Vertical Gates Design

ADO CONMAT INDIA

PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 1

Design of Vertical Lift Service Gates of

Budaun Irrigation Project

1.0 Technical Details :

No of gates required : 25Nos

Clear vent width : 18000mm

Clear vent height : 6200mm

Height of gate : 6500mm

Sill level : EL 157.100M

Pond level : EL 163.300M

HFL : EL 164.300M

Type of gate : Regulating

Top of pier : EL 167.000M

Design head FRL : 6.2M

HFL : 7.2M

Location of skin plate : Up stream

Location of seal : Up stream

Side seal C/C : 18150mm

Track C/C : 18700mm

End to end of groove : 19200mm

Hoisting speed : 0.3 to 0.7M/min

Designed : As per IS 4622 - 2003

2.0 Material:

ADO CONMAT INDIA


S No. Components Proposed Remarks

1

All structural members like skin plate, end

box, vertical stiffeners, horizontal girders,

Roller track girder, Sill beam seal Crest etc.,

Structural SteelIS : 2062 - 2006

Grade E250 QualityB

2 Rollers and Guide Rollers Cast Steel IS 1030

3 Roller pins and Guide Roller Pins Stainless Steel30Cr13

IS : 1570 (Part V)

4 Roller Track Stainless Steel20Cr13

IS : 1570 (Part V)

5 Seal Seats Stainless Steel04 Cr18 Ni 10

IS : 1570 (Part V)

6 SealsSynthetic or

Natural RubberIS : 11855

7 BearingsAnti Friction

BearingsSKF / FAG / NSK / ZKL

3.0 Permissible Stresses: As per IS:4622 - 2003

I. Embedded Parts & Gate Leaf – As per IS 4622 - Wet and Inaccessible condition

1. Structural steel – IS 2062 – 2006 Grade E250 Quality B

S.No Type of stresses Factor

Stresses in kg/cm2

Thk < 20mm

YP :2550kg/cm2

UTS:4180kg/cm2

Thk 20 – 40mm

YP : 2448kg/cm2

UTS:4180kg/cm2

1 Direct compression and

compression in bending

0.40YP 1020 979

2 Direct tension and tension in

bending

0.40YP 1020 979

3 Shear Stress 0.30YP 765 734

4 Combined stress 0.50YP 1275 1224

5 Bearing stress 0.45YP 1147 1102

C. Bearing stress in concrete = M – 250 – 62kg/cm2

4.0 Groove Details :

ADO CONMAT INDIA


4.0 Design of Gate Leaf :

ADO CONMAT INDIA


The gate leaf is designed as vertical lift roller gate made out of single Gate

with two elements connected with flexible joint. Each element is fitted with 4 rollers

working on self aligned spherical roller bearing mounted on stainless steel axle. The

axle is made with eccentricity of 5mm for fine adjustment at later date if required.

The U/S skin plate is fitted with Bulb type of molded rubber seals for sides and top,

flat type of rubber seals for bottom for water tightness.

The gate is being operated with Rope drum hoist of adequate capacity.

As per specification the gate is to be designed for FRL and to be checked for HFL

condition allowing 1.333 times of permissible stresses as per IS 4622.

C / C of side seals : 18150mm

C/C of tracks : 18700mm

Height of gate : 6500mm

Design Head FRL : 6.20M

HFL : 7.20M

Water thrust on the gate FRL = wLH2 / 2 = 1 X 18.15 X6.202 / 2 = 348.843t

HFL = wLh (H – h / 2) = 1 X 18.15 X 6.5 (7.2 – 6.5/ 2)

= 466.001t

% increase of load under HFL over FRL

= ((466.001 – 348.843) / 348.843) X 100 = 33.58% > 33⅓ %

Element Size

FRL Condition HFL Condition % of Increase

HFL Over

FRL

RemarksHead Thrust Head Thrust

Bottom 18.15X2.0 6.20 188.760t 7.20 225.06 19.2%<33⅓ % Designed for FRL

Top 18.15X4.5 4.20 160.083t 5.20 240.941 50.5%>33⅓ %

Designed for HFL

condition with

increased stresses

4.1 Design of Bottom Element :

4.1.1 FRL condition :

ADO CONMAT INDIA


C/C of seals : 18.15M

RA = 94.238t

RB = 94.522t

4.1.2 HFL condition :


RA = 110.075t

RB = 114.985t

4.2 Design of Top Element :

4.2.1 FRL condition :


RC = 94.964t

RD = 65.119t

4.2.2 HFL condition :


RC = 114.553t

RD = 126.389t

4.3 Design of Horizontal Girders :

ADO CONMAT INDIA


ConditionLoad on Girder ‘A’

in t

Load on girder ‘B’

in t

Load on girder ‘C’

in t

Load on girder

‘D’ in t

FRL 94.238 94.522 94.964 65.119

HFL 110.075 114.985 114.553 126.389

% of increase of

HFL over FRL16.80%<33⅓ % 21.65%<33⅓ % 20.6%<33⅓ % 94%>33⅓ %

Girder ‘A’, ‘B’ and ‘C’ is designed for FRL condition and Girder ‘D’ is designed for

