DYNAMIC PRESTRESS (I) PVT. LTD.

DESIGN OF 333 TON CAPACITY FREE POT / PTFE BEARING - TYPE FRB2

CLIENT : NHAI

EPC CONTRACTOR : M/s GKC PROJECT LIMITED

SUB CONTRACTOR : M/s PRA PROJECTS PRIVATE LIMITED

REHABILITATION AND UPGRADATION TO FOUR LANE OF BRIMITRAPUR - BRAHMANI BYPASS END

OF NH-23 ( NEW NH-143 ) KM. 211.200 TO KM. 217.100 & KM. 0.000 TO KM. 3.300 IN THE STATE OF
PROJECT : ODISHA UNDER NHDP PHASE-IV
{ BEARINGS FOR MAJOR BRIDGE AT CH : 2+120 BRAHMANI RIVER }

REFERENCE DRAWING : DPIL / PRA_ODISHA / BRAHMANI RIVER BRIDGE / CH : 2+120 / 333 TON FREE / TYPE FRB2
REFERENCE CODE : IRC:83 (Part III) - 2018 REVISION : R0
DESIGN PARAMETERS : SEISMIC ZONE : III
Material in contact with Bearing
a) Pedestal fck 45 Mpa (Concrete : M45 Grade)
b) Superstructure (Top) fck 45 Mpa (Concrete : M45 Grade)
Grade of Cast Steel : 340 -570W of IS:1030
Yield Strength fy : 340 N/mm2
Ultimate Strength fu : 570 N/mm2
ULS - Loads :
Normal Case
Max. Vertical Load Nsd,max : 3266.73 KN 333.0 TON
Min. Vertical Load Nsd,min : 1922.76 KN 196.0 TON
Horizontal force (Long) Vx,sd : 0.00 KN 0.0 TON
Horizontal force (Trans) Vy,sd : 0.00 KN 0.0 TON
Resultant Horizontal force Vxy,sd : 0.00 KN
Seismic Case
Max. Vertical Load Nsd,max : 3266.73 KN 333.0 TON
Min. Vertical Load Nsd,min : 1922.76 KN 196.0 TON
Horizontal force (Long) Vx,sd : 0.00 KN 0.0 TON
Horizontal force (Trans) Vy,sd : 0.00 KN 0.0 TON
Resultant Horizontal force Vxy,sd : 0.00 KN
SLS - Loads :
Normal Case
Max. Vertical Load Nsk,max : 2118.96 KN 216.0 TON
Min. Vertical Load Nsk,min : 1402.83 KN 143.0 TON
Horizontal force (Long) Vx,sk : 0.00 KN 0.0 TON
Horizontal force (Trans) Vy,sk : 0.00 KN 0.0 TON
Resultant Horizontal force Vxy,sk : 0.00 KN
Rotation θ (Given) : 0.0002 radians
Design Rotation θ = θmax + 0.005 = 0.0052 radians (Cl. 5.1.7)
Where θmax = θp + θv
Resultant rotation due to permanent action and long term effects , θp : 0.00012 radians
Resultant rotation due to variable action , θv : 0.00008 radians
Longitudinal Movement eL : (+/-) 60.00 mm ( 40.0 + 20 ) (Cl. 5.1.9)
Transverse Movement eT : (+/-) 26.00 mm ( 6 + 20 ) (Cl. 5.1.9)

