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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
(RAILWAY BOARD)
No.2013/Proj./DBR/Kochi/2/7
·) ·H~ ut€':;!'/;: ~
· "'C E:.' ~d on .. f:..?..~ ~-
.' ,_ ~t-- .Ji.~.e.~ ...
New Delhi , dated 2c:J .04.2015

Director Project,
Kochi Metro Rail Limited ,
Kochi Metro Rail Project,
g th floor, Revenue Tower,
Pa rk Avenue , Kochi
Kerala-682011 .

Sub: Approval of Design Basis Report (DBR) of Kochi Metro.

Ref RDSO 's letter No.UTHS/12/Civil dated 30 .3.2015.

The Design Basis Report (DBR) - (Version -6 R) March , 201 5 of Kochi Metro
Rai l Ltd . received through RDSO vide letter under reference above has been
examined and approval of Railway Board is hereby conveyed.
Accordingly , approved copy of DBR (Version-6 R March , 2015 ) is enclosed.

Encl : As above ~~ -
'0~?r: ~
< / - 0'01>.. \6

..r;, ~ (Ruth h~ngsan)

. /. ~ ? Director/Works/Planning
~~J< ,;r Railway Board.
Copy to:-

DG/RDSO , Lucknow ~~\('\\~

- ,,y/._
/ ·
,..
!
 KOCH/ METRO RAIL L TO.
(A joint venture company of Govt. of India & Govt. of Kerala)

KOCHI METRO RAIL LIMITED

KOCHI METRO RAIL PROJECT

STRUCTURAL DESIGN BASIS REPORT

FORVAIDUCT

Version-6R

March 2015

KOCHI METRO RAIL LTD.

s'h Floor, Revenue Tower, Park Avenue, Kochi
Kerala - 682011
Kochi Metro Rail Project

TABLE OF CONTENTS

1 INTRODUCTION ............................................................... ......................... .......... ............ l

1.1 Scope of Project ....................................................................................................... ............. 1
1.2 Aim of this Design Basis Document ............................................................. ............................ 1
2 UNITS ............................................................................................................................ . 1
3 TRACK GEOMETRY, TRACK STRUCTURE AND ROLLING STOCK ..................................... 1
4 ROADWAY AND RAILWAY CLEARANCES ........................................................................ 1
4.1 Clearances for Road Traffic .................................................................................................... 1
4.2 Clearances for Existing Railway Crossings ...................................................... .......................... 1
4.3 Clearances for RollingStock OF KOCHI METRO ......................................................................... 1
5 DESIGN LIFE & SERVICEABILITY ................................................................................... 1
6 MATERIALS PARAMETERS .............................................................................................. 2
6.1 Concrete ............................................................................................................................... 2
5.2 Prestressing Steel for Tendons ............................................................................................... 3
S.2.1 Young's Modulus .................................................. .................................................. ... .. ........... 3
: .2. 2 Prestressing Units .......................................................................................... .. ....................... 3
53 Reinforcement Steel (Rebars) ................................... ...... ........................................................ 3
5..! Structural Steel (for Composite Bridges & other structures if any) ..................... ........................ 3
7 LOADS TO BE CONSIDERED FOR DESIGN ......................................................................4
'· Dead Load ............................................................................................................................ 4
.1. 1 Self weight of structure (DL) ........... ... ..................................................................................... 4
.1. 2 Super Imposed Dead Load (SIDL) ............................................................................................4
" .2 Pre-stress Force (PR) ............................................................................................................. 5
" .3 Live load (LL) .......................................................................................................... .... .......... 5
.3.1
7.3. 2
.3.3
7.3.4
.3.5
7.4
.4.1
.4.2
7.4 .3
.5
7.6
7.7
7.8
7.9
7.1 0
 chi Metro Rail Project

- .: 1 Differential Settlement (DS) ................................................................................................... 9

7.12 Buoyancy loads ..................................................................................................................... 9
7.1 3 vehicle collision load (VCL) ..................................................................... ................................ 9
7. 14 Gradient Effect ....................................................................................... ............................... 9
7.15 Buffer Load ......................................................................................... ........ .......................... 9
7. 16 Vibaration Effect .................................................................................................................... 9
8 LOAD COMBINATIONS .................................................................................................... 9
- .1 Elementary Loads Definition ................................................................................................... 9
-.2 Load Combinations Methodology .......................................................................................... 11
9 DESIGN CHECK FOR CONCRETE STRUCTURE ....................................................... ....... 11
:..1 Allowable Stresses for concrete at Serviceability limit state ..................................................... 11
:.. 2 ULS Check for Prestressed cast-in Situ concrete/Composite Con'struction ................................. 11
9.3 ULS Check for RCC structure ................................................................................................ 11
10 DESIGN CHECK FOR STEEL STRUCTURE ..................................................................... 11
11 DURABILITY & CRACK WIDTH .................................................................................... 12
: :. .1 Durability ............................................................................................................................ 12
::.. 2 Concrete Cover ................................................................................................................... 12
: : .3 Crack Width Check ............................................................................................................. . 12
12 FATIGUE ...................................................................................................................... 12
: 2.1 General ............................................................................................................ ................... 12
:.2. 2 Prestressed Concrete Structures ...... , .................................................................................... 12
:.2.3
:2.4
13
14
15
16
17
:7.1 Bearing System ................................................................................................................... 14
:7.2 Replaceability of Bearings ................................................................................................... . 15
:.7.3 Uplift .................................................................................................................................. 15
18 SUPERSTRUCTURE SYSTEM OF VIADUCT ............................................................ ........ 15
19 DRAINAGE ........................................... ~ ....................................................................... 15
20 LIST OF DESIGN CODES AND STANDARDS, APPLICABILITY ...................................... 16
_0.1 IRS CODES (WITH LATEST VERSIONS) ................................................................................. 16
20.2 IRC Codes (wiTH LATEST VERSIONS) ................................................................................... 16
_Q.3 IS Codes (wiTH LATESTVERSIONS) .......... ............................................. ............................. . 17
20.4
20.5
Kochi Metro Rail Project