HFL condition

4.3.1 Design of Horizontal Girder ’A’ : (Designed for FRL condition)

Load on horizontal girder ‘A’ = 94964kg

RA = RB = 47482kg

BM = (94964 / 8) (2 X 1870 – 1815) = 22850713kgcms.

It is proposed to provide skin plate out of 16mm plate. After allowing corrosion

allowance of 1.5mm, the effective thickness is 14.5mm.

The Co-acting width:

L = 1870cm B1 = 103 / 2 = 51.5cm B2 = 42cm

L / B1 = 1870 / 51.5 = 36.31 V1 = 0.98

L / B2 = 1870 / 42 = 44.5 V2 = 0.86

Co-acting width = V1 B1 + V2 B2 = 0.98 X 51.5 + 0.86 X 42 = 88.74cm

But as per IS 800 – 1984 cl : 3.5.2.1 the Max. co-acting width of skin plate is 20t to

the innermost face of the stiffening.

Co-acting width = 40t + B = 40 X 1.45 + 30 = 88cm

Sectional properties are as follows:

ADO CONMAT INDIA


Area = 482.8cm2

IXX = 2705560cm4

Z1 = 35175cm3

Z2 = 35849cm3

Z3 = 24747cm3

i) Bending stress on U/S of skin plate = 22850713 / 35175 = 650kg/cm2 < 1020kg/cm2

ii) Bending stress on D/S of skin plate =22850713 / 35849 = 637kg/ cm2 < 1020kg/cm2

iii) Bending stress on D/S of flange =22850713 / 24747 = 923kg/ cm2 < 1020kg/cm2

iv) Shear stress = 47482 / (74.3 X 1.2) = 532.5kg/cm 2 < 765kg/cm2

Check for deflection :

Permissible deflection = L / 800 = 1870 / 800 = 2.337cms.

Actual deflection

= [94964 / (384 X 2047000 X 2705560)] [8 X 18703– 4X1870 X 18152 X 18153]

= 1.582cm < 2.337cm.

Design of Welds :

Weld strength required between Skin Plate and U/S Flange :

F1 = S A y / 2 I = (47482 X 88 X 1.45 X 76.195) / (2 X 2705560) = 85kg/cm length

Proposed 6mm fillet having strength of 0.7 X 0.6 X 765 = 321kg/cm length

Weld strength required between Web and U/S flange :

F2 = [47482 X (88 X 1.45 + 30 X 1.6) X 75.45] / (2 X 2705560) = 116kg/cm length

Proposed 6mm fillet having strength 321kg/cm length

Weld strength required between Web and D/S flange :



Weld strength required between D/S flanges :

F4 = (47482 X 27 X 1.6 X 108.23) / (2 X 2705560) = 50kg/cm length

ADO CONMAT INDIA



4.3.2 Design of Horizontal Girder ’B’ : (Designed for FRL condition)

Load on horizontal girder ‘B’ = 94522kg

RA = RB = 47261kg

BM = (94522 / 8) (2 X 1870 – 1815) = 22744356kgcms. It is proposed to provide skin plate out of 16mm plate. After allowing corrosion


Co-acting width :

L = 1870cm B1 = 103 / 2 = 51.5cm B2 = 50cm

L / B1 = 1870 / 51.5 = 36.31 V1 = 0.98

L / B2 = 1870 / 50 = 37.4 V2 = 0.86

Co-acting width = 0.98 X 51.5 + 0.86 X 50 = 93.47cm





Area = 482.8cm2

IXX = 2705560cm4

Z1 = 35175cm3

Z2 = 35849cm3

Z3 = 24747cm3



ADO CONMAT INDIA


iii) Bending stress on D/S of flange = 22744356 / 24747 = 919kg/ cm2 < 1020kg/cm2

iv) Shear stress = 47261 / (74.3 X 1.2) = 530kg/cm 2 < 765kg/cm2



Actual deflection

= [94522 / (384 X 2047000 X 2705560)] [8 X 18703– 4X1870 X 18152 X 18153]

= 1.492cm < 2.337cm.