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BEARING PARAMETERS : TYPE FRB2 : 333 TON FREE SLIDING POT / PTFE BEARING
I) POT :
Effective diameter of bottom plate (D5 + 2xA2) A = 400 mm
Diameter of Pot at Bottom A1 = 450 mm
Thickness of Pot at Base A2 = 25 mm
Depth of Pot A6 = 46 mm
Total Thickness of Pot AH1 = 71 mm
Outer Diameter of Pot A7 = 450 mm
Inner Diameter of Pot D5 = 350 mm
Pot Thickness Pth = 50 mm
II) ELASTOMERIC PAD :
Diameter of Elastomeric Pad D5 / Nt = 12.50 D5 = 350 mm
Thickness of Elastomeric Pad Nt = 28 mm
III) PISTON / CENTRE PLATE :
Diameter of Centre Plate C3 = 420 mm
Piston Diameter Dp = 346 mm
Overall Thicknes of Centre Plate C2 = 40 mm
Contact width of Piston w = 8 mm
Clearance between Pot top & Piston bottom edge hn = 10 mm
IV) P.T.F.E. :
Diameter L = 380 mm
Total Thickness tp = 8 mm
Projection h = 3 mm
V) S.S. Plate :
Length SSPL = 510 mm
Width SSPW = 440 mm
Thickness SSPt = 2 mm
VI) TOP PLATE :
Effective Diameter of Top plate (L + B5 x4) Ble = 432 mm
Length BL = 550 mm
Width BW = 480 mm
Thickness B2 = 26 mm
VII) ANCHOR BOLT :
Diameter of Bolt Db = 16 mm
Number of Bolts for Bottom N = 4 nos.
Number of Bolts for Top N = 4 nos.
Grade of Bolt = Gr. 4.6
VIII) LUGS :
Length Ll = 70 mm
Width Ll = 70 mm
Thickness Lt = 15 mm
Total Number of Lugs for Bottom = 4 nos.
Total Number of Lugs for Top = 4 nos.
IX) ANCHOR SLEEVES :
Diameter of Sleeve D = 40 mm
Sleeve length for Bottom 4 nos. Lb = 160 mm
Sleeve length for Top 4 nos. Lb = 160 mm

TOTAL THICKNESS OF BEARING = 124.0 mm

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DESIGN CHECK :
ELASTOMERIC PAD :
1) Diameter to Thickness Ratio (Cl. 5.2.3.5)
D5/Nt = 12.50 </= 15
2) Strain in Elastomer (Cl. 5.2.3.4)
τneo = 0.5 x D 5 x θ
Nt
= 0.0325 </= 0.15
3) Min. Average Compressive Stress under Normal condition (Cl. 5.2.3.3)
σneo-min = Nsk,min x 1000
π/4 x D52
= 19.98 > 2 N/mm2
4) The design maximum axial force Nsd in ULS condition shall meet the following condition under the critical combination
of actions : (Cl. 5.2.3.2)
Nsd,max ≤ NRd
Where,
Normal Case (ULS)
NRk = π / 4 x D52 x fck Where fck = 60 N/mm2
= 5772.69 kN
NRd = NRk Where γm = 1.3
γm
= 4440.53 kN
Nsd,max = 3266.73 kN
3266.73 < 4440.53
∴ Nsd,max ≤ NRd Hence Safe
Seismic Case (ULS)
NRk = π / 4 x D52 x fck Where fck = 60 N/mm2
= 5772.69 kN
NRd = NRk Where γm = 1.3
γm
= 4440.53 kN
Nsd,max = 3266.73 kN
3266.73 < 4440.53
∴ Nsd,max ≤ NRd Hence Safe

PTFE :
COMPRESSIVE STRESS VERIFICATION (as per Cl. 5.2.4.6)

