Central Expressway Section 2 – Package C Designed By : Nadeeka

Girder load testing- 30m continuous EBT 1-2

Reference Description Output

1.0. Introduction

As per the contract consultant of Central expressway section 2, has requested

from the contractor to validate the precast prestressed girders' load bearing
capacity. Therefore selected girders will be tested using 4 point loading system,
i.e. two supports and two symmetric point loads. 5.00m gap is proposed to
accommodate the volume of necessary concrete cubes. Selected girder is EBT 1-
2 which is the third span girder at theXinner edge.
X

x = 2.500 m

A B C D E

Fig.1: Graphical representation of loading system

Distance from A to E is the actual span of girder which is between bearing pads
1.1 Calculation Method

Externally Appling load is evaluated by equalizing girder bottom stress at service

in combination 1 (BS5400 P2) to that from the external loading.
A B C D E

Fig.2 Bending moment diagrams

Girder test loading system is adjusted get SLS combination 01 design stress at
point C. Due to the difference in shape of design bending moment diagram to that
of testing (as illustrated in above diagram) stresses of points B and D exceeds
their serviceability values at the testing.

Since bridge super structure is designed to its composite behavior, precast girders
top flange stress exceeds its designed value to achieve that of bottom stress.

If girders design shear stress exceeds in this testing procedure, girders is checked
for this additional shear force in this report.

Design Shear Force

Testing Shear Force

A B C D E

Additional Shear Force

(If present)

Fig.3 Shear force diagram

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 Testing Shear Force

A B C D E

Central Expressway
Additional ShearSection
Force 2 – Package C Designed By : Nadeeka
(If present)
Girder load testing- 30m continuous EBT 1-2
Reference Description Output

2.1 Creep Loss adjustment

Girder casted date = 10/04/2018
Anticipated Test Date = 08/07/2019
Age of girder = 464 days

CREEP
For the calculation of creep and shrinkage parameters it is assumed that
Relative humidity (RH) = 70%
Temperature (T) = 30 oC
Age of girder when stressing , jm = 5 days
water cement ratio (w/c) = 0.33
cement content (kg/m3) = 480

C.2 of Creep coefficient , ф

BS5400-4
:1990   kl k m kc ke k j
Degree of hardening m   
j m T  10 o 
= 5 x ( 30 + 10 )
= 200

Girder mid section

he = 2A
U
= 2 x 0.8044
6.844
= 0.235 m

BS5400-4
:1990 kL = 2.3
Figure 9 km = 1.41
Figure 10 kc = 0.7
Figure 11 ke = 0.82
Figure 12 kj = 0.71
Figure 13 ф = 1.32

SHRINKAGE
Shrinkage strain , Δcc = kL Kc ke kj

Figure 14 kL = 0.000275
Figure 11 kc = 0.70
Figure 15 ke = 0.78
Figure 13 kj = 0.71

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 Central Expressway Section 2 – Package C Designed By : Nadeeka
Girder load testing- 30m continuous EBT 1-2
Reference Description Output
Δcc = 1.07E-04

Shrinkage loss = shrinkage strain near x Es x As

the centroid of steel
= 1.07E-04 x 195 x 5100
= 106 kN

Area of the section A = 0.80440 m2

The distance to the Neutral from bottom = 1.107 m
Girder hight = 2.000 m
Second Moment of Area about N.A. I = 0.42090 m4
Sectional Modulus of bottom fiber Zb = 0.38021 m3
Sectional modulus of top fiber Zt = 0.47133 m3
Area of the tendons As = 5100 mm2
Stress at tendon location σc(N/mm ) 2
= P P e2 M
+ -
A I Zb
σc
creep loss = x ф x Es x As
Ec
Es = 195 kN/mm2
Ec = 34 kN/mm2
fcu = 50 N/mm3

Point B Point C Point D

CH40+221
30x5 Bending moment due to dead M (kNm) 2135 2200 2135 See comment
supported Force after all immediate losses P (kN) 5177 5212 5177
report 6.4
Eccentricity of tendon e (m) 0.830 0.840 0.830
Stress at tendon location σc(N/mm2) 10.70 10.83 10.7
Creep loss (kN) 414 419 414
Shrinkage loss 106 106 106
Force after creep loss (kN) 4657 4687 4657