Design of Welds :













4.3.3 Design of Horizontal Girder ’C’ : (Designed for FRL condition)

Load on horizontal girder ‘A’ = 94964kg

RA = RB = 47482kg

BM = (94964 / 8) (2 X 1870 – 1815) = 22850713kgcms.

It is proposed to provide skin plate out of 12mm plate. After allowing corrosion


ADO CONMAT INDIA


Co-acting width:

L = 1870cm B1 = 236 / 2 = 118cm B2 = 44cm

L / B1 = 1870 / 118 = 15.84 V1 = 0.955

L / B2 = 1870 / 44 = 42.5 V2 = 0.86

Co-acting width = 0.955 X 118 + 0.86 X 44 = 150cm





Area = 482.8cm2

IXX = 2705560cm4

Z1 = 35175cm3

Z2 = 35849cm3

Z3 = 24747cm3




iv) Shear stress = 47482 / (74.3 X 1.2) = 533kg/cm2 < 765kg/cm2



Actual deflection

= [94964 / (384 X 2047000 X 2705560)] [8 X 18703– 4X1870 X 18152 X 18153]

ADO CONMAT INDIA


= 1.550cm < 2.337cm.

Design of Welds :













4.3.4 Design of Horizontal Girder ’D’ :

Load under FRL = 65.119t

Load under HFL = 126.289t

Load equivalent to FRL under HFL = 126.289 / 1.33 = 94.954t

It is proposed to design for FRL equivalent load of 94.954t

Load on horizontal girder ‘D’ = 94954kg

RA = RB = 47977kg

BM = (94954 / 8) (2 X 1870 – 1815) = 22848306kgcms. It is proposed to provide skin plate out of 16mm plate. After allowing corrosion


Co-acting width:

L = 1870cm B1 = 236 / 2 = 118cm B2 = 170cm

L / B1 = 1870 / 118 = 15.84 V1 = 0.955

L / B2 = 1870 / 170 = 11 V2 = 0.76

ADO CONMAT INDIA


Co-acting width = 0.955 X 118 + 0.76 X 170 = 242cm





Area = 482.8cm2

IXX = 2705560cm4

Z1 = 35175cm3

Z2 = 35849cm3

Z3 = 24747cm3


ii) Bending stress on D/S of skin plate = 22848306 / 35849 = 637kg/ cm2 < 1020kg/cm2





Actual deflection

= [94954 / (384 X 2047000 X 2705560)] [8 X 18703– 4X1870 X 18152 X 18153]

= 1.518cm < 2.337cm.

ADO CONMAT INDIA


Design of Welds :













4.4 Design of End Box :

The disposition of rollers and horizontal girders are as shown.

4.4.1 Bottom Element :

i) FRL condition :

RA = 94.162t

RB = 94.598t

Max. Roller load = 94.162 / 2 = 47.299t 47.3t

Bending Moment = 94522 X 18 = 1701396kgcm

ii) HFL condition :

RA = 108.756t

RB = 116.304t

Max. Roller load = 116.304 / 2 = 58.152t

Equivalent FRL load = 58.152 / 1.33 = 43.723t


ADO CONMAT INDIA


4.4.2 Top Element :

i) FRL condition :

RA = 97.650t

RB = 62.433t

Max. Roller load = 97.650 / 3 = 48.825t 48.9t say 50t


ii) HFL condition :

RA = 113488kg

RB = 127454kg

Max. Roller load = 127.454 / 2 = 63.727t

Equivalent FRL load = 63.727 / 1.33 = 47.9t 48.0t


Proposed 785 X 16mm plate for end box.

ZXX = (4 X 1.6 X 542) / 6 = 3110cm3

Bending stress FRL = 1709352 / 3100

= 551kg/cm2 < 1020kg/cm2

HFL = 2275002 / 3100

= 734kg/cm2 < 1527kg/cm2

Max. Roller load = 50,000kg

Shear stress FRL = 50000 / (2 X 54 X 1.6)

= 289kg/cm2 < 765kg/cm2

Bearing stress FRL = 50000 / (2 X 8 X 2.8) = 1116kg/cm2 < 1147kg/cm2

4.5 Design of Roller :

Max Roller load FRL = 50t

Material cast steel IS : 1030 Grade 340 - 570W

Permissible stress = 1.6 X 570 X (10.2 / 1000) = 9.30t/cm2

Proposed 450 X 130mm tread width roller.

