Shutter Design

1 OF 28 HINDUSTAN CONSTRUCTION CO. LTD. MUMBAI. Subject : 10.5 M RCC SOLID SLAB IN LAND SPAN Details : Design of Formwork & Staging for Superstructure

SH. NO.

EW-II ( RJ - 7 )

REV.

BRIDGE NO : 295.740

DATE BY

PREAMBLE:

For constructing 10.5 m span RCC Solid Slab H- frames are proposed below the soffit of Solid Slab In this document the design of Formwork & Staging of H-frames & its supporting components is done.

REFERENCE DRGS : 1 ) HCC :

EW/34/FS-19

RCC SOLID SLAB GIRDER -10.5 M SPAN , G.A OF FORMWORK & STAGING OF BRIDGE @ 295.740

2 ) DEPT : NHAI/EW-II/RJ-7/NH76/BR-14/R-2

G.A OF BRIDGE AT CH 295.740

REFERENCE CODES : 1 ) IS - 800-1984 2) IS - 2062-1992 3) IS - 808-1989

4) IS - 806-1968

CODE OF PRACTICE FOR GENERAL CONSTRUCTION IN STEEL STEEL FOR GENERAL STRUCTURE PURPOSE- SPECIFICATION DIMENSIONS FOR HOT ROLLED STEEL BEAM, COLUMN, CHANNEL AND ANGLE SECTIONS USE OF STEEL TUBES IN GENERAL BUILDING CONSTRUCTION.

The General Arrangement of Formwork & Staging with H-frame in the cross section is as shown below.

WOODEN SLEEPER

HCC F 01 11 02 R - 0


SH. NO.

EW-II ( RJ - 7 )

REV.

BRIDGE NO : 295.740

DATE BY

DESIGN OF FORM PANELS BELOW CANTILEVER DECK SLAB :

Load Calculation : Thickness of Slab = Weight of Slab Live load on Formwork = Wt of Formwork =

1800 4.68 0.1 0.1 4.88

1.8 x 2.6 =

Total Load =

mm T/m2 2 T/m 2 T/m T/m2

( Max thk is Considered )

C.L. of support 12mm Skin Plate

Angle Stiffner 2440

C.L. of support 1210 PLAN

DESIGN OF SKIN PLATE : CHECK FOR BENDING :

Width of plate Length of plate Thk of plate=

1210 mm 1800 mm 12 mm 2

540.000 m3 324.000 m4

Z=1/6*b*d = I =Z *(d /2 ) = Use 4'x3' runner as a stiffner. C/C spacing of Stiffner Clear Span = ( 250-45/2 ) Max B.M = w * L2 / 8

312 mm 1700 mm 1.7629 T-m/m

σ=M/Z=

544 Kg/Cm2

<

650.1 Kg/Cm2

CHECK FOR DEFLECTION :

w= L=

48.8 KN/m/m 1700 mm

E= I=

2.0E+05 N/mm2 3240000.00 mm4/m

Actual deflection = 2.5wL4 / 384 E I 4.095 mm

HCC F 01 11 02 R - 0

5.23076923

SAFE


SH. NO.

EW-II ( RJ - 7 )

REV.

BRIDGE NO : 295.740

DATE BY

DESIGN OF COMBINED SECTION OF FORM PANELS FOR CANTILEVER DECK SLAB :

Size of Batten ISMC 100x50x5 Thickness of Flange Plate = Overhang of Flange Plate = 16 * thk of plate Depth of Angle Section = Width of Angle Section = Thk of Angle Section = Area of Angle Section = IXX of Angle Section = IYY of Angle Section = Cxx of Angle Section = Cyy of Angle Section =

Size of Angle : 0 0 100 50 5 1170 1867000 259000 39.95 14.88

mm mm mm mm mm 2 mm 4 mm 4 mm mm mm

Properties of Combined Section :

Reference Point "O" Ixx = Ymax = Zxx Bot= Zxx Top= rmin =

4 1866999.97 mm 14.88 mm 3 37340.00 mm mm3

Iyy = Xmax = Zyy =

4 259000.00 mm 39.95 mm 3 7463.98 mm

14.88 mm T/m2 m T/ m T/ m

Total Load on Formwork = C/C spacing of Stiffner = Total Load = say ~

4.88 0.25 1.22 0.34

C/C Span of Cross Member =

1.25 m

CHECK FOR BENDING :

