HMM INFRA LTD.

OWNER CONCESSIONAIRE
GUJARAT STATE ROAD DEVELOPMENT
CORPORATION GOVERNMENT OF M/S L&T AHMEDABAD
GUJARAT MALIYA TOLL WAY LIMITED

PROJECT:
CONSTRUCTION OF ROB IN LICU
OF L. C. NO.41 AT AHMEDABAD-
VIRMAGAM-MALIYA ROAD
PROJECT.

Title:
Design of Erection scheme Erection scheme For Idpl
Viramgam 71 Mtr SpanLHSCarriageway

doc no. HHS-10-2015-2178D

Sep-16
 HMM INFRA LTD,ANBALA
TITLE Design of Trolley and Track Beam PREPARED BY PS REV

VIRAMGAM-MALIYA ROAD PROJECT 71.1 CHECKED BY RKS DATE

PROJECT MTR OWG

L&T IDPL REF HHS-10-2015-2178D

CUSTOMER DRAWING NO.

1.0 Design of Trolley and Track Beam

1.1 General
This design note gives design of main componet of trolley.

Refrence drawings
8044/E/DD-121 (R1)
HHS-10-15-2178

Structural Steel work

Material specification

a Structural steel
All structural rolled section and built up section and profile are as per is 2062 - 2011

b Bolts and nuts

Bolts nut and washers are HTS and 8.8 grade.

c Welding
Welding shall accordance with IS 816 and IS:9595

d Pins
All pins shall be prehardened tensile steel of grade higher than 8.8 grade.

e Applicable design code

Code used for design of structural steel component is IS: 800 2007.

Basic Data's for Calculations :-

Modulus of elasticity = E = 2000000 kg/cm2
Yield Stress of Steel = fy = 250 N/mm2 = 2400 kg/cm2
Maximum Permissible Shear Stress = fs = 0.40 x fy = 980 kg/cm2
Maximum Permissible Bearing Stress = 0.75 x fy = 1875 kg/cm2
Maximum Permissible Bending Stress = 0.66 x fy = 1650 kg/cm2

1.2 Loads

Weight of steel truss = 405

Length of steel truss = 71.1
Per meter weight of steel truss 405/71.1/2 = 2.848
Max center to center of trolley = 10.94
Max reaction on each trolley 10.940x2.848 = 31.158
 0

9/17/2016

178D

MT
mtr
MT/mtr
mtr
MT
1.3 Design of Transport Trolley :
Different parts of Trolley as per the drawing referred above:
i) Beam B1 - Steel truss is directly rests on this beam.
ii) Wheel Assembly : There are total 2nos of wheels below each side trolley. These wheels are connects with
Beam B1 by Main Beam. 75 mm diameter pin is use to connect wheels with main beam.
1.4 Design of Beam B1 :

Reaction from steel truss(P) = 31.158

C/C of support (L) = 0.575
31.158

0.2875 0.2875

Max bending moment (M) PL/4 = 4.48

Max shear force (F) P/2 = 15.58

Here section considered for BeamB1 is 2 ISMB 300

Ay 117 cm2
IX 17980 cm4
Z 1198 cm3

Bending Stress M/Z = 373.873

< 1650
Hence safe

Shear stress Area of web(a) 30x0.77 = 23.1

F/2a = 337.21
< 980
Hence safe

Deflection PL3/48EI = 0.327

Allowable diflection L/325 = 1.769
Hence safe

1.5 Design of main beam below Beam B1

Reaction from Beam B1(P) = 15.58

C/C of support(L) = 1

15.58

0.5 0.5
 MT
mtr

MT-mtr
MT

Kg/cm2
Kg/cm2

Kg/cm2

mm
mm

MT
mtr
Max bending moment (M) PL/4 = 3.895
Max shear force (F) P/2 = 7.790
Here section considered for main beam is 2 ISMC 250 150mm C/C
MT-mtr
MT
 Ay 77.34 cm2
IX 7760 cm4
Z 614 cm3
Area of web(a) 36 cm

