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L&T-RAMBØLL

CONSULTING ENGINEERS LIMITED


Client:
Simhapuri Expressway Limited
KMC – BSCPL (Consortium), Banjara Hills, Hyderabad.
Project: Project No.:
Six Laning of Chilkaluripet – Nellore
Section of NH–5. C1102703
Title:
Design of Box Culverts for Type 1 Cross Document No.: Rev.:
Section DN001 0
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Notes:

1.

Revision Details:

0 08.02.11 First Submission LDV KKD KGN


Init. Sign. Init. Sign. Init. Sign.
Rev. Date Details
Prepared Checked Approved
Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

TABLE OF CONTENTS

1 Introduction .....................................................................................................................................1
1.1 Structural Arrangement .............................................................................................................1
2 Design Basis ...................................................................................................................................1
2.1 Loads ........................................................................................................................................1
2.1.1 Dead Load ......................................................................................................................1
2.1.2 Super Imposed Dead Load .............................................................................................2
2.1.3 Live Load ........................................................................................................................2
2.1.4 Braking forces .................................................................................................................2
2.1.5 Earth Pressure ................................................................................................................2
2.1.6 Seismic Forces ...............................................................................................................2
2.1.7 Live Load Surcharge.......................................................................................................2
2.2 Load Combinations ...................................................................................................................2
2.3 Materials....................................................................................................................................3
2.3.1 Concrete .........................................................................................................................3
2.3.2 Steel ................................................................................................................................3
2.3.3 Cover ..............................................................................................................................3
2.3.4 Wearing Coat ..................................................................................................................3
2.3.5 Soil ..................................................................................................................................3
3 Analysis and Design.......................................................................................................................3

4 Design of 2.0x2.0m Box Culvert ....................................................................................................4


4.1 Design Inputs ............................................................................................................................4
4.2 General Diagram with Loading ................................................................................................4
4.3 Idealised Structure of Box Culvert for STAAD Analysis ...........................................................5
4.4 Load Calculation ......................................................................................................................5
4.5 Braking Load. .........................................................................................................................11
4.6 Structural Design ...................................................................................................................11
4.7 STAAD Input file ....................................................................................................................14
5 Design of 2.0x2.5m Box Culvert ................................................................................................. 18
5.1 Design Inputs ......................................................................................................................... 18
5.2 General Diagram with Loading ..............................................................................................18
5.3 Idealised Structure of Box Culvert for STAAD Analysis ........................................................ 19
5.4 Load Calculation ....................................................................................................................19
5.5 Braking Load. .........................................................................................................................25
5.6 Structural Design ...................................................................................................................25
5.7 STAAD Input file ....................................................................................................................28
6 Design of 2.0x3.0m Box Culvert ................................................................................................. 32
6.1 Design Inputs ......................................................................................................................... 32
6.2 General Diagram with Loading ..............................................................................................32
6.3 Idealised Structure of Box Culvert for STAAD Analysis ........................................................ 33
6.4 Load Calculation ....................................................................................................................33
6.5 Braking Load. .........................................................................................................................39
6.6 Structural Design ...................................................................................................................39
6.7 STAAD Input file ....................................................................................................................42
7 Design of 3.0x3.0m Box Culvert ................................................................................................. 46
7.1 Design Inputs ......................................................................................................................... 46
7.2 General Diagram with Loading ..............................................................................................46
7.3 Idealised Structure of Box Culvert for STAAD Analysis ........................................................ 47
7.4 Load Calculation ....................................................................................................................47
7.5 Braking Load. .........................................................................................................................53
7.6 Structural Design ................................................................................................................... 53
7.7 STAAD Input file .................................................................................................................... 56

Table of Contents
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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

8 Design of 4.0x2.0m Box Culvert ................................................................................................. 60


8.1 Design Inputs ......................................................................................................................... 60
8.2 General Diagram with Loading ..............................................................................................60
8.3 Idealised Structure of Box Culvert for STAAD Analysis ........................................................ 61
8.4 Load Calculation ....................................................................................................................61
8.5 Braking Load. .........................................................................................................................67
8.6 Structural Design ................................................................................................................... 67
8.7 STAAD Input file .................................................................................................................... 70
9 Design of 4.0x2.5m Box Culvert ................................................................................................. 74
9.1 Design Inputs ......................................................................................................................... 74
9.2 General Diagram with Loading ..............................................................................................74
9.3 Idealised Structure of Box Culvert for STAAD Analysis ........................................................ 75
9.4 Load Calculation ....................................................................................................................75
9.5 Braking Load. .........................................................................................................................81
9.6 Structural Design ................................................................................................................... 81
9.7 STAAD Input file .................................................................................................................... 84
10 Design of 4.0x3.0m Box Culvert ................................................................................................. 88
10.1 Design Inputs ........................................................................................................................ 88
10.2 General Diagram with Loadin . ..............................................................................................88
10.3 Idealised Structure of Box Culvert for STAAD Analysis ....................................................... 89
10.4 Load Calculation . ..................................................................................................................89
10.5 Braking Load.. .......................................................................................................................95
10.6 Structural Design .................................................................................................................. 95
10.7 STAAD Input file ................................................................................................................... 98
11 Design of 5.0x3.0m Box Culvert ............................................................................................... 102
11.1 Design Inputs ...................................................................................................................... 102
11.2 General Diagram with Loadin .............................................................................................102
11.3 Idealised Structure of Box Culvert for STAAD Analysis ..................................................... 103
11.4 Load Calculation .................................................................................................................103
11.5 Braking Load. ......................................................................................................................109
11.6 Structural Design ................................................................................................................ 109
11.7 STAAD Input file ................................................................................................................. 112
12 Design of 6.0x2.0m Box Culvert ............................................................................................... 116
12.1 Design Inputs ...................................................................................................................... 116
12.2 General Diagram with Loadin .............................................................................................116
12.3 Idealised Structure of Box Culvert for STAAD Analysis ..................................................... 117
12.4 Load Calculation .................................................................................................................117
12.5 Braking Load. ......................................................................................................................123
12.6 Structural Design ................................................................................................................ 123
12.7 STAAD Input file ................................................................................................................. 126
13 Design of 6.0x2.5m Box Culvert ............................................................................................... 130
13.1 Design Inputs ...................................................................................................................... 130
13.2 General Diagram with Loadin .............................................................................................130
13.3 Idealised Structure of Box Culvert for STAAD Analysis ..................................................... 131
13.4 Load Calculation .................................................................................................................131
13.5 Braking Load. ......................................................................................................................137
13.6 Structural Design ................................................................................................................ 137
13.7 STAAD Input file ................................................................................................................. 140
14 Design of 6.0x3.0m Box Culvert ............................................................................................... 144
14.1 Design Inputs ...................................................................................................................... 144
14.2 General Diagram with Loadin .............................................................................................144
14.3 Idealised Structure of Box Culvert for STAAD Analysis ..................................................... 145
14.4 Load Calculation .................................................................................................................145
14.5 Braking Load. ......................................................................................................................151

Table of Contents
Page ii
Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

14.6 Structural Design ................................................................................................................ 151


14.7 STAAD Input file ................................................................................................................. 154
15 Design of 6.0x3.5m Box Culvert ............................................................................................... 158
15.1 Design Inputs ...................................................................................................................... 158
15.2 General Diagram with Loadin .............................................................................................158
15.3 Idealised Structure of Box Culvert for STAAD Analysis ..................................................... 159
15.4 Load Calculation .................................................................................................................159
15.5 Braking Load. ......................................................................................................................165
15.6 Structural Design ................................................................................................................ 165
15.7 STAAD Input file ................................................................................................................. 168
16 Design of 6.0x4.0m Box Culvert ............................................................................................... 172
16.1 Design Inputs ...................................................................................................................... 172
16.2 General Diagram with Loadin .............................................................................................172
16.3 Idealised Structure of Box Culvert for STAAD Analysis ..................................................... 173
16.4 Load Calculation .................................................................................................................173
16.5 Braking Load. ......................................................................................................................179
16.6 Structural Design ................................................................................................................ 179
16.7 STAAD Input file ................................................................................................................. 182

LIST OF TABLES
Table 1-1: Size of Box Culverts ................................................................................................................1

Table of Contents
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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

1 Introduction
The Government of India through Ministry of Shipping, Road Transportation and Road
Highway is augmenting the existing road to six-lane road in Chilkaluripet - Nellore section of
NH5 in the state of Andhra Pradesh, to enhance the capacity and safety for efficient
transhipment of goods and passengers. The design note presents the analysis and design of
precast single cell Box Culverts for Type-1 cross section with a widening width of 5.75m. The
sizes of box culverts designed are given in Table 1.1.

Table 1-1: Size of Box Culverts

Sl. No. Span (m) Clear Height (m)

1 2.0 2.0
2 2.0 2.5
3 2.0 3.0
4 3.0 3.0
5 4.0 2.0
6 4.0 2.5
7 4.0 3.0
8 5.0 3.0
9 6.0 2.0
10 6.0 2.5
11 6.0 3.0
12 6.0 3.5
13 6.0 4.0

1.1 Structural Arrangement


The Box Culvert consists of top slab, bottom slab and side walls. The panel width of all boxes
is taken as 1.0m. The top of the bottom slabs are flushed with the existing Culvert level.

2 Design Basis

2.1 Loads
Loads are considered as per IRC: 6-2010. The various loads considered are described
below.

2.1.1 Dead Load

Dead load is calculated according to their unit weights as mentioned in Section 2.3. It
consists of various components of the Box.

1 Introduction
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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

2.1.2 Super Imposed Dead Load

The super-imposed dead load consists of 65mm thick wearing coat, fill above top slab and
crash barrier. The density of wearing coat and fill is considered as per Section 2.3. The
maximum fill above top slab is taken as 300mm.

2.1.3 Live Load

As per IRC 6-2010, Class 70R Tracked, Class 70R Wheeled (Boggie load) and Class A train
of vehicles are considered. The distribution of live load is considered along and across the
traffic direction. Braking force is taken for vehicular type giving maximum intensity of live
load. As per Clause 208 of IRC: 6-2010, the impact factor is calculated and considered in the
analysis.

2.1.4 Braking forces

20% of live load is taken as braking force and applied at top of the box as part of live load.

2.1.5 Earth Pressure

Earth pressure at rest has been considered for analysis as the box structure is rigid. The
angle of internal friction of the fill (φ) is considered as 30 degrees. The co-efficient of earth
pressure works out to (1-sin φ) = 0.50.

2.1.6 Seismic Forces

As per Clause 219 of IRC: 6-2010, as the span is less than 10m, these forces are not
considered in the analysis.

2.1.7 Live Load Surcharge

As per Clause 214.1 of IRC: 6-2010, lateral pressure due to live load surcharge equivalent to
1.2m earth fill is considered for analysis. The lateral pressure is calculated as k0 times the
intensity of pressure and applied in the direction of earth pressure.

2.2 Load Combinations


The loads that act on the Box are Dead Load (DL), Super Imposed Dead Load (SIDL), Earth
Pressure (EP), Live Load (LL) and Live Load Surcharge on left and right simultaneously. The
load combinations considered are as below.

LC1 - DL+SIDL+EP+SSL Left

LC2 - DL+SIDL+EP+SSL Left+70R Tracked Load

LC3 - DL+SIDL+EP+SSL Left+70R Boggie Load

LC4 - DL+SIDL+EP+SSL Left+Class A

LC5 - DL+SIDL+EP+SSL Left+Vehicle Load+Braking Load

2 Design Basis
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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

LC6 - 0.2DL+0.3(Vehicle Load+Braking Load)

Load combination 6 is considered for obtaining the moments to cater for the transverse
reinforcement as per Clause 305.18 of IRC 21-2000.

2.3 Materials

2.3.1 Concrete

Grade of concrete used is M30. The unit weight of concrete is taken as 25kN/m3.

2.3.2 Steel

The grade of steel used is Fe 500.

2.3.3 Cover

As per Clause 304.3 of IRC 21-2000, the clear cover to reinforcement is as below.

For Top slab and side walls = 40mm

For bottom slab = 75mm

2.3.4 Wearing Coat

The unit weight of wearing coat is taken as 22kN/m3.

2.3.5 Soil

The unit weight of soil is considered as 20kN/m3. The safe bearing capacity of soil is
assumed as 150kN/m2.

3 Analysis and Design


The analysis is done using STAAD Pro. A width of 1.0m is considered for the analysis. The
structure is modelled as straight box for analysis purpose. The box section is assumed as
resting on soil springs. The sub grade modulus for the soil is calculated as 15000kN/m3. The
spring constant is calculated and applied accordingly. The box is modelled as below:

The top slab, stems and bottom slab are modelled at the C.G of the deck slab, stems and
CG of the bottom slab respectively. Unit width of the slab and stem is considered for the
estimation of section properties. The forces due to dead load, superimposed dead load,
lateral earth pressure, live load surcharge from sides are estimated and applied on the
model. For live load 70R tracked 70R boggie and Class A loads are calculated and applied
as live load for the model.

The earth pressure from C.L of top slab to top of top slab is applied as a concentrated load.
The LL surcharge is uniform throughout the height of the structure. The pressure due to LL
surcharge from C.L of top slab to top of top slab and from C.L of bottom slab and bottom of
bottom slab are counter balanced each other. Hence it is not considered.

3 Analysis and Design


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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

4 Design of 2.0 x 2.0m Box Culvert


4.1 Design Inputs

0.3

2.0
0.3

0.3

2.3

Clear Span = 2.0 m


Clear Height = 2.0 m
Top Slab Thickness = 0.3 m
Bottom Slab Thickness = 0.3 m
Side Wall Thickness = 0.3 m
Height of Fill = 0.3 m
Thickness of Wearing Coat = 0.065 m

Panel width = 1.0 m


Width of Carriage Way = 5.75 m

Angle of internal friction φ = 30 Degrees


Coefficient of Earth Pressure at Rest = 0.5
Dry Density of Fill above Top Slab = 20 kN/m3
Concrete Density = 25 kN/m3
Surcharge Live Load = 1.2 m
SBC Value Assumed = 150.0 kN/m2

4.2 General Diagram with Loading

Fill 0.3
(All dimensions in m)

0.3

Haunch (0.15x0.15)

2.0

0.3

0.3 2.0 0.3

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Total Span = 2.6 m


Total Height = 2.6 m
C/C Span = 2.3 m
C/C Height = 2.3 m

4.3 Idealised Structure of Box Culvert for STAAD Analysis


The Structure is Idealised in STAAD. Pro as shown below. The dimensions are considered as centre to centre.
The structural analysis has been done for one metre strip.
2.3 m

2.3 m

A
B D B A

Spacing Between 2 End Springs = 0.369 m


Spacing between 2 int springs = 0.781 m
Spacing between 2 end nodes of Side Wall at top = 0.150 m
Spacing between 2 end nodes of Side Wall at bottom = 0.150 m
Spacing between 2 int. nodes of Side wall = 0.5 m
Modulus of Subgrade reaction = 15000 kN/m3
Spring constants at end supports =15000x(0.369/2) = 2768 kN/m
Spring constant at Intermediate supports for the Box =15000x(0.369+0.781)/2 = 8625 kN/m
Spring constant at Int.Supports =15000x(0.781+0.781)/2) = 11715 kN/m
(Ref:pg:408,Foundation Analysis and Design by joseph E.Bowles (Fs=40*s.f*qa) and s.f = 2.5)

4.4 Load Calculation


4.4.1 Dead Load
Self Weight of Tob Slab = 0.3x1x25 = 7.50 kN/m
Self Weight of Bottom Slab = 0.3x1x25 = 7.50 kN/m
Self Weight of side Walls = 0.3x1x25 = 7.50 kN/m
Weight of Haunch = 0.15×0.15×0.5×2.5 = 0.28 kN

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

4.4.2 SIDL
Load due to Wearing Coat = 0.065x1x2.2 = 1.43 kN/m
Load due to Earth Fill = 0.3x1x20 = 6.00 kN/m
Weight of Crash Barrier = 0.3x2.5 = 7.50 kN/m
TOTAL = 14.93 kN/m
Total Base Area =2.6×1 = 2.60 m2
Total Average Bottom Pressure =(14.93+7.50+7.50+7.50+0.28+( 73.14×2.30))/2.60 = 79.21 kN/m2
Less than SBC So, Safe
4.4.3 Computation of Earth Pressure
SIDE A SIDE B

0.5*20*0.45 = 4.50 kN/m2 0.5 m


0.5*20*0.6 = 6.00 kN/m2 0.6 m
1.1 m
2
0.5*20*1.100 = 11.00 kN/m

1.6 m
0.5*20*1.600 = 16.00 kN/m2
2.1 m
0.5*20*2.100 = 21.00 kN/m2

2.6 m
0.5*20*2.600 = 26.00 kN/m2
0.5*20*2.750 = 27.50 kN/m2 2.8 m

4.4.4 Surcharge Live Load


Lateral Pressure due to Surcharge Live Load Equivalent to 1.2 m of Earth Fill = 12.00 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

4.4.5 Live Load


Case 1: When Class 70R Tracked Vehicle is Placed at the centre of the Slab
(65mm Wearing Coat Considered)
Direction of Traffic
Total Load

17.61 T
0.85

35 T 35 T

4.57 2.30

2.05

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 2.500 m
a = 2.3/2 1.150 m
b1 =0.85+0.065 0.915 m
α 3
beff α x a (1- a/lo) + b1
beff = 3x1.15x(1-1.15/2.3)+0.915 2.64 m Overlapping
Effective Width across traffic 3.80 m
Effective width less than widening width. So OK.
Width along the Span = 4.57+2×(0.065+0.300) 5.30 m
Effective width greater than c/c span
So width along the Span for Design 2.30 m
Load considered = 35/4.57×2.30 35.23 T
2
Load Intensity = 35.23/(2.3×3.80) 4.04 T/m
Impact factor = 25% 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 4.036x1.25 5.045 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 2 : When Class 70R Bogie Load (40T) is Placed at the centre of Slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.86

0.263

10 T 10 T

2.30 1.22

10 T 10 T

1.93

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.75 m


Calculation for Effective Width of Loading = b/ l0 0.43 m
a = 2.3/2-1.22/2 0.54 m
b1 =0.86+0.065 0.93 m
α 3
beff α x a (1- a/lo) + b1
beff = 30x0.54x(1-0.54/2.3)+0.925 2.16 m Overlapping
So effective Width across for Design 3.44 m
Effective width less than widening width. So OK.
Width along the Span = 0.263+2×(0.300+0.065) 0.993 No Overlapping
Effective width along Span 0.99 m
Effective width less than c/c span
So effective Width along span for Design 0.99 m
Load considered 20 T
Load Intensity = 20/(3.44×0.993) 5.85 T/m2
Impact factor 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 5.851x1.25 7.314 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 3 : When Class A (5.7 x 2 T) is Placed at the centre of slab


(65mm Wearing Coat Considered)

Direction of Traffic

5.7 T 1.8 5.7 T

0.25

2.30 0.5

1.2

5.7 T 5.7 T

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.435 m
a = 2.3/2-1.2/2 0.550 m
b1 0.57 m
α 3
beff α x a (1- a/lo) + b1
beff = 3x0.55x(1-0.55/2.3)+0.565 1.82 m Overlapping
Effective Width across for Design = 1.2+0.5+0.5/2+1.8+1.82/2 2.96 m
Effective width less than widening width. So OK.
Width along the Span = 0.25+(2×(0.300+0.065)) 0.98 m No Overlapping
Effective width along Span 0.98 m
Effective width less than c/c span
So effective Width along span for Design 0.98 m
Load considered 11.4 T
Load Intensity = 11.4/(2.96×0.980) 3.93 T/m2
Impact factor 50.00 %
Deduction in the I.F No deduction for fill < 0.6m 1.00
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 50x1 50.00 %

Increasing due to Impact (As per IRC-6-2000, Cl:211.6


= 3.93x1.5 5.90 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 4 : When two Class A (5.7 x 2T) is Placed at the centre of slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.5 0.5

0.25

1.2 2.30

1.8 1 1.8

5.7 T 5.7 T 5.7 T 5.7 T


Class A Wheeled Vehicle Class A Wheeled Vehicle

1.82 m 1.82 m 1.82 m 1.82 m

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 2.50 m
a =0.5×(2.30-1.2) 0.550 m
b1 0.565 m
α 3
beff α x a (1- a/lo) + b1
beff = 3x0.55x(1-0.55/2.3)+0.565 1.82 m Overlapping
Effective Width across for Design 5.76 m
Effective width greater than widening width. So beff for design is 5.75 m
Width along the Span =0.25+2×(0.300+0.065) 0.98 m No Overlapping
Effective width along Span 0.98 m
Effective width less than c/c span
So effective Width along span for Design 0.98 m
Load considered 22.8 T
Load Intensity = 22.8/(5.76×0.980) 4.04 T/m2
Impact factor 50.00 %
Increasing due to Impact (As per IRC-6-2000,
= 4.039x1.5 6.06 T/m2
Cl:211.6)
So design intensity = 73.14 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

4.5 Braking Load


Total Horizontal Load on top of the box =0.2×(10+10+10+10)×10 = 80.00 kN
Horizontal load per m width of the structure =80.00/5.75 = 13.91 kN/m

4.6 Structural Design


4.6.1 Summary of Moments (From STAAD Pro)
Design Moments (kNm)
Load Combinations Top Slab Bottom Slab Side Walls
Sagging Hogging Sagging Hogging Outer Inner
Maximum Moment 38 24 42 29 36 8
0.2 D.L+0.3 L.L 11 4 11 4 8 0

Design Bending Moments (kNm)


24.0 24.0
36.0 38.0 36.0

8.0 8.0

36.0
42.0 36.0
29.0 29.0
Maximum Moment in Top Slab at Mid Span = 38.00 kNm
Maximum Moment in Top Slab at Support = 24.00 kNm
Maximum Moment in Side Wall outer surface = 36.00 kNm
Maximum Moment in Side Wall inner surface = 8.00 kNm
Maximum Moment in Bottom Slab at Mid Span = 42.00 kNm
Maximum Moment in Bottom Slab at Support = 29.00 kNm
Depth of Top Slab = 300 mm
Depth of Side Wall = 300 mm
Depth of Bottom Slab = 300 mm
Grade of Concrete M30 σcbc = 10.00 kN/m2
Grade of Steel Fe500 σst = 240.0 kN/m2
Modular Ratio = 10.00
k = 1/(1+σst/m*σcbc) = 0.294
j = 1-k/3 = 0.902
Q = 0.5*k*j*σcbc = 1.33

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

4.6.2 Design of Top Slab


Depth Check
Considering clear cover of 75 mm for the base slab and 40 mm for all the othert faces
Depth of Top Slab Provided = 300 mm
Effective Depth Provided = 300-40-6 = 254 mm
Maximum Moment = 38.00 kNm
Effective Depth Required = SQRT(38/(1.33))*1000 = 169 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 300 mm Effective depth = 254 mm
Max moment on top surface = 24 kNm Steel reqd = 436.5 mm2
Provide 12mm @ 200mm C/C
Area of steel provided = 565.5 mm2
Max moment on bottom surface = 38 kNm Steel reqd = = 691.1 mm2
Provide 10 mm @ 100mm C/C
Area of steel provided = 785.4 mm2
Minimum Steel = 0.06 % of C/S = 152.4 mm2
Max moment mid top surface = 6 kNm Steel reqd = 108.7 mm2
Thus, Area of Steel Required = 152.4 mm2
Provide 10 mm dia @ 200mm C/C
Area of steel provided = 392.7 mm2
4.6.3 Design of Bottom Slab
Depth Check
Depth of Bottom Slab Provided = 300 mm
Effecetive Depth Provided = 300-75-6 = 219 mm
Maximum Moment = 42.00 kNm
Effective Depth Required = SQRT(42/(1.33))*1000 = 178 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 300 mm Effective depth = 219 mm
Max moment on top surface = 42 kNm Steel reqd = 885.9 mm2
Provide 12 mm dia @ 120mm C/C
Area of steel provided = 942.5 mm2
Max moment on bottom surface = 29 kNm Steel reqd = 611.7 mm2
Provide 10 mm dia @ 120mm C/C
Area of steel provided = 654.5 mm2
Minimum Steel = 0.06 % of C/S = 131.4 mm2
Max moment mid bot surface = 4 kNm Steel reqd = 72.5 mm2
Thus, Area of Steel Required = 131.4 mm2
Provide 10 mm dia @ 240mm C/C
Area of steel provided = 327.2 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

4.6.4 Design of Side Wall


Depth Check
Depth of side Wall Provided = 300 mm
Effective Depth Provided = 300-40-10/2 = 255 mm
Maximum Moment = 36.00 kNm
Effective Depth Required = SQRT(36/(1.33))*1000 = 164.7 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of wall = 300 mm Effective depth = 255.0 mm
Max moment on outer surface = 36 kNm Steel reqd = 652.2 mm2
Provide 10 mm dia @ 120 mm dia @
Area of steel provided = 654.5 mm2
Minimum reinforcement on the inner face
Minimum Steel = 0.06 % of C/S = 180.0 mm2
Max moment on inner surface = 8 kNm Steel reqd = 144.9 mm2
Thus, Area of Steel Required = 180.0 mm2
Provide 10 mm dia @ 240mm C/C
Area of steel provided = 327.2 mm2
4.6.5 Distribution Steel
Tob Slab
Case1 :
Minimum= Steel
0.12% Effective Area =1.2×254 = 304.8 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 11.0 kNm
Area of Steel Required = =11.00×10^6/(240.00×254×0.902) = 200.1 mm2
Thus, Area of Steel Required = 304.8 mm2
Provide 8 mm dia @ 160mm C/C
Area of steel provided = 314.2 mm2
Bottom Slab
Case1 :
Minimum= Steel
0.12% Effective Area = =1.2×219 = 262.8 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 11.0 kNm
Area of Steel Required = =11.00×10^6/(240.00×219×0.902) = 232.0 mm2
Thus, Area of Steel Required = 262.8 mm2
Provide 8 mm dia @ 190mm C/C
Area of steel provided = 264.6 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Side Wall
Case1 :
Minimum= Steel
0.12% Effective Area =1.2×255 = 306.0 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 8.0 kNm
Area of Steel Required = =8.00×10^6/(240.00×0.902×255) = 144.9 mm2
Thus, Area of Steel Required = 306.0 mm2
Provide 8 mm dia @ 160mm C/C
Area of steel provided = 314.2 mm2

4.7 STAAD Input file


STAAD PLANE
START JOB INFORMATION
ENGINEER DATE 17-JANUARY-11
END JOB INFORMATION
INPUT WIDTH 79
UNIT METER KN
JOINT COORDINATES
1 0 0 0
2 0 0.2 0
3 0 0.7 0
4 0 1.2 0
5 0 1.7 0
6 0 2.2 0
7 0 2.3 0
8 0.15 2.3 0
9 0.369 2.3 0
10 1.15 2.3 0
11 1.931 2.3 0
12 2.15 2.3 0
13 2.3 2.3 0
14 2.3 2.2 0
15 2.3 1.7 0
16 2.3 1.2 0
17 2.3 0.7 0
18 2.3 0.2 0
19 2.3 0 0
20 2.15 0 0
21 1.931 0 0
22 1.15 0 0
23 0.369 0 0

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

24 0.15 0 0
MEMBER INCIDENCES
1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10; 10 10 11;
11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17; 17 17 18; 18 18 19;
19 19 20; 20 20 21; 21 21 22; 22 22 23; 23 23 24; 24 24 1;
START GROUP DEFINITION
MEMBER
_TOPSLAB 7 TO 12
_BOTTOMSLAB 19 TO 24
_SIDEWALL1 1 TO 6
_SIDEWALL2 13 TO 18
END GROUP DEFINITION
DEFINE MATERIAL START
ISOTROPIC MATERIAL1
E 27.39e+006
POISSON 0.15
DENSITY 25
DAMP 2.8026e-044
END DEFINE MATERIAL
CONSTANTS
MATERIAL MATERIAL1 ALL
MEMBER PROPERTY INDIAN
7 TO 12 PRIS YD 0.3 ZD 1
1 TO 6 13 TO 18 PRIS YD 0.3 ZD 1
19 TO 24 PRIS YD 0.3 ZD 1
*CONSIDERING MOD. OF SUBGRADE RXN AS 15000 kN/sq.m
SUPPORTS
1 FIXED BUT FX FZ MX MY MZ KFY 2767.5
19 FIXED BUT MX MY MZ KFY 2767.5
23 21 FIXED BUT FX FZ MX MY MZ KFY 8625
22 FIXED BUT FX FZ MX MY MZ KFY 11715
****LOADING ON THE STRUCTURE****************
LOAD 1 DEAD LOAD
MEMBER LOAD
7 TO 12 UNI GY -7.5
19 TO 24 UNI GY -7.5
1 TO 6 UNI GY -7.5
13 TO 18 UNI GY -7.5
*********SIDL*******
LOAD 2 SIDL FOR FILL
*LOAD DUE TO (Wearing Coat + Crash Barrier+ FILL + HAUNCH)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
7 TO 12 UNI GY -15.21125
********EP AT REST********
*LOAD DUE TO EARTH PRESSURE AT BOTH SIDES
LOAD 3 EARTH PRESSURE
MEMBER LOAD
6 TRAP GX 6 4.5
5 TRAP GX 11 6
4 TRAP GX 16 11
3 TRAP GX 21 16
2 TRAP GX 26 21
1 TRAP GX 27.5 26
13 TRAP GX -4.5 -6
14 TRAP GX -6 -11
15 TRAP GX -11 -16
16 TRAP GX -16 -21
17 TRAP GX -21 -26
18 TRAP GX -26 -27.5
*LL SURCHARGE DUE TO FILL AT BOTH SIDES
LOAD 4 LL SURCHARGE
MEMBER LOAD
6 UNI GX 12
5 UNI GX 12
4 UNI GX 12
3 UNI GX 12
2 UNI GX 12
1 UNI GX 12
*********70 R TRACKED LOAD (Load considered 17T)*******
LOAD 5 70R TRACKED
MEMBER LOAD
7 TO 12 UNI GY -50.45
**********40 T BOGGIE LOAD*******
LOAD 6 BOGGIE
MEMBER LOAD
8 TO 11 UNI GY -73.14
********** CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 7 CLASS A WHEELED
MEMBER LOAD
8 TO 11 UNI GY -58.94
********** Two CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 8 CLASS A WHEELED

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
8 TO 11 UNI GY -60.58
*********BRAKING LOAD*********
LOAD 9 BRAKING LOAD DUE TO BOGGIE LOAD
JOINT LOAD
7 FX 13.91
****LOAD COMBINATIONS***************
LOAD COMB 10 DL + SIDL + EP + SUR
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 11 DL + SIDL + EP + SUR + 70R TRACKED + BRAKING
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0
LOAD COMB 12 DL + SIDL + EP + SUR + BOGGIE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0
LOAD COMB 13 DL + SIDL + EP + SUR + CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 7 1.0
LOAD COMB 14 DL + SIDL + EP + SUR + TWO CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 15 DL + SIDL + EP + SUR + BOGGIE + BRAKING FORCE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0 9 1.0
LOAD COMB 16 0.2 DL + 0.3 BOGGIE + 0.3 BRAKING FORCE
1 0.2 6 0.3 9 0.3
PERFORM ANALYSIS
PRINT MEMBER FORCES ALL
FINISH

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

5 Design of 2.0 x 2.5m Box Culvert


5.1 Design Inputs

0.3

2.5
0.3

0.3

2.3

Clear Span = 2.0 m


Clear Height = 2.5 m
Top Slab Thickness = 0.3 m
Bottom Slab Thickness = 0.3 m
Side Wall Thickness = 0.3 m
Height of Fill = 0.3 m
Thickness of Wearing Coat = 0.065 m

Panel width = 1.0 m


Width of Carriage Way = 5.75 m

Angle of internal friction φ = 30 Degrees


Coefficient of Earth Pressure at Rest = 0.5
Dry Density of Fill above Top Slab = 20 kN/m3
Concrete Density = 25 kN/m3
Surcharge Live Load = 1.2 m
SBC Value Assumed = 150.0 kN/m2

