DESIGN CALCULATION

POST TENSIONED PC-I SEGMENTAL GIRDER

JEMBATAN KA MASENG CIGOMBONG (BH. 89 INNER)
L=35.8 m; H=2.10 m; CTC=1.20 m; K-800

PT. DINAMIK STRUKTURAL SISTEM

Jl. Jatinegara Barat 4 No. 14-16 Jakarta Timur 13310
Tel : (021) 850 2539 Fax : (021) 819 2840
2020
Project : Jembatan KA Maseng Cigombong (BH. 89 Inner) Issued For : Information
Location : Jawa Barat Shop Drawing : -
Project No : DSS-1482-20 Design by : CC
Post-Tensioned I-Girder Design (L=35.8 m) Check by : EL
PT. Dinamik Struktural Sistem Date (Rev.) : 23-01-2020

1. BRIDGE DATA

Bridge Class = Class I Bina Marga Number of Girder, Ng = 4.00 Girder

Number of Span = 1 Span Total Wide of Bridge, Tw = 5.55 m
Beam Type = PC-I Segmental girder Number of Rail Way = 1 Way
Number of Segment = 5 Segments ( 6.5-7-8.8-7-6.5 )
Girder Length, Lg = 35.80 m Span Length, L = 35.00 m
Girder Spacing, s = 1.20 m Distance support-edge = 40.00 cm
t-slab = 25.00 cm t-deck slab, tds = 7.00 cm
t-ballast (J=1900 kg/m3) = 62.00 cm (t-deck slab=h-precast)
t-diaphragm = 20.00 cm h-diaphragm = 1.65 m
No. of Diaphragm Beam = 8.00 nos / girder h-barrier = 0.69 m
t-barrier = 0.30 m h-dapped end = 0.00 m
L-dapped end = 0.00 m L-railing = 0.3 m
h-curve = 0.00 m h-railing = 1m
L- drainage = 0.4 m h- drainage = 0.62 m
2. MATERIALS

2.1 Concrete PC-I GIRDER SLAB & DIAPHRAGM

Grade - K = 800.00 kg/cm2 500.00 kg/cm2
f'c= (0.76+0.2*log(sbk/150))*sbk = 724.32 kg/cm2 432.29 kg/cm2
Modulus Elasticity of Concrete, Ec = 3.82E+05 kg/cm2 2.95E+05 kg/cm2
Density, Jc = 2500.00 kg/m3 2400.00 kg/m3
n = Egirder/Eslab = 1.29
Allowable Stresses
At Transfer :
Concrete Quality Coef = 0.85 f ' c
f'ci = 615.67 kg/cm2
Eci = 3.52E+05 kg/cm2
Compression = 0.55 f ' ci
= 338.62 kg/cm2
Tension = 0.80 (f 'ci)0.5
= 19.85 kg/cm2
During Service :
Concrete Quality Coef = 1.00 f'c
f'c = 724.32 kg/cm2
Compression = 0.40 f'c
= 289.73 kg/cm2
Tension = 1.60 (f ' c)0.5
= 43.06 kg/cm2

2.2 Reinforcement
Diameter < 13 mm = U - 24 fy = 2400.00 kg/cm2
Diameter >/ =13 mm = U - 39 fy = 3900.00 kg/cm2
Modulus Elasticity, Es = 2.10E+06 kg/cm2

2.3 Post-Tensioning Strand dia 0.5" (12.70mm)

Uncoated Stress-Relieved Seven Wire Strand Grade 270-ASTM A416-90a,Low Relaxation Steel
Nominal Diameter = 12.70 mm
Nominal Cross Section Area, Aps = 98.71 mm2
Minimum Breaking Load = 184.00 kN
Nominal Mass = 0.775 kg/m'
Modulus Elasticity, Eps = 1.98E+06 kg/cm2
Ultimate Tensile Strength, fpu = 1860.00 MPa

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3. CODE REFERENCE
PERATURAN MENTERI PERHUBUNGAN REPUBLIK INDONESIA, No. PM 60 TAHUN 2012, SNI 1725-2016