C = 0.418 (50.00 X 2047) / (22.5 X 13) = 7.82t/cm2 < 9.30t/cm2

ADO CONMAT INDIA


4.6 Design of Bearings :

Max. Roller load = 50000kg

Min Bearing Static capacity required = 50000 X 1.5 X 9.81= 735750N

Proposed Spherical Roller Bearing 22226E : ID = 130, OD = 230, Thk = 64 with

pressed steel cage having Static capacity = 930KN

4.7 Design of Roller Axle :

Material proposed Stainless steel : 20Cr13 IS:1570 part-V

Yp = 490MPa UTS = 690MPa

Permissible stress : Bending = 2000kg/cm2

Shear = 1500kg/cm2

RA = RB = 25000kg

BM = (50000 / 8) (2 X 19.2 – 6.4) = 230000kgcm

Proposed 130 at bearing and 80 at end box.

ZXX = 216cm3

Area = 50cm2

Bending stress = 230000 / 216 = 1065kg/cm2 < 2000kg/cm2

Shear stress = 25000 / 50 = 500kg/cm2 < 1500kg/cm2

4.8 Design of girder at curtailment :

ADO CONMAT INDIA


Max. horizontal girder reaction = 94.964t

RA = RB = 47482kg

At Section AA :

Bending moment = 47482 X 45 – [(94964 / 1815) X (45 – 27.5)2 / 2]= 2128678kgcm

Sectional properties at section ‘AA’ are as follows :

Area = 312.76cm2

IXX = 29703cm4

Z1 = 12327cm3

Z2 = 13120cm3

Z3 = 5415cm3


ii) Bending stress on D/S of skin plate= 2128678 / 13120 = 162kg/ cm2 < 1020kg/cm2



At section BB :

Bending moment = 47482 X 117.5 – [(94964 / 1815) X (175 – 27.5)2 / 2]

= 7740187kgcm

Sectional properties at section ‘BB’ are as follows :

Area = 419.2cm2

IXX = 1707036cm4

ADO CONMAT INDIA


Z1 = 28915cm3

Z2 = 29646cm3

Z3 = 15716cm3


ii) Bending stress on D/S of skin plate= 7740187 / 29646 = 261kg/ cm2 < 1020kg/cm2



5.0 Design of Skin Plate and Vertical Stiffeners :

The Skin plate and disposition of vertical stiffeners are as shown.

5.1 Design of Skin plate & Vertical Stiffeners below Girder ‘A’ :

Head to the center of the panel = 6.2 – (0.42 / 2) = 5.99M

ie., p = 0.599kg/cm2

ADO CONMAT INDIA


b/a = 35 / 27 = 1.296 ‘K’ value for b/a = 1.296 is

11X = 22.68 11Y = 13.23

12X = 16.44 12Y = 55.44

13X = 50.16 13Y = 15.44

Bending stress in skin plate :

b = [(K / 100) X ((p X a2) / s2)] = [(K / 100) X (0.599 X 272) / 1.452] = 2.077K kg/cm2

11X = 47kg/cm2 < 1020kg/cm

2 11Y = 27kg/cm

2 < 1020kg/cm

2

12X = 34kg/cm2 < 1020kg/cm

2 12Y = 115kg/cm

2 < 1020kg/cm

2

13X = 104kg/cm2 < 1020kg/cm

2 13Y = 32kg/cm

2 < 1020kg/cm

2

Check for combined stress : Max on D/S of skin plate

x = 637 + 34 = 671kg/cm2 < 1020kg/cm

2

y = - 115kg/cm2 < 1020kg/cm

2

C = 6712 + 115

2 + 671 X 115 = 735kg/cm

2 < 1910kg/cm

2

Design of vertical stiffener :

Head to the center of the panel = 0.599kg/cm2

W1 = 2 X ½ X 17.52 X 0.599 = 183kg

W2 = 2 X 24.5 X 17.5 X 0.599 = 514kg

RA = 697kg

Point of application

ADO CONMAT INDIA


= (½ X 17.53 X ⅔) + (24.5 X 17.5 X 33) / [(17.52 / 2) + (24.5 X 17.5)] = 27.386cm

BM = 697 X 27.386 – [183 (27.386 – 17.5 X ⅔) + (514 / 19.5) X (9.8862 / 2)]

= 14923kgcm

The co-acting width of skin plate :

L = 42 B = 17.5

L/B = 2.4 V = 0.348

2VB = 2 X 0.348 X 17.5 = 12.18cm 12cm

It is proposed 200 X 10mm plate as stiffeners.

