RCC DESIGN REPORT OF BOX CULVERT(1X2.00X2.

00)
Kundral To Wazar
Name of Work :-Rehabilitation and upgradation of existing carriageway to two lanes with
paved shoulder standards from Kundral to Wazar section of NH -161A from km 52.730 to km
99.250 on EPC mode in the State of Maharashtra.

OWNER : : PUBLIC WORKS DEPARTMENT NH DIVISION,

CONTRACTOR CLIENT : AJAYDEEP CONSTRUCTION PVT. LTD.

T.P.F Engineering Pvt. Ltd

AUTHORITY'S ENGINEER : (Earlier Known as SNBAPL)
4th Floor, Pudhari Bhavan, Sector 30A,
Nr. Sanpada Railway Station,Vashi, Navi Mumbai 400 705, Tel.:
+ 91 224127 3303 /04 /05
Fax: + 91 224127 3306,E-mail: info@tpf.be

PROOF CONSULTANT : Ayoleeza Consultant Pvt.Ltd. 24B,Vasundhara

Gardens, Harihara Singh Lane,Bariatu,Ranchi-
834009,Jharkhand

DESIGN CONSULTANT ATUL ENGINEERING CONSULTANCY

SERVICES PVT. LTD. , 10, Sadanand, 4th Floor,
Opp. Bhabha Hospital, Near Deep Bungalow, Model
Colony, Pune- 411016

RCC DESIGN REPORT OF BOX CULVERT OF SIZE (1X2.00X2.00) AT Ch.74+235.

1
 INDEX

Sr. No. Descriptions Page no.

I. Design Considerations
i. Box Details 3
ii. Material Properties 3
II. Load Consideration
i. Earth Pressure 4
ii. Water Pressure 5
iii. Force due to temperature Gradient 6
iv. Live Load 8
III. Design Check
i. Check for Crack Width 12
ii. Serviceability check 13
iii. Check for shear 14
IV. Executive Summary 15
i. Load Summary 16

Page 2
 I. DESIGN CONSIDERATIONS:-

i. Box Details

a. Box clear width = 2.000 m

b. Box clear height = 2.500 m
c. Box barrel length = 15.00 m
d. Bottom slab thickness = 0.300 m
e. Top slab thickness = 0.250 m
f. Wall thickness = 0.250 m
g. Haunch (150 x 150)mm
h. Width of clear carriageway = 14.00 m
i. Width of Deck slab = 15.00 m
j. Assumed Width of Deck slab for analysis = 1.000 m
k. Thickness of PQC = 0.280 m
l. Width of crash barrier = 0.500 m
m. Height of Crash barrier = 1.000 m

ii. Material Property

a. Grade of Concrete = M35

Characteristic compressive cube strength of
b. 35 N/mm²
concrete at 28 days =
c. Density of Concrete (ρc) = 25 kN/m3
d. Secant modulus of Elasticity of Concrete = 32000 N/mm²
e. Mean compressive strength of concrete (fcm) = 45 N/mm²
f. Grade of Steel = Fe500
g. Yield Strength of Reinforcement (fy) 500 N/mm²
h. Elastic Modulus of Steel (Es) = 2 x 105 N/mm²
i. Mean axial tensile Strength of Concrete (fctm) = 2.8 N/mm²
j. Condition of Exposure Moderate
k. Wmax for Quasi Permanent Combination = 0.3 m
l. Density of Compacted Earth (ρce) = 20 kN/m3
m. Density of Water (ρw) = 10 kN/m3
n. Density of Wearing Coat (ρwc) 22 kN/m3
o. Angle of internal friction of soil ,Φ 30o

Page 3
 II. LOAD CALCULATIONS:

i. Earth Pressure:

Pressure Co-efficient,

Active earth pressure, (Ka) = 1 – Sin Φ = 0.33

1 + Sin Φ

At-rest condition, (Ko) = 1 – Sin Φ = 0.5

2m
2.5 m

0.5 x 20 x 2.95 ½ x 20 x 1.2

= 29.5 kN/m2/m = 12 kN/m2/m
(At-Rest) (Surcharge)

Page 4
ii. Water Pressure:

Pressure on Walls, 1 x 2.5 x 10 = 25 kN/m2/m

Pressure on bottom slab, 1 x 2.5 x 10 = 25 kN/m2/m

25 kN/m2/m

Fig: Water Pressure Distribution

Page 5
 iii. Forces due Temperature gradient: (IRC 6 – 2014)

Case 1: Temperature Rise

h1 = 0.3h < 0.15 m

h2 = 0.3h > 0.10 m
< 0.25 m
h3 = 0.3h < 0.15 m

αt = 12 x 10-6 /°C (Coefficient of Thermal Expansion)

E = 32 Gpa

O O

4 13.8
F1
h1
F2
Z2
Z1
F3
h2 Z3

Z4

h3 F4

2.1

Positive Temperature Gradient

Force (F) = E αt Adt

h1= h2= h3= 75mm

z1 =100 mm
z2 =87.5 mm
z3 =25 mm
z4 = 100 mm

F1= 198.7 kN
F2= 1.54 kN
F3= 57.6 kN
F4= 30.24 kN

Mt = F1Z1 + F1Z2 + F3Z3 + F4Z4

Mt=198.7*0.1 + 1.54*0.088 + 57.6*0.025 + 30.24*(-0.1)
Moment Due to Temperature Rise (Mt) =18.42 kNm

Page 6
Case 2: Temperature Fall

h1 = h4 = 0.2h
h2 = h3 = 0.25h

αt = 12 x 10-6 /°C (Coefficient of Thermal Expansion)

E = 32 Gpa

O O

9 .9 0 .7
F1
h1
F2

Z1 Z2
F3 h2
Z3

Z4
F4 Z5
Z6 h3

F5
F6 h4

O O

5 .8 0 .8

Force (F)=E αt Adt

Negative Temperature Gradient
h1= h4 = 50mm
h3= h2 = 62.5mm

z1 = 108.3 mm
z2 = 100 mm
z3 = 54.17 mm
z4 = 54.17 mm
z5 = 100 mm
z6 =108.3 mm

F1= 95.04 kN
F2= 13.44 kN
F3= 8.4 kN
F4= 9.6 kN
F4= 15.36 kN
F4= 55.68 kN

Mt = F1Z1 + F1Z2 + F3Z3 - F4Z 4 - F5Z5 - F6Z6

Mt = 95.04*0.12 + 13.44*0.1 + 8.4*0.054 - 9.6*(0.054) -15.36*0.1 - 55.68*0.12
Moment Due to Temperature Fall (Mt) =4.5 kNm

Page 7
 iv. LIVE LOADS:

• Dispersions lengths/width, (IRC: 21)

Width perpendicular to direction of traffic,

b= kx (1 - x/L) + a

b = Dispersion Length.
x = distance of wheel load from any support.
L = effective span - 2.25 m.
a = contact length of wheel with the surface of road parallel to supports after dispersion through wearing
coat = (g+2h).
g = length of contact level act of the wheel with the road surface parallel to supports.
h = thickness of wearing coat.
k = constant based on B/L.
B = width of slab = clear carriage way + 2 x (width of kerb) = 8.5m.

Loading for Class, (IRC: 6: 2014)

1. Class 70R (W),
2. Class 70R (T),
3. Class A,
4. Bogie Load

Fig: Wheel arrangement for Class 70R (W) Vehicle

Page 8
Fig: Wheel Position for 70R (T)

Fig: Axle Spacing for Bogie

Page 9
Fig: Wheel arrangement for Class A Vehicle

Page 10
 • Calculation of Load Intensities for various load class:

Class beff (m) aeff(m) A (m )

2 Combination Impact Load Factored Intensity
Factor Factor (kN) (kN) (kN/m 2/m)

70R(W) 5.038 2.25 11.33 1.5 1.25 340 637.5 56.26

70R(T) 6.860 4.75 32.585 1.5 1.22 700 1281 39.2

Class A 4.65 2.60 12.09 1.5 1.378 228 471.3 38.98

Bogie 5.038 2.25 11.33 1.5 1.25 400 750 66.16

Where,
beff = Effective width of slab.
a eff = Effective length of load.
A = Area of load dispersion.
Impact Factor as per IRC 6:2014, 208.1

• Braking Force Calculations 70R (T) (IRC: 6 – 2014, 211.2)


Pressure = .
  .  = 21.48 kN/m2

Actual load = 21.48 x 2.5 x 6.86 = 368.42 kN

Breaking Force, 10% of Load

= 0.1 x 368.42
= 36.84 kN

Horizontal force at each support = 18.42 kN

M = 1.2 x 18.42 = 22.104 kNm.

