PPS & PPD Joint Operation

PROJECT

RENTAL OF PRODUCTION LINE SEGAT AND SENG GAS PLANT PHASE-1

DATE REVISION PREPARE BY

: : :

30-Okt-10 1 PG

SUBJECT CLIENT

: :

CALCULATION FOR MAIN BRIDGE KALILA BENTU LIMITED

RENTAL OF PRODUCTION LINE SEGAT AND SENG GAS PLANT PHASE-1

CALCULATION FOR MAIN BRIDGE

REV

DATE

DESCRIPTION

PREPARED

CHECKED

REVIEW

CLIENT

25/11/10

Issue for Approval

PG

DJ

TLS

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I.

GENERAL 1.1 This Document present calculation of concrete bridge on main access road of rental of production segat and seng gas plant phase 1th project

1.2

CODE, STANDARTS AND REFERENCES A. Standard/Code SNI T - 12 - 2004 Perencanaan Struktur Beton Untuk Jembatan SNI T - 02 - 2005 Standard Pembebanan Jembatan ACI 318 - 05, Code Requirement for Structural Concrete

B. -

References Soil Investigation Report on Langgam Plant for Kalila Preliminary Design of bridge

C. -

Other Document Das, Braja. "Principle of foundation engineering". 1984. PWS-KENT Publising Company Bowles, J.E, " Foundation Analysis and Design". 1986. Mc Graw-hill.Inc Mac Gregor JG. "Reinforced Concrete Mechanic and Desain". 1997. Pretice Hall. Report of Maping tofografi on Langgam Plant for Kalila

1.3 BOX CULVERT CALCULATION

A.

BOX CULVERT DATA

Box Culvert Dimention Width of Total Box Height of Box (h + t + h) Width of 1(one) Box Thickness of Floor Thickness of Wall Thickness of Slab Found. L H L1 h1 h2 h3 = = = = = = 9000 4400 3000 400 400 400 mm mm mm mm mm mm

2 Wing Wall Dimention Length of Wing Wall Height of Wing Wall Thickness of Wing Wall Other Dimension Thickness of Plate Thickness of Aspal Height of Water ts ta th = = = 200 50 50 mm mm mm C d tw = = = 4000 1500 250 mm mm mm

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B.

Material Properties

Concrete Reinforced Concrete Elastic Modulus Poisson Number Shear Modulus Strain Coeficient

K fc' Ec G

= = = = =

300 24.9 23453 0.2 9772.083333 MPa 1.E-05 / C MPa MPa

Steel Rebar Diameter > 12 mm : U-39 Yield Stress Rebar Diameter 12 mm : U-24 Yield Stress fy = 240 Mpa fy = 390 Mpa

Specific Gravity Concrete Weight Lean Concrete Weight Overlay Weight Water Steel Wc W'c Wa Ww Ws = = = = = 25.00 24.00 20.00 9.80 77.00 kN/m3 kN/m3 kN/m kN/m
3 3

(rabat) (soil)

kN/m3

C.

LOADING ANALYSIS C.1. Selfweight

Ultimate load factor

KMS

1.3

Selfweight load category is a weight of structural material, bridges part and the non-structural element. It's permanently support on bridges The calculation assumed in 1 (one) meter width (perpindicular on drawing area) as follows :

Selfweight load Floor plate Wall plate QMS = h1 x Wc = PMS = H x h2 x Wc = 10 kN/m 44 kN

C.2. Superimposed Dead Load

Ultimate load factor

KMA =

Superimposed dead load is weight of material including non-structural elemen. They give a load to bridge and would be changes as bridge life time

3 The superimposed dead load : 1) Overlay thickness in future 2) Water trap due to badly drainage system

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NO.

Description

Thickness (m)

SG (kN/m3)

Load (kN/m)

1. 2.

