Client: NATIONAL HIGHWAYS AUTHORITY

OF INDIA

Project: CONSTRUCTION OF SIX LANE ELEVATED KONA EXPRESSWAY FROM KM

0.145 TO KM 7.337 OF NH-117 IN THE STATE OF WEST BENGAL ON EPC
MODE.

Title: DESIGN OF SHUTTERING AND STAGING ARRANGEMENT FOR PILE CAP

OF 4 PILE GROUPS

DESIGN
DATE REV.
NOTE NO.
13.04.2022 0
GPT/W-186/DES-06

GPT INFRAPROJECTS LIMITED

JC-25, SECTOR-III, SALT LAKE CITY
KOL KATA – 700 098
1.0 Preamble For pile cap form work side wall is supported by MS shutter board and waler
And waler is self supported by bolted together
1.1 Design Input
Length of pile cap = 5.1 m
Width of pile cap = 5.1 m
Depth of pile cap = 1.8 m

Volume of pile cap = 46.818 cum

Weight of pile cap = 121.7 t
Grade of rolled steel and MS plate = E 250
3
Unit weight of green concrete = 2.6 t/m
2
Unit weight of shuttering = 0.07 t/m
Grade of cuplock system props = Yst 240
For rolled section (Table-II , IRS steel bridge code)
Permisible bending stress = 160 Mpa
Permisible shear stress = 92 Mpa
Perm. Stress in axial tension = 150 Mpa
For 4.6 grade bolts (Table-II , IRS steel bridge code)
Perm. Stress in axial tension = 92 Mpa
Perm. Shear stress = 100 Mpa
Perm. Bearing stress = 230 Mpa

1.2 Load calculation

1.2.2 Load on side shuttering board
Maximum Lift height = 1.80 m
3
Volume of concrete = 46.818 m

Lateral Pressure on Side Shutter Board

Lateral pressure at bottom from poured concrete as per CIRIA guideline report no.108
Pmax(at bottom) = g [ C1R + C2 K(H-C1R) ] or gH
Whichever is smaller
g Weight density of concrete in KN/m3 = 26 KN/m
3

C1 [Link] on the size and shape of formwork = 1 (as per table-1)

C2 [Link] on constituent materials of concrete = 0.3 (as per table-1)
R rate of pouring of concrete in m/hr = 0.40 m/hr
T Concrete temperature at placing = 30 °C
H Vertical height in m = 1.80 m
K Temperature co-eff = (36/T+16)^2
= 0.612

Pmax = 21.602 kN/m

2 or 46.8 KN/m
2

> 20.000 kN/m2 (Min value as per IRC:87 Cl

Hence design Lateral Load Pmax = 2.200 t/m2 [Link].2)
= 0.220 kg/cm2
Pmax / ϒ = 21.602 / 26 = 0.83 m
Hence the pressure diagram as follows

0.83 m

0.97 m

21.602 KN/m2
Pressure diagram
2.1 Design of side shutter board
Size of board Length = 1.2 m
breadth = 0.6 m
MS sheathing thickness = 3.15 mm
Edge Angle = L50x50x6
Intermediate stiffener = 50x6 Flat

2.1.1 Design of side sheathing

Thickness of MS sheet = 3.15 mm
Span = 0.30 m
Load on deck plate = 2.20 t/m2

Max. B.M. 2.2 x 0.3^2/12 = 0.017 tm/m width

= 16.5 kgcm/cm width
Section modulus of MS plate 1 x 0.315^2/6 = 0.017 cm3
Bending Stress 16.5/0.017 = 970.59 kg/cm2
Maximum Permissible Bending Stress = 1569.60 kg/cm2
Which is > 970.59 kg/cm2
Safe
Shear force 2.2 x 0.3 / 2 = 0.330 t
Shear stress 330 / (0.315 x 100) = 10.48 kg/cm2
Allowable shear stress = 981.00 kg/cm2
Safe
M.O.I of MS shet per running meter
(100x0.315^3/12) = 0.26 cm4
4
Deflection at midspan = wl /145 EI
Modulus of elasticity of steel (E) = 2150000 kg/cm2
Deflection at midspan 1x2.2x0.3^4 x 10^9/(145 x 2150000 x 0.26) = 0.220 cm
Allowable deflection = 0.300 cm
Clause No. [Link] of IS: 800 - 1984 Safe

2.1.2 Design of intermediate stiffeners

Clear span = 0.6 m
c/c span considered = 0.600 m
Spacing = 0.300 m
Load on beam (2.2 x 0.3) = 0.660 t/m
Section provided = 50x6 flat
Depth = 5.000 cm
Width = 0.600 cm
Moments of Inertia (Ixx) = 6.250 cm4
Moduli of Section (Zxx) = 2.500 cm3
B.M. 0.66 x0.6^2/8 = 0.030 tm
S.F. 0.66 x 0.6/2 = 0.198 t
Section modulus required 0.03 x 10^4 / 150 = 2 cm3
Which is < 2.5 cm3
Safe
2
Shear stress 0.198 x 10^4 / 6 x 50 = 6.6 N/mm
2
Allowable shear stress < 100 N/mm
Safe
Deflection at midspan 5x0.66x0.6^4 x 10^9/(384 x 2150000 x 6.25) = 0.083 cm
Allowable deflection = 0.300 cm
Clause No. [Link] of IS: 800 - 1984 Safe
2.2 Design of waler beam for shutter board fixed at middle
c/c span = 1.100 m
Spacing = 0.700 m
Maximum udl due to side pressure 2.2 x 0.7 = 0.77 t/m
Section provided = MC 100
Section marked MC 100
weight (w) 9.2 kg/m
2
Sectional Area (A) 11.7 cm
Depth of Section (h) 100 mm
Width of Flange (b) 50 mm
Thickness of Flange (tf) 7.5 mm
Thickness of Web (tw) 4.7 mm
4
Moments of Inertia (Ixx) 186.7 cm
4
Moments of Inertia (Iyy) 25.9 cm
Radil of Gyration (rxx) 4 cm
Radil of Gyration (ryy) 1.49 cm
3
Moduli of Section (Zxx) 37.3 cm
3
Moduli of Section (Zyy) 7.5 cm

Allowable bending stresss = 150 Mpa

B.M. 0.77 x1.1^2/10 = 0.093 tm
S.F. 0.77 x 1.1/2 = 0.424 t
Section modulus required 0.09317 x 10^4 / 150 = 6.2 cm3
Which is < 7.5 cm3
Safe
2
Shear stress 0.4235 x 10^4 / 50 x 7.5x 2 = 5.65 N/mm
2
Allowable shear stress < 100 N/mm
Safe
Check for tie rod
Axial force 0.4235 x 2 = 0.847 t
Dia of tie rod = 12 mm
C/S area = 89 sq mm
Axial capacity in tension = 1.335 t
Safe