WALLS & BRIDGES (I) PVT LTD.

,
Plot No C 60, A P I E., Balanagar,
Hyderabad
OWNER:
Ministry of Transport & Highways,
National Highway Authority of India, New Delhi

PROJECT:
1. Proposed construction of Two lane ROB with spans (1x 21.0m + 1x63.4m+
1x21.0m) at Rly KM4/3-4 between Kakinada Town and Ramachandrapuram
stations on Kakinada Town - Kotipalli Section as part of two laning of NH-216
at NH KM.34.809 &
2. Proposed construction of Two lane ROB with spans (1x37.2m + 1x63.4m +
2x19.33m + 1x24.1m + 2x20.0m) at Rly KM 7/570-630 between Sarpavaram -
Kakinada Town station on Samalkota - Kakinada stations.for Proposed
Kakinada Bypass of Kathipudi - Ongole Section in the state of Andhra Pradesh.

Railway Division: Railway Zone:

South Central Railway South Central Railway
Vijayawada Division Secunderabad

EPC Contractor:
Kunal Structures (India) Pvt Ltd., Kunal
House, Ganga Park, Plot No:10,
Panchavati Road, Rajkot.
 INDEX

SNO PARTICULARS PAGE NO.

1 SAILENT FEATURE 1

2 STRESS SUMMARY 2

3 WIND FORCE CALCULATION 3

4 FORCE CALCULATION 6

5 TRACK BEAM 24 MTR SPAN DESIGN 9

6 TRACK BEAM 12 MTR SPAN DESIGN 12

7 DESIGN OF TRESTLE COLUMN 14

8 DESIGN OF ISOLATED FOOTING FOR TRESTLE COLUMN 17

9 PULLING ARRANGEMENT 19

10 STAAD FILE FOR TRACK BEAM 24 MTR 20

 1. SALIENT FEATURES OF BOW STRING GIRDER

Rail Top Level = 158.944 m

Track Formation Level = 158.544 m

Pedestal Top Level = 165.313 m

Assembly Level of Bow String Girder = 167.913 m

OVERALL LENGTH OF GIRDER = 63.4 m

EFFECTIVE SPAN = 62 m

OVERALL LENGTH OF TOP ARCH = 66.215 m

C/C DISTANCE BETWEEN TRUSS = 15.864 m

NO. OF PANELS = 10 NOS.

PANEL LENGTH = 6.2 m

Page - 1
 2. STRESS SUMMARY
TRACK BEAM 24 MTR SPAN DESIGN (RAILWAY TRACK PORTION ) stress summary
Actual Allowable Ratio
2 2
compression bending 1155.74 kg/cm 1973.163 kg/cm 0.586 safe
2 2
Shear Force 482.71 kg/cm 1000 kg/cm 0.483 safe

TRACK BEAM 12 MTR SPAN DESIGN (NON RAILWAY TRACK PORTION) stress summary
Actual Allowable Ratio
24m Beam Section used for 12m Beam also.

TRESTLE UNIT
Actual Allowable Ratio
2 2
compression bending 534.263 kg/cm 1650 kg/cm 0.324 safe
2 2
AXIAL compression 290.084 kg/cm 1452 kg/cm 0.200 safe
COMBINATION 0.39 <1

Page - 2
 3. WIND FORCES CALCULATION
A Codes & Refernces
The code used is IRC:6 :2017

B Assumptions and Data

Calculation of effective area and cg of girder
Distance of CG from C/L of
Nos
Sr.No. Members L (m) B (m) Area (m2) Area (m2) bottom beam
A Y A
1 Bottom Chord 63.4 1.2 76.08 1 76.08 0 0
2 Top Chord 66.215 1.2 79.458 1 79.458 4.4 349.615
3 Vertical 2.646 0.6 1.5876 2 3.1752 1.32 4.201
4 Vertical 5.432 0.6 3.2592 2 6.5184 2.72 17.704
5 Vertical 7.33 0.6 4.398 2 8.796 3.67 32.237
6 Vertical 8.436 0.6 5.0616 2 10.1232 4.22 42.700
7 Vertical 8.8 0.6 5.28 1 5.28 4.4 23.232

189.4308 469.689
Distance of CG of effective exposed area of girder from c/l of bottom chord
= 469.688962 / 189.4308 = 2.479 m

Ground level = 158.544 m

Bottom level of Temporary Longitudnal beam = 165.313 m
Depth of temporary longitudnal beam = 1.40 m
Depth of rolling arrangement = 0.6 m
height above ground level = 11.248 m
say = 12 mtr
2
wind pressure as per table 12 of IRC6 2017 for 15MTR height and 33m/s = 512.5 N/m
basic wind speed for plain terrain
As per fig 6 of IRC6-2017 basic wind speed at the location of rob = 33 m/s
C Load Calculation

Wind Load
=
2
Basic wind pressure 512.5 x33 x33 /33 /33 = 512.500 N/m
2
As per note 6 of table 12 of IRC 6:2017 for construction stage 0.7x 512.5 = 358.750 N/m
Calculation of exposed Area

Exposed Area os all individual members = 189.431 m2

Overall area of truss of arch shape=2/3trd of length x height = 2/3 x 63.4 x 8.8

= 371.947 m2

Solidity Ratio = Exposed Area = 189.431

Total Area 371.947
= 0.509
As per table C-1 Drag cofficient of IRC:6 of 2017 = 1.65

