STRUCTURE : STG COLUMN FORMWORK

INDEX

# Title Page
1 . Input Data 1-1

2 . Reference Drawing 2-2

3 . Preliminary Drawing 3-3

4 . Plyboard Design 4-4

5 . MS Angle Design 5-6

6 . Flat Bar Design 7-8

7 . Horizontal Pipe Design 9-10

8 . Tie Rod Design 11-11

9 . Vertical Pipe Design 12-13

10 . Diagonal Strut & Guy Support Design 14-15

11 . Update Drawing 16-16

12 . APPENDIXES

APPENDIX_A 17-17

APPENDIX_B 18-18

APPENDIX_C 19-19

APPENDIX_D 20-24

APPENDIX_1 25-25

APPENDIX_2 26-27

APPENDIX_3 28-28
 STRUCTURE : STG COLUMN FORMWORK

1. INPUT DATA
Ref. Drawing no:

1. 19FW-00UMB00-C04-0002-RA_Gas Turbine Generator Foundation Plan

Data :
i. f'c =
30 MPa [REF DWG]
ii. fy =
410 MPa [REF DWG]
iii. Wc = 25 kN/m3 [APPENDIX-A : Table 6.2.1: Unit Weight of Basic
Materials, BNBC-20154]

Let, Steel Ratio for 30MPa = 4350 psi = 2.17%; Wc=22.8+(0.63*2.17) = 25 ≈ 25 kN/m3 [APPENXIX-B: Min. & Max Steel Ratio as per ACI Code]

iv. Wst = 77 kN/m3 (APPENDIX-A : Table 6.2.1: Unit Weight of Basic

Materials, BNBC-2015)

v. Fy = 250 Mpa [APPENDIX-C : Steel Material, ASTM A36]

vii. E = 200,000 Mpa

Design Method = ASD

Compact & Non-Compact Check : [APPENDIX-D : Shape Classification as Per AISC]AISC]

1. ANGLE - 50X30X3
λ= b/t = 16.67
λp= 0.54√(E/Fy) = 15.27
λr= 0.91√(E/Fy) = 25.74
So, Flange is Noncmpact with no slenderness effect

2. FLAT BAR - 62X4

λ= h/b = 15.50
λp= 0.07(E/Fy) = 56.00
λr= 0.31(E/Fy) = 248.00
So, Compact & nonslenderness

3. MS PIPE-D50, T=2
λ= D/t = 25.00
λp= 0.07(E/Fy) = 56.00
λr= 0.31(E/Fy) = 248.00
So, Compact & nonslenderness

4. MS PIPE-D38, T=2.3
λ= D/t = 16.52
λp= 0.07(E/Fy) = 56.00
λr= 0.31(E/Fy) = 248.00
So, Compact & nonslenderness

5. C-CHANNEL - 100X50X5
λ= b/tf = 10.00
λp= 0.38√(E/Fy) = 10.75
λr= 1.0√(E/Fy) = 28.28
So, Flange is Compact

λ= h/tw = 18.00
λp= 3.76√(E/Fy) = 106.35
λr= 5.70√(E/Fy) = 161.22
So, Web is Compact
STRUCTURE : STG COLUMN FORMWORK

2. REFERENCE DRAWING
STRUCTURE : STG COLUMN FORMWORK

3. PRELIMINARY DRAWING
 STRUCTURE : STG COLUMN FORMWORK

4. MS Plate DESIGN

i. Column Size = 2600 X 2100

ii. Concrete Pouring Height = 3600 mm
Load Calculation :

i. Concrete Lateral Pressure

a) Wall ht., H = 3.60 m
b) Supply Rate = 20.00 cum/h
c) Concrete Pouring Area, A = 5.46 sqm
d) Volume of Concrete = 19.66 cum
e) Time of Completion = 0.98 h [ 19.66 / 20.00 ]
f) Rate of Rise, R = 3.66 m/h [ 3.60 / 0.98 ]
e) Concrete Temperatire, T = 32.00 OC
C1 = 4.80

Concrete Pressure will be Least value of the following criteria

i. P = C1 + 524R/(T+17.80) = 43.342 kPa [APPENDIX-1 : ACI-347]

