Table of Contents

Executive summary ................................................................................................................................. 3

1.0 Introduction ................................................................................................................................ 4
2.0 Bridge Design Summary .............................................................................................................. 5
2.1 Design Concept and Considerations ....................................................................................... 5
2.2 LUSAS MODELLER ................................................................................................................... 9
2.2.1 Preliminary box girder sections ...................................................................................... 9
2.2.2 Preliminary beam layout ............................................................................................... 10
2.2.3 Design actions ............................................................................................................... 11
2.3 Analysis results ...................................................................................................................... 14
2.4 Structure’s design ................................................................................................................. 15
3.0 Possible Project Risk Exposure .................................................................................................. 36
3.1 Risk Management Plan......................................................................................................... 36
3.1.1 Risk Identification.......................................................................................................... 37
3.1.2 Risk Analysis .................................................................................................................. 37
3.1.3 Risk Response Planning ................................................................................................. 37
3.1.4 Risk Responsibility ......................................................................................................... 38
3.2 Construction Safety Plan ....................................................................................................... 38
3.2.1 Objective of construction plan ...................................................................................... 38
3.2.2 Applicability................................................................................................................... 38
3.2.3 Implementation ............................................................................................................ 38
3.2.4 Reporting of injuries...................................................................................................... 39
3.2.5 Notification ................................................................................................................... 39
3.2.6 Basic Safety Rule ........................................................................................................... 39
3.2.7 Enforcement of basic safety rule .................................................................................. 40
3.3 Traffic Management Plan...................................................................................................... 41
3.3.1 Purpose of Traffic Management ................................................................................... 41
3.3.2 Applicability................................................................................................................... 41
3.3.3 Location ......................................................................................................................... 41
3.3.4 On-site Monitoring........................................................................................................ 41
3.3.5 Approval by city council ................................................................................................ 41
Reference .............................................................................................................................................. 42

2
Executive summary
Group 11 Construction Sdn Bhd is engaged in the construction of proposed 37m single span T-roff
Bridge which is 11.1m wide as consultant. The proposed location is at a near-coastal area in Perth,
WA. The longitudinal beam for the bridge is customized prestressed concrete T-roff section shown in
Figure 5 while the transverse beam will be customized section as stated in Section 2.2.2. The T-roff
girder will be design as pre-tensioned concrete structure. The end diaphragm will be a customized
section as shown in Figure 6. The design requirements and material properties suggested by the
client is simplified in Introduction. Design procedure and technical requirements for the T-roff
section are stated under Design Concept and Considerations. The loading for the design structures
will only include permanent load, superimposed permanent load and traffic load. Table 3 shows the
load cases for the design while Figure 8 shows the overall load cases (including combination load
cases) of the proposed project. All design calculations is under Structure’s design. The figure below
shoes the detailing for T-roff beam.

The reinforcements for the T-roff box girder are as below:

 Link N12-300
 Transverse N16-300
 Longitudinal (compression) N16-150
 Prestressing Strands : ROW A 2 x 15.2mm strands (7wires)
: ROW B 10 x 15.2mm strands (7wires) at 144mm C/C
: ROW C 12 x 15.2mm strands (7wires) at 118mm C/C
: ROW D 12 x 15.2mm strands (7wires) at 118mm C/C
: ROW E 10 x 15.2mm strands (7wires) at 144mm C/C

Figure 0: Typical detailing for T-roff section

3
1.0 Introduction
This purpose of project is to design a single span bridge which cross over a river at one of the rural
regions located in Perth, WA. The proposed location is exposed in near-coastal environment. The
proposed bridge has a clear span of 37m which consist of 3 precast teeroff beams. The teeroff beam
I design as simply supported beam. There will be semi-integral configuration at the abutment of the
bridge. Proposed precast beam will be steam cured. The project scope is limited to superstructure
(box girder) of the proposed bridge only. The design of superstructure shall comply with AS5100-
2017.

The box girder design is complying with the details given as shown below:

 Clear span between 2 abutments = 37, 000 mm

 Width of super structure = 11, 100 mm
 Width of roadway = 9, 600 mm
 Design lanes =2
 Type of box girder = T6 (Not LUSAS Standard sections)
 Concrete slab = 200 mm
 Wearing surface = 50 mm
 Jacking force, I = 75% of fpu
 Live load = M1600 moving traffic load (refer to AS5100.2)
S1600 stationary traffic load (refer to AS5100.2)

The box girder design is complying with the material properties given as shown below:

• Density of wearing surface, ρw = 2, 250 kg/m3

• Concrete density, ρc = 2, 650 kg/m3

• Concrete strength, f’c = 50 MPa

• Concrete strength at transfer, f’ci = 40 MPa

• Yield strength of reinforcement, fy = 500 MPa

• Modulus elasticity of reinforcement, Es = 200 GPa

• Modulus elasticity of tendon, Ep = 182.3 GPa

• Prestressing steel = 15.2 mm dia. 7 wire strands

4
2.0 Bridge Design Summary
2.1 Design Concept and Considerations
The client had limited the choice of material to precast concrete sections so the construction
methodology of the proposed project will be restricted to precast concrete structures. The precast
structures such as box girder will be cast in the concrete mould then steam cured in the factory
before delivering to the proposed site. For the proposed project, T-Roff girders steel tub void
formers are to be used, producing an open void which facilitates ease of inspection. Girders with
closed voids are not acceptable due to casting issues related to the accurate restraint of void
formers and the difficulty of verifying casting and compaction.

Prestressed concrete (PSC) girders are typically used for spans greater than 25 m (proposed
project span is 37m between 2 abutments) long. It is more economical to use than precast concrete
structures as precast concrete are cast off-site and under strict surveillance and quality management
during the manufacturing process. Precast structures have better thermal resistant and environment
resistant such as fires, insects, rain, wind damage, earthquakes, termites and decay than cast-on-site
concrete structures which is suitable at a near-coastal environment.