1 INTRODUCTION

This Design Basis Report pertains to Viaduct Portion of Kochi Metro Phase-1 from Alwaye to Petta
(22 Elevated Stations) & access Ramp (from Muttom station to Depot on surface) of Kochi Metro
Project.

1.1 SCOPE OF PROJECT

The Viaduct for Kochi Metro project comprises of simply supported Precast Pre Tensioned twin U
Girder, with RCC substructure and Bored Cast in situ pile foundation. Each track is to be
separately supported on single U girder. The standard gauge of 1435mm shall be followed. The
centre to centre distance between the two tracks shall be as per approved SOD of KMRL.
However, PSC I Girder/Balanced cantilever/steel composite girders have been proposed at
crossover/turnout/railway crossing/highway crossing.

1.2 AIM OF THIS DESIGN BASIS DOCUMENT

This Design Basis Report provides Design Criteria for Viaduct of Kochi Metro.

2 UNITS

The main units used for design shall be: [m], [mm], [t], [kN], [KN/m 2], [MPa], [ 0 C], [rad]

3 TRACK GEOMETRY, TRACK STRUCTURE AND ROLLING STOCK

Track Geometry, Track Structure & Rolling Stock should be as per the approved SOD of KMRL.

4 ROADWAY AND RAILWAY CLEARANCES

The viaduct runs along and crosses several existing roadways and existing railways . The following
sections outline the general clearance requirements for these crossings.

4.1 CLEARANCES FOR ROAD TRAFFIC

Clearance for road traffic shall be as per Road Authority of IRC requirement.

4.2 CLEARANCES FOR EXISTING RAILWAY CROSSINGS

Clearance for Railway Traffic should be as per Schedule of Dimensions of Indian Railways.
General Arrangement Drawing of railway crossing shall be approved by the relevant Railway
Authority.

4.3 CLEARANCES FOR ROLLINGSTOCK OF KOCHI METRO

Clearances for Rolling Stock should be as per the approved Schedule of Dimensions of KMRL.

5 DESIGN LIFE & SERVICEABILITY

PSC structure shall be as per clause 16.1.3 of IRS: CBC.

Page I
Kochi Metro Rail Project ...
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6 MATERIALS PARAMETERS

6.1 CONCRETE

I. Young's Modulus & Modular ratio

A. Young's Modulus

Clause no. 5.2.2.1 of IRS: CBC should be followed.

B. Modular Ratio:

Modular Ratio including long term effects such as creep shall be taken as follows (§ 5.2.6 of
IRS-CBC.

For tensile reinforcement, mt = 280/ fck

For compressive reinforcement, me= 420/ fck

II. Minimum Grade of Concrete & Cover

Minimum grade of concrete should be as per clause no 5.4.4 of IRS: CBC for exposure
condition defined in Clause 5.4.1 of IRS: CBC. The cover should be as per clause 15.9.2 of IRS:
CBC

III. Cement
The minimum cementitious material content shall be as per clause 5.4.5 & table 4 (c) of
IRS:CBC.

The maximum water-cement ratio shall be as per clause 5.4.3 & table 4(a) of IRS: CBC.

The total chloride content by weight of cement shall be as per clause clause 5.4.6 of IRS:
CBC.

IV. Density
Density of concrete shall be as per Table 1 of IS: 875 (part-I).

V. Poisson's Ratio
Poisson's ratio for all concrete: 0.15 to be decided by KMRL as applicable.

VI. Thermal Expansion Coefficient

Coefficient of thermal expansion (a) has been considered as per§ 2.6.2 of IRS-BR.

VII. Time-Dependent Characteristics of Materials

i) Long term losses should be calculated in accordance with clause 16.8.2 of IRS: CBC.
ii) The design shall be done according to construction sequence to be adopted in site.
iii) Validation of software should be done by KMRL.
Kochi Metro Rail Project {>!-!L~4
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6.2 PRESTRESSING STEEL FOR TENDONS

Prestressing steel shall be conforming to IS: 14268, class 2 Low Relaxation uncoated stress
relieved strands as per clause 4.6 of IRS-CBC.

6.2.1 Young's Modulus

Young's Modulus of Prestressing steel shall be as per clause 4.6.2 of IRS-CBC.

