DESIGN OF U TRAP RUTERN WALL

1.0 Design parameters:

Rail formation level = 51.2 m

Top of pile cap level = 45.1 m
Bottom of pile cap level = 43.3 m
Thickness of pile cap = 1.8 m
Width of return wall at top = 0.3 m
Width of return wall at bottom = 0.9 m
Distance between outer to outer face of return wall 7.85 m
Length of pile cap perpendicular to the traffic direction = 8.7 m
Length of pile cap along the traffic direction = 5.550 m

2.0 Sketches:
CL of track

Formation lvl.= 0.3 m

51.2 m
B= 3m
45º D= 1.525m

6.100 m
h1= 4.575m
Elevation

T.O.P.C.
45.1 m
0.9 m 1.8 m
B.O.P.C.
43.3 m

7.85 m

1.63 m

Plan

3.17 m 5.55 m

8.7 m
3.0 Dead load calculation:
3.1 Dead load of return wall
Thickness of return wall at top = 0.3 m
Thickness of return wall at bottom = 0.9 m
Height of return wall above pile cap = 6.1 m
Length of return wall = 5.55 m
3
Volume of one return wall = 20.313 m
Weight of one return wall = 50.783 T
Total weight from two return wall = 101.565 T

3.2 Dead load of pile cap

Length of pile cap in perpendicular to traffic direction = 8.7 m
Length of pile cap in traffic direction = 5.55 m
Thickness of pile cap = 1.8 m
3
Volume of pile cap = 86.913 m
Weight of pile cap = 217.283 T

4.0 Superimposed dead load calculation:

Dead load surcharge per meter length = 6.5 T/m
Total SIDL for 5.55 m length = 36.075 T

5.0 Vertical live load calculation:

Total EUDL(shear) for 5.55 m length = 91.79 T
Consider 350 mm balast cuhison
(Note : Please Refer Appendix XXIII(a) of IRS:Bridge Rules)

6.0 Vertical load due to earthfill:

Average length of earthfill perpendicular to the traffic direction = 6.65 m
Length of earthfill along the traffic direction = 5.55 m
Height of earthfill above pile cap = 6.1 m
3
Total volume of earthfill = 225.136 m
3
Consider unit weight of earthfill = 1.8 T/m
Total weight of earthfill = 405.244 T

7.0 Total vertical load at bottom of pile cap:

Total weight from two return wall = 101.565 T

Weight of pile cap = 217.283 T
SIDL = 36.075 T
EUDL = 91.790 T
Total weight of earthfill = 405.244 T
Total vertical load at B.O.P.C. = 851.957 T
 9.0 EARTH PRESSURE
9.1 ACTIVE EARTH PRTESSURE DUE TO BACKFILL
(Note : Please Refer CL. 5.7.1 Of IRS : Substructure & Foundation Code.)

φ = 30 ° = 0.524 radians
i = 0 ° = 0.000 radians
δ = 10.00 ° = 0.175 radians
α = 0 ° = 0.000 radians
γ = 1.8 T per cum

Co-efficient of active earth pressure

Ka = Cos2(φ-α)/[Cos2αCos(α+δ)[1+√((Sin(φ+δ)Sin(φ-i))/(Cos(α+δ)Cos(α-i)))]2]
Ka = 0.308
KaH= = 0.303

Earth pressure at base of return wall = KaγH

2
= 0.303x1.8x6.1 = 3.327 T/m
Total force on return wall due to active earth pressure =
= 0.5 x P a x H x L = 0.5x 3.327 x 6.1 x 5.55 = 56.318 T
Lever Arm w.r.t. Base of return wall = 6.1 / 3.0 = 2.033 m
Moment about Base of return wall = 56.318 x 2.033 = 114.494 T-m

9.2 ACTIVE EARTH PRESSURE DUE TO SURCHARGE EFFECT

Dead Load Surcharge = V = 6.5 T/m

Live Load Surchage = S = 13.7 T/m
Surcharge Width at Formation Level = B = 3m

P1 = (S + V)h1 x Ka/(B + 2D) = ((13.7+6.5) x4.575 x 0.303) / (3 + 2 x1.525)

