STRL DBR R6

MADHEPURA ELECTRIC LOCOMOTIVE PVT. LTD.
THE EMPLOYER MADHEPURA E-LOCO PROJECT

Tender Package: Fixed Price Lump Sum EPC Turnkey Contract
STRUCTURAL DESIGN BRIEF REPORT
Madhepura Electric Locomotive Pvt. Ltd Rev: 06 Page 1 of 49

Structural DBR Date: 28-10-2016
INDEX
Sl. No. CONTENTS PAGE NO.
1.0 INTRODUCTION 4
1.01 SCOPE OF WORK 5
1.2 DESCRIPTION OF FACTORY BUILDING 5
1.2.1 FUTURE EXPANSION OF MAIN FACTORY BUILDING 6
1.3 FUTURE EXPANSION OF LPC BUILDING 6
1.4 PHASE -1 WORK OF FACTORY BUILDING 7
1.5 TESTING BUIDING 9
1.6 TRANS BORDER 10
1.7 TRACK PIT 13
1.8 RAIL TRACK 14
1.9 DYNAMIC TEST TRACK 16
1.10 MOBILE SPRAYING RAMP 17
1.11 Bogie Load Test Bench 17
1.12 Wheel press: 17
1.11 ABOVE ROOF TYP. DETAILS 19
1.12 LIFE LINE 19
1.12.1 TURBO FAN FIXING DETAILS 20
1.12.2 POLYCARBONATE SHEET 20
1.12.3 ROOF SEALANT 20
1.13 ANALYSIS 21
2 LOADS 22
3 STRENGTH OF MATERIALS 23

Sl. No. CONTENTS PAGE NO.
4 METHOD OF DESIGN 23
5 LOAD COMBINATIONS 25
6 GRADE OF REINFORCEMENT STEEL 26
7 GRADE OF CONCRETE 26
8 NOMINAL COVER TO MEET DURABILITY REQUIREMENTS 27
9 MATERIAL SAFETY FACTORS 27
10 SERVICEABILITY CHECKS 28
11 TYPE OF SOFTWARE AND VERSION 29
12 EARTHQUAKE ANALYSIS 29
13 WIND ANALYSIS 33
14 DESIGN 33
15 DETAILING 35
16 FIRE RATING 35
17 SPECIAL NOTES FOR PEB 36
18 FLOORING AND EXPANSION JOINTS 37
19 ROADS 40
20 LIST OF CODES AND REFERENCES 41
ANNEXURE-A 42
ANNEXURE-B 44
ANNEXURE-C 46
ANNEXURE-D 49
REVISION/VERIFICATION HISTORY:
REVISIO
N DATE PREPARED BY CHECKED BY APPROVED BY
NUMBER
R0 10.06.2016 SRIKANTH RAMARAO R.B. RAJESHA

1.0 INTRODUCTION:
To Prepare this SSDBR, References are made as given below:
Reference Document Remarks &

S.no. Description
Numbers Revised date
1 ALSTOM inputs of Version V20
Refer Architectural
2 Building Characteristics -----
DBR
3 Architectural Drawings T3
Technical Specifications R1 Revised R1 dated
a) Civil and list of approved on 29-06-2016
makes
4 b)PEB and list of approved
makes
c) Civil bill of materials
d) PEB bill of materials
-------
5. Rail track DBR

1.01 Scope of work

S.NO. FACILITIES DETAILS
1 to 3 Factory building (PEB)
14b & 14c LPC of 2 bays + Bays expansion (PEB)
4a End of Cycle retro fit
4b Weighing
5a LV testing
5b Testing Office
9a Paint touch up area
9c Office
9d Compressor room
9e Awning
7 Client office
6 DTZ Control Center
11a & 11b First Aid room and office for factory-RCC and roof
Slab
12 & 13 Security 2 no.'s- RCC- With Roof Slab
14 Unloading bay Str.Canopy
14a Truck parking for LPC (Open Hard Surface
Parking Space) with Pave Blocks.
15 Change room & Office for LPC RCC Roof Slab
16 Loading bay Str.Canopy
17 Tunnel to factory (PEB)
18 Substation for Factory-RCC
18a & 5c Electrical panel room and Facilities-RCC-Roof
Slab
18b Substation for track (covered) RCC-Rrof Slab
19 Compressor room- RCC with Roof Slab
20 Water tanks & Pump room-Above Ground RCC
Tanks and pump room.
21 DG Yard (open) with Hard Pavement Surface
22 STP- RCC Tanks and associated Steel Shed Str.
23 Canteen + Recreation (G+1) RCC Framed with
RCC Slabs
24 Foundation and columns to be designed for G+ 2
structures for Admin building. Construction will be
G+1 only with provision to have additional floor in
future. Beam and column cover to be checked.
25 & 25A Scrap yard - 2 no (Open Yard + Partially Covered)
26 & 27 2 & 4 Wheeler Parking (Covered +Driveways)
28 HSD Tank and Tank form (Above Ground Storage
Space as per DG Sizing with Tank Form and
unloading platform and Containment wall as per
PESO) Fenced with Gate secured area.

