Vertical Gates Design PDF Free

ADO CONMAT INDIA
PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 1
Design of Vertical Lift Service Gates of

Budaun Irrigation Project
1.0 Technical Details :
♦ No of gates required : 25Nos
♦ Clear vent width : 18000mm
♦ Clear vent height : 6200mm
♦ Height of gate : 6500mm
♦ Sill level : EL 157.100M
♦ Pond level : EL 163.300M
♦ HFL : EL 164.300M
♦ Type of gate : Regulating
♦ Top of pier : EL 167.000M
♦ Design head FRL : 6.2M
HFL : 7.2M
♦ Location of skin plate : Up stream
♦ Location of seal : Up stream
♦ Side seal C/C : 18150mm
♦ Track C/C : 18700mm
♦ End to end of groove : 19200mm
♦ Hoisting speed : 0.3 to 0.7M/min
♦ Designed : As per IS 4622 - 2003

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2.0 Material:
S No. Components Proposed Remarks

All structural members like skin plate, end
IS : 2062 - 2006
1 box, vertical stiffeners, horizontal girders, Structural Steel
Grade E250 QualityB
Roller track girder, Sill beam seal Crest etc.,
2 Rollers and Guide Rollers Cast Steel IS 1030
30Cr13
3 Roller pins and Guide Roller Pins Stainless Steel
IS : 1570 (Part V)
20Cr13
4 Roller Track Stainless Steel
IS : 1570 (Part V)
04 Cr18 Ni 10
5 Seal Seats Stainless Steel
IS : 1570 (Part V)
Synthetic or
6 Seals IS : 11855
Natural Rubber
Anti Friction
7 Bearings SKF / FAG / NSK / ZKL
Bearings
3.0 Permissible Stresses: As per IS:4622 - 2003
I. Embedded Parts & Gate Leaf – As per IS 4622 - Wet and Inaccessible condition
1. Structural steel – IS 2062 – 2006 Grade E250 Quality B
Stresses in kg/cm2
S.No Type of stresses Factor Thk < 20mm Thk 20 – 40mm
2
YP :2550kg/cm YP : 2448kg/cm2
UTS:4180kg/cm2 UTS:4180kg/cm2
1 Direct compression and 0.40YP 1020 979
compression in bending
2 Direct tension and tension in 0.40YP 1020 979
bending
3 Shear Stress 0.30YP 765 734
4 Combined stress 0.50YP 1275 1224
5 Bearing stress 0.45YP 1147 1102
C. Bearing stress in concrete = M – 250 – 62kg/cm2

4.0 Groove Details :
ADO CONMAT INDIA
C / C O F R O L L E R T R A C K = 1 8 7 0 0
6 0 0
2 5 0 3 5 0
350
V E N T = 1 8 0 0 0
500
150
50
16
205
450
1650
743
900
580
606
1 9 0
450
1 6 1 6
16
16
59
100
250
150
F L O W
5 0 0
6 0 01 0 0
F / F O F S I D E G U I D E = 1 9 1 2 0
E N D T O E N D O F G R O O V E = 1 9 2 0 0
4.0 Design of Gate Leaf :

ADO CONMAT INDIA
The gate leaf is designed as vertical lift roller gate made out of single Gate
with two elements connected with flexible joint. Each element is fitted with 4 rollers
working on self aligned spherical roller bearing mounted on stainless steel axle. The
axle is made with eccentricity of 5mm for fine adjustment at later date if required.
The U/S skin plate is fitted with Bulb type of molded rubber seals for sides and top,
flat type of rubber seals for bottom for water tightness.
The gate is being operated with Rope drum hoist of adequate capacity.
As per specification the gate is to be designed for FRL and to be checked for HFL
condition allowing 1.333 times of permissible stresses as per IS 4622.
• C / C of side seals : 18150mm

• C/C of tracks : 18700mm
• Height of gate : 6500mm
• Design Head FRL : 6.20M
HFL : 7.20M
Water thrust on the gate FRL = wLH2 / 2 = 1 X 18.15 X6.202 / 2 = 348.843t
HFL = wLh (H – h / 2) = 1 X 18.15 X 6.5 (7.2 – 6.5/ 2)
= 466.001t
% increase of load under HFL over FRL
= ((466.001 – 348.843) / 348.843) X 100 = 33.58% > 33⅓ %
FRL Condition HFL Condition % of Increase

Element Size HFL Over Remarks
Head Thrust Head Thrust
FRL
Bottom 18.15X2.0 6.20 188.760t 7.20 225.06 19.2%<33⅓ % Designed for FRL
Designed for HFL
Top 18.15X4.5 4.20 160.083t 5.20 240.941 50.5%>33⅓ % condition with
increased stresses
3 6 . 3 0 0 t
4.1 Design of Bottom Element : 7 8 . 3 3 3
4.1.1 FRL condition :

6 .2
1 5 2 . 4 6 0 t
4 .2
4 5
A B
4 2 1 0 3 5 5
2 0 0
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C/C of seals : 18.15M
RA = 94.238t
RB = 94.522t
4.1.2 HFL condition :

3 6 . 3 0 0 t
C/C of seals : 18.15M 7 8 . 3 3 3
7 .2
1 8 8 . 7 6 0 t
5 .2
4 5
RA = 110.075t
A B
RB = 114.985t 4 2 1 0 3 5 5
2 0 0
4.2 Design of Top Element :

4.2.1 FRL condition :
C/C of seals : 18.15M 1 6 0 . 0 8 3 t
1 4 0
4 .2 M
RC = 94.964t
4 4 C 2 3 6 D 1 4 0 3 0
RD = 65.119t 4 5 0 c m
4.2.2 HFL condition :

1 8 3 . 0 8 3 t
C/C of seals : 18.15M
1 3 0
5 .2
5 7 . 1 7 3 t
0 .7
5 5
RC = 114.553t C D
4 4 2 3 6 1 7 0
4 5 0
RD = 126.389t
4.3 Design of Horizontal Girders :

