BBR (INDIA) PVT LTD

Registered Office:
No.318, 15th Cross, 6th Main, Sadashivanagar,
Bangalore – 560 080
Tel:080 4025 0000 / Fax : 080 4025 0001 /
e-mail: bbrindia@vsnl.in

PROPOSED HIGH LEVEL BRIDGE ACROSS RIVER GODAVARI ON NH16 SECTION

PROJECT:
NIZAMABAD JAGADALPUR STATE ANDRAPRADESH

DrgNo: SAI/2203/-05-R2
Design Loadings : INPUT VALUES REV: Case:Sesimic
Type of Bearing Free Pot Bearing R0 D:29-10-2012

V-max. = max. vertical imposed load KN 5395.5 KN

V-min. = min. vertical imposed load KN 5003.1 KN

H-L (N) = Horizontal longitudinal load KN 0 KN

H-Q (N) = Horizontal Transverse load KN 0 KN

E-L = longitudinal displacements. + / -mm 5 21 mm

E-Q Transverse displacement 5 mm

Tan - phi = tilting angle ( Radians) 0.01 rad

H-For (N) = Horizontal force KN 539.55 KN

PAGE 26
 BBR (INDIA) PVT LTD
Registered Office:
No.318, 15th Cross, 6th Main, Sadashivanagar,
Bangalore – 560 080
Tel:080 4025 0000 / Fax : 080 4025 0001 /
e-mail: bbrindia@vsnl.in

PROPOSED HIGH LEVEL BRIDGE ACROSS RIVER GODAVARI ON NH16 SECTION NIZAMABAD
PROJECT:
JAGADALPUR STATE ANDRAPRADESH

DrgNo: SAI/2203/-05-R2
Type of Bearing Free Pot Bearing
Notation Unit Value
di mm 475 V max 5395.5 kN
he mm 32 Qnty 14 Nos
X1 mm 10 Bending moment calculation
X2 mm 19 BOTTOM
S mm 10 Pedestal Dia 1075 mm
X2 mm De 475 mm
bp mm 55 LDA - Initial 635 mm
hc mm 51 L1 80
DRA mm 585 W 17.037 N/mm2
D-B mm 635 BM 54518.4284 N-mm
TT mm 40 TT-Calculated 38.18
TB mm 91
DPC mm 505 IRC:83(part III)-
TT-Minimum 11.88
2002-CL-926.3.1.2
TU mm 15
TD mm 44 TT-Provided 40.00 mm
DT mm 475 tu 19
U mm 4.5 Soffit DIA 1075 mm
TG - Eff mm 33 Loaded Dia top 543 mm
DG mm 607 DT1 475 mm
DESIGN PARAMETERS

LS mm 514
BS mm 514 BG 543 mm
LG mm 607 L1 34
BG mm 607 W1 23.299 N/mm2
LG-Provided mm 607 543
BG-Provided mm 607 BM1 13466.9 N/mm
TS mm 3
DWA mm 635 TG-Calculated 23.07 mm
N nos 4
DB mm 16 IRC:83(part III)-
TG-Minimum 13.58
2002-CL-926.3.1.2
Ab mm² 158
DS mm 36 TG-Provided 30.00 mm
LS mm 90 Tg min - Eff 33.00 33
FB N / mm² 80
fck, sub st N / mm² 55 Check for Dispersion CL -926.3.1.6.1
fck, sup st N / mm² 55 Pedestal side
A1, B mm² 907626 De+4*TT 635 mm
A2, B mm² 316692
AA, B 1.69 1.69 Soffit of girder side
A1, T mm² 907626 DT+4(TG+TS) 607 mm
A2, T mm² 231574
AA, T 1.77 1.98 For calculation of anchor
LT mm 18 Sleeve dimensions Value
LG mm 60 fck ,sub st N / mm² 55
Steel Grade - PB - N /s qmm 340
Steel Grade - PC - N / sqmm 230
Steel Grade - SP - N / sqmm 230

