r_71.1994.08.302_r0.pdf

HINDUSTAN CONSTRUCTION CO. LTD

SAINJ Hydro Electric Project

STRUCTURAL DESIGN OF POWER HOUSE COMPLEX (FIRST STAGE CONSTRUCTION)

Report No. R-71.1994.08.302

December / 2012

Hydropower Department

Structural Design of Power House Complex ( First Stage Construction) 2/61

Table of Contents

Page

ANNEXURES ................................................................................................................................ 3

Annexure 1 STAAD PRO- Analysis Results.................................................................................... 3

Annexure 2 Structural Design of different components. ................................................................... 3

LIST OF REFERENCES ................................................................................................................ 3

1 INTRODUCTION ........................................................................................................ 4

1.1 POWER HOUSE COMPLEX ...................................................................................... 4

1.2 SCOPE OF THE PRESENT REPORT ......................................................................... 4

2 GEOMETRY OF THE STRUCTURE .......................................................................... 5

3 MATERIAL PROPERTIES ......................................................................................... 8

3.1 CONCRETE PROPERTIES ......................................................................................... 8

4 BOUNDARY CONDITIONS ...................................................................................... 8

4.1 FIRST STAGE CONCRETE MODEL ......................................................................... 8

4.2 SECOND STAGE CONCRETE MODEL .................................................................... 8

5 DESIGN LOADS & LOAD COMBINATION ............................................................ 10

5.1 DEAD LOAD ............................................................................................................. 11

5.2 CRANE LOAD ........................................................................................................... 11 5.2.1 EOT Crane load data (First Stage Model) .................................................................... 11 5.2.2 EOT Crane load data (Second Stage Model) ............................................................... 11

5.3 EARTHQUAKE LOAD .............................................................................................. 12

5.4 LOAD COMBINATIONS ........................................................................................... 13

6 DESIGN OF VARIOUS CONCRETE ELEMENTS ................................................... 13

6.1 CRANE BEAM ........................................................................................................... 13 6.1.1 Modelling & Analysis ................................................................................................. 13 6.1.2 Design Criteria ............................................................................................................ 14

6.2 CRANE COLUMNS ................................................................................................... 14 6.2.1 Modelling & Analysis ................................................................................................. 14 6.2.2 Design Criteria ............................................................................................................ 14

6.3 FLOOR BEAMS ......................................................................................................... 15 6.3.1 Design Criteria ............................................................................................................ 15

6.4 TIE BEAMS ................................................................................................................ 15


6.4.1 Design Criteria ............................................................................................................ 15

6.5 INTERMEDIATE FLOOR COLUMNS ...................................................................... 15

6.5.1 Design Criteria ............................................................................................................ 15

6.6 CRANE AND INTERMEDIATE FLOOR COLUMNS FOUNDATION .................... 15 6.6.1 Design Criteria ............................................................................................................ 15

7 RESULTS ................................................................................................................... 16

7.1 Results for Crane- Beams ............................................................................................ 16

7.2 Results for Crane-Column ........................................................................................... 17

7.3 Results for Floor Beams .............................................................................................. 18

7.4 Results for Tie Beams ................................................................................................. 18

7.5 Results for Intermediate Columns ................................................................................ 19

8 REINFORCEMENT PROPOSED ............................................................................... 20

8.1 Crane-Beams ............................................................................................................... 20

8.2 Crane-Columns ........................................................................................................... 20

8.3 Floor-Beams ................................................................................................................ 20

8.4 Tie-Beams ................................................................................................................... 21

8.5 Intermediate-Columns ................................................................................................. 21

9 CONCLUSIONS ......................................................................................................... 22

ANNEXURES

Annexure 1 STAAD PRO- Analysis Results. Annexure 2 Structural Design of different components.

LIST OF REFERENCES

[1] IS 456 – 2000 – “Plain and Reinforced Concrete – Code of Practice” [2] Indian Standard IS 1893-2002, Criteria for Earthquake Resistant Design of Structures.


1 INTRODUCTION

Sainj hydro-electric project is located on the Sainj River which is a tributary of Beas River near village Niharni in Kullu district of Himachal Pradesh. The Sainj Hydroelectric Project is a run off the river scheme. The main components of diversion structures are a six gated barrage including intake structure. The intake structure is located at the right bank of sainj barge. At d/s of Intake structure, two underground intake ducts are proposed that shall bifurcate to connect the two underground desander caverns for desilting purpose. The water conductor system includes a 6360.75 m long headrace tunnel, a surge shaft and a pressure shaft. An underground powerhouse complex consists of Powerhouse cavern and transformer bay cavern. The Power house Cavern consists of erection bay, machine bays and auxiliary bay. The machine bay is sized to house two no’s of Pelton TG units of 50MW each.

1.1 POWER HOUSE COMPLEX

The power house complex has installed two unit’s of 50 MW each. The two separate Frame structure separated by EJ of plan dimensions of 18m long x 16m wide & 19m long x 16m wide ( refer DWG No: 71.1994.08.011) are proposed to accommodate two unit’s. The power house complex two unit’s are separated by 25mm expansion joint (EJ) with each other and also with erection bay & control block at the interface by 25mm EJ. The power house complex frame structure is constructed in two stages. In the first stage only the side column (main crane column) and crane beam along with intermediated tie beam will be constructed, while in the second stage floor slabs, connecting beam, and some additional column (refer DWG No: 71.1994.08.011 to 71.1994.08.016) will be constructed.

