DESIGN OF RCC BOX

PROPOSED BOX TUNNEL IN KOLKATA METRO LINE

DN SAS/2301/AFCONS

Rev 0 Dated 29.01.2023

CONTRACTOR
SAS INFRATECH
601-19, KIRTI MAHAL, RAJENDRA PLACE,
NEW DELHI -08.

CONSULTANT
M/s DEEPANKAR ENGINEERS AND CONSULTANTS

and

M/s ECOSPACE INFRASTRUCTURES

CLIENT
RAIL VIKAS NIGAM LTD.
 CONTENTS

S.N. DESCRIPTION PAGE NO

1.0 General data 1

2.0 Load Calculations 2
3.0 Earthquake load calculations 5
4.0 Design of box 7
5.0 Load Combinations 11
6.0 STAAD File 15
BMD & SFD 24
7.0 Ground settlement 40
 DESIGN OF BOX FOR METRO TUNNEL
1.0 GENERAL DATA

Material
Concrete Fck M 40 (Min strength of concrete at the time
Ec 31623 MPa
yc 25.0 kN/cum
Steel Fy Fe 500 D

Levels
MaximumGround Level GL.m 5.472 m
Max Ground water level GWL 2.00 m
Earth cushion 4.726 m
Top of box RL.tb 0.746 m
Thickness of Top slab Th.ts 1.100 m
Thickness of base slab Th.bs 1.100 m
Min top of base slab -5.504 m
Required clearance bvo 4.380 m
Width of opening W.bi 12.850 m
Long slope of drain 0.000 m
Cross slope in floor 0.000 m
Track section trk.ht 0.570 m
Pushing margin pm 0.200 m
Clear height of box 5.150
Say bv 5.150 m

Box
Clear height of box bv 5.150 m
Clear width of box-cell W.bi 12.850 m
No of cells 1 Nos
Wall thickness-outer 1.000 m
Top slab thickness Th.ts 1.100 m
Bottom slab thickness Th.bs 1.100 m
Overall ht of box OH.box 7.350 m
Overall width of box 12.850 m
Effective span of box 13.850 m
Effective Height of box 6.250 m
Haunch Size 0.300 m
Minimum steel 0.20 %

Loads
Earth cushion 4.726 m

SIDL 0.00 kN/m

Weight of track 20.00 kN/m (A)
Train load (Cl 1.5.2.3 of DBR)
Axle load 170.00 kN
Axle spacing (minimum) 2.45 m
Max Load/m along track 69.39 kN/m
Impact for long analysis 1.20
Design load/m of track 83.27 kN/m (B)
No of track plinth/ track 2.00 (C)
Total load due to track/ plinthTrk.wt 51.63 (A+B)/C
Effective span of box(SK) 13.85 m

Soil Properties
Density saturated of soil ys 20.0 kN/cum Cl 1.5.2.2 of DBR
Angle of int friction of soil, phi fb 30.00 d
Coeff of earth pr at rest, Ko 0.500
Earth pressure coefficients (by Coulomb's theory, Pl refer Cl 5.7 of IRS bridge rule) )
Coeff of active earth pr, Ka 0.304

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2.0 Load and Earth Pressure calculations at various critical levels

Load on Top slab of box

Earth Cushion 4.73 m
Earth Cushion for design Eh 4.73 m
Impact Imp 0.0%
Span 13.85
LL+Impact LL (In service) 50.00 kN/sqm (A) Cl 1.5.2.4 of DBR
Earth cushion+water = Eh ys 94.52 kN/sqm (B) (upto RL)
Total load on top of box 144.52 kN/sqm (A+B)

Earth Pressure @ c/l of top slab of box

For Max Water table with Ko Load EP (Ko)
=Ko Load
Saturated Earth Height Eh.sat=GL.m - GWL 3.47 m (from GWL)
Submerged earth height Eh.sub=Eh - Eh.sat+Th.ts/2 1.80 m
Load due to:
LL surcharge intensity LL 50.00 25.00 kN/sqm
Earth Height Saturated L.Esat=Eh.sat ys 69.44 34.72 (D)
Earth Height (submerged) L.Esub=Eh.sub (ys-1) 18.04 9.02 kN/sqm (E)
Water L.wat=10 Eh.sub 18.04 18.04 kN/sqm (F)
Earth+Water 105.52 61.78 kN/sqm (D+E+F)

For Water table below box with Active earth Pressure Load EP (Ka)
=Ka Load
Earth Height =Eh+Th.t 5.28 m
LL surcharge intensity LL 50.00 15.19 kN/sqm
Earth Height (saturated) =(Eh+Th.t) ys 105.52 32.05 kN/sqm

