DESIGN OF COMPOSITE STEEL GIRDER BRIDGE(WELDED)

6500 1676 1000

200 250 75

200

1050

2100

2300

2100

CROSS SECTION OF BRIDGE

INPUT DATA :
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 Length of the Girder Girder depth EUDL for Moment EUDL for Shear Coefficent of Dynamic Augument (CDA) Design EUDL for Moment / Girder Design EUDL for Shear / Girder Axle Load of Train ( 32.5 )t Distribution width of Load Dispersion Design wheel Load per meter width Tractive effort Braking force Unit weight of Concrete Area of Steel Girder = = = = = = = = = = = = = = 20.0 2500 M mm

DESIGN CRITERIA :
Ultimate Concrete Stress, Ultimate Steel Stress, Allow. stress of Concrete in Compression Modulus of Elasticity of Concrete Modulus of Elasticity of Steel f 'C = f 'y fC Ec Es fc fs m r k j R = = = = = = = = = = = 25.00 N/mm2 415.0 N/mm2 11.25 N/mm2 24000.00 N/mm2 200000 N/mm2 10.00 N/mm2 166.7 N/mm2 8 16.67 0.32 0.89 1.45

2065.5 kN 2272.4 kN 0.458 kN 1505.4 kN 1656.2 kN 318.5 kN 3.0 53.083 735.0 552.0 24.0 M kN/m kN kN

= =

75.272 kN / m 82.812 kN / m

Kn/m3 2 88000 mm

Bs 200 1540 mm

2300

mm = 971 mm

Bs

288 mm 200

ds

90

25

217

ys =

C.G of Steel Section

COMPOSITE SECTION

EQUIVELANT STEEL SECTION

Effective width of the Slab : i) One - third of the effective Span ii) Distance between centres of the rib
iii) 12 times the thickness of the slab + breadth of the rib Area of Steel Girder Area of composite Section Moment of inertia of the Steel section Equivalent moment of inertia of the composite section 1.0 Self wt. of the Steel Girder/m 2.0 Self wt. of the Slab/m 3.0 Rail, Sleeper and Ballast load on top of the Slab 4.0 EUDL / Girder for Live load with impact = (200L + 1000) N AS AC IS = = = = = = = = = = = 6666.7 mm 2300 mm 2410 mm

88000 mm2 145500 mm2 1.1504E+11 mm4 1.8735E+11 mm4 5.000 kN/m 21.840 kN/m 23.417 kN/m 75.272 kN/m

Ic

150

ds

Fatigue considerration: Total DL Shear per Girder Total DL + LL Shear per Girder Ratio of Minimum Shear & Maximum Shear Considering 2,000,000 Cycle K MS MC MA D Zb Z tc a) Bending Moment due to Self wt. of the Steel section b) Bending Moment due to Dead load of Concrete c) Bending Moment due to Rail, Sleeper, Ballast d) Bending Moment due to EUDL (Applied load) Over all depth of the Composite Section, Section modulus of Steel Section at bottom Section modulus of Composite Section at bottom Section modulus of Composite Section at bottom Maxi. Stress in Steel at bottom Shear(mini) Shear(maxi) = = = = = = = = = = 502.57 KN 2158.8 KN 0.2328 0.93 268.82 kN -m 1174.2 kN -m 1259.0 kN -m 4046.9 kN -m 2700 mm

MSU =

1E+08 mm3 2E+08 mm3 2E+08 mm3 MS Zb MC + MSU + Z bc < MA < 11.25 N / mm2 OK 165.00 N / mm2 OK MA

Z bc =

bc

= =

42.832 N / mm2 MC + MSU + Z bc 4.1978 N / mm2

Maxi. Stress in Concrete at top

c t

= =

Vartical Shear at support

= 1430.85 kN

Design of Shear Connector :The horizontal Shear at the top of the Steel section Fh = F * Bs*ds*(n - ds/2) m IC = Or Total = 382.47 N/mm 109958.79 N Fh = o.85 * fc' *Ac 2 = Design horizontal force Let us considered H H D = 150 mm = 6.8 > 4 Fh = D OK q n = 1.518 * H * d fCK = Total nos. of studs We know shear strength P S Pitch of the Shear connector, = KLS va = = = 20900 S 0.0183 n*Zr Vsr Vsr Where, Vf*Q I = = = = = = = Vsr Zr Pitch of the Shear connector Longitudinal Spacing Maximum Pitch of Shear connector = 764.93 N = 238 = 88 mm = 115 115 mm 500 600 mm 29.5 log(N) 52.12 19.00 = *d2 = Minimum Pitch of Shear connector = = 25225.8937 4*d L 2 = x = 1 n/4 = = 132 mm 4 * d2 38 * d 2 2 2861.7 kN 3.0 mm = 14025 N 349 Nos = 4887500.00 22 22 N 150 mm Long 4887500.00 N