1.2 SCOPE OF THE PRESENT REPORT

The scope of the present report is limited to the below

• Structural design of concrete elements (crane column & crane beam)

• To check whether the deformation behaviour of frame structure are within allowable range (expansion joint limit).

• To check whether the maximum foundation stresses are within the limit of safe bearing capacity.

• This report is limited to the structural design of crane column, crane beam & tie beam. The dowel reinforcement left for second stage construction for floor beam & intermediate column locations is also proposed.

A separate report will be submitted for analysis and structural design of floor slabs after receiving the actual cut out in slabs from E&M vendor.


2 GEOMETRY OF THE STRUCTURE

The typical model of power house complex (unit 1) frame structure for 1st and 2nd stage construction are shown in figure-1 to 3 below. The unit 1 frame structure is more critical since crane beam has a longer unsupported span in this layout.

Figure 1: Typical Model Geometry- Unit-1 (Isometric view-1)-First stage model.

Salient Features (First Stage Model):

Crane column size : 1.0m x 1.0m

Crane Column Start elevation : EL. 1336m

1336.0 masl

1359.7 masl

1354.4 masl


Crane beam size (wide x deep) : 1.0m x 1.2m

Crane beam top elevation : EL. 1359.70m

Tie beam size (wide x deep) : 0.4m x 0.6m

Finished Tie beam top level : EL. 1354.40m

Figure 2: Typical Model Geometry- Unit-1 (Isometric view-1)-Second stage concrete model.


Figure 3: Typical Model Geometry- Unit-1 (Isometric view-2)- Second stage concrete model.

Salient Features (Second Stage Model):

Crane column size : 1.0m x 1.0m

Crane beam size (wide x deep) : 1.0m x 1.2m

Floor column size : 0.5m x 0.5m

Floor beam size (wide x deep) : 0.5m x 0.8m

Tie beam size (wide x deep) : 0.4m x 0.6m

Floor thickness (for all floors) : 0.4m


General arrangement drawings of Power House can be referred from DWG No: 71.1994.08.011 TO 71.1994.08.016 & from DWG. No: 71.1994.08.021 TO 71.1994.08.023.

STAAD.Pro is used for frame analysis. Two different models as shown in figure 1 & 2 are used for analyzing first stage and second stage construction of Power house complex. Limit State method ( IS 456 :2000) is followed for structural design of various elements.

3 MATERIAL PROPERTIES

3.1 CONCRETE PROPERTIES

Concrete of grade : M30 / M25 (refer concrete outline drawings)

Unit weight of : 24.00 kN/m3

Poissons ratio : 0.17

Youngs modulus : fck5000 MPa

Safe Bearing Capacity of Rock(Assumed) : 150 T/m2

4 BOUNDARY CONDITIONS

The following boundary conditions are assumed in the numerical analysis of the first & second stage concrete model:

4.1 FIRST STAGE CONCRETE MODEL

• The nodes of bottom of Crane columns (EL. 1336.00 m) are considered as fixed in all degree of freedom. (Refer figure 4)

4.2 SECOND STAGE CONCRETE MODEL

• Fixity boundary conditions are assumed along the interface of Turbine/Generator concrete with floor slab at EL 1339.75m & EL. 1343.43m. (Refer figure 5)


Figure 4: Fixity Boundary condition shown for first stage model.


Figure 5: Fixity Boundary condition shown for Full second stage model.

5 DESIGN LOADS & LOAD COMBINATION

The following loads have been considered in the analysis:

• Dead Load (DL)

• Crane Load (CL)

• Earthquake Loads (EQ)


5.1 DEAD LOAD

Dead load of unit weight of RCC as 25 kN/m3 is assumed.

5.2 CRANE LOAD

The load considered for EOT crane mounted at the top of the beam are following

5.2.1 EOT Crane load data (First Stage Model)

• Wheel load (static)-Per wheel 196 kN

• Wheel load (dynamic-with impact factor)- Per wheel 245 kN

• Wheel base 7.0 m

• Span of EOT Crane 15.0 m

• Number of wheels at one side 4 no’s

• Longitudinal force due to breaking in LT movement (Per wheel) 12 kN

• Transverse force due to breaking CT movement (Per wheel) 12 kN

5.2.2 EOT Crane load data (Second Stage Model)

• Wheel load (static)-Per wheel 480.12 kN

• Parked Wheel Load (50% static)-Per wheel 240 kN

• Wheel load (dynamic-with impact factor)- Per wheel 600.7 kN

• Wheel base 7.0 m

• Span of EOT Crane 15.0 m

• Number of wheels at one side 4 no’s

• Longitudinal force due to breaking in LT movement (Per wheel) 24 kN

• Transverse force due to breaking CT movement (Per wheel) 24 kN

• Floor load at EL. 1347.80 (Operating Floor) 15 kPa

• Floor load (each) at EL. 1343.43 & at EL.1339.75 15 kPa


5.3 EARTHQUAKE LOAD

Response spectrum of IS: 1893-2002 has been used for seismic analysis. It is assumed that the construction site falls in Zone IV of earthquake zoning map of ref [2]. As per Ref. [2], the horizontal peak ground accelerations for Zone IV (Z) is 0.24g. Further 50% reduction in horizontal spectral acceleration has been assumed, since the structure is underground with hard rock strata.

