DESIGN OF 2850 KN (ULS) & 1992 KN (SLS) CAPACITY Free SLIDDING POT BEARINGS

Type (A1 ) P51 CONSTRUCTION OF MULTI -MODEL TRANSIT HUB AT THANE RAILWAY STATION EAST
REFERANCE CODE:- IRC:83 (Part III) - 2018
DESIGN PARAMETERS : DT: 07-06-2021
1) Grade of Concrete
a) Pedestal : 45 Mpa Min Size 900 X 900
b) Superstructure : 45 Mpa
Modulus of elasticity 34312.98368 Mpa

2) Permissible Stress in Concrete

Normal Case Seismic Case
a) Bottom sb : 22.50 N/mm2 28.13 N/mm2
b) Top st : 22.50 N/mm2 28.13 N/mm2
fcd : 20.10 N/mm2

3) Permissible Bearing Stress in Concrete

Normal Case Seismic Case
a) Bottom sbc : 14.85 N/mm2 18.56 N/mm2
b) Top stc : 14.85 N/mm2 18.56 N/mm2
4) Grade of Cast Steel : 340 -570W of IS:1030
Permissible stress in Cast Steel (Cl. 926.2.2) where fy = 340.0 N/mm2
sst : 204 N/mm2
sp : 255 N/mm2
5) Vertical Load For ULS case For SLS case
a) Vmax : 2850 KN 1992 KN
b) Vmin : 60.12 KN 140 KN
c) Vmax-ses : 2200 KN 1620 KN
d) Vmin-ses : 220 KN 360 KN
6) Horizontal Force under Normal Condition
a) Longitudinal Hbf : 0 KN 0 KN
b) Transverse Hbt : 0 KN 0 KN
c) Resultant HRn : 0.00 KN 0.00 KN
Since HRn < 10% of Vmax
HRn 285.00 KN 199.20 KN (Cl. 926.1.4)
7) Since Horizontal Force in Longitudinal Seismic is more than Transverse Seismic and Wind Condition
\ Horizontal Force under Seismic Condition
a) Longitudinal Hsl : 0 KN 0 KN
b) Transverse Hst : 0 KN 0 KN
c) Resultant HRs : 0.00 KN 0.00 KN
d) Wind:- Yes Yes
Since Hsl > HRs
HRs 220.00 KN 162.00 KN
8) Rotation (Normal, Seismic)
a) Resultant Rotation, q : 0.01 radians
b) Resultant rotation due to variable action positive rotation , qv : 0.0002 radians
c) Resultant rotation due to permanent action and long term effects , qp : 0.0098 radians
d) Resultant rotation due to variable action negative rotation , qv : 0.0020 radians
Assumed qp = 2 % of q & qv = 98 % of q
Since D5 / Tn = 13.64 As per table 5.1 of IRC:83 (Part III)-2018 Cl. 5.1.5.1.)
k1 = 1.981818182
k2 = 77.98181818

9) Longitudinal Movement
elng : + 50 mm - 50 mm

10) Transverse Movement

etran : + 20 mm - 20 mm

11) Vertical Movement

evrt : + 0 mm - 0 mm
upward downward

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 Design of POT PTFE Bearing
Ref. Code:-IRC 83-Part III-2018
Minimum grade of steel = 350 MPa
fu = 570 MPa
fy = 340 MPa
ϒm Cast Steel = 1.1
ϒc For concrete = 1.5
Pedestal height h = 300.00 mm
width b = 600.00 mm
length d = 600.00 mm

BEARING PARAMETERS 2850 KN FREE TYPE BEARING. QTY :- 1 NOS.