Bending Stress M/Z = 634.329

< 1650
Hence safe

Shear stress F/a = 216.377

< 980
Hence safe

Deflection PL3/48EI = 1.992

Allowable diflection L/325 = 3.077
Hence safe

1.6 Design of connecting pin of each wheel

This Pin is used to connect each wheel with Mian Beam.
Consider 8.8 graded High tensile steel pin of diameter 75 mm
Yield stress = 6400
Allowable Shear stress 0.4*6400 = 2560

Max reaction on Pin.(P) = 7.790

Area of pin pi/4*diameter 2
= 44.156
Shear stress 7.79*1000/2/44.156 = 176.409
hence safe
check for bending stress
max bending moment PL/4 = 0.292
Section modulus of pin pi/32*diameter3 = 41.40

Bending stress 0.292*100000/41.40 = 705.636

<0.66xFy = 4224
hence safe
Check for Bearing Stress
Consider 8mm thk washer plate is used here
Here Total thickness of connecting plate of wheel assembly = 23
Bearing stress 7790/2.3x7.5x2 = 225.78
<0.75xFy 4800
hence safe

1.7 Design of wheel

usefull Thread width of Rail (a) = 57
Reaction from main beam = 7.790
77896
Material Grade for wheel C55 MN 75 BH of material is 250
Diametr of wheel required (as per IS:3177) WxCdfxCsf =
Cl.8.6.6 1.5axCbhxCap
Cdf = 1.5
Kg/cm2
Kg/cm2

Kg/cm2
Kg/cm2

mm
mm

Kg/cm2
Kg/cm2

MT
cm2
Kg/cm2

MT/mtr
cm3

Kg/cm2
Kg/cm2

mm
Kg/cm2
Kg/cm2

mm
MT
N
 csf = 1.25
BH of material is 250 Cbh = 5.3
Cap = 1.17

Diametr of wheel required 77869x1.5x1.25 = 275.48

1.5x57x5.3x1.17
Provided 310mm diameter wheel having BH 250
mm
 Total thickness of wheel with Flanges 65+20+20 = 105
Bush for Wheel
Max Load = 7.790
I.D. of bush = 75
O.D. OF BUSH = 95
Material for bush Al. Bronze of IS: 305, Gr AB 1
UTS = 5100
Compressive Stress (0.04*UTS) = 204

Bearing stress 7790/7.5/9.5 = 109.327

1.8 Design of Track beam ( 19mtr span)

Reaction from Wheel = 7.790

Reaction due to trolley weight = 0.12
Total reaction 2x(7.790+0.12) = 15.819
Self weight of Track Beam = 0.4
C/C of support = 19

15.819 15.819 15.819 15.819

udl 0.4

A B

1.795 1 8.94 1 6.265

19
RA=39.08 RB=24.1947
Dig for max. BM
Max bending moment due to point load(M) = 159.96
Max bending moment due to UDL(M) = 18.05
Total BM = 178.01

15.819 15.819 15.82 15.819

` udl 0.4

1 8.94 1 8.06
19
Dig for max. Shear force
Max shear force when Three troley over beam(V) = 45.06
Max Shearforce due to UDL(M) = 3.8
Total shear force = 48.86

PROPERTIES OF 2 UB 610X229X140 WITH ADDITIONAL 16X180 TOP AND BOTTOM FLANGES

Additional top flange 16 mm 180 mm

Size of top flange 22.1 mm 230.2 mm
 mm

MT
mm
mm

Kg/cm2
Kg/cm2

Hence safe

MT
MT
MT
MT/mtr
mtr

MT-mtr
MT-mtr
MT-mtr

MT
MT-mtr
MT-mtr
Size of web 13.1 mm 573 mm
Size of Bottom flange 22.1 mm 230.2 mm
Additional bottom flange 16 mm 180 mm
Area = 508.8 cm2
Ina(MI) = 426729 cm4
Z = 13150 cm3
rmin = Sqrt( 426729 / 508.8 )= 28.960

Unsupported length of track beam = 340.000 cm

T/t 2.21/1.31 = 1.69 cm
<2
d/t 57.3/1.31 = 26 cm
<. 85
L/ryy 340/29.882 = 11.740 cm

