08/21/2018

DESIGN OF 6400 KN CAPACITY FIXED POT BEARINGS FOR BRIDGE A/C GANDAK RIVER
DESIGN PARAMETERS : DT: 04/03/14
1) Grade of Concrete
a) Pedestal : 45 Mpa SIZE: 1400*1400 MM
b) Superstructure : 45 Mpa
2) Permissible Stress in Concrete
Normal Case Seismic Case
a) Bottom sb : 22.50 N/mm2 28.13 N/mm2
b) Top st : 22.50 N/mm2 28.13 N/mm2
3) Permissible Bearing Stress in Concrete
Normal Case Seismic Case
a) Bottom sbc : 14.85 N/mm2 18.56 N/mm2
b) Top stc : 14.85 N/mm2 18.56 N/mm2
4) Grade of Cast Steel : 340 -570W of IS:1030
Permissible stress in Cast Steel (Cl. 926.2.2) where fy = 340.0 N/mm2
sst : 204 N/mm 2

sp : 255 N/mm2
5) Vertical Load
a) Vmax : 6376.0 KN
b) Vmin : 2550.0 KN
c) Vmax-ses : 6376.0 KN
d) Vmin-ses : 2550.0 KN
6) Horizontal Force under Normal Condition
a) Longitudinal Hbf : 490.5 KN
b) Transverse Hbt : 319 KN
c) Resultant HRn : 585.11 KN
Since HRn < 10% of Vmax
HRn 637.60 KN (Cl. 926.1.4)
7) Since Horizontal Force in Longitudinal Seismic is more than Transverse Seismic and Wind Condition
\ Horizontal Force under Seismic Condition
a) Longitudinal Hsl : 1668 KN
b) Transverse Hst : 1717 KN
c) Resultant HRs : 1717.00 KN
HRs 1594.00 KN Hrs < 25% *Vmax (Cl. 926.1.4)

8) Rotation (Normal, Seismic)

a) Resultant Rotation, q : 0.01 radians
b) Resultant rotation due to permanent action and long term effects , qp : 0.0040 radians
c) Resultant rotation due to variable action , qv : 0.0060 radians
Assumed qp = 40 % of q & qv = 60.0063 % of q
Since D5 / Tn = 13.25 As per table 3 of IRC:83 (Part III)-2002 Cl. 926.1.5.1)
k1 = 2
k2 = 70

Confidential Tefcon Bearings P. Ltd. 1 of 8

 08/21/2018

BEARING PARAMETERS 6400 KN QTY. : 03 Nos.

I) POT :
Effective diameter of bottom plate A1 = 730 mm
Diameter of Pot at Bottom A = 730 mm
Thickness of Pot at Base A2 = 50 mm
Depth of Pot A3 - A2 = 63.5 mm
Total Ht. of Pot A3 113.5
Outer Diameter of Pot A7 = 710 mm
Inner Diameter of Pot D5 = 530 mm
Horizontal Lever Arm A5 = 99 mm
Pot Thickness Pth = 90 mm

II) ELASTOMERIC PAD :

Diameter of Elastomeric Pad D5 = 530 mm
Thickness of Elastomeric Pad Tn = 40 mm
Effective Thickness of Elastomeric Pad Nt-eff = 36 mm

III) TOP PLATE :

Effective Diameter B1 = 730 mm
Diameter of Top Plate B = 730 mm
Diameter of Piston Dp = 528.75 mm
Diameter of Top plate at bottom face B3 = 525 mm
Thickness B2 = 51.25 mm
Overall thickness of Top Plate B6 = 83.25 mm
Distance of line of Horz. force from top B5 = 74.25 mm
Contact side width of Piston w = 18 mm
Piston recess Rc = 14 mm
IV) ANCHOR BOLT :
Diameter of Bolt Bf = 30 mm
Total Number of Bolts N = 8 nos.
Grade of Bolt = Grade 10.8
V) LUGS :
Length Ll = 100 mm
Width Ll = 100 mm
Thickness Lt = 33 mm

VI) ANCHOR SLEEVES :