ADO CONMAT INDIA
Load on Girder ‘A’ Load on girder ‘B’ Load on girder ‘C’ Load on girder
Condition
in t in t in t ‘D’ in t
FRL 94.238 94.522 94.964 65.119
HFL 110.075 114.985 114.553 126.389
% of increase of
16.80%<33⅓ % 21.65%<33⅓ % 20.6%<33⅓ % 94%>33⅓ %
HFL over FRL
∴ Girder ‘A’, ‘B’ and ‘C’ is designed for FRL condition and Girder ‘D’ is designed for
HFL condition
4.3.1 Design of Horizontal Girder ’A’ : (Designed for FRL condition)

Load on horizontal girder ‘A’ = 94964kg
9 4 9 6 4 k g
A 2 7 .5 l = 1 8 1 5 2 7 .5 B
RA = RB = 47482kg L = 1 8 7 0
BM = (94964 / 8) (2 X 1870 – 1815) = 22850713kgcms.
It is proposed to provide skin plate out of 16mm plate. After allowing corrosion
allowance of 1.5mm, the effective thickness is 14.5mm.
The Co-acting width:

L = 1870cm B1 = 103 / 2 = 51.5cm B2 = 42cm
L / B1 = 1870 / 51.5 = 36.31 ∴ V1 = 0.98
8 8
1 .4 5
L / B2 = 1870 / 42 = 44.5 ∴ V2 = 0.86

3 0
1 .6
∴ Co-acting width = V1 B1 + V2 B2 = 0.98 X 51.5 + 0.86 X 42 = 88.74cm

7 6 .9 2
7 5 .4 7
But as per IS 800 – 1984 cl : 3.5.2.1 the Max. co-acting width of skin plate is 20t to
the innermost face of the stiffening.
180
∴ Co-acting width = 40t + B = 40 X 1.45 + 30 = 88cm

Sectional properties are as follows: 1 . 2
1 0 9 .3 3
1 .6
2 7
3 0
1 .6
ADO CONMAT INDIA
Area = 482.8cm2
IXX = 2705560cm4
Z1 = 35175cm3
Z2 = 35849cm3
Z3 = 24747cm3
i) Bending stress on U/S of skin plate = 22850713 / 35175 = 650kg/cm2 < 1020kg/cm2
ii) Bending stress on D/S of skin plate =22850713 / 35849 = 637kg/ cm2 < 1020kg/cm2
iii) Bending stress on D/S of flange =22850713 / 24747 = 923kg/ cm2 < 1020kg/cm2
iv) Shear stress = 47482 / (74.3 X 1.2) = 532.5kg/cm 2 < 765kg/cm2
Check for deflection :

Permissible deflection = L / 800 = 1870 / 800 = 2.337cms.
Actual deflection
= [94964 / (384 X 2047000 X 2705560)] [8 X 18703– 4X1870 X 18152 X 18153]
= 1.582cm < 2.337cm.
Design of Welds :
Weld strength required between Skin Plate and U/S Flange :
F1 = S A y / 2 I = (47482 X 88 X 1.45 X 76.195) / (2 X 2705560) = 85kg/cm length
Proposed 6mm fillet having strength of 0.7 X 0.6 X 765 = 321kg/cm length
Weld strength required between Web and U/S flange :

F2 = [47482 X (88 X 1.45 + 30 X 1.6) X 75.45] / (2 X 2705560) = 116kg/cm length
Proposed 6mm fillet having strength 321kg/cm length
Weld strength required between Web and D/S flange :

Weld strength required between D/S flanges :
F4 = (47482 X 27 X 1.6 X 108.23) / (2 X 2705560) = 50kg/cm length
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4.3.2 Design of Horizontal Girder ’B’ : (Designed for FRL condition)

Load on horizontal girder ‘B’ = 94522kg
9 4 5 2 2 k g
A 2 7 .5 l = 1 8 1 5 2 7 .5 B
RA = RB = 47261kg L = 1 8 7 0
BM = (94522 / 8) (2 X 1870 – 1815) = 22744356kgcms.
Co-acting width:
L = 1870cm B1 = 103 / 2 = 51.5cm B2 = 50cm
L / B1 = 1870 / 51.5 = 36.31 ∴ V1 = 0.98
L / B2 = 1870 / 50 = 37.4 ∴ V2 = 0.86
∴ Co-acting width = 0.98 X 51.5 + 0.86 X 50 = 93.47cm
8 8
1 .4 5
3 0
1 .6
Sectional properties are as follows:
7 6 .9 2
7 5 .4 7
Area = 482.8cm2
IXX = 2705560cm4
Z1 = 35175cm3
180
Z2 = 35849cm3
1 . 2
3
Z3 = 24747cm
1 0 9 .3 3
1 .6
2 27 < 1020kg/cm2
iii) Bending stress on D/S of flange = 22744356 / 24747 = 919kg/ cm
3 0
1 .6
iv) Shear stress = 47261 / (74.3 X 1.2) = 530kg/cm 2 < 765kg/cm2

ADO CONMAT INDIA

Actual deflection
= [94522 / (384 X 2047000 X 2705560)] [8 X 18703– 4X1870 X 18152 X 18153]
= 1.492cm < 2.337cm.
Design of Welds :



4.3.3 Design of Horizontal Girder ’C’ : (Designed for FRL condition)

Load on horizontal girder ‘A’ = 94964kg
9 4 9 6 4 k g
A 2 7 .5 l = 1 8 1 5 2 7 .5 B
RA = RB = 47482kg L = 1 8 7 0
BM = (94964 / 8) (2 X 1870 – 1815) = 22850713kgcms.

