SOUTHERN RAILWAY

PROPOSED CONSTRUCTION OF RUBs IN LIEU OF

LC NO. 293A AT KM 882/700-800
DESIGN OF THRUST BED

DATE: NOTE NO.: REV.: SHEETS:

OCT-22 GRAVITAS/VIJAYA/RUB/293A 1 12

Submitted By

SUBMITTED TO
 1.0 DESIGN DATA: Working Limit
1.1 Concrete mix M: 25
Grade of steel Fe 500
σcbc = 11.5 N/mm² 35 N/mm²
σst = 278 N/mm² 500 N/mm²
τcmax = 2.3 N/mm² N/mm²
σcc = 9 N/mm² N/mm²
1.2 Nos. of track = 0 Nos. Relieving gdr.
Earth cushion (Including artificial embankment)= 1.03 m
Earth cushion (Below natural ground lvl.)= 0.35 m
Ballast cushion = 0.3 m
Soil density = 1.8 T/m³
Angle Φ for soil surrouding Box = 30 °= 0.524 Radian (Assumed)
Co-efficient of fric'n bet'n found'n & Thrust-bed = 0.4
Co-efficient of fric'n bet'n box Sides & sournding soil = 0.7
Co-efficient of fric'n bet'n Drag sheet & top soil = 0.2
Angle Φ for stacked loose soil= 1 °= 0.017 Radian (Assumed)
Factor of safety for passive resistance = 1
Reduction Factor for Active press. in case of rock(Fr) = 1
SBC of rock in case passive is taken from rock = 25 T/m2
Put "0" if passive from rock ,otherwise "1" = 1

Details of Main Thrust-Bed

1.3 Thrust bed length L = 12.5 m
Thrust bed width W = 23.5 m
Thrust bed depth = 0.8 m
Pocket no. across L = 5 Nos.

c/c Pocket across L = 1.8 m

Pocket no. along L = 6 Nos.
c/c Pocket along L = 2.05 m
Pocket size in plan = 0.5 m
Pocket depth = 6 m

1.4 BOX PROPERTIES

a. Overall span of box = 10.5 m
b. Thickness of horizontal slab = 0.75 m
c. Clear height of box = 5.35 m
d. Thickness of outer walls = 0.6 m
e. Thickness of inner walls = 0 m
f. Haunch size = 0.5 m
g. Overall Pushing length of box = 9 m
h. Length of one segment of box = 9 m
i. Nos. of segment = 1 Nos

j. Nos. of inner walls = 0 Nos

k. Embankment width at top = 27 m
l. Length of cutting edge at top = 0.01 m
m. Length of cutting edge at botom = 0.01 m
1.5 THRUST WALL DETAILS
a Height above Thrust bed = 0.5 m
b Width above Thrust bed = 0.65 m

1.6 ASSUMPTIONS
(a) No pushing when train passing on the box or standing on wall
(b) Excaved soil to be stacked beyond Thrust wall so as to provide surcharge pressure.
(c) No jack reaction to be taken from Thrust-wall
(d) In case of rock below box, dry sand layer is used as lubricating agent to reduce friction.
(e) Actually 1 : 1 slope can be maintained in cutting but for safer side angle is reduced.

.
MAIN BED OUTPUT SHEET

1) Total jacking force required = 703.7 T

2) Total resistance provided = 510.1 T
3) Bending moment to be developed in each pocket = 121.338 Tm
4) Moment of resistance of pocket = 2673.000 Tm

REINFORCEMENT DETAILS ( MAIN )

PROVIDED
Bar Mark BAR DIA SPACING
a 20 200
g 20 150
j 20 150

REINFORCEMENT DETAILS ( DISTRIBUTION )

PROVIDED
Bark Mark BAR DIA SPACING
h 10 150
k 10 150
 7) SHEAR REINFORCEMENT IN THRUST WALL (d )

Assuming 141 legged stirrups for complete width

DIA SPACING MM
10 150

CALCULATIONS
2.0 LOADING

2.1 Surface area of box:

Perimeter of box = 2 x (Overall height + Overall span)

=2x(10.5+0.6+5.35+0.75)=
34 m

Surface area = Length of segment x Perimeter of box

=9x34.4=
310
2.2 Load on top surface

(a)   P-way:- For Broad gauge 6.2 tonne /mt. run distributed on 3 mt at formation lvl.