The design consideration for location factor is ignored due to lack of information of the exact
location of the proposed site and proposed site plan. Therefore, this report will focus more on
permanent loads and imposed load acting on the proposed bridge. This proposed bridge design in
this project will be typical prestressed concrete girder design with no earthquake provision provided.

All designs shall comply with AS5100:2-2017, AS5100: 5-2017 and AS3600-2018. The design
loadings of the proposed bridge will be further discuss in Section 2.2. The design forces, moment and
torsion will be generated using LUSAS Bridge Modeller which can provide finite element analysis for
the proposed project. The design procedure shall be as below:

1. Preliminary reinforced and prestressed concrete section design

2. Design cable layout
3. Prestress losses
4. Check concrete stresses at transfer and at service
5. Design T-roff section
6. Design actions and load path
7. T-Roff Girder design. (Moment, Torsion and Shear)
8. Check combination effect of shear and torsion

5
Figure 1: Prestressed Concrete Box Girder Bridge with Span of 37 m

Figure 2: Cross Section of Box Girder Bridge with Design Strips

Figure 3: Girder Type T6

6
Technical requirements for T-roff girder:

T-Roff Girder voids (Refer to Chapter 14: Prestressed Concrete Girders)

Voids shall be made from standard 5 m and 2.5 m long forms. The standard void sizes have been
developed in coordination with the pre-casting industry and are designed to ensure the manufacture
of PSC girders is efficient, simplified and cost effective.

Voids are separated longitudinally by a diaphragm of concrete 150 mm wide containing one
set of steel reinforcement. The solid end blocks at each end of the girder will increase or decrease in
size to accommodate the standard void lengths.

An end block length is measured along the centreline of the girder. On square or slightly
skewed girders the end blocks may vary in length nominally from 2 m up to 3 m to avoid having a
non-standard void length.

T-Roff Girder void drainage (Refer to Chapter 14: Prestressed Concrete Girders)

30 mm diameter drain holes are required between the voids and in the end blocks, to drain the voids
prior to deck casting.

The 30 mm diameter drain holes shall not be located vertical between the strands, they
must be horizontal between voids and continue horizontally through the end block of the girder
each end.

If the bridge is subject to flooding, 100 mm diameter drain holes may be required at the
base and top of the voids to allow the voids to fill with water to prevent the bridge from potential
floatation.

Gaps between girders (Refer to Chapter 14: Prestressed Concrete Girders)

Standard practice is to space girders to allow a 30 mm gap between girder flanges, however this may
vary slightly depending on the width of girder flanges and the width of bridge deck. During
construction the gap is covered by approved high strength waterproof tape to prevent deck concrete
from leaking between the girders.

Strands (Refer to Chapter 14: Prestressed Concrete Girders)

Strands are to have 60 mm cover to any voids and forms, minimum.

7
Gaps and inclined girder ends (Refer to Chapter 14: Prestressed Concrete Girders)

A nominal gap of 50 mm is provided between the ends of girders on adjacent spans, and between
the ends of girders and the abutment ballast wall. When girders are being placed on site they are
lowered vertically into position. To provide adequate clearance it is important that the ends of the
girders be vertical once placed on the structure.

Therefore, girders are to be designed to have nominally vertical ends after installation. The
designer must make allowance for grades, vertical curves and rotation of the girder ends due to the
effects of the 100 day design hogs so that the required vertical ends are achieved.

Girder joints (Refer to Chapter 14: Prestressed Concrete Girders)

All girders joints shall be design as full height girders as shown in the figure below due to
shear forces and the required reinforcing level to overcome shear in compact environment.

Figure 4: Full height girder joints. Adapted from: Queensland Government, Girder joints.
2018, Image. Reproduced from: Chapter 14: Prestressed Concrete Girders.

8
2.2 LUSAS MODELLER
2.2.1 Preliminary box girder sections

1. LUSAS modeller does not have the desired Section width hence the box girder is designed
according to the requirements stated in the project brief. The figure below shows the precast
beam section of T-roff beams. Refer to Figure 3 for the beam dimensions.

Figure 5: Prestressed girder, T6 outcome and arbitrary section property calculator in Lusas Modeller.

2. The end diaphragm model was created. The concrete slab thickness is 200 mm. Hence, the
coordinates of this diaphragm are (0, 0), (0.5, 0), (0.5, 0.5), (1, 0.5), (1, 0.7) and (0, 0.7). Figure 6
shows the outcome of end diaphragm model.

9
 Figure 6: End diaphragm outcome and arbitrary section property calculator in Lusas Modeller.

2.2.2 Preliminary beam layout

The grillage width is 7.4 m and internal transverse beams are 17 evenly spaced. This resulted a box
dimension is 3.700 x 2.056 m. The outcome is shown in Figure 7.

(Figure 7: Grillage created using grillage wizard)

1. Transverse beam dimension was inputted by 0.2 x 2.056 m for depth and width respectively.
2. The torsion constant for transverse beam will be reduced 50%, which is about 0.0025 Then, the
T6 girder torsion constant will be deducted based on the 50% loss of transverse beam which is
0.0165.
3. T6 girder will be inputted in longitudinal and edge beams, concrete slab will be inputted in the
transverse beams and the diaphragm will be inputted in end diaphragm.

10
2.2.3 Design actions

Table 1: Loads inputted on the prestressed concrete box girder.

Load(s) Load shows on the LUSAS Modeller (Blue dots represent load)

Permanent

Superimposed
(bearer and
wearing
surface)

Stationary/
Moving Load
on lane 1

Stationary/
Moving Load
on lane 2

1. For superimposed dead load, the density of bearer and wearing surface are 2.45 kN / m3 and
2.87 kN / m3 respectively. The length for bearer and wearing surface are 0.75 m and 4.8 m
respectively.

11
2. For lane 1, all stationary and moving load will be set to include full load and lane 2 will be set as
exclude full load. The factor is 1 for unfactored design. All traffic load shall comply with Clause
7.2.4 and Clause 7.2.5 in AS5100:2-2017.
3. Deformed mesh diagrams were generated as shown in the table below. The scale factor is 200 in
LUSAS modeller.

