Design Check of Pipe Slab and Box Culverts

UECP-ICB-2B CONSTRUCTION OF KALUGANGA -
Project MORAGAHAKANDA TRANSFER CANAL(KMTC)

FROM 0+000 km TO 8+830 km Calc by CDM
Contract.No:
Component Culverts Date:22.03.2021
Reference Calculations Output
DESIGN CHECKS OF PIPE ENCASEMENTS, SLAB CULVERTS AND BOX CULVERTS
This report presents the detailed structural design checks of pipe encasement, slab culvert and box
culvert provided in the drawings. Most critical span and no soil cover loading scenario have been
considered for the sample verification.
1 References and Software
- EN 1990 : 2002 (EC0)

Basis of structural design
- EN 1991-1-1 : 2002 (EC1-1)

Actions on structures, General actions - Densities, self-weight, imposed loads for buildings
- EN 1991-2 : 2003 (EC1-2)

Action on structures, Traffic loads on bridges
- EN 1992-1-1 : 2004 (EC2-1)

Design of concrete structures - General rules and rules for buildings
- EN 1992-2 : 2005 (EC2-2)

Design of concrete structures - Concrete bridges design and detailing rules
- EN 206-1:2000
Concrete - Part 1: Specification, performance, production and conformity
- EN 197-1
Cement - Part 1: Composition, specifications and conformity criteria for common cements
- Sri Lanka National Annex to EN 1991 (SLNA EC1)
- Sri Lanka National Annex to EN 1992 (SLNA EC2)
- BS 8110 : 1997
Structural use of concrete
- Reinforced concrete design to Eurocodes (RCDE)

Prab Bhatt, Thomas J. MacGinley, Ban Seng Choo - 4th Edition
- Early - age thermal crack control in concrete (C660)

CIRIA C660 - London 2007
- PD 6687 - 1:2010 (PD6687)

Background paper to the National Annexes to BS EN 1992-1 and BS EN 1992-3
- Standard Method of Detailing Structural Concrete (IstructEM)

Institution of Structural Engineers UK
- Reinforcement Detailing to Mitigate Seismic Effects (RDMSE 2006)

Society of Structural Engineers Sri Lanka
- Foundation Analysis and Design (FAD)

Joseph E. Bowles, P.E., S.E - Fifth Edition
Page 1 of 27
Contract.No:
- Software
- PROKON 3.0
- Auto Cad 2016
- MS Excel 2013
2 Design Data and Parameters

2.1 Material Properties
3
EC1-Table A.1 Density of Concrete (ϒc) = 25 kN/m
Type of cement = Ordinary Portland Cement

CEM I according to EN 197
2.2 Durability Requirements
2.2.1 Bridge beams and slab
EC2-Table 4.1 Exposure class related to environmental conditions = XC2
EC2-Table E.1N Minimum strength class of concrete = C25/30

3
EN206- Table F.1 Minimum cement content = 280 kg/m
BS8007 Maximum Water to Cement ratio = 0.6
EC2-4.4.1.2(5) Structural class for design working life of 50 years = S4
Required design life = 100 years
Increasing structural class by 2 for design working life of 100 years
Structural class = S6
Reducing class by 2 considering member with slab geometry and special quality control of the concrete production
Design structural class = S4
EC2-Table 4.4N Minimum cover with regard to durability (cmin,dur) = 25 mm
SLNAEC2- Additive safety element (Δcdur,ϒ) = 0 mm

Table NA.1
EC2-Cl.4.4.1.2 Δcdur,st = 0 mm
(7),(8) Δcdur,add = 0 mm
EC2-Table 4.2 Minimum cover with regard to bond (cmin,b) = 25 mm
Eqn 4.2 Minimum cover (cmin) = max{cmin,b;cmin,dur+Δcdur,ϒ-Δcdur,st-Δcdur,add;10 mm}
= 25 mm
Page 2 of 27
Contract.No:
SLNAEC2- Δcdev = 10 mm
Table NA.1
Nominal cover (cnom) = cmin+Δcdev cnom
= 35 mm 35 mm
However, nominal cover of 50mm will be adopted as per the specification
EC2-Table 7.1N 2.3 Crack width control
Maximum allowable crack width for normal reinforced = 0.3 mm

