CR 13045 PIER R00 Calculation Report

STRUCTURAL DESIGN
Project:
EDGECOMBE INTERCHANGE
VIADUCT B0214, B0215
Client:
C.M.C. South Africa
Object:
Formworks for concrete

Bridge Piles
Calculated by:
Technical Department, Pilosio, Italy
Reference Code:
CR-13045-PIER-R00
Number
Description
Date
Authorization
00
Revision 00
18 Oct. 13
FB
Project: EDGECOMBE INTERCHANGE

Job No. 13045
15 October 2013
Sheet n. 2
FORMWORKS FOR CONCRETE BRIDGE PILES
1.0 OBJECT
This report relates to the static verification of a steel formwork that will be used for the casting of reinforced concrete bridge
piers.
The formwork in plant has a maximum external width of 4248mm and a height of 2048mm but, through modular panels, it
can reach a height maximum of 2648mm in plan. In elevation, the main formwork has a height of 2000mm, but with panels
of different heights it can reach a maximum elevation of 5000mm.
The main components that constitute the formwork are four essentially:
1. Rib steel plates with a cross section 100mm x 6mm and a variable length.
2. Vertical rib plates (at the bolted joints) having section size of 120mm x 8mm and a maximum length of 2000mm.
3. Sheet containment of the jet 4 mm thick.
4. Steel profiles of junction between the various panels with a dimension section 100mm x 50mm
Considering the type of use of the devices we just verify the structural resistance, with reference to the Dywidag tie rods, the
ribs and the bolted connection, since we consider negligible the effects of the deformations in the case the stresses are
adequately low.

Job No. 13045
15 October 2013
Sheet n. 3
This report is referred to the mentioned drawings:

PIERS BRIDGE B0215 (CASSERO PARTENZA E FUSTO PILA)
D
13045
B1
1/1
15.10.2013
PIER N.2 FIRST LIFT AND CASTING PHASES
13045
B2
1/1
15.10.2013
13045
B3
1/1
15.10.2013
13045
B4
1/1
15.10.2013
PIER N.5-9-21 FIRST LIFT AND CASTING PHASES
13045
B5
1/1
15.10.2013
13045
B6
1/1
15.10.2013
13045
B7
1/1
15.10.2013
13045
B8
1/1
15.10.2013
PIER N.10FIRST LIFT AND CASTING PHASES
13045
B9
1/1
15.10.2013
13045
B10
1/1
15.10.2013
13045
B11
1/1
15.10.2013
13045
B12
1/1
15.10.2013
13045
B13
1/1
15.10.2013
13045
B14
1/1
15.10.2013
13045
B15
1/1
15.10.2013
13045
B16
1/1
15.10.2013
13045
B17
1/1
15.10.2013
13045
B18
1/1
15.10.2013
13045
B19
1/1
15.10.2013
13045
B20
1/1
15.10.2013
13045
B21
1/1
15.10.2013
PIERS BRIDGE B0214 (CASSERO PARTENZA E FUSTO PILA)

D
13045
B22
1/1
15.10.2013
13045
B23
1/1
15.10.2013
13045
B24
1/1
15.10.2013
13045
B25
1/1
15.10.2013
13045
B26
1/1
15.10.2013
13045
B27
1/1
15.10.2013
13045
B28
1/1
15.10.2013
13045
B29
1/1
15.10.2013
13045
B30
1/1
15.10.2013

Job No. 13045
15 October 2013
Sheet n. 4
2.0 MATERIALS
Steel structures
S235 (Fe360)
Characteristic tensile strength
ftk
= 360N/mm
Characteristic yield strength
fyk
= 235N/mm
ftk
= 430N/mm
fyk
= 275N/mm
S275 (Fe430)
Bolts
High resistance bolts, class 8.8
ftk
= 800N/mm
fyk
= 640N/mm
ftk
= 1100N/mm
fyk
= 900N/mm
Area of tie rod 15 mm
= 177mm
Characteristic tensile force
Fm
= 195kN
Characteristic yield force
Fm
= 159kN
Allowable working load
Fawl
= 90kN
Dywidag tie rods

Job No. 13045
15 October 2013
Sheet n. 5
3.0 DESIGN CODES AND STANDARDS

UNI EN 1990:2006 13/04/2006 Eurocode 0 - Basis of structural design
UNI EN 1991-1-1:2004 01/08/2004 Eurocode 1 - Actions on structures
part 1-1: General actions - Densities, self-weight, imposed loads for buildings
UNI EN 1993-1-1:2005 01/08/2005 Eurocode 3 - Design of steel structures
part 1-1: General rules and rules for buildings
UNI EN 1993-1-8:2005 01/08/2005 Eurocode 3 - Design of steel structures
part 1-8: Design of joints

