Project :- Approach Viaducts to Rail Cum Road Bridge Across River Ganga at Ghazipur

Client :- Rail Vikas Nigam Limited

Contractor :- M/s GPT Infraproject Ltd.
Consultant :- -
Location :- Bearing for Spans MKD AP3-AP66

DESIGN DATE :- 10.04.2023 Rev. :- 0 Date of revision :- -

DESIGNED BY :- Prashant Type :- B5 Quantity :- 04 Nos.

Conc. Grade for Pedestal M 50

DESIGN CALCULATION FOR FREE FLOAT BEARING - 106 MT ( SLS ) / 148 MT (ULS)
Steel Grade for Superstructure (IS: 2062 Grade E350) 350

LOADINGS & INPUT PARAMETERS AS REQUIRED FOR DESIGN OF BEARING ASSEMBLY :

max = N sd max = 148.00 MT = 1451.41 kN

Vertical permanent = N sd permanent = 74.00 MT = 725.70 kN
minimum = N sd min = 32.00 MT = 313.82 kN
Design Loads
Transverse = Vy sd = 4.44 MT = 43.54 kN
Ultimate Limit Horizontal Longitudinal = Vx sd = 7.00 MT = 68.65 kN
State (ULS) Resultant = Vxy sd = 8.29 MT = 81.29 kN
Transverse = Ty sd = 10.00 mm
Translation / Movement in mm
Longitudinal = Tx sd = 50.00 mm
Transverse = q y sd = 0.010 radian
Rotation in Radians
Longitudinal = q x sd = 0.010 radian

max = N sk max = 106.00 MT = 1039.52 kN

Vertical permanent = N sk permanent = 77.00 MT = 755.12 kN
minimum = N sk min = 24.00 MT = 235.36 kN
Design Loads
Transverse = Vy sk = 3.18 MT = 31.19 kN
Servecability Horizontal Longitudinal = Vx sk = 5.00 MT = 49.03 kN
Limit State (SLS) Resultant = Vxy sk = 5.93 MT = 58.11 kN
Transverse = Ty sk = 10.00 mm
Translation / Movement in mm
Longitudinal = Tx sk = 50.00 mm
Transverse = q y sk = 0.010 radian
Rotation in Radians
Longitudinal = q x sk = 0.010 radian

ADDITIONAL CONSIDERATION FOR DESIGN OF BEARING ASSEMBLY AS PER CODE :

Movement in mm considerd for design calculation as Transverse = Ty sd 50.00 = + 25.00 / - 25.00

per clause no 5.1.9 of IRC : 83 (Part III) - 2018 Longitudinal = Tx sd 100.00 = + 50.00 / - 50.00

Permanent Action = qP = 0.0075 radian

Rotation in Radians as per clause no 5.1.7 of IRC : 83 Variable Action = qV = 0.0025 radian
(Part III) - 2018 Max Rotation = q max = 0.01 radian
Design Rotation = q max + 0.005 = 0.015 radian

BEARING & SIZE OF COMPONENTS :

Neoprene Pad Size dia. in mm = 210 di

Neoprene Pad thk. in mm = 16
No of Sealing Rings = 2
Total Thk of rings (in mm) = 4

P. T. F. E. Size dia. in mm = 220

P. T. F. E thk. in mm = 4.5 (2 mm Projected from Piston Surface & 2.5 mm inside the groove in Piston)

Pot Base effective dia (actual in mm) = 235

Pot Base Thickness (mm) = 12 kb
Pot internal dia. (mm) = 210
Pot Wall Outer to Outer dia (in mm) = 235 do
Pot depth (mm) = 29 hC
Pot Wall Thickness (mm) = 12.5

Gap Between pot wall & underside of piston (mm) = 10

Piston size (L x W) (mm) = 250 x 250

Piston Thickness above Spiggot (mm) = 12

Sheet 1 of 12
 Spiggot Projection (in mm) = 23
Vertical Face of Piston Provided (in mm) = 5