concrete members with exposure class XC4
However, 0.25mm will be adopted as the limit of crack with as per the specification
Note-: Continuous - full restraint condition is considered for design. Hence, no movement joints are
provided and the crack widths and spacings are controlled by the provision of appropriate
reinforcement.
Page 3 of 27
Contract.No:
3 Main structural features of the components
275mm thick
3.1 Reinforced pipe encasement for 900mm dia pipe
200mm thick
175mm thick
** 0.9m assumed as the top slab span though it is actually less in the encasements
3.2 Slab Culvert
Page 4 of 27
Contract.No:
3.3 Box Culvert
Page 5 of 27
Contract.No:
4 Actions
4.1 Load cases and combinations
Gk - All permanent actions on the structure
Self weight of structural elements = This action will automatically be

calculated by the program based
on the assigned material densities
Table A.6 EC1-1 Weight of asphalt concrete layer (50mm thick) = 23*0.050
2
= 1.15 kN/m
Weight of ABC fill = 24*0.15
2
= 3.6 kN/m
Section 4 EC1-2 Traffic Loads
Vertical Loads
AASHTO HS 20 loading
Table 4.2 EC1-2
Wheel load = 72.5 kN
Load intensity at the wheel points = 72.5/(0.25*0.5)

2
= 580 kN/m
Cl. 4.4 EC1-2 Horizontal forces (HF)
Eqn 4.6
Qlk = 360+2.7*3
= 368 kN
Page 6 of 27
Contract.No:
EPU - External earth and water pressure under ultimate condition
It has been assumed that the ground water level may reach to the top of Finished Ground Level.
EC7-Eqn C.1 Lateral earth pressure on vertical = Ka[∫ϒdz+q-u]+u-cKac

wall σa(z)
where,
Ka = coefficient of effective horizontal active earth pressure
(conservatively calculate using Rankine Theory)
= (1-sinφ')/(1+sinφ')
Kac = 2√Ka
ϒ = total weight density of retained ground
z = distance down the top of the wall
q = vertical surface load
3
u = pore water pressure w = 10 kN/m
c = cohesion
EC7-1 using Design Approach 1 , Combination 2 (conservative)

2.4.7.3.4.2
A2 "+" M2 "+" R4
ϒφ' = 1.25
ϒc' = 1.25
ϒϒ = 1.00
ϒG = 1.00
ϒQ = 1.30
2.3.1.1 ofEC2-3 ϒw = 1.20
& Annex B EC1-4
Backfill Soil
φd'/(0) 24.79
cd'(kN/m2) 0
ϒ/(kN/m3) 19
Ka 0.41
Kac 1.28
Values of Lateral Earth Pressures on walls/ (kN/m2)
Backfill, Surcharge &

Wall
Ground Water
Pipe z = 0 z= 1.35
encasem 12.27 32.34 Surcharge = 30.00 kN/m2 due to vehicles
ent walls
Box z = 0 z= 3
culvert 12.27 56.87
walls
Page 7 of 27
Contract.No:
Note-: These loads are applied to the Prokon model as area loads on shell elements. Wall pressures will be
conservatively applied as uniform average pressure.
Combinations for ULS verification
Cl. 4.5 EC1-2 ULS1 - 1.35*Gk + 1.50*Qk + EPU
Combinations for SLS & Fatigue verification
SLS1 - 1.0*Gk + 1.0*Qk
Page 8 of 27
Contract.No:
5 Support Conditions
For pipe encasement and box culvert

2
Assumed bearing capacity = 150 kN/m
3
FAD- 9-6 Modulus of subgrade reaction ks = 40*(SF)*qa kN/m
= 40*3*150
3
= 18000 kN/m
Nodal spring constant Ki = ks * Contributing area kN/m
For 0.1m x 0.1m shell elements

Corner nodes = 45 kN/m
End nodes = 90 kN/m
Internal nodes = 180 kN/m
For slab culvert

Simply supportted end conditions are assumed
Page 9 of 27
Contract.No:
6.0 Analysis Results and Designs of Reinforced Pipe Encasement
Results presents for most severe load combination
6.1 Analysis results
Ultimate design moment maximum = 22.10 kNm/m
Page 10 of 27
Contract.No:
Ultimate design shear maximum = 85.60 kN/m
A wB
+0
B +C D+9 E+0. +2.
+8.
F +9.5+
+2.8
Page 11 of 27
Contract.No:
A wB
+0 6.2 Design
B +C D+9 F of Reinforced
E+0. +2.
+8. +9.5+ Pipe Encasement
+2.8
Section thickness - 275 mm