Distribution width at top of box =3+10.5x0.5+1.03= 9.3 m

P-way load in T/m sq. will be =6.2/9.28x0= 0 T/m
2

=0x10.5= 0 T/Rmt

(b) Earth cushion = =1.8x1.03x10.5= 19 T/Rmt

2.3 Load on the bottom surface

(a) Self weight of box :

Volume of box = Volume of horizontal slab + Volume of outer walls

+ Volume of internal walls + Volume of haunch
=(2x10.5x0.75)+(2x5.35x0.6)+(2x0.5x0.5)+(0x0x5.35)=
22.67 cum. / m
Self Weight =22.67x2.5= 57

(b) Reaction due to load on top = 19.467 T/Rmt

Total Load =19.467+56.675= 76.142 T/Rmt

2.4 ACTIVE EARTH PRESSURE ON WALLS

f = 0.5 rad i= 0 rad

a = 0 rad d = 0.2 rad

Ka = Coefficient of active earth pressure = 0.308

Kah = Ka cos d = 0.303

(a) Intensity of earth pressure at top of box:

= Kah x W x H x Fr =0.303x1.8x(1.03+0.3)= 0.7 T/Mt.²

(b) Intensity of earth pressure at bottom of box:

=0.303x1.8x(1.03+0.3+0.75+5.35+0.75)=
4.5 T/Mt.²

Total Earth Pressure on walls =

18 T/Rmt

2.6 DIAGRAM FOR LOADING ON WALLS

0 T/Rmt

18
T/Rmt 18 T/Rmt

76.142 T/Rmt

3.0 JACKING FORCE REQUIRED

Side Length with cutting edge = 9

Top Length with cutting edge = 9
Bottom Length with cutting edge= 9

= μ x (Force on box side x Length of segment side including cutting edge)

=0.7x(0x9+2x17.782x9+76.142x9)=
= 704 T

As " Drag-sheet" is to be used on top of box ,m will be less than 0.4

This force will be provided by self weight of thrust bed, thrust wall and shear keys. Remaining will
be provided by passive resistance of thrust wall and shear keys.
3.1 SELF WEIGHT OF THRUST BED

Volume of thrust bed = Volume of thrust bed - Volume of pockets

=12.5x23.5x0.8-5x6x0.5x0.5x6=
190 cum.

Weight of thrust bed =2.5x(0+190)= 475 T

Factored weight for design (x1.25)= 594 T

3.2 SELF WEIGHT OF THRUST WALL

Wt. of thrust wall=2.5x((0.5x0.65x23.5)+0.5x(0+0)x0x23.5)= 19 T

Factored weight for design (x1.25)= 24 T

3.4 RESISTANCE OF SHEAR DOWELS:

kp = 4.3

Passive resistance = 875 T

Factored passive resistance (x1.7)= 1487.5 T

3.5 TOTAL RESISTANCE OFFERED

= m x (Thrust bed wt. + Thrust wall wt. + Shear key wt.) + Passive resistance by thrust wall and
shear keys
=0.4x(475+19.094+0)+0+875=
1072.638 T

Total resistance offered 1072.64

Factor of safety for sliding = Total jacking force required
= = 1.52418 > 1.5
703.75
OK

STRUCTURAL DESIGN BASED ON LIMIT STATE

4.0 LOADING

4.1 Surface area of box:

Perimeter of box = 2 x (Overall height + Overall span)

=2x(10.5+0.6+5.35+0.75)=
34 m

Surface area = Length of segment x Perimeter of box

=9x34.4=
310 sq.m.
4.2 Load on top surface

(a)   P-way:- For Broad gauge 6.2 tonne /mt. run distributed on 3 mt at formation lvl.