5.2 General Diagram with Loading

Fill 0.3
(All dimensions in m)

0.3

Haunch (0.15x0.15)

2.5

0.3

0.3 2.0 0.3

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Total Span = 2.6 m


Total Height = 3.1 m
C/C Span = 2.3 m
C/C Height = 2.8 m

5.3 Idealised Structure of Box Culvert for STAAD Analysis


The Structure is Idealised in STAAD. Pro as shown below. The dimensions are considered as centre to centre.
The structural analysis has been done for one metre strip.
2.3 m

2.8 m

A
B D B A

Spacing Between 2 End Springs = 0.369 m


Spacing between 2 int springs = 0.781 m
Spacing between 2 end nodes of Side Wall at top = 0.150 m
Spacing between 2 end nodes of Side Wall at bottom = 0.150 m
Spacing between 2 int. nodes of Side wall = 0.625 m
Modulus of Subgrade reaction = 15000 kN/m3
Spring constants at end supports =15000x(0.369/2) = 2768 kN/m
Spring constant at Intermediate supports for the Box =15000x(0.369+0.781)/2 = 8625 kN/m
Spring constant at Int.Supports =15000x(0.781+0.781)/2) = 11715 kN/m
(Ref:pg:408,Foundation Analysis and Design by joseph E.Bowles (Fs=40*s.f*qa) and s.f = 2.5)

5.4 Load Calculation


5.4.1 Dead Load
Self Weight of Tob Slab = 0.3x1x25 = 7.50 kN/m
Self Weight of Bottom Slab = 0.3x1x25 = 7.50 kN/m
Self Weight of side Walls = 0.3x1x25 = 7.50 kN/m
Weight of Haunch = 0.15×0.15×0.5×2.5 = 0.28 kN

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

5.4.2 SIDL
Load due to Wearing Coat = 0.065x1x2.2 = 1.43 kN/m
Load due to Earth Fill = 0.3x1x20 = 6.00 kN/m
Weight of Crash Barrier = 0.3x2.5 = 7.50 kN/m
TOTAL = 14.93 kN/m
Total Base Area =2.6×1 = 2.60 m2
Total Average Bottom Pressure =(14.93+7.50+7.50+7.50+0.28+( 73.14×2.30))/2.60 = 79.21 kN/m2
Less than SBC So, Safe
5.4.3 Computation of Earth Pressure
SIDE A SIDE B

0.5*20*0.45 = 4.50 kN/m2 0.5 m


0.5*20*0.6 = 6.00 kN/m2 0.6 m
1.2 m
2
0.5*20*1.225 = 12.25 kN/m

1.9 m
0.5*20*1.850 = 18.50 kN/m2
2.5 m
0.5*20*2.475 = 24.75 kN/m2

3.1 m
0.5*20*3.100 = 31.00 kN/m2
0.5*20*3.250 = 32.50 kN/m2 3.3 m

5.4.4 Surcharge Live Load


Lateral Pressure due to Surcharge Live Load Equivalent to 1.2 m of Earth Fill = 12.00 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

5.4.5 Live Load


Case 1: When Class 70R Tracked Vehicle is Placed at the centre of the Slab
(65mm Wearing Coat Considered)
Direction of Traffic
Total Load

17.61 T
0.85

35 T 35 T

4.57 2.30

2.05

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 2.500 m
a = 2.3/2 1.150 m
b1 =0.85+0.065 0.915 m
α 3
beff α x a (1- a/lo) + b1
beff = 3x1.15x(1-1.15/2.3)+0.915 2.64 m Overlapping
Effective Width across traffic 3.80 m
Effective width less than widening width. So OK.
Width along the Span = 4.57+2×(0.065+0.300) 5.30 m
Effective width greater than c/c span
So width along the Span for Design 2.30 m
Load considered = 35/4.57×2.30 35.23 T
2
Load Intensity = 35.23/(2.3×3.80) 4.04 T/m
Impact factor = 25% 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 4.036x1.25 5.045 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 2 : When Class 70R Bogie Load (40T) is Placed at the centre of Slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.86

0.263

10 T 10 T

2.30 1.22

10 T 10 T

1.93

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.75 m


Calculation for Effective Width of Loading = b/ l0 0.43 m
a = 2.3/2-1.22/2 0.54 m
b1 =0.86+0.065 0.93 m
α 3
beff α x a (1- a/lo) + b1
beff = 30x0.54x(1-0.54/2.3)+0.925 2.16 m Overlapping
So effective Width across for Design 3.44 m
Effective width less than widening width. So OK.
Width along the Span = 0.263+2×(0.300+0.065) 0.993 No Overlapping
Effective width along Span 0.99 m
Effective width less than c/c span
So effective Width along span for Design 0.99 m
Load considered 20 T
Load Intensity = 20/(3.44×0.993) 5.85 T/m2
Impact factor 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 5.851x1.25 7.314 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 3 : When Class A (5.7 x 2 T) is Placed at the centre of slab


(65mm Wearing Coat Considered)

Direction of Traffic

5.7 T 1.8 5.7 T

0.25

2.30 0.5

1.2

5.7 T 5.7 T

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.435 m
a = 2.3/2-1.2/2 0.550 m
b1 0.57 m
α 3
beff α x a (1- a/lo) + b1
beff = 3x0.55x(1-0.55/2.3)+0.565 1.82 m Overlapping
Effective Width across for Design = 1.2+0.5+0.5/2+1.8+1.82/2 2.96 m
Effective width less than widening width. So OK.
Width along the Span = 0.25+(2×(0.300+0.065)) 0.98 m No Overlapping
Effective width along Span 0.98 m
Effective width less than c/c span
So effective Width along span for Design 0.98 m
Load considered 11.4 T
Load Intensity = 11.4/(2.96×0.980) 3.93 T/m2
Impact factor 50.00 %
Deduction in the I.F No deduction for fill < 0.6m 1.00
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 50x1 50.00 %

Increasing due to Impact (As per IRC-6-2000,


= 3.93x1.5 5.90 T/m2
Cl:211.6 and 211.7)

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Case 4 : When two Class A (5.7 x 2T) is Placed at the centre of slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.5

0.5

0.25

1.2 2.30

1.8 1 1.8

5.7 T 5.7 T 5.7 T 5.7 T


Class A Wheeled Vehicle Class A Wheeled Vehicle

1.82 m 1.82 m 1.82 m 1.82 m

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 2.50 m
a =0.5×(2.30-1.2) 0.550 m
b1 0.565 m
α 3
beff α x a (1- a/lo) + b1
beff = 3x0.55x(1-0.55/2.3)+0.565 1.82 m Overlapping
Effective Width across for Design 5.76 m
Effective width greater than widening width. So beff for design is 5.75 m
Width along the Span =0.25+2×(0.300+0.065) 0.98 m No Overlapping
Effective width along Span 0.98 m
Effective width less than c/c span
So effective Width along span for Design 0.98 m
Load considered 22.8 T
Load Intensity = 22.8/(5.76×0.980) 4.04 T/m2
Impact factor 50.00 %
Increasing due to Impact (As per IRC-6-2000,
= 4.039x1.5 6.06 T/m2
Cl:211.6 and 211.7)
So design intensity = 73.14 kN/m2
Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

5.5 Braking Load


Total Horizontal Load on top of the box =0.2×(10+10+10+10)×10 = 80.00 kN
Horizontal load per m width of the structure =80.00/5.75 = 13.91 kN/m

5.6 Structural Design


5.6.1 Summary of Moments (From STAAD Pro)

Design Moments (kNm)


Load Combinations Top Slab Bottom Slab Side Walls
Sagging Hogging Sagging Hogging Outer Inner
Maximum Moment 36 30 41 38 42 12
0.2 D.L+0.3 L.L 11 4 12 4 8 0

Design Bending Moments (kNm)


30.0 30.0
42.0 36.0 42.0

12.0 12.0

42.0
41.0 42.0
38.0 38.0
Maximum Moment in Top Slab at Mid Span = 36.00 kNm
Maximum Moment in Top Slab at Support = 30.00 kNm
Maximum Moment in Side Wall outer surface = 42.00 kNm
Maximum Moment in Side Wall inner surface = 12.00 kNm
Maximum Moment in Bottom Slab at Mid Span = 41.00 kNm
Maximum Moment in Bottom Slab at Support = 38.00 kNm
Depth of Top Slab = 300 mm
Depth of Side Wall = 300 mm
Depth of Bottom Slab = 300 mm
Grade of Concrete M30 σcbc = 10.00 kN/m2
Grade of Steel Fe500 σst = 240.0 kN/m2
Modular Ratio = 10.00
k = 1/(1+σst/m*σcbc) = 0.294
j = 1-k/3 = 0.902
Q = 0.5*k*j*σcbc = 1.33

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

5.6.2 Design of Top Slab


Depth Check
Considering clear cover of 75 mm for the base slab and 40 mm for all the othert faces
Depth of Top Slab Provided = 300 mm
Effective Depth Provided = 300-40-6 = 255 mm
Maximum Moment = 36.00 kNm
Effective Depth Required = SQRT(36/(1.33))*1000 = 165 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 300 mm Effective depth = 255 mm
Max moment on top surface = 30 kNm Steel reqd = 543.5 mm2
Provide 10mm @ 120mm C/C
Area of steel provided = 654.5 mm2
Max moment on bottom surface = 36 kNm Steel reqd = = 652.2 mm2
Provide 10 mm @ 120mm C/C
Area of steel provided = 654.5 mm2
Minimum Steel = 0.06 % of C/S = 153.0 mm2
Max moment mid top surface = 10 kNm Steel reqd = 181.9 mm2
Thus, Area of Steel Required = 181.9 mm2
Provide 10 mm dia @ 240mm C/C
Area of steel provided = 327.2 mm2
5.6.3 Design of Bottom Slab
Depth Check
Depth of Bottom Slab Provided = 300 mm
Effecetive Depth Provided = 300-75-6 = 219 mm
Maximum Moment = 41.00 kNm
Effective Depth Required = SQRT(41/(1.33))*1000 = 176 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 300 mm Effective depth = 219 mm
Max moment on top surface = 41 kNm Steel reqd = 864.9 mm2
Provide 12 mm dia @ 130mm C/C
Area of steel provided = 870.0 mm2
Max moment on bottom surface = 38 kNm Steel reqd = 801.6 mm2
Provide 12 mm dia @ 130mm C/C
Area of steel provided = 870.0 mm2
Minimum Steel = 0.06 % of C/S = 131.4 mm2
Max moment mid bot surface = 17 kNm Steel reqd = 309.2 mm2
Thus, Area of Steel Required = 309.2 mm2
Provide 12 mm dia @ 260mm C/C
Area of steel provided = 435.0 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

5.6.4 Design of Side Wall


Depth Check
Depth of side Wall Provided = 300 mm
Effective Depth Provided = 300-40-12/2 = 254 mm
Maximum Moment = 42.00 kNm
Effective Depth Required = SQRT(42/(1.33))*1000 = 177.9 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of wall = 300 mm Effective depth = 254.0 mm
Max moment on outer surface = 42 kNm Steel reqd = 763.9 mm2
Provide 12 mm dia @ 140 mm dia @
Area of steel provided = 807.8 mm2
Minimum reinforcement on the inner face
Minimum Steel = 0.06 % of C/S = 180.0 mm2
Max moment on inner surface = 12 kNm Steel reqd = 218.2 mm2
Thus, Area of Steel Required = 218.2 mm2
Provide 10 mm dia @ 280mm C/C
Area of steel provided = 280.5 mm2
5.6.5 Distribution Steel
Tob Slab
Case1 :
Minimum
= 0.12%
Steel Effective Area =1.2×255 = 306.0 mm2
Case2 := 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 12.0 kNm
Area of Steel Required = =12.00×10^6/(240.00×255×0.902) = 217.4 mm2
Thus, Area of Steel Required = 306.0 mm2
Provide 8 mm dia @ 160mm C/C
Area of steel provided = 314.2 mm2
Bottom Slab
Case1 :
Minimum
= 0.12%
Steel Effective Area = =1.2×219 = 262.8 mm2
Case2 := 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 12.0 kNm
Area of Steel Required = =12.00×10^6/(240.00×219×0.902) = 253.1 mm2
Thus, Area of Steel Required = 262.8 mm2
Provide 8 mm dia @ 190mm C/C
Area of steel provided = 264.6 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Side Wall
Case1 :
Minimum
= 0.12%
Steel Effective Area =1.2×254 = 304.8 mm2
Case2 := 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 8.0 kNm
Area of Steel Required = =8.00×10^6/(240.00×0.902×254) = 145.5 mm2
Thus, Area of Steel Required = 304.8 mm2
Provide 8 mm dia @ 160mm C/C
Area of steel provided = 314.2 mm2

5.7 STAAD Input file


STAAD PLANE
START JOB INFORMATION
ENGINEER DATE 17-JANUARY-11
END JOB INFORMATION
INPUT WIDTH 79
UNIT METER KN
JOINT COORDINATES
1 0 0 0
2 0 0.2 0
3 0 0.8 0
4 0 1.4 0
5 0 2.0 0
6 0 2.7 0
7 0 2.8 0
8 0.15 2.8 0
9 0.369 2.8 0
10 1.15 2.8 0
11 1.931 2.8 0
12 2.15 2.8 0
13 2.3 2.8 0
14 2.3 2.7 0
15 2.3 2.0 0
16 2.3 1.4 0
17 2.3 0.8 0
18 2.3 0.2 0
19 2.3 0 0
20 2.15 0 0
21 1.931 0 0
22 1.15 0 0
23 0.369 0 0

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

24 0.15 0 0
MEMBER INCIDENCES
1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10; 10 10 11;
11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17; 17 17 18; 18 18 19;
19 19 20; 20 20 21; 21 21 22; 22 22 23; 23 23 24; 24 24 1;
START GROUP DEFINITION
MEMBER
_TOPSLAB 7 TO 12
_BOTTOMSLAB 19 TO 24
_SIDEWALL1 1 TO 6
_SIDEWALL2 13 TO 18
END GROUP DEFINITION
DEFINE MATERIAL START
ISOTROPIC MATERIAL1
E 27.39e+006
POISSON 0.15
DENSITY 25
DAMP 2.8026e-044
END DEFINE MATERIAL
CONSTANTS
MATERIAL MATERIAL1 ALL
MEMBER PROPERTY INDIAN
7 TO 12 PRIS YD 0.3 ZD 1
1 TO 6 13 TO 18 PRIS YD 0.3 ZD 1
19 TO 24 PRIS YD 0.3 ZD 1
**SUPPORT SPECS*********
*CONSIDERING MOD. OF SUBGRADE RXN AS 15000 kN/sq.m
SUPPORTS
1 FIXED BUT FX FZ MX MY MZ KFY 2767.5
19 FIXED BUT MX MY MZ KFY 2767.5
23 21 FIXED BUT FX FZ MX MY MZ KFY 8625.0
22 FIXED BUT FX FZ MX MY MZ KFY 11715.0
****LOADING ON THE STRUCTURE****************
**************
*********DL*****
LOAD 1 DEAD LOAD
MEMBER LOAD
7 TO 12 UNI GY -7.5
19 TO 24 UNI GY -7.5
1 TO 6 UNI GY -7.5
13 TO 18 UNI GY -7.5

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

*********SIDL*******
LOAD 2 SIDL FOR FILL
*(*LOAD DUE TO Wearing Coat + Crash Barrier+ FILL + HAUNCH)
MEMBER LOAD
7 TO 12 UNI GY -15.21
********EP AT REST********
*LOAD DUE TO EARTH PRESSURE AT BOTH SIDES
LOAD 3 EARTH PRESSURE
MEMBER LOAD
6 TRAP GX 6 4.5
5 TRAP GX 12.25 6
4 TRAP GX 18.5 12.25
3 TRAP GX 24.75 18.5
2 TRAP GX 31 24.75
1 TRAP GX 32.5 31
13 TRAP GX -4.5 -6
14 TRAP GX -6 -12.25
15 TRAP GX -12.25 -18.5
16 TRAP GX -18.5 -24.75
17 TRAP GX -24.75 -31
18 TRAP GX -31 -32.5
*********LL SURCHARGE *********
*LL SURCHARGE DUE TO FILL AT BOTH SIDES
LOAD 4 LL SURCHARGE
MEMBER LOAD
6 UNI GX 12
5 UNI GX 12
4 UNI GX 12
3 UNI GX 12
2 UNI GX 12
1 UNI GX 12
*********70 R TRACKED LOAD (Load considered 17T)*******
LOAD 5 70R TRACKED
MEMBER LOAD
7 TO 12 UNI GY -50.45
**********40 T BOGGIE LOAD*******
LOAD 6 BOGGIE
MEMBER LOAD
8 TO 11 UNI GY -73.14
********** CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 7 CLASS A WHEELED

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
8 TO 11 UNI GY -58.94
********** Two CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 8 CLASS A WHEELED
MEMBER LOAD
8 TO 11 UNI GY -60.58
*********BRAKING LOAD*********
LOAD 9 BRAKING LOAD DUE TO BOGGIE LOAD
JOINT LOAD
7 FX 13.91304348
****LOAD COMBINATIONS***************
LOAD COMB 10 DL + SIDL + EP + SUR
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 11 DL + SIDL + EP + SUR + 70R TRACKED
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0
LOAD COMB 12 DL + SIDL + EP + SUR + BOGGIE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0
LOAD COMB 13 DL + SIDL + EP + SUR + CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 7 1.0
LOAD COMB 14 DL + SIDL + EP + SUR + TWO CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 15 DL + SIDL + EP + SUR + BOGGIE + BRAKING FORCE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0 9 1.0
LOAD COMB 16 0.2 DL + 0.3 BOGGIE + 0.3 BRAKING FORCE
1 0.2 6 0.3 9 0.3
PERFORM ANALYSIS
PRINT MEMBER FORCES ALL
FINISH

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

6 Design of 2.0 x 3.0m Box Culvert


6.1 Design Inputs

0.3

3.0
0.3

0.3

2.3

Clear Span = 2.0 m


Clear Height = 3.0 m
Top Slab Thickness = 0.3 m
Bottom Slab Thickness = 0.3 m
Side Wall Thickness = 0.3 m
Height of Fill = 0.3 m
Thickness of Wearing Coat = 0.065 m

Panel width = 1.0 m


Width of Carriage Way = 5.75 m

Angle of internal friction φ = 30 Degrees


Coefficient of Earth Pressure at Rest = 0.5
Dry Density of Fill above Top Slab = 20 kN/m3
Concrete Density = 25 kN/m3
Surcharge Live Load = 1.2 m
SBC Value Assumed = 150.0 kN/m2

6.2 General Diagram with Loading

Fill 0.3
(All dimensions in m)

0.3

Haunch (0.15x0.15)

3.0

0.3

0.3 2.0 0.3

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Total Span = 2.6 m


Total Height = 3.6 m
C/C Span = 2.3 m
C/C Height = 3.3 m

6.3 Idealised Structure of Box Culvert for STAAD Analysis


The Structure is Idealised in STAAD. Pro as shown below. The dimensions are considered as centre to centre.
The structural analysis has been done for one metre strip.
2.3 m

3.3 m

A
B D B A

Spacing Between 2 End Springs = 0.369 m


Spacing between 2 int springs = 0.781 m
Spacing between 2 end nodes of Side Wall at top = 0.150 m
Spacing between 2 end nodes of Side Wall at bottom = 0.150 m
Spacing between 2 int. nodes of Side wall = 0.75 m
Modulus of Subgrade reaction = 15000 kN/m3
Spring constants at end supports =15000x(0.369/2) = 2768 kN/m
Spring constant at Intermediate supports for the Box =15000x(0.369+0.781)/2 = 8625 kN/m
Spring constant at Int.Supports =15000x(0.781+0.781)/2) = 11715 kN/m
(Ref:pg:408,Foundation Analysis and Design by joseph E.Bowles (Fs=40*s.f*qa) and s.f = 2.5)

6.4 Load Calculation


6.4.1 Dead Load
Self Weight of Tob Slab = 0.3x1x25 = 7.50 kN/m
Self Weight of Bottom Slab = 0.3x1x25 = 7.50 kN/m
Self Weight of side Walls = 0.3x1x25 = 7.50 kN/m
Weight of Haunch = 0.15×0.15×0.5×2.5 = 0.28 kN

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

6.4.2 SIDL
Load due to Wearing Coat = 0.065x1x2.2 = 1.43 kN/m
Load due to Earth Fill = 0.3x1x20 = 6.00 kN/m
Weight of Crash Barrier = 0.3x2.5 = 7.50 kN/m
TOTAL = 14.93 kN/m
Total Base Area =2.6×1 = 2.60 m2
Total Average Bottom Pressure =(14.93+7.50+7.50+7.50+0.28+( 73.14×2.30))/2.60 = 79.21 kN/m2
Less than SBC So, Safe
6.4.3 Computation of Earth Pressure
SIDE A SIDE B

0.5*20*0.45 = 4.50 kN/m2 0.5 m


0.5*20*0.6 = 6.00 kN/m2 0.6 m
1.4 m
2
0.5*20*1.350 = 13.50 kN/m

2.1 m
0.5*20*2.100 = 21.00 kN/m2
2.9 m
0.5*20*2.850 = 28.50 kN/m2

3.6 m
0.5*20*3.600 = 36.00 kN/m2
0.5*20*3.750 = 37.50 kN/m2 3.8 m

6.4.4 Surcharge Live Load


Lateral Pressure due to Surcharge Live Load Equivalent to 1.2 m of Earth Fill = 12.00 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

6.4.5 Live Load


Case 1: When Class 70R Tracked Vehicle is Placed at the centre of the Slab
(65mm Wearing Coat Considered)
Direction of Traffic
Total Load

17.61 T
0.85

35 T 35 T

4.57 2.30

2.05

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 2.500 m
a = 2.3/2 1.150 m
b1 =0.85+0.065 0.915 m
α 3
beff α x a (1- a/lo) + b1
beff = 3x1.15x(1-1.15/2.3)+0.915 2.64 m Overlapping
Effective Width across traffic 3.80 m
Effective width less than widening width. So OK.
Width along the Span = 4.57+2×(0.065+0.300) 5.30 m
Effective width greater than c/c span
So width along the Span for Design 2.30 m
Load considered = 35/4.57×2.30 35.23 T
2
Load Intensity = 35.23/(2.3×3.80) 4.04 T/m
Impact factor = 25% 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 4.036x1.25 5.045 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 2 : When Class 70R Bogie Load (40T) is Placed at the centre of Slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.86

0.263

10 T 10 T

2.30 1.22

10 T 10 T

1.93

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.75 m


Calculation for Effective Width of Loading = b/ l0 0.43 m
a = 2.3/2-1.22/2 0.54 m
b1 =0.86+0.065 0.93 m
α 3
beff α x a (1- a/lo) + b1
beff = 30x0.54x(1-0.54/2.3)+0.925 2.16 m Overlapping
So effective Width across for Design 3.44 m
Effective width less than widening width. So OK.
Width along the Span = 0.263+2×(0.300+0.065) 0.993 No Overlapping
Effective width along Span 0.99 m
Effective width less than c/c span
So effective Width along span for Design 0.99 m
Load considered 20 T
Load Intensity = 20/(3.44×0.993) 5.85 T/m2
Impact factor 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 5.851x1.25 7.314 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 3 : When Class A (5.7 x 2 T) is Placed at the centre of slab


(65mm Wearing Coat Considered)

Direction of Traffic

5.7 T 1.8 5.7 T

0.25

2.30 0.5

1.2

5.7 T 5.7 T

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.435 m
a = 2.3/2-1.2/2 0.550 m
b1 0.57 m
α 3
beff α x a (1- a/lo) + b1
beff = 3x0.55x(1-0.55/2.3)+0.565 1.82 m Overlapping
Effective Width across for Design = 1.2+0.5+0.5/2+1.8+1.82/2 2.96 m
Effective width less than widening width. So OK.
Width along the Span = 0.25+(2×(0.300+0.065)) 0.98 m No Overlapping
Effective width along Span 0.98 m
Effective width less than c/c span
So effective Width along span for Design 0.98 m
Load considered 11.4 T
Load Intensity = 11.4/(2.96×0.980) 3.93 T/m2
Impact factor 50.00 %
Deduction in the I.F No deduction for fill < 0.6m 1.00
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 50x1 50.00 %

Increasing due to Impact (As per IRC-6-2000, Cl:211.6


= 3.93x1.5 5.90 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 4 : When two Class A (5.7 x 2T) is Placed at the centre of slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.5

0.5

0.25

1.2 2.30

1.8 1 1.8

Class A Wheeled Vehicle 5.7 T 5.7 T 5.7 T 5.7 T Class A Wheeled Vehicle

1.82 m 1.82 m 1.82 m 1.82 m

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 2.50 m
a =0.5×(2.30-1.2) 0.550 m
b1 0.565 m
α 3
beff α x a (1- a/lo) + b1
beff = 3x0.55x(1-0.55/2.3)+0.565 1.82 m Overlapping
Effective Width across for Design 5.76 m
Effective width greater than widening width. So beff for design is 5.75 m
Width along the Span =0.25+2×(0.300+0.065) 0.98 m No Overlapping
Effective width along Span 0.98 m
Effective width less than c/c span
So effective Width along span for Design 0.98 m
Load considered 22.8 T
Load Intensity = 22.8/(5.76×0.980) 4.04 T/m2
Impact factor 50.00 %
Increasing due to Impact (As per IRC-6-2000, Cl:211.6
= 4.039x1.5 6.06 T/m2
and 211.7)
So design intensity = 73.14 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

6.5 Braking Load


Total Horizontal Load on top of the box =0.2×(10+10+10+10)×10 = 80.00 kN
Horizontal load per m width of the structure =80.00/5.75 = 13.91 kN/m

6.6 Structural Design


6.6.1 Summary of Moments (From STAAD Pro)

Design Moments (kNm)


Load Combinations Top Slab Bottom Slab Side Walls
Sagging Hogging Sagging Hogging Outer Inner
Maximum Moment 34 37 38 50 49 18
0.2 D.L+0.3 L.L 12 4 13 4 8 0

Design Bending Moments (kNm)


37.0 37.0
49.0 34.0 49.0

18.0 18.0

49.0
38.0 49.0
50.0 50.0
Maximum Moment in Top Slab at Mid Span = 34.00 kNm
Maximum Moment in Top Slab at Support = 37.00 kNm
Maximum Moment in Side Wall outer surface = 49.00 kNm
Maximum Moment in Side Wall inner surface = 18.00 kNm
Maximum Moment in Bottom Slab at Mid Span = 38.00 kNm
Maximum Moment in Bottom Slab at Support = 50.00 kNm
Depth of Top Slab = 300 mm
Depth of Side Wall = 300 mm
Depth of Bottom Slab = 300 mm
Grade of Concrete M30 σcbc = 10.00 kN/m2
Grade of Steel Fe500 σst = 240.0 kN/m2
Modular Ratio = 10.00
k = 1/(1+σst/m*σcbc) = 0.294
j = 1-k/3 = 0.902
Q = 0.5*k*j*σcbc = 1.33

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

6.6.2 Design of Top Slab


Depth Check
Considering clear cover of 75 mm for the base slab and 40 mm for all the othert faces
Depth of Top Slab Provided = 300 mm
Effective Depth Provided = 300-40-6 = 255 mm
Maximum Moment = 37.00 kNm
Effective Depth Required = SQRT(37/(1.33))*1000 = 167 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 300 mm Effective depth = 255 mm
Max moment on top surface = 37 kNm Steel reqd = 670.3 mm2
Provide 10mm @ 110mm C/C
Area of steel provided = 714.0 mm2
Max moment on bottom surface = 34 kNm Steel reqd = = 615.9 mm2
Provide 10 mm @ 110mm C/C
Area of steel provided = 714.0 mm2
Minimum Steel = 0.06 % of C/S = 153.0 mm2
Max moment mid top surface = 11 kNm Steel reqd = 200.1 mm2
Thus, Area of Steel Required = 200.1 mm2
Provide 10 mm dia @ 220mm C/C
Area of steel provided = 357.0 mm2
6.6.3 Design of Bottom Slab
Depth Check
Depth of Bottom Slab Provided = 300 mm
Effecetive Depth Provided = 300-75-6 = 219 mm
Maximum Moment = 50.00 kNm
Effective Depth Required = SQRT(50/(1.33))*1000 = 194 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 300 mm Effective depth = 219 mm
Max moment on top surface = 38 kNm Steel reqd = 801.6 mm2
Provide 12 mm dia @ 100mm C/C
Area of steel provided = 1131.0 mm2
Max moment on bottom surface = 50 kNm Steel reqd = 1054.7 mm2
Provide 12 mm dia @ 100mm C/C
Area of steel provided = 1131.0 mm2
Minimum Steel = 0.06 % of C/S = 131.4 mm2
Max moment mid bot surface = 12 kNm Steel reqd = 218.2 mm2
Thus, Area of Steel Required = 218.2 mm2
Provide 10 mm dia @ 200mm C/C
Area of steel provided = 392.7 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

6.6.4 Design of Side Wall


Depth Check
Depth of side Wall Provided = 300 mm
Effective Depth Provided = 300-40-12/2 = 254 mm
Maximum Moment = 49.00 kNm
Effective Depth Required = SQRT(49/(1.33))*1000 = 192.2 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of wall = 300 mm Effective depth = 254.0 mm
Max moment on outer surface = 49 kNm Steel reqd = 891.2 mm2
Provide 12 mm dia @ 110 mm dia @
Area of steel provided = 1028.2 mm2
Minimum reinforcement on the inner face
Minimum Steel = 0.06 % of C/S = 180.0 mm2
Max moment on inner surface = 18 kNm Steel reqd = 327.4 mm2
Thus, Area of Steel Required = 327.4 mm2
Provide 10 mm dia @ 220mm C/C
Area of steel provided = 357.0 mm2
6.6.5 Distribution Steel
Tob Slab
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×255 = 306.0 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 13.0 kNm
Area of Steel Required = =13.00×10^6/(240.00×255×0.902) = 235.5 mm2
Thus, Area of Steel Required = 306.0 mm2
Provide 8 mm dia @ 160mm C/C
Area of steel provided = 314.2 mm2
Bottom Slab
Case1 :
Minimum Steel
= 0.12% Effective Area = =1.2×219 = 262.8 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 13.0 kNm
Area of Steel Required = =13.00×10^6/(240.00×219×0.902) = 274.2 mm2
Thus, Area of Steel Required = 274.2 mm2
Provide 8 mm dia @ 180mm C/C
Area of steel provided = 279.3 mm2
Side Wall
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×254 = 304.8 mm2
Case2 : = 0.2DL+0.3LL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Maximum Bending Moment for Distribution Steel = 8.0 kNm


Area of Steel Required = =8.00×10^6/(240.00×0.902×254) = 145.5 mm2
Thus, Area of Steel Required = 304.8 mm2
Provide 8 mm dia @ 160mm C/C
Area of steel provided = 314.2 mm2

6.7 STAAD Input file


STAAD PLANE
START JOB INFORMATION
ENGINEER DATE 17-JANUARY-11
END JOB INFORMATION
INPUT WIDTH 79
UNIT METER KN
JOINT COORDINATES
1 0 0 0
2 0 0.2 0
3 0 0.9 0
4 0 1.7 0
5 0 2.4 0
6 0 3.2 0
7 0 3.3 0
8 0.15 3.3 0
9 0.369 3.3 0
10 1.15 3.3 0
11 1.931 3.3 0
12 2.15 3.3 0
13 2.3 3.3 0
14 2.3 3.2 0
15 2.3 2.4 0
16 2.3 1.7 0
17 2.3 0.9 0
18 2.3 0.2 0
19 2.3 0 0
20 2.15 0 0
21 1.931 0 0
22 1.15 0 0
23 0.369 0 0
24 0.15 0 0
MEMBER INCIDENCES
1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10; 10 10 11;
11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17; 17 17 18; 18 18 19;

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

19 19 20; 20 20 21; 21 21 22; 22 22 23; 23 23 24; 24 24 1;