6.2.1 Z direction Reinforcement
Detailed calculations presented are for the location with most critical design forces.
Parameter Value
Cnom 25.00 mm
2
Main direction R/F H 10 @ 250 314 mm /m
2
Secondary direction R/F H 10 @ 250 314 mm /m
Design for ultimate condition
Design for Bending
Parameter Value
MEd 22.10 kNm/m
NEd 0.00 kN/m
b 1000.00 mm
h 275.00 mm
d 235.00 mm
2
fck 25.00 N/mm
fyk 500.00 N/mm2
2
k0 0.016 - MEd/bd fck
EC2-1-1 Cl.3.1.7 k0' 0.167 > k0 singly reinforced section
z 231.63
0.95d 223.25
zdesign 223.25
As(req),bending 227.57 mm2/m - MEd/0.87fykz
As(req),d.tension 0.00 mm2/m - N/0.87fyk
As(req),tension face 227.57 mm2/m - As(req),bending + As(req),d.tension/2 227.57 mm2/m
As(req),compression face 0.00 mm2/m - As(req),d.tension/2 0.00 mm2/m
Design for Shear
Parameter Value
VEd 85.60 kN/m
b 1000.00 mm
d 235.00 mm
vEd 0.36 N/mm2 - VEd/bd
CRd,c 0.12 - Cl. 6.2.2 EC2-1-1
k 1.92 - -do-
Asl 314.16 mm2/m - -do-
ρl 0.001 - -do-
fck 25.000 N/mm2
vRd,c 0.345 N/mm2 -do-
vRd,c,min 0.47 N/mm2 -do-
(vRd,c)final 0.47 N/mm2 > vEd OK
Page 12 of 27
Contract.No:
Design for Service Condition
Deflection
Parameter Value
K 1.30
ρ0 0.0050 - Cl.7.4.2 EC2-1-1
2
fck 25.00 N/mm
ρ 0.0010 - Cl.7.4.2 EC2-1-1
(l/d)limit 241.33 - -do-
(l/d)provided 3.83 < (l/d)limit OK
l - Width of slab = 900 mm
6.3 Design summary for Reinforced Encasement
2
Maximum area of reinforcement required for main = 227.57 mm /m
direction
Clause 9.2.1.1 Minimum reinforcements to be provided = 0.0013bd

= 305.5
Clause 9.3 & 7.3.2 Minimum to be provided for slabs with less severe brittle = 1.2*227.57
2
EC2-1-1 failure = 273.084 mm /m
Main reinforcement proposed = T10 @ 250

2
= 314 mm /m OK
2
Maximum area of reinforcement required in secondary = 142.89 mm /m
longitudinal) direction
Minimum to be provided = 227.57*20%

2
= 45.514 mm /m
Secondary reinforcement proposed = T10 @ 250

2
= 314 mm /m OK
Page 13 of 27
Contract.No:
7.0 Analysis Results and Designs of Slab Culvert
Page 14 of 27
Contract.No:
Page 15 of 27
Contract.No:
Service design moment maximum = 58.00 kNm/m
A wB
+0
B +C D+9 E+0. +2.
+8.
F +9.5+
+2.8
Page 16 of 27
Contract.No:
A wB
+0 7.2 Design
B +C D+9 F of Slab+2.8
E+0. +2.
+8. Culvert
+9.5
+

