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Construction of 2 Nos. lane ROBs (Including Approaches & LHS) in lieu of Level crossing No. 104 &
Project 108 at Km. 555/4-5 at Sirohi road & Km 565/0-1 at Banas yard of Madar-Palanpur section of Ajmer
Division of North Western Railway
Client:- DFCCIL, Ajmer
Contractor BSP-SHC (JV) Jaipur
Location ROB at LC-108 on Madar-Palanpur Section
Design Date 13.04.2019 Rev. 00 Date of revision
Type T Quantity 3
Cone. Grade for Pedestal M 35
Cone. Grade for Superstructure M 35
| Actual Requirement I
Movement Requirement As Per IRC 83 Part ( III ) Cl. 926.1.6
Longitudinal Movement ( mm ) 0 (+ 0 /- 0 )(+ 0 /- 0 )
Transverse Movement ( mm ) 0 (+ 0 /- 0 )
Rotational Requirement
Rotation (Total) 0.01 0.01 x 1.3 = 0.013 radians
Rotation ( Due to Permanent Actions ) 0.008 0.008 x 1.3 = 0.0104 radians
Rotation ( Due to Variable Actions ) 0.002 0.002 x 1.3 = 0.0026 radians
PERMISSIBLE VALUE OF STRESS IN PAD, PTFE, STEEL & CONCRETE
Neoprene Pad Average Minimum Stress < 5 MPa AS PER IRC 83 PART (III) Cl.926.2 3.3
Neoprene Pad Average Stress < 35 MPa AS PER IRC 83 PART (III) Cl.926.2.3.2
Neoprene Pad Extreme Fibre Stress < 40 MPa AS PER IRC 83 PART (III) Cl.926.2.3.2
PTFE Stress (Average Preassure) < 40 MPa AS PER IRC 83 PART (III) CI.926.2.4.3
PTFE Stress (Extreme Fibre Preassure) < 45 MPa AS PER IRC 83PART (III) Cl.926.2.4.3
Steel Stress (Working) for Design Use 340 MPa (Grade-340-570W) AS PER IS -1030
Steel Stress (Working) for Design Use 240 MPa (Grade-B) AS PER IS - 2062
PERMISSIBLE CONCRETE STRESS IN NORMAL IN SEISMIC AS PER IRC 83 PART (III) Clause 926.2.1.1
PEDESTAL < 17.5 MPa < 21.875 MPa BEARING STRESS
SUPERSTRUCTURE < 17.5 MPa < 21.875 MPa BEARING STRESS
PEDESTAL < 11.66667 MPa < 14.58333 MPa FLEXURAL STRESS
SUPERSTRUCTURE < 11.66667 MPa < 14.58333 MPa FLEXURAL STRESS
IDESIGN INPUTS : I
Neoprene Pad Size dia. in mm = 240 > 180 Pedestal Size (mm) 660 x 660
Neoprene Pad thk. in mm = 16 > 16or16
No of Sealing Rings = 2
Total Thk of rings (in mm) = 4
Pot Base Effective dia. = 352 mm Available Pedestal Size (mm) = 660 x 660
Permissible Concrete Stress = (A1/A2)^.5*.25*fck AS PER IRC 83 PART (III) Cl 926 2.1.1
Permissible Concrete Stress = (A1/A2)^.5*.25*fck AS PER IRC 83 PART (III) Cl 926 2.1.1
Check Compression at edge of Neoprene Pad Max. Permitted = 15 % of T1 Thickness T1 is thickness of Pad less seal rings thickness
= 0.15 x 12 = 1.8 mm
Stress Check over Concrete surface due to Pot Base (Non Seismic)
1. Direct Bearing Stress due to Vertical Load (IRC 83 Part (III ) Clause 926.1.5 )
Stress = 1490.6184 x 1000 x 4 = 15.3254 Mpa < 17.5 Mpa OK
3.14 x 352 x 352
II. Flexural Stress due to induced Moment resultinq from resistance to Rotation
1)
di= 240 mm D/T ratio = 15
k1= 2.2 k2= 101
qp= 0.0104 qv = 0.0026 rad.