Distribution width at top of box = =3+10.5x0.5+1.03= 9.3 m

P-way load in T/m sq. will be = =6.2/9.28x0= 0 T/m
2

=0x10.5x2= 0 T/Rmt (FOS for SIDL is 2)

(b) Earth cushion = =1.8x1.03x10.5x1.25= 24 T/Rmt (FOS for Soil is 1.25)

4.3 Load on the bottom surface

(a) Self weight of box :

Volume of box = Volume of horizontal slab + Volume of outer walls

+ Volume of internal walls + Volume of haunch
=(2x10.5x0.75)+(2x5.35x0.6)+(2x0.5x0.5)+(0x0x5.35)=
22.67 cum. / m
Self Weight =22.67x2.5x1.25= 71 T/Rmt

(b) Reaction due to load on top = 24.334 T/Rmt

Total Load =24.334+70.844= 95.178 T/Rmt

4.4 ACTIVE EARTH PRESSURE ON WALLS

f = 0.5 rad i= 0 rad

a = 0 rad d = 0.2 rad

Ka = Coefficient of active earth pressure = 0.308

Kah = Ka cos d = 0.303

(a) Intensity of earth pressure at top of box:

= Kah x W x H x Fr =0.303x1.8x(1.03+0.3)x1.7=1.2 T/Mt.² (FOS 1.7)

(b) Intensity of earth pressure at bottom of box:

=0.303x1.8x(1.03+0.3+0.75+5.35+0.75)x1.7=
7.6 T/Mt.² (FOS 1.7)

Total Earth Pressure on walls =

30 T/Rmt

4.5 DIAGRAM FOR LOADING ON WALLS

0 T/Rmt

30
T/Rmt 30 T/Rmt

95.178 T/Rmt
4.6 JACKING FORCE REQUIRED

Side Length with cutting edge = 9

Top Length with cutting edge = 9
Bottom Length with cutting edge= 9

= μ x (Force on box side x Length of segment side including cutting edge)

=0.7x(0x9+2x30.229x9+95.178x9)=
= 980.5081 T

As " Drag-sheet" is to be used on top of box ,m will be less than 0.4

This force will be provided by self weight of thrust bed, thrust wall and shear keys. Remaining will

4.7 DESIGN OF THRUST WALL

Resistance offered by thrust wall

= μ x Weight of Box

=0.4x56.675x1.5x9/1.25=
= 244.836 T

Effective Depth Required (d) = 𝑀𝑢 = 1.22E+08 = 188.3706 mm

=
0.138 × 𝑓𝑐𝑘 × 𝑏 3450

Provided Depth = 575 mm > 188 mm OK

0.5𝑓𝑐𝑘 𝑏 𝑑 4.6𝑀𝑢
Ast for under-reinforced section = 1− 1− = 498 mm^2
𝑓𝑦 𝑓𝑐𝑘 𝑏 𝑑

Min Steel (0.2%) = 1300 mm^2

Check for Mu as per CBC Railway cl. 15.4.2.2

Mu = 0.87fyAst Z 1.76E+08

= 546.4

z= 0.95d = 546

Level arm (z) = 546 mm

Mu = 0.87fyAst Z = 30.89044 Tm/m > 12.2418 Tm/m OK

Spacing of 20 mm dia steel on tension side = 241.5385 mm c/c

(in one layer) say 200 mm c/c a

Use 0.12% steel on compression side parallel to main reinforcement = 780 mm^2
 CHECK FOR SHEAR AT BOTTOM OF STEM

Factor shear on wall = 245 T

= 21 T/m

Ultimate shear (Vu) = 21 T/m

Shear stress ' v ' = Vu/bd = 0.4 Mpa

Permissible shear stress as per table 15 & 16 of CBC = 0.4 Mpa for M25 and % Steel

0.362384 Mpa < 0.383 Mpa OK

Shear reinforcement is given by CBC Cl.15.5.4.1.1

Use 6 legs/m 10 mm dia.

sv = Asv0.87fyv = 189 mm
b(v+0.4*Svc)

Provide 6 legs/m 10 mm dia. at 150 mm c/c

4.8 DESIGN OF MAIN THRUST BED

Total jacking force required = 980.5081 T

The jacking force will be provided by 4 pins and is applied at 150 mm above bed

Jacking force/pin = Total force/Nos. of pins across length

=980.508/4= 245 T

Lever arm = Half dia. of jack + Half depth of pocket + Packing plate thickness
L/arm = 0.495 m