6.2.1 Main direction Reinforcement
Parameter Value
Cnom 50.00 mm
2
Main direction R/F H 20 @ 150 2094 mm /m
Secondary direction R/F H 16 @ 200 1005 mm2/m
Design for Bending
Parameter Value
MEd 86.00 kNm/m
NEd 0.00 kN/m
b 1000.00 mm
h 275.00 mm
d 215.00 mm 2
fck 25.00 N/mm
fyk 500.00 N/mm2
2
z 199.81
0.95d 204.25
zdesign 199.81
Design for Shear
Parameter Value
VEd 120.00 kN/m
b 1000.00 mm
d 215.00 mm 2
vEd 0.56 N/mm - VEd/bd
CRd,c 0.12 - Cl. 6.2.2 EC2-1-1
k 1.96 - -do-
Asl 2094.40 mm2/m - -do-
ρl 0.010 - -do-
fck 25.000 N/mm2
Page 17 of 27
Contract.No:
Deflection
Parameter Value
K 1.30
ρ0 0.0050 - Cl.7.4.2 EC2-1-1
fck 25.00 N/mm2
ρ 0.0046 - Cl.7.4.2 EC2-1-1
(l/d)limit 25.42 - -do-
Crack width due to service moment & direct tension
Parameter Value
Ms 58.00
Ns 0.00
b 1000.00
h 275.00
d 215.00
d' 56.00
As 2094
A's 1005
Es 200000.00 N/mm2 - Cl.3.2.7 EC2-1-1
2
Ecm 31000.00 N/mm - Table 3.1 EC2-1-1
φ(∞,t0) 3.00 - Cl.3.1.4 EC2-1-1
αe 25.81 - Cl.7.3.4 EC2-1-1
x 98.37 mm 2 - this value is obtained by solving a third order equation developed
fc 5.40 N/mm <0.45fck = 12.6N/mm2 OK Cl.7.2 EC2-1-1
2
fs 165.26 N/mm <0.8fyk = 400N/mm2 OK Cl. 7.2 EC2-1-1 Fatigue strength
kt 0.40 - Cl.7.3.4 EC2-1-1 verified
fct,eff = fctm 2.56 - -do-
ρp,eff 0.036 - -do-
εsm-εcm 0.000649 - -do-
k1 0.80 - -do-
k2 0.50 - -do-
k3 3.40 - -do-
k4 0.425 - -do-
φ 20.00 - -do-
c 66.00 - -do-
Sr,max 319.98 - -do-
Wk 0.208 < 0.25 mm OK
7.3 Design summary for Slab Culvert
2
direction for flexure
Clause 9.2 Minimum to be provided = 0.0013bd

2
EC2-1-1 = 279.5 mm /m
Page 18 of 27
Contract.No:

2
(to fulfill both ULS, SLS and Fatigue requirements) = 2094.9 mm /m OK
2

2
= 197.892 mm /m

2
(to fulfill both ULS, SLS and Fatigue requirements) = 1005 mm /m OK
Page 19 of 27
Contract.No:
8.0 Analysis Results and Designs of Box Culvert
Page 20 of 27
Contract.No:
Page 21 of 27
Contract.No:
Service design moment maximum = 40.00 kNm/m
A wB
+0
B +C D+9 E+0. +2.
+8.
F +9.5+
+2.8
Page 22 of 27
Contract.No:
A wB
+0 8.2 Design
B +C D+9 F of Box +2.8
E+0. +2.
+8. Culvert
+9.5
+

8.2.1 Main direction Reinforcement
Parameter Value
Cnom 50.00 mm
2
Z direction R/F H 20 @ 150 2094 mm /m
X direction R/F H 12 @ 200 565 mm2/m
Design for Bending
Parameter Value
MEd 45.00 kNm/m
NEd 0.00 kN/m
b 1000.00 mm
h 300.00 mm
d 240.00 mm 2
fck 25.00 N/mm
fyk 500.00 N/mm2
2
z 233.19
0.95d 228.00
zdesign 228.00
Design for Shear
Parameter Value
VEd 145.00 kN/m
b 1000.00 mm
d 240.00 mm 2
vEd 0.60 N/mm - VEd/bd
CRd,c 0.12 - Cl. 6.2.2 EC2-1-1
k 1.91 - -do-
Asl 2094.40 mm2/m - -do-
ρl 0.009 - -do-
fck 25.000 N/mm2
Page 23 of 27
Contract.No:
Deflection
Parameter Value
K 1.30
ρ0 0.0050 - Cl.7.4.2 EC2-1-1
fck 25.00 N/mm2
ρ 0.0019 - Cl.7.4.2 EC2-1-1
(l/d)limit 83.96 - -do-
Crack width due to service moment & direct tension
Parameter Value
Ms 40.00
Ns 0.00
b 1000.00
h 300.00
d 240.00
d' 56.00
As 2094
A's 1341
2
Es 200000.00 N/mm - Cl.3.2.7 EC2-1-1
Ecm 31000.00 N/mm2 - Table 3.1 EC2-1-1
φ(∞,t0) 3.00 - Cl.3.1.4 EC2-1-1
αe 25.81 - Cl.7.3.4 EC2-1-1
x 105.45 mm 2 - this value is obtained by solving a third order equation developed
2
fc 2.90 N/mm <0.45fck = 12.6N/mm OK Cl.7.2 EC2-1-1
fs 95.53 N/mm2 2
<0.8fyk = 400N/mm OK Cl. 7.2 EC2-1-1 Fatigue strength
kt 0.40 - Cl.7.3.4 EC2-1-1 verified
fct,eff = fctm 2.56 - -do-
ρp,eff 0.032 - -do-
εsm-εcm 0.000287 - -do-
k1 0.80 - -do-
k2 0.50 - -do-
k3 3.40 - -do-
k4 0.425 - -do-
φ 20.00 - -do-
c 62.00 - -do-
Sr,max 316.08 - -do-
Wk 0.091 < 0.25 mm OK
8.3 Design summary for Box Culvert
2
direction for flexure
Clause 9.2 Minimum to be provided = 0.0013bd

