IRC-112 Refresher: Precast Segmental Box Girder Design

REFRESHER COURSE ON IRC:112 B&SEC
Refresher Course on “Concrete Bridge Design using Code of Practice for Concrete Road Bridges (IRC 112)”
WORKED EXAMPLE OF A PSC BOX

GIRDER WITH SEGMENTAL & CAST-IN-
SITU TECHNIQUE AS PER “IRC-112”
AKHILESH GUPTA
SR. DESIGN ENGINEER,
B&S ENGINEERING CONSULTANTS
PVT. LTD.
NOIDA
CONTENTS B&SEC
1. GENERAL FEATURES
2. LONGITUDINAL ANALYSIS & DESIGN
3. ULTIMATE CHECK FOR FLEXURE
4. ULTIMATE CHECK FOR SHEAR & TORSION
5. TRANSVERSE ANALYSIS & DESIGN
6. CONSTRUCTION & ERECTION STAGE CHECKS
GENERAL FEATURES B&SEC
FIRST PRECAST SEGMENTAL BRIDGE WAS BUILD OVER THE RIVER

MARNE NEAR LUZANCY IN FRANCE IN 1946. BRIDGE SPAN IS 54M.
IN INDIA, GANDHI SETU BRIDGE BUILT OVER RIVER GANGA IN PATNA

IS THE FIRST LARGE SCALE BRIDGE CONSTRUCTED WITH PRECAST
SEGMENTAL TECHNIQUE . CONSTRUCTION STARTED IN 1972.
CONSTRUCTION METHODS FOR PRECAST SEGMENTAL BRIDGE

- SPAN BY SPAN ERECTION METHOD
- BALANCED CANTILEVER METHOD
ADVANTAGES OF PRECAST SEGMENTAL CONSTRUCTION

1. SPEED OF CONSTRUCTION
2. BETTER QUALITY CONTROL (GEOMETRY, MATERIAL,
WORKMANSHIP)
3. DECK OF COMPLICATED HORIZONTAL AND VERTICAL
ALIGNMENTS CAN BE EXECUTED
4. DECK OF VARIABLE DEPTH CAN BE EXECUTED
5. LOWER WEB INCLINATION CAN BE ACHIEVED
6. REDUCED REQUIREMENTS OF CLEAR COVER. THICKNESS OF
SECTIONS CAN BE REDUCED.
DISADVANTAGES OF PRECAST SEGMENTAL CONSTRUCTION
1. INVESTMENT IN EQUIPMENT
2. HANDLING, SEGMENT STORAGE & TRANSPORTATION
SPAN BY SPAN ERECTION METHOD
- OVERHEAD L.G. OR UNDERSLUNG GANTRY

- SPEED OF ERECTION <4 DAYS/SPAN FOR SPAN UPTO 40M WITHOUT
TRANSVERSE PT
- SEGMENT LENGTH (COST OF GANTRY VS SPEED OF ERECTION)
- MATCH CASTING OF SEGMENTS
METHODS OF SEGMENT MATCH CASTING

- LONG LINE METHOD
- SHORT LINE METHOD
IN MANY COUNTRIES PRECAST SEGMENTAL BRIDGES ARE

PROHIBITED, LIKE GERMANY.
BOX GEOMETRY RESTRICTIONS IN PRECAST SEGMENTAL :

STRAIGHT ALIGNMENT CURVED ALIGNMENT
THERE IS NO RESTRICTION - TOP FIBER SHOULD BE KEPT

OF BOX GEOMETRY STRAIGHT TO AVOID SHUTTER
CHANGES IN CURVED AND
TRANSITION ZONES
- NECESSARY CHANGES IN P & P

DETAILS REQD.
- CONSTRUCTABILITY ASPECT
JOINTS IN SEGMENTAL CONSTRUCTION
INDIAN CODE SP:65 IS SILENT ON DRY JOINT
CURRENTLY NO INDIAN CODE ON DRY JOINT

BENEFITS OF WET/EPOXY JOINTS WITH SHEAR KEYS

- DURABILITY (WATER TIGHTNESS OF JOINT)
- STRUCTURAL SAFETY (SMOOTH LOAD TRANSFER)
- PREVENTS LEAKAGE OF GROUT FROM PRESTRESSING DUCTS
- NO SEPARATE DESIGN CHECK FOR WET JOINTED(EPOXIED)
SHEAR KEYS IS REQUIRED
- SHEAR KEY BEHAVIOR IN CASE OF EPOXIED JOINTS HAS THE
SIMILAR FAILURE LOAD AS THAT OF MONOLITHIC SPECIMENS
EPOXY JOINTING OF SEGMENTS

- PREPARATION OF MATING SURFACES (WIRE BRUSHING ETC.)
- APPLICATION OF 1MM THICK EPOXY BY HAND
(THK. BECOMES NEGLIGIBLE AFTER PRESTRESSING)
- AXIAL COMPRESSION OF 0.3 MPA WITH TEMPORARY PT FOR
24 HOURS ON PREPARED MATING SURFACES
SHEAR KEYS
RECESS TO OOZE
BULKHEADS OUT EXCESS EPOXY
INWARD RECESS OUTWARD RECESS
Segment (n) DETAIL OF SHEAR KEY IN

SOFFIT/TOP SLAB
Segment (n+1)
PART JOINT OF TWO SEGMENTS (ELEVATION)

FIGURE C5.5.4.2.2-1 IN AASHTO LRFD
SMOOTH LOAD
TRANSFER
CORBEL – HIGH
FORCE
CONCENTRATION
ONLY FRICTION
LAUNCHING SCHEME
B&SEC
Rear Middle
Support Support Front
Support
SPAN-1 SPAN-2
SPAN-2 ERECTION IS COMPLETE, LAUNCHING GIRDER IS READY

FOR AUTO LAUNCHING TO SPAN-3.
STAGE-1
BRING REAR SUPPORT NEAR TO MIDDLE SUPPORT OVER SEGMENT
S3 OF SPAN-1, JACK IT UP TO TRANSFER A MINIMUM LOAD OF 10T
AND ANCHOR WITH SUPERSTRUCTURE.
LAUNCHING SCHEME
B&SEC
LAUNCHING SCHEME
B&SEC
Rear Middle
Support
SPAN-1 SPAN-2
STAGE-2
DEACTIVATE MIDDLE SUPPORT FROM DIAPHRAGM OF SPAN-1.
TRANSFER LOAD TO REAR SUPPORT & MOVE MIDDLE SUPPORT TO

DIAPHRAGM OF SPAN-2.
LAUNCHING SCHEME
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Rear Middle
Support
SPAN-1 SPAN-2
STAGE-3
TRANSFER LOAD TO MIDDLE SUPPORT & MOVE REAR SUPPORT TO

DIAPHRAGM OF SPAN-1
LAUNCHING SCHEME
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Rear Middle
Support
SPAN-1 SPAN-2
STAGE- 4
TRANSFER LOAD TO REAR SUPPORT & MOVE MIDDLE SUPPORT TO
DIAPHRAGM OF SPAN-2 .
LAUNCHING SCHEME
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Rear Hoist Middle

Support Support
Front
Support
SPAN-1 SPAN-2
SPAN-3
STAGE- 5
MOVE HOIST AT THE TAIL POSITION.