PAGE 27
 BBR (INDIA) PVT LTD
Registered Office:
No.318, 15th Cross, 6th Main, Sadashivanagar,
Bangalore – 560 080
Tel:080 4025 0000 / Fax : 080 4025 0001 /
e-mail: bbrindia@vsnl.in

PROPOSED HIGH LEVEL BRIDGE ACROSS RIVER GODAVARI ON NH16

PROJECT:
SECTION NIZAMABAD JAGADALPUR STATE ANDRAPRADESH

DrgNo: SAI/2203/-05-R2
Type of Bearing Free Pot Bearing
Notation Unit Permissible value Calculated Value Checks
Elastomer
σce Centre N / mm² 35 30.45 Ok
σce1 edge N / mm² 40 37.85 Ok
Pot Bottom/Pot ocver Cast steel)
su N / mm² 570 146.83 Ok
σat N / mm² 204 178.67 Ok
σbt N / mm² 224.4 171.17 Ok
lvm N / mm² 153 48.69 Ok
σe N / mm² 306 190.82 Ok
σp,(Hertz) N / mm² 255 133.93 Ok
Sliding material PTFE
σptfe (Center) N / mm² 40 30.45 Ok
DESIGN CHECKS

sptfe (edge) N / mm² 45 37.95 Ok

Pier/Sub structure
s C, Bot N / mm² 22.69 3.86 Ok
s CC, Bot N / mm² 23.28 17.04 Ok
sComb, Bot N / mm² 1 0.902 Ok
Soffit /Super Structure
s C, Topt N / mm² 22.69 3.34 Ok
s CC, Top N / mm² 30.44 18.65 Ok
sComb, Top N / mm² 1 0.760 Ok
Anchor
SR-Friction kN 1001
SR-Perm kN 51
H resu kN 540 1051 Ok
BS - Con N / mm² 18.15 3.90
BS - P con N / mm² 18.15 11.69 Ok
S-NL N / mm² 153 124.90 Ok
TB-BM mm 91 0.00 Ok

PAGE 28
Type of Bearing : Free Pot Bearing
Data :
V-max. Maximum vertical imposed load 5395.5 KN Clause Ref
V - min. Minimum vertical imposed load 5003.1 KN
H-L Horizonatal longitudinal force 0 KN
H-Q Horizontal transverse force 0 KN
H-R Frictional force ( 0.05 * V - max.) 0 KN
E-L Longitudinal dispacement 21 mm
E-Q Transverse displacement 5 mm
TanØ Tilting angle ( radians) 0.01 rad
H Horizontal force 539.55 KN

Design of Elastomer :
sce Safe elastomer stress, centre 35 N/mm² 926.2.3.2.
Safe elastomer stress, edge 40 N/mm² 926.2.3.2.
di Elastomer diameter 475 mm
he Elastomer height 32 mm
sce1,cal Elastomer stress, centre
V.max x 4 5395.5 x 4 x 1000 30.45 N / mm²
di² x π 475 ² x π x Ok
Safety factor Alpha N - factor dependent on di 475 14.84 926.2.3.6
he 32
Strain in elastomer
di x tanØ <0.15 475 x 0.01 0.0742 926.2.3.4
he x 2 32 x 2 Ok
Restoring Moment 1.3 926.2.3.5
Induced moments M.ed= di³ x (k1 Up + k2 Uv) 926.1.5.1
Table
Up 0.01 x 0.8 x 1.3 = 0.0104 k1 and Kk2 as per table (1) di/he K1 K2
Uv 0.01 x 0.2 x 1.3 = 0.0026 (Intermediate values may be 15.0 2.2 101
obtained by linear interpolation) 14.84 2.175 98.34
k1 2.175 K2 98.3 12.5 1.8 58.5
10 1.5 30.5
475 ³ x( 0.02262 + 0.2557 29827406 Nmm
M.rd 0.2 x di / 2 x H 926.1.5.2
0.2 x 475 x 0.5 x 539550 25628625 Nmm