B. M. = Jacking force/pin x Lever arm

=245.127x0.495=
= 121

Supporting area of pins = Half the pocket depth x c/c of pockets

=6x0.5x1.8=
= 5.4 m^2

Maximum force to be developed in bearing on pocket sides

= Supporting area of pins x 0.4 fck ( Cl. 15.6.3.3 of CBC for 0.4fck)
=5.4x10^6x0.4x25/10000=
5400 kN

Lever arm = 0.495 m

Moment of resistance of pocket =Maximum force x Lever arm

=5400x0.495=
2673 Tm > 121 OK
REINFORCEMENT FOR THRUST BED

Maximum B. M. = Total jacking force x lever arm

=980.508x0.495=
= 485 Tm

Effective Depth Required (d) = 𝑀𝑢 = 4.85E+09 = 245 mm

=
0.138 × 𝑓𝑐𝑘 × 𝑏 81075

Provided Depth = 725 mm > 245 mm OK

0.5𝑓𝑐𝑘 𝑏 𝑑 4.6𝑀𝑢
Ast for under-reinforced section = 1− 1− = 667.4979 mm^2
𝑓𝑦 𝑓𝑐𝑘 𝑏 𝑑
(for the full width)

Min Steel (0.2%) = 37600 mm^2

Check for Mu as per CBC Railway cl. 15.4.2.2

Mu = 0.87fyAst Z

= 689.8

z= 0.95d = 689

Level arm (z) = 689 mm

Mu = 0.87fyAst Z = 1126.52 Tm > 485.3515 Tm OK

Thrust bed is also provided with steel equally distributed at top and bottom to
withstand 1/3 of total jacking force which is in axial tension.
Reinforcement required for axial tension = 1/3 jacking force/0.87fy
=980.508x10000/(3x0.87x500)=
= 7513.472 mm^2

Half the steel is provided at top and half at bottom = 3756.736 mm^2
Total Steel required at bottom of thrust bed = 4424.234 mm^2
Provide Steel = 37600 mm^2

Spacing of 20 mm dia steel on tension side = 196.25 mm c/c

(in one layer) say 150 mm c/c g

Steel required at top of thrust bed = 37600 mm^2

Use 0.12% steel on compression side parallel to main reinforcement = 0 mm^2
Steel required at top of thrust bed ( Max of above two ) = 37600 mm^2

Spacing of 20 mm dia steel on tension side = 196.25 mm c/c

(in one layer) say 150 mm c/c j
 DISTRIBUTION STEEL
Use 0.12% steel on compression side parallel to main reinforcement = 11280 mm^2
Reinforcement on each surface = 5640 mm^2

Spacing of 10 mm dia steel on tension side = 327.0833 mm c/c

(in one layer) say 150 mm c/c

5.1 DESIGN OF DOWELS

As all the forces are already taken by thrust wall, no force is coming on shear walls.
Even though same passive pressure intensities (i.e. of thrust wall) are considered
for shear keys main steel will be less than minimum required.

Resistance offered by Thrust wall (Due to passive force of earth)= 875 T

Resistance offered by all shear keys(Due to passive force )= 875 T
No of Rows of Dowels = 6
Resistance offered by each row of dowels= 145.8333 T

Shear resistance of single dowel = 0.87*fy*Ast/sqrt(3) = 20.18823 T

Bearing resistance of concrete = 0.4*25*32*500/3 = 6.4 T
(With FOS of 3)
No. of dowels required in each row =145.833/6.4= 23

No of Rows of dowels = 6

Therefore, provide 26 dowels in 9 layers with grout of 60mm

5.2 CHECK FOR BEARING AT JACKING POINT LOCATION

=703.747/5=
Maximum jacking force per pocket 140.75 T
Diameter of jack = 300 mm

As 10 mm plate is provided with 450 mm width and 7000 mm in length;

the jacking force will be distributed on 450 x 450 mm area

Surface reinforcement of 10 mm @ 40 mm c/c (two mesh) is also provided

behind plate

Bearing Pressure =140.749x10000/(450x450)=

7 Mpa < 9 Mpa OK
(Allowable bearing stress)
In additional to protect concrete edges steel plate is attached to jacking point.
Two mesh of #10 mm @ 50 mm c/c. bothways are provided behind plate .
Additional stirrups & steel shown in drawing.