Job No. 13045
15 October 2013
Sheet n. 6
4.0 TIE RODS DESIGN

The verification of tie rods has been made evaluating the area of the formwork, related to the individual tie rods, through the
2
related areas of influence. A maximum concrete pressure 50kN/m has been considered.
With regards to the drawings provided by the manufacturer, it was pointed out that the areas of influence with major surface
are those in correspondence of the side panel having length of 3157mm, as shown below:
The maximum area of competence of the single threaded bar corresponds to 0.795m*0.813m = 0.65m approx.
2
Considering a concrete pressure on the formwork panel equal to 50kN/m the tensile load on tie rods is determined to be
2
50kN/m *0.65m = 32.5kN < 90kN (allowable working load of Dywidag tie rod).
According to the characteristics of the tie rods provided by the manufacturer, the verification is widely satisfied.

Job No. 13045
15 October 2013
Sheet n. 7
5.0 BOLT CONNECTIONS DESIGN

Although the external formwork is bound to the inner Dywidag tie rods, we have verified the strength of bolted joints
necessary for the assembly of the formwork. In particular the verification was performed on a portion of the panel in
correspondence to the inclined portion of formwork, as better indicated in the drawing below, assuming that it, at that point,
may be without threaded rods Dywidag contrast:
Assuming a maximum concrete pressure of 50kN/m and considering that each bolt can be traced to a specific area of
influence, the orthogonal forces acting on the panel have been determined (with approximation) and decomposing the
forces the individual components agents on the bolts (axial and shear) have been determined.
The verification was conducted according to the EC3, the verification is satisfied multiplying the forces obtained by a
coefficient = 1.50. For health and safety a single bolt resistant has been considered but it must be underlined that the union
bolted (for single area of influence that competes) is made by a pair of bolts Class 8.8, M20 and therefore the action should
be divided on both.

Job No. 13045
15 October 2013
Software: PROFILI - vers.7.7 (21 aprile 2009) Ing. Piero Gelfi
Sheet n. 8

Job No. 13045
15 October 2013
Sheet n. 9
6.0 STEEL VERTICAL RIBS DESIGN

We have performed a design of the vertical and horizontal ribs of the panel, considering the most stressed. We have
2
considered a maximum pressure of the concrete equal to 50kN/m and according to this value we have performed bending
design. We have considered the ribs shown in this drawing:
For the calculation , we have considered the scheme of calculation beam on two supports, with uniformly distributed load
(pressure of the concrete on the panel for the area of influence the single rib). The rib under calculation is obtained with a
steel plate of size 100mm x 6mm thick, welded with 4mm thickness metal sheet.
Tipo
T ribassata: bi=0.60 ht=10.40 bs=8.00 hs=0.40
Area
cm2
9.20
Jt
cm4
0.89
J 2-2
cm4
17.25
J 3-3 W 2-2
cm4
cm3
106.47 4.31
W 3-3
cm3
15.64
Wp 2-2
cm3
5.17
Wp 3-3
cm3
18.77

Job No. 13045
15 October 2013
Sheet n. 10
Fondamental combination SLU

G1*G1 + G2*G2 + P*P + Q1*Qk1 + Q2*02*Qk2 + Q3*03*Qk3 +
Cmb Tipo
1
SLU
2
SLU
3
SLU
4
SLU
Sigla Id
Comb. SLU A1 1
Comb. SLU A1 2
Comb. SLU A1 3
Comb. SLU A1 4
Cmb CDC 1/15...

1
1.35
2
1.35
3
1.00
4
1.00
CDC 2/16...
0.0
1.50
0.0
1.50
M = P*l /8 = (0.073*1.35 + 22.5*1.50)*0.8 /8 = 33.85*0.8 /8 = 21.66/8 = 2.708kNm

V = P*l/2 = 33.85*0.8/2 = 13.54kN
Steel check according to EC3

Mc,Rd = Wel*fyk/m,0 = 15640*275/1.05 = 4.096kNm
Vc,Rd = Av*fyk/(m,0*3) = 460*275/(1.05*3) = 69.55kN
M/Mc,Rd = 2.708/4.096 = 0.66 < 1.0

V/Vc,Rd = 13.54/69.55 = 0.19 < 1.0
f = 5/384*P*l /(EJ) = 5/384*33.85*80 /(106.47*2100000) = 0.081cm

all checks are satisfied
It should be noted that the horizontal ribs, being interrupted in correspondence of the vertical ones, are to be considered as
beams between two supports. As their length and their area of influence is less than the case analyzed , the verification at
decrease is automatically verified.