29 Truck Parking for factory (Open) Hard Surface
Area of Paver blocks
31 Metering Yard and .Room- RCC Framed Str. And
RCC Slab
32 Internal roads (Flexible pavement as per EPC
Design as per IRC 37
33 External roads (Flexible Pavements as per EPC
Contractor Design as per IRC 37
34 Admin- Visitor parking (Covered Parking of Steel
Str. And Precaoted Sheets)
35 Internal fencing for seggregation of Fitting and
LPC line side as per Plan.
36 Fire drill assembly-area Open to sky green area
37 Lockers and change rooms-RCC Framed Str. And
Slab.
38 Stabling track- As per Indian Railway Design
39 Dynamic test track- As per Indian Railway Design
T1 Transborder- As per Design Brief documents.
1.2 Description of Factory Buildings:

1.2.1 FUTURE EXPANSION OF MAIN FACTORY BUILDING
MAIN FACTORY Building will be expanded in future towards east side .The cladding
covered in the east will be dismantled & used in the future expansion area. Only
substructure will be common for future expansion.
1.3 FUTURE EXPANSION OF LPC BUILDING
LPC Building consist of 2/3 bays depending upon the cost proposals and further
bay wise expansion refer key plan

KEY PLAN FOR LPC BUILDING
1.4 Phase-1 Work of factory building

Refer Site Layout plan for Phasing information

Temporary sheeting for segregating construction area (phase-2) from production area
(phase-1)

1.5 Testing Building:

The testing building shall be designed for catenary loads 1000kg on PEB
structure.
Descriptions:
POOL: The main hall may be composed of a pool and the train tracks are
suspended on pillars. This particularity is directly linked to the kind of train will
have to test. The main objective is to allow an easy access for the testing
technicians to all compartments of the train/cars and allow people to work with the
respect of the ergonomic condition.
TRACK ON PILLARS: The tracks installed on pillars ( with suitable structural

design to cater to the load of Locomotive):
Refer to the 0100 - SMS elements Tracks for more details about tracks.
Tracks on pillars allows to fix all electrical network / pneumatic network /
light
A pit exists in the middle on the track to be able to go underneath the bogie.
The pit is around 800mm depth from the pool and so 1700mm from the top
of the rail
PLAN

INDICATIVE SECTION
Each of the Electrified lines ( with 25 KV catenaries) shall have provision of
switch controls to disconnect the power supply and have appropriate LOTO
and Interlocking provisions with the platform access. Kindly refer the attached
Reference document on Test buildings provided by Employer.

1.6 Trans border:

The trans-border, purpose of this specification, will ensure the handlings of railway
vehicles between buildings.
Total loading is considered in Floor for Trans-border is as follows :

[100 T Locomotive (1 section) + 4 T Loco-Mover + 90 T Traverses Dead
Weight(as input received from equipment manufacturer) = appx 200T ]
Considering with 4-Rail / 8 Wheel concepts in trans-border. So the Static load
in each wheel is to be limited as 35T/ wheel (without Impact Loading).
The rails embedded with Concrete shall be part of EPC contractor scope.

TYP. SECTION FOR TRANS-BORDER

Specifications:
This specification is for several trans borders.
The location of the transborders is presented on the site layout.
All transborders will move independently.
The displacements will be on rails
All trans borders will move the transit + the handling tractor which pushes
or pulls the transit
Refer document number:
MAD-appendix 2.1015-a-Summary technical specification of trasborder-V1

MAD-appendix 2.1015-b-Technical data Transborder-V6
MAD-appendix 2.1015-e-photo of existing Transborder-V1

1.7 Track Pit:

The use of pit is necessary when we need to have access under the product (car or at
train level) and no possibility to lift the product
The pit line facility is used for fitting / examining the Loco from underside, the pit line
consist of an RCC wall on suitable foundation with RCC beam below rail level. M35
concrete to be used for Pit wall and Beams with water proofing.
The pit line structure component is of levelling course of lean mix concrete and a
RCC
raft foundation in common for both the walls. RCC concrete wall of 450mm thick of
suitable height and an RCC beam of size 450mm width and height of 950mm. The
SGCI / MCI inserts are positioned / fixed in the beams concrete.
NOTE: Pit depth is 1.7m from rail top level.

Refer document number: MAD-appendix 2.101-b Pit specification-V5

MAD-appendix 2.101-e-photos of existing pits
MAD-appendix 2.101-g-protection pit solutions-V5.
1.8 Rail Track:

The Gauge Of The Track Provided In The Factory Is Broad Gauge Of 1.676m. All The
Outdoor Track Shall Be Provided With Ballasted Conventional Track Except The
Track At Heavy Trucks Circulating Area Outside The Fitting Lines. All Indoor Track
And In The Circulating Area As Mentioned Above Shall Be With Embedded Track.
The purpose is to move the cars from one station to another one. Total weight of
locomotive is 100MT and Tracks designed shall be 25MT Axial load. Accordingly sub
structure shall be designed based on the soil report.
Refer document number: MAD-appendix 2.100-b Tracks-V2.
Internal Track:

External Track:
The external tracks are resting on ballasts to refer the layout for detailed
junctions.