= 4.628 T/m
Total force on return wall due to surcharge effect = 4.628 x 5.55 = 25.685 T
Lever Arm w.r.t. Base of return wall = 4.575 / 2 = 2.288 m
Moment about Base of return wall = 25.685 x 2.2875 = 58.754 T/m

10.0 SEISMIC FORCE

(Note : Please refer RDSO guideline on seismic design of railway bridge)
Seismic Zone = V Z= 0.36
Importance Factor (I) = 1.5 Z/2R = 0.06
R= 3 Sa/g = 2.5

Design Horizontal Seismic Coefficient αh = 0.06 x 1.5 x 2.5 = 0.225

Design Vertical Seismic Coefficient αv = 2/3 x αh = 2/3 x 0.225 = 0.150

Total vertical load except pile cap = = 634.675 T

Horizontal seismic force for structure without pile cap= = 142.802 T
Lever arm from B.O.P.C = (6.1/2+1.8) = 4.85 m
Vertical load from pile cap = 217.283 T
Horizontal seismic force for pile cap= = 48.889 T
Lever arm for seismic force due to pile cap from B.O.P.C = 0.9 m
Total horizontal seismic force = = 191.690 T
Moment about B.O.P.C. = = 736.588 T-m
Total vertical seismic force = = 127.794 T

Summary of loads :

At base of return wall

Horizontal force = = 82.003 T
Moment at base of return wall = = 173.248 T-m

At bottom of pile cap

Total vertical load except seismic load = = 634.675 T
Total vertical seismic load = = 127.794 T
Total horizontal seismic load = = 191.69 T
Total moment due to seismic force = = 736.588 T-m
Design of Pile Foundation :-

8.7 m

3.6 m

1.63 m

P2 P1

3.17 m 5.55 m Traffic direction

P5 P4 P3

3.6 m

Note : Longitudinal direction = Parallal to track

Transverse direction = Perpendicular to track

[A] Salient Dimensions

a) Length of Pile Cap along Longitudinal Direction = 5.550 m

b) Length of Pile Cap along Transverse Direction = 8.70 m
c) Thickness of Pile Cap = 1.800 m
d) Diameter of Pile = 1.200 m
e) Total No. of Piles in the Pile Cap = 5 nos

[B] Salient Levels

a) Top of Pile Cap = 45.100 m
b) Pile Cut Off Level = 43.375 m
c) Bottom of Pile Cap = 43.300 m
d) Level at Depth of Fixity = 35.010 m
e) Founding Level = 16.500 m

[C] Other Salient Design Data

a) Total Length of Pile (from below Pile Cap) = 26.8 m
b) RL at Depth of Fixity Level = 35.010 m
c) Unit weight of Concrete = 2.5 T/m3
 Pile no. Long. Trans.
co-ord. co-ord.
xL(m) xT(m) N xL2 xT2
P1 1.145 1.800 1 1.31 3.24
P2 1.145 -1.800 1 1.31 3.24
P3 2.025 3.600 1 4.10 12.96
P4 2.025 0.000 1 4.10 0.00
P5 2.025 -3.600 1 4.10 12.96
Total ∑ 5 14.92 32.40

ZL1 = 13.03 m3 ZL2 = 7.370 m3

ZT1 = 18.00 m3 ZT2 = 9 m3

For P1 = P/N+ML/ZL1+MT/ZT1
P2 = P/N-ML/ZL1-MT/ZT1
P3 = P/N-ML/ZL2-MT/ZT2
P4 = P/N-ML/ZL2
P5 = P/N-ML/ZL2-MT/ZT2

Horizontal Load on Single Pile HR = (SQRT (HL^2 + HT^2 ))/ ∑N

Working Load condition :

All loads are in Ton
Load case : V ML MT HL HT
Case-I 1. Non seismic case : 634.675 0 0 0 0
Case-II 2.Transverse seismic 506.881 0 736.588 0 191.69
vertical seismic upward
Case-III 3. Transverse seismic 762.469 0 736.588 0 191.69
vertical seismic downward