P = 43.342 kN/sqm (control)

ii. P=25H = 90.000 kN/sqm 2.9mm Surface Plate

iii. P= 2000 psf = 98.760 kN/sqm

10
Therefore, P = 43.342 kN/sqm 00

Therefore, W = 43.342 kN/m

Moment Capacity Check : 150 150 <38x38x4

M= WL2/8 [=43.342*1000*150^2/8]
= 121,900.64 N-mm
t= 2.9 mm
S= at^2/6 mm3 b=L= 150 mm
= 1,401.67 [1000*2.9*2.9/6] a= 1000 mm
α= 0.15
M/S= 86.97 Mpa < 0.60*Fy = 150.00 Mpa
Hence OK

I= 2,032.42 mm4 [1000*2.9^3/12]

Deflection Check :
5WL4
∆=
384 EI
= 0.70 mm [=(5*43.342*150^4)/(384*200000*2032.42)]

∆all = L/180
= 0.83 mm Hence OK
 STRUCTURE : STG COLUMN FORMWORK

4. MS Plate DESIGN

Bending Stress Check :

0.75xPxb2 (a) [APPENDIX-2]
σ(max) =
t2 (1+1.61 α3)
= 86.50 Mpa [=(0.75*43.342*150^2)/(2.9^2*(1+1.61*0.15^3)]

σ(all) = 150.00 MPa (=0.60*250) Hence OK

Deflection Check :
0.1422xPxb4 (b) [APPENDIX-2]
∆P/(max)=
Et3 (1+2.21 α3)
= 0.63 mm [=(0.1422*43.342*150^4)/(200,000*2.9^3(1+2.21*0.15^3)]
∆(all)= 0.83 mm Hence OK
 STRUCTURE : STG COLUMN FORMWORK

5. ANGLE DESIGN

Size = < 38X38X4 @ 0.022 kN/m

150

2.9mm Surface Plate

150
Considering,
- 38x4 Flat Bar

Span Length, L = 150 mm

<38x38x4

Load Area= 150 X 150 mm

Load Calculation :

i. DL
a) Concrete Pressure = 43.34 kN/m2 = 6.50 kN/m (=43.34*0.15)
b) Self wt. of Surface Plate = 0.22 kN/m3 = 0.03 kN/m (=0.22*0.15)
c) Self wt. of MS Angle = - - = 0.022 kN/m
Total, WT= = 6.56 kN/m

Section Property Check:

M= WTL²/8 [=6.56*150*150/8]
= 18,441.18 N-mm

Sx/req= M/0.6*Fy [=18441.18/(0.60*250)]

= 122.94 mm3 < 1,964.83 mm3
. Hence OK
 STRUCTURE : STG COLUMN FORMWORK

5. ANGLE DESIGN

Ix= 3.92E+04 mm4

Deflection Check :
∆WT= 5WTL4/384EIx [=5*6.56*150^4)/(384*200,000*3.92E+04)
= 0.0055 mm

∆(all)= L/180 [=150/180]

= 0.83 mm Hence OK

Shear Check :

b/t = 9.50 [38/4]

Va = WTL/2 [=6.56*150/2]
= 491.76 N

A= bt
= 152.00 mm2

fa = Va / A
= 3.24 MPa

Fa = 0.4 Fy
= 100.00 MPa Hence OK
 STRUCTURE : STG COLUMN FORMWORK

6. FLAT BAR DESIGN

Size = - 38X4 @ 0.012 kN/m

150

2.9mm Surface Plate

150
Considering,

- 38x4 Flat Bar

Span Length, L = 150 mm

<38x38x4
Load Area= 150 X 150 mm

Load Calculation :
i. DL
a) Concrete Pressure = 43.34 kN/m2 = 6.50 kN/m (=43.34*0.15)
b) Self wt. of Surface Sheet = 0.22 kN/m3 = 0.03 kN/m (=0.65*0.15)
d) Self wt. of Flat Bar = - - = 0.012 kN/m
Total, WT= = 6.55 kN/m

Section Property Check:

M= WTL²/8 [=6.55*150*150/8]
= 18,412.22 N-mm

Sx/req= M/0.6*Fy [=31185.85/(0.60*250)]

= 122.75 mm3 < 2,562.70 mm3
. Hence OK
 STRUCTURE : STG COLUMN FORMWORK

6. FLAT BAR DESIGN

Ix= 1.83E+04 mm4

Deflection Check :
∆WT= 5WTL4/384EIx [=5*6.55*300^4)/(384*200,000*7.94*E+04)
= 0.01 mm

∆(all)= L/200 [=300/200]

= 0.75 mm Hence OK

Shear Check :

h/b = 9.50 [38/4]