As per Cl. 5.2.4.5 & Table 5.4 Characteristic Compressive Strength (fk) = 90 Mpa for 300 C
The value will be reduced by 2% per degree.
Max. ambient temperature : 45 ⁰C
Reduction : 30 %
2
∴ fk = 63 N/mm
L = 380 mm tp = 8 mm
γm = 1.4
Nsd,max ≤ fk x Ar / γm
where,
Ar = Aco (1 - 0.75 π e/L) Annexure B
Normal Case (ULS)
Aco = π/4 x L2
2
= 113411.76 mm
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σp = Nsd,max x 1000
π/4 x L2
= 28.80 N/mm2
µ, max = 1.2 As per Clause 5.2.4.7
10 + σp
= 0.031 O.K. also 0.030 ≤ µmax ≤ 0.080
Moment due to frictional resistance Mrd = 0.2 x (D5 / 2) x Vy,sd
= 0.00E+00 N-mm
Since D5 / Nt = 12.50 (As per table 3 of IRC:83 (Part III)-2018 table 5.1)
k1 = 1.800
k2 = 58.800
Moment due to resistance to rotation Med = D53 (k1 x θp + k2 x θv)
= 2.11E+05 N-mm
Total Induce Moment MTd = Mrd + Med
= 2.11E+05 N-mm
Eccentricity e ≤ L/8
e = MTd / Nsd,max
= 0.06 mm L/8 = 47.5 mm Hence Safe
Ar = Aco (1 - 0.75 π e/L)
= 113366.35
fk x Ar / γm = 5101.486 kN
Nsd,max = 3266.730 kN
Nsd,max ≤ fk x Ar Hence Safe
γm
Seismic Case (ULS)
Aco = π/4 x L2
2
= 113411.76 mm
σp = Nsd,max x 1000
π/4 x L2
= 28.80 N/mm2
µ, max = 1.2 As per Clause 5.2.4.7
10 + σp
= 0.031 O.K. also 0.030 ≤ µmax ≤ 0.080
Moment due to frictional resistance Mrd = 0.2 x (D5 / 2) x x Vy,sd
= 0.00E+00 N-mm
Moment due to resistance to rotation Med = D53 (k1 x θp + k2 x θv)
2.11E+05 N-mm
Total Induce Moment MTd = Mrd + Med
2.11E+05 N-mm
Eccentricity e ≤ L/8
e = MTd / Nsd,max
= 0.0646 mm L/8 = 47.5 mm Hence Safe
Ar = Aco (1 - 0.75 π e/L)
= 113366.35
fk x Ar / γm = 5101.486 kN
Nsd,max = 3266.730 kN
Nsd,max ≤ fk x Ar Hence Safe
γm
Protrusion 'h' of Sliding Surface : (Cl. 5.2.4.2 & Table 5.3)
Protrusion h = 1.75 + L/1200 ≥ 2.2
h = 2.067 mm
Protrusion ' h' provided = 3 mm Hence Safe
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POT :
Normal Case (ULS)
Pot Walls subjected to Tensile force : (Cl. 5.3.1.2.3)
Vsd ≤ VRd
Where,
γm = 1.10
fy = 340 N/mm2
AR = (A7 - D5) x A6
= 4600.00
Vsd = Ve,sd + VFxy,sd
Ve,sd = 4 x Nsd,max x Nt
π x D5
= 332.756 kN
2
VFxy,sd = √( V Fx,sd + V2Fy,sd)
= 0.00 kN
VRd = fy x AR
γm
= 1421.82 kN
Vsd = Ve,sd + VFxy,sd
= 332.756 kN
Vsd ≤ VRd Hence Safe
Pot Walls subjected to Shear force : (Cl. 5.3.1.2.4)
V'sd ≤ V'Rd
Where,
V'sd = Ve,sd + 1.5 x VFxy,sd
D5
0.95 kN/mm
V'Rd = fy x (A7 - D5)
2 x γm x √3
= 8.92 kN/mm
Vsd ≤ VRd Hence Safe
Pot base subjected to Tensile force : (Cl. 5.3.1.2.5)
Vsd ≤ VRd
Where,
Vsd = Ve,sd + VFxy,sd
= 332.76 kN
VRd = fy x Ap Where Ap = A1 x A2
γm
= 3090.91 kN
Vsd ≤ VRd Hence Safe
Seismic Case (ULS)
Pot Walls subjected to Tensile force : (Cl. 5.3.1.2.3)
Vsd ≤ VRd
Where,
γm = 1.10
fy = 340 N/mm2
AR = (A7 - D5) x A6
= 4600.00
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Vsd = Ve,sd + VFxy,sd
Ve,sd = 4 x Nsd,max x Nt
π x D5
= 332.756 kN
VFxy,sd = √( V2Fx,sd + V2Fy,sd)
= 0.00 kN
VRd = fy x AR
γm
= 1421.82 kN
Vsd = Ve,sd + VFxy,sd
= 332.756 kN
Vsd ≤ VRd Hence Safe
Pot Walls subjected to Shear force : (Cl. 5.3.1.2.4)
V'sd ≤ V'Rd
Where,
V'sd = Ve,sd + 1.5 x VFxy,sd
D5
0.95 kN /mm
V'Rd = fy x (A7 - D5)
2 x γm x √3
= 8.92 kN/mm
Vsd ≤ VRd Hence Safe
Pot base subjected to Tensile force : (Cl. 5.3.1.2.5)
Vsd ≤ VRd
Where,
Vsd = Ve,sd + VFxy,sd
= 332.76 kN
VRd = fy x Ap Where Ap = A1 x A2
γm
= 3477.27 kN
Vsd ≤ VRd Hence Safe

Contact surface : (Cl. 5.3.1.4.2)

Flat contact faces shall be verified , so that :
Vsd ≤ VRd
Where,
VRd = f y x D5 x w
1.5 x γm
Vsd = 0.000 N ( Design value of horizontal force in N)
w = 8.0 mm (width of piston face) (Provided)
2
fy = 340 N/mm (yield strength of material)
D5 = 350 mm (inner diameter of Pot)
γm = 1.10 (for cast steel)
VRd = 576969.697 N
Vsd ≤ VRd Hence Safe