D/T 64.19/2.21 = 29.376 cm

Yield Stress of Steel = fy = 250 N/mm2 =2400 kg/cm2

Maximum permissible bending stress as per Table 6.1b IS 800 1984 = 1590 Kg/cm2

Bending Stress M/Z = 1353.62 Kg/cm2

< 1590 Kg/cm2
Hence safe

Shear stress 48860/2*79.91 = 305.7 Kg/cm2

< 980 Kg/cm2
Hence safe

Check for deflection

Load P = 15.819 MT
Total length l = 1900 cm
Momment of inertia Ixx = 426729.0 cm4
Modulus of elastisity E = 2047000 Kg/cm2

Formula for deflection point load P.a(3l2-4a2)/48EI

Formula for deflection UDL 5wL4/384EI

Load P Distance a 3l2-4a2 deflection

15.819 626.5 9259991 2.189 c.m
15.819 726.5 8718791 2.390 c.m
15.819 1620.8 322029.44 0.197 c.m
15.819 1720.5 -1010481 -0.656 c.m
0.4 0.777 c.m
Total deflection 4.897 c.m

Allowable deflection L/325 5.846 c.m

Hence safe

Load bearing stiffener

Max shear force on single I section 48.6/2 = 24.43 MT

Allowable bearing stress = 1875 kg/cm2
cm
Bearing area required = 13.0293333333 cm2
2 nos Stiffeners provided 10x90
Bearing Area of stiifener = 18 cm2
Outstand should not be more than 12t 12x1.0 = 12 cm

Area of stiffener 2x1x9+2x1x1x20 = 58 cm2

Ixx = 173 cm4
r = 1.726 cm
effective length 0.7x100 = 70 cm

L/ryy 70/1.726 = 40.555

From IS 800 -1984 for L/r =40.5 and Fy= 250N/mm 2
Allowable stress = 1390 Kg/cm2
Safe load 1390x58 = 80620 kg
> 24430 kg
Which is sufficient

same stiffener is adopted as intermidiate stiffener at spacing 1700 c/c

Check for End connection bolt

Max Shear force of single girder = 24.43 MT

Thickness of Connecting Plate = 25 mm
Dia of bolt 24mm 8.8 grade bolt
As per IS 4000 Strength of bolt 0.25x2x212/1.4 = 3785.714285714 kg
No. of bolt required 29460/5300 = 6.453 Nos
Provide 8 nos bolts

1.9 Design of Track beam (13.5mtr span)

Reaction from Wheel = 7.790

Reaction due to trolley weight = 0.12
Total reaction 2x(7.790+0.12) = 15.819
Self weight of Track Beam = 0.3
C/C of support = 13.5

15.819 15.819
udl 0.3

4.25 1 8.25
13.5
RA=20.506 RB=11.319
Dig for max. BM
Max bending moment due to point load(M) = 87.15
Max bending moment due to UDL(M) = 6.834
Total BM = 103.38

15.819 15.819 15.819 15.819

 MT
MT
MT
MT/mtr
mtr

MT-mtr
MT-mtr
MT-mtr
 0.3

1 8.94 1 2.56
13.5
Dig for max. Shear force
 Max shear force (V) = 33.874
Max shear force due to UDL(M) = 2.025
Total shear force = 35.90

Size of top flange 22.1 mm 230.2 mm

Size of web 13.1 mm 573 mm
Size of Bottom flange 22.1 mm 230.2 mm

Area = 318.6 cm2

Ina(MI) = 236604 cm4
Z = 7244 cm3
rmin = Sqrt( 236604 / 318.6 )= 27.251

Unsupported length of track beam = 340.000 cm

T/t 2.21/1.31 = 1.69 cm
<2
d/t 57.3/1.31 = 26 cm
<. 75
L/ryy 340/27.251 = 12.476 cm

D/T 61.7/2.21 = 27.919 cm

Yield Stress of Steel = fy = 250 N/mm2 =2400 kg/cm2 = 1590

Bending Stress M/Z = 1427.09 Kg/cm2

< 1590.000 Kg/cm2
Hence safe

Shear stress 35900/2x1.31x5.73 = 239.1 Kg/cm2

< 980 Kg/cm2
Hence safe

Check for deflection

Load P = 15.819 MT
Total length l = 1350 cm
Momment of inertia Ixx = 236604.0 cm4
Modulus of elastisity E = 2047000 Kg/cm2