III. Coexistina Direct and Flexural Stress Check ( IRC 83 Part ( III ) Clause 926.2.1.3)
Stress= 15.3253885 + 1.2482 = 0.982723 <= 1 OK
17.5 11.667
22.50 15
Stress Check over Concrete surface due to Pot Base (Seismic)
1. Direct Bearing Stress due to Vertical Load (IRC 83 Part (III ) Clause 926.1.5 )
Stress = 1039.5102 x 1000 x 4 = 10.6874 Mpa < 21.875 Mpa OK
3.14 x 352 x 352
II. Flexural Stress due to induced Moment resultinq from resistance to Rotation
1)
di= 240 mm D/T ratio = 15
k1= 2.2 k2= 101
qp= 0.0104 qv = 0.0026 rad.
M. .e. d. = di3 x ( k 1 . q p + k 2. q v) (IRC 83 Part (III) Clause 926.1.5.1)
M. .e. d. 240 ^ 3 x( 2.2 x 0.0104 + 101 x 0.0026 )
= 3946475.52 N.mm
III. Coexistina Direct and Flexural Stress Check ( IRC 83 Part ( III ) Clause 926.2.1.3)
Stress= 10.687442 + 1.5483 = 0.594739 <= 1 OK
21.875 14.583
Stress Check over Concrete surface due to Top Slide Plate (Non Seismic)
II. Flexural Stress due to induced Moment resultinq from resistance to Rotation
1)
di= 240 mm D/T ratio = 15
k1= 2.2 k2= 101
qp= 0.0104 qv = 0.0026 rad.
2)
M. R D. = 0.2 x C x H ( IRC 83 Part (III) Clause 926.1.5.2)
C= 84.8528137 mm H= 82.37628 kN
M. e D . = 0.2 x 84.853 x 82.37628 x 1000
1397971.83 N.mm
Total Induced Moment (M. I D )= M. e. d + M. R D ( IRC 83 Part ( III) Clause 926.1.5.3)
Total Induced Moment (M.I D ) = 5344447.349 N.mm
Stress = 5344447.349
0.0982 x 364 x 364 x 364
= 1.12874994 MPa < 15 Mpa OK
III. Coexistina Direct and Flexural Stress Check ( IRC 83 Part ( III ) Clause 926.2.1.3)
Stress= 14.3315794 + 1.1287 = 0.915697 <= 1 OK
17.5 11.667
Stress Check over Concrete surface due to Top Slide Plate (Seismic)
II. Flexural Stress due to induced Moment resultinq from resistance to Rotation
1)
di= 240 mm D/T ratio = 15
k1= 2.2 k2= 101
qp= 0.0104 qv = 0.0026 rad.
2)
M. R D. = 0.2 x C x H ( IRC 83 Part (III) Clause 926.1.5.2)
C= 84.8528137 mm H= 158.103957 kN
M. e D . = 0.2 x 84.853 x 158.104 x 1000
2683113.12 N.mm
Total Induced Moment (M. I D )= M. e. d + M. R D ( IRC 83 Part ( III) Clause 926.1.5.3)
Total Induced Moment (M.I D )= = 6629588.64 N.mm
Stress = 6629588.6
0.0982 x 364 x 364 x 364
= 1.40017243 MPa < 14.58333 Mpa OK
III. Coexistina Direct and Flexural Stress Check ( IRC 83 Part ( III ) Clause 926.2.1.3)
Stress= 9.99439089 + 1.4002 = 0.552898 <= 1 OK
21.875 14.583
Stress Check over Pot Wall Section (In Non Seismic Case)
Check for Hoop tensile Stress on Pot wall Section ( IRC 83 Part ( III ) Clause 926.3.1.1.7.1)
Pressure from Pad due to Fluid Preassure (P1) = 240 x 16 x 32.97 = 101.436 MPa
2 X ( 26 x 24 )
Stress into Wall due to Horizontal Force (P2) = 82.4 x 1000 = 66.0066 MPa
2 x ( 26 x 24 )
Shear Stress at Cylinder Wall & Interface ( IRC 83 Part ( III ) Clause 926.3.1.1.7.2 )
