LOADS (BD 31/01, Section 2.4)

Hanson Precast Concrete Box Culvert Unit Page 1 of 11
48308/0001 20/04/12 15:8:57 VB 3.1.74
Client : MACOB Limited

Location : Pontardawe, Neath Port Talbot Unit Ref. No. PO1
Title : Redrow Homes, Alltwen, Pontardawe Calc. No. 15100413-1
Fill depth min=1.976m

Fill depth max=2.911m
Internal width (L) = 1.800m
Internal height (H) = 1.200m
Roof / Floor (d) = 0.150m
Wall thickness (t) = 0.150m
Chamfer (c) = 0.190m
Box length = 2.000m
Design span = 1.950m
Design height = 1.350m
Design standard = BS5400
Notes:
Applied loadings are in accordance with - BD 37/01 & BD 31/01 and analysis and section design is per
metre length of unit. Design span = 1.950m for bending moments. Worst case fill depth for bending =
2.91m
LOADS (BD 31/01, section 2.4)
(i) Permanent loads
Dead Loads
3 2
Self Weight 0.150 @ 24 kN/m = 3.6 kN/m
Self weight UDL = 1.15 x 3.6 x 1.950 = 8.07 kN (ULS)

= 1.0 x 3.6 x 1.950 = 7.02 kN (SLS)
Superimposed Dead Load:

3 3
Fill density = 19 kN/m x fill factor of 1.15 = 21.85 kN/m
3 2
Surfacing = 22 kN/m x 0.2 m = 4.4 kN/m
Fill & surfacing = (1.75 x 4.4 x 1.950) + (1.2 x 2.71 x 21.85 x 1.950) = 153.63 kN (ULS)
UDL = (1.2 x 4.4 x 1.950) + (1.0 x 2.71 x 21.85 x 1.950) = 125.8 kN (SLS)
Horizontal Earth Pressure on Walls (Design height = 1.350m)
K = 0.50 - for initial calculation (modify for max & min values later)
including HB surcharge, average vertical pressure: - (cl. 5.8.2.1 - BD 37/01)

2
Pv (ULS)= ((22 x 0.2) x 1.5) + 19 x ( 2.71 + 0.150 + 1.2/2 ) x 1.5 + (12.0 x 1.5) = 123.24kN/m
2
Pv (SLS)= (22 x 0.2) + 19 x ( 2.71 + 0.150 + 1.2/2 ) + 12.0 = 82.16kN/m
Total horizontal load = 0.5 x 123.24 x 1.350 = 83.19 kN
Copyright © Hanson Concrete Products Ltd 20/04/2012

48308/0001 20/04/12 15:8:57 VB 3.1.74

(ii) Vertical Live Loads
a) HA loading - Not applicable for fill depths > 0.6m
b) HA KEL loading - Not applicable for fill depths > 0.6m
c) HA Wheel loading
HA 100kN wheel load with distribution @ 1:2 through 2.91m fill distributed over 3.21m x 3.21m
2
HA 100kN wheel over 300mm square patch (equivalent to 1.1 N/mm contact pressure)
HA Wheels = 100 x 1.5 = 150kN (ULS)

ULS
HA Wheels = 100 x 1.2 = 120kN (SLS)
SLS
d) HB loading
HB - 30.0 units - 75.0 kN loads @ 1.000m centres axles @ 1.800m centres (minimum)
2
over 260.0mm sq patch (giving a contact pressure of 1.1 N/mm ) @ 1 in 2 gradient through 2.91m
fill.
i.e. distributed over 3.17m x 3.17m.
HB = 1.3 x 75.0 = 97.5kN (ULS)

ULS
*
HB = 1.1 x 75.0 = 82.5kN
SLS
* 30 units of HB

48308/0001 20/04/12 15:8:57 VB 3.1.74

(iii) Horizontal Live Loads
NB: Live surcharge included above in Horizontal earth pressure.
P'
Horizontal surface loads due to traction and braking
h = 1.350m Fill depth = 1.98m (min) Fill reduction factor = 0.083
HB vehicle only 30.0 units. Cover is greater than 0.600m so HB traction only.
P = 0.25 x 4 x 4 x 75.0 = 300.0kN. Vehicle width= 3.0 + 0.26 = 3.26m
Horizontal force dispersed over 3.26 + 1.98 = 5.24m at roof level
#Force P' = 0.083 x 300.0 / 5.24 = 4.74 kN per metre width
Ultimate load factors - Gamma F3 = 1.1 Gamma FL = 1.1
Thus free bending moment due to applied horizontal force
= P' x h/2 x Gamma F3 x Gamma FL
= 4.74 x 1.350/2 x 1.1 x 1.1
= 3.87 kNm per metre width