RELEASE FRONT SUPPORT.
MOVE LAUNCHING GIRDER & FRONT SUPPORT FORWARD TOWARDS
NEXT PIER
LAUNCHING SCHEME
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Rear Middle
Support
SPAN- 3
SPAN-2
STAGE- 6
MOVE LAUNCHING GIRDER TO ITS POSITION AS IN STAGE 1 &
TRANSFER ALL LOADS TO MIDDLE SUPPORT & FRONT SUPPORT
LAUNCHING SCHEME
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Trailer with
segment S1
STAGE- 7
BRING SEGMENT S1 ON TRAILER OVER ALREADY ERECTED SPAN
FOR ROAD BRIDGES, SEGMENTS MAY ALSO BE TRANSPORTED ON

LOW BEDDED TRAILERS.
LAUNCHING SCHEME
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STAGE- 8
SIMILARLY BRING OTHER SEGMENT ON TRAILER OVER ALREADY

ERECTED SPAN.
LAUNCHING SCHEME
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STAGE- 9
ERECT ALL SEGMENTS AND STRESS THE
CABLES.
ERECTION SEQUENCE
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STEPS OF ERECTION OF A SPAN:

- ERECTION OF L.G. IN POSITION
- DELIVERY OF SEGMENTS
- LIFTING OF SEGMENTS
- CHECK FOR DRY JOINT FITOUT OF ALL THE
SEGMENTS OF THE SPAN
- DISASSEMBLING ALL THE SEGMENTS
- GLUING OF SEGMENTS & TEMPORARY PT
- STRESSING PERMANENT PT
- REMOVE TEMPORARY PT AND CONNECTING PARTS
OF L.G.
CONSTRUCTION SEQUENCE
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LOAD TRANSFER BETWEEN SPAN AND L.G.:
- DIFFERENCE IN STIFFNESS OF THE L.G. AND ERECTED SPAN
- DEFLECTION OF ERECTED SPAN WITH POST-TENSIONING IS
LESS THAN THE DEFLECTION OF L.G.
- RELEASE OF HANGERS FROM MID-SPAN TOWARDS
SUPPORTS
- EXCESSIVE TENSION IN HANGERS CLOSE TO SUPPORTS
- SPAN JACKS CAN BE USED FOR ISOSTATIC SYSTEM
- ADJUSTMENTS & MONITORING
IRC:SP:65 CLAUSES
B&SEC
IRC:SP:65-2018: INTERNAL BONDED TENDONS

§ 3.5.3 - TORSION IN SEGMENTAL CONSTRUCTION
- ULTIMATE TORSION CAPACITY AS PER § 10.5 OF IRC:112
- 0.9 REDUCTION FACTOR
- LONGITUDINAL TENSION DEVELOP DUE TO TORSION & SHEAR
- NO CONTINUITY OF LONGITUDINAL REBAR
PRECOMPRESSED TENSILE ZONE (SOFFIT - SIMPLY SUPPORTED)

- SUPPLEMENTARY TENDON
- AVAILABLE SPARE AXIAL CAPACITY , (Mcap - M)/ Z
DECK SLAB : -
- AVAILABLE RESIDUAL COMPRESSION - PERMANENT LOADS + PT
- SUPPLEMENTARY TENDON
IRC:SP:65 CLAUSES
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IRC:SP:65-2018: INTERNAL BONDED TENDONS

§ 3.6.2 - ULTIMATE FLEXURAL CAPACITY AS PER SECTION-8 IRC:112
§ 3.5.2.1 - ULTIMATE SHEAR CAPACITY AS PER SECTION-10 IRC:112

§ 3.2.1 ALLOWABLE STRESS UNDER SLS RARE COMB.

- MAXIMUM COMPRESSIVE STRESS – 0.48 Fck
- MINIMUM COMPRESSIVE STRESS - 0.5 Mpa
(EARLIER VERSION OF CODE - 5% of PERM. LOAD , 0 -THERMAL CASE)
WORKED OUR EXAMPLE

GENERAL
ARRANGEMENT B&SEC
< KUNDLI A1 P2 P4 P5 P6 P7 P8 P9 A2 PALW
<< KUNDLI A1 P2 P4 P5 P6 P7 P8 P9 A2 PALW
BH-P1 BH-P3 BH-P5 BH-P7 BH-P9
BH-A1 BH-P2 BH-P4 BH-P6 BH-P8

BH-A2
GENERAL
ARRANGEMENT B&SEC
CONSTRUCTION TECH SPAN BY SPAN ERECTION
CONSTRUCTION PERIOD 400 DAYS
TOTAL LENGTH 600m x 2 = 1200m
NO. OF SEGMENTS 420 Nos
LAUNCHING SYSTEM OVERHEAD L.G.

LONGITUDINAL
SECTION B&SEC
CL EXP. JOINT CL EXP.

60000
CL BRG./DIAPHRAGM EFFECTIVE SPAN = 57.6M BRG./DIAPHRAGM CL
8500
3000 (WEB THK VARIES
2600 2900 3000 (TYP) FROM 540 TO 300)
S1
S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S10 S9 S8 S7 S6 S5 S4 S3 S2 S2
S1 S1
U
2100 51400 SOFFIT THK 250 2100
SOFFIT THK VARIES Deviator SOFFIT THK VARIES
FROM 350 TO 250 FROM 350 TO 250
block
21 NOS. OF SEGMENTS
LIFTING WEIGHT OF TYPICAL SEGMENT - 90 T (APPROX.)
SPAN/DEPTH RATIO - 16.5
DEVIATOR BLOCKS PROVIDED FOR FUTURE PRESTRESSING
DECK
CROSS-SECTION B&SEC
DECK
CROSS-SECTION B&SEC
1. GENERAL FEATURES
LONGITUDINAL ANALYSIS & DESIGN
B&SEC
STATIC ANALYSIS :
SPAN OF SUPERSTRUCTURE – 57.6M
WIDTH (AVG. DISTANCES B/W OUTSIDE FACES OF WEBS) –
10.6M
LENGTH/WIDTH RATIO – 5.4 > 2.5 (§ 4.6.1 AASHTO LRFD)
SUPERSTRUCTURE MAY BE IDEALISED AS A SINGLE-SPINE

BEAM.
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CHECK FOR SHEAR LAG EFFECTS
- EFFECTIVE FLANGE WIDTH AS PER §7.6.1.2 OF IRC:112-2011

- SECTION FULLY EFFECTIVE
CANTILEVER SIDE:
b1 = 3.725m
bm1 = 0.2 x 3.725 + 0.1 x 57.6
= 6.5m > b1
bm1 = 3.725 m
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SECTION PROPERTIES
A = 11.498m2 , Yt = 1.254m , Yb = 2.246m , IZ = 20.778m4

Zt = 16.57m3 , Zb = 9.25m3
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LOADS:
1. DEAD LOAD (SELFWEIGHT)

2. SIDL EXCEPT SURFACING
3. SIDL-SURFACING
4. LIVE LOAD
5. WIND LOAD
6. TEMPERATURE DIFFERENTIAL
7. VERTICAL SEISMIC
8. PRESTRESS
B&SEC
LOADS:
1. DEAD LOAD
c/l
Symmetry
36.95 T/M
28.75 T/M
CROSS-SECTIONAL AREA MID – 11.498 M2

