-: CLIENT :-

Shapoorji Pallonji Infrastructure Capital Co PVT Limited

-: CLIENT ENGINEER :-

Royal Haskoning DHV

-: CONTRACTOR :-

ITD CEMENTATION INDIA LIMITED

-: PROJECT :-
CONSTRUCTION OF BULK BERTH AND APPROACH TRESTLE FOR CHHARA PORT

-: TITLE :-
Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

Doc No. : DM 047119/Chhara/Design/001 Rev.: R0

Reference Dwg. : C10111-1202-CDC-EC-DWG-0222 (R2)
C10111-1202-CDC-EC-DWG-0225 (R2)

R1 Second Issue D. Jadhav 25-02-2020

R0 First Issue D. Jadhav 22-01-2020
Rev Description Prepared by Date

Copyright © This document is the property of ITD Cementation India Limited & must not be passed on to any third person or firm not
authorized by us, nor be copied/made use of in full or part by such person or firm without our prior permission in writing
 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

General Consideration
The purpose of this document is to check the stresses and crack width induced during the
lifting of Precast Transverse beam and Precast Long beam from concrete bed to yard.
Concrete grade used for pracast transverse beam M45
Concrete grade used for pracast Long beam M40
As per the execution programme, we have to lift precast long beam in 3 days after casting and
precast transvere beam in 5 days after casting. For that the concrete strength of 25 Mpa is
achieved by concrete mix design for precast Long beam and 30 Mpa for precast transverse beam.

Design Consideration:
Concrete strength after 3 days for Precast Long beam = 25 Mpa
Concrete strength after 5 days for Precast Transverse beam = 30 Mpa

Document Contents
A. Stress Check for Precast Transverse Beam
I. General
II. Loading Calculation
III. Sectional Properties of the Precast Transverse Beam Section
IV. Stress Check of Precast Transverse Beam
V. Crack width calculation for Precast Transverse Beam
VI. Conclusion

B. Stress Check for Precast Long Beam

I. General
II. Loading Calculation
III. Sectional Properties of Precast Long Beam
IV. Stress Check of Precast Long Beam
V. Crack width calculation Precast Long Beam
VI. Conclusion

ITD Cementation India Limited 2 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

A. Stress Check for Precast Transverse Beam

I. General
Length of Beam = 17.5 m
C/C of Lifting Hook Span, L = 12.5 m

II. Loading Calculation

a) Calculation for Selfweight of Precast Concrete
For Rectangle
Description L (m) B (m) T/D (m) Deduction Q (m³) W (T)
Bottom Slab 12.5 1.8 0.25 2.65 4.96 11.91
Side Walls(Long.)-1 12.5 0.25 1.8 3.25 4.81 11.55
0.25 0.35 0.25 0.02 0.05
Side Walls(Long.)-2 12.5 0.25 1.8 3.25 4.81 11.55
0.25 0.35 0.25 0.02 0.05
Corbel 0.7 0.25 0.2 0.35 0.84
End Wall 1.3 0.2 2.15 1.12 2.68

16.10 38.64
UDL = 3.09 T/m
For Trapezoidal
Description L (m) B (m) T/D (m) Deduction Q (m³) W (T) Depth UDL (T/m)
Side Wall 4.97 0.25 1.45 3.6 8.6 1150 1.38
Diaphragms 1.3 0.5 0.6 1.2 2.8 1750 2.1
4.8 11.5 1.87
20.9 50.09

b) Weight of Reinforcement Cage

Weight of Cage = 8T
UDL due to Cage = 0.46 T/m

c) Loading diagram
3.55 2.56
1.87 1.87 1.87
1.84
19.46 38.64
A B 1.13 0.5
0.85 10.5 1.15 0.5 1.27
1.07 0.5
12.5 4.97

d) Bending Moments
Max. sagging BM = = 56.20 T.m
Hogging BM @ Support 'B' = = -34.08 T.m
Hogging BM @ Pile opening = = -12.3 T.m
Saging BM @ Pile opening = = 16.1 T.m

e) Shear force
Shear Force @ B = 38.64 T
Shear Force @ A = 19.46 T

ITD Cementation India Limited 3 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

III. Sectional Properties of the Precast Transverse Beam Section

a) Properties of Precast Transverse beam @ Midspan section
200 1800 200
250 250

3 1300 3 200

50
4 4

1 1
750 500

**Note:- All dimensions shown in figure are in mm

taken.

2 250

GEOMETRIC Icg = Iself

ID WIDTH DEPTH Area CG from top A*y yt - y A * h2 Iself
SHAPE + A * h2
b (m) d (m) A (m2) y (m) (m3) h (m) (m4) (m4) (m4)
1 0.500 0.750 Rectangular 0.3750 0.3750 0.14063 0.0702 0.001848 0.017578 0.019426
2 1.300 0.250 Rectangular 0.3250 0.6250 0.20313 -0.1798 0.010507 0.000564 0.0111
3 0.400 0.200 Rectangular 0.0800 0.1000 0.00800 0.3452 0.009533 0.000089 0.0096
4 0.400 0.050 Triangular 0.0200 0.2200 0.00440 0.2252 0.001014 0.000001 0.0010
Total 0.8000 0.35616 0.0182 0.041134

Area of the section A = 0.8000 m2

Distance of centroid from top of girder yt = 0.4452 m
Distance of centroid from bottom of girder yb = 0.3048 m
Moment of inertia about centroidal axis Icg = 0.041134 m4
Section modulus w.r.t. top of girder Zt = 0.09239 m3
Section modulus w.r.t. bottom of girder Zb = 0.13495 m3

b) Properties of Precast Transverse beam @ B Support section

1800

250 1300 250

1 1
1750 1500

**Note:- All dimensions shown in figure are in mm

taken.

