Segmental Tunnel Design

GEOCONSULT India Pvt Ltd APPENDIX - 3
A company of the GEOCONSULT group

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AHMEDABAD METRO-LINK RAIL PROJECT PHASE I

DESIGN AND CONSTRUCTION OF UNDERGROUND STATIONS AND TUNNEL FROM CHAINAGE 14328.88M TO
Project:
CHAINAGE 11882.88M, INCLUDING EAST RAMP, TWIN BORED UNDERGROUND TUNNEL,NATM TUNNEL, CUT
AND COVER PORTION AND TWO UNDERGROUND STATIONS KANKARIA EAST AND KALUPUR STATION
Calculation for DEFINITIVE DESIGN OF SEGMENT LINING

1 INITIAL DATA
1.1 Concrete
Concrete Compressive Cylinder Strength fck = 50 N/mm2
Mean Tensile strength fctm = 4.07 N/mm2
Density of concrete = 25 KN/m3
Material factor γmc = 1.5
Mean compressive strength = fck +8 N/mm2 fcm = 58 N/mm2
fct = 4.61 N/mm2
Permissible flexural strength(as per Leonhardt), fct=0.34(fck)^2/3
Permissible flexural strength= fctd=fct/ϒm fctd = 3.1 N/mm2
1.2 Reinforcement
Yield Strength fyk = 500 N/mm2
Material factor γms = 1.15
1.3 Segment Geometry

Tunnel diameter at Intrados ID = 5800 mm
Segment thickness ts = 275 mm
Tunnel diameter at Extrados OD = 6350 mm
Internal radius of Tunnel Rin ,=ID/2 Rin = 2900
Internal radius of Tunnel Rex ,=OD/2 Rex = 3175
Mean diameter of tunnel Dm = 6075 mm
Segment width L = 1400 mm
Segment numbers = 5 + 1
Segment Angle (maximum) = 67.5 °
Segment Angle (minimum) = 0
Segment Angle (Key) = 22.5 °
Segment length (radial) = 3578.42 mm
Allowable Ovalisation = 1.00%
1.4 Segment Lining Properties

I value (for per meter length of segment) = 0.00174 m4/m
Young's Modulus (long term) = 1/2 short term E = 17,678 N/mm2
Poisson's Ratio νi = 0.15
1.5 Gasket Properties

Gasket
Gasket force (full gap closure) O FG = 30.00 KN/m
Gasket force (for 2 mm gap closure) FG10 = 16 KN/m
Load factor γ = 1.5
1.6 TBM Data
Shoe Length Ll = 1093 mm

No. of Shoes = 16
Operating thrust force/jack shoe = 1875 KN
Total operating thrust force = 30000 KN
Maximum thrust force/jack shoe Tf = 2660.9375 KN
Maximum Ram Thrust = 42575 KN
2.0 TUNNEL LOADING AND FORCES

maximum overburden case
2.1 Ground Properties
Young's Modulus- UnDrained Eg = 18000 KN/m2
Poisson's Ratio νg = 0.23
Bulk unit weight γ = 8 KN/m3
Unit weight of water γw = 10 KN/m3
Stress Ratio Ko = 0.50
Maximum overburden occurs at CH. = 13440m

Ground Level = 49.10 m
Distance from Tunnel axis to rail level = 2.10 m
Rail level = 32.39 m
Depth to cover (to tunnel axis) = 14.62 m
Groundwater level (m below ground level) = 49.10
Hydrostatic head to tunnel axis = 14.62 m
2.2 Ground Loading

Surcharge q2 = 50 KN/m2
Factored Surcharge = 75 KN/m2
(Factor = 1.5 )
Overburden = 119.7 KN/m2
Factored Overburden = 179.6 KN/m2
(Factor = 1.5 )
Combined loading on tunnel (at tunnel centerline)

Vertical component (unfactored) = 169.70 KN/m2
Vertical component (factored) = 254.55 KN/m2
Horizontal component (unfactored) = 84.85 KN/m2
Horizontal component (factored) = 127.28 KN/m2
2.3 Curtis Equation
Assume λ =unity. This implies that the lining is inserted immediately after the ground is excavated, allowing no relaxation of the
ground and imposing full loading on the lining - a consevative assumption.
Q1 = [Eg (1-νi2)Rm]/[El(1+νg)h]
Q3 = [R3Eg(1-νi2)]/[12ElIl(1+νg)]
Sn/So = [λ(1-Q 3)]/[1+Q 3]ω

St/So = [λ(1+2Q3)]/[1+Q3]ω
where, ω = [3-2νg]/[3-4νg]
λ = 1.0
ω = 1.22115
Q1 = 0.00894
Q3 = 1.660
Sn/So = -0.20
St/So = 1.33
2.3.1 Unfactored Loads

Po = 127.27 KN/m2
So = 42.42 KN/m2
Sn = -8.62 KN/m2
St = 56.42 KN/m2
Ni = 386.59 KN/m
N = -110.30 KN/m
M = 60.25 KN/m
2.3.2 Unfactored Radial Deformation
2*Sn*Rex4
Ur ,C nov = = 0.17626 mm
18 EI γ
Ur ,C v = 0.75 mm
18 EI γ
Ovalization Deofrmation =(Ur ,C nov + Ur ,C v)/2 = 0.46 mm
2.3.3 Factored Loads

Po = 190.92 KN/m2
So = 63.64 KN/m2
Sn = -12.93 KN/m2
St = 84.63 KN/m2
Ni = 579.90 KN/m
N = -165.45 KN/m
M = 90.37 KN/m
2.3..4 Summary of Forces

Unfactored
Thrust at axis, Ta = 496.89 KN/m
Thrust at crown, Tc = 276.29 KN/m
Bending Moment, M = 60.25 KNm/m
Factored
Thrust at axis, Taf = 745.36 KN/m
Thrust at crown, Tcf = 414.45 KN/m
Note: Forces here are per meter length and not per ring.
2.4 Railway Loading

2.4.1 Trackslab
Width at the top level of first stage concrete = 3314 mm

Depth of first stage concrete = 526 mm
Estimated cross-sectional area of trackslab = 1.1621 m2
Assumed density of trackslab = 25 KN/m3

Weight of trackslab W = 29.0527 KN/m run
Assume load carried by one segment and distributed evenly across segment, thus:
Hoop Load = W/2 x Cos (Segment Angle) = 5.559 KN/m run
Hoop Load = 5.559 KN/m
2.4.2 Trains
Max. vertical load on any one segment due to trains Vt = 16 Tons
= 160 KN
Using same rationale as for the trackslab system
2.5 Load Summary
Unfactored
Factored
Note: Hoop loads shown are the sum of those in section 2.3 and 2.4
4 RADIAL JOINT ROTATION

4.1 Maximum Joint Rotation
The maximum allowable ovalisation is 1.00% of internal diamenter
Thus the maximum allowable distortion to be considered is = 58 mm
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This will be considered for a 67.5 ° segment
Assume segment rotates as rigid bodies

OA = OB = 2900 mm
α = 56.25 °
OC = 1109.8 mm
CB = 1790.2 mm
AB = DE = 3222.3 mm
OE = 2929 mm
OG = 2871 mm
Equation of an ellipse:
(DF2/OG 2)+(OF2/OE2) = 1 Þ DF2 = (1- (OF2/OE2))OG 2
(OE2-OF2)+DF2 = DE 2
Substituting Eqn -1 in Eqn -2 yields:
[1-(OG2/OE2)]OF2 - 2OEXOF+(OE 2+OG 2-DE2) = 0
OF = 1107.3 mm
b = 55.57 °
Angular rotation, α-b = 0.68 °
Total rotation at joint due to movement of two adjacent segments, θ
θ = 1.352 °
= 0.024 rads
rotation angle in radians θ = 0.0236 radians
eccentricity due to joint rotation
= (R1xR2/(R1+R2)) x θ
ea = 23.603 mm
Misalignment Considered S = 5 mm
eccentricity due to misalignment of segments
= R1/(R1+R2) x S
er = 2.5 mm
Joint width wj = 145 mm
Caulking Groove width Cg = 61 mm
Eccentricity due to joint geometry
= h/2-(Cg +w/2)
eg = 4 mm
Eccentricity of thrust through the joint: (ea + e r + e g) = 30.10 mm
5 Overall Structural Buckling Check

Critical buckling load of a ring:
q = 3EI/R3
E = 17,678 N/mm2
I = 1,735,714,286 mm4/m
R = 3,038 mm
q (Critical buckling load) 3,285 KN/m2
Buckling Hoop Load = 9,977 KN/m
Design Hoop Load = 4,246 KN/m
DESIGN LOAD < BUCKLING LOAD HENCE SAFE
4.1.2 Unreinforced Curved Joint Design

b = 1.6 ???
α = 0.44-(0.4*(3/7)) Þ α = 0.2686
ft = Tensile strength of concrete = Lesser of 0.5Sqrt(f cu) or fcu/15
( but as per IS: 456) ft = 4.07 N/mm2
Ultimate load at no eccentricity, (N uo)