Formula for deflection point load P.a(3l2-4a2)/48EI

Formula for deflection UDL 5wL4/384EI

Load P Distance a 3l2-4a2 deflection

15.819 825 2745000 1.541 c.m
15.819 925 2045000 0.714 c.m
0.3 0.268 c.m
Total deflection 2.523 c.m

Allowable deflection L/600 2.250 c.m

Hence safe
 MT
MT-mtr
MT-mtr

cm
 HMM INFRA LTD,ANBALA

TITLE TRESTLES AND BEAM DESIGN CALCULATION PREPAR

VIRAMGAM-MALIYA ROAD PROJECT 71.1 MTR
PROJECT CHECKE
OWG
CUSTOMER L&T IDPL DOC. NO
2.0 DESIGN OF TRESTLE

Over all Length of Span = 71.1 mtr

Weight of span = 405 MT
Max load in Trestle 48.86x2= 97.7 MT as per Max shear force when two tro

No. of Trestles Under Each = 1 nos

Maximum Vertical load coming on the column = 97.7 MT

Horizontal force @ % 8.0 = 7.82 t

Column provid 4 NOS ISMC 250 box AT 150 CM. C/C both ways

ISMC 250 BOX 150

150

Rolled Steel ISMC250 (Dimension and its Properties):

Properties of ISMC 250
Ax = 39 cm2
Ixx = 3880 cm4
Iyy = 211 cm4
rmin = 2.37 cm
weight = 30.60 kg/m

Area of combined section = 312 cm2

Moment of inertia of combined section = 1786040.0 cm4
rxx of combined section = 75.66 cm
Z of combined section = 23813.87 cm3
Height of column considered(L)
Effective height
Hence λ L/rxx
Allowable slenderness ratio
Permissible compressive stress
Capacity of the column
Max. Bending moment
Bending stress , sbc =M/Z
Allowable Bending stress
Axial stress , sac
=P/A
Allowable axial stress, sas
Hence sbc/sbs + sac/sas
= 8m
2L = 1600 cm
= 21.15
= 180.00
= 1480 kg/cm2
= 461760 kg
= 461.8 t
> 97.7 t
8x7.82 = 62.54 t-m
6254000/23813.87 = 262.62 kg/cm2
= 1650 kg/cm2
97700/312 = 626.41 kg/cm2
= 1480.000 kg/cm2
= 0.5824 < 1
Design of Lacing System:

Lacing is designed for 8% of total axial force

Force on lacing system = 7.8176 MT

sectio used for lacing system = NB80x3.2mm thk pi

Ax = 8.61 cm2
rmin = 3.03 cm
L = 240 cm
L/rmin = 79.21 <

Hence , Permissible compressive stress = 1088 kg/cm2

Axial Compressive stress < 907.967 kg/cm3

DESIGN OF LONGITUDINAL BEAM

Max Reaction = 97.72 Mt

Max Reaction on each beam = 48.86 Mt
Center to Center support on member = 1.50 mtr
Max bending momenM WL/4 = 18.32Mt-mtr
Max Shear force F W/2 = 24.4 mt
Consider 2 ISMB 500 below member
Section modulus of member Z = 2740 cm3

Bending stressM/Z = 669 kg/cm2

Allowable Bending stress = 1650 kg/cm2

Area of ISMB500 Web = 102 cm2

Shear stress F/A = 240 kg/cm2
Allowable Shear stress = 980 kg/cm2

Load bearing stiffener

PARED BY PS REV 0

CKED BY RKSDATE ###

NO. HHS-08-2015-2178D

troley over beam

AS PER IS 3177
 considering max height

Ok
as per is:800 table 5.1

Ok

(Horizontal force x Ht of column)

m2
Ok
m2
m2
Ok
 as per IS:1161

Ok
145 ( cl.5.7.2.3 of IS:800-1984)