Vertical seismic coefficient is taken as 2/3 of horizontal acceleration (Ref. [2]). The Importance factor (I), reduction factor (R) are taken 1.5 & 5 respectively. Further 5% damping is assumed in the structure.

First Stage Model

In Plane direction

The computed time period corresponding to the fundamental mode of first stage model with in plane direction by STAAD is 1.10 sec. As per Ref [2], the seismic coefficients for DBE are assumed as following:

Horizontal Seismic Spectral Coefficient, αh (Cl.6.4.2) = g

S

R

IZA a

h **2

= = 0.032g

Vertical Seismic Spectral Coefficient, αv = (2/3)*αh = (2/3)*0.032 = 0.021g

Note: 50% reduction is done in computing above spectral accelerations.

Out of Plane direction

The computed time period corresponding to the fundamental mode of first stage model out of plane direction by STAAD is 2.13 sec. As per Ref [2], the seismic coefficients for DBE are assumed as following:


S

R

IZA a

h **2

= = 0.017g



Second Stage Model

In Plane direction

The computed time period corresponding to the fundamental mode of second stage model with in plane direction by STAAD is 0.33sec. As per Ref [2], the seismic coefficients for DBE are assumed as following:



S

R

IZA a

h **2

= = 0.09g



Out of Plane direction

The computed time period corresponding to the fundamental mode of second stage model out of plane direction by STAAD is 0.66 sec. As per Ref [2], the seismic coefficients for DBE are assumed as following:


S

R

IZA a

h **2

= = 0.053g



5.4 LOAD COMBINATIONS Following loading combinations have been considered in the analysis of power house complex for both models.

1. Self weight of structure + Crane Load (static load).

2. Self weight of structure + Crane Load (dynamic load).

3. Self weight of structure + 50% Crane Static (Parked crane Load) + Earthquake

load (100 % x direction + 30% z direction).

4. Self weight of structure + 50% Crane Static (Parked crane Load) + Earthquake

load (100 % z direction + 30% x direction).

6 DESIGN OF VARIOUS CONCRETE ELEMENTS

6.1 CRANE BEAM

6.1.1 Modelling & Analysis

The Crane beam is modelled as member element. Concrete properties of 1m wide & 1.1m deep have been proposed to crane beam, whereas the remaining 0.1m depth beam


dead weight together will rail dead weight is applied as line load of 3 kN/m. The crane beam is connected integrally with crane columns.

6.1.2 Design Criteria

Crane beam will be designed for the load combination mentioned in sec 5.4, where full crane load as mentioned in sec 5.2.2 will be considered for structural design. The most critical location of the wheel loads that can induce the maximum vertical bending moment will be located by using moving load option in Staad-pro. Similarly the most critical location of wheel loads that can induce the maximum shear force will be located. The depth of crane beam will be checked for the permissible deflection. The Crane beam will be designed for maximum bending moment, torsion & shear force. The reinforcement will also to be checked for the lateral bending moment in the crane beam. Ductile detailing will be done for beams as per IS:13920

Refer Annexure-I & II for analysis results & structural design of Crane beam. Refer Table 1a & 1b for critical bending moment values.

6.2 CRANE COLUMNS

6.2.1 Modelling & Analysis

The Crane column is modelled as member element. At bottom, the boundary condition of the column has been proposed as fixed. At top the column is connected integrally with crane beams & other beam location as shown in respective drawings.


Structural design of Crane column of First stage concrete model will be done for the maximum bending moments & axial force resulted from two independent analyses. In the first analysis, first stage concrete model will be analyzed for the load combination mentioned in sec 5.4, where crane load as mentioned in sec 5.2.1 will be considered. In the second analysis, second stage concrete model will be analyzed for the load combination mentioned in sec 5.4, where crane & floor load as mentioned in sec 5.2.2 will be considered. The Crane Column will be designed for biaxial bending moment & axial load induced by the most critical load combination from the two independent analyses. At the elevation of crane beam & tie beam, the crane column should have monolithical connection. Dowels will be left in column of first stage model for later stage raft & beam construction in second stage concreting. The dowels/reinforcement diameter & spacing will be done on the basis of structural analysis of second stage full model. Ductile detailing will be done for columns as per IS:13920. Refer Annexure-I & II for analysis results & structural design of crane columns. Refer Table 2 for possible critical bending moment & axial force values of columns.


6.3 FLOOR BEAMS


Intermediate floor beams will be designed for the load combination mentioned in sec 5.4, where full crane & floor load as mentioned in sec 5.2.2 will be considered for structural design. The second stage concrete model is considered for the structural design of intermediate floor beam to calculate the reinforcement in the beam so as to leave sufficient dowel reinforcement at Crane column interface. Refer Annexure-I & II for analysis results & structural design of Floor beams. Refer Table 3a & 3b for critical design loads.

6.4 TIE BEAMS


Tie beams will be designed for the load combination mentioned in sec 5.4, where full crane load as mentioned in sec 5.2.2 will be considered for structural design. The second stage concrete model is considered for the structural design of tie beam to calculate the reinforcement in the beam as this load combination will generate maximum bending moments.