6.2.2 Prestressing Units

Prestressing Units: 7K1~ 12K15, 19K1~

Jacking Force shall be as per Clause 16.8.1 of IRS CBC.

Transmission length of Pre-tensioned steel shall be as per §16.8.4.1 of IRS-CBC.

Other Parameters

Sheathing: Corrugated HDPE Duct shall be used as per clause 7.2.6.4.2 of IRS-CBC.

Wobble /Curvature shall be as per clause 16.8.3 of IRS: CBC.

Maximum Slip at anchorage = 6mm (to be decided based on pre-stressing anchorage system
adopted).

6.3 REINFORCEMENT STEEL (REBARS)

Only Thermo-mechanically treated reinforcement bars of grade SOOD (min.) conforming to

IS: 1786-2008 shall be adopted. The project is falling in Seismic Zone III.

6.4 STRUCTURAL STEEL (FOR COMPOSITE BRIDGES & OTHER STRUCTURES IF ANY)

I. Introduction

Structural steel shall ~e used for special composite bridges and for miscellaneous use such
as railing, supporting utilities, coverings etc.

II. Structural Steel for Miscellaneous Use

A. General
The design of miscellaneous structure shall be done as per IS: 800-2007.

Two types of structural steel shall be used as per the following standards:

a) IS: 4923 "Hollow steel sections for structural use with Yst 310"
b) IS: 2062-2011 "Steel for General Structural Purposes (Grade E240-B)"

The hollow steel sections shall be circular (CHS), square (SHS) or rectangular (RHS). Other
traditional rolled sections like plates, angles, channels, joists may also be used where
necessary.

The connections within the steel structure shall be effected es lly by direct weld ing of
SHS/RHS sections

Page3
Kochi Metro Rail Project

for main chord members as well bracings shall be 4mm as applicable for steel tubes in §6.3
of IS: 806.

Structural steel conforming to IS 2062-2011 shall be adopted in case high strength steel is
required.

A. Young's Modulus shall be as per clause A-1.3 of IRS steel bridge code.
B. Tensile Strength I Yield Strength shall be as per IS: 4923 for Hollow steel sections /as
per IS: 2062 for Structural steel.

III. Structural Steel for Composite Bridges

A. General
Structural steel conforming to IS 2062-2011 shall be adopted. The connections between
steel members shall be bolted and/or welded, with preference given to welded
connection. The welding shall only be done in shop and field welding shall not be
allowed.

IRS Steel Bridge Code 2003 and IRS Welded Bridge Code 1989 shall be followed for
design, wherever applicable for Rail/pedestrian bridges. HSFG bolt connections shall be
designed as per provisions of IRS steel bridge Code and provided as per provisions of IRS
B1 (Fabrication code).

B. Young's Modulus shall be as per clause A-1.3 of IRS steel bridge code.
C. Tensile Strength I Yield Strength
• Tensile strength shall be as per IS 2062-2011.
• Yield strength shall be as per IS 2062-2011.

IV. Composite action/Connection with concrete

Design of composite structure & connection between structures shall be done as per clause
17.3 & 17.4 of IRS CBC, IRC-22-2008, IS:3935 and IS:11384.

7 LOADS TO BE CONSIDERED FOR DESIGN

Followings are the various loads to be taken into consideration for analysis and design of
structures as prescribed in IRS: BR up to latest up-to-date correction slip.

7.1 DEAD LOAD

7.1.1 Self weight of structure (DL)

Dead load includes weight of structural component of bridge superstructure.

7.1.2 Super Imposed Dead Load (SIDL)

The following items shall be considered as SIDL:

(i) Rails + pads
(ii) Cable trough cell
(iii) Cable trays
(iv) Hand Rail
Kochi Metro Rail Project

(v) Third Rail

(vi) Miscellaneous (OCS, signaling)
(vi) Cables
(vii) Parapet
(viii) Plinths

7.2 PRE-STRESS FORCE (PR)

The pre-stressing force calculation will be as per § 16.8 of IRS-CBC. The loss of pre-stress due
to friction will be calculated as per § 16.8.3 of IRS CBC. The loss of pre-stress, other than friction
losses will be calculated as per § 16.8.2 of IRS-CBC.

7.3 LIVE LOAD (LL)

7.3.1 Railway Vehicular Load

Each component of the structure shall be designed I checked for all possible combinations of
these loads and forces. They shall resist the effect of the worst combination:

I a

i. ~ b ~
c

All axle loads =·16 tons

Maximum number of successive cars = 3

Where,

L = 21750 (Length of a car)

a = 2450 (Overhang)

b = 2200 (Wheel base in a bogie)

c = 12500 (Distance between Axle-2 and Axle-3 in t he car)

Moving load analysis shall be carried out in order to estimate maximum longitud inal force, max
shear and max BM. The simply supported structures shall be designed for Medium loading envelopes
as tabulated in annexure-1 of model DBR of RDSO. In general single track is supported by one U-
girder superstructure. In special cases, where both the tracks are supported by single
superstructure like !-Girder/Box girder, these superstructures and substructures will be checked
for one track loaded condition as well as both tracks loaded condition (Single Span as well as Both
Spans loaded condition).