2
EC2-1-1 = 312 mm /m
Page 24 of 27
Contract.No:

2
(to fulfill both ULS, SLS and Fatigue requirements) = 2094.9 mm /m OK
2

2
= 90.744 mm /m

2
(to fulfill both ULS, SLS and Fatigue requirements) = 565 mm /m OK
Page 25 of 27
Contract.No:
9.0 Design of Retaining Walls
2.5m high
4.0m high
Page 26 of 27
Contract.No:
5.0m high
Page 27 of 27

Design Check of Pipe Slab and Box Culverts

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UECP-ICB-2B CONSTRUCTION OF KALUGANGA -

Project MORAGAHAKANDA TRANSFER CANAL(KMTC)

DESIGN CHECKS OF PIPE ENCASEMENTS, SLAB CULVERTS AND BOX CULVERTS

1 References and Software

- EN 1990 : 2002 (EC0)

- EN 1991-1-1 : 2002 (EC1-1)

- EN 1991-2 : 2003 (EC1-2)

- EN 1992-1-1 : 2004 (EC2-1)

- EN 1992-2 : 2005 (EC2-2)

- Sri Lanka National Annex to EN 1991 (SLNA EC1)

- Sri Lanka National Annex to EN 1992 (SLNA EC2)

- Reinforced concrete design to Eurocodes (RCDE)

- Early - age thermal crack control in concrete (C660)

- PD 6687 - 1:2010 (PD6687)

- Standard Method of Detailing Structural Concrete (IstructEM)

- Reinforcement Detailing to Mitigate Seismic Effects (RDMSE 2006)

- Foundation Analysis and Design (FAD)

2 Design Data and Parameters

Type of cement = Ordinary Portland Cement

2.2 Durability Requirements

2.2.1 Bridge beams and slab

EC2-Table 4.1 Exposure class related to environmental conditions = XC2

EC2-Table E.1N Minimum strength class of concrete = C25/30

EC2-4.4.1.2(5) Structural class for design working life of 50 years = S4

Required design life = 100 years

Increasing structural class by 2 for design working life of 100 years

Design structural class = S4

EC2-Table 4.4N Minimum cover with regard to durability (cmin,dur) = 25 mm

SLNAEC2- Additive safety element (Δcdur,ϒ) = 0 mm

EC2-Table 4.2 Minimum cover with regard to bond (cmin,b) = 25 mm

Eqn 4.2 Minimum cover (cmin) = max{cmin,b;cmin,dur+Δcdur,ϒ-Δcdur,st-Δcdur,add;10 mm}

However, nominal cover of 50mm will be adopted as per the specification

EC2-Table 7.1N 2.3 Crack width control

Maximum allowable crack width for normal reinforced = 0.3 mm

3.2 Slab Culvert

4.1 Load cases and combinations

Gk - All permanent actions on the structure

Self weight of structural elements = This action will automatically be

Load intensity at the wheel points = 72.5/(0.25*0.5)

Cl. 4.4 EC1-2 Horizontal forces (HF)

EC7-Eqn C.1 Lateral earth pressure on vertical = Ka[∫ϒdz+q-u]+u-cKac

EC7-1 using Design Approach 1 , Combination 2 (conservative)

Values of Lateral Earth Pressures on walls/ (kN/m2)

Backfill, Surcharge &

Combinations for ULS verification

Cl. 4.5 EC1-2 ULS1 - 1.35*Gk + 1.50*Qk + EPU

Combinations for SLS & Fatigue verification

SLS1 - 1.0*Gk + 1.0*Qk

For pipe encasement and box culvert

For 0.1m x 0.1m shell elements

For slab culvert

Results presents for most severe load combination

6.1 Analysis results

Ultimate design moment maximum = 22.10 kNm/m

Section thickness - 275 mm

Design for ultimate condition

Design for Bending

As(req),compression face 0.00 mm2/m - As(req),d.tension/2 0.00 mm2/m

Design for Shear

Cl. 4.5 EC1-2 ULS1 - 1.35Gk + 1.50Qk + EPU

SLS1 - 1.0Gk + 1.0Qk