START GROUP DEFINITION
MEMBER
_TOPSLAB 7 TO 12
_BOTTOMSLAB 19 TO 24
_SIDEWALL1 1 TO 6
_SIDEWALL2 13 TO 18
END GROUP DEFINITION
DEFINE MATERIAL START
ISOTROPIC MATERIAL1
E 27.39e+006
POISSON 0.15
DENSITY 25
DAMP 2.8026e-044
END DEFINE MATERIAL
CONSTANTS
MATERIAL MATERIAL1 ALL
MEMBER PROPERTY INDIAN
7 TO 12 PRIS YD 0.3 ZD 1 ZD 1
1 TO 6 13 TO 18 PRIS YD 0.3 ZD 1 ZD 1
19 TO 24 PRIS YD 0.3 ZD 1 ZD 1
**SUPPORT SPECS*********
*CONSIDERING MOD. OF SUBGRADE RXN AS 15000 kN/sq.m
SUPPORTS
1 FIXED BUT FX FZ MX MY MZ KFY 2767.5 2767.5
19 FIXED BUT MX MY MZ KFY 2767.5 2767.5
23 21 FIXED BUT FX FZ MX MY MZ KFY 8625 8625.0
22 FIXED BUT FX FZ MX MY MZ KFY 11715 11715.0
****LOADING ON THE STRUCTURE****************
**************
*********DL*****
LOAD 1 DEAD LOAD
MEMBER LOAD
7 TO 12 UNI GY -7.5
19 TO 24 UNI GY -7.5
1 TO 6 UNI GY -7.5
13 TO 18 UNI GY -7.5
*********SIDL*******
LOAD 2 SIDL FOR FILL
*(*LOAD DUE TO Wearing Coat + Crash Barrier+ FILL + HAUNCH)
MEMBER LOAD

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

7 TO 12 UNI GY -15.21
********EP AT REST********
*LOAD DUE TO EARTH PRESSURE AT BOTH SIDES
LOAD 3 EARTH PRESSURE
MEMBER LOAD
6 TRAP GX 6 4.5
5 TRAP GX 13.5 6
4 TRAP GX 21 13.5
3 TRAP GX 28.5 21
2 TRAP GX 36 28.5
1 TRAP GX 37.5 36
13 TRAP GX -4.5 -6
14 TRAP GX -6 -13.5
15 TRAP GX -13.5 -21
16 TRAP GX -21 -28.5
17 TRAP GX -28.5 -36
18 TRAP GX -36 -37.5
*********LL SURCHARGE *********
*LL SURCHARGE DUE TO FILL AT BOTH SIDES
LOAD 4 LL SURCHARGE
MEMBER LOAD
6 UNI GX 12
5 UNI GX 12
4 UNI GX 12
3 UNI GX 12
2 UNI GX 12
1 UNI GX 12
*********70 R TRACKED LOAD (Load considered 17T)*******
LOAD 5 70R TRACKED
MEMBER LOAD
7 TO 12 UNI GY -50.45
**********40 T BOGGIE LOAD*******
LOAD 6 BOGGIE
MEMBER LOAD
8 TO 11 UNI GY -73.14
********** CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 7 CLASS A WHEELED
MEMBER LOAD
8 TO 11 UNI GY -58.94
********** Two CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 8 CLASS A WHEELED

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
8 TO 11 UNI GY -60.58
*********BRAKING LOAD*********
LOAD 9 BRAKING LOAD DUE TO BOGGIE LOAD
JOINT LOAD
7 FX 13.91
****LOAD COMBINATIONS***************
LOAD COMB 10 DL + SIDL + EP + SUR
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 11 DL + SIDL + EP + SUR + 70R TRACKED
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0
LOAD COMB 12 DL + SIDL + EP + SUR + BOGGIE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0
LOAD COMB 13 DL + SIDL + EP + SUR + CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 7 1.0
LOAD COMB 14 DL + SIDL + EP + SUR + TWO CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 15 DL + SIDL + EP + SUR + BOGGIE + BRAKING FORCE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0 9 1.0
LOAD COMB 16 0.2 DL + 0.3 BOGGIE + 0.3 BRAKING FORCE
1 0.2 6 0.3 9 0.3
PERFORM ANALYSIS
PRINT MEMBER FORCES ALL
FINISH

L&T Ramboll Consulting Engineers Limited Page 45


7 Design of 3.0 x 3.0m Box Culvert
7.1 Design Inputs

0.35

3.0
0.3

0.35

3.3

Clear Span = 3.0 m


Clear Height = 3.0 m
Top Slab Thickness = 0.35 m
Bottom Slab Thickness = 0.35 m
Side Wall Thickness = 0.30 m
Height of Fill = 0.3 m
Thickness of Wearing Coat = 0.065 m

Panel width = 1.0 m


Width of Carriage Way = 5.75 m

Angle of internal friction φ = 30 Degrees


Coefficient of Earth Pressure at Rest = 0.5
Dry Density of Fill above Top Slab = 20 kN/m3
Concrete Density = 25 kN/m3
Surcharge Live Load = 1.2 m
SBC Value Assumed = 150.0 kN/m2

7.2 General Diagram with Loading

Fill 0.3
(All dimensions in m)

0.4

Haunch (0.15x0.15)

3.0

0.4

0.3 3.0 0.3


Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Total Span = 3.6 m


Total Height = 3.7 m
C/C Span = 3.3 m
C/C Height = 3.4 m

7.3 Idealised Structure of Box Culvert for STAAD Analysis


The Structure is Idealised in STAAD. Pro as shown below. The dimensions are considered as centre to centre.
The structural analysis has been done for one metre strip.
3.3 m

3.4 m

A
B D B A

Spacing Between 2 End Springs = 0.417 m


Spacing between 2 int springs = 1.233 m
Spacing between 2 end nodes of Side Wall at top = 0.175 m
Spacing between 2 end nodes of Side Wall at bottom = 0.175 m
Spacing between 2 int. nodes of Side wall = 0.75 m
Modulus of Subgrade reaction = 15000 kN/m3
Spring constants at end supports =15000x(0.417/2) = 3128 kN/m
Spring constant at Intermediate supports for the Box =15000x(0.417+1.233)/2 = 12375 kN/m
Spring constant at Int.Supports =15000x(1.233+1.233)/2) = 18495 kN/m
(Ref:pg:408,Foundation Analysis and Design by joseph E.Bowles (Fs=40*s.f*qa) and s.f = 2.5)

7.4 Load Calculation


7.4.1 Dead Load
Self Weight of Tob Slab = 0.35x1x25 = 8.75 kN/m
Self Weight of Bottom Slab = 0.35x1x25 = 8.75 kN/m
Self Weight of side Walls = 0.3x1x25 = 7.50 kN/m
Weight of Haunch = 0.15×0.15×0.5×2.5 = 0.28 kN

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

7.4.2 SIDL
Load due to Wearing Coat = 0.065x1x2.2 = 1.43 kN/m
Load due to Earth Fill = 0.3x1x20 = 6.00 kN/m
Weight of Crash Barrier = 0.3x2.5 = 7.50 kN/m
TOTAL = 14.93 kN/m
Total Base Area =3.6×1 = 3.60 m2
Total Average Bottom Pressure =(14.93+8.75+8.75+7.50+0.28+( 59.11×3.30))/3.60 = 65.35 kN/m2
Less than SBC So, Safe

7.4.3 Computation of Earth Pressure


SIDE A SIDE B

0.5*20*0.475 = 4.75 kN/m2 0.5 m


2
0.5*20*0.65 = 6.50 kN/m 0.7 m
1.4 m
2
0.5*20*1.400 = 14.00 kN/m

2.2 m
2
0.5*20*2.150 = 21.50 kN/m
2.9 m
2
0.5*20*2.900 = 29.00 kN/m

3.7 m
0.5*20*3.650 = 36.50 kN/m2
0.5*20*3.825 = 38.25 kN/m2 3.8 m

7.4.4 Surcharge Live Load


Lateral Pressure due to Surcharge Live Load Equivalent to 1.2 m of Earth Fill = 12.00 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

7.4.5 Live Load


Case 1: When Class 70R Tracked Vehicle is Placed at the centre of the Slab
(65mm Wearing Coat Considered)
Direction of Traffic
Total Load

25.27 T
0.85

35 T 35 T

4.57 3.30

2.05

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 1.742 m
a = 3.3/2 1.650 m
b1 =0.85+0.065 0.915 m
α 2.94
beff α x a (1- a/lo) + b1
beff = 2.94x1.65x(1-1.65/3.3)+0.915 3.34 m Overlapping
Effective Width across traffic 4.15 m
Effective width less than widening width. So OK.
Width along the Span = 4.57+2×(0.065+0.350) 5.40 m
Effective width greater than c/c span
So width along the Span for Design 3.30 m
Load considered = 35/4.57×3.30 50.55 T
2
Load Intensity = 50.55/(3.3×4.15) 3.70 T/m
Impact factor = 25% 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 3.695x1.25 4.619 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 2 : When Class 70R Bogie Load (40T) is Placed at the centre of Slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.86

0.263

10 T 10 T

3.30 1.22

10 T 10 T

1.93

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.75 m


Calculation for Effective Width of Loading = b/ l0 0.30 m
a = 3.3/2-1.22/2 1.04 m
b1 =0.86+0.065 0.93 m
α 2.94
beff α x a (1- a/lo) + b1
beff = 2.940x1.04x(1-1.04/3.3)+0.925 3.02 m Overlapping
So effective Width across for Design 3.87 m
Effective width less than widening width. So OK.
Width along the Span = 0.263+2×(0.350+0.065) 1.093 No Overlapping
Effective width along Span 1.09 m
Effective width less than c/c span
So effective Width along span for Design 1.09 m
Load considered 20 T
Load Intensity = 20/(3.87×1.093) 4.73 T/m2
Impact factor 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 4.729x1.25 5.911 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 3 : When Class A (5.7 x 2 T) is Placed at the centre of slab


(65mm Wearing Coat Considered)

Direction of Traffic

5.7 T 1.8 5.7 T

0.25

3.30 0.5

1.2

5.7 T 5.7 T

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.303 m
a = 3.3/2-1.2/2 1.050 m
b1 0.57 m
α 2.94
beff α x a (1- a/lo) + b1
beff = 2.94x1.05x(1-1.05/3.3)+0.565 2.67 m Overlapping
Effective Width across for Design = 1.2+0.5+0.5/2+1.8+2.67/2 3.39 m
Effective width less than widening width. So OK.
Width along the Span = 0.25+(2×(0.350+0.065)) 1.08 m No Overlapping
Effective width along Span 1.08 m
Effective width less than c/c span
So effective Width along span for Design 1.08 m
Load considered 11.4 T
Load Intensity = 11.4/(3.39×1.080) 3.12 T/m2
Impact factor 50.00 %
Deduction in the I.F No deduction for fill < 0.6m 1.00
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 50x1 50.00 %

Increasing due to Impact (As per IRC-6-2000, Cl:211.6


= 3.118x1.5 4.68 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 4 : When two Class A (5.7 x 2T) is Placed at the centre of slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.5 0.5

0.25

1.2 3.30

1.8 1 1.8

5.7 T 5.7 T 5.7 T 5.7 T


Class A Wheeled Vehicle Class A Wheeled Vehicle

2.67 m 2.67 m 2.67 m 2.67 m

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 1.74 m
a =0.5×(3.30-1.2) 1.050 m
b1 0.565 m
α 2.94
beff α x a (1- a/lo) + b1
beff = 2.94x1.05x(1-1.05/3.3)+0.565 2.67 m Overlapping
Effective Width across for Design 6.18 m
Effective width greater than widening width. So beff for design is 5.75 m
Width along the Span =0.25+2×(0.350+0.065) 1.08 m No Overlapping
Effective width along Span 1.08 m
Effective width less than c/c span
So effective Width along span for Design 1.08 m
Load considered 22.8 T
Load Intensity = 22.8/(6.18×1.080) 3.67 T/m2
Impact factor 50.00 %
Increasing due to Impact (As per IRC-6-2000, Cl:211.6
= 3.671x1.5 5.51 T/m2
and 211.7)
So design intensity = 59.11 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

7.5 Braking Load


Total Horizontal Load on top of the box =0.2×(10+10+10+10)×10 = 80.00 kN
Horizontal load per m width of the structure =80.00/5.75 = 13.91 kN/m

7.6 Structural Design


7.6.1 Summary of Moments (From STAAD Pro)

Design Moments (kNm)


Load Combinations Top Slab Bottom Slab Side Walls
Sagging Hogging Sagging Hogging Outer Inner
Maximum Moment 66 49 70 57 60 18
0.2 D.L+0.3 L.L 19 7 19 5 10 0

Design Bending Moments (kNm)


49.0 49.0
60.0 66.0 60.0

18.0 18.0

60.0
70.0 60.0
57.0 57.0
Maximum Moment in Top Slab at Mid Span = 66.00 kNm
Maximum Moment in Top Slab at Support = 49.00 kNm
Maximum Moment in Side Wall outer surface = 60.00 kNm
Maximum Moment in Side Wall inner surface = 18.00 kNm
Maximum Moment in Bottom Slab at Mid Span = 70.00 kNm
Maximum Moment in Bottom Slab at Support = 57.00 kNm
Depth of Top Slab = 350 mm
Depth of Side Wall = 300 mm
Depth of Bottom Slab = 350 mm
Grade of Concrete M30 σcbc = 10.00 kN/m2
Grade of Steel Fe500 σst = 240.0 kN/m2
Modular Ratio = 10.00
k = 1/(1+σst/m*σcbc) = 0.294
j = 1-k/3 = 0.902
Q = 0.5*k*j*σcbc = 1.33

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

7.6.2 Design of Top Slab


Depth Check
Considering clear cover of 75 mm for the base slab and 40 mm for all the othert faces
Depth of Top Slab Provided = 350 mm
Effective Depth Provided = 350-40-6 = 304 mm
Maximum Moment = 66.00 kNm
Effective Depth Required = SQRT(66/(1.33))*1000 = 223 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 350 mm Effective depth = 304 mm
Max moment on top surface = 49 kNm Steel reqd = 744.6 mm2
Provide 10mm @ 100mm C/C
Area of steel provided = 785.4 mm2
Max moment on bottom surface = 66 kNm Steel reqd = = 1002.9 mm2
Provide 12 mm @ 100mm C/C
Area of steel provided = 1131.0 mm2
Minimum Steel = 0.06 % of C/S = 182.4 mm2
Max moment mid top surface = 12 kNm Steel reqd = 218.2 mm2
Thus, Area of Steel Required = 218.2 mm2
Provide 10 mm dia @ 200mm C/C
Area of steel provided = 392.7 mm2
7.6.3 Design of Bottom Slab
Depth Check
Depth of Bottom Slab Provided = 350 mm
Effecetive Depth Provided = 350-75-8 = 267 mm
Maximum Moment = 70.00 kNm
Effective Depth Required = SQRT(70/(1.33))*1000 = 230 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 350 mm Effective depth = 267 mm
Max moment on top surface = 70 kNm Steel reqd = 1211.1 mm2
Provide 16 mm dia @ 160mm C/C
Area of steel provided = 1256.6 mm2
Max moment on bottom surface = 57 kNm Steel reqd = 986.2 mm2
Provide 16 mm dia @ 160mm C/C
Area of steel provided = 1256.6 mm2
Minimum Steel = 0.06 % of C/S = 160.2 mm2
Max moment mid bot surface = 13 kNm Steel reqd = 236.4 mm2
Thus, Area of Steel Required = 236.4 mm2
Provide 10 mm dia @ 320mm C/C
Area of steel provided = 245.4 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

7.6.4 Design of Side Wall


Depth Check
Depth of side Wall Provided = 300 mm
Effective Depth Provided = 300-40-12/2 = 254 mm
Maximum Moment = 60.00 kNm
Effective Depth Required = SQRT(60/(1.33))*1000 = 212.7 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of wall = 300 mm Effective depth = 254.0 mm
Max moment on outer surface = 60 kNm Steel reqd = 1091.2 mm2
Provide 12 mm dia @ 100 mm dia @
Area of steel provided = 1131.0 mm2
Minimum reinforcement on the inner face
Minimum Steel = 0.06 % of C/S = 180.0 mm2
Max moment on inner surface = 18 kNm Steel reqd = 327.4 mm2
Thus, Area of Steel Required = 327.4 mm2
Provide 10 mm dia @ 200mm C/C
Area of steel provided = 392.7 mm2
7.6.5 Distribution Steel
Tob Slab
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×304 = 364.8 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 19.0 kNm
Area of Steel Required = =19.00×10^6/(240.00×304×0.902) = 288.7 mm2
Thus, Area of Steel Required = 364.8 mm2
Provide 8 mm dia @ 130mm C/C
Area of steel provided = 386.7 mm2
Bottom Slab
Case1 :
Minimum Steel
= 0.12% Effective Area = =1.2×267 = 320.4 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 19.0 kNm
Area of Steel Required = =19.00×10^6/(240.00×267×0.902) = 328.7 mm2
Thus, Area of Steel Required = 328.7 mm2
Provide 8 mm dia @ 150mm C/C
Area of steel provided = 335.1 mm2
Side Wall
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×254 = 304.8 mm2
Case2 : = 0.2DL+0.3LL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Maximum Bending Moment for Distribution Steel = 10.0 kNm


Area of Steel Required = =10.00×10^6/(240.00×0.902×254) = 181.9 mm2
Thus, Area of Steel Required = 304.8 mm2
Provide 8 mm dia @ 160mm C/C
Area of steel provided = 314.2 mm2

7.7 STAAD Input file


STAAD PLANE
START JOB INFORMATION
ENGINEER DATE 17-JANUARY-11
END JOB INFORMATION
INPUT WIDTH 79
UNIT METER KN
JOINT COORDINATES
1 0 0 0
2 0 0.2 0
3 0 0.9 0
4 0 1.7 0
5 0 2.4 0
6 0 3.2 0
7 0 3.4 0
8 0.15 3.4 0
9 0.417 3.4 0
10 1.65 3.4 0
11 2.883 3.4 0
12 3.15 3.4 0
13 3.3 3.4 0
14 3.3 3.2 0
15 3.3 2.4 0
16 3.3 1.7 0
17 3.3 0.9 0
18 3.3 0.2 0
19 3.3 0 0
20 3.15 0 0
21 2.883 0 0
22 1.65 0 0
23 0.417 0 0
24 0.15 0 0
MEMBER INCIDENCES
1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10; 10 10 11;
11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17; 17 17 18; 18 18 19;

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

19 19 20; 20 20 21; 21 21 22; 22 22 23; 23 23 24; 24 24 1;


START GROUP DEFINITION
MEMBER
_TOPSLAB 7 TO 12
_BOTTOMSLAB 19 TO 24
_SIDEWALL1 1 TO 6
_SIDEWALL2 13 TO 18
END GROUP DEFINITION
DEFINE MATERIAL START
ISOTROPIC MATERIAL1
E 27.39e+006
POISSON 0.15
DENSITY 25
DAMP 2.8026e-044
END DEFINE MATERIAL
CONSTANTS
MATERIAL MATERIAL1 ALL
MEMBER PROPERTY INDIAN
7 TO 12 PRIS YD 0.35 ZD 1 ZD 1 ZD 1
1 TO 6 13 TO 18 PRIS YD 0.3 ZD 1 ZD 1 ZD 1
19 TO 24 PRIS YD 0.35 ZD 1 ZD 1 ZD 1
**SUPPORT SPECS*********
*CONSIDERING MOD. OF SUBGRADE RXN AS 15000 kN/sq.m
SUPPORTS
1 FIXED BUT FX FZ MX MY MZ KFY 3127.5 2767.5
19 FIXED BUT MX MY MZ KFY 3127.5 2767.5
23 21 FIXED BUT FX FZ MX MY MZ KFY 12375 8625.0
22 FIXED BUT FX FZ MX MY MZ KFY 18495 11715.0
****LOADING ON THE STRUCTURE****************
**************
*********DL*****
LOAD 1 DEAD LOAD
MEMBER LOAD
7 TO 12 UNI GY -8.75
19 TO 24 UNI GY -8.75
1 TO 6 UNI GY -7.5
13 TO 18 UNI GY -7.5
*********SIDL*******
LOAD 2 SIDL FOR FILL
*(*LOAD DUE TO Wearing Coat + Crash Barrier+ FILL + HAUNCH)
MEMBER LOAD

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

7 TO 12 UNI GY -15.21
********EP AT REST********
*LOAD DUE TO EARTH PRESSURE AT BOTH SIDES
LOAD 3 EARTH PRESSURE
MEMBER LOAD
6 TRAP GX 6.5 4.75
5 TRAP GX 14 6.5
4 TRAP GX 21.5 14
3 TRAP GX 29 21.5
2 TRAP GX 36.5 29
1 TRAP GX 38.25 36.5
13 TRAP GX -4.75 -6.5
14 TRAP GX -6.5 -14
15 TRAP GX -14 -21.5
16 TRAP GX -21.5 -29
17 TRAP GX -29 -36.5
18 TRAP GX -36.5 -38.25
*********LL SURCHARGE *********
*LL SURCHARGE DUE TO FILL AT BOTH SIDES
LOAD 4 LL SURCHARGE
MEMBER LOAD
6 UNI GX 12
5 UNI GX 12
4 UNI GX 12
3 UNI GX 12
2 UNI GX 12
1 UNI GX 12
*********70 R TRACKED LOAD (Load considered 17T)*******
LOAD 5 70R TRACKED
MEMBER LOAD
7 TO 12 UNI GY -46.19
**********40 T BOGGIE LOAD*******
LOAD 6 BOGGIE
MEMBER LOAD
9 10 UNI GY -59.11
********** CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 7 CLASS A WHEELED
MEMBER LOAD
9 10 UNI GY -46.78
********** Two CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 8 CLASS A WHEELED

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
9 10 UNI GY -55.07
*********BRAKING LOAD*********
LOAD 9 BRAKING LOAD DUE TO BOGGIE LOAD
JOINT LOAD
7 FX 13.91
****LOAD COMBINATIONS***************
LOAD COMB 10 DL + SIDL + EP + SUR
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 11 DL + SIDL + EP + SUR + 70R TRACKED
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0
LOAD COMB 12 DL + SIDL + EP + SUR + BOGGIE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0
LOAD COMB 13 DL + SIDL + EP + SUR + CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 7 1.0
LOAD COMB 14 DL + SIDL + EP + SUR + TWO CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 15 DL + SIDL + EP + SUR + BOGGIE + BRAKING FORCE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0 9 1.0
LOAD COMB 16 0.2 DL + 0.3 BOGGIE + 0.3 BRAKING FORCE
1 0.2 6 0.3 9 0.3
PERFORM ANALYSIS
PRINT MEMBER FORCES ALL
FINISH

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

8 Design of 4.0 x 2.0m Box Culvert


8.1 Design Inputs

0.4

2.0
0.35

0.425

4.4

Clear Span = 4.0 m


Clear Height = 2.0 m
Top Slab Thickness = 0.400 m
Bottom Slab Thickness = 0.425 m
Side Wall Thickness = 0.350 m
Height of Fill = 0.3 m
Thickness of Wearing Coat = 0.065 m

Panel width = 1.0 m


Width of Carriage Way = 5.75 m

Angle of internal friction φ = 30 Degrees


Coefficient of Earth Pressure at Rest = 0.5
Dry Density of Fill above Top Slab = 20 kN/m3
Concrete Density = 25 kN/m3
Surcharge Live Load = 1.2 m
SBC Value Assumed = 150.0 kN/m2

8.2 General Diagram with Loading

Fill 0.3
(All dimensions in m)

0.4

Haunch (0.15x0.15)

2.0

0.4

0.4 4.0 0.4

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Total Span = 4.7 m


Total Height = 2.8 m
C/C Span = 4.4 m
C/C Height = 2.4 m

8.3 Idealised Structure of Box Culvert for STAAD Analysis


The Structure is Idealised in STAAD. Pro as shown below. The dimensions are considered as centre to centre.
The structural analysis has been done for one metre strip.

4.35 m

2.41 m

A
B D B A

Spacing Between 2 End Springs = 0.517 m


Spacing between 2 int springs = 1.105 m
Spacing between 2 end nodes of Side Wall at top = 0.200 m
Spacing between 2 end nodes of Side Wall at bottom = 0.213 m
Spacing between 2 int. nodes of Side wall = 0.5 m
Modulus of Subgrade reaction = 15000 kN/m3
Spring constants at end supports =15000x(0.517/2) = 3877.5 kN/m
Spring constant at Intermediate supports for the Box =15000x(0.517+1.1053)/2 = 12167.3 kN/m
Spring constant at Int.Supports =15000x(1.1053+1.105)/2) = 16579.5 kN/m
(Ref:pg:408,Foundation Analysis and Design by joseph E.Bowles (Fs=40*s.f*qa) and s.f = 2.5)

8.4 Load Calculation


8.4.1 Dead Load
Self Weight of Tob Slab = 0.4x1x25 = 10.00 kN/m
Self Weight of Bottom Slab = 0.425x1x25 = 10.63 kN/m
Self Weight of side Walls = 0.35x1x25 = 8.75 kN/m
Weight of Haunch = 0.15×0.15×0.5×2.5 = 0.28 kN

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

8.4.2 SIDL
Load due to Wearing Coat = 0.065x1x2.2 = 1.43 kN/m
Load due to Earth Fill = 0.3x1x20 = 6.00 kN/m
Weight of Crash Barrier = 0.3x2.5 = 7.50 kN/m
TOTAL = 14.93 kN/m
Total Base Area =4.7×1 = 4.70 m2
Total Average Bottom Pressure =(14.93+10.00+10.63+8.75+0.28+( 50.0×4.35))/4.70 = 55.72 kN/m2
Less than SBC So, Safe

8.4.3 Computation of Earth Pressure


SIDE A SIDE B

0.5*20*0.5 = 5.00 kN/m2 0.5 m


2
0.5*20*0.7 = 7.00 kN/m 0.7 m
1.2 m
2
0.5*20*1.200 = 12.00 kN/m

1.7 m
2
0.5*20*1.700 = 17.00 kN/m
2.2 m
2
0.5*20*2.200 = 22.00 kN/m

2.7 m
0.5*20*2.700 = 27.00 kN/m2
0.5*20*2.913 = 29.13 kN/m2 2.9 m

8.4.4 Surcharge Live Load


Lateral Pressure due to Surcharge Live Load Equivalent to 1.2 m of Earth Fill = 12.00 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

8.4.5 Live Load


Case 1: When Class 70R Tracked Vehicle is Placed at the centre of the Slab
(65mm Wearing Coat Considered)
Direction of Traffic
Total Load

33.32 T
0.85

35 T 35 T

4.57 4.35

2.05

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 1.322 m
a = 4.35/2 2.175 m
b1 =0.85+0.065 0.915 m
α 2.74
beff α x a (1- a/lo) + b1
beff = 2.74x2.175x(1-2.175/4.35)+0.915 3.89 m Overlapping
Effective Width across traffic 4.42 m
Effective width less than widening width. So OK.
Width along the Span = 4.57+2×(0.065+0.400) 5.50 m
Effective width greater than c/c span
So width along the Span for Design 4.35 m
Load considered = 35/4.57×4.35 66.63 T
2
Load Intensity = 66.63/(4.35×4.42) 3.46 T/m
Impact factor = 25% 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 3.464x1.25 4.329 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 2 : When Class 70R Bogie Load (40T) is Placed at the centre of Slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.86

0.263

10 T 10 T

4.35 1.22

10 T 10 T

1.93

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.75 m


Calculation for Effective Width of Loading = b/ l0 0.23 m
a = 4.35/2-1.22/2 1.57 m
b1 =0.86+0.065 0.93 m
α 2.74
beff α x a (1- a/lo) + b1
beff = 2.740x1.565x(1-1.565/4.35)+0.925 3.67 m Overlapping
So effective Width across for Design 4.20 m
Effective width less than widening width. So OK.
Width along the Span = 0.263+2×(0.400+0.065) 1.193 No Overlapping
Effective width along Span 1.19 m
Effective width less than c/c span
So effective Width along span for Design 1.19 m
Load considered 20 T
Load Intensity = 20/(4.20×1.193) 4.00 T/m2
Impact factor 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 3.996x1.25 4.995 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 3 : When Class A (5.7 x 2 T) is Placed at the centre of slab


(65mm Wearing Coat Considered)

Direction of Traffic

5.7 T 1.8 5.7 T

0.25

4.35 0.5

1.2

5.7 T 5.7 T

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.230 m
a = 4.35/2-1.2/2 1.575 m
b1 0.57 m
α 2.74
beff α x a (1- a/lo) + b1
beff = 2.74x1.575x(1-1.575/4.35)+0.565 3.32 m Overlapping
Effective Width across for Design = 1.2+0.5+0.5/2+1.8+3.32/2 3.71 m
Effective width less than widening width. So OK.
Width along the Span = 0.25+(2×(0.400+0.065)) 1.18 m No Overlapping
Effective width along Span 1.18 m
Effective width less than c/c span
So effective Width along span for Design 1.18 m
Load considered 11.4 T
Load Intensity = 11.4/(3.71×1.180) 2.60 T/m2
Impact factor 45.00 %
Deduction in the I.F No deduction for fill < 0.6m 1.00
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 45x1 45.00 %

Increasing due to Impact (As per IRC-6-2000,


= 2.604x1.45 3.78 T/m2
Cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 4 : When two Class A (5.7 x 2T) is Placed at the centre of slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.5 0.5

0.25

1.2 4.35

1.8 1 1.8

5.7 T 5.7 T 5.7 T 5.7 T


Class A Wheeled Vehicle Class A Wheeled Vehicle

3.32 m 3.32 m 3.32 m 3.32 m

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 1.32 m
a =0.5×(4.35-1.2) 1.575 m
b1 0.565 m
α 2.74
beff α x a (1- a/lo) + b1
beff = 2.74x1.575x(1-1.575/4.35)+0.565 3.32 m Overlapping
Effective Width across for Design 6.51 m
Effective width greater than widening width. So beff for design is 5.75 m
Width along the Span =0.25+2×(0.400+0.065) 1.18 m No Overlapping
Effective width along Span 1.18 m
Effective width less than c/c span
So effective Width along span for Design 1.18 m
Load considered 22.8 T
Load Intensity = 22.8/(6.51×1.180) 3.36 T/m2
Impact factor 45.00 %
Increasing due to Impact (As per IRC-6-2000,
= 3.36x1.45 4.87 T/m2
Cl:211.6 and 211.7)
So design intensity = 50.0 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

8.5 Braking Load


Total Horizontal Load on top of the box =0.2×(10+10+10+10)×10 = 80.00 kN
Horizontal load per m width of the structure =80.00/5.75 = 13.91 kN/m

8.6 Structural Design


8.6.1 Summary of Moments (From STAAD Pro)

Design Moments (kNm)


Load Combinations Top Slab Bottom Slab Side Walls
Sagging Hogging Sagging Hogging Outer Inner
Maximum Moment 89 55 109 48 69 9
0.2 D.L+0.3 L.L 20 11 19 7 14 0

Design Bending Moments (kNm)


55.0 55.0
69.0 89.0 69.0

9.0 9.0

69.0
109.0 69.0
48.0 48.0
Maximum Moment in Top Slab at Mid Span = 89.00 kNm
Maximum Moment in Top Slab at Support = 55.00 kNm
Maximum Moment in Side Wall outer surface = 69.00 kNm
Maximum Moment in Side Wall inner surface = 9.00 kNm
Maximum Moment in Bottom Slab at Mid Span = 109.00 kNm
Maximum Moment in Bottom Slab at Support = 48.00 kNm
Depth of Top Slab = 400 mm
Depth of Side Wall = 350 mm
Depth of Bottom Slab = 425 mm
Grade of Concrete M30 σcbc = 10.00 kN/m2
Grade of Steel Fe500 σst = 240.0 kN/m2
Modular Ratio = 10.00
k = 1/(1+σst/m*σcbc) = 0.294
j = 1-k/3 = 0.902
Q = 0.5*k*j*σcbc = 1.33

