LEBUHRAYA PERSISIRAN PANTAI BARAT KERJA-KERJA MENAIKTARAF

JALAN PERSEKUTUAN FT005 (TELUK INTAN KG. LEKIR) PERAK

DARUL RIDZUAN
JAMBATAN SULTAN YUSOF

TABLE OF CONTENTS

1.0 GENERAL INFORMATION............................................................................................................1

1.1 INTRODUCTION............................................................................................................................1
1.2 DESCRIPTION OF THE BRIDGE..................................................................................................1

2.0 DESIGN CRITERIA FOR BRIDGEWORK...................................................................................5

2.1 DESIGN STANDARDS AND CODE OF PRACTICE..................................................................................5

2.2 MATERIAL AND MATERIALS PROPERTIES..........................................................................................5
2.3 LOADING - DEAD LOAD....................................................................................................................6
2.4 LOADING - LIVE LOAD......................................................................................................................7
2.5 LOAD FACTORS AND LOAD COMBINATIONS.....................................................................................8

3.0 STRUCTURAL ANALYSIS..............................................................................................................9

3.1 METHOD OF ANALYSIS......................................................................................................................9

3.2 SOFTWARE FOR ANALYSIS.................................................................................................................9
3.3 NUMERICAL MODEL FOR STRUCTURAL ANALYSIS..........................................................................9
3.4 TRANSVERSE ANALYSIS OF SEGMENTAL BOX..................................................................12

4.0 STRUCTURAL DESIGN.................................................................................................................14

4.1 DESIGN CRITERIA AND REQUIREMENT..................................................................................14

5.0 PILE GROUP ANALYSIS...............................................................................................................16

Design Report
LEBUHRAYA PERSISIRAN PANTAI BARAT KERJA-KERJA MENAIKTARAF
JALAN PERSEKUTUAN FT005 (TELUK INTAN KG. LEKIR) PERAK
DARUL RIDZUAN
JAMBATAN SULTAN YUSOF

1.0GENERAL INFORMATION

1.1INTRODUCTION

The Government of Malaysia intends to widen existing road and to construct a

new road of Jalan FT05 from Teluk Intan to Kampung Lekir, Perak Darul
Ridzuan. Contractor Menuju Asas Sdn Bhd (MASB) has been appointed as
the Design and Built Contractor for the project.

Perunding ZAR Sdn Bhd (ZAR) has been appointed by MASB to carry out
the design work for all bridges structures for the project Kerja-Kerja
Menaiktaraf Jalan Persekutuan FT005 (Teluk-Intan Kg Lekir) and will
undertake the responsibility to provide the highest quality engineering
consultancy services in the implementation for the successful completion of
the work.

The project will provide a new bridge in addition to an existing bridge over
Sungai Perak with a new bridge two lanes dual carriageway included 1.5m
walkway and 3.0m shoulder on the deck of superstructure. The total length of
the main bridge is 350m.

Cast in situ segmental box girder by balance cantilever construction will be

adopted for the main bridge crossing Sungai Perak. The deck for new structure
is 11.5m wide and this will duplicate the width of the existing bridge.

1.2DESCRIPTION OF THE BRIDGE

The main span of Sultan Yusof Bridge is 350.0m long with span configuration
of 95m 160m 95m. The bridge is constructed by mean of cast in situ
variable depth balance cantilever method. The geometric and structural
configuration of this bridge module is shown in the following sketches:-

Figure 1 Elevation of bridge

Figure 2 Plan of Bridge

Figure 3 Typical Section of Bridge

Design Report 1
 Figure 1 - Elevation Figure 2 - Plan

Design Report 2
 Figure 3 Typical Section

Design Report 3
 The geometric and structural configuration of this bridge is as follows:-

Geometrical details of bridge

Span length = 95.0m 160.0m 95.0m
Overall width of new bridge = 11.5m
Skew angle of bridge = 00
Width of parapet = 0.5m

Information on R.C Deck and diaphragm beams

Thickness of R.C Slab = 250mm ~ 900mm
Size of end diaphragm = 1200 mm thick

Information on bearing
Type of bearing = Pot Bearing

Information on expansion joint

Type = Transflex

Design Report 4
2.0DESIGN CRITERIA FOR BRIDGEWORK

2.1DESIGN STANDARDS AND CODE OF PRACTICE

All design for the bridge superstructure is based on British Standards

augmented as necessary by other internationally recognized documents.
References is made in particular to the Standards and advice Notes issued by
the UK Department of Transport.