1.9 Dynamic Test Track

The railway track:
Will be situated along the edge of the site on a band of about 10m width, including a
pedestrian walkway of 1.0m width. Shall be designed to allow geometric variations
due to climatic conditions not affecting the capacity to carry out testing activities. Shall
be straight to allow the highest level of speed.
Shall be levelled with a maximum tolerance of 0.5%.Product to test:1,676m. Shall
have one point with a manually operated and lockable switch to connect with site
shunting yard.
Switch shall be interlocked with a key (part of a LOTO system) to secure the safety
management of the position. Bed will be composed of ballast according to the local
rules and regulations. Shall lie on concrete sleepers.
Refer details of MAD-appendix 2.14-b-dynamic test track specification V5.3

1.10 Mobile Spraying Ramp:

The spraying ramp must be compatible of distance between sprinklers and
Locomotives. To do that, several solutions maybe proposed by ramps spray supplier.
(Different sprinkler matrices removable, fix sprinklers with adaptable structure The
spraying ramp will move independently.
The displacement will be on rails or other solution (to be defined by manufacturer)
Two gutters one on each side of the railway track to recover water should be present.
On one side, one groove will remain open to allow suction pipe to take water and
bring it to the pump.
Equipment will be supply by MELPL & same of EPC continuing is to full fill execution
at provide Track, water supply and electric supply requirements & support at electrical
supplier & spraying ramp supplier will give details & requirements(layout & details
etc).
Refer detailed specifications of document 1018-b-technical spraying ramp-V4
1.11 Bogie Load Test Bench : REF DOC: 2011-03-14 BLTB
1.12 Wheel press: REF DOC: 2011-03-14 WP
Column Reaction, Anchor bolt template & Design ( Autocad) , Staad model
analysis and design shall be provided by the bidder along with their
proposal

Key Plan for Gantry Girder (Typ. Detail):

1.11 Above Roof typ. details:

1.12.1Life Line:
The factory fully operational , the maintenance of the roof needs to be planned
periodically. For people accessing the roof for this activity, a LADDER with vertical life
line system and a horizontal life line system on the roof surface to keep the persons
continuously attached and fall protection is recommended.
1.12.2 Turbo Fan Fixing Detail:

1.12.3 Polycarbonate sheet:
2mm thick polycarbonate sheet is resting on two purlin and with all round frame work
with safety weld mesh as per technical specifications
.
1.12.4 Roof sealants:
We are recommending DEKS Roof sealants.
Product Name: DEKSTRIP

1.13 Analysis
The above Buildings are analysed as a Space Frame. The modelled space
frame are analysed for dead loads (DL), live loads (LL), wind loads (WL) and seismic
loads (EQ) and their combinations (as per IS: 875) using STAAD Pro/ ETABS and
designed for limit states of Strength, serviceability including load combinations as per
IS: 1893(part-1). Effective lengths of columns are considered as per the standard
codes of practice. This structure are designed and detailed as per Indian codes of
practice only.
The Support Condition considered as follows:
Main Factory Building/LPC support considered as Fixed.
RCC Buildings support considered as Fixed.

2. LOADS
Note: Wherever reference to IS Code is made, the same shall be
taken as the latest revision (with all amendments issued.)
Dead load - The Dead Load in a Building shall comprise the weight of all walls,
partitions, floors and roofs and shall include the weights of all permanent
constructions in the buildings. The unit weight per mass of the materials and
parts or components of the building that are applicable to the determination of
dead load calculations are obtained by considering complying with IS-875 (Part 1)-
1978 and according to densities of the possible dead loads. (Ref. Annexure. A
Table-1).
Live load - Live loads on floors comprise all loads other than dead loads
produced by intended use or occupancy of a building including the weight of
movable partitions, distributed and concentrated loads, loads due to impact and
vibrations and dust load but excluding wind, seismic loads, etc. The minimum live
load on different floors for different purposes of usage are taken from IS 875:1987
(Part-2). (Refer Table -2).
Wind Load- Wind load calculation to be made by taking into account the random
variation of wind speed with time. Large majority of structures suffer wind induced
oscillations and are examined for such effects. Wind Loads are considered
according to IS-875 (Part 3)-2015 [Code of Practice for Design Loads (Other than
Earthquake) For Buildings and Structures].
Earthquake Load- Earthquakes cause random motion of ground, which can be
resolved in any three mutually perpendicular directions. This motion causes the
structure to vibrate. The response of the structure to the ground vibration is a
function of the nature of foundation soil, materials, form, size and mode of
construction of the structure, and the duration and the intensity of ground motion.
IS 1893: 2002 has been used for the earthquake analysis of the present structure.
As per IS 1893: 2002, Madhepura region falls under Zone V Relevant
earthquake parameters as per Zone V will be considered in the design.

3. STRENGTH OF MATERIAL
Purlins and Girts = 345 Mpa.
Hot rolled sections = 250Mpa.
Tube sections = 210/310 Mpa.
GalvalumeSheet = 550 Mpa.
Built up Plates: = Fe 490 B
Thickness of Plate Grade (Min. Yield Stress in Mpa)

< 20 345
20 - 40 330
> 40 320
RCC for the building shall be complying with concrete of Grade M25.(Fck-25 Mpa). All
reinforcement is high yield strength deformed bars of Grade Fe- 500 D.
4. METHOD OF DESIGN
All the structural elements in the building are designed with LIMIT STATE METHOD as
per Indian standards for R.C.C members& for Structural Steel members.
General Construction in Steel Code of Practice: IS 800-2007
Plain & Reinforced Concrete Code of Practice: IS 456-2000
Note: For design of structural steel members chapter 12 shall be included as per
IS800:2007.