4. GIRDER SECTION PROPERTIES

PC-I Girder Composite
Height of Girder = 2100.00 mm 2350.00 mm
w-top flange = 800.00 mm -
w-bot flange = 700.00 mm -
t-top flange = 200.00 mm -
t-bot flange = 250.00 mm -
h-top haunch = 120.00 mm -
h-bot haunch = 250.00 mm -
t-web = 200.00 mm -
h-web = 1280.00 mm -
b-precast = 80.00 mm -
h-precast = 70.00 mm -
Area = 7.52E+05 mm2 9.84E+05 mm2
Y bottom = 1011.95 mm 1297.64 mm
Moment Inertia, Ix = 4.14E+11 mm4 6.76E+11 mm4 PC-I GIRDER H= 2100
Top Sect Modulus,Wx-top = 3.80E+08 mm3 8.42E+08 mm3 (Top Fiber of Girder)
= 6.42E+08 mm3 (Top Fiber of Slab)
Bot Sect Modulus,Wx-bot = 4.09E+08 mm3 5.21E+08 mm3

5. LOADING
Loading Distribution
Inner Girder

Outer Inner Inner Outer DF

Ballast, Sleeper, Rail+ME 50.00% 100.00% 100.00% 50.00% 100.00%
DFbsl 0.1667 0.3333 0.3333 0.1667 0.33333
LL 50.00% 100.00% 100.00% 50.00% 100.00%
DFll 0.1667 0.3333 0.3333 0.1667 0.33333
Barrier+Railing+Drainage+Pedestal 100.00% 0.00% 0.00% 100.00% 0.00%
1200 1200 1200 DFbrd 0.5000 0.0000 0.0000 0.5000 0.0000

5.1 Dead Load

5.1.1 Self Weight of PC-I Girder
Q-girder = A . Jc
= 1880.75 kg / m
M-girder = 0,125 .Q-girder . L2
= 287989.84 kg.m
R-gider = 0,500 . Q-girder . L
= 32913.13 kg
5.1.2 Super Imposed Dead Load per Girder (Slab & Deck Slab)
Q-slab+deck = Tw . t-slab . Jc / Ng + ( s - w-top flange + 2 . b-precast ) . h-precast . Jc
= 926.58 kg / m
M-slab+deck = 0,125 . Q-slab+deck . L²
= 141882.56 kg.m
R-slab+deck = 0,500 . Q-slab+deck . L
= 16215.15 kg
5.1.3 Q-Ballast = (Tw- 3xt-barrier-t drainage) . t-ballast . J-ballast . DF bsl
= 1668.83 kg / m
M-ballast = 0,125 . Q-ballast . L2
= 255540.10 kg.m
R-ballast = 0,500 . Q-ballast . L
= 29204.58 kg
5.1.4 No. of Diaphragm = 8 nos
P-diaphragm = t-diaphragm . A-diaphragm . Jc
= 744.72 kg
M-diaphragm = 0.857 P.L
= 22341.60 kg.m
R-diaphragm = 3P
= 2234.16 kg
5.1.5 Q-barrier+railing + drainage = ((3t-bar . h-bar +t-railing . H-railing) . Jc + t-drainage . H-drainage . Jc +950 kg/m)*DFbrd
= 0.00 kg / m
M-barrier+railling + drainage = 0,125 . Q-curb . L2
= 0.00 kg.m
R-barrier+railing+drainage = 0,500 . Q-curb . L
= 0.00 kg
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 5.1.6 No. of Sleeper, Ns = Lg / 0.6m --> (Sleeper From African Azobe)
= 60 Unit
Q-sleeper per girder= 100 kg . Ns . Number of Rail Way . DFbsl/ ( Lg )
= 55.87 kg / m
M-sleeper = 0,125 . Q-curb . L2
= 8554.47 kg.m
R-sleeper = 0,500 . Q-curb . L
= 977.65 kg
5.1.7 Q-rail+ME per girder= 123.33 kg / m --> Rail Type R60 (60.34 kg/m each rail)
M-rail+ME = 0,125 . Q-curb . L2 ME (250 kg/m each rail way)
= 18885.42 kg.m
R-rail+ME = 0,500 . Q-curb . L
= 2158.33 kg

5.2 Live Load (RM 21)

5.2.1 Susunan kereta api terdiri dari 2 lokomotif + tender (19.2m) dengan kereta dengan jumlah unit sepanjang sisa bentang balok

Tender Lokomotif Tender Lokomotif

1.2 1.2 1.2 2.4 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 2.4 1.2 1.2 1.2 2.4 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

12 ton 12 ton 12 ton 12 ton 12 ton 12 ton 12 ton 12 ton 12 ton 12 ton 12 ton 12 ton 12 ton 12 ton 12 ton 12 ton 12 ton 12 ton 13 ton 13 ton 13 ton 13 ton 13 ton 13 ton 13 ton 13 ton 13 ton