Max B.M = w * L2 / 8 Zxx Top= σ bc= M / Z xx =

0.066 T-M 37.34 cm3 178 Kg/cm2

( 0.34 x 1.25 x 1.25 /8 ) <


w= 0.34 T/m L= 1.25 m Actual deflection = 5 wL4 / 384 E I

2 2.0E+05 N/mm 4 mm 1867000

E= I= 0.289 mm

3.7230769

DESIGN OF CROSS MEMBER BELOW DECK SLAB ( CANTILEVER PORTION ):

Load Calculation : Thickness of Slab = Weight of Slab = Live load on Formwork = Wt of Formwork =

0.35 x 2.6 =

Total Load = C / C Spacing of Cross Member = Load /m run = 1.37 x 1.25 = say ~

350 0.91 0.36 0.1

mm T/ m2 T/ m2 T/ m2

1.37 1250 1.713 1.8

T/ m2 mm T/ m T/ m 1.8 T/m

HCC F 01 11 02 R - 0

1650 Kg/cm2

SAFE


SH. NO.

EW-II ( RJ - 7 )

REV.

BRIDGE NO : 295.740

DATE BY

Cross Member 0.325

1.25

0.325

Max B.M = Max S.F = Max Deflection =

0.257 T-m 1.125 T 1.23 mm

Properties of Cross Member :

( REFER BEAMAX RESULT )

2ISMC 100

Ixx = rxx =

18.2 cm2 157 cm4 2.94 cm

Iyy = ryy =

41.9 cm3 58 cm4 1.79 cm

tw =

4.8 mm

Aw =

720 mm2

A=

Zxx =

CHECK FOR BENDING :

1250 mm

L / rmin

70

17.9 mm 75 mm 7.5 mm

D/T=

10

Corresponding Value of Stress :

2 153 N/mm

L= rmin = D= T=

Max B.M = Zxx = σ = M / Zxx =

(CLAUSE 6.2.3 IS : 800 -1984 )

0.257 T-M 3 41.9 cm 613 Kg/Cm2

<

1.125 T 2 7.2 cm 156 Kg/Cm2

<

1530 Kg/Cm2

SAFE

CHECK FOR SHEAR :

Max Shear = V = Aw = V / Aw =


Actual deflection =

HCC F 01 11 02 R - 0

1.23 mm

1000 Kg/Cm2 SAFE (CLAUSE 6.4.2.a IS : 800 - 1984 )


SH. NO.

EW-II ( RJ - 7 )

REV.

BRIDGE NO : 295.740

DATE BY

LONG MEMBER IN CANTILEVER DECK SLAB LVL :

As Cross member below the Cantilever Span , span about 1250 c/c , These Cross members are supported on Long Members which are placed on H-frame at 1.00m C/C Pont Loads from Cross Member =

1.8 T

( 1.125 +0.585 = 1.7 T )

1.250 Typ

1.00

1.00

Max B.M = wl/4 = Max S.F = Max Deflection =

Ixx = rxx = tw =

1.00

0.45 T-M 1.6 T 0.4 mm

Properties of Long Member : A=

1.00

1.00

( REFER BEAMAX CALCULATION )

2ISMC 75 X 40 Zxx =

18.2 cm2 157 cm4 2.94 cm 4.8 mm

Iyy = ryy = Aw =

41.8 cm3 57.5 cm4 1.777 cm 720 mm2

CHECK FOR BENDING : 1000 mm

L / rmin

56.26

17.77 mm 75 mm 7.5 mm

D/T=

10.00


2 157 N/mm

L= rmin = D= T=

(CLAUSE 6.2.3 IS : 800 -1984 )

Max B.M = Zxx =

0.45 T-M 3 41.8 cm

σ = M / Zxx =

1077 Kg/Cm2

<

1570 Kg/Cm2

1.6 T 2 7.2 cm 222 Kg/Cm2

<

1000 Kg/Cm2

SAFE

CHECK FOR SHEAR :


HCC F 01 11 02 R - 0

SAFE (CLAUSE 6.4.2.a IS : 800 - 1984 )


SH. NO.

