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REFORM CONSTRUCTION
Burak Can GLEN
oruh DURMU
Halil DEMRC
mer Ege ADALIER
Safiye Bircan IIK
INSTRUCTOR:
Alp CANER
Table of Contents
1.
INTRODUCTION................................................................................................ 5
a.
b.
2.
DESIGN CRITERIA............................................................................................. 9
a.
b.
Live Load....................................................................................................... 9
c.
Dead Loads:................................................................................................ 10
d.
3.
PIER DESIGN................................................................................................... 14
a.
General....................................................................................................... 14
b.
c.
Design Stage............................................................................................... 17
4.
FOUNDATION DESIGN..................................................................................... 21
1.
General....................................................................................................... 21
2.
3.
4.
5.
5.
COST ESTIMATION.......................................................................................... 27
6.
7.
CONCLUSION.................................................................................................. 31
8.
REFERENCES.................................................................................................. 32
List of Figures
Figure 1 Model of Rail Road Station........................................................................4
2
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
List Of Tables
Table 1 Excell Sheet for Beam Section Trials........................................................12
3
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
1. INTRODUCTION
Objective of this project is designing an elevated railroad station bridge. The project is
originally located in Astana, KAZAKHSTAN. The following figures are taken from the
original project.
When designing railway structures, the various sources of their loads must be considered, as
they would be with any other similar, non-railway structure.
In this very project, dead load consists of footings, columns, deck, ballast, ballast
protection wall, traverse and rails. Seismic load and impact factor are also to be considered. In
preliminary stage, seismic load is not taken into account.
Railway structures must perform under heavier loads. They have longer service lives.
They have different maintenance constraints compered to their highway counterparts.
(Because of these properties, railway structure design is influenced by maintenance issues
more than roadway structures.)
The high deflections in railway structures are not acceptable (in order to prevent
derailment). Hence, stability matters. That is why, maintenance concerns and fatigue
considerations need more attention and must be done in detail compared to the highway
industry. Different standards and specifications must be used. Welded connections and
continuous spans are good options for railway structures.
dynamic effecs of impact coming from the bridge to the railway, which is not desired for this
kind of an elevated railway bridge project. Ballast deck bridges have the track rails supported
on ballast, which is carried by the structural elements of the bridge. Ballast deck structures
offer advantages in ride and maintenance requirements. Unlike open decks, the track
alignment on ballast deck spans can be handled using standard track maintenance equipment.
Most railroads currently prefer ballast decks for new structures.
ii. Ballast : Ballast is the component of the structure composed of broken, sharp, strong,
angular stones-such as basalt or granite- which spreads the effects transferred from traverse
(such as vibration) without being exposed to permenant settlement and deflection. In brief,
ballast provides an elastic bed for the railway, thanks to its ability to distribute the incoming
load homogenously by the friction between stones. Ballast also serves as drainage and
protects the deck from mud, freeze, and decay by intercepting rail tracks from soil. The
depth of ballast must be between 30-60 cm. Ballast must be homogenous in terms of particle
size, with particles capable of passing through 6 cm sieve and not pass through 3 cm sieve.
iii. Traverse:
Traverse is the type of structure that transfers the load from specified load model and transfer
it through wider surface (ballast) and provides stability to track rails. It is essential for
eccentricity of the railway. The distance between the centroids of two traverse can be taken as
62-63 cm. For the Ankara-Eskiehir high-speed train railway, this distance is taken as 60 cm.
Traverse has to be made with a concrete stronger than Portland. Traverse also has an
advantage of minimizing noise and impact. Traverse can be preferred as timber, steel, plastic,
concrete monoblocks, or pre-stressed blocks. Timber is preferred due to its elasticity and the
fact that it does not damage ballast. Its maintenance is easy and cheap, however, timber
traverse is effected by moisture easily and is weak against drainage and fire, not to mention its
short life-time. Steel traverse is easier to produce, compared to timber. However, the
possibility of abrasion is significant which may reduce strength, and cause cracking where the
traverse are settled. To prevent this, connections must be done properly. Also, due to the lightweight property of steel traverse, stability can not be maintained as much as it is by timber or
concrete. All types of traverse have advantages and disadvantages due to the type of the
project, however, it must be considered that for the high-speed train railways, concrete
monoblock types are mostly preferred around the world, which is also suitable for this project.