However, for any other configuration (Axle load and Axle spacing) of Modern Rolling Stock

load configuration.
Kochi Metro Rail Project

7.3.2 DynamicAugmentation

CDA for longitudinal and transverse analysis shall be as per IRS: Bridge Rules.

7.3.3 Longitudinal Force

Braking and tractive forces shall be as per Modern Rolling Stock characteristics duly approved by
KMRL.

Where both the tracks are supported by a single superstructure/substructure, tractive force of
one track and braking force of another track will be taken in the same direction to produce worst
condition of loading. It shall be ensured by KMRL in service that trains on both the tracks are not
moving in the same direction. Same shall be incorporated in operating instructions of KMRL.

Where both the tracks are supported by a single superstructure, longitudinal forces shall be
calculated as per clause 2.8.4 of IRC Bridge Rules. The effect of long welded rail on longitudinal
forces will be calculated as per recommendation of UIC 774_3-R.

As per clause 2.8.5 of IRS Bridge Rules, in transverse/ longitudinal seismic condition, only 50% of
gross tractive effort I braking force will be considered.

7 .3.4 Centrifugal Forces Due to Curvature of Superstructure

The horizontal centrifugal force due to moving load in curved superstructure is to be considered
as per§ 2.5 of IRS: BR.

Where W is axle load in kN, vis maximum design speed in km/h and R is radius of curvature in
m. This force is assumed to act at a height of 1.830 m above rail top level

7 .3.5 Racking Force

The horizontal transverse loading due to racking specified in IRS: BR § 2.9 is applicable to design
of lateral bracing and does not need to be taken into account in the global analysis of loads on
the viaduct.

7.4 TEMPERATURE EFFECTS (TL)

7.4.1 General

a) A uniform temperature difference of ± 15° Celsius shall be used to calculate axial

strain/movements on bearings, expansion joints etc. (The difference between construction
temperature & maximum /minimum temperature). Maximum & Minimum temperature for
Kechi is 36°C & 19°C respectively and assuming construction takes place between 21 °C to
34°C.

b) The provision given in § 215.3 of IRC 6, shall be considered to compute effect of

differential temperature gradient in absence of any provisions in IRS code. The differential
gradient of temperature along depth of superstructure has been reproduced below for ready
reference.
Kochi Metro Rail Project

178' 10.6'

\ 1 h

o) -rr
h,
h
l
I ,- h3
0.8"/
I / -f
J /6,6 ' _j__
h4

Positive Temperature Difference

Negative Temperature Difference
h1 = 0.3h < 0.15m
h1 = h4 = 0.2h < 0.25m
hz = 0.3h > 0.1m
< 0.25m hz = h3 = 0.25h < 0.25m
h3 = 0.3h <0.15m

7.4.2 Resistance to movement of elastomeric bearings (BS)

Elastomeric bearing will resist movement/deformation of superstructure other than applied load
i.e. due to variation of temperature/creep strain/shrinkage strain etc. The bearing resistance shall
be calculated as per Clause 211.5.1.3 of IRC 6 duly ensuring provisions given in IRS: Bridge
Rules.

7 .4.3 Long welded rail forces

A rail structure interaction [RSI] analysis is required because the continuously welded running
rails are continuous over the deck expansion joints. The interaction occurs because the rails are
directly connected to the decks by fastening system .

1.1 Rail Structure interaction studies shall be done as per provisions of UIC 774-3 R with the
following parameters specified in consultation with track design engineers:

a. Track resistance in loaded and unloaded conditions.

b. Maximum additional stresses in rail in tension as well as compression on account of raii-
Structu re interaction.
c. Maximum vertical deflection of the girder ends.

2.0 Software and general methodology to be used for carrying out Rail-Structure interaction
analysis must be validated before adopting the same.

3.0 Representative stretches must be chosen for carrying out Rail-Structure interaction.

4.0 Checks must be performed for break in rail continuity due to unusual conditions like fractures
or for maintenance purposes.

5.0 RDSO Guidelines for carrying out RSI studies shall be referred.

6.0 LWR forces shall be considered in appropriate load combination as per IRS-CBC.
Kochi Metro Rail Project ~~~~·
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7.5 EMERGENCY WALKWAY (LFP)

The Layout of walkway shall be as per SOD of KMRL. The minimum emergency walkway width is .
800mm.

7.6 WIND LOAD (WL)

The wind load shall be calculated as per§ 2.11 of IRS: BRand IS: 875 (Part 3).

7.7 SEISMIC FORCE (EQ)

RDSO Guidelines issued in January 2015 on Seismic design of Railway Bridges will be followed.
These guidelines also covers load combination and ductile detailing aspect

7.8 ERECTION TEMPORARY LOADS (ETL)

Erection forces and effects shall be considered as per clause 2.13 of IRS: Bridge Rules. The
weight of all permanent and temporary material together with all other forces and effects which
can operate on any part of during erection shall be taken into account

7.9 DERAILMENT LOADS (DR)

For vertical considerations, check shall be made in accordance with the IRS Bridge Rules,
Appendix XXVIII with standard gauge in place of Broad gauge. For ULS and stability check,
loading shall be proportional as per maximum axle load.