48308/0001 20/04/12 15:8:57 VB 3.1.74

LOAD COMBINATIONS (BD31/01, section 2.5)

Analysis is performed by elastic methods. Free bending moments are calculated first on an element basis
and combined accordingly - (BS.5400 Part 4)
Combination 1:
(a) Roof / Floor (Gamma F3 = 1.1 at ULS , Gamma F3 = 1.0 at SLS)
Bending moments : -
At ULS Free bending moment fill = (1.1 x 153.63 x 1.950) / 8 = 41.19 kN-m
At SLS = (1.0 x 125.8 x 1.950) / 8 = 30.66 kN-m
At ULS Free bending moment self wt. = (1.1 x 8.07 x 1.950) / 8 = 2.16 kN-m
At SLS = (1.0 x 7.02 x 1.950) / 8 = 1.71 kN-m
Free bending moment HA UDL not applicable for fill depths > 0.6m
Free bending moment HA KEL
Not applicable for fill depths > 0.6m
Free bending moment HA 100kN
DS = 1.950M, HAP = 1.95M

At ULS (L1=28.37) = 1.1 x 28.37 x 1.950/8 = 7.61 kN-m
At SLS (L1=22.7) = 1.0 x 22.7 x 1.950/8 = 5.53 kN-m
Free bending moment HB wheels - single wheel at midspan gives worst case.
DS = 1.950M, HBP = 1.950M

At ULS (P2=49.58) = (1.1 x 49.58)/2 x (1.950/2 - 1.950/4) = 13.29 kN-m
At SLS (P2=41.95) = (1.0 x 41.95)/2 x (1.950/2 - 1.950/4) = 10.23 kN-m
Free bending moment totals : -
(1) FILL + S.Wt.

41.19 + 2.16 = 43.36 kN-m
(2) FILL + S.Wt. + HA100

41.19 + 2.16 + 7.61 = 50.96 kN-m
(3) FILL + S.Wt. + HBwheels

41.19 + 2.16 + 13.29 = 56.65 kN-m
56.65 kN-m used for design.
Fixed end moment (FEM) = 56.65 x 2/3 = 37.77 kN-m

48308/0001 20/04/12 15:8:57 VB 3.1.74

BD31/01, section 4.3.3 Shear Forces
Worst case fill depth for shear = 2.91m
Shear from fill = (1.1 x 153.63 x 1.205) / (2 x 1.950) = 52.21 kN
Shear from self weight = (1.1 x 8.07 x 1.205) / (2 x 1.950) = 2.74 kN
Shear from HA UDL =Not applicable for fill depths > 0.6m
Shear from HA KEL =Not applicable for fill depths > 0.6m
Shear from HA100 = (1.1 x 28.37 x 1.205) / (2 x 1.950) = 9.64 kN
Shear from HB Wheels =1.1 x 49.58 x 1.205 / (2 x 1.950) = 16.85 kN
Shear force totals : -
Fill + S.Wt. = 52.21 + 2.74 = 54.96 kN
Fill + S.Wt. + HA100 = 52.21 + 2.74 + 9.64 = 64.6 kN
Fill + S.Wt. + HB = 52.21 + 2.74 + 16.85 = 71.81 kN
Ultimate maximum shear = 71.81 kN
Combination 1:
(b) Walls ( Gamma F3 = 1.1 )
Surcharge included in this combination for worst effect. Similarly associated live load
not included for worst effect.
Free bending moment = (1.1 x 83.19 x 1.350) / 8 = 15.44 kN-m
Fixed end moment = (1.1 x 83.19 x 1.350) / 12 = 10.29 kN-m
K max = 0.6 (1.2 * K)
K min = 0.2 (0.4 * K)

48308/0001 20/04/12 15:8:57 VB 3.1.74

(c) Combined free wall and roof moments for design

3
Distribution factor S= 1 k= H ( d/t )
1+k L
3
k= (1.350/1.950) x (0.15/0.15) = 0.6923
s = 1 = 0.5909
1+ (0.6923)
Roof M -ve = 0.5909 x 37.77 = 22.32 kN-m

M +ve = 56.65 - 22.32 = 34.33 kN-m
Wall M -ve = ( 1 - 0.5909 ) x 10.29 = 4.21 kN-m