250

ITD Cementation India Limited 4 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

GEOMETRIC Icg = Iself

ID WIDTH DEPTH Area CG from top A*y yt - y A * h2 Iself
SHAPE + A * h2
b (m) d (m) A (m2) y (m) (m3) h (m) (m4) (m4) (m4)
1 0.500 1.750 Rectangular 0.8750 0.8750 0.76563 -0.4298 0.161637 0.223307 0.384944

Total 0.8750 0.76563 0.2233 0.384944

Area of the section A = 0.8750 m2

Distance of centroid from top of girder yt = 0.8750 m
Distance of centroid from bottom of girder yb = 0.8750 m
Moment of inertia about centroidal axis Icg = 0.384944 m4
Section modulus w.r.t. top of girder Zt = 0.43994 m3
Section modulus w.r.t. bottom of girder Zb = 0.43994 m3

c) Properties of Precast Transverse beam @ Pile opening

200 1800 200
250 250

2 1300 2 200

50
3 3

1 1
750 500

**Note:- All dimensions shown in figure are in mm

taken.

250

GEOMETRIC Icg = Iself

ID WIDTH DEPTH Area CG from top A*y yt - y A * h2 Iself
SHAPE + A * h2
b (m) d (m) A (m2) y (m) (m3) h (m) (m4) (m4) (m4)
1 0.500 0.750 Rectangular 0.3750 0.3750 0.14063 0.0702 0.001848 0.017578 0.019426
2 0.400 0.200 Rectangular 0.0800 0.1000 0.00800 0.3452 0.009533 0.000089 0.0096
3 0.400 0.050 Triangular 0.0200 0.2200 0.00440 0.2252 0.001014 0.000001 0.0010
Total 0.4750 0.15303 0.0177 0.030063

Area of the section A = 0.4750 m2

Distance of centroid from top of girder yt = 0.3222 m
Distance of centroid from bottom of girder yb = 0.4278 m
Moment of inertia about centroidal axis Icg = 0.030063 m4
Section modulus w.r.t. top of girder Zt = 0.09331 m3
Section modulus w.r.t. bottom of girder Zb = 0.07027 m3

ITD Cementation India Limited 5 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

IV. Stress Check of Precast Transverse Beam

A. Stress Check of Precast Transverse Beam w.r.t. section modulus
a) Stress Check @ Mid-span
Grade of steel Fy = 500 Mpa = 50000.0 T/m2
Grade of concrete Fck = 30 Mpa = 3000.0 T/m2
Perm. Stress in concrete scbc = 10.00 Mpa = 1000.0 T/m2
Perm. Stress in steel sst = 230 Mpa = 23000.0 T/m2
B.M. at the section M = 56.20 T-m

Compressive Stress @ top 608.3 T/m2 < 1000 T/sqm

Actual Stresses are within Permissible limit, Hence OK

b) Stress Check @ Support 'B'

Grade of steel Fy = 500 Mpa = 50000.0 T/m2
Grade of concrete Fck = 30 Mpa = 3000.0 T/m2
Perm. Stress in concrete scbc = 10.00 Mpa = 1000.0 T/m2
Perm. Stress in steel sst = 230 Mpa = 23000.0 T/m2
B.M. at the section M = 34.08 T-m

Compressive Stress @ Bottom 77.5 T/m2 < 1000 T/sqm

Actual Stresses are within Permissible limit, Hence OK

c) Stress Check @ Pile opening

Grade of steel Fy = 500 Mpa = 50000.0 T/m2
Grade of concrete Fck = 30 Mpa = 3000.0 T/m2
Perm. Stress in concrete scbc = 10.00 Mpa = 1000.0 T/m2
Perm. Stress in steel sst = 230 Mpa = 23000.0 T/m2
B.M. at the section M = 12.30 T-m

Compressive Stress @ Bottom 175.0 T/m2 < 1000 T/sqm

Actual Stresses are within Permissible limit, Hence OK

d) Stress Check @ Pile opening

Grade of steel Fy = 500 Mpa = 50000.0 T/m2
Grade of concrete Fck = 30 Mpa = 3000.0 T/m2
Perm. Stress in concrete scbc = 10.00 Mpa = 1000.0 T/m2
Perm. Stress in steel sst = 230 Mpa = 23000.0 T/m2
B.M. at the section M = 16.10 T-m

Compressive Stress @ Bottom 172.5 T/m2 < 1000 T/sqm

Actual Stresses are within Permissible limit, Hence OK

ITD Cementation India Limited 6 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

B. Stress Check for Precast Transverse Beam w.r.t. provided reinf.

a) Stress Check for @ Mid span
Actual width of flange Bf = 0.90 m
Bf as per IRC: 21 -2000 = Bw + 0.1 * lo = 2.25 m
c/c of bearings lo = 17.5 m
Width of flange Bf ( Min. of two above ) = 0.9 m
Grade of steel Fy = 500 Mpa = 50000.0 T/m2
Grade of concrete Fck = 30 Mpa = 3000.0 T/m2
Overall depth of Girder, D = 0.75 m
Clear cover = 75 mm
Modular Ratio m = 10
Effective depth d = 0.627 m
Perm. Stress in concrete scbc = 10.00 Mpa = 1000.0 T/m2
Perm. Stress in steel sst = 230 Mpa = 23000.0 T/m2
Dia. of bars of main reinf. F = 36 mm 40 Nos.
No. of Layers of Reinforcing Bars = 2
B.M. at the section Mt = 56.20 T-m
Shear Force at the section V = 38.64 Ton