Page 11
 III. Design Check

i. Check for Crack Width (For Quasi-permanent Comb)

(12.3.4 of IRC: 112-2011)

Wk = Sr max × (εsm - εcm)

 
    (  ) . 

εsm – εcm = σs 
≥ 

Where,
εsm = Mean Strain in reinforcement. hc eff = lesser of , 2.5 (h-d)
εcm = Mean strain in concrete between cracks. , (h-x) /3
, h/2
"
Ppeff = "

Aceff = Effective area of concrete in tension = b x hc eff

σsc = Stress in tension R/f
Kt = Factor dependent on load duration = 0.5,

Modular ratio, m = αe =
#

()^. ( )^.

$%& =  (
=  .
= 11377.07 N/mm².

m = (2 x 105 ) / 11377.07 = 17.5

Calculation table for allowable crack width

Deck Wall Raft

2.5(h-d) 140 202.5 202.5
(h-x)/3 61.28 67.1 78.23
h/2 125 125 150
X min, mm 66.16 48.7 65.31
Aceff 61280 67100 78230
As 904 565 791
Ppeff 0.0147 0.0084 0.0101
Srmax 413.55 740.71 658.96
Wk mm 0.281 0.239 0.305
OK. OK. OK.

Page 12
ii. Serviceability check – (top slab) [for rare combination]
(Cl. 12.2.1 pg 120 IRC: 112-2011)

Max compressive stress in conc. Under rare combination of loads shall be limited to 0.48 fck
= 0.48 x 35
=16.8 N/mm2

Max. Tensile stress in steel under rare combinations of loads shall be limited to 0.80 fy
=0.8 x500
= 400 N/ mm2
We have,
Moment M = 17.5 kN-m
Modular ratio m = 17.57

xu = 66.16 mm

To calculate cracked Moment of Inertia: -

)  *+
Icr = [
,
+ ( A x h2) ] + m x Ast x (d- xu)2
= 416.32 x 106 mm4

Stress in steel (σsc)

σsc = M/I x (d- xu ) x m
σsc = 113.1 N/mm2 < (Limiting σsc = 400 N/mm2 )

Stress in concrete (σc)

σc = M/I x xu
σc = 2.13 N/mm2 < (Limiting σc = 16.8 N/mm2 )
Hence, OK.

Similarly for Raft,

M = 28.8 kNm
M = 17.57
xu = 78.23
σsc = 186.12 N/mm2 < 400 N/mm2
σc = 3.52 N/mm2 < < (Limiting σc = 16.8 N/mm2 )
Hence OK.

Page 13
iii. Check for Shear
(Cl. 10.3.2 pg 88 IRC: 112-2011)

VED = Design shear Force = 106.76 (40 T)

For elements not requiring shear reinforcement,

VRdc ≥ [0.12 x k (80 x P1 x fck) 0.33 +0.15 x σ cp] b x d

> (Vmin + 0.15 x σ cp) b x d
> (0.031 x k 3/2 x fck ½ + 0.15 x σ cp) b x d

Where,

VRdc = design shear resistance without shear reinforcement

Vmin = (0.031 x k 3/2 x fck ½)

k = 1+-200/1
D = 400 (Near Supports), Cover – 50mm,
d= (400-50-6) = 344 mm
Thus, k = 1.76

σcp = Mean Compressive stress NED = Design value of applied axial force
σcp =NED / Ac < 0.2 fck fck = 35 mpa
= 5 x 10-4 Mpa

" 
23 = percentage of reinforcement = )4
< 0.02 Ast : 12mm @ 130mm c/c
i.e. 904 mm2
= 2.67 x 10-3 b = 1000mm
d = 344 mm
Thus,
VRdc = 141.25 kN > VED (106.76 kN)
VRdc min = 147.3 kN

Therefore, No Shear R/F Required.

Page 14
IV. Executive Summary 1x2x2.5m box Culvert section:

Page 15
*Mu: Refer Staad File for design moments.

ENCLOSURE:

1. Staad File,
Load-1: 40t Bogie Load
Load-2: 70R (T)

2. RCC Detail drawing.

Page 16