M +ve = 15.44 - 4.21 = 11.23 kN-m
Combined Moments - Checking at edge of chamfer
Roof M -ve = 22.32 - (0.265 x 2.0 x 56.65)/1.95 + (1.2 x 4.21) = 11.97 kN-m
M +ve = 34.33 - (0.4 x 0.569 x 4.21)* = 33.37 kN-m
Wall M -ve = (1.2 x 4.21) - (0.265 x 2.0 x 15.44 x 1.2)/1.35 + 22.32 = 20.1 kN-m
M +ve = (1.2 x 11.23) - (0.6378 x 22.32)** = -0.76 kN-m
* For minimum value omit surcharge and safety factors = 1.0 (see page 2) Pv = 70.16
Factor by (70.16 / 123.24) = 0.569 (K min applies)
** For minimum value omit traffic load off road take gamma FL = 1.0
From page 4 free B.M. total = (41.19 + 2.16) / 1.2 = 36.13
Therefore factor by (36.13 / 56.65) = 0.6378
Combination 3 (with temperature effects)
Overall width of culvert 2.100m is not greater than 3.000m so temperature effects and this load
combination may be ignored.

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Combination 4:
Sway distribution factor = (3k+1) / (6k+1) = 0.5970 for k = 0.6923 (see page 4)
Moments at corners = +/- 0.5970 x 3.8685 = +/- 2.31 kNm.
Check moments at edge of chamfer.
Roof braking moments = 2.31 - (0.265 x 2 x 2.31 / 1.95) = 1.682 kNm.
Wall braking moments = 2.31 - (0.265 x 2 x 2.31 / 1.35) = 1.403 kNm.
No increase at mid-span in roof and floor.

For HB vehicle need to account for reduced load factor.
From page 4: Maximum free bending moment
= 28.373 *+ 2.16 + (1.1/1.3) x 13.29

= 41.79 kN-m.
* Applicable for minimum fill depth
From page 4: Minimum free bending moment
= 28.373 * + 2.16 = 30.54 kN-m

48308/0001 20/04/12 15:8:57 VB 3.1.74

Thus from page 6: Combined Moments at edge of chamfer
Roof
Maximum: (22.32 - (0.265 x 2 x 56.65)/1.950) x (41.79/56.65) + (1.2 x 4.21) = 10.16 kN-m
Minimum: (22.32 - (0.265 x 2 x 56.65)/1.950) x (30.54/56.65) + (0.4 x 0.569 x 4.21) = 4.69 kN-m
Wall
Maximum: (1.2 x 4.21 - (0.265 x 2 x 15.44 x 1.2/1.35) + 22.32 x (41.79/56.65)
= 14.24 kN-m
Minimum: (0.4 x 0.569 x 4.21 - (0.265 x 2 x 15.44 x 0.569 x 0.4 / 1.35) + 22.32 x 30.54/56.65
= 11.61 kN-m
Maximum and minimum roof and wall moments for horizontal and vertical forces in combination - at edge
of chamfers:
Outer moment roof = 1.682 + 10.158 = 11.84 kN-m.
Outer moment wall = 1.403 + 14.24 = 15.64 kN-m.
Inner moment roof = 1.682 - 4.689 = -3.01 kN-m.
Inner moment wall = 1.403 - 11.608 = -10.21 kN-m.
(3) Design (BS.5400 Part 4) Unit length = 2000mm

2 2
fcu = 50.0 N/mm fy = 500.0 N/mm (minimum)
Crack inner face = 0.25mm Crack outer face = 0.25mm

Cover inner face = 30mm Cover outer face = 30mm
(a) Roof / Floor - midspan - Design moment = 33.37 x 2.000 = 66.75kN-m

2
Mu conc = 0.15 x 50 x 2000 x (150 - 30 - 16/2) = 188.16 kN-m
10 6 > 66.75 kN-m O.K.
Use 11 x T16 = 2211.68mm2
Z=  1 - 1.1 x 500 x 2211.68  x 112.0 < 0.95 x 112.0

 50 x 2000 x 112.0  Z = 99.84 mm
Mu steel = 0.87 x 500 x 99.84 x 2211.68 = 96.05 kN-m

10 6 > 66.75 kN-m O.K.