The following British Standards shall be used in the structural design

whenever is applicable:-

BS 8004 : 1986 Code of Practice for Foundations

BS 5400 Steel, Concrete and Composite Highway Bridges
Part 1 : 1988 General Statement
Part 2 : 1978 Specification for Loads
Part 3 : 1982 Code of Practice for Design of Steel bridges
Part 4 : 1990 Code of Practice for Design of Concrete Bridges
Part 9 : 1983 Bridge Bearings
Part 10 : 1980 Code of Practice for Fatigue

The following publications, issued by the UK Department of Transport, will be

used in the design

BD 20/92 Bridge Bearings Use of BS 5400 Part 9 : 1983

BD 37/01 Loads for Highway Bridges Use of BS 5400 Part 2 : 1978
BD 32/88 Piled Foundations
BD 33/94 Expansion Joints for Bridges

2.2MATERIAL AND MATERIALS PROPERTIES

2.2.1 Concrete

Elements Min. Conc. Grade Max aggregate

Superstructure - RC Elements 40 N/mm2 20mm
Substructure - RC Elements 40 N/mm2 20mm
Superstructure Pre stressed Elements 50 N/mm 2
20mm
Unit weight of concrete for all elements 24.5 kN/m3
Coefficient of Thermal expansion 12 x 10E-6/Degree
Young Modulus and Poisson Ratio as per BS5400 Part 4
Creep and shrinkage as per BS5400 Part 4

2.2.2 Reinforcement

Design Report 5
 High Yield Steel type 2 Deformed to BS 4449 or 4461 fy = 460 N/mm2
Mild Steel to BS 4449 or 4461 fy = 250 N/mm2

2.2.3 Pre-Stressing

Strand Properties
Size : 15.2 mm Low Relaxation Super strand
Specification : ASTM 416/85
Type : Relaxation Class 2 (2.5% at 1000hrs/70%
UTS)
Ultimate Tensile Strength : 1860 N/mm2
Minimum breaking load : 260 kN
Modulus of Elasticity : 195 kN/mm2
Coefficient of friction : 0.2/radians
Wobble factor : 0.0025/m

Cable Properties
No of strands : 19 to 31 strands per cable
Internal duct diameter : 95 mm to 127mm
Max jacking force, Po : 75% UTS

2.3LOADING - DEAD LOAD

The section of the report deals with the computation of the dead load and
superimposed dead load for the bridge.

a) The computation of dead load shall based on the following load

intensity:-

Concrete 24.5 kN/m3

Structural Steel 78.0 kN/m3

Premix 22.0 kN/m3

Earth fill 20.0 kN/m3

b) The calculation of dead load and SIDL are as given below:-

i) Premix of 100mm thick
Loading = 0.10 x 22

= 2.20 kN/m2

Design Report 6
 ii) Parapet
Parapet Cross Sectional Area = 0.30 m2
Total Loading = 0.30 x 24.5 +1 (railing)
= 8.35 kN/m
say = 9.0 kN/m

iii) End Diaphragm

End Diaphragm Sectional Area = 1.20 m2
Total Loading = 1.20 x 24.5
= 29.40 kN/m

c) Differential Settlement:-
The effect of differential settlements and/or movements of the support
due to soil subsidence shall be classified as a permanent action and
appropriately estimated values of predicted settlements should be
used. The following allowance for differential settlements shall
be taken into account for foundation movements.

Differential settlement = 10 mm

2.4LOADING - LIVE LOAD

The live load such as HA UDL/KEL and HB30/ HB45 will be generated and
applied to the numerical model using the special module in the software
known as Staad BEAVA based on the defined notional lanes and load patterns.

This section of the report presents the calculation of live loading to be

imposed on the bridge. The load computation is divided into five major parts:-

Computation of notional lane width

Computation of load intensity for HA
Computation of load intensity for HB30 and HB45
Load cases
Load patterns

2.4.1 Notional Lane Width

Overall width of premix area = 10.5 m

No of notional lane = 3
Width of each notional lane = 3.5m

2.4.2 Computation of HA Load Intensity

Design Report 7
 Loaded Length 160
Lane 1 reduction factor,1 1.0
Lane 2 reduction factor,2 1.0
Lane 3 reduction factor,2 0.6

KEL load intensity = 120kN per notional lane

2.4.3 Load Intensity

HB 30 = 4 axle 300kN each

HB 45 = 4 axle 450kN each

All the above loading will be combined and analyses accordingly to the
requirement stated in BD 37/01 to obtain the maximum and minimum forces
on the structural elements under consideration.

2.5LOAD FACTORS AND LOAD COMBINATIONS

Load factors and load combinations shall be in accordance with BS 5400 Part 2
as implemented by BD 37/01. All road surfacing shall be treated as
Superimposed dead loads other loads.

Design Report 8
3.0STRUCTURAL ANALYSIS

3.1METHOD OF ANALYSIS

The bridge structure shall be generally analysed using linear elastic

techniques. A full 3-dimension finite element model using the beam and plate
elements will be adopted for the analysis of bridge superstructure.

3.2SOFTWARE FOR ANALYSIS

STaadPro will be used for the analysis of bridge deck. Traffic load analysis will
make use of Staad BEAVA.

The Current version of Bridge Engineering Automated Vehicle Application

(B.E.A.V.A), Version 1.1, supports the UK BS5400 Part 2 Code and the American
AASHTO Standards.