R-train1 load maks = 54120.00 kg

M-train1 load maks = 451966.22 kg.m
35
5.2.2 2 lokomotif + tender (19.2m) diasumsikan beban merata 9.51429 ton/m untuk 1 lajur

Pendekatan momen maksimum

M-train2 load = 485625.00 kg.m
Pendekatan reaksi maksimum
R-train2 load = {Q-lokomotif+tender . L}/2
= 55500.00 kg

5.2.3 Q-pedestal = 0 kg/m Walking Person (500 kg/m2)

2
M-pedestal = 0,125 . Q-pedestal . L One side of bridge
= 0.00 kg.m L pedestal = 1.05 m
R-pedestal = 0,500 . Q-pedestal . L
= 0.00 kg

5.2.4 M-live load

Faktor Kejut (i) = 0.1 + 22.5 / (50 + L) = 0.3647059
M-live load = Max (M-train1; M-train2) x (1+i) + M-pedestal
= 662735.29 kg.m
6. MOMENTS Per GIRDER
6.1 Final Cumulative Moment at Mid Span
M-girder = 287990 kg.m M-transfer = M-girder
M-slab+deck = 141883 kg.m = 287989.85 kg.m
M-diaphragm = 22342 kg.m M-service1 = M-girder + M-slab+deck + M-diaphragm
M-Ba+S+Rail+ME = 282980 kg.m = 452214.01 kg.m
M-B+D+R = 0 kg.m M-service2 = M-ballast + M-B+S+R +D +ME + M - live load
M-live load = 662735 kg.m = 945715.29 kg.m

6.2 Final Cumulative Shear at Support

R-girder = 32913 kg
R-slab+deck = 4054 kg
R-diaphragm = 2234 kg
R-Ba+S+Rail+ME = 32341 kg
R-B+D+R = 0 kg
R-live load = 18935 kg

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7.0 ANALYSIST

7.1 Post-Tensioning Parameters

Tendon Profile

(in mm) Yt-end Yt-mid Yt-end

y-bottom (c.g.c) 1012.00 1012.00 1012.00
y-tendon (c.g.s) 1080.00 275.00 1080.00

Eccentricity
e = Y-bot - Yt-mid
= 736.95 mm

7.2 Post-Tensioning Required

7.2.1 At Transfer

Top Fiber
F-transfer < 1572.40 tons
Bottom Fiber
F-transfer < 1306.49 tons

7.2.2 During Service

Top Fiber
F-transfer > -1188.27 tons

Bottom Fiber
F-transfer > 979.90 tons

7.2.3 Post-Tensioning Force Selection

F-transfer = 1194.85 tons Average Jacking Force = 75.00 % UTS
F-service = 969.99 tons F-service/F-transfer = 0.81

7.3 Stresses Checking (at Mid-Span)

7.3.1 At Transfer
S-top = - F-transfer / A + F-transfer . e / Wx-top - M-girder / Wx-top
= -3.09 kg/cm2
S-bot = - F-transfer / A - F-transfer . e / Wx-bot + M-girder / Wx-bot
= -303.67 kg/cm2

7.3.2 During Service

Slab
S-top = - F-service / A + F-service . e / Wx-top - M-service1 / Wxc-top - M-service2 / Wxc-top.n
= -125.22 kg/cm2
PC-I girder
S-top = - F-service / A + F-service . e / Wx-top - M-service1 / Wx-top - M-service2 / Wxc-top
= -172.18 kg/cm2

S-bot = - F-service / A - F-service . e / Wx-bot + M-service1 / Wx-bot + M-service2 / Wxc-bot

= -11.57 kg/cm2

7.4 Tendon Configuration

After calculating the Prestress Losses as provided in this design calculation.

Effective Force at critical point = 54.38 % UTS
No. of Strands req = 95 nos.
One End Stressing
Tendon Type y-end (mm) y-mid (mm) JF (% UTS) JF (kN) Ext(mm) Eff. Coef (%UTS)
1 C1. SS-1905 1800 500 75.00 2622 233.64 0.54
2 C2. SS-1905 1500 375 75.00 2622 234.60 0.54
3 C3. SS-1905 1200 250 75.00 2622 235.56 0.55
4 C4. SS-1905 600 125 75.00 2622 238.23 0.55
5 C5. SS-1905 300 125 75.00 2622 239.94 0.56
6 n/a n/a n/a n/a n/a n/a n/a

Approximate Weight of Strands = 2635.775 kg / girder

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 7.5 Ultimate Moment Checking

