MTENTU Bridge in South Africa

Calculation sheet

design：

Auditing：

Approval：

Hubei Waco Formwork Co., Ltd

October 2024
 Table of Contents
1 Reference basis ............................................................................................................ 1
2 Calculation for Woodworking Beam Template System ........................................... 2
2.1 Calculation of lateral pressure ......................................................................... 2
2.2 Formwork calculation ........................................................................................ 3
2.2.1 Panel check ............................................................................................. 3
2.2.2 Strength check ........................................................................................ 4
2.2.3 Deflection check ..................................................................................... 4
2.3 Woodworking beam check ............................................................................... 4
2.3.1 Strength check ........................................................................................ 5
2.3.2 Deflection check ..................................................................................... 5
2.4 Calculation for channel steel back ridge ........................................................ 5
2.4.1 Strength verification calculation ........................................................... 5
2.4.2 Deflection check ..................................................................................... 6
2.4.3 Combined deflection check ................................................................... 6
2.5 Calculation for tension bolts............................................................................. 6
3 Calculation for embedment in concrete..................................................................... 7
3.1 Check calculation for concrete resistance to pulling .................................... 7
3.2 Check calculation for local pressure on concrete at anchor plate ............. 8
3.3 Check calculation for high-strength screws on tensile strength ............... 10
3.4 Check calculation for climbing cone ............................................................. 10
3.4.1 Check calculation for local pressure on concrete at climbing cone
10
3.4.2 Check calculation for climbing cone on shear force ....................... 10
3.5 Check calculation for stress bolt ................................................................... 11
3.5.1 Stress bolt shear resistance ............................................................... 11
3.5.2 Stress bolt tensile strength.................................................................. 11
3.5.3 Combined shear and tension strength .............................................. 12
4 Calculation for inner steel formwork system........................................................... 12
4.1 Check calculation for steel formwork ........................................................... 12
4.1.1 Formwork panel strength check ......................................................... 13
4.1.2 Deflection check ................................................................................... 13
4.2 Calculation for rib plate ................................................................................... 13
4.2.1 Strength check ...................................................................................... 14
4.2.2 Deflection check ................................................................................... 14
1 Reference basis

Load Code for Building Structures (GB 50009-2012)

Design Standards for Steel Structures (with Commentary [Separate Volume])
(GB 50017-2017)
Code for Design of Concrete Structures (GB 50010-2010)
Code for Construction of Concrete Structures (GB 50666-2011)
Code for Acceptance of Construction Quality of Concrete Structures (GB
50204-2015)
Compiled by Jiang Zhengrong, Handbook of Construction Calculation
Standard for Acceptance of Construction Quality of Steel Structures (GB
50205-2020)
Plywood for Concrete Formwork (GB/T 17656-2018)
Technical Specification for Safety of Construction Formwork (JGJ 162-2008)
Design Specification for Wind Resistance of Highway Bridges (JTG/T
3360-01-2018)
Compiled by Zhou Shuixing, Road and Bridge Construction Calculation Manual

1
2 Calculation for woodworking beam template system

2.1 Calculation of lateral pressure

The lateral pressure exerted by concrete on the formwork increases with the
pouring height of the concrete. However, when the pouring height reaches a certain
critical point, the lateral pressure no longer increases, and the lateral pressure at
this time is the maximum lateral pressure of the newly poured concrete. The pouring
height at which the lateral pressure reaches its maximum value is called the
effective head of concrete.
According to Appendix A.0.4 of the "Code for Construction of Concrete
Structures" (GB 50666-2011), the standard value of the lateral pressure of the
newly poured concrete on the formwork can be calculated using the following two
formulas, and the minimum value is taken:

F-------The standard value of the maximum lateral pressure of the newly poured
concrete on the formwork (kN/m2)
γc------The gravity density of concrete (kN/m3); 25 kN/m3
t0------The initial setting time (h) of the newly poured concrete can be
determined based on actual measurements. When there is a lack of experimental
data, the following formula can be used: t = 200/(T+15). As there is no actual on-site
test data available here, a value of 8 hours was assumed based on similar
engineering experience in the past.
β------Coefficient of influence of concrete slump. When the slump is greater
than 50mm and not greater than 90mm, β is taken as 0.85; When the slump is
greater than 90mm and not greater than 130mm, β is taken as 0.9; When the slump
is greater than 130mm and not greater than 180mm, β is taken as 1.0. In this case,
a value of 1 is taken.
V------Pouring speed which is obtained based on the ratio between concrete