Area = 37.40cm2

IXX = 1740cm4

Z1 = 269cm3

Z2 = 116cm3

Bending stress in compression = 14923 / 269 = - 55kg/cm2 < 1020kg/cm2

Bending stress in tension = 14923 / 116 = 129kg/cm2 < 1020kg/cm2

Check for combined stress :

x = - 32 – 55 = - 87kg/cm2 < 1020kg/cm

2

y = 104kg/cm2 < 1020kg/cm

2

C = 872 + 104

2 + 87 X 104 = 166kg/cm

2 < 1275kg/cm

2

5.2 Design of Skin plate and Vertical stiffener between Girder ‘A’ & ‘B’ :

Head to the center of the panel = 6.2 – (0.42 + 1.03 / 2) = 5.265M

ie., p = 0.527kg/cm2

ADO CONMAT INDIA



2X = 25.00 2Y = 7.91

3X = 50.00 3Y = 15.00

4X = 10.29 4Y = 34.30



2X = 77kg/cm2 < 1020kg/cm

2 2Y = 24kg/cm

2 < 1020kg/cm

2

3X = 154kg/cm2 < 1020kg/cm

2 2Y = 46kg/cm

2 < 1020kg/cm

2

4X = 32kg/cm2 < 1020kg/cm

2 2Y = 105kg/cm

2 < 1020kg/cm

2

Check for combined stress : Max. of D/S of skin plate

x = 637 + 32 = 669kg/cm2 < 1020kg/cm

2

y = - 105kg/cm2 < 1020kg/cm

2

C = 6692 + 105

2 + 669 X 105 = 727kg/cm

2 < 1275kg/cm

2

Design of vertical stiffeners :

Head to the centre of the panel = 0.527kg/cm2

W3 = 2 X ½ X 17.52 X 0.527 = 161kg

W4 = 2 X 68 X 17.5 X 0.527 = 1254kg

ADO CONMAT INDIA


RB = RC = 788kg

BM = 788 X 51.5 – (161 X 39.833 + (1254 / 2) (68 / 4) = 23510kgcm


L = 103 B = 17.5

L/B = 103 / 17.5 = 5.886 V = 0.834

2VB = 2 X 0.834 X 17.5 = 29.19cm 29cm


Area = 62.05cm2

IXX = 2233cm4

Z1 = 534cm3

Z2 = 129cm3




x = - 46 - 44 = - 90kg/cm2 < 1020kg/cm

2

y = + 154kg/cm2 < 1020kg/cm

2

C = 902 + 154

2 + 90 X 154 = 214kg/cm

2 < 1275kg/cm

2

5.3 Design of Skin plate and vertical stiffener above Girder ‘B’ :

Head to the center of the panel : 6.2 – (0.42 + 1.03 + 0.55 / 2) = 4.475M

ie., p = 0.448kg/cm2

ADO CONMAT INDIA



16X = 19.46 16Y = 11.95

17X = 9.17 17Y = 30.57

18X = 32.13 18Y = 9.64



16X = 51kg/cm2 < 1020kg/cm

2 16Y = 31kg/cm

2 < 1020kg/cm

2

17X = 24kg/cm2 < 1020kg/cm

2 17Y = 80kg/cm

2 < 1020kg/cm

2

18X = 84kg/cm2 < 1020kg/cm

2 18Y = 25kg/cm

2 < 1020kg/cm

2

Check for combined stress : Max. on D/S of skin plate.

x = 634 + 25 = 659kg/cm2 < 1020kg/cm

25

y = - 84kg/cm2 < 1020kg/cm

2

c = 6592 + 84

2 + 659 X 84 = 705kg/cm

2 < 1275kg/cm

2

Design of vertical stiffeners :

Head to the centre of the panel = 0.448kg/cm2

ADO CONMAT INDIA


W5 = 2 X ½ X 17.52 X 0.448 = 307kg

W6 = 2 X 37.5 X 17.5 X 0.448 = 588kg

RD = 895kg

Point of application

= (½ X 17.53 X ⅔ + 37.5 X 17.5 X 36.25) / [(17.52 / 2) + (37.5 X 17.5)] = 31.599cm

BM = 895 X 31.599 – [307 (31.599 – 17.5 X ⅔) + (588 / 37.5) X (14.0992 / 2)]

= 20603kgcm


L = 55 B = 17.5

L/B = 3.142 V = 0.432

2VB = 2 X 0.432 X 17.5 = 15.12cm ≈ 15cm


Area = 41.75cm2

IXX = 1869cm4

Z1 = 319cm3

Z2 = 120cm3




x = - 25 - 65 = - 90kg/cm2 < 1020kg/cm

2

y = + 84kg/cm2 < 1020kg/cm

2

C = 902 + 84

2 + 90 X 84 = 151kg/cm

2 < 1275kg/cm

2

Note : There is no need to check 2nd

element for bending moment in skin plate and short

stiffeners since the head is less than bottom element. How ever it is proposed to

provided stiffeners similar to that of bottom element.