2 2
Ast = 40715.0 mm = 0.04072 m

Bf2 = 0.900 Fc = 652.7

Df = 0.200
0.4408 m C1 = 91
C2 = 21
Fc1 = 357

2
Ast = 40715.0 mm
T

Bw = 0.500

Determination of Depth of Actual Neutral Axis From Top 'x' :

Following conditions are considered for determining the depth of N. A.

a) When x < Df
By equating moment of compression area and tension area about N.A.
Bf*x*x/2 = m*Ast*(d-x)
which gives equation of the type ax2 + bx - c = 0
Here, a = Bf/2 = 0.4500
b = m*Ast = 0.4072
c = m*Ast*d = 0.2553

Hence, x = -b + b2 + 4*a*c = 0.4262 Hence N.A. does not fall within Df

2*a

b) When x > Df
By equating moment of compression area and tension area about N.A.
Bf*Df*(x-Df/2) + Bw*(x-Df)*(x-Df)/2 = m*Ast*(d-x)
which gives equation of the type ax2 + bx - c = 0
Here, a = Bw/2 = 0.2500
b = (Bf-Bw)*Df + m*Ast = 0.487
c = [ (Bf-Bw)/2 ]* Df2 + m*Ast*d = 0.263

ITD Cementation India Limited 7 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

Hence, x = -b + b2 + 4*a*c = 0.4408 Hence N.A. falls outside of Df

2*a

Hence actual depth of N.A. ' x ' = 0.4408 m

Determination of Actual Stresses in Steel & Concrete

Following is the presentation for different stresses.
Fc = Max. comp. stress in concrete at top of precast T-beam.
Fc1 = Stress in concrete at the juction of Flange and web of precast T-beam

sst = Stress in reinforcement due to selfweight and insitu slab.

C1 = Compressive force resisted by flange portion of T-beam
C2 = Compressive force resisted by web portion of T-beam
Actual stresses in steel and concrete can be evaluated by equating the internal
moment to External Moment Mt
Mt = C1 * (d-X1) + C2 * (d-X2)
Here,
C1 = Bf * x * Fc/2 if x < Df and C1 = Bf* Df * (Fc + Fc1)/2 if x > Df
C2 = 0 if x < Df ; C2 = Bw * (x - Df) * Fc1/2 if x > Df
Fc1 = Fc *(x - Df)/x = 0.5463 Fc
X1 = x/3 if x < Df ; X1 = [(Fc+2*Fc1)/(Fc+Fc1)] * Df/3 if x > Df
X2 = 0 if x < Df ; X2 = Df + (x-Df)/3 if x > Df
Hence,
C1 = 0.139 Fc Tons
C2 = 0.033 Fc Tons
X1 = 0.0902 m
X2 = 0.2803 m
Therefore internal Moment = 0.0861 Fc T-m
External Moment Mt = 56.20 T-m
By euating Internal Moment and External Moment Fc can be calculated
Fc = 56.2 / 0.0861 = 652.73 T/m2
Fc1 = 356.57 T/m2
sst = m*(d-x)/x*Fc = 2757.22 T/m2
C1 = 90.84
C2 = 21.47

Summary of Stresses:-
Total compressive stress at top of cross beam = 652.73 < 1000 T/sqm
Actual Stresses are within Permissible limit, Hence OK

Total tensile stress in reinforcement = 2757.22 < 23000 T/sqm

Actual Stresses are within Permissible limit, Hence OK

ITD Cementation India Limited 8 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

b) Stress Check of Precast Transverse Beam w.r.t provided reinf. @ Support 'B'
Width of Cross Beam at bottom, B = 0.50 m
Grade of steel Fy = 500 Mpa = 50000.0 T/m2
Grade of concrete Fck = 30 Mpa = 3000.0 T/m2
Overall depth of Girder, D = 1.75 m
Clear cover = 75 mm
Modular Ratio m = 10
Effective depth d = 1.643 m
Perm. Stress in concrete scbc = 10.00 Mpa = 1000.0 T/m2
Perm. Stress in steel sst = 230 Mpa = 23000.0 T/m2
Dia. of bars of main reinf. F = 32 mm 4 Nos.
No. of Layers of Reinforcing Bars = 1
B.M. at the section Mt = 34.08 T-m

2 2
Ast = 3217.0 mm = 0.00322 m

B = 0.500 Fc = 225.8

0.3999 m
C = 23

2
Ast = 3217.0 mm
T

B = 0.500

Determination of Depth of Actual Neutral Axis From Top 'x' :

Following conditions are considered for determining the depth of N. A.

By equating moment of compression area and tension area about N.A.

Bf*(x)* (x/2) = m*Ast*(d-x)
which gives equation of the type ax2 + bx - c = 0
Here, a = B/2 = 0.2500
b = m*Ast = 0.032
c = m*Ast*d = 0.053

Hence, x = -b + b2 + 4*a*c = 0.3999

2*a

Hence actual depth of N.A. ' x ' = 0.3999 m

Determination of Actual Stresses in Steel & Concrete

Following is the presentation for different stresses.
Fc = Max. comp. stress in concrete at top of precast beam.

sst = Stress in reinforcement due to selfweight and insitu slab.