Aps = 9377.45 mm2

dp = 2075.00 mm
Rho-p = Aps / s. dp
= 0.003766044
fps = fpu [1 - 0.5 . Rho-p . fpu / f'c]
= 1768.32 MPa

a = (Aps . fps) / 0.85 . f'c . s

= 228.79 mm < 250 mm ===> Compression zone occurs entirely in slab
Mu-provided = 0.9 . fps . Aps . (d - a / 2)
= 29260.20 kN.m

Mu-required = 1.2 (M-self weight +diaphragm) + 1.3 M-slab + 2 (M-ballast+M-barrier+railing+drainage) + 2 M-live load
= 24017.58 kN.m < 29260.20 kN.m ===> O.K

Reinforcement Provided Try w/ 4 D- 16 mm fy 390 MPa

As = 803.84 mm2 fc' 71.1 MPa
concrete decking = 40.00 mm
d = 2310.00 mm
Rho = As / ( s . d )
= 0.0002900
w = 0.0015916
fps = fpu (1-0.5 [ Rho-p.fpu/fc + d. w /dp] )
= 1766.67 MPa
a = ( Aps.fps + As.fy ) / (0.85.fc.s )
= 232.91 mm < 250 mm ===> Compression zone occurs entirely in slab

Mn = Aps.fps.(dp-0.5a)+As.fy.(d-a/2)
= 33134.65 kN.m

Mu-provided = 0.9 Mn
= 29821.18 kN.m
Mu-required = 24017.58 kN.m < 29821.18 kN.m ===> O.K

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 7.6 Spacing of Stirrup Required
At Support
Vu = 1.2 (R-self weight +diaphragm) + 1.3 R-slab + 2 R-ballast +curb + 2R-live load
= 149998.39 kg
Mu = 0.00 kgm
d = 1020.00 mm < 0.8h = 1680 mm

Vc = ( (fc')^1/2 /20 + 5 (Vu.d/Mu)) .bw.d

= - kg

Vc min = (fc'^1/2 /6) .bw.d

= 192476.93 kg

Vc max = 0.4 (fc')^1/2 .bw.d

= 461944.64 kg
Vs = Vu/f - Vc
= -16008.23 kg

Use stirrup D13 fy = 3900 kg/cm2

Av = 2.6533 cm2
s = Av.fy.d/Vs
= -65.93 cm

At Mid Span

Spacing limits
s = 3/4 h or 60 cm
= 157.5 cm or 60 cm

7.7 Crack Moment Checking

kt = Ic / ( Ac . Ybot )
= 529.31 mm
ep = y-botc - y-mid
= 1022.64 mm
fr = 2 (f'c)^(0.5)
= 53.83 kg/cm2
Mcr = F-service ( ep+kt ) + fr.Wxc-bot
= 17857.52 kN.m
Mu-prov / Mcr = 1.67 > 1.20 (OK)

8.0 DEFLECTION

8.1 At mid span during Transfer Condition

At transfer
Self weight of girder
delta = 5qL4/(384Eci Ix)
= 25.19 mm
Post tensioning
W-balance = 8F-transfer.e/L2
= 6281.50 kg/m
M = F-transfer * ( Yend tendon -Ybot)
= 81249.80 kg.m
delta = 5qL4/(384Eci Ix) + ML2/(8Eci Ix)
= -75.61 mm
DL + PT = -50.42 mm

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 8.2 At Mid Span during Service Condition
Dead load
delta-self weight = 5qL4/(384Ec Ix)
= 23.23 mm
delta-slab = 5qL4/(384Ec Ix)/Number of Girder
= 2.86 mm
delta-ballast = 3.16 mm
delta-diaph = 1.81 mm
delta-C+S+R+ME = 0.34 mm

Post tension
W-balance = 8Fserv e /L2
= 5099.38 kg/m
M = F-service * ( Yend tendon -Ybot)
= 65959.42 kg.m
delta = -56.05 mm

Live load
delta-P = 0.00 mm
delta-Q = 32.75 mm
delta-LL = delta-P+delta-Q
= 32.75 mm
DL+PT+SDL+LL = 8.09 mm < L/800 == 43.75 mm

9.0 NATURAL FREQUENCY CHECKING

I - Girder Natural Frequency

mass ( m ) = Jc. A . L / g
= 67.33 kg. det2 / cm
3
stiff ( k ) = 48.E.I / L
= 16552.45 kg/cm
w = 15.68 rad / s > 2 rad / s

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10. STRESS CHECKING
1 End Stressing From Left