Earth Pressure @ c/l of base slab of box

For Max Water table with Ko Load EP (Ko)
=Ko Load
Saturated Earth Height Eh.sat=GL.m - GWL 3.47 m
Submerged earth height Eh.sub=Eh +OH.box - Eh.sat-Th.bs/2 8.05
Load due to:
LL surcharge intensity LL 50.00 25.00 kN/sqm
Earth Height Saturated L.Esat=Eh.sat ys 69.44 34.72
Earth Height (submerged) L.Esub=Eh.sub (ys-1) 80.54 40.27 kN/sqm
Water L.wat=10 Eh.sub 80.54 80.54 kN/sqm
Earth+SIDL 230.52 155.53 kN/sqm

For Water table below box with Active earth Pressure EP (Ka)
Earth Height =Eh + OH.box - Tb.bs/2 11.526 m
LL surcharge intensity LL 50.00 15.19 kN/sqm
Earth Height (saturated) =(Eh + OH.box - Tb.bs/2) ys 230.52 70.03 kN/sqm

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2.1 Load diagram for various loads

LC-1: DL (BOX WT)

Area of box section 42.97 sqm
Wt of box/m = Area . yc 1074.25 kN/m

77.56 kN/m

LC-2: SIDL (Earth cushion) 94.52 kN/m

-94.52 kN/m

LC-3: Live Load 50.00 kN/m

-50.00 kN/m

LC-4: Track load

51.63 kN each

=4 Trk.wt / Eff. Box span 14.91 kN/m

LC-5: Earh Pressure Ko Earh pressure at rest wih highest water table
61.78 61.78 kN/m

155.53 155.53 kN/m

LC-6: Earh Pressure at rest due to LL surcharge on Left wall

25.00 kN/m

25.00 kN/m
15.27 kN/m

LC-7: Earh Pressure at rest due to LL surcharge on Right wall

25.00 kN/m

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 25.00 kN/m
15.27 kN/m

LC-8: Earh Pressure Ka Active earh pressure wih water table below box
32.05 32.05 kN/m

70.03 70.03 kN/m

LC-9: Active Earh Pressure due to LL surcharge on Left wall

15.19 kN/m

15.19 kN/m
9.28 kN/m

LC-10: Active Earh Pressure due to LL surcharge on Right wall

15.19 kN/m

15.19 kN/m
9.28 kN/m

4
3.0 Earthquake Load calculations

For Raking only the free field deformation is considered ignoring the soil structure interaction.
(per Hashash’s Theory, Ref-1)
Seismic Parameters (Cl 1.5.2.8.1 of DBR)
Zone III
Importance factor I 1.50
PGA (Z) MDE 0.18 g
ODE 0.09 g
Depth to CL of box =GL.m - RL.tb + OB.box/2 8.401 m
Depth factor 0.900 for average depth within 6-15 m (Table-4, Ref-1)
Peak ground acceleration amax.MDE 0.162 g
Peak ground acceleration amax.ODE 0.081 g

Soil Properties in Bank

Top of Box RL.tb 0.75 m
Bottom of Box RL.bb -6.60 m
Bore hole location Bore hole Number Cu.(t/m2) N.average
Near start of pushing BH-3 3.5 15.0
Middle of pushing BH-2 3.9 11.5
Near end of pushing BH-1A 3.4 12.0
Average 3.6 12.8
Type of soil Stiff (SPT = 8 to 12)
Moment magnitude 7.0
Distance to source 50-100 km
Peak Ground Velocity Ratio Vs/amax 132.00 (Table-2, Ref-1)

ODE PGA (Z) 0.09 g

Vs 10.69 cm/s
Shear wave velocity Cm 250.00 m/s
Free field shear strain Ymax=Vs/Cm 0.00043
Height of box OH.box 7.350 m
Deflection at top 3.143 mm

Case-1 Point load 154.69 kN

Case-2 UVL 92.57 kN/m

Case-1 154.69 KkN

30.24 kN/m

Case-2 92.57 KkN/m

37.70 kN/m

5
 MDE PGA (Z) 0.18 g
Vs 21.38 cm/s
Shear wave velocity Cm 250.00 m/s
Free field shear strain Ymax=Vs/Cm 0.00086
Height of box OH.box 7.350 m
Deflection at top 6.287 mm

Case-1 Point load 309.38 kN

Case-2 UVL 185.14 kN/m

Case-1 309.38 KkN

60.48 kN/m

Case-2 185.14 KkN/m

75.40 kN/m

LC Load description Load Unit Remarks

11 0.09 g Racking Point Force (Towards Right) 154.69 kN
12 0.09 g Racking Distribution Force (Towards Right) 92.57 kN/m
13 0.18 g Racking Point Force (Towards Right) 309.38 kN
14 0.18 g Racking Distribution Force (Towards Right) 185.14 kN/m