Co-acting width:
L = 1870cm B1 = 236 / 2 = 118cm B2 = 44cm
ADO CONMAT INDIA
L / B1 = 1870 / 118 = 15.84 ∴ V1 = 0.955

L / B2 = 1870 / 44 = 42.5 ∴ V2 = 0.86
∴ Co-acting width = 0.955 X 118 + 0.86 X 44 = 150cm
8 8
Sectional properties are as follows:
1 .4 5
3 0
1 .6
Area = 482.8cm2
7 6 .9 2
7 5 .4 7
IXX = 2705560cm4
Z1 = 35175cm3
Z2 = 35849cm3
180
Z3 = 24747cm3
1 . 2
1 0 9 .3 3
1 .6
2 7 cm2 < 1020kg/cm2

iii) Bending stress on D/S of flange = 22850713 / 24747 = 923kg/
3 0
1 .6
iv) Shear stress = 47482 / (74.3 X 1.2) = 533kg/cm2 < 765kg/cm2

Actual deflection
= [94964 / (384 X 2047000 X 2705560)] [8 X 18703– 4X1870 X 18152 X 18153]
= 1.550cm < 2.337cm.
Design of Welds :
ADO CONMAT INDIA



4.3.4 Design of Horizontal Girder ’D’ :

Load under FRL = 65.119t
Load under HFL = 126.289t
Load equivalent to FRL under HFL = 126.289 / 1.33 = 94.954t
∴ It is proposed to design for FRL equivalent load of 94.954t
Load on horizontal girder ‘D’ = 94954kg
9 4 9 5 4 k g
A 2 7 .5 l = 1 8 1 5 2 7 .5 B
RA = RB = 47977kg L = 1 8 7 0
BM = (94954 / 8) (2 X 1870 – 1815) = 22848306kgcms.
Co-acting width:
L = 1870cm B1 = 236 / 2 = 118cm B2 = 170cm
L / B1 = 1870 / 118 = 15.84 ∴ V1 = 0.955
L / B2 = 1870 / 170 = 11 ∴ V2 = 0.76
∴ Co-acting width = 0.955 X 118 + 0.76 X 170 = 242cm
ADO CONMAT INDIA
Sectional properties are as follows: 8 8
1 .4 5
3 0
1 .6
Area = 482.8cm2
7 6 .9 2
7 5 .4 7
IXX = 2705560cm4
Z1 = 35175cm3
Z2 = 35849cm3
180
Z3 = 24747cm3
1 . 2
1 0 9 .3 3
ii) Bending stress on D/S of skin plate = 22848306 / 35849 = 637kg/ cm2 < 1020kg/cm2
iii) Bending stress on D/S of flange = 22848306 / 24747 = 923kg/ cm2 < 1020kg/cm2
1 .6
iv) Shear stress = 47977 / (74.3 X 1.2) = 538kg/cm2 < 765kg/cm
2 7
2
3 0
1 .6
Actual deflection
= [94954 / (384 X 2047000 X 2705560)] [8 X 18703– 4X1870 X 18152 X 18153]
= 1.518cm < 2.337cm.
Design of Welds :


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4.4 Design of End Box :

The disposition of rollers and horizontal girders are as shown.
4.4.1 Bottom Element :

i) FRL condition :
9 4 2 3 8 k g 9 4 5 2 2 k g
RA = 94.162t A B
1 8 6 7 1 8
1 0 3
RB = 94.598t
Max. Roller load = 94.162 / 2 = 47.299t ≈ 47.3t

Bending Moment = 94522 X 18 = 1701396kgcm
ii) HFL condition :
1 1 0 0 7 5 k g 1 1 4 9 8 5 k g
RA = 108.756t
A B
1 8 6 7 1 8
1 0 3
RB = 116.304t
Max. Roller load = 116.304 / 2 = 58.152t

Equivalent FRL load = 58.152 / 1.33 = 43.723t
4.4.2 Top Element :

i) FRL condition :
9 4 9 6 4 k g 6 5 1 1 9 k g
RA = 97.650t 1 8 C 2 0 0
2 3 6
D
1 8
RB = 62.433t
Max. Roller load = 97.650 / 3 = 48.825t ≈ 48.9t say 50t

ADO CONMAT INDIA
ii) HFL condition :

1 1 4 5 5 3 k g 1 2 6 3 8 9 k g
RA = 113488kg 1 8
C
2 0 0
D
1 8
2 3 6
RB = 127454kg
Max. Roller load = 127.454 / 2 = 63.727t

Equivalent FRL load = 63.727 / 1.33 = 47.9t ≈ 48.0t
Proposed 785 X 16mm plate for end box.
ZXX = (4 X 1.6 X 542) / 6 = 3110cm3
Bending stress FRL = 1709352 / 3100
P L 1 6 T + H 1K 2 . m m
= 551kg/cm2 < 1020kg/cm2
54
7 8 .5
HFL = 2275002 / 3100
= 734kg/cm2 < 1527kg/cm2
4
Max. Roller load = 50,000kg
2 0 .5
Shear stress FRL = 50000 / (2 X 54 X 1.6) 8
= 289kg/cm2 < 765kg/cm2

Bearing stress FRL = 50000 / (2 X 8 X 2.8) = 1116kg/cm2 < 1147kg/cm2
4.5 Design of Roller :
Max Roller load FRL = 50t
Material cast steel IS : 1030 Grade 340 - 570W
Permissible stress = 1.6 X 570 X (10.2 / 1000) = 9.30t/cm2
Proposed 450φ X 130mm tread width roller.

σC = 0.418 (50.00 X 2047) / (22.5 X 13) = 7.82t/cm2 < 9.30t/cm2
4.6 Design of Bearings :

Max. Roller load = 50000kg
Min Bearing Static capacity required = 50000 X 1.5 X 9.81= 735750N
Proposed Spherical Roller Bearing 22226E : ID = 130, OD = 230, Thk = 64 with

pressed steel cage having Static capacity = 930KN
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4.7 Design of Roller Axle :

Material proposed Stainless steel : 20Cr13 IS:1570 part-V
Yp = 490MPa UTS = 690MPa
Permissible stress : Bending = 2000kg/cm2
Shear = 1500kg/cm2
5 0 0 0 0 k g
RA = RB = 25000kg A
7 .6 6 .4 7 .6
B
2 1 .6
BM = (50000 / 8) (2 X 19.2 – 6.4) = 230000kgcm
Proposed 130φ at bearing and 80φ at end box.

