Revision History

Rev Revision Date Created by Checked by Approved by Description

AB SP METALKRAFT SUBMITTED AS PER SPEC AND

00 22-11-18 REQUIREMENT

AB SP METALKRAFT MODIFIED AS PER CLIENT

01 10-12-18 COMMENTS
KK SP METALKRAFT MODIFIED AS PER CLIENT
02 04-01-19 COMMENTS

Description latest Revision:

Employer

NTPC Limited
(A Government of India Enterprise)

Project

MEJA THERMAL POWER PROJECT (2 x 660 MW)

BALANCE WORKS FOR MAIN PLANT AND OFFSITE CIVIL WORKS
Sub-Contractor

SIMPLEX INFRASTRUCTURES LIMITED

KOLKATA- INDIA
Vendor Name: TITLE:

METALKRAFT FORMING METAL DECK SHEET : 52/324 – 976MM

INDUSTRIES PVT LTD

Rev.
NTPC Drg / Doc No : 0360-315B-PVC-U-1610B
02

RELEASED : For Approval

Page 1
 DESIGN CALCULATIONS OF DECKING PROFILE 52/324

OWNER NTPC LIMITED

CONTRACTOR SIMPLEX INFRASTRUCTURES LIMITED
SUB CONTRACTOR METALKRAFT FORMING INDUSTRIES PVT LIMITED
PROJECT MEJA THERMAL POWER PROJECT
PACKAGE BALANCE WORKS FOR MAIN PLANT AND OFFSITE CIVIL WORKS
DOC NO 0360-315B-PVC-U-1610B
JOB NO MTK-001
REV 02
DATE 04/01/2019

METALKRAFT[Page 1 of 11]
BASIC DESIGN DATA :
Type of Deck Profile 52/324
Thickness in lower limit(BMT -0.04) (t) 0.56 Mm
Yield strength of material (fy) 5500 Kg/cm2
Basic design stress (Allowable) (f)= (0.6 x fy) 3300 Kg/cm2
Modulus of elasticity (E) 2000000 Kg/cm2
Design Span of the deck panel (L) 1700 Mm
Total Load acting on deck panel (W) 450 Kg/m2
Overall width of deck panel (OW) 976 Mm
Covered width of deck panel (CW) 921 Mm

STEP- 1:Calculation of Gross sectional properties of deck panel :

METALKRAFT[Page 2 of 11]
 Assumptions Made In Calculations :-

1) Gross sectional properties are calculated for one module of panel.

2) Deck panel is considered as simple line element neglecting the smooth edges & curves.
3) For calculating gross sectional properties the panel is broken into triangles & rectangles.

Areas of the sections:

Area of rectangle Ar 17029.44 mm2

Area of segment-1 A1 3681.6 mm2
Area of segment-2 A2 512.2 mm2
Area of segment-3 A3 512.2 mm2
Area of segment-4 A4 7436.0 mm2
Area of segment-5 A5 512.2 mm2
Area of segment-6 A6 512.2 mm2
Area of segment-7 A7 3681.6 mm2

Calculation of Location of Neutral Axis:

Neutral axis is calculated using formula: -

 Yt= {((Ar*Yr)-(A1*Y1)-(A2*Y2).............)} / (Ar-A1-A2…............)

{Where Yr, Y1, Y2......is the distance of C.G of sections of 1,2.......from top and Ar,A1,A2....is area of section
1,2..........etc.}

METALKRAFT[Page 3 of 11]
 C.G. ofsegments from top:

C.G. of rectangle yr 26.28 mm

C.G. of segment-1 y1 26.00 mm
C.G. of segment-2 y2 17.34 mm
C.G. ofsegment-3 y3 34.82 mm
C.G. ofsegment-4 y4 22.52 mm
C.G. ofsegment-5 y5 34.82 mm
C.G. ofsegment-6 y6 17.34 mm
C.G. ofsegment-7 y7 26.00 mm
Neutral axis of the profile from top YT 24.92 mm

Moment of Inertia of segments about neutral axis:

MOI of the rectangle about neutral axis IR 3920395.065 mm4

MOI of the segment-1 about neutral axis I1 856678.92 mm4
MOI of the segment-2 about neutral axis I2 44671.64 mm4
MOI of the segment-3 about neutral axis I3 43724.81 mm4
MOI of the segment-4 about neutral axis I4 1730297.82 mm4
MOI of the segment-5 about neutral axis I5 43724.81 mm4
MOI of the segment-6 about neutral axis I6 44671.64 mm4
MOI of the segment-7 about neutral axis I7 856678.92 mm4

MOI of the full deck panel about neutral axis IdF 980102.77 mm4
Section modulus from top (IdF /YT) ZT 39329.97 mm3

METALKRAFT[Page 4 of 11]
Step-2: Calculation of Gross Sectional Properties of Deck Panel at Loading Conditions:

Assumptions Made In Calculations:

1) Under Gravity Loads, Section below the Neutral axis the section is considered fully effective.
Only the Top flange & Web member will be in compression and has to be checked for local
buckling.
2) Strength & Serviceability Calculations are done for one module of panel.
3) For First Iteration, Effective stress is taken as Allowable stress (i.e. f=0.6*fy).

STRENGTH CALCULATIONS:
ITERATION – 1:As per CL: 5.2.1.1 of IS: 801-1975 for stiffened elements Limiting width ratio is given by

 (W/t)lim = 1435/ (For MKS Units)

 (W/t)lim = 446/ (For SI Units)

(W/t)lim = 1435/ (Considered stress as Basic design stress for first iteration)

(W/t)lim = 1435/sq root3300 = 24.98

METALKRAFT[Page 5 of 11]
ForTop Flange of Panel:

Width of top flange (W) = 34 mm

Actual flat width ratio of top flange is (W/t)act= 56.67 mm

Hence (W/t)lim < (W/t)ACT LOCAL BUCKLING OCCURS

ForWeb of Panel:As Discussed above, half of web will be in compression, hence half of web element has
to be considered for effective width calculations. However conservatively two third of element can be
used in calculations

Actual width of web (w) = 55.6 mm

2/3 width of web = W = 36.7 mm

Actual ratio of web is (W/t)act= 61.17

Hence (W/t)lim<(W/t)ACT LOCAL BUCKLING OCCURS

Hence calculate the reduced width as per clause.

Where b is calculated as per CL: 5.2.1.1 of IS: 801-1975

 b= (For MKS Units)

 b= (For SI Units)

For Web:
Effective Width of web as per clause w = 19.22 mm
Locally buckled width (W-w) = 36.38 mm

Reduced web 36.38 mm

Areas of the sections:

Neutral axis of the profile from top YT 24.92 mm

METALKRAFT[Page 6 of 11]
 Moment of Inertia of segments about neutral axis:

MOI of the profile about neutral axis If 33079.83 mm4

MOI of the full deck panel about neutral axis IdF 980102.77 mm4
Section modulus from top (IdF /YT) ZT 39329.97 mm3

Loads acting on deck panel:

Self Weight of Sheeting = 8.80 kg/m2
Self Weight of Green Concrete = 450.0 kg/m2
Additional Construction Load = 100.0 kg/m2
Total Load = 558.8 kg/m2
Total UDL acting on panel (558.8*0.976*1.25)(W)
= 508.8 kg/m

Maximum bending moment induced M = WL2/8 = 183.81 Kg-m (1 Kg-m = 104 N-mm)
= 1828040 N-mm

Moment of resistance = MOR = 0.6*fy*ZT = 129788901 N-mm

Hence MOR˃ BM Hence ok

Bending stress induced (f =M/ ZT) = 46.74 N/mm2

Maximum stress induced = 467.4 kg/cm2

ITERATION – 2:

Basic Stress (f) for this iteration = 467.4 Kg/cm2

 (W/t)lim = 1435/ (For MKS Units)

 (W/t)lim = 446/ (For SI Units)

For Web :
Actual Flat width ratio ((24.92*55.6)/52/0.6) (w/t)act = 15.98

Limiting width to thickness ratio 1435/√𝑓 (w/t)lim = 24.98

METALKRAFT[Page 7 of 11]
Since the Actual (w/t) is less than Limiting (w/t) Ratio, it can be considered that further there will no
local buckling.