No. x (m) Mgirder Mslab Mballast Mdiap M B+R+D Msleeper Mrail+ME Mt + Impact Mpedestal Ptrans Pserv
kg.m kg.m kg.m kg.m kg.m kg.m kg.m kg.m kg.m kg kg

01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1139346 924259
02 6.10 165778.71 81673.39 147099.31 12809.18 0.00 4924.30 10871.22 381497.49 0.00 1172722 954228
03 13.10 269784.18 132913.27 239385.80 20926.63 0.00 8013.69 17691.55 620839.60 0.00 1211023 988620
04 17.50 287989.84 141882.56 255540.10 22341.60 0.00 8554.47 18885.42 662735.29 0.00 1194860 969999
05 21.90 269784.18 132913.27 239385.80 20926.63 0.00 8013.69 17691.55 620839.60 0.00 1171720 950786
06 28.90 165778.71 81673.39 147099.31 12809.18 0.00 4924.30 10871.22 381497.49 0.00 1134907 920219
07 35.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1102827 893583

No. x (m) Mtrans Mserv1 Mserv2 y e Stress at transfer (kg/cm2) Stress at service (kg/cm2) NOTE
kg.m kg.m kg.m cm cm top bottom slab top bottom

01 0.00 0.00 0.00 0.00 108.000 -6.80 -171.83 -132.50 -139.39 -139.39 -107.48
02 6.10 165778.71 260261.29 544392.32 61.661 39.53 -77.60 -228.69 -133.69 -160.72 -50.92 Joint S1-S2
03 13.10 269784.18 423624.08 885930.64 32.589 68.61 -13.52 -298.12 -125.67 -169.66 -23.57 Joint S2-S3
04 17.50 287989.84 452214.01 945715.28 27.500 73.70 -3.09 -303.67 -125.22 -172.18 -11.57 Mid Span
05 21.90 269784.18 423624.08 885930.64 32.589 68.61 -15.38 -286.30 -127.46 -171.45 -12.20 Joint S3-S4
06 28.90 165778.71 260261.29 544392.32 61.661 39.53 -76.51 -220.01 -132.71 -159.73 -43.12 Joint S4-S5
07 35.00 0.00 0.00 0.00 108.000 -6.80 -166.32 -128.25 -134.76 -134.76 -103.92

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11. PRESTRESS LOSSES CALCULATION (AVERAGE EFFECTICE FORCE)

Number of Turning Points =3

Stressing Mode = One End Stressing
11.1 MATERIAL PROPERTIES
UTS = 1860.00 N/mm2 % Jacking Force = 75.00 % UTS
Friction Coef = 0.22 Wobble = 0.0033
2
Es = 194.00 kN/mm Eci = 34.53 kN/mm2
fci = 60.34 N/mm2 Wedge Draw - in = 6 mm
Ft = 11709.53 kN Cross Section Area = 7.523E+05 mm2
2
Ft / Area = 15.56 N/mm
11.2 TENDON COORDINATES (IN METERS)
X 0 17.75 35.5
Y 1.080 0.275 1.080
11.3 PRESTRESS LOSSES
Elastic Deformation Loss = 43.72 MPa
Shrinkage Loss = 38.80 MPa
Creep Loss = 157.40 MPa

1ST END STRESSING

Average Wegde Set Distance = 14.14 m
2
Average Wedge Set Loss = 164.60 N/mm
Point x y friction Wset Relax Total Effective Prestress
No. [m] [m] [ N/mm2 ] [ N/mm2 ] [ N/mm2 ] [ N/mm2 ] [ N/mm2 ]
1 0.00 1.080 0.00 164.60 27.95 432.47 962.53
2 17.75 0.275 105.29 0.00 38.28 383.49 1011.51
3 35.50 1.080 202.63 0.00 21.77 464.32 930.68

EFFECTIVE FORCE COEFFICIENTS & EXPECTED ELONGATIONS

Point x y L. Angle R. Angle L. Extn R. Extn Transfer Service
No. [m] [m] ( rad ) ( rad ) ( mm ) ( mm ) Coef Coef
1 0.00 1.080 0.00000 0.00000 0.00 0.00 0.64 0.52
2 17.75 0.275 0.09046 0.09046 122.82 0.00 0.67 0.54
3 35.50 1.080 0.00000 0.00000 113.55 0.00 0.62 0.50
Total Elongation = 236.37 mm Total Angular Change = 0.18091 rad
-7% = 219.82 mm
+7% = 252.91 mm

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