govern the design, check for stresses
shall not be made for this condition.
 ADO CONMAT INDIA
PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 7

8.0 Design of lifting arrangement :

Hoist capacity = 55t
Load on each lifting side = 27.5t
LIFTING C/C=12600 M16 HEX SCREW FOR
LOCKING & 17.5Ø HOLES
IN-LOCK PLATE (TYP)
1860 10
10
380 550 550 380
10

75.5 75.5 300

90 50

150
12
5

250
12
240

280

Ø
50 90

12
440

300
280
80

500
400
R3

155
200

Ø10 DRAIN HOLE

100

10
12
280
180

0
12
12

100
1 12
200 00 200
20
280
20

494

500
400
345

10
12

5
10

600
800

8.1 Design of pulley pin :

Load on pulley shaft = SWL + self weight of pulley = 13750 + 105 = 13855kg
13855kg

RA = RB = 6927.5kg A 2.3 13 2.3 B

17.6

Bending moment = (13855 / 8) (2 X 17.6 – 13) = 38448kgcm

Proposed shaft  125mm.
Material IS 2062
ZXX = 192cm3 A = 123cm2
Bending stress = 38448 / 192 = 200kg/cm2 < 836kg/cm2
Shear stress = 6927.5 / 123 = 56kg/cm 2 < 765kg/cm2
 ADO CONMAT INDIA
PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 8

8.2 Design of cheek plate :

p = 13855 / (12.5 X 2.6) = 426kg/cm 2 13855kg
10 16
Max. tearing stress

150
T = p {[(2R)2 + d2] / [(2R)2 - d2]}
= 426 [(302 + 12.52) / (302 – 12.52)]
= 605kg/cm2 < 0.66 X 2550 X 0.95 / 0.11
= 1453kg/cm2 155

13855kg
8.3 Design of Pin – 2 : 13855kg

a b
C D
RC = RD = 13855kg 2 17.6 2
21.6

Bending moment = 13855 X 2 = 27710kgcm

Proposed 125mm Pin
Material IS 2062
ZXX = 192cm3
Area = 123cm2
Bending stress = 27710 / 192 = 144kg/cm2 < 836kg/cm2
Shear stress = 13855 / 123 = 113kg/cm2 < 765kg/cm2
200R
8.4 Design of Bracket welded to girder :

p = 13855 / (12.5 X 2) = 554.2kg/cm 2

Max. tearing stress along AB Ø 125

T = p {[(2R)2 + d2] / [(2R)2 - d2]}

= 554.2 [(302 + 12.52) / (302 – 12.52)]

= 674kg/cm2 < 1453kg/cm2

8.5 Design of weld between bracket and horizontal girder web :

Length of weld = 2 X 60 = 120cm
Load per cm length of weld = 13855 / 120 = 115kg/cm length.
Proposed 6mm fillet weld having strength of 428kg/cm length.
 ADO CONMAT INDIA
PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 9

9.0 Design of Dogging Beam :

The arrangement of dogging beam is shown in Drg. No. BHME - GEI – RGB-VGB -105.
Self weight of gate = 55500kg
The beam is supporting the gate on either side of gate at end box over the vent.
Load acting on beam with impact = 55500 X 1.1 / 2 = 30525kg
The loading on the beam is as follows :
30525kg

RA = RB = 15262.5kg A B
35 80 35
150

Bending moment = (30525 / 8) (2 X 150 – 80) = 839438kgcm

Proposed beam having following section : 11

2.0
Area = 108.0cm2

IXX = 7472cm4

20.0
24
ZXX = 623cm3

2.0
7.8
Bending stress = 839438 / 623 = 1347kg/cm2 < 1580kg/cm2 1.6 1.6

Shear stress = 15262.5 / (2 X 20 X 1.6) = 238kg/cm2 < 1020kg/cm2

10.0 Design of Spice Joint :

Hoist capacity = 55t

It is proposed to design the splice joint between the elements for a Max. load of 55t.
The bolts provided in the joint are in double shear.

No. of bolts provided in the joint = 360Nos.

Dia of bolts proposed = 16mm
F = (2 X  X d2 / 4) X fs X n
fn = 4F / (2 X  X d2 X n)
= 4 X 55000 / (2 X  X 1.6 X 360)
= 61 < 720kg/cm2
 ADO CONMAT INDIA
PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 10