CROSS-SECTIONAL AREA SUPPORT – 14.775M2
BENDING MOMENT(MID) - 12036 TM , S.F. (D EFFECTIVE) – 743T
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LOADS:
2. SIDL EXCEPT SURFACING
(CRASH BARRIER P1 TYPE , LOAD INTENSITY @ 0.76 T/M)

LOAD – 1.52 T/M (2 NOS. OF CRASH BARRIER)
3. SIDL-SURFACING
WEARING COAT THICKNESS – 65MM

(WEARING COAT LOAD INTENSITY @ 0.2 T/M2 )
LOAD – 3.93 T/M (CARRIAGEWAY WIDTH = 19.65M)
BENDING MOMENT(MID) – 2256 TM , S.F. (D EFFECTIVE) – 138T

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LOADS:
4. LIVE LOAD
STRUCTURE IS CLASSIFIED AS A 5 LANE
A) CLASS A- 1,2,3,4 OR 5 LANE

B) 1 LANE OF 70R WITH 1/2/3 LANE OF CLASS A
C) 2 LANE OF 70R WITH 1 LANE OF CLASS A
WHICHEVER PRODUCES WORST EFFECT HAS BEEN CONSIDERED
2 NOS. OF SUCCESIVE TRAINS OF VEHICLES CONSIDERED
IMPACT FACTOR – 8.8% (Span > 45m)

REDUCTION FACTOR – 10%(3 LANE), 20% (>=4 LANES)
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LOADS:
5. WIND LOAD AS PER §209.3 OF IRC:6-2014

WIND WITH LL CASE CONSIDERED
WIND VERTICAL FORCE ,

PZ - 778 N/m2 (0.6 Vz2)
A3 - 20.65 m
G- 2 (GUST FACTOR)
CL -0.75 (LIFT COEFF.)
Fv – 2.46 T/M
BENDING MOMENT(MID) – 1020TM

B&SEC
LOADS:
6. TEMPERATURE DIFFERENTIAL
- POSITIVE AND NEGATIVE TEMPERATURE DIFFERENCES
CONSIDERED AS PER §215.3 IRC:6-2014.
- DAILY VARIATION (SHORT TERM M.O.E. CONCRETE)
- DESIGN PROVISIONS IN IRC CODE APPLICABLE FOR ABOUT 50MM
THK. WEARING COURSE. (AASHTO LRFD MAY BE REFERRED FOR
THK. > 50MM)
B&SEC
LOADS:
7. VERTICAL SEISMIC AS PER § 7.3.2 OF IS:1893-2014 (PART-3)

- § 4.2.3 OF IRC:SP-114-2018
ESTIMATION OF FUNDAMENTAL TIME-PERIOD TV
L – SPAN (m) - 57.6

M – MASS PER UNIT LENGTH(Nm) – 11.5 X2.5*9810/9.81 = 28750
(SIDL, LIVE LOAD SHALL ALSO BE CONSIDERED)
EI – FLEXURAL RIGIDITY OF SUPERSTRUCTURE(Nm2) =
3.5E+10X20.778 =7.27E+11
TV – 0.42 sec.
Sa/g – 2.5
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Seismic Zone – 4
Z = 0.24 x 2/3 = 0.16
Importance Factor, I – 1.2 , Response Reduction Factor – 1.0
Seismic Coefficient – (0.16x0.5) x 2.5 x 1.2 = 0.24
UDL – 0.24* (11.5X2.5) – 6.9 T/M
BENDING MOMENT (AT MID SPAN ) – 2865 tm (approx.)
SUPERSTRUCTURE DESIGN SHOULD BE CAPABLE OF RESISTING

THE SHEAR FORCE AND BENDING MOMENTS UNDER ULS - SEISMIC
CASE.
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SUMMARY OF BENDING MOMENT & SHEAR FORCE

Live Load
Section
DL SIDL
Max BM case MAX SF case
BM (tm) SF (t) BM (tm) SF (t) BM (tm) SF (t) BM (tm) SF(t)
1-1 12036 0 2256 0 3058 31 2456 85
2-2 11288 208 2115 39 2959 63 2468 114
3-3 9046 416 1691 78 2571 107 2370 147
4-4 5315 625 985 118 1656 197 1503 197

5-5 6444 568 1199 107 1968 183 1795 183
6-6 2792 743 512 138 895 227 797 227
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LONGITUDINAL ANALYSIS AT MID SECTION:
THEORETICAL LONGITUDINAL STRESS AT A GIVEN PART OF THE

SECTION:
σ = P / A +/- P*E / Z +/- M / Z
WHERE,
M = APPLIED MOMENT
Z = ELASTIC MODULUS OF SECTION (I/YT OR I/YB)
A = CROSS-SECTIONAL AREA
P = TENDON FORCE
E = TENDON ECC. FROM CENTROID OF SECTION
PARAMETERS A, Z, M, σ(say 0.5Mpa) ARE KNOWN
E CAN BE ASSUMED (say 0.4m) AND PRESTRESS, P CAN BE
ESTIMATED.
VALUE OF P SHALL BE ENHANCED BY APPROXIMATE % OF LOSS
TO ARRIVE AT APPLIED P.
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B&SEC
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LOADS:
8. PRESTRESS
NO. OF PRESTRESSING CABLES - 27 NOS.
CABLE TYPE – 19T-15
CABLE AREA – 19 X 140 – 2660 MM2
STRESSING – BOTH END
SHEATHING – CORRUGATED HDPE
OUTER DIAMETER OF DUCT - 124 mm
% JACKING STRESSING – 76% OF UTS

B&SEC
- AS PER § 7.9.2(1) OF IRC 112, MAX FORCE APPLIED TO TENDON

DURING STRESSING SHALL NOT EXCEED 90% OF 0.1 % PROOF
LOAD (OR PROOF STRESS)
0.9*0.87 FP = 78.3% FP
MAXIMUM STRESS IN PT = 0.783 x 1860 = 1456 Mpa
- FOR POST TENSION WITH BONDED TENDONS TWO

CHARACTERISTIC VALUE OF PRESTRESSING FORCE SHALL BE
USED AS PER § 7.9.5 (6) OF IRC 112:
ϒSUP = 1.1 & = ϒINF = 0.9 (LONG TERM)
ϒSUP / ϒINF = 1 (CONSTRUCTION STAGE) – Amendments IRC:112
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CABLE LAYOUT
THE CABLE IS HAVING A STRAIGHT PORTION NEAR ANCHORAGE
FOLLOWED BY A PARABOLIC PROFILE. THE PARABOLIC PROFILE
IS FOLLOWED BY STRAIGHT LENGTH UP TO MID SPAN. THE
CABLE IS SYMMETRICAL ABOUT MID SPAN AND SHALL BE
STRESSED FROM BOTH ENDS SIMULTANEOUSLY.
C/L Symmetry
H
a b c h3
A B C D
“Jacking “ Start of straight “Start of vertical “point at mid
End” grade portion” parabolic profile” span”
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CABLE a b c H h3 Jacking
(m) (m) (m) (m) (m) force (t)
1 2.0 22.0 5.15 2.89 1.08 383.74
2 2.0 22.0 5.15 2.59 0.89 383.74
3 2.0 20.0 7.15 2.28 0.70 383.74
4 2.0 18.0 9.15 1.98 0.51 383.74
5 2.0 16.0 11.15 1.67 0.32 383.74
6 2.0 14.0 13.15 1.37 0.13 383.74
7 1.0 1.0 27.15 0.27 0.13 383.74
Similarly all 27 cables are defined