5. LOAD COMBINATIONS
Load cases/definition:
DL Dead Load including crane dead weight
LL Live Load
CL Collateral Load
CR Crane lifting load
EQX, EQZ Seismic load in X & Z directions
WL Wind load
TL Temperature load
Load combinations for Limit state of collapse for Steel design:
1.5 (DL + LL)
1.5 (DL + LL + CL) TL
1.5 (DL + LL + CL) + 1.05 CR TL
1.5 (DL + CR + CL) + 1.05 LL TL
1.5 (DL EQX)
1.5 (DL EQZ)
1.5 (DL + CL EQX) TL
1.5 (DL + CL EQZ) TL
1.2 (DL + LL + CL EQX) + 0.53 CR TL
1.2 (DL + LL + CL EQZ) + 0.53 CR TL
1.5 (DL WL)
1.5 (DL WL) TL
1.2 (DL + LL WL) + 0.53 CR TL
1.2 (DL + LL + CL) + 1.05 CR 0.6 EQX TL
1.2 (DL + LL + CL) + 1.05 CR 0.6 EQZ TL
1.2 (DL + LL) + 1.05 CR 0.6 WL TL
0.9 (DL + CL) 2.5 EQX TL (only for design of columns where Pr / Pd> 0.4)
0.9 (DL + CL) 2.5 EQZ TL (only for design of columns where Pr / Pd> 0.4)
1.2 (DL + CL) + 0.5 LL 2.5 EQX TL
(Only for design of columns where Pr / Pd> 0.4)
1.2 (DL + CL) + 0.5 LL 2.5 EQZ TL

(Only for design of columns where Pr / Pd> 0.4)

Load combinations for Serviceability (Deflection check) for Steel design:
DL + LL
DL + LL + CL TL
DL + LL + CL + CR TL
DL EQX
DL EQZ
DL + CL EQX TL
DL + CL EQZ TL
DL + 0.8 (LL + CL EQX + CR) TL
DL +0.8 ( LL + CL EQZ + CR) TL
DL WL
DL WL TL
DL + 0.8(LL WL+ CR) TL
Note: As per cl. 3.10 of IS 800: 2007, Up to 180m length of covered buildings,
Temperature load need not be considered if at least one bay is braced along
longitudinal direction.
Load combinations for Limit state of collapse for RCC design:

1.5 (DL + LL)
1.5 (DL + LL + CL)
1.5 (DL + LL + CL) + 1.05 CR
1.5 (DL + CR + CL) + 1.05 LL
1.5 (DL EQX)
1.5 (DL EQZ)
1.5 (DL + CL EQX)
1.5 (DL + CL EQZ)
1.2 (DL + LL + CL EQX) + 0.53 CR
1.2 (DL + LL + CL EQZ) + 0.53 CR
1.5 (DL WL)
1.2 (DL + LL WL) + 0.53 CR
1.2 (DL + LL + CL)+ 1.05 CR 0.6 EQX
1.2 (DL + LL + CL) + 1.05 CR 0.6 EQZ
1.2 (DL + LL) + 1.05 CR 0.6 WL

0.9 (DL + CL) 1.5 EQX
0.9 (DL + CL) 1.5 EQZ
Note: Crane load used in the above combinations for RC design is applicable
only for substructure design of PEB buildings. It is not used in rest of the
buildings where there is no crane.
Load combinations for Serviceability (Deflection check) for RCC design:

DL + LL
DL + LL + CL
DL EQX
DL EQZ
DL + CL EQX
DL + CL EQZ
DL + 0.8 (LL + CL EQX)
DL +0.8 (LL + CL EQZ)
DL WL
DL + 0.8(LL WL)
6.0 GRADE OF REINFORCEMENT STEEL

All reinforcement used shall be high yield strength deformed TMT bars of
Grade Fe- 500D confirming to IS 1786 indicated with a prefix F of with the appropriate
bar diameter.
7.0 GRADE OF CONCRETE

Minimum Grade of concrete will be as per codal provision confirming IS 456:
2000, for MODERATE environmental exposure condition (As per IS-456-2000
Table-3). Different Grades of concretes have been used to design the structural
elements as per the design requirement. The minimum cement content for different
grades of concrete and MODERATE environmental exposure condition will be as
per IS 456:2000.

Foundations - M25/M30
Columns & Pedestals: - M25
Beams & Slabs: - M25
Walls M25
Minimum cement content shall be as per provisions of IS: 456: 2000, for a
moderate environmental exposure condition.
8.0 NOMINAL COVER TO MEET DURABILITY REQUIREMENTS

Nominal Concrete cover shall not less than 20 mm for 'MODERATE' Exposure
Condition as per relevant codes.
Piles 75 mm
Pile caps 75 mm
Foundations 50mm
Columns & Pedestals: 40mm
Beams 25/30 mm
Slabs 20/25 mm
Walls 30mm
9.0 MATERIAL SAFTEY FACTORS

Partial factors of safety
For Concrete 1.5
For Reinforcement Steel 1.15
For Structural Steel

Resistance governed by Yielding, mo = 1.1
Resistance of member to buckling, mo = 1.1
Resistance governed by ultimate stress, m1 = 1.25