Nuo = ft/γmc x h x L x (b/α) Nuo = 4446.55156851 KN
Where, L = 1000 mm (i.e., per meter length)
Nus = Ultimate load at an eccentricity of 0.05h = 0.75 N uo
Nus = 3334.91367638 KN
Since the eccentricity of load exceeds 0.05h = 13.75 mm
Nue = 0.75 x Nuo x r
e/h = 0.10946529906
e/h r joint
0.05 1.00 rjoint = 0.82569465691
0.10 0.85
0.20 0.64 Þ Nue = 2753.62040385 KN
0.30 0.48
Factored working hoop thrust across the joint , Pu = 781.529 KN
Nue/P u = 3.5233759078
REINFORCEMENT NOT REQUIRED
5 RADIAL JOINT (Curved, Reinforced)
Splitting Failure
Splitting will occur at a load given by:
Nuc = 4.45 x ft x h +4Fst
( Fst = Ultimate strength of all anchored rebars within a distance from the joint surface equal to 0.8 times the
Fst = Ast x fy
segment thickness.)
factored design strenngth = Nuc = 4.45/γmc x ft x h + 4A st x ft/γms
Description of bars at one end:
Bar Nos. Bar Dia.
14 12 Ast = 2053.56 mm2
6 10 Reinfroncement per meter = 1466.82857143 mm2
Nuc = 5872.77476949 KN/m

Nuc /Pu = 7.51446826361
SPLITTING CHECK OK
Shear Failure
Shear failure will occur at or above a load given by
Nus = 6.75 x ft/γmc x h +2Fsts/γms
Fsts = Asts x fy (Fst = Charecteristic strength of the anchored reinforcing bars intersected by a shear failure line drawn at 26.5° to
the tangential line normal to the radius, positioned at the most eccentric point of contact in the joint.
Asts = 2053.56 mm2
Bar Nos. Bar Dia. Shear reinforcement per meter = 1466.82857143 mm2
14 12 Nus = 6314.14080639 KN/m
6 10 Nus/P u = 8.07921511789
SHEAR CHECK OK
5 CIRCUMFERENTIAL JOINT (Ram Load Capacity)

5.1 Ultimate Capacity
Nuo = Ft/γm x h x L x β/α
Calculate per segment, therefore L
= 3578.42045455 mm
Calculation of α is based on ram shoes= 3 Nos.
Contact width of circumferential joint = 154 mm
α
= 0.23474
= β 1.6
For one meter length , L= 1000 mm Nuo = 5087.8789506
Eccentricity is obtained from centereline of ram shoe and centreline of bearing area.
Ram to segment eccentricity =
Eccentricity is obtained from centereline of ram shoe and centreline of
bearing area.
Ram to segment eccentricity = 15 mm
Max. eccentricity when there is zero clearence between segment and
tailskin is = 25 mm ????
Total eccentricity = 40 mm
Therefore, e = 40 mm
0.05h = 13.75 mm
Since the eccentricity of load is greater than 0.05h, the ultimate load is given by:
Nue = 0.75 x Nuo x r
e/h r
0.05 1 e/h = 0.14545454545
0.1 0.85 r = 0.74298271976
0.2 0.64 Nue = 2835.15460539 KN/m
0.3 0.48
Circumference = 19.0755 m
Total ram load capacity = 54081.9916752 KN
Maximum design ram thrust = 42575 KN
RAM LOAD CAPACITY SUFFICIENT

5.2 Shear Stresses
The Ultimate joint shear strength is given by:
Nus = (6.75 x ft/γm x h) + (2 x Fsts) ???
For the circumferential joint a more even stress distribution over the joint is expected and hence "h" shall be taken as the full
segment thickness of 275 mm
Calculations ignoring reinforcement

Nus = 5038.6377008 N/mm
Ram Thrust per shoe (Maximum) Tr = 2660.9375 KN
Ram shoe length Lr = 1093 mm
Applied Load (Tr/Lr) = 2434.52653248 N/mm
SHEAR CHECK SATISFIED
5.3 Segment Misalignment

Distance of failure plane from segment edge = 0.3 m i.e., 300 mm
Consider TBM loading a segment which is supported by stepped segments:
Design TBM Load = 42575 KN
Load per unit length of circumferential face = 2231.92 KN/m
W = 669.58 KN
Segment shall be checked for failure planes at 30°, 45° and 60°
The hoop reinforcement is considered to act in tension and therefore provide resistance to shear force. The longitudinal
reinforcement, however, is not considered to provide any restraint.
The hoop reinforcement is provided as hook-type and therefore the required anchorage length is 16 times the bar diameter:
Anchorage length =
Failure planes are assumed to occur at a distance of 300 mm from the segment edge.
Consider only reinforcement which has sufficient anchorage length to develop bond. Thus for the 30° and 45° shear planes. Only
the outer layer of reinforcement is active. For the 60° shar plane the two outermost layers of reinforcement are active.
Nult = (ft/γm x Avtsinα) + Wcosα

Job no: I6079
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Project:
V ult = Wsinα
Design shear strength, Vn = μNult + (ft/γm x Avtcosα) but ≤0.2fcuAc
Where, μ = 1.4
A c = area of concrete resisting shear
No. of bars cut by shear plane at 30° = 1
0.2fcuAc
Angle, α (in °) A*vf (mm2) Nult (KN) Vult (KN) Vn (KN) (KN)
30 157 614.00 334.79 918.72 0
45 157 521.73 473.46 778.69
60 314 453.02 579.87 702.488
* based on 2 layers of reinforcement
6 MAIN REINFORCEMENT
6.1 Hoop Reinforcement
The contact stresses at the radial joints produce an eccentricity which creates a bending moment in the lining. This is not
accounted for in the curtis equations. To allow for this, the induced moment will be added to that from the curtis equations:
The eccentricity assumed in the lining is derived from the section 4.1
Eccentricity of thrust through the joint = 30.1029572419 mm
Eccentricity taken as larger of above value and 20 mm.
Hoop Load (from Curtis Equations) = 781.53 KN/m
Additional bending moment is given by 781.53 x 30.10296 = 23.5263 KNm/m
Bending moment from Curtis equations = = 90.3672 KNm/m
Total bending moment = = 113.893 KNm/m
fy = 500 N/mm2
fck = 50 N/mm2
b = 1400 mm
D = 275 mm
d' = 54 mm
Forces adjusted for segment length:
Pu = 1094.14058172 KN
Mu = 159.451 KNm/m
Pu/(fckbD) = 0.05683847178
Mu/(fckbD2) = 0.0301205931
d'/D = 0.19636363636
Using Design chart for d'/D = 0.1963636364 results in a required area of steel of zero to resist the applied axial
load and combined uniaxial bending as calculated above.
With reference to BS 8110 a minimum of 0.4 % steel should be provided .
0.2515 Pu/(bh) = 2.84192358889
100As/(bD) = 0.25153
As = 968.377296467 mm2
As req. = 484.189 mm2 (each face)
However in order to resist moments induced by lifting and handling of the segments, Provide
3 H 10 + 7 H 12
As prov. = 1026.78 mm2
REINF. IS SUFFICIENT,O.K.
6.2 Longitudinal Reinforcement

Provide minimum reinforecement according to BS 8110:
100As/Ac = 0.130
This is for fyk of 500 N/mm2
Since fyk = 500 N/mm2 the %age should be readjusted, Thus
Percentage = [0.13 x 460]/415 = 0.13
for one segment, the total area of steel required is = 1279.2853125 mm2
Area of steel per face = 639.64265625 mm2
Provide 17 No. T8 bars (each face)
As prov. = 854.08 mm2
REINF. IS SUFFICIENT,O.K.
6.3 Grouting Pressures
Assuming that the grout pressure will be 1 bar in excess of hydrostatic pressure and making a worst
case scenario assumption that the hydrostatic pressure to tunnel axis is: = 14.6
The grout pressure is given by: 10 m + 14.6 m = 24.6
Grout Pressure = = 246.15 KN/m2

This will impose a uniform hoop load on lininh thus:
Hoop Load = grout pressure x excavated tunnel radius
Factored Hoop Load = 937.8315 KN/m
Design Hoop Load = 745.3553125 KN/m
GROUT LOAD > DESIGN HOOP LOAD FAIL
Note: Unequal grouting pressure effects are avoided by the presence of grout holes in all segments.
6.4 Overall Structural Buckling Check

q = 3EI/R3
E = 18 N/mm2
I = 1.7E+09 mm4/m
R = 3037.5 mm
q (Critical buckling load) 3.28454823204 KN/m2
Buckling Hoop Load = 9.97681525484 KN/m
Design Hoop Load = 745.3553125 KN/m
DESIGN LOAD > BUCKLING LOAD NOT SAFE
7 BOLT DESIGN
Mean Radius Rm = 3037.5 mm

Segment Thickness h = 275 mm
Segment Angle = 67.5 °
Curved Length of Segment = 3578.42045455 mm
Cross Sectional area of segment As = 0.984065625 m2
Width of the segment = 1400 mm
Self weight of segment Ws = 34.442296875 KN
Load factor for self weight of segment = 1.4
Radial Bolts per segment = 2 Nos.
Circumferential bolts per segment = 3 Nos.
Bolt angle to horizontal = 25 °
Bolt Type T 24 (Grade 8.8) =
Shank dia of bolt = 24 mm
Shear strength of bolt rs = 375 N/mm2
As = 452.16 mm2
Shear Capacity, Ps = 118.608 KN
Tensile strength of bolt, rt = 560 N/mm2
At = 452.16 mm2
Tensile Capacity, = 177.91 KN
7.1 Forces due to selfweight of individual segment