Job No. 13045
15 October 2013
Sheet n. 11
7.0 DESIGNERS NOTES

Carry out all the operations of assembly and use of formwork according to the standards of safety of workers at the
workplace, with particular reference to temporary and/or mobile constructions sites;
carry out the assembly of the formwork in accordance with the construction drawings and directives provided by the
manufacturer;
limit, to the possible extent, the maximum pressure of the concrete even making reference to the graphs of
correlation between pressure and speed of ascent of the jet, however, without ever exceeding the maximum
allowable pressure established by the manufacturer of formwork;
check all the material before each use, any anomalies must be immediately reported to management.
October 2013

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STRUCTURAL DESIGN

C.M.C. South Africa

Formworks for concrete

Technical Department, Pilosio, Italy

Project: EDGECOMBE INTERCHANGE

FORMWORKS FOR CONCRETE BRIDGE PILES

Project: EDGECOMBE INTERCHANGE

FORMWORKS FOR CONCRETE BRIDGE PILES

This report is referred to the mentioned drawings:

PIER N.2 FIRST LIFT AND CASTING PHASES

PIER N.3 FIRST LIFT AND CASTING PHASES

PIER N.4 FIRST LIFT AND CASTING PHASES

PIER N.5-9-21 FIRST LIFT AND CASTING PHASES

PIER N.6 FIRST LIFT AND CASTING PHASES

PIER N.7 FIRST LIFT AND CASTING PHASES

PIER N.8 FIRST LIFT AND CASTING PHASES

PIER N.10FIRST LIFT AND CASTING PHASES

PIER N.11 FIRST LIFT AND CASTING PHASES

PIER N.12 FIRST LIFT AND CASTING PHASES

PIER N.13 FIRST LIFT AND CASTING PHASES

PIER N.14 FIRST LIFT AND CASTING PHASES

PIER N.15 FIRST LIFT AND CASTING PHASES

PIER N.16 FIRST LIFT AND CASTING PHASES

PIER N.17 FIRST LIFT AND CASTING PHASES

PIER N.18 FIRST LIFT AND CASTING PHASES

PIER N.19 FIRST LIFT AND CASTING PHASES

PIER N.20 FIRST LIFT AND CASTING PHASES

PIER N.22 FIRST LIFT AND CASTING PHASES

PIER N.23 FIRST LIFT AND CASTING PHASES

PIER N.24 FIRST LIFT AND CASTING PHASES

PIERS BRIDGE B0214 (CASSERO PARTENZA E FUSTO PILA)

PIER N.2 FIRST LIFT AND CASTING PHASES

PIER N.3 FIRST LIFT AND CASTING PHASES

PIER N.4 FIRST LIFT AND CASTING PHASES

PIER N.5 FIRST LIFT AND CASTING PHASES

PIER N.6 FIRST LIFT AND CASTING PHASES

PIER N.7 FIRST LIFT AND CASTING PHASES

PIER N.8 FIRST LIFT AND CASTING PHASES

PIER N.9 FIRST LIFT AND CASTING PHASES

PIER N.10 FIRST LIFT AND CASTING PHASES

Project: EDGECOMBE INTERCHANGE

FORMWORKS FOR CONCRETE BRIDGE PILES

Characteristic yield strength

Characteristic tensile strength

Characteristic yield strength

Characteristic yield strength

Characteristic tensile strength

Characteristic yield strength

Area of tie rod 15 mm

Characteristic tensile force

Characteristic yield force

Allowable working load

Dywidag tie rods

Project: EDGECOMBE INTERCHANGE

FORMWORKS FOR CONCRETE BRIDGE PILES

3.0 DESIGN CODES AND STANDARDS

Project: EDGECOMBE INTERCHANGE

FORMWORKS FOR CONCRETE BRIDGE PILES

4.0 TIE RODS DESIGN

M = Pl /8 = (0.0731.35 + 22.51.50)0.8 /8 = 33.85*0.8 /8 = 21.66/8 = 2.708kNm

f = 5/384Pl /(EJ) = 5/38433.8580 /(106.47*2100000) = 0.081cm