ADO CONMAT INDIA


6.0 Design of embedded parts :

Max. roller load = 50000kg

6.1. Design of Thickness of roller track plate : (When track with line contact)

t = 6 X 0.786 X 1.55 (P / l X r / E)

Where l = tread width in mm = 130

P = Wheel load in N = 490500N

r = radius of the wheel = 225mm

E = Modulus of elasticity = 200810.7N/mm2

t = 6 X 0.786 X 1.55 (490500 / 130) X (225 / 200810.7) = 15.03mm

As per technical specification minimum thickness of track plate is 20mm.

Proposed 200 X 20mm thick as track plate after machining.

Material 20 Cr 13 IS 1570 Part V Hardness 200 to 220BHN

6.3 Design of Roller Track :

The section proposed is as follows

Area = 282cm2

IXX = 68991cm4

Z1 = 3946cm3

Z2 = 2791cm3

6.2.1 Checking the Bearing stress in concrete :

b = 0.2813 X P[EC / (ES X I X w2)] 1/3

P =Roller load = 50000kg

EC = Young’s modulus of concrete (M200)

ES = Young’s modulus of steel (Ec / Es = 1/8.98)

I = Moment of Inertia = 68991cm4

w = width of plate contact with concrete = 25cm

b = 0.2813 X 50000 [(1/8.98) X (1 / 68991) X (1 / 252)] 1/3 = 19.297kg/cm2 < 52kg/cm2

ADO CONMAT INDIA


6.2.2 Check for Bending stress :

b = 0.5 X (50000 / 2791) [8.98 X 68991 / 25]1/3 = 261kg/cm2 < 979kg/cm2

6.2.3 Check for Shear stress in web :

Shear stress in web = 50000 / (2 X 35 X 3.2) = 223kg/cm2 < 893 kg/cm2

6.2.4 Check for Web Compression :

wheel load = 50000kg

Web thickness = 32mm

Under 45 dispersion of load

Web Compressive Stress = 50000 / (10.4 X 3.2)

= 1502kg/cm2 < 1958kg/cm2

6.2.5 Check for Pressure distribution under track :

Length of influence of pressure under track L = 3/2 X P / pw

= (3 / 2) X 50000 / (17.07 X 25) = 175cm

The rollers are spaced at 74cm apart hence the pressure distribution under track will

even overlap.

Max. Stress = 17.07 X 2 = 34.14kg/cm2 < 62kg/cm2

6.2.6 Check for Shear stress in concrete :

Roller load = 50000kg

Bearing stress in concrete 17.07kg/cm2

Length of shear = 2 X (10.9 + 47.5) = 82.59cm

Shear stress = Bearing stress in concrete X width of track

2 X Length of Shear

= (17.07 X 25) / (2 X 82.59)

= 2.6kg/cm2 < 5.0kg/cm2

Permissible punching shear as per IS800 clause

6.2.7 Design of welds in roller track :

ADO CONMAT INDIA


Max. shear force = 25000kg

IXX of section = 23454cm4

a. Weld between track plate and U/S flange :

F1 = SAy / 2I = (25000 X 20 X 2 X 16.48) / (2 X 68991) = 119kg/cm length

Proposed 6mm fillet weld having strength of 308kg/cm length

b. Weld between U/S flange and web :

F2 = SAy / 2I = [25000 (20 X 2 + 25 X 3.2) 15.4 / (2 X 68991)] = 335kg/cm length


c. Weld between web and D/S flange :

F3 = SAy / 2I = (25000 X 25 X 2.0 X 23.72) / (2 X 68991) = 215kg/cm length


7.0 Check for Earthquake effect :

ADO CONMAT INDIA


Due to horizontal acceleration, there will be an instantaneous hydro dynamic pressure

exerted on the gate in addition to hydro static pressure. The direction of the hydro

dynamic force is opposite to the direction that of earthquake acceleration. Based on the

assumption that water is incompressible, the hydrodynamic pressure at depth y below

the reservoir surface shall be determined as follows. (Cl. 7.2 of IS : 1893 – 1984).