Factored self weight of segment = 48.22 KN
Shear force/bolt = 21.85 KN
SHEAR O.K.
Tensile force/bolt KN = 10.189
TENSION O.K.
7.2 Forces due to perfectly Circular Ring
Assuming a perfectly circular ring and full gap closure (2 mm gap), the bolts will have to carry the maximum
gasket load of
Total circumferentail gasket force = Max.gasket force x circumference x γ L
Dia. at centre of gasket 30 KN/m, Thus: = 6.260 m
Total circumferentail gasket force = 471.723456 KN
Circumferential gasket force for 67.5 ° Segments = 85.8820909091 KN
\ Gasket force per bolt, FGB = 28.63 KN
Fshear FGB x Sin (Bolt angle to horizontal) \ Fshear = 12.10 KN
Allowable Shear, Ps = 118.608 KN
SHEAR O.K.
Fbolt FGB x Cos (Bolt angle to horizontal) Fbolt = 25.95 KN
Allowable Tension Pnom = 177.91 KN
TENSION O.K.
7.3 Forces due to Compression of Gasket by Bolts
For an ovalised ring, assume the maxim. gap closure obtained is 2 mm
Thus the gasket force FG10 = 16 KN/m
Total circumferential gasket force = 471.723456 KN
\ Gasket force per bolt FGB = 28.63 KN
Taking moments abouth the chamfered corner, Resultant R = 60.414890791 KN
Resolve R into Fbolt and Fshear

Fshear = 25.53 KN
SHEAR O.K.
Fbolt = 54.75
TENSION O.K.
7.4 Checking Worst case loading of self weight combined with bolt forces due to compresssion of gasket by bolts
Shear = \ Fs = 47.38
SHEAR O.K.
Tension = \ Ft = 64.94
TENSION O.K.
(Fs/Ps) + (Ft/Pnom) = 0.765 < 1.4 O.K.
9 FLOATATION CHECK
Minimum overburden occurs at: CH. = 13440m
Distance from tunnel axis to rail level = 2.1
Rail Level = 32.385 m
Depth of cover (to tunnel axis) = 14.615 m
Groundwater level 6.615
Uplift Force, (per meter length of tunnel) Fu = 310.518 KN

Overburden force, (per meter length of tunnel) Fd = 108.61272 KN
Weight of Concrete, (per meter length of tunnel) Wc = 131.144 KN
Net Downward Force = Fd + 0.9Wc = 226.642 KN
Factor of safety against uplift = 0.72988594408

> 1.1 NOT SAFE

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3.0 TUNNEL LOADING AND FORCES
Minimum over burden case
3.1 Ground Properties

Young's Modulus- UnDrained Eg = 50000 KN/m2
Poisson's Ratio νg = 0.23
Bulk unit weight γ = 18 KN/m3
Unit weight of water γw = 10 KN/m3
Stress Ratio Ko = 0.50
Maximum overburden occurs at CH. = 13720m

Distance from Tunnel axis to rail level = 2.10 m
Rail level = 38.45 m
Depth to cover (to tunnel axis) = 7.92 m
Groundwater level (m below ground level) = 48.47
3.2 Ground Loading

Surcharge q = 50 KN/m2
Factored Surcharge = 75 KN/m2
(Factor = 1.5 )
Overburden = 142.614 KN/m2
Factored Overburden = 213.92 KN/m2
(Factor = 1.5 )
Combined loading on tunnel (at tunnel centerline)

Vertical component (unfactored) = 192.61 KN/m2
Vertical component (factored) = 288.92 KN/m2
Horizontal component (unfactored) = 96.31 KN/m2
Horizontal component (factored) = 144.46 KN/m2
3.3 Curtis Equation
Assume λ =unity. This implies that the lining is inserted immediately after the ground is excavated, allowing no relaxation of the
ground and imposing full loading on the lining - a consevative assumption.
Q1 = [Eg (1-νi2)Rm]/[El(1+νg)h]
Q3 = [R3Eg(1-νi2)]/[12ElIl(1+νg)]
Sn/So = [λ(1-Q3)]/[1+Q3]ω
St/So = [λ(1+2Q3)]/[1+Q3]ω
where, ω = [3-2νg]/[3-4νg]
λ = 1.0
ω = 1.22115
Q1 = 0.02483
Q3 = 4.612
Sn/So = -0.53
St/So = 1.49
3.3.1 Unfactored Loads

Po = 144.46 KN/m2
So = 48.15 KN/m2
Sn = -25.38 KN/m2
St = 71.84 KN/m2
Ni = 438.80 KN/m
N = -125.20 KN/m
M = 32.42 KN/m
3.3.2 Unfactored Radial Deformation

Internal radius of Tunnel Rin ,=ID/2 Rin = 2900 mm
Internal radius of Tunnel Rex ,=OD/2 Rex = 3175 mm
Young's Modulus (long term) = 1/2 short term E = 17,678 N/mm2
I value (for per meter length of segment) = 0.00174 m4/m

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2*Sn*Rex4
Ur ,C nov = = 0.51882 mm
18 EI γ
(2*Sn+St)*Rex4
Ur ,C v = 1.01 mm
18 EI γ
Ovalization Deofrmation =(Ur ,C nov + Ur ,C v)/2 = 0.76 mm
3.3.3 Factored Loads

Po = 216.69 KN/m2
So = 72.23 KN/m2
Sn = -38.07 KN/m2
St = 107.76 KN/m2
Ni = 658.20 KN/m
N = -187.80 KN/m
M = 48.62 KN/m
3.3.4 Summary of Forces

Unfactored
Factored
Note: Forces here are per meter length and not per ring.
3.4 Railway Loading

3.4.1 Trackslab
Width at the top level of first stage concrete = 3314 mm

Depth of first stage concrete = 526 mm
Estimated cross-sectional area of trackslab = 1.1621 m2
Assumed density of trackslab = 25 KN/m3

Weight of trackslab W = 29.0527 KN/m run
Assume load carried by one segment and distributed evenly across segment, thus:
3.4.2 Trains
Max. vertical load on any one segment due to trains Vt = 16 Tons
= 160 KN
Using same rationale as for the trackslab system
3.5 Load Summary

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Unfactored
Factored
Note: Hoop loads shown are the sum of those in section 3.3 and 3.4
4 RADIAL JOINT ROTATION

4.14 Maximum Joint Rotation
The maximum allowable ovalisation is 0.86% of internal diamenter
Thus the maximum allowable distortion to be considered is = 49.88 mm
This will be considered for a 67.5 ° segment
Assume segment rotates as rigid bodies

OA = OB = 2900 mm
α = 56.25 °
OC = 1109.8 mm
CB = 1790.2 mm
AB = DE = 3222.3 mm
OE = 2925 mm
OG = 2875 mm

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Equation of an ellipse:
(DF2/OG2)+(OF2/OE2) = 1 Þ DF2 = (1- (OF2/OE2))OG2
(OE2-OF2)+DF2 = DE2
Substituting Eqn -1 in Eqn -2 yields:
[1-(OG2/OE2)]OF2 - 2OEXOF+(OE2+OG2-DE2) = 0
OF = 1107.6 mm
b = 55.67 °
Angular rotation, α-b = 0.58 °
Total rotation at joint due to movement of two adjacent segments, θ
rotation angle in radians θ = 0.0203 radians

eccentricity due to joint rotation
= (R1xR2/(R1+R2)) x θ
ea = 20.346 mm
Misalignment Considered S = 10 mm
eccentricity due to misalignment of segments
= R1/(R1+R2) x S
er = 5 mm
Joint width wj = 154 mm
Caulking Groove width Cg = 61 mm
Eccentricity due to joint geometry
= h/2-(Cg +w/2)
eg = -0.5 mm
Eccentricity of thrust through the joint: (e a + er + eg) = 24.85 mm
4.2 Unfactored moment after Joint Rotation

Unfactored Moment from Curtis Equation = 60.25 KNm
Unfactored Thrust from Curtis Equation = 533.07 KN/m
unfactored moment after Joint Rotation = 73.49 KNm
4.3 Bearing Check
Total Width of segment = 1.40 m
Working Hoop Load per segment (N w) = Ta.b = 695.65 Kn
Joint Length = Lj = b-2*50 = 1300.00 mm
Maximum Allowable Contact Pressure P max =2*fcu = 100.00 N/mm2
For calculating the peak contact pressure ,the relative Young's Modulus and and radius of the contact point are required .
Relative Young's Modulus =Erel = E = 9042.29 N/mm2
2(1-ν ) 2
Rrel = 1.00 m
Peak contact stress according to Hertz theory Ppeak = 39.25 N/mm2
Factor of Safety for Joint Bearing FOS joint Bearing = 2.55 Safe
5 Overall Structural Buckling Check
q = 3EI/R3
E = 17,678 N/mm2
I = 1,735,714,286 mm4/m
R = 3,038 mm
q (Critical buckling load) 3,285 KN/m2
Buckling Hoop Load = 9,977 KN/m
Design Hoop Load = 1,843 KN/m
DESIGN LOAD < BUCKLING LOAD HENCE SAFE
A company of the GEOCONSULT group Job no: I6079
Page No.:-