This is because concrete monoblock traverse provides extreme stability due to its heavy
weight, and protection for gauge. For an elevated high-speed railway bridge, stability is the
most important case.
2. DESIGN CRITERIA
In design stage, as code, The American Railway Engineering and Maintenance-of-Way
Association AREMA is chosen. AREMA is a simple and valid code for this type of design.
While designing an appropriate girder to be used, sections are chosen based on limitations of
AREMA. For the preliminary design stage, dead loads and live loads, and impact effects are
considered. Although seismic actions are to be taken into account, they have not been touched
upon during preliminary stage.
b. Live Load
For live load, two types of train models are considered; that are LM-71 and Cooper E-80
Models. Firstly, LM-71 is taken. However, since Cooper E-80 Model gives a heavier live
load and is appropriate for all AREMA limitations, Cooper E-80 is decided to use, to be on the
safe side.
In the figure below, the portion that creates the maximum moment on mid-span is shown.
According to this loading, for 25 m span, 4210 kN/lane is obtained. Two lanes are to be
designed; total live load is 8420 kN.
Mmax(Mid-span)=11520 kNm (One lane)
Mmax(Mid-span)=23040 kNm (Two lanes)
Mmax(Mid-span)=23040/5=4608 kNm per girder
c. Dead Loads:
Ballast: It must be noted that since the designed bridge is straight for 500m, no anti-drainage
plates are needed.
For ballast, basalt is taken as stone type, having basalt(broken)=1.954 t/m3. Dimensions of volume
of ballast is 25m*9m*0.5m, thus, the ballast volume is;
25*9*0.5=112.5 m3
The void ratio of basalt is 0.37, which indicates that 112.5*(1-0.37)=71 m 3 of crushed basalt
stone is needed.
Total ballast weight (One span): 1.954*71=139 t*9.96=1385 kN
Load per girder: 1385/5=277 kN per girder
Mmax(Ballast)=11*252/8=860 kNm per girder
Mmax(Ballast)=860*5=4300kNm
Traverse: As it is stated above, C55 concrete monoblocks are to be used. Not only
monoblocks are preferred universally for high-speed railways, but also suitable for this kind
of project due to its extreme stability. For this case, derailment is more critical than any other
railway project. Traverse are to be settled as there are going to be 60cm between centroids of
two traverse, and buried 10 cm to the ballast. The space between two traverse is taken as 30
cm. In such case, 42 traverse are to be settled for one lane, making 84 traverse for a 25 m
span.
The sections of traverse are;
10
11
Ballast: 1385 kN
Traverse: 202.57 kN
Ballast Protection Wall: 50 kN
Rail: 65 kN
Deck: 1687.5 kN
Girder: 761.2 kN
TOTAL LOAD: 12571.3 kN
12
Moreover, as we proportioning our section we took into account some limits which are:
D
* tw
<150
bf
* 2tf
<12
13
Figure 6 I-Section
bf >
D
6
<150 ..........................
bf
* 2tf
<12 ...........................
bf >
D
6 ...........................
(46.67)
(4)
(5cm>3.3cm)
3. PIER DESIGN
a. General
Designing the pier is one of the most important subject for the rail road. In preliminary design
stage, exact calculations were not done, however cross-sections are estimated with enough
accuracy. To design the cross-section several types of loads are needed.
14
First of all we decided to use Cooper E80 Train whose loads are determined by the AREMA.
After that, ballast, deck, rail and girder loads are determined. We make 2 analyses with 2
different girder loads. On the other hand, deck, rail and ballast loads are fixed to a value.
15
16
As it can be seen from the figures, to compute easily we do not divide the load according to
their affect but we divide it from the mid-point of the span to ease the preliminary
calculations.
Moreover combining these load combinations with each other we tried to find the most
appropriate live load arrangement for A-A section.
c. Design Stage
Column Head
After determining the live load and dead load; concrete column and the head of the column
was designed. To design the column head which is behave like beam we used the formulas
given in TS500. Kl value for materials that have been used (C50 and S420) is 150 mm 2/kN
17
and Km is equal to 119 mm 2/kN. (Uur Ersoy, 1984) We compare the calculated K which is
equal to:
b wd 2
K=
Md
P1-2-3-4-5 values are calculated under the light of dead and live load and maximum moment
has been calculating according to these values.
After calculating the maximum moment we tried to find the best fitting cross-section. As it
seems from the table below, the best section is 2000mmx1300mm. So the column head will be
2000mmx1300mmx9000mm.