ZXX = 216cm3
Area = 50cm2
Bending stress = 230000 / 216 = 1065kg/cm2 < 2000kg/cm2
Shear stress = 25000 / 50 = 500kg/cm2 < 1500kg/cm2
4.8 Design of girder at curtailment :
1 8 7 0 0
A B L if it n g C /C = 1 2 6 0 0
5 7 0
3 0 0
7 4 3
2 5 S P C S @ 3 5 0 = 8 7 5 0
1 8 9
1 6 3 0
1 8 1 6
1 6 1 6
A
W E B
S T IF F N E R 1 0
1
1 0 5 7
8 1 0
7
6
B
1 5 5 0 1 4 6 0 0
4 5 0 1 5 5 0 1 4 7 0 0
Max. horizontal girder reaction = 94.964t
A B
7 5 9 4 9 6 4 k g
RA = RB = 47482kg 4 5
A 2 7 .5 l = 1 8 1 5 2 7 .5 B
L = 1 8 7 0
A B
ADO CONMAT INDIA
At Section AA :
Bending moment = 47482 X 45 – [(94964 / 1815) X (45 – 27.5)2 / 2]= 2128678kgcm
Sectional properties at section ‘AA’ are as follows :

8 8
1 .4 5
2
Area = 312.76cm
3 0
1 .6
2 4 .0 9
2 2 .6 4
1 . 2
IXX = 29703cm4
Z1 = 12327cm3
7 4 .3
5 4 .8 6
Z2 = 13120cm3
Z3 = 5415cm3
1 .6
3 0
ii) Bending stress on D/S of skin plate= 2128678 / 13120 = 162kg/ cm2 < 1020kg/cm2
iii) Bending stress on D/S of flange = 2128678 / 5415 = 393kg/ cm2 < 1020kg/cm2
At section BB :
Bending moment = 47482 X 117.5 – [(94964 / 1815) X (175 – 27.5)2 / 2]
= 7740187kgcm
Sectional properties at section ‘BB’ are as follows :

8 8
1 .4 5
Area = 419.2cm2 3 0
1 .6
IXX = 1707036cm4 1 . 2
5 9 .0 3
5 7 .5 8
Z1 = 28915cm3
Z2 = 29646cm3
1 6 3 .0
Z3 = 15716cm3
1 0 8 .6 2
ii) Bending stress on D/S of skin plate= 7740187 / 29646 = 261kg/ cm2 < 1020kg/cm2
1 .6
iii) Bending stress on D/S of flange = 7740187 / 15716 = 492kg/

3 0
cm2 < 1020kg/cm2
ADO CONMAT INDIA
5.0 Design of Skin Plate and Vertical Stiffeners :

The Skin plate and disposition of vertical stiffeners are as shown.
4 5 0 1 5 5 0 1 4 7 0 0
1 5 5 0 1 4 6 0 0
1 0 5 7
6 1 0
7
8
1
1 0
1 6 1 6
W E B
1 8 1 6
S T IF F N E R
1 8 9
5 7 0
3 0 0 2 5 S P C S @ 3 5 0 = 8 7 5 0
1 8 7 0 0
F L O W
5.1 Design of Skin plate & Vertical Stiffeners below Girder ‘A’ :
Head to the center of the panel = 6.2 – (0.42 / 2) = 5.99M
ie., p = 0.599kg/cm2
s 1 2 y
1 5
1 7 .5
s 1 3 y
s 1 2 x
4 2
s
2 4 .5
1 1 x
a = 2 7
s 1 3 x
s 1 1 y
b = 3 5 b = 3 5
b/a = 35 / 27 = 1.296 ‘K’ value for b/a = 1.296 is
± σ11X = ± 22.68 ± σ11Y = ± 13.23
± σ12X = ± 16.44 ± σ12Y = ± 55.44
± σ13X = ± 50.16 ± σ13Y = ± 15.44

ADO CONMAT INDIA
Bending stress in skin plate :

σb = [(K / 100) X ((p X a2) / s2)] = [(K / 100) X (0.599 X 272) / 1.452] = 2.077K kg/cm2
2 2 2 2
± σ11X = ± 47kg/cm < 1020kg/cm ± σ11Y = ± 27kg/cm < 1020kg/cm
2 2 2 2
2 2 2 2
Check for combined stress : Max on D/S of skin plate

2 2
Σx = 637 + 34 = 671kg/cm < 1020kg/cm
2 2
Σy = - 115kg/cm < 1020kg/cm
2 2 2 2
σC = √ 671 + 115 + 671 X 115 = 735kg/cm < 1910kg/cm
Design of vertical stiffener :

Head to the center of the panel = 0.599kg/cm2
w 1 w 2
W1 = 2 X ½ X 17.52 X 0.599 = 183kg

W2 = 2 X 24.5 X 17.5 X 0.599 = 514kg
RA = 697kg 1 7 .5
A
1 7 . 5 2 4 . 5
4 2
Point of application
= (½ X 17.53 X ⅔) + (24.5 X 17.5 X 33) / [(17.52 / 2) + (24.5 X 17.5)] = 27.386cm
BM = 697 X 27.386 – [183 (27.386 – 17.5 X ⅔) + (514 / 19.5) X (9.8862 / 2)]
= 14923kgcm
The co-acting width of skin plate :