Frame Spacing ratio = 15.864 / 8.8 = 1.803

Shielding factor for multiple frame as per table C-2 of IRC:6 2017 = 0.55

Cf for inner side truss members 1.65 x 0.55 = 0.9075

Page 3
 As per Clause 209.3.3 Transverce wind force = PzxATxGxCD
. Where
2
Pz = 358.750 N/m
G = 2
Wind force on windward truss
358.750 x 2 x 1.65 x 189.4308 = 224262.39 N
= 22860.59 Kg
Wind force on leeward truss
358.750 x 2 x 0.9075 x 189.4308 = 123344.31 N
= 12573.32 Kg
Total wind load on both Leeward and windward direction = 35433.91 Kg

As per Cl. 209.3.5, upward and downward vertical Wind forces

Where
2
Pz = 358.750 N/m
G = 2
CL lift Coefficient = 0.75
2
Plan area of bottom cross beams = 249.4438 m
Vertical Wind Force
358.750 x 2 x 0.75 x 249.4438 = 134231.94 N
= 13683.17 Kg
WIND FORCES CALCULATION ON LONGITUDNAL BEAM (1400mm height)
A Codes & Refernces
The code used is IS 875-1987 (Part 3)- A code for practise for Design Loads for buildings and structures

B Assumptions and Data

height above ground level upto cg of temporary beam = 7.469 m
2
wind pressure as per table 12 of IRC6 2017 for 10mtr height = 463.7 N/m
Maximum wind speed during Assembly stage as per fig 6 of IRC 6 2017 = 33 m/s

C Load Calculation
i) Wind Load
=
2
Basic wind pressure 463.7 x33 x33 /33 /33 = 463.700 N/m
2
As per note 6 of table 12 of IRC 6:2017 for construction stage 0.7x 463.7 = 324.590 N/m
As per Clause 209.3.3 Transverce wind force = PzxATxGxC D
. Where
2
Pz = 324.590 N/m
G = 2
CD = 2.2
height of beam = 1.4 m
Transverce Wind force on beam .
324.59 x 2 x 1.4 x 2.2 = 1999.47 N/m
= 203.820 Kg/m

Page 4
 WIND FORCES CALCULATION FOR TRESTLE

A Codes & Refernces

The code used is IRC 6:2017

B Assumptions and Data

height above ground level upto bottom of temporary beam = 6.769 m
2
wind pressure as per table 12 of IRC6 2017 for 10mtr height = 463.7 N/m
Maximum wind speed during Assembly stageas per fig 6 of IRC 6 2017 = 33 m/s

C Load Calculation
i) Wind Load
=
2
Basic wind pressure 463.7 x33 x33 /33 /33 = 463.700 N/m
2
As per note 6 of table 12 of IRC 6:2017 for construction stage 0.7x 463.7 = 324.590 N/m
As per Clause 209.3.3 Transverce wind force = PzxATxGxC D
. Where
2
Pz = 324.590 N/m
G = 2
CD = 2
Width of trestle leg = 0.25 m
Wind force on trestle .
324.590 x 2 x 0.25 x 2 = 324.59 N/m
= 33.09 Kg/m

Page 5
 4. 63.4 MTR SPAN BOW STRING GIRDER (QTY-1 NOS)

NAME PARTS PART NAME DESCRIPTION THK WIDTH LENGTH QTY WEIGHT

BLB-1 - 11 MTS (Both Top & Bottom plate 25 780 11000 4 6735.30
Sides) Front & Back Side Plate 25 1150 11000 4 9930.25
BLB-2 - 11.5 MTS Top & Bottom plate 25 780 11500 4 7041.45
(Both Sides) Front & Back Side Plate 25 1150 11500 4 10381.63
BLB-3 - 11.5 MTS Top & Bottom plate 25 780 11500 4 7041.45
(Both Sides) Front & Back Side Plate 25 1150 11500 4 10381.63
BLB-4 - 11.7 MTS Top & Bottom plate 25 780 11700 4 7163.91
(Both Sides) Front & Back Side Plate 25 1150 11700 4 10562.18
BLB-5 - 7.7 MTS (Both Top & Bottom plate 25 780 7700 4 4714.71
Sides) Front & Back Side Plate 25 1150 7700 4 6951.18
BLB-6 - 10 MTS (Both Top & Bottom plate 25 780 10000 4 6123.00
Sides) Front & Back Side Plate 25 1150 10000 4 9027.50
Bottom Long Beam - Diaphram Plates & Other Misclleneous
Diaphram plates @
Non-Hanger Location DP1 18 750 1150 36 4387.37

Bottom Long Diaphram plates @

1 DP1 18 750 1150 18 2193.68
Beam(BLB) Details Hanger Location
DP2 25 750 1150 36 6093.56
Diaphram plates @L0 DP1 18 750 1150 4 487.49
Location DP2 25 750 1150 24 4062.38
End cover plate for
Bottom long beam Comes at LO Location 6 800 1200 4 180.86

