Design Calculations of 246 MT Fixed Bearing for Nepal Project 1

DESIGN DATE : 04-10-2018 REV : 0 Date of revision :

DESIGNED BY : PRAVEJ ALI Location: Nepal Quantity : Nos.

LOADINGS & REQUIREMENTS :

LOADS NON-SEISMIC SEISMIC

MT kN MT kN Conc. Grade for Pedestal M 45
Vertical ( Max. ) 213.12 2090 250.85 2460.04 Conc. Grade for Superstructure M 45
Vertical ( Min. ) 143.78 1410 163.16 1600.08
Horizantal Loads
Longitudinal 16.31 159.95 94.84 930.08
Transverse 0 0 57 558.99
Resultant 159.95 1085.13
Conc. Stress Pedestal Stress < 22.78 MPa < 28.47 MPa AS PER IRC 83 PART (III) Clause 926.2.1.1
Superstructure Stress < 22.5 MPa < 28.13 MPa AS PER IRC 83 PART (III) Clause 926.2.1.1

Actual Requirement As Per IRC 83 Part ( III ) Cl. 926.1.6

Movement Requirement
Longitudinal ( mm ) 0 (+ 0 /- 0 ) ( 0 /- 0 )
Transverse ( mm ) 0 (+ 0 /- 0 ) ( 0 /- 0 )
Rotation ( Total ) 0.005 0.005 x 1.3 = 0.0065 radians
Rotation ( Due to Permanent Actions ) 0.0025 0.0025 x 1.3 = 0.00325 radians
Rotation ( Due to Variable Actions ) 0.0025 0.0025 x 1.3 = 0.00325 radians
Neoprene Pad Stress < 35 Mpa AS PER IRC 83 PART (III) Cl.926.2.3.2
PTFE Stress (Working) < 40 MPa AS PER IRC 83 PART (III) Cl.926.2.4.3
Steel Stress (Working) for Design Use 340 MPa (Grade-340-570W) AS PER IS - 1030

DESIGN INPUTS :

Neoprene Pad Size dia. in mm = 370 No of Sealing Rings = 2

Total Thk of rings = 4.0
Neoprene Pad thk. in mm = 27
Calculation for Permissible Stresses in Pedestal Concrete
Pot Base effective dia (actual in mm) = 494
Bottom :-
Pot Base Thickness (mm) = 16
Pot Base Effective dia. = 494 mm
Pot internal dia. (mm) = 370
Loaded area ( A2 ) = 3.14 x 494 x 494 = 191665.43 mm2
Pot depth (mm) = 47 4

Pot Wall Thickness (mm) = 68.5 Available Pedestal Size = 1000 x 1000 mm

Piston effective contact area dia. (mm) = 494 Disp. area ( A1 ) = 3.14 x 1000 x 1000 = 785398.17 mm2
4
Piston Thickness above Spiggot (mm) = 16
Permissible Concrete Stress =
Spiggot Projection = 29
A1 x 0.25 x fck
Bolt Diameter = 20 Gr. 8.8 A2

No. of Bolts per component = 14 785398.17 x 11.25 = 22.77 MPa

191665.43
Bolt Flange Thickness = 16
Top :-

Piston Effective dia. = 494 mm

Loaded area ( A2 ) = 3.14 x 494 x 494 = 191665 mm2

4

Min. Superstructure Size = 988 x 988 mm

Available for Dispersion

Disp. area ( A1 ) = 3.14 x 988 x 988 = 766661.70 mm2

4

Permissible Concrete Stress =

A1 x 0.25 x fck
A2

766661.70 x 11.25 = 22.50 MPa

191665.43

DESIGNER MANUFACTURER :- SUPER ASIAN INDUSTRIES BALLABHGHAR

 Design Calculations of 246 MT Fixed Bearing for Nepal Project 2

DESIGN OUTPUTS : Non - Seismic ( IRC 83 Part ( III ) Clause 926.2.3 )

Neoprene Pad Stress = 2090.03 x 1000 = 19.43 < 35 MPa

0.7854 x 370 x 370

HENCE O. K.

Conc. Stress at Pot Base = ( IRC 83 Part ( III ) Clause 926.1.5 )

I. Direct Bearing Stress due to Vertical Load :-

Stress = 2090.03 x 1000

0.7854 x 494 x 494

= 10.90 MPa < 22.78 MPa

HENCE O. K.