Refer Annexure-I & II for analysis results & structural design of tie beams. Refer Table 4a & 4b for critical design loads.

6.5 INTERMEDIATE FLOOR COLUMNS


Intermediate floor Columns will be designed for the load combination mentioned in sec 5.4, where full crane & floor load as mentioned in sec 5.2.2 will be considered for structural design. The second stage concrete model is considered for the structural design of intermediate floor column to calculate the reinforcement in the column so as to leave sufficient dowel reinforcement from MIV floor raft. Refer Annexure-I & II for analysis results & structural design of intermediate floor column. Refer Table 5 for critical design loads.

6.6 CRANE AND INTERMEDIATE FLOOR COLUMNS FOUNDATION


A 0.9m thick concrete raft is proposed at MIV floor. During first stage concreting phase, this raft is integrally connected along the interface of circular tailrace pit. Hence no separate foundation for Crane columns or floor columns is foreseen. The Crane


Columns at U/s side shall start from MIV floor raft, where as the Crane Columns at D/s side shall also start from MIV floor level and is integrally connected with a 1m thick concrete wall of C/w Duct. The reinforcement for D/s Crane Columns is proposed to start from bottom of the C/w Duct wall foundation to result more conservative design. Further a 32mm dia grouted rock bolts have been proposed to connect the concrete raft to foundation rock integrally. By adopting the stitching mechanism of concrete to rock, it results very nominal flexure in the raft. Further, an adequate reinforcement of 20mm dia @ 250mm c/c is proposed at top and bottom side both ways of the raft.

7 RESULTS

Structural designs of individual members are mentioned in Annexure- II.

7.1 Results for Crane- Beams

Results of the Design moments and Shear for the Crane beams are presented below in Table 1a & Table 1b. Table 1a: Summary of Design Forces in 10m Span Crane-Beams.

END-1 END-2 SpanMoment type Hogging Hogging SaggingUn-factored Moment (kNm) 2220 1540 1930Un-factored shear (kN) 1440 1340

Factor of Safety 1.5 1.5 1.5

Factored Moment (kNm) 3330 2310 2895Factored shear (kN) 2160 2010

Design Moments & Shear for Crane Beam (Span 10m)

Factored values


Table 1b: Summary of Design Forces in 7m Span Crane-Beams.

END-1 END-2 SpanMoment type Hogging Hogging SaggingUn-factored Moment (kNm) 1100 661 1050Un-factored shear (kN) 1040 903

Factor of Safety 1.5 1.5 1.5

Factored Moment (kNm) 1650 992 1575

Factored shear (kN) 1560 1355

Design Moments & Shear for Crane Beam ( Span 7m)

Factored values

The moments and Shear obtained from STAAD results have been modified for Torsion as per Cl. 41.3.1 and Cl. 41.4.2 of IS 456: 2000. The summary of the required reinforcement is given in Annexure II.

7.2 Results for Crane-Column

Results of the Analysis of Crane column are presented below in Table 2.

Table 2: Summary of Design Forces in Crane-Column

Moment( My) IN PLANE

kNm

Moment( Mz) OUT OF

PLANE kNm

Axial Force kN

Top 1430 45 1290Bottom 188 171 1289

Top 1070 46 1480Bottom 207 161 1475

Factor of Safety Top 1.5 1.5 1.5Bottom 2145 67.5 1935

282 257 1934

Top 1605 69 2220Bottom 311 242 2213

Design Moments & Axial force for Crane Column

Column D-Line

Column B-line

Column D-Line

Column B-line

Factored Values

Note: Critical column from analysis is located at the intersection of B & 2 grid lines, between the EL 1354.1 & 1359.1 of 4.1m clear distance. Only the most critical column is presented in Annexure-I for structural design from Table 2.


7.3 Results for Floor Beams

Results of the Design moments and Shear for the floor beams are presented below in Table 3a & Table 3b. Table 3a: Summary of Design Forces in floor-Beams at EL. 1347.77.

Moment type Hogging Hogging SaggingUn-factored Moment (kNm) 226 201 132Un-factored shear (kN) 135 82

Torsion (kN) 153

Factor of Safety 1.5 1.5 1.5Factored Moment (kNm) 339 302 198Factored shear (kN) 203 123

Torsion (kN) 229.5

Design Moments & Shear for Floor Beam at EL . Top

Factored values

Table 3b: Summary of Design Forces in floor-Beams at EL. 1343.40.

Moment type Hogging Hogging SaggingUn-factored Moment (kNm) 205 82 107Un-factored shear (kN) 130 70

Torsion (kN) 83

Factor of Safety 1.5 1.5 1.5Factored Moment (kNm) 308 123 161


Torsion (kN) 124.5

Design Moments & Shear for Floor Beam at EL BOTTOM

Factored values

7.4 Results for Tie Beams

Results of the Design moments and Shear for the tie beams are presented below in Table 4a & Table 4b.


Table 4a: Summary of Design Forces in Tie beam.

Moment type Hogging Hogging Sagging

Un-factored Moment (kNm) 148 130 10Un-factored shear (kN) 93 89

Factor of Safety 1.2 1.2 1.2Factored Moment (kNm) 178 156 12Factored shear (kN) 112 107

Design Moments & Shear for Tie Beam ( Min. Span )

Factored values

Table 4b: Summary of Design Forces in Tie beam.