Horizontal force resisted by the compressive area of the concrete slab

MS Rod as Shear connector

Allowable Shear taken by one Shear connector

Let 'S' be the size of the welding all arround the bar with the top flange

382.47

n is the number of Shear connector in Cross - section Z r Shear fatigue resistance of an individual Shear connector V f Vertical Shear force under Fatigue load combination Q Area moment about N . A I C Moment of inertia of composite section d Dia of Shear connector N Number of Cycle

50078350.5 mm 3 1.8735E+11 mm4 22 2000000

2.5 d s

DESIGN OF RCC DECK SLAB :

53.08 kN 6.24 kN 100 350 2100 R1 = 138.93 kN 350 2100 R2 = 138.93 kN 312 1676 46.833 kN/m 4.8 kN/m 100 53.08 kN 312 6.24 kN

C 2300

1.0 Self wt. of deck slab 2.0 Self wt. of Ballast, Sleeper & Rail 3.0 Load per wheel 4.0 Parapet Load Maxi. (-) Moment at A Maxi. (+) Moment at C

= = = = = =

4.80 kN/m 46.833 kN/m 53.083 kN/m 6.24 kN/m

-25.93 kN - m 21.292 kN - m

DESIGN FOR CANTILIVER PART :

Maxi. (-) Moment at A Minimum flaxural strength Section modulus, Mcr Mcr Mcr Minimum flaxural strength Design Moment, MD = 25.93 Kn-M = 1.2 x Mcr = 19.70 x f 'c x Z b
3 0.0017 m

(Top Tension)

Zb = = = = d reqd. = d avil. = As = 16 mm

5.1914 Kn-M 6.2297 Kn-M 25.93 Kn-M 133.9 mm 142.00 mm OK 1228.5 mm2 / m @ 177 mm c/c

Use Y

DESIGN FOR MID SECTION :

Maxi. (+) Moment at C Minimum flaxural strength Section modulus, Minimum flaxural strength Design Moment, MD Mcr Mcr Mcr = 21.29 Kn-M

(Bottom Tension)

= 1.2 x Mcr = 19.70 x f 'c x Z b 3 0.0017 m = = = 5.1914 Kn-M 6.2297 Kn-M 21.29 Kn-M 121.33 mm 142.00 mm

Zb =

d reqd. = d avil. = Use Y

OK

A s = 1008.7 mm2 / m 16 mm @ 199 mm c/c

DISTRIBUTION REINF :
Distribution reinforcement is 67 % A dist. = Use Y 12 @ of the main reinforcement
2 675.8 mm

167

mm c/c

DESIGN OF PARAPET WALL :

200

1.47
1.050

kN/m

Moment at base

M d reqd. d avil. As Use Y

= 1.5435 = 32.668 = 144.00 = 72.11 @ 12 mm

Kn-M mm mm

OK

mm2 / m 1568 mm c/c

MINIMUM REINF. REQUIRMENT : A st = 500 mm2 12 mm 214 mm c/c ( Both Way )

Use Y

12

@ 214 mm c/c 12 @ 167 mm c/c 16 @

177 mm c/c

12 12

@ @

214 mm c/c 214 mm c/c

16

199 mm c/c

REINF. DETAILS OF DECK SLAB:

DESIGN OF STEEL GIRDER :

45

`
2500 45
375

20.00 M

375

LONG SECTION OF GIRDER

STRUCTUREAL DESIGN OF STEEL I GIRDER.

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0

DESIGN CRITERIA : M mm Yield stress of steel Allowable shear stress, Allowable bending stress, Permissible bearing stress, Allowable stress for tension, Allowable stress for compre. Shear stress in the weld fy va bc p t C
vf

Length of the Girder Girder depth EUDL for Moment EUDL for Shear Coefficent of Dynamic Augument (CDA) Design EUDL for Moment / Girder Design EUDL for Shear / Girder Tractive effort Braking force Unit wt. of Timber

= = = = = = = = = =

20.0 2500

= = = = = =

250.00 N/mm2 100.00 N/mm2 165.00 N/mm2 187.50 N/mm2 150.00 N/mm2 70.00 N/mm2 108.00 N/mm2

(Mpa)

2065.5 kN 2272.4 kN 0.458 kN 1505.4 1656.2 735.0 552.0 12.0 kN kN kN kN kN/m3

Weight of Rail Weight of Rail Length of Sleeper

= = =

60.00 kg/m 0.589 kn/m 2750 mm

700 mm tf= 45 mm

b
2500 mm

Width of Sleeper Thickness of Sleeper Spacing of Sleeper No.of Sleeper on top Slab Weight of Rail, Sleeper over a girder
Load per meter over a girder

= = = = = =

220 250 445 48

mm mm mm c/c nos.