II. Flexural Stress due to active Moment resulting from acting Horizontal Force :-

e= 16 + 27 + 2.5 = 45.5

Stress = 159.95 x 1000 x 45.5

0.0982 x 494 x 494 x 494

= 0.61 MPa

III. Flexural Stress due to induced Moment resulting from resistance to Rotation :-
( IRC 83 Part ( III ) Clause 926.1.5.1)
1) M. .e. d. = di 3 x ( k 1 . q p +k2.qv)

di = 370.00 mm
k1= 1.94
qp= 0.0033 rad.
k2= 72.43
qv= 0.0033 rad.

M. .e. d. = 370 ^ 3 x ( 1.95 x 0.00325 + 72.43 x 0.00325 ) = 12243017.7 N.mm

2) M. R. D. = 0.2 x C x H ( IRC 83 Part ( III ) Clause 926.1.5.2)

C= 185.00 mm
H= 159.95 kN

M. R. D. = 0.2 x 185 x 159.95 x 1000 = 5918113.171 N.mm

Total Induced Moment = M. .e. d. + M. R. D.

Total Induced Moment = 12243017.70 + 5918113.17 = 18161130.87 N.mm

Stress = 18161130.87
0.0982 x 494 x 494 x 494

= 1.53 MPa

Total Flexural Stress = 0.61 + 1.53 = 2.15 < 15 Mpa ( IRC 83 Part ( III ) Clause 926.2.1.2)

Total Stress = 10.90 + 2.15 = 13.05 < 22.78 MPa ( IRC 83 Part ( III ) Clause 926.2.1)

HENCE O. K.

IV. Coexisting Direct and Flexural Stress Check :- ( IRC 83 Part ( III ) Clause 926.2.1.3)

Stress = 10.90 + 2.15 = 0.622 < 1.00

22.77 15

HENCE O. K.

Conc. Stress at Piston Base = ( IRC 83 Part ( III ) Clause 926.1.5 )

I. Direct Bearing Stress due to Vertical Load :-

Stress = 2090.03 x 1000

0.7854 x 494 x 494

= 10.90 MPa < 22.5 MPa

HENCE O. K.

DESIGNER MANUFACTURER :-SUPER ASIAN INDUSTRIES BALLABHGHAR

 Design Calculations of 246 MT Fixed Bearing for Nepal Project 3

II. Flexural Stress due to active Moment resulting from acting Horizontal Force :-

e= 16 + 29 - 2.5 = 42.5 mm

Stress = 159.95 x 1000 x 42.5

0.0982 x 494 x 494 x 494

= 0.57 MPa

II. Stress Due to Induced Moment Resulting from Resistance to Rotation :- ( IRC 83 Part ( III ) Clause 926.1.5.1)

1) M. .e. d. = di 3 x ( k 1 . q p +k2.qv)

di = 370.00 mm
k1= 1.94
qp= 0.0033 rad.
k2= 72.43
qv= 0.0033 rad.

M. .e. d. = 370 ^ 3 x ( 1.95 x 0.00325 + 72.43 x 0.00325 ) = 12243017.7 N.mm

2) M. R. D. = 0.2 x C x H ( IRC 83 Part ( III ) Clause 926.1.5.2)

C= 185.00 mm
H= 159.95 kN

M. R. D. = 0.2 x 185 x 159.95 x 1000 = 5918113.171 N.mm

Total Induced Moment = M. .e. d. + M. R. D.

Total Induced Moment = 12243017.7 + 5918113.171 = 18161130.87 N.mm

Stress = 18161130.87
0.0982 x 494 x 494 x 494

= 1.53 MPa

Total Flexural Stress = 0.57 + 1.53 = 2.11 < 15 Mpa ( IRC 83 Part ( III ) Clause 926.2.1)

Total Stress = 10.90 + 2.11 = 13.01 < 22.5 MPa

HENCE O. K.

IV. Coexisting Direct and Flexural Stress Check :- ( IRC 83 Part ( III ) Clause 926.2.1.3)

Stress = 10.90 + 2.11 = 0.625 < 1.00

22.50 15

HENCE O. K.

Design of Pot Wall = ( IRC 83 Part ( III ) Clause 926.3.1.1.7)

Force from Pad = 370 x 27 x 19.43 = 194114.10 N(per 1 section of ring)

Pressure from Pad (P1) = 194114.10 = 30.15 Mpa

2 x ( 47 x 68.5 )

Total Horizontal Force into Wall = 159.95 kN

Total Horizontal Stress into Wall due to Horizontal Force (P2) =

= 159.95 x 1000 = 24.84 Mpa

2 x ( 47 x 68.5 )

Total P = P1 + P2 = 30.15 + 24.84 = 54.99

54.99 < 204 ( 340 x 0.6 = 204 Mpa ) ( IRC 83 Part ( III ) Clause 926.2.2 )

HENCE O. K.
 Design Calculations of 246 MT Fixed Bearing for Nepal Project 4

DESIGN OUTPUT SEISMIC : ( IRC 83 Part ( III ) Clause 926.2.3 )

Neoprene Pad Stress = 2460.04 x 1000 = 22.87 < 35 MPa

0.7854 x 370 x 370

HENCE O. K.