2
pouring height (thickness) and pouring time (m/h). In this case, as there is no actual
on-site test data available here, 1 m/h was assumed based on similar engineering
experience in the past.
H------The total height from the calculation position of concrete lateral pressure
to the top surface of the newly poured concrete (m). In this case, a value of 6 m is
assumed.
1
F = 0.28 ct0 V 1/2 = 0.28  25  8 112 = 56kN / m 2

F =  c H = 25x 6 = 150kN/m 2

The smallest of the two values, F = 56 kN/m2 is used as the standard value for
the lateral pressure of the formwork. The standard value for the horizontal load
generated by pouring concrete is 2 kN/m2. The load factors of 1.35 and 1.4 are
taken, respectively. Therefore, the total design load acting on the formwork is:

2.2 Formwork calculation

The formwork height is 6.15 m as the pouring height is 6 m. The panel is made
of 21mm plywood boards. The vertical back ridge adopts woodworking beams with
a cross-sectional size of 80x200, with an average spacing of no more than 300mm;
The horizontal back ridge adopts double 14 channel steel back ridges with a
maximum longitudinal spacing of 1100mm. D20 high-strength screws are used for
the pull rod with an average horizontal spacing of no more than 1300mm.

2.2.1 Panel check

By considering the panel as a three span continuous beam supported on a

wooden beam, the length of the panel is taken as 2440 mm, the width as b = 1000
mm, and the spacing between the wooden beams is l1 = 300mm.

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 2.2.2 Strength check

The line load acting on the panel is： q1 = qb = 78.4 1 = 78.4kN / m = 78.4 N / mm

Maximum pending moment of the panel:

M max = ql1 10 = (78.4x300x300)/10 = 7.06x105 N.mm

2

1
Section modulus of the panel： W = bh 2 6 = 1000x212 = 7.35x104 mm3
6
stress：  = M max W =7.06x105/6.1x104=11.57N/mm2 < f m =35 N/mm2 (Design

value of flexural strength of plywood)

Therefore, the calculations meet the requirements.

2.2.3 Deflection check

The standard loads adopted for the calculation of the deflection (without
considering vibration loads) are the following:

Line load: q2 = Fb = 56 1 = 56kN / m

Panel deflection:  = q2l 4 150EI = 56x3004 /(150x6.85x103 x7.72x105 ) = 0.57mm

With the moment inertia of the panel section equal to:

I = bh 3 / 12 = 1000x213 / 12 = 7.72x105 mm 4

And the moduli of elasticity of wood and steel are equal to 6.85x103 N/mm2
and .1x105 N/mm2, respectively.

Permissible deflection of the panel: [ ] = 300 / 400 = 0.75mm  0.57mm

Therefore, the calculations meet the requirements.

2.3 Woodworking beam check

The wooden beam can be calculated as a continuous beam supported on the
transverse back ridge with a spacing of l2 = 1100mm.

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 2.3.1 Strength check

The line load on the woodworking beam: q 3 = ql1 = 78.4x 0.3 = 23.52 N / mm

Maximum bending moment: M max = q 3l 22 / 10 = 0.1x23.52x110 0 2 = 2.85x10 6 N .mm

Section modulus of the woodworking beam:

W=(BH2-(B-b))h2/6 = 4.13x105 mm3
Stress: σ = M/W = 6.9N/mm2 < f = 13 N/mm2
Therefore, the calculations meet the requirements.
Moment of inertia of the woodworking beam:
1 1
=  BH 3 − ( B − b ) h3  = 80  2003 − ( 80 − 30 ) 1203  = 4.61107 mm4
12 12

2.3.2 Deflection check

The standard loads adopted for the calculation of the deflection (without
considering vibration loads) are the following:

Line load: q 4 = Fl1 = 56 x 0.3 = 16.8kN / m

Deflection of the wooden beams ：

 = q 4l 42 / 150EI = 16.8x11004 （
/ 150x6.85x103 x 4.61x107）= 0.52mm

Allowable deflection of wooden beams: [ ] = 1100 / 1000 = 1.1mm  0.52mm

Therefore, the calculations meet the requirements.

2.4 Calculation for channel steel back ridge

The channel steel is calculated as a continuous beam supported on tension
screws and can be calculated as a continuous beam supported on tension rods with
a span equal to l3 = 1300mm.

2.4.1 Strength verification calculation

Line load acting on the channel steel: q5 = ql2 = 78.4x1.1 = 86.24 kN/m

5
 1
Maximum bending moment: M max = q5 L23 = 0.1x86.24x13002=1.46x107 N mm
10
Section modulus of the double 14 channel steel:

W = 80.5  2 = 161cm3 = 1.61105 mm3

Stress:  = M max W = 1.46 107 1.61105 = 90.68 N / mm 2

Therefore, the calculations meet the requirements.