Table 2: Deformed mesh of load on the prestressed concrete box girder

Load(s) Deformed mesh diagram

Permanent

Superimposed
(bearer and
wearing
surface)

Stationary/
Moving Load
on lane 1

Stationary/
Moving Load
on lane 2

12
4. For unfactored load case, all the factors to be used are 1. However, for factored load case, the
load factored will be input in the data analysis to get the result of bending moment, shear and
torsion. All the load case factors are listed in Table 3 below. Accompanying lane factors are used
when more than 1 lane is loaded. Dynamic load allowances helps to model the dynamic and
vibratory effects of vehicles moving over bridges with typical road profile irregularities (Clause
7.7.1 from AS5100:2-2017). Refer to Table 7.7.2 for dynamic load allowance. Refer to Table 7.6
for accompanying lane factors. Refer to Table 7.10(A) for ultimate limit states and serviceability
service states’ load factor. All load factor is inputted in basic combination case.

Table 3: Unfactored and factored load factor for load case.

Dynamic
Ultimate Limit Accompanying
Load Total
States, Lane,
Allowance,
ALFi
1+( )

Permanent Load 1.2 - - 1.20

Superimposed Load 2.00

2.0 - -
(Wearing surface and barrier)
1 2.34
Moving Loads, M1600 (both
1.8 1.3
lanes) 0.8 1.87

1 1.8
Stationary Loads, S1600 (both
1.8 -
lanes) 0.8 1.44

1.3 1 2.34
Moving Load, M1600 (Lane 1)
1.8
Stationary Load, S1600 (Lane 2) - 0.8 1.44

1.3 0.8 1.87

Moving Load, M1600 (Lane 2)
1.8
Stationary Load, S1600 (Lane 1) - 1 1.80

Moving Load, M1600 (Lane 1) 1.8 1.3 - 2.34

Stationary Load, S1600 (Lane 1) 1.8 - - 1.80

Moving Load, M1600 (Lane 2) 1.8 1.3 - 2.34

Stationary Load, S1600 (Lane 2) 1.8 - - 1.80

5. All load cases were compile in a file called “Live Load Envelope” to obtain the maximum and
minimum of the bending moment, shear and torsion.

13
6. “Live Load Envelope Min” and “Live Load Envelope Max” are input in the basic combination load
case together with the permanent load and superimposed dead load, where the factor to be
used are listed in Table 3.
7. Figure 9 shows the load cases used for basic combination and final combination.

Figure 8: Load cases

2.3 Analysis results

Bending moment diagrams, shear force diagrams and torsion diagrams are attached in Appendix.
The detail readings for each load combination are also attached in the Appendix.

Table 4: Summary of Analysis Results

Unfactored Combination Factored combination

Bending Moment Max +ve 70.4 114.1

(kNm) Max -ve 9, 246.9 -14, 980.0

Shear Max +ve 1, 304.0 1,643.0

(kN) Max -ve -1, 298.4 -1, 636.0

Torsion Max +ve 37.3 136.7

(kNm) Max -ve -36.91 -135.1

14
2.4 Structure’s design
Design of Strand Pattern

Design of the Strand Pattern (at mid-span)

Use 15.2 mm diameter 7 wire strands, Area= 140 . Minimum break load= 250 KN, Minimum
tensile strength, = 1790 MPa [Table 3.3.1 As 5100.5].

Assume the following strand pattern for the mid-span section,

 First row= 10 strands (65mm from bottom)

 Second row= 12 strands (115mm from bottom)
 Third row= 12 strands (165mm from bottom)
 Fourth row= 10 strands (215mm from bottom)
 Fifth row= 2 strands (1450 mm from bottom)

( ) ( ) ( ) ( ) ( )
Centroid of strands = = 197mm

The prestressing force is 0.75 x 250= 187.5 kN per strand.

Check Stress at Transfer

Stress at Transfer
Prestressing force before losses= 46 x187.5= 8625 kN
Prestress losses due to Relaxation during curing= 10% [AS 5100.5, clause 3.3.4.4, for elevated temp
curing]

To calculate Elastic Shortening loss,

Prestressing force after relaxation loss= (1-10%) x 8625= 7, 762.5 kN
Concrete compressive stress at centroid of strands

Moment due to self-weight of girder at mid-span,

W= 1.14117 x 26.5= 30.24 kN /m

= W = x 30.24 x = 5174.82 kN/m

= + - = + - = 8.6 MPa

15
Elastic modulus of concrete at transfer, = 0.043 x √ = 31975 MPa

Prestress loss due to elastic shortening,

Δ = = 8.6 x = 49.03 MPa

( )
Prestress loss due to elastic shortening= x 100%= 3.66%

This prestress loss due to elastic shortening is “approximate” because we are using prestress force
with only relaxation loss when we calculate the elastic shortening, iteration is needed to find the
“exact” prestress losses.

Second iteration
Prestressing force = (1-10%- 3.66%) x 8625 = 7446.83 kN

Concrete compressive stress, at centroid of strands,

= + - = + - = 7.93 MPa

Prestress loss due to elastic shortening,

Δ = = 7.93 x = 45.2 MPa

( )
Prestress loss due to elastic shortening= x 100%= 3.37%

To be “exact” the prestress loss shall be the same as the prestress loss used in calculating the elastic
shortening in the beginning (which is 3.66%)

16
Third iteration
Prestressing force = (1-10%- 3.37%) x 8625 = 7471.84 kN

Concrete compressive stress, at centroid of strands,

= + - = + - = 7.98 MPa

Prestress loss due to elastic shortening,

Δ = = 7.98 x = 45.48 MPa

( )
Prestress loss due to elastic shortening= x 100%= 3.4%
The prestress loss is quite close to the value assumed when determining the prestressing force to
calculate the elastic shortening. Repeat one more iteration results in = 7471.84 kN, and loss due
to elastic shortening is 3.4%.