DESIGN AND CONSTRUCTION OF UNDERGROUND STATIONS AND TUNNEL FROM CHAINAGE 14328.88M
Project: TO CHAINAGE 11882.88M, INCLUDING EAST RAMP, TWIN BORED UNDERGROUND TUNNEL,NATM
TUNNEL, CUT AND COVER PORTION AND TWO UNDERGROUND STATIONS KANKARIA EAST AND
KALUPUR STATION
Calculation for DEFINITIVE SEGMENT LINING DESIGN

Checks For Radial Joints with Curtis Equation forces
Concrete Compressive Cylinder Strength fck [MPa] 50
Concrete Compressive Cube Strength fck,Cube [MPa] 50
Concrete Young's Modulus [MPa] 17,678
Poisson's Ratio νi 0.150
Load factor γr [-] 1.5
Permissible flexural strength(as per Leonhardt), fct MPa 4.61

fct=0.34(fck)^2/3
Permissible flexural strength= fctd=fct/ϒm fctd MPa 3.08
Eccentricity of thrust through the joint: e'= (ea + er + eg) [mm] 30.10
Fy_ULS N/mm^2 500
Material safety,steel 1.15
Fy_SLS N/mm^2 200
Depth of joint,a= 145 mm
Thickness of segment, h= 275 mm

Width of segment,l0 1400 mm
Length of bearing,lb =l0-100x2 1200 mm
Total width of chamfers grooves etc. c=(34.9+36.8+2.2+10+50.5+5) 139.4 mm
Build tolerances= 5 mm
Ecc. Due to ovalisation, ejrot= 23.603 mm
Radius of convex joint 2000 mm
Max thrust at axis 533.1 kN/m
Design thrust/per segment 1494.0 kN
Bending moment 0 kN-m
Max of M1=(M,No.ts/20,ejrot.No) 35.3 kN-m
M1 35.3 kN-m
k=(1-n2)/e.π 0.00002
b 26.48 mm
ex 28.6 mm
Half width of segment=y0 137.5 mm

Half width of loaded area=ypo 13.2 mm Shear link
ypo/yo 0.096 Bar mark dia Nos
.23No (as per BS 8110 Table 4.7) 343.6 kN 2 10 9
Ast 790.3 mm^2/segmen 3 10 13
Provided 1727.9 mm^2/segment
Check for bearing stress, Double Convex Joints
Design bearing stress No/(b *lb) 47.0 N/mm^2

Permissible stress,DC/7/13, clause 7.6.3 = 2.0 fcu, Max 105MPa 100.0 N/mm^2 OK
Check on Radial Anti -Splitting Steel (Hoop of Main Reinforcement Bar )
Diameter of Tension Bars ɸtr ɸtr.ladder

12 mm 12 mm
ntr ntr.ladder
No of Effective Anti spliting bars within 80% depth of
12 12
the segment
Effective steel area per metre 1938.8 mm2
Fstr = 843.0 kN/m

Yeild Strength of the anti -splitting reinforcement per
metre
Factored Design Strength =Nur = fctd*ts +Fstr
= 1689.0 kN/m
Factored Axial Hoop forces = 1316.4 kN/m
Factor of Safety for Radial Splitting = 1.3 Safe

= fctd*ts
Corner Shear = 846.0 kN/m
Facotr of Safety against corner Splitting = 0.6 Need to provide additional reinforcement at corner
Page No.:-

Project: TO CHAINAGE 11882.88M, INCLUDING EAST RAMP, TWIN BORED UNDERGROUND TUNNEL,NATM
TUNNEL, CUT AND COVER PORTION AND TWO UNDERGROUND STATIONS KANKARIA EAST AND
KALUPUR STATION

Checks For Radial Joints with staad Forces
Concrete Young's Modulus [MPa] 17,678
Fy_ULS N/mm^2 500
Fy_SLS N/mm^2 200

Width of segment,l0 1400 mm
Length of bearing,lb =l0-100x2 1200 mm
Total width of chamfers grooves etc. c=(34.9+36.8+2.2+10+50.5+5) 139.4 mm
Build tolerances= 5 mm
Ecc. Due to ovalisation, ejrot= 23.603 mm
Radius of convex joint 2000 mm
Design thrust/per segment 1843.0 kN
Bending moment 0.00 kN-m
Max of M1=(M,No.ts/20,ejrot.No) 43.5 kN-m
M1 43.5 kN-m
k=(1-n2)/e.π 0.00002
b 29.41 mm
ex 28.6 mm
Half width of segment=y0 137.5 mm

Half width of loaded area=ypo 14.7 mm Shear link
ypo/yo 0.107 Bar mark dia Nos
.23No (as per BS 8110 Table 4.7) 423.9 kN 2 10 9
Ast 974.9 mm^2/segmen 3 10 13
Check for bearing stress, Double Convex Joints
Design bearing stress No/(b *lb) 52.2 N/mm^2

Permissible stress,DC/7/13, clause 7.6.3 = 2.0 fcu, Max 105MPa 100.0 N/mm^2 OK
GEOCONSULT India Pvt APPENDIX - 3
Ltd
Job no: I6079
Page No.:
DESIGN AND CONSTRUCTION OF UNDERGROUND -
STATIONS AND TUNNEL FROM
Project: CHAINAGE 14328.88M TO CHAINAGE 11882.88M, INCLUDING EAST RAMP, TWIN
Calculation for BORED UNDERGROUND
DEFINITIVE TUNNEL,NATM
DESIGN OF SEGMENT LININGTUNNEL, CUT AND COVER PORTION AND
CHECK FOR RADIAL JOINT AND OVALISATION
3.1 Radial Joint Design

Change in diameter due to ovalisation = 59 mm
BB' = 29.5 mm
Angle AOB = 67.5 Degrees

OA = 3037.5 mm
OB = 3037.5 mm
AH = 2806.3 mm
OH = 1162.4 mm
HB = 1875.1 mm
Angle OBA = 56.25 Degrees
AB = 3375.1 mm
A'B' = 3375.1 mm
OB' = 3062.5 mm
OF' = 3012.5 mm
Solving for equation of ellipse:
OG = 1160.2 mm
GB' = 1902.3 mm
Angle OB'A' = 55.694 Degrees
Angular Rotation = 0.56 Degrees
Total Angular Rotation = 1.11 Degrees
= 0.0194 Radian
Rdaius of curve of Radial Joint = 2000 mm
Eccentricity due to ovalisation = 19.42 mm
3.2 DESIGN FORCES AT ULS

Nmax (kN/m) M (kNm/m)
1501 109
3.3 DESIGN FORCES AT SLS

Nmax (kN/m) M (kNm/m)
1072 77.9
3.4 WIDTH OF BEARING AREA

Based on Table 33 - of ROARK's Formulae for Stress & Strain - 6th Edition by Warren C Young
Concrete , fcu= 45 Mpa

E1 16770510 kN/m2
E2 16770510 kN/m2
u1 0.15
u2 0.15
D1 4 m
D2 4 m
KD (m) CE (m2/Kn) bULS (mm) bSLS(mm)

2 1.165737E-07 30 25
3.5 BEARING STRESS CHECK AT ULS

Contact Area , A= b x ( Ls - 50 x 2)
Bearing Stress = N/A
Ls (m) A (mm2)
1.4
DTP Highways 38911
and Traffic Technical Memorandum (Bridges) BE 5/75 cl. 303a allows the average compressive stress at the throat of a Freyssinet
Hinge to be twice the characteristic strength, fcu, but limited to a maximum of 105 N/mm2
Allowable Bearing Stress Actual Bearing Stress
N/mm2 N/mm2
90 58
3.6 BEARING STRESS CHECK AT SLS

Eccentricity of Load due to Rotation and Stepping , e = O ecc+1/2 Step
Step Oecc e (mm)

10 19.40 24.4
ypo (mm) ts (mm) y0 (mm)

12.65 275 113.10
0.11
Based on Table 4.7 from BS8110 Part1
0.23
P0 (kN/m) Fbst (kN/m) fy ( N/mm2)

1072 246.56 200
Area of Brusting Steel Required ( Per Segement) As,req = 1726 mm2
Provided Reinforcemnt steel with 0.80 Zone

Ladder Mat 12 Nos 12 T
U Bars 10 Nos 12 T
Links 8 Nos 8T
Brusting Steel provided ( Per Segment ) As,pro = 2888.8 mm2 OK, as As,pro > As,req
3.7 EARING STRESS CHECK AT ULS
Eccentricity of Load due to Rotation and Stepping , e = O ecc+1/2 Step
Step Oecc e (mm)

10 19.40 24.4
ypo (mm) ts (mm) y0 (mm)

14.97 275 113.10
0.13
Based on Table 4.7 from BS8110 Part1
0.23
P0 (kN/m) Fbst (kN/m) fy ( N/mm2)