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Rotation Capacity 5.3.1.5

i) A6 - Nt - (w - we) x 0.5 - (θ x 0.5 x D5) ≥ δ

where
δ= 0.01 x D5
= 3.50 mm
A6 - Nt - (w - we) x 0.5 - (θ x 0.5 x D5) For Flat contact face we = w
= 17.09 mm
A6 - Nt - (w - we) x 0.5 - (θ x 0.5 x D5) ≥ δ Hence Safe

ii) hp - (A6 - Nt) - (θ x 0.5 x C3) ≥ δ

where
δ = 0.01 x D5
= 3.50 mm
hp - (A6 - Nt) - (θ x 0.5 x C3) where hp = A6 - Nt + hn = 28
= 8.91 mm
hp - (A6 - Nt) - (θ x 0.5 x C3) ≥ δ Hence Safe

Design resistance of the Adjacent concrete structure (as per Cl. 5.2.1)
Frdu > Nsd,max
The Resistance of the concrete structure shall be calculated by :
Frdu = Aco x fcd x √ (Ac1 / Aco )
Where,
Aco = Loaded Area
Ac1 = Dispersed Area
fck = Characteristic compressive strength of concrete
fcd = Permissible direct compressive strength of concrete
= 0.67 x fck / 1.5
(i) For Bearing Bottom Plate :
Pedestal Size = 750 x 750
2
Ac1 = 441787.50 mm
2
Aco = 125664.00 mm
2
fcd = 20.10 N/mm
then, Frdu = 4735.96 kN
Nsd,max = 3266.73 kN
Frdu > Nsd,max Hence Safe

(ii) For Bearing Top Plate :

Top Dispersion Size = 750 x 750
2
Ac1 = 441787.50 mm
2
Aco = 146574.49 mm
2
fcd = 20.10 N/mm
then, Frdu = 5114.84 kN
Nsd,max = 3266.73 kN
Frdu > Nsd,max Hence Safe

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ANCHOR BOLTS : (Cl. 5.3.6)
Size of bolts Db = 16 mm
Effective area of bolt Ab = 157 mm2
Number of bolts n = 4
Grade of Bolt = Gr. 4.6
Ultimate Tensile Strength of Bolt fub = 400 N/mm2
Co-efficient of friction between steel & concrete γµ = 0.6
γm2 = 1.25
αv = 0.6
If Seismic Zone III µk = 0.6
Nsd,min = 1922.76 kN
Design shear resistance of single anchor (as per Annexure D) :
Fv,Rd = αv x fub x Ab
γm2
= 30.144 kN
Resistance in shear
Vxy,sd ≤ VRd
Where,
VRd = µk x Nsd,min + Vpd
γµ
Where, Vpd = n x Fv,Rd
= 120.58 kN
VRd = 2043.34 kN
Vxy,sd = 0.00 kN
Vxy,sd ≤ VRd Hence Safe
ANCHOR SLEEVE : (Cl. 5.3.6.4.2)
Diameter of Sleeve D = 40 mm
Sleeve length for Bottom Lb = 160 mm
Sleeve length for Top Ls = 160 mm
For Bottom fcd = 20.1 N/mm2
For Top fcd = 20.1 N/mm2
FR,du ≥ Fv,Rd
FR,du = D x L x fcd / √ 3
For Bottom FR,du = 74.27 kN
Fv,Rd = 30.14 kN
FR,du ≥ Fv,Rd Hence Safe
For Top FR,du = 74.27 kN
Fv,Rd = 30.14 kN
FR,du ≥ Fv,Rd Hence Safe
CHECK ON SIZE OF S.S.PLATE :
Size of the S.S.Plate in Longitudinal Direction SSPL = 510.0 mm
Size of the S.S.Plate in Transverse Direction SSPW = 440.0 mm
Longitudinal movement elng =' ± 60.0 mm
Transverse movement etran =' ± 26.0 mm
Diameter of PTFE L = 380 mm
Minimum size of the S.S.Plate required in Longitudinal Direction
= L + (2 x elng)
= 500.0 mm ≤ 510.0 mm HENCE OK
Minimum size of the S.S.Plate required in Transverse Direction
= L + (2 x etran)
= 432.0 mm ≤ 440.0 mm HENCE OK
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