Diameter of Sleeve D = 63 mm
Sleeve length for Bottom Lb = 450 mm
Sleeve length for Top Ls = 450 mm

Confidential Tefcon Bearings P. Ltd. 2 of 8

 08/21/2018

DESIGN CHECK :

I) ELASTOMERIC PAD :

1) Diameter to Thickness Ratio (Cl. 926.2.3.6)

D5/Tn = 13.25 </= 15
2) Strain in Elastomer (Cl. 926.2.3.4)
tneo = 0.5 x D5 x q
Nt-eff
= 0.0736 </= 0.15
3) Average Compressive Stress under normal condition (Cl. 926.2.3.2)
sneo = Vmax x 1000
p/4 x D52
= 28.90 < 35 N/mm2
4) Average Compressive Stress under Seismic condition (Cl. 926.2.3.2)
sneo-ses = Vmax-ses x 1000
p/4 x D52
= 28.90 < 35 N/mm2
5) Minimum Average Stress (Cl. 926.2.3.3)
sneo-min = Vmin x 1000
p/4 x D52
= 11.56 > 5 N/mm2
6) Moment due to resistance to rotation due to tilting stiffness of elastomeric pad (Cl. 926.1.5.1)
Me-d = D5 x [(k1 x qp) +(k2 x qv)]
3

= 6.37E+07 N-mm
7) Moment due to friction at the piston-cylinder contact surface under normal condition (Cl. 926.1.5.2)
MR-d(n) = 0.2 x (D5 / 2) x HRn x 1000
= 3.38E+07 N-mm
8) Moment due to friction at the piston-cylinder contact surface under Seismic condition (Cl. 926.1.5.2)
MR-d(s) = 0.2 x (D5 / 2) x HRs x 1000
= 8.45E+07 N-mm
9) Total induce Moment under normal condition (Cl. 926.1.5.3)
MT-d(n) = Me-d + MR-d(n)
= 9.75E+07 N-mm
10) Total induce Moment under Seismic condition (Cl. 926.1.5.3)
MT-d(s) = Me-d + MR-d(s)
= 1.48E+08 N-mm
11) Compressive Stress in Neoprene at Edges under normal condition (Cl. 926.2.3.2)
sneo(edge) = sneo + MT-d(n)
p/32 x D53
= 35.57 < 40 N/mm2
12) Compressive Stress in Neoprene at Edges under Seismic condition (Cl. 926.2.3.2)
snoe-s(edge) = sneo-ses + MT-d(s)
p/32 x D53
= 39.04 < 40 N/mm2

13) Check for deflection at perimeter

Deflection at the perimeter = 0.5 X D5 X q

Tn
= 0.066 < 0.15
It is o.k.

Confidential Tefcon Bearings P. Ltd. 3 of 8

 08/21/2018

II) POT :