(Section moment of inertia of the double 14 channel steel:

 = 564  2 = 1128cm4 = 1.128 107 mm4 )

2.4.2 Deflection check

The standard loads adopted for the calculation of the deflection (without
considering vibration loads) are the following:

The line load acting on the channel steel is: q6 = Fl2 = 56x1.1 = 61.6kN / m

Backbone deflection:

 = q6l3 4 / 150 EI = 61.6x1300 4 （

/ 150 x 2.1x105 x1.128x10 7）= 0.5mm

Allowable deflection of back ridge

[ ] = 1300 / 1000 = 1.3mm  0.5mm

Therefore, the calculations meet the requirements.

2.4.3 Combined deflection check

Checking the combined deflection of panels, wooden beams, and channel steel
back ribs:
 = 0.57 + 0.52 + 0.5 = 1.59mm  3mm
Therefore, the calculations meet the requirements for the formwork quality
during construction.

2.5 Calculation for tension bolts

6
 D20 screw is used as tension bolts; The maximum vertical spacing is 1100mm,
and the maximum horizontal spacing is 1300mm.
The tensile force that the bolt is subjected to is:
N = 78.4x1.1x1.3 = 112.1kN  250kN
Our company provides high-strength screws that are processed by rolling after
cold drawing. The actual failure point is about 250 kN, which translates to a safety
factor of more than twice of the pull rod. Therefore, the calculations meet the
requirements.

3 Calculation for embedment in concrete

The design value of the pulling force of an embedment part is 100 kN and the
design value of the shear force is 70KN.

3.1 Check calculation for concrete resistance to pulling

According to the "Road and Bridge Construction Calculation Manual", the
anchoring strength of the embedded parts calculated based on the failure of the
anchor plate column is the following:
Assuming that there is a sufficient distance between the embedded part and
the edge of the concrete in the vertical direction, the anchor plate bolt and the
surrounding concrete will be pulled out of the concrete in the shape of a conical
section under the action of axial force F.

Ft 32 = A ( s sin  +  s cos  )

7
 h(R + r)
For a single climbing cone： A =
sin 

b
As r = ； R = hctg + r ，and by experiment: when b/h = 0.19~1.9，  = 21 ,


 F = 0.0203 f c , substituting the variables to the Ft32 equation:

2  0.0203   2 
Ft 32 =  f c  h ctg 21 + bh  = 0.2 f c ( 2.3h 2 + bh )
sin 21  2 
In the formula:

fc Design value of concrete compressive strength; concrete must

reach strength of at least 15 MPa

h The height of anchor plate column after failure which is specified as
350mm
b Anchor plate side length which takes a value of 100mm

Ft 32 = 0.2 f c ( 2.3h 2 + bh ) = 0.2 15  ( 2.3  350 2 + 100  350 ) = 950250 N = 950.25kN

Considering various unfavorable factors, a safety factor of 2 was applied to the

result of the calculation, then Ft 32 = 475.1kN

The design value of pulling strength of a single embedded part is then equal to
100 kN < 475.1 kN which therefore meets the requirements.

3.2 Check calculation for local pressure on concrete at anchor plate

According to Article 6.6.1 of the Code for Design of Concrete Structures
(GB50010-2010), the section of the local compression zone of a concrete member
with indirect reinforcement shall meet the following requirements:

Fl  1.35c l f c Al n

Ab
l =
Al

In the formula:
Fl The design value of local load or local pressure acting on the local

8
compression surface

fc Design value of compressive strength of concrete, taken as 15 MPa

c Influence coefficient for concrete strength; The value is 1.0 as specified

in Article 6.3.1 of this specification

l Strength improvement coefficient of concrete under local compression

Al Local compression area of concrete

Al n Net area of concrete under local compression

Ab The base area for local compression calculation shall be determined in

accordance with Article 6.6.2 of this specification (please see figure below)
Then,

Ab 3.14  150  150

l = = =3
Al 3.14  50  50

and

1.35 c l f c Al n = 1.35 1 3 15  3.14 ( 50  50 − 10 10 ) = 457812 N = 457.8kN

As the design value of pulling force of a single embedded part system is 100
kN < 457.8 kN, it therefore meets the requirements.

9
 Specifications of Article 6.6.2 of the Code for Design of Concrete Structures
(GB50010-2010)

3.3 Check calculation for high-strength screws on tensile strength

D20 high-strength screws with a length of 300mm are adopted for this
calculation. The specifics of this calculation are in Section 2.5 of this document As
the force required until failure is 250 kN > 100 kN, it therefore meets the
requirements.