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

8.6.2 Design of Top Slab


Depth Check
Considering clear cover of 75 mm for the base slab and 40 mm for all the othert faces
Depth of Top Slab Provided = 400 mm
Effective Depth Provided = 400-40-6 = 352 mm
Maximum Moment = 89.00 kNm
Effective Depth Required = SQRT(89/(1.33))*1000 = 259 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 400 mm Effective depth = 352 mm
Max moment on top surface = 55 kNm Steel reqd = 721.8 mm2
Provide 12mm @ 150mm C/C
Area of steel provided = 754.0 mm2
Max moment on bottom surface = 89 kNm Steel reqd = = 1168.0 mm2
Provide 16 mm @ 150mm C/C
Area of steel provided = 1340.4 mm2
Minimum Steel = 0.06 % of C/S = 211.2 mm2
Max moment mid top surface = 4 kNm Steel reqd = 60.8 mm2
Thus, Area of Steel Required = 211.2 mm2
Provide 10 mm dia @ 300mm C/C
Area of steel provided = 261.8 mm2
8.6.3 Design of Bottom Slab
Depth Check
Depth of Bottom Slab Provided = 425 mm
Effecetive Depth Provided = 425-75-8 = 342 mm
Maximum Moment = 109.00 kNm
Effective Depth Required = SQRT(109/(1.33))*1000 = 287 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 425 mm Effective depth = 342 mm
Max moment on top surface = 109 kNm Steel reqd = 1472.3 mm2
Provide 16 mm dia @ 120mm C/C
Area of steel provided = 1675.5 mm2
Max moment on bottom surface = 48 kNm Steel reqd = 648.4 mm2
Provide 10 mm dia @ 120mm C/C
Area of steel provided = 654.5 mm2
Minimum Steel = 0.06 % of C/S = 205.2 mm2
Max moment mid bot surface = 6 kNm Steel reqd = 91.2 mm2
Thus, Area of Steel Required = 205.2 mm2
Provide 10 mm dia @ 240mm C/C
Area of steel provided = 327.2 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

8.6.4 Design of Side Wall


Depth Check
Depth of side Wall Provided = 350 mm
Effective Depth Provided = 350-40-12/2 = 304 mm
Maximum Moment = 69.00 kNm
Effective Depth Required = SQRT(69/(1.33))*1000 = 228.1 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of wall = 350 mm Effective depth = 304.0 mm
Max moment on outer surface = 69 kNm Steel reqd = 1048.5 mm2
Provide 12 mm dia @ 100 mm dia @
Area of steel provided = 1131.0 mm2
Minimum reinforcement on the inner face
Minimum Steel = 0.06 % of C/S = 210.0 mm2
Max moment on inner surface = 9 kNm Steel reqd = 136.8 mm2
Thus, Area of Steel Required = 210.0 mm2
Provide 10 mm dia @ 200mm C/C
Area of steel provided = 392.7 mm2
8.6.5 Distribution Steel
Tob Slab
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×352 = 422.4 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 20.0 kNm
Area of Steel Required = =20.00×10^6/(240.00×352×0.902) = 262.5 mm2
Thus, Area of Steel Required = 422.4 mm2
Provide 8 mm dia @ 110mm C/C
Area of steel provided = 457.0 mm2
Bottom Slab
Case1 :
Minimum Steel
= 0.12% Effective Area = =1.2×342 = 410.4 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 19.0 kNm
Area of Steel Required = =19.00×10^6/(240.00×342×0.902) = 256.6 mm2
Thus, Area of Steel Required = 410.4 mm2
Provide 10 mm dia @ 190mm C/C
Area of steel provided = 413.4 mm2
Side Wall
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×304 = 364.8 mm2
Case2 : = 0.2DL+0.3LL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Maximum Bending Moment for Distribution Steel = 14.0 kNm


Area of Steel Required = =14.00×10^6/(240.00×0.902×304) = 212.7 mm2
Thus, Area of Steel Required = 364.8 mm2
Provide 8 mm dia @ 130mm C/C
Area of steel provided = 386.7 mm2

8.7 STAAD Input file


STAAD PLANE
START JOB INFORMATION
ENGINEER DATE 19-JANUARY-11
END JOB INFORMATION
INPUT WIDTH 79
UNIT METER KN
JOINT COORDINATES
1 0 0 0
2 0 0.2 0
3 0 0.7 0
4 0 1.2 0
5 0 1.7 0
6 0 2.2 0
7 0 2.4 0
8 0.175 2.4 0
9 0.517 2.4 0
10 1.622 2.4 0
11 2.728 2.4 0
12 3.833 2.4 0
13 4.175 2.4 0
14 4.35 2.4 0
15 4.35 2.2 0
16 4.35 1.7 0
17 4.35 1.2 0
18 4.35 0.7 0
19 4.35 0 0
20 4.35 0 0
21 4.175 0 0
22 3.833 0 0
23 2.728 0 0
24 1.622 0 0
25 0.517 0 0
26 0.175 0 0
MEMBER INCIDENCES

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10; 10 10 11;
11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17; 17 17 18; 18 18 19;
19 19 20; 20 20 21; 21 21 22; 22 22 23; 23 23 24; 24 24 25; 25 25 26; 26 26 1;
START GROUP DEFINITION
MEMBER
_TOPSLAB 7 TO 13
_BOTTOMSLAB 20 TO 26
_SIDEWALL1 1 TO 6
_SIDEWALL2 14 TO 19
END GROUP DEFINITION
DEFINE MATERIAL START
ISOTROPIC MATERIAL1
E 27.39e+006
POISSON 0.15
DENSITY 25
DAMP 2.8026e-044
END DEFINE MATERIAL
CONSTANTS
MATERIAL MATERIAL1 ALL
MEMBER PROPERTY INDIAN
7 TO 13 PRIS YD 0.4 ZD 1
1 TO 6 14 TO 19 PRIS YD 0.35 ZD 1
20 TO 26 PRIS YD 0.425 ZD 1
**SUPPORT SPECS*********
*CONSIDERING MOD. OF SUBGRADE RXN AS 15000 kN/sq.m
SUPPORTS
1 FIXED BUT FX FZ MX MY MZ KFY 3877.5
20 FIXED BUT MX MY MZ KFY 3877.5
22 25 FIXED BUT FX FZ MX MY MZ KFY 12167.5
24 23 FIXED BUT FX FZ MX MY MZ KFY 16580
****LOADING ON THE STRUCTURE****************
**************
*********DL*****
LOAD 1 DEAD LOAD
MEMBER LOAD
7 TO 13 UNI GY -10
20 TO 26 UNI GY -10.625
1 TO 6 UNI GY -8.75
14 TO 19 UNI GY -8.75
*********SIDL*******
LOAD 2 SIDL FOR FILL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

*(*LOAD DUE TO Wearing Coat + Crash Barrier+ FILL + HAUNCH)


MEMBER LOAD
7 TO 13 UNI GY -15.21
********EP AT REST********
*LOAD DUE TO EARTH PRESSURE AT BOTH SIDES
LOAD 3 EARTH PRESSURE
MEMBER LOAD
6 TRAP GX 7 5
5 TRAP GX 12 7
4 TRAP GX 17 12
3 TRAP GX 22 17
2 TRAP GX 27 22
1 TRAP GX 29.125 27
14 TRAP GX -5 -7
15 TRAP GX -7 -12
16 TRAP GX -12 -17
17 TRAP GX -17 -22
18 TRAP GX -22 -27
19 TRAP GX -27 -29.13
*********LL SURCHARGE *********
*LL SURCHARGE DUE TO FILL AT BOTH SIDES
LOAD 4 LL SURCHARGE
MEMBER LOAD
6 UNI GX 12
5 UNI GX 12
4 UNI GX 12
3 UNI GX 12
2 UNI GX 12
1 UNI GX 12
*********70 R TRACKED LOAD (Load considered 17T)*******
LOAD 5 70R TRACKED
MEMBER LOAD
7 TO 13 UNI GY -43.29
**********40 T BOGGIE LOAD*******
LOAD 6 BOGGIE
MEMBER LOAD
9 UNI GY -49.95 0.46 1.11
10 UNI GY -49.95
11 UNI GY -49.95 0.00 0.65
********** CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 7 CLASS A WHEELED

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
9 UNI GY -37.77 0.46 1.11
10 UNI GY -37.77
11 UNI GY -37.77 0.00 0.65
********** Two CLASS A VEHICLE LOAD(TWO 5.7Tx4) ****
LOAD 8 TWO CLASS A WHEELED
MEMBER LOAD
9 UNI GY -48.73 0.46 1.11
10 UNI GY -48.73
11 UNI GY -48.73 0.00 0.65
*********BRAKING LOAD*********
LOAD 9 BRAKING LOAD
JOINT LOAD
7 FX 13.91
****LOAD COMBINATIONS***************
LOAD COMB 10 DL + SIDL + EP + SUR
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 11 DL + SIDL + EP + SUR + 70R TRACKED
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0
LOAD COMB 12 DL + SIDL + EP + SUR + BOGGIE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0
LOAD COMB 13 DL + SIDL + EP + SUR + CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 7 1.0
LOAD COMB 14 DL + SIDL + EP + SUR + TWO CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 15 DL + SIDL + EP + SUR + BOGGIE + BRAKING FORCE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0 9 1.0
LOAD COMB 16 0.2 DL + 0.3 BOGGIE + 0.3 BRAKING FORCE
1 0.2 6 0.3 9 0.3
PERFORM ANALYSIS
PRINT MEMBER FORCES ALL
FINISH

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

9 Design of 4.0 x 2.5m Box Culvert


9.1 Design Inputs

0.425

2.5
0.35

0.45

4.4

Clear Span = 4.0 m


Clear Height = 2.5 m
Top Slab Thickness = 0.425 m
Bottom Slab Thickness = 0.450 m
Side Wall Thickness = 0.350 m
Height of Fill = 0.3 m
Thickness of Wearing Coat = 0.065 m

Panel width = 1.0 m


Width of Carriage Way = 5.75 m

Angle of internal friction φ = 30 Degrees


Coefficient of Earth Pressure at Rest = 0.5
Dry Density of Fill above Top Slab = 20 kN/m3
Concrete Density = 25 kN/m3
Surcharge Live Load = 1.2 m
SBC Value Assumed = 150.0 kN/m2

9.2 General Diagram with Loading

Fill 0.3
(All dimensions in m)

0.4

Haunch (0.15x0.15)

2.5

0.5

0.4 4.0 0.4

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Total Span = 4.7 m


Total Height = 3.4 m
C/C Span = 4.4 m
C/C Height = 2.9 m

9.3 Idealised Structure of Box Culvert for STAAD Analysis


The Structure is Idealised in STAAD. Pro as shown below. The dimensions are considered as centre to centre.
The structural analysis has been done for one metre strip.

4.35 m

2.94 m

A
B D B A

Spacing Between 2 End Springs = 0.542 m


Spacing between 2 int springs = 1.089 m
Spacing between 2 end nodes of Side Wall at top = 0.213 m
Spacing between 2 end nodes of Side Wall at bottom = 0.225 m
Spacing between 2 int. nodes of Side wall = 0.625 m
Modulus of Subgrade reaction = 15000 kN/m3
Spring constants at end supports =15000x(0.542/2) = 4065.0 kN/m
Spring constant at Intermediate supports for the Box =15000x(0.542+1.0887)/2 = 12230.3 kN/m
Spring constant at Int.Supports =15000x(1.0887+1.089)/2) = 16330.5 kN/m
(Ref:pg:408,Foundation Analysis and Design by joseph E.Bowles (Fs=40*s.f*qa) and s.f = 2.5)

9.4 Load Calculation


9.4.1 Dead Load
Self Weight of Tob Slab = 0.425x1x25 = 10.63 kN/m
Self Weight of Bottom Slab = 0.45x1x25 = 11.25 kN/m
Self Weight of side Walls = 0.35x1x25 = 8.75 kN/m
Weight of Haunch = 0.15×0.15×0.5×2.5 = 0.28 kN

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

9.4.2 SIDL
Load due to Wearing Coat = 0.065x1x2.2 = 1.43 kN/m
Load due to Earth Fill = 0.3x1x20 = 6.00 kN/m
Weight of Crash Barrier = 0.3x2.5 = 7.50 kN/m
TOTAL = 14.93 kN/m
Total Base Area =4.7×1 = 4.70 m2
Total Average Bottom Pressure =(14.93+10.63+11.25+8.75+0.28+( 43.29×4.35))/4.70 = 49.82 kN/m2
Less than SBC So, Safe

9.4.3 Computation of Earth Pressure


SIDE A SIDE B

0.5*20*0.5125 = 5.13 kN/m2 0.5 m


2
0.5*20*0.725 = 7.25 kN/m 0.7 m
1.4 m
2
0.5*20*1.350 = 13.50 kN/m

2.0 m
2
0.5*20*1.975 = 19.75 kN/m
2.6 m
2
0.5*20*2.600 = 26.00 kN/m

3.2 m
0.5*20*3.225 = 32.25 kN/m2
0.5*20*3.450 = 34.50 kN/m2 3.5 m

9.4.4 Surcharge Live Load


Lateral Pressure due to Surcharge Live Load Equivalent to 1.2 m of Earth Fill = 12.00 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

9.4.5 Live Load


Case 1: When Class 70R Tracked Vehicle is Placed at the centre of the Slab
(65mm Wearing Coat Considered)
Direction of Traffic
Total Load

33.32 T
0.85

35 T 35 T

4.57 4.35

2.05

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 1.322 m
a = 4.35/2 2.175 m
b1 =0.85+0.065 0.915 m
α 2.74
beff α x a (1- a/lo) + b1
beff = 2.74x2.175x(1-2.175/4.35)+0.915 3.89 m Overlapping
Effective Width across traffic 4.42 m
Effective width less than widening width. So OK.
Width along the Span = 4.57+2×(0.065+0.425) 5.55 m
Effective width greater than c/c span
So width along the Span for Design 4.35 m
Load considered = 35/4.57×4.35 66.63 T
2
Load Intensity = 66.63/(4.35×4.42) 3.46 T/m
Impact factor = 25% 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 3.464x1.25 4.329 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 2 : When Class 70R Bogie Load (40T) is Placed at the centre of Slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.86

0.263

10 T 10 T

4.35 1.22

10 T 10 T

1.93

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.75 m


Calculation for Effective Width of Loading = b/ l0 0.23 m
a = 4.35/2-1.22/2 1.57 m
b1 =0.86+0.065 0.93 m
α 2.74
beff α x a (1- a/lo) + b1
beff = 2.740x1.565x(1-1.565/4.35)+0.925 3.67 m Overlapping
So effective Width across for Design 4.20 m
Effective width less than widening width. So OK.
Width along the Span = 0.263+2×(0.425+0.065) 1.243 Overlapping
Effective width along Span 3.44 m
Effective width less than c/c span
So effective Width along span for Design 3.44 m
Load considered 40 T
Load Intensity = 40/(4.20×3.443) 2.77 T/m2
Impact factor 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 2.769x1.25 3.462 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 3 : When Class A (5.7 x 2 T) is Placed at the centre of slab


(65mm Wearing Coat Considered)

Direction of Traffic

5.7 T 1.8 5.7 T

0.25

4.35 0.5

1.2

5.7 T 5.7 T

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.230 m
a = 4.35/2-1.2/2 1.575 m
b1 0.57 m
α 2.74
beff α x a (1- a/lo) + b1
beff = 2.74x1.575x(1-1.575/4.35)+0.565 3.32 m Overlapping
Effective Width across for Design = 1.2+0.5+0.5/2+1.8+3.32/2 3.71 m
Effective width less than widening width. So OK.
Width along the Span = 0.25+(2×(0.425+0.065)) 1.23 m Overlapping
Effective width along Span 3.41 m
Effective width less than c/c span
So effective Width along span for Design 3.41 m
Load considered 22.8 T
Load Intensity = 22.8/(3.71×3.410) 1.80 T/m2
Impact factor 45.00 %
Deduction in the I.F No deduction for fill < 0.6m 1.00
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 45x1 45.00 %

Increasing due to Impact (As per IRC-6-2000,


= 1.802x1.45 2.61 T/m2
Cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 4 : When two Class A (5.7 x 2T) is Placed at the centre of slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.5

0.5

0.25

1.2 4.35

1.8 1 1.8

5.7 T 5.7 T 5.7 T 5.7 T


Class A Wheeled Vehicle

3.32 m 3.32 m 3.32 m 3.32 m

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 1.32 m
a =0.5×(4.35-1.2) 1.575 m
b1 0.565 m
α 2.74
beff α x a (1- a/lo) + b1
beff = 2.74x1.575x(1-1.575/4.35)+0.565 3.32 m Overlapping
Effective Width across for Design 6.51 m
Effective width greater than widening width. So beff for design is 5.75 m
Width along the Span =0.25+2×(0.425+0.065) 1.23 m Overlapping
Effective width along Span 3.41 m
Effective width less than c/c span
So effective Width along span for Design 3.41 m
Load considered 45.6 T
Load Intensity = 45.6/(6.51×3.410) 2.33 T/m2
Impact factor 45.00 %
Increasing due to Impact (As per IRC-6-2000,
= 2.326x1.45 3.37 T/m2
Cl:211.6 and 211.7)
So design intensity = 43.3 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

9.5 Braking Load


Total Horizontal Load on top of the box =0.2×2×33.32×10 = 133.26 kN
Horizontal load per m width of the structure =133.26/5.75 = 23.18 kN/m

9.6 Structural Design


9.6.1 Summary of Moments (From STAAD Pro)

Design Moments (kNm)


Load Combinations Top Slab Bottom Slab Side Walls
Sagging Hogging Sagging Hogging Outer Inner
Maximum Moment 101 59 129 67 78 15
0.2 D.L+0.3 L.L 24 11 30 10 16 0

Design Bending Moments (kNm)


59.0 59.0
78.0 101.0 78.0

15.0 15.0

78.0
129.0 78.0
67.0 67.0
Maximum Moment in Top Slab at Mid Span = 101.00 kNm
Maximum Moment in Top Slab at Support = 59.00 kNm
Maximum Moment in Side Wall outer surface = 78.00 kNm
Maximum Moment in Side Wall inner surface = 15.00 kNm
Maximum Moment in Bottom Slab at Mid Span = 129.00 kNm
Maximum Moment in Bottom Slab at Support = 67.00 kNm
Depth of Top Slab = 425 mm
Depth of Side Wall = 350 mm
Depth of Bottom Slab = 450 mm
Grade of Concrete M30 σcbc = 10.00 kN/m2
Grade of Steel Fe500 σst = 240.0 kN/m2
Modular Ratio = 10.00
k = 1/(1+σst/m*σcbc) = 0.294
j = 1-k/3 = 0.902
Q = 0.5*k*j*σcbc = 1.33

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

9.6.2 Design of Top Slab


Depth Check
Considering clear cover of 75 mm for the base slab and 40 mm for all the othert faces
Depth of Top Slab Provided = 425 mm
Effective Depth Provided = 425-40-6 = 377 mm
Maximum Moment = 101.00 kNm
Effective Depth Required = SQRT(101/(1.33))*1000 = 276 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 425 mm Effective depth = 377 mm
Max moment on top surface = 59 kNm Steel reqd = 723.0 mm2
Provide 12mm @ 150mm C/C
Area of steel provided = 754.0 mm2
Max moment on bottom surface = 101 kNm Steel reqd = = 1237.6 mm2
Provide 16 mm @ 150mm C/C
Area of steel provided = 1340.4 mm2
Minimum Steel = 0.06 % of C/S = 226.2 mm2
Max moment mid top surface = 8 kNm Steel reqd = 122.4 mm2
Thus, Area of Steel Required = 226.2 mm2
Provide 10 mm dia @ 300mm C/C
Area of steel provided = 261.8 mm2
9.6.3 Design of Bottom Slab
Depth Check
Depth of Bottom Slab Provided = 450 mm
Effecetive Depth Provided = 450-75-8 = 367 mm
Maximum Moment = 129.00 kNm
Effective Depth Required = SQRT(129/(1.33))*1000 = 312 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 450 mm Effective depth = 367 mm
Max moment on top surface = 129 kNm Steel reqd = 1623.8 mm2
Provide 16 mm dia @ 120mm C/C
Area of steel provided = 1675.5 mm2
Max moment on bottom surface = 67 kNm Steel reqd = 843.4 mm2
Provide 12 mm dia @ 120mm C/C
Area of steel provided = 942.5 mm2
Minimum Steel = 0.06 % of C/S = 220.2 mm2
Max moment mid bot surface = 10 kNm Steel reqd = 153.0 mm2
Thus, Area of Steel Required = 220.2 mm2
Provide 10 mm dia @ 240mm C/C
Area of steel provided = 327.2 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

9.6.4 Design of Side Wall


Depth Check
Depth of side Wall Provided = 350 mm
Effective Depth Provided = 350-40-16/2 = 302 mm
Maximum Moment = 78.00 kNm
Effective Depth Required = SQRT(78/(1.33))*1000 = 242.5 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of wall = 350 mm Effective depth = 302.0 mm
Max moment on outer surface = 78 kNm Steel reqd = 1193.1 mm2
Provide 16 mm dia @ 160 mm dia @
Area of steel provided = 1256.6 mm2
Minimum reinforcement on the inner face
Minimum Steel = 0.06 % of C/S = 210.0 mm2
Max moment on inner surface = 15 kNm Steel reqd = 229.4 mm2
Thus, Area of Steel Required = 229.4 mm2
Provide 10 mm dia @ 160mm C/C
Area of steel provided = 490.9 mm2
9.6.5 Distribution Steel
Tob Slab
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×377 = 452.4 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 30.0 kNm
Area of Steel Required = =30.00×10^6/(240.00×377×0.902) = 367.6 mm2
Thus, Area of Steel Required = 452.4 mm2
Provide 10 mm dia @ 170mm C/C
Area of steel provided = 462.0 mm2
Bottom Slab
Case1 :
Minimum Steel
= 0.12% Effective Area = =1.2×367 = 440.4 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 30.0 kNm
Area of Steel Required = =30.00×10^6/(240.00×367×0.902) = 377.6 mm2
Thus, Area of Steel Required = 440.4 mm2
Provide 10 mm dia @ 170mm C/C
Area of steel provided = 462.0 mm2
Side Wall
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×302 = 362.4 mm2
Case2 : = 0.2DL+0.3LL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Maximum Bending Moment for Distribution Steel = 16.0 kNm


Area of Steel Required = =16.00×10^6/(240.00×0.902×302) = 244.7 mm2
Thus, Area of Steel Required = 362.4 mm2
Provide 8 mm dia @ 130mm C/C
Area of steel provided = 386.7 mm2

9.7 STAAD Input file


STAAD PLANE
START JOB INFORMATION
ENGINEER DATE 19-JANUARY-11
END JOB INFORMATION
INPUT WIDTH 79
UNIT METER KN
JOINT COORDINATES
1 0 0 0
2 0 0.2 0
3 0 0.9 0
4 0 1.5 0
5 0 2.1 0
6 0 2.7 0
7 0 2.9 0
8 0.175 2.9 0
9 0.542 2.9 0
10 1.631 2.9 0
11 2.719 2.9 0
12 3.808 2.9 0
13 4.175 2.9 0
14 4.35 2.9 0
15 4.35 2.7 0
16 4.35 2.1 0
17 4.35 1.5 0
18 4.35 0.9 0
19 4.35 0 0
20 4.35 0 0
21 4.175 0 0
22 3.808 0 0
23 2.719 0 0
24 1.631 0 0
25 0.542 0 0
26 0.175 0 0
MEMBER INCIDENCES

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10; 10 10 11;
11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17; 17 17 18; 18 18 19;
19 19 20; 20 20 21; 21 21 22; 22 22 23; 23 23 24; 24 24 25; 25 25 26; 26 26 1;
START GROUP DEFINITION
MEMBER
_TOPSLAB 7 TO 13
_BOTTOMSLAB 20 TO 26
_SIDEWALL1 1 TO 6
_SIDEWALL2 14 TO 19
END GROUP DEFINITION
DEFINE MATERIAL START
ISOTROPIC MATERIAL1
E 27.39e+006
POISSON 0.15
DENSITY 25
DAMP 2.8026e-044
END DEFINE MATERIAL
CONSTANTS
MATERIAL MATERIAL1 ALL
MEMBER PROPERTY INDIAN
7 TO 13 PRIS YD 0.425 ZD 1
1 TO 6 14 TO 19 PRIS YD 0.35 ZD 1
20 TO 26 PRIS YD 0.45 ZD 1
**SUPPORT SPECS*********
*CONSIDERING MOD. OF SUBGRADE RXN AS 15000 kN/sq.m
SUPPORTS
1 FIXED BUT FX FZ MX MY MZ KFY 4065
20 FIXED BUT MX MY MZ KFY 4065
22 25 FIXED BUT FX FZ MX MY MZ KFY 12230
24 23 FIXED BUT FX FZ MX MY MZ KFY 16330
****LOADING ON THE STRUCTURE****************
**************
*********DL*****
LOAD 1 DEAD LOAD
MEMBER LOAD
7 TO 13 UNI GY -10.625
20 TO 26 UNI GY -11.25
1 TO 6 UNI GY -8.75
14 TO 19 UNI GY -8.75
*********SIDL*******
LOAD 2 SIDL FOR FILL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

*(*LOAD DUE TO Wearing Coat + Crash Barrier+ FILL + HAUNCH)


MEMBER LOAD
7 TO 13 UNI GY -15.21
********EP AT REST********
*LOAD DUE TO EARTH PRESSURE AT BOTH SIDES
LOAD 3 EARTH PRESSURE
MEMBER LOAD
6 TRAP GX 7.25 5.125
5 TRAP GX 13.5 7.25
4 TRAP GX 19.75 13.5
3 TRAP GX 26 19.75
2 TRAP GX 32.25 26
1 TRAP GX 34.5 32.25
14 TRAP GX -5.125 -7.25
15 TRAP GX -7.25 -13.5
16 TRAP GX -13.5 -19.75
17 TRAP GX -19.75 -26
18 TRAP GX -26 -32.25
19 TRAP GX -32.25 -34.50
*********LL SURCHARGE *********
*LL SURCHARGE DUE TO FILL AT BOTH SIDES
LOAD 4 LL SURCHARGE
MEMBER LOAD
6 UNI GX 12
5 UNI GX 12
4 UNI GX 12
3 UNI GX 12
2 UNI GX 12
1 UNI GX 12
*********70 R TRACKED LOAD (Load considered 17T)*******
LOAD 5 70R TRACKED
MEMBER LOAD
7 TO 13 UNI GY -43.29
**********40 T BOGGIE LOAD*******
LOAD 6 BOGGIE
MEMBER LOAD
8 9 UNI GY -34.62
10 UNI GY -34.62
11 12 UNI GY -34.62
********** CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 7 CLASS A WHEELED

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
8 9 UNI GY -26.14
10 UNI GY -26.14
11 12 UNI GY -26.14
********** Two CLASS A VEHICLE LOAD(TWO 5.7Tx4) ****
LOAD 8 TWO CLASS A WHEELED
MEMBER LOAD
7 TO 9 UNI GY -33.72
10 UNI GY -33.72
11 TO 13 UNI GY -33.72
*********BRAKING LOAD*********
LOAD 9 BRAKING LOAD
JOINT LOAD
7 FX 23.18
****LOAD COMBINATIONS***************
LOAD COMB 10 DL + SIDL + EP + SUR
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 11 DL + SIDL + EP + SUR + 70R TRACKED
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0
LOAD COMB 12 DL + SIDL + EP + SUR + BOGGIE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0
LOAD COMB 13 DL + SIDL + EP + SUR + CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 7 1.0
LOAD COMB 14 DL + SIDL + EP + SUR + TWO CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 15 DL + SIDL + EP + SUR + TRUCK + BRAKING FORCE
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0 9 1.0
LOAD COMB 16 0.2 DL + 0.3 TRACK + 0.3 BRAKING FORCE
1 0.2 5 0.3 9 0.3
PERFORM ANALYSIS
PRINT MEMBER FORCES ALL
FINISH

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

10 Design of 4.0 x 3.0m Box Culvert


10.1 Design Inputs

0.425

3.0
0.375

0.45

4.4

Clear Span = 4.0 m


Clear Height = 3.0 m
Top Slab Thickness = 0.425 m
Bottom Slab Thickness = 0.450 m
Side Wall Thickness = 0.375 m
Height of Fill = 0.3 m
Thickness of Wearing Coat = 0.065 m

Panel width = 1.0 m


Width of Carriage Way = 5.75 m

Angle of internal friction φ = 30 Degrees


Coefficient of Earth Pressure at Rest = 0.5
Dry Density of Fill above Top Slab = 20 kN/m3
Concrete Density = 25 kN/m3
Surcharge Live Load = 1.2 m
SBC Value Assumed = 150.0 kN/m2

10.2 General Diagram with Loading

Fill 0.3
(All dimensions in m)

0.43

Haunch (0.15x0.15)

3.0

0.45

0.38 4.0 0.38

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Total Span = 4.75 m


Total Height = 3.88 m
C/C Span = 4.38 m
C/C Height = 3.44 m

10.3 Idealised Structure of Box Culvert for STAAD Analysis


The Structure is Idealised in STAAD. Pro as shown below. The dimensions are considered as centre to centre.
The structural analysis has been done for one metre strip.