Shear stress at cylinder & base interface considering 1 mm slice
Fluid Pressure ( SP1 ) = 16 X 32.967 = 21.97774 Mpa
24
Horizontal Force ( SP2 ) = 1.5 x 82.376 x 1000 = 21.4522 Mpa
240 x 24
Total Shear Stress at Cylinder wall (SP) = SP1 + SP2 = 21.97774 Mpa + 21.45216 Mpa = 43.4299 Mpa
Total Shear Stress at Cylinder wall (SP) = 43.4299 Mpa < 153 Mpa OK
Bendinq Stress at Cylinder & Base Interface:- ( IRC 83 Part ( III ) Clause 926.3.1.1.7.3 )
Bending stress at cylinder & base interface considering 1 mm slice
Fluid Pressure ( BP1 ) = 6 x 32.967 x 16 x 16 = 43.9555 Mpa
2 x 24 x 24
Horizontal Force ( BP2) = 1.5 x 6 x 82.37628 x 1000 x( 16 + 2.5 )
240 x 24 x 24
Horizontal Force ( BP2 ) = 99.2162227 Mpa
Total Bending Stress at Cylinder wall (BP) = (BP1 + BP2) = 43.95548 Mpa + 99.21622 Mpa = 143.172 Mpa
Total Bending Stress at Cylinder wall (BP) = 143.1717 Mpa < 224.4 Mpa OK
Equivalent Stress due to combined effect of Bendinq & Shear :- ( IRC 83 Part ( III ) Clause 926.3.1.1.7.4 )
IRC 83 Part ( III ) Clause 926.2.2.5 )
Equivalent Stress / Combined Stress = ( 3 x SP2 + BP2 ) ^ 0.5
= ( 3 x 1886.1561 + 20498.14 ) ^ 0.5
= 161.730041 Mpa < 306 Mpa OK
Check for Hoop tensile Stress on Pot wall Section ( IRC 83 Part ( III ) Clause 926.3.1.1.7.1)
Pressure from Pad due to Fluid Preassure (P1) = 240 x 16 x 22.99 = 70.7381 MPa
2 X ( 26 x 24 )
Stress into Wall due to Horizontal Force (P2) = 158.1 x 1000 = 126.686 MPa
2 x ( 26 x 24 )
Shear Stress at Cylinder Wall & Interface ( IRC 83 Part ( III ) Clause 926.3.1.1.7.2 )
Shear stress at cylinder & base interface considering 1 mm slice
Fluid Pressure ( SP1 ) = 16 X 22.99 = 15.32658 Mpa
24
Horizontal Force ( SP2 ) = 1.5 x 158.1 x 1000 = 41.1729 Mpa
240 x 24
Total Shear Stress at Cylinder wall (SP) = SP1 + SP2 = 15.32658 Mpa + 41.17291 Mpa = 56.4995 Mpa
Total Shear Stress at Cylinder wall (SP) = 56.49949 Mpa < 153 Mpa OK
Bendinq Stress at Cylinder & Base Interface:- ( IRC 83 Part ( III ) Clause 926.3.1.1.7.3 )
Bending stress at cylinder & base interface considering 1 mm slice
Fluid Pressure ( BP1 ) = 6 x 22.99 x 16 x 16 = 30.6532 Mpa
2 x 24 x 24
Horizontal Force ( BP2) = 1.5 x 6 x 158.104 x 1000 x( 16 + 2.5 )
240 x 24 x 24
Horizontal Force ( BP2 ) = 190.424688 Mpa
Total Bending Stress at Cylinder wall (BP) = (BP1 + BP2) = 30.65317 Mpa + 190.4247 Mpa = 221.078 Mpa
Total Bending Stress at Cylinder wall (BP) = 221.0779 Mpa < 224.4 Mpa OK
Equivalent Stress due to combined effect of Bendinq & Shear :- ( IRC 83 Part ( III ) Clause 926.3.1.1.7.4 )
IRC 83 Part ( III ) Clause 926.2.2.5 )
Equivalent Stress / Combined Stress = ( 3 x SP2 + BP2 ) ^ 0.5
= ( 3 x 3192.1922 + 48875.42 ) ^ 0.5