Slide Plate effective contact area dia. (mm) = 270

Slide Plate Thickness (mm) = 19
Stainless Steel = Gr. 304 Thk.(mm) = 3
Effective thickness of Slide Plate = 22
Slide Plate Dimension ( Rectangle L X W) in mm = 340 x 280
Stainless Steel size (L x W) in mm = 330 x 270

Bolt Diameter = 16 Gr. 8.8 Length of Bolt = 40 mm

No. of Bolts per component = 4
Bolt Flange Thickness = 12

Dowels / Sleeves for Bottom Pedestal (in mm) = 40 Dia x 120 mm

Top Adopter Plate for Top Superstructure (in mm) = 455 x 280 x 24 mm

Total Height of Bearing Assembly (in mm) = 87

Steel Stress (Working) for Design Use 340 MPa (Grade-340-570W) AS PER IS - 1030
Steel Stress (Working) for Design Use 350 MPa (Grade-B) AS PER IS - 2062

1 - Design of Elastomeric Preassure Pad

If,
N sd = Design Maximum Axial Force in ULS Condition = 1451.41 kN
NRk = characteristic value of resistance of elastomeric pad = 2077110 N
gm = partial saftey factor = 1.3
di = Diameter of Elastomeric Pad in mm = 210 mm
he = thickness of confined elastomeric preassure pad = 16 mm
2
fe,k = characteristic contact strength of elastomeric pad = 60 N/mm
q = design rotation angle in radian = 0.015 radians

Design Check :- As per Clause No - 5.2.3.2 of IRC : 83 (Part - III) - 2018

p
N Rk = x di 2 x fe,k
4

= 0.785 x 210 x 210 x 60

= 2077110 N say 2077.11 kN

N Rk
N rd =
gm

2077110
= = 1597776.923 N = 1597.777 KN
1.3

N sd < N rd

So, 1451.407 < 1597.78 RESULT = OK

Rotation Capacity -

Compression at edge of Neoprene Pad Max. Permitted = 15 % of he

(Thickness of Pad less seal rings thickness)
= 0.15 x 12.0 = 1.8 mm

Rotation ( Radius ) = As per Clause No - 5.2.3.4 of IRC : 83 (Part - III) - 2018

1.8 = 0.017 radians > 0.015 radians

210 x 0.5
RESULT = OK

D/T ratio of Elastomer di As per Clause No - 5.2.3.5 of IRC : 83 (Part - III) - 2018
< 15
he

210
= 13.13 < 15
16 RESULT = OK

Sheet 2 of 12
2 - Design of PTFE As per Clause No - 5.2.4.5 & 5.2.4.6 of IRC : 83 (Part - III) - 2018

The permissible stress is reduced due to exceeding the category temperature above 30°.
Max. ambient temperate: 48 °C
Reduction: 36 %
Assuming,
L = = 220.00 mm e
fk = characteristic compressive strength = 90.00 MPa
gm = partial saftey factor = 1.40
k = reduction factor w.r.t. temperature = 0.64 Ar
Ar = reduced area
Now L
N sd max < fk x Ar x k
gm

APTFE = p = 37994 mm 2
x DPTFE 2
4

Z = 2 + 12 + 23 - 2.5 = 34.5 mm

Moment due to Horizontal Force (Mz) = Vxy,sd x Z

= 2804581.3 N-mm

Total Moment (MT) = MT,d + Mz

= 3446741.18 + 2804581

= 6251322.43 N-mm

Eccentricity (e) = MT,d = 4.31 mm

Nsd,max

Ar = APTFE ( 1 - 0.75 p e )
L

Ar = 37994 ( 1 - 0.75 p 4.31 )

220.00

2
Ar = 36241.3868 mm

Hence, 1451.41 < 90.00 x 36241.39 x 0.64

1.40

1451.41 kN < 1491.07 kN RESULT = OK

3 - Design check for Pot Base Diameter

Restraint Moment due to Rotation of Elastomeric Pad (ULS Condition) As per Clause No - 5.1.5.1 of IRC : 83 (Part - III) - 2018