EW-II ( RJ - 7 )

REV.

BRIDGE NO : 295.740

DATE BY


Actual deflection =

0.40 mm

DESIGN OF H-FRAME BELOW CANTILEVER DECK SLAB :

Max. Load on one Leg of H-frame = P =

( 1.254 + 0.54 = 1.79 T )

1.8 T

Properties of 40 NB (M) Pipe : ( Table 1 of IS 1161:1998 ) A= L= rmin =

2

4.53 cm 1500 mm 1.6 cm


L / rmin

845 Kg/Cm2

Axial Capacity of 40NB ( M ) Pipe section = P = P = A * σac =

93.75

=

( Table 2 of IS : 806 )

3.83 T

DESIGN OF FORM PANELS BELOW GIRDER SOFFIT:

Load Calculation : Thickness of Slab = Weight of Slab Live load on Formwork = Wt of Formwork =

0.85 x 2.6 =

Total Load =

850 2.21 0.36 0.10 2.67

mm T/m2 T/m2 T/m2 T/m2


HCC F 01 11 02 R - 0

>

1.8

SAFE


SH. NO.

EW-II ( RJ - 7 )

REV.

BRIDGE NO : 295.740

DATE BY

625 Angle Stiffner 1250

C.L. of support

625




500 mm 1250 mm 4 mm

Z = 1 / 6 * b * d2 = I =Z *(d /2 ) =

2.667 cm3/m 0.533 cm4/m

Use ISA 75 X 75 X 6 as a stiffner. C/C spacing of Stiffner Clear Span = ( 250-75/2 ) 2

250 mm 213 mm 0.012 T-m/m

Max B.M = w * L / 10 σ=M/Z=

452 Kg/Cm2

<

1650 Kg/Cm2


w= L=

26.7 KN/m/m 212.5 mm

E= I=

2.0E+05 N/mm2 5333.33 mm4/m

Actual deflection = 2.5wL / 384 E I 4

0.332 mm

DESIGN OF COMBINED SECTION OF FORM PANELS FOR GIRDER SOFFIT :

Thickness of Flange Plate = Overhang of Flange Plate = 16 * thk of plate Depth of Angle Section = Width of Angle Section = Thk of Angle Section = Area of Angle Section = IXX of Angle Section = IYY of Angle Section = Cxx of Angle Section =

HCC F 01 11 02 R - 0

Size of Angle : ISA75X75X6 4 mm 64 mm 75 mm 75 mm 6 mm 2 866 mm 4 457000 mm 4 457000 mm 20.6 mm

SAFE


SH. NO.

EW-II ( RJ - 7 )

REV.

BRIDGE NO : 295.740

DATE BY

Cyy of Angle Section =

20.6 mm

Properties w.r.to. "O" MEMBER

Ixx

WIDTH

DEPTH

THK

AREA=A

X

Y

AX

mm

mm

mm

mm2

mm

mm

mm

mm

mm

4 75

6

536 866

67 84.6

77.00 20.6

35912.00 73263.6

41272 17839.6

714.67 457000

PLATE 134 X 4 134 ANGLE 75 X 75 X 6 75

1402

TOTAL

109176

77.87 56.13 42.16 36.84

3

4

59112

134

Position of C.G from "O"

X1 = X2 = Y1 = Y2 =

AY 3

mm mm mm mm

(from left ) (from right) (from bottom) (from Top)

64

Properties of Combined Section :

Reference Point "O" Ixx = Ymax = Zxx Bot= Zxx Top= rmin =

1510871 42.16 35835 41014 31.16

4

Iyy = Xmax = Zyy =

mm mm mm3 3 mm

4

mm 77.87 mm 3 17485 mm

1361590.41

mm

Total Load on Formwork = C/C spacing of Stiffner = Total Load = say ~

2.67 0.25 0.67 0.7

C/C Span of Cross Member =

T/m2 m T/ m T/ m

0.625 m

CHECK FOR BENDING :