1) Direct Bearing Stress in concrete due to vertical load under normal condition (Cl. 926.1.5)
sn = Vmax x 1000
p/4 x A12
= 15.23 < 22.5 N/mm2
2) Direct Bearing Stress in concrete due to vertical load under Seismic condition (Cl. 926.1.5)
sses = Vmax-ses x 1000
p/4 x A12
= 15.23 < 28.1 N/mm2
3) Flexural Stress due to active moment resulting from acting Horizontal Load under Normal Condition
sn-f = HRn x 1000 x A5
p/32 x A13
= 1.65 N/mm2
4) Flexural Stress due to active moment resulting from acting Horizontal Load under Seismic Condition
sses-f = HRs x 1000 x A5
p/32 x A13
= 4.13 N/mm2
5) Flexural Stress due to induced Moment resulting from resistance to Rotation under normal condition
sn-e = MT-d(n)
p/32 x A13
= 2.54 N/mm2
6) Flexural Stress due to induced Moment resulting from resistance to Rotation under Seismic condition
sses-e = MT-d(s)
p/32 x A13
= 3.88 N/mm2
7) Total Flexural stress under normal condition (Cl. 926.2.1.2)
sn-tf = sn-f + sn-e
= 4.19 < 14.85 N/mm2
8) Total Flexural stress under Seismic condition (Cl. 926.2.1.2)
sses-tf = sses-f + sses-e
= 8.01 < 18.56 N/mm2
9) Co-existing Direct & Flexural Stress under normal condition (Cl. 926.2.1.3)
sn + sn-tf = 0.95922 </= 1
sb sbc
10) Co-existing Direct & Flexural Stress under Seismic condition (Cl. 926.2.1.3)
sses + sses-tf = 0.97324 </= 1
1.25 x sb 1.25 x sbc
11) Hoop Stress in Pot under normal condition (Cl. 926.3.1.1.7.1)
Qn = (sneo x D5 x Tn) + (HRn x 1000)
2Pth x (A3-A2)
= 109.39 < 204 N/mm2
12) Hoop Stress in Pot under Seismic condition (Cl. 926.3.1.1.7.1)
Qs = (sneo-ses x D5 x Tn) + (HRs x 1000)
2Pth x (A3-A2)
= 193.06 < 204.0 N/mm2
13) Shear stress at cylinder wall and base interface considering 1mm radial slice under normal condition
Fluid Pressure tvm1 = sneo x Tn
Pth
= 12.84 N/mm2
Horizontal Pressure tvm2 = 1.5 x HRn x 1000
D5 x Pth
= 20.05 N/mm2
Total Shear Stress tvm = tvm1+ tvm2
= 32.89 < 153.0 N/mm2 (Cl. 926.3.1.1.7.2)
14) Bending stress at cylinder wall and base interface considering 1mm radial slice under normal condition
Fluid Pressure sbt1 = 6 x sneo x Tn 2
2 x Pth2
= 17.13 N/mm2
Horizontal Force sbt2 = 1.5 x 6 x HRn x 1000 x (Tn + w/2)
D5 x Pth2
= 65.50 N/mm2
Total Bending Stress sbt = sbt1 + sbt2
= 82.62 < 224.4 N/mm2 (Cl. 926.3.1.1.7.3)

Confidential Tefcon Bearings P. Ltd. 4 of 8

 08/21/2018

15) Equivalent Combined Stress

seqc = (sbt + 3 x tvm )
2 2 1/2

= 100.36 < 306 N/mm2 (Cl. 926.3.1.1.7.4)

16) Shear stress at cylinder wall and base interface considering 1mm radial slice under Seismic condition
Fluid Pressure tvm1 = sneo-ses x Tn
Pth
= 12.84 N/mm2
Horizontal Pressure tvm2 = 1.5 x HRs x 1000
D5 x Pth
= 50.13 N/mm2
Total Shear Stress tvm = tvm1+ tvm2
= 62.97 < 153.0 N/mm2 (Cl. 926.3.1.1.7.2)
17) Bending stress at cylinder wall and base interface considering 1mm radial slice under Seismic condition
Fluid Pressure sbt1 = 6 x sneo-ses x Tn 2
2 x Pth2
= 17.13 N/mm2
Horizontal Force sbt2 = 1.5 x 6 x HRs x 1000 x (Tn + w/2)
D5 x Pth2
= 163.74 N/mm2
Total Bending Stress sbt = sbt1 + sbt2
= 180.87 < 224.4 N/mm2 (Cl. 926.3.1.1.7.3)
18) Equivalent Combined Stress
seqc = (sbt + 3 x t
2
vm
)
2 1/2

= 211.21 < 306.0 N/mm2 (Cl. 926.3.1.1.7.4)

III) TOP PLATE :

1) Average Compressive Stress in concrete under normal condition (Cl. 926.1.5)