10.0 SERVICEABILITY CHECKS

FOR STEEL BUILDINGS:
Vertical Deflections
Live/Wind Load Deflections
Purlins (Elastic Cladding) Span /150
Rafter (Elastic cladding) Span /180
Crane load (Electric operated up to 50T) Span /750
For Lateral Deflections
Wind load deflections (Elastic cladding) Height/150
Earth quake deflections Height/250
Crane + Wind ----Gantry (Lateral) 10mm
(Relative displacement between rails supporting crane)
Crane + Wind ---Column/Frame (Elastic cladding) Height /200
Special Concentrically Braced frames should be shown to withstand inelastic

deformation corresponding to a joint rotation of at least 0.04 radians without
degradation in strength and stiffness below the full yield value.
FOR RCC BUILDINGS:

a. For Deflections:
The final deflection due to all loads including the effect of temperature, creep, and
shrinkage measured from the as-cast level of the supports of floors, roofs and all
other horizontal members should not normally exceed span/250. The deflection
including the effect of temperature, creep and shrinkage occurring after the erection
of partitions and the application of finishes should not normally exceed span/350 or
20 mm.
b. Lateral Drift (Wind):
Under transient wind load the lateral sway at the top should not exceed H/500, where
H is the total height of the building.
c. Lateral Drift (Seismic):

The storey drift in any storey due to minimum specified design lateral force, with
partial load factor of 1, shall not exceed 0.004 times the storey height.
d. For cracking:
Surface crack width shall not exceed 0.3 mm in general and for water retaining
structure it is limited to 0.1 mm.
11.0 SOFTWARES USED:
STAAD Pro. V8i
STAAD Pro is comprehensive structural engineering software that addresses all
aspects of structural engineering including model development, verification, analysis,
design and review of results. Here STAAD Pro is mainly used for analysis & design
of steel Structures.
ETABS (Version 9.7.4)
ETABS stands for Extended Three Dimensional Analysis of Building System.
ETABS is an engineering software product that caters to multi-story building analysis
and design. Modelling tools and templates, code-based load prescriptions, analysis
methods and solution techniques, all coordinate with the grid-like geometry unique to
this class of structure. Here ETABS are mainly used for analysis & design of RCC
Structures.
AUTODESK - AUTOCAD 2016
AUTOCAD software used for drafting of 2D structural drawings.
12.0 EARTHQUAKE ANALYSIS: (GENERAL)
Being located in the high seismic zone perched on the boundary of the tectonic plate
joining the Himalayan tectonic plate near the Bihar-Nepal Border and having six sub-
surface fault lines penetrating through its Gangetic planes in four directions,
Madhepura is vulnerable to the worst kind of disaster caused by earthquake of near
maximum intensity. Out of eleven districts in Zone V ,Dharbhanga,
The earthquake analysis shall be carried out for dead loads (DL), live loads
(LL), piping, crane and equipments.
And refer Allianz document.


The proposed structure in this site shall be analyzed for seismic forces. Earthquake
analysis shall be carried out using STAAD-pro V8i for Steel Structures & ETABS for
RCC Structures as per the provisions of IS-1893: 2002 (Part 1 and 4). The nodal
mass shall be obtained as per the recommendations of IS-1893: 2002 regarding the
load combinations. The Response reduction factor shall be taken 4.5 for Steel
structures
As per IS 1893 base shear shall be calculated as
Vb = Ah x W

Where, Ah is base shear co-efficient and W is the nodal mass of all the floors.
For Steel Building
Analysis Parameters Clause/Table of
IS-1893:2002(part 1 & 4)
Zone factor, Z 0.36 Table 2 (P.No. 16)
Importance factor, I 1.75 Table 5 (P.No. 13) Part4
Steel building 4 or 5
Response factor, RF Table 23 (P.No. 87)
depending on connections
SS 2 -
ST 2 -
DM 0.02 for Steel -
To be calculated for each Clause 7.6.2 of IS 1893
Px
structure individually Part I
To be calculated for each Clause 7.6.2 of IS 1893 of
Pz
structure individually Part - I
DT As per soil report analysis -----
For RCC Building

Analysis Parameters Clause/Table of
IS-1893:2002(part 1 & 4)
Zone factor, Z 0.36 Table 2 (P.No. 16)
Importance factor, I 1.0 Table 5 (P.No. 13) Part4
Response factor, RF 5 Table 23 (P.No. 87)
SS 2 -
ST 1 -
DM 0.05 for RCC -
To be calculated for each Clause 7.6.2 of IS 1893
Px
structure individually Part I
To be calculated for each Clause 7.6.2 of IS 1893 of
Pz
structure individually Part - I
DT As per soil report analysis -----

Where:
SS = Rock or soil sites factor (=1 for hard soil, 2 for medium soil, 3 for soft
soil). Depending on type of soil, average response acceleration coefficient
S a /g is calculated corresponding to 2% damping. Refer Clause 6.4.5 of IS:
1893 (Part 1) -2002.
ST = Optional value for type of structure (=1 for RC frame building, 2 for Steel
frame building, 3 for all other buildings).
DM=Damping ratio to obtain multiplying factor for calculating S a /g for different

damping. Damping will be considered based on type of structures
corresponding to which multiplying factor will be taken referring Table 3 of IS:
1893(Part 1)-2002.
DT= Depth of foundation below ground level = 2 to 3.5 meters as per soil
report
Px&Py= 0.085 x( h ) 0.75 for Steel and Px & Py= 0.09 x h /( D ) 0.5
Clause 7.6.2 of
IS:1893(Part 1)-2002 for RCC buildings .
13.0 WIND ANALYSIS
The proposed structure shall be analyzed for wind forces as per IS: 875-2015.
Analysis is carried out by using Staad Pro and the coefficients and wind pressure are
calculated as per the provisions made by IS: 875-2015.
As per IS: 875-2015 Design Wind Speed can be calculated as
Where k1- probability factor (risk coefficient) (see 6.3.1)

k2 - Terrain, roughness and height factor (see 6.3.2)
k3 Topography Factor (see 6.3.3) &
k4 importance factor for the cyclonic region (see 6.3.4)

