25-11-2024 1 FOR SUBMISSION DS SK SM

DATE REV. NO. DESCRIPTION Designed Checked Approved

REVISIONS

RPG GROUP
KEC INTERNATIONAL LIMITED

CLIENT : CMRL

PROJECT : CMRL-Phase 2-C5-ECV03 - Elevated

CONSULTANT : AEON

SUPPLIER / CONTRACTOR: KEC INTERNATIONAL Pvt Ltd

JOB No. O-21-CMRL-ECV 03

TITLE: VIADUCT

Design check of I-girder lifting arrangement

TOTAL NO. OF REV.
PAGES
DOC.No. O 21 - C M R L - E C V 3 - TW - IL - 0 0 5 8
1

RELEASED FOR PRELIMINARY TENDER INFORMATION P APPROVAL CONSTRUCTION

 KEC INTERNATIONAL LIMITED
PROJECT: ECV03 CMRL- C5 Date
TITLE: Design check of I-girder lifting arrangement DESIGNED CHECKED 25-11-2024
DOCUMENT NO. O21-cmrl-ecv-03-TW-IL-0058 DS SK

REVISION RECORD PAGE

REVISION DESCRIPTION OF REVISION DATE

1 For Approval Submission 25-11-2024
 KEC INTERNATIONAL LIMITED
PROJECT: ECV03 CMRL- C5 Date
TITLE: Design check of I-girder lifting arrangement DESIGNED CHECKED 25-11-2024
DOCUMENT NO. O21-cmrl-ecv-03-TW-IL-0058 DS SK

CONTENTS

Sl.no. ITEM Page No

1.0 Introduction
2.0 Scope
3.0 Standards and Codes of Practice & Reference drawings
4.0 Design check of Lifting beam
5.0 Design of pin
6.0 Design of Weld
7.0 Check for macalloy bar Tension
 KEC INTERNATIONAL LIMITED
PROJECT: ECV03 CMRL- C5 Date
TITLE: Design check of I-girder lifting arrangement DESIGNED CHECKED 25-11-2024
DOCUMENT NO. O21-cmrl-ecv-03-TW-IL-0058 DS SK

1.0 Introduction
This design document covers the Lifting arrangement for I-girder

2.0 Scope
The scope of this design document covers the design check of Lifting beam, lifting plate
and macalloy bar

3.0 Standards and Codes of Practice & Reference drawings

IS :800-2007 ; Code of practice for general construction in steel
SP6_1-1964 (Reaffirmed 1998); Handbook for structural engineers
 KEC INTERNATIONAL LIMITED
PROJECT: ECV03 CMRL- C5 Date
TITLE: Design check of I-girder lifting arrangement DESIGNED CHECKED 25-11-2024
DOCUMENT NO. O21-cmrl-ecv-03-TW-IL-0058 DS SK

4.0 Design check of Lifting beam

4.1 Data & Assumptions
IS 2062 : 2011
Table:2 Grade of steel = E250
IS:800-2007 2
Table:1 Yield Stress of steel (fy) = 250 N/mm
IS:800-2007 2
Table:1 Ultimate Stress of steel ( fu ) = 410 N/mm
IS:800-2007 2
CL:2.2.4.1 Modulus of elasticity of steel ( E ) = 200000 N/mm
IS:800-2007
Table:4 Partial Safety Factor for Loads ( γf ) = 1.5
IS:800-2007
Table:5 Factor of safety for yielding and buckling ( γm0 ) = 1.1
IS:800-2007
Table:5 Factor of safety for ultimate stress ( γm1 ) = 1.25
4.2 Loading
I- girer self weight = 55 MT
Impact factor = 0.2
Impact load = 11 MT
Total load considerd = 66 MT
Number of Maccolley bar support on each beam = 2 nos:
Load on beam = 33 MT
Load on macalloy bar = 16.5 MT
33 t
A B
1m

Typical Loading case

RA = 16.5 t
RB = 16.5 t
Shear force = 16.5 t
BM max = 8.25 t-m
factored BM = 12.38 t-m
factored SF = 24.75 t
200
10
1 Top FL Pl. 200 x 10 30 120
2 Web Pl. 10 x 200 220 10 200
3 Bottom FL. Pl. 200 x 10 10
200
 KEC INTERNATIONAL LIMITED
PROJECT: ECV03 CMRL- C5 Date
TITLE: Design check of I-girder lifting arrangement DESIGNED CHECKED 25-11-2024
DOCUMENT NO. O21-cmrl-ecv-03-TW-IL-0058 DS SK

Sectional properties
A Ytop AY Ixx Iyy
2 3 4
Nos Member mm mm mm mm mm4
1 Top FL Pl. 2000 5 10000 66666.66667 6666666.667
2 Web Pl. 4000 110 440000 61733333.33 16933333.33
3 Bottom FL. Pl 2000 215 430000 92466666.67 6666666.667
Total 8000 880000 154266666.7 30266666.67
Ӯ = Σ AY/Σ A = 880000 / 8000 = 110 mm
Ze =Ixx / Ӯ = 1402424.24 mm3
Zp = 620000 mm3
Shape factor, Zp/Ze = 0.44
Radius of Gyration, r min = 61.51 mm
Effective length of the beam = 1000 mm
Section classification
Check for Outstanding element of compression flange
Table:2 Outstanding width, b = 30 mm
IS:800:2007 b/tf = 30/10 = 3.0
< 8.4
Plastic
Check for Internal element of compression flange
Table:2 Internal element width, b = 120 mm
IS:800:2007 b/tf = 120/10 = 12.00
< 29.3
Plastic
Check for web
Table:2 Depth of web, d = 200 mm
IS:800:2007 d/tw= 200 / 10 = 20
< 84
Plastic