4.38 m

3.44 m

A
B D B A

Spacing Between 2 End Springs = 0.553 m


Spacing between 2 int springs = 1.090 m
Spacing between 2 end nodes of Side Wall at top = 0.213 m
Spacing between 2 end nodes of Side Wall at bottom = 0.225 m
Spacing between 2 int. nodes of Side wall = 0.75 m
Modulus of Subgrade reaction = 15000 kN/m3
Spring constants at end supports =15000x(0.5525/2) = 4143.8 kN/m
Spring constant at Intermediate supports for the Box =15000x(0.5525+1.09)/2 = 12318.8 kN/m
Spring constant at Int.Supports =15000x(1.09+1.090)/2) = 16350.0 kN/m
(Ref:pg:408,Foundation Analysis and Design by joseph E.Bowles (Fs=40*s.f*qa) and s.f = 2.5)

10.4 Load Calculation


10.4.1 Dead Load
Self Weight of Tob Slab = 0.425x1x25 = 10.63 kN/m
Self Weight of Bottom Slab = 0.45x1x25 = 11.25 kN/m
Self Weight of side Walls = 0.375x1x25 = 9.38 kN/m
Weight of Haunch = 0.15×0.15×0.5×2.5 = 0.28 kN

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

109.4.2 SIDL
Load due to Wearing Coat = 0.065x1x2.2 = 1.43 kN/m
Load due to Earth Fill = 0.3x1x20 = 6.00 kN/m
Weight of Crash Barrier = 0.3x2.5 = 7.50 kN/m
TOTAL = 14.93 kN/m
Total Base Area =4.8×1 = 4.75 m2
Total Average Bottom Pressure =(14.93+10.63+11.25+9.38+0.28+( 43.21×4.38))/4.75 = 49.58 kN/m2
Less than SBC So, Safe
10.4.3 Computation of Earth Pressure
SIDE A SIDE B

0.5*20*0.5125 = 5.13 kN/m2 0.5 m


0.5*20*0.725 = 7.25 kN/m2 0.7 m
1.5 m
2
0.5*20*1.475 = 14.75 kN/m

2.2 m
0.5*20*2.225 = 22.25 kN/m2
3.0 m
0.5*20*2.975 = 29.75 kN/m2

3.7 m
0.5*20*3.725 = 37.25 kN/m2
0.5*20*3.950 = 39.50 kN/m2 4.0 m

10.4.4 Surcharge Live Load


Lateral Pressure due to Surcharge Live Load Equivalent to 1.2 m of Earth Fill = 12.00 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

10.4.5 Live Load


Case 1: When Class 70R Tracked Vehicle is Placed at the centre of the Slab
(65mm Wearing Coat Considered)
Direction of Traffic
Total Load

33.51 T
0.85

35 T 35 T

4.57 4.38

2.05

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 1.314 m
a = 4.375/2 2.188 m
b1 =0.85+0.065 0.915 m
α 2.74
beff α x a (1- a/lo) + b1
beff = 2.74x2.1875x(1-2.1875/4.375)+0.9153.91 m Overlapping
Effective Width across traffic 4.43 m
Effective width less than widening width. So OK.
Width along the Span = 4.57+2×(0.065+0.425) 5.55 m
Effective width greater than c/c span
So width along the Span for Design 4.38 m
Load considered = 35/4.57×4.38 67.01 T
2
Load Intensity = 67.01/(4.375×4.43) 3.46 T/m
Impact factor = 25% 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 3.457x1.25 4.321 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 2 : When Class 70R Bogie Load (40T) is Placed at the centre of Slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.86

0.263

10 T 10 T

4.38 1.22

10 T 10 T

1.93

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.75 m


Calculation for Effective Width of Loading = b/ l0 0.23 m
a = 4.375/2-1.22/2 1.58 m
b1 =0.86+0.065 0.93 m
α 2.74
beff α x a (1- a/lo) + b1
beff = 2.740x1.5775x(1-1.5775/4.375)+0.9253.69 m Overlapping
So effective Width across for Design 4.20 m
Effective width less than widening width. So OK.
Width along the Span = 0.263+2×(0.425+0.065) 1.243 Overlapping
Effective width along Span 3.44 m
Effective width less than c/c span
So effective Width along span for Design 3.44 m
Load considered 40 T
Load Intensity = 40/(4.20×3.443) 2.76 T/m2
Impact factor 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 2.763x1.25 3.454 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 3 : When Class A (5.7 x 2 T) is Placed at the centre of slab


(65mm Wearing Coat Considered)

Direction of Traffic

5.7 T 1.8 5.7 T

0.25

4.38 0.5

1.2

5.7 T 5.7 T

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.229 m
a = 4.375/2-1.2/2 1.588 m
b1 0.57 m
α 2.74
beff α x a (1- a/lo) + b1
beff = 2.74x1.5875x(1-1.5875/4.375)+0.5653.34 m Overlapping
Effective Width across for Design = 1.2+0.5+0.5/2+1.8+3.34/2 3.72 m
Effective width less than widening width. So OK.
Width along the Span = 0.25+(2×(0.425+0.065)) 1.23 m Overlapping
Effective width along Span 3.41 m
Effective width less than c/c span
So effective Width along span for Design 3.41 m
Load considered 22.8 T
Load Intensity = 22.8/(3.72×3.410) 1.80 T/m2
Impact factor 45.00 %
Deduction in the I.F No deduction for fill < 0.6m 1.00
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 45x1 45.00 %

Increasing due to Impact (As per IRC-6-2000,


= 1.797x1.45 2.61 T/m2
Cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 4 : When two Class A (5.7 x 2T) is Placed at the centre of slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.5 0.5

1.2 0.25 4.38

1.8 1 1.8

5.7 T 5.7 T 5.7 T 5.7 T


Class A Wheeled Vehicle Class A Wheeled Vehicle

3.34 m 3.34 m 3.34 m 3.34 m

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 1.31 m
a =0.5×(4.38-1.2) 1.588 m
b1 0.565 m
α 2.74
beff α x a (1- a/lo) + b1
beff = 2.74x1.5875x(1-1.5875/4.375)+0.5653.34 m Overlapping
Effective Width across for Design 6.52 m
Effective width greater than widening width. So beff for design is 5.75 m
Width along the Span =0.25+2×(0.425+0.065) 1.23 m Overlapping
Effective width along Span 3.41 m
Effective width less than c/c span
So effective Width along span for Design 3.41 m
Load considered 45.6 T
Load Intensity = 45.6/(6.52×3.410) 2.33 T/m2
Impact factor 45.00 %
Increasing due to Impact (As per IRC-6-2000,
= 2.326x1.45 3.37 T/m2
Cl:211.6 and 211.7)
So design intensity = 43.2 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

10.5 Braking Load


Total Horizontal Load on top of the box =0.2×2×33.51×10 = 134.03 kN
Horizontal load per m width of the structure =134.03/5.75 = 23.31 kN/m

10.6 Structural Design


10.6.1 Summary of Moments (From STAAD Pro)

Design Moments (kNm)


Load Combinations Top Slab Bottom Slab Side Walls
Sagging Hogging Sagging Hogging Outer Inner
Maximum Moment 99 69 131 83 88 21
0.2 D.L+0.3 L.L 25 11 31 11 17 0

Design Bending Moments (kNm)


69.0 69.0
88.0 99.0 88.0

21.0 21.0

88.0
131.0 88.0
83.0 83.0
Maximum Moment in Top Slab at Mid Span = 99.00 kNm
Maximum Moment in Top Slab at Support = 69.00 kNm
Maximum Moment in Side Wall outer surface = 88.00 kNm
Maximum Moment in Side Wall inner surface = 21.00 kNm
Maximum Moment in Bottom Slab at Mid Span = 131.00 kNm
Maximum Moment in Bottom Slab at Support = 83.00 kNm
Depth of Top Slab = 425 mm
Depth of Side Wall = 375 mm
Depth of Bottom Slab = 450 mm
Grade of Concrete M30 σcbc = 10.00 kN/m2
Grade of Steel Fe500 σst = 240.0 kN/m2
Modular Ratio = 10.00
k = 1/(1+σst/m*σcbc) = 0.294
j = 1-k/3 = 0.902
Q = 0.5*k*j*σcbc = 1.33

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

10.6.2 Design of Top Slab


Depth Check
Considering clear cover of 75 mm for the base slab and 40 mm for all the othert faces
Depth of Top Slab Provided = 425 mm
Effective Depth Provided = 425-40-6 = 377 mm
Maximum Moment = 99.00 kNm
Effective Depth Required = SQRT(99/(1.33))*1000 = 273 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 425 mm Effective depth = 377 mm
Max moment on top surface = 69 kNm Steel reqd = 845.5 mm2
Provide 12mm @ 130mm C/C
Area of steel provided = 870.0 mm2
Max moment on bottom surface = 99 kNm Steel reqd = = 1213.1 mm2
Provide 16 mm @ 130mm C/C
Area of steel provided = 1546.6 mm2
Minimum Steel = 0.06 % of C/S = 226.2 mm2
Max moment mid top surface = 11 kNm Steel reqd = 155.4 mm2
Thus, Area of Steel Required = 226.2 mm2
Provide 10 mm dia @ 260mm C/C
Area of steel provided = 302.1 mm2
10.6.3 Design of Bottom Slab
Depth Check
Depth of Bottom Slab Provided = 450 mm
Effecetive Depth Provided = 450-75-8 = 365 mm
Maximum Moment = 131.00 kNm
Effective Depth Required = SQRT(131/(1.33))*1000 = 314 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 450 mm Effective depth = 365 mm
Max moment on top surface = 131 kNm Steel reqd = 1658.0 mm2
Provide 16 mm dia @ 120mm C/C
Area of steel provided = 1675.5 mm2
Max moment on bottom surface = 83 kNm Steel reqd = 1050.5 mm2
Provide 20 mm dia @ 240mm C/C
Area of steel provided = 1309.0 mm2
Minimum Steel = 0.06 % of C/S = 219.0 mm2
Max moment mid bot surface = 14 kNm Steel reqd = 197.8 mm2
Thus, Area of Steel Required = 219.0 mm2
Provide 10 mm dia @ 240mm C/C
Area of steel provided = 327.2 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

10.6.4 Design of Side Wall


Depth Check
Depth of side Wall Provided = 375 mm
Effective Depth Provided = 375-40-16/2 = 327 mm
Maximum Moment = 88.00 kNm
Effective Depth Required = SQRT(88/(1.33))*1000 = 257.6 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of wall = 375 mm Effective depth = 327.0 mm
Max moment on outer surface = 88 kNm Steel reqd = 1243.2 mm2
Provide 16 mm dia @ 160 mm dia @
Area of steel provided = 1256.6 mm2
Minimum reinforcement on the inner face
Minimum Steel = 0.06 % of C/S = 225.0 mm2
Max moment on inner surface = 21 kNm Steel reqd = 296.7 mm2
Thus, Area of Steel Required = 296.7 mm2
Provide 10 mm dia @ 160mm C/C
Area of steel provided = 490.9 mm2
10.6.5 Distribution Steel
Tob Slab
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×377 = 452.4 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 31.0 kNm
Area of Steel Required = =31.00×10^6/(240.00×377×0.902) = 379.9 mm2
Thus, Area of Steel Required = 452.4 mm2
Provide 10 mm dia @ 170mm C/C
Area of steel provided = 462.0 mm2
Bottom Slab
Case1 :
Minimum Steel
= 0.12% Effective Area = =1.2×365 = 438.0 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 31.0 kNm
Area of Steel Required = =31.00×10^6/(240.00×365×0.902) = 392.3 mm2
Thus, Area of Steel Required = 438.0 mm2
Provide 10 mm dia @ 170mm C/C
Area of steel provided = 462.0 mm2
Side Wall
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×327 = 392.4 mm2
Case2 : = 0.2DL+0.3LL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Maximum Bending Moment for Distribution Steel = 17.0 kNm


Area of Steel Required = =17.00×10^6/(240.00×0.902×327) = 240.2 mm2
Thus, Area of Steel Required = 392.4 mm2
Provide 8 mm dia @ 120mm C/C
Area of steel provided = 418.9 mm2

10.7 STAAD Input file


STAAD PLANE
START JOB INFORMATION
ENGINEER DATE 19-JANUARY-11
END JOB INFORMATION
INPUT WIDTH 79
UNIT METER KN
JOINT COORDINATES
1 0 0 0
2 0 0.2 0
3 0 1.0 0
4 0 1.7 0
5 0 2.5 0
6 0 3.2 0
7 0 3.4 0
8 0.1875 3.4 0
9 0.5525 3.4 0
10 1.643 3.4 0
11 2.733 3.4 0
12 3.8225 3.4 0
13 4.1875 3.4 0
14 4.375 3.4 0
15 4.375 3.2 0
16 4.375 2.5 0
17 4.375 1.7 0
18 4.375 1.0 0
19 4.375 0 0
20 4.375 0 0
21 4.1875 0 0
22 3.8225 0 0
23 2.733 0 0
24 1.643 0 0
25 0.5525 0 0
26 0.1875 0 0
MEMBER INCIDENCES

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10; 10 10 11;
11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17; 17 17 18; 18 18 19;
19 19 20; 20 20 21; 21 21 22; 22 22 23; 23 23 24; 24 24 25; 25 25 26; 26 26 1;
START GROUP DEFINITION
MEMBER
_TOPSLAB 7 TO 13
_BOTTOMSLAB 20 TO 26
_SIDEWALL1 1 TO 6
_SIDEWALL2 14 TO 19
END GROUP DEFINITION
DEFINE MATERIAL START
ISOTROPIC MATERIAL1
E 27.39e+006
POISSON 0.15
DENSITY 25
DAMP 2.8026e-044
END DEFINE MATERIAL
CONSTANTS
MATERIAL MATERIAL1 ALL
MEMBER PROPERTY INDIAN
7 TO 13 PRIS YD 0.425 ZD 1
1 TO 6 14 TO 19 PRIS YD 0.375 ZD 1
20 TO 26 PRIS YD 0.45 ZD 1
**SUPPORT SPECS*********
*CONSIDERING MOD. OF SUBGRADE RXN AS 15000 kN/sq.m
SUPPORTS
1 FIXED BUT FX FZ MX MY MZ KFY 4143.75
20 FIXED BUT MX MY MZ KFY 4143.75
22 25 FIXED BUT FX FZ MX MY MZ KFY 12318.8
24 23 FIXED BUT FX FZ MX MY MZ KFY 16350
****LOADING ON THE STRUCTURE****************
**************
*********DL*****
LOAD 1 DEAD LOAD
MEMBER LOAD
7 TO 13 UNI GY -10.625
20 TO 26 UNI GY -11.25
1 TO 6 UNI GY -9.375
14 TO 19 UNI GY -9.375
*********SIDL*******
LOAD 2 SIDL FOR FILL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

*(*LOAD DUE TO Wearing Coat + Crash Barrier+ FILL + HAUNCH)


MEMBER LOAD
7 TO 13 UNI GY -15.21
********EP AT REST********
*LOAD DUE TO EARTH PRESSURE AT BOTH SIDES
LOAD 3 EARTH PRESSURE
MEMBER LOAD
6 TRAP GX 7.25 5.125
5 TRAP GX 14.75 7.25
4 TRAP GX 22.25 14.75
3 TRAP GX 29.75 22.25
2 TRAP GX 37.25 29.75
1 TRAP GX 39.5 37.25
14 TRAP GX -5.125 -7.25
15 TRAP GX -7.25 -14.75
16 TRAP GX -14.75 -22.25
17 TRAP GX -22.25 -29.75
18 TRAP GX -29.75 -37.25
19 TRAP GX -37.25 -39.50
*********LL SURCHARGE *********
*LL SURCHARGE DUE TO FILL AT BOTH SIDES
LOAD 4 LL SURCHARGE
MEMBER LOAD
6 UNI GX 12
5 UNI GX 12
4 UNI GX 12
3 UNI GX 12
2 UNI GX 12
1 UNI GX 12
*********70 R TRACKED LOAD (Load considered 17T)*******
LOAD 5 70R TRACKED
MEMBER LOAD
7 TO 13 UNI GY -43.21
**********40 T BOGGIE LOAD*******
LOAD 6 BOGGIE
MEMBER LOAD
8 9 UNI GY -34.54
10 UNI GY -34.54
11 12 UNI GY -34.54
********** CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 7 CLASS A WHEELED

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
8 9 UNI GY -26.07
10 UNI GY -26.07
11 12 UNI GY -26.07
********** Two CLASS A VEHICLE LOAD(TWO 5.7Tx4) ****
LOAD 8 TWO CLASS A WHEELED
MEMBER LOAD
7 TO 9 UNI GY -33.72
10 UNI GY -33.72
11 TO 13 UNI GY -33.72
*********BRAKING LOAD*********
LOAD 9 BRAKING LOAD
JOINT LOAD
7 FX 23.31
****LOAD COMBINATIONS***************
LOAD COMB 10 DL + SIDL + EP + SUR
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 11 DL + SIDL + EP + SUR + 70R TRACKED
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0
LOAD COMB 12 DL + SIDL + EP + SUR + BOGGIE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0
LOAD COMB 13 DL + SIDL + EP + SUR + CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 7 1.0
LOAD COMB 14 DL + SIDL + EP + SUR + TWO CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 15 DL + SIDL + EP + SUR + TRUCK + BRAKING FORCE
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0 9 1.0
LOAD COMB 16 0.2 DL + 0.3 TRACK + 0.3 BRAKING FORCE
1 0.2 5 0.3 9 0.3
PERFORM ANALYSIS
PRINT MEMBER FORCES ALL
FINISH

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

11 Design of 5.0 x 3.0m Box Culvert


11.1 Design Inputs

0.425

3.0
0.4

0.475

5.4

Clear Span = 5.0 m


Clear Height = 3.0 m
Top Slab Thickness = 0.425 m
Bottom Slab Thickness = 0.475 m
Side Wall Thickness = 0.400 m
Height of Fill = 0.3 m
Thickness of Wearing Coat = 0.065 m

Panel width = 1.0 m


Width of Carriage Way = 5.75 m

Angle of internal friction φ = 30 Degrees


Coefficient of Earth Pressure at Rest = 0.5
Dry Density of Fill above Top Slab = 20 kN/m3
Concrete Density = 25 kN/m3
Surcharge Live Load = 1.2 m
SBC Value Assumed = 150.0 kN/m2

11.2 General Diagram with Loading

Fill 0.3
(All dimensions in m)

0.43

Haunch (0.15x0.15)

3.0

0.48

0.40 5.0 0.40

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Total Span = 5.80 m


Total Height = 3.90 m
C/C Span = 5.40 m
C/C Height = 3.45 m

11.3 Idealised Structure of Box Culvert for STAAD Analysis


The Structure is Idealised in STAAD. Pro as shown below. The dimensions are considered as centre to centre.
The structural analysis has been done for one metre strip.

5.40 m

3.45 m

A
B D B A

Spacing Between 2 End Springs = 0.590 m


Spacing between 2 int springs = 1.407 m
Spacing between 2 end nodes of Side Wall at top = 0.213 m
Spacing between 2 end nodes of Side Wall at bottom = 0.238 m
Spacing between 2 int. nodes of Side wall = 0.75 m
Modulus of Subgrade reaction = 15000 kN/m3
Spring constants at end supports =15000x(0.59/2) = 4425.0 kN/m
Spring constant at Intermediate supports for the Box =15000x(0.59+1.4067)/2 = 14975.3 kN/m
Spring constant at Int.Supports =15000x(1.4067+1.407)/2) = 21100.5 kN/m
(Ref:pg:408,Foundation Analysis and Design by joseph E.Bowles (Fs=40*s.f*qa) and s.f = 2.5)

11.4 Load Calculation


11.4.1 Dead Load
Self Weight of Tob Slab = 0.425x1x25 = 10.63 kN/m
Self Weight of Bottom Slab = 0.475x1x25 = 11.88 kN/m
Self Weight of side Walls = 0.4x1x25 = 10.00 kN/m
Weight of Haunch = 0.15×0.15×0.5×2.5 = 0.28 kN

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

11.4.2 SIDL
Load due to Wearing Coat = 0.065x1x2.2 = 1.43 kN/m
Load due to Earth Fill = 0.3x1x20 = 6.00 kN/m
Weight of Crash Barrier = 0.3x2.5 = 7.50 kN/m
TOTAL = 14.93 kN/m
Total Base Area =5.8×1 = 5.80 m2
Total Average Bottom Pressure =(14.93+10.63+11.88+10.00+0.28+( 34.57×5.40))/5.80 = 40.41 kN/m2
Less than SBC So, Safe
11.4.3 Computation of Earth Pressure
SIDE A SIDE B

0.5*20*0.5125 = 5.13 kN/m2 0.5 m


0.5*20*0.725 = 7.25 kN/m2 0.7 m
1.5 m
2
0.5*20*1.475 = 14.75 kN/m

2.2 m
0.5*20*2.225 = 22.25 kN/m2
3.0 m
0.5*20*2.975 = 29.75 kN/m2

3.7 m
0.5*20*3.725 = 37.25 kN/m2
0.5*20*3.963 = 39.63 kN/m2 4.0 m

11.4.4 Surcharge Live Load


Lateral Pressure due to Surcharge Live Load Equivalent to 1.2 m of Earth Fill = 12.00 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

11.4.5 Live Load


Case 1: When Class 70R Tracked Vehicle is Placed at the centre of the Slab
(65mm Wearing Coat Considered)
Direction of Traffic
Total Load

35.00 T

0.85
35 T 35 T

4.57 5.40

2.05

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 1.065 m
a = 5.4/2 2.700 m
b1 =0.85+0.065 0.915 m
α 2.516
beff α x a (1- a/lo) + b1
beff = 2.516x2.7x(1-2.7/5.4)+0.915 4.31 m Overlapping
Effective Width across traffic 4.63 m
Effective width less than widening width. So OK.
Width along the Span = 4.57+2×(0.065+0.425) 5.55 m
Effective width greater than c/c span
So width along the Span for Design 5.40 m
Load considered = 35/4.57×5.40 70.00 T
2
Load Intensity = 70.00/(5.4×4.63) 2.80 T/m
Impact factor = 10 + ((25-10)/(9-5)) x (9-5.4) 24 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 23.5x1 24 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 2.799x1.235 3.457 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 2 : When Class 70R Bogie Load (40T) is Placed at the centre of Slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.86

0.263

10 T 10 T

5.40 1.22

10 T 10 T

1.93

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.75 m


Calculation for Effective Width of Loading = b/ l0 0.19 m
a = 5.4/2-1.22/2 2.09 m
b1 =0.86+0.065 0.93 m
α 2.516
beff α x a (1- a/lo) + b1
beff = 2.5160x2.09x(1-2.09/5.4)+0.925 4.15 m Overlapping
So effective Width across for Design 4.43 m
Effective width less than widening width. So OK.
Width along the Span = 0.263+2×(0.425+0.065) 1.243 Overlapping
Effective width along Span 3.44 m
Effective width less than c/c span
So effective Width along span for Design 3.44 m
Load considered 40 T
Load Intensity = 40/(4.43×3.443) 2.62 T/m2
Impact factor 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 2.62x1.25 3.275 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 3 : When Class A (5.7 x 2 T) is Placed at the centre of slab


(65mm Wearing Coat Considered)

Direction of Traffic

5.7 T 1.8 5.7 T

0.25

5.40 0.5

1.2

5.7 T 5.7 T

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.185 m
a = 5.4/2-1.2/2 2.100 m
b1 0.57 m
α 2.516
beff α x a (1- a/lo) + b1
beff = 2.516x2.1x(1-2.1/5.4)+0.565 3.79 m Overlapping
Effective Width across for Design = 1.2+0.5+0.5/2+1.8+3.79/2 3.95 m
Effective width less than widening width. So OK.
Width along the Span = 0.25+(2×(0.425+0.065)) 1.23 m Overlapping
Effective width along Span 3.41 m
Effective width less than c/c span
So effective Width along span for Design 3.41 m
Load considered 22.8 T
Load Intensity = 22.8/(3.95×3.410) 1.69 T/m2
Impact factor 45.00 %
Deduction in the I.F No deduction for fill < 0.6m 1.00
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 45x1 45.00 %

Increasing due to Impact (As per IRC-6-2000, Cl:211.6


= 1.695x1.45 2.46 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 4 : When two Class A (5.7 x 2T) is Placed at the centre of slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.5 0.5

0.25

5.40
1.2

1.8 1 1.8

5.7 T 5.7 T 5.7 T 5.7 T


Class A Wheeled Vehicle Class A Wheeled Vehicle

3.79 m 3.79 m 3.79 m 3.79 m

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 1.06 m
a =0.5×(5.40-1.2) 2.100 m
b1 0.565 m
α 2.516
beff α x a (1- a/lo) + b1
beff = 2.516x2.1x(1-2.1/5.4)+0.565 3.79 m Overlapping
Effective Width across for Design 6.75 m
Effective width greater than widening width. So beff for design is 5.75 m
Width along the Span =0.25+2×(0.425+0.065) 1.23 m Overlapping
Effective width along Span 3.41 m
Effective width less than c/c span
So effective Width along span for Design 3.41 m
Load considered 45.6 T
Load Intensity = 45.6/(6.75×3.410) 2.33 T/m2
Impact factor 45.00 %
Increasing due to Impact (As per IRC-6-2000, Cl:211.6
= 2.326x1.45 3.37 T/m2
and 211.7)
So design intensity = 34.6 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

11.5 Braking Load


Total Horizontal Load on top of the box =0.2×2×35.00×10 = 140.00 kN
Horizontal load per m width of the structure =140.00/5.75 = 24.35 kN/m

11.6 Structural Design


11.6.1 Summary of Moments (From STAAD Pro)

Design Moments (kNm)


Load Combinations Top Slab Bottom Slab Side Walls
Sagging Hogging Sagging Hogging Outer Inner
Maximum Moment 118 97 156 98 119 23
0.2 D.L+0.3 L.L 27 17 34 14 23 0

Design Bending Moments (kNm)


97.0 97.0
119.0 118.0 119.0

23.0 23.0

119.0
156.0 119.0
98.0 98.0
Maximum Moment in Top Slab at Mid Span = 118.00 kNm
Maximum Moment in Top Slab at Support = 97.00 kNm
Maximum Moment in Side Wall outer surface = 119.00 kNm
Maximum Moment in Side Wall inner surface = 23.00 kNm
Maximum Moment in Bottom Slab at Mid Span = 156.00 kNm
Maximum Moment in Bottom Slab at Support = 98.00 kNm
Depth of Top Slab = 425 mm
Depth of Side Wall = 400 mm
Depth of Bottom Slab = 475 mm
Grade of Concrete M30 σcbc = 10.00 kN/m2
Grade of Steel Fe500 σst = 240.0 kN/m2
Modular Ratio = 10.00
k = 1/(1+σst/m*σcbc) = 0.294
j = 1-k/3 = 0.902
Q = 0.5*k*j*σcbc = 1.33

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

11.6.2 Design of Top Slab


Depth Check
Considering clear cover of 75 mm for the base slab and 40 mm for all the othert faces
Depth of Top Slab Provided = 425 mm
Effective Depth Provided = 425-40-6 = 375 mm
Maximum Moment = 118.00 kNm
Effective Depth Required = SQRT(118/(1.33))*1000 = 298 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 425 mm Effective depth = 375 mm
Max moment on top surface = 97 kNm Steel reqd = 1194.9 mm2
Provide 20mm @ 260mm C/C
Area of steel provided = 1208.3 mm2
Max moment on bottom surface = 118 kNm Steel reqd = = 1453.6 mm2
Provide 16 mm @ 130mm C/C
Area of steel provided = 1546.6 mm2
Minimum Steel = 0.06 % of C/S = 225.0 mm2
Max moment mid top surface = 9 kNm Steel reqd = 118.1 mm2
Thus, Area of Steel Required = 225.0 mm2
Provide 10 mm dia @ 260mm C/C
Area of steel provided = 302.1 mm2
11.6.3 Design of Bottom Slab
Depth Check
Depth of Bottom Slab Provided = 475 mm
Effecetive Depth Provided = 475-75-10 = 390 mm
Maximum Moment = 156.00 kNm
Effective Depth Required = SQRT(156/(1.33))*1000 = 343 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 475 mm Effective depth = 390 mm
Max moment on top surface = 156 kNm Steel reqd = 1847.8 mm2
Provide 20 mm dia @ 170mm C/C
Area of steel provided = 1848.0 mm2
Max moment on bottom surface = 98 kNm Steel reqd = 1160.8 mm2
Provide 16 mm dia @ 170mm C/C
Area of steel provided = 1182.7 mm2
Minimum Steel = 0.06 % of C/S = 234.0 mm2
Max moment mid bot surface = 13 kNm Steel reqd = 170.6 mm2
Thus, Area of Steel Required = 234.0 mm2
Provide 10 mm dia @ 170mm C/C
Area of steel provided = 462.0 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

11.6.4 Design of Side Wall


Depth Check
Depth of side Wall Provided = 400 mm
Effective Depth Provided = 400-40-16/2 = 352 mm
Maximum Moment = 119.00 kNm
Effective Depth Required = SQRT(119/(1.33))*1000 = 299.5 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of wall = 400 mm Effective depth = 352.0 mm
Max moment on outer surface = 119 kNm Steel reqd = 1561.7 mm2
Provide 16 mm dia @ 120 mm dia @
Area of steel provided = 1675.5 mm2
Minimum reinforcement on the inner face
Minimum Steel = 0.06 % of C/S = 240.0 mm2
Max moment on inner surface = 23 kNm Steel reqd = 301.8 mm2
Thus, Area of Steel Required = 301.8 mm2
Provide 10 mm dia @ 120mm C/C
Area of steel provided = 654.5 mm2
11.6.5 Distribution Steel
Tob Slab
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×375 = 450.0 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 34.0 kNm
Area of Steel Required = =34.00×10^6/(240.00×375×0.902) = 418.8 mm2
Thus, Area of Steel Required = 450.0 mm2
Provide 10 mm dia @ 170mm C/C
Area of steel provided = 462.0 mm2
Bottom Slab
Case1 :
Minimum Steel
= 0.12% Effective Area = =1.2×390 = 468.0 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 34.0 kNm
Area of Steel Required = =34.00×10^6/(240.00×390×0.902) = 402.7 mm2
Thus, Area of Steel Required = 468.0 mm2
Provide 10 mm dia @ 160mm C/C
Area of steel provided = 490.9 mm2
Side Wall
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×352 = 422.4 mm2
Case2 : = 0.2DL+0.3LL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Maximum Bending Moment for Distribution Steel = 23.0 kNm


Area of Steel Required = =23.00×10^6/(240.00×0.902×352) = 301.8 mm2
Thus, Area of Steel Required = 422.4 mm2
Provide 10 mm dia @ 180mm C/C
Area of steel provided = 436.3 mm2

11.7 STAAD Input file


STAAD PLANE
START JOB INFORMATION
ENGINEER DATE 19-JANUARY-11
END JOB INFORMATION
INPUT WIDTH 79
UNIT METER KN
JOINT COORDINATES
1 0 0 0
2 0 0.2 0
3 0 1.0 0
4 0 1.7 0
5 0 2.5 0
6 0 3.2 0
7 0 3.5 0
8 0.2 3.5 0
9 0.59 3.5 0
10 1.997 3.5 0
11 3.403 3.5 0
12 4.81 3.5 0
13 5.2 3.5 0
14 5.4 3.5 0
15 5.4 3.2 0
16 5.4 2.5 0
17 5.4 1.7 0
18 5.4 1.0 0
19 5.4 0 0
20 5.4 0 0
21 5.2 0 0
22 4.81 0 0
23 3.403 0 0
24 1.997 0 0
25 0.59 0 0
26 0.2 0 0
MEMBER INCIDENCES

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10; 10 10 11;
11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17; 17 17 18; 18 18 19;
19 19 20; 20 20 21; 21 21 22; 22 22 23; 23 23 24; 24 24 25; 25 25 26; 26 26 1;
START GROUP DEFINITION
MEMBER
_TOPSLAB 7 TO 13
_BOTTOMSLAB 20 TO 26
_SIDEWALL1 1 TO 6
_SIDEWALL2 14 TO 19
END GROUP DEFINITION
DEFINE MATERIAL START
ISOTROPIC MATERIAL1
E 27.39e+006
POISSON 0.15
DENSITY 25
DAMP 2.8026e-044
END DEFINE MATERIAL
CONSTANTS
MATERIAL MATERIAL1 ALL
MEMBER PROPERTY INDIAN
7 TO 13 PRIS YD 0.425 ZD 1
1 TO 6 14 TO 19 PRIS YD 0.4 ZD 1
20 TO 26 PRIS YD 0.475 ZD 1
**SUPPORT SPECS*********
*CONSIDERING MOD. OF SUBGRADE RXN AS 15000 kN/sq.m
SUPPORTS
1 FIXED BUT FX FZ MX MY MZ KFY 4425
20 FIXED BUT MX MY MZ KFY 4425
22 25 FIXED BUT FX FZ MX MY MZ KFY 14975
24 23 FIXED BUT FX FZ MX MY MZ KFY 21100
****LOADING ON THE STRUCTURE****************
**************
*********DL*****
LOAD 1 DEAD LOAD
MEMBER LOAD
7 TO 13 UNI GY -10.625
20 TO 26 UNI GY -11.875
1 TO 6 UNI GY -10
14 TO 19 UNI GY -10
*********SIDL*******
LOAD 2 SIDL FOR FILL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

*(*LOAD DUE TO Wearing Coat + Crash Barrier+ FILL + HAUNCH)


MEMBER LOAD
7 TO 13 UNI GY -15.21
********EP AT REST********
*LOAD DUE TO EARTH PRESSURE AT BOTH SIDES
LOAD 3 EARTH PRESSURE
MEMBER LOAD
6 TRAP GX 7.25 5.125
5 TRAP GX 14.75 7.25
4 TRAP GX 22.25 14.75
3 TRAP GX 29.75 22.25
2 TRAP GX 37.25 29.75
1 TRAP GX 39.625 37.25
14 TRAP GX -5.125 -7.25
15 TRAP GX -7.25 -14.75
16 TRAP GX -14.75 -22.25
17 TRAP GX -22.25 -29.75
18 TRAP GX -29.75 -37.25
19 TRAP GX -37.25 -39.63
*********LL SURCHARGE *********
*LL SURCHARGE DUE TO FILL AT BOTH SIDES
LOAD 4 LL SURCHARGE
MEMBER LOAD
6 UNI GX 12
5 UNI GX 12
4 UNI GX 12
3 UNI GX 12
2 UNI GX 12
1 UNI GX 12
*********70 R TRACKED LOAD (Load considered 17T)*******
LOAD 5 70R TRACKED
MEMBER LOAD
8 TO 12 UNI GY -34.57
**********40 T BOGGIE LOAD*******
LOAD 6 BOGGIE
MEMBER LOAD
9 UNI GY -32.75
10 UNI GY -32.75
11 UNI GY -32.75
********** CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 7 CLASS A WHEELED

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
9 UNI GY -24.56
10 UNI GY -24.56
11 UNI GY -24.56
********** Two CLASS A VEHICLE LOAD(TWO 5.7Tx4) ****
LOAD 8 TWO CLASS A WHEELED
MEMBER LOAD
7 TO 9 UNI GY -33.72
10 UNI GY -33.72
11 TO 13 UNI GY -33.72
*********BRAKING LOAD*********
LOAD 9 BRAKING LOAD
JOINT LOAD
7 FX 24.35
****LOAD COMBINATIONS***************
LOAD COMB 10 DL + SIDL + EP + SUR
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 11 DL + SIDL + EP + SUR + 70R TRACKED
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0
LOAD COMB 12 DL + SIDL + EP + SUR + BOGGIE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0
LOAD COMB 13 DL + SIDL + EP + SUR + CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 7 1.0
LOAD COMB 14 DL + SIDL + EP + SUR + TWO CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 15 DL + SIDL + EP + SUR + TRUCK + BRAKING FORCE
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0 9 1.0
LOAD COMB 16 0.2 DL + 0.3 TRACK + 0.3 BRAKING FORCE
1 0.2 5 0.3 9 0.3
PERFORM ANALYSIS
PRINT MEMBER FORCES ALL
FINISH

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

12 Design of 6.0 x 2.0m Box Culvert


12.1 Design Inputs

0.45

2.0
0.45

0.5

6.5

Clear Span = 6.0 m


Clear Height = 2.0 m
Top Slab Thickness = 0.450 m
Bottom Slab Thickness = 0.500 m
Side Wall Thickness = 0.450 m
Height of Fill = 0.3 m
Thickness of Wearing Coat = 0.065 m

Panel width = 1.0 m


Width of Carriage Way = 5.75 m

Angle of internal friction φ = 30 Degrees


Coefficient of Earth Pressure at Rest = 0.5
Dry Density of Fill above Top Slab = 20 kN/m3
Concrete Density = 25 kN/m3
Surcharge Live Load = 1.2 m
SBC Value Assumed = 150.0 kN/m2

12.2 General Diagram with Loading

Fill 0.3
(All dimensions in m)

0.45

Haunch (0.15x0.15)

2.0

0.50

0.45 6.0 0.45

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Total Span = 6.90 m


Total Height = 2.95 m
C/C Span = 6.45 m
C/C Height = 2.48 m

12.3 Idealised Structure of Box Culvert for STAAD Analysis


The Structure is Idealised in STAAD. Pro as shown below. The dimensions are considered as centre to centre.
The structural analysis has been done for one metre strip.