1501 345.23 400
Area of Brusting Steel Required ( Per Segement) As,req = 1208 mm2
Provided Reinforcemnt steel with 0.80 Zone

Ladder Mat 12 Nos 12 T
U Bars 10 Nos 12 T
Links 8 Nos 8T
Brusting Steel provided ( Per Segment ) As,pro = 2889 mm2 OK, as As,pro > As,req
Page No.: -

Project:

Checks for Circumferential Joints
Design Thrust of TBM Ftbm [KN] 42,575
No. of rams nr [-] 16

Safety factor of ram force γr [-] 1.3
Eccentricity of ram er [mm] 15
Eccentricity of contact area ec [mm] 10
Design Stress in steel, Fy_ULS N/mm^2 500
Assume stress in steel,Fy_SLS, ref. table 7.2N & 7.3N EC2 N/mm^2 200
Material factor conc. 1.5

Width of segment= 3578.4 mm
Reduced thickness due to ecc. Of contact area, h0, (h/2- ec) x 2 255 mm
Reduced width of contact area, a1, (a/2- er) x 2 115 mm
Reduced thickness due to ecc, h' 225 mm
TBM, operational face pressure 2230.79 kN/m
Design operational face pressure,maxm( 1.3 x Pr_operatioal 2900.03 kN/m
Design Thrust Force No (FTBM / nr x gr) 3459.22 kN
fcd 33.33 N/mm^2
Ac0 115 x 1092.81
Ac1 255 x 1092.81
Design bearing stress = No/(b *lb) 27.53 N/mm^2
Permissible stress,6.7 EC2 49.64 N/mm^2
Design bearing stress < Permissible stress OK
Design Thrust Force per shoe = 3459 kN
Length of ram Shoe considered = 1093 mm
Load per shoe,No = 3165 kN/m
Half width of segment=y0 = 137.5 mm
Half width of loaded area=ypo = 57.5 mm
ypo/yo = 0.418
0.189 No (as per BS 8110 Table 4.7) = 595.7 kN
Bursting Stress = Fbst/(0.9 x yo x 2) = 2.4 N/mm^2
Concrete Compressive Cylinder Strength,Fck = 50 N/mm^2
Permissible flexural strength(as per Leonhardt), fct=0.34(fck)^2/3 = 4.61 N/mm^2
Permissible flexural strength= fct=fct/gm = 3.08 N/mm^2
Bursting Stress < Permissible flexural strength ok
Splitting Check on Circumferential Joint
Diameter of Tension Bars ɸtr2 mm ɸtr3

= 10 = 10 mm
Minimum number of bar per 6 Nos ntr3 = 6
arms ntr2 = Nos
Effective Area of anti -splitting reinforcement = 942.48 mm2

Yeild strength of anti-splitting reinforcement per arm = 410 kN
Design strength for anti-splitting strength = 2xfctdxtsxLshoe +Anti-splitting Strength of Reinforcement
Where Lshoe = 1093 mm

ts = 275 mm
Operating thrust force/jack shoe = 1875 kN
Design strength for anti-splitting strength = 2259.1 kN
Factor of Safety against circumferential splitting = 1.20 Safe
1
Page No.:-

Project:

Concrete Compressive Strength fck [MPa] 50
Ftbm [KN] 42,575

Design Thrust of TBM

Reduced thickness due to ecc. Of contact area, h0, (h/2- e c) x 2 255 mm
Design operational face pressure,maxm( 1.5x Pr_operatioal) 3346.18 kN/m
Design Thrust Force No (F TBM / nr x gr) 3991.41 kN
fcd 33.33 N/mm^2
Ac0 115 x 700.00
Ac1 255 x 1092.81
OK
Resultant splitting tension force= .25 N (1-a1/h') 272.65
ULS steel 1081.21 mm^2/m
ULS steel/segment 3869.01 mm^2/segment Shear link
SLS steel 1136.05 mm^2/m Mark dia Nos
SLS steel/segment 4065.26 mm^2/segment 16,16a 8 16
Design Steel 4065.26 05 10 46
Page No.:-

Project:

Ftbm [KN] 51,090

** load factors reduced to maximum thrust force machine can
γr [-] 1.25 provide.
Safety factor of ram force

Reduced thickness due to ecc. Of contact area, h0, (h/2- e c) x 2 255 mm
fcd 33.33 N/mm^2
Ac0 114 x 700.00
Ac1 275 x 1092.81
OK
ULS steel/segment 3394.94 mm^2/segment Shear link
SLS steel/segment 4922.67 mm^2/segment 13,16 8 16
Design Steel 4922.67 05 10 54
Page No.:-

Project:

Checks for Circumferential Joints in another direction
Ftbm [KN] 42,575


Thickness of segment, h= 1192.67 mm
Reduced thickness due to ecc. Of contact area, h0, (h/2- e c) x 2 1172.67 mm
Reduced thickness due to ecc, h' 1142.67 mm
Design Thrust Force No (F TBM / nr x gr) 3991.41 kN
fcd 33.33 N/mm^2
Ac0 770 x 115.00
Ac1 1142.6667 x 255.00
OK
ULS steel/segment 198.35 mm^2/segment Reinforcement Details
SLS steel/segment 208.41 mm^2/segment 4 12 4
Design Steel 208.41
Page No.:-

Project:

Checks for Circumferential Joints in another direction
Design Thrust of TBM Ftbm [KN] 42,575


Reduced thickness due to ecc. Of contact area, h0, (h/2- ec) x 2 255 mm
Design Thrust Force No (FTBM / nr x gr) 3459.22 kN
fcd 33.33 N/mm^2
Ac0 1092.81 x 115 mm2
Ac1 1092.81 x 255 mm2
Design bearing stress < Permissible stress OK
Design Thrust Force per shoe = 3459 kN
Length of ram Shoe considered = 1093 mm
Load per shoe,No = 3165 kN/m
Half width of segment=y0 = 137.5 mm
Half width of loaded area=ypo = 57.5 mm
ypo/yo = 0.418
0.195 No (as per BS 8110 Table 4.7) = 615.8 kN
Bursting Stress = Fbst/(0.9 x yo x 2) = 2.5 N/mm^2
Concrete Compressive Cylinder Strength,Fck = 50 N/mm^2
Permissible flexural strength(as per Leonhardt), fct=0.34(fck)^2/3 = 4.61 N/mm^2
Permissible flexural strength= fat=fct/gm = 3.08 N/mm^2
Bursting Stress < Permissible flexural strength ok
1
Page No.:-

Project:

Checks Against Grout Loads
Density of Water γw [KN/m3] 10
External Raius of Tunnel Rex Rex mm 3175

Permissible flexural strength(as per Leonhardt), fct=0.34(fck)^2/3 fct MPa 4.61
Permissible flexural strength= fctd=fct/ϒm fctd MPa 3.08

Hydrostatic Pressure at Tunnel Axis ( Assume Ground Water at GWL) 17 mm

Maximum Grout Pressure as per ODS = =zγw +1 bar 270 KN/m2
= 0.27 N/mm^2
Grout Hoop Thrust Tgrout = Pgmax*Rex = 857.25 kN/m
Factored Hoop Thrust Tgrout .f 1.4 * Pgmax = 1200.2 kN/m
Diameter of Tension Bars ɸtr ɸtr.ladder
12 mm 12 mm
ntr ntr.ladder
No of Effective Anti spliting bars within 80% depth of the segment 12 Nos 12 Nos
Effective steel area per metre 1938.8 mm2
Fstr = 843.0 kN/m

Yeild Strength of the anti -splitting reinforcement per metre
Factored Design Strength =Nur = fctd*ts +Fstr
Factored Axial Hoop forces = 1689.0 kN/m

=
Factored Design Strength =Nur = 1689.0 kN/m
Factor of Safety against Splitting due to Grout FOS = 1.41 Safe
Assuming bad build eccentricity ebb = 10.00 mm
12.00 (Include this moment in

Moment due to gouting at bad build eccentricity = kNm/m
design)
Page No.: -

DESIGN AND CONSTRUCTION OF UNDERGROUND STATIONS AND TUNNEL FROM
BORED UNDERGROUND TUNNEL,NATM TUNNEL, CUT AND COVER PORTION AND
TWO UNDERGROUND STATIONS KANKARIA EAST AND KALUPUR STATION

1 TYPICAL BOLT DESIGN
Internal radius of segmental lining 2900.0 [mm]
Segment thickness 275.0 [mm]

External radius of segmental lining 3175.0 [mm]
Mean radius 3037.5 [mm]
Segment angle 67.50 [deg]
Cross sectional area of segment 0.984 [m2]
Length of segment 1400 [mm]
Unit weigth of concrete 25 [kN/m³]
Selfweight of segment 34.44 [kN]
3.44 [t]
Curved Length of Segments 3578.42 mm
Load factor for self weight 1.50 [-]
Radial bolt type 25 [mm]
Circumferential bolt type 25 [mm]
Bolt angle to horizontal 25 [deg]
Radial Bolts per segment 2 Nos.
Circumferential bolts per segment 2 Nos.
Bolt capacities:
Material safety factor for steel gM2= 1.25
Factor k2 = 0.9
EC 3 Part: 1-8 Factor av = 0.6
Ultimate tensile strength of radial bolt fub = 700 [N/mm2]
Ultimate tensile strength of circumeferential bolt fub = 700 [N/mm2]
Shear strength of radial bolt, fv,RD = av x fub / gM2 = 336 [N/mm2]