L = 42 B = 17.5
L/B = 2.4 ∴ V = 0.348
2VB = 2 X 0.348 X 17.5 = 12.18cm ≈ 12cm

ADO CONMAT INDIA
It is proposed 200 X 10mm plate as stiffeners.
1 2
Area = 37.40cm2
1 .4 5
6 .4 6
IXX = 1740cm4
Z1 = 269cm3 1 . 0
20
1 4 .9 9
Z2 = 116cm3
Bending stress in compression = 14923 / 269 = - 55kg/cm2 < 1020kg/cm2

Bending stress in tension = 14923 / 116 = 129kg/cm2 < 1020kg/cm2
Check for combined stress :

2 2
Σx = - 32 – 55 = - 87kg/cm < 1020kg/cm
2 2
Σy = 104kg/cm < 1020kg/cm
σC = √ 872 + 1042 + 87 X 104 = 166kg/cm2 < 1275kg/cm2
5.2 Design of Skin plate and Vertical stiffener between Girder ‘A’ & ‘B’ :
Head to the center of the panel = 6.2 – (0.42 + 1.03 / 2) = 5.265M
ie., p = 0.527kg/cm2
s4 y
15
1 7 .5
s4 x
s2 y s3 y
b = 103
68
s2 x s3 x
b = 88
1 7 .5
a = 3 5 a = 3 5

ADO CONMAT INDIA
± σ2X = ± 25.00 ± σ2Y = ± 7.91
± σ3X = ± 50.00 ± σ3Y = ± 15.00
± σ4X = ± 10.29 ± σ4Y = ± 34.30

2 2 2 2
2 2 2 2
2 2 2 2
Check for combined stress : Max. of D/S of skin plate

2 2
Σx = 637 + 32 = 669kg/cm < 1020kg/cm
2 2
Σy = - 105kg/cm < 1020kg/cm
2 2 2 2
σC = √ 669 + 105 + 669 X 105 = 727kg/cm < 1275kg/cm
Design of vertical stiffeners :
Head to the centre of the panel = 0.527kg/cm2
W 3 W 4 W 3
W3 = 2 X ½ X 17.52 X 0.527 = 161kg
W4 = 2 X 68 X 17.5 X 0.527 = 1254kg
1 7 .5
B C
1 7 . 5 6 8 1 7 . 5
RB = RC = 788kg
1 0 3
BM = 788 X 51.5 – (161 X 39.833 + (1254 / 2) (68 / 4) = 23510kgcm

ADO CONMAT INDIA
L = 103 B = 17.5
L/B = 103 / 17.5 = 5.886 ∴ V = 0.834
2VB = 2 X 0.834 X 17.5 = 29.19cm ≈ 29cm
2 9
Area = 62.05cm2
1 .4 5
4 .1 8
IXX = 2233cm4
Z1 = 534cm3 1 . 0
1 7 .2 7
20
Z2 = 129cm3


2 2
Σx = - 46 - 44 = - 90kg/cm < 1020kg/cm
2 2
Σy = + 154kg/cm < 1020kg/cm
2 2 2 2
σC = √ 90 + 154 + 90 X 154 = 214kg/cm < 1275kg/cm
5.3 Design of Skin plate and vertical stiffener above Girder ‘B’ :
Head to the center of the panel : 6.2 – (0.42 + 1.03 + 0.55 / 2) = 4.475M
ie., p = 0.448kg/cm2
s 1 6 y
b = 40
s 1 8 x
3 7 .5
s 1 6 x
s 1 8 y
55
s 1 7 x
1 7 .5
s 1 7 y
15
a = 3 5 a = 3 5
ADO CONMAT INDIA
± σ16X = ± 19.46 ± σ16Y = ± 11.95
± σ17X = ± 9.17 ± σ17Y = ± 30.57
± σ18X = ± 32.13 ± σ18Y = ± 9.64

2 2 2 2
2 2 2 2
2 2 2 2
Check for combined stress : Max. on D/S of skin plate.

2 25
Σx = 634 + 25 = 659kg/cm < 1020kg/cm
2 2
Σy = - 84kg/cm < 1020kg/cm
2 2 2 2
σc = √ 659 + 84 + 659 X 84 = 705kg/cm < 1275kg/cm
Design of vertical stiffeners :

Head to the centre of the panel = 0.448kg/cm2 w 5 w 6
W5 = 2 X ½ X 17.52 X 0.448 = 307kg

1 7 .5
W6 = 2 X 37.5 X 17.5 X 0.448 = 588kg

D
RD = 895kg 1 7 .5 3 7 . 5
Point of application 5 5
ADO CONMAT INDIA
= (½ X 17.53 X ⅔ + 37.5 X 17.5 X 36.25) / [(17.52 / 2) + (37.5 X 17.5)] = 31.599cm

BM = 895 X 31.599 – [307 (31.599 – 17.5 X ⅔) + (588 / 37.5) X (14.0992 / 2)]
= 20603kgcm

L = 55 B = 17.5
L/B = 3.142 ∴ V = 0.432
2VB = 2 X 0.432 X 17.5 = 15.12cm ≈ 15cm
Area = 41.75cm2 1 5
1 .4 5
IXX = 1869cm4
5 .8 6
Z1 = 319cm3
1 . 0
20
1 5 .5 9
Z2 = 120cm3


2 2
Σx = - 25 - 65 = - 90kg/cm < 1020kg/cm
2 2
Σy = + 84kg/cm < 1020kg/cm
2 2 2 2
σC = √ 90 + 84 + 90 X 84 = 151kg/cm < 1275kg/cm
nd
Note : There is no need to check 2 element for bending moment in skin plate and short
stiffeners since the head is less than bottom element. How ever it is proposed to
provided stiffeners similar to that of bottom element.