I) POT :
Effective diameter of bottom plate A1 = D5 + (2XA2) = 363 mm
Diameter of Pot at Bottom A = A1 = 425 mm Do
Thickness of Pot at Base A2 = 31.5 mm kb
Depth of Pot A6 = A3-A2 = 36 mm hc=A3-kb

Total Ht. of Pot A3 = A2+Tn+w+2 = 67.5 mm

Outer Diameter of Pot A7 = 390 mm do

Inner Diameter of Pot D5 = 300 mm di
Horizontal Lever Arm A5 = A2+Tn+(w/2) = 59.5 mm
Pot Thickness (A7-D5)/2 = 45 mm
II) ELASTOMERIC PAD : (Cl-5.2.3.5)
Diameter of Elastomeric Pad D5 = 300 mm OK
Thickness of Elastomeric Pad he Tn = 22 mm OK
Effective Thickness of Elastomeric Pad Nt-eff = Tn-4 = 18 mm

III) PISTON / CENTRE PLATE :

Size of Centre Plate (C3 x C3) = 330 mm
Piston Diameter Dp = 299 mm
Overall Thicknes of Centre Plate C2 = 40 mm
Contact width of Piston w = 12 mm
Piston recess hn = 12 mm

IV) P.T.F.E. :
Length & Width L = 310 mm
Thickness t = 4.5 mm

V) S.S. Plate :
Length SSPl = 410 mm
Width SSPw = 370 mm
Thickness SSPt = 3 mm

VI) TOP PLATE :

Effective Length & Width B1 = 356 mm Dp
Diameter of Piston Dp = 299 mm
Length BL = 450 mm
Width BW = 410 mm
Thickness B2 = 23 mm
Distance of line of Horz. force from top B5 = 23 mm

X) GUIDE / END CONSTRAINT :

Length El = 0 mm
Width Eb = 0 mm
Height Eh = 0 mm
VII) ANCHOR BOLT :
Diameter of Bolt Bf = 20 mm
Total Number of Bolts N = 4 nos.
Grade of Bolt = Grade 8.8

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 VIII)LUGS :
Length Ll = 75 mm
Width LW = 75 mm
Thickness Lt = 25 mm

IX) ANCHOR SLEEVES :

Diameter of Sleeve D = 50 mm
Sleeve length for Bottom Lb = 200 mm
Sleeve length for Top Ls = 200 mm
BEARING THICKNESS THK = 121.5 mm
b1 354

DESIGN CHECK :

I) ELASTOMERIC PAD :

1) Diameter to Thickness Ratio (Cl. 5.2.3.5)

D5/Tn = 13.64 </= 16 OK
2) Strain in Elastomer (Cl. 5.2.3.4)
tneo = 0.5 x D5 x q
Nt-eff
= 0.08 </= 0.15 OK

3) Design value of resistance of the elastoneric pad normal case - NRd (Cl. 5.2.3.2) ULS
Fek is the charasteristic contact strength of the elastomer = 60.00 Mpa
ϒm partial factor 1.30
Characteristic value of resistance of the elastomeric pad - NRK
NRK = π/4 di2 fe,k
= 4241.15 kN

Design value NRd = NRK

ϒm
NRd = 3262.42 kN
Nsd < NRd____OK

4) Design value of resistance of the elastoneric pad seismic case - NRd (Cl. 5.2.3.2) ULS
Fek is the charasteristic contact strength of the elastomer = 60.00 Mpa
ϒm partial factor 1.30
Characteristic value of resistance of the elastomeric pad - NRK
NRK = π/4 di2 fe,k
= 4241.15 kN

Design value NRd = NRK

ϒm
NRd = 3262.42 kN
Nsd < NRd____OK

5) Minimum Average Stress (Cl. 5.2.3.3) SLS

sneo-min = Vmin x 1000
p/4 x D52
= 1.98 < 2 N/mm2 `
ANTI-UPLIFT ARRANGMENT IS MADE AND CALCULATION ARE ADDING ACCORDINGLLY
5) Moment due to resistance to rotation due to tilting stiffness of elastomeric pad (Cl. 5.1.5.1) ULS-SLS
Me-d = D53 x [(k1 x qp) +(k2 x qv)]
= 9.45E+05 N-mm

6) Moment due to friction at the piston-cylinder contact surface under normal condition (Cl. 5.1.5.2)