Supporting Stiffners inner Stiffners 20 555 1099 16 1532.18

Outer Stiffners 20 220 820 16 453.16
Cover Plate for For inner Stiffners 6 576 800 4 86.81
Supporting Stiffners
For Outer Stiffners 6 772 800 4 116.36
Cover Plate for Joint 3948674.644
For Joint at BLB & TAB 30 8 7439.30
at L0 & U0
Bottom Long Beam - Splice Plates
Zone-6,7,8,9,10 (BLB Top & Bottom Splice plate 30 700 1500 20 4945.50
Splice Joint) Front & Back side plate 30 1100 1500 20 7771.50
16 859 3000 18 5826.08
Bottom center cross web
16 859 9000 9 8739.12
beam ( I-Section )
25 300 3000 18 3179.25
@ Hanger Location - top flange
9 No's 25 300 9000 9 4768.88
36 425 3000 18 6485.67
bottom flange
36 425 9000 9 9728.51
16 859 3032 40 13084.95
Bottom center cross web
16 859 9000 20 19420.27
beam ( I-Section )
25 300 3032 40 7140.36
@ Non - Hanger top flange
Location - 20 No's 25 300 9000 20 10597.50
36 425 3032 40 14566.33
bottom flange
36 425 9000 20 21618.90
Web plate Splice 25 750 1300 58 11097.94
Bottom center cross
top flange inner Splice plate 36 150 1300 58 3196.21
Bottom Center beam - Splice Plate
2 Bottom flange outer Splice plate 25 475 1300 29 3514.35
& End Cross Beam Details
Bottom flange inner Splice plate 25 150 1300 58 2219.59
Details
36 380 3000 8 2577.31
Bottom end cross Top & Bottom plate
36 380 9000 4 3865.97
beam
36 848 3000 8 5751.48
End Beams - Box Front Side Plates ( Front & Back )
36 848 9000 4 8627.21
Beams (2 no's)
Side plates - splice plates 36 800 1300 8 2351.23
& Splice Plate Details
Top & Bottom - splice plates 36 340 1300 8 999.27
Supporting Stiffners @ Centre Cross Beam 20 150 150 290 512.21
DP Plates &
Supporting Stiffners @ End Cross Beam 20 150 150 20 35.33
Supporting Stiffners
DP Plates in End Bottom Cross Beam(Box Section) 25 328 848 12 655.03
At End Bottom Cross beam - L 150 x 150 x 12 - 27.2 Kg / Mtr 800 8 174.08
Stiffener Cleat Angles
At Bottom Center Cross beam - L 150 x 150 x 12 - 27.2 Kg / Mtr 800 116 2524.16
At End Bottom Cross beam - SHS 220 X 220 X 12 - 75.47 Kg / Mtr 1635 2 246.79
Bottom Cross Beam -
At Bottom Center Cross beam - SHS 220 X 220 X 12 - 75.47 Kg / Mtr 2027 28 4283.38
SHS Section Beams
Packing Plates for SHS Section 12 270 270 60 412.03

Page 6
 Top plate 25 780 11834 2 3622.98
TAB-1 - 11.893 MTS
Bottom plate 25 780 9892 2 3028.44
(Both Sides)
Side Plates (Front & Back) 25 12476314 4 9793.91
Top plate 25 780 11776 2 3765.65
TAB-2 - 11.664 MTS
Bottom plate 25 780 11518 2 3683.29
(Both Sides)
Side Plates (Front & Back) 25 13390695 4 10511.70
Top plate 25 780 12300 2 3765.65
TAB-3 - 12.162 MTS
Bottom plate 25 780 12031 2 3639.51
(Both Sides)
Side Plates (Front & Back) 25 13985908 4 10978.94
Top plate 25 780 12154 2 3720.95
TAB-4 - 12.018 MTS
Bottom plate 25 780 11888 2 3639.51
(Both Sides)
Side Plates (Front & Back) 25 13820867 4 10849.38
Top plate 25 780 8297 2 2540.13
TAB-5 - 8.204 MTS
Bottom plate 25 780 8116 2 2484.71
(Both Sides)
Side Plates (Front & Back) 25 9435031 4 7406.50
Top plate 25 780 10217 2 3127.93
TAB-6 - 10.294 MTS
Bottom plate 25 780 8311 2 2544.41
(Both Sides)
Side Plates (Front & Back) 25 10637209 4 8350.21
Top Arch Beam
4 Top Arch Beam Splice Top & Bottom Splice plate 30 700 1400 20 4615.80
Details ( TAB )
Plate Front & Back side plate 30 1100 2000 20 10362.00
DP2 Plate @ H-1 & H-9 Hanger Location - type-1 25 750 1319 4 776.56
DP2 Plate @ H-1 & H-9 Hanger Location - type-2 25 750 1310 4 771.26
DP2 Plate @ H-1 & H-9 Hanger Location - type-3 25 750 1325 4 780.09
DP2 Plate @ H-1 & H-9 Hanger Location - type-4 25 750 1305 4 768.32
DP2 Plate @ H-2 & H-8 Hanger Location - type-1 25 750 1241 4 730.64
DP2 Plate @ H-2 & H-8 Hanger Location - type-2 25 750 1235 4 727.11
DP2 Plate @ H-2 & H-8 Hanger Location - type-3 25 750 1244 4 732.41
DP2 Plate @ H-2 & H-8 Hanger Location - type-4 25 750 1232 4 725.34
DP Plate Details DP2 Plate @ H-3 & H-7 Hanger Location - type-1 25 750 1191 4 701.20
DP2 Plate @ H-3 & H-7 Hanger Location - type-2 25 750 1188 4 699.44
DP2 Plate @ H-3 & H-7 Hanger Location - type-3 25 750 1193 4 702.38
DP2 Plate @ H-3 & H-7 Hanger Location - type-4 25 750 1185 4 697.67
DP2 Plate @ H-4 & H-6 Hanger Location - type-1 25 750 1162 4 684.13
DP2 Plate @ H-4 & H-6 Hanger Location - type-2 25 750 1150 4 677.06
DP2 Plate @ H-4 & H-6 Hanger Location - type-3 25 750 1163 4 684.72
DP2 Plate @ H-4 & H-6 Hanger Location - type-4 25 750 1159 4 682.36
DP2 Plate @ H-5 Hanger Location 25 750 1151 8 1355.30
25 380 7000 14 7308.35
Top & Bottom plate
25 380 4000 28 8352.40
25 550 7000 14 10577.88
Top Tie Beam Side Plates ( Front & Back )
25 550 4000 28 12089.00
Supporting Stiffners 20 150 150 28 49.46
Top Tie Beam DP Plates for Top Tie Beam 18 350 550 28 761.61
5 & Lateral Bracing Top & Bottom plate 25 480 9500 24 21477.60
Beam Details Top Lateral Bracing Side Plates ( Front & Back ) 25 500 9500 24 22372.50
Beam Supporting Stiffners 20 150 150 24 42.39
DP Plates for Top Lateral Bracing Beam 18 450 500 24 763.02
Top & Bottom Splice Plates 30 350 400 28 923.16
Top Tie Beam - Splice
Plates Side Splice plates(Front & Back) 30 500 500 28 1648.50