Max B.M = w * L2 / 10 Zxx Top= σ bc= M / Z xx =

0.027 T-M 35.83 cm3 76 Kg/cm2

( 0.7 x 0.625 x 0.625 /10 ) <

1650 Kg/cm2

SAFE


w= 0.7 T/m L= 0.625 m Actual deflection = 2.5 wL4 / 384 E I

E= I=

2 2.0E+05 N/mm 4 1510871 mm

0.023 mm

DESIGN OF CROSS MEMBER BELOW SOFFIT SLAB :

Cross member for Cantilever Deck Slab are placed at 1250 c/c, whereas,Cross member for Girder Soffit slab are placed at 625 c/c, Loading on Cross Member From Central Solid Slab :

Thickness of Solid Slab = Weight of Slab = Live load on Formwork = Wt of Formwork =

0.85 x 2.6 =

Total Load = C / C Spacing of Cross Member = ( width ) Load /m run =

HCC F 01 11 02 R - 0

850 2.21 0.36 0.1


2.67 T/ m2 625 mm 1.669 T/ m


SH. NO.

EW-II ( RJ - 7 )

REV.

BRIDGE NO : 295.740

DATE BY

1.70 T/ m

say ~

GIRDER SOFFIT

0.35

1.25

1.0

1.25

1.0

2

Max B.M = wl /8 = Max S.F = Max Deflection =

0.33 T-m 1.14 T 0.75 mm

Properties of Cross Member : A= Ixx = rxx = tw =

1.25

FROM BEAMMAX

2ISMC 75 X 40 Zxx =

18.2 cm2 157 cm4 2.94 cm 4.8 mm

Iyy = ryy = Aw =

41.8 cm3 57.5 cm4 1.777 cm 720 mm2

CHECK FOR BENDING : L= rmin =

1250 mm 17.77 mm

L / rmin

70.33

D= T=

75 mm 7.5 mm

D/T=

10.00


2 151 N/mm


(CLAUSE 6.2.3 IS : 800 -1984 )

0.33 T-m 3 41.8 cm 789 Kg/Cm2

<

1510 N/mm2

SAFE

1.14 T 7.2 cm2 158 Kg/Cm2

<

1000 Kg/Cm2

SAFE

CHECK FOR SHEAR : Max Shear = V = Aw = V / Aw =

(CLAUSE 6.4.2.a IS : 800 - 1984 )

CHECK FOR DEFLECTION : Actual deflection =

HCC F 01 11 02 R - 0

0.75 mm

SAFE

0.35


SH. NO.

EW-II ( RJ - 7 )

REV.

BRIDGE NO : 295.740

DATE BY

LONG MEMBER IN CENTRAL PORTION OF GIRDER AT SOFFIT LVL :

As Cross member below the Girder soffit, span at 0.625m c/c , These Cross members are supported on Long Members which are placed on H-frame at 1.25m C/C Pont Loads from Cross Member =

2.1 T

( 1.14 +0.87 = 2.0 T )

0.625 Typ

1.00

1.00

1.00

Max B.M = wl/4 = Max S.F = Max Deflection =

1.00

0.525 T-M 2.5 T 0.23 mm

Properties of Cross Member :

1.00

( REFER BEAMAX CALCULATION )

2ISMC 100X50

Ixx = rxx =

24.4 cm2 384 cm4 3.97 cm

Iyy = ryy =

76.8 cm3 111 cm4 2.13 cm

tw =

5 mm

Aw =

1000 mm2

A=

Zxx =

CHECK FOR BENDING : 1250 mm

L / rmin

58.61

21.33 mm 100 mm 7.7 mm

D/T=

12.99


2 154 N/mm

L= rmin = D= T=


(CLAUSE 6.2.3 IS : 800 -1984 )

0.525 T-M 3 76.8 cm 684 Kg/Cm2

<

2.5 T 2 10 cm 250 Kg/Cm2

<

1540 Kg/Cm2

SAFE

CHECK FOR SHEAR :



Actual deflection =

HCC F 01 11 02 R - 0

0.23 mm

1000 Kg/Cm2 SAFE (CLAUSE 6.4.2.a IS : 800 - 1984 )


SH. NO.

EW-II ( RJ - 7 )

REV.