sc(avt-n) = Vmax x 1000
p/4 x B12
= 15.23 < 22.50 N/mm2
2) Average Compressive Stress in concrete under Seismic condition (Cl. 926.1.5)
sc(avt-s) = Vmax-ses x 1000
p/4 x B12
= 15.23 < 28.13 N/mm2
3) Flexural Stress due to active moment resulting from acting Horizontal Load under Normal Condition
sc-f = HRn x 1000 x B5
p/32 x B13
= 1.24 N/mm2
4) Flexural Stress due to active moment resulting from acting Horizontal Load under Seismic Condition
sc(ses-f) = HRs x 1000 x B5
p/32 x B13
= 3.10 N/mm2
5) Flexural Stress due to induced Mome
.
sc(n-c) = MT-d(n)
p/32 x B13
= 2.55 N/mm2
6) Flexural Stress due to induced Moment resulting from resistance to Rotation under Seismic condition
sc(ses-c) = MT-d(s)
p/32 x B13
= 3.88 N/mm2
7) Total Flexural stress under normal condition (Cl. 926.2.1.2)
sct(n-f) = sc-f + sc(n-c)
= 3.79 < 14.85 N/mm2
8) Total Flexural stress under Seismic condition (Cl. 926.2.1.2)
sct(ses-f) = sc(ses-f) + sc(ses-c)
= 6.98 < 18.56 N/mm2
9) Co-existing Direct & Compressive Flexural Stress under normal condition (Cl. 926.2.1.3)
sc(avt-n) + sct(n-f) = 0.932 </= 1
st stc
10) Co-existing Direct & Compressive Flexural Stress under Seismic condition (Cl. 926.2.1.3)
sc(avt-s) + sct(ses-f) = 0.917597 </= 1
1.25 x st 1.25 xstc

Confidential Tefcon Bearings P. Ltd. 5 of 8

 08/21/2018

11) Effective contact width of piston cylinder interface (Cl. 926.3.1.3.1)

Since HRs > HRn We
= 1.3*H/(6p*Dp)
= 15.33 mm < 18 mm (Provided)
12) Minimum Theoritical Depth of effective contact width of piston at design rotation
= A6 - Tn - We - q(D5 / 2)
= 5.52 mm > 5 mm (Cl. 926.3.1.3.3)
13) Minimum Theoretical clearance between the pot top & the Top plate bottom edge at design rotation
= hn -5.5- q(C3 / 2)
= 5.88 mm > 5 mm (Cl. 926.3.1.3.4)
IV) ANCHOR BOLTS : (Cl. 926.3.6.2)
Size of bolts Bf = 30 mm
Effective area of bolt Ab = 572.265 mm2
Number of bolts n = 8
Co-efficient of friction between steel & concrete m = 0.2
Grade of Bolt = Grade 10.8
Permissible shear stress tvf = 237 N/mm2
i) Total resistive force against the shifting of bearing under normal condition
= Vmin x m + n x Ab x tvf
1000
= 1595.01 kN > HRn = 637.60 kN
ii) Total resistive force against the shifting of bearing under Seismic condition
= Vmin-ses x m + n x Ab x tvf
1000
= 1595.01 kN > HRs = 1594.00 kN
V) ANCHOR SLEEVES : (Cl. 926.3.6.5)
Diameter of Sleeve D = 63 mm
Sleeve length for Bottom Lb = 450 mm
Sleeve length for Top Ls = 450 mm

Peak stress scpk = 3 x Ab x tvf

DxL
Peak stress under Seismic condition
For Bottom Plate scpk = 14.35 < 18.73 N/mm2
For Top Plate scpk = 14.35 < 18.73 N/mm2
VI) LUGS
Thickness of Lug Lt = 33 mm
Length of Lug Ll = 100 mm
Area of Bolt Hole Ab = 804.25 mm2 1056
Area of Lugs Al = 3300.00 mm2
Effective area of lug Ae = 2495.75 mm2 ###

Horizontal force on each lug under normal condition

Hln = HRn
n
= 637.60
8
= 79.70 kN
Stress on lug due to horizontal force under normal condition
Sln = Hln x 1000
Ae
= 79700
2495.7504
= 31.93 < 153 N/mm2 35.51693
Horizontal force on each lug under Seismic condition
Hls = HRs
n
= 1594.00
8
= 199.25 kN
Stress on lug due to horizontal force under Seismic condition
Sls = Hls x 1000
Ae
= 199250
2495.7504
= 79.84 < 153 N/mm2 88.79234

Confidential Tefcon Bearings P. Ltd. 6 of 8

 08/21/2018

Confidential Tefcon Bearings P. Ltd. 7 of 8

Grade 4.6 80
Grade 8.8 160
Grade 9.8 180
Grade 10.9 200