Vb Basic Wind Speed
Design Wind Pressure

Pz = 0.6 x Vz2
Where Pz - Design Wind Pressure in N/m2 at a height z
Vz Design Wind Velocity in m/s at a height z
Wind Force on Building/Structure
F = (Cpe Cpi) x A x Pd
Where Cpe External Pressure Coefficient
Cpi Internal pressure Coefficient
A Surface area of structural unit/cladding unit
Pd Design wind pressure
Analysis Clause/Table of
Parameters IS-875:2015(Part 3)
(Latest code to be followed as per pre
bid clarification)
City Madhepura
Basic Wind Speed 47 m/s Clause 5.2
k1 1 As applicable
k2 1.0 (for 10m Ht) As applicable
k3 1 As applicable
K4 As applicable As applicable
14.0 DESIGN:-
Super Structure: Steel
All the structural steel elements shall be designed as per IS 800-2007. All the
frames and beams shall be checked for deflection as per the allowable limits.
Super Structure: R.C.C Frames (Beams & Columns):
All the structural R.C.C elements shall be designed as per IS 456-2000. All the
columns and beams shall be check for deflection as per the allowable limits. All the
slabs shall be designed using Spread Sheets and checked for deflection as per the

allowable limits.
Sub Structure:-
Refer bid document volume 4-4.12 for soil report
However, EPC contractor refer this soil report & satisfy himself with new set of
geotechnical tests if required at his cost.
EPC contractor to submit necessary modelling, design documents & drawings

for all buildings to the design consultant for Notice of No Objection before
execution.
After soil improvement technique, another sample test of Geotechnical tests to know
the improvement of soils tests like MSAV, Cyclic plate load tests, CPT or SPT tests or
applicable tests.
All the soil improvement techniques, pre tests & subsequent post test shall be verified
by IIT or IISC (3rd party ) at the cost of contractor.
15.0 DETAILING-
The Building is located in Seismic Zone V, So All the structural elements are detail
as per SP-34 & IS 13920. Proper curtailments details are follow to get the economy
and ease in construction at site.
16.0 FIRE RATING:
The structure is designed for 2 hour fire rating for staircases and lift core location and
for other areas of buildings. The concrete structural walls shall be designed and
constructed as per IS codes. The structural adequacy is checked as per standards
with respect to the fire rating with normal reinforcement as per gravity/lateral loading
design and with minimum cover to the reinforcement.
Min size of member for 2 hour rating
Slabs : 125mm
Beams : 200mm
Columns : 300mm

Cover
The Clear Cover is the distance from the outer face of the structural element from
outer reinforcing rods. It is essential to avoid the exposure of reinforcing rod to the
environment.
SL Cover(mm)
Member
No Simply supported Continuous
1. Beams 35 35
2. Slabs 25 25
3. Columns 40 40
17.0 SPECIAL NOTES FOR PEB:
1. 3D Modelling and Analysis to be performed.

2. Max rainfall of 140mm/hr. or as per meteorological department shall be
considered for the entire design of gutters and header pipe.
3. Internal pressure coefficient shall be 0.5 for partially enclosed building.
4. For roof bracing, tubular section shall be considered. Elevation bracing to be
avoided and to be designed as portal columns.
5. Bottom of base plate shall be 400 mm below FFL for internal column and 850
mm below FFL for external column.
6. For GI high strength Bolts of Grade 8.8/10.8 shall be at locations of Splice
plate connections in portal, column, jack beams, rafters.
7. Connections: All shop connections shall be by welding, preferably by
submerged arc welding. Field connections or light members such as purlin,
girts and inaccessible beams shall be done by MS bolts with nuts. All major
connections shall be designed with high strength friction grip bolts of Unbrako/
TVS make. However, field connections for mild steel can be designed with
welding, if so desired during detailed engineering stage.
8. DOWNTAKES: UPVC rain water down take pipes of Class 4, conforming to IS
4985-2000 of the following sizes including necessary fittings like clamps,
bends, shoes etc., shall be used for downward flow of rain water.
9. Only Touch-up paints at site.
10. Proof checking cost of PEB structure under EPC scope & shall be from IIT
vetting like Mumbai, Delhi &Chennai.
11. PEB structure shall be earth connected.
12. PEB structure shall protected against lighting.

18.0 FLOORING & EXPANSION JOINTS:-
Vacuum Dewatered Flooring (VDF) is used to achieve High Strength, Longer

Life, Better Finish and Faster Work. This type of floor is suitable for high abrasion
&Fork lift movement. The VDF is a system for laying high quality concrete floor in 4m
x 4m blocks using dowel rods or dowel plates in one direction and groove cut in
perpendicular direction. Factory ground load will be designed for 25kN/sq.m UDL i.e.
Grade Slab resting on PCC, GSB on the Subgrade well compacted with proctor
density of 95%.
Floor intensity of 250kn/sq.m(Annexure C) shall be resting on structural slab
and inturn resting on pile foundations.
Flooring expansion joint will be aligned with building expansion joint as per IS
code.
Flooring Specifications above VDF:-
EPC contractor to provide for applying floor seal approved equivalent over the
finished VDF flooring for hardening, Dust proofing, Improved abrasion resistance &
chemical resistance as per manufacturers specification complete in all respect.
GENERAL NOTES:
1. All Rail Maintenance platform columns are resting on VDF with HILTI
connection.
2. Top of rail should match with finished floor level.
3. Pit and track in the floor shall be designed as per document number: MAD-
appendix 2.101-b-pit specifications

Typ. Expansion joint:
Note: Steel fibres dosage shall be as per design requirements.