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 MR-d(n) = 0.2 x C x Vd C=D5/2 ULS
= 8.55E+06 N-mm

7) Moment due to friction at the piston-cylinder contact surface under Seismic condition (Cl. 5.1.5.2)
MR-d(s) = 0.2 x C x Vd ULS
= 6.60E+06 N-mm

8) Moment due to friction at the piston-cylinder contact surface under normal condition (Cl. 5.1.5.2)
MR-d(n) = 0.2 x C x Vd C=D5/2 SLS
= 5.88E+06 N-mm

9) Moment due to friction at the piston-cylinder contact surface under Seismic condition (Cl. 5.1.5.2)
MR-d(s) = 0.2 x C x Vd SLS
= 4.78E+06 N-mm

10) Total induce Moment under normal condition (Cl. 5.1.6) ULS
MT-d(n) = Me-d + MR-d(n)
= 9.50E+06 N-mm

11) Total induce Moment under Seismic condition (Cl. 5.1.6) ULS
MT-d(s) = Me-d + MR-d(s)
= 7.55E+06 N-mm

12) Total induce Moment under normal condition (Cl. 5.1.6) SLS
MT-d(n) = Me-d + MR-d(n)
= 6.82E+06 N-mm

13) Total induce Moment under Seismic condition (Cl. 5.1.6) SLS
MT-d(s) = Me-d + MR-d(s)
= 5.72E+06 N-mm

II) POT :

Particular recommendations for design of POT bearings

Pot Wall Subjected to tensile forces for normal condition Clause 5.3.1.2.3 ULS
AR = (do-di) * hc = 3240 mm
Vesd = 4*Nsd*he/(pi*di) = 266.11 kN
Vfxysd = sqrt(Vfxsd^2+Vfysd^2) = 0.00 kN
Vsd = Vesd + Vfxysd = 266.11 kN
Vrd = fy*AR/ϒm = 1001.454545 kN
Vsd < Vrd ------ OK

Pot Wall Subjected to tensile forces for seismic condition Clause 5.3.1.2.3 ULS
AR = (do-di) * hc = 3240 mm
Vesd = 4*Nsd*he/(pi*di) = 205.42 kN
Vfxysd = sqrt(Vfxsd^2+Vfysd^2) = 0.00 kN
Vsd = Vesd + Vfxysd = 205.42 kN
Vrd = fy*AR/ϒm = 1001.454545 kN
Vsd < Vrd ------ OK

POT Wall Subjected to Shear forces for normal condition Clause 5.3.1.2.4 ULS
V'sd = (Vesd+1.5 Vfxysd)/di = 887.02 1/m kN
V'rd = (fy (do-di))/(2 ϒm sqrt(3)) = 8030.417 1/m kN
V'sd < V'rd ------ OK

POT Wall Subjected to Shear forces for seismic condition Clause 5.3.1.2.4 ULS
V'sd = (Vesd+1.5 Vfxysd)/di = 684.72 1/m kN
V'rd = (fy (do-di))/(2 ϒm sqrt(3)) = 8030.417 1/m kN
V'sd < V'rd ------ OK

POT base Subjected to Tensile forces for normal condition Clause 5.3.1.2.5 ULS
Ap = do kb = 0.0123 m2
Vsd = 266.11 kN
TVrd = (fy Ap)/ϒm = 3797.18 kN
Vsd < TVrd------ OK

POT base Subjected to Tensile forces for seismic condition Clause 5.3.1.2.5 ULS
Ap = do kb = 0.0123 m2
Vsd = 205.42 kN
TVrd = (fy Ap)/ϒm = 3797.18 kN
Vsd < TVrd------ OK

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 Minimum Thickness of POT base shall not be less than 2.5% of inner diameter of the POT cylinder
Clause 5.3.1.3
T2 min = 2.5% di = 7.5 mm
T2 = provided thickness of the POT base = 31.5 mm
T2min < T2------ OK