C = Compressive force resisted by Top Portion
Actual stresses in steel and concrete can be evaluated by equating the internal
moment to External Moment Mt
Mt = C * (d-X)
Here,
C = B * x * Fc/2

ITD Cementation India Limited 9 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

Hence,
C= 0.100 Fc Tons
X = x/3= 0.1333 m
Therefore internal Moment = 0.1509 Fc T-m
External Moment Mt = 34.08 T-m
By euating Internal Moment and External Moment Fc can be calculated
Fc = 34.08 / 0.1509 = 225.84 T/m2
sst = m*(d-x)/x*Fc = 7020.3 T/m2
C= 22.58 T/m2

Summary of Stresses :-
Total compressive stress at top of cross beam = 225.84 < 1000 T/sqm
Actual Stresses are within Permissible limit, Hence OK

Total tensile stress in reinforcement = 7020.30 < 23000 T/sqm

Actual Stresses are within Permissible limit, Hence OK

ITD Cementation India Limited 10 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

c) Stress Check of w.r.t provided reinf. @ Pile opening due to hogging moment
Width of Cross Beam at bottom, B = 0.50 m
Grade of steel Fy = 500 Mpa = 50000.0 T/m2
Grade of concrete Fck = 30 Mpa = 3000.0 T/m2
Overall depth of Girder, D = 0.75 m
Clear cover = 75 mm
Modular Ratio m = 10
Effective depth d = 0.643 m
Perm. Stress in concrete scbc = 10.00 Mpa = 1000.0 T/m2
Perm. Stress in steel sst = 230 Mpa = 23000.0 T/m2
Dia. of bars of main reinf. F = 32 mm 4 Nos.
16 mm 2 Nos.
No. of Layers of Reinforcing Bars = 1
B.M. at the section Mt = 12.30 T-m

2 2
Ast = 3619.1 mm = 0.00362 m

B = 0.500 Fc = 362.8

0.2412 m
C = 22

2
Ast = 3619.1 mm
T

B = 0.500

Determination of Depth of Actual Neutral Axis From Top 'x' :

Following conditions are considered for determining the depth of N. A.

By equating moment of compression area and tension area about N.A.

Bf*(x)* (x/2) = m*Ast*(d-x)
which gives equation of the type ax2 + bx - c = 0
Here, a = B/2 = 0.2500
b = m*Ast = 0.036
c = m*Ast*d = 0.023

Hence, x = -b + b2 + 4*a*c = 0.2412

2*a

Hence actual depth of N.A. ' x ' = 0.2412 m

Determination of Actual Stresses in Steel & Concrete

Following is the presentation for different stresses.
Fc = Max. comp. stress in concrete at top of precast beam.

sst = Stress in reinforcement due to selfweight and insitu slab.

C = Compressive force resisted by Top Portion
Actual stresses in steel and concrete can be evaluated by equating the internal
moment to External Moment Mt
Mt = C * (d-X)

ITD Cementation India Limited 11 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

Here,
C = B * x * Fc/2
Hence,
C= 0.060 Fc Tons
X = x/3= 0.0804 m
Therefore internal Moment = 0.0339 Fc T-m
External Moment Mt = 12.30 T-m
By euating Internal Moment and External Moment Fc can be calculated
Fc = 12.3 / 0.0339 = 362.83 T/m2
sst = m*(d-x)/x*Fc = 6044.16 T/m2
C= 21.88 T/m2

Summary of Stresses :-
Total compressive stress at top of cross beam = 362.83 < 1000 T/sqm
Actual Stresses are within Permissible limit, Hence OK

Total tensile stress in reinforcement = 6044.16 < 23000 T/sqm

Actual Stresses are within Permissible limit, Hence OK

ITD Cementation India Limited 12 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

d) Stress Check for @ pile opening due to sagging moment

Actual width of flange Bf = 0.90 m
Bf as per IRC: 21 -2000 = Bw + 0.1 * lo = 2.25 m
c/c of bearings lo = 17.5 m
Width of flange Bf ( Min. of two above ) = 0.9 m
Grade of steel Fy = 500 Mpa = 50000.0 T/m2
Grade of concrete Fck = 30 Mpa = 3000.0 T/m2
Overall depth of Girder, D = 0.75 m
Clear cover = 75 mm
Modular Ratio m = 10
Effective depth d = 0.641 m
Perm. Stress in concrete scbc = 10.00 Mpa = 1000.0 T/m2
Perm. Stress in steel sst = 230 Mpa = 23000.0 T/m2
Dia. of bars of main reinf. F = 36 mm 4 Nos.
No. of Layers of Reinforcing Bars = 1
B.M. at the section Mt = 16.10 T-m
Shear Force at the section V = 19.46 Ton

2 2
Ast = 4071.5 mm = 0.00407 m

Bf2 = 0.900 Fc = 312.0

Df = 0.200
0.1998 m C1 = 28
C2 = 0
Fc1 = 0

2
Ast = 4071.5 mm
T

Bw = 0.500

Determination of Depth of Actual Neutral Axis From Top 'x' :

Following conditions are considered for determining the depth of N. A.

a) When x < Df
By equating moment of compression area and tension area about N.A.
Bf*x*x/2 = m*Ast*(d-x)
which gives equation of the type ax2 + bx - c = 0
Here, a = Bf/2 = 0.4500
b = m*Ast = 0.0407
c = m*Ast*d = 0.0261