Conc. Stress at Pot Base = ( IRC 83 Part ( III ) Clause 926.1.5 )

I. Direct Bearing Stress due to Vertical Load :-

Stress = 2460.04 x 1000

0.7854 x 494 x 494

= 12.84 MPa < 28.47 MPa

HENCE O. K.

II. Flexural Stress due to active Moment resulting from acting Horizontal Force :-

e= 16 + 27 + 2.5 = 45.5

Stress = 1085.13 x 1000 x 45.5

0.0982 x 494 x 494 x 494

= 4.17 MPa

III. Flexural Stress due to induced Moment resulting from resistance to Rotation :-
( IRC 83 Part ( III ) Clause 926.1.5.1)
1) M. .e. d. = di 3 x ( k 1 . q p +k2.qv)

di = 370.00 mm
k1= 1.94
qp= 0.0033 rad.
k2= 72.43
qv= 0.0033 rad.

M. .e. d. = 370 ^ 3 x ( 1.95 x 0.00325 + 72.43 x 0.00325 ) = 12243017.7 N.mm

2) M. R. D. = 0.2 x C x H ( IRC 83 Part ( III ) Clause 926.1.5.2)

C= 185.00 mm
H= 1085.13 kN

M. R. D. = 0.2 x 185 x 1085.14 x 1000 = 40149886.8 N.mm

Total Induced Moment = M. .e. d. + M. R. D.

Total Induced Moment = 12243017.7 + 40149886.8 = 52392904.5 N.mm

Stress = 52392904.5
0.0982 x 494 x 494 x 494

= 4.43 MPa

Total Flexural Stress = 4.17 + 4.43 = 8.60 < 18.75 Mpa ( IRC 83 Part ( III ) Clause 926.2.1.2)

Total Stress = 12.84 + 8.60 = 21.43 < 28.47 MPa

HENCE O. K.

IV. Coexisting Direct and Flexural Stress Check :- ( IRC 83 Part ( III ) Clause 926.2.1.3)

Stress = 12.84 + 8.60 = 0.9094 < 1.00

28.47 18.75

HENCE O. K.

Conc. Stress at Piston Base = ( IRC 83 Part ( III ) Clause 926.1.5 )

 Design Calculations of 246 MT Fixed Bearing for Nepal Project 5

I. Direct Bearing Stress due to Vertical Load :-

Stress = 2460.04 x 1000

0.7854 x 494 x 494

= 12.84 MPa < 28.13 MPa

HENCE O. K.

II. Flexural Stress due to active Moment resulting from acting Horizontal Force :-

e= 16 + 29 - 2.5 = 42.5 mm

Stress = 1085.13 x 1000 x 42.5

0.0982 x 494 x 494 x 494

= 3.90 MPa

II. Stress Due to Induced Moment Resulting from Resistance to Rotation :- ( IRC 83 Part ( III ) Clause 926.1.5.1)

1) M. .e. d. = di 3 x ( k 1 . q p +k2.qv)

di = 370.00 mm
k1= 1.94
qp= 0.0033 rad.
k2= 72.43
qv= 0.0033 rad.

M. .e. d. = 370 ^ 3 x ( 1.95 x 0.00325 + 72.43 x 0.00325 ) = 12243017.7 N.mm

2) M. R. D. = 0.2 x C x H ( IRC 83 Part ( III ) Clause 926.1.5.2)

C= 185.00 mm
H= 1085.13 kN

M. R. D. = 0.2 x 185 x 1085.14 x 1000 = 40149886.8 N.mm

Total Induced Moment = M. .e. d. + M. R. D.

Total Induced Moment = 12243017.7 + 40149886.8 = 52392904.5 N.mm

Stress = 52392904.5
0.0982 x 494 x 494 x 494

= 4.43 MPa

Total Flexural Stress = 3.90 + 4.43 = 8.32 < 18.75 Mpa ( IRC 83 Part ( III ) Clause 926.2.1)

Total Stress = 12.84 + 8.32 = 21.16 < 28.13 MPa

HENCE O. K.