As = 491 [mm2]
Shear capacity, Fv,RD = fv,RD x As = 164.9 [kN]
Shear strength of circumeferential bolt, fv,RD = av x fub / gM2 = 336 [N/mm2]

As = 491 [mm2]
Tensile strength of radial bolt, ft,RD = k2 x fub / gM2 = 504 [N/mm2]

At = 491 [mm2]
Tensile capacity, Ft,RD = ft,RD x At = 247.3 [kN]
Tensile strength of circumeferential bolt, ft,RD = k2 x fub / gM2 = 504 [N/mm2]

At = 491 [mm2]
Forces due to selfweight of individual segment
Factored segment weight , Fsw Fsw = 51.7 [kN]
Shear force/bolt , FSb Fsb = 23.4 [kN]
Fsb < Fv,RD SHEAR O.K.
Tension force/bolt , Ftb Ftb = 10.9 [kN]
Page No.: -


1 TYPICAL BOLT DESIGN
Ftb< Ft,RD Tension O.K.
Forces due to Compression of Gasket by Bolts
Dia. at centre of gasket 6.26 m
For an ovalised ring, assume the maxim. gap closure obtained is 10 mm
Thus the gasket force FG10 = 22.00 kN/m
Total circumferential gasket force = 22 * 3.14 * 6.26 * 1.5= 648.62 kN
Circumferential gasket force = 22 * 3578.42045454545/ 1000 * 1.5= 118.09 kN
Gasket force per bolt, FGB = = 118.087875 / 2 = 59.04 kN
Taking moments abouth the chamfered corner, Resultant , R = 124.61 kN
Resolve R into Ftension and Fshear

Fshear = 52.66 kN
Fshear < Fv,RD SHEAR O.K.
Ftension= 112.93 kN
Ftension< Ft,RD TENSION O.K.
Self weight combined with Forces due to compresssion of gasket by bolts
Total Shear, Ftot,shear = Fshear + Fsb Ftot,shear = 76.07 kN
Ftot,shear < Fv,RD SHEAR O.K.
Total Tension, Ftot,tension = Ftension + Ftb Ftot,tension= 123.85 kN
Ftot,tension< Ft,RD TENSION O.K.
Combined Shear and Tension
(Ftot, shear / Fv,RD) + (Ftot, tension / 1.4 *Ft,RD) <= 1.0 0.819 <= 1.0
ok
Page No.: -


1 BOLT DESIGN
Internal radius of segmental lining 2900.0 [mm]
Segment thickness 275.0 [mm]

External radius of segmental lining 3175.0 [mm]
Mean radius 3037.5 [mm]
Segment angle 67.50 [deg]
Cross sectional area of segment 0.984 [m2]
Length of segment 1400 [mm]
Unit weigth of concrete 25 [kN/m³]
Selfweight of segment 34.44 [kN]
3.44 [t]
Load factor 1.40 [-]
Radial bolts per segment 2 [-]
Distance betwwen first and last radial bolt 800 [mm]
Circumferential bolts per segment 2 [-]

Radial bolt type Grade 8.8 M24 [mm]
Circumferential bolt type Grade 8.8 M24 [mm]
Radial Bolts per segment 2 Nos.
Circumferential bolts per segment 2 Nos.
EC 3 Part: 1-8 Bolt capacities:

Material safety factor for steel gM2= 1.25
Faktor k2 = 0.9
Faktor av = 0.6
Ultimate tensile strength of radial bolt fub = 700 [N/mm2]
Ultimate tensile strength of circumeferential bolt fub = 700 [N/mm2]
Shear strength of radial bolt, fv,RD = av x fub / gM2 = 336 [N/mm2]

As = 353 [mm2]
Shear strength of circumeferential bolt, fv,RD = av x fub / gM2 = 336 [N/mm2]

As = 353 [mm2]
Tensile strength of radial bolt, ft,RD = k2 x fub / gM2 = 504 [N/mm2]

At = 353 [mm2]
Tensile strength of circumeferential bolt, ft,RD = k2 x fub / gM2 = 504 [N/mm2]

At = 353 [mm2]
Factored segment weight 48.2 [kN]
Shear force/bolt 21.9 [kN]
SHEAR O.K.
Tension force/bolt 10.2 [kN]
SHEAR O.K.
Forces due to Compression of Gasket by Bolts
System 1
Segment centre of gravity 2.87 [m]

Horiz. distance between bolt and centre of grav. 1.097 [m]
Horiz. distance between bolt and support 2.53 [m]
Vertical distance between bolt and support 1.35 [m]
Horizontal / vertical force 17.77 [kN]

Design load on bolt 25.14 [kN]
Less than 177.9 Stress check ok
System 2
3 bolts per segments
alpha = 67.500 535 [mm]

Leverarm 1 (1 bolt) alpha = 0.000 398 [mm]
Leverarm 2 (2 bolts) alpha = 45.000 166 [mm]
Max design bolt force 62.9 [kN]

Less than 177.9 Stress check ok
Page No.: -

DESIGN AND CONSTRUCTION OF UNDERGROUND STATIONS AND
TUNNEL FROM CHAINAGE 14328.88M TO CHAINAGE 11882.88M,
Project: INCLUDING EAST RAMP, TWIN BORED UNDERGROUND
TUNNEL,NATM TUNNEL, CUT AND COVER PORTION AND TWO
UNDERGROUND STATIONS KANKARIA EAST AND KALUPUR
STATION

Check For Gasket Forces
(1) Input: Dimensions & Properties
Max Force Fmax 30.00 [kN/m]

Groove width (bottom) w1 26 [mm]
Edge distance of groove h 31.88 [mm]
Characteristic compressive cylinder strength fck 50 [N/mm2]
Safety Factor γ 1.5 [-]
(2) Concrete Design Shear Stress (Members without shear reinforcement)

Factor, k Refer to table below [-] 6.2.2 (1)
Minimum resistance shear stress, vmin Refer to table below [N/mm2] Eq 6.3N
Factor, k1 0.15 [-] 6.2.2 (1)
σcp 0.00 [N/mm2] 6.2.2 (1)
hg 57.9 [mm]
VRd,c,min Refer to table below [kN/m] Eq 6.2.b
(3) Derivation of shear stress along failure plane

2.1 Considering Equilibrium of forces
V  0 p   * sin     * cos      * tan  
H  0  * sin     * cos  
2.2 Equation forces Shear Stress:
1 F5 min
F5 min   * cos    *
 * tan    sin    1 
sin    tan   
 * cos 

 sin   
Note: v along the failure plane equal to τ
1 Fmax 1
vg  * * 
sin    1  l 
 tan    * cos 
 sin   
(4) Shear Stress and Forces due to compression of Gasket

Failure Angle Failure Factor Shear Shear Stress Design Shear Shear Design Check
Plane Resistance Check Force Resistance
Length
α l k vmin vg vmin > vg Vmax VRd,c,min VRd,c,min > Vmax

[°] [mm] [-] [N/mm2] [N/mm2] [-] [KN/m] [-]
5 664.0 1.55 0.48 0.07 OK 44.83 316.77 OK
10 333.3 1.77 0.59 0.13 OK 44.32 195.00 OK
15 223.6 1.95 0.67 0.19 OK 43.47 150.20 OK
20 169.2 2.00 0.70 0.25 OK 42.29 118.45 OK
25 136.9 2.00 0.70 0.30 OK 40.78 95.86 OK
30 115.8 2.00 0.70 0.34 OK 38.97 81.03 OK
35 100.9 2.00 0.70 0.37 OK 36.86 70.63 OK
40 90.0 2.00 0.70 0.38 OK 34.47 63.03 OK
45 81.8 2.00 0.70 0.39 OK 31.82 57.29 OK
50 75.6 2.00 0.70 0.38 OK 28.93 52.89 OK
55 70.7 2.00 0.70 0.37 OK 25.81 49.46 OK
60 66.8 2.00 0.70 0.34 OK 22.50 46.78 OK
65 63.9 2.00 0.70 0.30 OK 19.02 44.70 OK
70 61.6 2.00 0.70 0.25 OK 15.39 43.11 OK
Page No.: -

DESIGN AND CONSTRUCTION OF UNDERGROUND STATIONS AND
TUNNEL FROM CHAINAGE 14328.88M TO CHAINAGE 11882.88M,
Project:
INCLUDING EAST RAMP, TWIN BORED UNDERGROUND
TUNNEL,NATM TUNNEL, CUT AND COVER PORTION AND TWO
UNDERGROUND STATIONS KANKARIA EAST AND KALUPUR STATION

Check For Gasket Forces-2
(1) Input: Dimensions & Properties
Gasket Type Datwyler
Max Force Fmax 30.00 [kN/m]
Groove width (bottom) w1 26 [mm]
Groove width (top) w2 30.29 [mm]
Groove depth t 7 [mm]
Edge distance of groove h 31.88 [mm]
Groove flank f 7.32 [mm]
Angle groove flank β 73 [o]
Charakteristic compressive cylinder strength fck 50 [N/mm2]
Safety Factor γ 1.5 [-]
(2) Concrete Design Shear Stress (Members without shear reinforcement)