67.987 kN 3.276 kN/m

A tw = 10 mm

tf=

d1 =

45 mm

Self wt. of Plate Girder = Self wt. of Plate Girder/m = Total uniform load, w' = Maxi. Shear force V = Maxi. Bending moment, M = Let the thickness of web, tw =

2065.50 kN/m 103.28 kN/m 240.65 kN/m 2000.94 kN 12938.1 kN - m 10 mm ( directly exposed to weather and unpainted ) = d1 d1

Economical depth of Plate Girder

= 3080.3 mm 2500 mm 2500 Selected web Plate size = x 10 mm Minimum web thickness of web from Shear considaration t w (mini) = 8.0038 < tw OK

DESIGN OF FLANGE : Approximate flange area required Af b Area of flange = ( 2b + t w ) x t f = ( 2 x 12 x t f + 8 ) x t f

2 24 t f 2 24 t f

= =

2 31365 mm

The flange outstand should not be greater than 12 x t f 12 x t f

+ +

8 tf 8 tf

= -

31365 31365 40 mm = 0

tf

35.984 mm

600 mm Width of the flange Plate = 784.13 2 2 Calculated area of flange = 24000 mm < 31365 mm NOT OK t f = 45 mm Increase flange thickness, Let Width of flange = 697 700 mm 2 2 > 31365 mm OK Area of flange = 31500 mm Hance provide a flange Plate of size = 700 x 45 mm

CHECK BY MOMENT INERTIA METHOD :

I xx

3 = t wd 12

2*

w f * t f3 12

+ (w f * t f)* (d/2 + t f ) 2

4 1.1504E+11 mm

Maxi. bending stress bc = M y I CONNECTION BY WELDING :

145.64 N / mm2 <

165.0

N / mm2 OK

Welds are designed for horizontal Shear V * Ay Horizontal shear per unit length, = Ixx Vertical Shear force, V = 2000.9 kN Area moment of the flange about N - A, A y I xx
2 = 2 * A f * (d/2)

3 40083750 mm

+ )* d2 2 =

t w * d3 12 mm4

6 Horizontal Shear / mm SIZE OF WELD :

= ( Af +

Aw

1.115E+11

719.6 N / mm

Welding is done on both side of the web The strength of well is given by P = Where, S K L
vf

KLS va

= = = =

Size of the weld in mm Constant = 0.7 Effective length of the weld in mm Shear stress in the weld in N / mm2 719.6 = 2 x ( 0.7 x S

2 = 108 N / mm

x 108 )

4.7592 mm 45 mm thick Plate is 10 mm mm mm mm long = 84.047 mm

But minimum size of a fillet weld for a Let us provide an intermittent fillet weld The effective weld length 4 S = 40 Mini effective weld length, L = 40 Provide intermittent fillet welds of 40 Pitch of welds =

Strength of weld on both face of web Horizontal shear / mm length

130 mm Clear spacing between the welds should not be more than 12 t w or 200 mm Maxi. Clear spacing = 120 mm, C/C spacing of welds = 160.00 mm Provide 40 mm Long fillets welds at a Pitch of BEARING STIFFENER : Maxi. Shear force V = 2000.94 kN 2 Permissible bearing stress, p = 187.5 N/mm 2 The bearing area required, A = 10672 mm Let the thickness of bearing stiffener = t bs Out stand bbs should not be more than Use 2 bearing stiffener of b bs mm wide
2 24 t bs = 10671.7

130.00 mm (Provide continuous welding)

12 t bs 2 * (t bs x 12 bs ) = A

t bs = 21.087 mm 30 mm Therefore, out stand = 360 mm 200 mm 12000 mm2 Bearing area provided = > 10671.7 mm2

OK

As per I S specification the bearing stiffener should be designed as column with a distance of the web 20 times the thickness of web ( t w ) on both side as a part of the stifferers. Length of web as stiffener = 2 x
30