P = CSnWh

Where P = Hydrodynamic pressure in kg/cm2 at a depth y.

n = Design horizontal seismic co-efficient = Io – (cl. 3.4.2.3 –a of IS 1893)

= 1 X 3 X 0.02 = 0.06

CS = Co-efficient which varies with shape and depth.

= (Cm / 2) {(y / h) (2 – y / h) + (y / h) (2 – y / h)}

Cm = 0.73 from table – 10 of IS 1893, y = 3.8M, h = 3.8M

= (0.73 / 2) {1 X (2 – 1) + 1 (2 – 1)} = 0.73

W = Unit weight of water = 1000kg/m3

h = Depth of reservoir = 6.5M.

P = 0.73 X 0.06 X 1000 X 6.5 = 284.7kg/cm = 0.2847t/M2

Hence percentage of increase in pressure = (0.2847 / 6.5) X 100 = 4.42%

Permissible increase in stresses = 33.33% > 4.42%

As earthquake forces are not critical and do not govern the design, check for

stresses shall not be made for this condition.

8.0 Design of lifting arrangement :

Hoist capacity = 55t

ADO CONMAT INDIA


Load on each lifting side = 27.5t

8.1 Design of pulley pin :

Load on pulley shaft = SWL + self weight of pulley = 13750 + 105 = 13855kg

RA = RB = 6927.5kg

Bending moment = (13855 / 8) (2 X 17.6 – 13) = 38448kgcm

Proposed shaft 125mm.

Material IS 2062

ZXX = 192cm3 A = 123cm2


Shear stress = 6927.5 / 123 = 56kg/cm2 < 765kg/cm2

8.2 Design of cheek plate :

p = 13855 / (12.5 X 2.6) = 426kg/cm2

ADO CONMAT INDIA


Max. tearing stress

T = p {[(2R)2 + d2] / [(2R)2 - d2]}

= 426 [(302 + 12.52) / (302 – 12.52)]

= 605kg/cm2 < 0.66 X 2550 X 0.95 / 0.11

= 1453kg/cm2

8.3 Design of Pin – 2 :

RC = RD = 13855kg

Bending moment = 13855 X 2 = 27710kgcm

Proposed 125mm Pin

Material IS 2062

ZXX = 192cm3

Area = 123cm2


Shear stress = 13855 / 123 = 113kg/cm2 < 765kg/cm2

8.4 Design of Bracket welded to girder :

p = 13855 / (12.5 X 2) = 554.2kg/cm2

Max. tearing stress along AB

T = p {[(2R)2 + d2] / [(2R)2 - d2]}

= 554.2 [(302 + 12.52) / (302 – 12.52)]

= 674kg/cm2 < 1453kg/cm2

8.5 Design of weld between bracket and horizontal girder web :

Length of weld = 2 X 60 = 120cm

Load per cm length of weld = 13855 / 120 = 115kg/cm length.

Proposed 6mm fillet weld having strength of 428kg/cm length.

9.0 Design of Dogging Beam :

The arrangement of dogging beam is shown in Drg. No. BHME - GEI – RGB-VGB -105.

Self weight of gate = 55500kg

ADO CONMAT INDIA


The beam is supporting the gate on either side of gate at end box over the vent.

Load acting on beam with impact = 55500 X 1.1 / 2 = 30525kg

The loading on the beam is as follows :

RA = RB = 15262.5kg

Bending moment = (30525 / 8) (2 X 150 – 80) = 839438kgcm

Proposed beam having following section :

Area = 108.0cm2

IXX = 7472cm4

ZXX = 623cm3


Shear stress = 15262.5 / (2 X 20 X 1.6) = 238kg/cm2 < 1020kg/cm2

10.0 Design of Spice Joint :

Hoist capacity = 55t

It is proposed to design the splice joint between the elements for a Max. load of 55t.

The bolts provided in the joint are in double shear.

No. of bolts provided in the joint = 360Nos.