As per IS 806 table 2

Ok

tr

m2
Ok

m2
Ok
 HMM INFRA LTD,ANBALA

PREPARED
TITLE DESIGN OF ISOLATED FOOTING PS REV 0
BY

VIRAMGAM-MALIYA ROAD PROJECT 71.1 MTR CHECKED

PROJECT OWG BY RKS DATE 9/17/2016

L&T IDPL
CUSTOMER HHS-08-2015-2178D

DESIGN OF ISOLATED FOOTING SIZE 3X 3X 0.3

GRID No. Short Bars
Axial Load = 977 KN Y 12 @ 15 c/c
as per trestle design calculation
self weight of trestle = 30 KN
self wt of footing= 66.15 KN Long Bars
Total Load on footing = 1073.15 KN Y 12 @ 15 c/c
Assumed bearing capacity of soil= 150 KN/sq mt.
Grade of concrete= M25 Grade of steel= Fe415
Size of Column= b= 1500 D= 1500
Area of footing=Total Load on footing/bearing capacity
Area of footing= 7.15433 sq mt. App.Side of footing 2.67 mt
Size of footing= lx= 3 ly= 3
Provided area of footing= 9 sqmt> 7.1543 sqmt Hence safe
Bending Moment(Mu)
Net upward pressure intensity= 119.239 KN/sqmt < 150 KN/sqmt
NUPI due to factored load=1.5*Total load/provided area of footing
NUPI due to factored load= 178.858 KN/sq mt.
Mu= 1/2*NUPI*(lx-b)/2*(lx-b)/2 per mt.
Mu= 50.3039 KN-mt
Adopt over all depth= 300 mm
Effective cover = 50 mm
Effective depth(d) = 238 mm
Area of tension steel is given by Mu=0.87*fy*Ast(d-fy*Ast/(fck*lx)
By solving the equation Ast= 489.445 sq mm
% of steel=100*Ast/(bd)= 0.2056 %
Min. steel as per IS.456-1978=0.15% 489.44 sq mm
Use 12 mm bars 150 mm c/c
1Y 12 113.04 sqmm then 753.6 > 489 Hence Safe

Check for shear

One way action
The critical section is taken at a distance "d" away from the face of column
Factored Shear force(Vu)=NUPI*((lx-b)/2-d)
Vu= 91.575 KN
Nominal Shear stress(Tv)=Vu/bd
Tv= 0.3848 N/sqmm
Shear strength of M25 concrete with 0.3166 % steel
Tc= 0.4 N/sqmm > Tv Hence OK
TABLE 19 AS PER IS 456
Shear two way action
The critical section is taken at a distance 0.5d away from the face of column
Shear force (Vu)=NUPI(Area of footing-((b+d)*(D+d)))
Vu= 1069.5 KN
Nominal Shear stress(Tv)=Vu/Bod
Perimeter of section(Bo)=2((b+d)+(D+d))
Bo= 6952 mm
Tv= 0.64636 N/sqmm
Shear strength of M20 concrete with T'c=Ks Tc where Ks=(0.5+Bc)
Bc=b/D= 1 Therefore Ks= 1.5 Since Ks< or =1
T'c=Tc=0.25SQRT OF 20=1.11> 0.64636 Hence OK
 PROJECT

TITLE PULLING ARRANGEMENT DESIGN PREPARED BY PS

VIRAMGAM-MALIYA ROAD PROJECT 71.1 MTR

CHECKED BY RKS
PROJECT OWG

L&T IDPL
CUSTOMER HHS-08-

DESIGN Of PULLING ARRANGEMENT

1.1 Weight of steel truss =

Length of steel truss =
Cofficient of friction as per IS 3177 with anti friction bearing C-2.1 General =
Total weight to be pulled 405 x 0.080 =
No. of electrical winch machine used =
Load on each winch machine 32.4 / 2.000 =
No. of Effective falls provided by 3 sheeve pulley used for pulling mechanisum =
Load on each winch machine after using 3 sheeve pulley 16.2 / 5 =

Provide 2 nos. electrical winch machine having Pulling capacity 10Mt each

1.2 Diameter of wire rope provided =

Breaking force of wire rope as per IS 2266 construction 6x37 fibre core grade 1570 =
Fector of safety for pulling =
Pulling Capacity of wire rope 363 / 5 =
=
Load on wire rope =
HNCE S
 REV 0

DATE
9/17/2016

HHS-08-2015-2178D

405 MT
71.1 mtr
0.080
32.4 MT
2 nos
16.2 MT
5 nos
3.24 MT

28 mm
363 KN
5
72.6 KN
7.408 MT
3.24 MT
HNCE SAFE