Stress at Naked girder

σ1 σ2t σ3t σ4t

+ -

- + =
-
- +
σ1 σ2b σ3b σ4b

direct stress bending bending resulting

due to stress due to stress due to stress at
prestress prestress self weight transfer

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 Central Expressway Section 2 – Package C Designed By : Nadeeka
Girder load testing- 30m continuous EBT 1-2
Reference Description Output

At Point B/D
αxP 4657
σ1 = - = - = -5.790 N/mm2
A 0.8044 x 1000

αxPxe 3866
σ2b = - = - = -10.167 N/mm2
Zb 0.38021 x 1000

αxPxe 3866
σ2t = = = 8.202 N/mm2
Zt 0.47133 x 1000

Mg 2135
σ3b = = = 5.615 N/mm2
Zb 0.38021 x 1000

Mg 2135
σ3t = - = - = -4.530 N/mm2
Zt 0.471327 x 1000

stress in bottom fiber

σ4b = σ1 + σ2b + σ3b
= -5.790 + -10.167 + 5.615
= -10.3 N/mm2

stress in top fiber

σ4t = σ1 + σ2t + σ3t
= -5.790 + 8.202 + -4.530
= -2.1 N/mm2

At Point C
αxP 4687
σ1 = - = - = -5.827 N/mm2
A 0.8044 x 1000

αxPxe 3937
σ2b = - = - = -10.356 N/mm2
Zb 0.38021 x 1000

αxPxe 3937
σ2t = = = 8.354 N/mm2
Zt 0.47133 x 1000

Mg 2200
σ3b = = = 5.786 N/mm2
Zb 0.38021 x 1000

4
 Central Expressway Section 2 – Package C Designed By : Nadeeka
Girder load testing- 30m continuous EBT 1-2
Reference Description Output

Mg 2200
σ3t = - = - = -4.668 N/mm2
Zt 0.471327 x 1000

stress in bottom fiber

σ4b = σ1 + σ2b + σ3b
= -5.83 + -10.36 + 5.79
= -10.4 N/mm2

stress in top fiber

σ4t = σ1 + σ2t + σ3t
= -5.83 + 8.35 + -4.67
= -2.1 N/mm2

Calculation summary
Point B Point C Point D
Naked girder Bottom Stress -10.3 -10.4 -10.3
(N/mm2) Top Stress -2.1 -2.1 -2.1

Composite girder Bottom Stress -4.6 -2.1 -5.8

CH57+850
30x5
Com 1 (N/mm2) Top Stress -9.7 -5.7 -9.2
supported
report

+ =

Precast girder stress Stress due to loading Composite girder stress

Fig.4 Representing stress evaluation

Precast girders'

Point B Point C Point D

Stress gap Bottom Stress 5.7 8.3 4.5
(N/mm2) Top Stress 7.6 3.6 7.1

Moment = Stress x Sectional modulus

Moment required to Bottom Stress 2183 3155 1727
equate stress(kNm) Top Stress 3574 1677 3338

Externally applied Moment = 3155 kNm (Selected for test)

Final stresses in girder Point B Point C Point D

5
 Central Expressway Section 2 – Package C Designed By : Nadeeka
Girder load testing- 30m continuous EBT 1-2
Reference Description Output
Bottom Stress -2.0 -2.1 -2.0
Stress (N/mm2)
Top Stress -8.8 -8.8 -8.8

Therefore from above loading precast girders' bottom stress is achieved.

11.95 5.00 11.95

Fig.5 Loading system

Weight(W) of external load to create the mo = 3155 / 11.95 = 264 kN

Number of cubes 1m3 units = 264 / 24 = 11

3. Shear Check

Shear force due to self weight at point B & D = 51 kN

Shear force due to loading at point B & D = 264 kN
Total shear force = 315 kN
Design shear force = 532 kN
Testing shear > Design shear force
Therefore girders' testing shear force exceeds its ULS shear force.
Therefore girder should be checked for its checking shear force.

