APPDCL - SDSTPS,

UNITS # 1 & 2 (2 x 800 MW) - KRISHNAPATNAM TATA Projects Limited Structural Design of Box Culvert
STRUCTURAL DESIGN OF BOX CULVERT

5. DESIGN DATA FOR CLEAR SPAN UP TO 2.0 M: 300

Clear span L = 3000 mm A B

Clear height H = 2000 mm

Thickness of wall T = 300 mm 2000
Thickness of Base slab D = 300 mm
Thickness of Cover slab T1 = 300 mm
Total height = 2600 mm
D C
Soil density gd = 18 kN/m3 0.75
Angle of internal friction for soil f = 30 300

Coeff of earth pressure at rest = 0.50

Density of concrete = 25 kN/m3 300 3000 300

Safe bearing capacity SBC = 140 kN/m2 Minimum Recommended as per Geo Technical Investigation
Report
Live load surcharge (Height of soil) = 1.2 m As per IRC 6 clause 217.1
Surcharge load = 1.2*18 kN/m2
= 21.6 kN/m2
Road WC thick above culvert d = 0.150 m
Density of road material rd = 25 kN/m3
Width considered = 1000 mm
Clear cover c = 50 mm As per IRC 21 Severe Exposer for Coastal Area
Dia of main reinf. Dmain. = 12 mm
Eff.depth d = 244 mm
Design As per IRC 21 Elastic Theory
Factor for dead Load = 1.0
Factor for live Load = 1.0
Load calculations:
1. Dead load :
Self weight of cover slab = 7.50 kN/m2
Self weight of base slab = 7.50 kN/m2
Road WC weight = 3.75 kN/m2
(0.15x25x1) Refer Clause 5
Dead load ( per unit area) = 18.75 kN/m2
Self weight of wall (bothsides) = 30.00 kN/m
Total dead load per m run of culvert = (18.75*3.3)+30
= 91.88 kN

2. Earth pressure :
Earth pressure at bottom Ko*yd*H = 0.5*18*2.6
Earth pressure at bottom we = 23.40 kN/m²
Total pressure due to earth = 0.5*23.4*2.6
= 30.42
Moment due to earth pressure = 30.42*2.6/3
= 26.36 kNm/m
3. Surcharge load :
Surcharge load ws = 21.6 kN/m²
Pressure due to surcharge = 0.5*21.6*2.6
= 28.08 kN/m
Moment due to surcharge = 28.08*2.6/2
= 36.50 kNm/m

4.Water pressure :
Unit weight of water ww = 9.81 kN/m²
Water pressure on wall = (1/2)*9.81*(2.6)^2
= 33.16
Moment due to water pressure = 33.16*2.6/3
Moment due to water pressure = 28.739 kNm/m

Doc. No. TPL-069-CAL-C-6003, Rev. R2 Vol I Page 1 of 53 FICHTNER INDIA

APPDCL - SDSTPS,
UNITS # 1 & 2 (2 x 800 MW) - KRISHNAPATNAM TATA Projects Limited Structural Design of Box Culvert
5.Wheel Load :
Type of Vehicle = IRC Class A

Distance in m
114 114
kN kN

0.5 1.3 0.5

m m m

Live load on cover slab = 228 kN

Impact Factor = 25% IRC 6-2000 clause 211.3

Calculation of Effective Width of Dispersion

Length of Culvert (ie Road width) b = 5.5 m
Effective span of Slab lo = 3.3 m
Ratio of Width of Slab to Eff. span of Slab b/lo = 5.5/3.3
= 1.667
Constant (From Table IRC 21) α = 2.88 Clause 305.16.2
Distance of centroid of Conc. load a = 1.65 m
Breadth of conc. area of load bl = 0.5+(2*0.15)
0.8 m
Effective width of dispersion bef = αa*(1-(a/lo))+bl
= 2.88*1.65*(1-1.65/3.3)+0.8
= 3.18 m
Centre to centre distance of track = 1.8 m
Net effective width of dispersion for the tracks = 1.8+3.18 m
after allowing for overlapping = 4.98 m
Length of load in vehicle = 3.2 m
Effective length of dispersion = 3.2+2*(0.3+0.15)
= 4.1 m
Effective length of dispersion is greater than the actual span.
Hence intensity of loads needs to be reduced proportionately.
Reduced Load = 228*3.3/4.1
= 183.51 kN
Intensity of load with Train vehicle = (1+0.25)*183.51/(4.98*3.3)
= 14.0 kN/m2
Type of Vehicle = IRC Class A train vehicle

Distance in m 1.1 3.2 1.2

27 kN 27 114 114
kN kN kN
0.15 0.95 0.15 0.25 0.95 0.25
1.3
B

Total Wheel Load = 200 kN (Since one row wheel

Impact Factor = 25 % load on the culvert)
Width of wheel base along the length of culvert = 500 mm
Distance between Axles s = 1.3 m
Distance between wheels d1,d2,d3 = 1.1 3.2 1.2