Hence, x = -b + b2 + 4*a*c = 0.1998 Hence N.A. falls within Df

2*a

b) When x > Df
By equating moment of compression area and tension area about N.A.
Bf*Df*(x-Df/2) + Bw*(x-Df)*(x-Df)/2 = m*Ast*(d-x)
which gives equation of the type ax2 + bx - c = 0
Here, a = Bw/2 = 0.2500
b = (Bf-Bw)*Df + m*Ast = 0.121
c = [ (Bf-Bw)/2 ]* Df2 + m*Ast*d = 0.034

ITD Cementation India Limited 13 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

Hence, x = -b + b2 + 4*a*c = 0.1998 Hence N.A. falls within Df

2*a

Hence actual depth of N.A. ' x ' = 0.1998 m

Determination of Actual Stresses in Steel & Concrete

Following is the presentation for different stresses.
Fc = Max. comp. stress in concrete at top of precast T-beam.
Fc1 = Stress in concrete at the juction of Flange and web of precast T-beam

sst = Stress in reinforcement due to selfweight and insitu slab.

C1 = Compressive force resisted by flange portion of T-beam
C2 = Compressive force resisted by web portion of T-beam
Actual stresses in steel and concrete can be evaluated by equating the internal
moment to External Moment Mt
Mt = C1 * (d-X1) + C2 * (d-X2)
Here,
C1 = Bf * x * Fc/2 if x < Df and C1 = Bf* Df * (Fc + Fc1)/2 if x > Df
C2 = 0 if x < Df ; C2 = Bw * (x - Df) * Fc1/2 if x > Df
Fc1 = Fc *(x - Df)/x = -0.0010 Fc
X1 = x/3 if x < Df ; X1 = [(Fc+2*Fc1)/(Fc+Fc1)] * Df/3 if x > Df
X2 = 0 if x < Df ; X2 = Df + (x-Df)/3 if x > Df
Hence,
C1 = 0.090 Fc Tons
C2 = 0.000 Fc Tons
X1 = 0.0666 m
X2 = 0.0000 m
Therefore internal Moment = 0.0516 Fc T-m
External Moment Mt = 16.10 T-m
By euating Internal Moment and External Moment Fc can be calculated
Fc = 16.1 / 0.0516 = 312.02 T/m2
Fc1 = -0.31 T/m2
sst = m*(d-x)/x*Fc = 6890.05 T/m2
C1 = 28.05
C2 = 0

Summary of Stresses:-
Total compressive stress at top of cross beam = 312.02 < 1000 T/sqm
Actual Stresses are within Permissible limit, Hence OK

Total tensile stress in reinforcement = 6890.05 < 23000 T/sqm

Actual Stresses are within Permissible limit, Hence OK

ITD Cementation India Limited 14 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

V. Crack width calculation Precast Transverse Beam

a) Crack width calculation @ Midspan
Design Parameters:-
Depth of section, h = 750 mm
Width of section, b = 500 mm
Minimum clear cover, Cmin = 75 mm
Dia. of main tensional bar(db),Ф = 36 mm
No. of bar, n = 40
Spacing of bar, s = 109 mm
Grade of concrete, = M 30
Grade of reinforcement, = Fe 500
Modulus of elasticity of steel, Es = 200 KN/mm²
Depth of crack check level, a = 750 mm
Bending Moment @ Section = 562.00 KN-m
Design Moment,M = 562.00 KN-m
Dia. of top compession bar(db),Ф = 32 mm
Spacing of top reinforcement, s = 109 mm
No. of bar, n = 4
The Crack Width of the section is checked at point A, at soffit of beam between the mid point of
consecutive two main longitidunal bar.

The design crack width (Wcr) at a selected level, A on the surface of the section
with max. moment is,

Where,
acr = Shortest distance from the selected level on the surface to a longitudinal bar
εm = Average strain of steel at the selected level.
x = Depth of neutral axis = 440.8 mm

Calculation of acr :-
Effective cover dc = Cmin + db/2
= 123 mm

= 116.53 mm

ε
Calculation of Average Strain of Steel, m :-

Where,
ε1 = Strain at the selected level based on a cracked sectional analysis.
= εS x (a-X)/(d-X)
εS = Strain in the longitudinal reinforcement.
Lever Arm, J = 500.5 mm

Total tension force covered by reinforcement,

T= M/J
= 1122.989 kN STRAIN STRESS

ITD Cementation India Limited 15 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

As per Hooks Law,

Es = (fs/εs)
εs = (fs/Es)
fs = Stress developed at reinforcement.
= T/Ast Ast = 40715.0 mm²
= 27.6 MPa < 0.87fy < 435 Mpa, Safe.

Therefore, εs = 0.000138

ε1 = εS x (a-X)/(d-X) d= 627 mm
= 0.000229

Therefore, εm = ε1 -[{b x (h-X) x (a-X)}/{3 x ES x Ast x (d-X)}]

= 0.000218 Crack is developed

Crack Width, Wcr = 3 x acr x εm / [1 + {2 x (acr - Cmin)/(h-X)}]

= 0.060211 mm < 0.1 mm, Hence OK (for Severe condition)

ITD Cementation India Limited 16 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

b. Crack width calculation for Precast Transverse Beam @ Support 'B'

Design Parameters:-
Depth of section, h = 1750 mm
Width of section, b = 500 mm
Minimum clear cover, Cmin = 75 mm
Dia. of main tensional bar(db),Ф = 32 mm
No. of bar, n = 4
Spacing of bar, s = 94 mm
Grade of concrete, = M 30
Grade of reinforcement, = Fe 500
Modulus of elasticity of steel, Es = 200 KN/mm²
Depth of crack check level, a = 1750 mm
Bending Moment @ Section = 340.77 KN-m
Design Moment,M = 340.77 KN-m
The Crack Width of the section is checked at point A, at soffit of beam between the mid point of
consecutive two main longitidunal bar.