IV. Coexisting Direct and Flexural Stress Check :- ( IRC 83 Part ( III ) Clause 926.2.1.3)

Stress = 12.84 + 8.32 = 0.9002 < 1.00

28.13 18.75

HENCE O. K.

Design of Pot Wall = ( IRC 83 Part ( III ) Clause 926.3.1.1.7)

Force from Pad = 370 x 27 x 22.87 = 228479.36 N(per 1 section of ring)

Pressure from Pad (P1) = 228479.36 = 35.4837 Mpa

2 x ( 47 x 68.5 )

Total Horizontal Force into Wall = 1085.13 kN

Total Horizontal Stress into Wall due to Horizontal Force (P2) =

= 1085.13 x 1000 = 168.52 Mpa

2 x ( 47 x 68.5 )

Total P = P1 + P2 = 35.48 + 168.52 = 204.01

204.0 < 204 ( 340 x 0.6 = 204 Mpa ) ( IRC 83 Part ( III ) Clause 926.2.2 )

HENCE O. K.
 Design Calculations of 246 MT Fixed Bearing for Nepal Project 6

MISCELLANEOUS DESIGN CHECKS :

Rotation Capacity - ( IRC 83 Part ( III ) Clause 926.2.3 )

Check Compression at edge of Neoprene Pad

Max. Permitted = 15 % of T1

= 0.15 x 23.0 = 3.45 mm

Thickness T1 is thickness of Pad less seal rings thickness

Rotation ( Radius ) = ( IRC 83 Part ( III ) Clause 926.2.3 )

3.45 = 0.0186 radians

370 x 0.5

> 0.0065 radians

HENCE O. K.

D/T ratio of Neoprene Pad = ( IRC 83 Part ( III ) Clause 926.2.3 )

370 = 13.70 < 15

27

HENCE O. K.

Vertical Face of Piston required = ( IRC 83 Part ( III ) Clause 926.3.1.3.1 )

Width = 1.3 ( Seismic H load ) x 1000

( Pot dia - 1.5) x 0.75 x 340

= 1.3 x 1085.13 x 1000

368.5 x 0.75 x 340

= 15.01 > 5 mm HENCE O. K.

Bolt Design = Non Seismic Seismic

( IRC 83 Part ( III ) Clause 926.3.6 )
Total Horizontal Force acting = 159.95 kN 1085.13 kN

Contribution to resistance by Bolts ( F1) :-

No of bolts used = 14 Nos. Bolt Diameter = 20 mm

C. Sec. Area of one Bolt = 245 mm2 Total C. Sec. Area of Bolts = 3430 mm2

Shear Strength of the Bolt Gr. 8.8 = 190.00 Mpa Shear Strength in Seismic = 190.00 Mpa

Total Shear Force Offered By the Bolts ( F1 ) =

3430 x 190 = 651.70 kN 3430 x 190 = 651.70 kN

1000 1000

Contribution to resistance by Friction ( F2 ) :-

Vertical Load ( Min. ) = 1410.02 kN 1600.08 kN

Co - efficient of Friction between Concrete and Steel as 0.2

Frictional Force ( F2 ) =

1410.02 x 0.2 = 282.00 kN 1600.08 x 0.2 = 320.02 kN

Total Resistance offered =

( F1 + F2 ) > 159.95 kN ( F1 + F2 ) > 1085.13 kN

651.7 + 282 > 159.95 kN 651.7 + 320.02 > 1085.13 kN

933.70 > 159.95 kN 971.72 > 1085.13 kN

HENCE O. K. HENCE O. K.
 Design Calculations of 246 MT Fixed Bearing for Nepal Project 7

Dowels Design (Pedestals) = ( IRC 83 Part ( III ) Clause 926.3.6.5 )

Size = Dia. = 50 mm
Length = 190 mm

Non Seismic Seismic

Horizontal Force over the Dowels By Bolts =

3 x 245 x 190 = 139650 N 3 x 245 x 190 = 139650 N

Stress = 139650.00 = 139650.00

50 x 190 50 x 190

= 14.70 < 15.00 Mpa = 14.70 < 18.56 Mpa

HENCE O. K. HENCE O. K.

Dowels Design (Superstructure) = ( IRC 83 Part ( III ) Clause 926.3.6.5 )

Size = Dia. = 50 mm
Length = 190 mm

Non Seismic Seismic

Horizontal Force over the Dowels By Bolts =

3 x 245 x 190 = 139650 N 3 x 245 x 190 = 139650 N

Stress = 139650.00 = 139650.00

50 x 190 50 x 190

= 14.70 < 15.00 Mpa = 14.70 < 15.00 Mpa

HENCE O. K. HENCE O. K.