Me,d = di 3 x ( k1 qP + k2 qV )

= 9261000 x ( 1.90 x 0.0075 + 69.434 x 0.0025 )

= 1739604.76 N. mm

Resistance to rotation due to Pot/Piston Contact (ULS Condition) As per Clause No - 5.1.5.2 of IRC : 83 (Part - III) - 2018

MR,d = 0.2 x C x Vxy sd

= 0.2 x 210 x 81.29

2

= 1707136.42 N. mm

Toal Resistance to Rotation

MT,d = Me,d + MR,d As per Clause No - 5.1.6 of IRC : 83 (Part - III) - 2018

Sheet 3 of 12
 = 1739604.76 + 1707136

= 3446741.18 N. mm

Flexural Stress due to induced Moment resulting from resistance to Rotation :-

M1 MT,d MT,d
= Z = p
x D3
32

M1 = 3446741.18
0.098125 x 235 x 235 x 235

M1 = 2.71 MPa

Stress due to active Moment resulting from acting Horizontal Force :- As per Clause No - 5.1.4 of IRC : 83 (Part - III) - 2018

M2 = Vxy sd x e
p
x D3
32

e = 12 + 16 + 2.5 = 30.5

= 81.29 x 1000 x 30.5

0.098125 x 235 x 235 x 235

M2 = 1.95 MPa

Total Flexural Stress = M1 + M2 < 0.48 f ck

= 2.71 + 1.95 < 24 MPa

Total Flexural Stress = 4.65 MPa < 24 MPa RESULT = OK

Pressure in Concrete Structure at Bottom (Sub-structure) - ULS

Aco = loaded area for no ecentricity
N sd max < Ar x s c sub Ar = reduced area
D = Pot Base effective dia (actual in mm)
Aco = p 2 = 43351.63 mm 2
x D
4

e = 12 + 16 + 2.5 = 30.5 mm

Ar = Aco ( 1 - 0.75 p e )
L

Ar = 43351.625 ( 1 - 0.75 p 30.5 )

235

Ar = 30094.5262 mm 2

s c sub = 66.52 MPa

Available Pedestal size = 700.00 x 700.00

So, s c sub = N sd max = 1451.41 x 1000

Ar 30094.53

= 48.23 MPa < 66.52 MPa RESULT = OK

4 - Design check for Top Component Diameter

Restraint Moment due to Rotation of Elastomeric Pad (ULS Condition) As per Clause No - 5.1.5.1 of IRC : 83 (Part - III) - 2018

3
Me,d = di x ( k1 qP + k2 qV )

= 9261000 x ( 1.90 x 0.0075 + 69.434 x 0.0025 )

= 1739604.76 N. mm

Resistance to rotation due to Pot/Piston Contact (ULS Condition) As per Clause No - 5.1.5.2 of IRC : 83 (Part - III) - 2018

MR,d = 0.2 x C x Vxy sd

Sheet 4 of 12
 = 0.2 x 210 x 81.29
2

= 1707136.42 N. mm

Toal Resistance to Rotation

MT,d = Me,d + MR,d As per Clause No - 5.1.6 of IRC : 83 (Part - III) - 2018

= 1739604.76 + 1707136

= 3446741.18 N. mm

Stress due to induced Moment resulting from resistance to Rotation :-

M1 MT,d MT,d
= Z = p
x D3
32

M1 = 3446741.18
0.098125 x 270 x 270 x 270

M1 = 1.78 MPa

Stress due to active Moment resulting from acting Horizontal Force :- As per Clause No - 5.1.4 of IRC : 83 (Part - III) - 2018