6.45 m

2.48 m

A
B D B A

Spacing Between 2 End Springs = 0.640 m


Spacing between 2 int springs = 1.723 m
Spacing between 2 end nodes of Side Wall at top = 0.225 m
Spacing between 2 end nodes of Side Wall at bottom = 0.250 m
Spacing between 2 int. nodes of Side wall = 0.5 m
Modulus of Subgrade reaction = 15000 kN/m3
Spring constants at end supports =15000x(0.64/2) = 4800 kN/m
Spring constant at Intermediate supports for the Box =15000x(0.64+1.7233)/2 = 17725 kN/m
Spring constant at Int.Supports =15000x(1.7233+1.723)/2) = 25850 kN/m
(Ref:pg:408,Foundation Analysis and Design by joseph E.Bowles (Fs=40*s.f*qa) and s.f = 2.5)

12.4 Load Calculation


12.4.1 Dead Load
Self Weight of Tob Slab = 0.45x1x25 = 11.25 kN/m
Self Weight of Bottom Slab = 0.5x1x25 = 12.50 kN/m
Self Weight of side Walls = 0.45x1x25 = 11.25 kN/m
Weight of Haunch = 0.15×0.15×0.5×2.5 = 0.28 kN

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

12.4.2 SIDL
Load due to Wearing Coat = 0.065x1x2.2 = 1.43 kN/m
Load due to Earth Fill = 0.3x1x20 = 6.00 kN/m
Weight of Crash Barrier = 0.3x2.5 = 7.50 kN/m
TOTAL = 14.93 kN/m
Total Base Area =6.9×1 = 6.90 m2
Total Average Bottom Pressure =(14.93+11.25+12.50+11.25+0.28+( 30.91×6.45))/6.90 = 36.17 kN/m2
Less than SBC So, Safe

12.4.3 Computation of Earth Pressure


SIDE A SIDE B

0.5*20*0.525 = 5.25 kN/m2 0.5 m


2
0.5*20*0.75 = 7.50 kN/m 0.8 m
1.3 m
2
0.5*20*1.250 = 12.50 kN/m

1.8 m
2
0.5*20*1.750 = 17.50 kN/m
2.3 m
2
0.5*20*2.250 = 22.50 kN/m

2.8 m
0.5*20*2.750 = 27.50 kN/m2
0.5*20*3.000 = 30.00 kN/m2 3.0 m

12.4.4 Surcharge Live Load


Lateral Pressure due to Surcharge Live Load Equivalent to 1.2 m of Earth Fill = 12.00 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

12.4.5 Live Load


Case 1: When Class 70R Tracked Vehicle is Placed at the centre of the Slab
(65mm Wearing Coat Considered)
Direction of Traffic
Total Load

35.00 T

0.85
35 T 35 T

4.57 6.45

2.05

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.891 m
a = 6.45/2 3.225 m
b1 =0.85+0.065 0.915 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x3.225x(1-3.225/6.45)+0.915 4.72 m Overlapping
Effective Width across traffic 4.84 m
Effective width less than widening width. So OK.
Width along the Span = 4.57+2×(0.065+0.450) 5.60 m
Effective width less than c/c span
So width along the Span for Design 5.60 m
Load considered = 35/4.57×6.45 70.00 T
2
Load Intensity = 70.00/(5.6×4.84) 2.59 T/m
Impact factor = 10 + ((25-10)/(9-5)) x (9-6.45) 20 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 19.5625x1 20 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 2.585x1.195625 3.091 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 2 : When Class 70R Bogie Load (40T) is Placed at the centre of Slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.86

0.263

10 T 10 T

6.45 1.22

10 T 10 T

1.93

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.75 m


Calculation for Effective Width of Loading = b/ l0 0.16 m
a = 6.45/2-1.22/2 2.62 m
b1 =0.86+0.065 0.93 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.360x2.615x(1-2.615/6.45)+0.925 4.59 m Overlapping
So effective Width across for Design 4.66 m
Effective width less than widening width. So OK.
Width along the Span = 0.263+2×(0.450+0.065) 1.293 Overlapping
Effective width along Span 3.54 m
Effective width less than c/c span
So effective Width along span for Design 3.54 m
Load considered 40 T
Load Intensity = 40/(4.66×3.543) 2.42 T/m2
Impact factor 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000, cl:211.6
= 2.424x1.25 3.030 T/m2
and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 3 : When Class A (5.7 x 2 T) is Placed at the centre of slab


(65mm Wearing Coat Considered)

Direction of Traffic

5.7 T 1.8 5.7 T

0.25

6.45 0.5

1.2

5.7 T 5.7 T

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.155 m
a = 6.45/2-1.2/2 2.625 m
b1 0.57 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x2.625x(1-2.625/6.45)+0.565 4.24 m Overlapping
Effective Width across for Design = 1.2+0.5+0.5/2+1.8+4.24/2 4.17 m
Effective width less than widening width. So OK.
Width along the Span = 0.25+(2×(0.450+0.065)) 1.28 m Overlapping
Effective width along Span 3.51 m
Effective width less than c/c span
So effective Width along span for Design 3.51 m
Load considered 22.8 T
Load Intensity = 22.8/(4.17×3.510) 1.56 T/m2
Impact factor 36.00 %
Deduction in the I.F No deduction for fill < 0.6m 1.00
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 36x1 36.00 %

Increasing due to Impact (As per IRC-6-2000,


= 1.558x1.36 2.12 T/m2
Cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 4 : When two Class A (5.7 x 2T) is Placed at the centre of slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.5 0.5

0.25

1.2 6.45

1.8 1 1.8

5.7 T 5.7 T 5.7 T 5.7 T


Class A Wheeled Vehicle Class A Wheeled Vehicle

4.24 m 4.24 m 4.24 m 4.24 m

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.89 m
a =0.5×(6.45-1.2) 2.625 m
b1 0.565 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x2.625x(1-2.625/6.45)+0.565 4.24 m Overlapping
Effective Width across for Design 6.97 m
Effective width greater than widening width. So beff for design is 5.75 m
Width along the Span =0.25+2×(0.450+0.065) 1.28 m Overlapping
Effective width along Span 3.51 m
Effective width less than c/c span
So effective Width along span for Design 3.51 m
Load considered 45.6 T
Load Intensity = 45.6/(6.97×3.510) 2.26 T/m2
Impact factor 36.00 %
Increasing due to Impact (As per IRC-6-2000,
= 2.259x1.36 3.07 T/m2
Cl:211.6 and 211.7)
So design intensity = 30.9 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

12.5 Braking Load


Total Horizontal Load on top of the box =0.2×2×35.00×10 = 140.00 kN
Horizontal load per m width of the structure =140.00/5.75 = 24.35 kN/m

12.6 Structural Design


12.6.1 Summary of Moments (From STAAD Pro)

Design Moments (kNm)


Load Combinations Top Slab Bottom Slab Side Walls
Sagging Hogging Sagging Hogging Outer Inner
Maximum Moment 134 130 164 111 161 13
0.2 D.L+0.3 L.L 28 26 33 21 33 0

Design Bending Moments (kNm)


130.0 130.0
161.0 134.0 161.0

13.0 13.0

161.0
164.0 161.0
111.0 111.0
Maximum Moment in Top Slab at Mid Span = 134.00 kNm
Maximum Moment in Top Slab at Support = 130.00 kNm
Maximum Moment in Side Wall outer surface = 161.00 kNm
Maximum Moment in Side Wall inner surface = 13.00 kNm
Maximum Moment in Bottom Slab at Mid Span = 164.00 kNm
Maximum Moment in Bottom Slab at Support = 111.00 kNm
Depth of Top Slab = 450 mm
Depth of Side Wall = 450 mm
Depth of Bottom Slab = 500 mm
Grade of Concrete M30 σcbc = 10.00 kN/m2
Grade of Steel Fe500 σst = 240.0 kN/m2
Modular Ratio = 10.00
k = 1/(1+σst/m*σcbc) = 0.294
j = 1-k/3 = 0.902
Q = 0.5*k*j*σcbc = 1.33

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

12.6.2 Design of Top Slab


Depth Check
Considering clear cover of 75 mm for the base slab and 40 mm for all the othert faces
Depth of Top Slab Provided = 450 mm
Effective Depth Provided = 450-40-6 = 402 mm
Maximum Moment = 134.00 kNm
Effective Depth Required = SQRT(134/(1.33))*1000 = 318 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 450 mm Effective depth = 402 mm
Max moment on top surface = 130 kNm Steel reqd = 1493.9 mm2
Provide 16mm @ 130mm C/C
Area of steel provided = 1546.6 mm2
Max moment on bottom surface = 134 kNm Steel reqd = = 1539.9 mm2
Provide 16 mm @ 130mm C/C
Area of steel provided = 1546.6 mm2
Minimum Steel = 0.06 % of C/S = 241.2 mm2
Max moment mid top surface = 4 kNm Steel reqd = 46.0 mm2
Thus, Area of Steel Required = 241.2 mm2
Provide 10 mm dia @ 260mm C/C
Area of steel provided = 302.1 mm2
12.6.3 Design of Bottom Slab
Depth Check
Depth of Bottom Slab Provided = 500 mm
Effecetive Depth Provided = 500-75-10 = 415 mm
Maximum Moment = 164.00 kNm
Effective Depth Required = SQRT(164/(1.33))*1000 = 352 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 500 mm Effective depth = 415 mm
Max moment on top surface = 164 kNm Steel reqd = 1825.6 mm2
Provide 20 mm dia @ 160mm C/C
Area of steel provided = 1963.5 mm2
Max moment on bottom surface = 111 kNm Steel reqd = 1235.6 mm2
Provide 16 mm dia @ 160mm C/C
Area of steel provided = 1256.6 mm2
Minimum Steel = 0.06 % of C/S = 249.0 mm2
Max moment mid bot surface = 8 kNm Steel reqd = 91.9 mm2
Thus, Area of Steel Required = 249.0 mm2
Provide 10 mm dia @ 160mm C/C
Area of steel provided = 490.9 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

12.6.4 Design of Side Wall


Depth Check
Depth of side Wall Provided = 450 mm
Effective Depth Provided = 450-40-16/2 = 402 mm
Maximum Moment = 161.00 kNm
Effective Depth Required = SQRT(161/(1.33))*1000 = 348.4 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of wall = 450 mm Effective depth = 402.0 mm
Max moment on outer surface = 161 kNm Steel reqd = 1850.1 mm2
Provide 16 mm dia @ 100 mm dia @
Area of steel provided = 2010.6 mm2
Minimum reinforcement on the inner face
Minimum Steel = 0.06 % of C/S = 270.0 mm2
Max moment on inner surface = 13 kNm Steel reqd = 149.4 mm2
Thus, Area of Steel Required = 270.0 mm2
Provide 10 mm dia @ 100mm C/C
Area of steel provided = 785.4 mm2
12.6.5 Distribution Steel
Tob Slab
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×402 = 482.4 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 33.0 kNm
Area of Steel Required = =33.00×10^6/(240.00×402×0.902) = 379.2 mm2
Thus, Area of Steel Required = 482.4 mm2
Provide 10 mm dia @ 160mm C/C
Area of steel provided = 490.9 mm2
Bottom Slab
Case1 :
Minimum Steel
= 0.12% Effective Area = =1.2×415 = 498.0 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 33.0 kNm
Area of Steel Required = =33.00×10^6/(240.00×415×0.902) = 367.3 mm2
Thus, Area of Steel Required = 498.0 mm2
Provide 10 mm dia @ 150mm C/C
Area of steel provided = 523.6 mm2
Side Wall
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×402 = 482.4 mm2
Case2 : = 0.2DL+0.3LL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Maximum Bending Moment for Distribution Steel = 33.0 kNm


Area of Steel Required = =33.00×10^6/(240.00×0.902×402) = 379.2 mm2
Thus, Area of Steel Required = 482.4 mm2
Provide 10 mm dia @ 160mm C/C
Area of steel provided = 490.9 mm2

12.7 STAAD Input file


STAAD PLANE
START JOB INFORMATION
ENGINEER DATE 19-JANUARY-11
END JOB INFORMATION
INPUT WIDTH 79
UNIT METER KN
JOINT COORDINATES
1 0 0 0
2 0 0.3 0
3 0 0.8 0
4 0 1.3 0
5 0 1.8 0
6 0 2.3 0
7 0 2.5 0
8 0.225 2.5 0
9 0.64 2.5 0
10 2.363 2.5 0
11 4.087 2.5 0
12 5.81 2.5 0
13 6.225 2.5 0
14 6.45 2.5 0
15 6.45 2.3 0
16 6.45 1.8 0
17 6.45 1.3 0
18 6.45 0.8 0
19 6.45 0 0
20 6.45 0 0
21 6.225 0 0
22 5.81 0 0
23 4.087 0 0
24 2.363 0 0
25 0.64 0 0
26 0.225 0 0
MEMBER INCIDENCES

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10; 10 10 11;
11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17; 17 17 18; 18 18 19;
19 19 20; 20 20 21; 21 21 22; 22 22 23; 23 23 24; 24 24 25; 25 25 26; 26 26 1;
START GROUP DEFINITION
MEMBER
_TOPSLAB 7 TO 13
_BOTTOMSLAB 20 TO 26
_SIDEWALL1 1 TO 6
_SIDEWALL2 14 TO 19
END GROUP DEFINITION
DEFINE MATERIAL START
ISOTROPIC MATERIAL1
E 27.39e+006
POISSON 0.15
DENSITY 25
DAMP 2.8026e-044
END DEFINE MATERIAL
CONSTANTS
MATERIAL MATERIAL1 ALL
MEMBER PROPERTY INDIAN
7 TO 13 PRIS YD 0.45 ZD 1
1 TO 6 14 TO 19 PRIS YD 0.45 ZD 1
20 TO 26 PRIS YD 0.5 ZD 1
**SUPPORT SPECS*********
*CONSIDERING MOD. OF SUBGRADE RXN AS 15000 kN/sq.m
SUPPORTS
1 FIXED BUT FX FZ MX MY MZ KFY 4800
20 FIXED BUT MX MY MZ KFY 4800
22 25 FIXED BUT FX FZ MX MY MZ KFY 17725
24 23 FIXED BUT FX FZ MX MY MZ KFY 25850
****LOADING ON THE STRUCTURE****************
**************
*********DL*****
LOAD 1 DEAD LOAD
MEMBER LOAD
7 TO 13 UNI GY -11.25
20 TO 26 UNI GY -12.5
1 TO 6 UNI GY -11.25
14 TO 19 UNI GY -11.25
*********SIDL*******
LOAD 2 SIDL FOR FILL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

*(*LOAD DUE TO Wearing Coat + Crash Barrier+ FILL + HAUNCH)


MEMBER LOAD
7 TO 13 UNI GY -15.21
********EP AT REST********
*LOAD DUE TO EARTH PRESSURE AT BOTH SIDES
LOAD 3 EARTH PRESSURE
MEMBER LOAD
6 TRAP GX 7.5 5.25
5 TRAP GX 12.5 7.5
4 TRAP GX 17.5 12.5
3 TRAP GX 22.5 17.5
2 TRAP GX 27.5 22.5
1 TRAP GX 30 27.5
14 TRAP GX -5.25 -7.5
15 TRAP GX -7.5 -12.5
16 TRAP GX -12.5 -17.5
17 TRAP GX -17.5 -22.5
18 TRAP GX -22.5 -27.5
19 TRAP GX -27.5 -30.00
*********LL SURCHARGE *********
*LL SURCHARGE DUE TO FILL AT BOTH SIDES
LOAD 4 LL SURCHARGE
MEMBER LOAD
6 UNI GX 12
5 UNI GX 12
4 UNI GX 12
3 UNI GX 12
2 UNI GX 12
1 UNI GX 12
*********70 R TRACKED LOAD (Load considered 17T)*******
LOAD 5 70R TRACKED
MEMBER LOAD
8 TO 12 UNI GY -30.91
**********40 T BOGGIE LOAD*******
LOAD 6 BOGGIE
MEMBER LOAD
9 UNI GY -30.3 0.81 1.72
10 UNI GY -30.3
11 UNI GY -30.3 0 0.91
********** CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 7 CLASS A WHEELED

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
9 UNI GY -21.19 0.81 1.72
10 UNI GY -21.19
11 UNI GY -21.19 0 0.91
********** Two CLASS A VEHICLE LOAD(TWO 5.7Tx4) ****
LOAD 8 TWO CLASS A WHEELED
MEMBER LOAD
9 UNI GY -30.73 0.81 1.72
10 UNI GY -30.73
11 UNI GY -30.73 0 0.91
*********BRAKING LOAD*********
LOAD 9 BRAKING LOAD
JOINT LOAD
7 FX 24.35
****LOAD COMBINATIONS***************
LOAD COMB 10 DL + SIDL + EP + SUR
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 11 DL + SIDL + EP + SUR + 70R TRACKED
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0
LOAD COMB 12 DL + SIDL + EP + SUR + BOGGIE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0
LOAD COMB 13 DL + SIDL + EP + SUR + CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 7 1.0
LOAD COMB 14 DL + SIDL + EP + SUR + TWO CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 15 DL + SIDL + EP + SUR + TRUCK + BRAKING FORCE
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0 9 1.0
LOAD COMB 16 0.2 DL + 0.3 TRACK + 0.3 BRAKING FORCE
1 0.2 5 0.3 9 0.3
PERFORM ANALYSIS
PRINT MEMBER FORCES ALL
FINISH

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

13 Design of 6.0 x 2.5m Box Culvert


13.1 Design Inputs

0.45

2.5
0.45

0.5

6.5

Clear Span = 6.0 m


Clear Height = 2.5 m
Top Slab Thickness = 0.450 m
Bottom Slab Thickness = 0.500 m
Side Wall Thickness = 0.450 m
Height of Fill = 0.3 m
Thickness of Wearing Coat = 0.065 m

Panel width = 1.0 m


Width of Carriage Way = 5.75 m

Angle of internal friction φ = 30 Degrees


Coefficient of Earth Pressure at Rest = 0.5
Dry Density of Fill above Top Slab = 20 kN/m3
Concrete Density = 25 kN/m3
Surcharge Live Load = 1.2 m
SBC Value Assumed = 150.0 kN/m2

13.2 General Diagram with Loading

Fill 0.3
(All dimensions in m)

0.45

Haunch (0.15x0.15)

2.5

0.50

0.45 6.0 0.45

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Total Span = 6.90 m


Total Height = 3.45 m
C/C Span = 6.45 m
C/C Height = 2.98 m

13.3 Idealised Structure of Box Culvert for STAAD Analysis


The Structure is Idealised in STAAD. Pro as shown below. The dimensions are considered as centre to centre.
The structural analysis has been done for one metre strip.

6.45 m

2.98 m

A
B D B A

Spacing Between 2 End Springs = 0.640 m


Spacing between 2 int springs = 1.723 m
Spacing between 2 end nodes of Side Wall at top = 0.225 m
Spacing between 2 end nodes of Side Wall at bottom = 0.250 m
Spacing between 2 int. nodes of Side wall = 0.625 m
Modulus of Subgrade reaction = 15000 kN/m3
Spring constants at end supports =15000x(0.64/2) = 4800 kN/m
Spring constant at Intermediate supports for the Box =15000x(0.64+1.7233)/2 = 17725 kN/m
Spring constant at Int.Supports =15000x(1.7233+1.723)/2) = 25850 kN/m
(Ref:pg:408,Foundation Analysis and Design by joseph E.Bowles (Fs=40*s.f*qa) and s.f = 2.5)

13.4 Load Calculation


13.4.1 Dead Load
Self Weight of Tob Slab = 0.45x1x25 = 11.25 kN/m
Self Weight of Bottom Slab = 0.5x1x25 = 12.50 kN/m
Self Weight of side Walls = 0.45x1x25 = 11.25 kN/m
Weight of Haunch = 0.15×0.15×0.5×2.5 = 0.28 kN

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

13.4.2 SIDL
Load due to Wearing Coat = 0.065x1x2.2 = 1.43 kN/m
Load due to Earth Fill = 0.3x1x20 = 6.00 kN/m
Weight of Crash Barrier = 0.3x2.5 = 7.50 kN/m
TOTAL = 14.93 kN/m
Total Base Area =6.9×1 = 6.90 m2
Total Average Bottom Pressure =(14.93+11.25+12.50+11.25+0.28+( 30.91×6.45))/6.90 = 36.17 kN/m2
Less than SBC So, Safe

13.4.3 Computation of Earth Pressure


SIDE A SIDE B

0.5*20*0.525 = 5.25 kN/m2 0.5 m


2
0.5*20*0.75 = 7.50 kN/m 0.8 m
1.4 m
2
0.5*20*1.375 = 13.75 kN/m

2.0 m
2
0.5*20*2.000 = 20.00 kN/m
2.6 m
2
0.5*20*2.625 = 26.25 kN/m

3.3 m
0.5*20*3.250 = 32.50 kN/m2
0.5*20*3.500 = 35.00 kN/m2 3.5 m

13.4.4 Surcharge Live Load


Lateral Pressure due to Surcharge Live Load Equivalent to 1.2 m of Earth Fill = 12.00 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

13.4.5 Live Load


Case 1: When Class 70R Tracked Vehicle is Placed at the centre of the Slab
(65mm Wearing Coat Considered)
Direction of Traffic
Total Load

35.00 T

0.85
35 T 35 T

4.57 6.45

2.05

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.891 m
a = 6.45/2 3.225 m
b1 =0.85+0.065 0.915 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x3.225x(1-3.225/6.45)+0.915 4.72 m Overlapping
Effective Width across traffic 4.84 m
Effective width less than widening width. So OK.
Width along the Span = 4.57+2×(0.065+0.450) 5.60 m
Effective width less than c/c span
So width along the Span for Design 5.60 m
Load considered = 35/4.57×6.45 70.00 T
2
Load Intensity = 70.00/(5.6×4.84) 2.59 T/m
Impact factor = 10 + ((25-10)/(9-5)) x (9-6.45) 20 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 19.5625x1 20 %
Increasing due to Impact (As per IRC-6-2000,
= 2.585x1.195625 3.091 T/m2
cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 2 : When Class 70R Bogie Load (40T) is Placed at the centre of Slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.86

0.263

10 T 10 T

6.45 1.22

10 T 10 T

1.93

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.75 m


Calculation for Effective Width of Loading = b/ l0 0.16 m
a = 6.45/2-1.22/2 2.62 m
b1 =0.86+0.065 0.93 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.360x2.615x(1-2.615/6.45)+0.925 4.59 m Overlapping
So effective Width across for Design 4.66 m
Effective width less than widening width. So OK.
Width along the Span = 0.263+2×(0.450+0.065) 1.293 Overlapping
Effective width along Span 3.54 m
Effective width less than c/c span
So effective Width along span for Design 3.54 m
Load considered 40 T
Load Intensity = 40/(4.66×3.543) 2.42 T/m2
Impact factor 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000,
= 2.424x1.25 3.030 T/m2
cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 3 : When Class A (5.7 x 2 T) is Placed at the centre of slab


(65mm Wearing Coat Considered)

Direction of Traffic

5.7 T 1.8 5.7 T

0.25

6.45 0.5

1.2

5.7 T 5.7 T

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.155 m
a = 6.45/2-1.2/2 2.625 m
b1 0.57 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x2.625x(1-2.625/6.45)+0.565 4.24 m Overlapping
Effective Width across for Design = 1.2+0.5+0.5/2+1.8+4.24/2 4.17 m
Effective width less than widening width. So OK.
Width along the Span = 0.25+(2×(0.450+0.065)) 1.28 m Overlapping
Effective width along Span 3.51 m
Effective width less than c/c span
So effective Width along span for Design 3.51 m
Load considered 22.8 T
Load Intensity = 22.8/(4.17×3.510) 1.56 T/m2
Impact factor 36.00 %
Deduction in the I.F No deduction for fill < 0.6m 1.00
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 36x1 36.00 %

Increasing due to Impact (As per IRC-6-2000,


= 1.558x1.36 2.12 T/m2
Cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 4 : When two Class A (5.7 x 2T) is Placed at the centre of slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.5

0.5

0.25

1.2 6.45

1.8 1 1.8

5.7 T 5.7 T 5.7 T 5.7 T


Class A Wheeled Vehicle Class A Wheeled Vehicle

4.24 m 4.24 m 4.24 m 4.24 m

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.89 m
a =0.5×(6.45-1.2) 2.625 m
b1 0.565 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x2.625x(1-2.625/6.45)+0.565 4.24 m Overlapping
Effective Width across for Design 6.97 m
Effective width greater than widening width. So beff for design is 5.75 m
Width along the Span =0.25+2×(0.450+0.065) 1.28 m Overlapping
Effective width along Span 3.51 m
Effective width less than c/c span
So effective Width along span for Design 3.51 m
Load considered 45.6 T
Load Intensity = 45.6/(6.97×3.510) 2.26 T/m2
Impact factor 36.00 %
Increasing due to Impact (As per IRC-6-2000,
= 2.259x1.36 3.07 T/m2
Cl:211.6 and 211.7)
So design intensity = 30.9 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

13.5 Braking Load


Total Horizontal Load on top of the box =0.2×2×35.00×10 = 140.00 kN
Horizontal load per m width of the structure =140.00/5.75 = 24.35 kN/m

13.6 Structural Design


13.6.1 Summary of Moments (From STAAD Pro)

Design Moments (kNm)


Load Combinations Top Slab Bottom Slab Side Walls
Sagging Hogging Sagging Hogging Outer Inner
Maximum Moment 141 131 176 117 161 17
0.2 D.L+0.3 L.L 30 25 36 20 32 0

Design Bending Moments (kNm)


131.0 131.0
161.0 141.0 161.0

17.0 17.0

161.0
176.0 161.0
117.0 117.0
Maximum Moment in Top Slab at Mid Span = 141.00 kNm
Maximum Moment in Top Slab at Support = 131.00 kNm
Maximum Moment in Side Wall outer surface = 161.00 kNm
Maximum Moment in Side Wall inner surface = 17.00 kNm
Maximum Moment in Bottom Slab at Mid Span = 176.00 kNm
Maximum Moment in Bottom Slab at Support = 117.00 kNm
Depth of Top Slab = 450 mm
Depth of Side Wall = 450 mm
Depth of Bottom Slab = 500 mm
Grade of Concrete M30 σcbc = 10.00 kN/m2
Grade of Steel Fe500 σst = 240.0 kN/m2
Modular Ratio = 10.00
k = 1/(1+σst/m*σcbc) = 0.294
j = 1-k/3 = 0.902
Q = 0.5*k*j*σcbc = 1.33

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

13.6.2 Design of Top Slab


Depth Check
Considering clear cover of 75 mm for the base slab and 40 mm for all the othert faces
Depth of Top Slab Provided = 450 mm
Effective Depth Provided = 450-40-6 = 402 mm
Maximum Moment = 141.00 kNm
Effective Depth Required = SQRT(141/(1.33))*1000 = 326 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 450 mm Effective depth = 402 mm
Max moment on top surface = 131 kNm Steel reqd = 1505.4 mm2
Provide 16mm @ 120mm C/C
Area of steel provided = 1675.5 mm2
Max moment on bottom surface = 141 kNm Steel reqd = = 1620.3 mm2
Provide 16 mm @ 120mm C/C
Area of steel provided = 1675.5 mm2
Minimum Steel = 0.06 % of C/S = 241.2 mm2
Max moment mid top surface = 5 kNm Steel reqd = 57.5 mm2
Thus, Area of Steel Required = 241.2 mm2
Provide 10 mm dia @ 240mm C/C
Area of steel provided = 327.2 mm2
13.6.3 Design of Bottom Slab
Depth Check
Depth of Bottom Slab Provided = 500 mm
Effecetive Depth Provided = 500-75-10 = 415 mm
Maximum Moment = 176.00 kNm
Effective Depth Required = SQRT(176/(1.33))*1000 = 364 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 500 mm Effective depth = 415 mm
Max moment on top surface = 176 kNm Steel reqd = 1959.1 mm2
Provide 20 mm dia @ 150mm C/C
Area of steel provided = 2094.4 mm2
Max moment on bottom surface = 117 kNm Steel reqd = 1302.4 mm2
Provide 16 mm dia @ 150mm C/C
Area of steel provided = 1340.4 mm2
Minimum Steel = 0.06 % of C/S = 249.0 mm2
Max moment mid bot surface = 9 kNm Steel reqd = 103.4 mm2
Thus, Area of Steel Required = 249.0 mm2
Provide 10 mm dia @ 300mm C/C
Area of steel provided = 261.8 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