The design crack width (Wcr) at a selected level, A on the surface of the section
with max. moment is,

Where,
acr = Shortest distance from the selected level on the surface to a longitudinal bar
εm = Average strain of steel at the selected level.
x = Depth of neutral axis = 399.9 mm

Calculation of acr :-
Effective cover dc = Cmin + db/2
= 107 mm

= 100.87 mm

ε
Calculation of Average Strain of Steel, m :-

Where,
ε1 = Strain at the selected level based on a cracked sectional analysis.
= εS x (a-X)/(d-X)
εS = Strain in the longitudinal reinforcement.
Lever Arm, J = (h-dc-X/3)
1509.7 mm

Total tension force covered by reinforcement,

T= M/J
= 225.718 kN STRAIN STRESS

ITD Cementation India Limited 17 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

As per Hooks Law,

Es = (fs/εs)
εs = (fs/Es)
fs = Stress developed at reinforcement.
= T/Ast Ast = 3217.0 mm²
= 70.2 MPa < 0.87fy < 435 Mpa, Safe.

Therefore, εs = 0.000351

ε1 = εS x (a-X)/(d-X) d= 1643 mm
= 0.000381

Therefore, εm = ε1 -[{b x (h-X) x (a-X)}/{3 x ES x Ast x (d-X)}]

= 1.18E-06 Crack is developed

Crack Width, Wcr = 3 x acr x εm / [1 + {2 x (acr - Cmin)/(h-X)}]

= 0.000345 mm < 0.1 mm, Hence OK (for Severe condition)

ITD Cementation India Limited 18 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

c. Crack width calculation for Precast Transverse Beam @ Pile opening due to hogging BM
Design Parameters:-
Depth of section, h = 750 mm
Width of section, b = 500 mm
Minimum clear cover, Cmin = 75 mm
Dia. of main tensional bar(db),Ф = 16 32 mm
No. of bar, n = 2 4
Spacing of bar, s = 86 mm
Grade of concrete, = M 30
Grade of reinforcement, = Fe 500
Modulus of elasticity of steel, Es = 200 KN/mm²
Depth of crack check level, a = 750 mm
Bending Moment @ Section = 123.00 KN-m
Design Moment,M = 123.00 KN-m
The Crack Width of the section is checked at point A, at soffit of beam between the mid point of
consecutive two main longitidunal bar.

The design crack width (Wcr) at a selected level, A on the surface of the section
with max. moment is,

Where,
acr = Shortest distance from the selected level on the surface to a longitudinal bar
εm = Average strain of steel at the selected level.
x = Depth of neutral axis = 241.2 mm

Calculation of acr :-
Effective cover dc = Cmin + db/2
= 107 mm

= 99.32 mm

ε
Calculation of Average Strain of Steel, m :-

Where,
ε1 = Strain at the selected level based on a cracked sectional analysis.
= εS x (a-X)/(d-X)
εS = Strain in the longitudinal reinforcement.
Lever Arm, J = (h-dc-X/3)
562.6 mm

Total tension force covered by reinforcement,

T= M/J
= 218.628 kN STRAIN STRESS

ITD Cementation India Limited 19 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

As per Hooks Law,

Es = (fs/εs)
εs = (fs/Es)
fs = Stress developed at reinforcement.
= T/Ast Ast = 3619.1 mm²
= 60.4 MPa < 0.87fy < 435 Mpa, Safe.

Therefore, εs = 0.000302

ε1 = εS x (a-X)/(d-X) d= 643 mm
= 0.000382

Therefore, εm = ε1 -[{b x (h-X) x (a-X)}/{3 x ES x Ast x (d-X)}]

= 0.000234 Crack is developed

Crack Width, Wcr = 3 x acr x εm / [1 + {2 x (acr - Cmin)/(h-X)}]

= 0.063673 mm < 0.1 mm, Hence OK (for Severe condition)

ITD Cementation India Limited 20 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

d) Crack width calculation @ pile opening due to sagging moment

Design Parameters:-
Depth of section, h = 750 mm
Width of section, b = 500 mm
Minimum clear cover, Cmin = 75 mm
Dia. of main tensional bar(db),Ф = 36 mm
No. of bar, n = 4
Spacing of bar, s = 86 mm
Grade of concrete, = M 30
Grade of reinforcement, = Fe 500
Modulus of elasticity of steel, Es = 200 KN/mm²
Depth of crack check level, a = 750 mm
Bending Moment @ Section = 161.00 KN-m
Design Moment,M = 161.00 KN-m
Dia. of top compession bar(db),Ф = 32 mm
Spacing of top reinforcement, s = 86 mm
No. of bar, n = 4
The Crack Width of the section is checked at point A, at soffit of beam between the mid point of
consecutive two main longitidunal bar.