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AS PER § 7.9.3.2 OF IRC 112, FOLLOWING LOSSES OF

PRESTRESS IN POST TENSIONING IS CONSIDERED IN DESIGN.
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1. Loss due Friction & Wobble Loss (§ 7.9.3.2 (2))

IF P IS THE JACKING FORCE THEN LOSS IN FORCE AT ANY OTHER
POINT:
PO = P x e-(µӨ+KX)
(K IS WOBBLE COEFF. , µ IS FRICTION COEFF. , e IS EXPONENTIAL)
WOBBLE & FRICTION COEFF. AS PER TABLE 7.1 OF IRC-112
FOR HDPE/PLASTIC DUCTS

WOBBLE COEFF., K - 0.002
FRICTION COEFF., µ - 0.17
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Manual Loss Calculation for Cable 6
7.8%
LOSS
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2. Losses due to Anchorage Draw-In (Slip loss) (§ 7.9.3.2(3))

 When the cable is anchored, the wedges move over small distance before the
wires are firmly griped by the wedges. Movement of wedges is calledWedge Set.
 Due to movement of the wedge, the force in the cable gets reduced near the
anchorages. It is calculated as:
Area of Stress diagram

 Slip value
E Slip value = 6mm
Half Slip area = 158.6tm
Po Cable Stress (0.5 x As x Es x Slip)
19T15 TENDON
Area of the stress diagram

P1
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C/L
382.2 SYMMETRY
TOTAL SLIP AREA

SLIP LOSS DIAGRAM FOR CABLE 6
MANUAL VERIFICATION OF SLIP LOSS:
0.5X15.33X(383.74-364.26) = 150 tm ~ Half Slip Area of 158.6 tm
FORCES IN CABLES AFTER SLIP
Cable Slip FA (t) FB (t) FC (t) FD (t) Avg.

distance Force
(t)
6 15.33 344.7 346.3 363.13 353.7 355.6
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STRESS CHECK IN SUPERSTRUCTURE

PERMISSIBLE STRESSES
fck of Concrete = 50 N/mm2

First Stage Prestressing after 28 Days Factor = 1.10
Permissible Compressive Stress = 0.48 x 5100 =2448 t/m2
Mean Tensile Strength of Concrete, fctm =0.0 t/m2
Ec of Concrete (t/m2) 3.5E+06 Table 6.5 (IRC 112)

Residual Shrinkage Strain 1.86E-04 Clause 6.4.2.6 (IRC 112)
Creep Strain per 10MPa 3.92E-04 Clause A2.5 (IRC 112)
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 SECTION 1-1 (At Mid Span)

SECTION PROPERTIES Yt Yb Zt Zb A
1.254 2.246 16.57 9.25 11.498
AFTER FRICTION Net Force After Friction & Slip
No.of Cables in AND SLIP 27
Net Eccentricity, e = Yb – ecc.
Prestressing Force(t) 10464
Eccentricity from soffit level, ecc.(m) 0.44
Stress at Top Stress at

Description Force Moment t/sqm Bottom t/sqm
Part Cum. Part Cum.
DEAD LOAD 12036 726 726 -1301 -1301
Prestress P 10464 910 1636 910 -391
Prestress Moment P*e -18870 -1139 498 2040 1649
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 Elastic Shortening Loss (clause 7.9.3.2 (1))

0.5*Stress at CG of cables*m*(No of cables)*Area of 1cable
Stress at Top 497.63
Stress at Bottom 1648.7
Stress at CG of Cables 1503.2
Loss due to Elastic Shortening of Cables 287.64
-288/11.5+519/16.57
-288/11.5-519/9.25
Stress at
Description Force Moment Stress at Top Bottom
Part Cum. Part Cum.
Elastic Shortening (I) -288 519 6 504 -81 1568
=287.64*(2.246-0.44)
yb ecc.
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Relaxation Loss in Steel

Just like concrete member undergoes shortening, the steel wires also try to
increase it’s length under constant stress. The code gives loss as percentage
depending upon the stress level. (Clause 6.3.6 of IRC 112)
Initial Stress Relaxation Loss for Low

Relaxation steel (%)
0.5 fp 0
0.6 fp 1.25
0.7 fp 2.5
0.8 fp 4.5
The values are 1000 hr. value. For the loss at infinity, multiply by 3.
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 Relaxation Loss in Steel (10464-288)/27
Average Force in Cables 376.90 t

Avg Force / UTS for Cables (376.9/504.9) 0.746
Relaxation Loss (t) 1066.54 t
Initial Stress Relaxation Loss for Relaxation loss = 3.43 * 3 = 10.3 %
Low Relaxation(%)
10.3 * (0.746 UTS) * 27 / 100 = 1067 t
0.5 fp 0
0.6 fp 1.25
-1067/11.5+1923/16.57
0.7 fp 2.5
0.8 fp 4.5 -1067/11.5-1923/9.25
Stress at
Description Force Moment Stress at Top Bottom
Part Cum. Part Cum.
Relaxation Loss -1067 1923 23 527 -301 1267
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CALCULATION OF SHRINKAGE STRAINS

Material Properties
Concrete Grade for PSC Girder M50
Grade of Steel Fe500
Perimeter of Composite Section,
44.553 m
exposed to drying
Sequence of Casting & Stressing
1st stage stressing 28 days
Autogeneous Shrinkage
(Refer Table 6.6 of
Total Auto. Shrinkage Strain, eca x 106 75 IRC:112)
Shrinkage strain variation with time :
Res. Auto Sh. Strain
DAYS bas
(1 - bas)xeca
28 0.653 26.03 x 10(-6)
Auto. Shrinkage bet. 28- infinity 26.03 x 10(-6)
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Drying Shrinkage
Notional size of cross section, ho 0.516 m (Refer Clause 6.4.2.6 (4),
Coefficient, Kh 0.700 (Refer Table 6.7, IRC:112)
Humidity Considered 80 %
Unrestrained Drying Sh. Strain, ecdx106 240.0 (Refere Table 6.8, IRC:112)
Age of Concrete at the end of curing, ts 5 days (Refer Eq 6.15, IRC:112)
Res. Drying Sh Strain
DAYS bds(t,ts) ecd(t) x 106
(ecd(∞)-ecd(t)) x 106
28 0.0467 7.85 160.14
∞ 1 168.0 0.00
Drying Sh. between 28-∞ days 160.14 x 10(-6)
TOTAL SHRINKAGE STRAIN eca(t) ecd(t) Total Shrinkage Strain, ecs
Total Shrinkage between 28-∞ days 26.03 160.14 186.18 x 10(-6)
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Shrinkage Loss
When the beam shrinks (loss of water), the beam undergoes shortening of its
length. This will lead to loss in prestressing force.
(Shrinkage Strain - Clause 6.4.2.6 of IRC:112)
Loss in pre stress force = Strain *E steel *Area
= 0.000186 x 1.99 x 107 x 27 x 0.00266 = 265.83t