Stress in groove and groove flank σgf 0.99 [N/mm2]
Force on groove flank Ff 0.14 [kN/m]
Factor, k Refer to table below [-] 6.2.2 (1)
Minimum resistance shear stress, vmin Refer to table below [N/mm2] Eq 6.3N
Factor, k1 0.15 [-] 6.2.2 (1)
σcp 0.00 [N/mm2] 6.2.2 (1)
VRd,c,min Refer to table below [kN/m] Eq 6.2.b
(3) Shear Stress and Force due to compression of Gasket

Failure Failure Plane Factor Shear Shear Force Shear Design
Angle Length Resistance Resistance Check
α l k vmin Vd VRd,c,min VRd,c,min > Fd

[°] [mm] [-] [N/mm2] [KN/m] [-]
5 32.0 2.00 0.70 0.20 22.40 OK
10 32.4 2.00 0.70 0.20 22.66 OK
15 33.0 2.00 0.70 0.20 23.10 OK
20 33.9 2.00 0.70 0.20 23.74 OK
25 35.2 2.00 0.70 0.20 24.62 OK
30 36.8 2.00 0.70 0.20 25.76 OK
35 38.9 2.00 0.70 0.19 27.24 OK
40 41.6 2.00 0.70 0.19 29.13 OK
45 45.1 2.00 0.70 0.18 31.56 OK
50 49.6 2.00 0.70 0.17 34.71 OK
55 55.6 2.00 0.70 0.16 38.90 OK
60 63.8 2.00 0.70 0.15 44.63 OK
65 75.4 2.00 0.70 0.14 52.80 OK
70 93.2 2.00 0.70 0.12 65.24 OK
GEOCONSULT India Pvt Ltd APPENDIX -3A

Job no: I6079
- Page No.: -

DESIGN AND CONSTRUCTION OF UNDERGROUND STATIONS AND TUNNEL FROM CHAINAGE
Project: 14328.88M TO CHAINAGE 11882.88M, INCLUDING EAST RAMP, TWIN BORED UNDERGROUND
TUNNEL,NATM TUNNEL, CUT AND COVER PORTION AND TWO UNDERGROUND STATIONS KANKARIA
EAST AND KALUPUR STATION

1 VACUUM LIFTING
Mean diameter of tunnel = 6075.00 mm

Mean Radius = 3037.50 mm
Segment Thickness = 275.00 mm
Width of the segment = 1400.00 mm
Self weight of one standard,W = 33.07 kN
Material factor of safety,concrete, gm = = 1.5

Partial safety Factor Loading, g1 = = 1.00
Partial safety factor Dynamic/ loading ,gd = = 5.00
Fcu assumed = 10.00 mPa
Permissible flexural strength(as per Leonhardt), fct=0.34(fcu)^2/3 = 1.58 mPa
Permissible flexural strength= fat=fct/gm = 1.05 mPa
Vacuum Lifting of segments

Assuming that segment being lifted by two nos 571mm x 1230 vaccum pads .
The bending moment is caused by the selfweight of segemnt and the suction of segment.
Refer to Staad modelling

There are rigid link (with end release) at multiple joint supports that represents the suction pad is modelled at distance of le.
0.75 m (approx)
Assuming the middle pad is not working
Moment at face of lifter , BMFace= = 2.469 kNm
Design Moment at face of lifter , BMFace_d= g1 *gd * BMFace = = 12.345 kNm
Concrete stress=BMFace_dx 6 / (b. t^2) = 0.6995986 Mpa ok
Moment at face of middle , BMspan= = 1.19 kNm

Design Moment at face of lifter , BMSpan_d= g1 *gd * BMSpan = 5.925 kNm
Concrete stress=BMSpan_dx 6 / (b. t^2) = 0.3357733 Mpa ok

Job no: I6073
- Page No.: -
MUMBAI METRO LINE 3 CONTRACT UGC- 04

Design and Construction of Underground Section including three Underground Stations at Siddhi
Project:
Vinayak, Dadar and Shitladevi Temple and Associated Tunnels

1 Demoulding of Segments

Partial safety factor Dynamic/ loading ,gd = = 5.00
Permissible flexural strength(as per Leonhardt), fct=0.34(fcu)^ 2/3 = 1.58 mPa
Vacuum Lifting of segments

Assuming that segment being lifted Gantry crane with 1900mm contact area
The bending moment is caused by the selfweight of segemnt and the Cantilever Portion of segment.

There are hinged link at multiple joint supports that represents the gantry crane lifting is modelled for distance of le.
1.9 m (approx)
Moment at face of lifter , BM Face= = 3.4 kNm

Design Moment at face of lifter , BMFace_d= g1 *gd * BMFace = = 17 kNm

Job no: I6079
- Page No.: -

Project: TO CHAINAGE 11882.88M, INCLUDING EAST RAMP, TWIN BORED UNDERGROUND TUNNEL,NATM TUNNEL,
CUT AND COVER PORTION AND TWO UNDERGROUND STATIONS KANKARIA EAST AND KALUPUR
STATION
Calculation for PRELIMINARY SEGMENT LINING DESIGN

1 STACKING

Geometry
Assuming support line at 1000 mm radially Span L1= = 1578.47 mm

Plan length of standard segment,L plan = 3375.09 mm
Plan length of span = 1560.77 mm
UDL freom self weight of segment, w=W/Lplan = 9.80 KN/m

Partial safety factor Dynamic /loading ,gd = = 5.00
Permissible flexural strength(as per Leonhardt), fct=0.34(fcu)^2/3 = 1.78 mPa
Single Segment selfweight intrados up
Refer to Staad modelling using singgle support at centre

Moment at face of middle , BM_middle= = 9.80 kNm
Design Moment at face of lifter , BM_middle_d, M1= g1 *gd * BM_Middle = 49.00 kNm
Concrete stress=BM_middle_dx 6 / (b. t^2) = 2.78 Mpa not ok
Above check is provided for stacking of segments with single support condition and infact , same is not allowed to do in site

Job no: I6079
- Page No.: -

Project: TO CHAINAGE 11882.88M, INCLUDING EAST RAMP, TWIN BORED UNDERGROUND TUNNEL,NATM TUNNEL,
CUT AND COVER PORTION AND TWO UNDERGROUND STATIONS KANKARIA EAST AND KALUPUR
STATION
Calculation for PRELIMINARY SEGMENT LINING DESIGN

Single Segment with additional support at 1m away from end

Moment at face of lifter , BMFace_stack= = 2.33 kNm
Design Moment at face of lifter , BMFace_d= M2= g1 *gd * BMFace-Stack = 11.64 kNm
Multiple Segment with additional support at quarter point for bottom segment
Assuming shift of support x5 = = 0.05 m

num= = 5
Total no of segments=n+1 = 6
=
Moment at face of lifter , BMFace,M3= g1(num-1) W / 2. x5+ g1. gd. W /2. x5+M2 = 19.07 kNm

Job no: I6079
- Page No.: -

Project:

1 HANDLING WITH ERECTOR
The segments are supported at the central erector socket and a pair of lateral supports.
The gripping device at the erector socket is being pre-stressed against the lateral supports.
The following stages / cases are considered:
- Case 1: Pre-stressing of gripping device against lateral supports


Partial safety factor Dynamic loading ,gd = = 2.00
Fcu = 40.00 MPa
Permissible flexural strength(as per Leonhardt), fct=0.34(fcu)^2/3 = 3.98 MPa
Permissible flexural strength= fat=fct/gm = 2.65 MPa
- Case 1: Pre-stressing of gripping device against lateral supports
Prestressing force of erector socket, Fa = 120.00 kN
Lateral supporting Force Fs1= Fa / 4 Fs1= = 30.00 kN

Fs2= Fa / 4 Fs2= = 30.00 kN
Distance between erector socket and lateral support a1= = 0.34 m

a2= = 0.60 m
Bending moment at centre of segment= Mm1= Fs1.a1+Fs2.a2
Moment at face of lifter , BMFace= = 28.20 kNm

Concrete stress=BMFace_dx 6 / (b. t^2) = 1.60 MPa
ok
Pull-out of socket
Maximum pull-out force 2 *gd * Fs = 240.00 kN
Pull-out resistance= = 250.00 kN

Job no: I6079
- Page No.: -

Project:
Check for Punching shear
Shear V= gd .W = 66.13 kN
Socket length d= = 180.00 mm
Socket diameter d_s= = 70.00 mm
Perimeter of critical section at 1.5 d, u=π (3d+d_s) = 1916.37 mm
Shear stress n1 =V/ u.d = 0.19 MPa

K= 1+SQRT(200/d)<=2 = 2.00
nmin =0.035 K3/2 fck0.5 = 0.63 MPa
ok
APPENDIX-4A
GEOCONSULT India Pvt Ltd
Page no -