BRIDGE NO : 295.740

DATE BY

DESIGN OF H-FRAME BELOW GIRDER SOFFIT :

Max. Load on one Leg of Prop = P =

(1.95+ 1.70= 3.7 T )

3.8 T

Properties of 50 NB (M) Pipe : ( Table 1 of IS 1161:1998 ) A= L= rmin =

2

6.41 cm 1500 mm 2.02 cm


L / rmin

950 Kg/Cm2

Axial Capacity of 50NB ( M ) Pipe section = P = P = A * σac = X

HCC F 01 11 02 R - 0

74.26

=

( Table 2 of IS : 806 )

6.09 T

>

3.8

SAFE

12 OF 28 SH. NO. R0 11.05.12 NITESH REF

HCC F 01 11 02 R - 0


HCC F 01 11 02 R - 0


HCC F 01 11 02 R - 0


HCC F 01 11 02 R - 0


HCC F 01 11 02 R - 0


HCC F 01 11 02 R - 0


HCC F 01 11 02 R - 0


Iyy 4

mm

802035 457000

ced at 625 c/c,

HCC F 01 11 02 R - 0


HCC F 01 11 02 R - 0


HCC F 01 11 02 R - 0


HCC F 01 11 02 R - 0

DESIGN OF FORM PANELS BELOW CANTILEVER DECK SLAB :

Load Calculation : Thickness of Slab = Weight of Slab Live load on Formwork = Wt of Formwork = Total Load =

1800 4.68 0.1 0.1 4.88

1.8 x 2.6 =

mm T/m2 T/m2 T/m2 T/m2

( Max thk is Considered )


Angle Stiffner 1800




1210 mm 1800 mm 12 mm

Z = 1 / 6 * b * d2 = I =Z *(t /2 ) =

540.000 m3 324.000 m4

Use 4'x3' runner as a Batten C/C spacing of Stiffner Clear Span = ( 1800-100 ) Max B.M = w * L2 / 8

312 mm 1700 mm 1.7629 T-m/m

σ=M/I=

544 Kg/Cm2

650 Kg/Cm2


w= L=

27 KN/m/m 1700 mm

E= I=

Actual deflection = 5wL4 / 384 E I 4.531 mm

200000 N/mm2 3240000.00 mm4/m Allowable deflection = L / 325 <

5.54

Load Calculation : Thickness of Slab = Weight of Slab = Live load on Formwork = Wt of Formwork =

1.8 x 2.6 =

Total Load = C / C Spacing of Cross Member = Load /m run = 5.14 x 0.6 = say ~

1800 4.68 0.36 0.1


5.14 600 3.084 3.1

T/ m2 mm T/ m T/ m 1.8 T/m Cross Member

0.325

Max B.M = Max S.F = Max Deflection =

Ixx = rxx = tw =

0.325

0.465 T-m 2.79 T 5.538462 mm

Properties of Cross Member : A=

1.25

( REFER BEAMAX RESULT )

ISMC 100

11.7 cm2 157 cm4 3.66 cm 4.8 mm

Zxx = Iyy = ryy = Aw =

41.9 cm3 58 cm4 2.23 cm 720 mm2

CHECK FOR BENDING :

1800 mm

L / rmin

81

22.3 mm 100 mm 8 mm

D/T=

12.5


2 165 N/mm

L= rmin = D= T=

(CLAUSE 6.2.3 IS : 800 -1984 )

Max B.M = Zxx =

0.465 T-M 3 41.9 cm

σ = M / Zxx =

1110 Kg/Cm2

<

1650 Kg/Cm2

2.79 T 2 7.2 cm 388 Kg/Cm2

<

1000

CHECK FOR SHEAR :


Kg/Cm2

(CLAUSE 6.4.2.a IS : 800 - 1984 ) CHECK FOR DEFLECTION :

Actual deflection = 5wL4 / 384 E I 0.634 mm

Allowable deflection = L / 325 <

5.54

x thk is Considered )

SAFE

SAFE

Cross Member

ER BEAMAX RESULT )

USE 6.2.3 IS : 800 -1984 )

SAFE

SAFE USE 6.4.2.a IS : 800 - 1984 )

SAFE

Shutter Design

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