The design crack width (Wcr) at a selected level, A on the surface of the section
with max. moment is,

Where,
acr = Shortest distance from the selected level on the surface to a longitudinal bar
εm = Average strain of steel at the selected level.
x = Depth of neutral axis = 199.8 mm

Calculation of acr :-
Effective cover dc = Cmin + db/2
= 109 mm

= 99.18 mm

ε
Calculation of Average Strain of Steel, m :-

Where,
ε1 = Strain at the selected level based on a cracked sectional analysis.
= εS x (a-X)/(d-X)
εS = Strain in the longitudinal reinforcement.
Lever Arm, J = 574.4 mm

Total tension force covered by reinforcement,

T= M/J
= 280.292 kN STRAIN STRESS

ITD Cementation India Limited 21 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

As per Hooks Law,

Es = (fs/εs)
εs = (fs/Es)
fs = Stress developed at reinforcement.
= T/Ast Ast = 4071.5 mm²
= 68.8 MPa < 0.87fy < 435 Mpa, Safe.

Therefore, εs = 0.000344

ε1 = εS x (a-X)/(d-X) d= 641 mm
= 0.000429

Therefore, εm = ε1 -[{b x (h-X) x (a-X)}/{3 x ES x Ast x (d-X)}]

= 0.000289 Crack is developed

Crack Width, Wcr = 3 x acr x εm / [1 + {2 x (acr - Cmin)/(h-X)}]

= 0.078992 mm < 0.1 mm, Hence OK (for Severe condition)

VII. Conclusion
By considering concrete strength 30 Mpa after 5 days, compressive stresses induced during lifting
of beam at midspan, at support 'B' and pile opening location are well within permissible limits.
Also, crack width devloped at midspan, support 'B' and pile opening location during lifting operation
are within permissible limit.

ITD Cementation India Limited 22 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

B. Stress Check for Precast Long Beam

I. General
Span, L = 14.2 m
Density of concrete = 2.5 Mt/m³

II. Loading Calculation

C/S Area of Long Beam = 0.7025 m²
Self weight of Long Beam = 2.5 * 0.7025 = 1.76 t/m
Bending Moment, M = wL^2 / 8 = 44.36 tm
Shear Force, V = wL/2 = 12.50 t

III. Sectional Properties of Precast Long Beam

Properties of Mid-section
800

150
1

2 2
50

3
1300 1100

500
**Note:- All dimensions shown in figure are in mm

taken.

500

GEOMETRIC CG from Icg = Iself +

ID WIDTH DEPTH Area A*y yt - y A * h2 Iself
SHAPE top A * h2
b (m) d (m) A (m2) y (m) (m3) h (m) (m4) 4
(m ) (m4)
1 0.800 0.150 Rectangular 0.1200 0.0750 0.00900 0.5330 0.034091 0.000225 0.034316
2 0.300 0.050 triangular 0.0075 0.1667 0.00125 0.4413 0.001461 0.000001 0.0015
3 0.500 1.150 Rectangular 0.5750 0.7250 0.41688 -0.1170 0.007871 0.063370 0.0712

Total 0.7025 0.42713 0.0636 0.107019

Area of the section A = 0.7025 m2

Distance of centroid from top of girder yt = 0.6080 m
Distance of centroid from bottom of girder yb = 0.6920 m
Moment of inertia about centroidal axis Icg = 0.107019 m4
Section modulus w.r.t. top of girder Zt = 0.17602 m3
Section modulus w.r.t. bottom of girder Zb = 0.15465 m3

IV. Stress Check of Precast Long Beam

a) Stress Check w.r.t. section modulus
Grade of steel Fy = 500 Mpa = 50000.0 T/m2
Grade of concrete Fck = 25 Mpa = 2500.0 T/m2
Perm. Stress in concrete scbc = 8.33 Mpa = 833.0 T/m2
Perm. Stress in steel sst = 230 Mpa = 23000.0 T/m2
B.M. at the section M = 44.36 T-m
Compressive Stress @ top 252.0 T/m2 < 833 T/sqm
Actual Stresses are within Permissible limit, Hence OK

ITD Cementation India Limited 23 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

b) Stress Check for Precast Long Beam w.r.t. provided reinf.

Actual width of flange Bf = 0.80 m
Bf as per IRC: 21 -2000 = Bw + 0.1 * lo = 1.92 m
c/c of bearings lo = 14.2 m
Width of flange Bf ( Min. of two above ) = 0.8 m
Grade of steel Fy = 500 Mpa = 50000.0 T/m2
Grade of concrete Fck = 25 Mpa = 2500.0 T/m2
Overall depth of Girder, D = 1.3 m
Clear cover = 50 mm
Modular Ratio m = 10
Effective depth d = 1.194 m
Perm. Stress in concrete scbc = 8.33 Mpa = 833.0 T/m2
Perm. Stress in steel sst = 230 Mpa = 23000.0 T/m2
Dia. of bars of main reinf. F = 32 mm 10 Nos.
No. of Layers of Reinforcing Bars = 2
B.M. at the section Mt = 44.36 T-m
Shear Force at the section V = 12.50 Ton

2 2
Ast = 8042.5 mm = 0.00804 m

Bf2 = 0.800 Fc = 287.7

Df = 0.150
0.4278 m C1 = 28
C2 = 13
Fc1 = 187

2
Ast = 8042.5 mm
T

Bw = 0.500

Determination of Depth of Actual Neutral Axis From Top 'x' :

Following conditions are considered for determining the depth of N. A.

a) When x < Df
By equating moment of compression area and tension area about N.A.
Bf*x*x/2 = m*Ast*(d-x)
which gives equation of the type ax2 + bx - c = 0
Here, a = Bf/2 = 0.4000
b = m*Ast = 0.0804
c = m*Ast*d = 0.0960