TYP. CONSTRUCTION JOINT:
TYP. FLOORING SECTION:

Roads
For the design of BTroads the CBR to be considered as per soil report.

19.0 LIST OF CODES & REFERENCES
IS 800-2007 : General construction in steel & Code of Practice

IS:4562000: Code of practice for plain and reinforced concrete
IS: 875 2015: Code of practice for design loads (other than Earthquake) for
Buildings &structures.
IS: 875 PART 1: Dead Loads
IS: 875 PART 2: Imposed Loads
IS: 875 PART 3: Wind Loads
IS: 875 PART 5: Special Loads & Load Combinations.
IS: 1893 (Part 1) 2002: Criteria for earthquake resistant design of Structures.
IS: 1893 (Part 4)-2005: Criteria For Earthquake Resistant Design of Structures
Industrial Structures Including Stack Like Structures.
SP 38 :Hand book of Typified Designs for Structures with steel Roof trusses
SP40: Hand book on Structures with Steel Portal frame.
SP - 16 : Design aids for reinforced concrete to IS: 456- 1978
SP 34: Handbook on concrete reinforcement detailing.
IS: 13920-2002: Ductile detailing of reinforced concrete structures subjected to
seismic forces.
SP64: Hand book of practise for design loads.
IS: 3370 PART-1 TO 2 2009 : Concrete Structures For Storage Of Liquids
IS: 3370 PART- 3 TO 4 1999 : Concrete Structures For Storage Of Liquids

ANNEXURE-A
A BUILDINGS
1 MAD-appendix 2.10-b-Carbodyshell building - V3
2 MAD-appendix 2.10-e-carbodyshell building photos - V1
3 MAD-appendix 2.11-b-detail power trap door
4 MAD-appendix 2.11-b-fitting building - V5
5 MAD-appendix 2.11-b-trap door-V1
6 MAD-appendix 2.11-e-fitting building photos-V1
7 MAD-appendix 2.13 - EHS_WMS_006 - safety requirements for
static testing activities
8 MAD-appendix 2.13-b-lock out tag out - V1
9 MAD-appendix 2.13-b-testing building specification-V4
10 MAD-appendix 2.13-e-testing building photos
11 MAD-appendix 2.14-b-dynamic test track specification V5.3
12 MAD-appendix 2.14-b-EHS_WMS_007 - safety requirements for
dynamic testing activities V1.2
13 MAD-appendix 2.14-e-dynamic test track photos - V1
14 MAD-appendix 2.15-b-warehouse building - V2
15 MAD-appendix 2.17-b-standard chemical storage workshop - V5
16 MAD-appendix 2.17-e-chemical storage photos
17 MAD-appendix 2.18-b-Office-facilities building - V2
18 MAD-appendix 2.19-b-Environment - Waste Management V3
19 MAD-appendix 2.19-e-environment - waste area - V1
20 MAD-appendix 2.23-b-socials building - V2
21 MAD-appendix 2.24-bcolor coding of rigid pipe V1
22 MAD-appendix 2.24-blighting of work places V2.2
23 MAD-appendix 2.24-b-Technical Data general-V3
24 MAD-appendix 2.100-b-Tracks - V2
25 MAD-appendix 2.101-b-Pit specification - V5
26 MAD-appendix 2.101-e-photos of existing pits
27 MAD-appendix 2.101-g-protection pit solutions - V5
28 MAD-appendix 2.104-b-technical data industrial doors - V3
29 MAD-appendix 2.105-b-catenary specification - V1
30 MAD-appendix2.200-5S - factory marking - V8
31 DRAFT EHS-WMS-001 V2
32 DTZ SPECIFICATION
33 SITE SPECIFICATIONS
34 DRAFT - 0014-b-dynamic test track specification V9

B EQUIPMENTS
1 MAD-appendix 2.1015-a-summary tech. spec. of transborder - V1
2 MAD-appendix 2.1015-b-Technical data transborder - V6
3 MAD-appendix 2.1015-e-photos of existing transborder - V1
4 MAD-appendix 2.1016-a-summary tech. spec. of train cars turning
table - V1
5 MAD-appendix 2.1016-b-technical data train cars turning table-V4
6 MAD-appendix 2.1016-e-photos of turning table - V1

7 MAD-appendix 2.1018-a-summary tech. spec. of spraying ramp -
V1
8 MAD-appendix 2.1018-b-technical data spraying ramp- V4
9 MAD-appendix 2.1018-e-photos of existing spraying ramp - V1
10 MAD-appendix 2.1019-a-summary tech. spec. of overhead crane -
V1
11 MAD-appendix 2.1019-b-technical data overhead crane - V4
12 MAD-appendix 2.1019-e-photos of existing crane - V1
13 MAD-appendix 2.1020-a-summary tech. spec. of weighing system -
V1
14 MAD-appendix 2.1020-b-technical data trainset weighing system-
V4
15 MAD-appendix 2.1020-e-photos of existing weighing system - V1