Additionally, for derailment loads "Sacramento derailment criteria" shall be checked. This criterion ·
corresponds to the application of 40% of one coach weight applied horizontally as a 3m long
uniform impact load on the U-girder top flange/deck slab. This derailment load corresponds to an
ULS load. For SLS combinations (Group V) a 1/1.75 coefficient will be applied to the derailment
load.
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7.10 FORCES ON PARAPET

The parapets shall be designed to resist lateral horizontal force & a vertical force of l.SOkN/m
applied simultaneously at the top of the parapet as per§ 2. 10 of IRS: BR.

7.11 DIFFERENTIAL SETTLEMENT (OS)

Differential Settlement between two adjacent viaduct piers shall be as follows

i) 12 mm for Long Term Settlement;

ii) 6 mm for Short Term Settlement
The allowable settlement for pile group is 25mm (as per 15:2911-Part 4), hence differential
settlement between two foundations is considered as half of 25mm i.e. 12mm as long term
settlement. The short term settlement of 6mm is considered to cater for bearing replacement
condition.

Differential settlement shall be considered only in the design of continuous structures, if any.

7.12 BUOYANCY LOADS

The design of the foundation shall be done considering water table at ground level. Buoyancy
effect has been ignored for viaduct structure above ground.

7.13 VEHICLE COLLISION LOAD (VCL)

The vehicle collision load shall be considered as per clause 222 of IRC:6.

7.14 GRADIENT EFFECT

The load due to longitudinal gradient effect shall be considered as applicable.

7.15 BUFFERLOAD

The buffer load shall be considered as applicable.

7.16 VIBARATION EFFECT

The vibration effect shall also be considered as applicable.

8 LOAD COMBINATIONS

8.1 ELEMENTARY LOADS DEFINITION

Elementary loads taken into account are:

Elementary load
=>ead Load DL
Super Imposed Loads SIDL
S rinkage & Creep sc
;)restress PS
...:. ,•e load I LL I Train Weight

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Dynamic Impact I
Force due to curvature or Transverse eccentricity CF
Longitudinal Force ( tractive, Braking) LF
Live Load on Foot Path* LFP
When Live load on Foot path is considered then No CDA
shall be applied on Train Live Load to account for
stationary train under emergency condition.
Overall temperature effect OT
Differential Temperature DT
Long welded rail forces LR
Racking forces RF
Forces on parapets PP
Wind pressure effect : WL Longitudinal Direction WLx
Transverse Direction WLz
Earthquake EQ Longitudinal direction EQ X

Transverse direction EQ z
I Vertical direction EQ v
Buoyancy B
Differential settlement DS
Derailment Load DR

1Frictional Restraint FR

The analysis and design will be carried out for all possible cases of rolling tra in loads. All the
supporting structures, such as superstructure, bearings, substructure and foundations shall be
checked for the most onerous cases.

Lll: Used for Deck Torsion, Bearing Compression, Uplift check, Shaft check,
Foundation check

LL2: Used for Shaft check, Foundation check

Kochi Metro Rail Project ;\.~ .
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LL3: Used for Deck check, Bearing Compression check, Shaft check, Foundation check

LL4: Used for shaft check, Foundation check, Shear Key check

8.2 LOAD COMBINATIONS METHODOLOGY

The ULS and SLS load combinations and partial safety factors for loads should be followed as per
clause 11.2, clause 11.3 and Table 12 of IRS CBC. However, for load combination 2, RDSO
guidelines on seismic design of Railway Bridges : January 2015 shall be followed.

9 DESIGN CHECK FOR CONCRETE STRUCTURE

9.1 ALLOWABLE STRESSES FOR CONCRETE AT SERVICEABILITY LIMIT STATE

The stresses at transfer and construction stage during service for prestressed cast in situ and
segmental construction shall be as per clause 16.4.2.2 (Concrete Compressive stress Limitations),
16.4.2.3 (Steel stress Limitations), 16.4.2.4(Cracking), 17.3.3(0ther types of Connections) and ,
17.4 (Composite Concrete Constructions) of IRS CBC.

Clause 10.2(Serviceability Limit States) of IRS CBC shall be used for RCC construction (Beams,
columns and slabs).

9.2 ULS CHECK FOR PRESTRESSED CAST-IN SITU CONCRETE/COMPOSITE

CONSTRUCTION

Clause 16.4.3 (Ultimate Limit State: Flexure) to clause 16.4.6 (Longitudinal shear) of IRS CBC
shall be applicable for cast-in situ Prestressed construction whereas for composite construction
clause 17.4 (Composite Concrete Constructions) shall be used.

9.3 ULS CHECK FOR RCC STRUCTURE

Section Capacity check for RCC Beams (ULS) for the superstructure should conform to clause
15.4 of IRS CBC. The design of RCC slabs shall conform to clause 15.5 of IRS CBC. The design
of column should conform to clause 15.6 of IRS CBC.