Calculate fibre stress and the bottom and top of the section:
Stress at bottom of section,

= + - = + x 947.05- x 947.05= 8.24

MPa

Stress at top of section,

= + - = + x 802.95- x 802.95= 7.98 MPa

Stresses at Transfer
Allowable stress limit at transfer and for crack control due to flexure (AS5100.5, Cl.8.1.6.2 and
Cl.8.6.2)

• Maximum stress limit = 0.6 x fcp = 0.6 x 40 = 24 MPa

• Minimum stress limit = -0.25 √fcp =-0.25 x √40 = -1.58 MPa (tension is –ve in this case)

Summary
• Maximum stress at transfer, = 8.24 MPa < 24 MPa, OK

• Minimum stress at transfer, = 7.98 MPa > -1.58 MPa, OK

17
Therefore, transfer stresses at mid-span are within the allowable limits.
Hypothetical Thickness
For girder only,
= (1082+100+840+1708+1392.25) x2+1600+1390 = 13, 234.5 mm
= mm2

Hence, = (2x )/13,234.5 = 172.45 mm

For composite section,

= 3700+1600+(100+840+1708) x2+(1536+2x1392.25+1390)/2 = 13,451.25 mm
= + 3,700 x 200 = 1.88117 x mm2

Hence, = (2x1.88117 x )/ 13,451.25= 279.7 mm

Therefore, for 1-100 days, = 172.45 mm, and for 100 days to 3 years, = 279.7 mm.

Shrinkage and Creep Loss

Shrinkage

• At 1 day, =172.45 mm, = 0.05 (from the equation)

• At 100 days, =172.45 mm, = 0.79 (from the equation)

• At 100 days, changes from 172.45 mm to 279.7 mm.

In obtaining value at 30 years, = 279.7 mm is not directly applicable because in the first 100
days, the shrinkage has already occurred with = 172.45 mm.

As an approximation, the average value of = 172.45 mm and = 279.7 mm is used to calculate

at 30 years.

• At 30 years, = (172.45+279.7)/2=226.08 mm, =1.17 (from the equation)

Hence, from 1 day to 100 days, = (0.79‐0.05) =0.74

From 100 days to 30 years, = (1.17 ‐0.79) =0.38

From 1 day to 30 years, = (0.74+0.38) =1.12

18
Creep

• At 1 day, =172.45 mm, = 0.05 (from the equation)

• At 100 days, =172.45 mm, = 0.77 (from the equation)

• At 30 years, =226.08 mm, =1.25 (from the equation)

Hence from 1 day to 100 days, = (0.77 ‐0.05)= 0.72

From 100 days to 30 years, = (1.25 ‐0.77)= 0.48

From 1 day to 30 years, = (0.72+0.48)= 1.20

Obtain maturity coefficient, , which depends on the age of the concrete ( ), from 3.1.8.3 in
AS5100.5.

• At 30 years, maturity coefficient =0.54

• Obtain basic creep coefficient from Table 3.1.8.2 in AS5100.5.

• For fc’=50 MPa, creep factor

• = 2.4

From Cl. 3.1.7, AS5100.5:

• Design shrinkage strain,

= +

= x (1.0 - )

= (0.06 ’ – 1.0) x 50 x

= (1-0.008 ’) x

( = 1000x for Perth Area

19
Prestress Loss due to Shrinkage in Concrete

Cl. 3.1.7 AS5100.5, shrinkage strain at 30 years:

= +

= x (1.0 - )

= (0.06 ’ – 1.0) x 50 x

= (0.06x 50- 1.0) x 50 x

= 100 x

= x (1.0 - )

( )
= 100 x x (1.0 - )

= 100 x

= (1-0.008 ’) x

= (1-0.008 x 50) x 1000x

= 800 x

= 1.12 (calculated earlier)

= 0.5 for a bear-coastal environment [3.1.7.2]

= 1.12 x 0.5 x 800 x = 448 x

=100 x + 448 x = 548 x

Loss of prestress due to shrinkage of concrete [3.4.3.2]

x / (1+15 / )

=548 x x 182250/(1+15x0.01)

=86.85MPa

(Assume = 1% of )

Shrinkage loss (force) = 86.85 x 140 = 12159 N = 12.159 kN

20
•Shrinkage loss (percentage) = 12.159/187.5 = 6.48% (the applied prestressing force = 187.5 kN

Prestress Loss due to Creep in Concrete

Cl.3.1.8.1 AS5100.5, creep strain at 30 years,

= /

= 1.2 (calculated earlier)

= 2.4/[1+log(t)] = 0.536, for t = 30 years

= 0.5 (near coastal)

= 1.0 (f’c ≤ 50MPa)

= 2.4 (Table 3.1.8.2)

= 1.2 x 0.536 x 0.5 x 1.0 x 2.4= 0.772

Thus, = 0.772 x ( / )= 0.772 x (7.97/31975)= 192 x

Note that the value from Table 3.1.8.3 is 1.59 in this case, which is double the calculated value. Use
1.59 instead of 0.772.

Loss of prestress due to creep of the concrete [3.4.3.3]

x = 0.8 / x

= 0.8 x 1.59 x (7.93/31975) x 182250

= 57.49 MPa

Creep loss (force) = 57.49 x 140 = 8048.6 = 8.0486 kN

Creep loss (percentage) = 8.0486/187.5 = 4.29%

= sustained stress in the concrete at the level of tendons calculated using initial prestressing
force + sustained portions of all live loads.

(Consider no sustained live load for a bridge girder)

21
Elastic Shortening Loss

Prestress loss at 30 years due to elastic shortening will be less than the loss at transfer, because the
prestressing force at 30 years is smaller than the one at transfer and the concrete has gained full
strength with higher modulus of elasticity.