6.0 Design of embedded parts :
Max. roller load = 50000kg
6.1. Design of Thickness of roller track plate : (When track with line contact)
t = 6 X 0.786 X 1.55 √ (P / l X r / E)
Where l = tread width in mm = 130
ADO CONMAT INDIA
P = Wheel load in N = 490500N

r = radius of the wheel = 225mm
E = Modulus of elasticity = 200810.7N/mm2
t = 6 X 0.786 X 1.55 √ (490500 / 130) X (225 / 200810.7) = 15.03mm

As per technical specification minimum thickness of track plate is 20mm.
Proposed 200 X 20mm thick as track plate after machining.

Material 20 Cr 13 IS 1570 Part V Hardness 200 to 220BHN
6.3 Design of Roller Track :

The section proposed is as follows 2 0
2 .0
Area = 282cm2
3 .2
1 7 .4 8
IXX = 68991cm4
35
3 . 2
Z1 = 3946cm3
2 4 .7 2
Z2 = 2791cm3 2 .0
2 5
6.2.1 Checking the Bearing stress in concrete :

σb = 0.2813 X P[EC / (ES X I X w2)] 1/3
P =Roller load = 50000kg
EC = Young’s modulus of concrete (M200)
ES = Young’s modulus of steel (Ec / Es = 1/8.98)
I = Moment of Inertia = 68991cm4
w = width of plate contact with concrete = 25cm
σb = 0.2813 X 50000 [(1/8.98) X (1 / 68991) X (1 / 252)] 1/3 = 19.297kg/cm2 < 52kg/cm2

6.2.2 Check for Bending stress :
σb = 0.5 X (50000 / 2791) [8.98 X 68991 / 25]1/3 = 261kg/cm2 < 979kg/cm2
6.2.3 Check for Shear stress in web :

Shear stress in web = 50000 / (2 X 35 X 3.2) = 223kg/cm2 < 893 kg/cm2
ADO CONMAT INDIA
6.2.4 Check for Web Compression :

50000kg
wheel load = 50000kg
Web thickness = 32mm
2.0
Under 45° dispersion of load
45°
3.2
Web Compressive Stress = 50000 / (10.4 X 3.2)
10.4cm
= 1502kg/cm2 < 1958kg/cm2
6.2.5 Check for Pressure distribution under track :

Length of influence of pressure under track L = 3/2 X P / pw
= (3 / 2) X 50000 / (17.07 X 25) = 175cm
The rollers are spaced at 74cm apart hence the pressure distribution under track will
even overlap.
Max. Stress = 17.07 X 2 = 34.14kg/cm2 < 62kg/cm2
6.2.6 Check for Shear stress in concrete : 3 5 1 2 .5
Roller load = 50000kg

Bearing stress in concrete 17.07kg/cm2
1 0 .9
v 2X
Length of shear = √ 2 X (10.9 + 47.5) = 82.59cm
3 . 2
Shear stress = Bearing stress in concrete X width of track
2 X Length of Shear
2 5
= (17.07 X 25) / (2 X 82.59)
= 2.6kg/cm2 < 5.0kg/cm2
Permissible punching shear as per IS800 clause
4 7 .5
v2X
6.2.7 Design of welds in roller track :

Max. shear force = 25000kg
IXX of section = 23454cm4
a. Weld between track plate and U/S flange :
F1 = SAy / 2I = (25000 X 20 X 2 X 16.48) / (2 X 68991) = 119kg/cm length
Proposed 6mm fillet weld having strength of 308kg/cm length
ADO CONMAT INDIA
b. Weld between U/S flange and web :

F2 = SAy / 2I = [25000 (20 X 2 + 25 X 3.2) 15.4 / (2 X 68991)] = 335kg/cm length
c. Weld between web and D/S flange :

F3 = SAy / 2I = (25000 X 25 X 2.0 X 23.72) / (2 X 68991) = 215kg/cm length
7.0 Check for Earthquake effect :

Due to horizontal acceleration, there will be an instantaneous hydro dynamic pressure
exerted on the gate in addition to hydro static pressure. The direction of the hydro
dynamic force is opposite to the direction that of earthquake acceleration. Based on the
assumption that water is incompressible, the hydrodynamic pressure at depth y below
the reservoir surface shall be determined as follows. (Cl. 7.2 of IS : 1893 – 1984).
ADO CONMAT INDIA
P = CSαnWh
Where P = Hydrodynamic pressure in kg/cm2 at a depth y.
αn = Design horizontal seismic co-efficient = βIαo – (cl. 3.4.2.3 –a of IS 1893)
= 1 X 3 X 0.02 = 0.06
CS = Co-efficient which varies with shape and depth.
= (Cm / 2) {(y / h) (2 – y / h) + √ (y / h) (2 – y / h)}
Cm = 0.73 from table – 10 of IS 1893, y = 3.8M, h = 3.8M
= (0.73 / 2) {1 X (2 – 1) + √ 1 (2 – 1)} = 0.73
W = Unit weight of water = 1000kg/m3
h = Depth of reservoir = 6.5M.
P = 0.73 X 0.06 X 1000 X 6.5 = 284.7kg/cm = 0.2847t/M2
Hence percentage of increase in pressure = (0.2847 / 6.5) X 100 = 4.42%
Permissible increase in stresses = 33.33% > 4.42%
L IF T IN G C /C = 1 2 6 0 0 M 16 H EX S CR E W FO R
As earthquake forces are not critical and do not govern the
L O Cdesign, check
K IN G & 1 7 .5 Ø H O L E for
S
IN -L O C K P L A T E (T Y P )
stresses shall not be made for this condition.
1860 10
10
380 550 550 380
7 5 .57 5 .5 300
10
50
12
150
90
25
Ø1
250
240
280
90
12
440
50
300
280
8.0 Design of lifting arrangement : 400
80
500
R3
Hoist capacity = 55t 155
Load on
Ø 1 0each
D R A INlifting
H O L E side = 27.5t
200
100
12
100
280
180
12
12
100
12
1
200 00 200
20
280
20
494
500
400
345
10
12
600
5
10
800
ADO CONMAT INDIA
8.1 Design of pulley pin :