Moment type Hogging Hogging Sagging

Un-factored Moment (kNm) 94 82 15Un-factored shear (kN) 26 13

Factor of Safety 1.2 1.2 1.2Factored Moment (kNm) 113 98 18


Design Moments & Shear for Tie Beam ( Max. Span)

Factored values

7.5 Results for Intermediate Columns

Results of the Design moments and Shear for the intermediate column are presented below in Table 5.

Table 5: Summary of Design Forces in Intermediate Column.

Moment( My) IN PLANE

kNm

Moment( Mz) OUT OF

PLANE kNm

Axial Force kN

Top 88 74 244Bottom 69 57 240

Factor of Safety 1.5 1.5 1.5Top 132 111 366Bottom 103.5 86 360

Design Moments & Axial force for Intermediate Column

Intermediate Column

Factored Values


8 REINFORCEMENT PROPOSED

8.1 Crane-Beams

The summary of Proposed Reinforcement in Crane-Beams is as shown in Table 7

Table 7: Summary of Proposed Reinforcement in Crane-Beams

Sl. No.

Beam Top Reinforcement

Bottom Reinforcement

Shear Reinforcement*

Remarks

1 10m Span

10 Nos. 36 Dia 9 Nos. 36 Dia 12φ @100 c/c ( 4 legged)

Provide 2 Nos 20 Dia bars / face as side r/f

2 7m Span



*Note: Refer suitable drawings for actual reinforcement arrangement.

8.2 Crane-Columns

The summary of Proposed Reinforcement in crane-columns is as shown below in Table 8

Table 8: Summary of Proposed Reinforcement in Crane-Columns (Model-1)


8.3 Floor-Beams

The summary of Proposed Reinforcement in Floor-Beams is as shown in Table 9.

Sl. No.

Column Column Each Face Reinforcement

Transverse hoop Reinforcement*

1 All crane columns

5 Nos. 32 Dia 12φ @100 c/c


Table 9: Summary of Proposed Reinforcement in Floor-Beams

Sl. No.

Beam Top Reinforcement



Remarks

1 At EL.1347.77



2 At EL.1343.4 & EL.1339.72




8.4 Tie-Beams

The summary of Proposed Reinforcement in Tie-Beams is as shown in Table 10.

Table 10: Summary of Proposed Reinforcement in Tie-Beams

Sl. No.

Tie Beam Top Reinforcement



1 1.9m clear Span


2 9m & 6m clear Span



8.5 Intermediate-Columns

The summary of Proposed Reinforcement in intermediate-columns is as shown below in Table 11.

Table 11: Summary of Proposed Reinforcement in Intermediate Columns.


Sl. No.

Column Column Each Face Reinforcement

Transverse hoop Reinforcement*

1 All intermediate columns

3 Nos. 25 Dia 12φ @100 c/c


9 CONCLUSIONS

Based on the analysis following conclusion can be made

• The proposed reinforcement for various concrete elements is designed for most

critical load combinations.

• Continuous raft is provided as the crane column footings.

• The maximum vertical deflection in the crane beam (10 m span beam center to center

) is of 8.2mm for the critical load combination.

• The maximum horizontal deflection in the frame structure ( first stage model) is of

12.5 mm for the critical load combination, which is under allowable limit of 25mm

Expansion joint.

• The bending moments developed at crane column footing are not significiant,

therefore Nominal reinforcement of 20mm dia at 250mm spacing c/c is provided.


ANNEXURE-I

(STAAD PRO- Analysis Results) FIRST STAGE STAAD MODEL


Figure 1: Unfactored Bending moment diagram envelope for Crane Beam along D-line.

Figure 2: Unfactored Shear Force diagram envelope for Crane Beam along D-line. Note: Critical Bending moment and shear force location for crane beam (along D-line) occurs when right most crane wheel is approx. 1.2m from the right most column.

1930 kNm

1670 kNm

1050 kNm

2220 kNm

661 kNm

903 kN

1040 kN

1440 kN

1340 kN

1260 kNm


Figure 3: Unfactored Out of Plane Bending moment envelope for Crane Column along D-line. Note: Critical out of plane Bending moment for crane column (along D-line) occurs when right most crane wheel are to at right most part of the structure.


Figure 4: Unfactored Maximum Inplane Bending moment diagram at bottom of the Crane Column ( along D-line). ( result of load combination with seismic load)


Figure 5: Unfactored Maximum Inplane Bending moment diagram at top of the Crane Column (along D-line).( right most crane wheel is approx. 1.2m from the right most column)


Figure 6: Unfactored Maximum Axial force diagram for Crane Column ( right most crane wheel is approx. 1.2m from the right most column)


Figure 7: Unfactored Maximum Axial force diagram for Crane Column. (CG of the crane wheel is exactly at the middle crane column)

1060 kN

1660 kN

300 kN

888 kN


STAAD RESULTS-SECOND STAGE MODEL


Figure 8: Vertical INPLANE bending moment envelope for floor beam at EL. 1347.770.

154 kNm

145 kNm

226kNm

197 kNm

126 kNm

106 kNm

123 kNm

152 kNm

83 kNm

132 kNm

116 kNm

201 kNm

117 kNm

115 kNm

92 kNm


Figure 9: Shear force envelope for floor beam at EL. 1347.770.