M-Sum M.ed + M.rd 29827406 + 25628625 55456031.4258 Nm 926.1.5.3

W-eatx π x di³ π x 475 ^3 10521574.2241 mm3

32 32

Moment due to horizontal loads = (HХ x a1 )/ W eat-x 2.13

Where a1 = [(X2/2)+he] 41.5

Uce2 cal Elastomer stress due to Rotation and Horizontal force

M-Sum 55456031.43 5.27 N/mm² Ok
W-eatx 10521574.22
Total stress on elastomer
Uce1,cal + Uce2 cal 30.45 + 7.40 37.85 N/mm² Ok

Min. Average stress in Elastomer 5.00 926.2.3.3

V.min x 4 ### x 4 x 1000 28.23 N / mm²
di² x π 475 ²x π Ok

PAGE 29
Pressure between Ring and Cover SIG - P
Uu (ultimate tensile strength of the steel material of piston / cylinder) ### N/mm²
Up( safe steel stress ) N /mm ² ### N/mm²
Parabolic load distribution factor = 1.50 926.3.1.1.7.2
X1 1.5 x di x tanØ + 6 1.5 x ### x 0.010 + 6 10 mm
2 2
X1 (adopted ) mm 10 mm
X 2 = di / 2 x tanØ+ 16 475 x 0.01 + 16 18.375 mm
2
X - 2 ( adopted ) mm 19 mm
Up Permissible bearing stress of steel( 0.75*fy) ### N/mm²
s = ( 1.3 x H / (dp x Up ) 1.3 x 539.6 x 1000 8.58 mm
474 x ###

dp Diameter of pistion =di-1 474 mm

dc Diameter of cylinder ### mm
Up,cal 1.3 x H /dp x s 1.3x 539.55 x 10³ 146.83 N/mm² ok
474 x 10
Curved contact surface between Piston and cylinder shall be designed 926.3.1.3.2
We Effective contact width of contact surface in 15mm

s ( adopted min.value 5.00 mm) In case s >15 ,then recalculate S and X - 2 10 mm

Hoop tensile stress in the cross section of the cylinder wall due to 926.3.1.1.7.1
Uat1 Fluid pressure (di x he x Uce)/(2x bp xhc)

at2 Horizontal force H/(2x bp xhc)

Uat = Permissible stress in axial tension ( 0.6 x fy ) ### N/mm² 926.2.2.1
Uat, cal = Tensional stress in ring Uat1+Uat2
bp = Thickness of cylinder wall 55 mm
hc = height of cylinder wall he + x2 32 + 19 51.00 mm
Shear stress in ring from horizontal forces.
lvm Permissible steel shear stress in steel ### N/mm² 926.2.2.3

Uat1 Fluid pressure di x he xUce 475 x 32 x 30.45 82.50 N/mm²

2x bp xhc 2 x 55 x 51

Uat2 Horizontal force H 540 x 1000 96.18 N/mm²

2x bp xhc 2 x 55 x 51

Uat, cal = Uat1 + Uat2 82.50 + 96.18 178.67

Ok
The effect of the HERTZ Stress at the mating interface shall be calculated using following
0.6 x √[{(H x Es/We x dc)} x ( 1-dn/dc)]

sp( Hertz Stress) allowable 0.75 x fy ### N/mm² 926.3.32.2.1

0.6 x √[ 539550 x 210000 x ( 1 - 474 )

10 x 475 475

0.6 √( 23668169.54 x 0.0021 ) 133.93 N/mm²

Ok
sp( Hertz Stress) allowable > sp( Hertz Stress) cal

PAGE 30
Ring turned completely : 926.3.1.1.7.2
Shear Stress at Cylinder wall and base interface calculated considering 1mm radial Slice of cylinder due to

1 Uvm1, Fluid pressure he x Uce 32 x 30.45 17.715 N/mm2

bp 55

2 Uvm2 Horizontal force 1.5 x H 1.5 x 539550 30.979 N/mm2

di x bp ### x 55

Uvm , Permissible shear stress of (0.45*fy) 153 N/mm2 926.2.2.3

Uvm total Uvm1 + Uvm2 17.715 + 30.979 48.694

Ok

Bending stress at cylinder and base interface calculated 926.3.1.1.7.3

considering 1mm radial sice of the cylinder due to
1 Fluid pressure,Ubt1
6 x Uce x he² 6 x 30.45 x 32 ² 30.921 N/mm2
2 x bp² 2 x 55 ²