Flat contact surface under normal condition(NOT REQUIRED) Clause 5.3.1.4.1 ULS
𝑉_𝑅𝑑= (𝑓𝑦 𝑑_𝑖 𝑤)/(1.5 𝛾_𝑚 ) VRd = 741.818182 kN
𝑉_𝑅𝑑= (15 〖𝑓𝑢〗^2 𝑅 𝑑𝑖)/(𝐸𝑠 〖𝛾𝑚〗^2 )
Vsd < VRd_____OK

Flat contact surface under seismic condition(NOT REQUIRED) Clause 5.3.1.4.1 ULS
𝑉_𝑅𝑑= (𝑓𝑦 𝑑_𝑖 𝑤)/(1.5 𝛾_𝑚 ) VRd = 741.818182 kN

Vsd < VRd_____OK

𝑉_𝑅𝑑= (15 〖𝑓𝑢〗^2 𝑅 𝑑𝑖)/(𝐸𝑠 〖𝛾𝑚〗^2 )
Curved contact surface under normal condition Clause 5.3.1.4.2 ULS
Radius of contact surface R = 150 mm
𝑉_𝑅𝑑= (15 〖𝑓𝑢〗^2 𝑅 𝑑𝑖)/(𝐸𝑠 〖𝛾𝑚〗^2 )
VRd = 906.23 kN

Vsd < VRd_____OK

Curved contact surface under seismic condition Clause 5.3.1.4.2 SLS

Radius of contact surface R = 150 mm
𝑉_𝑅𝑑= (15 〖𝑓𝑢〗^2 𝑅 𝑑𝑖)/(𝐸𝑠 〖𝛾𝑚〗^2 )
𝑤_𝑒=3.04 √((1.5 × 𝑉_(𝐹𝑥𝑦,𝑠𝑑) VRd = 906.23 kN
× 𝑅)/(𝐸𝑠 × 𝑑𝑖))
Vsd < VRd_____OK

Design rotation ϴ Clause 5.1.7

ϴavg. = ϴv + ϴv' ϴavg. = 0.0118
ϴmax = ϴp + ϴv ϴmax = 0.0100
ϴ = ϴmass + 0.005 ϴ = 0.0150
< 0.03___OK

Effective contact width 𝑤_𝑒=3.04 √((1.5 × 𝑉_(𝐹𝑥𝑦,𝑠𝑑) Clause 5.3.1.4.2 ULS

× 𝑅)/(𝐸𝑠 × 𝑑𝑖)) we = 0.00 mm

we + ϴ di < w we + ϴ di = 4.500 mm
w = 12 mm
we + ϴ di < w____OK

Reduced area for eccentric loading Annexure B ULS

Lever arm for horizontal force = 59.5 mm
Horizontal force H = 285.00 kN
Moment M = 16.9575 kNm
Vertical force V = 2850 kN
Ar = Aco (1- 0.75 π e/L) e = 5.950 mm
e < L/8 - OK
Aco = 70685.8 mm2
Ar = 67382.6 mm2

III) Sliding Check

Slid path SA,d Cl. 5.1.8

SA,d = nv x ϴv,range x di/2 < 5 x ST
nv = 1.00E+06 nos.
POM seal and carbon filled PTFE seal ST = 2000 m
ϴv,range = 0.0050 rad

SA,d = 750 m < 5 x ST

5 x ST = 10000 m

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 Sliding Surface for Guides (PTFE) 'S' Cl.5.2.4.3

Protrusion 'h' h = 1.75+ L/1200 >2.2 h = 2.2000 mm >= 2.2 OK

Thickness 'tp' 2.2h < tp±8.0 tp = 4.84 mm
tp±8.0 = 12.5 mm
2.2h < tp±8.0 ---- OK

s = Ap/(uxh) x (tp-h)/h

Coefficient of friction for PTFE 'µmax'

o
minimum effective temperature = 40 C

average pressure for normal condition σp = 29.7 Mpa

average pressure for seismic condition σp = 22.9 Mpa

µmax for Normal condition µmax = 0.0303

𝐹_𝑅𝑑𝑢= 𝐴_𝑐0×𝑓_𝑐𝑑×√(𝐴_𝑐1/𝐴_𝑐0 ) ≤3×𝑓_𝑐𝑑×𝐴_𝑐0 0.03 < µmax < 0.08
µmax for Seismic condition µmax = 0.0365
0.03 < µmax < 0.08