M2 = Vxy sd x e
p
x D3
32

e = 2.5 + 18 + 12 + 3 + 2 = 37.5

= 81.29 x 1000 x 37.5

0.098125 x 270 x 270 x 270

M2 = 1.58 MPa

Total Stress = M1 + M2 < 168.0

= 1.78 + 1.58 < 168.0 MPa

Total Stress = 3.36 MPa < 168.0 MPa RESULT = OK

Pressure in Steel Structure at Top (Super-structure) - ULS

Aco = loaded area for no ecentricity
N sd max < Ar x s c super Ar = reduced area
D = Slide Plate effective contact area dia. (mm)
2
Aco = p 2 = 57226.5 mm
x D
4

e = 2.5 + 18 + 12 + 3 + 2 = 37.5 mm

Ar = Aco ( 1 - 0.75 p e )
L

Ar = 57226.5 ( 1 - 0.75 p 37.5 )

270

2
Ar = 38499.1717 mm

s c super = 405.31 MPa

Top Dispersion Area Available = 700.00 x 700.00

So, s c super = N sd max = 1451.41 x 1000

Ar 38499.17

= 37.70 MPa < 405.31 MPa RESULT = OK

5 - Design check for Flat Contact Surface (Vertical Face of Piston) As per Clause No - 5.3.1.4.1 of IRC : 83 (Part - III) - 2018

Vxy sd < VRd w = inner diameter of pot in mm

gm = partial saftey factor = 1.1
VRd = fy x di x w fy = yield strength of material

Sheet 5 of 12
1.5 x gm

Sheet 6 of 12
 w = Vxy sd x 1.5 x gm
fy x di

w = 81.29 x 1000 x 1.5 x 1.1

350 x 208.5

w = 1.84 mm Calculated & Provided is = 5.00 mm RESULT = OK

5 - Design check for Pot Base Thickness As per Clause No - 5.3.1.3 of IRC : 83 (Part - III) - 2018

Pot Base thickness > 2.5 % OF POT INNER DIAMETER

Minimum Required Thickness of Pot Base = 5.25 mm

Provided Thickness of Pot Base = 12 mm RESULT = OK

Check for the Thickness of Pot in Bending : Bottom

Maximum Vertical Load N sd max = 1451.41 kN

Pot Base Effective contact dia. (mm) = 235 mm
Effective area of the Pot Base in contact to concrete = 3.14 x 235 x 235 = 43373.61 mm2
4

Concrete Stress on Bottom Plate = 1451.41 x 1000 = 33.46 MPa

43373.61

Diameter of the Loaded Area (Pad) = 210 mm

Projection of Bottom Plate each side = 235 - 210 = 12.50 mm

2

Bending Moment of Bottom Plate 33.46 x 12.50 x 12.50 = 2614.29 N-mm

2

Thk. Of Bottom Plate required for B. M.

√ 2614.29
1
x
x
6
340
= 6.80 mm

Thk. Of Bottom Plate required for B. M. = Calculated Thk. 6.80 mm < Provided 12.00 mm

RESULT = OK

6 - Design check for Top Plate Thickness As per Clause No - 5.3.1.3 of IRC : 83 (Part - III) - 2018

Pot Base thickness > 4 % OF Thickness of Steel backing plate for sliding component
Digonal Length = 440
Minimum Required Thickness of Slide Plate = 17.6 mm
Provided Thickness of Slide Plate = 19 mm RESULT = OK

Check for the Thickness of Top Plate in Bending : Bottom

Maximum Vertical Load N sd max = 1451.41 kN

Slide Plate Effective contact dia. (mm) = 270 mm
2
Effective area of the Slide Plate in contact to concrete = 3.14 x 270 x 270 = 57255.53 mm
4

Concrete Stress on Top Slide Plate = 1451.41 x 1000 = 25.35 MPa

57255.53

Diameter of the Loaded Area (PTFE) = 220 mm

Projection of Top Slide Plate each side = 270 - 220 = 25.00 mm

2

Bending Moment of Top Slide Plate 25.35 x 25.00 x 25.00 = 7921.76 N-mm
2

Thk. Of Top Slide Plate required for B. M.