50 kN

82 kN

75 kN

92 kN

72 kN 72 kN

135 kN



85 kNm

142 kNm

198kNm

178 kNm

156 kNm

46 kNm

70 kNm

128 kNm 73 kNm

90 kNm

205 kNm

65 kNm

107 kNm

41 kNm 90 kNm



51 kNm

99 kNm

71 kNm

133 kNm

101 kNm

40 kNm

51 kNm

122 kNm

68 kNm

59 kNm

40 kNm

59 kNm

18 kNm

75 kNm

24 kNm


Figure 12: Unfactored Inplane Bending moment envelope at top of the Crane Column (along D-line). Note: Critical bending moment location occurs when right most crane wheel is approx. 1.2m from the right most column.

34 kNm 10 kNm

43 kNm

435 kNm 515 kNm 502 kNm

661 kNm 935 kNm 1070 kNm

145 kNm 68 kNm

68 kNm

98 kNm 33 kNm 113 kNm

182 kNm 200 kNm 222 kNm

288 kNm

141 kNm

70 kNm


Figure 13: Unfactored Out of plane Bending moment envelope of crane column along D line.


Figure 14: Unfactored axial force diagram of Crane Column (along D-line). Note: Results shown when the CG of crane is exactly at the top of the middle column

2310 kN

2570 kN

2320 kN

2140 kN

962 kN

720 kN

435 kN

161 kN

360 kN

470 kN

380 kN

825 kN


Figure 15: Unfactored axial force diagram of Crane Column (along D-line). Note: Results shown when right most crane wheel is approx. 1.2m from grid No: 2.

716 kN

1180 kN

1930 kN

2000 kN

844 kN

1120 kN

1360kN

1510 kN

1640 kN


Figure 16: Unfactored Inplane Bending moment envelope of Tie Beam (along B-line)

Figure 17: Unfactored shear force diagram envelope of Tie beam along B line


Figure 18: Unfactored Inplane Bending moment envelope at top of the Crane Column (along B-line). Note: Critical bending moment location occurs when right most crane wheel is approx. 1.2m from the right most column.

5 kNm 1 kNm 24 kNm



422 kNm 458 kNm 411 kNm


1430 kNm 1230 kNm 626 kNm


Figure 19: Unfactored Out of plane Bending moment envelope of crane column along B line.

21 kNm

1 kNm

8 kNm

75 kNm

17 kNm

15 kNm

62 kNm

65 kNm

108 kNm

497 kNm

552 kNm

580 kNm


Figure 20: Unfactored Inplane Bending moment envelope of Intermediate.

2 kNm

88 kNm

85 kNm

35 kNm

30kNm

10 kNm

69 kNm

66 kNm

8 kNm

15 kNm

27 kNm

21 kNm

7 kNm

5 kNm

2 kNm

10 kNm

35 kNm

37 kNm

20kNm


Figure 21: Unfactored Out of plane Bending moment envelope of Intermediate Columns.

30 kNm

27 kNm

31 kNm

17 kNm

11 kNm

59 kNm

74 kNm

44 kNm

57 kNm

26 kNm

30 kNm

8 kNm

8 kNm

14 kNm

3 kNm


Figure 22: Unfactored axial force diagram of Intermediate Columns.

219 kNm

421 kNm

536 kNm

141 kNm

260 kNm

507 kNm

351 kNm

284 kNm

244 kNm

472 kNm

566 kNm


ANNEXURE-II

(Structural Design of Different Components)


Material Data:Characteristic strength of concrete fck = 30 Mpa

Characteristic strength of steel fy = 500 Mpa

Nominal Cover to be provided d' = 40 mm

Design Input:

Overall Depth of the Beam D = 1100 mm

Width of the Beam b = 1000 mm

Diameter of Stirrup = 12 mm

Diameter of main Reinforcement bar = 36 mm

Effective depth of beam d = 1030 mm

Design Loads:

(Refer STAAD file for the Loads and Load combinations)

Design Moments

Maximum Factored Support Moment at Top = 3330 kN-m

Maximum Factored Span Bottom Moment = 2895 kN-m

Design for Bottom Reinforcement:

Factored span moment = 2895 kN-m

Area of steel Ast = 7335 mm2

Minimum reinforcement as per IS 13920 cl. 6.2.1(b) (0.24*sqrt(fck)*b*d/fy) = 2708 mm2

Diameter of bar to be used = 36 mm

Sectional area of bar = 1018 mm2

Number of bars required = 7.2

Provide 9 - 36 dia bars

Design for Top Reinforcement:

Factored Support Moment Mu = 3330 kN-m

Maximum Factored Torsion Tu = 147 kN-m

Equivalent Factored Bending moment due to Torsion Tu x ((1+D/b) /1.7) Mt = 182 kN-m

As per Clause 41.4.2.1

Total Factored support bending moment = 3512 kN-m






Provide 10 - 36

0.5 x fck x{1- [1 - 4.6xMz/(fckxbd2)] 0.5 } x b x d


fy

fy

Structural Design of Crane Beam ( Span 10m )


Design for Side face Reinforcement

Overall Depth of beam D = 1100 mm

Width of beam b = 1000 mm

Minimum each side face reinforcement as per IS 456 - 2000 cl. 26.5.1.3(0.05%*b*d) = 550 mm2