Va = WTL/2 [=6.55*300/2]
= 490.99 N

A= bt
= 248.00 mm2

fa = Va / A
= 1.98 MPa

Fa = 0.4 Fy
= 100.00 MPa Hence OK
 STRUCTURE : STG COLUMN FORMWORK

7. HORIZONTAL PIPE & C-CHANNEL DESIGN

Size =
D= 38 mm O/O
t= 2.3 mm
I= 41,265.90 mm4 [APPENDIX-7 : online sectional property calculator)
Self wt. of Pipe= 2.030 kg/m = 0.02 kN/m

Double Horizontal Pipe 960+

C-Channel @ 960

500 500 Vertical-Pipe

Load Calculation :
a) Load from Concrete Pressure = 43.34 kN/sqm 1200x600 PANEL SIZE
b) Load from 2.9mm Surface Sheet = 0.22 kN/sqm Angle = 4.8 m = 0.106 kN
c) Load from Frame = 0.205 kN/sqm Flat bar = 3.6 m = 0.042 kN
= 43.77 kN/sqm Total = 0.148 kN
= 21.01 kN/m [=43.78*0.48] Wt. per sqm = 0.205 kN/sqm

d) Self weight of MS Pipe = 0.04 kN/m [0.02*2]

Total Load on Double Horizontal Pipe, W T 21.05 kN/m

Section Property Check:

M= WTL²/8 [=19.30*480*480/8] [ L= = 480 mm}
= 606,236.56 N-mm

Sx/req= M/0.6*Fy [=606236.56/(0.60*250)]

= 4,041.58 mm3 < 4,343.78 mm3
. Hence OK
 STRUCTURE : STG COLUMN FORMWORK

7. HORIZONTAL PIPE & C-CHANNEL DESIGN

Ix= 8.25E+04 mm4 [Double Horizontal Pipe = 2*41265.9]

Deflection Check :
∆WT= 5WTL4/384EIx [=5*21.05*480^4)/(384*200,000*8.25*E+04)
= 0.881 mm

∆(all)= L/180 [=480/180]

= 2.67 mm Hence OK

Shear Check :

Va= WTL/2 [=21.05*480/2]

= 5,051.97 N

A w= 257.96 mm2

fa = Va / A w
= 19.58 MPa

Fa = 0.4 Fy
= 100.00 MPa Hence OK

Horizontal Pipe 960+

C-Channel @ 960

500 500 Vertical C-Channel

Load Calculation :
a) Load from Concrete Pressure = 43.34 kN/sqm
b) Load from 2.9mm Surface Sheet = 0.22 kN/sqm
c) Load from Frame = 0.205 kN/sqm
= 43.77 kN/sqm
= 21.01 kN/m [=43.78*0.48]

d) Self weight of MS c-Channel = 0.073 kN/m

Total Load on Double Horizontal Pipe, W T 21.08 kN/m

Section Property Check:

M= WTL²/8 [=21.08*480*480/8] [ L= = 480 mm}
= 607,196.45 N-mm

Sx/req= M/0.6*Fy [=607196.45/(0.60*250)]

= 4,047.98 mm3 < 6,310.12 mm3
. Hence OK
 STRUCTURE : STG COLUMN FORMWORK

7. HORIZONTAL PIPE & C-CHANNEL DESIGN

Iy= 2.25E+05 mm4

Deflection Check :
∆WT= 5WTL4/384EIx [=5*21.08*480^4)/(384*200,000*2.25E+04)
= 0.32 mm

∆(all)= L/180 [=480/180]

= 2.67 mm Hence OK

Shear Check :

Va= WTL/2 [=21.03*480/2]

= 5,059.97 N

A w= 450 mm2 [90*5]

fa = Va / A w
= 11.24 MPa

Fa = 0.4 Fy
= 100.00 MPa Hence OK
 STRUCTURE : STG COLUMN FORMWORK

8. TIE ROD DESIGN

Load on Horizontal Pipe = 21.05 kN/m

Load on Horizontal C-Channel = 21.08 kN/m
[Horizontal Pipe @ 960 & Vertical C-Channel @ 500]
Load for a Single Tie Rod, Pa = 47.41 kN [(21.05+21.08*2)*0.50*1.5] F.S.= 1.5

Cross Sectional Area of Tie Rod, Ab = Pa / 0.6*Fy

= 192.73 sqmm [3.21/(0.60*410]