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Creep Loss
Creep is the increased strain in the structure due to sustained loads. It
depends upon the age of loading and compressive stress present in the
structure.
(Creep Strain - Clause 6.4.2.7 of IRC:112)
Creep Strain at Start (per 10Mpa stress) 3.9E-04

Avg. Stress at CG of Cables 977.77
Creep Loss in Cables 537.00
Loss in pre stress force = Strain *E steel *Area
= 0.00039 x 1.99 x 107 x 27 x 0.00266 = 557.4t ( for 10Mpa Stress)
Total Creep loss = 557.4 / 10* 9.58 Mpa = 537 t

B&SEC
CALCULATION OF CREEP STRAINS

Creep Coeff. as per Annex A2 of IRC112
a1 = 0.802
a2 = 0.939
a3 = 0.854
b(fcm) = 2.424
fRH = 1.126
Beta(to) for 28 days loading = 0.488
bH = 1280.87
fo = fRH x b(fcm) x b(to) = 1.334
DAYS bc(t,to) f(t,to)
28 0.000 0.000
∞ 1.000 1.334
Modulus of Elasticity, Ec 34000 Mpa
Elastic Strain per 10 Mpa stress 2.94E-04 (10/Ec)
Total Creep Strain 3.92E-04 per 10 Mpa
B&SEC
Description Force Moment Stress at Top Stress at Bottom

Part Cum. Part Cum.
SIDL 2256.30 136.17 663.41 -243.89 1023.08
2256/16.57 -2256/9.25
Shrinkage -265.82 479.36 5.81 669.23 -74.94 948.15

-266/11.5+479/16.57
Creep -537.00 968.40 11.74 680.97 -151.38 796.77
OK OK
Live Load 3057.97 184.56 865.5 -330.55 466.21

< 2448 OK >0 OK
B&SEC
SUMMARY OF LOSSES
INITIAL JACKING FORCE = 383.74 t (0.76UTS)
LOSS DUE TO LOSS %age

ELASTIC SHORTENING 10.67t 2.8
RELAXATION OF CABLE 39.52t 10.3
SHRINKAGE 9.85t 2.6
CREEP 19.90t 5.2
TOTAL LOSS 79.9t 20.8
B&SEC
Sections Considered for Analysis:

SYMMETRY CL
CL EXP. JOINT
HALF SPAN=30m.
7200 7200 7200 7200
2000 8500
d
1200 SEC SEC SEC SEC SEC SEC
6-6 4-4 5-5 3-3 2-2 1-1
(L/8) (L/4) (3L/8) (L/2)
Section at Every 1/8 of span, Start and End of Flaring and

Section at Effective Depth
B&SEC
SLS Combinations (Rare):
Case1: 1.0 (DL+SIDL1) +1.2 SIDL2+1.0 LL+0.6 TF+1.0 PS {LL (L)+Temp Fall(A)}
Case2: 1.0 (DL+SIDL1) +1.2 SIDL2+1.0 LL+0.6 TR+1.0 PS {LL (L)+Temp Rise(A)}
Case3: 1.0 (DL+SIDL1) +1.2 SIDL2+0.75 LL+1.0 TF+1.0 PS {Temp Fall (L)+LL (A)}
Case4: 1.0 (DL+SIDL1) +1.2 SIDL2+0.75 LL+1.0 TR+1.0 PS {Temp Rise(L)+LL (A)}
Case5: 1.0 (DL+SIDL1) +1.2 SIDL2+1.0 LL+0.6 W+1.0 PS {LL (L)+Wind (A)}
Case6: 1.0 (DL+SIDL1) +1.2 SIDL2+0.75 LL+1.0 W+1.0 PS {LL (L)+Wind (A)}
SIDL1- Crash Barrier SIDL2 – Wearing Coat, Temp – Temperature, LL – Live Load
(L) = Leading & (A) = Accompanying
B&SEC
Temperature Fall Case with

LL leading and Temperature
accompanying
Temperature Fall Case with

LL accompanying and
Temperature Leading
B&SEC
Temperature Rise
Case with LL leading
and Temperature
accompanying
Temperature Rise
Case with LL
accompanying and
Temperature Leading
B&SEC
COMBINATION WITH WIND LOAD

section Distance from Mid span Bending Moment (t-m)
1-1 0 1020
Since BM due to LL is much more than wind, hence LL leading case is
considered. i.e. Load factor for wind = 0.6, for LL =1.0
Stress at
Stress at
Bottom
top (t/m2)
SECTION 1-1 (t/m2)
Wind downward 36.83 -65.96
Due to other loads DL, SIDL, Pre St, 100%LL &
Losses 865.52 466.21
Final Stress 902.35 400.25
< 2448 OK >0 OK
DISTORTIONAL ANALYSIS
B&SEC
DISTORTIONAL ANALYSIS OF THE BOX GIRDER

TWISTING MOMENT OR MOMENT DUE TO ECCENTRIC LOADING ON
THE BOX GIRDER CAUSES TWO EFFECTS:
1. TORSIONAL SHEAR FLOW (PURE TORSION) WHICH IS DEALT IN

LONGITUDINAL ANALYSIS.
2. DIFFERENTIAL BENDING OF TOP & BOTTOM SLABS, WHICH IN

TURN CAUSES TRANSVERSE DISTORTION AND LONGITUDINAL
WARPING AND OF THE BOX GIRDER
3. ANALYSIS IS BASED ON THE THEORY OF BEAM ON ELASTIC

FOUNDATIONS.
REFERENCE – AN INTRODUCTION TO STRUCTURAL DESIGN OF CONCRETE

BRIDGES BY DERRICK BECKETT
B&SEC
B&SEC
TWISTING OF MIDSPAN
SECTION DUE TO TORSION
ADDITIONAL TWISTING OF MIDSPAN

SECTION WITH DISTORTION
B&SEC
B&SEC
DISTORTIONAL ANALYSIS OF THE BOX GIRDER

1. TORSIONAL STIFFNESS OF BOX GIRDER IS REDUCED DUE TO
DISTORTION OF CROSS-SECTION
2. INCREASE IN QTY. OF TRANSVERSE REBAR BY AROUND 5-10%
3. INCREASE IN QTY. OF LONGITUDINAL PT BY AROUND 5%
4. DISTORTION IS VERY CRITICAL IN CASE OF WIDE DECK

STRUCTURES(WITH DIVIDED CARRIAGEWAYS) ESPECIALLY IN
CASE OF THE SPECIAL VEHICLE LOADING
5. TO CURB THE EFFECTS OF DISTORTION, DIAPHRAGM SHALL BE

PROPOSED AT THE CENTER OF THE SPAN
B&SEC
BASIC DESIGN STEPS
1. BEF CALCULATION MODEL
2. CALCULATION OF SPRING CONSTANTS

3. CALCULATION OF EQUIV. LOAD CAUSING DISTORTION
EQUIVALENT LOAD - (P*E/D)
P – AXLE LOAD , E – TRANS. ECC. , D – C/C DISTANCE B/W WEBS
M.O.I OF BEF MODEL , Ib = I / 4
B&SEC
BASIC DESIGN STEPS
4. PERFORM MOVING LOAD ANALYSIS
5. NOTE DEFLECTIONS AND ESTIMATE TRANSVERSE BENDING
MOMENTS AND ADD TO TRANSVERSE FLEXURE MOMENTS
6. NOTE LONGITUDINAL WARPING MOMENTS
7. CALCULATE WARPING STRESSES AND ADD TO THE STRESS
ESTIMATED UNDER LONGITUDINAL ANALYSIS
IN CASE OF 3D-FEM MODELLING, COMPLICATED EFFECTS OF