Number of bars = 1.8

Spacing should not exceed 300 mm or web thickness whichever is less

Spacing of bars 336 mm

Provide 2 -

Design Shear Reinforcement

Max. Factored Shear Force Vu = 2160 kN

Max. Factored Torsional Moment Tu = 147 kN-m

Width of the beam b = 1000 mm

Equivalent shear Force Ve = Vu+ 1.6*Tu/b Ve = 2395 kN

Equivalent Shear stress τve = Ve/(b*d) τve = 2.33 N/mm2

% of Tensile reinforcement provided at support As = 0.99 %

0.8xfck / ( 6.89xAs ) β = 3.52

Design shear strength of section for the provided tensile reinf. at support τc = 0.65 N/mm2

Spacing of the stirrup reinforcement sv = 100 mm

Diameter of Stirrup to be used = 12 mm

Centre to centre distance between corner bars in the direction of width b1 = 896 mm

Centre to centre distance between corner bars in the direction of depth d1 = 960 mm

Asv = 246 mm2

Min. transverse reinforcement Asv = 385 mm2

Max. of above two values = 385 mm2


Nos. of legs required = 3.4

Provide 12 @ 100 mm c/c

20 dia bars at equal spacing on each face

mm dia 4-legged stirrups

Asv = (Sv*(Tu/b1+Vu/2.5))/(d1*0.87*fy)Calculated area of transverse reinforcement as per 41.4.3-IS:456

Asv =( (τve-τc)*b*Sv)/(0.87*fy)





Design Input:






Design Loads:


Design Moments


Maximum Factored Span Moment = 1575 kN-m










Factored End Moment Mu = 992 kN-m

Factored Torsion Tu = 123 kN-m









Provide 5 - 36



fy

fy

Structural Design of Crane Beam ( Span 7m )











Provide 2 -








0.8xfck / ( 6.89xAs ) β = 3.52






Asv = 163 mm2











DESIGN INPUT

Grade of Concrete M-25

Grade of Steel Fe-500

Compressive Strength of Concrete fck = 25 N/mm2

Characteristic strength of reinforcement Steel fy = 500 N/mm2

Clear cover = 50 mm

Diameter of lateral tie = 12 mm

Width of column b = 1000 mm

Depth of column D = 1000 mm

Starting Elevation of column = 1354.10 m

Top Elevation of column = 1359.10 m

Unsupported length of column L = 4.10 m

REINFORCEMENT DETAILS

Dia of bars used = 32 mm

Effective cover d' = 78 mm

Percentage of reinforcemnt used p = 1.29 %

STAAD RESULTS (FACTORED)

Axial Force Pu = 1935.00 kN

Moment within Plane My = 2145.00 kN-m

Moment out of plane Mz = 67.50 kN-m

Corresponding torsion Tu = 12.00 kN-m

DESIGN MOMENTS ( within Plane )

Maximum bending moment from STAAD My = 2145.00 kN-m

Equivalent bending moment for torsion Mey = 14.12 kN-m

Effective length of column Ley = L = 4.10 m

Slenderness ratio Ley/D = 4.10

Minimum eccentricity ez = 41.53 mm

Moment due to minimum eccentricity My,min = 80.37 kN-m

Additional moment due to eccnetricity May = 0.00 kN-m

Design Moment with in Plane Muy = 2159 kN-m

CRANE COLUMN ALONG B-LINE- SECOND STAGE (1000X1000)

Mey = (Tu/1.7)*(1+D/b)

MAX(Ley/500+D/30,20)

P*ez

DESIGN OF COLUMN FOR MAXIMUM MY

P*D/2000*(Ley/D)^2


DESIGN MOMENTS (Out of Plane)

Maximum bending moment from STAAD Mz = 67.50 kN-m

Equivalent bending moment for torsion Mez = 14.12 kN-m

Effective length of column Lez = L = 5.45 m

Slenderness ratio Lez/b = 5.45

Minimum eccentricity ey = 44.23 mm

Moment due to minimum eccentricity Mz,min = 85.59 kN-m

Additional moment due to eccnetricity Maz = 0.00 kN-m

Design Moment out of Plane Muz = 86 kN-m

MOMENT CAPACITY ( within Plane )

d'/D = 0.078

p/fck = 0.051

Pu/(fckbD) = 0.077

Referring Chart 48 of SP-16 Muy,l/(fckbD2) = 0.105

Muy,l = 2625 kN-m

MOMENT CAPACITY (Out of Plane)

d'/b = 0.078

p/fck = 0.051

Pu/(fckbD) = 0.077

Referring Chart 49 of SP-16 Muz,l/(fckDb2) = 0.100

Muz,l = 2500 kN-m

COLUMN SECTION CHECK

Area of steel As = 12870 mm2

Ac = 987130 mm2

Puz = 0.45fckAc + 0.75fyAs Puz = 15931 kN

Pu/Puz = 0.12

an = 1.00

Muy/Muy,l = 0.82

Muz/Muz,l = 0.03

= 0.86 < 1.00(Muy/Muy,l)an+(Muy/Muy,l)an

Mez = (Tu/1.7)*(1+b/D)

MAX(Lez/500+b/30,20)

P*ey

P*b/2000*(Lez/b)^2





Design Input:






Design Loads:


Design Moments


Maximum Factored Support Moment at bottom = 198 kN-m


Factored moment = 198 kN-m








Factored Moment Mu = 339 kN-m

Factored Torsion at the Support Tu = 230 kN-m









Provide 5 - 25

Structural Design of Floor Beam at EL. 1347.77



fy

fy











Provide 2 -

Design For Maximum Shear







0.8xfck / ( 6.89xAs ) β = 5.22






Asv = 373 mm2














Design Input:






Design Loads:


Design Moments


Maximum Factored Support Moment at bottom = 161 kN-m


Factored moment = 161 kN-m








Factored Moment Mu = 308 kN-m










Provide 4 - 25



fy

fy

Structural Design of Floor Beam at EL. 1343.4 & EL 1339.72











Provide 2 -

Design For Maximum Shear







0.8xfck / ( 6.89xAs ) β = 6.52






Asv = 341 mm2














Design Input:






Design Loads:


Design Moments

Maximum Factored Moment( Hogging) = 178 kN-m

Maximum Factored Span Moment ( Sagging) = 60 kN-m










Factored Hogging Moment Mu = 178 kN-m










Provide 4 - 20

Structural Design of Tie Beam ( at Minimum span location)



fy

fy









0.8xfck / ( 6.89xAs ) β = 6.65






Asv = 150 mm2





Provide 12 @ 300 mm c/cmm dia 2-legged stirrups







Design Input:






Design Loads:


Design Moments

Maximum Factored Moment( Hogging) = 110 kN-m

Maximum Factored Span Moment ( Sagging) = 60 kN-m










Factored Hogging Moment Mu = 110 kN-m










Provide 3 - 20

Structural Design of Tie Beam ( at Max. span location)



fy

fy









0.8xfck / ( 6.89xAs ) β = 6.65






Asv = 54 mm2

Min. transverse reinforcement Asv = -49 mm2




Provide 10 @ 300 mm c/cmm dia 2-legged stirrups




DESIGN INPUT

Grade of Concrete M-25

Grade of Steel Fe-500

Compressive Strength of Concrete fck = 25 N/mm2

Characteristic strength of reinforcement Steel fy = 500 N/mm2

Clear cover = 40 mm

Diameter of lateral tie = 12 mm

Width of column b = 500 mm

Depth of column D = 500 mm

Starting Elevation of column = 1347.77 m

Top Elevation of column = 1343.40 m

Unsupported length of column L = 4.37 m

REINFORCEMENT DETAILS

Dia of bars used = 25 mm

Effective cover d' = 65 mm

Percentage of reinforcemnt used p = 1.56 %

STAAD RESULTS (FACTORED)

Axial Force Pu = 366.00 kN

Moment within Plane My = 132.00 kN-m

Moment out of plane Mz = 111.00 kN-m

Corresponding torsion Tu = 22.50 kN-m

DESIGN MOMENTS ( within Plane )

Maximum bending moment from STAAD My = 132.00 kN-m

Equivalent bending moment for torsion Mey = 26.47 kN-m

Effective length of column Ley = L = 4.37 m

Slenderness ratio Ley/D = 8.74

Minimum eccentricity ez = 25.41 mm

Moment due to minimum eccentricity My,min = 9.30 kN-m

Additional moment due to eccnetricity May = 0.00 kN-m

Design Moment with in Plane Muy = 158 kN-m

INTERMEDIATE COLUMN ( 500 X 500)

Mey = (Tu/1.7)*(1+D/b)

MAX(Ley/500+D/30,20)

P*ez

DESIGN OF COLUMN FOR MAXIMUM MY

P*D/2000*(Ley/D)^2


DESIGN MOMENTS (Out of Plane)

Maximum bending moment from STAAD Mz = 111.00 kN-m

Equivalent bending moment for torsion Mez = 26.47 kN-m

Effective length of column Lez = L = 4.37 m

Slenderness ratio Lez/b = 8.74

Minimum eccentricity ey = 34.15 mm

Moment due to minimum eccentricity Mz,min = 12.50 kN-m

Additional moment due to eccnetricity Maz = 0.00 kN-m

Design Moment out of Plane Muz = 137 kN-m

MOMENT CAPACITY ( within Plane )

d'/D = 0.129

p/fck = 0.062

Pu/(fckbD) = 0.059

Referring Chart 48 of SP-16 Muy,l/(fckbD2) = 0.100

Muy,l = 313 kN-m

MOMENT CAPACITY (Out of Plane)

d'/b = 0.129

p/fck = 0.062

Pu/(fckbD) = 0.059

Referring Chart 49 of SP-16 Muz,l/(fckDb2) = 0.100

Muz,l = 313 kN-m

COLUMN SECTION CHECK

Area of steel As = 3900 mm2

Ac = 246100 mm2

Puz = 0.45fckAc + 0.75fyAs Puz = 4231 kN

Pu/Puz = 0.09

an = 1.00

Muy/Muy,l = 0.51

Muz/Muz,l = 0.44

= 0.95 < 1.00(Muy/Muy,l)an+(Muy/Muy,l)an

Mez = (Tu/1.7)*(1+b/D)

MAX(Lez/500+b/30,20)

P*ey

P*b/2000*(Lez/b)^2

r_71.1994.08.302_r0.pdf

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