• Assume the elastic shortening loss is similar to the one at transfer

• Prestressing force = (1- 3.4%- 10%- 6.48%- 4.29%) x 8625= 6,538.61 KN

• Bending moment due to the weight of deck slab

Weight of deck slab = 3.7x 0.2 x26.5 = 19.61 kN/m

Bending moment at mid-span = 1/8x 19.61x = 3355.76 kNm

• Stress at centroid of strand

= + -

( )
= + -

=3.95 MPa

• Elastic modulus of concrete at 30 years,

= 0.043x x √50 = 35750MPa

• Prestress loss due to elastic shortening

Δ = = 3.95 x = 22.51 MPa

• Prestress loss due to elastic shortening = (140x22.51)/187500x100% = 1.68%

Second iteration

• Prestressing force = (1-1.68%-10%-6.48%-4.29%)x 8625 = 6688.69 kN

• Concrete compressive stress, at centroid of strands

= + -

( )
= + -

22
 = 4.93 MPa

• Prestress loss due to elastic shortening,

Δ = = 4.93 x = 28.1 MPa

• Prestress loss due to elastic shortening = (140x28.1)/187500x100% = 2.09%

Prestress loss (1.68%) is close enough to the loss in previous iteration  stop iteration.

Loss and Prestress at 30 years

Loss at 30 years: Relaxation loss= 10.0%

Elastic shortening loss= 2.09%

Shrinkage loss= 6.48%

Creep loss= 4.29%

Total=22.86%

• Prestressing force, P = (1-22.86%) x 8625 = 6,653.33 KN

Loads

Self-weight of girder = x26.5 = 30.24 kN/m

Weight of deck slab = 0.2x 3.7 x 26.5 = 19.61 kN/m

Deck wearing surface = 0.05x 3.7 x 22 = 4.07 kN/m

Span length = 37 m, at mid-span:

• = 1/8x 30.24 x = 5,174.82 kNm

• Ms = 1/8x 19.61x = 3,355.76 kNm

• Mdws = 1/8x 4.07 x = 696.48 kNm

From structural analysis,

= 655 kNm

23
 = 2,990 kNm

Service Stresses

= = = 9.83 MPa

= = x 947.05= 11.08 MPa

= ( )= x (1750-947.05)= 9.4 MPa

( ) ( )
= = x 947.05= 17.72 MPa

( ) ( )
= ( )= (1750-947.05)= 15.02MPa

= = x 1306.16= 0.91 MPa

= ( )= x (1750-1306.16)= 0.31 MPa

= = x 1400.16= 0.25 MPa

= ( )= x (1750-1400.16)= 0.22 MPa

= = x 1400.16= 3.77 MPa

= ( )= x (1750-1400.16)= 0.94 MPa

24
Service Stresses

= + - - - - = 9.83+ 11.08- 17.72- 0.91- 0.25- 3.77= -1.74 MPa

= - + + + + =9.83- 9.4+ 15.02+ 0.31+ 0.22+ 0.94= 16.7 MPa

Allowable stress limit [8.6.2 and 8.1.6.2 in AS5100.5]

Maximum stress limit at service = 0.6 fc’ = 0.6x50 = 30 MPa

Minimum stress limit at service = -0.25 √fc’ =-0.25x √50 = -1.77 MPa

Stress check:

• For SM1600 Loading

Minimum stress at service, = -1.74 MPa > -1.77 MPa (OK)

Maximum stress at service, =16.7 MPa < 30 MPa (OK)

25
Ultimate moment capacity
Dead loads:
Self-weight of girder = 1.141170 x 26.5 = 30.24 kN/m
Weight of deck slab = 0.2 x 3.7 x 26.5 =19.61kN/m
Deck wearing surface = 0.05 x 3.7 x 22 = 4.07 kN/m

Span length = 37 m, at mid-span:

Mg = 1/8 x 30.24 x 372 = 5,174.82 kNm
Ms = 1/8 x 19.61 x 372 = 3,355.76 kNm
Mdws = 1/8 x 4.07 x 372 = 696.48 kNm

Moment at mid-span due to traffic loads from structural analysis:

Mp = 655 kNm
Msm = 2,990 kNm
Mhlp = 3,741 kNm

Calculate ultimate moment , M* (Clause 8.1 of AS 5100.5),

• Load factor
• for dead load (girder, deck slab and parapet) = 1.2
• for superimposed dead load (deck wearing surface) =2.0
• for live load SM1600 loading = 1.8
• for live load HLP400 loading = 1.5

• Maximum live load moment,

• for SM1600 loading = 1.8 x 2990 = 3,614 kNm
• for HLP400 loading = 1.5 x 3741 = 5,612 kNm (more critical)

• M*=1.2x(5,174.82+3,355.76+655)+2.0x696.48+1.5x3,741=18,027 kNm

Calculate effective depth,

• The strands in the top flange do not contribute to the flexural strength of the section.

26
 ( ) ( ) ) ( ) ( )
• Find the CG of bottom strands,

• dp=1,750+200-197=1,753 mm
Determine the strand stress σpu at ultimate state [8.1.7,AS5100.5],

( )

Where,
k1=0.4
k2=(46x197x1,790)/(840x1,753x50)=0.22 (assume no Ast and Asc)
• *8.1.3, AS5100.5+
• γ = 1.05-0.007fc’=1.05-0.007*(50)=0.70
• Hence, σpu=1790x[1-(0.4x0.22)/0.70]=1790x0.87429 = 1,565MPa
• Total tensile force in bottom strands, Ft = 46x197x1,565 = 14,182,030 N = 14,182 KN

Check the position of neutral axis,

• Since our design doesn’t include kerb, therefore, Fc1 equal to zero
• Compressive force in the slab, Fc2=Ft-0= 14,182 - 0 = 14,182 KN
• Depth of compression zone, x = 14,182,030/(0.85x40x1,753)= 238mm
• Since x is larger than 180 mm of slab thickness, compression zone extend to the girder.
• Check neutral axis depth, kU (Cl.8.1.5, AS5100.5)
Depth of compression zone, γkUd = 238 mm
Hence, kUd = 238/0.7 = 340 mm and kU = 340/1,753 = 0.2 < 0.36 (OK!)