Overlay thickness Water

0.05 0.05

20.00 9.80 QMA

1.00 0.49 1.49

C.3. Traffic Load Line Load "D" (TD)

Ultimate load factor

KTD

The vehicle load as a line load "D" divide to uniformly distributed load (UDL) and knife edge load (KEL) The discription of load was described as picture 1 The intencity of "UDL" load ( q (kPa) ) would be depend on magnitude of length of traffic length Picture 2 is describe that condition or as "q" equation

q= q=

8 kPa

for L 30 m

8 * (0.5 + 15/L)for L > 30 m

Picture 1. Line Load "D"

Picture 2. Uniformly Distributed Load (UDL) Intencity

So, for the section length then KEL

L1 q p

= = =

3 m 8 kPa 24 kN/m

4 A dynamic factor (DLA) q PTD = (1 + DLA) * p = = = 0.4 , then 8 kN/m 34 kN

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Truck Load (TT)

Ultimate load factor

KTT

The live load on bridges floor is double tire by truck (truck load) load of load of T1 T2 = = 100 kN 25 kN (middle and rear) (front)

Dynamic load factor

DLA

0.4

So, a truck load to become

PTT1 = (1 + DLA) * T

140 kN

(meddle and rear)

PTT2 = (1 + DLA) * T

35 kN

(front)

C.4. Breaking Load Ultimate load factor Kww = 2

Breaking and vehicle acceleration should be consider as a load The load direction along bridge length and giving influence to floor bridge It's should be calculated 5% due to line load "D" without dynamic load factor

Assume 1(one) m width

TB

5% * (q * L + p)

2.4

kN

C.5. Active Soil Pressure Ultimate load factor KTA = 1.25

A soil section behind wall abutmen should be consider due to superimposed load of traffic condition It's should be equal to thickness of soil around that area, They are same with load of vehicle on that side 0.6 m, as uniformly distributed load and

Soil Parameter Compressive soil Shear angle of soil Cohession factor ws C = = = 17.2 35 0 kN/m derajat kPa

Reduction factor of shear angle

KcR '

0.7

So, the calculation should be

tan -1 (KcR * tan )

= =

0.4557 26.1112

rad
o

Coefficient of active soil pressure

Ka

tan2 (45o - ' / 2)

0.3409

5 Load of soil pressure are QTA1 = 0.6 * ws * Ka = 3.5182 kN/m

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QTA2 C.6. Wind load Ultimate load factor KEW

QTA1 + H * ws * Ka

29.3182

kN/m

1.25

Superimposed of wind load on horisontal direction applying on bridge floor The transformation of wind load on vehicle to bridge floor should be follow a equation :

Wind load friction factor Wind speed

Cw Vw

= =

1.2 35 m/det

Wind load on vehicle are

Tw

0.0012*Cw*(Vw)2

1.764

kN/m

The transformation to vertical load on

2.0 m

(h)

and length of wheel axis are

1.75 m

(x)

So, transformation load to bridge floor are

QEW

0.5*h / x * TEW

1.008

kN/m

C.7. Temperature Ultimate load factor KET = 1.20

The Temperatur should be consider due to stress and deformation The differences of temperature should be taking a half due to consideration influence condition on bridge floor

Maximum temperature Minimum temperature Strain coeficien of concrete Elastic modulus of concrete The differences of temperature

Tmax Tmin Ec T

= = = = =

40 o C 15 o C 1.E-05 23453 12.5 o C / C MPa

C.8. Earthquake load

The main equation are with, TEQ Kh I Wt C S

= = = = = = Kh = C * S

TEQ = Kh * I * Wt

Horisontal load on base (kN) Earthquake coeficien Importan factor Weight of structure including superimposed of dead load Base shear coeficient for earthquake area, time, and soil condition Structure type factor due to dactility of bridge structure

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Time different of structure equation : T with, g KP

= = gravitation acceleration (= 9.8 m/det2) stiffness of structure = 2 * * [ Wt / ( g * KP ) ]

Design parameter of bridge location Soil condition Earthquake mapping Base shear coeficient = = = sedang 3 0.18

Type of structure due to plastic condition S with, F

where : = 1.25 - 0.025 * n and F 1 = 1*F

F n

= =

type of structur factor number of plastic joint due to horisontal deformation

Plastic joint for bridge are

n F S

= = =

3 , then 1.175 1.175

Horisontal load coeficient

Kh

= =

C*S 0.2115

Bridge should be serve more than 2.000 unit of vehicle per day so, the importance factor ( I ) = 1

