Date Rev

TECHNOCRAFT INDUSTRIES ( I) LTD.

19-01-2023 SPL
Project :- Design of MACH deck Panel System (2400 X 1200)
Details :-
1.0 Design Basis Report

1.1 STRUCTURE FOR PANEL

INTRODUCTION:
This design basis report is for the design and construction of Panel for formwork of Conv. RCC Slab.

Formwork forms part of temporary works. The temporary works should

satisfy static equilibrium at every stage of construction, taking into account dead load,
erection loads and wind loads if any etc complete.

1.2 Applicable codes: CIRIA report 1985

BS5950:2000

1.3 Method of analysis: Working stress / allowable stress design method

1.4 Design Parameter:

3
Concrete self weight = 25 kN/m (2500 kg/m3)
2
D.L.Shutter = 0.5 kN/m
2
Construction Load = 1.5 kN/m

1.5 Loads and Load combinations:

Basic Loads cases : 1. DL : Dead load
2. LL : Live load (Concrete Self Wt)

Load Combinations: 1 DL + 1 LL (SLS)

1.4DL + 1.6 LL (ULS)

1.6 Applicable computer Software: STAAD Pro V8i

 Date Rev
TECHNOCRAFT INDUSTRIES ( I) LTD.
19-01-2023 SPL
Project :- Design of MACH deck Panel System (2400 X 1200)
Details :-

2.0 Material of Construction :

a. Aluminium :
Alloy AA6061 - T6 or 6005A - T61
Yield stress = 275 Mpa
Aluminum IS 5052 Grade
Elongation % = 8
Equivalent alloys ASTM B221M

b. Ply Thickness = 1.2 cm = 12 mm

3 3
Density = 650 Kg/m = 6.5 KN/m
Eply = 106690 kg/cm2 = 106.69 N/mm2
Allowable bending stress = 150 Kg/cm2 = 15 N/mm2

SIDE RAIL SECTION Properties

2
E = 70000 N/mm
2
Area = 11.68 cm
4
Ixx = 521.67 cm
3
Zxx = 53.296 cm
2
allowable bending stress = 179.28695 N/mm
Permi. Bending Moment = 9.5552774 KNm
Permi. shear force = 49.75 KN
Weight = 3.25 Kg/m
Yeild Stress = 275 N/mm2
Depth = 178.06 mm

RIB SECTION Properties

E = 70000 N/mm2
Area = 3.602 cm2
Ixx = 67.31 cm4
Zxx = 11.23 cm3
allowable bending stress = 172.73871 N/mm2
Permi. Bending Moment = 1.9398557 KNm
Permi. shear force = 25.52 KN
Weight = 1 Kg/m
2
Yeild Stress = 275 N/mm
Depth = 114.3 mm
END RAIL SECTION
Properties
E = 70000 N/mm2
Area = 6.38 cm2
Ixx = 205.97 cm4
Zxx = 26.126 cm3
2
allowable bending stress = 178.04999 N/mm
Permi. Bending Moment = 4.6517339 KNm
Permi. shear force = 40.04 KN
Weight = 1.8 Kg/m
Yeild Stress = 275 N/mm2
Depth = 152.66 mm
 Date Rev
TECHNOCRAFT INDUSTRIES ( I) LTD.
19-01-2023 SPL
Project :- Design of MACH deck Panel System (2400 X 1200)
Details :-

3.1 General Arrangement drgs for Aluminum Panel 2400 X 1200

General arrangement for Slab Panel 2400 X 1200

Load Calculation for 0.3m thk slab

3
Concrete Density (Wet Concrete) 25 kN/m
2
Construction Imposed Load 1.5 KN/m
2
Self wt. of Shuttering. 0.5 KN/m

Thickness of concrete Slab 0.3 m

2
Self weight of Concrete Slab 7.5 KN/m

2
Total Load on Slab Shutter 9.5 KN/m
 Date Rev
TECHNOCRAFT INDUSTRIES ( I) LTD.
19-01-2023 SPL
Project :- Design of MACH deck Panel System (2400 X 1200)
Details :-

3.2 Design Of Densified Wooden Ply

(please refer attached annexure for refernce)