Bearing Plate Bearing Plate for

6 Bottom Plate of Bottom Long beam LO Location 30 1000 1000 8 1884.00
Details Bottom Long Beam

Comes on Top of
7 STUDS Dim: 25mm x 200mm - 181no's in a row Unit weight - 843 Grams 22444 18920.29
bottom Cross Beams

Weight of span without hanger 546.5

Per meter weight of span 546.501 / 63.4 = 4.310 MT
2

Page 7
 Front and Back Side plate 32 580/1100 5245 8 8969.02
H-1(Left side) & H-
Side Plate(Right) 25 800 2727 4 1712.56
9(Right side)
Side plate(Left) 25 800 2418 4 1518.50
Front and Back Side plate 32 580/1100 7920 8 12002.66
H-2(Left side) & H-
Side Plate(Right) 25 800 5504 4 3456.51
8(Right side)
Side plate(Left) 25 800 5286 4 3319.61
Front and Back Side plate 32 580/1100 9723 8 14069.26
H-3(Left side) & H-
Side Plate(Right) 25 800 7387 4 4639.04
7(Right side)
Side plate(Left) 25 800 7246 4 4550.49
Front and Back Side plate 32 580/1100 10750 8 15249.83
H-4(Left side) & H-
Side Plate(Right) 25 800 8467 4 5317.28
6(Right side)
Side plate(Left) 25 800 8400 4 5275.20
Front and Back Side plate 32 580/1100 11049 4 7796.64
3 Hanger Details H-5(Centre Hanger) Side Plate(Right) 25 800 8800 2 2763.20
Side plate(Left) 25 800 8800 2 2763.20

Stiffner Clips at
Hangers edges(Top & Top & Bottom Side Stiffners for H-1 to H-9 20 250 250 288 1413.00
Bottom)

Cover plate @ Top - Left side of Hanger 6 257 800 18 174.31

Stiffener Cover Plates Cover plate @ Top - Right side of Hanger 6 430 800 18 291.64
Cover plate @ Bottom Left & Right side of Hanger 6 356 800 36 482.91
DP1 for H-1 & H-9 18 550 800 8 497.38
DP1 for H-2 & H-8 18 550 800 12 746.06
DP Plate Details DP1 for H-3 & H-7 18 550 800 12 746.06
DP1 for H-4 & H-6 18 550 800 16 994.75
DP1 for H-5 18 550 800 16 994.75

C/C of Each node = 6.2 mtr

1no. L1 hanger weight = 3.29 MT
1no. L2 hanger weight = 5.00 MT
1no. L3 hanger weight = 6.12 MT
1no. L4 hanger weight = 6.83 MT
1no. L5 hanger weight = 7.40 MT
Weight of 1 no Trolley = 1 MT
Bowsting girder nodal load as moving load at each node
Bowstring girder nodal loads+roller weight
L0 L1/U1 L2/U2 L3/U3 L4/U4 L5/U5 L6/U6 L7/U7 L8/U8 L9/U9
14.4 31.0 32.7 33.8 34.5 35.1 34.5 33.8 32.7 31.0
Nodal load considering extra 10% for impact factor,
L0 L1/U1 L2/U2 L3/U3 L4/U4 L5/U5 L6/U6 L7/U7 L8/U8 L8/U8
15.8 34.1 36.0 37.2 38.0 38.6 38.0 37.2 36.0 34.1
Wind reaction
1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02