Earthquake load are where

TEQ
Wt

= = =

Kh * I * Wt 1/2 * ( QMS + QMA ) * L + 1/2 * PMS 73.705 kN

7 so,

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TEQ

= =

Kh * I * Wt 15.589 kN

The dynamic of soil condition due to earthquake load should be consider as dynamic soil pressue (KaG)

Kh

= =

tan-1 (Kh) cos2 ( ' - ) / [ cos2 * { 1 + (sin ' *sin ( ' - ) ) / cos } ]

KaG =

KaG - Ka

Based on last equation, then = 4.4 m H

Ka ws rad

= = =

0.340909136 17.2 tan (Kh)

-1

Kh '

= =

0.2115 0.45573

kN/m3 = 0.20843

Dynamic soil pressure

QEQ = Hw * ws * KaG then,

cos2 ( ' - ) KaG =

0.94008

[ cos2 * { 1 + (sin ' *sin ( ' - ) ) / cos } ]

1.274813

0.737426076 KaG - Ka = 0.39651694

KaG =

Dynamic soil pressure are

QEQ

30.00840201 kN/m

C.8. Ultimit load combination

No

Description Permanent Load

K-1

K-2

K-3

K-4

K-5

1 2 3

(MS) (MA) (TA)

Temporary Load (TD)

1.3 2 1.25

1.3 2 1.25

1.3 2 1.25

1.3 2 1.25

1.3 2 1.25

4 5 6

2 2 2 2 1 1

1 1

(TT) (TB)
Environment Load

7 8 9 10

(EW) (ET) (EQ) (EQ)

1 1

1 1

1.2 1.2

1.2 1.2 1 1

C.8. Structure Analyze To determine a structure behaviour use a computer program SAP 2000 with Frame-2D model for axial force, moment and shear force The input and result of SAP 2000 should be as picture below :

8 C.8.1. Loading input Selfweight (MS)

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Superimposed dead load (MA)

Active soil pressure (TA)

9 Line load (TD)

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Truck load (TT)

Breaking load (TB)

10 Wind load (EW)

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Static eartquake and soil dynamic pressure (EQ)

C.8.2. Output Element Force Load Combination - 1 Axial Force

11 Shear Force

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Ultimate Moment

Load Combination - 2 Axial Force

12 Shear Force

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Ultimate Moment

Load Combination - 3 Axial

13 Ultimate Moment

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Shear Force

Load Combination - 4 Axial

14 Ultimate Moment

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Shear Force

Load Combination - 5 Axial

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Ultimate Moment

Shear Force

C.8.3. Ultimate Force Acting on floor slab Ultimate Moment Mul Mut Shear Force Vu = = = 154.1 kNm 173.2 kNm 211.4 kN

Acting on wall Axial force Ultimate Moment Pu Mul Mut Shear Force Vu = = = = 531.5 kN 79.77 kNm 14.95 kNm 54.02 kN

Support Reaction No Joint Komb-1 kN 1 2 3 4 1 3 5 7 324 492 492 326 Komb-2 kN 273 530 386 182 Komb-3 kN 324 492 492 326 Komb-4 kN 273 531 386 182 Komb-5 kN 161 202 200 169 Max kN 324 531 492 326

16 C.8.4. Floor slab calculation Flexural Negative Concrete Area

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Negative Moment Concrete quality Steel quality Thickness of concrete slab length of rebar due to concrete side Steel elastic modelus, Es concrete stress distribution factor Compressive Yield Stress

Mu = f'c = fy = h= d' = Es = 1 = b = 1*0.85*fc'/fy*600/(600+fy) = Rmax = 0.75*b*fy*{1-0.5*0.75*b*fy/(0.85*fc')} =

173.2 24.9 390 400 35 2E+05 0.85 0.028 6.598

kNm Mpa Mpa mm mm Mpa

reduction factor Ultimate Moment Effective thickness of concrete slab Assume 1 (one) m Nominal Moment Moment factor