√ 7921.76
1
x
x
6
340
= 11.83 mm

Thk. Of Top Slide Plate required for B. M. Calculated Thk. 11.83 mm < Provided 19.00 mm

RESULT = OK

7 - Design check for Pot Wall

Pot Wall Subjected to Tensile Force As per Clause No - 5.3.1.2.3 of IRC : 83 (Part - III) - 2018

V sd < VRd

Sheet 7 of 12
 V sd = V e. sd + Vxy sd

= 140.87 + 81.29

= 222.16 kN

V e. sd = 4 x N sd max x he
p x di

= 4 x 1451.41 x 1000 x 16
3.14 x 210

= 140870.588 N

VRd = fy x AR
gm

= 340 x 725
1.1

= 224090.909 N = 224.09 kN

AR = ( do - di ) x hC

= ( 235 - 210 ) x 29

2
= 725 mm

So, V sd < VRd

222.16 < 224.09 kN RESULT = OK

Pot Wall Subjected to Shear Force As per Clause No - 5.3.1.2.4 of IRC : 83 (Part - III) - 2018

V' sd < V'Rd

V' sd = V e. sd + 1.5 x Vxy sd

di

= 140870.588 + 1.5 x 81292.21

210

= 1251.47 N - mm

V'Rd = fy x ( do - di )
2 x gm x √ 3

= 340 x ( 235 - 210 )

2 x 1.1 x √ 3

= 2230.67 N - mm

So, V' sd < V'Rd

1251.47 < 2230.67 N - mm RESULT = OK

Pot Wall Subjected to Tensile Force As per Clause No - 5.3.1.2.5 of IRC : 83 (Part - III) - 2018

V sd < VRd

V sd = V e. sd + Vxy sd

= 140.87 + 81.29

= 222.16 kN

VRd = fy x AP
gm

= 340 x 2820
1.1

= 871636.364 N = 871.64 kN

AP = do x kb

Sheet 8 of 12
Sheet 9 of 12
 = 235 x 12

2
= 2820 mm

So, V sd < VRd

222.16 < 871.64 kN RESULT = OK

8. Calculation of Anchorage As per Clause No - 5.3.6.2.1 of IRC : 83 (Part - III) - 2018

Shear Resistance per Shear Plane

where,
Vxy sd < VRd µk = 0.6 Friction Factor Steel to Concrete Surface
gm = 1.2 (Safety Factor against Sliding)
VRd µk n = 4 No of bolts used
= x N sd min + Vpd
gm Gr. = 8.8 Grade of Bolt
Dbo = 16 mm Bolt Diameter
2
0.6 A = 157 mm Area of Bolt in Shear
= x 313.82 + 241.152
1.2 fub = 800 N/mm2 Spec. min. Yield Strength
gm2 = 1.25 partial saftey factor for bolts
= 398.06 kN av = 0.6 Factor as per Annexure D
fu = 570 N/mm2 Tensile Strength of Cast Steel
Vpd = n x Fv,Rd t = 12 mm Flange Thk.
k2 = 0.9
Vpd = 4 x 60.288

Vpd = 241.152 kN

Fv,Rd = av x fub x A
gm2

Fv,Rd = 0.6 x 800 x 157

1.25

Fv,Rd = 60288 N = 60.288 kN

So, Vxy sd < VRd

81.29 < 398.06 RESULT = OK

Bearing Resistance

Fb,Rd = 1.25 x fu x d x t
gm2

= 1.25 x 570 x 16 x 12
1.25

Fb,Rd = 109440 N = 109.44 kN

Vpd = n x Fb,Rd

Vpd = 4 x 109.44 x 0.8

VRd = 350.208 kN

So, Vxy sd < VRd

81.29 < 350.208 RESULT = OK

8. Design of Anchor Sleeves in Pedestal Concrete As per Clause No - 5.3.6.4 of IRC : 83 (Part - III) - 2018

F vRd < F Rdu

f cd = 0.67 x f ck
1.5

f cd = 22.33 MPa
(As per Amendement No 1 / IRC : 83 (Part III) - 2018)

Sheet 10 of 12
 F Rdu 1.33 x D sleeve x L sleeve x f cd
=
sqrt (3)

= 1.33 x 40 x 120 x 12.89

F Rdu = 82.32 MPa

So, F vRd < F Rdu

60.29 < 82.32 MPa RESULT = OK

9. Design Check for Sliding Capacity

Slide Plate Dimension used = 340 mm length x 280 mm wide

Effective Dimeter of PTFE = 220 mm dia.