Total reaction on each node

16.8 35.1 37.0 38.2 39.0 39.6 39.0 38.2 37.0 35.1

82.48847 172.341 181.551 187.594 191.414 194.477 191.414 187.594 181.551 172.341

Page 8
 5. TRACK BEAM 24 MTR SPAN DESIGN (RAILWAY TRACK PORTION)
Loads

Reaction on each trolley = 39.65 MT

C/C of trolley = 6.20 mtr
Self weight of Track Beam = 0.80 MT/mtr
Construction live load on Beam = 0.55 MT/mtr
C/C of support = 24 mtr
Analysis of track beam is done on STAAD pro software
Max bending moment due to point load(from staad) = 435.25 MT-mtr
Max bending moment due to UDL(M) = 97.33 MT-mtr
Total BM = 532.58 MT-mtr
Max Shear due to point load(from staad) = 91.90 MT
Max Shear due to UDL = 16.22 MT
Total Shear Force = 108.13 MT
Design of Track beam (I girder 24mtr span)
Provided 2nos. Plate Girders placed 775mm apart with top and bottom flanges 400x25 and web plate 1350x16
Properties of plate girder
2
Area = 924.16 cm
Ytop Ay/A = 76.7 cm
Ybot = 63.3 cm
4
Ixx = 2918283.647 cm
3
Ztop = 38062.186 cm
3
Zbot = 46081.656 cm
rxx = 56.194 cm

Mean flange thickness T = 31.000 mm

Overall depth D = 1400.000 mm
T/t = 1.938
d/t = 83.625
L/rxx = 42.709
D/T = 45.161
5 2
Y = 26.5x10 /(l/rxx) = 1452.79 MPA
X = Y[1+1/20 (l yT/D)2] = 1484.92 MPA
Coefficient k1 = 1.00 Coefficient k2 = 0.00
Yield strength of material = 250.000 MPA
Elastic critical stress in bending compression fcbx = k1 x (X+k2Y) x (c2/c1) = = 1781.90
Maximum permissible bending stress = = 157.85 MPA
Permissible stress with 25% increase due to wind load = = 197.32 MPA
2
Bending Stress M/Z = 1155.74 Kg/cm
2
Permissible stress < 1973.163 Kg/cm
Hence safe

2
Shear stress = 482.7 Kg/cm
2
< 1000 Kg/cm
Hence safe

Load bearing stiffener

Max shear force on single I section 54.06 MT

2
Allowable bearing stress 1875 kg/cm
2
Bearing area required 28.83 cm

Page 9
2 nos Stiffeners provided 20x400
2
Bearing Area of stiifener 160 cm
Outstand should not be more than 12t 12x2 24 cm

2
Area of stiffener 2x2x24 96 cm
4
Ixx 2304 cm
r 4.90 cm
effective length 0.7x140 98 cm

L/ryy 98/4.90 20.004

2
From IS 800 -1984 for L/r =20.0 and Fy= 250N/mm
2
Allowable stress 2230 Kg/cm
Safe load 2230x96 214080 kg
54063 kg
Which is sufficient

Check for deflection

Max deflection due to point load from staad = 33.682 mm
Max deflection due to dead load from staad = 1.001 mm
Total Actual deflection = 34.683 mm
Allowable deflection L/600 40.000 mm
Inherent stiffness of Bow String Girder will not allow Rolling Girder to deform, hence SAFE

Splice design
Design B.M at the Splice Location (Splice joint designed for maximum B.M. & S.F.) 532.58 MT-mtr
Maximum Shear force on the Rolling girder = 108.13 MT
Stress in the Top flange 2
= 1155.74 Kg/cm
Stress in the Bottom flange 1155.74 2
= Kg/cm
Maximum tensile / compressive force in flange = 115.57 MT

Provide 24mm dia HTS bolts in single shear

Strength of bolt:
a) In single shear
Diameter of bolt = 24.00 mm
Area of bolt = 353.00 mm2
Permissible shear stress = 80x1000x0.7/235 (Cl. 8.9.4.3 IS:800-1984) = 238.30 MPa
Strength of bolt in single shear = 8.57 MT
b) In bearing
Permissible bearing stress in bolt = 350.00 Mpa
Thickness of cover plate = 25.00 mm
Thickness of flange plate = 25.00 mm
Strength of bolt in bearing = 21.41 MT
Hence Strength of bolt = (Min. of strength in single shear and bearing) = 8.57 MT
Provide 4 rows of bolts
Hence no. of bolts in one row = 3.4
Provide 6 bolts in a row
Strength of joint = 8.57 x 4 x 6 = 205.80 kN
SAFE
Check for strength of splice plate:
Thickness of splice plate = 50.00 mm
Width of splice plate on one side of web = 182.00 mm
Diameter of bolt = 24.00 mm
Cross section area of splice plate = 9100.00 mm2
Deduct area of holes 1 nos (holes are staggered) = 1200.00 mm2
Net area of cover plate = 7900.00 mm2
Permissible tensile stress in splice plate = 0.6 x 250 = 150.00 Mpa
Strength of both splice plates = 241.59 MT
SAFE