Calculate the ultimate moment capacity,

Mu = Fc2 x (d-238/2)
= 14,182 x (1,753-119)
= 14,182 x 1,634
= 23,173,388 kNmm
= 23173kNm

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 • ϕ MU = 0.8 x 23173 = 18,538.4 kNm
• Since ϕ MU is larger than M* (= 18,027kNm), the section is OK at the mid-span.

Therefore, the ultimate moment capacity of our design is 18,538kNm.

Design for Shear and Torsion

• Shear and torsion are largest near the supports.

• Critical section occurs at the end of solid part near the support.
• Length of solid section may vary depending on many factors.
• In our design, the end of solid section is taken as span/20.

So, 37/20 =1.85 m, therefore, assume edge of void: 1.85m from bearing.

Section Properties

Ag 1,141,170 mm2 T-roff Girder only

Ig 4.56x1011 mm4
Section Properties
Acomp 1,782,650 mm2 Girder and slab
Icomp 9.7112 x mm4
Normal steel Ast 0 mm2 in flexural tension zone
Apt 11411.7 mm2 in flexural tension zone
Prestressing steel
Ap 9062 mm2 46 of 197mm2-tendons

(a) Determine design action

Traffic loads
From structural analysis, at section A (in KN and m)

SM1600
V T M
393.9 17.11 806.3
408.5 16.5 812.6
33.11 25.49 714.5

• Factored Loads: 1.8*SM1600

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 • Dynamic load allowance (DLA) = 1.3*SM1600 [7.7.2 - AS5100.2]
• V, T and M values with DLA and Load Factors (in kN and m)

SM1600
V T M
921.73 40.04 1,886.74
902.79 38.61 1,901.48
77.48 59.64 1,671.93

Shear force and moment due to self-weight of girder, deck slab and deck wearing surface

Factored Load = 1.2x30.24 + 1.2x19.61 + 2.0x4.07 = 69.76 kN/m

At support face, V = 67.96*(37/2-1.85) = 1,131.5 kN
At support face, M = 67.96*(37/2*1.85-1.85^2/2) = 2,209.6 kNm

• Total of traffic and dead loads, at section A (in kN and m)

SM1600
V T M
2,053.23 40.04 4,096.34
2,034.29 38.61 4,111.08
1,208.98 59.64 3,881.53

(b) Calculate Tcr

Acp = 1141170 mm2

uc = 10480 mm2
f'c = 50 MPa

cp = 13.4 MPa

29
 √ √( )
√

(c) Determine Pv ; Pv = vertical component of all the prestressing at the section being considered.
• Tendons are straight, no Pv from the analysis.
From Clause 8.2.1.3,

Pv = 0 kN
V*min = 1208.98 kN
[8.2.1.3] Not applicable when Pv < V*min
additional V* = 1.2Pv-V*min = 0 kN

Therefore, V*=0

(d) Determine shear strength

• Check web crushing *8.2.2.3+

bv w-kd d) = (125-0.5*0) = 125mm [8.2.1.5] Pretensioned member, assumed no duct

0.72 D < dv = d- ud/2 < 0.9d [8.2.1.9] Based on Ultimate moment design

Therefore, dv = 1753 - 238/2 = 1634mm

= distance between the resultants of the tensile and compressive forces due to flexure

= 0.7fpb for bonded tendons outside the transfer length, or sp for unbonded tendons

[8.2.4.3/8.2.4.4]

= perimeter of the centre-line of the closed transverse torsion reinforcement

= area enclosed by shear flow path, including any area of holes therein

30
 = area enclosed by centre-line of exterior closed transverse torsion reinforcement, including
area

of holes (if any)

=(1475+1661)/2*(1950) 2,994,880 mm2

= 2,994,880 mm2
In our design, kud = dn = 340 mm
uh =(1600-40)+(1950-40)*2+1536= 6,916 mm

v x) 27.25 deg.

v = angle btw inclined Asv and Ast 90 deg.

v x) 0.476 rad.

v = angle btw inclined Asv and Ast 1.571 rad.

[8.2.4.3] For shear

[8.2.4.4] for shear and torsion

Refer to the calculation in the [Table 2.3.2] , -0.002 ≤ x = ≤ 0; x = -0.00025

( ) ( )
( )( )( )( ) (at service)
( )

Shear reduction factor, = 0.7

Vu,max = 0.7(2286.4)= 1,600 kN

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Check web crushing due to combined shear and torsion [8.2.4.5]

For a box section

• check against / ; / = 433mm
= = 125mm

• For > /
substitute V*, , , dv, T*, , , ,max in [Eq. (8.2.4.5(1)]
N.A. [Check]

• For /
substitute V*, , , dv, T*, , , ,max in [Eq. (8.2.4.5(2)]

𝑉 𝑃𝑣 𝑇 ∅𝑉𝑢 𝑚𝑎𝑥
+ ≤
𝑏𝑣 𝑑𝑣 𝑡𝑤 𝐴𝑜 𝑏𝑣 𝑑𝑣

32
At Section A
( )
+ ≤

10.05 + 0.063 = 10.11 > 7.8 Not OK; increase the section, or the length of the solid

• Calculate [8.2.4.1]
Use the case when ≥ .min

𝑘𝑣 [ ] 𝑘𝑣 [( ] = 0.4
( 𝜀𝑥 ) ( ))

√ = 0.4*√50*125*1,634/1,000 = 578KN

(e) check if stirrups are required [8.2.1.6], ie.,

V* > 0.5 ( + ); T* > 0.25 ;

Check if V* = 2053.23 > 0.5*0.7(578+0); T* = 40.04 > 0.25*0.7*753

V* = 2053.23 > 202.3; T* = 40.04 < 131.8 , thus no require transverse

(f) Design shear strength [8.2.3.1] u V*eq

Calculate Veq for a box section from 8.2.1.2(5)