3.4 Check calculation for climbing cone

3.4.1 Check calculation for local pressure on concrete at climbing

cone

Similar to section 2.5.2. and the local pressure of concrete at the climbing cone
is calculated as the following:

1.35c l f c Al n = 1.35 1 3 15  3.14  29  29 = 160424 N = 160.4kN  100kN

It therefore meets the requirements.

3.4.2 Check calculation for climbing cone on shear force

As the climbing cone is made of 45# steel, the design value of shear strength
is 178 N/mm2. Calculating for the smallest shear section:

10
 V = 3.14  (19 19 − 10 10 ) 178 = 145878 N = 145.9kN

Because this value is greater than the shear force of a single embedded part –
70 kN, it therefore meets the requirements.
3.5 Check calculation for stress bolt

For the adopted M30 stress bolt, the effective area is 561 mm 2, and the
material is 35 CrMo. The design values for tensile and shear strengths are:

f = 500 N / mm 2 , fV = 310 N / mm 2

3.5.1 Stress bolt shear resistance

As the design value of shear force of a single embedment is V = 70kN, then,

V 70000
= = = 124.8 N / mm2  fV = 310 N / mm2
A 561

3.5.2 Stress bolt tensile strength

As the design value of tensile strength of a single embedment is F =100kN,

then,
F 100000
= = = 178.3N / mm2  f = 500 N / mm2
A 561

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 3.5.3 Combined shear and tension strength

     
2 2 2 2
 178.3   124.8 
  +  =   +  = 0.54  1
 500   310   500   310 
It therefore meets the requirements.

4 Calculation for inner steel formwork system

4.1 Check calculation for steel formwork

The short side of the inner cell is equipped with a steel form which is divided
into two units. The angle tie rods are connected, and the steel form is equipped with
a 6-mm panel. The formwork is equipped with a double-sided reinforcement plate of
8-mm thick. The maximum horizontal spacing is 340 mm, and the vertical spacing is
200 mm.

Layout of the inner steel formwork.

Design layout of the inner steel formwork.

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 4.1.1 Formwork panel strength check

Consider the formwork panel as a three span continuous beam supported on

the reinforcement plate, with a calculated width of b = 1000mm. The spacing
between the reinforcement plates is l = 200mm.

The line load acting on the panel is: q1 = qb = 78.4 1 = 78.4kN / m = 78.4 N / mm

Maximum bending moment of the panel:

M max = ql1 10 = (78.4x200x200)/10= 7.06x105 N-mm

2

1
Section modulus of the panel: W = bh 2 6 = 1000x62 = 6x103 mm3
6
Maximum stress on the panel:  = M max W = 7.06x105/6x103 = 117.7 N/mm2

< f m = 215 N/mm2

It therefore meets the requirements.

4.1.2 Deflection check

The standard loads adopted for the calculation of the deflection (without
considering vibration loads) are the following:

Line load： q2 = Fb = 56 1 = 56kN / m

Panel deflection：ω = ql4/(150EI) = 0.16mm

Permissible deflection of the formwork panel:
[ω] = 200/400 = 0.5 > 0.16mm
It therefore meets the requirements.
(Moment of inertia of the panel: I = bh3/12 = 1.8x104 mm4
E – Modulus of elasticity，Wood: 6.85x103 N/mm2, Steel: 2.1x105 N/mm2)

4.2 Calculation for rib plate

The double rib plate is supported on the tension screw as the main back rib,
and can be calculated as a continuous beam supported on the tension rods with a
span equal to 600mm.

13
 4.2.1 Strength check

Line load acting on the ribbed plate: q5 = ql2 = 78.4x1.1 = 86.24 kN/m

Maximum bending moment:

1
M max = q5 L23 = 0.1x86.24x6002 = 3.1x106 N-mm
10
Section modulus of the double ribbed plate: W = 1.3x2x104 = 2.6x104 mm3
Maximum stress: σ = M/W = 119 N/mm2
It therefore meets the requirements.
(Section modulus of the single-sided ribbed plate:
1
W = bh 2 6 = 8x1002 = 1.3x104 mm3)
6

4.2.2 Deflection check

The standard loads adopted for the calculation of the deflection (without
considering vibration loads) are the following:

The line load acting on the double ribbed plate is: q6 = Fl2 = 56x1.1 = 61.6kN / m

Deflection of the double ribbed plate:

ω = ql4/(150EI) = 0.19mm
Moment of inertia of the double ribbed plate:
I = 2xbh3/12 = 1.3x106 mm4
Allowable deflection of the double ribbed reinforcement plate:
[ω] = 600/400 = 1.5 > 0.19mm
It therefore meets the requirements.

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