Page 10
Design of web splice plate
Max. shear force at splice = 108.13 MT
Strength of bolt: splice plates are provided on both sides of web
a) In double shear
Diameter of bolt = 24.00 mm
Area of bolt = 353.00 mm2
Permissible shear stress = 80x1000x0.7/235 (Cl. 8.9.4.3 IS:800-1984) = 238.30 MPa
Strength of bolt in double shear = 17.15 MT
b) In bearing
Permissible bearing stress in bolt = 350.00 Mpa
Thickness of cover plate = 12.00 mm
Thickness of web plate = 16.00 mm
Strength of bolt in bearing = 10.28 MT
Hence Strength of bolt = (Min. of strength in single shear and bearing) = 10.28 MT
Provide 2 rows of bolts
Hence no. of bolts in one row = 5.3
Provide 10 bolts in a row
Strength of joint = 10.28 x 2 x 10 = 205.50 MT
SAFE
Check for strength of cover plate:
Thickness of cover plate = 12.00 mm
Depth of cover plate on one side of joint = 1100.00 mm
Diameter of bolt = 24.00 mm
Cross section area of cover = 13200.00 mm2
Deduct area of holes 10 nos = 2880.00 mm2
Net area of cover plate = 10320.00 mm2
Permissible tensile stress in cover plate = 0.6 x 250 = 150.00 Mpa
Strength of cover plate = 315.60 MT
SAFE

Page 11
6 TRACK BEAM 12 MTR SPAN DESIGN (NON RAILWAY TRACK PORTION)
Design of Track beam (I girder 12mtr span)

Section provided for 24m span is used for 12m span as well. As the span has reduced and same section
used
separate design calculations not provided

Page 12
Section Properties of Rolling Girder

Plate Width Depth 2 4 4

S.No Area (mm ) Y (mm) AxY Ȳ-Y (mm) IXX (mm ) M.I (mm )
description (mm) (mm)
1 Top Flange 800 25 20000 1387.5 27750000 754.215 1041666.667 11377837381
2 Web plate 32 1338 42816 706 30228096 72.715 6387590592 6613976976
3 Bottom Flange 800 37 29600 18.5 547600 614.785 3376866.667 11191022109
92416 58525696

775
25
1400

16

37

400 400

Ȳ=𝐴1 𝑌1+𝐴2 𝑌2+𝐴3 𝑌3+𝐴4 𝑌4+𝐴5 𝑌5+𝐴6 𝑌6+𝐴7 = 633.285 mm

4
M.I About XX = 2.9E+10 mm
3
Sectional Madulas top (Ztop) = 4.6E+07 mm
3
Sectional Madulus bottom (Zbottom) = 4.6E+07 mm

Provide 12mm thick additional plate below 25mm bottom flange in central 12m length of 24m span,

Page 13
 7. DESIGN OF TRESTLE COLUMN
Height of column = 6.8 mtr
Max span of Track Beam = 24.0 mtr
Maximum reaction on trestle shall be on max & its adjoining span
Length of track beam over railway track = 24.00 mtr
length of adjoining track beam of railway track = 12.00 mtr
Segment length of track beam causing Horizontal force in trestle 24.00 12.00 = 18.00 mtr

Vertical load in Trestle from track beam (from STAAD analysis of track beam) = 48.1 MT
Vertical Load due to Track beam self weight = 16.2 MT
Weight of top beam and trestle = 8.8 MT
Maximum Vertical load coming on the column = 83.1 MT
Maximum Vertical load+30% Wt. of Bracing & Lacing of track beam, bolts & nuts coming on the column = 87.94 MT

Horizontal force in bottom longitudnal force = 2606.70 kg

Horizontal force in Top arch = 2606.70 kg
Horizontal force in vertical = 1303.35 kg
Transverce Wind Load from Bow string girder = 6516.74 kg
= 6.52 MT
Lever Arm of trolley top to Trestle base = 8.77 mtr
Transverce wind load from Longitudnal track beam = 3.67 MT
Lever Arm of Longitudnal track beam to Trestle base = 7.47 mtr
Transverce wind load on Trestle = 0.56 MT/m
Lever Arm of Trestle top to column base = 6.77 mtr

Total Bending moment due to transverse wind force on trestle = 86.44 MTm

Longitudinal force due to rolling effect (8% of vertical force) = 5.95 MT

Total Bending moment due to Longitudnal force = 44.41 MTm

properties of trestle unit:

Properties of SHS 250x250x8
2
Ax = 75.79 cm
4
Ixx = 7315.7 cm
weight 2150 = 59.50 kg/m

1500

properties of built up section consiting of four SHS 250x250x8

2
Area of combined section = 303.16 cm
4
Moment of inertia of combined section = 1213481.4 cm
rxx of combined section = 63.27 cm

properties of built up statging consiting 9 cribs

2
Area of combined section = 303.16 cm
4
Moment of inertia of combined section = 1213481.4 cm
rxx of combined section = 63.27 cm
3
Zxx of combine section = 16179.75 cm

considerin
= g max
Height of column considered(L) 6.77 m height
Effective height 2L = 1353.8 cm
Hence λ L/rxx 1353.8 / 63.27 = 21.40

Page 14
Allowable slenderness ratio = 180.00 SAFE
Elastic critical stress in axial compression fcc = p2 E/(lmax)2 = 4548.15
148.18 N/mm2
2
Permissible compressive stress = 1452.17714 kg/cm
Capacity of the column = 440242.023 kg
= 440.2 t
> 83.1 t SAFE