𝑉𝑒𝑞 𝑉𝑒𝑞 = 2,066.3KN

𝑇 𝑑𝑠
𝑉
𝐴𝑜
∅𝑉𝑢 ∅(𝑉𝑢𝑐 𝑉𝑢𝑠 𝑃𝑣 )
≥ 𝑉𝑒𝑞
Thus, 𝑉𝑒𝑞
𝑉𝑢𝑠 𝑉𝑢𝑐
∅
𝑃𝑣
Vus = 2066.3/0.7 - 578 - 0 = 2374KN

Determine Asv.min for shear [8.2.5.2]

Use perpendicular shear reinforcement [8.2.5.2(1)]

𝑉𝑢𝑠 𝑆 𝐴𝑠𝑣
𝐴𝑠𝑣 𝑆 ( ) ( )
= 1.5mm
(𝑓𝑠𝑦 𝑓 𝑑𝑣 )𝑐𝑜𝑡𝜃𝑣

33
Therefore, use spacing S = 300 mm, = 450 mm2

(g) Design for Torsion

Determine transverse reinforcement when there is torsion, Asw [8.2.5.5]
𝐴𝑠𝑤
𝑇𝑢𝑠 fsy.f = yield strength of reinforcement used as fitments
𝑆
≥ 𝑇𝑐𝑟 𝑦
≥ use y1 = 1,950-80= 1,870mm, assumed 40mm cover top & bottom
𝑓𝑠𝑦 𝑓

Asw ≥ 0.2*1870/500 * 300 = 224.4 mm2 , Use spacing S = 300 mm

Torsional resistance: 𝐴𝑠𝑤 𝑓𝑠𝑦 𝑓

us
𝑇𝑢𝑠 𝐴𝑜 𝑆
co (𝜃𝑣 )

For T* = 40.04 kNm

𝐴𝑠𝑤
/ 𝑆
co ( )

= 501 mm2 , For S = 300 mm, and greater than 224.4, use this value

Therefore, total transverse reinforcement = 450 + 501 = 951 mm2 @ 300 mm

Hence, Use 4 legs of N16@300mm spacing.

(h) Additonal longitudinal reinforcement and tendons on flexural tension side [8.2.7]
For shear with torsion
𝑇 𝑢ℎ [8.2.7(1)]
∆𝐹𝑡𝑑 (𝑉 𝛾𝑝 𝑃𝑣 ∅𝑉𝑢𝑠 ] [ ] co (𝜃𝑣 )
𝐴𝑜

∆𝐹𝑡𝑑 [( ) ] * + co ( )

∆𝐹𝑡𝑑 [ ] [ ] co ( )

= 2,901 KN

Additional reinforcement
∆𝐴𝑠 𝑓𝑠𝑦 ∆𝐴𝑝 𝜎𝑝𝑢 [8.2.7(3)]
≥ ∆𝐹𝑡𝑑 /∅
34
 ∆𝐴𝑠 ≥
/
∆𝐴𝑠 mm2 Adding this As to the required As at the flexural tension side
≥

(i) Additonal longitudinal reinforcement and tendons on flexural compression side [8.2.8]
For shear with torsion

𝑇 𝑢ℎ [8.2.8(1)]
∆𝐹𝑐𝑑 (𝑉 𝛾𝑝 𝑃𝑣 ∅𝑉𝑢𝑠 ] * + co (𝜃𝑣 ) 𝐹𝑐 )
𝐴𝑜
𝑀
𝐹𝑐 /
𝑑𝑣
Approximated value, must check𝑘𝑁
from bending theory, assume no axial force

∆𝐹𝑐𝑑 [( ) ] * + co ( ) - 1257
= 1644 KN

Additional reinforcement
∆𝐴𝑠 𝑓𝑠𝑦 ∆𝐴𝑝 𝜎𝑝𝑢
≥ ∆𝐹𝑐𝑑 /∅
∆𝐴𝑠 ≥
/
∆𝐴𝑠 ≥ 𝑚𝑚^

Adding this As to the required As at the flexural compression side

(j) Check the extension of longitudinal reinforcement [8.2.9]

when transverse reinforcement is required
The extension distance = do v) = (1,950-35)*cot(27.3) = 3,710 mm Approximated value

General Detailing [8.3]

continuation of negative moment reinforcement and tendons
shear strength requirements when tensile reinforcement is terminated
anchorage of flexural reinforcement
bundled bars

Development Length [13] in AS5100.5

35
stress development of normal steel reinforcement/tendons
lapped splices
coupling of tendons

3.0 Possible Project Risk Exposure

This section of the design report is the risk management plan to cater for the possible risk exposure
for the project. The management plan below is a typical risk management plan for a project. The
client and the contractor could have different risk management plan based on their company.

1. Meeting

Weekly progress meeting is very important for every member in the company so that the ongoing
task given and new task distribution can be updated. Besides, all members can make and agree the
critical decision. The decision and task will be written on the weekly progress report to ensure that
the project is proceeded on the right track.

2. Risk Management Plan

There are several risks can be listed and encountered in this project. During the construction phase,
many unexpected events will occur. By predicting the impacts of risk, risk management is made to
identify and solve the risks. Thus, identification of risk, risk analysis, risk response planning and risk
responsibility are stated in the plan.

3.1 Risk Management Plan

Throughout the life of this project, risk management is used to identify, analyze and prepare
responses to risk factors. Moreover, the scope and the objective of the project can be defined by
proper risk management so that the future events can be controlled easily. Besides, risk
management plan also provides more and better understanding through interrogation of an area by
informing the decisions.

The stakeholders and relevant authorities are important to attend a regular meeting so that
the possible activities and constraints that may involve in the project can be communicated and
discussed. Thus, the potential of risk can be determined by reducing or allocating the risks. Other
than that, it also provides a rational basis for better decision based on each risk.

36
 There are several risks can be encountered in this project. During the construction of the
bridge, many unexpected events will occur and the risk management plan is used by predicting the
possible impacts of risk and solving the possible risks. Identification of risk, risk analysis, risk
response planning and risk responsibility are included in the risk management plan.