10 DESIGN CHECK FOR STEEL STRUCTURE

The design of steel structure, composite girders and shear studs shall be carried out by IRS Steel
Bridge code/ IRS welded Bridge Code.
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11 DURABILITY & CRACK WIDTH

11.1 DURABILITY

Provision of clause 5.4 of IRS-CBC shall be followed.

11.2 CONCRETE COVER

The cover should be as per clause 15.9.2 of IRS: CBC.

11.3 CRACK WIDTH CHECK

For SLS Combination GI, crack width in reinforced concrete members shall be calculated as per
clause 15.9.8.2.1 of IRS CBC.

The allowable crack width should be as per clause 10.2.1(a) based on the exposure condition
defined in clause 5.4.1 of IRS CBC and table-10 of IRS:CBC.

12 FATIGUE

12.1 GENERAL

Fatigue phenomenon shall be analyzed only for those structural elements that are subjected to
repetition of significant stress variation (under traffic load). Thus generally the fatigue shall be
regarded only for deck structural part supporting the tracks.

12.2 PRESTRESSED CONCRETE STRUCTURES

The fatigue shall be checked as per clause 13.4 of IRS CBC.

12.3 REINFORCED CONCRETE STRUCTURES

The fatigue shall be checked as per clause 13.4 of IRS CBC.

12.4 STEEL STRUCTURES

Clause 3.6 of IRS Steel Bridge Code (up to correction slip 18) I clause 13.2 of IRS welded Bridge
Code shall govern. If f.. values are required to be used, the train closest to the actual train
formation proposed to be run on the metro system shall be used. Otherwise, detailed counting of
cycles shall be done.

13 PILE FOUNDATIONS

Based on available geotechnical report, it is anticipated that all foundations will be piled
foundation. Foundation analysis and design will be based on IRS Code for Substructure. The
forces applied by the pier are transferred to the bottom of the pile cap for this purpose. Pile 1 pile
cap systems will be analyzed by rivet theory as well as bending theory. The various specific
assumptions made for the pile and pile cap design are as follows:

Page 12
}
Kochi Metro Rail Project

ii) The vertical capacity of the pile shall be based on static formula given in IS: 2911 (Part-
1/Section- 2). For pile carrying capacity, the SLS check only will be considered and no
reference will be made to ULS combinations. Under load combination 1 of IRS CBC, vertical
load on pile shall not exceed safe vertical load. The permissible increase in vertical pile
capacity under load combination 2 & 3 of IRS CBC, would be taken as per provision of
IS2911:2010 & IS1893:Partl. Uplift load on pile shall not exceed uplift capacity calculated
based on provision given on IS: 2911 (Part-1/Section- 2).

iii) The lateral load capacity of pile shall be evaluated by carrying out actual field load test on full
scale pile as suggested in clause 6.5.2 of IS 2911 (part-1, sec-2)-2010.

iv) The following limiting values shall not be exceeded for computation of safe vertical load :

a) Results of sub-surface investigation will be used for adopting the value of angle of
internal friction <j> and cohesion of soil, c.
b) Angle of wall friction will be taken as equal to <j> deg.
c) Co-efficient of earth pressure "K" shall be 1.0 on conservative side [ra nge of "K" is 1.0 to
1.5 as per Annex B of IS-2911 (Part 1/Sec 2:2010)].
d) Maximum overburden pressure at bottom of pile for calculation of shaft resista nce and
end bearing resistance should be limited to 15 t imes the diameter of pile for <j> < or equal
to 30° which may be increased to 20 times the diameter of t he pile for <j>> or equal to
40°.
e) The entire overburden will be assumed fully submerged for the purpose of calculation of
safe load.
f) Factor of safety to arrive at working load shall be as per IS: 2911 (Part-1/Section- 2).
g) For piles passing through cohesive strata and terminating in the granular stratum, a
penetration of at least twice the diameter of the pile shaft should be given in to the
granular stratum.

v) Bulk density corresponding to' 100% saturation shall be calculated and used for worki ng out
submerged density of soil.

vi) Initial load tests (not on working pile) will be cond ucted first for determination of safe vertica l
and lateral loads as per IS: 2911 (Part 4) 1985 (Reaffirmed 2010) . The safe load shall be
taken as least of (a) load calculated from the initial load test and (b) the calculated safe load
based on static formula. Initial test is proposed to be conducted for a load of 2.5 times as per
the safe vertical load based on static formula.

vii) The working load on pile for vertical and horizontal loads shall be verified through ro utine
load tests during construction. The working load capacity of pile for vertical and horizontal
loads should be checked by conducting routine tests during construction as per provisions
given in IS 2911 (Part-4) 1985 (Reaffirmed 2010). The number of test shall be carried out as
per§ 709.2.4 of IRC-78-2000.