= 241.768473 Mpa < 306 Mpa OK
Stress Check in Guide Bar (In Non Seismic) (IRC 83 Part ( III ) Clause 926.3.5.5 )
Shear Stress (SS)= 82.37628 x 1000 = 14.20281 < 153 Mpa OK
290 x 20
Eccentricity = 1.5 + 2 + 6 = 11.00
Moment ( M ) = 82.37628 x 1000 X 11.00 = 906139.08 N-mm
Flexural Stress (FS)= M
Lx( H)2 /6
Flexural Stress (FS)= 906139.1 x 6 = 46.8693 < 204 Mpa OK
290 x 20 x 20
Equivalent Stress due to combined effect of Bendinq & Shear :- ( IRC 83 Part ( III ) Clause 926.3.1.1.7.4 )
IRC 83 Part ( III ) Clause 926.2.2.5 )
Equivalent Stress / Combined Stress = ( 3 x SS2 + FS2 ) ^ 0.5
= ( 3 x 201.71972 + 2196.728 ) ^ 0.5
= 52.9328533 Mpa < 306 Mpa OK
Stress Check in Guide Bar (In Seismic) (IRC 83 Part ( III ) Clause 926.3.5.5 )
Shear Stress (SS)= 158.103957 x 1000 = 27.2593 < 153 Mpa OK
290 x 20
Eccentricity = 1.5 + 2 + 6 = 11.00
Moment ( M ) = 158.103957 x 1000 x 11.00 = 1739143.525 N-mm
Flexural Stress (FS)= M
Lx( H)2 /6
Flexural Stress (FS)= 1739144 x 6 = 89.9557 < 204 Mpa OK
290 x 20 x 20
Equivalent Stress due to combined effect of Bendinq & Shear :- ( IRC 83 Part ( III ) Clause 926.3.1.1.7.4 )
IRC 83 Part ( III ) Clause 926.2.2.5 )
Equivalent Stress / Combined Stress = ( 3 x SS2 + FS2 ) ^ 0.5
= ( 3 x 743.06959 + 8092.028 ) ^ 0.5
= 101.593487 Mpa < 306 Mpa OK
Slide Plate Dimension used = 365 mm length x 346 mm wide ( IRC 83 Part ( III ) Clause 926.3.2.4 )
Effective Dia of Concrete at top = 364 mm dia.
Preset= = 0.00 mm
In order to satisfy the 330clause no 926.3.2.4, instead of PTFE effective dia of top plate is considered. 80 mm
Longitudinal Movement = 365 - 364 = 1 mm
M'ment possible in one direction = 1 + 0 = 0.5 mm >= 0 mm OK
2
M'ment possible in other direction = 1 + 0 = 0.5 mm >= 0 mm
Guides = 2
Inside Dimension of Slide Plate = 346 -( 20 + 20 )= 306 mm
Length of Piston = 306 -( 10 + 5 )= 291 mm
Design for the Anchoring Arrangement (Bolts & Dowels) for Fixing of Bearing
Total Tensile Force Resisted By the Bolt = 628 x 285 = 178.98 kN 628 x 285 = 178.98 kN
1000 1000
Non Seismic
Horizontal Force over the Dowels By Bolts 3 x 157 x 190 = 89490 N
Stress = 89490 = 11.18625 Mpa < 11.6667 Mpa OK
40 x 200
Seismic
Horizontal Force over the Dowels By Bolts 3 x 157 x 190 = 89490 N
Stress = 89490 = 11.18625 Mpa < 14.5833 Mpa OK
40 x 200
Non Seismic
Horizontal Force over the Dowels By Bolts 3 x 157 x 190 = 89490 N
Stress = 89490 = 11.18625 Mpa < 11.6667 Mpa OK
40 x 200
Seismic
Horizontal Force over the Dowels By Bolts 3 x 157 x 190 = 89490 N
Stress = 89490 = 11.18625 Mpa < 14.5833 Mpa OK
40 x 200
Stress on lug due to horizontal force= 20.59407 x 1000 = 30.64594 Mpa 39.526 x 1000 = 58.8184 Mpa
672 672
30.6459375 < 153 Mpa HENCE OK 58.8184 < 153 Mpa HENCE OK