WORKING LOAD CONDITION

Pile no. Load Cases

Case-I Case-II Case-III
P1 126.94 142.30 193.42
P2 126.94 60.46 111.57
P3 126.94 183.22 234.34
P4 126.94 101.38 152.49
P5 126.94 19.53 70.65
Max. 172.40 192.04 232.93 Adding Self Weight of Pile
Min. 172.40 61.09 101.99
HR (T) 0.00 38.34 38.34

Maximum design pile Capacity on Pile = 232.93 T

Maximum horizontal pile capacity = 38.34 T
Ultimate Limit State :
All loads are in Ton
Load case : V ML MT HL HT
Case-I 1. Non seismic case : 1137.897 0 0 0 0
Case-II 2.Transverse seismic 851.770 0 883.906 0 230.028
vertical seismic upward
Case-III 3. Transverse seismic 1158.475 0 883.906 0 230.028
vertical seismic downward

ULTIMATE LOAD CONDITION

Pile no. Load Cases

Case-I Case-II Case-III
P1 227.58 219.46 280.80
P2 227.58 121.25 182.59
P3 227.58 268.57 329.91
P4 227.58 170.35 231.70
P5 227.58 72.14 133.48
Max. 273.04 314.03 375.37 Adding Self Weight of Pile
Min. 273.04 117.61 178.95
HR (T) 0.000 46.006 46.006

Pmax = 375.37 T
Corresponding Horizontal load = = 46.006 T
Pmin = 117.61 T
Corresponding Horizontal load = = 46.006 T

DESIGN OF RCC PILE

The Pile is designed as per the "Charts for the Design of Circular columns" to SP:16.
(A) Material Property
Grade of Concrete ( fck ) = 35 MPa
Grade of Reinforcement ( fy ) = 500 MPa

(B)Section Property
Diameter of Pile Section (D) = 1200 mm
Clear cover = 75 mm
Diameter of Outer Links = 12 mm
Diameter of main vertical Reinforcement = 25 mm
After multiplication of reduction factor with fixed head pile and free head pile , semi fix head
pile capacity moment is calculated
Moment per tonne Horizontal load = 3.36 t-m/m
Effective Cover (d') = (75 + 12 + 25 / 2) = 99.5 mm
d'/D = 99.5 / 1200 = 0.083 mm

(C) Critical Load Case 1 (Minimum load case)

Axial Load Pu(minimum load) = 117.61 T
Moment Mu = 46.006 x 3.36 = 154.58 T-m
2
Pu /fck D = 0.023
Mu / fck D3 = 0.026

From Chart- 60 of SP: 16 - 1980, which corresponds to Fe - 500 grade of Reinforcement

p/fck = 0.015
p = 0.525 %
Therefore; Asc = ( π / 4 x 1200^2x0.525%) = 5937.610 mm2
(D) Critical Load Case 2 (Maximum load case)
Axial Load Pu = 375.37 T
Moment Mu = 46.006 x 3.36 = 154.58 T-m
2
Pu /fck D = 0.074
Mu / fck D3 = 0.026

From Chart- 60 of SP: 16 - 1980, which corresponds to Fe - 500 grade of Reinforcement

p/fck = 0.01
p = 0.35 %
Therefore; Asc = ( π / 4 x 1200^2x0.35%) = 3958.407 mm2

(E) Reinforcement Computation

[Refer Cl: 5.11.1 of IS: 2911 Part 1 Sec 2 ]
Minimum % of Reinforcement in a Circular Section = 0.40 %
( π / 4 x 1200^2x0.4%) = 4523.9 mm2
Design Reinforcement = 5937.6 mm2

Let us provide
In Layer - I 20 nos. 25 mm diameter bars as Main Reinforcement
Provide T- 12 @ 150 mm c/c as Lateral Ties