Pile integrity tests shall be carried out as per requirement.

viii) Spacing between the piles shall generally be not be less than 3 times the diameter of pile in
soil and 2.5 times the diameter when founded on rock.

ix) Pile design shall be done according to § 15.6 of IRS CBC. However, for crack control in piles,
§ 15.6.7 of IRS CBC will be modified to the extent that actual axial load wil l be considered
to act simultaneously.

x)

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14 PILE CAP

The following design methodology shall be adopted for design of pi le cap.

a) Pile cap shall be designed based § 15.8.3.1 of IRS -CBC. No su pport f rom soil below pile
cap shall be considered.
b) The thickness of the pile cap shall be kept minimum 1.5 times diameter of the piles for
multiple-pile group as per § 709.5.4 of IRC78-2000 section VII and revised vide notification
number 54 dated 28th May 2009.
c) The top of pile cap shall be kept about 500 mm below the existing ground level/road level
and weight of the earth cover will be applied on top of pile cap when unfavorable. The ea rth
cover on pile cap for any favorable effect (stability, soil horizontal capacity) will be neglected .
d) The structural design of the pile cap shall be carried out as per §10 .2.2 & §15 .4 and §15.8 .3
of IRS CBC.
e) Contribution of pile cap in resisting vertical compressive force as open foundation will be
ignored and pile cap weight will also be taken by the piles.

15 PIERS

The viaduct superstructure is typically supported on single cast-in-place RC pier. The shape of t he
pier has been chosen to follow the flow of forces and to satisfy both economy and aesthetics.

Cantilever piers/portal piers shall be provided to suit site conditions where superstructure is under
curve and shall be designed for specific eccentricities.

Circular pier/Rectangular/Capsule type pier (rectangular with semi-circular ends) will be adopted
as per design requirement. Architectural elements (grooves etc.) shall be neglected duri ng section
check of pier. Pier analysis and design will be based on § 15.6 of IRS CBC and effective length of
a cantilever column for the purpose of slenderness will be taken as 2.3 * clear height between
the restraints in both directions.

16 PIERCAP

Pier cap should be designed as corbels if shear span to effective depth ratio is less than 0.6 as
per clause 17.2.3 of IRS: CBC. In other case, it shall be designed as flexural member.

17 BEARING SYSTEM AND ITS DESIGN METHODOLOGY

17.1 BEARING SYSTEM

Considering the span configuration and safety aspects of the structural system (in normal and
seismic condition), it is proposed to adopt elastomeric bea rings placed underneath the U-girder/
PSC-girders for transfer of vertical forces and a reaction block (protruding above the pier head)
for transfer of in-plane forces. The elastomeric bearing shall be designed as per UIC 772 2-R -
1989 along with IRC: 83 Part-II, wherever UIC code is not clear.

POT cum PTFE bearings may be provided if elastomeric bearings are not possible to design for
special spans. POT-PTFE bearing shall be designed as per IRC: 83 Part-III 2002.
Kochi Metro Rail Project

17.2 REPLACEABILITY OF BEARINGS

While finalizing the proposed bearing system, it shall be kept in mind that accessibility and
replacement of each part of bearing are of paramount importance as the design life of bearings is
shorter than that of the structure. Keeping in view the above cited criteria, all the bearings and
pier caps will be detailed for replacement of bearings in the future.

Special Low Height jacks shall be employed to replace bearings, if minimum vertical
clearance is less than 400mm as stipulated in clause 15.9.11.4 of IRS: CBC.

17.3 UPLIFT

If required, a holding-down device connecting the deck and the pier head shall be placed in order
to prevent the deck from overturning. The holding-down device may be integrated in the pot-
bearing system or be a separate system constituted of bars embedded in pier cap and viaduct
with appropriate details, permitting translation/rotation. Other systems can also be foreseen.

Due to the lack of appropriate guidelines in Indian codes, the design criteria for holding down
device (upward force limit requiring holding down device, design formulas) will be taken from the
latest international practice (AASHTO, MOTC codes).

18 SUPERSTRUCTURE SYSTEM OF VIADUCT

The superstructure of the viaduct comprises of simply supported Precast Pre Tensioned twin U
girders span. In general, super structure (U Girder) will be accommodating one track as per
approved SOD of KMRL.

However at crossovers I turnouts I railway crossings/ highway crossings, PSC I Girder 1 Balanced
cantilever/Steel composite girders have been proposed.

The minimum dimensions shall be considered as per Clause 16.9.6 of IRS CBC.

Design of superstructure should be done in accordance with construction

methodology/construction sequence to be adopted during execution by KMRL.

19 DRAINAGE

For Drainage of Deck, the provrsrons of clause 10.4.1.1 & clause 15.2.2 IRS: CBC shall be
followed. In addition, the drainage pipes will be embedded in the pier columns to avoid
aesthetics problems and will consist of double wall HDPE corrugated pipes of ID 250 mm. A
water collection box with cover will be located at the top of the drainage pipe to collect any
water spilling onto the pier cap and to provide a maintenance point for the vertical drainage pipe.

The top of deck slab will be profiled so as to collect the run-off water at single points by providing
a cross slope of 2.5%. Two longitudinal drainage paths are provided within each U-girder and two
drainage inlet pipes at each end of U-girder will be provided to collect the run-off. The vertical
alignment of the viaduct will be set at a minimum gradient of 0.25% to ensure longitudinal
drainage. In locations where the longitudinal gradient of the alignment is less than 0.25%, a
minimum gradient of 0.25% shall be introduced into the U-girders to ensure longitudinal drainage
and the height of the track plinth shall vary.