48308/0001 20/04/12 15:8:57 VB 3.1.74

(b) External corners - Design moment = 20.1 x 2.000 = 40.19kN-m

2
Mu conc = 0.15 x 50 x 2000 x (150 - 30 - 12/2) = 194.94 kN-m
10 6 > 40.19 kN-m O.K.
Use 11 x T12 = 1244.07mm2
Z=  1 - 1.1 x 500 x 1244.07  x 114.0 < 0.95 x 114.0

 50 x 2000 x 114.0  Z = 107.16 mm
Mu steel = 0.87 x 500 x 107.16 x 1244.07 = 57.99 kN-m

10 6 > 40.19 kN-m O.K.
(c) Inner face at corner - Design moment = -0.76 x 2.000 = -1.51kN-m
Use 7 x T10 = 549.78mm2
Z=  1 - 1.1 x 500 x 549.78  x 115.0 ≥ 0.95 x 115.0

 50 x 2000 x 115.0  Z = 0.95 x 115.0 = 109.25 mm
Mu steel = 0.87 x 500 x 109.25 x 549.78 = 26.13 kN-m

10 6 > -1.51 kN-m O.K.
(d) Check shear - Design shear = 71.81 x 2.000 = 143.62kN

2
v= 143.62 x 1000 = 0.630 N/mm
2000 x (150 - 30 - (12/2))
From table 9 ξs = 1.447 for d1 = 114.0mm
2
Thus vc = 0.630 = 0.44 N/mm
1.447
2
From table 8 - 50N/mm concrete
2
Minimum Ast = 0.205 % = (0.205 / 100) x (150 - 30 - 12/2) x 2000 = 466.42 mm
Shear steel provided = 1244.07 + 549.78 = 1793.85 which is ≥ 466.42 OK

48308/0001 20/04/12 15:8:57 VB 3.1.74

(c) Crack Control - Check for worst case Unit length U = 2.000m
Check for 30 units of H.B. loading / H.A. loading
x = -3*Ast/100 + √ ( (3Ast/100) * (3Ast/100) + 4 (3Ast/100) d1 * U )

2*U
2
Roof: For Ast = 2211.68mm d1=112.0mm h=150mm x = 46.58mm
From P.2 & P.4 = (30.66 + 1.71 + 10.23) x 34.33 / 56.65

Mservice (roof)/m - (0.4 x 0.569 x 4.21) / 1.1 = 25.82 - 0.87 = 24.95kN-m/m
Total Mservice (roof) = 24.95 x 2.000 = 49.9kN-m
Steel strain Est = Mserv / ( Ast * (d1 - x/3) ) * ES
6 5 -3
Est = 49.9 x 10 / 2211.68 x (112.0 - 46.58/3) x 2 x 10 = 1.169 x 10
-3 -3
E1 = Est * (h - x) / (d1 - x) = 1.169 x 10 x (150 - 46.58)/ (112.0 - 46.58) = 1.848 x 10
Acr = 91.17mm
-3
Crack width = (3 x 1.848 x 10 x 91.17) / (1 + 2 x ((91.17 - 30)/(150 - 46.58)))
= 0.2316mm which is ≤ 0.25mm OK
2
Corners: For Ast = 1244.07mm d1=114.0mm h=150mm x = 37.73mm
From P.2 & P.4 = (30.66 + 1.71 + 10.23) x 22.32 / 56.65

Mservice (wall)/m + ((1.2 x 4.21 x 82.16/123.24) / 1.1)
- (0.265 x 2.0 x 15.44 x 82.16/123.24 x 1.2)/(1.35 x 1.1))
= 16.78 + 3.06 - 4.41
= 15.44kN-m/m
Total Mservice (wall) = 15.44 x 2.000 = 30.87kN-m
Steel strain Est = Mserv / ( Ast * (d1 - x/3) ) * ES
6 5 -3
Est = 30.87 x 10 / 1244.07 x (114.0 - 37.73/3) x 2 x 10 = 1.223 x 10
-3 -3
E1 = Est * (h - x) / (d1 - x) = 1.223 x 10 x (150 - 37.73)/ (114.0 - 37.73) = 1.801 x 10
Acr = 92.42mm
-3
Crack width = (3 x 1.801 x 10 x 92.42) / (1 + 2 x ((92.42 - 30)/(150 - 37.73)))
= 0.2364mm which is ≤ 0.25mm OK

48308/0001 20/04/12 15:8:57 VB 3.1.74

Note: Transverse steel - 0.12% per face.
Check Deflexion (cl 4.2.3 - BD31/01)
Max permitted deflexion = 0.015 x minimum cover
= 0.015 x 1.98 x 1000 = 29.64mm
Max live load moment = 42.6 - 30.66 - 1.71 = 10.23

(SLS)
Deflexion ∆ = 20 x 10.23 x 1.950 x 1.950 x 1000 = 0.23mm

3
(150)
Deflexion ∆ (0.23mm) < max permitted deflexion (29.64mm) ∴φ0 Ο.Κ.

LOADS (BD 31/01, Section 2.4)

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Hanson Precast Concrete Box Culvert Unit Page 1 of 11

48308/0001 20/04/12 15:8:57 VB 3.1.74

Client : MACOB Limited

Fill depth min=1.976m