10.0 Gate weight C.G calculations:

S.No Description Size Nos Weight x Wx

2000 X 16 – 18950 1 4760.2 0.8 3808.0
1 Skin plate
4500 X 16 – 18950 1 10710.5 0.8 8568.0
785 X 16 – 2000 4 788.8 40.85 32222.0
785 X 16 – 4500 4 1774.7 40.85 72496.0
190 X 10 – 785 20 234.2 40.85 9566.0
2 End Box
300 X 10 – 300 16 113.0 59.60 6737.0
140 X 10 – 280 8 24.6 61.00 1502.0
280 X 20 thick 8 98.4 59.60 5869.0
300 X 16 – 18478 4 2785.0 2.4 6684.0
1800 X 12 – 18478 4 12532.5 93.2 1168029.0
3 Horizontal girder 300 X 16 – 19130 4 2883.3 184.0 530527.0
270 X 16 – 14600 4 1980.5 185.6 367581.0
130 X 10 – 1616 32 527.8 102.4 54047.0
1816 X 10 – 6500 5 4633.0 92.4 428089.0
4 Vertical stiffener 200 X 10 – 6500 40 4082.0 11.2 45718.0
150 X 16 – 3200 5 301.4 184.0 113835.0
450 Ø roller 140 thread width
5 Roller assembly with 22226E bearing and 140Ø 8 1704.0 59.6 101558.0
axle – 213kg/asm
6 Side guide 40kg/assy 4 160.0 38.9 6224.0
7 Top channel ISMC 250 X 82 - 18478 1 632.0 13.7 8658.0
160 X 16 – 18360 2 737.9 ---- -----
8 Splice plate
160 X 16 – 700 4 56.3 40.85 2298.0
200 X 10 – 1700 4 106.8 92.8 9911.0
9 Typical joints
150 X 16 – 460 5 43.3 174.3 7547.0
44Ø X 127 – 6500 2 58.5 ---- ----
60 x 10 – 6500 4 122.5 ---- ----
10 Seal assembly 90 x 14 flat seal – 18100 1 50.0 ---- ----
80 x 10 – 18100 1 113.7 ---- ----
20 x 20 – 8100 1 56.8 ---- ----
Lifting
11 Arrangement with 1500kg/assembly 2 3000.0 ---- ----
bottom block
12 Fasteners 200kg 1 200.0 ---- ----
55271.7 2991474.0

x = 2991474.0 / 52271.7 = 57.2cm Adopted 57cm.

 ADO CONMAT INDIA
PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 11

11.0 Hoist Capacity Calculations:

1) Weight of gate: 55500kg
2) Water thrust on the gate = 348843kg
3) Roller friction
F = P/R(fa X r + fr)
Where F = Roller friction in kg
P = Water thrust =348843kg
R = 22.5cm
fa = Coeff. of friction = 0.015 for Antifriction bearing
r = 9cm (Bearing ID 130, OD 230 and 64thick)
fr = 0.1
 F = (348843 / 22.5) (0.015 X 9 + 0.1) = 3643kg
4) Seal friction:
Side seal friction: 2 X  X b X h X l
= (2 X 1.5 X 4.4 X 0.31 X 620) = 2537kg
5) Friction due to seal pre compression = 2 X 620 X 1 X 1.5 = 1860kg
6) Guide friction = (55500 / 100) X 5 = 2775kg

Note : No check is required for self closing since the self weight of gate is more than
frictions and seating pressure required.

A CWT of 50t including counter weight box is provided to reduce the hoist weight 25t
since it is connected in two falls.

Hoist capacity required:

Self weight of gate : 55,500.00
Roller Friction : 3,643.00
Seal Friction : 2,537.00
Friction due to seal pre compression : 1,860.00
Guide friction : 2,775.00
66,315.00
Add 20% reserve capacity : 13,263.00
79,578.00
Less - 25,000.00
54,578.00

Proposed 55t Rope Drum hoist for operation of the same.

 ADO CONMAT INDIA
PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 12

12.0 Design of Counter weight Box:

The counter weight box including self wt. = 50000kg
Designed for with impact load of 55000kg
It is proposed to suspend the counter weight at 1750mm span.

55000kg

RA = RB = 27500kg A B
70 1750 70
1890

Bending moment = 27500 X [(1750 / 2) – (1890 / 4)] = 11068750kgcm

75

1.0
Proposed beam having following section : 1.5 1.5

70
1.0 1.0
Area = 410cm2

130
IXX = 1009717cm4

ZXX = 15299cm3

1.0
Bending stress = 11068750 / 15299
= 723kg/cm2 < 1480kg/cm2
Shear stress = 27500 / (2 X 123 X 1) = 112kg/cm2 < 1200kg/cm2

Permissible deflection = span / 750 = 1750 / 750 = 2.333

Deflection = (5 X 50000 X 18903) / (384 X 2047000 X 1009717) = 2.13cm < 2.333cm

Bearing stress = 45000 / (70 X 1800) = 0.357kg/cm2 <1680kg/cm2

However L75 X 75 X 8 stiffeners is proposed at 750mm C/C

A counter weight of 45t is proposed.

45t counter weight is to be provided at 3.5t/m 3 density MS scrap and concrete.