DISTORTION, WARPING AND SHEAR LAG ARE AUTOMATICALLY
ACCOUNTED.
1. GENERAL FEATURES
ULTIMATE SHEAR & TORSION
B&SEC
LOAD COMBINATIONS (ULS CHECK)
ULS COMBINATIONS:
Case1: 1.35 (DL+ SIDL-1)+1.75 SIDL-2+1.50 LL+0.9 W {LL (L)+Wind (A)}
Case2: 1.35 DL+1.35 SIDL-1+1.75 SIDL-2+1.15 LL+1.5 W {Wind (L)+LL (A)}
Case3: 1.35 DL+1.35 SIDL-1+1.75 SIDL-2+0.20 LL+1.5 S {Seismic Comb.}
The section is checked for flexure, shear & torsion under ULS condition.
ULTIMATE FLEXURE CHECK
B&SEC
ULTIMATE MOMENT CAPACITY CHECK

STEP 1:ESTABLISH CONCRETE STRESS STRAIN
STEP 2: ESTABLISH PRESTRESS STRESS STRAIN
STEP3: DIVIDED CROSS-SECTION INTO SMALL SLICES
STEP4: ITERATE TO FINALISE NEUTRAL AXIS

(FORCE IN CONCRETE = FORCE IN PT)
B&SEC
STEP 1 - CONCRETE STRESS AND STRAIN PLOT
25.00
20.00
15.00
10.00
5.00
0.00
0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50
Eq. 6.21 IRC:112
CONCRETE STRAIN
B&SEC
 CONCRETE STRESS AND STRAIN

x/Xu Strain x 10-3 Stress (Mpa)
0.00 3.50 22.33
0.10 3.15 22.33
0.20 2.80 22.33
0.30 2.45 22.33
0.40 2.10 22.33
0.45 1.93 22.30
0.50 1.75 21.98
0.55 1.58 21.32
0.60 1.40 20.32
0.65 1.23 18.98
0.70 1.05 17.29
0.75 0.88 15.27
0.80 0.70 12.90
0.85 0.53 10.19
0.90 0.35 7.13
0.95 0.18 3.74
1.00 0.00 0.00
B&SEC
STEP 2 : PRESTRESS STRESS AND STRAIN PLOT
Stress
Strain Stress, fy
(Mpa)
6.635E-03 1294 0.80 fy
7.467E-03 1359 0.84 fy
8.216E-03 1407 0.87 fy
9.465E-03 1456 0.90 fy
1.288E-02 1537 0.95 fy
1.288E-02 1537 fy
Sample Calculation:
0.002 + 0.9 x 1860 / (1.15 x 195000)
Fig 6.3 of IRC:112

B&SEC
STEP 3 – SLICING OF CROSS-SECTION

B&SEC
STEP 4 – NEUTRAL AXIS ESTIMATION, FC = FP

B&SEC
ESTIMATE MOMENT CAPACITY
Mc = Σ FC1 x [N.A. FROM TOP – ds1/2] + FC2 x [N.A. FROM TOP – ds1 –
ds2/2] + ……………..
Mp = ΣFP1 x (D- N.A. – d1) + FP2 x (D- N.A. – d2) + ……………..
Wherein ds1 , ds2 are the slice thickness (35mm in our case)
Moment Capacity = Mc+ Mp = 21493 + 302507 = 324000 KNM

Reduced Moment Capacity = 324000 x 0.95 = 307800 KN (Segmental)
Design Moment – 240680 KN (Factored)
B&SEC
Z1 – 0.19M (Mc / FC )
Z2 – 2.74M (MP / FP )
Z1 – C.G. OF FORCE IN CONCRETE FROM N.A.
Z2 - C.G. OF FORCE IN P.T. FROM N.A.
Z = Z1+Z2 = LEVER ARM, Z ALSO TO BE

2.93M (Lever Arm Factor)
USED FOR SHEAR CHECK
SPARE CAPACITY = (M – Mcap) / Z = (307800 – 240680)/2.93
= 22900 KN
THIS SPARE CAPACITY CAN UTILISED TO CATER LONGITUDINAL
STEEL REQUIREMENT DUE TO TORSION.
1. GENERAL FEATURES
B&SEC
ULTIMATE SHEAR CAPACITY

STEP 1: CHECK SECTION IS CRACKED OR UN-CRACKED. I.E.
TENSILE STRESS AT TENSION FACE IS LESS THAN FCTD (0
MPA FOR SEGMENTAL)
(IF UN-CRACKED, CONSIDER VERTICAL PRESTRESS IN
SHEAR)
STEP 2: CHECK SHEAR CAPACITY OF SECTION WITHOUT
SHEAR REINFORCEMENT (AS PER CLAUSE 10.3.2 OF IRC
112).
STEP3: CHECK SHEAR CAPACITY AGAINST WEB CRUSHING.
(0.9 FACTOR)
STEP4: CALCULATE SHEAR REINFORCEMENT.
FLARING LENGTH OF GIRDER IS DECIDED BY SHEAR CHECK.

B&SEC
ULTIMATE SHEAR CHECK

Location 6-6 4-4 2-2
S.No.
Distance from Mid Span 25.300 21.600 7.200
A. SHEAR FORCE & CORRESPONDING MOMENTS
1 Ultimate Shear Force, Vu KN 15693.4 13324.7 5164.6
2 Effect of Vertical Prestress, Vpr KN -5805.8 -4468.0 -186.4
Ultimate Design Moment

3 KN.m 59514.1 112725.1 231439.7
Mcomp1
B&SEC
B. CHECK WHETHER SECTION IS CRACKED OR UNCRACKED ?
0 Mpa( If Segmental)
Maximum Allowable Tensile
4 Mpa 1.640 1.640 1.640
Stress, fctd = fctk,0.05/gc =
5 Horiz Comp of PR after losses KN 77674.5 77698.5 79276.2
6 Ecc of Cables from c.g of Sec. m 1.115 1.401 1.801
7 Avg Comp. Str, fcp (P/A only) Mpa 5.84 6.42 6.89
8 Avg Comp. Str, fcp (P/A+Pe/Z) Mpa 14.21 17.72 22.33
9 fcd = 0.67 x fck / gc Mpa 22.33 22.33 22.33
10 scp = Min. of (NED/Ac, 0.2 fcd) Mpa 4.47 4.47 4.47
Stress at bottom fibre due to
11 Mpa 8.45 6.01 -2.69
Prestress & Flexural Moment
12 Total Tensile Stress at bottom Mpa 8.45 6.01 -2.69
13 "Cracked" or "Un-cracked" ? UNCRACKED UNCRACKED CRACKED
14 Net Design Shear Force, VED KN 9887.6 8856.7 5164.6
B&SEC
C. CHECK FOR SHEAR CAPACITY OF SECTION WITHOUT SHEAR
WIDTH (3x 0.3m=0.9m) SHOULD BE CONSIDERED
REINFORCEMENT
15 Overall Width, bo m 1.690 1.293 1.088
16 Outer Dia of Sheathing Duct, f m 0.125 0.125 0.125
17 Effective Width, bwc (bo-1.2f) m 1.240 0.843 0.638
18 Overall Depth, d m 3.5 3.5 3.5
19 C.G of Strands from soffit, yb m 1.064 0.820 0.445
20 Effective Depth , db = d - yb m 2.436 2.680 3.055
S = A.x = Moment of the area
21 m3 7.888 7.064 7.064
above C.G of Section about C.G
22 I.bwc / S m2 3.542 2.550 1.878
23 k1 1.0 1.0 1.0
B&SEC
C. CHECK FOR SHEAR CAPACITY OF SECTION WITHOUT SHEAR REINFORCEMENT
24 K=1+Sqrt (200/d) <= 2 1.287 1.273 1.256