(F) Check for Reinforcement Percentage

Gross Concrete Area Ac = 1.131 m2
Total Reinforcement Area As = 0.010 m2

Reqd. R/F (%) Actual R/F (%) Remarks

0.52 0.88 OK
Design of Pile Cap :-

Transverse direction
8.7 m
3.6 m
A B

1.63
P2 P1

3.17 5.55 Traffic direction/

Longitudinal direction

P5 P4 P3

A B
0.9 m 3.6 m
7.85 m

6.1 m

A B

1.8 m

A B
1.225 1.8 1.8 1.225
P5 P2 P4 P1 P3

Thickness of pile cap = = 1.8 m

Height of earthfill upto formation level = 6.1 m
Width of return wall at top = = 0.3 m
Width of return wall at bottom = = 0.9 m
Length of return wall = = 5.55 m
Distance between outer to outer face of return wall = 7.85 m
Distance between inner to inner face of return wall = 6.05 m
Diameter of pile = = 1.2 m
Grade of Concrete = = M 35
Grade of Steel = = Fe 500
Unit weight of earthfill = = 1.8 T
Summary of Pile Reactions (in T) [ULS Condition] : Case-III is Critical
Pile no. Pile Reaction
P1 280.80
P2 182.59
P3 329.91
P4 231.70
P5 133.48

Computation for Moment

Transverse Moments at Face of Return wall stem (Section A-A)
(Note : Consider fixed end support at return wall stem and pile cap junction)
Moment from Pile Reactions (P1,P2,P4) = Pab 2/L2
= (280.801 x 4.825 x 1.225^2 /6.05^2) + (182.589x1.225x4.825^2/6.05^2)
+(231.695x3.025x3.025^2/6.05^2) = 373.030 T-m

Balancing Moment from backfill soil in ULS Condition = wL2/12

Weight of soil fill per meter width (w) = 6.1x5.55x1.8x1.25 = 76.174 T
Hence balancing moment = 76.174x6.05^2/12 = 232.347 T-m

Design Bending Moment (BMA-A) = 140.683 T-m

Hence, Design moment per meter width of pile cap = 25.348 T-m

Overall depth of pile cap = = 1.8 m

Clear cover = = 75 mm
Effective depth of pile cap (d)= 1800 - 75 -12.5
= 1712.5 mm
Lever Arm (z) = 0.95 x d
= 1626.88 mm

Moment of resistance Mr = 0.15 x fck x b x d2

= 0.15 x 35 x 1000 x 1712.5^2/10^7
= 1539.64 T-m Hence Ok

Moment of resistance due to steel = Mr = 0.87 x fy x z

Reinforcement required = 25.348 x 10^7) / (0.87 x 500 x 1626.88)
2
= 358.178 mm

As per Cl: 15.9.4.1 of IRS Concrete Bridge Code;

Minimum reinforcement required = 0.20% of bd
2
= 3425 mm

Hence Allow minimum reinforcement

Dia of Reinforcement provided = 25 mm

Spacing of reinforcement provided = 125 mm
2
Ast Provided = 3927 mm
Ast Provided > Ast Required Hence Ok
Provide 25 mm tor bar @ 125 mm c/c in both face along transverse direction of pile cap
Distribution Steel:
Minimum area of secondary reinforcement :-
As per Cl: 15.9.4.2 of IRS Concrete Bridge Code; = 0.12% of bd
2
= 2055 mm
Dia of Reinforcement provided = 20 mm
Spacing of reinforcement provided = 125 mm
2
Ast Provided = 2513 mm
Ast Provided > Ast Required Hence Ok
Provide 20 mm tor bar @ 125 mm c/c in both face along longitudinal direction of pile cap

Check for Shear:

Checking of Shear force has been done at "d" distance from the face of the return wall
So available length of pile cap beyond "d" distance = 6050-1712.5
= 4337.5 mm
= 4.3375 m
`
Total shear force due to upward pile reaction (P1,P2,P4)
280.801+182.589+231.695 = 695.09 T
Balancing shear due to backfill soil
4.3375x5.55x6.1x1.8 x 1.25 = 330.40 T
So Design Shear Force = 364.68 T
Shear Stress (τv) = Vu / bd
2
= 0.38 N/mm
Now, 0.75 x sqrt( fck) = 4.44 Mpa