MAX Bending moment in trestle = 86.44 t-m

2
Bending stress , sbc =M/Z 8644236.1 / 16179.8 = 534.26 kg/cm
2
Allowable Bending stress = 1650 kg/cm SAFE
2
Allowable bending stress with 1.33% increase = 2194.5 kg/cm
2
Axial stress , sac =P/A 87941.946 / 303.16 = 290.08 kg/cm
2
Allowable axial stress = 1452.177 kg/cm SAFE
when wind speed exceeds 30KMPH, the pulling of girder shaal be stopped.
2
Allowable axial stress 1.33% increase, sas = 1931.396 kg/cm
Hence sbc/sbs + sac/sas = 0.39 < 1
SAFE

Design of Trestle Bracing System:

= as per
Section used for lacing system SHS 80X80X4.8 IS:1161
rmin = 3.04 cm
L = 125 cm SAFE

L/rmin = 28.78 < 140 ( cl.5.7.2.3 of IS:800-1984)

Design of bracing for connecting two trestles in transverce direction

Distance between trestles = 150 cm
Height of trestless for bracing purpose = 66 cm
Length of bracing = Sqrt ( 150 ^ 2+ 66 ^ 2
= Sqrt ( 22500 + 4356 )/ 2 = 81.94 cm
Using SHS 80x80x4.8 Ixx = 127.58 cm4
Area = 13.85
rmin = 3.04
Slenderness ratio = 0.85 X 81.939 / 3.04 = 22.911
< 180
HENCE SAFE
Design of bracing for connecting two trestles in longitudnal direction
Distance between trestles = 1200 cm
Height of trestles for bracing purpose = 300 cm
Length of bracing = Sqrt ( 1200 ^ 2+ 300 ^ 2
= Sqrt ( 1440000 + 90000 )/ 2 = 618.466 cm
Using 2 ISMC100 Ixx = 384 cm
Area = 24.4
rmin = 3.97
Slenderness ratio = 0.85 X 618.4658438 / 3.97 = 132.417
< 180
HENCE SAFE

Page 15
DESIGN OF LONGITUDINAL BEAM

Max Reaction = 32.16 Mt

Center to Center support on member = 1.20 mtr
Maximum Bending Moment
`
32.163 ` 32.163

0.6 0.6

0.2125 0.775 0.2125

1.20
Design for max. Shear force
Moment about B = 38.595
Reaction at A = 32.163
Reaction at B = 32.163
Max shear force due to point load = 32.163 MT

Max bending moment due to point load(M) = 12.463 MT-mtr

Consider 2 ISMB 400 below member
3
Section modulus of member Z = 2040 cm
2
Bending stress M/Z 12.46 / 2040 = 611 kg/cm
2
Allowable Bending stress = 1650 kg/cm SAFE

2
Area of ISMB400 Web = 71.2 cm
2
Shear stress F/A 32162.7 / 71.2 = 452 kg/cm
2
Allowable Shear stress = 980 kg/cm SAFE

Check for Concrete Bearing Strength

Grade of Concrete used = 25
As per IS 456 CL 34.4
Bearing strength of concrete 0.45 Fck = 0.45 x 25 = 11.25 N/mm
2

Maximum vertical load on each column of trestle = 207.69 kN

Size of base plate = 430 x 430 mm
Actual Bearing pressure 207.688 x1000 / 430 x 430 = 1.12 N/mm2
HENCE SAFE

Page 16
 8. DESIGN OF ISOLATED FOOTING FOR TRESTLE COLUMN SUPPORTING 24M BEAM
SIZE 5 X 5 X 0.6
GRID No. Short Bars
Axial Load(as per trestle calculation) = 830.7535 KN Max Load on trestle
self wt of footing= = 367.5 KN Long Bars
Total vertical Load on footing = 1198.254 KN Y 16 @ 11 c/c
max moment in trestle = 864.42 KNm
Assumed bearing capacity of soil= = 160 KN/sq mt.
Grade of concrete= M25 Grade of steel= Fe415
Size of Column= b= 1500 D= 2150
Size of footing provided
Width = 5 m
Length = 5 m
Area of footing = 25 sqmt
3
Section modulus of footing = 20.833 m
Net upward pressure intensity= 1198.2535 / 25 47.9301 KN/sqmt < 160 KN/sqmt
Pressure on footing 1198.254 + 864.42 = 89.42247 KN/sq mt.
due to vertical and wind load 25 20.833
Assuming bearing capacity with 1.33% increase < 200 KN/sq mt.
Bending Moment(Mu)
Mu= 1/2*NUPI*(lx-b)/2*(lx-b)/2 per mt.
Max Mu 0.5 X 134.134 X( 5 - 1.5 )/ 2
X( 5 - 1.5 )/ 2
Mu= 205.392 KN-mtr
Adopt over all depth= 600 mm
Effective cover = 50 mm
Reinforcemet to be used 8 mm
Effective depth(d) = 542 mm
Mu/bd2 0.699
By solving the equation Ast= 1086.25 sq mm
% of steel=100*Ast/(bd)= 0.200 %
Min. steel as per IS.456-1978 0.15 % 813 sq mm
Use 16 mm bars@ 110 mm c/c
Area of 16 mm = 3.14 / 4 x 16 ^2 201 sqmm
Area Provided = 1826.91 > 1086.25 Hence Safe
SAFE