DESIGN AND CONSTRUCTION OF UNDERGROUND STATIONS AND TUNNEL FROM CHAINAGE 14328.88M TO CHAINAGE
Project:
11882.88M, INCLUDING EAST RAMP, TWIN BORED UNDERGROUND TUNNEL,NATM TUNNEL, CUT AND COVER PORTION
AND TWO UNDERGROUND STATIONS KANKARIA EAST AND KALUPUR STATION

Check For Pull-out of erector socket

lnner diameter Di mm 5800
Segment Thickness d mm 275
Depth to centre of gasket hg' mm 44.9
Subtended angle of segemnt q [deg] 67.5
Distance between erector socket and support a1 mm 340
Distance between erector socket and support a2 mm 600
Width of segment bs mm 1400
Unit weight of concrete kN/m^3 25
No of segment no 5
Forces in gasket Fgmax kN/m 30.00
Pullout capacity of socket kN 250.00
Safety factor gasket force gg 1.40
Applying cosine rule to calculate A

A2=B2+C2-2*B*C* Cos(f) C=Rf/2 2900 mm
B=C+d-hg 3130.1 mm
qe=q/2 33.75 deg
A= 1764.3 mm
Applying sine rule to calculate angles and lever arm x 2

a=arcsin[(sin(qe) * C)/A] 66.0 deg
b=90° -a 24.0 deg
x2= 718.86 mm
Force act on erector socket and grout hole during placing of segment
Wt of each ordinary segment 34.44 kN
Maximum force of gasket for TBM erector along radial joint
FD=Fgmax*bs 42 kN
Equation Horizontal force ΣFx=0 F 2= 0 kN
-F2-F1+FE-FD * sin (q/2)=0
FE=F2+F1+FD * sin (q/2) 127.7 kN

Factored load,F E * gg 178.8 kN
Equation Vertical force ΣFy=0
FG-F3-FD * cos (q/2)=0
F3=FD * cos (q/2)-FG 0.5 kN
Equation Moment about ,R ΣMR=0

-F1 *a- FG* d/2+ F2 * a + FD * x2=0
F1-1=[- FG/2 * d/2+F 2-1 * a1/2 +FD/2 *x2]/ a1
F1-1 37.4 kN
F1-2=[ -FG/2 * d/2+F 2-2 * a2/2 +FD/2 *x2]/ a1
F1-2 21.2 kN
Conclusion
Pullout load capacity of proposed socket P>F E * gg ok
COMMENTS
PROJECT: Lucknow Metro-LKCC06 Update reference
REF: Splitting steel at Radial Joint
DESIGNED BY: Adh JOB NO: 16071
CHECKED BY: DATE: 10-Jun-22

Fy_ULS N/mm^2 500
Fy_SLS N/mm^2 240
Calculation is based on Leonhard and not to EC2 (6.6.3)
Depth of joint,a= 135 mm a1=b-2e 74.794086 Please check whether Leonhard can be used in India.
Thickness of segment, h= 275 mm h'=h-2e 214.79409 We may go ahead with Leonhard,can please forward material.
Width of segment 1400 mm
a1=a-2e' 74.794 mm If convex joint, the touching length is much smaller
h'=h-2e' 214.794 mm

Design 746.3 kN/m
Max splitting tensile stress= .45 N (1 - a1/h')/h' 1.5 < 4.07 Us factored N in the calculation
Resultant splitting tension force= .25 N (1-a1/h') 86.9 kN/m Factored
ULS steel 280 mm^2/m
ULS steel/segment 392 mm^2/segment Shear link
SLS steel 361.9 mm^2/m dia Nos
SLS steel/segment 506.7 mm^2/segment 12 10
Design Steel 506.7 mm^2/m 10 10
Please include bearing capacity check.
Included .
But which sheet to keep bearing check for radial joint or splitting check ??
Geoconsult Asia Singapore 06/10/2022

GEOCONSULT India Pvt Ltd APPENDIX -2
Job No.: I 6043

DESIGN AND CONSTRUCTION OF UNDERGROUND STATIONS AND TUNNEL
PROJECT FROM CHAINAGE 14328.88M TO CHAINAGE 11882.88M, INCLUDING EAST
RAMP, TWIN BORED UNDERGROUND TUNNEL,NATM TUNNEL, CUT AND
COVER PORTION AND TWO UNDERGROUND STATIONS KANKARIA EAST AND
KALUPUR STATION
Calculation for Maximum Ground Cover
INPUT
Geometry Lining Properties
Chainage = 10+135 Ec = 35355 MPa
GL = 118.78 m nc = 0.2
RL = 102.79 m d= 0.275 m
ro = 3.175 m b= 1m
dra = 2.10 m A= 0.275 m2
Taxis = 104.89 m I= 0.002 m4
13.89 m rm = 3.038 m
h= 0.957
s= 60.00 kPa
Soil Profile (up to Tunnel Axis)

Zw 24.40 m
Geo. Unit Z0 Z1 gs gw g' Z 0 * g'
m m kN/m 3
kN/m 3
kN/m3 kPa
Silt (ML) above GW 13.89 0.00 20.00 0.00 20.00 277.80
Silt (ML) below GW 0.00 0.00 20.00 0.00 20.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00
sz 277.80 kPa
g= 24.31 kN/m3
Eg = 72 MPa
ng = 0.3
K0 = 0.5
AHMEDABAD METRO-LINK RAIL PROJECT PHASE I Job No.: I 6043
CHAINAGE 14328.88M TO CHAINAGE 11882.88M, INCLUDING EAST RAMP, TWIN
PROJECT BORED UNDERGROUND TUNNEL,NATM TUNNEL, CUT AND COVER PORTION AND
Calculation for Maximum Ground Cover
Sectional Forces due to Earth Pressure neglecting shear stresses between extrados and ground
pv 337.8 kN/m2
p0 168.9 kN/m2
Rs 0.395
Mmax 73.509 kN.m/m
Nc 776.315 kN/m
Nb 832.457 kN/m
u0 3.690 mm
Thrust (Nep) kN/m Bending Moment (Mep) kN.m/m

Crown Nc 776.315 Mmax 73.509
Bench Nb 832.457 - Mmax -73.509
Invert Nc 776.315 Mmax 73.509
Sectional Forces due to Water Pressure
Hw -10.51
u Nw Mw
kPa kN/m kN.m/m
Crown -136.810 50.752 -48.203
Bench -105.06 16.799 54.929
Invert -73.31 127.701 -61.655
Resulting Sectional Forces
N M
kN/m kN.m/m
Crown 827.067 25.306
Bench 849.257 -18.580
Invert 904.016 11.854

Segmental Tunnel Design

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GEOCONSULT India Pvt Ltd APPENDIX - 3

A company of the GEOCONSULT group

AHMEDABAD METRO-LINK RAIL PROJECT PHASE I

Calculation for DEFINITIVE DESIGN OF SEGMENT LINING

1.3 Segment Geometry

Allowable Ovalisation = 1.00%

1.4 Segment Lining Properties

1.5 Gasket Properties

1.6 TBM Data

Shoe Length Ll = 1093 mm

2.0 TUNNEL LOADING AND FORCES

Maximum overburden occurs at CH. = 13440m

2.2 Ground Loading

Combined loading on tunnel (at tunnel centerline)

2.3 Curtis Equation

Sn/So = [λ(1-Q 3)]/[1+Q 3]ω

2.3.1 Unfactored Loads

2.3.2 Unfactored Radial Deformation

Ovalization Deofrmation =(Ur ,C nov + Ur ,C v)/2 = 0.46 mm

2.3.3 Factored Loads

2.3..4 Summary of Forces

2.4 Railway Loading

Width at the top level of first stage concrete = 3314 mm

Assumed density of trackslab = 25 KN/m3

4 RADIAL JOINT ROTATION

A company of the GEOCONSULT group

AHMEDABAD METRO-LINK RAIL PROJECT PHASE I

Calculation for DEFINITIVE DESIGN OF SEGMENT LINING

Assume segment rotates as rigid bodies

5 Overall Structural Buckling Check

DESIGN LOAD < BUCKLING LOAD HENCE SAFE

4.1.2 Unreinforced Curved Joint Design

Ultimate load at no eccentricity, (N uo)

Factored working hoop thrust across the joint , Pu = 781.529 KN

5 RADIAL JOINT (Curved, Reinforced)

Nuc = 5872.77476949 KN/m

5 CIRCUMFERENTIAL JOINT (Ram Load Capacity)

RAM LOAD CAPACITY SUFFICIENT

Calculations ignoring reinforcement

SHEAR CHECK SATISFIED

5.3 Segment Misalignment

A company of the GEOCONSULT group

AHMEDABAD METRO-LINK RAIL PROJECT PHASE I

Calculation for DEFINITIVE DESIGN OF SEGMENT LINING

6.2 Longitudinal Reinforcement

Percentage = [0.13 x 460]/415 = 0.13

Grout Pressure = = 246.15 KN/m2

6.4 Overall Structural Buckling Check

DESIGN LOAD > BUCKLING LOAD NOT SAFE

Mean Radius Rm = 3037.5 mm

7.1 Forces due to selfweight of individual segment

Resolve R into Fbolt and Fshear

Uplift Force, (per meter length of tunnel) Fu = 310.518 KN

Net Downward Force = Fd + 0.9Wc = 226.642 KN

Factor of safety against uplift = 0.72988594408