Design of Staging for Bridge deck slab Superstructure

Data :
Length of the bridge = 75000 mm = 75 m
Width of the Bridge = 12150 mm = 12.15 m
Area = 911.25 Sq.m
Maximum depth at solid section = 1.993 m
Weight of Steel = 3.29 KN/Sqm
Shutter Weight = 60 Kg/Sq.m = 600 N/Sq.m = 0.6 KN/Sq.m

Shuttering Arrangement :
Shuttering Ply size = 2.44 x 1.22 m
Shuttering Ply Thickness = 12 mm
Main Frame Angle = 50 x 50 x 6 mm
Internal Stiffner = 50 x 50 x 6 mm
Secondary Beam = ISMC 75*40 @ 0.85 m c/c
Primary Beam = ISMB 150 @ 1.5 m c/c

Spacing of cuplock = 1 m c/c in both directions

STAGING DESIGN OF DECK SLAP

A. LOADS
Maximum Load = = 3.29 KN/Sq.m
Weight of shuttering = 0.6 KN/Sq.m
Ply (31 kg/2.4*1.22) = 0.1 KN/Sq.m
Angle Frame (5*2.44+2*1.22)*4.5/(2.44*1.22) = 0.221 KN/Sq.m
Live loads during concreting = 3.6 KN/Sq.m
Total Load DL+LL = 8 KN/Sq.m

B Shuttering Arrangement
Shuttering Ply size = 2.44x1.22 m
Shutter Ply thickness = 12 mm
Main frame Angle = 50x50x6 mm
Internal stiffners = 50x50x6 mm @ 0.305 m c/c
Secondary Beams = ISMC75*40 @ 0.85m c/c
Primary Beams = ISMB150 @ 1.5m c/c

C Design check for Ply Strength

Weight of Ply = 31 Kg
Shuttering Ply Thickness = 12 mm
Maximum Bending Moment = wl2/10 = 8*2.44*.3052/10
= 0.18 KN-m
Section modules of Ply = 30.5 *1.22*2/6
= 7.57 cm3
Bending Stress = M/Z
= 24.00 N/mm2

Allowable Bending stress = 150 N/mm2

= 24.00 < 150 N/mm2
Provided Plywood is safe against bending

D Design check for Angle Strength ISA 50x50x6 mm

Total load on Angle = 8x0.305
"W" = 2.44 KN/m
Effective spacing of Secondary Beams L = 0.85 m
Weight of ISA 50*50*6 = 4.5 Kg/m
Steel Table Pg no-8
Sectional Area = 5.68 cm2
Sectional Modulus Zxx = 3.6 cm3 Steel Table Pg no-9
Permissible Bending Stress = 155 N/mm2 (i.e, 0.62*250=155)
Maximum Bending Moment = WL2/10
= 2.44X1000X0.85X0.85/10
= 176.29 N-m
Bending stress = M/Z
= 176.29x1000/(3.6x1000)
= 48.97 N/mm2
Permissible Bending Stress = 155 N/mm2
= 48.97 < 155 N/mm2
 Provided Angle is safe against bending
Maximum Shear force = WL/2 = 2.44X0.85/2
= 1.037 KN
Shear Stress = Shear force/Area
= 1.037x1000/5.68x100
= 1.826 < 95 N/mm2
Provided Angle is safe against shear (i.e, 0.38fy)

Maximum Deflection at center (for UDL) = 5/384* WL^4/EI

= 5/384*(9*1000*305^4)/(10^3*2*10^5*12.9*10^4)
Maximum Deflection at center = 0.035 < 3.667 mm
(i.e, L/180=0.66*1000/180)
Provided Angle is safe against deflection

E Design check for Secondary Beam:

Load/Unit Area = 8 KN/Sq.m
Self weight of ISMC 75*40 = 6.8 Kg/m
Sectional Area of ISMC 75*40 = 8.67 cm2
Load area = 1x0.85
= 0.85
Load = 0.85x8
= 6.8 KN
Maximum Bending Moment = 1.5WL2/8
= 0.921 KN-m
Required Section Modulus Zxx = 0.921x1000x10/1650
= 5.582 < 20.3 cm3
Steel table pg no-7
Therfore proposed section of ISMC 75*40(with Zxx 20.3) is safe
Maximum shear force = 1.5 W/2
= 5.10 KN
Shear Stress = Shear force/Area
= 5.88 < 95 N/mm2
Provided Angle is safe against Shear

Maximum Deflection at center (for UDL) = 5/384* WL^4/EI

= 5/384*(8*1000*850^4)/(10^3*2*10^5*76.0*10^4)
Maximum Deflection at center = 1.073 < 3.667 mm
(i.e, L/180=0.66*1000/180)
Provided ISMC is safe against Deflection

F Design check for main/primary beam:

Load on main beam as calculated above = 8 KN
Self weight of beam = 0.15 KN Steel Table pg no-2
Total load = 8.15 KN
Sectional Area of ISMB 150 = 19 cm2 Steel Table,table no-4
Maximum Bending moment = 1.5 WL2/8
= (1.5*9.15*1^2)/8
= 3.44 KN-m
Required section modulus Zxx = 20.84 cm3
= 20.84 < 96.9 cm3
Therfore proposed section of ISMB 150 (with Zxx 96.9) is safe
Maximum Shear force = 1.5 WL/2 = (1.5*8.15*1)/2
= 9.169 KN
Shear Stress = Shear Force/Area
= (9.169*10^3)/(19*10^2)
= 4.83 < 95 N/mm2
Provided Angle is safe against shear
Maximum Deflection at center (for UDL) = 5/384* WL^4/EI
= 5/384*(8.15*1000*1500^4)/(10^3*2*10^5*76*10^4)
Maximum Deflection at center = 3.534 < 4.722 mm
= (i.e, L/180=0.85*1000/180)
Provided ISMB Section is safe against Deflection

G Design check for Cuplock

Spacing of cup lock = 1.5 m c/c in both directions
Properties of Cuplock Section
 Diameter D = 40 mm diameter medium pipe
Type = Medium duty pipe
Radius of Gyration r = 1.6 cm
Sectional Area As = 4.6 cm2
Section Modulus Z = 4.86 cm3
Bracing/Ledger pipe are tied and braced @ = 1 m c/c on vertical and horizontal
Therefore unsupported length of staging Cuplock = 1.5 m = 150 cm
Load in each Cup lock as above = 8 KN
Weight of secondary Beam = 0.068 KN
Weight of main/primary Beam = 0.15 KN
Total load = 8.218 KN

Spacing of steel Cuplock = 1.5 m c/c in both directions

= 1.5 Sq.m
Load per 1.5 sq.m = 12.327 KN/Sq.m
Load per 1 sq.m = 12.327 KN/Sq.m

Slenderness Ratio L/r = 150/1.6

= 93.75

Allowable stress in steel

90 = L/r = 90 N/mm2 Steel Table, Table-19
100 = L/r = 80 N/mm2 pg no-70
Therefor allowable stress in steel for
L/r = 93.75 = 86.25 N/mm2

Therefore allowable load = 86.25*4.6*10^2

= 39675.0 N
= 39.7 KN

Allowable load with factor of safety of 1.5 = 39.7/1.5

= 26.45 KN
= 26.45 > 12.33 KN
Therefore proposed section is safe