NPCIL-SIMPLEX BOUNDARY WORKS-HANDLING

Handling of Precast column-footing and precast

prestressed hollowcore slabs

Construction of Precast property cum Security boundary wall using

RCC columns and Hollow core slabs for residential complex of
Jaitapur Nuclear Power Project, Village Madban, Taluka Rajapur,
District Ratnagiri
For

Rev Date Description Prepared by Signature Approved by Signature

0 22-08-2015 First Issue Nitesh Singh Ashok Raisinghani

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Handling-Transport design of precast column-footing

Synopsis:

Precast concrete column footings for NPCIL are to be produced at Simplex factory at
Khopoli, Maharashtra. The production of the column-footing shall be done horizontally. The
de-moulding of the column footing shall be done after concrete achieves a compressive
strength of 15 N/mm2.

Design:

During the de-moulding operation, the columns shall be lifted in a manner shown in the
image below:

During this operation the column shall act like a simply supported beam trying to undergo
deflection under self weight. This analysis is shown ahead considering the factored weight
of column being converted to UDL.

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Based upon the above section, for M15 grade at de-moulding, the amount of steel required
is

Ast = 64.50 mm2 < Ast,prov.=326 mm2 (2-T12+2-T8, refer to design document)

Therefore OK.

Crack width calculation:

Consider modulus of elasticity of steel Es = 2 x 105 N/mm2

Consider permissible stress in bending compression for M15 concrete = σcbc=5 N/mm2

Consider distance of T12 rebar from central portion of soffit =Acr=67.56mm

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280 280
Modular ratio 3 × 𝜎𝑐𝑏𝑐 = 3 ×5 = 18.67

Let x be the depth of neutral axis

∴ 0.5𝑏𝑥 2 = 𝑚𝐴𝑠𝑡(𝑑 − 𝑥)

0.5 × 350 × 𝑥 2 = 18.67 × 326 × (341 − 𝑥)

Solving the above quadratic equation:

𝑥 = 92.885𝑚𝑚

Cracked moment of inertia (Icr):

𝑏𝑥 3
𝐼𝑐𝑟 = ( ) + 𝑚𝐴𝑠𝑡𝑟 2
3

Where 𝑟 = (𝑑 − 𝑥) = 341 − 92.885 = 248.114 𝑚𝑚

350 × 92.8853
𝐼𝑟 = ( ) + 18.67 × 326 × 248.1142
3

𝐼𝑟 = 468113487.3 𝑚𝑚4

Cover to bar Cmin= 45+8=53mm

Distance of rebar from central portion of column soffit Acr=62.04mm

𝑀×𝑟 20.81 ×106 ×248.114

𝑓𝑠 = 𝑚 ( )=18.67× ( )=205.89 N/mm2
𝐼𝑟 468113487.3

31.215
where M = working bending moment on column = = 20.81 𝑘𝑁𝑚
1.5

𝑓 ℎ−𝑥 205.89 400−92.885

𝜀1 = (𝐸𝑠 ) [𝑑−𝑥]=( 2×105 ) × [341−92.885] = 0.00127
𝑠

𝑏(ℎ − 𝑥)(ℎ − 𝑥) 350 × (400 − 92.885)(400 − 92.885)

𝜀𝑚 = 𝜀1 − = 0.00127 −
3𝐸𝑠𝐴𝑠𝑡(𝑑 − 𝑥) 3 × 2 × 105 × 326 × (341 − 92.885)
= 0.000594

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Maximum crack width:

3𝐴𝑐𝑟𝜀𝑚 3×62.04×.000594
Wcr=[ 2(𝐴𝑐𝑟−𝐶𝑚𝑖𝑛) ]=[ 2(62.04−53) ] = 0.1𝑚𝑚
1+ 1+
ℎ−𝑥 400−92.885

= 0.1𝑚𝑚 𝑓𝑜𝑟 𝑠𝑒𝑣𝑒𝑟𝑒 𝑐𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛 𝑝𝑒𝑟 𝐼𝑆456: 200 𝑐𝑙𝑎𝑢𝑠𝑒 𝑛𝑜. 35.3.2

Thus it is OK to de-mould the column at M15 grade of concrete.

We shall place the element in curing yard, cover it with hessian cloth and do water curing
for 5 days, excluding the day of casting.

On the 6th day after casting, the concrete shall achieve 60% of final strength. Based upon
above calculations, it is deemed that the element is ready for transport on the morning of
7th day from the day of casting.

Handling-Transport design of precast hollowcore slabs

Synopsis:

Precast prestressed concrete hollow core slabs for NPCIL shall be produced using slip form
machine at Simplex factory, Khopoli, Maharashtra. The de-stressing of slabs shall be done
after concrete attains 25 N/mm2 of compressive strength. The strength after 28 days shall
be 60 N/mm2.

The subsequent pages illustrate that the allowable tensile and compressive stresses in
hollow core slabs are within permissible limits even if slabs are de-stressed at 15 N/mm2
and 28 day compressive strength is maintained to 30 N/mm2. The calculations consider 4%
stress loss caused due to 12mm slippage and even losses that do not take place at de-
stressing. Thus the design considers the worst conditions.

However to achieve durability and take care of unforeseen stresses during transport, the
design indents of 25 N/mm2 for de-stressing and 60 N/mm2 for 28 day strength have been
provided.

We shall place the slabs in curing yard, cover it with hessian cloth and do water curing for 5
days, excluding the day of casting. On the 6th day after casting, the concrete shall achieve
60% of final strength. Based upon subsequent calculations, it is deemed that the element is
ready for transport on the morning of 7th day from the day of casting.

PTO

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