IV) TOP PLATE :

Design resistance of the adjacent concrete structure. (Cl. 5.2.1.1) ULS

fcd = 20.10 Mpa
b1 = 425.000 mm
𝐹_𝑅𝑑𝑢= 𝐴_𝑐0×𝑓_𝑐𝑑×√(𝐴_𝑐1/𝐴_𝑐0 ) ≤3×𝑓_𝑐𝑑×𝐴_𝑐0 d1 = 425.000 mm
b2 = 600.000 mm < 3b1
d2 = 600.000 mm < 3d1

h > (b2-b1) OK
h > (d2-d1) OK

Ac0 = 180625.00 mm2

Ac1 = 360000.00 mm2

FRdu = 5125.50 kN
3 fcd Ac0 = 10891.6875 kN
Frdu < 3 fcd Ac0 OK

Maximum strain in bedding grout/concrete Cl 5.2.1.3 ULS

Limiting strain in concrete = 0.0035
Stress for normal condition = 46.72 Mpa
Strain for normal condition = 0.001361 OK

Stress for seismic condition = 33.59 Mpa

Strain for seismic condition = 0.000979 OK

Steel bearing component Cl 5.2.2

Limiting strain steel = 0.0035
Stress for normal condition = 43.52 Mpa
Strain for normal condition = 0.000218 OK

Stress for seismic condition = 33.59 Mpa

Strain for seismic condition = 0.000168 OK

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 Additional geometrical conditions for required rotation capacity (Cl. 5.3.1.5)
hc-he-(w-we)x0.5 - (ϴx0.5xdi) > δ
hp-(hc-he) - (ϴx0.5xDp) > δ
Flat contact surface w = 12 mm
we = 12.00 mm
δ = 3.00 mm
hc-he-(w-we)x0.5 - (ϴx0.5xdi) = 11.75 > δ OK
hp-(hc-he) - (ϴx0.5xDp) = 7.76 > δ OK

V) ANCHOR BOLTS :

Resistance in shear (Cl.5.3.6.2) ULS

Steel on concrete Seismic Zone III µk = 0.6
Ƴµ = 1.2
Edge distance = 30 mm
c/c distance = 60 mm
Minimum fastening thread length = 24 mm
Nsd,min = 60.12 kN
n = 4 nos.
A=As = 244.95 mm2
Fub = 800 Mpa
αv = 0.6
Ƴm2 = 1.25
Design shear resistance of single anchor
Fvrd = αv x fub x A / Ƴm2 Fvrd = 94.06 kN
Design value of anchorage resistance in shear
Vpd = n X Fvrd Vpd = 376.24 kN
Anchorage strength/frictional resistance
Vrd = µk/Ƴµ X Nsd,min + Vpd Vrd = 406.30 kN
Vxy,sd = 285.00 kN
Vxy,sd < Vrd OK

VI) ANCHOR SLEEVES : ULS

(Cl.5.3.6.4)
Diameter of sleeve = 50 mm
Sleeve length for Bottom = 200 mm
Sleeve length for Top = 200 mm
Resistance offered by concrete Frdu = D X L X fcd/(3)^1/2 Frdu = 116.05 KN
Design shear resistance of single anchor Fvrd = 94.06 KN
Frdu > Fvrd OK

VII) LUGS ULS

Thickness of Lug Lt = 25 mm
Length of Lug Ll = 75 mm
Area of Bolt Hole Ab = 600.00 mm2
Area of Lugs Al = 1875.00 mm2
Effective area of lug Ae = 1275.00 mm2