Preset in Long. Direction = 0.00 mm

Longitudinal Movement = 340.00 - 220 = 120 mm

M'ment possible in one direction = 120 / 2 + 0 = 60.00 mm > 50.00 mm

RESULT = OK
M'ment possible in other direction = 120 / 2 - 0 = 60.00 mm > 50.00 mm
RESULT = OK

Transverse Movement = 280.00 - 220 = 60 mm

M'ment possible in one direction = 60 / 2 + = 30.00 mm > 25.00 mm

RESULT = OK
M'ment possible in other direction = 60 / 2 - = 30.00 mm > 25.00 mm
RESULT = OK

10. Weld Strength Calculation for Top Adopter Plate

Top Adopter Plate Size ( mm ) = 455 x 280 x 24 mm

The Top Adopter plate will be continuously fillet welded to the Steel Girder by a weld of 8 mm Thickness by all sides

Length of weld = 2 x ( 455 + 280 ) = 1470

Area of Weld = 1470 x 8 = 11760 mm2

Effective Area of weld, taking in account throat thickness

= 11760 x 0.7 = 8232 mm2

Strength of Weld = 110 N / mm2

Assuming that the weld has to resist total Horizontal force acting over the Top Adopter plate

Force resistance capacity of weld > Vxy sd kN

8232 x 110 N/mm2 > 81.29 kN

905.52 kN > 81.29 kN RESULT = OK

11. Requirement of clearance

Variation due to rotation 1.80 mm As per Clause No - 5.2.3.4 of IRC : 83 (Part - III) - 2018
Minimum clearance required 2.10 mm As per Clause No - 5.3.1.5 of IRC : 83 (Part - III) - 2018
Gap required in rotation 3.90 mm
Gap Provided 10.00 mm
RESULT = OK

15. Check for Permissible Stresses on the Adjacent Concrete Structure As per Clause No 5.2.1.1 of IRC : 83 (Part - III) - 2018

The resistance of the concrete structure shall be calculated from the below expression -

F Rdu = A c0 x f cd x Sqrt ( A c1 / A c0 ) < 3 x f cd x A c0

F Rdu = 55225 x 22.33 x 2.98 < 3 x 22.33 x 55225

F Rdu = 3.67 Mpa < 3.70 Mpa Result : - OK / SAFE

Sheet 11 of 12
Where -
F Rdu = Resistance offered by concrete in ULS Condition Loading
A c0 = Loaded Area = 235 x 235 mm = 55225 mm 2

f cd = Permissible Direct Compressive Strength of Concrete, 0.67 x f ck = 22.33 Mpa

calculated as = 1.5
f ck = is the characterstic compressive strength of concrete
A c1 = Dispersed Area, Width of Dispersed area in either direction (Longitudinal & Transverse) shall be limited to maximum three
times the width of loaded area

2
A c1 = 700 x 700 mm Min Pedestal Size Provided so Area = 490000 mm

= Sqrt ( A c1 / A c0 ) < 3

= Sqrt ( 490000 / 55225 )

= 2.98 < 3 Result : - OK / SAFE

16. Neoprene Pad Minimum Average Stress in SLS Condition = As per Clause No 5.2.3.3 of IRC : 83 (Part - III) - 2018

235.36 x 1000 = 6.80 > 2 Mpa

0.785 x 210 x 210
RESULT = OK

- - - - - - - - - - - - - - - End of Design Sheet - - - - - - - - - - - - - - -

Sheet 12 of 12