Dia of bolts proposed = 16mm

F = (2 X X d2 / 4) X fs X n

fn = 4F / (2 X X d2 X n)

= 4 X 55000 / (2 X X 1.6 X 360)

= 61 < 720kg/cm2

10.0 Gate weight C.G calculations:

S.No Description Size Nos Weight x Wx

1 Skin plate2000 X 16 – 189504500 X 16 – 18950

11

4760.210710.5

0.80.8

3808.08568.0

ADO CONMAT INDIA


2 End Box

785 X 16 – 2000785 X 16 – 4500190 X 10 – 785300 X 10 – 300140 X 10 – 280 280 X 20 thick

44201688

788.81774.7

234.2113.0

24.698.4

40.8540.8540.8559.6061.0059.60

32222.072496.0

9566.06737.01502.05869.0

3 Horizontal girder

300 X 16 – 184781800 X 12 – 18478 300 X 16 – 19130270 X 16 – 14600130 X 10 – 1616

444432

2785.012532.5

2883.31980.5

527.8

2.493.2

184.0185.6102.4

6684.01168029.0

530527.0367581.0

54047.0

4 Vertical stiffener1816 X 10 – 6500200 X 10 – 6500150 X 16 – 3200

5405

4633.04082.0

301.4

92.411.2

184.0

428089.045718.0

113835.0

5 Roller assembly450 Ø roller 140 thread width with 22226E bearing and 140Ø axle – 213kg/asm

8 1704.0 59.6 101558.0

6 Side guide 40kg/assy 4 160.0 38.9 6224.0

7 Top channel ISMC 250 X 82 - 18478 1 632.0 13.7 8658.0

8 Splice plate160 X 16 – 18360160 X 16 – 700

24

737.956.3

----40.85

-----2298.0

9 Typical joints200 X 10 – 1700150 X 16 – 460

45

106.843.3

92.8174.3

9911.07547.0

10 Seal assembly

44Ø X 127 – 6500 60 x 10 – 650090 x 14 flat seal – 1810080 x 10 – 1810020 x 20 – 8100

24111

58.5122.5

50.0113.7

56.8

--------------------

--------------------

11Lifting

Arrangement with bottom block

1500kg/assembly 2 3000.0 ---- ----

12 Fasteners 200kg 1 200.0 ---- ----

55271.7 2991474.0

x = 2991474.0 / 52271.7 = 57.2cm Adopted 57cm.

11.0 Hoist Capacity Calculations:

1) Weight of gate: 55500kg

2) Water thrust on the gate = 348843kg

3) Roller friction

F = P/R(fa X r + fr)

ADO CONMAT INDIA


Where F = Roller friction in kg

P = Water thrust =348843kg

R = 22.5cm

fa = Coeff. of friction = 0.015 for Antifriction bearing

r = 9cm (Bearing ID 130, OD 230 and 64thick)

fr = 0.1

F = (348843 / 22.5) (0.015 X 9 + 0.1) = 3643kg

4) Seal friction:

Side seal friction: 2 X X b X h X l

= (2 X 1.5 X 4.4 X 0.31 X 620) = 2537kg

5) Friction due to seal pre compression = 2 X 620 X 1 X 1.5 = 1860kg

6) Guide friction = (55500 / 100) X 5 = 2775kg

Note : No check is required for self closing since the self weight of gate is more than

frictions and seating pressure required.

A CWT of 50t including counter weight box is provided to reduce the hoist weight 25t

since it is connected in two falls.

Hoist capacity required:

Self weight of gate : 55,500.00

Roller Friction : 3,643.00

Seal Friction : 2,537.00

Friction due to seal pre compression : 1,860.00

Guide friction : 2,775.00

66,315.00

Add 20% reserve capacity : 13,263.00

79,578.00

Less - 25,000.00

54,578.00

Proposed 55t Rope Drum hoist for operation of the same.

12.0 Design of Counter weight Box:

The counter weight box including self wt. = 50000kg

Designed for with impact load of 55000kg

It is proposed to suspend the counter weight at 1750mm span.

ADO CONMAT INDIA


RA = RB = 27500kg

Bending moment = 27500 X [(1750 / 2) – (1890 / 4)] = 11068750kgcm

Proposed beam having following section :

Area = 410cm2

IXX = 1009717cm4

ZXX = 15299cm3

Bending stress = 11068750 / 15299

= 723kg/cm2 < 1480kg/cm2

Shear stress = 27500 / (2 X 123 X 1) = 112kg/cm2 < 1200kg/cm2

Permissible deflection = span / 750 = 1750 / 750 = 2.333

Deflection = (5 X 50000 X 18903) / (384 X 2047000 X 1009717) = 2.13cm < 2.333cm

Bearing stress = 45000 / (70 X 1800) = 0.357kg/cm2 <1680kg/cm2

However L75 X 75 X 8 stiffeners is proposed at 750mm C/C

A counter weight of 45t is proposed.

45t counter weight is to be provided at 3.5t/m3 density MS scrap and concrete.

Documents

Vertical Gates Design