Load on pulley shaft = SWL + self weight of pulley = 13750 + 105 = 13855kg
13855kg
RA = RB = 6927.5kg A 2.3 13
17.6
2.3 B
Bending moment = (13855 / 8) (2 X 17.6 – 13) = 38448kgcm

Proposed shaft φ 125mm.
Material IS 2062
ZXX = 192cm3 A = 123cm2
Shear stress = 6927.5 / 123 = 56kg/cm2 < 765kg/cm2
8.2 Design of cheek plate :

p = 13855 / (12.5 X 2.6) = 426kg/cm2 13855kg
Max. tearing stress 1 01 6
σT = p {[(2R) + d ] / [(2R) - d ]}
2 2 2 2
150
= 426 [(302 + 12.52) / (302 – 12.52)]

= 605kg/cm2 < 0.66 X 2550 X 0.95 / 0.11
155
ADO CONMAT INDIA
= 1453kg/cm2
8.3 Design of Pin – 2 :

13855kg 13855kg
a b
C 2 1 7.6 2
D
RC = RD = 13855kg 21.6
Bending moment = 13855 X 2 = 27710kgcm

Proposed 125mmφ Pin
Material IS 2062
ZXX = 192cm3
Area = 123cm2
Shear stress = 13855 / 123 = 113kg/cm2 < 765kg/cm2
200R
8.4 Design of Bracket welded to girder :
p = 13855 / (12.5 X 2) = 554.2kg/cm2
Max. tearing stress along AB Ø 125
σT = p {[(2R)2 + d2] / [(2R)2 - d2]}
= 554.2 [(302 + 12.52) / (302 – 12.52)]
= 674kg/cm2 < 1453kg/cm2
8.5 Design of weld between bracket and horizontal girder web :

Length of weld = 2 X 60 = 120cm
Load per cm length of weld = 13855 / 120 = 115kg/cm length.
Proposed 6mm fillet weld having strength of 428kg/cm length.
9.0 Design of Dogging Beam :

The arrangement of dogging beam is shown in Drg. No. BHME - GEI – RGB-VGB -105.
Self weight of gate = 55500kg
The beam is supporting the gate on either side of gate at end box over the vent.
Load acting on beam with impact = 55500 X 1.1 / 2 = 30525kg
The loading on the beam is as follows :
30525kg
A B
35 80 35
150
ADO CONMAT INDIA
RA = RB = 15262.5kg
Bending moment = (30525 / 8) (2 X 150 – 80) = 839438kgcm
Proposed beam having following section : 1 1
2 .0
Area = 108.0cm2
IXX = 7472cm4
24
2 0 .0
ZXX = 623cm3
2 .0
7 . 8
Bending stress = 839438 / 623 = 1347kg/cm2 < 1580kg/cm2 1 . 16 . 6
Shear stress = 15262.5 / (2 X 20 X 1.6) = 238kg/cm2 < 1020kg/cm2
10.0 Design of Spice Joint :

Hoist capacity = 55t
It is proposed to design the splice joint between the elements for a Max. load of 55t.
The bolts provided in the joint are in double shear.
No. of bolts provided in the joint = 360Nos.

Dia of bolts proposed = 16mm
F = (2 X π X d2 / 4) X fs X n
fn = 4F / (2 X π X d2 X n)
= 4 X 55000 / (2 X π X 1.6 X 360)
= 61 < 720kg/cm2
10.0 Gate weight C.G calculations:
S.No Description Size Nos Weight x Wx

2000 X 16 – 18950 1 4760.2 0.8 3808.0
1 Skin plate
4500 X 16 – 18950 1 10710.5 0.8 8568.0
2 End Box 785 X 16 – 2000 4 788.8 40.85 32222.0
785 X 16 – 4500 4 1774.7 40.85 72496.0
190 X 10 – 785 20 234.2 40.85 9566.0
300 X 10 – 300 16 113.0 59.60 6737.0
140 X 10 – 280 8 24.6 61.00 1502.0
ADO CONMAT INDIA
280φ X 20 thick 8 98.4 59.60 5869.0

300 X 16 – 18478 4 2785.0 2.4 6684.0
1800 X 12 – 18478 4 12532.5 93.2 1168029.0
3 Horizontal girder 300 X 16 – 19130 4 2883.3 184.0 530527.0
270 X 16 – 14600 4 1980.5 185.6 367581.0
130 X 10 – 1616 32 527.8 102.4 54047.0
1816 X 10 – 6500 5 4633.0 92.4 428089.0
4 Vertical stiffener 200 X 10 – 6500 40 4082.0 11.2 45718.0
150 X 16 – 3200 5 301.4 184.0 113835.0
450 Ø roller 140 thread width
5 Roller assembly with 22226E bearing and 140Ø 8 1704.0 59.6 101558.0
axle – 213kg/asm
6 Side guide 40kg/assy 4 160.0 38.9 6224.0
7 Top channel ISMC 250 X 82 - 18478 1 632.0 13.7 8658.0
160 X 16 – 18360 2 737.9 ---- -----
8 Splice plate
160 X 16 – 700 4 56.3 40.85 2298.0
200 X 10 – 1700 4 106.8 92.8 9911.0
9 Typical joints
150 X 16 – 460 5 43.3 174.3 7547.0
44Ø X 127 – 6500 2 58.5 ---- ----
60 x 10 – 6500 4 122.5 ---- ----
10 Seal assembly 90 x 14 flat seal – 18100 1 50.0 ---- ----
80 x 10 – 18100 1 113.7 ---- ----
20 x 20 – 8100 1 56.8 ---- ----
Lifting
11 Arrangement with 1500kg/assembly 2 3000.0 ---- ----
bottom block
12 Fasteners 200kg 1 200.0 ---- ----
55271.7 2991474.0
x = 2991474.0 / 52271.7 = 57.2cm Adopted 57cm.
11.0 Hoist Capacity Calculations:

1) Weight of gate: 55500kg
2) Water thrust on the gate = 348843kg
3) Roller friction
F = P/R(fa X r + fr)
Where F = Roller friction in kg
P = Water thrust =348843kg
R = 22.5cm
fa = Coeff. of friction = 0.015 for Antifriction bearing
r = 9cm (Bearing ID 130, OD 230 and 64thick)
ADO CONMAT INDIA
fr = 0.1
∴ F = (348843 / 22.5) (0.015 X 9 + 0.1) = 3643kg
4) Seal friction:
Side seal friction: 2 X µ X b X h X l
= (2 X 1.5 X 4.4 X 0.31 X 620) = 2537kg
5) Friction due to seal pre compression = 2 X 620 X 1 X 1.5 = 1860kg
6) Guide friction = (55500 / 100) X 5 = 2775kg
Note : No check is required for self closing since the self weight of gate is more than
frictions and seating pressure required.
A CWT of 50t including counter weight box is provided to reduce the hoist weight 25t
since it is connected in two falls.
Hoist capacity required:

Self weight of gate : 55,500.00
Roller Friction : 3,643.00
Seal Friction : 2,537.00
Friction due to seal pre compression : 1,860.00
Guide friction : 2,775.00
66,315.00
Add 20% reserve capacity : 13,263.00
79,578.00
Less - 25,000.00
54,578.00
Proposed 55t Rope Drum hoist for operation of the same.
12.0 Design of Counter weight Box: 7 5

The counter weight box including self wt. = 50000kg
1 . 5 1 . 5
1 .0
Designed for with impact load of 55000kg

It is proposed to suspend the counter weight at 1750mm span. 7 0
1 . 0 1 . 0
5
500
0kg
RA = RB = 27500kg
A B
7
0 1
750 7
0
1
890
130
Bending moment = 27500 X [(1750 / 2) – (1890 / 4)] = 11068750kgcm

1 .0
ADO CONMAT INDIA
Proposed beam having following section :
Area = 410cm2
IXX = 1009717cm4
ZXX = 15299cm3
Bending stress = 11068750 / 15299

= 723kg/cm2 < 1480kg/cm2
Shear stress = 27500 / (2 X 123 X 1) = 112kg/cm2 < 1200kg/cm2
Permissible deflection = span / 750 = 1750 / 750 = 2.333
Deflection = (5 X 50000 X 18903) / (384 X 2047000 X 1009717) = 2.13cm < 2.333cm
Bearing stress = 45000 / (70 X 1800) = 0.357kg/cm2 <1680kg/cm2
However L75 X 75 X 8 stiffeners is proposed at 750mm C/C
A counter weight of 45t is proposed.
45t counter weight is to be provided at 3.5t/m3 density MS scrap and concrete.


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ADO CONMAT INDIA

Design of Vertical Lift Service Gates of

1.0 Technical Details :

♦ No of gates required : 25Nos

♦ Clear vent width : 18000mm

♦ Clear vent height : 6200mm

♦ Height of gate : 6500mm

♦ Sill level : EL 157.100M

♦ Pond level : EL 163.300M

♦ Type of gate : Regulating

♦ Top of pier : EL 167.000M

♦ Design head FRL : 6.2M

♦ Location of skin plate : Up stream

♦ Location of seal : Up stream

♦ Side seal C/C : 18150mm

♦ Track C/C : 18700mm

♦ End to end of groove : 19200mm

♦ Hoisting speed : 0.3 to 0.7M/min

♦ Designed : As per IS 4622 - 2003

S No. Components Proposed Remarks

3.0 Permissible Stresses: As per IS:4622 - 2003

C. Bearing stress in concrete = M – 250 – 62kg/cm2

4.0 Design of Gate Leaf :

• C / C of side seals : 18150mm

FRL Condition HFL Condition % of Increase

4.1 Design of Bottom Element : 7 8 . 3 3 3

4.1.1 FRL condition :

C/C of seals : 18.15M

4.1.2 HFL condition :

4.2 Design of Top Element :

4.2.2 HFL condition :

4.3 Design of Horizontal Girders :

4.3.1 Design of Horizontal Girder ’A’ : (Designed for FRL condition)

BM = (94964 / 8) (2 X 1870 – 1815) = 22850713kgcms.

The Co-acting width:

L / B2 = 1870 / 42 = 44.5 ∴ V2 = 0.86

∴ Co-acting width = V1 B1 + V2 B2 = 0.98 X 51.5 + 0.86 X 42 = 88.74cm

∴ Co-acting width = 40t + B = 40 X 1.45 + 30 = 88cm

Check for deflection :

Weld strength required between Web and U/S flange :

Weld strength required between Web and D/S flange :

4.3.2 Design of Horizontal Girder ’B’ : (Designed for FRL condition)

BM = (94522 / 8) (2 X 1870 – 1815) = 22744356kgcms.

∴ Co-acting width = 0.98 X 51.5 + 0.86 X 50 = 93.47cm

iv) Shear stress = 47261 / (74.3 X 1.2) = 530kg/cm 2 < 765kg/cm2

Check for deflection :

Weld strength required between Web and U/S flange :

Weld strength required between Web and D/S flange :

Weld strength required between D/S flanges :

4.3.3 Design of Horizontal Girder ’C’ : (Designed for FRL condition)

BM = (94964 / 8) (2 X 1870 – 1815) = 22850713kgcms.

L / B1 = 1870 / 118 = 15.84 ∴ V1 = 0.955

∴ Co-acting width = 0.955 X 118 + 0.86 X 44 = 150cm

∴ Co-acting width = 40t + B = 40 X 1.45 + 30 = 88cm

2 7 cm2 < 1020kg/cm2

iv) Shear stress = 47482 / (74.3 X 1.2) = 533kg/cm2 < 765kg/cm2

Weld strength required between Web and U/S flange :