Pot Interface = Non Seismic ( IRC 83 Part ( III ) Clause 926.3.1.1.7 ) Seismic

Shear stress at cylinder & base interface considering 1 mm slice

Fluid Pressure ( P1 ) = 27 x 19.4308 = 27 x 22.87

68.5 68.5

= 7.66 Mpa = 9.01 Mpa

Horizontal Force ( P2 ) = 1.5 x 159.95 x 1000 = 1.5 1085.13 x 1000

370 x 68.5 370 x 68.5

= 9.47 Mpa = 64.22 Mpa

= 7.66 + 9.47 = 9.01 + 64.22

Total Stress = 17.13 < 153 Mpa = 73.24 < 153 Mpa

HENCE O. K. HENCE O. K.

Bearing stress at cylinder & base interface considering 1 mm slice

2
Fluid Pressure ( P1 ) = 19.5 x ( 27.0 ) / 2 ) 6 = ( 22.9 x ( 27.0 )2/2)6
2
( 68.5 ) ( 68.5 )2

= 9.06 Mpa = 10.66 Mpa

Horizontal Force ( P2 ) = 1.5 x 1000 x 160 ( 27 + 2.5 ) x 6 = 1.5 x 1000 x 1085.14 ( 27 + 2.5 ) x 6
2 2
370 x ( 68.5 ) 370 x ( 68.5 )

= 24.46 Mpa = 165.95 Mpa

Total Stress = 9.06 + 24.5 = 10.66 + ####

= 33.52 < 224.4 Mpa = 176.6 < #### Mpa

HENCE O. K. HENCE O. K.

Combined stress at cylinder & base interface considering 1 mm slice

= ( ( 33.53 )2+ ( 3x(

2
17.13 ) )
1/2 2
= ( ( 176.61 ) + ( 3x (
2
#### ) )
1/2

= 44.76 < 306 Mpa = 217.45 < 306 Mpa

HENCE O. K. HENCE O. K.
 Design Calculations of 246 MT Fixed Bearing for Nepal Project 8

Stress into Lugs because of Horizontal Force

Total Horizontal Force on Bearing =

Non - Seismic = 159.95 kN Seismic = 1085.13 kN

Effective Length of Lug taking Shear =

3 x 20 = 60 mm

Thickness of Lug =
16 mm

Total Cross Sectional Area of Each Lug =

60 x 16 = 960 mm2

Number of Lugs in Each Bearing = 14 Nos.

Horizontal Force on Each Lug = 159.95 = 11.42 kN 1085.13 = 77.51 kN

14 14

Stress on Lug due to Hor. Force =

Stress = 11.43 x 1000 = 12 MPa 77.51 x 1000 = 80.8 MPa

960 < 153 Mpa 960 < 153 Mpa

HENCE O. K. HENCE O. K.

Check for Thickness of Piston in Bending :- Top

Maximum Vertical Load = 2090.03 kN

Effectice Dia of Piston = 494 mm

Effective area of the Top Plate in 3.14 x 494 x 494 = 191665.43 mm2
contact to concrete = 4

Stress to Conc. at Top Plate = 2090.03 x 1000 = 10.9046 N/mm

191665.4262

Diameter of the Loaded Area (Pad) = 370 mm

Projection of the Piston = 494 - 370 = 62.00 mm

2

Bending Moment at the Top B. M. = 10.90 x 62 x 62 = 20958.56 N-mm

2

Thk. Of Top Plate required to cater the B. M. = 20958.56 x 6 = 23.68 mm < 45 mm Hence O. K.
1 x 224.4

Check for the Thickness of Pot in Bending : Bottom

Maximum Vertical Load = 2090.03 kN

Pot Base Effective contact dia. (mm) = 494 mm

Effective area of the Pot Base in 3.14 x 494 x 494 = 191665.43 mm2
contact to concrete = 4

Concrete Stress on Bottom Plate = 2090.03 x 1000 = 10.90 MPa

191665.43

Diameter of the Loaded Area (Pad) = 370 mm

Projection of Bottom Plate each side = 494 - 370 = 62.00 mm

2

Bending Moment of Bottom Plate = 10.90 x 62 x 62 = 20959 Nmm / mm - width

2

Thk. Of Bottom Plate required to cater the B. M. = 20958.56 x 6 = 23.68 mm < 63 mm Hence O. K.
1 x 224.4