13.6.4 Design of Side Wall


Depth Check
Depth of side Wall Provided = 450 mm
Effective Depth Provided = 450-40-16/2 = 402 mm
Maximum Moment = 161.00 kNm
Effective Depth Required = SQRT(161/(1.33))*1000 = 348.4 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of wall = 450 mm Effective depth = 402.0 mm
Max moment on outer surface = 161 kNm Steel reqd = 1850.1 mm2
Provide 16 mm dia @ 100 mm dia @
Area of steel provided = 2010.6 mm2
Minimum reinforcement on the inner face
Minimum Steel = 0.06 % of C/S = 270.0 mm2
Max moment on inner surface = 17 kNm Steel reqd = 195.4 mm2
Thus, Area of Steel Required = 270.0 mm2
Provide 10 mm dia @ 100mm C/C
Area of steel provided = 785.4 mm2
13.6.5 Distribution Steel
Tob Slab
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×402 = 482.4 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 36.0 kNm
Area of Steel Required = =36.00×10^6/(240.00×402×0.902) = 413.7 mm2
Thus, Area of Steel Required = 482.4 mm2
Provide 10 mm dia @ 160mm C/C
Area of steel provided = 490.9 mm2
Bottom Slab
Case1 :
Minimum Steel
= 0.12% Effective Area = =1.2×415 = 498.0 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 36.0 kNm
Area of Steel Required = =36.00×10^6/(240.00×415×0.902) = 400.7 mm2
Thus, Area of Steel Required = 498.0 mm2
Provide 10 mm dia @ 150mm C/C
Area of steel provided = 523.6 mm2
Side Wall
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×402 = 482.4 mm2
Case2 : = 0.2DL+0.3LL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Maximum Bending Moment for Distribution Steel = 32.0 kNm


Area of Steel Required = =32.00×10^6/(240.00×0.902×402) = 367.7 mm2
Thus, Area of Steel Required = 482.4 mm2
Provide 10 mm dia @ 160mm C/C
Area of steel provided = 490.9 mm2

13.7 STAAD Input file


STAAD PLANE
START JOB INFORMATION
ENGINEER DATE 19-JANUARY-11
END JOB INFORMATION
INPUT WIDTH 79
UNIT METER KN
JOINT COORDINATES
1 0 0 0
2 0 0.3 0
3 0 0.9 0
4 0 1.5 0
5 0 2.1 0
6 0 2.8 0
7 0 3.0 0
8 0.225 3.0 0
9 0.64 3.0 0
10 2.363 3.0 0
11 4.087 3.0 0
12 5.81 3.0 0
13 6.225 3.0 0
14 6.45 3.0 0
15 6.45 2.8 0
16 6.45 2.1 0
17 6.45 1.5 0
18 6.45 0.9 0
19 6.45 0 0
20 6.45 0 0
21 6.225 0 0
22 5.81 0 0
23 4.087 0 0
24 2.363 0 0
25 0.64 0 0
26 0.225 0 0
MEMBER INCIDENCES

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10; 10 10 11;
11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17; 17 17 18; 18 18 19;
19 19 20; 20 20 21; 21 21 22; 22 22 23; 23 23 24; 24 24 25; 25 25 26; 26 26 1;
START GROUP DEFINITION
MEMBER
_TOPSLAB 7 TO 13
_BOTTOMSLAB 20 TO 26
_SIDEWALL1 1 TO 6
_SIDEWALL2 14 TO 19
END GROUP DEFINITION
DEFINE MATERIAL START
ISOTROPIC MATERIAL1
E 27.39e+006
POISSON 0.15
DENSITY 25
DAMP 2.8026e-044
END DEFINE MATERIAL
CONSTANTS
MATERIAL MATERIAL1 ALL
MEMBER PROPERTY INDIAN
7 TO 13 PRIS YD 0.45 ZD 1
1 TO 6 14 TO 19 PRIS YD 0.45 ZD 1
20 TO 26 PRIS YD 0.5 ZD 1
**SUPPORT SPECS*********
*CONSIDERING MOD. OF SUBGRADE RXN AS 15000 kN/sq.m
SUPPORTS
1 FIXED BUT FX FZ MX MY MZ KFY 4800
20 FIXED BUT MX MY MZ KFY 4800
22 25 FIXED BUT FX FZ MX MY MZ KFY 17725
24 23 FIXED BUT FX FZ MX MY MZ KFY 25850
****LOADING ON THE STRUCTURE****************
**************
*********DL*****
LOAD 1 DEAD LOAD
MEMBER LOAD
7 TO 13 UNI GY -11.25
20 TO 26 UNI GY -12.5
1 TO 6 UNI GY -11.25
14 TO 19 UNI GY -11.25
*********SIDL*******
LOAD 2 SIDL FOR FILL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

*(*LOAD DUE TO Wearing Coat + Crash Barrier+ FILL + HAUNCH)


MEMBER LOAD
7 TO 13 UNI GY -15.21
********EP AT REST********
*LOAD DUE TO EARTH PRESSURE AT BOTH SIDES
LOAD 3 EARTH PRESSURE
MEMBER LOAD
6 TRAP GX 7.5 5.25
5 TRAP GX 13.75 7.5
4 TRAP GX 20 13.75
3 TRAP GX 26.25 20
2 TRAP GX 32.5 26.25
1 TRAP GX 35 32.5
14 TRAP GX -5.25 -7.5
15 TRAP GX -7.5 -13.75
16 TRAP GX -13.75 -20
17 TRAP GX -20 -26.25
18 TRAP GX -26.25 -32.5
19 TRAP GX -32.5 -35.00
*********LL SURCHARGE *********
*LL SURCHARGE DUE TO FILL AT BOTH SIDES
LOAD 4 LL SURCHARGE
MEMBER LOAD
6 UNI GX 12
5 UNI GX 12
4 UNI GX 12
3 UNI GX 12
2 UNI GX 12
1 UNI GX 12
*********70 R TRACKED LOAD (Load considered 17T)*******
LOAD 5 70R TRACKED
MEMBER LOAD
8 TO 12 UNI GY -30.91
**********40 T BOGGIE LOAD*******
LOAD 6 BOGGIE
MEMBER LOAD
9 UNI GY -30.3 0.81 1.72
10 UNI GY -30.3
11 UNI GY -30.3 0 0.91
********** CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 7 CLASS A WHEELED

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
9 UNI GY -21.19 0.81 1.72
10 UNI GY -21.19
11 UNI GY -21.19 0 0.91
********** Two CLASS A VEHICLE LOAD(TWO 5.7Tx4) ****
LOAD 8 TWO CLASS A WHEELED
MEMBER LOAD
9 UNI GY -30.73 0.81 1.72
10 UNI GY -30.73
11 UNI GY -30.73 0 0.91
*********BRAKING LOAD*********
LOAD 9 BRAKING LOAD
JOINT LOAD
7 FX 24.35
****LOAD COMBINATIONS***************
LOAD COMB 10 DL + SIDL + EP + SUR
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 11 DL + SIDL + EP + SUR + 70R TRACKED
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0
LOAD COMB 12 DL + SIDL + EP + SUR + BOGGIE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0
LOAD COMB 13 DL + SIDL + EP + SUR + CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 7 1.0
LOAD COMB 14 DL + SIDL + EP + SUR + TWO CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 15 DL + SIDL + EP + SUR + TRUCK + BRAKING FORCE
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0 9 1.0
LOAD COMB 16 0.2 DL + 0.3 TRACK + 0.3 BRAKING FORCE
1 0.2 5 0.3 9 0.3
PERFORM ANALYSIS
PRINT MEMBER FORCES ALL
FINISH

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

14 Design of 6.0 x 3.0m Box Culvert


14.1 Design Inputs

0.475

3.0
0.475

0.525

6.5

Clear Span = 6.0 m


Clear Height = 3.0 m
Top Slab Thickness = 0.475 m
Bottom Slab Thickness = 0.525 m
Side Wall Thickness = 0.475 m
Height of Fill = 0.3 m
Thickness of Wearing Coat = 0.065 m

Panel width = 1.0 m


Width of Carriage Way = 5.75 m

Angle of internal friction φ = 30 Degrees


Coefficient of Earth Pressure at Rest = 0.5
Dry Density of Fill above Top Slab = 20 kN/m3
Concrete Density = 25 kN/m3
Surcharge Live Load = 1.2 m
SBC Value Assumed = 150.0 kN/m2

14.2 General Diagram with Loading

Fill 0.3
(All dimensions in m)

0.48

Haunch (0.15x0.15)

3.0

0.53

0.48 6.0 0.48

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Total Span = 6.95 m


Total Height = 4.00 m
C/C Span = 6.48 m
C/C Height = 3.50 m

14.3 Idealised Structure of Box Culvert for STAAD Analysis


The Structure is Idealised in STAAD. Pro as shown below. The dimensions are considered as centre to centre.
The structural analysis has been done for one metre strip.

6.48 m

3.50 m

A
B D B A

Spacing Between 2 End Springs = 0.678 m


Spacing between 2 int springs = 1.707 m
Spacing between 2 end nodes of Side Wall at top = 0.238 m
Spacing between 2 end nodes of Side Wall at bottom = 0.263 m
Spacing between 2 int. nodes of Side wall = 0.75 m
Modulus of Subgrade reaction = 15000 kN/m3
Spring constants at end supports =15000x(0.6775/2) = 5081 kN/m
Spring constant at Intermediate supports for the Box =15000x(0.6775+1.7067)/2 = 17882 kN/m
Spring constant at Int.Supports =15000x(1.7067+1.707)/2) = 25601 kN/m
(Ref:pg:408,Foundation Analysis and Design by joseph E.Bowles (Fs=40*s.f*qa) and s.f = 2.5)

14.4 Load Calculation


14.4.1 Dead Load
Self Weight of Tob Slab = 0.475x1x25 = 11.88 kN/m
Self Weight of Bottom Slab = 0.525x1x25 = 13.13 kN/m
Self Weight of side Walls = 0.475x1x25 = 11.88 kN/m
Weight of Haunch = 0.15×0.15×0.5×2.5 = 0.28 kN

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

14.4.2 SIDL
Load due to Wearing Coat = 0.065x1x2.2 = 1.43 kN/m
Load due to Earth Fill = 0.3x1x20 = 6.00 kN/m
Weight of Crash Barrier = 0.3x2.5 = 7.50 kN/m
TOTAL = 14.93 kN/m
Total Base Area =7.0×1 = 6.95 m2
Total Average Bottom Pressure =(14.93+11.88+13.13+11.88+0.28+( 30.56×6.48))/6.95 = 35.97 kN/m2
Less than SBC So, Safe

14.4.3 Computation of Earth Pressure


SIDE A SIDE B

0.5*20*0.5375 = 5.38 kN/m2 0.5 m


2
0.5*20*0.775 = 7.75 kN/m 0.8 m
1.5 m
2
0.5*20*1.525 = 15.25 kN/m

2.3 m
2
0.5*20*2.275 = 22.75 kN/m
3.0 m
2
0.5*20*3.025 = 30.25 kN/m

3.8 m
0.5*20*3.775 = 37.75 kN/m2
0.5*20*4.038 = 40.38 kN/m2 4.0 m

14.4.4 Surcharge Live Load


Lateral Pressure due to Surcharge Live Load Equivalent to 1.2 m of Earth Fill = 12.00 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

14.4.5 Live Load


Case 1: When Class 70R Tracked Vehicle is Placed at the centre of the Slab
(65mm Wearing Coat Considered)
Direction of Traffic
Total Load

35.00 T

0.85
35 T 35 T

4.57 6.48

2.05

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.888 m
a = 6.475/2 3.238 m
b1 =0.85+0.065 0.915 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x3.2375x(1-3.2375/6.475)+0.9154.74 m Overlapping
Effective Width across traffic 4.84 m
Effective width less than widening width. So OK.
Width along the Span = 4.57+2×(0.065+0.475) 5.65 m
Effective width less than c/c span
So width along the Span for Design 5.65 m
Load considered = 35/4.57×6.48 70.00 T
2
Load Intensity = 70.00/(5.65×4.84) 2.56 T/m
Impact factor = 10 + ((25-10)/(9-5)) x (9-6.475) 19 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 19.46875x1 19 %
Increasing due to Impact (As per IRC-6-2000,
= 2.558x1.1946875 3.056 T/m2
cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 2 : When Class 70R Bogie Load (40T) is Placed at the centre of Slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.86

0.263

10 T 10 T

6.48 1.22

10 T 10 T

1.93

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.75 m


Calculation for Effective Width of Loading = b/ l0 0.15 m
a = 6.475/2-1.22/2 2.63 m
b1 =0.86+0.065 0.93 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.360x2.6275x(1-2.6275/6.475)+0.9254.61 m Overlapping
So effective Width across for Design 4.66 m
Effective width less than widening width. So OK.
Width along the Span = 0.263+2×(0.475+0.065) 1.343 Overlapping
Effective width along Span 3.64 m
Effective width less than c/c span
So effective Width along span for Design 3.64 m
Load considered 40 T
Load Intensity = 40/(4.66×3.643) 2.35 T/m2
Impact factor 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000,
= 2.354x1.25 2.942 T/m2
cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 3 : When Class A (5.7 x 2 T) is Placed at the centre of slab


(65mm Wearing Coat Considered)

Direction of Traffic

5.7 T 1.8 5.7 T

0.25

6.48 0.5

1.2

5.7 T 5.7 T

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.154 m
a = 6.475/2-1.2/2 2.638 m
b1 0.57 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x2.6375x(1-2.6375/6.475)+0.5654.25 m Overlapping
Effective Width across for Design = 1.2+0.5+0.5/2+1.8+4.25/2 4.18 m
Effective width less than widening width. So OK.
Width along the Span = 0.25+(2×(0.475+0.065)) 1.33 m Overlapping
Effective width along Span 3.61 m
Effective width less than c/c span
So effective Width along span for Design 3.61 m
Load considered 22.8 T
Load Intensity = 22.8/(4.18×3.610) 1.51 T/m2
Impact factor 36.00 %
Deduction in the I.F No deduction for fill < 0.6m 1.00
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 36x1 36.00 %

Increasing due to Impact (As per IRC-6-2000,


= 1.513x1.36 2.06 T/m2
Cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 4 : When two Class A (5.7 x 2T) is Placed at the centre of slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.5

0.5

0.25

1.2 6.48

1.8 1 1.8

5.7 T 5.7 T 5.7 T 5.7 T


Class A Wheeled Vehicle Class A Wheeled Vehicle

4.25 m 4.25 m 4.25 m 4.25 m

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.89 m
a =0.5×(6.48-1.2) 2.638 m
b1 0.565 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x2.6375x(1-2.6375/6.475)+0.5654.25 m Overlapping
Effective Width across for Design 6.98 m
Effective width greater than widening width. So beff for design is 5.75 m
Width along the Span =0.25+2×(0.475+0.065) 1.33 m Overlapping
Effective width along Span 3.61 m
Effective width less than c/c span
So effective Width along span for Design 3.61 m
Load considered 45.6 T
Load Intensity = 45.6/(6.98×3.610) 2.20 T/m2
Impact factor 36.00 %
Increasing due to Impact (As per IRC-6-2000,
= 2.197x1.36 2.99 T/m2
Cl:211.6 and 211.7)
So design intensity = 30.6 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

14.5 Braking Load


Total Horizontal Load on top of the box =0.2×2×35.00×10 = 140.00 kN
Horizontal load per m width of the structure =140.00/5.75 = 24.35 kN/m

14.6 Structural Design


14.6.1 Summary of Moments (From STAAD Pro)

Design Moments (kNm)


Load Combinations Top Slab Bottom Slab Side Walls
Sagging Hogging Sagging Hogging Outer Inner
Maximum Moment 148 133 192 129 164 26
0.2 D.L+0.3 L.L 32 24 40 21 32 0

Design Bending Moments (kNm)


133.0 133.0
164.0 148.0 164.0

26.0 26.0

164.0
192.0 164.0
129.0 129.0
Maximum Moment in Top Slab at Mid Span = 148.00 kNm
Maximum Moment in Top Slab at Support = 133.00 kNm
Maximum Moment in Side Wall outer surface = 164.00 kNm
Maximum Moment in Side Wall inner surface = 26.00 kNm
Maximum Moment in Bottom Slab at Mid Span = 192.00 kNm
Maximum Moment in Bottom Slab at Support = 129.00 kNm
Depth of Top Slab = 475 mm
Depth of Side Wall = 475 mm
Depth of Bottom Slab = 525 mm
Grade of Concrete M30 σcbc = 10.00 kN/m2
Grade of Steel Fe500 σst = 240.0 kN/m2
Modular Ratio = 10.00
k = 1/(1+σst/m*σcbc) = 0.294
j = 1-k/3 = 0.902
Q = 0.5*k*j*σcbc = 1.33

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

14.6.2 Design of Top Slab


Depth Check
Considering clear cover of 75 mm for the base slab and 40 mm for all the othert faces
Depth of Top Slab Provided = 475 mm
Effective Depth Provided = 475-40-6 = 427 mm
Maximum Moment = 148.00 kNm
Effective Depth Required = SQRT(148/(1.33))*1000 = 334 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 475 mm Effective depth = 427 mm
Max moment on top surface = 133 kNm Steel reqd = 1438.9 mm2
Provide 16mm @ 120mm C/C
Area of steel provided = 1675.5 mm2
Max moment on bottom surface = 148 kNm Steel reqd = = 1601.2 mm2
Provide 16 mm @ 120mm C/C
Area of steel provided = 1675.5 mm2
Minimum Steel = 0.06 % of C/S = 256.2 mm2
Max moment mid top surface = 8 kNm Steel reqd = 86.5 mm2
Thus, Area of Steel Required = 256.2 mm2
Provide 10 mm dia @ 240mm C/C
Area of steel provided = 327.2 mm2
14.6.3 Design of Bottom Slab
Depth Check
Depth of Bottom Slab Provided = 525 mm
Effecetive Depth Provided = 525-75-10 = 440 mm
Maximum Moment = 192.00 kNm
Effective Depth Required = SQRT(192/(1.33))*1000 = 380 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 525 mm Effective depth = 440 mm
Max moment on top surface = 192 kNm Steel reqd = 2015.8 mm2
Provide 20 mm dia @ 140mm C/C
Area of steel provided = 2244.0 mm2
Max moment on bottom surface = 129 kNm Steel reqd = 1354.4 mm2
Provide 16 mm dia @ 140mm C/C
Area of steel provided = 1436.2 mm2
Minimum Steel = 0.06 % of C/S = 264.0 mm2
Max moment mid bot surface = 12 kNm Steel reqd = 129.8 mm2
Thus, Area of Steel Required = 264.0 mm2
Provide 10 mm dia @ 280mm C/C
Area of steel provided = 280.5 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

14.6.4 Design of Side Wall


Depth Check
Depth of side Wall Provided = 475 mm
Effective Depth Provided = 475-40-16/2 = 427 mm
Maximum Moment = 164.00 kNm
Effective Depth Required = SQRT(164/(1.33))*1000 = 351.6 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of wall = 475 mm Effective depth = 427.0 mm
Max moment on outer surface = 164 kNm Steel reqd = 1774.3 mm2
Provide 16 mm dia @ 110 mm dia @
Area of steel provided = 1827.8 mm2
Minimum reinforcement on the inner face
Minimum Steel = 0.06 % of C/S = 285.0 mm2
Max moment on inner surface = 26 kNm Steel reqd = 281.3 mm2
Thus, Area of Steel Required = 285.0 mm2
Provide 10 mm dia @ 110mm C/C
Area of steel provided = 714.0 mm2
14.6.5 Distribution Steel
Tob Slab
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×427 = 512.4 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 40.0 kNm
Area of Steel Required = =40.00×10^6/(240.00×427×0.902) = 432.7 mm2
Thus, Area of Steel Required = 512.4 mm2
Provide 10 mm dia @ 150mm C/C
Area of steel provided = 523.6 mm2
Bottom Slab
Case1 :
Minimum Steel
= 0.12% Effective Area = =1.2×440 = 528.0 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 40.0 kNm
Area of Steel Required = =40.00×10^6/(240.00×440×0.902) = 420.0 mm2
Thus, Area of Steel Required = 528.0 mm2
Provide 10 mm dia @ 140mm C/C
Area of steel provided = 561.0 mm2
Side Wall
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×427 = 512.4 mm2
Case2 : = 0.2DL+0.3LL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Maximum Bending Moment for Distribution Steel = 32.0 kNm


Area of Steel Required = =32.00×10^6/(240.00×0.902×427) = 346.2 mm2
Thus, Area of Steel Required = 512.4 mm2
Provide 10 mm dia @ 150mm C/C
Area of steel provided = 523.6 mm2

14.7 STAAD Input file


STAAD PLANE
START JOB INFORMATION
ENGINEER DATE 19-JANUARY-11
END JOB INFORMATION
INPUT WIDTH 79
UNIT METER KN
JOINT COORDINATES
1 0 0 0
2 0 0.3 0
3 0 1.0 0
4 0 1.8 0
5 0 2.5 0
6 0 3.3 0
7 0 3.5 0
8 0.2375 3.5 0
9 0.6775 3.5 0
10 2.384 3.5 0
11 4.091 3.5 0
12 5.7975 3.5 0
13 6.2375 3.5 0
14 6.475 3.5 0
15 6.475 3.3 0
16 6.475 2.5 0
17 6.475 1.8 0
18 6.475 1.0 0
19 6.475 0 0
20 6.475 0 0
21 6.2375 0 0
22 5.7975 0 0
23 4.091 0 0
24 2.384 0 0
25 0.6775 0 0
26 0.2375 0 0
MEMBER INCIDENCES

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10; 10 10 11;
11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17; 17 17 18; 18 18 19;
19 19 20; 20 20 21; 21 21 22; 22 22 23; 23 23 24; 24 24 25; 25 25 26; 26 26 1;
START GROUP DEFINITION
MEMBER
_TOPSLAB 7 TO 13
_BOTTOMSLAB 20 TO 26
_SIDEWALL1 1 TO 6
_SIDEWALL2 14 TO 19
END GROUP DEFINITION
DEFINE MATERIAL START
ISOTROPIC MATERIAL1
E 27.39e+006
POISSON 0.15
DENSITY 25
DAMP 2.8026e-044
END DEFINE MATERIAL
CONSTANTS
MATERIAL MATERIAL1 ALL
MEMBER PROPERTY INDIAN
7 TO 13 PRIS YD 0.475 ZD 1
1 TO 6 14 TO 19 PRIS YD 0.475 ZD 1
20 TO 26 PRIS YD 0.525 ZD 1
**SUPPORT SPECS*********
*CONSIDERING MOD. OF SUBGRADE RXN AS 15000 kN/sq.m
SUPPORTS
1 FIXED BUT FX FZ MX MY MZ KFY 5081.25
20 FIXED BUT MX MY MZ KFY 5081.25
22 25 FIXED BUT FX FZ MX MY MZ KFY 17881.3
24 23 FIXED BUT FX FZ MX MY MZ KFY 25600
****LOADING ON THE STRUCTURE****************
**************
*********DL*****
LOAD 1 DEAD LOAD
MEMBER LOAD
7 TO 13 UNI GY -11.875
20 TO 26 UNI GY -13.125
1 TO 6 UNI GY -11.875
14 TO 19 UNI GY -11.875
*********SIDL*******
LOAD 2 SIDL FOR FILL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

*(*LOAD DUE TO Wearing Coat + Crash Barrier+ FILL + HAUNCH)


MEMBER LOAD
7 TO 13 UNI GY -15.21
********EP AT REST********
*LOAD DUE TO EARTH PRESSURE AT BOTH SIDES
LOAD 3 EARTH PRESSURE
MEMBER LOAD
6 TRAP GX 7.75 5.375
5 TRAP GX 15.25 7.75
4 TRAP GX 22.75 15.25
3 TRAP GX 30.25 22.75
2 TRAP GX 37.75 30.25
1 TRAP GX 40.375 37.75
14 TRAP GX -5.375 -7.75
15 TRAP GX -7.75 -15.25
16 TRAP GX -15.25 -22.75
17 TRAP GX -22.75 -30.25
18 TRAP GX -30.25 -37.75
19 TRAP GX -37.75 -40.38
*********LL SURCHARGE *********
*LL SURCHARGE DUE TO FILL AT BOTH SIDES
LOAD 4 LL SURCHARGE
MEMBER LOAD
6 UNI GX 12
5 UNI GX 12
4 UNI GX 12
3 UNI GX 12
2 UNI GX 12
1 UNI GX 12
*********70 R TRACKED LOAD (Load considered 17T)*******
LOAD 5 70R TRACKED
MEMBER LOAD
8 TO 12 UNI GY -30.56
**********40 T BOGGIE LOAD*******
LOAD 6 BOGGIE
MEMBER LOAD
9 UNI GY -29.42 0.745 1.71
10 UNI GY -29.42
11 UNI GY -29.42 0 0.965
********** CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 7 CLASS A WHEELED

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
9 UNI GY -20.56 0.75 1.71
10 UNI GY -20.56
11 UNI GY -20.56 0 0.965
********** Two CLASS A VEHICLE LOAD(TWO 5.7Tx4) ****
LOAD 8 TWO CLASS A WHEELED
MEMBER LOAD
9 UNI GY -29.88 0.745 1.71
10 UNI GY -29.88
11 UNI GY -29.88 0 0.965
*********BRAKING LOAD*********
LOAD 9 BRAKING LOAD
JOINT LOAD
7 FX 24.35
****LOAD COMBINATIONS***************
LOAD COMB 10 DL + SIDL + EP + SUR
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 11 DL + SIDL + EP + SUR + 70R TRACKED
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0
LOAD COMB 12 DL + SIDL + EP + SUR + BOGGIE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0
LOAD COMB 13 DL + SIDL + EP + SUR + CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 7 1.0
LOAD COMB 14 DL + SIDL + EP + SUR + TWO CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 15 DL + SIDL + EP + SUR + TRUCK + BRAKING FORCE
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0 9 1.0
LOAD COMB 16 0.2 DL + 0.3 TRACK + 0.3 BRAKING FORCE
1 0.2 5 0.3 9 0.3
PERFORM ANALYSIS
PRINT MEMBER FORCES ALL
FINISH

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

15 Design of 6.0 x 3.5m Box Culvert


15.1 Design Inputs

0.475

3.5
0.475

0.55

6.5

Clear Span = 6.0 m


Clear Height = 3.5 m
Top Slab Thickness = 0.475 m
Bottom Slab Thickness = 0.550 m
Side Wall Thickness = 0.475 m
Height of Fill = 0.3 m
Thickness of Wearing Coat = 0.065 m

Panel width = 1.0 m


Width of Carriage Way = 5.75 m

Angle of internal friction φ = 30 Degrees


Coefficient of Earth Pressure at Rest = 0.5
Dry Density of Fill above Top Slab = 20 kN/m3
Concrete Density = 25 kN/m3
Surcharge Live Load = 1.2 m
SBC Value Assumed = 150.0 kN/m2

15.2 General Diagram with Loading

Fill 0.3
(All dimensions in m)

0.48

Haunch (0.15x0.15)

3.5

0.55

0.48 6.0 0.48

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Total Span = 6.95 m


Total Height = 4.53 m
C/C Span = 6.48 m
C/C Height = 4.01 m

15.3 Idealised Structure of Box Culvert for STAAD Analysis


The Structure is Idealised in STAAD. Pro as shown below. The dimensions are considered as centre to centre.
The structural analysis has been done for one metre strip.

6.48 m

4.01 m

A
B D B A

Spacing Between 2 End Springs = 0.703 m


Spacing between 2 int springs = 1.690 m
Spacing between 2 end nodes of Side Wall at top = 0.238 m
Spacing between 2 end nodes of Side Wall at bottom = 0.275 m
Spacing between 2 int. nodes of Side wall = 0.875 m
Modulus of Subgrade reaction = 15000 kN/m3
Spring constants at end supports =15000x(0.7025/2) = 5269 kN/m
Spring constant at Intermediate supports for the Box =15000x(0.7025+1.69)/2 = 17944 kN/m
Spring constant at Int.Supports =15000x(1.69+1.690)/2) = 25350 kN/m
(Ref:pg:408,Foundation Analysis and Design by joseph E.Bowles (Fs=40*s.f*qa) and s.f = 2.5)

15.4 Load Calculation


15.4.1 Dead Load
Self Weight of Tob Slab = 0.475x1x25 = 11.88 kN/m
Self Weight of Bottom Slab = 0.55x1x25 = 13.75 kN/m
Self Weight of side Walls = 0.475x1x25 = 11.88 kN/m
Weight of Haunch = 0.15×0.15×0.5×2.5 = 0.28 kN

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

15.4.2 SIDL
Load due to Wearing Coat = 0.065x1x2.2 = 1.43 kN/m
Load due to Earth Fill = 0.3x1x20 = 6.00 kN/m
Weight of Crash Barrier = 0.3x2.5 = 7.50 kN/m
TOTAL = 14.93 kN/m
Total Base Area =7.0×1 = 6.95 m2
Total Average Bottom Pressure =(14.93+11.88+13.75+11.88+0.28+( 30.56×6.48))/6.95 = 36.06 kN/m2
Less than SBC So, Safe

15.4.3 Computation of Earth Pressure


SIDE A SIDE B

0.5*20*0.5375 = 5.38 kN/m2 0.5 m


2
0.5*20*0.775 = 7.75 kN/m 0.8 m
1.7 m
2
0.5*20*1.650 = 16.50 kN/m

2.5 m
2
0.5*20*2.525 = 25.25 kN/m
3.4 m
2
0.5*20*3.400 = 34.00 kN/m

4.3 m
0.5*20*4.275 = 42.75 kN/m2
0.5*20*4.550 = 45.50 kN/m2 4.6 m

15.4.4 Surcharge Live Load


Lateral Pressure due to Surcharge Live Load Equivalent to 1.2 m of Earth Fill = 12.00 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

15.4.5 Live Load


Case 1: When Class 70R Tracked Vehicle is Placed at the centre of the Slab
(65mm Wearing Coat Considered)
Direction of Traffic
Total Load

35.00 T

0.85
35 T 35 T

4.57 6.48

2.05

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.888 m
a = 6.475/2 3.238 m
b1 =0.85+0.065 0.915 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x3.2375x(1-3.2375/6.475)+0.9154.74 m Overlapping
Effective Width across traffic 4.84 m
Effective width less than widening width. So OK.
Width along the Span = 4.57+2×(0.065+0.475) 5.65 m
Effective width less than c/c span
So width along the Span for Design 5.65 m
Load considered = 35/4.57×6.48 70.00 T
2
Load Intensity = 70.00/(5.65×4.84) 2.56 T/m
Impact factor = 10 + ((25-10)/(9-5)) x (9-6.475) 19 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 19.46875x1 19 %
Increasing due to Impact (As per IRC-6-2000,
= 2.558x1.1946875 3.056 T/m2
cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 2 : When Class 70R Bogie Load (40T) is Placed at the centre of Slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.86

0.263

10 T 10 T

6.48 1.22

10 T 10 T

1.93

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.75 m


Calculation for Effective Width of Loading = b/ l0 0.15 m
a = 6.475/2-1.22/2 2.63 m
b1 =0.86+0.065 0.93 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.360x2.6275x(1-2.6275/6.475)+0.9254.61 m Overlapping
So effective Width across for Design 4.66 m
Effective width less than widening width. So OK.
Width along the Span = 0.263+2×(0.475+0.065) 1.343 Overlapping
Effective width along Span 3.64 m
Effective width less than c/c span
So effective Width along span for Design 3.64 m
Load considered 40 T
Load Intensity = 40/(4.66×3.643) 2.35 T/m2
Impact factor 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000,
= 2.354x1.25 2.942 T/m2
cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 3 : When Class A (5.7 x 2 T) is Placed at the centre of slab


(65mm Wearing Coat Considered)

Direction of Traffic

5.7 T 1.8 5.7 T

0.25

6.48 0.5

1.2

5.7 T 5.7 T

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.154 m
a = 6.475/2-1.2/2 2.638 m
b1 0.57 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x2.6375x(1-2.6375/6.475)+0.5654.25 m Overlapping
Effective Width across for Design = 1.2+0.5+0.5/2+1.8+4.25/2 4.18 m
Effective width less than widening width. So OK.
Width along the Span = 0.25+(2×(0.475+0.065)) 1.33 m Overlapping
Effective width along Span 3.61 m
Effective width less than c/c span
So effective Width along span for Design 3.61 m
Load considered 22.8 T
Load Intensity = 22.8/(4.18×3.610) 1.51 T/m2
Impact factor 36.00 %
Deduction in the I.F No deduction for fill < 0.6m 1.00
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 36x1 36.00 %