The user defines the width of the carriageway as straight or curved parallel
lines, BEAVA then automatically calculates the following in accordance with
the selected code:

Number of Notional Lanes (Traffic Lanes)

Influence lines along the centre line of notional lanes

Loaded length along the Lanes

Critical location of uniformly distributed load

Critical location of knife edge load

Critical location of vehicle load

Maximum effect value

Associates effects values

Loading arrangements for the effects requested can be displayed on the

model. The added live load cases can be combined with dead loads in the
normal way of Staad.Pro load combination generation.

3.3NUMERICAL MODEL FOR STRUCTURAL ANALYSIS

The entire bridge superstructure will be analysed using a 3 dimensional beam

and plate model. The beams/end diaphragm and deck slab are represented by
the beam elements respectively.

Appendix 1 of this report is dedicated to global structural analysis by using

STAAD PRO software. The input is listed and the output is summarised and
tabulated.

Design Report 9
 The numerical model for the complete structure adopted in structural analysis
is described in this section and graphically illustrated in the following figures.

Figure 4 Numerical model of main bridge

Figure 5 Numerical model of deck showing variable depth SBG

Figure 4 Numerical model of main bridge

Design Report 10
 Figur
e5
Num
eric
al
mod
el of
deck
sho
wing
vari
able
dept
h
SBG

3.4TRANSVERSE ANALYSIS OF SEGMENTAL BOX

Design Report 11
 For segmental box design for reinforcement, the segment is modeled
transversely to represent box girder segment. One meter length of the box
girder is modeled using beam element.

The model is subjected to load effect from dead load include weight of
concrete, parapet and 100mm thick of wearing course.

For maximum load effect from traffic load, the box segment is subjected to HB
45 loading as moving load of 4 point load in series with each one is 112.5kN.
The input file for the STAAD PRO is attached in Appendix 4 of this report. The
result of the analysis and the design of segmental box girder is also presented
in the Appendix 4.

Figure 6 Numerical model for transverse analysis

Design Report 12
 Figure 7 Moving due to HB45

Design Report 13
4.0STRUCTURAL DESIGN

4.1DESIGN CRITERIA AND REQUIREMENT

4.1.1 Concrete Crack Width

The maximum permissible crack width at SLS and minimum cover to

reinforcement are determined from the recommendation given in Table 1 and
13 of BS 5400: Part 4 taking into account the global and local environmental
conditions.

4.1.2 Cover to Reinforcement

The nominal cover is determined in accordance with Table 13 of BS 5400: Part

4 using SEVERE environment.

The nominal cover adopted;

i) 40mm in fascias and abutment headwall

ii) 50mm in abutments, pile caps and transition slabs
iii) 35mm in deck slab and diaphragm
iv) 75mm in abutment, pile caps and pile in contact with ground

4.1.3 Pre Stressing Design

The pre stressing design shall be designed in accordance with BS 5400 Part 4 :
Section 6. For the calculations of allowable stresses at Serviceability Limit
State, reference is made to section 9.

Engineering software ADAPT ABI is used to analyse longitudinal stress

distribution in the segmental box. Section 2 of this report present the input
file for ADAPT ABI used in the longitudinal design. Section 3 of this report
present the output file of the ADAPT ABI for stress analysis during construction
and service life of the bridge. Most of the stresses are within the allowable
limit as specified in the code.

All pre stressing design are required to comply with the Ultimate Limit State
requirement for the above loadings under the load combination 1 to 5.

The followings are the requirement for stresses check:

HA only (Load comb 1) Class 1
HA + HB 30 (Load comb 1) Class 1
HA+HB30 or HB45 (Load comb 2-5) Class 2

Design Report 14
4.1.4 Reinforced Concrete Design

All reinforced concrete elements shall be design accordance with BS 5400 Part
4: Section 5. At Ultimate Limit State. All R.C. elements shall be designed to
resist the maximum/minimum forces from HA/HB45 loading under load
combination 1 to 5.

Pier loading and analysis is done as part of global analysis in Appendix 2.

Column load from the analysis was extracted and summarized. Maximum load
effect was identified and Column capacity was calculated.

Appendix 5 of this report presents the capacity check of pier. Load carrying
capacity of pier was calculated by using software Structural Bridge Design
from AUTODESK. Load carried by the pier shall not exceed structural capacity
of pier calculated in Appendix 5.

Figure 8 Pier Section for End Pier

Figure 8 Pier Section for Main Pier

Design Report 15
Design Report 16
5.0PILE GROUP ANALYSIS

The pile chosen for the design is 700mm spun pile with a working load of
1200kN.

The total vertical load, horizontal load due to the effects of earth pressure,
surcharge loads and the effects of temperature or traction is determined. Total
pier load at end span is less than allowable working load of pile.

Pile group analysis is done to check maximum load effect in individual pile due
to various load combination.

The pile design load is checked not to exceed allowable geotechnical capacity
of pile

Design Report 17