Construction of Grade Separator at 4+225, 9+350 VUP at 6+930, including of

Crash Barrier, Friction Slab (At Approaches) & Drain Work from Km 0+000 to
KM10+000 of Rupnager-Phagwara Road Project (Four laning of Phagwara -
Rupnager Section of NH - 344 from Km. 00.000 (design Chainage) to Km. 80.820
(Design Chainage), in the state of Punjab)

DESIGN OF CRIB STAGING FOR 40 M CAST IN SITU PSC GIRDER AND

SHUTTERING

INTRODUCTION

This Design Document presents the calculation for staging arrangement for the
continuous units.
The staging arrangement for this bridge comprises crib scaffolding.

DESIGN PARAMETERS

Weight of concrete = 2600 Kg/m3

Construction Superimposed Load = 360 Kg/m3
Weight of shuttering plates = 50 Kg/m2

Height of PSC Girder = 2.5 m

STAGING ARRANGEMENT

Let
Max Spacing of Cribs in Longitudinal Direction = 2.000 m
Max Spacing of Cribs in Transverse Direction = 1.730 m
Spacing of Secondary Runner = 1.200 m
Max Spacing of Primary Runner = 2.000 m

DESIGN OF SECONDARY RUNNER

Secondary Runner

1951 kg/m

2.000 m 2.000 m0
Primary Runner over Crib

Reaction from Girder on Secondary Runner = 1681.22 kg/m

Using ISMB 150 as Secondary Runner,
Self Weight of Secondary Runner = 14.9 kg/m
Total Load on Secondary Runner = 1696.12 kg/m
Add 15% extra for unforeseen loads.
Gross Load on Secondary Runner = 1951 kg/m
Continuous Span of Secondary Runner = 2.00 m
Bending Moment at Support = 780.4 kgm
Bending Moment at Span = 780.4 kgm
Max Shear Force = 1687.615 kg

Section Properties of ISMB 150 are:

2
Area = 19 cm rxx = 6.18 cm
Weight per unit length = 14.9 kg/m ryy = 1.66 cm
3
Depth of section, D = 150 mm Zxx = 96.9 cm
3
Width of Flange, B = 80 mm Zyy = 13.1 cm
4
Thickness of flange, T = 7.6 mm Ixx= 726.4 cm
Thickness of web, t = 4.8 mm

Check for Stresses:

Yield Stress fy = 250 MPa

As per Table G.2 of IRC:24,
Allowable bending tension = 0.62*250= = 155 MPa
1
Actual bending tension = M/Zxx = 80.53 MPa
OK
l= 200 cm
l /r min = 120.48 Say 130
D/T = 19.7 Say 20
d1/t = 28.1 < 85
T/t = 1.58 <=2
From Tables G.6, G.7 and G.8 of IRC:24,
k1 = 1 k2 = 0.50 c2/c1 = 1
X= 251 Y= 135
Therefore,
f cb = 318.5
From Table G.5 of IRC:24,
Allowable bending compression = 111 MPa
Increasing it by 20% as per Cl G4.6.2.1,
Permissible Bending Stress = 133 MPa
Actual bending compression = M/Zxx 80.53 MPa
OK
As per Table G.2 of IRC:24,
Allowable average shear stress = 0.38*fy= 95 MPa
Actual average shear stress = V/Dt 23.43 MPa
OK

Calculation of Deflection:
Permissible Deflection l /600 3.33 mm
4
Actual deflection= 5wl 2.9 mm
384 EI OK

Hence provide ISMB 150 as secondary runner for middle 5.8 portion

DESIGN OF PRIMARY RUNNER

Primary Runner
W W W W

1.730 m 1.730 m
Transverse Crib
W= 1543.5 kg

Reaction from Secondary Runner at one third points = 1543.5 kg/m

Using ISMB 200 as Primary Runner,
Self Weight of Primary Runner = 25.4 kg/m
Continuous Span of Secondary Runner = 1.730 m
Bending Moment at Support = 971.21 kgm
Bending Moment at Span = 973.62 kgm
Max Reaction on Crib = 3134.63 kg
Max Shear Force = 3134.63 kg

Section Properties of ISMB 200 are:

2
Area = 32.33 cm rxx = 8.32 cm
Weight per unit length = 25.4 kg/m ryy = 2.15 cm
3
Depth of section, D = 200 mm Zxx = 223.5 cm

2
 3
Width of Flange, B = 100 mm Zyy = 30 cm
4
Thickness of flange, T = 10.8 mm Ixx= 2235.4 cm
Thickness of web, t = 5.7 mm
Check for Stresses:

Yield Stress fy = 250 MPa

As per Table G.2 of IRC:24,
Allowable bending tension = 0.62*250= = 155 MPa
Actual bending tension = M/Zxx = 43.56 MPa
OK
l= 200 cm
l /r min = 93.02 Say 95
D/T = 200/10.8= 18.5 Say 20
d1/t = (200-2*10.8)/5.7= 31.3 <= 85
T/t = 10.8/5.7= 1.89 <=2
From Tables G.6, G.7 and G.8 of IRC:24,
k1 = 1 k2 = 0.50 c2/c1 = 1
X= 464 Y= 327
Therefore,
f cb = 627.5
From Table G.5 of IRC:24,
Allowable bending compression = 138 MPa
Increasing it by 20% as per Cl G4.6.2.1,
Permissible Bending Stress = 166 MPa
Actual bending compression = M/Zxx 43.56 MPa
OK
As per Table G.2 of IRC:24,
Allowable average shear stress = 0.38*fy= 95 MPa
Actual average shear stress = V/Dt = 27.50 MPa
OK

Calculation of Deflection:
Permissible Deflection l /600 3.33 mm
Actual deflection= Wl 1.5 0.32 mm
28EI OK

Hence provide ISMB 200 as primary runner.

DESIGN OF CRIBS
Cribs of 450x450 Plan Size built-up with ISA 50 shall be used.
Basic Property of ISA 50x50x6: Y
(refer IS:808-1989)
Weight per m: 4.5 kg/m
2
Sectional Area (A): 5.68 cm
450
4
IXX : 12.9 cm X X
I : 4
YY 12.9 cm
C =C :
XX YY 1.45 cm
Y

Thickness of Flange, t = 6 mm 4-ISA50x50x6

Calculation for Capacity of Whole Crib:
2
Gross area of Crib: 0.002272 m

C.g. Distance from top:

=(450/2000) = 0.22500 m
3
 4 4
Ix-x (I about x-axis) (m ): 0.0001012 m

Total Height of Cribs = 5000 mm

l =
Effective length of member: xx 1.4*5000= 7000 mm
2
Area of member under compression = 0.0023 m
r =
Radii of gyration : xx (0.00010/0.0023)^0.5*1000 = 211.04 mm
Maximum slenderness ratio: l= 7000/211.04 = 33.16
Yeild Stress of Steel : 250 MPa
As per Table G.2 of IRC:24,
Allowable stress in axial compression, sac : 124 MPa
Load carrying capacity of the whole section = 28.24 t
Calculation of Load on Cribs :
Total load coming on to the top of crib = 3.13 t
Selfweight of the crib 5000/1000*4.5*1.2/1000 = 0.03 t
(add 20% for bracing)
Total Load = 3.16 t
Design Maximum Axial Force (Compression) = 3.16 t
< 28.24 t
OK
Design of Lacing:
Use 16 dia rod for lacing
As per IRC:24 Cl 507.7.2, the lacing is designed for 2.5% of axial load.
The design vertical load on cribs = 3.16 t
Design load on lacing = 0.08 t
Length of lacing = l= (460^2+430^2)^0.5 630 mm
2 0.5
r= I/A = (D /16) 4 mm
l/r = 157.4
Yeild Stress of Steel : 250 MPa
As per Table G.2 of IRC:24,
Allowable stress in axial compression, sac : 42 MPa
Allowable Load = 0.474 t
OK
Design of Crib Under Wind Condition:

Wind pressure = 240.0 Kg/sqm

Considering cribs beside the railway portion,
The area of deck = 12.05 x 0.725 8.74 sqm
Wind load on Deck= 2.10 t
No of Crib Rows 6.00
Wind Load on Crib from Deck = 0.35 t
Considering cribs area, the wind load on cribs =
8.725*0.45*240/1000 = 0.9423 t
Total wind load on crib = 1.29 t
Max Height of Deck from Base 10.1 m
Line of Action of Resultant Wind Pr from Base 5.05 m
The transverse spacing of crib = 2.500m
Vertical load on cribs due to wind load = 1.29*5.05/2.500 2.605 t
Total Load on Crib including Wind Case 4.97 t
< 28.24 OK
4
Design of Foundation under Crib:

Load on each intermediate Crib = 3.16 t

Load on each outer Crib = 3.16 t
Assumed foundation size = 0.80 m x 0.80 m x 0.20 m

2
Net Base Pressure = 5.6 t/m
2
< 10.0 t/m
OK
2
Base Pressure in Wind Case 11.81 t/m
2
< 12.5 t/m
Moment M = 11.81 x 0.75 x 0.15 ^2/2
= 0.100 tm
Section Modulus of Pedestal Z= 0.00281 m3
Bending Stress M/Z = 35.417 t/m2
= 0.354 MPa
Permissible Stress in M15 Concrete in Tension = 0.400 MPa
OK