Doc. No. TPL-069-CAL-C-6003, Rev. R2 Vol I Page 2 of 53 FICHTNER INDIA

APPDCL - SDSTPS,
UNITS # 1 & 2 (2 x 800 MW) - KRISHNAPATNAM TATA Projects Limited Structural Design of Box Culvert

Calculation of Effective Width of Dispersion

Ratio of Width of Slab to Eff. span of Slab b/lo = 1.667
Constant (From Table IRC 21) α = 2.88 Clause 305.16.2
Distance of centroid of Conc. load a = 1.65 m
Breadth of conc. area of load bl = 0.8 m
Width of dispersion in the span direction = 1.05 m
Effective width of dispersion of one Wheel bef = αa*(1-(a/lo))+bl
= 2.88*1.65*(1-1.65/3.3)+0.8
= 3.18 m
Total width of dispersion for 4 Wheels = 8.68 m
Intensity of load under wheeled vehicle = 1.25*200/(8.68*1.05)
= 27.43 kN/m2
Hence Intensity of Wheeled Vehicle is considered
5. Live load due to Wheel = 27.43 kN/m2
Total live load per m run of culvert = 27.43*3.3
= 90.52 kN
Check for base pressure :

Total vertical load (DL + LL) per m run = 182.40 kN

= 182.40 kN
Base Pressure due to vertical load = 182.395/3.3*1 kN/m2
55.27 kN/m2 < 140 kN/m2 SBC
SAFE
Loads
Total load on cover slab = 27.43+7.5+3.75
= 38.68 kN/m2
Fixed End Moments
Considering each member as a separate fixed member

Top Slab wl(d+l)2/12 = 38.68*((3000+300)/1000)^2/12

= 35.10 kNm
Bottom Slab wld2/12 = 55.27*((3000+300)/1000)^2/12
= 50.16 kNm
Side wall wsl2/12 = 28.08*((2000+300)/1000)^2/12
= 12.38
wel2/20 = 23.4*((2000+300)/1000)^2/20)
= 6.19
wel2/30 = 23.4*((2000+300)/1000)^2/30)
= 4.13

MAB = MBA = Max(wl(d+l)2/12 , wld2/12+ wll /8)

= 35.10 kNm
MDC = MCD = wl2/12
= 50.16 kNm
MDA = MCB = wsl2/12 + wel2/20
= 18.57 kNm
MAD = MBC = wsl2/12 + wel2/30
16.50 kNm
Moment Distribution
-24.18 24.18
6.27 -6.27
-4.65 4.65
A 9.30 -9.30 B
24.18

-35.10 35.10
-16.50

-9.30

7.90

-6.27

-24.18
-35.99

18.57

15.80

35.99
-4.65

6.27

50.16 -50.16
D -15.80 15.80 C

7.90 -7.90
-6.27 6.27
35.99 -35.99

Doc. No. TPL-069-CAL-C-6003, Rev. R2 Vol I Page 3 of 53 FICHTNER INDIA

APPDCL - SDSTPS,
UNITS # 1 & 2 (2 x 800 MW) - KRISHNAPATNAM TATA Projects Limited Structural Design of Box Culvert
Design moments
Top Slab fixed moment = 24.18 kNm
Span moment = 28.47 kNm
Walls = 35.99 kNm
BottomSlab fixed moment = 35.99 kNm
Span moment = 39.25 kNm
Design shear
Top Slab = 58.02 kN
Walls = 37.20 kN
BottomSlab = 82.91 kN
Max Shear = 82.91 kN
Max Shear stress = 0.34 N/mm2
Maximum allowable shear stress = 1.90 N/mm2 Clause 304.7.1 IRC 21-2000
K for solid slabs = 1.00
Permissible shear stress = 0.33 N/mm2
Size of haunch = 150 mm
Shear in base slab at haunch point = 74.62 kN
Shear stress = 0.306 N/mm2 < 0.326 N/mm2

Design of Top Slab

SAFE
Concrete grade M25
Steel grade Fe500

Clear cover = 50 mm
Moment Mu, = 28.47 kNm/m
t = 240 N/m2
j = 0.9
d = 244 mm
Ast Required ='M / tjd
= 540 mm2
12 tor @ 200 c/c provided = 565 mm2 provided
= 0.23 % OK

Design of Wall
Moment Mu, = 35.99 kNm/m
t = 240 N/m2
j = 0.9
d = 244 mm
Ast Required ='M / tjd
= 683 mm2
12 tor @ 150 c/c provided = 754 mm2 provided
= 0.31 % OK

Design of Bottom Slab

Moment Mu, = 39.25 kNm/m
t = 240 N/m2
j = 0.9
d = 244 mm
Ast Required ='M / tjd
= 745 mm2
The additional reinforcement
16 tor @ 150 c/c provided = 1340 mm2 provided provided is to take care of the
shear stress in the base slab.
= 0.55 % OK

Distributors Reinforcement
Minimum % of steel = 0.12 %
Ast / m Ast Required = 0.0012 x 300 x 1000
= 360 mm2 required
10 tor @ 200 c/c provided = 393 mm2 provided
= 0.16 % OK

Doc. No. TPL-069-CAL-C-6003, Rev. R2 Vol I Page 4 of 53 FICHTNER INDIA