Ultimate shear force due to testing = 51 x 1.15 + 264 x 1.1

349 kN

3.1.Section uncracked in flexure

BS5400
Part4(1990) Vco = 0.67* b*h*sqrt(ft2+fcp*ft) + vertical component of the
Cl.6.3.4.2 inclined prestress
Eq 28
n

Vco = Ultimate shear resistance of the section uncracked in flexure

b = breadth of the member

h = overall depth of the member = 2000 mm
ft = 0.24√(fcu) = 1.70 N/mm2
fcp = Compressive stress at the centroidal axis due to prestress
Cl.4.2.3 & = ϒfl x(Pe/A) = 0.87 x(Pe/A)
Cl.4.3.3.3

Calculation of shear capacity , Vco

Point C D E

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 Central Expressway Section 2 – Package C Designed By : Nadeeka
Girder load testing- 30m continuous EBT 1-2
Reference Description Output
Dist. X mm 11.950 14.450 16.950
b mm 200 200 200
Area m 0.80 0.80 0.80
fcp 5.04 5.07 5.04
0.67* b*h*sqrt(ft2+fcp*ft)kN 906 908 906
Peffective 4657 4687 4657
e 830 840 830
Deflected tendons inclination 0.00 0.00 0.00
Vertical component of the
18.6 18.7 18.6
prestress
Vco kN 925 927 925

3.2.Section cracked in flexure

Vcr = Ultimate shear resistance of the section cracked in flexure
BS5400 Vcr = 0.037* b*d*sqrt(fcu) + Mcr*V/M
Part4(1990) Mcr = Cracking moment of the section
Cl.6.3.4.3 = [ 0.37*sqrt(fcu) + fpt] * I/y
Eqn 29 y = Distance from centroid to extreme tensile fibre
I = Second moment of area
fpt = Stress due to prestress only at the tensile fibre at y
= ϒfl Pe/A + ϒfl Pe x e x y / I

Calculation of shear capacity , Vcr

Point C D E
Dist. X mm 11.95 14.45 16.95
Area m 0.80 0.80 0.80
I m4 0.42 0.42 0.42
ym 1.11 1.11 1.11
fpt Nmm-2 13.88 14.08 13.88
Peffective 4657 4687 4657
Effective Eccentricity,e mm 830 840 830
V kN 349 0 349
M kNm 5290 5355 5290
Mcr 6292 6367 6292
Mcr*V/M 415 0 415
0.037* b*d*sqrt(fcu) 61 61 61
Vcr kN 476 61 476
Vc kN 476 61 476
Vc is equal to lesser of Vco and Vcr

10.2.1.3.Calculation of shear reinforcement for section

BS5400
Part4(1990) If Vc > V (Asv/Sv)*(0.87*fyv/b) =0.4 N/mm2
Cl.6.3.4.4 where, fyv = Characteristic strength of the links
Asv = Total cross sectional area of the leg of the links
Sv = Link spacing along the length of the beam

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 Central Expressway Section 2 – Package C Designed By : Nadeeka
Girder load testing- 30m continuous EBT 1-2
Reference Description Output
If Vc < V (A sv
/S v
)=(V+0.4bd t
-Vc)/(0.87*f yv
*d t
)

dt = depth from the extreme compression fiber to the

longitudinal bars
= 2000 - 35 - 12 - 16/2
= 1945 mm

Assume 10 mm Diameter tor Steel

Asv = 78.5 mm2
fyv = 460 N/mm2

Calculation of shear and trosion reinforcement for Exterior girder

Point C D E
Dist. X mm 11.95 14.45 16.95
V kN 349 0 349
Vc kN 476 61 476
Vc >V Yes Yes Yes
b mm 200 200 200
(Asv/Sv) 0.20 0.20 0.20
Sv mm 785 785 785
Shear Link per meter 1.27 1.27 1.27
Section 10 of Torsion Link per meter 3.08 3.08 3.08
the super
structure Total link per meter 4.35 4.35 4.35
design report Final Sv mm 230 230 230

Even girders' testing shear force exeeds its design shear force, Provided T10
@ 150 c/c links are sufficient to bear the testing load.

4. Deflection
Expected deflection for test load at B and D = 17.7 mm
Expected deflection for test load @ mid span = 18.2 mm
Using the FEM on CSI bridge

5. Expected strain in girder

Neglecting embedded steel in concrete and assuming 28 day elastic modulus of

concrete
E= 34 kN/mm2
Strain = Stress
E
Point B Point C Point D
Bottom 0.0002440 0.0002440 0.0002440
Strain in Girder
Top 0.0001969 0.0001969 0.0001969

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 Central Expressway Section 2 – Package C Designed By : Nadeeka
Girder load testing- 30m continuous EBT 1-2
Reference Description Output