Check for shear

One way action
The critical section is taken at a distance "d" away from the face of column
Factored Shear force(Vu)=NUPI*((lx-b)/2-d)
= 89.422 x( 5 - 1.5 )/ 2 - 0.542
Vu= 108.0223 KN
Nominal Shear stress(Tv)=Vu/bd
= 108022.35 / 542 x 1000
Tv= 0.199 N/sqmm
Shear strength of M25 concrete with
Area of steel = 1826.909 / 1000 / 542 x 100
= 0.337 %
As per Table 19 IS 456:2007
Tc= 0.39 N/sqmm > Tv Hence SAFE

Shear two way action

The critical section is taken at a distance 0.5d away from the face of column
Shear force (Vu)=NUPI(Area of footing-((b+d)*(D+d)))
= 89.422 X( 25 -( 1500 + 542 )/ 1000
X( 2150 + 542 )/ 1000 )
Vu= 1744.001 KN
Nominal Shear stress(Tv)=Vu/Bd
Perimeter of section(Bo)=2((b+d)+(D+d))
Bo= 2 X( 1500 + 542 )+( 2150 + 542 ))
Bo= 9468 mm
Tv= 1744000.8 / 9468 x 542
Tv= 0.340 N/sqmm
Shear strength of M20 concrete with T'c=Ks Tc where Ks=(0.5+Bc)
Bc=b/D= 0.698 Therefore Ks= 1.19767 Since Ks< or =1

T'c=Tc=0.25SQRT OF 20 = 1.118 > 0.340 Hence SAFE

Page 17
Check for sliding
Sliding force=Horizontal force = 10% of Vertical force = 11.983 MT
Resistance force = 119.825 MT
Base Soil angle of internal friction = 25 deg
Resistance against sliding Tan 25 x Resistance force
0.5 x 119.82535 = 59.913 MT
> 11.983 MT
SAFE

Uplift calculation
Max uplift on foundation pad = 847.135 knm
Restraining momment 1198.254 x 2.5 = 2995.63 knm
Fector of safety against overturrning 2995.634 / 847.1351 = 3.536
> 1.200
SAFE

Page 18
 9. PULLING ARRANGEMENT
Weight of steel truss with temporary arrangement = 700 MT
Length of steel truss = 63.4 mtr
Cofficient of friction = 0.050
Total weight to be pulled 700 x 0.050 = 35 MT
No. of Hydraulic Jacks used = 2 nos

Load on each Hydraulic Jack 35 / 2 = 17.5 MT

Provide 2 nos. Hydraulic Jacks having capacity 20Mt each

Checking of support during lowering with jacks

Maximum reaction on each jack 700 / 4 = 175 MT
Minimum supported wooden blocks 2x900x250 mm
Base area of wooden blocks = 4500 cm2
Pressure under wooden blocks = 38.88889 kg/cm2
Eccentricity of jacks = 0 cm
Total moment due to horizontal force 8% of vertical load = 1400000 kgcm
Section modulus of wooden block = 81250 cm3
Actual bending stress 1400000 / 81250 = 17.23077 kg/cm2
Permissible = 103 kg/cm2
safe
Stability against overturrning
Overturrning momment = 14 MTm
Stability momment 175 x 0.9/2 = 78.75 MTm
fector of safety 78.75 / 14 = 5.625
> 2

Page 19
10 STAAD REPORT FOR TRACK BEAM 24 MTR
STAAD SPACE
START JOB INFORMATION
JOB NAME MANCHERIAL ROB
JOB PART ROLLING GIRDER
ENGINEER NAME VS
ENGINEER DATE 10-06-2021
END JOB INFORMATION
INPUT WIDTH 72
PAGE LENGTH 1000
UNIT METER KN
JOINT COORDINATES
1 0 0 0; 2 0.5 0 0; 3 23.5 0 0; 4 24 0 0;
MEMBER INCIDENCES
1 1 2; 2 2 3; 3 3 4;
MEMBER PROPERTY AMERICAN
1 TO 3 TAPERED 1.4 0.016 1.4 0.475 0.025 0.475 0.037
DEFINE MATERIAL START
ISOTROPIC STEEL
E 2.05e+008
POISSON 0.3
DENSITY 76.8195
ALPHA 1.2e-005
DAMP 0.03
G 7.88462e+007
TYPE STEEL
STRENGTH FY 250000 FU 410800 RY 1.5 RT 1.2
END DEFINE MATERIAL
CONSTANTS
MATERIAL STEEL ALL
DEFINE MOVING LOAD
TYPE 1 LOAD 82.488 172.341 181.551 187.594 191.414 194.477 191.414 -
187.594 181.551 172.341 82.488
DIST 6.2 6.2 6.2 6.2 6.2 6.2 6.2 6.2 6.2 6.2
SUPPORTS
2 PINNED
3 FIXED BUT FX MZ
LOAD GENERATION 86
TYPE 1 -62 0 0 XINC 1
PERFORM ANALYSIS
PARAMETER 1
CODE INDIAN
PRINT SUPPORT REACTION LIST 1 4
FINISH

Page 20