2 Horizontal force Ubt2 1.5 x 6 x H x ha

di x bp²
ha= Height of application of design horizontal force from cylinder wall above base interface.

he + X2 32 + 19 41.5 mm
2 2

1.5 x 6 x 539550 x 41.5 140.250 N/mm2

### x 55 ^2
Ubt, Permissible bending stress (0.66*fy) ### N/mm2

Ubt,cal Ubt1+Ubt2 30.921 + 140.250 171.171 N/mm2

Ue permissible equivalent stress in steel =0.9 xfy) ### N/mm2 926.2.2.5

Ue , combined stress √(Ubt² + 3 x Uvm²)

Ue ,cal. = combined stress √( 171.171 ²+ 3 x 48.69 ²) 190.82 N/mm²

Hence , (Uecal<Ue ) N mm ² Ok

Pot Bottom
Thickness of base plate ( TT ) of the pot must be atleast 2.5% of piston diameter and in any
case shall not be less than 12 mm.
T T = ( thickness of base plate ) = di * 2.5% 11.88 mm
Adopted value of TT mm ( if T T is < 12 mm adopt 12 mm ) 40 mm
TB =(thickness of pot bottom) T T + he + X2
40.00 + 32 + 19 91 mm

POT COVER :
TU Flange thickness of cover 15 mm
TD Thickness of cover (TU+X1+x2) 15 + 10 + 19 44 mm
TD min TD-2.5 41.5 42 mm

PAGE 31
Stressing in Sliding Material: ( PTFE sheet )
Thickness of PTFE sheet mm 4.5 mm
DT =Diameter of sliding material 475 mm
sptfe =safe sliding material stress At centre 40 N/mm² clause Ref
At edge 45 N/mm² 926.2.4.3
FT = area of sliding material DT2 X π 475 ²x π 177206 mm ²
4 4

WT =resistance moment DT³ x π 475 ³ x π 10521598.83 mm3

32 32
Uptf =total stressing in sliding material
1 V-MAX 5396 x 1000 30.45 N/mm²
FT 177205.875

2 TD - X2 We 4.5 x H 44 - 10 + 4.5 x 539550 2.23 N/mm²

2 WT 2 10521598.828

3=Stress due to Rotational effect on ptfe sheet

MSUM 55456031.4 5.27 N/mm²
WT 10521598.8
Hence,sptfe=(1+2+3) N/mm² 30.45 + 2.23 + 5.27 37.95 N/mm²
Hence , UptCal < UptfeN/mm² OK

LS = length of stainless plate 475 + 2 x 21 x 1.3 + 10 513.8 mm

BS = breadth of stainless plate 475 + 2 x 5 x 1.3 + 10 513.8 mm
TS=Thickness of steel plate 3 mm

Concrete Pressure Abutment side / Support side

LDA = Final value 475 + 4 x 40 635 mm

WAT =resistance moment LDA³ x π 635 ³x π 25137441.3 mm3

32 32
scc, cal = Calculated direct compressive stress
1 Vmax x 4 5395500 x 4 17.04 N/mm²
LDA² xπ 635  ³x π
Uc, cal = Calculated compressive flexural stress
2 TT + he + We x H
2 WAT
40 + 32 + 10 x 539550 1.65 N/mm²
2 25137441.35
Stresses on concrete due to due to rotation.
3 MSum 55456031.43 2.21 N/mm²
WAT 25137441.35
Grade of concrete M 55 N /mm² clause Ref
Uco = 0.25 * fck 13.75 N/mm² 926.2.1.1
Ucc=Average Permissible direct bearing pressure in concrete .
PD = Pedestal Diameter 1075 mm
A1 = Dispersed concentric area = ( PD^2 x π ) / 4 907625.75 mm²
A2 = Loaded area =( LDA² x π) /4 316692.17 mm²
Ucc=sco√ (A1 / A2) <= 2 1.69
Calculate concrete stress for Ok
Uc = Allowable compressive flexural stress in concrete
Uc = 0.33 x fck (Permissible compressive flexural stress in cponcrete) 22.69 N/mm² 926.2.1.2
Ucc = 0.25 x fck x sqrt (A1 / A2) ( Allow direct bearing stress) 23.28 N/mm²
Ucc, cal = 1 17.04 N/mm²
U c, cal = 2 + 3 1.65 + 2.21 3.86 N/mm²