Dia, of Rod, d= [4Ab/3.1416]^1/2

d= 15.7 mm

Let, d= 16 mm

So provide 16mm Tie Rod @ 500 along Horizontal and 960 along Vertical pipes
 STRUCTURE : STG COLUMN FORMWORK

9. VERTICAL C-CHANNEL DESIGN

Horizo
ntal
Pipe
960+
C-
Chann
el @
960

Vertica
l C-
Chann
el @
500

Load Calculation :
a) Point Load of single Horizontal Pipe Bracing = - kN [21.05*0.50] [Load will be carried by Tie Rod & Horizontal Pipe Bracing]
Point Load for 4nos Horizontal Bracing= - kN [4*10.52]

b) Point Load of single Horizontal C-Channel Bracing = 10.54 kN [21.08*0.50]

Point Load for 4nos Horizontal Bracing= 42.17 kN [4*10.54]

c) Self weight of MS C-Channel = 0.07 kN/m

Equivalent 'UDL on 3.6 0m Vertical Pipe, W T = 23.57 kN/m [(42.17/3.60+0.07)*2]

Section Property Check: [Tie Rod Spacing @ 960 along Vertical C-Channel]
M= WTL²/8 [=23.57*960*960/8] [L= = 960 mm]
= 2,715,506.49 N-mm

Sx/req= M/0.6*Fy [=43709.78/(0.60*250)]

= 18,103.38 mm3 < 28,658.30 mm3
. Hence OK

Ix= 1.40E+06 mm4

Deflection Check :
∆WT= 5WTL4/384EIx [=5*0.97*600^4)/(384*200,000*4.13*E+04)
= 0.931 mm

∆(all)= L/180 [=500/180]

= 4.80 mm Hence OK
 STRUCTURE : STG COLUMN FORMWORK

9. VERTICAL C-CHANNEL DESIGN

Shear Check :

Va = WTL/2 [=23.57*960/2]
= 11,314.61 N

A w= 257.96 mm2
=

fa = Va / A w
= 43.86 MPa

Fa = 0.4 Fy
= 100.00 MPa Hence OK
 STRUCTURE : STG COLUMN FORMWORK

10. DIAGONAL STRUT & GUY SUPPORT DESIGN

Size =
D= 50 mm O/O
t= 2 mm
I= 87,009.60 mm4 [APPENDIX-7 : online sectional property calculator)
Self wt. of Pipe= 2.368 kg/m = 0.023 kN/m

H'

Vertical-Pipe

Guy Support

3600
Strut Bracing
1800
Strut Bracing :
t
a) Min. Horizontal Load, H = 1.50 kN/m [ACI-247]

Horizontal Load at 1800mm from Bottom should be

H'= 3.60/1.80*1.5 1000
= 3.38 kN/m at top of Wall Form Length
1500

t = sqrt ( 1.80^2+1.00^2)
2.06 m

(Tension) Compression in Diagonal Strut = H'x2.06/1.00

7.54 kN/m of Wall

Let, Diagonal Strut will be placed @ 1500

Load on each Diagonal Struct = 11.31 kN [7.54*1.5]

Load Capacity Check :

Unbraced Condition :
k= 1
Leff = 2,059.13 mm
kLeff/Rgx = 121.27 < 200 Hence OK

π2EI
Critical Load on Props, Pcr =
(kLeff)2

= 40.47 kN = 4,126.32 kg

Safe Load = 16.19 kN [40.47/F.S.=2.5] > 11.31 kN

Strut Spacing @ 1500 is OK.

 STRUCTURE : STG COLUMN FORMWORK

10. DIAGONAL STRUT & GUY SUPPORT DESIGN

Guy Support :
a) Min. Horizontal Load, H = 1.50 kN/m [APPENDIX-3 : ACI-247]

H'= 3.60/3.60*1.50
= 1.50 kN/m at top of Wall Form Length

t = sqrt ( 3.6^2+1.50^2)
3.90 m

Tension in Guy Support = H'x3.90/1.50

3.90 kN

Let, Guy Support @ 1500 = 5.85 kN [3.90*1.5]

Cross Sectional Area of Tie Rod, Ab = 1.5*Pa / 0.6*Fy F.S 1.5

= 53.51 sqmm [4.68/(0.60*410)]

Dia, of Rod, d= [4Ab/3.1416]^1/2

d= 8.3 mm

Let, d= 10 mm

Guy Support (10mm dia Rod or equivalent) Spacing @ 1500 is OK.