Ply = 1.2 cm Thk b= 1.00 m width

Design Data Eply 1.1E+07 KN/sq.m.
Loadings
Concrete Pressure on panel = 9.50 KN/sq.m.
Thk Span Load
(m) (m) KN/M2
0.012 0.35 9.50 As Ribs are at 0.36 m c/c.
Bending Moment = w x l2 ( for critical check )
8
= 9.50 x 0.35 x 0.35
8
= 0.1455 KNm

Bending Stress = M /Z
2 2
Allowable bending stress = 150 Kg/cm = 15 N/mm

Z = bt2 / 6

6
hence t = 0.1455 x 10 x 6
1000 x 15
= 7.63 mm = 7.63 mm< 12 mm, Safe

I = b t3 / 12
4 4
= 14.4 Cm = 1.44E-07 m

Deflection = [ ( 5 W L³ ) / ( 384 E I ) ]
= 5 x 9.50 x 0.35 x 0.35 3
384 x 10669000 x 1.44E-07
= 0.00072 m
= 0.725 mm < 1.296 mm Hence safe

Continuity effect considered for deflection

Allowable deflection = L / 270 i.e 1.296 mm
 Date Rev
TECHNOCRAFT INDUSTRIES ( I) LTD.
19-01-2023 SPL
Project :- Design of MACH deck Panel System (2400 X 1200)
Details :-

3.3 Design of Secondary Beam (RIB SECTION)

Member Span Load Spacing Loading Ixx Zxx E value

(m) KN/m2 Leff. For loading KN/m Cm 4 Cm 3 N/mm2
RIB 1.150 9.500 0.35 3.33 67.31 11.23 70000

Checks:

a Bending = W x l2 / 8 (Simply Supported Beam)

2
Moment = 3.33 1.15 ∕ 8

= 0.5497 KN.m < 1.93985573 KN.m Safe

b Shear Force = Wxl / 2

= 3.33 1.15 2

= 1.91 KN < 25.52 KN Safe

c Deflection = [ ( 5 W L³ ) / ( 384 E I ) ]

= 5 x 3.33 x 1150 4
384 x 70000 x 673100

= 1.607 mm < 4.44 mm Safe

Allowable deflection = L / 270 i.e < 4.44 mm

 Date Rev
TECHNOCRAFT INDUSTRIES ( I) LTD.
19-01-2023 SPL
Project :- Design of MACH deck Panel System (2400 X 1200)
Details :-

3.4 Design of Secondary Beam (End Rail Section)

Member Span Load Spacing Loading Ixx Zxx E value

(m) KN/m2 Leff. For loading KN/m Cm 4 Cm 3 N/mm2
END RAIL 1.150 9.500 0.35 3.33 205.97 26.126 70000

Checks:

a Bending = W x l2 / 10 (Continous Beam)

2
Moment = 3.33 1.15 ∕ 10

= 0.4397 KN.m < 4.65173392 KN.m Safe

b Shear Force = Wxl / 2

= 3.33 1.15 2

= 1.91 KN < 49.75 KN Safe

c Deflection = [ ( 5 W L³ ) / ( 384 E I ) ]

= 5 x 3.33 x 1150 4
384 x 70000 x 2059700

= 0.315 mm < 4.44 mm Safe

Allowable deflection = L / 270 i.e < 4.44 mm

Note : the deflection will occur at centre of panel, at Rib section & Side rail section and Not at
End rail section & Side rail section
 Date Rev
TECHNOCRAFT INDUSTRIES ( I) LTD.
19-01-2023 SPL
Project :- Design of MACH deck Panel System (2400 X 1200)
Details :-
3.5 Design of Main Beam (Side Rail Section)

Member Span Load Spacing Loading Ixx Zxx E value

(m) KN/m2 Leff. For loading KN/m Cm 4 Cm 3 N/mm2
SIDE RAIL 2.323 9.500 0.6 5.70 521.67 53.296 70000

Checks:

a Bending = W x l2 / 10 (Continous Beam)

2
Moment = 5.70 2.32 ∕ 10

= 3.0759 KN.m < 9.5552774 KN.m Safe

b Shear Force = Wxl / 2

= 5.70 2.32 2

= 6.62 KN < 49.75 KN Safe

c Deflection = [ ( 5 W L³ ) / ( 384 E I ) ]

= 5 x 5.70 x 2323 4
384 x 70000 x 5216700

= 3.551 mm < 8.88 mm Safe

Allowable deflection = L / 270 i.e < 8.88 mm

Total Deflection = (Ply + Rib section + Side Rail section)

@ Centre of panel
= 5.883 mm