Increasing due to Impact (As per IRC-6-2000,


= 1.513x1.36 2.06 T/m2
Cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 4 : When two Class A (5.7 x 2T) is Placed at the centre of slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.5

0.5

0.25

1.2 6.48

1.8 1 1.8

5.7 T 5.7 T 5.7 T 5.7 T


Class A Wheeled Vehicle Class A Wheeled Vehicle

4.25 m 4.25 m 4.25 m 4.25 m

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.89 m
a =0.5×(6.48-1.2) 2.638 m
b1 0.565 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x2.6375x(1-2.6375/6.475)+0.5654.25 m Overlapping
Effective Width across for Design 6.98 m
Effective width greater than widening width. So beff for design is 5.75 m
Width along the Span =0.25+2×(0.475+0.065) 1.33 m Overlapping
Effective width along Span 3.61 m
Effective width less than c/c span
So effective Width along span for Design 3.61 m
Load considered 45.6 T
Load Intensity = 45.6/(6.98×3.610) 2.20 T/m2
Impact factor 36.00 %
Increasing due to Impact (As per IRC-6-2000,
= 2.197x1.36 2.99 T/m2
Cl:211.6 and 211.7)
So design intensity = 30.6 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

15.5 Braking Load


Total Horizontal Load on top of the box =0.2×2×35.00×10 = 140.00 kN
Horizontal load per m width of the structure =140.00/5.75 = 24.35 kN/m

15.6 Structural Design


15.6.1 Summary of Moments (From STAAD Pro)

Design Moments (kNm)


Load Combinations Top Slab Bottom Slab Side Walls
Sagging Hogging Sagging Hogging Outer Inner
Maximum Moment 151 138 210 137 168 36
0.2 D.L+0.3 L.L 33 24 44 19 32 0

Design Bending Moments (kNm)


138.0 138.0
168.0 151.0 168.0

36.0 36.0

168.0
210.0 168.0
137.0 137.0
Maximum Moment in Top Slab at Mid Span = 151.00 kNm
Maximum Moment in Top Slab at Support = 138.00 kNm
Maximum Moment in Side Wall outer surface = 168.00 kNm
Maximum Moment in Side Wall inner surface = 36.00 kNm
Maximum Moment in Bottom Slab at Mid Span = 210.00 kNm
Maximum Moment in Bottom Slab at Support = 137.00 kNm
Depth of Top Slab = 475 mm
Depth of Side Wall = 475 mm
Depth of Bottom Slab = 550 mm
Grade of Concrete M30 σcbc = 10.00 kN/m2
Grade of Steel Fe500 σst = 240.0 kN/m2
Modular Ratio = 10.00
k = 1/(1+σst/m*σcbc) = 0.294
j = 1-k/3 = 0.902
Q = 0.5*k*j*σcbc = 1.33

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

15.6.2 Design of Top Slab


Depth Check
Considering clear cover of 75 mm for the base slab and 40 mm for all the othert faces
Depth of Top Slab Provided = 475 mm
Effective Depth Provided = 475-40-6 = 427 mm
Maximum Moment = 151.00 kNm
Effective Depth Required = SQRT(151/(1.33))*1000 = 337 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 475 mm Effective depth = 427 mm
Max moment on top surface = 138 kNm Steel reqd = 1493.0 mm2
Provide 16mm @ 120mm C/C
Area of steel provided = 1675.5 mm2
Max moment on bottom surface = 151 kNm Steel reqd = = 1633.6 mm2
Provide 16 mm @ 120mm C/C
Area of steel provided = 1675.5 mm2
Minimum Steel = 0.06 % of C/S = 256.2 mm2
Max moment mid top surface = 12 kNm Steel reqd = 129.8 mm2
Thus, Area of Steel Required = 256.2 mm2
Provide 10 mm dia @ 240mm C/C
Area of steel provided = 327.2 mm2
15.6.3 Design of Bottom Slab
Depth Check
Depth of Bottom Slab Provided = 550 mm
Effecetive Depth Provided = 550-75-10 = 465 mm
Maximum Moment = 210.00 kNm
Effective Depth Required = SQRT(210/(1.33))*1000 = 398 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 550 mm Effective depth = 465 mm
Max moment on top surface = 210 kNm Steel reqd = 2086.3 mm2
Provide 20 mm dia @ 140mm C/C
Area of steel provided = 2244.0 mm2
Max moment on bottom surface = 137 kNm Steel reqd = 1361.0 mm2
Provide 16 mm dia @ 140mm C/C
Area of steel provided = 1436.2 mm2
Minimum Steel = 0.06 % of C/S = 279.0 mm2
Max moment mid bot surface = 17 kNm Steel reqd = 183.9 mm2
Thus, Area of Steel Required = 279.0 mm2
Provide 10 mm dia @ 260mm C/C
Area of steel provided = 302.1 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

15.6.4 Design of Side Wall


Depth Check
Depth of side Wall Provided = 475 mm
Effective Depth Provided = 475-40-16/2 = 427 mm
Maximum Moment = 168.00 kNm
Effective Depth Required = SQRT(168/(1.33))*1000 = 355.9 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of wall = 475 mm Effective depth = 427.0 mm
Max moment on outer surface = 168 kNm Steel reqd = 1817.5 mm2
Provide 16 mm dia @ 110 mm dia @
Area of steel provided = 1827.8 mm2
Minimum reinforcement on the inner face
Minimum Steel = 0.06 % of C/S = 285.0 mm2
Max moment on inner surface = 36 kNm Steel reqd = 389.5 mm2
Thus, Area of Steel Required = 389.5 mm2
Provide 10 mm dia @ 110mm C/C
Area of steel provided = 714.0 mm2
15.6.5 Distribution Steel
Tob Slab
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×427 = 512.4 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 44.0 kNm
Area of Steel Required = =44.00×10^6/(240.00×427×0.902) = 476.0 mm2
Thus, Area of Steel Required = 512.4 mm2
Provide 10 mm dia @ 150mm C/C
Area of steel provided = 523.6 mm2
Bottom Slab
Case1 :
Minimum Steel
= 0.12% Effective Area = =1.2×465 = 558.0 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 44.0 kNm
Area of Steel Required = =44.00×10^6/(240.00×465×0.902) = 437.1 mm2
Thus, Area of Steel Required = 558.0 mm2
Provide 10 mm dia @ 140mm C/C
Area of steel provided = 561.0 mm2
Side Wall
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×427 = 512.4 mm2
Case2 : = 0.2DL+0.3LL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Maximum Bending Moment for Distribution Steel = 32.0 kNm


Area of Steel Required = =32.00×10^6/(240.00×0.902×427) = 346.2 mm2
Thus, Area of Steel Required = 512.4 mm2
Provide 10 mm dia @ 150mm C/C
Area of steel provided = 523.6 mm2

15.7 STAAD Input file


STAAD PLANE
START JOB INFORMATION
ENGINEER DATE 19-JANUARY-11
END JOB INFORMATION
INPUT WIDTH 79
UNIT METER KN
JOINT COORDINATES
1 0 0 0
2 0 0.3 0
3 0 1.2 0
4 0 2.0 0
5 0 2.9 0
6 0 3.8 0
7 0 4.0 0
8 0.2375 4.0 0
9 0.7025 4.0 0
10 2.393 4.0 0
11 4.083 4.0 0
12 5.7725 4.0 0
13 6.2375 4.0 0
14 6.475 4.0 0
15 6.475 3.8 0
16 6.475 2.9 0
17 6.475 2.0 0
18 6.475 1.2 0
19 6.475 0 0
20 6.475 0 0
21 6.2375 0 0
22 5.7725 0 0
23 4.083 0 0
24 2.393 0 0
25 0.7025 0 0
26 0.2375 0 0
MEMBER INCIDENCES

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10; 10 10 11;
11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17; 17 17 18; 18 18 19;
19 19 20; 20 20 21; 21 21 22; 22 22 23; 23 23 24; 24 24 25; 25 25 26; 26 26 1;
START GROUP DEFINITION
MEMBER
_TOPSLAB 7 TO 13
_BOTTOMSLAB 20 TO 26
_SIDEWALL1 1 TO 6
_SIDEWALL2 14 TO 19
END GROUP DEFINITION
DEFINE MATERIAL START
ISOTROPIC MATERIAL1
E 27.39e+006
POISSON 0.15
DENSITY 25
DAMP 2.8026e-044
END DEFINE MATERIAL
CONSTANTS
MATERIAL MATERIAL1 ALL
MEMBER PROPERTY INDIAN
7 TO 13 PRIS YD 0.475 ZD 1
1 TO 6 14 TO 19 PRIS YD 0.475 ZD 1
20 TO 26 PRIS YD 0.55 ZD 1
**SUPPORT SPECS*********
*CONSIDERING MOD. OF SUBGRADE RXN AS 15000 kN/sq.m
SUPPORTS
1 FIXED BUT FX FZ MX MY MZ KFY 5268.75
20 FIXED BUT MX MY MZ KFY 5268.75
22 25 FIXED BUT FX FZ MX MY MZ KFY 17943.8
24 23 FIXED BUT FX FZ MX MY MZ KFY 25350
****LOADING ON THE STRUCTURE****************
**************
*********DL*****
LOAD 1 DEAD LOAD
MEMBER LOAD
7 TO 13 UNI GY -11.875
20 TO 26 UNI GY -13.75
1 TO 6 UNI GY -11.875
14 TO 19 UNI GY -11.875
*********SIDL*******
LOAD 2 SIDL FOR FILL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

*(*LOAD DUE TO Wearing Coat + Crash Barrier+ FILL + HAUNCH)


MEMBER LOAD
7 TO 13 UNI GY -15.21
********EP AT REST********
*LOAD DUE TO EARTH PRESSURE AT BOTH SIDES
LOAD 3 EARTH PRESSURE
MEMBER LOAD
6 TRAP GX 7.75 5.375
5 TRAP GX 16.5 7.75
4 TRAP GX 25.25 16.5
3 TRAP GX 34 25.25
2 TRAP GX 42.75 34
1 TRAP GX 45.5 42.75
14 TRAP GX -5.375 -7.75
15 TRAP GX -7.75 -16.5
16 TRAP GX -16.5 -25.25
17 TRAP GX -25.25 -34
18 TRAP GX -34 -42.75
19 TRAP GX -42.75 -45.50
*********LL SURCHARGE *********
*LL SURCHARGE DUE TO FILL AT BOTH SIDES
LOAD 4 LL SURCHARGE
MEMBER LOAD
6 UNI GX 12
5 UNI GX 12
4 UNI GX 12
3 UNI GX 12
2 UNI GX 12
1 UNI GX 12
*********70 R TRACKED LOAD (Load considered 17T)*******
LOAD 5 70R TRACKED
MEMBER LOAD
8 TO 12 UNI GY -30.56
**********40 T BOGGIE LOAD*******
LOAD 6 BOGGIE
MEMBER LOAD
9 UNI GY -29.42 0.715 1.69
10 UNI GY -29.42
11 UNI GY -29.42 0 0.965
********** CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 7 CLASS A WHEELED

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
9 UNI GY -20.56 0.715 1.69
10 UNI GY -20.56
11 UNI GY -20.56 0 0.965
********** Two CLASS A VEHICLE LOAD(TWO 5.7Tx4) ****
LOAD 8 TWO CLASS A WHEELED
MEMBER LOAD
9 UNI GY -29.88 0.72 1.69
10 UNI GY -29.88
11 UNI GY -29.88 0 0.965
*********BRAKING LOAD*********
LOAD 9 BRAKING LOAD
JOINT LOAD
7 FX 24.35
****LOAD COMBINATIONS***************
LOAD COMB 10 DL + SIDL + EP + SUR
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 11 DL + SIDL + EP + SUR + 70R TRACKED
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0
LOAD COMB 12 DL + SIDL + EP + SUR + BOGGIE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0
LOAD COMB 13 DL + SIDL + EP + SUR + CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 7 1.0
LOAD COMB 14 DL + SIDL + EP + SUR + TWO CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 15 DL + SIDL + EP + SUR + TRUCK + BRAKING FORCE
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0 9 1.0
LOAD COMB 16 0.2 DL + 0.3 TRACK + 0.3 BRAKING FORCE
1 0.2 5 0.3 9 0.3
PERFORM ANALYSIS
PRINT MEMBER FORCES ALL
FINISH

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

16 Design of 6.0 x 4.0m Box Culvert


16.1 Design Inputs

0.475

4.0
0.475

0.55

6.5

Clear Span = 6.0 m


Clear Height = 4.0 m
Top Slab Thickness = 0.475 m
Bottom Slab Thickness = 0.550 m
Side Wall Thickness = 0.475 m
Height of Fill = 0.3 m
Thickness of Wearing Coat = 0.065 m

Panel width = 1.0 m


Width of Carriage Way = 5.75 m

Angle of internal friction φ = 30 Degrees


Coefficient of Earth Pressure at Rest = 0.5
Dry Density of Fill above Top Slab = 20 kN/m3
Concrete Density = 25 kN/m3
Surcharge Live Load = 1.2 m
SBC Value Assumed = 150.0 kN/m2

16.2 General Diagram with Loading

Fill 0.3
(All dimensions in m)

0.48

Haunch (0.15x0.15)

4.0

0.55

0.48 6.0 0.48

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Total Span = 6.95 m


Total Height = 5.03 m
C/C Span = 6.48 m
C/C Height = 4.51 m

16.3 Idealised Structure of Box Culvert for STAAD Analysis


The Structure is Idealised in STAAD. Pro as shown below. The dimensions are considered as centre to centre.
The structural analysis has been done for one metre strip.

6.48 m

4.51 m

A
B D B A

Spacing Between 2 End Springs = 0.703 m


Spacing between 2 int springs = 1.690 m
Spacing between 2 end nodes of Side Wall at top = 0.238 m
Spacing between 2 end nodes of Side Wall at bottom = 0.275 m
Spacing between 2 int. nodes of Side wall = 1m
Modulus of Subgrade reaction = 15000 kN/m3
Spring constants at end supports =15000x(0.7025/2) = 5269 kN/m
Spring constant at Intermediate supports for the Box =15000x(0.7025+1.69)/2 = 17944 kN/m
Spring constant at Int.Supports =15000x(1.69+1.690)/2) = 25350 kN/m
(Ref:pg:408,Foundation Analysis and Design by joseph E.Bowles (Fs=40*s.f*qa) and s.f = 2.5)

16.4 Load Calculation


16.4.1 Dead Load
Self Weight of Tob Slab = 0.475x1x25 = 11.88 kN/m
Self Weight of Bottom Slab = 0.55x1x25 = 13.75 kN/m
Self Weight of side Walls = 0.475x1x25 = 11.88 kN/m
Weight of Haunch = 0.15×0.15×0.5×2.5 = 0.28 kN

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

16.4.2 SIDL
Load due to Wearing Coat = 0.065x1x2.2 = 1.43 kN/m
Load due to Earth Fill = 0.3x1x20 = 6.00 kN/m
Weight of Crash Barrier = 0.3x2.5 = 7.50 kN/m
TOTAL = 14.93 kN/m
Total Base Area =7.0×1 = 6.95 m2
Total Average Bottom Pressure =(14.93+11.88+13.75+11.88+0.28+( 30.56×6.48))/6.95 = 36.06 kN/m2
Less than SBC So, Safe

16.4.3 Computation of Earth Pressure


SIDE A SIDE B

0.5*20*0.5375 = 5.38 kN/m2 0.5 m


2
0.5*20*0.775 = 7.75 kN/m 0.8 m
1.8 m
2
0.5*20*1.775 = 17.75 kN/m

2.8 m
2
0.5*20*2.775 = 27.75 kN/m
3.8 m
2
0.5*20*3.775 = 37.75 kN/m

4.8 m
0.5*20*4.775 = 47.75 kN/m2
0.5*20*5.050 = 50.50 kN/m2 5.1 m

16.4.4 Surcharge Live Load


Lateral Pressure due to Surcharge Live Load Equivalent to 1.2 m of Earth Fill = 12.00 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

16.4.5 Live Load


Case 1: When Class 70R Tracked Vehicle is Placed at the centre of the Slab
(65mm Wearing Coat Considered)
Direction of Traffic
Total Load

35.00 T

0.85
35 T 35 T

4.57 6.48

2.05

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.888 m
a = 6.475/2 3.238 m
b1 =0.85+0.065 0.915 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x3.2375x(1-3.2375/6.475)+0.9154.74 m Overlapping
Effective Width across traffic 4.84 m
Effective width less than widening width. So OK.
Width along the Span = 4.57+2×(0.065+0.475) 5.65 m
Effective width less than c/c span
So width along the Span for Design 5.65 m
Load considered = 35/4.57×6.48 70.00 T
Load Intensity = 70.00/(5.65×4.84) 2.56 T/m2
Impact factor = 10 + ((25-10)/(9-5)) x (9-6.475) 19 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 19.46875x1 19 %
Increasing due to Impact (As per IRC-6-2000,
= 2.558x1.1946875 3.056 T/m2
cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 2 : When Class 70R Bogie Load (40T) is Placed at the centre of Slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.86

0.263

10 T 10 T

6.48 1.22

10 T 10 T

1.93

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.75 m


Calculation for Effective Width of Loading = b/ l0 0.15 m
a = 6.475/2-1.22/2 2.63 m
b1 =0.86+0.065 0.93 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.360x2.6275x(1-2.6275/6.475)+0.9254.61 m Overlapping
So effective Width across for Design 4.66 m
Effective width less than widening width. So OK.
Width along the Span = 0.263+2×(0.475+0.065) 1.343 Overlapping
Effective width along Span 3.64 m
Effective width less than c/c span
So effective Width along span for Design 3.64 m
Load considered 40 T
Load Intensity = 40/(4.66×3.643) 2.35 T/m2
Impact factor 25 %
Deduction in the I.F No deduction for fill < 0.6m 1.0
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 25x1 25 %
Increasing due to Impact (As per IRC-6-2000,
= 2.354x1.25 2.942 T/m2
cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 3 : When Class A (5.7 x 2 T) is Placed at the centre of slab


(65mm Wearing Coat Considered)

Direction of Traffic

5.7 T 1.8 5.7 T

0.25

6.48 0.5

1.2

5.7 T 5.7 T

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.154 m
a = 6.475/2-1.2/2 2.638 m
b1 0.57 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x2.6375x(1-2.6375/6.475)+0.5654.25 m Overlapping
Effective Width across for Design = 1.2+0.5+0.5/2+1.8+4.25/2 4.18 m
Effective width less than widening width. So OK.
Width along the Span = 0.25+(2×(0.475+0.065)) 1.33 m Overlapping
Effective width along Span 3.61 m
Effective width less than c/c span
So effective Width along span for Design 3.61 m
Load considered 22.8 T
Load Intensity = 22.8/(4.18×3.610) 1.51 T/m2
Impact factor 36.00 %
Deduction in the I.F No deduction for fill < 0.6m 1.00
Actual Impact factor (As per IRC-6-2000, cl:211.3) = 36x1 36.00 %

Increasing due to Impact (As per IRC-6-2000,


= 1.513x1.36 2.06 T/m2
Cl:211.6 and 211.7)

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Case 4 : When two Class A (5.7 x 2T) is Placed at the centre of slab
(65mm Wearing Coat Considered)

Direction of Traffic

0.5

0.5

0.25

1.2 6.48

1.8 1 1.8

5.7 T 5.7 T 5.7 T 5.7 T


Class A Wheeled Vehicle Class A Wheeled Vehicle

4.25 m 4.25 m 4.25 m 4.25 m

Intensity Calculation

Effective Width of Loading (Type 1) =b 5.750 m


Calculation for Effective Width of Loading = b/ l0 0.89 m
a =0.5×(6.48-1.2) 2.638 m
b1 0.565 m
α 2.36
beff α x a (1- a/lo) + b1
beff = 2.36x2.6375x(1-2.6375/6.475)+0.5654.25 m Overlapping
Effective Width across for Design 6.98 m
Effective width greater than widening width. So beff for design is 5.75 m
Width along the Span =0.25+2×(0.475+0.065) 1.33 m Overlapping
Effective width along Span 3.61 m
Effective width less than c/c span
So effective Width along span for Design 3.61 m
Load considered 45.6 T
Load Intensity = 45.6/(6.98×3.610) 2.20 T/m2
Impact factor 36.00 %
Increasing due to Impact (As per IRC-6-2000,
= 2.197x1.36 2.99 T/m2
Cl:211.6 and 211.7)
So design intensity = 30.6 kN/m2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

16.5 Braking Load


Total Horizontal Load on top of the box =0.2×2×35.00×10 = 140.00 kN
Horizontal load per m width of the structure =140.00/5.75 = 24.35 kN/m

16.6 Structural Design


16.6.1 Summary of Moments (From STAAD Pro)

Design Moments (kNm)


Load Combinations Top Slab Bottom Slab Side Walls
Sagging Hogging Sagging Hogging Outer Inner
Maximum Moment 152 146 216 155 174 48
0.2 D.L+0.3 L.L 34 24 47 19 32 0

Design Bending Moments (kNm)


146.0 146.0
174.0 152.0 174.0

48.0 48.0

174.0
216.0 174.0
155.0 155.0
Maximum Moment in Top Slab at Mid Span = 152.00 kNm
Maximum Moment in Top Slab at Support = 146.00 kNm
Maximum Moment in Side Wall outer surface = 174.00 kNm
Maximum Moment in Side Wall inner surface = 48.00 kNm
Maximum Moment in Bottom Slab at Mid Span = 216.00 kNm
Maximum Moment in Bottom Slab at Support = 155.00 kNm
Depth of Top Slab = 475 mm
Depth of Side Wall = 475 mm
Depth of Bottom Slab = 550 mm
Grade of Concrete M30 σcbc = 10.00 kN/m2
Grade of Steel Fe500 σst = 240.0 kN/m2
Modular Ratio = 10.00
k = 1/(1+σst/m*σcbc) = 0.294
j = 1-k/3 = 0.902
Q = 0.5*k*j*σcbc = 1.33

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

16.6.2 Design of Top Slab


Depth Check
Considering clear cover of 75 mm for the base slab and 40 mm for all the othert faces
Depth of Top Slab Provided = 475 mm
Effective Depth Provided = 475-40-6 = 427 mm
Maximum Moment = 152.00 kNm
Effective Depth Required = SQRT(152/(1.33))*1000 = 339 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 475 mm Effective depth = 427 mm
Max moment on top surface = 146 kNm Steel reqd = 1579.5 mm2
Provide 16mm @ 120mm C/C
Area of steel provided = 1675.5 mm2
Max moment on bottom surface = 152 kNm Steel reqd = = 1644.4 mm2
Provide 16 mm @ 120mm C/C
Area of steel provided = 1675.5 mm2
Minimum Steel = 0.06 % of C/S = 256.2 mm2
Max moment mid top surface = 17 kNm Steel reqd = 183.9 mm2
Thus, Area of Steel Required = 256.2 mm2
Provide 10 mm dia @ 240mm C/C
Area of steel provided = 327.2 mm2
16.6.3 Design of Bottom Slab
Depth Check
Depth of Bottom Slab Provided = 550 mm
Effecetive Depth Provided = 550-75-10 = 465 mm
Maximum Moment = 216.00 kNm
Effective Depth Required = SQRT(216/(1.33))*1000 = 404 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of slab = 550 mm Effective depth = 465 mm
Max moment on top surface = 216 kNm Steel reqd = 2145.9 mm2
Provide 20 mm dia @ 130mm C/C
Area of steel provided = 2416.6 mm2
Max moment on bottom surface = 155 kNm Steel reqd = 1539.9 mm2
Provide 16 mm dia @ 130mm C/C
Area of steel provided = 1546.6 mm2
Minimum Steel = 0.06 % of C/S = 279.0 mm2
Max moment mid bot surface = 25 kNm Steel reqd = 270.5 mm2
Thus, Area of Steel Required = 279.0 mm2
Provide 10 mm dia @ 260mm C/C
Area of steel provided = 302.1 mm2

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

16.6.4 Design of Side Wall


Depth Check
Depth of side Wall Provided = 475 mm
Effective Depth Provided = 475-40-16/2 = 427 mm
Maximum Moment = 174.00 kNm
Effective Depth Required = SQRT(174/(1.33))*1000 = 362.2 mm
Depth Provided is Sufficient
Reinforcement Details
Depth of wall = 475 mm Effective depth = 427.0 mm
Max moment on outer surface = 174 kNm Steel reqd = 1882.4 mm2
Provide 16 mm dia @ 100 mm dia @
Area of steel provided = 2010.6 mm2
Minimum reinforcement on the inner face
Minimum Steel = 0.06 % of C/S = 285.0 mm2
Max moment on inner surface = 48 kNm Steel reqd = 519.3 mm2
Thus, Area of Steel Required = 519.3 mm2
Provide 10 mm dia @ 100mm C/C
Area of steel provided = 785.4 mm2
16.6.5 Distribution Steel
Tob Slab
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×427 = 512.4 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 47.0 kNm
Area of Steel Required = =47.00×10^6/(240.00×427×0.902) = 508.5 mm2
Thus, Area of Steel Required = 512.4 mm2
Provide 10 mm dia @ 150mm C/C
Area of steel provided = 523.6 mm2
Bottom Slab
Case1 :
Minimum Steel
= 0.12% Effective Area = =1.2×465 = 558.0 mm2
Case2 : = 0.2DL+0.3LL
Maximum Bending Moment for Distribution Steel = 47.0 kNm
Area of Steel Required = =47.00×10^6/(240.00×465×0.902) = 466.9 mm2
Thus, Area of Steel Required = 558.0 mm2
Provide 10 mm dia @ 140mm C/C
Area of steel provided = 561.0 mm2
Side Wall
Case1 :
Minimum Steel
= 0.12% Effective Area =1.2×427 = 512.4 mm2
Case2 : = 0.2DL+0.3LL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

Maximum Bending Moment for Distribution Steel = 32.0 kNm


Area of Steel Required = =32.00×10^6/(240.00×0.902×427) = 346.2 mm2
Thus, Area of Steel Required = 512.4 mm2
Provide 10 mm dia @ 150mm C/C
Area of steel provided = 523.6 mm2

16.7 STAAD Input file


STAAD PLANE
START JOB INFORMATION
ENGINEER DATE 19-JANUARY-11
END JOB INFORMATION
INPUT WIDTH 79
UNIT METER KN
JOINT COORDINATES
1 0 0 0
2 0 0.3 0
3 0 1.3 0
4 0 2.3 0
5 0 3.3 0
6 0 4.3 0
7 0 4.5 0
8 0.2375 4.5 0
9 0.7025 4.5 0
10 2.393 4.5 0
11 4.083 4.5 0
12 5.7725 4.5 0
13 6.2375 4.5 0
14 6.475 4.5 0
15 6.475 4.3 0
16 6.475 3.3 0
17 6.475 2.3 0
18 6.475 1.3 0
19 6.475 0 0
20 6.475 0 0
21 6.2375 0 0
22 5.7725 0 0
23 4.083 0 0
24 2.393 0 0
25 0.7025 0 0
26 0.2375 0 0
MEMBER INCIDENCES

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10; 10 10 11;
11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17; 17 17 18; 18 18 19;
19 19 20; 20 20 21; 21 21 22; 22 22 23; 23 23 24; 24 24 25; 25 25 26; 26 26 1;
START GROUP DEFINITION
MEMBER
_TOPSLAB 7 TO 13
_BOTTOMSLAB 20 TO 26
_SIDEWALL1 1 TO 6
_SIDEWALL2 14 TO 19
END GROUP DEFINITION
DEFINE MATERIAL START
ISOTROPIC MATERIAL1
E 27.39e+006
POISSON 0.15
DENSITY 25
DAMP 2.8026e-044
END DEFINE MATERIAL
CONSTANTS
MATERIAL MATERIAL1 ALL
MEMBER PROPERTY INDIAN
7 TO 13 PRIS YD 0.475 ZD 1
1 TO 6 14 TO 19 PRIS YD 0.475 ZD 1
20 TO 26 PRIS YD 0.55 ZD 1
**SUPPORT SPECS*********
*CONSIDERING MOD. OF SUBGRADE RXN AS 15000 kN/sq.m
SUPPORTS
1 FIXED BUT FX FZ MX MY MZ KFY 5268.75
20 FIXED BUT MX MY MZ KFY 5268.75
22 25 FIXED BUT FX FZ MX MY MZ KFY 17943.8
24 23 FIXED BUT FX FZ MX MY MZ KFY 25350
****LOADING ON THE STRUCTURE****************
**************
*********DL*****
LOAD 1 DEAD LOAD
MEMBER LOAD
7 TO 13 UNI GY -11.875
20 TO 26 UNI GY -13.75
1 TO 6 UNI GY -11.875
14 TO 19 UNI GY -11.875
*********SIDL*******
LOAD 2 SIDL FOR FILL

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

*(*LOAD DUE TO Wearing Coat + Crash Barrier+ FILL + HAUNCH)


MEMBER LOAD
7 TO 13 UNI GY -15.21
********EP AT REST********
*LOAD DUE TO EARTH PRESSURE AT BOTH SIDES
LOAD 3 EARTH PRESSURE
MEMBER LOAD
6 TRAP GX 7.75 5.375
5 TRAP GX 17.75 7.75
4 TRAP GX 27.75 17.75
3 TRAP GX 37.75 27.75
2 TRAP GX 47.75 37.75
1 TRAP GX 50.5 47.75
14 TRAP GX -5.375 -7.75
15 TRAP GX -7.75 -17.75
16 TRAP GX -17.75 -27.75
17 TRAP GX -27.75 -37.75
18 TRAP GX -37.75 -47.75
19 TRAP GX -47.75 -50.50
*********LL SURCHARGE *********
*LL SURCHARGE DUE TO FILL AT BOTH SIDES
LOAD 4 LL SURCHARGE
MEMBER LOAD
6 UNI GX 12
5 UNI GX 12
4 UNI GX 12
3 UNI GX 12
2 UNI GX 12
1 UNI GX 12
*********70 R TRACKED LOAD (Load considered 17T)*******
LOAD 5 70R TRACKED
MEMBER LOAD
8 TO 12 UNI GY -30.56
**********40 T BOGGIE LOAD*******
LOAD 6 BOGGIE
MEMBER LOAD
9 UNI GY -29.42 0.715 1.69
10 UNI GY -29.42
11 UNI GY -29.42 0 0.965
********** CLASS A VEHICLE LOAD(5.7Tx2) ****
LOAD 7 CLASS A WHEELED

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Six Laning of Chilkaluripet – Nellore Section of NH–5. C1102703
Design of Box Culverts for Type 1 Cross Section DN001 Rev. 0

MEMBER LOAD
9 UNI GY -20.56 0.715 1.69
10 UNI GY -20.56
11 UNI GY -20.56 0 0.965
********** Two CLASS A VEHICLE LOAD(TWO 5.7Tx4) ****
LOAD 8 TWO CLASS A WHEELED
MEMBER LOAD
9 UNI GY -29.88 0.715 1.69
10 UNI GY -29.88
11 UNI GY -29.88 0 0.965
*********BRAKING LOAD*********
LOAD 9 BRAKING LOAD
JOINT LOAD
7 FX 24.35
****LOAD COMBINATIONS***************
LOAD COMB 10 DL + SIDL + EP + SUR
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 11 DL + SIDL + EP + SUR + 70R TRACKED
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0
LOAD COMB 12 DL + SIDL + EP + SUR + BOGGIE
1 1.0 2 1.0 3 1.0 4 1.0 6 1.0
LOAD COMB 13 DL + SIDL + EP + SUR + CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 7 1.0
LOAD COMB 14 DL + SIDL + EP + SUR + TWO CLASS A WHEELED
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 15 DL + SIDL + EP + SUR + TRUCK + BRAKING FORCE
1 1.0 2 1.0 3 1.0 4 1.0 5 1.0 9 1.0
LOAD COMB 16 0.2 DL + 0.3 TRACK + 0.3 BRAKING FORCE
1 0.2 5 0.3 9 0.3
PERFORM ANALYSIS
PRINT MEMBER FORCES ALL
FINISH

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