Maximum stress induced f(MAX) 1381.5 Kg/cm2

Allowable stress f(A) 1530.0 Kg/cm2

SERVICEABILITY CALCULATIONS:
ITERATION – 1:

As per CL: 5.2.1.1 of IS: 801-1975 for stiffened elements Limiting width ratio for serviceability
determination is given by,

 (W/t)LIM = 1850/ (For MKS Units)

 (W/t)LIM = 574/ (For SI Units)

(W/t)lim = 1850/ (Considered stress as Basic design stress for first iteration)

(W/t)lim = 1850/SQ ROOT(3300) = 32.21

For Top Flange of Panel:

Width of top flange (W) = 34 mm

Actual flat width ratio of top flange is (W/t)act= 56.7

Hence (W/t)lim < (W/t)ACT LOCAL BUCKLING

For Web of Panel:As Discussed above, half of web will be in compression, hence half of web element
has to be considered for effective width calculations. However conservatively two third of element can
be used in calculations

Actual width of web (w) = 55.6 mm

2/3 width of web = W = 37.06 mm

Actual ratio of web is (W/t)act= 66.17 mm

Hence (W/t)lim<(W/t)ACT LOCAL BUCKLING OCCURS

METALKRAFT[Page 8 of 11]
Hence calculate the reduced width as per clause.

Where b is calculated as per CL: 5.2.1.1 of IS: 801-1975

 b= (For MKS Units)

 b= (For SI Units)

For Flange:
Effective Width of web as per clause w = 20.46 mm

For Web:
Effective Width of web as per clause w = 21.89 mm
Locally buckled width of web (W- w) = 15.17 mm

Total reduced web length 40.43

Areas of the sections:

Neutral axis of the profile from top YT 24.92 mm

Moment of Inertia of segments about neutral axis:

MOI of the profile about neutral axis If 33079.83 mm4

MOI of the full deck panel about neutral axis IdF 980102.77 mm4
Section modulus from top (IdF /YT) ZT 39329.97 mm3

Bending stress induced (M/ ZT) (f) = 137.58 N/mm2

Basic stress for next iteration (f) = 1375.8 kg/cm2

ITERATION – 2:

 (W/t)LIM = 1850/ (For MKS Units)

 (W/t)LIM = 574/ (For SI Units)

METALKRAFT[Page 9 of 11]
 For flange :
Actual Flat width ratio for flange 56.7

w/t limiting = 53.33

For Web :
Actual Flat width ratio for Web
(((22.54*55.6)/52)/0.6) (w/t)act = 14.46
Limiting width to thickness ratio 1850/√𝑓 (w/t)lim = 32.20

Hence (W/t)lim< (W/t)ACT NO LOCAL BUCKLING

Since the Actual (w/t) is less than Limiting (w/t) Ratio, it can be considered that further there
Will be no Local Buckling.

Maximum stress induced f(MAX) 1375.8 Kg/cm2

Allowable tress f(A) 1530.0 Kg/cm2

RESULT: Max. Stress induced is < Allowable stress. HENCE SAFE

NOTE: Since buckled width calculations for deflection are more conservative than strength
calculations, moment of inertia based on strength calculations have been used for deflection
calculation.

METALKRAFT[Page 10 of 11]
 DEFLECTION CALCULATIONS:

Total load on deck panel 450 kg/m2

Total UDL acting on deck panel (W) 508.8 kg/m
Design span (L) 1700 mm
Modulus of elasticity (E) 2 x 105 N/mm2

Max deflection induced = wl4/ 185EI

=5.9 mm

Limiting deflection =Span / 250 (As per NTPC Specifications)

= 1700 / 250
= 6.8 mm

Result: if max deflection induced < Limiting 5.9 < 6.8

deflection ,Design is safe else design is not safe Design is safe

METALKRAFT[Page 11 of 11]