25 Vmin= 0.031 K3/2 fck 1/2 Mpa 0.320 0.315 0.309
26 VRd.c,min =[Vmin+(0.15σcp)]bwd] KN 2991.0 2224.4 1908.4
27 Area of Tension Steel, Asl mm2 71820.0 71820.0 71820.0
28 r1 = Asl / (bw.d) ≤ 0.02 0.020 0.020 0.020
VRdc (For sections uncracked)
29 KN 10091.0 7265.4 -
I.bwc/S x ((fctd)2+k1.scp.fctd)0.5 (*0.9)
VRdc (For Cracked Sections)
30 VRd.c =[0.12 KN - - 2635
K(80ρ1fck)0.33+(0.15σcp)]bwd (*0.9)
31 Is Shear Reinforcement Reqd ? REQD. REQD. REQD.
B&SEC
D. CHECK FOR SHEAR CAPACITY OF SECTION AGAINST WEB

CRUSHING (WITH SHEAR REINFORCEMENT) TO BE CALCULATED
32 acw 1.200 1.200 1.200
33 Assumed angle of variable strut degree 35.0 35.0 35.0
34 Lever Arm, z = 0.9 x d m 2.192 2.412 2.749
35 v1 = 0.6 x [1-fck/310] 0.503 0.503 0.503
VR,dmax =
36 KN 17231.8 12879.8 11122.7
acw.bw.z.v1.fcd/(cotq+tanq)
SHEAR CAPACITY OF SEC
38 KN 15281.4 11422.0 9863.8
= 0.9*(Min of VED & VR,dmax)
SECTION SECTION SECTION
39 Check adequacy of section
ADEQUATE ADEQUATE ADEQUATE
B&SEC
E. CHECK FOR TORSION: (Clause 10.5.2 of IRC 112)
40 Ultimate Torsion, TED KNm 5187.3 4516.5 2577.1
41 Area enclosed by centerlines, Ak m2 33.77 33.77 34.48
42 Area. of cross section within outer perim., A m2 38.27 38.27 38.27
43 Outer Perimeter, u m 30.115 30.115 30.115
44 Side wall length, z m 3.5 3.5 3.5
45 Average wall thickness, tef = (A/u) m 1.27 1.27 1.27
46 Limiting value tef for webs m 0.61 0.47 0.39
47 Shear Stress in wall t =TED / 2Ak tef Mpa 0.13 0.14 0.09
48 Torsional Shear Force V KN 268.80 234.03 130.79
49 Total Design shear force VED KN 10156.41 9090.76 5295.39
50 Design torsional resistance TRDmax KN-m 262013.5 200363.3 172251.8
51 TED/TRdmax + VED/Vrdmax 0.61 0.73 0.49
52 Check OK OK OK
53 Perimeter of area AK, UK m 29.31 29.741 29.741
54 Long Reinf for Resisting Torsion ASL cm2/m 2.523 2.196 1.227
55 Trans Reinf for Resisting Torsion AST cm2/m 1.237 1.077 0.602
B&SEC
F. CALCULATION OF SHEAR REINFORCEMENT
56 fywd = fyk / gm Mpa 434.8 434.8 434.8
Minimum Shear Reinft. Ratio

57 = 0.0010 0.0010 0.0010
rw,min = 0.072 x (fck)0.5 / fyk
Min. Reinft. mm2/
58 1263.1 858.1 650.1
Asw,min / S = rw. bw. Sina m
Reinforcement Required,
mm2/
59 Asw / S = VED / (z x fywd x 7461.2 6069.9 3101.9
m
cotq)
SIMILARLY SECTION IS CHECKED FOR MAXIMUM TORSION AND
CORRESPONDING SHEAR
1. GENERAL FEATURES
TRANSVERSE ANALYSIS & DESIGN
B&SEC
TRANSVERSE ANALYSIS - LINE BEAM MODEL OF UNIT WIDTH
STAAD PRO V8I PACKAGE USED FOR ANALYSIS
LOADS CONSIDERED:
1. DEAD LOAD(SELF-WEIGHT)
2. SIDL-CB
3. SIDL-WC
4. FPLL
5. LIVE LOAD (DISPERSION AS PER ANNEXURE-B3 OF IRC:112-2011)
6. THERMAL GRADIENT
TRANSVERSE REBAR COMBINATION
B&SEC
 AST (DECK AND SOFFIT SLAB)

AST LONGITUDINAL ANALYSIS
(MAX. TORSION CASE)
+
AST (TRANSVERSE FLEXURE)
 AST (WEBS)
AST LONGITUDINAL ANALYSIS
(MAX. SHEAR + CORRES. TORSION CASE) OR (MAX. TORSION +
CORRES. SHEAR CASE)
+
AST (TRANSVERSE FLEXURE)
B&SEC
DESIGN OF SEGMENT S1 (DIAPHRAGM)
TENSION
COMPRESSION
- CHECK FOR LOCATION OF OPENING IN DIAPHRAGM

B&SEC
DESIGN OF SEGMENT S1 (DIAPHRAGM)

DESIGN OF DIAPHRAGM IS DONE BY USING STRUT AND TIE
METHOD FOR FOLLOWING LOAD CASES:
A) JACK UP CONDITION: CRITICAL WHILE JACKING UP THE

SUPERSTRUCTURE FOR REPLACEMENT OF BEARINGS.
B) LAUNCHING CONDITION: CRITICAL WHEN MIDDLE SUPPORT

OF LAUNCHER IS PLACED OVER SEGMENT AND SEGMENT IS
SUPPORTED OVER TEMPORARY SUPPORTS I.E. AT JACKS
LOCATION.
C) SERVICE CONDITION
DESIGN OF DIAPHRAGM IS ALSO DONE FOR CORBEL ACTION OF

FUTURE PRE STRESSING CABLES AND ALSO CHECKED FOR
PUNCHING SHEAR.
B&SEC
REINFORCEMENT DETAILING OF END SEGMENT SHALL BE

CAREFULLY DONE CONSIDERING THE CONGESTION DUE TO
PRESENCE OF ANCHORAGE CONES AND OTHER
REINFORCEMENTS.
1. GENERAL FEATURES
CONSTRUCTION SEQUENCE CHECK
B&SEC
ERECTION SCHEME:
CL PIER Middle CL PIER
Support
Rear Support
Front Support
S3
MAXIMUM REACTION ON MIDDLE SUPPORT = 650 T (ONLY LAUNCHER)