PAGE 32
Ucc, cal /Ucc + Uc, cal / s c <= 1 17.04 + 3.86 0.90 926.2.1.3
23.28 22.6875 OK
Concrete Pressure. Bridge Underside:
LG = length of sliding plate. 607 mm
BGminimum = breadth of sliding plate. 607 mm
Effective size of sliding plate DT+4x(TS+TG) 475 + 4 x( 3+ 30 ) 607 mm
W AT = resistance moment. (π x BG)/32 π x 607  21956696 mm3
32
Ucc, cal = Calculated direct compressive stress
1 Vmax x 4 5395.5 x 10³ x 4 18.65 N/mm²
B G x π 607 x π
Uc, cal = Calculated compressive flexural stress
2 ( TG+TS) x (H ) /W AT
Lever arm - a1 TG+TS 30 + 3
33.0 mm
33 x 540 x 10³ 0.81 N/mm²
21956695.709
Stresses on concrete due to due to rotation.
3 = MSum / WAT 55456031.42578 2.53 N/mm²
21956695.70903
Grade of concrete M 55
s Co = 0.25 x fck 13.75 N/mm²
PD = Pedestal size - contact area on the soffit of bridge, reqd min 1075 mm
A1 = Dispersed concentric area = PD^2 907974.56 mm²
A2 = Loaded area = DG Dia DG² x π /4 289490.38 mm²
√ (A1 / A2) <= 2 1.77 Ok
Calculate for stresses
U c = 0.33 x fck (all comp flexural stress) 22.69 N/mm²
U cc = 0.25 x fck x √(A1 / A2) ( Allow average direct compressive stress in concrete) 30.44 N/mm²
Ucc, cal = 1 18.65 N/mm²
U c, cal = 2 + 3 2.53 + 0.81 3.34 N/mm²
s cc, cal/U cc + Uc, cal / U c <= 1 0.76
18.65 + 3.34 Ok
30.44 22.6875
Anchor Bolts
The total resistive force against shifting of the bearing, Due to friction
H perm 1 = min of ( u x Nmin )
where - u 0.20 coeff of friction between steel & concrete Min vertical load -

Hperm 1 0.2 x 5003 1000.6 kN

Considered H perm 1 1001 kN
Due to shear resistance of bolts, H perm 2 = ( n x Ab x, permis stress) / 1000
n = no of bolts : Grade of bolts - 10.90 4 nos
Dia of bolt 16 mm
Ab = effective area of bolts 158 mm²
Perm stress 4.6 Gr 80
8.8 Gr 191
10.9 Gr 238
H perm 2 51 kN
H perm = H perm1 + H perm 2 51 + 1001 1051 kN

PAGE 33
Anchor Sleeve Ok
L - length of sleeve 90 mm
D - Dia of the sleeve 36 mm
Average bearing stress in concrete, s cav = (Ab x perm stress) / (L x D) 3.90 N/mm²
Considering triangular distribution, bearing stress in concrete,
sctr = 2.0 x s - cav 7.79 N/mm²
Considering incremental factor, Up = 1.50 , peak stress,
speak = 1.50 x s - ctr 11.69 N/mm²
s peak < 0.330 x fck Grade of concrete on superstructure M 55 22.69 N/mm²
Lugs
Lugs
Thickness of lug - LT 18 mm
Length of lug - LG 60 mm
Effective area of lug ,Eal 60 x 18 1080 mm²
Horizontal force on each lug , S-NL = H or H res / No of bolts
540 / 4 134.89 kN
124.90 N/mm²
134.89 x 1000 ok
1080

PAGE 34