3.1.1 Risk Identification

The risk must be clarified so that proper action can be taken into it. Environment factor, physical
factor and financial factor are classified as the possible risks.

Risk identification is the process of determining risks that could potentially prevent the project from
achieving its objectives. Generally, before construction, during construction, and after construction
are 3 main stages of the risks in the construction.

3.1.2 Risk Analysis

The evaluation of individual risks and the evaluation of the all risks are the methods to analyze the
risks. For the individual risk evaluation, analysis based on the probability of the event occurs and the
impacts of the event are needed. By determining the most concern and intolerable risks, risk
management matrix method is used.

3.1.3 Risk Response Planning

With the help of project planning, ways to improve the opportunities can be determined. Moreover,
the threats of the project goals can be minimized. Thus, the loss of this project will be reduced. To
ensure that the level of threats will be reduced, the actions or choices must be planned well. By
solving the risks in this project, response strategies for threats and response strategies for
opportunities are the two main strategies.

37
3.1.4 Risk Responsibility

Responsibility among each stakeholder is important in the risk identification process. Thus, the
stakeholders must have the ability to recognize danger and clarify the issue well. Besides, they are
required to identify the circumstances dispassionately.

3.2 Construction Safety Plan

The construction safety in this project is managed by using the construction plan. It will full comply
with the PTA requirements and policies.

3.2.1 Objective of construction plan

To ensure the prevention of injuries, health hazards and environment impacts, the company is
compulsory to make a construction safety plan with the following descriptions:

1. Process for recognizing the possible hazard which will harm the relevant people that
involved in this project.

2. Procedure for preventing the accidents occur.

3. Solutions that can be applied for the accidents.

3.2.2 Applicability

The construction safety plan is applied for everyone Thus, who is on the construction sites or other
position in this project must follow the construction plan. With the works at a minimal risk, the
criteria of the construction safety plan must be fulfilled by the project clients and the project teams.

3.2.3 Implementation

In every month, the safety in every area must be evaluated once and report the safety conditions to
the project manager in this project. By achieving a maximum involvement of the relevant people in
this plan, the actions are shown as follows:

38
 1. Management commitment to the construction safety plan

2. Hazard analysis must be conducted for everyone

3. Effective and strict construction safety training session

4. Audio safety announcement or presentation given at the jobsite

3.2.4 Reporting of injuries

The injuries reports must be prepared by the company. After an injury happens, every worker is
compulsory to fill the form within the 24 hours. Although there is no medical treatment, employee
must make a report to their leaders. In addition, the person who does not report the injury within 24
hours without any special reason can immediately terminated by the company.

3.2.5 Notification

The serious injury or death cases should be immediately notified to the head office and safety officer.
Apart from that, the signature and time noted are taken to prove the evidence of the incident such
as the statement of witness or videos from the CCTV. Besides, the relevant people in the incident are
required to submit alcohol and drugs testing. Moreover, safety officer will involve in the
investigation of the incident.

3.2.6 Basic Safety Rule

1. Every site worker is required to wear safety helmet at all time. Any changes for the safety
helmet are strictly prohibited.

2. For the eye protection at all time, every site worker must wear safety googles. In the
operations of grinding or jack hammering, the workers are required to wear mono googles.

3. Every site worker must have proper clothing all the time. Shirts must be attached with tee
sleeve and the pants must be long. Moreover, the workers must wear sturdy work boot with
slip resistant soles. Sports shoes or slippers are strictly restricted in the construction site.

39
 4. Illegal drugs or alcoholic beverage are strongly restricted for everyone on all the working
places.

5. Smoking is restricted in all the working places.

6. No fighting among the workers or colleagues in all the working places.

7. Before being used, all the equipment in the construction site must be checked daily.

8. All the dangerous conditions must be immediately reported to the Safety Officer so that
actions can be taken to solve the conditions.

9. Warning signs or tags must be obeyed by everyone in this project.

10. Scaffold Tag must be placed in a visible spot so that everyone is able to see.

3.2.7 Enforcement of basic safety rule

Everyone in this project will be checked by the safety officer whether everyone obeys the basic
safety rule time by time. Besides, the person who disobeyed the safety rule will be issued a notice
which is written by the safety officer. The actions made towards the people who disobeyed the rules
are as follows:

1. The person who disobeyed the safety rule may face suspension or immediate termination.

2. The person who received the notice more than three times within half year will be
terminated.

3. The person who fail to report injury may result in immediate termination.

40
3.3 Traffic Management Plan
The construction traffic in this project can be managed by the traffic management plan. Due to the
existing traffic flow, the traffic management plan is important to prevent the delaying of the project.

3.3.1 Purpose of Traffic Management

The main objective of traffic management is to ensure that the operation flow of the road network
will be smooth. Once this project started, the surrounding road traffic in the construction site will
become busy as many heavy vehicles will be drove into the construction site. Thus, an effective
traffic management plan may minimize the delaying of the project.

3.3.2 Applicability
It is applicable for any vehicles entering the construction site in this project.

3.3.3 Location

Due to different construction site, different existing traffic flow will occur. Thus, different traffic
management plan will be made to encounter the problems in the traffic flow.

3.3.4 On-site Monitoring

All the signs must be installed starting at least 150m away from the construction site to ensure that
the drivers can notice and slow down. For the emergency case, the name and contact number of the
in-charge person must be shown properly. Other than that, the sign boards must be installed at good
spots so that the vision of the drivers will not be blocked. Furthermore, the safety traffic speed must
be studied and surveyed. Then, it can be applied on the construction site.

3.3.5 Approval by city council

The proposal of traffic management plan must be early submitted to the city council. After the plan
is approved by the city council, the construction can begin.

41
Reference
Queensland Government. 2013. “Chapter 14: Prestressed Concrete Girders.” In Drafting and Design

Presentation Standards: Structural Drafting Standards. 3rd ed. Queensland, Australia:

Department of Transport and Main Roads.

Wells Concrete. 2019. “BENEFITS OF PRECAST.” https://www.wellsconcrete.com/benefits-of-

precast/

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