Horizontal force on each lug under normal condition

Hln = HRn
n
= 285.00
4
= 71.25 kN
Stress on lug due to horizontal force under normal condition
Sln = Hln x 1000
Ae
= 71250
1275.00
= 55.88 < 153 N/mm2

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 Horizontal force on each lug under Seismic condition
Hls = HRs
n
= 220.00
4
= 55.00 kN
Stress on lug due to horizontal force under Seismic condition
Sls = Hls x 1000
Ae
= 55000
1275.00
= 43.14 < 153 N/mm2

Check for Thickness of POT in Bending : Top

Maximum vertical load Vmax = 2850.00 kN
Effective Length / Width of Topplate Ble = 356 mm
Size of Loaded Area (PTFE) L = 310 mm
Projection of the Topplate = Ble - L
2
= 23 mm
Stress to concrete at Topplate = Vmax x 1000
Ble2
sct = 22.488 N/mm2
Bending Moment at the Top = sct x Projection2
2
BM = 5947.994 N.mm
Thickness of Topplate required to cater the Bending Moment
= BM Where sbt = 0.66 x fy
1/6 x sbt
12.611 mm < 23 mm Hence OK

Check for Thickness of POT in Bending : Bottom

Maximum vertical load Vmax = 2850.00 kN

Effective Dia. Of POT A
Dia. of Loaded Area (Pad) D5
Projection of the Piston
Stress to concrete at POT
scb
Bending Moment at the Top
= 363 mm
= 300 mm
= A - D5
2
= 31.5 mm
= Vmax x 1000
p/4 x A2
= 27.553 N/mm2
= scb x Projection 2

2
BM = 13669.514 N
Thickness of Topplate required to cater the Bending Moment
= BM Where sbt = 0.66 x fy
1/6 x sbt
19.118 mm < 31.5 mm Hence OK

A) Design of bracket for pre-compression arrangement for Sliding

bearings (Free in Both. Direction) :-

The minimum load req. to satisfy the condition of 2 Mpa.

( of IRC 83:2018 (Part III) )
D5
Diameter of Elastomeric300
Padmm mm
Vmin = 2 X 0.785 X mm X mm / 1000
Vmin = 142 KN
The minimum load60 available
KN. =
The difference for which the bracket is to be designed.
= 142 - 60 KN
= 82 KN.
(The bearing will be compresed by 82 KN force in the compression machine in our factory. After compression the bearing top
and bottom will be welded with the help of assembly patti of size 50 mm X 20 mm X 100 mm. to retain the compression load.)

Design of anti-uplift arrangement :-

= 41 KN. (Given in the load data.)

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 = 41 X 1.25 (Add 25 % extra as safety factor.)
= 51 KN.
So each bracket is to be designed for 51 KN load uplift.

1) Design of Projection : (Bracket)

Bending Moment, M = force x Dist.

= 51 KN x 25 N-mm
= 1279375
= 125 KN N-mm
x 10 mm = 1250 E+3 N-mm

Bending stress, s = M / Z
= 1E+06 /(1/6) x 60 x 25 x 25
= 205 N/mm2 < 224.4 N/mm2

Shear stress , ss = F / A
= 51 KN / ( 60 x 25 )
= 34 N/mm2 < 153 N/mm2

Combined stress Cs = 2
(s + (3 x σs 2))1/2

= 213.059 N/mm2 < 306 N/mm2

1) Design of Projection : (Lower Bracket)

Bending Moment, M = force x Dist.

= 51 KN x 25 N-mm
= 1279375 N-mm

Bending stress, s = M / Z
= 1E+06 /(1/6) x 60 x 25 x 25
= 205 N/mm2 < 224.4 N/mm2

Shear stress , ss = F / A
= 51 KN / ( 60 x 25 )
= 34 N/mm2 < 153 N/mm2

Combined stress Cs =
(s2 + (3 x σs 2))1/2

= 213.059 N/mm2 <306 N/mm2

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