Now 100 As/ bd = 100 x 3927 / ( 1000 x 1712.5)

= 0.23 %
Now As per table 15 of IRS CBC
τc = 0.37+ {(0.44-0.37)/(0.25-0.15)}*(0.23-0.15)
= 0.43 Mpa
Now As per table 16 of IRS CBC
s= Max ( (500 /1712.5)^0.25, 0.7)
= 0.735

Therefore Allowable shear stress (sτc) = 0.316 Mpa

(As per Cl. No. 15.8.3.2 of IRS- CBC)

Shear Capacity at the critical section =

= 0.316 x 1712.5 x 5.55 /10
= 300.34 < 364.68 T
Hence Shear reinforcement Required
Now in this case τv > s τc So as per table no 14 of IRS CBC

Asv = bsv (τ + 0.4- s τc)/(0.87 fyv)

Now Consider,
sv = 125 mm d= 1712.5 mm
b= 5550 mm τv = 364.68 T
fyv= 415 Mpa s τc = 300.34 T
 So, Asv = 125 x (364.681+ 0.4 - 300.34)x 10^4 /( 0.87 x415 x 1712.5)
2
= 130.885 mm

So Asv required per meter width of pile cap = 130.885 / 5.55

2
= 23.583 mm

Provided dia of bar= 10 mm @ 125 mm c/c in longitudinal direction

Asv provided = 0.7854 x 10^ 2 x 1000 /125

2 2
= 628.319 mm > 23.583 mm
Hence Ok
Provided dia of bar= 10 mm @ 375 mm c/c in Transverse direction
Design of Return wall Stem :-

Bending Moment at the base of Return wall = = 173.248 T-m

Factored Design Moment at the Section = = 294.522 T-m
Total length of return wall = = 5.550 m
Design moment per meter length of return wall = = 53.067 T-m/m

Thickness of return wall at the junction of pile cap = = 900 mm

Clear cover = = 75 mm
Effective depth of return wall stem = = 815 mm
Lever Arm(z) = 0.95 d = = 774.25 mm
Grade of Concrete = M 35
Grade of Steel = Fe 500

Moment of resistance Mr = 0.15 x fck x b x d2

= 0.15 x 35 x 1000 x 815^2/10^7
= 348.718 T-m Hence Ok

Check for Reinforcement:

Moment of resistance due to steel = Mr = 0.87 x fy x z

Reinforcement Required (Ast) = 53.067 x 10^7 /(0.87 x 500 x 774.25)
2
1575.629 mm

Minimum area of main reinforcement :- = 0.20% of bd

2
(As per Cl: 15.9.4.1 of IRS Concrete Bridge Code) = 1630 mm

Provide Reinforcement of diameter = = 20 mm

Spacing of reinforcement = = 150 mm
2
Area of steel provided per meter length of stem = = 2094.395 mm
Hence Ok

Distribution Steel:
Minimum area of secondary reinforcement :-
As per Cl: 15.9.4.2 of IRS Concrete Bridge Code; = 0.12% of bd
2
= 978 mm
Dia of Reinforcement provided = 16
Spacing of reinforcement provided = 150
2
Ast Provided = 1340 mm
Ast Provided > Ast Required Hence Ok

Check for Shear:

Total shear force acting on return wall stem = = 82.003 T

Factored design shear force acting at the section = = 139.405 T
Design shear force per meter length of wall = = 25.118 T/m
 Shear Stress (τv) = 25.118/(1 x 0.815)
2
= 30.82 T/m
= 0.308 Mpa
Now 100 As/ bd = 100 x 2094.395 / (1000 x815)
= 0.271 %
Now As per table 15 of IRS CBC
τc = 0.44+ {(0.56-0.44)/(0.50-0.25)}*(0.50-0.271)
= 0.55 Mpa
Now As per table 16 of IRS CBC
s= Max ( (500 /815)^0.25, 0.7)
= 0.885
Therefore Allowable shear stress (sτc) 0.885
= x 0.55
(As per Cl. No. 15.8.3.2 of IRS- CBC) = 0.487
In This case τv<sτc Hence Ok