20

tw

400

mm

200

10

200 20 t w = 200 mm =

20 t w 200 mm

Effective area of stiffener Radius of gyration ,

A I xx r

= = =

2 16000 mm 4 172300000 mm

103.77 mm

Effective length of the web = 1750 mm Slenderness ratio of the bearing stiffener = 16.864 ac = 148.63 N / mm2 Permissible axial compression stress OK Safe load = 2378.04 kN > 2000.9 kN Provide 200 mm x 30 mm Plate as stiffeners

CONNECTION BY WELDING : Let us provide 6 mm size intermittent fillet weld Strength of weld / mm = 453.6 N / mm Required strength of weld / mm = 200.09 N / mm < 453.6 N / mm OK The length of intermittent fillet weld is taken as 10 t bs = 300 mm C / C spacing of fillet weld = 680.08 mm Maxi. c / c spacing of fillet weld = 16 t bs = 480 mm 300 mm Provide 300 mm long fillet welds at a spacing of 300 mm INTERMEDIATE STIFFENERS : For an unstiffened web the minimum required thickness is as below t w (mini) = d va 1.0 816 va = 80.04 N / mm t w (mini) 2.0 t w (mini) = 27.409 mm = 29.411 mm

= d fy 1344 = d 85

3.0

t w (mini)

29.412 mm

The web thickness provided is 8 mm, which is quite less than required if it to be unstiffened. So, intermidiate stiffenrs will be required Vertical stiffeners to be provided if the web thickness as calculated below is more than the web thickness provided. 1.0 t w (mini) = d2 f y 3200 = d2 200 = 12.353 mm

2.0

t w (mini)

12.50 mm

The web thickness provided is 8 mm which is less than 12.50 mm Therfore, Vertical stiffeners will be provided A horizontal stiffener will be required at a distance of 2/5 of the distance from the compression flange to the N . A, if the web thickness as calculated below is more than that provided. 1.0 2.0 t w (mini) t w (mini) = d2 f y 4000 d2 = = 9.8821 mm

2500 2 = 500 mm from the x 2 5 compression flange. Another horizontal stiffener will be required at the N . A if the web thickness as calculated below is more than the provided one. t w (mini) 1.0 = d2 f y = 6.176 mm 6400 t w (mini) d2 2.0 = = 6.25 mm 400 6.25 mm. So, horizontal stiffener at N . A is not required. Web thickness provided is more than VERTICAL STIFFENERS : The smaller clear panel dimenssion of vertical stiffener > 180 t w = 1800 mm Therefore, Vertical stiffener should be provided at a spacing less than 1800 mm Number of stiffeners = 11 Nos. Actual smaller clear panel dimenssion = 1818.2 mm 1800 mm 1800 mm. A horizontal stiffener will be provided at 500 mm Provide vertical stiffeners at spacing of from the compression flange. 2000 mm d = 1400 mm c/c Spacing of stiffeners c = 0.9 d > 0.7 d = Provide vertical stiffeners at a spacing of 1400 mm c/c d 200 tw = Shear stress va = From Table 6.6A of I. S : 800 - 1984, for d tw
2 80.038 N / mm

= 10.00 mm 250 Therefore, a horizontal stiffener will be provided at

200

and c =
2

0.7 d

va = 100.00 N / mm OK Minimum required thickness of vertical stiffener for shear consideration. t vs = 8.0038 mm 10 mm

Maxi. Outstand of vertical stiffener Required moment of inertia =

>

12 t vs =

120

mm

110

mm

3 3 1.5 d t = 3139106.2 mm4 c2 I Moment of inertia of the vertical stiffener about the face of the web = 4436666.67 mm4 xx

>

3139106.2 mm4

OK

Use I. S. F Connection :

110

mm x

10 mm

125 t kN / m Where, h = h Shear force = 113.64 kN / m = 113.64 N / mm Let us provide a 3 mm size of the intermittent filled weld Strength of weld / mm = 226.80 N / mm > 113.64 N / mm OK The length of the intemittent fillet weld is taken as 10 t = 100 mm C / C Spacing of welds = 399.17 mm But the c / c spacing of the weld 16 t or 300 mm which ever is less Connection are designed to rasist a shear of C / C spacing of weld = Provide 3 mm size weld HORIZONTAL STIFFENERS : 160 mm 100 mm long welds at c /c spacing of

Outstand of stiffener

110

mm

200 L + 1000 N / m

160 mm on both sides of the web.