Hence, x = -b + b2 + 4*a*c = 0.3996 Hence N.A. does not fall within Df

2*a

b) When x > Df
By equating moment of compression area and tension area about N.A.
Bf*Df*(x-Df/2) + Bw*(x-Df)*(x-Df)/2 = m*Ast*(d-x)
which gives equation of the type ax2 + bx - c = 0
Here, a = Bw/2 = 0.2500
b = (Bf-Bw)*Df + m*Ast = 0.125
c = [ (Bf-Bw)/2 ]* Df2 + m*Ast*d = 0.099

ITD Cementation India Limited 24 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

Hence, x = -b + b2 + 4*a*c = 0.4278 Hence N.A. falls outside of Df

2*a

Hence actual depth of N.A. ' x ' = 0.4278 m

Determination of Actual Stresses in Steel & Concrete

Following is the presentation for different stresses.
Fc = Max. comp. stress in concrete at top of precast T-beam.
Fc1 = Stress in concrete at the juction of Flange and web of precast T-beam

sst = Stress in reinforcement due to selfweight and insitu slab.

C1 = Compressive force resisted by flange portion of T-beam
C2 = Compressive force resisted by web portion of T-beam
Actual stresses in steel and concrete can be evaluated by equating the internal
moment to External Moment Mt
Mt = C1 * (d-X1) + C2 * (d-X2)
Here,
C1 = Bf * x * Fc/2 if x < Df and C1 = Bf* Df * (Fc + Fc1)/2 if x > Df
C2 = 0 if x < Df ; C2 = Bw * (x - Df) * Fc1/2 if x > Df
Fc1 = Fc *(x - Df)/x = 0.6494 Fc
X1 = x/3 if x < Df ; X1 = [(Fc+2*Fc1)/(Fc+Fc1)] * Df/3 if x > Df
X2 = 0 if x < Df ; X2 = Df + (x-Df)/3 if x > Df
Hence,
C1 = 0.099 Fc Tons
C2 = 0.045 Fc Tons
X1 = 0.0697 m
X2 = 0.2426 m
Therefore internal Moment = 0.1542 Fc T-m
External Moment Mt = 44.36 T-m
By euating Internal Moment and External Moment Fc can be calculated
Fc = 44.36 / 0.1542 = 287.68 T/m2
Fc1 = 186.81 T/m2
sst = m*(d-x)/x*Fc = 5152.42 T/m2
C1 = 28.47
C2 = 12.97

Summary of Stresses:-
Total compressive stress at top of cross beam = 287.68 < 833 T/sqm
Actual Stresses are within Permissible limit, Hence OK

Total tensile stress in reinforcement = 5152.42 < 23000 T/sqm

Actual Stresses are within Permissible limit, Hence OK

ITD Cementation India Limited 25 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

V. Crack width calculation Precast Long Beam

Design Parameters:-
Depth of section, h = 1300 mm
Width of section, b = 500 mm
Minimum clear cover, Cmin = 50 mm
Dia. of main tensional bar(db),Ф = 32 mm
No. of bar, n = 10
Spacing of bar, s = 86 mm
Grade of concrete, = M 25
Grade of reinforcement, = Fe 500
Modulus of elasticity of steel, Es = 200 KN/mm²
Depth of crack check level, a = 1300 mm
Bending Moment @ Section = 443.60 KN-m
Design Moment,M = 443.60 KN-m
Dia. of top compession bar(db),Ф = 12 mm
Spacing of top reinforcement, s = 86 mm
No. of bar, n = 5
The Crack Width of the section is checked at point A, at soffit of beam between the mid point of
consecutive two main longitidunal bar.

The design crack width (Wcr) at a selected level, A on the surface of the section
with max. moment is,

Where,
acr = Shortest distance from the selected level on the surface to a longitudinal bar
εm = Average strain of steel at the selected level.
x = Depth of neutral axis = 427.8 mm

Calculation of acr :-
Effective cover dc = Cmin + db/2
= 106.5 mm

= 98.85 mm

ε
Calculation of Average Strain of Steel, m :-

Where,
ε1 = Strain at the selected level based on a cracked sectional analysis.
= εS x (a-X)/(d-X)
εS = Strain in the longitudinal reinforcement.
Lever Arm, J = 1067.2 mm

Total tension force covered by reinforcement,

T= M/J
= 415.669 kN STRAIN STRESS

ITD Cementation India Limited 26 of 27

 Stress Check for Precast Transverse Beam (PTB) and Precast Long Beam (PLB) during Lifting.

As per Hooks Law,

Es = (fs/εs)
εs = (fs/Es)
fs = Stress developed at reinforcement.
= T/Ast Ast = 8042.5 mm²
= 51.7 MPa < 0.87fy < 435 Mpa, Safe.

Therefore, εs = 0.000258

ε1 = εS x (a-X)/(d-X) d= 1193.5 mm
= 0.000294

Therefore, εm = ε1 -[{b x (h-X) x (a-X)}/{3 x ES x Ast x (d-X)}]

= 0.000191 Crack is developed

Crack Width, Wcr = 3 x acr x εm / [1 + {2 x (acr - Cmin)/(h-X)}]

= 0.051047 mm < 0.1 mm, Hence OK (for Severe condition)

VI. Conclusion
By considering concrete strength 25 Mpa after 3 days, compressive stresses induced during lifting
of beam at midspan location are well within permissible limits.
Also, crack width devloped at midspan and during lifting operation are within permissible limit.

ITD Cementation India Limited 27 of 27