= Mu = d = h - d' = b= Mn = Mu / = Rn = Mn*10 / (b * d ) = Rn < Rmax (Oke)

6 2

0.8 173.20 365 1000 216.5 1.625 kNm mm mm kNm

Rebar ratio = 0.85*fc'/fy * {1-(1-2*Rn/(0.85*fc')} = Minimum rebar ratio Use of rebar ratio Rebar area Use of rebar diameter Length of rebar Rebar final dimension (main rebar) min = 25%(1.4/fy) = = As = * b * d = D-19 S = / 4 * D2 * b / As = D19 - 150 As = 1889 mm2 Oke 0.0043 0.0009 0.0043 1584.253 19 178.9 150 mm2 mm

shrink or divide rebar should be 50% of main rebar As' = 50% * As = Use of rebar diameter Length of rebar Rebar final dimension (main rebar) D-13 S' = / 4 * D2 * b / As' = D13-125 As' = 884.4 mm2 Ok 944.6 13 mm 140.4 150

Flexural Positive Concrete Area

Momen rencana tumpuan Concrete quality Steel quality Thickness of concrete slab length of rebar due to concrete side Steel elastic modelus, Es concrete stress distribution factor Kuat tekan beton, Tegangan leleh baja,

Mu = f'c = fy = h= d' = Es = 1 = b = 1*0.85*fc'/fy*600/(600+fy) =

154.1 24.9 390 400 35 2E+05 0.85 0.028 6.598

kNm Mpa Mpa mm mm Mpa

Rmax = 0.75*b*fy*{1-0.5*0.75*b*fy/(0.85*fc')} =

17 reduction factor Ultimate Moment Effective thickness of concrete slab Assume 1 (one) m Nominal Moment Moment factor = Mu = d = h - d' = b= Mn = Mu / = Rn = Mn*10 / (b * d ) = Rn < Rmax Rebar ratio = 0.85*fc'/fy * {1-(1-2*Rn/(0.85*fc')} = Minimum rebar ratio Use of rebar ratio Rebar area min = 25%(1.4/fy) = = As = * b * d = 0.0038 0.0009 0.0038 1402.477 mm2 (Oke)
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0.8 154.06 365 1000 192.575 1.445 kNm mm mm kNm

Use of rebar diameter Length of rebar Rebar final dimension (main rebar)

D-19 S = / 4 * D2 * b / As = D19 - 150 As =

19 202.1 150

mm

1889 mm2

Oke

shrink or divide rebar should be 50% of main rebar As' = 50% * As = Use of rebar diameter Length of rebar Rebar final dimension (main rebar) D-13 S' = / 4 * D2 * b / As' = D13-125 As' = 1061 mm2 Ok 944.6 13 mm 140.4 125

Shear Area

Shear Force Compressive Concrete Tebal efektif slab beton, Ditinjau slab selebar,

Vu = fc' = d= b= Vc = ( fc') / 6 * b * d *10-3 =

211.37 24.9 400 1000 332.666 0.75 249.499

kN Mpa mm mm kN

Reduction factor

= * Vc =

kN

Vc

>

Vu

Need a minimum shear bar

Shear force for rebar 71.985 kN Vs = Vu / 2 = 105.685 kN

Use of rebar diameter Length shear bar on y axis Rebar area Length of rebar Rebar final dimension (main rebar)

DSy = Asv = /4 * D2 * (b / Sy) = Sx = Asv * fy * d / ( Vs *103 ) = DJarak arah x, Sx = Jarak arah y, Sy =