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4.0 DESIGN OF BOX

LOAD FACTORS CONSIDERED Cl 1.5.3 of DBR

ULS Normal Seismic
DL 1.50 1.50 1.2
SIDL/Back fill 1.50 1.50 1.2
EP 1.5 / 0.9 1.50 1.2
LL 1.50 - 0.6 In EQ case, 50% LL = 1.2 x 0.5 = 0.6
EQ - 1.50 1.2

SLS Normal
DL 1.00
SIDL/Back fill 1.00
EP 1.00
LL 1.00

Based on above, detaild load combinations for STAAD analysis are given in para 5.0.
Using above load factors, analysis has been carriedout in STAAD Pro for load combinations given in para 5.0.

4.1 BM SUMMERY (FROM STAAD ANALYSIS) AND DESIGN

BMD for basic load cases 1-14 are given in para 6.1.
BM Diagram for Envelope for LC 41-144 and LC 201-201 (para 5.0) given in para 6.2
From the BM Envelope for ULS cases, values are summarised below.
(For support values, section taken at face of wall/slab ignoring haunch)
2100 2220
A A
2690 3610 2680
I . B I

BM
Load case 0 0
J J
2580.0 2580

2990 3970 2990

K . F K
2330 2320
E E
Mu b D d Mu/bd^2 Ast Ast.min
kN.m mm mm mm sqmm sqmm
1 TOP-MID (B, D) 3610.0 1000 1100 1034 3.38 9136 2068
2 TOP-END (A) 2220.0 1000 1100 1009 2.18 5465 2018
4 BOTTOM-MID (F, H) 3970.0 1000 1100 1009 3.90 10567 2018
5 BOTTOM-END (A) 2330.0 1000 1100 1009 2.29 5761 2018
7 WALL INSIDE (J) 0.0 1000 1000 940 0.00 0 1880
8 WALL-0.25 H from center 2785.0 1000 1000 909 3.37 8015 1818
9 WALL-TOP (I) 2690.0 1000 1000 909 3.26 7700 1818
10 WALL-BOTTOM (K) 2990.0 1000 1000 909 3.62 8709 1818
12 Long steel (0.3 x BM) 1191 1000 1100 1009 1.17 2822 2018

dia + dia spacing Provide Ast pt

mm mm mm mm sqmm %
1 TOP-MID (B, D) 32 25 142 110 11774 1.14 O.K.
2 TOP-END (A) 32 25 237 110 11774 1.17 O.K.
4 BOTTOM-MID (F, H) 32 32 152 110 14623 1.45 O.K.
5 BOTTOM-END (E) 32 32 279 110 14623 1.45 O.K.
7 WALL INSIDE (J) 20 0 167 110 2856 0.30 O.K.
8 WALL-0.25 H from center 32 16 125 110 9139 1.01 O.K.
9 WALL-TOP (I) 32 16 131 110 9139 1.01 O.K.
10 WALL-BOTTOM (K) 32 32 185 110 14623 1.61 O.K.
12 Long steel 0.20% Ast 2822 Provide 20 T 110 c/c
0T
4.2 SF SUMMERY (FROM STAAD ANALYSIS) AND DESIGN

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 SFD for basic load cases 1-14 are given in para 6.3
SF Diagram for Envelope for LC 41-144 and LC 201-201 (para 5.0) given in para 6.4
From the SF Envelope for ULS cases, values are summarised below.
(For support values, section taken at distance of deff from face of wall/slab ignoring haunch)

1420 1420
A1 A2

457 512
SF E1
Load case

Values at deff from face of wall

873 1590 1590 630

E C1 C2 E

V @ deff b d tv pt tc.s tv-tc.s

kN mm mm MPa % MPa MPa
1 TOP-END (A1) 1420 1000 1009 1.41 1.17 0.72 0.69
2 TOP-END (A2) 1420 1000 1009 1.41 1.17 0.72 0.69
4 BOTTOM-END (C1) 1590 1000 1009 1.58 1.45 0.79 0.79
5 BOTTOM-END (C2) 1590 1000 1009 1.58 1.45 0.79 0.79
7 WALL-END (E) 873 1000 909 0.96 1.61 0.83 0.13
WALL-END (E1) 512 1000 909 0.56 1.61 0.83 0.00

For M40 Concrete, tc.s as per table 19 of IS 456 pt 0.25 0.50 0.75 1.00 1.25
tc.s 0.38 0.51 0.60 0.68 0.74

Asv/sv=max(tv-tcs)/0.87/415 dia Legs Lat c/c long c/c long c/c

sqmm/m mm Nos mm calc(mm) prov(mm)
1 TOP-END (A1) 1.90 16 1 330 320 220 O.K.
2 TOP-END (A2) 1.90 16 1 330 320 220 O.K.
4 BOTTOM-END (C1) 2.18 16 1 330 279 220 O.K.
5 BOTTOM-END (C2) 2.18 16 1 330 279 220 O.K.
7 WALL-END (E) 1.11 12 1 330 309 220 O.K.
WALL-END (E1) 1.11 12 1 330 309 220 O.K.