18
Column
After preliminary design of the column head finished, column has been designed according to
the loads coming from the column head. Also to determine the column cross-sections we used
0,1*fcd*Ac=P (Karayollar Genel Mdrl, 2015) in order not to add moment interaction.
Moreover, at column section we roughly calculated reinforcing steel in order to estimate the
cost of the structure.
19
At the end of the calculations it has seemed that we need cross-sections with dimensions
1600mmx3600mm. And steel area estimated by assuming all moment carried by the steel
reinforcement and as it seen from the table above 32x32 steel needed. In calculations second
order moment has not calculated. They will be calculated in advanced design.
20
4. FOUNDATION DESIGN
1. General
According to calculation, 6 piles which is 12 m length 0.8 m diameter concrete piles were
designed for carrying nearly 12000 kN load which comes from structure. 2 piles were
designed in longitudinal direction of bridge whereas 3 piles were used in lateral direction of
bridge. Dimension of footing is 6m*6m. Necessary check was done according to TS500 code
for reinforcement calculation. Necessary explanations and soil constants can be found from
Soil Investigation and Soil Properties section.
3.1 m to 6.6 m depth from the ground surface. The grain size of gravel is observed medium
fine and partially coarse. At the bottom layer pinky, yellowish brown, very stiff partially
limestone creation clay and silty clay and at some level sandy gravel which belongs to
Glba Formation is encountered.
Laboratory Tests Results
According the tests results, soils compromising the upper clayey layer are classified mostly as
GC, SC with some GM. The underlying clay layer are mostly classified as CH and some CL
and. The characteristics of the soil are shown below.
Subsoil Units
Gravelly
Clayey Sand
Parameters
Internal Friction Angle
Cohesion
Unit Weight
Elastic Modulus
Symbol
Es
Proposed Value
35.0
0 kPa
19 kN/m3
30000 KPa
Symbol
Cu
Es
Proposed Value
0
15 kPa
19 kN/m3
150 KPa
35000 KPa
Symbol
Cu
Es
Proposed Value
0
25 kPa
19,5 kN/m3
225 KPa
60000 KPa
Subsoil Units
Clay 1
Parameters
Internal Friction Angle
Cohesion
Unit Weight
Undrained shear strength
Elastic Modulus
Subsoil Units
Clay 2
Parameters
Internal Friction Angle
Cohesion
Unit Weight
Undrained shear strength
Elastic Modulus
CN
N1
N60
Nave(B=7m Nave(B=6m)
22
1,5
20
28,5
34
57
4,5
28
85,5
25
109
7,5
12
122,5
9,3
23
138,7
10,5
30
149,5
8
9
12,4
13,5
34
25
166,6
176,5
10
15,4
29
193,6
11
16,5
37
203,5
12
18,5
27
221,5
13
19,5
32
230,5
14
21,5
23
248,5
15
16
22,5
24,3
26
34
257,5
273,7
17
25,5
31
284,5
18
27,1
50
298,9
19
28,5
50
311,5
20
30
45
325
1,83196
2
1,29539
3
1,05768
4
0,93675
4
0,88363
1
0,83042
5
0,79986
8
0,75770
7
0,73615
0,70288
8
0,68557
8
0,65713
1
0,64417
4
0,62040
6
0,60946
7
0,591155
0,57982
6
0,56568
7
0,55412
8
0,54249
7
36
27
44
33
29
21
23
17
10
19
14
23
17
25
18
18
13
20
15
25
18
17
12
20
15
14
10
15
20
11
15
17
12
28
21
27
20
24
18
38
38
Total
Load(KN)
(qn)all(KN/m2 qnet(KN/m2
Gw(m) H(m)
B(m)
depth(m)
Cw
)
)
320,061224
15683
5,5
1
7
3,5 0,7812
326,5416
5
23
qall>qnet
OK
d=1m
= 1.0
Vpd = N1-Fa
Fa= qsp (b+d)(h+d)
PUNCHING
Qult = Qs + Qp
Qult = Ultimate Bearing Capacity
Qs = Bearing due to friction
Qp = Bearing due to tip
Qs = fs * As (for sand)
fs = v * K * tan ()
Qs = *cu* As (for clay)
Qp = Nc* cu* Ap
24
Pile
Capacity
Qult(KN) Qp(KN)
Qs(KN) Qs2(KN) Qs1(KN)
2795,5599 824,668071 1970,89 1722,37 248,513
7
6
2
8
7
Cu
6 Piles
Qtotal(KN)
16773,3598
Ks
150
Nc
D(m)
0,5
v0'
7
92,25
tan()
0,43
0,49
Depth(m)
1
12
Qtotal>Total
Load
OK
Consolidation settlement due to piles were calculated below by using 2:1(V:H) pressure
distribution.