ANNEXURE - B
DEAD LOADS
1. Bare Galvalume Sheets with insulation (single skin)
=0.0005x7850x1=0.003925kN/m2
2. Bracings = 0.05 kN/ m2
3. Purlins = 0.08 kN/ m2
All together Dead load of 0.25 KN/ m2 shall be considered
Table-1 Density of Materials:
N
Description Unit Value Remarks
o
1 RCC kN/m3 25 -
2 Steel kN/m3 78.5 -
3 Saturated soil kN/m3 20 -
4 Brick work 230 thk. kN/m3 20 Including plastering

Table 2 Live Loads
Sl.No Description Unit Value

1 Roof Load kN/m2 0.75
2 Factory ground load(Grade slab) kN/m2 25
3 Factory suspended slab resting on piles kN/m2 250
Office area
1. Fixed Partition office kN/m2 2.5
2. Computer Room kN/m2 3.5
3. File Storage Room kN/m2 5
4. Corridors, stairways, halls kN/m2 4
5. Toilets kN/m2 2.5
Canteen
1 Restaurant kN/m2 4
2 Kitchen kN/m2 4
3 Balcony kN/m2 4
4 Corridors kN/m2 4
5 Stairways kN/m2 4
6 Elevator machine room kN/m2 10
7 Toilet kN/m2 2.0
Admin Building
1 Room kN/m2 2
2 Corridors kN/m2 3
3 Stairways kN/m2 3.5
4 Balcony kN/m2 3
Collatral Loads:
A SuspendedLoad of 25 kg/ m2 has beenconsidered for various services like

HVAC ducts, Light fixtures and Supply pipe lineslike sprinkler pipes, gas pipelines,
cabletrays, Fire hydrant, main rail pipe.
Note: No Solar panel Loads on Roof.

ANNEXURE - C
A) Wind Loads for Production Block:
Design wind Speed (vz) = Vb* K1* K2 *K3 m/sec
Basic wind speed (Vb) = 55 m/sec
Probability Factor (K1) = Refer Table-1, page 11, IS 875-Part 3
Terrain Height and Structure size factor (K2) = Table-2, page 12, IS: 875-part 3
Topography factor (K3)=Refer clause 5.3.3.1, IS 875- part 3
Vz=55*K1*K2*K2
Design wind Pressure Pz = 0.6 * Vz2
Wind load on individual members F= (Cpe +/- Cpi) * A * Pz
Cpe = External Pressure Coefficients
Cpi = Internal Pressure Coefficients = +/- 0.5 (for Medium openings)
A = Surface Area of Structural elements or Cladding units
B) Calculation of Pressure Coefficients for Production Block:
IS: 875 Part (3) we can obtain external pressure coefficients from the following data
H = Height of Building
W=The lesser horizontal dimension of Building
L= The greater horizontal dimension of Building
Roof slope = 1 in 10
B) Calculation of Pressure Coefficients for Production Block:
IS: 875 Part (3) we can obtain external pressure coefficients from the following data
H = Height of Building
W=The lesser horizontal dimension of Building
L=The greater horizontal dimension of Building.
ANNEXURE - D
Hatched Portion Floor slab to be design 25 t/sq.m(Uniform Load)


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MADHEPURA ELECTRIC LOCOMOTIVE PVT. LTD.

THE EMPLOYER MADHEPURA E-LOCO PROJECT

STRUCTURAL DESIGN BRIEF REPORT

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Sl. No. CONTENTS PAGE NO.

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Sl. No. CONTENTS PAGE NO.

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To Prepare this SSDBR, References are made as given below:

Reference Document Remarks &

1 ALSTOM inputs of Version V20

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1.01 Scope of work

PESO) Fenced with Gate secured area.

1.2 Description of Factory Buildings:

1.3 FUTURE EXPANSION OF LPC BUILDING

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KEY PLAN FOR LPC BUILDING

1.4 Phase-1 Work of factory building

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Madhepura Electric Locomotive Pvt. Ltd Rev: 06 Page 8 of 49

1.5 Testing Building:

TRACK ON PILLARS: The tracks installed on pillars ( with suitable structural

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1.6 Trans border:

Total loading is considered in Floor for Trans-border is as follows :

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TYP. SECTION FOR TRANS-BORDER

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MAD-appendix 2.1015-a-Summary technical specification of trasborder-V1

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1.7 Track Pit:

NOTE: Pit depth is 1.7m from rail top level.

Refer document number: MAD-appendix 2.101-b Pit specification-V5

1.8 Rail Track:

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1.9 Dynamic Test Track

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1.10 Mobile Spraying Ramp:

1.11 Bogie Load Test Bench : REF DOC: 2011-03-14 BLTB

1.12 Wheel press: REF DOC: 2011-03-14 WP

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Key Plan for Gantry Girder (Typ. Detail):

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1.11 Above Roof typ. details:

1.12.2 Turbo Fan Fixing Detail:

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1.12.3 Polycarbonate sheet:

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Thickness of Plate Grade (Min. Yield Stress in Mpa)

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(Only for design of columns where Pr / Pd> 0.4)

Load combinations for Limit state of collapse for RCC design:

1.2 (DL + LL) + 1.05 CR 0.6 WL

Load combinations for Serviceability (Deflection check) for RCC design:

6.0 GRADE OF REINFORCEMENT STEEL

7.0 GRADE OF CONCRETE

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