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The drainage inlet pipes at the end of the U-girders will be directed to pipes embedded in the pier
cap, which collect to the vertical drainage pipe in the pier column.

20 LIST OF DESIGN CODES AND STANDARDS, APPLICABILITY

The IRS Codes shall be followed in principle. Although main clauses have been mentioned in the
DBR, the other relevant clauses as available in the IRS codes shall also be followed, wherever,
applicable. If provisions are not available in IRS, the order of preference shall be as follows,
unless specified otherwise:
For Railway loading related issues:
i. UIC Codes
ii. Euro Codes
iii. Any other code which covers railway loading.
For other Design/detailing related issues:
i. IRC
ii. IS
iii. Euro Code
iv. Other National Codes

20.1 IRS CODES {WITH LATEST VERSIONS)

IRS Substructure & Foundation Code

IRS Bridge Rules

IRS Concrete Bridge Code

IRS Steel Bridge Code

IRS Fabrication Code (Bl)

IRS Welded Bridge Code

IITK-RDSO Guidelines on Seismic Design of Railway Bridges

20.2 IRC CODES (WITH LATEST VERSIONS)

IRC:S Standard Specification & Code of Practice for Road Bridges - General Features
of Designs

IRC:6 Standard Specification & Code of Practice for Road Bridges - Loads and
Stresses

IRC:22 Standard Specification & Code of Practice for Road Bridges, Section VI -
Composite Construction for Road Bridges

IRC:24 Standard Specification & Code of Practice for Road Bridges, Section V - Steel
Road Bridges

IRC:112 Code of Practice for Concrete Bridges

IRC:78 Standard Specification & Code of Practice for Road Bridges - Section
Foundations & Sub-structure
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IRC:83(I) Sta da'"C S:::;,e:- ~cz · & Code of Practice for Road Bridges, Part-I Metallic
Bea . ::;

IRC:83(II) & Code of Practice for Road Bridges, Pa rt-II Elastomeric

Bea ~;s

IRC:83(III) S:a ~~--= :::e::- - · " & Code of Practice for Road Bridges, Part-III Pot, Pot-
Guide Bearings

20.3 IS CODES (WITH ST ERSIO S)

IS:269 . Heat Portland Cement

IS:383 -:JeCS :..._ x'"Se c.-::: "e aggregate from natural sources for concrete

IS:432 ed: m tensile steel-bars (Part 1)

IS:456 CRETE - CODE OF PRACTICE

IS:800

IS:875

IS: 1080 .., : shallow foundations in soils (Other than Raft, Ring

IS:l343 e:--stressed Concrete -based essentially on CP-110

IS:1364 & nuts of product grades A & B Part 1 (Part 1

e -a ge 11:6 to M64)

IS: 13920 e "~reed concrete structures subjected to seismic

e
IS:1489

IS:1786

IS: 1893 es·stant Design of structures

IS:1904

IS:1905

IS:2062

I5:2502 Code of ra · e • - 3e · g and Fixing of Bars for Concrete Reinforcement

IS:2911 Code of Practice - Je5 & Constr. of Pile Foundations Part 1

(Part 1/5ec2) Concrete Piles Secti:r 2 5o-ed Cast-in-situ Piles (with amendments)

15:2911 Code of Practice , - Jes " & Constr. of Pile Foundations Part 4 Load test on
Piles

15:2950 Designs and Constru cRaft Foundations

15:3935
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IS:4326 Code of Practice for Earthquake Resistant Design and construction of Buildings

IS:4923 Hollow steel sections for structural use -specification

IS:8009 Calculation of settlement of shallow foundations

IS:8112 Specifications for 43 Grade Ordinary Portland cement

IS:8500 Structural Steel -Micro alloyed (Medium and high strength quantities)

IS:9103 Specifications for 53 Grade Ordinary Portland cement

IS:11384 Code of Practice for Composite Construction in Structural Steel and Concrete

IS:12070 Code of Practice for Design and Construction of Shallow Foundations on Rocks

IS:12269 Specifications for 53 Grade Ordinary Portland cement

IS:14268 Uncoated Stress Relieved Low relaxation Seven-ply Strands for pre stressed
Concrete

IS:14593 Design and Construction of Bored Cast-in-Situ Piles Founded on Rocks

20.4 BS CODES (WITH LATEST VERSIONS)

BS:4447 Specifications for the Performance of Prestressing Anchorages for Post-

Tensioned Construction

BS:4486 Specifications for High Tensile Steel bars used for Prestressing

BS:5400 Code of Practice for Design of Concrete Bridges Part 4-1990

BS:5400 Code of Practice for Fatigue Part 10-1990

BS:8006 Code ofPractice for Strengthened Reinforced soils and other fills- 1995

BS:8007 Design of Concrete Structures for Retaining Aqueous Liquids

20.5 OTHERS (WITH LATEST VERSIONS)

UIC-774-3R Track Bridge Interaction

UIC-772-2R Code for the Use of Rubber Bearings for Rail Bridges

CEB-FIP Model Code 1990 for concrete structures

FIP Recommendations for the Acceptance of Post-Tensioning Systems

MORT&H Specifications for Road and Bridge Works

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