13 600 221.108 326.37 13 300 600

mm mm mm2

mm mm

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Control of Pons Shear

Conc. Quality

300

Compressive

f'c = fv = 0.3 * fc' = PTT = =

24.9 1.50 0.6 140 140000 0.3 0.4 0.1 0.5 900 1100

Mpa Mpa

Requirement of pons shear Reduction factor Wheel load on slab

kN N m m m m mm mm

Thickness of slab

a= h= ta = b= u = a + 2 * ta + h = v = b + 2 * ta + h = 0.9 1.1 m m = =

Width effective Shear area Nominal of shear force

d= Av = 2 * (u + h) * d = Pn = Av * fv =

365.000 949000

mm mm2

1420650.147 N

* Pn = 852390.0884 N Ultimate factor Wheel load ultimate on slab KTT = Pu = KTT * PTT = 2.0 280000 < C.8.4. Wall rebar calculation Flexural Axial rebar Axial ultimate force Ultimit moment Conc. Quality K Assume 1 (one) m Thickness of wall length of rebar due to concrete side h' = h - 2*d' = 300 mm 300 Compressive Pu = Mu = fc' = b= h= d' = h'/h = Ag = b * h = = Pu / (fc'.Ag) = 531.52 79.77 24.90 1000 400 50 0.75 400000 0.053 mm2 kN kNm Mpa mm mm mm N * Pn Oke

19 = Mu / ( fc'.Ag.h ) = Plot dan value into P-M interaction diagram Rebar ratio Rebar area needed Use of rebar diameter Compressive area same with stress area = As = * b * h = D= 1.0% 4000 22 mm2 mm 0.020

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As (tekan) = As (tarik) = 1/2 * As = Length of rebar Used Possitive rebar Negative rebar Layer 1 1 s = /4*D2*b /(1/2*As) =

2000 189.97

mm2 mm

Dia. 22 22 -

Length 175 175

= 0.053 = 0.020

C.8.4. Foundation calculation Soil Capacity Width of base box culert found., L = 5.50 m Depth of box culvert found., Z = 1.00 m Weight of soil volume, ws = 18.4 kN/m3 Shear angle of soil, = 5.5 L= Z= ws = = 9 m 1 m 18.4 kN/m3 5.5

20 Cohession, C = 0.012 kg/cm2 C= 0.18 kg/cm2

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Based on Meyerhoff (Sondir Data) Soil capacity qa = qc / 50 * [ ( L + 0.30 ) / L ]2 qc = L= qa = qc / 50 * [ ( L + 0.30 ) / L ]2 = qa = kg/cm2 3 9 0.064 6.407 kg/cm2 m kg/cm2 kN/m2

qc = konus value in Z depth, 3 kg/cm2 L = Width of foundation,

Based on Bowles (SPT) Soil capacity, and qa = 12.5 * N * [ (L + 0.3) / L ] * Kd Kd = 1 + 0.33 * Z / L N= L= Z= Kd = 1 + 0.33 * Z / L = Takel, Kd = qa = 12.5 * N * [ (L + 0.3) / L ] * Kd = kN/m2 1.33 2 9 1 1.037 1.037 26.781 kN/m2 hit/30 cm m m 1.33 Oke

N = SPT value based on examination, 12 hit/30 cm L = Width of foundation, Z = Depth of foundation,

Rekapitulation of soil capacity No Description 1 Test of Sondir (Meyerhoff) 2 Test of SPT (Bowles) Minimum soil capacity, qa = Nominal soil capacity qa = Reduction factor, Soil capacity = * qa = qa 6.407 26.781 6.407 6.407 0.65 4.164333333 kN/m2 kN/m2 kN/m2 kN/m2 kN/m2

Controlling of soil capacity Assume base width as Box culvert length Reaction force on support b= L= P1 = P2 = P3 = P4 = Ultimit load on base Base foundation area, Ultimit stress on base foundation Pu = P1 + P2 +P3 + P4 = A=L*b= Qu = Pu / A = 2 9 324 531 492 326 1673 18 92.944 Not Safe m m kN kN kN kN kN m2 kN/m2

Because of calculation result, the soil capacity can't serve working load to support box culvert bridge

Pile support calculation

Pile material Pile Size Pile length

: : :

PC Square Pile 250 . 250 20 m

Allawable Capasity shall be describe as follow:

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Condition

Q Comp Kn

Q Tens Kn 61.85 74.22

Q Lat Kn 16 19.2

Permanen

181 217

Temporary

Number of Pile Control pile individual capasity by upper structure load compression load Number of Pile Load on pile actual Capasity one pile P single < P pile capacity P tot n Psingle = P tot/n 1673 kN 42 Pcs 39.833 Kn 181 kn Oke