(Provide continuous welding)

A horizontal stiffener be provided at 500 mm from the compression flange. Let the thickness of horizontal stiffener be t = 10 mm ( minimum thickness of the web ) Maxi. Outstand = 12 t = 120 mm Consider a filet section = 100 x 10 mm 3 4 = 2871235.8 mm Moment of inertia required = 4 C t C = Actual distance between vertical stiffeners = 1400 mm t = Minimum required thickness = 8.0038 mm 4 4 > 2871235.8 mm OK Moment of Inertia provided = 3333333.33 mm Connection : Provide 3 mm size 8 mm long fillet weld at a c / c spacing of 128 mm ( 16 t = 160 mm )

3 mm size continuous fillet welding

VERTICAL STIFFENERS : CONNECTION :

ISF 100 x 10 mm ( Horizontal Stiffener )

500

ISF

110

10 mm ( Vertical Stiffener )

1400

mm

HORIZONTAL STIFFENERS:

DESIGN OF LATERAL BRACING : Lateral braching is provided at the compression flange level. The diagonals in tension will be effective only. The influence line diagram for the bracing system show the diagonals are in tention. The force in the members L0U1 and L12U9 will be maximum and also equal. Therefore, L0U1 or L0U9 is designed and the same section is provided for the other diagonals. Lateral force is condiderd = 9000 N/m

U0
2.3 M

U1

U2

U3

U4

U5

U6

U7

U8

U8

U9

L0

L1

L2

L3

L4
20

L5 m

L6

L7

L8

L9

L10

@ 2.3 m each panal

TOP VIEW: U0
2.3 M

U1

U2

U3

U4

U5

U6

U7

U8

U8

U9

L0

L1

L2

L3

L4 20 m

L5

L6

L7

L8

L9

L10

@ 2.3 m each panal

x 2

0.9 x 2

I L D For L0U1 : Consider the section x - x and taking the moment about L10
Sin L0 U1 45
o

(Unit load place at L0)

L0 U1

x
o

20.0

= sin

1
45

Force in L0U1

= 1 2 114551.299 N

= 1

x 1

20.0

x 2

2 Area A = 763.68 mm Since the angle will not be accessible for clearing and painting thickness < 8 mm provide ISA 100 x 65 is tried from IS Handbook No. 1. The relevant properties of the section, Shear center Cx x = 32.80 mm

8 mm

A 1 .= ( 100 A 2 .= ( 65

3 A1

4 4

) x 8 ) x 8

= =

768 488

mm 2 mm 2

3 A1 + A 2

0.8252

Net area provided Load carrying capacity CONNECTION :

= =

2 1121.8 mm > 168265 N

114551 N PB

OK

114551.30

N
31.0

Let the force resisted by the weld near the outer edge of flange be PB. Taking moment about A
PB x 100 PB = = 114551.30 37572.8 N x 32.80

Force resisted by the weld at A PA = 76978.47 = N 5 mm weld for making the connection.

Let us provide a size of weld S Length of welds 37572.8 B And 76978.47 A = = 0.7 x 203.65 = = 0.7 x 99.399

32.80

A B

x S x 108.00 100 mm x S x mm 108.00

204

Force in the end strut Area of Angle required Let us try 90 x

L0 U 0

= =

90000 N
2 1285.7 mm

x 8 mm from IS Hand book No. 1. The releveant properties are 2 1379 mm A = 17.5 mm Radius of gyration r = The strut will be welded to the flange plate girder 90 Area

CONNECTION :

PB

25.1

A
90

90000

N
25.1

Slenderness ratio of the strut For = 111.71 and fy ac

= = =

111.71

Axial comprassive stress Load carrying capacity

250.00 N/mm2 82.86 N/mm2 114263.94 N

>

45

45

90000 N

OK

Let the force resisted by the weld near the outer edge of flange be PB. Taking moment about A
PB x 90 PB = = 90000 25100.0 N x 25.10

Force resisted by the weld at A PA = 64900.0 N Let us provide a size of weld S = Length of welds 25100.0 = B And 64900.00 A = = 0.7 x 171.69 B = 0.7 x 66.402 A

mm weld for making the connection.

x 108

70 mm

x 108 mm

175

DESIGN CROSS - FRAME : U0 90000 N L0

2500

Bottom strut A 2300 B

Two end frames one at each end of the plate girder are provided. In cross - frames double diagonals are provided of which one in tension is assumed to be effective. = 45 0 Froce in one diagonal U0A Cos 45 o = 90000 N U0A = 127280 N Provide ISA 100 x 65 x 8 mm, Load carrying capacity of the Angle = > 127280 N OK 168265 N as design for the lateral bracing. The connection will also be the same as designed in for the section in lateral bracing system. Provide a nominal section say 90 x 90 x 8 mm for the bottom strut. Intermediate cross frames at every 4 m are provided. Since the lateral forae = 36000 N which is very less so, provide 75 x 75 x 8 mm angles for diagonals as well as for struts.