(Soed=H*mv*)
consolidation
settlement
mv(clay1)
mv(clay2)
5,50E8,00E-05
05
2(Kp 3(Kp
a)
a)
70,878 41,243
169,2885815
61
92
1(Kpa)
Soed (cm)
1,10E-01
Table 16 Consolidation Settlement Calculations
Consolidation settlement is 0,1 cm, therefore structure is safe. The drawings of the structure
are showed on the next page.
25
26
5. COST ESTIMATION
In this step of the project, only the material costs are calculated. At the final design, the
quantity take off calculations will be performed and total cost estimation will be submitted.
Beam Section
Dimensions of the beam:
*tf = 5 cm
*tw= 3 cm
*bf = 0.4 m
*D = 1.4 m
*Hi = 1.3 m
Cross Sectional Area = (0.05*0.4)*2+(1.3*0.03) = 0.079 m2
Length of span = 25 m
Number of sections in span = 5
Volume of steel = 25*5*0.079 = 9.875 m3
Number of span = 20
Total volume of steel = 20*9.875 = 197.5 m3
Weight of steel = 197.5*7850/1000 = 1550.4 tons
Unit price of weathering steel is 2300 TL/ton
Steel price = 2300*1550.4 = 3 565 920 TL
Column Section
Dimensions of the rectangular column:
*a = 3.1 m
*b= 1.6 m
27
*h= 10.5 m
Cross Sectional Area = 3.1*1.6 = 4.96 m2
Volume of column = 4.96* 10.5 = 52.08 m3
Number of columns = 20
Dimensions of the column head:
*a = 9 m
*b= 2 m
*h= 1.3 m
Cross Sectional Area = 2*9 = 18 m2
Volume of column = 18* 1.3 = 23.4 m3
Total volume of concrete for column = 20*(52.08+23.4) = 1509,6 m3
Unit price of concrete is 120 TL /m3
Concrete price for column = 1509.6 * 120 = 181 152 TL
Steel Reinforcement
For column we used 3230 steel
For column head we used 4530 steel
Unit mass per meter for 30 steel =3.30 kg/m
Length of reinforcement used for column = 11 * 32 =352 m
Length of reinforcement used for column head = 1.5 * 45 = 67.5 m
Total reinforcement used for one pier = 352+67.5 = 419.5 m
For 20 pier = 20* 419.5 = 8390 m
Reinforcement weight = 8390*3.3 = 27 687 kg
Unit price of reinforcement is 1700 TL/ton
Reinforcement price = 27687 /1000*1700 = 47 068 TL
Excavation
Volume of excavation = 3.5*8*8 = 224 m3
Unit Price of excavation = 2,6 TL /m3
28
Number of footing = 20
Excavation Price = 20*224*2,6 = 11 648 TL
Deck
Cross Sectional Area = 0.3*9 = 2.7 m2
Span length = 25
Volume of concrete = 25* 2.7 = 67.5 m3
Number of span = 20
Total volume of concrete for deck = 20*67.5 = 1350 m3
Unit price of concrete is 120 TL /m3
Concrete price for column = 1350 * 120 = 162 000 TL
Ballast
Cross Sectional Area = 0.5*9 = 4.5 m2
Span length = 25
Volume of ballast to be filled = 25* 4.5 = 112.5 m3
ebasalt(rockfill) = 0.37
Volume of basalt to be used = 112.5*(1-0.37) = 71 m3
Number of span = 20
Total volume of basalt = 20*71 = 1420 m3
Weight of basalt = 1420*1954/1000 = 2774.7 tons
Unit price of basalt is 26 TL/ton
Basalt price = 26*2774.7= 72 142.2 TL
Traverse
Weight of one traverse = 0.242 tons
Number of traverse in one span (Two lanes) = 84
Weight of traverse in one span = 84*0.242 = 20.33 tons
Number of span = 20
29
30
7. CONCLUSION
31
8. REFERENCES
Wai-Fah Chen, L. D. (1999). Brigde Engineering Handbook. Florida: CRC Press LLC.
32