Bending check
tf = 10 mm
Table:10 class = c
Table:7 Imperfection factor, αLT = 0.49
 KEC INTERNATIONAL LIMITED
PROJECT: ECV03 CMRL- C5 Date
TITLE: Design check of I-girder lifting arrangement DESIGNED CHECKED 25-11-2024
DOCUMENT NO. O21-cmrl-ecv-03-TW-IL-0058 DS SK

IS:800:2007 C/C Distance between flange, hf = 210 mm

Table:16 LLT = 1 x 1000 = 1000 mm
IS:800:2007 LLT / Radius of Gyration, r min = 1000 / 61.51 = 16.26

Cl:8.2.2.1 = 6366419337.08
IS:800:2007 Nmm
Non-Dimensional slenderness ratio
= 0.16
= 0.50
Bending stress Reduction Factor, χLT

= 1.0 <= 1

Design Bending compressive stress,

= 232.41 N/mm2
Since this is a plastic section ,
βb = 1
Design Bending strength, = 14.41 t-m
Maximum Factored Bending Moment = 12.38 t-m
OK
Shear check
Shear area, Aw = 2 x 10 x 200 = 4000 mm2
Design shear strength = Aw x fy /(√3 x Ƴmo) = 52.49 t
Maximum factored shear force = 24.75 t
OK
Check for shear buckling
For a web without stiffeners
= 20
< 67
Invalid
0.6 x Vd = 0.6 x 52.49 = 31.49 t
Maximum Factored shear force, Vf = 24.75 t
It is a low shear case, Hence OK
 KEC INTERNATIONAL LIMITED
PROJECT: ECV03 CMRL- C5 Date
TITLE: Design check of I-girder lifting arrangement DESIGNED CHECKED 25-11-2024
DOCUMENT NO. O21-cmrl-ecv-03-TW-IL-0058 DS SK

5.0 Design of pin

Diameter of the pin = 50 mm

Grade of pin = 8.8 Grade
2
Yield strength of pin = 640 N/mm
2
Ultimate strength of pin = 800 N/mm
Length of pin = 90 mm
5.1 Check for shear
2
Shear area =π*0.78*50^2/4= 1530.75 mm
IS 800-2007
Cl 8.4.1
Design Shear Strength of a rod, Vdb = Fy x Asb / (√3 x γm0 ) = = 90.5 MT
Maximum Factored shear force = 49.5 MT
SAFE

Utilization 54.7 %
5.2 Check for bearing capacity of pin on plate
IS 800 : 2007
Clause - 10.3.4 End distance of the fastener along bearing direction e= 79.5 mm
Pitch distance of the fastener along bearing direction p= 125.0 mm
Diameter of the hole d0 = 53.0 mm
2
Ultimate tensile stress of the pin fub = 800.0 N/mm
2
Ultimate tensile stress of the plate fu = 410 N/mm
Nominal diameter of the pin d= 50.0 mm
Thickness of the plate t= 25 mm
IS 800 : 2007
Table 5 Partial safety factor, ɣmb = 1.25
Kb is smaller of e/3d0, p/3do - 0.25, fub/fu , 1.0 .
e/3d0 = 0.5
(p/3do) - 0.25 0.5
fub/fu 2.0
Therefore, Kb = 0.5
Nominal bearing strength of a pin, Vnpb 2.5 *Kb*d*t*fu = 640.6 KN
Design bearing strength of the pin on plate, Vdpb Vdpb = Vnpb/ɣmb = 51.3 MT
Actual load on one plate 24.75 MT
SAFE

Utilization 48.3 %
 KEC INTERNATIONAL LIMITED
PROJECT: ECV03 CMRL- C5 Date
TITLE: Design check of I-girder lifting arrangement DESIGNED CHECKED 25-11-2024
DOCUMENT NO. O21-cmrl-ecv-03-TW-IL-0058 DS SK

6.0 Design of Weld

6.1 Force summary
Factored Axial Force = 0.0 MT
Factored Vertical Shear force = 49.5 MT
Factored Horizontal Shear force = 0.0 MT
Factored Major Bending Moment = 0 MT-m
Factored Minor Bending Moment = 0 MT-m
Tension force calculation
Lever arm at major direcction, Lma = 100 mm
Lever arm at minor direcction, Lmi = 100 mm
= Mzto/ major
Tension due Lma moment Tma = 0.00 MT
= Myto/ minor
Tension due Lmi moment Tmi = 0.00 MT
6.2 Design
Factored shear force = 0.00 MT
Factored tensile force = 49.50 MT
2
Ultimate strength of fillet weld (fwn) = 400 N/mm
Cl:10.5.7.1.1 2
IS 800-2007
Design strength of fillet weld (fwd) fwd=fwn /(𝛾𝑚w∗√3) = 185 N/mm
Thickness of weld provided = 8 mm
Length of weld provided (Perimeter of beam) = 600 mm

Cl:10.5.10.1.1
IS 800-2007
Equivalent stress of weld (fe) fe=√fa2+3q2 = 146.00 N/mm
2

SAFE

7.0 Check for macalloy bar Tension

Fu of macalloy bar = 1030 N/mm2
Nominal Dia of macalloy bar = 32 mm
Cross sectional area of Bar = 804.25 mm2
Failure load of 32 dia macalloy bar = 84.44 MT
Safe working capacity of bar =0.7xFu = 59.11 MT
> 24.75 MT
SAFE