MAXIMUM REACTION ON MIDDLE SUPPORT = 1600 T (WITH SEGMENTS)
MAXIMUM REACTION ON FRONT SUPPORT = 1800 T (WITH SEGMENTS)
SUPERSTRUCTURE, SUBSTRUCTURE AND FOUNDATION DESIGN SHALL

BE REVIEWED FOR CONSTRUCTION STAGE.
CONSTRUCTION & ERECTION STAGE CHECKS
B&SEC
1. DESHUTTERING (FORMS REMOVED AT 20 Mpa)

2. LIFTING (GENERALLY AT 30 Mpa)
3. 2 TIER STACKING
4. REAR SUPPORT ON SEGMENT S3
5. ANCHORING OF SEGMENT
6. ANY OTHER CONSTRUCTION LOAD
PRIMARY DESIGN CHECKS :

1. TRANSVERSE FLEXURE
2. PUNCHING SHEAR
B&SEC
CHECK OF SEGMENT FOR LIFTING CONDITION
HALF PLAN
B&SEC
CHECK OF SEGMENT FOR 2-TIER STACKING
SEGMENTS PLACED ON 3
SUPPORTS
- ISOSTATIC SYSTEM
VARY SIZES OF SLEEPERS –

PUNCHING & FLEXURE
REQUIREMENTS
B&SEC
CHECK OF SEGMENT S3 FOR LOAD FROM REAR SUPPORT
B&SEC
CHECK OF SEGMENT S3 FOR LOAD FROM REAR SUPPORT

Box Reinforcement Box Shuttering
Box Segment
DESIGN CHECKS ARE SAME FOR BOTH THE

CONSTRUCTION METHODS.
CAST-IN-SITU PRECAST SEGMENTAL
SLS - TENSILE STRESS IN PERMITTED NOT PERMITTED
CONCRETE
ULTIMATE SHEAR - REDUCTION(0.9)
ULTIMATE MOMENT - REDUCTION(0.95)
CAPACITY
ULTIMATE TORSIONAL - NO REINORCEMENT
CHECK CONTINUITY
TRANSVERSE ANALYSIS - ADDITIONAL CHECK
FOR CONSTRUCTION
LOADS
Send your feedback/questions to:

akhileshgupta@bsecpl.in

IRC-112 Refresher: Precast Segmental Box Girder Design

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IRC-112 Refresher: Precast Segmental Box Girder Design

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REFRESHER COURSE ON IRC:112 B&SEC

WORKED EXAMPLE OF A PSC BOX

FIRST PRECAST SEGMENTAL BRIDGE WAS BUILD OVER THE RIVER

IN INDIA, GANDHI SETU BRIDGE BUILT OVER RIVER GANGA IN PATNA

CONSTRUCTION METHODS FOR PRECAST SEGMENTAL BRIDGE

ADVANTAGES OF PRECAST SEGMENTAL CONSTRUCTION

SPAN BY SPAN ERECTION METHOD

- OVERHEAD L.G. OR UNDERSLUNG GANTRY

METHODS OF SEGMENT MATCH CASTING

IN MANY COUNTRIES PRECAST SEGMENTAL BRIDGES ARE

BOX GEOMETRY RESTRICTIONS IN PRECAST SEGMENTAL :

THERE IS NO RESTRICTION - TOP FIBER SHOULD BE KEPT

- NECESSARY CHANGES IN P & P

JOINTS IN SEGMENTAL CONSTRUCTION

INDIAN CODE SP:65 IS SILENT ON DRY JOINT

CURRENTLY NO INDIAN CODE ON DRY JOINT

BENEFITS OF WET/EPOXY JOINTS WITH SHEAR KEYS

EPOXY JOINTING OF SEGMENTS

INWARD RECESS OUTWARD RECESS

Segment (n) DETAIL OF SHEAR KEY IN

PART JOINT OF TWO SEGMENTS (ELEVATION)

FIGURE C5.5.4.2.2-1 IN AASHTO LRFD

SPAN-2 ERECTION IS COMPLETE, LAUNCHING GIRDER IS READY

TRANSFER LOAD TO REAR SUPPORT & MOVE MIDDLE SUPPORT TO

TRANSFER LOAD TO MIDDLE SUPPORT & MOVE REAR SUPPORT TO

Rear Hoist Middle

MOVE HOIST AT THE TAIL POSITION.

FOR ROAD BRIDGES, SEGMENTS MAY ALSO BE TRANSPORTED ON

SIMILARLY BRING OTHER SEGMENT ON TRAILER OVER ALREADY

STEPS OF ERECTION OF A SPAN:

IRC:SP:65-2018: INTERNAL BONDED TENDONS

PRECOMPRESSED TENSILE ZONE (SOFFIT - SIMPLY SUPPORTED)

IRC:SP:65-2018: INTERNAL BONDED TENDONS

§ 3.5.2.1 - ULTIMATE SHEAR CAPACITY AS PER SECTION-10 IRC:112

§ 3.2.1 ALLOWABLE STRESS UNDER SLS RARE COMB.

WORKED OUR EXAMPLE

< KUNDLI A1 P2 P4 P5 P6 P7 P8 P9 A2 PALW

<< KUNDLI A1 P2 P4 P5 P6 P7 P8 P9 A2 PALW

BH-P1 BH-P3 BH-P5 BH-P7 BH-P9

BH-A1 BH-P2 BH-P4 BH-P6 BH-P8

CONSTRUCTION TECH SPAN BY SPAN ERECTION

CONSTRUCTION PERIOD 400 DAYS

TOTAL LENGTH 600m x 2 = 1200m

NO. OF SEGMENTS 420 Nos

LAUNCHING SYSTEM OVERHEAD L.G.

CL EXP. JOINT CL EXP.

S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S10 S9 S8 S7 S6 S5 S4 S3 S2 S2

LENGTH/WIDTH RATIO – 5.4 > 2.5 (§ 4.6.1 AASHTO LRFD)

SUPERSTRUCTURE MAY BE IDEALISED AS A SINGLE-SPINE

CHECK FOR SHEAR LAG EFFECTS

- EFFECTIVE FLANGE WIDTH AS PER §7.6.1.2 OF IRC:112-2011

A = 11.498m2 , Yt = 1.254m , Yb = 2.246m , IZ = 20.778m4

1. DEAD LOAD (SELFWEIGHT)

CROSS-SECTIONAL AREA MID – 11.498 M2

2. SIDL EXCEPT SURFACING

(CRASH BARRIER P1 TYPE , LOAD INTENSITY @ 0.76 T/M)

WEARING COAT THICKNESS – 65MM

BENDING MOMENT(MID) – 2256 TM , S.F. (D EFFECTIVE) – 138T

STRUCTURE IS CLASSIFIED AS A 5 LANE

A) CLASS A- 1,2,3,4 OR 5 LANE

2 NOS. OF SUCCESIVE TRAINS OF VEHICLES CONSIDERED

IMPACT FACTOR – 8.8% (Span > 45m)

5. WIND LOAD AS PER §209.3 OF IRC:6-2014

Loss in pre stress force = Strain E steel Area

Loss in pre stress force = Strain E steel Area