NOTE : For shear stirrup calculations, Fyv considered as Fe 415

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4.3 CRACK WIDTH

Base Mid Base End Top Mid Top End Wall Base
Fck M 40 M 40 M 40 M 40 M 40
Fy 500 500 500 500 500
m 7 7 7 7 7
Ec 31623 31623 31623 31623 31623
Es 200000 200000 200000 200000 200000
Bar dia mm 32 32 32 32 32
Bar spacing mm 110 110 110 110 110
Cnom mm 50 70 50 70 70
As (provided) sqmm 14623 14623 11774 11774 14623
D mm 1100 1100 1100 1100 1000
d mm 1009 1009 1034 1009 909
n 0.455 0.263 0.383 0.214 0.420
nd mm 459.14 265.63 395.75 216.12 381.85
C=T= kN 3060.91 1770.86 2638.34 1440.83 2545.68
M kN.m 2620.0 1630.0 2380.0 1350.0 1990.0
Mreqd 2620.0 1630.0 2380.0 1350.0 1990.0
Diff 0 0 0 0 0
ss = T/As MPa 209.3 121.1 224.1 122.4 174.1
es = ss/Es 0.00105 0.00061 0.00112 0.00061 0.00087
e1 = es (D-nd)/(D-nd-Cnom) 0.00114 0.00066 0.00121 0.00066 0.00098

em=e1-3.8D/(Es.As)(0.75E-6) 0.00093 0.00031 0.00097 0.00023 0.00076

acr mm 69.91 86.08 69.91 86.08 86.08
crack width mm 0.184 0.076 0.192 0.057 0.186
<= 0.2

I.cracked 7677333 6935798 7354163 6041602 5823961

I.gross cm4 11091667 11091667 11091667 11091667 8333333 Average
ratio 0.692 0.625 0.663 0.545 0.699 0.645
Adopt 0.600
To adjust the EI of system for cracked I, reduce Ec to 0.60xEc. = 18970

4.4 CHECK FOR FLOATATION

Water table considered at 2.00 m (RL of water table)

X-sectional area of box 28.27 sqm

Self wt of box, SW 706.75 kN/m
Wt of earth fill, EW 1214.58 kN/m

Hydrostatic pr at base 8.6 m

86.0 kN/sqm
1105.6 kN/m

Total downward load 1729.2 kN/m 0.9 SW+0.9 EW

FOS 1.56 > 1.1 O.K.

During service, Track etc will be laid, which will further increase the FOS.

9
4.5 DESIGN OF JACKING POCKETS

Maximum load occurs at base of box, hence only base pockets need to be designed.
Other pockets to follow the same design.

X-sectional area of box 28.27 sqm

Self wt of box, SW 706.75 kN/m
Wt of earth fill, EW 1214.58 kN/m

Total downward load 1921.33 kN/m

Overall Width of box 12.850 m

Av Base pressure 149.52 kN/sqm

Longitudinal steel
Pocket depth 0.65 m 0.9 m
Span of projection 0.65 m 0.9 m
BM in projected slab 31.59 kN.m/m 60.56 kN.m/m
Mu 47.38 kN.m/m 90.83 kN.m/m

Thickness of projected slab 400 mm 400 mm

deff 340 mm 340 mm
Width 1000 1000
Mu/bd2 0.41 0.79
Ast 325 sqmm/m 630 sqmm/m
pt 0.10 % 0.19 %
Provide 20T @ 968 mm c/c 498 mm c/c
Provided 20T @ 150 mm c/c 150 mm c/c O.K.

Transverse steel
Box length equal to pocket depth is considered as ineffective for taking the transverse load.
Hence provide steel on this span as extra at edge of box.
Reinforcement required in bottom slab
Mid-span 9136 sqmm/m (Top mid)
Ends 5761 sqmm/m
maximum of two 9136 sqmm/m
Reinforcement in 900mm 8222 sqmm
Dispersion width (L/4) 3.463 m
total steel reqd in disp width = 8222 + 3.46 x 9136 = 39855 sqmm
Already provided 11774 sqmm/m (Top mid)
40767 sqmm in L/4
Extra required -912 sqmm
Provide 6x25T at each face 2946 sqmm OK

10